Thank you for your attendance and attention.

Where are we?

The Training Center

Davenport, Iowa
Located adjacent to John Deere Davenport Works
Coal Valley Demo Site
Arizona Facility

Sacaton, Arizona
Located 45 miles south of Phoenix
 Who and how?

Who do we Train? How do we train?

• Dealers
• Company Field Personnel
• Partner Technical Schools
• Customers
• Classroom Instruction
• Field Training
• Distance Learning through John
Deere University
• Videos and CDs
 Retention Rate Pyramid

5%
Lecture

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Ra
10

M
n %

et
tio
Reading

ho
n

20
te

d
%
Re

of
Audio/Visual

Le
30
e
ag

ar
on
er

ni
Demonstrati

ng
Av

50
%
up D i s cu ssion/
75 Gr o
% Interaction
90 Doing It
%
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Te aching I
 K-SERIES 4WD LOADERS

Welcome

Capstone Certification
 Introductions

• Who are you?

• Where are you from?
• What dealer do you work at?
• Do you work in the shop or field service?
• How long have you been a technician?
• What are your hobbies?
Shop Walk Around
ADU Simulation
 Technical Overview

In the Technical Overview lesson you will identify the following:

– Engines
– Electrical
– Powertrain
– Hydraulics
 Engines

In the engines lesson, you will…

– Identify the engines used in the K-Series loaders
– Identify the type of fuel systems used on the 4045, 6068, 6090 and 6135
– Identify major engine components of the 4045, 6068, 6090 and 6135
– Identify the Tier 3 components that make up the PowerTECH E engine
– Identify the Tier 3 components that make up the PowerTECH Plus engine
 Engine Configurations

444K JD 4045 PowerTech E

524K JD 6068 PowerTech E

544K JD 6068 PowerTech E

624K JD 6068 PowerTech Plus

644K JD 6068 PowerTech Plus

724K JD 6090 PowerTech Plus

744K JD 6090 PowerTech Plus

824K JD 6135 PowerTech Plus

844K JD 6135 PowerTech Plus

 4045/6068 PowerTech E

6 8
0
444K JD 4045 PowerTech E

6 45
524K JD 6068 PowerTech E 6068

544K JD 6068 PowerTech E

40 4045
Connecting Rods, Caps, and Pistons

- 4045 & 6068 Engines use aluminum pistons

- Offset crown due to the offset injectors
 2-Valve Cylinder Head

4045

• 2 valve cylinder head

• Injectors positioned at 14 degrees of
vertical position

6068
Standard Turbocharger
 Low Pressure Fuel System

All PowerTech engines have a low pressure fuel system

Final Fuel Filter

Primary Fuel Filter

Water-in-Fuel Sensor
 High-Pressure Common Rail
and Injector Leak-Off

Injector Leak-Off Line

Fuel Filters

Transfer Pump

High Pressure High Pressure

Common Rail Fuel Filters
Fuel Pump
 6068/6090 PowerTech Plus

624K JD 6068 PowerTech Plus

6068

6 8
644K

724K
JD 6068 PowerTech Plus

JD 6090 PowerTech Plus 0

6 90
60
744K JD 6090 PowerTech Plus

6090
Connecting Rods, Caps, and Pistons
4-Valve Cylinder Head
 Variable Geometry Turbo (VGT)

Turbine Actuator

Turbo speed sensor Compressor

 Variable Geometry Turbo Actuator

• Cooled by engine coolant

• Adjusts vanes inside turbo to ensure
proper exhaust pressures
– Correct amount of exhaust gas and
fresh air mixing
– Control turbo boost
• Runs through an adaptive learning
cycle when first activated
– ECU will read from fully closed
position of actuator arm to fully open
– When replacing the actuator, it should
not be electronically connected until
fully installed on engine
Variable Geometry Turbocharger

Variable Turbine Inlet Vanes

 Variable Geometry Turbo Vanes

Vanes Open Vanes Closed

 Cooled Exhaust Gas Recirculation
(EGR)

6090 EGR Cooler

6068
 High-Pressure Common Rail
Fuel System

High Pressure
Common Rail

Rail Pressure Sensor

High Pressure Fuel Pump

 Injector Leak-Off

Injector Leak-Off Line

Fuel Injector
Glow Plugs

Glow Plugs
 6135 PowerTech Plus

5
824K JD 6135 PowerTech Plus

3
844K JD 6135 PowerTech Plus

61
6135
Piston
Gallery-cooled Pistons
4-Valve Cylinder Head
Variable Geometry Turbocharger (VGT)

Exhaust Gas
Variable Geometry Recirculation
VGT Actuator Turbo (VGT) Cooler
 Electronic Unit Injectors

Quick Connect Pumping Section

Electrical Connection

Clamping area
Service O-Rings

Actuator Section

Injector Section
 ECU Inputs & Outputs

Inputs
Fuel Rail Pressure
Fuel Temp
Engine Coolant Temp
Low Pressure Fuel Pump
Engine Intercooler Air Temp
Manifold Air Temp High Pressure Fuel Solenoids
Exhaust Temp
Exhaust Gas Recirculation Valve
Compressor Inlet Temp
Engine Air Filter Restriction Switch ECU Variable Geometry Turbo
Fuel Pressure
6 Fuel Injectors
Water in Fuel
Engine Oil Pressure Start Aid Solenoid

Manifold Air Pressure

Start Relay
Throttle Position Outputs
Crankshaft Position
Camshaft Position
Turbo Speed
 Engines Lesson Summary

In the engines lesson, you…

– Identified the engines used in the K-Series loaders
– Identified the type of fuel systems used on the 4045, 6068, 6090 and 6135
– Identified major engine components of the 4045, 6068, 6090 and 6135
– Identified the Tier 3 components that make up the PowerTECH E engine
– Identified the Tier 3 components that make up the PowerTECH Plus engine
 Electrical System

By the end of this lesson, you will be able to:

– Identify the controllers that communicate on the CAN networks
– Identify the inputs/outputs of the SSM, ADU, TCU, ECU and FLC
– Identify the circuits controlled by the SSM, ADU, TCU, ECU and FLC and describe their
function
– Trace flow through start circuit and park brake circuit
– Perform the tasks using the monitor
– Describe the operation of the following options
• Reversing Fan
• Ride Control
• Auto-Differential Lock
• Joystick Steering
• Lockup Torque Converter
• Auto-Ether
• Rearview Camera and
Radar Object Detection (ROD)
• Embedded Payload Scale (EPS)
– Identify the location of the Service ADVISORTM connector
– Describe the process for downloading software using the John Deere Custom Performance
(JDCP) web site
– Describe where to retrieve the master security code
 Glossary of Terms

Click on the
tab above for a list of acronyms
and other definitions.
 Controller Area Network (CAN)

CAN 1

CAN 2
Advanced Display Unit (ADU)
 Advanced Display Unit (ADU)

X48

SWITCHED
J M12 YEL
B M13 GRN
POWER
FROM F13 P13 RED H R12 BLK
BATTERY P33 RED F
POWER A
FROM F33
D A34 ORG
G R34 BLK (VIDEO SHIELD)
E
K
G01 BLK C
R
S
H2
ADVANCED DISPLAY
UNIT (ADU)
Sealed Switch Module (SSM)
Sealed Switch Module (SSM)
Sealed Switch Module (SSM)
 Flex Load Controller (FLC)

P21

P21
B10

IMPORTANT: There is nothing serviceable inside the FLC.

 FLC 3 Amp Drivers

3 amp drivers control:

• Horn
• Boom Height Kick Out Detent Coil
• Return-To-Dig/Float Detent Coil
• Brake Lights
• Marker and Tail Lights
• Turn Signals
• Four-Way Flashers
• Ride Control On/Off Solenoids (2)
• Ride Control Boom Solenoid
• Pilot Enable/Boom Down Solenoid
• Reversing Fan Solenoid
• Axle Disconnect Solenoid
• Pin Disconnect Solenoid
• A/C Compressor Clutch
• Heated Mirrors
• Front and Rear Washer Pumps
• Front and Rear Wiper High Speed
• Joystick Steering Valve
• Secondary Steering
 FLC 3 Amp Drivers

3 amp Drivers

3 amp Drivers
 Flex Load Controller (FLC)

6 amp drivers control:

• Front and Rear Wiper Low Speed
• All Work Lights
• Drive Lights

6 amp Drivers
 Flex Load Controller (FLC)

15 amp driver controls:

• Beacon Light Circuit

15 amp Driver
Replacing the FLC
 Transmission Control Unit (TCU)

TCU Controls:
– Clutch engagement solenoids
– Park brake
– Back-up alarm
– Clutch cut-off
– Neutral start
When servicing the TCU
– Two separate part numbers
• 4-speed—part number starts with “4”
• 5-speed—part number starts with “5”
– New TCU requires the ignition power to be
cycled twice
Transmission Sensors
 Clutch Pack and Solenoid
Engagement Chart

4-Speed Transmission

444-724 744-844
 Clutch Pack and Solenoid
Engagement Chart

5-Speed Transmission with Lockup Torque Converter

644-724 744-844
 TCU Operating Modes

Four Operating Modes

• Normal
– Normal operation with no faults detected
• Substitute Clutch Control
– Time based shift
– TCU missing critical information
– Operator may notice “aggressive shifting”
• Limp Home Mode
– TCU detects fault with transmission
control system
– Only operates in one gear, both forward
and reverse
– Usually caused by clutch slippage or
over-speed
• Transmission Shutdown
– TCU detects severe fault
– Shut down all control solenoids
– Caused by a faulty solenoid circuit
 Practice Using the Monitor

Click on the ADU

to practice using
the monitor.
Security – Master Code
Security
Security
Start Circuit Animation

Click here to launch the animation

Start Circuit

WAIT TO START
 Auto-Idle

Criteria to START, and CONTINUE Auto-Idle

Timer:
• System voltage is within specification MACHINE ENGINE IDLE
ENGINE
• No throttle is commanded by the operator MODEL SPEED
• Engine, transmission and hydraulic system 4045/606 444K, 524K, 544K,
900 to 750 rpm
temperatures are within normal operating 8 624K, 644K
temperature 6090 724K, 744K 900 to 700 rpm
• Machine is in neutral and is not moving
• 6135 824K, 844K 900 to 650 rpm
Engine load is less than 40%
• Auto idle, auto shutdown, or clutch calibration
menus are not being accessed in the monitor
Timer continues if
Criteria are met Auto-Idle
additional criteria Timer expires
and maintained Timer begins
are met

• FLC sends message

over CAN to ECU
requesting reduced Auto-Shutdown not enabled Auto-Idle continues
engine speed
• FLC disables hydraulics, Go to Auto-Shutdown
clutch calibration, and Auto-Shutdown enabled
sequence
reversing fan
 Auto-Shutdown

Criteria to END Auto-Shutdown:

• Throttle position greater than 2%
• Engage a gear (actual)
• Vehicle speed greater than 0.3 mph (0.5 kph)
• Hydraulics enabled
• Park brake released
• Auto idle, auto shutdown, or clutch calibration
menus accessed in the monitor

Same parameters that

Auto-Idle Auto-Shutdown Auto-Shutdown
timer expires timer begins apply to Auto-Idle are Timer expires
met and maintained

Pop-up message appears

on ADU, displaying Ignition power turned off,
30 second countdown machine shuts down
to machine shutdown
Clutch Cut-off Circuit

Clutch Cut-off Setting: Voltage:

Level Slope 1.28
Small Slope 1.98
Steep Slope 2.62
Boom Height Kick-Out
Return-To-Carry and Boom Float
 Return-to-Dig
444K—824K Z-Bar

RTD Magnet

RTD Rod
 Return-to-Dig
844K and Powerllel
Pilot Enable Circuit
Proportional Fan

FLC Monitors:
– Engine coolant temperature
– Manifold air temperature
– Hydraulic oil temperature
– Transmission oil temperature
– Ambient air temperature
– On/off status of the air conditioning
Park Brake Circuit Animation
Park Brake Circuit
Engine Out of Fuel
 Engine Stop Button and Park Brake Logic

Park Brake will apply if the STOP

switch is:
• Pressed once with ground speed less
than 0.3 mph (0.5 kph)
• Pressed twice above 0.3 mph (0.5 kph)
– First press stops engine, ignition
remains on
• Held for longer than 1 second
Park Brake Circuit
Engine Compartment Light

FROM
TO VEC F20
FLC A2
 Option Circuits

• Reversing Fan • Auto-Ether

• Ride Control • Rearview Camera and Radar
• Auto-Differential Lock Object Detection (ROD)
• Joystick Steering • Embedded Payload Scale
• Lockup Torque Converter • Secondary Steering
Reversing Fan

Note: Once the reversing fan

has completed a cycle, the
reversing sequence cannot be
activated again for one minute.
Ride Control Circuit
Auto-Differential Lock
 Auto-Differential Lock

To ENGAGE, the FLC Compares: Will DISENGAGE if:

1. Calculated Ground Speed:
– Transmission Output Shaft Speed
– Final Gear Ratio
– Tire Size
2. Actual Ground Speed:
– Selected Gear
– Machine Direction
– Actual Ground Speed (Radar)
– Vehicle speed increases by 1.2 mph (2
kph)
– Transmission Output Shaft Speed Goes to
Zero
– Machine Changes Direction
– Brake Pedal is Pressed

IMPORTANT: Auto-Differential Lock will only engage when

ground speed is less than 7.5 mph (12 kph).
Joystick Steering
 Lockup Torque Converter

Input Criteria Sensor(s) Controller

Engaged Gear FNR TCU
Engine Speed Torque Converter Input Speed TCU
Torque Converter Input Speed and
Load TCU
Torque Converter Output Speed
Ground Speed Calculated via output shaft speed TCU
Transmission
Transmission Oil Temperature TCU
Oil Temperature
Throttle Throttle Position ECU
Brake Brake Pedal TCU
Boom Height Boom Position FLC

Torque Boom Velocity Calculated via Boom Position FLC

Converter
Lockup
Solenoid
 Auto-Ether

• Optional on 444-544 and 724-844

• 624 and 644 are equipped with glow plug start aids

Ether Injection Times

444-544 724-844
Fuel Temperature °C (°F) -30 (-22) -25 (-13) -17 (1.4) -16.9 (1.58) -30 (-22) -25 (-13) -17 (1.4) -3 (26.6) -2.9 (26.78)
Ignition On (seconds) 1.5 1 0.5 0 1.5 1 0.5 0.5 0

444-544 724-844
Fuel Temperature °C (°F) -17 (1.4) -16.9 (1.58) -3 (26.6) -2.9 (26.78)
Cranking (seconds) 30 0 30 0

444-544 724-744 824-844

Fuel Temperature °C (°F) -17 (1.4) -16.9 (1.58) -25 (-13) -17 (1.4) -12 (10.4) -17 (1.4) -12 (10.4) -5 (23)
Ignition On (seconds) 3 0 5 3 0 10 5 0
 Rearview Camera and
Radar Object Detection (ROD)

Radar
Sensor

Rearview
Camera
 Rearview Camera and
Radar Object Detection (ROD)
 Rearview Camera and
Radar Object Detection (ROD)
 Embedded Payload Scale (EPS)

744K—844K

444K—724K
Embedded Payload Scale
Secondary Steering
Service ADVISOR™ Connector

Service ADVISOR
9-Pin connector
Download Software and
Program Controllers
 Electrical System Lesson Summary

In this lesson, you learned how to:

– Identify the controllers that communicate on the CAN networks
– Identify the inputs/outputs of the SSM, ADU, TCU, ECU and FLC
– Identify the circuits controlled by the SSM, ADU, TCU, ECU and FLC and describe their function
– Trace flow through start circuit and park brake circuit
– Perform the tasks using the monitor
– Describe the operation of the following options
• Reversing Fan
• Ride Control
• Auto-Differential Lock
• Joystick Steering
• Lockup Torque Converter
• Auto-Ether
• Rearview Camera and
Radar Object Detection (ROD)
• Embedded Payload Scale (EPS)
– Identify the location of the Service ADVISORTM connector
– Describe the process for downloading software using the John Deere Custom Performance (JDCP)
web site
– Describe where to retrieve the master security code
 Powertrain

By the end of this lesson, you will be able to:

– Locate and Identify the powertrain components
– Explain the operation of a Powershift Transmission
– Explain the function of the components in the transmission control valve.
– Use a Clutch/Solenoid Engagement Chart and identify what clutches/solenoids are
engaged to obtain a speed and a direction
– Explain the operation of the Lock-up Torque Converter/5-speed transmission
– Explain the operation of the Rear Axle Disconnect
– Describe the type of axles and differentials used in the various K-series 4WD Loaders
– Recall the operational characteristics of the Park Brake
 Powertrain Components

Transmission

Rear Axle

Park Brake

Rear Driveshaft

Front Driveshaft

Front Axle
 ZF® Transmissions

• Standard 4 speeds forward, 3 reverse

• Electronic Controlled Shift Modulation

Model ZF Designation
444K WG130
524K-544K WG160
624K WG190
644K-724K WG210
744K-824K WG260
844K WG310

844K transmission shown

624K transmission shown

 ZF® Transmission Speed Sensors

Torque
Torque Converter
Converter Output
Input Speed Speed
Sensor Sensor
(Impeller) (Turbine)

Internal Clutch
Speed Sensor

Output Shaft
Speed Sensor
 Torque Converter Speed Sensors

Torque Converter Input Speed Sensor Torque

• Monitors Impeller rotation Converter
Output
• Same as Engine rpm Speed
• Speed can be displayed on monitor Sensor
(Turbine)

Torque Converter Output Speed Sensor

• Monitors Turbine Speed
• Used to calculate load on the powertrain
• Speed can be viewed on monitor

Torque
Converter
Input Speed
Sensor
(Impeller)
Internal Clutch Speed Sensor

Internal Clutch
Speed Sensor

Monitors directional clutch pack rotation

 Output Shaft Speed Sensor

• Hall effect 3 wire sensor

• Requires 24 volts to operate

Output Shaft
Speed Sensor
ZF® Transmission Control Valve Test Ports

Torque Converter-In
System Pressure
Pressure

2nd Speed
High Range
Forward

Low Range
Forward Reverse

3rd Speed 1st Speed

 Transmission Oil Flow

MAIN PRESSURE
CONVERTER PRESSURE
LUBE/COOLER PRESSURE OIL FILTER
RETURN PRESSURE CONTROL VALVE

CONVERTER
MINIMUM PRESSURE
REGULATING VALVE TO PARK
BRAKE
TORQUE
CONVERTER TO
COOLER TRANSMISSION
OIL PUMP

CONVERTER SUCTION FROM

RELIEF SCREEN COOLER
VALVE
MANIFOLD
FLEX
PLATE
 Torque Converter Operation

TURBINE IMPELLER
TORQUE CONVERTER
INPUT SPEED
SENSOR
TRANSMISSION
PUMP

TURBINE IMPELLER
SHAFT SHAFT

STATOR

FREEWHEELING CLUTCH
Clutch Pack Operation
 Transmission Control Valve

PRESSURE PRESSURE
REGULATING REDUCING
VALVE VALVE

SOLENOID
CONNECTOR

DAMPER BOOSTER
VALVE VALVE
COVER

MODULATION
CIRCUIT

HOUSING VALVING
 Transmission Pressure
Regulating Circuit

• Pressure regulating valve sets main transmission pressure

• Pressure reducing valve reduces main pressure for proportional solenoids
 Modulation Circuit

• Each clutch has own modulation circuit

• Proportional solenoid – Controlled by TCU
• Booster valve – routes oil to clutch pack
• Dampening Valve – allows for smooth, quiet operation of booster valve
 Transmission Modulation Circuit

Modulation
2 mm Orifice
Circuit
Dampening Valve

Booster Valve
Filter

Proportional
Solenoid
Valve

Clutch Pack Clutch Pack

Engaged NOT Engaged
 5-Speed Transmission/
Lock-up Torque Converter

– 5 speed forward/3 speed reverse transmission

with lock up torque converter
– Electronic controlled shift modulation and
automatic converter lock
– Two modes: automatic and off
 5-Speed Transmission/
Lock-up Torque Converter

Input Criteria Sensor(s) Controller

Engaged Gear FNR TCU

Engine Speed Torque Converter Input Speed TCU

Load Torque Converter Input Speed TCU

and Torque Converter Output
Speed

Ground Speed Calculated via output shaft TCU

speed

Transmission Oil Transmission Oil Temperature TCU

Temperature

Throttle Throttle Position ECU

Brake Brake Pedal TCU

Boom Height Boom Position FLC

Boom Velocity Calculated via Boom Position FLC

 5-Speed Transmission/
Lock-up Torque Converter

TURBINE
IMPELLER

LOCK-UP CLUTCH PLATES

 Park Brake Assembly

• Oil level is important

• Overfilling can cause the
park brake to overheat
 Park Brake Solenoid Valve Manifold

Park Brake
Check Valve
Solenoid
Park Brake Solenoid Valve
Park Brake

• Can be released manually

• Requires 200 – 250 psi to release
• Do not tow over 500 yards and 2 mph
 ZF Model MTL-3065 Axles 444K

ZF model MTL-3065
• Midboard planetary final drives
– 3 planet pinion gears evenly distribute stress, power and
shock load for extended life
– Axle seals protected by planetary casing—no direct path for
debris to wrap around shafts and damage seals
• Wet Disk Brakes
– Hydraulically actuated, oil cooled, self adjusting, self
equalizing, multi-disk brakes
– Braking on high speed, low-torque side of final drive for
improved efficiency over wheel speed brakes
– First recommended inspection is 5000 Hours!
• Remote mounted breather filters minimize contamination risk
• Single point oil fill, multi-point oil drain (see red arrows)

444K 524K 544K 624K 644K 724K 744K 824K 844K

Axle ZF MTL-3065 TM IV TM IV TM IV TM IV TM IV TM II TMII ZF AP420

Planetarie Out-
Mid-Board In-Board In-Board In-Board In-Board In-Board In-Board In-Board
s Board
Multiple Single Single Single Single Single Single Single Multiple
Brakes
Wet Disk Wet Disk Wet Disk Wet Disk Wet Disk Wet Disk Wet Disk Wet Disk Wet Disk
TeamMate IV Axles 524K-724K
 Wet Disk Brakes

Actuating Piston
Brake Disk
Backing Plate
Brake Inspection

Inspection Ports
 Oil Level Check

Axle dipstick
Axle Input Cover

Oil Seal

Grease Barrier

Metal Guard
 444K-724K Axle Coolers

• Optional on 444-724
• Coolers mounted in Quad Cool area
• Pumps mounted to left side of engine
Axle Pumps

Axle Coolers
 Rear Axle Disconnect

Rear Axle
Disconnect Collar
Teammate II Axles 744K-824K

Brake Inspection Ports

 Teammate II Axles 744K-824K

Brake Disk

Backing Plate

Actuating Piston
 Teammate II Axles 744K-824K

Axle pumps Axle filters

ZF® Model AP420 Axle – 844K
 844K Axles

SNAP RING BRAKE PISTON

BACKING PLATE
Axle Circulation Pumps

Oil Sample Port

• Both axles have their own pump and cooler

• Driven off auxiliary drive on left side of engine
• Oil sample ports provided for both axles
Axle Coolers

Axle Coolers
 Powertrain Lesson Summary

In this lesson, you learned how to:

– Locate and Identify the powertrain components
– Explain the operation of a Powershift Transmission
– Explain the function of the components in the transmission control valve.
– Use a Clutch Engagement Chart and identify what clutches are engaged to obtain a speed
and a direction
– Explain the operation of the Lock-up Torque Converter/5-speed transmission
– Explain the operation of the Rear Axle Disconnect
– Describe the type of axles and differentials used in the various K-series 4WD Loaders
– Recall the operational characteristics of the Park Brake
 Hydraulics

By the end of this lesson you will be able to:

– Locate and identify the major hydraulic components
– Define the terms Load Sense and Differential Pressure
– Recall the operation of the Pump Displacement Control Valve
– Recall the function of the Steering pre-compensator Valve
– Identify the components on the Hydraulic Manifold
– Identify the components on the Loader Control Valve
– Recall the function of the Power Limiting Valve
– Explain the operation of the Hydraulic Driven Fan
– Explain the operation of the Ride Control Circuit
– Explain the operation of the Secondary Steering Circuit
 Hydraulics

• 444K-724K System
– Pilot operated
– Closed Center
– Pressure-flow compensating
– Load sensing
– One main pump
– Fixed displacement fan drive pump
• 744K-844K System
– Closed Center
– Load sensing
– 2 main pumps
– Variable displacement fan drive pump

444K 524K 544K 624K 644K 724K 744K 824K 844K

Pump(s) Rexroth Rexroth Rexroth Rexroth Parker Parker 2- Parker 2- Parker 2- Parker
Control Valve VP170 VP170 VP170 VP170 PC55 PC55 VG80 VG80 VG80
System Type PCLS PCLS PCLS PCLS PCLS PCLS LS LS LS
 Hydraulic Reservoir

Breather Filter

Sight Gauge
Hydraulic Return Filter

Restriction Switch

Return Filter
 Main Hydraulic Pump

Load Sense Test Port

Hydraulic Pump
 Hydraulic Terms

• Pump Discharge Pressure - Pressure reading taken as close to the pump outlet as possible

• Load Sense – Highest Work Port Pressure

• Differential Pressure – Difference between Pump Discharge and Load Sense

 Pump Displacement Control Valve

Pressure
Cut-off Valve

Differential
Pressure Valve Load Sense Relief Valve
Pump Control
Hydraulic Pump Manifold
 Steering Pre-Compensator Valve

Steering
Pre-Compensator
Valve
STEERING
VALVE

STEERING
CYLINDERS
Pilot Pressure Reducing Valve

Pilot Pressure
Reducing Valve
 Differential Lock & Park Brake

Differential Lock Park Brake

Solenoid Valve Solenoid Valve
 Pilot Enable Solenoid Valve, Accumulator
Solenoid Valve, Check Valve #1

Check Valve #1

Pilot Enable
 Differential Lock Solenoid Valve

Differential Lock
Solenoid Valve
 Park Brake Circuit

Park Brake
Check
Solenoid Valve
Valve #2
 Shuttle Check LS-1

LS-1 Shuttle Check

744K-824K Hydraulic Pump Manifold
744K-844K Hydraulic Pump Manifold
Load Sense Relief &
Power Management
 Pre-Compensator and Priority Valve

Boom Down
Accumulator
Solenoid

Pilot Enable Park Brake

Solenoid Valve Solenoid
 Hydraulic Manifold

Park Brake Load sense relief Valve

Solenoid

Pilot Enable
Solenoid Valve

Boom Down
Accumulator
Solenoid

Pressure
Reducing
Valve
844K Hydraulic Manifold

LS Scenario Pump Displacement

Steering Only Pump 2
Loader Only Pump 1 = Pump 2
Steer < Loader Pump 1 = Pump 2
Steer > Loader Pump 2 > Pump 1
 444K-624K Loader Control Valve

Outlet

Boom
Bucket

Inlet Auxiliary
 444K-624K Loader Control Valve

Orifice Checks
Circuit Relief Valve
 Variable Compensator, Lift Check
& Check Valves

Variable Compensator Lift Check

C1 & C2
Compensator Animation
Tank Pressure Reducing Valve
 644K-724K Control Valve

Inlet
Bucket

Boom Auxiliary

Outlet

Load Sense Relief

Compensators
 744K-824K Control Valve

Auxiliary Clipper
Relief

Bucket Inlet Section

Boom
Load Sense
Outlet Section Check Valves
 Load Sense Circuit

Check valves route the highest load sense signal to the pump displacement control valve.
 844K Control Valve

Boom

Bucket

Auxiliary

Split Manifold

Clipper Relief
844K Control Valve
 Fan Drive Circuit

Model Fan System

444K-724K Gear pump--gear motor
744K-844K Variable displacement, axial piston pump--fixed displacement, axial piston motor

Fan Pump

444K-724K 744K-844K
 Fan Pump and Motor
444K-724K

Fan Motor

Fan Pump
 Fan Manifold
444K-724K

Proportional Reverse
Solenoid Solenoid

Reverse
Solenoid

Proportional
Solenoid
 Fan Pump and Motor
744K-844K

Fan Pump and

Control Valve

Fan Motor
Non-Reversing Manifold
744K-824K
Fan Drive Circuit
 Ride Control Components

Ride Control Valve Ride Control Accumulator

Bucket Pressure Switch

 Ride Control Valve

ON/OFF Solenoids

Boom Solenoid

Test Port
Ride Control Animation
Ride Control
 Secondary Steering

• Provides temporary oil flow to the steering

• Consists of:
– Secondary steering pump
– Secondary steering motor
– Manifold that contains pressure switch and two check valves
• Located inside engine frame to left of transmission
Secondary Steering
Secondary Steering
Pin Disconnect
Hydraulic Power Management Valve

HYDRAULIC POWER
MANAGEMENT VALVE

PROPORTIONAL
RELIEF VALVE
Joystick Steering Valve
 Joystick Steering Valve

Pilot Pressure

Servo’s Transducer
 Hydraulics Lesson Summary

In this lesson, you learned how to:

– Locate and identify the major hydraulic components
– Define the terms Load Sense and Differential Pressure
– Recall the operation of the Pump Displacement Control Valve
– Recall the function of the Steering pre-compensator Valve
– Identify the components on the Hydraulic Manifold
– Identify the components on the Loader Control Valve
– Recall the function of the Power Limiting Valve
– Explain the operation of the Hydraulic Driven Fan
– Explain the operation of the Ride Control Circuit
– Explain the operation of the Secondary Steering Circuit