Terex Old Handbook Troubleshooting

Technician Service Hand Book –
Backhoe Loader
1 HELP LINE NUMBER 0120 - 4729000
Important safety information
Most accident that involves product operation, maintenance and repair is caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazard
situations before an accident occurs. A person must be alert to potential hazards. This person should
have the necessary training, skills and tools to perform these functions properly
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
DO NOT OPERATE OR PERFORM ANY LUBRICATION, MAINTENANCE OR

REPAIR ON THIS PRODUCT, UNITL YOU HAVE READ AND UNDERSTOOD
THE OPERATION, MAINTENANCE AND REPAIR INFORMATION
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”.
The meaning of this safety alert symbol is as follows:
ATTENTION! BECOME ALERT! Your safety is involved
One cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method
or operating technique that is not specifically recommended by Terex is used, you must satisfy yourself
that it is safe for you and for others. You should also ensure that the product will not be damaged or be
made unsafe by the operation, lubrication, maintenance or repair procedure that you choose.
General torque information
Prior to installation of any hardware, ensure that components are in near new condition. Bolts and
threads must not be worn or damaged. Threads must not have burrs or nicks. Hardware must be free of
rust and corrosion. Clean the hardware with a noncorrosive cleaner. Do not lubricate the fastener
threads except for the rust preventive.

General torque specification
Torque specifications – decimal hardware
Use torque in this chart when special torques are not given. This torques applies to fasteners with both
UNC and UNF threads.
Grade 5 bolts, nuts and studs Grade 8 bolts, nuts and studs
Thread size
Pounds inches Newton meters Pounds inches Newton meters
1/4 inch 8 to 11 12 to 15 12 to 15 16 to 20
5/16 inch 17 to 21 23 to 28 24 to 29 33 to 39
3/8 inch 35 to 42 48 to 57 45 to 54 61 to 73
7/16 inch 54 to 64 73 to 87 70 to 84 95 to 114
1/2 inch 80 to 96 109 to 130 110 to 132 149 to 179
9/16 inch 110 to 132 149 to 179 160 to 192 217 to 260
5/8 inch 150 to 180 201 to 244 220 t0 264 298 to 358
3/4 inch 270 to 324 366 to 439 380 to 456 515 to 618
7/8 inch 400 to 480 542 to 651 600 to 720 814 to 976
1.0 inch 580 to 696 787 to 944 900 to 1080 1220 to 1465
1-1/8 inch 800 to 880 1085 to 1193 1280 to 1440 1736 to 1953
1-1/4 inch 1120 to 1240 1519 to 1681 1820 to 2000 2468 to 2712
1-3/8 inch 1460 to 1680 1900 to 2278 2380 to 2720 3227 to 3688
1-1/2 inch 1940 to 2200 2631 to 2983 3160 to 3560 4285 to 4827

Grade 8.8 bolts, nuts and studs Grade 10.9 bolts, nuts and studs
Thread size 8.8 10.9
Pounds inches Newton meters Pounds inches Newton meters
M4 2 to 3 3 to 4 3 to 4 4 to 5
M5 5 to 6 7 to 8 7 to 8 9 to 11
M6 8 to 9 11 to 12 11 to 13 15 to 18
M8 19 to 23 26 to 31 27 to 32 37 to 43
M10 38 to 45 52 to 61 54 to 64 73 to 87
M12 66 to 79 90 to 107 93 to 112 125 to 150
M14 106 to 127 144 to 172 149 to 179 200 to 245
M16 160 to 200 217 to 271 230 to 280 310 to 380
M20 320 to 380 434 to 515 450 to 540 610 to 730
M24 500 to 600 675 to 815 780 to 940 1050 to 1275
M30 920 to 1100 1250 to 1500 1470 to 1770 2000 to 2400
M36 1600 to 1950 2175 to 2600 2580 to 3090 3500 to 4200
Measuring bolt thread size

Using a caliper, take the diameter
of the bolt thread. Take the
diameter at the plain shank portion
of the bolt, if available. If there is
no plain shank portion, make sure
you are measuring across the
outside tips of the thread.

Torque specification (hydraulic fittings)
N – Thread diameter
Tube OD / Hose ID Thread size Pound inch Newton meters
37 degree flare fitting
1/4 inch / 6.4 mm 7/16 – 20 6 to 12 8 to 16
5/16 inch / 7.9 mm 1/2 – 20 8 to 16 11 to 22
3/8 inch / 9.5 mm 9/16 – 18 10 to 25 14 to 34
1/2 inch / 12.7 mm 3/4 – 16 15 to 42 20 to 57
5/8 inch / 15.9 mm 7/8 – 14 25 to 58 34 to 70
3/4 inch / 19.0 mm 1-1/16 – 12 40 to 80 54 to 108
7/8 inch / 22.2 mm 1-3 / 16 – 12 60 to 100 81 to 135
1.0 inch / 25.4 mm 1-5 / 16 – 12 75 to 117 102 to 158
1-1/4 inch / 31.8 mm 1-5/8 – 12 125 to 165 169 to 223
1-1/2 inch / 38.1 mm 1-7/8 – 12 210 to 250 285 to 338

Loctite product chart
Working temperature
Strength (steel/steel)
range – Fahrenheit
(steel/steel) time
Fixture/full cure
Gap (inches)
Description
Product
Colour
in lbs
#3 Brown 24 H Form a gasket (works with oil, fuel or grease

80 Yellow Fast Weatherstrip adhesive
123 Clear Parts cleaner fluid
220 Blue 0.076 65/164 -54 to 122 24 H Wicking threadlocker
221 Purple 0.127 86/50 -54 to 150 24 H Low strenght threadlocker
222 Purple 0.127 51/28 -54 to 150 10 min Low strenght threadlocker
225 Brown 0.254 51/28 -54 to 150 7 min Low strenght threadlocker
242 Blue 0.127 92/57 -54 to 150 10 min Medium strenght threadlocker
262 Red 0.127 184/218 -54 to 150 5 min High strenght threadlocker
270 Green 0.177 184/368 -54 to 150 3 min High strenght threadlocker
272 Red 0.254 207/311 -54 to 234 30 min High temperature, high strength
275 Green 0.254 241/345 -54 to 150 3 min High strenght threadlocker
290 Green 0.076 97/403 -54 to 150 6 min Wicking threadlocker
*404 Clear 0.156 224 psi -54 to 82 30 sec Instant adhesive
*406 Clear 0.101 224 psi -54 to 82 15 sec Surface insensitive adhesive
*409 Clear 0.203 175 psi -54 to 82 50 sec Gel instant adhesive
*414 Clear 0.156 175 psi -54 to 82 30 sec Instant adhesive
*415 Clear 0.254 175 psi -54 to 82 50 sec Gap filling instant adhesive (metal)
*416 Clear 0.254 175 psi -54 to 82 50 sec Gap filling instant adhesive (plastic)
*420 Clear 0.05 175 psi -54 to 82 15 sec Wicking instant adhesive
*422 Clear 0.05 196 psi -54 to 82 60 sec Gap filling instant adhesive
*430 Clear 0.127 175 psi -54 to 82 20 sec Metal bondind adhesive
*445 White 6.35 140 psi -54 to 82 5 min Fast setting 2 part epoxy
*454 Clear 0.254 224 psi -54 to 82 15 sec Surface insensitive gel instant adhesive
*495 Clear 0.101 175 psi -54 to 82 20 sec General purpose instant adhesive
*496 Clear 0.127 175 psi -54 to 82 20 sec Metal bondind adhesive
504 Orange 0.076 52 psi -54 to 150 90 sec Rigid gasket eliminator
510 Red 0.05 70 psi -54 to 206 30 min High temperature, gasket eliminator
515 Purple 0.254 52 psi -54 to 150 1H Gasket eliminator 515
518 Red 0.076 35 psi -54 to 150 1H Gasket eliminator 578 for aluminum
542 Brown 152/106 -54 to 150 2H Hydraulic sealant
545 Purple 28/23 -54 to 150 4H Low strenght hydraulic sealant
549 Red 0.05 175 psi -54 to 150 4H Instant seal plastic gasket
567 Orange 35 psi -54 to 206 4H Pipe sealant for stainless steel
568 Brown 0.381 175 psi -54 to 150 12 H Plastic gasket
569 Brown 0.254 28/46 -54 to 150 1H Hydraulic sealant
571 White 0.381 46/23 -54 to 150 2H Pipe sealant
572 White 92/31 -54 to 150 24 H Gasketing

Oil viscosity / oil operating range (Engine)
A: Fahrenheit temperature B: Centigrade temperature

Conversion tables
Linear measure
Inches X 2.54 = Centimeters Centimeters X 0.3937 = inches
Yards X 0.9144 = Meters Meters X 3.2808 = Feet
Square measure
Sq inches X 6.452 = sq. cent. Meters Cent. Meter X 0.155 = Sq. inches
Sq. feet X 0.0929 = Sq. meters Sq. meters X 10.764 = Sq. feet
Weights
Pounds X 0.45359 = kilograms Kilograms X 2.2046 = Pounds
Tonnes X 0.9842 = Tonnes Tonnes X 1.0161 = Tonnes
Pressure and Torque
Lbs. Per. Sq.Inch X 0.0703 = Kgs.per.Sq.Centimeter X 14.244 =

Kgs.per.Sq.Centimeter Lbs.per.Sq.Inch
Kilopascal X 0.145 = Pounds per square inch Pounds per square inch X 6.895 = kilopascal
Newton meters X 0.7376 = Pound feet Pound feet X 1.356 = Newton meters
Newton meters X 0.1019 = KGF meter KGF meter X 9.807 = Newton meters
Temperature
5 X (F⁰ - 32) = C⁰ 9 X C⁰ = F⁰
9 5

Product Specifications
Machine Model
Particulars
TX 760 TLB 740S TLB 844S
Engine make KOEL KOEL KOEL
Engine Model 4R1040 4R 1040 4R 1040 T
Gross power 90 HP 76 HP 90 HP
Transmission 4F/4R 4F/4R 4F/4R
Transmission oil refill 15 L 15 L 15 L
Travel speed (1st gear) 5.4 Km/h 5.4 Km/h 5.4 Km/h
Travel speed (2nd gear) 8.7 Km/h 8.7 Km/h 8.7 Km/h
Travel speed (3rd gear) 19.9 Km/h 19.9 Km/h 19.9 Km/h
Travel speed (4th gear) 40.0 Km/h 40.0 Km/h 40.0 Km/h
Hydraulic pump flow (P1 + P2) 142 PLM 119 LPM 142 LPM
Hydraulic system refill capacity 90L 90 L 90 L
Main relief pressure 225 bar 225 bar 225 bar
Turning circle 8.4 m 8.4 m 8.4 m
Rear axle refill capacity 17.5 L 17.5 L 17.5 L
Battery 12V 135A 12V 135A 12V 135A
Loader bucket 1.0 cum 1.0 cum 1.0 cum
Backhoe bucket 0.25 cum 0.25 cum 0.25 cum
Front tyre (65 psi) 12.5 X 18 12.5 X 18 12.5 X 18
Rear Tyre (35 psi) 16.9 X 28 16.9 X 28 16.9 X 28

Maintenance Checklist
Hours
Check points on the machine
10 100 500 1000 1500 2000
Engine Checks
Check mounting bolts √ √ √ √ √
Coolant level & antifreeze strength √ √ √ √ √ √
Air cleaner/pre cleaner √ √ √ √ √ √
Exhaust system for leaks & mounting √ √ √ √ √ √
Fan belt tension & condition √ √ √ √ √ √
Fuel system for leaks √ √ √ √ √ √
External oil leaks √ √ √ √ √ √
Cleanliness of radiator & oil cooler √ √ √ √ √ √
Engine RPM check √ √ √ √ √ √
Drain water separator √ √ √ √ √ √
Flush clean fuel tank √ √
Transmission checks
Oil level check √ √ √ √ √ √
Check mounting bolts √ √ √ √ √
Check clutch pressure √ √ √ √
Check condition of drive shaft √ √ √ √ √ √
Rear axle & brake
Check oil level √ √ √ √ √ √
Check mounting bolts √ √ √ √ √ √
Check brake functioning √ √ √ √ √ √

Tire condition and pressure √ √ √ √ √ √
Hydraulic system
Oil level √ √ √ √ √ √
Cylinder rod leaks and damages √ √ √ √ √ √
Pipe work & couplers damage or leaks √ √ √ √ √ √
Check mounting bolts of major components √ √ √ √
Check all machine operations √ √ √ √ √ √
Check system pressure √ √
Electrical system
Battery electrolyte level check √ √ √ √ √ √
Battery terminal condition & tightness √ √ √ √ √ √
Horn functioning √ √ √ √ √ √
All lights and accessories √ √ √ √ √ √
Check functioning of starter motor & alternator √ √ √ √ √ √
Body and frame √ √ √ √ √ √
All pivot pins check & grease √ √ √ √ √ √
All hinges lubricate √ √ √ √ √ √
General damages √ √ √ √ √ √
Seat belt condition √ √ √ √ √ √
Paint condition √ √ √ √ √ √
Door locks &wind shield condition √ √ √ √ √ √
Sliding rear door functioning √ √ √ √ √ √

General maintenance procedures
Air cleaner Transmission and torque converter
1) Check for loose or damaged hose

1. Leaks around cooler hose
clamps on securing turbocharger air inlet
connections
tube
2. Rubbing, damaged or worn hoses
2) Look for tears, cracks or other damage
3. Rubbing, damaged or worn wiring
which would prevent a tight seal
harness or connectors
between the hood and filter housing of
air leaks Check for oil or dirt buildup at the
3) Look for signs of dirt tracks as an following locations
indicator of air leaks
1. Transmission output shaft
Transmission mountis 2. Sealing surface between the back
and front halves of the
transmission
3. Sealing surface between the
transmission housing and engine
flywheel
4. Drain and fill plugs
Drive shaft and parking brake
1) Loose or damaged bolts

2) Cracked or damaged washer
3) Cracked or damaged mounts bracket
4) Wear, damage or cracking of upper or
lower runner support pads. There
should be no metal to metal contact

1. Check drive shaft for loose or missing Harness connector inspection
U joint retainer bolts
2. Worn or loose U joint or drive shaft
splines
3. Grease leaking from U joint seals or
from drive shaft splines seals. Grease
leakage in these areas would indicate
possible seal damage
4. Check parking brake for proper
operations
5. Excessive pad or rotor wear
6. Loose or damaged caliper mechanism
or cable 1. Check for connectors not properly
secured in place
2. Rubbing against machine frames
Wiring harness inspection
3. Rubbing against sharp edges
4. Dirt or moisture accumulation at the
connectors
Steering cylinder, tie rods and
linkages
1. Check for tubes, hoses and wiring

harness rubbing against one another,
sharp corners and bolt heads
2. Check for tubes, hoses and wiring
harness not properly secured, missing
1. Oil leaks indicated by dirt or buildup
clips and/or wire ties and clips not
around the cylinder lip seal
attached
2. Oil leaks at hose connections
3. Damaged to cylinder rod
4. Damage or wear to linkages, fasteners
and grease fitting
5. Cracked or blown out grease boots
6. Check tie rod retaining bolts

Work lights Cab mounts
Check rod lights, turn signals, hazard 1. Loose or damaged mounting bolts
flashers, work lights and other lights for 2. Cracked or damaged washers
3. Cracked or damaged mounts brackets
1. Proper operation
4. Wear, damage, cracking of upper and
2. Cracked or broken lenses
lower rubber support pads. There
3. Damaged wiring harness
should be no metal to metal contact
Batteries and battery cables Backhoe control valve
1. Battery posts and cables for corrosion

1. Leaks around connection points for
or damage
hose and control valve components
2. For rubbing, damaged or worn cables
2. Rubbing, damaged or worn hoses
3. Battery hold down for proper function
3. Rubbing, damaged or worn wiring
and tightness
harness and connectors

Cab exterior Lower boom area
1. Bent or damaged cab structure 1. Hoses connections for leaks

2. Cracked or broken glass 2. Hose for rubbing, damaged or wear
3. Damaged or missing mirror 3. Grease fittings for damage or wear
4. Worn or broken windshield wiper arms 4. Boom lock for proper operation and
or wiper blades damage to cable or locking mechanism
5. Damaged reset area
Cab mounts 6. Loose or broken foot pin retainer and
or irregular pin bores
Backhoe bucket
1. Proper functioning of seat and seat

belt
2. Wear or damage to seat belt
3. Proper function of door and latches 1. Excessive wear on the bucket tip
4. Worn or broken window latches or 2. Damage to the bucket tip adapter
slides 3. Damage or missing retainer pins
5. Damaged or inoperable gauges and 4. Excessive wear or wear plates
controls

Tires and rims Hydraulic pump
1. Proper inflation of tyres 1. Leaks around hose connection points

2. Cuts, cracks, split or busies in the 2. Rubbing, damaged or worn hoses
tread or sidewall area. Bumps or 3. Loose or damaged hose clamps on
bulges may indicate tyre separations pump suction lines
3. Safe tread depth
4. Tread worn down to the built in wear
Hydraulic cylinders
5. Tyre cords or exposed fabric
6. Uneven tread wear
7. Cracks, pits from corrosion or other
v visible damage to rims
Fenders
1. Oil leaks indicated by dirt or oil buildup

around the cylinder lip seal
2. Oil leaks at hose connections
3. Damage to cylinder rods
1. Bent or damaged fenders and mounting

brackets
2. Loose or missing mounting bolts

Pivot pins inspection Loader control valve
1. Loose or broken flange mounting bolts 1. Leaks around connections points for
2. Elongated bolt hole hose and control valve components
3. Loose or missing pin retainer bolts 2. Rubbing, damaged or worn hoses
4. Irregular shaped pin bores 3. Rubbing, damaged or worn wiring
harness and connectors
Steering arms and kingpins
Rear differential and axle
1. Structural damage
2. Excessive play and loose or missing Check the following areas for leaks
retainer plates in kingpins
3. Improper lubrication and damaged or 1. Sealing surface between the axle
missing grease fittings housing and the differential housing
4. Damaged, missing or improperly 2. Sealing surface between the drive shaft
adjusted stop bolts and differential carrier
3. Oil drain and fill plugs
4. Hoses and connectors to service brake
Check for loose or damaged axle

mounting bolts

Final drive and wheel spindles Exhaust system for leaks and
mounting
Check final drive oil level. If the oil level is

low, check the following areas for leaks 1. Loose connection at the cylinder head
joint leading to carbon deposits around
1. Sealing surface between the planetary exhaust manifold and pipes
housing and the final drive housing 2. Loose or broken manifold bolts
2. Special seal located between axle 3. Cracks or other damage in the
housing and the back of the final drive manifold housing
housing 4. Carbon deposit around turbocharger
3. Oil leakage around the drain and fill mounting due to loose mounting bolts
plugs 5. Loose connections at joints
Engine mounting bolts 6. Loose turbocharger mounting bolts
7. Oil leakage around turbocharger oil
lines
8. Loose or damaged hose clamps on air
inlet tube and compressor housing
Fan belt pulleys, belts, water

pump & fan drive
1. Loose or damaged mounting bolts.

2. Cracked or damaged washer
3. Cracked or damaged mounting
bracket. Wear, damage, cracking of
upper and lower rubber support pads.
There should be no metal to metal
contact

1. Check belt drives for worn, cracked or Cooling fan, fan guard, shroud
broken belt
2. Check proper belt tension
3. Check water pump for coolant leaks
around water pump mounting flange
Observe engine exhaust colors
1. Loose, damaged or missing bolts

2. Loose or damaged fan guard
3. Loose or damaged fan shroud
4. Damaged, cracked or missing engine
fan blades
5. If any part found to be defective,
replace with new parts
1. Start the machine and observe the
exhaust colours Listen for unusual noises
2. White smoke after initial startup could
indicate coolant in the engine cylinders
3. Blue smoke during startup may indicate
oil in the engine cylinders
4. Continuous black smoke could indicate
an improper air/fuel mixture
5. Continuous grey smoke may indicate a
fuel timing problem
1. Excessive noise coming from hydraulic

pump could indicate either pump
cavitation or loose or failed bearings
2. Excessive noise coming from engine
compartment could indicate, fuel
injector damaged, engine bearing
damaged or valve train damage

General troubleshooting information (transmission)
WARNING
When the oil in the transmission gets hot, it causes the air to expand and build pressure in the
transmission sump.
Pressure can remain in the transmission after the engine is stopped
Personal injury can occur if pressure is not released before any service is performed on the
transmission
To prevent possible injury, remove the cap from the oil filler tune before any fitting, hose or component
in the transmission is loosened, tightened, removed and/or adjusted.
The cap must be replaced when the tests and/or adjustments are completed.
The bucket and the other attachments must always be flat on the ground before service is performed.
When it is necessary for an attachment to be raised while tests and/or adjustment are being performed,
be sure the correct supports are in place. In case of the bucket, it must be in the full dump position.
Move the machine to a location away from travel of other machines
Wear the seat belt and be sure that other personnel are not near the machine when the engine is
running and tests or adjustments are being performed.
Procedure
When you are defining a transmission problem use the following procedure.
First, perform visual checks. Next perform the operation checks and verify the symptom.
Lastly, perform the instrument tests if the cause of the problem has not been found.
Once the problem is defined, proceed to troubleshooting
Since there may be more than one cause for a particular problem, the troubleshooting section may
suggest specific instructions. The troubleshooting section may also suggest the performance of
instrument tests.
These inspections and these tests aid in determining the most probable cause.

The list cannot give all possible problems and all possible corrections. The service personnel must find
the problem and the source. Then, the service personnel must make the necessary repairs.
During the diagnosis of a problem in the transmission, remember that correct oil flow, correct
temperature and correct pressure are necessary for proper operation.
The pump creates oil flow. Oil pressure is caused by resistance to the oil flow. Oil sump temperature
must be a minimum of 52 ⁰C during diagnosis.
When more checks are necessary, use the appropriate hydraulic gauges.
1. Finding the solution to a problem can be made easier if the following information is known.
2. The performance of the system decreases rapidly if the level of the oil in the transmission is not
within specification. Also, the performance of the system decreases rapidly if the viscosity of the
oil in the transmission is not in accordance with the specifications.
a. If the oil level is too low, the machine can malfunction completely.
b. Oil that is too viscous can cause the filter bypass valve to open. When the filter bypass
valve opens, oil is sent back to the sump. This causes a loss in machine speed and a
loss in performance.
3. There is a direct relationship between engine speed and the performance of the transmission
a. The engine speed must reach HIGH IDLE when the throttle pedal is pressed to the
HIGH IDLE position
b. The performance of the transmission will be affected if the engine is not in HIGH IDLE.
This condition will also interfere with troubleshooting
4. It is possible for the engine to run at a speed lower than HIGH IDLE, even though the throttle
pedal is pressed to the HIGH IDLE position.
a. One of the following conditions or a combination of the following conditions could cause
the low speed. A defective throttle control linkage, low quality of fuel, poor condition of
fuel filter and air in the fuel system

Transmission hydraulic schematic
Turner
Transmission
Carraro Transmission

Pressure chart
Tapping point Specification

System Condition Remarks
Turner Carraro Turner Carraro
Engine at high idle and
F 20 Oil pump pressure transmission direction control 13.5 to 15.5 bar 13 bar No adjustment
lever in neutral position
Reverse clutch
H 19 transmission direction control 12.5 to 15.5 bar 13 bar No adjustment
pressure
lever in reverse position
Forward clutch
G 18 transmission direction control 12.5 to 15.5 bar 13 bar No adjustment
pressure
lever in forward position
Torque converter
I 22 transmission direction control 7.5 bar 9 bar No adjustment
relief vavle
Oil cooler back
NA 17 transmission direction control 0.5 to 2.5 bar 5 bar No adjustment
presure

TROUBLESHOOTING PROCEDURE
PROBLEM – TRANSMISSION PUMP

PRESSURE IS LOW
Remove the cold start relief valve. Inspect
the spring for any cracks or bend. If found
Step 1 – Check transmission filter
to be defective replace with new spring
6190034M1. Inspect the ball for any wear
or scratches and if found to be defective,
replace with new ball 6190033M1. Inspect
the ball seating area for any wear or
scratches and if found to be defective,
replace with new seat 6190006M1. Install
the valve with new 6190035M1 O ring and
tighten to a torque of 46 to 60 Nm. Check
whether the problem is resolved and if
Remove the transmission filter, cut open Step 3 – Service the clutch pressure
the filter and inspect for any chocking due regulating valve
to contamination or heavy metal particles. If
contamination found, install a new filter
6190810M1 and tighten to a torque 7 to 10
Nm and change the transmission oil 10003
15 liters. Check whether the problem has
been resolved and if problem persists
proceed to step2. If heavy metal particles
found, remove the transmission from the
machine and conduct a through internal
inspection.
Step 2 – Service the cold start relief
Remove the clutch pressure regulating
valve and inspect seal for any damage. If
the seals found to be defective replace with
new seal kit 6190189M91. Install the valve
back and tighten to a torque of 46 to 60
Nm. Check whether the problem is resolved
and if problem persists proceed to step4

If found to be defective, replace with new
Step 4 – Check for any block in the pump kit 852M91. Tighten the pump
housing drilled passages retaining bolt to a torque of 18 to 31 Nm.
Reinstall the transmission
PROBLEM – TORQUE CONVERTER

PRESSURE LOW
Step 1 - Check machine history

for transmission overheating
Check whether the transmission had
Remove all the pressure checking plugs overheating problem and if so proceed
and thoroughly clean the passages by air. with overheating troubleshooting
Ensure the air pressure should not exceed procedure refer page no. 28. If there
15 bar. Install the plugs back, check was no overheating program, proceed to
whether the problem has been resolved step 2
and if the problem persists, proceed to
step5 Step 2 – Service the torque
converter relief valve
Step 5 – Repair or replace the
transmission pump
Remove the relief valve from the

transmission. Inspect the condition of
seal/O ring. If found to be defective
replace with new 6190190M91 seal kit.
Remove the transmission from the Install the valve back and tighten to a
machine and remove the transmission torque of 23 to 30 Nm. Check whether the
pump. Dismantled the pump assembly and problem is resolved, else replace with new
inspect for any wear or scratches on the 6190153M91. Check whether the problem
drive gear, driven gear and its contact is resolved, else proceed to step 3
areas in the pump housing.

Step 3 – Check torque converter Remove the dipstick from the transmission
which is located on left hand side of the
machine inside the engine compartment.
Wipe the dip stick with clean cloth, insert
and remove dip stick back. The oil level
should be within LOW and HIGH marks. If
found to be low, add fresh 1G0003
transmission oil. Check whether the problem
has been resolved, else proceed to step2
Step 2 – Check transmission oil

condition
Remove the torque converter from the
machine and install with new 3518299M91
torque converter. Install the mounting plate
and tighten the plate retaining bolts to a
torque of 41 to 54 Nm. Install the torque
converter assembly on the engine flywheel,
adjust run out to 0.02 mm and tighten torque
converter assembly retaining bolt to a torque
of 18 to 31 Nm.
PROBLEM – MACHINE DOES NOT

MOVE IN EITHER DIRECTION Remove the drain/magnetic plug collect
about 100 ml of oil into a suitable container
Step 1 – Check transmission oil and check for any contaminations like, water
level entry, dust entry, blacking of oil, low
viscosity, high viscosity etc and also inspect
the plug for any metal particles. If the oil
found to be contaminated, flush the entire
system and install the drain plug with new
6190126M1 seal and tighten to a torque of
30 to 55 Nm. Fill transmissions with fresh
1G0003 transmission oil 15 lts. If any metal
particles found, remove the transmission
and conduct through internal inspection,
else proceed to step 3
Step 3 – Check functioning of
NEUTRALIZER SWITCH
Refer forward/reverse control circuit –

page no 101

If found to be defective replace the
Step 4 – Check condition of complete assembly, else proceed to step
forward/reverse fuse 9
Step 9 – Check transmission
page no 101
Step 5 – Check condition of dump

fuse

page no 101
forward/reverse switch
Refer forward/reverse control circuit – Remove the transmission from the

page no 101 machine and conduct a thorough internal
inspection. STOP
pressure PROBLEM - MACHINE MOVES IN ONLY
Refer transmission pressure chart – page ONE DIRECTION
no 23 Step 1 – Check transmission oil
Step 8 – Check speed selection level
lever
Remove the dipstick from the transmission

which is located on left hand side of the
machine inside the engine compartment.
Remove the speed selection lever. Check
Wipe the dip stick with clean cloth, insert
the seating 6190143 M91for any rubbing or
and remove dip stick back. The oil level
abnormal wear. Check for free movement of
should be within LOW and HIGH marks. If
the lever 6190142 M1 and check the lever
found to be low, add fresh 1G0003
rail assembly for proper
transmission oil. Check whether the problem
contact/engagement with the shift fork.
has been resolved, else proceed to step2

Step 2 – Check transmission oil Step 5 – Check functioning of
condition forward/reverse solenoid

page no 101

pressure
Refer transmission pressure chart – page

Transmission overheating no.23
Remove the drain/magnetic plug collect

about 100 ml of oil into a suitable container
and check for any contaminations like, water
entry, dust entry, blacking of oil, low
viscosity, high viscosity etc and also inspect
the plug for any metal particles. If the oil
found to be contaminated, flush the entire
system and install the drain plug with new
6190126M1 seal and tighten to a torque of
30 to 55 Nm. Fill transmissions with fresh
Remove the transmission from the
1G0003 transmission oil 15 lts. If any metal
machine and conduct a thorough internal
particles found, remove the transmission
inspection
and conduct through internal inspection,
else proceed to step 3
PROBLEM – TRANSMISSION
Step 3 – Check functioning of OVERHEATING
forward/reverse fuse
Refer forward/reverse control circuit – Step 1 – Check oil level

page no 101
Refer page no.26
Step 4 – Check functioning of Step 2 – Check oil condition

forward/reverse switch
Refer page no. 26
page no 101
Step 3 – Check oil temperature
sender

cooler
Check for any loose or broken connection at

the sender. Remove the harness and check
1. Ensure the cooler core is not plugged with
for any corrosion at the terminal. If any
mud or debris
corrosion found clean the terminal. Remove
the sender, clean the sender stem. Reinstall 2. Ensure there is no leaks, loose connections
the sender and tighten to a torque of 20 to or loose cooler mounting bolts and shrouds
27 Nm. Connect the harness. Operate the 3. Check the machine history for any indication
machine and check for any overheating. If of other system overheating. If other
the transmission overheats, proceed to step systems are also overheating, check the fan,
4 fan belt etc.
Step 4 – Check transmission oil 4. Measure temperature difference across

cooler top and bottom tank. If the ∆T > 15⁰C
temperature indicator bulb
or ∆T < 10⁰C, cooler is chocked. Service the
cooler. STOP

pressure
Refer transmission pressure chart – page
no 23
Check for any loose or broken connection at

the bulb. Remove the harness and check for
any corrosion at the terminal. If any
corrosion found clean the terminal. If still
problem persists check for any short in the
bulb circuit. Refer page no 101. If no short
circuit found, proceed to step 5

PROBLEM – FORWARD/REVERSE
Remove all the pressure checking plugs and
CLUTCH PRESSURE LOW thoroughly clean the passages by air.
Ensure the air pressure should not exceed
15 bar. Install the plugs back, check whether
forward/reverse solenoid
the problem has been resolved and if the
Refer forward/reverse control circuit – problem persists, proceed to step4
page no 101
Step 4 – Check condition of
Step 2 – Service the forward/reverse forward/reverse clutch piston seals.
modulation valve.
Remove and dismantled the transmission.

Remove the modulation valve. Ensure the
Check the condition of the forward/reverse
condition of the seals, valve and valve stem
clutch piston seals. Also check the seal
for any wear, scoring or scratches. Also
contact area in the piston housing. If found
check the valve contact area in the body
to be defective replace with 6194129 M1
assembly. If found to be defective replace
new piston assembly. STOP
the complete 6190820 M91 valve solenoid
assembly. Use 6190399 M1 seals 4 Nos for
installation of the valve assembly PROBLEM – CLUTCH ENGAGEMENT IS
SLOW AND TRANSMISSION MAKES
Step 3 – Check for any block in the
ROUGH SHIFT
housing drilled passages
level.
Refer page no. 26

Step 2 – Check transmission oil Check drive shafts for:
condition
1) Ensure that the male and female
Refer page no. 26 part are in line with reference to
the cross mounting faces
2) Loose or missing U-joint retainer
pressure bolts
Refer transmission pressure chart – page 3) Worn or loose U-joints or drive
no 23 shaft spline
Step 4 – Check transmission 4) Grease leaking from U-joint seals

or from drive shaft spline seal
Check the condition of synchronizer, shift
fork, shift collar, shift rails, detent ball & a. Grease leakage in these
spring. areas would indicate
possible seal damage
PROBLEM – ABNORMAL NOISE FROM
TRANSMISSION Step 4 – Check transmission
mounting bolts
level
Refer page no. 23

condition
Refer page no. 26
Step 3 – Check drive shaft
1. Check the condition of the mounting

pads. If found to be defective replace the
6106848 M91 mounting pads.
2. Check the torque of the mounting bolts. If

found to be loose torque the mounting
bolts to 395 Nm.
3. Check the torque of mounting bolts at

flywheel housing. If found to be loose
torque the bolts to 140 Nm

Step 5 – Check transmission Ensure that the shift lever is not having any
abnormal bent or rubbing with any other
Remove the transmission from the components. If found to be rubbing, adjust
machine, dismantle and check the as necessary. If found to be bent replace
conditions of all the bearings, gear etc. If with new 1K0062 gear lever assembly.
found to be defective, repair/replace as
necessary.
PROBLEM – DIFFICULT IN GEAR
SELECTION OR GEAR SELECTION
LEVER IS HARD TO OPERATE OR
JUMPING OUT OF GEAR OR GEAR
REMAINS ENGAGED

level.
Refer page no. 23

Remove the transmission from the
condition machine and conduct a thorough internal
Refer page no. 26 inspection
Step 3 – Check shift lever for wear

or bend

Hydraulic system
General troubleshooting information
Procedure
WARNING
Sudden movement of the machine or release of oil under pressure can cause serious injury to persons
or near the machine.
To prevent possible injury, perform the procedure that follows before troubleshooting the hydraulic
system.
The lift circuit (both loader and backhoe) has high oil pressure when the lift boom raises the front of the
machine. DO NOT STOP THE ENGINE with the front of the machine is off of the ground
Move the machine to a smooth, horizontal location. Move away from other machines and personnel.
Lower all the attachments to the ground.
Permit only one operator on the machine. Keep all other personnel away from the machine
Engage the parking brake
Stop the engine
Move the hydraulic control levers to all positions so that the pressure in the hydraulic system is
released
Carefully loosen the hydraulic tank fill cap so that the pressure in the tank is released
Tighten the filler cap on the hydraulic tank
The pressure in the system has now been released. The lines can be removed or the components can
be removed
Definition of problem
Follow this procedure in order to define a problem with the hydraulic system. First, perform visual
checks. Next, perform operational checks. Lastly, perform instrument tests. This procedure helps
indentify hydraulic system problems. Once the problem is defined, go to troubleshooting. The
troubleshooting section lists the probable causes of a known problem, the troubleshooting section may

suggest specific inspections or instrument test to be done. These inspections and test helps identify the
most probable causes.
During a diagnosis of the hydraulic system, remember that correct oil flow, correct temperature and
correct pressure are necessary for correct operation. The output of the pump increases with increase in
engine speed and the output of the pump decreases when engine speed is decreased. Oil pressure is
caused by resistance to the flow of oil.
Use appropriate tools in order to measure the following conditions
Drift rate in the attachment circuits. Circuit drift is caused by leakage past the following components,
cylinder pistons, control valves spools, load check valve, line relief valves, make-up valves and leaks in
external lines. Excessive drive can be caused by problems with one component or excessive drift can
be caused by problem with a combination of components.
Cycle time in the attachment circuit. Cycle times that are longer than the cycle times that are shown
in the charts are the result of the following conditions: leakage, pump wear and pump speed. If the
basic operational checks indicate circuit leakage that is excessive, perform pressure tests in order to
identify the problem.
Visual inspection
WARNING
Hydraulic oil pressure can remain in the hydraulic system on this machine after the engine and pump
have been stopped. Serious injury can result if this pressure is not released before any service is done
on the hydraulic systems. In order to prevent possible injury, release the hydraulic system pressure
before working on any fitting, hose or hydraulic component.
Lower all attachments to the ground before service is started. If the hydraulic system must be service,
testing or adjusted with the attachment in the raised position, the attachments and lift cylinders must be
supported properly.
Always move the machine to a location away from the travel of other machines. Be sure that other
personnel are not near the machine when the engine is running and tests or adjustments are being
made.
Personal injury or death can result from improperly checking for a leak.

Always use a board or cardboard when checking for a leak. Escaping fluid under pressure, even a pin
hole size leak, can penetrate body tissue, causing serious injury and possible death. If fluid is injected
into the skin, it must be treated immediately by a doctor familiar with this type of injury.
In order to identify hydraulic problems, a visual inspection of the hydraulic system should be performed
first. Stop the engine, and lower the attachments to the ground. In order to remove the hydraulic tank
filler can, turn the filler cap counterclockwise. Allow the tank pressure to escape before removing the
filler cap. Make the following inspections:
1. Check all hydraulic oil line connections for damage and for leaks
2. Follow all hydraulic lines from the attachment to the valve. Check the lines and connections for
damage and for leaks.
3. Check the control valves for leaks
4. Check the pump and connections for damage and for leaks
5. Follow the pump lines to the tank and to the valves. Check the hydraulic lines for damage and
for leaks and check the hydraulic tank for damage and for leaks.
6. Check the oil level in the tank
7. Remove the filter element. Check for particles in the filter elements. A magnet separates the
ferrous particles from the nonferrous particles.
8. Inspect the control linkage for damaged components.
Operational checks
1. The operational checks can be used to find the following conditions: leakage in the system, bad
valves and bad pumps. The speed of the rod movement can be used to check the condition of
the cylinders. Also, the speed of the rod movement can be used to check the condition of the
pump.
2. The oil in the hydraulic system must be the oil which is recommended in the operation and
maintenance manual and at a temperature of 65⁰C.
3. The lift circuit and the tilt circuit are connected in a series circuit. The series circuit is not
completely continuous. The hydraulic pump and the main relief valve are common to all circuits.
Each circuit has a load check valve in order to help prevent cylinder drift when the valve spool is
first moved.
4. Relief valve help give protection to system components from excessive system pressure. The
main relief valve is also a makeup valve. Makeup valves allow extra oil to the cylinders.
Extend and retract implement cylinder
Extend each implement cylinder several times and retract each implement cylinder several times.
Observe the cylinder while the cylinder extends. Also observe the cylinder while the cylinder retracts.
The movement must be uniform and the movement must be regular

Listen for noise from the pump
Listen for the sound of the relief valves. When the bucket is empty, the relief valves must not open
except the when the cylinders are fully extended or when the cylinders are fully retracted.
The pressure setting of the relief valve can lower the performance of the machine. A high pressure
setting causes a reduction in the life of hoses and in other parts of the system.
Allow the cylinders to travel full stroke in each direction
Put each control valve in the HOLD position while the implement is off the ground. Watch for excessive
cylinder rod drift.
Hydraulic Circuit – backhoe loader
NEUTRAL
System operation (NEUTRAL)

1) Oil is drawn from the reservoir through a strainer into the tandem gear pumps.
2) Oil from inner gear pump flows to steering priority flow valve
3) If the steering orbital valve is in neutral, the oil is directed to the loader control valve. As the oil
enters the control valve the flow is restricted by a bypass compensating spool which is in the

closed position, at this point the pressure begins to rise and opens the spool against 20 bar
rated spring allowing the oil to enter the loader control valve block.
4) The open centre loader control valve is a two spool mono block which supplies oil to the loader
lift and bucket tilt function.
5) Oil from outer pump flows through the un-loader valve and joins flow from the inner pump prior
to the oil flowing to the loader control valve and the backhoe valve
6) The 7 spool backhoe control valve is of the closed centre type. If all spools are in the neutral
position oil passes through a parallel gallery through a return line 6 bar rated check valve
through the return line filter and cooler back to tank.
7) The back pressure valve keeps pressure in circuit for operation of backhoe / loader functions
8) When a backhoe function is operated, a spool is actuated in the backhoe control valve, flow is
blocked to tank. A load sensing signal is sent to the loader control valve, which closes the
loader control valve and allows all pump flow to the backhoe valve.
9) If loader function are operated, oil is present at the loader valve

System operation (loader lift spool selected)
Operation of the loader spool closes the open centre gallery and directs the flow of oil along the
pressure gallery into the loader lift port. A check valve in the pressure gallery prevents movement of the
service until residual pressure in the loader service has been overcome by pump pressure.
Oil coming back from the return side of the loader lift cylinder passes through the spool valve into a
return gallery. This oil then return to tank through the backhoe control valve opens the 6 bar check
valve and allows the oil to pass through the return line filter and cooler back to tank.
When pressure is created by using any of the services reaches the unloader relief valve setting of 207
bar the unloader valve opens and allows the oil from the outer pump to discharge directly back to the
reservoir. The inner pump will continue to supply the service until the pressure reaches 225 bar at
which point the main relief valve in the loader control valve opens.

System operation backhoe swing (slew) spool selected
The backhoe control valve is a closed centre, load sensing, and flow sharing 7 spool valves. The new
mono block valve features pressure compensation on the slew section only. By locating the pressure
compensators after the spool it allows flow to all backhoe services during multi functions operation to
keep the cylinders working together.
In this example a spool has been selected to swing the backhoe attachment. On selection of the spool
load sense pressure is relayed through a small bore hose to the spring side of the bypass compensator
in the loader control valve. The load sense pressure plus spring pressure closes off the bypass
compensator diverting the flow from both pumps directing to the backhoe control valve. The flow then
opens the pressure compensator allowing the oil to flow between the swing spool to the respective port
of left and right swing cylinders.
Return oil from the swing cylinders flows through the return gallery of the valve through the 6 bar check
valve through the return line filter and cooler back to tank.
Unloader & steering priority valve
The backhoe loader fitted with the combined oil control steering priority / unloader manifold uses two
hydraulic pumps both delivering 21 GPM at 2200 engine RPM and 16.5 GPM at 2200 RPM. The power

needed to drive both pumps up to maximum relief valve pressure of 225 bar is more than the engine
delivers, so an unloading valve is used to divert all the flow from pump P2 to tank when the load
pressure reached 207 bar. The hydraulic services can then continue working at a reduced speed using
the flow from the remaining pump P1.
The output from P1 is delivered first to a load sensing steering priority spool. This spool delivers oil to a
steering orbital unit according to the demand of the steering wheel. When sufficient oil is supplied, the
spool shifts to divert excess oil to join the flow from P1 to supply the main hydraulic functions.
Unloader valve operations

Oil from P2 enters the valve, flows through the check valve and combines with the flow from the
steering priority spool and exits through port EF to the loader & backhoe control valves. A drilling in the
block feeds oil from EF back to the end of the unloader spool, through the orifice in the centre of the
spool, through the spring chamber to the relief valve and solenoid valve. When pressure in EF exceeds
207 bar, the relief valve opens and oil begins to flow from EF through orifice in the spool through the
relief valve to tank. The pressure drop created across the orifice and acting on the end of the spool
exceeds the force of the spring allowing the spool to shift opening P2 to tank. When pressure in EF falls
below the setting of the relief valve, it closes the flow through the orifice stops, pressure equalizes at
each end of the spool, the spool is then shifted to its original position by the spring. Oil from pump P2
passes through the check valve again to combine with the flow from P1 to give full flow to the hydraulic
control valves. Similarly when the solenoid valve is energized the oil flows along the same path causes
pressure drop across the orifice and the spool shifts across and opens pump P2 to tank.
Steering priority valve operation

Oil from pump P1 enters the centre port of the steering priority spool and is diverted to the controlled
flow port CF. pressure in CF is sensed through 2 small drillings in the spool and is directed to the end of
the spool through a 0.030 inches diameter orifice. When sufficient oil is diverted to the steering orbital
unit to satisfy the steering requirement, pressure in CF rises and when it exceeds the setting of the
spring, the spool begins to shift and the excess flow is diverted to EF to combine with the flow from
pump P2 to the hydraulic control valves. A load sense hose directs pressure from the steering orbital
back in to LS. Thus regardless of the speed of the turning of the steering wheel and regardless of the
flow demanded by the steering orbital, the spool always maintains the pressure at CF (9 bar) higher
than the load at the steering orbital unit.

Steering System
P – From pump to control

valve
T – To hydraulic reservoir
R – Right turn
L – Left turn
LS – Load sensing
The steering system is a closed centre system. The steering system is part of the main hydraulic
system. Hydraulic tank provides oil for both the steering and implement hydraulic system. The oil than
returns to the tank is first filter, cooled before returning to the hydraulic tank. If you operate the
machine, oil flows from the hydraulic tank to the hydraulic pump. The oil then flows into the priority
valve. The oil that is not used by the steering system flows to the loader/backhoe control valve. The
priority valve contains the spool for the priority valve. The steering orbital valve is located behind a
panel in the operator station. The steering orbital valve is connected to the steering column. Oil flows
from the priority valve into the steering orbital through an inlet check valve.
When the steering wheel is not turning, the oil from pump P1 flows to the loader / backhoe control valve
and back to tank. An inlet check valve in the metering pump (steering) prevents steering kickback in the
event of external forces. The check valve is between the pump supply and the ports for return oil. The
two check valves allow steering capability when the engine is not running. The check valve allows oil to
flow from the hydraulic tank. This oil flows to the inlet for the metering pump. The oil flows in order to re-
circulate between the metering pump and the steering cylinder.
Front steering cylinder is located on the front axle. The cylinder has one piston and the cylinder is
double ended with two rod ends. When you turn the steering wheel, the metering pump directs oil to
one site of the piston.

Steering Metering Pump
1. Outlet to tank
2. Metering pump inlet check valve
3. Inlet from pump
4. Passage
5. Passage from gerotor
6. Gerotor
7. Passage to gerotor
8. Sleeve
9. Makeup valve
10. Drive
11. Drive pin
12. Springs
13. Shaft spool
(A) Control section
(B) Pump section
The metering pump has two main section, control section (A) and pump section (B). These two sections
work together in order to send oil to the steering cylinder. The metering pump is located in the front of
the can behind a panel near the steering column. Both the direction of a turn and the speed of a turn
are controlled by the metering pump. As the steering wheel is turned faster, there is an increase in the
flow of oil to the steering cylinder. The increased flow of oil to the steering cylinder causes the steering
cylinder to move farther. The increased flow oil also causes the steering cylinder to move faster. This
causes the machine to turn faster.
When the steering wheel is not being turned, control section (A) is in the NEUTRAL position. The
metering pump is a closed centre valve so there is no alignment between the passages in the spool
and orifice in the sleeve in this position. In the neutral position, the oil that flows into control sections (A)
flows through orifices to the hydraulic tank. This allows cooler oil to enter the metering pump. The pump
has a port for the load sensing signal. The line from this port is connected to the priority valve. Some of
the flow of the inlet oil that is in the neutral position also flows back to the priority valve. This oil keeps
the spool in the priority valve slightly open. This oil keeps the spool ready for a quick response to the
steering demands.
When the steering wheel is turned for a right turn, pump oil opens check valve (2) and flows into the
metering pump through inlet (3) and passage (4). The oil flows from passage (4) into gerotor (6)
through passage (7). As the steering wheel turns, gerotor pump (6) turns. This causes the flow of oil
from the pump. The oil flows through passage (5). The oil is then directed to the steering cylinders

through the right turn port. As the oil flows out to the cylinder through the right port for a right turn,
return oil from the cylinder is coming back into the metering pump through the left port. This oil is sent
to the tank through outlet (1). When the steering wheel starts to turn, shaft spool (13) drive pin (11) and
drive (10) also start to turn. Sleeve (8) does not start to turn at the same time as the spool because the
diameter of the holes in the sleeve is slightly larger than the diameter of the drive pin (11). This allows
shaft spool (13) to turn inside sleeve (8). As the shaft turns, small holes align with the grooves. The
alignment of these holes and grooves provides the path for oil flow to gerotor (6) and to the steering
cylinder. Centering springs (12) are compressed, when the spool moves in relation to the sleeve. When
the steering wheel is not turning, centering springs move the spool to a neutral position. When the
rotation of the steering wheel is stopped, the wheels stay in that position. The steering wheel must be
turned in the opposite direction in order to make a left turn. The steering wheel must be turned in the
opposite direction for travel that is straight.
Spool and sleeve
8. Sleeve
13. Shaft spool
14. Holes for the drive pin
15. Small holes for oil flow
16. Grooves for oil flow
17. Slots for springs
When the steering wheel is turned for a left turn, oil flows into inlet (3). Oil flows through passage (4)
and oil flows through passage (7) into gerotor (6). Oil flows from gerotor (6) through passage (5) and oil
flows through sleeve. Oil flows through the combination of the shaft and spool. The sleeve and the shaft
spool are turned in the opposite direction of the right hand turn. The movement in the opposite direction
allows a different allows a different set of holes to line up. The movement in the opposite direction
provides a path for oil to the left turn port. Oil flows from the left turn port to the steering cylinder.

Pump gears in the pump section
10. Drive
11. Drive pin
18. Rotor
19. Stator
Note: The rotor and the stator are part of

gerotor.
If the unit is taken apart for any reason, drive pin (11) and rotor (18) must be aligned, before the unit is
reassembled.
Mast side shift operations

Locking operation
The side shift lock solenoid is mounted in the end cover of the backhoe valve. Solenoid valve is
controlled by the switch for the mast side shift lock. In order to de-energize the side shift slide lock
solenoid, the bottom of the switch for the mast lock must be pressed. The solenoid is not energized in
the locked position. Oil from the hydraulic pump causes check valve to move to the right. When the
check valve moves the oil that is in line flows past the check valve. Then the oil flows into the piston for
the slide lock. Piston moves right against slide rails of the stabilizer frame. When the piston forces the
slide rails to contact slide bars, this prevents the slide frame from moving during digging operations.
The pressure to the piston of the slide lock is charged to the system pressure, whenever an implement
or the steering system is used.
Unlocking operation
When the backhoe needs to be positioned, the pressure on the piston of slide lock must be released.
When the operator depresses the top of the switch for the mast lock, mast slide lock solenoid is
energized. When the solenoid is energized, the solenoid allows the oil inline to drain to hydraulic tank.
Most of the pressure oil in the line is blocked at check valve. An orifice in the check valve allows a small
amount of oil to flow past the check valve and through solenoid valve. The oil then flows back to the
hydraulic tank. The oil to the cylinders in the side shift slide lock solenoid is free to return through
solenoid valve back to the hydraulic tank.
Testing and adjusting
Main relief valve pressure test (Open centre port)

1. Work the t machine e until hydra
aulic oil tem
mp is at 50 degrees Ce elsius. Parkk the machinne at level
ground d
2. Lock th he backhoe attachment in transportt position an nd lower load der bucket tot ground. Shut
S off the
enginee.
3. Conne ect a pressurre gauge 0 - 400 bar at test
t port C and at D.
4. Port C will indicate e the un-loader pressure e setting and Port D willl indicate thhe main presssure relief
valve setting.
s
5. Clear Personnel away from machine, start s the enngine and run at 220 00 rpm. Keep all the
implemments in neutral position and read th he pressure gauge
g and the
t pressure e should be 300
3 psi (20
bar).
6. Operatte Loader fu unction to bo
ottom out a cylinder. Prressure shou uld be 3250 psi (225 ba ar) on both
the preessure gauges.
7. Operatte Backhoe function to bottomb out a cylinder. Pressure
P sho
ould be 3250 0 psi(225 ba
ar) on both
the preessure gauges
8. Removve the pressure gauge frrom the test port C and install the te est port coveer.
9. Operatte the backh hoe Boom up u function slowly
s with cylinder
c botttomed out, the
t pressure e at port C
should reach 3000 0 psi 207 ba ar then dropp off to 0 pssi. Adjust re
elief valve att unloader valve
v (B) if
requireed.
10. If presssure is not to
o the spec.
11. Adjust Pressure att the Proper relief valve if necessaryy.
i. The
T MRV Prressure at th he Loader co ontrol valve.
ii. The
T URV Prressure at th he Unloader valve (B)
Main rellief valve pressure

e test (Close centre port)
1. Work the
t machine e until hydra
aulic oil tem
mp is at 50 degrees Ce elsius. Parkk the machin
ne at level
ground
d
2. Lock th
he backhoe attachment in transportt position an nd lower load
der bucket tot ground. Shut
S off the
engine
e.
3. Conneect a pressurre gauge 0 - 400 bar at test
t port C and at D.
46 HELP LINE NUMBER

R 0120 - 47
729000
4. Port C will indicate the un-loader pressure setting and Port D will indicate the main pressure relief
valve setting.
5. Clear Personnel away from machine, start the engine and run at 2200 rpm. Keep all the
implements in neutral position and read the pressure gauge and the pressure should be 300 psi (20
bar).
6. Operate Loader function to bottom out a cylinder. Pressure should be 3250 psi (225 bar) on both
the pressure gauges.
7. Operate Backhoe function to bottom out a cylinder. Pressure should be 3250 psi(225 bar) on both
the pressure gauges
8. Remove the pressure gauge from the test port C and install the test port cover.
9. Operate the backhoe Boom up function slowly with cylinder bottomed out, the pressure at port C
should reach 3000 psi 207 bar then drop off to 0 psi. Adjust relief valve at unloader valve (B) if
required.
10. If pressure is not to the spec.
11. Adjust Pressure at the Proper relief valve if necessary.
i. The MRV Pressure at the Loader control valve.
ii. The URV Pressure at the Unloader valve (B)
Steering System Pressure Check

Work the machine until the temperature of the hydraulic oil reaches 50⁰C.
Park the machine on firm and flat ground
Dump the bucket, raise the loader beam and install the safety strut
Stop the engine and release the pressure from the hydraulic system
Open the hood
Install a pressure gauge 0 – 400 bar at test port D
Start the engine and run at 2200 rpm
Turn the steering wheel to full lock on either directions and check the relief pressure setting. The
pressure gauge should read 170 to 175 bar
Adjust the relief valve in the orbital steering unit if the pressure is not within specification
Adjustment
Note: The relief valve need not to be adjusted unless the steering system pressure is not correct on
test. The valve can be adjusted on the machine or on a test bench. This instruction describes setting on
the machine.
1) Park the machine on firm level ground

2) Fully crowd the bucket, raise the loader beam and install the safety strut
3) Lower the backhoe stabilizer to the ground. Do not raise the machine
4) Stop the engine and release pressure from hydraulic system

5) Install the test equipment
6) Remove the plug (1) from the steering unit (4) and turn the setting plug (3) in or out by one turn
a. Note: To increase system pressure, screw the setting plug (3) in. To reduce system
pressure, screw the setting plug (3) out.
7) Install the plug (1) in the steering unit and carry out the relief valve test
8) Note the change in pressure and carryout further adjustments to set the correct pressure if
required
9) After the final adjustment, install a new O ring seal (2) on the plug (1) and install the plug (1)
10) Remove the test equipment
Releasing pressure in hydraulic system

1) Park the machine on a level ground
2) Lower the loader and the backhoe attachments to the ground and raise the stabilizer off the
ground
3) Shut off the engine
4) Remove the hydraulic tank fill cap
5) Move all the loader and backhoe control levers in all direction several times until the loader and
the backhoe are fully rested on the ground
6) Refit the hydraulic tank fill cap

Hydraulic System Pressure Chart
Sl.No System Condition Specification Adjustment Part No.
Adjust
Main relief Engine at high idle and lock either Part No.
1 225 bar pressure
valve stabilizer in fully raised position 10X1363
setting screw
Should reach
Adjust
Unloader Engine at high idle and lock either 207 bar and Part No.
2 pressure
relief valve stabilizer in fully raised position then drops to 0 10X1439
setting screw
bar
Backhoe Engine at high idle and lock boom in No adjustment. Part No.
3 310 bar
boom raise fully raised position Replace ARV 10X1402
Backhoe Engine at high idle and lock boom in No adjustment. Part No.
4 240 bar
boom lower fully lowered position Replace ARV 10X1403
Engine at high idle and lock stick in No adjustment. Part No.

5 Stick IN 280 bar
fully IN position Replace ARV 10X1406
Engine at high idle and lock stick in No adjustment. Part No.

6 Stick OUT 265 bar
fully OUT position Replace ARV 10X1405
Engine at high idle and lock bucket in No adjustment. Part No.

7 Bucket close 280 bar
fully closed position Replace ARV 10X1406
Engine at high idle and lock bucket in No adjustment. Part No.

8 Bucket open 280 bar
fully open position Replace ARV 10X1406
Engine at high idle and lock loader in No adjustment. Part No.

9 Loader raise 240 bar
fully raised position Replace ARV 10X1403
Loader Engine at high idle and lock loader in No adjustment. Part No.
10 310 bar
dump fully dump position Replace ARV 10X1416
Loader tilt Engine at high idle and lock loader in No adjustment. Part No.
11 345 bar
back full tilt back position Replace ARV 10X1417
Not
Steering Engine at high idle and lock steering No adjustment.
12 175 bar serviced
system cylinder fully turned to right side Replace ARV
separately
Swing Engine at high idle and lock swing No adjustment. Part No.
13 240 bar
(LHS/RHS) either in LHS/RHS direction Replace ARV 10X1611

Hydraulic pump flow test
1) Park the machine on a level surface

2) Work the machine until the hydraulic oil temperature reaches 50⁰C
3) Raise the loader beam and install the safety strut and stop the engine
4) Release the pressure from hydraulic system
5) Remove the operator’s cabin floor plate
6) Connect the flow meter to the outlet port (1) of the inner (80 l/min) section of the hydraulic pump
7) Connect the pressure gauge to the test port in the pump outlet piping
8) Start the engine and run at 2200 rpm
9) Check that the pump outlet pressure (225 bar) and flow (80 l/min) are within specification
10) If the pump flow rate is less than the specification, replace the pump
11) Stop the engine and release the pressure in hydraulic system
12) Remove the test equipments from inner pump
13) Install the test equipment to the outer pump port (4)
14) Connect the pressure gauge to the test port (5)
15) Start the engine and run it at 2200 rpm
16) Check that the pump outlet pressure (207 bar) and flow (62 l/min) are within specification
17) If the pump flow rate is less than the specification, replace the pump
18) Slowly raise the loader beam till the cylinder is completely retracted. This will raise the system
pressure until the unloader valve operates
19) Record the unloader valve operating pressure
20) When the unloader valve operates, check that the pump outlet pressure is within 0 to 5 bar and
that the outlet flow is 0 l/min
21) Check that the unloader valve operating pressure is within specification
22) If the unloader valve operating pressure is outside the specified limits, replace the unloader
valve
23) Slowly increase the pressure to 175 bar and check that the flow rate for the outer pump (62
l/min) section of the pump has been restored
24) Remove the test equipment and install the operator’s cabin floor plate

Pump flow test chart
Specification Machine Model

TX 760 TLB 740 TLB 844
Pump Engine RPM
Flow (LPM) @ 225 bar
1000 36 34 36
1500 54 51 54
Pump (P1)
1800 65 62 65
2200 80 76 80
1000 28 19 28
1500 42 29 42
Pump (P2)
1800 50 35 50
2200 62 43 62
Note: Pump efficiency should be more than 80% of a new pump flow rate
Back pressure valve pressure test
1) Park the machine on a level surface

2) Stop the engine and release the pressure from hydraulic system
3) Lift the floor mat and remove the plate that gives access to the backhoe control valve

4) Install the tee fitting (3) on port T2 of the control valve and connect a 0 – 100 bar pressure
gauge to the tee fitting (3)
5) Start the engine
6) With the engine at low idle, note the pressure indicated on the pressure gauge
7) Increase the engine speed to 2200 rpm and record the pressure reading (both low and high idle)
a. Specification
b. Engine at low idle - 34 to 35 bar
c. Engine at high idle - 49 to 50 bar
8) If the back pressure valve operating pressure is outside the limits given in the specifications,
51replace the backhoe valve
9) Fully crowd the backhoe bucket and hold it stalled. Check that the pressure indicted on the
pressure gauge is between 52 to 53 bar
Flushing the hydraulic system

Follow this procedure during the below said conditions
1. Water entry in the system

2. Topping of wrong grade of oil by over sight
3. Failures of major components like pump, control valve etc
1) Start and run the engine at 1500 rpm

2) Completely retract the cylinders of all attachments on the machine
a. If retracting the cylinder rods causes the attachment to be raised, block the attachment
in place before proceeding to the next step.
b. Any attachment or part of an attachment that is raised must be supported with
acceptable equipment to prevent the attachment from falling
3) Loosen and remove the hydraulic tank filler cap
4) Drain the hydraulic oil from the reservoir
a. The reservoir holds approximately 45 liters of oil
b. Have available acceptable equipment to drain the hydraulic oil
c. Remove the drain plug from the bottom of the reservoir
5) Remove the hydraulic oil filter
6) Install a new hydraulic oil filter
7) Install the drain plug
8) Fill the hydraulic reservoir with 43 liters of Terex hydraulic fluid
9) Move each control lever in both directions to release pressure in the hydraulic circuits
10) Disconnect the line from the rod end and closed end of each cylinder
11) Be sure all control levers are in the NEUTRAL position
12) Start the engine and run the engine at low idle
Note: Check the oil level in the hydraulic reservoir frequently while doing step 13. Have another
person hold a container under the hydraulic lines while you do step 13
13) Slowly move each control lever in both directions until oil begins to flow from the open line.
Hold the control lever in place until clean flows from the open line
14) Stop the engine
a. Note: any attachment or part of an attachment that is raised must be supported with
acceptable equipment to prevent the attachment from falling

15) Connect the line to the closed end of each cylinder
16) Start the engine and run the engine at low idle
17) Slowly and completely extend all cylinders. As the piston rod comes out of the cylinder, oil will
be pushed out of the rod end of the cylinder.
18) Support the loader frame so that the loader frame will stay in the raised position
19) Stop the engine
20) Connect the lines to the rod end of the cylinders
21) Check the oil lever in the hydraulic reservoir. All oil as required
22) Install the filler cap for the reservoir
Servicing a hydraulic cylinder

Tools for service
Adjustable hook spanner Torque Wrench 0 – 280 kgf-m
Allen Key 4 to 10 mm Bend screwdriver 6” to 8”

Terminology for various complaints on hydraulic cylinder performance
1. Leakage from Cap end cover (CEC) port

2. Cushioning plunger scored / damaged
3. Cushioning ring damaged / wrongly assembled
4. Longitudinal crack on Piston rod
5. Leakage from Head end cover (HEC) port
6. Pin hole on piston rod
7. Pit mark on piston rod
8. Rod eye bore under size / over size
9. Piston rod broken from piston rod – Rod eye joint
10. Transverse crack on piston rod
11. Rod seal leakage
12. Leakage from HEC O-ring
13. Scoring lines on piston rod
14. Scoring lines on tube ID
15. Piston seal damage / Internal leakage
16. Leakage from Tube – CEC weld joint
17. CEC bore under size / over size
18. CEC grease nipple thread damage
19. Rod eye grease nipple thread damage

Do’s and Don’ts on hydraulic cylinders
Do’s
1) Use soft lint-free cloth, never use cotton waste it may contain metal chips which will damage
working surface of the components
2) Periodically clean the dust / mud accumulated on Wiper seals
3) Use recommended tools to service hydraulic cylinder
4) Clean the stabilizer box periodically
5) Ensure that the oil is in cold condition before opening the cylinder
6) Ensure that the cylinder is assembled and disassembled in clean dust free atmosphere
7) Ensure usage proper lifting tackles (Rope, Belts, etc.) while handling the cylinder
8) Apply hand brake while excavation
9) Apply grease on extended piston rod, if any welding is being carried out near the cylinder. This
is to avoid welding spatters from getting stuck on the piston rod surface. Wipe off the grease
after welding is completed
10) Before replacing new rubber components like O-ring and seals, immerse in hydraulic oil and
then replace
11) Use only the specified grade (ISO VG-46) of oil to avoid malfunctioning of the product and for
optimum safety and performance
12) Use Grease gun to ensure proper greasing and apply grease at all the greasing points
periodically
13) Ensure that there are no obstructions at the working area like electrical line, inflammable
material, etc.
14) Check and tighten the hydraulic fittings, bolts and nuts periodically
15) Check the hydraulic oil contamination and change if required. Maximum oil contamination
allowed in system is NAS 11 or ISO 20/17
16) Check the filter elements and change if necessary
17) Check the oil level in the hydraulic tank regularly and fill it to the recommended level, if required
Don’ts
1) Don’t operate the machine beyond the specified load / pressure limit
2) Don’t use the bucket to push rocks, boulders, etc.
3) Don’t move the machine when the stabilizer cylinders are in extended position
4) Don’t load the bucket unevenly
5) Don’t work under an unsupported Shovel
6) Don’t use the Hydraulic cylinder as a conductor for welding purpose.
7) If you have to weld on structure connect earth wire to the structure only not on the chassis
8) Earth must be given close to the point of welding
9) Don’t paint on the working surface of the piston rods and wiper seal

10) Don’t change the relief pressure setting on the control valve
11) Don’t operate on uneven and soft ground
12) Don’t heat hydraulic cylinder while dismantling
13) Don’t open hydraulic connections without releasing the system pressure
14) Don’t carry out welding without removing the battery terminals
Disassembly & assembly procedure
Disassembly procedure – slew cylinders
1) Remove the cylinder from the Equipment

2) Clean the cylinder using good clean cloth. Ensure that dirt does not go inside the cylinder
through ports
3) Hold the cylinder on a Bench vise firmly with proper support by using Rexin on the outer surface
to prevent any damages on the outer tube. Mark a straight line on tube and HEC before
disassembly to make the reassembly easy
4) Use blunt chisel and remove Head end cover caulking
5) Unscrew the Head end cover (5) by using adjustable hoot spanner
6) Gently pull out the piston rod (2) along with Head end cover from the tube s/a (1)
7) Hold the piston rod s/a on a Bench vise firmly with proper support by using Rexin
8) Remove the piston seals (12,13&14) gently by using bend screwdriver and unscrew the grub
screw (6) by using Allen key
9) De-torque and remove the piston (3) by using torque wrench after removing the grub screw (6)
and steel ball (7)
10) Remember the direction of cushioning ring (4) and gently remove the same from piston groove

11) Remove the head end cover (5) from the piston rod gently
12) Remove the snap ring (10), wiper (19), primary rod seal (20), secondary rod seal (21), O-ring
(17) and backup ring (18) from head end cover (5) by using bend screwdriver
13) Remove the O-ring (15) and back up ring (16) by using the screw driver
Inspection and cleaning procedure
1) Clean all the components by using good clean cloth and hydraulic oil. Any rust on the
components should be removed by smooth emery sheet
2) Ensure that head end cover seal grooves, piston rod end threads and port threads are cleaned
properly
3) Check the piston rod for any dents, scoring lines or any other abnormalities, if found piston rod
needs to be replaced along with piston
4) Check for any scoring lines or damages in tube Id. If found tube s/a needs to be replaced
5) Check head end cover for damages or dents. Small dents / damages can be removed by
polishing. However if the damages are heavy, components need to be replaced
6) Check and ensure that port threads and piston rod threads are not damaged
7) Once dismantled seal kit should be replaced with a new one
Assembly procedure
1) Assemble the rod seals, wiper, O-ring and back up ring on the head end cover. Ensure that seal
lips face against pressure side
2) Smear little hydraulic oil inside the head end cover (at seal kit and wiper area). Gently insert
sub-assembled HEC on to the Piston rod. Ensure that seal lip is not reversed or twisted during
assembly. Check for smooth movement of head end cover on piston rod
3) Place the cushioning ring in piston, apply Loctite 262 / Anabond 115 on piston threads, then
engage the piston with Piston rod threads and tighten the same to the specified torque by using
torque wrench
4) Place steel ball, apply Loctite 242/ Ana bond 118 on grub screw and tighten the same on piston.
Assemble the piston seals and bearing strips. Ensure that during assembly piston seal is not
expanded more
5) Hold the tube s/a on Bench wise, smear little hydraulic oil inside the tube s/a
6) Apply hydraulic oil on piston seals and Petroleum jelly on head end cover O-ring and insert the
piston rod s/a into the tube s/a. Tap the head end cover gently during entry into the tube. Ensure
that head end cover O-ring is not cut during entry
7) Tighten the head end cover by using adjustable hook spanner to the previously marked position
8) Caulk the head end cover effectively

Disassembly and assembly – other cylinders
Follow the procedure below for servicing loader lift, loader tilt, stabilizer, boom, stick and bucket
cylinders
Disassembly procedure
1) Remove the cylinder from the Equipment

2) Clean the cylinder using good clean cloth. Ensure that dirt does not go inside the cylinder
through ports
3) Hold the cylinder on a Bench vise firmly with proper support by using Rexin on the outer surface
to prevent any damages on the outer tube. Mark a straight line on tube and HEC before
disassembly to make the reassembly easy
4) Use blunt chisel and remove head end cover caulking
5) Unscrew the Head end cover (4) by using adjustable hoot spanner
6) Gently pull out the piston rod (2) along with head end cover from the tube s/a (1)
7) Hold the piston rod s/a on a Bench vise firmly with proper support by using Rexin
8) Remove the piston seals (10,11,&12) gently by using bend screwdriver
9) Remove the snap ring (8) by using screw driver and unscrew the grub screw (7) by using Allen
key
10) De-torque the piston (3) by using torque wrench and remove the same from piston rod
11) Remove the head end cover (4) from the piston rod gently
12) Remove the wiper (19), primary rod seal (17), secondary rod seal (18), O-ring (15) and backup
ring (16) from head end cover (4) by using bend screwdriver
13) Remove the O-ring (13) and back up ring (14) from the piston by using the bend screw driver
Inspection and cleaning procedure
1) Clean all the components by using good clean cloth and hydraulic oil. Any rust on the
components should be removed by smooth emery sheet

2) Ensure that head end cover seal grooves, piston rod end threads and port threads are cleaned
properly
3) Check the piston rod for any dents, scoring lines or any other abnormalities, if found piston rod
needs to be replaced along with piston
4) Check for any scoring lines or damages in tube Id. If found tube s/a needs to be replaced
5) Check head end cover for damages or dents. Small dents / damages can be removed by
polishing. However if the damages are heavy, components need to be replaced
6) Check and ensure that port threads and piston rod threads are not damaged
7) Once dismantled seal kit should be replaced with a new one
Assembly procedure
1) Assemble the rod seals, wiper, O-ring and back up ring in the head end cover. Ensure that seal
lips face against pressure side
2) Smear little hydraulic oil inside the head end cover (at seal kit and wiper area). Gently insert
sub-assembled HEC on to the Piston rod. Ensure that seal lip is not reversed or twisted during
assembly. Check for smooth movement of head end cover on piston rod
3) Apply Loctite 262 / Anabond 115 on piston threads, engage the sub-assembled piston with
Piston rod threads and tighten the same to the specified torque by using torque wrench
4) Apply Loctite 242/ Anabond 118 on grub screw and tighten the same on piston. Fix the snap
ring by using screw driver.
5) Assemble the piston seals and bearing strips on piston. Ensure that during assembly piston seal
is not expanded more
6) Hold the tube s/a on Bench wise, smear little hydraulic oil inside the tube s/a
7) Apply hydraulic oil on piston seals and Petroleum jelly on head end cover O-ring and insert the
piston rod s/a into the tube s/a. Tap the head end cover gently during entry into the tube. Ensure
that head end cover O-ring is not cut during entry
8) Tighten the head end cover by using adjustable hook spanner to the previously marked position
9) Caulk the head end cover effectively
Cylinder performance check
1) Pull the piston rod and push it back to check the smoothness of Assembly
2) Mount the cylinder on to the equipment and operate at idle speed, to check for leakages
3) Ensure that the air is not trapped in the cylinder by cycling the cylinder at low Idle for 2 minutes

Hydraulic cylinder seal kit part numbers
Machine Model
Cylinder Remarks
TLB844S TLB740S TX760
Steering 10X0134 10X0134 10X0134 Till M/c. No. 3998
Steering 10X1774 10X1774 10X1774 M/c. No. 3999 onwards
Loader lift 10X1354 10X1637 10X1354
Loader tilt 10X0155 10X0155 10X0155
Swing 10X0092 10X0092 10X0092 55 mm rod diameter
Swing 10X1755 10X1755 10X1755 45 mm rod diameter
Stabilizer (RH & LH) 10X0069 10X0069 10X0069 Till M/c. No 3890
Stabilizer (RH & LH) 10X1783 10X1783 10X1783 M/c. No.3891 onwards
Backhoe boom 10X0197 10X0197 10X0197
Backhoe dipper 10X0241 10X1626 10X0241
Backhoe bucket 10X0175 10X0175 10X0175 Till M/c. No. 3349
Backhoe bucket 10X1700 10X1700 10X1700 M/c. No. 3350 onwards

Cylinders troubleshooting and probable causes
Problem Cause Remedy
¾ Excessive Seal wear ¾ Check oil contamination and change, if required

¾ Piston rod scored ¾ Apply emery, if scoring is mild. Replace the piston rod,
if the scoring is deep
¾ Replace the piston rod*
Rod seal
¾ Weld arcing ¾ Replace the seal kit and assemble the seal in right
leakage ¾ Seal assembled wrongly direction*
¾ Piston rod bend ¾ Reset the system pressure, if it is malfunctioning and
replace the piston rod*
¾ Air bleed the system properly and change the oil if
¾ Oil temperature high contaminated*
¾ Scoring in tube ID ¾ Check for side loads on cylinder (Wear on rod eye /
CEC face) and adjust alignment suitably. Change tube
Internal s/a if badly scored*
¾ Tube ID rusting ¾ Remove the rust with emery, change tube s/a, if rust is
Leakage
¾ External damage more
¾ Air in hydraulic circuit ¾ Replace the outer tube
¾ Piston seal damaged ¾ Air bleed the hydraulic system*
¾ Replace the complete seal kit*
¾ External damage on tube ¾ Replace the tube s/a and other damaged components
¾ Piston rod bend ¾ Check the system pressure and replace the PR s/a*
¾ Foreign particles in the ¾ Check the filter and oil, replace if required
Tube ID scored
system ¾ Replace the filter
¾ Filter ineffective / clogged ¾ Add shims and align the axis suitably
¾ Excessive clearance at
mountings
¾ Seal wrongly assembled ¾ Change the seal kit*
External ¾ Weld leakage ¾ Rework or replace the component, if it is not re-
¾ Leakage through casting workable*
leakage (Other
¾ Ineffective sealing due to rust ¾ Change the defective component*
than Rod seal) in the cylinder ID ¾ Rework by emery or replace the failure component
¾ Excessive system pressure ¾ Check and reset the system pressure, if required*
Piston rod ¾ More than recommended ¾ Use the system within recommended load. Educate
load applied the driver
bend / Break ¾ Excessive side loads ¾ Check the condition of bushes, pins, shims and
¾ External damage replace if required
¾ Change the piston rod assembly*
¾ Rust on rod due to ¾ Clean the mud periodically from the piston rod
accumulation of mud on ¾ Protect the piston rods from chemical attach. Apply
piston rod petroleum jelly when the machine is not in use for
Plating Defects
¾ Peel off due to piston rod more period
exposure to chemical ¾ Apply grease on piston rod when carry out welding
environment near rod
¾ Weld Arcing

Troubleshooting procedure
PROBLEM –
HYDRAULIC SYSTEM Adjust the engine RPM if it is not within
SLOW OPERATION / NOT TAKING LOAD specification. Check the performance of
(NO ENOUGH POWER) the machine and if the problem still
persists, proceed to step 3
Step 1 – Check hydraulic oil level
Step 3 – Check hydraulic system
pressure.
Refer page no 45 for pressure checking

procedures
Step 4 – Check hydraulic flow
Refer page no 50 for pump flow checking

procedures
Problem – Any one of the implement

1. Park the machine on flat ground and (loader lift, loader tilt, boom, stick,
place the loader on the ground
bucket, swing & stabilizer) system
2. Close the loader bucket
slow
3. Bring the backhoe boom up, close the
dipper and bucket fully Step 1 – Check hydraulic oil level
4. Retract the stabilizer legs
5. Shut off the engine Refer page no. 62
6. Oil should be visible in the sight gauge
as per the above picture Step 2 – Check implement control
linkages
Step 2 – Check engine performance
Ensure that the engine RPM is within

specification
Low idle – 750 RPM
High idle – 2200 RPM
Stall – 1950 RPM

Ensure that the control levers are not Ensure there are no leaks, loose
binding and moves freely. Check for connections or loose cooler mounting bolts
proper torque for lever retaining bolts and and shrouds
lock rings
3) Check the machine history for any
indication of other system overheating. If
Step 3 – Check hydraulic system other systems are also overheating, check
pressure. the fan, fan belt etc.
Refer page no 45 for pressure checking 4) Measure temperature difference across

procedures cooler top and bottom tank. If the ∆T >
15⁰C or ∆T < 10⁰C, cooler is chocked.
Service the cooler
PROBLEM – HYDRAULIC SYSTEM
OVERHEATING Step 3 – Check hydraulic system
pressures
Step 1 – Check hydraulic oil level Refer page no 45 for hydraulic system
pressure checking procedure
Refer page no 62
Step 4 – Flush the hydraulic system

Step 2 – Check hydraulic oil cooler
Refer page no 52 for hydraulic system
flushing procedure
Problem: Anyone of the hydraulic

implements drifting
Step 1 – Check control linkages
1. Ensure the cooler core is not plugged

with mud or debris

1. Check the lever for any binding 3) Disconnect the hose 1H0200 at
2. Check for proper adjustment loader control valve and collect the oil in
a suitable container
If found okay, proceed to step 2 4) Check the torque of the dummy plug
(shown in the above figure)
Step 2 – Check system pressure.
pressure checking procedure Problem: Hydraulic system main
relief valve pressure is within
Step 3 – Perform blocked cylinder test specification but system
1. Retract the drifting cylinder operates slowly
completely Step 1: Check the unloader pressure
2. Disconnect the hose from the rod end
of the cylinder Refer page no 45 for hydraulic pressure
3. Use suitable dummy plug and block checking procedure
the remove hose
4. Operate the cylinder in retract
position and collect the oil leaking Step 2: Check the supply voltage
from the cylinder rod end port a for the unloader solenoid
suitable container
5. If the oil leaking through the rod end
port of the cylinder is excess, replace
the cylinder seal kit
Problem: Only backhoe attached

operates slowly
At the unloader solenoid, without removing

the harness, with multimeter, check for 12V
supply across the 2 wires with the dump
switch in OFF position. If 12V is present,
check the solenoid circuit. Refer page no.
106. If 12V is not present, remove the
solenoid valve and check the condition of
seals and valve. If found to be defective
1) Shut off the engine replace/repair the valve 10X1373 as
2) Remove the hydraulic oil fill cap and necessary. Operate and check the machine
release the pressure inside the whether the problem is resolved and if not
hydraulic tank check both the pump flow. Refer page no 50

Problem: Engine lugs while Without removing the harness from the
solenoid, with the dump switch in ON
operating loader attachment position, check for 12V supply across the 2
wires. If 12V is present, service the
unloader valve assembly. Refer Unloader
Step1: Check the condition of pump control schematic on page no 106 for
dump fuse further details. If 12V not present proceed to
step 4
Step3: Check solenoid circuit
With ignition and dump switch in ON

position, check for 12V supply across wire
orange/white and chassis. 12V should be
present and if not check the wire and dump
relay. Refer page no 106. If 12V present,
check for continuity across wire black and
chassis. Continuity should be present and if
not check the black wire.
Remove the fuse (10A) from its base. Check
whether the fuse is intact and it is not blown.
If found blown replace with 1D0127 fuse.
Check the fuse base terminal for any Step4: Check proper functioning
corrosion and if found clean the terminals.
of dump switch
Step2: Check the unloader pressure. 1. Without removing the harness from the
switch, check for continuity across wire
Refer page no 45 for hydraulic system black and chassis. Continuity should be
pressure checking procedure present. If continuity is not present, check
black wire.
Step3: Check supply voltage of 2. Remove the harness from the switch.
unloader solenoid With the switch in ON position, check
continuity across the 2 terminals of the
switch. Continuity should be present and
if not replace the switch

3. With or without removing the harness
from the switch, check for continuity Step3: Check steering system
across orange/red wire at switch and pressure
dump relay ends. Continuity should be
present, else check wire. Refer page no 45 for hydraulic system
4. Check proper functioning of hydraulic
pump dump relay and its circuit. Refer
page no. 106
Problem: Machine steers in
Problem: Machine does not steer only one direction
in both the direction
Step1: Check the hydraulic oil level Step1: Check the hydraulic oil
level.
Refer page no 62
Refer page no. 62
Step2: Ensure both LHS and

Step2: Check steering system
RHS king pins are lubricated
pressure

Step3: Check hand metering pump

(orbital valve)
Check whether both the king pins is

lubricated. With help of the loader bucket, lift
the machine off the ground, remove the
steering cylinder mounting pin at any one
end, steer any one wheel manually. The
wheel should steer freely. If the wheel is
binding, remove both the kind pins and Disconnect all the hoses from the orbital
replace/repair as necessary. If the wheels valve. Dismantle the orbital valve 1H0067
are free to turn, proceed to step 3 and conduct a thorough internal inspect and
repair/replace the parts causing problem

Problem: Machine hard to steer
Step1: Check the hydraulic oil level
Refer page no. 61
Step2: Check proper functioning of

steering column Disconnect all the hoses from the orbital
valve. Dismantle the orbital valve 1H0067
and conduct a thorough internal inspect and
repair/replace the parts causing problem
Problem: Machine steers slow in

either one or both the direction
Step1: Check the hydraulic oil

level.
Refer page no. 61
Step2: Check steering system

Remove the steering column from the
pressure
machine. Rotate the column shaft several
times and check whether the shaft is Refer page no 45 for hydraulic system
binding. If binding is noticed, remove the pressure checking procedure
column shaft and check the condition of the
thrust bearings and its contact area in the
Step3: Check steering cylinder for
shaft. If the bearings are worn out, replace
internal leak
with 10X0424 thrust bearing. If the bearing
contact area in the shaft is worn out, replace
the complete column assembly 1J0008
Step3: Check hand metering pump

(orbital valve)

Electrical System
WARNING: Spark can fly from electrical WARNING: When the battery electrolyte is
system or the engine. Before you operate this frozen, the battery can explode. If you try to
machine in an area which may contain charge the battery or try to jump start and
inflammable vapor completely ventilate the run the engine using another battery, to
area prevent battery electrolyte from freezing,
keep the battery at full charge
WARNING: A spark or naked flame can
cause hydrogen in a battery to explode. To
avoid all risk of explosion, follow these CAUTION: Always connect/disconnect
instructions: leads to/from the battery while the charger
Turn the battery master switch key to the is switch off
OFF position (circuit disconnected).
When disconnecting the battery cable, always CAUTION: If the battery temperature rises
disconnect the negative (-) cable first. to 60⁰C stop the charging process and
To reconnect the battery cables, always allow the battery to cool.
connect the negative (-) cables last.
Never use metal parts to short circuit the
terminals of a battery CAUTION: Always measure battery
Do not weld, grind or smoke near a battery. temperature in the centre cell
CAUTION: Always place a damp cloth over

WARNING: A battery produces explosive
the vent covers when charging a battery
gases. Keep all flames, sparks and cigarettes
away. Provide adequate ventilation when
charging the battery or when using it in an CAUTION: Use hot water to remove all
enclosed space. Always wear eye protection evidence of corrosion from battery terminal
and protective clothing when working on or post and connections, then smear with
near a battery. petroleum jelly or other non-acid grease.
WARNING: Battery acid causes severe

burns. The battery contains sulphuric acid.
Avoid contact with skin, eyes or clothing.
Antidote:
External: Flush with water
Internal: Drink large quantities of water or
milk. Follow with milk of magnesia, a beaten
egg or vegetable oil. Do not give fluids that
induce vomiting. Call a doctor immediately.
Eyes: Flush with water for 15 minutes and get
prompt medical attention.

General troubleshooting procedures
Wiring harness (open circuit) – Test
An open is a failure of an electrical circuit that results in no flow of electrical current. An open circuit is
usually caused by failed electrical wires or poor connections of electrical connectors. If an electrical
wire or a connection is broken, the flow of electrical current through the circuit is interrupted. A normally
closed circuit will have less than 5 ohms of resistance. The following procedure explains the test for an
open cir66cuit.
Test for an open circuit
1. Identify the connector and the wire numbers of the suspect circuits.
2. Turn the key start and the disconnect switch to the OFF position
3. Disconnect the component from the wiring harness
4. At one of the disconnected harness connections, place a jumper wire from the contact of the
suspect wire to frame ground.
5. At the other connector of the machine harness, use the multimeter probes to measure the
resistance from the contact of the suspect wire to frame ground.
Expected result: The resistance is less than 5 ohms
OK – The resistance is less than 5 ohms. The harness circuit is correct.
STOP
Not OK: The resistance is greater than 5000 ohms. There is an open in the machine harness.
Repair: Repair the machine harness or replace the machine harness.
STOP
Wiring harness (short circuit) – Test
A short circuit is a failure of an electrical circuit that results in undesired electrical current. Usually, a
short circuit is a bypass of the circuit across a load. For example, a short across the wires in a circuit for
a lamp produces too much current in the wires but no current is felt at the lamp. The lamp is shorted
out. The resistance in a normal circuit can vary, but the resistance between a particular circuit and other
unrelated circuits is always greater than 5000 ohms. The following procedure explains the test for a
short circuit.
Test for a short circuit
1. Identify the connector and the wire color of the suspect circuits.

2. Turn the key start switch and the disconnect switch to the OFF position
3. Disconnect the component from the wiring harness
4. At the machine harness connector, place one of the multimeter probes on the contact of the
suspect wire
5. Use the other multimeter probe to check the resistance across all other contacts in the
connector(s) of the frame ground.
Expected result: The resistance is greater than 5000 ohms for all the measurements.
OK: The resistance is greater than 5000 ohms for all the measurements. The harness circuits are
correct.
STOP
Not OK: The resistance is less than 5 ohms. There is a short in the machine harness. The short is
between the suspected wire and the wire with the lowest resistance measurement.
Repair: Repair the machine harness or replace the machine harness.
STOP
Digital multimeter
The digital multimeter is highly accurate and used to find the precise value of any type of
voltage, current or resistance. Powered by a 9 volt alkaline battery, the meter is sealed against
dirt, dust and moisture.

Liquid crystal display
The meter’s liquid crystal display or LCD uses display segments and indicators. Digital
readings are displayed on a 4000 count display with polarity (±) indication and automatic
decimal point placement. When the meter is turned ON, all display segments and annunciators
appear briefly during a self test. The digital display updates four times per second, except
when frequency readings are taken. Then the update is three times per second.
The analog display is a 32 segment pointer that updates at 40 times per second. The display
segments have a pointer that “rolls” across them indicating a measurement change. The
display also uses indicators to abbreviate various display modes and meter functions.
Push buttons
The buttons on the meter are used to perform additional functions. This lesson will cover only
the range button. The additional buttons will be covered later in the course as they apply to the
type of measurement taken.

When it is first switch on and a measurement is made, the meter automatically selects a range
and displays the work AUOT in the upper left. Pressing the range button will put the meter in
manual range mode and display the range scale in the lower right. With each additional press
of the range button, the next increment will be displayed. Press and hold the range button to
return to the auto range mode. The yellow button can be used to back light the meter display.
Rotary switch
Various meter functions are selected by turning the meter’s rotary switch. Each time the rotary
switch is moved from OFF to a function setting, all display segments and indicators turn on as
part of a self test routine. Moving clockwise from the OFF switch, the first three positions on
the rotary switch are used for measuring AC voltage, DC voltage and DC millivolts. The top
position is used for measuring resistance. The next position will allow the meter to check
diodes. The last two positions are used for measuring AC and DC current in amperes, milli-
amperes and micro-amperes.

Meter lead inputs
Depending on the measurement you wish to make, the meter leads will have to be placed in
the correct terminals. Notice the insides of the input terminals are color-coded red or black.
The positive lead can go in any of the red inputs.
The common terminal is used for most measurements. The black lead will always remain in
the COM terminal.
The first input terminal, on the left side of the meter is for measuring amps. This input is fused
at 10 amps continuous (20A for 30 seconds)
The next position to the right is for measuring milliamps or microamps. No more than 400
milliamps can be measured when the rotary with is in this position. If you are unsure of a
circuit’s amperage, you may want to start out with the red meter lead in the 10 amp input jack.
The input terminal on the right side of the meter is for measuring voltage, resistance and diode
test.

Overload display indicator
While making some measurements you may see OL displayed. OL indicates that the value
being measured is outside the limits for the range selected. The following conditions can lead
to an overload display.
1. In auto range, a high resistance reading indicates an open circuit

2. In manual range, a high resistance reading indicates an open circuit or incorrect scale
selected
3. In manual range, a voltage reading that exceeds the range selected
4. When performing a diode check, voltage readings greater than 3.0 volts or open test
leads
Input terminal and limits
The following chart shows the meter functions, the minimum display reading, maximum display
reading and maximum input for the digital multimeter.
Measuring AC/DC voltage
When using the multimeter to make voltage measurements it is important to remember that the
voltmeter must always be connected in parallel with the load or circuit under test. The accuracy

of the multimeter is approximately ± 0.01% in the five AC/DC voltage ranges with an input
impedance of approximately 10 MΏ when connected in parallel.
To measure voltages perform the following tasks:
1. Make sure the circuit is turned ON

2. Place the black meter lead in the COM input port on the meter and the red lead in the
VOLT/OHM input port
3. Place the rotary switch in the desired position AC or DC
4. Place the black meter lead in the on the low side or the ground side of the component or
circuit being measured
5. Place the red meter lead in the on the high side or the positive side of the component or
circuit being measured
Measuring voltage drop
Observe the circuit in the above figure. The test leads are connected in parallel across the
circuit load. With a 12 volt power source connected to the load, the meter should read a
voltage drop equal to the source voltage or 12 volts.
If the meter reads a voltage drop less than 12 volts, it would indicate that an un-wanted
resistance was present in the circuit. A logical process would be to measure the voltage drop
across the closed switch contacts. If a voltage reading was present it would indicate that the
switch contact were corroded, required the switch to be replaced.

Note: In actual measurements the meter reading will not exactly equal the power source
voltage, because the individual wires will offer some small resistance. In most practical
applications, a voltage drop of 0.1 volts is acceptable for normal circuit wiring conditions.
Measuring AC/DC current
When using the multimeter to make current measurement it is necessary that the meter probes
must be connected in SERIES with the load or circuit under test. To toggle between alternating
and direct current measurements, use the BLUE pushbutton.
When measuring current, the meter’s internal shunt resistors develop a voltage across the
meter’s terminal called “burden voltage”. The burden voltage is very low, but could possible
affect precision measurements.
When measuring current flow, the Fluke 87 multimeter is designed with low resistance to not
affect the current flow in the circuit. When measuring current in a circuit, always start with red
lead of the multimeter in the Amp input (10A fused) of the meter. Only move the red lead into
the mA/µA input after you have determined the current is below the mA/µA input maximum
current rating (400 mA).
The meter has a “buffer” which allows it to momentarily measure current flows higher than
10A. This buffer is designed to handle the “surge” current when a circuit is first turned on. As
stated earlier, the meter is capable of reading 2- amps for a period not to exceed 30 seconds.

Note: Re-emphasize that the leads must always be connected in SERIES with the load or
circuit when measuring current flow.
To measure current, perform the following tasks:
1. Place the black multimeter input lead in the COM port and the red lead in the A (amp)
port
2. Create an open in the circuit, preferably by “pulling” the fuse, or by “opening” the switch
3. Place the leads in series with the circuit, so that the circuit amperage is flowing through
the meter
4. Apply power to the circuit
Caution: If the current flow exceeds the rating of the fuse in the meter, the fuse will “open”
Measuring current flow

Measuring resistance
When using the multimeter to make resistance measurements it is necessary to turn off the
circuit power and discharge all capacitors before attempting in-circuit measurements. If an
external voltage is present across the component being tested, it will be impossible to record
an accurate measurement.
The digital multimeter measures resistance by passing a known current through the external
circuit or component and measures the respective voltage drop. The meter then internally
calculates the resistance using the Ohm’s law equation R = E/I. It is important to remember,
the resistance displayed by the meter is the total resistance through all possible paths between
the two meter probes. To accurately measure most circuits or components it is therefore
necessary to isolate the circuit or component from other paths.
Additionally, the resistance of the test leads can affect the accuracy when the meter is in its
lowest (400 ohm) range. The expected error is approximately 0.1 to 0.2 ohms for a standard
pair of test leads. To determine the actual error, short the test leads together and reads the
value displayed on the meter.
Note: Re-emphasize that the circuit or component needs to be isolated to measure accurately.
There is an exception to this rule when measuring certain electronic components, such as,
transistors and diodes, but for this course it is recommended that the circuit or component be
isolated.

To accurately measure resistance, perform the following tasks:
Make sure the circuit or component power is turned OFF
Place the red lead in the jack marked volt/ohms and the black lead in the jack marked COM
Place the rotary selector in the Ώ position
Place the meter leads ACROSS the component or circuit being measured
Note: It is important that your fingers are not touching the tips of the meter leads when
performing resistance measurements. Internal body resistance can affect the measurement.
Note: In the above circuit, the power source is isolated from the circuit by “opening” the switch.
It also, isolated the resistor from any path that may affect the accuracy of the measurement.

Circuit faults
There are several ways that a circuit can malfunction. Most electrical malfunctions are caused
by opens, shorts, grounds, and high resistance or intermittent.
Opens:
An “open” in any part of a circuit is, in effect, an extremely high resistance that results in no
current flow in the circuit. An open can be caused by a failed component such as a switch or
fuse, or a broken wire or connector. The physical location of the “open” determines how the
circuit will react. In a series circuit, any open connection will result in no current flow in the
circuit. The below figure shows an open in a series circuit. The switch acts as an open and
therefore, no current will flow through the two loads when the setich is open.
Troubleshooting series open circuit
Troubleshooting an open circuit is easily accomplished using a multimeter and measuring

source voltage. If source voltage is available at the connection ahead of the switch and not
available on the load slide of the switch, the switch contacts are open. If voltage is available on
the “load side” it would be necessary to continue checking the circuit until the open is
identified.

Troubleshooting parallel open circuit
In a parallel circuit, identifying open depends on where the open occurs. If the open occurs in
the main line, none of the loads or components will work. In effect, all parallel branches will not
operate. Additionally, an open in the return ground path would have the same effect as an
open in the main line. An open in the return ground path is referred to as an “open ground”
If the open occurs in any of the branches below the main line, only the load on that specific
branch is affected. All other branch loads will operate normally. The above figure shows an
example of an open in the main line and in a parallel branch.
Open in main and parallel branch
when trouble shooting or diagnosing an open in a circuit, the result is normally a component
that fails to operate or function. Since most circuits are protected with some tupe of a fuse or
circuit protection device, it is recommended that the fuse or device be checked visually. If a
visual check does not reveal an open condition, remove the device and perform a continuity
check to ensure that the device is functional. The next most probable place to check for an
open is at the component itself. Using a multimeter and a electrical schematic determine if
system or source vontage is available. If voltage is not present at the component, the next step
is to determine what other electrical devices, such as, switches or connectros are in the circuit
path. Eliminate those devices, starting at the easitest location and working back toward the
voltage source.
Short circuit
A short in a circuit is a direct electrical connection between two points, usually a very lod
resistance or opposition to current flow. It most often describes an unwanted or incorrect
electrical connection and may draw higher than expected current. In describing malfunctions

caused by elelctrical shorts, the types of shorts is usually identified as a “short to ground” or a
“short to power”.
A short to ground occurs when current flow is grounded before it was intended to be. This
usually happens when wire insulated breaks and the condutor actually comes in contact with
the machine ground. The effect of a short to ground depends on the design of the circuit and
on its location in relationship to other circuit components, such as, protection devices,
switches, loads etc.
Short occuring after protection device
The above figure shows the short occuring after the protection device and switch,but before
the cirucit load (lamp). In this example, a low resistance path to ground occurs whenever the
switch is turned on and source voltage is available. The result of this unwanted path will result
in a blown fuse (or tripped breaker) when the switch is turned on.

Short occurs before the switch
The above shows the short to ground occuring before the switch. This condition is often
referred to as a “dead short”. In this situation, the fuse will “blow” anytime circuit voltage is
applied.
Short to power before switchs
a short to power or supply occurs when one circuit is shorted to another circuit. The symptoms
of a short to power again depends on the location of the short. The result of this type condition
generally causes one or both circuits to operate improperly, such as a component being

energized when it is not supposed to be. The root cause of this condition is typically caused by
worn or frayed electrical wiring. Also, this condition rarely causes protection devices to “open”
or damage to other components.The above figure shows the short to power occurring before
the controlling devices (switches). This condition allows both switches to control the two loads.
Short occurs after and before load
The above figure show the short to power occurring after the load in one branch and before the
load in the other. In this case, if the switch controlling circuit #2 is turnedon, the load does
illuminate, but if the switch controlling circuit #1 is turned on, a direct short to ground occurs
resulting in the fuse “blowing”
Grounds: A grounded circuit usually results in a component failing to operate. As discussed

earlier, a grounded condition indicates that the circuit has an unwanted path to the machine
frame. As stated earlier, the effect on the circuit is determined by where the ground occurs.
High resistance: Circuit malfuncations also occur when resistance levels become too high.
The circuit effect usually results in the component failiing to operate or the component does not
operate according to specification. A typical cause of high resistance is a build up of
corrosionor dirt on connections and contacts.
Intermittents: An intermittnent condition occurs when contact or connections become loose or

when internal component part break. The problem usually results in lights flickering, or
components working intermittently. This problem usually apperars as the result of vibrations or
machine moving and are not easily diagnosed because the condition corrects itself when the
machine is stopped.

Testing electrical components
Testing proper functioning of relay
Provide power to the relay and if possible, turn on all equipment that is powered by the relay
contacts. The engine can either be off or running
Connect the multimeter across the terminals as shown in the above figure to check system
voltage at the relay coil terminals. The multimeter should read 11V. If the voltage is less than
specified or zero, proceed with the following steps.
Connect the multimeter between the battery side of the relay coil and machine ground.
The multimeter should read system voltage. If not there is a faulty connection between
The source of battery positive and the positive connection of the coil. Correct this fault
before proceeding with the test.
If system voltage is present between the positive side of the coil and ground, but not to
the ground side of the coil, then there is a faulty connection between the ground side of
the coil and frame ground. Correct fault before proceeding.

Checking to see if system voltage is available across the relay coil terminals
Connect the multimeter as shown above to check for system voltage at the relay contact
battery terminal. If no voltage is present, correct this condition before proceeding
Checking to see if system voltage is available at the relay contact battery terminal
1) After you are sure that system voltage is present across the relay coil terminals and at
the contact battery terminal, you are ready to check the relay contacts (switch). Connect
the multimeter (200V capability) across the contact terminals as shown in the above.
2) If the relay contacts are closed during these conditions, the meter should read less than
0.5 volt maximum. For relay contacts that are open under these conditions, the meter
should read system voltage
3) Disconnect positive wire (A) as shown above from the coil terminal. This should cause
the contacts to change positions (closed contacts to open and open contacts to close).
As you touch and remove wire (A) to the coil terminal, you should hear a “clicking” noise

caused by the contacts opening and closing. This indicates a good relay coil, meaning it
is not “open”
4) With wire (A) disconnected, measure voltage drop across the contact terminals. Leave
the meter connected as shown above. The meter should show system voltage for relay
contacts which were formerly closed, but are now open. For relay contacts which were
formerly open, but are now closed, the meter should show the voltage drop to be less
than 0.5 V. reconnect wire (A) and repeat this test several times to verify the results.
5) When wire (A) is disconnected the voltage across the contact terminals MUST alternate
between system voltage and the allowable voltage 0.5V across the contact terminals. If
this does not occur, replace the relay
a. If the voltage across the relay contacts remains constant during this step, either
the relay is defective or the circuit to the load is open or turned off
b. If the circuit to the load is not open, replace the relay as stated
c. If the circuit to the load is open, correct the problem and repeat the entire contact
operation test beginning with step 2.
Battery inspection before test or charge
Reject the battery if:
1) The electrolyte is excessively low

2) Electrolyte levels vary by more than 20mm in between cells
3) Battery case, lid or mounting are cracked or damaged
4) Terminals are damaged or loose in the case
Test the open circuit voltage
Test equipment – digital multimeter
Do the open circuit voltages test as follows:

1) The engine must be stopped and all electrical circuits switched off this test
2) Measure the open circuit voltage of the battery only if it has not been charged or
discharged in the past 16 hours. If the machine has recently been started, switch on the
headlights for 15 seconds then wait one minute before testing.
3) Connect the multimeter directly across both battery terminals and note the voltage. If
the measured volts is 12.5V or above no action required. Below 12.5V, recharge the
battery.
Testing the battery voltage under load
Test equipment – 0 to 20 V digital voltmeter
Note: This test can be made with the starter motor still installed on the machine.
Do the battery voltage under load test as follows
Check condition of battery
Connect the voltmeter across the terminals as shown and operate the starter key switch
The volt meter should read approximately 9 V. A low voltage reading indicates excessive
current flow in the circuit due to low resistance

Diagnostic test with the battery fitted on the machine

Testing the starter motor terminal voltage under load
1) Open the starter access hood

2) Remove the protective covers
3) Connect the voltmeter between the starter input terminal and earth. Crank the engine,
the voltmeter reading should not be more than 0.5V lower than in the battery voltage
under load test.
4) A low reading (more than 0.5V difference between tests 1 and 2) indicate high
resistance in cables or contacts
5) High reading indicate high resistance in the starter motor itself
6) Install the protective covers
7) Close the starter access hood
Testing the voltage drop on the insulated line
This test can be made with the starter motor still installed on the machine

1) Open the starter access door
2) Connect the voltmeter between the starter terminal and the battery terminal
3) When the starter switch is open, the voltmeter should register battery voltage. When the
starter switch is closed, the voltmeter should read practically zero
4) A high voltmeter reading indicates a high resistance in the starter circuit. Check all the
insulated connections
5) Do the voltage drop across the solenoid contact.
Testing the voltage drop across the solenoid contacts
This test can be made with the starter motor still installed on the machine
1) Remove the protective cover on the starter

2) Connect voltmeter across the two main solenoid terminals
3) When the starter switch is open, the voltmeter should register battery voltage. When the
starter switch is closed the reading should be zero or fractional value
4) A zero or fractional reading indicates that the high resistance deduced in the voltage
drop on the insulated line test must be due to either high resistance in the starter cables
or solenoid connections. A high reading (similar to the voltage drop on the insulated line
test) indicates a faulty solenoid or connection.
5) Install the protective cover

Testing the continuity of contacts
1) Open the hood and remove the protective cover

2) Connect the voltmeter between motor and solenoid negative terminals and operate
starter switch
3) No voltage indicates a faulty solenoid. Replace the solenoid
4) 12V registered but motor fails to operate indicates faulty motor. Replace the starter
motor
5) 12V registered and motor operates, test the voltage drop across the contacts.
Testing the voltage drop across the contacts
Connect the voltmeter across the solenoid terminals and operate starter switch
Voltage across the terminals should be zero, if more, the solenoid is faulty and must be
changed
If solenoid is satisfactory, service the starter motor

Alternator
Note: preliminary testing may rectify a fault in the charging circuit and prevent the requirement
to carry out other tests contained in this section
1) Open the access door

2) Examine the circuit cable connections. Make sure the connections are clean and tight
3) Examine the components and wiring of the circuit. Make sure there are no signs of
damage or overheating
4) Examine the alternator drive belt. Make sure the tension is correct
5) Examine the battery and the battery connections. Make sure the battery and the battery
connections are in good condition
6) If the above preliminary tests do not rectify the fault, continue the fault diagnosis
process.
General alternator diagnostics

Battery indicator light stays out under all conditions
Flat battery Test the battery
Bad connection or broken cable Continuity test
Blown bulb or faulty switch Continuity test
Failed regulator Maximum output and voltage regulator

tests. Replace regulator or change
alternator if readings are low
Failed field windings Maximum output and voltage regulator

test. Replace alternator if readings are low
Internal short circuit (probably surge diode) To test diode, wire into a battery circuit
(two wires and a 5 watt bulb). When the
terminal is connected to positive and the
body to negative, the bulb should not light.
If it does, fit a new diode. The bulb should
light when the connectors are reversed)
Battery indicator light stays on (dims as engine speed increased, goes out at high

engine speed)
Short circuit to earth Continuity test. Voltage drop test
Slack fan belt Re-tighten or replace
Battery not charging
Battery in poor condition Test open circuit voltage. Charge/replace

battery as necessary
Voltage control faulty Voltage regulator test. Change regulator
High resistance (bad connection) Continuity test. Renew or clean

connections
Leak to earth Continuity test. Renew or clean

connections
Battery overcharging (early bulb failure, high consumption of distilled water)
Voltage control Voltage regulator test. Change regulator
Battery indicator light on when engine stationary (dims at cut-in speed and
remains dim at high speed)
Internal short circuit Maximum output test. Service or change

the alternator

Testing cable continuity
1) Open the access door

2) If necessary, remove the protective covers
3) Set the start switch (2) to the run position and check that the warning light (1)
illuminates
4) Using a voltmeter, check for battery voltage at the alternator main output lead (5) or the
main stud terminal (7). If the voltmeter shows a low or zero voltage, inspect the
electrical wiring for damage, and the connections for security.
5) Using a voltmeter, check for battery voltage at the indictor cable (6). If the voltmeter
shows a low or zero voltage, inspect the electrical wiring for damage and the
connections for security.
6) Set the start switch to OFF.
7) Remove the voltmeter
8) If necessary, install the protective covers
9) Close the access door

Testing the voltage regulator
Make sure, before you test the voltage regulator, that a well charged battery is installed on the
machine
1) Remove the access door and protective covers

2) Disconnect the battery earth cable
3) Connect an ammeter in series with the main output lead (5) or the main stud terminal
(6) from the alternator. Connect a voltmeter across the battery terminals
4) Reconnect the battery earth cable
5) Start and run the engine at maximum speed until the ammeter reading is less than 10A
6) Set the engine speed to 1000 rpm. Make sure the voltmeter shows a reading between
14.0 V to 14.4 V. if the reading is higher, there is a high resistance in the circuit.
7) Locate and rectify the high resistance in the circuit
8) Switch off the engine
9) Remove the test equipments and install the door and protective covers

Testing the voltage drop
1) Open the access door and remove the protective cover

2) Connect a voltmeter between the battery positive terminal and the alternator main
output lead (6) or the main stud terminal (7)
3) Start and run the engine at maximum speed
4) Switch on all vehicle electrical loads. Make sure the voltmeter (A) reading is not more
than 0.5V
5) Switch the engine off
6) Disconnect the voltmeter
7) Connect the voltmeter between the battery earth terminal and the alternator body (5)
8) Start and run the engine at maximum speed. Switch and run the engine at maximum
speed. Switch on all vehicle electrical loads. Make sure the voltmeter (8) reading is not
more than 0.25V
9) Switch the engine off
10) Remove the test equipments and install access door and protective cover

Testing the alternator output
Tools required
Two 150A ammeters, 0 to 20V voltmeter, photo tachometer and variable resistor – 70A
This test can be done while the alternator is still installed on the machine, but you must
disconnect all the vehicle wiring from the alternator and use the slave leads, the battery and
the bulb
1) Remove the access door and protective cover

2) Connect the alternator into the circuit shown, but do not start the engine or run the
alternator
3) Adjust the variable resistance (1) until the ammeter registers equal to or just above the
alternator maximum rated output (55A, 70A or 100A)
4) If necessary, start the engine
5) Slowly increase the speed of the alternator
6) If necessary, use the photo tachometer to set the engine speed to 542 rpm or set the
alternator speed to 1500 rpm. Make sure the voltmeter shows a reading of 13.5V and
the warning light (2) goes off
7) If necessary, use the photo tachometer to set the engine speed to 2168 rpm or ser the
alternator speed to 6000 rpm. Make sure the ammeter A1 shows a reading as per
specification of the alternator being tested.
8) If the ammeter A1 reading is not correct, stop the engine. If installed, remove the
suppression capacitor and do the steps 3 through 7 again

9) If the ammeter A1 readings are still not correct, examine and test the rectifier diodes,
the rotor resistance and the stator windings as necessary.
10) If necessary, install the suppression capacitor
11) If necessary start the engine
12) If necessary, use the photo tachometer to set the engine speed to 2168 rpm or set the
alternator speed to 6000 rpm until the ammeter A1 shows a reading less than 10A.
make sure the voltmeter (V) shows a reading between 13.6 to 14.4 V
13) If the voltmeter reading is not within the limits, stop the engine and replace the regulator
and brush box assembly
14) Disconnect the alternator from the test circuit
15) Connect all the vehicle wiring
Relay and fuse locations
Relay

Tyre General Maintenance Practices
• NEVER re-inflate a tyre that have been • NEVER install tubes that have buckled
run flat or seriously underinflated or creased
without removing and checking for tyre • ALWAYS use new tubes in a new tyre
or rim damage • NEVER use a tube in a casing larger or
• ALWAYS use specialized tools as smaller than that for which the tube was
recommended by tyre suppliers for designed by the manufacturer
mounting and demounting of tyres • ALWAYS check to be sure tube is
• ALWAYS inspect inside of tyre for loose clean before installing in the tyre.
cords, cuts, penetrating objects, or other • ALWAYS lubricate with approved tyre
carcass damage. Repairable damage mounting lubricant. Never use anti-
should be repaired before installing freeze, silicones or petroleum base
tube. Tyres with irreparable damage lubricants
should be discarded • NEVER hit tyre or rim with hammer
• ALWAYS clean and inspect rim • ALWAYS use extension hose with a
• NEVER rework, weld, heat or braze gauge and a clip-on chuck so that
rims operator may stand aside during
• ALWAYS check rim diameter to be sure inflation
it exactly matches rim diameter molded • ALWAYS inspect valve cores and
on tyre sealing cap for proper air retention.
• ALWAYS inspect the inside of tyre for Replace damaged or leaky cores or
dirt, liquids or foreign material and
remove before installing the tube

Terex Old Handbook Troubleshooting

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Terex Old Handbook Troubleshooting

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Technician Service Hand Book –

DO NOT OPERATE OR PERFORM ANY LUBRICATION, MAINTENANCE OR

The meaning of this safety alert symbol is as follows:

ATTENTION! BECOME ALERT! Your safety is involved

General torque information

2 HELP LINE NUMBER 0120 - 4729000

Pounds inches Newton meters Pounds inches Newton meters

7/16 inch 54 to 64 73 to 87 70 to 84 95 to 114

1/2 inch 80 to 96 109 to 130 110 to 132 149 to 179

3 HELP LINE NUMBER 0120 - 4729000

Thread size 8.8 10.9

Pounds inches Newton meters Pounds inches Newton meters

M12 66 to 79 90 to 107 93 to 112 125 to 150

M14 106 to 127 144 to 172 149 to 179 200 to 245

M16 160 to 200 217 to 271 230 to 280 310 to 380

M20 320 to 380 434 to 515 450 to 540 610 to 730

M24 500 to 600 675 to 815 780 to 940 1050 to 1275

M30 920 to 1100 1250 to 1500 1470 to 1770 2000 to 2400

M36 1600 to 1950 2175 to 2600 2580 to 3090 3500 to 4200

Measuring bolt thread size

4 HELP LINE NUMBER 0120 - 4729000

Tube OD / Hose ID Thread size Pound inch Newton meters

37 degree flare fitting

1/4 inch / 6.4 mm 7/16 – 20 6 to 12 8 to 16

5/16 inch / 7.9 mm 1/2 – 20 8 to 16 11 to 22

3/8 inch / 9.5 mm 9/16 – 18 10 to 25 14 to 34

1/2 inch / 12.7 mm 3/4 – 16 15 to 42 20 to 57

5/8 inch / 15.9 mm 7/8 – 14 25 to 58 34 to 70

3/4 inch / 19.0 mm 1-1/16 – 12 40 to 80 54 to 108

7/8 inch / 22.2 mm 1-3 / 16 – 12 60 to 100 81 to 135

1.0 inch / 25.4 mm 1-5 / 16 – 12 75 to 117 102 to 158

1-1/4 inch / 31.8 mm 1-5/8 – 12 125 to 165 169 to 223

1-1/2 inch / 38.1 mm 1-7/8 – 12 210 to 250 285 to 338

5 HELP LINE NUMBER 0120 - 4729000

#3 Brown 24 H Form a gasket (works with oil, fuel or grease

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A: Fahrenheit temperature B: Centigrade temperature

7 HELP LINE NUMBER 0120 - 4729000

Inches X 2.54 = Centimeters Centimeters X 0.3937 = inches

Yards X 0.9144 = Meters Meters X 3.2808 = Feet

Pounds X 0.45359 = kilograms Kilograms X 2.2046 = Pounds

Tonnes X 0.9842 = Tonnes Tonnes X 1.0161 = Tonnes

Pressure and Torque

Lbs. Per. Sq.Inch X 0.0703 = Kgs.per.Sq.Centimeter X 14.244 =

8 HELP LINE NUMBER 0120 - 4729000

Engine Model 4R1040 4R 1040 4R 1040 T

Transmission 4F/4R 4F/4R 4F/4R

Transmission oil refill 15 L 15 L 15 L

Hydraulic system refill capacity 90L 90 L 90 L

Main relief pressure 225 bar 225 bar 225 bar

Turning circle 8.4 m 8.4 m 8.4 m

Rear axle refill capacity 17.5 L 17.5 L 17.5 L

Battery 12V 135A 12V 135A 12V 135A

Loader bucket 1.0 cum 1.0 cum 1.0 cum

Backhoe bucket 0.25 cum 0.25 cum 0.25 cum

Front tyre (65 psi) 12.5 X 18 12.5 X 18 12.5 X 18

Rear Tyre (35 psi) 16.9 X 28 16.9 X 28 16.9 X 28

9 HELP LINE NUMBER 0120 - 4729000

Check mounting bolts √ √ √ √ √

Coolant level & antifreeze strength √ √ √ √ √ √

Air cleaner/pre cleaner √ √ √ √ √ √

Exhaust system for leaks & mounting √ √ √ √ √ √