John Deere 4210 4310 4410 Compact Utility Tractor (TM1985) Shop Manual

JOHN DEERE
WORLDWIDE COMMERCIAL & CONSUMER

EQUIPMENT DIVISION
1985
November 2002
Compact Utility Tractors

4210, 4310 and 4410
TM1985 DECEMBER 2002
TECHNICAL MANUAL
North American Version

Litho in U.S.A.Litho in USA
INTRODUCTION
Manual Description
Introduction
This technical manual is written for an experienced Safety

technician and contains sections that are specifically for
this product. It is a part of a total product support program.
The manual is organized so that all the information on a Specifications and Information
particular system is kept together. The order of grouping is
as follows:
• Table of Contents Engine
• Specifications and Information
• Identification Numbers
• Tools and Materials Electrical
• Component Location
• Schematics and Harnesses
Power Train (Gear)
• Theory of Operation
• Operation and Diagnostics
• Diagnostics Power Train (Hydro)
• Tests and Adjustments
• Repair
• Other
Power Train (ePRT)
NOTE: Depending on the particular section or system
being covered, not all of the above groups may be
used. Power Train (Final Drive)
The bleed tabs for the pages of each section will align with
the sections listed on this page. Page numbering is
consecutive from the beginning of the Safety section Hydraulics
through the last section.
We appreciate your input on this manual. If you find any
errors or want to comment on the layout of the manual Steering
please contact us.
Brakes
Miscellaneous
All information, illustrations and
specifications in this manual are based
on the latest information at the time of
publication. The right is reserved to
make changes at any time without
notice.
COPYRIGHT© 2002
Deere & Co.
John Deere Worldwide Commercial and
Consumer Equipment Division
All rights reserved
Previous Editions
COPYRIGHT©
Introduction
INTRODUCTION
Introduction -4
SAFETY
Handle Fluids Safely - Avoid Fires
Safety
Recognize Safety Information Be Prepared For Emergencies
MIF
This is the safety-alert symbol. When you see this symbol

on your machine or in this manual, be alert to the potential
for personal injury.
Follow recommended precautions and safe servicing
practices.
Understand Signal Words

MIF
A signal word - DANGER, WARNING, or CAUTION - is
used with the safety-alert symbol. DANGER identifies the • When you work around fuel, do not smoke or work near
most serious hazards. heaters or other fire hazards.
DANGER or WARNING safety signs are located near • Store flammable fluids away from fire hazards. Do not
specific hazards. General precautions are listed on incinerate or puncture pressurized containers.
CAUTION safety signs. CAUTION also calls attention to • Make sure machine is clean of trash, grease, and
safety messages in this manual. debris.
• Do not store oily rags; they can ignite and burn
Replace Safety Signs spontaneously.
• 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.
Use Care In Handling And Servicing Batteries
MIF
Replace missing or damaged safety signs. See the

machine operator’s manual for correct safety sign
placement.
MIF
Safety -1
SAFETY
Prevent Battery Explosions Wear Protective Clothing
• Keep sparks, lighted matches, and open flame away
from the top of battery. Battery gas can explode.
• Never check battery charge by placing a metal object
across the posts. Use a volt-meter or hydrometer.
• Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
Prevent Acid Burns

MIF
• Sulfuric acid in battery electrolyte is poisonous. It is Wear close fitting clothing and safety equipment
strong enough to burn skin, eat holes in clothing, and appropriate to the job.
cause blindness if splashed into eyes.
Prolonged exposure to loud noise can cause impairment or
Avoid acid burns by: loss of hearing. Wear a suitable hearing protective device
such as earmuffs or earplugs to protect against
1. Filling batteries in a well-ventilated area.
objectionable or uncomfortable loud noises.
2. Wearing eye protection and rubber gloves.
Operating equipment safely requires the full attention of the
3. Avoiding breathing fumes when electrolyte is added. operator. Do not wear radio or music headphones while
4. Avoiding spilling or dripping electrolyte. operating machine.
5. Use proper jump start procedure.

Use Care Around High-pressure Fluid Lines
If you spill acid on yourself:
Avoid High-Pressure Fluids
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 10 - 15 minutes.
4. Get medical attention immediately.
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or vegetable
oil. MIF
3. Get medical attention immediately. Escaping fluid under pressure can penetrate the skin
causing serious injury.
Avoid injury from escaping fluid under pressure by stopping
the engine and relieving pressure in the system before
disconnecting or connecting hydraulic or other lines.
Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid
injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available from Deere &
Company Medical Department in Moline, Illinois, U.S.A.
Safety -2
SAFETY
Avoid Heating Near Pressurized Fluid Lines Park Machine Safely
MIF
MIF Before working on the machine:

Flammable spray can be generated by heating near 1. Lower all equipment to the ground.
pressurized fluid lines, resulting in severe burns to yourself
and bystanders. Do not heat by welding, soldering, or using 2. Stop the engine and remove the key.
a torch near pressurized fluid lines or other flammable 3. Disconnect the battery ground strap.
materials. Pressurized lines can be accidentally cut when
heat goes beyond the immediate flame area. 4. Hang a “DO NOT OPERATE” tag in operator station.
Service Machines Safely Support Machine Properly And Use Proper

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

MIF
scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get If you must work on a lifted machine or attachment,
caught, severe injury could result. securely support the machine or attachment.
Remove rings and other jewelry to prevent electrical shorts Do not support the machine on cinder blocks, hollow tiles,
and entanglement in moving parts. or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
Follow recommended procedures in this manual.
Use Proper Tools
Lifting heavy components incorrectly can cause severe
Use tools appropriate to the work. Makeshift tools and injury or machine damage. Follow recommended
procedures can create safety hazards. Use power tools procedure for removal and installation of components in the
only to loosen threaded parts and fasteners. For loosening manual.
and tightening hardware, use the correct size tools. DO
NOT use U.S. measurement tools on metric fasteners.
Avoid bodily injury caused by slipping wrenches. Use only Work In Clean Area
service parts meeting John Deere specifications.
Before starting a job:
1. Clean work area and machine.
2. Make sure you have all necessary tools to do your job.
3. Have the right parts on hand.
4. Read all instructions thoroughly; do not attempt
shortcuts.
Safety -3
SAFETY
Using High Pressure Washers solvent or paint stripper containers and other flammable
material from area. Allow fumes to disperse at least 15
Directing pressurized water at electronic/electrical minutes before welding or heating.
components or connectors, bearings, hydraulic seals, fuel
injection pumps or other sensitive parts and components
may cause product malfunctions. Reduce pressure and Avoid Harmful Asbestos Dust
spray at a 45 to 90 degree angle. Avoid breathing dust that may be generated when handling
components containing asbestos fibers. Inhaled asbestos
Illuminate Work Area Safely fibers may cause lung cancer.
Illuminate your work area adequately but safely. Use a Components in products that may contain asbestos fibers
portable safety light for working inside or under the are brake pads, brake band and lining assemblies, clutch
machine. Make sure the bulb is enclosed by a wire cage. plates, and some gaskets. The asbestos used in these
The hot filament of an accidentally broken bulb can ignite components is usually found in a resin or sealed in some
spilled fuel or oil. way. Normal handling is not hazardous as long as airborne
dust containing asbestos is not generated.
Work In Ventilated Area Avoid creating dust. Never use compressed air for cleaning.
Avoid brushing or grinding material containing asbestos.
When servicing, wear an approved respirator. A special
vacuum cleaner is recommended to clean asbestos. If not
available, apply a mist of oil or water on the material
containing asbestos. Keep bystanders away from the area.
Service Tires Safely
MIF
Engine exhaust fumes can cause sickness or death. If it is

necessary to run an engine in an enclosed area, remove
the exhaust fumes from the area with an exhaust pipe
extension.
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.
MIF
Warning: California Proposition 65 Warning Explosive separation of a tire and rim parts can cause
Gasoline engine exhaust from this product contains serious injury or death.
chemicals known to the State of California to cause cancer, Do not attempt to mount a tire unless you have the proper
birth defects, or other reproductive harm. equipment and experience to perform the job.
Diesel engine exhaust and some of its constituents are Always maintain the correct tire pressure. Do not inflate the
known to the State of California to cause cancer, birth tires above the recommended pressure. Never weld or heat
defects, and other reproductive harm. a wheel and tire assembly. The heat can cause an increase
in air pressure resulting in a tire explosion. Welding can
Remove Paint Before Welding Or Heating structurally weaken or deform the wheel.
Avoid potentially toxic fumes and dust. Hazardous fumes When inflating tires, use a clip-on chuck and extension
can be generated when paint is heated by welding, hose long enough to allow you to stand to one side and
soldering, or using a torch. Do all work outside or in a well NOT in front of or over the tire assembly. Use a safety cage
ventilated area. Dispose of paint and solvent properly. if available.
Remove paint before welding or heating: If you sand or Check wheels for low pressure, cuts, bubbles, damaged
grind paint, avoid breathing the dust. Wear an approved rims or missing lug bolts and nuts.
respirator. If you use solvent or paint stripper, remove
stripper with soap and water before welding. Remove
Safety -4
SAFETY
Avoid Injury From Rotating Blades, Augers Direct exposure to hazardous chemicals can cause serious
And PTO Shafts injury. Potentially hazardous chemicals used with John
Deere equipment include such items as lubricants,
coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
Dispose Of Waste Properly

MIF Improperly disposing of waste can threaten the
Keep hands and feet away while machine is running. Shut environment and ecology. Potentially harmful waste used
off power to service, lubricate or remove mower blades, with John Deere equipment include such items as oil, fuel,
augers or PTO shafts. coolant, brake fluid, filters, and batteries. Use leakproof
containers when draining fluids. Do not use food or
beverage containers that may mislead someone into
Service Cooling System Safely drinking from them. Do not pour waste onto the ground,
down a drain, or into any water source. Inquire on the
proper way to recycle or dispose of waste from your local
environmental or recycling center, or from your John Deere
dealer.
Live With Safety
MIF
Explosive release of fluids from pressurized cooling system

can cause serious burns.
Shut off machine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop to
relieve pressure before removing completely.
Handle Chemical Products Safely

MIF
Before returning machine to customer, make sure machine

is functioning properly, especially the safety systems. Install
all guards and shields.
MIF
Safety -5
SAFETY
Safety -6
SPECIFICATIONS & INFORMATION TABLE OF CONTENTS
Specifications & Information
Table of Contents
General Specifications .....................................9

Metric Fastener Torque Values ......................9
Metric Fastener Torque Values—Grade 7 ...10
Inch Fastener Torque Values .......................11
Gasket Sealant Application ..........................12
O-Ring Seal Service Recommendations ......12
Face Seal Fittings with
Inch Stud Ends Torque.................................12
Face Seal Fittings with
Metric Stud Ends Torque..............................13
O-Ring Face Seal Fittings ............................14
O-Ring Boss Fittings ....................................14
Fuels and Lubricants......................................15
Diesel Fuel Specifications ............................15
Diesel Fuel Lubricity .....................................15
Diesel Fuel Storage......................................16
Engine Oil.....................................................16
Engine Break–in Oil......................................16
Alternative Lubricants...................................17
Synthetic Lubricants .....................................17
Lubricant Storage .........................................17
Mixing Of Lubricants.....................................17
Chassis Grease............................................17
Transaxle Oil ................................................18
Coolant Specifications ...................................19
Engine Coolant.............................................19
Engine Coolant Drain Interval ......................19
Serial Number Locations ...............................20
Machine Product Identification Number .......20
Engine Serial Number ..................................20
Transaxle Serial Number..............................20
Interlock System .............................................20
Interlock System...........................................20
Specifications & Information Table of Contents - 7

SPECIFICATIONS & INFORMATION TABLE OF CONTENTS
Specifications & Information Table of Contents - 8

SPECIFICATIONS & INFORMATION GENERAL SPECIFICATIONS
General Specifications
Metric Fastener Torque Values
4.8 8.8 9.8 10.9 12.9

Property
Class
and 4.8 8.8 9.8 10.9 12.9
Head
Markings 4.8 8.8 9.8 10.9 12.9 12.9
Property 5 10 10 12
Class
and
10
10
12
5
Nut 5 10 10 12
Markings
TS1163
TS1163
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
a a a a a a
Lubricated Dry Lubricated Dry Lubricated Dry Lubricateda Drya
SIZE N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft
M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5
M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35
M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70
M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 190
M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300
M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410
M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580
M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800
M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000
M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500
M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000
M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500
• DO NOT use these hand torque values if a different when tightening.

torque value or tightening procedure is given for a specific
• When bolt and nut combination fasteners are used,
application. Torque values listed are for general use only
torque values should be applied to the NUT instead of the
and include a ± 10% variance factor. Check tightness of
bolt head.
fasteners periodically. DO NOT use air powered wrenches.
• Tighten toothed or serrated-type lock nuts to the full
• Shear bolts are designed to fail under predetermined
torque value.
loads. Always replace shear bolts with identical grade.
• Fasteners should be replaced with the same class.
Make sure fastener threads are clean and that you properly
start thread engagement. This will prevent them from failing
Specifications & Information General Specifications - 9

a
“Lubricated” means coated with a lubricant such as
engine oil, or fasteners with phosphate and oil
coatings. “Dry” means plain or zinc plated (yellow
dichromate—Specification JDS117) without any
lubrication.
Reference: JDS-200
Metric Fastener Torque Values—Grade 7
Size Steel or Gray Aluminum

Iron Torque Torque
N•m (lb-ft) N•m (lb-ft)
M6 11 (8) 8 (6)
M8 24 (18) 19 (14)
M10 52 (38) 41 (30)
M12 88 (65) 70 (52)
M14 138 (102) 111 (82)
M16 224 (165) 179 (132)

Inch Fastener Torque Values
1 or 2b 5 5.1 5.2 8 8.2

SAE
Grade
and Head No Marks
Markings
2 5 8
SAE
Grade No Marks
and Nut
Markings
TS1162
TS1162
b
Grade 1 Grade 2 Grade 5, 5.1 or 5.2 Grade 8 or 8.2
a a a a a a
Lubricated Dry Lubricated Dry Lubricated Dry Lubricateda Drya
SIZE N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft
1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5
5/16 7.7 5.5 10 7 12 9 15 11 20 15 25 18 28 21 35 26
3/8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46
7/16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75
1/2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115
9/16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160
5/8 67 50 85 62 105 78 135 100 170 125 215 160 215 160 300 225
3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400
7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650
1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975
1-1/8 470 300 510 375 470 300 510 375 900 675 1150 850 1450 1075 1850 1350
1-1/4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550
1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
• DO NOT use these hand torque values if a different • Tighten toothed or serrated-type lock nuts to the full
torque value or tightening procedure is given for a specific torque value.
application. Torque values listed are for general use only a
“Lubricated” means coated with a lubricant such as
and include a ± 10% variance factor. Check tightness of
engine oil, or fasteners with phosphate and oil
fasteners periodically. DO NOT use air powered wrenches.
coatings. “Dry” means plain or zinc plated (yellow
• Shear bolts are designed to fail under predetermined dichromate—Specification JDS117) without any
loads. Always replace shear bolts with identical grade. lubrication.
b
• Fasteners should be replaced with the same class. “Grade 2” applies for hex cap screws (not hex bolts)
Make sure fastener threads are clean and that you properly up to 152 mm (6 in.) long “Grade 1” applies for hex cap
start thread engagement. This will prevent them from failing screws over 152 mm (6 in.) long, and for all other types
when tightening. of bolts and screws of any length.
• When bolt and nut combination fasteners are used, Reference: JDS-G200
torque values should be applied to the NUT instead of the
bolt head.

SPECIFICATIONS & INFORMATION O-RING SEAL SERVICE
Gasket Sealant Application providing complete coverage. This can be judged by the
appearance of the joint once it is put together. Excessive
Cleaning: amounts of will cause incorrect bearing end play, extend
cure time, and will cause runoff of the material. A small
Clean both surfaces that will be joined using 100%
isopropyl alcohol. Wipe excess off with a clean cloth. bead or buildup at the joint is permissible and indicates
Cleaner/degreaser can be substituted for isopropyl alcohol. good dispersion through the joint. Excess can be wiped
from the joint. Joining should take place within three
How to Dispense/Apply/Assemble Gasket Sealants: minutes after sealant application.
Dispense approximately 1 to 2 ounces of flexible form-in- Apply proper cap screw torque and sequence as
place gasket on a clean sheet or table top. Avoid using applicable. Allow a minimum of 30 minutes before air test or
excess amounts that may be exposed for long periods of adding oil for test stand usage.
time. This will help prevent contamination from surrounding
atmosphere such as dust with metal content. Disassembly:
Cured material can be removed with a wire brush or
Using an ink roller or similar devise, apply to one surface of
scraper. Chemical cleaners are available for customer use,
the joint by loading the roller from a plastic sheet and
should they be deemed necessary.
transferring the material in a thin film to the joint. The
application should be the thinnest film possible, but
O-Ring Seal Service Recommendations
Face Seal Fittings with Inch Stud Ends Torque
Stud End Tube Nut
Straight Stud and Tube Nut Swivel Nut

Lock Nut
Tube Nut
Stud End
90° Swivel Elbow and Tube Nut
90° Adjustable Stud Elbow
Bulkhead Union and Bulkhead Lock Nut
MIF
Nominal Tube OD/Hose ID Face Seal Tube/Hose End O-Ring Stud Ends
Metric Inch Tube OD Thread Tube Nut/ Bulkhead Thread Straight Fitting
Tube Size Swivel Nut Lock Nut Size or Lock Nut
OD Torque Torque Torque
mm Dash in. mm in. N•m lb-ft N•m lb-ft in. N•m lb-ft
Size
-3 0.188 4.76 3/8-24 8 6
6 -4 0.250 6.35 9/16-18 16 12 12 9 7/16-20 12 9
8 -5 0.312 7.94 1/2-20 16 12
10 -6 0.375 9.52 11/16-16 24 18 24 18 9/16-18 24 18
12 -8 0.500 12.70 13/16-16 50 37 46 34 3/4-16 46 34
Specifications & Information O-Ring Seal Service Recommendations - 12

Nominal Tube OD/Hose ID Face Seal Tube/Hose End O-Ring Stud Ends
Metric Inch Tube OD Thread Tube Nut/ Bulkhead Thread Straight Fitting
Tube Size Swivel Nut Lock Nut Size or Lock Nut
OD Torque Torque Torque
mm Dash in. mm in. N•m lb-ft N•m lb-ft in. N•m lb-ft
Size
16 -10 0.625 15.88 1-14 69 51 62 46 7/8-14 62 46
-12 0.750 19.05 1-3/16-12 102 75 102 75 1-1/16-12 102 75
22 -14 0.875 22.22 1-3/16-12 102 75 102 75 1-3/16-12 122 90
25 -16 1.000 25.40 1-7/16-12 142 105 142 105 1-5/16-12 142 105
32 -20 1.25 31.75 1-11/16-12 190 140 190 140 1-5/8-12 190 140
38 -24 1.50 38.10 2-12 217 160 217 160 1-7/8-12 217 160
NOTE: Torque tolerance is +15%, -20%
Face Seal Fittings with Metric Stud Ends Torque
Stud End Tube Nut
Groove for Metric Identification

Swivel Nut
Straight Stud and Tube Nut Lock Nut
Tube Nut
Groove for Metric
Identification Stud End
90° Swivel Elbow and Tube Nut
90° Adjustable Stud Elbow
Bulkhead Union and Bulkhead Lock Nut
MIF
Nominal Tube OD/Hose ID Face Seal Tube/Hose End O-Ring Stud Ends, Straight Fitting or
Lock Nut
Metri Inch Tube OD Thread Hex Tube Nut/ Bulkhead Thread Hex Steel or Aluminu
c Size Siz Swivel Lock Nut Size Siz Gray Iron m Torque
Tube e Nut Torque e Torque
OD Torque
mm Das in. mm in. mm N• lb-ft N• lb-ft mm mm N• lb-ft N• lb-ft

h m m m m
Size
6 -4 0.250 6.35 9/16-18 17 16 12 12 9 M12X1.5 17 21 15.5 9 6.6
8 -5 0.312 7.94
M14X1.5 19 33 24 15 11

Nominal Tube OD/Hose ID Face Seal Tube/Hose End O-Ring Stud Ends, Straight Fitting or
Lock Nut
Metri Inch Tube OD Thread Hex Tube Nut/ Bulkhead Thread Hex Steel or Aluminu
c Size Siz Swivel Lock Nut Size Siz Gray Iron m Torque
Tube e Nut Torque e Torque
OD Torque
mm Das in. mm in. mm N• lb-ft N• lb-ft mm mm N• lb-ft N• lb-ft

h m m m m
Size
10 -6 0.375 9.52 11/16-16 22 24 18 24 18 M16X1.5 22 41 30 18 13
12 -8 0.500 12.70 13/16-16 24 50 37 46 34 M18X1.5 24 50 37 21 15
16 -10 0.625 15.88 1-14 30 69 51 62 46 M22X1.5 27 69 51 28 21
-12 0.750 19.05 1-3/16-12 36 102 75 102 75 M27X2 32 102 75 46 34
22 -14 0.875 22.22 1-3/16-12 36 102 75 102 75 M30X2 36
25 -16 1.000 25.40 1-7/16-12 41 142 105 142 105 M33X2 41 158 116 71 52
28 M38X2 46 176 130 79 58
32 -20 1.25 31.75 1-11/16-12 50 190 140 190 140 M42X2 50 190 140 85 63
38 -24 1.50 38.10 2-12 60 217 160 217 160 M48X2 55 217 160 98 72
NOTE: Torque tolerance is +15%, -20%

IMPORTANT: Avoid damage! DO NOT allow hoses
to twist when tightening fittings. Use two
O-Ring Face Seal Fittings wrenches to tighten hose connections; one to
hold the hose, and the other to tighten the swivel
A fitting.
6. Tighten fitting or nut to torque value shown on the chart

per dash size stamped on the fitting.
O-Ring Boss Fittings

1. Inspect boss O-ring boss seat. It must be free of dirt and
defects. If repeated leaks occur, inspect for defects with a
B magnifying glass. Some raised defects can be removed
A with a slip stone.
MIF
B
1. Inspect the fitting sealing surfaces (A). They must be A
free of dirt or defects.
2. Inspect the O-ring (B). It must be free of damage or
defects.
3. Lubricate O-rings and install into groove using
petroleum jelly to hold in place.
4. Push O-ring into the groove with plenty of petroleum
jelly so O-ring is not displaced during assembly. MIF
5. Index angle fittings and tighten by hand-pressing joint 2. Put hydraulic oil or petroleum jelly on the O-ring (A).
together to ensure O-ring remains in place. Place electrical tape over the threads to protect

SPECIFICATIONS & INFORMATION FUELS AND LUBRICANTS
O-ring from nicks. Slide O-ring over the tape and into the tighten special nut or straight fitting the number of flats
groove (B) of fitting. Remove tape. shown.
Fuels and Lubricants
Diesel Fuel Specifications
c CAUTION: Avoid injury! California

A
C
B Proposition 65 Warning: Diesel engine
exhaust and some of its elements from this
product are known to the State of California
to cause cancer, birth defects, or other
reproductive harm.
MIF
In general, diesel fuels are blended to satisfy the low air
3. For angle fittings, loosen special nut (A) and push temperature requirements of the geographical area in
special washer (B) against threads so O-ring can be which they are sold.
installed into the groove of fitting.
In North America, diesel fuel is usually specified to ASTM
4. Turn fitting into the boss by hand until special washer or D975 and sold as either Grade 1 for cold air temperatures
washer face (straight fitting) contacts boss face and O-ring or Grade 2 for warm air temperatures.
is squeezed into its seat.
If diesel fuels being supplied in your area DO NOT meet
5. To position angle fittings (C), turn the fitting counter- any of the above specifications, use diesel fuels with the
clockwise a maximum of one turn. following equivalent properties:
6. Tighten straight fittings to torque value shown on chart. • Cetane Number 40 (minimum)
For angle fittings, tighten the special nut to value shown in
the chart while holding body of fitting with a wrench. A cetane number greater than 50 is preferred, especially
for air temperatures below –20°C (–4°F) or elevations
above 1500 m (5000 ft).
Thread Size Torquea Number of
Flatsb • Cold Filter Plugging Point (CFPP)
N•m lb-ft The air temperature at which diesel fuel begins to cloud
or jell — at least 5°C (9°F) below the expected low air
3/8-24 UNF 8 6 2 temperature range.
7/16-20 UNF 12 9 2 • Sulfur Content of 0.05% (maximum)
Diesel fuels for highway use in the United States now
1/2-20 UNF 16 12 2
require sulfur content to be less than 0.05%.
9/16-18 UNF 24 18 2 If diesel fuel being used has a sulfur content greater than
3/4-16 UNF 46 34 2 0.05%, reduce the service interval for engine oil and
filter by 50%.
7/8-14 UNF 62 46 1-1/2 Consult your local diesel fuel distributor for properties of the
1-1/16-12 UN 102 75 1 diesel fuel available in your area.
1-3/16-12 UN 122 90 1 Diesel Fuel Lubricity

1-5/16-12 UN 142 105 3/4 Diesel fuel must have adequate lubricity to ensure proper
1-5/8-12 UN 190 140 3/4 operation and durability of fuel injection system
components. Fuel lubricity should pass a minimum of
1-7/8-12 UN 217 160 1/2 3300 gram load level as measured by the BOCLE scuffing
a test.
Torque tolerance is ± 10 percent.
b
To be used if a torque wrench cannot be used. After
tightening fitting by hand, put a mark on nut or boss; then
Specifications & Information Fuels and Lubricants - 15

Diesel Fuel Storage Merchandise Sales Guide;
• Lubrication Sales Manual PI7032.
IMPORTANT: Avoid damage! DO NOT USE
GALVANIZED CONTAINERS—diesel fuel stored in Engine Break–in Oil
galvanized containers reacts with zinc coating in
the container to form zinc flakes. If fuel contains
water, a zinc gel will also form. The gel and flakes IMPORTANT: Avoid damage! ONLY use a quality
will quickly plug fuel filters and damage fuel break-in oil in rebuilt or remanufactured engines
injectors and fuel pumps. for the first 5 hours (maximum) of operation. DO
NOT use oils with heavier viscosity weights than
It is recommended that diesel fuel be stored ONLY in a SAE 5W-30 or oils meeting specifications API SG
clean, approved POLYETHYLENE PLASTIC container or SH, these oils will not allow rebuilt or
WITHOUT any metal screen or filter. This will help prevent remanufactured engines to break-in properly.
any accidental sparks from occurring. Store fuel in an area
that is well ventilated to prevent possible igniting of fumes The following John Deere oil is PREFERRED:
by an open flame or spark, this includes any appliance with • BREAK–IN ENGINE OIL.
a pilot light.
John Deere BREAK–IN ENGINE OIL is formulated with
special additives for aluminum and cast iron type engines
IMPORTANT: Avoid damage! Keep all dirt, scale,
to allow the power cylinder components (pistons, rings, and
water or other foreign material out of fuel.
liners as well) to “wear-in” while protecting other engine
Keep fuel in a safe, protected area and in a clean, properly components, valve train and gears, from abnormal wear.
marked (“DIESEL FUEL”) container. DO NOT use de-icers Engine rebuild instructions should be followed closely to
to attempt to remove water from fuel. DO NOT depend on determine if special requirements are necessary.
fuel filters to remove water from fuel. It is recommended John Deere BREAK–IN ENGINE OIL is also recommended
that a water separator be installed in the storage tank for non-John Deere engines, both aluminum and cast iron
outlet. BE SURE to properly discard unstable or types.
contaminated diesel fuel and/or their containers when
The following John Deere oil is also recommended as a
necessary.
break-in engine oil:
Engine Oil • TORQ–GARD SUPREME®—SAE 5W-30.

If the above recommended John Deere oils are not
Use the appropriate oil viscosity based on the expected air
available, use a break-in engine oil meeting the following
temperature range during the period between
specification during the first 5 hours (maximum) of
recommended oil changes. Operating outside of these
operation:
recommended oil air temperature ranges may cause
premature engine failure. • SAE 5W-30—API Service Classification SE or higher.
The following John Deere oil is PREFERRED:
IMPORTANT: Avoid damage! After the break-in
• TORQ–GARD SUPREME®—SAE 5W-30; period, use the John Deere oil that is
• PLUS–50®—SAE 15W-40; recommended for this engine.
Other oils may be used if above John Deere oils are not
available, provided they meet one of the following
specifications:
• SAE 15W-40—API Service Classification CH-4 or
higher;
• SAE 10W-30—API Service Classification CG-4 (4-
cycle) or higher;
John Deere Dealers: You may want to cross-reference the
following publications to recommend the proper oil for your
customers:
• Module DX,ENOIL2 in JDS–G135;
• Section 530, Lubricants & Hydraulics, of the John Deere

Synthetic Lubricants
Synthetic lubricants may be used in John Deere equipment
if they meet the applicable performance requirements
(industry classification and/or military specification) as
shown in this manual.
The recommended air temperature limits and service or
lubricant change intervals should be maintained as shown
in the operator’s manual.
BREAK-IN OIL
Avoid mixing different brands, grades, or types of oil. Oil
SAE 5W-30
manufacturers blend additives in their oils to meet certain
specifications and performance requirements. Mixing
different oils can interfere with the proper functioning of
these additives and degrade lubricant performance.
Lubricant Storage
All machines operate at top efficiency only when clean
lubricants are used. Use clean storage containers to
handle all lubricants. Store them in an area protected from
dust, moisture, and other contamination. Store drums on
PREFERRED their sides. Make sure all containers are properly marked
AIR TEMPERATURE as to their contents. Dispose of all old, used containers and
their contents properly.
M58275
John Deere Dealers: You may want to cross-reference the Mixing Of Lubricants
following publications to recommend the proper oil for your
customers: In general, avoid mixing different brands or types of
lubricants. Manufacturers blend additives in their lubricants
• Module DX,ENOIL4 in JDS–G135;
to meet certain specifications and performance
• Section 530, Lubricants & Hydraulics, of the John Deere requirements. Mixing different lubricants can interfere with
Merchandise Sales Guide; the proper functioning of these additives and lubricant
• Lubrication Sales Manual PI7032. properties which will downgrade their intended specified
performance.
Alternative Lubricants
Chassis Grease
Conditions in certain geographical areas outside the United
States and Canada may require different lubricant Use the following grease based on the air temperature
recommendations than the ones printed in this technical range. Operating outside of the recommended grease air
manual or the operator's manual. Consult with your John temperature range may cause premature failures.
Deere Dealer, or Sales Branch, to obtain the alternative The following John Deere grease is PREFERRED:
lubricant recommendations.
• NON-CLAY HIGH-TEMPERATURE EP GREASE®—
JDM J13E4, NLGI Grade 2.
IMPORTANT: Avoid damage! Use of alternative
lubricants could cause reduced life of the • Multi-Purpose SD Polyurea Grease
component. • Multi-Purpose HD Lithium Complex Grease
If alternative lubricants are to be used, it is recommended Other greases may be used if above preferred John Deere
that the factory fill be thoroughly removed before switching grease is not available, provided they meet the following
to any alternative lubricant. specification:
• John Deere Standard JDM J13E4, NLGI Grade 2.

Transaxle Oil
These machines are equipped with a internal wet disc
brake transmission.
NLGI Grade 2
JDM J13E4
HY-GARD
Low Viscosity
AIR TEMPERATURE
M58275

following publications to recommend the proper grease for AIR TEMPERATURE
your customers: MIF
• Module DX,GREA1 in JDS–G135;
IMPORTANT: Avoid damage! Transaxle is filled
• Section 530, Lubricants & Hydraulics, of the John Deere with John Deere HY-Gard® (J20C) transmission
Merchandise Sales Guide; oil at the factory. DO NOT mix oils
• Lubrication Sales Manual P17032. Do not use type “F” automatic transmission fluid.
Use only Hy-Gard® (J20C) or Low Viscosity Hy-Gard
(J20D) transmission oil.
John Deere Hy-Gard transmission oil is specially
formulated to provide maximum protection against
mechanical wear, corrosion, and foaming.
The following John Deere oil is PREFERRED:
• Hy-Gard J20C Oil
The following oil is also recommended if above preferred oil
is not available:
• Low Viscosity Hy-Gard J20D Oil
IMPORTANT: Avoid damage! If operating

temperatures are below -18°C (0°F), you must use
Low Viscosity HY-GARD® or transmission
damage will occur.
Use the appropriate oil viscosity based on the air

temperature ranges. Operating outside of these
recommended oil air temperature ranges may cause
premature gear case failure.

SPECIFICATIONS & INFORMATION COOLANT SPECIFICATIONS
following publications to recommend the proper oil for your IMPORTANT: Avoid damage! To prevent engine
customers: damage, DO NOT use pure anti-freeze or less
than a 50% anti-freeze mixture in the cooling
• Module DX,ENOIL2 in JDS–G135; system. DO NOT mix or add any additives/
• Section 530, Lubricants & Hydraulics, of the John Deere conditioners to the cooling system in Lawn and
Merchandise Sales Guide; Grounds Care/Golf and Turf Division equipment.
Water used to dilute engine coolant concentrate
• Lubrication Sales Manual PI7032. must be of high quality—clean, clear, potable
water (low in chloride and hardness—Table 1) is
Coolant Specifications generally acceptable. DO NOT use salt water.
Deionized or distilled water is ideal to use.
Engine Coolant Coolant that is not mixed to these specified levels
and water purity can cause excessive scale,
The engine cooling system, when filled with a proper sludge deposits, and increased corrosion
dilution mixture of anti-freeze and deionized or distilled potential.
water, provides year-round protection against corrosion,
cylinder or liner pitting, and winter freeze protection down Property Requirements
to –37°C (–34°F).
Total Solids, Maximum 340 ppm (20 grns/gal)
The following John Deere coolant is PREFERRED:
• PRE-DILUTED DIESEL ENGINE ANTI-FREEZE/ Total Hardness, Max. 170 ppm (10 grns/gal)
SUMMER COOLANT™ (TY16036).
Chloride (as Cl), Max. 40 ppm (2.5 grns/gal)
This coolant satisfies specifications for “Automobile and
Light Duty Engine Service” and is safe for use in John Sulfate (as SO4), Max. 100 ppm (5.8 grns/gal)
Deere Lawn and Grounds Care/Golf and Turf Division
Mix 50 percent anti-freeze concentrate with 50 percent
equipment, including aluminum block gasoline engines and
distilled or deionized water. This mixture and the prediluted
cooling systems.
mixture (TY16036) will protect the cooling system down to
The above preferred pre-diluted anti-freeze provides: –37°C (–34°F) and up to 108°C (226°F).
• adequate heat transfer Certain geographical areas may require lower air
• corrosion-resistant chemicals for the cooling system temperature protection. See the label on your anti-freeze
container or consult your John Deere dealer to obtain the
• compatibility with cooling system hose and seal material latest information and recommendations.
• protection during extreme cold and extreme hot weather
operations Engine Coolant Drain Interval
• chemically pure water for better service life When using John Deere Pre-Diluted (TY16036)
• compliance with ASTM D4656 (JDM H24C2) Automobile and Light Duty Engine Service coolants, drain
specifications and flush the cooling system and refill with fresh coolant
mixture every 36 months or 3,000 hours of operation,
If above preferred pre-diluted coolant is not available, the
whichever comes first.
following John Deere concentrate is recommended:
When using John Deere Concentrate (TY16034)
• DIESEL ENGINE ANTI-FREEZE/SUMMER COOLANT
Automobile and Light Duty Engine Service coolants, drain
CONCENTRATE™ (TY16034).
and flush the cooling system and refill with fresh coolant
If either of above recommended engine coolants are not mixture every 24 months or 2,000 hours of operation,
available use any Automobile and Light Duty Engine whichever comes first.
Service ethylene glycol base coolant, meeting the
If above John Deere Automobile and Light Duty Engine
following specification:
Service coolants are not being used, drain, flush, and refill
• ASTM D3306 (JDM H24C1). the cooling system according to instructions found on
Read container label completely before using and follow product container or in equipment operator’s manual or
instructions as stated. technical manual.
Specifications & Information Coolant Specifications - 19

SPECIFICATIONS & INFORMATION SERIAL NUMBER LOCATIONS
Serial Number Locations Interlock System
Machine Product Identification Number Interlock System

When ordering parts or submitting a warranty claim, it is It is important to understand the interlock system and how it
IMPORTANT that the machine product identification works. Before performing the checkout procedures,
number (PIN) and component serial numbers are included. become familiar with the interlock system so that an
The location of the PIN and component serial numbers are interlock function will not be mistaken for a machine
shown. problem.
START
SST and
ePowrReverser NO
Main Shift
In Neutral
MX5200
ON
Located on right side of frame. PTO
OFF
Engine Serial Number
START NO
STARTER
ENGAGEMENT
MIF
For the starting motor to engage and the engine to run, the
following conditions must be met simultaneously:
MX10704
• SST and ePowrReverser machines must have the
Located on top of engine. transmissions in Neutral
• PTO switch in OFF position.
Transaxle Serial Number
MX10703
Located on left side of flywheel/transmission housing.
Specifications & Information Serial Number Locations - 20

SPECIFICATIONS & INFORMATION INTERLOCK SYSTEM
OFF RUN
SEAT
ON
ON
BRAKE
OFF
ON
PTO
OFF
TIME DELAY
ENGINE
SHUTDOWN STOPS
DELAY
MODULE
FUEL
ENGINE
SHUTOFF
SOLENOID RUNS
MIF
For the engine to run, one of the following must occur:

• Operator must be on the seat when the rear PTO is
engaged and the park brake is disengaged.
• When operator is NOT on the seat, if the rear PTO is
engaged, the park brake MUST BE engaged.
If the operator is operating a PTO driven attachment and
rises off the seat, the attachment and engine will stop.
In order to operate PTO driven attachments, the following
conditions must occur:
• Operator sitting on operator seat.
• Throttle lever moved to the desired position.
• Park brake not engaged.
• PTO switch in the ON position.
Specifications & Information Interlock System - 21

SPECIFICATIONS & INFORMATION INTERLOCK SYSTEM
Specifications & Information Interlock System - 22

ENGINE - DIESEL TABLE OF CONTENTS
Rocker Arm Assembly ................................. 58
Engine - Diesel
Table of Contents
Cylinder Head and Valves
Removal and Installation ............................. 60
Cylinder Head and Valves
Specifications .................................................25 Disassembly and Assembly......................... 61
General Specifications .................................25 Valve Seats.................................................. 62
Repair Specifications....................................26 Valve Recession .......................................... 64
Tests and Adjustment Specifications ...........31 Valve Guides ............................................... 64
Operational Tests .........................................31 Valve Springs............................................... 65
Torque Values, Non-Standard Fasteners.....32 Exhaust Manifold ......................................... 65
Special Tools................................................32 Intake Manifold ............................................ 65
Other Materials.............................................32 Grind Valve Seats........................................ 66
Theory of Operation .......................................33 Lap Valves ................................................... 66
Fuel and Air System Operation ....................33 Measure Piston-To-Cylinder Head
Cooling System Operation ...........................34 Clearance .................................................... 66
Lubrication System Operation ......................35 Piston and Connecting Rod ......................... 67
Diagnostics .....................................................36 Piston Inspection ......................................... 70
Engine Troubleshooting ...............................36 Cylinder Bore ............................................... 73
Diagnostic Table...........................................41 Crankshaft Rear Oil Seal ............................. 75
Tests and Adjustments ..................................43 Crankshaft Front Oil Seal ............................ 75
Cylinder Compression Test ..........................43 Crankshaft and Main Bearings .................... 75
Slow Idle Adjustment....................................44 Flywheel and Coupling ................................ 78
Valve Clearance Adjustment ........................44 Camshaft ..................................................... 79
Connecting Rod Side Play Check ................46 Camshaft Followers ..................................... 81
Connecting Rod Bearing Timing Gear Cover ...................................... 83
Clearance Check..........................................46 Idler Gear..................................................... 84
Crankshaft End Play Check .........................47 Timing Gear Cover Mounting Plate ............. 85
Crankshaft Main Bearing Oil Pan and Strainer .................................... 85
Clearance Check..........................................47 Oil Pump ...................................................... 85
Valve Lift Check ...........................................48 Thermostat and Water Pump....................... 86
Camshaft End Play Check ...........................49 Fuel Filter Assembly .................................... 88
Timing Gear Backlash Check.......................49 Component Location Fuel Supply................ 89
Fuel Injection Nozzle Test ............................49 Fuel Injection Pump ..................................... 90
Thermostat Opening Test.............................51 Fuel Injection Nozzles.................................. 92
Injection Pump Static Timing Adjustment.....51 Starting Motor Removal and Installation...... 95
Injection Pump Timing Starting Motor
Adjustment (EPA Engines)...........................53 Disassembly and Assembly......................... 96
Fan/Alternator Drive Belt Adjustment ...........53 Starting Motor Inspection/Test..................... 98
Radiator Bubble Test....................................53 Starting Motor Gear Train ............................ 99
Cooling System Pressure Test.....................54 Starting Motor Solenoid ............................. 101
Radiator Pressure Cap Test.........................54 Alternator Removal and Installation........... 102
Engine Oil Pressure Test .............................55 Alternator Disassembly.............................. 102
Fuel Transfer Pump Tests............................55 Alternator Components.............................. 105
Fuel System Leakage Test...........................56
Bleed Fuel System .......................................56
Repair...............................................................57
Engine Removal ...........................................57
Rocker Cover Removal and Installation .......58
Engine - Diesel Table of Contents - 23

ENGINE - DIESEL TABLE OF CONTENTS
Engine - Diesel Table of Contents - 24

ENGINE - DIESEL SPECIFICATIONS
Specifications
Make. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yanmar
Model 4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNE82A
Model 4310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNE84
Model 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNE88
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-Cycle Diesel
Gross Power:
4210 @ 2600 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2 kW (27.0 hp)
4310 @ 2600 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.2 kW (31.2 hp)
4410 @ 2600 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.8 kW (34.6 hp)
Torque (at rated speed):
4210 @ 2600 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.0 N•m (52.4 lb-ft)
4310 @ 2600 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.5 N•m (57.9 lb-ft)
4410 @ 2600 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.9 N•m (64.8 lb-ft)
Torque (max):
4210 @ 1600 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.4 N•m (61.5 lb-ft)
4310 @ 1700 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.2 N•m (69.5 lb-ft)
4410 @ 1700 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.9 N•m (77.4 lb-ft)
Number of Cylinders (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bore:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 mm (3.23 in.)
4310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 mm (3.31 in.)
4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 mm (3.46 in.)
Stroke:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 mm (3.31 in.)
4310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 mm (3.54 in.)
4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 mm (3.54 in.)
Displacement:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.33 L (81.2 cu in.)
4310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.496 L (91.3 cu in.)
4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.642 L (100.2 cu in.)
Firing Order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3 - 2
Direction of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counterclockwise (viewed from flywheel)
Combustion System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Injection Type
Compression Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5 to 1
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid
Oil Capacity (w/filter):
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approximately 3.82 L (4.04 qt)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approximately 4.31 L (4.55 qt)
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal
Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 950 ± 25 rpm
High Idle (All - No Load). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2810 ± 25 rpm
Engine - Diesel Specifications - 25

Repair Specifications
Valve Train:
Rocker Arm Shaft OD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.97 - 15.98 mm (0.628 - 0.629 in.)
Rocker Arm Shaft Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.95 mm (0.628 in.)
Rocker Arm and Shaft Support Bushing ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.00 - 16.02 mm (0.630 - 0.631 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.09 mm (0.633 in.)
Oil Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 - 0.05 mm (0.001 - 0.002 in)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Push Rod Bend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0 - 0.03 mm (0.0 - 0.001 in.)
Cylinder Head and Valves:

Cylinder Head Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0 - 0.05 mm (0.0 - 0.002 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Intake Valve Seat Width:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36 - 1.53 mm (0.054 - 0.060 in.)
4210 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.98 mm (0.078 in.)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.07 - 1.24 mm (0.042 - 0.049 in.)
4310, 4410 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.74 mm (0.069 in.)
Exhaust Valve Seat Width:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66 - 1.87 mm (0.066 - 0.074 in.)
4210 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 mm (0.089 in.)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24 mm - 1.45 mm (0.042 - 0.049 in.)
4310, 4410 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.94 mm (0.076 in.)
Intake Valve Stem OD:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.95 - 6.96 mm (0.274 - 0.274 in.)
4210 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 mm (0.272 in.)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.96 - 7.98 mm (0.313 - 0.314 in.)
4310, 4410 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 mm (0.311 in.)
Exhaust Valve Stem OD:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.94 - 6.96 mm (0.273 - 0.274 in.)
4210 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 mm (0.272 in.)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.96 - 7.97 mm (0.313 - 0.314 in.)
4310, 4410 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 mm (0.311 in.)
Valve Head Thickness (All):
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24 - 1.44 mm (0.049 - 0.057 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.35 - 1.55 mm (0.053 - 0.061 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.)
Intake Valve Recession:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 - 0.50 mm (0.012 - 0.020 in.)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.31 - 0.51 mm (0.012 - 0.020 in.)
Wear Limit (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.039 in.)
Exhaust Valve Recession (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 - 0.5 mm (0.012 - 0.020 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.039 in.)

Valve Guide Stem-To-Guide Oil Clearance:
Intake (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 - 0.07 mm (0.001 - 0.003 in.)
Exhaust (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.08 mm (0.002 - 0.003 in.)
4210 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
4310, 4410 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Valve Guide ID:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.00 - 7.02 mm (0.275 - 0.276 in.)
4210 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.08 mm (0.279 in.)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.01 - 8.03 mm (0.315 - 0.316 in.)
4310, 4410 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10 mm (0.319 in.)
Valve Guide Projection:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm (0.472 in.)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 mm (0.591 in.)
Valve Spring Free Length:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.4 mm (1.748 in.)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.0 mm (1.654 in.)
Maximum Spring Inclination (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 mm (0.044 in.)
Valve Spring Tension (Measured With Spring Compressed 1.0 mm (0.039 in.):
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.61 - 2.71 kg (7.96 - 5.98 lb)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 - 3.10 kg (5.20 - 6.83 lb)
Valve Seat Surface Angle (All):
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45°
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30°
Valve Timing (All):
Intake Valve Opens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10° - 20° BTDC
Intake Valve Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40° - 50° ABDC
Exhaust Valve Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51° - 61° BBDC
Exhaust Valve Closes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13° - 23° ATDC
Piston-to-Cylinder Head Clearance (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.66 - 0.78 mm (0.026 - 0.031 in.)
Connecting Rod
Large End Bearing ID:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.00 - 46.02 mm (1.811 - 1.812 in.)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 - 51.01 mm (2.008 - 2.008 in.)
Large End Bearing Thickness (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.49 - 1.50 mm (0.059 - 0.059 in.)
Oversize. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.625 mm (0.064 in.)
Oil Clearance:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 - 0.09 mm (0.002 - 0.004 in.)
4210 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 - 0.07 mm (0.002 - 0.003 in.)
4310, 4410 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
Connecting Rod Side Play (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 - 0.4 mm (0.008 - 0.016 in.)
Piston Rings
First Compression Piston Ring Groove Width:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.065 - 2.08 mm (0.081 - 0.082 in.)

4310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.065 - 2.08 mm (0.081 - 0.082 in.)
4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.06 - 2.075 mm (0.081 - 0.082 in.)
First Compression Piston Ring Width (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.97 - 1.99 mm (0.078 - 0.078 in.)
First Compression Ring Minimum Side Clearance:
4210, 4310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.075 - 0.110 mm (0.003 - 0.004 in.)
4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.070 - 0.105 mm (0.003 - 0.004 in.)
Second Compression Piston Ring Groove Width:
4210, 4310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.035 - 2.05 mm (0.080 - 0.081 in.)
4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.025 - 2.04 mm (0.080 - 0.080 in.)
Second Compression Piston Ring Width (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.97 - 1.99 mm (0.078 - 0.078 in.)
Second Compression Piston Ring Minimum Side Clearance:
4210, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.045 - 0.08 mm (0.002 - 0.003 in.)
4310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035 - 0.07 mm (0.001 - 0.003 in.)
Oil Control Piston Ring Groove Width (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.015 - 4.03 mm (0.158 - 0.159 in.)
Oil Control Piston Ring Width (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.97 - 3.99 mm (0.156 - 0.157 in.)
Oil Control Piston Ring Minimum Side Clearance (All). . . . . . . . . . . . . . . . . . . . . . . 0.025 - 0.06 mm (0.001 - 0.002 in.)
Piston Ring End Gap (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.059 in.)
Piston Pin
Piston Pin OD:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.99 - 23.00 mm (0.905 - 0.906 in.)
4210 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.90 mm (0.902 in.)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.99 - 26.00 mm (1.023 - 1.024 in.)
4310, 4410 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.90 mm (1.020 in.)
Piston Pin Bushing ID:
All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.025 - 23.038 mm (0.906 - 0.907 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.10 mm (0.909 in.)
Piston Pin-To-Rod Bore Oil Clearance (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 - 0.047 mm (0.001 - 0.002 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 mm (0.008 in.)
Piston Pin Bore (In Piston) ID
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.00 - 23.008 mm (0.9055 - 0.906 in.)
4210 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.02 mm (0.906 in.)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.00 - 26.009 mm (1.023 - 1.024 in.)
4310, 4410 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.02 mm (1.024 in.)
Piston Pin-To-Piston Oil Clearance:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00 - 0.017 mm (0.0 - 0.0007 in.)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00 - 0.022 mm (0.0 - 0.0009 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)
Piston
Standard Piston OD:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.95 - 81.98 mm (3.226 - 3.227 in.)
4210 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.90 mm (3.224 in.)
4310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.95 - 83.98 mm (3.305 - 3.306 in.)

4310 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.90 mm (3.303 in.)
4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.95 - 87.98 mm (3.462 - 3.464 in.)
4410 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.90 mm (3.461 in.)
Oversize Piston OD:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.20 - 82.23 mm (3.236 - 3.237 in.)
4210 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.144 mm (3.234 in.)
4310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.20 - 84.23 mm (3.315 - 3.316 in.)
4310 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.10 mm (3.311 in.)
4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.20 - 88.23 mm (3.472 - 3.474 in.)
4410 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.10 mm (3.469 in.)
Cylinder Bore ID
Standard Bore ID:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.00 - 82.03 mm (3.228 - 3.229 in.)
4210 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.20 mm (3.236 in.)
4310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.00 - 84.03 mm (3.307 - 3.308 in.)
4310 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.20 mm (3.315 in.)
4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.00 - 88.03 mm (3.465 - 3.466 in.)
4410 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.20 mm (3.472 in.)
Oversize Bore ID:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.25 - 82.28 mm (3.238 - 3.239 in.)
4310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.25 - 84.28 mm (3.317 - 3.318 in.)
4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.25 - 88.28 mm (3.474 - 3.476 in.)
Piston-to-Cylinder Clearance:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035 - 0.065 mm (0.014 - 0.0026 in.)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040 - 0.070 mm (0.0016 - 0.0027 in.)
Cylinder Roundness (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.01 - 0.03 mm (0 - 0.001 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.)
Cylinder Taper (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00 - 0.01 mm (0 - 0.0004 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.)
Deglazing (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° crosshatch pattern
Deboring (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° crosshatch pattern
Crankshaft and Main Bearings

Connecting Rod Crankshaft Journal OD:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.95 - 42.96 mm (1.691 - 1.691 in.)
4210 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.91 mm (1.689 in.)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.95 - 47.96 mm (1.888 - 1.888 in.)
4310, 4410 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.91 mm (1.886 in.)
Main Bearing Journal OD:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.95 - 46.96 mm (1.848 - 1.849 in.)
4210 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.91 mm (1.847 in.)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.95 - 53.96 mm (2.124 - 2.124 in.)
4310, 4410 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.91 mm (2.122 in.)

Main Bearing Oil Clearance:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 - 0.09 mm (0.002 - 0.004 in.)
4210 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 - 0.07 mm (0.002 - 0.003 in.)
4310, 4410 (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
Crankshaft Bend (Maximum - All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.001 in.)
Crankshaft End Play (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 - 0.27 mm (0.004 - 0.011 in.)
Camshaft
Camshaft End Play (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.25 mm (0.002 - 0.010 in.)
Camshaft Bend (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 0.02 mm (0 - 0.001 in.)
Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Camshaft Side Gap (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.25 mm (0.002 - 0.010 in.)
Lobe Height (Intake and Exhaust - All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.64 - 38.77 mm (1.521 - 1.526 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.40 mm (1.512 in.)
Bearing Journal OD (All):
Flywheel Side and Gear Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.93 - 44.95 mm (1.769 - 1.770 in.)
Intermediate Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.91 - 44.94 mm
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.85 mm (1.766 in.)
Oil Clearance (Gear and Flywheel Ends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 - 0.13 mm (0.002 - 0.005 in.)
Oil Clearance (Intermediate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 - 0.12 mm (0.003 - 0.005 in.)
Camshaft Followers
Stem OD (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.98 - 11.99 mm (0.471 - 0.472 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.93 mm (0.470 in.)
Bore ID (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.00- 12.02 mm (0.472 - 0.473 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.05 mm (0.474 in.)
Oil Clearance (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.01 - 0.04 mm (0.0004 - 0.0016 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)
Idler Gear
Shaft OD (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.95 - 45.98 mm (1.809 - 1.810 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.93 mm (1.808 in.)
Bushing ID (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.00 - 46.03 mm (1.811 - 1.812 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.08 mm (1.814 in.)
Clearance (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Oil Pump
Rotor Shaft OD to Side Cover Hole ID Clearance (All) . . . . . . . . . . . . . . . . . . . . . . . . 0.01 - 0.04 mm (0.001 - 0.002 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.08 in.)
Inner Rotor and Outer Rotor-to-Pump Body Side Clearance:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.10 mm (0.002 - 0.004 in.)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.09 mm (0.001 - 0.004 in.)
Wear Limit (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Outer Rotor to Pump Body Clearance (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.16 mm (0.004 - 0.006 in.)

Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Inner Rotor to Outer Rotor Clearance Wear Limit (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Tests and Adjustment Specifications

Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 - 0.25 mm (0.006 - 0.010 in.)
Connecting Rod Side Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 - 0.4 mm (0.008 - 0.016 in.)
Connecting Rod Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 - 0.07 mm (0.002 - 0.003 in.)
Crankshaft End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 - 0.27 mm (0.004 - 0.011 in.)
Crankshaft Main Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 - 0.07 mm (0.001 - 1.003 in.)
Camshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.25 mm (0.002 - 0.010 in.)
Timing Gear Backlash:
All Except Oil Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 - 0.15 mm (0.003 - 0.005 in.)
Oil Pump Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.11 - 0.19 mm (0.004 - 0.008 in.)
Fuel Injection Nozzle:
Opening Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19600 + 1000/-0 kPa (2843 + 145/-0 psi)
Leakage at 11032 kPa (1600 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .None for a minimum of 10 seconds
Chatter and Spray Pattern at 19600 ± 1000 kPa (2843 ± 145 psi):
Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chatter Sound
Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Stream
Fast Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Atomized Spray; 150° Spray Pattern
Alternator Drive Belt Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15 mm (0.4 - 0.6 in.)
Fuel Injection Pump Timing:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12° ± 1° BTDC
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11° ± 1° BTDC
Operational Tests
Cooling System Test Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 ± 15 kPa (12.8 ± 2.2 psi)
Thermostat Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69.5 - 72.5° C (157 - 163° F)
Minimum Lift Height above 85° C (185° F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 mm (0.135 in.)
Radiator Cap Opening Pressure (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9 ± 0.15 kg/cm2 88 ± 15 kPa (12.8 ± 2.2 psi)
Cylinder Compression Pressure @250 RPM:
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3334 kPa (483 psi)
4210 (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3138 kPa (455 psi)
4310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3334 kPa (483 psi)
4310 (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3138 kPa (455 psi)
4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3530 kPa (512 psi)
4410 (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3334 kPa (483 psi)
Difference Between Cylinders (Maximum - All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 kPa (42 psi)
Oil Pressure:
4210 (Rated Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 ± 50 kPa (42 ± 7.2 psi)
4310, 4410 (Rated Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338 ± 50 kPa (49 ± 7.2 psi)
Slow Idle (All - Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 kPa (8.7 psi)
Oil Relief Valve Opening Pressure (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 - 392 kPa (43 - 57 psi)
Oil Pressure Switch Opening Pressure (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 - 62 kPa (6 - 9 psi)

Torque Values, Non-Standard Fasteners
Cylinder Head Bolts (Lubricating Oil Applied):
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 - 71 N•m (49 - 52 lb-ft)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 - 91 N•m (63 - 67 lb-ft)
Connecting Rod Bolts (Lubricating Oil Applied):
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 - 41 N•m (27 - 30 lb-ft)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 - 54 N•m (33 - 40 lb-ft)
Flywheel Mounting Bolts (All - Lubricating Oil Applied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 - 88 N•m (62 - 65 lb-ft)
Main Bearing Bolts (Lubricating Oil Applied):
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.5 - 80.4 N•m (56 - 59 lb-ft)
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 - 100 N•m (71 - 74 lb-ft)
Crankshaft Pulley Bolt (All - Lubricating Oil Applied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 - 122 N•m (83 - 90 lb-ft)
Fuel Injector Nozzle Nut (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 - 8.8 N•m (60 - 78 lb-in.)
Governor Weight Support Nut (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 - 49 N•m (33 - 36 lb-ft)
Rocker Arm Mounting Cap Screw and Nut (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (19 lb-ft)
Oil Pump Mounting Cap Screw (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (18 lb-ft)
Starting Motor Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N•m (35 lb-ft)
Special Tools
NOTE: Order tools according to information given in the U.S. SERVICE-GARD™ Catalog or in the European
Microfiche Tool Catalog (MTC).
Number Name Use
D15001NU Magnetic Follower Holder Kit Hold cam followers when removing and installing
camshaft
JDF13 Nozzle Cleaning Kit Use to clean fuel injection nozzles.
D-20019WI Valve Guide Knurler Use to knurl inside diameter of valve guides.
JDE118 Valve Guide Driver Use to remove and install valve guides in cylinder head.
D-20021WI Valve Guide Reamer Use to ream out valve guides.
Other Materials
Number Name Use
TY15130 LOCTITE® John Deere Form-In-Place Gasket Seals rear oil seal case and flywheel
housing to engine block. Seals oil pan
to timing gear housing and engine
block.
TY9370 LOCTITE® No. 242 Thread Lock and Sealer (Medium Apply to threads of crankshaft pulley
Strength) cap screw.
LOCTITE® is a registered trademark of the Loctite Corp.

ENGINE - DIESEL THEORY OF OPERATION
Theory of Operation The injection nozzle prevents flow until high pressure is
reached, opening the valve and spraying atomized fuel into
the combustion chamber. Injection lines contain trapped
Fuel and Air System Operation fuel whenever injection is not taking place.
Function: A small amount of fuel leaks past the nozzle valve to
lubricate the fuel injection nozzle. This leakage combines
Fuel system supplies fuel to injection nozzles.
with excess fuel from the injection pump and is returned to
The air intake system filters and supplies air needed for tank. Any air in the fuel system is bled out with return fuel to
combustion. the fuel tank.
Theory of Operation: A fuel level sensor mounted in the fuel tank informs the
operator of the fuel level.
Air Intake System:

Engine intake air enters the inlet hose (A) behind the grille,
and flows into the air filter body (B). The air cleaner also
E has a rubber, one way, unloading valve (C), that ejects
heavy dirt particles from the air stream during engine
operation before they reach the filters. The operator can
D squeeze the valve to remove the large particles. The air
cleaner elements filter the air, which then flows through
hose (D) to the intake manifold.
B
C An air filter restriction indicator (E) at the rear of the air
cleaner informs the operator when the air filter needs
servicing.
M94772
Fuel System:
A mechanical fuel transfer pump (A) draws fuel from the
tank outlet. The low pressure fuel from the fuel pump flows
through the filter/water separator (B) to the fuel the injector
pump inlet (C). The injection pump then directs high
pressure fuel through the injector lines (D) for combustion.
Excess fuel is returned, along with fuel from the injectors,
through the return line (E) to the fuel tank.
If the unit runs out of fuel, there are two air bleed lines that
allow air to escape from the top of the filter and the injection
pump. These two lines allow the system to be self bleeding.
The engine speed is controlled by the throttle lever and rod.
The rod is connected to the injection pump governor control
lever. The fuel shutoff solenoid controls the injection pump
shutoff shaft. When the solenoid is retracted (key in the
START or ON position), the engine can be started. When
the key is turned off, return springs on the shutoff shaft,
extend the solenoid, moving the shutoff linkage to the
shutoff position. The solenoid also closes if the machine is
operated in an unsafe condition. See “Engine Shutoff
Circuit Operation” in the Electrical section.
The injection pump meters fuel as determined by the
governor and delivers it at high pressure to the injection
nozzles.
Engine - Diesel Theory of Operation - 33

Cooling System Operation
MX1026 When coolant system pressure exceeds 88.3 kPa (12.8

psi), a valve in the radiator cap opens to allow coolant to
Function: discharge into the coolant recovery tank.
The coolant pump circulates coolant through the cooling When temperature is reduced, a vacuum is produced in the
system, drawing hot coolant from the engine block, radiator and coolant is drawn back out of the coolant
circulating it through the radiator for cooling. recovery tank through a valve in the radiator cap.
Theory of Operation: A coolant temperature sensor informs the operator of the
engine coolant temperature and warns of a high
The pressurized cooling system includes the radiator, water
temperature condition by lighting a lamp.
pump, fan and thermostat.
During the warm-up period, the thermostat remains closed Thermostat Settings:
and the impeller type coolant pump draws coolant from the Start To Open . . . . . . . . . . . . 69.5 - 72.5° C (157 - 163° F)
bypass tube. Coolant from the pump flows to the cylinder
block water jacket and up through the cylinder head Fully Opened . . . . . . . . . . . . . . . . . . . . . . . 85° C (185° F)
providing a fast warm-up.
Once the engine has reached operating temperature, the
thermostat opens and coolant is pumped from the bottom
of the radiator via the lower radiator hose into the cylinder
block. Here it circulates through the block and around the
cylinders.
From the block, coolant is then directed through the
cylinder head, and into thermostat housing. With the
thermostat open, warm engine coolant passes through the
housing into the top of the radiator where it is circulated to
dissipate heat.

Lubrication System Operation
A
L C
D
J
I
E
F
PUMP PRESSURE OIL
PRESSURE FREE OIL
MIF A drilled passage from the rear camshaft bearing through

the cylinder block and cylinder head supplies lubricating oil
Function: to the rocker arm shaft (B). The hollow shaft distributes oil
A full pressure system lubricates engine parts with filtered to the rocker arms (A), cam followers and valves.
oil. Lubrication oil is supplied to the fuel injection pump (H)
from the main oil galley through external oil lines.
Theory of Operation:
An oil pressure sensor (K) activates an indicator light to
The pressure lubrication system consists of a positive
alert the operator to shut down the engine if oil pressure
displacement gear-driven pump (F), oil strainer (G), full flow
drops below specification.
oil filter (J), oil pressure regulating valve and an electrical
pressure warning switch. (K)
The pump draws lubrication oil from the oil pan through a
strainer and a suction tube. The oil is then pumped through
an oil passage to the oil filter and through the engine block
main oil galley (L).
From the main oil galley, oil is forwarded under pressure to
the crankshaft main bearing journals (C) and idler gear
bushing (E). Drilled cross-passages in the crankshaft (I)
distribute the oil from the main bearings to connecting rod
bearings.
Lube oil holes in main bearing oil grooves direct oil to the
camshaft bearings (D).

ENGINE - DIESEL DIAGNOSTICS
Diagnostics Symptom: Engine Starting Problems
Yes - Engine starting procedure ok. Go to next
Engine Troubleshooting procedure.
c CAUTION: Avoid Injury! Engine radiator Symptom: Engine Starts But Does Not
Continue Running
fluid is extremely hot during operation.
(1) Exhaust smoke absent?
c CAUTION: Avoid Injury! The engine may No - Go to next step.

Yes - Fuel filter clogged - replace fuel filter.
start to rotate at any time. Keep hands away
from all moving parts when testing. Yes - Clogged or cracked fuel lines - clean or
replace fuel lines.
Engine System
Yes - Water in fuel - check and repair.
Symptom: Engine Starting Problems Yes - Air entering fuel system - check and repair
(1) Engine starts? fuel supply system.
No - Battery voltage low - recharge battery. Yes - Fuel volume to injection pump low - check or
replace fuel transfer pump.
No - Starting motor defective - repair or replace
starting motor. Yes - Improper engine oil viscosity/type - replace
engine oil and filter.
No - Alternator defective - repair or replace
alternator. Yes - Improper intake or exhaust valve clearance -
adjust valve clearance.
No - Open circuit in wiring - repair wiring.
Yes - Crankshaft pin or bearing seized - regrind
No - Fuel filter clogged - replace fuel filter.
crank and replace bearings.
No - Clogged or cracked fuel lines - clean or
Yes - Piston ring end gaps not correct - stagger
replace fuel lines.
piston ring gaps.
No - Fuel volume to injection pump low - check or
Yes - Governor not functioning properly - repair or
replace governor.
No - Water in fuel - check and repair.
Yes - Improper intake or exhaust valve clearance -
No - Improper engine oil viscosity/type - replace adjust valve clearance.
(2) Excess exhaust smoke?
No - Improper intake or exhaust valve clearance -
Yes - Clogged air filter - clean or replace air filter.
Yes - Seized intake/exhaust valve - replace valve
No - Improper timing between injection pump,
and check valve guide.
intake and exhaust valves - adjust valve clearance.
Check valve timing. Yes - Seized intake/exhaust valve - replace valve
No - Seized intake/exhaust valve - replace valve
and check valve guide. Yes - Broken or seized piston ring - replace rings
and check cylinder.
No - Broken or seized piston ring - replace rings
and check cylinder. Yes - Piston ring, piston or cylinder worn - bore or
hone cylinder and replace piston.
No - Piston ring, piston or cylinder worn - bore or
Symptom: Low Engine Output
No - Crankshaft pin or bearing seized - regrind
(1) Exhaust color NORMAL?
No - Go to next step.
No - Air entering fuel system - check and repair
fuel supply system. Yes - Fuel filter clogged - replace fuel filter.
Engine - Diesel Diagnostics - 36

Symptom: Low Engine Output Symptom: Low Engine Output
Yes - Air entering fuel system - check and repair (3) Exhaust color BLACK?
fuel supply system.
Yes - Clogged or cracked fuel lines - clean or
Yes - Water pump/alternator belt loose - adjust fan
replace fuel lines.
belt tension.
Yes - Improper intake or exhaust valve clearance -
Yes - Engine running too hot - check thermostat,
fan belt tension.
Yes - Compression leakage from valve seat - grind
Yes - Improper timing between injection pump,
valve seat; regrind valves.
Yes - Seized intake/exhaust valve - replace valve Check valve timing.
Yes - Coolant level low - check cooling system for
Yes - Leaking cylinder head gasket - replace head level/leaks.
gasket.
Yes - Malfunctioning thermostat - check or replace
Yes - Crankshaft pin or bearing worn - regrind thermostat.
Yes - Engine at high altitude/temperature - use
Yes - Improper engine oil viscosity/type - replace higher output engine.
Yes - Clogged exhaust pipe - clean exhaust pipe.
Yes - Wrong type of fuel - drain and replace fuel.
Yes - Retarded fuel injection pump timing - check
Yes - Fuel volume to injection pump low - check or and adjust fuel injection pump timing.
Yes - Uneven volume of fuel injected - check fuel
(2) Exhaust color WHITE? injector pump and injectors.
No - Go to next step. Yes - Poor fuel injection pattern - clean or replace
fuel injector nozzles.
Yes - Poor fuel injection pattern - clean or replace
Yes - Retarded fuel injection pump timing - check
and adjust fuel injection pump timing.
injector pump and injectors.
Symptom: Exhaust Problems
Yes - Broken or seized piston ring - replace rings
and check cylinder. (1) Exhaust color WHITE under load?
Yes - Piston ring, piston or cylinder worn - bore or No - Go to next step.

hone cylinder and replace piston. Yes - Water in fuel - check and repair.
Yes - Piston ring end gaps not correct - stagger Yes - Engine running too cool - check thermostat.
piston ring gaps.
Yes - Piston rings installed incorrectly - install
piston rings correctly. Yes - Poor fuel injection pattern - clean or replace
Yes - Intake/Exhaust valves worn - check valve
guides and stems. Yes - Uneven volume of fuel injected - check fuel
Yes - Improper timing between injection pump,
intake and exhaust valves - adjust valve clearance. Yes - Improper timing between injection pump,
Check valve timing. intake and exhaust valves - adjust valve clearance.
Check valve timing.

Symptom: Exhaust Problems Symptom: Engine Runs Rough
Yes - Retarded fuel injection pump timing - check Yes - Improper timing between injection pump,
and adjust fuel injection pump timing. intake and exhaust valves - adjust valve clearance.
Check valve timing.
Yes - Advanced fuel injection pump timing - check
and adjust fuel injection pump timing. Yes - Improper intake or exhaust valve clearance -
and check cylinder. Yes - Compression leakage from valve seat - grind
Yes - Piston ring, piston or cylinder worn - bore or
hone cylinder and replace piston. Yes - Seized intake/exhaust valve - replace valve
piston rings correctly. Yes - Broken or seized piston ring - replace rings
and check cylinder.
(2) Exhaust color BLACK under load?
Yes - Engine at high altitude/temperature - use
higher output engine.
Yes - Crankshaft pin or bearing worn - regrind
Yes - Connecting rod bolt loose - check for
Yes - Clogged exhaust pipe - clean exhaust pipe. damage and re-torque bolts.
Yes - Excessive volume of fuel injected - check Yes - Foreign matter in combustion chamber -
fuel injector pump and injectors. remove head and inspect for damage.
Yes - Advanced fuel injection pump timing - check Yes - Excessive timing gear backlash - measure
and adjust fuel injection pump timing. timing gear backlash.
Yes - Retarded fuel injection pump timing - check (3) Uneven combustion sound?
Yes - Clogged exhaust pipe - clean exhaust pipe.
injector pump and injectors. Yes - Water in fuel - check and repair.
Yes - Improper timing between injection pump, Yes - Wrong type of fuel - drain and replace fuel.
Check valve timing.
(4) Engine surges during idle?
Symptom: Engine Runs Rough Yes - Water in fuel - check and repair.
(1) Loud knocking noise during combustion? Yes - Uneven volume of fuel injected - check fuel
No - Go to next step. injector pump and injectors.
Yes - Advanced fuel injection pump timing - check Yes - Poor fuel injection pattern - clean or replace
and adjust fuel injection pump timing. fuel injector nozzles.
(2) Misfiring Yes - Broken or seized piston ring - replace rings
and check cylinder.

Symptom: Engine Runs Rough Symptom: Engine Runs Rough
Yes - Crankshaft pin or bearing worn - regrind Yes - Go through diagnostic procedures and/or go
crank and replace bearings. back to steps procedures for “Engine Runs
Rough”.
replace governor.
Fuel Consumption
(5) Engine surges UNDER LOAD?
System: Fuel Consumption Excessive
(1) Excessive fuel consumption?
Yes - Poor fuel injection pattern - clean or replace valve seat; regrind valves.
Yes - Engine running too cool - check thermostat.
injector pump and injectors. Yes - Excessive volume of fuel injected - check
fuel injector pump and injectors.
replace governor. Yes - Poor fuel injection pattern - clean or replace
and check valve guide. No - Go through diagnostic procedures.

Lubrication
Yes - Crankshaft pin or bearing worn - regrind System: Lubricating Oil
crank and replace bearings. (1) Excessive oil consumption?
(6) Excessive engine vibration? No - Go to next step.
No - Go to next step. Yes - Broken or seized piston ring - replace rings
Yes - Poor fuel injection pattern - clean or replace and check cylinder.
fuel injector nozzles. Yes - Piston ring, piston or cylinder worn - bore or
Yes - Uneven volume of fuel injected - check fuel hone cylinder and replace piston.
injector pump and injectors. Yes - Piston ring end gaps not correct - stagger
Yes - Seized intake/exhaust valve - replace valve piston ring gaps.
and check valve guide. Yes - Piston rings installed incorrectly - install
Yes - Broken or seized piston ring - replace rings piston rings correctly.
and check cylinder. Yes - Foreign matter in combustion chamber -
Yes - Crankshaft pin or bearing seized - regrind remove head and inspect for damage.
crank and replace bearings. Yes - Intake/Exhaust valves worn - check valve
Yes - Crankshaft pin or bearing worn - regrind guides and stems.
crank and replace bearings. Yes - Improper engine oil viscosity/type - replace
Yes - Connecting rod bolt loose - check for engine oil and filter.
damage and re-torque bolts. Yes - External/Internal oil leak - repair.
Yes - Governor not functioning properly - repair or Yes - Excessive volume of fuel injected - check
replace governor. fuel injector pump and injectors.
Yes - Advanced fuel injection pump timing - check (2) Fuel in crankcase?
(7) Poor return to low speed?
Yes - Governor not functioning properly - repair or and check cylinder.
replace governor.

System: Lubricating Oil Symptom: Temperature Problems
Yes - Seized intake/exhaust valve - replace valve Yes - Water pump/alternator belt loose - adjust fan
and check valve guide. belt tension.
Yes - Piston ring, piston or cylinder worn - bore or Yes - Excessive volume of fuel injected - check
hone cylinder and replace piston. fuel injector pump and injectors.
(3) Water in crankcase? Yes - Engine at high altitude/temperature - use
higher output engine.
(2) Low water temperature?
Yes - Leaking cylinder head gasket - replace head
gasket. Yes - Engine running too cool - check thermostat.
Yes - Cracked water jacket - repair or replace Yes - Malfunctioning thermostat - check or replace
water jacket. thermostat.
(4) Low oil pressure?
Compression
Yes - Oil level low - add oil.
Symptom: Overall Compression Problems
Yes - Oil filter clogged - replace oil filter.
(1) Low Compression?
Yes - Improper engine oil viscosity/type - replace
engine oil and filter. Yes - Oil filter clogged - replace oil filter.
Yes - External/Internal oil leak - repair. Yes - Improper engine oil viscosity/type - replace
Yes - Crankshaft pin or bearing worn - regrind
crank and replace bearings. Yes - Excessive volume of fuel injected - check
fuel injector pump and injectors.
Yes - Connecting rod bolt loose - check for
damage and re-torque bolts. Yes - Compression leakage from valve seat - grind
Yes - Cracked water jacket - repair or replace
water jacket. Yes - Seized intake/exhaust valve - replace valve
Yes - Oil pressure relief valve worn - clean, adjust
or replace relief valve. Yes - Broken or seized piston ring - replace rings
and check cylinder.
Coolant Yes - Piston ring, piston or cylinder worn - bore or
Symptom: Temperature Problems
(1) Overheating?
Yes - Piston ring end gaps not correct - stagger
Yes - Leaking cylinder head gasket - replace head piston ring gaps.
gasket.
Yes - Broken or seized piston ring - replace rings piston rings correctly.
and check cylinder.
Yes - Foreign matter in combustion chamber -
Yes - Engine running too hot - check thermostat, remove head and inspect for damage.
fan belt tension.
Yes - Intake/Exhaust valves worn - check valve
Yes - Coolant level low - check cooling system for guides and stems.
level/leaks.
Yes - Cracked water jacket - repair or replace
Symptom: Intake Manifold Pressure Problem
water jacket. (1) Low pressure?
Yes - Malfunctioning thermostat - check or replace No - Go to next step.
thermostat.

Symptom: Intake Manifold Pressure Problem Symptom: Intake Manifold Pressure Problem
Yes - Improper intake or exhaust valve clearance - Yes - Excessive volume of fuel injected - check fuel
adjust valve clearance. injector pump and injectors.
valve seat; regrind valves. Diagnostic Table
Yes - Seized intake/exhaust valve - replace valve and
Test Conditions:
check valve guide.
• Machine parked on level surface.
• Park brake engaged.
Yes - Engine at high altitude/temperature - use higher
output engine. • Key switch off unless indicated otherwise.
(2) High pressure?
Test/Check Point Normal Condition If Not Normal
Engine dipstick and exterior engine Oil level between “L” and “H” marks. Change oil and inspect for
surface source of contamination.
Oil not burnt, or contaminated with metal Check gaskets, seals, plugs,
particles, fuel, or coolant. cylinder head, block, and
intake manifold and
breather.
No external leakage, filter clean. Change oil filter.
Coolant tank and radiator Coolant level between marks on tank when Add proper coolant mix.
engine is warm.
Coolant in radiator full to top.
Coolant not contaminated with oil, fuel or Drain and flush system.
discolored brown. Check for source of
contamination.
Radiator screen free of debris. Clean or replace.
Hoses not cracked or leaking; clamps and Pressure test radiator and
radiator cap tight. cap.
Water pump/alternator belt tight; not glazed Replace and adjust belt
or cracked. tension.
Fan blades not damaged or warped. Replace fan.
Fuel tank, pump, lines, filter, filter Fuel level correct, not contaminated; correct Drain and clean fuel tank.
shutoff valve grade of fuel; no water or debris in filter Add fresh fuel. Replace
bowl/water separator. filters.
Filter shutoff valve in “ON” position. Move to “ON” position.
Fuel hoses not cracked or leaking. Replace.
Fuel hose clamps tight. Replace or tighten.
Fuel tank does not have vacuum. Replace fuel tank vent hose.

Air filter and air intake Air filter outlet hose not cracked; clamps Replace hose and/or tighten
tight. clamps.
Elements not plugged. Air filter housing Replace element or housing.
sealed; no dirt tracking inside filter element.
Replace indicator.
Air filter restriction indicator not leaking
Fuel shutoff solenoid (Key in “START” Fuel shutoff solenoid must pull in and stay in If solenoid will not pull in and
position when key is returned to “ON”. Listen for hold in, see Fuel Shutoff
clicking as key is cycled. Solenoid Circuit Diagnosis in
Electrical section.
Fuel filter/water separator Fuel level visible in filter bowl. Drain water from bowl.
Fuel bowl not full of water. Replace fuel filter. Recheck.
Fuel present at injector pump inlet hose. Test fuel pump.
Hand throttle control lever linkage. Full movement of governor control arm from Repair; replace or adjust
Throttle pedal linkage (gear only). idle to full speed. linkage.
GEAR ONLY; Pedal stop on frame under
foot pedal adjusted correctly.
Intake and exhaust valves Valve clearance within specification (engine Adjust valves. See “Tests
cold). and Adjustments” in this
section.
Valves not sticking. Check valve guides and
stems.
Fuel is reaching injectors Crack fuel injection lines at injectors. Crank No fuel present: Check fuel
engine. (Be sure fuel shutoff solenoid has shutoff valve is open, fuel
pulled in.) Fuel leaks out. level in tank, inspect filter/
separator element. Test fuel
pump.
Injectors are working properly Injector spray pattern is normal and Check spray pattern and
cracking pressure is within specifications. cracking pressure. See
“Tests and Adjustments” in
this section. Replace
injectors.
Perform cylinder compression test at Cylinder compression within specification. Rebuild engine.
fuel injector ports Pressure difference between cylinders
within specification.
Flywheel and starting motor Minimum cranking rpm within specification. See “Starter Amp Draw Test”
in Electrical section.
Fuel injection pump static timing test Timing should be correct. Have injection pump static
(Remove pump as the LAST possible timing adjustment performed
solution.) by a qualified service repair
shop. See “Tests and
Adjustments” in this section.
Injection pump slow idle speed Engine runs at 1000 ± 25 rpm. See “Slow Idle Adjustment”
(engine running) in this section.

ENGINE - DIESEL TESTS AND ADJUSTMENTS
Injection pump fast idle speed Engine runs at 2850 ± 25 rpm. See “Fast Idle Speed
(engine running) Adjustment” in this section.
Governor Engine runs smoothly through out rpm Have governor torque
range with low smoke and good power. capsule adjusted by a
certified CARB/EPA service
center.
Oil pressure sender port Oil pressure to specification. Test engine oil pressure.
See “Tests and Adjustments”
in this section.
Thermostat Opening temperature within specification. Perform thermostat opening

test. See “Tests and
Adjustments” in this section.
Muffler Not restricted. Replace muffler.
Tests and Adjustments JDG560 Adapter.

4. Disconnect the fuel control solenoid connector.
Cylinder Compression Test
IMPORTANT: Avoid damage! DO NOT overheat
Reason: starting motor during test.
To determine the condition of the pistons, rings, cylinder 5. Crank the engine for five seconds with the starting
walls and valves. motor. Minimum cranking speed is 250 rpm.
Equipment: 6. Record the pressure reading for each cylinder.
• JT01682 Compression Gauge Assembly Specifications:
• JDG560 Adapter Cylinder Compression Pressure
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3334 kPa (483 psi)
Procedure:
4210 (Minimum) . . . . . . . . . . . . . . . . . 3138 kPa (455 psi)
1. Remove the injection nozzles.
4310 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3334 kPa (483 psi)
4310 (Minimum) . . . . . . . . . . . . . . . . . 3138 kPa (455 psi)
4410 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3530 kPa (512 psi)
4410 (Minimum) . . . . . . . . . . . . . . . . . 3334 kPa (483 psi)
Difference Between Cylinders
(Maximum- All) . . . . . . . . . . . . . . . . . . . . 294 kPa (42 psi)
Results:
• If the pressure reading is below specification, perform
“Radiator Bubble Test” to help determine the cause of
A
compression loss.
B
T6333EU
2. Install the heat protector from end of injector and install

JDG560 adapter (A).
3. Install JT01682 Compression Gauge Assembly (B) and
Engine - Diesel Tests and Adjustments - 43

Slow Idle Adjustment Results:
IMPORTANT: Avoid damage! The slow idle

adjustment is the only adjustment that can be B
made on this engine.
The fast idle and torque capsule adjustments are

pre-set by the engine manufacturer to comply
with strict EPA/CARB emissions requirements,
and are adjustable ONLY by authorized diesel
service facilities. A
Reason:
To achieve proper slow idle rpm setting. Provides adequate
rpm to keep the engine running smoothly without stalling.
MX9887
Equipment:
• If the slow idle rpm is not according to specifications,
• JT05719 Hand Held Digital Tachometer
loosen the nut (A) and turn the slow idle stop screw (B)
NOTE: Make sure the air cleaner is clean and not clockwise to increase the engine speed, or
restricted. Replace the air cleaner element as counterclockwise to decrease the engine speed until the
necessary. slow idle speed is correct. After adjustment, tighten the nut.
Procedure: Valve Clearance Adjustment

1. Place a small piece of reflective tape on the crankshaft
pulley. Reason:
2. Start the engine and run for 5 minutes to attain To be sure the valves are fully opening and closing at the
operating temperature. correct time, and not wearing the valve train unnecessarily.
3. Move the throttle lever to slow idle position. Equipment:
4. Use JT05719 Hand Held Digital Tachometer to check • Feeler Gauge
engine speed at the crankshaft pulley.
• 10 mm End Wrench
5. Visually check that the injection pump throttle lever is
against slow idle stop screw. Slow idle speed is set to • Flat Blade Screwdriver
specification. • 17 mm Wrench
Specifications: Procedure:
SST and ePowrReverser Machines . . . . . . 950 ± 50 rpm 1. The engine must be cool (room temperature) before the
eHydro Machines . . . . . . . . . . . . . . . . . . . 1000 ± 50 rpm valve clearance is checked.
2. Be sure ignition key is OFF before attempting to turn
engine by hand.
3. Open the hood and remove the engine side covers.
4. Remove the rocker arm cover. See “Rocker Cover
Removal and Installation” on page 58.

14° Direction
BTDC of Engine
Rotation
12°
BTDC
Center Line
1
T6105BF
Flywheel Timing Marks
9. To adjust the valves, loosen the lock nut (D) and turn the
MIF
adjusting screw (C) until the blade of the feeler gauge can
5. Locate the inspection hole in right side of the be inserted between the rocker arm and valve cap. Hold the
transmission tunnel. The flywheel can be seen inside the adjusting screw while tightening the lock nut.
inspection hole.
10.Recheck the valve clearance after tightening the lock
NOTE: “Top dead center (TDC)” is when the piston is at nut.
its’ highest point of travel in the cylinder on the
compression stroke. Specification:
Number one cylinder is located at rear of engine Valve Clearance . . . . . 0.15 - 0.25 mm (0.006 - 0.010 in.)
(flywheel side).
6. Turn the crankshaft pulley while watching the flywheel
inside the inspection hole. Align the number one TDC mark
(A) on the flywheel with the pointer on the tunnel.
NOTE: When top dead center is reached, the rocker
arms for that cylinder will be motionless as the
crankshaft if rotated. If rocker arms are still moving
when TDC is approached, rotate crankshaft one full Normal Not Normal
revolution and try again. MIF
7. Try to move rocker arms and/or push rods for No. 1 11.Check that the valve cap on the valve stem remained
cylinder: seated on the valve and inside the valve spring retainer.
• If the rocker arms and push rods are loose, the piston 12.Turn the crankshaft pulley counter clockwise (as viewed
is at TDC on the compression stroke. Go to step 8. from operator’s seat or flywheel end) approximately 2/3 of a
• If the rocker arms and/or push rods are not loose, revolution (240°) while watching the observation hole for
rotate the flywheel one revolution (360°), and recheck the number three timing mark.
the rocker arms and push rods. 13.Check that the rocker arms and push rods for cylinder
number three are loose.
C 14.Repeat steps 7 - 13 for number three cylinder.
15.Repeat steps 7 - 11 for number two cylinder.
D
16.Replace the rocker arm cover, air cleaner bracket and
housing, and the muffler.
17.Replace the engine side covers and hood.
B
MX1194
8. Slide a feeler gauge between the valve cap (B) and

rocker arm to measure the clearance.

Connecting Rod Side Play Check Procedure:
1. Remove the oil pan, and oil pickup.
Reason:
To determine proper side clearance between the crankshaft IMPORTANT: Avoid damage! The connecting rod
and the connecting rod. caps must be installed on the same connecting
rod and in the same direction to prevent
Equipment: crankshaft and connecting rod damage.
• Feeler Gauge
2. Remove the connecting rod cap.
NOTE: The engine must be removed from the machine 3. Wipe oil from the bearing insert and the crankshaft
to perform this test. journal.
Procedure: 4. Put a piece of PLASTIGAGE® (A), or an equivalent,
along the full length of the bearing insert approximately 6
1. Remove the oil pan, crankcase extension, oil pick-up,
mm (0.25 in.) off center.
and balancer assembly.
2. Insert a feeler gauge, according to specifications,
between the connecting rod cap and the crankshaft.
M35351
5. Turn the crankshaft approximately 30° from bottom dead

center.
6. Install the connecting rod end cap and original rod bolts.
Tighten the rod bolts to specification.
Specifications:
M82116A Connecting Rod Bolt Torque

4210 . . . . . . . . . . . . . . . . . . . . . 37 - 41 N•m (27 - 30 lb-ft)
3. Connecting rod side play is 0.2 - 0.4 mm (0.008 - 0.016
in.). 4310, 4410 . . . . . . . . . . . . . . . . 44 - 54 N•m (33 - 40 lb-ft)
Results: 7. Remove the rod bolts and the connecting rod cap.
• If the side play exceeds specification, replace the NOTE: The flattened PLASTIGAGE® (A) will be found
bearing inserts or the connecting rod. on either the bearing insert or crankshaft journal.
8. Use the graduation marks on the envelope (C) to
Connecting Rod Bearing Clearance Check compare the width of the flattened PLASTIGAGE at its
widest point. The number within the graduation marks
Reason: indicates the bearing clearance in inches or millimeters
To measure oil clearance between connecting rod bearing depending on which side of the envelope is used.
and crankshaft journal.
Equipment:
• PLASTIGAGE®
NOTE: The engine must be removed from the machine
to perform this procedure.

M82117A
9. Measure the connecting rod bearing oil clearance.

A
Specification: B
Connecting Rod Bearing Oil Clearance M82118A
4210 . . . . . . . . . . . . . . . 0.04 - 0.09 mm (0.002 - 0.004 in.)
1. Fasten the dial indicator (B) to engine and position
Wear Limit . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.) indicator tip on end of crankshaft (A).
4310, 4410 . . . . . . . . . . 0.04 - 0.07 mm (0.002 - 0.003 in.)
IMPORTANT: Avoid damage! Do not use
Wear Limit . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.) excessive force when moving crankshaft to avoid
damaging bearings.
Results:
• If the clearance exceeds the wear limit specification, 2. Push the crankshaft toward rear as far as possible.
replace the bearing inserts. 3. Zero the dial indicator.
• Remove the PLASTIGAGE®. 4. Using a bar, gently pry the crankshaft as far forward as
possible.
Crankshaft End Play Check 5. Crank shaft end play is 0.09 - 0.27 mm (0.004 - 0.011
in.).
Reason:
To determine proper side clearance between the crankshaft Results:
and the engine block. • If the end play exceeds 0.27 mm (0.011 in.), replace the
thrust bearings.
Equipment:
• Dial Indicator Crankshaft Main Bearing Clearance Check
Procedure: Reason:
NOTE: Crankshaft end play can be measured at front To measure oil clearance between main bearing and
end or rear end of crankshaft. Procedure is performed crankshaft journal.
from the rear end. The flywheel is removed to show
detail. Equipment:
• PLASTIGAGE®
to perform this test.
Procedure:
1. Remove the oil pan, and oil pickup.

Specification:
IMPORTANT: Avoid damage! Main bearing caps
must be installed on the same main bearing and in Main Bearing Oil Clearance
the same direction to prevent crankshaft and main 4210 . . . . . . . . . . . . . . . 0.04 - 0.09 mm (0.002 - 0.004 in.)
bearing damage. Wear Limit . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
2. Remove the main bearing cap. 4310, 4410 . . . . . . . . . . 0.04 - 0.07 mm (0.002 - 0.003 in.)
3. Wipe oil from the bearing insert and the crankshaft Wear Limit . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
journal.
Results:
• If the clearance exceeds the wear limit specification,
replace the bearing inserts.
A • Remove PLASTIGAGE®.
®PLASTIGAGE is a registered trademark of the DANA
Corporation.
Valve Lift Check

Reason:
M35382 Check wear on cam lobes, followers, and/or push rods.
4. Put a piece of PLASTIGAGE® (A), or an equivalent, Equipment:
along the full length of the bearing insert approximately 6
mm (0.25 in.) off center. • Dial Indicator
5. Install the main bearing cap and bolts. Tighten the bolts Procedure:
to specification.
1. Remove the rocker arm cover. See “Rocker Cover
Specification: Removal and Installation” on page 58.
Main Bearing Bolt Torque 2. Adjust the valve clearance.

4210 . . . . . . . . . . . . . . . . . . 76.5 - 80.4 N•m (56 - 59 lb-ft)
4310, 4410 . . . . . . . . . . . . . . . 96 - 100 N•m (71 - 74 lb-ft)
6. Remove the bolts and main bearing caps.

NOTE: The flattened PLASTIGAGE® (B) will be found
on either the bearing insert or crankshaft journal.
T6333DT
3. Fasten the dial indicator to the engine and position the

B indicator tip on the valve retainer. The valve must be fully
closed and the rocker arm must move freely.
4. Zero the dial indicator.
M82119A
5. Manually turn the crankshaft pulley clockwise (from the
7. Use the graduation marks (C) on the envelope to fan end).
compare the width of the flattened PLASTIGAGE® at its
6. Observe the dial indicator as the valve is moved to the
widest point. The number within the graduation marks
full open position. Repeat for each valve.
indicates the bearing clearance in inches or millimeters,
depending on which side of the envelope is used.

Results: Timing Gear Backlash Check
• The valve lift should be the same for all valves. If one or
Reason:
more valves have less travel than the others, remove and
inspect the camshaft, followers and push rods. See To check for wear between meshing gears, resulting in
“Camshaft” on page 79. If the camshaft, followers and push excessive noise and poor engine performance.
rods are within specification remove and inspect the
cylinder head. See “Cylinder Head and Valves Removal Equipment:
and Installation” on page 60. • Dial Indicator
Camshaft End Play Check Procedure:

1. Measure the backlash between meshing gears.
Reason:
2. The backlash for all gears EXCEPT the oil pump gear is
To determine proper side clearance between camshaft 0.07 - 0.15 mm (0.003 - 0.006 in.).
gear end journal and thrust plate.
3. The backlash for the oil pump gear is 0.11 - 0.19 mm
Equipment: (0.004 - 0.008 in.).
• Dial Indicator Results:
Procedure: • If the backlash exceeds specifications, replace meshing
gears as a set:
1. Remove the timing gear cover. See “Timing Gear Cover”
on page 83. Idler Gear, Camshaft Gear, Crankshaft Gear, Oil Pump
Gear AND/OR Idler Gear, Fuel Injection Pump Gear.
2. Fasten the dial indicator to the engine and position
indicator tip on end of camshaft.
Fuel Injection Nozzle Test
3. Push the camshaft toward the rear as far as possible.
c CAUTION: Avoid Injury! Escaping fluid

4. Zero the dial indicator.
5. Pull the camshaft forward as far as possible.
under pressure can penetrate the skin
causing serious injury. Avoid the hazard by
relieving pressure before disconnecting
hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
If an accident occurs, see a doctor

immediately. Any fluid injected into the skin
must be surgically removed within a few
hours or gangrene may result. Doctors
M37512 unfamiliar with this type of injury should
6. Standard end play is 0.05 - 0.25 mm (0.002 - 0.010 in.). reference a knowledgeable source. Such
information is available from the Deere &
Results: Company Medical Department in Moline,
Illinois, U.S.A.
• If the end play exceeds 0.25 mm (0.010 in.), remove the
camshaft and replace the thrust plate.
Reason:
To determine opening pressure, leakage, chatter and spray
pattern of the fuel injection nozzle.
Equipment:
• D01110AA Adapter Set
• D01109AA Diesel Fuel Injection Nozzle Tester

• 23622 Straight Adapter Results:
• Container • Fuel should not leak from the nozzle when the nozzle is
pressurized.
Connections:
• If the injection nozzle leaks fuel, disassemble and
inspect the nozzle assembly for contamination. Inspect the
B valve seating surface. Replace the nozzle assembly if
C necessary.
D
A Procedure 3:
E
Test the fuel injection nozzle chatter and spray pattern
following the nozzle tester manufacturer's instructions.
1. Pressurize nozzle to19600 kPa (2843 psi).
F 2. With slow hand lever movement there should be a
“chatter” sound.
3. With fast hand lever movement the nozzle should exhibit
an even, fine atomized spray pattern (G).
4. Place a sheet of white paper 30 cm (12 in.) below the
nozzle. The injection spray should form a perfect circle on
the paper.
Results:
M35913
1. Connect the fuel injection nozzle (F) to D01109AA

Diesel Fuel Injection Nozzle Tester (A) using parts 36352
(B), 23617 (C), 23621 (D) from D01110AA Adapter Set,
and 23622 straight adapter.
IMPORTANT: Avoid damage! Use clean filtered

diesel fuel when testing injection nozzles to get
best test results.
G
Procedure 1:
Test the fuel injection nozzle opening pressure following the
Nozzle Tester manufacturer's instructions.
The opening pressure is 19600 + 1000/-0 kPa (2843 + 145/
-0 psi).
Results:
• If the pressure reading does not meet specification,
disassemble the injection nozzle and inspect for H
contamination or a stuck valve. If necessary, add or remove M82121A
shims to change opening pressure.
• If nozzle chatter or the spray pattern does not meet
Procedure 2: specifications, disassemble the injection nozzle and inspect
the nozzle assembly for contamination. Inspect the valve
Test fuel injection nozzle leakage following the nozzle seating surface. Replace the nozzle assembly if necessary.
tester manufacturer's instructions.
• If there is excessive difference in the spray angle or
1. Dry the nozzle completely using a lint-free cloth. injection angle, incomplete atomizing or sluggish starting/
2. Pressurize the nozzle to 19600 kPa (2843 psi). stopping of injection (H), disassemble the injection nozzle
and inspect the nozzle assembly for contamination.
3. Watch for leakage from nozzle spray orifice. Replace the nozzle assembly if necessary.

Thermostat Opening Test Injection Pump Static Timing Adjustment
Reason: Reason:
To determine opening temperature of thermostat. To make sure that the injection pump timing is set to
manufacturers specification.
Equipment:
• Thermometer Equipment:
• Timing Tool (Made from high pressure pipe, nut and a
• Glass Container
clear plastic straw**)
• Heating Unit ** straw from WD40, carburetor cleaner, brake parts
cleaner, etc.
Procedure:
• External fuel supply
c CAUTION: Avoid Injury! DO NOT allow Procedure:

thermostat or thermometer to rest against
the side or bottom of glass container when IMPORTANT: Avoid damage! The injection pump
heating water. Either may rupture if timing should be correct. The timing is set at the
overheated. factory, and will not normally change during the
life of the engine. Check and adjust the timing
1. Suspend the thermostat and a thermometer in a only as the last option, or if there is reason to
container of water. believe the timing has been altered.
2. Heat and stir the water. Observe the opening action of Check the fuel, fuel supply system, injectors, air
the thermostat as the water heats up. intake system and cylinder compression before
continuing.
3. Remove the thermostat and observe the closing action
as it cools. NOTE: If the injection pump has been removed from
engine without disturbing engine crankshaft and pump
gear, perform step 1 to obtain a close starting point,
then perform the entire timing procedure.
1. Align the arrow or line on the injection pump flange on
the mark noted during pump removal.
NOTE: Normal rotation, as viewed from the flywheel
end, is counterclockwise. The number one fuel
injection line is toward the flywheel.
M82122A
Results:
• The thermostat should begin opening at 69.5 - 72.5° C
(157 - 163° F) and be fully open at 85° C (185° F).
• Replace the thermostat if the fully open lift height is less
than 8 mm (0.31 in.), or if the closing action is not smooth
and slow.
M57132
2. Remove the number one fuel injection line.

10.Slowly turn the flywheel counterclockwise (as viewed
from the flywheel end) until the fuel in the straw just starts
to move. Stop rotating the flywheel the instant the fuel
B begins to move.
NOTE: If there is no fuel movement, engine may be on
exhaust stroke. Rotate flywheel 360° and repeat test.
A Drill Out
(#45 drill bit)
Direction
30 - 50 mm of Engine
(1.2 - 2.0 in.) Rotation
14° E
BTDC
Injection 12°
Pump BTDC
1
MIF
3. Install the timing tool (A) and clear straw (B). Flywheel Timing Marks
4. Remove the access panel from the flywheel housing. MIF
5. Prime the pump to fill it with fuel. 11.Check the injection pump timing marks on the flywheel.
6. Disconnect battery negative (-) terminal and remove fuel The 14° mark on the flywheel must line up with the center
shutoff solenoid. of the timing hole (E) in the flywheel housing.
7. Turn the flywheel counterclockwise (as viewed from the Results:

flywheel end) until the timing tool straw has fuel showing.
• If the timing is not within specifications, loosen the pump
mounting bolts and turn the pump toward the engine block
to retard the timing or away from the block to advance the
timing. Recheck the timing.
14° Direction If the timing did not change, remove pump and have tested
BTDC of Engine by an authorized diesel injection service shop.
D
Rotation
12° • If the timing is correct, remove timing tool, install number
BTDC one injection line, install the access cover to the flywheel
E housing.
1
Flywheel Timing Marks
MIF
8. Turn the crankshaft pulley clockwise (back) until the No.

1 cylinder top dead center (TDC) mark (C) and pump timing
marks (D) have gone past the center of the timing hole in
the flywheel housing (E) by at least 50 mm (2 in.).
9. Snap the straw with your finger until the level of the fuel,
or a bubble, is set part way up the straw. This will be the
point to watch for fuel movement.

Injection Pump Timing Adjustment (EPA Fan/Alternator Drive Belt Adjustment
Engines)
Reason:
To keep proper tension on the belt to drive the water pump
and the alternator. To prevent shortened belt and bearing
life.
Equipment:
• JDG529 or JDST28 Belt Tension Gauge
• Straight Edge
Procedure:
1. Check the belt tension between the fan and alternator
using a belt tension gauge and a straight edge.
MX1339A
EPA engines have EPA compliance sticker on rocker arm

cover as shown above.
c CAUTION: Avoid Injury! DO NOT attempt to

adjust the fuel injection pump timing. For
most engine problems, the fuel injection
pump timing will not have to be adjusted. If M54014
the engine performed well at one time, then 2. With applied force of 98 N (22 lb-force) the belt
performance dropped, the fuel injection deflection is 10 - 15 mm (0.4 - 0.6 in.).
timing is NOT the problem. Fuel injection
timing, once set by the engine manufacturer, Results:
should NOT change during the life of the
• If deflection is not within specifications, loosen both
engine.
alternator mounting cap screws/nuts. Apply force to
FRONT alternator housing only (near the belt) until tension
IMPORTANT: Avoid damage! Fuel injection pump is correct. Tighten cap screws/nuts.
timing should NOT change during the life of the
engine unless the pump has been altered illegally,
or there is excessive wear to the camshaft
Radiator Bubble Test
injection pump cam lobes and lifters. Reason:
First check the fuel quality, fuel supply, fuel To determine if compression pressure is leaking from
injectors, air intake system, and engine cylinder.
compression in all cylinders before considering
fuel injection timing problems. Equipment:
• JDG560 Adapter
If all other possibilities have been ruled out and it
is determined that the fuel injection pump and Procedure:
governor assembly are in need of repair, they 1. With the coolant at the proper level and the radiator cap
must be replaced ONLY as complete assemblies. tight, run the engine for 5 minutes to bring it to operating
temperature.
Only an authorized factory trained technician is
allowed to remove and install these assemblies 2. Remove the cap from the recovery tank.
3. Check for bubbles coming from the overflow hose at the
bottom of the tank.

• If bubbles are present, isolate the source of the
compression leak.
4. Remove the injection nozzles.
5. Install JDG560 Adapter in the injection port of the
cylinder to be tested.
6. Move the piston to the bottom of the stroke with intake
and exhaust valves closed.
7. Connect the hose from a compressed air source to the
adapter.
8. Apply shop air pressure into the cylinder.
T6333AW
9. Check for bubbles in the recovery tank or air escaping
from the muffler, air cleaner or oil fill opening. Results:
10.Repeat for each cylinder.
• Pressure should hold to 88 ± 15 kPa (12.8 ± 2.2 psi). If
pressure decreases, check for leaks. Repair leaks or
Results:
replace parts as necessary.
• If bubbles are present in the recovery tank, check for
cracks in the cylinder head and block. Check for a damaged • If the pressure test still indicates leakage after all
head gasket. external leaks have been stopped, a defective head gasket,
cracked block, or cylinder head may be the cause. See
• If air escapes from the muffler, check for a worn exhaust “Radiator Bubble Test” on page 53.
valve.
• If air escapes from the air cleaner, check for a worn Radiator Pressure Cap Test
intake valve.
• If air escapes from the engine oil fill, check for worn Reason:
piston rings. Test the radiator cap for operating in the correct pressure
range.
Cooling System Pressure Test Equipment:
Reason: • D05104ST Cooling System Pressure Pump
Inspect the cooling system for leaks. • JDG692 Radiator Pressure Test Kit (Adapters)
Equipment: Procedure:
• D05104ST Cooling System Pressure Pump 1. Install the radiator cap (A) on the pressure pump.
• JDG692 Radiator Pressure Test Kit (Adapters) 2. Apply pressure. Pressure valve in the cap should open
at 88 kPa (12.8 psi).
Procedure:
1. Remove the cap and attach the pressure pump to
radiator.
2. Apply pressure according to specifications, not to
exceed 97 kPa (14 psi).
3. Check for leaks throughout the cooling system. After 15
seconds the minimum pressure is 88 kPa (12.8 psi).
T6333AX
Results:
• If the cap leaks, retighten and test again. Replace the
cap if pressure is not within specification.

Engine Oil Pressure Test Specification:
Oil Pressure
Reason:
4210 . . . . . . . . . . . . . . . . . . 0.29 ± 0.05 MPa (42 ± 7.2 psi)
To determine if the engine bearings or the lubrication 4310, 4410 . . . . . . . . . . . . . 0.34 ± 0.05 MPa (49 ± 7.2 psi)
system components are worn.
Results:
Equipment:
• If the oil pressure is not within specifications, inspect the
• JT03017 Hose Assembly oil pump.
• JT05577 Pressure Gauge (100 psi) • If the oil pump is within specifications, the engine may
• JT03349 Connector have parts worn beyond specifications. See “Engine
Troubleshooting” on page 36.
Procedure:
1. Remove the oil pressure sender. Fuel Transfer Pump Tests
Pressure Test
A
Reason:
To determine supply pump operating pressure.
Equipment:
• JDG356 Fuel Pump Pressure Test Kit
Procedure:
B
C
B
T6471FB MX1155
2. Install JTO3349 Connector (C). 1. Disconnect the transfer pump to injector pump hose (A).
3. Connect JTO3017 Hose Assembly (B) and JTO5577 2. Install the hose and gauge to outlet side of transfer
Pressure Gauge (A). pump (B).
3. Crank or start engine, or operate transfer pump with
IMPORTANT: Avoid damage! DO NOT run the hand primer lever (C) if equipped.
engine if there is insufficient oil pressure!
4. Record fuel pressure reading on gauge.
4. Start the engine. If the pressure reading is below 0.06
MPa (8.7 psi) at slow idle rpm, STOP THE ENGINE. Results:
5. If the oil pressure is at least 0.06 MPa (8.7 psi) run the • If the pressure is below specification, replace the fuel
engine approximately five minutes to heat the oil. Check supply pump.
the oil pressure at 2700 rpm.

Specification: 3. Apply 34 - 69 kPa (5 - 10 psi) air pressure to fuel supply
hose until all fuel is drained from the system.
Fuel Pressure . . . . . . . . . . . . . . . . 29 kPa (4.2 psi) min.)
4. Plug the end of the fuel return hose.
Flow Test
5. Apply 34 - 69 kPa (5 - 10 psi) air pressure to the fuel
Conditions: system at the fuel supply line. DO NOT exceed a maximum
pressure of 103 kPa (15 psi).
Fuel Temperature For Tests. . . . . . . 15 - 25°C (59 - 77°F)
6. Apply liquid soap and water solution to all joints and
Procedure: connections in the fuel system, and inspect for leaks.
1. Disconnect fuel shutoff solenoid wire. Results:
• Find leaks and repair or replace parts as necessary.
D
Bleed Fuel System
All engines are equipped with an automatic air venting
system which makes the fuel system self-bleeding.
• Assure that all fuel line connections are securely
tightened.
• Add fuel to the fuel tank.
• Crank the engine to allow fuel system to bleed itself.
MX1156
2. Disconnect fuel transfer pump outlet hose from fuel

injection pump (D). Collect fuel in graduated container (E)
as key switch is turned to “START” position to crank engine
15 seconds. Compare fuel amount to specification.
Specification:
Fuel Flow 15 sec. . . . . . . . . . . . . . . . 50 mL (1.5 oz min.)
Fuel System Leakage Test

Reason:
Tests the fuel system plumbing for external leakage. This
test also determines if air is entering the fuel system at
connections, allowing fuel to siphon back to tank.
Procedure:
1. Disconnect the fuel supply line and return line at the fuel
tank.
2. Place the fuel return line into a suitable container to
catch drained fuel.
c CAUTION: Avoid Injury! DO NOT apply more

than 103 kPa (15 psi) air pressure to the fuel
system. Damage to the injection pump or
personal injury may result.

ENGINE - DIESEL REPAIR
Repair 23.Remove the steering wheel.
24.Remove the control panel.
Engine Removal 25.Remove the left side shield.
1. Split the machine between the flywheel housing and the 26.Disconnect the wiring harness, oil pressure switch, and
tunnel. See “Machine Splitting - Front” in the appropriate ground wires from the engine.
power train section.
27.Remove the return springs, and the left side brake
2. Remove the hood. pedals.
3. Drain the coolant from the radiator and the engine block. 28.Remove the bushing from the brake pedal shaft.
4. Drain the lubrication oil, and the fuel tank. 29.Remove the return spring, cotter pin, and washer from
5. Remove the battery. the brake pedal shaft, and remove the right side pedal with
the pedal shaft from the machine.
6. Remove the muffler.
30.Label and remove the fuel hoses from the fuel tank.
7. Remove the coolant overflow tank.
31.Loosen the dash board support, and pull the support
8. Remove the air cleaner. toward the rear of the machine.
9. Remove the radiator coolant hoses. 32.Lift out the fuel tank.
10.Disconnect the hydraulic cooler lines. 33.Remove the pedal support.
11.Remove the radiator. 34.Install lifting brackets to the cylinder head.
12.Remove the dipstick and tube. 35.Install the engine hoist to the lift brackets. Lift the engine
13.Remove the starting motor wires. slightly and safely support the machine frame.
14.Disconnect the intake manifold air heater. NOTE: Use more than one support to support the
frame. The frame will pivot on the front axle, and could
slip off of a single support.
C
36.Disconnect the front wiring harness.
Fuel Filter
D
E
A B
M94772a
15.Disconnect the throttle rod (A).

16.Label and disconnect the fuel hoses (B).
17.Remove the fuel filter shield and fuel filter (C) from the
engine.
MX9840
18.Disconnect the fuel solenoid.
37.Label the hydraulic lines (D) and hoses from the
19.Disconnect the oil pressure sending unit. steering control unit (E) and disconnect.
20.Remove the hood support. 38.Remove the flywheel from the engine. See “Flywheel
21.Disconnect the fuel tank sending unit. and Coupling” on page 78.
22.Remove the flasher, if equipped. 39.Remove the flywheel housing from the engine.
Engine - Diesel Repair - 57

NOTE: The flywheel housing is heavy. Use an 2. Install the breather plate and a new O-Ring (G) before
assistant, and proper tools to remove and lift the replacing breather cover.
flywheel housing.
3. Inspect the rocker cover gasket (H), and O-rings (I) and
The starting motor may be removed with the flywheel
(J) for before reinstalling the rocker arm cover. Replace if
housing. damaged.
40.With the frame supported, and the engine attached to 4. Clean the cylinder head surface and install the rocker
the engine hoist, remove the cap screws that fasten the cover to the cylinder head. Install the rocker cover nuts.
engine oil pan to the frame (eight on each side). Lift and
slide the engine out of the back of the frame. Place the
engine on a bench or suitable engine stand. Rocker Arm Assembly
NOTE: The engine is heavy and is a tight fit to the Removal/Installation and Disassembly/Assembly:
frame. Use an engine hoist and an assistant to remove 1. Remove the rocker cover. See “Rocker Cover Removal
the engine from the frame. and Installation” on page 58.
2. Remove the rocker arm end support and rocker arm
Rocker Cover Removal and Installation center support mounting cap screws.
Removing: 3. Lift the rocker arm assembly from the cylinder head and
set the assembly on a bench.
D NOTE: If the rocker arm shaft assembly is to be
E disassembled, replace components in same location
G on the rocker arm shaft they were removed from.
B 4. Note the positions of the rocker arm assembly
A components. Slide the components off the rocker arm
F
shaft.
J 5. Lift the push rods from the cylinder head and note the
order of removal for reassembly.
6. Inspect the rocker arm components and push rods.
7. Reinstall the push rods to their original location in the
I cylinder head, with the ball shaped end down in head.
8. Lubricate all parts with clean oil during assembly.
9. Assemble the rocker arm assembly components in the
reverse order of removal.
10.Place the rocker arm assembly on the cylinder head.
C • Align the rocker arms with the valves and push rods.
• Align the rocker arm end supports and center
H
supports with the corresponding holes in the head.
M91950
11.Install the rocker arm support cap screws. Tighten the
1. Remove the air cleaner and muffler. cap screws to 26 N•m (19 lb-ft).
2. Remove three rocker cover nuts (A). 12.Adjust the valve clearance.
3. Remove the breather hose (B).
4. Remove the rocker cover (C) from the cylinder head.
5. Remove the breather cap (D), plate (E), and baffle (F).
6. Wash the baffle in a safe solvent and blow dry with air.
Replace the baffle if it comes apart or is deteriorated.
Installing:
1. Install the baffle.

A B
C
D
G
H
I
M L
M91949B
A - Shaft End Support (2) Inspection:

B - Cap Screw, M8 x 50 (6)
C - Jam Nut (6)
D - Adjuster Screw (6)
E - Spring (3)
F - Rocker Arm
G - Rocker Arm Shaft
H - Plug (2)
I - Stud
J - Push Rod (6)
K - Valve Caps (6)
L - Center Support (2)
M - Cap Screw, M8 x 25
M35262
1. Measure the outer diameter of the rocker arm shaft.

• Rocker arm shaft OD is 15.97 - 15.98 mm (0.628 -
0.629 in.).
• Replace the rocker arm shaft if the OD is less than
15.95 mm (0.628 in.).

Inspect Rocker Arm Contact Surfaces:
C A
M76398
1. Check the surface of the adjusting screw that contacts

the push rod (A) for wear. Replace the adjusting screw (B) if
M82022A it is worn or damaged.
2. Measure the inner diameters of the rocker arms and 2. Check the surface (C) of the rocker arm that comes in
supports. contact with the valve cap for wear. Replace rocker arm if
necessary.
• Standard ID is 16.00 - 16.02 mm (0.630 - 0.631 in.).
3. Check the socket portion of the push rod where the
• Replace the rocker arms or supports if the ID is more valve clearance adjusting screw contacts the push rod.
than 16.09 mm (0.633 in.). Replace the push rod if it is worn or damaged.
3. Measure the rocker arm shaft to rocker arm bushing oil
clearance. Oil clearance is the difference between the OD Cylinder Head and Valves Removal and
of the rocker arm shaft and the ID of the rocker arms.
Installation
• Standard oil clearance is 0.02 - 0.05 mm (0.001 -
0.002 in.). Removing:
• If the clearance exceeds 0.14 mm (0.006 in.) replace 1. Remove the rocker arm cover. See “Rocker Cover
the rocker arm shaft and rocker arms. Removal and Installation” on page 58.
2. Remove the rocker arm assembly, push rods and valve
Measure bending of push rod:
caps. See “Rocker Arm Assembly” on page 58.
3. Remove the exhaust and intake manifolds. See
“Exhaust Manifold” on page 65.
4. Remove the water pump. See “Thermostat and Water
Pump” on page 86.
5. Remove the fuel injection nozzles. See “Fuel Injection
Length
Nozzles” on page 92.
M82023A
1. Place the push rod on a flat surface. Use a feeler gauge

to measure any gaps between the push rod and flat
surface.
• Replace any push rod with more than (0.03 mm
(0.001 in.) bend.

A Exhaust Manifold Side
Timing Gear End

Flywheel End
7 1 10
13 3 6 12
11 5 4 14
9 2 8
Intake Manifold Side
Cylinder Head Bolt- Tightening Order
MIF
4. Dip the head bolts in clean engine oil, install and tighten
in the sequence shown, in three stages of gradually-
increasing torque. Tighten the head bolts to specification.
Specification:
M91949A
Cylinder Head Bolt Torque:
4210 Initial Torque . . . . . . . . . . . . . . . . . 35 N•m (26 lb-ft)
8 14 5
2 12 9 3 Second Step Torque. . . . . . . . . . . . . . . . 48 N•m (36 lb-ft)
Final Torque . . . . . . . . . . . . . . . . . . . . . . 69 N•m (51 lb-ft)
4 10 11 1
4310-4410 Initial Torque. . . . . . . . . . . . . 44 N•m (33 lb-ft)
6 13 7
Second Step Torque. . . . . . . . . . . . . . . . 62 N•m (45 lb-ft)
MIF
Final Torque . . . . . . . . . . . . . . . . . . . . . . 88 N•m (65 lb-ft)
6. Remove the cylinder head bolts (A) in the order shown.
7. Remove the cylinder head from the engine block. IMPORTANT: Avoid damage! Cylinder head bolts
8. Disassemble and inspect the cylinder head and valves. must be checked for proper torque after 50 hours
See “Cylinder Head and Valves Disassembly and of engine operation.
Assembly” on page 61.
5. Install the fuel injection nozzles. See “Fuel Injection
Installing: Nozzles” on page 92.
1. Reassemble the cylinder head and valves. See 6. Install the water pump. See “Thermostat and Water
“Cylinder Head and Valves Disassembly and Assembly” on Pump” on page 86.
page 61. 7. Install the exhaust and intake manifolds. See “Exhaust
Manifold” on page 65, and “Intake Manifold” on page 65.
IMPORTANT: Avoid damage! The oil passage in
8. Install the rocker arm assembly, push rods and valve
the gasket must be located over the oil passage
caps.
in cylinder block.
2. Place a new cylinder head gasket on the engine block. Cylinder Head and Valves Disassembly and
Dowels in the engine block will assist in aligning the gasket.
Assembly
3. Place the cylinder head on the engine block. Dowels in
the engine block will again assist in alignment. Removing:
1. Remove the valve caps from the valves. The valve caps
should be installed on the valves they were removed from.
2. Compress the valve spring using a valve spring
compressor and remove the collet halves, retainer, valve
spring and valve stem seal for each valve.
3. The intake and exhaust valve guides are press fit.

Replace the guides only if necessary. See Valve Guides.”
NOTE: The valve seats are not replaceable. If
inspection of the cylinder head reveals valve seats that
are damaged or worn beyond repair, the cylinder head
must be replaced. See “Valve Seats” below for
inspecting valve seats.
4. Inspect all remaining parts for wear or damage.
Installing:
IMPORTANT: Avoid damage! Do not reuse stem

seals if removed. Used seals will leak. M82028A
1. Install new valve stem seals over the valve guides. 1. To measure the cylinder head flatness, place a
straightedge along each of the four sides and each
2. Apply clean engine oil on intake and exhaust valve
diagonal. Measure clearance between straight edge and
stems during assembly.
combustion surface with a feeler gauge.
3. Install the valve springs with smaller pitch end or paint
• Standard distortion is 0.05 mm (0.002 in.) or less.
mark toward cylinder head.
• If the distortion exceeds 0.05 mm (0.002 in.), but is
4. Compress the valve springs and retainer until the collet less than 0.15 mm (0.006 in.) resurface the cylinder
halves are able to be installed in the grooves of the valve head.
stem.
• If the distortion is 0.15 mm (0.006 in.) or more,
5. Carefully release the tension on the spring compressor.
replace the cylinder head.
6. Tap on the end of the valve with a plastic hammer to
2. If the cylinder head was resurfaced:
ensure the collet halves have seated properly on the valve
stem. • Measure piston-to-cylinder head clearance. See
“Measure Cylinder Head To Piston Clearance.”
7. Repeat for the remaining valves.
• Measure valve recession. See “Cylinder Head And
8. Measure valve recession if new valves were installed.
Valves Disassembly and Assembly.”
See “Valve Recession.”
• Measure valve seat width. See “Valve Seats.”
NOTE: After each valve has been assembled, tap on
top of valve stem with a plastic hammer to seat
retainer. Valve Seats
Inspection/Replacement:
Before inspection, thoroughly clean all components of
carbon or dirt.
Cylinder Head:
MIF M82029A
1. Measure the valve seat widths.

Specification:
Valve Seat Width:
4210 . . . . . . . . . . . . . . . 1.36 - 1.53 mm (0.054 - 0.060 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . 1.98 mm (0.078 in.)
4310, 4410 . . . . . . . . . . 1.07 - 1.24 mm (0.042 - 0.049 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . 1.74 mm (0.069 in.) 43 mm 60 mm
Exhaust Valve Seat Width: (1.7 in.) (2.4 in.)
4210 . . . . . . . . . . . . . . . 1.66 - 1.87 mm (0.066 - 0.074 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . 2.27 mm (0.089 in.)
4310, 4410 . . . . . . . . . . 1.24 - 1.45 mm (0.049 - 0.057 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . 1.94 mm (0.076 in.)
2. If necessary, grind the valve seats to meet

specifications. See “Grind Valve Seats.”
Intake and Exhaust Valves:
M82031A
3. Measure the valve stem diameter at two locations, as

shown.
Specification:
Intake Valve Stem OD:
4210 . . . . . . . . . . . . . . . 6.95 - 6.96 mm (0.274 - 0.274 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . 6.90 mm (0.272 in.)
4310, 4410 . . . . . . . . . . 7.96 - 7.98 mm (0.313 - 0.314 in.)
M35307 Wear Limit . . . . . . . . . . . . . . . . . . . . . 7.90 mm (0.311 in.)
1. Check the valves for out-of-round, bent or warped Exhaust Valve Stem OD
condition using a valve inspection center. Replace valve if 4210 . . . . . . . . . . . . . . . 6.94 - 6.96 mm (0.273 - 0.274 in.)
necessary. Wear Limit . . . . . . . . . . . . . . . . . . . . . 6.90 mm (0.272 in.)
4310, 4410 . . . . . . . . . . 7.96 - 7.97mm (0.313 - 0.314 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . 7.90 mm (0.311 in.)
• If the valve stem diameter is less than the wear limit,

A
replace the valve.
MIF
2. If the valve faces are worn, burned or pitted, grind valves

to proper face angle.
• If the valve head thickness (A) is less than 0.50 mm
(0.020 in.) after grinding, replace the valve.

Valve Recession 3. Subtract the valve stem OD from the valve guide ID to
obtain the oil clearance.
A Specification:
Valve Stem-To-Guide Oil Clearance

Intake Valve:
All. . . . . . . . . . . . . . . . . 0.04 - 0.07 mm (0.001 - 0.003 in.)
Wear Limit - 4210 . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Wear Limit - 4310, 4410 . . . . . . . . . . 0.20 mm (0.008 in.)
Exhaust Valve:
All. . . . . . . . . . . . . . . . . 0.05 - 0.08 mm (0.002 - 0.003 in.)
Wear Limit - 4210 . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Wear Limit - 4310, 4410 . . . . . . . . . . 0.20 mm (0.008 in.)
• If the ID of the valve guide is less than the wear limit,

determine the guide-to-stem oil clearance (guide diameter
minus stem diameter).
• If the oil clearance exceeds 0.15 mm (0.006 in.) but is
less than 0.20 mm (0.008 in.), knurl the valve guides using
D-20019WI Valve Guide Knurler
M82032A
• If clearance exceeds 0.20 mm (0.008 in.), replace valve
1. Measure valve recession (A) using a depth gauge. guides using JDE118 Valve Guide Driver.
Specification:
Intake Valve Recession: A
4210 . . . . . . . . . . . . . . . 0.30 - 0.50 mm (0.012 - 0.020 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.039 in.)
4310, 4410 . . . . . . . . . . 1.07 - 1.24 mm (0.042 - 0.049 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.039 in.)
Exhaust Valve Recession:
All . . . . . . . . . . . . . . . . . . . 0.3 - 0.5 mm (0.012 - 0.020 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.039 in.)
• New valve guides must be cooled in a container of liquid
Valve Guides nitrogen or equivalent before driving into cylinder head.
1. Clean the valve guides using a valve guide brush. • The intake and exhaust valve guides are different. The
exhaust valve guide has one groove and the intake valve
2. Measure the valve guide inside diameter.
guide has none.
Specification: • Install the valve guides with the tapered ends down.
Intake Valve ID: Push the valve guides into the cylinder head until the valve
4210 . . . . . . . . . . . . . . 7.00 - 7.015 mm (0.275 - 0.276 in.) guide projection (A) is within specification.
Wear Limit . . . . . . . . . . . . . . . . . . . . . 7.08 mm (0.279 in.) Specification:

4310, 4410 . . . . . . . . . . 8.01 - 8.03 mm (0.315 - 0.316 in.) Valve Guide Projection
Wear Limit . . . . . . . . . . . . . . . . . . . . . 8.10 mm (0.319 in.) 4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm (0.472 in.)
Exhaust Valve Recession: 4310, 4410 . . . . . . . . . . . . . . . . . . . . . . . 15 mm (0.591 in.)

All . . . . . . . . . . . . . . . . . . . 0.3 - 0.5 mm (0.012 - 0.020 in.)
• Ream the inside diameter of valve guides using D-
Wear Limit . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.039 in.) 20021WI Valve Guide Reamer.

Valve Springs Exhaust Manifold
M8 x 22
M8 x 60
M8
M94810
M82034A
1. Remove the muffler and gasket (A).
1. Measure the valve spring free length.
2. Remove the exhaust manifold (B) and gasket (C).
Specification: 3. Clean the mating surfaces, and replace the exhaust
Valve Spring Free Length manifold gasket.
4210 . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.4 mm (1.75 in.) 4. Install the exhaust manifold. Tighten all fasteners.
4310, 4410 . . . . . . . . . . . . . . . . . . . . . . 42 mm (1.654 in.)
Intake Manifold
M8 x 35
A
A C
B
M8 x 25
M94811
1. Remove the fuel filter bracket (not shown).

M82035A 2. Remove the intake air heater (A).
2. Measure the spring inclination (A). 3. Remove the fuel injection lines (not shown).
• Replace the spring if the measurement exceeds 1.10 4. Remove the intake manifold (B).
mm (0.044 in.). 5. Clean the mating surfaces, and replace the intake
manifold gasket (C).
6. Install the intake manifold.
7. Replace the intake air heater gasket (D), and install the
intake air heater.

8. Install the fuel injection lines. 6. Lap the valves. See “Lap Valves.”
9. Tighten all fasteners to specification. If the valve recession exceeds the maximum specifications
or the seats cannot be reconditioned, replace the valves or
Grind Valve Seats the cylinder head.
NOTE: LIGHTLY grind the valve seats for only a few Lap Valves
seconds to avoid excessive valve seat width.
NOTE: Use a rubber type lapping tool for valves
1. Grind the intake valve seat using a 30° seat grinder and without a lapping tool groove slit.
the exhaust valve seat using a 45° seat grinder. Follow the
tool manufacturers instructions. If the seat does not make proper contact, lap the valve into
the seat:
M82041A
M82039A
1. Apply a small amount of fine lapping compound to the
2. Measure the valve seat width after grinding.
face of the valve.
2. Turn the valve to lap the valve to the seat.
B 3. Lift the valve from the seat every 8 to 10 strokes. Lap
until a uniform ring appears around the surface of the valve
face.
4. Wash all parts in solvent to remove lapping compound.
D Dry all parts.
C
5. Check the position of the lap mark on the valve face.
15° A Lap marks must be on or near the center of the valve face.
Measure Piston-To-Cylinder Head Clearance

Cylinder
Head 1. Place three 10 mm (0.4 in.) long pieces of 1.5 mm (0.06
in.) diameter soft wire in three positions on the flat part of
the piston head.
MIF 2. Install the cylinder head and old gasket. Install cylinder
3. If the seat width (A) is too wide after grinding, grind the head bolts and tighten in proper sequence. See “Cylinder
lower seat surface (B) using a 70° seat grinder until the Head and Valves Removal and Installation.”
seat width is close to specifications. 3. Slowly turn the crankshaft one complete revolution.
4. Grind the upper seat surface (C) using a 15° seat 4. Remove the cylinder head and gasket.
grinder until the seat width is narrowed to specifications.
5. If the valve seats (D) are ground, measure valve
recession. See “Cylinder Head and Valves Disassembly
And Assembly.” Check the contact pattern between the
seat and valve with bluing dye.

M82042A
5. Measure the thickness of the flattened section of each

piece of wire. Calculate the average thickness of the wires
to obtain the piston-to-cylinder head clearance
specification.
C
• If the clearance is less than 0.64 - 0.82 mm (0.025 -
0.032 in.), replace cylinder head. See “Cylinder Head
and Valves Removal and Installation.”
B
Piston and Connecting Rod
A
to perform this procedure.
Removing:
1. Remove the oil pan, and oil pickup tube.
M82196AB
2. Remove the cylinder head. See “Cylinder Head and
Valves Removal and Installation.” 8. Remove the rod bolts (A), connecting rod cap (B) and
bearing inserts (C).
3. Check the cylinder bore for ridges. These ridges can
cause damage to piston if ridge is not removed.
IMPORTANT: Avoid damage! The pistons and
4. If necessary, remove any ridge from the top of the cylinders are matched. Pistons must be installed
cylinder bore using a ridge reamer. in the cylinders from which they are removed.
5. Measure the connecting rod side play. See “Connecting 9. Note the connecting rod alignment mark in relation to
Rod Side Play Check.” the cylinders. Starting at the flywheel end with cylinder
6. Measure the crankshaft end play. See “Crankshaft End number one, then two, etc.
Play.” 10.Push the piston and connecting rod out of the cylinder
7. Measure the connecting rod bearing clearance. See bore using a wooden dowel.
“Connecting Rod Bearing Clearance Check.” 11.Disassemble and inspect all parts for wear or damage.
IMPORTANT: Avoid damage! Keep the connecting 12.Inspect the cylinder bore. See “Cylinder Bore.”
rods and rod caps together. Rods and caps are a
Installation:
matched set. Note the alignment marks on each
part. • Apply clean engine oil to all parts during installation.
• Always replace the connecting rod bolts. DO NOT reuse
the bolts.

4. Match the connecting rods to caps using alignment
IMPORTANT: Avoid damage! Pistons must be marks (H). Install the rod caps.
installed in the cylinders from which they were
removed and in the same direction. Be careful not 5. Dip the entire connecting rod bolt in clean engine oil.
to damage the crankshaft rod journals while Install new bolts and tighten to specification.
installing pistons.
Specification:
1. Assemble the piston and connecting rod. See Connecting Rod Bolt Torque
“Disassembly” below. 4210 . . . . . . . . . . . . . . . . . . . . . 37 - 41 N•m (27 - 30 lb-ft)
4310, 4410 . . . . . . . . . . . . . . . . 44 - 54 N•m (33 - 40 lb-ft)
E
6. If a new piston and connecting rod were installed, stamp
a number corresponding to the cylinder number on the
connecting rod and rod cap.
7. Install the cylinder head. See “Cylinder Head and Valves
Removal and Installation.”
8. Install the oil pan, and oil pickup tube.
Disassembly:
D IMPORTANT: Avoid damage! Pistons must be

installed on the same connecting rod they were
G removed from.
F
L
H
G A
M82196AB J
I
2. Install the piston and connecting rod into the cylinder I
from which it was removed. The alignment mark on the
connecting rod (D) and/or the piston size mark (E) on top of
piston should point toward the fuel injection pump.
IMPORTANT: Avoid damage! Do not touch

K
bearing insert surfaces. Oil and acid from your
finger will corrode the bearing surface.
3. Install the bearing inserts to the connecting rod and rod
cap, aligning tangs (F) with grooves (G).
IMPORTANT: Avoid damage! Connecting rod

M82197AE
caps must be installed on the same connecting
rods they were removed from. • Put a mark on each piston and connecting rod to aid in
assembly.

• Remove snap rings (I) from piston pin (J) and remove
pin. P
• The piston pin bushing (K) is a press fit in the

connecting rod. Remove the bushing only if replacement is
necessary.
• Inspect all parts for wear or damage. Replace as N
necessary. O
• Remove the 1st and 2nd compression rings (L) and oil
ring with expander (M).
Assembly:
• Apply clean engine oil to all parts during assembly.
M82046A
IMPORTANT: Avoid damage! The pistons must be 4. Install the oil ring over the expander with the ring gap
installed on the same connecting rod they were (N) opposite (180°) of the expander ends (O).
removed from.
5. Install the second compression ring, with the small
diameter of taper toward top of piston, in the middle groove.
E
Turn the ring until the gap (P) is 120° away from the oil ring
gap (N).
120°
120°
N
120°
D Q
M82198AB
1. Assemble the piston to the connecting rod with piston

mark (E) on the same side as the connecting rod stamped
mark (D). If a new connecting rod is used, assemble the M82199A
piston to the connecting rod with piston mark opposite the
connecting rod bearing insert groove (G). Be sure the oil 6. Install the first compression ring (chrome plated), with
hole in the piston pin bushing is aligned with the hole in the the manufacturer's mark “R”, “T” or “RN” (near the ring gap)
connecting rod. toward the top of the piston, in the top groove. Turn the ring
until the gap (Q) is 120° away from the second ring gap.
2. Install the piston pin (J) and retaining/snap rings.
3. Install an oil ring expander (M) in the bottom ring groove
of the piston, with the ends above either end of the piston
pin.

Piston Inspection Result:
• If the bearing oil clearance exceeds the wear limit
Connecting Rod Bearing:
grind the crankshaft connecting rod journals and install
1. Install the connecting rod cap and bearing inserts on the undersized bearing inserts, or replace the bearing
connecting rod. Install the old connecting rod bolts and inserts and the crankshaft.
tighten to specification.
Piston Ring Groove:
Specification:
Connecting Rod Bolt Torque
4210 . . . . . . . . . . . . . . . . . . . . . 37 - 41 N•m (27 - 30 lb-ft)
4310, 4410 . . . . . . . . . . . . . . . . 44 - 54 N•m (33 - 40 lb-ft)
M35360
1. With the rings installed on the piston, measure the

piston ring groove side clearance. Measure at several
places around each piston.
2. Replace the rings or the piston if the clearances exceed
specification.
Specification:
M82048a
First Compression Ring Groove- Side Clearance
2. Measure the connecting rod bearing diameter.
All. . . . . . . . . . . . . . . . . 0.08 - 0.11 mm (0.003 - 0.004 in.)
Specification: Second Compression Ring Groove- Side Clearance
Connecting Rod Bearing ID: 4210, 4410 . . . . . . . . . . 0.04 - 0.07 mm (0.001 - 0.003 in.)
4210 . . . . . . . . . . . . . 46.00 - 46.02 mm (1.811 - 1.812 in.) 4310 . . . . . . . . . . . . . . . 0.05 - 0.08 mm (0.002 - 0.003 in.)
4310, 4410 . . . . . . . . 51.00 - 51.01 mm (2.008 - 2.008 in.) Oil Control Ring Groove- Side Clearance
All . . . . . . . . . . . . . . . . 0.03 - 0.06 mm (0.001 - 0.002 in.)
Result:
• Replace the bearing inserts if the bearing diameter is
not within specification.
3. Measure the oil clearance between the bearing inserts
and the crankshaft, and verify that the clearance is within
specification.
Specification:
Connecting Rod Bearing Oil Clearance
4210 . . . . . . . . . . . . . . . 0.04 - 0.09 mm (0.002 - 0.004 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
4310, 4410 . . . . . . . . . . 0.04 - 0.07mm (0.002 - 0.003 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)

Piston Ring End Gap: Piston Pin Diameter:
M82050A
30 mm 1. Measure the piston pin diameter. Measure the diameter
(1.18 in.)
at six places. Replace any pin that is not within
B specification.
M82049A
Specification:
1. Use a piston to push the ring (A) approximately 30 mm
(1.18 in.) from the bottom of the cylinder bore. Measure the Piston Pin OD
piston ring end gap (B). 4210 . . . . . . . . . . . . . 22.99 - 23.00 mm (0.905 - 0.906 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . 22.90 mm (0.902 in.)
Specification:
4310, 4410 . . . . . . . . 25.99 - 26.00 mm (1.023 - 1.024 in.)
Piston Ring End Gap
All . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . 25.90 mm (1.020 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.059in.) Piston Pin Bore:
M37683
1. Measure the pin bore diameter in the piston.

Specification: • If the bushing diameter exceeds the wear limit,
replace bushing.
Piston Pin Bore ID
4210 . . . . . . . . . . . . . 23.00 - 23.01 mm (0.906 - 0.906 in.) 2. Piston pin-to-rod bore oil clearance is the bore ID minus
the pin OD.
Wear Limit . . . . . . . . . . . . . . . . . . . . 23.02 mm (0.906 in.)
• If the bushing clearance (bushing ID minus pin OD)
4310, 4410 . . . . . . . . 26.00 - 26.01 mm (1.024 - 1.024 in.)
exceeds specification replace the bushing or the piston
Wear Limit . . . . . . . . . . . . . . . . . . . . 26.02 mm (1.024 in.) pin.
2. Piston pin-to-piston oil clearance is the bore ID minus Specification:

the pin OD.
Piston Pin-to-Rod Bore Oil Clearance
Specification: All. . . . . . . . . . . . . . . . . 0.03 - 0.05 mm (0.001 - 0.002 in.)
Piston Pin-to-Piston Oil Clearance Wear Limit . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)

(All). . . . . . . . . . . . . . . . . 0.00 - 0.02 mm (0.00 - 0.001 in.)
NOTE: The piston pin bushing is a press fit. Replace
Wear Limit . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.) the bushing using a driver set. When installing the
bushing, make sure to align the oil hole in the bushing
• If the piston pin bore exceeds the wear limit, replace the with the hole in the connecting rod.
piston.
• If the piston pin is less than the wear limit, replace the Piston Diameter:
piston pin. NOTE: If the engine has had a previous major overhaul,
• If the bore clearance exceeds the wear limit replace the oversize pistons and rings may have been installed.
piston, piston pin or both. Pistons and rings are available in 0.25 mm (0.010 in.)
oversize.
Piston Pin Bushing:
23 mm (0.905 in.)
M82200A
M82051A
1. Measure the piston pin bushing diameter in the

connecting rod.
Specification:
Piston Pin Bushing ID
4210 . . . . . . . . . . . . . 23.02 - 23.04 mm (0.906 - 0.907 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . 23.10 mm (0.909 in.)
M82052A
4310, 4410 . . . . . . . . 26.03 - 26.04 mm (1.025 - 1.025 in.)
1. Measure the piston diameter perpendicular to the piston
Wear Limit . . . . . . . . . . . . . . . . . . . . 26.10 mm (1.028 in.) pin bore 23 mm (0.905 in.) from the bottom of the piston
skirt.

Specification: Specification:
Standard Piston OD: Standard Cylinder Bore ID:
4210 . . . . . . . . . . . . . 77.95 - 77.98 mm (3.069 - 3.070 in.) 4210 . . . . . . . . . . . . . 78.00 - 78.03 mm (3.071 - 3.072 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . 77.90 mm (3.067 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . 78.20 mm (3.079 in.
4310 . . . . . . . . . . . . . 83.95 - 83.98 mm (3.305 - 3.306 in.) 4310 . . . . . . . . . . . . . 84.00 - 84.03 mm (3.307 - 3.308 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . 83.90 mm (3.303 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . 84.20 mm (3.315 in.)
4410 . . . . . . . . . . . . . 87.95 - 87.98 mm (3.462 - 3.464 in.) 4410 . . . . . . . . . . . . . 88.00 - 88.03 mm (3.465 - 3.466 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . 87.90 mm (3.461 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . 88.20 mm (3.472 in.)
Oversize Piston OD: Oversize Cylinder Bore ID:
4210 . . . . . . . . . . . . . 78.20 - 78.23 mm (3.079 - 3.080 in.) 4210 . . . . . . . . . . . . . 78.25 - 78.28 mm (3.081 - 3.082 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . 78.15 mm (3.077 in.) 4310 . . . . . . . . . . . . . 84.25 - 84.28 mm (3.317 - 3.318 in.)
4310 . . . . . . . . . . . . . 84.20 - 84.23 mm (3.315 - 3.316 in.) 4410 . . . . . . . . . . . . . 88.25 - 88.28 mm (3.474 - 3.476 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . 84.10 mm (3.311 in.) Piston-to-Cylinder Clearance
4410 . . . . . . . . . . . . . 88.20 - 88.23 mm (3.472 - 3.474 in.) 4210 . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 mm (0.002 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . 88.10 mm (3.469 in.) 4310, 4410 . . . . . . . . . . . . . . . . . . . . 0.055 mm (0.002 in.)
Cylinder Roundness
• If the piston diameter is less than the wear limit, install a All. . . . . . . . . . . . . . . . . 0.00 - 0.01 mm (0.00 - 0.000 4in.)
new piston.
Wear Limit . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.)
Cylinder Taper
Cylinder Bore All. . . . . . . . . . . . . . . . . 0.00 - 0.01 mm (0.00 - 0.0004 in.)
NOTE: If the engine has had a previous major overhaul, Wear Limit . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.
the cylinders may have been bored oversize. Pistons
and rings are available in 0.25 mm (0.010 in.) oversize. • If the cylinder bore standard ID exceeds the wear limit,
have the cylinder rebored.
• If the cylinder is rebored, oversize pistons and rings
must be installed.
• If the cylinder bore exceeds the oversize bore ID,
replace the cylinder block.
• If the piston-to-cylinder bore clearance (cylinder bore ID
minus piston OD) exceeds specification, replace the
cylinder block, piston or both; or rebore cylinder and install
oversize piston and rings.
• Slight uneven wear, flaws, or minor damage may be
corrected by deglazing. See “Cylinder Bore.”
Deglazing:
IMPORTANT: Avoid damage! If the cylinder bores

are to be deglazed with crankshaft installed in
engine, put clean shop towels over crankshaft to
protect journal and bearing surfaces from any
abrasives.
M82053A 1. Deglaze the cylinder bores using a flex-hone with 180
1. Measure the cylinder bore diameter at three positions; grit stones.
top, middle and bottom. At these three positions, measure
in both directions; along the crankshaft center line and the
direction of the crankshaft rotation.

30 - 40°
M82054A
2. Use the flex-hone as instructed by the manufacturer to

obtain a 30 - 40° crosshatch pattern as shown.
IMPORTANT: Avoid damage! Do not use gasoline,

kerosene or commercial solvents to clean
cylinder bores. Solvents will not remove all M52959
abrasives from cylinder walls. 5. Run the drill press at about 250 rpm. Move the hone up
3. Remove excess abrasive residue from the cylinder walls and down in order to obtain a 30 - 40° crosshatch pattern.
using a clean dry rag. Clean the cylinder walls using clean NOTE: Measure the bore when the cylinder is cool.
white rags and warm soapy water. Continue to clean the
cylinder until white rags show no discoloration. 6. Stop the press and check the cylinder diameter.
Reboring: NOTE: Finish should not be smooth. It should have a

30 - 40° crosshatch pattern.
NOTE: The cylinder block can be rebored to use
oversize pistons and rings. Pistons and rings are 7. Remove the rigid hone when the cylinder is within 0.03
available in 0.25 mm (0.010 in.) oversize. mm (0.001 in.) of desired size.
8. Use a flex hone with 180 grit stones for honing to final
1. Align the center of bore to the drill press center.
size.
IMPORTANT: Avoid damage! Check stone for 9. Check the bore for size, taper and out-of-round. See
wear or damage. Use a rigid hone with 300 grit Inspection procedures.
stones.
IMPORTANT: Avoid damage! Do not use solvents
2. Adjust the hone so the lower end is even with the lower to clean the cylinder bores. Solvents will not
end of cylinder bore. remove all the metal particles and abrasives
3. Adjust the rigid hone stones until they contact the produced during honing.
narrowest point of the cylinder.
10.Clean the cylinder thoroughly using warm soapy water
4. Coat the cylinder with honing oil. The hone should turn until clean white rags show no discoloration.
by hand. Adjust the hone if it is too tight.
11.Dry the cylinder and apply engine oil.

Crankshaft Rear Oil Seal Crankshaft Front Oil Seal
Replacement:
1. Split the machine between the flywheel housing and the
tunnel. See “Machine Splitting Front” in the Hydrostatic
Power Train section for eHydro machines; “Machine
Splitting Front” in the Gear Power Train section for SST
machines; or “Machine Splitting Front” in the A
ePowrReverser Power Train section for ePowrReverser
machines.
2. Remove the drive coupling. B
3. Remove flywheel. See “Flywheel.”
M82203A
B 1. Remove the timing gear cover (A). See “Timing Gear
A
Cover.”
C
2. Replace the oil seal (B). Install new seal with the lip
toward inside of gear housing cover, flush with the surface
of the cover.
Crankshaft and Main Bearings

Removing:
1. Check the crankshaft end play. See “Crankshaft End
Play Check.”
2. Remove the cylinder head. See “Cylinder Head and
Valves Removal and Installation.”
M82349A 3. Remove the rear oil seal. See “Crankshaft Rear Oil
4. Remove the rear oil seal (A), case-to-crankcase Seal.”
extension cap screws and the oil seal case-to- crankcase 4. Remove the timing gear cover mounting plate. See
cap screws (B). “Timing Gear Cover.”
5. Remove the rear oil seal case (C). 5. Check the crankshaft rod bearing clearance. See
6. Replace the oil seal using an appropriate seal driver, “Connecting Rod Bearing Clearance Check.”
with the lip toward the cylinder block, flush with the surface
of the oil seal case. IMPORTANT: Avoid damage! Connecting rod
NOTE: If the crankshaft is grooved at the oil seal rods from which they were removed. Note the
contact point, the seal can be installed 3 mm (0.12 in.) alignment marks on the caps and rods.
farther into the oil seal case.
6. Check the crankshaft main bearing clearance. See
7. Install the oil seal case to the crankcase and crankcase
“Crankshaft Main Bearing Clearance Check.”
extension.
IMPORTANT: Avoid damage! Main bearing caps
must be installed on the same main bearings
from which they were removed.
7. Remove the connecting rod bolts and rod caps. Discard

the connecting rod bolts.
8. Push the pistons and connecting rods away from
crankshaft.

5. Install the thrust bearings, with the oil grooves facing
away from the cap, in the number “1” main bearing cap.
6. Install the main bearing caps in their original locations
with arrows pointing toward the flywheel side of the engine.
D
IMPORTANT: Avoid damage! DO NOT use high

speed power tools or air wrenches to tighten
main bearing bolts.
7. Dip each main bearing bolt entirely in clean engine oil.

C
Install the bolts and tighten. DO NOT tighten to
specifications.
E
8. Using a soft-faced hammer, tap the front end of the
B crankshaft then the rear end of the crankshaft to align the
thrust bearings.
A 9. Tighten the main bearing bolts to specification. When
tightening, start at the center main bearing cap and work
your way out, alternating to the ends. Turn the crankshaft
by hand. If it does not turn easily, disassemble the parts
and find the cause.
Specification:
M91948C
Main Bearing Bolt Torque
9. Remove the main bearing bolts (A), caps (B) and cap
4210 . . . . . . . . . . . . . . . . . . 76.5 - 80.4 N•m (56 - 59 lb-ft)
thrust bearings (C).
4310, 4410 . . . . . . . . . . . . . . . 96 - 100 N•m (71 - 74 lb-ft)
10.Remove the crankshaft (D).
11.Remove the block thrust bearings and main bearing
IMPORTANT: Avoid damage! The connecting rod
inserts (E).
12.Inspect all parts for wear or damage. rods they were removed from.
Never reuse connecting rod bolts, replace with
Installing: new.
• Apply clean engine oil to all parts during installation.
10.Match the connecting rod caps to the rods using
alignment marks. Install the caps to the rods.
IMPORTANT: Avoid damage! Do not touch
bearing insert surfaces. Oil and acid from your 11.Dip entire connecting rod bolt in clean engine oil. Install
finger will corrode the bearing surface. new bolts to the rods, and tighten to specification.
1. Install the grooved bearing inserts in the crankshaft Specification:

bearing bores, aligning the tangs with the slots in the bores.
Connecting Rod Bolt Torque:
2. Install the block thrust bearings with the oil grooves 4210 . . . . . . . . . . . . . . . . . . . . . 37 - 41 N•m (27 - 30 lb-ft)
facing away from the engine block.
4310, 4410 . . . . . . . . . . . . . . . . 44 - 54 N•m (33 - 40 lb-ft)
3. Install the crankshaft.
12.Install the timing gear cover mounting plate. See
4. Install the bearing inserts in the main bearing caps,
“Timing Gear Cover Mounting Plate.”
aligning the tangs with the slots in the caps.
13.Install the rear oil seal. See “Crankshaft Rear Oil Seal.”
NOTE: The main bearing caps have “raised arrows”
that are stamped with numbers. Both correspond to 14.Install the flywheel. See “Flywheel.”
their location on the engine block. Install all bearing 15.Install the timing gear cover. See “Timing Gear Cover.”
caps with the “arrow” toward the flywheel end of the
16.Install the front oil seal. See “Crankshaft Front Oil Seal.”
engine. Install the bearing caps beginning with the
thrust bearing cap (no number), number 1, then 2, etc. 17.Install the oil pan.
The main bearing cap at the gear train end does not
have a number.

• Inspect the crankshaft gear for chipped or broken teeth.
Replace if necessary.
To Replace Gear:
1. Remove the gear from crankshaft using a knife-edge
puller and a press.
D
B
C
M82062A
• If the journal diameter (C) is less than the

specification, but greater than the wear limit, have the
journals ground undersize by a qualified machine shop.
A • If journals are ground, undersize bearing inserts
must be installed. Bearing inserts are available in 0.25
mm (0.010 in.) undersize.
• If the journal diameter is less than the wear limit,
replace the crankshaft.
M82060A
2. Heat new gear to approximately 150°C (302°F). Install Specification:

gear with timing mark (A) toward press table. Align slot in Connecting Rod Journal OD (C):
gear with key (B) in shaft. Press crankshaft into gear until 4210 . . . . . . . . . . . . . 42.95 - 42.96 mm (1.691 - 1.691 in.)
gear is tight against crankshaft shoulder.
Wear Limit . . . . . . . . . . . . . . . . . . . . 42.91 mm (1.689 in.)
c CAUTION: Avoid injury! DO NOT heat oil over

4310, 4410 . . . . . . . . 47.95 - 47.96 mm (1.888 - 1.888 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . 47.91 mm (1.886 in.)
182° C (360° F). Oil fumes or oil can ignite
above 193° C (380° F). Use a thermometer. Main Bearing Journal OD (D):
Do not allow a flame or heating element to 4210 . . . . . . . . . . . . . 46.95 - 46.96 mm (1.848 - 1.849 in.)
come in direct contact with the oil. Heat the Wear Limit . . . . . . . . . . . . . . . . . . . . . 46.91 mm (1.847 in.
oil in a well-ventilated area. Plan a safe
handling procedure to avoid burns. 4310, 4410 . . . . . . . . 53.95 - 53.96 mm (2.124 - 2.124 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . 53.91 mm (2.122 in.)
5. Install the bearing inserts and main bearing caps on the

main bearings. Tighten the main bearing bolts to
specification.
Specification:
M82061A
Main Bearing Bolt Torque
3. Inspect the crankshaft for bend using V-blocks and a dial
4210 . . . . . . . . . . . . . . . . . . 76.5 - 80.4 N•m (56 - 59 lb-ft)
indicator. Turn the crankshaft slowly and read variations on
the indicator. If the variation is greater than 0.02 mm (0.001 4310, 4410 . . . . . . . . . . . . . . . 96 - 100 N•m (71 - 74 lb-ft)
in.), replace the crankshaft.
4. Measure the crankshaft connecting rod journal and
main bearing journal diameters at several places around
each journal.

M82063
6. Measure the main bearing inner diameter.

B
• Subtract the main bearing journal OD of the
crankshaft from the main bearing ID to obtain the main
bearing oil clearance.
Specification: MX1413
Main Bearing Oil Clearance 2. Mark coupling as to which side faces flywheel for proper
4210 . . . . . . . . . . . . . . . 0.04 - 0.09 mm (0.002 - 0.004 in.) reassembly.
Wear Limit . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.) 3. Remove four coupling cap screws (A) and remove
4310, 4410 . . . . . . . . . . 0.04 - 0.07 mm (0.002 - 0.003 in.) coupling (B) from the flywheel.
Wear Limit . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
• If the crankshaft is within specification, but the main

bearing oil clearance exceeds the wear limit, replace the C
bearing inserts.
• If the crankshaft is not within specification, have
crankshaft journals ground undersize by a qualified
machine shop and install undersized bearing inserts.
• If the crankshaft is worn past the wear limit, replace
the crankshaft. E D
7. Clean and inspect the oil passages in the main bearing
journals, connecting rod journals and main bearing bores in
cylinder block.
8. Inspect the crankshaft for cracks or damage. Replace if
necessary.
MX1414
Flywheel and Coupling 4. Remove the flywheel mounting cap screws (C) and
remove the flywheel (D) from crankshaft.
Removal/Installation:
5. Dowel pin (E) in the crankshaft correctly locates the
IMPORTANT: Avoid damage! Always install new flywheel on the crankshaft.
flywheel mounting bolts. 6. Install the flywheel. Apply lubrication oil to the flywheel
bolts and tighten to specification.
1. Split the machine between the flywheel housing and the
tunnel. See “Machine Splitting Front” in the Hydrostatic Torque Specification:
Power Train section for eHydro machines; “Machine
Splitting Front” in the Gear Power Train section for CST Flywheel Bolts . . . . . . . . . . . . 83 - 88 N•m (62 - 65 lb-ft)
machines; or “Machine Splitting Front” in the SyncReverser
7. Installation of the flex-plate, clutch or coupling, is the
Power Train section for SRT machines.
reverse of removal.

Camshaft
Removing:
A
1. Remove the rocker arm assembly and push rods. See B
“Rocker Arm Assembly.”
2. Remove the timing gear cover. See “Timing Gear
Cover.” 2
3. Check the camshaft end play. See “Camshaft End Play
2 3
Check.”
3
4. Check the backlash of the timing gears. See “Timing
D 1
Gear Backlash Check.”
NOTE: If a magnetic follower holder kit is not available, 1
turn engine until oil pan is upward, to hold cam
followers away from camshaft. E
E
5. Hold the cam followers away from the camshaft using a
magnetic follower holder kit such as D15001NU. C
6. Rotate the crankshaft and align the timing marks.

MIF
IMPORTANT: Avoid damage! DO NOT allow the Picture Note: Viewed From Gear Case
camshaft lobes to hit any bearing surfaces while
removing the camshaft. Machined surfaces can 1. Rotate the crankshaft to align the timing marks (1, 2 and
be damaged. 3).
NOTE: The fuel injection drive gear (A), the camshaft
7. Remove two thrust plate mounting cap screws, the
gear (B) and the crankshaft gear (C) all must be
thrust plate, and the camshaft.
correctly timed to the idler gear (D). It is not necessary
8. Inspect all parts for wear or damage. to time the oil pump gear (E).
Due to the odd number of teeth on the idler gear, timing
Installing: marks will only align periodically.
• Apply clean engine oil on all parts during installation.
2. Install the camshaft.
IMPORTANT: Avoid damage! DO NOT allow 3. Install the thrust plate and cap screws.
camshaft lobes to hit bearing surfaces while 4. Install the timing gear cover. See “Timing Gear Cover.”
installing camshaft. Machined surfaces and
bearings can be damaged. 5. Install the push rods and rocker arm assembly. See
“Rocker Cover Removal/Installation.”

D
M82068A
2. Install the thrust plate (C) if removed. Install the gear (B)
with timing mark “C” side toward press table. Align the slot
in the gear with key (D) in shaft. Press the camshaft into
gear until gear is tight against camshaft shoulder.
A • Thrust plate must spin freely on camshaft.
MIF
1. Check the camshaft side gap using a feeler gauge.

• If the side gap (A) exceeds 0.05 - 0.25 mm (0.002 -
0.010 in.), remove the camshaft gear (B) and replace
thrust plate (C).
2. Remove the gear (if required) from camshaft using a
knife-edge puller and a press.
• Inspect the gear for chipped or broken teeth. Replace
the gear if necessary.
Gear Removal/Installation:
M82069A
c CAUTION: Avoid injury! DO NOT heat oil over 3. Inspect the camshaft for bend using V-blocks and a dial
indicator. Turn the camshaft slowly and read variations on
182° C (360° F). Oil fumes or oil can ignite
above 193° C (380° F). Use a thermometer. the indicator.
Do not allow a flame or heating element to • If the variation is greater than 0.02 mm (0.001 in.),
come in direct contact with the oil. Heat the replace the camshaft.
oil in a well-ventilated area. Plan a safe
handling procedure to avoid burns.
1. Heat the gear in oil to approximately 150°C (300°F).
IMPORTANT: Avoid damage! Be sure thrust plate E

is not between camshaft gear and camshaft
shoulder while installing gear.
M82070A
4. Measure the camshaft lobe height (E).

• Camshaft lobe height is 38.64 - 38.77 mm (1.521 -
1.526 in.).
• If the lobe height is less than 38.40 mm (1.512 in.),
replace the camshaft.

G
K
F L
M82073
M82071A
9. Measure the intermediate (K) and flywheel end (L)
5. Measure the camshaft journal diameters. camshaft bore diameters.
• Gear housing (F) and flywheel (G) end camshaft • Standard camshaft bore ID is 45.00 - 45.025 mm
journal OD is 44.93 - 44.95 mm (1.769 - 1.770 in.). (1.772 - 1.773 in.).
• Intermediate (H) camshaft journal OD is 44.91 - • If the bore diameter exceeds 45.10 mm (1.776 in.),
44.94 mm (1.768 - 1.769 in.). replace cylinder block.
• If the journal diameters are less than 44.85 mm • If the bore clearance (bore ID minus camshaft journal
(1.766 in.), replace the camshaft. OD) exceeds 0.20 mm (0.008 in.), replace camshaft,
cylinder block or both.
I • Apply John Deere Form-In-Place Gasket, or an
equivalent, on the outer edge of the plug. Install the plug
until it bottoms in the bore.
Camshaft Followers
Removing/Installing:
1. Remove the camshaft. See “Camshaft.”
J 2. Remove the oil pan and strainer.
M82072 IMPORTANT: Avoid damage! Cam followers must

be installed in the same bores from which they
6. Measure the camshaft bushing (I) diameter at the gear
were removed.
housing end.
• Standard camshaft bushing ID is 44.99 - 45.06 mm 3. Put a mark on each cam follower and the cylinder block
(1.771 - 1.774 in.). bore to aid in installation.
• Replace the bushing If the diameter exceeds 4. Remove the cam followers.
45.10 mm (1.776 in.). 5. Inspect all parts for wear or damage.
• If the bushing clearance (bushing ID minus camshaft 6. Apply clean engine oil to all parts during installation.
journal OD) exceeds 0.20 mm
(0.008 in.), replace the bushing, camshaft or both. • Installation is done in the reverse order of removal.
7. Replace the camshaft bushing using a chisel. Be careful

not to push the bushing inside the engine.
8. Align the oil holes (J) in new bushing and cylinder block.
Install bushing using a driver set.

Inspection:
B A
M82074A
1. Inspect the cam follower contact surface for normal

contact (A) or abnormal wear (B). Replace if necessary.
M82075A
2. Measure the cam follower stem diameter.

• Standard cam follower stem OD is 11.98 - 11.99 mm
(0.471 - 0.472 in.).
• If the stem diameter is less than 11.93 mm (0.470
in.), replace cam follower.
3. Measure the cam follower bore diameter in the cylinder
block.
• Standard cam follower bore ID is 12.00 - 12.02 mm
(0.472 - 0.473 in.).
• If the cam follower bore diameter exceeds 12.05 mm
(0.474 in.), replace the cylinder block.
• Standard cam follower bore clearance is 0.01 - 0.04
mm (0.0004 - 0.002 in.).
• If the bore clearance (bore ID minus follower stem
OD) exceeds 0.12 mm (0.005 in.), replace the cam
follower, cylinder block or both.

Timing Gear Cover
B C
D
E
A
H F
H
AA
G I
K E
Z
Y
X
W
L
V M
N
U
P
T O
Q E
D
S R
M91955
A - Cap Screw, M8 x 30 R - Cap Screw, M8 x 16

B - Cap Screw, M8 x 20 S - Cap Screw, M8 x 85
C - Seal Washer T - Cap Screw, M8 x 45
D - Cover U - O-Ring
E - Gasket (3 used) V - Oil Fill Cap
F - Mounting Plate W - Dowel
G - Bolt, M8 x 16 X - O-Ring
H - Form-In-Place Gasket Y - Stud, M8 x 22
I - Cap Screw, M8 x 55 Z - Nut
J - Timing Gear Cover AA- O-Ring
K - Stud, M10
L - Cap Screw
M - Cover (3 used)
N - O-Ring
O - Cap Screw, M8 x 12
P - Seal Washer, M8
Q - Oil Seal

Removal/Installation: Idler Gear
1. Remove the alternator and belt.
Cover.”
2. Check the backlash of timing gears. See “Timing Gear
Backlash Check.”
C
NOTE: Due to the odd number of teeth on the idler
gear, timing marks will only align periodically. When all
B timing marks on gears align, the piston closest to the
water pump is at TDC on compression stroke. Number
A one cylinder is closest to the flywheel.
3. Rotate the crankshaft and align the timing marks.
M57125
2. Remove the fan (A), spacer (B) and pulley (C).

3. Remove the crankshaft pulley cap screw and washer. C
4. Remove the crankshaft pulley using a two-jaw puller.
NOTE: It is not necessary to remove end cover and O- B
ring or fuel injection pump gear cover to remove timing
gear cover.
5. Remove the mounting cap screws and timing gear
cover.
6. Inspect the crankshaft oil seal for wear or damage. A
M82209A
• Replace the oil seal using a driver set. Install the seal
4. Remove two cap screws (A), shaft (B) and 43T gear (C).
with lip toward inside of gear housing cover. Install the
seal flush with surface of cover. 5. Inspect all parts for wear or damage.
Installation is done in the reverse order of removal.
6. Inspect the gear for chipped or broken teeth. Replace if
E
necessary.
• Measure the idler gear shaft diameter.
• Standard idler gear shaft OD is 45.95 - 45.98 mm
(1.809 - 1.810 in.).
• If the shaft diameter is less than 45.93 mm (1.808
D in.), replace idler gear shaft.
7. Measure the idler gear bushing diameter.
• Standard idler gear bushing ID is 46.00 - 46.03 mm
M35295 (1.811 - 1.812 in.).
7. Installation is done in the reverse order of removal. • Replace the bushing if diameter exceeds 46.03 mm
• Replace the seal washer. (1.812 in.).
• Align the pin (D) in crankshaft pulley with the hole (E) • If the bore clearance (bushing ID minus shaft OD)
in the crankshaft gear. Install the crankshaft pulley. exceeds 0.15 mm (0.006 in.), replace the bushing,
shaft, or both.
• Adjust the fan/alternator drive belt tension.

To Replace The Bushing:
D
C
B B
M82210A
1. Replace the bushing using a driver set.

2. Align the oil holes in bushing (D) and idler gear (C). A
3. Install the bushing flush with surface of idler gear. M82215A
3. Remove the mounting cap screws (A), the oil pump (B)
Timing Gear Cover Mounting Plate and gasket (C).
Removing/Installing: 4. Inspect all parts for wear or damage.
1. Remove the camshaft. See “Camshaft.” Oil Pump Disassembly/Assembly:

2. Remove the idler gear. See “Idler Gear.”
3. Remove the fuel injection pump.
4. Remove the oil pump. See “Oil Pump.”
5. Remove the mounting cap screws and plate.
6. Replace the O-Rings.
F E
7. Installation is the reverse of removal.
D
G
Oil Pan and Strainer
to remove the oil pan. M82216A
1. Remove the oil pan. 1. The gear (D) is press fit on rotor shaft (E). Remove gear
using a knife edge puller and a press.
2. Remove the oil pick up strainer.
2. Inspect all parts for wear or damage.
3. Clean and inspect all parts.
3. Coat all parts with clean engine oil.
4. Install the oil pick up strainer.
4. Install the outer rotor (F) with identification mark (G)
5. Install the oil pan. facing toward rotor shaft assembly.
6. Fill the engine with correct engine oil. 5. Measure the rotor shaft outer diameter and the shaft
hole diameter in cover.
Oil Pump • Standard clearance is 0.01 - 0.04 mm (0.001 - 0.002
in.).
• Replace the pump if the clearance is greater than 0.2
mm (0.008 in.).
Cover.”
2. Check the oil pump gear backlash. Replace the oil pump
assembly if backlash is more than 0.12 mm (0.005 in.).

M51571
6. Check the rotor recess.

• Standard rotor recess is 0.03 - 0.09 mm (0.001 - M76428
0.004 in.).
9. Check the oil pressure relief valve. If the relief valve
• Replace the pump if the recess exceeds 0.15 mm piston (H) is sticking in the pump body, clean parts to allow
(0.006 in.). free movement of the piston in pump body.
10.Inspect the spring (I) for cracks. The spring is not
serviceable. If damage is identified, replace the oil pump
assembly.
Thermostat and Water Pump

Inspection:
1. Inspect the water pump for coolant leakage. If the origin
of the leak cannot be determined, test the cooling system.
See “Cooling System Pressure Test.”
M51572 • If coolant is leaking at the pulley flange:
7. Measure outer rotor-to-pump body clearance. The shaft seal is defective. Replace the water pump.
• Standard clearance is 0.10 - 0.16 mm (0.004 - 0.006 • If coolant is leaking between the cylinder head and
in.). the pump housing:
The gasket between the head and the pump is
• Replace the pump if the clearance is more than 0.25 defective. Remove the water pump and replace the
mm (0.010 in.). gasket.
2. Inspect the water pump for a worn bearing shaft by
removing the fan belt and checking for excessive
movement of the fan. Replace the water pump if excessive
movement is noticed.
• If the bearing shaft is making noise when operating:
Check the fan belt tension. If adjustment does not
relieve the noise, the bearing shaft is defective. Replace
the water pump.
M51573
8. Check inner-to-outer rotor clearance.

• Replace the pump if clearance is more than 0.15 mm
(0.006 in.).

D
S
E
F
G
I
J
R
K
M
L
Q
P
T O N
M91821
A - Cap Screw, M8 x 20 Replacement:

B - Cover 1. Open the engine drain valve to drain coolant.
C - Gasket
2. Disconnect the coolant temperature sensor lead.
D - Thermostat
3. Disconnect the upper and lower radiator hoses.
E - Gasket
F - Plug 4. Remove the fan/alternator drive belt.
G - Gasket 5. Remove the cap screws, fan, spacer and pulley.
H - Temperature Switch 6. Remove the mounting cap screws, pump and gasket.
I - Water Pump
7. Inspect the pump for wear or damage.
J - Cap Screw, M8 x 60
K - Pulley 8. Test the thermostat for proper operation. See
“Thermostat Opening Test.”
L - Spacer
M - Fan 9. Installation is done in the reverse order of removal.
N - Cap Screw, w/washer, M6 x 25 10.Adjust the fan/alternator drive belt tension.
O - Fan Belt
P - Cap Screw, M8 x 55
Q - Gasket
R - Plug
S - Gasket
T - Drain Valve

Fuel Filter Assembly
M82370B
1. Remove the retaining ring (A) from the mounting base

(B) while holding on to the filter cover (C).
2. Remove the filter cover from the mounting base.
3. Remove and replace the O-rings (D) and filter element
(E).
4. Be sure the spring (F) is in the filter cover and place the
filter element in the filter cover.
5. Before installing the filter cover and element in the
mounting base, verify the O-ring is in the groove inside the
mounting base.
6. Install the filter cover and the element in the mounting
base.
7. Place the retaining ring over filter cover and screw on
the mounting base to retain filter cover to mounting base.
IMPORTANT: Avoid damage! Tighten only enough

to keep the filter assembly from leaking.
Overtightening the retaining nut may damage the
filter cover or retaining ring.

Component Location Fuel Supply
B
J
K D
H
I
G
MX9747
A - Fuel Tank G - Transfer Pump

B - Return Fuel Hose H - Transfer Pump-to-Filter Hose
C - Fuel Filter-to-Injection Pump Hose I - Fuel Filter
D - Nozzle Leak-Off Hose (Short) J - Fuel Tank-to-Transfer Pump Hose
E - Nozzle Leak-Off Hose (Long) K - Drain Valve
F - Air Vent Check Valve

Fuel Injection Pump 8. Remove three mounting nuts (B).
Removing:
c CAUTION: Avoid injury! Escaping fluid under

pressure can penetrate the skin causing
serious injury. Avoid the hazard by relieving
B
pressure before disconnecting hydraulic or
other lines. Tighten all connections before
applying pressure. Search for leaks with a
piece of cardboard. Protect hands and body
from high pressure fluids.

unfamiliar with this type of injury should
reference a knowledgeable source. Such
information is available from the Deere & MX9675
Company Medical Department in Moline,
Illinois, U.S.A. 9. Remove the access cover from the front of the timing
gear cover.
IMPORTANT: Avoid damage! Never steam clean 10.Rotate engine until “B” marks on injector pump gear and
or pour cold water on an injection pump while the idler gear (B) are aligned.
pump is running or warm. Doing so can damage
the pump.
C
1. Clean the injection pump lines and area around the
pump using parts cleaning solvent or steam cleaner.
D
2. Loosen the fuel injection line nuts. When loosening the
nuts on the injector pump, use another wrench to keep the
delivery valves from loosening.
3. Loosen the line clamps, and remove the fuel injection
lines.
4. Disconnect the fuel filter hoses.
5. Remove the external lube line.
6. Disconnect the fuel shutoff solenoid.
MX2355
Picture Note: Timing gear cover removed for photo

only. Timing gear cover does not need to be
removed for injector pump removal.
A
IMPORTANT: Avoid damage! DO NOT loosen four
cap screws (C) attaching gear to hub! This gear/
hub assembly times the injector pump camshaft
in relation the crankshaft for precise timing of
EPA engines. This procedure is done at the pump
manufacturing plant and cannot be duplicated in
M82230 the field!
7. Note the position of the timing marks (A) on the injection 11.Remove nut (D).
pump and the gear cover mounting plate.

4. Align marks on mounting plate and injection pump, to
same place as when removed, and tighten mounting nuts
to specifications.
5. Place a thin bead of John Deere form in place gasket on
the cover, and install the cover.
6. Connect fuel shutoff solenoid wire.
7. Connect hoses to/from fuel filter.
8. Install fuel injection lines and tighten line clamps.
Specification:
Injector Line Nuts. . . . . . . . . . . . 30 - 35Nm (22 - 25 lb ft)
IMPORTANT: Avoid damage! If the oil has been

drained out of the fuel injection pump housing,
MX9676 add oil as necessary. The fuel injection pump can
12.Use a puller to remove the gear from the injection pump be damaged if operated without the proper
shaft. Remove the puller. The gear remains in the timing amount of oil.
gear cover. 9. Remove the fill plug and add clean engine oil to the
13.Remove the injection pump and O-Ring. housing. Add until the oil begins to drip out of external lube
line inlet.
IMPORTANT: Avoid damage! DO NOT attempt to 10.Install the external lube line. When installing the line, put
service the injection pump or governor. If unit is one copper washer between the mounting bolt head and
in need of repair, it must be serviced by a lube line and the other between the lube line and housing.
qualified fuel injection repair shop. If replacement
is necessary, replace entire unit. If a new injection pump is being installed, check and adjust
injection pump static timing. See “Injection Pump Static
Installing: Timing Adjustment.”
1. Install new O-ring to the injection pump.

2. Put injection pump onto back of gear cover mounting
plate. Install three mounting nuts. Do not tighten. Align key
on shaft with keyway in gear. Be sure to align marks on
gears made during removal.
3. Install nut on timing gear. Tighten to specification.
Specification:
Timing Gear Nut . . . . . . . . . . . 58 - 68 N•m (43 - 50 lb ft)
MX1399

Fuel Injection Nozzles
A
Removing: B
IMPORTANT: Avoid damage! Never steam clean C

or pour cold water on injection pump while the
pump is running or warm. Doing so can damage
the pump.
D
1. Clean the injection pump lines and area around the
pump using a parts cleaning solvent or steam cleaner.
E
c CAUTION: Avoid injury! Escaping fluid under F

pressure can penetrate the skin causing
serious injury. Avoid the hazard by relieving
pressure before disconnecting hydraulic or
other lines. Tighten all connections before
applying pressure. Search for leaks with a
piece of cardboard. Protect hands and body
from high pressure fluids.

M82092A
unfamiliar with this type of injury should
reference a knowledgeable source. Such 4. Remove clamps (B) and leakoff hoses (C).
information is available from the Deere & 5. Remove nuts and retaining plates (A).
Company Medical Department in Moline,
Illinois, U.S.A. 6. Remove injection nozzle (D), ring (E) and Teflon heat
protector (F). If ring and protector stay in cylinder head,
2. Loosen fuel injection line connectors-to-nozzles slightly thread a cap screw into protector and pull from cylinder
to relieve pressure in the fuel system. head.
NOTE: Nozzles are matched to the cylinders. If
removing more than one nozzle, tag nozzles, according G
H
to the cylinder from which it was removed.
3. Loosen line clamp(s) and remove fuel injection lines. I
M82126
7. If nozzles are stuck in cylinder head:

• Grind the head of a cap screw (I) so it fits inside a nut
from an old injection line (J).
• Use two nuts (H) to attach a large flat washer (G) to
the cap screw.
• Install assembly onto nozzle (D) and use a puller and
slide hammer to pull nozzle from cylinder head.

8. Test injection nozzles. See “Fuel Injection Nozzle Test.” 6. After assembly is complete, test injection nozzle. See
“Fuel Injection Nozzle Test.”
Installing:
Installation is done in reverse order of removal.
• Install a new ring and heat protector when installing
injection nozzles.
Disassembly/Assembly:
NOTE: If servicing more than one nozzle, keep parts for
each nozzle separate from one another.
1. Remove retaining nut (S) and disassemble internal parts
of injection nozzle. Keep parts organized for ease of
assembly.
2. Clean and inspect nozzle assembly. See “Cleaning/
Inspection.”
Q
T
M82093A
3. Carefully clamp injector body (L) in a soft-jaw vice.

NOTE: Insert the same number of shims (M) that were
removed from injector. Number of shims will affect the
opening pressure of the fuel nozzle and will be tested
after assembly.
4. Reassemble fuel nozzle in the order shown above.
5. Tighten retaining nut to 6.8 - 8.8 N•m (60 - 78 lb-in.).

Cross Section: 1. Remove anti-corrosive grease from new or
reconditioned nozzles by washing them thoroughly in
diesel fuel.
IMPORTANT: Avoid damage! Never use a steel

L
brush to clean nozzles as this will distort the
spray hole.
2. Remove carbon from used nozzles, and clean by

washing in diesel fuel. If parts are coated with hardened
K carbon or lacquer, it may be necessary to use a brass wire
brush (supplied in Nozzle Cleaning Kit).
M
R
M82094A
3. After removing carbon or lacquer from the exterior of

nozzle, inspect sealing surfaces between separator plate
O
(P) and nozzle body (R) for nicks or scratches.
T
P 4. Contact area of separator plate (both parts) must not be
scored or pitted. Use an inspection magnifier (No. 16487 or
equivalent) to aid in making the inspection.
S
5. Check nozzle contact surface on separator plate for
Q
wear. If contact surface is more than 0.10 mm (0.004 in.),
replace nozzle assembly.
R
M37684
K. Return Pipe P. Separator Plate
L. Injector Body Q. Nozzle Valve
M. Shim(s) R. Nozzle Body R
N. Spring S. Retaining Nut
O. Spring Seat T. Index Pin M82095A
6. Inspect the piston (large) part of nozzle valve (P) to see

Cleaning/Inspection: that it is not scratched or scored and that lower (tip) end of
NOTE: To clean nozzles properly, JDF13 Nozzle valve is not broken. If any of these conditions are present,
Cleaning Kit is recommended. The Cleaning Kit is replace the nozzle assembly.
available through the John Deere SERVICEGARD™ 7. Further inspect the nozzle assembly by performing a
Catalog. slide test. Use the following procedure:

• Dip the nozzle valve (P) in clean diesel fuel. Insert
valve in nozzle body (Q).
• Hold nozzle vertical, and pull valve out about 1/3 of
its engaged length.
• Release valve. Valve should slide down to its seat by
its own weight.
Replace nozzle assembly if the valve does not slide freely
to its seat.
Starting Motor Removal and Installation

Removing:
IMPORTANT: Avoid damage! Always disconnect

the negative cable from the battery before
working on any electrical components.
MX9839
1. Remove the alternator. See “Alternator Removal And

Installation.”
2. Remove the nut securing the battery cable and wires on
the starting motor (A).
3. Disconnect the starting motor solenoid wire (B).
4. Remove the cap screws securing the starting motor to
the bell housing. Remove the starting motor.
Installing:
• DO NOT overtighten the starting motor cap screws!
Tighten the starting motor cap screws to 88 N•m (65 lb-ft).

Starting Motor Disassembly and Assembly
C D
B
A E
J
F
M94643
A - Motor Disassembly:
B - Field Coil
C - Armature
D - Brush Spring
A
E - Brush
F - Plunger
G - Solenoid
H - Overrunning Clutch
I - Pinion
J - Idler Gear
K - Drive Gear
C
M82233A
1. Disconnect the field lead (A).

2. Remove the cover screws (B).
3. Remove the cap screws (C) that secure the motor to the
clutch housing.

7. Remove the brush holder (K).
D M
L
M91666 M36759
4. Separate the cover (D) from the motor (E). 8. Remove the armature (L) from the field coil housing (M).
9. Inspect and test the brushes, holder, field coil and
armature. See “Starting Motor Inspection/Test.”
Assembly:
Assembly is done in the reverse order of disassembly.
NOTE: Apply multipurpose grease to bearing cup
inside rear cover.
N
E
F
G
M91667
5. Remove motor (E), armature (F), and brush holder (G) K

as a unit from the clutch housing (H).
NOTE: Brushes are not serviceable separately. If the
brushes require replacement, the entire brush holder,
with brushes attached, must be replaced.
M36754
IMPORTANT: Avoid damage! When installing the

rear cover, be sure the field coil brush wires (N)
do not touch the cover. Turn the brush holder (K)
J
slightly to take up slack in the brush wires. Press
the wires inward to clear the rear cover.
M36754
6. Pry the brush springs (I) away and pull the negative
brushes (J) up enough to allow the springs to hold the
brushes in place.

Starting Motor Inspection/Test • Be sure the brush lead is not touching the frame. If
there is continuity, the coil is grounded and the field coil
housing assembly must be replaced.
O
P
IMPORTANT: Avoid damage! Do not clean
I
armature with solvent. Solvent can damage
insulation on windings. Use only mineral spirits
and a soft bristle brush.
5. Test for open field coil:

• Touch one probe of tester to each field coil brush.
• If there is no continuity, the field coil is open and the
A field coil housing assembly must be replaced.
6. Inspect armature. Look for signs of dragging against
pole shoes.
K
7. Inspect commutator. Look for roughness, burned bars,
M82234 or any material which might cause short circuits between
bars. If necessary, clean and touch up with 400 sandpaper.
1. Measure brush lengths (A). Minimum brush length is 8.5
NEVER use emery cloth. Clean all dust from armature
mm (0.335 in.). Replace brush if length is below minimum.
when finished.
NOTE: Test brush holder using an ohmmeter or test
NOTE: Test armature windings using an ohmmeter or
light.
test light.
2. Test brush holder (K):
• Touch one probe of tester to negative brush holder
(O) and other probe to field brush holder (P).
• If there is continuity, replace the brush holder. S
3. Inspect springs (I) for wear or damage. Replace if

necessary.
NOTE: Test field coil using an ohmmeter or test light.
Q
T
M82236
8. Test for grounded windings:

• Touch probes on one commutator bar (S) and
armature shaft (T). Armature windings are connected in
series, so only one commutator bar needs to be
checked.
R • If test shows continuity, a winding is grounded and

the armature must be replaced.
9. Test for open circuit windings:
• Touch probes on two different commutator bars.
• If test shows no continuity, there is an open circuit
and the armature must be replaced.
M82235
4. Test for grounded field winding:

• Touch one probe of tester to field coil brush (Q) and
other probe to field coil housing (R).

Starting Motor Gear Train
Disassembly/Inspection:
D
A
MIF
10.Test for short circuit windings using a growler.

• Put armature in a growler and hold a hacksaw blade
above each slot while slowly rotating armature.
• If coil is shorted, the blade will vibrate on the slot.
B C
NOTE: A short circuit most often occurs because of
copper dust or filings between two commutator
segments.
11.If test indicates short circuit windings, clean the
commutator of dust and filings. Check the armature again. M82233
If the test still indicates a short circuit, replace the 1. Remove the field wire (A) and two motor-to-clutch
armature. housing cap screws (B).
12.Inspect armature cover and housing bearings for wear 2. Remove the motor (C) from the clutch housing (D).
or damage. Replace if necessary.
To Replace Bearings:
NOTE: The bearings are press fit.
E
M82238
3. Remove two clutch housing-to-solenoid housing screws

(E) to separate the clutch housing from the solenoid/motor
assembly.
M82237
1. Remove the bearings using a knife-edge puller set.
IMPORTANT: Avoid damage! Install both bearings

with the sealed side toward armature.
2. Install a new housing bearing (U) tight against the

shoulder of the shaft using an appropriate size socket that
only presses on the inner race of the bearing.
3. Install a new cover bearing (U) tight against the shoulder
of the shaft using a driver set.

7. Put the clutch housing assembly into a soft-jawed vice,
F as shown.
8. Tighten the vise slowly, until the drive gear compresses.
9. While holding the clutch assembly, slowly open the vise
until all spring compression is relieved.
c CAUTION: Avoid injury! The shaft could be

propelled from the clutch unit with
considerable force if the spring is not
allowed to extend fully while in the vise!
10.Remove the circlip (K) and retainer (L).
C
D
M82239
4. Remove the plunger spring (F).
J
A
B
I
M82242
11.Remove the drive gear (A), spring (B), and clutch (C)
assembly from the housing (D).
H
G
G
F
M82240
5. Remove the retainer (G), five rollers (H), and pinion gear
(I).
6. Remove the steel ball (J).
L B
K
E
M82243A
12.Remove the toothed washer (E), spring (F), and clutch

shaft (G).
13.Inspect all parts for wear or damage.
M82241

Assembly:
G
• Apply multipurpose grease to bearings, clutch shaft,
springs, pinion gears, retainer, rollers and steel ball.
• Install the large washer with the flat side toward the
clutch assembly.
• Install the retainer with the cupped side away from the
clutch assembly.
Starting Motor Solenoid

Disassembly/Inspection:
A
M36771
C 5. Inspect the contact plates (G) for excessive burning or
pitting. Contacts and plunger come as a kit. If contacts or
plunger are defective, replace all the parts with the kit.
Assembly:
I
H
M82233A
1. Disconnect the field lead (A).

2. Remove three screws (B), the cover and gasket (C).
M36771
F
D NOTE: The assembly sequence of the left and right
terminals is similar. Be sure solenoid terminal lead (H)
is installed between terminal bolt and contact plate.
E Also, be sure smaller contact plate (I) is on the left
side.
M82245
3. Remove the plunger (D).

4. Inspect the copper washer (E) and spring (F).

Alternator Removal and Installation Specification:
Exposed Brush Length:
Removing:
Minimum . . . . . . . . . . . . . . . . . . . . . . . . 4.5 mm (0.17 in.)
IMPORTANT: Avoid damage! Always disconnect Maximum. . . . . . . . . . . . . . . . . . . . . . . 10.5 mm (0.41 in.)

the negative cable from the battery before Rotor Slip Ring Diameter (Min.) . . . . . . 14 mm (0.55 in.)
working on any electrical components. Pulley Nut Torque. . . . . . . . . . . . . . . . . . 69 N•m (51 lb-ft)
1. Remove the negative cable from the battery. Belt Deflection at 98 N (22 lb-force)
2. Remove the left side panels as required to access the . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15 mm (0.4 - 0.6 in.)
alternator.
Disassembly:
NOTE: Clamp the pulley in a soft jaw vise and use an
C
air impact wrench to remove the pulley nut.
A
E
D
M91672
M52469
3. Lift the plastic protective cover (A) from the positive (red)
1. Remove the pulley nut (D) and pulley (E).
lead. Remove the nut and washer, and remove the lead
from the alternator stud.
4. Remove the wire harness connector (B) from the
G
alternator and move the wiring harness to the side F
5. Remove the mounting bolts (C). Remove the alternator.
Installing:
H
• Tighten the drive belt. See “Fan/Alternator Drive Belt
Adjustment.”
Alternator Disassembly
M52470
Equipment: 2. Remove the nut, washer and insulator from the battery
• Volt-Ohm-Amp Meter terminal post (F).
• 13 Ton Bearing Puller Set 3. Remove three screws (G) securing the cover (H) to the
body. Remove the cover.
• Soldering Gun (120 Watt Capacity)
• Solder (Only 60 - 40 Resin Core)
• Sandpaper (No. 00 or 400-grit silicon carbide paper).

K
R
I
M52475
M52472
9. Slide the rotor out of the front frame.
4. Remove two screws securing the brush holder and
cover to the body. Remove the brush holder and cover. 10.Remove the bearing retainer plate (Q).
NOTE: Remember the location of the short screw (J) on 11.Press bearing (R) from the case.
the regulator tab, and the long screw (L) on the brush
Inspection:
holder.
5. Remove the three screws securing the voltage regulator
(K) to body. Remove the voltage regulator. S
M
M52474
1. Inspect bearing (S) for smooth rotation. Replace if

M52471 necessary.
6. Remove four screws (M) and straighten the wire leads. 2. Inspect slip rings (T) for dirt or rough spots. If necessary,
7. Remove the rectifier (N). use No. 00 sandpaper or 400-grit silicon carbide paper to
polish the rings.
P 3. Measure the outer diameter of the slip rings. Replace

O the rotor if less than 14 mm (0.55 in.).
4. Check for continuity between slip rings using an
ohmmeter or continuity tester. Replace the rotor assembly
if there is no continuity.
5. Check for continuity between the slip rings and the rotor
core (U). Replace the rotor assembly if there is continuity.
NOTE: Use an ohmmeter that is sensitive to 0 - 1 ohm.
A 6. Inspect the stator for defective insulation, discoloration,
or burned odor.
M52473 NOTE: The stator is not serviced separately. If the
8. Remove cap screws and nuts (O) and slide off the rear stator is bad it must be replaced as part of the frame
case assembly (P). assembly.

7. Check for continuity between each of the four stator NOTE: Check that the rotor fan does not contact the
leads and the body. Replace the frame assembly if there is case, and that the rotor assembly turns smoothly in the
continuity. bearing.
NOTE: Set the ohmmeter to the K ohm range.
Y
Z
U
M91674
M52477
IMPORTANT: Avoid damage! The short screw is
8. Check for continuity between the main lead (U) and installed in the regulator tab (Y). If the longer
each diode lead (V). Reverse the ohmmeter leads and screw (Z) is installed in the brush holder. If
recheck. If there is continuity in one direction, but not the installed in the wrong position it will contact the
other, the diode is working correctly. Replace any diode or frame and will cause damage to the charging
rectifier plate that is not working correctly. system.
• Clamp the pulley in a soft jaw vise. Install the pulley nut.
Tighten the nut to 69 N•m (51 lb-ft).
4.5 mm
(0.17 in.)
M52478
9. Measure the length of the brush protruding from the

holder. The minimum dimension is 4.5 mm (0.17 in.).
Replace the brushes if worn below the minimum. Maximum
exposed new brush length is 10.5 mm (0.41 in.).
W
X
M52479
10.Check for continuity between the brush and terminal

(W). Check for continuity between the brush and terminal
(X). There should be continuity only at these points.
Assembly:
Assembly procedure is the reverse of disassembly.

Alternator Components
M
L
K
J
I
H
G
D
N
C
B
A
Y
Z
X O
P
Q
R
T S
V
W
M91878
A - Nut O - Cover
B - Pulley P - Screw
C - Spacer (40 amp only) Q - Brush Assembly
D - Front Frame R - Screw
E - Stator S - Screw
F - Stud T - Regulator
G - Bearing U - Diode Assembly
H - Cover V - Cap Screw
I - Screw W - Rear Frame
J - Rotor X - Nut
K - Bearing Y - Nut
L - Cover Z - Insulator Bushing
M - Thrust Washer (40 amp)
N - Cap Screw


ELECTRICAL TABLE OF CONTENTS
Y2 Fuel Shutoff Solenoid ........................... 144
Electrical
Table of Contents
Troubleshooting........................................... 145
eHydro Electronic Operating System
Troubleshooting Flowchart ........................ 145
General Information......................................113 ePowrReverser Electronic Operating System
Reading Electrical Schematics...................113 Fault Codes ............................................... 146
Theory Of Operation Information................114 ePowrReverser Electronic Operating System
Diagnostic Information................................114 Fault Code Chart ....................................... 146
Wire Color Abbreviation Chart....................114 eHydro Electronic Operating System
Common Circuit Tests................................115 Fault Codes ............................................... 150
Conductors For 12 Volt Circuits .................115 eHydro Electronic Operating System
Specifications ...............................................116 Fault Code Chart ....................................... 151
System Specifications ................................116 Theory and Diagnosis ................................. 154
Component Location....................................118 ePowrReverser - e MatchOS Electronic
Instrument Panel ........................................118 Operating System ...................................... 154
Machine Front Section ...............................119 eHydro - e MatchOS Electronic
Machine Rear Section ................................120 Operating System ...................................... 155
Load Center................................................121 Power Circuit Operation............................. 158
System Schematics ......................................122 Power Circuit Electrical Schematic ............ 161
Schematic and Wiring Harness Legend .....122 Power Circuit Diagnosis............................. 165
W1 Main Electrical Schematic....................124 Cranking Circuit Operation ........................ 171
W2 SST and W3 ePowrReverser Cranking Circuit Electrical Schematic........ 172
Electrical Schematic ...................................128 Cranking Circuit Diagnosis ........................ 173
W4 eHydro and Cruise Control Manifold Heater and Light
Electrical Schematic ...................................129 Circuit Operation........................................ 175
W1 Main Wiring Harness............................131 Manifold Heater and Light
W2 SST Jumper Plug Wiring Harness .......135 Circuit Electrical Schematic ....................... 176
W3 ePowrReverser Wiring Harness...........135 Manifold Heater and Light
W4 eHydro Wiring Harness........................137 Circuit Diagnosis........................................ 177
W5 Cruise Control Fuel Supply Circuit Operation.................... 179
Wiring Harness (standard) .........................139 Fuel Supply Circuit Electrical Schematic -
W6 Cruise Control W1 Main with W2 SST and W3 ePowrReverser
Wiring Harness (optional)...........................139 ................................................................... 180
W1 Main Wiring Harness Fuel Supply Circuit Electrical Schematic -
Color Codes ...............................................139 W1 Main with W4 eHydro .......................... 182
W2 SST Jumper Wiring Harness Fuel Supply Circuit Diagnosis.................... 184
Color Codes ...............................................142 Engine Shutoff Circuit Operation ............... 189
W3 ePowrReverser Wiring Harness Engine Shutoff Circuit Electrical Schematic -
Color Codes ...............................................142 W1 Main with W2 SST and W3 ePowrReverser
W4 eHydro Wiring Harness ................................................................... 191
Color Codes ...............................................143 Engine Shutoff Circuit Electrical Schematic -
W5 eHydro Cruise Control Wiring Harness W1 Main with W4 eHydro .......................... 193
Color Codes (standard) ..............................143 Engine Shutoff Circuit Diagnosis ............... 195
W6 eHydro Cruise Control Wiring Harness Charging Circuit Operation ........................ 201
Color Codes (optional) ...............................144 Tachometer Circuit Operation.................... 201
S13 Brake Switch - eHydro ........................144 Hour Meter Circuit Operation..................... 201
T1 Flywheel Speed Sensor - eHydro .........144 Charging, Tachometer and Hour Meter
T2 MFWD Speed Sensor - eHydro ............144 Circuit Electrical Schematic ....................... 202
Electrical Table of Contents - 107

Charging, Tachometer and Hour Meter Mid PTO Circuit Electrical Schematic ........ 248
Circuit Diagnosis ........................................203 Mid PTO Circuit Diagnosis......................... 249
ePowrReverser - Forward Drive MFWD Circuit Operation............................ 254
Circuit Operation ........................................205 MFWD Circuit Electrical Schematic ........... 255
ePowrReverser - Forward Drive MFWD Circuit Diagnosis............................ 256
Circuit Electrical Schematic........................206 Instrument Panel Lights
ePowrReverser - Forward Drive Circuit Operation........................................ 258
Circuit Diagnosis ........................................207 Instrument Panel Lights
ePowrReverser - Reverse Drive Circuit Electrical Schematic ....................... 259
Circuit Operation ........................................210 Instrument Panel Lights
ePowrReverser - Reverse Drive Circuit Diagnosis........................................ 260
Circuit Electrical Schematic........................211 Light Circuit Operation ............................... 262
ePowrReverser - Reverse Drive Lights Circuit Electrical Schematic............. 263
Circuit Diagnosis ........................................212 Lights Circuit Diagnosis ............................. 264
eHydro - Forward Drive Turn Signal Lights Circuit Operation.......... 267
Circuit Operation ........................................215 Turn Signal Lights
eHydro - Forward Drive Circuit Electrical Schematic ....................... 268
Circuit Electrical Schematic........................217 Turn Signal Lights
eHydro - Forward Drive Circuit Diagnosis........................................ 269
Circuit Diagnosis ........................................218 Diverter Valve
eHydro - Reverse Drive Circuit Operation (optional)........................ 273
Circuit Operation ........................................221 Diverter Valve
eHydro - Reverse Drive Circuit Electrical Schematic (optional) ....... 274
Circuit Electrical Schematic........................223 Diverter Valve
eHydro - Reverse Drive Circuit Diagnosis (optional)........................ 275
Circuit Diagnosis ........................................224 Tests and Adjustments ............................... 277
eHydro - Cruise Control Ground Circuit Test.................................... 277
Circuit Operation (standard) .......................227 Battery Voltage and
eHydro - Cruise Control Specific Gravity Test.................................. 277
Circuit Electrical Schematic (standard) ......228 Battery - Charge ........................................ 278
eHydro - Cruise Control Battery - Load Test .................................... 279
Circuit Diagnosis (standard) .......................229 Unregulated Amperage Test...................... 279
eHydro - Cruise Control Regulated Amperage and
Circuit Operation (optional) ........................233 Voltage Test............................................... 280
eHydro - Cruise Control Starting Motor Solenoid Test ..................... 280
Circuit Electrical Schematic (optional)........234 Starting Motor Amperage Draw Test ......... 281
eHydro - Cruise Control No-Load Amperage Draw and
Circuit Diagnosis (optional) ........................235 RPM Test................................................... 281
eHydro - Load Match and Motion Match Relay Test.................................................. 282
Circuit Operation ........................................239 Engine Oil Pressure Switch Test ............... 283
eHydro - Load Match and Motion Match Engine Coolant Temperature
Circuit Electrical Schematic........................240 Sensor Test ............................................... 284
eHydro - Load Match and Motion Match Manifold Heater Test ................................. 284
Control Circuit Diagnosis............................241 Key Switch Test ......................................... 284
Rear PTO Circuit Operation .......................243 Fuse Test................................................... 285
Rear PTO Circuit Electrical Schematic.......244 Control Panel Light Test ............................ 285
Rear PTO Circuit Diagnosis .......................245 Diode Block Test........................................ 286
Mid PTO Circuit Operation .........................247 Light Switch Test ....................................... 286

Seat Switch Test ........................................287 eHydro - Electronic Operating System
Transmission Neutral Switch Test - Automatic Calibration................................. 312
SST and ePowrReverser............................287
Turn Signal Switch Test .............................288
Rear PTO Switch Test................................288 European Electrical Section ....................... 315
Mid PTO Switch Test..................................289 European Electrical Theory ....................... 315
MFWD, Rear PTO and Mid PTO Component Location ................................... 316
Solenoid Test .............................................289 Instrument Panel........................................ 316
Cruise Control Switch Test - eHydro ..........290 Machine Front Section............................... 317
Res/+, Set/- Switch Test - eHydro ..............290 Machine Rear Section ............................... 318
Brake Switch Load Center ............................................... 319
Test and Adjustment - eHydro....................291 System Schematics ..................................... 320
Park Brake Switch Schematic and Wiring Harness Legend .... 320
Test and Adjustment ..................................291 W1 Main Electrical Schematic ................... 323
Fuel Gauge Sensor Test ............................292 W2 SST and W3 ePowrReverser
Fuel Shutoff Solenoid Test .........................292 Electrical Schematic .................................. 328
Bottom of Clutch Switch Test and W4 eHydro and Cruise Control
Adjustment - ePowrReverser .....................293 Electrical Schematic .................................. 329
MFWD Switch Test.....................................293 W1 Main Wiring Harness ........................... 331
Load Match Switch Test - eHydro ..............294 W2 SST Jumper Plug Wiring Harness....... 336
Motion Match Switch Test ..........................294 W3 ePowrReverser Wiring Harness .......... 336
Diverter Valve Solenoid Test......................295 W4 eHydro Wiring Harness ....................... 338
Proportional Drive Solenoid W5 Cruise Control
Test - ePowrReverser ................................295 Wiring Harness (standard)......................... 340
Proportional Drive Solenoid W6 Cruise Control
Test - eHydro..............................................296 Wiring Harness (optional) .......................... 340
F-N-R Switch Test - ePowrReverser ..........296 W1 Main Wiring Harness Color Codes ...... 341
Test and Calibration Kit ..............................297 W2 SST Jumper Wiring Harness
ePowrReverser - Clutch Position Color Codes............................................... 344
Potentiometer Test .....................................297 W3 ePowrReverser Wiring Harness
ePowrReverser - Clutch Position Color Codes............................................... 344
Potentiometer Adjustment ..........................298 W4 eHydro Wiring Harness
ePowrReverser - Color Codes............................................... 345
Pressure Transducer Test..........................299 W5 eHydro Cruise Control Wiring Harness
ePowrReverser - Color Codes (standard) ............................. 345
Proportional Solenoid Test .........................301 W6 eHydro Cruise Control Wiring Harness
eHydro - Throttle Position Color Codes (optional)............................... 346
Potentiometer Test .....................................303 S13 Brake Switch - eHydro........................ 346
eHydro - Throttle Position Potentiometer T1 Flywheel Speed Sensor - eHydro......... 346
Adjustment and Calibration ........................304 T2 MFWD Speed Sensor - eHydro............ 346
eHydro - Drive Pedal Y2 Fuel Shutoff Solenoid ........................... 346
Potentiometer Test .....................................305 Troubleshooting........................................... 347
eHydro - Drive Pedal Potentiometer eHydro Electronic Operating System
Adjustment and Calibration ........................307 Troubleshooting Flowchart ........................ 347
eHydro - Flywheel Speed Sensor ePowrReverser Electronic
Test ............................................................308 Operating System Fault Codes.................. 348
eHydro - MFWD Speed Sensor Test..........309 ePowrReverser Electronic
eHydro - Proportional Solenoid Test ..........311 Operating System Fault Code Chart.......... 348

eHydro Electronic ePowrReverser - Reverse Drive
Operating System Fault Codes ..................352 Circuit Operation........................................ 414
eHydro Electronic ePowrReverser - Reverse Drive
Operating System Fault Code Chart ..........353 Circuit Electrical Schematic ....................... 415
Theory and Diagnosis ..................................356 ePowrReverser - Reverse Drive
ePowrReverser - e MatchOS Electronic Circuit Diagnosis........................................ 416
Operating System.......................................356 eHydro - Forward Drive
eHydro - e MatchOS Electronic Circuit Operation........................................ 419
Operating System.......................................357 eHydro - Forward Drive
Power Circuit Operation .............................360 Circuit Electrical Schematic ....................... 421
Power Circuit Electrical Schematic.............363 eHydro - Forward Drive
Power Circuit Diagnosis .............................368 Circuit Diagnosis........................................ 422
Cranking Circuit Operation .........................374 eHydro - Reverse Drive
Cranking Circuit Electrical Schematic ........375 Circuit Operation........................................ 425
Cranking Circuit Diagnosis .........................376 eHydro - Reverse Drive
Manifold Heater and Light Circuit Electrical Schematic ....................... 427
Circuit Operation ........................................378 eHydro - Reverse Drive
Manifold Heater and Light Circuit Diagnosis........................................ 428
Circuit Electrical Schematic........................379 eHydro - Cruise Control
Manifold Heater and Light Circuit Operation (standard) ...................... 431
Circuit Diagnosis ........................................380 eHydro - Cruise Control
Fuel Supply Circuit Operation ....................382 Circuit Electrical Schematic (standard)...... 432
Fuel Supply Circuit Electrical Schematic - eHydro - Cruise Control
W1 Main with W2 SST and W3 ePowrReverser Circuit Diagnosis (standard) ...................... 433
...................................................................383 eHydro - Cruise Control
Fuel Supply Circuit Electrical Schematic - Circuit Operation (optional)........................ 437
W1 Main with W4 eHydro...........................385 eHydro - Cruise Control
Fuel Supply Circuit Diagnosis ....................387 Circuit Electrical Schematic (optional) ....... 438
Engine Shutoff Circuit Operation................393 eHydro - Cruise Control
Engine Shutoff Circuit Electrical Schematic - Circuit Diagnosis (optional)........................ 439
W1 Main with W2 SST and W3 ePowrReverser eHydro - Load Match and Motion Match
...................................................................395 Circuit Operation........................................ 443
Engine Shutoff Circuit Electrical Schematic - eHydro - Load Match and Motion Match
W1 Main with W4 eHydro...........................397 Circuit Electrical Schematic ....................... 444
Engine Shutoff Circuit Diagnosis................399 eHydro - Load Match and Motion Match
Charging Circuit Operation.........................405 Control Circuit Diagnosis ........................... 445
Tachometer Circuit Operation ....................405 Front PTO Clutch Circuit Operation........... 447
Hour Meter Circuit Operation .....................405 Front PTO Clutch
Charging, Tachometer and Hour Meter Circuit Electrical Schematic ....................... 448
Circuit Electrical Schematic........................406 Front PTO Clutch Circuit Diagnosis........... 449
Charging, Tachometer and Hour Meter Rear PTO Circuit Operation....................... 450
Circuit Diagnosis ........................................407 2-Speed PTO Lights .................................. 450
ePowrReverser - Forward Drive Rear PTO Circuit Electrical Schematic ...... 451
Circuit Operation ........................................409 Rear PTO Circuit Diagnosis....................... 453
ePowrReverser - Forward Drive Mid PTO Circuit Operation......................... 455
Circuit Electrical Schematic........................410 Mid PTO Circuit Electrical Schematic ........ 456
ePowrReverser - Forward Drive Mid PTO Circuit Diagnosis......................... 457
Circuit Diagnosis ........................................411 MFWD Circuit Operation............................ 461

MFWD Circuit Electrical Schematic............462
MFWD Circuit Diagnosis ............................463
Instrument Panel Lights
Circuit Operation ........................................465
Circuit Electrical Schematic........................466
Circuit Diagnosis ........................................467
Light Circuit Operation................................469
Brake Lights Operation...............................469
Lights Circuit Electrical Schematic .............470
Lights Circuit Diagnosis..............................471
Turn Signal Lights Circuit Operation ..........475
Hazard Switch Operation ...........................475
Turn Signal and Hazard Lights
Circuit Electrical Schematic........................476
Turn Signal Lights Circuit Diagnosis ..........477
Diverter Valve Circuit Operation (optional).483
Diverter Valve
Circuit Electrical Schematic (optional)........484
Diverter Valve Circuit Diagnosis (optional).485


ELECTRICAL GENERAL INFORMATION
General Information contains a device identifying letter (H) and number (I).
The identifying letter is always the same for a specific
Reading Electrical Schematics component, but the identifying numbers are numbered
consecutively from upper left to lower right. The terminal
The schematic is made up of individual circuits laid out in a designation (J) is placed directly outside the symbol next to
sequence of related functions. It is formatted with all power the connecting wire path. Switch positions (K) are also
wires (A) across the top and all ground wires (B) across the placed directly outside the symbol. The solid line (L) shows
bottom. Current flow is generally from top to bottom the position the switch is currently in and dash lines (M)
through each circuit and component. All components are represent other switch positions.
shown in the OFF position. The diagram does not list
connector (C) information unless needed to avoid Each circuit is identified at the bottom of the drawing by a
confusion. If the connector is shown, the number next to it section number (N) and section name (O).
is the terminal pin location (D) in the connector. The circuit number (P) and wire color (Q) of the wires are
Each component is shown by a symbol (E), its name (F), shown directly next to the wire path.
and an identification code (G). The identification code
S1 Key On Off
Switch F2 414 Seat Seat
Wht
15 Amp Yel/ S2
Wht
B Fuse Blk Seat A
Red Red
Switch
800
X1 S1
X2 X3 Pink D
X3 D
M 6
Start C K2
Ignition
210 Run Relay
Red
Off 30 87
L K J
F3 85
15 Amp 86
Fuse
F1 K1
Fusible Start
Relay 710
Link X3 Pur
H
1
215
Org X2
721
Pur/
Wht
Red 805 Pnk/Blk F
W3
Engine X3
Wiring X4
B S E Yel/
G T1 Harness Wht T2
I Ignition
X3 Ignition X5
G1 M1 H Coil Yel/Wht Yel/Wht Coil
Battery Starting P
M Motor
Blk B E1 Yel/ E2 Q
Spark Wht Spark
Plug Plug
W1 Wht Blk/Yel
Shielded F
E O C N
Ground 105 Blk
SE1-Power and Starting Circuit SE2-Ignition and Interlock Circuit SE3-PTO and Interlock
MIF used consistently on all diagrams in this section.

The same component name and identification code are Components can be easily cross-referenced.
Electrical General Information - 113

Theory Of Operation Information Wire Color Abbreviation Chart
The theory of operation stories divide the electrical system Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black
into individual circuits by function. Each circuit is isolated Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue
from the main wiring schematic and only shows the
components that are used in it. The story contains Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown
information on function, operating conditions, and theory of Grn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green
operation. The circuit schematics are drawn with the Gry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gray
components in the operating position, with the power, or
battery positive, into them across the top and the ground, or Org. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange
battery negative, across the bottom. Pnk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink
Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple
Diagnostic Information Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
The diagnostic procedures is used to test the complete Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tan
circuit regardless of the problem or complaint. Select a Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White
symptom or system from the quick check or
troubleshooting chart and follow the test procedures under Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow
that heading. Blk/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black/White
The diagnostic procedure lists: Blu/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue/White
• Test conditions Brn/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown/White
• Test sequence Brn/Yel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown/Yellow
• Test location Dk Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Blue

Dk Brn/Lt Grn . . . . . . . . . . . . . . Dark Brown/Light Green
• Normal reading
Dk Brn/Red . . . . . . . . . . . . . . . . . . . . . . Dark Brown/Red
• Check or test to perform if reading is not normal
Dk Brn/Yel . . . . . . . . . . . . . . . . . . . . . .Dark Brown/Yellow
When performing the test or check, be sure to set your
machine up to the TEST POINT/PROCEDURES listed in Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Green
the first column and follow the sequence carefully. The Lt Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue
middle RESULTS column gives the reading or condition
Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Green
that should be obtained in BOLD print. If the results of the
test or check are not normal, perform the test, check, or Org/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange/White
adjustment listed below the BOLD print. The system Pnk/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink/Black
diagram that accompanies each test procedure is drawn to
Pur/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Purple/White
resemble machine components. The leader line points to
the exact point the test is to be made. Red/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black
Red/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/White
Wht/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Black
Wht/Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red
Yel/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Black
Yel/Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Red
Yel/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/White

Common Circuit Tests High Resistance or Open Circuit:
Shorted Circuit:
M85601 MIF
High resistance or open circuits usually result in slow, dim

or no component operation (i.e. poor, corroded, or
disconnected connections). Voltage at the component will
be low when the component is in operation. To test for high
resistance and open circuits:
M85600 MIF
1. Check all terminals and grounds of the circuit for
A shorted circuit may result in the wrong component corrosion.
operating (i.e. improper wire-to-wire contact). To test for a
2. If terminals are not corroded or loose, the problem
shorted or improperly wired circuit:
3. is in the component or wiring.
1. Turn component switch ON.
2. Start at the controlling switch of the component that Grounded Circuit:
should not be operating.
3. Follow the circuit and disconnect wires at connectors
until component stops operating.
4. Shorted or improper connections will be the last two
wires disconnected.
M85602 MIF
Grounded circuits usually result in no component operation

or a blown fuse.
Conductors For 12 Volt Circuits
STRANDED CONDUCTORS FOR 12 VOLT CIRCUITS
SAE WIRE SIZE (GAUGE) 20 18 16 14 12 10
METRIC WIRE SIZE (MM) 0.5 0.8 1.0 2.0 3.0 5.0
TYPICAL STRANDING 7 X 28 16 X 30 19 X 29 19 X 27 19 X 25 19 X 23
MINIMUM CONDUCTOR AREA 1072 1537 2336 3702 5833 9343

IN CIRCULAR MILS

ELECTRICAL SPECIFICATIONS
Specifications
System Specifications
Battery
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12VDC
BCI Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22NF
CCA Rating (Amps @ -18° C (0° F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 amps
Reserve Capacity (minutes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.265 or above
Electrolyte Required Fill (Approx.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt.)
Load Test (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 amps for 15 seconds
Starting Motor
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Solenoid Shift
Size (4210) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 kW (1.6 hp)
Size (4310 and 4410). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 kW (1.9 hp)
Amp Draw (on vehicle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 amps (maximum)
No-Load Amp Draw (free running) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 amps (maximum) @ 4440 rpm
Alternator
Regulated Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2 - 14.8 VDC
Unregulated Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 VAC
North American / European

Rating (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 amps
Unregulated Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 amps (minimum)
European
Rating (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 amps
Unregulated Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 amps (minimum)
Fuel Shutoff Solenoid (Dual Coil)

Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VDC
Pull-In Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 VDC
Half Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 VDC
Sensors
Engine Coolant Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approximately 40 - 700 ohms
Engine Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Closes (light ON to OFF) @ 49 kPa (7.1 psi)
ePowrReverser Pressure Transducer Threshold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137.9 kPa (20.0 psi)
Fuel Gauge
Fuel Gauge Resistance (variable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 5 - 110 ohms
Fuel Gauge Voltage (variable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.72 - 0.87 VDC
Electrical Specifications - 116

ELECTRICAL SPECIFICATIONS
Manifold Heater
Resistance (through element) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approximately 0.3 - 0.5 ohms
Lighting
Headlights (halogen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Watts, Type H4
Turn/Tail Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37/8 Watts - Type 1157
Hazard Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Watt, Type 1156
Instrument Panel Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 Watts - Bayonet Base
Electrical Specifications - 117

ELECTRICAL COMPONENT LOCATION
Component Location
Instrument Panel
B D
C
A
E
F
G H I J K L
M P
O
N
MX9726
A - Fuel Gauge
B - Left Turn Light
C - Engine Tachometer
D - Right Turn Light
E - Engine Coolant Temperature Gauge
F - Hour Meter
G - PTO Light
H - Cruise Indicator Light (opt. eHydro)
I - Cold Start Light
J - Discharge Light
K - Park Brake Light
L - Oil Pressure Light
M - Turn Signal Switch
N - Load Match Switch (opt. eHydro)
O - Light Switch
P - Throttle Lever
Electrical Component Location - 118

Machine Front Section
L M
N
O
K
J P
I
H
F
E
D
C
Q
S
T
X W
MIF
A - Battery M - Instrument Panel

B - Headlights N - Light Switch
C - Frame Ground O - Load Match Switch (opt. eHydro)
D - Engine Coolant Temperature Switch P - Turn Signal Switch
E - Fuel Shutoff Solenoid Q - Drive Controller (ePowrReverser and eHydro)
F - Manifold Heater R - X5 Connector
G - Flywheel Speed Sensor (eHydro) S - Load Center
H - Fuel Gauge Sensor T - Diagnostic Connector
I - Key Switch U - Engine Oil Pressure Switch
J - Park Brake Switch V - Starting Motor Solenoid and Starting Motor
K - Brake Switch (eHydro) W - Fusible Link
L - Throttle Position Potentiometer X - Alternator

Machine Rear Section
Q
J K O R
N
I M
L
P
H S
G
V W
MIF
A - Forward Solenoid (ePowrReverser and eHydro) L - Mid PTO Solenoid (option)

B - Reverse Solenoid (ePowrReverser and eHydro) M - MFWD Solenoid (option)
C - Forward Pedal Potentiometer (eHydro) N - Rear PTO Solenoid
D - Reverse Pedal Potentiometer (eHydro) O - Back-up Alarm Connector
E - Cruise/Max Speed Switch (opt. eHydro) P - Tail/Turn Lights
F - Res/+ Set/- Switch (opt. eHydro) Q - Hazard Lights
G - Mid PTO Switch (option) R - Right Lights Connectors
H - Rear PTO Switch S - Seat Switch
I - Status Indicator Light (ePowrReverser and T - Left Lights Connectors
eHydro) U - MFWD Speed Sensor (eHydro)
J - Motion Match Switch (ePowrReverser and V - Transmission Neutral Switch (SST and
eHydro) ePowrReverser)
K - MFWD Switch W - W7 Jumper wire (eHydro)

Load Center
I K M
A B
J L N
C D
O P
Q R S T
U V W
E F
X Z
G
H
Y AA
MX9720
A - V1 - Diode Block W - F12 - Fuse 10A stored in F11 for drive controller
B - V2 - Diode Block calibration start up.
C - K1 - Manifold Heater Relay X - K13 - Neutral Relay
D - K4 - Engine Run Relay Y - K14 - Mid PTO Interlock Relay
E - K2 - Start Relay Z - K15 - Mid PTO Lockout Relay
F - K5 - Trailer Connector Power Relay (opt.) AA- K16 - Mid PTO Relay
G - K3 - Fuel Shutoff Solenoid Pull-in Relay
H - K6 - Fuel Shutoff Solenoid Timer Module
I - K7 - Turn Signal Interlock Relay
J - K8 - Turn Signal Latch Relay
K - K9 - Right Turn Light Relay
L - K10 - Left Turn Light Relay
M - K11 - Rear PTO Interlock Relay
N - K12 - PTO interlock Relay
O - F1 - Fuse 30A
P - F3 - Fuse 30A
Q - F5 - Fuse 20A
R - F6 - Fuse 20A
S - F7 - Fuse 20A
T - F8 - Fuse 20A
U - F10 - Fuse 10A
V - F11 - Blank, used in F12 for drive controller
calibration start up.

ELECTRICAL SYSTEM SCHEMATICS
System Schematics H8-Left Turn Light
H9-Oil Pressure Light
Schematic and Wiring Harness Legend H10-Instrument Lights
A1-Electronic Drive Controller (ePowrReverser) H11-ePowrReverser Indicator Light
A2-Electronic Drive Controller (eHydro) H12-Backup Alarm (ePowrReverser)
B1-Fuel Gauge Sensor H13-eHydro Indicator Light
B2-Engine Oil Pressure Switch H14-Backup Alarm (eHydro)
B3-Engine Coolant Temperature Sensor K1-Manifold Heater Relay
B4-Forward Pressure Transducer (ePowrReverser) K2-Start Relay
B5-Reverse Pressure Transducer (ePowrReverser) K3-Fuel Shutoff Solenoid Pull-in Relay
E1-Left Hazard Light K4-Engine Run Relay
E2-Right Hazard Light K5-Trailer Connector Power Relay (optional)
E3-Left Tail/Turn Light K6-Fuel Shutoff Solenoid Timer Module
E4-Right Tail/Turn Light K7-Turn Signal Interlock Relay
E5-Left Headlight K8-Turn Signal Latch Relay
E6-Right Headlight K9-Right Turn Light Relay
E7-Left Work Light K10-Left Turn Light Relay
E8-Right Work Light K11-Rear PTO Interlock Relay
F1-Fuse 30A K12-PTO Interlock Relay
F2-Fuse 30A (Used with trailer connector option) K13-Neutral Relay
F3-Fuse 30A K14-Mid PTO Interlock Relay
F4-Not Used K15-Mid PTO Lockout Relay
F5-Fuse 20A K16-Mid PTO Relay
F6-Fuse 20A M1-Starting Motor
F7-Fuse 20A P1-Engine Tachometer
F8-Fuse 20A P2-Hour Meter
F10-Fuse 10A P3-Fuel Gauge
F1-Fuse 10A used in F12 for drive controller calibration P4-Engine Coolant Temperature Gauge
start up.
R1-Manifold Heater
F12-Blank, uses fuse in F11 for drive controller calibration
R2-Clutch Position Potentiometer (ePowrReverser)
start up.
R3-Forward Pedal Potentiometer (eHydro)
G1-Battery
R4-Throttle Position Potentiometer (eHydro)
G2-Alternator
R5-Reverse Pedal Potentiometer (eHydro)
H1-Backup Alarm
S1-Key Switch
H2-PTO Light
S2-Seat Switch
H3-Cold Start Light
S3-Transmission Neutral Switch (SST and ePowrReverser)
H4-Park Brake Light
S4-Park Brake Switch
H5-Discharge Light
S5-Rear PTO Switch
H6-Right Turn Light
S6-Mid PTO Switch
H7-Cruise Indicator Light
S7-MFWD Switch
Electrical System Schematics - 122

S8-Turn Signal Switch X11-W1 Main Wiring Harness to E2 Right Hazard Light
S9-Light Switch X12-W1 Main Wiring Harness to E2 Right Hazard Light
S10-F-N-R Switch (ePowrReverser) X13-W1 Main Wiring Harness to E3 Left Tail/Turn Light
S11-Clutch Switch (ePowrReverser) X14-W1 Main Wiring Harness to E3 Left Tail/Turn Light
S12-Motion Match Switch (ePowrReverser) X15-W1 Main Wiring Harness to E4 Right Tail/Turn Light
S13-Brake Switch (eHydro) X16-W1 Main Wiring Harness to E4 Right Tail/Turn Light
S14-Load Match Switch (eHydro) X17-W1 Main Wiring Harness to E7 Left Work Light
S15-Res/Accel, Set/Decel Switch (eHydro) X18-W1 Main Wiring Harness to E3 Left Tail/Turn Light
S16-Cruise Control/Max Speed Switch (eHydro) X19-W1 Main Wiring Harness to E8 Right Work Light
S17-Motion Match Switch (eHydro) X20-W1 Main Wiring Harness to E4 Right Tail/Turn Light
T1-Flywheel Speed Sensor (eHydro) X21-W3 ePowrReverser Wiring Harness to A1 Electronic
Drive Controller
T2-MFWD Speed Sensor (eHydro)
X22-W3 ePowrReverser Wiring Harness to A1 Electronic
V1-Diode Block
Drive Controller Diagnostic Interface (ePowrReverser)
V2-Diode Block
W1-Frame Ground Drive Controller Diagnostic Interface (ePowrReverser)
Y1-Starting Motor Solenoid X24-W3 ePowrReverser Wiring Harness to R2 Clutch
Y2-Fuel Shutoff Solenoid Position Potentiometer (ePowrReverser)
Y3-MFWD Solenoid X25-W4 eHydro Wiring Harness to A2 Electronic Drive

Controller
Y4-Main PTO Solenoid
X26-W4 eHydro Wiring Harness to A2 Electronic Drive
Y5-Mid PTO Solenoid Controller Diagnostic Interface (eHydro)
Y6-Forward Proportional Solenoid (ePowrReverser) X27-W4 eHydro Wiring Harness to W5 Cruise Control
Y7-Reverse Proportional Solenoid (ePowrReverser) Wiring Harness
Y8-Reverse Proportional Solenoid (eHydro) X28-W4 eHydro Wiring Harness to R3 Forward Pedal
Potentiometer
Y9-Forward Proportional Solenoid (eHydro)
X29-W4 eHydro Wiring Harness to T1 Flywheel Speed
Connectors: Sensor
X1-W1 Main Wiring Harness to Fusible Link X30-W4 eHydro Wiring Harness to R4 Throttle Position
X2-W1 Main Wiring Harness to Y2 Fuel Shutoff Solenoid Potentiometer
X3-W1 Main Wiring Harness to W8 Diverter Valve Wiring X31-W4 eHydro Wiring Harness to T2 MFWD Speed
Harness Sensor
X4-W1 Main Wiring Harness to S3 Transmission Neutral X32-W4 eHydro Wiring Harness to R5 Reverse Pedal
Switch (SST and ePowrReverser) Potentiometer
X4-W1 Main Wiring Harness to W7 Jumper Wire (eHydro) Wiring Harnesses:

X5-W1 Main Wiring Harness to W2 SST Jumper Wiring W1-Main Wiring Harness
Harness, or W3 ePowrReverser Wiring Harness, or W4
W2-SST Jumper Plug Wiring Harness
eHydro Wiring Harness
W3-ePowrReverser Wiring Harness
X6-W1 Main Wiring Harness to Trailer Connector
W4-eHydro Wiring Harness
X7-W1 Main Wiring Harness to Instrument Panel
W5-Cruise Control Wiring Harness (standard)
W6-Cruise Control Wiring Harness (optional)
X9-W1 Main Wiring Harness to E1 Left Hazard Light
W7-Jumper Wire (eHydro)
X10-W1 Main Wiring Harness to E1 Left Hazard Light
W8-Diverter Valve Wiring Harness (optional)

W1 Main Electrical Schematic
002A Red 002A Red
Fuse Block Internal Link
002D Red
B
F1 4 G
Fuse
012 G2
Red 1 6 572A Red 072A Red IG
L
Alternator F2
2 5 072B Red X3 562C Red 325
P 334 Fuse
Yel (used
Dk Grn
3 212A Red 072C F5 Fuse with
Red 562D Red 562A Red X5 trailer
S1 Key
7 385B Dk Grn A option)
Switch 562E Red
Start
Run
Off 572B Red X5
Acc. 334 Yel
385A Dk Grn H 385A Dk Grn
Aid
002C
Off
S2 Seat 325 Dk Grn
Red Switch 539A 1
Wht 2 556 Lt Blu
(Off Seat)
572D Red 3
002B Red 385C (On Seat)
Dk Grn V1 Diode
539D Wht 539B Wht 4
Block 1
X1 F10
30 86 K1 5 212B
518A Gry
521 Fuse
Manifold 6 Brn Red
Fusible Heater 539C Wht X5
Link 87A 87 85 Relay 552
X5 to W2 SST, J Red
383
S3 Transmission
Org 050E Neutral Switch W3 ePRT,
(SST and ePRT) In Neutral F X5
Blk In Gear
W4 eHydro
050F X4 Wiring Harness
Blk 572C 518B Gry X4 573A Org
Red
R1 Manifold 30 86 X4 X4 002D
Heater K2 X5
Red
Start W7 eHydro 303 E 252
002A Red 87A 87 85 Relay V1 Lt Blu Red
Diode Jumper
30 86 K4
309 Wht Block 1 Wire Engine
B A 010E Blk 7 8 302A Red Run
010F 87A 87 85 Relay 212C
010Z Blk 302B Red
Blk
Red K5
86 30
X2 302C Red Trailer
050F Blk Relay
M 85 87 87A (opt.)
Wht 222
050G Blk Red 7
M1 Y2 Fuel
Starting Shutoff 050H Blk X6 Trailer
Motor Solenoid Connector
Wht 30 86 K6 (opt.)
Blk
Red Y1 X2 Fuel Solenoid
Starting Timer Module
Motor 329 304 Org
85 87 87A
Solenoid Wht
562P Red
X2 30 86 K3 Fuel
G1
010N Shutoff
Battery Blk Solenoid 305
X5
Blk Dk Grn
87A 87 85 Pull-in Relay
L
W1 010F
010AJ 010T
Frame Blk Blk
Blk 010T Blk
Ground 050A Blk 050A Blk
010D Blk 010D Blk
010P Blk 010P Blk
010C Blk 010C Blk
W1 562P Red
Frame Unswitched Power Switched Power
Ground Unswitched Ground
Secondary Switched Power
MIF

A B 122C Red
F3 Fuse
154A 122D
Red 155 166
Yel 556 V2 Diode
Dk Grn Lt Blu
K7 86 30 Lt Blu
86 30 K8 573D Block 2 115E
Accessory Org
Relay Hazard 30 86 K12 PTO 166 7 Dk Grn
85 87 87A Relay Interlock Lt Blu 125E
010T 155 85 87 87A
Relay 8 9 Dk Grn
Blk Dk Grn 010M 154B
Blk 87A 87 85
Yel 533 010AA
154A Yel Org Blk
556 Lt Blu
334 Yel
115E
385A Dk Grn
115F
325 Dk Grn 125E
On
S4 Park 154D 115F
125F
Brake Switch Yel Dk Grn
Off 86 30 K9 154E 125F 154C Yel
562B Red B C 586 Lt Blu Right Yel Dk Grn 133 Org
Turn 86 30 K10 143 Org
577A Pur A D 505 Dk Grn 85 87 87A
Relay Left
143
Org Turn 334 Yel
85 87 87A
010S Relay
010U 133
S5 Rear Blk Blk Org 385A Dk Grn
PTO Switch On
586 Lt Blu
562F Red Off
562G Red A B 574C Yel 574A Yel
C
577B Pur D E 582 Red
562G Red F
578 Gry 325 Dk Grn
G
562H Red H
573B Org
X5
G
505 519
573A Org Dk Grn Pur 562L Red
30 86 K13
V2 Diode 1
Block 2 Neutral
S6 Mid 87A 87 85 Relay
PTO Switch On 546 010AB 562K 562M
2 Lt Blu Blk Red Red
Off
579A Wht A B 583 Org 583 Org
C
D E
F
562H Red G 579C
H 577C Pur 573C 546
562J Red Org Lt Blu Wht
86 30 K11 Rear 86 30
PTO
Y4 574B
Interlock 85 87 87A
S7 MFWD Unlock Rear PTO 85 87 87A
Relay
Switch Yel 533 010AC 581
010W
Lock Solenoid Org Blk Brn
Blk
562J 1 555 Wht K14 Mid
Red 2 582 579D
010AF Red Wht
PTO
3 557 Pur
555
Blk K15 Mid 86 30 Latch
010 AK Blk 7 8
Wht PTO Relay
Y3 Lockout
MFWD Relay 85 87 87A
010T
Blk Solenoid 010AM 581
010AG Blk Brn
050A Blk Blk
010D Blk
010P Blk
010C Blk
562P Red
Unswitched Power Switched Power

Secondary Switched Power Unswitched Ground
MIF

X8
B
P3 H9 Oil P4 Engine
Fuel Coolant
Pressure Temperature
H10 Gauge Light Gauge
Dash
Light Q t0
X7 X7
D E
C J E
X8 X8 X8
353 347 359
Org Pur Wht
H6 H8 Left
Right Turn
Light t0
Turn B1 Fuel
Light Gauge
Sensor P
B3 Engine
Coolant
Temperature
Q B2 Engine Oil Switch
Pressure
050B Switch (NC)
Blk
334 Yel X7
A
385A Dk Grn
C H3 Cold H5
586 Lt Blu X8 Start Discharge
574A Yel X7 K Light Light
B
325 Dk Grn X8 + _
F
562L Red X8
A
F12 Fuse
562M Red 311 Brn X5
H4 Park P2 Hour
D
Brake Meter
562N Light (Opt.)
H2 PTO
Red
Light
583 Org P n/min
P1 Engine
Tachometer
583 562P Red

D
Org H7 Cruise
K16 X8 Indicator
86 30
Mid PTO 050D X5 X5 Light
Blk
Relay B 050C C 264
85 87 87A Blk Yel
010AL 594
Blk Yel
Y5
Mid PTO G
X8
Solenoid
010AH
Blk
050A Blk
010D Blk
562P Red
Unswitched Power Switched Power Control Panel

MIF

125C Dk Grn X9 X10 010G Blk

122A Red
E1 Left
V2 Diode
Hazard Light
Block 2 186
4 Lt Blu
154C Yel 176
5 6 Lt Blu
S8 Turn E2 Right
Signal Switch Hazard Light
(0) Right 115C Dk Grn X11 X12 010L Blk
(1) Off
(2) Left
X6 1 103 Org
115E 115D Flasher
5 186 Lt Blu
115F 115A Dk Grn 4
125E X6
125D
3 2 122A Red
125F 125A Dk Grn 3
176 Lt Blu
125B 115B
Dk Grn Dk Grn
133 Org
143 Org 143 Org
E D
X7 X7 X6 Trailer
Connector
F8 Fuse 118A Gry 6
118D Gry
010J
1 Blk
138C
Gry 147C
147A Pur Pur 2
S9 Light
Switch
(0) Off B 010C
(1) Hazard F6 133 147B Blk
Org Pur
(2) Road Fuse
(3) Field A
X17
118C Gry
1
122B Red 103 Org
X13 X14
B
2 E7 Left
138A Gry E3 Left
3
Work
137 Org Tail/Turn Light
4 Light
118B
Gry
138B 147D
F7 Fuse X15
119C Wht Gry X16 Pur
119D 119A
Wht 119B Wht X19
Wht E4 Right E8 Right
X8 E6 Right Work
B
Tail/Turn
E5 Left Headlight Light Light
Headlight 010A
010B Blk Blk
X18 X20 X17 X19

010P
010X 010Y 010H 010K
W1 Blk
Blk Blk Blk Blk
010C Blk

MIF

W2 SST and W3 ePowrReverser Electrical Schematic
W3 ePRT Electrical Schematic

W2 SST Jumper Plug X22 to X23 to S12
Diagnostic Diagnostic Motion Match
X5
A 519 Wht Interface Interface Switch
X5 to W1 521 Brn X22 X23 Off
E
Main Wiring G 519 Wht 924 925 926 927 050H 562F On
Harness Yel Dk Lt Pur Blk Red
L 521 Brn Grn Blu 562E Red
269 Wht
S11
Clutch
Switch Top of Travel
Bottom of Travel
X5 596 Lt Blu
A 562A Red 562D Red Y6
B 050A Blk
X5 to W1 S10 Forward
D 311 Brn
Main Wiring E 303 Org F-N-R Proportional
Harness G 519B Wht Switch Forward Solenoid
H 572 Red Neutral
696
J 539 Wht Reverse Lt Blu
L 521 Brn
686 Lt Blu
562C Red 519C Wht
X21 687B Pur 694
303 Org Yel
A1
696 Lt Blu
A2
697 Pur
A3
688 Gry
B1
694 Yel
B2
695 Dk Grn
B3
924 Yel
C1 H12 687C
925 Dk Grn Pur 697
C2 Backup Alarm
572 Red Pur
C3
687A Pur
D1
521 Brn 050F
D2
926 Lt Blu Blk
D3
686 Lt Blu 695
E1
A1 E2
596 Lt Blu Dk Grn
Electronic 311 Brn
E3
519A Wht Y7
Operating F1 Reverse
269 Wht
System F2
F3
539 Wht Proportional
Controller 677 Pur Solenoid
G1
050B Blk
G2 677
G3 Pur
676 Lt Blu B5
H1
H2 673D Org
Reverse
H3
591Brn
m Pressure
J1 Transducer
J2 676
J3 050E
562B Red Lt Blu
Blk
K1 B4
927 Pur
K2 673C Org Forward
K3
673A Org
m Pressure
R2
Clutch Position Transducer
H11 ePRT 688 Potentiometer 050D
Indicator Gry Blk
673B Org X24
Light
591 Brn X24
050G X24
Blk 050C Blk
Unswitched Power Switched Power Secondary Switched Power Unswitched Ground

MIF

W4 eHydro and Cruise Control Electrical Schematic
X26 to
Diagnostic
Interface
X26
924 925 050C S14
Yel Dk Blk
Grn Load Match
X5 Switch
B 050A Blk
C 264 Yel Off
D 311 Brn On
X5 to W1 E 521 Brn
F 552A Red 552D Red
Main Wiring 268 Gry
G 519 Wht
Harness J 539 Wht
K 562 Red
L 521 Brn
S13
Brake
Switch
Off
On
552C Red
247 Pur
X25
539 Wht
A1
267 Pur 267 Pur
A2
562B Red 552E Red
A3
673A Org 673A Org
B1
265 Dk Grn 265 Dk Grn
B2
238 Gry 238 Gry
B3
264 Yel
C1
550A Blk 550A Blk
C2
269 Wht 269 Wht
C3
519 Wht
D1
D2
562 Red
D3
925 Dk Grn
E1
A2 050B Blk
E2
Electronic E3
311 Brn
Operating 203 Org
F1
686 Lt Blu 686 Lt Blu
System F2
341 Brn 341 Brn
Controller F3
247 Pur
G1
499 Wht 499 Wht
G2
502 Red 502 Red
G3
268 Gry
H1
924 Yel
H2
687 Pur 687 Pur
H3
688 Gry
J1
J2
J3
696 Lt Blu
K1
K2 696
697 Pur Lt Blu Y9
K3
Forward
Proportional
688 697
Pur 050D Solenoid
Gry Y8 203
Blk
H13 eHydro Reverse Org H14
Indicator Proportional Backup
Light Solenoid Alarm
050E
050F 050G
Blk
Blk Blk

MIF

S16 S18 Cruise W5 Cruise

Cruise/Max Speed Switch Control Wiring
Switch Off
W6 Cruise Harness (standard)
On
Control Wiring Cruise ON
Harness (option) Momentary
Off
562C Red 238 Gry
Max Speed ON
562C Red 238 Gry 562B Red
267 Pur 265 Dk Grn
562A
Red
S15
Res/+, Set/- X27
Switch
552E 265 238
Dk Grn Gry
Res + Red R3
Off Forward Pedal
Set -
673D Org X28 Potentiometer
562B Red 266 Lt Blu
265 Dk Grn
562A 686 Lt Blu X28

Red
X27 X27 550D Blk X28

552E 265 266 267 238
Red Dk Grn Lt Blu Pur Gry 673C Org X29 T1 Flywheel
Speed Sensor
267 Pur
341 Brn X29
673A Org
265 Dk Grn X29
550C Blk
238 Gry R4
S17 Throttle Position
550A Blk Motion Match X30 Potentiometer
673B Org
269 Wht
Switch
Off
On 499 Wht X30

269 Wht 673F Org
550B Blk X30
686 Lt Blu
673G Org X31 T2 MFWD
341 Brn
Speed Sensor
499 Wht
502 Red 502 Red X31
687 Pur 550F Blk X31

R5
Reverse Pedal
266 Lt Blu
673E Org X32 Potentiometer
687 Pur X32
550E Blk X32

MIF

W1 Main Wiring Harness
Diode Block 2 2 2
Diode
1 3 1 3
Block 1
K11 K12
5 5
DB2
K7
K9 K10
DB1
4 6 4 6
Fuse 8 8
9 9
K8
7 7
Block
Diode Block
K1
K4
Socket Layout
F1
F2
F3
F4
B
B
A
B
A
A
Relays 1 3 4 6 7 9
F5
F6
F8
F7
B
B
A
A
F10
F11
F12
F9
A
A
B
A
B
B
K2
K5
2 5 8
Diode Block
K13 K14
K15 K16
K17 K18
Schematic
K6
K3
30 87 86
86 85
87A 87A
Relay/Fuse Relays 87
Load Center 85 30
B1 Relay Socket
Fuel Gauge Layouts
Sensor 353
B2 Engine Oil 86 30
050B Pressure
Switch (NC)
010N
329 85 87 87A
302C 010C
Y2 Fuel 010D Relay
347 Schematic
Shutoff 050A
Solenoid 010P
383 W1 Ground
R1 Manifold Heater 302A
302B
302C
E5 Left Headlight
119B
B
A C
AA
G2 G2
010B Alternator Alternator
3 2 1
325 334
B3 Engine 359
072A
Coolant 002A
Temperature
Switch
002A
X1 To
B
119A Fusible
A C
Link
M1 Starting
010A 309 Motor
A
E6 Right Y1
Headlight Starting 002B
Motor 002C
Solenoid
Fusible Link
MIF

WIRING SPLICES
010M
010A 125A
010U
010B 125B 125C
010A 010W 125
010N 125E 125D
010S
010P 125F
010AJ
X7 To Control 010C
Panel Circuit Board X8 To Control 010G 010K
Panel Circuit Board 010H 010B 010L
125B 010J 010Y
115B 264 347 010X
325 562A
D E F 586 562L
C B A
F G H J K 010Z 562E
385A 334 E D C B
562L
A 010D 010AA 562B 562
359 562F
574A 010AM 010C 010AB 562C
119D 562D
010AD 010AC
353
010AL
050D
010AF
010AD
010D 010AG
X5 To W2 SST, 010AK
010AH
W3 ePRT or W4 eHydro
Wiring Harness S4
Park Brake
311 264 Switch
303 050C 562B 586
552 F E D C B A 562A B C
A D
M L K J H G
385A 577A 505
305 519 385B
539C 385C
572B 122B 138A
3
122A 2 B S9 Light
103 103
1
115A 4 1 Switch
125A 5
3
2
4
6
176 186 137

072A 072B 572A
S8 Turn 072B 5 6 385B
Signal Switch 572A 072C
4 7
572B
3 S1 Key
572C 212A 212A 2 1
8
Switch
212B
572D 012
212C
X3 To W8
Diverter Valve Wiring Harness
119A 562C 573A

119B 573B
539B
119C 573C
539C 010C
119D 573D
539D Relay/Fuse
AA Block Harness
050A 122A 138A 579A 010A
050B 115A 122B 138B 579B
050C 115B 122C 138C 579C
115C 579D 147A
050D 122D
115D 147B
050E 125
115E 147C
115F 147D
562
BB
118A
118B
118C
X4 To S3
118D
Transmission
Neutral Switch
(SST and ePRT)
A B
573A 518B
X4 (eHydro uses W7
jumper wire)
MIF

X6 Trailer Connector
(Option) (from rear of connector)
010J Blk
147C Pur 1
6 118D Gry
2
7
3 5
125D Dk Grn 115D Dk Grn
4
222 Red
Red
574C 583
562F/562G 579A
582 S6 Mid
577B A B C
A B C
PTO Switch
562G/562H
D E F
578 D E F
G H
573B 562H/562J
G H
577C
S5 Rear
PTO Switch
S7 MFWD
Switch
557 10 9
3 6
577A
577B 562J 2 5
1 4
577C
S2 Seat Switch 555 8 7
562E 557 010AK Y3 MFWD and

A
B Y4 Rear PTO Solenoid

539D 555
574B
A B C D
010AG
010AF
BB
574A Y5 Mid PTO
010B 010D
574B Solenoid
X13 To E3 574C 010AH
X15 To E4 A B
Left Tail/Turn Light Right Tail/Turn Light
133 143 594
118C X14 To E3 Left Tail/Turn Light 118B X16 To E4 Right Tail/Turn Light
125C X10 To E1 Left Hazard Light 115C X12 To E2 Right Hazard Light
010G X9 To E1 Left Hazard Light 010L X11 To E2 Right Hazard Light
010X X18 To E3 Left Tail/Turn Light 010Y X20 To E4 Right Tail/Turn Light
MIF

Diode Block Wire Connections
1 2 3 4 5 6 7 8 9
DB1 539A 556 572D 539A/539B 521 518A 010Z/010E 302A ---
DB2 578 579B --- 186 154B/154C 176 115E 166 125E
Fuse Block Wire Connections
Size A B F9 10A --- ---
F1 30A 002 012 F10 10A 212B 552
F2 --- 002C 252 F11 10A --- ---
F3 30A 002 122C F12 --- 562M/562N 311

(calibration)
F4 --- 002D ---
NOTE: Fuses F2 and F4 are used with trailer
F5 20A 072C 562D/562K connection option, Fuse F6 is used with work light
option, Fuse F11 is moved to F12 to start the
F6 20A 137 147A
calibration procedure.
F7 20A 138B 119C
F8 20A 138C 118A
Relay Wire Connections
86 85 30 87 87A
K1 385C 050E/050F 002B 383 ---
K2 518A/518B 010E/010F 572C 309 ---
K3 304 010F/010T 329 010AJ ---
K4 303 050F/050G 002D 302B ---
K5 212C 050G/050H 252 222 ---
K6 050H 304 521 305 562P
K7 154A 010T 122D 155 ---
K8 155 010M 166 154A/154B ---
K9 154C/154D 010S 115F 143 ---
K10 154D 010U 125F 133 ---
K11 573C 010W 546 533 ---
K12 556 010AA 573D --- 533
K13 519 010AB 505 546 ---
K14 579C 010AC 562K/562M 581 ---
K15 582 010AM 579D --- 581
K16 583 010AL 562N/562P 594 ---

W2 SST Jumper Plug Wiring Harness
519 519
G A
X5 To W1
FEDCBA
Main Wiring
Harness
521 M F 521
MIF
W3 ePowrReverser Wiring Harness
S10 F-N-R Switch
X5 To W1 686 519C
Main Wiring D C B A
Harness
050A 562C 687B
311
562A 303
519B
572 521
539
562
X21 To ePRT
Controller CC
697 695 572 926 311 539 673A
687
696 269 519

694 050B
925
521
596 927
303 688 924 687A 686 519A 677 676 591 562B
R2
Clutch
Position 050C
562D 596 Potentiometer 591
S11 673B
Bottom of Clutch
Switch
MIF

W3 ePRT WIRING SPLICES

050D
050A 050E 562A 562D
050B 050 050F 562B 562 562E
050C 050G 562C 562F
050H
673A 673C
673
673B 673D
519B
519A 519
519C
X22 To 687A
687 687C
Diagnostic Interface X23 To 687B
925 926 Diagnostic Interface

562F 050H
924 927
S12
Motion Match
Switch
269
562E
050
CC
673
688
050G
H11 ePRT
Indicator Lamp
H12
Back Up Alarm
687C 050F
Y6 Forward B5 Reverse
Proportional Pressure
Valve Transducer
B A 673D 050E
673C
B A
694
696 677
697 050D
695 676
Y7 Reverse B4 Forward
Valve Transducer
MIF

W4 eHydro Wiring Harness
S14
Load Match
Switch X26 To
X5 To W1 Diagnostic Interface
268
Main Wiring 925
Harness 552D
264 311
050A 521
924 050C
552A
519
521
539 562
552 050
X25 To eHydro DD
Controller
552B 238 269 562 311 341 502 687 697
267 686
265 499
550A 924
266
050B
539 673A 264 519 925 203 247 268 688 696 341
C B A
550C 673C
T1 Flywheel
Speed Sensor
550B
R4 499 S13 247
Throttle 673B Brake 552C
Position Switch
Potentiometer
MIF

W4 eHydro WIRING SPLICES

050C
552A
050A 050D
552B
050 050E 552 552E
050B 552C
050F 552D
050G
H13 eHydro
Indicator Lamp
673D 688 S17
550A 550D 673A
673B 673
673E 050F Motion Match
550B 550 550E 673F
550C 550F 673C Switch
673G
269
673F
X27 to W5 or W6
Cruise Control
Wiring Harness
552E A B C D E
265
238
266
267
673G
502
550
550F
DD C B A
673
T2 MFWD
Speed Sensor
203 050G
H14
Back Up Alarm
696 050D 050E 697
Y9 Forward Y8 Reverse
Proportional Proportional
Solenoid Solenoid
673D 673E
686 687
R3 550D R5 550E
Forward Reverse
Potentiometer Potentiometer
MIF

W5 Cruise Control Wiring Harness (standard)
S16
Cruise X27 to W4
Switch eHydro
562B Wiring Harness
238 265 562A 562C
A B C D E
562A
562B 562C
265
238
MIF
W6 Cruise Control Wiring Harness (optional)

S16
Cruise/Max Speed
Switch
238 X27 to W4
562C eHydro
267 562B Wiring Harness
562A 562C
S15
Res/+ A B C D E
562A
Set/- 265
Switch 238
266
266
267
562B
265
MIF
W1 Main Wiring Harness Color Codes Size/No./Color Wire Connection Points
Size/No./Color Wire Connection Points 1.2 010H Blk Splice 010B, E7
2.0 002A Red Y1, G2 1.2 010J Blk Splice 010B, X6
2.0 002B Red X1 Fusible Link, K1 1.2 010K Blk Splice 010B, E8
2.0 002C Red X1 Fusible Link, F2 0.8 010L Blk Splice 010B, E2
2.0 002D Red F4, K5 0.5 010M Blk Splice 010A, K8
1.0 010A Blk Splice 010A, E6 1.0 010N Blk Splice 010A, Y2
1.0 010B Blk Splice 010A, E5 1.0 010P Blk Splice 010A, W1
1.5 010C Blk Splice 010B, W1 0.5 010S Blk Splice 010A, K9
1.0 010D Blk Splice 010C, W1 0.5 010T Blk K3, K7
0.5 010E Blk V1, K2 0.5 010U Blk Splice 010A, K10
0.5 010F Blk K2, K3 0.5 010W Blk Splice 010A, K11
0.8 010G Blk Splice 010B, E1 0.8 010X Blk Splice 010B, E3
0.8 010Y Blk Splice 010B, E4

Size/No./Color Wire Connection Points Size/No./Color Wire Connection Points
0.5 010Z Blk Splice 010C, V1 0.8 118B Gry Splice 118, E4
0.5 010AA Blk Splice 010C, K12 0.8 118C Gry Splice 118, E3
0.5 010AB Blk Splice 010C, K13 1.0 118D Gry Splice 118, X6
0.5 010AC Blk Splice 010C, K14 1.0 119A Wht Splice 119, E6
1.0 010AD Blk Splice 010C, Splice 010D 1.0 119B Wht Splice 119, E5
0.8 010AF Blk Splice 010D, Y4 1.0 119C Wht Splice 119, F7
0.8 010AG Blk Splice 010D, Y3 1.0 119D Wht Splice 119, H10
0.8 010AH Blk Splice 010D, Y5 1.0 122A Red Splice 122, S8
1.0 010AJ Blk Splice 010A, K3 1.5 122B Red Splice 122, S9
0.5 010AK Blk Splice 010D, S7 1.5 122C Red Splice 122, F3
0.5 010AL Blk Splice 010B, K16 1.0 122D Red Splice 122, K7
0.5 010AM Blk Splice 010C, K15 1.0 125A Dk Grn Splice 125, S8
1.5 012 Red F1, S1 0.8 125B Dk Grn Splice 125, H8
1.2 050A Blk Splice 050, W1 0.8 125C Dk Grn Splice 125, E1
0.5 050B Blk Splice 050, B1 1.0 125D Dk Grn Splice 125, X6
0.8 050C Blk Splice 050, X5 0.8 125E Dk Grn Splice 125, V2
1.0 050D Blk Splice 050, X8 0.8 125F Dk Grn Splice 125, K10
0.8 050E Blk Splice 050, K1 0.8 133 Org K10, E3
0.5 050F Blk K1, K4 1.2 137 Org S9, F6
0.5 050G Blk K4, K5 1.2 138A Gry Splice 138, S9
0.5 050H Blk K5, K6 1.2 138B Gry Splice 138, F7
0.8 072A Red Splice 072, G2 1.0 138C Gry Splice 138, F8
1.0 072B Red Splice 072, S1 0.8 143 Org K9, E4
1.0 072C Red Splice 072, F5 1.2 147A Pur Splice 147, F6
1.0 103 Org S8, S9 1.2 147B Pur Splice 147, E7
1.0 115A Dk Grn Splice 115, S8 1.2 147C Pur Splice 147, X6
0.8 115B Dk Grn Splice 115, H6 1.2 147D Pur Splice 147, E8
0.8 115C Dk Grn Splice 115, E2 0.8 154A Yel K7, K8
1.0 115D Dk Grn Splice 115, X6 0.8 154B Yel K8, V2
0.8 115E Dk Grn Splice 115, V2 0.8 154C Yel V2, K9
0.8 115F Dk Grn Splice 115, K9 0.8 154D Yel K9, K10
1.0 118A Gry Splice 118, F8 0.8 155 Dk Grn K7, K8

0.8 166 Lt Blu V2, K8 0.5 533 Org K11, K12
0.8 176 Lt Blu S8, V2 0.5 539A Wht V1, V1
0.8 186 Lt Blu S8, V2 0.5 539B Wht Splice 539, V1
0.5 212A Red S1, Splice 212 0.5 539C Wht Splice 539, X5
0.5 212B Red Splice 212, F10 0.5 539D Wht Splice 539, S2
0.5 212C Red Splice 212, K5 0.5 546 Lt Blu K11, K13
1.2 222 Red K5, X6 0.5 552 Red X5, F10
1.0 252 Red K5, F2 0.5 555 Wht S7, Y3
0.8 264 Yel H8, X5 0.5 556 Lt Blu K12, V1
1.0 302A Red Splice 302, V1 0.5 557 Pur S7, S7
1.0 302B Red Splice 302, K4 0.8 562A Red Splice 562, X5
1.0 302C Red Splice 302, Y2 0.5 562B Red Splice 562, S4
0.5 303 Lt. Blu K4, X5 0.8 562C Red Splice 562, X3
0.5 304 Org K3, K6 0.8 562D Red Splice 562, F5
0.5 305 Dk Grn X5, K6 0.8 562E Red Splice 562, S2
1.0 309 Wht K2, Y1 0.8 562F Red Splice 562, S5
0.5 311 Brn F12, X5 0.8 562G Red S5, S5
0.8 325 Dk Grn X8, G2 0.8 562H Red S5, S6
1.2 329 Wht Y2, K3 0.8 562J Red S6, S7
0.8 334 Yel G2, X7 0.5 562K Red F5, K14
0.5 347 Pur B2, X8 0.8 562L Red Splice 562, X8
0.5 353 Org B1, X8 0.5 562M Red K14, F10
0.5 359 Wht B3, X8 0.8 562N Red F12, K16
1.2 383 Org K1, R1 0.8 562P Red K16, K6
0.8 385A Dk Grn Splice 385, X7 1.0 572A Red Splice 572, S1
1.0 385B Dk Grn Splice 385, S1 0.8 572B Red Splice 572, X5
1.0 385C Dk Grn Splice 385, K1 1.0 572C Red Splice 572, K2
0.5 505 Dk Grn S4, K13 0.5 572D Red Splice 572, V1
0.5 518A Gry V1, K2 0.5 573A Org Splice 573, X4
0.5 518B Gry K2, X4 0.5 573B Org Splice 573, S5
0.5 519 Pur K13, X5 0.5 573C Org Splice 573, K11
0.5 521 Brn V1, K6 0.5 573D Org Splice 573, K12

0.5 574A Yel Splice 574, X7 0.5 269 Wht A1, S11
0.8 574B Yel Splice 574, Y4 0.5 303 Org A1, X5
0.8 574C Yel Splice 574, S5 0.5 311 Brn X5, A1
0.5 577A Pur Splice 577, S4 0.5 519A Wht Splice 519, A1
0.5 577B Pur Splice 577, S5 0.5 519B Wht Splice 519, X5
0.5 577C Pur Splice 577, S6 0.5 519C Wht Splice 519, S10
0.8 578 Gry S5, V2 0.5 521 Brn X5, A1
0.5 579A Wht Splice 579, S6 0.5 539 Wht X5, A1
0.5 579B Wht Splice 579, V2 0.8 562A Red Splice 562, X5
0.5 579C Wht Splice 579, K14 0.5 562B Red Splice 562, A1
0.5 579D Wht Splice 579, K15 0.5 562C Red Splice 562, S10
0.5 581 Brn K14, K15 0.5 562D Red Splice 562, S11
0.5 582 Red S5, K15 0.5 562E Red Splice 562, S12
0.5 583 Org S6, K16 0.5 562F Red Splice 562, X23
0.5 586 Lt Blu S4, X8 0.8 572 Red X5, A1
0.8 594 Yel K16, Y5 0.5 591 Brn A1, R2
0.5 596 Lt Blu S11, A1

W2 SST Jumper Wiring Harness Color Codes
0.8 673A Org Splice 673, A1
Size/No./Color Wire Connection Points 0.5 673B Org Splice 673, R2
0.8 519 Wht X5, X5 0.5 673C Org Splice 673, B4
0.8 521 Brn X5, X5 0.5 673D Org Splice 673, B5
0.5 676 Lt Blu B4, A1

W3 ePowrReverser Wiring Harness Color
Codes 0.5 677 Pur B5, A1
0.5 686 Lt Blu A1, S10

Size/No./Color Wire Connection Points
0.5 687A Pur Splice 687, A1
0.8 050A Blk Splice 050, X5
0.5 687B Pur Splice 687, S10
0.5 050B Blk Splice 050, A1
0.5 687C Pur Splice 687, H12
0.5 050C Blk Splice 050, R2
0.5 688 Gry A1, H11
0.5 050D Blk Splice 050, B4
0.5 694 Yel Y6, A1
0.5 050E Blk Splice 050, B5
0.5 695 Dk Grn Y7, A1
0.5 050F Blk Splice 050, H12
0.5 696 Lt Blu Y6, A1
0.5 050G Blk Splice 050, H11
0.5 697 Pur Y7, A1
0.5 050H Blk Splice 050, X23

0.5 924 Yel A1, X22 0.5 550C Blk Splice 550, T1
0.5 925 Dk Grn A1, X22 0.5 550D Blk Splice 550, R3
0.5 926 Lt Blu A1, X22 0.5 550E Blk Splice 550, R5
0.5 927 Pur A1, X22 0.5 550F Blk Splice 550, T2
0.8 552A Red Splice 552, X5

W4 eHydro Wiring Harness Color Codes
0.5 552B Red Splice 552, A2
Size/No./Color Wire Connection Points 0.5 552C Red Splice 552, S13
0.8 050A Blk Splice 050, X5 0.5 552D Red Splice 552, S14
0.5 050B Blk Splice 050, A2 0.8 552E Red Splice 552, X27
0.5 050C Blk Splice 050, X26 0.5 562 Red X5, A2
0.5 050D Blk Splice 050, Y9 0.8 673A Org Splice 673, A2
0.5 050E Blk Splice 050, Y8 0.5 673B Org Splice 673, R4
0.5 050F Blk Splice 050, H13 0.5 673C Org Splice 673, T1
0.5 050G Blk Splice 050, H14 0.5 673D Org Splice 673, R3
0.8 203 Org A2, H14 0.5 673E Org Splice 673, R5
0.5 238 Gry A2, X27 0.5 673F Org Splice 673, S17
0.5 247 Pur A2, S13 0.5 673G Org Splice 673, T2
0.5 264 Yel X5, A1 0.5 686 Lt Blu A2, R3
0.5 265 Dk Grn A2, X27 0.5 687 Pur A2, R5
0.5 266 Lt Blu A2, X27 0.5 688 Gry A2, H13
0.5 267 Pur A2, X27 0.5 696 Lt Blu A2, Y9
0.5 268 Gry A2, S14 0.5 697 Pur A2, Y8
0.5 269 Wht A2, S17 0.5 924 Yel A2, X26
0.5 311 Brn X5, A2 0.5 925 Dk Grn A2, X26
0.5 341 Brn A2, T1
W5 eHydro Cruise Control Wiring Harness
0.5 499 Wht A2, R4
Color Codes (standard)
0.8 502 Red A2, T2
0.5 519 Wht X5, A2
0.5 238 Gry X27, S16
0.5 521 Brn X5, X5
0.5 265 Dk Grn X27, S16
0.5 539 Wht X5, A2
0.5 562A Red Splice 562, X27
0.8 550A Blk Splice 550, A2
0.5 562B Red Splice 562, S16
0.5 550B Blk Splice 550, R4
0.5 562C Red Splice 562, S16

W6 eHydro Cruise Control Wiring Harness T2 MFWD Speed Sensor - eHydro
Color Codes (optional)
T2 MFWD
Size/No./Color Wire Connection Points Speed Sensor
0.5 238 Gry X27, S16
0.5 265 Dk Grn X27, S15
0.5 266 Lt Blu X27, S15
0.5 267 Pur X27, S16
0.5 562A Red Splice 562, X27 673G Org

502 Red X31 To W4
0.5 562B Red Splice 562, S15 eHydro Wiring
550F Blk Harness
0.5 562C Red Splice 562, S16
MIF
S13 Brake Switch - eHydro

Y2 Fuel Shutoff Solenoid
S13 Brake
Switch
Y2 Fuel
Shutoff Solenoid
552C Red
247 Pur Blk
MIF
T1 Flywheel Speed Sensor - eHydro

X2 To W1
Main Wiring Harness
T1 Flywheel Wht
Speed Sensor Wht
MIF
673C Org
341 Brn X29 To W4
eHydro Wiring
550C Blk Harness
MIF

ELECTRICAL TROUBLESHOOTING
Troubleshooting
eHydro Electronic Operating System Troubleshooting Flowchart
Operator
Action
System Function No or Abnormal function

Decision
Solid ON Fault Light Flashing Code
Off
Diagnose problem
Calibrate system according to error
Calibration Mode
flash code
Check Power
to Controller
OK
Check Fault
Light Bulb
Replace Controller Yes

OK
No Spare Controller Fault not detectable or not

available? related to Controller
Check all
Not OK external switches OK
Fix external switches

OK Check hydraulic
Not OK
system
Need to connect to
computer with Fix hydraulic system
diagnostic software
Graphic
Electrical Troubleshooting - 145

ePowrReverser Electronic Operating System Each fault will have to be corrected and cleared one by one
Fault Codes should there be multiple faults.
When the first fault has been cleared, the electronic
Purpose: operating system will reset. When the vehicle is operated,
The LED status indicator light flashes in specific sequences the electronic operating system will flash the next fault code
of flashes to provide a visual indication of fault diagnostic that is recorded if there are any problems that still exist.
codes. These fault codes will aid in the diagnosis of The electronic operating system has 19 different fault
operational problems that may occur. codes available to assist with diagnostics. Each fault code
is a two digit number spelled out by the flash code.
Operation:
Long
Flash Flash
ON
Off Off Off

Period Period Period
Starting Light 1st 2nd
2 seconds ON digit digit
=4 =1
The fault code 41 for example, would be shown by the light

being on for 2 seconds then a 1 second off then 4 flashes
followed by a 1 second off then 1 flash. The cycle would
then start over and repeat until the fault is corrected.
The 2 second on light is used to indicate the start of a new
A
cycle while the off periods are used to break up the flashes.
The 4 flashes would indicate the digit 4 in 41 and the 1
flash would indicate the digit 1.
Whenever reading a fault flash code be sure to let the code
cycle several times while reading the code to be sure you
are at the beginning of the code.
Once a code has been read, it can then be matched to the
fault code chart to explain what the electronic operating
system is reading as a problem and what corrective action
is needed to positively identify and correct the source of the
fault.
MX10694
ePowrReverser Electronic Operating System
During normal operation the status indicator light (A) will
illuminated for approximately 4 seconds when the key is
Fault Code Chart
turned on as part of a self test, then the light will not be The starting light “—” = 2.0 second
illuminated. The status indicator light will begin to flash a
specific fault code when an operational command input is The flash “•” = 0.5 second
given and any one or more parts of that circuit are not OFF period “/” = 1 to 2 seconds.
operating properly.
The flash code begins with the starting light.
The status indicator light will begin to flash a fault code that
will help identify the problem. If more than one fault exists
the first fault which has been detected will be displayed
before the controller displays any additional faults that may
exist. If for example, the controller reads a fault on both
forward and reverse switches, the controller will flash the
forward fault code and will not display the reverse fault code
until the forward fault has been corrected.

FAULT FLASH FAULT CAUSE STARTING TEST RESET ACTION
CODE SEQUENCE POINT
11 -/•/• Controller sees a forward and F-N-R Switch Correct fault.

neutral input at the same time
Machine does not Clutch pressed to BOT, and F-N-R
drive switch placed in neutral to clear error
status.
12 -/•/•• Controller sees a reverse and F-N-R Switch Correct fault.

Machine does not neutral input at the same time Clutch pressed to BOT, and F-N-R
status.
13 -/•/••• Controller sees a forward and F-N-R Switch Correct fault.

reverse input at the same time
status.
14 -/•/•••• Controller does not see a F-N-R Switch Correct fault.

forward, reverse or neutral
input
status.
15 -/•/••••• Controller does not see neutral F-N-R Switch Correct fault.
Machine does not input when power is turned on Clutch pressed to BOT, and F-N-R
status.
16 -/•/•••••• Controller does not see BOT Clutch Switch Correct fault.
input from clutch switch when
power is turned on
status.
21 -/••/• Controller sees forward input Forward Correct fault.

but does not receive a Proportional
feedback from forward solenoid and
pressure transducer Forward Pressure
status.
Transducer
Test forward proportional solenoid
and wiring.
Test forward pressure transducer
and wiring.
Test hydraulic system.
22 -/••/•• Controller sees reverse input Reverse Correct fault.

Machine does not but does not receive a Proportional Clutch pressed to BOT, and F-N-R
drive feedback from reverse solenoid and switch placed in neutral to clear error
pressure transducer Reverse Pressure status.
Transducer
Test reverse proportional solenoid
and wiring.
Test reverse pressure transducer
and wiring.

CODE SEQUENCE POINT
23 -/••/••• Controller sees forward or Reverse Correct fault.

neutral input but receive a Proportional
Engine stops, Clutch pressed to BOT, and F-N-R
feedback from reverse solenoid and
Power cut to fuel switch placed in neutral to clear error
pressure transducer Reverse Pressure
shutoff circuit. status.
Transducer
Test reverse proportional solenoid
and wiring.
Test reverse pressure transducer
and wiring.
24 -/••/•••• Controller sees reverse or Forward Correct fault.

Engine stops, neutral input but receive a Proportional Clutch pressed to BOT, and F-N-R
Power cut to fuel feedback from forward solenoid and switch placed in neutral to clear error
shutoff circuit. pressure transducer Forward Pressure status.
Transducer
and wiring.
Test forward pressure transducer
and wiring.
25 -/••/••••• Clutch pedal is press to bottom Clutch Switch Correct fault.

and controller does not see a
BOT input but does see
feedback from forward
pressure transducer
Test clutch switch.
26 -/••/•••••• Clutch pedal is press to bottom Clutch Switch Correct fault.

feedback from reverse
pressure transducer
Test clutch switch.
27 -/••/••••••• System pressure drops below Hydraulic filter Correct fault.

100 psi for longer than 5
Machine does not Hydraulic system Clutch pressed to BOT, and F-N-R
seconds. This is an indicator
that the hydraulic system filter
status.
may be clogged.
Change hydraulic filter.
31 -/•••/• Inch pedal potentiometer is out Clutch Position Adjust clutch position potentiometer
Machine does not of range on the low end. Potentiometer to within specification. See
drive ePowrReverser Potentiometer
Calibration.
32 -/•••/•• Inch pedal potentiometer is out Clutch Position Adjust clutch position potentiometer
of range on the high end. Potentiometer to within specification. See
Machine does not
ePowrReverser Potentiometer
drive
Calibration.

CODE SEQUENCE POINT
41 -/••••/• Seat switch open (no operator Seat Switch Seat switch closed (operator
present) longer than 1 second. present), Correct fault.
Machine does not
drive F-N-R switch placed in neutral to
clear error status.
42 -/••••/•• Clutch BOT switch reads as Clutch Switch Correct fault.

Machine does not closed (pressed) and clutch Clutch Position Clutch pressed to BOT, and F-N-R
drive position potentiometer shows Potentiometer switch placed in neutral to clear error
pedal as being pressed less status.
than half way to full travel.
51 -/•••••/• Controller sees forward input Forward Correct fault.

but does not receive a proportional
feedback from forward solenoid
proportional solenoid
status.
and wiring.
52 -/•••••/•• Controller sees reverse input Reverse Correct fault.

feedback from reverse solenoid
status.
and wiring.
53 -/•••••/••• Controller sees feedback from Proportional Correct fault.

either forward or reverse solenoids
proportional solenoid greater
than 1.17 volts for more than
status.
50ms.
Possible extremely high
magnetic interference.
61 -/••••••/• Controller does not see relay K4 engine run Correct fault.
Machine does not logic after startup relay, K6 fuel Clutch pressed to BOT, and F-N-R
drive solenoid timer switch placed in neutral to clear error
module, and K13 status.
neutral relay

eHydro Electronic Operating System Fault When the first fault has been cleared, the electronic
Codes operating system will reset. When the vehicle is operated
the electronic operating system will flash the next fault code
Purpose: that is recorded if there are any problems that still exist.
The LED status indicator light flashes in specific sequences The electronic operating system has 12 different fault
of four flashes to provide a visual indication of fault codes available to assist with diagnostics. Each fault code
diagnostic codes. These fault codes will aid in the diagnosis is a combination of four long and/or short flashes.
of operational problems that may occur.
Long Short Long Short
Operation: Flash Flash Flash Flash
1st Off Off

digit Period Period
2nd
digit
3rd
digit
4th
digit
A fault code of 2 long and 2 short flashes (example shown)

would be signaling that the reverse pedal potentiometer is
malfunctioning or is out of calibration.
When the reverse potentiometer is recalibrated, adjusted,
A
or replaced, the electronic operating system would reset,
clearing the fault code and resuming normal operation.
This code would flash two long flashes followed by two
short flashes followed by an off period. This sequence
would then repeat itself until the correction is made and
power to the controller cycled off and back on.
The long flash is approximately 1.0 second, the short flash
is approximately 0.5 second and the off period is
approximately 4 seconds. The flash code begins after the
off period. Whenever reading a fault flash code be sure to
let the code cycle several times while reading the code to
be sure you are at the beginning of the code.
MX10694
Once a code has been read, it can be matched to the fault
During normal operation the status indicator light (A) will code chart to explain what the electronic operating system
illuminated for approximately 4 seconds when the key is is reading as a problem and what corrective action is
turned on as part of a self test, then the light will not be needed to positively identify and correct the source of the
illuminated. The status indicator light will begin to flash a fault.
specific fault code when an operational command input is
given and any one or more parts of that circuit are not
operating properly.
each fault will be displayed before the controller repeats the
fault codes. If for example, the controller reads a fault on
both forward and reverse pedals, the controller will flash the
forward fault code then the reverse fault code and then it
will repeat the cycle.
Each fault will have to be corrected and clear one by one
should there be multiple faults.

eHydro Electronic Operating System Fault OFF period = 3 to 4 seconds.
Code Chart The flash code begins after the off period.
The long flash “—” = 1.0 second Whenever reading a fault flash code be sure to let the code
The short flash “•” = 0.5 second
FAULT FLASH STARTING FAULT CAUSE MACHINE RESPONSE RESET ACTION

CODE SEQUENCE TEST POINT
1 •-•• Forward Pedal Normal Operation:

Potentiometer
Voltage signal is out of No drive in either Power recycled through off
range. direction. to clear error status.
Input is not calibrated. Sensor has to be re-
calibrated.
Calibration Routine:
Voltage signal is out of Calibration routine Power recycled through off

range. stops. to clear error status.
Calibration repeated after
signal is back within range.
2 --•• Reverse Pedal Normal Operation:

Potentiometer
calibrated.

3 •••- Throttle Normal Operation:

Position
Potentiometer Voltage signal is out of Load Match is disabled; Power recycled through off
range. loss of performance. to clear error status.
calibrated.


4 ••-• Flywheel Normal Operation:

Speed Sensor
Output current exceeds Load Match and cruise Power recycled through off
a certain value without control will be disabled; to clear error status.
detecting an engine loss of performance.
speed. MFWD speed
must also be available
at same time.
Missing engine speed Load Match is disabled. Engine speed has to be

or signal exceeds rpm adjusted.
tolerance.
Calibration repeated.
5 •--• MFWD Speed Normal Operation:

Sensor
Output current exceeds Cruise control will be Power recycled through off
a certain value without disabled; loss of to clear error status.
detecting an MFWD performance.
speed. Engine speed
at same time.
Missing MFWD speed Calibration routine MFWD signal has to be

or signal exceeds rpm stops. available.
tolerance. Calibration repeated.
6 -••- Cruise Normal Operation:

Control/Max
Speed Switch Both inputs are active Load Match and cruise Power recycled through off
at the same time. control will be disabled; to clear error status.
loss of performance.
7 --•- Res/+ Set/- Normal Operation:

Switch
Both inputs are active Load Match and cruise Power recycled through off
8 ---- Off-Seat Normal Operation:

Command
Drive command No drive in either Error status will reset when
selected while the seat direction. seat switch is placed in on
switch is in open position.
position.
Threshold calibration No drive in either Error status will reset when

while the seat switch in direction. seat switch is placed in on
open position. position.
Calibration can then be
continued.

9 -••• Simultaneous Normal Operation:

command
from Forward Controller receives a No drive in either Error status will reset when
and Reverse command from both direction. both pedal commands
pedals at the same return to zero.
time.
No fault situation. Flash code will be None

present, no other
machine response.
10 •--- Valve output Normal Operation:

to Forward or
Reverse coil The calculated value No drive in either Power recycled through off
for the coil resistance direction. to clear error status.
exceeds the valid range
due to open or short
circuit.
The calculated value No drive in either Power recycled through off

circuit.
11 -•-- Sensor supply Normal Operation:

(S/N voltage
- H120712 Voltage is out of range. No drive in either Power recycled through off
direction. to clear error status.
- H131963
- H141271
11 ••-- Sensor supply Normal Operation:

(S/N voltage
H120713 - Voltage is out of range. No drive in either Power recycled through off
H131964 -
H141272 -
12 •••••••••• Software Normal Operation:

•••••
No application software No machine operation. Replace Controller.
(continuous) loaded into the
Download correct software.
microprocessor.
13 -•-• Brake switch Normal Operation:

(S/N input
H120713 - Brake engaged Cruise not available to Release brake.
set. Adjust or replace brake
H131964 -
switch.
H141272 -

ELECTRICAL THEORY AND DIAGNOSIS
Theory and Diagnosis While this will cause the machine to be a bit more jerky, it
will provide for extremely quick clutch engagement.
ePowrReverser - e MatchOS Electronic Placing the motion match switch in the off position (B) will
Operating System give clutch engagement the sensitivity that is typical to
most normal operating conditions.
Function:
Drive Controller Inputs and Outputs
The purpose of the electronic drive operating system is to
control drive clutch engagement. Additionally the electronic Analog Inputs
operating system provides for selecting between two 1. Forward Pressure Transducer
responsiveness levels.
2. Reverse Pressure Transducer
General Theory: 3. Forward Proportional Solenoid Feedback
The electronic operating system is a preprogrammed 4. Reverse Proportional Solenoid Feedback
electrical device that allows the operator to control the
5. Clutch Position Potentiometer
machine drive direction via the electrical inputs from the F-
N-R lever switch. Under normal operating conditions, this Digital Inputs
creates an output to the corresponding directional control 1. Diagnostic Interface
solenoid in the transmission.
2. Starting Circuit Signal
The output current to the directional solenoid is either
constant when the clutch is fully released or proportional 3. Reverse Signal from F-N-R Switch
when the clutch pedal is being pressed down. When the 4. Fuel Shutoff Relay Logic
clutch pedal is completely pressed down, no output current
will be provided to either directional solenoid. 5. Diagnostic Interface
6. Forward Signal from F-N-R Switch
The rate of clutch engagement is also controlled by the
electronic operating system to smoothly ramp the machine 7. Clutch Switch
into motion.
8. Neutral Signal from F-N-R Switch
Two different settings provide for either quicker or slower 9. Motion Match Switch
clutch engagement. This operation is controlled by the
operator placing the motion match switch in either the on or 10.Seat Switch (operator presence)
off position. The change in this setting will take effect as 11.Calibration Fuse (used temporarily during calibration)
soon as the switch is changed.
Digital Output
Motion Match Switch: 1. Ground Circuit
The motion match feature allows the operator to select how 2. Fuel Shutoff Relay Logic
reactive the machine is to engaging the clutch.
3. Forward Proportional Solenoid
4. Reverse Proportional Solenoid
A
5. Fault Light
MX10694
Placing the motion match switch in the on position (A) will

give the transmission quicker response from F-N-R switch
position.
Electrical Theory and Diagnosis - 154

eHydro - e MatchOS Electronic Operating then immediately beginning to travel in the opposite
System direction of travel.
Both the deceleration to neutral and the deceleration to
Function: direction change have an immediate or “knee” deceleration
The purpose of the electronic drive operating system is to before following the ramped pattern back to a stop. The
control both the drive direction and speed of the machine. amount of deceleration used for the knee value is based
Additionally the electronic operating system provides for upon a percentage of output being produced. If the knee
setting a maximum travel speed, cruise control, pedal value is set at 70, then the speed of the machine would be
aggressiveness, and load match to prevent stalling the reduced to 70% of the current drive speed almost
engine during operation. immediately with the release of the directional pedal being
used. The deceleration would then follow the ramped
Each of these additional functions has the ability to be setting back to a stop.
turned on or off by the operator.
Generally deceleration within a drive direction is the most
General Theory: conservative deceleration with decel to neutral being
slightly more aggressive and decel to a direction change
The electronic operating system is a preprogrammed
being the most aggressive stopping action.
machine drive direction and speed via the electrical inputs Cruise Control:
from the forward and reverse foot pedals. Under normal
operating conditions, this creates an output to the The cruise control feature allows the operator to set and
corresponding directional control valve coil in the hold a speed setting that the operator desires without
transmission. having to press and hold the forward pedal.
The output current to the directional valve coil is
proportional to the pedal position. The forward and reverse A C
pedals have an adjustable proportional setting. This setting
allows for greater control, comfort and smoother operation
around neutral. The same proportional setting affects both
the forward and reverse command.
The rate of acceleration and deceleration is also controlled
by the electronic operating system to smoothly ramp the
speed up and down.
Two different settings provide for either quicker or slower
acceleration or deceleration. This operation is controlled by
the operator placing the motion match switch in either the B
on or off position. The change in this setting will take effect
as soon as the switch is changed.
MX10682
While the acceleration has one setting with the motion
match in either the on or off positions, the deceleration Placing the cruise control switch (A) to the on position,
function has three settings. enables the cruise control function. Momentarily pressing
the Set / - switch (B) will then set the cruise speed at the
Deceleration has settings for coasting to a slower speed
speed being traveled.
without stopping or changing direction, coasting back to the
neutral position, and stopping when changing directions. Once set, the electronic operating system monitors the
vehicle speed and varies the current to the transmission
Decelerating to a slower speed in the same direction allows
forward directional solenoid to maintain travel speed at the
for controlled operation within the direction of travel by
set point.
reducing the jerking that may occur as a result of pedal
movement by the operator as well as simply slowing to a The cruise speed setting can be increased and decreased
lower rate of speed. while the machine is being driven by momentarily pressing
either the Res / + switch (C) to increase the maximum
The deceleration to neutral setting allows for a controlled
speed or the Set / - switch (B) to decrease the maximum
return to the stopped position when the pedal is completely
speed setting.
released.
Using the Res / + switch or the Set / - switch to change the
The deceleration for directional change setting allows for
cruise speed setting will become effective immediately
the ramping to control the deceleration speed to a stop and
without returning to neutral.

The increase/decrease amount is a percentage of the limited to the speed the operator was traveling at as long as
actual machine speed. the max speed switch remains in the on position.
Pressing either the brake or reverse pedals will disengage The max speed setting can be increased and decreased
the cruise function. The last speed setting is stored in the while the machine is being driven by momentarily pressing
controller and if the operator is pressing the forward pedal, either the Res / + (C) switch to increase the maximum
the Res / + switch can be pressed to ramp back to the speed or the Set / - (B) switch to decrease the maximum
stored speed. speed setting.
Turning the cruise switch off, erases the stored setting. NOTE: Pressing the Set / - switch at any speed less
If changes in machine loading or range gear position than the current maximum speed setting will replace
settings do not allow for return to the previous speed the Max Speed setting with a new setting based upon
setting, the controller will attempt to return to the speed the pedal position at the time the Set / - switch is
setting by sending either the maximum (fastest speed pressed.
possible) or minimum (slowest speed possible) drive Using the Res / + switch or the Set / - switch to change the
current to the transmission forward directional solenoid. max speed setting will become effective immediately
without returning to neutral. The increase/decrease amount
Max Speed:
is a percentage of the actual machine speed.
The max speed feature allows the operator to set the
Depressing the Res / + switch while in neutral will increase
maximum speed the machine will travel when the drive
the max speed setting the same as if the machine were
pedal is fully depressed.
being driven.
If the operator needs to return to a specific travel speed, the
Depressing the Set / - switch while in neutral will disengage
max speed setting will allow the machine to return to this
the max speed setting.
specific speed setting while maintaining proportional
acceleration and deceleration. The max speed function is also disengaged when the max
speed switch is turned off. Disengagement will become
The max speed setting is a machine speed taken from the
effective immediately.
MFWD speed sensor so that the machine speed is limited
to that setting regardless of gear position, drive direction or Once the max speed setting is set it will be stored and is
terrain features. available until it is replaced by another setting or if the
electronic operating system is replaced. Placing the max
Unlike cruise control, the max speed setting requires the
speed switch in the on position will enable the last
operator to press and hold the drive pedal to obtain a travel
maximum speed setting.
function.
Motion Match Switch:
C The motion match feature allows the operator to select how
reactive the machine is compared to drive pedal
movement.
A
MX10682
Placing the max speed switch (A) to the on position,

enables the max speed function. Pressing the drive pedal B
to obtain the travel speed desired then momentarily
pressing the Set / - switch (B) sets the max speed.
The maximum travel speed of the machine will then be MX10682

Placing the motion match switch in the on position (A) will Digital Inputs
give the transmission higher response sensitivity to drive
1. Load Match Switch
pedal movement.
2. Brake Switch
While this will cause the machine to be a bit more jerky, it
will provide for extremely quick changes in speed or 3. Cruise control Res/+ Switch
direction. 4. Cruise control Set/- Switch
Placing the motion match switch in the off position (B) will 5. Cruise Control/Max Speed Switch
give the drive pedals the sensitivity that is typical to most
normal operating conditions. 6. Seat Switch (operator presence)
7. Calibration Fuse (used temporarily during calibration)
Load Match Switch:
Frequency Inputs
Load match is used to eliminate operators stalling the
engine during a typical application such as loader work. A 1. Flywheel Speed Sensor
throttle position sensor is installed to read the no-load 2. MFWD Speed Sensor
engine rpm set point.
Digital Output
If the engine rpm drops far enough below the set point
1. Backup Alarm
value, the current sent to the transmission drive valve coils
is reduced to allow the engine to recover. The greater the 2. Neutral State Light
load on the engine, the greater the reduction in current. 3. Cruise Active Light
If cruise control is active and the load match comes on, the 4. Fault Light
cruise speed output is ‘held’ at whatever speed it is
currently operating at until load match goes back to 100%. Valve Output
1. Forward Solenoid Coil
2. Reverse Solenoid Coil
MX9722
The load match switch (A) can be turned on or off to allow

the operator to disable the load match function if desired.
The load match feature will have no effect if the machine is
not being driven when the stalling load is being placed on
the engine.

Analog Inputs
1. Forward Pedal Potentiometer
2. Reverse Pedal Potentiometer
3. Throttle Position Sensor
4. Motion Match Switch

Power Circuit Operation Switched Power - Run - SST, ePowrReverser, and
eHydro Main Circuits:
Function:
In addition to the voltage present at the locations of the
To provide unswitched and switched power to the primary unswitched power circuits, voltage must be present at the
electrical components whenever the battery is properly following components during the following conditions: key
connected. switch in the run position, transmission in neutral, PTO(s) in
off position, park brake locked, MFWD in unlock position,
The power circuits are divided among the unswitched
operator off seat:
power circuit, switched power circuits (key switch in run,
start, or aid positions), and secondary power circuits. The • Key Switch terminals 3 and 5
secondary power circuits become energized when
• Alternator terminal IG
switched power circuits energize relays, providing current
paths to the secondary circuits. The secondary power • F5 Fuse
circuits will not be energized if the relays controlling the • X3 Connector
current path(s) fail.
• Seat Switch
Unswitched Power: • Park Brake Switch terminals A, B, C and D
Voltage must be present at each of the following • X8 Connector terminals A and K
components with the key switch in the off position
• Rear PTO Switch terminals A, D, F, G and H
• Battery positive terminal
• Mid PTO Switch terminals A, G and H
• Starting motor solenoid B terminal
• MFWD Switch terminals 1 and 2
• Alternator terminal B
• V2 Diode Block terminals 1 and 2
• Manifold Heater Relay terminal 30
• MFWD Solenoid
• F1 Fuse
• K2 Start Relay terminal 86
• Key Switch terminal 1
• K5 Trailer Relay terminal 86 (if equipped)
• Engine Run Relay terminal 30
• K6 Fuel Solenoid Timer Module terminals 30 and 87A
• F2 Fuse (if equipped)
• K11 Rear PTO Interlock Relay terminal 86
• F3 Fuse
• K12 PTO Interlock Relay terminal 30
• Turn Signal Interlock Relay terminal 30
• K13 Neutral Relay terminal 30
• Light Switch terminal B
• K14 Mid PTO Interlock Relay terminal 30
• Turn Signal Switch terminal 2
• K15 Mid PTO Lockout Relay terminal 30
• K4 Engine Run Relay terminal 30
• K16 Mid PTO Relay terminal 30
• K5 Trailer Relay terminal 30 (if equipped)
NOTE: The S3 transmission neutral switch is installed
The positive battery cable connects the battery to the
in SST and ePowrReverser machines. In eHydro
starting motor. The starting motor bolt is used as the 12 volt
machines the S3 transmission neutral switch is not
DC tie point for the rest of the electrical system.
used, and a jumper wire is installed in the X4
The battery cables and the starting motor tie point connector - eliminating the S3 switch.
connections must be good for the vehicle electrical system
• S3 Transmission Neutral Switch (SST and
to work properly. The ground cable and positive cable
ePowrReverser)
connections are equally important. Proper starting motor
operation depends on these cables and connections to • eHydro Jumper Wire (eHydro)
carry high current. • V1 Diode Block terminals 6 and 5
With the exception of the B terminal of the alternator, the
• X5 Connector terminals A, E, F and K
electrical circuit is protected by the fusible link beyond the
starting motor tie point. The fusible link is a short piece of • F10 Fuse
wire that is designed to fail if current load is too high or a These circuits are controlled by the key switch and are
short occurs. protected by the fusible link and the F1 fuse.

Switched Power - Run - ePowrReverser Specific • K4 Engine Run Relay terminal 87
Circuits:
• V1 Diode Block terminal 8
In addition to the main machine circuits, voltage must be
• Y2 Fuel Shutoff Solenoid
present at the following components of the ePowrReverser
machine during the following conditions: motion match • K5 Trailer Relay terminal 87 (if equipped)
switch off, bottom of clutch switch not pressed, and the F- • K6 Fuel Solenoid Timer Module for approximately 3
N-R switch in the N (neutral) position: second
• Motion Match Switch terminal 2 • K3 Fuel Shutoff Solenoid Pull-in Relay terminal 86 for
• Bottom of Clutch Switch terminal A approximately 3 second
• F-N-R Switch terminal D and B • K11 Rear PTO Interlock Relay terminal 30 and 87
• X21 Connector terminals A1, D2, E2, F1 and K1 • K12 PTO Interlock Relay terminal 87A
• X23 Connector terminals A • K13 Neutral Relay terminal 87
These circuits are controlled by the key switch and are • K14 Mid PTO Interlock Relay terminal 87
protected by the fusible link and the F1 fuse. • K15 Mid PTO Lockout Relay terminal 87A
Switched Power - Run - eHydro specific Circuits: These circuits are controlled by the key switch and are
protected by the fusible link and the F1 fuse.
present at several components of the eHydro machine. Switched Power - Aid:
Those circuits that are inputs to the drive controller should
be at 12 volts (battery voltage), while those circuits that are Voltage must be present at the following components with
outputs of the drive controller should be at 5 volts during the key switch in the aid position (key pushed in when
the following conditions: load match, brake switch, motion placed in the run or start position) and the other switches in
match, cruise switch and Res/+, Set/- switches in off the following conditions: transmission in neutral, PTO(s) in
position if equipped. off position, park brake locked, MFWD in unlock position,
operator off seat:
• Load Match Switch terminal 2, (12 volts),
• Key Switch terminal 7
• Brake Switch terminal A and B, (12 volts),
• K1 Manifold Heater Relay terminal 86
• Res/+, Set/- Switch terminal 2 (if equipped), (12 volts),
• X7 Connector terminal C
• Cruise/Max Speed Switch terminal 2 (if equipped), (12
volts), These circuits are controlled by the key switch and are
• X25 Connector terminals A3, D1 and G1, (12 volts),
• X27 Connector terminals A, (12 volts), Secondary Switched Power - Aid:
• X25 Connector terminals B1 (5 volts), Secondary switched voltage must be present at the
following components with the key switch in the aid position
• Motion Match Switch terminal 2, (5 volts), (key pushed in when placed in the run or start position):
• Forward Pedal Potentiometer terminal C, (5 volts), • K1 Manifold Heater Relay terminal 87
• Reverse Pedal Potentiometer terminal C, (5 volts), • R1 Manifold Heater
• Throttle Position Potentiometer terminal A, (5 volts), These circuits are controlled by the key switch and are
• Flywheel Speed Sensor terminal A, (5 volts), protected by the fusible link and the F1 fuse.
• MFWD Speed Sensor terminal A, (5 volts),
These circuits are controlled by the key switch and are
Secondary Switched Power - Run:

Secondary switched voltage must be present at the
following components during the following conditions: key
switch in the run position, transmission in neutral, PTO(s) in
off position, park brake locked, MFWD in unlock position,
operator off seat:

Switched Power - Start:
Voltage must be present at the following components
during the following conditions: key switch in the start
position, transmission in neutral, PTO(s) in off position,
park brake locked, MFWD in unlock position, operator off
seat:
• Key Switch terminals 5 and 6
• Start Relay terminal 30
• Diode Block terminals 3 and 2
• K12 PTO Interlock Relay terminal 86
• X5 Connector terminal G
• K2 Start Relay terminal 86 (If start criteria are met)
• X21 Connector terminal C3 (ePowrReverser)
NOTE: These components are in addition to the
components that would have power with the key switch
in the run position. However, voltage would not be
present at the trailer relay (terminal 86) with the key
switch in the start position.
Secondary Switched Power - Start:

Secondary voltage must be present at the following
components during the following conditions: key switch in
the start position, transmission in neutral, PTO(s) in off
position, park brake locked, MFWD in unlock position,
operator off seat:
• Start Relay terminal 87
• Starting Motor terminal A

Power Circuit Electrical Schematic
002A Red 002A Red 122C
Fuse Block Internal Link Red
002D Red
G2 B F3 Fuse
4 Alternator G
F1 F2
012
Fuse Red 1 6 572A Red 072A Red IG Fuse
(used
2 5 072B Red X3 562C Red with
trailer
3 212A Red 072C F5 Fuse option)
Red 562D Red 562A Red X5
S1 Key
7 385B Dk Grn A
Switch 562E Red
Start
Run
Off 572B Red X5
Acc. X7 C
385A Dk Grn H
Aid
002C
Off
S2 Seat
Red Switch 1
(Off Seat) 2 556 Lt Blu
572D Red 3
002B Red 385C (On Seat) H3 Cold
Dk Grn V1 Diode
Block 1 Start
X1 4
Light
30 86 K1 5 521 Brn
Manifold 518A Gry 6
Fusible Heater
Link 87A 87 85 Relay
F10
383
S3 Transmission 212A
Neutral Switch Fuse
Org In Neutral Red
(SST and ePRT)
In Gear
X4 X4 573A Org 573A Org 552
572C 518B Gry Red
Red
R1 Manifold X4 X4 F
Heater
30 86
K2 X5
Start W7 eHydro 252
002A Red 87A 87 85 Relay Red
Jumper
309 Wht Wire
K5
B A
212C Trailer
Red Relay
002D X5
Red (opt.)
303 E 86 30
V1 Lt Blu
Diode 86 K4
M Block 1
30
Engine 85 87 87A
7 8 302A Red Run 222
M1 87A 87 85 Red 7
Relay
Starting Y1 302B
Starting Red X6 Trailer
Motor X2 302C Red Connector
Motor (opt.)
Red Solenoid
G1 Wht 30 86
Y2 Fuel K6
Battery Fuel Solenoid
Shutoff
Solenoid 85 87 87A Timer Module
Blk Wht
X2 562P Red
X2 305
Dk Grn X5
L
Unswitched Power Switched Primary Power Secondary Switched Power

Control Panel Switched AID Power Switched START Power

122C Red S9 Light

Switch
S8 Turn (0) Off
Signal Switch (1) Hazard 556
(0) Right Lt Blu
(2) Road 573D
122D (1) Off Org
Red (3) Field
(2) Left 30 86 K12 PTO
86 30 K7 1 1
Flasher 122B Interlock
Accessory Red Relay
85 87 87A
Relay 4
B
2 87A 87 85
122A 533
2 Red Org
3 3
4
556 Lt Blu
562L Red X8
A
H9 Oil
On
S4 Park Pressure
Brake Switch Light
Off
C 586 Lt Blu X8 P3
562B Red B P4 Engine
K Fuel Coolant
577A Pur A D 505 Dk Grn X5 Gauge Temperature
H4 Park Gauge
505 G J
519 Brake Q
S5 Rear Dk Grn Pur Light X8
PTO Switch 30 86 t0
K13 347
Neutral C Pur
On
Relay
P E
87A 87 85 X8
562F Red Off X8
546 B1 Fuel 353
562G Red A B Lt Blu Gauge Org 359
577B Pur C Wht
D E 578 Gry Sensor
F
562G Red G
H
562H Red 573B Org
Q t0
573A Org
V2 Diode 1
Block 2
B2 Engine Oil B3 Engine
Pressure Coolant
2 Switch (NC) Temperature
S6 Mid Switch
PTO Switch On
Off 573C 546 P

Org Lt Blu
579A Wht A B
86 30 K11 Rear
C
D E PTO F12
F 562K
562H Red G Interlock Fuse
H 577C Pur Red 562M Red
562J Red 85 87 87A
Relay 579C
533
Org Wht
86 30
K14 Mid
S7 MFWD PTO
Unlock 579D
Switch Latch
Lock Wht 85 87 87A
86 K15 Mid Relay
562J 1 555 Wht 30 581
Red 2 PTO Brn
3 Lockout 562P Red
85 87 87A 562N
7 8
555
Relay Red
562P Red 581
Wht Brn
Y3 86 30 K16
MFWD Mid PTO
Solenoid Relay
85 87 87A



W2 SST Jumper Plug
X5 S12
A 519 Wht
Motion Match
X5 to W1 521 Brn Switch
E
Main Wiring G 519 Wht X23
Harness 562F Off
L 521 Brn Red On
X5
A 562A Red 562E Red
E 303 Org
G 519B Wht S11
H 572 Red
Clutch
J 539 Wht
L 521 Brn Bottom of Travel

596 Lt Blu
562D Red
S10
F-N-R
Switch Forward
X21 Neutral
303 Org Reverse
A1
562C Red 519C Wht
572 Red
C3
521 Brn
D2
A1 E2
596 Lt Blu
Electronic
519A Wht
Operating F1
System 539 Wht
F3
Controller
B5
673D Org
Reverse
m Pressure
Transducer
562B Red B4
K1 673C Org Forward
673A Org 673B Org X24 m Pressure
K3
Transducer
X24 R2
Clutch Position
Potentiometer
X24


W4 eHydro Power Circuit

W5 Cruise Control (standard) W6 Cruise Control (option) Power Circuit
Power Circuit
S18 Cruise S16
Switch Cruise/
Off Cruise ON
Max Speed
Off
On Switch Max Speed ON
Momentary
X5 562C Red
562C Red
E 521 Brn
F 552A Red 562B Red
519 Wht
S15
G
J 539 Wht
Res/+, Set/-
562A Switch
K 562 Red Red Res +
L 521 Brn
Off
S14 X27 Set -
Load Match 562B Red
Switch 562A
Off Red
On
X27
552D Red X27 R3
552E Forward Pedal
Red
S13
Brake X28
Switch
Off
X28
On
X25 X29 T1 Flywheel
552C Red 673C Org
539 Wht 247 Pur Speed Sensor
A1
A3
552B Red X29
673A Org
B1
X29 R4
A2 Throttle Position
Electronic 269 Wht 673B Org X30 Potentiometer
C3
Operating 519 Wht
D1
System
562 Red X30
Controller D3
X30

247 Pur
G1 Speed Sensor
X31
S17
Motion Match
Switch X31 R5
Off Reverse Pedal
On
269 Wht 673F Org
X32
X32


Power Circuit Diagnosis
Test Conditions:
• Key switch in off position
• Transmission(s) in neutral
• Park brake locked
• Mid PTO in the off position
• Rear PTO in the off position
• Operator off seat
Test/Check Point Normal If Not Normal
1. Battery positive terminal Battery voltage Test battery. See “Battery Voltage and Specific Gravity Test” on
page 277.
2. Starting motor solenoid B Battery voltage Check battery cable and connections.
terminal
3. Alternator terminal B Battery voltage Check 002A Red wire and connections.
4. Manifold heater relay Battery voltage Test fusible link. Check 002B Red wire and connections.
5. F1 Fuse Battery voltage Test fusible link. Check 002C Red wire and connections.
6. Key switch Battery voltage Test F1 fuse. Check 012 Red wire and connections.
7. Engine run relay Battery voltage Test fusible link. Check 002D Red wire and connections.
8. F3 Fuse Battery voltage Test fusible link. Check 002C Red wire and connections.
9. Turn signal interlock relay Battery voltage Test F3 fuse. Check 122C and 122D Red wires and
connections.
10. Light switch Battery voltage Test F3 fuse. Check 122C and 122B Red wires and
connections.
11. Turn signal switch Battery voltage Test F3 fuse. Check 122C and 122A Red wires and
connections.
12. F2 Fuse (if equipped) Battery voltage Test fusible link. Check 002C Red wire and connections.
13. K5 Trailer relay (if Battery voltage Test F2 fuse. Check 252 Red wire and connections.
equipped)

S1 Key Switch S9 Light Switch
K5 Trailer
Relay Socket
(optional)
86
13
30
10
87A
87
S8 Turn
6 122B Signal Switch
5 012 Red
85
F1 Fuse Red
A B 252
12
F2 Fuse Red
A B
8
F3 Fuse
122C Red 122A Red
A B
002D Red
11
002C K4 Engine Run

Red Relay Socket
K1 Manifold Heater
86
Relay Socket 002D

30
Red
87A
4
87
86
30
85
87A
7
87
85
K7 Turn Signal
Interlock Relay Socket
002B Red 85 87A 87

122D Red 30 86
Fusible M1
Link Starting
Motor
002A Red
3
G2 Alternator
G1 Battery
W1
Frame Ground
1

Test Conditions:
• Key switch in run position, engine off
14. Key switch Battery voltage Test key switch.
15. Alternator terminal IG Battery voltage Check 072B and 072A Red wires and connections.
16. F5 Fuse Battery voltage Check 072B and 072C Red wires and connections.
17. X3 Connector Battery voltage Test F5 fuse. Check 562D and 562C Red wires and
connections.
18. Seat switch Battery voltage Check 562D and 562E Red wires and connections.
19. Rear PTO switch Battery voltage Check 562F and 562G Red wires and connections.
20. Mid PTO switch Battery voltage Check 562H Red wires and connections.
21. MFWD switch Battery voltage Check 562J Red wires and connections.
22. MFWD solenoid Battery voltage Check 555 Wht wire and connections. If OK, replace MFWD
switch.
23. Park brake switch Battery voltage Check 562B Red wires and connections.
24. Park brake switch Battery voltage Check 577C and 577A Pur wires and connections. If OK,
replace mid PTO switch.
25. Rear PTO switch Battery voltage Check 577C and 577B Pur wires and connections. If OK,
26. X8 Connector Battery voltage Check 586 Lt Blu wire and connections. If OK, replace park
brake switch.
27. K13 Neutral relay Battery voltage Check 505 Dk Grn wire and connections. If OK, replace park
brake switch.
28. X8 Connector Battery voltage Check 562L Red wires and connections.
29. F10 Fuse Battery voltage Check 562M Red wires and connections.
30. X5 Connector Battery voltage Check 562A Red wires and connections.
31. K14 Mid PTO lockout relay Battery voltage Check 562K Red wires and connections.
32. K16 Mid PTO relay Battery voltage Check 562N Red wires and connections.

X3 Connector to
W8 Diverter Valve To W2, W3
Wiring Harness or W4 Wiring S2 Seat
562C Harness Switch
S1 Key Switch 16 Red 562A
17 Red X5
072B 072C A
Red Red F5 Fuse 562D Red 562E Red
A B 562L Red
072A
14 Red
K16 Mid PTO 18
Relay
G2 Alternator 85 87A 87
30 86
562M F12 Fuse
G2 Alternator
Red Socket
Connector
32 562N Red A B
29
562F
Red
S5 Rear PTO Switch
15
562G
Red
K14 Mid PTO
Latch Relay
S6 Mid PTO Switch
85 87A 87
30 86 562B
25 Red
562K Red
31 577B S4 Park
Pur 19
Brake
Switch
577C Pur
562H Red 24
K13 Neutral 577A
20 562A Red Relay Pur
85 87A 87
30 86
23
27 519 Pur +12 VDC
Switched 586
505 Lt Blu
562L Red Dk Grn
X5-W1 Main 30
Wiring Harness 586 Lt Blu
Y4 Rear
X8-W1 Main PTO Solenoid
Wiring Harness
28 To Control Panel Y3 MFWD
Solenoid
26
562J
Red 21
S7 MFWD Switch 555 Wht
22

Test Conditions:
33. Mid PTO switch Battery voltage Test V2 diode block. Check 578 Gry, 579B and 579A Wht wires
and connections. If OK, replace rear PTO switch.
34. K14 Mid PTO latch relay Battery voltage Check 579B and 579C Wht wires and connections.
35. K15 Mid PTO lockout relay Battery voltage Check 579B and 579D Wht wires and connections.
36. K12 PTO interlock relay Battery voltage Check 573B and 573D Org wires and connections. If OK,
replace rear PTO switch.
37. K11 Rear PTO interlock Battery voltage Test K12 PTO interlock relay. Check 533 Org wire and
relay connections.
38. K11 Rear PTO interlock Battery voltage Check 573B and 573C Org wires and connections. If OK,
relay replace rear PTO switch.
39. X4 Connector Battery voltage Check 573B and 573A Org wires and connections. If OK,
40. K6 Fuel solenoid timer Battery voltage Test transmission neutral switch (SST and ePowrReverser).
module Test V1 diode block. Check 518A Gry, 518B Gry and 521B Brn
wires and connections.
41. X5 Connector Battery voltage Test transmission neutral switch (SST and ePowrReverser).
Test V1 diode block. Check 518A Gry, 518B Gry and 521A Brn
42. K4 Engine run relay Battery voltage Check 303 Lt Blu wire and connections. Check W2, W3 or W4
wiring harness X5 connector wires from K terminal to E
terminal.
43. K13 Neutral relay Battery voltage Check 519 Pur wire and connections. Check W2, W3 or W4
terminal.

S1 Key Switch V2 Diode Block

2
578 Gry
1 3
072B Red 072C Red F5 Fuse 562D Red
5
A B 4 6
562F
8 579B
Red 7 9
Wht
S3 Transmission S5 Rear PTO Switch
Neutral Switch K12 PTO
(SST and ePRT) 562G
Interlock
012 Red
Relay
Red
39
B 85
30
87A 87
86
F1
Fuse W7 eHydro 573B 573D
Org 36
002C Jumper Plug Org
A (eHydro) 577B
Red 562H
Pur
573A Org Red
518A
Gry 533
Fusible 518B Gry K11 Rear PTO Org
Link Interlock Relay
002D Red 85 87A 87 37
30 86
+12 VDC V1 Diode
Block 573C
2 38 Org
W2, W3 or W4
Wiring Harness 1 3
518B S6 Mid PTO Switch
5 Gry
X5 4 6 33
8 546
L 7 9
41 579A Lt Blu
521 Wht
X5
E Brn
K4 Engine
303 42 K15 Mid PTO
Run Relay 577C
Lt Blu Lockout Relay
Socket Pur
577B Pur
86
002D 85 87A 87
30 86
30
305 Red S4 Park

87A
87
Dk Grn
Brake Switch
35
85
579D Wht
050F Blk 050G Blk 577A

K13 Neutral Pur
050H Relay
050E Blk K6 Fuel
Blk Solenoid
85 87A 87
505
30 86 43
Timer K14 Mid PTO Dk Grn
86
Latch Relay
30
521 Brn
87A
87
87
579C 519 Pur X5
85 87A
30 86 Wht
85
050A 40 +12 VDC G

Blk Switched
34 From W2, W3
W1 or W4 Wiring
Frame Harness
Ground

Cranking Circuit Operation
Function:
To energize the starting motor solenoid and engage the
starting motor to crank the engine.
Operating Conditions:
• Key switch in start position
• Transmission in neutral
• Rear PTO disengaged (disengages mid PTO)
c CAUTION: Avoid injury! Always lock park

brake when starting the engine.
The power circuit (fusible link, 002C Red wire, F1 fuse, and
012 Red wire) provides voltage to the key switch.
When placed in the start position, the key switch provides
current to the start relay contact (572A and 572C Red to
terminal 30 of start relay).
The start relay coil is energized through a circuit consisting
of: the key switch (terminal 5), 072B and 072C Red wires,
F5 fuse, 562D, 562F, and 562G Red wires, rear PTO switch
(OFF position), 573A and 573B Org wires, X4 connector to
transmission neutral switch (SST and ePowrReverser
machines), or W7 jumper wire (eHydro machine) and 518B
Gry to the start relay.
This engages the start relay allowing current from the 572C
red wire to the 309 Wht wire energizing the starting motor
solenoid. With the starting motor solenoid energized, the
starting motor solenoid contacts close and high current
from the battery passes through the battery cable and
solenoid contacts to the starting motor. The starting motor
cranks the engine.
To allow the engine to start the fuel shutoff solenoid must
also be energized to pull-in and hold-in the fuel shutoff
solenoid. See “Fuel Supply Circuit Operation” on page 179
for a detailed description of the fuel circuit.

Cranking Circuit Electrical Schematic
F1 4
012
Fuse Red 1 6 572A Red
072C F5 Fuse
2 5 072B Red Red 562D Red
3 S5 Rear
S1 Key PTO Switch
7
Switch
On
562F
Start Off
Run Red
Off 562G Red A B
Acc. C
D E
F
562G Red G
Aid 573B Org
002C H
Red Off
V1 Diode
1
Block 1
X1
2 556 Lt Blu
572D Red 3
Fusible
Link
S3 Transmission
Neutral Switch In Neutral
(SST and ePRT)
In Gear
X4 X4 573A Org
572C 518B Gry
Red
30 86 X4 X4
K2
Start W7 eHydro
87A 87 85 Relay
Jumper
010E Wire
309 Wht
Blk
556
B A
573D Lt Blu
Org
010Z
K12 PTO 30 86
Blk
Interlock
Relay 87A 87 85
M
533 010AA
Org Blk
M1
Starting
Motor
Red
Y1 K11 Rear
Starting PTO 86 30
Motor
Solenoid Interlock
G1 Relay 85 87 87A
Battery 010W 533
Blk Org
Blk
W1
Frame 010D
Ground Blk
010P Blk
W1
Frame
Ground


Cranking Circuit Diagnosis
Test Conditions:
• PTO off
1. Rear PTO switch Battery voltage See “Power Circuit Diagnosis” on page 165.
2. K12 PTO interlock relay Battery voltage Check 573B and 573D Org wires and connections.
3. X4 connector Battery voltage Check 573A and 573B Org wires and connections.
4. K2 Start relay Battery voltage Test transmission neutral switch (SST and ePowrReverser).
Check W7 jumper wire and connections (eHydro). Check 518B
Gry wire and connections.
Test Conditions:
• Fuel shutoff solenoid disconnected
• PTO off
5. K2 Start relay Battery voltage Check 572A and 572C Red wires and connections. If OK,
replace key switch.
6. Starting motor solenoid Battery voltage Check 309 Wht wire and connections. If OK, replace starting
relay.
7. K12 PTO interlock relay Battery voltage Test V1 diode block. Check 556 Lt Blu and 572D and 572A Red

S1 Key Switch
F5 Fuse
562D Red
A B
S5 Rear PTO Switch 562F
Red K12 PTO 533 Org
Interlock Relay
562G
572A Red 85 87A 87
30 86
Red
2 6
573D
573B Org
Org 556
012 Red
Lt Blu
B S3 Transmission
Neutral Switch 1
F1 (SST and ePRT)
Fuse
W7 eHydro
Jumper Wire
4 (eHydro)
518B 573B Org
Gry 3
002C
5 556 Lt Blu
86
Red
30
572C Red 572D Red

87A
87
85
V1 Diode K11 Rear PTO 533 Org

Block 2 Interlock Relay
K2 Start
Relay 1 3
85 87A 87
5 30 86
4 6
8 573C
7 9
Org
Fusible
Link
M1 Starting Motor
309 Wht
G1 Battery
W1
Frame Ground

Manifold Heater and Light Circuit Operation
Function:
To provide an added source of heat for the combustion
chamber during cold starts, especially below 5°C (40°F)
and to illuminate a light on the instrument panel and
indicate to the operator that voltage is being provided to the
manifold heater.
• Key switch must be in the start or run position and
pushed in to the aid position.
The ignition system is designed to inject diesel fuel into the
piston cylinder where heat from compression ignites the
fuel and air mixture. When starting a cold engine,
compression may not provide enough heat to ignite the
fuel. The manifold heater is installed to provide added heat
to the incoming combustion air.
The manifold heater is energized (heated) when the key
switch is placed in the aid position (key pushed into switch).
The key can be pushed into the aid position with the key in
either the start or run position. The manifold may be
preheated by pushing in the key, with the switch in the run
position, for up to 3 seconds before turning the key to the
start position.
When the key switch is in the aid position, current is
provided to the K1 manifold heater relay coil (terminal 86)
through the 385B and 385C Dk Grn wires. When the relay
coil is energized, the relay contacts close and unswitched
power (002B Red wire - terminal 30) flows through the
contacts and 383 Org wire to the manifold heater.
The H3 cold start indicator light in the instrument panel
provides a visual indication that the key is in the aid position
and the manifold heater relay is being energized. In this
position battery voltage is provided to the H3 cold start light
through the 385B and 385A Dk Grn wires, X7 connector
(terminal C), and instrument panel circuit board. A circuit
board run provides voltage to the H3 cold start light.
A ground circuit path for the instrument panel circuit board
is provided though the X8 connector (terminal D), and
050D and 050A Blk wires.

Manifold Heater and Light Circuit Electrical Schematic
F1 4
012
Fuse Red 1 6
A B
2 5
3
S1 Key
7 385B Dk Grn
Switch
Start
Run
Off
Acc.
385A Dk Grn X7
Aid C
002C
Red Off
002B Red
385C
X1 Dk Grn
30 86 K1
Fusible Manifold H3 Cold
Link Heater Start
87A 87 85
Relay Light
383
Org 050E
Blk
R1 Manifold
Heater
B A
M1
Starting D
Motor X8
Red 050D
Blk
G1
Battery
Blk
W1
Frame
Ground 050A Blk 050A Blk
W1
Frame
Ground
Unswitched Power Control Panel Unswitched Ground

Manifold Heater and Light Circuit Diagnosis
Test Conditions:
• K1 manifold heater relay removed
1. Key switch Battery voltage See “Power Circuit Diagnosis” on page 165.
2. K1 manifold heater relay Battery voltage Check 002B Red wire and connections. See “Power Circuit
Diagnosis” on page 165.
Test Conditions:
• Key switch in aid position (pushed in), engine off
• K2 start relay removed
3. Key switch Battery voltage Test key switch
4. K1 manifold heater relay Battery voltage Check 383 Org wire and connections. Check K1 relay. See
“Relay Test” on page 282.
5. X7 connector Battery voltage, H3 Test cold start lamp. Check 385B and 385A Dk Grn wires and
cold start light connections.
illuminated.
Test Conditions:
• K1 manifold heater relay installed
6. Manifold heater Battery voltage Check 385B and 385C Dk Grn wires and connections.
Test Conditions:
• Meter set to ohm scale
• Meter negative lead connected to frame ground

7. Manifold heater Maximum 0.1 ohm Check manifold heater element. Replace manifold heater as
resistance needed.
8. X7 connector Less than 0.2 ohm Check 050D and 050A Blk wires and connections.
resistance
NOTE: If the tests above are performed with normal the instrument panel.
results, and the cold start light does not work, replace
X7-W1 Main Wiring Harness

S1 Key Switch To Control Panel
5
3
385B Dk Grn 385A
Dk Grn
385B
Dk Grn 1
012 Red 050D

Blk
8
385A Dk Grn 050A
Blk
4 385C
Dk Grn
W1
Frame Ground
R1 Manifold
2
86
Heater
30
002B Red
87A
87
85
6 7
K1 Manifold Heater
Relay Socket
383 Org
383 Org
F1
Fuse
002B Red
002C Red
Fusible Link
M1 Starting Motor
G1 Battery
W1 Frame Ground

Fuel Supply Circuit Operation When the key switch is placed in either the run or start
positions, current from the switched power circuit is
Function: provided to the K6 timer module through either the seat
switch and V1 diode block or the rear PTO switch,
To start or stop the supply of fuel to the engine.
transmission neutral switch (SST and ePowrReverser) or
Operating Conditions (Starting Machine): W7 jumper plug (eHydro) and V1 diode block.
• Key switch must be in the start position This circuit causes the K6 timer module to set its time delay
circuit as well as provide power to the engine run relay. The
• PTO disengaged engine run relay will energize, closing its contacts to
• Transmission in neutral provide current from the unswitched power circuit wire
002D Red to the 302B and 302C Red wires.
Operating Conditions (Machine Running, Operator ON
This energizes the hold-in coil of the fuel shutoff solenoid
Seat):
and provides voltage to the pull-in coil.
• Key switch must be in the run position
At the same time that the engine run relay is being
• Operator on seat energized, the K6 timer module will provide temporary
• PTO disengaged or engaged current to the K3 fuel solenoid pull-in relay. With the fuel
solenoid pull-in relay energized, a ground path is created
• Transmission in any gear for the pull-in coil of the fuel shutoff solenoid. This allows
the fuel shutoff solenoid to overcome the spring loaded fuel
Operating Conditions (Machine Running, Operator Off
valve.
Seat):
After approximately 3 second the timer module will cut
• Key switch must be in the run position power to the fuel solenoid pull-in relay. This will open the
• Reverser lever in neutral (ePowrReverser) relay contacts and remove the ground path for the pull-in
coil.
A ground path for the fuel shutoff solenoid hold-in coil is
• Rear PTO can be engaged
provided through the 010N and 010P Blk wires.
• Pack brake locked
A latching circuit is provided to maintain voltage to the
• Operator can leave seat engine run relay after the PTO is engaged.
Theory of Operation: This circuit allows the operator to leave the seat only after
the following sequence of events has been followed: the
The fuel system is designed to inject fuel into the piston transmission placed in neutral and the park brake locked.
cylinder where heat from compression ignites the fuel and The operator may then leave the seat and engage the PTO.
air mixture.
The engine will shutoff if either the park brake is released
Fuel is provided to the engine when the fuel shutoff or the transmission is placed in gear without having an
solenoid is energized. The fuel shutoff solenoid contains operator present on the seat.
two coils to open the fuel valve. The pull-in coil, in
conjunction with the hold-in coil, overcomes the spring
loaded fuel valve. The hold-in coil keeps the fuel valve open
after the pull-in coil current is removed through the K6 timer
module and the K3 pull-in relay.
The fuel shutoff solenoid is initially energized and pulled in
when the engine run relay contacts close. Voltage is
provided to both of the fuel shutoff solenoid coils (pull-in
and hold-in), which provide enough pull on the solenoid
plunger to overcome the shutoff solenoid spring.
The fuel shutoff solenoid pull-in coil needs a high current
pulse through it to overcome the solenoid spring. After the
solenoid opens (overcomes the spring) a lower current will
hold the solenoid open. The combination of the K3 fuel
shutoff relay and K6 timer module provide a means to
remove the current flow through the fuel shutoff solenoid
pull-in coil after the solenoid opens.

Fuel Supply Circuit Electrical Schematic - W1 Main with W2 SST and W3 ePowrReverser
002D Red
556 Lt Blu
F1 4
012
072C F5 Fuse
2 5 072B Red Red 562D Red 562A Red 562A Red
3 562E Red
S1 Key
7
Switch 572B Red
Start 303 Lt Blu
Run
Off S2 Seat
Acc.
Switch 539A 1
Wht 2 556 Lt Blu
Aid (Off Seat)
002C
Off 572D Red 3
Red (On Seat)
V1 Diode
539D Wht 539B Wht 4
Block 1
5
521
518A Gry 6 Brn
X1 573A Org
539C Wht 539C Wht

Fusible
Link S3 Transmission
Neutral Switch
In Neutral
(SST and ePRT)
In Gear
X4 X4
572C 518B Gry
Red
30 86
K2
Start 002D
Red
87A 87 85 Relay 303
309 Wht V1 Lt Blu 562K
Diode Red
B A 30 86 K4
Block 1 Engine
010E Blk 7 8 302A Red Run
010F 87A 87 85 Relay
010Z Blk 302B 562M
Blk
Red 050F Red
X2 Blk
M 302C Red
050G
M1 Blk 562N
Wht 050E Red
Starting Y1
Motor Y2 Fuel 050H Blk
Starting Shutoff Blk
Red Motor Solenoid 30 86 K6
Solenoid Wht
G1 Blk Fuel Solenoid
Battery X2 Timer Module
85 87 87A
329 304 Org
Blk Wht
562P Red
W1 X2 30 86 K3 Fuel
Frame 010N Shutoff
Ground Blk Solenoid
87A 87 85 Pull-in Relay 305 Dk Grn
W1 010AJ 010F
Blk Blk
Frame
Ground 050A Blk
010D Blk
010P Blk
Unswitched Power Switched Power Secondary Switched Power

Timer Module Switched Power Unswitched Ground

556 Lt Blu
W3 ePRT Wiring Harness
562A Red X5 A 562A Red
562F Red 303 Lt Blu X5 E 303 Org
572B Red X5 H 572 Red
S5 Rear W2 SST Jumper Plug

PTO Switch 556
573D X5
Lt Blu
Org
A 519 Wht
On 30 86 K12 PTO
562F Red Off Interlock E 521 Brn
Relay G 519 Wht
562G Red A B 87A 87 85
577B Pur C 533 010AA
D E L 521 Brn
F Org Blk
562G Red G
H 573B Org
562H Red
X5 G 519B Wht
573A Org
539C Wht X5 J 539 Wht
S4 Park 303 Org

Brake Switch A1
On
X21
Off
572 Red
C C3
B A1
521 Brn
D 505 Dk Grn Electronic D2
577A Pur A
Operating
519A Wht
505 519 System F1
Dk Grn Pur Controller
S6 Mid 539 Wht
30 86 K13 F3
PTO Switch
Neutral G2
050B Blk
On Relay
87A 87 85
562B Red
Off 546 010AB K1
Lt Blu Blk
A B
C
D E
562H Red F
G
H 577C Pur
S10
F-N-R
Switch Forward
573C 546 Neutral
Org Lt Blu
86 30 K11 Rear Reverse
PTO
Interlock 562C Red 519C Wht
85 87 87A
Relay
010W 533
Blk Org
305 Dk Grn X5 L 521 Brn
W1
Frame
Ground X5 B 050A Blk
010D Blk
010P Blk


Fuel Supply Circuit Electrical Schematic - W1 Main with W4 eHydro
002D Red
556 Lt Blu
F1 4
012
072C F5 Fuse F10 Fuse
5 072B Red Red 562D Red 552 Red
2
3 212A Red 562E Red

S1 Key 212B Red
7
Switch
Start 303 Lt Blu
Run
Off S2 Seat
Acc.
Switch 539A 1
Wht 2 556 Lt Blu
Aid (Off Seat)
002C
Off 572D Red 3
Red (On Seat)
V1 Diode
539D Wht 539B Wht 4
Block 1
5
521
518A Gry 6 Brn
X1 573A Org
539C Wht 539C Wht

Fusible
Link
572C 518B Gry X4 X4 573A Org

Red
30 86 W7 eHydro
K2
Start Jumper 002D
Red
Relay Wire
87A 87 85 303
Diode Red
B A 30 86 K4
Block 1 Engine
010F 87A 87 85 Relay
010Z Blk 302B 562M
Blk
Red 050F Red
X2 Blk
M 302C Red
050G
M1 Blk 562N
Wht 050E Red
Starting Y1
Solenoid Wht
85 87 87A
329 304 Org
Blk Wht
562P Red
W1 X2 30 86 K3 Fuel
Frame 010N Shutoff
Ground Blk Solenoid
W1 010AJ 010F
Blk Blk
Frame
Ground 050A Blk
010D Blk
010P Blk


556 Lt Blu
552 Red X5 552A Red

F
562F Red 303 Lt Blu X5 E 521 Brn
S5 Rear
PTO Switch 556
573D
Lt Blu
Org
On 30 86 K12 PTO
562F Red Off Interlock
Relay
562G Red A B 87A 87 85
577B Pur D
C 533 010AA
E
F Org Blk
562G Red G
H 573B Org
562H Red
X5 519 Wht
573A Org
G
539C Wht 539C Wht X5 539 Wht
J
S4 Park
Brake Switch
On
X25
539 Wht
Off A1
C 552B Red
B A3
577A Pur A D 505 Dk Grn

A2
505 519 Electronic
Dk Grn Pur
S6 Mid Operating
30 86 K13
PTO Switch System 519 Wht
Neutral D1
On Relay Controller
87A 87 85
Off 546 010AB
Lt Blu Blk
050B Blk
A B E2
C
D E
562H Red F
G
H 577C Pur
573C 546
Org Lt Blu
86 30 K11 Rear
PTO
Interlock
85 87 87A
Relay
010W 533
Blk Org
305 Dk Grn 305 Dk Grn X5 L 521 Brn
W1
Frame
010D Blk
010P Blk


Fuel Supply Circuit Diagnosis
Test Conditions:
1. K4 Engine run relay Battery voltage Test Fusible link. Test battery.
2. Key switch Battery voltage Test F1 fuse. Test Fusible link. Test battery.
3. K6 Fuel solenoid timer Continuity to ground Check 050H, 050G, 050F, 050E and 050A Blk wires and
module connections.
4. K3 Fuel shutoff solenoid Continuity to ground Check 010F, 010E, 010Z and 010D Blk wires and connections.
pull-in relay
5. X2 connector Continuity to ground Check 010N and 010P Blk wires and connections.
Test Conditions:
• Key switch in run position
• Operator on seat
• PTO off
6. K6 Fuel solenoid timer Battery voltage Test F5 fuse. Check 072B, 072C Red, 562D, 562K, 562M, 562N,
module and 562P Red wires and connections. If ok, replace key switch.
7. Seat switch Battery voltage Test F5 fuse. Check 072B, 072C Red, 562D and 562E Red wires
and connections. If ok, replace key switch.
8. X5 Connector Battery voltage Check 539D and 539C Wht wires and connections. If ok, replace
seat switch.
9. K6 Fuel solenoid timer Battery voltage Test V1 diode block. Check 539D and 539B Wht and 521 Brn wires
module and connections.
10. K4 Engine run relay Battery voltage Check 305 Dk Grn, 521 Brn, (303 Org ePowrReverser), and 303 Lt
Blu wires and connections. If ok, replace K6 timer module.
11. X2 Connector Battery voltage Check 302B and 302 Red wires and connections. If ok, replace K4
engine run relay.
12. Rear PTO switch Battery voltage Test F5 fuse. Check 072B, 072C Red, 562D, 562F, and 562G Red
wires and connections. If ok, replace key switch.
13. X4 Connector Battery voltage Check 573A and 573B Org wires and connections. If ok, replace
rear PTO switch.
14. K6 Fuel solenoid timer Battery voltage Test V1 diode block. Check 518A and 518B Gry and 521 Brn wires
module and connections (SST and ePowrReverser). If ok, replace
transmission neutral switch.

S2 Seat
S1 Key Switch 562A Switch
Red X5
A 7
072B Red 072C Red F5 Fuse 562D Red 562E Red
539D
8
562F Wht
S3 Transmission S5 Rear PTO Switch Red
Neutral Switch
(SST and ePRT) 539C Wht X5
562G Red
012 J
2
Red
13
573B
Org
W7 eHydro
518A Gry Jumper Wire
(eHydro) 12
K2 Start 518B Gry 573A Org
Relay
539B
86
Wht
30
F1
87A
87
Fuse
539A
V1 Diode Wht
85
002D Red Block
1
010F Blk 010E Blk
4
010D Blk
5
8
2
002C X5
+12 VDC Red
9
6
3
L
518B Gry
Fusible Link
X5
W2, W3 or W4 E
Wiring Harness 10 3
303 K6 Fuel
Lt Blu Solenoid
050H 14
Blk Timer
86
9
K4 Engine Run
30
86
87A
305
87
Relay Socket 521

30
Dk Grn Brn
87A
87
85
562P
1
85
Red
050E Blk 050F Blk 6
050G Blk
X2 To Y2
050A
Fuel Shutoff
Blk 302B Red 302C Red
010N Blk Solenoid
304 Org
5
86
30
010P Blk 010AJ Blk 329 Wht 11

87A
87
W1 K3 Fuel Shutoff
85
Frame 4 Solenoid Pull-in

Ground
010F Blk Relay

Test Conditions:
• Key switch turned from off to run position while performing each test.
• PTO off
15. K3 Fuel shutoff solenoid Battery voltage for Check 304 Org wire and connections. If ok, replace K6 fuel
pull-in relay approximately 3 solenoid timer module.
seconds, then less
than 0.2 volts.
16. X2 connector Continuity to ground Check 329 Wht, 010AJ and 010P Blk wires and connections. If
for approximately 3 ok, replace K3 fuel shutoff solenoid pull-in relay.
seconds, then infinity.
Test Conditions:
• Key switch in to run position
• PTO off
• K12 PTO interlock relay removed
17. K12 PTO interlock relay Battery voltage Check 573B and 573D Org wires and connections. If ok,
18. K11 Rear PTO interlock Battery voltage Check 573B and 573C Org wires and connections. If ok,
19. Mid PTO switch Battery voltage Test F5 fuse. Check 072B, 072C Red, 562D, 562F, 562G and
562H Red wires and connections.
20. Park brake switch Battery voltage Check 577C and 577A Pur wires and connections. If ok,
21. K13 Neutral relay Battery voltage Check 505 Dk Grn wire and connections. If ok, replace park
brake switch.
22. K11 Rear PTO interlock Battery voltage Check 546 Lt Blu wire and connections. If ok, replace K13
relay neutral relay.
23. K12 PTO interlock relay Battery voltage Check 533 Org wire and connections. If ok, replace K11 rear
PTO interlock relay.
24. K11 Rear PTO interlock Continuity to ground Check 010W and 010P Blk wires and connections.
relay

25. K12 PTO interlock relay Continuity to ground Check 010AA and 010D Blk wires and connections.
26. K13 neutral relay Continuity to ground Check 010AB and 010D Blk wires and connections.

S2 Seat
Red X5
A
539D
562F Wht
S3 Transmission S5 Rear PTO Switch Red
Neutral Switch
(SST and ePRT) 539C Wht X5
562G Red
012 J
Red
K12 PTO
Interlock 23
573B Relay
Org
W7 eHydro 85 87A 87
518A Gry Jumper Wire 30 86
(eHydro) 25
573D
K2 Start 518B Gry 573A Org
Org
Relay
17
539B
86
556 Lt Blu
Wht
30
F1
87A
87
Fuse
539A 533
V1 Diode Wht Org
85
002D Red Block 1 K11 Rear PTO

010F Blk 010E Blk
7
Interlock Relay
4
010D Blk
5
85 87A 87
30 86
8
24
002C X5
+12 VDC Red 22 18
9
6
L
518B Gry 573C
Fusible Link S6 Mid PTO Switch
X5 Org
305
W2, W3 or W4 E
Dk Grn
Wiring Harness 303 K6 Fuel
Lt Blu Solenoid
050H 577C 546
Timer Lt Blu
86
Blk Pur
K4 Engine Run
30
86
87A
87
Relay Socket 521 S4 Park

30
Brn 562H Red Brake

87A
87
85
19 Switch
562P
20
85
Red
050E Blk 050F Blk
050G Blk
050A K13 Neutral
Blk 302B Red 302C Red Relay 577A
010N Blk 26 Pur
304 Org 85 87A 87 505
15 30 86
Dk Grn
86
21
519 Pur X5
30
010P Blk 010AJ Blk 329 Wht

87A
87
G
W1 K3 Fuel Shutoff 16 X2 To Y2
+12 VDC Switched
85
Frame Solenoid Pull-in Fuel Shutoff

Ground From W2, W3 or W4
010F Blk Relay Solenoid
Wiring Harness

Engine Shutoff Circuit Operation Seat Switch Circuit
The seat switch is the main and most direct circuit to
Engine Shutoff Function:
provide power to the K6 solenoid timer module and K4
To cut power to the fuel shutoff solenoid and stop the engine run relay coil.
machine engine when desired or in an unsafe operating
Power is provided through the key switch, 072B and 072C
condition.
Red wires, F5 fuse, 562D and 562E Red wires, S2 seat
switch (operator on seat), 539D and 539B Wht wires, V1
diode block (terminals 4 to 5), 521 Brn wire, K6 solenoid
• Engine running timer module, 305 Dk Grn wire, X5 connector to the 521
• Operator on seat Brn wire of the W2 (SST), W3 (ePowrReverser), or W4
(eHydro) wire harness.
Engine MUST STOP when: On ePowrReverser machines the 521 Brn wire provides
• Operator places the key switch in the off position input to the A1 drive controller. The drive controller then
provides output to the 303 Org wire, X5 connector to the
or;
303 Lt Blu wire of the W1 main wiring harness and the K4
• PTO is engaged, and engine run relay coil.
• Operator gets out of seat On SST and eHydro machines the 521 Brn wire jumpers
or (eHydro); from the K to the E terminal of the X5 connector. This
provides power to the 303 Lt Blu wire of the W1 main wiring
• Operator gets out of seat, and harness and the K4 engine run relay coil.
• Park brake is not engaged This seat circuit provides voltage to the engine run relay for
or (SST and ePowrReverser); normal operator on seat operation of the machine.
• Transmission is in gear, and PTO OFF Circuit
• Operator gets out of seat The S5 rear PTO switch is the second path to provide
NOTE: If transmission is in neutral and the PTO is power to the K4 engine run relay coil.
disengaged, and then the park brake is set, the The rear PTO switch in combination with the transmission
operator can leave the seat and then engage the rear neutral switch (SST and ePowrReverser) provides power to
PTO. the fuel circuit. Power is provided from the key switch to the
072B and 072C Red wires, F5 fuse, 562A, 562D, 562F and
Theory of Operation: 562G Red wires, rear PTO switch (PTO disengaged), 573A
Fuel is supplied to the engine provided that operating and 573B Org wires, S3 transmission neutral switch (SST
conditions are met. See “Fuel Supply Circuit Operation” on and ePowrReverser) or W7 jumper wire (eHydro), 518B
page 179. and 518A Gry wires, V1 diode block (terminals 6 to 5), 521
Brn wire, X5 connector to the 521 Brn, K6 solenoid timer
When the operator places the key switch in the off position
module, 305 Dk Grn wire, X5 connector to the 521 Brn wire
or if an unsafe condition is created, the engine will stop by
of the W2 (SST), W3 (ePowrReverser), or W4 (eHydro)
having the fuel supply to the engine shut off.
wire harness.
The fuel supply is shut off when voltage to the K4 engine On ePowrReverser machines the 521 Brn wire provides
run relay coil is removed, its contacts open, power to the Y2 input to the A1 drive controller. The drive controller then
fuel shutoff solenoid coils is removed and the solenoid provides output to the 303 Org wire, X5 connector to the
closes. 303 Lt Blu wire of the W1 main wiring harness and the K4
Power to the K4 engine run relay coil comes from the K6 engine run relay coil.
solenoid timer module, V1 diode block (terminal 5), and is
On SST and eHydro machines the 521 Brn wire jumpers
provided to the diode block (terminals 4 or 6) through
from the K to the E terminal of the X5 connector. This
different circuits. The different circuits allow for a variety of
operating conditions to exist and maintain fuel supply to the
harness and the K4 engine run relay coil.
engine.
This circuit provides voltage to the engine run relay if the
PTO is disengaged and the transmission is in neutral, with
or without the operator in the seat.

PTO ON, Operator OFF Seat The K12 PTO/Start interlock relay is de energized,
(operator off seat), and power is supplied across its
A third circuit provides power from the switched power
normally closed contacts (terminals 87A to 30) to 573A,
circuit through the mid PTO switch, park brake switch, and
573B, 573C and 573D Org wires.
the K11, K12 and K13 safety relays.
This provides a latch circuit that will continue to provide
The park brake switch and the K11, K12 and K13 relays, in
current to the K4 engine run relay.
conjunction with the rear PTO switch, create a self-latching
circuit. The rear and mid PTOs must be disengaged, the The 573A, 573B, 573C and 573D Org wires, provide power
transmission must be in neutral, and the park brake must to the S3 transmission neutral switch (SST and
be engaged to create the circuit. On ePowrReverser ePowrReverser) or W7 jumper wire (eHydro), 518B and
machines the reverser lever must also be in the neutral 518A Gry wires, V1 diode block (terminals 6 to 5), 521 Brn
position. On eHydro machines, the drive pedals being in wire, K6 solenoid timer module, 305 Dk Grn wire, X5
neutral will indicate a neutral drive condition. connector to the 521 Brn wire of the W2 (SST), W3
(ePowrReverser), or W4 (eHydro) wire harness.
Once the latch circuit is established the PTO can be
engaged. The latching circuit will remain energized until the On ePowrReverser machines the 521 Brn wire provides
park brake switch is disengaged, the operator gets on the input to the A1 drive controller. The drive controller then
seat, or the key switch is placed in the start position. provides output to the 303 Org wire, X5 connector to the
On ePowrReverser machines, if the reverser lever is shifted 303 Lt Blu wire of the W1 main wiring harness and the K4
into a drive direction or on eHydro machines, if either drive engine run relay coil.
pedal is pressed, power will be eliminated from the latching On SST and eHydro machines the 521 Brn wire jumpers
circuit. from the K to the E terminal of the X5 connector. This
Power is provided to the S4 park brake switch through the
key switch, 072B and 072C Red wires, F5 fuse, 562A,
562D, 562F 562G and 562H Red wires, mid PTO switch The PTO can now be engaged, and power will remain to
and 577C and 577A Pur wires to the park brake switch. the K4 engine run relay through the park brake switch,
latching relay circuit with the operator off the seat.
With the park brake locked, power is provided through the
park brake switch and 505 Dk Grn wire to the K13 neutral If the park brake is disengaged without the operator on the
relay (terminal 30). Power is provided to the K13 neutral seat, the engine will stop.
relay coil (terminal 86) through the W2 wiring harness
jumper wire on SST machines, F-N-R switch on
ePowrReverser machines and the drive pedals in neutral
and A2 drive controller on eHydro machines.
Power is supplied to either the F-N-R switch
(ePowrReverser) or A2 drive controller and the drive pedals
(eHydro) from the switched power circuit. With the F-N-R
switch in neutral and the brake switch locked, power is
supplied to the 519B (ePowrReverser) or 519 Wht wire, X5
connector, 519 Pur wire and the K13 neutral relay coil
(terminal 86).
With the K13 coil energized, and power to the K13 contact
(terminal 30), power is provided through the K13 contacts
and 546 Lt Blu wire to the K11 rear PTO interlock relay
(terminal 30).
The K11 rear PTO interlock relay is energized as result of
the rear PTO switch being in the disengaged position and
power being provided to 573A, 573B, 573C and 573D Org
wires.
The power continues through the K11 contacts, and the
533 Org wire to K12 (terminal 87A).

Engine Shutoff Circuit Electrical Schematic - W1 Main with W2 SST and W3 ePowrReverser
002D Red
556 Lt Blu
F1 4
012
Fuse Red 1 6
072C F5 Fuse
3 562E Red
S1 Key
7
Switch
Start 303 Lt Blu
Run
Off S2 Seat
Acc.
Switch 539A 1
Wht 2 556 Lt Blu
Aid (Off Seat)
002C
Off 3
Red (On Seat)
V1 Diode
539D Wht 539B Wht 4
Block 1
5
521
518A Gry 6 Brn
X1 573A Org
539C Wht 539C Wht

Fusible
Neutral Switch
In Neutral
(SST and ePRT)
In Gear
X4 X4
518B Gry
002D
Red
303
V1 Lt Blu 562K
Diode Red
B A 30 86 K4
Block 1 Engine
010Z Blk 7 8 302A Red Run
87A 87 85 Relay
302B 562M
Red 050F Red
X2 Blk
M 302C Red
050G
M1 Blk 562N
Wht 050E Red
Starting Y1
Solenoid Wht
85 87 87A
Blk
562P Red
W1 X2
Frame 010N
Ground Blk
305 Dk Grn
W1
Frame
Ground 050A Blk
010D Blk
010P Blk


556 Lt Blu
W3 ePRT Wiring Harness
S5 Rear W2 SST Wiring Harness

PTO Switch 556
573D X5
Lt Blu
Org
A 519 Wht
On 30 86 K12 PTO
562F Red Off Interlock E 521 Brn
Relay G 519 Wht
562G Red A B 87A 87 85
577B Pur C 533 010AA 521 Brn
D E
Org L
F Blk
562G Red G
H 573B Org
562H Red
X5 G 519B Wht
573A Org
539C Wht X5 J 539 Wht
S4 Park 303 Org

Brake Switch A1
On
X21
Off
C
B A1
521 Brn
D 505 Dk Grn Electronic D2
577A Pur A
Operating
519A Wht
505 519 System F1
Dk Grn Pur Controller
S6 Mid 539 Wht
30 86 K13 F3
PTO Switch
Neutral G2
050B Blk
On Relay
87A 87 85
562B Red
Off 546 010AB K1
Lt Blu Blk
A B
C
D E
562H Red F
G
H 577C Pur
S10
F-N-R
Switch Forward
573C 546 Neutral
Org Lt Blu
PTO
85 87 87A
Relay
010W 533
Blk Org
W1
Frame
010D Blk
010P Blk


Engine Shutoff Circuit Electrical Schematic - W1 Main with W4 eHydro
002D Red
556 Lt Blu
F1 4
012
Fuse Red 1 6
072C F5 Fuse
2
3 212A Red 562E Red 562F Red

S1 Key
7 F10 Fuse
Switch 212B Red
Start 303 Lt Blu

Run
Off S2 Seat
Acc.
Switch 539A 1
Wht 2 556 Lt Blu
Aid (Off Seat)
002C
Off 3
Red (On Seat)
V1 Diode
539D Wht 539B Wht 4
Block 1
5
521
518A Gry 6 Brn
X1 573A Org
539C Wht 539C Wht

Fusible
Link
518B Gry X4 X4 573A Org
W7 eHydro
Jumper 002D
Red
Wire
303
V1 Lt Blu 562K
Diode Red
B A 30 86 K4
Block 1 Engine
87A 87 85 Relay
302B 562M
Red 050F Red
X2 Blk
M 302C Red
050G
M1 Blk 562N
Wht 050E Red
Starting Y1
Solenoid Wht
85 87 87A
Blk
562P Red
W1 X2
Frame 010N
Ground Blk
305 Dk Grn
W1
Frame
Ground 050A Blk
010D Blk
010P Blk


556 Lt Blu

552 Red X5 552A Red
F
S5 Rear
PTO Switch 556
573D
Lt Blu
Org
On 30 86 K12 PTO
562F Red Off Interlock
Relay
562G Red A B 87A 87 85
577B Pur D
C 533 010AA
E
F Org Blk
562G Red G
H 573B Org
562H Red
X5 519 Wht
573A Org
G
539C Wht 539C Wht X5 539 Wht
J
S4 Park
Brake Switch
On
X25
539 Wht
Off A1
C 552B Red
B A3

A2
505 519 Electronic
Dk Grn Pur
S6 Mid Operating
30 86 K13
PTO Switch System 519 Wht
Neutral D1
On Relay Controller
87A 87 85
Off 546 010AB
Lt Blu Blk
050B Blk
A B E2
C
D E
562H Red F
G
H 577C Pur
573C 546
Org Lt Blu
86 30 K11 Rear
PTO
Interlock
85 87 87A
Relay
010W 533
Blk Org
W1
Frame
010D Blk
010P Blk


Engine Shutoff Circuit Diagnosis
Test Conditions:
Test Conditions:
• Rear PTO in on position
• Park brake unlocked
3. Seat switch Battery voltage Test F5 fuse. Check 072B, 072C Red, 562D and 562E Red wires
and connections. If ok, replace key switch.
4. K6 fuel solenoid timer Battery voltage Test V1 diode block. Check 539D, 539B Wht, 521 Brn wires and
module connections. If ok, replace seat switch.
5. K4 Engine run relay Battery voltage Check 305 Dk Grn, 521 Brn, (303 Org ePowrReverser), and 303 Lt
Blu wires and connections. If ok, replace K6 timer module.
6. X2 connector Battery voltage Check 302C and 302B Red wires and connections. If ok, replace
K4 engine run relay.
Test Conditions:
• PTO in off position
8. Rear PTO switch Battery voltage Test F5 fuse. Check 072B, 072C Red, 562D, 562F and 562G Red
9. X4 connector Battery voltage Check 573B and 573A Org wires and connections. If OK, replace
rear PTO switch.

module connections.

To W2, W3 S2 Seat
or W4 Wiring 562A Switch
S1 Key Switch Red X5
Harness
A 3
To W2, W3
562F 539D or W4 Wiring
S3 Transmission S5 Rear PTO Switch Red Wht Harness
Neutral Switch 539C
(SST and ePRT) 562G
012 Wht X5
2 Red
Red J
9 K12 PTO
573B Interlock
Org Relay
85 87A 87
W7 eHydro 30 86
518A Jumper Wire
Gry (eHydro) 8 573D
002C 573A Org Org
Red
539B Wht
Fusible 518B Gry 556 Lt Blu

533
Link Org
539A
V1 Diode Wht
002D Red Block K11 Rear PTO
+12 VDC Interlock Relay
1
7
85 87A 87
5
30 86
W2, W3 or W4
8
Wiring Harness 573C

X5 Org
9
6
L S6 Mid PTO Switch

518B Gry
X5
E 305
546
5 Dk Grn
303 Lt Blu
K6 Fuel
Lt Blu Solenoid 10
050H
K4 Engine Run Timer 4
86
Blk
Relay Socket 577C
30
86
87A
Pur S4 Park
87
521 562H Red

30
Brn Brake
87A
87
85
Switch
1 562P
85
Red
050E Blk 050F Blk 577A
050G Blk
050A K13 Neutral Pur
Blk Relay
302B Red 302C Red 85 87A 87

30 86 505
010N Blk
Dk Grn
519 Pur X5
G
X2 To Y2
Fuel Shutoff 6
W1 +12 VDC Switched
Solenoid 7
Frame From W2, W3 or W4
Ground Wiring Harness

Test Conditions:
• Key switch in to run position, engine off
• PTO off
11. K12 PTO interlock relay Battery voltage Check 573B and 573D Org wires and connections. If ok,
12. K11 Rear PTO interlock Battery voltage Check 573B and 573C Org wires and connections. If ok,
brake switch.
16. K13 Neutral relay Battery voltage ePowrReverser - Check 519A, 519B, 519C Wht and 519 Pur
wires and connections. If ok, replace F-N-R switch.
eHydro - Check 247 Pur, 519 Wht and 519 Pur wires and
connections. Check drive pedals for neutral condition.
relay
Test Conditions:
NOTE: Set these conditions in order starting with the key switch and ending with the rear PTO switch.
1. Key switch in run position, engine off
2. Operator off seat
3. Transmission(s) in neutral
4. Park brake locked
5. Rear PTO on

22. K6 fuel solenoid timer Battery voltage Test V1 diode block. Check 573B and 573A Org, 539D and
module 539B Wht, and 521 Brn wires and connections. If ok, replace
K12 interlock relay.

To W2, W3 S2 Seat
or W4 Wiring 562A Switch
S1 Key Switch Red X5
Harness
A
To W2, W3
562F 539D or W4 Wiring
S3 Transmission S5 Rear PTO Switch Red Wht Harness
Neutral Switch 539C
(SST and ePRT) 562G
012 Wht X5
Red
Red J
K12 PTO
Interlock 18
573B
Org Relay
85 87A 87
W7 eHydro 30 86
518A Jumper Wire 20
Gry (eHydro) 573D
002C 573A Org 11 Org
Red
539B Wht
Fusible 518B Gry 556 Lt Blu

533
Link Org
539A
V1 Diode Wht
002D Red Block K11 Rear PTO
+12 VDC Interlock Relay
1
7
85 87A 87
5
30 86
W2, W3 or W4
8
573C 19
2
Wiring Harness
X5 Org
12
9
6
L S6 Mid PTO Switch 17

518B Gry
X5
E 305
546
Dk Grn
303 Lt Blu
K6 Fuel
Lt Blu Solenoid
050H
K4 Engine Run Timer 22
86
Blk
Relay Socket 577C
30
86
87A
562H Red Pur S4 Park

87
521
30
Brn Brake
87A
87
13
85
Switch
562P 14
85
Red
050E Blk 050F Blk 577A
050G Blk
050A K13 Neutral Pur
Blk Relay
302B Red 302C Red 85 87A 87

30 86 505
010N Blk
21 16 Dk Grn
15
519 Pur X5
G
X2 To Y2
Fuel Shutoff +12 VDC Switched
W1
Frame Solenoid From W2, W3 or W4
Ground Wiring Harness

Charging Circuit Operation Tachometer Circuit Operation
Function: Function:
To maintain proper battery voltage. To indicate engine rpm to the operator.
Operating Conditions: Operating Conditions:

• Key switch in run position • Key switch in run position
• Engine running • Engine running
Theory of Operation: Theory of Operation:

The charging system consists of the G2 alternator with an Pulsed current flows from the “P” terminal of the alternator
integrated voltage regulator/rectifier. Charging output is to the instrument panel (X8 connector, terminal F) through
controlled by a regulator/rectifier. The status of the charge the 325 Dk Grn wire.
rate is indicated by the H5 discharge light.
With the key switch in the run position, battery sensing Hour Meter Circuit Operation
circuit current flows from battery positive terminal to the
starting motor terminal, fusible link, 002C Red wire, F1 Function:
fuse, 012 Red wire, S1 key switch, 072B and 072A Red To indicate engine hours of use to the operator.
wires to the alternator voltage regulator/rectifier. The
battery sensing circuit allows the voltage regulator/rectifier Operating Conditions:
to monitor battery voltage.
A rotating permanent magnet in the alternator induces AC
• Engine running
current in the alternator stator coils. The AC current flows to
the voltage regulator/rectifier. The voltage regulator/rectifier Theory of Operation:
converts AC current to DC current needed to charge the
battery. The hour meter is integrated into the instrument panel and
does not have any external wiring. The hour meter
If battery voltage is low, the regulator/rectifier allows DC operates only when the engine is running. The hour meter
current to flow to the battery to charge it through the battery uses the engine tachometer circuit for power. If the
charging circuit (002A Red). When the battery is fully tachometer is not functioning, the hour meter will not work.
charged, the voltage regulator/rectifier stops current flow to See “Charging Circuit Operation” on page 201 for
the battery. information on tachometer and hour meter diagnosis.
If the alternator output current falls below system usage or
is insufficient to maintain a preset voltage, the voltage
regulator/rectifier provides current to turn on the discharge
light through the 334 Yel wire, X7 connector, and the
instrument panel circuit board.
The alternator is grounded through the mounting hardware
to the engine.
If the voltage regulator is grounded to the alternator cover,
the alternator produces unregulated amperage. See
“Unregulated Amperage Test” on page 279.

Charging, Tachometer and Hour Meter Circuit Electrical Schematic
002A Red
F1 4 G2
012 B Alternator
Fuse Red 1 6
G
072A Red
2 5 072B Red
IG L
3 P 334
072C 325
Red Yel
S1 Key Dk Grn
334 Yel X7
7
Switch
A
Start F5 H5
Run Fuse Discharge
Off
Acc. Light
Aid _
002C +
Red Off
562D
Red
X1
562 Splice 562L Red X8
A
Fusible
Link
325 Dk Grn X8
F
002A Red P2 Hour

Meter
B A
(Opt.)
n/min
P1 Engine
Tachometer
M
D
M1 X8
Starting 050D
Motor Blk
Red Y1
Starting 050A Blk
Motor
Solenoid
G1 W1
Battery Frame
Blk Ground
W1
Frame
Ground
Control Panel Unswitched Ground

Charging, Tachometer and Hour Meter Circuit Diagnosis
Test Conditions:
• Transmission in neutral position
• PTO off
1. Battery positive terminal Battery voltage Test battery. See “Battery Voltage and Specific Gravity Test” on
page 277.
2. Starting motor “B” terminal Battery voltage Check battery and starting motor cable connections.
3. Alternator “B” terminal Battery voltage Check 002A Red cable and connections to battery.
Test Conditions:
• Alternator plug disconnected
4. Alternator connector Battery voltage Check 072A and 072B Red wires and connections. See “Power
Circuit Diagnosis” on page 165.
Test Conditions:
• Alternator plug connected
• X7 and X8 connectors to instrument panel disconnected
5. X8 connector Battery voltage Test F5 fuse. Check 562L and 562D Red wires and
connections.
6. X8 connector 0.04 volts Check 325 Dk Grn wire and connections.
7. X7 connector 0.45 volts Check 334 Yel wire and connections.
8. X8 connector Continuity to ground Check 050D and 050A Blk wire and connections.
Test Conditions:
• Key switch in run position, engine running
• PTO off

9. Alternator Minimum 12.2 volts See “Regulated Amperage and Voltage Test” on page 280.
Replace voltage regulator/rectifier.
10. Battery 12.4 volts or higher Check for excessive load on electrical system.
NOTE: If the tests above are performed with normal results, and the tachometer and/or hour meter do not work,
replace the instrument panel.
M1 Starting Motor
Fusible Link 002C Red
002B Red S1 Key Switch
F1 Fuse
002A Red 012 Red
2
9 072B
3 Red
G1 Battery 072A Red
072C
Red
F5
Fuse
1 10
562D
G2 Alternator Red
Connector
G2 Alternator
W1 4
325
Frame
Ground Dk Grn
334 Yel
562L Red
050A
Blk 050D Blk
7
334 Yel 5
562L Red
8
6
050D Blk
325 Dk Grn
X7-W1 Main Wiring Harness X8-W1 Main Wiring Harness
To Control Panel To Control Panel
050A Blk 050D Blk

ePowrReverser - Forward Drive Circuit The proper conditions for a forward function will be:
Operation • 12.0 volt input on wire 562B Red, power on,
Function: • 12.0 volt input on wire 539 Wht wire, operator on seat,
The forward drive circuit causes the electronic operating • 5.0 volt output on wire 673A, 673B, 673C and 673D Org
system to engage the forward drive clutch to propel the wire, potentiometer and pressure transducer power,
machine in a controlled forward direction. • Continuity to ground on 050A, 050B, 050C, 050D, 050E,
Additionally the electronic operating system provides for 050F, and 050G Blk wire, potentiometer and pressure
setting the load match function. transducer ground,
• 12.0 volt input on 686 Lt Blu wire, F-N-R switch in
Operating Conditions: forward position,
• Key switch in run position • Input less than 0.2 volt on 687A, 687B, and 687C Pur
• Engine running wires, reverse input wires,
• Operator on seat • Input 0.1 - 0.4 volt on 676 Lt Blu wire, forward pressure
transducer, prior to drive command, and 3.3 - 4.7 volts
• Park brake unlocked during drive command.
• Transmission in gear
• Input 0.1 - 0.4 volt on 677 Pur wire, reverse pressure
transducer,
The electronic operating system is a preprogrammed • Less than 0.2 volts on 688 Gry wire, unless a
electrical device that allows the operator to control the operational problem has been detected, drive controller
machine forward drive function via the electrical inputs from status light,
the F-N-R switch. Under normal operating conditions, this • Output 660 +25/-50 mA on 696 Lt Blu wire, forward
creates an output to the forward proportional solenoid in proportional solenoid energized at full drive, and
the transmission which in turn engages the forward drive
• No output current on 697 Pur wire, reverse proportional
clutch.
solenoid not energized.
Current is supplied to the A1 electronic operating system
With the proper commands, the drive controller will ramp
controller (drive controller) from the switched power circuit.
the output to the forward proportional solenoid to allow the
With the key switch in the run position, current is supplied
machine to travel forward at a speed based upon the
to the 072C red wire, F5 fuse, 562D and 562A Red wires,
engine rpm and the range gear selected.
X5 connector of the W3 wiring harness to the 562A and
562B Red wires and the X21 connector and the drive
controller.
This circuit powers the drive controller to allow for drive
control operation. The 673A Org wire splices to the 673B,
673C and 673D Org wires to provide current from the drive
controller to the clutch position potentiometer, forward
pressure transducer, and reverse pressure transducer
respectively.
When the F-N-R lever is placed in the forward position,
current flows across the F-N-R switch to the drive controller
through the 686 Lt Blu wire. The drive controller then
processes this input command into an output command if
the proper operating conditions exist. The output command
(current) to the forward proportional solenoid can be either
full voltage from the F-N-R switch when the clutch pedal is
fully released or proportional to the clutch pedal position
potentiometer when the clutch pedal is pressed down.

ePowrReverser - Forward Drive Circuit Electrical Schematic
S12
Motion Match
Switch Off
F5
072C 562D On
Red Fuse Red
+12VDC 562E Red
269 Wht
S11
562A 562A
Clutch
Red X5 Red
A
Bottom of Travel
S2 Seat 596 Lt Blu
Switch
562D Red Y6
Forward
(Off Seat) S10 Proportional
(On Seat) F-N-R Solenoid
Switch Forward
562E Red
539D Wht Neutral
539C 696
Reverse Lt Blu
Wht
686 Lt Blu
X5 562C Red
X21 J 694
Yel
A1
696 Lt Blu
A2
697 Pur
A3
688 Gry
B1
B2 694 Yel
B3 695 Dk Grn
C1
697
C2
Pur
C3
D1
D2
A1 D3
E1 686 Lt Blu 695
Electronic E2 596 Lt Blu Dk Grn
Operating E3
System F1 Y7
269 Wht
Controller F2 Reverse
F3 539 Wht
Proportional
G1
050B Blk Solenoid
G2
G3
H1 676 Lt Blu
H2
H3
591Brn
J1 676
J2 Lt Blu
J3 R2 B4
562B Red
K1 Clutch Position 673C Org Forward
K2
673A Org 673B Org X24 Potentiometer m Pressure
K3
Transducer
591 Brn X24 050D
688 Blk
Gry
050A Blk X5 B 050A Blk 050C Blk X24 H11 ePRT
Indicator
Light
050G
W1 Blk
Frame
Ground
Switched Power Controller Power Output Unswitched Ground

Controller Input Controller Signal Output

ePowrReverser - Forward Drive Circuit Diagnosis
Test Conditions:
• Key switch in run position, engine not running
• F-N-R switch in neutral
• Clutch pedal not pressed in
• Motion match switch off
• X5 connector disconnected
1. X5 Connector Battery voltage See “Power Circuit Diagnosis” on page 165.
2. X5 Connector Battery voltage Check 539C and 539D Wht wires and connections. If ok,
replace seat switch.
Test Conditions:
3. Bottom of clutch switch Battery voltage Check 562D and 562A Red wires and connections of the W3
wiring harness.
4. Motion match switch Battery voltage Check 562E and 562A Red wires and connections of the W3
wiring harness.
5. F-N-R switch Battery voltage Check 562C and 562A Red wires and connections of the W3
wiring harness.
6. X21 connector Battery voltage Check 562B and 562A Red wires and connections of the W3
wiring harness.
7. X21 connector Battery voltage Check 539 Wht wire and connections of the W3 wiring harness.
8. Backup alarm connector Continuity to ground Check 050A, 050B, 050C, 050D, 050E, 050F and 050G Blk
wires and connections of the W3 wiring harness.
9. Clutch position 5.0 ± 0.2 volts Check 673A and 673B Org wires and connections of the W3
potentiometer wiring harness.
10. Forward pressure 5.0 ± 0.2 volts Check 673A and 673C Org wires and connections of the W3
transducer wiring harness.

Test Conditions:
• Machine on jack stands (wheels free to spin)
• Range transmission in gear position A
• F-N-R switch in forward
• Engine running with throttle at low idle
• MFWD off
11. A1 drive controller at X21 Battery voltage Test F-N-R switch. Check 686 Lt Blu wire and connections of
connector the W3 wiring harness.
12. Forward proportional 660 +25/-50 mA Check 696 Lt Blu and 694 Yel wires and connections of the W3
solenoid wiring harness. Test forward proportional coil.
13. A1 drive controller at X21 3.3 - 4.7 volts Test forward pressure transducer. Check 676 Lt Blu wire and
connector connections of the W3 wiring harness.

+12 VDC S11 Bottom of

050A Blk
Ground Clutch Switch
+12 VDC
3
2
539 Wht 562D Red
X5-W1 Main
Wiring Harness 562A Red
1 596 Lt Blu
S17 Motion S10

Match F-N-R Switch
Switch
269 Wht 5
562E Red
4 562C Red
686 Lt Blu
519C Wht
A1 Electronic
Operating System 687B Pur
Controller
3
A 1 2
B4 Forward
Pressure Transducer
676 Lt Blu
11 050D Blk
7 K
10
673C Org
B5 Reverse
13 Pressure Transducer
6 8
H12 Backup
Alarm 677 Pur
687C Pur
050E Blk
673D Org
050F Blk
R2 Clutch
Position
Y7 Reverse Y6 Forward
Potentiometer
Proportional Proportional 9
Solenoid Solenoid
673B Org
12 591 Brn
050C Blk
696 Lt Blu
694 Yel
H13 ePRT Electronic
697 Pur 688 Gry
Operating System
Controller Status
050G Blk
695 Dk Grn Indicator Light

ePowrReverser - Reverse Drive Circuit The proper conditions for a reverse function will be:
The reverse drive circuit causes the electronic operating • 5.0 volt output on wire 673A, 673B, 673C and 673D Org
system to engage the reverse drive clutch to propel the wire, potentiometer and pressure transducer power,
machine in a controlled reverse direction. • Continuity to ground on 050A, 050B, 050C, 050D, 050E,
• 12.0 volt input on 687B Pur wire, F-N-R switch in
Operating Conditions: reverse position,
• Key switch in run position • Input less than 0.2 volt on 686 Lt Blu wire, forward input
• Engine running wire,
transducer,
during drive command.
machine reverse drive function via the electrical inputs from status light,
the F-N-R switch. Under normal operating conditions, this • Output 660 +25/-50 mA on 697 Pur wire, reverse
creates an output to the reverse proportional solenoid in proportional solenoid energized at full drive, and
the transmission which in turn engages the reverse drive
• No output current on 696 Lt Blu wire, forward
clutch.
proportional solenoid not energized.
the output to the reverse proportional solenoid to allow the
machine to travel reverse at a speed based upon the
controller.
respectively.
When the F-N-R lever is placed in the reverse position,
through the 687B Pur wire. The drive controller then
(current) to the reverse proportional solenoid can be either

ePowrReverser - Reverse Drive Circuit Electrical Schematic
S12
Motion Match
Switch Off
F5
072C 562D On
Red Fuse Red
+12VDC 562E Red
269 Wht
S11
562A 562A Clutch
Red X5 Red Switch Top of Travel
A
Bottom of Travel
S2 Seat 596 Lt Blu
Switch
562D Red Y6
Forward
Switch Forward
562E Red
539D Wht Neutral
539C 696
Reverse Lt Blu
Wht
X5 562C Red
X21 H 687B Pur 694
Yel
A1
A2 696 Lt Blu
697 Pur
A3
688 Gry
B1
B2 694 Yel
B3 695 Dk Grn 697
C1 H12 Pur
C2 Backup Alarm
C3 687A Pur 687C Pur
D1
D2 050F 695
A1 D3 Blk Dk Grn
E1
Electronic 596 Lt Blu
E2 Y7
Operating E3 Reverse
System F1
F2 269 Wht Proportional
Controller
F3 539 Wht Solenoid
677 Pur
G1
050B Blk
G2
G3 677
688 Pur
H1 B5
H2 Gry
673D Org Reverse
H3
J1
591Brn
H11 ePRT
Indicator
m Pressure
J2 Transducer
Light
J3 R2 050E
562B Red 050G
K1
Blk
Clutch Position Blk
K2
673A Org 673B Org X24 Potentiometer
K3
591 Brn X24
050A Blk X5 B 050A Blk 050C Blk X24
W1
Frame
Ground


ePowrReverser - Reverse Drive Circuit Diagnosis
Test Conditions:
2. X5 Connector Battery voltage Test seat switch. Check 539C and 539D Wht wires and
connections.
Test Conditions:
wiring harness.
wiring harness.
wiring harness.
wiring harness.
10. Reverse pressure 5.0 ± 0.2 volts Check 673A and 673D Org wires and connections of the W3

Test Conditions:
• F-N-R switch in reverse
• MFWD off
11. A1 drive controller at X21 Battery voltage Test F-N-R switch. Check 687B and 687A Pur wires and
12. Reverse proportional 660 +25/-50 mA Check 697 Pur and 965 Dk Grn wires and connections of the
solenoid W3 wiring harness. Test reverse proportional coil.
13. A1 drive controller at X21 3.3 - 4.7 volts Test reverse pressure transducer. Check 677 Pur wire and

S11 Bottom of
+12 VDC 050A Blk
+12 VDC 3
2
562D Red
X5-W1 Main 539 Wht
1 596 Lt Blu
S10
S17 Motion F-N-R Switch
Match
Switch 5
269 Wht
562E Red
562C Red
4 686 Lt Blu
519C Wht
A1 Electronic
Controller
3
A 1 2
B4 Forward
Pressure Transducer
11
676 Lt Blu
7 050D Blk
K
673C Org
B5 Reverse
13
Pressure Transducer
6 8
H12 Backup
Alarm 677 Pur
687C Pur
050E Blk
673D Org 10
050F Blk
R2 Clutch
Position
Potentiometer
Solenoid Solenoid
673B Org
591 Brn
050C Blk
696 Lt Blu
12
694 Yel
H13 ePRT Electronic
688 Gry
697 Pur Operating System
Controller Status
050G Blk

eHydro - Forward Drive Circuit Operation The proper conditions for a forward function will be:
• 12.0 volt input on wire 552B Red, power on,
Function:
• 12.0 volt input on wire 539 Wht wire, operator on seat,
The forward drive circuit causes the electronic operating
system to propel the machine in a controlled forward • 5.0 volt output on wire 673A Org wire, potentiometer
direction. and sensor power,
Additionally the electronic operating system provides for • Continuity to ground on 550A Blk wire, potentiometer
setting the following functions during a forward drive: and sensor ground,
• Maximum travel speed, • Continuity to ground on 050B Blk wire, drive controller
ground,
• Cruise control,
• Input greater than 0.4 volt but less than 4.5 volts on 686
• Motion match (acceleration/deceleration), and
Lt Blu wire, forward pedal pressed,
• Load match. • Input frequency 2011 Hz ± 10% at 950 rpm or 5821 Hz
Each of these additional functions has the ability to be ± 10% at 2750 rpm on 341 Brn wire, engine speed sensor,
Wht wire, throttle position potentiometer,
• Key switch in run position • Input frequency 190 Hz ± 10% at 950 rpm or 550 Hz ±
10% at 2750 on 502 Red wire, MFWD speed sensor,
• Engine running
• Input less than 0.8 volt on 687 Pur wire, reverse pedal
• Operator on seat not pressed,
• Park brake locked • Less than 0.2 volts on 688 Gry wire, unless a
• Range transmission in A range operational problem has been detected, drive controller
status light,
Theory of Operation: • Output less than 950 mA +25/-50 mA nominal at full
The electronic operating system is a preprogrammed drive on 696 Lt Blu wire, forward proportional solenoid
electrical device that allows the operator to control the energized, and
machine forward drive function and speed via the electrical • No output current on 697 Pur wire, reverse proportional
inputs from the forward foot pedal. Under normal operating solenoid not energized.
conditions, this creates an output to the forward
proportional solenoid in the transmission. With the proper commands, the drive controller will ramp
Current is supplied to the A2 electronic operating system machine to travel forward at a speed proportional to the
controller (drive controller) from the switched power circuit. position of the forward pedal based upon the engine rpm
With the key switch in the run position, current is supplied and the range gear selected.
X5 connector of the W4 wiring harness to the 552A and The rate of acceleration and deceleration is controlled by
552B Red wires and the X25 connector and the drive the drive controller to smoothly ramp the speed up and
controller. down. Two different settings provide for either quicker or
slower acceleration or deceleration. This operation is
This circuit powers the drive controller to allow for drive controlled by the operator placing the motion match switch
control operation. The 673A Org wire splices to the 673B, in either the on or off position. The change in this setting
673C, 673D, 673E, 673F and 673G Org wires to provide will take effect as soon as the switch is changed.
current from the drive controller to the throttle position
potentiometer, flywheel speed sensor, forward pedal While acceleration has one setting in each position (on or
potentiometer, reverse pedal potentiometer, motion match off) of the motion match switch, the deceleration function
switch and the MFWD speed sensor respectively. has three settings.
When the forward pedal is pressed, current flows across The three deceleration settings are as follows:
the forward pedal potentiometer and back to the drive • coasting to a slower speed in the same direction,
controller through the 686 Lt Blu wire. The drive controller
• coasting back to the neutral position, and
then processes this input command into an output
command if the proper operating conditions exist. The • stopping when changing directions.
output command (current) to the forward proportional
solenoid is proportional to the pedal position.

movement by the operator as well as simply slowing to a
lower rate of speed.
released.
then immediately beginning to travel in the opposite
direction of travel.
direction change have an immediate or “knee” deceleration
before following the ramped pattern back to a stop. The
amount of deceleration used for the knee value is based
upon a percentage of output being produced. If the knee
value is set at 70, then the speed of the machine would be
reduced to 70% of the current drive speed almost
immediately with the release of the forward pedal. The
deceleration would then follow the ramped setting back to a
stop.
If at any time during the drive function the drive controller
detects a problem with any of the input or output
commands, the drive controller will provide intermittent
output current to wire 688 Gry and the H13 status indicator
light. The status indicator will then flash a code based upon
the intermittent output current. This code can then be
matched to the fault code chart to assist the diagnosis of
the problem. See “eHydro Electronic Operating System
Fault Code Chart” on page 151.

eHydro - Forward Drive Circuit Electrical Schematic
F10
212A 212B
Red Red Fuse 552 Red
+12VDC
F5 W4 eHydro Wiring Harness R3

072C 562D Forward Pedal
Red Fuse Red X28 Potentiometer
+12VDC 673D Org
S2 Seat 686 Lt Blu X28

Switch
562E (Off Seat)
Red 550D Blk X28
(On Seat)
539D Wht 539C Wht 673C Org X29 T1 Flywheel

Speed Sensor
341 Brn X29

X5 X5
J F
550C Blk X29
X25 552A
Red
S17 Motion R4
539 Wht Throttle Position
A1 Match Switch
A2 673B Org X30 Potentiometer
552B Red Off
A3
673A Org
B1 On
B2 499 Wht X30
269 Wht 673F Org
B3
C1
550A Blk
C2 550B Blk X30
269 Wht
C3
D1
D2 673G Org X31 T2 MFWD
D3 Speed Sensor
A2 E1
050B Blk
Electronic E2 502 Red X31
E3
Operating F1
686 Lt Blu
System F2 X31
341 Brn 550F Blk
Controller F3 R5
G1 Reverse Pedal
499 Wht
G2
502 Red 673E Org X32 Potentiometer
G3
H1
H2 X32
687 Pur 687 Pur
H3
688 Gry
J1
J2 X32
J3 550E Blk
696 Lt Blu
K1 688
K2 Gry
697 Pur
K3 697 H13 eHydro
Pur Y8 Indicator
Reverse Light
Proportional 050F
Solenoid 696 Blk
050A Blk B 050A Blk 050E Lt Blu Y9
Blk
Forward
Proportional
050D Solenoid
W1 Blk
Frame
Ground

Controller Input Controller Signal Output Component Ground

eHydro - Forward Drive Circuit Diagnosis
Test Conditions:
• MFWD off
• Max speed/cruise switch off
connections.
4. Forward pedal 5.0 - 4.7 volts Check 673A and 673D Org wires and connections of the W4
5. Forward pedal 0.7 ± 0.08 volts Adjust forward pedal potentiometer to specification. If
potentiometer Early Models S/N - specification can not be attained, replace potentiometer.
H120712, - H131963,
- H141271
0.6 ± 0.1 volts
Late Models S/N
H120713 -, H131964 -
, H141272 -
6. Forward pedal Continuity to ground Check 550A and 550D Blk wires and connections of the W4
7. Flywheel sensor 5.0 - 4.7 volts Check 673A and 673C Org wires and connections of the W4
wiring harness.
8. Flywheel sensor Continuity to ground Check 550A and 550C Blk wires and connections of the W4
wiring harness.
9. Throttle position 5.0 - 4.7 volts Check 673A and 673B Org wires and connections of the W4
10. Throttle position 0.7 ± 0.08 volts Adjust throttle position potentiometer to specification. If
H120712, - H131963,
- H141271
0.6 ± 0.1 volts
Late Models S/N
H120713 -, H131964 -
, H141272 -

11. Throttle position Continuity to ground Check 550A and 550B Blk wires and connections of the W4
12. MFWD speed sensor 5.0 - 4.7 volts Check 673A and 673G Org wires and connections of the W4
wiring harness.
13. MFWD speed sensor Continuity to ground Check 550A and 550G Blk wires and connections of the W4
wiring harness.
14. Reverse pedal 5.0 - 4.7 volts Check 673A and 673E Org wires and connections of the W4
15. Reverse pedal 0.7 ± 0.08 volts Adjust reverse pedal potentiometer to specification. If
H120712, - H131963,
- H141271
0.6 ± 0.1 volts
Late Models S/N
H120713 -, H131964 -
, H141272 -
16. Reverse pedal Continuity to ground Check 550A and 550E Blk wires and connections of the W4
17. Motion match switch 5.0 ± 0.2 volts Check 673A and 673F Org wires and connections of the W4
wiring harness.
Test Conditions:
• Forward drive pedal fully pressed
• MFWD off
• Load match switch off
18. Forward pedal 3.6 - 4.5 volts Replace forward pedal potentiometer
potentiometer
19. Forward proportional 950 +25/-50 mA at full Check 696 Lt Blu wire and connections of the W4 wiring
solenoid drive, Wheels spinning harness. Test forward proportional coil. Check forward
proportional coil. If either the coil or the valve are replaced, run
the calibration procedure.
20. Reverse proportional Continuity to ground Check reverse pedal potentiometer

solenoid

+12 VDC 050A Blk R3 Forward Pedal

Ground 552A Red Potentiometer
+12 VDC
4
1
539 Wht 673D Org
X5-W1 Main
2 550D Blk
S17 Motion 5 6
Match 18
Switch T2 MFWD
269 Wht Speed Sensor
673F Org
7
17
A2 Electronic 673C Org
Operating System 341 Brn
Controller
550C Blk
8
R4 Throttle
539 Wht Position
Potentiometer
552B Red
9
673A Org
673B Org
269 Wht
550A Blk 499 Wht
050B Blk 550B Blk
10 11
T1 Flywheel
Speed Sensor
S14 Backup 3 12
Alarm
673G Org
203 Org
502 Red
550F Blk 13
050G Blk
Y8 Reverse R5 Reverse Pedal
Y9 Forward
Proportional Potentiometer
Proportional
Solenoid
Solenoid 14
19 673E Org
687 Pur
696 550E Blk
Lt Blu
15 16
20
050D Blk
H13 eHydro Electronic
697 Pur 688 Gry
Operating System
Controller Status
050F Blk
050E Blk Indicator Light

eHydro - Reverse Drive Circuit Operation The proper conditions for a reverse function will be:
• 12.0 volt input on wire 552B Red; power on,
Function:
• 12.0 volt input on wire 539 Wht wire; operator on seat,
The reverse drive circuit causes the electronic operating
system to propel the machine in a controlled reverse • 5.0 volt output on wire 673A Org wire; potentiometer
Additionally the electronic operating system provides for • Continuity to ground on 550A Blk wire; potentiometer
setting the following functions during a reverse drive: and sensor ground,
• Motion match (acceleration/deceleration), and • Continuity to ground on 050B Blk wire; drive controller
ground,
• Load match.
• Input less than 0.8 volt on 686 Lt Blu wire; forward pedal
Both of these additional functions has the ability to be
not pressed,
• Input frequency 2011 Hz ± 10% at 950 rpm or 5821 Hz
Operating Conditions: ± 10% at 2750 rpm on 341 Brn wire, engine speed sensor,
• Key switch in run position • Input greater than 0.4 volt but less than 4.5 volts on 499
Wht wire; throttle position potentiometer,
• Engine running
• Operator on seat • Input frequency 190 Hz ± 10% at 950 rpm or 550 Hz ±
• Range transmission in A range Pur wire; reverse pedal pressed,
Theory of Operation: • Less than 0.2 volts on 688 Gry wire, unless a
operational problem has been detected; drive controller
The electronic operating system is a preprogrammed status light,
machine reverse drive function and speed via the electrical • No output current on 696 Lt Blu wire; forward
inputs from the reverse foot pedal. Under normal operating proportional solenoid not energized, and
conditions, this creates an output to the reverse • Output less than 950 +25/-50 mA nominal at full drive on
proportional solenoid in the transmission. 697 Pur wire; reverse proportional solenoid energized.
Current is supplied to the A2 electronic operating system With the proper commands, the drive controller will ramp
controller (drive controller) from the switched power circuit. the output to the reverse proportional solenoid to allow the
With the key switch in the run position, current is supplied machine to travel reverse at a speed proportional to the
to the 072C red wire, F5 fuse, 562D and 562A Red wires, position of the reverse pedal based upon the engine rpm
X5 connector of the W4 wiring harness to the 552A and and the range gear selected.
controller. The rate of acceleration and deceleration is controlled by
the drive controller to smoothly ramp the speed up and
This circuit powers the drive controller to allow for drive down. Two different settings provide for either quicker or
control operation. The 673A Org wire splices to the 673B, slower acceleration or deceleration. This operation is
673C, 673D, 673E, 673F and 673G Org wires to provide controlled by the operator placing the motion match switch
current from the drive controller to the throttle position in either the on or off position. The change in this setting
potentiometer, flywheel speed sensor, forward pedal will take effect as soon as the switch is changed.
potentiometer, reverse pedal potentiometer, motion match
While acceleration has one setting in each position (on or
switch and the MFWD speed sensor respectively.
off) of the motion match switch, the deceleration function
When the reverse pedal is pressed, current flows across has three settings.
the reverse pedal potentiometer and back to the drive
The three deceleration settings are as follows:
controller through the 687 Pur wire. The drive controller
then processes this input command into an output • coasting to a slower speed in the same direction,
command if the proper operating conditions exist. The • coasting back to the neutral position, and
output command (current) to the reverse proportional
solenoid is proportional to the pedal position. • stopping when changing directions.

released.
immediately with the release of the reverse pedal. The
stop.

eHydro - Reverse Drive Circuit Electrical Schematic
F10
212A 212B
+12VDC

+12VDC 673D Org

Switch
562E (Off Seat)
Red 550D Blk X28
(On Seat)

Speed Sensor
341 Brn X29

X5 X5
J F
550C Blk X29
X25 552A
Red
S17 Motion R4
A1 Match Switch
552B Red Off
A3
673A Org
B1 On
B2 499 Wht X30
269 Wht 673F Org
B3
C1
550A Blk
C2 550B Blk X30
269 Wht
C3
D1
D3 Speed Sensor
A2 E1
050B Blk
E3
Operating 203 Org
F1
686 Lt Blu
System F2
203 X31
341 Brn 550F Blk
Controller F3 Org R5
G1 Reverse Pedal
499 Wht
G2
G3
H1 H14
H2 Backup Alarm X32
687 Pur 687 Pur
H3
688 Gry
J1
J2 050G X32
J3 Blk 550E Blk
696 Lt Blu
K1
K2 688
697 Pur
K3 697 Gry
Pur Y8 H13 eHydro
Reverse Indicator
Proportional Light
Solenoid 696 050F
050A Blk B 050A Blk 050E Lt Blu Y9 Blk
Blk
Forward
Proportional
050D Solenoid
W1 Blk
Frame
Ground


eHydro - Reverse Drive Circuit Diagnosis
Test Conditions:
• MFWD off
connections.
H120712, - H131963,
- H141271
0.6 ± 0.1 volts
Late Models S/N
H120713 -, H131964 -
, H141272 -
wiring harness.
wiring harness.
H120712, - H131963,
- H141271
0.6 ± 0.1 volts
Late Models S/N
H120713 -, H131964 -
, H141272 -

wiring harness.
wiring harness.
H120712, - H131963,
- H141271
0.6 ± 0.1 volts
Late Models S/N
H120713 -, H131964 -
, H141272 -
wiring harness.
Test Conditions:
• Reverse drive pedal fully pressed
• MFWD off
18. Reverse pedal 3.6 - 4.5 volts Replace reverse pedal potentiometer
potentiometer
19. Reverse proportional 950 +25/-50 mA at full Check 697 Pur wire and connections of the W4 wiring harness.
solenoid drive, Wheels spinning Test reverse proportional coil. Check reverse proportional coil. If
either the coil or the valve are replaced, run the calibration
procedure.
20. Forward proportional Continuity to ground Check forward pedal potentiometer

solenoid


+12 VDC
4
1
539 Wht 673D Org
X5-W1 Main
2 550D Blk
S17 Motion 5 6
Match
Switch T2 MFWD
673F Org
7
17
Controller
550C Blk
8
R4 Throttle
539 Wht Position
Potentiometer
562B Red
9
673A Org
673B Org
269 Wht
550A Blk 499 Wht
050B Blk 550B Blk
10 11
T1 Flywheel
Speed Sensor
3 12
S14 Backup
Alarm
673G Org
203 Org
502 Red
550F Blk 13
050G Blk
Y9 Forward
Proportional
Solenoid
Solenoid 14
20 673E Org
687 Pur
696 550E Blk
Lt Blu
18 15 16
19
050D Blk H13 eHydro Electronic
697 Pur 688 Gry Operating System
Controller Status
050F Blk Indicator Light
050E Blk

eHydro - Cruise Control Circuit Operation W5 cruise control wiring harness.
(standard) When the cruise control switch is in the on position current
is provided to the 238 Gry wire of the W5 and W4 wiring
Function: harnesses to the A2 drive controller. This input, turns on
To control the machines forward drive speed at a constant the logic circuit used to maintain the drive speed.
speed that can be repeated without having to hold the The next input signal needed to activated the cruise circuit
forward drive pedal at that speed. is an input from the forward pedal potentiometer on wire
686 Lt Blu. This circuit causes an output on the 696 Lt Blu
wire to the forward proportional solenoid which in turn
• Key switch in run position, causes the machine to move forward.
• Engine running, Once the drive controller receives an input from the forward
• Operator on seat, pedal potentiometer, the cruise control switch may be
pressed to the set position momentarily to set the drive
• Park brake unlocked, speed.
• Forward pedal pressed to desired speed while setting At the moment the set signal is received by the drive
the drive speed, and controller, drive controller records the inputs from the
• Cruise switch on and pressed to the set position MFWD speed sensor. The drive controller then supplies an
momentarily when the desired drive speed is attained. output current to the forward proportional solenoid to
maintain the speed recorded at the MFWD speed sensor.
The cruise control will remain engaged until the brake is
depressed; the key switch is turned to the off position, the If changes in machine loading or range gear position
cruise control switch is placed into the off position, the settings do not allow for return to the previous speed
reverse pedal being depressed, or from no speed signal setting, the controller will attempt to return to the speed
input to the controller from the MFWD speed sensor. setting by sending either the maximum (fastest speed
possible) or minimum (slowest speed possible) current to
Theory of Operation: the forward proportional solenoid. If the machine is driving
either up or down a grade, the drive controller will increase
The cruise control uses the electronic operating system
or decrease the output current to the forward proportional
controller (drive controller) to allow the operator to set and
solenoid to maintain the speed at the MFWD speed sensor.
hold a forward drive speed setting that the operator desires
If the operator changes the throttle position, the drive
without having to press and hold the forward pedal.
controller will again vary the output to the forward
The cruise control circuit uses the forward pedal proportional solenoid to maintain the drive speed at the
potentiometer, flywheel speed sensor, throttle position MFWD speed sensor.
potentiometer, and the MFWD speed sensor to provide
input to the drive controller. The drive controller then
process these inputs to provide output current to the
forward proportional solenoid.
Placing the cruise control switch to the on position, enables
the cruise control function. Momentarily pressing the cruise
switch to the set position will then set the cruise speed at
the speed being traveled. Once set, the drive controller
monitors the vehicle speed and varies the current to the
forward proportional solenoid to maintain travel speed at
the set point.
To change the drive speed while the machine is being
driven is done by disengaging the cruise control circuit and
resetting the cruise setting. Pressing either the brake or
reverse pedals, or placing the cruise switch in the off
position will disengage the cruise function.
Unswitched power is provided to the cruise control switch
from the 212A and 212B Red, F10 fuse, 552 Red wire in
the W1 main wiring harness, X5 connector, 552A and 552E
Red wires in the W4 eHydro wiring harness, X27
connector, and the 562A, 562B, and 562C Red wires in the

eHydro - Cruise Control Circuit Electrical Schematic (standard)
F10
212A 212B
W5 Cruise
+12VDC Control Wiring
Harness (standard)
F5
072C 562D S18 Cruise
Red Fuse Red
+12VDC Switch
Off
S2 Seat On
Switch Momentary
(Off Seat) 562C Red 238 Gry
(On Seat) 562B Red

265 Dk Grn
562E Red
539D Wht 562A
W4 eHydro
539C
Wht Red Wiring Harness
X5 X5 X27
R3
X25 J F Forward Pedal
552A 552E 265 238
539 Wht Red Potentiometer
A1 Red Dk Grn Gry 673D Org X28
A2
552B Red
A3
673A Org
B1 686 Lt Blu X28
265 Dk Grn
B2
238 Gry
B3
C1 264 Yel
550A Blk 550D Blk X28
C2
C3 S13
D1
Brake T1 Flywheel
D2 Off 673C Org X29 Speed Sensor
D3 Switch
A2
E1 On X29
Electronic E2
050B Blk 341 Brn
552C Red
Operating E3 247 Pur
System 550C Blk X29
F1
686 Lt Blu
Controller F2 R4
341 Brn
F3 Throttle
247 Pur
G1
499 Wht 673B Org X30 Potentiometer
G2
502 Red
G3
H1
499 Wht X30
H2
H3
688 Gry
J1
J2 550B Blk X30
J3
696 Lt Blu
K1
K2 T2 MFWD
C 688 673G Org X31
K3 Speed Sensor
X5 Gry
264 H13 eHydro 502 Red X31

X8 G Yel Indicator
H7 Cruise Light X31
550F Blk
Indicator
050F
Light Blk 696
Lt Blu Y9
Forward
X8 Proportional
D
050D 050D Solenoid
Blk Blk
050A Blk X5 B 050A Blk
W1
Frame
Ground Switched Power Controller Power Output

eHydro - Cruise Control Circuit Diagnosis (standard)
NOTE: Test forward and reverse drive function before testing the cruise control function. Correct all drive function
faults before beginning cruise control diagnostics.
Test Conditions:
• X25 connector to drive controller disconnected
• Cruise switch on
2. Cruise control switch Battery voltage See “Power Circuit Diagnosis” on page 165.
4. Brake switch Battery voltage See “Power Circuit Diagnosis” on page 165.
5. Brake switch Less than 0.2 volts Test brake switch. Adjust brake switch. Verify pedal returns to
full release (off) position.
connections.
8. Forward pedal 5.0 - 4.7 volts Check 673A and 673D Org wires and connections.
potentiometer
potentiometer specification can not be obtained, replace potentiometer.
10. Forward pedal Continuity to ground Check 550A and 550D Blk wires and connections.
potentiometer
11. Flywheel sensor 5.0 - 4.7 volts Check 673A and 673C Org wires and connections.
12. Flywheel sensor Continuity to ground Check 550A and 550C Blk wires and connections.
13. Throttle position 5.0 - 4.7 volts Check 673A and 673B Org wires and connections.
potentiometer
15. Throttle position Continuity to ground Check 550A and 550B Blk wires and connections.
potentiometer
16. MFWD speed sensor 5.0 - 4.7 volts Check 673A and 673G Org wires and connections.

17. MFWD speed sensor Continuity to ground Check 550A and 550G Blk wires and connections.
18. X25 Connector Battery voltage Test cruise control switch. Check 238 Gry wire and connections.
Test Conditions:
• MFWD off
• Cruise control switch on and pressed to set position
19. X25 Connector Battery voltage Test cruise control switch. Check 265 Dk Grn wire and
connections.
Test Conditions:
• MFWD off
• Forward drive pedal fully pressed then released after cruise has been set
• X25 connector to drive controller connected
20. Forward proportional 950 +25/-50 mA with Check 696 Lt Blu wire and connections of the W4 wiring
solenoid pedal fully depressed harness. Test forward proportional coil. Check forward

Test Conditions:
• MFWD off
• Engine running with throttle at low idle then moved to fast idle after cruise has been set
• Brake pedal pressed during step 22 only
21. Forward proportional Wheels spinning at Test flywheel speed sensor. Test MFWD speed sensor. Check
solenoid the same speed as 341 Brn and 502 Red wires and connections.
low idle. Current
decreased as rpm
increase.
22. Brake switch Battery voltage. Test brake switch. Adjust brake switch. Check 247 Pur wire and
Wheels stop spinning. connections.

S18 Cruise
Control
+12 VDC 050A Blk Switch
Ground 552A Red 2
+12 VDC 562C
1 Red 562B
X5-W1 Main 539 Wht Red
Wiring Harness
3
6
265 Dk Grn
562A
Red 238 Gry
4
S13 552E
Brake 552C Red Red R3 Forward
Switch Pedal
Potentiometer
247 Pur
8
5
22
673D Org
A2 Electronic
Operating System 686 Lt Blu
Controller 550D Blk
9 10
539 Wht T2 MFWD

Speed Sensor
552B Red
11
673A Org 18
550A Blk 673C Org
050B Blk 341 Brn
550C Blk
12
R4 Throttle
19 Position
Potentiometer
13
S14 Backup 7
673B Org
Alarm
499 Wht
203 Org
550B Blk
050G Blk
14 15
Y9 Forward
T1 Flywheel
Proportional
Speed Sensor
Solenoid
20 21
16
696 673G Org

Lt Blu 502 Red
550F Blk 17
050D Blk

eHydro - Cruise Control Circuit Operation Pressing either the brake or reverse pedals will disengage
(optional) the cruise function. The last speed setting is stored in the
drive controller and if the operator is pressing the forward
Function: pedal, the Res / + switch can be pressed momentarily to
ramp back to the stored speed. Turning the cruise switch
To control the machines forward drive speed at a constant
off, will disengage the cruise function and erase the stored
speed that can be repeated without having to hold the
setting.
forward drive pedal at that speed.
Unswitched power is provided to the cruise on/off switch
Operating Conditions: from the 562 Red series of wires and is protected by the F5
fuse. The 562 Red series of wires include 562D and 562A
• Key switch in run position,
in the W1 main wiring harness, X5 connector, 562A and
• Engine running, 562E in the W4 eHydro wiring harness, X27 connector, and
• Operator on seat, the 562A and 562C wires in the W5 cruise control wiring
harness.
• Park brake unlocked,
When the cruise on/off switch is in the on position current is
• Cruise switch on, provided to the 238 Gry wire of the W5 and W4 wiring
• Forward pedal pressed to desired speed while setting harnesses to the A2 drive controller. This input, turns on
the drive speed, and the logic circuit used to maintain the drive speed.
• Set/- switch pressed momentarily when the desired The next input signal needed to activated the cruise circuit
drive speed is attained. is an input from the forward pedal potentiometer on wire
depressed; the key switch is turned to the off position, the
causes the machine to move forward.
cruise control switch is placed into the off position, the
reverse pedal being depressed, or from no speed signal Once the drive controller receives an input from the forward
input to the controller from the MFWD speed sensor. pedal potentiometer, the Set/- switch may be momentarily
pressed to set the drive speed.
At the moment the Set/- switch is pressed the drive
The cruise control uses the electronic operating system controller records the inputs from the MFWD speed sensor.
controller (drive controller) to allow the operator to set and The drive controller then supplies an output current to the
hold a forward drive speed setting that the operator desires forward proportional solenoid to maintain the speed
without having to press and hold the forward pedal. recorded at the MFWD speed sensor.
The cruise control circuit uses the forward pedal If changes in machine loading or range gear position
potentiometer, flywheel speed sensor, throttle position settings do not allow for return to the previous speed
potentiometer, and the MFWD speed sensor to provide setting, the controller will attempt to return to the speed
input to the drive controller. The drive controller then setting by sending either the maximum (fastest speed
process these inputs to provide output current to the possible) or minimum (slowest speed possible) current to
forward proportional solenoid. the forward proportional solenoid. If the machine is driving
Placing the cruise control switch to the on position, enables either up or down a grade, the drive controller will increase
the cruise control function. Momentarily pressing the Set / - or decrease the output current to the forward proportional
switch will then set the cruise speed at the speed being solenoid to maintain the speed at the MFWD speed sensor.
traveled. If the operator changes the throttle position, the drive
Once set, the drive controller monitors the vehicle speed proportional solenoid to maintain the drive speed at the
and varies the current to the forward proportional solenoid MFWD speed sensor.
to maintain travel speed at the set point.
The cruise speed setting can be increased and decreased
while the machine is being driven by momentarily pressing
either the Res / + switch to increase the maximum speed or
the Set / - switch to decrease the maximum speed setting.

eHydro - Cruise Control Circuit Electrical Schematic (optional)
F10
212A 212B
Red Red Fuse 552 Red S16 W6
+12VDC Cruise ON
Cruise/Max Speed Off
Cruise Control
Switch Max Speed ON Wiring Harness
F5
072C 562D 238 Gry
Fuse 562C Red
Red Red 267 Pur
+12VDC
S15
Res/+, Set/-
S2 Seat Switch
Switch Res +
Off
(Off Seat)
Set -
(On Seat) 266 Lt Blu
562B Red
562E Red 265 Dk Grn
539D Wht W4 eHydro
539C 562A
Wht
Wiring Harness
Red
X5 X5 X27 X27
R3
265 266 267 238
539 Wht 552A 552E
A1 Red Red
Dk Grn Lt Blu Pur Gry X28 Potentiometer
267 Pur 673D Org
A2
552B Red
A3
673A Org
B1 686 Lt Blu X28
265 Dk Grn
B2
238 Gry
B3
264 Yel
C1 X28
550A Blk 550D Blk
C2
C3 S13
D1
Brake T1 Flywheel
D3 Switch
A2
E1 On X29
Electronic E2
050B Blk 341 Brn
552C Red
System 550C Blk X29
F1
686 Lt Blu
Controller F2 R4
341 Brn
F3 Throttle
247 Pur
G1
G2
502 Red
G3
H1
499 Wht X30
H2
H3
688 Gry
J1
266 Lt Blu X30
J2 550B Blk
J3
696 Lt Blu
K1
K2 T2 MFWD
C 688 673G Org X31
K3 Speed Sensor
X5 Gry

X8 G Yel Indicator
H7 Cruise Light X31
550F Blk
Indicator
050F
Light Blk 696
Lt Blu Y9
Forward
X8 Proportional
D
050D 050D Solenoid
Blk Blk
W1
Frame

eHydro - Cruise Control Circuit Diagnosis (optional)
Test Conditions:
• Max speed/cruise switch on
2. Cruise/Max speed switch Battery voltage See “Power Circuit Diagnosis” on page 165.
3. Res/+, Set/- switch Battery voltage See “Power Circuit Diagnosis” on page 165.
5. Brake switch Less than 0.2 volts Test brake switch. Adjust brake switch. Verify pedal returns to
full release (off) position.
connections.
8. Forward pedal 5.0 - 4.7 volts Check 673A and 673D Org wires and connections.
potentiometer
10. Forward pedal Continuity to ground Check 550A and 550D Blk wires and connections.
potentiometer
13. Throttle position 5.0 - 4.7 volts Check 673A and 673B Org wires and connections.
potentiometer
15. Throttle position Continuity to ground Check 550A and 550B Blk wires and connections.
potentiometer

18. X25 Connector Battery voltage Test cruise/max speed switch. Check 238 Gry wire and
connections.
Test Conditions:
• MFWD off
• Set/- switch pressed
19. X25 Connector Battery voltage Test Res/+, Set/- switch. Check 265 Dk Grn wire and
connections. Check 552B Red wire for power. Place switch in
Res/+ position and check 266 Lt Blu wire and connections.
Test Conditions:
• MFWD off
• Set/- switch pressed momentarily
solenoid pedal fully depressed harness. Test forward proportional coil. If either the coil or the
valve are replaced, run the calibration procedure.

Test Conditions:
• MFWD off
21. Forward proportional Wheels spinning at Test flywheel speed sensor. Test MFWD speed sensor. Check
solenoid the same speed as 341 Brn and 502 Red wires and connections.
low idle. Current
decreased as rpm
increase.
22. Brake switch Battery voltage. Test brake switch. Adjust brake switch. Check 247 Pur wire and
Wheels stop spinning. connections.

562B Red
S15 Res/+ S16 Cruise/Max
+12 VDC 050A Blk Set/- Switch Speed Switch
Ground 552A Red 265
+12 VDC 562C
Dk Grn
1 Red
X5-W1 Main 539 Wht
Wiring Harness
3 266 2 267
Lt Blu Pur
6
562A 238 Gry

Red
4
S13 552E
Switch Pedal
Potentiometer
247 Pur
8
5 22
673D Org
A2 Electronic
Controller 550D Blk
9 10
18 T2 MFWD
539 Wht
Speed Sensor
19 552B Red
11
673A Org
550A Blk 673C Org
050B Blk 341 Brn
550C Blk
12
R4 Throttle
Position
Potentiometer
13
S14 Backup 7
673B Org
Alarm
499 Wht
203 Org
550B Blk
050G Blk
14 15
Y9 Forward
T1 Flywheel
Proportional
Speed Sensor
Solenoid
20 21
16
696 673G Org

Lt Blu 502 Red
550F Blk 17
050D Blk

eHydro - Load Match and Motion Match Function, Motion Match:
Circuit Operation To allow the operator to change how quickly the pedals
respond to being pressed or released.
Function, Load Match:
To prevent the engine from stalling during heavy loading Operating Conditions, Motion Match:
situations while driving. • Key switch in run position
Operating Conditions, Load Match: • Engine running
• Key switch in run position • Operator on seat
• Engine running • Park brake unlocked
• Operator on seat • Motion match switch on
• Park brake unlocked Theory of Operation, Motion Match:

• Load match switch on The rate of acceleration and deceleration is controlled by
• Operator driving machine the drive controller to smoothly ramp the speed up and
down. Two different settings provide for either quicker or
Theory of Operation, Load Match: slower acceleration or deceleration. This operation is
controlled by the operator placing the motion match switch
in either the on or off position. The change in this setting
engine during a typical application such as loader work or
will take effect as soon as the switch is changed.
mowing grass that has light and heavy growth areas. A
throttle position sensor is installed to read the no-load Current is supplied to the A2 electronic operating system
engine rpm set point. controller (drive controller) from the switched power circuit.
is reduced to allow the engine to recover. The greater the
load on the engine, the greater the reduction in current.
controller.
The load match switch can be turned on or off to allow the This circuit powers the drive controller to allow for drive
operator to disable the load match function if desired. control operation. The 673A Org wire splices to the 673B,
The load match feature will have no effect if the machine is 673C, 673D, 673E, 673F and 673G Org wires to provide
not being driven when the stalling load is being placed on current from the drive controller to the throttle position
the engine. potentiometer, flywheel speed sensor, forward pedal
Unswitched power is provided to the load match on/off
switch from the 562 Red series of wires and is protected by
the F5 fuse. The 562 Red series of wires include 562D and When the motion match switch is in the on position, current
562A in the W1 main wiring harness, X5 connector, 552A is provided to the 269 Wht wire, X25 connector and the A2
and 552D in the W4 eHydro wiring harness. drive controller which in turn uses this input to supply the
lower responding pedal setting.
When the load match switch is in the on position, current is
provided to the 268 Gry wire, X25 connector and the A2
drive controller. The drive controller uses this input signal to
activate the load match logic within the software.

eHydro - Load Match and Motion Match Circuit Electrical Schematic
F10
212A 212B
+12VDC
F5
072C 562D
Red Fuse Red
+12VDC
S2 Seat W4 eHydro
Switch Wiring Harness
(Off Seat)
(On Seat)
562E Red
539D Wht 539C S14
Wht
Load Match
Switch
X5 X5
X25 J F Off
539 Wht 552A
A1 On
Red
A2 552D Red
552B Red 268 Gry
A3
673A Org
B1
B2
B3
C1 S17
550A Blk Motion Match
C2
269 Wht
C3 Switch
Off
D1
D2 On
A2 D3
E1 269 Wht 673F Org
Electronic E2
050B Blk
Operating E3
System F1
Controller F2
341 Brn
F3
G1
499 Wht
G2 T1 Flywheel
G3
268 Gry 673C Org X29 Speed Sensor
H1
H2
341 Brn X29
H3
J1
J2 550C Blk X29
J3
R4
K1
Throttle
K2
K3 673B Org X30 Potentiometer
499 Wht X30
050A Blk X5 B 050A Blk 550B Blk X30
W1
Frame
Ground
Switched Power Controller Power Output

eHydro - Load Match and Motion Match Control Circuit Diagnosis
Test Conditions:
connections.
3. Load match switch Battery voltage See “Power Circuit Diagnosis” on page 165.
4. Motion match switch 5.0 - 4.7 volts Check 673A and 673D Org wires and connections.
5. X25 Connector Less than 0.2 volts Test load match switch. Check 268 Gry wire and connections.
6. X25 Connector Less than 0.2 volts Test motion match switch. Check 269 Wht wire and
connections.
Test Conditions:
• Load match switch on
• Motion match switch on
7. X25 Connector Battery voltage Test load match switch. Check 268 Gry wire and connections.
8. X25 Connector 5.0 - 4.7 volts Test motion match switch. Check 269 Wht wire and
connections.

Test Conditions:
• Engine running at full throttle
• MFWD off
• Brake pedal pressed to stall engine during test
9. Forward proportional solenoid 950 +25/-50 mA dropping Test flywheel speed sensor. Check 341 Brn and 502 Red
as engine stalls. wires and connections.
+12 VDC 050A Blk S14 Load

Ground 552A Red Match Switch
+12 VDC
268 Gry
1
X5-W1 Main 539 Wht 562D Red
Wiring Harness
2 3
S17 Motion
A2 Electronic
Match Switch
Operating System
Controller 269 Wht
673F Org
6 539 Wht
8
562B Red 4 R4 Throttle
Position
673A Org 673B Org
Potentiometer
673A Org 269 Wht
550A Blk
050B Blk 499 Wht
502 Red
268 Gry 550B Blk
5
T1 Flywheel
7 Speed Sensor
673G Org
502 Red
550F Blk
MIF

Rear PTO Circuit Operation Current for this circuit is provided from the 562F and 562G
Red wire connection on the rear PTO switch to the 562H
Function: Red wire, mid PTO switch (terminals G and H), 577C and
577B Pur wires, rear PTO switch (terminals D and E), 582
To engage the rear PTO and illuminate a light on the
instrument panel to alert the operator that the PTO is Red wire, to the K15 mid PTO lockout relay. This energizes
engaged. the mid PTO lockout relay and cuts power to the mid PTO
latching circuit. (See “Mid PTO Circuit Operation” on
Operating Conditions: page 247.)
• Key switch in run or start position
• Rear PTO switch engaged
The rear PTO switch is used as an interlock to the fuel
supply circuit and the mid PTO as well as engaging the rear
PTO.
In the off (normally closed) position the rear PTO switch
supplies current to the fuel supply circuit. If the rear PTO is
engaged and the operator leaves the seat, current is
removed form the fuel supply circuit unless the park brake
is engaged prior to engaging the rear PTO and leaving the
seat.
The rear PTO is also used as an interlock for the mid PTO
circuit. (See “Mid PTO Circuit Operation” on page 247).
The mid PTO switch must be engaged and then the rear
PTO switch engaged to activate the mid PTO. To disengage
the mid PTO the operator must first disengage the rear
PTO switch and then the mid PTO switch.
With the key in start or run position, battery voltage is
provided to the rear PTO switch through the S1 key switch,
072B and 072C Red wires, F5 fuse and 562A, 562D and
562F Red wires.
With the PTO engaged, the rear PTO switch is in the on
(open) position, and voltage is supplied across the rear
PTO switch (terminals A and B) from the 562F and 562G
Red wires to the 574A, 574B and 574C Yel wires. The 574B
Yel wire supplies current to the Y4 rear PTO solenoid to
energize the solenoid and engage the rear PTO.
The ground circuit for the rear PTO solenoid is provided
though the 010AF and 010D Blk wires.
At the same time the 574A Yel wire supplies current to the
X7 connector (terminal B), to the instrument panel circuit
board. A circuit board run provides voltage to the H2 PTO
indicator light.
When the rear PTO switch is in the on position the switch
also provide current to the K15 mid PTO lockout relay. This
circuit prevents the mid PTO from being engaged out of
sequence.

Rear PTO Circuit Electrical Schematic
F1 4
012
Fuse Red 1 6
2 5 072B Red
072C
3 Red
S1 Key
7 F5
Switch
Fuse
Start S5 Rear
Run 562D PTO Switch
Off Red
Acc. On
Aid 562E Red 562F Red Off

002C
Red Off 574A Yel
562G Red A B 574C Yel
C
F
562G Red G
H
562H Red
582 579D
X1 Red Wht
S6 Mid K15 Mid 86 30
PTO Switch PTO
Fusible
Link Lockout
On 85 87 87A
Relay
010AM 581
Off Brn
Blk
A B
C
D E
F
562H Red G
H 577C Pur
574B
Yel
Y4
Rear PTO
Solenoid
S2 Seat 010AF
Switch 539A 1 Blk
B A Wht 2 556 Lt Blu
X7
(Off Seat) B
3
(On Seat)
V1 Diode H2 PTO
Block 1 Light
539D Wht 539B Wht 4
5
M
6
M1
Starting 573D 556
Motor Org Lt Blu
K12 PTO 30 86
Red
Interlock
Relay 87A 87 85 D
533 010AA
Org Blk X8
G1
050D
Battery Blk
Blk
010D Blk
W1
Frame
Ground 050A Blk
W1
Frame
Ground
Unswitched Power Switched Power Unswitched Ground

Secondary Switched Power Control Panel

Rear PTO Circuit Diagnosis
Test Conditions:
• Rear PTO off
• Mid PTO off
1. Seat switch Battery voltage Check F5 fuse. Test key switch.
2. Mid PTO switch Battery voltage Check 562A, 562F, 562G and 562H Red wires and
connections. Check F5 fuse. Test key switch.
3. Rear PTO switch Battery voltage Check 577C and 577B Pur wires and connections. Test mid
PTO switch.
Test Conditions:
• Rear PTO on
• Mid PTO off
4. Rear PTO solenoid Battery voltage Check 574B and 574C wires and connections. Test Rear PTO
switch.
5. Mid PTO lockout relay Battery voltage Check 582 Red wire and connections.
6. X7 connector Battery voltage Check 574A and 574C wires and connections. Test Rear PTO
switch.
Test Conditions:
• Rear PTO on
• Mid PTO off
• X7 connector connected
7. Instrument panel PTO light PTO lamp illuminated Test PTO lamp. Check 050D and 050A Blk wires and
(not shown) connections to ground. If OK, replace instrument panel.
8. PTO seat interlock relay Battery voltage Test seat switch. Test V1 diode block. Check 539D, 539B and
539A wires and connections. Check 556 Lt Blu wire and
connections.

S2 Seat
Switch
F5 Fuse
562D Red 562E Red
+12 VDC
556
562F Lt Blu
1 539D
Red
S5 Rear PTO Switch Wht 2
539A Wht
1 3
5
4 6
8
539B Wht 7 9
57 V1 Diode Block
4C
Ye
l
S6 Mid PTO Switch
3 K12 PTO 533 Org
Interlock Relay
562G
577B
Red
Pur 85 87A 87 556
30 86
Lt Blu
573D Org
8
577C Pur
562H Red K15 Mid PTO 581 Brn

Lockout Relay
2
85 87A 87
30 86
579D Wht
582 5
Red
Y4 Rear PTO
Solenoid
Y3 MFWD
Solenoid
X7-W1 Main
Wiring Harness
To Instrument Panel
574A 574B
Yel 6 Yel
W1
Frame
Ground

Mid PTO Circuit Operation The ground circuit for the mid PTO solenoid is provided
though the 010AH and 010D Blk wires.
Function:
Then the rear PTO switch can be engaged to allow the
To engage the mid PTO and illuminate a light on the hydraulic and mechanical portions of the PTO system to
instrument panel to alert the operator that the PTO is run the mid PTO.
engaged.
With the rear PTO engaged, the rear PTO switch is in the
on (open) position, and voltage is supplied across the rear
• Key switch in run position Red wires to the 574A, 574B and 574C Yel wires. The 574B
• Operator on seat Yel wire supplies current to the Y4 rear PTO solenoid to
energize the solenoid and engage the rear PTO.
• Mid PTO Switch engaged
then; though the 010AF and 010D Blk wires.
• Rear PTO Switch engaged At the same time the 574A Yel wire supplies current to the
X7 connector (terminal B), to the instrument panel circuit
board. A circuit board run provides voltage to the H2 PTO
The mid PTO circuit starts in the off position allowing indicator light.
current to energize the mid PTO latch circuit.
With the key in start or run position, battery voltage is is provided though the X8 connector (terminal D), and
provided to the mid PTO latch circuit through the S1 key 050D and 050A Blk wires.
switch, 072B and 072C Red wires, F5 fuse and 562A,
562D, 562F, 562G and 562H Red wires, mid PTO switch
(terminals G and H), 577C and 577B Pur wires, rear PTO
switch (terminals D and F), 578 Gry wire, V2 diode
(terminals 1 and 2), 579A, 579B, 579C and 579D Wht
wires.
The 579A Wht wire supplies current back to the mid PTO
switch (terminal A), wire 579C Wht provides current to the
K15 mid PTO lockout relay (terminal 30) and wire 579D
Wht provides current to the K14 mid PTO latch relay
(terminal 86).
With the mid PTO latch relay energized, current is provided
across the relay (terminals 30 to 87) from wire 562K Red to
581 Brn and mid PTO lockout relay (terminal 87A).
When the mid PTO lockout relay is not energized current is
provided across the relay (terminals 87A and 30) to the
579D, 579C and 579A Wht wires. The 579 Wht wires
If the rear PTO switch is engaged before the mid PTO
switch, current will be provided from the rear PTO switch to
the 582 Red wire and the mid PTO lockout relay coil
(terminal 86). This will energize the lockout relay causing
the relay to break the latch circuit back to the 579 Wht
wires.
Engaging the mid PTO switch will break the path between
the 562H Red and 577C Pur wires. Breaking this current
path will prevent the rear PTO switch from providing current
to the mid PTO lockout relay.
At the same time the mid PTO switch is providing current to
the 583 Org wire and the K16 mid PTO relay. This will
energize the mid PTO relay and supply current to the Y5
mid PTO solenoid.

Mid PTO Circuit Electrical Schematic
4 S1 Key 539A 1
Switch Wht 2 556 Lt Blu
6
1 573D
3 Org
2 5 072B Red V1 Diode 30 86 K12 PTO
072C 539B Wht 4
Block 1 Interlock
3 Red 5 Relay
S5 Rear 87A 87 85
7 F5 6 533
PTO Switch Org
Fuse
Start On
Run 562D
Off Red 562F Red Off
Acc. 562G Red A B 574C Yel
562A
577B Pur C
582 Red X7
Aid Red
D E B
F
Off 562G Red G 578 Gry
562H Red H
573B Org H2 PTO
Light
012
Red
S4 Park
F1 Brake Switch 574A Yel
Fuse D
On Y4
S2 Seat X8
Switch Off 574B Rear PTO
Yel Solenoid 050D
(Off Seat) C V2 Diode Blk
002C B
Red 577A Block 2 1
(On Seat) Pur D
562E A 505
X1 Red Dk Grn 010AF
539D Wht Blk
2
Fusible
Link
X5 579C 562K
Wht Red W1
505 519 G K14 Mid
S6 Mid Dk Grn Pur 86 30 Frame
PTO Switch 30 86 PTO Ground
K13
Latch
Neutral 85 87 87A
On
Relay Relay
87A 87 85 010AC 581
Off 546 010AB Blk Brn
583 Org Lt Blu Blk

579A Wht A B
C
D E
F
562H Red G
H
577C Pur
583 562N
B A Org Red
573C 546 86 K16
Org 30
Lt Blu
86 30 K11 Rear Mid PTO
PTO Relay
85 87 87A
Interlock 010AL 594
M 85 87 87A Yel
010W 533 Relay Blk
Blk Org
M1
582 579D
Starting Red Wht
Motor K15 Mid 86 30
Red PTO Y5
Lockout Mid PTO
85 87 87A
Relay Solenoid
010AM 581 010AH
Blk Brn Blk
G1 010P
Battery W1 Blk 010D Blk
Blk Frame
Ground
W1
Frame
Ground

Mid PTO Circuit Diagnosis
Test Conditions:
• Rear PTO off
• Mid PTO off
1. Seat switch Battery voltage Check F5 fuse. Test key switch.
2. Mid PTO switch Battery voltage Check 562A, 562F, 562G and 562H Red wires and
connections. Check F5 fuse. Test key switch.
3. Park brake switch Battery voltage Test mid PTO switch. Check 577C and 577A Pur wires and
connections.
4. K13 neutral relay Battery voltage Test park brake switch. Check 505 Dk Grn wire and
connections.
5. K13 neutral relay Battery voltage Check 519 Pur and 521 Brn wires and connections. See “Power
Circuit Operation” on page 158.
6. Rear PTO switch Battery voltage Test mid PTO switch. Check 577C and 577B Pur wires and
connections.
7. Mid PTO switch Battery voltage Test V2 diode block. Check 579A and 579B Wht wires and
connections.
8. K14 Mid PTO latch relay Battery voltage Test V2 diode block. Check 579C and 579B Wht wires and
connections.
9. K15 Mid PTO lockout relay Battery voltage Test V2 diode block. Check 579A and 579B Wht wires and
connections.
10. K14 Mid PTO latch relay Battery voltage Check 562A and 562K Red wires and connections. Check F5
fuse. Test key switch.
11. K16 Mid PTO relay Battery voltage Check 562A and 562N Red wires and connections. Check F5
fuse. Test key switch.
12. K15 Mid PTO lockout relay Battery voltage Test the K14 mid PTO latch relay and K15 mid PTO lockout
relay. Check 581 Brn wire and connections.
13. K11 Rear PTO interlock Battery voltage Test the rear PTO switch. Check 573B and 573C Org wires and
relay connections.
14. K12 PTO interlock relay Battery voltage Test the rear PTO switch. Check 573B and 573D Org wires and
connections.
15. K11 Rear PTO interlock Battery voltage Test the K13 neutral relay. Check 546 Lt Blu wire and
relay connections.
16. K12 PTO interlock relay Battery voltage Test the K11 rear PTO interlock relay and K12 PTO interlock
relay. Check 533 Org wire and connections.

S2 Seat
Switch
556
1 Lt Blu
F5 Fuse
+12 VDC 562D Red 562E Red 2
Switched 539A Wht
1 3
to 562K and
539D 5
562F 562N Red 4 6
S5 Rear PTO Switch Wht
Red 8
539B Wht 7 9
562G
Red V1 Diode Block
V2 Diode 579B K12 PTO 16
Block Wht Interlock 533 Org
574C Yel Relay
2
578 Gry
1 3 85 87A 87
30 86
5
S6 Mid PTO Switch 573B 4 6
6 Org 8 14 556
7 9 Lt Blu
577B
Pur 573D
Org
583
Org S4 Park
Brake Switch
577C
Pur 577A Pur
7 562H Red 3
K11 Rear PTO
2 Interlock Relay
533 Org
57
9A 85
30
87A 87
86
Wh 13
K15 Mid PTO 12 t
Lockout Relay 546 Lt Blu
15 505
573C K13 Neutral Dk Grn
85 87A 87
30 86 582 Red Org Relay
9 579D Wht 85 87A 87

30 86
K16 Mid PTO 594 5

Relay Yel 4
519 Pur
K14 Mid PTO 581 85 87A 87
30 86 Y4 Rear PTO +12 VDC
Latch Relay Brn
11 Solenoid Switched
583 Org
85 87A 87 Y3 MFWD
30 86 579C Wht Solenoid
562N
Red Y5 Mid PTO
10 562K 8
Red +12 VDC Solenoid
+12 VDC
574B
Yel
X7-W1 Main
Wiring Harness
To Instrument Panel
574A
Yel 594 Yel

Test Conditions:
• Mid PTO on
• Rear PTO off
17. Mid PTO switch Less than 0.2 VDC Test mid PTO switch. Test V2 diode block.
18. Mid PTO switch Battery voltage Test the K14 mid PTO latch relay and K15 mid PTO lockout
relay. Check 581 Brn wire and connections.
19. K16 Mid PTO relay Battery voltage Test mid PTO switch. Check 583 Org wire and connections.
20. Mid PTO solenoid Battery voltage Test K16 mid PTO relay. Check 594 Yel wire and connections.
Test Conditions:
• Mid PTO on
• Rear PTO on
21. Rear PTO solenoid Battery voltage Test Rear PTO switch. Check 574B and 574C wires and
connections.
22. X7 connector Battery voltage Test Rear PTO switch. Check 574A and 574C wires and
connections.
23. Mid PTO lockout relay Less than 0.2 VDC Test rear PTO switch. Check 582 Red wire and connections.
Test Conditions:
• Mid PTO on
• Rear PTO on
23. Instrument panel PTO light PTO lamp illuminated Test PTO lamp. Check 050D and 050A Blk wires and
(not shown) connections to ground. If ok, replace instrument panel.

24. PTO seat interlock relay Battery voltage Test seat switch. Test V1 diode block. Check 539D, 539B and
539A wires and connections. Check 556 Lt Blu wire and
connections.

S2 Seat
Switch
556
Lt Blu
F5 Fuse
+12 VDC 562D Red 562E Red 2
Switched 539A Wht
1 3
to 562K and
539D 5
562F 562N Red 4 6
S5 Rear PTO Switch Wht
Red 8
539B Wht 7 9
562G
Red V1 Diode Block
V2 Diode 579B K12 PTO
Block Wht Interlock 533 Org
574C Yel Relay
2
578 Gry
1 3 85 87A 87 24
30 86
5
S6 Mid PTO Switch 573B 4 6
Org 8 556
577B 7 9 Lt Blu
Pur 573D
Org
583
Org S4 Park
Brake Switch
577C
Pur 577A Pur
18 17 K11 Rear PTO

562H Red Interlock Relay
533 Org
57
9A 85
30
87A 87
86
Wh
K15 Mid PTO t
Lockout Relay 546 Lt Blu
23 505
573C K13 Neutral Dk Grn
85 87A 87
30 86 582 Red Org Relay
579D Wht 85 87A 87
30 86
K16 Mid PTO 594

Relay Yel
519 Pur
K14 Mid PTO 581 85 87A 87 19
30 86 Y4 Rear PTO +12 VDC
Latch Relay Brn
Solenoid Switched
583 Org
85 87A 87 Y3 MFWD
30 86 579C Wht Solenoid
562N
Red Y5 Mid PTO
562K
Red +12 VDC Solenoid
+12 VDC
574B
Yel
X7-W1 Main
21
22 Wiring Harness
To Instrument Panel
574A
Yel 594 Yel
20

MFWD Circuit Operation
Function:
To engage the MFWD and illuminate a light on the
instrument panel to alert the operator that the MFWD is
engaged.
• MFWD switch in the on position
The MFWD function spring loaded to the engaged position.
When the MFWD switch is in the unlock position current is
supplied to the MFWD solenoid which in turn unlocks the
MFWD pin in the transmission.
provided to the MFWD switch through the S1 key switch,
072B and 072C Red wires, F5 fuse and 562A, 562D, 562F,
562G, 562H and 562J Red wires to the MFWD switch
(terminal 2).
When the MFWD switch is in the unlock position, current
flows across the MFWD switch (terminals 2 and 1) to the
555 Wht wire and the Y3 MFWD solenoid. The MFWD
solenoid is then energized and pulls the MFWD lock pin
into the unlocked position and the machine will operate in
rear wheel drive.
The ground circuit path for the MFWD solenoid is provided
though the 010AG and 010D Blk wires.
When the MFWD switch is in the lock position, current flows
across the MFWD switch (terminals 2 and 3) to the 557 Pur
wire which jumpers back to the MFWD switch (terminal 8)
and illuminates the indicator light in the switch. The MFWD
solenoid is then de energized and releases the MFWD lock
pin and the machine will operate in four wheel drive.
The ground circuit path for the MFWD indicator light is
provided though the 010AK and 010D Blk wires.

MFWD Circuit Electrical Schematic
F1 4
012
Fuse Red 1 6
F5 Fuse
2 5 072B Red 072C Red 562D Red
S5 Rear
3
PTO Switch
S1 Key
7
Switch On
Start 562F Red Off

Run 562G Red A B
Off C
Acc. D E
F
562G Red G
Aid H
562H Red
Off
002C S6 Mid
Red PTO Switch
X1 On
Off
Fusible A B
Link D
C
E
F
562H Red G
H
562J Red
S7 MFWD
Switch
Unlock
Lock
B A 562J 1 555 Wht
Red 2
3 557 Pur
010 AK Blk 7 8 555
Wht
Y3
M MFWD
Solenoid
010AG
M1 Blk
Starting 010D Blk 010D Blk
Motor
Red Y1 W1
Starting Frame
Motor Ground
Solenoid
G1
Battery
Blk
W1
Frame
Ground

MFWD Circuit Diagnosis
Test Conditions:
• MFWD switch in unlock position
• PTO off
1. MFWD switch Battery voltage Check F5 fuse. Test key switch. See “Power Circuit Operation”
on page 158.
2. MFWD solenoid Battery voltage Check 555 Wht wire and connections. Test MFWD switch.
3. MFWD solenoid Less than 0.1 ohms Check 010AG and 010D Blk wires and connections.
resistance to ground.
Test Conditions:
• MFWD switch in lock position
• PTO off
4. MFWD switch Battery voltage, Check 557 Pur wire and connections. Test MFWD switch.
indicator light
illuminated.
5. MFWD switch Less than 0.1 ohms Check 010AK and 010D Blk wires and connections.

S1 Key Switch
F5 Fuse
072B Red 072C Red 562D Red
S5 Rear PTO Switch
562F
Red
S6 Mid PTO Switch
562G Red
562H Red
S7 MFWD Switch 4
5
010AK Blk
557 Pur
W1
55 Frame
562J Red 5W Ground
ht
557 Pur
1 Y4 Rear
PTO Solenoid
Y3 MFWD
Solenoid
555 Wht
2
010AG
Blk
3
W1
Frame
Ground

Instrument Panel Lights Circuit Operation Theory of Operation:
The fuel level in the fuel tank is measured by the B1 fuel
Engine Oil Pressure Circuit Function:
gauge sensor. The sensor is a variable resistor. The
To alert operator of low engine oil pressure. resistance is set by movement of a mechanical linkage
connected to a float in the fuel tank. The 5 to 95 ohm
Operating Conditions: variable resistance creates a variable voltage difference
• Key switch in run or start position across the P3 fuel gauge. The voltage difference ranges
from approximately 5.72 VDC (fuel tank full) to
Theory of Operation: approximately 0.87 VDC (fuel tank empty).
With the engine off and key switch in the run position, Park Brake Light Circuit Operation Function:
engine oil pressure will be below 49 kPa (7.1 psi). The oil
pressure switch will be in the normally closed position. The To alert operator of the park brake being locked.
closed position completes a circuit path to ground and
illuminates the H9 light. This informs the operator that the Operating Condition:
light is functional. • Key switch in run or start position
The light goes out when the engine oil pressure is at or • Park brake locked
above 49 kPa (7.1 psi), opens the B2 engine oil pressure
switch, and removes the ground circuit from the engine oil Theory of Operation:
pressure light. With the key in start or run position, battery voltage is
provided to the park brake switch through the S1 key
Engine Coolant Temperature Circuit Operation
switch, 072B and 072C Red wires, F5 fuse and 562A, 562B
Function:
and 562D Red wires. See “Power Circuit Operation” on
Inform the operator of engine and coolant operating page 158.
temperature.
With the park brake locked, the park brake switch contacts
Operating Conditions: close. Voltage is provided through the park brake switch
contacts (terminals B to C), 586 Lt Blu wire, and X8
• Key switch in run or start position connector (terminal K) to the instrument panel circuit board.
A circuit board run provides voltage to the H4 park brake
Theory of Operation: indicator light.
The engine coolant temperature sensor is a variable A ground circuit path for the instrument panel circuit board
resistor, providing a ground circuit path for the temperature is provided though the X8 connector (terminal D), and
gauge. As the engine coolant heats, the resistance 050D and 050A Blk wires.
decreases. As the resistance decreases, more current is
allowed to flow across the engine coolant temperature
gauge causing the needle raise and indicate a higher
temperature.
The temperature gauge circuit is part of the machine
instrument panel.
The engine coolant temperature sensor resistance is
approximately 40 - 700 ohms.
Fuel Gauge Circuit Function:

Inform the operator of the fuel level in the fuel tank.

Instrument Panel Lights Circuit Electrical Schematic
F1 4
012
Fuse Red 1 6
F5
072B Red 072C Red Fuse 562D Red 562L Red X8
2 5
A
3
S1 Key
7
Switch
Start P3
Run Fuel
Off Gauge
Acc.
Aid
002C
Off S4 Park Q
Red
Brake Switch
On H9 Oil
Off Pressure
586 Lt Blu X8 Light
X1 562B Red B C
K
D
A
Fusible H4 Park P4 Engine
Link Brake Coolant
Light Temperature
Gauge
P t0
C J E
B A X8 X8 X8
353 347 359
Org Pur Wht
D
M X8
050D
t0
Q
Blk
M1
Starting B1 Fuel 050B B3 Engine
Motor Gauge
Blk Coolant
Sensor Temperature
Red Switch
P
050A Blk
G1 B2 Engine Oil
Battery W1
Frame Pressure
Blk Switch (NC)
Ground
W1
Frame
Ground


Instrument Panel Lights Circuit Diagnosis
Test Conditions:
• X8 connector to instrument panel disconnected
1. X8 connector Battery voltage Check F5 fuse. Test key switch. See “Power Circuit Operation”
on page 158.
2. X8 connector Less than 0.1 ohms Check 050D and 050A Blk wires and connections.
3. X8 connector Battery voltage, park Check 586 Lt Blu wire and connections. Test park brake switch.
brake light illuminated. Test park brake lamp.
Test Conditions:
• X8 connector to instrument panel connected
4. Engine oil pressure switch Less than 0.1 VDC Check 347 Pur wire and connections. Test switch.
5. Engine oil pressure switch Less than 0.1 ohms Check engine ground. If engine ground is OK, replace oil
(347 Pur wire disconnected) resistance to ground. pressure switch.
6. Engine coolant temperature Continuity to ground Disconnect temperature sensor lead. Use a jumper wire to
sensor through sensor - connect 359 Wht wire to ground. Temperature gauge should
resistance depends on move to maximum temperature position.
engine temperature
Gauge does not move. - Check 359 Wht wire and connections.
(40 - 700 ohms).
Replace control panel.
Sensor threads not
corroded. Gauge moves. - Replace sensor.
7. Fuel gauge sensor Tank empty - Check 353 Org wire and connections. Check battery negative
approximately 0.1 cable, 050B and 050A Blk wires and connections. Test fuel
VDC sensor. Use a jumper wire to connect 353 Org wire to battery
Tank full - frame ground. Fuel gauge should move to maximum position.
approximately 5.7 Gauge does not move. - Replace control panel.
VDC
NOTE: If all of the tests above are performed, and the

control panel lamps are good, and the indicator lights
still do not work, replace the instrument panel.

F5 Fuse
S1 Key Switch
562B Red
S4 Park Brake Switch
586
Lt Blu 562L Red
353 Org
353 Org
562L Red 050D Blk
1
359 Wht
7
3
347
586 Lt Blu Pur
353
347 Pur 359 Wht Org
X8-W1 Main Wiring

Harness To Control Panel 2 050D Blk
B1 Fuel Gauge Sensor 050B

Blk
050D Blk
347
359
Pur
Wht
050A
4 5 Blk
6
W1
Frame
Ground
B2 Engine Oil Pressure Switch B3 Engine Coolant Temperature Switch

Light Circuit Operation Light Switch Field Position:
In the field position, voltage is removed from the turn signal
Function:
switch (terminal 1). However, voltage remains to the
Provides current to the headlights, tail lights, hazard lights, headlights (light switch terminal 3), and is provided to the
work lights and control panel lights, in combinations work lights (light switch terminal 4).
depending upon the position the light switch is placed in.
Voltage is provided from the light switch (terminal 4),
through the 137 Org wire to the F6 fuse. The F6 fuse
provides voltage, through the 147A, 147B and 147D Pur
• Light switch in either hazard, road or field position. wires, to the work lights. Voltage is also provided to the X6
trailer connector (terminal 2) through the 147A and 147C
Theory of Operation: Pur wires.
Power for the light switch is unswitched and provided
through the F3 fuse, 122C and 122B Red wires. Power for
the turn signal light switch is provided through the F3 fuse,
122C and 122A Red wires.
Light Switch Hazard Position:

In the hazard position, voltage is provided from the light
switch (terminal 2) through the 103 Org wire to the S8 turn
signal switch.
From the turn signal switch intermittent voltage is provided
to both the 115A and 125A Dk Grn wire. Wire 115A and
115C Dk Grn provide intermittent current to the right
hazard light while wire 125A and 125C Dk Grn provide
intermittent current to the left hazard light.
The ground path for the left hazard light is provided by
010G and 010C Blk wires and the right hazard light is
provided by 010L and 010C Blk wires.
Light Switch Road Position:

In the road position, voltage is provided from the light
switch (terminal 2) through the same circuits as when the
light switch is in the hazard position. This circuit causes the
hazard light to flash.
In addition, voltage is provided from the light switch
(terminal 3) though the 138A, 138B and 138C Gry wires to
the F7 and F8 fuses. The F7 fuse provides voltage to the
left headlight through the 119C and 119B Wht wires, and to
the right headlight through the 119C and 119A Wht wires.
Voltage is also provided to the instrument panel dash lights
through the 119C and 119D Wht wires and X8 connector
(B terminal).
The F8 fuse provides voltage to the left taillight through the
118A and 118C Gry wires, and the right taillight through the
118A and 118B Gry wires. Voltage is also provided to the
X6 trailer connector (terminal 6) through the 118A and
118D Gry wires.

Lights Circuit Electrical Schematic
F3 Fuse
122C Red
010L Blk
010G Blk
010C
X11
W1 Blk E2 Right
X9 S8 Turn
Hazard
Light Signal Switch
E1 Left
(0) Right
Hazard X12 (1) Off
Light (2) Left
115C
X10 Dk Grn 1 103 Org
Flasher
115D X6 115A
125C 5 Dk Grn 4 S9 Light
Dk Grn
X6 125A Switch
125D 2 122A Red
3 Dk Grn 3
4 (0) Off
F1
012 (1) Hazard
Fuse Red 1 6
(2) Road
(3) Field
2 5
1
122B
3 103 Org
Red
S1 Key B
2
7 138A Gry
Switch
3
Start 137 Org
Run 4
Off
Acc.
002C F7 Fuse
Red 119C Wht 138B Gry
Aid
X1 Off
119A Wht 138C
E6 Right Gry
Fusible 119B Wht F8
Link Headlight
Fuse
119D
E5 Left 118A
010A Gry F6
Wht Headlight 010B Blk Blk
B Fuse
X8 010P 147A
W1 Blk
Pur
B A
X6
118D Gry
147C 6
118C Gry 2
147D 1
M H10 Pur
X13 X14 147B
Dash Pur X19
M1 Light E3 Left
118B X17
Starting Tail/Turn
Light
Gry E7 Left E8 Right
Motor Work
D X16 Work
Red X18 Light
X8 Light
050D X15
Blk
G1 E4 Right X19
050A X17
Battery Tail/Turn
Blk X20
Blk Light 010J
010X 010Y 010H 010K
W1 Blk Blk Blk Blk
010C Blk Blk
Frame W1
Ground Frame
Ground

Lights Circuit Diagnosis
Test Conditions:
• Light switch in hazard position
• X7 to control panel disconnected
1. Light switch Battery voltage Check F3 fuse.
2. Turn signal switch Battery voltage Check F3 fuse.
3. Turn signal switch Battery voltage Test light switch. Check 103 Org wire and connections.
4. Turn signal switch Intermittent battery Test turn signal switch.

voltage
5. Right hazard light Intermittent battery Check 115A and 115C Dk Grn wires and connections.
voltage
6. X7 control panel connector Intermittent battery Check 115A and 115B Dk Grn wires and connections.
voltage
7. Left hazard light Intermittent battery Check 125A and 125C Dk Grn wires and connections.
voltage
8. X7 control panel connector Intermittent battery Check 125A and 125B Dk Grn wires and connections.
voltage
Test Conditions:
• Light switch in road position
9. F7 fuse Battery voltage Check F7 fuse. Check 138A and 138B Gry wires and
connections. Test light switch.
10. Right headlight Battery voltage Check 119C and 119A Wht wires and connections.
11. Left headlight Battery voltage Check 119C and 119B Wht wires and connections.
12. F8 fuse Battery voltage Check F8 fuse. Check 138A and 138C Gry wires and
connections.
13. Right tail light Battery voltage Check 118A and 118B Gry wires and connections.
14. Left tail light Battery voltage Check 118A and 118C Gry wires and connections.
15. X6 connector (if used) Battery voltage Check 147A and 147C Pur wires and connections.
Test Conditions:
• Light switch in field position

16. X6 fuse Battery voltage Check F6 fuse. Check 137 Org wire and connections.
17. X6 connector (if used) Battery voltage Check 147A and 147C Pur wires and connections.

S9 Light Switch
4
122B 3
Red 103
Org
103 122B
Org Red
122A Red
138A 122C 2
1
Gry Red
138C Gry 4
137 125A
138B F3 S8 Turn Signal Switch Dk Grn
Org
Gry Fuse
16 F6
F8 Fuse F7
Fuse To E7 and E8 Fuse +12 VDC 115A
Work Lights Dk Grn
147B Pur 147A 119C Wht
12 Pur 9
118A 147D Pur
147C
Gry 118B Gry
Pur
118C Gry
17 15 To X6 E6 Right Headlight
trailer
147C Pur connector
10
119A Wht
X7-W1 Main
Wiring Harness
To Instrument Panel E5 Left Headlight
11
115B 119B Wht
125B Dk Grn
Dk Grn 8 6
E1 Left
Hazard Light E2 Right
Hazard Light
7 125C 115C
Dk Grn Dk Grn 5
125C Dk Grn 115C Dk Grn
E4 Right
Tail/Turn
Light
118C 118B
Gry 118B Gry
Gry
118C Gry
13
E3 Left
14
Tail/Turn
Light

Turn Signal Lights Circuit Operation Turn Signal Switch Right Position:
With the light switch in any position and the turn signal
Turn Signal Switch Function:
switch in the right position, constant voltage is provided to
Provides intermittent current to the tail lights and hazard the S8 left switch contact. The contact provides constant
lights. voltage (terminal 3) to the left hazard light. Constant
voltage is also provided from the S8 left switch contact to
Operating Condition: the flasher unit in the turn signal switch. The flasher unit
• Turn signal switch off position provides intermittent voltage to the S8 right switch contact.
The intermittent voltage is provided (terminal 4) to the right
• Light switch in either hazard or road position hazard light through the 115A and 115C Dk Grn wires.
or,
• Turn signal switch in the left position, light switch in any
position
or,
• Turn signal switch in the right position, light switch in any
position.
Unswitched power is provided to the turn signal switch
through the 122A Red wire (terminal 2). Switched power is
provided from the light switch (terminal 2) through the 103
Org wire (terminal 1).
With the turn signal switch in the off position, and the light
switch in either the hazard or road position, voltage enters
the turn signal switch through the 103 Org wire (terminal 1).
The voltage from the 103 Org wire goes to the flasher unit
inside the turn signal switch.
The flasher unit produces an intermittent voltage output
that is provided to the wiring harness at terminals 3 and 4
of the turn signal switch.
Intermittent voltage is provided to the left hazard light
through the 125A and 125C Dk Grn wires. Intermittent
voltage is provided to the Right hazard light through the
115A and 115C Dk Grn wires.
Turn Signal Switch Left Position:

With the light switch in any position, and the turn signal
switch in the left position, constant voltage is provided to
the right switch contact. The contact provides constant
voltage (terminal 4) to the right hazard light. Constant
voltage is also provided from the S8 right switch contact to
the flasher unit in the turn signal switch. The flasher unit
provides intermittent voltage to the S8 left switch contact.
The intermittent voltage is provided (terminal 3) to the left
hazard light through the 125A and 125C Dk Grn wires.

Turn Signal Lights Circuit Electrical Schematic
F3 Fuse
122C Red
010G Blk
010L Blk
154A 122D X9 010C
Yel Red W1
E1 Left X11
Blk
86 30 K7 S8 Turn
Hazard Signal Switch
Turn Signal Light
Interlock Relay E2 Right
85 87 87A (0) Right
010T
Hazard (1) Off
155 Light
Blk Dk Grn V2 Diode (2) Left
115E X12 1
X10 Flasher
166 7 Dk Grn 115C 115A 186 Lt Blu
Lt Blu 125E 125C Dk Grn Dk Grn 4
8 9 Dk Grn Dk Grn 125A 2 122A Red
Dk Grn 3
F1 4
012 176 Lt Blu
Fuse 166
Red 1 6 Lt Blu X6
125D
86 30 K8 3
2 5 Turn Signal
Latch Relay
3 85 87 87A
S1 Key 010M 154B
Switch
7 Blk Yel
115D X6
5
Start
Run
Off
Acc.
002C V2 Diode 176
Red
Aid 6 Lt Blu
Off 154C
X1 Yel 186
5 4 Lt Blu
Fusible 154D 115F

Yel Dk Grn
Link 86 30
K9 Right 154E 125F
Yel Dk Grn
Turn
86 30 K10 Left
85 87 87A Relay
143 Turn
Org Relay
010S 85 87 87A
B A Blk 133
Org
010U
Blk
010F 115B 125B
Blk Dk Grn Dk Grn
143 D E
M Org 133 X7
Org
010E
M1 Blk X15 X16
X13 X14
Starting
Motor E3 Left
Red E4 Right
010Z Tail/Turn
G1 Blk Tail/Turn Light H6 Right
Light H8 Left
Battery Turn Turn
X20 X18 Light Light
010D
Blk Blk
W1 D
Frame 010P X8
Ground Blk
010X 050D
010Y Blk
Blk 010C Blk Blk
W1 050A Blk
Frame
Ground

Turn Signal Lights Circuit Diagnosis
Test Conditions:
• Key switch in off position, engine off
• Light switch in off position
• Turn signal switch in left position
1. Turn signal switch Battery voltage Test turn signal switch.
2. Right hazard light Battery voltage Check 115A and 115C Dk Grn wires and connections.
3. X7 connector Battery voltage Check 115A and 115B Dk Grn wires and connections.

voltage
5. Right tail/turn light Battery voltage Check 143 Org wire and connections. Test K7, K8 and K9
relays. Check 154A, 154B, 154C, 154D and 154E Yel wires and
connections. Test V2 diode block. Check 115E and 115A Dk
Grn wires and connections.

voltage
7. Left hazard light Intermittent battery Check 125A and 125C Dk Grn wires and connections.
voltage
8. X7 connector Intermittent battery Check 125A and 125B Dk Grn wires and connections.
voltage
9. Left tail/turn light Intermittent battery Check 133 Org wire and connections. Test K7, K8 and K10
voltage relays. Check 154A, 154B, 154C, 154D and 154E Yel wires and

+12 VDC
S8 Turn
K7 Turn Signal 6 Signal Switch
Interlock Relay F3
Fuse
85 87A 87
30 86
122C 186 Lt Blu
122D Red Red 122A Red
154A
Yel V2 Diode Block
K8 Turn Signal 1
2
Latch Relay 3
154C Yel 1 4
154B Yel 5 176 Lt Blu
85 87A 87 4 6
30 86 155 Dk Grn
8
7 9
166 Lt Blu 125E
115E Dk Grn
K9 Right Turn Relay Dk Grn
143 Org
85 87A 87
30 86 154D Yel 186 Lt Blu
115F Dk Grn
K10 Left Turn Relay 115A

133 Org
Dk Grn
85 87A 87
30 86 154E Yel
125F Dk Grn 125A

Dk Grn
X7-W1 Main 115B Dk Grn

Wiring Harness
To Control Panel
115B
125B Dk Grn
Dk Grn 8 3 E2 Right
E1 Left Hazard Light
Hazard Light
115C 115C Dk Grn
Dk Grn
7 125C 2
Dk Grn
125C Dk Grn
143
Org 143 Org
9 133
Org E4 Right 5
133 Org Tail/Turn
E3 Left Light
Tail/Turn
Light

Test Conditions:
• Key switch in off position, engine off
• Light switch in off position
• Turn signal switch in right position
voltage
11. Right hazard light Intermittent battery Check 115A and 115C Dk Grn wires and connections.
voltage
12. X7 connector Intermittent battery Check 115A and 115B Dk Grn wires and connections.
voltage
voltage
14. Right tail/turn light Intermittent battery Check 143 Org wire and connections. Test K7, K8 and K9
voltage relays. Check 154A, 154B, 154C, 154D and 154E Yel wires and
15. Turn signal switch Battery voltage Test turn signal switch.
16. Left hazard light Battery voltage Check 125A and 125C Dk Grn wires and connections.
17. X7 connector Battery voltage Check 125A and 125B Dk Grn wires and connections.
18. Left tail/turn light Battery voltage Check 133 Org wire and connections. Test K7, K8 and K10
relays. Check 154A, 154B, 154C, 154D and 154E Yel wires and

+12 VDC
S8 Turn
K7 Turn Signal 15 Signal Switch
Interlock Relay F3
Fuse
13
85 87A 87
30 86
122C 186 Lt Blu
122D Red Red 122A Red
154A V2 Diode Block 10

K8 Turn Signal
Yel 2
Latch Relay
154C Yel 1 3
154B Yel 5 176 Lt Blu
85 87A 87
155 Dk Grn 4 6
30 86
8
7 9
166 Lt Blu 125E
115E Dk Grn
K9 Right Turn Relay Dk Grn
143 Org
85 87A 87
30 86 154D Yel 186 Lt Blu
115F Dk Grn
K10 Left Turn Relay 115A

133 Org
Dk Grn
85 87A 87
30 86 154E Yel
125F Dk Grn 125A

Dk Grn
X7-W1 Main 115B Dk Grn

Wiring Harness
To Control Panel
115B
125B Dk Grn
Dk Grn 17 12 E2 Right
E1 Left Hazard Light
Hazard Light
115C 115C Dk Grn
Dk Grn
16 125C 11
Dk Grn
125C Dk Grn
143
Org 143 Org
18 133
Org E4 Right 14
133 Org Tail/Turn
E3 Left Light
Tail/Turn
Light

Diverter Valve Circuit Operation (optional)
Function
Provides power to hydraulic diverter solenoid circuit.
Operating Conditions
• Key switch in run position.
Theory of Operation
Current is supplied to the diverter valve circuit from the
switched power circuit. With the key switch in the run
position, current is supplied to the 072C red wire, F5 fuse,
562D and 562C Red wires, X3 connector to the W8 wiring
harness to the 562C, 562B, and 562A Red wires and the
S19 diverter valve enable switch.
When the S19 diverter valve enable switch is in the off
position current flow is stopped at the switch.
When the S19 diverter valve enable switch is in the on
positions, current flows from the 562A Red wire across the
enable switch to the 783 Org wire to the normally open
terminal (87) of the K17 diverter valve latch relay.
When the S19 diverter valve enable switch is in the set
terminal (87) of the K17 diverter valve latch relay. At the
same time, current flows from the 562B Red wire across
the enable switch to the 784A Yel wire which splices to the
784B, 784C, 784D, 784E, and 784F Yel wires.
The 784B Yel wire supplies current to the indicator light
within the S19 switch. The 784C wire supplies current to
the K17 diverter valve latch relay common terminal (30).
The 784D wire supplies current to the K17 diverter valve
latch relay coil terminal (86). The 784E Yel wire supplies
current to the banded end of the V3 diode. The 784F Yel
wire supplies current to the Y10 diverter solenoid.
With the 784 Yel group of wires energized, the 784D Yel
wire energizes the K17 diverter valve latch relay. The relay
pulls in to connect the common terminal (30) to the
normally open terminal (87). This connects the 784 Yel
group of wires to the 783 Org wire. The 783 Org wire has
power as long as the S19 diverter valve enable switch is in
either the set or on positions. This provides the latch for the
relay to continue to provide current to the Y10 diverter
solenoid until the enable switch is place back into the off
position, or the key switch is turned off.
When the diverter valve circuit is energized, the indicator
light within the S19 diverter valve enable switch will be
illuminated to provide a visual indicator to the operator that
the diverter valve circuit is available for use.
The V3 diode is used across the relay coil to collapse the
magnetic field of the coil quicker and reduce arcing across
the relay contacts.

Diverter Valve Circuit Electrical Schematic (optional)
S19
Diverter Valve
Enable Switch 784F Yel
X34
Y10 Diverter
Off Solenoid
On
Set
X3 562C Red 562A Red 783 Org
562B Red 784A Yel
010A Blk 784B Yel 784E Yel X34
010E
Blk
784C 784D
Yel Yel
30 86 K17 Diverter
Valve Latch X33
87A 87 85 Relay A
010B V3
Blk
Diode
C
X33
010B Blk 010C
Blk
010C Blk
010E Blk
010D
W1 Blk
Frame
Ground
MIF
Diverter Valve Wiring Harness (optional)
Y10 Diverter
Solenoid
S19 010E 784F
Diverter Valve A B
Enable Switch V3 Diode

784A 010C 784E
783 10 9
3 6
562A 2 5
X3 To W1 Main
1 4 562B 010
8 7 562 Wiring Harness
784B 010A 784 562C
W8 Diverter Valve
Wiring Splices
010D 010C
010A
010B 010 010D
010E
562A
784C 010B To W1 Ground 562B 562 562C
K17 Diverter
784A
Valve Latch 784C 784B
784
Relay 784D 784E
784F
784D 783
MIF

Diverter Valve Circuit Diagnosis (optional)
Test Conditions:
1. Diverter valve enable switch Battery voltage Check X3 connector, 562A, 562B, and 562C wires and
connections. See Switched Power Circuit Diagnosis.
2. Diverter valve enable switch Continuity to ground Check 010A and 010D Blk wires and connections.
3. Diverter valve latch relay Continuity to ground Check 010B and 010D Blk wires and connections.
4. Diverter solenoid Continuity to ground Check 010E and 010D Blk wires and connections.
5. Diode Continuity to ground Check 010C and 010D Blk wires and connections.
Test Conditions:
• Diverter valve enable switch in on position
6. Diverter valve latch relay Battery voltage Check 783 Org wire and connections. If ok, replace diverter
valve enable switch.
Test Conditions:
• Diverter valve enable switch pressed to set position then released to the on position
7. Diverter valve enable switch Battery voltage Check 784B and 784A Yel wires and connections. Test diverter
valve enable switch. Test diverter valve latch relay.
8. Diverter valve latch relay Battery voltage Check 784C and 784A Yel wires and connections. Test diverter
9. Diverter valve latch relay Battery voltage Check 784D and 784A Yel wires and connections. Test diverter
10. Diverter solenoid Battery voltage Check 784F and 784A Yel wires and connections. Test diverter
11. Diode Battery voltage Check 784E and 784A Yel wires and connections. Test diverter

+12 VDC
X3 Y10 Diverter
Solenoid
562C
Red
S19 10
Diverter Valve
Enable Switch
784F Yel
2
010A Blk 784B Yel
562A Red 4
562B Red 010E V3 Diode
Blk
1
5
1 783
784A 11
Org
Yel
7
784E Yel
010C
Blk
K17 Diverter
Valve Latch
Relay
784C
Yel
9 8
784D
Yel
K17 Diverter
86 30 Valve Latch
783 Org 87 87A 85
Relay Socket
6 3
010B
010B Blk Blk
010E Blk
010C Blk
010D
Blk
W1
Frame
Ground

ELECTRICAL TESTS AND ADJUSTMENTS
Tests and Adjustments Battery Voltage and Specific Gravity Test
Ground Circuit Test Reason:
Reason: To check voltage and determine condition of battery.
To check for opens, loose terminal wire crimps, poor Equipment:

connections, or corrosion in the ground circuit. The
• Voltmeter or JTO5685 Battery Tester
voltmeter method checks ground connections under load.
• Hydrometer Procedure
Equipment:
• Clean battery terminals and top of battery
• Ohmmeter or Voltmeter
Procedure:
Ohmmeter Procedure:
1. Turn key switch to off position. Lock park brake.
2. Connect ohmmeter negative (black) lead to negative (-)
c CAUTION: Avoid injury! Sulfuric acid in battery
electrolyte is poisonous. It is strong enough to
terminal of battery. Put meter positive (red) lead on burn skin, eat holes in clothing, and cause
negative terminal of battery and record reading. Reading blindness if splashed into the eyes.
should be 0.1 ohm or less.
Avoid the hazard by:
3. Put meter red lead on ground terminal of circuit or
component to be tested that is closest to the battery Filling batteries in a well-ventilated area.
negative terminal. Resistance reading must be very close Wearing eye protection and rubber gloves.
to or the same as the battery negative terminal reading. Avoiding breathing fumes when electrolyte is
Work backwards from the battery on the ground side of the added. Avoid spilling or dripping electrolyte.
problem circuit until the resistance reading increases above Use proper jump-start procedure.
0.1 ohms. The problem is between the last two test points. If you spill acid on yourself:
If a problem is indicated, disconnect the wiring harness
Flush your skin with water. Apply baking soda
connector to isolate the wire or component and check
or lime to help neutralize the acid. Flush your
resistance again. Maximum allowable resistance in the
eyes with water for 10 - 15 minutes. Get medical
circuit is 0.1 ohms. Check both sides of connectors closely
attention immediately
as disconnecting and connecting may temporarily solve
problem. If acid is swallowed:
Voltmeter Procedure: Drink large amounts of water or milk. Then

drink milk of magnesia, beaten eggs, or
1. Put transmission in neutral. Lock park brake. Put PTO vegetable oil. Get medical attention
switch in off position. Turn key switch to run position. immediately.
2. Connect voltmeter negative (black) lead to negative (-)
1. Park machine safely with park brake locked.
terminal of battery.
2. Inspect battery terminals and case for breakage or
3. Put meter positive (red) lead on ground terminal of
cracks.
component to be tested. Be sure the component circuit is
activated (key switch in run position) so voltage will be 3. Check electrolyte level in each battery cell. Add clean,
present at the component. Record voltage. Voltage must be soft water as needed. If water added, charge battery for 20
greater than 0 but less than 1 volt. Some components will minutes at 10 amps.
have a very small voltage reading on the ground side and 4. Remove surface charge by placing a small load on the
still be operating correctly. battery for 15 seconds.
Results:
• If resistance is above 0.1 ohms, check for open wiring,
loose terminal wire crimps, poor connections, or corrosion
in the ground circuit
• If voltage is 0, the component is open
• If voltage is greater than 1 volt, the ground circuit is bad.
Check for open wiring, loose terminal wire crimps, poor
connections, or corrosion in the ground circuit.
Electrical Tests and Adjustments - 277

Battery - Charge
D.C. AMPS D.C. VOLTS Reason:
To increase battery charge after battery has been
discharged.
Equipment:
• Battery charger (variable rate)
Procedure:
MIF
5. Check battery voltage with voltmeter or JTO5685

Battery Tester.
Battery Charger
and Booster
MIF
1. Connect variable rate charger to battery.

NOTE: Maximum charge time at boost setting is 10
minutes. Allow an additional 5 minutes for each 10
degrees below 70 degrees F.
2. Start charger at slow rate. Increase charge rate one
setting at a time. Check charger ammeter after 1 minute at
each setting. Maintain 10 amp charge rate. Use boost
setting as necessary.
MIF
3. Check if battery is accepting a 10 amp charge after 10
6. Use an hydrometer to check for a minimum specific
minutes at boost setting.
gravity of 1.265 with less than 50 point variation in each cell
at full charge at 26.7°C (80°F). • Battery will not accept 10 amp charge after 10
minutes at boost setting: replace battery
Results:
• Battery is accepting 10 amp charge after 10 minutes
• Battery voltage less than 12.4 VDC, charge battery at boost setting, and battery did not need water: go to
• Battery voltage more than 12.4 VDC, test specific steps 6 and 7
gravity • Battery is accepting 10 amp charge after 10 minutes
• All cells less than 1.175, charge battery at 10 amp rate at boost setting, but battery did need water or all cells
were below 1.175: go to steps 4 and 5
• All cells less than 1.225 with less than 50 point variation,
charge battery at 10 amp rate IMPORTANT: Avoid damage! Decrease charge rate if
• All cells more than 1.225 with less than 50 point battery gases or bubbles excessively or becomes
variation, load test battery too warm to touch.
• More than 50 point variation: replace battery 4. Set charger at 15 - 25 amps.
Specifications: 5. Check specific gravity after 30 minutes (60 minutes for
maintenance-free battery).
Minimum battery voltage . . . . . . . . . . . . . . . . 12.4 volts
Minimum specific gravity NOTE: If battery was discharged at slow or unknown
. . . . . . . . . . . . . . 1.225 with less than 50 point variation rate, charge at 10 - 15 amps for 6 - 12 hours
(Maintenance-free battery: 12 - 24 hours). If battery was
discharged at fast rate, charge at 20 - 25 amps for 2 - 4
hours (Maintenance-free battery: 4 - 8 hours).

• More than 50 point variation between cells: replace Unregulated Amperage Test
battery
Reason:
• Less than 50 point variation between cells: go to
steps 6 and 7 To determine charging output of the alternator stator.
6. Continue charging battery until specific gravity is 1.230 -
Equipment:
1.265 points.
• JTO5712 Current Gun
7. Load test battery. See “Battery - Load Test” on
page 279. Conditions:
1. Put JTO5712 Current Gun over alternator red wire.
Battery - Load Test
2. Set current gun for DC current.
Reason:
Procedure:
To check condition of battery under load.
NOTE: See “Battery - Charge” on page 278 before IMPORTANT: Avoid damage! Perform this test
applying a load to battery. quickly to prevent damage to the battery. DO NOT
apply full load to battery for more than 10 seconds.
Equipment:
1. Park machine safely with park brake locked.
2. Raise hood and remove engine side covers.
D.C. AMPS D.C. VOLTS

3. Start and run engine at high idle.
MIF
A
• JTO5685 Battery Tester
• or equivalent
NOTE: Use the procedures given with the tester. M91220
4. Insert a small phillips screwdriver through the hole (A) in

Procedure: rear cover of alternator to ground the regulator to the rear
1. Turn load knob of tester clockwise until amperage cover. Read amperage on current gun.
reading is equal to:
Specifications:
• Cold cranking amperage rating (use blue scale)
Minimum unregulated amperage . . . . . . . . . . . 40 amps
or,
• Three times ampere hour rating (use black scale) Results:
2. Hold for 15 seconds and turn load knob of tester off. If reading does not meet specifications, verify voltage at the
alternator regulated terminal and good alternator ground. If
3. Read battery voltage. voltage and ground are ok, replace the alternator.
Results:
• If the battery does not indicate 9.6 volts or more, replace
battery

Regulated Amperage and Voltage Test 6. Turn load knob clockwise (in) until voltage on voltage
tester scale reads 11 volts for 5 seconds only to partially
Reason: drain battery.
To determine the regulated voltage (charging) output of the 7. Quickly turn load knob completely counter-clockwise
alternator. (out) to off position.
NOTE: Battery must be in a good state of charge. 8. Start and run engine at high idle (2850 rpm). Battery
voltage should read between 14.2 - 14.8 VDC.
Equipment:
9. Turn load knob clockwise (in) until voltage on tester
• JTO5712 Current Gun voltage scale (B) reads 11 volts and look at current gun for
• Voltmeter a minimum reading of 13.5 amps.
10.Quickly turn load knob completely counterclockwise
• JTO5685 Battery Tester
(out) to off position.
Procedure: 11.After load test, battery voltage (B) should return to the
1. Park machine safely with park brake locked. voltage level prior to test.
2. Raise hood and remove engine side covers. Results:

3. Disconnect three pin connector from alternator. • If current gun amp reading is below specification, test for
unregulated voltage output. If unregulated voltage output
IMPORTANT: Avoid damage! Turn load knob (A) fully test meets specifications and you have verified voltage to
counterclockwise (out) into off position before ground to regulator/rectifier, replace regulator/rectifier.
making any test connections.
• If at any time voltage increase exceeds 14.8 VDC,
replace regulator/rectifier.
C B
Specifications:
High Idle Voltage . . . . . . . . . . . . . . . . . . 14.2 - 14.8 VDC

Minimum High Idle Amperage. . . . . . . . . . . . 13.5 Amps
A
Starting Motor Solenoid Test

Reason:
To determine if the starting motor is defective.
Equipment:
• Jumper wire
JTO5712
Current Gun
c CAUTION: Avoid injury! This test will cause

engine to turn over. Engine may start. Ensure
fuel shutoff solenoid is disconnected,
transmission is in neutral and PTO is
M91292 disengaged.
4. Connect JTO5712 Current Gun to voltmeter and put
around positive (red) battery cable going to starting motor. Procedure:
Set current gun for DC current. 1. Park machine safely in neutral with park brake locked.
5. Connect battery tester to battery. 2. Raise hood and remove engine side covers.
3. Disconnect fuel shutoff solenoid wire connector.
IMPORTANT: Avoid damage! Perform these tests
quickly to prevent damage to battery tester. Do not
apply full load to battery for more than 5 - 10
seconds.

IMPORTANT: Avoid damage! Turn load knob (A) fully

counterclockwise (out) into off position before
making any test connections.
D C
B
A
C
B
A
M91309
4. Disconnect 309 Wht wire from starting motor solenoid

terminal (A).
MIF
5. Connect jumper wire to positive (+) battery terminal and
briefly jump to starting motor solenoid terminal (A). 4. Connect JTO5685 Battery Tester (B) to battery.
5. Crank engine and read voltage on meter (C).
Results:
6. Turn key switch to the off position. Adjust load knob until
• Starting motor runs - solenoid is good, test cranking battery voltage reads the same as when cranking.
circuit wiring.
7. Read amperage on meter (D).
• Starting motor does not run - go to next step.
8. Turn load knob fully counterclockwise.
1. Remove rubber boot from terminal (B).
2. Remove plastic cover from terminal (C). Results:
3. Connect jumper wire between starting motor solenoid • If amperage is greater than 150 amps, test starting
large terminals (B and C). motor No-Load RPM and Amperage to determine if the
starting motor is binding or damaged.
Results: • If the starting motor is good, check internal engine
• Starting motor runs - replace starter. components for binding or damage.
• Starting motor does not run - check battery cables, then
replace starting motor. No-Load Amperage Draw and RPM Test
Reason:
Starting Motor Amperage Draw Test
To determine if starter is binding or has excessive
Reason: amperage draw under no-load.
To determine the amperage required to crank the engine Equipment:
and check starter motor operation under load.
• JTO2153 Current Clamp
Equipment: • JT05791 Multitester
• JTO5685 Battery Tester • JTO5719 Hand-Held Digital Tachometer
Procedure: • Jumper Cables
1. Park machine safely in neutral with park brake locked. • Jumper wire
2. Raise hood and remove engine side covers. Procedure:
3. Disconnect fuel shutoff solenoid wire connector.
NOTE: Check that battery is fully charged and of proper
size to ensure accuracy of test.

1. Park machine safely in neutral with park brake locked. 3. Remove starting motor assembly from machine and
place starting motor in vice.
Starting Motor
Terminal
JTO2153
Current Clamp
JTO5791
Multitester
Solenoid
Terminal
M91293
4. Connect jumper cables to a 12 volt battery. Relay Test

5. Connect positive (+) cable to solenoid battery terminal
Results:
on starting motor.
6. Connect negative (-) cable to starting motor body. To check relay terminal continuity in the energized and de-
energized condition.
7. Attach Current Gun to positive (+) cable.
Equipment:
IMPORTANT: Avoid damage! Perform these tests • Ohmmeter or continuity tester
quickly to prevent damage to starting motor.
Complete test in 20 seconds or less. • 12 volt battery and small jumper wires
8. Use a jumper wire to briefly connect positive (+) starting Procedure:

motor terminal to solenoid terminal. Starting motor should 1. Park machine safely in neutral with park brake locked.
engage and run.
2. Open plastic panel below steering column support.
9. Read and record starting motor amperage and rpm.
3. Remove relay from fuse and relay load center.
Results: 4. Check terminal continuity using an ohmmeter or
• If solenoid “clicks” or chatters and starting motor does continuity tester.
not turn, replace starting motor.
• If pinion gear engages and starting motor doesn’t turn,
replace starting motor.
• If starting motor engages and runs, but amperage is
more than 60 Amps at 4440 rpm, repair or replace starting
motor.
• If free-running rpm is less than 4000 rpm, repair or
replace starting motor.

Results:
86 30
30
85 87 87a
A
86
D
87a M91345
B 3. Disconnect 347 Pur wire from engine oil pressure switch

85 (A).
C 87
E 4. Connect black lead of ohmmeter to engine block and red
lead of ohmmeter to terminal of switch.
M91294
5. Measure resistance between terminal and engine block.
• There should be continuity between terminals A (30)
and B (87a). Results:
• There should be approximately 80 ohms resistance • There should be continuity between terminal and
between terminals C (85) and D (86). ground.
• There should not be continuity between any other • If there is no continuity between terminal and ground;
terminals. replace the oil pressure switch.
1. Connect a small jumper wire from battery positive (+) NOTE: Be sure to apply Pipe Sealant with TEFLON® to
terminal to relay terminal C (85). threads of switch anytime it is installed.
2. Connect a small jumper wire from relay terminal D (86)
TEFLON® is a registered trademark of the DuPont
to battery negative terminal (-).
Company.
Results: 1. Start and run engine.
• There should be continuity between terminals A (30) 2. Measure resistance between terminal and engine block.
and E (87).
Results:
• If continuity is not correct, replace relay.
There should be no continuity between switch terminal and
ground with the engine running.
Engine Oil Pressure Switch Test
• If the switch does have continuity to engine block
Reason: (ground) with engine running, check engine oil pressure.
To determine if engine oil pressure switch is functioning • If oil pressure meets specification; replace the oil
properly, to warn operator that oil pressure has dropped pressure switch.
below minimum operating pressure.
Equipment:
• Ohmmeter
Procedure:
NOTE: Perform test with engine at room temperature.
1. Park machine safely in neutral with park brake locked.

Engine Coolant Temperature Sensor Test Manifold Heater Test
Reason: Reason:
To verify coolant temperature sensor is functioning To test proper operation of manifold heater.
properly.
Equipment:
Equipment: • Ohmmeter
• Ohmmeter
Procedure:
Procedure: 1. Park machine safely in neutral with park brake locked.
NOTE: Perform test with engine at room temperature. 2. Raise hood and remove engine side covers.
3. Disconnect 359 Wht wire from engine coolant
temperature sensor.
4. Measure resistance between terminal and sensor body.
5. If resistance does not meet specification, replace
coolant temperature switch.
A
6. Drain engine coolant and remove coolant temperature
switch.
M91879
A 3. Remove manifold heater lead from terminal (A).

4. Check continuity across terminal (A) and frame ground.
The reading should be between 0.3 - 0.5 ohms.
Results:
• If manifold heater does not have between 0.3 - 0.5 ohms
M91295 resistance, replace heater unit.
7. Place sensor (A) in antifreeze solution heated to
approximately 96°C (205°F). Measure resistance while Key Switch Test
sensor is heated.
Reason:
8. If resistance does not meet specification, replace
coolant temperature sensor. To verify that key switch functions properly.
Specifications: Equipment:
Variable Resistance . . . . . . . . . . . . . . . . . 40 - 700 ohms • Ohmmeter or continuity tester
Procedure:
2. Remove four screws securing key switch panel to
steering column support and pull away from steering
column enough to access key switch connector.
3. Disconnect key switch from wiring harness.
4. Remove key switch and panel from machine.

5. Use an ohmmeter or continuity tester to test switch
continuity in off, run, start, and aid (key pushed in)
positions.
A
4
E
6
1 D
2 5
7 C
Start
Run F B M49391
Off
Acc. 4. Check visually for broken filament (A).
Aid
Off Spare A 5. Connect ohmmeter or continuity tester to each end of
fuse.
6. Check for continuity.
M91296
Results:
Key Switch Continuity:
• If continuity is not indicated, replace the fuse.
Switch Position . . . . . . . . . . . . . . . . Terminal Continuity
OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and A Control Panel Light Test
ACCESSORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and B
Reason:
RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and B
To verify that bulb has continuity.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and C
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and D Equipment:
START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and D • Ohmmeter or continuity tester
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and E
Procedure:
AID (Key in RUN position and PUSHED IN) . . . A and B
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and C
2. Remove four screws securing dash panel to steering
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and D column support and lift enough to access bulb sockets.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and F 3. Remove bulb from socket.
Results:
• If any continuity is not correct, replace the switch.
A
Fuse Test
Reason:
To verify that fuse has continuity.
Equipment:
• Ohmmeter or continuity tester
Procedure: M49392
1. Park machine safely in neutral with park brake locked. 4. Check visually for broken filament (A).
2. Open plastic panel below steering column support. 5. Connect ohmmeter or continuity tester to each terminal
of bulb.
3. Remove fuse from load center.
6. Check for continuity.

Results: • If a diode has continuity in both directions, or has no
continuity, replace diode block.
• If continuity is not indicated, replace bulb.
Diode Block Test Light Switch Test
Reason: Reason:
To verify that light switch functions properly.
To verify that diodes in diode block are functioning properly.
Equipment: Equipment:
• Ohmmeter, continuity tester or diode tester
Procedure: Procedure:
NOTE: Terminal positions are indicated on diode block.
2. Remove four screws securing dash panel to steering
1. Park machine safely in neutral with park brake locked. column support and lift enough to access light switch
2. Open plastic panel below steering column support. connector.
3. Remove diode block from load center. 3. Disconnect light switch from wiring harness.
4. Connect ohmmeter or continuity tester to each diode as 4. Remove light switch from machine.
indicated in table. 5. Use an ohmmeter or continuity tester to test switch
5. Check for continuity. continuity in off, hazard, road, and field positions.
A C D F H K
(0) Off
3
(1) Hazard
B E J B C (2) Road 2
A
(3) Field
E
1
F
2
B
B
3 1 Not Used
K 4
D 4
J
H M91297
M91301 Light Switch Continuity:

Red Test Lead Black Test Lead Continuity Switch Position. . . . . . . . . . . . . . . . Terminal Continuity
(+) (-) OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and 1
A B Yes HAZARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and 2
C B Yes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and 1
ROAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and 2
D E Yes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and 3
F E Yes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and 1
H J Yes FIELD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and 3
K J Yes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and 1
Results:
Results:
• Each diode should have continuity in one direction only.
• If any continuity is not correct, replace the switch.

Seat Switch Test Transmission Neutral Switch Test - SST and
ePowrReverser
Reason:
To verify that seat switch functions properly. Reason:
To verify that transmission neutral switch functions properly.
Equipment:
• Ohmmeter or continuity tester Equipment:
Procedure:
1. Park machine safely in neutral with park brake locked. Procedure:
2. Raise seat. 1. Park machine safely in neutral with park brake locked.
3. Disconnect seat switch from wiring harness. 2. Disconnect transmission neutral switch from wiring
harness.
Operator Off
Operator On On
Off
A A
B
B
M91686
M91298
3. Check continuity across switch terminals A and B.
4. Check continuity across switch terminals A and B. There Continuity should exist. If no continuity exists, ensure that
should be no continuity. gear selector is in neutral.
5. Depress seat switch plunger. Continuity should exist 4. If continuity can be obtained when transmission is in
between terminals A and B. neutral;
Results: • Place gear selector in any gear,
• If continuity is not correct, replace seat switch. • Check for continuity through switch. There should be no
continuity.
1. If continuity does not match specifications:
• Remove switch from transmission housing.
• Test switch for continuity. The switch is normally closed.
Depress contact ball on end of switch and check continuity.
Switch should be open (no continuity with ball depressed).
1. Replace switch if correct continuity can not be obtained.
Transmission Neutral Switch Continuity:

Switch Position. . . . . . . . . . . . . . . . Terminal Continuity
NORMALLY CLOSED (In Neutral) . . . . . . . . . . . A and B
BALL DEPRESSED (In Gear). . . . . . . . . . No Continuity

Turn Signal Switch Test Rear PTO Switch Test
Reason: Reason:
To verify that turn signal switch functions properly. To verify proper operation of the rear PTO switch.
• Ohmmeter • Ohmmeter
1. Park machine safely in neutral with park brake locked. 1. Park machine safely in neutral with park brake locked.
2. Remove four screws securing dash panel to steering 2. Open the right side control panel to access the rear PTO
column support and lift enough to access turn signal switch switch.
connector.
3. Disconnect rear PTO switch from wiring harness.
3. Disconnect turn signal switch from wiring harness.
On
(0) Right B
(1) Off Off
(2) Left A B
F C
C
1 D E
Flasher
F
5 A G
H A F
4 B
2
ON D
3 D
6 C E
E
M91299 H
G
continuity in off, left, and right positions. MIF

Turn Signal Switch Continuity:
continuity in off and on positions.
OFF
Rear PTO Switch Continuity:
A to B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ohms
A to C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ohms
OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and C
B to C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 ohms
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D and F
Left Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G and H
A to B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . variable ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and B
A to C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ohms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D and E
A to D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . open
Results:
A to E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ohms
• If continuity is not correct or is present in any other
A to F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . variable combination, replace rear PTO switch.
A to F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 ohms
Right Position
A to C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . continuity
Results:
• If any resistance value is not correct, replace the turn
signal switch.

Mid PTO Switch Test MFWD, Rear PTO and Mid PTO Solenoid Test
Reason: Reason:
To verify that the rear PTO switch functions properly. To verify that the solenoid coil is operating properly.
• Ohmmeter or continuity tester • Ohmmeter or continuity tester
2. Open the right side control panel to access the mid PTO 2. Access the solenoids on the right side of the machine
switch. under the operator’s floor platform.
3. Disconnect mid PTO switch from wiring harness. 3. Disconnect the solenoids from wiring harness.
Rear PTO
Solenoid
B MFWD
Solenoid
ON
Mid PTO
Solenoid
A G
On
Off
B
A
A
G H B
H
A
MIF B
A
B
continuity in off and on positions.
MIF
Mid PTO Switch Continuity:
4. Use an ohmmeter or continuity tester, check if continuity
Switch Position . . . . . . . . . . . . . . . . Terminal Continuity exist between solenoid terminals.
OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G and H 5. If resistance does not meet specifications or is present
ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and B in any other combination, replace solenoid.
Results: Specifications:
• If continuity is not correct, replace mid PTO switch. A to B. . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 - 11.5 ohms
1. Check for grounds or shorts by connecting tester to one

coil terminal and the other to bare metal of coil case.
Results:
• Replace solenoid if continuity is present from either
terminal to solenoid coil case.

Cruise Control Switch Test - eHydro Res/+, Set/- Switch Test - eHydro
Reason: Reason:
To verify that the cruise control switch functions properly. To verify proper operation of the Res/+, Set/- switch.
2. Open the right side control panel to access the cruise 2. Open the right side control panel to access the res/+,
control switch. set/- switch.
3. Disconnect cruise control switch from wiring harness. 3. Disconnect res/+, set/- switch from wiring harness.
Cruise ON Res/+
OFF OFF
Max Speed ON Set/-
A
A
B
B
C
C
MIF MIF
4. Use an ohmmeter or continuity tester to test switch 4. Use an ohmmeter or continuity tester to test switch
continuity. continuity.
Cruise Control Switch Continuity: Res/+, Set/- Switch Continuity:

Switch Position . . . . . . . . . . . . . . . . Terminal Continuity Switch Position. . . . . . . . . . . . . . . . Terminal Continuity
OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . None OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . None
Cruise ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and B Res/+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and B
Max Speed ON . . . . . . . . . . . . . . . . . . . . . . . . . . B and C Set/- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and C
Results: Results:
• If continuity is not correct, or exists in any other • If continuity is not correct, or exists in any other
combination than shown above, replace the switch. combination than shown above, replace the switch.

Brake Switch Test and Adjustment - eHydro Park Brake Switch Test and Adjustment
Reason: Reason:
To verify that the brake switch functions properly. To verify that the park brake switch functions properly.
2. Remove the right side engine and steering column 2. Remove the right side engine and steering column
covers. covers.
3. Disconnect brake switch from wiring harness. 3. Disconnect park brake switch from wiring harness.
Released
On
Pressed
Off
D
A
C
C
B
A B
D
B A
C M91300
MIF 4. Use an ohmmeter or continuity tester to test switch

4. Use an ohmmeter or continuity tester to test switch continuity.
continuity.
Park Brake Switch Continuity:
Brake Switch Continuity: Switch Position. . . . . . . . . . . . . . . . Terminal Continuity
Switch Position . . . . . . . . . . . . . . . . Terminal Continuity Released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and C
Released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and D
Pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and B Pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . None
Results: Results:
• If continuity is not correct, or exists in any other • If continuity is not correct, or exists in any other
combination than shown above, replace the switch. combination than shown above, replace the switch.
Adjustment Procedure: Adjustment Procedure:

1. Unlock park brake. 1. Lock parking brake.
2. Loosen switch bracket hardware. 2. Loosen switch bracket hardware.
3. Move switch until switch plunger closes. 3. Move switch until switch plunger is about 3 mm (1/8 in.)
from bottoming.
4. Check that switch does not bottom when brake pedal is
released. 4. Check that switch does not bottom when parking brake
is fully set. Increase clearance if needed.
5. Tighten bracket hardware.
6. Check that switch opens when brake pedal is
depressed. 6. Check switch operation.

Fuel Gauge Sensor Test Fuel Shutoff Solenoid Test
Reason: Reason:
To verify that the fuel gauge sensor is operating properly. To verify that the solenoid coils are operating properly.
• Ohmmeter or continuity tester • Ohmmeter
• Voltmeter
Procedure:
2. Raise hood. 1. Park machine safely in neutral with park brake locked.
3. Turn key switch to run position. 2. Raise hood and remove engine right side cover.
3. Disconnect fuel shutoff solenoid connector.
Org Wire
Blk Wire
A
Float
C
M91652 B
M87349
4. Disconnect Org wire from fuel sensor and check fuel
gauge. The fuel gauge must drop to empty. If not, See 4. Using an ohmmeter or continuity tester, check if
“Power Circuit Operation” on page 158. continuity exists between all solenoid terminals.
5. Short the Org wire to the black wire connector on the 5. If resistance does not meet specifications, replace fuel
fuel sensor. The gauge must rise to full. If not, test the fuel shutoff solenoid.
sensor ground circuit. 6. Check for grounds or shorts by connecting tester to one
6. If the gauge does not correctly indicate fuel levels based coil terminal and the other to bare metal of coil case.
on the two tests above, proceed to step 9. 7. Replace fuel shutoff coil if continuity is present.
7. Disconnect fuel gauge sensor wires.
Specifications:
8. Remove sensor from fuel tank.
A to B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 ohms
9. Using an ohmmeter connected to fuel gauge sensor
contacts, check if continuity exists between terminals. If A to C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4 ohms
continuity exists, measure resistance across terminals as B to C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.0 ohms
float and float arm are moved through full range of motion.
1. Connect fuel shutoff solenoid connector.
Specifications:
2. Listen for click when fuel shutoff solenoid pulls in when
Variable Resistance . . . . . . . . . . . . . . . . . . . 5 - 95 ohms the key switch turned to run position with the park brake
locked.
Results:
• If resistance does not meet specifications, replace fuel Results:
gauge sensor. • If click is not heard when fuel shutoff solenoid pulls in,
See “Fuel Supply Circuit Operation” on page 179.

Bottom of Clutch Switch Test and Adjustment MFWD Switch Test
- ePowrReverser
Reason:
Reason: To verify proper operation of the MFWD switch.
To verify proper operation of the bottom of clutch switch.
Equipment:
Equipment: • Ohmmeter or continuity tester
Procedure:
1. Park machine safely in neutral with park brake locked. 2. Open the right side control panel to access the MFWD
2. Remove the left side engine cover. switch.
3. Disconnect bottom of clutch switch from wiring harness. 3. Disconnect MFWD switch from wiring harness.
On
Unlock D
Off Lock
B E
D A
A C
C
E D B
C
B
B A
D
A C
M91300

continuity.
MIF
Bottom of Clutch Switch Continuity:
Switch Position . . . . . . . . . . . . . . . . Terminal Continuity continuity.
Released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and C
MFWD Switch Continuity:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and D
Pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . None
Unlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and B
Results: Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and C
• If continuity is not correct, or exists in any other Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . D and E
combination than shown above, replace the switch.
Results:
Adjustment Procedure:
• If continuity is not correct, or exists in any other
1. Loosen switch bracket hardware. combination than shown above, replace the switch.
2. Press clutch pedal fully down.
3. Move switch until switch plunger is about 3 mm (1/8 in.)
from bottoming.
4. Check that switch does not bottom when clutch pedal is
fully pressed. Increase clearance if needed.
6. Check switch operation.

Load Match Switch Test - eHydro Motion Match Switch Test
Reason: Reason:
To verify proper operation of the load match switch. To verify proper operation of the motion match switch.
2. Remove four screws securing dash panel to steering 2. Open the right side control panel to access the motion
column support and lift enough to access load match match switch.
switch connector.
3. Disconnect motion match switch from wiring harness.
3. Disconnect load match switch from wiring harness.
Off
Off On
On A
MIF
4. Check continuity across switch terminals A and B. There

MIF
should be no continuity in the off position.
4. Check continuity across switch terminals A and B. There
5. Toggle the switch to the on position. Continuity should
should be no continuity in the off position.
exist between terminals A and B.
5. Toggle the switch to the on position. Continuity should
exist between terminals A and B. Results:
• If continuity is not correct, replace motion match switch.
Results:
• If continuity is not correct, replace load match switch.

Diverter Valve Solenoid Test Proportional Drive Solenoid Test -
ePowrReverser
Reason:
To verify that the diverter valve solenoid has proper coil Reason:
resistance and is not shorted to ground. To verify proper operation of the proportional drive solenoid
coil.
Equipment:
• Ohmmeter Equipment:
Procedure:
2. Disconnect solenoid. 1. Park machine safely in neutral with park brake locked.
2. Access the solenoids on the bottom of the tunnel
section under the operator’s floor platform.
3. Disconnect the solenoids from wiring harness.
A B
MX4781
3. Check resistance between solenoid terminals (A and B).

4. Check for continuity between either terminal and A
solenoid coil housing. B
Results MIF
• If resistance does not meet specifications, replace 4. Use an ohmmeter or continuity tester, check if continuity
solenoid. exist between solenoid terminals.
• If continuity exists between either terminal and coil 5. If resistance does not meet specifications or is present
housing, replace solenoid. in any other combination, replace solenoid.
Specifications Specifications:
Diverter Valve Solenoid Coil Resistance . . . . 6.7 ohms A to B. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 - 10.5 ohms

coil terminal and the other to bare metal of coil case.
Results:
• Replace solenoid if continuity is present from either
terminal to solenoid coil case.

Proportional Drive Solenoid Test - eHydro F-N-R Switch Test - ePowrReverser
Reason: Reason:
To verify proper operation of the proportional drive solenoid To verify proper operation of the F-N-R switch.
coil.
Equipment:
Equipment: • Ohmmeter
Procedure:
2. Unlock the F-N-R shiftier cover and remove covers.
2. Access the solenoid connectors on the right side of the
3. Disconnect F-N-R switch from wiring harness.
machine under the operator’s floor platform.
4. Remove the F-N-R switch by removing the two screws
3. Disconnect the solenoids from wiring harness. and locknuts.
Forward
Neutral
Reverse
C
D B
A
A A
B B
C
MIF
D
4. Use an ohmmeter or continuity tester, check if continuity
exist between solenoid terminals. MIF
5. If resistance does not meet specifications or is present 5. Use an ohmmeter or continuity tester to test switch
in any other combination, replace solenoid. continuity.
Specifications: F-N-R Switch Continuity:

A to B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 - 7.0 ohms Switch Position. . . . . . . . . . . . . . . . Terminal Continuity
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D and C
coil terminal and the other to bare metal of coil case. Neutral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D and B
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D and A
Results:
• Replace solenoid if continuity is present from either Results:
terminal to solenoid coil case. • If continuity is not correct, or exists in any other
combination than shown above, replace the switch.

Test and Calibration Kit ePowrReverser - Clutch Position
Potentiometer Test
Function:
To set the initial voltage readings on the potentiometers Reason:
and test and diagnose the potentiometers, pressure To verify proper voltage input and output of the clutch
transducers, speed sensors, and solenoid coils. position potentiometer with the pedal in the Top of Travel
(TOT) and Bottom of Travel (BOT) positions.
Equipment
• JDG1575 Test Kit Equipment:
• JDG1575 Test Kit
Theory:
The Test and Calibration Kit is intended to be used to both Procedure:
diagnose and set-up the operational components used to 1. Park machine safely in neutral with park brake locked.
engage and control the drive function on those
ePowrReverser and eHydro model machines equipped with 2. Inspect the linkage between clutch pedal and
the e-MatchOS Electronic Operating System. potentiometer for wear, damage or looseness. Repair or
replace as needed.
With the proper jumper wires connected to the test and
calibration kit, the following components can be tested and/
or set on the ePowrReverser machine: E
F
B
• Clutch Position Potentiometer, set-up and test for D
voltage,
• Forward Proportional Solenoid, test for current flow,
• Reverse Proportional Solenoid, test for current flow, G
• Forward Pressure Transducer, test for voltage, and

• Reverse Pressure Transducer, test for voltage.
With the proper jumper wires connected to the test and
calibration kit, the following components can be tested and/ H
or set on the eHydro machine:
• Throttle Position Potentiometer, set-up and test for
voltage,
• Forward Pedal Position Potentiometer, set-up and test
for voltage,
C A
• Reverse Pedal Position Potentiometer, set-up and test
MX17140
for voltage,
3. Connect the red lead to the volt, ohms, Hz input jack (A)
• Forward Proportional Solenoid, test for current flow,
of the multimeter and the voltage A terminal (B) of the
• Reverse Proportional Solenoid, test for current flow, breakout box.
• Flywheel Speed Sensor, test for frequency, and 4. Connect the black lead to the com input jack (C) of the
• MFWD Speed Sensor, test for frequency. multimeter and the voltage C terminal (D) of the breakout
box.
5. Connect the 3 pin extender harness (E) into the 3 pin
connector (F) of the breakout box.
6. Set the multimeter to the DCV position (G).
7. Set breakout box switch to the off position (H).

13.The BOT voltage should be within specification. If not,
J adjust potentiometer.
14.Release the clutch pedal to the TOT position.
15.The TOT voltage should be within specification. If not,
replace the clutch position potentiometer.
16.Unplug the position Y connector from the machine
wiring harness and the clutch potentiometer.
17.Connect the machine wiring harness to the clutch
K potentiometer.
Specification:
I
Input Voltage. . . . . . . . . . . . . . . . . . . . . . . . 5.0 ± 0.2 volts
TOT Signal Voltage. . . . . . . . . . . . . . . . . . . 3.5 - 4.8 volts
BOT Signal Voltage . . . . . . . . . . . . . . . . . . 0.8 ± 0.1 volts
L
ePowrReverser - Clutch Position

Potentiometer Adjustment
Reason:
To adjust the clutch position potentiometer for the proper
MX9821 voltage with the pedal in the Bottom of Travel (BOT)
positions.
8. Connect the position sensor Y connector (I) between the
clutch position potentiometer (J), the machine wiring Equipment:
harness (K), and the extender harness (L).
9. Turn the key switch to the run position.
10.The input voltage should be within specification. If not, Procedure:
See “Power Circuit Operation” on page 158. 1. Park machine safely in neutral with park brake locked.
2. Inspect the linkage between clutch pedal and
potentiometer for wear, damage or looseness. Repair or
M
replace as needed.
E
F
B D
MX17141
11.Move the red lead on the breakout box from the A

A
terminal to the B terminal (M). C
12.Fully depress the clutch pedal to the BOT position. MX17141

3. Connect the red lead to the volt, ohms, Hz input jack (A) 15.The TOT voltage should be within specification. If not,
of the multimeter and the voltage B terminal (B) of the replace the clutch position potentiometer.
breakout box.
4. Connect the black lead to the com input jack (C) of the wiring harness and the clutch potentiometer.
multimeter and the voltage C terminal (D) of the breakout
17.Connect the machine wiring harness to the clutch
box.
potentiometer.
connector (F) of the breakout box. Specification:
6. Set the multimeter to the DCV position (G). BOT Signal Voltage . . . . . . . . . . . . . . . . . . 0.8 ± 0.1 volts
7. Set breakout box switch to the off position (H). TOT Signal Voltage. . . . . . . . . . . . . . . . . . . 3.5 - 4.8 volts
Lock Nut Torque . . . . . . . . . . . . . . . . 3.4 N•m (30.0 lb-in.)
M
ePowrReverser - Pressure Transducer Test

Reason:
To test the forward or reverse pressure transducer input
and output voltage.
M NOTE: This tests the pressure transducers only. It does
J
not check for presence of oil pressure. Refer to the
K Hydraulics Section for pressure tests.
I NOTE: If a transducer is suspected to be faulty, switch

the connections for the proportional valves and the
transducers to see if the problem goes to the opposite
direction. If the problem goes to the opposite direction,
the transducer is faulty. If not, then the wiring to the
L
drive controller or the drive controller is faulty.
Test Equipment
Procedure:
MX9821 1. Park machine safely in neutral with park brake locked.
clutch position potentiometer (J), the machine wiring
10.Loosen the lock nuts (M) enough that the potentiometer
will stay in place without turning, but can be rotated by C
hand.
11.Fully depress the clutch pedal to the BOT position.
12.Rotate the potentiometer until the meter reading is B
A
IMPORTANT: Avoid damage! Torque specification is

critical.
13.With the calibration kit still attached, tighten the two nuts
to specification, being sure that the voltage reading does MX9824
not change. 2. Remove the two screw (A) from the rear of the access
14.Release the clutch pedal to the TOT position. cover (B).

3. Loosen the four screws (C) toward the front of the
access cover (B) and remove the cover.
H
I
E O
G
P N
J
MX9826
10.Connect the pressure sensor Y connector (N) between

the reverse pressure transducer (O), the machine wiring
F D harness (P), and the extender harness (Q).
MX17141 11.Turn the key switch to the run position.
4. Connect the red lead to the volt, ohms, Hz input jack (D) 12.The input voltage should be within specification. If not,
of the multimeter and the voltage B terminal (E) of the See “Power Circuit Operation” on page 158.
breakout box.
5. Connect the black lead to the com input jack (F) of the
multimeter and the voltage C terminal (G) of the breakout R
box.
6. Connect the 3 pin extender harness (H) into the 3 pin
connector (I) of the breakout box.
7. Set the multimeter to the DCV position (J).
8. Set breakout box switch to the off position (K).
MX17140
13.Move the red lead on the breakout box from the B

terminal to the A terminal (R).
14.Start and run the engine at low idle.
15.The neutral voltage should be within specification. If not,
L M
replace the reverse pressure transducer.
MX9825 16.Fully depress and then release the clutch pedal.
9. The pressure transducers and the proportional
solenoids are marked for forward (L) or reverse (M).

ePowrReverser - Proportional Solenoid Test
c CAUTION: Avoid injury! Be certain the park Reason:
brake is locked and the range transmission is
in neutral before placing the F-N-R in gear. To test the forward or reverse proportional valve coils for
proper input current.
NOTE: The following faults may shut the engine off
when shifting to the F or R position: NOTE: If a proportional valve coil is suspected to be
faulty, switch the connections for the proportional
• faulty transducer, valves and the transducers to see if the problem goes
• faulty wiring between transducer and controller, or to the opposite direction. If the problem goes to the
opposite direction, the proportional valve coil is faulty.
• low oil pressure. If not, then the wiring to the drive controller or the drive
If this occurs, correct the problem before continuing. controller is faulty.
17.Place the F-N-R shift lever in the reverse position. Equipment

18.The in gear voltage should be within specification. If not, • JDG1575 Test Kit
replace the reverse pressure transducer.
Procedure:
19.Place the F-N-R switch in neutral and shut the engine
off. 1. Park machine safely in neutral with park brake locked.
20.Unplug the pressure sensor Y connector from the
machine wiring harness and the reverse pressure
transducer.
21.Connect the machine wiring harness to the reverse
pressure transducer.
22.Repeat this procedure for the forward pressure C
transducer.
23.When completed, verify that all four connectors are
securely connected.
B
24.Install the access cover and tighten the six screws to
specification. A
Specification:
Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . 5.0 ± 0.2 volts
Signal Voltage, Neutral. . . . . . . . . . . . . . . . 0.1 - 0.4 volts
MX9824
Signal Voltage, In Gear at Idle . . . . . . . . . . 3.3 - 4.7 volts
Access Cover Screws . . . . . . . . . . 8.5 N•m (75.0 lb-in.) 2. Remove the two screw (A) from the rear of the access
cover (B).
3. Loosen the four screws (C) toward the front of the
access cover (B) and remove the cover.

J
K
P
Q
E G
D F
I
MX9829
H 10.Connect the e-PRT Y connector (N) between the

MX17142
forward proportional solenoid (O), the machine wiring
harness (P), and the extender harness (Q).
4. Connect the red lead to the mA input jack (D) of the
multimeter and the current A terminal (E) of the breakout 11.Start and run the engine at low idle with the operator on
box. the seat and the range transmission in neutral.
5. Connect the black lead to the com input jack (F) of the 12.Fully depress and then release the clutch pedal.
multimeter and the current com terminal (G) of the breakout 13.Set breakout box switch to test position.
box.
14.Place the F-N-R shift lever in the forward position.
6. Connect the 2 pin extender harness (H) into the 2 pin
15.The amperage reading should be within specification. If
connector (I) of the breakout box.
not, See “Proportional Drive Solenoid Test -
7. Set the multimeter to the DC mA position (J). ePowrReverser” on page 295, or see ePowrReverser drive
8. Set breakout box switch to the off position (K). circuit diagnosis.
16.Place the F-N-R switch in neutral and stop the engine.
17.Unplug the ePowrReverser adaptor harness from the
machine wiring harness and the forward proportional
solenoid.
18.Connect the machine wiring harness to the forward
proportional solenoid.
19.Repeat this procedure for the reverse proportional
solenoid.
20.When completed, verify that all four connectors are
securely connected.
21.Install the access cover and tighten the six screws to
specification.
M
Specification:
L
NOTE: Amperage value may be either positive or
MX9825 negative.
9. The pressure transducers and the proportional TOT Amperage . . . . . . . . . . . . . . . . . . . . .660 +25/-50 mA
solenoids are marked for forward (L) or reverse (M).
Access Cover Screws . . . . . . . . . . . 8.5 N•m (75.0 lb-in.)

eHydro - Throttle Position Potentiometer Test
Reason: J
To verify the throttle position potentiometer for proper

voltage with the throttle in the low and high idle positions.
Equipment
• JDG1575 Test Kit K
Procedure:
2. Remove the right side cowl panel.
3. Inspect the linkage between throttle lever and
replace as needed.
I
F E
L
B D
G MX9835

throttle position potentiometer (J), the machine wiring
A
H 10.Turn the key switch to the run position.
11.The input voltage should be within specification. If not,
See “Power Circuit Operation” on page 158.
C
M
MX17140
of the multimeter and the voltage A terminal (B) of the
breakout box.
5. Connect the black lead to the com input jack (C) of the
box.
8. Set breakout box switch to off position (H).
MX17141
12.Move the red lead on the breakout box from the A

terminal to the B terminal (M).
13.Set throttle to low idle position.

14.The low idle voltage should be within specification. If eHydro - Throttle Position Potentiometer
not, adjust potentiometer. Adjustment and Calibration
15.Set throttle to high idle position.
Reason:
16.The high idle voltage should be within specification. If
the voltage is within specification, calibrate the throttle To adjust the throttle position potentiometer for the proper
position potentiometer. If not, replace and adjust the throttle voltage with the throttle lever in the low and high idle
position potentiometer. positions.
17.Turn the key switch to the off position. Equipment:

18.Unplug the position Y connector from the machine • JDG1575 Test Kit
wiring harness and the throttle potentiometer.
19.Connect the machine wiring harness to the throttle
potentiometer. 1. Park machine safely in neutral with park brake locked.
20.Install the right side cowl panel. 2. Remove the right side cowl panel.
3. Inspect the linkage between throttle lever and
Specification:
Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . 5.0 ± 0.2 volts replace as needed.
Low Idle Position Signal Voltage. . . . . . . . 0.4 - 1.0 volts
High Idle Position Signal Voltage . . . . . . . 3.2 - 4.5 volts E
F
B
D
C A
MX17141
of the multimeter and the voltage B terminal (B) of the
breakout box.
box.
8. Set breakout box switch to the off position (H).

Calibration Procedure:
1. Turn key switch to the off position.
M M 2. Unplug the position Y connector from the machine
wiring harness and the throttle potentiometer.
3. Connect the machine wiring harness to the throttle
potentiometer.
J
K 4. Set the throttle lever to the low idle position.
MX9835
9. Connect the position sensor Y connector (I) between the MX10694

throttle position potentiometer (J), the machine wiring
6. The fault light (N) should display the 3 short and 1 long
flash (• • • -) fault code.
10.Turn the key switch to the run position.
7. Wait 5 seconds then move the throttle lever to the high
11.Loosen the lock nuts (M) enough that the potentiometer idle position.
will stay in place without turning, but can be rotated by
8. After 5 seconds the fault light should turn off.
hand.
9. When the flash code ends the throttle position
12.Set the throttle to the low idle position.
potentiometer is calibrated.
13.Rotate the potentiometer until the meter reading is
10.Install the right side cowl panel.
IMPORTANT: Avoid damage! Torque specification is eHydro - Drive Pedal Potentiometer Test
critical.
Reason:
14.With the calibration kit still attached, tighten the two nuts To verify the drive pedal potentiometers for proper voltage
to specification, being sure that the voltage reading does input and output with the pedal in the released or Top of
not change. Travel (TOT) and pressed in or Bottom of Travel (BOT)
15.Set the throttle to the high idle position. positions.
16.The high idle voltage should be within specification. If Equipment
the voltage is within specification, calibrate the throttle
position potentiometer. If not, replace and adjust the throttle • JDG1575 Test Kit
position potentiometer.
Procedure:
Specification: 1. Park machine safely in neutral with park brake locked.
Low Idle Position Signal Voltage. . . . . . . . 0.8 ± 0.1 volts 2. Remove cover from forward and reverse pedal bracket
High Idle Position Signal Voltage . . . . . . . 3.8 - 4.5 volts located under operator’s floor platform.
Lock Nut Torque . . . . . . . . . . . . . . . 3.4 N•m (30.0 lb-in.) 3. Inspect the linkage between the drive pedals and
potentiometers for wear, damage or looseness. Repair or
replace as needed.

F E
D B M
C A
MX17143
4. Connect the red lead to the volt, ohms, Hz input jack (A) MX17144
of the multimeter and the voltage C terminal (B) of the 12.Move the red lead on the breakout box from the C
breakout box. terminal to the B terminal (M).
5. Connect the black lead to the com input jack (C) of the 13.Verify pedal is released and at the top of travel (TOT)
multimeter and the voltage A terminal (D) of the breakout position.
box.
14.The TOT voltage should be within specification. If not,
6. Connect the 3 pin extender harness (E) into the 3 pin adjust potentiometer.
15.Fully depress the drive pedal being tested to the bottom
7. Set the multimeter to the DCV position (G). of travel (BOT) position.
8. Set breakout box switch to off position (H). 16.The BOT voltage should be within specification. If the
voltage is within specification, calibrate the drive pedal
potentiometer. If not, replace and adjust the drive pedal
J K potentiometer.
17.Turn the key switch to the off position.
wiring harness and the drive pedal potentiometer.
19.Connect the machine wiring harness to the drive pedal
potentiometer.
L
20.Repeat this procedure for the remaining drive pedal
potentiometer if needed.
21.Install the drive potentiometer cover.
I Specification:
MX9841 Input Voltage. . . . . . . . . . . . . . . . . . . . . . . . 5.0 ± 0.2 volts
Picture Note: Reverse potentiometer shown. TOT Position Signal Voltage1 . . . . . . . . . . 0.6 - 0.8 volts
9. Connect the position sensor Y connector (I) between the TOT Position Signal Voltage2 . . . . . . . . . . 0.4 - 0.8 volts
drive potentiometer (J) being tested, the machine wiring BOT Position Signal Voltage . . . . . . . . . . . 3.6 - 4.5 volts
1. Early Models S/N - H120712, - H131963, - H141271
2. Late Models S/N H120713 -, H131964 -, H141272 -
See “Power Circuit Operation” on page 158.

eHydro - Drive Pedal Potentiometer
M
Adjustment and Calibration J K
Reason: M
To adjust the drive pedal potentiometer for the proper

voltage with the drive pedals in the TOT and BOT positions.
Equipment:
• JDG1575 Test Kit L
2. Remove cover from forward and reverse pedal bracket
I
located under operator’s floor platform.
MX9841
3. Inspect the linkage between the pedals and
potentiometers for wear, damage or looseness. Repair or Picture Note: Reverse potentiometer shown.
replace as needed. 9. Connect the position sensor Y connector (I) between the
drive pedal potentiometer (J) being tested, the machine
wiring harness (K), and the extender harness (L).
F E
D
B 11.Loosen the lock nuts (M) enough that the potentiometer
will stay in place without turning, but can be rotated by
hand.
12.With the pedal in the TOT position, rotate the
G
potentiometer until the meter reading is within specification.
IMPORTANT: Avoid damage! Torque specification is

A critical.
H
13.With the calibration kit still attached, tighten the two nuts
to specification, being sure that the voltage reading does
not change.
14.Fully depress the pedal being tested to the BOT
position.
C 15.The BOT voltage should be within specification. If the
voltage is within specification, calibrate the drive
MX17144
potentiometer. If not, replace and adjust the potentiometer.
4. Connect the red lead to the volt, ohms, Hz input jack (A) 16.Turn the key switch to the off position.
of the multimeter and the voltage B terminal (B) of the
breakout box. 17.Repeat this procedure for the remaining drive pedal
potentiometer if needed.
multimeter and the voltage A terminal (D) of the breakout Specification:
box.
TOT Position Signal Voltage1 . . . . . . . . . 0.7 ± 0.08 volts
TOT Position Signal Voltage2 . . . . . . . . . . 0.6 ± 0.1 volts
BOT Position Signal Voltage . . . . . . . . . . . 3.6 - 4.5 volts
1. Early Models S/N - H120712, - H131963, - H141271

2. Late Models S/N H120713 -, H131964 -, H141272 -

Calibration Procedure: eHydro - Flywheel Speed Sensor Test
1. Turn key switch to the off position.
Reason:
2. Unplug the position Y connector from the machine
To verify proper input voltage to the flywheel speed sensor
wiring harness and the drive potentiometer.
and proper output frequency with the engine running at
3. Connect the machine wiring harness to the drive both low and high idle.
potentiometer.
4. Drive pedals must be in the TOT position. Equipment
Procedure:
N
2. Verify engine rpm is set correctly.
• Low idle 950 rpm.
• High idle 2750 rpm.
Adjust as needed before testing the flywheel speed sensor.
See Engine Section.
F E
D B
MX10694
6. The fault light (N) should display the 1 short, 1 long, and G
2 short flash (• - • •) fault code for forward or the 2 long and
2 short flash (- - • •) fault code for reverse.
7. Wait 5 seconds then move the pedal being calibrated to
H
the BOT position.
8. After 5 seconds the fault light should turn off.
9. When the flash code ends the drive potentiometer being
tested is calibrated.
10.Repeat this procedure for the remaining drive pedal
potentiometer if needed. C A
11.Turn the key switch to the off position. MX17143
12.Install the drive potentiometer cover. 3. Connect the red lead to the volt, ohms, Hz input jack (A)
of the multimeter and the voltage C terminal (B) of the
breakout box.
multimeter and the voltage A terminal (D) of the breakout
box.

16.The frequency should be within specification. If not,
replace the flywheel speed sensor.
J 18.Unplug the speed sensor adaptor harness from the
machine wiring harness and the flywheel speed sensor.
19.Connect the machine wiring harness to the flywheel
K speed sensor.
Specification:
L Input Voltage. . . . . . . . . . . . . . . . . . . . . . . . 5.0 ± 0.2 volts
Frequency at 950 rpm . . . . . . . . . . . . . . . . . . 2011 ± 10%
Frequency at 2750 rpm . . . . . . . . . . . . . . . . . 5821 ± 10%
I eHydro - MFWD Speed Sensor Test
MX9842 Reason:
8. Connect the speed sensor Y connector (I) between the To verify proper input voltage to the MFWD speed sensor
flywheel sensor (J), the machine wiring harness (K), and and proper output frequency.
the extender harness (L).
Equipment
See “Power Circuit Operation” on page 158. Procedure:
M c CAUTION: Avoid injury! MFWD is normally

engaged. All four wheels must be free to turn.
2. Place machine safely on jack stands so that all wheels
are off the ground and free to spin.
F E
D B
A
H
MX17144
11.Move the red lead on the breakout box from the C

12.Press the button labeled Hz on the multimeter.
C
MX17143
replace the flywheel speed sensor. 3. Connect the red lead to the volt, ohms, Hz input jack (A)
of the multimeter and the voltage C terminal (B) of the
15.Move the throttle lever to the high idle position.
breakout box.

multimeter and the voltage A terminal (D) of the breakout
box.
5. Connect the 3 pin extender harness (E) into the 3 pin M
J
K
MX17144
11.Move the red lead on the breakout box from the C

12.Place the range transmission in gear position A.
L
I 13.Press the button labeled Hz on the multimeter.
15.Fully depress the forward drive pedal.
MX9843
17.Move the throttle lever to the high idle position with
8. Connect the speed sensor Y connector (I) between the forward pedal fully depressed.
MFWD sensor (J), the machine wiring harness (K), and the
extender harness (L). 18.The frequency should be within specification. If not,
See “Power Circuit Operation” on page 158. 20.Unplug the speed sensor adaptor harness from the
machine wiring harness and the MFWD speed sensor.
21.Connect the machine wiring harness to the MFWD
speed sensor.
Specification:
Input Voltage. . . . . . . . . . . . . . . . . . . . . . . . 5.0 ± 0.2 volts
Frequency at Low Idle . . . . . . . . . . . . . . . . 190 Hz ± 10%
Frequency at High Idle. . . . . . . . . . . . . . . . 550 Hz ± 10%

eHydro - Proportional Solenoid Test
Reason:
To test the forward or reverse proportional valve coils for
proper input current.
J K
Equipment L
Procedure:
MX9844
G 7. Connect the e-HYDRO Y connector (I) between the
H
forward proportional solenoid (J), the machine wiring
8. Start and run the engine at low idle with operator in seat
and range transmission in neutral.
9. Set breakout box switch to test position.
B D 10.Fully depress the forward drive pedal.
A C NOTE: If valve or valve coil have been replaced, the

F controller will need to be recalibrated, See “eHydro -
Electronic Operating System Automatic Calibration”
on page 312.
11.The amperage reading should be within specification. If
E not, See “Proportional Drive Solenoid Test - eHydro” on
MX17142 page 296, or see eHydro drive circuit diagnosis.
2. Connect the red lead to the mA input jack (A) of the 12.Turn the key switch to the off position.
multimeter and the current A terminal (B) of the breakout
13.Unplug the eHydro adaptor harness from the machine
box.
wiring harness and the proportional solenoid.
14.Connect the machine wiring harness to the proportional
multimeter and the current com terminal (D) of the breakout
solenoid.
box.
15.Repeat this procedure for the remaining proportional
solenoid.
5. Set the multimeter to the DC mA position (G). Specification:
6. Set breakout box switch to the off position (H). NOTE: Amperage value may be either positive or
negative.
BOT Amperage . . . . . . . . . . . . . . . . . . . . .950 +25/-50 mA

eHydro - Electronic Operating System NOTE: The calibration fuse may be located in either the
Automatic Calibration F9 or the F11 position in the load center. If the fuse is in
the F9 position, the F10, and F12 positions will be
Reason: empty. If the fuse is located in the F11 position, there
will be a fuse in the F10 position as well.
To calibrate the electronic operating system to match the
components if any one or more of the following
components have been replaced:
K11 K12
DB2
K7 K8
K9 K10
• Proportional valve.
DB1
• Proportional valve coil.
• Drive controller.
K1
K4
• Complete hydrostatic transmission.
F1
F2
F3
F4
B
B
A
A
F5
F6
F8
F7
B
B
A
A
Procedure: Entering Calibration Mode
F10
F11
F12
F9
A
A
B
B
K2
K5
2. Verify that both the high and low engine rpm are set to
K13 K14
K15 K16
K17 K18
specification before starting calibration.
K6
K3
c CAUTION: Avoid injury! MFWD is normally
engaged. The wheels will spin during the B C B C
calibration process. Be certain that all four MIF
wheels are safely supported by jack stands and
that all other persons and objects are clear of 6. Move the 10 amp fuse (B) from its original position of F9
the wheels. or F11, one position to the right to the F10 or F12 (C)
position in the load center.
NOTE: Be sure the wheels can spin freely as the 7. Start and run the engine at low idle with the operator on
calibration process cannot detect any resistance that the seat.
may be present. This will result in faulty calibration
results.
3. Place the machine on jack stands and fully release the D
park brake.
4. Set the range transmission to gear position A and have
an operator on the seat.
MX10682
8. When the calibration mode is active, the fault code light

A (D) is switched on solid.
9. Once the fault code light is switched on solid, move the
10 amp fuse back to its original position.
10.The fault code light (D) will flash a 4-digit flash code,
MX10682
beginning with the forward pedal. As soon as a sensor is
Picture Note: Cruise Control option shown. calibrated properly the corresponding flash code will
5. Place the MFWD switch (A) in the off position. disappear and the next fault code in the calibration
sequence will begin.

When the calibration process has been successfully 13.The fault code light should flash the threshold fault code
completed the fault code light will be off. of 1 short and three long flashes (• - - -). If not, the throttle
potentiometer is not adjusted properly. Adjust the throttle
11.Exit the calibration mode by shutting off the machine
potentiometer and recalibrate.
and waiting at least three seconds before restarting the
engine. 14.When the fault code light flashes the threshold fault
code of one short and three long flashes (• - - -), begin the
Procedure: Calibration Sequence valve threshold calibration for the forward valve.
1. Enter the calibration mode. 15.Fully depress the forward pedal and hold until there is a
slight wheel movement then release the pedal.
• If there is no wheel movement after 25 seconds,
A check the hydraulic supply to the valve and the wiring to
the valve and recalibrate.
16.When the fault code light flashes the threshold fault
code of one short and three long flashes (• - - -), begin the
valve threshold calibration for the reverse valve.
17.Fully depress the reverse pedal and hold until there is a
slight wheel movement then release the pedal.
• If there is no wheel movement after 25 seconds,
check the hydraulic supply to the valve and the wiring to
the valve and recalibrate.
MX10682 18.When the calibration has been completed no fault code

should be displayed. If a fault code is being displayed, See
2. When the fault code light (A) flashes the forward fault “eHydro Electronic Operating System Fault Code Chart” on
code of one short, one long and two short flashes (• - • •), page 151.
begin the forward pedal calibration.
3. Leave forward pedal in TOT position for 5 seconds.
4. Fully depress and hold the forward pedal for 5 seconds
then release the pedal.
5. The fault code light should flash the reverse fault code of
two long and two short flashes (- - • •). If not, the forward
potentiometer is not adjusted properly. Adjust the forward
6. When the fault code light flashes the reverse fault code
of two long and two short flashes (- - • •), begin the reverse
pedal calibration.
7. Leave reverse pedal in TOT position for 5 seconds.
8. Fully depress and hold the reverse pedal for 5 seconds
then release the pedal.
9. The fault code light should flash the throttle fault code of
three short and one long flashes (• • • -). If not, the reverse
potentiometer is not adjusted properly. Adjust the reverse
10.When the fault code light flashes the throttle sensor fault
code of three short and one long flashes (• • • -), begin the
throttle sensor calibration.
11.Leave the throttle lever in the low idle position for 5
seconds.
12.Move the throttle lever to the high idle position for 5
seconds and leave at high idle.


ELECTRICAL EUROPEAN EUROPEAN ELECTRICAL SECTION
Electrical European
European Electrical Section
European Electrical Theory

The European road machines have the same electrical
circuits as the North American machines with the addition
of lighting circuits required to meet EEC Machinery
Directives.
The main electrical wiring harness is specific to the
European models, and is identical among all of the
European 4210, 4310 and 4410 series machines.
Lighting additions include the hazard lights switch, flasher
relay, brake lights, position lights, and additional control
panel indicator lights (2-speed PTO, and trailer indicator
lights).
The European machines have front and 2-speed PTOs
(540 and 750 rpm) with control panel indicator lights.
The European machine wiring harness contains the same
wires (both color and number) as the North American
machines, with additional wires required for the additional
circuits.
There are variations between the North American and
European main wiring harnesses in connector to wire pin
locations and numbers. While some circuits such as the
Cranking Circuit may be identical, other circuits contain
differences that require using the diagnosis sections
specific to either North American or European machines.
Common components (such as the key switch, fuel shutoff
solenoid, or park brake switch) are cross referenced to the
shared Electrical Tests and Adjustments section. See
“Tests And Adjustments”. The tests and adjustments given
in this section can be used by any North American or
European service technician.
Electrical European European Electrical Section - 315

ELECTRICAL EUROPEAN COMPONENT LOCATION
Component Location
Instrument Panel
B D
A C E
F G H J K L
I
M N O P Q R
S T
X
W
V
MIF
A - Fuel Gauge
B - Left Turn Light
C - Engine Tachometer
D - Right Turn Light
E - Engine Coolant Temperature Gauge
F - 750 rpm Rear PTO Light
G - Mid PTO Light
H - Front PTO Light
I - Hour Meter
J - Bulb Integrity Light
K - Trailer 1 Light
L - Trailer 2 Light
M - 540 rpm Rear PTO Light
N - Cruise Indicator Light (opt. eHydro)
O - Cold Start Light
P - Discharge Light
Q - Park Brake Light
R - Engine Oil Pressure Light
S - Hazard Lights Switch
T - Horn Switch
U - Turn Signal Switch
V - Load Match Switch (opt. eHydro)
W - Light Switch
X - Throttle Lever
Electrical European Component Location - 316

Machine Front Section
L M
N
O
K
J P
I
H
F
E
D
C
Q
T
B
U
V
A
Y X
MIF M - Light Switch

A - Battery N - Instrument Panel
B - Headlights O - Load Match Switch (opt. eHydro)
C - Frame Ground P - Turn Signal Switch
D - Engine Coolant Temperature Switch Q - Drive Controller (ePowrReverser and eHydro)
E - Fuel Shutoff Solenoid R - X5 Connector
F - Manifold Heater S - Load Center
G - Flywheel Speed Sensor (eHydro) T - K19 Flasher
H - Fuel Gauge Sensor U - Diagnostic Connector
I - Key Switch V - Engine Oil Pressure Switch
J - Park Brake Switch W - Starting Motor Solenoid and Starting Motor
K - Brake Switch (eHydro) X - Fusible Link
L - Throttle Position Potentiometer Y - Alternator

Machine Rear Section
J K O R
N
I M
L
P
H S
G
V
W
MIF K - Cruise/Max Speed Switch (opt. eHydro)

A - Forward Solenoid L - Mid PTO Solenoid
B - Reverse Solenoid M - MFWD Solenoid
C - Forward Pedal Potentiometer N - Rear PTO Solenoid
D - Reverse Pedal Potentiometer O - Back-up Alarm Connector
E - Rear PTO Switch P - Tail/Turn Lights
F - MFWD Switch Q - Hazard Lights
G - Mid PTO Switch R - Right Lights Connectors
H - Status Indicator Light (ePowrReverser and S - Seat Switch
eHydro) T - Left Lights Connectors
I - Motion Match Switch (ePowrReverser and U - MFWD Speed Sensor (eHydro)
eHydro) V - Transmission Neutral Switch
J - Res/+ Set/- Switch (opt. eHydro) W - W6 Jumper wire (eHydro)

Load Center
I
A B
C D
K L M N
O P Q R
S T U V
E F
W Y AA
G
H
X Z AB
MX9720 W - K13 - Neutral Relay

A - V1 - Diode Block X - K14 - Mid PTO Interlock Relay
B - V2 - Diode Block Y - K15 - Mid PTO Lockout Relay
C - K1 - Manifold Heater Relay Z - K16 - Mid PTO Relay
D - K4 - Engine Run Relay AA- K17 - PTO Relay
E - K2 - Start Relay AB- K18 - Brake Light Relay
F - K5 - Trailer Connector Power Relay
G - K3 - Fuel Shutoff Solenoid Pull-in Relay
H - K6 - Fuel Shutoff Solenoid Timer Module
I - K11 - Rear PTO Interlock Relay
J - K12 - PTO interlock Relay
K - F1 - Fuse 30A
L - F2 - Fuse 30A
M - F3 - Fuse 30A
N - F4 - Fuse 30A
O - F5 - Fuse 20A
P - F6 - Fuse 20A
Q - F7 - Fuse 20A
R - F8 - Fuse 20A
S - F9 - Fuse 10A
T - F10 - Fuse 10A
U - F11 - Fuse 10A used in F12 for drive controller
V - F12 - Blank, use F11 for drive controller

ELECTRICAL EUROPEAN SYSTEM SCHEMATICS
System Schematics G1-Battery
G2-Alternator
Schematic and Wiring Harness Legend H1-Backup Alarm
A1-Electronic Drive Controller (ePowrReverser) H3-Cold Start Light
A2-Electronic Drive Controller (eHydro) H4-Park Brake Light
B1-Fuel Gauge Sensor H5-Discharge Light
B2-Engine Oil Pressure Switch H6-Right Turn Light
B3-Engine Coolant Temperature Sensor H7-Cruise Indicator Light
B4-Forward Pressure Transducer (ePowrReverser) H8-Left Turn Light
B5-Reverse Pressure Transducer (ePowrReverser) H9-Oil Pressure Light
B6-Horn H11-ePowrReverser Indicator Light
E1-Left Front Turn/Hazard Light H12-Backup Alarm (ePowrReverser)
E2-Left Rear Turn/Hazard Light H13-eHydro Indicator Light
E3-Right Front Turn/Hazard Light H14-Backup Alarm (eHydro)
E4-Right Rear Turn/Hazard Light H15-Front PTO Light
E5-Left Headlight H16-Mid PTO Light
E6-Right Headlight H17-750 rpm PTO Light
E7-Left Work Light H18-540 rpm PTO Light
E8-Right Work Light H19-Trailer 2 Light
E9-Left Front Position Light H20-Bulb Integrity Light
E10-Left Rear Position Light H21-Trailer 1 Light
E11-Left Brake Light K1-Manifold Heater Relay
E12-Right Front Position Light K2-Start Relay
E13-Right Rear Position Light K3-Fuel Shutoff Solenoid Pull-in Relay
E14-Right Brake Light K4-Engine Run Relay
E15-License Plate Light K5-Trailer Connector Power Relay
F1-Fuse 30A K6-Fuel Shutoff Solenoid Timer Module
F2-Ruse 30A K11-Rear PTO Interlock Relay
F3-Fuse 30A K12-PTO Interlock Relay
F4-Fuse 30A K13-Neutral Relay
F5-Fuse 20A K14-Mid PTO Interlock Relay
F6-Fuse 20A K15-Mid PTO Lockout Relay
F7-Fuse 20A K16-Mid PTO Relay
F8-Fuse 20A K17-PTO Relay
F9-Fuse 10A K18-Brake Light Relay
F10-Fuse 10A K19-Flasher
F11-Fuse 10A used in F12 for drive controller calibration M1-Starting Motor)
start up.
P1-Engine Tachometer
F12-Blank, uses fuse in F11 for drive controller calibration
P2-Hour Meter
start up.
P3-Fuel Gauge
Electrical European System Schematics - 320

P4-Engine Coolant Temperature Gauge Y7-Reverse Proportional Solenoid (ePowrReverser)
R1-Manifold Heater Y8-Reverse Proportional Solenoid (eHydro)
R2-Clutch Position Potentiometer (ePowrReverser) Y9-Forward Proportional Solenoid (eHydro)
R3-Forward Pedal Potentiometer (eHydro) Y10-Front PTO Clutch
R4-Throttle Position Potentiometer (eHydro)
Connectors:
R5-Reverse Pedal Potentiometer (eHydro)
X1-W1 Main Wiring Harness to Fusible Link
S1-Key Switch X2-W1 Main Wiring Harness to Y2 Fuel Shutoff Solenoid
S2-Seat Switch
X3-W1 Main Wiring Harness to Backup Alarm
S3-Transmission Neutral Switch
X4-W1 Main Wiring Harness to S3 Transmission Neutral
S4-Park Brake Switch Switch
S5-Rear PTO Switch X5-W1 Main Wiring Harness to W2 SST Jumper Wiring
Harness, or W3 ePowrReverser Wiring Harness, or W4
S6-Mid PTO Switch
eHydro Wiring Harness
S7-MFWD Switch
S8-Turn Signal Switch
S9-Light Switch
X9-W1 Main Wiring Harness to Left Front Lights
S10-F-N-R Switch (ePowrReverser)
X10-W1 Main Wiring Harness to E2 Left Turn/Hazard Light
S11-Clutch Switch (ePowrReverser)
X11-W1 Main Wiring Harness to Right Rear Lights
S12-Motion Match Switch (ePowrReverser)
X12-W1 Main Wiring Harness to E4 Right Turn/Hazard
S13-Brake Switch (eHydro) Light
S14-Load Match Switch (eHydro) X13-W1 Main Wiring Harness to E11 Left Brake Light
S15-Res/Accel, Set/Decel Switch (eHydro) X14-W1 Main Wiring Harness to E10 Left Rear Position
S16-Cruise Control/Max Speed Switch (eHydro) Light
S17-Motion Match Switch (eHydro) X15-W1 Main Wiring Harness to E14 Right Brake Light
S18-Front PTO Switch X16-W1 Main Wiring Harness to E13 Right Rear Position
Light
S19-540 rpm PTO Switch
X17-W1 Main Wiring Harness to E7 Left Work Light
S20-750 rpm PTO Switch
X18-W1 Main Wiring Harness to Left Rear Lights
S21-Brake Light Switch
X19-W1 Main Wiring Harness to E8 Right Work Light
S22-Hazard Light Switch
X20-W1 Main Wiring Harness to Right Front Lights
S23-Horn Switch
T1-Flywheel Speed Sensor (eHydro) Drive Controller
T2-MFWD Speed Sensor (eHydro) X22-W3 ePowrReverser Wiring Harness to A1 Electronic
V1-Diode Block Drive Controller Diagnostic Interface (ePowrReverser)
V2-Diode Block X23-W3 ePowrReverser Wiring Harness to A1 Electronic
Drive Controller Diagnostic Interface (ePowrReverser)
W1-Frame Ground
X24-W3 ePowrReverser Wiring Harness to R2 Clutch
Y1-Starting Motor Solenoid
Position Potentiometer (ePowrReverser)
Y2-Fuel Shutoff Solenoid
X25-W4 eHydro Wiring Harness to A2 Electronic Drive
Y3-MFWD Solenoid Controller
Y4-Main PTO Solenoid X26-W4 eHydro Wiring Harness to A2 Electronic Drive
Y5-Mid PTO Solenoid Controller Diagnostic Interface (eHydro)
Y6-Forward Proportional Solenoid (ePowrReverser) X27-W4 eHydro Wiring Harness to W5 Cruise Control

Wiring Harness
X28-W4 eHydro Wiring Harness to R3 Forward Pedal
Potentiometer
X29-W4 eHydro Wiring Harness to T1 Flywheel Speed
Sensor
X30-W4 eHydro Wiring Harness to R4 Throttle Position
Potentiometer
X31-W4 eHydro Wiring Harness to T2 MFWD Speed
Sensor
X32-W4 eHydro Wiring Harness to R5 Reverse Pedal
Potentiometer
X34-W1 Main Wiring Harness to S21 Brake Light Switch
X36-W1 Main Wiring Harness to E1 Left Front Turn/Hazard
Light
X37-W1 Main Wiring Harness to E3 Right Front Turn/
Hazard Light
X39-W1 Main Wiring Harness to E15 License Plate Light
X40-W1 Main Wiring Harness to E9 Left Front Position
Light
X41-W1 Main Wiring Harness to E12 Right Front Position
Light
Wiring Harnesses:
W1-Main Wiring Harness
W2-SST Jumper Plug Wiring Harness
W3-ePowrReverser Wiring Harness
W4-eHydro Wiring Harness
W5-Cruise Control Wiring Harness (standard)
W6-Cruise Control Wiring Harness (optional)

W1 Main Electrical Schematic
002A Red F3 Fuse
Fuse Block Internal Link 122C Red
F4 Fuse 042C
X3 002D Red Red
562C Red
F1 4
012 072D Red 072D Red
072A Red 072A Red
385A Dk Grn
2 5 072B Red
562K Red 562K Red
3 212A Red 072C F5 Fuse 556 Lt Blu
S1 Key
7 385B Dk Grn 562F Red A
Switch
562E Red 562F Red
Start
Run 385A Dk Grn
Off
Acc. 572B Red X5
S2 Seat H
Aid
002C Switch 539A 1
Red Off
Wht 2 556 Lt Blu
(Off Seat)
572D Red 3
(On Seat)
002B Red 385C V1 Diode
Dk Grn Block 1 X5 to W2 SST,
539D Wht 539B Wht 4
X1 5 W3 ePRT, W4 eHST
521
30 86 K1 518A Gry 6 Brn Wiring Harness
Manifold X5
Fusible Heater 539C Wht
Link 87A 87 85 Relay J
383 S3 Transmission
Org 050E Neutral Switch In Neutral
Blk In Gear
050F X4
Blk X4 575B Dk Grn
572C 518B Gry
Red
R1 Manifold 30 86 002D
Heater K2 X5 F2
Red
Start 303 E Fuse
002A Red 87A 87 85 Relay V1 Lt Blu F10
Diode 30 86 K4 212B Fuse
Block 1 Red
309 Wht Engine
B A 010F 87A 87 85 Relay 212C 252 552
010Z Blk Red Red Red
Blk 302B
Red 86
X2 302C Red
30 K5 F X5
Trailer
050F Blk Relay
M 85 87 87A
050G Blk
Wht 222
Red X33
M1 Y2 Fuel
Shutoff 521 A
Starting Brn
050H Blk
Motor Solenoid
Wht 30 86 K6
Blk 010J B
Red Y1 X2 Fuel Solenoid Blk
Starting Timer Module X33 Trailer
Motor 329 85 87 87A
Solenoid Wht
304 Org Connector
562S Red
X2 30 86 K3 Fuel
G1
010N Shutoff
X5
Blk Dk Grn
010AJ L
010F 050C Blk
Blk Blk 562S Red
B
050A Blk 050A Blk
010D Blk 010D Blk
010P Blk 010P Blk
010C Blk 010C Blk
Unswitched Power Switched Primary Power

MIF

002A Red 002A Red

122C Red 122C Red
042C Red 042C Red
072D Red 072D Red

072A Red 072A Red
385A Dk Grn 385A Dk Grn
562K Red 562K Red
S4 Park
562B Red Brake Switch
On
Off
S18 Front C 586 Lt Blu
562B Red B
PTO Switch
On D 505 Dk Grn
577A Pur A
562L Red Off
562N Red A B 737C Pur 737B Pur
C
D E
575A Dk Grn F
G
H 573A Org
737A Pur 010AR Blk

S5 Rear
PTO Switch On Y10
Front PTO W1
562F Red Off
Clutch
562G Red A B 574C Yel 574C Yel
C
F
562G Red G 578 Gry
H 1
562H Red 573B Org F12
V2 Diode 562K
Block 2 Red Fuse
2 562M Red 311 Brn X5
579C D
Wht
86 30
K14 Mid
S6 Mid PTO
Latch 573C 594B
PTO Switch On
Yel
85 87 87A Org
Off
Relay 562P 86 30
010AC 581
Red K17
583 Org Blk Brn
579A Wht A B PTO
C
D E Relay 85 87 87A
F 562S Red
562H Red G 010T
H 577C Pur
562J Red 582 579D Blk
583
Red Wht Org
86 30 K15 Mid 86 30 K16
S7 MFWD Unlock PTO
Switch Mid PTO 743
Lock Lockout Relay
85 87 87A Org
1 555 Wht Relay 85 87 87A
562J Red 2 Y3 010AN 581 010AP 594C
3 557 Pur Blk Brn Blk Yel
MFWD
010 AM Blk 7 8
Solenoid 594A
Yel
Y5
Mid PTO
010AG
Blk Solenoid
562S Red 010AH
Blk
050A Blk
010D Blk
010P Blk
010C Blk

MIF

002A
002A Red Red
122C Red 122C Red
042C Red 042C Red
072D Red 072D Red

072A Red
385A Dk Grn B G2
G Alternator
556 Lt Blu 072A
Red IG
L
P 334
575D 556 X7
Dk Grn Lt Blu 325 Yel A H5
30 86 K12 Dk Grn Discharge
PTO X8 F
586 Lt Blu Light
Interlock
505 Dk Grn 87A 87 85 Relay X7 C _
533 010AA
385A Dk Grn +
Org Blk
737B Pur
X35A
562L Red X8 A
586 Lt Blu K H4 Park H15 Front
X8 Brake PTO Light
Light
S19 540 rpm

P
PTO Switch Off
On
574C Yel 574A Yel X7 B
777 Pur
X5
G
H18 540
505 519 S20 750 rpm PTO Light
Dk Grn Pur PTO Switch
30 86 K13 n/min
Neutral Off H3 Cold

Relay On P1 Engine
87A 87 85 Start Tachometer
546 010AB 574B Yel X7 F Light
Lt Blu Blk 757 Pur
P2 Hour
575C 546 H17 750
Dk Grn Lt Blu Meter
86 30 K11 Rear PTO Light
PTO
Interlock
85 87 87A
Relay
010W 533
Blk Org
Y4
Rear PTO
Solenoid G H7 Cruise H16 Mid
574D X8 Indicator
Yel Light (Option) PTO Light
264
010AF Yel D
D X35
Blk C X8
X5 743
Org
050D
Blk
050A Blk
010D Blk
010P Blk
010C Blk

MIF

Internal Ground
Connections
122B Red
042C Red E1 Left Front

Turn/Hazard E3 Right Front
072D Red
Light Turn/Hazard
Light
S22 X36
Hazard On E2 Left Rear
042B
Switch Off Red 072D
Red Turn/Hazard X10
102 Red Light
3
2
1 115C Dk Grn X37
17
125C Dk Grn
18 S8 Turn E4 Right Rear
050K Blk 127C Pur
10 5 Signal (0) Right X12 Turn/Hazard
Switch (1) Off Light
(2) Left 115C 115E 115F
49 K19 1 115A Dk Grn Dk Grn Dk Grn
Flasher Flasher
5 Dk Grn 115D Dk Grn A
49a 127D Pur 127B Pur 4
050J Blk
X38 Trailer
31 C3 C C2 2 125C 125E 125F
127A Pur 3 Dk Grn Dk Grn Dk Grn Connector
125A
144 148 146 C
6 Dk Grn 125D Dk Grn
Yel Gry Lt Blu
562L Red X8 A
G E F
X35
125B 115B
Dk Grn Dk Grn
H20 Bulb X7
H19 Trailer H21 Trailer X7
Integrity E D
2 Light Light 1 Light
H8 Left H6 Right
2 1 Turn Turn
Light Light
042A
Red S21 Brake
Light Switch
X34
Off
D S23 Horn 122A
On Red
Blu X8 Switch
Blu
050D
Blk
X34
903
116 042D Org
Lt Blu Red
86 30 K18
Brake
B6
Light Horn
85 87 87A Relay
010M 136A 010AK
Blk Lt Blu Blk
050A Blk 050A Blk

010D Blk
010P Blk 010P Blk
010C Blk 010C Blk

MIF

S9 Light Internal Ground

Switch (0) Off Connections
(1) Hazard E8 Right Work
(2) Road Light (Option)
(3) Field X19 X19
147C Pur Pur Blk 010K Blk
1
122B Red 103A Org
B
2 103B E7 Left Work
138 Gry 103C Org
Org Light (Option)
3 X17
137 Pur F6 Fuse Pur
X17
147A Pur 147B Pur Blk 010H Blk
4
E6 Right F7 F8
Fuse Fuse
010A Blk Headlight 119A Wht 119C Wht
118A E15 License
Gry
E5 Left 119D Plate Light
Wht F9 X39 X39
Headlight 118E Gry Gry Blk 010AL Blk
010B Blk 119B Wht
X8 Fuse
B 128A
Gry E9 Left Front
Position Light
P3 Fuel X40
118C Gry Gry Blk 010G Blk
Gauge
X9
H9 Oil
Q Pressure 118B E13 Right Rear
Light Gry
Position Light
P4 Engine X16 Gry Blk 010L Blk
Coolant
Temperature 136D X11
Gauge X15 Lt Blu
Lt Blu
t0 E14 Right X38 Trailer

Brake Light Connector
118D Gry B
E
136B Lt Blu
C J 128B Gry D
X8 B1 Fuel X8 E E12 Right Front
353 Gauge X8 Position Light
347
Org Sensor
Pur
359 128D Gry X41 Gry Blk 010Y Blk
Wht
X20
Q B2 Engine
Oil Pressure E10 Left Rear
Switch (NC) Position Light
050B
Blk X14
128C Gry Gry Blk 010X Blk
P X13 X18
136C Lt Blu Lt Blu
E11 Left
B3 Engine Brake Light
050A Blk t0 Coolant
Temperature
010P Blk
Sensor
010C Blk

MIF

W2 SST and W3 ePowrReverser Electrical Schematic

W2 SST Jumper Plug X22 to X23 to S12
Diagnostic Diagnostic Motion Match
X5
A 519 Wht Interface Interface Switch
X5 to W1 521 Brn X22 X23 Off
E
Main Wiring G 519 Wht 924 925 926 927 050H 562F On
Harness Yel Dk Lt Pur Blk Red
L 521 Brn Grn Blu 562E Red
269 Wht
S11
Clutch
Bottom of Travel
X5 596 Lt Blu
A 562A Red 562D Red Y6
B 050A Blk
X5 to W1 S10 Forward
D 311 Brn
Main Wiring E 303 Org F-N-R Proportional
Harness G 519B Wht Switch Forward Solenoid
H 572 Red Neutral
696
J 539 Wht Reverse Lt Blu
L 521 Brn
686 Lt Blu
562C Red 519C Wht
X21 687B Pur 694
303 Org Yel
A1
696 Lt Blu
A2
697 Pur
A3
688 Gry
B1
694 Yel
B2
695 Dk Grn
B3
924 Yel
C1 H12 687C
925 Dk Grn Pur 697
C2 Backup Alarm
572 Red Pur
C3
687A Pur
D1
521 Brn 050F
D2
926 Lt Blu Blk
D3
686 Lt Blu 695
E1
A1 E2
596 Lt Blu Dk Grn
Electronic 311 Brn
E3
519A Wht Y7
Operating F1 Reverse
269 Wht
System F2
F3
Controller 677 Pur Solenoid
G1
050B Blk
G2 677
G3 Pur
676 Lt Blu B5
H1
H2 673D Org
Reverse
H3
591Brn
m Pressure
J1 Transducer
J2 676
J3 050E
562B Red Lt Blu
Blk
K1 B4
927 Pur
K2 673C Org Forward
K3
673A Org
m Pressure
R2
Clutch Position Transducer
H11 ePRT 688 Potentiometer 050D
Indicator Gry Blk
673B Org X24
Light
591 Brn X24
050G X24
Blk 050C Blk

MIF

W4 eHydro and Cruise Control Electrical Schematic
X26 to
Diagnostic
Interface
X26
924 925 050C S14
Yel Dk Blk
Grn Load Match
X5 Switch
B 050A Blk
C 264 Yel Off
D 311 Brn On
X5 to W1 E 521 Brn
F 552A Red 552D Red
Main Wiring 268 Gry
G 519 Wht
Harness J 539 Wht
K 562 Red
L 521 Brn
S13
Brake
Switch
Off
On
552C Red
247 Pur
X25
539 Wht
A1
267 Pur 267 Pur
A2
562B Red 552E Red
A3
673A Org 673A Org
B1
265 Dk Grn 265 Dk Grn
B2
238 Gry 238 Gry
B3
264 Yel
C1
550A Blk 550A Blk
C2
269 Wht 269 Wht
C3
519 Wht
D1
D2
562 Red
D3
925 Dk Grn
E1
A2 050B Blk
E2
Electronic E3
311 Brn
Operating 203 Org
F1
System F2
341 Brn 341 Brn
Controller F3
247 Pur
G1
499 Wht 499 Wht
G2
502 Red 502 Red
G3
268 Gry
H1
924 Yel
H2
687 Pur 687 Pur
H3
688 Gry
J1
J2
J3
696 Lt Blu
K1
K2 696
697 Pur Lt Blu Y9
K3
Forward
Proportional
688 697
Pur 050D Solenoid
Gry Y8 203
Blk
H13 eHydro Reverse Org H14
Indicator Proportional Backup
Light Solenoid Alarm
050E
050F 050G
Blk
Blk Blk

MIF

S16 S18 Cruise W5 Cruise

Cruise/Max Speed Switch Control Wiring
Switch Off
W6 Cruise Harness (standard)
On
Control Wiring Cruise ON
Harness (option) Momentary
Off
562C Red 238 Gry
Max Speed ON
562C Red 238 Gry 562B Red
267 Pur 265 Dk Grn
562A
Red
S15
Res/+, Set/- X27
Switch
552E 265 238
Dk Grn Gry
Res + Red R3
Off Forward Pedal
Set -
562B Red 266 Lt Blu
265 Dk Grn
562A 686 Lt Blu X28

Red
X27 X27 550D Blk X28

552E 265 266 267 238
Red Dk Grn Lt Blu Pur Gry 673C Org X29 T1 Flywheel
Speed Sensor
267 Pur
341 Brn X29
673A Org
265 Dk Grn X29
550C Blk
238 Gry R4
S17 Throttle Position
550A Blk Motion Match X30 Potentiometer
673B Org
269 Wht
Switch
Off
On 499 Wht X30

269 Wht 673F Org
550B Blk X30
686 Lt Blu
341 Brn
Speed Sensor
499 Wht
502 Red 502 Red X31
687 Pur 550F Blk X31

R5
Reverse Pedal
266 Lt Blu
687 Pur X32
550E Blk X32

MIF

W1 Main Wiring Harness
B1
Fuel Gauge B2 Engine Oil
Sensor Pressure
353
Switch (NC)
050B Y2 Fuel
Shutoff
Solenoid
347
010N
329 010C W1 Ground
302C 010D
050A
010P K19
010AR Flasher
102 144
148 146
383
127D 050J
R1 Manifold Heater
302
E5 Left
B6 Horn Headlight 575
119B
AA
903 010AK G2 G2
010B Alternator Alternator 119 050
325 334
B3 Engine 359
072A
Coolant 002A
Temperature
Switch
737A
002A
010AR
Y10
Front PTO 002B
M1 Starting
Clutch 309
Motor
Y1 002C
119A Starting X1 To
Motor
Solenoid Fusible Link
010A Fusible
E6 Right Link
Headlight
MIF

X7 To X8 To
Instrument Panel X35 To Instrument Panel
125B Instrument Panel 264 347
115B 757 146 325 586
D E F 148 144 F G H J K
385A
C B A
334
E F G H
359
E D C B
562L
A
X5 To W2 ePRT D C B A
119D
or W3 eHydro 777 353
Wiring Harness 743 737B
050D
311 264
303 050C S21
552 Brake
562A B A
F E D C
Switch
M L K J H G
305 519
539C 116
572B 042A
122B 138
S8 Turn 3
Signal Switch 385 S9 Light
2 B
127B 103A 4 1 Switch
127A
103
125A 115A 137
572A
072B
5 6 385B
S1 Key 4 7
S22 Hazard
Switch Switch 212 3 8
2 1
050K 125C
072 012
042B 115C
102 127C 572 903 122A 737C
072D S23 Horn 562N
127 562L S18 Front
Switch PTO Switch
122 575A
573A
737
Load Center
562
212
S4
539 042 Park Brake
Switch
AA 562B 586
119 050 575 010A 010C
115 577A 505
125
562C X3 To H1
Backup Alarm
BB
X4 To S3
Neutral Switch
(ePowrReverser)
575B 518B
X4 (eHydro uses
a jumper wire)
MIF

X38
E15 118E Trailer
License Connector
136B
Plate Light 128B
D E F
010AL C B A
115D
125D
118D
S2 X33
Seat Trailer
Switch Connector
562E
539D 222
010J
BB 147 118 128 136
CC
S19 010B
540 PTO
Switch X13 To E2
Left Turn/Hazard Light
574A S20 125F
777
750 PTO X14 To E10 Left Rear Position Light
574B Switch 128C
757 X13 To E11 Left Brake Light
136C
X40 To E9 118C X9 To Left Front Lights
Left Front Position Light 010G
X18 To Left Rear Lights
X36 To E1 125E 010X
Left Front Turn/Hazard Light
S7 MFWD
583 S6 Mid Switch
S5 Rear 579A PTO Switch
PTO Switch 557
574C 562K
562F/562G
582 562H/562J 577C 555
577B
557 010AM
562G/562H 578
573B
Y3 MFWD and
Y4 Rear PTO Solenoid
574D 555
010AG
577 010AF
CC
Y5 Mid PTO
574 010D Solenoid
010AH
X12 To E4
Right Turn/Hazard Light
115F 594A
118B X16 To E13 Right Rear Position Light

136D X15 To E14 Right Brake Light
X41 To E12 128D
Right Front Position Light 010Y X20 To Right Front Lights
X37 To E3 115E
010L X11 To Right Rear Lights
Right Front Turn/Hazard Light
MIF

Relay/Fuse
Diode Block 2 Load Center
Relays
87
Diode Block 1
30 86
K11 K12
DB2
K7 K8
K9 K10
86
DB1
85
87A 87A
87 Fuse Block
85 30
K1
K4
Relay Socket
F1
F2
F3
F4
B
B
A
A
Layouts Relays
F5
F6
F8
F7
B
B
B
B
A
A
F10
F11
F12
F9
A
A
B
B
86 30
K2
K5
K13 K14
K15 K16
K17 K18
K6
K3
85 87 87A
Relay
Schematic
Relays
2 2 1 3 4 6 7 9
1 3 1 3
5 5
4 6 4 6 2 5 8
8 8
7 9 7 9 Diode Block
Schematic
Diode Block
Socket Layout
W1 Main Wiring Harness Splices

010A 072B 072C 128B 572A 572C
010M 072 572
010B 072D 072A 128A 128 128C 572B 572D
010A 010W
010N 128D
010AJ
010P
103B 573A
103 103A 573 573C
103C 147B 573B
010C 147A 147
147C
010G 010K
010H 010B 010L
115A 115D 574A 574C
010J 010Y 574
115B 115 115E 136B 574B 574D
010X
115C 115F 136A 136 136C
136D
010Z 575B
010D 118B 575A 575 575C
010AA
010AN 118C 212B 575D
010C 010AB 118A 118 212A 212
010AK 118D 212C
010AC
010AD 118E
010AP
577B
302A 577A 577 577C
302 302C
119A 119C 302B
010AD 010AF 119
119B 119D
010AL 010D 010AG
010AH 579B
010AM 385B
385 579A 579 579C
385A 385C
122A 579D
122 122C
122B
042A 042C
042
042B 042D 539C 594B
539 539B 594A 594
125A 125D 539D 594C
125B 125 125E
050A 050C 125C 125F
050B 050D 737B
050 737A 737
050J 050E 562A 562B 737C
050K 562C 562E
127A 562
562N 562F
127B 127 127D 562L 562D
127C
MIF

Diode Block Wire Connections
1 2 3 4 5 6 7 8 9
DB1 539A 556 572D 539A/539B 521 518A 010Z/010E 302A ---
DB2 578 579B --- --- --- --- --- --- ---
Fuse Block Wire Connections

F8 20A 103B 118A
Size A B F9 20A 103C 128A
F1 30A 002 012 F10 10A 212B 552
F2 30A 002C 252 F11 10A --- ---
F3 30A 002 122C F12 --- 562M/562P 311
(calibration)
F4 20A 002D 042C
NOTE: Fuse F6 is used with work light option, Fuse F11
F5 20A 072C 562D/562K
is moved to F12 to start the calibration procedure.
F6 20A 137 147A
F7 20A 138 119C
Relay Wire Connections
86 85 30 87 87A
K1 385C 050E/050F 002B 383 ---
K2 518A/518B 010E/010F 572C 309 ---
K3 304 010F/010T 329 010AJ ---
K4 303 050F/050G 002D 302B ---
K5 212 050G/050H 252 222 ---
K6 050H 304 521 305 562S
K11 575C 010W 546 533 ---
K12 556 010AA 575D --- 533
K13 519 010AB 505 546 ---
K14 579C 010AC 562K/562M 581 ---
K15 582 010AN 579D --- 581
K16 583 010AP 562P/562S 594C ---
K17 573C 010T 594B --- 743
K18 116 010M 042D 136A ---

W2 SST Jumper Plug Wiring Harness
519 519
G A
X5 To W1
FEDCBA
Main Wiring
Harness
521 M F 521
MIF

S10 F-N-R Switch
X5 To W1 686 519C
Main Wiring D C B A
Harness
050A 562C 687B
311
562A 303
519B
572 521
539
562
X21 To ePRT
Controller CC
697 695 572 926 311 539 673A
687
696 269 519

694 050B
925
521
596 927
303 688 924 687A 686 519A 677 676 591 562B
R2
Clutch
Position 050C
562D 596 Potentiometer 591
S11 673B
Bottom of Clutch
Switch
MIF

W3 ePRT WIRING SPLICES

050D
050A 050E 562A 562D
050B 050 050F 562B 562 562E
050C 050G 562C 562F
050H
673A 673C
673
673B 673D
519B
519A 519
519C
X22 To 687A
687 687C
Diagnostic Interface 687B
X23 To
925 926 Diagnostic Interface
562F 050H
924 927
S12
Motion Match
Switch
269
562E
050
CC
673
688
050G
H11 ePRT
Indicator Lamp
H12
Back Up Alarm
687C 050F
Y6 Forward B5 Reverse
Valve Transducer
B A 673D 050E
673C
B A
694
696 677
697 050D
695 676
Y7 Reverse B4 Forward
Valve Transducer
MIF

S14
Load Match
Switch X26 To
X5 To W1 Diagnostic Interface
268
Main Wiring 925
Harness 552D
264 311
050A 521
924 050C
552A
519
521
539 562
552 050
X25 To eHydro DD
Controller
552B 238 269 562 311 341 502 687 697
267 686
265 499
550A 924
266
050B
539 673A 264 519 925 203 247 268 688 696 341
C B A
550C 673C
T1 Flywheel
Speed Sensor
550B
R4 499 S13 247
Throttle 673B Brake 552C
Position Switch
Potentiometer
MIF

W4 eHydro WIRING SPLICES

050C
552A
050A 050D 552B
050 050E 552 552E
050B 552C
050F 552D
050G
H13 eHydro
Indicator Lamp
673D 688 S17
550A 550D 673A
673B 673
673E 050F Motion Match
550B 550 550E 673F
550C 550F 673C Switch
673G
269
673F
X27 to W5 or W6
Cruise Control
Wiring Harness
552E A B C D E
265
238
266
267
673G
502
550
550F
DD C B A
673
T2 MFWD
Speed Sensor
203 050G
H14
Back Up Alarm
696 050D 050E 697
Y9 Forward Y8 Reverse
Proportional Proportional
Solenoid Solenoid
673D 673E
686 687
R3 550D R5 550E
Forward Reverse
Potentiometer Potentiometer
MIF

W5 Cruise Control Wiring Harness (standard)
S16
Cruise X27 to W4
Switch eHydro
562B Wiring Harness
238 265 562A 562C
A B C D E
562A
562B 562C
265
238
MIF
W6 Cruise Control Wiring Harness (optional)
S16
Cruise/Max Speed
Switch
238 X27 to W4
562C eHydro
267 562B Wiring Harness
562A 562C
S15
Res/+ A B C D E
562A
Set/- 265
Switch 238
266
266
267
562B
265
MIF

W1 Main Wiring Harness Color Codes Size/No./Color Wire Connection Points
Size/No./Color Wire Connection Points 0.8 010AK Blk Splice 010C, B6
2.0 002A Red Y1, G2 0.8 010AL Blk Splice 010D, E15
2.0 002B Red X1 Fusible Link, K1 0.5 010AM Blk Splice 010D, S7
2.0 002C Red X1 Fusible Link, F1 0.5 010AN Blk Splice 010C, K15
2.0 002D Red F2, F3, F4, K5 0.5 010AP Blk Splice 010C, K16
1.0 010A Blk Splice 010A, E6 1.0 010AR Blk W1, Y10
1.0 010B Blk Splice 010A, E5 1.5 012 Red F1, S1
1.5 010C Blk Splice 010B, W1 1.0 042A Red Splice 042, S21
1.0 010D Blk Splice 010C, W1 1.0 042B Red Splice 042, S22
0.5 010E Blk V1, K2 1.0 042C Red Splice 042, F4
0.5 010F Blk K2, K3 1.0 042D Red Splice 042, K18
0.8 010G Blk Splice 010B, E1, E9 1.2 050A Blk Splice 050, W1
1.2 010H Blk Splice 010B, E7 0.5 050B Blk Splice 050, B1
1.2 010J Blk Splice 010B, X33 0.8 050C Blk Splice 050, X5
1.2 010K Blk Splice 010B, E8 1.0 050D Blk Splice 050, X8
0.8 010L Blk Splice 010B, E4, E13 0.8 050E Blk Splice 050, K1
0.5 010M Blk Splice 010A, K18 0.5 050F Blk K1, K4
1.0 010N Blk Splice 010A, Y2 0.5 050G Blk K4, K5
1.0 010P Blk Splice 010A, W1 0.5 050H Blk K5, K6
0.5 010T Blk K3, K17 1.0 050J Blk Splice 050, K19
0.5 010W Blk Splice 010A, K11 1.0 050K Blk Splice 050, S22
0.8 010X Blk Splice 010B, E2, E14 0.8 072A Red Splice 072, G2
0.8 010Y Blk Splice 010B, E3, E12 1.0 072B Red Splice 072, S1
0.5 010Z Blk Splice 010C, V1 1.0 072C Red Splice 072, F5
0.5 010AA Blk Splice 010C, K12 1.0 072D Red Splice 072, S22
0.5 010AB Blk Splice 010C, K13 1.0 102 Red S22, K19
0.5 010AC Blk Splice 010C, K14 1.0 103A Org Splice 103, S9
1.0 010AD Blk Splice 010C, Splice 010D 1.0 103B Red Splice 103, F8
0.8 010AF Blk Splice 010D, Y4 1.0 103C Org Splice 103, F9
0.8 010AG Blk Splice 010D, Y3 1.0 115A Dk Grn Splice 115, S8
0.8 010AH Blk Splice 010D, Y5 0.8 115B Dk Grn Splice 115, H8
1.0 010AJ Blk Splice 010A, K3 0.8 115C Dk Grn Splice 115, S22

1.0 115D Dk Grn Splice 115, X38 0.8 136C Lt Blu Splice 136, E11
0.8 115E Dk Grn Splice 115, E3 0.8 136D Lt Blu Splice 136, E14
0.8 115F Dk Grn Splice 115, E4 1.2 137 Org S9, F6
0.8 116 Lt Blu S21, K18 1.2 138 Gry S9, F7
1.0 118A Gry Splice 118, F8 0.8 144 Yel K19, X35
0.8 118B Gry Splice 118, E13 0.8 146 Lt Blu K19, X35
0.8 118C Gry Splice 118, E9 1.2 147A Pur Splice 147, F6
1.0 118D Gry Splice 118, X38 1.2 147B Pur Splice 147, E7
0.8 118E Gry Splice 118, E15 1.2 147C Pur Splice 147, E8
1.0 119A Wht Splice 119, E6 0.8 148 Gry K19, X35
1.0 119B Wht Splice 119, E5 0.5 212A Red S1, Splice
1.0 119C Wht Splice 119, F7 0.5 212B Red Splice, F10
1.0 119D Wht Splice 119, X8 0.5 212C Red Splice, K5
1.0 122A Red Splice 122, S23 1.2 222 Red K5, X33
1.5 122B Red Splice 122, S9 1.0 252 Red K5, F2
1.5 122C Red Splice 122, F3 0.8 264 Yel X8, X5
1.0 125A Dk Grn Splice 125, S8 1.0 302A Red Splice 302, V1
0.8 125B Dk Grn Splice 125, H6 1.0 302B Red Splice 302, K4
0.8 125C Dk Grn Splice 125, S22 1.0 302C Red Splice 302, Y2
1.0 125D Dk Grn Splice 125, X38 0.5 303 Lt. Blu K4, X5
0.8 125E Dk Grn Splice 125, E1 0.5 304 Org K3, K6
0.8 125F Dk Grn Splice 125, E2 0.5 305 Dk Grn X5, K6
0.8 127A Pur Splice 127, S8 1.0 309 Wht K2, Y1
0.8 127B Pur Splice 127, S8 0.5 311 Brn F11, X5
0.8 127C Pur Splice 127, S22 0.8 325 Dk Grn X8, G2
0.8 127D Pur Splice 127, K19 1.2 329 Wht Y2, K3
0.8 128A Gry Splice 128, F9 0.8 334 Yel G2, X7
1.0 128B Gry Splice 128, X38 0.5 347 Pur B2, X8
0.8 128C Gry Splice 128, E10 0.5 353 Org B1, X8
0.8 128D Gry Splice 128, E12 0.5 359 Wht B3, X8
1.2 136A Lt. Blu Splice 136, K18 1.2 383 Org K1, R1
1.0 136B Lt. Blu Splice 136, X38 0.8 385A Dk Grn Splice 385, X7

1.0 385B Dk Grn Splice 385, S1 1.0 572A Red Splice 572, S1
1.0 385C Dk Grn Splice 385, K1 0.8 572B Red Splice 572, X5
0.5 505 Dk Grn S4, K13 1.0 572C Red Splice 572, K2
0.5 518A Gry V1, K2 0.5 572D Red Splice 572, V1
0.5 518B Gry K2, S3 0.5 573A Org Splice 573, S18
0.5 519 Pur K13, X5 0.5 573B Org Splice 573, S5
0.5 521 Brn V1, K6 0.5 573C Org Splice 573, K17
0.5 533 Org K11, K12 0.8 574A Yel Splice 574, S19
0.5 539A Wht V1, V1 0.8 574B Yel Splice 574, S20
0.5 539B Wht Splice 539, V1 0.8 574C Yel Splice 574, S5
0.5 539C Wht Splice 539, X5 0.8 574D Yel Splice 574, Y4
0.5 539D Wht Splice 539, S2 0.5 575A Dk Grn Splice 574, S18
0.5 546 Lt Blu K11, K13 0.5 575B Dk Grn Splice 574, S3
0.5 552 Red F10, X5 0.5 575C Dk Grn Splice 574, K11
0.5 555 Dk Grn S7, Y3 0.5 575D Dk Grn Splice 574, K12
0.5 556 Lt Blu K12, V1 0.5 577A Pur Splice 577, S4
0.5 557 Pur S7, S7 0.5 577B Pur Splice 577, S5
0.8 562A Red Splice 562, X5 0.5 577C Pur Splice 577, S6
0.5 562B Red Splice 562, S4 0.8 578 Gry S5, V2
0.8 562C Red Splice 562, X3 0.5 579A Wht Splice 579, S6
0.8 562D Red Splice 562, F5 0.5 579B Wht Splice 579, V2
0.8 562E Red Splice 562, S2 0.5 579C Wht Splice 579, K14
0.8 562F Red Splice 562, S5 0.5 579D Wht Splice 579, K15
0.8 562G Red S5, S5 0.5 581 Brn K14, K15
0.8 562H Red S5, S6 0.5 582 Red S5, K15
0.8 562J Red S6, S7 0.5 583 Org S6, K16
0.5 562K Red F5, K14 0.5 586 Lt Blu S4, X8
0.8 562L Red S18, X8 0.8 594A Yel Splice 594, Y5
0.5 562M Red K14, F11 0.8 594B Yel Splice 594, K17
0.8 562N Red Splice 562, S18 0.5 594C Yel Splice 594, K16
0.5 562P Red K16, F11 1.0 737A Pur Splice 737, Y10
0.5 562S Red K16, K6 0.5 737B Pur Splice 737, X35

0.8 737C Pur Splice 737, S18 0.5 562D Red Splice 562, S11
0.5 743 Org K17, X35 0.5 562E Red Splice 562, S12
0.5 757 Pur X7, S20 0.5 562F Red Splice 562, X23
0.5 777 Pur X7, S19 0.8 572 Red X5, A1
0.8 903 Org S23, B6 0.5 591 Brn A1, R2
0.5 596 Lt Blu S11, A1

W2 SST Jumper Wiring Harness Color Codes
0.8 673A Org Splice 673, A1
Size/No./Color Wire Connection Points 0.5 673B Org Splice 673, R2
0.8 519 Wht X5, X5 0.5 673C Org Splice 673, B4
0.8 521 Brn X5, X5 0.5 673D Org Splice 673, B5
0.5 676 Lt Blu B4, A1

W3 ePowrReverser Wiring Harness Color
Codes 0.5 677 Pur B5, A1
0.5 686 Lt Blu A1, S10

0.5 687A Pur Splice 687, A1
0.8 050A Blk Splice 050, X5
0.5 687B Pur Splice 687, S10
0.5 050B Blk Splice 050, A1
0.5 687C Pur Splice 687, H12
0.5 050C Blk Splice 050, R2
0.5 688 Gry A1, H11
0.5 050D Blk Splice 050, B4
0.5 694 Yel Y6, A1
0.5 050E Blk Splice 050, B5
0.5 695 Dk Grn Y7, A1
0.5 050F Blk Splice 050, H12
0.5 696 Lt Blu Y6, A1
0.5 050G Blk Splice 050, H11
0.5 697 Pur Y7, A1
0.5 050H Blk Splice 050, X23
0.5 924 Yel A1, X22
0.5 269 Wht A1, S11
0.5 925 Dk Grn A1, X22
0.5 303 Org A1, X5
0.5 926 Lt Blu A1, X22
0.5 311 Brn X5, A1
0.5 927 Pur A1, X22
0.5 519A Wht Splice 519, A1
0.5 519B Wht Splice 519, X5
0.5 519C Wht Splice 519, S10
0.5 521 Brn X5, A1
0.5 539 Wht X5, A1
0.5 562C Red Splice 562, S10

W4 eHydro Wiring Harness Color Codes Size/No./Color Wire Connection Points
Size/No./Color Wire Connection Points 0.5 552C Red Splice 552, S13
0.8 050A Blk Splice 050, X5 0.5 552D Red Splice 552, S14
0.5 050B Blk Splice 050, A2 0.8 552E Red Splice 552, X27
0.5 050C Blk Splice 050, X26 0.5 562 Red X5, A2
0.5 050D Blk Splice 050, Y9 0.8 673A Org Splice 673, A2
0.5 050E Blk Splice 050, Y8 0.5 673B Org Splice 673, R4
0.5 050F Blk Splice 050, H13 0.5 673C Org Splice 673, T1
0.5 050G Blk Splice 050, H14 0.5 673D Org Splice 673, R3
0.8 203 Org A2, H14 0.5 673E Org Splice 673, R5
0.5 238 Gry A2, X27 0.5 673F Org Splice 673, S17
0.5 247 Pur A2, S13 0.5 673G Org Splice 673, T2
0.5 264 Yel X5, A1 0.5 686 Lt Blu A2, R3
0.5 265 Dk Grn A2, X27 0.5 687 Pur A2, R5
0.5 266 Lt Blu A2, X27 0.5 688 Gry A2, H13
0.5 267 Pur A2, X27 0.5 696 Lt Blu A2, Y9
0.5 268 Gry A2, S14 0.5 697 Pur A2, Y8
0.5 269 Wht A2, S17 0.5 924 Yel A2, X26
0.5 311 Brn X5, A2 0.5 925 Dk Grn A2, X26
0.5 341 Brn A2, T1

W5 eHydro Cruise Control Wiring Harness
0.5 499 Wht A2, R4 Color Codes (standard)
0.8 502 Red A2, T2
0.5 519 Wht X5, A2
0.5 238 Gry X27, S16
0.5 521 Brn X5, X5
0.5 265 Dk Grn X27, S16
0.5 539 Wht X5, A2
0.5 562A Red Splice 562, X27
0.8 550A Blk Splice 550, A2
0.5 562B Red Splice 562, S16
0.5 550B Blk Splice 550, R4
0.5 562C Red Splice 562, S16
0.5 550C Blk Splice 550, T1
0.5 550D Blk Splice 550, R3
0.5 550E Blk Splice 550, R5
0.5 550F Blk Splice 550, T2

W6 eHydro Cruise Control Wiring Harness T2 MFWD Speed Sensor - eHydro
Color Codes (optional)
T2 MFWD
Size/No./Color Wire Connection Points Speed Sensor
0.5 238 Gry X27, S16
0.5 265 Dk Grn X27, S15
0.5 266 Lt Blu X27, S15
0.5 267 Pur X27, S16
0.5 562A Red Splice 562, X27 673G Org

X31 To W4
502 Red eHydro Wiring
0.5 562B Red Splice 562, S15
550F Blk Harness
0.5 562C Red Splice 562, S16
MIF
S13 Brake Switch - eHydro

Y2 Fuel Shutoff Solenoid
Y2 Fuel
S13 Brake Shutoff Solenoid
Switch
Blk
562C Red
247 Pur
X2 To W1
MIF Main Wiring Harness
Wht
Wht
T1 Flywheel Speed Sensor - eHydro
MIF
T1 Flywheel
Speed Sensor
673C Org
X29 To W4
341 Brn eHydro Wiring
Harness
550C Blk
MIF

ELECTRICAL EUROPEAN TROUBLESHOOTING
Troubleshooting
eHydro Electronic Operating System Troubleshooting Flowchart
Operator
Action
System Function No or Abnormal function

Decision
Solid ON Fault Light Flashing Code
Off
Diagnose problem
Calibrate system according to error
Calibration Mode
flash code
Check Power
to Controller
ok
Check Fault
Light Bulb
Replace Controller Yes

ok
No Spare Controller Fault not detectable or not

available? related to Controller
Check all
Not ok external switches ok
Fix external switches

ok Check hydraulic
Not ok
system
Need to connect to
computer with Fix hydraulic system
diagnostic software
Graphic
Electrical European Troubleshooting - 347

ePowrReverser Electronic Operating System Each fault will have to be corrected and cleared one by one
Fault Codes should there be multiple faults.
Purpose: operating system will reset. When the vehicle is operated,
The LED status indicator light flashes in specific sequences the electronic operating system will flash the next fault code
of flashes to provide a visual indication of fault diagnostic that is recorded if there are any problems that still exist.
codes. These fault codes will aid in the diagnosis of The electronic operating system has 19 different fault
operational problems that may occur. codes available to assist with diagnostics. Each fault code
is a two digit number spelled out by the flash code.
Operation:
Long
Flash Flash
ON
Off Off Off

Period Period Period
Starting Light 1st 2nd
2 seconds ON digit digit
=4 =1
The fault code 41 for example, would be shown by the light

being on for 2 seconds then a 1 second off then 4 flashes
followed by a 1 second off then 1 flash. The cycle would
then start over and repeat until the fault is corrected.
The 2 second on light is used to indicate the start of a new
A
cycle while the off periods are used to break up the flashes.
The 4 flashes would indicate the digit 4 in 41 and the 1
flash would indicate the digit 1.
Once a code has been read, it can then be matched to the
fault code chart to explain what the electronic operating
system is reading as a problem and what corrective action
is needed to positively identify and correct the source of the
fault.
MX10694
ePowrReverser Electronic Operating System
Fault Code Chart
turned on as part of a self test, then the light will not be The starting light “—” = 2.0 second
specific fault code when an operational command input is The flash “•” = 0.5 second
given and any one or more parts of that circuit are not OFF period “/” = 1 to 2 seconds.
operating properly.
The flash code begins with the starting light.
the first fault which has been detected will be displayed
before the controller displays any additional faults that may
exist. If for example, the controller reads a fault on both
forward and reverse switches, the controller will flash the
forward fault code and will not display the reverse fault code
until the forward fault has been corrected.

CODE SEQUENCE POINT
11 -/•/• Controller sees a forward and F-N-R Switch Correct fault.

neutral input at the same time
status.
12 -/•/•• Controller sees a reverse and F-N-R Switch Correct fault.

Machine does not neutral input at the same time Clutch pressed to BOT, and F-N-R
status.
13 -/•/••• Controller sees a forward and F-N-R Switch Correct fault.

reverse input at the same time
status.
14 -/•/•••• Controller does not see a F-N-R Switch Correct fault.

forward, reverse or neutral
input
status.
15 -/•/••••• Controller does not see neutral F-N-R Switch Correct fault.
Machine does not input when power is turned on Clutch pressed to BOT, and F-N-R
status.
16 -/•/•••••• Controller does not see BOT Clutch Switch Correct fault.
input from clutch switch when
power is turned on
status.
21 -/••/• Controller sees forward input Forward Correct fault.

but does not receive a Proportional
feedback from forward solenoid and
pressure transducer Forward Pressure
status.
Transducer
Test forward proportional solenoid and
wiring.
Test forward pressure transducer and
wiring.
22 -/••/•• Controller sees reverse input Reverse Correct fault.

Machine does not but does not receive a Proportional Clutch pressed to BOT, and F-N-R
drive feedback from reverse solenoid and switch placed in neutral to clear error
pressure transducer Reverse Pressure status.
Transducer
Test reverse proportional solenoid and
wiring.
Test reverse pressure transducer and
wiring.

CODE SEQUENCE POINT
23 -/••/••• Controller sees forward or Reverse Correct fault.

neutral input but receive a Proportional
feedback from reverse solenoid and
pressure transducer Reverse Pressure
Transducer
Test reverse proportional solenoid and
wiring.
Test reverse pressure transducer and
wiring.
24 -/••/•••• Controller sees reverse or Forward Correct fault.

Engine stops, neutral input but receive a Proportional Clutch pressed to BOT, and F-N-R
Power cut to fuel feedback from forward solenoid and switch placed in neutral to clear error
shutoff circuit. pressure transducer Forward Pressure status.
Transducer
wiring.
Test forward pressure transducer and
wiring.
25 -/••/••••• Clutch pedal is press to bottom Clutch Switch Correct fault.

feedback from forward
pressure transducer
Test clutch switch.
26 -/••/•••••• Clutch pedal is press to bottom Clutch Switch Correct fault.

feedback from reverse
pressure transducer
Test clutch switch.
27 -/••/••••••• System pressure drops below Hydraulic filter Correct fault.

100 psi for longer than 5
Machine does not Hydraulic system Clutch pressed to BOT, and F-N-R
seconds. This is an indicator
that the hydraulic system filter
status.
may be clogged.
Change hydraulic filter.
31 -/•••/• Inch pedal potentiometer is out Clutch Position Adjust clutch position potentiometer to
Machine does not of range on the low end. Potentiometer within specification. See
drive ePowrReverser Potentiometer
Calibration.
32 -/•••/•• Inch pedal potentiometer is out Clutch Position Adjust clutch position potentiometer to
of range on the high end. Potentiometer within specification. See
Machine does not
ePowrReverser Potentiometer
drive
Calibration.

CODE SEQUENCE POINT
41 -/••••/• Seat switch open (no operator Seat Switch Seat switch closed (operator present),
present) longer than 1 second. Correct fault.
Machine does not
drive F-N-R switch placed in neutral to clear
error status.
42 -/••••/•• Clutch BOT switch reads as Clutch Switch Correct fault.

Machine does not closed (pressed) and clutch Clutch Position Clutch pressed to BOT, and F-N-R
drive position potentiometer shows Potentiometer switch placed in neutral to clear error
pedal as being pressed less status.
than half way to full travel.
51 -/•••••/• Controller sees forward input Forward Correct fault.

feedback from forward solenoid
status.
wiring.
52 -/•••••/•• Controller sees reverse input Reverse Correct fault.

feedback from reverse solenoid
status.
wiring.
53 -/•••••/••• Controller sees feedback from Proportional Correct fault.

either forward or reverse solenoids
proportional solenoid greater
than 1.17 volts for more than
status.
50ms.
Possible extremely high
magnetic interference.
61 -/••••••/• Controller does not see relay K4 engine run Correct fault.
Machine does not logic after startup relay, K6 fuel Clutch pressed to BOT, and F-N-R
drive solenoid timer switch placed in neutral to clear error
module, and K13 status.
neutral relay

eHydro Electronic Operating System Fault operating system will reset. When the vehicle is operated
Codes the electronic operating system will flash the next fault code
that is recorded if there are any problems that still exist.
Purpose: The electronic operating system has 12 different fault
The LED status indicator light flashes in specific sequences codes available to assist with diagnostics. Each fault code
of four flashes to provide a visual indication of fault is a combination of four long and/or short flashes.
diagnostic codes. These fault codes will aid in the diagnosis
of operational problems that may occur. Long Short Long Short
Flash Flash Flash Flash
Operation:
1st Off Off
digit Period Period
2nd
digit
3rd
digit
4th
digit
A fault code of 2 long and 2 short flashes (example shown)

would be signaling that the reverse pedal potentiometer is
malfunctioning or is out of calibration.
When the reverse potentiometer is recalibrated, adjusted,
or replaced, the electronic operating system would reset,
A
clearing the fault code and resuming normal operation.
This code would flash two long flashes followed by two
short flashes followed by an off period. This sequence
would then repeat itself until the correction is made and
power to the controller cycled off and back on.
The long flash is approximately 1.0 second, the short flash
is approximately 0.5 second and the off period is
approximately 4 seconds. The flash code begins after the
off period. Whenever reading a fault flash code be sure to
let the code cycle several times while reading the code to
be sure you are at the beginning of the code.
MX10694 Once a code has been read, it can be matched to the fault
code chart to explain what the electronic operating system
is reading as a problem and what corrective action is
needed to positively identify and correct the source of the
turned on as part of a self test, then the light will not be
fault.
specific fault code when an operational command input is
given and any one or more parts of that circuit are not
operating properly.
each fault will be displayed before the controller repeats the
fault codes. If for example, the controller reads a fault on
both forward and reverse pedals, the controller will flash the
forward fault code then the reverse fault code and then it
will repeat the cycle.
Each fault will have to be corrected and clear one by one
should there be multiple faults.

eHydro Electronic Operating System Fault OFF period = 3 to 4 seconds.
Code Chart The flash code begins after the off period.
The long flash “—” = 1.0 second Whenever reading a fault flash code be sure to let the code
The short flash “•” = 0.5 second

1 •-•• Forward Pedal Normal Operation:

Potentiometer
calibrated.

2 --•• Reverse Pedal Normal Operation:

Potentiometer
calibrated.

3 •••- Throttle Normal Operation:

Position
Potentiometer Voltage signal is out of Load Match is disabled; Power recycled through off
range. loss of performance. to clear error status.
calibrated.


4 ••-• Flywheel Normal Operation:

Speed Sensor
Output current exceeds Load Match and cruise Power recycled through off
a certain value without control will be disabled; to clear error status.
detecting an engine loss of performance.
speed. MFWD speed
at same time.
Missing engine speed Load Match is disabled. Engine speed has to be

or signal exceeds rpm adjusted.
tolerance.
5 •--• MFWD Speed Normal Operation:

Sensor
Output current exceeds Cruise control will be Power recycled through off
a certain value without disabled; loss of to clear error status.
detecting an MFWD performance.
speed. Engine speed
at same time.
Missing MFWD speed Calibration routine MFWD signal has to be

or signal exceeds rpm stops. available.
tolerance. Calibration repeated.
6 -••- Cruise Normal Operation:

Control/Max
Speed Switch Both inputs are active Load Match and cruise Power recycled through off
7 --•- Res/+ Set/- Normal Operation:

Switch
Both inputs are active Load Match and cruise Power recycled through off
8 ---- Off-Seat Normal Operation:

Command
Drive command No drive in either Error status will reset when
selected while the seat direction. seat switch is placed in on
switch is in open position.
position.
Threshold calibration No drive in either Error status will reset when

while the seat switch in direction. seat switch is placed in on
open position. position.
Calibration can then be
continued.

9 -••• Simultaneous Normal Operation:

command
from Forward Controller receives a No drive in either Error status will reset when
and Reverse command from both direction. both pedal commands
pedals at the same return to zero.
time.
No fault situation. Flash code will be None

present, no other
machine response.
10 •--- Valve output Normal Operation:

to Forward or
Reverse coil The calculated value No drive in either Power recycled through off
circuit.
The calculated value No drive in either Power recycled through off

circuit.
11 -•-- Sensor supply Normal Operation:

(S/N voltage
- H120712 Voltage is out of range. No drive in either Power recycled through off
- H131963
- H141271
11 ••-- Sensor supply Normal Operation:

(S/N voltage
H120713 - Voltage is out of range. No drive in either Power recycled through off
H131964 -
H141272 -
12 •••••••••• Software Normal Operation:

•••••
No application software No machine operation. Replace Controller.
(continuous) loaded into the
Download correct software.
microprocessor.
13 -•-• Brake switch Normal Operation:

(S/N input
H120713 - Brake engaged Cruise not available to Release brake.
set. Adjust or replace brake
H131964 -
switch.
H141272 -

ELECTRICAL EUROPEAN THEORY AND DIAGNOSIS
Theory and Diagnosis While this will cause the machine to be a bit more jerky, it
will provide for extremely quick clutch engagement.
ePowrReverser - e MatchOS Electronic Placing the motion match switch in the off position (B) will
Operating System give clutch engagement the sensitivity that is typical to
most normal operating conditions.
Function:
The purpose of the electronic drive operating system is to
control drive clutch engagement. Additionally the electronic Analog Inputs
operating system provides for selecting between two 1. Forward Pressure Transducer
responsiveness levels.
2. Reverse Pressure Transducer
General Theory: 3. Forward Proportional Solenoid Feedback
The electronic operating system is a preprogrammed 4. Reverse Proportional Solenoid Feedback
machine drive direction via the electrical inputs from the F-
N-R lever switch. Under normal operating conditions, this Digital Inputs
creates an output to the corresponding directional control 1. Diagnostic Interface
solenoid in the transmission.
2. Starting Circuit Signal
The output current to the directional solenoid is either
constant when the clutch is fully released or proportional 3. Reverse Signal from F-N-R Switch
when the clutch pedal is being pressed down. When the 4. Fuel Shutoff Relay Logic
clutch pedal is completely pressed down, no output current
will be provided to either directional solenoid. 5. Diagnostic Interface
6. Forward Signal from F-N-R Switch
The rate of clutch engagement is also controlled by the
electronic operating system to smoothly ramp the machine 7. Clutch Switch
into motion.
8. Neutral Signal from F-N-R Switch
Two different settings provide for either quicker or slower 9. Motion Match Switch
clutch engagement. This operation is controlled by the
operator placing the motion match switch in either the on or 10.Seat Switch (operator presence)
off position. The change in this setting will take effect as 11.Calibration Fuse (used temporarily during calibration)
soon as the switch is changed.
Digital Output
Motion Match Switch: 1. Ground Circuit
The motion match feature allows the operator to select how 2. Fuel Shutoff Relay Logic
reactive the machine is to engaging the clutch.
3. Forward Proportional Solenoid
4. Reverse Proportional Solenoid
A
5. Fault Light
MX10694
Placing the motion match switch in the on position (A) will

give the transmission quicker response from F-N-R switch
position.
Electrical European Theory and Diagnosis - 356

eHydro - e MatchOS Electronic Operating The deceleration for directional change setting allows for
System the ramping to control the deceleration speed to a stop and
Function: direction of travel.
The purpose of the electronic drive operating system is to Both the deceleration to neutral and the deceleration to
control both the drive direction and speed of the machine. direction change have an immediate or “knee” deceleration
Additionally the electronic operating system provides for before following the ramped pattern back to a stop. The
setting a maximum travel speed, cruise control, pedal amount of deceleration used for the knee value is based
aggressiveness, and load match to prevent stalling the upon a percentage of output being produced. If the knee
engine during operation. value is set at 70, then the speed of the machine would be
Each of these additional functions has the ability to be immediately with the release of the directional pedal being
turned on or off by the operator. used. The deceleration would then follow the ramped
setting back to a stop.
General Theory:
Generally deceleration within a drive direction is the most
The electronic operating system is a preprogrammed
conservative deceleration with decel to neutral being
slightly more aggressive and decel to a direction change
machine drive direction and speed via the electrical inputs
being the most aggressive stopping action.
from the forward and reverse foot pedals. Under normal
operating conditions, this creates an output to the Cruise Control:
corresponding directional control valve coil in the
transmission. The cruise control feature allows the operator to set and
hold a speed setting that the operator desires without
The output current to the directional valve coil is
having to press and hold the forward pedal.
proportional to the pedal position. The forward and reverse
pedals have an adjustable proportional setting. This setting
allows for greater control, comfort and smoother operation A C
around neutral. The same proportional setting affects both
the forward and reverse command.
The rate of acceleration and deceleration is also controlled
by the electronic operating system to smoothly ramp the
speed up and down.
Two different settings provide for either quicker or slower
acceleration or deceleration. This operation is controlled by
the operator placing the motion match switch in either the
on or off position. The change in this setting will take effect
as soon as the switch is changed. B
While the acceleration has one setting with the motion

match in either the on or off positions, the deceleration
function has three settings. MX10682
Deceleration has settings for coasting to a slower speed Placing the cruise control switch (A) to the on position,
without stopping or changing direction, coasting back to the enables the cruise control function. Momentarily pressing
neutral position, and stopping when changing directions. the Set / - switch (B) will then set the cruise speed at the
speed being traveled.
for controlled operation within the direction of travel by Once set, the electronic operating system monitors the
reducing the jerking that may occur as a result of pedal vehicle speed and varies the current to the transmission
movement by the operator as well as simply slowing to a forward directional solenoid to maintain travel speed at the
lower rate of speed. set point.
The deceleration to neutral setting allows for a controlled The cruise speed setting can be increased and decreased
return to the stopped position when the pedal is completely while the machine is being driven by momentarily pressing
released. either the Res / + switch (C) to increase the maximum
speed or the Set / - switch (B) to decrease the maximum
speed setting.

Using the Res / + switch or the Set / - switch to change the to obtain the travel speed desired then momentarily
cruise speed setting will become effective immediately pressing the Set / - switch (B) sets the max speed.
without returning to neutral.
The maximum travel speed of the machine will then be
The increase/decrease amount is a percentage of the limited to the speed the operator was traveling at as long as
actual machine speed. the max speed switch remains in the on position.
Pressing either the brake or reverse pedals will disengage The max speed setting can be increased and decreased
the cruise function. The last speed setting is stored in the while the machine is being driven by momentarily pressing
controller and if the operator is pressing the forward pedal, either the Res / + (C) switch to increase the maximum
the Res / + switch can be pressed to ramp back to the speed or the Set / - (B) switch to decrease the maximum
stored speed. speed setting.
Turning the cruise switch off, erases the stored setting. NOTE: Pressing the Set / - switch at any speed less
If changes in machine loading or range gear position than the current maximum speed setting will replace
settings do not allow for return to the previous speed the Max Speed setting with a new setting based upon
setting, the controller will attempt to return to the speed the pedal position at the time the Set / - switch is
setting by sending either the maximum (fastest speed pressed.
possible) or minimum (slowest speed possible) drive Using the Res / + switch or the Set / - switch to change the
current to the transmission forward directional solenoid. max speed setting will become effective immediately
Max Speed:
The max speed feature allows the operator to set the
Depressing the Res / + switch while in neutral will increase
maximum speed the machine will travel when the drive
the max speed setting the same as if the machine were
pedal is fully depressed.
being driven.
If the operator needs to return to a specific travel speed, the
Depressing the Set / - switch while in neutral will disengage
max speed setting will allow the machine to return to this
the max speed setting.
specific speed setting while maintaining proportional
acceleration and deceleration. The max speed function is also disengaged when the max
speed switch is turned off. Disengagement will become
The max speed setting is a machine speed taken from the
effective immediately.
MFWD speed sensor so that the machine speed is limited
to that setting regardless of gear position, drive direction or Once the max speed setting is set it will be stored and is
terrain features. available until it is replaced by another setting or if the
electronic operating system is replaced. Placing the max
Unlike cruise control, the max speed setting requires the
speed switch in the on position will enable the last
operator to press and hold the drive pedal to obtain a travel
maximum speed setting.
function.
MX10682
Placing the max speed switch (A) to the on position,

enables the max speed function. Pressing the drive pedal

Motion Match Switch:
The motion match feature allows the operator to select how
reactive the machine is compared to drive pedal
movement.
A MX9722
The load match switch (A) can be turned on or off to allow

the operator to disable the load match function if desired.
The load match feature will have no effect if the machine is
not being driven when the stalling load is being placed on
the engine.

B
Analog Inputs
1. Forward Pedal Potentiometer
MX10682 2. Reverse Pedal Potentiometer
Placing the motion match switch in the on position (A) will 3. Throttle Position Sensor
give the transmission higher response sensitivity to drive
pedal movement. 4. Motion Match Switch
While this will cause the machine to be a bit more jerky, it Digital Inputs
will provide for extremely quick changes in speed or 1. Load Match Switch
direction.
2. Brake Switch
Placing the motion match switch in the off position (B) will
3. Cruise control Res/+ Switch
give the drive pedals the sensitivity that is typical to most
normal operating conditions. 4. Cruise control Set/- Switch
5. Cruise Control/Max Speed Switch
Load Match Switch:
6. Seat Switch (operator presence)
engine during a typical application such as loader work. A 7. Calibration Fuse (used temporarily during calibration)
throttle position sensor is installed to read the no-load Frequency Inputs
engine rpm set point.
1. Flywheel Speed Sensor
value, the current sent to the transmission drive valve coils 2. MFWD Speed Sensor
is reduced to allow the engine to recover. The greater the Digital Output
1. Backup Alarm
If cruise control is active and the load match comes on, the
cruise speed output is ‘held’ at whatever speed it is 2. Neutral State Light
currently operating at until load match goes back to 100%. 3. Cruise Active Light
4. Fault Light
Valve Output
1. Forward Solenoid Coil
2. Reverse Solenoid Coil

Power Circuit Operation short occurs.
Function: Switched Power - Run - SST, ePowrReverser, and

eHydro Main Circuits:
To provide unswitched and switched power to the primary
electrical components whenever the battery is properly In addition to the voltage present at the locations of the
connected. unswitched power circuits, voltage must be present at the
following components during the following conditions: key
The power circuits are divided among the unswitched
switch in the run position, transmission in neutral, PTO(s)
power circuit, switched power circuits (key switch in run,
off, park brake locked, MFWD unlocked, operator off seat:
start, or aid positions), and secondary power circuits. The
secondary power circuits become energized when • Key switch terminals 3 and 5
switched power circuits energize relays, providing current • Alternator terminal IG
paths to the secondary circuits. The secondary power
circuits will not be energized if the relays controlling the • Hazard switch terminals 1 and 2
current path(s) fail. • K19 Flasher terminal 49
Unswitched Power: • F5 Fuse
Voltage must be present at each of the following • K14 Mid PTO interlock relay terminal 30
components with the key switch in the off position: • F11 Fuse
• Battery positive terminal • K16 Mid PTO relay terminal 30
• Starting motor solenoid B terminal • K6 Fuel solenoid timer module terminals 87A and 30
• Alternator terminal B • X3 Connector
• Manifold heater relay terminal 30 • X5 Connector terminals A
• F1 Fuse • Seat switch
• Key switch terminal 1 • Front PTO switch terminal A, G, and H
• K4 Engine run relay terminal 30 • X8 Connector terminals A, C, E, and K
• F2 Fuse • Rear PTO switch terminals A, D, F, G, and H
• K5 Trailer relay terminal 30 • K17 PTO relay terminal 86
• F3 Fuse • V2 Diode block terminals 1 and 2
• Light switch terminal B • K15 Mid PTO relay terminal 30
• Horn switch • K11 Rear PTO interlock relay terminal 86
• F4 Fuse • K12 PTO interlock relay terminal 30
• Hazard switch terminal 3 • Transmission neutral switch
• Brake light switch • K2 Start relay terminal 86
• K18 Brake light relay terminal 30 • V1 Diode block terminal 6 and 5
The positive battery cable connects the battery to the • Mid PTO switch terminals A, G, and H
starting motor. The starting motor bolt is used as the 12
• MFWD switch terminals 1 and 2
Volt DC tie point for the rest of the electrical system.
• MFWD solenoid
The battery cables and the starting motor tie point
connections must be good for the vehicle electrical system • Park brake switch terminals A, B, C, and D
to work properly. The ground cable and positive cable • K13 Neutral relay terminal 30
connections are equally important. Proper starting motor
operation depends on these cables and connections to • K5 Trailer relay terminal 86
carry high current. These circuits are controlled by the key switch and are
With the exception of the B terminal of the alternator, the protected by the fusible link and the F1 fuse.
electrical circuit is protected by the fusible link beyond the
starting motor tie point. The fusible link is a short piece of
wire that is designed to fail if current load is too high or a

Switched Power - Run - ePowrReverser specific Secondary Switched Power - Run:
Circuits:
In addition to the main machine circuits, voltage must be following components during the following conditions: key
present at the following components of the ePowrReverser switch in the run position, transmission in neutral, PTO(s)
machine during the following conditions: motion match off, park brake locked, MFWD unlocked, operator off seat:
switch off, bottom of clutch switch not pressed, and the F-
• K4 Engine run relay terminals 86 and 87
N-R switch in the N (neutral) position:
• V1 Diode block terminal 8
• Motion match switch terminal 2
• Y2 Fuel shutoff solenoid
• Bottom of travel clutch switch terminal A and B
• X33 Trailer connector terminal A
• F-N-R switch terminal D and B
• K6 Fuel solenoid timer module terminal 87
• X21 Connector terminals E2, F1, and K1
• K3 Fuel shutoff solenoid pull-in relay terminal 86 for
• X23 Connector terminals A approximately 3 second
• K11 Rear PTO interlock relay terminal 30 and 87
• K12 PTO interlock relay terminal 87A
Switched Power - Run - eHydro specific Circuits: • K13 Neutral relay terminal 87
• K14 Mid PTO interlock relay terminal 87
present at several components of the eHydro machine.
Those circuits that are inputs to the drive controller should • K15 Mid PTO lockout relay terminal 87A
be at 12 volts (battery voltage), while those circuits that are • Brake light switch terminal 2
outputs of the drive controller should be at 5 volts during
the following conditions: load match, brake switch, motion • K18 Brake light relay terminals 86 and 87
match, cruise switch and Res/+, Set/- switches in off • X38 Trailer connector terminal E
position if equipped.
• E14 Right brake light
• Load match switch terminal 2, (12 volts),
• E11 Left brake light
• Brake switch terminal A and B, (12 volts),
• Res/+, Set/- Switch terminal 2 (if equipped), (12 volts), protected by the fusible link and the F1 fuse.
• Cruise/max speed switch terminal 2 (if equipped), (12
Switched Power - Aid:
volts),
Voltage must be present at the following components with
• X25 Connector terminals A3 and G1, (12 volts),
the key switch in the aid position (key pushed in when
• X25 Connector terminals B1 (5 volts), placed in the run or start position) and the other switches in
• Motion match switch terminal 2, (5 volts), the following conditions: transmission in neutral, PTO(s) off,
park brake locked, MFWD unlocked, operator off seat:
• Forward pedal potentiometer terminal C, (5 volts),
• Key switch terminal 7
• Reverse pedal potentiometer terminal C, (5 volts),
• K1 Manifold heater relay terminal 86
• Throttle position potentiometer terminal A, (5 volts),
• X7 Connector terminal C
• Flywheel speed sensor terminal A, (5 volts),
• MFWD speed sensor terminal A, (5 volts), protected by the fusible link and the F1 fuse.
protected by the fusible link and the F1 fuse. Secondary Switched Power - Aid:
following components with the key switch in the aid position
(key pushed in when placed in the run or start position):
• K1 Manifold heater relay terminal 87
• R1 Manifold heater

Switched Power - Start:
Voltage must be present at the following components
during the following conditions: key switch in the start
position, transmission in neutral, PTO(s) off, park brake
locked, MFWD unlocked, operator off seat:
• Key Switch terminals 5 and 6
• K2 Start relay terminal 30
• Diode block terminals 3 and 2
• K12 PTO interlock relay terminal 86
• X5 Connector terminal G
• X21 Connector terminal C3 (ePowrReverser)
NOTE: These components are in addition to the
components that would have power with the key switch
in the run position. However, voltage would not be
present at the trailer relay (terminal 86) with the key
switch in the start position.
Secondary Switched Power - Start:

Secondary voltage must be present at the following
components during the following conditions: key switch in
the start position, transmission in neutral, PTO(s) off, park
brake locked, MFWD unlocked, operator off seat:
• Start relay terminal 87
• Starting motor terminal A

Power Circuit Electrical Schematic
002A Red 002A Red
F3 Fuse
Fuse Block Internal Link 122C Red
F4 Fuse 042C
X3 002D Red Red
562C Red
F1 4
012 072D Red 072D Red
072A Red 072A Red
2 5 072B Red
562K Red 562K Red
3 212A Red 072C F5 Fuse 556 Lt Blu
S1 Key
7 385B Dk Grn A
Switch
562B 562F 562N Red
Start
Run
Off
Acc.
S2 Seat
Aid Switch
002C
Red Off (Off Seat)
572B Red X5
(On Seat)
H 575B
002B Red 562E Red Dk Grn
539A 1
Wht 2 556 Lt Blu
X1
385C 572D Red 3
Dk Grn V1 Diode
Fusible Block 1
Link 4 F10
30 86 K1 5 521 Brn 212B
Manifold Fuse
518A Gry Red
Heater 6
87A 87 85 Relay 552
Red
383 S3 Transmission
Org Neutral Switch In Neutral F X5
In Gear
X4 X4 575B Dk Grn
572C 518B Gry
Red
R1 Manifold 30 86
Heater K2
Start 002D X5
Red F2
87A 87 85 Relay Fuse
002A Red V1 303 E
Diode Lt Blu
309 Wht 30 86 K4
Block 1
Engine
7 8 302A Red
B A 385A Run
87A 87 85 Relay
Dk Grn 212C 252
C 302B
Red Red Red
X7 X2 302C Red
86 30 K5
M H3 Cold Wht Trailer
Start Y2 Fuel Relay
85 87 87A
Shutoff 521
M1 Light Brn 222
Solenoid X33
Starting Wht 30 86
Red
Blk K6
Motor A
X2 Fuel Solenoid
Red Y1 Timer Module X33 Trailer
329 85 87 87A Connector
Starting 304 Org
Motor Wht
562S Red
Solenoid X2 30 86 K3 Fuel
Shutoff 305
G1 Solenoid X5
Dk Grn
Battery 87A 87 85 Pull-in Relay
L


002A Red 002A Red
122C Red 122C Red
042C Red 042C Red
072D Red 072D Red

072A Red 072A Red
562L Red
562K Red
556 Lt Blu
S4 Park
Brake Switch
On
Off
S18 Front X8
562B Red B C 586 Lt Blu K
PTO Switch
On D 505 Dk Grn
577A Pur A
562L Red Off H4 Park
562N Red A B Brake Light
C
D E
575A Dk Grn F
G
H 573A Org P
573C
S5 Rear Org
575D 556
Dk Grn Lt Blu
PTO Switch On
86 30 30 86 K12 PTO
562F Red Off V2 Diode Interlock
562G Red A B Block 2 85 87 87A Relay
C 87A 87 85
577B Pur D E 533 010AA
F
578 Gry 1 2
562G Red G Org Blk
H
573B Org
562H Red
562K
Red X5
562M Red G
S6 Mid 505 519
579C
PTO Switch On
Wht Dk Grn Pur
86 30
K14 Mid 30 86 K13
Off
PTO
579A Wht 583 Org Neutral
A B
C
Latch Relay
D 85 87 87A 87A 87 85
E
F
Relay 546
562H Red G 581
H 577C Pur 579D Brn Lt Blu
562J Red
Wht
86 30 K15 Mid
F12 Fuse
S7 MFWD Unlock
PTO 575C 546
Switch Lockout Dk Grn Lt Blu
Lock 85 87 87A 86 K11 Rear
Relay 30
1 555 Dk Grn 581 PTO
562J Red 2 Brn Interlock
3 85 87 87A
8 555 Relay
7 562S Red 562P 533
Dk Grn Org
Y3 Red
MFWD
86 30 K16
Solenoid
Mid PTO
562S Red
Relay
85 87 87A


002A Red
S9 Light
122C Red 122C Red
Switch
042C Red (0) Off
(1) Marker
072D Red 072D Red
122C (2) Road
072A Red
S22 Red
(3) Field
562L Red
Hazard On 042B 1
Switch Off Red
102 Red 122B Red
3 2
2 B
1
17 3
S23 Horn 122A
18 Red 4
Switch
10 5
G2 K19
Flasher
Alternator B
49
G 042A S21 Brake
072A Red Red
IG 49a Light Switch
L
P 31 C3 C C2 X34
Off
On
562L Red X8 Blu
Blu
A
H5 H9 Oil
Discharge X34
Pressure
Light Light 116 Lt Blu
_ P4 Engine 042D
+ Coolant Red
Temperature 86 30 K18
Gauge Brake
Light
85 87 87A E13 Right Rear
t0 Relay
136A Position Light
Lt Blu
P3 X16
E Gry Blk
Fuel
Gauge X8 X11
X15
136D Lt Blu Lt Blu
359
Q Wht
E14 Right
B3 Engine Brake Light
C Coolant
P1 Engine X8 Temperature X38
136B Lt Blu Trailer
Tachometer P2 Hour Sensor E Connector
Meter 353
Org E10 Left Rear
t0
n/min Position Light
B1 Fuel X14
Gauge Gry Blk
Sensor
X13 X18
136C Lt Blu Lt Blu
Q
E11 Left
Brake Light



W2 SST Jumper Plug
X5 S12
A 519 Wht
Motion Match
X5 to W1 521 Brn Switch
E
Main Wiring G 519 Wht X23
Harness 562F Off
L 521 Brn Red On
X5
A 562A Red 562E Red
E 303 Org
G 519B Wht S11
H 572 Red
Clutch
J 539 Wht
L 521 Brn Bottom of Travel

596 Lt Blu
562D Red
S10
F-N-R
Switch Forward
X21 Neutral
303 Org Reverse
A1
562C Red 519C Wht
572 Red
C3
521 Brn
D2
A1 E2
596 Lt Blu
Electronic
519A Wht
Operating F1
System 539 Wht
F3
Controller
B5
673D Org
Reverse
m Pressure
Transducer
562B Red B4
K1 673C Org Forward
673A Org 673B Org X24 m Pressure
K3
Transducer
X24 R2
Clutch Position
Potentiometer
X24


W4 eHydro Power Circuit

W5 Cruise Control (standard) W6 Cruise Control (option) Power Circuit
Power Circuit
S18 Cruise S16
Switch Cruise/
Off Cruise ON
Max Speed
Off
On Switch Max Speed ON
Momentary
X5 562C Red
562C Red
E 521 Brn
F 552A Red 562B Red
519 Wht
S15
G
J 539 Wht
Res/+, Set/-
562A Switch
K 562 Red Red Res +
L 521 Brn
Off
S14 X27 Set -
Load Match 562B Red
Switch 562A
Off Red
On
X27
552D Red X27 R3
552E Forward Pedal
Red
S13
Brake X28
Switch
Off
X28
On
X25 X29 T1 Flywheel
552C Red 673C Org
539 Wht 247 Pur Speed Sensor
A1
A3
552B Red X29
673A Org
B1
X29 R4
A2 Throttle Position
Electronic 269 Wht 673B Org X30 Potentiometer
C3
Operating 519 Wht
D1
System
562 Red X30
Controller D3
X30
247 Pur 673G Org X31 T2 MFWD

G1 Speed Sensor
X31
S17
Motion Match
Switch X31 R5
Off Reverse Pedal
On
269 Wht 673F Org
X32
X32


Power Circuit Diagnosis
Test Conditions:
• Mid PTO off
• Rear PTO off
1. Starting motor solenoid Battery voltage Check battery cable and connections. Test battery. See Battery
Test.
2. Alternator terminal B Battery voltage Check 002A Red wire and connections.
3. Manifold heater relay Battery voltage Test fusible link. Check 002B Red wire and connections.
4. Engine run relay Battery voltage Test fusible link. Check 002D Red wire and connections.
5. Key switch Battery voltage Test F1 fuse. Check 012 Red wire and connections. Test fusible
link. Check 002C Red wire and connections.
6. K5 Trailer relay Battery voltage Test F2 fuse. Check 252 Red wire and connections.
7. Light switch Battery voltage Test F3 fuse. Check 122C and 122B Red wires and
connections.
8. Horn switch Battery voltage Test F3 fuse. Check 122C and 122A Red wires and
connections.
9. X34 Brake light switch Battery voltage Test F4 fuse. Check 042C and 042A Red wires and
connector connections.
10. Brake light relay Battery voltage Test F4 fuse. Check 042C and 042D Red wires and
connections.
11. Hazard switch Battery voltage Test F4 fuse. Check 042C and 042B Red wires and
connections.

S1 Key Switch S9 Light Switch
212 Red K5 Trailer

Relay Socket
86
6
30
5 122B
87A
012
87
Red
F1 Fuse Red
S23 Horn
85
252 Switch
F2 Fuse Red
8
F3 Fuse
122C Red 122A Red
F4 Fuse X34 Brake

042C Red
Light Switch
Connector
002D Red
K4 Engine Run K18 Brake

K1 Manifold Heater Relay Socket Light Relay
Relay Socket 002D
86
Red
3
86
30
85 87A 87
87A
042A Red
87
30
30 86 9
87A
87
85
4
042D Red S22 Hazard
85
10
Switch
002C
Red
002B Red
Fusible M1 042B Red

Link Starting 11
Motor
002A Red
2
G1 Battery G2 Alternator
1
W1 Battery
Frame Ground

Test Conditions:
• Mid PTO off
• Rear PTO off
12. Key switch Battery voltage Replace key switch.
13. Alternator terminal IG Battery voltage Check 072B and 072A Red wires and connections.
14. Hazard switch Battery voltage Check 072B and 072C Red wires and connections.
15. K19 Flasher Battery voltage Check 102 Red wire and connections. If ok, replace hazard
switch.
16. K6 Fuel solenoid timer Battery voltage Check 562S, 562P, 562M, and 562K Red wires and
module connections. Test F5 fuse.
17. Seat switch Battery voltage Check 562D and 562E Red wires and connections. Test F5
fuse.
18. Park brake switch Battery voltage Check 562D and 562B Red wires and connections. Test F5
fuse.
19. X8 Connector Battery voltage Check 586 Lt Blu wire and connections. If ok, replace park
brake switch.
20. X8 Connector Battery voltage Check 562L, 562N, and 562D Red wires and connections. Test
F5 fuse.
21. X8 Connector Battery voltage Test fuel gauge circuit. If ok, replace instrument panel.
22. X8 Connector Battery voltage Test engine coolant temperature gauge circuit. If ok, replace
instrument panel.
23. MFWD switch Battery voltage Check 562J, 562H, 562G, 562F, and 562D Red wires and
connections. Test F5 fuse.
24. MFWD solenoid Battery voltage Check 555 Wht wire and connections. If ok, replace MFWD
switch.
25. Rear PTO switch Battery voltage Check 577C and 577B Pur wires and connections. If ok,
27. K13 Neutral relay Battery voltage Test park brake switch. Check 505 Dk Grn wire and
connections.
28. X5 Connector Battery voltage Check 562A Red wire and connections. Test F5 fuse.
29. X3 Connector Battery voltage Check 562C Red wire and connections. Test F5 fuse.

S2 Seat
X3 Connector
S1 Key Switch Switch
29 562C 17
072B 072C Red
Red Red F5 Fuse 562D Red 562E Red
12
072D
Red
G2 Alternator 072A
S18 Front
G2 Alternator Red 28 PTO Switch
Connector X5-W1 Main
562N
S22 Hazard Wiring Harness
Red
Switch
13
562L
K19 Flasher Red
14 S5 Rear PTO Switch
562G
Red 562B
102
Red
Red
S6 Mid PTO Switch
K14 Mid PTO 15
Latch Relay 25
85 87A 87 577B S4 Park
30 86 Brake
Pur 19
Switch
562K Red 577C Pur
562H Red 26
562M F12 Fuse
Red Socket K13 Neutral 577A
562J Pur
A B Red Relay
K16 Mid PTO
85 87A 87
Relay 30 86 519 Pur +12 VDC
Switched 18
85 87A 87
562P
30 86 Red 27 505 Dk Grn 586
Lt Blu
562L Red
586 Lt Blu
562S Red Y4 Rear
20 X8-W1 Main PTO Solenoid
16
Wiring Harness Y3 MFWD
19 To Control Panel Solenoid
S7 MFWD Switch
86
21
30
87A
22
87
23
85
K6 Fuel Solenoid 555 Wht

Timer Module
24

Test Conditions:
• Mid PTO off
• Rear PTO off
30. Mid PTO switch Battery voltage Test rear PTO switch. Test V2 diode block. Check 578 Gry,
579B and 579A Wht wires and connections.
31. K14 Mid PTO latch relay Battery voltage Check 579B and 579C Wht wires and connections.
32. K15 Mid PTO lockout relay Battery voltage Check 579B and 579D Wht wires and connections.
33. Front PTO switch Battery voltage Check 573B and 573A Org wires and connections. If ok,
34. K17 Mid PTO light relay Battery voltage Check 573B and 573C Org wires and connections. If ok,
35. K12 PTO interlock relay Battery voltage Check 575A and 575D Dk Grn wires and connections. If ok,
replace front PTO switch.
36. K11 Rear PTO interlock Battery voltage Check 575A and 575C Dk Grn wires and connections. If ok,
relay replace front PTO switch.
37. K12 PTO interlock relay Battery voltage Check 533 Org wire and connections. Test K12 PTO interlock
relay.
38. X4 Connector Battery voltage Check 575A Dk Grn wire and connections. If ok, replace front
PTO switch.
39. K6 Fuel solenoid timer Battery voltage Test transmission neutral switch. Test V1 diode block. Check
module 518A Gry, 518B Gry and 521B Brn wires and connections.
40. X5 Connector Battery voltage Check 305 Dk Grn wire and connections. If ok, replace fuel
solenoid timer module.
41. K4 Engine run relay Battery voltage Check 303 Lt Blu wire and connections. Check W2, W3 or W4
terminal.
42. K13 Neutral relay Battery voltage Check 519 Pur wire and connections. Check W2, W3 or W4
terminal.

S1 Key Switch V2 Diode Block

2
578 Gry
1 3
5
4 6
562F
S5 Rear 8 579B
Red 7 9
S18 Front PTO Switch Wht
PTO Switch
562G
Red K12 PTO
012 Interlock
Red Relay 37
B
573A 85 87A 87
30 86
F1 Org
Fuse 577B 573B
002C 35
Pur Org
Red A K17 Mid PTO 33
Light Relay 575A 575D
Dk Grn Dk Grn
85 87A 87 533
30 86 S3
Org
Transmission K11 Rear PTO
Fusible
Neutral Switch Interlock Relay
Link 573C Org
34 38
85 87A 87
30 86
+12 VDC
575C
002D Red 36
575B Dk Grn Dk Grn
W2, W3 or W4
Wiring Harness 518A S6 Mid PTO Switch
546
X5 Gry
30 Lt Blu
L
579A
40
V1 Diode Wht
X5 Block
E 562H
K4 Engine 2 Red
303 41 1 3
Run Relay 518B
Lt Blu
Socket 5 Gry
4 6 577C Pur
86
002D 8
30
Red 7 9
87A
87
521
K15 Mid PTO
85
Brn S4 Park Lockout Relay

Brake Switch
050F Blk 050G Blk 546 85 87A 87
30 86
Lt Blu
050E K13 Neutral 577A
Pur 33
Blk K6 Fuel Relay 579D Wht
305 050H Solenoid 85 87A 87
Dk Grn Blk Timer 30 86 42
505
86
050A Dk Grn K14 Mid PTO

30
Blk 521 Brn Latch Relay

87A
87
519 Pur X5
579C
39 +12 VDC G 85 87A 87
Wht
85
30 86
Switched
W1 From W2, W3
Frame or W4 Wiring
Ground 32
Harness

Cranking Circuit Operation
Function:
To energize the starting motor solenoid and engage the
starting motor to crank the engine.
• Rear PTO disengaged (disengages mid PTO)
c CAUTION: Avoid injury! ALWAYS engage

park brake when starting the engine.
The power circuit (fusible link, 002C Red wire, F1 fuse, and
012 Red wire) provides voltage to the key switch.
When placed in the start position, the key switch provides
current to the start relay contact (572A and 572C Red wires
to terminal 30 of start relay).
The start relay coil is energized through a circuit consisting
of: the key switch (terminal 5), 072B and 072C Red wires,
F5 fuse, 562D, 562F, and 562G Red wires, rear PTO switch
(OFF position), 573A and 573B Org wires, front PTO switch
(OFF position), 575A Dk Grn wire, X4 connector to
transmission neutral switch and 518B Gry to the start relay.
This engages the start relay allowing current from the 572C
Red wire to the 309 Wht wire energizing the starting motor
solenoid.
With the starting motor solenoid energized, the starting
motor solenoid contacts close and high current from the
battery passes through the battery cable and solenoid
contacts to the starting motor. The starting motor cranks
the engine.
To allow the engine to start the fuel shutoff solenoid must
also be energized to pull-in and hold-in the fuel shutoff
solenoid. See “Fuel Supply Circuit Operation” on page 382
for a detailed description of the fuel circuit.

Cranking Circuit Electrical Schematic
F1 4
012
A B
2 5 072B Red
S5 Rear
3 072C F5 Fuse PTO Switch
S1 Key On
7 A B A
Switch
562F Red Off
Start 562G Red A B
Run C
Off D E
Acc. 572B Red X5 562G Red G
F
H 573B Org
G
Aid
002C 539A 1
Red Off
Wht 2 556 Lt Blu
572D Red 3
V1 Diode
4
Block 1
X1 5
518A Gry 6
Fusible S18 Front

Link PTO Switch
S3 Transmission On
Neutral Switch
Off
In Neutral A B
C
In Gear D E
X4 X4 575B Dk Grn F
572C 518B Gry G
573A Org
H
Red
30 86
K2
Start
87A 87 85 Relay
010E
Blk
575D 556
309 Wht Dk Grn Lt Blu
30 86 K12 PTO
B A
Interlock
87A 87 85 Relay
533 010AA
Org Blk
M
010Z
M1 Blk 575C
Starting Dk Grn
Motor 86 30 K11 Rear
PTO
Red Y1
Starting Interlock
85 87 87A
Motor Relay
010W 533
Solenoid Blk Org
G1
Battery
Blk 010D Blk
010P Blk
W1 Frame
Ground


Cranking Circuit Diagnosis
Test Conditions:
• PTO off
1. Rear PTO switch Battery voltage Test F5 fuse. Check 562G, 562F, 562D, 072C, and 072B Red
wires and connections. If ok, replace key switch. See Power
Circuit Diagnosis
2. Front PTO switch Battery voltage Check 573A and 573B Org wires and connections. If ok,
3. X4 connector Battery voltage Check 575A and 575B Dk Grn wires and connections. If ok,
4. K2 Start relay Battery voltage Check 518B Gry wire and connections. If ok, replace
transmission neutral switch.
Test Conditions:
• PTO off
5. K2 Start relay (terminal 30) Battery voltage Check 572A and 572C Red wires and connections. If ok,
replace key switch.
6. Starting motor solenoid Battery voltage Check 309 Wht wire and connections. If ok, replace K2 start
relay.
7. Starting motor Starting motor Test Starting motor.

cranking engine.

S1 Key Switch
562F
S5 Rear Red
S18 Front PTO Switch
PTO Switch K12 PTO 533 Org
562G Interlock Relay
Red
85 87A 87
30 86
573A
Org
012 Red 573B
1 Org
2
575A 575D
F1 Dk Grn Dk Grn
Fuse
S3
Transmission
Neutral Switch
3
4
518B 575B Dk Grn
Gry 572A
002C Red
5
86
Red
30
572C Red 572D Red

87A
87
85
V1 Diode
Block 2
K2 Start 556 Lt Blu
1 3
Relay
5
4 6
8
7 9 K11 Rear PTO 533 Org
Interlock Relay
Fusible 85 87A 87
30 86
Link 7
575C
Dk Grn
M1 Starting Motor
309 Wht G1 Battery
W1
Frame Ground

Manifold Heater and Light Circuit Operation
Function:
To provide an added source of heat for the combustion
chamber during cold starts, especially below 5°C (40°F)
and to illuminate a light on the instrument panel and
indicate to the operator that voltage is being provided to the
manifold heater.
• Key switch must be in the start or run position and
pushed in to the aid position.
The ignition system is designed to inject diesel fuel into the
piston cylinder where heat from compression ignites the
fuel and air mixture. When starting a cold engine,
compression may not provide enough heat to ignite the
fuel. The manifold heater is installed to provide added heat
to the incoming combustion air.
The manifold heater is energized (heated) when the key
switch is placed in the aid position (key pushed into switch).
The key can be pushed into the aid position with the key in
either the start or run position. The manifold may be
preheated by pushing in the key, with the switch in the run
position, for up to 3 seconds before turning the key to the
start position.
When the key switch is in the aid position, current is
provided to the K1 manifold heater relay coil (terminal 86)
through the 385B and 385C Dk Grn wires. When the relay
coil is energized, the relay contacts close and unswitched
power (002B Red wire - terminal 30) flows through the
contacts and 383 Org wire to the manifold heater.
The H3 cold start indicator light in the instrument panel
provides a visual indication that the key is in the aid position
and the manifold heater relay is being energized. In this
position battery voltage is provided to the H3 cold start light
through the 385B and 385A Dk Grn wires, X7 connector
(terminal C), and instrument panel circuit board. A circuit
board run provides voltage to the H3 cold start light.

Manifold Heater and Light Circuit Electrical Schematic
F1 4
012
Fuse Red 1 6
A B
2 5
3
S1 Key
7 385B Dk Grn
Switch
Start
Run
Off
Acc.
385A Dk Grn X7
Aid C
002C
Red Off
002B Red
385C
X1 Dk Grn
30 86 K1
Fusible Manifold H3 Cold
Link Heater Start
87A 87 85
Relay Light
383
Org 050E
Blk
R1 Manifold
Heater
B A
M1
Starting D
Motor X8
Red 050D
Blk
G1
Battery
Blk
050A Blk 050A Blk
W1
Frame
Ground

Manifold Heater and Light Circuit Diagnosis
Test Conditions:
1. Key switch Battery voltage See Power Circuit Diagnosis
2. K1 manifold heater relay Battery voltage Check 002B Red wire and connections. See Power Circuit
Diagnosis.
Test Conditions:
3. Key switch Battery voltage Test key switch
4. K1 manifold heater relay Battery voltage Check 383 Org wire and connections. Check K1 relay. See
“Relay Test”. Replace relay as needed.
5. X7 connector Battery voltage, H3 Test cold start lamp. Check 385B and 385A Dk Grn wires and
cold start light connections.
illuminated.
Test Conditions:
• K1 manifold heater relay installed
6. Manifold heater Battery voltage Check 385B and 385C Dk Grn wires and connections.
Test Conditions:
• Meter set to ohm scale
• Meter negative lead connected to frame ground

7. Manifold heater Maximum 0.1 ohm Check manifold heater element. Replace manifold heater as
resistance needed.
8. X7 connector Less than 0.2 ohm Check 050D and 050A Blk wires and connections.
resistance
NOTE: If the tests above are performed with normal the instrument panel.
results, and the cold start light does not work, replace
X7-W1 Main Wiring Harness

S1 Key Switch To Control Panel
5
3
385B Dk Grn 385A
Dk Grn
385B
Dk Grn 1
012 Red 050D

Blk
8
385A Dk Grn 050A
Blk
4 385C
Dk Grn
W1
Frame Ground
R1 Manifold
2
86
Heater
30
002B Red
87A
87
85
6 7
K1 Manifold Heater
Relay Socket
383 Org
383 Org
F1
Fuse
002B Red
002C Red
Fusible Link
M1 Starting Motor
G1 Battery
W1 Frame Ground

Fuel Supply Circuit Operation When the key switch is placed in either the run or start
positions, current from the switched power circuit is
Function: provided to the K6 timer module through either the seat
switch and V1 diode block or the rear PTO switch, front
To start or stop the supply of fuel to the engine.
PTO switch, transmission neutral switch and V1 diode
Operating Conditions (Starting Machine): block.
• Key switch must be in the start position This circuit causes the K6 timer module to set its time delay
circuit as well as provide power to the engine run relay. The
• PTO disengaged engine run relay will energize, closing its contacts to
• Transmission in neutral provide current from the unswitched power circuit wire
002D Red to the 302B and 302C Red wires.
Operating Conditions (Machine Running, Operator ON
This energizes the hold-in coil of the fuel shutoff solenoid
Seat):
and provides voltage to the pull-in coil.
• Key switch must be in the run position
At the same time that the engine run relay is being
• Operator on seat energized, the K6 timer module will provide temporary
• PTO on or off current to the K3 fuel solenoid pull-in relay. With the fuel
solenoid pull-in relay energized, a ground path is created
• Transmission in any gear for the pull-in coil of the fuel shutoff solenoid. This allows
the fuel shutoff solenoid to overcome the spring loaded fuel
Operating Conditions (Machine Running, Operator OFF
valve.
Seat):
After approximately 3 second the timer module will cut
• Key switch must be in the run position power to the fuel solenoid pull-in relay. This will open the
• Park brake locked relay contacts and remove the ground path for the pull-in
coil.
A ground path for the fuel shutoff solenoid hold-in coil is
• PTO can be on
provided through the 010N and 010P Blk wires.
• Operator can leave seat
A latching circuit is provided to maintain voltage to the
Theory of Operation: engine run relay after the PTO is engaged.
The fuel system is designed to inject fuel into the piston This circuit allows the operator to leave the seat only after
cylinder where heat from compression ignites the fuel and the following sequence of events has been followed: the
air mixture. transmission placed in neutral, the park brake locked, and
then engage the PTO. The operator may then leave the
Fuel is provided to the engine when the fuel shutoff seat.
solenoid is energized. The fuel shutoff solenoid contains
two coils to open the fuel valve. The pull-in coil, in The engine will shutoff if either the park brake is released
conjunction with the hold-in coil, overcomes the spring or the transmission is placed in gear without having an
loaded fuel valve. The hold-in coil keeps the fuel valve open operator present on the seat.
after the pull-in coil current is removed through the K6 timer
module and the K3 pull-in relay.
The fuel shutoff solenoid is initially energized and pulled in
when the engine run relay contacts close. Voltage is
provided to both of the fuel shutoff solenoid coils (pull-in
and hold-in), which provide enough pull on the solenoid
plunger to overcome the shutoff solenoid spring.
The fuel shutoff solenoid pull-in coil needs a high current
pulse through it to overcome the solenoid spring. After the
solenoid opens (overcomes the spring) a lower current will
hold the solenoid open. The combination of the K3 fuel
shutoff relay and K6 timer module provide a means to
remove the current flow through the fuel shutoff solenoid
pull-in coil after the solenoid opens.

Fuel Supply Circuit Electrical Schematic - W1 Main with W2 SST and W3 ePowrReverser
002D Red
556 Lt Blu
F1 4
012
072C F5 Fuse
3 562E Red
S1 Key
7 572B Red
Switch
303 Lt Blu
Start
Run
Off S2 Seat
Acc.
Switch 539A 1
Wht 2 556 Lt Blu
Aid (Off Seat)
002C
Off 572D Red 3
Red (On Seat)
V1 Diode 575A Dk Grn
539D Wht 539B Wht 4

Block 1
5
521
518A Gry 6 Brn
X1
539C Wht 539C Wht
Fusible
Neutral Switch In Neutral
In Gear
X4 X4
572C 518B Gry
Red
30 86
K2
Start 002D
Red
87A 87 85 Relay 303
Diode Red
B A 30 86 K4
Block 1 Engine
010F 87A 87 85 Relay
010Z Blk 302B 562M
Blk
Red 050F Red
X2 Blk
M 302C Red
050G
M1 Blk 562P
Wht 050E Red
Starting Y1
Solenoid Wht
85 87 87A
329 304 Org
Blk Wht
562S Red
W1 X2 30 86 K3 Fuel
Frame 010N Shutoff
Ground Blk Solenoid
W1 010AJ 010F
Blk Blk
Frame
Ground 050A Blk
010D Blk
010P Blk


556 Lt Blu
303 Lt Blu X5 E 303 Org

562F Red
572B Red X5 H 572 Red
S18 Front
PTO Switch W2 SST Wiring Harness
556 X5
On 575D
Lt Blu
Dk Grn A 519 Wht
Off 30 86 K12 PTO
E 521 Brn
A B
Interlock
C Relay G 519 Wht
D E 87A 87 85
575A Dk Grn F L 521 Brn
G 533 010AA
H 573A Org Org Blk
575B Dk Grn
539C Wht X5 G 519B Wht
S5 Rear 539C Wht X5 J 539 Wht

PTO Switch
On 303 Org
A1
562F Red Off
562G Red A B
X21
C
F
C3
562G Red G
573B Org
A1
H 521 Brn
562H Red Electronic D2
Operating
S4 Park 519A Wht
System F1
Brake Switch Controller 539 Wht
F3
On
050B Blk
Off 505 519 G2
Dk Grn Pur
C 86 562B Red
B 30 K13 K1
577A Pur A D 505 Dk Grn Neutral

87A 87 85 Relay
546 010AB
S6 Mid Lt Blu Blk
PTO Switch S10
F-N-R
On Switch Forward
575C 546
Off Dk Grn Neutral
Lt Blu
A B
C PTO
D E
562H Red G
F Interlock 562C Red 519C Wht
577C Pur 85 87 87A
H Relay
010W 533
Blk Org
W1
Frame
010D Blk
010P Blk


Fuel Supply Circuit Electrical Schematic - W1 Main with W4 eHydro
002D Red
556 Lt Blu
F1 4
012
072C F5 Fuse F10 Fuse
2
3 212A Red 562E Red

S1 Key 212B Red
7
Switch
Start 303 Lt Blu
Run
Off S2 Seat
Acc.
Switch 539A 1
Wht 2 556 Lt Blu
Aid (Off Seat)
002C
Off 572D Red 3
Red (On Seat) 575A Dk Grn
V1 Diode
539D Wht 539B Wht 4
Block 1
5
521
518A Gry 6 Brn 539C Wht
X1
539C Wht
Fusible
Neutral Switch
In Neutral
In Gear
X4 X4 575A Dk Grn
572C 518B Gry
Red
30 86
K2
Start 002D
Red
87A 87 85 Relay 303
Diode Red
B A 30 86 K4
Block 1 Engine
010F 87A 87 85 Relay
010Z Blk 302B 562M
Blk
Red 050F Red
X2 Blk
M 302C Red
050G
M1 Blk 562P
Wht 050E Red
Starting Y1
Solenoid Wht
85 87 87A
329 304 Org
Blk Wht
562S Red
W1 X2 30 86 K3 Fuel
Frame 010N Shutoff
Ground Blk Solenoid
W1 010AJ 010F
Blk Blk
Frame
Ground 050A Blk
010D Blk
010P Blk


556 Lt Blu
552 Red X5 552A Red

F
S18 Front
PTO Switch
575D
On Dk Grn
556
Off Lt Blu
A B 30 86 K12 PTO
D
C
E Interlock
575A Dk Grn G
F Relay
H
573A Org 87A 87 85
533 010AA
Org Blk
575B Dk Grn
539C Wht X5 519 Wht

G
S5 Rear 539C Wht X5 539 Wht
PTO Switch
J
On
562F Red Off

X25
562G Red A B
C 539 Wht
577B Pur D E
A1
F
562G Red G 552B Red
H 573B Org A3
562H Red
S4 Park A2
Brake Switch 505 519 Electronic
Dk Grn Pur Operating
On 30 86 K13 System 519 Wht
D1
Off Neutral Controller
C 87A 87 85 Relay
B
546 010AB
577A Pur A D 505 Dk Grn Lt Blu Blk E2
050B Blk
S6 Mid
PTO Switch
On
575C 546
Off Dk Grn Lt Blu
86 30 K11 Rear
A B
C PTO
D E
562H Red F Interlock
G 85 87 87A
H 577C Pur Relay
010W 533
Blk Org
W1
Frame X5
Ground B 050A Blk
010D Blk
010P Blk


Fuel Supply Circuit Diagnosis
Test Conditions:
3. K6 Fuel solenoid timer Continuity to ground Check 050H, 050G, 050F, 050E and 050A Blk wires and
module connections.
4. K3 Fuel shutoff solenoid Continuity to ground Check 010F, 010E, 010Z and 010D Blk wires and connections.
pull-in relay
Test Conditions:
• PTO off
6. K6 Fuel solenoid timer Battery voltage Test F5 fuse. Check 072B, 072C, 562K, 562M, 562P, and 562S
module Red wires and connections. If ok, replace key switch.
7. Seat switch Battery voltage Test F5 fuse. Check 072B, 072C Red, 562D and 562E Red
8. X5 Connector Battery voltage Check 539D and 539C Wht wires and connections. If ok,
replace seat switch.
9. K6 Fuel solenoid timer Battery voltage Test V1 diode block. Check 539D and 539B Wht and 521 Brn
module wires and connections.
10. K4 Engine run relay Battery voltage Check 305 Dk Grn, X5 connector, and 303 Lt Blu wires and
connections. If ok, replace K6 timer module.
11. X2 Connector Battery voltage Check 302B and 302C Red wires and connections. If ok,
replace K4 engine run relay.
12. Rear PTO switch Battery voltage Test F5 fuse. Check 072B, 072C, 562D, 562F, and 562G Red
14. X4 Connector Battery voltage Check 573A and 573B Org wires and connections. If ok,

15. K6 Fuel solenoid timer Battery voltage Test V1 diode block. Check 518A and 518B Gry and 521 Brn
module wires and connections. If ok, replace transmission neutral
switch.

S2 Seat
Red X5
A 7
S18 Front PTO Switch 539D

562F Wht
S5 Rear PTO Switch Red
562G Red
012
2
Red
S3 Transmission
Neutral Switch 573B
13 Org
14
518A Gry
12 8
K2 Start 518B Gry 575A Dk Grn 573A Org
Relay 539C
Wht X5
539B
86
J
Wht
30
F1
87A
87
Fuse
539A
V1 Diode Wht
85
002D Red Block
1
010F Blk 010E Blk
4
010D Blk
5
8
2
002C X5
+12 VDC Red
9
6
3
L
518B Gry
Fusible Link
X5
W2, W3 or W4 E
Wiring Harness 10 3
303 K6 Fuel
Lt Blu Solenoid
050H 15
Blk Timer
86
9
K4 Engine Run
30
86
87A
305
87
Relay Socket 521

30
Dk Grn Brn
87A
87
85
562S
1
85
Red
050E Blk 050F Blk 6
050G Blk
X2 To Y2
050A
Fuel Shutoff
Blk 302B Red 302C Red
010N Blk Solenoid
304 Org
5
86
30
010P Blk 010AJ Blk 329 Wht 11

87A
87
W1 K3 Fuel Shutoff
85
Frame 4 Solenoid Pull-in

Ground
010F Blk Relay

Test Conditions:
• Key switch turned from off to run position while performing each test.
• PTO off
16. K3 Fuel shutoff solenoid Battery voltage for 3 Check 304 Org wire and connections. If ok, replace K6 fuel
pull-in relay seconds, then less solenoid timer module.
than 0.2 volts.
17. X2 connector Continuity to ground Check 329 Wht, 010AJ and 010P Blk wires and connections. If
for 3 seconds, then ok, replace K3 fuel shutoff solenoid pull-in relay.
infinity.
Test Conditions:
• PTO off
18. K12 PTO interlock relay Battery voltage Check 575B and 575D Dk Grn wires and connections. If ok,
19. K11 Rear PTO interlock Battery voltage Check 575B and 575C Dk Grn wires and connections. If ok,
relay replace front PTO switch.
brake switch.
relay


S2 Seat
Red X5
A

S5 Rear
PTO Switch 562F Wht
Red
539C Wht X5
562G Red
012 J
Red
K12 PTO
S3 Transmission 24
Interlock
Neutral Switch 573B Relay
Org
85 87A 87
518A Gry 30 86
573A Org 26
K2 Start 518B Gry 575A Dk Grn
575D
Relay
18 Dk Grn
86
539B
30
F1 556 Lt Blu
87A
87
Fuse Wht
539A 533
V1 Diode Wht Org
85

010F Blk 010E Blk
7
Interlock Relay
4
010D Blk
5
85 87A 87
30 86
8
25
002C X5 575C
+12 VDC Red Dk Grn 23 19
9
6
L
518B Gry
X5 305
W2, W3 or W4 E
Dk Grn
Lt Blu Solenoid
050H 577C 546
Timer Lt Blu
86
Blk Pur
K4 Engine Run
30
86
87A
87

30
Brn 562H Red Brake

87A
87
85
20 Switch
562S
21
85
Red
050E Blk 050F Blk
050G Blk
050A K13 Neutral
010N Blk 27 Pur
304 Org 85 87A 87 505
16 30 86
Dk Grn
86
22
519 Pur X5
30
010P Blk 010AJ Blk 329 Wht

87A
87
G
W1 K3 Fuel Shutoff 17 X2 To Y2
+12 VDC Switched
85
Frame Solenoid Pull-in Fuel Shutoff

010F Blk Relay Solenoid
Wiring Harness

Engine Shutoff Circuit Operation switch (operator on seat), 539D and 539B Wht wires, V1
diode block (terminals 4 to 5), 521 Brn wire, K6 solenoid
Engine Shutoff Function: timer module, 305 Dk Grn wire, X5 connector to the 521
Brn wire of the W2 (SST), W3 (ePowrReverser), or W4
To cut power to the fuel shutoff solenoid and stop the
machine engine when desired or in an unsafe operating (eHydro) wire harness.
condition. On ePowrReverser machines the 521 Brn wire provides
input to the A1 drive controller. The drive controller then
Operating Conditions: provides output to the 303 Org wire, X5 connector to the
• Engine running 303 Lt Blu wire of the W1 main wiring harness and the K4
engine run relay coil.
Engine MUST STOP when: from the K to the E terminal of the X5 connector. This
• Operator places the key switch in the off position.
or;
This seat circuit provides voltage to the engine run relay for
• PTO off, normal operator on seat operation of the machine.
• Operator gets out of seat, and
PTO OFF Circuit
• Park brake is locked.
The front and rear PTO switches are the second path to
or; provide power to the K4 engine run relay coil.
• Operator gets out of seat, and The rear PTO switch in combination with the front PTO
• Transmission is in gear. switch and transmission neutral switch provides power to
the fuel circuit. Power is provided from the key switch to the
NOTE: If transmission is in neutral and the PTO is 072B and 072C Red wires, F5 fuse, 562A, 562D, 562F and
disengaged, and then the park brake is set, the 562G Red wires, rear PTO switch (PTO off), 573A and
operator can engage the rear PTO and then leave the 573B Org wires, S18 front PTO switch (PTO off), 575A Dk
seat. Grn wire, S3 transmission neutral switch, 518B and 518A
Gry wires, V1 diode block (terminals 6 to 5), 521 Brn wire,
Theory of Operation: X5 connector to the 521 Brn, K6 solenoid timer module,
Fuel is supplied to the engine provided that operating 305 Dk Grn wire, X5 connector to the 521 Brn wire of the
conditions are met. See “Fuel Supply Circuit Operation” on W2 (SST), W3 (ePowrReverser), or W4 (eHydro) wire
page 382. harness.
When the operator places the key switch in the off position On ePowrReverser machines the 521 Brn wire provides
or if an unsafe condition is created, the engine will stop by input to the A1 drive controller. The drive controller then
having the fuel supply to the engine shut off. provides output to the 303 Org wire, X5 connector to the
303 Lt Blu wire of the W1 main wiring harness and the K4
The fuel supply is shut off when voltage to the K4 engine
engine run relay coil.
run relay coil is removed, its contacts open, power to the Y2
fuel shutoff solenoid coils is removed and the solenoid On SST and eHydro machines the 521 Brn wire jumpers
closes. from the K to the E terminal of the X5 connector. This
Power to the K4 engine run relay coil comes from the K6
solenoid timer module, V1 diode block (terminal 5), and is
provided to the diode block (terminals 4 or 6) through This circuit provides voltage to the engine run relay if the
different circuits. The different circuits allow for a variety of PTO is off and the transmission is in neutral, with or without
operating conditions to exist and maintain fuel supply to the the operator in the seat.
engine.
PTO ON, Operator OFF Seat
Seat Switch Circuit A third circuit provides power from the switched power
The seat switch is the main and most direct circuit to circuit through the mid PTO switch, park brake switch, and
provide power to the K6 solenoid timer module and K4 the K11, K12 and K13 safety relays.
engine run relay coil. The park brake switch and the K11, K12 and K13 relays, in
Power is provided through the key switch, 072B and 072C conjunction with the mid PTO switch, create a self-latching
Red wires, F5 fuse, 562D and 562E Red wires, S2 seat circuit. The front, rear, and mid PTOs must be off, the

transmission must be in neutral, and the park brake must connector to the 521 Brn wire of the W2 (SST), W3
be locked to create the circuit. On ePowrReverser (ePowrReverser), or W4 (eHydro) wire harness.
machines the reverser lever must also be in the neutral
On ePowrReverser machines the 521 Brn wire provides
position. On eHydro machines, the drive pedals being in
input to the A1 drive controller. The drive controller then
neutral will indicate a neutral drive condition. provides output to the 303 Org wire, X5 connector to the
Once the latch circuit is established the PTO can be on. 303 Lt Blu wire of the W1 main wiring harness and the K4
The latching circuit will remain energized until the PTO engine run relay coil.
switch is placed in the off position or the park brake is
unlocked, eliminating power to the circuit.
from the K to the E terminal of the X5 connector. This
On ePowrReverser machines, if the reverser lever is shifted provides power to the 303 Lt Blu wire of the W1 main wiring
into a drive direction or on eHydro machines, if either drive harness and the K4 engine run relay coil.
pedal is pressed, power will be eliminated from the latching
The PTO can now be engaged, and power will remain to
circuit.
the K4 engine run relay through the park brake switch,
Power is provided to the S4 park brake switch through the latching relay circuit with the operator off the seat.
key switch, 072B and 072C Red wires, F5 fuse, 562A, If the park brake is unlocked without the operator on the
562D, 562F 562G and 562H Red wires, mid PTO switch seat, the engine will stop.
and 577C and 577A Pur wires to the park brake switch.
With the park brake locked, power is provided through the
park brake switch and 505 Dk Grn wire to the K13 neutral
relay (terminal 30). Power is provided to the K13 neutral
relay coil (terminal 86) through the W2 wiring harness
jumper wire on SST machines, F-N-R switch on
ePowrReverser machines and the drive pedals in neutral
and A2 drive controller on eHydro machines.
Power is supplied to either the F-N-R switch
(ePowrReverser) or A2 drive controller and the drive pedals
(eHydro) from the switched power circuit. With the F-N-R
switch in neutral and the park brake locked, power is
supplied to the 519B (ePowrReverser) or 519 Wht wire, X5
connector, 519 Pur wire and the K13 neutral relay coil
(terminal 86).
With the K13 coil energized, and power to the K13 contact
(terminal 30), power is provided through the K13 contacts
and 546 Lt Blu wire to the K11 rear PTO interlock relay
(terminal 30).
The K11 rear PTO interlock relay is energized as result of
both the front and rear PTO switches being in the
disengaged position and power being provided to 573A and
573B Org and 575A, 575B, 575C, and 575D Dk Grn wires.
The power continues through the K11 contacts, and the
533 Org wire to K12 (terminal 87A).
The K12 PTO/Start interlock relay is de energized,
(operator off seat), and power is supplied across its
normally closed contacts (terminals 87A to 30) to 575A,
575B, 575C and 575D Dk Grn wires.
This provides a latch circuit that will continue to provide
current to the K4 engine run relay.
The 575A, 575B, 575C and 575D Dk Grn wires, provide
power to the S3 transmission neutral switch, 518B and
518A Gry wires, V1 diode block (terminals 6 to 5), 521 Brn
wire, K6 solenoid timer module, 305 Dk Grn wire, X5

Engine Shutoff Circuit Electrical Schematic - W1 Main with W2 SST and W3 ePowrReverser
002D Red
556 Lt Blu
F1 4
012
Fuse Red 1 6
072C F5 Fuse
3 562E Red
S1 Key
7
Switch
Start 303 Lt Blu
Run
Off S2 Seat
Acc.
Switch 539A 1
Wht 2 556 Lt Blu
Aid (Off Seat)
002C
Off 3
Red (On Seat)
V1 Diode
539D Wht 539B Wht 4
Block 1
5
521
518A Gry 6 Brn
X1 575A Dk Grn
539C Wht 539C Wht

Fusible
Neutral Switch
In Neutral
In Gear
X4 X4
518B Gry
002D
Red
303
V1 Lt Blu 562K
Diode Red
B A 30 86 K4
Block 1 Engine
87A 87 85 Relay
302B 562M
Red 050F Red
X2 Blk
M 302C Red
050G
M1 Blk 562P
Wht 050E Red
Starting Y1
Solenoid Wht
85 87 87A
Blk
562S Red
X2
010N
Blk
305 Dk Grn
050A Blk
W1 010D Blk
Frame 010P Blk
Ground


556 Lt Blu
S18 Front 575D W2 SST Wiring Harness

PTO Switch Dk Grn X5
556
Lt Blu A 519 Wht
On
30 86 K12 PTO E 521 Brn
Off
Interlock G 519 Wht
A B Relay
C 87A 87 85 L 521 Brn
D E
F 533 010AA
575A Dk Grn G Org Blk
H 573A Org
575B Dk Grn X5 F 519B Wht

539C Wht
539C Wht X5 H 539 Wht
S5 Rear
PTO Switch
303 Org
On A1
562F Red Off

X21
562G Red A B
C
577B Pur D E
F A1
562G Red G 521 Brn
H 573B Org Electronic D2
562H Red
Operating
S4 Park 519A Wht
System F1
Brake Switch Controller 539 Wht
F3
On
050B Blk
Off G2
505 519
C Dk Grn Pur 562B Red
B 86 K1
30 K13
Neutral
87A 87 85 Relay
546 010AB
S6 Mid Lt Blu Blk S10
PTO Switch F-N-R
On Switch Forward
575C 546
Dk Grn Neutral
Off Lt Blu
A B
C
PTO
D E
F
562H Red G 85 87 87A
H 577C Pur Relay
010W 533
Blk Org
W1
Frame
010D Blk
010P Blk


Engine Shutoff Circuit Electrical Schematic - W1 Main with W4 eHydro
002D Red
556 Lt Blu
F1 4
012
Fuse Red 1 6
A B 072C F5 Fuse
2
A B
3 212A Red 562E Red
S1 Key
Switch
7 F10 Fuse
212B Red
Start 303 Lt Blu

Run
Off S2 Seat
Acc.
Switch 539A 1
Wht 2 556 Lt Blu
Aid (Off Seat)
002C
Off 3
Red (On Seat)
V1 Diode
539D Wht 539B Wht 4
Block 1
5
521
518A Gry 6 Brn
X1 575A Dk Grn
539C Wht 539C Wht

Fusible
Neutral Switch
In Neutral
In Gear
X4 X4 575A Dk Grn
518B Gry
002D
Red
303
V1 Lt Blu 562K
Diode Red
B A 30 86 K4
Block 1 Engine
87A 87 85 Relay
302B 562M
Red 050F Red
X2 Blk
M 302C Red
050G
M1 Blk 562P
Wht 050E Red
Starting Y1
Solenoid Wht
85 87 87A
Blk
562S Red
X2
010N
Blk
305 Dk Grn
050A Blk
W1 010D Blk
Frame 010P Blk
Ground


556 Lt Blu
552 Red X5 552A Red

F
S18 Front
PTO Switch
575D
On Dk Grn
556
Off Lt Blu
A B 30 86 K12 PTO
D
C
E Interlock
575A Dk Grn G
F Relay
H 573A Org 87A 87 85
533 010AA
Org Blk
575B Dk Grn
539C Wht X5 519 Wht

G
S5 Rear 539C Wht X5 539 Wht
PTO Switch
J
On
562F Red Off

X25
562G Red A B
C 539 Wht
577B Pur D E
A1
F
562G Red G 552B Red
H
573B Org A3
562H Red
S4 Park A2
Brake Switch 505 519 Electronic
Dk Grn Pur Operating
On 30 86 K13 System 519 Wht
D1
Off Neutral Controller
C 87A 87 85 Relay
B
546 010AB
577A Pur A D 505 Dk Grn Lt Blu Blk E2
050B Blk
S6 Mid
PTO Switch
On
575C 546
Off Dk Grn Lt Blu
86 30 K11 Rear
A B
C PTO
D E
562H Red F Interlock
G 85 87 87A
H 577C Pur Relay
010W 533
Blk Org
X5 B 050A Blk
010D Blk
010P Blk
W1 Frame
Ground


Engine Shutoff Circuit Diagnosis
Test Conditions:
Test Conditions:
• Rear PTO on
3. Seat switch Battery voltage Test F5 fuse. Check 072B, 072C Red, 562D and 562E Red
module connections. If ok, replace seat switch.
5. K4 Engine run relay Battery voltage Check 305 Dk Grn, 521 Brn, (303 Org ePowrReverser), and
303 Lt Blu wires and connections. If ok, replace K6 timer
module.
6. X2 connector Battery voltage Check 302C and 302B Red wires and connections. If ok,
replace K4 engine run relay.
Test Conditions:
• PTO off
8. Rear PTO switch Battery voltage Test F5 fuse. Check 072B, 072C Red, 562D, 562F and 562G
Red wires and connections. If ok, replace key switch.

10. X4 connector Battery voltage Check 575A Dk Grn wire and connections. If ok, replace front
PTO switch.
module connections.

S2 Seat
Red X5
A 3

S5 Rear
PTO Switch 562F Wht
Red
539C Wht X5
562G Red
012 J
2 Red
K12 PTO
S3 Transmission
Interlock
Neutral Switch 9 573B
10 Relay
Org
85 87A 87
518A Gry 8 30 86
573A Org
518B Gry 575A Dk Grn
575D
Dk Grn
F1 539B
556 Lt Blu
Fuse Wht
539A 533
V1 Diode Wht Org
7
Interlock Relay
4
5
85 87A 87
30 86
8
002C X5 575C
+12 VDC Red Dk Grn
9
6
L
518B Gry
X5 305
W2, W3 or W4 E
Dk Grn
Wiring Harness 5 303 K6 Fuel
Lt Blu Solenoid 11
050H 577C 546
Timer 4
Blk Lt Blu
86
Pur
K4 Engine Run
30
86
87A
87

30
Brn 562H Red Brake

87A
87
85
1 Switch
562S
85
Red
050E Blk 050F Blk
050G Blk
050A K13 Neutral
010N Blk Pur
85 87A 87 505
30 86
Dk Grn
X2 To Y2 519 Pur X5
Fuel Shutoff 6
7 G
Solenoid
W1
Frame +12 VDC Switched
Wiring Harness

Test Conditions:
• Key switch in to run position, engine off
• PTO off
11. K12 PTO interlock relay Battery voltage Check 575A, 575B, and 575D Dk Grn wires and connections. If
ok, replace front PTO switch.
12. K11 Rear PTO interlock Battery voltage Check 575A, 575B, and 575C Dk Grn wires and connections. If
relay ok, replace front PTO switch.
brake switch.
16. K13 Neutral relay Battery voltage ePowrReverser - Check 519A, 519B, 519C Wht and 519 Pur
wires and connections. If ok, replace F-N-R switch.
eHydro - Check 247 Pur, 519 Wht and 519 Pur wires and
connections. Check drive pedals for neutral condition.
relay
Test Conditions:
1. Key switch in run position, engine off
2. Operator off seat
3. Transmission(s) in neutral
4. Park brake locked
5. Rear PTO on

22. K6 fuel solenoid timer Battery voltage Test V1 diode block. Check 575A, 575B and 575D Dk Grn,
module 518A and 518B Gry, and 521 Brn wires and connections. If ok,
replace K12 interlock relay.

S2 Seat
Red X5
A

S5 Rear
PTO Switch 562F Wht
Red
539C Wht X5
562G Red
012 J
2 Red
K12 PTO
S3 Transmission 18
Interlock
Neutral Switch 573B Relay
Org
85 87A 87
518A Gry 30 86
573A Org 20
518B Gry 575A Dk Grn
575D
Dk Grn
11
F1 539B
556 Lt Blu
Fuse Wht
539A 533
V1 Diode Wht Org
7
Interlock Relay
4
5
85 87A 87
30 86
8
002C X5 575C 19
12
+12 VDC Red Dk Grn 17
9
6
L
518B Gry
X5 305
W2, W3 or W4 E
Dk Grn
Lt Blu Solenoid
050H 22 577C 546
Timer Lt Blu
Blk
86
Pur
K4 Engine Run
30
86
87A
87

30
Brn 562H Red Brake

87A
87
85
13 Switch
562S
14
85
Red
050E Blk 050F Blk
050G Blk
050A K13 Neutral
010N Blk Pur
85 87A 87 505
30 86
Dk Grn
16
21
X2 To Y2 15 519 Pur X5
Fuel Shutoff G
Solenoid
W1
Frame +12 VDC Switched
Wiring Harness

Charging Circuit Operation Tachometer Circuit Operation
Function: Function:
To maintain battery voltage between 12.4 and 13.2 volts. To indicate engine rpm to the operator.
Operating Conditions: Operating Conditions:

• Key switch in run position • Key switch in run position
• Engine running • Engine running
Theory of Operation: Theory of Operation:

The charging system consists of the G2 alternator with an Pulsed current flows from the “P” terminal of the alternator
integrated voltage regulator/rectifier. Charging output is to the instrument panel (X8 connector, terminal F) through
controlled by a regulator/rectifier. The status of the charge the 325 Dk Grn wire.
rate is indicated by the H5 discharge light.
With the key switch in the run position, battery sensing Hour Meter Circuit Operation
circuit current flows from battery positive terminal to the
starting motor terminal, fusible link, 002C Red wire, F1 Function:
fuse, 012 Red wire, S1 key switch, 072B and 072A Red To indicate engine hours of use to the operator.
wires to the alternator voltage regulator/rectifier. The
battery sensing circuit allows the voltage regulator/rectifier Operating Conditions:
to monitor battery voltage.
A rotating permanent magnet in the alternator induces AC
• Engine running
current in the alternator stator coils. The AC current flows to
the voltage regulator/rectifier. The voltage regulator/rectifier Theory of Operation:
converts AC current to DC current needed to charge the
battery. The hour meter is integrated into the instrument panel and
does not have any external wiring. The hour meter
If battery voltage is low, the regulator/rectifier allows DC operates only when the engine is running. The hour meter
current to flow to the battery to charge it through the battery uses the engine tachometer circuit for power. If the
charging circuit (002A Red). When the battery is fully tachometer is not functioning, the hour meter will not work.
charged, the voltage regulator/rectifier stops current flow to See “Charging Circuit Operation” on page 405 for
the battery. information on tachometer and hour meter diagnosis.
If the alternator output current falls below system usage or
is insufficient to maintain a preset voltage, the voltage
regulator/rectifier provides current to turn on the discharge
light through the 334 Yel wire, X7 connector, and the
instrument panel circuit board.
The alternator is grounded through the mounting hardware
to the engine.
If the voltage regulator is grounded to the alternator cover,
the alternator produces unregulated amperage. See
“Unregulated Amperage Test”.

Charging, Tachometer and Hour Meter Circuit Electrical Schematic
002A Red
F1 4 G2
012 B Alternator
Fuse Red 1 6
G
072A Red
2 5 072B Red
IG L
3 P 334
072C 325
S1 Key Red Dk Grn
Yel X7
7 334 Yel A
Switch
Start F5 H5
Run Fuse Discharge
Off
Acc. Light
Aid _
002C +
Red Off
562D
Red
X1
562 Splice 562L Red X8
A
Fusible
Link
325 Dk Grn X8
F
002A Red P2 Hour

Meter
B A
(Opt.)
n/min
P1 Engine
Tachometer
M
D
M1 X8
Starting 050D
Motor Blk
Red Y1
Starting
Motor
Solenoid
G1
Battery
Blk 050A Blk
W1
Frame Unswitched Power Switched Power
Ground

Charging, Tachometer and Hour Meter Circuit Diagnosis
Test Conditions:
• Transmission in neutral position
• PTO off
1. Battery positive terminal Battery voltage Test battery. See Battery Test.
2. Starting motor “B” terminal Battery voltage Check battery and starting motor cable connections.
3. Alternator “B” terminal Battery voltage Check 002A Red cable and connections to battery.
Test Conditions:
• Alternator plug disconnected
4. Alternator connector Battery voltage Check 072A and 072B Red wires and connections. See “Power
Circuit Diagnosis”.
Test Conditions:
• Alternator plug connected
• X7 and X8 connectors to Instrument panel disconnected
5. X8 connector Battery voltage Test F5 fuse. Check 562L and 562D Red wires and
connections.
6. X8 connector 0.04 volts Check 325 Dk Grn wire and connections.
7. X7 connector 0.45 volts Check 334 Yel wire and connections.
8. X8 connector Continuity to ground Check 050D and 050A Blk wire and connections.
Test Conditions:
• Key switch in run position, engine running
• PTO off

9. Alternator Minimum 12.2 volts See “Regulated Amperage and Voltage Tests”. Replace voltage
regulator/rectifier.
10. Battery 12.4 volts or higher Check for excessive load on electrical system.
NOTE: If the tests above are performed with normal work, replace the instrument panel.
results, and the tachometer and/or hour meter do not
M1 Starting Motor
Fusible Link 002C Red
002B Red S1 Key Switch
F1 Fuse
002A Red 012 Red
2
9 072B
3 Red
G1 Battery 072A Red
072C
Red
F5
Fuse
1 10
562D
G2 Alternator Red
Connector
G2 Alternator
W1 4
325
Frame
Ground Dk Grn
334 Yel
562L Red
050A
Blk 050D Blk
7
334 Yel 5
562L Red
8
6
050D Blk
325 Dk Grn
X7-W1 Main Wiring Harness X8-W1 Main Wiring Harness
To Control Panel To Control Panel
050A Blk 050D Blk

ePowrReverser - Forward Drive Circuit The proper conditions for a forward function will be:
The forward drive circuit causes the electronic operating • 5.0 volt output on wire 673A, 673B, 673C and 673D Org
system to engage the forward drive clutch to propel the wire, potentiometer and pressure transducer power,
machine in a controlled forward direction. • Continuity to ground on 050A, 050B, 050C, 050D, 050E,
• 12.0 volt input on 686 Lt Blu wire, F-N-R switch in
Operating Conditions: forward position,
• Key switch in run position • Input less than 0.2 volt on 687A, 687B, and 687C Pur
• Engine running wires, reverse input wires,
• Park brake unlocked during drive command.
transducer,
machine forward drive function via the electrical inputs from status light,
the F-N-R switch. Under normal operating conditions, this • Output 660 +25/-50 mA on 696 Lt Blu wire, forward
creates an output to the forward proportional solenoid in proportional solenoid energized at full drive, and
the transmission which in turn engages the forward drive
• No output current on 697 Pur wire, reverse proportional
clutch.
solenoid not energized.
machine to travel forward at a speed based upon the
controller.
respectively.
When the F-N-R lever is placed in the forward position,
through the 686 Lt Blu wire. The drive controller then
(current) to the forward proportional solenoid can be either

ePowrReverser - Forward Drive Circuit Electrical Schematic
S12
Motion Match
Switch Off
F5
072C 562D On
Red Fuse Red
+12VDC 562E Red
A B 269 Wht
S11
562A 562A
Clutch
Red X5 Red
A
Bottom of Travel
S2 Seat 596 Lt Blu
Switch
562D Red Y6
Forward
Switch Forward
562E Red
539D Wht Neutral
539C 696
Reverse Lt Blu
Wht
686 Lt Blu
X5 562C Red
X21 J 694
Yel
A1
696 Lt Blu
A2
697 Pur
A3
688 Gry
B1
B2 694 Yel
B3 695 Dk Grn
C1
697
C2
Pur
C3
D1
D2
A1 D3
E1 686 Lt Blu 695
Electronic E2 596 Lt Blu Dk Grn
Operating E3
System F1 Y7
269 Wht
Controller F2 Reverse
F3 539 Wht
Proportional
G1
050B Blk Solenoid
G2
G3
H1 676 Lt Blu
H2
H3
591Brn
J1 676
J2 Lt Blu
J3 R2 B4
562B Red
K1 Clutch Position 673C Org Forward
K2
673A Org 673B Org X24 Potentiometer m Pressure
K3
Transducer
591 Brn X24 050D
688 Blk
Gry
050A Blk X5 B 050A Blk 050C Blk X24 H11
ePowrReverser
Indicator Light
050G
W1 Blk
Frame
Ground


ePowrReverser - Forward Drive Circuit Diagnosis
Test Conditions:
connections.
Test Conditions:
wiring harness.
wiring harness.
wiring harness.
wiring harness.
10. Forward pressure 5.0 ± 0.2 volts Check 673A and 673C Org wires and connections of the W3

Test Conditions:
• F-N-R switch in forward
• MFWD off
11. A1 drive controller at X21 Battery voltage Test F-N-R switch. Check 686 Lt Blu wire and connections of
connector the W3 wiring harness.
12. Forward proportional 660 +25/-50 mA Check 696 Lt Blu and 694 Yel wires and connections of the W3
solenoid wiring harness. Test forward proportional coil. Check forward
proportional coil.
13. A1 drive controller at X21 3.3 - 4.7 volts Test forward pressure transducer. Check 676 Lt Blu wire and

S11 Bottom of
+12 VDC 050A Blk
+12 VDC 3
2
562D Red
X5-W1 Main 539 Wht
1 596 Lt Blu
S17 Motion S10

Match F-N-R Switch
Switch
269 Wht 5
562E Red
4 562C Red
686 Lt Blu
519C Wht
A1 Electronic
Controller
3
A 1 2
B4 Forward
Pressure Transducer
676 Lt Blu
11 050D Blk
K
7 10
673C Org
B5 Reverse
13
Pressure Transducer
6 8
H12 Backup
Alarm 677 Pur
687C Pur
050E Blk
673D Org
050F Blk
R2 Clutch
Position
Potentiometer
Solenoid Solenoid
673B Org
12 591 Brn
050C Blk
696 Lt Blu
694 Yel
H13 ePowrReverser
697 Pur 688 Gry
Operating System
Controller Status
050G Blk

ePowrReverser - Reverse Drive Circuit The proper conditions for a reverse function will be:
The reverse drive circuit causes the electronic operating • 5.0 volt output on wire 673A, 673B, 673C and 673D Org
system to engage the reverse drive clutch to propel the wire, potentiometer and pressure transducer power,
machine in a controlled reverse direction. • Continuity to ground on 050A, 050B, 050C, 050D, 050E,
• 12.0 volt input on 687B Pur wire, F-N-R switch in
Operating Conditions: reverse position,
• Key switch in run position • Input less than 0.2 volt on 686 Lt Blu wire, forward input
• Engine running wire,
transducer,
during drive command.
machine reverse drive function via the electrical inputs from status light,
the F-N-R switch. Under normal operating conditions, this • Output 660 +25/-50 mA on 697 Pur wire, reverse
creates an output to the reverse proportional solenoid in proportional solenoid energized at full drive, and
the transmission which in turn engages the reverse drive
• No output current on 696 Lt Blu wire, forward
clutch.
proportional solenoid not energized.
the output to the reverse proportional solenoid to allow the
machine to travel reverse at a speed based upon the
controller.
respectively.
When the F-N-R lever is placed in the reverse position,
through the 687B Pur wire. The drive controller then
(current) to the reverse proportional solenoid can be either

ePowrReverser - Reverse Drive Circuit Electrical Schematic
S12
Motion Match
Switch Off
F5
072C 562D On
Red Fuse Red
+12VDC 562E Red
269 Wht
S11
562A 562A Clutch
Red X5 Red Switch Top of Travel
A
Bottom of Travel
S2 Seat 596 Lt Blu
Switch
562D Red Y6
Forward
Switch Forward
562E Red
539D Wht Neutral
539C 696
Reverse Lt Blu
Wht
X5 562C Red
X21 H 687B Pur 694
Yel
A1
696 Lt Blu
A2
697 Pur
A3
688 Gry
B1
B2 694 Yel
B3 695 Dk Grn 697
C1 H12 Pur
C2 Backup Alarm
C3 687A Pur 687C Pur
D1
D2 050F 695
A1 D3 Blk Dk Grn
E1
Electronic 596 Lt Blu
E2 Y7
Operating E3 Reverse
System F1
F2
Controller
F3 539 Wht Solenoid
G1 677 Pur
050B Blk
G2
G3 677
688 Pur
H1 B5
H2 Gry
673D Org Reverse
H3
J1
591Brn
H11 ePRT
Indicator
m Pressure
J2 Transducer
Light
J3 R2 050E
562B Red 050G
K1
Blk
Clutch Position Blk
K2
673A Org 673B Org X24 Potentiometer
K3
591 Brn X24
050A Blk X5 B 050A Blk 050C Blk X24
W1
Frame
Ground


ePowrReverser - Reverse Drive Circuit Diagnosis
Test Conditions:
connections.
Test Conditions:
wiring harness.
wiring harness.
wiring harness.
wiring harness.
10. Reverse pressure 5.0 ± 0.2 volts Check 673A and 673D Org wires and connections of the W3

Test Conditions:
• F-N-R switch in reverse
• MFWD off
11. A1 drive controller at X21 Battery voltage Test F-N-R switch. Check 687B and 687A Pur wires and
12. Reverse proportional 660 +25/-50 mA Check 697 Pur and 965 Dk Grn wires and connections of the
solenoid W3 wiring harness. Test reverse proportional coil.
13. A1 drive controller at X21 3.3 - 4.7 volts Test reverse pressure transducer. Check 677 Pur wire and

S11 Bottom of
+12 VDC 050A Blk
+12 VDC 3
2
562D Red
X5-W1 Main 539 Wht
1 596 Lt Blu
S10
S17 Motion F-N-R Switch
Match
Switch 5
269 Wht
562E Red
562C Red
4 686 Lt Blu
519C Wht
A1 Electronic
Controller
3
A 1 2
B4 Forward
Pressure Transducer
11
676 Lt Blu
7 050D Blk
K
673C Org
B5 Reverse
13
Pressure Transducer
6 8
H12 Backup
Alarm 677 Pur
687C Pur
050E Blk
673D Org 10
050F Blk
R2 Clutch
Position
Potentiometer
Solenoid Solenoid
673B Org
591 Brn
050C Blk
696 Lt Blu
12
694 Yel
H13 ePRT Electronic
688 Gry
697 Pur Operating System
Controller Status
050G Blk

eHydro - Forward Drive Circuit Operation The proper conditions for a forward function will be:
• 12.0 volt input on wire 562B Red, power on,
Function:
• 12.0 volt input on wire 539 Wht wire, operator on seat,
The forward drive circuit causes the electronic operating
system to propel the machine in a controlled forward • 5.0 volt output on wire 673A Org wire, potentiometer
Additionally the electronic operating system provides for • Continuity to ground on 550A Blk wire, potentiometer
setting the following functions during a forward drive: and sensor ground,
• Maximum travel speed, • Continuity to ground on 050B Blk wire, drive controller
ground,
• Cruise control,
• Motion match (acceleration/deceleration), and
Lt Blu wire, forward pedal pressed,
• Load match. • Input frequency 2011 Hz ± 10% at 950 rpm or 5821 Hz
Each of these additional functions has the ability to be ± 10% at 2750 rpm on 341 Brn wire, engine speed sensor,
Wht wire, throttle position potentiometer,
• Key switch in run position • Input frequency 190 Hz ± 10% at 950 rpm or 550 Hz ±
• Engine running
• Input less than 0.8 volt on 687 Pur wire, reverse pedal
• Operator on seat not pressed,
• Park brake locked • Less than 0.2 volts on 688 Gry wire, unless a
• Range transmission in A range operational problem has been detected, drive controller
status light,
Theory of Operation: • Output less than 950 +25/-50 mA nominal at full drive on
The electronic operating system is a preprogrammed 696 Lt Blu wire, forward proportional solenoid energized,
electrical device that allows the operator to control the and
machine forward drive function and speed via the electrical • No output current on 697 Pur wire, reverse proportional
inputs from the forward foot pedal. Under normal operating solenoid not energized.
conditions, this creates an output to the forward
proportional solenoid in the transmission. With the proper commands, the drive controller will ramp
Current is supplied to the A2 electronic operating system machine to travel forward at a speed proportional to the
controller (drive controller) from the switched power circuit. position of the forward pedal based upon the engine rpm
With the key switch in the run position, current is supplied and the range gear selected.
X5 connector of the W4 wiring harness to the 562A and The rate of acceleration and deceleration is controlled by
562B Red wires and the X25 connector and the drive the drive controller to smoothly ramp the speed up and
controller. down. Two different settings provide for either quicker or
slower acceleration or deceleration. This operation is
This circuit powers the drive controller to allow for drive controlled by the operator placing the motion match switch
control operation. The 673A Org wire splices to the 673B, in either the on or off position. The change in this setting
673C, 673D, 673E, 673F and 673G Org wires to provide will take effect as soon as the switch is changed.
current from the drive controller to the throttle position
potentiometer, flywheel speed sensor, forward pedal While acceleration has one setting in each position (on or
potentiometer, reverse pedal potentiometer, motion match off) of the motion match switch, the deceleration function
switch and the MFWD speed sensor respectively. has three settings.
When the forward pedal is pressed, current flows across The three deceleration settings are as follows:
the forward pedal potentiometer and back to the drive • coasting to a slower speed in the same direction,
controller through the 686 Lt Blu wire. The drive controller
• coasting back to the neutral position, and
then processes this input command into an output
command if the proper operating conditions exist. The • stopping when changing directions.
output command (current) to the forward proportional
solenoid is proportional to the pedal position.

released.
immediately with the release of the forward pedal. The
stop.

eHydro - Forward Drive Circuit Electrical Schematic
F10
212A 212B
+12VDC

+12VDC 673D Org

Switch
562E (Off Seat)
Red 550D Blk X28
(On Seat)

Speed Sensor
341 Brn X29

X5 X5
J F
550C Blk X29
X25 552A
Red
S17 Motion R4
A1 Match Switch
552B Red Off
A3
673A Org
B1 On
B2 499 Wht X30
269 Wht 673F Org
B3
C1
550A Blk
C2 550B Blk X30
269 Wht
C3
D1
D3 Speed Sensor
A2 E1
050B Blk
E3
Operating F1
686 Lt Blu
System F2 X31
341 Brn 550F Blk
Controller F3 R5
G1 Reverse Pedal
499 Wht
G2
G3
H1
H2 X32
687 Pur 687 Pur
H3
688 Gry
J1
J2 X32
J3 550E Blk
696 Lt Blu
K1 688
K2 Gry
697 Pur
K3 697 H13 eHydro
Pur Y8 Indicator
Reverse Light
Proportional 050F
Solenoid 696 Blk
050A Blk B 050A Blk 050E Lt Blu Y9
Blk
Forward
Proportional
050D Solenoid
W1 Blk
Frame
Ground


eHydro - Forward Drive Circuit Diagnosis
Test Conditions:
• MFWD off
connections.
potentiometer Early Models S/N - specification can not be attained, replace potentiometer
H120712, - H131963, -
H141271
0.6 ± 0.1 volts
Late Models S/N
H120713 -, H131964 -,
H141272 -
wiring harness.
wiring harness.
H120712, - H131963, -
H141271
0.6 ± 0.1 volts
Late Models S/N
H120713 -, H131964 -,
H141272 -

wiring harness.
wiring harness.
H120712, - H131963, -
H141271
0.6 ± 0.1 volts
Late Models S/N
H120713 -, H131964 -,
H141272 -
wiring harness.
Test Conditions:
• MFWD off
18. Forward pedal 3.6 - 4.5 volts Replace forward pedal potentiometer
potentiometer
19. Forward proportional 950 +25/-50 mA at full Check 696 Lt Blu wire and connections of the W4 wiring
solenoid drive, Wheels spinning harness. Test forward proportional coil. Check forward
20. Reverse proportional Continuity to ground Check reverse pedal potentiometer

solenoid


+12 VDC
4
1
539 Wht 673D Org
X5-W1 Main
2 550D Blk
S17 Motion 5 6
Match 18
Switch T2 MFWD
673F Org
7
17
Controller
550C Blk
8
R4 Throttle
539 Wht Position
Potentiometer
552B Red
9
673A Org
673B Org
269 Wht
550A Blk 499 Wht
050B Blk 550B Blk
10 11
T1 Flywheel
Speed Sensor
3 12
S14 Backup
Alarm
673G Org
203 Org
502 Red
550F Blk 13
050G Blk
Y9 Forward
Proportional
Solenoid
Solenoid 14
19 673E Org
687 Pur
696 550E Blk
Lt Blu
15 16
20
050D Blk
H13 eHydro Electronic
697 Pur 688 Gry
Operating System
Controller Status
050F Blk
050E Blk Indicator Light

eHydro - Reverse Drive Circuit Operation The proper conditions for a reverse function will be:
• 12.0 volt input on wire 562B Red; power on,
Function:
• 12.0 volt input on wire 539 Wht wire; operator on seat,
The reverse drive circuit causes the electronic operating
system to propel the machine in a controlled reverse • 5.0 volt output on wire 673A Org wire; potentiometer
Additionally the electronic operating system provides for • Continuity to ground on 550A Blk wire; potentiometer
setting the following functions during a reverse drive: and sensor ground,
• Motion match (acceleration/deceleration), and • Continuity to ground on 050B Blk wire; drive controller
ground,
• Load match.
• Input less than 0.8 volt on 686 Lt Blu wire; forward pedal
Both of these additional functions has the ability to be
not pressed,
• Input frequency 2011 Hz ± 10% at 950 rpm or 5821 Hz
Operating Conditions: ± 10% at 2750 rpm on 341 Brn wire, engine speed sensor,
• Key switch in run position • Input greater than 0.4 volt but less than 4.5 volts on 499
Wht wire; throttle position potentiometer,
• Engine running
• Operator on seat • Input frequency 190 Hz ± 10% at 950 rpm or 550 Hz ±
• Range transmission in A range Pur wire; reverse pedal pressed,
Theory of Operation: • Less than 0.2 volts on 688 Gry wire, unless a
operational problem has been detected; drive controller
The electronic operating system is a preprogrammed status light,
machine reverse drive function and speed via the electrical • No output current on 696 Lt Blu wire; forward
inputs from the reverse foot pedal. Under normal operating proportional solenoid not energized, and
conditions, this creates an output to the reverse • Output less than 950 +25/-50 mA nominal at full drive on
proportional solenoid in the transmission. 697 Pur wire; reverse proportional solenoid energized.
Current is supplied to the A2 electronic operating system With the proper commands, the drive controller will ramp
controller (drive controller) from the switched power circuit. the output to the reverse proportional solenoid to allow the
With the key switch in the run position, current is supplied machine to travel reverse at a speed proportional to the
to the 072C red wire, F5 fuse, 562D and 562A Red wires, position of the reverse pedal based upon the engine rpm
X5 connector of the W4 wiring harness to the 562A and and the range gear selected.
controller. The rate of acceleration and deceleration is controlled by
the drive controller to smoothly ramp the speed up and
This circuit powers the drive controller to allow for drive down. Two different settings provide for either quicker or
control operation. The 673A Org wire splices to the 673B, slower acceleration or deceleration. This operation is
673C, 673D, 673E, 673F and 673G Org wires to provide controlled by the operator placing the motion match switch
current from the drive controller to the throttle position in either the on or off position. The change in this setting
potentiometer, flywheel speed sensor, forward pedal will take effect as soon as the switch is changed.
While acceleration has one setting in each position (on or
off) of the motion match switch, the deceleration function
When the reverse pedal is pressed, current flows across has three settings.
the reverse pedal potentiometer and back to the drive
The three deceleration settings are as follows:
controller through the 687 Pur wire. The drive controller
then processes this input command into an output • coasting to a slower speed in the same direction,
command if the proper operating conditions exist. The • coasting back to the neutral position, and
output command (current) to the reverse proportional
solenoid is proportional to the pedal position. • stopping when changing directions.

released.
immediately with the release of the reverse pedal. The
stop.

eHydro - Reverse Drive Circuit Electrical Schematic
F10
212A 212B
+12VDC

+12VDC 673D Org

Switch
562E (Off Seat)
Red 550D Blk X28
(On Seat)

Speed Sensor
341 Brn X29

X5 X5
J F
550C Blk X29
X25 552A
Red
S17 Motion R4
A1 Match Switch
552B Red Off
A3
673A Org
B1 On
B2 499 Wht X30
269 Wht 673F Org
B3
C1
550A Blk
C2 550B Blk X30
269 Wht
C3
D1
D3 Speed Sensor
A2 E1
050B Blk
E3
Operating 203 Org
F1
686 Lt Blu
System F2
203 X31
341 Brn 550F Blk
Controller F3 Org R5
G1 Reverse Pedal
499 Wht
G2
G3
H1 H14
H2 Backup Alarm X32
687 Pur 687 Pur
H3
688 Gry
J1
J2 050G X32
J3 Blk 550E Blk
696 Lt Blu
K1
K2 688
697 Pur
K3 697 Gry
Pur Y8 H13 eHydro
Reverse Indicator
Proportional Light
Solenoid 696 050F
050A Blk B 050A Blk 050E Lt Blu Y9 Blk
Blk
Forward
Proportional
050D Solenoid
W1 Blk
Frame
Ground


eHydro - Reverse Drive Circuit Diagnosis
Test Conditions:
• MFWD off
connections.
4. Forward pedal potentiometer 5.0 - 4.7 volts Check 673A and 673D Org wires and connections of the W4
wiring harness.
5. Forward pedal potentiometer 0.7 ± 0.08 volts Adjust forward pedal potentiometer to specification. If
Early Models S/N - specification can not be attained, replace potentiometer
H120712, - H131963, -
H141271
0.6 ± 0.1 volts
Late Models S/N
H120713 -, H131964 -,
H141272 -
6. Forward pedal potentiometer Continuity to ground Check 550A and 550D Blk wires and connections of the W4
wiring harness.
wiring harness.
wiring harness.
H120712, - H131963, -
H141271
0.6 ± 0.1 volts
Late Models S/N
H120713 -, H131964 -,
H141272 -

wiring harness.
wiring harness.
H120712, - H131963, -
H141271
0.6 ± 0.1 volts
Late Models S/N
H120713 -, H131964 -,
H141272 -
wiring harness.
Test Conditions:
• Reverse drive pedal fully pressed
• MFWD off
18. Reverse pedal 3.6 - 4.5 volts Replace reverse pedal potentiometer
potentiometer
19. Reverse proportional 950 +25/-50 mA at full Check 697 Pur wire and connections of the W4 wiring harness.
solenoid drive, Wheels spinning Test reverse proportional coil. Check reverse proportional coil. If
either the coil or the valve are replaced, run the calibration
procedure.
20. Forward proportional Continuity to ground Check forward pedal potentiometer

solenoid


+12 VDC
4
1
539 Wht 673D Org
X5-W1 Main
2 550D Blk
S17 Motion 5 6
Match
Switch T2 MFWD
673F Org
7
17
Controller
550C Blk
8
R4 Throttle
539 Wht Position
Potentiometer
562B Red
9
673A Org
673B Org
269 Wht
550A Blk 499 Wht
050B Blk 550B Blk
10 11
T1 Flywheel
Speed Sensor
S14 Backup 3 12
Alarm
673G Org
203 Org
502 Red
550F Blk 13
050G Blk
Y9 Forward
Proportional
Solenoid
Solenoid 14
20 673E Org
687 Pur
696 550E Blk
Lt Blu
18 15 16
19
050D Blk H13 eHydro Electronic
697 Pur 688 Gry Operating System
Controller Status
050F Blk Indicator Light
050E Blk

eHydro - Cruise Control Circuit Operation Unswitched power is provided to the cruise control switch
(standard) from the 212A and 212B Red, F10 fuse, 552 Red wire in
the W1 main wiring harness, X5 connector, 552A and 552E
Function: Red wires in the W4 eHydro wiring harness, X27
connector, and the 562A, 562B, and 562C Red wires in the
W5 cruise control wiring harness.
forward drive pedal at that speed. When the cruise control switch is in the on position current
is provided to the 238 Gry wire of the W5 and W4 wiring
Operating Conditions: harnesses to the A2 drive controller. This input, turns on
the logic circuit used to maintain the drive speed.
The next input signal needed to activated the cruise circuit
• Engine running,
is an input from the forward pedal potentiometer on wire
• Operator on seat, 686 Lt Blu. This circuit causes an output on the 696 Lt Blu
• Park brake unlocked, wire to the forward proportional solenoid which in turn
• Forward pedal pressed to desired speed while setting
the drive speed, and Once the drive controller receives an input from the forward
pedal potentiometer, the cruise control switch may be
• Cruise switch on and pressed to the set position pressed to the set position momentarily to set the drive
momentarily when the desired drive speed is attained. speed.
The cruise control will remain engaged until the brake is At the moment the set signal is received by the drive
depressed; the key switch is turned to the off position, the controller, drive controller records the inputs from the
cruise control switch is placed into the off position, the MFWD speed sensor. The drive controller then supplies an
reverse pedal being depressed, or from no speed signal output current to the forward proportional solenoid to
input to the controller from the MFWD speed sensor. maintain the speed recorded at the MFWD speed sensor.
Theory of Operation: If changes in machine loading or range gear position
settings do not allow for return to the previous speed
The cruise control uses the electronic operating system
setting, the controller will attempt to return to the speed
controller (drive controller) to allow the operator to set and
setting by sending either the maximum (fastest speed
hold a forward drive speed setting that the operator desires
possible) or minimum (slowest speed possible) current to
without having to press and hold the forward pedal.
the forward proportional solenoid. If the machine is driving
The cruise control circuit uses the forward pedal either up or down a grade, the drive controller will increase
potentiometer, flywheel speed sensor, throttle position or decrease the output current to the forward proportional
potentiometer, and the MFWD speed sensor to provide solenoid to maintain the speed at the MFWD speed sensor.
input to the drive controller. The drive controller then If the operator changes the throttle position, the drive
process these inputs to provide output current to the controller will again vary the output to the forward
forward proportional solenoid. proportional solenoid to maintain the drive speed at the
Placing the cruise control switch to the on position, enables MFWD speed sensor.
the cruise control function. Momentarily pressing the cruise
switch to the set position will then set the cruise speed at
the speed being traveled. Once set, the drive controller
monitors the vehicle speed and varies the current to the
forward proportional solenoid to maintain travel speed at
the set point.
To change the drive speed while the machine is being
driven is done by disengaging the cruise control circuit and
resetting the cruise setting. Pressing either the brake or
reverse pedals, or placing the cruise switch in the off
position will disengage the cruise function.

eHydro - Cruise Control Circuit Electrical Schematic (standard)
F10
212A 212B
W5 Cruise
+12VDC Control Wiring
Harness (standard)
F5
072C 562D S18 Cruise
Red Fuse Red
+12VDC Switch
Off
S2 Seat On
Switch Momentary
(Off Seat) 562C Red 238 Gry
(On Seat) 562B Red

265 Dk Grn
562E Red
539D Wht 562A
W4 eHydro
539C
Wht Red Wiring Harness
X5 X5 X27
R3
552A 552E 265 238
539 Wht Red Potentiometer
A1 Red Dk Grn Gry 673D Org X28
A2
552B Red
A3
673A Org
B1 686 Lt Blu X28
265 Dk Grn
B2
238 Gry
B3
C1 264 Yel
550A Blk 550D Blk X28
C2
C3 S13
D1
Brake T1 Flywheel
D3 Switch
A2
E1 On X29
Electronic E2
050B Blk 341 Brn
552C Red
System 550C Blk X29
F1
686 Lt Blu
Controller F2 R4
341 Brn
F3 Throttle
247 Pur
G1
G2
502 Red
G3
H1
499 Wht X30
H2
H3
688 Gry
J1
J2 550B Blk X30
J3
696 Lt Blu
K1
K2 T2 MFWD
C 688 673G Org X31
K3 Speed Sensor
X5 Gry

X8 G Yel Indicator
H7 Cruise Light X31
550F Blk
Indicator
050F
Light Blk 696
Lt Blu Y9
Forward
X8 Proportional
D
050D 050D Solenoid
Blk Blk
W1
Frame

eHydro - Cruise Control Circuit Diagnosis (standard)
Test Conditions:
• Cruise switch on
5. Brake switch Less than 0.2 volts Test brake switch. Adjust brake switch. Verify pedal returns
to full release (off) position.
connections.
8. Forward pedal potentiometer 5.0 - 4.7 volts Check 673A and 673D Org wires and connections.
specification can not be obtained, replace potentiometer.
10. Forward pedal potentiometer Continuity to ground Check 550A and 550D Blk wires and connections.
13. Throttle position potentiometer 5.0 - 4.7 volts Check 673A and 673B Org wires and connections.
14. Throttle position potentiometer 0.7 ± 0.08 volts Adjust throttle position potentiometer to specification. If
15. Throttle position potentiometer Continuity to ground Check 550A and 550B Blk wires and connections.

18. X25 Connector Battery voltage Test cruise control switch. Check 238 Gry wire and
connections.
Test Conditions:
• MFWD off
19. X25 Connector Battery voltage Test cruise control switch. Check 265 Dk Grn wire and
connections.
Test Conditions:
• MFWD off
proportional coil. If either the coil or the valve are replaced,
run the calibration procedure.

Test Conditions:
• MFWD off
21. Forward proportional Wheels spinning at the Test flywheel speed sensor. Test MFWD speed sensor.
solenoid same speed as low idle. Check 341 Brn and 502 Red wires and connections.
Current decreased as
rpm increase.
22. Brake switch Battery voltage. Wheels Test brake switch. Adjust brake switch. Check 247 Pur wire
stop spinning. and connections.

S18 Cruise
Control
+12 VDC 050A Blk Switch
Ground 552A Red 2
+12 VDC 562C
1 Red 562B
X5-W1 Main 539 Wht Red
Wiring Harness
3
6
265 Dk Grn
562A
Red 238 Gry
4
S13 552E
Switch Pedal
Potentiometer
247 Pur
8
5 22
673D Org
A2 Electronic
Controller 550D Blk
9 10
539 Wht T2 MFWD

Speed Sensor
552B Red
11
673A Org 18
550A Blk 673C Org
050B Blk 341 Brn
550C Blk
12
R4 Throttle
19 Position
Potentiometer
13
S14 Backup 7
673B Org
Alarm
499 Wht
203 Org
550B Blk
050G Blk
14 15
Y9 Forward
T1 Flywheel
Proportional
Speed Sensor
Solenoid
20 21
16
696 673G Org

Lt Blu 502 Red
550F Blk 17
050D Blk

eHydro - Cruise Control Circuit Operation Pressing either the brake or reverse pedals will disengage
(optional) the cruise function. The last speed setting is stored in the
drive controller and if the operator is pressing the forward
Function: pedal, the Res / + switch can be pressed momentarily to
ramp back to the stored speed. Turning the cruise switch
off, will disengage the cruise function and erase the stored
setting.
forward drive pedal at that speed.
Unswitched power is provided to the cruise on/off switch
Operating Conditions: from the 562 Red series of wires and is protected by the F5
fuse. The 562 Red series of wires include 562D and 562A
in the W1 main wiring harness, X5 connector, 562A and
• Engine running, 562E in the W4 eHydro wiring harness, X27 connector, and
• Operator on seat, the 562A and 562C wires in the W5 cruise control wiring
harness.
• Park brake unlocked,
When the cruise on/off switch is in the on position current is
• Cruise switch on, provided to the 238 Gry wire of the W5 and W4 wiring
• Forward pedal pressed to desired speed while setting harnesses to the A2 drive controller. This input, turns on
the drive speed, and the logic circuit used to maintain the drive speed.
• Set/- switch pressed momentarily when the desired The next input signal needed to activated the cruise circuit
drive speed is attained. is an input from the forward pedal potentiometer on wire
depressed; the key switch is turned to the off position, the
cruise control switch is placed into the off position, the
reverse pedal being depressed, or from no speed signal Once the drive controller receives an input from the forward
input to the controller from the MFWD speed sensor. pedal potentiometer, the Set/- switch may be momentarily
pressed to set the drive speed.
At the moment the Set/- switch is pressed the drive
The cruise control uses the electronic operating system controller records the inputs from the MFWD speed sensor.
controller (drive controller) to allow the operator to set and The drive controller then supplies an output current to the
hold a forward drive speed setting that the operator desires forward proportional solenoid to maintain the speed
without having to press and hold the forward pedal. recorded at the MFWD speed sensor.
The cruise control circuit uses the forward pedal If changes in machine loading or range gear position
potentiometer, flywheel speed sensor, throttle position settings do not allow for return to the previous speed
potentiometer, and the MFWD speed sensor to provide setting, the controller will attempt to return to the speed
input to the drive controller. The drive controller then setting by sending either the maximum (fastest speed
process these inputs to provide output current to the possible) or minimum (slowest speed possible) current to
forward proportional solenoid. the forward proportional solenoid. If the machine is driving
Placing the cruise control switch to the on position, enables either up or down a grade, the drive controller will increase
the cruise control function. Momentarily pressing the Set / - or decrease the output current to the forward proportional
switch will then set the cruise speed at the speed being solenoid to maintain the speed at the MFWD speed sensor.
traveled. If the operator changes the throttle position, the drive
Once set, the drive controller monitors the vehicle speed proportional solenoid to maintain the drive speed at the
and varies the current to the forward proportional solenoid MFWD speed sensor.
to maintain travel speed at the set point.
The cruise speed setting can be increased and decreased
while the machine is being driven by momentarily pressing
either the Res / + switch to increase the maximum speed or
the Set / - switch to decrease the maximum speed setting.

eHydro - Cruise Control Circuit Electrical Schematic (optional)
F10
212A 212B
Red Red Fuse 552 Red S16 W6
+12VDC Cruise ON
Cruise/Max Speed Off
Cruise Control
Switch Max Speed ON Wiring Harness
F5
072C 562D 238 Gry
Fuse 562C Red
Red Red 267 Pur
+12VDC
S15
Res/+, Set/-
S2 Seat Switch
Switch Res +
Off
(Off Seat)
Set -
(On Seat) 266 Lt Blu
562B Red
562E Red 265 Dk Grn
539D Wht W4 eHydro
539C 562A
Wht
Wiring Harness
Red
X5 X5 X27 X27
R3
265 266 267 238
539 Wht 552A 552E
A1 Red Red
Dk Grn Lt Blu Pur Gry X28 Potentiometer
267 Pur 673D Org
A2
552B Red
A3
673A Org
B1 686 Lt Blu X28
265 Dk Grn
B2
238 Gry
B3
264 Yel
C1 X28
550A Blk 550D Blk
C2
C3 S13
D1
Brake T1 Flywheel
D3 Switch
A2
E1 On X29
Electronic E2
050B Blk 341 Brn
552C Red
System 550C Blk X29
F1
686 Lt Blu
Controller F2 R4
341 Brn
F3 Throttle
247 Pur
G1
G2
502 Red
G3
H1
499 Wht X30
H2
H3
688 Gry
J1
266 Lt Blu X30
J2 550B Blk
J3
696 Lt Blu
K1
K2 T2 MFWD
C 688 673G Org X31
K3 Speed Sensor
X5 Gry

X8 G Yel Indicator
H7 Cruise Light X31
550F Blk
Indicator
050F
Light Blk 696
Lt Blu Y9
Forward
X8 Proportional
D
050D 050D Solenoid
Blk Blk
W1
Frame

eHydro - Cruise Control Circuit Diagnosis (optional)
Test Conditions:
2. Cruise/Max speed switch Battery voltage See “Power Circuit Diagnosis” on page 368.
3. Res/+, Set/- switch Battery voltage See “Power Circuit Diagnosis” on page 368.
5. Brake switch Less than 0.2 volts Test brake switch. Adjust brake switch. Verify pedal returns
to full release (off) position.
connections.
8. Forward pedal potentiometer 5.0 - 4.7 volts Check 673A and 673D Org wires and connections.
10. Forward pedal potentiometer Continuity to ground Check 550A and 550D Blk wires and connections.
13. Throttle position potentiometer 5.0 - 4.7 volts Check 673A and 673B Org wires and connections.
14. Throttle position potentiometer 0.7 ± 0.08 volts Adjust throttle position potentiometer to specification. If
15. Throttle position potentiometer Continuity to ground Check 550A and 550B Blk wires and connections.

18. X25 Connector Battery voltage Test cruise/max speed switch. Check 238 Gry wire and
connections.
Test Conditions:
• MFWD off
• Set/- switch pressed
19. X25 Connector Battery voltage Test Res/+, Set/- switch. Check 265 Dk Grn wire and
connections.
Check 552B Red wire for power. Place switch in Res/+
position and check 266 Lt Blu wire and connections.
Test Conditions:
• MFWD off
proportional coil. If either the coil or the valve are replaced,
run the calibration procedure.

Test Conditions:
• MFWD off
21. Forward proportional Wheels spinning at the Test flywheel speed sensor. Test MFWD speed sensor.
solenoid same speed as low idle. Check 341 Brn and 502 Red wires and connections.
Current decreased as
rpm increase.
22. Brake switch Battery voltage. Wheels Test brake switch. Adjust brake switch. Check 247 Pur wire
stop spinning. and connections.

562B Red
S15 Res/+ S16 Cruise/Max
+12 VDC 050A Blk Set/- Switch Speed Switch
Ground 552A Red 265
+12 VDC 562C
Dk Grn
1 Red
X5-W1 Main 539 Wht
Wiring Harness
3 266 2 267
Lt Blu Pur
6
562A 238 Gry

Red
4
S13 552E
Switch Pedal
Potentiometer
247 Pur
8
5 22
673D Org
A2 Electronic
Controller 550D Blk
9 10
18 T2 MFWD
539 Wht
Speed Sensor
19 552B Red
11
673A Org
550A Blk 673C Org
050B Blk 341 Brn
550C Blk
12
R4 Throttle
Position
Potentiometer
13
S14 Backup 7
673B Org
Alarm
499 Wht
203 Org
550B Blk
050G Blk
14 15
Y9 Forward
T1 Flywheel
Proportional
Speed Sensor
Solenoid
20 21
16
696 673G Org

Lt Blu 502 Red
550F Blk 17
050D Blk

eHydro - Load Match and Motion Match Function, Motion Match:
Circuit Operation To allow the operator to change how quickly the pedals
respond to being pressed or released.
Function, Load Match:
To prevent the engine from stalling during heavy loading Operating Conditions, Motion Match:
situations while driving. • Key switch in run position
Operating Conditions, Load Match: • Engine running
• Key switch in run position • Operator on seat
• Engine running • Park brake unlocked
• Operator on seat • Motion match switch on
• Park brake unlocked Theory of Operation, Motion Match:

• Load match switch on The rate of acceleration and deceleration is controlled by
• Operator driving machine the drive controller to smoothly ramp the speed up and
down. Two different settings provide for either quicker or
Theory of Operation, Load Match: slower acceleration or deceleration. This operation is
controlled by the operator placing the motion match switch
in either the on or off position. The change in this setting
engine during a typical application such as loader work or
will take effect as soon as the switch is changed.
mowing grass that has light and heavy growth areas. A
throttle position sensor is installed to read the no-load Current is supplied to the A2 electronic operating system
engine rpm set point. controller (drive controller) from the switched power circuit.
is reduced to allow the engine to recover. The greater the
controller.
The load match switch can be turned on or off to allow the This circuit powers the drive controller to allow for drive
operator to disable the load match function if desired. control operation. The 673A Org wire splices to the 673B,
The load match feature will have no effect if the machine is 673C, 673D, 673E, 673F and 673G Org wires to provide
not being driven when the stalling load is being placed on current from the drive controller to the throttle position
the engine. potentiometer, flywheel speed sensor, forward pedal
Unswitched power is provided to the load match on/off
switch from the 562 Red series of wires and is protected by
the F5 fuse. The 562 Red series of wires include 562D and When the motion match switch is in the on position, current
562A in the W1 main wiring harness, X5 connector, 552A is provided to the 269 Wht wire, X25 connector and the A2
and 552D in the W4 eHydro wiring harness. drive controller which in turn uses this input to supply the
lower responding pedal setting.
When the load match switch is in the on position, current is
provided to the 268 Gry wire, X25 connector and the A2
drive controller. The drive controller uses this input signal to
activate the load match logic within the software.

eHydro - Load Match and Motion Match Circuit Electrical Schematic
F10
212A 212B
+12VDC
F5
072C 562D
Red Fuse Red
+12VDC
S2 Seat W4 eHydro
Switch Wiring Harness
(Off Seat)
(On Seat)
562E Red
539D Wht 539C S14
Wht
Load Match
Switch
X5 X5
X25 J F Off
539 Wht 552A
A1 On
Red
A2 552D Red
552B Red 268 Gry
A3
673A Org
B1
B2
B3
C1 S17
550A Blk Motion Match
C2
269 Wht
C3 Switch
Off
D1
D2 On
A2 D3
E1 269 Wht 673F Org
Electronic E2
050B Blk
Operating E3
System F1
Controller F2
341 Brn
F3
G1
499 Wht
G2 T1 Flywheel
G3
268 Gry 673C Org X29 Speed Sensor
H1
H2
341 Brn X29
H3
J1
J2 550C Blk X29
J3
R4
K1
Throttle
K2
K3 673B Org X30 Potentiometer
499 Wht X30
050A Blk X5 B 050A Blk 550B Blk X30
W1
Frame
Ground
Switched Power Controller Power Output

eHydro - Load Match and Motion Match Control Circuit Diagnosis
Test Conditions:
connections.
3. Load match switch Battery voltage See “Power Circuit Diagnosis” on page 368.
4. Motion match switch 5.0 - 4.7 volts Check 673A and 673D Org wires and connections.
5. X25 Connector Less than 0.2 volts Test load match switch. Check 268 Gry wire and
connections.
6. X25 Connector Less than 0.2 volts Test motion match switch. Check 269 Wht wire and
connections.
Test Conditions:
7. X25 Connector Battery voltage Test load match switch. Check 268 Gry wire and
connections.
8. X25 Connector 5.0 - 4.7 volts Test motion match switch. Check 269 Wht wire and
connections.

Test Conditions:
• Engine running at full throttle
• MFWD off
• Brake pedal pressed to stall engine during test
9. Forward proportional solenoid 950 +25/-50 mA dropping Test flywheel speed sensor. Check 341 Brn and 502 Red
as engine stalls. wires and connections.
+12 VDC 050A Blk S14 Load

Ground 552A Red Match Switch
+12 VDC
268 Gry
1
X5-W1 Main 539 Wht 562D Red
Wiring Harness
2 3
S17 Motion
A2 Electronic
Match Switch
Operating System
Controller 269 Wht
673F Org
6 539 Wht
8
562B Red 4 R4 Throttle
Position
673A Org 673B Org
Potentiometer
673A Org 269 Wht
550A Blk
050B Blk 499 Wht
502 Red
268 Gry 550B Blk
5
T1 Flywheel
7 Speed Sensor
673G Org
502 Red
550F Blk

Front PTO Clutch Circuit Operation
Function:
To engage the front PTO clutch and illuminate a light on the
instrument panel to alert the operator that the PTO is on.
• Front PTO switch engaged,
• Operator on seat,
or;
• Operator off seat then,
• Transmission in neutral, and
• Park brake locked.
The front PTO clutch circuit is used to energize the electric
PTO clutch and to interlock the fuel shutoff solenoid circuit
to ensure that the machine is properly parked and placed in
neutral if the operator wants to leave the seat with the front
PTO engaged see See “Fuel Supply Circuit Operation” on
page 382.
The switched power circuit provides current to the front
PTO switch from the key switch through the 072B and 072C
Red wires, F5 fuse, 562D, and 562N Red wires. When the
front PTO switch is in the on position current is then
supplied to the 737A, 737B, and 737C Pur wires, Y10 front
PTO clutch, X35 connector (terminal A) and the H15 front
PTO light on the instrument panel.

Front PTO Clutch Circuit Electrical Schematic
F1 4
012
Fuse Red 1 6
2 5 072B Red
3 072C
Red
S1 Key
7
Switch
F5
Start Fuse
Run
Off
Acc.
Aid 562D
002C Red
Red Off
S18 Front
PTO Switch
X1 On
Off
562N Red 737B Pur X35 A
Fusible A B 737C Pur
C
Link D E
F
G
H
Y10
Front PTO
737A
Pur
Clutch
H15 Front
PTO Light
B A 010AR
Blk
M1
Starting
Motor
Red Y1
Starting D
Motor
Solenoid X8
G1
Battery 050D
Blk
Blk
010AR Blk
050A Blk
W1 Frame
Ground


Front PTO Clutch Circuit Diagnosis
Test Conditions:
• Front, mid and rear PTOs off
1. Front PTO switch Battery voltage Check 072B, 072C, 562D, and 562N Red wires and
connections. Check F5 fuse. If ok, replace key switch.
2. Y10 Front PTO clutch Battery voltage Check 737C and 737A Pur wires and connections. If ok,
connector replace front PTO switch.
3. X35 connector Battery voltage Check 737C and 737B Pur wires and connections. If ok,
4. Y10 Front PTO clutch Continuity to ground Check 010AR Blk wire and connections.
connector
F5 Fuse
+12 VDC 562D Red
Switched
562N
S18 Front PTO Switch
Red
737C Pur
010AR Blk
010AR Blk X35-W1 Main
737A Pur 737B Pur Wiring Harness
To Instrument Panel
4
2
737A Pur
737B Pur
3

Rear PTO Circuit Operation Current for this circuit is provided from the 562F and 562G
Red wire connection on the rear PTO switch to the 562H
Function: Red wire, mid PTO switch (terminals G and H), 577C and
577B Pur wires, rear PTO switch (terminals D and E), 582
To engage the rear PTO and illuminate a light on the
instrument panel to alert the operator that the PTO is on. Red wire, to the K15 mid PTO lockout relay. This energizes
the mid PTO lockout relay and cuts power to the mid PTO
Operating Conditions: latching circuit. See “Mid PTO Circuit Operation”.
• Engine running
2-Speed PTO Lights
• Rear PTO switch engaged
• PTO shifter engaged in either 540 or 750 rpm Function:
To alert operator of rear PTO being engaged, and which
Theory of Operation: speed range is selected.
The rear PTO switch is used as an interlock to the fuel
supply circuit, See “Fuel Supply Circuit Operation” on Operating Condition:
page 382 and the mid PTO as well as engaging the rear The rear PTO must be engaged, and the rear PTO range
PTO. selector must be placed in either the 540 rpm range or the
In the off (normally closed) position the rear PTO switch 750 rpm range.
supplies current to the fuel supply circuit through the front
PTO switch. If the either the rear PTO or front PTO is Theory of Operation:
engaged and the operator leaves the seat, current is With the key in the run position and the rear PTO engaged,
removed form the fuel supply circuit unless the battery voltage is provided to the S19 540 rpm switch and
transmission is in neutral, the park brake is engaged, prior S20 750 rpm switch through the form the S5 rear PTO
to leaving the seat and engaging either PTO. switch and wires 574C, 574A and 574B Yel.
The rear PTO is also used as an interlock for the mid PTO When the rear PTO range selector is placed in the 540 rpm
circuit. See “Mid PTO Circuit Operation”. The mid PTO position, the S19 540 rpm PTO switch is closed, and
switch must be engaged and then the rear PTO switch provides a current path through the switch, 777 Pur wire,
engaged to activate the mid PTO. To disengage the mid and X7 connector (terminal B) to the control panel circuit
PTO the operator should first disengage the rear PTO board. A circuit board run provides voltage to the H18 540
switch and then the mid PTO switch. PTO indicator light.
With the key in start or run position, battery voltage is When the rear PTO range selector is placed in the 750 rpm
provided to the rear PTO switch through the S1 key switch, position, the S20 750 rpm PTO switch is closed, and
072B and 072C Red wires, F5 fuse and 562A, 562D and provides a current path through the switch, 757 Pur wire,
562F Red wires. and X7 connector (terminal F) to the control panel circuit
With the PTO engaged, the rear PTO switch is in the on board. A circuit board run provides voltage to the H17 750
(open) position, and voltage is supplied across the rear PTO indicator light.
Red wires to the 574A, 574B and 574C Yel wires. The
574C wire splices to the 574A, 574B and 574D Yel wires.
The 574A wire supplies current to the S19 540 rpm PTO
switch while the 574B wire supplies current to the S20 750
rpm switch and the 574D wire supplies current to the Y4
rear PTO solenoid to energize the solenoid and engage the
rear PTO.
though the 010AF and 010D Blk wires.
When the rear PTO switch is in the on position the switch
also provide current to the K15 mid PTO lockout relay. This
circuit prevents the mid PTO from being engaged out of
sequence.

Rear PTO Circuit Electrical Schematic
4 562K Red
6
1 S5 Rear
F5 Fuse X5 PTO Switch
2 5 072B Red 072C Red 562D Red 562A Red
A On
3
562E Red 562F Red Off
S1 Key
7 562G Red A 574C Yel
Switch B
S2 Seat 577B Pur D
C
E 582 Red
Start Switch 539A 1 562G Red G
F
578 Gry
Run Wht 2 556 Lt Blu H
(Off Seat) 562H Red 573B Org
Off 3
Acc. (On Seat) 556 Lt Blu
V1 Diode
Aid 539D Wht 539B Wht 4
Block 1
012 Off S18 Front
Red 5
521 PTO Switch
518A Gry 6 Brn
F1 On
Fuse Off
539C Wht
X5
A B
H C
002C D E
Red S3 Transmission 575A Dk Grn G
F
H
573A Org
Neutral Switch
575B Dk Grn
In Neutral
X1 In Gear 577A Pur
X4 X4
518B Gry
Fusible
Link
Fuse Block Internal Link X5
002D 303 E
V1 Red Lt Blu 579A Wht
Diode 30 86 K4
Block 1 Engine
B A 87A 87 85 Relay
010Z Blk
302B
Red 050F Blk
X2 302C Red
050G
M Blk S6 Mid
Wht PTO Switch
Y2 Fuel
M1 Shutoff On
Starting Solenoid 521 050H
Wht Brn Blk Off
Motor Blk
X2 30 86 K6 579A Wht A B
Red 010F C
Blk Fuel Solenoid D E
F
Timer Module 562H Red G
85 87 87A 577C Pur
329 304 Org H
Wht
562S Red
X2 30 86 K3 Fuel
G1
010N Shutoff
X5
Blk Dk Grn
010AJ L
010F 050C Blk 050E
Blk Blk Blk
B
050A Blk 050A Blk
010D Blk 010D Blk
010P Blk 010P Blk
W1 Frame
Ground


S19 540 rpm

562K Red
PTO Switch
Off
On
574A Yel X7
777 Pur B
574C Yel
H18 540
S20 750 rpm PTO Light
582 Red
PTO Switch
578 Gry
Off
556 Lt Blu On
574B Yel
757 Pur
X7
F
H17 750
575B Dk Grn PTO Light
S4 Park
Brake Switch
On
Off
C
B
577A Pur D 505 Dk Grn 575D 556

A Dk Grn Lt Blu
30 86 K12 PTO
1
Interlock
V2 Diode 87A 87 85 Relay
Block 2 562K 533 010AA
Red Org Blk
2
562M Red
X5
579C G
505 519
Wht 562P Dk Grn Pur
86 30
K14 Mid Red
30 86 K13
PTO
Latch Neutral
85 87 87A Relay 87A 87 85 Relay
010AC 581 546 010AB
Blk Brn Lt Blu Blk
582 579D
Red Wht
86 30 K15 Mid
575C 546
PTO Dk Grn Lt Blu
Lockout 86 30 K11 Rear
85 87 87A Relay PTO
010AN 581 Interlock
Blk Brn 85 87 87A
Relay
010W 533
562S Red Blk Org
574D D
Yel X8
Y4
Rear PTO 050D
Solenoid 010AF
Blk
Blk
050A Blk 050A Blk
010D Blk
010P Blk


Rear PTO Circuit Diagnosis
Test Conditions:
• Rear PTO on with front and mid PTOs off
• 2-Speed PTO shifter in 540 rpm position
1. Rear PTO switch Battery voltage Check 072B, 072C, 562D, and 562F Red wires and
2. Mid PTO switch Battery voltage Check 072B, 072C, 562D, 562F, 562G, and 562H Red wires
and connections. Check F5 fuse. If ok, replace key switch.
4. Rear PTO solenoid Battery voltage Check 574C and 574D Yel wires and connections. If ok, replace
rear PTO switch.
5. K15 Mid PTO lockout relay Battery voltage Check 582 Red wire and connections. If ok, replace rear PTO
switch.
6. 540 rpm PTO switch Battery voltage Check 574C and 574A Yel wires and connections. If ok, replace
rear PTO switch.
7. X7 connector Battery voltage Check 777 Pur wire and connections. If ok, 540 rpm PTO
switch.
Test Conditions:
8. 750 rpm PTO switch Battery voltage Check 574C and 574B Yel wires and connections. If ok, replace
rear PTO switch.
switch.
Test Conditions:
• 2-Speed PTO shifter in 540 rpm then 750 rpm position

10. Instrument panel 540 rpm PTO lamp illuminated Test PTO lamp. Check 050D and 050A Blk wires and
PTO light (not shown) connections to ground. If ok, replace instrument panel.
F5 Fuse
562D Red
+12 VDC
562F K15 Mid PTO
S5 Rear PTO Switch 581 Brn
Red Lockout Relay
85 87A 87
30 86
5
579D Wht
57
4C
Ye 582
l Red
S6 Mid PTO Switch
3
562G
577B
Red
Pur
1
577C Pur
2
562H Red
Y4 Rear PTO
S19 540 rpm 574A Yel Solenoid
PTO Switch
574A Yel Y3 MFWD
6 Solenoid
777
Pur
574D
574B Yel Yel
4
W1
S20 750 rpm Frame
PTO Switch 757 Ground
Pur
8
777 Pur
574B Yel 7
757 Pur X7 Main Wiring Harness

9 To Control Panel

Mid PTO Circuit Operation At the same time the mid PTO switch is also providing
current to the 583 Org wire and the K16 mid PTO relay.
Function: This will energize the mid PTO relay and supply current to
the 594C and 594A Yel wires, Y5 mid PTO solenoid and the
To engage the mid PTO and illuminate a light on the
instrument panel to alert the operator that the PTO is on. 594B Yel wire and the K17 mid PTO light relay (terminal
30).
Operating Conditions: When the rear PTO switch is in the on position, no current
• Key switch in run position will flow to the K17 mid PTO light relay coil to energize the
relay. This will allow the contacts to remain in the normally
• Operator on seat closed position. Current will then flow from the 594B Yel
• Mid PTO on wire at terminal 30 across the relay to terminal 87A
(normally closed contacts) to the 743 Org wire, X35
then;
connector and the H16 mid PTO light on the instrument
• Rear PTO on panel.
Theory of Operation: A ground circuit path for the instrument panel circuit board
The mid PTO circuit starts in the off position allowing 050D and 050A Blk wires.
current to energize the mid PTO latch circuit.
The ground circuit for the mid PTO solenoid is provided
With the key in start or run position, battery voltage is though the 010AH and 010D Blk wires.
provided to the mid PTO latch circuit through the S1 key
switch, 072B and 072C Red wires, F5 fuse and 562A, Then the rear PTO switch can be engaged to allow the
562D, 562F, 562G and 562H Red wires, mid PTO switch hydraulic and mechanical portions of the PTO system to
(terminals G and H), 577C and 577B Pur wires, rear PTO run the mid PTO.
switch (terminals D and F), 578 Gry wire, V2 diode With the rear PTO engaged, the rear PTO switch is in the
(terminals 1 and 2), 579A, 579B, 579C and 579D Wht on (open) position, and voltage is supplied across the rear
wires. PTO switch (terminals A and B) from the 562F and 562G
The 579A Wht wire supplies current back to the mid PTO Red wires to the 574A, 574B, 574C, and 574D Yel wires.
switch (terminal A), wire 579C Wht provides current to the The 574D Yel wire supplies current to the Y4 rear PTO
K15 mid PTO lockout relay (terminal 30) and wire 579D solenoid to energize the solenoid and engage the rear
Wht provides current to the K14 mid PTO latch relay PTO.
(terminal 86). The ground circuit for the rear PTO solenoid is provided
With the mid PTO latch relay energized, current is provided though the 010AF and 010D Blk wires.
across the relay (terminals 30 to 87) from wire 562K Red The 574A Yel wire supplies current to the 540 rpm PTO
(See “Switched Power Circuit”) to 581 Brn and mid PTO switch while the 574B Yel wire supplies current to the 750
lockout relay (terminal 87A). rpm PTO switch. From one of these two switches current is
When the mid PTO lockout relay is not energized current is supplied to the X7 connector (terminal B or F), to the
provided across the relay (terminals 87A and 30) to the instrument panel circuit board. A circuit board run provides
579D, 579C and 579A Wht wires. The 579 Wht wires voltage to either the H18 540 rpm PTO indicator light or the
H17 750 rpm PTO indicator light.
If the rear PTO switch is engaged before the mid PTO
switch, current will be provided from the rear PTO switch to A ground circuit path for the instrument panel circuit board
the 582 Red wire and the mid PTO lockout relay coil is provided though the X8 connector (terminal D), and
(terminal 86). This will energize the lockout relay causing 050D and 050A Blk wires.
the relay to break the latch circuit back to the 579 Wht
wires.
Engaging the mid PTO switch will break the path between
the 562H Red and 577C Pur wires. Breaking this current
path will prevent the rear PTO switch from providing current
to the mid PTO lockout relay.

Mid PTO Circuit Electrical Schematic
F1 4
012 S19 540 rpm
Fuse Red 1 6 PTO Switch
2 5 072B Red Off

On
3 072C
Red 574A Yel
S1 Key 777 Pur
Switch
7 F5
Fuse 562K Red H18 X7
Start S20 750 rpm 540 rpm B
Run PTO Switch
Off 562D PTO Light
Acc. Red S5 Rear
PTO Switch Off
Aid On
002C On
Red Off
574B Yel
562F Red Off 757 Pur
562G Red A B 574C Yel
C
F
562G Red G
578 562M Red
X1 562H Red H
Gry
562K
1 Red
Fusible V2 Diode
Link 579C
Block 2 Wht
86 30
K14 Mid
2
PTO
Latch
85 87 87A Relay
S6 Mid
010AC 581
PTO On Blk Brn
Switch
Off
579A Wht 583 Org 582 579D
A B
C
Red Wht
D E 86 30 K15 Mid
562H Red F
G
577C Pur PTO X7
H F
Lockout
85 87 87A Relay H17 750
B A
010AN 581 PTO Light
Blk Brn
M Y4
562P
583
Red 574D
Rear PTO
M1 Org
K16 Yel Solenoid
Starting 86 30 H16 Mid
Motor Mid PTO PTO Light
Relay
Red Y1 85 87 87A 010AF
594B
Starting 010AP 594C
Yel
Blk
Motor Blk Yel
Solenoid 86 30 K17 Mid
594A PTO Light
G1 Yel D
Battery Y5 85 87 87A Relay D X35
X8
Blk Mid PTO 010T 743
Solenoid Blk Org 743 Org 050D
010AH Blk
Blk
050A Blk 050A Blk
010D Blk
W1 Frame
Ground


Mid PTO Circuit Diagnosis
Test Conditions:
1. Mid PTO switch Battery voltage Check 072B, 072C, 562D, 562F, 562G and 562H Red wires and
3. Mid PTO switch Battery voltage Check 578 Gry, 579B and 579A Wht wires and connections.
Test D2 diode block. If ok, replace rear PTO switch.
4. K14 Mid PTO latch relay Battery voltage Check 578 Gry, 579B and 579C Wht wires and connections.
5. K14 Mid PTO latch relay Battery voltage Check 072B, 072C, and 562K Red wires and connections.
Check F5 fuse. If ok, replace key switch.
6. K15 Mid PTO latch relay Battery voltage Check 578 Gry, 579B and 579D Wht wires and connections.
7. K16 Mid PTO relay Battery voltage Check 072B, 072C, 562K, 562M, and 562P Red wires and
Test Conditions:
• Mid PTO on
• Front and rear PTOs off
8. Rear PTO switch Less than 0.5 volts Test V2 diode block. If ok, replace mid PTO switch.
9. K16 Mid PTO relay Battery voltage Check 583 Org wire and connections. If ok, replace mid PTO
switch.
10. Mid PTO solenoid Battery voltage Check 594C and 594A Yel wires and connections. If ok, replace
K16 mid PTO relay.
11. K17 Mid PTO light relay Battery voltage Check 594C and 594B Yel wires and connections. If ok, replace
K16 mid PTO relay.

F5 Fuse
+12 VDC 562D Red to 562K and
Switched A B 562P Red

Red
562G
Red
V2 Diode 579B
Block Wht
574C Yel
2
578 Gry
1 3
5
S6 Mid PTO Switch 4 6
8 2 8
577B 7 9
Pur
583 574A Yel S19 540 rpm

Org PTO Switch
577C
Pur
3 562H Red
1
57 574B Yel S20 750 rpm
9A PTO Switch
Wh
K15 Mid PTO t
Lockout Relay
85 87A 87
757 777
30 86 582 Red K16 Mid PTO 594C Pur Pur
Relay Yel
6 579D Wht
85 87A 87
30 86 777 Pur
9
K14 Mid PTO 581 7 X7-W1 Main

Brn 583 Org
Latch Relay Wiring Harness
562P To Instrument Panel
85
30
87A 87
86 579C Wht Red 757 Pur
+12 VDC
5 562K Y4 Rear PTO
4
Red Solenoid
+12 VDC
Y3 MFWD
Solenoid
K17 Mid PTO
Light Relay Y5 Mid PTO
Solenoid
85 87A 87
30 86
574D
Yel
11 594B Yel
743 Org
743 Org 10
X35-W1 Main 594A Yel

Wiring Harness
To Instrument Panel

Test Conditions:
• Mid PTO on
• Rear PTO on
12. X35 Connector Battery voltage Check 743 Org wire and connections. If ok, replace K17 mid
PTO light relay.
13. Rear PTO solenoid Battery voltage Check 574C and 574D Yel wires and connections. If ok, replace
rear PTO switch.
14. 540 rpm PTO switch Battery voltage Check 574C and 574A Yel wires and connections. If ok, replace
rear PTO switch.
switch.
Test Conditions:
• Mid PTO on
• Rear PTO on
16. 750 rpm PTO switch Battery voltage Check 574C and 574B Yel wires and connections. If ok, replace
rear PTO switch.
switch.
Test Conditions:
• 2-Speed PTO shifter in 540 rpm then 750 rpm position

F5 Fuse
+12 VDC 562D Red to 562K and
Switched A B 562P Red

Red
562G
Red
V2 Diode 579B
Block Wht
574C Yel
2
578 Gry
1 3
5
S6 Mid PTO Switch 4 6
8
577B 7 9
Pur
583 574A Yel S19 540 rpm

Org PTO Switch
577C
Pur
562H Red
14
57 574B Yel S20 750 rpm

9A PTO Switch
Wh
K15 Mid PTO t
Lockout Relay
85 87A 87
757 777
30 86 582 Red K16 Mid PTO 594C Pur Pur 16
Relay Yel
579D Wht
85 87A 87
30 86 777 Pur
K14 Mid PTO 581 X7-W1 Main 15

Brn 583 Org
Latch Relay Wiring Harness
To Instrument Panel 17
562P
85
30
87A 87
86 579C Wht Red 757 Pur
+12 VDC
562K Y4 Rear PTO
Red Solenoid
+12 VDC
Y3 MFWD
Solenoid
K17 Mid PTO
Light Relay Y5 Mid PTO
Solenoid
85 87A 87
30 86
574D
Yel
594B Yel
743 Org 13
743 Org
X35-W1 Main 594A Yel

Wiring Harness 12
To Instrument Panel

MFWD Circuit Operation
Function:
To engage the MFWD and illuminate a light on the
instrument panel to alert the operator that the MFWD is on.
• MFWD switch in the on position
The MFWD function spring loaded to the engaged position.
When the MFWD switch is in the unlock position current is
supplied to the MFWD solenoid which in turn unlocks the
MFWD pin in the transmission.
provided to the MFWD switch through the S1 key switch,
072B and 072C Red wires, F5 fuse and 562A, 562D, 562F,
562G, 562H and 562J Red wires to the MFWD switch
(terminal 2).
When the MFWD switch is in the unlock position, current
flows across the MFWD switch (terminals 2 and 1) to the
555 Wht wire and the Y3 MFWD solenoid. The MFWD
solenoid is then energized and pulls the MFWD lock pin
into the unlocked position and the machine will operate in
rear wheel drive.
The ground circuit path for the MFWD solenoid is provided
though the 010AG and 010D Blk wires.
When the MFWD switch is in the lock position, current flows
across the MFWD switch (terminals 2 and 3) to the 557 Pur
wire which jumpers back to the MFWD switch (terminal 8)
and illuminates the indicator light in the switch. The MFWD
solenoid is then de energized and releases the MFWD lock
pin and the machine will operate in four wheel drive.
The ground circuit path for the MFWD indicator light is
provided though the 010AK and 010D Blk wires.

MFWD Circuit Electrical Schematic
F1 4
012
Fuse Red 1 6
F5 Fuse
2 5 072B Red 072C Red 562D Red
S5 Rear
3
PTO Switch
S1 Key
7
Switch On
Start 562F Red Off

Run 562G Red A B
Off C
Acc. D E
F
562G Red G
Aid H
562H Red
Off
002C S6 Mid
Red PTO Switch
X1 On
Off
Fusible A B
Link D
C
E
F
562H Red G
H
562J Red
S7 MFWD
Switch
Unlock
Lock
B A 562J 1 555 Dk Grn
Red 2
3 557 Pur
010 AK Blk 7 8 555
Dk Grn
Y3
M MFWD
Solenoid
010AG
M1 Blk
Starting
Motor
Red Y1
Starting
Motor
Solenoid
G1
Battery
Blk
010D Blk 010D Blk
W1
Frame
Ground

MFWD Circuit Diagnosis
Test Conditions:
• MFWD switch in unlock position
• PTO off
1. MFWD switch Battery voltage Check 072B, 072C, 562D, 562F, 562G, 562H, and 562J Red
wires and connections. Check F5 fuse. If ok, replace key switch.
2. MFWD solenoid Battery voltage Check 555 Wht wire and connections. If ok, replace MFWD
switch.
3. MFWD solenoid Less than 0.1 ohms Check 010AG and 010D Blk wires and connections.
Test Conditions:
• MFWD switch in lock position
• PTO off
4. MFWD switch MFWD indicator light Check 557 Pur wire and connections. If ok, replace MFWD
illuminated. switch.
5. MFWD switch Less than 0.1 ohms Check 010AK and 010D Blk wires and connections.

S1 Key Switch
F5 Fuse
A B
S5 Rear PTO Switch
562F
Red
S6 Mid PTO Switch
562G Red
562H Red
S7 MFWD Switch 4
5
010AK Blk
557 Pur
W2 Battery
55 Frame
562J Red 5D Ground
kG
557 Pur rn
1 Y4 Rear
PTO Solenoid
Y3 MFWD
Solenoid
555
Dk Grn
2
010AG
Blk
3
W2 Battery
Frame
Ground

Instrument Panel Lights Circuit Operation Theory of Operation:
The fuel level in the fuel tank is measured by the B1 fuel
Engine Oil Pressure Circuit Function:
gauge sensor. The sensor is a variable resistor. The
To alert operator of low engine oil pressure. resistance is set by movement of a mechanical linkage
connected to a float in the fuel tank. The 5 to 95 ohm
Operating Conditions: variable resistance creates a variable voltage difference
• Key switch in run or start position across the P3 fuel gauge. The voltage difference ranges
from approximately 5.72 VDC (fuel tank full) to
Theory of Operation: approximately 0.87 VDC (fuel tank empty).
With the engine off and key switch in the run position, Park Brake Light Circuit Operation Function:
engine oil pressure will be below 49 kPa (7.1 psi). The oil
pressure switch will be in the normally closed position. The To alert operator of the park brake being locked.
closed position completes a circuit path to ground and
illuminates the H9 light. This informs the operator that the Operating Condition:
light is functional. • Key switch in run or start position
The light goes out when the engine oil pressure is at or • Park brake locked
above 49 kPa (7.1 psi), the B2 engine oil pressure switch
pens, and removes the ground circuit from the engine oil Theory of Operation:
pressure light. With the key in start or run position, battery voltage is
provided to the park brake switch through the S1 key
Engine Coolant Temperature Circuit Operation
switch, 072B and 072C Red wires, F5 fuse and 562D and
Function:
562B Red wires. See “Power Circuit Diagnosis”.
Inform the operator of engine and coolant operating
With the Park brake locked, the park brake switch contacts
temperature.
close. Voltage is provided through the park brake switch
Operating Conditions: contacts (terminals B to C), 586 Lt Blu wire, and X8
connector (terminal K) to the instrument panel circuit board.
• Key switch in run or start position A circuit board run provides voltage to the H4 park brake
indicator light.
The engine coolant temperature sensor is a variable is provided though the X8 connector (terminal D), and
resistor, providing a ground circuit path for the temperature 050D and 050A Blk wires.
gauge. As the engine coolant heats, the resistance
decreases. As the resistance decreases, more current is
allowed to flow across the engine coolant temperature
gauge causing the needle to raise and indicate a higher
temperature.
The temperature gauge circuit is part of the machine
instrument panel.
The engine coolant temperature sensor resistance is
approximately 40 - 700 ohms.
Fuel Gauge Circuit Function:

Inform the operator of the fuel level in the fuel tank.

Instrument Panel Lights Circuit Electrical Schematic
F3 S9 Light
Fuse 122C Red Switch
(0) Off
(1) Marker
F1 4 (2) Road
012
Fuse Red 1 6 (3) Field
1
2 5 072B Red
122B Red
2
072C B F7 Fuse
3 138 Gry 119C Wht
A Red
S1 Key 3
Switch
7 F5 119D
4 Wht
Fuse
Start B 562L Red X8
Run
562D A X8
Off B
Red 562N
Acc.
Red P3
002C
Aid Fuel
Off S4 Park Gauge
Red
Brake Switch
On Q
562B Off
Red 586 Lt Blu X8 H9 Oil
X1 B
C
K Pressure
D
A Light P4 Engine
Fusible H4 Park
Coolant
Link Brake Temperature
Light Gauge
P t0
C J E
B A X8 X8 X8
B1 Fuel 353 347 359
Gauge Org Pur Wht
Sensor
M
t0
Q
M1
Starting 050B B3 Engine
Motor Blk Coolant
Temperature
Red Switch
D P
X8
050D
G1 Blk B2 Engine Oil
Battery Pressure
Blk Switch (NC)
050A Blk
W1
Frame
Ground

Instrument Panel Lights Circuit Diagnosis
Test Conditions:
• X8 connector to instrument panel disconnected
• Light switch in road or field position
1. X8 connector Battery voltage Check F5 fuse. Test key switch. See Power Circuit Switched
Circuits.
2. X8 connector Less than 0.1 ohms Check 050D and 050A Blk wires and connections.
3. X8 connector Battery voltage Check 586 Lt Blu wire and connections. If ok, replace park
brake switch.
4. Light switch Battery voltage Check 002A, 122C, and 122B Red wires and connections. Test
F3 fuse.
5. X8 connector Battery voltage Check 138 Gry, 119C and 119D Wht wires and connections.
Test F7 fuse. If ok, replace light switch.
Test Conditions:
• X8 connector to instrument panel connected
6. Engine oil pressure switch Less than 0.1 VDC Check 347 Pur wire and connections. Test switch. See Engine
Oil Pressure Switch Test.
7. Engine oil pressure switch Less than 0.1 ohms Check engine ground. If engine ground is ok, replace oil
(347 Pur wire disconnected) resistance to ground. pressure switch.
8. Engine coolant temperature Continuity to ground Disconnect temperature sensor lead. Use a jumper wire to
sensor through sensor - connect 359 Wht wire to ground. Temperature gauge should
resistance depends on move to maximum temperature position.
engine temperature
Gauge does not move. - Check 359 Wht wire and connections.
(40 - 700 ohms).
Replace control panel.
Sensor threads not
corroded. Gauge moves. - Replace sensor.
9. Fuel gauge sensor Tank empty - Check 353 Org wire and connections. Check battery negative
approximately 0.1 cable, 050B and 050A Blk wires and connections. Test fuel
VDC sensor. See “Fuel Gauge Sensor Test”. Use a jumper wire to
Tank full - connect 353 Org wire to battery frame ground. Fuel gauge
approximately 5.7 should move to maximum position. Gauge does not move. -
VDC Replace control panel.
NOTE: If all of the tests above are performed, and the control panel lamps are good, and the indicator lights still do
not work, replace the instrument panel.

F3 Fuse
122C Red 122B Red
+12 VDC
S9 Light Switch
F5 Fuse
122B
Red
S1 Key Switch
4
562B Red 138

Gry
S4 Park Brake Switch

F7
Fuse
586
Lt Blu 562L Red
119C
353 Org 119D Wht Wht
119D Wht 5 353 Org

050D Blk
562L Red
359 Wht
1 9
3
347
586 Lt Blu Pur
353
347 Pur 359 Wht Org
X8-W1 Main Wiring

Harness To Control Panel 2 050D Blk
B1 Fuel Gauge Sensor 050B

Blk
050D Blk
347
359
Pur
Wht
6 050A
Blk
7 8
W1
Frame
Ground
B2 Engine Oil Pressure Switch B3 Engine Coolant Temperature Switch

Light Circuit Operation Light Switch Field Position:
In the field position, voltage is removed from the marker
Function:
lights (light switch terminal 2). However, voltage remains to
Provides current to the headlights, tail lights, marker lights, the headlights (light switch terminal 3), and is provided to
work lights and control panel lights, in combinations the work lights (light switch terminal 4).
depending upon the position the light switch is placed in.
Voltage is provided from the light switch (terminal 4),
through the 137 Pur wire to the F6 fuse. The F6 fuse
provides voltage, through the 147A, 147B, and 147C Pur
• Light switch in either marker, road or field position. wires, to the work lights.
Theory of Operation: The ground path for the work lights is provided by 010H,
010K, and 010C Blk wires.
Power for the light switch is unswitched and provided
through the F3 fuse, 122C and 122B Red wires.
Brake Lights Operation
Light Switch Marker Position:
Function:
In the marker position, voltage is provided from the light
switch (terminal 2) through the 103 Org wire to the F8 and Provide power to the brake lights when the brake pedal is
F9 fuses. From the F8 fuse voltage is provided to the 118A depressed.
Gry wire which splices to the 118B Gry wire and the right
rear position light, 118C Gry wire and the left front position Operating Conditions:
light, 118D Gry wire and the X38 trailer connector, and The brake pedal must be depressed.
118E Gry wire and the license plate light.
From the F9 fuse voltage is provided to the 128A Gry wire
which splices to the 128B Gry wire and the X38 trailer Unswitched power is provided to the S21 brake switch and
connector, 128C Gry wire and the left rear position light, the K18 brake light relay (terminal 30) through the F4 fuse,
128D Gry wire and the right front position light. 042C, 042A, and 042D Red wires.
The ground path for the marker lights is provided by 010G, When the brake pedal is depressed, the brake switch
010L, 010X, 010Y, 010AL and 010C Blk wires. closes. The closed brake switch contacts provide power to
the brake light relay coil (terminal 86). When the brake light
Light Switch Road Position: relay coil is energized, the relay contacts close. The closed
contacts provide a current path to the right brake light
In the road position, voltage is provided from the light
through the 136A and 136D Lt Blu wires, the left brake light
switch (terminal 2) through the same circuits as when the
through the 136A and 136C Lt Blue wires; and, the X38
light switch is in the marker position. This circuit causes the
trailer connector (terminal E) though the 136A and 136B Lt
marker lights to be illuminated.
Blue wires.
In addition, voltage is provided from the light switch
(terminal 3) though the 138 Gry wire to the F7 fuse. The F7
fuse provides voltage to the left headlight through the 119C
and 119B Wht wires, and to the right headlight through the
119C and 119A Wht wires. Voltage is also provided to the
instrument panel dash lights through the 119C and 119D
Wht wires and X8 connector (B terminal).
The ground path for the headlights is provided by 010A,
010B, and 010P Blk wires. The ground path for the dash
lights is provided from the instrument panel by the 050D
and 050A Blk wires.

Lights Circuit Electrical Schematic
S9 Light
Switch
(0) Off
(1) Hazard
E6 Right
(2) Road
119A Wht Headlight 010A Blk
(3) Field
1
122B
Red 103A Org 103B Org
E5 Left
2
B F7 Fuse Headlight
138 Gry 119C Wht 119B Wht 010B Blk
3
137 Pur 119D 103C
Wht Org
4 E8 Right Work
X8 Light (Option)
F6 Fuse B X19 X19
147A Pur 147C Pur Pur Blk 010K Blk
F9 F8 E7 Left Work
P3 Fuel 147B
Gauge Fuse Fuse Pur Light (Option)
X17 X17
122C Pur Blk 010H Blk
128A 118A
Red Q 0
t Gry Gry
F3
P4 Engine
Fuse Coolant E15 License
Temperature Plate Light
F4 Fuse Gauge X39 X39
118E Gry Gry Blk 010AL Blk
042C
Red D E9 Left Front
X8 Position Light
002C X40
Red 042A 118C Gry Gry Blk 010G Blk
Red 050D
S21 Brake Blk X9
Light Switch 118B E13 Right Rear
Gry Position Light
X1 X34 Off
X16
On Gry Blk 010L Blk
Fusible Blu
Blu X11
Link X15
136D Lt Blu Lt Blu
X38 Trailer
E14 Right Connector
X34 Brake Light
118D Gry B
116 042D
136B Lt Blu E
Lt Blu Red
B A K18 86 30
128B Gry D
Brake
Light E12 Right Front
Relay 85 87 87A
Position Light
M 010M 136A
128D Gry X41 Gry
Blk Lt Blu Blk 010Y Blk
Red M1 E10 Left Rear X20

Starting Position Light
Motor 128C
Gry X14
Gry Blk 010X Blk
G1
Battery X13 X18
136C Lt Blu Lt Blu
Blk 050A Blk E11 Left
Brake Light 010P Blk
010C Blk
W1 Frame
Ground Unswitched Power Secondary Switched Power

Lights Circuit Diagnosis
Test Conditions:
• Light switch in marker position
1. Light switch Battery voltage Test F3 fuse. Check 122B and 122C Red wires and
connections.
2. X38 Trailer connector Battery voltage Test F8 fuse. Check 103A, 103B Org, 118A, and 118D Gry
wires and connections. If ok, replace light switch.
3. License plate light Battery voltage Test F8 fuse. Check 103A, 103B Org, 118A, and 118E Gry
4. Left front position light Battery voltage Test F8 fuse. Check 103A, 103B Org, 118A, and 118C Gry
5. Right rear position light Battery voltage Test F8 fuse. Check 103A, 103B Org, 118A, and 118B Gry
6. X38 Trailer connector Battery voltage Test F9 fuse. Check 103A, 103C Org, 128A, and 128B Gry
7. Right front position light Battery voltage Test F9 fuse. Check 103A, 103C Org, 128A, and 128D Gry
8. Left rear position light Battery voltage Test F9 fuse. Check 103A, 103C Org, 128A, and 128C Gry
Test Conditions:
• Light switch in road position
9. Right headlight Battery voltage Test F7 fuse. Check 138 Gry, 119C and 119A Wht wires and
connections. If ok, replace light switch.
10. Left headlight Battery voltage Test F7 fuse. Check 138 Gry, 119C and 119B Wht wires and
11. X8 Instrument panel Battery voltage Test F7 fuse. Check 138 Gry, 119C and 119D Wht wires and
connector connections. If ok, replace light switch.
Test Conditions:
• Light switch in field position

12. Right Work light Battery voltage Test F6 fuse. Check 137 Pur, 147A and 147C Pur wires and
13. Left Work light Battery voltage Test F6 fuse. Check 137 Pur, 147A and 147B Pur wires and

S9 Light Switch
F3
Fuse
122B Red 122B Red
+12 VDC
F9
128A Gry Fuse
103 Org
F8
Fuse
X38 Trailer 118A Gry
Connector 1
137 138
Org Gry
2
118D F6 F7
Gry Fuse Fuse
E8 Right 12
Work Light 147A 119C
128B 147C Pur Pur
Gry 6 Wht
X39 License
118E Plate Connector
Gry E7 Left 13
Work Light
3 147B Pur
E12 Right Front

Position Light
E9 Left Front E6 Right 9
Position Light Headlight
128D 119A Wht
Gry
118C
Gry 7
4 E5 Left 10
Headlight 119B Wht
119D Wht 11
X8 Instrument
Panel Connector
E13 Right Rear

Position
Light
128C 118B
Gry 118B
128C Gry
Gry
Gry
E10 Left Rear 5
8
Position
Light

Test Conditions:
• Brake pedal depressed
1. Brake switch Battery voltage Test F4 fuse. Check 042C and 042A Red wires and
connections.
2. K18 Brake light relay Battery voltage Test F4 fuse. Check 042C and 042D Red wires and
connections.
3. K18 Brake light relay Battery voltage Check 116 Lt Blu wire and connections. If ok, replace brake
switch.
4. Right Brake light Battery voltage Check 136A and 136D Lt Blu wires and connections. If ok,
replace brake light relay.
5. Left Brake light Battery voltage Check 136A and 136C Lt Blu wires and connections. If ok,
6. X38 Trailer connector Battery voltage Check 136A and 136B Lt Blu wires and connections. If ok,
F4
Fuse
042C Red 042D Red
+12 VDC
A B
042A X38 Trailer
S21 Brake Red Connector
Light Switch K18 Brake 136B
Light Relay Lt Blu
85 87A 87
30 86
1
6
2 136B
3
116 Lt Blu Lt Blu
136C 136D
Lt Blu Lt Blu 136D
136C Lt Blu
Lt Blu
E11 Left E14 Right 4
5
Brake Brake
Light Light

Turn Signal Lights Circuit Operation Right Turn Signal Theory of Operation:
With the turn signal switch in the LEFT position, and the
Turn Signal Switch Function:
hazard switch in the off position, voltage from the K19
Provides intermittent power to either the left front and rear flasher (terminal 49a) enters the turn signal switch (terminal
turn/hazard lights and control panel turn indicator light, or 3) through the 127D and 127A Pur wires.
the right front and rear turn/hazard lights and control panel
The turn signal switch completes a current path through the
turn indicator light.
switch contacts (terminal 3 to terminal 6). From the turn
signal switch (terminal 6), voltage is provided to the left
Operating Condition:
front turn/hazard light through the 125A and 125E Dk Grn
Key switch in the run position, hazard switch in the off wires, the left rear turn/hazard light through the 125A and
position, and turn signal switch in either left or right 125F Dk Grn wires, the X13 trailer connector (terminal C)
position. through the 125A and 125D Dk Grn wires, the control panel
Left turn light through the 125A and 125B Dk Grn wires,
Theory of Operation: and the hazard switch (terminal 18) through the 125A and
Switched power is provided from the key switch (terminal 5) 125C Dk Grn wires.
through the 072B and 072D Red wires to the hazard switch Each of the turn/hazard lights has a ground connection to
(terminal 1). the battery frame ground. When power is supplied to the
With the hazard switch in the off position, the switched turn/hazard lights, a complete circuit path is formed. When
power is provided through the hazard switch (terminal 1 to the circuit is formed, the internal circuits in the K19 flasher
terminal 2) and 102 Red wire to the K19 flasher (terminal provide an intermittent voltage output. This intermittent
49). voltage is provided to the turn/hazard lights through the
circuit paths described above.
The internal circuits of the K19 flasher provide an
intermittent output (terminal 49a) if a circuit path is provided
through a load component to the battery frame ground. The Hazard Switch Operation
flasher unit in the turn signal switch is not used in this
application. Placing the turn signal switch in either the right Hazard Switch Function:
or left position provides a circuit path through a load Provides intermittent power to all of the turn/hazard lights.
component (turn/hazard lights) to ground.
Right Turn Signal Theory of Operation:
Hazard switch in on position.
With the turn signal switch in the right position, and the
hazard switch in the off position, voltage from the K19 Theory of Operation:
flasher (terminal 49a) enters the turn signal switch (terminal With the hazard switch in the on position, unswitched
4) through the 127D and 127B Pur wires. power is provided through the hazard switch (terminal 3 to
The turn signal switch completes a current path through the terminal 2) and 102 Red wire to the K19 flasher (terminal
switch contacts (terminal 4 to terminal 5). From the turn 49). The internal circuits of the K19 flasher provide an
signal switch (terminal 5), voltage is provided to the right intermittent output (terminal 49a) if a circuit path is provided
front turn/hazard light through the 115A and 115E Dk Grn through a load component to the battery frame ground.
wires, the right rear turn/hazard light through the 115A and
The circuit path is created when the K19 flasher output
115F Dk Grn wires, the X38 trailer connector (terminal A)
power is provided through the 127D and 127C Pur wires to
through the 115A and 115D Dk Grn wires, the control panel
the hazard switch input (terminal 5). The contacts in the
right turn light through the 115A and 115B Dk Grn wires,
hazard switch (terminal 5 to terminals 17 and 18) complete
and the hazard switch (terminal 17) through the 115A and
the circuit path to all of the turn/hazard lights through the
115C Dk Grn wires.
115 Dk Grn and 125 Dk Grn wires to the left front and rear
Each of the turn/hazard lights has a ground connection to turn/hazard lights, the right front and rear turn/hazard
the battery frame ground. When power is supplied to the lights, the X38 trailer connector (terminals C and A) and
turn/hazard lights, a complete circuit path is formed. When both of the control panel turn indicator lights.
the circuit is formed, the internal circuits in the K19 flasher
The hazard switch has an internal indicator light that is
provide an intermittent voltage output. This intermittent
provided with intermittent power from the K19 flasher.
voltage is provided to the turn/hazard lights through the
circuit paths described above.

Turn Signal and Hazard Lights Circuit Electrical Schematic
F4 Fuse
+12 VDC 042C Red X9
Blk 010G Blk
Unswitched
E1 Left Front
072D Red
Turn/Hazard
Light
+12 VDC 072B Red
X36 X18 010X Blk
Switched Blk
S22
Hazard E2 Left Rear
Switch 042B
Red Turn/Hazard
On Light
Off Blk X20 010Y Blk
072D
102 Red
3
Red X10
2
1 115C Dk Grn
17
125C Dk Grn E3 Right Front
050K Blk 18 Turn/Hazard
127C Pur
Light
10 5
X11 010L Blk
X37 Blk
S8 Turn E4 Right Rear

K19 Signal
Flasher Turn/Hazard
Switch Light
49 (0) Right X12
(1) Off
(2) Left 115C 115E 115F
050J Blk 49a 127D Pur Dk Grn Dk Grn Dk Grn
1 115A
Flasher
31 C3 C C2 127B 5 Dk Grn
Pur 4 115D Dk Grn A
144 148 146
Yel Gry Lt Blu 127A 125C 125E 125F
Pur 3
2 Dk Grn Dk Grn Dk Grn X38 Trailer
Connector
X35 G 6 125A Dk Grn
E F
125D Dk Grn C
125B 115B
Dk Grn Dk Grn
H20 Bulb
H19 Trailer Integrity H21 Trailer X7 X7
2 Light Light 1 Light E D
2 1
H8 Left H6 Right
Turn Turn
Light Light
D
X8
050D
Blk
050A Blk 010C Blk
W1 Frame
Ground


Turn Signal Lights Circuit Diagnosis
Test Conditions:
• Turn signal switch in off position
• Hazard switch in off position
1. Hazard switch Battery voltage Test F4 fuse. Check Fusible link, 042B, 042C, 002D, and 002C
Red wires and connections.
2. Hazard switch Battery voltage Check 072D and 072B Red wires and connections. If ok,
replace key switch.
3. K19 Flasher Battery voltage Check 102 Red wire and connections. If ok, replace hazard
switch.
4. K19 Flasher Continuity to ground Check 050J and 050A Blk wires and connections.
5. Turn signal switch 7.5 - 8.0 volts Check 127D, 127B, and 127A Pur wires and connections. If ok,
replace K19 flasher.
6. Hazard switch 7.5 - 8.0 volts Check 127D and 127C Pur wires and connections. If ok,
replace K19 flasher.
Test Conditions:
• Turn signal switch in off position
• Hazard switch in on position
7. Hazard switch Intermittent battery Check 127D and 127C Pur wires and connections. Test hazard
voltage switch and K19 flasher.
8. Left Front turn/hazard light Intermittent battery Check 125E and 125C Dk Grn wires and connections. If ok,
voltage replace hazard switch.
9. Left Rear turn/hazard light Intermittent battery Check 125F and 125C Dk Grn wires and connections. If ok,
10. X38 Trailer Connector Intermittent battery Check 125D and 125C Dk Grn wires and connections. If ok,
11. X7 Instrument panel Intermittent battery Check 125B and 125C Dk Grn wires and connections. If ok,
connector voltage replace hazard switch.
12. Right Front turn/hazard Intermittent battery Check 115E and 115C Dk Grn wires and connections. If ok,
light voltage replace hazard switch.
13. Right Rear turn/hazard Intermittent battery Check 115F and 115C Dk Grn wires and connections. If ok,
light voltage replace hazard switch.
14. X38 Trailer Connector Intermittent battery Check 115D and 115C Dk Grn wires and connections. If ok,

15. X7 Instrument panel Intermittent battery Check 115B and 115C Dk Grn wires and connections. If ok,
connector voltage replace hazard switch.

S22
S8 Turn Hazard
Signal Switch Switch 042B Red
(+12 VDC
125C Dk Grn Unswitched)
1
127C Pur
102 Red
127A Pur 6
7 072D Red
127B Pur (+12 VDC Switched)
5
115C 2
5 Dk Grn
K19 Flasher
115A
125A Dk Grn
Dk Grn
127D 4
Pur
146 Lt Blu
144 148 Gry 102 Red
Yel X35 Instrument 144 Yel 3
146 Panel Connector
Lt Blu 148
Gry 115D Dk Grn
X7 Instrument
14 Panel Connector
115D
Dk Grn
11
10
125D 125B
X38 Dk Grn 125B Dk Grn
Trailer Dk Grn
115B
125F 125E 115E 115F 15
Dk Grn
Dk Grn Dk Grn Dk Grn Dk Grn
X10 X36 X37 X12
E2 Left Rear E4 Right Rear

Turn/Hazard Turn/Hazard
Light 8
Light
125E 12
9 Dk Grn 13
115E
125F Dk Grn 115F
Dk Grn Dk Grn
E1 Left Front E3 Right Front
Light Light

Test Conditions:
• Hazard switch in on position
16. X35 Instrument panel Intermittent battery Check 148 Gry wire and connections. If ok, replace K19 flasher.
connector voltage
17. X35 Instrument panel Intermittent battery Check 146 Lt Blu wire and connections. If ok, replace K19
connector voltage flasher.
18. X35 Instrument panel Intermittent battery Check 144 Yel wire and connections. If ok, replace K19 flasher.
connector voltage
Test Conditions:
• Turn signal switch in left position
19. Turn signal switch Intermittent battery Check 127D and 127A Pur wires and connections. Test hazard
20. Left Front turn/hazard light Intermittent battery Check 125E and 125A Dk Grn wires and connections. If ok,
voltage replace turn signal switch.
21. Left Rear turn/hazard light Intermittent battery Check 125F and 125A Dk Grn wires and connections. If ok,
22. X38 Trailer Connector Intermittent battery Check 125D and 125A Dk Grn wires and connections. If ok,
23. X7 Instrument panel Intermittent battery Check 125B and 125A Dk Grn wires and connections. If ok,
connector voltage replace turn signal switch.
Test Conditions:
• Turn signal switch in right position
19. Turn signal switch Intermittent battery Check 127D and 127B Pur wires and connections. Test hazard
20. Left Front turn/hazard light Intermittent battery Check 125E and 125A Dk Grn wires and connections. If ok,
21. Left Rear turn/hazard light Intermittent battery Check 125F and 125A Dk Grn wires and connections. If ok,

22. X38 Trailer Connector Intermittent battery Check 125D and 125A Dk Grn wires and connections. If ok,
23. X7 Instrument panel Intermittent battery Check 125B and 125A Dk Grn wires and connections. If ok,
connector voltage replace turn signal switch.

S22
S8 Turn Hazard
Signal Switch Switch 042B Red
(+12 VDC
125C Dk Grn Unswitched)
127C Pur
102 Red
127A Pur
072D Red
127B Pur (+12 VDC Switched)
19
24 115C
Dk Grn
K19 Flasher
115A
125A Dk Grn
Dk Grn
127D
Pur
18 146 Lt Blu
148 Gry 102 Red
144
Yel X35 Instrument 144 Yel
Panel Connector
146 148
Lt Blu Gry 16 115D Dk Grn
17 X7 Instrument
27 Panel Connector
115D
Dk Grn
23
22
125D 125B
X38 125B Dk Grn
Dk Grn Dk Grn
Trailer
115B
125F 125E 115E 115F 28
Dk Grn
Dk Grn Dk Grn Dk Grn Dk Grn
X10 X36 X37 X12
E2 Left Rear E4 Right Rear

Light 20
Light
125E 25
21 Dk Grn 26
115E
125F Dk Grn 115F
Dk Grn Dk Grn
E1 Left Front E3 Right Front
Light Light

Diverter Valve Circuit Operation (optional)
Function
Provides power to hydraulic diverter valve circuit.
Operating Conditions
• Key switch in run position.
Theory of Operation
Current is supplied to the diverter valve circuit from the
switched power circuit. With the key switch in the run
position, current is supplied to the 072C red wire, F5 fuse,
562D and 562C Red wires, X3 connector to the W8 wiring
harness to the 562C, 562B, and 562A Red wires and the
S19 diverter valve enable switch.
When the S19 diverter valve enable switch is in the off
position current flow is stopped at the switch.
When the S19 diverter valve enable switch is in the on
terminal (87) of the K17 diverter valve latch relay.
When the S19 diverter valve enable switch is in the set
terminal (87) of the K17 diverter valve latch relay. At the
same time, current flows from the 562B Red wire across
the enable switch to the 784A Yel wire which splices to the
784B, 784C, 784D, 784E, and 784F Yel wires.
The 784B Yel wire supplies current to the indicator light
within the S19 switch. The 784C wire supplies current to
the K17 diverter valve latch relay common terminal (30).
The 784D wire supplies current to the K17 diverter valve
latch relay coil terminal (86). The 784E Yel wire supplies
current to the banded end of the V3 diode. The 784F Yel
wire supplies current to the Y10 diverter solenoid.
With the 784 Yel group of wires energized, the 784D Yel
wire energizes the K17 diverter valve latch relay. The relay
pulls in to connect the common terminal (30) to the
normally open terminal (87). This connects the 784 Yel
group of wires to the 783 Org wire which has power as long
as the S19 diverter valve enable switch is in either the set
or on positions. This provide the latch for the relay to
continue to provide current to the Y10 diverter solenoid
until the enable switch is place back into the off position, or
the key switch is turned off.
When the Diverter valve circuit is energized, the indicator
light within the S19 diverter valve enable switch will be
illuminated to provide a visual indicator to the operator that
the diverter valve circuit is available for use.
The V3 diode is used across the relay coil to collapse the
magnetic field of the coil quicker and reduce arcing across
the relay contacts.

Diverter Valve Circuit Electrical Schematic (optional)
S19
Diverter Valve
Enable Switch 784F Yel X34
Y10 Diverter
Off Solenoid
On
Set
X3 562C Red 562A Red 783 Org
562B Red 784A Yel
010A Blk 784B Yel 784E Yel X34
010E
Blk
784C 784D
Yel Yel
30 86 K17 Diverter
Valve Latch X33
87A 87 85 Relay A
010B V3
Blk
Diode
C
X33
010B Blk 010C
Blk
010C Blk
010E Blk
010D
W1 Blk
Frame
Ground
MIF
Diverter Valve Wiring Harness (optional)
Y10 Diverter
Solenoid
S19 010E 784F
Diverter Valve A B
Enable Switch V3 Diode

784A 010C 784E
783 10 9
3 6
562A 2 5
X3 To W1 Main
1 4 562B 010
8 7 562 Wiring Harness
784B 010A 784 562C
W8 Diverter Valve
Wiring Splices
010D 010C
010A
010B 010 010D
010E
562A
784C 010B To W1 Ground 562B 562 562C
K17 Diverter
784A
Valve Latch 784C 784B
784
Relay 784D 784E
784F
784D 783
MIF

Diverter Valve Circuit Diagnosis (optional)
Test Conditions:
1. Diverter valve enable switch Battery voltage Check X3 connector, 562A, 562B, and 562C wires and
connections. See Switched Power Circuit Diagnosis.
2. Diverter valve enable switch Continuity to ground Check 010A and 010D Blk wires and connections.
3. Diverter valve latch relay Continuity to ground Check 010B and 010D Blk wires and connections.
4. Diverter solenoid Continuity to ground Check 010E and 010D Blk wires and connections.
5. Diode Continuity to ground Check 010C and 010D Blk wires and connections.
Test Conditions:
• Diverter valve enable switch in on position
6. Diverter valve latch relay Battery voltage Check 783 Org wire and connections. If ok, replace diverter
valve enable switch.
Test Conditions:
• Diverter valve enable switch pressed to set position then released to the on position
7. Diverter valve enable switch Battery voltage Check 784B and 784A Yel wires and connections. Test diverter
8. Diverter valve latch relay Battery voltage Check 784C and 784A Yel wires and connections. Test diverter
9. Diverter valve latch relay Battery voltage Check 784D and 784A Yel wires and connections. Test diverter
10. Diverter solenoid Battery voltage Check 784F and 784A Yel wires and connections. Test diverter
11. Diode Battery voltage Check 784E and 784A Yel wires and connections. Test diverter

+12 VDC
X3 Y10 Diverter
Solenoid
562C
Red
S19 10
Diverter Valve
Enable Switch
784F Yel
2
010A Blk 784B Yel
562A Red 4
562B Red 010E V3 Diode
Blk
1
5
1 783
784A 11
Org
Yel
7
784E Yel
010C
Blk
K17 Diverter
Valve Latch
Relay
784C
Yel
9 8
784D
Yel
K17 Diverter
86 30 Valve Latch
783 Org 87 87A 85
Relay Socket
6 3
010B
010B Blk Blk
010E Blk
010C Blk
010D
Blk
W1
Frame
Ground

POWER TRAIN - GEAR TABLE OF CONTENTS
Power Train - Gear
Table of Contents
Specifications ...............................................489
General Specifications ...............................489
Repair Specifications..................................489
Torque Specifications.................................489
Special or Essential Tools ..........................489
Other Materials...........................................489
Component Location....................................490
Traction Clutch (SST).................................490
Pinion Shaft and Drive Shaft (SST)............492
3 Speed Synchro Transmission (SST) .......493
Clutch Pedal and Linkage ..........................495
Tests and Adjustments ................................496
Clutch Adjustment ......................................496
Repair.............................................................496
Machine Splitting (Front) ............................496
Traction Clutch Removal ............................500
Clutch Regulator
Removal and Installation ............................501
Traction Clutch Disassembly......................502
Input Shaft Disassembly.............................504
Traction Clutch Installation ........................505
Clutch Shimming Procedure.......................507
Snubber Shimming Procedure ...................509
Clutch Shaft Removal and Installation .......511
3-Speed Transmission Removal ................512
3 Speed Synchronized Transmission.........513
Power Train - Gear Table of Contents - 487

POWER TRAIN - GEAR TABLE OF CONTENTS
Power Train - Gear Table of Contents - 488

POWER TRAIN - GEAR SPECIFICATIONS
Specifications
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9x3 SST Synchro Shift
Number of Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Forward, 3 Reverse
Hydraulic Reservoir Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 L (6.3 gal)
Clutch Pedal Free Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 mm (0.78 in.)
Friction (Clutch) Pack (minimum thickness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.2 mm (1.031 in.)
Clutch Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.83 mm (0.111 in.)
Clutch Spring (minimum free length) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.3 mm (2.02 in.)
Torque Specifications
SCV Port Tube Hydraulic Line Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 – 57 N•m (30 – 43 lb-ft)
Gear Housing to Transmission Housing Cap Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . 126 – 154 N•m (95 – 115 lb-ft)
Front Clutch Cover to Housing (Tunnel) Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 – 29 N•m (17 – 22 lb-ft)
Clutch Hub to Transmission Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 N•m (100 lb-ft)
Spring Retainer to Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (98 lb-in.)
Special or Essential Tools
Special or Required Tools

Tool Name Tool No. Tool Use
Splitting Stands and Brackets JTO7335 -1,2,3 Used to support the machine components when splitting the
machine (front or rear).
Clutch Shimming Fixture JDG 1259 Used to measure clutch and clutch housing to establish
correct shimming.
Other Materials
Other Material
Part No. Part Name Part Use
TY6305 John Deere Clean and Cure Primer Cleans parts and speeds cure of sealant.
TY16021 John Deere High Flex Form-In-Place Sealing Flange Assemblies
Gasket
TY6333 Moly High Temperature EP Grease
TY22034 John Deere SuperLube®
TY9370 / TY9477 Thread Lock and Sealer On dowel pins and certain cap screws.
(#242 LOCTITE®) (Medium Strength)
Power Train - Gear Specifications - 489

POWER TRAIN - GEAR COMPONENT LOCATION
Component Location
Traction Clutch (SST)
N
O
P
G
Q H
R I
S J
T
K
U
W V L
B
C
Y D
AA Z
AB
E
AC F
AD AE
AF
Z
AG
AL
AG
AA AI
AN AJ
AK
AQ AK
AK
AL AM
AO
AP
MX9899
Power Train - Gear Component Location - 490

A - Ball Bearing
B - Snap Ring
C - Snap Ring
D - Gear
E - Input Shaft
F - Ball Bearing
G - Spacer
H - Bearing
I - Bearing Race
J - Clutch Basket
K - Washer
L - Piston
M - Clutch Plates
N - Hub
O - Washer
P - Nut
Q - Spring (4)
R - Plug
S - Cap Screw (4 used)
T - Snubber
U - Shim
V - Shim
W - Lifter Pin
X - Lift Arm
Y - Clutch Cover
Z - Pin (2 used)
AA- Bearing (2 used)
AB- Cap
AC- Plug (Filter Bypass)
AD- O-Ring
AE- Spring
AF- Ball
AG- Seal
AH- Seal
AI - Shaft
AJ- Plug
AK- O-Ring (3 used)
AL- Tube
AM- Regulator Block
AN- Regulator Valve
AO- Cap Screw (2 used)
AP- Elbow Fitting
AQ- Filter

Pinion Shaft and Drive Shaft (SST)
F
H
E
J
D
C
B
L
A
J
G K
R
Q
P
O
N
M
M95092A
A - Shaft K - Sleeve
B - Gear L - Pinion Shaft (24T)
C - Bearing M - Snap Ring
D - Thrust Washer N - Ball Bearing (2 used)
E - Bearing Housing O - Gear (33T)
F - Cap Screw P - Spacer
G - Dowel Pin (2 used) Q - Gear (38T)
H - Coupler R - Gear (26T)
I - Shaft S - Drive Shaft
J - Spring Pin (2 used)

3 Speed Synchro Transmission (SST)
F M
K
L
E
D
Q
B C
B
J D
A
C
P
O
I
L M
I
K AB
N
Y AC
Z AA
U
T
J S
AB AC
R
V X
W
MX8736

A - Snap Ring
B - Ball Bearing (4 used)
C - Thrust Washer (2)
D - Ball (2)
E - Gear
F - Synchronizer Assembly (2)
G - Gear
H - Shaft
I - Snap Ring
J - Insert (4 used)
K - Fork (2)
L - Pin (2)
M - Rail
N - Gear
O - Gear
P - Bearing
Q - Snap Ring
R - Shaft
S - Gear
T - Bearing
U - Thrust Washer
V - Dowel Pin
W - Bearing Housing
X - Ball and Spring (2)
Y - Interlock Pin
Z - Plate
AA- Cap Screw (2)
AB- Shift Gate (2)
AC- Pin (2)

Clutch Pedal and Linkage
C
D
A
E F
B G
H
J
I K
L
M
O
Q
R
N
P
S
U T
W
X
MIF M - Spherical Rod End

A - Shaft N - Cap Screw
B - Bearing O - Cap Screw (Stop)
C - Bushing P - Washer
D - Spacer Q - Bracket
E - Snap Ring R - Lock Nut
F - Thrust Washer S - Rod
G - Bushing T - Nut
H - Pedal U - Turnbuckle
I - Clutch Spring V - Rod
J - Snap Ring W - Lever
K - Thrust Washer X - Washer
L - Lock Nut Y - Cotter Pin

POWER TRAIN - GEAR TESTS AND ADJUSTMENTS
Tests and Adjustments Repair
Clutch Adjustment Machine Splitting (Front)

Procedure: NOTE: It is not necessary to remove the clutch housing
from the engine unless engine is being removed. Split
the machine between the tunnel and clutch housing as
outlined in the story below.
Prepare the Machine:

1. Remove any mid or front attachments and mid or front
20 mm (0.78 in.) PTO shaft.
2. Park machine on a level surface. Engage park brake,
shut off engine.
C 3. Disconnect battery negative terminal.

D 4. Remove floor mat.
5. Remove operator’s platform. See “Operators Platform”
in Miscellaneous section.
6. Remove left and right closeout panels.
7. Remove seat and seat platform. See “Seat and Seat
Support” in Miscellaneous section.
8. Remove fenders. See “Rear Fenders” in Miscellaneous
section.
9. Cycle all hydraulic controls to relieve system pressure.
NOTE: Hydraulic reservoir contains approximately 24L
B
A (6.3 gal) of oil. Have a suitable container ready to catch
drain oil.
MIF
10.Drain hydraulic reservoir.
1. If the linkage or pedal have been removed or disturbed,
complete all steps. If the linkage has not been removed or 11.If machine is equipped with an SCV, raise right rear of
disturbed, complete only steps three, seven, and eight. machine and support on suitable stands.
2. Remove cotter pin (A) and disconnect the clutch rod 12.Remove right rear wheel and tire.
from the clutch arm (B).
3. Hold turnbuckle (C) on the clutch linkage and loosen I
lock nuts (D).
4. Move the clutch lever up until the clutch shaft contacts
the clutch lift lever (no freeplay).
5. Hold the clutch lever at this position and adjust the
turnbuckle until the linkage will enter the clutch arm hole.
6. Install the clutch rod, washer and cotter pin.
7. Adjust the turnbuckle until the clutch pedal has 20 mm
(0.780 in.) free travel, measured at center of clutch pedal
face.
8. Hold the turnbuckle and tighten the lock nuts.
MX9771
13.Disconnect four work port tubes (A) from SCV.
Power Train - Gear Tests and Adjustments - 496

POWER TRAIN - GEAR REPAIR
M91982
21.Disconnect hydraulic pressure tube (F) at rear gear

pump.
MX9748
14.Remove cap screws (B) that attach tube support bracket

to frame. Remove tube support bracket and tubes as an
assembly.
G
15.Install right rear wheel and tire.
16.Locate and disconnect all electrical connectors
attaching wiring harness to switches and lights on rear half
of machine. Unfasten wiring harness from cable clips and
move harness away from rear half of machine.
MX9782
22.Remove cap screw (G) and hydraulic pressure tube

clamp.
H
D
C
MX9816
17.Disconnect brake return spring (B) from brake lever.

18.Disconnect lower brake rod (C) from brake lever. MX9743
19.Side Mount Parking Brake Only: Disconnect park brake 23.Disconnect hydraulic supply tube (H) at SCV or manifold
rod from brake lever - located in hole (D). block. Remove tube.
20.Remove five cap screws and left operator’s platform 24.If equipped: Remove MFWD drive shaft and couplers by
support. removing spring pin in rear coupler and sliding coupler onto
shaft until clear of stub shaft. If needed, repeat at other end
of drive shaft.
Power Train - Gear Repair - 497

25.Remove oil filter. 34.Roll machine halves apart.
26.Disconnect oil tube from clutch housing/filter.
Assemble Machine Sections:
NOTE: Splines on all drive shafts and couplers must be
aligned before machine sections are bolted together.
1. Align splines on transmission drive shaft and torsional
damper.
2. Move machine sections together and retain with nine
I cap screws. Tighten cap screws to 126 - 154 N•m (95 - 115
lb-ft).
3. Remove cap screws retaining splitting stands to
machine sections. Remove splitting stands.
MX9762
27.Loosen hose clamp and disconnect suction tube (I) from

manifold. K
MX9762
J
4. Connect suction tube (K) to manifold. Tighten hose
clamp.
M95007
28.Remove cotter pin and washer, and disconnect linkage

rod (J) from clutch lever.
NOTE: When attaching JTO 7335 splitting stands to I
tunnel section, use the supplied right angle brackets,
and attach to holes in underside of tunnel section.
29.Using suitable cap screws, attach four JTO 7335
splitting stands to machine sections. Adjust splitting stands
so that wheels contact the floor, and are parallel to the
machine wheels.
30.Remove nine cap screws connecting tunnel to flywheel
housing. Note length and locations of cap screws when
removing.
MX9743
31.Check for, and disconnect any additional accessory
5. Install hydraulic supply tube (L) to machine. Connect
wires or hydraulic tubes connecting rear half to front half
hydraulic supply tube to SCV or manifold block. Tighten
before splitting machine.
tube nut to 55 - 79 N•m (40 - 59 lb-ft).
32.Release park brake and place gear shift in NEUTRAL.
33.Gently pry around edges of flanges to separate machine
halves.

D
G
D
M91982
B
6. Connect hydraulic pressure tube (G) to rear gear pump.
MX9816
Tighten tube nut to 55 - 79 N•m (40 - 59 lb-ft).
12.Attach lower brake rod (D) to brake lever. Retain with
pin, or pin, cotter pin, and washer.
13.Side Mount Parking Brake Only: Attach park brake rod
to brake lever (D). Retain with clip pin.
H
14.If removed, install brake return spring (B) to brake lever
and ROPS cap screw.
15.Route wiring harness through cable clips. Locate and
connect all electrical connectors attaching wiring harness
to switches and lights on rear half of machine.
MX9782
7. Install cap screw (H) and hydraulic pressure tube clamp.

8. Install left operator’s platform support. Retain with five
cap screws.
B
9. Connect oil tube to clutch cover on transmission.
Tighten to 40 - 57 N•m (30 - 43 lb-ft).
10.Install a new hydraulic oil filter.
11.If equipped, install MFWD drive shaft and couplers.
Slide couplers onto shafts, and retain with spring pins.
MX9748
16.If machine is equipped with an SCV, install SCV tube

support bracket and tubes as an assembly. Install cap
screws (B) to attach tube support bracket to frame.
17.Raise right rear of machine and support on suitable
stands. Remove right rear wheel and tire.

Traction Clutch Removal
I Procedure:
1. Perform machine split between flywheel housing and
tunnel housing. See “Machine Splitting Front”.
A
MX9771
18.Connect four work port tubes (A) to SCV. Tighten tube

nuts to 40 - 57 N•m (30 - 43 lb-ft).
19.Connect battery negative (–) terminal.
20.Install fenders. See “Rear Fenders” in Miscellaneous YZ4436
section.
2. Remove eight cap screws securing clutch cover to
21.Install kick plate. See “Close Out Panel” in tunnel housing.
Miscellaneous section.
3. Remove clutch cover.
22.Install seat and seat platform. See “Seat and Seat
23.Install left and right closeout panels.
24.Install operator’s platform. See “Operator’s Platform” in
the Miscellaneous section.
25.Install floor mat.
26.Refill hydraulic oil reservoir to proper level.
27.Bleed air from hydraulic system. See “Hydraulic System
Bleed Procedure” in Hydraulics section.
B
C
M95331
4. Remove clutch lifter pin (B) and clutch snubber (C).

NOTE: There are shims on both sides of the clutch
snubber. Retain all shims for possible use during
assembly.

Clutch Regulator Removal and Installation
D Removal:
M95284
5. Alternately loosen clutch spring plate retaining cap

screws (D) in small increments and remove plate (E).
YZ4442
1. Remove two capscrews (A) from block.
M95285
YZ4443
6. Remove clutch retaining nut (F) and slide clutch off of
2. Pick up and slide block off tube in clutch cover.
shaft.
H
B
YZ4444
3. Remove tube (B) from clutch cover.

M95313
7. Remove bearing race (G) and spacer (H). IMPORTANT: Avoid damage! Always lubricate and
8. Inspect parts for wear or damage replace as needed. install new O-rings when servicing.
4. Remove and replace O-rings on tube.

Installation:
Installation is reverse of removal.
Traction Clutch Disassembly

Special or Required Tools:
• Calipers
• Bearing Drivers
Procedure:
YZ4446
M95038
YZ4447 NOTE: The clutch piston and hub may only be

assembled one way to operate properly. There are
5. Remove and inspect regulator and O-rings. Replace, if
small assembly marks (A) on them, but you may find it
needed.
helpful to mark the piston post (B) and hub (C) with a
marking pen.
M95039
1. Mark piston post (B) and piston (D) with permanent

marking pen for reassembly.
YZ4448
6. Remove and replace O-ring (C) on block.

7. Remove fittings. Inspect and replace O-rings, if needed.

M95040 MVC-822
2. Remove hub and clutch plates from basket. 5. Measure thickness of each clutch plate. Minimum
thickness: 2.83 mm (0.111 in.). If clutch plate measures
less than minimum specification, replace plate.
M95053
3. Inspect needle bearing (E), race (G), and thrust washer

for wear or damage.
NOTE: If bearing is being replaced, replace race and MVC-825
thrust washer also.
6. Measure thickness of entire clutch plate pack. Minimum
4. If replacement of bearing is necessary, drive bearing out thickness: 26.2 mm (1.031 in.). If clutch pack measures
with appropriate bearing driver. When installing new less than minimum specification, replace clutch pack.
bearing, drive only on the side that the numbers are
stamped on. Drive bearing in until it is slightly below flush
on both sides.
M95055
7. Inspect friction areas of hub and piston for wear.

Replace parts as needed.

IMPORTANT: Avoid damage! DO NOT spin

bearings using compressed air. Damage to
bearing balls, cage and races could result.
M95056
11.Measure no load length of each spring. If spring length

is less than 51.3 mm (2.02 in.), replace spring.
Input Shaft Disassembly

M95057
• Bearing Puller
8. Clean spring plate bearing (G) in suitable solvent. Dry
with compressed air. Procedure:
9. Inspect bearing for discolored or burned balls and/or
races. Check balls and races for spalling or cracking. Roll
bearing by hand to check for rough turning or excessive
looseness or play between balls and races. Replace
bearing as required.
Front Towards Back Towards

Flat Side of Raised Side of
Spring Plate Spring Plate
M95061
1. Using a bearing puller and press, remove bearings.

M95060 bearings using compressed air. Damage to
10.Bearing is designed for side loads and must be installed
in the proper direction as shown. 2. Clean bearings in suitable solvent. Dry with compressed
air.
3. Inspect bearings for discolored or burned ball and/or
races. Check balls and races for spalling or cracking. Roll
bearing by hand to check for rough turning or excessive
looseness or play between balls and races. Replace
bearings as required.

M95334
M95064
2. If input shaft (A) was removed, slide input shaft into
4. Remove snap rings (A) and slide gear from shaft. transmission tunnel. Turn input shaft and make sure input
shaft is properly engaged in PTO shaft splined collar.
Clutch Assembly:
YZ4247
5. Inspect gear teeth for damage. Inspect splines and

bearing areas of shaft for wear or damage.Replace parts
as required.
Traction Clutch Installation

Procedure:
NOTE: Gasket surfaces must be absolutely clean down
to bare metal for form-in-place gasket to work properly.
M95071
Scrape old material off with a sharp gasket scraper and
then use a chemical gasket remover to clean mounting 1. Lay hub assembly on workbench with splined hub facing
surfaces. up.
1. Remove any old gasket material from clutch cover and
transmission housing tunnel.
MX1386

NOTE: There are two styles of metal clutch plates. The
old style on the left has dimples on the surface. The
new “wavy plate” style on the right has a smooth
surface. Do not mix the two styles together.
Gap
Incorrect
Correct
M95068 & M95069
5. Verify proper assembly by making sure piston contacts

M95072
clutch plates.
2. Install a clutch friction disc, then metal plate, then disk,
then plate etc.
3. Line up tabs on clutch discs.
M95081
6. Place thrust washer (B) on clutch.

7. Slide clutch basket down over clutch assembly.
D
M95074
4. Line up assembly marks and put piston on hub

assembly. C
NOTE: The clutch piston and hub may only be

assembled one way to operate properly. Make sure M95329
assembly marks are lined up.
8. Slide spacer (C) and bearing race (D) onto clutch shaft.

Clutch Shimming Procedure
Tools Required:
• JDG 1259 Clutch Shim Fixture
E
Measure Clutch:
M95285
9. Make sure the thrust washer is properly positioned in A

the clutch assembly. While applying pressure to the clutch
parts to keep the thrust washer in place, slide clutch on
shaft.
10.Install belleville washer (E) with side marked “OUT” M95333
toward outside.
1. Install lifter pin (A) without any shims and without the
11.Install nut (F), flat side out, and tighten to 135 N•m (100 clutch snubber.
lb-ft).
2. Seat the clutch back toward the transmission by tapping
the assembly lightly with a soft mallet.
H A
JDG 1259
M95284
12.Install a spring (G) on each of the four posts and then M95335
spring retainer (H) on the clutch. Secure spring retainer 3. Install JDG 1259 over the lifter pin of the clutch. The
with four cap screws and tighten cap screws to 11 N•m (98 overall height of the fixture must be known before
lb-in.). installation. The JDG 1259 is 177.8 mm (7.00 in) high.
4. Measure from the top of the fixture to the top of the lifter
pin and record the measurement.
5. Subtract this number from the height of the fixture.This
is dimension “A”.
6. Write this measurement on the clutch with a marking
pen.

Measure Clutch Housing:
1. Position clutch cover assembly with opening up.
M95043A
• Place a 9.5 mm (0.375 in.) diameter ball in the lifter

YZ4441
lever pocket.
2. Turn clutch pedal control lever clockwise to the
• Place the 17.78 mm (0.700 in.) thick bar across the
disengaged position (B). Lifter lever will be in the raised
housing.
position when the clutch pedal control lever is in the correct
position. • Measure from the top of the bar to the top of the ball
in the lifter lever pocket. Record measurement. Add the
size of the ball 9.5 mm (0.375 in.) and subtract the size
of the bar 17.78 mm (0.700 in.) to recorded
measurement. Add 3mm (0.118 in.). This is dimension
“B”.
Determining Correct amount of Shims:

1. Subtract dimension “A” from dimension “B” to determine
Dimension value “C” which can be zero or greater.
“B”
2. If “C” is zero, assemble without shims.
3. If “C” is greater than zero, add shims equal to dimension
“C” + 0.3/- 0.0mm (+0.012 /- 0.000 in.) between the lifter pin
and the bearing.
4. Install shims on lifter pin.
M95153
3. Measure dimension “B” from the bottom of the pocket in

each lifter lever to the face of the housing.

Snubber Shimming Procedure
Procedure:
NOTE: The drive clutch must be properly shimmed
before shimming the snubber.
A M95365
6. Install clutch shims (E) on the lifter pin and slide lifter pin
and snubber into clutch bearing.
Installing Clutch Cover:
IMPORTANT: Avoid damage! Mating surfaces

must be completely clean of gasket material. Use
a single edged razor blade and gasket removing
C
B compound to clean surfaces to bare metal.
M95341 1. Clean form in place gasket material from mating surface
1. Install clutch shims (determined from previous with a gasket scraper or single sided razor blade and
procedure), snubber (A) without snubber shims, and lifter gasket removing compound.
pin (B). 2. Install new input shaft oil seal.
2. Hold snubber and lifter pin firmly against front of clutch
and measure the gap between the snubber fingers and
lifter pin shoulder with a feeler gauge (C).
NOTE: The gap should not be less than 1.14 mm (0.045
in.) or more than 1.40 mm (0.055 in).
3. Subtract 1.27 mm (0.050 in.) from measurement in
previous step. This is the thickness of shim pack to be used
between the front surface of clutch snubber and bottom
surface of lifter pin shoulder.
4. Measure shims to be installed individually, do not
measure with the shims stacked together.
M95288
3. Mark position of snubber locating tabs on clutch

housing.
M95042B
5. Install snubber shims (D) to the lifter pin.

Snubber Check Procedure:
(Optional: Check if transmission is removed from
differential housing.
NOTE: Check should be made with transmission in
horizontal position.
NOTE: Check must be made with transmission in 2nd
gear. If shifter is not on the unit, turn shift rod
counterclockwise and push in, or if shift rod and cover
are not on trans, top fork rod should be in forward
position.
M95332
4. Hold clutch cover on center tunnel housing and place

marks where clutch housing is marked.
NOTE: Four of the slots on the snubber are larger than
the others. The larger slots must be lined up with the
tabs on the clutch housing.
5. Line up larger slots on clutch snubber with marks on
center section.
6. Place a 2 mm (1/16 in.) uniform bead of TY16021 John YZ4319
Deere Form-in-Place Gasket around the mating surface of
the clutch cover. 1. Place transmission in 2nd gear.
2. Attach a dial or pointer type torque wrench to output
IMPORTANT: Avoid damage! Clutch cover must shaft of transmission.
come up against hollow dowels on each side 3. Engage clutch and rotate the output shaft at
before cap screws are installed or the snubber is approximately 10 rpm. Observe torque while rotating shaft.
not positioned correctly. Check position of Torque should be approximately 9.5 N•m (84 lb-in.).
snubber slots and re-align as necessary. Record reading.
4. Fully disengage the clutch, thus applying the snubber,
and repeat step three. Record the observed torque.
1
7 5. Subtract the reading from step three from the reading
from step four. The results must be greater than 5.4 N•m
3 6 (48 lb-in.) but not exceed 8.1 N•m (72 lb-in.).
6. If the results are not within this range, re-shim the
snubber accordingly. That is, add shims to increase torque,
or remove shims to decrease torque.
5 4
8
2
YZ4436
7. Install clutch cover, and tighten cap screws to 28 N•m

(20 lb-ft) in sequence shown.

Clutch Shaft Removal and Installation
Removal:
1. Split machine between flywheel housing and tunnel.
See “Machine Splitting (Front)” on page 496.
2. Remove cap screws and clutch housing. See “Traction
Clutch Removal” on page 500.
M95290
6. Inspect lift lever (D) for wear or damage. Replace if

needed.
Installation:
MX4437
1. Install a new shift shaft seal in housing.
3. Remove pin (A) from clutch housing.
M95290
2. Install clutch shaft into housing.

M95290
3. Align clutch shaft properly to allow installation of
4. Remove clutch shaft (B) from housing. retaining pin.
M95210 YZ4437
5. Remove shift shaft seal (C) in housing. 4. Apply thread locking compound to clutch shaft retaining
pin (A) and install retaining pin into clutch housing.

3-Speed Transmission Removal
Procedure: F
1. Split machine between the tunnel and the differential

housing. See “Machine Splitting Rear” in the Final Power
Train section.
2. Remove tunnel from the flywheel housing. See
“Machine Splitting Front”.
3. Remove traction clutch. See “Collar Shift And Sync Shift
Traction Clutch Removal”.
M94868
6. If equipped, rotate MFWD shift lever (E) until shoe (F)

clears shift collar.
B
A
M95313
4. Remove bearing race (A) and spacer (B) from shaft.
M94868
7. Remove shaft, gear, and shift collar as an assembly.
MX4440
5. If not already done, remove drive shaft (C). F

H
M94870
8. Remove spring pin (G) and slide shift shaft out of tunnel.
9. Inspect bearing (H) for wear or damage. Replace if
necessary.

10.Inspect shoe (F) for wear or damage. Replace if 3 Speed Synchronized Transmission
necessary.
Disassembly:
YZ4319
11.On left side of tunnel, remove four cap screws and

shifter assembly.
YZ4248
1. Remove two spring pins (J) and two shift gate blocks
(K).
YZ4439
12.Remove two cap screws (I) and three speed

transmission.
MX1369
2. Remove two cap screws (L) and cover plate (M).

MX1366
3. Remove interlock pin (N). MX1368
NOTE: Do not push shift rods too far into shift rod 5. Rotate assembly away from shift forks, and remove.
housing (O). Housing contains two detent balls and
springs which may be lost.
MX9877
MX1365
4. Using a plastic mallet, drive both shift rods toward gears
6. Remove cap screw (P) and idler shaft and gear
and shafts. Tap on end of output shaft to loosen shafts and
assembly (Q).
gears, and remove reverse shaft and pinion shaft from
bearing plate.
Q
M95298
7. Remove thrust washer, gear, and bearing from shaft.

Inspect parts for wear or damage. Replace as needed.
NOTE: Use care when removing shift rods from shift
rod housing. Cover holes (R) in guide block to avoid
loosing detent balls and springs.

Pinion Shaft Disassembly:
MX1359
1. Using a suitable puller, or press, remove bearings from

pinion shaft.
2. Inspect bearings for wear or damage. Replace if
needed.
MX1371
33T 26T
8. Remove two shift rods and forks from guide block. R
38T
MX1360
3. Slide 33 tooth gear, spacer (R), 38 tooth gear, and 26

MX1367 tooth gear from pinion shaft.
9. Remove two detent balls and springs from shift rod Pinion Shaft Assembly:
housing. Inspect parts for wear or damage. Replace parts
Assembly is the reverse of disassembly.
as needed.
• Lubricate parts liberally with hydraulic oil before
assembling.
M95164
10.Inspect shift fork inserts for wear or damage. Replace if MX1361

necessary.
• Install 38 tooth gear with raised side of hub facing
toward spacer as shown.
• Install 26 tooth gear, 38 tooth gear, spacer (R), and 33
tooth gear. Press bearings onto pinion shaft.

Output Shaft Disassembly:
T
S
M95299
2. Remove ball from hole in shaft.
M95297
1. Remove snap ring (S). 36T
2. Using a suitable puller or press, remove bearing (T) from

end of shaft.
M95300
3. Remove 36 tooth gear.
M95298
B
1. Remove thrust washer.
MX1348
4. Remove bearing (A) and brass synchronizer ring (B).

MX1350
5. Remove snap ring (C) and synchronizer assembly (D).

MX1351
7. Remove bearing from other end of shaft.
F
G
MX1349
MX1352
6. Remove 43 tooth gear and brass synchronizer ring (E).
8. Remove thrust washer (F), ball (G), and gear (H).

I MX1356
J
12.Check gear teeth (L) for wear, chips, or breaks. Replace
as needed.
MX1353
9. Remove snap ring (I) and synchronizer assembly (J).
MX1362
K
13.Remove two retainer springs (M) from synchronizer
assembly.
IMPORTANT: Avoid damage! Note positions of

the ends of the retaining springs (1). The ends of
MX1354
each spring have to be rested in the same strut
10.Remove gear and brass synchronizer ring (K). (2) on each side of the assembly.
MX1355
11.Inspect shaft for wear or damage on all machined areas.

Check all splines. Replace shaft if needed.

Synchronizer Wear Measurement Procedure:
1
C
B
2
D
E
MX1363
14.Check all synchronizer parts for wear or damage. MX8739
1. Mark the synchronizer rings and synchronizers for

location on the shaft. It is important that each synchronizer
ring be measured against the gear it was assembled to.
2. Position gear on a stable surface with the synchronizer
cone up. Install the corresponding synchronizer ring (A)
and synchronizer (B) to the gear. Place the opposite gear
(C) on top of the synchronizer for added weight to stabilize
the synchronizer ring during measurements.
3. Measure the gap between the gear and the
synchronizer ring (D) with a feeler gage (E) at 3 positions
around the ring approximately 120 degrees apart. The
three measurements must be within 0.18mm (0.007 in.) of
each other. If the measurements do not meet this criteria,
N reposition the synchronizer ring on the gear. Repeat
measurements and repositioning until the 0.18mm (0.007
in.) criteria is met.
NOTE: Synchronizer assembly and brass synchronizer
MX1358 rings are not serviced individually. If any parts are
needed, entire assembly must be replaced.
15.Check brass synchronizer ring for worn or missing teeth
(N). 4. The synchronizer ring gap is the average of the final
measurements at the three positions. Replace
synchronizer if clutching teeth are worn or the gap is less
than 0.25mm (0.010 in.).

Output Shaft Assembly:
IMPORTANT: Avoid damage! Lubricate all parts

liberally with clean hydraulic oil during assembly.
31T
MX1353
3. Install synchronizer assembly with oil grooves (A) facing

up, and retain with snap ring (B). Synchronizer assembly
M95312 should be placed on shaft with four oil grooves facing up.
1. Install 31 tooth gear onto output shaft.
F
G
MX1364 MX1352
2. Make sure slots are aligned with detent blocks when 4. Install 36 tooth gear (H), and ball (G). Install thrust
installing brass ring to synchronizer assembly. washer (F) with wider side toward gear.

7. Install synchronizer assembly (D), snap ring (C), and
bearing (E). Synchronizer should be placed on shaft with
four oil grooves (A) facing up.
M95306
5. Using a press, or suitable bearing driver and a soft-

faced mallet, install bearing to end of shaft.
M95299
8. Install 36 tooth gear and install ball into hole in shaft.
43T
M95305
M95298
6. On other end of shaft, install 43 tooth gear.
9. Install thrust washer.
D E
MX1348

S P
T Q
MX1365
4. Install idler shaft (Q) to bearing plate. Retain with cap

M95297 screw (P).
10.Using a press, or a suitable driver and a soft-faced 5. Rotate shift rods to correct positions.
mallet, install bearing (T) onto end of shaft. Retain with
snap ring (S).
Assembly:
MX1368
6. Install output shaft into bearing plate and shift forks.

YZ4257
1. Hold the ball and spring in with a punch and install the
shift rod assembly.
2. Repeat for second shift rod.
M95296
3. Install bearing, gear, and thrust washer onto idler shaft MX9877
(Q). 7. Install pinion shaft, and output shaft into bearing plate.

Using a plastic mallet, tap shafts, gears, and two shift rods
into bearing plate.
K
MX1366
YZ4248
8. Properly align shift rods, and install interlock pin (N) into
10.Install two shift gate blocks (K). Retain with two spring
shaft housing (O).
pins (J).
Installation:
L
M
I
MX1369
YZ4439
9. Install cover plate (M) and retain with two cap screws
1. Align two bearings and two shift rods with holes in
(L).
tunnel. Install transmission into housing and retain with two
cap screws (I).
IMPORTANT: Avoid damage! Replace O-rings and

seals. Used O-rings and seals will leak.

M95199
2. Install a new MFWD drive shaft seal at front of tunnel.
M94869
5. Insert MFWD drive shaft assembly into tunnel.
M94876
3. Install a new MFWD shift shaft seal into tunnel.
G E
M94868
6. Engage shoe (F) to shift collar and rotate MFWD shift

lever (E) to draw MFWD shaft into place.
M94870
4. Slide MFWD shift shaft into tunnel and through shift

arm. Retain shift arm to shaft with spring pin (G).

11.Assemble machine tunnel and differential housing
sections. See “Machine Splitting Rear” in the Final Power
Train section.
12.Assemble machine flywheel housing and tunnel
C sections. See “Machine Splitting (Front)” on page 496.
MX4440
7. Install drive shaft (C).
YZ4319
8. On left side of tunnel, install shifter assembly and retain

with four cap screws.
M95313
9. Install spacer (B) and bearing race (A) to input shaft.

10.Install clutch. See “Traction Clutch Installation” on
page 505.


POWER TRAIN - HYDROSTATIC TABLE OF CONTENTS
Power Train - Hydrostatic
Table of Contents
Specifications ...............................................529
General.......................................................529
Hydrostatic Pump/Motor Assembly:
Hydrostatic Pump .......................................529
Hydrostatic Motor .......................................529
Other Materials...........................................530
Hydraulic Hoses and Lines.........................531
Hydrostatic System Schematic...................532
Hydrostatic System
Schematic (continued)................................533
Diagnostics ...................................................534
Symptom Table ..........................................534
Hydrostatic Power Train .............................535
Theory of Operation .....................................536
eHydro Transmission Operation.................536
Hydrostatic Pump Pressure Test................538
Charge Pump Pressure Test......................539
Hydraulic System Bleed Procedure............540
Repair.............................................................541
Forward and Reverse
Potentiometers ...........................................541
Forward and Reverse
Pedals Assembly........................................542
Hydrostatic Transmission
Power Train - Hydrostatic Table of Contents - 527

POWER TRAIN - HYDROSTATIC TABLE OF CONTENTS
Power Train - Hydrostatic Table of Contents - 528

POWER TRAIN - HYDROSTATIC SPECIFICATIONS
Specifications
General
Hydrostatic Pump/Motor Assembly:

Hydrostatic Pump
Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sauer-Danfoss
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable Piston Pump
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JD LVA10836
Nominal Displacement (maximum/rev). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 cm3/rev (3.11 cu in./rev)
Minimum Pressure Relief Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38500 kPa (5585 psi)
Charge Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-1310 kPa (160-190 psi)
Hydrostatic Motor
Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sauer-Danfoss
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed Displacement Axial Piston Motor
Nominal Displacement (fixed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.5 cm3/rev (2.65 cu in./rev)
Forward and Reverse Pressure Relief Valve Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 N•m (58 lb-ft)
Charge Pressure Relief Valve Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 N•m (58 lb-ft)
Filter Nipple. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft)
Charge Pressure Diagnostic Port Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 – 16 N•m (115 – 142 lb-in.)
Transmission to Tunnel Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 – 154 N•m (95 – 115 lb-ft)
SCV Pressure Tube to Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 – 79 N•m (40 – 59 lb-ft)
SCV Pressure Tube to SCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 – 79 N•m (40 – 59 lb-ft)
SCV Work Port Tubes to SCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 – 57 N•m (30 – 43 lb-ft)
Charge Pressure Tubes to Transmission Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 – 79 N•m (40 – 59 lb-ft)
Tunnel Section to Differential Housing Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 – 105 N•m (51 – 75 lb-ft)
Tunnel Section to Clutch Housing Cap Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 – 105 N•m (51 – 75 lb-ft)
Proportional Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 19 N•m (10 - 14 lb-ft)
Solenoid Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5 N•m (24 - 48 lb-in.)
Tie Bolt Seal Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 23 N•m (156 - 204 lb-in.)
Trunnion Cover Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 - 37 N•m (23 - 27 lb-ft)
Power Train - Hydrostatic Specifications - 529

POWER TRAIN - HYDROSTATIC SPECIFICATIONS

Splitting Stands and Brackets JT07335-1,2,3 Splitting machine.
2,000 kPa (300 psi) Gauge JT03344 Checking charge pressure.
68947 kPa (10,000 psi) Gauge JT03362 Checking system pressure.
Hose With Quick Coupler JT03364 Checking system pressure.
Hose With Quick Coupler JT03017 Checking charge pressure.
7/16-20 M 37° X 7/16-20 M 37° Elbow JT03240 Checking system and charge pressure.
Quick Coupler F X 7/16-20 F 37° Adapter JT03264 Checking system and charge pressure.
Quick Coupler M X M14-1.5 ORB JT05480 Checking system pressure.
Adapter
Other Materials
Other Material
TY16285 John Deere Clean and Cure Primer Prime Gasket Surfaces for Faster Curing of
Form-in-Place Gaskets.
TY16021 John Deere High Flex Form-In-Place Gasket Hydrostatic Transmission to Tunnel Seal
TY15934 John Deere General Purpose Gasket Dressing Sealing Gaskets and Hoses
Power Train - Hydrostatic Specifications - 530

POWER TRAIN - HYDROSTATIC COMPONENT LOCATION
Component Location
Hydraulic Hoses and Lines
C
B
E
G
I
MIF E - Steering Control Unit (SCU)

A - Hydraulic Oil Cooler F - Steering Return Line
B - Front Gear Pump G - Hydrostatic Unit
C - Suction Tube Manifold (Oil Supply) H - Oil Suction Filter
D - Steering (Charge Pressure) Supply Line I - Cooler Return Line
Power Train - Hydrostatic Component Location - 531

Hydrostatic System Schematic
Steering Cylinder
Left (L) Right (R)
Left Right To Transmission Tunnel
Relief Valve
Power
10342 kPa
Steering Valve
1500 psi
P T
Steering Wheel
Engine
Gear Pump
(Front)
Suction Filter
Sump Oil
Intake Screen
Charge Pressure/Tunnel Lubrication Oil
High Pressure Oil
Sump Steering Oil
MIF

Hydrostatic System Schematic (continued)
Pump Case
Relief Valve
Spin-On Filter 1200 kPa

175 psi
Oil Cooler Oil Cooler

Bypass
Relief Valve
300-900 kPa
45-130 psi
M3
System 38500 kPa

eHydro Relief 5585 psi
Hydraulic Valve M1
Pump
51.0 cm3/rev
Hydraulic
Proportional Motor
Solenoid Valve 43.5 cm3/rev
System
Relief
38500 kPa
Valve
5585 psi
M2
Proportional
Solenoid Valve Hydrostatic Transmission
M5 M4
Make-Up/Closed Loop Relief Oil

High Pressure Oil
Sump Oil
Charge Pressure Oil
MIF

POWER TRAIN - HYDROSTATIC DIAGNOSTICS
Diagnostics Symptom: Machine Movement Problem
Yes - Forward/Reverse proportional valve
Symptom Table malfunction
Symptom: Machine Movement Problem (4) Low Power?
(1) Wheels On Machine Will Not Rotate? Yes - Hydraulic oil level low in transaxle
Yes - Check torsional damper between engine and Yes - Low charge pressure. See Tests and
pump Adjustments section.
Yes - Hydraulic oil level low in transaxle Yes - Main drive pressure relief valve stuck open.
See Tests and Adjustments section.
Yes - Low charge pressure. See Tests and
Adjustments section. Yes - Air in system. See Hydraulic System Bleed
Procedure.
Yes - Internal pump or motor damage or excessive
wear Yes - Hydrostatic pump output pressure too low.
Yes - Parking brake engaged or malfunctioning
Yes - Transaxle malfunction. See Final Drive Power
wear
Train section.
(5) Wheels Rotate In One Direction Only?
Yes - Forward/Reverse proportional valve
malfunction Yes - Main drive pressure relief valve stuck open.
Yes - Pedal potentiometers neutral position not
properly adjusted, Debris under pedal(s) or pedal Yes - Forward/Reverse proportional valve
return spring problem malfunction
Yes - Seat switch malfunction Yes - Pedal potentiometers neutral position not
properly adjusted, Debris under pedal(s) or pedal
(2) Noisy Pump or Motor?
return spring problem
Yes - Hydraulic oil level low in transaxle
(6) Machine Does Not Move When Forward or
Yes - Main drive pressure relief valve stuck open. Reverse Pedals Are Pressed?
Yes - Hydraulic oil level low in transaxle
Yes - Air in system. See Hydraulic System Bleed
Yes - Low charge pressure. See Tests and
Procedure.
Adjustments section.
wear
wear
(3) Sluggish Response To Changes In Speed?
Yes - Transaxle malfunction. See Final Drive Power
Yes - Hydraulic oil level low in transaxle Train section.
Yes - Low charge pressure. See Tests and Yes - Forward/Reverse proportional valve
Adjustments section. malfunction
Yes - Main drive pressure relief valve stuck open. Yes - Pedal potentiometers neutral position not
See Tests and Adjustments section. properly adjusted, Debris under pedal(s) or pedal
return spring problem
Yes - Air in system. See Hydraulic System Bleed
Procedure. Yes - Seat switch malfunction
Yes - Hydrostatic pump output pressure too low. (7) Cruise Control Does Not Work?
Yes - Parking brake engaged or park brake switch
Yes - Internal pump or motor damage or excessive misadjusted or malfunctioning
wear
Power Train - Hydrostatic Diagnostics - 534

POWER TRAIN - HYDROSTATIC DIAGNOSTICS
Symptom: Machine Movement Problem
Yes - Transmission or engine speed sensor
malfunction. See Electrical section.
(8) Load Match Does Not Work?
Yes - Engine speed sensor malfunction. See
Electrical section.
Yes - Throttle position sensor out of range or not
calibrated correctly
Hydrostatic Power Train

Test Conditions: • Operator in Seat
Control Pedals Pedals should press and return Check for broken return springs or debris/
freely. damage to pedals
Test Conditions: • Start engine and run at slow idle
Directional Pedals are in neutral Machine should not creep forward or Check control pedals for debris, or
position. backward. damage preventing full return to neutral
position.
Move forward or reverse pedal slowly Machine should accelerate smoothly Check transaxle for proper fluid level.
from neutral to maximum travel speed forward or backwards. Check hydraulic tubing, and connections
position. for leaks.
Perform system flow and pressure
checks to verify proper operation of
charge pump and hydrostatic pump.
Control pedal in full forward position. Machine should move forward. Check pedals and linkage to forward/
reverse potentiometers for damage.
Check electrical connections.
Check forward drive pressure relief valve.
Check charge pressure.
Control pedal in full reverse position. Machine should move backward. Check pedals and linkage to forward/
reverse potentiometers for damage.
Check electrical connections.
Check reverse drive pressure relief valve.
Check charge pressure.
Power Train - Hydrostatic Diagnostics - 535

POWER TRAIN - HYDROSTATIC THEORY OF OPERATION
Theory of Operation
eHydro Transmission Operation
D
Top View
E
G
F
I
C
D
Side View
H
F
K E G
High Pressure Oil Passages (Forward / Reverse)

Charge Pressure Oil
MIF
Power Train - Hydrostatic Theory of Operation - 536

POWER TRAIN - HYDROSTATIC THEORY OF OPERATION
Function: When a valve opens, hydraulic oil is routed to an end of the
servo piston (H). The hydraulic oil moves the servo piston
The hydrostatic system provides a means to transfer power
either forward or backward. A pin from the swash plate
from the engine to the three speed range transmission and
rides in a groove on the servo piston and the swash plate
then the final drive for the wheels. It provides infinitely
variable speed control, forward or reverse, by foot pedal rotates when the servo piston moves.
operation. As long as the forward and reverse pedals are released,
the swash plate is level and no oil is being pumped.
Principles of Operation:
Rotating the swash plate off center changes the distance
The hydrostatic system is a closed loop fluid power system the pistons (I) travel inside the piston bore of the rotating
that consists of a charge pump on the left front side of the assembly. Because the input shaft rotates in one direction,
engine, and a piston pump/motor assembly, which is driven the direction that the swash plate is rotated from center
by a flexible coupler (A) attached to the flywheel. determines the direction of fluid flow to the drive motor
(forward or reverse). The number of degrees the swash
Charge Pump plate is rotated, determines how much fluid will be
The charge pump is a gear type positive displacement displaced (speed).
pump mounted to the left front side of the engine. The hydrostatic pump provides hydraulic fluid to the
This pump provides pressurized fluid to the SCU (Steering hydrostatic drive motor (E) through passages in the center
Control Unit). Return oil from the SCU is routed through the section. Hydraulic fluid in the power train circulates one
filter mounted to the front of the center section, and then direction or the other in a closed loop. Fluid leaves the
into the hydrostatic pump to provide replacement fluid to hydrostatic pump and flows through the hydrostatic motor
the closed loop of the hydrostatic transmission. and is returned to the hydrostatic pump, not the reservoir.
Fluid that leaves this closed loop circuit, via leakage to
Hydrostatic Pump case drain, is replenished by fluid from the charge pump.
The hydrostatic pump is an axial piston, variable Fluid may also be dumped from the high pressure side of
displacement piston pump. It is mounted directly to the the loop to the low pressure side if the machine encounters
front of the tunnel. The input shaft (B) splines are driven by a heavy load or stalls out. This happens through the high
the flexible coupler attached to the engine flywheel. Any pressure relief valves.
time the engine is running the input shaft is rotating.
Hydrostatic Motor
NOTE: The PTO drive shaft is splined to the other end The hydrostatic motor (E) is a high torque axial piston
of the input shaft. motor. The motor is located on the rear of the center
The hydrostatic pump (C) is splined to the center of the section. The hydrostatic motor drives the input shaft (J) for
input shaft. The pistons ride on the swash plate (D). As a three speed range gear transmission which transfers
long as the swash plate is level, the pistons do not move in power to the wheels. See Final Drive Section.
or out of the drive pump as it rotates. When high pressure oil is pumped to the hydrostatic motor
Oil flow from the cylinder block to the drive motor (E) is it is provided to one side of the motor cylinder or the other.
controlled by changing the angle of the swash plate. This The high pressure oil forces pistons out of the motor
angle is changed when the forward or reverse pedals are cylinder. The pistons follow the contour of the fixed swash
pushed. Pushing a forward or reverse pedal will change the plate (K) creating rotary motion of the motor cylinder. The
output of the forward or reverse potentiometer. The voltage delivery side determines rotary direction.
value coming from the pedal potentiometer is fed into the The pistons continue to move out of the cylinder and follow
electronic control module, which sends a variable signal to the fixed angle swash plate until they are no longer aligned
the coils on the forward or reverse proportional pressure with the oil delivery port. Since oil is no longer being
reducing valves (F and G). displaced to the pistons, they no longer add to the rotary
The proportional valves control the flow of hydraulic oil to motion of the motor. But, the next pistons in line are filling
each end of the servo piston (H) which is directly linked to with oil and the rotary motion is continued.
the swash plate. As the motor group continues to rotate, its pistons are
NOTE: The control module will only send a signal to a pressed by the fixed angle swash plate and oil is forced
valve coil if all logic input signals are present within from the piston bores. The displaced oil is returned to the
correct value ranges. Only one valve will open at a hydrostatic pump through the center section.
time. Oil will be provided to only one end cylinder of The motor output shaft is splined to the motor and rotates
the servo piston at a time. in the same direction as the piston block. The output shaft
is splined to the rear transmission input drive shaft (J).
Power Train - Hydrostatic Theory of Operation - 537

POWER TRAIN - HYDROSTATIC TESTS AND ADJUSTMENTS
Tests and Adjustments Procedure:
1. Run machine until hydraulic oil is at operating
Hydrostatic Pump Pressure Test temperature.
2. Turn key switch to OFF position.
Reason:
To ensure that internal parts of hydrostatic pump are not
worn excessively, and the relief valves are operating c CAUTION: Avoid Injury! AVOID SUDDEN
properly. TRACTOR MOVEMENT. Machine could move
suddenly causing severe injury or damage
Equipment: to equipment during test procedure.
• JT03362 - 10,000 psi Gauge Perform test in open area. Keep all
personnel away from front or rear of
• JT03364 - Hose With Quick Coupler machine.
• JT03240 - 7/16-20 M 37° X 7/16-20 M 37° Elbow
3. Cycle all controls to relieve any pressure that may be in
• JT03264 - Quick Coupler F X 7/16-20 F 37° Adaptor the hydraulic system.
• JT05480 - Quick Coupler M X M14-1.5 ORB Adapter
A
B
JT03362
JT03240
JT05480
MX9752
4. Locate forward test port (A) and reverse test port (B) on
JT03264
hydrostatic transmission inside tunnel opening.
5. Remove test port plugs.
JT03364 6. Install one JT05480 male quick coupler into each test
port.
M91847
IMPORTANT: Avoid damage! Make sure that the

hydraulic fluid is visible in sight glass.
Insufficient hydraulic fluid could cause system to
run dry and damage pump and motor.
IMPORTANT: Avoid damage! Do not allow valves

to relieve for more than 10 seconds or hydraulic
oil may overheat.
MX9885
Power Train - Hydrostatic Tests and Adjustments - 538

7. Attach JT03362 gauge and hose assembly as shown to hydrostatic pump is worn or damaged and must be
each test port adaptor. replaced. Internal rotating parts on hydrostatic transmission
assembly are not serviceable. Remanufactured
transmissions are available and must be replaced as
complete units.
Charge Pump Pressure Test

Reason:
To ensure that charge pump is operating at specified
pressure to supply oil to hydrostatic pump.
Equipment:
• JT03344 - 2,000 kPa (300 psi) Gauge
• JT03017 - Hose With Quick Coupler
• JT03240 - 7/16-20 M 37° X 7/16-20 M 37° Elbow
MX9884 • 7/16-20 M 37° X M12-1.5 ORB Adaptor
8. Position gauges so they can be read from operator’s
seat.
JTO3362
NOTE: Make sure the load match switch is in the OFF
position. Pressure reading may not get up to relief JTO3240
pressure if switch is on.
9. Perform test from operator’s seat. Make sure the load
match switch is in the OFF position. Apply firm pressure
to right and left brake pedals. Place range transmission
shift lever in “C” (high) position. Start engine and run at full
throttle.
c CAUTION: Avoid Injury! If brakes fail to M12-1.5

prevent wheels from turning, STOP TEST
IMMEDIATELY. Repair or adjust brakes as JTO3017
necessary before resuming test. See Brake
Section.
10.Slowly depress forward directional pedal and observe

gauge. Gauge should slowly rise to 37128-38500 kPa MX9886
(5385-5585 psi) and relief valve may open with an
audible squealing noise. Procedure:
11.Repeat same procedure with reverse pedal. 1. Run machine until hydraulic oil is at operating
temperature
Specifications:
2. Park machine on a level surface and set park brake.
• Pump pressure should reach 37128-38500 kPa (5385-
5585 psi) in either direction and then relieve.
4. Shift transmission to NEUTRAL.
Results:
• If pressure will not reach 37128 kPa (5385 psi) in either IMPORTANT: Avoid damage! Make sure to relieve
direction, check charge pressure. See “Charge Pump system pressure before loosening any system
Pressure Test” on page 539. lines or hoses.
• If charge pressure is good and hydrostatic pump 5. Cycle all controls to relieve any pressure that may be in
pressure will not get up to relief pressure in both directions, the hydraulic system.

• To check charge pressure relief valve, remove
transmission oil filter. Locate and remove valve cap (C).
A
YZ4467A
MX11678
6. Locate the hydraulic manifold block on the right side of
• Inspect all parts for wear or damage. If any parts are
the tunnel.
suspect, relief valve must be replaced as an entire
7. Assemble test equipment as shown and install to test assembly.
port (A).
• Charge pressure relief pressure can be adjusted by
8. Start engine and run at high idle, record pressure. changing the amount of shims behind the spring.
Procedure with Diverter Kit Installed: • Shims come in thicknesses of 0.025mm (0.010in.),
0.050mm (0.020in.), and 1.27mm (0.050in.)
1. Disconnect fitting from bottom right of block (B).
• 0.025mm (0.010in.) shim changes pressure
2. Install T-fitting and connect pressure gauge. approximately 69 kPa (10 psi)
3. Start engine and run at high idle, record pressure. • 0.050mm (0.020in.) shim changes pressure
approximately 138 kPa (20 psi)
Specifications:
• 1.27mm (0.050in.) shim changes pressure
Charge Pressure (High Idle) 1172 - 1310 kPa (170 - 190 approximately 517 kPa (75 psi)
psi)
Results: Hydraulic System Bleed Procedure

• Charge pressure should reach specification. Reason:
• If pressure reading cannot be obtained, the mesh inlet To remove air trapped in the hydraulic system which will
filter may be restricted, the suction line filter may be prevent proper operation.
restricted, the front hydraulic pump may be defective, or the
charge pressure relief valve may be worn or stuck open. Procedure:
IMPORTANT: Avoid damage! If contamination is

found in hydraulic system filter or inside
reservoir, flush entire hydraulic system, clean
inlet strainer, and replace all filters.
NOTE: Fill the hydraulic oil filter with new oil before
installing.
1. Install a new hydraulic oil filter.
2. Fill the transaxle with specified JDM J20D (preferred) or
C
J20C oil to the proper level in sight glass.
MX11681

POWER TRAIN - HYDROSTATIC REPAIR
Repair
Forward and Reverse Potentiometers

Removal:
This procedure applies to one or both of the forward or
reverse potentiometers.
IMPORTANT: Avoid damage! Do not loosen or

remove potentiometers unless they need to be
replaced. The potentiometer output must be
calibrated for logic controller function. If the
potentiometer is not set within a correct output
range, the machine will not operate forward or
M91946 reverse.
3. Disconnect electrical connector to fuel shutoff solenoid. 1. Safely park machine.
4. Turn the key to START and hold for 10 seconds. Turn the 2. Locate and remove cover from forward and reverse
key to OFF. pedal bracket located under operator’s floor platform.
5. Reconnect wires to fuel shutoff solenoid.
6. Raise machine front end and support on suitable E
stands.
7. Start the engine and run at low idle.
D
C
8. Slowly turn the steering wheel left and right until wheels
turn smoothly indicating that any trapped air has been bled
D
back to the reservoir.
B
9. Operate rockshaft several times until it operates
smoothly.
C
10.Stop the engine and check the hydraulic reservoir oil
level. Fill as needed. Check all line connections for leaks;
tighten if necessary. A
11.Lower the machine to the ground. MX9810

12.Drive machine in forward and reverse several times until 3. Mark wiring harness connectors (A) and forward and
transmission operates smoothly. reverse potentiometers to aide re-connection. Disconnect
wiring harness connectors.
4. Remove e-clips (B) from link(s) (C) connecting rotary
arm (D) to pedal arm. Disconnect link from rotary arm.
5. Remove lock nuts (E). Remove rotary arm assembly.
6. Remove potentiometer.
Power Train - Hydrostatic Repair - 541

Forward and Reverse Pedals Assembly
H Disassembly:
I 1. Safely park machine.
2. Remove forward and reverse pedals.
3. Locate and remove cover from forward and reverse
pedal bracket under floor operator’s platform.
4. Remove operator’s platform. See procedure in
5. Mark wiring harness connectors and forward and
reverse potentiometers for aide in installation. Disconnect
MX9803
wiring harness connectors from forward and reverse
potentiometers.
7. Remove e-clip from rotary arm and remove arm from
cover. Replace o-ring (I) and (H) before reassembly. 6. Remove socket head cap screws and forward and
reverse foot pedals from arms.
Installation: 7. Remove three cap screws securing pedal assembly to
NOTE: The forward and reverse potentiometers must foot deck.
be accurately set after replacement. See “eHydro
Potentiometer Adjustment” in the Electrical section. A
1. Install cap screws through potentiometer and place in

bracket. Install rotary arm and cover. As needed, use a
small amount of grease to hold o-ring(s) in place during
assembly.
B
2. Install and tighten lock nuts enough that the
potentiometer will stay in place without turning, but can be
rotated by hand.
3. If removed, repeat steps for second potentiometer and
rotary arm assembly.
IMPORTANT: Avoid damage! Torque specification

MX9798
is critical.
8. Remove e-clips (A) securing link (B) between reverse
4. Perform potentiometer calibration and tighten lock nuts pedal and potentiometer and remove link.
to specification.
5. Install cover.
C
Specification:
Lock Nut Torque . . . . . . . . . . . . . . . 3.4 N•m (30.0 lb-in.)
MX9808
9. Remove e-clips securing second link (C) Remove link

end from potentiometer arm and rotate link against forward
pedal.

13.Remove lock nuts (F) and cap screws from
C potentiometer. Remove rotary arm and cover assembly (G).
MX9801
MX9803
10.Place pedal assembly on a hard flat surface and push
center of assembly down (compressing springs) until pedal 14.Remove e-clip from rotary arm and remove arm from
stop bracket (D) can be removed. Release assembly cover. Replace o-ring (I) and (H) before reassembly.
allowing springs to relax.
Assembly:
11.Remove link (C) from forward pedal.
NOTE: The forward and reverse potentiometers must
be accurately set after replacement. See “eHydro -
E Potentiometer Calibration” in the Electrical section.
MX9805
12.Remove pin securing drilled axle (E) in bracket. Slide

axle out of bracket and remove reverse pedal, washer, MX9804
forward pedal and axle.
1. Install cap screws through potentiometer and place in
bracket. Install rotary arm and cover. As needed, use a
small amount of grease to hold o-ring(s) in place during
G
assembly.
2. Install and tighten lock nuts enough that the
potentiometer will stay in place without turning, but can be
rotated by hand.
F
3. Repeat steps for second potentiometer and rotary arm
assembly.
MX9802

MX9806 MX9807
4. Install springs to pedals. Hold forward pedal in bracket 8. Rotate link (C) and place it through hole in rotary arm
and place end of spring (A) through hole in bracket. (E). Secure link with two e-clips.
MX9809
MX9799
5. Slide pivot axle through bracket and forward pedal.
Install washer (B) onto pivot axle. 9. Install second link (F) between reverse pedal and rotary
arm. Secure link with e-clips (G).
6. Place reverse pedal into position and slide axle through
pedal and bracket. Secure axle in place with pin. 10.Secure assembly
11.Calibrate potentiometers to correct positions. Tighten
C lock nuts to specification.
D Specification:
MX9801
7. Install link (C) and rotate until resting on pedal arm.

Place assembly on hard flat surface and press down center
until pedal stop (D) can be slid into place.

Forward and Reverse Pedals Explode
B D
E
M
A
C
D
D
J
H J
F
L M
I
K
J
N
H
G
K
MIF
A - Forward Pedal Arm Machine Splitting (Front)

B - Reverse Pedal Arm
NOTE: It is not necessary to remove the flywheel
C - Washer, Non-Metallic
housing from the engine unless engine is being
D - Bushing removed. Split the machine between the tunnel and
E - Spring, Forward Torsion flywheel housing as outlined in the story below.
F - Spring, Reverse Torsion
G - Rotary Arm
H - Link 1. Remove any mid or front attachments and mid or front
I - O-Ring PTO shaft.
J - O-Ring 2. Park machine on a level surface. Engage park brake,
K - Rotary Arm Assembly shut off engine.
L - Axle 3. Disconnect battery negative terminal.
M - Potentiometer 4. Remove floor mat.
N - Pedal Stop Bracket

5. Remove seat and seat support. See “Seat and Seat
Support” on page 818 in Miscellaneous section.
on page 821 in Miscellaneous section.
7. Remove fenders. See “Rear Fenders” on page 819 in
c CAUTION: Avoid injury! To avoid injury from B

escaping hydraulic oil under pressure,
relieve the pressure in the system by
stopping the engine and operating all
hydraulic control valves.
NOTE: Transaxle contains approximately
26 L (6.8 gal) of oil. Have a suitable container ready to
catch drain oil.
9. Drain transaxle.
10.If machine is equipped with an SCV: MX9748
• Raise right hand rear of machine and support on • Remove cap screws (B) attaching tube support
suitable stands. bracket to frame. Remove tube support bracket and
tubes as an assembly.
• Remove right hand rear wheel and tire.
• Install right hand rear wheel and tire.
attaching wiring harness to switches and lights on rear half
C
E
MX9771
• Disconnect four work port tubes (A) from SCV.

D
MX9772
12.Remove cotter pin and washer (C). Disconnect brake

rods (D) from brake lever (E) on each side of machine.

M91982
13.Disconnect hydraulic pressure tube (F) at rear hydraulic

pump.
MX9749
16.Remove hydrostatic transmission oil filter.
G
MX9782
14.Remove cap screws (G) and hydraulic tube clamps on

left side of machine near brake lever (arrow).
MX9751
H 17.Disconnect oil line on right side of flywheel housing.
MX9743
15.Disconnect hydraulic supply tube (H) at SCV valve.
MX9750

18.Drive pin (I) out of MFWD drive shaft coupler and slide
coupler onto drive shaft until clear of stub shaft.
19.Disconnect two oil lines (J) from hydrostatic
transmission.
N
MX9762
22.Loosen hose clamp and disconnect suction tube (N)

from manifold.
23.Using suitable cap screws, attach JTO7335 splitting
MX9773 stands to machine sections. Adjust splitting stands so that
20.Remove five cap screws (K) and left hand operator’s wheels contact the floor, and are parallel to the machine
platform support. wheels.
24.Remove nine cap screws connecting tunnel to flywheel
housing. Note length and locations of cap screws when
M removing.
IMPORTANT: Avoid damage! Check for, and

disconnect any additional accessory wires or
hydraulic tubes connecting rear half to front half
before splitting machine.
25.Release park brake and place range shift in NEUTRAL.

26.Gently pry around edges of flanges to separate machine
halves.
L
27.Roll machine halves apart.
MX9781 Assemble Machine Sections:

21.Disconnect wiring harness connectors from forward and NOTE: Splines on all drive shafts and couplers must be
reverse pedal potentiometers (L). Remove cap screws (M) aligned before machine sections are bolted together.
and the right hand operator’s platform support.
1. Align splines on hydrostatic transmission drive shaft and
engine flywheel.
2. Move machine sections together and retain with nine
cap screws. Tighten cap screws to 126 – 154 N•m (95 –
115 lb-ft).
3. Remove cap screws retaining splitting stands to
machine sections. Remove splitting stands.

MX9750
MX9762
7. Connect two hydrostatic charge pressure tubes (J) to
4. Connect suction tube (L) to manifold. Tighten hose hydrostatic transmission. Tighten to 40 – 57 N•m (30 – 43
clamp. lb-ft). Check opposite ends of both tubes to make sure they
are tight.
MX9773
5. Install left hand operator’s platform support. Retain with

five cap screws (K).
M MX9749
8. If equipped, install MFWD drive shaft and couplers.

Slide couplers onto shafts, and retain with spring pin (I).
Install oil filter.
MX9781
6. Install right operator’s platform support and retain with

cap screws (M).

MX9743
9. Connect hydraulic supply tube to SCV or manifold block. MX9772

Tighten tube nut to 55 – 79 N•m (40 – 59 lb-ft).
12.Attach brake rod (D) to brake lever (E). Retain with
washer and new cotter pin (C). Repeat on right side of
machine.
13.Route wiring harness through cable clips. Locate and
connect all electrical connectors attaching wiring harness
to switches and lights on rear half of machine.
M91982
B
10. Connect hydraulic pressure tube (F) to rear gear pump.
Tighten tube nut to 55 – 79 N•m (40 – 59 lb-ft).
MX9748
14.If machine is equipped with an SCV, install SCV tube

support bracket and tubes as an assembly. Install cap
screws (B) to attach tube support bracket to frame.
MX9782
11.Install cap screws and tube clamps (G). 15.Raise right hand rear of machine and support on
suitable stands. Remove right hand rear wheel and tire.

c CAUTION: Avoid injury! Hydrostatic

transmission is heavy! Make sure
transmission supported by a chain hoist or
similar device before removing the last cap
screw.
A
A
MX9771
16.Connect four work port tubes (A) to SCV. Tighten tube

nuts to 40 – 57 N•m (30 – 43 lb-ft).
17.Connect battery negative (–) terminal.
18.Install fenders. See “Rear Fenders” on page 819 in
Miscellaneous section. MX9779
19.Install seat and seat platform. See “Seat and Seat 3. Attach chain hoist or similar device to hydrostatic unit.
Support” on page 818 in Miscellaneous section. Remove the four cap screws (A) from the front side of the
center section. Note the different lengths and location of
20.Install operator’s platform. See “Operators Platform” on
cap screws for reassembly.
page 821 in Miscellaneous section.
21.Install floor mat.
22.Refill hydraulic oil reservoir to proper level.
Bleed Procedure” on page 540.
A
Hydrostatic Transmission Removal and
Installation
Removal:
1. Park machine on level surface. Stop engine and release
hydraulic pressure by operating all controls.
c CAUTION: Avoid injury! Avoid injury from MX9788

escaping hydraulic oil under pressure.
4. While supporting transmission with chain hoist, remove
Relieve system pressure by stopping engine
the last cap screw (A) from the other side of the tunnel
and operating all hydraulic controls.
flange.
2. Separate flywheel housing and tunnel section. See 5. If necessary, gently pry the transmission off of the dowel
“Machine Splitting (Front)” on page 545. pins and remove from tunnel section.

MX9789
6. Shafts (B and C) may partially disengage or come out

with hydro unit.
Installation:
1. Make sure bearings on shafts (B and C) are fully seated
in their bores.
MX9831
1. Thoroughly clean flanges of transmission and tunnel

before applying sealant.
2. Apply a bead of TY16021 sealant to flanges of tunnel
(A) and install guide pins (B).
3. Slide the transmission on the guide pins and maneuver
transmission splines into shaft collars. Install cap screws
attaching transmission to tunnel, longer cap screws in the
holes with alignment bushings. Tighten to specification.
Torque Specifications:
Mounting Cap Screw . . . . (126 - 154 N•m (95 - 115 lb-ft)

POWER TRAIN EPOWRREVERSER TABLE OF CONTENTS
Power Train ePowrReverser
Table of Contents
Specifications ...............................................555
General Specifications ...............................555
Repair Specifications..................................555
Other Materials...........................................556
Clutch Housing ...........................................557
ePowrReverser Clutch ...............................558
4-Speed Transmission ...............................559
ePowrReverser Control Valve
Operation....................................................561
ePowrReverser Clutch Operation –
Forward and Reverse.................................564
Proportional Solenoid Valve
Operation....................................................566
4-Speed Transmission Operation...............567
ePowrReverser System Pressure Test ......568
ePowrReverser Clutch Pressure Test ........568
ePowrReverser Lube Pressure Test ..........569
Repair.............................................................570
ePowrReverser Traction Clutch
Removal .....................................................573
Disassembly ...............................................575
Assembly....................................................578
Input Shaft
Disassembly and Assembly .......................582
Installation ..................................................583
Clutch Cover Disassembly .........................584
Clutch Cover Assembly ..............................586
4-Speed Transmission Removal ................587
4-Speed Transmission Disassembly ..........590
4-Speed Transmission Assembly...............596
Shift Cap Disassembly and Assembly........602
MFWD Cylinder Disassembly/Assembly ....603
Valve Manifold Disassembly/Assembly......605
Connector Disassembly/Assembly.............606
4-Speed Transmission Installation .............607
Power Train ePowrReverser Table of Contents - 553

POWER TRAIN EPOWRREVERSER TABLE OF CONTENTS
Power Train ePowrReverser Table of Contents - 554

POWER TRAIN EPOWRREVERSER SPECIFICATIONS
Specifications
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 X 12 ePowrReverser Synchronized Shift
Number of Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Forward, 12 Reverse
ePowrReverser Clutches
Friction Plate (minimum thickness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27 mm (0.129 in.)
Separator Plate (minimum thickness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.92 mm (0.0756 in.)
Belleville Spring Washer Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.026 - 3.476 mm (0.119 - 0.137 in.)
Test Pressures
System Pressure (at low idle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 930 - 1200 kPa (135 - 175 psi)
System Pressure (at high idle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 965 - 1200 kPa (140 - 175 psi)
Lube Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 - 300 kPa (26 - 44 psi)
MFWD Pressure (at high idle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 965 - 1200 (140 - 175 psi)
Center Plate to Housing Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 N•m (63 lb-ft)
Clutch Cover to Tunnel Housing Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 44 N•m (22 - 32.8 lb-ft)
Coil Nut to Proportional Valve Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 - 7.4 N•m (45 - 65 lb-in.)
Cover Plate Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (21 lb-ft)
Hydraulic Hose to Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8 - 18.4 N•m (9.6 - 13.8 lb-ft)
Filter Bypass Plug to Clutch Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.0 - 17.3 N•m (8.8 - 12.7 lb-ft)
Fitting to Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 24 N•m (12 - 18 lb-ft)
Jam Nut to Clevis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 - 46.8 N•m (23 - 35 lb-ft)
Line Clamp Cap Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 - 12.5 N•m (6.1 - 9.2 lb-ft)
Main Pressure Regulator to Clutch Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.9 - 47.5 N•m (25 - 35 lb-ft)
Pressure Transducer to Clutch Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 - 26 N•m (15 - 19 lb-ft)
Proportional Valve to Clutch Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 20 N•m (12 - 15 lb-ft)
Retainer Plate to Bearing Plate Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 - 30 N•m (15 - 22.3 lb-ft)
Reverse Case to Front Cover Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 - 23 N•m (14 - 17 lb-ft)
SCV Port Tube Hydraulic Line Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 - 57 N•m (30 - 43 lb-ft)
Shift Cap to Tunnel Section Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 - 30 N•m (15 - 22 lb-ft)
Shoulder Bolt to Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3 - 27.5 N•m (13.5 - 20.3 lb-ft)
Suction Tube Manifold to Differential Housing Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . 30 - 44 N•m (22 - 32.8 lb-ft)
Transmission Assembly to Tunnel Section Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 - 105 N•m (51 - 77 lb-ft)
Tunnel Section to Differential Housing Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 - 105 N•m (51 - 77 lb-ft)
Valve Cartridge To Valve Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6 - 16.3 N•m (10 - 12 lb-ft)
Valve Manifold to Tunnel Section Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2 - 18.3 N•m (9 - 13.5 lb-ft)
Power Train ePowrReverser Specifications - 555

POWER TRAIN EPOWRREVERSER SPECIFICATIONS
IMPORTANT: Avoid damage! Press on the outer

race of a bearing if it is being pressed into an ID.
Press on the inner race of a bearing if it is being
pressed onto the OD of a shaft.
Note: It is common practice to press on the
numbered side of a bearing whenever possible.

Clutch Spring Compressor JDG1650 To compress spring on clutch packs.
Pressure Fitting Kit JDG1497 Used to check system pressure.
90 degree M14 Fitting with O-Ring 38H5025 with T7784 Used to check clutch lube pressure.
Splitting Stands and Brackets JTO 7335-1,2,3 Used to split machine.
Other Materials
Other Material
TY6305 John Deere Clean and Cure Primer Clean mating surfaces; helps speed
curing.
TY6304 John Deere Form in Place Gasket Between axle and differential housings,
transmission tunnel, etc.
TY9370 Thread Lock and Sealer On dowel pins, all internal cap screws, and
(#242 LOCTITE® (Medium Strength) certain external cap screws.
Power Train ePowrReverser Specifications - 556

POWER TRAIN EPOWRREVERSER COMPONENT LOCATION
Component Location
Clutch Housing
T U
S
V
R
Q
P
O
N
C
K
F
A I J
E H
C D
I
A M
L N
B A
A J K
H
D
A
W
D
Y X
AA
YZ81201A
Picture Note: ePowrReverser Clutch Cover Group I - Bore Sleeve(2)

A - Ball (5) 1 J - Seal Ring (4)
B - Seal K - Snap Ring (2)
C - Plug (2) L - Spring 4
D - Ball (7)2 M - Stake 5
E - Dowel Pin N - O-Ring (4)
F - Spring O - Bearing
G - Clutch Cover Assembly3 P - Shaft
H - Bushing (2) Q - Snap Ring
R - Gear
S - Snap Ring
1. This part is non-serviceable.
2. This part is non-serviceable. 4. This part is non-serviceable.
3. Includes items A, D, I, L & M 5. This part is non-serviceable.
Power Train ePowrReverser Component Location - 557

T - Bearing X - Pressure Transducer (2)
U - Gear Y - Valve (2)
V - Gear Z - Cap Screw (8)
W - Regulator AA- Oil Filter
ePowrReverser Clutch
O
N
M
L
K
J
I
H
E
P
D
C
B
A
Picture Note: Clutch Assembly

A - Bearing
B - Hub Gear
C - O-Ring
D - Retainer Ring
E - End Plate
F - Friction Plate (4)
G - Separator Plate (3)
H - Backup Plate
I - Belleville Spring
J - Snap Ring
K - Spring Retainer
L - Spring
M - O-Ring
N - Piston
O - O-Ring
P - Clutch Basket

4-Speed Transmission
YZ81196A
Picture Note: 4-Speed Pinion Shaft

A - Coupler
B - Shaft
C - Pinion Shaft
D - Pin (2)
E - Coupler

J
I K
W L
H
M N
O
J
G
V
F R
I
E X Z
Y S
D P
B
C P
B G
A Q
A T
AB AA
AC U
AG P
AD
AE
AF
AH
AD
AC
AI
Z
AJ I
YZ81197A R - Ball (2)
Picture Note: 4-Speed Transmission S - Spring (2)
A - Snap Ring (2) T - Insert (4)
B - Bearing (2) U - Fork (2)
C - Gear V - Dowel Pin (2)
D - Spacer W - Bearing
E - Gear X - Shaft2
F - Gear Y - Snap Ring
G - Plug (2) Z - Washer (2)
H - Shaft1 AA- Gear
I - Bearing (3) AB- Bearing
J - Cap Screw (2) AC- Snap Ring (2)
K - Retainer (Support) AD- Synchronizer (2)
L - Plate AE- Gear
M - Pin AF- Shaft
N - Cap Screw (2) AG- Ball (2)
O - Gate (2) AH- Gear
P - Pin (4) AI - Gear
Q - Shift Rail (2) AJ- Snap Ring
1. Includes item G. 2. Includes item G.

POWER TRAIN EPOWRREVERSER THEORY OF OPERATION
Theory of Operation
ePowrReverser Control Valve Operation
YZ4243
The ePowrReverser hydraulic system receives its supply The oil that is regulated to 160-psi supplies the Main PTO,
from the power steering return line. This oil then runs mid PTO, MFWD and traction clutches. Two proportional
through a filter. When the filter begins to clog up, the valves, one for forward and one for reverse, control the
pressure drop across the filter increases. The filter bypass traction clutches. When the direction is selected, the
monitors this pressure drop. If the pressure drop is equal or corresponding proportional valve opens and allows the oil
greater than 38 psi, the filter bypass opens and directs the to go to the clutch and activate it. The pressure transducer
flow to lube circuit by passing the control valves. checks for the correct pressure.
The filtered oil then is regulated to a nominal pressure of
160-psi for the traction clutches and hydraulic system. The
flow that passes through the pressure regulator lubricates
the clutches. The lube circuit also has a relief valve. If the
lube pressure rises above 44 psi, the valve opens and
allows the pressure to be relieved.
Power Train ePowrReverser Theory of Operation - 561

YZ4246
The component hydraulic system receives its regulated

supply oil from the clutch cover which goes into the
solenoid valve manifold. When the mid-PTO or MFWD is
turned on, the valve cartridge opens and the supply oil
flows to the component cylinder. The oil then activates the
cylinder. When the main PTO is turned on, the valve
cartridge opens. The supply oil must flow through an orifice
before going through the valve cartridge and onto the
clutch. The orifice modulates how fast the PTO clutch is
engaged.

Valve Cartridge
Main PTO Line
Mid PTO
MFWD Line
Input Pressure
Sump
Coil
YZ4285
Function:
To supply necessary hydraulic oil to the Main PTO clutch,
MFWD cylinder, and mid-PTO cylinder for actuation of
these functions.
The hydraulic oil comes to the valve regulated to 160 psi.
This pressure is supplied to all of the valve cartridges by
the manifold. When the operator engages one of the
systems (Main PTO, MFWD, mid-PTO), the coil for that
valve cartridge is energized. This pulls the valve cartridge
open, allowing the regulated oil pressure to flow through
the valve and to the system. The Main PTO valve has an
orifice in the manifold for modulation of the PTO clutch
when turned on. The valves are normally in the off position
and are set to dump hydraulic oil to sump, from the
systems.

ePowrReverser Clutch Operation – Forward and Reverse
Proportional Valve
Pressure Passage
Lube Passage
Clutch Piston
Clutch Hub
Clutch Basket
YZ4242
Forward: Power is transferred from the input shaft, splined to the

engine damper, to the clutch hub, by way of a constant gear
The clutches are wet type, and are lubricated and cooled
mesh. When the clutch is engaged, the friction plates are
by a stream of pressurized oil from oil passages drilled
locked to the separator plates and power is transferred from
inside the clutch shaft.
the clutch hub to the clutch basket. The clutch basket is
When the lever on the steering column is placed in the splined to the forward shaft on the four speed transmission
forward position and the clutch pedal is released, the and transmits power to it.
controller sends a signal to the forward proportional valve.
The valve sends the regulated hydraulic pressure to the
clutch through the clutch shaft. This hydraulic pressure
pushes the piston towards the clutch pack and applies
pressure to the pack, engaging the clutch. The friction
plates are splined to the clutch hub and the separator
plates are splined to the clutch basket. Whenever there is
no hydraulic pressure applied to the clutch, the clutch is
held in a disengaged position by a return spring.

57 Tooth Gear
Clutch
Pack
Clutch Shaft Clutch Basket

Clutch Piston
Input Gear & Shaft
Pressure Passage
Lube Passage
Clutch Hub
YZ4286
Reverse: mesh. When the clutch is engaged, the friction plates are
locked to the separator plates and power is transferred from
The clutches are wet type, and are lubricated and cooled
the clutch hub to the clutch basket. The clutch basket is
by a stream of pressurized oil from oil passages drilled
splined to the reverse shaft on the four speed transmission.
inside the clutch shaft.
Both forward and reverse shafts have a 57 tooth gear
When the lever on the steering column is placed in the splined to the shafts and these gears are in a constant
reverse position and the clutch pedal is released, the mesh. The power is transferred from the reverse shaft to
controller sends a signal to the reverse proportional valve. the forward shaft through the 57 tooth gears. The forward
The valve sends the regulated hydraulic pressure to the shaft then transfers the power to the four speed
clutch through the clutch shaft. This hydraulic pressure transmission.
pushes the piston towards the clutch pack and applies
pressure to the pack, engaging the clutch. The friction
plates are splined to the clutch hub and the separator
plates are splined to the clutch basket. Whenever there is
no hydraulic pressure applied to the clutch, the clutch is
held in a disengaged position by a return spring.
Power is transferred from the input shaft, splined to the
engine damper, to the clutch hub, by way of a constant gear

Proportional Solenoid Valve Operation
A B
C E F G I
D
H
N M
L K J
O SYSTEM PRESSURE OIL

P PRESSURE FREE OIL
Q PROPORTIONAL SOLENOID VALVE

YZ4307
Picture Note: Proportional Solenoid Valve from going to the clutch port (H). The inlet supply (I) must
pass through a filter screen (L) before reaching the orifice
A - Solenoid Coil
(M). The filter screen is used to trap large particles,
B - Armature preventing them from contaminating the orifice. The orifice
C - Push Pin is used to meter the inlet flow into the pilot cavity (N). The
D - Ball passage from the inlet supply port is always open to the
E - Seat pilot cavity, regardless of the spool position, to maintain a
F - Sump Port pressure source to the pilot cavity.
G - Spool Pilot cavity operation enables the valve to work at a current
H - Clutch Port level that the control unit is capable of controlling. The
I - Inlet Supply armature (B), push pin (C), and ball (D) configuration
controls the pilot cavity pressure which in turn provides the
J - Spring
force required to move the main spool.
K - Feedback Passage
With the solenoid valve de-energized, flow is free to travel
L - Screen
from the clutch port (H) to the sump port (F). The orifice (M)
M - Orifice
is used to meter the flow into the pilot cavity (N). Flow
N - Pilot Cavity coming into the pilot cavity then passes through the seat
O - System Pressure Oil (E) and past the ball (D), which is in the open position when
P - Pressure Free Oil the solenoid coil (A) is de-energized. This flow then travels
Q - Proportional Solenoid Valve—De-Energized out through slots on the outside threads of the valve to
connect to the sump port (F).
The proportional solenoid valve (Q) is a pilot operated,
pressure reducing cartridge valve. Its function is to provide Because the ball has no restriction to the flow of fluid
a regulated pressure to the clutch port that can be exiting the pilot cavity, no pressure is built up in the pilot
controlled by the control unit to a pressure less than the cavity to act against the spool end. A bias spring (J) is
supply pressure. Variations in inlet pressure will not affect located on the opposite end of the spool to maintain spool
the regulated pressure setting as long as the inlet pressure position and prevents any slight pressure build up from
remains higher than the desired regulated pressure. actuating the clutch. The bias spring requires a nominal
pressure of 83 KPa (.008273 bar) (12 psi) to start spool
In operation, supply pressure enters the inlet supply port (I) movement.
where it is blocked by a spool (G) which prevents the flow

To provide proportional control, the solenoid coil (A) is the pressure in the clutch to rise.
energized by the use of a pulse-width-modulated (PWM)
The clutch port pressure is fed to the spring end of the
signal by a varying duty cycle of 0% to 100%. The
main spool via the feedback passage (K), causing the main
increased duty cycle acts to increase the effective current
spool to close as the clutch pressure and spring force
in the solenoid coil windings (A) causing an increase in the becomes equal to the pilot cavity pressure. The output
magnetic force. As the duty cycle increases the magnetic pressure from the valve is zero at zero current and
force on the armature (B) increases, causing the push pin increases to within 103 kPa (1 bar) (15 psi) of the inlet
(C) to push against the ball (D) to restrict flow exiting the pressure as the current to the coil is increased. At
pilot cavity (N). This restriction causes a rise in pressure in approximately 100% duty cycle, the ball (D) rests against
the pilot cavity (N) and applies a force on the end of the the seat (E); the flow past the seat is essentially stopped;
main spool (G) causing it to move and compress the spring and the pressure in the pilot cavity (N) is the same as the
(J). As the spool (G) moves, it closes the passage from the supply pressure at the inlet supply port (I) minus the bias
clutch port (H) to the sump port (F) and begins to open pressure from the spring.
slightly the supply pressure port (I). The flow of oil causes
4-Speed Transmission Operation
3rd Gear 4th Gear 2nd Gear 1st Gear
C
C
B
Forward and Reverse

Clutch Shafts To Range
Transmission
YZ4245
Function: shaft. The four gears on the driven shaft turn independently
from the driven shaft. Two synchromesh collars (C) are
To transfer power from the directional clutches to the range
splined to the driven shaft (B) and can be shifted
transmission at various speeds controlled by the operator.
individually forward or backward to engage the one of the
Theory of Operation: gears to the driven shaft.
When the ePowrReverser transmission is engaged in either The driven shaft transfers power to the range transmission.
forward or reverse, there is rotation of the input shaft (A)
going into the transmission. There are four gears on the
shaft.
There are four corresponding gears on the driven shaft (B)
that are constantly meshed to the four gears on the input

POWER TRAIN EPOWRREVERSER TESTS AND ADJUSTMENTS
Tests and Adjustments
A
ePowrReverser System Pressure Test
Reason:
B
To ensure that adequate oil pressure is being supplied to
the proportional valves and manifold block.
Tools Required:
• JTO3240 - 7/16-20 M 37° X 7/16-20 M 37° Elbow
• 7/16-20 M 37° X M12-1.5 ORB Adaptor
• JTO3344 - 2000 kPa (300 psi) Gauge YZ4467A
• JTO3017 - Hose with Quick Coupler 7. Install test equipment in test port (A).
Procedures: 8. Start engine and run at high idle.
1. Park machine on a level surface. 9. Start engine and run at high idle, record pressure.
2. Turn key switch to OFF position. If specifications cannot be obtained, the manifold or
hydraulic line may be restricted; or a proportional valve may
3. Shift range to neutral and set brakes.
be defective.
c CAUTION: Avoid injury! Make sure to relieve Procedure with Diverter Kit Installed
1. Disconnect fitting from bottom of block (B).
system pressure before loosening any
system lines or hoses. 2. Install T-fitting and connect pressure gauge.
4. Cycle all controls to relieve any pressure that may be in 3. Start engine and run at high idle, record pressure.
the hydraulic system.
Specifications:
Pressure at low engine rpm . 931 - 1206 kPa (135 - 175
psi)
Pressure at high engine rpm 9651 - 1206 kPa (145 - 175
psi)
ePowrReverser Clutch Pressure Test

Tool Kit Required:
System Pressure Kit JDG1497:
• Quick Connect
• Tee Fitting Assembly
• Gauge
• Hose
Procedures:
1. Park machine on a level surface.
MX9886
5. Assemble test gauge as shown.
6. Locate the hydraulic manifold block on the right side of
the tunnel. 4. Underneath the machine, at the front of the tunnel,
locate the clutch cover.
5. Remove wiring harness from transducers.
Power Train ePowrReverser Tests and Adjustments - 568

POWER TRAIN EPOWRREVERSER TESTS AND ADJUSTMENTS
NOTE: The pressure transducers are clearly marked
“FOR” (forward) and “REV” (reverse) on the clutch
cover housing. Remove either forward or reverse
transducer, depending on the pressure being checked.
YZ4478
7. Install male quick connect into pressure transducer port

YZ4463
on clutch cover.
A - Forward or Reverse Pressure Transducer1
8. Install pressure transducer into tee fitting port and
6. Remove pressure transducer (A) from clutch port being attach gauge and hose to tee fitting port.
tested.
9. Attach tee fitting assembly to male quick connect.
10.Connect pressure transducer to wiring harness and tie-
up tee fitting assembly to avoid pulling on wiring harness
and interference with MFWD shaft.
11.Start engine and run at high idle.
12.Shift F/R selector to correct direction.
13.Check pressure reading on gauge.System Pressure At
High Idle (140-175 psi (965.27-1206.58 kPa)
If specifications cannot be obtained, the filter may be
restricted; the clutch O-rings or seal rings may be worn; or
the system regulator or proportional valve may be
defective.
ePowrReverser Lube Pressure Test
YZ4477 Tools Required:

• 90 degree M14 Fitting - 38H5025
• O-Ring - T7784
• Gauge2
• Hose
Procedures:
1. Park machine on a level surface.
1. Technician removes either Forward or Reverse Pressure Transducer
depending on which pressure is being tested. The transducers are clearly
marked “FOR” and “REV”. 2. Use gauge from ePowrReverser System Pressure Kit.
Power Train ePowrReverser Tests and Adjustments - 569

POWER TRAIN EPOWRREVERSER REPAIR
4. Underneath the machine, at the front of the tunnel, Repair
locate the clutch cover.
Machine Splitting (Front)
NOTE: It is not necessary to remove the flywheel
housing from the engine unless engine is being
removed. Split the machine between the tunnel and
flywheel housing as outlined in the story below.

PTO shaft.
2. Park machine on a level surface. Engage park brake,
shut off engine.
3. Disconnect battery negative terminal.
4. Remove floor mat.
YZ4464 5. Remove fenders.
5. Remove oil filter (A) from clutch cover. 6. Remove seat and seat support. See “Seat and Seat
6. Remove the plug (B) from the side of the clutch cover.
Install O-ring to 90 degree M14 fitting and fitting to clutch 7. Remove seat closeout panel.
cover. 8. Remove operator’s platform.
7. Attach hose and gauge onto quick connect.
8. Reinstall oil filter.
9. Start engine and run at high idle.
c CAUTION: Avoid injury! To avoid injury from
escaping hydraulic oil under pressure,
10.Check pressure reading on gauge and record. relieve the pressure in the system by
stopping the engine and operating all
11.Shift F/R selector to forward. hydraulic control valves.
12.Check pressure reading on gauge and record.
13.Shift F/R selector to reverse.
NOTE: Transaxle contains approximately
14.Check lube pressure reading on gauge and record. 26 L (6.3gal) of oil. Have a suitable container ready to
If specification cannot be obtained, the lube relief spring catch drain oil.
may be broke; the lube relief seat may be damaged or have 10.Drain transaxle.
debris on it; or the lube relief stake may be broke.
11.If machine is equipped with an SCV:
Specification: • Raise right hand rear of machine and support on
Lube Pressure. . . . . . . . . . . . 180 - 300 kPa (26 - 44 psi) suitable stands.
• Remove right hand rear wheel and tire.
Power Train ePowrReverser Repair - 570

N
A
MX11583
MX11579
12.Remove five cap screws (K) and left hand operator’s
• Disconnect four work port tubes (A) from SCV. platform support.
C attaching wiring harness to switches and lights on rear half
MX11595 E
• Remove wire clamp cap screw (B).

• Disconnect cable from foot throttle and bracket.
• Remove cap screws (C) attaching tube support D
bracket to frame. Remove right operators platform
support and tubes as an assembly.
MX9772
14.Remove cotter pin and washer (C) from brake rod.

Disconnect brake rod (D) from brake lever (E) on each side
of machine.

J
G
F
MX11580
15.Remove cotter pin and washer (F) from front of brake

rod. Disconnect brake rods from front brake lever (G) on
MX11582
each side of machine and remove brake rods.
18.Disconnect hydraulic supply tube (J) at SCV valve and
remove tube from machine.
L
M
M91982
N
16.Disconnect hydraulic pressure tube (H) at rear hydraulic
pump. O
MX11581
I
19.Remove oil filter (arrow). Disconnect oil lines (K and L).
Disconnect wire connections on forward and reverse
proportional valves (M) and pressure transducers (N).
20.Drive pin (O) out of MFWD drive shaft coupler and slide
coupler onto drive shaft until clear of stub shaft.
MX11580
17.Remove cap screws (I) and hydraulic tube clamps on

left side of machine. Note location of spacer between
bracket and machine.

MX9762
MX11607
21.Disconnect oil line at manifold (P). Remove two cap
screws for line clamps (Q). 24.Remove two long cap screws (S) from inside of flywheel
housing.
Loosen hose clamps (R) and disconnect suction tube from
manifold.
IMPORTANT: Avoid damage! Check for, and
22.Using suitable cap screws, attach JTO7335 splitting disconnect any additional accessory wires or
stands to machine sections. Adjust splitting stands so that hydraulic tubes connecting rear half to front half
wheels contact the floor, and are parallel to the machine before splitting machine.
wheels.
25.Place range shift in NEUTRAL.
S 26.Gently pry around edges of flanges to separate machine
halves.
27.Roll machine halves apart.
ePowrReverser Traction Clutch Removal

Procedure:
NOTE: Oil filter on clutch cover must be removed
before machine is split.
MX11606
23.Remove six cap screws (S) connecting outside of tunnel

to flywheel housing. Note length and locations of cap
screws when removing.

YZ4272
YZ4434 4. Remove seal rings from Forward and Reverse clutch

shafts.
1. Perform machine split between flywheel housing and
tunnel housing. See “Machine Splitting (Front)” on 5. Remove snap ring from Forward and Reverse clutch
page 570. shafts.
YZ4273
YZ4271 6. Remove Forward and Reverse clutch assemblies.
2. Remove eight cap screws securing clutch cover to

tunnel housing.
3. Remove clutch cover.
IMPORTANT: Avoid damage! Squeeze ring to

find split and separate far enough to remove seal
rings from shaft.

ePowrReverser Traction Clutch Disassembly
• Calipers
• Bearing Drivers
• JDG1650 Spring Compressor
Procedure:
YZ4274
7. Mark tunnel housing and helical gears “F” and “R” to

distinguish placement for assembly purposes.
YZ4277
1. Remove clutch hub from clutch assembly.
c CAUTION: Avoid injury! Use extreme care

YZ4275
when removing retainer ring. Wear
appropriate safety equipment.
8. Slide both gears out far enough so bearing on input
shaft clears the tunnel housing.
9. Remove input shaft assembly.
YZ4276
10.Remove Forward and Reverse helical gears. YZ4278
2. Remove retainer ring from clutch assembly.

5. Remove snap ring from clutch basket.
6. Release spring and remove spring compressor.
YZ4279
3. Turn clutch assembly over and remove clutch basket

from clutch pack.
c CAUTION: Avoid injury! Spring under

pressure. Use extreme care when removing
snap ring and releasing spring.
YZ4281
7. Remove spring retainer and spring.
YZ4282
8. Reinstall clutch basket on clutch shaft.
YZ4280
4. Place spring compressor on spring retainer and press

down, using press.

YZ4288
12.Remove inner and outer O-ring from piston.

13.Inspect piston for wear or damage and replace, if
YZ4283 necessary.
9. Release piston by applying shop air pressure to shaft.
NOTE: Lubricate O-ring.
YZ4289
YZ4287 14.Inspect and replace O-ring on hub, if necessary.
10.Remove piston.
IMPORTANT: Avoid damage! If replacement of
11.Inspect clutch basket for damage and replace, if
bearing is necessary, press bearing out with
necessary.
appropriate bearing driver. When installing new
bearing, press only on numbered side of
IMPORTANT: Avoid damage! If inner O-ring on bearing. Drive bearing in until it is slightly below
piston is cut or damaged, inspect the basket flush of hub on both sides.
shaft for burrs or damage.
15.Inspect needle bearing for wear or damage and replace,
if necessary.

YZ4291 YZ4293
Picture Note: Separator Plates 19.Inspect backup plate (piston plate) and end plate for
wear or damage. Replace, if necessary.
ePowrReverser Traction Clutch Assembly

NOTE: Apply J20C or J20D to all O-rings, seals and
seal rings before installation.
YZ4290
Picture Note: Measure Clutch Plate Thickness

16.Inspect and measure each separator plate and replace
if plate is burned, worn or out of spec. Separator Plate
YZ4288
(Minimum Thickness) 1.92 mm (0.076 in.).
1. Lubricate and install inner and outer O-ring to piston.
17.Inspect and measure each wavy friction plate and
replace if damaged or out of spec. Friction Plate (Minimum 2. Lubricate inside of piston, basket shaft and clutch
Thickness) 3.27 mm (0.129 in.). basket to avoid damage to piston O-rings.
IMPORTANT: Avoid damage! Be careful not to

damage inner O-ring on piston. Keep piston
parallel with basket when pushing piston onto
shaft.
YZ4292
18.Inspect and measure belleville spring. Replace if

damaged or out of spec. Belleville Spring Height 3.026 -
3.476 mm (0.119 - 0.137 in.).

c CAUTION: Avoid injury! Make sure snap

ring is fully seated before removing spring
compressor.
YZ4294
3. Hand twist piston down on basket shaft until piston

bottoms out.

pressure. Use extreme care during
installation.
YZ4280
Picture Note: Compress Spring To Install Snap

Ring
5. Install snap ring.
IMPORTANT: Avoid damage! Make sure O-ring

on hub is lubricated.
YZ4281
4. Install spring and spring retainer in clutch basket. Install

spring retainer with oil grooves up. Using spring
compressor, press spring and retainer far enough to install
snap ring.

YZ4296
6. Install end plate on hub with flat side up.
YZ4298
8. Install separator plate.

NOTE: There are 4 friction plates and 3 separator
plates. The friction plate is the first and last installed.
9. Repeat steps 7 and 8 simultaneously until all plates are
installed.
YZ4297
7. Install friction plate with chamfered edge of tooth down.
YZ4299
10.Install backup plate (piston plate) with flat side down.

YZ4244
11.Install belleville spring with cup against backup plate.

NOTE: Make sure all tabs are aligned.
YZ4301
Picture Note: Plate Below Groove/Hub Flush W/

Shaft
13.Flip assembly over.
14.Make sure hub face is flush with basket shaft.
c CAUTION: Avoid injury! Watch for pinch

points. Make sure retainer ring is all the
way in groove.
YZ4300
12.Place clutch basket over clutch pack.

NOTE: It may be necessary to shake clutch pack into
place until retainer plate is below retainer groove of
clutch basket.
YZ4302
15.Install retainer ring.

16.Repeat steps 1 through 15 to assemble other clutch.

Input Shaft Disassembly and Assembly
• Bearing Puller
• Bearing Driver
Disassembly:
A
M95064
5. Remove snap rings (A) and slide gear from shaft.
YZ4247 Assembly:
1. Inspect gear teeth for damage. Inspect splines and
bearing areas of shaft for wear or damage. Replace parts
as required.

YZ4303
1. Slide gear onto shaft.
M95061
2. Using a bearing puller and press, remove bearings.

3. Clean bearings in suitable solvent. Dry with compressed
air.
4. Inspect both bearings for discolored or burned ball and/
or races. Check balls and races for spalling or cracking.
Roll bearing by hand to check for rough turning or
YZ4304
excessive looseness or play between balls and races.
Replace bearings as required. 2. Install snap rings.

YZ4305
3. Using a suitable bearing driver, press bearings onto

shaft.
ePowrReverser Traction Clutch Installation

Procedure:
YZ4275
3. Install input shaft assembly.
NOTE: Gasket surfaces must be absolutely clean down
to bare metal for form-in-place gasket to work properly.
Scrape old material off with a sharp gasket scraper and
then use a chemical gasket remover to clean mounting
surfaces.
1. Remove any old gasket material from clutch cover and
transmission housing tunnel.
YZ4273
4. Install forward and reverse clutch packs, aligning gears

with input shaft gear.
YZ4276
2. Install forward and reverse gears. Raised side of gear

hubs go toward bearings.
NOTE: Pull Forward and Reverse gears out enough to
install input shaft bearing into tunnel. Turn input shaft
and make sure PTO shaft is properly installed.
YZ4306
5. Install snap ring to forward and reverse clutch packs.

Other Material
TY16021 John Deere Form- To apply between
In-Place Gasket axle and differential
housings,
transmission tunnel,
etc.
Clutch Cover Disassembly

Procedure:
YZ4272
6. Lubricate and install seal rings.

NOTE: Make sure both dowels are in tunnel housing.
7. Lubricate bore sleeves or end of shafts.
YZ4310
1. Remove and replace main pressure regulator valve if

system pressure is out of tolerance. System Pressure At
High Idle 965 - 1206 kPa (140 - 175 psi)
YZ4271
8. Apply form-in-place gasket to clutch cover and install

cover to tunnel section.
YZ4311
9. Install and tighten cap screws. Clutch Cover to Tunnel
Housing Cap Screws 30 - 44 N•m (2 2 - 32.8 lb-ft) 2. Remove filter bypass plug, spring and dowel.

YZ4313
6. Remove pressure transducers. Inspect O-rings for

damage and replace if necessary.
7. Inspect O-rings on fitting and replace if necessary.
YZ4312
3. Remove coil nut and coil from proportional valve.
IMPORTANT: Avoid damage! DO NOT attempt to C

repair the proportional valve. It must be serviced
as an assembly only. A
A
B
YZ4313
YZ4308
4. Remove proportional valve. Inspect and replace valve
8. Inspect bushings (A) for wear or damage. If damaged,
assembly if necessary.
replace clutch cover assembly.
5. Inspect O-rings and replace if necessary.
9. Check spring (B) in lube relief valve. If spring is broken,
replace clutch cover assembly.
10.Remove and replace oil seal (C), if necessary.
YZ4309

Clutch Cover Assembly
Procedure:
YZ4311 YZ4309
1. Lubricate dowel. Install dowel, spring and filter bypass 4. Install and tighten pressure transducers. Pressure
plug into clutch cover. Transducer to Clutch Cover 20-26 N•m (15-19 lb-ft)
2. Tighten filter bypass plug. Filter Bypass Plug to Clutch
Cover 12.0-17.3 N•m (8.8-12.7 lb-ft)
YZ4310
3. Install and tighten main regulator to clutch cover. Main

Pressure Regulator to Clutch Cover 33.9-47.5 N•m (25-35
lb-ft)
YZ4315
5. Install and tighten proportional valves to clutch cover.

Proportional Valve to Clutch Cover 16-20 N•m (12-15 lb-ft)

YZ4312 YZ4317
6. Install coil with connector on both proportional valves, 3. Disconnect and remove all hydraulic lines from valve
as shown. manifold which is located on right-rear side of tunnel.
4. Remove four cap screws from valve manifold and
IMPORTANT: Avoid damage! DO NOT substitute
remove manifold.
the proportional valve nut or coil nut. Using a
different nut will effect valve operation.
7. Install and tighten both nuts on each proportional valve.
Coil Nut to Proportional Valve Cartridge 5.1-7.4 N•m (45-65
lb-in.).
4-Speed Transmission Removal

Procedure:
NOTE: Remove hydraulic line, cap screws and clamps
holding valve manifold pressure line to clutch cover.
1. Split machine between flywheel housing and tunnel.
See “Machine Splitting (Front)” on page 570.
2. Remove forward and reverse traction clutch assemblies
and input shaft assembly. See “ePowrReverser Traction YZ4316
Clutch Removal” on page 573.
5. Remove and replace O-ring from tunnel section.
YZ4318
6. Remove cap screws and clamps holding MFWD

hydraulic line from tunnel section. Remove hydraulic hoses.

YZ4320
7. Remove cotter pin and clevis pin from clevis connecting

to MFWD lever.
YZ81195
Picture Note: Cap Screw Location In Tunnel

Housing
A - Small Cap Screws on Right Side
B - Extra Long Cap Screw with Dowel
YZ4321
C - Long Cap Screws on Left Side
8. Disconnect and remove suction tube manifold, gasket D - Long Cap Screw with Dowel
and suction screen from differential housing. Discard
E - Small Cap Screws
gasket.
11.Remove two cap screws (A) from tunnel housing on
right-hand side as shown.
12.Remove long bolt (B) from bottom of tunnel housing as
shown.
NOTE: Note length and location of cap screws. Cap
screws must be installed at same locations.
13.Remove remaining six cap screws (C - E) from tunnel
housing.
14.Separate tunnel housing from differential housing, using
rubber mallet.
MX11677
9. On left-hand side of tunnel, drive out roll pin. Remove

four cap screws and shifter assembly.
10.Secure tunnel section with harness before removing cap
screws.

M94869
17.Remove shaft, gear, and shift collar as an assembly.
YZ4322
15.Remove drive shaft.
M94870
18.Remove spring pin and slide shift shaft out of tunnel.

19.Inspect bearing for wear or damage. Replace, if
necessary.
20.Inspect shoe for wear or damage. Replace, if necessary.
M94868
16.Rotate MFWD shift lever until shoe clears shift collar.
YZ4265
21.Remove two cap screws and 4-speed transmission

assembly.

4-Speed Transmission Disassembly
Procedure:
YZ4250
3. Remove interlock pin.

NOTE: Do not push shift rods too far into guide block.
Guide block contains two detent balls and springs
which may be lost.
A
YZ4248
1. Remove two spring pins and shift gate blocks (A).
D
C
B
YZ4251
4. Using a plastic or rubber mallet, drive both shift rods

toward gears and shafts. Tap on end of output shaft (B) to
loosen shafts and gears, and remove reverse shaft (C) and
pinion shaft (D) from bearing plate.
YZ4249
2. Remove two cap screws and cover plate.
YZ4252
5. Rotate output shaft away from shift forks and remove.

NOTE: Use care when removing shift rods from guide
block. Guide block contains two detent balls and
springs.
YZ4254
8. Remove two detent balls and springs from guide block.

Inspect parts for wear or damage. Replace parts as
needed.
YZ4253
6. Remove two shift rods and forks from guide block.
YZ4255
9. Inspect bearings on reverse shaft for wear or damage.

To replace, use a suitable bearing puller or press.
Pinion Shaft Disassembly:
M95164
7. Inspect shift fork inserts for wear or damage. Replace if

necessary.
M95166
1. Using a suitable puller or press, remove bearing from

end of pinion shaft.
2. Inspect bearing for wear or damage. Replace if
necessary.

B
A
C D
YZ4256
3. Using a suitable puller or press, remove bearing (A), 33

tooth gear (B), spacer, 38 tooth gear (C), and 26 tooth gear
(D) from pinon shaft.
M95171
Pinion Shaft Assembly: 3. Remove thrust washer.
Assembly is the reverse of disassembly.
• Lubricate parts liberally with hydraulic oil before
assembling.
• Install 38 tooth gear with larger flange facing toward
spacer.
M95172
4. Remove ball from hole in shaft.
M95169
1. Remove snap ring.
M95173
5. Remove 56 tooth gear.
M95170

end of shaft.

M95177
9. Remove spring from each side of shift collar.

M95174
6. Remove synchronizer ring.
M95178
10.Remove shift collar from hub.

M95175
7. Remove roller bearing.
M95179
11.Remove three inserts.
M95191
8. Removing snap ring and shift collar assembly.

M95183
15.Remove thrust washer.
M95180
12.Remove synchronizer ring.
M95184
16.Remove ball.
M95181
13.Remove 43 tooth gear.
M95185
M95182 17.Remove 36 tooth gear and synchronizer ring (A).
14.Flip output shaft over and remove bearing.

M95178
M95186
21.Remove shift collar from hub.
18.Remove snap ring.
M95179
22.Remove three inserts.

M95187
19.Remove shift collar.
M95188
M95177 23.Remove synchronizer ring. Check all synchronizer parts
20.Remove one spring from each side of shift collar. for wear or damage.

M95189
26.Remove 31 tooth gear.

27.Visually inspect all parts for wear, cracks or
discoloration.
MX1358
4-Speed Transmission Assembly
24.Check brass sychronizer ring for worn or missing teeth.
NOTE: Synchronizer assembly and brass synchronizer Pinion Shaft Assembly:
rings are not serviced individually. If any parts are NOTE: Apply J20C or J20D to all O-rings, seals and
needed, entire assembly must be replaced. seal rings before installation.
IMPORTANT: Avoid damage! Lubricate parts

liberally with hydraulic oil before assembling.
NOTE: Install 38 tooth gear with larger flange facing

toward spacer.
B
A
MX1415
25.To measure synchronizer wear, lay brass ring on gear C D

and measure gap between gear and brass ring with a feeler
gauge. If gap is less than 0.25 mm (0.010 in), replace YZ4256
synchronizer assembly. 1. Using a press, install 26 tooth gear (D), 38 tooth gear
(C), spacer, 33 tooth gear (B) and bearing (A) to pinion
shaft.

M95166
M95179
2. Using a press, install bearing onto end of pinion shaft.
Output Shaft assembly:
IMPORTANT: Avoid damage! Lubricate all parts

liberally with clean hydraulic oil during
assembly.
M95178
3. Install three inserts onto shift collar hub and hub

assembly into shift collar.
IMPORTANT: Avoid damage! The tang of each

spring must be assembled in the same insert.
M95189
1. Install 31 tooth gear.
M95177
4. Install two springs to retain detent inserts in shift collar.

NOTE: When installing shift collar onto shaft, make
M95188
sure inserts on shift collar align properly with slots in
2. Install synchronizer ring with notches facing up. synchromesh ring and four oil grooves on shift collar
face out.

M95184
8. Install ball into hole in shaft.

M95187
5. Install shift collar assembly onto output shaft.
M95183
9. Retain ball with thrust washer.
M95186
6. Retain shift collar to shaft with snap ring.
M95182
A 10.Dip bearing in hydraulic oil. Using a press, install

bearing onto end of shaft.
M95185
7. Install synchronizer ring (A) and 36 tooth gear.

M95178
M95181 13.Install three inserts onto shift collar hub. Install hub and
11.Turn shaft assembly over and install 43 tooth gear. inserts into shift collar.
IMPORTANT: Avoid damage! The tang of each

spring must be assembled in the same insert.
M95180
12.Install synchronizer ring onto gear with slots facing up. M96177
14.Install two springs to retain detent inserts in shift collar.

NOTE: When installing shift collar onto shaft, be sure
inserts on shift collar align properly with slots in
synchromesh ring and four oil grooves on shift collar
face out.
M95179

M95173
18.Install 56 tooth gear.
M95191
15.Install shift collar assembly onto shaft and retain with

snap ring.
M95172
19.Install ball into hole in shaft.
M95175
16.Install roller bearing.
M95171
20.Retain ball with thrust washer.
M95174
17.Install shift collar.

1. Install one spring and detent ball into guide block. Using
a pin punch, compress the spring and hold ball while
installing shift rod and fork assembly. Be sure shift rod and
fork assembly is installed into correct hole.
M95170
21.Dip bearing in hydraulic oil. Using a press, install

bearing onto end of shaft.
YZ4258
YZ4259
M95169 2. Repeat step 1 to install second spring, detent ball, and
22.Install snap ring. shift rod/fork assembly.
23.Check gears on output shaft. All four gears should rotate

on shaft.
Gear and Shifter Assembly:
YZ4260
3. Install output shaft/gears assembly onto shift forks.
YZ4257

YZ4261
4. Install pinion shaft onto output shaft. Install reverse shaft

(A), pinion shaft (B), and output shaft (C) into bearing plate
at the same time, using a plastic or rubber mallet.
YZ4248
8. Install two gate blocks onto rods. Retain with spring

pins.
9. Test transmission operation by moving the shift forks
and rotating the output and pinion shafts to ensure that all
four speeds of the transmission operate smoothly and
correctly.
Shift Cap Disassembly and Assembly

Disassembly:
YZ4262
5. Move shift rods/forks to center (Neutral) position.

Lubricate and install interlock pin.
YZ4325
1. Remove plug from shift cap. Inspect O-ring for wear or

damage and replace if necessary.
YZ4249
6. Install retainer plate.

7. Install and tighten cap screws. Retainer Plate to Bearing
Plate Cap Screws 20-38 N•m (15-22.3 lb-ft)

4. Inspect clevis and shift shaft for wear or damage. Drive
pin out of clevis, if necessary.
c CAUTION: Avoid injury! Do not damage

bushing located behind seal, during seal
removal.
A
IMPORTANT: Avoid damage! Lubricate seal

before installing.
YZ4324
Picture Note: Align Pin Hole (A) W/ Plug Hole
YZ4328
B
5. Remove and replace oil seal from shift cap.
YZ4329 Assembly:
Picture Note: Drive Pin (B) Out of Lever & Shaft Assembly is reverse of disassembly.
2. Orient pin hole (A) of shift shaft and lever through plug • Drive pin flush to surface of lever.
hole. Remove pin (B).
MFWD Cylinder Disassembly/Assembly

Disassembly:
YZ4318
YZ4326
3. Pull out shift shaft and remove shift lever. 1. Disconnect and remove all hydraulic hoses.
YZ4327

2. Install cylinder.
3. Apply medium strength threadlock to shoulder bolt.
4. Install and tighten shoulder bolt (A). Shoulder Bolt to
Cylinder 18.3-27.5 N•m (13.5-20.3 lb-ft)
YZ4320
2. Remove cotter and clevis pin. B
YZ4331
5. Hold the MFWD lever all the way to rear of transaxle.

YZ4330 6. Adjust clevis until holes line up with lever.
3. Remove shoulder bolt. 7. Turn clevis out (away from cylinder) 1/2 turn.
NOTE: Replace cylinder if faulty. 8. Tighten jam nut (B) against clevis. Jam Nut To Clevis
31.2-46.8 N•m (23.2-34.8 lb-ft)
4. Remove cylinder assembly from housing.
5. Remove fittings and inspect O-rings for wear or
damage. Replace, if necessary.
Assembly:
NOTE: Apply J20C or J20D to all O-rings.
IMPORTANT: Avoid damage! DO NOT back-off

more than 1/2 thread or revolution when aligning
fitting to prevent thread distortion and impaired
sealing ability.
YZ4332
9. Install clevis pin and cotter pin.

YZ4330
1. Apply pipe thread sealant to fittings. Install and orient

fittings to cylinder. Fitting to Cylinder 16-24 N•m (12-18 lb-
ft)

YZ4318
10.Connect and tighten all hydraulic hoses. Hydraulic Hose

to Fitting 12.8-18.4 N•m (9.6-13.8 lb-ft)
Valve Manifold Disassembly/Assembly

YZ4336
Disassembly:
YZ4337
3. Remove valve cartridge from manifold. Inspect cartridge

and O-rings for damage. Replace if necessary.
YZ4334
1. Remove fittings and plugs. Inspect fittings, plugs, and O-

rings for wear or damage. Replace if necessary.
YZ4338
4. Remove orifice plug. Inspect O-ring and replace if

necessary.
YZ4335
2. Remove coil nut and coil from valve cartridge.

Disassembly:
YZ4340
YZ4339 1. Using appropriate tool, remove connector lock cover.

5. Remove orifice.
6. Repeat steps 2 and 3 to remove other cartridges.
Assembly is reverse of Disassembly.
IMPORTANT: Avoid damage! DO NOT substitute

the coil nut. Using a different nut will effect valve
operation.
Coil Nut to Proportional Valve Cartridge 5.4-8.1 N•m (4-
6 lb-ft)
Valve Cartridge To Manifold 13.6-16.3 N•m (10-12 lb-ft)
Connector Disassembly/Assembly
YZ4341
2. Simultaneously, press down on tab and remove

connector from connector housing.
3. Repeat for all connector pins.
YZ4267
On the 4-pin connector, Pin A and B goes to the main

PTO and Pin C and D goes to the MFWD. The 2-pin
connector goes to the Mid PTO.

Assembly: 4-Speed Transmission Installation
Procedure:
NOTE: Shift to neutral and spin output shaft to check
for free and easy rotation of gears.
YZ4343
1. Push new connector pin into connector housing until

locked in.
YZ4265
1. Align three bearings and two shift rods with holes in

tunnel. Install transmission into housing.
2. Install and tighten cap screws. Transmission Assembly
to Tunnel Section Cap Screws 70-115 N•m (51-77 lb-ft)
IMPORTANT: Avoid damage! Replace O-rings

and seals. Used O-rings and seals will leak.
YZ4342
2. Snap cover onto connector housing assembly.
M95199
3. Install a new MFWD drive shaft seal at front of tunnel.

M94876
4. Install a new MFWD shift shaft seal into tunnel.
YZ4266
7. Engage shoe (A) to shift collar (B) and rotate MFWD

shift lever to draw MFWD shaft into place.
M94870
5. Slide shift shaft into tunnel and through shift arm. Retain
shift arm to shaft with spring pin.
YZ4322
8. Install drive shaft (C).
c CAUTION: Avoid injury! Use proper lifting

equipment when installing tunnel housing
to differential housing. Weight of housing
M94869
exceeds 100 pounds.
6. Insert MFWD drive shaft assembly into tunnel.

IMPORTANT: Avoid damage! Cap Screws must
be installed as shown.

YZ4333
11.Apply form-in-place gasket to shifter assembly mounting

surface. Make sure shifter lever is positioned correctly in
YZ81195 shift gates.
Picture Note: Install Tunnel Housing
A - Small Cap Screws on Right Side
B - Extra Long Cap Screw with Dowel
C - Long Cap Screws on Left Side
D - Long Cap Screw with Dowel
E - Small Cap Screws1
9. Apply form-in-place gasket to tunnel housing and install
tunnel housing to differential housing.
10.Install and tighten cap screws to 70-105 N•m (51-77 lb-
ft).
MX11677
IMPORTANT: Avoid damage! Shift gates must be
in neutral position. 12.Install shifter assembly. Tighten cap screws to 20-30
N•m (15-22 lb-ft).
13.Install roll pin.
YZ4461
Picture Note: Slide Gasket On Suction Screen

1. Apply medium strength threadlock to cap screws.

14. Clean suction screen with solvent. Clean the machined
surface of the differential housing making sure all of the old
gasket material is removed.
NOTE: Gasket should fit against shoulder on end of
suction screen.
Make sure gasket is flat against the machined surface
of differential housing.
15.Slide gasket onto suction screen. Install suction screen
assembly into differential housing.
YZ4317
19.Install valve manifold block to tunnel section. Install and

tighten cap screws. ePowrReverser Valve Block to Tunnel
Section Cap Screws 12.2-18.3 N•m (9-13.5 lb-ft)
A 20.Connect and tighten hydraulic lines. Clamp lines to
YZ4263 housing. Hydraulic Line To Fittings 12.8-18.4 N•m (9.6-13.8
lb-ft) Line Clamp Cap Screws 8.3-12.5 N•m (6.1-9.2 lb-ft)
16.Install suction tube manifold to differential housing.
21.Install forward and reverse traction clutch assemblies
NOTE: If plug (A) is removed, apply teflon pipe sealant and input shaft assembly. See “ePowrReverser Traction
to plug. Install and tighten plug. Plug to Suction Tube Clutch Installation” on page 583.
Manifold (40.5-49.5 NŽm (31.5-38.5 lb-ft)
22.Assemble machine tunnel and differential housing
17.Install and tighten cap screws. Suction Tube Manifold to sections. See “Machine Splitting (Rear)” in the Final Drive
Differential Housing Cap Screws 30-44 N•m (22-32.8 lb-ft) Power Train section.
18.Install MFWD cylinder assembly. See “MFWD Cylinder 23.Assemble machine flywheel housing and tunnel
Assembly” in this section. sections. See “Machine Splitting (Front)” on page 570.
IMPORTANT: Avoid damage! Make sure new O- Other Material

ring has been installed in tunnel section.
housings,
etc.
housings,
etc.
YZ4316
Picture Note: O-Ring in Tunnel Section

POWER TRAIN - FINAL DRIVE TABLE OF CONTENTS
Range Transmission
Power Train - Final Drive
Table of Contents
Removal and Installation ........................... 650
Final Drive Removal .................................. 662
Specifications ...............................................613 Final Drive Installation ............................... 665
General Specifications ...............................613 Final Drive Disassembly,
Repair Specifications..................................613 Inspection and Assembly........................... 668
Torque Specifications.................................613 Differential.................................................. 669
Front Axle MFWD.......................................614 Differential Lock
Special or Essential Tools ..........................614 Removal and Installation ........................... 671
Other Materials...........................................614 PTO Component Location........................... 673
Component Location....................................616 PTO Assembly........................................... 673
Range Shift Transmission ..........................616 PTO Clutch and Brake............................... 674
Axle Shaft and Brake - Right ......................618 Rear PTO................................................... 675
Axle Shaft and Brake - Left ........................620 2-Speed PTO (European).......................... 676
Differential Lock..........................................622 Mid PTO..................................................... 677
MFWD Drive Shaft (SST) ...........................623 Mid PTO Drive Shaft.................................. 678
MFWD Drive Shaft PTO Theory of Operation ............................ 679
(ePowrReverser and eHydro).....................624 Power Transmission -
MFWD Axle Component Location ..............625 PTO Clutch and Brake............................... 679
MFWD Final Drive Power Transmission - Rear PTO............... 680
Component Location ..................................626 Power Transmission -
MFWD Differential 2-Speed PTO (European).......................... 681
Component Location ..................................627 Power Transmission - Mid PTO................. 682
Theory of Operation .....................................628 PTO Troubleshooting .................................. 683
Power Transmission - Troubleshooting Table ............................... 683
Range Transmission ..................................628 PTO Repair ................................................... 684
MFWD Drive Shaft .....................................630 Rear PTO Removal and Installation .......... 684
MFWD Front Axle.......................................631 Rear PTO Shafts and Gears
Diagnostics ...................................................632 Disassembly and Assembly....................... 687
Final Drive System Diagnosis ....................632 2-Speed PTO Shafts and Gears
Final Drive Diagnosis .................................632 Disassembly .............................................. 690
Tests and Adjustments ................................633 2-Speed PTO Shafts and Gears
Differential Backlash Adjustment................633 Assembly ................................................... 694
Main Shifter Adjustment .............................634 PTO Clutch and Brake
Repair.............................................................634 Removal and Installation ........................... 698
MFWD Output Shaft PTO Input Hub
Removal and Installation ............................634 Disassembly and Assembly....................... 702
MFWD Drive Shaft PTO Clutch and Brake
Removal and Installation ............................637 Disassembly and Assembly....................... 702
MFWD Removal .........................................637 Mid PTO Removal and Installation ............ 711
MFWD Final Drive Cover Mid PTO Disassembly and Assembly........ 712
Removal and Inspection.............................637 MFWD Drive Shaft
MFWD Spindle Shaft..................................638 (ePowrReverser and eHydro) .................... 717
MFWD Final Drive Housing........................640
MFWD Spindle Housing .............................641
MFWD Differential .....................................641
Pinion Depth Setup and Adjustment .........644
Machine Splitting (Rear).............................646
Power Train - Final Drive Table of Contents - 611

POWER TRAIN - FINAL DRIVE TABLE OF CONTENTS
Power Train - Final Drive Table of Contents - 612

POWER TRAIN - FINAL DRIVE SPECIFICATIONS
Specifications
Transaxle Oil:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere J20D
Capacity (SST and ePowrReverser Machines). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.0 L (6.3 gal)
Capacity (eHydro Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.0 L (6.8 gal)
PTO Speeds (At 2600 Engine rpm)

Rear PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540 rpm
Mid PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 rpm
MFWD Oil
Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 L (7.4 qt)
PTO Clutch/Brake Specifications:
Friction Disc (minimum thickness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27 - 3.43 mm (0.129 - 0.135 in.)
Separator Plate (minimum thickness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.92 mm (0.0756 in.)
Clutch Hydraulic Pressure at High Idle (ePRT and SST) . . . . . . . . . . . . . . . . . . . . . . . . 860 - 1035 kPa (125 - 150 psi)
Clutch Hydraulic Pressure at High Idle (eHydro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100 - 1310 kPa (160 - 190 psi)
Belleville Spring Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.026 - 3.476 mm (0.119 - 0.137 in.)
Pinion and Ring Gear Specifications:

Differential Ring Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.25 mm (0.004 - 0.010 in.)
Front Wheel Alignment:

Toe In Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 3 mm (0.0 - 0.12 in.)
Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13°
Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10°
Steering Angle:
Inward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54°
Outward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62°
PTO Cover Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Final Drive to Transmission Housing Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 N•m (225 lb-ft)
Ring Gear Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 N•m (50 lb-ft)
Pinion Shaft Lock Nut (Upper and Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 - 122 N•m (70 - 90 lb-ft)
Mid PTO Housing to Transmission Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 - 44 N•m (27 - 33 lb-ft)
PTO Bearing Retainer Plate Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 - 80 N•m (43 - 66 lb-ft)
Rear Cover to Differential Housing Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 - 60 N•m (30 - 44 lb-ft)
Power Train - Final Drive Specifications - 613

Differential Housing to Transmission Tunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 - 105 N•m (52 - 77 lb-ft)
Cover Plate to Rear Cover Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 12 N•m (72 - 106 lb-in.)
Cylinder to Mid PTO Gear Box Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 - 47 N•m (25 - 35 lb-ft)
Front Axle MFWD

(Loctite® Number If Required)
Front Wheel Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 -147 N•m (87 - 108 lb-ft)
Final Drive Cover Cap Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 38 N•m (22 - 28 lb-ft)
Differential Carrier to MFWD Cap Screws (262). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 - 68 N•m (45 - 50 lb-ft)
Tie Rod Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 - 129 N•m (85 - 95 lb-ft)
Tie Rod Socket (262) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 - 129 N•m (85 - 95 lb-ft)
Differential Ring Gear Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 N•m (50 lb-ft)
Differential Bearing Retainer Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 - 68 N•m (40 - 50 lb-ft)
Pinion Retaining Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 - 176 N•m (120 - 130 lb-ft)
MFWD Housing to Spindle Housing Cap Screw (262) . . . . . . . . . . . . . . . . . . . . . . . . . . 286 - 316 N•m (210 - 230 lb-ft)

Splitting Stands and Brackets JTO7335 -1,2,3 Used to support the machine components when splitting the
machine (front or rear).
Range Transmission Detent JDG 1260 Used to compress internal spring and ball to insert range shift.
Ball Installer
Spring Compressor JDG1650 Used to compress clutch spring during clutch disassembly and
assembly.
Pinion Depth and Backlash JDG 1395A Used to calculate MFWD pinion depth if carrier housing is
Setup replaced
Other Materials
Other Material
TY6305 John Deere Clean and Cure Primer Cleans parts and speeds cure of sealant.
TY15130 / TY15934 John Deere Sealant Seals transaxle and final drive case halves.
TY6333 Moly High Temperature EP Grease
TY22034 John Deere SuperLube®
TY9370 / TY9477 Thread Lock and Sealer
(#242 LOCTITE®) (Medium Strength)

Other Material
TY6304 Loctite Sealant Seals the final drive housings to the transmission
(#515 LOCTITE®) housing, and front axle final drive cover to the final
drive housing.
#262 LOCTITE® Loctite Thread Lock and Sealer Apply to front axle spindle housing cap screws and
(High Strength) to the MFWD housing cap screws.
T43514 Loctite Thread Lock and Sealer Apply to threads of pinion shaft retaining pin and to
(#277 LOCTITE®) (High Strength) threads of ring gear retaining cap screws.
TY15941 Loctite Retaining Compound Seals front axle final drive housing cap.
(#620 LOCTITE®) (High Strength)
TY16021 John Deere High Flex Form-In-Place Sealing flange assemblies
Gasket
TY15934 John Deere General Purpose Gasket Sealing gaskets and hoses
Dressing

POWER TRAIN - FINAL DRIVE COMPONENT LOCATION
Component Location
Range Shift Transmission
A
C F
B
D E G
H
I
R J
S
Q V N C
K
T P I G
U J
Fix O M
H
W
L
W X
AA
AB
AC
AD
AE AF
AD
AG
AH
AI
AJ
AK
AM AL
AN
AT
AK
AU
AO AV
AP
AW
AQ
AX
AK
AS AT
AR
AY
AZ
BA
MX9728A
Power Train - Final Drive Component Location - 616

A - Cap Plug AW- Spacer
B - Lever AX- Gear
C - Spring Pin AY- Snap Ring
D - Shaft AZ- Gear
E - Cap Screw (8 Used) BA- Snap Ring
F - Ring Gear
G - Thrust Washer
H - Gear
I - Gear
J - Thrust Washer
K - Screw
L - Differential Gear Housing
M - Cross Shaft
N - Washer (8 Used)
O - Lever
P - Shift Block
Q - Detent Ball
R - Spring
S - Pin
T - Snap Ring (2 Used)
U - Detent Shaft
V - E-Clip
W - Shift Fork (2 Used)
X - Pinion
Y - Bearing
Z - Spacer
AA- Gear
AB- Sleeve
AC- Splined Sleeve
AD- Shift Collar
AE- Bearing Race
AF- Gear
AG- Splined Sleeve
AH- Bearing Race
AI - Gear
AJ- Thrust Washer
AK- Bearing Assembly
AL- Shim
AM- Bearing Plate
AN- Bearing
AO- Pin
AP- Cap Screw
AQ- Nut (2 Used)
AR- Washer
AS- Gear (MFWD)
AT- Bearing (2 Used)
AU- Shaft with Gear
AV- Gear

Axle Shaft and Brake - Right
A G
B H
D I
J
C
E
K
AC
L
T M
S N
O
U P
2
P
P
B
R
V
Q
W
C Q
Q
AE
Y
AI
AD
AB Z
AA J
B
AF
AG
AH
MIF

A - Differential Lock Arm
B - Spring Pin
C - Washer (7 Used)
D - Snap ring
E - Seal
F - Cap Screw (6 Used)
G - Housing
H - Dowel Pin
I - Bearing
J - Gear (73T)
K - Snap Ring
L - Cap Screw
M - Retainer Plate
N - Balls (5 Used)
O - Actuator Plate (Assembly Includes M and N)
P - Brake Plate
Q - Friction Disc
R - Springs (3 Used)
S - Pinion Shaft
T - Bearing
U - Differential Lock Shaft
V - Shift Fork
W - Spring
X - Shift Collar
Y - Housing
Z - Shim
AA- Bearing
AB- Seal
AC- Cap Screw (2 Used)
AD- Seal Cover
AE- Axle Shaft
AF- O-Ring
AG- Brake Shaft
AH- Brake Arm
AI - Cap Screw (3 Used)

Axle Shaft and Brake - Left
B
A
C
A
K J F
G
I
H
L M
X
X N
V
Q
Y
Y
P
Y
O
W
T
S
MIF

A - Dowel Pin (2)
B - Housing
C - Cap Screw (6 Used)
D - Bearing
E - Seal
F - Seal Cover
G - Cap Screw (3 Used)
H - Axle Shaft
I - Brake Arm
J - Spring Pin
K - Cap Screw (2 Used)
L - Snap Ring
M - Gear (73T)
N - Bearing
O - O-Ring
P - Brake Shaft
Q - Cap Screw (5 Used)
R - Bearing
S - Pinion Shaft
T - Actuator Plate (Assembly Includes U, V, and W)
U - Spring (3 Used)
V - Balls (5 or 7 Used)
W - Actuator Plate
X - Friction Disc (3 Used)
Y - Brake Plate

Differential Lock
E G
A
B
A
C
ePRT and SST
Lever Location D
E
F
A
E H
E
L
J eHydro Lever
I Location
MX9732
A - Washer (7 Used)
B - Snap Ring
C - Shift Fork
D - Shaft
E - Pin (4 Used)
F - Spring
G - Seal
H - Lever
I - Shim
J - Housing
K - Shift Collar
L - Shaft

MFWD Drive Shaft (SST)
B
C
A
L D
K E F
J
M
B
H
I
O
P
Q
R
S
M95045A
A - Snap Ring
B - Spring Pin
C - Shaft
D - Bearing
E - Washer
F - Seal
G - Lever
H - Gear
I - Shift Collar
J - Spring
K - Shoe
L - Lever
M - Ball
N - Shaft
O - Snap Ring
P - Bearing
Q - Bearing
R - Snap Ring
S - Seal

MFWD Drive Shaft (ePowrReverser and eHydro)
C D
B
E
I
H
G
F
A
D
J
L
P
M
N
O
R
S
T
U
MX9692 Q - Seal
A - Shoe R - Shaft
B - Retainer S - Bearing
C - Lever T - Bearing
D - Spring Pin (2) U - Snap Ring
E - Shaft V - Seal
F - Shift Collar
G - Gear
H - Washer
I - Bearing
J - Cylinder
K - Bolt
L - Nut
M - Yoke
N - Lever
O - Cotter Pin
P - Pin

MFWD Axle Component Location
D
A C
B E
J
K
L
N
M
R
S Q
MX9724
A - Axle Housing
B - Bushing
C - Thrust Plate
D - Thrust Adjusting Bolt
E - Jam Nut
F - Front Axle Support
G - Dipstick
H - Axle Identification
I - Axle Shaft
J - Snap Ring
K - Shim(s) A/R
L - Bearing
M - Bevel Gear 12T
N - Tie Rod
O - Castle Nut
P - Steering Cylinder
Q - Differential
R - Seal
S - Bushing
T - Axle Support

MFWD Final Drive Component Location
E
G
A
B
C
D
X Y
Z
AA
AB AC
M AD
AE
N
S
T
U
V
MX9723

A - Snap Ring R - Ball Bearing
B - Shim(s) A/R S - Snap Ring
C - Bearing T - Bevel Gear 12 T
D - Bevel Gear 12T U - Washer
E - Bevel Gear 15T V - Snap Ring
F - Bearing W - Cover
G - Spindle Housing X - Snap Ring
H - Wear Sleeve Y - Ball Bearing
I - Seal Z - Bevel Gear 41T
J - Tapered Bearing AA- Spacer
K - Bearing Cone AB- Bearing
L - Bearing Cone AC- Outer Drive Cover
M - Tapered Bearing AD- Seal
N - Locking Washer AE- Hub Shaft
O - Special Nut
P - Spindle Shaft MFWD Differential Component Location
Q - Snap Ring
B K M
N
G
C H
D L
E
I
P
Q
F O
J R
M91838
A - Cap Screw (4 Used) K - Thrust Washer (2 Used)

B - Bearing Retainer (2 Used) L - Bevel Gear (2 Used)
C - Bearing Cup (2 Used) M - Washer (2 Used)
D - Bearing Cone (2 Used) N - Pinion Bevel Gear (2 Used)
E - Shim(s) A/R O - Cap Screw
F - Pinion 10T P - Bearing Cone
G - Ring Gear 50T Q - Bearing Cup
H - Pinion Shaft R - Shim(s) A/R
I - Pin S - Cap Screw
J - Differential Gear T - Differential Housing

POWER TRAIN - FINAL DRIVE THEORY OF OPERATION
Theory of Operation
Power Transmission - Range Transmission
Drive 24 Tooth Gear (Gear)

Shaft 30 Tooth Gear (Hydro)
44 Tooth Gear (Gear)

39 Tooth Gear (Hydro)
28 Tooth Gear
14 Tooth Gear (Gear)
Counter Shaft
Pinion Shaft
Pinion Gear
34 Tooth (Gear)
27 Tooth (Hydro)
23 Tooth Gear Shift Collar Shift Collar
36 Tooth Gear
20 Tooth Gear (Gear) 50 Tooth Gear (Gear)
45 Tooth Gear (Hydro) Ring Gear
Input Power
Power Transfer
Pinion Power
MFWD Power Transfer
A-range Power Transfer
B-range Power Transfer
C-range Power Transfer
MIF
Power Train - Final Drive Theory of Operation - 628

Function: Theory (Hydro):
The range transmission provides a means for transferring Power is provided to the range shift transmission through
engine power to the differential pinion gear at three the drive shaft which is splined to the motor shaft of the
different gear ratios. hydrostatic transmission. The 30 tooth gear is in constant
mesh with the 27 tooth gear. The 27 tooth gear is splined to
Theory (SST and ePowrReverser): the counter shaft. Power is transmitted through the 30 tooth
Power is provided to the range shift transmission through gear to the 27 tooth gear, and to the counter shaft. In order
the drive shaft which is splined to the output shaft of the for power to be transferred to the pinion shaft, the operator
SST or ePowrReverser transmission. The 24 tooth gear is must select a range; A, B, or C.
in constant mesh with the 34 tooth gear. The 34 tooth gear A-range:
is splined to the counter shaft. Power is transmitted through
the 24 tooth gear to the 34 tooth gear, and to the counter The counter shaft is a shaft and 18 tooth gear machined as
shaft. In order for power to be transferred to the pinion a single part. This 18 tooth gear is in constant mesh with
shaft, the operator must select a range; A, B, or C. the 45 tooth gear on the pinon shaft. The 45 tooth gear
rotates freely on the pinion shaft. When the operator
A-range: selects A range, the two shift collars are moved by a
The counter shaft is a shaft and 14 tooth gear machined as mechanical linkage to the rear most position. The front shift
a single part. This 14 tooth gear is in constant mesh with collar does not engage a gear. The rear shift collar
the 50 tooth gear on the pinon shaft. The 50 tooth gear engages the cogs of the 45 tooth gear, linking the gear to
rotates freely on the pinion shaft. When the operator the splined collar below the shift collar, transmitting power
selects A range, the two shift collars are moved by a from the counter shaft, through the 18 tooth gear, 45 tooth
mechanical linkage to the rear most position. The front shift gear, shift collar, splined collar, and into the pinion shaft,
collar does not engage a gear. The rear shift collar and finally to the pinion gear.
engages the cogs of the 50 tooth gear, linking the gear to B-range:
the splined collar below the shift collar, transmitting power
The 28 tooth gear is splined to the counter shaft, and is in
from the counter shaft, through the 14 tooth gear, 50 tooth
constant mesh with the 36 tooth gear on the pinion shaft.
gear, shift collar, splined collar, and into the pinion shaft,
The 36 tooth gear rotates freely on the pinion shaft. When
and finally to the pinion gear.
the operator selects B range, the two shift collars are
B-range: moved by a mechanical linkage slightly forward. The front
The 28 tooth gear is splined to the counter shaft, and is in shift collar does not engage a gear. The rear shift collar
constant mesh with the 36 tooth gear on the pinion shaft. engages the cogs of the 36 tooth gear, linking the gear to
The 36 tooth gear rotates freely on the pinion shaft. When the splined collar below the shift collar, transmitting power
the operator selects B range, the two shift collars are from the counter shaft, through the 28 tooth gear, 36 tooth
moved by a mechanical linkage slightly forward. The front gear, shift collar, splined collar, and into the pinion shaft,
shift collar does not engage a gear. The rear shift collar and finally to the pinion gear.
engages the cogs of the 36 tooth gear, linking the gear to C-range:
the splined collar below the shift collar, transmitting power
The 39 tooth gear is splined to the counter shaft, and is in
from the counter shaft, through the 28 tooth gear, 36 tooth
constant mesh with the 25 tooth gear on the pinion shaft.
gear, shift collar, splined collar, and into the pinion shaft,
The 25 tooth gear rotates freely on the pinion shaft. When
and finally to the pinion gear.
the operator selects C range, the two shift collars are
C-range: moved by a mechanical linkage to the far forward position.
The 44 tooth gear is splined to the counter shaft, and is in The rear shift collar slides completely onto the 36 tooth
constant mesh with the 20 tooth gear on the pinion shaft. gear cogs, and does not engage the splined collar below it.
The 20 tooth gear rotates freely on the pinion shaft. When The front shift collar engages the cogs of the 25 tooth gear,
the operator selects C range, the two shift collars are linking the gear to the splined collar below the shift collar,
moved by a mechanical linkage to the far forward position. transmitting power from the counter shaft, through the 39
The rear shift collar slides completely onto the 36 tooth tooth gear, 25 tooth gear, shift collar, splined collar, and into
gear cogs, and does not engage the splined collar below it. the pinion shaft, and finally to the pinion gear.
The front shift collar engages the cogs of the 20 tooth gear,
linking the gear to the splined collar below the shift collar,
transmitting power from the counter shaft, through the 44
tooth gear, 20 tooth gear, shift collar, splined collar, and into
the pinion shaft, and finally to the pinion gear.

MFWD Drive Shaft
B
C
MFWD Engaged
B C
MFWD Disengaged
A
E
MIF normally engaged. When ePowrReverser and eHydro

Picture Note: Drive Shaft viewed from Left Side machines are started, the hydraulic cylinder has no
hydraulic pressure to it and is retracted. This places the
Function: shift collar (A) in the engaged position and the MFWD is
engaged.
The MFWD drive shaft provides a means to transfer power
from the pinion shaft to the front axle. Theory (MFWD Disengaged):
Theory (MFWD Engaged): The MFWD is disengaged by rotating the cross-shaft (F),
moving the shift collar (A) off gear (B). The gear rotates
The MFWD is engaged by placing a shift collar (A) between
freely on the MFWD drive shaft (D).
a gear (B) that is engaged to a gear on the pinion shaft (C)
of the transmission and splines machined into the MFWD On SST machines the cross-shaft (F) is rotated with a
drive shaft (D). mechanical lever and linkage.
The shift collar is moved by a shoe that is attached to a On ePowrReverser and eHydro machines the hydraulic
cross-shaft through the transmission. The cross-shaft may cylinder extends to rotate the cross-shaft. The cylinder is
be rotated by a mechanical lever or a hydraulic cylinder (E). extended when the MFWD switch is pressed. The switch
activates a hydraulic valve solenoid coil to provide
The cross-shaft is rotated mechanically on SST machines.
pressurized oil to the cylinder. See “PTO and MFWD
The hydraulic cylinder rotates the cross-shaft on all
Hydraulic Operation” on page 741 in the Hydraulics
ePowrReverser machines, and eHydro machines with
section, and “MFWD Circuit Operation” in the Electrical
MFWD.
section.
ePowrReverser and eHydro machines have the MFWD

MFWD Front Axle
Top View
C
Rear View
H B
E
G
F
A
MFWD Drive Shaft
MX9811 shaft.
Picture Note: Left spindle viewed from rear; The bevel gear (F) splined to the bottom of the spindle shaft
Differential viewed from top. is engaged to the bevel gear (G). The bevel gear is splined
to the wheel hub shaft (H).
Function:
The front axle provides a means to transfer power from the
drive shaft to the front wheels.
Theory:
The differential pinion (A) is splined to the MFWD drive
shaft. The MFWD drive shaft transfers power from the
transmission pinion to the front axle. The differential pinion
drives the differential ring gear (B). The ring gear is bolted
to the differential gear housing (C).
The right and left axle shaft are splined into the differential
in the center of the axle and drive the right and left wheel
spindles through bevel gears.
The bevel gears (D) are splined to the axle and the spindle
shaft (E) and transfer power from the axle to the spindle

POWER TRAIN - FINAL DRIVE DIAGNOSTICS
Diagnostics Symptom: Range Transmission Problems
Yes - Drive shaft gear or counter shaft gear worn /
Final Drive System Diagnosis no longer serviceable.
Symptom: Range Transmission Problems Yes - Low/medium/high gears worn / no longer
serviceable.
(1) Range Transmission Does Not Engage?
Yes - Bearings on pinion shaft/counter shaft worn
Yes - Cogs on gear or shift collar damaged or
or damaged.
worn / no longer serviceable.
Yes - Pinion and ring gear worn or damaged.
Yes - Drive shaft gear or counter shaft gear worn /
no longer serviceable. (5) One Gear Will Not Engage?
Yes - A/B/C gears worn / no longer serviceable. Yes - Cogs on gear or shift collar damaged or
Yes - Shift linkage worn or damaged.
(6) Differential Noisy?
(2) Range Transmission Will Not Stay Engaged?
Yes - Pinion and ring gear worn or damaged.
Symptom: MFWD Problems
Yes - Detent ball spring broken.
(1) MFWD Will Not Engage or Will Not Stay
Yes - Shift linkage worn or damaged. Engaged?
(3) Range Transmission Noisy In Neutral? Yes - MFWD shift linkage worn or damaged.
Yes - Drive shaft gear or counter shaft gear worn / Yes - Cogs on MFWD shift collar or gear damaged
no longer serviceable. or worn / no longer serviceable.
Yes - Low/medium/high gears worn / no longer (2) MFWD Noisy?
serviceable.
Yes - Front differential or final drive worn or
Yes - Bearings on pinion shaft/counter shaft worn damaged.
or damaged.
(4) Range Transmission Noisy In Gear?
Final Drive Diagnosis
Range Shift Lever Smooth operation; engages gear. Lubricate linkage. Replace damaged
parts.
Rear Wheels Smooth, quiet operation in forward or Check differential locking lever
reverse motion; wheels do not scrub disengages when not depressed.
when turning. Replace damaged parts in differential.
Differential Locking Lever Smooth operation; engages Lubricate linkage. Replace damaged
differential lock. parts.
Front Wheels (MFWD) Smooth, quiet operation in forward or Replace damaged parts in front
reverse motion; wheels do not scrub differential.
excessively when turning.
MFWD Lever Smooth operation; engages MFWD. Lubricate linkage or replace damaged
parts.
Power Train - Final Drive Diagnostics - 632

POWER TRAIN - FINAL DRIVE TESTS AND ADJUSTMENTS
Tests and Adjustments To Adjust Backlash:
1. If not already removed, remove right hand final drive.
Differential Backlash Adjustment See “Final Drive Removal” on page 662.
2. Remove brake disks and plates. See “Brake
Reason:
Disassembly and Inspection” on page 806 in Brake section.
To place the differential ring gear in proper relationship with
3. Remove differential lock fork. See “Differential Lock
the differential input pinion shaft.
IMPORTANT: Avoid damage! Always check and

adjust backlash after pinion shaft adjustment has B
been made. See “Adjust Pinion Depth:” on
page 659. Do not adjust backlash unless the ring
gear was replaced or the amount of shims are in
question.
Procedure:
1. To ensure carrier and bearings are seated properly:
While slowly rotating the differential housing carrier, use a
soft faced mallet to lightly tap the face of the ring gear to
move it and the carrier toward the right side of the machine.
C
A
M94797
4. If not already done, remove differential lock collar (B).

5. Remove right brake/differential lock collar housing (C).
M94799
M94812
6. Remove shim(s) (D) located behind bearing housing to
decrease backlash, or add shim(s) to increase backlash.
2. Attach dial indicator (A) to the transmission housing.
NOTE: For each 0.001" of shim added, backlash will
3. Locate the contact point of the dial indicator toward the
increase approximately 0.0007".
outer part of the ring gear tooth and as close to 90° to the
Shims are available in 0.07 mm (0.003 in.), 0.13 mm
tooth as possible.
(0.005 in.), and 0.25 mm (0.010 in.) and 0.5 mm (0.020
4. While holding the differential pinion shaft stationary at in.) thicknesses.
the pinion, rotate the ring gear and note the backlash
reading on the dial indicator. 7. Install right brake/differential lock collar housing and
brake assembly. Reassemble and tighten to specification.
5. Rotate ring gear 1/2 turn, and recheck backlash.
8. Recheck backlash after removing or installing shims.
Specification:
Backlash . . . . . . . . . . 0.10 – 0.25 mm (0.004 – 0.010 in.)
Power Train - Final Drive Tests and Adjustments - 633

POWER TRAIN - FINAL DRIVE REPAIR
Main Shifter Adjustment Repair
Procedure:
MFWD Output Shaft Removal and Installation
Removal:
D
1. Split machine at rear of tunnel. See “Machine Splitting
(Rear)” on page 646.
A
NOTE: ePRT and SST lever located on right side of
case, eHydro lever located on left side of case.
MX9874
A
1. Place the transmission and shifter in the forward right
hand gate of the H pattern (A).
M94868
2. Loosen bolts (B) if they are not already loose.
3. Rotate rod (C) fully clockwise. 2. Rotate shift lever (A) until shoe (B) clears shift collar.
NOTE: This clamping must be done to ensure that the

joint will not move during bolt tightening.
4. While pushing shift lever against the right hand wall of
the H pattern (D), clamp the adjustable plates together (E)
with any locking pliers type tool.
5. Tighten the bolts (B) and remove the clamp.
Results:
Place the shift lever in neutral.
• The shift lever should move from side to side using a
very light force. If the lever moves lightly initially, but
increases in needed force before being centered in the
opposite side of the H pattern, the adjustment procedure
must be repeated or improper shifting may occur. M94869
NOTE: Dirt build-up can cause hard shifting. Do not 3. Remove shaft, gear, and shift collar as an assembly.
lubricate support bushing. Lubricant will only attract
dust and grit and make shifting difficult.
• Check for dirt build-up in the support bushing. Remove
dirt and clean bushing.
Power Train - Final Drive Repair - 634

Remove Shift Shaft: Disassemble MFWD Drive Shaft:
B
M94871
D
1. Using a suitable puller, remove bearing from end of
M94870 shaft. Inspect bearing for smooth operation, damage, or
wear. Replace as necessary.
1. Remove spring pin (C) and slide shift shaft out of tunnel.
2. Inspect bearing (D) for wear or damage. Replace if IMPORTANT: Avoid damage! DO NOT spin bearing
necessary. using compressed air. Damage to bearing balls,
3. Inspect shoe (B) for wear or damage. Replace if cage, and races could result.
necessary.
IMPORTANT: Avoid damage! Old O-rings,

gaskets, and seals will leak. When servicing,
always install new O-rings, gaskets, and seals.
M94872
2. Remove washer.
M94876
4. Replace shift shaft seal.
Installation:
Installation is the reverse of removal.
• Install a new shift shaft seal before installing shift shaft.
M94873
3. Remove gear.
NOTE: Shift collar on SST retains two steel balls under
spring pressure. Use care when removing collar to
prevent balls from being lost.

M94874 YZ4350
4. Wrap shaft in a shop towel to prevent balls (SST only) 2. Using a suitable tool, remove seal from tunnel and end
(E) from being lost. Remove shift collar (F). of shaft.
NOTE: Call-out (G) indicates location of snap ring
groove (SST models only).
G E F
YZ4352
3. Remove snap ring retaining bearing. Remove bearing.

M94875 Inspect bearing for damage or wear. Replace if needed.
5. Remove two steel balls, spring, and snap ring (SST 4. Install bearing.
only) from shaft.
IMPORTANT: Avoid damage! Old O-rings,
Assemble MFWD Drive Shaft:
gaskets, and seals will leak. When servicing,
Assembly is the reverse of disassembly. always install new O-rings, gaskets, and seals.
• Install two steel balls and spring (SST only) to shaft 5. Using a suitable driver, install a new seal.
using a suitable hose clamp to compress spring and hold
balls in place while shift collar is being installed.
Front Seal and Bearing Replacement:

1. Split machine between flywheel housing and tunnel
sections. See “Machine Splitting (Front)” on page 545 in
the Hydrostatic Power Train section for eHydro machines;
“Machine Splitting (Front)” on page 496 in the Gear Power
Train section for SST machines; or “Machine Splitting
(Front)” on page 570 in the ePowrReverser Power Train
section for ePowrReverser machines.

MFWD Drive Shaft Removal and Installation NOTE: If the spindle housings are going to be removed
from the axle housing, it is easier to remove them while
Removal: the axle housing is bolted in place.
M95006
1. Remove the spring pins (A) from the drive shaft splined
couplers (front and rear).
2. Support the drive shaft and slide the splined couplers on
to the drive shaft splines (B). Remove drive shaft from the
machine.
Installation:
M89678
6. Lower the axle an inch or two from the frame with a floor
jack. Remove drive shaft and collar from pinion shaft.
MFWD Removal Lower the axle to the floor.
1. Remove the roll pin from the rear differential drive shaft 7. Inspect the axle pivots for wear or damage.
collar and slide the collar on to drive shaft.
2. Disconnect tie rod and steering cylinder. MFWD Final Drive Cover Removal and
3. Raise the front of the machine. Support the frame. Inspection
4. Support the MFWD with a floor jack. Removal and Inspection:
1. Drain the differential and the final drive housing being
serviced.
2. Raise and support the final drive being serviced.
3. Remove the wheel and tire from the final drive.
4. Remove eight cap screws. Separate the final drive cover
and hub shaft assembly from the final drive housing.
NOTE: The final drive cover is sealed to the final drive
housing. It may be necessary to pry the cover from the
housing using the two reliefs on the sides of the cover.
M89677
5. Remove the axle support mounting cap screws (A).

A C
D
B A
C B
D
E
F
G
H
I
MX1438
F E
A - Final Drive Housing MX9811
B - Snap Ring
3. Place the ball bearing (A), spacer (B), bevel gear (C),
C - Bearing and ball bearing (D) on the hub shaft. Secure with snap
D - Bevel Gear 41T ring (E).
E - Spacer
4. Apply John Deere Sealant TY6304 to the mating
F - Bearing surface (F) of the final drive cover. Install the final drive
G - Final Drive Cover cover to the final drive housing. Tighten the cap screws to
H - Seal specification.
I - Hub Shaft
Specification:
J - Cap Screw (8 Used)
Cap Screw Torque . . . . . . . . . 30 – 38 N•m (22 – 28 lb-ft)
5. Remove the snap ring (B).
6. Press the hub shaft (I) from the final drive cover, MFWD Spindle Shaft
bearings, and bevel gear.
7. Disassemble the remaining components from the final Removal and Disassembly:
drive cover assembly.
8. Clean and inspect all parts. Replace any unserviceable
components.
Installation:
1. Coat the outer surface of a new hub seal with John
Deere Sealant TY15130. Replace the hub seal.
2. Install the hub shaft through the seal and cover.
M89686
1. Carefully remove the spindle cap from the bottom of the

housing.

A
M89690
M89687
5. Remove the snap ring (B) from the spindle housing.
2. Remove the snap ring (A) from the spindle shaft.
M89691
6. Remove the spindle shaft and bearing from the spindle

housing.
7. Remove the snap ring and bearing from the spindle
shaft. Inspect all parts, and replace components as
necessary.
M89688
3. Remove the shim(s), and lower bevel gear (12T) from

the spindle shaft. Save any shim(s) from between the
spacer and the lower bevel gear.
M89689
4. Remove the lower bevel gear from the spindle shaft.

Assembly and Installation: MFWD Final Drive Housing
Disassembly:
1. Remove the final drive cover. See “MFWD Final Drive
Cover Removal and Inspection” on page 637.
2. Remove the final drive spindle shaft. See “MFWD
Spindle Shaft” on page 638.
B
F
A
E
C
C
E
F
G
H
MIF B
1. Install the bearing (A) and snap ring (B) on the spindle MIF
shaft. 3. Straighten the any tabs on the locking washer (A) that
2. Install the spindle shaft assembly in the final drive are securing the retaining nut (B) in place. Remove the
housing. retaining nut from the final drive housing.
3. Install the internal snap ring (C) in the final drive 4. Remove the final drive housing (C) from the spindle
housing. housing (D), and put the final drive housing in a vise.
4. Install the bevel gear 12T (D), any shim(s) (E), the 5. Remove the bearing cups and bearing cones from the
washer (F), and snap ring (G) on the spindle shaft. final drive housing. Clean and inspect all components.
Replace any unserviceable components.
5. Install the final drive cover to the final drive housing, if
removed. 6. Remove the seal (E) and seal sleeve (F) from the
spindle housing.
6. To set the backlash of the lower final drive, shim the
bevel gear to achieve 0.64 – 0.76 mm (0.025 – 0.030 in.) of Assembly:
end play.
The end play sets 0.13 – 0.18 mm (0.005 – 0.007 in.) of 1. Clean the seal sleeve, replace if worn or scratched.
backlash. 2. Replace the final drive housing seal (E).
7. Apply John Deere TY15941 retaining compound to the 3. Install the bearing cups and cones in the final drive
final drive housing cap (H) and install. housing (C).
4. Install the spindle housing to the final drive housing.
5. Install the locking washer (A) to the spindle housing.
6. Install bearing retaining spanner nut (B) on the final
drive housing. To correctly install the nut:

• Tighten the spanner nut to 40.7 ±2.7 N•m (30 ±2 lb-
ft). Oscillate the final drive housing on the spindle
A
housing several times to seat the bearing. C
B
• Shock the wheel end by hitting end stops with a soft

mallet.
• Retighten the nut to 40.7 ±2.7 N•m (30 ±2 lb-ft).
• Bend a locking washer tab into slot in nut.
7. Install the spindle shaft. See “MFWD Spindle Shaft” on
page 638.
8. Install the final drive cover. See “MFWD Final Drive
D
MFWD Spindle Housing

Removal and Disassembly:
1. Remove the final drive housing. See “MFWD Final Drive
MX9811
A - Shim
2. Remove four cap screws fastening the spindle housing
to the MFWD housing. B - Bearing
C - Axle Gear 12T
3. Remove the internal snap ring from the spindle housing.
D - Snap Ring
4. Remove the bearing and axle gear (12T) assembly from
• Shim the bearing and axle gear to 0.15 – 0.28 mm
the spindle housing.
(0.006 – 0.011 in.) of end play, to achieve 0.10 – 0.20
5. Remove the bearing and upper bevel gear (15T) mm (0.004 – 0.008 in.) backlash.
assembly from the spindle housing.
5. Apply John Deere TY6304 sealant to the mating
6. If necessary press the bearings from the gears. surfaces of the MFWD housing and the spindle housing.
NOTE: The bearings are pressed onto the gears, and 6. Install the spindle housing to the MFWD housing:
are slip fits into the housing. • Apply John Deere TY9371 to the threads, and install
7. Clean and inspect all parts. Replace any unserviceable four cap screws fastening the spindle housing to the
parts. MFWD housing.
• Tighten the cap screws to 286 – 316 N•m (211 – 233
Assembly and Installation: lb-ft).
1. Install the bearing and upper bevel gear (15T) assembly 7. Install the final drive housing.
to the spindle housing.
2. Install the bearing and axle gear (12T) assembly to the MFWD Differential
spindle housing.
3. Install the internal snap ring to the spindle housing. Removal and Disassembly:
4. Set the backlash of the axle gear: 1. Raise and support front of machine.
• Measure the distance between the bearing and the 2. Drain oil from front axle housing and both final drives.
snap ring at several locations. 3. Disconnect tie rod and steering cylinder.
4. Remove four cap screws fastening each spindle housing
to the MFWD axle housing and remove spindles/final drives
as an assembly).
5. Remove both axle shafts from the MFWD housing.
6. Remove the roll pin from the rear MFWD drive shaft.
See “MFWD Drive Shaft Removal and Installation” on
page 637.

7. Remove cap screws fastening the differential carrier Assembly and Installation:
housing to the MFWD axle housing and remove carrier
assembly. H
G
8. Mark the bearing caps and the carrier housing to assure
E F
they are assembled in their original positions. Remove the
cap screws for the bearing caps.
D
9. Remove the differential case from the differential carrier
housing.
C
10.Remove ring gear cap screws. Remove the ring gear
from the differential case. B
A
NOTE: The differential case and internal parts come as
I
an assembly. If any damage is apparent there is no J
K
need to disassemble the case, the whole assembly L
must be replaced. N M
M91838A
11.If internal damage is suspected disassemble the
differential case assembly and inspect all parts. A - Nut
B - O-Ring
NOTE: Remove the differential case bearings only if
C - Spacer
necessary. Mark the bearing caps and the carrier
housing to assure they are assembled in their original D - Carrier Housing
positions. Make sure shims between the bearings and E - Inner Shim
the differential case are retained and marked as to F - Bearing Cup
which side they were on so they may be installed to G - Bearing Cone
their original position. H - Pinion
12.Clean and inspect all parts and check parts for wear. I - Outer Shim
Replace any unserviceable parts. J - Bearing Cup
13.Remove the pinion nut. Do not discard the nut at this K - Bearing Cone
time. L - O-Ring
14.Remove the differential pinion from the differential M - Spacer
carrier housing. N - Seal
1. Assemble the bearing cone (G) to the pinion (H).
IMPORTANT: Avoid damage! The pinion
retaining nut is a special “torque prevailing” nut. • The inner shim(s) (E) are under the bearing cup (F)
ALWAYS replace this nut DO NOT reuse. and set the pinion height. If the original pinion is being
NEVER tighten a torque prevailing nut with an used, use the original shims, or install new shims the
impact wrench. same thickness as the original shims.
ALWAYS use a torque wrench to correctly
tighten torque prevailing nuts.
A
15.Disassemble the pinion shaft assembly.
NOTE: The ring gear and pinion gear are serviced as an
assembly. If either the ring gear or pinion has wear or
damage both must be replaced.
16.Clean and inspect all parts and check parts for wear.
B
Replace any unserviceable parts.
MX1027

• If the ring and pinion are being replaced, notice the
(+) or (–) number (A) on the end of the pinion gear. This D E
C
indicates the best running position of each particular
gear set in thousandths of an inch. If the number on the F
new set is not the same as the number on the one being G
replaced, adjust the height by adding or removing inner
shim(s) (E) from the original shim pack according to the
H
dimension etched in the head of the pinion.
• Example: If the old pinion reads +2 and the new
pinion is marked –1, add 0.003 in. shims to the original
shim pack.
NOTE: Number (B) on pinion and ring gear indicate
matched set. Make sure numbers on ring and pinion
gears match before assembling. I
M91838B
4. Install the washers (C) to the side gears (D) and install
side gears into differential case (I).
5. Install concave washers (E) onto pinion gears (F). Install
pinion gears to side gears and turn gears to align with hole
in differential case. Install shaft (G) and secure with roll pin
(H).
B
MX1027
• Assemble the inner bearing cup (F) and any shims

(E) in the differential carrier housing.
• Install the pinion (H) in the differential carrier
housing:
• Place the pinion in the carrier housing, and install the
spacer (C), outer shim (I), bearing cone (K), O-ring (B),
seal (M), spacer (L), and the old nut (A).
2. Tighten the old pinion nut to 135 – 165 N•m (100 – 120
lb-ft) and check the rotation of the pinion:
• It should require 0.8 – 1.4 N•m (7 – 12 lb-in.) of
torque to rotate on the pinion.
M81838C
• If the pinion does not turn within specification, adjust
the shim pack. Add shims if torque is too high, remove 6. Install the ring gear to the differential case. Tighten the
shims if torque is too low. ring gear bolts to 79 – 88 N•m (58 – 65 lb-ft).
3. When the pinion is shimmed correctly replace the old NOTE: There may be several shims on each side of
pinion retaining nut with a new pinion retaining nut. Tighten differential case.
the new nut to 135 – 165 N•m (100 – 120 lb ft), and
recheck the rotation of the pinion.
NOTE: The differential case and all parts shown above
are serviced as an assembly only.

11.Apply John Deere Sealant TY6304 to the differential
carrier housing.
J M
12.Install the differential carrier housing to the MFWD
K
housing.
13.Apply John Deere TY9370 thread lock and sealer to all
cap screws securing the differential carrier housing.
Tighten the cap screws to specification.
Specification:
Backlash . . . . . . . . 0.076 – 0.178 mm (0.003 – 0.007 in.)
Differential Carrier Housing Cap Screw Torque
. . . . . . . . . . . . . . . . . . . . . . . . 88 – 94 N•m (65 – 70 lb-ft.)
L Pinion Depth Setup and Adjustment

Required Only If Differential Carrier Housing Is Replaced
Using Any Gear Set That Was Not Installed With That
M91838D
Carrier Housing At The Factory
7. If bearings (J) were removed, place original shims (K) or Tools Required:
new shims equaling the same thickness, on the same side
• JDG 1395A Differential Setup Tool Kit
of the differential assembly (L) they were removed from.
Install new bearings on the differential assembly. Procedure:
8. Using marks made during disassembly, install the
bearing caps (M) in their original positions. Tighten the cap B
screws for the bearing caps to 54 – 68 N•m (40 – 50 lb-ft).
• The bearing shim(s) (K), control the ring and pinion
backlash and the preload of the differential bearings. If
the original differential case, bearings, and gear set are
being used, install the original shims, or new shims
totalling the original thickness.
• If the differential case bearings or gear set are being
replaced, set the bearing preload and gear backlash by
adding or removing shim(s) between the ring gear side
bearing and differential case. A
• Shim the bearings to a preload of 0.025 – 0.089 mm
(0.001 – 0.0035 in.).
9. Install the differential case assembly to the differential
carrier housing. Check gear backlash with a dial indicator. MX11615
• Gear backlash is adjusted by changing the shim pack 1. Remove inner pinion bearing cup (if installed) and retain
thickness on the ring gear side bearing. Removing any shims from behind cup for possible re-use. Install tool
shims increases backlash, adding shims decreases (A) into pinion bearing bore.
backlash. 2. Install tool (B) across differential bearing saddles.
3. While holding the tool (B) down, measure the distance
IMPORTANT: Avoid damage! Whatever shim
between the two tools with a feeler gauge. (This value will
thickness is added to one side of the differential
generally be between 0.635 – 0.864 mm (0.026 – 0.034
case must be removed from the other side. Or
in.), But it is acceptable to have measurements between
whatever shims are removed from one side must
0.45 – 0.96 mm (0.018 – 0.038 in.). Record the
be added to the other to keep bearing preload
measurement.
from changing.
10.Adjust backlash to specification.

Determining Differential Bearing Preload:
C
D
MX11617
4. Locate the (+) or (–) number (C) on the end of the pinion
gear. This number indicates the best running position of
each particular gear set in thousandths of an inch.
MX11616
5. The shim pack thickness to be used under the pinion
1. Place the bearing substitute tool (D) on each side of the
bearing cup is calculated as follows:
differential case.
• Use the feeler gauge thickness dimension measured
2. Pry the differential back and forth with a small bar to
in step 3.
seat the bearing tools against the outer edges of bearing
• If the number on the pinion is a (+) number bores.
SUBTRACT that number in thousandths of an inch from
3. Pry the differential all the way over against one of the
the feeler gauge thickness dimension measured in step
bearing tools.
3.
4. Using a feeler gauge, measure the gap between the
• If the number on the pinion is a (–) number ADD that
differential carrier and the bearing tool (E). Record the
number in thousandths of an inch to the feeler gauge
measurement.
thickness dimension measured in step 3.
5. Add 0.025 – 0.089 mm (0.001 – 0.0035 in.) to the
• After calculating shim pack thickness, assemble a
measurement for bearing preload.
shim pack measuring the exact amount calculated
above and place it under the pinion bearing cup. 6. Assemble a shim pack measuring the exact amount of
the calculation above.
Differential Backlash Adjustment:

NOTE: Pinion shaft assembly must be installed.
1. Install pinion shaft per assembly/installation instructions
on page 626.
2. Divide the shim pack assembled in the previous step
into two stacks with the thickness of the two stacks being
as equal as possible.
3. Install one shim pack and a bearing substitute tool on
each side of the differential case.

Machine Splitting (Rear)
PTO shaft.
3. Remove seat and seat support.
4. Remove seat close out panels. See “Seat Close Out
Panel” on page 818.
on page 821.
6. Remove fenders. See “Rear Fenders” on page 819.
7. Remove left and right closeout panels. See “Seat Close
Out Panel” on page 818.
8. Disconnect the battery negative terminal.
MX11629
4. Install dial indicator to measure ring gear movement.

c CAUTION: Avoid Injury! Relieve hydraulic
pressure from system by stopping the
5. Hold the pinion gear shaft to keep it from moving. Rotate engine and operating all hydraulic control
the ring gear back and forth, and observe readout on dial valves.
indicator. 9. Cycle all hydraulic controls to relieve system pressure.
Specification: NOTE: Hydraulic reservoir contains approximately 26 L
Backlash . . . . . . . . 0.076 – 0.178 mm (0.003 – 0.007 in.) (6.8 gal) of oil. Have a suitable container ready to catch
drain oil.
Results:
10.Drain hydraulic reservoir.
IMPORTANT: Avoid damage! Whatever shim 11.Locate and disconnect all electrical connectors
thickness is added to one side of the differential attaching wiring harness to switches and lights on rear half
case must be removed from the other side. Or of machine. Unfasten wiring harness from cable clips and
whatever shims are removed from one side must move harness away from rear half of machine.
be added to the other to keep bearing preload
from changing.
• If necessary, adjust backlash. Gear backlash is adjusted

by changing the shim pack thickness on the ring gear side
bearing. Removing shims increases backlash, adding
shims decreases backlash.
• When backlash is correct, remove bearing substitute
tools and install bearings.
• Install the bearing caps. Tighten the cap screws for the
bearing caps to 54 – 68 N•m (40 – 50 lb-ft) and recheck MIF
backlash. 12.Disconnect lower brake rods at rear brake levers.
NOTE: On hydrostatic models, differential lock lever
(C) is located on the left side of the machine. On gear
models, it is located on the right side.

H
C
MX9743
16.Disconnect hydraulic pressure tube (H) at three valve

manifold and move tube aside.
MX9817
Picture Note: eHydro Model Shown

13.Remove cotter pin (D) and washer, and disconnect
differential lock rod (E) from lever. Move rod aside. I
MX9771
MX9782 17.If equipped, disconnect SCV work port tubes (I) at SCV.
14.Remove cap screw (F) and SCV pressure tube clamp.
M91982
MX9748
15.Disconnect pressure tube (G) at rear gear pump.
18.Remove cap screws (J) that attach tube support bracket
to frame. Remove tube support bracket and tubes as an
assembly.

Assemble Machine Halves:
MX9762 M94891
19.Remove cap screws (K). Remove suction tube manifold 1. If removed, install PTO drive shaft (N) to tunnel (front)
(L) and inspect strainer screen. Clean screen if necessary. section of machine.
20.Remove hydraulic lines and MFWD cylinder.
Splitting the Machine:
IMPORTANT: Avoid damage! Check for, and O

disconnect any additional accessory wires or
hydraulic tubes connecting rear half to front half
before splitting machine. P
1. Using four suitable cap screws, secure two JTO7335

splitting stands to the tunnel, or engine section of the
machine. Adjust splitting stands so that wheels contact the
floor, and are parallel to the machine wheels.
2. Using suitable stands or an overhead crane, support the
differential housing of the machine to prevent it from
tipping.
3. Remove all cap screws attaching tunnel section to
differential housing. Note length and locations of cap MX11577
screws when removing.
Picture Note: eHydro Shown
4. Gently pry around edges to separate machine halves.
2. Install drive shaft (O) and coupler (P) to tunnel (range
5. Roll engine and tunnel section away from differential transmission) section of machine.
housing.
3. Clean mating surfaces of tunnel and differential housing
to remove old sealant.
4. Apply a bead of John Deere TY6304 Form in Place
Gasket to flanges of one of the machine sections.
5. Roll front section of machine to rear section.
6. Align machine halves:
• Adjust splitting stands as required to align shafts,
locator bushings, and cap screw holes.
• Using a suitable wire hook, lift and support the PTO
drive shaft while applying light pressure to the machine
halves until PTO shaft engages splines on clutch/brake
coupler. If necessary, rotate PTO stub shaft at rear of
machine to align splines on shaft with coupler.

• If necessary, use a suitable wire hook to raise drive
shaft slightly to align gear teeth and shaft end with gears
and bearing in bearing plate.
7. Move machine sections together and retain with cap
screws in locations as noted during disassembly. Tighten
cap screws to 70 – 105 N•m (52 – 77 lb-ft). L
8. Remove splitting stands.

NOTE: On hydrostatic models, differential lock lever is
located on the left side of the machine. On gear
models, it is located on the right side.
MX9762
D 12.Attach suction hose (L) and secure with hose clamps.
G
MX9817
Picture Note: Hydrostatic Model Shown

9. Reconnect differential lock rod (E) to lever (C). Install M91982
washer and a new cotter pin (D). 13.Attach SCV pressure tube to rear gear pump. Tighten
tube nut (G) to 55 – 79 N•m (40 – 59 lb-ft).
MIF
10.Reconnect lower brake rods at rear brake levers.

• (Insert end of rod through brake lever and secure
with washer and cotter pin.
MX9743
11.Reconnect main PTO, mid PTO, MFWD hydraulic lines
and MFWD cylinder if equipped. 14.Attach SCV pressure tube to SCV. Tighten tube nut (H)
to 55 – 79 N•m (40 – 59 lb-ft).

18.Route wiring harness to rear of machine. Connect
electrical connectors as marked at disassembly.
F 19.Install operator’s platform. See “Operators Platform” on
page 821.
20.Install seat close out panel. See “Seat Close Out Panel”
on page 818.
21.Install seat support. See “Seat and Seat Support” on
page 818.
22.Install seat.
23.Install fenders. See “Rear Fenders” on page 819.
MX9782
24.Connect the battery negative terminal.
15.Install tube clamp to SCV pressure tube. Retain with
cap screw (F). 25.Refill hydraulic oil reservoir to proper level.
Bleed Procedure” on page 747.
Range Transmission Removal and Installation

Removal:
J NOTE: Removal and installation of main PTO and mid

PTO hydraulic lines must be performed when splitting
the machine.
1. Split machine at rear of tunnel. See “Machine Splitting
(Rear)” on page 646.
MX9748 A
16.Install tube support bracket and tubes as an assembly.

Install cap screws (J) that attach tube support bracket to
frame.
MX11577
2. Remove drive shaft and coupler (A) from bearing plate

(B) as an assembly.
MX9771
17.Connect SCV work port tubes (I) to SCV. Tighten tube

nuts to 40 – 57 N•m (30 – 43 lb-ft).

YZ4450
6. Remove the E-clip with a needle nose pliers.

YZ4353
3. Remove spring pin (C) from shift lever arm. Push shift
shaft into case as far as it will go.
F
G
YZ4347
4. Remove the five capscrews and the mid PTO gearbox YZ4472
(D). Remove the mid PTO gear box only. You do not need 7. Remove roll pin retaining detent shaft (F) and pull out
to remove the rear PTO shafts and gears or the mid PTO detent shaft. Remove four cap screws (G) from bearing
shaft. plate.
NOTE: Ball and spring for shift detent will fall into
E differential housing.
8. Pry around edges of cover to loosen shafts and
bearings. Do not attempt to remove at this time.
YZ4449
5. Locate the E-clip (E) on the detent shaft.

11.Retrieve ball and spring from differential case.
Disassembly:
YZ4473
9. Using a suitable pin punch or screwdriver, rotate shift

fork assembly (H) clockwise on shift collars to clear housing
during removal. M94839
NOTE: This will not work on all machines. If you are 1. Remove shim pack from transmission cover and gears.
unable to rotate the assembly from the lever, you must
remove the rockshaft assembly to gain access to the
spring pin which retains the lever to the shaft. After
removing the spring pin you can rotate the shifter
block to allow transmission removal from the housing. G
M94840
2. Remove snap ring (G) from end of counter shaft.

Remove 34 tooth gear (H).
M94862
10.Remove range transmission with shift forks as an

assembly.

Differential Pinion Shaft Removal & Disassembly:
L
I
K
M94814
1. Remove two nuts (K) and washer from end of pinion

M94841
shaft. Remove gear (L).
3. Using a press or plastic mallet, remove counter shaft (I)
and gears from bearing plate as an assembly.
K
M
L
M94815
2. Using a press or a plastic mallet, remove pinion shaft

(M) from outer bearing cone and bearing plate.
M94842
4. Remove gear (J), spacer (K), and gear (L) from counter
shaft.
IMPORTANT: Avoid damage! DO NOT spin bearing

using compressed air. Damage to bearing balls,
cage, and races could result.
5. Inspect bearing for smooth operation, wear, or damage. M94843

Replace as necessary, using a suitable puller or press. 3. Inspect outer bearing for smooth operation, wear, or
damage. Replace as necessary.


bearing balls, cage, and races could result.
M94845
6. Using a suitable bearing driver and plastic mallet or

press, remove drive shaft bearing from bearing plate.
Inspect bearing for smooth operation, wear, or damage.
Replace as necessary.
M94817
4. Remove spacer washer (N) from pinion shaft. Inspect

inner bearing for smooth operation, wear, or damage.
Replace as necessary.
M94818
7. Using a suitable puller or press, remove inner bearing

M94844
cone and spacer from pinion shaft.
5. Remove snap ring (O) and counter shaft bearing from

bearing plate. Inspect bearing for smooth operation, wear,
or damage. Replace as necessary.
NOTE: It is not necessary to remove snap ring from
drive shaft bearing to remove bearing from bearing P
plate. Snap ring locates bearing to proper depth.
M94819
8. Remove gear (P) and bushing (Q).

M94820 M94823
9. Remove shift collar. 12.Remove bushing.
M94821
M94824
10.Remove splined sleeve.
13.Remove shift collar.
M94822
11.Remove gear (R). M94825
14.Remove splined sleeve.

M94826
M94828
15.Remove gear (S).
17.Remove spacer.
M94827
16.Remove bushing. M94829
18.Using a suitable puller or press, remove bearing from

pinion shaft. Inspect bearing for smooth operation, wear, or
Assembly:
IMPORTANT: Avoid damage! DO NOT spin bearing

using compressed air. Damage to bearing balls,
cage, and races could result.
1. Inspect all parts to ensure that they are in good

condition. Replace as necessary. Dip press-fit parts in
hydraulic oil before assembling.
2. Press bearing onto pinion shaft.
3. Install spacer.

4. Install bushing.
5. Install gear (S). O
6. Install splined sleeve.
7. Install shift collar.
8. Install bushing.
9. Install gear (R).
10.Install splined sleeve.
11.Install shift collar.
M94844
15.If removed, install counter shaft bearing into bearing

plate. Retain with snap ring (O).
P
M94819
12.Install bushing (Q), and gear (P).
M94845
16.If removed, install drive shaft bearing into bearing plate

as shown using a press.
M94818
13.Install spacer on top of gear.

14.Using a suitable bearing driver or press, install bearing
onto shaft with the flat side towards the spacer.
NOTE: Bearings must be replaced as a set. Keep
bearings, races, and inner and outer spacers together.
M94817
17.Install spacer washer (N) on top of bearing cone.

M94815
18.Install pinion shaft (M) with gears through bearing plate

and outer bearing cone. Press or drive outer bearing cone
onto shaft until it contacts the spacer washer.
M94842
22.Press bearing onto end of counter shaft. Install gear (J),

spacer (K), and gear (L) onto shaft.
I
M94814
19.Install 23 or 25 tooth gear (L).

NOTE: Apply John Deere TY9370 Thread Lock to inner
and outer nuts when installing.
20.Install washer and inner nut. Tighten nut to 95 - 120
N•m (70 - 90 lb-ft). Rotate the pinion shaft back and forth
to seat bearing while tightening.
M94841
21.Install outer nut (K). Tighten nut to 95 - 120 N•m (70 - 90
lb-ft). 23.Using a press, or plastic mallet, install counter shaft (I)
into bearing and bearing plate.

M94840
24.Install gear (G) onto end of shaft. Retain with snap ring
(H).
Adjust Pinion Depth:

NOTE: Adjust pinion depth only if ring gear and pinion M94839
were replaced. If ring and pinion were not replaced,
use same shim pack, or same number of shims as were 2. Install the shim pack onto the bearing plate, and check
removed at disassembly. measurement from bearing face to shim pack to be sure
that it is within specification.
Specification:
Pinion Depth . . . 168.58 – 168.84 mm (6.637 – 6.647 in.)
Installation:
NOTE: Complete shift fork assembly if shift fork was
disassembled.
M94857
1. Measure from the mounting face of the bearing plate to

the rear of the bearing on the pinion shaft. Calculate the
amount of shims required to bring this dimension within
specification, and make up the appropriate shim pack.
NOTE: Shims are 0.25 mm (0.010 in.) each. M94859
1. Install detent ball and spring into shift fork assembly.

M94860
2. Insert JDG 1260 detent ball tool into shift fork to retain
ball and spring during installation.
IMPORTANT: Avoid damage! Shift forks are each

marked with an “F”. This marking should face
bearing plate (front of machine).
JDG 1260
M94862
4. Remove guide bushings from differential housing and

install to bearing plate to hold shim pack in place during
installation.
5. While holding shift fork assembly in place, install range
transmission to differential housing. If necessary, use
detent shaft and cap screws to help with alignment. Check
to make sure counter shaft bearing is properly aligned with
bore at rear of differential housing while installing.
6. Using a plastic mallet, tap on end of pinion shaft to seat
bearing in differential housing bore.
M94861 IMPORTANT: Avoid damage! Damage to bearings

or transmission may result if pinion bearing and
3. Install shift fork assembly to shift collars on range
counter shaft bearing are not properly aligned
transmission.
when tightening four cap screws retaining
transmission to differential housing.

A
YZ4475
10.Align holes and drive roll pin into detent shaft.
YZ4473
7. Rotate shift fork assembly (A) into place. Be sure shift

fork pin engages slot in shift lever inside case.
B
YZ4449
11.Install E-clip on detent shaft through the mid PTO

gearbox opening.
YZ4474
8. Apply TY9370 medium strength thread locker to cap

screws and install four cap screws and tighten to 50 – 60
N•m (36 – 44 lb-ft).
9. Insert detent shaft (B) into hole in cover. Align shift fork
assembly through MFWD bearing hole and push detent
shaft through shift fork and into rear of differential housing.
Detent shaft tool JDG 1260 will drop into bottom of
YZ4476
12.Remove suction screen from the bottom of the

transmission. Clean gasket surface.

JDG 1260
E
YZ4347
16. Clean gasket surfaces and place a small bead of

M94863
TY6304 on gasket surface of transmission. Install mid PTO
13.Using a magnetic pickup or similar tool, retrieve JDG gearbox (E).
1260 detent ball tool from differential housing. Clean
suction screen if necessary, install new gasket and place 17.Assemble machine halves. See “Machine Splitting
screen back in transmission. Install suction elbow. (Rear)” on page 646.
NOTE: Make sure shift lever engages pin on range shift Final Drive Removal
block.
Left Hand Final Drive Removal:
NOTE: Hydrostatic model machine has differential
C locking lever located on left hand final drive housing.
1. Raise rear of machine and support on suitable stands.
2. Remove draft arms and adjustable sway bars. See “3-
Point Hitch” on page 817.
3. Remove wheel and tire.
YZ4353
14.Pull shift shaft out, and install shift lever arm. Install
spring pin (C). Check shift lever for proper operation.
15.Check differential backlash and adjust if necessary. See
“Differential Backlash Adjustment” on page 633. MIF

G
F
H I
D
J
C
MX9816 MX9856
4. Disconnect brake return spring (B) from brake lever. 8. (eHydro Model) Remove cotter pin (E) and washer(s)
and disconnect differential lock rod (F) from differential lock
5. Disconnect lower brake rod (C) from brake lever.
lever (G).
6. Side Mount Parking Brake Only: Disconnect park brake
9. (eHydro Model) Remove roll pin (H) and differential lock
rod from brake lever (D).
lever from shaft.
A 10.Remove roll pin (I) and brake lever (J) from shaft.
c CAUTION: Avoid Injury! Final drive/axle

housings weigh approximately 34 kg (75 lbs.)
each. If necessary, use a suitable lifting
device or get assistance before removing
cap screws securing final drive to
transmission housing.
MX9815
7. Support ROPS using an overhead crane. Remove eight K

cap screws (A) and nuts retaining ROPS to final drive
housing. Remove lower support plate.
MX9857
11.Remove eight cap screws (K) securing final drive to

12.Gently pry around edges of cover and remove final drive
from transmission housing.

Right Hand Final Drive Removal:
Q
NOTE: Gear machines have differential locking lever
located on right hand final drive housing. R
T
1. Raise rear of machine and support on suitable stands.
2. Remove draft arms and adjustable sway bars. See “3- S
Point Hitch” on page 817.
3. Remove wheel and tire. U
MX11584
8. (SST and ePowrReverser Models) Remove cotter pin

L (Q) and washer and disconnect differential lock rod (R)
from differential lock lever (S).
9. (SST and ePowrReverser Models) Remove roll pin (T)
and differential lock lever from shaft.
M 10.Remove roll pin (U) and brake lever (V) from shaft.

MX9849
4. Disconnect brake rod (L) from brake lever.

housings weigh approximately 34 kg (75
5. Disconnect brake return spring (M) from brake lever.
lbs.) each. If necessary, use a suitable lifting
6. Side Mount Parking Brake Only: Disconnect park brake device or get assistance before removing
rod from brake lever (D). cap screws securing final drive to
O
M
P
MX9850
MX9857
7. Support ROPS using an overhead crane.Remove four
11.Remove eight cap screws (W) securing final drive to
cap screws (O) and nuts retaining ROPS to final drive
housing. Remove spring (M). Remove lower support plate
(P). 12.Gently pry around edges of cover and remove final drive
from transmission housing.

Final Drive Installation
Left Hand Final Drive Installation:

X Y
M94700
3. Install pinion shaft (Y) through brake plates and disks,

and into differential carrier.
4. Make sure mating surfaces of final drive and
transmission housing are clean and dry. Apply a bead of
M94693 LOCTITE™ 515 sealant to the flanges of the final drive
1. Install a new differential lock shaft seal (X) into final housing.
drive housing.

M94688
2. Remove pinion shaft (Y) from final drive assembly.
IMPORTANT: Avoid damage! Be sure that pinion

shaft bottoms out in brake plates and disks before
installing final drive assembly. Damage to final
drive, brake parts, and differential may result from
MX9857
improper installation.
5. Install final drive onto transmission housing and retain
with eight cap screws (W). Apply Loctite® 515 to cap
screws. Tighten cap screws to 305 N•m (225 lb-ft).

E M
I
G
J
MX9856 MX9816
6. (eHydro Model) Install differential lock lever (G) onto 10.Attach lower brake rod (N) to brake lever. Retain with
shaft. Retain with roll pin. cotter pin and washer.
7. (eHydro Model) Attach differential lock rod (F) to 11.Side Mount Parking Brake Only: Attach park brake rod
differential lock lever. Retain with washer and cotter pin (E). to brake lever hole (M). Retain with clip pin.
8. Install brake lever (J) onto brake shaft. Retain with roll 12.If not attached: Install brake return spring (L) to brake
pin (I). lever and ROPS cap screw.
NOTE: Install brake spring (L) on front inside cap Right Hand Final Drive Installation:
screw before securing cap screw with nut.

O
M94706
MX9850
1. Install a new differential lock shaft seal (Z) into final drive
9. Align ROPS base plate on final drive housing. Install housing.
lower support plate and retain with eight cap screws (O)
and nuts. Tighten cap screws and nuts to specification. IMPORTANT: Avoid damage! Be sure that pinion
shaft bottoms out in brake plates and disks before
Torque Specification:
installing final drive assembly. Damage to final
Cap Screws and Nuts. . . . . . . . . . . . 305 N•m (225 lb-ft) drive, brake parts, and differential may result from
improper installation.

T
R
MX11584
M94705
5. (SST and ePowrReverser Model) Install differential lock
2. Install pinion shaft through brake plates, disks, and lever (S) onto shaft. Retain with roll pin (T).
differential lock collar, and into differential carrier.
6. (SST and ePowrReverser Model) Attach differential lock
3. Make sure mating surfaces of final drive and rod (R) to differential lock lever. Retain with cotter pin (Q)
transmission housing are clean and dry. Apply a bead of and washer.
LOCTITE® 515 sealant to the flanges of the final drive
housing. 7. Install brake lever (V) onto brake shaft. Retain with roll
pin (U).
c CAUTION: Avoid Injury! Final drive/axle NOTE: Install brake spring (L) on front inside cap
screw before securing cap screw with nut.
cap screws securing final drive to O
MX9850
MX9857 8. Align ROPS base plate on final drive housing. Install

4. Install final drive onto transmission housing and retain lower support plate and retain with four cap screws (O) and
with eight cap screws (W). Apply Loctite® 515 to indicated nuts. Tighten to 340 N•m (250 lb-ft).
(arrow) cap screw. Tighten cap screws to 305 N•m (225 lb-
ft).

3. Remove pinion shaft (B) from bearing.
4. Using a press, remove axle shaft from final drive
housing.
MX9816
9. Attach lower brake rod (N) to brake lever. Retain with YZ4354
clevis pin or pin, cotter pin, and washer.
5. Remove three cap screws (C) and seal retainer plate.
10.Side Mount Parking Brake Only: Attach park brake rod
to brake lever hole (M). Retain with clip pin.
11.If not attached: Install brake return spring (L) to brake
lever.
Final Drive Disassembly, Inspection and

Assembly
Disassembly:
NOTE: Hydrostatic model left hand final drive is shown
in the following story. Right hand drive disassembly,
inspection and assembly is basically the same.
1. Remove final drive to be serviced from the machine.
See “Final Drive Removal” on page 662.
M94690
6. Remove and replace seal. Inspect bearings for smooth

operation, excessive wear, or damage. Replace as
required, using a suitable puller.
D E
M94688
2. Remove snap ring (A) retaining gear to axle shaft.

Remove gear. YZ4355

7. Inspect bearings (D & E) for wear or damage. Replace if
necessary, using a suitable puller.
A
M94693
M94797
8. Remove differential lock shaft seal (F).
4. If not already done, remove differential lock collar (A).
Assembly: 5. Remove right hand brake/differential lock collar housing.
Parts are assembled in the reverse order of disassembly,
except for the differential lock shaft seal.
Install differential lock shaft seal after axle assembly
installation.
IMPORTANT: Avoid damage! Replace O-rings and

seals. Used O-rings and seals will leak.
• Lubricate bearings with transmission oil before installing

into housing.
Differential
Removal: M94798
1. Remove right hand final drive. See “Final Drive 6. Remove shims.
Removal” on page 662.
2. Remove brake assembly. See “Brake Disassembly and
Inspection” in the Brakes section.
3. Remove differential lock fork. See “Differential Lock
M94799
7. Remove differential carrier (B) from left pinion shaft and


Disassembly:
E
C
M94800 M94802
1. Remove bearing (C) from differential. 5. Remove eight cap screws (E).
6. Using a plastic mallet, separate ring gear from
IMPORTANT: Avoid damage! DO NOT spin differential housing.
bearing using compressed air. Damage to
2. Inspect bearing for smooth operation, wear, or damage.

F
D
M94803
7. Locate pinion shaft retaining pin (F). Heat retaining pin

and differential carrier to melt thread locking adhesive.
Remove pin.
G
M94801
3. Remove bearing (D).

bearing using compressed air. Damage to
4. Inspect bearing for smooth operation, wear, or damage.

NOTE: Cap screws retaining ring gear to differential
housing are held in place with LOCTITE®
M94804
8. Remove pinion shaft (G) from differential housing.

Differential Lock Removal and Installation
Removal:
I 1. Remove rockshaft assembly. See “Rockshaft Removal
and Installation” on page 757.
2. Remove right hand final drive assembly. See “Final
Drive Removal” on page 662.
H
J A
D
M94806
C
9. Rotate bevel gears (H) and remove differential pinion
gears (I) and cupped pinion washers (J) from differential
housing.
MX9856
H
3. (eHydro Model) Remove cotter pin (A) and washer and
disconnect differential lock rod (B) from differential lock
lever (C).
4. (eHydro Model) Remove roll pin (D) and differential lock
lever from shaft.
5. Remove rear PTO shafts and gears. See “Rear PTO
K Removal and Installation” on page 684.
H 6. Remove PTO clutch/brake assembly. See “PTO Clutch
and Brake Removal and Installation” on page 698.
M94807
10.Remove two bevel gears (H) and two thrust washers (K)
F
from differential housing.
G
11.Clean all components in a suitable solvent.
12.Inspect all parts for wear or damage. Replace as
required.
Assembly:
E
Assembly of the differential is the reverse of disassembly.
• Apply LOCTITE® 277 to threads of pinion shaft
retaining pin.
• Apply LOCTITE® 277 to threads of ring gear retaining
cap screws. YZ4270
• Tighten 10 mm ring gear retaining cap screws to 68 N•m 7. Remove roll pin (E) from right hand side of shift fork.
(50 lb-ft). NOTE: Spring is under tension.
• Adjust backlash of differential. See “Differential
8. Remove roll pin (F) from left hand side of spring.
Backlash Adjustment” on page 633.

9. Remove remaining roll pin (G) between spring and shift Installation:
fork.
Installation of the differential lock fork is the reverse of
removal.
IMPORTANT: Avoid damage! Note the number of
shims and their location on either side of snap
A
ring (H) to aid in reassembly.
B
H
M94795
10.Slide shaft to right, and remove from differential

housing.
11.Remove washer, spring, and shift fork from center of
differential housing. Remove shift collar from right hand
side of differential housing.
MIF
NOTE: When installing shims, adjust shift fork (A) so

that there is approximately 0.51 - 2.0 mm (0.020 - 0.080
in.) (B) of space between the differential carrier (C) and
the shift collar (D).

POWER TRAIN - FINAL DRIVE PTO COMPONENT LOCATION
PTO Component Location
PTO Assembly
A
C D
H
B G
F
A
I
J
D
MX11856
A - O-Ring
B - Tube
C - Ball
D - Cap Screw (4)
E - Bore Sleeve (non-serviceable)
F - Bearing
G - Snap Ring
H - Washer
I - Cap Screw
J - Tube
K - Bearing Retainer
L - Dowel (2)
M - Snap Ring
Power Train - Final Drive PTO Component Location - 673

PTO Clutch and Brake
O
M N
L
K
J
I
H
F
E
D
C
B
G
Q
R
S
T
W D
F E
MX9683 Q - Hub
A - Bearing (2) R - Snap Ring
B - Hub S - Bearing
C - Bearing T - Snap Ring
D - Snap Ring (2) U - Pin (4)
E - End Plate (2) V - Shaft and Basket
F - Separator Plate (6) W - Ball (Non-Serviceable)
G - Friction Disk (7)
H - Backup Plate
I - Belleville Spring
J - Snap Ring
K - Spring Retainer
L - Spring
M - O-Ring
N - Piston
O - O-Ring
P - Seals (3)

Rear PTO
J
I L
K
N
O
B
A
M95035
A - Bearing
B - Snap Ring
C - Gear 67T
D - Shaft
E - Bearing
F - Shaft with Gear
G - Bearing
H - Seal
I - Cover
J - Cap Screw (10 Used)
K - Seal Cover
L - Shoulder Bolt (2 Used)
M - Sight Glass
N - Plug
O - Cap Screw (2 Used)
P - Bushing (2 Used)

2-Speed PTO (European)
N
M
P
L O
A
K
B
Q
C R
J
S
I
AL
H
D
D G R
AK AI E
AJ AH
F
AG V
G U
AF G
W T
AE
X
AD F
X
AC Y
Z
AA
AB
M95037 U - O-Ring
A - Lever V - Seal
B - Cap Screw W - Gear 67T
C - Shaft X - Bearing
D - Spring Pin Y - Gear 50T
E - Cap Z - Pinion Shaft
F - Snap Ring AA- Shift Collar
G - Bearing AB- Thrust Washer
H - Thrust Washer AC- Bearing
I - Pinion Shaft AD- Gear 65T
J - Bearing AE- Shaft
K - Detent Shaft AF- Lever
L - Snap Ring AG- Shift Fork
M - Cover AH- Spring
N - Cap Screw AI - Ball
O - Seal Cover AJ- Dowel Pin
P - Shoulder Bolt AK- Lever
Q - Sight Glass AL- O-Ring
R - Cap Screw
S - Plug
T - Bushing

Mid PTO
E
D
K
B
L
M
N
A
O
P
MX9733
A - Shoulder Bolt (2)

B - Plate
C - Cylinder
D - O-Ring
E - O-Ring
F - Piston
G - Spring
H - Shift Fork
I - Pin
J - Housing
K - Bearing
L - Gear
M - Snap Ring
N - Bearing
O - Snap Ring
P - Shaft
Q - Seal

Mid PTO Drive Shaft
D I
F J
H
G
E
D
C
B
A
N
R
S L
T P
O
MX9734
A - Cap
B - Shaft
C - Spring Pin
D - Thrust Washer (2)
E - Needle Bearing
F - Gear 27T
G - Bearing
H - Snap Ring
I - Plug
J - Cap Screw
K - O-Ring
L - Bearing (2)
M - Snap Ring
N - Gear
O - Shaft
P - Shaft with Gear
Q - Gear
R - Bearing
S - Snap Ring
T - Plug

POWER TRAIN - FINAL DRIVE PTO THEORY OF OPERATION
PTO Theory of Operation
Power Transmission - PTO Clutch and Brake
A B
Pressure Oil
F D E
Lube Oil
MIF When the operator pulls the PTO switch to the ON position,
the hydraulic control valve is activated and supplies
Function: pressure oil (C) to the PTO clutch. The PTO clutch piston is
The PTO clutch (A) provides a means for disengaging the moved forward by the hydraulic pressure. As the piston
PTO output shaft from the engine. The PTO brake (B) is moves forward, the spring pressure applied to the brake by
provided to positively stop the rotation of the PTO system the piston, through the four pins (E), is removed and
when the PTO clutch is disengaged. The PTO clutch and disengages the brake. At the same time, the piston (D) is
PTO brake work simultaneously. Both mid and rear PTO applying pressure to the PTO clutch pack and engaging the
are affected by the operation of the PTO clutch and PTO PTO clutch. The pressure applied to the clutch pack locks
brake. the plates (splined to the clutch basket (F)), to the friction
plates (locked to the clutch hub (G)). Power is transferred
Theory: from the input shaft to the clutch hub, through the friction
The PTO clutch is engaged or disengaged by the operator plates and separator plates to the clutch basket, and finally
through an electrical switch. The PTO brake is to the PTO drive shaft (H).
automatically applied by a spring when the PTO clutch is A locking tab on the outside of the brake hub allows the
disengaged. PTO drive shaft to rotate approximately 300°, which, in turn
The PTO brake (B) is a spring loaded multi-plate wet brake allows the PTO stub shaft to rotate approximately 63° to aid
and is normally engaged, preventing the PTO clutch shaft in aligning the splines of an attachment drive shaft during
from rotating. The PTO clutch is a multi-plate wet clutch hook-up.
and is normally disengaged.
Power Train - Final Drive PTO Theory of Operation - 679

Power Transmission - Rear PTO
14 Tooth Gear
PTO Drive Shaft
PTO Pinion Shaft
(From Clutch/Brake
Unit)
67 Tooth Gear
PTO Stub Shaft
50 Tooth Gear
Idler Shaft
Input Power
PTO Power
Mid PTO Power Transfer
MIF rotates in a clockwise direction. The rear PTO always turns

clockwise when looking at the end of the PTO shaft from
Function: the rear of the machine. The rear PTO runs independently
The rear PTO provides a means for transferring engine of the machine forward or rearward motion, or rate of travel.
power to rear mounted attachments. Speed of the PTO is dependent on engine RPM. The rear
PTO is limited to 580 RPM at maximum engine speed.
Theory:
Power is provided to the PTO gear power train through PTO
clutch and PTO drive shaft. Power is not transferred until
the operator pulls the PTO switch. See “Power
Transmission - PTO Clutch and Brake” on page 679. The
PTO drive shaft turns in a counter-clockwise direction and
is coupled directly to the PTO pinion shaft. The PTO pinion
shaft is a shaft and 14 tooth gear machined as a single
part. This 14 tooth gear is in constant mesh with the 67
tooth gear which is splined to the PTO stub shaft, and

Power Transmission - 2-Speed PTO (European)
14 Tooth Gear
18 Tooth Gear
PTO Shaft (From

Clutch/Brake Unit)
PTO Pinion Shaft
67 Tooth Gear
PTO Stub Shaft
65 Tooth Gear
Shift Collar
Idler Shaft Input Power

Power Transfer (750 RPM)
Power Transfer (540 RPM)
50 Tooth Gear
PTO Power
Mid PTO Power Transfer
MIF When the operator moves the PTO speed control lever
from the center (neutral) position to the HIGH or LOW
Function: position, it moves the shift collar through a mechanical
The rear PTO provides a means for transferring engine linkage. The shift collar couples the PTO stub shaft to the
power to rear mounted attachments. 65 tooth gear, transferring power from the pinion shaft,
through the gear to the shift collar, and to the stub shaft.
Theory:
The rear PTO always turns clockwise when looking at the
Power is provided to the PTO gear power train through PTO end of the PTO shaft from the rear of the machine. The rear
clutch and PTO drive shaft. Power is not transferred until PTO runs independently of the machine forward or
the operator engages the PTO lever See “Power rearward motion, or rate of travel. Speed of the PTO is
Transmission - PTO Clutch and Brake” on page 679. The dependent on engine RPM. The rear PTO is limited to 580
PTO drive shaft turns in a counter-clockwise direction and RPM at maximum engine speed (low speed) and 800 RPM
is coupled directly to the PTO pinion shaft. The PTO pinion (high speed).
shaft is a shaft with a 14 tooth, and 18 tooth gear machined
as a single part. The 14 tooth gear is in constant mesh with
the 67 tooth gear. The 18 tooth gear is in constant mesh
with the 65 tooth gear. Both the 65 and 67 tooth gears
rotate freely on the PTO stub shaft. Power is not transferred
to the PTO stub shaft until the shift collar is moved to
engage one of the two gears.

Power Transmission - Mid PTO
Cylinder 14 Tooth Gear

(Solenoid Operated)
PTO Drive Shaft
Shift Fork
67 Tooth Gear
Rear PTO Stub Shaft
25 Tooth Gear
SIDE VIEW
Mid PTO
Stub Shaft
25 Tooth Gear
50Tooth Gear
Idler Shaft
27 Tooth Gear
25 Tooth Idler Shaft

Gear
Input Power Mid PTO

TOP VIEW Rear PTO Power Drive Shaft
17 Tooth Gear
Mid PTO Power Transfer SIDE VIEW
Mid PTO Power
MIF mesh with the 67 tooth gear, and is in constant mesh with
the 17 tooth gear on the mid PTO drive shaft. The mid PTO
Function: drive shaft rotates in a clockwise direction. Power is
The mid PTO provides a means for transferring engine transmitted through the mid PTO drive shaft to the 25 tooth
power to mid mount attachments such as a mower deck. It gear, which is splined to the drive shaft, and is in constant
also provides a means for engaging and disengaging mesh with the 27 tooth gear. The 27 tooth gear is splined to
engine power to the mid PTO stub shaft. the PTO stub shaft and rotates in a clockwise direction.
When the operator selects the mid PTO; a shift fork moves
Theory:
the 25 tooth gear, which is splined to the PTO stub shaft, to
Power is provided to the mid PTO through the 67 tooth gear the rear-most position, engaging the teeth of the 27 tooth
which is splined to the rear PTO shaft and rotates in a gear, and allowing power to be transmitted from the 27
clockwise direction. See “Power Transmission - Rear PTO” tooth gear, through the 25 tooth gear, and to the mid PTO
on page 680. Power is not transferred until the operator stub shaft.
engages PTO lever. See “Power Transmission - PTO Clutch
and Brake” on page 679. A 50 tooth gear is in constant

POWER TRAIN - FINAL DRIVE PTO TROUBLESHOOTING
PTO Troubleshooting Symptom: 2 Speed PTO Problems
Troubleshooting Table worn / no longer serviceable.
Symptom: Rear PTO Problems Yes - Gears and/or bearings worn / no longer
serviceable.
(1) Rear PTO Will Not Engage
Yes - 2 speed shift linkage worn or damaged.
Yes - PTO clutch damaged or worn / no longer
serviceable. (2) 2-Speed PTO Will Not Stay Engaged?
Yes - Cogs on gear or shift collar damaged or Yes - Cogs on gear or shift collar damaged or
worn / no longer serviceable. worn / no longer serviceable.
Yes - Gears and/or bearings worn / no longer Yes - Detent ball spring broken (Region II, 2-
serviceable. Speed PTO).
Yes - Oil pressure not sufficient to PTO clutch.
Shaft seal or piston)-ring leaking.
(2) Rear PTO Will Not Stay Engaged?
Yes - Detent ball spring broken (Region II, 2-
Speed PTO).
(3) Rear PTO Slips?
Yes - PTO clutch damaged or worn / no longer
serviceable.
Yes - Oil pressure not sufficient to PTO clutch.
Shaft seal or piston)-ring leaking.
(4) Rear PTO Noisy?
Yes - Gears and/or bearings worn / no longer
serviceable.
(5) Rear PTO Does Not Stop Quickly Enough
When Disengaged?
Yes - PTO brake worn / no longer serviceable.
Symptom: Mid PTO Problems

(1) Mid PTO Does Not Engage?
Yes - Gears and/or bearings worn / no longer
serviceable.
Yes - Hydraulic cylinder for mid PTO not operating.
(2) Mid PTO Will Not Stay Engaged?
Symptom: 2 Speed PTO Problems

(1) 2-Speed PTO Will Not Engage?
Power Train - Final Drive PTO Troubleshooting - 683

POWER TRAIN - FINAL DRIVE PTO REPAIR
PTO Repair
Rear PTO Removal and Installation

Removal:
D D
1. Park machine on a level surface, shut off engine, and
set park brake.
2. If necessary, remove center lift link, draft arms, and
adjustable draft links.
A M94711
7. Remove four cap screws (D) and rear PTO shield

support bracket.
NOTE: Top center and bottom center cap screws in
rear cover are longer.
M94710
3. Remove two cap screws (A), spacers, nuts, and rear

E
PTO shield assembly.
4. Remove drawbar.
MX9735
5. Remove two cap screws (B) and rear draw bar bracket M94711
(C). 8. Remove eight cap screws (E).
NOTE: Capacity of the hydraulic system is 9. If necessary, loosen two rear most cap screws attaching
approximately 26 liters (6.8 gal) for eHydro models; or final drive housings to differential housing (arrows).
24 liters (6.3 gal) for SST and ePowrReverser models.
10.Gently pry around edges of cover to break sealant.
6. Drain hydraulic oil from transaxle. Wobble shaft and pull at the same time to remove rear
cover, shafts and gears as a unit.
Power Train - Final Drive PTO Repair - 684

NOTE: If equipped, mid PTO shaft may come out of
differential housing with rear cover, or may fall into
Installation:
IMPORTANT: Avoid damage! Replace all O-rings,

gaskets, and seals. Used or damaged O-rings,
gaskets and seals will leak.
• Thoroughly clean mating surfaces of rear cover and

transmission housing to remove all traces of old sealant.
• If machine is equipped with two speed PTO, place shift M94731
arm in forward position when installing. Make sure shift fork 4. Remove mid PTO shaft from bottom of differential
pin engages shift arm yoke. housing. When shaft is removed, gear may fall into
• Lay a bead of TY16021 Sealant on flange surfaces of differential housing. Retrieve gear and install on front end
differential housing. of shaft.
• Two longer cap screws are placed in the top center and Installation:
bottom center holes.
• If machine is equipped with a mid PTO, follow steps
outlined below.
• Tighten cap screws retaining rear cover to 40 N•m (30 A
lb-ft).
Mid PTO Equipped Machines:
G I
YZ4363
1. Remove cup plug, snap ring (A) and bearing from rear
F PTO cover.
2. Inspect bearing for wear or damage. Replace if needed.
MX9736
1. Disconnect hydraulic line (F) from mid PTO cylinder.

2. Remove five cap screws (G) and mid PTO gear box (H)
from right side of differential housing. Disconnect oil line (I)
if it interferes with removal of housing (H).
3. Remove rear PTO cover as outlined on previous page.

6. Apply form-in-place gasket to rear cover.
YZ4365
• Removal:
a. Remove cup plug.
b. Remove snap ring.
c. Remove bearing from front of differential housing.
• Installation:
a. Install new bearing from front of differential housing.
b. Install snap ring.
c. Install cap plug. YZ4361
7. Install cover with shafts and gears as an assembly into

differential housing. Do not install cap screws at this time.
YZ4367
3. Install mid PTO shaft assembly into differential housing.

4. Install shaft and gear into front bearing in differential
case.
NOTE: Cap screw will be used to align the mid PTO
shaft into the designated hole of the rear cover.
YZ4357
8. Guide mid PTO shaft into rear cover, using cap screw.
Simultaneously, press mid PTO bearing into rear cover until
bearing bottoms out in bore, using suitable driver.
YZ4358
5. Insert M6 cap screw (A) to end of shaft.

11.Install PTO guard support (C) and ten cap screws (D).
Install the two longer cap screws (E) in the location shown.
Tighten all cap screws to 40 N•m (30 lb-ft).
12.If loosened, tighten two rear most cap screws attaching
final drive housings to differential housing (arrows).
13.Clean mating surfaces of mid PTO gear case and
14.Lay a bead of TY16021 Sealant on flange surfaces of
15.Install mid PTO gear case to differential housing, and
retain with five cap screws. Tighten cap screws to 55 N•m
(40 lb-ft).
YZ4366
9. Install snap ring. 16.Connect hydraulic lines.
Rear PTO Shafts and Gears Disassembly and

Assembly
NOTE: For 2-speed PTO disassembly procedure, See
“2-Speed PTO Shafts and Gears Disassembly” on
page 690.
1. Remove rear PTO drive shaft and gears as an
assembly.
C
YZ4364
10.Apply permaflex sealant to OD of cup plug and install

plug into rear cover.
YZ4356
D
2. Remove pinion shaft (A).
D
E
M94711

6. Inspect 67 tooth gear for wear or damage. Replace if
needed.
7. Inspect outer output shaft bearing for smooth operation,
wear or damage. Replace if needed.
M94713
3. Remove cap screw (B) from cover that retains the idler
shaft (C). Remove idler shaft, 50 tooth gear, and bearings
as an assembly. M94715
8. Remove O-ring (E) from end of idler shaft. Remove

67T gear.
YZ4359
4. Using a plastic mallet, remove output shaft (D), 67 tooth

gear, and bearings from rear cover.
M94716
9. Remove bearings from gear. If necessary, remove snap

ring (F). Inspect bearings for smooth operation, wear or
damage. Replace if needed.
YZ4360
5. Inspect inner output shaft bearing for smooth operation,

wear or damage. Replace if needed.

Assembly:
G IMPORTANT: Avoid damage! DO NOT spin

bearing using compressed air. Damage to bearing
balls, cage, and races could result.
NOTE: Before beginning assembly, be sure that all

components are clean, and in good condition.
IMPORTANT: Avoid damage! Use liberal amounts

of transmission oil to lubricate components as
they are assembled. DO NOT use grease or other
heavy lubricants unless they are specifically
called for.
M94722
10.Remove two screws and seal retainer (G). 1. Clean mating surface of rear cover to remove old gasket
material.
11.Using a suitable seal driver, remove seal.
IMPORTANT: Avoid damage! If sight glass is

removed, it must be installed so that the holes are
vertical and horizontal (see alignment lines in
photo above).
12.If removed, install sight glass.

• Apply pipe thread sealant to gauge.
NOTE: DO NOT back off more than 1/2 turn for
orientation.
• Install sight glass into rear cover with openings for
sight glass at top and bottom.
• Tighten gauge to 48 - 72 N•m (36 - 54 lb-ft). M94728
2. Install bearings and snap ring into 50 tooth gear.

H
gaskets, and seals will leak.
M94729
13.Inspect pinion shaft bearing (H) in cover for smooth

operation, wear or damage. Replace if needed.
M94715
3. Install idler gear onto idler shaft.

4. Install a new O-ring (E) onto idler shaft.

8. Install output shaft, gear and bearings into cover as an
assembly. Use care to avoid damaging shaft seal.
YZ4360
M94713
5. If removed, install snap ring (I) onto output shaft. Install
67 tooth gear against snap ring. 9. Install seal retainer (G) and secure with two cap screws.
A
H
C
YZ4356
10.Install idler shaft (C) and gear into cover. Retain with
cap screw.
M94729
11.Install pinion shaft (A) into cover.
6. If removed, install pinion shaft bearing (H) into cover.
NOTE: Check shafts to ensure that they are properly
7. Using a suitable driver, install a new PTO shaft seal (J) installed in cover; if bearings are not fully seated in
in cover. cover, cover may break when PTO is installed onto
transmission housing and attaching cap screws are
tightened.
2-Speed PTO Shafts and Gears Disassembly

NOTE: The following procedure is for a machine
equipped with a mid-PTO. Machines not equipped with
a mid-PTO are similar.
1. Remove rear PTO drive shaft and gears as an
assembly. See “Rear PTO Removal and Installation” on
page 684.
YZ4359

YZ4428
4. Remove idler shaft (C) and gear as an assembly.

YZ4426
2. Remove pinion shaft. D
M94715
5. Remove O-ring (D) from end of idler shaft. Remove

gear.
B
YZ4427
3. Remove cap screw (B) from cover that retains the idler
shaft.
M94716
6. Remove bearings from gear. If necessary, remove snap

ring (E). Inspect bearings for smooth operation, wear or
damage. Replace if needed.

I H
M94717
7. (Mid PTO Equipped Machines) Remove roller bearing

from bottom hole in cover. Inspect bearing for smooth
operation, wear, or damage. Replace as necessary.
M94720
F
10.Remove shift shaft (H), ball, and spring from shift fork. If
necessary, remove snap ring (I).
M94718
8. If necessary, remove snap ring (F) from hole in cover.
M94721
11.Using a plastic mallet, remove PTO stub shaft and gears

from cover as an assembly.
M94719
9. Slide shift collar up and remove 2-speed shift fork and

shaft (G) from cover.
NOTE: Ball and spring in shift fork may jump and be
lost. Use care when removing shift shaft from fork.

M94722
12.Remove two screws and seal retainer (J). YZ4430
13.Using a suitable seal driver, remove seal. 15.Remove washer (L) and gear from shaft.
NOTE: If sight glass is removed, it must be installed so
that the holes are vertical and horizontal (see M
alignment lines in photo above).
K
YZ4431
16.Remove shift collar (M).
YZ4429
14.Using a suitable puller, remove bearing (K) from end of

PTO shaft. Inspect bearings for smooth operation, wear or
YZ4432
17.Remove bearing from drive end of shaft. If necessary,

clean surface of shaft to remove paint for easier bearing
removal. Inspect bearing for smooth operation, wear or

20.Remove pinion shaft bearing (O) from cover. Inspect
bearing for smooth operation, wear or damage. Replace if
needed.
N 2-Speed PTO Shafts and Gears Assembly
P
YZ4433
18.Remove washer (N). Remove large gear and bearings

as an assembly.
M94730
1. Using a suitable driver, install a new PTO stub shaft seal

(P) into rear cover until flush with outer surface.
M94728
19.Remove bearings from gear. Inspect bearings for

smooth operation, wear or damage. Replace as necessary.
M94722
O 2. Install seal retainer plate (J) to rear cover, secure with

two screws.
IMPORTANT: Avoid damage! If sight glass is

removed, it must be installed so that the holes are
vertical and horizontal (see alignment lines in
photo above).
3. If removed, install sight glass.

• Apply pipe thread sealant to gauge.
NOTE: DO NOT back off more than 1/2 turn for
orientation.
• Install sight glass into rear cover with openings for
sight glass at top and bottom.
• Tighten gauge to 48 - 72 N•m (36 - 54 lb-ft).
M94729

YZ4433
7. Install 67 tooth gear and washer (N) onto stub shaft.

M94729
4. Install pinion shaft bearing (O) into rear cover.
M94717 YZ4432
5. If equipped, install mid-PTO roller bearing into rear 8. Install bearing.

cover.
YZ4431
M94728 9. Install shift collar (M) onto 67 tooth gear.

6. Install bearings and snap ring into 67 tooth gear.

YZ4430
10.Install 65 tooth gear and washer (L) onto stub shaft.
M94721
12.Install stub shaft and gears into rear cover.
YZ4429
M94720
11.Install bearing (K) onto end of stub shaft.
13.Assemble shift shaft, ball, and spring into shift fork.

17.Install a new O-ring (D) onto idler shaft.
G
YZ4428
M94719
14.Slide shift collar up, and slide shift fork into groove on
collar. Install shift fork and shaft (G) as an assembly into
rear cover.
YZ4427
18.Install idler shaft (C) with gear into rear cover. Retain
with cap screw (B). Tighten cap screw to 55 N•m (40 lb-ft).
M94716
A
15.Install bearings and snap ring (E) into idler gear.
YZ4426
19.Install pinion shaft (A) into rear cover.

M94715 20.Install drive shaft and gears to machine. See “Rear PTO
16.Install idler gear onto idler shaft. Removal and Installation” on page 684.

PTO Clutch and Brake Removal and
Installation
Removal:
1. Remove rear PTO drive shaft and gears. See “Rear
PTO Shafts and Gears Disassembly and Assembly” on
page 687.
2. If equipped, remove 2-speed PTO shift shaft.
3. If not already done, remove PTO stub shaft.
YZ4371
6. Disconnect and remove hydraulic line and fitting from

differential housing. Inspect O-rings on fitting and replace if
needed.
YZ4362 YZ4372
4. Remove spacer from PTO drive shaft.
YZ4373
7. Remove PTO pressure tube.

8. Remove and replace O-rings on PTO pressure tube.
YZ4369
5. Remove cap screw and lube tube.
YZ4370
YZ4368
9. Remove four cap screws and bearing plate assembly.

YZ4375
12.Inspect bearing for wear or damage. Replace if needed.

If replacing bearing, remove snap ring.
YZ4374
10.Inspect stop on bearing plate for damage. Replace

plate, if necessary.
YZ4377
13.Remove PTO clutch and brake assembly.
YZ4376
11.Inspect bore sleeve for wear or damage. Replace if

needed.
YZ4378
14.Remove PTO input hub.

NOTE: PTO drive shaft may come out of tunnel with
PTO clutch and brake assembly.
15.Remove PTO drive shaft.

PTO Clutch and Brake Installation: 2. Install PTO clutch/brake assembly into differential
housing.
The procedure outlined below can be performed without
removing the rockshaft, as long as the technician uses care
and precision during assembly. Otherwise, removal of the
rockshaft may be necessary to install the PTO clutch and
brake assembly. See “Rockshaft Removal and Installation”
in the Hydraulic section.

YZ4551
1. Install PTO drive shaft into PTO input hub and clutch/
brake assembly.
NOTE: The PTO clutch/brake assembly consists of the
PTO drive shaft, PTO input hub and PTO clutch and
brake assembly.
It may be necessary to turn the engine flywheel to
rotate the PTO drive shaft to align the splines of the
drive shaft with the splines of the input shaft.
YZ4460 and YZ4452
3. Measure the distance (A) between the end of the PTO

clutch/brake shaft and the front surface of the differential
housing to make sure the PTO brake/clutch assembly is
completely installed.
The PTO Clutch/Brake Shaft End to Differential Housing
Front Surface measurement should be within specification.
Measurement “A”. . . . 98.54 - 103.1 mm (3.88 - 4.06 in.)
IMPORTANT: Avoid damage! DO NOT back out

once you have started installing the bearing
plate. You may run the risk of pulling the PTO
clutch/brake assembly out which would mean
reinstalling the PTO clutch/brake assembly.
YZ4459 and YZ4377

YZ4370
8. Install and connect hydraulic line to fitting. Tighten to

specification
YZ4368
4. Install bearing plate assembly.

5. Apply medium strength threadlock to cap screws.
Tighten cap screws retaining bearing plate to specification.
IMPORTANT: Avoid damage! Apply oil liberally to

the pressure tube O-rings before installing.
YZ4369
9. Install lube tube. Apply medium strength threadlock to

cap screw. Install and tighten cap screw to specification.
YZ4372
6. Install PTO pressure tube. YZ4362
10.Install spacer to PTO drive shaft.

11.Install rear PTO drive shaft and gear cover assembly.
Specifications:
Bearing Plate Cap Screws. . . 60 - 88 N•m (43 - 65 lb-ft)
Fitting to Differential Housing 16 - 24 N•m (12 - 18 lb-ft)
Hydraulic Line to Fitting
YZ4371 . . . . . . . . . . . . . . . . . . . 12.8 - 18.4 N•m (113 - 122 lb-in.)
7. Install fitting and tighten to specification. Lube Tube Cap Screw . . . . . . 9 - 11 N•m (80 - 97 lb-in.)

PTO Input Hub Disassembly and Assembly
c CAUTION: Avoid injury! Use extreme
caution when removing snap ring
YZ4383
2. Remove snap ring.

YZ4379
3. Remove brake hub.
Inspect hub and bearings for wear or damage. Replace, if
needed, using suitable driver.
PTO Clutch and Brake Disassembly and

Assembly
• JDG1650 Spring Compressor YZ4386
Procedure: 4. Inspect bearing and snap ring. Replace, if needed,

using suitable driver.
5. Turn assembly over.

caution when removing snap ring.
YZ4384
1. Remove three seal rings.


extreme pressure. Use caution when
compressing spring and removing snap
ring.
YZ4382
6. Remove snap ring. YZ4381
9. Install spring compressor and compress spring.

YZ4388
11.Release and remove spring compressor. Remove

YZ4387
spring retainer and spring.
7. Turn assembly over and remove clutch.
8. Inspect bearing for wear and damage and replace, if
needed. Use suitable puller and driver, if replacing.

YZ4380
12.Apply air to PTO clutch/brake shaft to release piston.

Remove piston. YZ4389
14.Remove four pins. Inspect for damage and replace if

needed.
15.Turn assembly over.
YZ4288
13.Remove and replace inner and outer O-ring of piston.

Inspect piston for damage. Replace if necessary.
YZ4390

YZ4290
19.Inspect and measure each wavy friction plate and

replace if plate is damaged or less than 3.27 mm (0.129
in.) thick.
YZ4391
YZ4293
20.Inspect backup plate and retainer plate for wear or

damage. Replace, if necessary.
YZ4392
17.Turn assembly over and remove brake pack.
YZ4291
18.Inspect and measure each separator plate and replace

if plate is burned, worn or less than 1.92 mm (0.0756 in.)
thick.
YZ4398
21.Inspect the clutch basket assembly for wear or damage.

Replace, if necessary.
Specification (Minimum Thickness):

Separator Plates . . . . . . . . . . . . . . . 1.92 mm (0.0756 in.)
Friction Plates. . . . . . . . . . . . . . . . . . 3.27 mm (0.129 in.)
Assembly:
YZ4392
1. Check and verify friction plate and separator plate YZ4454

thickness.
2. Install brake pack beginning with separator plate and
NOTE: Brake pack contains three separator plates and ending with friction plate.
three friction plates. Clutch pack contains four wavy
friction plates and three separator plates.
YZ4453
YZ4456
3. Install retainer plate.

4. Install retainer ring.

YZ4288
9. Lubricate and install inner and outer O-ring to piston.

Lubricate inside of piston, basket shaft and clutch basket to
avoid damage to piston O-rings.
YZ4457
5. Install brake hub assembly.

NOTE: Snap ring can not be installed until brake hub is
completely seated through all plates.
6. Install snap ring.
7. Turn assembly over.
YZ4397
10.Hand twist piston down on basket shaft until piston

bottoms out.
YZ4389
8. Lubricate and install pins.

NOTE: Check for free movement of pins in bores.

YZ4292
15.Check and verify belleville spring height to specification.

16.Install input hub assembly.
YZ4388
11.Install spring and spring retainer.

caution when compressing spring and
installing snap ring.
YZ4399
17.Install belleville spring with cup up.
YZ4381
12.Compress spring and spring retainer, using spring

compressor.
13.Install snap ring.
14.Release and remove spring compressor.

YZ4401
20.Install friction plate.
YZ4400
18.Install backup plate with flat surface up.
YZ4291
YZ4402
21.Install separator plate.

22.Repeat last two steps until all plates are installed.
YZ4290
19.Check and verify friction plate and separator plate

thickness.
IMPORTANT: Avoid damage! The friction plate is

the first and last plate installed.

YZ4405
YZ4403
25.Verify measurement.
23.Install retainer plate.

caution when installing snap ring.
YZ4458
26.Turn assembly over and lubricate and install three seal

rings to shaft.
YZ4404
24.Install snap ring. Specification:

Belleville Spring . . . 3.026 - 3.476 mm (0.119 - 0.137 in.)
IMPORTANT: Avoid damage! Make sure the input
Separator Plates (minimum) . . . . . 1.92 mm (0.0756 in.)
hub assembly has passed through all of the
clutch plates. A verification measure is about 7.9 Friction Plates (minimum) . . . . . . . 3.27 mm (0.1295 in.)
mm (5/16 in.) from the top of the hub spline to
the surface of the retainer plate.

Mid PTO Removal and Installation 1. Apply high flex form-in-place gasket compound to
mounting surface and PTO gear box.
Removal:
1. Remove rear cover, and rear PTO shafts and gears. See
“Rear PTO Removal and Installation” on page 684.
M94731
2. Remove mid PTO shaft from bottom of differential YZ4347

housing. When shaft is removed, gear may fall into 2. Install mid PTO gear box to right side of differential
differential housing. Retrieve gear. housing.
3. Install cap screws (A) and tighten to specification.
4. Install and connect hydraulic lines to mid PTO gear box.
A
YZ4358
5. Install mid PTO shaft assembly in bore at bottom of

YZ4347 differential housing.
3. Disconnect and remove hydraulic lines from mid PTO 6. Screw cap screw in end of mid PTO shaft to help with
gear box. the alignment of the mid PTO shaft assembly into the rear
cover.
4. Remove the cap screws (A) and mid PTO gear box from
right side of differential housing. 7. Install rear cover, and rear PTO shafts and gears. See
“Rear PTO Removal and Installation” on page 684.
Installation:
IMPORTANT: Avoid damage! Replace all O-rings, Mid PTO to Housing Cap Screws
gaskets, and seals. Used or damaged O-rings, . . . . . . . . . . . . . . . . . . . . . . . . . 36 - 44 N•m (27 - 33 lb-ft)
Hydraulic Line to Fitting
NOTE: Apply J20C or J20D to all O-rings, seals and . . . . . . . . . . . . . . . . . . . 12.8 - 18.4 N•m (113 - 122 lb-in.)

Mid PTO Disassembly and Assembly
Disassembly:
1. Remove mid PTO housing. See “Mid PTO Removal and
Installation” on page 711. H
YZ4408
4. Remove snap ring (H) from groove in mid PTO case.
YZ4406
2. Remove two screws (E) and seal retainer (F).
YZ4409
5. Remove shaft assembly.
YZ4407
3. Remove seal (G) from output shaft.
M94773
6. Remove snap ring (I) retaining bearing to shaft.

shaft. Inspect bearing for smooth operation, wear or
damage. Replace if necessary.
YZ4413
10.Remove cylinder and fitting.
YZ4410
8. Remove plug (J) from mid PTO gear box.
YZ4412
K 11.Inspect O-ring on cylinder and fitting. Replace if

necessary.
YZ4414
YZ4411
9. Tilt shift fork (K), and remove gear.

15.Remove and replace O-ring from piston. Inspect piston
and shift fork for wear or damage. Replace if needed.
NOTE: Press on OD of bearing.
YZ4416
12.Align pin hole to plug hole of gear box. Compress

spring, using a c-clamp or other suitable tool. M94719
16.Inspect bearing for smooth operation, wear or damage.

Assembly:
NOTE: Liberally lubricate all press-fit parts with
hydraulic oil to aid assembly.
YZ4415
13.Remove pin (L) from shift fork. Remove c-clamp.
YZ4415
YZ4417
14.Remove piston assembly from gear box.
YZ4419
1. Install spring on to piston.

YZ4418

2. Install piston and spring into mid PTO gear box.
3. Install shift fork onto piston. Note orientation of the shift
fork.
4. Using c-clamp and long pin punch, align shift fork pin
hole to mid PTO gear box plug hole and drive pin flush into
shift fork.
5. Remove c-clamp.
6. Apply lubricant to piston o-ring and end of piston shaft.
YZ4421
9. Tilt shift fork/drive gear assembly down into mid PTO

gear box and install shaft and bearing assembly into case
and drive gear.
YZ4420
7. Install drive gear onto shift fork. H
NOTE: Press on OD of bearing.
YZ4422
10.Install snap ring (H) to retain shaft and bearing

assembly to case.
M94773
8. Using a press, drive bearing onto shaft. Retain with

snap ring.
YZ4423
11.Install a new seal (G), using a suitable driver.

YZ4424
12.Install seal retainer (F) and secure with two screws (E).
13.Install and tighten cylinder assembly.
YZ4425
14.Install and tighten plug.

15.Install mid PTO assembly. See “Mid PTO Removal and
Installation” on page 711.

MFWD Drive Shaft (ePowrReverser and eHydro)
MX9692


HYDRAULICS TABLE OF CONTENTS
Rockshaft Leakage Test ............................ 751
Hydraulics
Table of Contents
Rockshaft Position Feedback Linkage
Adjustment................................................. 751
Repair............................................................ 752
Specifications ...............................................721 Rockshaft Filter Replacement.................... 752
Hydraulic Specifications .............................721 Hydraulic Gear Pump ................................ 752
Repair Specifications..................................722 Rockshaft Removal and Installation .......... 757
Torque Specifications.................................722 Rockshaft Disassembly and Assembly...... 758
Component Location and Schematics ......724 Rockshaft Lift Arms
Steering Pump Components, SST .............724 Removal and Installation ........................... 765
Steering Pump Schematic, SST.................725 Dual SCV Linkage ..................................... 769
Steering System Components, Dual SCV Disassembly and Assembly: ..... 770
ePowrReverser...........................................726 Hydraulic Cylinder Repair .......................... 772
Steering System Schematics,
ePowrReverser...........................................727
Steering System
Components, eHydro .................................729
Steering System
Schematics, eHydro ...................................730
SCV and Rockshaft
System Components ..................................732
SCV and Rockshaft
System Schematics....................................733
Manifold Block Schematics ........................735
Single SCV Schematics .............................736
Diverter Valve Schematic ...........................737
SST Hydraulic Operation............................738
ePowrReverser Hydraulic Operation..........739
eHydro Hydraulic Operation .......................740
PTO and MFWD Hydraulic Operation ........741
Main PTO Clutch Operation .......................742
Rockshaft Operation...................................744
Troubleshooting ...........................................745
Hydrostatic (eHydro) Troubleshooting........745
Diagnostics ...................................................746
Hydraulics...................................................746
Hydraulic System Bleed Procedure............747
Rate of Drop/Stop Valve Adjustment..........747
Lift Arms Adjustment ..................................747
System Pressure/Flow Test .......................748
System Pressure Adjustment .....................748
Steering Pressure Test...............................749
Lube Pressure Test - ePowrReverser ........749
Charge Pressure Test - eHydro .................749
Main PTO Clutch Pressure Test.................750
Rockshaft Lift Cycle Test............................750
Hydraulics Table of Contents - 719

HYDRAULICS TABLE OF CONTENTS
Hydraulics Table of Contents - 720

HYDRAULICS SPECIFICATIONS
Specifications
Hydraulic Specifications
Hydraulic Oil:
Capacity (SST and ePowrReverser Machines). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.8 L (6.3 gal)
Capacity (eHydro Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.7 L (6.8 gal)
4210 Machines (at Rated Engine RPM):

System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14650 kPa (2125 psi)
Steering Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10340 kPa (1500 psi)
Steering Pump Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 L/min (5.3 gpm)
Steering Pump Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 cm3/rev (0.549 cu in./rev)
Implement Pump Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.5 L/min (7.0 gpm)
Implement Pump Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9 cm3/rev (0.726 cu in./rev)
Total Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.5 L/min (12.3 gpm)
Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gear
4310 and 4410 Machines (at Rated Engine RPM):

System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17240 kPa (2500 psi)
Steering Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10340 kPa (1500 psi)
Steering Pump Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 L/min (5.3 gpm)
Steering Pump Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 cm3/rev (0.549 cu in./rev)
Implement Pump Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.5 L/min (8.6 gpm)
Implement Pump Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6 cm3/rev (0.891 cu in./rev)
Total Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.5 L/min (13.9 gpm)
Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gear
SST Machines:
System Regulated Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 965 - 1206 kPa (145 - 175 psi)
ePowrReverser Machines:
Clutch Pressure (at high idle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 965 - 1206 kPa (145 - 175 psi)
Filter Bypass Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 kPa (38 psi)
Lube Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 kPa (44 psi)
eHydro Machines (All Models):

System Regulated Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 kPa (175 psi)
Pump Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 cm3/rev (3.1 cu in./rev)
Motor Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.5 cm3/rev (2.65 cu in./rev)
Loop Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38470 kPa (5580 psi)
Charge Pressure (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1380 kPa (200 psi)
eHydro Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PV Axial Piston
eHydro Motor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MF Axial Piston
Hydraulics Specifications - 721

Suction Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 mesh
Rockshaft and Lift Arms:

Lift Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1/2 to 3 seconds
Drop Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1/2 to 3 seconds
Lift Arm Drop in 5 minutes with Rate of Drop/Stop Valve Closed (Maximum) . . . . . . . . . . . . . . . . . . . . . 51 mm (2 in.)
Lift Arm Raise Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50°
Lift Arm Lower Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20°
Total Lift Arm Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70°
Variance Between Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5° Maximum
Main PTO:
Clutch Hydraulic Pressure at Full Throttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 860 – 1380 kPa (125 – 200 psi)
Rockshaft Specifications:
Splined Sleeve Minimum OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.5 mm (1.832 in.)
Bushing Maximum ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2 mm (1.738 in.)
Gear Pump:
Shaft Bushing ID (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.15 mm (0.754 in.)
Shaft Bearing Surface OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.95 mm (0.746 in.)
Bushing Minimum Thickness - Steering (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.57 mm (0.534 in.)
Bushing Minimum Thickness - Implement (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.02 mm (0.749 in.)
Drive/Idler Gear Minimum Thickness
Front Pump (Steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.43 mm (0.371 in.)
4200 Rear Pump (Implement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.99 mm (0.590 in.)
4300/4400 Rear Pump (Implement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.63 mm (0.694 in.)
J-Tube Nuts (SCV or Manifold Block to Rockshaft). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 – 89 N•m (60 – 67 lb-ft)
SCV Tube to Quick Disconnect Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 – 57 N•m (38 – 42 lb-ft)
SCV Work Port Tubes to Adaptor Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 – 57 N•m (38 – 42 lb-ft)
Tube Nut to Rockshaft Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N•m (21 lb-ft)
Manifold Block, or SCV Valve to Tunnel Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 N•m (47 lb-ft)
Adapter Fitting to Pump (Front Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (180 lb-in.)
Pump to SCU Tube Nut (Front Gear Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 N•m (37 lb-ft)
Suction Tube Elbow Cap Screws (Front Gear Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (84 lb-in.)
Adapter Fitting to Pump (Rear Gear Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N•m (21 lb-ft)
Pump to SCV Tube Nuts (Rear Gear Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 N•m (51 lb-ft)
Pump to Mounting Plate Cap Screws (Front or Rear Gear Pump). . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (192 lb-in.)
Pump Cover Cap Screws - M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N•m (240 lb-in.)
Pump Cover Cap Screws - M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 N•m (40 lb-ft)
Rockshaft Cap Screws (10.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 N•m (60 lb-ft)

Rockshaft Cap Screws (8.8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 N•m (40 lb-ft)
Rockshaft Cylinder Head Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 N•m (60 lb-ft)
Lift Arm to Splined Shaft Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 N•m (50 lb-ft)
Rockshaft Control Valve-to-Rockshaft Housing Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft)
SCV Torque Specifications:

Cover Socket Head Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 N•m (168 lb-in.)
Valve Spring Retainer Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (133 lb-in.)
Load Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (212 lb-in.)
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 N•m (37 lb-ft)
Lever Assembly Cap Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)

HYDRAULICS COMPONENT LOCATION AND SCHEMATICS
Component Location and Schematics
Steering Pump Components, SST
From Manifold
Main PTO Clutch Shaft
Power Steering Valve
Pressure Valve
Lube Oil Port
To Main PTO Clutch

Valve Manifold
Steering Cylinder
Mid PTO
Cylinder
Suction Filter
MIF
Hydraulics Component Location and Schematics - 724

Steering Pump Schematic, SST
Steering Cylinder Pressure

Valve
L R Lube Oil for

Clutches
1100 kPa
Left Right 160 psi
Diverter Diverter
P T
1.1938
Orifice
Relief Valve
10342 kPa Power Valve Manifold

1500 psi Steering Valve
P T
Mid PTO
Cylinder
Steering Wheel
Main PTO
Clutch
9.0 cm3/rev
Gear Pump
(Front)
Suction Sump Oil

Filter Charge Pressure/Tunnel Lubrication Oil
High Pressure Oil
Steering Oil
Sump Lube Oil for Clutches
MIF

Steering System Components, ePowrReverser
From Manifold
Gear Pump
(Front)
Lube Pressure Test Port
Forward Clutch
Reverse Clutch
Steering Cylinder
Relief To Main PTO Clutch

Valve Valve Manifold
Pressure Transducer
Proportional
Solenoid Valve
Mid PTO
Cylinder
Suction Filter
MFWD Cylinder
MIF

Steering System Schematics, ePowrReverser
Lube Pressure
Test Port
Spin-On Filter
with Bypass 1100 kPa 300 kPa
160 psi 44 psi
Relief Lube Oil

Valve Pressure
260 kPa
Valve
38 psi
Filter
Bypass
Clutch
Lube Oil
Power
Steering
Valve
T
Proportional
Solenoid Valve
Forward Clutch
Proportional
Solenoid Valve
Reverse Clutch
m m
Sump Oil
Charge Pressure/Tunnel Lubrication Oil Reverse Clutch Forward Clutch
High Pressure Oil Pressure Transducer Pressure Transducer
Steering Oil
Clutch Lube Oil
MIF

Steering System Schematics, ePowrReverser (continued)
Diverter Diverter
Port Port
P T
1.1938
Orifice
Valve Manifold
Mid PTO
Cylinder
MFWD
Cylinder
Main PTO
Clutch
Sump Oil
High Pressure Oil
Steering Oil
Clutch Lube Oil
MIF

Steering System Components, eHydro
From Manifold
Relief
Valve
Steering Cylinder
To Main PTO Clutch
Valve Manifold
Suction Filter
Mid PTO
Cylinder
MFWD Cylinder
MIF

Steering System Schematics, eHydro
Steering Cylinder
Pump Case
L R Relief Valve
Left Right
1200 kPa
175 psi
Oil Cooler Spin-On Filter
Relief Valve
Oil Cooler
Bypass
Relief Valve
Power
10350 kPa Steering
1500 psi Valve 300-900 kPa
45-130 psi
P T
Steering Wheel
Engine
9 cm3/rev
Gear Pump
(Front)
Sump Oil
Suction
Filter
High Pressure Oil
Steering Oil
Make-Up/Closed Loop Relief Oil
Sump
MIF

Steering System Schematics, eHydro (continued)
T P Diverter Ports
Valve Manifold
1.1938
Orifice
Mid PTO
MFWD
Main PTO Cylinder
Cylinder
Clutch
M3
System 38500 kPa

Hydraulic Valve M1
Pump
51.0 cm3/rev
Hydraulic
Proportional Motor
System
Relief
38500 kPa
Valve
5585 psi
M2
Proportional
Solenoid Valve
M5 M4
MIF

SCV and Rockshaft System Components
Power Beyond
Rockshaft Filter
System Pressure Relief Valve
3 Spool SCV
Rockshaft Filter
Piston Cover Single SCV
Rockshaft Relief Valve
Rate of Drop/Stop Valve

Rockshaft Control Arm
Main Spool Valve
Gear Pump
Lowering Valve
(Rear)
Cylinder
Suction Filter Rockshaft Filter
Position Feedback Linkage
MIF

SCV and Rockshaft System Schematics
Rockshaft Filter
100 Mesh
Screen
P PB T
System Pressure
Relief Valve
4210
To Steering 14650 kPa (2125 psi)
11.9 cm3/rev (4210) 4310/4410
14.6 cm3/rev 17240 kPa (2500 psi)
(4310/4410)
9 cm3/rev Load Check Valve
Gear Pump Gear Pump
Engine
B A
Load Check Valve

Suction Filter
D C
150 Mesh
Intake Filter Load Check Valve
F E
Sump Oil
SCV Work Port Oil
High Pressure Oil
Rockshaft Pressure Oil
Rockshaft Work Pressure Oil
Rockshaft Cylinder Oil 3 Spool Selective Control Valve (SCV)
MIF

SCV and Rockshaft System Schematics (continued)
Unload Valve
48 kPa
(7 psi)
Lowering Valve
Load Check Valve
Flow
Control
Valve Main Spool Valve
Rockshaft
Control Valve
Rate of Drop/Stop Valve
Rockshaft
Relief Valve
20680 kPa
(3000 psi)
Piston Cover
Cylinder
Rockshaft
MIF

Manifold Block Schematics
Single SCV
To Rockshaft
Rockshaft Filter
From PTO Valve To Rockshaft
P PB T
System
Pressure
Relief
Valve
Test Port
4200
14651 kPa(2125 psi)
4300/4400
17236 kPa (2500 psi)
Manifold Block
NOTE: The manifold block can be replaced Sump Oil

by either the 1 spool selective control valve (SCV) SCV Work Port Oil
or the 3 spool SCV Rockshaft Pressure Oil
MIF

Single SCV Schematics
Rockshaft Filter
System Pressure
Relief Valve
Power Beyond
Kit
To Rockshaft
9 cm3/rev (4210) To Power Beyond / Rockshaft

18 cm3/rev
(4310/4410)
P PB T
Gear Pump
4200
14651 kPa(2125 psi)
Engine 4300/4400
17236 kPa (2500 psi)
System
Pressure
Relief
Valve
Suction Filter
150 Mesh Load Check Valve

Intake Filter
B A
Sump Oil
SCV Work Port Oil
High Pressure Oil Single SCV
Rockshaft Pressure Oil
MIF

Diverter Valve Schematic
Rockshaft Filter
PTO Valve
2500 psi T
Steering
Gear Pump
Engine
Implement B A
Gear Pump
Suction Filter
150 Mesh D C
Intake Filter
Sump Oil
SCV Work Port Oil E
F
Charge Pressure Oil
(P3 Port of Charge Filter)
High Pressure Oil
3 Spool Selective Control Valve (SCV)
D C B A
Diverter Valve
D2 D1 C2 C1 B2 B1 A2 A1
A2
B2
C2
D2
D1 C1 B1 A1
MIF

HYDRAULICS THEORY OF OPERATION
Theory of Operation
SST Hydraulic Operation
Pressure
Valve
Lube Oil for

Clutches
1100 kPa
160 psi
Diverter Diverter
P T
Valve Manifold
1.1938
Orifice
Mid PTO
Cylinder
Main PTO
Clutch
MIF
Theory
The SST hydraulic system receives its oil supply from the
power steering return line. This flow of oil is regulated to
1100 kPa (160 psi). The regulated oil is used to supply the
hydraulic system for the main PTO and mid PTO.
The flow going through the regulating pressure valve is
then sent through the filter and is used for traction clutch
lubrication.
Hydraulics Theory of Operation - 738

ePowrReverser Hydraulic Operation
Lube Pressure
Test Port
Spin-On Filter 1100 kPa 300 kPa

To Valve
with Bypass 160 psi 44 psi Manifold
Relief Lube Oil

Valve Pressure
Valve
Filter 260 kPa
Bypass 38 psi Clutch
Lube Oil
Proportional
Solenoid Valve
Forward Clutch
Proportional
Solenoid Valve
Reverse Clutch
m m
Sump Oil
Reverse Clutch Forward Clutch
Pressure Transducer Pressure Transducer
Clutch Lube Oil
MIF valve opens and allows the pressure to be relieved.
Theory The oil that is regulated to 1100 kPa (160 psi) travels to
either the hydraulic system for main PTO, mid PTO, and
The ePowrReverser hydraulic system receives its supply MFWD or the traction clutches. Two proportional valves,
from the power steering return line. This oil is then run one for forward and one for reverse, control the oil going to
through a filter. When the filter begins to clog, the pressure the traction clutches. When the direction is selected, the
drop across the filter increases. The filter bypass monitors corresponding proportional valve opens and allows the oil
this pressure drop. If the pressure drop across the filter is to go to the clutch and activate it. The pressure transducer
equal or greater than 260 kPa (38 psi) the filter bypass checks for the correct pressure.
opens. This allows oil flow to go around the filter and on to
the lube circuit.
The filtered oil then is regulated to a pressure of 1100 kPa
(160 psi) for the traction clutches and hydraulic system.
The flow that goes through the pressure regulator then is
used for clutch lubrication. The lube circuit also has a relief
valve. If the lube pressure rises above 300 kPa (44 psi) the

eHydro Hydraulic Operation
Pump Case
Relief Valve
Spin-On Filter 1200 kPa

175 psi
Oil Cooler Oil Cooler

Bypass
Relief Valve
300-900 kPa
45-130 psi
M3
System 38500 kPa

Hydraulic Valve M1
Pump
51.0 cm3/rev
Hydraulic
Proportional Motor
System
Relief
38500 kPa
Valve
5585 psi
M2
Proportional
Solenoid Valve
M5 M4
Sump Oil
High Pressure Oil
MIF

Theory PTO and MFWD Hydraulic Operation
The eHydro hydraulic system receives its supply from the
Function:
power steering return line. This oil is pumped through an oil
cooling radiator in front of the main radiator. A cooler To supply necessary hydraulic oil to the main PTO clutch,
bypass relief valve monitors pressure drop across the MFWD cylinder, and mid-PTO cylinder for actuation of
radiator. If the pressure drop across the radiator is equal or these functions.
greater than 300-900 kPa (45-130 psi) the radiator bypass
opens. This allows oil flow to go around the radiator and on Theory of Operation:
to the hydrostatic transmission.
Diverter Diverter D
The oil then passes through a screw on filter. The filtered oil B
Port Port
is regulated to a pressure of 1200 kPa (175 psi) for the
hydrostatic transmission. The flow that goes through the P T
pressure regulator relief is returned to sump.
The charge pressure oil that is regulated to 1200 kPa (175
psi) travels to the hydraulic system for main PTO, mid PTO, A
1.1938
and MFWD through port M3; the transmission proportional
Orifice
solenoid valves; and the hydraulic pump and motor make-
up oil line.
The proportional valves, one for forward and one for
reverse, control the oil going to the servo control of the
hydraulic pump. The proportional valves are controlled by
the electronic logic controller. See controller theory in the
Electrical section.
C
The hydraulic pump is connected directly to the engine and Mid PTO
is rotating any time the engine is running. The swash plate Cylinder
MFWD
of the hydraulic pump is servo controlled and remains flat Main PTO
Cylinder
unless one of the proportional valves opens and the servo Clutch
B
rotates the plate. When the swash plate rotates, oil is
pumped through the transmission to rotate the hydraulic
motor. Oil is pumped either direction through the
transmission depending on which direction the hydraulic C
pump swash plate is rotated. The direction of the oil flow
controls the direction of motor rotation.
Only the side of the pump and motor circuit loop that the
pump is sending oil into has high pressure. The other side
of the circuit loop provides a return route for the hydraulic
motor oil and supply oil for the hydraulic pump. If the low
pressure side falls below 1200 kPa (175 psi) the check
valve opens and charge pressure oil enters the circuit to
make-up any lost oil. A
The system relief valves open if the hydraulic pump

pressure exceeds 38500 kPa (5585 psi) on the motor drive D
side of the circuit.
The M1 and M2 pressure ports provide locations that may
MIF
be used for checking the charge pressure of 1200 kPa (175
psi) and the motor drive pressure of 38500 kPa (5585 psi). The component hydraulic system receives its regulated oil
The higher drive pressure and lower charge pressure will supply (A) from either the clutch cover on the
be at the opposite ports when the machine is in reverse as ePowrReverser and SST or from the transmission M3 port
compared to the pressures when the machine is in forward. on the eHydro. The supply goes into the solenoid valve
manifold (B). When the mid-PTO, MFWD or main PTO is
activated, a valve cartridge opens and the supply oil flows
to the component cylinder. The oil then activates the
cylinder.

The hydraulic oil (A) is supplied to the valve regulated to When the main PTO (shown above) is activated, the
1200 kPa (175 psi) on eHydro models and 1100 kPa (160 solenoid (C) valve cartridge opens. The supply oil must flow
psi) on SST and ePowrReverser models. This pressure is through an orifice (E) before going through the valve
supplied to all of the valve cartridges by the manifold (B). cartridge and onto the clutch. The orifice modulates how
The valves are normally in the off position and are set to fast the PTO clutch is engaged. See “Main PTO Clutch
sump the hydraulic oil from the systems. The valve Operation” on page 742.
cartridges (C) are spring loaded and oil pressure in the mid
PTO cylinder, MFWD cylinder and main PTO clutch is Main PTO Clutch Operation
relieved to sump (D).
Function:
B
Diverter Diverter D The PTO clutch provides a means for disengaging the PTO
Port Port output shaft from the engine. The PTO brake is provided to
P T positively stop the rotation of the PTO system when the
PTO clutch is disengaged. The PTO clutch and PTO brake
work simultaneously. Both the mid and rear PTO are
affected by the operation of the PTO clutch and PTO brake.
A
1.1938 The rear PTO shaft is engaged directly from the clutch. The
Orifice mid PTO gears are driven by gears engaged to the rear
PTO. The mid PTO gears are only engaged when they are
shifted into gear. They are shifted into gear when the mid
PTO solenoid located in the solenoid valve manifold is
activated.
Theory:
C The PTO clutch (A) is engaged or disengaged by the
Mid PTO operator through an electrical switch. The PTO brake (B) is
Cylinder MFWD automatically spring applied when the PTO clutch is
Cylinder disengaged. The PTO brake is a spring loaded multi-plate
Main PTO
Clutch wet brake and is normally engaged, preventing the PTO
B clutch shaft (C) from rotating. The PTO clutch is a multi-
plate wet clutch and is normally disengaged.
When the operator pulls the PTO switch to the on position,
the hydraulic control valve is activated and supplies
C
hydraulic pressure to activate the PTO clutch. The oil has to
flow through an orifice. the orifice restricts the initial flow
and pressure. The restriction modulates how fast the PTO
clutch is engaged.
The PTO clutch piston is moved forward by the hydraulic
pressure. As the piston (D) moves forward, the spring
pressure applied to the brake by the piston, through the
four pins (E), is removed and disengages the brake. At the
same time, the piston is applying pressure to the PTO
A
clutch pack and engaging the PTO clutch. The pressure
applied to the clutch pack locks the plates (splined to the
D clutch basket (F)), to the friction plates (locked to the clutch
E hub (G)). Power is transferred from the input shaft to the
clutch hub, through the friction plates and separator plates
MIF to the clutch basket, and finally to the PTO drive shaft.
When the operator engages one of the systems (main PTO A locking tab on the outside of the brake housing allows the
shown), the coil for that valve cartridge is energized. This PTO drive shaft to rotate approximately 300°, which, in turn
pulls the valve cartridge (C) up to the open position allows the PTO stub shaft to rotate approximately 63° to aid
allowing the regulated oil to flow through the valve and to in aligning the splines of an attachment drive shaft during
the system. hook-up.

Main PTO Clutch
A B
F D E
MIF

Rockshaft Operation
E
B
MIF
Rockshaft Operation
Charge pressure oil is provided to the rockshaft control
valve from the SCV valve block. The oil is filtered through a E G
100 mesh screen (A).
The rockshaft is operated by moving the lift control lever. F
The lever rotates a cross-shaft (B) that is linked to the
rockshaft control valve (C).
The control valve contains two spools, the main spool (D)
for raising and lowering the rockshaft and one for rockshaft
position sensing. When the cross-shaft is rotated, the
control linkage pushes in the main spool or allows the main
spool spring to back the spool out of the control valve.
When the spool is pushed in, charge oil is allowed to enter
the piston cylinder and the rockshaft arms raise.
The rate of drop/stop valve (E) controls the rate at which oil
enters and leaves the cylinder. Turning the control knob
under the front of the operators seat changes the rate of
drop/stop valve setting from fully open to fully closed.
MIF
With the rate of drop/stop valve (E) fully open, Charge oil,
controlled by the control valve, passes through a passage
into the piston cover (F), past the rate of drop/stop valve
and into the cylinder.

HYDRAULICS TROUBLESHOOTING
Cylinder pressure can be measured at port (G). If too great of a load is placed on the rockshaft arms the
check ball (B) moves against spring pressure, opens the
valve and dumps oil (C) to the rockshaft sump housing.
H G
Troubleshooting
Hydrostatic (eHydro) Troubleshooting

Symptom: Performance Problems
(1) Poor Transmission Performance?
Yes - Loss of charge pressure.
Yes - Low hydraulic fluid level.
E
Yes - Plugged filter.
Yes - Improper current to solenoid valve.
Yes - Solenoid valve malfunction.
Yes - Plugged screens at solenoid valve.
Yes - Worn rotating kit components.
MIF
Yes - Parking brake is on.
As the rate of drop/stop valve is closed, charge oil entering
the cylinder has to go around the valve. Check ball (H) is Yes - Ballasted too heavily.
raised and oil is channeled around the valve. This action Yes - Wrong valve installed.
allows oil to enter the cylinder while the check ball prevents
oil from leaving the cylinder. This allows the rockshaft to be (2) Complete Loss of Transmission Power?
raised and locked into position. Yes - Loss of charge pressure.
Pressure Relief Valve Operation: Yes - Low hydraulic fluid level.
Yes - No current to solenoid valves.
Yes - Failure of high pressure components in
A pump or motor.
B
Yes - Mechanical failure at 3-speed gear box or
drive line.
(3) Poor Braking Performance / Excessive
C Rollout?
Yes - Solenoid valve malfunction.
Yes - Improper current to solenoid.
Yes - Worn components in transmission.
Yes - Wrong valve installed.
(4) Machine Creeps In Neutral?
Yes - Solenoid valve is getting current input.
Yes - Solenoid valve is stuck on.
Yes - Threshold set-point incorrect (software
MIF
setting).
The pressure relief valve (A) is a spring loaded valve that
opens when the rockshaft cylinder pressure becomes Yes - Improper neutral adjustment made in field.
greater than 20680 kPa (3000 psi). Yes - Worn servo piston components.
Hydraulics Troubleshooting - 745

HYDRAULICS DIAGNOSTICS
Symptom: Performance Problems Symptom: Performance Problems
(5) Machine Moves When Started? Yes - Reduction in hydro efficiency increases
charge flow demand.
Yes - Solenoid valve is getting current input.
Yes - Cut or worn seal ring on servo piston.
Yes - Solenoid valve is stuck on.
Yes - Leakage past the charge pressure relief
(6) Excessive Pedal Movement To Begin Travel?
valve.
Yes - Threshold set-point incorrect (software
setting).
Diagnostics
Yes - Sticky solenoid valve.
Yes - Low charge pressure. Hydraulics
Yes - Improper neutral adjustment made in field. Test Conditions:
Yes - Worn servo piston components. • Machine sitting on level ground outdoors in an area
(7) Loss of Charge Pressure? clear of obstructions.
Yes - Engine speed too low to develop required • Hydraulic oil in reservoir at proper level.
charge flow. • Speed range selector in “NEUTRAL.”
Yes - Inefficient charge pump not providing • Park brake engaged.
required flow.
• Engine running at full throttle.
Yes - Charge flow diverted to hydro (steering, • Sufficient weight on lift arms to allow self-lowering.
MFWD, etc.).
• Rockshaft rate of drop/stop valve fully open.
Yes - Extreme temperature increases demand but
reduces flow.
Move rockshaft lift control to full raise Lift arms raise to full lift height. Perform Rockshaft Position
(rearward) position. Feedback Adjustment. See
“Rockshaft Position Feedback
Linkage Adjustment” on
page 751.
Move rockshaft lift control to full lower Lift arms lower to full down position. Open rockshaft rate of drop/stop
(forward) position. valve fully. Make sure draft
sensing control lever (if equipped)
is in the full forward position.
Perform Rockshaft Position
Feedback Adjustment. See
“Rockshaft Position Feedback
Linkage Adjustment” on
page 751.
Hydraulics Diagnostics - 746

HYDRAULICS TESTS AND ADJUSTMENTS
Tests and Adjustments Rate of Drop/Stop Valve Adjustment
Reason:
Hydraulic System Bleed Procedure
To ensure that lift arms lower rear attachment completely
Reason: and lower it at a safe rate of speed.
To remove air trapped in the hydraulic system which will
Equipment:
prevent proper operation.
• BW13586 Ballast Box
Procedure:
Procedure:
NOTE: Fill the new hydraulic oil filter with new oil
before installing. 1. Park machine on a level surface and set park brake.
2. Shift transmission to “neutral”.
1. Install a new hydraulic oil filter.
3. Install BW13586 ballast box, or approximately 227 kg
2. Fill the transaxle with specified JDM J20D (preferred) or
(500 lb), on the three point hitch.
J20C oil to the proper level on dipstick.
4. Start engine and run at fast idle (2500-2700 rpm).
5. Put lift control lever in full UP position.
A 6. Raise weight as high as it will go.
7. Close rate of drop/stop valve.
8. Put lift control lever in full DOWN position.
9. Open rate of drop stop valve 1-1/2 to 2 turns.
10.Time duration of drop cycle from full up to full down.
Specifications:
Rockshaft Drop Time . . . . . . . . . . . . . 2-1/2 to 3 seconds
Results:
M91948 If the weight lowers slower than specified time, open
3. Disconnect connector (A) to fuel shutoff solenoid. rockshaft rate of drop/stop valve until specification is met. If
weight drop time will not meet specification, the rate of
4. Turn the key to START and hold for 10 seconds. Turn the
drop/stop valve may be clogged or faulty, or the rockshaft
key to OFF.
control valve may be faulty. See “Rockshaft Disassembly
5. Reconnect wires to fuel shutoff solenoid. and Assembly” on page 758.
6. Raise machine front end and support on suitable
stands. Lift Arms Adjustment
7. Start the engine and run at low idle.
Reason:
8. Slowly turn the steering wheel left and right until wheels
To ensure that lift arms are operating through the correct
turn smoothly indicating that any trapped air has been bled
range of motion.
back to the reservoir.
9. Operate rockshaft several times until it operates Procedure:
smoothly. 1. Park machine on a level surface and set park brake.
10.Stop the engine and check the hydraulic reservoir oil 2. Shift transmission to NEUTRAL.
level. Fill as needed. Check all line connections for leaks;
tighten if necessary. 3. Start engine and use hydraulics to rotate rockshaft to full
UP position.
11.Lower the machine to the ground.
4. Using angle gage, check lift arms against specifications.
12.(eHydro Model) Drive machine in forward and reverse If not correct, remove lift arm and reset. See “Rockshaft
several times until transmission operates smoothly. Disassembly and Assembly” on page 758.
Hydraulics Tests and Adjustments - 747

5. Compare angle of second lift arm with first, they should Implement System Specifications:
be within 5° of each other. If not, reset lift arms on splines
4210 Pressure. . . . . . . . . . . . . . . . . 14650 kPa (2125 psi)
and/or replace rockshaft.
4210 Flow . . . . . . . . . . . . . . . . . . . . 26.5 L/min (7.0 gpm)
Specifications: 4310 and 4410 Pressure . . . . . . . . 17240 kPa (2500 psi)
Lift Arm Raise Angle . . . . . . . . . . . . . . . . . . . . . . . . . . 50° 4310 and 4410 Flow . . . . . . . . . . . . 32.5 L/min (8.6 gpm)
Lift Arm Lower Angle . . . . . . . . . . . . . . . . . . . . . . . . . . 20°
Results:
Total Lift Arm Range . . . . . . . . . . . . . . . . . . . . . . . . . . 70°
• Pressure too Low: If system pressure reading cannot be
Maximum Variance Between Arms . . . . . . . . . . . . . . . . 5° reached, mesh filter may be restricted. Suction line may be
restricted or leaking air. Pump may be worn. See “Hydraulic
System Pressure/Flow Test Gear Pump” on page 752.
• Flow too low: Mesh filter may be restricted. Suction line
Reason:
may be restricted or leaking air. Pump may be worn. See
To ensure that hydraulic pump pressure and flow are “Hydraulic Gear Pump” on page 752.
maintained at sufficient levels for rockshaft and SCV
attachment operation, and to determine if hydraulic pump is
worn.
System Pressure Adjustment
NOTE: On machines equipped with a manifold block in
Equipment: place of an SCV, system pressure is set at the factory,
• JT05689 - Adapter Fitting (1-1/16-12 M 37° X 1-14 F and should not require adjustment.
ORFS) (2 Required)
Reason:
• JT03012 - Adapter Fitting (3/4 F NPT X 1-1/16-12 F 37°
Sw) (2 Required) To adjust hydraulic pressure so that system pressure is
maintained at correct levels to perform work without
• JT05984 - In-Line Flow Meter With Pressure Gauge causing damage to the hydraulic system.
• JT03377 - Hose (3/4 M NPT X 3/4 M NPT X 10’) (2
Required) Equipment:
• JT05689 - Adapter Fitting (1-1/16-12 M 37° X 1-14 F
Procedure: ORFS) (2 Required)
1. Park machine on a level surface and set park brake. • JT03012 - Adapter Fitting (3/4 F NPT X 1-1/16-12 F 37°
2. Shift transmission to NEUTRAL. Sw) (2 Required)
• JT05984 - In-Line Flow Meter With Pressure Gauge
c CAUTION: Avoid Injury! Make sure to relieve • JT03377 - Hose (3/4 M NPT X 3/4 M NPT X 10’) (2
Required)
system lines or hoses.
Procedure:
4. Remove hydraulic tube between rear pump and SCV
valve.
5. Connect test equipment between rear pump and PTO c CAUTION: Avoid Injury! Make sure to relieve
valve. Open valve on flow meter fully. system pressure before loosening any
c CAUTION: Avoid Injury! Do not close valve the hydraulic system.

4. Remove hydraulic tube between rear pump and SCV
on flow meter fully. Pump pressure may
exceed working pressure of hose. valve.
5. Connect test equipment between rear pump and SCV
7. Slowly close valve on flow meter until working pressure valve. Open valve on flow meter fully.
is reached. Record flow reading on gauge.

7. Move SCV control lever to open SCV valve to a closed
work port (dead head).
8. Check pressure reading on gauge.
c CAUTION: Avoid Injury! Make sure to relieve
System Pressure Specifications:
3. Remove hydraulic hose on left side of steering cylinder.
4210 . . . . . . . . . . . . . . . . . . . . . . . . . 14650 kPa (2125 psi)
4. Attach gauge to left steering hose.
4310 and 4410 . . . . . . . . . . . . . . . . . 17240 kPa (2500 psi)
NOTE: Turning steering wheel to the right will cause
Results: hydraulic oil to leak out of disconnected cylinder port.
Turn wheel only to left when performing test.
6. Turn steering wheel to the left. While turning wheel,
check pressure reading on gauge.
Specification
Steering Pressure (±10%) . . . . . . . 10340 kPa (1500 psi)
Results:
A
• No pressure: Steering hoses may be incorrectly
MIF connected to the SCU. Check hose connections.
• Pressure too low: Turn system pressure relief valve (A) • Pressure too low: Relief valve in SCU may be stuck
clockwise until pressure reading is within specification. open or defective; perform steering system test, See
NOTE: If system pressure will not meet specification, “Steering System Test” on page 785, or gear pump may be
pump may be worn. Perform system pressure/flow test worn; disassemble and inspect pump. See “Gear Pump
See “System Pressure/Flow Test” on page 748. Disassembly and Inspection:” on page 753.
• Pressure too high: Relief valve in SCU may be clogged
• Pressure too high: Turn system pressure relief valve
or defective.
counter-clockwise until pressure reading is within
specification.
Lube Pressure Test - ePowrReverser
Steering Pressure Test See “ePowrReverser Lube Pressure Test” on page 569 in
the ePowrReverser Power Train section.
Reason:
To ensure that steering pump pressure is maintained at Charge Pressure Test - eHydro
correct level for steering without causing damage to the
system, and to determine if hydraulic pump is worn. See “Charge Pump Pressure Test” on page 539“in the
eHydro Power Train section.
Equipment:
• JT03375 - Adapter Fitting (7/16-20 M 37° X 9/16-18 M
ORFS)
• JT03117 - 0-14000 kPa (0-2000 psi) Pressure Gauge
• JT03017 Hose w/Quick Disconnect Fitting
Procedure:

Main PTO Clutch Pressure Test Results:
• Pressure is within specification: Check PTO clutch for
Reason:
repair.
To test hydraulic pressure to the main PTO. If correct
• No pressure or pressure is low: Check charge pressure,
pressure is supplied to the clutch, clutch malfunctions can
PTO solenoid valve and orifice.
be isolated to the clutch assembly. If low or no pressure is
supplied to the clutch, clutch malfunctions can be isolated Specification:
to the hydraulic system.
PTO Clutch Pressure . . . . 860 - 1380 kPa (125 - 200 psi)
Equipment:
• 0 - 2000 kPa; or, 0 - 300 psi Pressure Gauge Rockshaft Lift Cycle Test
Procedure: Reason:
1. Park machine on a level surface and set park brake. To ensure that hydraulic system is functioning correctly and
capable of lifting rated load.
2. Shift transmission(s) to NEUTRAL.
3. Place PTO switch in OFF position. Equipment:
• BW13586 Ballast Box
c CAUTION: Avoid Injury! Make sure to relieve Procedure:


5. Locate the hydraulic valve manifold on the right side of 227 kg
the machine. (500 lbs)
MIF

3. Install ballast box, or approximately 227 kg (500 lb), on
the three point hitch.
4. Open rate of drop/stop valve completely.
5. Start engine and run at fast idle.
YZ4480
6. Move lift control lever to full UP position.
6. Remove plug from PTO clutch pressure port (A).
7. Time duration of lift cycle from full down to full up.
7. Install quick connect fitting (B) or equivalent. Install hose
and pressure gauge to quick connect fitting. Specifications
8. Start machine and engage PTO. Rockshaft Lift Time . . . . . . . . . . . . . . 2-1/2 to 3 seconds
9. Check pressure gauge for pressure.
Results:
If the weight raises slower than specified there may be
internal leakage in the lift cylinder or rockshaft control
valve.

Rockshaft Leakage Test Rockshaft Position Feedback Linkage
Adjustment
Reason:
To ensure that hydraulic system is functioning correctly and Reason:
capable of lifting rated load. To ensure that draft arms raise to maximum lift height
without engaging relief valve.
Equipment:
• BW13586 Ballast Box Procedure:
1. Position machine on a level surface and set park brake.
Procedure:
3. Position lift control lever in the full forward (down)
position and provide enough weight on lift arms to allow self
lowering.
NOTE: Make sure the PTO shield is in place, and is in
227 kg good condition before performing adjustment. Make
(500 lbs) sure rubber bumper (A) is in place on PTO shield.
4. Start engine.
5. Move lift control lever to full raise position (back).
MIF

2. Shift transmission to NEUTRAL. 350±3 mm
(13.8±0.12 in.)
3. Install BW13586 ballast box, or approximately 227 kg
(500 lb), on the three point hitch.
4. Start engine and run at fast idle (2500-2700 rpm).
D
5. Put lift control lever in full UP position. B
6. Raise weight as high as it will go.
7. Close rate of drop/stop valve.
A
8. Shut off engine. MIF
9. Measure distance weight drops in five minutes. 6. Using a tape measure, measure from the top of the PTO
10.Restart engine, open rate of drop/stop valve fully and shield (B) to the center of the pin (C) in end of lift arm. Lift
raise weight to full UP position. arm should raise to 350±3 mm (13.8±0.12 in.) as shown,
without engaging the relief valve. Check that there is 25.4
11.Shut off engine. mm (1 in.) of slack above the vertical height.
12.Measure distance weight drops in five minutes.
Results:
Specifications If specification is not met, lengthen the lift arm position
Drop in 5 Minutes (Maximum) . . . . . . . . . . 51 mm (2 in.) feedback rod (D) to increase, or shorten to reduce the
maximum height until within specification. The relief valve
Results: should not engage.
If the weight drops farther than specified distance with the
stop/drop valve closed (first test) there may be leakage in
the cylinder, relief valve or drop/stop valve.
If the weight drops farther with the drop/stop valve open
(second test) than it did in the first test, there may be
leakage in the rockshaft control valve.

HYDRAULICS REPAIR
Repair Installation:
IMPORTANT: Avoid damage! Replace all O-rings

Rockshaft Filter Replacement
and seals. Used or damaged O-rings and seals
Removal: will leak.
NOTE: If changes in the operation of the 3-point hitch C B

B
lift capacity are detected or the rockshaft control valve
should begin to react slowly, erratic or fail to cycle
properly; performance of this service procedure may
be required. D
1. Park machine safely and shut off engine. MX9876
1. Install new O-rings (B) and washer (C).
c CAUTION: Avoid injury! Before performing 2. Assemble springs, filter and housing. Tighten housing
end to 69 N•m (51 lb-ft).
this service procedure involving he
hydraulic system, the rockshaft must be
completely lowered. IMPORTANT: Avoid damage! Install filter
housing to hydraulic tubes with the removable
2. Lower rockshaft completely to relieve hydraulic pressure end (marked “OUT”) toward the left side (toward
from the system. rockshaft control valve).
NOTE: Loosening the hydraulic fittings will cause 3. Install filter housing to hydraulic lines with removable
hydraulic oil to leak. Place a rag or container under end (D) to left side.
each fitting to absorb any oil.
4. Tighten tube nuts to filter to 28 N•m (21 lb-ft).
5. Start machine and cycle rockshaft several times and
check for leaks.
Hydraulic Gear Pump

A
Removal:
1. Remove engine side panels.
2. Put a drain pan under the pumps to catch oil.
MX9875
3. Unscrew nuts (A) and remove filter housing.

4. Disassemble filter housing. Clean or replace filter as
needed.
M91982
3. Disconnect suction manifold and pressure tube from

pump(s) to be removed.
4. Each pump has two socket head cap screws securing
the it to the engine drive housing, and two through socket
head cap screws to the other pump.
Hydraulics Repair - 752

HYDRAULICS REPAIR
5. Remove the pump.
Installation: C
1. Install new body seals on the suction fittings and

pressure tubes. Secure to the pump with cap screws.
Tighten to 9 N•m (84 lb-in.).
2. Install new gaskets on the pump mounting flanges.
3. Align the splines on the pump input shaft with splines on
the engine drive. Insert the pump into the engine housing.
4. Secure each pump with socket head cap screws.
Tighten cap screws to 22 N•m (192 lb-in.).
5. Inspect the suction manifold for damage or cracking.
Replace if necessary. MX9707
4. Inspect the inside of the pump cover (C) for wear or

Gear Pump Disassembly and Inspection: damage.
NOTE: Available pump components are serviced only
in the seal kit for the pump. Verify the availability of
pump components before disassembling the pump.
D E F
IMPORTANT: Avoid damage! Replace all body G
seals, gaskets, and seals any time the pump is
opened. Used or damaged body seals, gaskets
H
and seals will leak.
1. Remove the pump from the engine.
MX9708
5. Remove the seal (F) and backing ring (G) from the rear
pump bushings (D, E).
A B 6. Replace the body seal (H).
MX9706
2. Remove two M8 socket head cap screws (A) and two MX9709
M10 socket head cap screws (B) securing the rear pump
7. Remove the front cover (I).
cover to the pump body and front cover.
8. Inspect the outside of the front cover for wear or
3. Remove the rear pump cover.
damage.

HYDRAULICS REPAIR
9. Inspect the shaft seal (J) for cracks, wear, or damage. If
necessary replace the shaft seal. M
D
L
E
N
D
MX9712
MX9710
14.Note the location and markings on the front and rear
10.Inspect the inside of the front cover for scoring, wear, or bushings (D, E) to assure correct orientation at assembly.
damage.
15.Remove the front bushings, drive gear (L), and driven
gear (N) from the pump housing (M).
K K E L D
E D F
G
D N E
MX9713
MX9711 16.Remove the bushings (D, E) from the gears (L, N).
11.Remove the seal (F) and backing ring (G) from the front 17.Inspect the gear and bushing faces for scoring,
pump bushings (D, E). scratches, or damage.
12.Inspect two alignment dowels (K) for damage. Replace if 18.Inspect the drive gear (L) shaft splines and bearing
required. surfaces for wear or damage.
13.Replace the body seal (H). 19.Inspect the gear shaft bearing surfaces for wear or
NOTE: The dowels may remain in the either the pump damage.
cover or body when the cover is removed. 20.Inspect inside of bushings for scoring or excessive
scratching.
21.Inspect pump housing internal surfaces for scoring or
scratching. Replace pump if damaged.

HYDRAULICS REPAIR
Assembly:
B
MX9716
A
4. Install the front bushings (B) into the pump housing, and
MX9714 onto the drive gear and idler gear shafts.
1. Lubricate all parts with hydraulic oil before assembly.
NOTE: The bushings should be oriented so that the
2. Install the rear bushings (A, B) into the pump housing opening formed by the seal faces the top of the pump.
bore as shown. Push the bushings in by hand until they are
flush with the back of the pump housing. 5. Replace the seal backing ring and seal in the front and
rear bushings.
NOTE: The bushings should be oriented so that the
opening formed by the seal faces the top of the pump. NOTE: The seal and the backing ring MUST be installed
in the correct orientation. The flat side of the seal must
face the bushings. The flat side of the backing ring
C must face the pump cover.
6. Replace the front and rear body seals.
7. Install front cover over the drive gear shaft and onto
pump body.
8. Install rear cover and secure the covers with two M8 and
two M10 socket head cap screws. Tighten M8 and M10 cap
screws to specification.
9. Install the pump to the engine.
D M8 Cap Screws. . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.)
M10 Cap Screws. . . . . . . . . . . . . . . . . . . 43 N•m (32 lb-ft)
MX9715
3. Lay the back of the pump body on a clean, flat surface.

Install the drive gear (C) and driven gear (D) into the pump
body and rear bushings.
NOTE: The driven gear is symmetrical and can be
placed in the pump body either end first.

HYDRAULICS REPAIR
I
A
B
E
C
D
D
C
H E
G
E
C
D
G
H
D
C
K E
B
F I
MIF H - Driven Gear

A - Suction Manifold I - Drive Gear Shaft Seal
B - Front Cover J - Rear Pump (Rockshaft)
C - Seal K - Front Pump (Steering)
D - Backing Ring
E - Body Seal
F - Bushings
G - Drive Gear

HYDRAULICS REPAIR
Rockshaft Removal and Installation
Removal
E
1. Remove seat and seat support. See “Seat and Seat
Support” on page 818.
MX9741
6. Remove four cap screws (E) retaining front of SCV valve

B B to front of seat bracket.
F
MX9737
2. Disconnect hydraulic supply line (A) and both ends of

rockshaft filter line (B).
3. Remove rockshaft filter line.
MX9743
7. Remove bracket (F) from the ROPS assembly.

8. Disconnect wiring harness from the PTO and MFWD
solenoids (if equipped), right tail light assembly, and ground
MX9738
speed sensor (if equipped). Pull wires clear of the
4. Remove four cap screws (C) from inside of fenders. rockshaft.
MX9740
5. Remove two cap screws (D) retaining bracket to front of

rockshaft.

HYDRAULICS REPAIR
Rockshaft Disassembly and Assembly
Disassemble:
F
C
MX9742 D
E
9. Remove two cap screws (G) securing range shifter to
rockshaft.
MX9756
10.Remove all cap screws securing rockshaft to differential
1. Remove two cap screws (B) that retain control lever (A)
housing.
to lever arm (E). Remove control lever.
NOTE: Rockshaft is heavy! Use a hoist or have an 2. Remove lock nut (F), lever arm (E), two belleville
assistant help remove rockshaft. washers (D), and one flat washer (C).
11.Remove rockshaft.
Installation
Installation is performed in the reverse order of removal.
• Clean sealing surfaces of rockshaft and final drive
housing. Install a new bead of sealant (TY16021) on
transaxle rockshaft mounting surface. G
• If lift arms have been removed they must be reset. See

“Lift Arms Adjustment” on page 747.
• Tighten tube nuts to rockshaft to 69 N•m (51 lb-ft).
• Tighten tube nuts to rockshaft filter to 69 N•m (51 lb-ft).
• Tighten 8.8 grade cap screws to 55 N•m (40 lb-ft). MX9757
• Tighten 10.9 grade cap screws to 80 N•m (60 lb-ft). 3. Remove two cap screws (G).
MX9758
4. Remove shaft support tube (H).

HYDRAULICS REPAIR
MX9559
M94652
5. Remove remaining cap screws and rockshaft valve
cover (I). 9. Replace three O-rings (N).
Q
K
J
R
MX9760
6. Remove two snap rings (J), two flat washers, and link M94653
(K).
10.Remove cotter pin (O) and washer, and disconnect
position feedback rod (P) from feedback lever (Q).
11.Remove spring pin (R), and feedback lever.
MX9761 M94663
7. Remove two washers (L). 12.Slide limiter (S) away from rockshaft housing. Remove
8. Remove three socket head cap screws (M) and woodruff key.
rockshaft control valve.

HYDRAULICS REPAIR
T
S
M94658
18.Remove plastic cap on top of cylinder head.

W
M94654
13.Remove lift control shaft (T) from rockshaft housing.

Remove limiter (S) and rubber washer (U).
14.Remove position feedback shaft (W) from housing.
15.Replace O-rings on lift control and position feedback
shafts.
X
M94659
19.Remove plug and spring.
M94655
16.Remove relief valve (X).

M94662
20.Remove ball.
M94658
M94656 21.Remove two cap screws (Y) and rate of drop/stop valve
17.Replace two O-rings in relief valve. stem.

HYDRAULICS REPAIR
M94657 M94661
22.Replace O-ring in end of valve stem. 25.Place a suitable bolt in threaded hole in end of piston.
Remove piston.
M94667
26.Replace inner and outer piston rings.
Assemble:
M94660 IMPORTANT: Avoid damage! Replace all O-rings

23.Remove cylinder head. Replace O-rings in cylinder and seals. Used or damaged O-rings and seals
head. will leak.
NOTE: When assembling, DO NOT lubricate Belleville

washers or lift control lever friction surfaces.
1. Install a new inner and outer piston rings.
Z
IMPORTANT: Avoid damage! Use care when
installing piston into cylinder bore to prevent
damage to piston rings. Be sure piston rings are
centered in cylinder bore and properly seated in
piston ring groove during installation.
2. Lubricate piston and rings liberally with hydraulic oil.

Using a plastic mallet, install piston into cylinder bore.
3. Install new O-rings into cylinder head.
4. Install cylinder head into cylinder bore. Retain with two
M94668 lower cap screws. Tighten cap screws to 80 N•m (60 lb-ft).
24.Remove rate of drop/stop valve spool (Z). Replace O-
ring on spool.

HYDRAULICS REPAIR
M94658
9. Install plastic cap on top of cylinder head.

M94668
5. Install a new O-ring onto rate of drop/stop valve spool

(Z). Install rate of drop/stop valve spool into bore in cylinder
head.
6. Install a new O-ring into end of rate of drop/stop valve
stem. Install rate of drop/stop valve stem onto cylinder head
and retain with two cap screws.
M94656
10.Install two new O-rings in relief valve.
M94662
7. Install ball.
M94655
11.Install relief valve (X). Tighten to 50 N•m (37 lb-ft).
M94659
8. Install plug and spring.

HYDRAULICS REPAIR
U
P
T O
S
Q
R
W
M94653
M94654 18.Install feedback lever (Q) onto feedback shaft. Retain

with spring pin (R).
12.If removed, install washers onto lift control (T) and
position feedback (W) shafts. 19.Connect position feedback rod (P) to position feedback
lever. Retain with washer and cotter pin (O).
13.If removed, install snap rings onto lift control and
position feedback shafts.
14.Install new O-rings onto lift control and position
feedback shafts.
15.Install lift control shaft into rockshaft housing. Install N
rubber washer (U) and limiter (S) onto shaft.
16.Install position feedback shaft into housing.
M94652
20.Install new O-rings (N) into rockshaft control valve and

S
rockshaft housing at rockshaft valve mounting surface.
M94663
17.Install woodruff key into shaft. Slide limiter over woodruff

key and against rockshaft housing.

HYDRAULICS REPAIR
MX9761 MX9758
21.Install rockshaft control valve and retain with three 24.Install shaft support tube (H) onto lift control shaft and
socket head cap screws (M). Tighten cap screws to 39 N•m retain with two cap screws. Tighten cap screws to 80 N•m
(29 lb-ft). (60 lb-ft).
22.Install two washers (L). IMPORTANT: Avoid damage! Make sure that
Belleville washers are correctly installed with
cupped sides of each pair of washers facing each
other.
A
K
B
MX9760 F
C
23.Install link (K). Retain with two flat washers, and two D
snap rings (J). E
M94646
25.Install washer (C), two belleville washers (D), and lever

arm (E) to shaft. Retain with lock nut (F).
NOTE: Lever arm should be installed so that when the
lever if in the full forward (down) position, the lever arm
is parallel to the ground.
26.Install control lever (A) to lever arm (E). Retain with two
cap screws (B).

HYDRAULICS REPAIR
Rockshaft Lift Arms Removal and Installation
E
Removing:
NOTE: Lift arms may be removed with rockshaft
assembly installed in machine. DO NOT remove
splined cross shaft unless rockshaft is first removed
from machine. Internal components will fall into
transmission if splined cross shaft is removed while
rockshaft is attached to transmission.
M94640
4. If not already done, use center punch to mark (E)

splined cross shaft and lift arm.
5. Remove lift arm from splined cross shaft.
G
M91998
1. Remove snap ring (A) and washer from end of cam

plate pin. Disconnect position feedback rod (B).
2. Remove cap screw (C) from end of rockshaft.
NOTE: Two spring pins (D) retain cam plate to
rockshaft. F
M91364
D
6. Remove washer (F) from splined cross shaft.
7. Remove outer O-ring (G) from groove in housing.
NOTE: DO NOT remove splined cross shaft unless
rockshaft is first removed from vehicle. Internal
components will fall into transmission if splined cross
shaft is removed while rockshaft is on transmission.
If rockshaft assembly is still installed on transmission,
remove right lift arm only.
M91999
3. Remove cam plate.

HYDRAULICS REPAIR
M94641
M91368
8. Remove right side lift arm and splined cross shaft from 10.Remove two splined sleeves (I) from housing.
housing as a unit.
NOTE: Beveled ends of the splined sleeves should face
NOTE: DO NOT remove splined cross shaft unless inward.
rockshaft is first removed from vehicle. Internal There is an O-ring in ID of beveled end of splined
components will fall into transmission if splined cross sleeve.
shaft is removed while rockshaft is on transmission.
If rockshaft assembly is still installed on transmission,
remove right lift arm only.
M91365
11.Remove inner O-ring (J) from bore of rockshaft housing.
H
K
M94642
9. If necessary, remove spring pin (H) and separate

rockshaft lever arm and piston rod. Remove lever arm and
piston rod from rockshaft housing.
NOTE: Inner O-ring may come out of bore with splined M91366
sleeve when removed. 12.Remove O-rings (K) from bevelled end of splined
sleeves.
13.Inspect splines on ID of splined sleeves for damage.
Inspect OD for grooves or excessive wear. Replace as
required.
14.Measure OD of splined sleeves. If not in specification,
replace.

HYDRAULICS REPAIR
15.Measure ID of bushing (L) in housing. If not in
specification, replace.
Specification:
Splined Sleeve Minimum OD . . . . . . 46.5 mm (1.832 in.)
Bushing Maximum ID . . . . . . . . . . . . 44.2 mm (1.738 in.)
Installing:

and seals. Used or damaged O-rings and seals
will leak.
1. If required, use a piloted bushing driver to install new M94644

bushings (L) into rockshaft housing. 7. Install washer onto rockshaft against right side lift arm.
2. Install two new inner O-rings (J) into rockshaft housing NOTE: Install shaft carefully to prevent splined cross
against bushings. shaft from knocking O-ring out of groove in bevelled
3. Install new O-rings (K) into bevelled end of two splined end of splined sleeve.
sleeves.
8. Install right side lift arm and rockshaft into right splined
4. Install right side splined sleeve into rockshaft housing sleeve in rockshaft housing.
with bevel to the inside.
M91369
M91371 9. Align punch marks on splined cross shaft and rockshaft

lever arm and install cross shaft through lever arm and into
5. Install new outer O-ring (G) into groove between splined
housing.
sleeve and rockshaft housing.
10.Install left side splined bushing into rockshaft housing
6. Align punch marks and assemble right side lift arm to
and onto splined cross shaft.
splined cross shaft. Secure with large washer, and cap
screw. 11.Install outer O-ring (G) into groove between splined
sleeve and rockshaft housing.

HYDRAULICS REPAIR
G
A
M91364
12.Install washer (F) onto splined cross shaft.

M91998
15.Install cam plate and retain with cap screw (C).

E
16.Attach position feedback rod and retain with washer and
snap ring (A).
NOTE: Whenever the rockshaft feedback mechanism
has been disturbed, be sure to adjust Rockshaft
Position Feedback Linkage. See “Rockshaft Position
Feedback Linkage Adjustment” on page 751.
Specifications:
Lift Arm Raise Angle (Above Horizontal) . . . . . . . . . . 50°
Lift Arm Lower Angle (Below Horizontal) . . . . . . . . . 20°
Total Lift Arm Range . . . . . . . . . . . . . . . . . . . . . . . . . . 70°
M89408
Maximum Variance Between Lift Arms . . . . . . . . . . . . 5°
13.Align punch marks (E) on lift arm and splined cross

shaft, and install left side lift arm onto shaft.
M91999
14.Replace spring pins in lift arm or cam plate if damaged.

HYDRAULICS REPAIR
Dual SCV Linkage
E
D
F M
N
A C
H
J G
A
K
MIF
A - Link Rod Dual SCV Linkage Disassembly:

B - Pin NOTE: Remove drilled pin closest to machine first.
C - Guide Bar
D - Spacer 1. Remove spring pin and washer from drilled pin (H)
securing bellcrank to SCV valve. Remove second spring
E - Lock Nut
pin and washer from drilled pin securing second bellcrank
F - Drilled Pin to SCV.
G - Bell Cranks
2. Remove two lock nuts securing bottom of link rods (A) to
H - Drilled Pin bellcranks (G).
I - Lock Arm
3. Remove cotter pin from end of drilled pin (F). Remove
J - Lock Lever
pin (F) and bellcranks (G).
K - Lock Gate
L - Control Rod with Boot 4. Remove lock nut and cap screw securing lock lever (J).
Remove lever.
M - Seat Bracket
N - SCV 5. Remove lock nut and cap screw securing lock arm (I) to
seat bracket (M).
6. Secure pin (B) with a flat blade screw driver and remove
lock nut (E).

HYDRAULICS REPAIR
7. Slide pin out of seat bracket (M), spacer (D), control rod
D
(L), and guide bar (C). E F
8. Remove link rods (A) from control rod (L) and pin (B) as
necessary. H
Dual SCV Linkage Assembly:

Installation is performed in the reverse order of removal.
A C G
• Apply a heavy duty water resistant grease to the main
B !
shifter pivot points.
M91397
Dual SCV Disassembly and Assembly:
A - Seal
SCV Disassembly: B - Washer
C - O-ring
D - Spacer
E - Spool
F - Small Balls
G - Spring
H - Ball
I - Detent Cap
3. Slide spool with detent assembly out of valve body.
1
4. Inspect spool and valve body for signs of wear or
damage. If worn or damaged, replace entire selective
M91395
control valve assembly.
1. Remove four socket head cap screws (1) on end cover. 5. Remove spacer from spool.
Remove end cover. Replace end cover gasket.
6. Remove seal, backing washer, and O-ring from valve
NOTE: Valve spools are similar. Center valve section body. Replace O-ring and seal.
does NOT contain a detent assembly.
2 I
F
M91398
7. Remove detent cap (I) by inserting a suitable pin punch

M91396 into the threaded hole and pressing inward to release
spring tension on balls (F). Slide detent cap off end of
2. Hold spring slightly compressed and remove spring
spool.
retainer plug (2) and valve spring retainer. Remove spring.
NOTE: Use care when removing valve spool and detent
assembly from valve body. Detent cap may come off,
and balls may fall out and be lost. Push valve spool out
from lever side to remove.

HYDRAULICS REPAIR
I
F
M91399
8. Remove detent cap.

9. Remove four small balls.
M91398
5. Using a suitable pin punch, press on the ball in the end

of the spool to slightly compress the spring. Slide detent
cap over four small balls.
NOTE: When properly installed, the four small balls will
retain the larger ball, and maintain spring pressure on
G H the larger ball.
M91647
6. Install spacer onto spool.
7. slide spool into valve body.
10.Remove larger ball (H), and spring (G).
8. Install O-ring, backing washer, and seal into valve body.
Valve Spools Assembly:
9. Install spring, spring retainer, and valve spring retainer
plug. Tighten plug to 15 N•m (133 lb-in.).
and seals. Used or damaged O-rings and seals 10.Install end cover. Retain with four socket head cap
will leak. screws. Tighten cap screws to 19 N•m (14.5 lb-ft).
1. Install spring and ball into end of valve spool. 11.Install lever assembly. Retain with four cap screws.
Tighten cap screws to 40 N•m (30 lb-ft).
Load Check Valves Removal:

I
H
G
A
F
E
M91648
MIF
2. Apply a small amount of general purpose grease into 1. Remove valves (A).
the holes for the small balls (F) on the valve spool.
B C D
3. Insert four small balls into holes in valve spool.
4. Slide detent cap (I) over end of valve spool. Do not slide
over balls at this time.
M91649
2. Replace O-ring (B).

HYDRAULICS REPAIR
3. Inspect spring (C) and valve poppet (D) for wear or
damage. Replace if necessary.
Load Check Valves Installation:

G
M91651
E 2. Replace O-rings (F) and backing washers (G).
3. Inspect valve for wear or damage. Replace if necessary.
Relief Valve Installation:

MIF
IMPORTANT: Avoid damage! Replace all O-rings and seals. Used or damaged O-rings and seals
and seals. Used or damaged O-rings and seals will leak.
will leak.
• Tighten relief valve to 50 N•m (37 lb-ft).
• Tighten check valve to 24 N•m (18 lb-ft).
NOTE: If replacement of relief valve was necessary, or
Relief Valve Removal: if relief valve setting was changed, perform SCV
pressure relief valve adjustment. See “System
Pressure Adjustment” on page 748.
E
Hydraulic Cylinder Repair

Cylinder Disassembly and Assembly:
IMPORTANT: Avoid damage! Clamping cylinder

in a vise at the middle or rod end of barrel may
damage the barrel. Clamp only at the cylinder
base end.
Extend rod to remove oil or air between rod
M91650 piston and rod guide. Excessive amounts of
1. Remove valve (E). trapped oil or air will expand seals and make
disassembly more difficult.
1. Open both ports and drain all oil fro cylinder.

2. Extend rod fully.
3. Clean outside surface of cylinder with suitable solvent
and dry to prevent dirt and debris from entering cylinder
barrel.

HYDRAULICS REPAIR
A
C
MX11647
MX11662
7. Install filler ring (C), supplied with cylinder seal kit, into
4. Remove external snap ring (A). barrel snap ring groove in the direction shown to prevent
snap ring from engaging in barrel snap ring groove during
removal.
B E D
F G
MX11663 H
5. Using a wooden dowel or brass drift, drive rod guide (B) MX11665
into cylinder past barrel snap ring groove.
8. Pull rod assembly (D) with snap ring (E) from cylinder
6. Remove any debris in barrel snap ring groove. barrel.
NOTE: Install rod end in soft-jawed vise in order to
IMPORTANT: Avoid damage! If filler ring (C) is
remove nut.
installed backwards, snap ring may not
disengage and filler ring could be damaged. 9. Remove nut (F), piston (G) and rod guide (H).
10.Remove groove filler ring from snap ring groove. Do not
use for reassembly.
NOTE: When removing seals from piston and rod
guide, do not damage, mark or score any surface that
contacts the seals.
C
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.
MX11664

HYDRAULICS REPAIR
MX11667
3. Install a plastic tie band around cap seal (J) with the
smooth side against the seal.
MX11650
4. Pull cap seal across land into position over seal
13.Inspect groove in cylinder barrel. If necessary, clean expander using the plastic tie band.
groove and remove nicks, burrs, or rust from inside of barrel
using emery cloth.
IMPORTANT: Avoid damage! For proper fit, the
14.Clean inside of barrel using a safe solvent and blow dry backup rings must be installed with the radius
using compressed air. toward the seal expander.
NOTE: There are two different piston types. Refer to 5. Install back-up rings (K) with radius (L) toward seal
the steps below which pertain to your piston. expander (I).
TYPE I Pistons (Four Piece Piston Seal): TYPE II Pistons (Two Piece Piston Seal):
NOTE: All parts must be clean and dry before NOTE: All parts must be clean and dry before
assembly. assembly.
L L N
I
K J K
MX11668
MX11666
1. Install O-ring (M).
1. Install seal expander (I).
NOTE: Cap seal (N) can be made more pliable by
NOTE: Cap seal (J) can be made more pliable by putting the seal in hot water for approximately 5
putting the seal in hot water for approximately 5 minutes.
minutes.
Install cap seal as quickly as possible once it has been
Install cap seal as quickly as possible once it has been removed from the water and dried to keep the amount
removed from the water and dried to keep the amount of time that seal is stretched to a minimum.
of time that seal is stretched to a minimum.
2. Push seal (N) on end of piston.
2. Push cap seal (I) on end of piston.

HYDRAULICS REPAIR
S R
T
N P
MX11669
3. Install a plastic tie band around cap seal with the

smooth side against the seal.
4. Pull cap seal across land into position over O-ring (M)
E
using the plastic tie band.
For ALL Pistons: MX11656
1. Check if cap seal is loose. Seal must fit tight against

Q
seal expander and not turn. If seal can be turned, it has
stretched too much and can be damaged during assembly
into barrel.
NOTE: Protect cap seal by placing shim stock (O) or P
protective material between seal and clamp when
compressing.
MX11658
O
S E
R
T
MX11655
2. If necessary, shrink cap seal to original size by using a

ring compressor or hose clamp. Seal will also shrink to its
MX11657
original size if left for a minimum of 8 hours before installing
assembly into barrel. 3. Install seals (Q) and (P), snap ring (E), O-ring (R), back-
up ring (S) and O-ring (T).
NOTE: Seal (P) must be installed with the lip facing
inside of cylinder as shown. NOTE: Install rod end in soft-jawed vise in order to
tighten nut.

HYDRAULICS REPAIR
E
G
U H F
MX11660
MX11670
9. Apply light film of clean hydraulic oil on seals and
chamfer (V) of barrel.
4. Install external snap ring (U), rod guide (H), piston (G)
and nut (F) on rod. 10.Compress the internal snap ring using a hose clamp
until snap ring is seated in groove on rod guide and then
5. Apply light coat of LOCTITE 242 and tighten to torque loosen a little.
specification. If 45 degree torque turn is specified, go to
next step. If no torque turn is specified, go to Step 9. NOTE: Remove hose clamp once internal snap ring has
entered cylinder bore to prevent damage to external O-
ring.
11.Drive rod guide (E) into barrel until snap ring seats in the
barrel groove.
12.Pull forward on rod to ensure that it has locked.
MX11671
6. Put tape around a socket. Make marks on the tape to

divide the socket into 1/8’s. The marks will be 45 degrees
apart. These will serve as a visual reference to determine
torque tightening plus 45 degrees.
MX11662
13.Install snap ring (A).

H
5/8-18 UNF-2A. . . . . . . . . . . . . . . . . . . . 130 N•m (96 lb-ft)
3/4-16 UNF-2A. . . . . . . . . . . . . . . . . . . 210 N•m (155 lb-ft)
M12 x 1.5 . . . . . . . . . . . . . . . . . . . . . . . . 100 N•m (74 lb-ft)
Torque Specification (Plus 45 Degrees):

G
M16 x 1.5 . . . . . . . . . . . . 50 N•m (37 lb-ft) + 45 degrees)
MX1672
7. Tape a piece of wire on the rod guide (H), over the

piston (G), pointing to one of the marks on the socket.
8. Turn piston nut beyond the snug torque, 45 degrees.

STEERING TABLE OF CONTENTS
Steering
Table of Contents
Specifications ...............................................779
Steering Specifications...............................779
Steering Components - eHydro..................780
Steering System Schematic .......................781
All Models:..................................................782
Hydrostatic Model:......................................782
SST or ePowrReverser Models:.................782
Diagnostics ...................................................782
Steering Operation .....................................782
Component Diagnosis ................................784
Steering System Test .................................785
Toe-in Adjustment MFWD ..........................785
Toe-in Adjustment 2-WD ............................786
Repair.............................................................786
Steering Cylinder
Removal and Installation MFWD................786
Steering Cylinder
Removal and Installation 2-WD..................787
Steering Wheel
Tilt Steering Mechanism
Steering Control Unit (SCU)
Tie Rod
Removal and Installation 2-WD..................790
Tie Rod
Disassembly and Assembly 2-WD .............791
Tie Rod
Removal and Installation MFWD................791
Steering Table of Contents - 777

STEERING TABLE OF CONTENTS
Steering Table of Contents - 778

STEERING SPECIFICATIONS
Specifications
Steering Specifications
Steering Wheel OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356 mm (14.0 in.)
Front Steering Angle: Maximum Inward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54°
Front Steering Angle: Maximum Outward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62°
Maximum Rotation of Steering Wheel -
Steering at Maximum Right or Left and Constant Torque Applied to Steering Wheel. . . . . . . . . . . . . . . . . . . . . 5 rpm
Toe-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 3 mm (0 - 0.125 in.)
Lubrication Interval:
Tie Rod Ends, Front Axle Pivot Pin (Normal Conditions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Every 50 hours
Tie Rod Ends, Front Axle Pivot Pin (Dusty Conditions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Every 10 hours
Steering Wheel Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 - 49 N•m (29 - 36 ft-lb)
Wheel Mounting Bolts:
Front and Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 N•m (72 lb-ft)
Front Wheel with Ribbed Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 N•m (50 lb-ft)
Steering Cylinder Hose Ends:
Hose to Cylinder Adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 24 N•m (150 - 212 lb-in.)
Tube Nut to Hose at Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 - 47 N•m (24 - 34 lb-ft)
SCU Hose Ends:
Cylinder Tube to Hose at SCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 24 N•m (150 - 212 lb-in.)
Pressure or Return Hose to Adaptor Fitting on SCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 - 47 N•m (24 - 34 lb-ft)
SCU to Machine Cap Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 38 N•m (22 - 28 lb-ft)
Adaptor Fittings to SCU Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 16 N•m (124 - 142 lb-in.)
Tie Rod to Spindle Arm Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 - 129 N•m (85 - 95 lb-ft)
Tie Rod to Steering Cylinder Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 - 129 N•m (85 - 95 lb-ft)
Steering Cylinder (Dual End):

Steering Cylinder to Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - 31 N•m (18 - 22 lb-ft)
Left Hand Bracket to Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 - 122 N•m (85 - 90 lb-ft)
Steering Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 - 37 N•m (19 - 27 lb-ft)
Ball Joint to Cylinder Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 - 129 N•m (85 - 95 lb-ft)
Steering Cylinder (Single End):

Cylinder to Spindle Arm Castle Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 - 129 N•m (85 - 95 lb-ft)
Hose Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 - 37 N•m (19 - 27 lb-ft)
Cylinder to Spindle Arm Castle Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 - 129 N•m (85 - 95 lb-ft)
Steering Cylinder to Mounting Bracket Cap Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 - 38 N•m (22 - 28 lb-ft)
Steering Cylinder Bracket to Front Axle Cap Screws and Nuts. . . . . . . . . . . . . . . . . . . . 126 - 154 N•m (94 - 115 lb-ft)
Steering Specifications - 779

STEERING COMPONENT LOCATION
Component Location
Steering Components - eHydro
B
R D
L E
PT
A E
O
B
P
C
F
E
A
M
K
I G
J
N
L
MIF I - Engine Mounted Hydraulic Pump

A - Pressure Hose J - Pressure Line (to SCU)
B - Left Turn Hose K - Right Turn Hose
C - Right Turn Hose L - Left Turn Hose
D - Plug M - Rod End (To Tie Rod)
E - Return Hose (Tank) N - Steering Cylinder
F - Steering Control Unit (SCU) O - Hydraulic Oil Cooler
G - Hydrostatic Transmission P - Suction Tube Elbow
H - Cartridge Filter (Reservoir to Pump)
Steering Component Location - 780

STEERING COMPONENT LOCATION
Steering System Schematic
Steering Cylinder
Left (L) Right (R)
Left Right
Relief Valve
POWER
10342 kPa
STEERING VALVE
1500 psi
P T
Steering Wheel
Engine
7.5 or 8.2 cm3/rev

Gear Pump
(Front)
To Transmission Tunnel
150 Mesh
Intake Filter
Sump
MIF
Steering Component Location - 781

STEERING THEORY OF OPERATION
Theory of Operation Diagnostics
All Models: Steering Operation

The front hydraulic pump supplies hydraulic pressure to the Symptom: Steering Function Problems
steering control unit (SCU). The SCU utilizes an open
center control valve to operate the steering cylinder. When (1) Steering pulls in one direction?
the steering wheel is turned, the SCU directs hydraulic No - Go to next step.
pressure to the appropriate steering cylinder hose, pushing
the steering cylinder ram, which pivots the front spindles Yes - Tire size incorrect, out-of-round, or air
and wheels. The SCU has no relief valve. The SCU and pressure incorrect.
steering cylinder are not rebuildable, and must be replaced Yes - Spindles and/or bearings worn or not
as complete units. lubricated sufficiently.
Yes - Tie rod ends loose or worn.
Hydrostatic Model:
Yes - Toe-in incorrect.
Excess oil from the SCU passes through a tee fitting on the
left side of the machine, in front of the fuse panel. Oil Yes - Steering cylinder rod (tie rod) bent or
travels either to the oil cooler, mounted in the front of the damaged.
machine, or directly to the hydrostatic unit. Oil entering the Yes - Wheel bearing retaining nut loose.
hydrostatic unit passes through a cartridge filter. The
hydrostatic unit is a combination motor and pump, and Yes - Wheel bearings worn or lost lubricating
operates as a closed loop. Most of the hydraulic oil properties.
delivered to this unit passes by the charge pressure relief Yes - Front steering suspension weak or unstable.
valve, and returns to the reservoir. A small amount of oil
flows through the hydrostatic unit, providing internal (2) Steers hard left, right, or both?
lubrication, then returns to the reservoir. Pressurized oil is No - Go to next step.
also supplied to port M3 and then to the valve manifold.
Yes - Spindles and/or bearings worn or not
lubricated sufficiently.
SST or ePowrReverser Models:
Excess oil from the SCU passes through the filter and
returns to the reservoir. Yes - Toe-in incorrect.
Yes - Steering cylinder rod (tie rod) bent or
damaged.
Yes - Wheel bearings worn or lost lubricating
properties.
Yes - Tire size incorrect, out-of-round, or air
pressure incorrect.
Yes - Steering wheel and/or shaft splines worn or
stripped.
Yes - SCU leaking internally.
Yes - Steering cylinder leaking internally.
(3) Steering locks in hard left or right turns?
damaged.
Steering Theory of Operation - 782

STEERING DIAGNOSTICS
Symptom: Steering Function Problems Symptom: Steering Function Problems
(4) Steering wheel pulls upward? Yes - Steering wheel and/or shaft splines worn or
stripped.
Yes - Steering wheel nut loose, stripped, or fallen
Yes - Steering control unit mounting loose.
off.
(9) Steering wheel turns, but wheels do not?
off.
(5) Steering wanders?
damaged.
(10) Steering wheel tilt does not lock?
No - Go through diagnostic procedures and/or go
back to previous steps.
properties.
Yes - Tilt steering locking mechanism worn or
Yes - Tire size incorrect, out-of-round, or air
damaged.
pressure incorrect.
Yes - Steering wheel and/or shaft splines worn or Symptom: Steering Noise
stripped.
(1) Noise during turns or over rough terrain?
off. No - Go to next step.
Yes - Front steering suspension weak or unstable. Yes - Spindles and/or bearings worn or not
(6) Steering shimmies or vibrates?
Yes - Front steering suspension weak or unstable.
Yes - Spindles and/or bearings worn or not properties.
(2) Wheel bearing noise?
No - Go through diagnostic procedures and/or go
Yes - Wheel bearing retaining nut loose. back to previous step.
Yes - Wheel bearings worn or lost lubricating Yes - Spindles and/or bearings worn or not
properties. lubricated sufficiently.
Yes - Tire size incorrect, out-of-round, or air Yes - Wheel bearing retaining nut loose.
pressure incorrect.
Yes - Front steering suspension weak or unstable. properties.
(7) Front wheels “plow” loose soil to sides?
Yes - Toe-in incorrect.
(8) Steering wheel spins freely?
Steering Diagnostics - 783

STEERING DIAGNOSTICS
Component Diagnosis
Rims Runout not excessive Replace rims

Wheel bolts tight Tighten to specification
Tires Runout not excessive Remount or replace tires

Tires properly inflated Inflate tires to proper pressure
Wheel Bearings Wheels rotate freely without rough Replace bearings

spots
Pinion Shaft and Hub Shaft Assemblies tight and turn smoothly Tighten or replace assemblies
Final Drive Housing Fastened securely Tighten fasteners to specification
Front Axle Mounting Pivot Pivot bushing not worn or binding Replace bushing
Tie Rod Castle nut tight. Tighten castle nuts; install cotter pin.
Tie Rod (steering cylinder rod) Replace worn or damaged steering
straight; toe-in correct. cylinder; adjust toe-in.
Steering Cylinder Assembly fastened securely Tighten cylinder

Operates from stop-to-stop smoothly Replace cylinder
with little effort; not leaking
Steering Cylinder Control Fastened securely to frame Fasten securely

Not leaking Tighten fittings, replace SCU
Upper Steering Shaft Bushings Not worn Replace steering column
Steering Wheel and Leaping No cracks or breaks Replace components as necessary

Deer Emblem Installed properly; nut tightened to Install and tighten properly
specification
Steering Diagnostics - 784

STEERING TESTS AND ADJUSTMENTS
Tests and Adjustments Toe-in Adjustment MFWD
Reason:
Steering System Test
To ensure proper wheel tracking when turning, and to
Reason: prevent tire scrub and premature tire wear.
To check steering control unit and steering cylinder
Tools:
operation and check for internal leakage.
• Wrenches
Tools:
• Tape Measure
• Torque wrench
• Tire scribing tool
• Caps for hydraulic lines
Procedure:
Procedure:
NOTE: If both tie rod ends were removed, screw-in the
1. Run the machine until the hydraulic fluid is at operating rod end until the distance from the lock nut to the end
temperature. of the threads is approximately 22 mm (.875 in).
2. Turn the steering wheel to the full right position. Apply Tighten the lock nuts.
constant torque to the steering wheel retaining nut, and
count the steering wheel rotations in one minute.
3. Repeat the procedure turning the steering wheel to the
full left position.
4. Stop engine.
A
Results:
B
• If the rotation in left or right hand direction exceeded five
rotations in one minute, the steering system has internal
leakage. To determine whether it’s the SCU or cylinder that
is leaking, proceed as follows:
Procedure:
1. Label and remove both left and right hydraulic hoses at
the steering cylinder.
2. Cap the ends of both hoses. MX1190
3. Repeat the SCU test. 1. Jack up front axle so tires are off of floor.
2. Rotate tire by hand and scribe a line near the center of
Results: each of the front tires.
• If the rotation speed is now below five rotations in one 3. Measure and record the distance between the lines at
minute, replace the steering cylinder. the front and the rear of the tire at about axle height. The
• If the rotation speed remains above five rotations in one front measurement should be 0 - 3 mm (0 - 0.125 in.) less
minute, replace the SCU. than the rear measurement.
NOTE: One of the tie rod ends and jam nut has left
hand threads.
4. If measurement is not correct, loosen jam nuts (A) on
both ends of tie rod and turn the tie rod (B) using a wrench
to increase or decrease the amount of toe until the
measured dimension is within specifications.
5. Tighten the jam nuts.
Specifications:
Toe In. . . . . . . . . . . . . . . . . . . . . . 0 - 3 mm (0 - 0.125 in.)
Steering Tests and Adjustments - 785

STEERING REPAIR
Toe-in Adjustment 2-WD Repair
Reason:
Steering Cylinder Removal and Installation
To ensure proper wheel tracking when turning, and to MFWD
prevent tire scrub and premature tire wear.
Removal:
Tools:
• Wrenches
• Tape Measure B
• Pliers
Procedure:
Measure
MX0979
NOTE: Cylinder ball end studs are tapered. Use a tie

rod end removal tool to avoid damaging threads if
cylinder is to be re used.
Measure
1. Mark hoses (A) and disconnect from cylinder.
M91751
2. Remove cotter pins and castle nuts (B).
1. Jack up front axle so tires are off of floor. 3. Remove cylinder.
2. Rotate tire by hand and scribe a line near the center of
each of the front tires. Installation:
3. Measure and record the distance between the lines at 1. Inspect rubber boots on ends of cylinder. Replace boots
the front and the rear of the tire at about axle height. if necessary.
Measurement at front of tire should be slightly less than 2. Install cylinder and tighten castle nuts to specification. If
measurement at rear (toed in). slots in castle nut do not line up with cotter pin hole,
4. Compare measurement to specifications, and adjust tie continue tightening nut until next slot lines up.
rod to increase or decrease the amount of toe until the 3. Connect hoses to cylinder.
dimension is within specifications.
5. Tighten the lock nut. Specifications:
Castle Nuts . . . . . . . . . . . . . 115 - 129 N•m (85 - 95 lb-ft)
Specifications:
Hose Ends. . . . . . . . . . . . . . . . 26 - 37 N•m (19 - 27 lb-ft)
Toe In . . . . . . . . . . . . . . . . . . . . . . 0 - 3 mm (0 - 0.125 in.)
Steering Repair - 786

STEERING REPAIR
Steering Cylinder Removal and Installation 2- Steering Wheel Removal and Installation
WD
Removal:
Removal: 1. Remove steering wheel center cap.
2. Remove lock nut.
A
3. Remove steering wheel. If necessary, use a suitable
puller.
Installation:
B
B
C NOTE: Lubricate the steering shaft splines and taper
with general purpose grease before installing steering
wheel to allow easy removal.
M95282
1. Remove white center cap plastic retaining ring from
1. Label and disconnect both steering hoses (A) from the
steering wheel.
steering cylinder.
2. Install steering wheel and retain with nut. Tighten
2. Place a wrench on each of the tie rods (C) on the ends
steering wheel nut to specification.
of the cylinder rod (B), and turn to remove one side.
3. Install plastic retaining ring to steering wheel center cap.
3. Place a wrench on the flats, or a suitable tool through
the hole in the end of the cylinder rod where the tie rod was 4. Install center cap and retaining ring to steering wheel.
removed to prevent the cylinder rod from turning.
Specification:
4. Place a wrench on the remaining tie rod, and remove.
Steering Wheel Nut . . . . . . . . 39 - 49 N•m (29 - 36 lb-ft)
5. Remove three cap screws, lock washers, and nuts
attaching steering cylinder and left hand bracket to front
axle. Move steering cylinder to left to remove from right Tilt Steering Mechanism Removal and
hand bracket. Remove cylinder. Installation
Installation: Removal:
1. Install the steering cylinder into right hand bracket, and 1. Remove steering wheel.
secure left hand bracket to the front axle with three cap 2. Remove control panel. See “Control Panel” on
screws, lock washers, and nuts. Tighten cap screws to 126 page 822.
- 154 N•m (94 - 115 lb-ft).
NOTE: Keep a firm grip on spring retainer while
2. Attach cylinder end to spindle arm. Secure with castle
releasing spring tension.
nut. Tighten to 115 - 129 N•m (85 - 95 lb-ft). Install cotter
pin to secure nut.
3. Connect steering hoses to fittings on cylinder. Tighten
connectors to 17 - 24 N•m (150 - 212 lb-in.).
4. Adjust toe-in. See “Toe-in Adjustment 2-WD” on A
page 786.
MX9698

STEERING REPAIR
3. Press down on the spring retainer (A), and twist the
spring retainer 90 degrees which releases it from the tilt
collar.
E
B
MX9699
6. Remove four socket head cap screws and remove the

two caps (E).
MX9701
4. Remove retainer, spring (B), and lock collar (C).
D MX9700
7. Tilt the shaft and collar (F) toward the springs (G) and
disconnect the springs.
MX9702
5. Remove the snap ring (D).

STEERING REPAIR
MX9705
10.Remove pin and springs. Inspect all parts for wear or

MX9703 damage. Replace parts as necessary.
8. Remove shaft from tilt collar. Inspect all parts for wear or
NOTE: When installing springs, install ends with
damage
tighter loops onto pin
NOTE: Place a rubber band through springs and on
casting as shown to keep springs and pin from falling Installation:
out during disassembly/assembly. 1. Install the springs onto the pin with the more tightly
closed end loops onto the pin. Hold the springs or secure
with rubber band to keep them from falling out during
installation.
2. Install the bottom casting with the springs toward the top
and secure with four socket head screws.
3. Install steering shaft into tilt collar. Do not install snap
ring at this time.
4. Tilt the shaft and collar (F) toward the springs (G) and
connect the springs.
5. Align the splines on the steering shaft to the SCU shaft
and slide shaft and collar into place.
6. Install the caps.
7. Pull up on the steering shaft and install the snap ring.
8. Install lock collar (C), spring and retainer (B),
H
9. Push down on the spring retainer, engage the tabs into
the slots on the tilt collar, and turn clockwise
MX9704
9. Remove four socket head cap screws (H) and lift the
bottom casting from the steering control unit.

STEERING REPAIR
Steering Control Unit (SCU) Removal and 5. Install the control panel lower shroud.
Installation 6. Install the control panel.
Removal: 7. Install the steering wheel.
1. Remove the steering wheel. 8. Fill the hydraulic system to the proper level; bleed the
system if required.
2. Remove the control panel. See “Control Panel” on
page 822. Specifications:
3. Remove the control panel lower shroud. SCU Adapter Fittings . . . . 14 - 19 N•m (124 - 168 lb-in.)
4. Remove the tilt steering assembly. See “Tilt Steering SCU Mounting Cap Screws . . 30 - 38 N•m (22 - 28 lb-ft)
Mechanism Removal and Installation” on page 787. Small Hoses To SCU . . . . 19 - 27 N•m (168 - 240 lb-in.)
Large hoses To SCU . . . . . . . 40 - 57 N•m (30 - 42 lb-ft)
B Tie Rod Removal and Installation 2-WD

Removal:
B
A
A M91331
MX9717 M91757
5. Label and remove the four hydraulic hoses (A). 1. Remove cotter pin (A) and castle nut (B) from each rod
end attaching tie rod to spindle arm.
NOTE: The SCU has no serviceable components. If the
SCU does not meet specifications, the unit must be 2. Using a ball joint separator, disconnect ball joint end
replaced. from spindle arm (C). Remove tie rod.
6. Remove four cap screws (B) and star washers. Remove Installation:
the SCU from the machine.
1. If installing ball joint previously used, inspect boot. If
boot is damaged, or in poor condition, replace tie rod end.
Installation:
2. Insert threaded end of ball joint into hole in spindle arm.
1. Replace O-rings in adapter fittings.
3. Install castle nut to rod end.
2. Install adapter fittings to the SCU ports. Tighten to
specification. 4. Tighten castle nut to 115 - 129 N•m (85 - 95 lb-ft).
NOTE: Unevenly or improperly torquing cap screws 5. Install cotter pin.
attaching SCU to machine can result in distortion of 6. Lubricate tie rod end using general purpose grease.
the valve body, and premature failure of the SCU. Follow lubrication procedure outlined in the maintenance
3. Install the SCU to the machine. Fasten with four cap section of the operator’s manual.
screws and star washers. Tighten to specification. 7. Adjust toe-in. See “Toe-in Adjustment 2-WD” on
4. Install the hydraulic hoses to the adapter fittings. Tighten page 786.
cylinder hoses to specification. Tighten pressure and return
hoses to specification.

STEERING REPAIR
Tie Rod Disassembly and Assembly 2-WD Tie Rod Removal and Installation MFWD
Disassembly: Removal:
1. Remove ball joint boots from ball joints and clean parts
thoroughly using a suitable solvent.
MIF
2. Measure length (A) of tie rod from clamped tube end to

lubrication fitting on rod end. Record measurement.
3. Loosen cap screw and nut (B) on tie rod clamp.
4. Remove rod end from tie rod tube.
5. Loosen locking nut on adjustable rod end.
6. Unscrew adjustable rod end from tie rod.
7. Inspect ball joints for damage, wear, and smooth
operation. Replace if necessary. A
A
Assembly: MX1401
1. If installing ball joint previously used, inspect boot. If 1. Remove cotter pins from castle nuts (A) and remove
necessary, replace tie rod end. castle nuts.
2. If removed, thread locking nut onto adjustable tie rod 2. Using a tie rod end separator, remove tie rod ends from
end. spindles.
3. Install threaded rod end into tie rod so that
NOTE: If removing tie rod ends, one of the tie rod ends
approximately half the threads are showing.
and jam nut has left hand threads.
4. Install plain rod end into tie rod. Measure from end of tie
rod tube to lubrication fitting on tie rod end. Install so that Installation:
dimension is same as that recorded before disassembly. 1. Inspect tie rod end boots. If necessary, replace boots.
Tighten clamp to retain rod end in tie rod tube.
2. Insert tie rod ends into holes in spindle arms.
5. Adjust toe-in. See “Toe-in Adjustment 2-WD” on
page 786. 3. Install two castle nuts to rod ends.
4. Tighten castle nuts (A) to specification.
5. Install the cotter pins. If slots in castle nuts don’t align
with holes after torquing, tighten nuts until next slot aligns.
6. Lubricate tie rod ends using general purpose grease.
Follow lubrication procedure outlined in the maintenance
section of the operator’s manual.
7. Adjust toe-in. See “Toe-in Adjustment MFWD” on
page 785.
Specifications:
Castle Nuts . . . . . . . . . . . . . . 75 - 108 N•m (55 - 80 lb-ft)

STEERING REPAIR

BRAKES TABLE OF CONTENTS
Brakes
Table of Contents
Specifications ...............................................795
Brakes: .......................................................795
Transaxle Oil: .............................................795
Torque Specifications:................................795
Additional Materials: ...................................795
Brake Housing............................................796
Parking Brake (Side Mount) .......................797
Brake Pedals and Linkage
(SST North American) ................................798
(SST European) .........................................799
(ePowrReverser North American) ..............800
(ePowrReverser European)........................801
(eHydro North American) ...........................802
Brakes ........................................................803
Diagnostics ...................................................804
Brakes ........................................................804
Brake Pedal Adjustment.............................805
Parking Brake Adjustment -
Side Mount .................................................805
Parking Brake Adjustment -
Console Mount ...........................................805
Repair.............................................................806
Brake Disassembly and Inspection ............806
Brake Assembly .........................................807
Brake Pedal
Removal and Installation - eHydro .............808
Brake Pedal Removal and Installation -
SST and ePowrReverser............................810
Parking Brake Linkage
Brakes Table of Contents - 793

BRAKES TABLE OF CONTENTS
Brakes Table of Contents - 794

BRAKES SPECIFICATIONS
Specifications
Brakes:
Brake Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet Multiple Disk
Brake Pedal Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 - 76 mm (2.5 - 3.0 in.)
Pedal Free Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - 40 mm (1.06 - 1.58 in.)
Total Brake Actuation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 - 64 mm (2.0 - 2.5 in.)
Pedal Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 mm (0.08 in.) or Less
Friction Disk and Plate Pack Thickness (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.51 mm (0.650 in.)
Brake Cam to Brake Plate Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 - 0.9 mm (0.025 - 0.035 in.)
Transaxle Oil:
Capacity (Hydrostatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.0 L (6.8 gal)
Capacity (Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.0 L (6.3 gal)
Wheel Mounting Bolts:
Front and Rear Wheel Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 N•m (103 lb-ft)
Front wheels (Model 4210 Equipped With 4.0 x 15 F2 Ribbed Tires) . . . . . . . . . . . . . . . . . . . . . . . . . . 68 N•m (50 lb-ft)
Front Wheels (Model 4310 Equipped With 5.0 x 15 F2 Ribbed Tires) . . . . . . . . . . . . . . . . . . . . . . . . . . 68 N•m (50 lb-ft)
Clutch Rod Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 - 44 N•m (27 - 33 lb-ft)
Left Hand Brake Lever Cap Screw (SST & ePowrReverser Only) . . . . . . . . . . . . . . . . . . . . . 36 - 44 N•m (27 - 33 lb-ft)
Additional Materials:
Thread Sealant (General Purpose) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TY9370 6 ml (0.2 oz)
Sealant (For Flanges) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TY16021 50 ml (1.7 oz)
Brakes Specifications - 795

BRAKES COMPONENT LOCATION
Component Location
Brake Housing
C
D E
C
A
MIF
A - Brake Arm D - Balls

B - Brake Cam E - Actuator Plate
C - Brake Retainer Plate F - Friction Disks and Plates
Brakes Component Location - 796

Parking Brake (Side Mount)
G
D
MIF E - Link
A - 2 Speed PTO Lever (European) F - Release Button
B - Brake Shaft Assembly G - Handle
C - Clevis H - Ratchet
D - Park Brake Cable I - Brake Lever

Brake Pedals and Linkage (SST North American)
C K
J
B
D
A
D
E
G
MX9851
A - Brake Pedal
B - Brake Pedal Return Spring
C - Brake Shaft
D - Upper Brake Rod
E - Lower Brake Rod
F - Adjustment Turnbuckle
G - SST Clutch Pedal
H - Clutch Rod
I - Clutch Pedal Return Spring
J - Park Brake Rod
K - Park Brake Engagement Lever

Brake Pedals and Linkage (SST European)
B
D
I
A
D
K
G
F
H
K
J
L
MX9852
A - Brake Pedal
C - Brake Shaft
D - Upper Brake Rod
E - Lower Brake Rod
G - SST Clutch Pedal
H - Clutch Rod
J - Park Brake Lever
K - Park Brake Bellcrank
L - Park Brake Connecting Cable

Brake Pedals and Linkage (ePowrReverser North American)
C L
K
H D
A
D
E
G
MX9854
A - Brake Pedal
C - Brake Shaft
D - Upper Brake Rod
E - Lower Brake Rod
G - ePowrReverser Clutch Pedal
H - Clutch Linkage Plate
J - Potentiometer
K - Park Brake Rod
L - Park Brake Engagement Lever

Brake Pedals and Linkage (ePowrReverser European)
H D
A
D
E
G
K
M
MX9855
A - Brake Pedal
C - Brake Shaft
D - Upper Brake Rod
E - Lower Brake Rod
G - ePowrReverser Clutch Pedal
H - Clutch Linkage Plate
J - Potentiometer
K - Park Brake Lever
L - Park Brake Bellcrank
M - Park Brake Connecting Cable

Brake Pedals and Linkage (eHydro North American)
B
C
E
A
F
F J
I I
J G
L
K
MX9853
A - Park Brake Linkage

B - Cam Lever
C - Pivot Bolt
D - Engagement Lever
E - Shaft, Brake
F - Upper Brake Rod
G - Pedal, Brake
H - Pedal, Brake
I - Shaft
J - Lever
K - Lower Brake Rod
L - Turnbuckle

BRAKES THEORY OF OPERATION
Theory of Operation differential housing slows or stops the rear drive wheels.
Removing pressure from the pedal allows the brake arm
Brakes return spring and brake pedal return spring to pull the pedal
back to the original position, releasing the brakes.
The mechanical wet disk brakes operate on each rear
wheel of the machine. The brakes are engaged by the The side mount parking brake uses cables extending from
operator applying pressure to the brake pedals. When the park brake shaft assembly down to the brake levers on
pressure is applied to a brake pedal, the pedal pulls the the final drive case, and is engaged with the park brake
front brake rod up. The brake rod pulls on the bellcrank lever. It operates independently of the brake pedals. The
which pivots, pulling on the lower brake rod. The lower parking brake lever is pulled up, pulling the link which turns
brake rod pulls on the brake lever (A) on the final drive the park brake shaft. On the park brake shaft are two cam
housing. arms which pull the park brake cables. The park brake
cables pull the brake levers (A) on the final drive case. The
Inside the housing, the cam (B) on the brake lever pushes park brake is locked in position by a ratchet on the park
against a tab (C) on the brake actuator. The brake actuator brake lever. The brake disks are held in position until the
is rotated, moving angled ramps against captive steel balls park brake release button is pushed, and the park brake
(D). As the actuator rotates, the balls and ramps force the lever is pushed down.
actuator against the friction disks (E) and plates (F), and in
turn the differential housing. The friction plates are held in The dash mount parking brake mechanically latches the
position by the cam which rests in a U-shaped slot. The brake foot pedal in position after it is pressed down by the
friction disks are splined to the axle shaft. The friction operator. Its operation is dependent on use of the brake
between the friction disks and the separator plate/ pedal.
B C
D
A
MIF
Brakes Theory of Operation - 803

BRAKES DIAGNOSTICS
Diagnostics Symptom: Brake Problems
Yes - Brake lever cam and/or actuator worn.
Brakes
Yes - Actuator/balls/housing worn or damaged.
Symptom: Brake Problems
(6) Oil Leaking From Final Drive Case At Brake
(1) Steering Pulls In One Direction? Arm?
No - Go to next step. Yes - Replace brake arm seal.
Yes - Brakes improperly adjusted.
Yes - Brakes worn or no longer serviceable.
Yes - Brake friction/stationary plates worn or
damaged.
Yes - Brake linkage damaged/binding.
Yes - Brake pedal interlock not connected.
(2) Brakes Drag or Slow To Release?
Yes - Brake return spring weak/damaged/missing.
(3) Brakes Not Effective?
Yes - Brakes worn - no longer serviceable.
damaged.
(4) Excessive Pedal Travel?
damaged.
(5) Noise During Braking?
damaged.
Brakes Diagnostics - 804

BRAKES TESTS AND ADJUSTMENTS
Tests and Adjustments Parking Brake Adjustment - Side Mount
1. To adjust the parking brake:
Brake Pedal Adjustment
• Remove close out panel under seat.
Reason: • Remove the clevis pin attaching the park brake cable
To set the brake linkage free play to allow full pedal to the park brake shaft (right hand) or brake lever on the
movement and full application of the brake disks on the rear final drive housing (left hand).
axle shafts. The brakes are adjusted using adjustable • Loosen the locking nut which locks the clevis to the
turnbuckles to lengthen or shorten the brake rods. cable.
Tools: • Turn the clevis.
• Ruler 2. Adjust clevis on the left brake so that the park brake
begins to engage with 3 clicks of park brake lever travel.
• Wrenches The park brake should be fully engaged at 4 or 5 clicks.
Reattach clevis.
Procedure:
3. Remove right brake clevis pin, and repeat procedure on
right brake. Reattach clevises.
IMPORTANT: Avoid damage! Improper park brake

C
adjustment can cause excessive heat and wear
C on brakes. Be sure brakes disengage fully when
the park brake lever is released.
4. Release the park brake, and check to ensure that the

D machine rolls freely with the park brake disengaged.
Parking Brake Adjustment - Console Mount

The parking brake operation with the console mounted on
off knob is dependent on the brake pedal adjustment.
Proper adjustment of the brake pedal linkage ensures
65 - 76 mm proper operation of the parking brake. See “Brake Pedal
(2.5 - 3.0 in.) Adjustment.”
M91325
1. Loosen locking nuts (C) on brake rod turnbuckle (D).

2. Turn turnbuckle on rod to adjust free play.
3. Adjust the left hand and right hand turnbuckle until the
pedal free play is 27 - 40 mm (1.06 - 1.58 in.), and the total
brake pedal stroke is 63 - 76 mm (2.5 - 3.0 in.).
4. The difference between left and right side pedal free
play (pedal differential) should be less than
2 mm (0.08 in).
Results:
If the brakes are adjusted correctly:
• The wheel brakes will begin engagement when the
pedals are pressed 27 - 40 mm (1.06 - 1.58 in.).
Brakes Tests and Adjustments - 805

BRAKES REPAIR
Repair
E
Brake Disassembly and Inspection
1. Remove the final drive from the machine. See “Final D
Drive Removal” in Power Train section.
M94697
4. Remove friction disks (D) and plates (E).

5. Measure plate and disk pack thickness.
A Specification:
Friction Disk and Plate Pack
Thickness (Minimum) . . . . . . . . . . 16.51 mm (0.650 in.)
M94705
2. Remove pinion shaft (A) from transmission housing.

F
IMPORTANT: Avoid damage! Brake plates and
disks may fall out when actuator is removed. Use
care to prevent damage to disks and plates.
B B
C G
M94695
6. Remove cam shaft (F).

7. Replace O-ring (G).
M94694
3. Remove five cap screws (B) and actuator assembly (C).
Brakes Repair - 806

BRAKES REPAIR
Brake Assembly
H IMPORTANT: Avoid damage! If installing new
friction disks, soak friction disks in hydraulic oil
for 1 hour before assembling.
M94698
8. Lay actuator assembly on bench and remove three

springs (H).
K
I
J
M94699
NOTE: Be certain the steel balls locate into the ramps

of the actuator.
1. Dip the steel balls (J) in transmission oil. Install steel
balls into brake retainer plate (K).
NOTE: Actuator plate will only fit onto steel balls and
retainer plate one way. Align actuator plate and retainer
plate so that spring tangs line up.
2. Install actuator plate onto steel balls and retainer plate.
M94699
9. Remove actuator plate (I) and steel balls (J). H
10.Inspect all parts for wear or damage. Replace any worn

or damaged components.
M94698
3. Install three springs (H) onto spring tangs.
IMPORTANT: Avoid damage! If installing new

friction disks, soak friction disks in hydraulic oil
for one hour before assembling.
Brakes Repair - 807

BRAKES REPAIR
Brake Pedal Removal and Installation -
F eHydro
E Removing:
G
D 1. Remove cowl panels. See “Cowl Panel” in
A
B
M94696
4. Dip the separator plates and the friction disks in

transmission oil. Install a brake plate (E) into final drive
housing, followed by a disk (D), plate, disk, plate, disk.
5. Install a new O-ring (G) onto brake cam shaft (F), and
install cam shaft into final drive housing.
C
B MX9860
L
2. Remove snap ring and washer (A) from end of brake
C pedal pivot shaft.
3. Remove cotter pin and washer (B) from brake rod.
c CAUTION: Avoid injury! Brake return spring

is under high tension. Wear safety glasses
and gloves when removing or installing
spring from pedal.
4. Disconnect brake return spring (C) from brake pedals.

5. Remove left brake pedal.
M94694
6. Dip brake actuator (C) in hydraulic oil and install into

final drive housing. Retain loosely with five cap screws (B).
7. Adjust brake cam to brake plate gap (L) to specification.
8. Tighten cap screws to specification. D
9. Install the final drive housing to the transaxle. See “Final

Drive Installation” in Power Train section.
Specifications:
Brake Cam to Brake Plate Gap . . . 0.6 - 0.9 mm (0.025 -
0.035 in.)
Cap Screw Torque . . . . . . . . . . . . . . . . 43 N•m (32 lb-ft) MX9861
6. Remove spacer (D).
Brakes Repair - 808

BRAKES REPAIR
10.Slide brake pedal shaft assembly (H) out from machine.
E
MX9865
11.Remove inner and outer bushings from frame.

MX9862 12.Inspect all parts for wear or damage. Replace any worn
or damaged components.
7. Loosen set screw (E). Remove two keys (F) and pedal.
Installing:
1. Install the inner and outer bushings in the right side of
D frame.
C
B
A
MX9863
8. Remove inner spacer (D).
H
G
MX9866
2. Hold the park brake micro switch lever (A) up and slide
the brake shaft assembly (B) into machine frame.
3. Connect upper brake rod to brake shaft and retain with
cotter pin (C).
MX9864
9. Remove cotter pin (G) and disconnect brake rod.
Brakes Repair - 809

BRAKES REPAIR
F
E
spring from pedal.
9. Attach brake pedal return springs (L).

D 10.Adjust the brakes. See “Brake Pedal Adjustment”.
Brake Pedal Removal and Installation - SST

and ePowrReverser
MX9863
Removing:
4. On left hand side of machine, install inner and outer
bushings (E and F), and spacer (D). 1. Remove side panels.
H
I
A
C
MX9861
MX9889
5. Install the two keys (H). Install Right hand brake pedal
(G). Tighten set screw (I) on right hand brake pedal. Picture Note: ePowrReverser Shown
6. Install spacer (D). 2. Remove cotter pin and washer (A) from end of brake
rod.
3. Disconnect brake rod (B) from brake lever.
J L
4. Remove cap screw (C) and washer from end of brake
pedal pivot shaft.
5. Remove brake lever from end of brake pedal pivot shaft.
K
c CAUTION: Avoid injury! Clutch return spring
spring from pedal.
6. Disconnect clutch return spring (D) from clutch pedal.
MX9860
7. Install left hand brake pedal. Retain with washer and

snap ring (J).
8. Install brake rod to pedal and secure with washer and
cotter pin (K).
Brakes Repair - 810

BRAKES REPAIR
11.Remove spacer (J).
12.Remove inner and outer bushings (L).

G

E spring from pedal.
O
N
M
F
MX9890
7. ePowrReverser only: Remove cap screw and nut (E)

holding clutch potentiometer link plate (F) to clutch pedal.
8. Remove snap ring (G) and washer.
NOTE: Front of lower brake rod may have to be
disconnected to obtain enough clearance for top brake
rod to clear pedal.
9. Remove clutch pedal.
MX9896
H
13.On right side of machine, disconnect brake return spring
(M) from right brake pedal.
14. Remove cotter pin and washer (N) from right hand
brake rod.
15.Remove snap ring and washer (O) from pedal shaft.
16.Remove right hand brake pedal.
MX9891
O
10.Remove outer washer, snap ring, and inner washer (H).
P
L J
MX9893
17.Remove shoulder bolt (O) from park brake lock arm (P)
and remove arm. Inspect arm for wear or damage, replace
MX9892 arm if teeth are worn.
Brakes Repair - 811

BRAKES REPAIR
MX9894
18.Pull out left pedal and shaft as an assembly. MX9895
21.Inspect teeth for parking brake on inside of right pedal.

Replace if worn or damaged.
Installing:
Q
c CAUTION: Avoid injury! Clutch and brake

return springs are under high tension. Wear
safety glasses and gloves when removing or
installing springs from pedals.
1. Install left hand brake lever. Retain with washer and cap
screw (C). Tighten cap screw to 36 - 44 N•m (27 - 33 lb-ft).
MX9897 2. ePowrReverser only: Attach clutch potentiometer link
plate and retain with cap screw (E) and nut. Tighten nut to
19.Remove and inspect inner and outer pedal shaft support
36 - 44 N•m (27 - 33 lb-ft).
bushings (Q) on each side of machine. Replace any worn
or damaged parts 3. Attach clutch pedal return spring (D).
NOTE: If the parking brake has been removed,
R S complete the parking brake installation and adjustment
before adjusting the service brakes.
4. Adjust the brakes. See “Brake Pedal Adjustment”.
MX9898
20.If left pedal needs to be removed from shaft, remove nut

and washer (R). Use a soft hammer and drive pedal off of
taper in the direction shown. Inspect key (S) and all other
parts for wear or damage. Replace any damaged parts.
Brakes Repair - 812

BRAKES REPAIR
Parking Brake Linkage Removal and
Installation G
F
Side Mount Parking Brake:
Removing:
1. Remove seat. See “Seat and Seat Support” in
2. Remove closeout panel. See “Seat Closeout Panel” in C D
3. Raise right hand rear of machine and support on a
suitable stand. E
4. Remove right hand rear wheel and tire.
M91990
5. Remove right hand fender. See “Rear Fenders” in
10.On left hand side of machine, remove cotter pin (C) and
washer, and disconnect differential lock rod (D) from pedal
6. Unplug wiring harness connector from park brake (E).
switch.
11.Remove cotter pin (F) and washer, and disconnect
7. If equipped, remove cotter pin and washer and range shift lever rod (G) from shift arm at final drive
disconnect two-speed PTO rod at final drive housing. housing.
A I
J
M91991
12.On left hand side of machine, remove two cap screws

(H) that attach park brake lever to bracket.
13.Remove five cap screws (I) and two spacers (J) that
attach park brake assembly to rockshaft valve cover.
Remove park brake lever and linkage as an assembly.
14.Inspect all parts for wear and damage. Replace as
required.
B
A
M91993
8. Remove spring locking pin and disconnect left hand

park brake clevis (A) from brake arm on cross shaft.
9. Remove two cap screws (B) attaching park brake shaft
pivot bracket to rockshaft housing.
Brakes Repair - 813

BRAKES REPAIR
Installing:
• After installing, adjust park brake. See “Parking Brake
Adjustment - Side Mount.”
Dash Mount Parking Brake:
Removing:
1. Remove orange park brake knob.
2. Remove right hand upper cowl panel. See “Cowl Panel”
in Miscellaneous section.
A
B
MIF
3. Disconnect return spring (A) from bracket.

4. Remove cotter pin (B) and washer from parking brake
actuator rod. Remove rod.
5. Remove bolts (C) and nuts securing bracket and pivot
lever.
6. Remove bracket and lever.
7. Inspect all parts for wear or damage. Pay particular
attention to engagement teeth on lever. Replace parts as
required.
Installing:
• Ensure switch levers are positioned properly.
Brakes Repair - 814

MISCELLANEOUS TABLE OF CONTENTS
Miscellaneous
Table of Contents
Repair.............................................................817
3-Point Hitch...............................................817
Seat and Seat Support ...............................818
Seat Close Out Panel.................................818
Rear Fenders .............................................819
Roll Over Protection System (ROPS).........820
Front Wheels ..............................................820
Rear Wheels...............................................820
Floor Mat ....................................................821
Side Panels ................................................821
Operators Platform .....................................821
Steering Wheel...........................................821
Control Panel..............................................822
Fuse Panel Cover.......................................822
Grille ...........................................................822
Battery ........................................................822
Key Switch Panel .......................................823
Cowl Panel .................................................823
Engine Hood...............................................823
Fuel Tank ...................................................824
Miscellaneous Table of Contents - 815

MISCELLANEOUS TABLE OF CONTENTS
Miscellaneous Table of Contents - 816

MISCELLANEOUS REPAIR
Repair 1. Remove spring clip (C) from pin on front of adjustable
sway bar. Remove pin.
3-Point Hitch 2. Remove spring pin (D) from hitch pin on bottom of
adjustable lift link (E).
Center Lift Link Removal:
3. Support draft arm and adjustable sway bar and remove
hitch pin and two retainers.
4. Remove lynch pin (F) from anchor pin at front of draft
arm.
5. Remove adjustable sway bar and draft arm.
Installation:
Adjustable (Right) and Fixed (Left) Lift Link Removal:

A
B
G
MX9871
1. Disconnect center lift link from storage hook.

2. Remove lynch pin (A) from hitch pin attaching center lift
link to bracket on rockshaft.
3. Support center lift link and remove hitch pin (B).
Remove center lift link.
H
Installation:
Draft Arm & Adjustable Sway Bar Removal: M95264
1. Remove lynch pin (G) from rockshaft at top of lift link

(H).
2. Remove lift link.
C
Installation:
MX9845
Miscellaneous Repair - 817

Seat and Seat Support C
Removal: D
1. Disconnect seat switch electrical connector.
MX9870
3. Pull the SCV lever boot (C), out of the opening in the
A closeout panel. Pull the rate of drop control knob (D) off of
the shaft. Remove five cap screws (E) from bottom of
closeout panel.
4. If equipped, remove MFWD knob (SST only).
MX9868
2. Lift boot around seat frame and remove four cap screws
(A) at front and rear of seat support.
3. Remove seat and seat support from machine as an
assembly.
Installation: F
Seat Close Out Panel

Removal:
MX9869
5. Remove six remaining cap screws (F) from back of

B closeout panel and remove panel.
A
Installation:
MX9869
1. Remove cap(s) on shift knob(s) (A) to left of seat.

Remove cap screw(s) and knob(s).
2. Pull handle off of rockshaft control lever (B).

Rear Fenders
Removal:
1. Safely park machine.
2. Remove rear wheel(s). G
MX9872
5. Remove the three fasteners (F) securing fender to seat

support bracket and ROPS.
6. If not already removed, remove cap screw (G) securing
MX9873 fender to ROPS.
3. Remove three lock nuts (A) and carriage bolts securing

IMPORTANT: Avoid damage! It may be necessary
front of fender to operator’s platform.
for an assistant to support the fender when
removing the last cap screw securing it to the
ROPS.
7. Support fender and remove nut (D) and washer securing

fender to ROPS. Remove fender.
Installation:
D
C
B E
MX11769
4. (Right Fender - ePRT and eHydro Machines:)

• Remove nut and washer (B).
• Remove two screws (C).
• Remove two capscrews (D) and cover (E).
• Lift control panel on top of fender and disconnect all
electrical connectors from switches.

Roll Over Protection System (ROPS) Torque Specifications:
ROPS Cap Screws and Nuts . . . . . . . 305 N•m (225 lb-ft)
Removal:
1. Remove rear wheels and tires. See “Rear Wheels” on Front Wheels
page 820.
2. Remove seat and seat support. See “Seat and Seat Removal:
Support” on page 818. 1. Loosen lug nuts slightly before raising machine front
3. Remove rear fenders. See “Rear Fenders” on page 819. axle.
4. Remove seat close out panels. See “Seat Close Out 2. Raise front of machine and lower onto support stands
Panel” on page 818. so that machine is supported by front axle.
5. Disconnect wiring harness electrical connectors from NOTE: If the front wheels are being removed to perform
wiring inside roll bar (warning light connectors, work light work on the front axles, lower machine onto suitable
connectors, tail light connectors). stands that will support the machine by the frame.
3. Remove lug bolts and wheel.
c CAUTION: Avoid Injury! The approximate Installation:
weight of the ROPS is 57 kg (125 lb). Do not
attempt to remove ROPS without an 1. Install wheel onto axle, insert lug bolts and lightly tighten
assistant or overhead crane. bolts.
2. Raise front of machine, remove support stands and
lower machine to floor.
3. Tighten lug bolts to following specification:
Specifications:
Lug Bolt Torque . . . . . . . . . . . . . . . . . . 122 N•m (90 lb-ft)
4210 with 4.0x15 F2 Ribbed Tires . . . . . 68 N•m (50 lb-ft)
E 4310 with 5.0x15 F2 Ribbed Tires . . . . . 68 N•m (50 lb-ft)
Rear Wheels
F
Removal:
IMPORTANT: Avoid damage! If both rear wheels

are to be removed, support the machine frame in
MX9836 a manner that will prevent the frame from pivoting
6. Remove and discard four cap screws (E) and nuts on the front axle.
securing ROPS to support plates (F) on underside of rear 1. Loosen lug bolts slightly before raising machine rear
axle. axle.
7. Lift ROPS to clear machine, and remove. 2. Raise rear of machine and lower onto support stands so
that machine is supported by rear axle.
Installation:
Installation is the reverse of removal. NOTE: If the rear wheels are being removed to perform
work on the rear axles, lower machine onto suitable
c CAUTION: Avoid injury! Replace the cap

stands that will support the machine frame.
3. Remove lug bolts and wheel.
screws whenever the ROPS is removed.
Always use new, non-flanged, grade 10.9 Installation:
cap screws.
1. Install wheel onto axle, insert lug bolts and lightly tighten
• Tighten hardware to specifications: bolts.
2. Raise rear of machine, remove support stands and

lower machine to floor. 5. Remove six cap screws, lock nuts, and washers from
rubber isolators attaching platform to frame.
3. Tighten lug bolts to specification.
6. If equipped, remove cotter pin and washer, and
Specifications: disconnect differential lock rod from pedal. Move pedal
Lug Bolt Torque . . . . . . . . . . . 88 - 108N•m (65 - 80 lb-ft) toward rear of machine to clear operator’s platform.
7. Lift operator’s platform slightly, and slide rearward.
Floor Mat Remove operator’s platform. Inspect rubber isolators for
cracks and deterioration. Replace as necessary.
Removal:
Installation:
1. Remove fuse panel cover. See “Fuse Panel Cover” on
page 822. Installation is the reverse of removal.
2. Remove plastic rivets holding rubber mat to floor plate.

Steering Wheel
3. Lift and remove floor mat.
Removal:
Installation:
1. Remove steering wheel center cap.
2. Remove lock nut.
Side Panels 3. Remove steering wheel. If necessary, use a suitable
puller.
Removal:
Installation:
1. Raise hood and support with hood prop latch.
NOTE: Lubricate the steering shaft splines with
2. Pull out side panel lock clips and turn to release top of
general purpose grease before installing steering
panel.
wheel.
3. Tilt top of side panel out. Lift and remove panel from
machine.
Installation:
1. Position the two tabs on the bottom of the side panel on
the wire loops welded to the machine frame.
2. Lower the side panel into position, making sure the
panel lock clips are in the correct position to go through the
slots in the top of the side panels.
3. Tilt panel into position and onto lock clips. Pull and turn
lock clips to lock panel to machine. Fold lock clips flat.
4. Close and latch the hood.
M91921
Operators Platform
1. Remove center cap retaining ring from steering wheel.
Removal:
2. Install steering wheel and retain with nut. Tighten
1. Remove fuse panel cover See “Fuse Panel Cover” on steering wheel nut to 39 - 49 N•m (29 - 36 lb-ft).
page 822.
3. Install plastic retaining ring to steering wheel center cap.
2. Remove floor mat.
4. Install center cap and retaining ring to steering wheel.
NOTE: Wheel and tire removed for clarity.
3. Remove six lock nuts (A) and carriage bolts securing
operator’s platform to fenders.
4. (eHydro Model) Remove two nuts and carriage bolts
securing forward pedal. Remove pedal. Repeat for reverse
pedal.

Control Panel
Removal: A
1. Disconnect negative (–) battery cable.
2. Remove steering wheel. See “Steering Wheel” on
page 821.
3. Remove throttle control knob.
NOTE: On ePowrReverser machines, remove left cowl
and remove two bolts securing the reverser lever
bracket. Install in reverse order.
4. Remove screws securing control panel; lift off the panel.
5. Lift rear of panel and tilt panel forward. Reach under
panel and spread tilt steering lever arms away from
steering column steering wheel tilt mechanism. MX9837
6. Lift panel up and disconnect all wiring harness 4. Tilt top of grille forward and disconnect the headlight
connectors to control panel. connectors (A).
7. Remove control panel. 5. Lift and remove grille from machine.
Installation: Installation:
Installation is the reverse of removal. 1. Slide the bottom of the grille under the battery tray.
Insert the locating tabs on the bottom of the grille into the
wire loops welded to the machine frame.
Fuse Panel Cover
2. Connect the headlights.
Removal: 3. Tilt grille into position and onto lock clips. Pull and turn
1. Remove two cap screws from right and left side top lock clips to lock grille to machine. Fold lock clips flat.
edge of cover. 4. Install side panels.
2. Open fuse panel door. Remove two cap screws from top 5. Lower the hood.
edge of cover inside door.
3. Tilt top of cover towards seat. Battery
4. Lift and remove cover.
Removal:
Installation: 1. Remove grille. See “Grille” on page 822.
A
Grille
Removal:
1. Open hood and support on hood prop latch.
B
2. Remove side panels.
3. Pull out 2 panel lock clips at top of grille, and turn to
release top of grille. C
M95024
2. Disconnect negative (–) battery cable (A).

3. Disconnect positive (+) battery cable (B).
4. Loosen two cap screws (C) and battery hold downs.
5. Remove battery.
Installation:
1. Clean both battery terminals before installation.
2. Check for proper battery fluid level.
3. Install battery and secure with battery hold down A
clamps.
4. Connect positive (+) battery terminal clamp. Tighten B
positive battery clamp bolt securely.
5. Connect negative (–) battery terminal clamp. Tighten
negative battery clamp bolt securely. M91770
8. Support panel and remove cap screw (B) from side of

Key Switch Panel panel at bottom. Remove shroud panel.
9. Repeat for other side.
Removal:
1. Disconnect battery negative (-) cable Installation:
2. Remove fuse panel cover. See “Fuse Panel Cover” on Installation is the reverse of removal.
page 822.
3. Remove two screws attaching key switch panel to Engine Hood
console. Slide key switch panel down and away from
Removal:
console.
1. Open hood and support on hood prop latch.
4. Disconnect key switch electrical connector and remove
panel. NOTE: An assistant may be required to support hood
during removal.
Installation:
2. Remove four cap screws and nuts attaching hood to left
and right hinges.
3. Remove hood.
Cowl Panel
Installation:
Removal:
1. Remove side panels.
page 821.
3. Remove control panel. See “Control Panel” on
page 822.
4. Remove fuse panel cover. See “Fuse Panel Cover” on
page 822.
5. Remove key switch panel. See “Key Switch Panel” on
page 823.
6. Raise hood and support with hood prop latch.
7. Remove cap screw under rear of hood at top front of
cowl panel.

Fuel Tank
Removal:
H
1. Park machine on level surface, shut engine off, engage
park brake.
2. Allow machine and engine to cool before attempting to G
service fuel system.
3. Remove engine side panels.
page 821.
5. Remove control panel. See “Control Panel” on
page 822. M91317
6. Remove key switch panel. See “Key Switch Panel” on 16.Loosen screw (G) on clamp holding fuel gauge sender
page 823. wiring harness to fuel tank. Turn clamp to release harness.
7. Remove cowl panels. See “Cowl Panel” on page 823. 17.Remove two nuts (H) and lock washers connecting
8. Remove hood. See “Engine Hood” on page 823. wires to fuel gauge sender. Remove wires.
9. Remove brake pedal shaft. See “Brake Pedal Removal

and Installation” in Brake section.
I
A
B
M95271
18.If necessary, drain coolant overflow tank and disconnect

hose from radiator to tank.
19.Remove cap screw (I) and coolant overflow tank.
MX9878
10.Remove two cap screws (A) on each side of hood J

support frame (B) and remove hood support frame.
11.Disconnect throttle link (C) at engine by pulling rod
outward.
12.Drain fuel from tank into a suitable container.
13.Label and remove fuel lines from fuel tank. K
14.Remove fuel overflow drain hose (D).

15.Remove drain cock (E) and fuel hose elbow (F) from fuel
tank. MX9838
20.Remove two cap screws (J), washers and rubber

isolators (K) securing bottom of steering support to frame.

L
M
MX9878
21.Remove two nuts (L), four washers, and two cap screws
(M) from rubber isolators (N) that secure top of steering
support to frame.
NOTE: An assistant may be required to tilt steering
support while removing fuel tank.
22.Tilt steering support toward rear of machine and remove
tank from frame.
Installation:


INDEX
Numerics Drive Shaft (Mid PTO) . . . . . . . . . . . . . . . . . . . . . .678
EEC Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . .316
2-Speed PTO
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694
Final Drive (MFWD) . . . . . . . . . . . . . . . . . . . . . . . .626
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 690
4-Speed Transmission Hydrostatic Hoses and Lines . . . . . . . . . . . . . . . . .531
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596 PTO (2-Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . .676
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590 PTO (Mid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .677
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607 PTO (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .675
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587 Range Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .616
ePowrReverser Clutch . . . . . . . . . . . . . . . . . . . . . .558
A Control Panel Removal and Installation . . . . . . . . . . . .822
Avoid Harmful Asbestos Dust . . . . . . . . . . . . . . . . . . . . . 4 Coolant, Engine, Specifications . . . . . . . . . . . . . . . . . . .19
Avoid Injury Cowl Panel Removal and Installation . . . . . . . . . . . . . .823
Rotating Blades, Augers And PTO Shafts . . . . . . . . 5 D
Axle (MFWD) Components . . . . . . . . . . . . . . . . . . . . . 625
Diagnosis
B Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Battery Removal and Installation . . . . . . . . . . . . . . . . . 822 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .746
Brake Hydrostatic Power Train (eHydro) . . . . . . . . . . . . .534
Component Location Left Side . . . . . . . . . . . . . . . 620 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .784
Component Location Right Side . . . . . . . . . . . . . . 618 Diagnostics
PTO Final Drive Power Train . . . . . . . . . . . . . . . . . . . . .632
Disassembly and Assembly . . . . . . . . . . . . . . 702 Diesel Fuel Lubricity . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Removal and Installation . . . . . . . . . . . . . . . . 698 Diesel Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . .15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 804 Diesel Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Differential
C Assembly and Installation . . . . . . . . . . . . . . . . . . . .671
California Proposition 65 Warning . . . . . . . . . . . . . . . . . . 4 Backlash Adjustment . . . . . . . . . . . . . . . . . . . . . . .633
Clutch Lock Fork Removal & Installation . . . . . . . . . . . . . .671
PTO Removal & Disassembly . . . . . . . . . . . . . . . . . . . .669
Disassembly and Assembly . . . . . . . . . . . . . . 702 Differential (MFWD) Components . . . . . . . . . . . . . . . . .627
Removal and Installation . . . . . . . . . . . . . . . . 698 Differential Lock Components . . . . . . . . . . . . . . . . . . . .622
SST Dispose of Waste Properly . . . . . . . . . . . . . . . . . . . . . . . .5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 502 Drive Shaft (MFWD) Components
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 505 ePRT and eHydro . . . . . . . . . . . . . . . . . . . . . . . . . .717
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 Drive Shaft (MFWD) Components, SST . . . . . . . . . . . .623
Shimming Procedure . . . . . . . . . . . . . . . . . . . 507 Drive Shaft (Mid PTO) Components . . . . . . . . . . . . . . .678
Clutch Adjustment
E
ePRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
Clutch Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . 586 Electrical
Clutch Shaft Battery Removal and Installation . . . . . . . . . . . . . .822
SyncShift (SST) Charging Circuit Operation . . . . . . . . . . . . . . . . . . .202
Removal & Installation . . . . . . . . . . . . . . . . . . 511 Charging, Tachometer, and Hour Meter
Clutch Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . 584 Circuit Diagnosis . . . . . . . . . . . . . . . . . . . .204
Component Location Charging, Tachometer, and Hour Meter
4-Speed Transmission . . . . . . . . . . . . . . . . . . . . . 559 Circuit Electrical Schematic . . . . . . . . . . . .203
Axle (MFWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625 Common Circuit Tests . . . . . . . . . . . . . . . . . . . . . .116
Axle Shaft and Brake Component Location . . . . . . . . . . . . . . . . . . . . . . .119
Left Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620 Conductors for 12 Volt Circuits . . . . . . . . . . . . . . . .116
Right Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . 618 Cranking Circuit Diagnosis . . . . . . . . . . . . . . . . . . .174
Clutch Housing, ePRT . . . . . . . . . . . . . . . . . . . . . 557 Cranking Circuit Electrical Schematic . . . . . . . . . .173
Differential (MFWD) . . . . . . . . . . . . . . . . . . . . . . . 627 Cranking Circuit Operation . . . . . . . . . . . . . . . . . . .172
Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . 622 Cruise Control
Drive Shaft (MFWD) Circuit Diagnosis, eHydro Optional . . . . . .236
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623 Cruise Control
ePRT and eHydro . . . . . . . . . . . . . . . . . . . . . . 717 Circuit Diagnosis, eHydro Standard . . . . .230
Index - 1
INDEX
Cruise Control Circuit Electrical Motion Match Circuit
Schematic, eHydro Optional . . . . . . . . . . 235 Electrical Schematic, eHydro . . . . . . . . . . .241
Cruise Control Circuit Electrical Motion Match Circuit Operation, eHydro . . . . . . . .240
Schematic, eHydro Standard . . . . . . . . . . 229 Power Circuit Diagnosis . . . . . . . . . . . . . . . . . . . . .166
Cruise Control Circuit Operation, Power Circuit Electrical Schematic . . . . . . . . . . . . .162
eHydro Optional . . . . . . . . . . . . . . . . . . . . 234 Power Circuit Operation . . . . . . . . . . . . . . . . . . . . .159
Cruise Control Circuit Operation, Rear PTO Circuit Diagnosis . . . . . . . . . . . . . . . . . .246
eHydro Standard . . . . . . . . . . . . . . . . . . . 228 Rear PTO Circuit Electrical Schematic . . . . . . . . . .245
Diagnostic Information . . . . . . . . . . . . . . . . . . . . . 114 Rear PTO Circuit Operation . . . . . . . . . . . . . . . . . .244
Diverter Valve Circuit Diagnosis . . . . . . . . . . . . . . 276 Reverse Drive Circuit Diagnosis, eHydro . . . . . . . .225
Diverter Valve Circuit Electrical Schematic . . . . . . 275 Reverse Drive Circuit
Diverter Valve Circuit Operation . . . . . . . . . . . . . . 274 Diagnosis, ePowrReverser . . . . . . . . . . . .213
Diverter Valve Wiring Harness . . . . . . . . . . . . . . . 275 Reverse Drive Circuit
Engine Shutoff Circuit Diagnosis . . . . . . . . . . . . . 196 Electrical Schematic, eHydro . . . . . . . . . . .224
Engine Shutoff Circuit Electrical Schematic, Reverse Drive Circuit
SST and ePowrReverser . . . . . . . . . . . . . 192 Electrical Schematic, ePowrReverser . . . .212
Engine Shutoff Circuit Electrical Schematic, Reverse Drive Circuit Operation, eHydro . . . . . . . .222
eHydro . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 Reverse Drive Circuit
Engine Shutoff Circuit Operation . . . . . . . . . . . . . 190 Operation, ePowrReverser . . . . . . . . . . . .211
Forward Drive Circuit Diagnosis, eHydro . . . . . . . 219 Schematic and Wiring Harness Legend . . . . . . . . .123
Forward Drive Circuit Diagnosis, ePowrReverser . 208 Signal Lights Circuit Diagnosis . . . . . . . . . . . . . . . .270
Forward Drive Circuit Electrical Schematic, Signal Lights Circuit Electrical Schematic . . . . . . .269
eHydro . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Signal Lights Circuit Operation . . . . . . . . . . . . . . . .268
Forward Drive Circuit Electrical Schematic, Solenoid Connector
ePowrReverser . . . . . . . . . . . . . . . . . . . . 207 Disassembly/Assembly . . . . . . . . . . . . . . . . . .606
Forward Drive Circuit Operation, eHydro . . . . . . . 216 Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296
Forward Drive Circuit Operation, Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
ePowrReverser . . . . . . . . . . . . . . . . . . . . 206 System Schematics . . . . . . . . . . . . . . . . . . . . . . . .123
Fuel Supply Circuit Diagnosis . . . . . . . . . . . . . . . . 185 Tachometer Circuit Operation . . . . . . . . . . . . . . . .202
Fuel Supply Circuit Electrical Schematic, Test and Adjustments . . . . . . . . . . . . . . . . . . . . . . .278
SST and ePowrReverser . . . . . . . . . . . . . 181 Theory and Diagnosis . . . . . . . . . . . . . . . . . . . . . .155
Fuel Supply Circuit Electrical Schematic, Theory of Operation Information . . . . . . . . . . . . . .114
eHydro . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Fuel Supply Circuit Operation . . . . . . . . . . . . . . . . 180 W1 Main Electrical Schematic . . . . . . . . . . . . . . . .125
Hour Meter Circuit Operation . . . . . . . . . . . . . . . . 202 W1 Main Wiring Harness . . . . . . . . . . . . . . . . . . . .132
Instrument Panel Lights Circuit Diagnosis . . . . . . 261 W1Main Wiring Harness Wire Color Codes . . . . . .140
Instrument Panel Lights W2 Jumper Plug Wiring Harness . . . . . . . . . . . . . .136
Circuit Electrical Schematic . . . . . . . . . . . 260 W2 SST Jumper Wiring Harness Color Codes . . .143
Instrument Panel Lights Circuit Operation . . . . . . 259 W2 and W3 SST and ePowrReverser
Light Circuit Diagnosis . . . . . . . . . . . . . . . . . . . . . 265 Electrical Schematic . . . . . . . . . . . . . . . . .129
Light Circuit Electrical Schematic . . . . . . . . . . . . . 264 W3 ePowrReverser Wiring Harness . . . . . . . . . . . .136
Light Circuit Operation . . . . . . . . . . . . . . . . . . . . . 263 W3 ePowrReverser Wiring Harness
Load Match Circuit Diagnosis, eHydro . . . . . . . . . 242 Color Codes . . . . . . . . . . . . . . . . . . . . . . . .143
Load Match Circuit Electrical Schematic, W4 eHydro Wiring Harness . . . . . . . . . . . . . . . . . .138
eHydro . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 W4 eHydro Wiring Harness Color Codes . . . . . . . .144
Load Match Circuit Operation, eHydro . . . . . . . . . 240 W4 eHydro and Cruise Control
MFWD Circuit Diagnosis . . . . . . . . . . . . . . . . . . . . 257 Electrical Schematic . . . . . . . . . . . . . . . . .130
MFWD Circuit Electrical Schematic . . . . . . . . . . . 256 W5 Cruise Control Wiring Harness,
MFWD Circuit Operation . . . . . . . . . . . . . . . . . . . . 255 eHydro Standard . . . . . . . . . . . . . . . . . . . .140
Manifold Heater Circuit Diagnosis . . . . . . . . . . . . 178 W5 eHydro Optional, Cruise Control
Manifold Heater Circuit Electrical Schematic . . . . 177 Wiring Harness Color Codes . . . . . . . . . . .145
Manifold Heater Circuit Operation . . . . . . . . . . . . 176 W5 eHydro Standard, Cruise Control
Mid PTO Circuit Diagnosis . . . . . . . . . . . . . . . . . . 250 Wiring Harness Color Codes . . . . . . . . . . .144
Mid PTO Circuit Electrical Schematic . . . . . . . . . . 249 W6 Cruise Control Wiring Harness,
Mid PTO Circuit Operation . . . . . . . . . . . . . . . . . . 248 eHydro Optional . . . . . . . . . . . . . . . . . . . . .140
Motion Match Circuit Diagnosis, eHydro . . . . . . . . 242 Wire Color Abbreviation Chart . . . . . . . . . . . . . . . .115
Index - 2
INDEX
eHydro Electronic Operating System Engine Shutoff Circuit Operation . . . . . . . . . . . . . .393
Fault Code Chart . . . . . . . . . . . . . . . . . . . 152 European Electrical Theory . . . . . . . . . . . . . . . . . .315
eHydro Electronic Operating System Forward Drive Circuit Diagnosis, eHydro . . . . . . . .422
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . 151 Forward Drive Circuit Diagnosis,
eHydro Electronic Operating System ePowrReverser . . . . . . . . . . . . . . . . . . . . .411
Troubleshooting Flowchart . . . . . . . . . . . . 146 Forward Drive Circuit
eHydro eMatchOS Electronic Electrical Schematic, eHydro . . . . . . . . . . .421
Operating System . . . . . . . . . . . . . . . . . . 156 Forward Drive Circuit
ePowrReverser Electronic Operating System Electrical Schematic, ePowrReverser . . . .410
Fault Code Chart . . . . . . . . . . . . . . . . . . . 147 Forward Drive Circuit Operation, eHydro . . . . . . . .419
ePowrReverser Electronic Operating System Forward Drive Circuit Operation,
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . 147 ePowrReverser . . . . . . . . . . . . . . . . . . . . .409
ePowrReverser eMatchOS Electronic Operating Front PTO Circuit Diagnosis . . . . . . . . . . . . . . . . . .449
System . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Front PTO Circuit Electrical Schematic . . . . . . . . .448
Electrical, Component Location Front PTO Circuit Operation . . . . . . . . . . . . . . . . . .447
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Fuel Supply Circuit Diagnosis . . . . . . . . . . . . . . . .387
Load Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Fuel Supply Circuit Electrical Schematic,
Machine Front Section . . . . . . . . . . . . . . . . . . . . . 120 SST and ePowrReverser . . . . . . . . . . . . . .383
Machine Rear Section . . . . . . . . . . . . . . . . . . . . . 121 Fuel Supply Circuit
Electrical, EEC Electrical Schematic, eHydro . . . . . . . . . . .385
2 Speed PTO Lights Circuit Operation . . . . . . . . . 450 Fuel Supply Circuit Operation . . . . . . . . . . . . . . . .382
Brake Lights Circuit Operation . . . . . . . . . . . . . . . 469 Hazard Switch Circuit Operation . . . . . . . . . . . . . .475
Charging Circuit Operation . . . . . . . . . . . . . . . . . . 405 Hour Meter Circuit Operation . . . . . . . . . . . . . . . . .405
Charging, Tachometer, and Hour Meter Instrument Panel Lights Circuit Diagnosis . . . . . . .467
Circuit Diagnosis . . . . . . . . . . . . . . . . . . . 407 Instrument Panel Lights Circuit
Charging, Tachometer, and Hour Meter Electrical Schematic . . . . . . . . . . . . . . . . .466
Circuit Electrical Schematic . . . . . . . . . . . 406 Instrument Panel Lights Circuit Operation . . . . . . .465
Component Location . . . . . . . . . . . . . . . . . . . . . . . 316 Light Circuit Operation . . . . . . . . . . . . . . . . . . . . . .469
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . 316 Lights Circuit Diagnosis . . . . . . . . . . . . . . . . . . . . .471
Load Center . . . . . . . . . . . . . . . . . . . . . . . . . . 319 Lights Circuit Electrical Schematic . . . . . . . . . . . . .470
Machine Front Section . . . . . . . . . . . . . . . . . . 317 Load Match Circuit Diagnosis . . . . . . . . . . . . . . . . .445
Machine Rear Section . . . . . . . . . . . . . . . . . . 318 Load Match Circuit Electrical Schematic . . . . . . . .444
Cranking Circuit Diagnosis . . . . . . . . . . . . . . . . . . 376 Load Match Circuit Operation . . . . . . . . . . . . . . . . .443
Cranking Circuit Electrical Schematic . . . . . . . . . . 375 MFWD Circuit Diagnosis . . . . . . . . . . . . . . . . . . . .463
Cranking Circuit Operation . . . . . . . . . . . . . . . . . . 374 MFWD Circuit Electrical Schematic . . . . . . . . . . . .462
Cruise Control Circuit Diagnosis, MFWD Circuit Operation . . . . . . . . . . . . . . . . . . . .461
eHydro Optional . . . . . . . . . . . . . . . . . . . . 439 Manifold Heater Circuit Diagnosis . . . . . . . . . . . . .380
Cruise Control Circuit Diagnosis, Manifold Heater Circuit Electrical Schematic . . . . .379
eHydro Standard . . . . . . . . . . . . . . . . . . . 433 Manifold Heater Circuit Operation . . . . . . . . . . . . .378
Cruise Control Circuit Electrical Schematic, Mid PTO Circuit Diagnosis . . . . . . . . . . . . . . . . . . .457
eHydro Optional . . . . . . . . . . . . . . . . . . . . 438 Mid PTO Circuit Electrical Schematic . . . . . . . . . . .456
Cruise Control Circuit Electrical Schematic, Mid PTO Circuit Operation . . . . . . . . . . . . . . . . . . .455
eHydro Standard . . . . . . . . . . . . . . . . . . . 432 Motion Match Circuit Diagnosis . . . . . . . . . . . . . . .445
Cruise Control Circuit Operation, Motion Match Circuit Electrical Schematic . . . . . . .444
eHydro Optional . . . . . . . . . . . . . . . . . . . . 437 Motion Match Circuit Operation . . . . . . . . . . . . . . .443
Cruise Control Circuit Operation, Power Circuit Diagnosis . . . . . . . . . . . . . . . . . . . . .368
eHydro Standard . . . . . . . . . . . . . . . . . . . 431 Power Circuit Electrical Schematic . . . . . . . . . . . . .363
Diverter Valve Circuit Diagnosis . . . . . . . . . . . . . . 485 Power Circuit Operation . . . . . . . . . . . . . . . . . . . . .360
Diverter Valve Circuit Electrical Schematic . . . . . . 484 Rear PTO Circuit Diagnosis . . . . . . . . . . . . . . . . . .453
Diverter Valve Circuit Operation . . . . . . . . . . . . . . 483 Rear PTO Circuit Electrical Schematic . . . . . . . . . .451
Diverter Valve Wiring Harness . . . . . . . . . . . . . . . 484 Rear PTO Circuit Operation . . . . . . . . . . . . . . . . . .450
Engine Shutoff Circuit Diagnosis . . . . . . . . . . . . . 399 Reverse Drive Circuit Diagnosis, eHydro . . . . . . . .428
Engine Shutoff Circuit Electrical Schematic, Reverse Drive Circuit Diagnosis,
SST and ePowrReverser . . . . . . . . . . . . . 395 ePowrReverser . . . . . . . . . . . . . . . . . . . . .416
Engine Shutoff Circuit Electrical Schematic, Reverse Drive Circuit
eHydro . . . . . . . . . . . . . . . . . . . . . . . . . . . 397 Electrical Schematic, eHydro . . . . . . . . . . .427
Index - 3
INDEX
Reverse Drive Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Electrical Schematic, ePowrReverser . . . 415
Reverse Drive Circuit Operation, eHydro . . . . . . . 425
F
Reverse Drive Circuit Fenders (Rear) Removal and Installation . . . . . . . . . . .819
Operation, ePowrReverser . . . . . . . . . . . 414 Final Drive
System Schematics . . . . . . . . . . . . . . . . . . . . . . . 320 Disassembly, Inspection and Assembly . . . . . . . . .668
System Schematics and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .665
Wiring Harness Legend . . . . . . . . . . . . . . 320 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .662
Tachometer Circuit Operation . . . . . . . . . . . . . . . . 405 Final Drive (MFWD) Components . . . . . . . . . . . . . . . . .626
Theory and Diagnosis . . . . . . . . . . . . . . . . . . . . . . 356 Floor Mat Removal and Installation . . . . . . . . . . . . . . .821
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 347 Front Axle
Turn Signal Lights Circuit Operation . . . . . . . . . . . 475 Final Drive Cover Removal & Inspection . . . . . . . .637
Turn Signal and Hazard Lights MFWD
Circuit Diagnosis . . . . . . . . . . . . . . . . . . . 477 Drive Shaft Removal & Installation . . . . . . . . .637
Turn Signal and Hazard Lights Final Drive Cover Installation . . . . . . . . . . . . . .638
Circuit Electrical Schematic . . . . . . . . . . . 476 Final Drive Housing Disassembly . . . . . . . . . .640
W1 Main Electrical Schematic . . . . . . . . . . . . . . . 323 Final Drive Housing Installation . . . . . . . . . . . .641
W1 Main Wiring Harness . . . . . . . . . . . . . . . . . . . 331 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .637
W1 Main Wiring Harness Color Codes . . . . . . . . . 341 Spindle Housing
W2 Jumper Plug Wiring Harness . . . . . . . . . . . . . 336 Removal and Disassembly . . . . . . . . .641
W2 SST Jumper Wiring Harness Spindle Shaft Assembly and Installation . . . . .640
Color Codes . . . . . . . . . . . . . . . . . . . . . . . 344 Spindle Shaft Removal and Disassembly . . . .638
W2 SST and W3 ePowrReverser Front Axle (MFWD)
Electrical Schematic . . . . . . . . . . . . . . . . . 328 Differential Removal & Disassembly . . . . . . . . . . .641
W3 ePowrReverser Wiring Harness . . . . . . . . . . . 336 Final Drive Housing Assembly . . . . . . . . . . . . . . . .640
W3 ePowrReverser Wiring Harness Final Drive Housing Disassembly . . . . . . . . . . . . . .640
Color Codes . . . . . . . . . . . . . . . . . . . . . . . 344 Fuel Tank Removal and Installation . . . . . . . . . . . . . . .824
W4 eHydro Wiring Harness . . . . . . . . . . . . . . . . . 338 Fuse Panel Cover Removal & Installation . . . . . . . . . .822
W4 eHydro Wiring Harness Color Codes . . . . . . . 345 G
W4 eHydro and Cruise Control
Electrical Schematic . . . . . . . . . . . . . . . . . 329 Grill Removal and Installation . . . . . . . . . . . . . . . . . . . .822
W5 Cruise Control Wiring Harness H
Color Codes, eHydro Standard . . . . . . . . 345
Handle Chemical Products Safely . . . . . . . . . . . . . . . . . .5
W5 Cruise Control
Handling And Servicing Batteries . . . . . . . . . . . . . . . . . . .1
Wiring Harness, eHydro Standard . . . . . . 340
Hood Removal and Installation . . . . . . . . . . . . . . . . . . .823
W6 Cruise Control Wiring Harness
Hydraulic Pressure Tests - ePRT Lube . . . . . . . . . . . .569
Color Codes, eHydro Optional . . . . . . . . . 346
Hydraulics
W6 Cruise Control Wiring Harness,
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .746
eHydro Optional . . . . . . . . . . . . . . . . . . . . 340
Specifications
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .721
Fault Code Chart . . . . . . . . . . . . . . . . . . . 353
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .722
eHydro Electronic Operating System F
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .722
ault Codes . . . . . . . . . . . . . . . . . . . . . . . . 352
Hydrostatic System
Component Location . . . . . . . . . . . . . . . . . . . . . . .531
Troubleshooting Flowchart . . . . . . . . . . . . 347
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .534
eHydro eMatchOS Electronic
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .529
Operating System . . . . . . . . . . . . . . . . . . 357
ePowrReverser Electronic Operating System I
Fault Code Chart . . . . . . . . . . . . . . . . . . . 348 Illuminate Work Area Safely . . . . . . . . . . . . . . . . . . . . . . .4
ePowrReverser Electronic Operating System Input Shaft Disassembly/Assembly . . . . . . . . . . . . . . . .582
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . 348
ePowrReverser eMatchOS Electronic Operating K
System . . . . . . . . . . . . . . . . . . . . . . . . . . . 356 Key Switch Panel Removal and Installation . . . . . . . . .823
Engine
Coolant Specifications . . . . . . . . . . . . . . . . . . . . . . 19 L
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Live With Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Index - 4
INDEX
Lubrication Control Valve Operation . . . . . . . . . . . . . . . . . . . . .561
Alternative Lubricants . . . . . . . . . . . . . . . . . . . . . . . 17 Hydraulic Pressure Tests . . . . . . . . . . . . . . . . . . . .569
Engine Break-In Oil . . . . . . . . . . . . . . . . . . . . . . . . . 16 System Pressure Test . . . . . . . . . . . . . . . . . . . . . .568
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Traction Clutch Assembly . . . . . . . . . . . . . . . . . . . .578
Engine Oil-North America . . . . . . . . . . . . . . . . . . . . 16 Traction Clutch Disassembly . . . . . . . . . . . . . . . . .575
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Traction Clutch Installation . . . . . . . . . . . . . . . . . . .583
Mixing of Lubricants . . . . . . . . . . . . . . . . . . . . . . . . 17 Traction Clutch Removal . . . . . . . . . . . . . . . . . . . .573
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ePowrReverser Clutch . . . . . . . . . . . . . . . . . . . . . .558
Synthetic Lubricants . . . . . . . . . . . . . . . . . . . . . . . . 17 PRT Shift Cap Disassembly and Assembly . . . . . . . . .602
PTO
M 2-Speed
MFWD Components . . . . . . . . . . . . . . . . . . . . . . . . . . .676
Cylinder Disassembly/Assembly . . . . . . . . . . . . . . 603 Shafts & Gears Assembly . . . . . . . . . . . . . . . .694
Differential Removal & Disassembly . . . . . . . . . . . 641 Shafts & Gears Disassembly . . . . . . . . . . . . . .690
Drive Shaft Removal & Installation . . . . . . . . . . . . 637 Clutch & Brake
Final Drive Assembly . . . . . . . . . . . . . . . . . . . . . . 640 Disassembly and Assembly . . . . . . . . . . . . . . .702
Final Drive Cover Removal and Installation . . . . . . . . . . . . . . . . .698
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 638 Mid
Removal & Inspection . . . . . . . . . . . . . . . . . . 637 Components . . . . . . . . . . . . . . . . . . . . . . . . . . .677
Final Drive Housing Disassembly and Assembly . . . . . . . . . . . . . . .712
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 640 Removal and Installation . . . . . . . . . . . . . . . . .711
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 641 Rear
Final Drive Housing Disassembly . . . . . . . . . . . . . 640 Components . . . . . . . . . . . . . . . . . . . . . . . . . . .675
Output Shaft Shafts & Gears
Removal and Installation . . . . . . . . . . . . . . . . 634 Disassembly & Assembly . . . . . . . . . . . . .687
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 637 Removal & Installation . . . . . . . . . . . . . . . .684
Spindle Housing Theory of Operation
Removal and Disassembly . . . . . . . . . . . . . . . 641 Clutch and Brake . . . . . . . . . . . . . . . . . . . . . . .679
Spindle Shaft Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .680
Assembly and Installation . . . . . . . . . . . . . . . . 640 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .683
Removal and Disassembly . . . . . . . . . . . . . . . 638 Park Machine Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Machine Identification Number . . . . . . . . . . . . . . . . . . . 20 Power Train
Machine Splitting Final Drive
Front - SyncShift (SST) . . . . . . . . . . . . . . . . . . . . . 496 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . .632
Rear Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .632
SyncShift (SST) . . . . . . . . . . . . . . . . . . . . . . . 646 Final Power Train Specifications . . . . . . . . . . . . . .613
Mid PTO Hydrostatic (eHydro) Specifications . . . . . . . . . . . .529
Disassembly and Assembly . . . . . . . . . . . . . . . . . 712 Prevent Acid Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Removal and Installation . . . . . . . . . . . . . . . . . . . 711 Prevent Battery Explosions . . . . . . . . . . . . . . . . . . . . . . . .2
O Proportional Solenoid Valve
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . .566
O-Ring Boss Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
O-Ring Face Seal Fittings . . . . . . . . . . . . . . . . . . . . . . . 14 R
Operator’s Platform Removal and Installation . . . . . . . 821 ROPS Removal and Installation . . . . . . . . . . . . . . . . . .820
P Range Shift Components . . . . . . . . . . . . . . . . . . . . . . .616
Range Transmission Removal and Installation . . . . . . .650
PRT Reading Electrical Schematics . . . . . . . . . . . . . . . . . . .113
4-Speed Transmission . . . . . . . . . . . . . . . . . . . . . 559 Rear Fenders Removal and Installation . . . . . . . . . . . .819
4-Speed Transmission Assembly . . . . . . . . . . . . . 596 Rear PTO
4-Speed Transmission Disassembly . . . . . . . . . . 590 Disassembly and Assembly . . . . . . . . . . . . . . . . . .687
4-Speed Transmission Installation . . . . . . . . . . . . 607 Rear PTO Removal and Installation . . . . . . . . . . . . . . .684
4-Speed Transmission Removal . . . . . . . . . . . . . . 587 Recognize Safety Information . . . . . . . . . . . . . . . . . . . . . .1
Clutch Cover Assembly . . . . . . . . . . . . . . . . . . . . 586 Remove Paint Before Welding Or Heating . . . . . . . . . . . .4
Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 557 Repair
Clutch Pressure Test . . . . . . . . . . . . . . . . . . . . . . 568 Battery Removal and Installation . . . . . . . . . . . . . .822
Clutch Valve Disassembly . . . . . . . . . . . . . . . . . . 584 Control Panel Removal and Installation . . . . . . . . .822
Index - 5
INDEX
Cowl Panel Removal and Installation . . . . . . . . . . 823 Steering Wheel
Differential Removal and Installation . . . . . . . . . . . . . . . . .821
Assembly and Installation . . . . . . . . . . . . . . . . 671 SyncShift (SST)
Lock Fork Removal & Installation . . . . . . . . . . 671 Clutch Shaft
Removal & Disassembly . . . . . . . . . . . . . . . . 669 Removal & Installation . . . . . . . . . . . . . . . .511
Final Drive Input Shaft Disassembly . . . . . . . . . . . . . . . . .504
Disassembly, Inspection and Assembly . . . . . 668 Snubber Shimming Procedure . . . . . . . . . . . . .509
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 665 Traction Clutch
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 662 Disassembly . . . . . . . . . . . . . . . . . . . . . . .502
Floor Mat Removal and Installation . . . . . . . . . . . 821 Installation . . . . . . . . . . . . . . . . . . . . . . . . .505
Front Wheel Removal and Installation . . . . . . . . . 820 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .500
Fuel Tank Removal and Installation . . . . . . . . . . . 824 Shimming Procedure . . . . . . . . . . . . . . . . .507
Fuse Panel Cover Removal & Installation . . . . . . 822 Three Point Hitch
Grill Removal and Installation . . . . . . . . . . . . . . . . 822 Removal and Installation . . . . . . . . . . . . . . . . .817
Hood Removal and Installation . . . . . . . . . . . . . . . 823 Replace Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Hydrostatic Power Train . . . . . . . . . . . . . . . . . . . . 541
Key Switch Panel Removal and Installation . . . . . 823
S
MFWD Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . .20
Drive Shaft Removal & Installation . . . . . . . . . 637 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Final Drive Cover Installation . . . . . . . . . . . . . 638 Service Machines Safely . . . . . . . . . . . . . . . . . . . . . . . . . .3
Final Drive Cover Removal & Inspection . . . . 637 Service Tires Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Final Drive Housing Disassembly . . . . . . . . . . 640 Side Panels Removal & Installation . . . . . . . . . . . . . . .821
Final Drive Housing Installation . . . . . . . . . . . 641 Snubber Shimming Procedure
Output Shaft Removal and Installation . . . . . . 634 SyncShift (SST) . . . . . . . . . . . . . . . . . . . . . . . . . . .509
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 637 Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296
Spindle Housing Specifications
Removal and Disassembly . . . . . . . . 641 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Spindle Shaft Assembly and Installation . . . . 640 Diesel Fuel Lubricity . . . . . . . . . . . . . . . . . . . . . . . . .15
Spindle Shaft Diesel Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . .16
Removal and Disassembly . . . . . . . . 638 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Machine Splitting Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646 General
Machine Splitting - Front Power Train
Sync Shift (SST) . . . . . . . . . . . . . . . . . . . . . . . 496 Hydrostatic . . . . . . . . . . . . . . . . . . . . . . . . .529
Mid PTO Hydraulics
Disassembly and Assembly . . . . . . . . . . . . . . 712 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .721
Removal and Installation . . . . . . . . . . . . . . . . 711 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .722
Operator’s Platform Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .722
Removal and Installation . . . . . . . . . . . . . . . . 821 Torque
PTO Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . .722
2-Speed Splitting the Machine
Shafts & Gears Assembly . . . . . . . . . . . . 694 Front - SyncShift (SST) . . . . . . . . . . . . . . . . . . . . .496
Shafts & Gears Disassembly . . . . . . . . . . 690 Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .646
Clutch & Brake Steering
Removal and Installation . . . . . . . . . . . . . 698 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .784
Rear Shafts & Gears Steering Control Unit (SCU) Test . . . . . . . . . . . . . .785
Removal and Installation . . . . . . . . . . . . . 684 Steering Cylinder Test . . . . . . . . . . . . . . . . . . . . . .785
Rear Shafts & Gears Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . .782
Disassembly & Assembly . . . . . . . . . 687 Steering Wheel Removal and Installation . . . . . . . . . . .821
Range Transmission Support Machine Properly . . . . . . . . . . . . . . . . . . . . . . . .3
Removal and Installation . . . . . . . . . . . . . 650 T
Rear Fenders Removal and Installation . . . . . . . . 819
Rear Wheel Removal and Installation . . . . . . . . . 820 Tests and Adjustments
Roll Over Protective Structure (ROPS) Differential
Removal and Installation . . . . . . . . . . . . . . . . 820 Backlash Adjustment . . . . . . . . . . . . . . . . . . . .633
Side Panel Removal & Installation . . . . . . . . . . . . 821 Hydrostatic Power Train . . . . . . . . . . . . . . . . . . . . .538
Index - 6
INDEX
Steering Control Unit (SCU) Test . . . . . . . . . . . . . 785 Transmission Neutral Switch Test,
Steering Cylinder Test . . . . . . . . . . . . . . . . . . . . . 785 SST and ePowrReverser . . . . . . . . . . . . . .288
Tests and Adjustments, Electrical . . . . . . . . . . . . . . . . 278 Turn Signal Switch Test . . . . . . . . . . . . . . . . . . . . .289
Battery Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 Unregulated Amperage Test . . . . . . . . . . . . . . . . .280
Battery Load Test . . . . . . . . . . . . . . . . . . . . . . . . . 280 Theory and Diagnosis
Battery Voltage and Specific Gravity Test . . . . . . 278 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Bottom of Clutch Switch Test and Adjustment, Electrical, EEC . . . . . . . . . . . . . . . . . . . . . . . . . . . .356
ePowrReverser . . . . . . . . . . . . . . . . . . . . 294 Theory of Operation
Brake Switch Test and Adjustment, eHydro . . . . . 292 Control Valve Operation, ePRT . . . . . . . . . . . . . . .561
Clutch Potentiometer Adjustment, PTO
ePowrReverser . . . . . . . . . . . . . . . . . . . . 299 Clutch and Brake . . . . . . . . . . . . . . . . . . . . . . .679
Clutch Potentiometer Test, ePowrReverser . . . . . 298 Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .680
Cruise Control Switch Test, eHydro . . . . . . . . . . . 291 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .782
Diode Block Test . . . . . . . . . . . . . . . . . . . . . . . . . . 287 Three Point Hitch
Drive Pedal Potentiometer Adjustment, eHydro . . 308 Removal and Installation . . . . . . . . . . . . . . . . . . . .817
Drive Pedal Potentiometer Calibration, eHydro . . 308 Torque Specifications
Drive Pedal Potentiometer Test, eHydro . . . . . . . 306 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .722
Electronic Operating System Automatic Hydrostatic Power Train (eHydro) . . . . . . . . . . . . .529
Diagnostics, eHydro . . . . . . . . . . . . . . . . . 313 Torques
Engine Coolant Temperature Sensor Test . . . . . . 285 Face Seal Fittings
Engine Oil Pressure Switch Test . . . . . . . . . . . . . 284 Inch Stud Ends . . . . . . . . . . . . . . . . . . . . . . . . . .12
F-N-R Switch Test, ePowrReverser . . . . . . . . . . . 297 Metric Stud Ends . . . . . . . . . . . . . . . . . . . . . . . .13
Flywheel Speed Sensor Test, eHydro . . . . . . . . . 309 Inch fastener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Fuel Gauge Sensor Test . . . . . . . . . . . . . . . . . . . . 293 Metric Fastener . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Fuel Shutoff Solenoid Test . . . . . . . . . . . . . . . . . . 293 Metric Fastener-Grade 7 . . . . . . . . . . . . . . . . . . . . .10
Fuse Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286 Traction Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . .578
Ground Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 Traction Clutch Disassembly . . . . . . . . . . . . . . . . . . . .575
Instrument Panel Light Test . . . . . . . . . . . . . . . . . 286 Traction Clutch Installation . . . . . . . . . . . . . . . . . . . . . .583
Key Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . 285 Traction Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . .573
Light Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . 287 Troubleshooting
Load Match Switch Test, eHydro . . . . . . . . . . . . . 295 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .804
MFWD Speed Sensor Test, eHydro . . . . . . . . . . . 310 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
MFWD Switch Test . . . . . . . . . . . . . . . . . . . . . . . . 294 Electrical, EEC . . . . . . . . . . . . . . . . . . . . . . . . . . . .347
MFWD, Rear PTO, and Mid PTO Solenoid Test . 290 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Manifold Heater Test . . . . . . . . . . . . . . . . . . . . . . 285 Final Drive Power Train . . . . . . . . . . . . . . . . . . . . .632
Mid PTO Switch Test . . . . . . . . . . . . . . . . . . . . . . 290 PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .683
Motion Match Switch Test . . . . . . . . . . . . . . . . . . . 295
No Load Amperage Draw and RPM Test . . . . . . . 282
U
Park Brake Switch Test and Adjustment . . . . . . . 292 Understand Signal Words . . . . . . . . . . . . . . . . . . . . . . . . .1
Pressure Transducer Test, ePowrReverser . . . . . 300 Use Proper Lifting Equipment . . . . . . . . . . . . . . . . . . . . . .3
Proportional Drive Solenoid Test, eHydro . . . . . . 297 Use Proper Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Proportional Drive Solenoid Test, Using High Pressure Washers . . . . . . . . . . . . . . . . . . . . .4
ePowrReverser . . . . . . . . . . . . . . . . . . . . 296 V
Proportional Solenoid Test, eHydro . . . . . . . . . . . 312
Proportional Solenoid Test, ePowrReverser . . . . . 302 Valve Manifold
Rear PTO Switch Test . . . . . . . . . . . . . . . . . . . . . 289 Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . .605
Regulated Amperage and Voltage Test . . . . . . . . 281 W
Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Wear Protective Clothing . . . . . . . . . . . . . . . . . . . . . . . . .2
Resume Set Speed Switch Test, eHydro . . . . . . . 291
Wheels
Seat Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Front Wheels Removal and Installation . . . . . . . . .820
Starting Motor Amperage Draw Test . . . . . . . . . . 282
Rear Wheels Removal and Installation . . . . . . . . .820
Starting Motor Solenoid Test . . . . . . . . . . . . . . . . 281
Work In Clean Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Test and Calibration Kit . . . . . . . . . . . . . . . . . . . . 298
Work In Ventilated Area . . . . . . . . . . . . . . . . . . . . . . . . . .4
Throttle Potentiometer Adjustment, eHydro . . . . . 305
Throttle Potentiometer Calibration, eHydro . . . . . 305
Throttle Potentiometer Test, eHydro . . . . . . . . . . . 304
Index - 7
-8

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John Deere 4210 4310 4410 Compact Utility Tractor (TM1985) Shop Manual

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JOHN DEERE

WORLDWIDE COMMERCIAL & CONSUMER

Compact Utility Tractors

TM1985 DECEMBER 2002

North American Version

This technical manual is written for an experienced Safety

Recognize Safety Information Be Prepared For Emergencies

This is the safety-alert symbol. When you see this symbol

Understand Signal Words

Use Care In Handling And Servicing Batteries

Replace missing or damaged safety signs. See the

Prevent Acid Burns

5. Use proper jump start procedure.

MIF Before working on the machine:

Service Machines Safely Support Machine Properly And Use Proper

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

Service Tires Safely

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

Dispose Of Waste Properly

Live With Safety

Explosive release of fluids from pressurized cooling system

Handle Chemical Products Safely

Before returning machine to customer, make sure machine

General Specifications .....................................9

Specifications & Information Table of Contents - 7

Specifications & Information Table of Contents - 8

Metric Fastener Torque Values

4.8 8.8 9.8 10.9 12.9

• DO NOT use these hand torque values if a different when tightening.

Specifications & Information General Specifications - 9

Metric Fastener Torque Values—Grade 7

Size Steel or Gray Aluminum

N•m (lb-ft) N•m (lb-ft)

M10 52 (38) 41 (30)

M12 88 (65) 70 (52)

M14 138 (102) 111 (82)

M16 224 (165) 179 (132)

Specifications & Information General Specifications - 10

1 or 2b 5 5.1 5.2 8 8.2

Specifications & Information General Specifications - 11

O-Ring Seal Service Recommendations

Face Seal Fittings with Inch Stud Ends Torque

Stud End Tube Nut

Straight Stud and Tube Nut Swivel Nut

-3 0.188 4.76 3/8-24 8 6

6 -4 0.250 6.35 9/16-18 16 12 12 9 7/16-20 12 9

8 -5 0.312 7.94 1/2-20 16 12

10 -6 0.375 9.52 11/16-16 24 18 24 18 9/16-18 24 18

12 -8 0.500 12.70 13/16-16 50 37 46 34 3/4-16 46 34

Specifications & Information O-Ring Seal Service Recommendations - 12

16 -10 0.625 15.88 1-14 69 51 62 46 7/8-14 62 46

-12 0.750 19.05 1-3/16-12 102 75 102 75 1-1/16-12 102 75

22 -14 0.875 22.22 1-3/16-12 102 75 102 75 1-3/16-12 122 90

NOTE: Torque tolerance is +15%, -20%

Face Seal Fittings with Metric Stud Ends Torque

Stud End Tube Nut

Groove for Metric Identification

mm Das in. mm in. mm N• lb-ft N• lb-ft mm mm N• lb-ft N• lb-ft

6 -4 0.250 6.35 9/16-18 17 16 12 12 9 M12X1.5 17 21 15.5 9 6.6

Specifications & Information O-Ring Seal Service Recommendations - 13

mm Das in. mm in. mm N• lb-ft N• lb-ft mm mm N• lb-ft N• lb-ft

10 -6 0.375 9.52 11/16-16 22 24 18 24 18 M16X1.5 22 41 30 18 13

12 -8 0.500 12.70 13/16-16 24 50 37 46 34 M18X1.5 24 50 37 21 15

16 -10 0.625 15.88 1-14 30 69 51 62 46 M22X1.5 27 69 51 28 21