You are on page 1of 490

240 and 250

Skid Steer
Serial No. ( 100100 - )

TECHNICAL
MANUAL

John Deere
Commercial Worksite Products
TM1747 (Nov00)
Replaces TM1747 (July99)

Litho in U.S.A
240 and 250 TM1747 (Nov2000)
Skid Steer
INTRODUCTION

This technical manual is written for an experienced


technician and contains sections that are specifically for
this product. It is a part of a total product support Safety
program.

Specifications and
Information

The manual is organized so that all the information on a


particular system is kept together. The order of grouping
is as follows:
• Table of Contents
• Specifications
• Theory of Operation
Engine (Diesel)
• Troubleshooting Diagram
• Diagnostics
• Tests & Adjustments Electrical
• Repair

Note: Depending on the particular section or system Power Train


being covered, not all of the above groups may be
used. (Chain Case and Axles)

Power Train
Power Train
(Hydrostatic)
Each section will be identified with a symbol rather than a
number. The groups and pages within a section will be Steering
consecutively numbered.

Brakes

All information, illustrations and specifications in this


manual are based on the latest information available at
the time of publication. The right is reserved to make
Hydraulics
changes at any time without notice.

We appreciate your input on this manual. To help, there


are postage paid post cards included at the back. If you
find any errors or want to comment on the layout of the
manual please fill out one of the cards and mail it back to
us.
Miscellaneous

COPYRIGHT© 2000
JOHN DEERE COMMERICAL WORKSITE PRODUCTS
Knoxville, Tennessee
All rights reserved
Previous Editions
Copyright© 1999 Deere & Company

11/22/00 1-1
SAFETY

RECOGNIZE SAFETY INFORMATION HANDLE FLUIDS SAFELY—AVOID


FIRES
Be Prepared For Emergencies

This is the safety-alert symbol. When you see this


symbol on your machine or in this manual, be alert to
the potential for personal injury.

Follow recommended precautions and safe servicing


practices.

Understand Signal Words


A signal word—DANGER, WARNING, or CAUTION—is
used with the safety-alert symbol. DANGER identifies
the most serious hazards.

DANGER or WARNING safety signs are located near


specific hazards. General precautions are listed on
When you work around fuel, do not smoke or work near
CAUTION safety signs. CAUTION also calls attention to
heaters or other fire hazards.
safety messages in this manual.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
REPLACE SAFETY SIGNS
Make sure machine is clean of trash, grease, and
debris.

Do not store oily rags; they can ignite and burn


spontaneously.

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance


service, hospital, and fire department near your
telephone.

Replace missing or damaged safety signs. See the


machine operator’s manual for correct safety sign
placement.

1-2 11/22/00
SAFETY

USE CARE IN HANDLING AND USE CARE AROUND HIGH-


SERVICING BATTERIES PRESSURE FLUID LINES
Avoid High-Pressure Fluids

Prevent Battery Explosions


• Keep sparks, lighted matches, and open flame
away from the top of battery. Battery gas can
explode. Escaping fluid under pressure can penetrate the skin
• Never check battery charge by placing a metal causing serious injury.
object across the posts. Use a volt-meter or
hydrometer.
• Do not charge a frozen battery; it may explode.
Warm battery to 16°C (60°F). Avoid injury from escaping fluid under pressure by
stopping the engine and relieving pressure in the
Prevent Acid Burns system before disconnecting or connecting hydraulic or
other lines. Tighten all connections before applying
• Sulfuric acid in battery electrolyte is poisonous. It is pressure.
strong enough to burn skin, eat holes in clothing,
and cause blindness if splashed into eyes. Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
• Avoid acid burns by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves. If an accident occurs, see a doctor immediately. Any
3. Avoiding breathing fumes when electrolyte is fluid injected into the skin must be surgically removed
added. within a few hours or gangrene may result. Doctors
4. Avoiding spilling or dripping electrolyte. unfamiliar with this type of injury should reference a
5. Using proper jump start procedure. knowledgeable medical source. Such information is
available from Deere & Company Medical Department
in Moline, Illinois, U.S.A., (1-800-822-8262 U.S.A. or
• If you spill acid on yourself:
Canada).
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the
acid.
3. Flush your eyes with water for 10—15 minutes.
4. Get medical attention immediately.

• If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.

11/22/00 1-3
SAFETY

Avoid Heating Near Pressurized Service Machines Safely


Fluid Lines

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


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

Flammable spray can be generated by heating near


pressurized fluid lines, resulting in severe burns to Remove rings and other jewelry to prevent electrical
yourself and bystanders. Do not heat by welding, shorts and entanglement in moving parts.
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can be Use Proper Tools
accidentally cut when heat goes beyond the immediate
flame area. Use tools appropriate to the work. Makeshift tools and
procedures can create safety hazards. Use power tools
only to loosen threaded parts and fasteners. For
USE SAFE SERVICE PROCEDURES loosening and tightening hardware, use the correct size
tools. DO NOT use U.S. measurement tools on metric
Wear Protective Clothing fasteners. Avoid bodily injury caused by slipping
wrenches. Use only service parts meeting John Deere
specifications.

Park Machine Safely

Wear close fitting clothing and safety equipment


appropriate to the job.

Prolonged exposure to loud noise can cause M55689


impairment or loss of hearing. Wear a suitable hearing
protective device such as earmuffs or earplugs to Before working on the machine:
protect against objectionable or uncomfortable loud 1. Lower all equipment to the ground.
noises. 2. Relieve hydraulic pressure.
3. Stop the engine and remove the key.
4. Disconnect the battery ground strap.
Operating equipment safely requires the full attention of 5. Hang a “DO NOT OPERATE” tag in operator
the operator. Do not wear radio or music headphones station.
while operating machine.

1-4 11/22/00
SAFETY

Support Machine Properly and Use Work In Ventilated Area


Proper Lifting Equipment

Engine exhaust fumes can cause sickness or death. If it


If you must work on a lifted machine or attachment, is necessary to run an engine in an enclosed area,
securely support the machine or attachment. remove the exhaust fumes from the area with an
exhaust duct system.

Do not support the machine on cinder blocks, hollow


tiles, or props that may crumble under continuous load. If you do not have an exhaust duct system, open the
Do not work under a machine that is supported solely by doors and get outside air into the area.
a jack. Follow recommended procedures in this manual.
WARNING: California Proposition 65
Warning
Lifting heavy components incorrectly can cause severe
injury or machine damage. Follow recommended Diesel engine exhaust and some of its constituents are
procedure for removal and installation of components in known to the State of California to cause cancer, birth
the manual. defects, and other reproductive harm.

Work In Clean Area Remove Paint Before Welding or


Heating
Before starting a job:
Avoid potentially toxic fumes and dust. Hazardous
1. Clean work area and machine. fumes can be generated when paint is heated by
2. Make sure you have all necessary tools to do your welding, soldering, or using a torch. Do all work outside
job. or in a well-ventilated area. Dispose of paint and solvent
3. Have the right parts on hand. properly. Remove paint before welding or heating. If you
4. Read all instructions thoroughly; do not attempt sand or grind paint, avoid breathing the dust. Wear an
shortcuts. approved respirator. If you use solvent or paint stripper,
remove stripper with soap and water before welding.
Using High Pressure Washers Remove solvent or paint stripper containers and other
Directing pressurized water at electronic/electrical flammable material from area. Allow fumes to disperse
components or connectors, bearings, hydraulic seals, at least 15 minutes before welding or heating.
fuel injection pumps or other sensitive parts and
components may cause product malfunctions. Reduce
pressure and spray component at a 45 to 90 degree
angle.

Illuminate Work Area Safely


Illuminate your work area adequately but safely. Use a
portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire
cage. The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.

11/22/00 1-5
SAFETY

SERVICE TIRES SAFELY SERVICE COOLING SYSTEM


SAFELY

Explosive separation of a tire and rim parts can cause


serious injury or death.
Explosive release of fluids from pressurized cooling
system can cause serious burns.
Do not attempt to mount a tire unless you have the Shut off machine. Only remove filler cap when cool
proper equipment and experience to perform the job. enough to touch with bare hands. Slowly loosen cap to
Always maintain the correct tire pressure. Do not inflate first stop to relieve pressure before removing
the tires above the recommended pressure. Never weld completely.
or heat a wheel and tire assembly. The heat can cause
an increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.

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


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

Check wheels for low pressure, cuts, bubbles, damaged


rims or missing lug bolts and nuts.

1-6 11/22/00
SAFETY

HANDLE CHEMICAL PRODUCTS LIVE WITH SAFETY


SAFELY

Direct exposure to hazardous chemicals can cause


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

A Material Safety Data Sheet (MSDS) provides specific Before returning machine to customer, make sure
details on chemical products: physical and health machine is functioning properly, especially the safety
hazards, safety procedures, and emergency response systems. Install all guards and shields.
techniques. Check the MSDS before you start any job
using a hazardous chemical. That way you will know
exactly what the risks are and how to do the job safely.
Then follow procedures and recommended equipment.

Dispose of Waste Properly


Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste
used with John Deere equipment include such items as
oil, fuel, coolant, brake fluid, filters, and batteries. Use
leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them. Do not pour waste onto the
ground, down a drain, or into any water source. Inquire
on the proper way to recycle or dispose of waste from
your local environmental or recycling center, or from
your John Deere dealer.

11/22/00 1-7
SAFETY

This page intentionally left blank.

1-8 11/22/00
SPECIFICATIONS AND INFORMATION CONTENTS

CONTENTS
SPECIFICATIONS AND INFORMATION
Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ELECTRICAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HYDRAULICS AND HYDROSTATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIMENSIONS—240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIMENSIONS—250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RECOMENDED LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
METRIC FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . 5
METRIC FASTENER TORQUE VALUES—GRADE 7 . . . . . . . . . . . . . . . 6
INCH FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
O-RING SEAL SERVICE RECOMMENDATIONS . . . . . . . . . . . . . . . . . . 8
FACE SEAL FITTINGS WITH INCH STUD ENDS TORQUE . . . . . . . . . . . . . . . . . . . 8
FACE SEAL FITTINGS WITH METRIC STUD ENDS TORQUE . . . . . . . . . . . . . . . . . 9
O-RING FACE SEAL FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
O-RING BOSS FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIESEL FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
LUBRICITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ENGINE OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-CYCLE DIESEL ENGINE OIL—NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . 12
BREAK-IN DIESEL ENGINE OIL—NORTH AMERICA. . . . . . . . . . . . . . . . . . . . . . . 13
HYDROSTATIC TRANSMISSION AND HYDRAULIC OIL—NORTH AMERICA. . . . 13
CHAIN CASE OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHAIN CASE OIL—NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
GENERAL APPLICATION GREASE SPECIFICATIONS . . . . . . . . . . . . 15
GREASE—NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
COOLANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIESEL AND GASOLINE ENGINE COOLANT—NORTH AMERICA . . . . . . . . . . . . 15
SUPPLEMENTAL COOLANT ADDITIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIESEL AND GASOLINE ENGINE COOLANT DRAIN INTERVAL—NORTH
AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SKID STEER PRODUCT IDENTIFICATION NUMBER. . . . . . . . . . . . . . . . . . . . . . . 17
ENGINE SERIAL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

11/22/00 2-1
SPECIFICATIONS SPECIFICATIONS AND INFORMATION

SPECIFICATIONS

ENGINE
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .John Deere
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel
Engine Model Number
• 240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3029D
• 250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3029T
Net Horsepower at rated engine RPM (2400 RPM)
• 240 (S/N -240852). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.3 kW (46 hp)
• 240 (S/N 240853- ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 kW (51 hp)
• 250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.5 kW (61 hp)
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 mm (4.17 in.)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 mm (4.33 in.)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 L (179 cu in.)
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.8:1
Rated Engine RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2400
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Full pressure
Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full flow (replaceable)
Air Cleaner . . . . . . . . . . . . . . .Dry paper with primary and secondary elements
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid-cooled

FUEL SYSTEM
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel #2
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In-line replaceable filter
Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric
Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rotary injection

ELECTRICAL SYSTEM
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-volt, electric start
Charging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator, 55 amp
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .750 CCA (cold cranking amps)

CAPACITIES
Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.7 L (15 gal)
Hydraulic Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6 L (4.1 gal)
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 L (6 gal)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 L (10 qt)
Engine Oil (with Filter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 L (6.9 qt)
Chain Case (per Side). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4 L (3 gal)

2-2 11/22/00
SPECIFICATIONS AND INFORMATION SPECIFICATIONS

HYDRAULICS AND HYDROSTATICS


Hydrostatic Pumps
• Type. . . . . . . . . . . . . . . . . . . . . . . Tandem variable displacement piston pump
• Displacement (Max) . . . . . . . . . . . . . . . . . . .40.6 cm3 (2.48 in3) per revolution
Hydrostatic Motors
• Type. . . . . . . . . . . . . . . . . . . . . . . . . GEROLER® fixed displacement 30 series
Hydraulic/Charge Pump (Standard Flow)
• 240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.1 L/min (13 gpm)
• 250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.7 L/min (15 gpm)
Hydraulic/Charge Pump with High-Flow (Optional)
• 240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.8 L/min (22.4 gpm)
• 250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98.1 L/min (25.9 gpm)
Hydrostatic System Relief Pressure . . . . . . . . . . . . . . . . 34 474 kPa (5000 psi)
Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1448 kPa (210 psi)
Hydraulic Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 spool open center
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spin-on canister
Hydraulic System Relief Pressure. . . . . . . . . . . . . . . . . . 21 374 kPa (3100 psi)
Boom Circuit Relief Pressure . . . . . . . . . . . . . . . . . . . . . 22 753 kPa (3300 psi)
Bucket Circuit Relief Pressure (early models only) . . . . . . . . . . . . . . . . . . . . N/A
Note: Bucket relief valve should have been removed in Safety PIP 99KV004 or 00KV007
Boom Breakout Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1406 kg (3100 lb)
Bucket Breakout Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2495 kg (5500 lb)

DIMENSIONS—240
(See note below.)

Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2811 kg (6195 lb)


SAE Rated Operating Capacities . . . . . . . . . . . . . . . . . . . . . . . 681 kg (1500 lb)
Maximum Ground Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7 km/h (7.3 mph)
Overall Operating Height. . . . . . . . . . . . . . . . . . . . . . . . . . . 3599 mm (141.7 in.)
Height to ROPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1915 mm (75.4 in.)
Height to Hinge Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2895 mm (114 in.)
Overall Width (less Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . 1627 mm (64.1 in.)
Overall Width (with Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1676 mm (66 in.)
Overall Length (less Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . 2591 mm (102 in.)
Overall Length (with Bucket) . . . . . . . . . . . . . . . . . . . . . . . . 3196 mm (125.8 in.)
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1075 mm (42.3 in.)
Ground Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 mm (8.2 in.)
Dump Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2255 mm (88.8 in.)
Dump Reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 738 mm (29.1 in.)
Dump Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees
Bucket Rollback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 degrees
Angle of Departure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 degrees

NOTE: Standard tires (10 x 16.5) and 66 in. foundry bucket used in
determining dimensions.

GEROLER is a registered trademark of Eaton Corporation.

11/22/00 2-3
SPECIFICATIONS SPECIFICATIONS AND INFORMATION

DIMENSIONS—250
(See note below.)

Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2854 kg (6290 lb)


SAE Rated Operating Capacities . . . . . . . . . . . . . . . . . . . . . . . 794 kg (1750 lb)
Maximum Ground Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4 km/h (7.1 mph)
Overall Operating Height. . . . . . . . . . . . . . . . . . . . . . . . . . . 3637 mm (143.2 in.)
Height to ROPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1950 mm (76.8 in.)
Height to Hinge Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2925 mm (115.2 in.)
Overall Width (less Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . 1750 mm (68.9 in.)
Overall Width (with Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1829 mm (72 in.)
Overall Length (less Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . 2591 mm (102 in.)
Overall Length (with Bucket) . . . . . . . . . . . . . . . . . . . . . . . . 3196 mm (125.8 in.)
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1075 mm (42.3 in.)
Ground Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 mm (9.6 in.)
Dump Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2290 mm (90.2 in.)
Dump Reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715 mm (28.1 in.)
Dump Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees
Bucket Rollback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 degrees
Angle of Departure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 degrees

NOTE: Standard tires (12 x 16.5) and 72 in. foundry bucket used in
determining dimensions.

TIRES
240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 x 16.5
250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 x 16.5

RECOMENDED LUBRICANTS
Engine Oil . . . . . . . . . . . . . . . . . . . . . John Deere TORQ-GARD SUPREME® or
PLUS-50®
(See ENGINE OIL in the ENGINE section for cold weather oil)
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere COOL-GARD™
Hydraulic Oil and Hydrostatic Oil . . . . . . . . . . . . . . . . . John Deere HY-GARD®
John Deere Low Viscosity HY-GARD® (cold weather operation)
Grease . . . . . . . . . . . . . . . . . John Deere HIGH TEMPERATURE EP GREASE
John Deere MOLY HIGH TEMPERATURE EP GREASE (non-clay)
Chain Case Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere HY-GARD®
John Deere Low Viscosity HY-GARD® (cold weather operation)
John Deere TORQ-GARD SUPREME® or PLUS-50®

HY-GARD, TORQ-GARD SUPREME and PLUS-50 are is a registered trademarks of Deere & Company.

2-4 11/22/00
SPECIFICATIONS AND INFORMATION METRIC FASTENER TORQUE VALUES

METRIC FASTENER TORQUE VALUES


4.8 8.8 9.8 10.9 12.9
Property
Class
and 4.8 8.8 9.8 10.9 12.9
Head
Markings 4.8 8.8 9.8 10.9 12.9 12.9

Property 5 10 10 12
Class
and

10
10

12
5

Nut 5 10 10 12
Markings
TS1163

Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

Lubricateda Drya Lubricateda Drya Lubricateda Drya Lubricateda Drya

SIZE N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft

M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5

M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35

M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70

M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120

M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 109

M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300

M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410

M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580

M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800

M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000

M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500

M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000

M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750

M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500

DO NOT use these hand torque values if a different torque value or tightening procedure is given for a specific
application. Torque values listed are for general use only and include a ±10% variance factor. Check tightness of
fasteners periodically. DO NOT use air powered wrenches.
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same class. Make sure fastener threads are clean and that you properly
start thread engagement. This will prevent them from failing when tightening.
When bolt and nut combination fasteners are used, torque values should be applied to the NUT instead of the bolt
head.
Tighten toothed or serrated-type lock nuts to the full torque value.
a. “Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry”
means plain or zinc plated (yellow dichromate - Specification JDS117) without any lubrication.

Reference: JDS—G200.

11/22/00 2-5
METRIC FASTENER TORQUE VALUES—GRADE 7 SPECIFICATIONS AND INFORMATION

METRIC FASTENER TORQUE VALUES—GRADE 7

Steel or Gray Aluminum


Iron Torque Torque
Size
N•m lb-ft N•m lb-ft

M6 11 8 8 6

M8 24 18 19 14

M10 52 38 41 30
M12 88 65 70 52

M14 138 102 111 82

M16 224 165 179 132

2-6 11/22/00
SPECIFICATIONS AND INFORMATION INCH FASTENER TORQUE VALUES

INCH FASTENER TORQUE VALUES


1 or 2b 5 5.1 5.2 8 8.2
SAE
Grade
and Head No Marks
Markings

2 5 8
SAE
Grade No Marks
and Nut
Markings
TS1162

Grade 1 Grade 2b Grade 5, 5.1 or 5.2 Grade 8 or 8.2

Lubricateda Drya Lubricateda Drya Lubricateda Drya Lubricateda Drya

SIZE N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft

1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5

5/16 7.7 5.5 10 7 12 9 15 11 20 15 25 18 28 21 35 26

3/8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46

7/16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75

1/2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115

9/16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160

5/8 67 50 85 62 105 78 135 100 170 125 215 160 215 160 300 225

3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400

7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650

1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975

1-1/8 470 300 510 375 470 300 510 375 900 675 1150 850 1450 1075 1850 1350

1-1/4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950

1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550

1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350

DO NOT use these hand torque values if a different torque value or tightening procedure is given for a specific
application. Torque values listed are for general use only and include a ±10% variance factor. Check tightness of
fasteners periodically. DO NOT use air powered wrenches.
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same grade. Make sure fastener threads are clean and that you properly
start thread engagement. This will prevent them from failing when tightening.
When bolt and nut combination fasteners are used, torque values should be applied to the NUT instead of the bolt
head.
Tighten toothed or serrated-type lock nuts to the full torque value.
a. “Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry”
means plain or zinc plated (yellow dichromate - Specification JDS117) without any lubrication.
b. “Grade 2” applies for hex cap screws (not hex bolts) up to 152 mm (6-in.) long. “Grade 1” applies for hex
cap screws over 152 mm (6-in.) long, and for all other types of bolts and screws of any length.

Reference: JDS—G200.

11/22/00 2-7
O-RING SEAL SERVICE RECOMMENDATIONS SPECIFICATIONS AND INFORMATION

O-RING SEAL SERVICE RECOMMENDATIONS

FACE SEAL FITTINGS WITH INCH STUD ENDS TORQUE

Stud End Tube Nut

Stud Straight and Tube Nut Swivel Nut


Lock Nut
Tube Nut
Stud End
90° Swivel Elbow and Tube Nut
90° Adjustable Stud Elbow
Bulkhead Union and Bulkhead Lock Nut

Nominal Tube OD/Hose ID Face Seal Tube/Hose End O-Ring Stud Ends

Metric Tube Nut/ Bulkhead


Thread Straight Fitting or
Tube Inch Tube OD Thread Size Swivel Nut Lock Nut
Size Lock Nut Torque
OD Torque Torque

Dash
mm in. mm in. N•m lb-ft N•m lb-ft in. N•m lb-ft
Size
-3 0.188 4.76 3/8-24 8 6
6 -4 0.250 6.35 9/16-18 16 12 12 9 7/16-20 12 9
8 -5 0.312 7.94 1/2-20 16 12
10 -6 0.375 9.52 11/16-16 24 18 24 18 9/16-18 24 18
12 -8 0.500 12.70 13/16-16 50 37 46 34 3/4-16 46 34
16 -10 0.625 15.88 1-14 69 51 62 46 7/8-14 62 46
-12 0.750 19.05 1-3/16-12 102 75 102 75 1-1/16-12 102 75
22 -14 0.875 22.22 1-3/16-12 102 75 102 75 1-3/16-12 122 90
25 -16 1.000 25.40 1-7/16-12 142 105 142 105 1-5/16-12 142 105
32 -20 1.25 31.75 1-11/16-12 190 140 190 140 1-5/8-12 190 140
38 -24 1.50 38.10 2-12 217 160 217 160 1-7/8-12 217 160

NOTE: Torque tolerance is plus 15 minus 20%.

2-8 11/22/00
SPECIFICATIONS AND INFORMATION O-RING SEAL SERVICE RECOMMENDATIONS

FACE SEAL FITTINGS WITH METRIC


STUD ENDS TORQUE
Stud End Tube Nut

Groove For Metric Identification


Swivel Nut
Stud Straight and Tube Nut Lock Nut
Tube Nut
Groove For Metric
Identification Stud End
90° Swivel Elbow and Tube Nut
90° Adjustable Stud Elbow
Bulkhead Union and Bulkhead Lock Nut

O-Ring Stud Ends,


Nominal Tube OD/Hose ID Face Seal Tube/Hose End
Straight Fitting or Lock Nut

Tube Nut/
Metric Bulkhead Steel or
Thread Hex Swivel Thread Hex Aluminum
Tube Inch Tube OD Lock Nut Gray Iron
Size Size Nut Size Size Torque
OD Torque Torque
Torque

Dash
mm in. mm in. mm N•m lb-ft N•m lb-ft mm mm N•m lb-ft N•m lb-ft
Size
6 -4 0.250 6.35 9/16-18 17 16 12 12 9 M12X1.5 17 21 15.5 9 6.6
8 -5 0.312 7.94
M14X1.5 19 33 24 15 11
10 -6 0.375 9.52 11/16-16 22 24 18 24 18 M16X1.5 22 41 30 18 13
12 -8 0.500 12.70 13/16-16 24 50 37 46 34 M18X1.5 24 50 37 21 15
16 -10 0.625 15.88 1-14 30 69 51 62 46 M22X1.5 27 69 51 28 21
-12 0.750 19.05 1-3/16-12 36 102 75 102 75 M27X2 32 102 75 46 34
22 -14 0.875 22.22 1-3/16-12 36 102 75 102 75 M30X2 36
25 -16 1.000 25.40 1-7/16-12 41 142 105 142 105 M33X2 41 158 116 71 52
28 M38X2 46 176 130 79 58
32 -20 1.25 31.75 1-11/16-12 50 190 140 190 140 M42X2 50 190 140 85 63
38 -24 1.50 38.10 2-12 60 217 160 217 160 M48X2 55 217 160 98 72

NOTE: Torque tolerance is plus 15 minus 20%.

11/22/00 2-9
O-RING SEAL SERVICE RECOMMENDATIONS SPECIFICATIONS AND INFORMATION

O-RING FACE SEAL FITTINGS .

Sealing Surface

Special Nut

Special Washer Angle Fitting

O-Ring

Sealing Surface
3. For angle fittings, loosen special nut and push
special washer against threads so O-ring can be
installed into the groove of fitting.
1. Inspect the fitting sealing surfaces. They must be 4. Turn fitting into the boss by hand until special
free of dirt or defects. washer or washer face (straight fitting) contacts
2. Inspect the O-ring. It must be free of damage or boss face and O-ring is squeezed into its seat.
defects. 5. To position angle fittings, turn the fitting counter-
3. Lubricate O-rings and install into groove using clockwise a maximum of one turn.
petroleum jelly to hold in place. 6. Tighten straight fittings to torque value shown on
4. Push O-ring into the groove with plenty of chart. For angle fittings, tighten the special nut to
petroleum jelly so O-ring is not displaced during value shown in the chart while holding body of
assembly. fitting with a wrench.
5. Index angle fittings and tighten by hand pressing
joint together to insure O-ring remains in place. STRAIGHT FITTING OR SPECIAL NUT TORQUE
6. Tighten fitting or nut to torque value shown on the
chart per dash size stamped on the fitting. Do not Torquea
allow hoses to twist when tightening fittings. Thread Number
Size of Flatsb
N•m lb-ft
O-RING BOSS FITTINGS 3/8-24 UNF 8 (6) 2
1. Inspect boss O-ring boss seat. It must be free of dirt
and defects. If repeated leaks occur, inspect for 7/16-20 UNF 12 (9) 2
defects with a magnifying glass. Some raised
1/2-20 UNF 16 (12) 2
defects can be removed with a slip stone.
9/16-18 UNF 24 (18) 2
Groove
O-Ring 3/4-16 UNF 46 (34) 2

7/8-14 UNF 62 (46) 1-1/2

1-1/16-12 UN 102 (75) 1

1-3/16-12 UN 122 (90) 1

1-5/16-12 UN 142 (105) 3/4


1-5/8-12 UN 190 (140) 3/4

2. Put hydraulic oil or petroleum jelly on the O-ring. 1-7/8-12 UN 217 (160) 1/2
Place electrical tape over the threads to protect O- a. Torque tolerance is ± 10%.
ring from nicks. Slide O-ring over the tape and into b. To be used if a torque wrench cannot be used.
the groove of fitting. Remove tape. After tightening fitting by hand, put a mark on nut or
boss; then tighten special nut or straight fitting the
number of flats shown.

2 - 10 11/22/00
SPECIFICATIONS AND INFORMATION DIESEL FUEL SPECIFICATIONS

DIESEL FUEL SPECIFICATIONS STORAGE

In general, diesel fuels are blended to satisfy the low air IMPORTANT: DO NOT USE GALVANIZED
temperature requirements of the geographical area in CONTAINERS—diesel fuel stored in galvanized
which they are sold. containers reacts with zinc coating in the
• Use Grade No. 2-D fuel at temperatures above 4°C container to form zinc flakes. If fuel contains
(40°F). water, a zinc gel will also form. The gel and
flakes will quickly plug fuel filters and damage
• For maximum filter life, sediment and water should fuel injectors and injection pumps.
not be more than 0.10%.
• The cetane number should be 45 minimum. If you
operate your machine where air temperatures are It is recommended that diesel fuel be stored ONLY in a
normally low or in high altitudes, you may need fuel clean, approved POLYETHYLENE PLASTIC container
with a higher cetane number. WITHOUT any metal screen or filter. This will help
• Cloud Point - For cold weather operation, cloud prevent any accidental sparks from occurring. Store
point should be 6°C (10°F) below lowest normal air fuel in an area that is well ventilated to prevent possible
temperature. igniting of fumes by an open flame or spark, this
• In winter use special winter fuel or add an anti- includes any appliance with a pilot light.
gelling compound to fuel to maintain its proper
viscosity.
IMPORTANT: Keep all dirt, scale, water or other
If diesel fuel being used has a sulfur content foreign material out of fuel.
greater than 0.5%, reduce the service interval
for engine oil and filter by 50%. Keep fuel in a safe, protected area and in a clean,
properly marked (“DIESEL FUEL”) container. DO NOT
Bio-Diesel Fuels with bio-degradable properties that use de-icers to attempt to remove water from fuel. DO
meet specification DIN 51606 or equivalent may be
NOT depend on fuel filters to remove water from fuel. It
used.
is recommended that a water separator be installed in
the storage tank outlet. BE SURE to properly discard
Consult your local diesel fuel distributor for properties
unstable or contaminated diesel fuel and/or their
of the diesel fuel available in your area.
containers when necessary.

c WARNING
California Proposition 65 Warning: Diesel engine
exhaust and some of its elements from this
product are known to the State of California to
cause cancer, birth defects, or other
reproductive harm.

LUBRICITY
Diesel fuel must have adequate lubricity to ensure
proper operation and durability of fuel injection system
components. Fuel lubricity should pass a minimum of
3300 gram load level as measured by the BOCLE
scuffing test.

11/22/00 2 - 11
ENGINE OIL SPECIFICATIONS SPECIFICATIONS AND INFORMATION

ENGINE OIL SPECIFICATIONS

4-CYCLE DIESEL ENGINE OIL—


NORTH AMERICA
Use the appropriate oil viscosity based on the expected

SAE 30
air temperature range during the period between

SAE 15W-40
recommended oil changes. Operating outside of these
recommended oil air temperature ranges may cause
premature engine failure.

SAE10W-30
The following oil is preferred AFTER first 100 hours of

SAE 5W-30
break-in oil is used:
• John Deere TORQ-GARD SUPREME or John
Deere PLUS-50

Other oils may be used if they meet one of the


following:
• API Service Classification CE
• API Service Classification CD
• CCMC Specification D5
• CCMC Specification D4 PREFERRED

AIR TEMPERATURE M58275


If John Deere TORQ-GARD SUPREME or John Deere
PLUS-50 engine oil and a John Deere oil filter are
used after first 100 hours, the oil and filter service
interval may be extended by 50%.
If diesel fuel exceeding 0.5% sulfur content is used,
reduce the service interval for engine oil and filter by
50%.
Oils meeting Military Specification MIL-L-46167B may
be used as arctic oils.

2 - 12 11/22/00
SPECIFICATIONS AND INFORMATION ENGINE OIL SPECIFICATIONS

BREAK-IN DIESEL ENGINE OIL— HYDROSTATIC TRANSMISSION AND


NORTH AMERICA HYDRAULIC OIL—NORTH AMERICA
Use the following oil viscosity based on the air
IMPORTANT: ONLY use this specified break-in oil
temperature range. Operating outside of the
in rebuilt or remanufactured engines for the first
recommended oil air temperature range may cause
100 hours (maximum) of operation. DO NOT use
premature hydrostatic transmission or hydraulic system
PLUS-50®, SAE 15W40 oil or oils meeting
failures.
specifications API CG-4 or API CF-4, these oils
will not allow rebuilt or remanufactured engines
to break in properly. IMPORTANT: DO NOT use BIO-HY-GARD® in this
system.
The following John Deere oil is PREFERRED:
• BREAK-IN ENGINE OIL.
The following John Deere engine oils are
John Deere BREAK-IN ENGINE OIL is formulated PREFERRED:
with special additives for aluminum and cast iron type • John Deere HY-GARD®.
engines to allow the power cylinder components
• John Deere low viscosity HY-GARD® (cold weather
(pistons, rings, and liners as well) to “wear in” while
operation only).
protecting other engine components, valve train and
gears, from abnormal wear. Engine rebuild instructions
should be followed closely to determine if special
requirements are necessary.

John Deere BREAK-IN ENGINE OIL is also


recommended for non-John Deere engines, both
aluminum and cast iron types.

If this preferred John Deere oil is not available, use a JD HY-GARD


break-in engine oil meeting the following specification
during the first 100 hours of operation:
LOW VIS JD HY-GARD
• API Service Classification CE or higher.

IMPORTANT: After the break-in period, use the


John Deere oil that is recommended for this
engine.

AIR TEMPERATURE M58275


BREAK-IN OIL

AIR TEMPERATURE M58275

11/22/00 2 - 13
CHAIN CASE OIL SPECIFICATIONS SPECIFICATIONS AND INFORMATION

CHAIN CASE OIL SPECIFICATIONS

CHAIN CASE OIL—NORTH


AMERICA
Use the following oil viscosity based on the air

SAE 30
temperature range. Operating outside of the

SAE 15W-40
recommended oil air temperature range may cause
premature chain case failure.

SAE 10W-40

SAE 5W-30
IMPORTANT: DO NOT use BIO-HY-GARD® in this

SAE 5W-30
chain case.

The following John Deere oils are PREFERRED:


• John Deere HY-GARD®
• John Deere Low Viscosity HY-GARD®
(cold weather operation)
• John Deere TORQ-GARD SUPREME or
PLUS-50

Other oils may be used if above preferred John Deere AIR TEMPERATURE
oils are not available, provided they meet the following
specification: M58275

• API Service Classification SG or higher.


JD HY-GARD

LOW VIS JD HY-GARD

AIR TEMPERATURE M58275

2 - 14 11/22/00
SPECIFICATIONS AND INFORMATION GENERAL APPLICATION GREASE SPECIFICATIONS

GENERAL APPLICATION GREASE COOLANT SPECIFICATIONS


SPECIFICATIONS
DIESEL AND GASOLINE ENGINE
GREASE—NORTH AMERICA COOLANT—NORTH AMERICA
Use the following grease based on the air temperature The engine cooling system, when filled with a proper
range. Operating outside of the recommended grease dilution mixture of anti-freeze and deionized or distilled
air temperature range may cause premature failures. water, provides year-round protection against
corrosion, cylinder or liner pitting, and winter freeze
protection down to –37°C (–34°F).
IMPORTANT: ONLY use a quality grease in this
application. DO NOT mix any other greases in The following John Deere coolants are PREFERRED:
this application. DO NOT use any BIO-GREASE
in this application. • John Deere COOL-GARD
• John Deere ANTIFREEZE/SUMMER COOLANT

The following John Deere greases are PREFERRED: These coolants satisfy specifications for “Automobile
and Light Duty Engine Service” and are safe for use in
• John Deere MOLY HIGH TEMPERATURE EP John Deere Lawn and Grounds Care/Golf and Turf
GREASE Division equipment, including aluminum block gasoline
• John Deere HIGH TEMPERATURE EP GREASE engines and cooling systems.
(Non-Clay)
Other greases may be used if they meet one of the The above preferred pre-diluted coolants provide:
following:
• adequate heat transfer
• SAE Multipurpose EP Grease with a maximum of • corrosion-resistant chemicals for the cooling
5% molybdenum disulfide system
• SAE Multipurpose EP Grease • compatibility with cooling system hose and seal
material
Greases meeting Military Specification MIL-G-10924F
• protection during extreme cold and extreme hot
may be used as arctic grease.
weather operations
• chemically pure water for better service life
• compliance with ASTM D4656 (JDM H24C2)
specifications

If above preferred pre-diluted coolants are not


available, the following John Deere concentrate is
recommended:
JD High Temp EP
JD Moly High Temp EP

• DIESEL ENGINE ANTI-FREEZE/SUMMER


NLGI Grade 2

COOLANT CONCENTRATE™ (TY16034).

If the above recommended engine coolants are not


available use any Automobile and Light Duty Engine
Service ethylene glycol base coolant, meeting the
following specification:
• ASTM D3306 (JDM H24C1).

Read container label completely before using and


follow instructions as stated.

AIR TEMPERATURE M58275

11/22/00 2 - 15
COOLANT SPECIFICATIONS SPECIFICATIONS AND INFORMATION

IMPORTANT: To prevent engine damage, DO NOT The use of non-recommended supplemental coolant
use pure anti-freeze or less than a 50% anti- additives may result in additive drop-out and gelation
freeze mixture in the cooling system. Water of the coolant.
used to dilute engine coolant concentrate must Add the manufacturer’s recommended concentration
be of high quality—clean, clear, potable water of supplemental coolant additive. DO NOT add more
(low in chloride and hardness—see table below) than the recommended amount.
is generally acceptable. DO NOT use salt water.
Deionized or distilled water is ideal to use.
Coolant that is not mixed to these specified
levels and water purity can cause excessive
DIESEL AND GASOLINE ENGINE
scale, sludge deposits, and increased corrosion COOLANT DRAIN INTERVAL—
potential. NORTH AMERICA
When using John Deere Concentrate (TY16034)
Water Quality Automobile and Light Duty Engine Service coolants,
drain and flush the cooling system and refill with fresh
Property Requirements coolant mixture every 24 months or 2,000 hours of
operation, whichever comes first.
Total Solids, Maximum 340 ppm (20 grns/gal)
If above John Deere Automobile and Light Duty Engine
Total Hardness, Max. 170 ppm (10 grns/gal) Service coolants are not being used, drain, flush, and
Chloride (as Cl), Max. 40 ppm (2.5 grns/gal) refill the cooling system according to instructions found
on product container or in equipment operator’s manual
Sulfate (as SO4), Max. 100 ppm (5.8 grns/gal) or technical manual.

Mix 50 percent anti-freeze concentrate with 50 percent


distilled or deionized water. This mixture and the pre-
diluted mixture (TY16036) will protect the cooling
system down to –37°C (–34°F) and up to 108°C
(226°F).

Certain geographical areas may require lower air


temperature protection. See the label on your anti-
freeze container or consult your John Deere dealer to
obtain the latest information and recommendations.

SUPPLEMENTAL COOLANT
ADDITIVES
The concentration of coolant additives is gradually
depleted during engine operation. For all
recommended coolants, replenish additives between
drain intervals by adding a supplemental coolant
additive every 12 months or as determined necessary
by coolant testing.
John Deere COOLANT CONDITIONER is
recommended as a supplemental coolant additive in
John Deere engines.

IMPORTANT: Do not add a supplemental coolant


additives when the cooling system is drained
and refilled with John Deere ANTIFREEZE/
SUMMER COOLANT or John Deere COOL-
GARD.

If other coolants are used, consult the coolant supplier


and follow the manufacturer’s recommendation for use
of supplemental coolant additives.

2 - 16 11/22/00
SPECIFICATIONS AND INFORMATION SERIAL NUMBER LOCATION

SERIAL NUMBER LOCATION ENGINE SERIAL NUMBER


When ordering parts or submitting a warranty claim, it
is IMPORTANT that you include the skid steer product
identification number and the component serial
numbers.
The location of skid steer product identification number
and component serial numbers are shown.

SKID STEER PRODUCT


IDENTIFICATION NUMBER

Engine Serial Number


KV18598

Product Identification Number

KV18593

11/22/00 2 - 17
SERIAL NUMBER LOCATION SPECIFICATIONS AND INFORMATION

This page intentionally left blank.

2 - 18 11/22/00
DIESEL ENGINE CONTENTS

CONTENTS
DIESEL ENGINE
Page

56SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CYLINDER HEAD AND VALVES SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 7
CYLINDER BLOCK, LINERS, PISTONS, AND RODS SPECIFICATIONS . . . . . . . . . 9
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONS . . . . . . . . 11
CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS . . . . . . . . . . . . . . . . . . 12
LUBRICATION SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
COOLING SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FUEL SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ENGINE SYSTEM—DIAGNOSIS AND TESTS SPECIFICATIONS . . . . . . . . . . . . . 15
FUEL SYSTEM—OPERATION AND TESTS SPECIFICATIONS . . . . . . . . . . . . . . . 15
CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SEALANT APPLICATION GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . 18
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PRELIMINARY ENGINE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
GENERAL TUNE-UP RECOMMENDATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TEST THERMOSTAT OPENING TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CHECK ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
MEASURE ENGINE BLOW-BY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CYLINDER COMPRESSION PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FUEL SUPPLY PUMP PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FAST AND SLOW IDLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FUEL INJECTION PUMP TIMING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CHECK AND ADJUST VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
ENGINE REPAIR STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
MOUNT ENGINE ON REPAIR STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ENGINE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
RADIATOR REMOVAL, INSPECTION, and INSTALLATION. . . . . . . . . . . . . . . . . . . 41
CLEAN ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
ENGINE DISASSEMBLY SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
ENGINE ASSEMBLY SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
CYLINDER HEAD–EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
CHECK VALVE LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
REMOVE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
CLEAN INJECTION NOZZLE BORES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
VALVE ACTUATING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
REMOVE VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
CHECKING CYLINDER HEAD FLATNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
CLEAN VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
MEASURE VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

11/22/00 3-1
CONTENTS DIESEL ENGINE

Page

CLEAN AND INSPECT VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50


LAPPING VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
CHECK VALVE RECESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
REMOVE VALVE SEAT INSERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
VALVE SEAT INSERT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSPECT AND MEASURE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
GRIND VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
INSPECT AND MEASURE VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
INSPECT VALVE ROTATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
INSTALL VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSTALL CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
TORQUE TURN TIGHTENING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
CHECKING ROCKER ARM SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALL ROCKER ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALL ROCKER ARM COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
FINAL WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
CYLINDER BLOCK EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
REMOVE PISTONS AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . 59
MEASURE CYLINDER LINER BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
REMOVE CYLINDER LINERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
CYLINDER LINER DEGLAZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
CYLINDER BLOCK CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
CHECK PISTON COOLING JETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
CAM FOLLOWER BORE MEASURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
MEASURE CAMSHAFT BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
REMOVE CAMSHAFT BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
INSTALL CAMSHAFT BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
MEASURE CRANKSHAFT BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
REPLACE CRANKSHAFT BEARING CAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
CYLINDER BLOCK TOP DECK FLATNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
MEASURE CYLINDER LINER PROTRUSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
LINER PACKING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
LINER O-RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
INSTALL CYLINDER LINERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
MEASURE CONNECTING ROD BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
ROD BEARING CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
CONNECTING ROD BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
REPLACE CONNECTING ROD BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
MEASURE PISTON PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
CLEAN AND INSPECT PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
MEASURE PISTON PIN BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
PISTON TOP RING GROOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
PISTON SECOND AND THIRD RING GROOVES . . . . . . . . . . . . . . . . . . . . . . . . . 69
PISTON HEAD AND SKIRT CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSTALL PISTON RINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

3-2 11/22/00
DIESEL ENGINE CONTENTS

Page

PISTON RINGS STAGGERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70


PISTON/LINER SET INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
ASSEMBLE PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
INSTALL PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
MEASURE PISTON PROTRUSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
COMPLETE FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
REMOVE CRANKSHAFT PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
INSTALL CRANKSHAFT PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
FLYWHEEL RING GEAR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
INSTALL BALL BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
INSTALL FLYWHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
CRANKSHAFT REAR OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
FLYWHEEL HOUSING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
MEASURING CRANKSHAFT END PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
REMOVE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
MEASURE CRANKSHAFT JOURNAL DIAMETER . . . . . . . . . . . . . . . . . . . . . . . . . 80
DETERMINE CRANKSHAFT MAIN BEARING CLEARANCE . . . . . . . . . . . . . . . . . 81
REGRINDING CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
CRANKSHAFT REGRINDING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
MICRO-FINISHING SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
REPLACE CRANKSHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
INSTALL MAIN BEARING INSERTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALL 2-PIECE THRUST BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALL 6-PIECE THRUST BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
CRANKSHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
MEASURE TIMING GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
REMOVE CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
MEASURE CAMSHAFT JOURNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
MEASURE HEIGHT OF CAM LOBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
REPLACE CAMSHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
TACHOMETER PICK-UP PIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
INSTALL CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
MEASURE CAM FOLLOWER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
MEASURE IDLER GEAR END PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
REMOVE FRONT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
IDLER GEAR BUSHING AND SHAFT MEASURE . . . . . . . . . . . . . . . . . . . . . . . . . . 87
IDLER GEAR BUSHING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
REMOVE IDLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
INSTALL IDLER SHAFT SPRING PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
INSTALL IDLER SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
INSTALL FRONT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
INSTALL UPPER TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
INSTALL LOWER TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

11/22/00 3-3
CONTENTS DIESEL ENGINE

Page

INSTALL OIL DEFLECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91


INSTALL TIMING GEAR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
INSTALL CRANKSHAFT FRONT OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
INSTALL WEAR RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
REMOVE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
REPLACE OIL COOLER NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
INSTALL OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
REMOVE OIL PRESSURE REGULATING VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . 93
REPLACE OIL PRESSURE REGULATING VALVE SEAT . . . . . . . . . . . . . . . . . . . . 93
INSTALL OIL PRESSURE REGULATING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 94
REPLACE OIL DIPSTICK GUIDE ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
REPLACE OIL BYPASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
REPLACE OIL PUMP STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
REMOVE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
GEAR AXIAL CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
GEAR RADIAL CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
OIL PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
OIL PUMP INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
INSTALL OIL PAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
WATER PUMP—EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
REMOVE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
DISASSEMBLE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
ASSEMBLE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
INSTALL WATER PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
REMOVE/INSTALL THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
COLD START ADVANCE WIRE HARNESS (IF EQUIPPED). . . . . . . . . . . . . . . . . 101
COOLING SYSTEM DEAERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
CHECK FAN/ALTERNATOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
INSTALL FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
BLOCK HEATER (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
CHECK AIR INLET PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
EXHAUST MANIFOLD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
REMOVE TURBOCHARGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
CHECK RADIAL BEARING CLEARANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
CHECK AXIAL BEARING END PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
REPAIR TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
PRELUBE TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
INSTALL TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
TURBOCHARGER BREAK-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
TURBOCHARGER RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
REPLACE FUEL/WATER SEPARATOR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . 107
REPLACE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
REMOVE STANADYNE DB4 FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . 108
REPAIR OF INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
INSTALL STANADYNE DB4 FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . 110

3-4 11/22/00
DIESEL ENGINE CONTENTS

Page

REMOVE FUEL INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111


CLEAN FUEL INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
FUEL INJECTION NOZZLE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
FUEL INJECTION NOZZLE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
ADJUST FUEL INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
INSTALL FUEL INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
BLEED FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
ENGINE BREAK-IN INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
ENGINE BREAK-IN OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
USING STANADYNE "TIME-TRAC" AS TACHOMETER. . . . . . . . . . . . . . . . . . . . . 116
TURBOCHARGER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
CHECK TURBOCHARGER BOOST PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 117
DIAGNOSING TURBOCHARGER MALFUNCTIONS. . . . . . . . . . . . . . . . . . . . . . . 117
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
COLD START ADVANCE SYSTEM OPERATION (IF EQUIPPED) . . . . . . . . . . . . . 118
FUEL INJECTION NOZZLES—GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 119
DIAGNOSING FUEL SYSTEM MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 119
TESTING FUEL INJECTION NOZZLES ON A RUNNING ENGINE . . . . . . . . . . . . 120
STARTING MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
EXPLODED VIEW OF STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
STARTING MOTOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
STARTING MOTOR TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 124
DISASSEMBLY OF STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
TESTING SOLENOID SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
TESTING BRUSHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
POSITIVE BRUSH REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
TESTING ARMATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
TESTING FIELD WINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
CHECKING OVERRUNNING CLUTCH PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
ASSEMBLY OF STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
TORQUE SPECIFICATIONS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
ALTERNATOR SPECIFICATIONS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
ALTERNATOR—EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
ALTERNATOR—IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
DISASSEMBLE—ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
TESTING ALTERNATOR BRUSH/REGULATOR ASSEMBLY. . . . . . . . . . . . . . . . . 134
TESTING ALTERNATOR ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
TESTING ALTERNATOR STATOR/RECTIFIER BRIDGE ASSEMBLY . . . . . . . . . . 135
REPLACE RECTIFIER BRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
ASSEMBLE ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

11/22/00 3-5
CONTENTS DIESEL ENGINE

This page intentionally left blank.

3-6 11/22/00
DIESEL ENGINE

SPECIFICATIONS

CYLINDER HEAD AND VALVES SPECIFICATIONS

DIMENSIONS OF NEW PARTS WEAR TOLERANCE


Thickness of new cylinder head . . . . . . . . . . . . . . . . . . . . .104.87—105.13 mm
(4.129—4.139 in.)
Maximum permissible amount to be machined
from cylinder head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.03 in.)
Minimum thickness of cylinder head . . . . . . . . . . . . . . . . 104.11 mm (4.099 in.)
Maximum permissible out-of-flat of cylinder
head sealing surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.)
Combustion face surface finish . . . . . . . . . . . . . . . . . . . . 1.6—3.2 micron C.L.A.
(64—128 micro-in)

Valve stem diameter (standard):


• Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.864—7.884 mm
(0.3096—0.3104 in.)
• Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.848—7.874 mm
(0.3090—0.3100 in.)

Bore for valve stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.912—7.938 mm


(0.3115—0.3125 in.)
Clearance between bore and valve stem . . . . . . . . . . . . . . . . . . 0.05—0.10 mm. . . . . . . . . . . . 0.15 mm
(0.002—0.004 in.). . . . . . . . . . . (0.006 in.)
Valve stem oversize, stem diameter larger
than standard by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.38 mm (0.015 in.)
0.76 mm (0.030 in.)
Valve seat angle (intake and exhaust). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Valve face angle (intake and exhaust). . . . . . . . . . . . . . . . . . . . . . 29.25 ± 0.25°
Maximum valve seat runout . . . . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.)
Maximum valve face runout. . . . . . . . . . . . . . . . . . . . . . . 0.038 mm (0.0015 in.)

Valve recess (below cylinder head surface):


• Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61—1.11mm. . . . . . . . . . . . .1.63 mm
(0.024—0.044 in.). . . . . . . . . . . (0.064 in.)
• Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22—1.72 mm . . . . . . . . . . . . 2.26 mm
(0.048—0.068 in.). . . . . . . . . . . (0.089 in.)

Valve seat width (intake and exhaust) . . . . . . . . . . . . . . . . . . . . . 1.50—2.00 mm


(0.059—0.079 in.)

(Continued on next page)

C.L.A. (Center Line Average) corresponds to a measure of surface texture.

11/22/00 3-7
SPECIFICATIONS DIESEL ENGINE

DIMENSIONS OF NEW PARTS WEAR TOLERANCE


Valve head diameter:
• Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.47—46.73 mm
(1.830—1.840 in.)
• Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.37—42.63 mm
(1.668—1.678 in.)

Firing order—3 cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 - 3

Valve clearance (engine cold):


• Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.)
• Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.018 in.)

Valve lift (zero valve clearance):


• Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.56—12.37 mm. . . . . . . . . . . 11.13 mm
(0.455—0.487 in.). . . . . . . . . . . (0.438 in.)
• Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.28—12.12 mm. . . . . . . . . . . 10.85 mm
(0.444—0.477 in.). . . . . . . . . . . (0.427 in.)

Rocker arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . .19.99—20.02 mm. . . . . . . . . . . 19.94 mm


(0.787—0.788 in.). . . . . . . . . . . (0.785 in.)
Rocker arm bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . .20.07—20.12 mm. . . . . . . . . . . 20.17 mm
(0.790—0.792 in.). . . . . . . . . . . (0.794 in.)
Rocker arm shaft spring tension
at a length of 46 mm (1.81 in.) . . . . . . . . . . . . . . . . . . . . . 18—27 N (4—6 lb)
Valve springs free height . . . . . . . . . . . . . . . . . . . . . . approx. 54 mm (2.125 in.)
Valve spring tension:
• At a length of 46 mm (1.81 in.) . . . . . . . . . . . . . . . . . 240—280 N (54—62 lb)
• At a length of 34.5 mm (1.36 in.) . . . . . . . . . . . . . . 590—680 N (133—153 lb)

3-8 11/22/00
DIESEL ENGINE SPECIFICATIONS

CYLINDER BLOCK, LINERS, PISTONS, AND RODS SPECIFICATIONS

DIMENSIONS OF NEW PARTS WEAR TOLERANCE


Centerline of main bearing
bore-to-top deck of cyl. block. . . . . 301.98—302.11 mm (11.889—11.894 in.)
Maximum acceptable block out-of-flat . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.)
Cam follower bore ID. . . . . . . . . . . . . . . . . 31.70—31.75 mm (1.248—1.250 in.)
Cam followers OD . . . . . . . . . . . . . . . . . . . 31.62—31.64 mm (1.245—1.246 in)
Cam follower clearance . . . . . . . . . . . . . . . . . 0.06—0.13 mm (0.002—0.005 in.)
Camshaft bore without bushing. . . . . . . . . 55.98—56.01 mm (2.204—2.205 in.)

Camshaft bore with bushing (No. 1 only)


• Cyl. block bore for bushing installation . 59.96—59.99 mm (2.361—2.362 in.)
• Bushing ID (installed) . . . . . . . . . . . . . . 55.96—55.99 mm (2.203—2.204 in.)

Crankshaft main bearing bores . . . . . . . . . 84.46—84.48 mm (3.325—3.326 in.)


Lower block bore for seating liner . . . . . 115.75—115.80 mm (4.557—4.559 in.)
Upper block bore for seating liner . . . . . 120.70—120.75 mm (4.752—4.754 in.)
OD of liner at upper bore. . . . . . . . . . . . 120.61—120.69 mm (4.748—4.751 in.)
OD of liner at lower bore
(measured 10 mm (0.39 in.)
below lower shoulder) . . . . . . . . . . 115.695—115.735 mm (4.555—4.556 in.)
Clearance between liner and cylinder
block at lower bore . . . . . . . . . . . . . . . 0.015—0.105 mm (0.0006—0.004 in.)
Clearance between liner and cylinder
block at upper bore . . . . . . . . . . . . . . . . . . 0.10—0.14 mm (0.004—0.005 in.)
Cylinder liner ID. . . . . . . . . . . . . . . . . 106.49—106.52 mm (4.1925—4.1937 in.)
• Maximum permissible wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.01 in.)
• Maximum permissible taper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
• Maximum permissible out-of-round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)

Liner counterbore depth in block . . . . . . . . . . 5.95—5.99 mm (0.234—0.236 in.)


Liner height above block . . . . . . . . . . . . . . . 0.01—0.10 mm (0.0004—0.004 in.)
Maximum permissible height difference
at nearest point of two adjacent liners. . . . . . . . . . . . . . . 0.03 mm (0.001 in.)
Thickness of liner shim CD15466 . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Thickness of liner shim R65833 . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)
Minimum dimension for proper
compression of liner packing. . . . . . . . . . . . . . . . . . . . . . 0.13 mm (0.005 in.)
Piston OD at 19 mm (0.74 in.) from
bottom of skirt and measured
90° to piston pin . . . . . . . . . . . . 106.381—106.399 mm (4.1882—4.1890 in.)
Piston-to-cylinder liner clearance,
measured at bottom of skirt. . . . . . . . . . 0.09—0.14 mm (0.0035—0.0055 in.)

(Continued on next page)

11/22/00 3-9
SPECIFICATIONS DIESEL ENGINE

DIMENSIONS OF NEW PARTS WEAR TOLERANCE


Piston height:
• Measured from center of piston
pin bore to top of piston . . . . . . . . . . . . . 66.27—66.33 mm (2.609—2.611 in.)

Piston protrusion above block . . . . . . . . . . . . 0.08—0.35 mm (0.003—0.014 in.)

Piston pin bore:


• (Straight rod end). . . . . . . . . . . . . . . . 32.003—32.013 mm (1.256—1.260 in.)
• (Tapered rod end) . . . . . . . . . . . . . 41.285—41.295 mm (1.6254—1.6258 in.)

Piston pin OD:


• (Straight rod end). . . . . . . . . . . . . . 31.994—32.000 mm (1.2596—1.2598 in.). . 0.013 mm (0.0005 in.)
• (Tapered rod end) . . . . . . . . . . . . . . . 41.27—41.28 mm (1.6248—1.6252 in.). . 0.013 mm (0.0005 in.)

Rod pin bushing ID:


• (Straight rod end). . . . . . . . . . . . . . 32.010—32.036 mm (1.2602—1.2612 in.). . . . 0.05 mm (0.002 in.)
• (Tapered rod end) . . . . . . . . . . . . . . . 41.300—41.326 mm (1.626—1.627 in.). . . . 0.05 mm (0.002 in.)

Pin-to-bushing oil clearance:


• (Straight rod end). . . . . . . . . . . . . . . . . 0.01—0.042 mm (0.0004—0.0016 in.). . . . 0.10 mm (0.004 in.)
• (Tapered rod end) . . . . . . . . . . . . . . . . . 0.02—0.056 mm (0.0008—0.002 in.). . . . 0.10 mm (0.004 in.)

Connecting rod bearing


(assembled) ID . . . . . . . . . . . . . . . 69.848—69.898 mm (2.7499—2.7519 in.)
Bearing-to-journal clearance . . . . . . . . . 0.023—0.099 mm (0.0009—0.0039 in.). . . . 0.16 mm (0.006 in.)
Connecting rod bore for bearing . . . . . . 73.660—73.686 mm (2.900—2.901 in.)
Undersize connecting rod
bearings available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.01 in.)
Piston cooling orifice flow (each). . . . . . . . . . . . . . . . . . . . 1.5 L/min (1.4 qt/min)

Some piston pin bores are elliptical, the width being 0.038 mm (0.0015 in.) wider than specification given.

3 - 10 11/22/00
DIESEL ENGINE SPECIFICATIONS

CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONS

DIMENSIONS OF NEW PARTS WEAR TOLERANCE


Crankshaft end play:
• Engine with 6-piece thrust bearing . . . . . . 0.03—0.35 mm (0.001—0.014 in.). . . . . 0.50 mm (0.02 in.)
Oversize thrust washers available . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)

Crankshaft main journals OD (std.). . . . 79.324—79.350 mm (3.123—3.124 in.)


• Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.013 mm (0.0005 in.). . . 0.03 mm (0.0012 in.)
• Out-of-roundness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.013 mm (0.0005 in.). . . 0.075 mm (0.003 in.)
Main bearings assembled ID (std.) . . . . 79.396—79.440 mm (3.126—3.127 in.)
Crankshaft to main bearing clearance . 0.046—0.116 mm (0.0018—0.0046 in.). . . . 0.15 mm (0.006 in.)
Undersize bearing available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 (0.01 in.)

Crankshaft conrod OD (std.) . . . . . . . . . 69.799—69.825 mm (2.748—2.749 in.)


• Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.013 mm (0.0005 in.). . . 0.03 mm (0.0012 in.)
• Out-of-roundness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.013 mm (0.0005 in.). . . 0.075 mm (0.003 in.)

Crankshaft OD for front pulley . . . . . . 37.988—38.014 mm (1.4956—1.4966 in.)


Flywheel pilot bearing bore diameter 39.967—39.993 mm (1.5735—1.5745 in.)

11/22/00 3 - 11
SPECIFICATIONS DIESEL ENGINE

CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS

DIMENSIONS OF NEW PARTS WEAR TOLERANCE


Camshaft journal OD. . . . . . . . . . . . . 55.872—55.898 mm (2.1997—2.2007 in.). . . 55.85 mm (2.199 in.)
Camshaft bore to journal clearance . . . . . . . 0.10—0.15 mm (0.004—0.006 in.). . . . 0.18 mm (0.007 in.)
Camshaft end play . . . . . . . . . . . . . . . . . . . . 0.08—0.23 mm (0.003—0.009 in.). . . . 0.38 mm (0.015 in.)
Camshaft thrust plate thickness . . . . . . . . 3.935—3.985 mm (0.155—0.157 in.). . . . . . 3.8 mm (0.15 in.)
Cam follower OD . . . . . . . . . . . . . . . . . . . . 31.62—31.64 mm (1.245—1.246 in.)
Cam follower to bore clearance. . . . . . . . . . . 0.06—0.13 mm (0.002—0.005 in.)

Camshaft lobe height:


• Intake lobe . . . . . . . . . . . . . . . . . . . . . . . . . 6.93—7.42 mm (0.273—0.292 in.). . . . 6.68 mm (0.263 in.)
• Exhaust lobe . . . . . . . . . . . . . . . . . . . . . . . 6.76—7.26 mm (0.266—0.286 in.). . . . 6.50 mm (0.256 in.)

Helical timing gear backlash between:


• Upper idler/crankshaft gear . . . . . . . . . . . 0.07—0.30 mm (0.003—0.012 in.). . . . 0.40 mm (0.016 in.)
• Upper idler/camshaft gear . . . . . . . . . . . . 0.07—0.35 mm (0.003—0.014 in.). . . . 0.51 mm (0.020 in.)
• Upper idler/injection pump gear. . . . . . . . . 0.07—0.35 mm (0.003—0.014 in.). . . . 0.51 mm (0.020 in.)
• Lower idler/crankshaft gear . . . . . . . . . . . . 0.07—0.35 mm (0.003—0.014 in.). . . . 0.51 mm (0.020 in.)
• Lower idler/oil pump gear . . . . . . . . . . . . 0.04—0.38 mm (0.0016—0.015 in.). . . . 0.40 mm (0.016 in.)

Spur timing gear backlash between:


• Upper idler/crankshaft gear . . . . . . . . . . . 0.04—0.35 mm (0.0016—0.014 in.). . . . 0.60 mm (0.024 in.)
• Upper idler/camshaft gear . . . . . . . . . . . . . 0.08—0.45 mm (0.003—0.018 in.). . . . 0.85 mm (0.033 in.)
• Upper idler/injection pump gear. . . . . . . . . 0.08—0.45 mm (0.003—0.018 in.). . . . 0.85 mm (0.033 in.)
• Lower idler/crankshaft gear . . . . . . . . . . . 0.04—0.35 mm (0.0016—0.014 in.). . . . 0.65 mm (0.025 in.)
• Lower idler/oil pump gear . . . . . . . . . . . . . 0.08—0.40 mm (0.003—0.016 in.). . . . 0.75 mm (0.030 in.)

Idler gear shaft OD:


• Upper with helical gear and lower
with helical or spur gear . . . . . . . . . 44.437—44.463 mm (1.7495—1.7505 in.). . . 44.41 mm (1.748 in.)
• Upper with spur gear . . . . . . . . . . . . 69.759—69.775 mm (2.7464—2.747 in.)

Idler gear bushing ID:


• Upper with helical gear and lower
with helical or spur gear . . . . . . . . . . . 44.501—44.527 mm (1.752—1.753 in.). . . 44.55 mm (1.754 in.)
• Upper with spur gear . . . . . . . . . . . 69.827—69.857 mm (2.7491—2.7503 in.)

Idler gear/bushing clearance:


• Upper with helical gear and lower
with helical or spur gear . . . . . . . . . . . . 0.038—0.09 mm (0.0015—0.0035 in.). . . . 0.15 mm (0.006 in.)
• Upper with spur gear . . . . . . . . . . . . . . 0.052—0.098 mm (0.002—0.0038 in.)

Hub width of idler gear . . . . . . . . . . . . . 21.975—22.025 mm (0.865—0.867 in.). . . 21.93 mm (0.863 in.)
Width of idler shaft . . . . . . . . . . . . . . . . . . 22.17—22.27 mm (0.873—0.877 in.)
End play of idler gear . . . . . . . . . . . . . . . . . . 0.14—0.29 mm (0.006—0.012 in.). . . . 0.40 mm (0.016 in.)

Spring pins protrude from shaft:


• On lower idler gear . . . . . . . . . . . . . . . . . . . . . 6.5—7 mm (0.256—0.275 in.)
• On upper idler gear
Helical gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 4—4.5 mm (0.157—0.177 in.)
Spur gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5—8.5 mm (0.295—0.335 in.)

3 - 12 11/22/00
DIESEL ENGINE SPECIFICATIONS

LUBRICATION SYSTEM SPECIFICATIONS

DIMENSIONS OF NEW PARTS WEAR TOLERANCE


Oil pump:
• Bore of drive shaft in pump housing . . . . . . . . . . . . . . . . . .16.05—16.08 mm. . . . . . . . . . . . 0.08 mm
(0.632—0.633 in.). . . . . . . . . . . (0.003 in.)
• Diameter of idler shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.32—12.34 mm. . . . . . . . . . . 0.013 mm
(0.485—0.486 in.). . . . . . . . . . (0.0005 in.)
• Diameter of drive shaft journal. . . . . . . . . . . . . . . . . . . . . . .16.02—16.03 mm. . . . . . . . . . . 0.025 mm
(0.630—0.631 in.). . . . . . . . . . . (0.001 in.)
• Radial clearance between gear and pump housing. . . . . . . . . 0.10—0.16 mm. . . . . . . . . . . . 0.20 mm
(0.004—0.006 in.). . . . . . . . . . . (0.008 in.)
• Thickness of gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.15—41.20 mm. . . . . . . . . . . . 0.05 mm
(1.620—1.622 in.). . . . . . . . . . . (0.002 in.)
• Axial clearance between gears and pump cover . . . . . . . . . . . 0.05—0.17 mm. . . . . . . . . . . . 0.22 mm
(0.002—0.007 in.). . . . . . . . . . (0.0085 in.)

Spring of oil pressure regulating valve:


• Free length of spring (approx.). . . . . . . . . . . . . . . . . . . . . . . . 120 mm (4.7 in.)
• Spring calibration at a length of
42.5 mm (1.68 in.) . . . . . . . . . . . . . . . . . . . . . . . . . . 60—75 N (13.5—16.5 lb)

Minimum oil pressure at 1000 rpm


(slow idle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 kPa (40 psi) minimum

Spring of by-pass valve:


• Free length (approx.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 mm (2.00 in.)
• Spring calibration at a length of 29 mm (1.14 in.) . . . 79—96.5 N (18—22 lb)

COOLING SYSTEM SPECIFICATIONS

DIMENSIONS OF NEW PARTS WEAR LIMIT


Impeller recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.01 in.)
Thermostat opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82°C (180°F)
Fan belt tension (method 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578—622 N. . . . . . . . . . 378—423 N
(130—140 lb) (85—94 lb)
Fan belt tension (method 2) . . . . . . . . . . .6.38 mm (0.25 in.) deflection halfway
between the two pulleys
with 89 N (20 lb) force applied.
Fan tip clearance adjustment . . . . . . . . . . . . . . . . 10 ± 1.0 mm (0.40 ± 0.04 in.)

11/22/00 3 - 13
SPECIFICATIONS DIESEL ENGINE

FUEL SYSTEM SPECIFICATIONS

FUEL INJECTION PUMP STATIC TIMING:


STANADYNE DB4 injection. Align marks on pump flange and engine front plate.

FUEL INJECTION PUMP DYNAMIC TIMING:

Rated Speed
Model Pump Part # Dynamic Timing
(rpm)

240 RE500441 6° 2400

240 RE501933 17° 2400

240 RE505093 14.5° 2400

250 RE500442 7° 2400

250 RE504984 7° 2400

DIMENSIONS OF NEW PARTS WEAR LIMIT

FUEL INJECTION NOZZLES


Number of nozzle tip orifice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Diameter of nozzle tip orifice. . . . . . . . . . . . . . . . . . . . . . . 0.27 mm (0.0106 in.)

Opening pressure of a new or reconditioned nozzle with new internal parts:


• For setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 400—24 900 kPa. . . 25 500—26 100 kPa
(3540—3620 psi). . . . . .(3700—3780 psi)
• For checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 100 kPa min.. . . . . . 25 200 kPa min.
(3500 psi). . . . . . . . . . . (3660 psi)

Opening pressure of a used nozzle:


• For setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 000—23 600 kPa. . . 24 150—24 700 kPa
(3340—3420 psi). . . . . .(3500—3580 psi)
• For checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 800 kPa min.. . . . . . 22 950 kPa min.
(3170 psi). . . . . . . . . . . (3330 psi)

Return leakage at test pressure of


10 300 kPa (1500 psi) . . . . . . . . . . . . . . . . . . . . . 14 drops / 30 seconds max.. . . . . . . . . . . 10 drops /
. . . . . . 30 seconds max.

3 - 14 11/22/00
DIESEL ENGINE SPECIFICATIONS

ENGINE SYSTEM—DIAGNOSIS AND TESTS SPECIFICATIONS


Engine compression pressure at 150—200 rpm cranking speed:
• Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2400 kPa (350 psi)
• Maximum difference between cylinders. . . . . . . . . . . . . . . . . 350 kPa (50 psi)

Minimum engine oil pressure at normal operating temperature:


• at 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 kPa (40 psi)
• at rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 kPa (50 psi)

Engine blow-by at crankcase vent tube, maximum at full load rated speed:
• Model 3029D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 m3/h (141 cu-ft/h)
• Model 3029T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 m3/h (225 cu-ft/h)

Engine oil consumption:


• Normal . . . . . . . . . . . . . . . . . . . . . . . . . . Up to 0.5% of fuel consumption rate
• Overhaul point . . . . . . . . . . . . . . . . . . Above 0.625% of fuel consumption rate

NOTE: Oil consumption should be measured over a 100 hour period.

FUEL SYSTEM—OPERATION AND TESTS SPECIFICATIONS


Fuel supply pump:
• Normal pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 25—30 kPa (3.5—4.5 psi)
• Minimum pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 kPa (2.0 psi)
• Minimum flow at WOT (wide open throttle)
or 2400 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 L/min (0.42 gpm)

CAPACITIES
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.7 L (15 gal)
Hydraulic reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6 L (4.1 gal)
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.7 L (6 gal)
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 L (10 qt)
Engine oil (with filter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 L (6.9 qt)
Chain case (per side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4 L (3 gal)

11/22/00 3 - 15
SPECIAL OR ESSENTIAL TOOLS DIESEL ENGINE

SPECIAL OR ESSENTIAL TOOLS


NOTE: Order tools according to information given in the U.S. SERVICEGARD™ Catalog or in the
European Microfiche Tool Catalog (MTC).

Spring Compression Tester. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D01168AA


End Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D17024BR
Lifting Eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .JD-244
Torque Wrench Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .JD-307
Nozzle Bore Cleaning Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDE39
Timing Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDE81-4
Flywheel Turning Tool . . . . . . . . . . . . . . . . . . . . . JDE83 or JDG820 (formerly JDE81-1)
Valve Spring Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDE138
Valve Seat Insert Installing Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG675
Valve Seat Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG676
Valve Stem Seal Installer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG678
Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG680
Nozzle Puller Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG716
Flexible Cylinder Hone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D17004BR
Groove Cleaning Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D17015BR
Dial Indicator . . . . . . . . . . . . . . . . . . .(English, in.) D17526CI or (Metric, mm) D17527CI
Ring Groove Wear Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG957
Piston Ring Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDE84
Piston and Liner Height Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG451
Connecting Rod Bushing Remover and Installer . . . . . . . . . . . . . . . . . . . . . . . . JDG738

NOTE: JDG738 consists of the following components:


A–Remover/Replacer Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG738-1
B–Installer Pilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG738-2
C–Receiver Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG738-3
D–Remover/Replacer Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG738-4
E–Installer Pilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG738-5
F–Receiver Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG738-6

Camshaft Bushing Service Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .JDG739B

NOTE: JDG739B consists of the following components:


A–Bushing Remover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG739-1
B–Flat Bottom Legs (3/8-16) (3). . . . . . . . . . . . . . . . . . . . . . . . . JDG739-2
C–Removing/Installing Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG739-3
D–Bushing Installer Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG739-4
E–Bushing Installer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDB739-5B
F–Tapered Bottom Leg (3/8-16) . . . . . . . . . . . . . . . . . . . . . . . . . JDG739-6
G–Tapered Bottom Leg (M8 x 1.25). . . . . . . . . . . . . . . . . . . . . . JDG739-7
H–Flat Bottom Leg (M8 x 1.25) (3). . . . . . . . . . . . . . . . . . . . . . . JDG739-8

Cylinder Liner Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .KCD10001


Piston/Liner Height Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KJD10123
Piston Ring Expander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KJD10140
Dial Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Metric, mm) FKM10103 or D17527C1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . or (English, in.) D17526C1
FKM10103 is part of KJD10123 Piston/Liner height gauge.

3 - 16 11/22/00
DIESEL ENGINE SPECIAL OR ESSENTIAL TOOLS

Slide Hammer Seal Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG22


Vibration Damper Puller Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG410
Rear Crankshaft Wear Sleeve Puller. . . . . . . . . . . . . . . . . . . . . . . JDG645E or JDG698
Gear Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG794 (Formerly JDH7)
Oil Seal/Wear Sleeve Installer Set . . . . . . . . . . . . . . . . . . . . . . KCD10002A or JT30040
Magnetic Follower Holder Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D15001NU
Idler Gear Bushing Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .JD-252
Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG537
Gear Timing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JD-254A
Timing Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDE81-4
Flywheel Turning Tool . . . . . . . . . . . . . . . . . . . . . JDE83 or JDG820 (formerly JDE81-1)
Idler Gear Installer Pilot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .JDG791A
Front Crankshaft Oil Seal Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KJD10164
Bushing Driver (A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JD-248A
Handle (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG536 (D15001NU)
Bearing Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JD-262A
Seal Remover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG22
O-Ring Seal Tool Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG127
Tension Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG529
Seal Installing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .JD-258
Injection Nozzle Puller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDE38B
Nozzle Bore Cleaning Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDE39
3/4 in. Special Crowsfoot Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDF22
Injection Pump Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .JDG670A
Nozzle Puller Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG716
Injection Nozzle Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG949
Injection Nozzle Tester (R. BOSCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JT25510
Fuel Pressure Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KJD10109
“TIME TRAC” Basic Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JT07154
“TIME-TRAC” Diesel Engine Timing Tester. . . . . . . . . . . . . . .FKM10429A (or JT07158)

NOTE: FKM10429A contains the following components:


A-Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FKM10429-1
B-Sensor Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FKM10429-4
C-6mm Clamp-On Transducer . . . . . . . . . . . . . . . . . . . . . . . .FKM10429-5
D-Instruction Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FKM10429-8
E-Timing Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FKM10429-6
F-Timing Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDE81-4
G-Magnetic Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FKM10465-1
H-Transducer Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FKM10465-2
J-1/4”Clamp-On Transducer . . . . . . . . . . . . . . . . . . . . . . . . . .FKM10465-3
K-Magnetic Probe Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG793
L-Magnetic Probe Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG821

9/16 in. SOI Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JT07155


Universal Pressure Test Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FKM10002 or JT05470
Compression Test Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FKM10021

11/22/00 3 - 17
SEALANT APPLICATION GUIDELINES DIESEL ENGINE

SEALANT APPLICATION GUIDELINES


Listed below are sealants which have been tested and are used by the John Deere factory to control leakage and
assure hardware retention. Use the following recommended sealants when assembling your John Deere engine
to assure quality performance.

JOHN DEERE
CONTENT PRODUCT EXAMPLE OF USE
PART NUMBER

TY9370 6 ml tube LOCTITE 242 Cap screws:


Thread Lock & Sealer Crankshaft pulley
Medium Strength (blue) Flywheel

TY9371 6 ml tube LOCTITE 271 Studs:


Thread Lock & Sealer Water pump-to-cylinder block
High Strength (clear) Injection pump-to-front plate
Exhaust manifold-to-turbocharger
Oil filter nipple

T43514 50 ml tube LOCTITE 277 Steel cap plugs:


Plastic Gasket Cylinder block, cylinder head
High Strength (red) Water pump

DD15664 or 25 ml tube LOCTITE 515 Flywheel housing-to-cylinder block


TY6304 50 ml bottle Flexible Sealant Front plate/Timing gear-to-oil pan
General Purpose (purple)

TY9374 or 6 ml tube LOCTITE 592 Pipe plugs:


TY9375 50 ml bottle Pipe Sealant with Teflon Cylinder block, water pump
(white) Dipstick tube threads
Temperature sending unit

TY15969 50 ml bottle LOCTITE 609 Wear ring sleeve-to-crankshaft


Retaining Compound
(green)

3 - 18 11/22/00
DIESEL ENGINE TROUBLESHOOTING

TROUBLESHOOTING
Problem or

Exhaust smoke white when

Exhaust smoke black when

Coolant in oil/oil in coolant


Engine starts but does not

Engine surges under load


Symptom

Air intake pressure drop

Air intake pressure rise


High fuel consumption

High oil consumption


Engine surges at idle
Engine will not start

Low engine output

Low oil pressure


continue to run
Check or

under load

under load
Solution

Fuel in oil
Improper intake/exhaust valve
● ● ● ●
clearance

Intake/exhaust valve leaking ● ● ● ●

Intake/exhaust valve seized ● ● ● ● ● ●

Cylinder head gasket leaking ● ●

Broken or seized piston ring ● ● ● ● ● ● ●

Piston ring, piston, or cylinder


● ● ● ● ●
worn

Crankshaft pin or bearing seized ● ● ● ●

Ring gaps not positioned


● ● ●
properly

Improper piston ring placement ● ● ●

Crankshaft pin or bearing worn ● ● ●

Connecting rod bolt loose ●

Foreign matter trapped in


● ●
combustion chamber
Excessive timing gear backlash ● ●

Intake/exhaust valve guide


● ● ●
worn

Governor not functioning


● ● ●
properly

Improper injection timing,


● ● ● ●
intake/exhaust valves

Engine running too cool ● ●

Engine running too hot ●

Coolant level low ●

Cracked water jacket ●

Fan belt loose ●

Improper engine oil viscosity/


● ● ● ● ●
type

11/22/00 3 - 19
TROUBLESHOOTING DIESEL ENGINE

Problem or

Exhaust smoke white when

Exhaust smoke black when

Coolant in oil/oil in coolant


Engine starts but does not

Engine surges under load


Symptom

Air intake pressure drop

Air intake pressure rise


High fuel consumption

High oil consumption


Engine surges at idle
Engine will not start

Low engine output

Low oil pressure


continue to run
Check or

under load

under load
Solution

Fuel in oil
Engine oil leaking ● ●

Oil pump worn ●

Oil filter clogged ●

Pressure control valve worn ●

Oil quantity low ●

Advanced injection pump timing ● ●

Retarded injection pump timing ● ● ● ●

Wrong type of fuel ● ● ●

Water in fuel ● ● ● ● ● ●

Fuel filter clogged ● ● ●

Air entering fuel system ● ● ●

Clogged or cracked fuel line ● ● ●

No fuel ● ●

Injection pump volume


● ● ● ● ●
insufficient

Injection pump volume


● ● ● ●
excessive

Incorrect spray pattern at fuel


● ● ● ● ● ●
injection nozzle

Air filter clogged ● ● ● ●

High altitude/temperature
● ● ● ●
operation

Exhaust system restricted ● ● ●

Inspect starter motor ●

Inspect alternator ●

Electrical system

troubleshooting

3 - 20 11/22/00
DIESEL ENGINE DIAGNOSIS

DIAGNOSIS

Conditions:
• Machine parked on level surface.
• Park brake engaged.
• Key switch off unless indicated otherwise.
Test/Check Point Normal If Not Normal
Engine Oil Check
Engine dipstick and Oil level between “L” and “H” marks. Oil Change oil and inspect for source of
exterior engine surface. not burnt, or contaminated with metal contamination. Check gaskets, seals,
particles, fuel, or coolant. No external plugs, cylinder head, block and intake
leakage, filter clean. manifold and breather. Change oil filter.
Cooling System Check
Coolant tank and Coolant level between marks on tank Add proper coolant mix.
radiator. when engine is warm.
Coolant in radiator full to top.
Coolant not contaminated with oil, fuel, Drain and flush system. Check for
or discolored brown. source of contamination.
Radiator screen free of debris. Clean or replace.
Water pump not leaking. Inspect water pump. (See WATER
PUMP.)
Hoses not cracked or leaking, clamps Pressure test radiator and cap. (See
and radiator cap tight. COOLING SYSTEM PRESURE TEST.)
Fan belt tight, not glazed or cracked. Replace and adjust belt tension. (See
FAN/ALTERNATOR DRIVE BELT
ADJUSTMENT.)
Fan blades not damaged or warped. Replace fan.
Fuel System Check
Fuel tank, pump, lines, Fuel level correct, not contaminated, Drain and clean fuel tank. Add fresh fuel.
filter and filter shutoff correct grade of fuel, no water. Replace filters.
valve. Fuel pump in-line filter free of debris.
Fuel hoses not cracked or leaking. Replace.
Fuel hose clamps tight. Replace or tighten.
Air Intake System
Check
Air filter and air intake. Air filter hose not cracked, clamps tight. Replace and tighten clamps.
Element not plugged. Air filter housing Replace element or housing.
sealed, no dirt tracking inside filter
element.
Fuel Pump Check
Fuel filter and fuel pump. Fuel level increases in filter. See FUEL PUMP POWER CIRCUIT
(Key switch in RUN Fuel pump operating - listen for DIAGNOSIS in ELECTRICAL section.
position.) humming sound. Test fuel pump pressure. (See FUEL
Fuel present in return hose at fuel pump. SUPPLY PUMP PRESSURE TEST.)
Replace fuel filter.

11/22/00 3 - 21
DIAGNOSIS DIESEL ENGINE

DIAGNOSIS (CONTINUED)

Test/Check Point Normal If Not Normal


Throttle Cable Check
Throttle lever and cable. Linkage not binding and adjusted Repair, replace, or adjust cable. (See
correctly. THROTTLE CONTROL ADJUSTMENT.)

Valve Check
Intake and exhaust Cold engine. Valve clearance within Check and adjust. (See VALVE
valves. specification. CLEARANCE CHECK AND
Valves not sticking. ADJUSTMENT.)
Check valve guides and stems.
Fuel Injector Check
Fuel at injectors. (Key in Crack fuel injection lines at injectors. Check spray pattern and cracking
START position - engine Fuel shutoff solenoid pulled in. pressure. (See FUEL INJECTION
cranking.) NOZZLE TEST.) Replace injectors. (See
Engine must crank. CRANKING CIRCUIT DIAGNOSIS in
ELECTRICAL section.)
Cylinder Compression
Check
Injector ports. (Key in Cylinder compression within Perform cylinder compression test. (See
START position.) specification. Pressure difference CYLINDER COMPRESSION
between cylinders within specification. PRESSURE TEST.)
Starter Check
Flywheel and starter. Minimum cranking rpm within See STARTER AMP DRAW TEST in
specification. ELECTRICAL section.
Injection Pump Check
Injection pump timing Timing should be correct. Remove pump Perform injection pump static timing
inspection. (Key OFF.) as the LAST possible solution. adjustment. (See INJECTION PUMP
STATIC TIMING ADJUSTMENT.) Have
pump tested by an EPA certified Service
Repair Shop.
Fast and Slow Idle
Check
Injection pump idle Engine runs smooth under load. Engine See SLOW IDLE ADJUSTMENT and
settings. (Engine rpm to specification. FAST IDLE ADJUSTMENT.
running).
Oil Pressure Check
Oil pressure sender port. Oil pressure in specification. Test engine oil pressure. (See ENGINE
OIL PRESSURE TEST.)
Thermostat Check
Thermostat. (Engine at Clean from corrosion, rust, or debris. Replace thermostat.
operating temperature.) Opening temperature within Perform thermostat opening test. (See
specification. THERMOSTAT OPENING TEST.)
Muffler Check
Muffler. Not restricted. Replace muffler.

3 - 22 11/22/00
DIESEL ENGINE TESTS AND ADJUSTMENTS

TESTS AND ADJUSTMENTS TEST THERMOSTAT OPENING


PRELIMINARY ENGINE TESTING TEMPERATURE
The following preliminary tests will help determine if Reason:
the engine can be tuned-up to restore operating To determine opening temperature of thermostat.
efficiency, or if engine overhaul is required.
• After engine has stopped for several hours, loosen Equipment:
crankcase drain plug and watch for any water to • Thermometer
drain out. A few drops due to condensation is
• Glass Container
normal, but more than this would indicate
problems which require engine repair. • Heating Plate
• With engine stopped, inspect engine coolant for oil
film. With engine running, inspect coolant for air
bubbles. Either condition would indicate problems
which require engine repairs rather than just a
tune-up.
• Perform compression test. Pressure below
specifications indicates problems which require
engine repair.

GENERAL TUNE-UP
RECOMMENDATIONS
As a general rule, an engine tune-up is not necessary
if all recommended Operator’s Manual hourly service
procedure are performed on schedule. If your engine
performance is not within the rated application
guidelines and if engine condition does not require
overhaul, the following service procedures are
recommended to help restore engine to normal
operating efficiency.
1. Change engine oil and filter. RG5971

2. Replace fuel filter and water separator. Procedure:


3. Clean crankcase vent tube.
Visually inspect thermostat for corrosion or damage.
4. Clean and flush cooling system. Replace as necessary.
5. Test thermostat and pressure cap.
6. Check condition of coolant hoses and fan belt.
7. Check air intake system. Replace air cleaner
elements.
c CAUTION
8. Check exhaust system.
DO NOT allow thermostat or thermometer to rest
9. Inspect turbocharger and check boost pressure.
against the side or bottom of container when
10. Check fuel injection system: heating water. Either may rupture if overheated.
• Have injection pump checked by your Authorized
Stanadyne workshop.
1. Remove thermostat. (See REMOVE
• Clean injection nozzles and adjust opening THERMOSTAT.)
pressure.
2. Suspend thermostat and a thermometer in a
• Adjust slow idle speed and perform a dynamic container of water.
timing.
3. Stir the water as it heats. Observe opening action of
11. Check engine oil pressure. thermostat and compare temperatures with
12. Check engine valve clearance. specification given in chart below.
13. Check electrical system.
NOTE: Due to varying tolerances of different suppliers,
initial opening and full open temperatures may
vary slightly from specified temperatures.

11/22/00 3 - 23
TESTS AND ADJUSTMENTS DIESEL ENGINE

Procedure:
Thermostat Test Specifications
NOTE: Use gauge from FKM10002 or JT05470
Rating Initial Opening Full Open Universal Pressure Test Kit if available.
(Range) (Nominal)
Otherwise, use gauge with a reading range of
71°C (160°F) 69-72°C (156-162°F) 84°C (182°F) 0–600 kPa (0–87 psi) minimum.

77°C (170°F) 74-78°C (166-172°F) 89°C (192°F)


1. Before checking oil pressure, warm up engine to
82°C (180°F) 80-84°C (175-182°F) 94°C (202°F) allow the lubricating oil to reach operating
temperature.
89°C (192°F) 86-90°C (187-194°F) 101°C (214°F) 2. Attach pressure gauge.
90°C (195°F) 89-93°C (193-200°F) 103°C (218°F) 3. At 93°C (200°F) operating temperature, gauge
should show a minimum pressure of:
92°C (197°F) 89-93°C (193-200°F) 100°C (213°F)
• 279 kPa (40 psi) at 1000 rpm
96°C (205°F) 94-97°C (201-207°F) 105°C (221°F)
• 350 kPa (50 psi) at rated speed
99°C (210°F) 96-100°C (205-212°F) 111°C (232°F)

MEASURE ENGINE BLOW-BY


4. Remove thermostat and observe its closing action
as it cools. In ambient air the thermostat should
close completely. Closing action should be smooth Reason:
and slow.
To determine the condition of piston, rings and cylinder
5. If thermostat is defective, replace thermostat.
walls.

CHECK ENGINE OIL PRESSURE Equipment:


• Standard Gas Gauge
Reason: • Hose
To determine if engine bearings or lubrication system
components are worn. Procedure:
1. Place a hose with a standard gas gauge over end of
Equipment: crankcase vent tube.
• JT03017 Hose Assembly 2. Run engine at rated speed (engine at operating
temperature and run-in, with at least 100 operating
• JT05577 Pressure Gauge (100 psi)
hours), full load.
• JT03349 Connector
3. Measure blow-by over a period of 5 minutes.
Multiply figure obtained by 12 (hourly rate) and
then compare with specifications.

Specifications:
3029D. . . . . . . . . . . . . . . . . . . . . . 4 m3/h (141 cu ft/h)
3029T . . . . . . . . . . . . . . . . . . . . . . 6 m3/h (225 cu ft/h)
If blow-by is lower, there is no excessive wear
between piston rings and liners. For a further check,
carry out cylinder compression pressure test. If blow-
by is higher, there is excessive wear between piston
rings and liners, resulting in loss of engine power.
Overhaul the engine.

CD30686

NOTE: A generic PowerTech 2.9 L engine is shown.


Skid steer engine is similar.

3 - 24 11/22/00
DIESEL ENGINE TESTS AND ADJUSTMENTS

CYLINDER COMPRESSION
PRESSURE TEST

Reason:
To determine the condition of the pistons, rings,
cylinder walls and valves.

Equipment:
FKM10021 Compression Test Kit

Procedure:

NOTE: Before beginning check, ensure that battery is CD30685


fully charged and injection nozzle area is Compression pressure must be 2400 kPa (350 psi)
thoroughly cleaned. minimum. The difference between the highest and
lowest cylinder must be less than 350 kPa (50 psi).
1. Start engine and run at slow idle for 10 to 15 This test must be performed at a minimum cranking
minutes. speed of 150 rpm.
2. Remove fuel injection nozzles.

A
A

B
B
C
C
CD30432

C
C D
D

3. Install 19.58– 90.578 adapter (A) in injection nozzle


bore with R73788 nozzle spacer (B) and two (2)
R92352 nozzle seals (C). Install holding plate (D).
Attach test gauge FKM10022 to adapter.
4. Push throttle lever to "slow Idle" position. Turn
crankshaft for a few seconds with starting motor.

11/22/00 3 - 25
TESTS AND ADJUSTMENTS DIESEL ENGINE

FUEL SUPPLY PUMP PRESSURE Procedure:

Reason: NOTE: Before checking engine speed, make sure


engine has reached its normal operating
To determine supply pump operating pressure. temperature.

All indicated speeds apply to an engine not


Equipment: under load. The maximum permissible speed
JT03115 Gauge (0—150 psi) with Male Quick Coupler. variation is ± 50 rpm for slow idle speed and
± 50 rpm for fast idle speed.
JT01609 Female Quick Coupler Adapter.

Test Gauge

Inlet
A

Outlet

CD30681
KV18011
1. Disconnect speed control rod at fuel injection pump.
2. Move pump throttle lever against pump fast idle
Procedure: adjusting screw (A). Check engine speed and
compare with specifications.
1. Remove plug from auxiliary outlet port on fuel filter
base. Specification:
2. Install test gauge as shown.
240 Fast Idle Speed . . . . . . . . . . . . . . . 2450±50 rpm
3. Start engine. Fuel pump should maintain positive
minimum pressure of 15–30 kPa (0.15–0.30 bar) 250 Fast Idle Speed . . . . . . . . . . . . . . . 2400±50 rpm
(2–4.5 psi). A low pressure can be due to a
NOTE: Fast idle is set by the factory, then the fast idle
clogged filter element or a defective supply pump.
adjusting screw (A) is sealed to prevent
Replace filter element then check pressure again.
tampering. Fast idle adjustment can only be
If reading is still below specification, replace
performed by an authorized EPA certified
supply pump.
service center.
NOTE: The fuel pump is not repairable and therefore
3. Move pump throttle lever in slow idle position
should be replaced when defective.
against slow idle adjusting screw (B). Check
engine speed and adjust to specifications.
FAST AND SLOW IDLE Specifications:
ADJUSTMENT 240 Slow Idle Speed. . . . . . . . . . . . . . . 1175±50 rpm
250 Slow Idle Speed. . . . . . . . . . . . . . . 1175±50 rpm
Reason: 4. Turn screw (B) clockwise to increase and counter-
clockwise to decrease engine speed.
To ensure an adequate slow idle rpm that will allow the
engine to run smoothly without stalling and to ensure
specified fast idle speed setting.

Equipment:
JT05801 Clamp-on Electronic Tachometer.

3 - 26 11/22/00
DIESEL ENGINE TESTS AND ADJUSTMENTS

FUEL INJECTION PUMP TIMING Install Timing Sensor


ADJUSTMENT

Dynamic Timing

Reason:
To make sure injection pump timing is set to
specification.

Equipment:
JT07158 Time-Trac. CD30195
Install FKM10429-6 timing sensor (E) between No. 1
nozzle and high pressure fuel line.
Using two wrenches, tighten sensor and fuel pressure
line to 30 N•m (22 lb-ft).
D

IMPORTANT: Timing sensor must be installed at


nozzle end of No. 1 fuel injection line. Sensor
G MUST BE installed on No.1 injection line of all
3-cylinder engines.

H
C

J I
K E
B
CD30441

A. Meter C

B. Sensor Clamp
C. 6 mm Clamp-On Transducer CD30673
D. Instruction Manuals
E. Timing Sensor NOTE: If clearance does not allow proper installation
F. Timing Pin of the timing sensor (E), FKM10429-5 or
G. Magnetic Probe FKM10465-3 clamp-on transducer (C) can be
H. Transducer Cable installed close to injection nozzle. Remove
I. 1/4" Clamp-On Transducer paint on injection line before installation.
J. Magnetic Probe Adapter
K. Magnetic Probe Adapter

JT07158 (or FKM10429A) TIME-TRAC electronically


indicates the start of injection with respect to the piston
top dead center (TDC), and allows accurate setting of
injection pump timing to provide optimum engine
performance while complying with exhaust emission
regulations.

11/22/00 3 - 27
TESTS AND ADJUSTMENTS DIESEL ENGINE

Install Magnetic Probe

CD30442
KV18568

IMPORTANT: Use JDG81-4 timing pin (A) in


Installation of flywheel housing with smooth
flywheel housing timing hole (B) to ensure
timing hole:
engine is NOT stopped at No. 1 TOP DEAD
CENTER. At No. 1 TDC, flywheel timing hole will 1. Install JDG821 magnetic probe adapter (F) into
align with flywheel housing timing hole (B). The flywheel housing smooth hole (B). Lightly tap
magnetic probe (D) would be damaged when adapter to lock into position.
engine is started. 2. Insert magnetic probe (D) into adapter until
contacts flywheel. Pull magnetic probe back out to
provide 0.65 mm (0.025 in.) recommended air gap.

KV18075

G. Magnetic Probe
H. Timing Sensor
I. Sensor Clamp

CD30443

Installation of flywheel housing with tapped timing


hole:
1. Install JDG793 magnetic probe adapter (C) into
flywheel housing tapped hole (B) until it bottoms.
2. Insert magnetic probe (D) into adapter until
contacting flywheel. Back out hex head of adapter
two flats and tighten lock nut (E), this will provide
the 0.65 mm (0.025 in.) recommended air gap.

3 - 28 11/22/00
DIESEL ENGINE TESTS AND ADJUSTMENTS

Timing Sensor and Magnetic Probe Connection

E
F
CD30447

3. Press "MAG PROBE" key. A default "trig level"


D value of 30% will appear. Then type in 70 to enter
a 70% "trig level" and press the "ENTER" key.
4. A default "Offset" value of 20.0° will now appear.
A B Type in 0.0 to enter a 0.0° "Offset" value and press
the "ENTER" key.
C
CD30446

1. Connect timing sensor (A) or clamp-on transducer


to meter socket "SR" (B) with FKM10429-4 sensor
clamp (C) and FKM10429-2 transducer cable (D).
Also connect ground cable wire.

IMPORTANT: Observe correct polarity to avoid


possible damage to meter. CD30204
5. The display will now show "Calibrate?". The meter
2. Connect magnetic probe (E) to meter socket "MP" is now ready to accept a timing sensor signal for
(F). calibration.
6. Press "ENTER" to perform calibration. Run engine
at 1,300 rpm. The display will automatically show
Check Fuel Injection Pump Timing the engine speed.

CD30205
CD30202 7. Once 1300 rpm is displayed, press "ENTER" key.
"Calibrating..." will then appear on the display for a
1. Press the "ON/CLEAR" key. The display will show
short period of time.
"Time-Trac", then "Model TT1000", then "R = 0".

NOTE: If the meter loses the engine speed signal or


NOTE: At this point, meter can be used as tachometer.
the engine is not running, the display will show
"Eng. not running". This message flashes three
2. Start the engine and run for 10 minutes to bring to times before the meter returns to tachometer
operating temperature. mode. To restart the procedure, press "MAG
PROBE" key (step 3).

11/22/00 3 - 29
TESTS AND ADJUSTMENTS DIESEL ENGINE

CD30449

IMPORTANT: Stop engine prior to making timing


adjustments. Injection pump can seize if
CD30448 adjustment is made with engine running.
8. Run engine at fast idle speed then load engine
down gradually to rated speed (see
SPECIFICATIONS) using dynamometer or any 10. Stop engine and, if necessary, rotate injection
other system allowing to load engine. pump as follows:
9. Record engine speed rpm and timing degrees. • If below specification, rotate pump towards engine
block.
• If above specification, rotate pump away from
Pump Timing Specifications engine block.

Rated NOTE: 1 mm (0.039 in.) offset on the injection pump


Pump Dynamic flange corresponds approximately to 2° on the
Model Speed
Part # Timing meter display.
(rpm)

240 RE500441 6° 2400


11. Recheck timing until specified timing is obtained.
240 RE501933 17° 2400 12. After adjustment, grind the engine front plate mark
to avoid any confusion with the original timing
240 RE505093 14.5° 2400 adjustment.
250 RE500442 7° 2400
NOTE: If the injection pump has to be removed from
250 RE504984 7° 2400 engine and reinstalled without any change,
mark both the front plate and the injection
pump flange to allow the installation of injection
NOTE: If display shows "R + 1,500 No Probe", the pump at the same location. In case of repair
magnetic probe has not been installed or replacement of injection pump, perform
properly, air gap exceeds 0.65 mm (0.025") or dynamic timing.
there is debris on the back of the flywheel.
Check for proper air gap or clean the back side
of the flywheel.

CD30198

3 - 30 11/22/00
DIESEL ENGINE TESTS AND ADJUSTMENTS

CHECK AND ADJUST VALVE Adjust valve clearance as directed in VALVE


ADJUSTMENT SEQUENCE.
CLEARANCE
VALVE ADJUSTMENT SEQUENCE
Reason: Firing order is 1-2-3.
To achieve correct engine operation.
A
Equipment: E D E D E D
Feeler Gauge
B
Procedure:
The valve clearance must be adjusted when engine is
cold.
E D E D E D

CD30549

A. Front of Engine
B. No. 1 Piston at TDC Compression Stroke
C. No. 1 Piston at TDC Exhaust Stroke
D. Intake Valve
CD30544
E. Exhaust Valve
Using JDE83 or JDG820 Flywheel Turning Tool (A),
rotate engine flywheel in running direction (clockwise 1. Using JDE81-4 Timing Pin, lock No. 1 piston at
viewed from water pump) until No.1 piston (front) has TDC compression stroke (B).
reached top dead center (TDC) on compression 2. Adjust valve clearance on No. 1 and 2 exhaust
stroke. Insert timing pin JDE81-4 (B) into flywheel valves and No. 1 and 3 intake valves.
bore. 3. Turn crankshaft 360° and reinsert timing pin.
4. Adjust valve clearance on No. 3 exhaust valve and
No. 2 intake valve.

CD30545

NOTE: When No. 1 piston is at TDC on compression


stroke, valve springs of No. 1 cylinder are not
under tension.

VALVE CLEARANCE SPECIFICATIONS


Intake valve. . . . . . . . . . . . . . . . . . . . . 0.31—0.38 mm
(0.012—0.015 in.)

Exhaust valve . . . . . . . . . . . . . . . . . . 0.41—0.048 mm


(0.016—0.019 in.)

11/22/00 3 - 31
REPAIR DIESEL ENGINE

REPAIR

ENGINE REPAIR STAND

c CAUTION
This repair stand should be used only by
qualified service technicians familiar with this
equipment.

To maintain shear strength specifications, alloy


steel SAE Grade 8 or higher cap screws must be
used to mount adapters or engine.
D05225ST
For full thread engagement, be certain that
D05225ST Adapter tapped holes in adapters and engine blocks are
clean and not damaged. A thread length
engagement equal to 1-1/2 screw diameters
minimum is required to maintain strength
requirements.

To avoid structural damage or personal injury,


do not exceed the maximum weight capacity.
When engine weight is more than 450 kg (992 lb),
it is recommended to use additional support.

To prevent possible personal injury due to


engine slippage, recheck to make sure engine is
solidly mounted before releasing support from
engine lifting device.

R26420N Never permit any part of the body to be


D01003AA Repair Stand positioned under a load being lifted or
suspended. Accidental slippage may result in
To facilitate engine repair, the D01003AA repair stand personal injury.
can be used in conjunction with D05225ST adapter.

3 - 32 11/22/00
DIESEL ENGINE REPAIR

MOUNT ENGINE ON REPAIR STAND ENGINE REMOVAL/INSTALLATION

NOTE: Engine and pumps weigh approximately 907


kg (2000 lb.) Be sure Engine Repair Stand and
Engine Hoist have adequate capacity.

Equipment:
Engine Repair Stand
Engine Hoist - 1000 kg (2200 lb.) capacity

Engine Removal:
1. Remove bucket or any other attachments
CD30527
2. Park skid steer on flat level surface. Place blocks in
front of and behind tires.
1. Use a 73 mm spacer at hole (A) and a 79 mm 3. Start engine and raise boom arms to the fully raised
spacer at hole (B). position, and engage boom locks.
2. Mount engine to adapter using the cap screws
4. Disconnect battery, negative (–) cable first then
listed below at the hole locations as shown:
positive (+) cable.
Holes A and B . . . . 14 mm (9/16-12 x 4-1/2 in.) 5. Raise ROPS and ensure ROPS is locked in
Hole C . . . . . . . . . 38 mm (9/16-12 x 1-1/12 in.) position.
3. Drain all engine oil and coolant. 6. Remove top, rear, and side engine panels.

IMPORTANT: Hydraulic lock occurs when trapped


oil in the oil filter housing drains through the
turbocharger, the exhaust and intake manifolds, c CAUTION
and then into the cylinder head. After starting
the engine, the trapped oil in the manifold and Explosive release of fluids from pressurized
head is released into the cylinders filling them cooling system can cause serious burns. Shut
with oil causing hydraulic lock and severe off engine. Only remove filler cap when cool
engine damage. enough to touch with bare hands. Slowly loosen
cap to first stop to relieve pressure before
removing cap completely.

D
NOTE: Approximate cooling system capacity is 9.5 L
(10 qt).

CD30528
Radiator Drain Valve
4. Disconnect oil inlet line at turbocharger (D) to
prevent hydraulic lock. Drain Hose

KV13939

7. Route radiator drain hose out access panel on left


side of frame. Open radiator drain valve and drain
coolant through drain hose into proper container.
8. Disconnect cab heater hoses (if equipped) from the
engine.

11/22/00 3 - 33
REPAIR DIESEL ENGINE

NOTE: Approximate hydraulic oil reservoir capacity is


15.6 L (4.1 gal). Finger
Guard
Upper Radiator
9. Remove bottom engine access cover located under Hose
rear of skid steer.

Rear Drain Plug

KV13940

KV13964

10. Remove front and rear hydraulic oil reservoir drain


plugs and drain hydraulic oil into proper container.

Inlet
Lower Radiator Hose

KV13941

12. Remove finger guard from radiator fan shroud.


13. Remove upper and lower radiator hoses.

NOTE: Use caps or plugs to cover all openings to


Outlet
prevent contamination of hydraulic oil.

KV18010

11. Disconnect inlet line from fuel filter. Close all


openings using caps or plugs to prevent Hydraulic Oil Cooler Hoses
contamination of fuel system. Remove filter base
and attach to engine using wire or plastic tie.

KV13058

14. Disconnect hydraulic oil cooler hoses. Use caps or


plugs to cover openings to prevent contamination.

3 - 34 11/22/00
DIESEL ENGINE REPAIR

Latch Bracket

Filler Tube

Cap Screw
Intake Hose

Air Cleaner
KV18841 KV13948

15. Remove filler tube-to-radiator support cap screw. 22. Disconnect intake hose from intake manifold or
16. Remove engine cover latch bracket. Repeat for turbocharger if equipped.
opposite side of radiator. 23. Disconnect air filter restriction sensor connector.
24. Remove air cleaner/intake hose assembly from
mounting bracket.
Recovery Bottle
NOTE: Close all openings using caps or plugs to
prevent contamination.

Hydraulic Oil Hose

KV18012

17. Disconnect coolant recovery hose from radiator


filler neck and remove coolant recovery bottle.
18. Remove cap screws from both sides of radiator/
hydraulic oil cooler mounting bracket. Harness Connector
19. Remove radiator and oil cooler assembly using a
lifting strap and suitable hoist. KV13949

25. Remove hydraulic oil hose from filter manifold.


Close all openings using caps or plugs.
26. Disconnect brake solenoid harness connector.
Wiring Connector

Cap Screws
Fuel Leak-Off Line

KV13064
Mounting Bracket
KV13950
NOTE: Tag or label all wires and connectors to aid
during installation.
27. Remove four cap screws and mounting bracket.
20. Disconnect coolant temperature sensor wiring Move bracket with hydraulic oil filter and filter
connector. manifold forward away from engine.
21. Disconnect fuel leak-off line.

11/22/00 3 - 35
REPAIR DIESEL ENGINE

Cylinder Block Heater

Wiring Lead

Throttle Linkage Wire Harness Retainer


KV18840 KV18836

28. Disconnect wiring lead from fuel shut-off solenoid. 33. Bend wire harness retainer back and move harness
29. Disconnect throttle linkage from bracket and fuel away from engine.
injection pump. 34. Disconnect cylinder block heater connector (if
equipped).

NOTE: Engine oil pressure sensor not shown in photo.

30. Disconnect two wiring leads from engine oil


pressure sensor located below exhaust manifold.
Cut wire tie straps as necessary.

Preheat Relay

Front Engine
Mounting Bolt

KV31115

Alternator

Manifold Preheater

Rear Engine
Mounting Bolts

Starter KV13957

35. Remove front and rear engine mounting bolts.

KV18842

31. Disconnect all wire leads and connectors from


preheat relay, manifold preheater, starter, and
alternator. Cut all tie straps as necessary.
32. Disconnect backup alarm if equipped.

3 - 36 11/22/00
DIESEL ENGINE REPAIR

B
KV15160
F

c CAUTION
Boom lock pins must remain in place. Be sure
that boom is adequately supported by boom lock
KV13985
pins.
43. Install lifting sling around hydrostatic pump and
mounting plate. Attach hoist and take up slack in
36. Remove boom lock linkage mounting plate (A) cap sling.
screws. Disconnect boom lock linkage (B) from
44. Remove pump flange-to-engine flywheel cover cap
levers (C) and (D). Remove mounting plate,
screws. Remove mounting plate cap screws,
leaving boom lock pins and levers in place.
washers, and nuts.
45. Remove remaining flywheel cover cap screws.
Remove flywheel cover.

KV13976
Cap Screw
37. Install JD244 lifting brackets to engine. Attach
JDG23 lifting sling to bracket.
38. Attach a suitable hoist to engine and take out the Coupling
slack on lifting chain.
39. Label and remove hoses from hydrostatic pump KV31121
assembly.
40. Disconnect steering linkage from hydrostatic pump 46. Remove eight coupling-to-flywheel cap screws.
arms. Remove coupling.
47. Install engine on repair stand. (See MOUNT
ENGINE ON REPAIR STAND.)
NOTE: Make sure all lines, hoses, and electrical wiring
are removed and do not entangle with engine
during removal. Engine Installation:

41. Remove engine/hydrostatic pump assembly. IMPORTANT: Before installing engine make sure
42. Lower engine to floor and block. all electrical wiring, lines, and hoses are moved
away from engine.

11/22/00 3 - 37
REPAIR DIESEL ENGINE

Torque Specification:
Pump Flange-to-flywheel . . . . . . 140 N•m (105 lb-ft)
cover cap screw
Mounting bracket cap screw . . . . 140 N•m (105 lb-ft)
Mounting bracket . . . . . . . . . . . . . 305 N•m (225 lb-ft)
cap screw and nut

Washer
Grommet
Cap Screw Nut
Bushing 140 N•m (105 lb-ft)

Grommet

Washer

KV13987
Rear Engine Mount

IMPORTANT: If bushings have flat sides, flat side


should be parallel to machine sides.
Cap Screw Cap Screw
305 N•m (225 lb-ft) 140 N•m (105 lb-ft)
Install Coupling and Flywheel Cover: KV13985

3. If removed, install cap screws, washers, and nuts


on both sides of hydrostatic pump mounting
bracket. Tighten cap screws to specification as
shown.

Cap Screw

Coupling

KV31121
KV13976
1. Place coupling on flywheel and install eight 4. Install engine/pump assembly. Remove hoist and
coupling-to-flywheel cap screws. Tighten to lifting brackets.
63 N•m (46 lb-ft).

Install Hydrostatic Pumps:


1. Install bushings, upper grommets, and upper
washers of front and rear engine mounting
hardware as shown above before lowering engine
into position.
Rear Engine
2. If removed, install two pump flange-to-engine Mounting Bolts
flywheel cover cap screws. Tighten cap screws to
140 N•m (105 lb-ft).
KV13957

3 - 38 11/22/00
DIESEL ENGINE REPAIR

IMPORTANT: If bushings have flat sides, flat side removal.


should be parallel to machine sides. DO NOT 11. Install wire ties as necessary.
ROTATE while tightening mount hardware.

5. Install lower grommets, lower washers, nuts, and


bolts of front and rear engine mounting hardware.
Tighten to 305 N•m (225 lb-ft).
Wiring Lead
NOTE: Inspect hydraulic fittings and O-rings for
damage. Replace as necessary.
Throttle Linkage
6. Connect hoses to hydrostatic pump assembly.
KV18840

Block Heater Connector 12. Connect fuel shut-off solenoid wiring lead.
13. Connect throttle linkage to fuel injection pump and
bracket.

NOTE: Engine oil pressure sensor not shown in photo.

14. Connect two engine oil pressure sensor wiring


leads. Sensor is located below exhaust manifold.
Wire Harness Retainer
KV18836
Cap Screws
7. Route wiring harness, lines, and hoses as needed.
Bend wire harness retainer back into position.
8. Connect cylinder block heater lead (if equipped).
9. Connect steering linkage.

Preheat Relay

Mounting Bracket
KV13950

15. Install hydraulic oil filter and air cleaner mounting


bracket using four cap screws. Tighten cap screws
securely.
Alternator

Hydraulic Oil Hose


Manifold Preheater

Starter Harness Connector

KV13949

16. Connect hydraulic oil hose and tighten clamp.


KV18842
17. Connect harness connector to solenoid connector
10. Connect all wire leads, cables, and connectors to on filter manifold.
the preheat relay, manifold preheater, starter, and 18. Install air cleaner and intake hose. Connect
alternator using the tags or labels installed during harness to air filter restriction sensor.

11/22/00 3 - 39
REPAIR DIESEL ENGINE

Latch Bracket

Filler Tube
Coolant Temperature
Sender
Cap Screw
Fuel Leak-Off Line

KV18841

KV13064 25. Install engine cover latch bracket on both sides of


radiator support.
19. Connect fuel leak off line and tighten clamp.
26. Install and tighten hydraulic oil fill hose cap screw.
20. Connect harness to coolant temperature sender.

Ground Cable Hydraulic Oil Cooler Hoses


Recovery Tank

KV13058
KV18012
21. Install radiator/hydraulic oil cooler assembly. NOTE: Replace all O-rings and seals. Used or
22. Install coolant recovery bottle and connect hose to damaged O-rings and seals will leak.
radiator filler neck.
23. Check for fan tip clearance. Fan shroud should
have tip clearance of 10 ± 1.0 mm 27. Install new O-ring seals and connect hydraulic oil
(0.40 ± 0.04 in.) to shroud cutout. cooler hoses. Tighten hoses securely.

NOTE: Make sure ground cable is installed under cap


screw as shown above.
24. Apply threadlock (medium strength) on threads of
mounting cap screws. Install cap screws on both
sides of radiator. Tighten cap screws to 29 N•m
(21 lb-ft).

3 - 40 11/22/00
DIESEL ENGINE REPAIR

35. Close drain valve and fill radiator with proper


Finger
coolant to top of filler neck.
Guard 36. Connect backup alarm harness if equipped.
Upper Radiator
Hose 37. Install and connect boom lock plate and linkage.
38. Connect battery positive (+) cable then the negative
(–) cable.
39. Disengage ROPS lock and lower ROPS. Install cab
retaining washers and nuts.
40. Start engine and run for two minutes at slow idle.
Operate all hydraulic/hydrostatic controls. Check
for oil, fuel and coolant leaks. Shut engine off and
check coolant and hydraulic oil levels. Add or drain
KV13940
coolant and oil as necessary.
41. Purge air from cab heater (if equipped). See CAB
HEATER in MISCELLANEOUS section.
42. Repeat procedure at fast idle to make sure all air is
removed from system.
43. Install all side, top and rear engine panels, and
access covers.

RADIATOR REMOVAL, INSPECTION,


AND INSTALLATION
Lower Radiator Hose

KV13941
28. Install cooling fan finger guard. Tighten cap screws
to 26 N•m (19 lb-ft).
29. Install upper and lower radiator hoses. Tighten all
hose clamps securely.
30. Connect cab heater hoses to engine (if equipped).

Inlet

TS281

c CAUTION
Outlet Explosive release of fluids from pressurized
cooling system can cause serious burns. Shut
KV18010 off engine. Only remove filler cap when cool
enough to touch with bare hands. Slowly loosen
31. Install fuel filter base with filter. Connect inlet line to
cap to first stop to relieve pressure before
filter base.
removing cap completely.
32. Install hydraulic oil reservoir drain plugs and tighten
securely.
Removal:
NOTE: Approximate hydraulic oil reservoir capacity is
1. Open top and rear panels and remove side engine
15.6 L (4.1 gal.).
panels.
2. Disconnect battery, negative (-) cable first.
33. Fill hydraulic oil reservoir with clean hydraulic oil.
34. Install bottom engine access cover. NOTE: Approximate cooling system capacity is 9.5 L
(10 qt).
NOTE: Approximate cooling system capacity is 9.5 L
(10 qt).

11/22/00 3 - 41
REPAIR DIESEL ENGINE

Latch Bracket

Filler Tube

Cap Screw
Radiator Drain Valve
Finger
Guard
Drain Hose

KV13939 KV18841
3. Route radiator drain hose out of access panel on 6. Remove cooling fan finger guard.
left side of frame. 7. Remove cap screw, retaining hydraulic filler tube to
4. Open radiator drain valve and drain coolant. support.
8. Remove engine access cover latch bracket. Repeat
Finger procedure on opposite side of radiator.
Guard
Upper Radiator
Hose

Coolant Recovery Hose

Cap Screws

KV13940

KV13992
9. Remove four cap screws securing fan shroud. Move
fan shroud away from fan and towards engine,
away from radiator.
10. Disconnect coolant recovery hose from filler neck
and remove coolant recovery bottle.
Cap Screws

Lower Radiator Hose

KV13941

5. Remove upper and lower radiator hoses.

KV18010

11. Remove two cap screws and move fuel filter


assembly away from radiator support.
12. Attach a suitable lifting strap and hoist to radiator.

3 - 42 11/22/00
DIESEL ENGINE REPAIR

Installation:

Cap Screw

Cap Screw
KV13993

KV13993
NOTE: Some models have a spacer washer between 1. Install radiator in support brackets. Apply medium
the support bracket and radiator mounting strength threadlock to both cap screws. Install and
flange. Retain for reuse. tighten only left side cap screw to 29 N•m
(21 lb-ft).
13. Remove one cap screw on each side of radiator
support and remove radiator. Shroud does not
need to be removed with radiator.
Washer

c CAUTION
Reduce compressed air to less than 210 kPa
(30 psi) when using for cleaning purposes. Clear
area of bystanders, guard against flying chips,
and wear personal protection equipment
including eye protection.

14. Check radiator for debris lodged in fins. Clean KV31119


radiator using compressed air or pressure washer.
2. Inspect clearance between right radiator mounting
15. Inspect radiator for bent fins, cracks, and damaged flange and support bracket. If it is in excess of
seams. Repair or replace radiator as necessary. 3mm (0.120 in.), insert washers (24H1353) as
needed to reduce the gap to 1–3mm
(0.040–0.0120 in.). Install and tighten cap screw to
Notch Fan Shroud
29 N•m (21 lb-ft).
3. Install fan shroud using four cap screws.
4. Check for tip clearance. Fan shroud should have
clearance of 10 ± 1.0 mm (0.40 ± 0.40 in.) to fan
shroud cut out.

Latch Bracket

Filler Tube

KV13059 Cap Screw

16. Install fan shroud over cooling fan, if removed, with


upper radiator hose notch at top as shown in
photo.

NOTE: Inspect all shroud and radiator seals. Replace


as needed. KV18841
5. Install engine cover latch brackets and hydraulic
filler tube cap screw.

11/22/00 3 - 43
REPAIR DIESEL ENGINE

on an injection pump while it is still warm. To do


so may cause pump parts to seize.

Coolant Recovery Hose

Cap screws

KV13992
6. Install coolant recovery bottle and connect recovery
hose to filler neck.
7. Install fuel filter assembly.

Finger
Guard
Upper Radiator
Hose

KV13940

Lower Radiator Hose


KV13941
8. Connect upper and lower radiator hoses.
9. Install finger guard. Tighten cap screws to 26 N•m
(20 lb-ft).
10. Close drain valve and fill radiator with proper
coolant to top of filler neck.
11. Connect battery, positive (+) cable first.
12. Install top, rear, and side engine panels.

CLEAN ENGINE
1. Close all openings with caps and plugs. If electrical
components are not removed prior to cleaning,
cover with plastic and tape securely to prevent
moisture from entering.
2. Steam-clean engine thoroughly.

IMPORTANT: Never steam-clean or pour cold water

3 - 44 11/22/00
DIESEL ENGINE REPAIR

ENGINE DISASSEMBLY SEQUENCE ENGINE ASSEMBLY SEQUENCE


The following sequence is suggested when complete The following assembly sequence is suggested when
disassembly for overhaul is required. engine has been completely disassembled. Be sure to
check run-out specifications, clearance tolerances,
1. Drain engine oil. Check engine oil for metal
torques, etc. as engine is assembled. Refer to the
contaminates.
appropriate repair section when assembling engine
2. Remove fan belts, fan, alternator, and muffler. components.
3. Remove turbocharger (if equipped) and exhaust
manifold. 1. Install all plugs (and serial number plates) in
cylinder block that were removed to service block.
4. Remove rocker arm cover with vent tube. On
engines having an Option Code label on rocker 2. Install clean piston cooling orifices and new
arm cover, be careful not to damage label. camshaft bushings.
5. Remove rocker arm assembly and push rods. Keep 3. Install cylinder liners without O-rings and measure
rods in sequence. Check for bent push rods and protrusion. Install liners with O-rings.
condition of wear pad contact surfaces on rockers. 4. Install crankshaft and main bearings.
6. Remove thermostat housing and bypass tube. 5. Install flywheel housing, rear oil seal, and flywheel.
7. Remove high-flow pump (if equipped). 6. Install pistons and rods. Check for piston protrusion.
8. Remove oil cooler piping and water pump. 7. Install oil system bypass valve.
9. Remove dipstick, oil filter, and engine oil cooler. 8. Install front plate.
Discard standard-flow oil cooler if oil contained 9. Install oil outlet tube, O-ring in block, and oil pump.
metal particles. 10. Install injection pump on front plate.
10. Remove starting motor. 11. Install high-flow pump (if equipped).
11. Remove fuel lines. 12. Install camshaft, timing gears, and oil deflector.
12. Remove injection lines, injection pump, and 13. Time all gears to TDC, No. 1 cylinder on
injection nozzles. compression stroke.
13. Remove cylinder head. 14. Install timing gear cover (with new front seal).
14. Remove cam followers. Keep in same sequence as 15. Install oil pan.
removed. 16. Install oil pressure regulating valve (if equipped).
15. Remove oil pan. 17. Install cam follower in the same sequence as
16. Remove crankshaft pulley. removed.
17. Remove oil pressure regulating valve assembly. 18. Install cylinder head gasket, cylinder head, push
18. Remove timing gear cover. rods, and rocker arm assembly.
19. Remove oil pump drive gear, outlet tube (and its O- 19. Install injection nozzles (with new seals) and
ring in block), and pump body. injection lines.
20. Remove oil deflector, timing gears, and camshaft. 20. Install fuel lines.
Perform wear checks. 21. Install starting motor.
21. Remove engine front plate. 22. Install engine oil cooler, new oil filter, and dipstick.
22. Remove oil system bypass valve. Never clean or reuse a contaminated standard-
23. Remove flywheel and flywheel housing. flow oil cooler, install a new one.
24. Stamp cylinder number on rod (if required). 23. Install thermostat housing with thermostat.
Remove pistons and rods. Perform wear checks 24. Install exhaust manifold and turbocharger. Pre-lube
with Plastigage™. the turbocharger.
25. Remove main bearings and crankshaft. Perform 25. Install water pump and hoses.
wear checks with Plastigage™. 26. Install crankshaft pulley.
26. Remove cylinder liners and mark each one with 27. Install alternator, fan, and fan belts.
cylinder number from which removed. 28. Adjust valves and install rocker arm cover.
27. Remove piston cooling orifices. 29. Install vent tube.
28. Remove balancer shaft and camshaft bushings (if 30. Install muffler.
equipped).
31. Fill engine with clean oil and proper coolant.
29. Remove cylinder block plugs and serial number
32. Perform engine break-in and perform normal
plate (as required) when block is to be put in a "hot
standard performance checks.
tank".
30. Clean out liner bores (upper and lower areas) with
nylon brush.
31. Measure cylinder block.

Plastigage is a trademark of DANA Corp.

11/22/00 3 - 45
REPAIR DIESEL ENGINE

CYLINDER HEAD–EXPLODED VIEW

E
D

CD30531

A. Cylinder Head C. Cylinder Head Gasket E. Rocker Arm Cover


B. Valve Seat D. Cylinder Head Bolt (1/2-13 F. Vent Tube
UNC x 112 mm[4.41 in.])

3 - 46 11/22/00
DIESEL ENGINE REPAIR

CHECK VALVE LIFT REMOVE CYLINDER HEAD

C
A

CD30532

D
NOTE: Measuring valve lift can give an indication of E CD30533
wear on cam lobes.
NOTE: A generic PowerTech 2.9 L engine is shown.
1. Rotate engine and determine valve locations as Skid steer engine is similar.
indicated under VALVE CLEARANCE in this
section. Before removal, mark all parts so that they can
2. Adjust valve to zero clearance. be installed in their original positions.
3. Position dial indicator on valve rotator and adjust
indicator to "0".
1. Drain engine coolant.
4. Rotate engine and observe indicator reading as
2. Remove muffler.
valve moves to the fully open position. Compare
readings with specifications. 3. Remove exhaust manifold (A). On turbocharged
engine, disconnect oil inlet line (B) and oil return
5. Repeat above procedure for all valves and readjust
line (C), then remove the exhaust manifold,
valves to specified clearance after this operation.
turbocharger, and crossover pipe.
6. If valve lift is not within specification, remove and
4. Remove thermostat housing (D), bypass tube (E),
inspect camshaft.
and thermostat.

Valve Lift at 0.00 mm (0.00 in.) clearance:

Intake valves . . . . . . . . . . . . . . . . . 11.56—12.37 mm


(0.455—0.487 in.)
Wear tolerance . . . . . . . . . . . . . 11.13 mm (0.438 in.)

Exhaust valves . . . . . . . . . . . . . . . . 11.28—12.12 mm


0.444—0.477 in.)
Wear tolerance . . . . . . . . . . . . . 10.85 mm (0.427 in.)
KV18569
5. Remove fuel leak-off (F) and fuel delivery lines (G)
as assemblies.
6. Remove fuel injection nozzles (H).

NOTE: Removal of fuel injection nozzles is necessary


to prevent them being damaged when cylinder
head is removed.

11/22/00 3 - 47
REPAIR DIESEL ENGINE

KV18570 CD30537

NOTE: A generic PowerTech 2.9 L engine is shown. 14. Lift cylinder head from block. If cylinder head sticks,
Skid steer engine is similar. use a soft hammer to tap cylinder head. Do not
use screwdriver or pry-bar which can damage the
7. Remove air inlet adapter (I). sealing surface.
8. Remove crankcase vent hose (J).
9. Remove rocker arm cover (K). NOTE: Do not turn crankshaft after removal of cylinder
head until each liner has been secured with
washer and cap screw.

CLEAN INJECTION NOZZLE BORES

KV18571
10. Remove rocker arm assembly (L).
11. Remove all push rods.

CD30538

IMPORTANT: Always turn the tool clockwise


through the bore, even when pulling back.
Otherwise tool will get dull.

Using special tool JDE39 (A), remove carbon deposits


from bores of fuel injection nozzles.
KV18076
12. In case of cylinder head failure, record torque of
each bolt before removing. These values can be
asked by the factory for further investigations. To
record bolt torque, proceed as follows:
• Mark a reference mark (in-line) on socket (M) and
cylinder head surface (N).
• Loosen bolt at least 1/4 turn then, using a torque
wrench, retighten until reference marks align.
• Record torque.
13. Remove all cylinder head bolts.

3 - 48 11/22/00
DIESEL ENGINE REPAIR

VALVE ACTUATING PARTS

D
C

G
F

A I

L
K

CD30379
A. Cam Follower D. Support G. Keepers J. Metering Seal
B. Push Rod E. Shaft H. Rotator K. Valve Seat Insert
C. Rocker Arm F. Plug I. Spring L. Valve

REMOVE VALVES AND VALVE CHECKING CYLINDER HEAD


SPRINGS FLATNESS

L103629
L30699
1. Using JDE138 Valve Spring Compressor, compress
the valve springs far enough to remove keepers. Maximum permissible flatness is 0.08 mm (0.003 in.).
2. Release spring tension and remove valve rotator Machined surface of cylinder head must be re-faced if
and valve spring. Mark each part so that it can be flatness is more than specified maximum.
assembled in the same position it was removed
from.
3. Remove valves, marking them for assembly. NOTE: Maximum permissible amount to be machined
4. Remove valve stem seals from valve guide tower. from cylinder head is 0.76 mm (0.03 in.).
After any head machining, always recheck
valve recesses.

11/22/00 3 - 49
REPAIR DIESEL ENGINE

CLEAN VALVE GUIDES If valve guide-to-stem oil clearance exceeds the wear
limit, oversize valve stems 0.38 mm (0.015 in.) and
0.76 mm (0.030 in.) are available. Have valve guides
reamed by a qualified workshop to assure a proper
guide-to-stem clearance.

CD30539

Using a plastic brush, clean valve guides.

NOTE: A few drops of light oil or kerosene will make


cleaning of valve guides easier.
CD30548

NOTE: Production valve guides have a very shallow


MEASURE VALVE GUIDES spiral cut (arrow), similar to a thread, to
lubricate the valve stem with a metered supply
of oil. Be sure, when valve guides are reamed
that this groove is restored.

CLEAN AND INSPECT VALVE SEATS

CD30550

Using a micrometer, measure valve guides then


compare with specifications.

Valve Guide Specifications:


CD30540
Valve guide bore diameter in a new 1. Use an electric hand drill with D17024BR End
cylinder head . . 7.912—7.938 mm (0.312—0.313 in.) Brush to remove all carbon on valve seats.
2. Inspect seats for excessive wear, cracks, or
New guide-to-valve stem damage.
clearance. . . . . . . . 0.05—0.10 mm (0.002—0.004 in.)

Maximum permissible
clearance. . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)

3 - 50 11/22/00
DIESEL ENGINE REPAIR

LAPPING VALVE SEATS After lapping valve seat or machining combustion face,
install re-faced or new valves in cylinder head and
check valve recess (A).

Valve Recess Specifications:

Intake. . . . . . . . . . . 0.61—1.11 mm (0.024—0.044 in.)

Wear tolerance . . . . . . . . . . . . . . 1.63 mm (0.064 in.)


Exhaust . . . . . . . . . 1.22—1.72 mm (0.048—0.068 in.)

Wear tolerance . . . . . . . . . . . . . . 2.26 mm (0.089 in.)


When maximum valve recess is reached, replace
valve seat inserts.

CD30380 REMOVE VALVE SEAT INSERTS


Check seat width and contact pattern between seat Valve seat inserts are made of sintered metal. The
and valve with blueing. If necessary lap the valve onto following method, performed by experienced
its seat using a lapping tool and lapping compound. personnel or specialized workshop, can be used to
remove inserts.
IMPORTANT: Always check valve recess in
cylinder head after lapping, as described in this Using an Arc Welder
section.
1. Protect the valve guide by installing a cap screw or
dowel in guide to protect from weld spatter.
CHECK VALVE RECESS

RG7761

RG4756

RG7813
2. Protect the cylinder head surface with a non-
CD30541 flammable welder’s cloth (A). Apply a thin bead of
weld (B) around internal diameter of valve seat
insert.

11/22/00 3 - 51
REPAIR DIESEL ENGINE

VALVE SEAT INSERT INSTALLATION

RG7763

3. Allow insert to cool and use a screwdriver (C) or


similar tool and carefully pry insert from bore.
4. After removal of inserts, thoroughly clean area
around valve seat bore and inspect for damage or
cracks. Replace cylinder head as necessary.
RG5653

Machining Valve Seat Insert 1. Freeze the valve seat inserts to –30° C (–22° F).
2. Using JDG676 Pilot Driver (A) and JDG675 Valve
Seat Insert Installing Adapter (B), install valve seat
inserts.
3. Lap valve seats to maintain correct valve recess
and valve to valve seat sealing. (See LAPPING
VALVE SEATS.)

INSPECT AND MEASURE VALVES


Thoroughly clean and inspect valves to help determine
if they can be reused. Replace valves that are burned,
RG5606 cracked, eroded, or chipped.

1. Machine insert according to valve seat bore


specifications as shown, until a thin layer of
material stays in cylinder head.
2. Remove rest of material and clean valve seat bore.

Intake Valve Seat Insert Bore Specifications:


A. . . . . . . . 47.104—47.130 mm (1.8545—1.8555 in.)
B. . . . . . . . . . . . . . . . 3.45 mm (0.136 in.) Reference
C. . . . . . . . . 9.936—10.064 mm (0.3912—0.3962 in.)
D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38—42°
E. Maximum radius. . . . . . . . . . 0.5 mm (0.019 in.) T82053

1. Measure valve stem diameter and compare with


Exhaust Valve Seat Insert Bore Specifications:
corresponding valve guide diameter to check
A. . . . . . . . 42.987—43.013 mm (1.6924—1.6934 in.) clearance. (See MEASURE VALVE GUIDES.)
B. . . . . . . . . . . . . . . . 3.82 mm (0.150 in.) Reference
C. . . . . . . . . 9.936—10.064 mm (0.3912—0.3962 in.) Valve Stem Diameter Specifications:
D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38—42° Intake Valve. . . . . . . . . . . . . . . . . . 7.864—7.884 mm
E. Maximum radius. . . . . . . . . . 0.5 mm (0.019 in.) (0.3096—0.3104 in.)
Exhaust Valve . . . . . . . . . . . . . . . . . 7.848—7.874 mm
Replacement Valve Seat Insert OD: (0.3090—0.3100 in.)
Intake. . . . . 47.155—47.181 mm (1.8565—1.8575 in.)
Exhaust . . . 43.038—43.064 mm (1.6944—1.6954 in.)

3 - 52 11/22/00
DIESEL ENGINE REPAIR

INSPECT AND MEASURE VALVE


SPRINGS

RG4234

2. Check for valve face run-out and bent valves.


T82054
Maximum permissible
run-out of valve face:. . . . . . . 0.038 mm (0.0015 in.)
Valve Spring Specifications:

GRIND VALVES Spring Free Length 0 N (0 lb)


Height . . . . . . . . . . . . . . . . . . . . . 54.0 mm (2.125 in.)

Spring Compressed 240—280 N (54—62 lb)


Height . . . . . . . . . . . . . . . . . . . . . . 46.0 mm (1.81 in.)

Spring Compressed 590—680 N (133—153 lb)


Height . . . . . . . . . . . . . . . . . . . . . . 34.5 mm (1.36 in.)

INSPECT VALVE ROTATORS


RG4755

Serviceable valves should be re-faced to specified


angle (A).
Valve Face Specification
Angle (A) . . . . . . . . . . . . . . . . . . . . . . . . 29.25° ± 0.25°

T91224

Valve rotators cannot be repaired. Replace valve


rotators when valves are replaced or ground.
Ensure that valve rotators turn freely in both directions.
Replace if defective.

11/22/00 3 - 53
REPAIR DIESEL ENGINE

INSTALL VALVES
1. Apply engine oil to valve stems and guides.
2. Insert valves in head (in same location as found
during removal).

NOTE: Valves must move freely and seat properly.

CD30233

NOTE: After having installed the valves, strike end of


each valve three times with a soft mallet to
ensure proper positioning of the keepers.

INSTALL CYLINDER HEAD

RG5654

3. Using JDG678 Valve Stem Seal Installer (A), slide


seal (B) over valve stem and onto valve guide
tower (C).

RG4718

1. Clean tapped holes in cylinder block using JDG680


Tap (or any 1/2-13 UNC-2A tap). Use compressed
air to remove debris or any fluid from cap screw
holes.

RG5655
IMPORTANT: Ensure that cam followers (A) are
4. Install valve springs and rotators. present before installing cylinder head.
5. Compress valve springs using JDE138 Valve
Spring Compressor and install new keepers on
valves.

CD30693

2. Install new cylinder head gasket dry (without


sealant).

3 - 54 11/22/00
DIESEL ENGINE REPAIR

TORQUE TURN TIGHTENING


METHOD

9 5 10
4 6 14

12 3 1 11
8 2 7

B B KV15177

3. Install two guide studs in cylinder block at locating


holes (B).
4. Without guide studs, the Viton O-ring attached to
cylinder head gasket (at rocker arm oil passage) KV31107
could be damaged when positioning cylinder head
A. Reference Mark
on engine block to align cap screw holes.
B. 60° Mark
5. Position cylinder head over guide studs and lower
into place on cylinder block.
6. Dip cap screws entirely in clean engine oil. To ensure that the full 60° angle is reached (Step C.),
7. Remove guide studs and install cap screws in all the following procedure can be used:
open bores. Step A. Make a mark (A) on socket and make a
8. Tighten cap screws in sequence to the torque second mark (B) 60° counterclockwise from the
specified, beginning with No. 1. Use JD-307 first.
Torque Wrench Adapter if necessary. Step B. Place socket on cap screw and transfer
mark (A) to cylinder head.
Step 1. Tighten all cap screws to Step C. Tighten (in sequence) all cap screws until
. . . . . . . . . . . . . . . . . . . . . . . . . . . 100 N•m (75 lb-ft) second mark on socket aligns with mark on
Step 2. Tighten all cap screws to cylinder head.
. . . . . . . . . . . . . . . . . . . . . . . . . . 150 N•m (110 lb-ft)
Step 3. Wait 5 minutes and tighten all cap screws NOTE: The torque turn method eliminates the need to
to . . . . . . . . . . . . . . . . . . . . . . . . 150 N•m (110 lb-ft) re-torque the cylinder head bolts after the first
Step 4. Tighten each cap screw an additional hours of engine operation. However, valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60° ± 10° clearance adjustment is still required.

11/22/00 3 - 55
REPAIR DIESEL ENGINE

CHECKING ROCKER ARM SHAFT Assembling


I 1. Lubricate shaft, bores of rocker arms and supports.
2. Slide springs, rocker arms, and supports onto shaft.
Assemble in the same order in which they were
removed during disassembly.
C
IMPORTANT: The oil supply hole (C) in the shaft
must be in line with the oil supply hole (D) of
A
cylinder head.

3. Install bowed washers (B) and new plugs (A) on


shaft.
B

CD30381
INSTALL ROCKER ARM ASSEMBLY

D C

CD30382

A. Plug CD30536
B. Bowed Washer
1. Install push rods in same location from which they
C. Oil Supply Hole in Rocker Arm Shaft
were removed.
D. Oil Supply Hole in Cylinder Head

NOTE: Valve stem tips are specially hardened, wear


Disassembling and Checking caps are not required.
1. Remove plugs (A) and bowed washers (B) from
rocker arm shaft.
2. Slide springs, rocker arms, and supports off rocker 2. Position rocker arm assembly (A) on engine.
arm shaft, identifying their sequence for 3. Lubricate the rocker arms with engine oil.
reassembly in the same order. 4. Tighten attaching cap screws to 50 N•m (35 lb-ft).
3. Clean all parts with solvent and dry with 5. Adjust valve clearance. (See CHECK AND ADJUST
compressed air. VALVE CLEARANCE.)
4. Check all parts for good condition (See
SPECIFICATIONS for part dimensions).
5. Replace parts as necessary.

NOTE: If the rocker arm has been damaged by a valve


failure, replace it together with the
corresponding push rod, valve rotator, and
keepers.

3 - 56 11/22/00
DIESEL ENGINE REPAIR

INSTALL ROCKER ARM COVER FINAL WORK

CD30546
1. Install rocker arm cover with built-in sealing ring
(without sealant).
2. Install cap screws (A) by hand and tighten to
10 N•m (89 lb-in.), starting from center and
moving towards both front and rear ends of the
cover. DO NOT OVERTIGHTEN.

KV14267

1. Install parts previously removed.


2. Check crankcase vent tube hose (A) for proper
condition. Replace if necessary. When installing,
be sure that the hose is not pinched.
3. Start engine and check for oil and coolant leaks.
4. Run engine for 30 minutes at mid-throttle (1,500
RG6322 rpm) or perform break-in if engine has been
The sealing ring (B) is reusable. In case of leak, overhauled.
proceed as follows: 5. Check valve clearances and adjust when
necessary.
1. Remove sealing ring.
2. Clean cover sealing ring groove with acetone and
dry with compressed air. NOTE: Re-torquing cylinder head bolts is not required.
3. Install new sealing ring with grease in cover groove.
4. Cut the sealing ring slightly longer than necessary.
5. Place the sealing ring ends edge to edge then
press the sealing ring all the way around cover to
ensure proper installation.

11/22/00 3 - 57
REPAIR DIESEL ENGINE

CYLINDER BLOCK EXPLODED VIEW

D
C
E
F

H
A

J I

CD30551
A. Cylinder Block D. Piston Rings G. Liner Seals
B. Cylinder Liner E. Piston Pin H. Oil Pressure Regulating Valve Seat
C. Piston F. Snap Ring I. Oil Bypass Valve
J. Connecting Rod

3 - 58 11/22/00
DIESEL ENGINE REPAIR

REMOVE PISTONS AND


CONNECTING RODS
1. Remove cylinder head, oil pan, and oil pump.

CD30554

6. Remove connecting rod and piston assembly


through the cylinder liner.
CD30552

2. Install large flat washers (A) with cap screws (B) to


hold cylinder liners down.
3. De-carbonize cylinder liners.

A
B

RG7464

7. Remove and discard piston pin snap rings.


8. Press piston pin out of bore and separate piston
and rod.
CD30553

IMPORTANT: On engines having PRECISION


JOINT™ rods, make and alignment mark (B) on
side of rod and cap to provide correct
orientation during assembly.

4. Mark rods, pistons, and caps to ensure correct


assembly in same location.
5. Remove rod cap screws and caps (A).

PRECISION JOINT is a trademark of Deere & Company

11/22/00 3 - 59
REPAIR DIESEL ENGINE

MEASURE CYLINDER LINER BORE REMOVE CYLINDER LINERS

CD30556

1. Measure liner bore at four points of ring travel. CD30384

1. Mark liners and cylinder block then pull liners out of


Cylinder Liner Bore Specifications: cylinder block using KCD10001 Puller.
Cylinder liner ID . . . . . . . . . . . . . 106.49—106.52 mm
(4.1925—4.1937 in.)
Maximum wear . . . . . . . . . . . . . . . 0.25 mm (0.01 in.)
Maximum taper. . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Maximum out-of-round . . . . . . . 0.05 mm (0.002 in.)

2. Compare liner measurements with piston skirt


diameter. If clearance between piston skirt and
liner is not within specification, replace liner and
piston.

Piston-to-Cylinder Liner Specification: RG4745


Clearance (measured . . . . . . . . . . . . 0.09—0.14 mm 2. Remove O-rings (A) from groove in cylinder block
at bottom of skirt). . . . . . . . . . (0.0035—0.0055 in.) (B). Also remove packing (C) from liner (D).

NOTE: Oversize liners do not exist. Install a complete


set including standard liner and piston.

3 - 60 11/22/00
DIESEL ENGINE REPAIR

CYLINDER LINER DEGLAZING CHECK PISTON COOLING JETS

R26164 RG6426

1. Place cylinder liners in a suitable clamping device. 1. Check each piston cooling jet (A) for plugging or
2. Use D17004BR Flex-Hone to de-glaze liner. Follow damage.
instructions supplied with tool to obtain 45°
crosshatch pattern.
NOTE: A cooling jet failure could cause damage to
pistons, piston pins, rod pin bushings and
NOTE: After de-glazing, clean cylinder liner bore with liners.
a mixture of warm water and soap. Rinse with
clear water until rinse water is clear. Dry with
clean towels and coat bore with clean engine 2. Reinstall jets and tighten to 10 N•m (7.5 lb-ft).
oil.
CAM FOLLOWER BORE MEASURE
IMPORTANT: Do NOT use gasoline, kerosene, or :
commercial solvents to clean liners.

CYLINDER BLOCK CLEANING

T81656

Cam Follower Bore Specifications:


Cam follower bore ID . . . . . . . . . . . 31.70—31.75 mm
R26166 (1.248—1.250 in.)
1. Remove liner O-rings from cylinder block. Clean Maximum clearance . . . . . . . . . . 0.13 mm (0.005 in.)
block with cleaning solvent or pressure steam. If diameter is more than specified, install a new
2. Make sure all passages and openings are free from cylinder block. Service bushings are not available
sludge, rust, and grease. through service parts.
3. Use D17015BR Cleaning Brush to clean liner O-
ring grooves.

11/22/00 3 - 61
REPAIR DIESEL ENGINE

MEASURE CAMSHAFT BORE

CD30340

CD30557 3. Tighten nut until bushing is free of block bore.

Camshaft Bore Specifications: INSTALL CAMSHAFT BUSHING


Camshaft bore without bushing . . 55.98—56.01 mm
(2.204—2.205 in.)
Camshaft bore with bushing (No. 1 only)
cylinder block bore for
bushing installation . . . . . . . . . . . . 59.96—59.99 mm
(2.361—2.362 in.)
Bushing ID (installed) . . . . . . . . . . 55.96—55.99 mm
(2.203—2.204 in.)
If only diameter of No.1 camshaft bore with bushing is
more than specified, replace the bushing. In other CD30558
cases, install a new cylinder block.
Install camshaft bushing using JDG739B as follows:
1. Apply TY6333 grease to internal diameter and
REMOVE CAMSHAFT BUSHING outside diameter of bushing.

CD30389
CD30388

Extract camshaft bushing using JDG739B tool as 2. Slide bushing onto driver so notched end (A) of
follows: bushing will be toward front end of engine when
installed.
1. Assemble threaded spacers (A) and forcing plate
(B) to cylinder block (C).
2. Insert bushing puller (D) into camshaft bushing IMPORTANT: Bushing must be installed so oil
bore. supply hole (arrow) aligns with oil drilling in
block bore.

3. Tighten forcing screw until flange of driver bottoms


against face of block.

3 - 62 11/22/00
DIESEL ENGINE REPAIR

MEASURE CRANKSHAFT BORE CYLINDER BLOCK TOP DECK


FLATNESS
Measure cylinder block top deck flatness using a
precision straightedge. If flatness is not as specified,
resurface cylinder block according to specifications
below:

CD7271

Crankshaft Bore Specifications:


Crankshaft bore ID . . . . . . . . . . . . . 84.46—84.48 mm
(3.325—3.326 in.)
CD30560

NOTE: Before measuring, the cap screws must be


tightened to 135 N•m (100 lb-ft).

If diameter is more than specified or bearing cap is


damaged, replace all caps and line bore to
specifications.

REPLACE CRANKSHAFT BEARING


CAPS
Replacement bearing caps are supplied with
unfinished bore (undersize radius 41.4 mm [1.63 in.]). CD30561
1. Install replacement caps in block and tighten cap Top deck out-of-flat . . . . . . . . . . 0.08 mm (0.003 in.)
screws to 135 N•m (100 lb-ft). Top deck surface finish (CLA) . . . . 0.8—3.2 micron
(32—128 micro-in)
Maximum wave deep . . . . . 8 micron (320 micro-in.)
Crankshaft bore centerline-
to-top deck.. . . . . . . . . . . . . . . . . 301.98—302.11 mm
(11.889—11.894 in.)
Liner counterbore depth (A) . . . . . . . 5.95—5.99 mm
(0.234—0.236 in.)

CD30559
2. After having positioned block on a boring machine,
bore new bearing caps to 84.46—84.48 mm
(3.325—3.326 in.) diameter. Take care to remain
within the specified dimension (A) (crankshaft bore
center line to block top face).
Distance (A) . . . . . . . . . . . . . . . . 301.98—302.11mm
(11.889—11.894 in.)
IMPORTANT: Make sure all crankshaft bearing
bores are in alignment.

11/22/00 3 - 63
REPAIR DIESEL ENGINE

MEASURE CYLINDER LINER


PROTRUSION

CD30199

4. If liner protrusion or permissible difference is above


specifications, apply lapping compound to liner
RG6439
flange shoulder in the block. Install liner then,
A. Liner protrusion using KCD10001 special tool, turn to left and right
to rub off enough material to seat liner as
necessary.

CD30563

1. Install liner without packing or O-rings. If liner does CD30564


not rotate smoothly by hand, remove liner and
polish lower pilot bore in block with emery cloth or 5. If protrusion is below specifications, install one liner
D17015BR brush. shim (A) under liner flange. Two sizes of shims are
2. Align liner and cylinder block marks, then secure at available: 0.05 mm (0.002 in.) and 0.10 mm (0.004
four points with cap screws and thick washers in.).
(approx. 3 mm—0.118 in.). Tighten to 100 N•m
(74 lb-ft).
IMPORTANT: ONLY ONE SHIM IS ALLOWED PER
3. Using KJD10123 Gauge, measure liner protrusion CYLINDER. If liner requires more than one shim,
(A) at four points. install either a new liner or cylinder block.

Liner Protrusion Specifications:


Liner protrusion . . . . . . . . . . . . . . . . . 0.01—0.10 mm
(0.0004—0.004 in.)
Maximum permissible difference between
adjacent cylinders . . . . . . . . . . . 0.03 mm (0.001 in.)

3 - 64 11/22/00
DIESEL ENGINE REPAIR

LINER PACKING INSTALLATION INSTALL CYLINDER LINERS


Apply lubricating soap to new packing and install over 1. Slide liner together with shim and packing into its
liner until it contacts liner shoulder. Liner packing must bore in cylinder block.
be compressed to a minimum of 0.13 mm (0.005 in.).

A A

B
B

C D CD30565
CD7134
2. Seat liners using KCD10001 special tool.
A. Cylinder Liner 3. Secure liners by means of large washers and cap
B. Packing screws.
C. Improper Installation
D. Proper Installation MEASURE CONNECTING ROD
BEARING
LINER O-RING INSTALLATION
Apply lubricating soap to new O-rings. Install O-rings NOTE: Before measuring, connecting rod cap screws
in respective grooves. must be tightened according to specifications.

CD7135
CD7120
A. Rectangular Section Packing
B. Red or White O-Ring
C. Black O-Ring
D. Cylinder Liner
E. Cylinder Block

CD7121
Measure OD of rod journal on crankshaft. Tighten rod
cap screws to specification and measure ID of rod
bearing. Subtract journal dimension from rod bearing
dimension. The result is clearance.

11/22/00 3 - 65
REPAIR DIESEL ENGINE

Specifications: CONNECTING ROD BUSHING


Tightening torque
Initial . . . . . . . . . . . . . . . . . . . . . . . 56 N•m (40 lb-ft)
Final. . . . . . . . . . . . . . . . . . . . . . . . . Plus 90°—100°
Bearing (assembled) ID . . . . . . . 69.848—69.898 mm
(2.7499—2.7519 in.)
Crankshaft journal OD . . . . . . . . 69.799—69.825 mm
(2.748—2.749 in.)
Maximum permissible clearance . . . . . . . . 0.16 mm
(0.006 in.)

If clearance is not within specifications, grind


crankshaft journals to match under size bearings.
Under size bearings are only available in 0.25 mm CD30566
(0.01 in.) under standard size.
Straight Pin-End (3029D)

NOTE: Under size crankshafts may be also available


through the regular service parts channel.

ROD BEARING CLEARANCE

CD30567

Tapered Pin-End (3029T)

NOTE: 3029D engines are equipped with straight pin-


end connecting rods while 3029T engines
receive the tapered pin-end connecting rods.
RG6405

1. Remove connecting rod cap. Place a piece of


If diameter or clearance are more than specified,
Plastigage™ in the center of the bearing. Install
replace connecting rod bushing for the 3029T engines
cap and tighten cap screws according to
and replace connecting rod/piston pin assembly for the
specifications.
3029D engines.
2. Remove cap and compare the width of
Plastigage™ with scale provided on the side of Specifications:
package to determine clearance. Connecting rod bushing ID
Max. permissible clearance. . . . 0.16 mm (0.006 in.) 3029D. . . . . . . . . . . . . . . . . . . . . . 32.010—32.036 mm
(1.2602—1.2612 in.)
3029T . . . . . . . . . . . . . . . . . . . . . . 41.300—41.326 mm
(1.626—1.627 in.)
Pin-to-bushing clearance
3029D. . . . . . . . . . . . . . . . . . . . . . . . . 0.01—0.042 mm
(0.0004—0.0016 in.)
3029T . . . . . . . . . . . . . . . . . . . . . . . . . 0.02—0.056 mm
(0.0008—0.002 in.)
Maximum. . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)

3 - 66 11/22/00
DIESEL ENGINE REPAIR

REPLACE CONNECTING ROD


BUSHING
Using JDG738 Connecting Rod Bushing Service Set,
proceed as follows:

RG7132

4. Slide bushing (A) onto JDG738-1 driver (B) and


install JDG738-2 pilot ring (C) onto O-ring end of
driver.
RG7130 5. Apply TY6333 grease to:
• Outside diameter of bushing
• Outside diameter of pilot ring
• Inside diameter of rod pin bore

RG7131

1. Slide driver JDG738-1 (A) into one side of rod


bushing (C). Turn driver until taper on driver flange
RG7236
matches up with taper on bushing.
2. Install receiver cup JDG738-3 onto opposite side of 6. Insert driver into rod pin bore so pilot ring pilots in
rod bushing. rod bore and bushing taper aligns with taper on
driver flange. Align oil hole in bushing (D) with oil
hole in end of rod (E).
NOTE: Stud in cup keeps rod properly located on the 7. Install JDG738-3 receiver cup (F) onto opposite
cup. Use JDG738-2 pilot ring (B) as a hollow side of rod so taper on rod aligns with taper on
spacer when pressing bushing out of rod. receiver cup.
8. Press bushing into rod until edge of bushing is flush
3. Using hydraulic press, push bushing out of rod until machined surface on connecting rod face.
driver and bushing fall into receiver cup.
IMPORTANT: Oil holes MUST be aligned. If holes
are not aligned, remove and discard bushing
then re-install a NEW bushing. DO NOT attempt
to reuse a bushing.

9. Have the new bushing reamed by a specialized


workshop to obtain an oil clearance of 0.020 to
0.056 mm (0.0008 to 0.002 in.) with piston pin.

11/22/00 3 - 67
REPAIR DIESEL ENGINE

MEASURE PISTON PIN MEASURE PISTON PIN BORE

T81604 RG6283

Piston Pin OD Specifications: Specifications:


3029D . . . . . . . . . . . . . . . . . . . . . . . 31.994—32.000m 3029D. . . . . . . . . . . . . . . . . . . . . . . . 32.003—32.013m
(1.2596—1.2598 in.) (1.356—1.560 in.)
3029T . . . . . . . . . . . . . . . . . . . . . . . . 41.27—41.28 mm 3029T . . . . . . . . . . . . . . . . . . . . . . 41.285—41.295mm
(1.6248—1.6252 in.) (1.6254—1.6258 in.)
Wear tolerance . . . . . . . . . . . . . 0.013 mm (0.005 in.)
NOTE: Some piston pin bores are elliptical, the width
Pin-to-bushing clearance: being 0.038 mm (0.0015 in.) larger than the
3029D . . . . . . . . . . . . . . . . . . . . . . . . 0.01—0.042 mm bore specifications.
(0.0004—0.0016 in.)
3029T . . . . . . . . . . . . . . . . . . . . . . . . . 0.02—0.056 mm
(0.0008—0.002 in.) If bore is not within specifications, replace piston/liner
set.
Maximum. . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)

If diameter is less or clearance is more than specified, PISTON TOP RING GROOVE
replace pin/bushing assembly for the 3029T engines
and replace connecting rod/piston pin assembly for the
3029D engines.

CLEAN AND INSPECT PISTONS


Clean pistons, using a commercial cleaner and a jet
rinse gun or glass bead blasting machine.

c CAUTION
RG4746
Follow manufacturer’s instruction exactly. DO A. Piston Can Be Used Again
NOT ALLOW CHEMICAL TO COME IN CONTACT B. Discard Piston and Replace
WITH SKIN OR EYES; chemical contains
creosotes which can be very harmful. C. JDG957 Gauge
D. Tool Shoulder-to-Ring Land Clearance

Use JDG957 wear gauge to check wear of top


Check piston for cracks, excessive skirt wear, or any
compression ring groove.
other damages.

NOTE: Do not attempt to stamp top of piston. Distance


from top of piston and top of first ring is 4 mm
(0.16 in.) and therefore the top ring groove
inserted in piston may be damaged.

3 - 68 11/22/00
DIESEL ENGINE REPAIR

PISTON SECOND AND THIRD RING INSTALL PISTON RINGS


GROOVES Use KJD10140 or any other suitable piston ring
expander for a proper installation and to prevent any
damage to the piston.

RG5625

1. Use a new piston ring and feeler gauge. Ring


CD30568
groove clearance must not exceed 0.20 mm
(0.008in.).
2. If clearance exceeds specification, install a new
piston. D

PISTON HEAD AND SKIRT


CHECKING

CD30569

CD30391

1. Check piston for scuffing, scoring, or signs of E B


overheating.
C
2. Measure piston diameter 19 mm (0.74 in.) from
bottom of skirt and 90° from piston pin. F
KV18888
A. Top Ring
Specifications:
B. Second Ring
Piston OD at 19 mm (0.74 in.) from bottom of skirt C. Oil Control Ring
and measured 90° from piston pin
D. KJD10140 Piston Ring Expander
. . . . . . . . . . . . . . . . . . . . . . . . . 106.381—106.399 mm
E. Blue Mark
(4.1882—4.1890 in.)
F. Yellow Mark

11/22/00 3 - 69
REPAIR DIESEL ENGINE

1. Install oil control ring (C) in bottom ring groove over PISTON/LINER SET INFORMATION
ring expander. Be sure that the ring expander and
the wire are correctly fitted.
2. Install second ring (B) in center ring groove. Second
ring can be identified by a yellow paint mark (F).
Proper installation is obtained when this mark is to
the left of end gap.
3. Install top ring (A) in top ring groove. Top ring can
be identified by a blue paint mark (E). Proper
installation is obtained when this mark is directly
above yellow mark (F).

PISTON RINGS STAGGERING

F
CD30579

A A. Liner
E
B B. Piston
C. Piston Ring Set
D. Liner Seal Set

C D
IMPORTANT: Do not intermix assemblies having
tongue-and-groove rod with assemblies having
PRECISION JOINT™ rod on the same engine.
Check parts catalog for correct application.

A. Piston Head Service piston is available only as an assembly and


B. Top Compression Ring Gap includes items listed above.
C. Oil Control Ring Gap
D. Expander Ring Gap
NOTE: Liner, piston ring set and liner seal set are
E. Bottom Compression Ring Gap available separately.
F. Front of Engine

Piston/Liner sets may be packaged in an anti-


Stagger piston rings as shown. corrosion bag and therefore are not coated with oil or
grease. Before opening the bag, be sure that the parts
will be installed immediately to prevent any risk of
parts corroding.

PRECISION JOINT is a trademark of Deere & Company

3 - 70 11/22/00
DIESEL ENGINE REPAIR

ASSEMBLE PISTON AND 2. Coat piston pin (B) with engine oil and insert it
through piston and connecting rod bores. Install
CONNECTING ROD NEW piston pin retaining rings (C) with sharp edge
of ring facing away from piston pin. Make sure
retaining rings are seated correctly in their
B grooves.
C
A
INSTALL PISTON AND
CONNECTING ROD

CD30571

A. “FRONT” Mark on Connection Rod


B. Piston Pin
C. Piston Pin Retaining Ring

A. Tongue-and Groove Rod and Cap


B. PRECISION JOINT Rod and cap

NOTE: Early engines have the traditional tongue-and-


groove between the connection rod and cap
(A). Later engines have the PRECISION
JOINT™ rod and cap (B). Installation of both
rods is similar, with differences noted.
KV18572

D. Camshaft Side IMPORTANT: Different style rods MUST NOT be


intermixed on the same engine.
E. Centerline of Liner Bore
F. Combustion Chamber Offset
NOTE: Pistons must be installed in the cylinder liner
from which they were removed.
NOTE: Pistons must be installed on connecting rods
from which they were removed. If a new piston/
liner set is to be installed, DO NOT remove
piston from liner. Push piston out of liner
bottom only far enough to install piston pin.

1. Assemble pistons and connecting rods, making


sure the word "FRONT" (A) on the side or top of
the piston and on the side of the connecting rod
are on the same side.

NOTE: If "FRONT" is not visible on side or top of


piston, install piston on rod so that offset in
combustion bowl of piston is opposite camshaft CD30572
side of engine. The long side of the connecting
rod should face camshaft side of block. 1. Coat pistons and rings with clean engine oil. Install
pistons in liners, using JDE84 piston ring
compressor.

11/22/00 3 - 71
REPAIR DIESEL ENGINE

NOTE: Make sure that "FRONT" mark on the top of


each piston faces toward front end of cylinder
block.

2. Push piston down until top ring is in liner.

B
A
CD30574

6. Apply clean engine oil to bearing insert. Install cap


on connecting rod with tabs (C) to same side.

CD30573

3. Install bearing insert in connecting rod with tab (A)


in groove (B).

KV18573

PRECISION JOINT rod cap.

NOTE: Due to the manufacturing process,


PRECISION JOINT rod and cap each have two
grooves, while the bearing insert (A) has a
single tab (B). Only one groove will be used in KV18574
each. One groove (C) will remain unused.
IMPORTANT: Never use connecting rod cap
4. Apply clean engine oil on insert and crankshaft screws more than once for final engine
journal. Carefully place connecting rod against assembly.
crankshaft journal.
5. Install bearing insert in connecting rod cap with tab Cap screws used on PRECISION JOINT style
in groove. rod and cap are 3 mm (0.120 in.)shorter than
those used on tongue-and-groove style rod and
cap.
IMPORTANT: On PRECISION JOINT rod
assemblies, be sure cap is oriented properly
and that it is correctly aligned on rod, with 7. Apply clean oil to NEW connecting rod cap screws
edges flush and interlocking surfaces sealed and tighten alternately to 56 N•m (40 lb-ft).
tightly. 8. Torque-turn all cap screws 90—100° as follows:
• 72Position the wrench parallel to engine axis (D).
• Tighten until the wrench is perpendicular to engine
axis (E).

3 - 72 11/22/00
DIESEL ENGINE REPAIR

9. Check for proper side clearance in all rods. Each 7. If protrusion is out of specifications, check all
rod must have a slight side-to-side movement. concerned parts to determine the cause.

MEASURE PISTON PROTRUSION

NOTE: Press down on top of piston to remove


clearances before measuring piston
protrusion.

CD30575

1. Place KJD10123 Gauge (with flat side up) on


cylinder block so that indicator point rests on block
surface.

B
A

CD30005

A. Centerline of Cylinder Liner Bore


B. Piston at "TDC"

3. Set dial indicator at "zero".


4. While pressing gauge downward, turn crankshaft
until piston is at "TDC" position (B).
5. Measure in two places across centerline of cylinder
liner bore (A).
6. Piston protrusion should not exceed 0.25 mm
(0.010 in.) when KJD10123 is used.

NOTE: If KJD10123 Gauge is not available, use


JDG451 or a dial indicator as shown. In this
case, the piston protrusion should not exceed
0.35 mm (0.014 in.).

11/22/00 3 - 73
REPAIR DIESEL ENGINE

COMPLETE FINAL ASSEMBLY 2. Cylinder block has some orifices which are in
relation either with the lubrication or coolant
system. When assembling an engine, be sure that
coolant lines are connected to corresponding
coolant ports and oil lines to oil ports. Apply
torques as indicated.
3. Be sure that piston cooling jets (H) and oil gallery
steel caps (J) are installed.

CD30577
KV18077
Rear Left View 4. Service cylinder block may have additional side
mounting bosses (K). If these bosses interfere with
the chassis or other machine components, grind
concerned area.

IMPORTANT: Be sure, when grinding, that


particles do not enter dipstick hole (L).

CD30576
Front Right View
KV18078
Torques/Specifications:
A. Coolant drain (1/4 in.) . . . . . . . . . 17 N•m (13 lb-ft) 5. Oil gallery ball (M) is provided with service cylinder
B. Turbocharger oil return (1/2 in.) . 45 N•m (33 lb-ft) block, but may not be installed. In this case,
C. 1/2 cyl. for dipstick tube . . . . . . . 67 N•m (50 lb-ft) proceed as follows:
D. Oil galleries (1/8 in.). . . . . . . . . . . 17 N•m (13 lb-ft) • Put ball (M) in oil passage (N).
E. Coolant gallery (side) (1/4 in.) . . 17 N•m (13 lb-ft) • Drive in ball using an appropriate driver (O) until
F. Rear coolant gallery (1 in.) . . . . . 45 N•m (33 lb-ft) ball bottoms.
G. Oil gallery (3/8 in.) . . . . . . . . . . . . 45 N•m (33 lb-ft) • Check for proper installation. The distance
between pan rail and top of ball should be
1. Install all components previously removed. Apply approximately 54 mm (2.16 in.).
following recommendations then perform engine
test.

3 - 74 11/22/00
DIESEL ENGINE REPAIR

REMOVE CRANKSHAFT PULLEY FLYWHEEL REMOVAL

c CAUTION
Flywheel is heavy. Plan a proper lifting
procedure to avoid personal injury.

CD30580
A
1. Remove pulley attaching cap screw.
2. Using JDG410 Puller or any other suitable puller,
remove pulley from crankshaft.

INSTALL CRANKSHAFT PULLEY


RG5632

1. Remove two cap screws and install guide studs in


their place (shown installed) then remove the other
cap screws.
2. Install two 1/2-13 UNC or M10 cap screws (length
100 mm/4 in.) into the threaded holes (A) to push
flywheel off crankshaft and to facilitate flywheel
handling.

NOTE: If the flywheel does not have the threaded


CD30581 holes (A), install two cap screws (for handling
flywheel) into clutch system threaded holes
1. Install shaft key (A). then, using a soft hammer, gently tap on
2. Position pulley on crankshaft with washer (B) and flywheel to un-stick it.
cap screw (C).
3. Tighten to 150 N•m (110 lb-ft).

11/22/00 3 - 75
REPAIR DIESEL ENGINE

FLYWHEEL RING GEAR INSTALL BALL BEARING


REPLACEMENT
A

E C
B

T90596 RG6345

A. 27487 Driver C. 27493 Disk


1. Drive ring gear off with a brass drift and hammer.
B. 27508 Disk D. Ball Bearing
E. Flywheel
2. Heat new ring gear to 150°C (300°F) using either
heated oil, oven heat, or flame heat.
NOTE: Some flywheels have a ball bearing (D) which
needs to be installed with flywheel removed
from engine.
c CAUTION
Drive new ball bearing into engine side of flywheel
Oil fumes or oil can ignite above 190° C (380°F). using 27487 driver (A), 27508 disk (B) and 27493 disk
When heating ring gear, use a thermometer and (C) from D01045AA or other bearing driver set, until
do not exceed 180°C (360°F). Heat the oil in a bearing bottoms in bore. Check bearing for smooth
well ventilated area. Plan a safe handling operation.
procedure to avoid burns.

INSTALL FLYWHEEL
IMPORTANT: If flame is used to heat ring gear, be
sure gear is heated uniformly around
circumference.

CD7140

1. Install two guide studs in crankshaft.


2. Place flywheel on studs and slide into position
RG3838 against crankshaft.
3. Tap heated ring gear into place against flywheel IMPORTANT: Always replace flywheel cap screws
shoulder. Chamfered edge of teeth (A) must be when flywheel has been removed.
toward engine.
3. Install cap screws and tighten crosswise to 160
N•m (120 lb-ft).
NOTE: Be sure complete ring gear circumference is
flush against shoulder of flywheel.

3 - 76 11/22/00
DIESEL ENGINE REPAIR

CRANKSHAFT REAR OIL SEAL

Removal:

B
RG5639

4. Position JDG698 on end of crankshaft then install


three 2-1/2 in. sheet metal screws with washers
into slots. Evenly tighten screws until plate is flush
with rear face of crankshaft.
5. Tighten forcing screw until seal and wear sleeve
assembly is removed from engine.

Using JDG645E

CD30584

The crankshaft rear oil seal (A) and the wear sleeve
(B) composes a non-separable part. To remove this oil
seal/wear sleeve assembly, the two following
procedures can be used depending on special tool
availability:

Using JDG698

CD30243

1. Place and center JDG645E cap screws and driver


plate assembly onto crankshaft rear face. Then,
using snap ring pliers, set the thinner shoulder of
ring tool between sleeve flange and seal case.

RG5638

1. Adjust forcing screw on JDG698 tool and position


screw so it centers tool on crankshaft flange.
2. Use the slots in JDG698 tool as a template, mark
three locations on seal casing where screws
should be installed for removal purposes. Remove
tool from crankshaft flange.
CD30244
3. Drill a 3/16 in. hole through wear sleeve lip and seal
casing at the three marked locations. 2. Secure the assembly with a clamp then gradually
tighten the screw until wear sleeve is extracted.

11/22/00 3 - 77
REPAIR DIESEL ENGINE

Installation:

CD30586

CD30396 1. The oil seal/wear sleeve assembly can be installed


using JT30040 or KCD10002A tools. Due to a
3. Cut the rubber lip now accessible and remove it. diameter change of the crankshaft bore, it may be
necessary to suppress the pilot pin (A) from tools
(KCD10002 shown, JT30040 similar). With this
modification, KCD10002 becomes KCD10002A.

CD30397

4. Using a punch and a hammer, tap the seal case


toward engine at any location until seal case T81204
pivots. 2. Apply a light coating of LOCTITE 609 (TY15969)
completely around the leading edge of crankshaft
flange.

CD30247

5. Using JDG22 Slide Hammer Puller, extract seal T81205


case. 3. Position the guide plate from JT30040 or
KCD10002A tool over dowel with two cap screws.
Finger tighten both cap screws until they contact
the pilot.
4. Using the oil seal/wear sleeve assembly with open
side toward engine, center the guide plate, and
tighten cap screws.
5. Slide driver onto guide and gradually tighten the
cap screw or nut until driver bottoms.

3 - 78 11/22/00
DIESEL ENGINE REPAIR

FLYWHEEL HOUSING MEASURING CRANKSHAFT END


REPLACEMENT PLAY
1. Remove flywheel and oil pan.
NOTE: It is recommended to measure crankshaft end
c CAUTION play prior to removing crankshaft to determine
condition of thrust bearings.

AVOID INJURY. Flywheel housing weighs


approximately 20 to 40 kg (43 to 86 lbs.).

B
B

A A B CD7144
B
CD7141 Check crankshaft end play using a dial indicator and
compare with specifications.
2. Remove four 5/8 in. cap screws (B) and eight 3/8 in.
cap screws (A). Remove flywheel housing.

A
CD30220

A. Oversized Thrust Washers


B. Front of Engine
CD30585
C. Rear Bearing Cap Side
3. Clean mating surfaces and install new gasket (C). If end play is still not within specification with new
standard 2-piece or 6-piece thrust bearings, install a
5-piece thrust bearing with oversized thrust washers.
NOTE: On certain applications, the open holes need
to be sealed. Apply TY6304 Flexible Sealant to
threads of cap screws. NOTE: Oversized thrust bearing set contains three
0.18 mm (0.007 in.) oversized thrust washers
to be installed as shown.
4. Install flywheel housing with the eight cap screws
(A).
5. Tighten 3/8 in. cap screws (A) initially to 30 N•m
(23 lb-ft). Finally, tighten screws to 50 N•m
(35 lb-ft).
6. Install the four 5/8 in. cap screws (B) and tighten to
230 N•m (170 lb-ft).

11/22/00 3 - 79
REPAIR DIESEL ENGINE

REMOVE CRANKSHAFT MEASURE CRANKSHAFT JOURNAL


DIAMETER

CD30587

1. Identify main bearing caps to assure correct CD30588


placement during reassembly. 1. Measure diameter of all crankshaft journals at
2. Attach nylon slings (or other suitable lifting slings) to several points around journal and compare with
crankshaft. specifications.
3. Carefully lift crankshaft out of cylinder block. Crankshaft Journal Specifications:
Main journal diameter
(std.) . . . . . 79.324—79.350 mm (3.123—3.124 in.)
CRANKSHAFT INSPECTION Maximum wear
1. Clean crankshaft thoroughly, especially oil Taper . . . . . . . . . . . . . . . . . . . 0.03 mm (0.0012 in.)
passages from crankshaft bearings to connecting Out-of-roundness . . . . . . . . . 0.075 mm (0.003 in.)
rod bearings.

CD7149
CD7147
2. Install main bearing inserts and caps then tighten
2. Check crankshaft for cracks or signs of load stress
cap screws to 135 N•m (100 lb-ft), then measure
(see illustration for critical areas of load stress in a
ID of main bearing (assembled) and compare with
crankshaft.).
specifications.
3. Inspect both shoulders of thrust bearing journal for
Main Bearings (Assembled) ID Specifications:
scores or unevenness.
Main bearings assembled
ID (standard) . . . . . . . . . . . . . . 79.396—79.440 mm
(3.126—3.127 in.)
Clearance . . . . . . . . . . . . . . . . . . 0.046—0.116 mm
(0.0018—0.0046 in.)
Maximum wear . . . . . . . . . . . . 0.15 mm (0.006 in.)

NOTE: This clearance can also be determined using


Plastigage™.
If engine had a previous major overhaul and
under-size bearing inserts were used, I.D. and
O.D. dimensions listed above may not be the
same as those recorded. However, the bearing
clearance should be within specifications.

3 - 80 11/22/00
DIESEL ENGINE REPAIR

3. If crankshaft journal diameter or clearance are not CRANKSHAFT REGRINDING


within specifications, replace crankshaft or grind
journals to match under-size bearings. Under-size GUIDELINES
bearings are only available in 0.25 mm (0.01 in.) If the crankshaft is to be ground, use the following
under standard size. recommended guidelines:
1. Determine the size to which the journals are to be
NOTE: Under-size crankshafts may be also available ground according to the measures taken during
through regular service parts channel. inspections.
2. If one or more main or connecting rod journals
require grinding, then grind all of the main journals
DETERMINE CRANKSHAFT MAIN or all of the connecting rod journals to the same
BEARING CLEARANCE required size. Grind clockwise (as viewed from
forward end of crankshaft.).
3. Care must be taken to avoid localized heating which
often produces grinding cracks. Use coolant
generously to cool the crankshaft while grinding.
Do not crowd the grinding wheel into the work.
4. Polish or lap (clockwise) the ground surfaces to the
specified finish (see MICRO-FINISHING
SPECIFICATIONS in this section). The ground
journals will be subject to excessive wear unless
polished smooth.

NOTE: When thrust surfaces are ground and an


RG7528 oversize washer is used, crankshaft end play
specification must be maintained.
1. Place a strip of Plastigage™ in the center of the
bearing.
2. Install cap and tighten cap screws to 135 N•m 5. If the thrust surfaces of the crankshaft are worn or
(100 lb-ft). grooved excessively, they must be ground and
polished. An oversize thrust washer set is
3. Remove cap and compare the width of
available.
Plastigage™ with scale provided on side of
package to determine clearance. 6. Stone the edge of all oil holes in the journal
surfaces smooth to provide a radius of
approximately 1.50 mm (0.060 in.).
REGRINDING CRANKSHAFT 7. After grinding has been completed, inspect the
crankshaft by the fluorescent magnetic particle
method, or other similar method to determine if
IMPORTANT: Crankshaft grinding should be cracks have originated due to the grinding
carried out ONLY by experienced personnel on operation.
equipment capable of maintaining crankshaft 8. De-magnetize the crankshaft.
size and finish specifications. 9. Thoroughly clean the crankshaft and oil passages
with solvent. Dry with compressed air.
If journals are worn, tapered, out-of-round, scored or
damaged, the crankshaft journals should be ground
and correct under-size bearing inserts installed.
Under-size bearing inserts available: 0.25 mm
(0.01 in.).

NOTE: This cast iron crankshaft can be ground only


once to 0.25 mm (0.01 in.) under standard
size. Crankshaft must be lapped afterwards
according to the micro-finishing specifications
given in this section.

11/22/00 3 - 81
REPAIR DIESEL ENGINE

MICRO-FINISHING SPECIFICATIONS REPLACE CRANKSHAFT GEAR

The following specifications are required when cast NOTE: Gear can be replaced without removing the
iron crankshafts have to be ground: crankshaft.
Center Line Average (C.L.A) . . . . . . . . . . 0.2 micron
(8 micro-in.)
or better

Skewness parameter (Sk) . . . . . . . . . . . . . . Negative

Bearing Ratio (Tp) With 1% Tp Reference Line:


C
B
0.22 micron (8.8 micro-in.) depth . . . . Tp more than
20%
A
0.38 micron (15.2 micro-in.) depth . . . Tp more than
80% RG7238

0.64 micron (25.6 micro-in.) depth . . . Tp more than A. No. 1123 Pulling Attachment
90% B. Disc
C. D01200AA Push Puller
Final journal finishing operation must be done in
clockwise direction (as viewed from forward end of 1. Pull gear using D01200AA Push Puller or any
crankshaft.). suitable puller.
2. Remove woodruff key from crankshaft and remove
any burrs from gear journal.
IMPORTANT: DO NOT attempt to grind cast iron
3. Install a new woodruff key in crankshaft keyway.
crankshafts if above specifications cannot be
obtained. 4. Heat new gear to 180°C (360°F).

c CAUTION
Oil fumes or oil can ignite above 190°C (380°F).
Use a thermometer to ensure that a temperature
of 180°C (360°F) is not exceeded. Do not allow a
flame or heating element to come into direct
contact with the oil. Heat the oil in a well-
ventilated area. Plan a safe handling procedure
to avoid burns.

JDG794

CD30398

5. Drive gear, with chamfered side toward engine, onto


crankshaft using JDG794 driver.

3 - 82 11/22/00
DIESEL ENGINE REPAIR

INSTALL MAIN BEARING INSERTS INSTALL 6-PIECE THRUST


BEARING

CD30589

A. Bearing Insert Tab CD30399


B. Cylinder Block Slot Install two thrust washers in the block and two on
bearing cap. The oil grooves (A) must face towards
Install main bearing inserts, making sure that tab (A) crankshaft thrust surfaces.
on the inserts engages in slot (B) in cylinder block and
main bearing caps. Ensure that oil bores of bearing
inserts are aligned with oil passages in cylinder block. CRANKSHAFT INSTALLATION
1. Apply a liberal coating of clean engine oil to bearing
INSTALL 2-PIECE THRUST surfaces and crankshaft journals and install
crankshaft.
BEARING 2. Dip all main bearing cap screws in clean engine oil
and position them with washers in the bearing
caps.

A
A

T88557
CD30590

1. Install one thrust bearing (A) from 2-piece thrust


bearing set in rear web of cylinder block and the
other in rear bearing cap.

CD30250
3. Install all bearing caps (B) according to the
identification marks stamped on them, and so that
tabs (A) of both bearing halves are on the same
side. Install all cap screws finger-tight.
4. Apply an initial torque not exceeding 20 N•m
(14 lb-ft).

11/22/00 3 - 83
REPAIR DIESEL ENGINE

5. Using a soft-face hammer, move crankshaft first


towards the rear and then towards the front to align
the rear thrust washers.

IMPORTANT: Before tightening rear cap screws,


ensure that rear thrust washer of cap is aligned
with rear thrust washer of block.

6. Tighten all cap screws to 135 N•m (100 lb-ft).


7. Check for free rotation and end play of the
crankshaft.
CD7104

MEASURE TIMING GEAR Using a dial indicator, check camshaft end play.
BACKLASH Camshaft end play . . . . . . . . . . . . . . . 0.08—0.23 mm
(0.003—0.009 in.)
Measure backlash between gears using a dial Maximum wear . . . . . . . . . . . . . . 0.38 mm (0.015 in.)
indicator and compare with specifications.
Thrust plate thickness . . . . . . . . . . 3.935—3.985 mm
If backlash is not correct, install new gears. (0.155—0.157 in.)
Maximum wear . . . . . . . . . . . . . . . . 3.8 mm (0.15 in.)

A B NOTE: If end play exceeds specifications, check


thickness of thrust plate as this determines end
play.

REMOVE CAMSHAFT

C
D

CD30591
A. Camshaft/Upper Idler Gear CD30593
B. Injection Pump/Upper Idler Gear
C. Upper Idler/Crankshaft Gear NOTE: Camshaft can be removed from engine without
D. Crankshaft/Lower Idler Gear removing cylinder head by holding cam
E. Oil Pump/Lower Idler Gear followers away from camshaft lobes with
D15001NU Magnetic Holding Set.
Camshaft End Play Measure
NOTE: Mark parts so that they can be installed in their
original positions.

3 - 84 11/22/00
DIESEL ENGINE REPAIR

MEASURE HEIGHT OF CAM LOBE


Measure longest and shortest diameter of each cam.
Subtract shorter diameter from longer diameter to find
the height of the cam lobe. If any lobe is not of the
correct height, install a new camshaft.
A

CD30592

IMPORTANT: When removing camshaft, be careful


that lobes do not damage the bearing surfaces
in bores. CD30594

Camshaft Lobe Height Specifications:


1. Remove cylinder head, cam followers and fuel
pump. Intake lobe . . . . . . 6.93—7.42 mm (0.273—0.292 in.)
2. Remove cap screws (A) and pull camshaft straight Maximum wear . . . . . . . . . . . . . . 6.68 mm (0.263 in.)
out. Exhaust lobe. . . . . 6.76—7.26 mm (0.266—0.286 in.)
MEASURE CAMSHAFT JOURNAL Maximum wear . . . . . . . . . . . . . . 6.50 mm (0.256 in.)

IMPORTANT: To keep the initial working condition


between cam lobes and cam followers, always
replace cam followers when installing a new
camshaft.

REPLACE CAMSHAFT GEAR


1. Remove gear from camshaft using a press.
2. Install shaft key on camshaft end.
CD30594

Camshaft Journal Specifications:


A
Camshaft journal OD . . . . . . . . . 55.872—55.898 mm
(2.1997—2.2007 in.)

Maximum wear . . . . . . . . . . . . . 55.85 mm (2.199 in.)

Max. clearance between bore


and camshaft journal . . . . . . . . . 0.18 mm (0.007 in.)
CD30595
If diameter or clearance is not within specifications,
replace camshaft. 3. Install gear with timing mark (A) away from
camshaft.
4. Press gear on shaft until flush with shoulder on
IMPORTANT: To keep the initial working condition camshaft.
between cam lobes and cam followers, always
replace cam followers when installing a new
camshaft.

11/22/00 3 - 85
REPAIR DIESEL ENGINE

TACHOMETER PICK-UP PIN MEASURE CAM FOLLOWER


REMOVAL

RG6324
CD30200
Measure cam follower OD and compare with
1. Drill and tap an extraction hole of approx. 6 mm
specifications.
(0.250 in.) diameter and 12 mm (0.500 in.) depth in
center of pin. Cam Follower Specifications:
2. Using a self-made puller (spacer, washer, screw), Cam follower OD . . . . . . . . . . . . . . 31.62—31.64 mm
pull out the tachometer pick-up pin. (1.124—1.246 in.)

Cam follower to bore clearance . . . . 0.06—0.13 mm


INSTALL CAMSHAFT (0.002—0.005 in.)

If diameter or clearance is not within specifications or if


the follower face is flat or concave, replace cam
follower.

MEASURE IDLER GEAR END PLAY

CD30596

1. Before installation of the tachometer drive shaft (A),


check the diameter of the knurled shaft area (B). If
diameter exceeds 12.92 mm (0.5087 in.), rework
shaft to 12.88—12.92 mm (0.5071—0.5087 in.).
2. Coat camshaft with clean engine oil. On engines CD7155
with camshaft bushing, lubricate the inner Using a dial indicator, check end play of upper and
circumference of bushing with TY6333 grease. lower idler gears:
3. Install camshaft and thrust plate (C) in cylinder End play . . . . . . . . 0.14—0.29 mm (0.006—0.012 in.)
block.
Maximum wear . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
4. Install cap screws (D) and tighten to 50 N•m
(35 lb-ft).
REMOVE FRONT PLATE
IMPORTANT: To keep the initial working condition 1. Proceed as follows in case of front plate
between cam lobes and cam followers, always replacement:
replace cam followers (E) when installing a new
camshaft. IMPORTANT: Replacement front plates do not have
any injection pump timing marks. It is extremely
important that the timing be accurately
transferred from original front plate to the
replacement plate in the exact location for
proper injection pump timing.

3 - 86 11/22/00
DIESEL ENGINE REPAIR

IDLER GEAR BUSHING AND SHAFT


MEASURE

CD30186

• Build a template as shown.


• Attach template to previous front plate using three CD7159
3/8 in. cap screws and transfer timing mark from
previous front plate (A) to template (B) with a
pencil.
• Attach template to new front plate and transfer
timing mark to the new front plate (C) using a
scribe.
2. Remove upper and lower idler gears.
3. Remove camshaft, fuel injection pump, and oil
pump.

CD7160

If clearance is more than specified, replace worn parts


with new ones.

Idler Gear Specifications:


Idler gear shaft OD:
Upper with helical gear and lower
KV18575 with helical or spur gear . . . . 44.437—44.463 mm
4. Remove five countersunk screws (D) and lift off (1.7495—1.7505 in.)
front plate. Upper with spur gear . . . . . . . 69.759—69.775 mm
(2.7464—2.747 in.)
Idler gear bushing ID:
Upper with helical gear and lower
with helical or spur gear . . . . 44.501—44.527 mm
(1.752—1.753 in.)
Upper with spur gear . . . . . . . 69.827—69.857 mm
(2.7491—2.7503 in.)
Idler gear/bushing clearance:
Upper with helical gear and lower
with helical or spur gear . . . . . . . 0.038—0.09 mm
(0.0015—0.0035 in.)
Upper with spur gear . . . . . . . . . 0.052—0.098 mm
KV18576 (0.002—0.0038 in.)
5. Remove oil bypass valve and spring (E). Maximum wear . . . . . . . . . . . . 0.15 mm (0.006 in.)

11/22/00 3 - 87
REPAIR DIESEL ENGINE

IDLER GEAR BUSHING INSTALL IDLER SHAFT SPRING PIN


REPLACEMENT

A
B

RG6459
CD7161

D
NOTE: Bushing for spur upper idler gear is not
available separately. Install a new idler gear/
bushing assembly.

1. Press worn idler gear bushing out of gear.

IMPORTANT: The upper and lower idler gears


require different bushings.
CD30401
• Upper Idler Gear: Being pressure lubricated, this
gear is specified with a smooth-bore bushing.
• Lower Idler Gear: Being splash lubricated, this NOTE: The upper idler shaft for engine with auxiliary
gear is specified with a lube-groove fitted bushing. drive (spur gear) has a spring pin to allow a
proper orientation of the shaft oil holes (C) and
2. Press in new bushing with JD-252 Driver and of the thrust washer ears (A) to clear space
JDG537 Handle so that it is flush with one side of around countersunk front plate screw (B).
the gear.

Press spring pin until protrusion (D) is obtained.


REMOVE IDLER SHAFT Spring pin protrusion (D) . . . . . . . . . . . 7.5—8.5 mm
(0.295—0.335 in.)

CD30599

Remove upper or lower idler shaft by driving shaft out


of the front plate. Remove thrust washer.

3 - 88 11/22/00
DIESEL ENGINE REPAIR

INSTALL IDLER SHAFTS INSTALL FRONT PLATE

A
B

C
D
A
G
E

CD30255
F CD30600
A. Upper Idler Shaft
A. T23442 Stud (Qty 3)
B. AT21191 Plug (5/16") (6 used)
C. R79854 Bushing
D. AT22919 Plug (3/8") (2 used)
E. Front Plate
F. Countersunk Screw (5 used)
G. Gasket

B 1. Install injection pump studs (A) on front plate using


Loctite 271.

CD30256
H
B. Lower Idler Shaft

H
IMPORTANT: Oil hole in upper idler shaft must be
properly indexed to provide adequate
lubrication to idler gear bushing. H

1. Install thrust washers (A and B) with sharp edge


toward front plate.
2. Place idler shaft in front plate bore with oil hole CD30695
oriented approximately 45° to the left of top center.
On engine with auxiliary drive, make sure that H. Injection Pump Stud Locations
spring pin of upper shaft is in line with thrust
washer and front plate holes. NOTE: Standard front plate (without auxiliary drive
3. Press shaft into front plate until thrust washer is extension) have several injection pump stud
fully seated. locations. Use holes marked (H).

NOTE: Idler shaft is secured to front plate when gear 2. On standard front plate only, install the 5/16" plugs
bolt or nut are tightened. (B) and the 3/8" plugs (D) as shown. Bushing (C)
is not required for this application.

11/22/00 3 - 89
REPAIR DIESEL ENGINE

INSTALL UPPER TIMING GEAR


1. Adjust No. 1 piston to TDC using JDE83 or JDG820
I (formerly JDE81-1) Flywheel Turning Tool and
JDE81-4 Timing Pin.

CD30598

I. Oil Bypass Valve


3. Install oil bypass valve (I) and spring in cylinder
block.
CD30601

2. Install camshaft then, with JD-254A Timing Tool on


F crankshaft end and directed toward center of
camshaft, turn camshaft until gear timing mark (A)
aligns with timing tool.

CD30697

4. Install gasket (G) and front plate. Place new


external tooth washers onto five countersunk
screws (F) then tighten to 35 N•m (25 lb-ft).
CD30602
IMPORTANT: Cut off protruding edge of gasket 3. Install fuel injection pump.
only after timing gear cover has been tightened.
4. Using JD-254A Timing Tool, align the timing mark
"3" (for 3 cylinder engines) with the timing tool.

KV18079

5. Lubricate shaft and gear bushing (D) with TY6333


grease.
6. Install idler gear on shaft without turning camshaft
gear or injection pump gear. On engine with spur
gear, use JDG791A Pilot Tool (C) to guide gear
onto shaft. Install upper idler gear with part
number visible.

3 - 90 11/22/00
DIESEL ENGINE REPAIR

INSTALL OIL DEFLECTOR

CD30604

7. Install washer, with sharp edge toward timing cover, CD30608


and bolt (B). Tighten to 110 N•m (80 lb-ft). Install oil deflector (A) and O-ring (B) when equipped,
8. Recheck gear timing to make sure it is correct. on forward end of crankshaft.

INSTALL LOWER TIMING GEAR INSTALL TIMING GEAR COVER

9 15 12
11 14
13
10
24
2

A 6
1
CD30605 5 8

7 4
1. Install oil pump and lower idler gear.
2. Install new bolt with washer (A) from oil pump side. 3
17
Install washer, with sharp edge toward timing
cover, and new nut on gear side then tighten to 16
110 N•m (80 lb-ft).
19
NOTE: Engine may be equipped with a self-locking oil 23 21
20 18 22
pump nut. In this case, tighten to 85 N•m
(63 lb-ft). Do not apply any punch marks. CD30609
3. Install oil pump gear on pump shaft, tighten hex nut 1. Install new gasket on front plate.
to 75 N•m (55 lb-ft) and secure with three center 2. Install cover on engine and apply the following
punch marks. torques in sequence:
Cover cap screws (1—17) . . . . . . . . 50 N•m (35 lb-ft)
Oil pan cap screws (18—23) . . . . . . 50 N•m (35 lb-ft)
A. Magnetic pick-up . . . . . . . . . . . . . 15 N•m (11 lb-ft)
B. Injection pump gear plug . . . . . . 30 N•m (22 lb-ft)
C. Oil pressure valve plug . . . . . . . . 95 N•m (70 lb-ft)

11/22/00 3 - 91
REPAIR DIESEL ENGINE

INSTALL WEAR RING

KV18577

NOTE: A generic PowerTech 2.9 L engine is shown. CD30612


Skid steer engine is similar.
1. When equipped, install the wear ring with
3. Install oil filler neck or block-off plate then tighten chamfered side (A) toward engine. Be sure that the
cap screws (F) to: O-ring is in place against the oil deflector.
Aluminum neck . . . . . . . . . . . . . . . . 50 N•m (35 lb-ft) 2. Install shaft key.
Composite neck . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)
Block-off plate . . . . . . . . . . . . . . . . . 50 N•m (35 lb-ft)
REMOVE OIL COOLER
4. Cut off protruding edge of gasket.

INSTALL CRANKSHAFT FRONT OIL


SEAL
A

B CD30271

A. Inlet Line from Water Pump


B. Outlet Line to Water Pump
CD30611 C. Nipple
1. Place new seal onto KJD10164 Seal Installer (A) 1. Disconnect inlet line (A) and outlet line (B) at oil
with open side toward engine, then slide the cooler.
assembly onto crankshaft end. 2. Remove nipple (C) and lift out oil cooler.
2. Install pulley cap screw with washer (B), then 3. Discard packing.
tighten until driver bottoms.

CD30698

NOTE: KJD10164 tool set contains a spacer (C) to be


used only on older crankshafts with the forward
end being 35 mm (1.378 in.).

3 - 92 11/22/00
DIESEL ENGINE REPAIR

REPLACE OIL COOLER NIPPLE REMOVE OIL PRESSURE


REGULATING VALVE

CD30275
CD30620

1. Remove oil cooler nipple (A). Remove oil pressure regulating valve plug. Check
2. Press in new nipple so that threaded end faces valve cone for excessive wear and damaged sealing
outward. face.
Spring tension at a length
of 42.5 mm (1.68 in.). . . . 60 to 75 N (13.5 to 16.5 lb).
INSTALL OIL COOLER
REPLACE OIL PRESSURE
REGULATING VALVE SEAT

JD-248A

813

CD30617

1. Install new packing between oil cooler and cylinder


block.
2. Attach oil cooler with nipple (A). Tighten to 35 N•m CD7175A
(25 lb-ft).
1. Remove valve seat bushing, using a suitable puller.
3. Connect coolant lines to oil cooler.
2. Drive in new bushing, using special tools JD-248A
4. Install oil filter. and JDG536 or OTC813 until driver contacts
cylinder block.

IMPORTANT: Do not damage the slightly


protruding edge of the bushing as it is a sealing
face.

11/22/00 3 - 93
REPAIR DIESEL ENGINE

INSTALL OIL PRESSURE REPLACE OIL BYPASS VALVE


REGULATING VALVE

A CD30622
CD30413 1. Remove timing gear cover and front plate.
2. Remove oil bypass valve and spring (A). Inspect
valve and spring for damage.
NOTE: One or several shims (A) may be used to
adjust the oil pressure. 3. Check spring calibration:
79 to 96.5 N (18 to 22 lb) when spring is
compressed at 29 mm (1.14 in.) length.
1. Install valve, spring, shims, washer, and plug in 4. Install oil bypass valve and spring.
timing gear cover.
5. Install front plate and timing gear cover.
2. Tighten plug to 95 N•m (70 lb-ft).

REPLACE OIL DIPSTICK GUIDE REPLACE OIL PUMP STRAINER


ADAPTER

CD30623

1. Remove oil pan.


2. Loosen the two lower cap screws (A) and remove
oil strainer.
KV18013
3. Install new strainer with new O-ring and tighten cap
screws to 50 N•m (35 lb-ft).
1. Loosen jam nut and unscrew dipstick guide adapter. 4. Install oil pan.
2. Apply sealing compound on threads of new guide
adapter.
3. Install new dipstick guide adapter and adjust height
(A) to 130.8 mm (5.15 in.).
4. Tighten jam nut.

3 - 94 11/22/00
DIESEL ENGINE REPAIR

REMOVE OIL PUMP GEAR RADIAL CLEARANCE

C
CD7178

CD7176
Radial clearance between
gear and pump housing . . . . . . . . . 0.10 to 0.16 mm
1. Remove oil pan and timing gear cover. (0.004 to 0.006 in.)
2. Remove nut (A) from pump shaft. Max. permissible radial
3. Pull gear (B) from conical shaft of pump, using a clearance. . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
suitable puller.
4. Remove the 3 cap screws (C) attaching pump
housing to front plate. OIL PUMP SPECIFICATIONS

GEAR AXIAL CLEARANCE

T81953

Bore of drive shaft in


pump housing . . . . . . . . . . . . . . . 16.05 to 16.08 mm
CD7177
(0.632 to 0.633 in.)
Max. permissible wear . . . . . . . . 0.08 mm (0.003 in.)
Thickness of gears . . . . . . . . . . . 41.15 to 41.20 mm Drive shaft O.D. . . . . . . . . . . . . . . . 16.02—16.03 mm
(1.62 to 1.622 in.) (0.630—0.631 in.)
Axial clearance . . . . . . . . . . . . . . . . . 0.05 to 0.17 mm Max. permissible wear . . . . . . . 0.025 mm (0.001 in.)
(0.002 to 0.007 in.) Idler shaft O.D. . . . . . . . . . . . . . . . 12.32 to 12.34 mm
Max. permissible axial (0.485 to 0.486 in.)
clearance. . . . . . . . . . . . . . . . . . 0.22 mm (0.0085 in.)
Max. permissible wear . . . . . . 0.013 mm (0.0005 in.)

T81781

11/22/00 3 - 95
REPAIR DIESEL ENGINE

OIL PUMP INSTALLATION

L
C
E
A

D
H
M

N
J
B
K
I
F

G
CD30416

A. Cylinder Block Seal H. Housing


B. O-Ring (Outlet Tube) I. Outlet Tube
C. O-Ring (Oil Strainer Tube) J. Strainer
D. Drive Shaft K. Cover
E. Spring Pin L. Cap Screws (3 or 4 used)
F. Gears M. Drive Gear
G. Shaft N. Nut

KV18080
CD30624

1. Install new seal (A) in cylinder block. NOTE: Service oil pump kit has two outlet tubes.
2. Install O-rings in pump cover (for outlet tube) and Install tube (I) without paint mark.
on oil strainer tube.
3. Install drive shaft with gear and idler gear in pump
housing. Both gears must turn freely.
4. Install outlet tube, strainer, and pump cover.

KV18578
5. Attach oil pump assembly to front plate, tightening
cap screws (L) to 50 N•m (35 lb-ft).

3 - 96 11/22/00
DIESEL ENGINE REPAIR

6. Rotate pump shaft, again making sure that pump 2. Select and install the correct gasket for the oil pan
gears turn freely. being used.
7. Install pump drive gear (M) and a new nut (N).
Tighten to 75 N•m (55 lb-ft).

CD30627

T81782
NOTE: A generic PowerTech 2.9 L engine is shown.
Skid steer engine is similar.
NOTE: Engine may be equipped with a self-lock nut. In
this case, tighten to 85 N•m (63 lb-ft). Do not
apply any punch marks. 3. Install oil pan and tighten cap screws as follows:
Oil pan (all types) to timing
8. Secure the nut by applying three center punch gear cover . . . . . . . . . . . . . . . . . . . 50 N•m (35 lb-ft)
marks. Sheet metal oil pan to block
and flywheel housing. . . . . . . . . . 50 N•m (35 lb-ft)
Aluminum oil pan to block
INSTALL OIL PAN and flywheel housing. . . . . . . . . . 50 N•m (35 lb-ft)
Cast iron pan to block and flywheel housing:
SAE 5 screws (3 dashes) . . . . . . . 50 N•m (35 lb-ft)
SAE 8 screws (6 dashes) . . . . . . . 70 N•m (50 lb-ft)

4. Install a new seal on cylindrical drain plug. Tighten


as follows:
Cylindrical plug . . . . . . . . . . . . . . . . 70 N•m (50 lb-ft)
Conical plug . . . . . . . . . . . . . . . . . . . 55 N•m (40 lb-ft)

CD30626

1. Place LOCTITE 515 Sealant (or an equivalent


sealant) on oil pan rail where flywheel housing,
front plate, and timing gear cover are attached to
the cylinder block.

NOTE: A tube of LOCTITE 515 Sealant is provided


with overhaul gasket set. This tube is also
available under part number DD15664.

11/22/00 3 - 97
REPAIR DIESEL ENGINE

WATER PUMP—EXPLODED VIEW

CD30628

A. Housing C. Seal E. Gasket


B. Bearing Shaft D. Impeller F. Rear Cover
G. Hub (or Pulley)

REMOVE WATER PUMP


1. Remove fan and sheet metal pulley when equipped.

B
A

C CD30629
2. Disconnect water pump hoses (A).
3. Remove attaching screws (B) and nut (C). Lift out
water pump.

3 - 98 11/22/00
DIESEL ENGINE REPAIR

DISASSEMBLE WATER PUMP 3. Using a suitable puller, remove pulley (B) or hub
from bearing shaft (C).
4. Support pulley end of housing, then using a 13 mm
(0.5 in.) driver, simultaneously remove impeller (D)
from bearing shaft and bearing shaft from pump
housing (E). Discard bearing and impeller.
5. Using a suitable driver, remove seal (F) from pump
housing and discard.

E D

CD30630

CD30631
6. Inspect water pump housing, cover, and pulley for
wear, debris, cracks or other damage. Replace as
necessary.

A. Rear Cover
B. Pulley
C. Bearing Shaft
D. Impeller
E. Pump Housing
F. Seal
G. Weep Hole

CD30632
NOTE: When water pump operation is abnormal or
when coolant drains from weep hole (G), H. Pre-Assembled Water Pump
disassemble water pump as follows.

1. Remove rear cover (A) and discard gasket NOTE: Complete or pre-assembled (H) water pumps
. are available for service as well as a seal kit
including bearing shaft (C), impeller (D), seal
(F), and gasket set.

CD30662
2. Measure dimension (X) as shown and retain for use
in pump assembly.

11/22/00 3 - 99
REPAIR DIESEL ENGINE

ASSEMBLE WATER PUMP

A B

CD30636

CD30633 4. Place pump housing under a press and support on


pulley end of shaft.
1. Use JD-262A (A) to install bearing shaft.
2. Press bearing shaft into housing until bearing face
is flush with housing. A flat washer (B) can be used
to stop the driver and ensure a proper installation.

CD30637

5. Using special tool JD-262A, press impeller onto


pump shaft until recess of 0.25 mm (0.5 in.) is
KV18579 obtained.

3. Support water pump on shaft end. Using the


installation tool (D) included in the seal kit, install
water pump seal (E) over shaft until seal bottoms
on shoulder (C) of housing.

KV18554

6. Place pump housing under a press and support on


impeller end of shaft.

CD30635

NOTE: Install seal dry. Installation tool (D) must be


used as it exerts the proper pressure on seal
and therefore avoids risk to damage the seal
faces.

3 - 100 11/22/00
DIESEL ENGINE REPAIR

3. Remove thermostat cover from cylinder head (C).


4. Test thermostat (F) in hot water for correct opening
and closing temperature (see TEST
THERMOSTAT in this section). Replace if
defective.
5. Remove gasket material from gasket surfaces.

X
D
E

KV18081
7. Install pulley or hub to dimension (X) obtained step G
2 of water pump disassembly.

F
INSTALL WATER PUMP
1. Attach pump rear cover to pump housing using a
new gasket and tighten cap screws to 45 N•m
(33 lb-ft).
D
CD30641

6. Using guide studs (D), install a new gasket (E) onto


cylinder head.
B 7. Place thermostat (F) in cover with jiggle pin (G) on
top for a proper deaeration.
8. Using a screwdriver to hold thermostat in place,
install cover. Tighten cap screws to 50 N•m
B
(35 lb-ft).
A
9. Install bypass tube into thermostat cover. Tighten
clamp.
10. Fill cooling system and check for leaks.
C CD30629
2. Install water pump, placing a new gasket between
the pump cover and cylinder block. Tighten cap COLD START ADVANCE WIRE
screws (B) to 50 N•m (35 lb-ft) and nut (C) to HARNESS (IF EQUIPPED)
40 N•m (30 lb-ft).
3. Connect coolant hoses (A).

REMOVE/INSTALL THERMOSTAT

CD30682

The cold start advance wire harness allows easy start-


up when the engine is cold. The temperature signal is
supplied by switch (A) located in thermostat cover.
CD30640 This switch must be tightened to 5 N•m (3.5 lb-ft).
1. Visually inspect area around thermostat cover (A)
for leaks. Partially drain coolant from system.
2. Remove bypass tube (B) from thermostat cover.

11/22/00 3 - 101
REPAIR DIESEL ENGINE

COOLING SYSTEM DEAERATION

C
CD30645
CD30642

Deaeration is normally accomplished by the jiggle pin


(A) in thermostat flange area. However a pocket of air
can stay on the top rear of engine. Using a spring scale (B) and straightedge (C):
Apply a force of 89 N (20 lb). The belt should deflect
6.38 mm (0.25 in.).

B D

CD30643

When refilling cooling system, loosen coolant


temperature sensor or plug at the rear of cylinder head
(B) to allow air to escape.
If machine has a cab heater (optional), see CAB
HEATER DEAERATION in the MISCELLANIOUS
section.
E
CD30646
CHECK FAN/ALTERNATOR BELT
TENSION 2. If adjustment is necessary, loosen alternator nuts
(D) and (E). Pull alternator frame outward until belt
1. Check belt tension using one of following methods: tension is correct.

IMPORTANT: Do not pry against the alternator rear


frame. Do not tighten or loosen belts while they
are hot.
A
3. Tighten alternator bracket nuts firmly.
4. Run engine for 10 minutes then check belt tension.

CD30644

Using JDG529 Tension Gauge (A):


New Belt Tension:
Single belt . . . . . . . . . . . . . 578—622 N (130—140 lb)
Used Belt Tension:
Single belt . . . . . . . . . . . . . . . 378—423 N (85—94 lb)

3 - 102 11/22/00
DIESEL ENGINE REPAIR

INSTALL FAN
1. Inspect fan blades for damage. Damaged blades
reduce cooling system efficiency and throw the fan
out of balance. Replace if necessary.

NOTE: 240 and 250 Skid Steer machines use a


blower-type fan. Take care not to install the fan Knurled
improperly. Fan is not reversible. Refer to Nut
illustration.

Wire
Connector

KV31112

6. Unscrew knurled nut and disconnect wire


connector.

CD30649
Blower Fan (Top View)

2. On water pump with hub, install first the sheet metal


pulley.
3. Install fan with spacer if required.
4. Install cap screws. Tighten as follows:
5/16 in. cap screws. . . . . . . . . . . . . . 30 N•m (22 lb-ft)
3/8 in. cap screws. . . . . . . . . . . . . . . 50 N•m (35 lb-ft)

Heating
BLOCK HEATER (OPTIONAL) Jam Nut Element
KV31111
Removal:
1. Park skid steer safely.
2. Raise ROPS. (See RAISING ROPS in the IMPORTANT: Heater element is bent to avoid
MISCELLANEOUS Section) interference with cylinder block walls. DO NOT
TURN the heater element. Doing so will damage
3. Remove any attachment from skid steer Quik-Tatch.
the heater element.
4. Raise boom and engage boom locks.
5. Drain radiator.
7. Hold heating elment in place and loosen jam nut.
8. Remove jam nut.

11/22/00 3 - 103
REPAIR DIESEL ENGINE

Mark
Toward
Outside
of Block

Fitting

Fitting Heating
Element Mark
KV31108 KV31110

NOTE: If heating element will be reused, make a mark IMPORTANT: Note where the offset in the heating
on the element to determine position for element. Offset must go to the out side of block
reassembly. (right side of engine).

9. Keep heating element from rotating and unscrew 3. Install element into engine, making sure offset is
fitting from block. Remove fitting and heating towards the outside of the block. Holding element
element from block. from rotating, tighten fitting into block.
4. Hold element in place and install jam nut and
tighten.
Installation:
5. Connect wire connector and install knurled nut.
6. Fill radiator.
7. Lower ROPS.
8. Operate engine and check for leaks.

CHECK AIR INLET PIPE

Heating
B
Element
O-Ring
A
Fitting

KV31109

1. Install new O-ring on heating element. C


2. Apply TY9374 Pipe Sealant with Teflon to the CD30653
threads of the fitting.

NOTE: A generic PowerTech 2.9 L engine is shown.


Skid steer engine is similar.

1. Loosen hose clamps (A) holding air inlet hose.


2. Remove air inlet pipe (B).
3. Inspect inlet pipe for serviceability. Repair or
replace if cracked or damaged.

3 - 104 11/22/00
DIESEL ENGINE REPAIR

4. Inspect machined mating surfaces of cylinder head


and inlet pipe. Clean as required, using a scraper
and/or wire brush and compressed air.
5. To install inlet pipe, reverse removal procedure and B
use new gaskets.
6. Make sure that air inlet hose is in good condition.
Tighten hose clamps securely.
7. Tighten air inlet pipe attaching cap screws (C) to
50 N•m (35 lb-ft). A

EXHAUST MANIFOLD INSPECTION D

1. Remove muffler.
2. On engines with turbocharger, remove
turbocharger. C

CD30661

2. Loosen clamp (A) holding the air inlet pipe.


3. Disconnect oil inlet line (B) and return tube (C).
Plug turbocharger orifices immediately to prevent
entry of dirt.
4. Remove air cleaner hose.
5. Remove muffler connection.
6. Unscrew the four bolts (D) and remove
turbocharger assembly from exhaust manifold.

A
CD30654
CHECK RADIAL BEARING
CLEARANCE
NOTE: A generic PowerTech 2.9 L engine is shown.
Skid steer engine is similar.

3. Remove cap screws (A) and lift off exhaust


manifold.
4. Inspect exhaust manifold for serviceability. Replace
if cracked or damaged.
5. To install exhaust manifold, reverse removal
procedure and use new gaskets.

NOTE: When using gaskets with one steel-backed


side, the non-steel backed side must face
toward the cylinder head.
CD30658
1. Remove compressor cover.
6. Tighten exhaust manifold attaching cap screws to 2. Install a dial indicator against shaft end.
50 N•m (35 lb-ft).
3. Move shaft alternately toward and away from
indicator. Range of travel should not exceed
0.51 mm (0.20 in.).
REMOVE TURBOCHARGER 4. If radial clearance is not within specifications,
1. Thoroughly clean exterior of turbocharger and replace turbocharger.
surrounding area.

11/22/00 3 - 105
REPAIR DIESEL ENGINE

CHECK AXIAL BEARING END PLAY INSTALL TURBOCHARGER

B
CD30659
E
1. Using a dial indicator with indicator rod against A
shaft, measure axial end play.
CD30661
2. Move shaft axially back and forth by hand. Indicator
reading should not exceed 0.14 mm (0.005 in.). 1. Install turbocharger on exhaust manifold (A) with a
If axial end play is not within specifications, replace new gasket (B). Tighten cap screws (C) to 30 N•m
turbocharger. (20 lb-ft).
2. If not done previously, prelube turbocharger, then
connect the oil supply line (D). Tighten to 25 N•m
REPAIR TURBOCHARGER (18 lb-ft).
Due to special tooling and highly specialized personnel 3. Connect the oil return tube (E). Tighten to 80 N•m
required, turbochargers can be serviced only by an (60 lb-ft).
authorized workshop. 4. Connect exhaust system and air hoses.
Complete turbochargers are available through service
parts channel. Individual components for repair are not IMPORTANT: Be sure that the air hose connections
available. are tight to prevent entry of dirt into engine.

PRELUBE TURBOCHARGER

CD30660

IMPORTANT: DO NOT spin the rotor assembly with


compressed air. Rotor may seize due to high
speed reached.

Fill oil inlet or drain port with clean engine oil and spin
rotating assembly (by hand) to properly lubricate
bearings.

3 - 106 11/22/00
DIESEL ENGINE REPAIR

TURBOCHARGER BREAK-IN REPLACE FUEL/WATER


SEPARATOR FILTER
IMPORTANT: A new or repaired turbocharger does
not have adequate oil supply. Perform the
following steps to prevent damage to
turbocharger.

LV2112

1. To avoid engine starts, proceed as follows:


• Disconnect electrical cable (A) from fuel injection
pump.
• Crank engine by means of starter motor until
needle of engine oil pressure gauge is in green
zone or indicator light (engine oil pressure) goes
out.

IMPORTANT: DO NOT crank engine for more than


30 seconds at a time. Excessive cranking can
cause starter damage. Allow starter to cool for 2
minutes before cranking again.

TURBOCHARGER CD30665
RECOMMENDATIONS A. Retaining Ring
In most cases, turbocharger damage is caused by B. Filter Element
improper start-up and shutdown procedure. Always C. Sediment Glass Bowl (Optional)
idle the engine for at least 30 seconds (no load) after D. Bleed Screw
start-up and before shutdown. E. Drain Screw (2 used)

IMPORTANT: Should the engine stall when 1. Unfasten filter retaining ring (A) and remove filter
operating under load, IMMEDIATELY restart the element (B).
engine to prevent overheating of turbocharger
parts.
NOTE: For a cleaner service, seal the old element with
the plug provided with the new element.

2. If equipped, remove sediment glass bowl (C) from


filter element and install it onto the new element.

11/22/00 3 - 107
REPAIR DIESEL ENGINE

REMOVE STANADYNE DB4 FUEL


INJECTION PUMP

CD30667
Y RG6293
3. Install dust seal (F) as shown.
4. Position new element in proper location then tighten
about 1/3 turn until retaining ring fits into the IMPORTANT: Never steam clean or pour cold water
detent. DO NOT overtighten. on a fuel injection pump while the pump is
5. To ensure that the fuel system is primed, turn the running or while it is warm. Seizure of internal
key switch to the RUN position and wait 20 components can occur.
seconds before starting the engine.
1. Clean fuel injection pump, lines, and area around
pump with cleaning solvent or a steam cleaner.
REPLACE FUEL PUMP 2. Check for the presence of timing marks on front
plate (X) and injection pump flange (Y). If
necessary, mark both the pump and the front plate.

B
B C E
G
B
A

C A
KV31120

1. Disconnect battery negative (–) cable. KV18082 F


2. Disconnect harness plug (A) at fuel pump.
3. Disconnect and plug both fuel lines (B). 3. Disconnect the following elements:
4. Remove two screws (C) securing fuel pump to fuel A. Cold start advance connector(if equipped)
tank. B. Fuel shut-off ground terminal
C. Fuel shut-off positive terminal
D. Speed control linkage
NOTE: Fuel pump is not repairable, Replace if non-
E. Fuel return line
operational.
F. Fuel supply line
G. Fuel injection lines
5. Installation is reverse order of removal.

IMPORTANT: Always use a backup wrench when


loosening or tightening fuel injection lines at
injection pump to prevent rotation of the
discharge fitting.

8. Plug all open connections on pump and fuel lines.


Do not use fibrous material.

3 - 108 11/22/00
DIESEL ENGINE REPAIR

REPAIR OF INJECTION PUMP


To comply with the exhaust emission regulations, for
which this engine is certified, the repair or adjustment
of the injection pump can be only performed by an
Authorized Stanadyne workshop.
Only complete injection pump is available for service.
When injection pump needs to be replaced, perform a
dynamic timing during installation on engine.

KV18581

9. Remove plug (I) from mounting hole in timing gear


cover.

NOTE: Use care when removing nut and washer. If


dropped, it will be necessary to remove the
engine front covers to retrieve them.

10. Remove nut (J) and washer securing the fuel


injection pump drive gear to pump shaft.

JDG670A

CD30317

11. Attach special tool JDG670A to gear. Remove the


three nuts holding fuel injection pump to engine
front plate.
12. Turn cap screw of special tool clockwise until pump
shaft is loosened from conical seat of drive gear.
13. Remove center forcing screw from JDG670A tool
and tighten the two screws of the tool until gear is
pulled against cover. This will avoid that gear
becomes disengaged from upper idler gear.
14. Pull fuel injection pump backward from the three
studs.

NOTE: When removing fuel injection pump, be careful


not to lose the pump shaft Woodruff key.

11/22/00 3 - 109
REPAIR DIESEL ENGINE

INSTALL STANADYNE DB4 FUEL INJECTION PUMP

H
J
G
F
K

A
B

D I

C
L

E
CD30670

A. Front Plate D. Stud (3 used) G. Return Line J. Injection Line No. 2


B. Pump Flange E. Nut (3 used) H. Injection Line No. 1 K. Injection Line No. 3
C. O-Ring F. Woodruff Key I. Pump Outlet L. Supply Line

1. Using a new O-ring (C), slide housing onto the 3. Push drive gear firmly onto shaft taper. Install
three studs (D), inserting shaft in drive gear. washer and nut (M) then tighten to 200 N•m
(150 lb-ft). Install mounting plug onto timing gear
cover.
NOTE: Make sure that the Woodruff key (F) is seated
properly.

2. Screw the three nuts (E) onto studs and hand-


tighten at this time.
X

Y RG6293

4. Align timing mark on pump flange (X) with timing


mark on front plate (Y) then tighten nuts to 25 N•m
(18 lb-ft).
M
NOTE: In case of replacement of injection pump,
CD30671 install injection pump with studs in middle of
flange slots. Then perform a dynamic timing.
NOTE: Use care when installing nut and washer. If
dropped, it will be necessary to remove the
engine front covers to retrieve them.

3 - 110 11/22/00
DIESEL ENGINE REPAIR

5. Connect injection line No. 1 (H) to outlet (I) and


continue counter-clockwise with injection line No. 2
(J) and No. 3 (K). Tighten to 25 N•m (18 lb-ft)
using JDF22 socket and a backup wrench. C
6. Connect:
• Fuel supply line (L) and tighten to 30 N•m (23 lb-
ft)
• Fuel return line(G) and tighten to 15 N•m (11 lb-ft)
• Shut-off system and speed control linkage
• Cold start advance system (if equipped)
CD30676
• Throttle cable bracket
2. Using two wrenches as shown, disconnect fuel
injection line (E) from nozzle to be removed.
REMOVE FUEL INJECTION NOZZLE 3. Remove cap screw (F).

IMPORTANT: Before removal, carefully remove all


dirt from the cylinder head around fuel injection
nozzles and blow clean with compressed air in JDG716
order to prevent any dirt entering the cylinder or
valve seats. Plug the bore in the cylinder head
after fuel injection nozzle has been removed.
Cap fuel line openings as soon as they are
removed.

Fit protecting caps immediately over the nozzle


tips and the line connections to avoid damage CD30324
to the nozzles when handling them.

Do not bend the fuel pressure lines, as this may


affect their durability and breakdowns may IMPORTANT: Do not use screwdrivers or similar
occur. When loosening the fuel pressure lines, tools for removal, as they may cause irreparable
hold male union of nozzle line. damage to the injection nozzles.

Removal: 4. Pull injection nozzle out of cylinder head, using


JDE38B Injection Nozzle Puller.

A CLEAN FUEL INJECTION NOZZLE


D
E
D C NOTE: Before testing a fuel injection nozzle with a
nozzle tester, remove both sealing rings and
B thoroughly clean outside of injection nozzle.

B Remove the carbon stop seal from groove in nozzle


body using suitable pliers. Pull seal washer from the
A C nozzle body and discard carbon stop seal and seal
washer.
B Place fuel injection nozzle in solvent or clean Diesel
F fuel until accumulated deposits are saturated. Clean
KV31118 body and tip with brass wire brush. NEVER use a steel
1. Loosen end fuel lines (A) and tube nuts (B). wire brush or scraper for this purpose.
Remove leak-off lines (C) and tee fittings (D) as an
assembly. Immediately cap or plug all openings.
IMPORTANT: When removing sealing rings and
cleaning the nozzle, take care not to damage the
teflon coating of the nozzle body above the
groove for the carbon stop seal.

11/22/00 3 - 111
REPAIR DIESEL ENGINE

FUEL INJECTION NOZZLE TEST 4. Deviations from the regular spray pattern or angle
may be due to the complete or partial clogging of a
nozzle orifice. In this case the fuel issues in a jet
rather than in a fine spray.

A Chatter Test
Make sure nozzle orifices are free. When working
pump of fuel injection nozzle tester at 60 strokes per
minute (gauge shut-off valve closed), a definite
characteristic "chatter" should be heard. If this is not
the case, the nozzle valve may be bent or tight in its
guide because of the lacquer deposits which have
B accumulated. This can be corrected only by
disassembling the nozzle.

Checking Valve Stem and Guide Wear


L30741 1. Connect fuel injection nozzle to the nozzle tester
with the tip raised a little higher than its opposite
end.
NOTE: Testing the performance of a nozzle while the
2. Cover the tip and pump the tester to a pressure of
engine is running is not an accurate test. To
10 300 kPa (1500 psi). Keep the pressure constant
obtain a true check of nozzle performance, use
and observe how much fuel leaks out of the nozzle
a nozzle tester JT25510 (A) and pressure line
return end. After the first drop has formed, count
KJD10109 (B), as shown under Special Tools.
the drops for 30 seconds; there should be 3 to 10
drops.
IMPORTANT: Use only carefully filtered diesel fuel
for testing the injection nozzles, dirty fuel will
severely damage the precision parts of a nozzle. Opening Pressure Test

NOTE: Absolute opening pressure is less important


c CAUTION than equal opening pressure of all nozzles.
Max. permissible variation is 700 kPa (100
psi).
The nozzle tip must always point away from the
operator. The fuel issuing from an orifice can 1. Close gauge shut-off valve and actuate the pump
penetrate clothes and skin and thus cause several times to allow the nozzle valve to seat
severe infection. properly.
2. Open gauge shut-off valve. Pump the pressure up
1. Connect the nozzle to the tester so that the axis of to the point where the pressure gauge needle falls
the nozzle forms an angle of approx. 30° to the rapidly. This point (take reading) is the nozzle valve
vertical and the spray of fuel is directed opening pressure. Minimum opening pressure
downwards. should be:
2. Check all connections for leaks. Close the gauge 3029D:
shut-off valve and flush (bleed) the nozzle by New or Reconditioned . . . . . . . . . . . . . . . 25 235 kPa
operating test pump rapidly. (3660 psi) Minimum
Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 856 kPa
Spray Pattern Test (3170 psi) Minimum
1. Close gauge shut-off valve and operate the pump 3029T:
lever at 60 strokes per minute. New or Reconditioned . . . . . . . . . . . . . . . 23 166 kPa
2. If the fuel injection nozzle is working properly, the (3360 psi) Minimum
fuel should issue through all nozzle orifices in a Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 960 kPa
fine, evenly shaped spray cone. This spray cone is (3330 psi) Minimum
inclined from the centerline of the nozzle body, but
should be distributed. 3. If spray pattern and valve seat test (see below) are
3. For a better check, place a piece of paper or good but the opening pressure test is
cardboard at a suitable distance below the nozzle unsatisfactory, adjust opening pressure. (See
and check the appearance of the damp circular ADJUST FUEL INJECTION NOZZLE.)
spots made by the fuel.

3 - 112 11/22/00
DIESEL ENGINE REPAIR

Checking Valve Seat 2. Loosen lock nut (B) of pressure adjusting screw (C).
1. Connect the nozzle to tester in horizontal position. 3. Connect nozzle to tester, then using JDG949
Operate the pump lever rapidly to bleed the nozzle Special Wrench, adjust opening pressure by
and allow the valve to seat. turning the pressure adjusting screw (C).
2. Dry the tip of the nozzle thoroughly. Now operate 4. Tighten lock nut (B) to 10 N•m (7 lb-ft), then check
the pump lever slowly until the indicated pressure opening pressure.
is approximately 2800 to 3500 kPa (28 to 35 bar) 5. Carefully screw lift adjusting screw (D) until it
(400 to 500 psi) below opening pressure (see bottoms on spring seat (E).
opening pressure above). 6. Unscrew lift adjusting screw with the number of
3. Keep watching the nozzle. The nozzle tip must stay turns as specified.
dry (visual check) after a period of 5 seconds. 7. Tighten lock nut of lift adjusting screw to 5 N•m
4. Work the pump lever quickly several times in (3.5 lb-ft).
succession to make the nozzle spray in the normal 8. Check opening pressure.
way. After the last stroke of the pump, observe
again. If the nozzle is not quite leakproof,
disassemble for servicing.

FUEL INJECTION NOZZLE


DISASSEMBLY

NOTE: If all tests prove that the nozzle performs


properly, no further service is necessary and
the nozzle can be used as is. (See INSTALL
FUEL INJECTION NOZZLE). If an injection
nozzle is not operating properly and must be
disassembled for cleaning and/or
reconditioning, see your Stanadyne dealer.

ADJUST FUEL INJECTION NOZZLE

CD30674

A. Lock Nut
B. Lock Nut
C. Adjusting Screw
D. Adjusting Screw
E. Spring Seat
1. Loosen and remove lock nut (A) of lift adjusting
screw (D).

11/22/00 3 - 113
REPAIR DIESEL ENGINE

INSTALL FUEL INJECTION NOZZLE

A I
A
F

G B

H
C B

C CD30323

E C

H
CD30675
CD30676
A. Tee Fitting
2. Install nozzle in cylinder head. Install and hand
B. Cap Screw tighten cap screw (B). Do not tighten at this time.
C. Fuel Injection Line 3. Connect fuel injection line (C) to nozzle. Tighten to
D. Carbon Stop Seal 30 N•m (23 lb-ft) using two wrenches as shown.
E. Seal Washer 4. Tighten cap screw (B) to 37 N•m (27 lb-ft).
F. Seal 5. Install leak-off lines (I) and tee fittings (A) as an
G. Tube Nut assembly. Connect leak-off fuel lines to ends of
H. Protective Caps leak-off line assembly. Tighten all leak-off line nuts
to 5 N•m (44 lb-in.).

IMPORTANT: Before installation, be sure nozzle is


clean and free from oil and grease. BLEED FUEL SYSTEM
The fuel system utilizes an automatic priming system.
IMPORTANT: Each time an injection nozzle is To ensure that the fuel system is primed, turn the key
removed from cylinder head, replace the carbon switch to the RUN position and wait 20 seconds before
stop seal (D). starting the engine.

1. Slide seal washer (E) onto nozzle body. Using JD-


258 Pilot Tool, slide the new carbon stop seal until
it fits properly into the groove.

3 - 114 11/22/00
DIESEL ENGINE REPAIR

ENGINE BREAK-IN INSTRUCTIONS


Use a dynamometer to perform the following break-in
procedure. Fill engine crankcase with oil specified in
"ENGINE BREAK-IN OIL".

Time Load Engine Speed Remarks

5 minutes No load 800 rpm

5 minutes No load 1,500 to 2,300 rpm

10 minutes 1/4 load 2,000 to rated speed Check oil pressure and
coolant temperature.
15 minutes 1/2 load 2,000 to rated speed Check for fluid leakage.
15 minutes 1/2 to 3/4 load 2,000 to rated speed

10 minutes 3/4 to full load Rated speed

After break-in, run the engine for 1 or 2 minutes at After engine overhaul, fill the engine with John Deere
mid-throttle, no load, before shutting it off. Check and ENGINE BREAK-IN OIL.
reset the valve clearances.
If John Deere ENGINE BREAK-IN OIL is not available,
use a diesel engine oil meeting one of the following
NOTE: It is not necessary to retorque the cylinder during the first 100 hours of operation:
head cap screws once the engine is broken in. • API Service Classification CE
• ACEA Specification
After the break-in period, use John Deere PLUS-50• or
During the first 100 hours of operation, avoid
other diesel engine oil as recommended in this
overloading, excessive idling, and no-load operation.
manual.
After 100 hours, drain the crankcase oil and change
the oil filter. Fill the crankcase with oil of the specified
viscosity. IMPORTANT: Do not use PLUS-50 oil or engine oils
meeting API CG4, API CF4, ACEA E3, or ACEA
E2 performance levels during the first 100 hours
ENGINE BREAK-IN OIL of operation of a new or rebuilt engine. These
New engines are filled at the factory with John Deere oils will not allow the engine to break-in
ENGINE BREAK-IN OIL. During the break-in period, properly.
add John Deere ENGINE BREAK-IN OIL as needed to
maintain the specified oil level.
Change the oil and filter after the first 100 hours of
operation of a new or rebuilt engine.

11/22/00 3 - 115
REPAIR DIESEL ENGINE

USING STANADYNE "TIME-TRAC" TURBOCHARGER OPERATION


AS TACHOMETER

F B

A
A
C
E
B C A

D
L30869
CD30206
A. Shaft
A. Clamp-On Transducer FKM10429-5 B. Turbine Housing
B. Cable FKM10429-3 C. Turbine Wheel
C. Timing Meter FKM10429-1 D. Center Housing
E. Compressor Wheel
F. Compressor Housing

A The turbine wheel (C) is driven by the hot engine


exhaust gases. These gases flowing through the
turbine housing (B) act on the turbine wheel causing
shaft (A) to turn.
Compressor wheel (E) draws in filtered air and
discharges the compressed air into the intake manifold
B where it is then delivered to engine cylinders.
Engine oil under pressure from the engine lubrication
CD30207 system is forced through passages in center housing
(D) to the bearings.
The STANADYNE "TIME-TRAC" meter can be used
as a tachometer by using clamp-on transducer
FKM10429-5 (A) on any high-pressure line.

Operating Instructions
1. Remove paint and thoroughly clean the area of the
high-pressure line to which the clamp-on
transducer is to be attached.
2. Install transducer (A) and connect cable
FKM10429-3 (B) between transducer and timing
meter (C). Also connect ground wire.
3. Switch the meter ON by pressing the "ON/CLEAR"
key and start the engine.

3 - 116 11/22/00
DIESEL ENGINE REPAIR

CHECK TURBOCHARGER BOOST Oil on Compressor Wheel or in Compressor


Housing (Oil Being Forced Through Center
PRESSURE Housing)
• Excessive crankcase pressure
• Air intake restriction

Oil Dripping from Housing in Intake or Exhaust


Manifold
• Damaged or worn journal bearings
• Rotating assembly unbalanced
• Damage to turbine or compressor wheel or blade
• Dirt or carbon build-up on wheel or wheels
A • Bearing wear
CD30687 • Oil starvation or insufficient lubrication
• Shaft seals worn
• Excessive crankcase pressure
NOTE: A generic PowerTech 2.9 L engine is shown.
Skid steer engine is similar.
Noise or Vibration
(Do not confuse the whine heard during rundown with
Attach pressure gauge (A) to any air inlet port.
noise which indicates a bearing failure).
Before checking boost pressure, warm up engine to
• Bearings not lubricated (insufficient oil pressure)
allow the lubricating oil to reach operating
temperature. • Air leak in engine intake or exhaust manifold
• Improper clearance between turbine wheel and
Observe pressure reading on gauge. Reading should turbine housing
be at least 60 kPa (9 psi) when engine is developing
rated horsepower at full load speed. If the reading is • Broken blades (or other wheel failures)
lower, check the following:
• Restriction in the air cleaner Drag in Turbine Wheel
• Leak in air intake system between turbocharger • Carbon build-up behind turbine wheel caused by
and cylinder head coked oil or combustion deposits
• Defective turbocharger • Dirt build-up behind compressor wheel caused by
air intake leaks
• Bearing seizure or dirty or worn bearings caused
DIAGNOSING TURBOCHARGER by excessive temperatures, unbalanced wheel,
MALFUNCTIONS dirty oil, oil starvation, or insufficient lubrication

Lack of Engine Power FUEL INJECTION PUMP


• Clogged manifold system The fuel injection pump is a sealed unit and is not
• Foreign material lodged in compressor, impeller, serviceable. The pump must be returned to an
or turbine authorized service center for repair.
• Excessive dirt build-up in compressor
• Leak in engine intake or exhaust manifold
• Rotating assembly bearing failure

Engine Emits Black or Grey Smoke


• Excessive build-up in compressor or turbine
• Turbine housing cracked or attaching screws loose
• Exhaust manifold gaskets blowing

11/22/00 3 - 117
REPAIR DIESEL ENGINE

COLD START ADVANCE SYSTEM The engine utilizes a cold start advance system to aid
in starting and operating a cold engine.
OPERATION (IF EQUIPPED)
The cold advance system is a solenoid assembly (A)
in relation with the advance piston (E), and connected
through the wires (B) to a thermo-switch (F) located in
thermostat cover.
When coolant temperature is below 50°C (122°F), the
solenoid valve (C) is activated and opens the cold
advance circuit. This directs transfer pump pressure to
the cold advance piston (D), forcing the advance
piston to the fully advanced position.
When coolant temperature reaches 50°C (122°F), the
solenoid valve (C) is no longer activated and due to
the spring action, closes the cold advance circuit.
CD30696
The normal advance is now running and is controlled
by the speed and load advance mechanism.
The cold advance system is connected to the fuel
shut-off terminals as follows:
• Red wire to positive terminal (G)
• Black wire to negative (ground) terminal (H)

CD30692

CD30691

A. Cold Start Advance Solenoid Assembly


B. Electrical Wires for Thermo-Switch Connection
C. Solenoid Valve
D. Cold Advance Piston
E. Advance Piston
F. Thermo-Switch
G. Fuel Shut-Off Positive Terminal
H. Fuel Shut-Off Negative Terminal

3 - 118 11/22/00
DIESEL ENGINE REPAIR

FUEL INJECTION NOZZLES— Fuel injection nozzles are of the multi-orifice type.
GENERAL INFORMATION The nozzle spray tip (1) forms an integral unit with
nozzle body (4) from which it cannot be separated.
The injection nozzle is secured in the cylinder head by
three superimposed spring clamps which press on a
location clamp and a cap screw. The contact pressure
is limited by a spacer ring. The nozzle is sealed in the
cylinder head at its lower end with a carbon stop seal
(2). The top end is sealed with seal washer (5).
Location clamp (19) ensures correct position of the
complete fuel injection nozzle in the cylinder head. The
leak-off line is connected by tee fitting (14), which is
fitted on the nozzle body and secured with grommet
(18) and hex nut (17).
The fuel injection nozzle works basically in the same
way as a normal spray type nozzle. Its opening
pressure is adjusted by the pressure adjusting screw
(16). The valve lift of nozzle valve (3) is adjusted by lift
adjusting screw (12) located in pressure adjusting
screw (16).
The carbon stop seal (2) prevents carbon from
collecting around nozzle in cylinder head. The fuel
injection nozzles have four orifices.

DIAGNOSING FUEL SYSTEM


MALFUNCTIONS

CD30040 Fuel Not Reaching Fuel Injection Nozzles


• Fuel filter clogged
1. Spray Tip
• Fuel line clogged or restricted
2. Carbon Stop Seal
• Fuel transfer pump pressure too low
3. Nozzle Valve
• Air in fuel system
4. Nozzle Body
• Fuel return line restricted
5. Seal Washer
• Loss of fuel through leakage
6. Connection for Injection Line
7. Nozzle Valve Guide
8. Union Nut Engine Hard to Start or Will Not Start
9. Spring Seat • Water, dirt or air in fuel system
10. Adjustable Pressure Spring • Fuel filter clogged
11. Spacer Washer • Shut-off knob stuck
12. Lift Adjusting Screw • Fuel lines clogged or restricted
13. Lock Nut • Fuel injection nozzles dirty or faulty
14. Tee Fitting • Fuel injection pump faulty
15. Lock Nut • Fuel transfer pump faulty incorrect timing
16. Pressure Adjusting Screw • Fuel injection pump metering valve stuck in closed
17. Hex Nut position (check speed-control linkage)
18. Grommet
19. Location Clamp
Engine Starts and Stops
20. Nipple
21. Filter Screen • Water in fuel
22. Fuel Pressure Line • Filter clogged
• Air in fuel system
• Fuel lines clogged or restricted
• Fuel injection pump return line damaged

11/22/00 3 - 119
REPAIR DIESEL ENGINE

Engine Runs Irregularly or Stalls Frequently • Excessive wear in valve guides


• Filter clogged
• Air in fuel system TESTING FUEL INJECTION
• Fuel injection nozzles faulty or dirty
• Fuel lines clogged or restricted
NOZZLES ON A RUNNING ENGINE
• Incorrect timing Run engine at intermediate speed under no load.
• Water in fuel Slowly loosen fuel pressure line at one of the injection
nozzles so that the fuel escapes at the line connection
• Fuel injection pump return line restricted
and is not forced through the nozzle (nozzle not
• Fuel injection nozzle leak-off line clogged opening). If there is a change in engine speed, this
indicates that the nozzle is in order. If there is no
change in engine speed, nozzle is faulty.
Poor Engine Idling
Repeat test consecutively at each of the remaining
• Air in fuel system
nozzles.
• Fuel injection nozzles dirty or faulty
• Incorrect timing When a faulty fuel injection nozzle is found, remove it
and check thoroughly. (See FUEL INJECTION
• Automatic advance of fuel injection pump faulty or NOZZLE TEST.)
not operating
• Fuel lines clogged or restricted
• Water in fuel
• Fuel injection pump return line restricted
• Fuel injection nozzle leak-off line clogged

Lack of Engine Power


• Air cleaner restricted
• Incorrect timing
• Automatic advance or cold advance of fuel
injection pump faulty or not operating
• Fuel filter clogged
• Fuel injection nozzle leak-off line clogged
• Fuel injection nozzles faulty or nozzle valve
sticking
• Fuel injection pump return line restricted
• Fuel injection pump housing is not full of fuel
• Water in fuel
• Speed control linkage incorrectly adjusted

Engine Emits Black or Grey Smoke


• Fuel injection nozzles faulty or nozzle valves
sticking
• Incorrect timing
• Automatic advance of fuel injection pump faulty or
not operating
• Air cleaner element clogged or dirty

Engine Emits Blue or White Smoke


• Cranking speed too low
• Incorrect timing
• Automatic advance or cold advance of injection
pump faulty or not operating
• Injection nozzles faulty or nozzle valves sticking
• Excessive wear in liners and/or stuck piston rings
• Engine does not get hot

3 - 120 11/22/00
DIESEL ENGINE STARTING MOTOR

STARTING MOTOR From field windings, current flows through armature


windings (I) to ground, making contact through
commutator brushes (H).
IMPORTANT: Never operate starting motor longer Strong magnetic fields are set up by current flow
than 30 seconds. Allow at least 2 minutes for through field windings and armature windings.
cooling and battery recovery before operating Windings are arranged so that magnetic fields
again. Overheating caused by excessive constantly repel each other, rotating armature.
operation will seriously damage starting motor.

THEORY OF OPERATION

A C D

F E
B

G J

H I
RG1313

A. Wire from Relay


B. Cable from Battery
C. Pull-In Winding
D. Hold-In Winding
E. Solenoid Plunger
F. Main Contacts
G. Field Windings
H. Commutator Brushes
I. Armature Windings
J. Shunt Windings

When wire from relay (A) is energized, current flows


through both pull-in winding (C) and hold-in winding
(D) to ground.
Current through windings engages solenoid plunger
(E), which closes main contacts (F). When main
contacts close, current through pull-in windings stops.
Current continues through hold-in winding, keeping
solenoid engaged and main contacts closed.
With main contacts closed, current flows from battery
cable (B) to starting motor at a very high rate. Four
heavy field windings (G) carry current to commutator
brushes (H).
Light shunt windings (J) are wrapped together with two
of the heavy field windings. Shunt windings are
connected to solenoid switch terminal and directly to
ground. They provide additional low speed torque to
assist engine rotation and prevent overspeeding of
motor.

11/22/00 3 - 121
STARTING MOTOR DIESEL ENGINE

THEORY OF OPERATION—CONTINUED

B
J
C

D
H
E
G F CD30450

A. Solenoid E. Commutator I. Pinion


B. Field Winding F. Armature J. Engaging Lever
C. Rear Bearing G. Gear Reduction Assembly
D. Brush H. Overrunning Clutch

When solenoid (A) engages, it pulls engaging lever (J). The two windings cancel each other, and solenoid is
Lever pushes overrunning clutch drive (H) to engage released.
pinion in starter gear on flywheel. As armature (F)
A spring pushes solenoid back to disengaged position.
turns, it cranks engine.
This opens main contacts and shuts off current to field
When engine starts, overrunning clutch spins freely on windings and armature.
shaft. This prevents overspeeding of armature by
Shift lever retracts overrunning clutch drive,
flywheel.
disengaging pinion from flywheel.
When key switch is released, current to solenoid hold-
In this reduction-type starter, the speed of armature
in winding is shut off. Current can feed through both
rotation is reduced by the gear reduction assembly
pull-in and hold-in windings from main contacts, but
(G).
direction of current is reversed in pull-in winding.

3 - 122 11/22/00
DIESEL ENGINE STARTING MOTOR

EXPLODED VIEW OF STARTING MOTOR

KV18083

A. Pivot Pin J. Bushing S. Brush (4 used)


B. Engaging Lever/Plunger K. Armature T. Brush Spring
C. Solenoid Spring L. Field Frame U. Clip
D. Gear Reduction Assembly M. Brush Plate V. Field Winding
E. Solenoid Body N. Shim (2 used) W. Pole Shoe Screw
F. Cover O. Rear Bearing X. Field Winding Terminal
G. Overrunning Clutch P. Clip Y. Solenoid Attaching Screw
H. Pinion Stop Q. Plastic Cap
I. Retaining Ring R. Through-Bolt (2 used)

11/22/00 3 - 123
STARTING MOTOR DIESEL ENGINE

STARTING MOTOR
SPECIFICATIONS
Weight . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 kg (10.6 lb)
Brush length:
New . . . . . . . . . . . . . . . . . . . . . . . . . 14 mm (0.55 in.)
Worn (mimimum) . . . . . . . . . . . . . . 8.5 mm (0.22 in.)
Pinion:
Number of teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.54

STARTING MOTOR TORQUE KV18085


SPECIFICATIONS 5. Separate gear reduction/solenoid/overrunning
Starting motor-to-engine . . . . . . . . 50 N•m (37 lb-ft) clutch assembly (G) from drive end housing (H).
Solenoid attaching screw . . . . . . . 3 N•m (27 lb-in.) 6. Push pinion stop (I) toward pinion to have access to
the retaining ring (J).
Field winding terminal nut. . . . . . 10 N•m (88 lb-in.)
7. Remove retaining ring and slide pinion stop off
Through-bolts. . . . . . . . . . . . . . . . . 7 N•m (62 lb-in.)
shaft.

DISASSEMBLY OF STARTING
MOTOR

KV18086

8. Remove pivot pin (K).

CD30452
1. Disconnect field winding cable (A).
2. Unscrew the two through-bolts (B).

KV18087

9. Separate overrunning clutch/engaging lever/mobile


KV18084 core assembly (M) from gear reduction/solenoid
body assembly (L).
NOTE: Do not unscrew the pole shoe screws (D) as it
is difficult to perform the tightening procedure.

3. Separate electric motor (E) from complete front


assembly (F).
4. Unscrew the screw (C) holding the contactor, using
a TORX™ screwdriver.

3 - 124 11/22/00
DIESEL ENGINE STARTING MOTOR

KV18088 KV18091

10. Remove two screws (N) retaining contactor. 14. Position and push the disassembly sleeve (U) on
the shaft to hold brushes in their housing and
remove the armature.

NOTE: The disassembly sleeve (U) is provided with


the brush repair kit available through John
Deere Parts.

KV18089

11. Before disassembly, mark both the rear bearing (P)


and the field frame (O) to aid in assembly.
12. Remove rear plastic cap (R) and clip (Q).
CD30461

15. Slide carbon brush plate away from the field frame.
16. Loosen and remove the four brush clips from the
plate. Take care to avoid losing the four springs.
17. Remove the disassembly sleeve.

KV18090

13. Remove the rear bearing (S).

NOTE: Two shims (T) are located on each side of rear


bearing.
CD30462

18. Push the two positive brushes inwards and remove


the brush plate from the field frame.

11/22/00 3 - 125
STARTING MOTOR DIESEL ENGINE

TESTING SOLENOID SWITCH POSITIVE BRUSH REPLACEMENT

CD30463 CD30465

1. Check for continuity between terminals (A) and (B).


If there is no continuity, replace the solenoid NOTE: This operation requires specialized soldering
switch. tools. If not available, have the brushes
replaced by a local electrical repair station.
2. Check for continuity between terminals (A) and (C).
If there is continuity, replace the solenoid switch.
3. Apply appropriate voltage (12V or 24V) between 1. Cut off old brush at end of brush strand (A).
terminal (A) and ground. Connect the ohmmeter 2. Solder new brush using a 40—60% tin-lead mixing.
between terminals (B) and (C). Replace the Heat to 230°C (446°F).
solenoid switch if the resistance is not infinity.
TESTING ARMATURE
NOTE: Solenoid switch is available as a John Deere
service part.

TESTING BRUSHES

CD30466

1. Check the armature insulation by connecting an


ohmmeter between the commutator (A) and the
shaft (B). If test shows continuity (needle
movement), the armature is grounded.
CD30464 2. Check for armature condition. Space between bars
must be clean and of even depth. Small defects
1. Check positive brushes (A) by connecting an can be eliminated using sandpaper and a lathe.
ohmmeter between brushes and plate. The 3. If insulation is defective or armature is quite worn,
resistance should be infinity. replace the complete starting motor.
2. Inspect brushes. Brushes must move freely in their
guides. Minimum length for worn brush is 8.5 mm.
3. If defective, replace the brush plate assembly.

NOTE: Brush plate assembly is available as a John


Deere Service part.

3 - 126 11/22/00
DIESEL ENGINE STARTING MOTOR

TESTING FIELD WINDING CHECKING OVERRUNNING


CLUTCH PINION

CD30467
CD30468
1. Check insulation by connecting an ohmmeter
between brush (A) and field frame (B). If 1. Check for pinion tooth condition. Slight damage on
ohmmeter indicator swings toward zero, a teeth can be eliminated by grinding.
grounded circuit is indicated.
2. Connect ohmmeter between brush (A) and terminal
(C). Resistance should be below 1 ohm. NOTE: Damage on teeth can be caused by a
3. If defective, replace the complete starting motor. malfunction of electrical system. Check also
electrical circuit for proper operation (switch,
relay, etc.).

2. Turn overrunning clutch pinion by hand. Clutch


pinion should turn freely on shaft in overrunning
direction only.
3. If defective, replace overrunning clutch pinion.

NOTE: Overrunning clutch pinion is available as a


John Deere service part.

11/22/00 3 - 127
STARTING MOTOR DIESEL ENGINE

ASSEMBLY OF STARTING MOTOR

CD30469

Assemble starting motor in the reverse sequence of TORQUE SPECIFICATIONS:


disassembly procedure.
Starting motor-to-engine . . . . . . . . . 50 N•m (35 lb-ft)
Use petroleum-base grease to lightly coat mechanical
Solenoid attaching screw . . . . . . . . 3 N•m (27 lb-in.)
part assemblies such as shaft in nose bushing, gear
reduction train, overrunning clutch pinion on shaft and Field winding terminal screw . . . . 10 N•m (88 lb-in.)
shaft rear bearing. Through-bolts. . . . . . . . . . . . . . . . . . 7 N•m (62 lb-in.)
(See STARTER in the ELECTRICAL section.)

3 - 128 11/22/00
DIESEL ENGINE ALTERNATOR

ALTERNATOR
J

W G

Y B+

A I H

B X Z D+

C
B-
F

REG. E

D KV15183

A. Alternator D. Regulator H. Protection Device


B. Current Coil (Stator) E. Battery I. Diode Trio
C. Exiting Coil (Rotor) F. Indicator Light J. Rectifier Diode Bridge
G. Ignition Switch

THEORY OF OPERATION Equipment:

The alternator is a synchronous three-phase NOTE: Order tools according to information given in
generator. The current coil is located in the stator, and the U.S. SERVICE-GARD Catalog or in
the exiting current is supplied by the diode trio (I) European Microfiche Tool Catalog (MTC).
through the regulator (D+ circuit), two carbon brushes
and slip rings to the exiting coil in the rotor.
The alternator is normally driven by the fan belt from
the engine crankshaft. The rotor is supported by two
permanently lubricated bearings.
The alternator generates alternating current which is
then transformed into direct current by the rectifier
diode bridge (J).
The alternating windings are delta-connected. The coil
ends X, Y, and Z are connected to the rectifier diode
as shown. Alternating current is generated in each
stator coil (B) of the alternator. During one revolution
of the rotor (C), the voltage in the stator coil rises from RW11274
0 to the positive maximum, drops to 0, rises to the
negative maximum and again drops to 0. The current Digital Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . JT05791
then flows through the diode and terminal B+ directly
to the positive pole of the battery. Test electrical components for voltage, resistance, or
current flow. It is especially good for measuring low
A sealed electronic regulator is used to regulate voltage or high resistance circuits.
alternator voltage. This regulator, which cannot be
adjusted, limits the alternator voltage to approximately
14 volts.
A protection device (H), including a Zener diode and a
capacitor, protects diode from voltage surges and
suppresses radio interference.

11/22/00 3 - 129
ALTERNATOR DIESEL ENGINE

ALTERNATOR SPECIFICATIONS:
Rotor winding resistance . . . . . . . . . . . . 2.95 ohms
Stator resistance . . . . . . . . . . . . . . . . . . . 0.00 ohms
Alternator output voltage . . . . . . . . 13.5–14.2 volts
Alternator rated amps . . . . . . . . . . . . . . . . . 55 amps
Working temperature range . . . . . . –40°C to +90°C
(–104°F to +194°F)
Maximum D+ terminal current load . . . . . . 0.5 amp
Maximum continuous alternator speed 13 000 rpm
Nominal alternator speed . . . . . . . . . . . . . .6000 rpm
Minimum brush length . . . . . . . . . . 7 mm (0.28 in.)
Single groove pulley diameter . . . 85 mm (3.35 in.)

Torque Specifications:
Alternator pulley nut . . . . . . . . . . . 40 N•m (29 lb–ft)
B+ terminal nut . . . . . . . . . . . . . . . 4 N•m (35 lb-in.)
B– terminal nut . . . . . . . . . . . . . . . 3 N•m (27 lb-in.)
Through-bolts . . . . . . . . . . . . . . . . 3 N•m (27 lb-in.)

3 - 130 11/22/00
DIESEL ENGINE ALTERNATOR

ALTERNATOR—EXPLODED VIEW

G
F
E

D
H

C
B
I
A

M
K

KV15184

A. Pulley Nut (M14 x 1.5) G. Spring Coil


B. Lock Washer H. Stator
C. Pulley I. Front Bearing
D. Fan J. Front Housing
E. Rotor K. Regulator and Brush Assembly
F. Rear Bearing L. Rectifier Bridge Assembly
M. Capacitor
N. Rear Housing

11/22/00 3 - 131
ALTERNATOR DIESEL ENGINE

TROUBLESHOOTING
Problem or

Alternator indicator

Alternator indicator

Alternator indicator
engine not running
light stays off with

light stays on with

light stays on with


Symptom

(alternator is not

(alternator is not
charging) at any

charging) at low
engine running

engine running
ignition on and

overcharging
Check or

Battery
speed

speed
Loose connection
Check wiring leads
z

Regulator failure
Replace brush/regulator z
assembly

Stator failure (short-circuit) z


Drive belt loose or broken
Adjust tension or replace
z

Loose connection
Check wiring leads
z

Brush/regulator or capacitor
failure z
Replace parts

Diode failure
Replace complete rectifier z
bridge

Stator failure
Replace complete alternator
z

Rotor failure
Replace complete alternator
z

Alternator speed too low


Use smaller alternator pulley
z

Low electrical consumption


Use regulator with narrower z
regulation range (RE69380)

Regulator failure
Replace regulator
z

3 - 132 11/22/00
DIESEL ENGINE ALTERNATOR

ALTERNATOR—IDENTIFICATION

CD30471
4. Disconnect wire (D) from terminal. Remove two
CD30470 screws and washers (E). Remove brush/regulator
The information for parts identification is stamped on assembly by tilting top of regulator up and away
the body of the alternator. from alternator.

DISASSEMBLE—ALTERNATOR

NOTE: Before removing alternator from engine; tag or


label all wiring connectors to aid during
installation.

1. Remove alternator from engine. Tag or label wiring


connectors to aid during installation.
KV18092
5. Remove three bolts (F) from front housing side.

ZT10613

2. Remove pulley nut (A), lock washer, pulley, and fan


KV18093
from shaft.
6. Place alignment marks along the alternator to note
the orientation of housing. Split alternator by
carefully prying at slot (G) using a screwdriver
against housing.

ZT10614

3. Remove shaft key (B) and spacer (C) from shaft.

11/22/00 3 - 133
ALTERNATOR DIESEL ENGINE

2. Touch each brush with test leads. No continuity


should be found even if either brush can slip up or
down in its channel. If there is continuity, replace
the brush/regulator assembly.

KV18094
7. Remove rotor/front housing assembly (I) from
stator/rear housing assembly (H).
CD30476

3. Check for continuity between brush (B) and wire


(C).
4. Connect regulator to an electrical source
corresponding to the nominal voltage, the “+” at
the wire (C) and the “–” (ground) on the body (E).
Continuity between brush (D) and body should be
observed in one direction only.

If defective, replace the brush/regulator assembly.

KV18095

8. Remove capacitor (M). Remove two nuts and


washers (K) from rear housing. Remove “B+”
terminal nut and washers (N). Remove “W”
terminal nut and washers (L). Remove stator/
rectifier bridge assembly from rear housing.

TESTING ALTERNATOR BRUSH/


REGULATOR ASSEMBLY

CD30475

1. Check brushes (A) for free movement against


spring tension. If either brush is worn to an
exposed length of 7 mm (0.27 in.) or less, replace
the brush/regulator assembly. Also replace if the
brushes are cracked or oil-soaked.

3 - 134 11/22/00
DIESEL ENGINE ALTERNATOR

TESTING ALTERNATOR ROTOR TESTING ALTERNATOR STATOR/


RECTIFIER BRIDGE ASSEMBLY

CD30477
CD30479
1. Inspect slip rings (A) of rotor for scoring or rough
surface. Polish slip rings sparingly with No. 00 1. Inspect stator winding (A) for discoloration or a
sand paper. burned odor indicating a short circuit.
2. Check stator for grounds by connecting an
ohmmeter between each stator lead (B) and stator
frame (C). Resistance should be infinity.
Replace complete alternator if any defect is noted.

CD30478
2. Connect ohmmeter between both slip rings of the
rotor. Resistance should be 2.95 ohms.
3. Check the rotor for insulation by connecting an
ohmmeter between each slip ring and shaft (B). CD30480
Resistance should be infinity. 3. Check positive diodes by connecting an ohmmeter
If insulation, resistance, or slip ring are defective, between each phase terminal (D) and the “B+”
replace complete alternator. plate (E), then reverse the polarity.
4. Check negative diodes by connecting an ohmmeter
between each phase terminal (D) and the “B–”
plate (F) or ground, then reverse the polarity.
5. Check the diode trio by connecting an ohmmeter
between each phase terminal (D) and the “D+”
terminal (G), then reverse the polarity.
A diode with a high reading in one direction and a low
reading in the other direction is good. A diode with the
same reading in both directions is bad. If any diode
fails the test, replace the entire rectifier bridge.

11/22/00 3 - 135
ALTERNATOR DIESEL ENGINE

REPLACE RECTIFIER BRIDGE

CD30484
5. Hand press rotor/front housing assembly into rear
CD30481 housing using alignment marks.
1. To replace the rectifier bridge, un-solder the leads 6. Install the three mounting bolts (F) with washers.
of phase winding (A) and “W” terminal (B) using a Tighten to 3 N•m (27 lb-in.).
soldering iron.
2. Position the replacement rectifier bridge and solder
phase winding leads. Solder “W” terminal at the
proper location.

ASSEMBLE ALTERNATOR

CD30485
7. Install brush/regulator assembly with care. Tilt it so
that the brushes contact the rotor slip rings.
Secure brush/regulator with the two screws and
washers (G). Attach wire to terminal (H).

CD30482
1. Install stator and rectifier bridge into rear housing
using alignment mark.

CD30486
8. Install shaft key (J), spacer (K) and fan (L).

CD30483
2. Secure rectifier bridge to rear housing by the two
nuts and washers (A). Install capacitor (B) with nut
and washer (C). Tighten nuts (A) and (C) to 3 N•m
(27 lb-in.).
3. Install insulated washer, flat washer, capacitor wire,
lock washer, and nut on “B+” terminal (D). Tighten
to 4 N•m (35 lb-in.). CD30487
4. Install insulated washer, flat washer, spade 9. Install pulley (M) with lock washer and nut (N).
terminal, lock washer, and nut on “W” terminal (E). Tighten to 40 N•m (29 lb–ft).
Tighten to 3 N•m (27 lb-in.). 10. Install alternator on engine and connect wiring
connectors.

3 - 136 11/22/00
ELECTRICAL CONTENTS

CONTENTS
ELECTRICAL
Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ELECTRICAL DIAGNOSTIC INFORMATION . . . . . . . . . . . . . . . . . . . . . 7
READING ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
THEORY OF OPERATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
COMMON CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WIRE COLOR ABBREVIATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LEGEND FOR ELECTRICAL COMPONENTS. . . . . . . . . . . . . . . . . . . . . 9
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MAIN SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ELECTRICAL WIRE HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ENGINE WIRE HARNESS (W1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ROPS WIRE HARNESS (W2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DUAL FLASHER WIRE HARNESS (W3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
COLD START WIRE HARNESS (W4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CAB HEATER/DEFROSTER WIRE HARNESS (W5, W6, W7). . . . . . . . . . . . . . . . . 25
BACKUP ALARM WIRE HARNESS (W8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
WIPER/WASHER WIRE HARNESS (W9). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
TROUBLESHOOTING CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
THEORY OF OPERATION AND DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 29
POWER AND CRANKING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 29
POWER AND CRANKING CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . 31
POWER AND CRANKING CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 32
POWER AND CRANKING CIRCUIT TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . 35
FUEL AND PREHEAT CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
FUEL AND PREHEAT CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
FUEL CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
FUEL CIRCUIT TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
PREHEAT CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
PREHEAT CIRCUIT TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
CHARGING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
CHARGING CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
CHARGING CIRCUIT DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
CHARGING CIRCUIT TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT OPERATION . . . . 49
BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT SCHEMATIC . . . . 50
BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT DIAGNOSIS. . . . . 51
BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT TEST POINTS . . . 55
GAUGES AND WARNING LIGHTS CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . 56
GAUGES AND WARNING LIGHTS CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . 59
SEAT BELT WARNING LIGHT CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 60
SEAT BELT WARNING LIGHT CIRCUIT TEST POINTS . . . . . . . . . . . . . . . . . . . . . 62
PARK BRAKE SWITCH AND WARNING LIGHT CIRCUIT DIAGNOSIS . . . . . . . . . 63

11/22/00 4-1
CONTENTS ELECTRICAL

Page

PARK BRAKE SWITCH AND WARNING LIGHT CIRCUIT TEST POINTS . . . . . . . 65


AIR FILTER RESTRICTION WARNING LIGHT CIRCUIT DIAGNOSIS . . . . . . . . . . 66
AIR FILTER RESTRICTION WARNING LIGHT CIRCUIT TEST POINTS . . . . . . . . 67
HYDRAULIC OIL OVERTEMPERATURE WARNING LIGHT
CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
HYDRAULIC OIL OVERTEMPERATURE WARNING LIGHT
CIRCUIT TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
HYDRAULIC FILTER RESTRICTION WARNING LIGHT
CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
HYDRAULIC FILTER RESTRICTION WARNING LIGHT
CIRCUIT TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
FUEL GAUGE CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
FUEL GAUGE CIRCUIT TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
ENGINE OVERTEMPERATURE WARNING LIGHT CIRCUIT DIAGNOSIS . . . . . . 75
ENGINE OVERTEMPERATURE WARNING LIGHT CIRCUIT TEST POINTS . . . . 76
COOLANT TEMPERATURE GAUGE CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . 77
COOLANT TEMPERATURE GAUGE CIRCUIT TEST POINTS. . . . . . . . . . . . . . . . 79
ENGINE OIL PRESSURE WARNING LIGHT CIRCUIT DIAGNOSIS . . . . . . . . . . . 80
ENGINE OIL PRESSURE WARNING LIGHT CIRCUIT TEST POINTS . . . . . . . . . 81
ENGINE OIL PRESSURE GAUGE CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . 82
ENGINE OIL PRESSURE GAUGE CIRCUIT TEST POINTS . . . . . . . . . . . . . . . . . 84
HIGH FLOW CIRCUIT (OPTIONAL) OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 85
HIGH FLOW CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
HIGH FLOW CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
HIGH FLOW CIRCUIT TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
LIGHTS CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
LIGHTS CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
LIGHTS CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
LIGHT CIRCUIT TEST POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
DUAL FLASHER CIRCUIT (OPTIONAL) OPERATION . . . . . . . . . . . . . . . . . . . . . . 98
DUAL FLASHER CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
DUAL FLASHER CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
DUAL FLASHER CIRCUIT TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
CAB HEATER/DEFROSTER CIRCUIT (OPTIONAL) OPERATION . . . . . . . . . . . . 104
CAB HEATER/DEFROSTER CIRCUIT SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . 105
CAB HEATER/DEFROSTER CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 106
CAB HEATER/DEFROSTER CIRCUIT TEST POINTS . . . . . . . . . . . . . . . . . . . . . 110
BACKUP ALARM CIRCUIT (OPTIONAL) OPERATION. . . . . . . . . . . . . . . . . . . . . 111
BACKUP ALARM CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
BACKUP ALARM CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
BACKUP ALARM CIRCUIT TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
WIPER/WASHER CIRCUIT (OPTIONAL) OPERATION . . . . . . . . . . . . . . . . . . . . 115
WIPER/WASHER CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
WIPER/WASHER CIRCUIT DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
WIPER/WASHER CIRCUIT TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

4-2 11/22/00
ELECTRICAL CONTENTS

Page

TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120


BATTERY TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
CHARGE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
REGULATED AMPERAGE AND VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . 123
STARTER LOADED AMPERAGE DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
STARTER NO-LOAD AMPERAGE AND RPM TESTS . . . . . . . . . . . . . . . . . . . . . . 125
STARTER SOLENOID TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
AIR FILTER RESTRICTION SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
ENGINE COOLANT TEMPERATURE SENDER/SWITCH TEST . . . . . . . . . . . . . . 127
COLD WEATHER START SWITCH TEST (MODEL 250 ONLY) . . . . . . . . . . . . . . . 128
ENGINE OIL PRESSURE SWITCH/SENDER TEST . . . . . . . . . . . . . . . . . . . . . . . 129
MANIFOLD PREHEATER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
MANIFOLD PREHEATER RELAY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
KEY SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
PARK BRAKE SWITCH TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
PRE-HEATER SWITCH TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
LIGHT SWITCH TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
CAB DOOR SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
DUAL FLASHER SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
HIGH-FLOW SWITCH TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
BLOWER SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
WIPER/WASHER SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
FUEL LEVEL SENDER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
SEAT SAFETY SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
SEAT BELT SWITCH TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
HYDRAULIC OIL OVERTEMPERATURE SWITCH TEST . . . . . . . . . . . . . . . . . . . 137
PARK BRAKE SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
BOOM LOCKOUT SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
BUCKET LOCKOUT SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
HYDRAULIC OIL FILTER RESTRICTION SWITCH TEST . . . . . . . . . . . . . . . . . . . 139
COMPONENT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
AIR FILTER RESTRICTION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
COOLANT TEMPERATURE SENDER/SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 140
COLD WEATHER START SWITCH (MODEL 250 ONLY) . . . . . . . . . . . . . . . . . . . . 140
ENGINE OIL PRESSURE SWITCH/SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
MANIFOLD PREHEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
MANIFOLD PREHEAT RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
INSTRUMENT PANEL COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . 143
KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
INSTRUMENT PANEL SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
CAB HEATER THERMOSTAT (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
SEAT SAFETY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

11/22/00 4-3
CONTENTS ELECTRICAL

Page

SEAT BELT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147


STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
HYDRAULIC OIL OVERTEMPERATURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 148
PARK BRAKE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
HYDRAULIC OIL FILTER RESTRICTION SWITCH. . . . . . . . . . . . . . . . . . . . . . . . 149
BACKUP ALARM (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

4-4 11/22/00
ELECTRICAL CONTENTS

This page intentionally left blank.

11/22/00 4-5
SPECIFICATIONS ELECTRICAL

SPECIFICATIONS
Battery
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BCI Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Cold Cranking Amps at –18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750
Reserve Capacity at 27°C (80°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180 minutes
Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.225 or above
Electrolyte Required Fill (Approx.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt)
Load Test (Minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 amp for 15 seconds

Alternator
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 amps
Regulated Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 amps (min)
Unregulated Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 amps (min)
Regulated Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.5—14.2 volts
Resistor at 25°C (77°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47—53 ohms
Rotor Winding Resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.95 ohms
Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 mm (0.28 in.)

Alternator Torques
Alternator Pulley Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (29 lb-ft)
B+ Terminal Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (35 lb-in.)
B– Terminal Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 N•m (26 lb-in.)
Through-Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 N•m (26 lb-in.)

Starter
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetic solenoid shift
Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 kW
Loaded (on Vehicle) Draw . . . . . . . . . . . . . . . . . . . . . . . 350 amps (max), 8.5 volts (min)
No-load (Free-Spinning) Draw. . . . . . . . . . . . . . . . . . . . . . . 90 amps (max) at 3500 rpm

Fuel Gauge Sensor Resistance


Full Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.0—33.5 ohms
Empty Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244—250 ohms

Fuel Shutoff Solenoid


Hold-In Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 amp (max) continuous

Engine Coolant Temperature Sensor Resistance


At 20°C (68°F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21—2.69 k-ohms
At 0—30°C (32—86°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.65—5.88 k-ohms

Engine Coolant Temperature Switch


Closing Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116°C (241°F)

Hydraulic Oil Overheat Switch


Close temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.4 ± 2.8°C (220 ± 5°F)
Open temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87.8°C (190°F) minimum

Pre-Heater
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.70—1.65 ohms

Lighting
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 W, halogen type
Rear, Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.5 W, incandescent type 1156
Rear, Running (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . .10 W, incandescent type R19/10

4-6 11/22/00
ELECTRICAL ELECTRICAL DIAGNOSTIC INFORMATION

ELECTRICAL DIAGNOSTIC INFORMATION

READING ELECTRICAL SCHEMATICS


The schematic is made up of individual circuits laid out in a sequence of related functions. It is formatted with all
power wires (A) across the top and all ground wires (B) across the bottom. Current flow is generally from top to
bottom through each circuit and component. All components are shown in the OFF position. The diagram does not
list connector (C) information unless needed to avoid confusion. If the connector is shown, the number next to it is
the terminal pin location (D) in the connector.
Each component is shown by a symbol (E), its name (F), and an identification code (G). The identification code
contains a device identifying letter (H) and number (I).
The identifying letter is always the same for a specific component, but the identifying numbers are numbered
consecutively from upper left to lower right. The terminal designation (J) is placed directly outside the symbol next
to the connecting wire path. Switch positions (K) are also placed directly outside the symbol. The solid line (L)
shows the position the switch is currently in and dash lines (M) represent other switch positions.
Each circuit is identified at the bottom of the drawing by a section number (N) and section name (O).
The circuit number (P) and wire color (Q) of the wires are shown directly next to the wire path.
The same component name and identification code are used consistently on all diagrams in this section.
Components can be easily cross-referenced.

M46311

11/22/00 4-7
ELECTRICAL DIAGNOSTIC INFORMATION ELECTRICAL

THEORY OF OPERATION WIRE COLOR ABBREVIATION


INFORMATION CHART
The theory of operation divides the electrical system Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black
into individual circuits by function. Each circuit is Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue
isolated from the main wiring schematic and only Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown
shows the components that are used in it. The story
Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green
contains information on function, operating conditions,
and theory of operation. The circuit schematics are Gry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gray
drawn with the components in the operating position, Org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange
with the power, or battery positive, into them across the Pnk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink
top and the ground, or battery negative, across the Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple
bottom. Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tan
COMMON CIRCUIT TESTS Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White
Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow
Blk/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . Black/White
Shorted Circuit: Blu/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue/White
A shorted circuit may result in the wrong component Dk Blu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dark Blue
operating (i.e., improper wire-to-wire contact). To test Dk Brn/Lt Grn . . . . . . . . . . . . . Dark Brown/Light Green
for a shorted or improperly wired circuit: Dk Brn/Red. . . . . . . . . . . . . . . . . . . . . Dark Brown/Red
1. Turn component switch ON. Dk Brn/Yel . . . . . . . . . . . . . . . . . . . Dark Brown/Yellow
2. Start at the controlling switch of the component that Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Green
should not be operating. Lt Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue
3. Follow the circuit and disconnect wires at Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Green
connectors until component stops operating.
Org/Wht . . . . . . . . . . . . . . . . . . . . . . . . . Orange/White
4. Shorted or improper connections will be the last two
wires disconnected. Pnk/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink/Black
Pur/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . Purple/White
Red/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black
High Resistance or Open Circuit: Red/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/White
High resistance or open circuits usually result in slow, Wht/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Black
dim, or no component operation (i.e., poor, corroded, or Wht/Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red
disconnected connections). Voltage at the component Yel/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Black
will be low when the component is in operation. To test
for high resistance and open circuits: Yel/Red . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Red
Yel/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/White
1. Check all terminals and grounds of the circuit for
corrosion.
2. If terminals are not corroded or loose, the problem NOTE: Beginning in 2001, all wires will be solid colors
is in the component or wiring. and will no longer include stripes. Each wire
will have a circuit number stamped into the
insulation to aid in circuit tracing. The color on
Grounded Circuit: the schematics, text and wiring diagrams in this
Grounded circuits usually result in no component manual will be correct less the stripe color; i.e.
operation or a blown fuse. wire 425 yel/blk will become wire 425 yel. This
will be a running change not associated with
any serial number or model change.

4-8 11/22/00
ELECTRICAL LEGEND FOR ELECTRICAL COMPONENTS

LEGEND FOR ELECTRICAL COMPONENTS


A1—Heater Control Circuit Board (SE10, W5) S2—Park Brake Switch (SE1, W2)
B1—Air Filter Restriction Switch (SE6, W1) S3—Manual Preheat Switch (SE2, W2)
B2—Hydraulic Overtemperature Switch (SE6, W1) S4—Seat Switch (SE4, W2)
B3—Hydraulic Oil Filter Restriction Switch (SE6, W1) S5—Seat Belt Switch (SE4, W2)
B4—Fuel Level Sender (SE6, W1) S6—Work Lights Switch (SE7, W2)
B5—Engine Overtemperature Switch and Coolant S7—Dual Flasher Switch (SE8, W3)
Temperature Sender (SE6, W1)
S8—High Flow Switch (SE9, W2)
B6—Engine Low Oil Pressure Switch and Oil Pressure
S9—Blower Switch (SE10, W5)
Sender (SE6, W1)
S10—Backup Alarm Switch (Rear) (SE11, W8)
B7—Cold Start Switch (Model 250) (SE3, W4)
S11—Backup Alarm Switch (Front) (SE11, W8)
E1—Left Front Work Light (SE7)
S12—Wiper/Washer Switch (SE12, W9)
E2—Right Front Work Light (SE7)
S13—Cab Door Switch (SE5)
E3—Left Tail Light (SE7)
V1—High Flow Valve Diode (SE9, W1)
E4—Right Tail Light (SE7)
W1—Engine Harness (with High Flow Option)
E5—Rear Work Light (SE7)
W2—ROPS Harness (with High Flow Option)
E6—Left Hazard Light (SE8)
W3—Dual Flasher Harness (Optional)
E7—Right Hazard Light (SE8)
W4—Cold Start Wire Harness (Model 250)
F1—Accessories Fuse (SE1, W1)
W5—Cab Heater/Defroster ROPS Harness (Optional)
F2—Seat Switch/Seat Belt Fuse (SE1, W1)
W6—Cab Heater/Defroster Heater Unit Harness
F3—Key Switch Fuse (SE1, W1)
(Optional)
F4—Interlock Fuse (SE3, W1)
W7—Cab Heater/Defroster Engine Harness (Optional)
F5—Cab Heater Fuse (SE10, W7)
W8—Backup Alarm Harness (Optional)
F6—Backup Alarm Fuse (SE11, W8)
W9—Wiper/Washer Harness (Optional)
G1—Battery (SE1)
X1—Engine Harness-to-ROPS Harness Connector
G2—Alternator (SE4, W1) (SE1, SE2, SE3, SE4, SE7, SE9, W1, W2)
H1—Instrument Cluster (SE6) X2—Engine Harness-to-ROPS Harness Connector
H2—Backup Alarm (SE11, W8) (SE3, SE5, SE6, W1, W2)
X3—Auto Preheat Connector (Optional) (SE2, W2)
K1—Start Relay (SE1, W1)
K2—Preheat Relay (SE2, W1) X4—Shutdown Module Connector (SE3, W2)

K3—Fuel Relay (SE3, W1) X5—Alternator Resistor Connector (SE5, W1)

K4—Accessory Relay (SE7, W1) X6—Instrument Cluster Connector (SE6, W2)

K5—Dual Flasher Relay (SE8, W3) X7—Instrument Cluster Connector (SE6, W2)

K6—High Flow Relay (SE9, W1) X8—Instrument Cluster Connector (SE6, W2)

K7—Cab Heater Relay (SE10, W7) X9—Shutdown Module Connector (SE6, W2)

M1—Starting Motor (SE1, W1) X10—Service Plug Connector (SE6, W1)

M2—Fuel Pump (SE3, W1) X11—(12-Volt) Accessory Connector (Frame) (SE7,


W1, W7, W8)
M3—Blower (SE10, W6)
X12—Accessory Ground Connector (SE8, W2, W3,
M4—Wiper Motor (SE12, W9) W9)
M5—Washer Pump (SE12, W9) X13—(12-Volt) Accessory Connector (ROPS) (SE7,
R1—Manifold Preheater (SE2, W1) W2, W3)

R2—Alternator Resistor (SE4) X14—Dual Flasher Relay Connectors (SE8, W3)

R3—Cab Heater Thermostat (SE10, W5) X15—Right Front Work Light Connector (SE7, W2)

S1—Key Switch (SE1, W2) X16—High Flow Valve Diode Connector (SE9, W1)

11/22/00 4-9
LEGEND FOR ELECTRICAL COMPONENTS ELECTRICAL

X17—Left Front Work Light Connector (SE7, W2)


X18—Right Tail Light Connector (SE7, W2)
X19—Rear Work Light Connector (SE7, W2)
X20—Left Tail Light Connector (SE7, W2)
X21—Seat Switch Pigtail Connector (SE4, SE5, W2)
X22—Accessory Ground Connector (Frame) (SE7,
W1, W7, W8)
X23—Left Hazard Light Connectors (SE8, W3)
X24—Right Hazard Light Connectors (SE8, W3)
X25—Cab Heater Engine Harness-to-ROPS Harness
Connector (SE10, W5, W7)
X26—Cab Heater ROPS Harness-to-Heater Harness
Thermostat Connector (SE10, W5, W6)
X27—Cab Heater ROPS Harness-to-Heater Harness
Main Connector (SE10, W5, W6)
X28—Cab Heater Engine Harness B+ to Starter (W7)
X29—Cab Heater Engine Harness Ground (W7)
X30—Cab Heater Unit Harness Blower Ground (W6)
X31—Cab Heater Unit Harness Blower Low Speed
Connector (W6)
X32—Cab Heater Unit Harness Blower High Speed
Connector (W6)
X33—Door Switch Harness Connector (SE5, W9)
X99—Interlock Connector (SE4, SE7, W2, W9)
Y1—Fuel Shutoff Solenoid (SE3, W1, W4)
Y2—Bucket Lock Solenoid (SE5, W1)
Y3—Boom Lock Solenoid (SE5, W1)
Y4—Park Brake Solenoid (SE5, W1)
Y5—High Flow Valve Solenoid (SE9, W1)
Y6—Cold Start Advance Solenoid (Model 250) (SE3,
W4)
Y7—Cab Heater Temperature Control Valve (SE10,
W6)

4 - 10 11/22/00
ELECTRICAL COMPONENT LOCATION

COMPONENT LOCATION

X17 Left Front Work


Light Connector

X13 12-Volt
Accessory
Connector
X12 Accessory
X2 Engine/ROPS Harness X15 Right Front Work
Ground
Connector Light Connector
Connector
X20 Left Tail Light X99 Interlock
Connector Connector

X19 Rear Work Light


Connector
X1 Engine/ROPS Harness
X18 Right Tail Light Connector
Connector

B1 Air Filter
B3 Hydraulic Oil Filter Restriction Switch
Restriction Switch

Ground Y3 Boom Lock


Solenoid
Y4 Park Brake
Solenoid
B5 Coolant Over Temperature Y2 Bucket Lock
Switch and Coolant Solenoid
Temperature Sender Fuse
K2 Preheat Block
Relay

G2 Alternator
Terminal B (-)

K3 Fuel
G2 Alternator Relay
Terminal B (+) K1 Start
Relay
K4 Accessory
Relay

M1 Starting B4 Fuel Level X22 Accessory


Motor Sender Ground Connector

B2 Hydraulic
G1 Battery Overtemp Switch
M2 Fuel Pump X11 12-Volt Accessory
B6 Engine Low Oil Connector
Pressure Switch and Pressure Sender
Cold Start KV13044
Fuel Injection Y1 Fuel Shutoff
Sender
Pump Solenoid

11/22/00 4 - 11
COMPONENT LOCATION ELECTRICAL

COMPONENT LOCATION (CONT)


X12 Accessory Ground X99 Interlock Connector
Connector

S9 Blower Switch
S12 Wiper/Washer Switch
R3 Cab Heater Temperature
Control Thermostat M4 Wiper Motor

X33 Door Switch


X27 Cab Heater ROPS Harness Connector
M3 Blower
Harness-to-Heater
X26 Cab Heater ROPS
Harness Main
Harness-to-Heater
Connector
Harness Thermostat
Connector

S13 Cab Door Switch

A1 Heater Control
Circuit Board Y7 Cab Heater
Temperature Control
Valve
H2 Backup Alarm X25 Cab Heater Engine
Harness-to-ROPS
Harness Connector
F5 Cab Heater Fuse (15A) M5 Washer Pump

X29 Cab Heater Ground


S11 Backup Alarm Switch (front)

S10 Backup Alarm Switch (rear)


F6 Backup Alarm Fuse (10A)

K7 Cab Heater Relay

X22 Accessory
Ground Connector

X11 12-Volt Accessory


Connector
KV31060

4 - 12 11/22/00
ELECTRICAL ELECTRICAL SCHEMATIC

ELECTRICAL SCHEMATIC

MAIN SCHEMATIC
F1 Accessories Fuse
25 Amp
445 Yel 445 Yel
550 Yel/Wht 550 Yel/Wht
15 Amp 226 Red 226 Red
720 Pur 720 Pur
725 Pur/Wht 725 Pur/Wht
F3 708 Pur 708 Pur
Key Switch Fuse 706 Pur 706 Pur
231 Red 231 Red
550 Yel/Wht 500 Yel/Red 502 Yel 502 Yel
5 Amp
505 Yel 501 Yel 501 Yel (A1)
X2 503 Yel 503 Yel
F2 (C1) 725 Pur/Wht 508 Yel
720 Pur
Seat Switch Fuse S1 5 Amp
X1 (C2)
Key 721 Pur 721 Pur 722 Pur

225 Red Switch 0 Acc Engage X2 (C1)


F4
1 Off Run Interlock Fuse
708 Pur 706 Pur 2 Run Release
B,C 506 Yel 504 Yel
3 Start S3 512 Yel
X1 (A2) 0,1,2 7 140 Blk Manual
250 Red Preheat 515 Yel
6
5B
4
4 Switch
2B
S2 1
813 Grn

225 Red 1 2
Park 4
Brake On Off 802 Dk Grn
3 7
705 Pur Switch X3 813 Grn (1) X4
709 Pur 5
3 560 Yel/Blk To Auto Preheat 508 Yel (2)
220 Red (Optional) 995 (3) 990
X1 (A3) 931 Gry
701 Dk Blu Gry/Blk Wht
(1)
X2 To Shutdown
K1 30 86 B7
(2) (C5) Module
Start Cold Start
(Optional)
Relay 87a 87 85 930 Switch
(3) 995 Gry/Blk
Gry (250 Only)
X2 (C4) K3 30 86
(4)
930 Gry Fuel
700 Pur t Relay 87a 87 85

251 Red Fuse Link 112 Blk


130 Blk 373 Org
200 Red 200 Red
Red 241 Red 240 Red
Fuse Link Y6 655 Wht 200 Red
372 Red
B S K2 Cold Start
141 Advance Y1
Preheat Solenoid
Blk Fuel
Relay (250 Only) 010 Blk M2
140 Shutoff M
G1 M 920
Blk Solenoid Fuel
Red/Wht
Battery (12V) M1 114 Blk Pump
R1 X1 (C5)
Starting 108 116 Blk 116 Blk 118 Blk
Manifold
Motor Blk
Preheater
(B1)
Engine
Ground
(C1)

001C Red 001C Red

SE1 - POWER AND CRANKING CIRCUIT SE2 - PREHEAT CIRCUIT SE3 - FUEL CIRCUIT

KV31050

11/22/00 4 - 13
ELECTRICAL SCHEMATIC ELECTRICAL

445 Yel 445 Yel


550 Yel/Wht 550 Yel/Wht
226 Red 226 Red
720 Pur 720 Pur
725 Pur/Wht 725 Pur/Wht
708 Pur 708 Pur
706 Pur 706 Pur 511 Yel
231 Red 452 Yel 452 Yel
502 Yel 502 Yel 502 Yel
(A1) 501 Yel
503 Yel 503 Yel
713 Pur 725 Pur/Wht
X1 (A1) 720 Pur
722 Pur
Y3 503 Yel 707 Pur 226 Red (A) X10
Off S5 (2) X9
231 Red 711 Pur Boom Lock 960 Wht/Blk 510 Yel (B) Service
Seat Belt Switch (3) To Shutdown
On 970 Wht/Blu (C)
Y2 Solenoid (4) Module
708 Pur Plug
810 Dk Grn Bucket 126 Blk 750 750 (D)
2 1 (1) Pur/Blk Pur/Blk
Lock
232 Red Solenoid X2 (C2)
S4 Off 742 Pur/Blk X8 X8 X6 X6 X6 X6 X6
Seat X21 452 Yel
On 741 Pur/Blk X2 (B5) (D) (F) (H) (C) (D) (G) (B)
Switch 230 740
X7 (H)
740
Red 715 Pur Pur/Blk Pur/Blk
2 1
801 Pnk
X21 X6 (F)
800 Pnk H1
802 Dk Grn
Y4 X6 (E) Instrument
802 Dk Grn Cluster
810Grn Park Brake
Solenoid X2 (B4) X7 (G)
730 Pur/Wht 730
Pur
X99 (A) (A) X8 (C)
472 X33 600 Brn
X7 (D)
600 Brn
Interlock 991 Dk Grn Door Switch
Connector Wht (B) Harness Connector X2 (B1)
813 Grn 470
Dk Grn X7 X7 X7 X8 X7 X8 X7 X8
X99 (B) (A) (C) (B) (E) (E) (B) (F) (A)
S13 On
Door Off 345 Pnk 325 Dk Grn/Wht 335 Dk Grn 900 Blk/Wht 300 Org/Wht 320 Org 620 Tan 625 Tan/Wht 128 Blk
Without Switch
Cab 2 1 X2 X2 X2 X2 X2 X2 X2 X2
G2 Door (A5) (A3) (A4) (C3) (A1) (A2) (B2) (B3)
With Cab Door
Alternator
325 Dk Grn/Wht 335 Dk Grn 300 Org/Wht 320 Org 620 Tan 625 Tan/Wht
345 Pnk 900 Blk/Wht
G X5 (2) 126 Blk
200 Red B+ 3
D+ 600 Brn
WK G
U 47 Ohm
452 Yel Q t P P
P t P t
100 Blk
R2 X5 (1) B1
101 Blk Air Filter B2 B3 B4
B– Alternator
Resistor Restriction Hydraulic Hydraulic Fuel Level B5 B6
Switch Overtemper- Oil Filter Sender Engine Overtemperature Engine Low Oil Pressure
ature Switch Restriction Switch and Coolant Switch and Oil
(B1)
105 Blk 102 Blk 106 Blk Switch 104 Blk
Temperature Sender Pressure Sender (B2)

(C1) (C2)

001C Red 001C Red

SE4 - CHARGING CIRCUIT SE5 - BOOM/BUCKET LOCKOUT AND PARK BRAKE CIRCUIT SE6 - GAUGES AND WARNING LIGHTS CIRCUIT

KV31051

4 - 14 11/22/00
ELECTRICAL ELECTRICAL SCHEMATIC

445 Yel 460 Yel 460 Yel


550 Yel/Wht 455 Yel 455 Yel
003 Yel 003 Yel
000A Blk 000A Blk
511 Yel 511 Yel 511 Yel

502 Yel 502 Yel

460 Yel/Wht A Off


86 30
S7 C On
X13 A, C
K4 85 87 87a A Off Dual
453
Accessory 451 Yel/Wht Flasher Back
B Front Work/Tail Lights
Relay Yel/Wht Switch Light
C Front/Rear Work/Tail Lights 2B 3
A, B, C
450 Yel/Wht
X99 7 103 Blk
X1 (B2) (C)
452 Yel 451 Yel/Wht 450 Yel/Red 5B 475 Brn/Wht 480
6
Indicator Yel/Red
452 2B 3
454 Yel Yel 129 Blk Light X14
X11 128 Blk
473 Brn
K5
12-Volt S6 Dual
Accessory Work Lights Flasher
(Frame) Switch Relay
X14 X14
X22 Accessory
Ground
(Frame)
482 Yel/Blk
476 Brn 481
470 Brn
Yel/Blk
126 127
471 Brn 477 Brn Blk Blk X23A X24A
110 Blk
103 Blk
E1 X17 E2 X15 E3 X20 E4 X18 E5 X19 E7
Left Right Left Right Rear Right
E6
Front Front Tail Tail Work Hazard
Left
Work Work Light Light Light Light
Hazard
Light X17 Light X15 X20 X18 X19
Light
101 Blk 129 Blk
X12 X23B X24B
103 Blk
124 Blk
102 Blk 107 Blk 106 Blk 105 Blk
128 Blk
101 Blk 101 Blk

(B2) (B3)

(C2) (C3)

001C Red 001C Red

SE7 - LIGHTS CIRCUIT SE8 - DUAL FLASHER CIRCUIT

KV31052

11/22/00 4 - 15
ELECTRICAL SCHEMATIC ELECTRICAL

460 Yel 460 Yel


455 Yel
003 Yel
000A Blk
511 Yel 002 Red

502 Yel A Off


A Off 010A Wht
B Low 008 Blu
B Run 013A Yel
S9 A, B, C C High
1 2 3 4
A, B, C C On Blower X26
Switch 9 Back
(20)
Back Light
Light X26
2B
3 811 Pnk R3 (17)
2B 3
Cab Heater 455 Yel
5B
X1 7 6 Indicator Thermostat X26
Light (18) F6
7 Indicator (A4) H2
005 Org 001B Red Backup
Light Backup Alarm
S8 003 Yel K7 Alarm
811 Pnk
High Cab F5 Fuse S11
X27 86 87 87a 008 Blu 101 Blk
Flow K6 Heater Cab Heater Fuse Backup Alarm
812 Grn 86 30 (C)
Switch High 000B Blk 85 30
Relay 15 Amp Switch (Front)
013A Yel
Flow 001A X25 X27 Off
85 87 87a 010A Wht
Relay Red (A) (E) On
813 Grn 000A Blk 001 Red
812 Grn 458 Yel
450 Yel A
012 Red B
X1 (A5) 004 Yel 004 Yel
011 Org
X27
X25 (B) S10
(B) X27
Backup Alarm
815 Grn (D) 001C Red
013B Yel Switch (Rear)
814 Grn 000B Blk Off
V1 005 Org
000A Blk On
High Flow 457 Yel
A B C D E F G H
Valve Diode M
A B
142 Blk
A1
Heater Control
Y5 M3 Circuit Board 010B Wht
119 Blk
High Flow Blower
Valve Solenoid 000B Blk 009 Grn
6 5 4 3 2 1
X16
109 Blk Y7
Cab Heater Temperature
Control Valve
117 Blk

101 Blk

(B3)

(C3) (C3)

001C Red

SE9 - HIGH FLOW CIRCUIT SE10 - CAB HEATER/DEFROSTER CIRCUIT SE11 - BACKUP ALARM CIRCUIT

KV31053

4 - 16 11/22/00
ELECTRICAL ELECTRICAL SCHEMATICS

460 Yel

460 Yel

S12
Wiper/Washer Switch
A Off

B Wiper
C Washer
Back
7 Light 111 Blk

5B
6 463 Yel/Blk
1 465 Yel/Red
2B Indicator
466 Yel 10 Light

462
Yel
461
Yel/Wht

463
Yel/Blk

465 Yel/Red
4
466 Yel 5 M M4
6 Wiper Motor
461 2
Yel/Wht

110
Blk
B
M5 W
Washer Pump
A

111
Blk 101
112 Blk
Blk
(C3)

SE12 - WIPER/WASHER CIRCUIT

KV31054

11/22/00 4 - 17
ELECTRICAL SCHEMATICS ELECTRICAL

This page intentionally left blank.

4 - 18 11/22/00
ELECTRICAL ELECTRICAL WIRE HARNESSES

ELECTRICAL WIRE HARNESSES


M2
ENGINE WIRE HARNESS (W1) A1 = 231 B1 = Plug C1 = 550
Fuel Pump B6
A2 = 225 B2 = 451 C2 = 501
A3 = 705 B3 = Plug C3 = Plug 814 118 512 Engine
Wire 117
Circuit A4 = 811 B4 = Plug C4 = Plug B A Low Oil
Size Color Termination Points Y1
Number Pressure Switch
(mm2) A5 = 812 B5 = Plug C5 = 116
B A
655
Fuel
and Pressure Sender
100 5.0 Blk G2, Ground V1 Shutoff
C
High Flow Solenoid
101 3.0 Blk G2, Splice 1 5 1 Valve Diode 625
620
5 1 B
102 0.8 Blk B2 (B), Splice 1 5 1 X16 300
A High Flow
103 2.0 Blk X22, Splice 1
Valve Diode 320
104 0.8 Blk B4 (A), Splice 1 X1
Connector
Harness
105 0.8 Blk B1 (B), Splice 1 Connector B5
106 0.8 Blk B3, Splice 1 Engine Over Temperature Switch
108 0.8 Blk K2, Splice 1 and Coolant Temperature Sender
Splice 1
109 0.8 Blk Y5 (B), Splice 1
110 0.8 Blk K4 (85), Splice 1 512 110 101 812 815
501 Y3
813
112 0.8 Blk K1 (85), Splice 1 Splice 2 112 102
105 814 Splice 9 Boom Lock 713
114 0.8 Blk K3 (85), Splice 1 510 114
511 106 Solenoid
515 116
116 2.0 Blk X1 (C4), Splice 1 108 742

B A
118
109
117 0.8 Blk V1 (A), Splice 1 452 451
103
118 0.8 Blk M2 (B), Splice 1 Splice 3 104
711 713 711
450
454 117 Splice 6
119 0.8 Blk K6 (85), Splice 1

B A
119 715 722
200 5.0 Red M1, G2 741
104 B4 741 742 Y2
220 5.0 Red K1 (30), Splice 8 Fuel Level Bucket Lock
740 Splice 5
225 2.0 Red F3, X1 (A2) 900 Sender Solenoid

A
X2

B
226 0.8 Red F3, X10 (A)
Harness 705 Splice 4
231 0.8 Red F2, X1 (A1) Connector X22
708 709
240 8.0 Red K2, Splice 7 Accessory
Ground
241 3.0 Red Fuse M1, Splice 7 103 (Frame)
Link
5 1 A
250 5.0 Red F2, Splice 8
5 1 B
251 2.0 Red Fuse M1, Splice 8 5 1 C 454
Link Plug
300 0.8 Org/Wht B5, X2 (A1) X11
A1 = 300 B1 = 600 C1 = 721 12-Volt Accessory
320 0.8 Org B5, X2 (A2)
A2 = 320 B2 = 620 C2 = 750 (Frame)
325 0.8 Dk Grn/Wht B2 (A), X2 (A3) 445 110 220 112 515 114 511 119
A3 = 325 B3 = 625 C3 = 900
335 0.8 Dk Grn B3, X2 (A4) A4 = 335 B4 = 730 C4 = 930
A5 = 345 B5 = 740 C5 = 995 Plug Plug Plug Plug
345 0.8 Pink B1 (A), X2 (A5)
445 2.0 Yel F1, K4 (30) 450 700 813
550 709 995 655 811
450 2.0 Yel/Wht K4 (87), Splice 3
722 231 K4 K1 K3 K6
451 2.0 Yel/Wht X1 (B2), Splice 3 445 225/226
Accessory Start Fuel High Flow
452 0.8 Yel X5 (1), Splice 3 D C B A
Relay Relay Relay Relay
454 2.0 Yel X11, Splice 3 Fuse Block 721 250 (Optional)
F1 = Accessories Fuse
25

15

226
5

F2 = Seat Switch Fuse 750 510


708
F3 = Key Switch Fuse
F4 = Interlock Fuse X10
F4 F1 F2 F3 Service Plug KV18017A

11/22/00 4 - 19
ELECTRICAL WIRE HARNESSES ELECTRICAL

M1 Ground Wire
100 Circuit
Starting Motor 700 Size Color Termination Points
Number
Terminal B M1 mm2
K2
108 Starting Motor 501 2.0 Yel X1 (C2), Splice 2
Preheat Terminal S G2
510 0.8 Yel X10 (B), Splice 2
Relay Alternator
100/101
Terminal B (–) 511 0.8 Yel Splice 2, K6 (87)
930 241
251 512 0.8 Yel M2 (A), Splice 2
Splice 7
515 1.0 Yel K3 (87), Splice 2
Splice 8 G2
200 Alternator 550 0.8 Yel/Wht K4 (86), X1 (C1)
K2 920
Preheat 250 240
Terminal B (+) 600 0.8 Brn X2 (B1), X5 (2)
Relay 220 200 620 0.8 Tan B6 (WK), X2 (B2)
240 920 625 0.8 Tan/Wht B6 (G), X2 (B3)
R1
Manifold 655 1.0 Wht K3 (87), Y1 (S)
Preheater 700 3.0 Pur K1 (87), M1
705 0.8 Pur X1 (A3), Splice 4
708 0.8 Pur X10 (C), Splice 4
709 0.8 Pur K1 (86), Splice 6
711 0.8 Pur Y2 (B), Splice 6
713 0.8 Pur Y3 (B), Splice 6
715 0.8 Pur Y4 (A), Splice 6
X5
721 0.8 Pur X2 (C1), F4
Alternator Resistor
Connector 722 0.8 Pur F4, Splice 6
452 730 0.8 PurWht Y4 (B), X2 (B4)
1
740 0.8 Pur/Blk X2 (B5), Splice 5
2
741 0.8 Pur/Blk Y2 (A), Splice 5
600
335 106 742 0.8 Pur/Blk Y3 (A), Splice 5
B3
750 0.8 Pur/Blk X2 (C2), X10 (D)
Hydraulic Oil A B
Filter Restriction 811 0.8 Pink X1 (A4), K6 (86)
Switch 812 0.8 Dk Grn X1 (A5), Splice 9
813 0.8 Dk Grn K6 (87), Splice 9
102 A B A B A B Y4
325
814 0.8 Dk Grn V1 (B), Splice 9
Park Brake Solenoid
B2
815 0.8 Dk Grn Y5 (A), Splice 9
Hydraulic
Overtemp 900 0.8 Blk/Wht B4 (B), X2 (C3)
Switch 345 105 815 109 715 730
920 8.0 Red/Wht K2, R1
B1 Y5
High Flow 930 0.8 Gry K2, X2 (C4)
Air Filter
Restriction Valve 995 0.8 Gry/Blk K3 (86), X2 (C5)
Switch (Optional)

KV18017B

4 - 20 11/22/00
ELECTRICAL ELECTRICAL WIRE HARNESSES

ROPS WIRE HARNESS (W2)


Wire Switch Connector
Circuit Terminal Numbering
Size Color Termination Points
Number A = Plug X6
(mm2) 7 9 B = 750 Instrument
4 1 C = 970
101 1.0 Blk X17 (B), Splice 2 5B 2B F D = 725 Cluster
E
6 3 D
G E = 802 Connector
102 1.0 Blk X15 (B), Splice 2 F = 800
C H
8 10 G = 720
103 1.0 Blk S6, (7), Splice 2 B H = 960
A J J = Plug
105 1.0 Blk X19 (B), Splice 2 K K = Plug
106 1.0 Blk X18 (B), Splice 2 720/721
107 1.0 Blk X20 (B), Splice 2 560 505 140
116 2.0 Blk X1 (C5), Splice 2
A = 345 X7
D E B = 335
F Instrument
S2 C = 325
124 2.0 Blk X12, Splice 2 C
Cluster
725
Park Brake B
D = 600
126 0.8 Blk X9 (1), Splice 2 Switch A
E = 300 Connector
141 G F = 620
128 0.8 Blk X8 (C), Splice 2 H G = 730
701 H = 740
130 0.8 Blk X3 (2), Splice 2 S3
140 0.8 Blk S2 (7), Splice 2 Manual 506 D
Preheat E A = 625 X8
141 0.8 Blk S3 (7), Splice 2 C B = 320
Switch 931
B
Instrument
C = 128
142 0.8 Blk S8, Splice 2 A D = 503 Cluster
F E = 900 Connector
225 2.0 Red S1, X1 (A2) F = 707
230 0.8 Red X21 (A), S4 (1)
550 500
231 0.8 Red S5 (2), X1 (A1) S1 225
Splice 1 Splice 2 Splice 3
232 0.8 Red S5 (2), X21 Key
Switch
300 0.8 Org/Wht X2 (A1), X7 (E) 500 501 128 116 470 476
705/706 560 504 140 101 471
320 0.8 Org X2 (A2), X8 (B) 503
505 141 124 473 477
502
325 0.8 Dk Grn/Wht X2 (A3), X7 (C) 471 506 126 105
508 130 106 452
335 0.8 Dk Grn X2 (A4), X7 (B) A 142 107
B
345 0.8 Pink X2 (A5), X7 (A) 103
X15 102 S8
450 2.0 Yel/Red S6 (5B), X99 (1) S6
Right Front Work High Flow
451 2.0 Yel/Wht X1 (B2), X13 Light Connector Switch Work 450/452
502 142 Lights 475 103 X17
802/813 (Optional) AB
452 1.0 Yel S6 (2B), S6 (5B) 126 706/707 left Work
130 Switch
701 Light Connector
453 2.0 Yel/Wht X13, X99 (1) 508
470 1.0 Brn X17 (A), Splice 3 X4 811 812 473 452 470 101
Shutdown 995 960 504
471 1.0 Brn X15 (A), Splice 3 970
930/931
Module
473 1.0 Brn S6 (3), Splice 3 Connector X9 X3
475 1.0 Brn/Wht S6 (6), X19 (A) 990 Shutdown Auto Preheat Connector
Module (Optional)
476 1.0 Brn X18 (A), Splice 3 990
Connector
477 1.0 Brn X20 (A), Splice 3
500 2.0 Yel/Red S1 (2), Splice 1

990

KV18018A

11/22/00 4 - 21
ELECTRICAL WIRE HARNESSES ELECTRICAL

Wire
Circuit
Size Color Termination Points
Number
5 1 A
A1 = 231 B1 = Plug C1 = 550 (mm2)
5 1 B A2 = 225 B2 = 451 C2 = 501
5 1 C A3 = 705 B3 = Plug C3 = Plug 501 2.0 Yel X1 (C2), Splice 1
A4 = 811 B4 = Plug C4 = Plug 502 0.8 Yel S8 (5B), Splice 1
A5 = 812 B5 = Plug C5 = 116
503 0.8 Yel X8 (D), Splice 1
504 0.8 Yel X3 (4), Splice 1
X1 505 0.8 Yel S2 (5B), Splice 1
Engine/ROPS 506 0.8 Yel S3 (2B), Splice 1
Harness Connector X18
Right Tail Light 508 0.8 Yel X4 (2), Splice 1
451/
124
A 476 550 0.8 Yel/Wht S1 (4), X1 (C1)
453 B 106
560 0.8 Yel/Blk S1(3), S2 (6)
X19
600 0.8 Brn X2 (B1), X7 (D)
Rear Work Light
X13 620 0.8 Tan X2 (B2), X7 (F)
X12 A 475
12-Volt
Accessory B 105 625 0.8 Tan/Wht X2 (B3), X6 (A)
Accessory
Ground Connector
Connector X20 701 0.8 Dk Blu S3 (4), X3 (1)
(ROPS)
(ROPS) Left Tail Light
705 0.8 Pur S1 (5), X1 (A3)
A 477
B 107 706 0.8 Pur S1 (5), X9 (2)
707 0.8 Pur X8 (F), X9 (2)
720 0.8 Pur S2 (4), X6 (G)
721 0.8 Pur S2 (4), X2 (C1)
725 0.8 Pur/Wht S2 (1), X6 (D)
730 0.8 Pur X2 (B4), X7 (G)
X2 740 0.8 Pur/Blk X2 (B5), X7 (H)
Engine/ROPS
Harness Connector 750 0.8 Pur/Blk X2 (C2), X6 (B)
800 0.8 Pink X21 (B), X6 (F)
801 0.8 Pink X21 (B), S4 (2)

450/453 C 802 0.8 Dk Grn X4 (1), X6 (E)


5 1
5 1 B 810 0.8 Dk Grn S5, X99 (2)
810 5 1
X99 A 811 0.8 Pink S8 (3), X1 (A4)
Interlock Connector
813 812 0.8 Dk Grn X1 (A5), S8 (2B)
813 0.8 Dk Grn X4 (1), X99 (3)
991 A1 = 300 B1 = 600 C1 = 721
900 0.8 Blk/Wht X2 (C3), X8 (E)
A2 = 320 B2 = 620 C2 = 750
A3 = 325 B3 = 625 C3 = 900 930 0.8 Gry X2 (C4), X3 (3)
991
A4 = 335 B4 = 730 C4 = 930 931 0.8 Gry S3 (3), X3 (3)
A5 = 345 B5 = 740 C5 = 995
960 0.8 Wht/Blk X6 (H), X9 (3)
810
970 0.8 Wht/Blu X6 (C), X9 (4)
S5
232/231 Seat Belt 990 0.8 Wht X4 (2), X4 (3)
Switch 991 991 0.8 Wht X99 (2), X99 (3)
S4
X21 Seat 995 0.8 Gry/Blk X2 (C5), X4 (3)
Seat Switch AB Switch
232 800 801
Pigtail
Connector
230 801 230
KV18018B

4 - 22 11/22/00
ELECTRICAL ELECTRICAL WIRE HARNESSES

DUAL FLASHER WIRE HARNESS (W3)

460 126
X13
12-Volt
Accessory X12
(ROPS) Accessory
Ground
(ROPS)

Switch Connector
Terminal Numbering
7 9
4 1
5B 2B
6 3
8 10

126
K5 127
Dual Flasher
Relay 480

481
482

129 481

X24B X23A
Right Hazard Left Hazard
Light Connectors Light Connectors
X24A X23B

127
482 128

S7
Dual Flasher 128
Switch 129

460
480
KV18014

11/22/00 4 - 23
ELECTRICAL WIRE HARNESSES ELECTRICAL

COLD START WIRE HARNESS (W4)

B7
Cold Start
Switch
(Model 250)

373 372

372 010
Y1
Fuel Shutoff
Solenoid

373 010

Y6
Cold Start Advance
Solenoid
(Model 250)

KV18533

4 - 24 11/22/00
ELECTRICAL WIRE HARNESSES

CAB HEATER/DEFROSTER WIRE HARNESS (W5, W6, W7)


Switch Connector Wire
Empty Circuit Termination
Terminal Numbering Size Color
Number Points
7 9 X27 (mm2)
4 1 001B F Main Connector
S9 5B 2B A 004 000A 3.0 Blk X25(B), X27(D)
002 E B ROPS-to-Heater
000B Blower Switch 6 3 000B 0.8 Blk X27(D), S9(7)
D C
8 10 001A 3.0 Red X25(A), S9(2B)
001B 005
001A 000A/000B 001B 3.0 Red S9(5B), X27(E)
005 002 0.8 Red R3(C), S9(9)
ROPS Harness (W5)
004
004 2.0 Yel S9(3), X27(B)
X26 005 3.0 Org S9(6), X27(C)
20 17 Thermostat Connector
ROPS-to-Heater 008 0.8 Blu R3(B), X26(17)
010A 0.8 Wht R3(A), X26(18)
013A 008
010A
Empty 010A 013A 0.8 Yel R3(D), X26(20)
008 A X25
B Harness Connector
C
013A/013B 012 011
002 D
001 009
013A R3 010A/010B
Cab Thermostat A B 000A
001A 000B 008

A1
012 Heater Control
009 Circuit Board ABCDEFGH
Empty
Empty 6 1 013B
004 5 2
001B 001 4 3 010B
A B 001C A F
001C Y7
B E
C D
011 Heater Valve
X28
F5 005 000A/
Starter B+ 000B
Heater Fuse (15A) X27
Main Connector
ROPS-to-Heater M3
001A X25 Blower
000A
Harness Connector X29
X30
Engine Harness (W7) Engine Ground
A Heater Unit Harness (W6)
B 000A 17 20 004

Engine Harness (W7) X26 X31


000A 008 013A Thermostat Connector
X11 010A Empty ROPS-to-Heater X32 005
12-Volt
003 Accessory
(Frame) Wire Wire
Wire Circuit Termination Circuit Termination
Circuit Termination Size Color Size Color
Size Color Number Points Number Points
Number Points (mm2) (mm2)
(mm2)
X22 000A 3.0 Blk X27(D), X30 010A 0.8 Wht X26(18), A1(B)
000A 3.0 Blk X25(A), X29 Accessory Ground
(Frame) 000B 0.8 Blk X27(D), A1(A) 010B 0.8 Wht A1(B), Y7(3)
000B 0.8 Blk X22, K7(85) 001A 000B 001 1.0 Red X27(E), A1(D) 011 0.8 Org A1(F), Y7(4)
001A 3.0 Red K7(30), X25(A)
004 2.0 Yel X27(B), X31 012 0.8 Red A1(E), Y7(6)
001B 3.0 Red F5(A), K7(87) K7 30 85
Cab Heater 87A Empty 005 3.0 Org X27(C), X32 013A 0.8 Yel X26(20), A1(C)
001C 3.0 Red X28, F5(B)
Relay 86 87 008 0.8 Blu X26(17), A1(H) 013B 0.8 Yel A1(C), Y7(2)
003 0.8 Yel X11, K7(86)
003 001B 009 0.8 Blu A1(G), Y7(1)
KV31055

11/22/00 4 - 25
ELECTRICAL WIRE HARNESSES

BACKUP ALARM WIRE HARNESS (W8)

450
A

B
456
455/456

F6
Backup Alarm
Fuse
X11 10 amp
12-Volt 455
Accessory
(Frame)

101

H2
Backup Alarm

100
+
458

X22
Accessory Ground
(Frame)

100/101

B A

457 Wire
450 Circuit Termination
Size Color
Number Points
S10 (mm2)
Backup Alarm
Switch (Rear) 100 2.0 Blk X22, X22
101 0.8 Blk X22, H2(–)
450 0.8 Yel F6(A), S10(A)
B A 455 2.0 Yel X11, F6(B)
458 457 456 2.0 Yel X11, F6(B)
457 0.8 Yel S10(B), S11(A)
S11 458 0.8 Yel S11(B), H2(+)
Backup Alarm
Switch (Front)

KV31080

4 - 26 11/22/00
ELECTRICAL ELECTRICAL WIRE HARNESSES

WIPER/WASHER WIRE HARNESS (W9)

460 472
100 100/101
X99 470
Interlock
Connector
X12
Accessory Ground
Switch Connector
Terminal Numbering
7 9
4 1
5B 2B
6 3
8 10

465
111 X33
461/462 Door Switch
460/466 Harness Connector
470
463

462 472
S12 466
465 461
Wiper/Washer
Switch
4 5 6 M4
1 2 3 Wiper Motor

101 Blank Blank


110 110
111
Splice 1
112

Wire
Circuit Termination
Size Color
Number Points
(mm2)
100 2.0 Blk X12, X12
101 0.8 Blk X12, Splice 1
110 0.8 Blk Splice 1, M4(2)
111 0.8 Blk Splice 1, S12(7)
112 0.8 Blk Splice 1, M5(A)
460 0.8 Yel X99(C), S12(5B)
461 0.8 Yel/wht S12(2B), M4(6)
462 0.8 Yel/wht S12(2B), S12(10)
463 0.8 Yel/blk S12(6), M5(B)
465 0.8 Yel/red M4(4), S12(1)
466 0.8 Yel S12(5B), M4(5) M5
Washer Pump
470 0.8 Dk Grn X99(B), X33(B)
463 B A
472 0.8 Dk Grn X99(A), X33(A) 112
KV31081

11/22/00 4 - 27
TROUBLESHOOTING CHART ELECTRICAL

TROUBLESHOOTING CHART

Battery not charging or overcharging

Warning lamps or fuel gauge stay on


Problem or
Symptom

Fuel shutoff solenoid not working

Boom/bucket control not working


Road/work lights do not operate
Preheater not working properly

Hour meter does not operate


Engine will not shut off

Fuel pump will not run


Engine will not crank

Engine will not start


Check or

or will not light


Solution

properly

properly
See cranking circuit diagnosis z

Test battery and connections z z z

See charging circuit diagnosis z

See lights circuit diagnosis z

See hydraulic boom and bucket


z
lockout circuit diagnosis

See preheat circuit diagnosis z z

Check fuel shutoff solenoid circuit


z z z
See fuel circuit diagnosis
See power circuit diagnosis z z z z z z z z z z

Check fuel pump ground circuit z z

See appropriate circuit diagnosis


z z z z
indicated by warning light that is on

4 - 28 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

THEORY OF OPERATION AND DIAGNOSIS

NOTE: Beginning in 2001, all wires will be solid colors Operating Conditions:
and will no longer include stripes. Each wire Voltage must be present at terminal 1 of the key switch
will have a circuit number stamped into the (S1).
insulation to aid in circuit tracing. The color on
the schematics, text and wiring diagrams in this
manual will be correct less the stripe color; i.e. Theory of Operation:
wire 425 yel/blk will become wire 425 yel. This
will be a running change not associated with With the key switch (S1) in the RUN position, voltage is
any serial number or model change. present at the following components:
• Terminal 86 (coil) of the accessory relay (K4)
• Terminal 23 of manual preheat switch (S3)
POWER AND CRANKING CIRCUIT • Terminal 5B of the park brake switch (S2)
OPERATION • Terminal 30 of the fuel relay (K3)
• Fuel pump (M2
UNSWITCHED POWER CIRCUITS • Terminal B of service plug (X10)
• Terminal 4 of auto preheat connector (X3)
• Terminal 5B of high-flow switch (S8)
Function: • Terminal 30 of high-flow relay (K6)
Provide power to the primary machine components • Terminal G of instrument cluster connector (X6)
whenever the battery is connected. • Terminal 2 of shutdown module( X4)

Operating Conditions: With the key switch (S1) in the ACCESSORY position,
Voltage must be present at the following components voltage is present at terminal 86 (coil) of the accessory
with the key switch in the OFF position: relay (K4).
• Terminal B of starting motor (M1)
• Terminal 30 of start relay (K1) CRANKING CIRCUIT
• Terminal 30 of accessory relay (K4)
• Terminal 1 of the seat switch (S4) Function:
• Terminal 2 of seat belt switch (S5)
To energize the starting motor (M1) and crank the
• Terminal A of the service plug (X10)
engine.
• Terminal 1 of the key switch (S1)
• Terminal V1 of the preheat relay (K2)
• Terminal B+ of Alternator (G2) Operating Conditions:
To crank the engine, the park brake switch (S2) must
be in the ENGAGE position and the key switch (S1)
Theory of Operation: must be in the START position.
The positive battery cable (red) connects to terminal B
of the starting motor (M1). Power is routed through wire
251 red which acts as a fuse link in case of excessive Theory of Operation:
current drain and is then routed through wire 250 red to With the key switch (S1) in the START position, current
fuses F1, F2, and F3. From fuse F3, power goes to from terminal 1 flows out terminal 2 through wire 500
terminal 1 of the key switch (S1). yel/red to terminal 5B of the park brake switch (S2).
With the park brake switch in the ENGAGE position,
current flows from terminal 6 through wire 560 yel/blk
SWITCHED POWER CIRCUIT back to terminal 3 of the key switch. From the key
switch, current flows from terminal 5 through wires 705
pur and 709 pur to the coil of the start relay (K1). The
Function:
start relay energizes and current flows through its
Provides power to primary components depending on contacts to the solenoid of the starting motor (M1) and
the position of the key switch (S1). the starting motor cranks.

11/22/00 4 - 29
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

This page intentionally left blank.

4 - 30 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

POWER AND CRANKING CIRCUIT SCHEMATIC

445 Yel To Accessory


Relay Contacts
F1
Accessory
Fuse
231 Red
To Seat Belt and Seat Switches
F2
Seat Switch
Fuse
226 Red
To Service Plug
F3
Key
Switch S1 550 Yel/Wht To Accessory
Fuse Key Switch Relay Coil
225 0 Accessory
Red 1 Off
2 Run C Engage
X1 3 Start
S2 B Run
(A2) 0,1,2
Park
A Release
Brake B,C
4
Switch
250 7
Red
6
225 Red 1 2 500 Yel/Red 505 Yel 5B

140
Blk
705 Pur 5 3
To Preheat
Relay 560 Yel/Blk

X1
706
(A3) Pur X9 Shutdown
(2) Module Connector To X8 (F)
707 Pur on
705
240 Pur H1 Instrument
Red
708 Pur
X10 (C) Cluster

709
Service
220 Red Plug
Pur

251 Red 241 30 86


Fuse Link Red K1
Fuse Start Unswitched Power
Link Relay
87 85
Red 700 Pur Switched Power
112
B S Blk

G1 Ground Circuit
M1
Battery Starting
Motor
M

Engine
Ground KV15154

11/22/00 4 - 31
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

POWER AND CRANKING CIRCUIT DIAGNOSIS


Test Conditions:
• Key switch in the OFF position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.

Test/Check Point Normal If Not Normal

1. Battery positive (+) post. 11.8—13.2 volts Test battery. (See BATTERY TEST in this
section.)

2. Red wire on starting motor. Battery voltage. Test red wire from battery to starting motor.

3. Wire 220 red at terminal 30 on (K1) Battery voltage. Test wire 220 red and 251 red to (K1) start
start relay. relay.

4. Wire 250 red on (F3) key switch fuse. Battery voltage. Test wires 250 red and 251 red between (F3)
key switch fuse and B terminal of starting
motor.

5. Accessory fuse (F1) (25-amp). Battery voltage. Test accessory fuse (F1) and replace as
necessary.

6. Seat switch/seat belt fuse (F2) (5-amp). Battery voltage. Test seat switch/seat belt fuse (F2) and replace
as necessary.

7. Key switch fuse (F3) (15-amp). Battery voltage. Test key switch fuse (F3) and replace as
necessary.

8. Wire 225 red at terminal A2 on (X1) Battery voltage. Test wire 225 red between (F3) key switch fuse
engine/ROPS harness connector. and (X1) engine/ROPS harness connector.

9. Wire 225 red at terminal A2 on (X1) Battery voltage. Test connector (X1) engine/ROPS harness
engine/ROPS harness connector. connector. Make sure wires are properly
crimped in the terminals.

10. Wire 225 red at terminal 1 on (S1) key Battery voltage. Test wire 225 red between (X1) engine/ROPS
switch. harness connector and (S1) key switch.

4 - 32 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

Test Conditions:
• Park Brake Switch in ENGAGE position.
• Key switch in RUN position.

Test/Check Point Normal If Not Normal

11. Wire 500 yel/red at terminal 2 on (S1) Battery voltage. Replace (S1) key switch.
key switch.

12. Wire 550 yel/wht at terminal 4 on (S1) Battery voltage. Replace (S1) key switch.
key switch.

13. Wire 505 yel at terminal 5B on (S2) Battery voltage. If battery voltage is not present, test wires 500
park brake switch. Park brake yel/red and 505 yel between (S1) key switch
switch back and (S2) park brake switch.
lighting is on.
If back lighting is not on, test ground circuit wire
140 blk from (S2) park brake Switch to ground.
If Ground circuit is good, replace (S2) park
brake switch.

14. Wire 560 yel/blk at terminal 3 on (S1) Battery voltage. Test wire 560 yel/blk from (S1) key switch to
key switch. (S2) park brake switch.

15. Wire 560 yel/blk wire at terminal 6 on Battery voltage. Replace (S2) park brake switch.
(S2) park brake switch.

11/22/00 4 - 33
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

Test Conditions:

NOTE: When performing tests, do not hold key switch


in START position for longer than 10 seconds
to avoid overheating starting motor and
discharging battery.

• Park Brake Switch in ENGAGE position.


• Key Switch in START position.
Test/Check Point Normal If Not Normal

16. Wire 705 pur at terminal 5 on Battery voltage. Replace (S1) key switch.
(S1) key switch.
17. Wire 705 pur at terminal A3 on Battery voltage. Test wire 705 pur from (S1) key switch to (X1)
(X1) engine/ROPS harness engine/ROPS harness connector.
connector.

18. Wire 705 pur at terminal A3 on Battery voltage. Test connector (X1) engine/ROPS harness
(X1) engine/ROPS harness connector. Make sure wires are properly
connector crimped in the terminals.

19. Wire 709 pur at terminal 86 on Battery voltage. Test wires 709 pur and 705 pur between (X1)
(K1) start relay. engine/ROPS harness connector and (K1) start
relay.

20. Wire 700 pur at terminal 87 on Battery voltage. Test (K1) start relay. If relay is good, test ground
(K1) start relay. circuit wire 112 blk from (K1) start relay to
ground.

21. Wire 700 pur at terminal S on Battery voltage. (M1) If battery voltage is not present, test wire 700
(M1) starting motor. starting motor cranks. pur.
If battery voltage is present and (M1) starting
motor does not crank, check starting motor-to-
engine block ground. If starting motor-to-engine
block ground is good, test starting motor.
Repair or replace starting motor as necessary.

4 - 34 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

POWER AND CRANKING CIRCUIT TEST POINTS


S2
Park Brake Switch

13

To Accessory
Relay

550 Yel/Wht 14
S1
Key Switch 505 Yel G2
500 Yel/Red
Alternator
11
140 Blk
560 Yel/Blk
12
100 Blk
16
10

705 Pur 17
9
15
225 Red
8

18 101 Blk
X1
Engine/ROPS
Harness Connector

225 Red

705 Pur 116 Blk

K1
Start Relay 220 Red
5
19 709 Pur
6
250 Red
3 20 7
112 Blk F4

700 Pur F1
4 F2
251 Red
F3
Fuse Link

Red

21

M1
Starting Motor

KV31061

11/22/00 4 - 35
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

FUEL AND PREHEAT CIRCUIT OPERATION

FUEL CIRCUIT PREHEAT CIRCUIT

Function: Function:
To energize the fuel shutoff solenoid which allows fuel To provide current to the manifold preheater (R1).
flow through the fuel injector pump.

Operating Conditions:
Operating Conditions: Voltage must be present at one terminal of the preheat
Voltage must be present at the fuel pump (M2), relay (K2), regardless of the position of the key switch
terminal 86 of the fuel relay (K3), and at fuel shut-off (S1). Voltage must be present at terminal 2B of the
solenoid (Y1) when the key switch is in the START or manual preheat switch (S3) when the key switch is in
RUN position. the START or RUN position.

Theory of Operation: Theory of Operation:


Current to terminal 30 of the fuel relay (K3) is supplied While holding the manual preheat switch (S3) in the
by wires 515 yel. With the key switch (S1) in the START ON position, current flows to the primary terminal (coil)
or RUN position, current flows to the fuel pump (M2) of the preheat relay (K2). The preheat relay energizes
and terminal 86 (coil) of the fuel relay (K3) energizing and current flows to the manifold preheater (R1) and
the fuel pump and coil of the fuel relay. With the fuel heats the air entering the engine to make starting
relay energized, current flows to the fuel shutoff easier.
solenoid (Y1) which allows fuel to flow through the fuel
injection pump.

4 - 36 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

FUEL AND PREHEAT CIRCUIT SCHEMATIC

500
To Key Yel/Red
Switch
506
Yel

S3
Manual
Preheat
To Switch 501
Starting 2B Yel 508
Motor Yel
504
4 On Off Yel
3 7

141
241 Blk
Red X4
Fuse 931 2 990 Wht
Link Gry
701 Dk Blu
X3 515
(1) Yel
512 3
(2) Auto Yel
Preheat 995
(3) Gry/Blk
(Option)
(4) X2
(C5)
995
240 Red
930 Gry/Blk
Gry
130 30 86
K2 M2 M K3
Blk Fuel Fuel
Preheat 87 85
Relay Pump Relay
118 Blk 114
Blk
108 Blk
920
Red/Wht 655
Wht
Y1
Fuel
Shutoff
R1 Solenoid
Manifold
Preheater

Unswitched Power

Power from Key Switch

Preheat Circuit

Fuel Shutoff Circuit

Ground Circuit

KV15155

11/22/00 4 - 37
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

FUEL CIRCUIT DIAGNOSIS


Test Conditions:
• Key switch in OFF position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.

Test/Check Point Normal If Not Normal

1. Battery positive (+) post. 11.8—13.2 volts Test battery. (See BATTERY TEST in this
section.)

2. Red wire on (M1) starting motor. Battery voltage. Test red wire from battery to starting motor.

3. Wire 250 red on (F3) key switch fuse. Battery voltage. Test wires 250 red and 251 red between (M1)
starting motor and (F3) key switch fuse.

4. Wire 225 red on (F3) key switch fuse. Battery voltage. Test (F3) key switch fuse and replace as
necessary.

5. Wire 225 red at terminal A2 on (X1) Battery voltage. Test wire 225 red between (F3) key switch fuse
engine/ROPS harness connector. and (X1) engine/ROPS harness connector.

6. Wire 225 red at terminal A2 on (X1) Battery voltage. Test connector (X1) engine/ROPS harness
engine/ROPS harness connector. connector. Make sure wires are properly
crimped in the terminals.

7. Wire 225 red at terminal 1 on (S1) key Battery voltage. Test wire 225 red between (X1) engine/ROPS
switch. harness connector and (S1) key switch.

Test Conditions:

NOTE: When performing tests, do not hold key switch


in START position for longer than 10 seconds
to avoid overheating starting motor and
discharging battery.

• Key switch in START position.

Test/Check Point Normal If Not Normal

8. Wire 500 yel/red at terminal 2 on (S1) Battery voltage. Replace (S1) key switch.
key switch.

4 - 38 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

Test Conditions:
• Engine stopped.
• Key switch in RUN position.

Test/Check Point Normal If Not Normal

9. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.

10. Wire 508 yel at terminal 2 on Battery voltage. Test wires 508 yel and 500 yel/red between
(X4) shutdown module connector. (S1) key switch and (X4) shutdown module
connector.

11. Wire 995 gry/blk at terminal 3 Battery voltage. Test (X4) shutdown module connector and wire
on (X4) shutdown module 990 wht. Make sure wires are properly crimped
connector. in terminals. Repair wire and/or replace
connector as necessary.

12. Wire 995 gry/blk at terminal Battery voltage. Test wire 995 gry/blk between (X4) Shutdown
C5 on (X2) engine/ROPS harness module connector and (X2) engine/ROPS
connector. harness connector.

13. Wire 995 gry/blk at terminal Battery voltage. Test (X2) engine/ROPS harness connector.
C5 on (X2) engine/ROPS harness Make sure wires are properly crimped in the
connector. terminals.

14. Wire 995 gry/blk at terminal 86 Battery voltage. Test wire 995 gry/blk between (X2) engine/
on (K3) fuel relay. ROPS harness connector and (K3) fuel relay.

15. Wire 501 yel at terminal C2 on Battery voltage. Test wires 501 yel and 500 yel/red between
(X1) engine/ROPS harness (X1) engine/ROPS harness connector and (s1)
connector. key switch.

16. Wire 501 yel at terminal C2 on Battery voltage. Test connector (X1) engine/ROPS harness
(X1) engine/ROPS harness connector. Make sure wires are properly
connector. crimped in the terminals.

17. Wire 515 yel at terminal 30 on Battery voltage. Test wire 515 yel between (X1) engine/ROPS
(K3) fuel relay. harness connector and (K3) fuel relay.

18. Wire 655 wht at terminal 87 on Battery voltage. Test ground circuit wire 114 blk to ground. If
(K3) fuel relay. ground circuit is good, test (K3) fuel relay.
Replace relay as necessary.
19. Wire 655 wht at (Y1) fuel Battery voltage. If battery voltage is not present, test wire 655
shutoff solenoid. Solenoid clicks when wht between (Y1) fuel shutoff solenoid and (K3)
wire is removed and fuel relay. If battery voltage is present and
connected. solenoid does not click, replace (Y1) fuel
shutoff solenoid.

20. Wire 512 yel at (M2) fuel Battery voltage. Fuel If battery voltage is not present, test wires 512
pump. pump running (listen). yel and 501 yel between (M2) fuel pump and
(X1) engine/ROPS harness connector.
If battery voltage is present and pump is not
running, test ground circuit wire 118 blk from
(M2) Fuel Pump to ground. If ground is good
replace (M2) Fuel Pump.

11/22/00 4 - 39
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

FUEL CIRCUIT TEST POINTS

S1
Key Switch
8 9

500 Yel/Red

225 Red M2
7 Fuel Pump
508 Yel 6 X1
501 Yel Engine/ROPS
10
Harness Connector
990 Wht
5 512 Yel

X4 15 20
Shutdown Module 995 Gry/Blk 12 501 Yel
Connector 118 Blk
11 X2
Engine/ROPS
Harness Connector
16
225 Red
13 4
515 Yel F4
995 Gry/Blk 19 F1
Y1
655 Wht Fuel Shutoff F2
Solenoid F3
14
250 Red
17 118 Blk
3

K3
Fuel Relay
101 Blk 100 Blk
114 Blk 18

G2
Alternator

251 Red
Fuse Link

Red
1

M1
Starting Motor

KV31062

4 - 40 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

PREHEAT CIRCUIT DIAGNOSIS


Test Conditions:
• Key switch in OFF position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.
Test/Check Point Normal If Not Normal

1. Battery positive (+) post. 11.8—13.2 volts Test battery. (See BATTERY TEST in this
section.)

2. Red wire on (M1) starting motor. Battery voltage. Test red wire from battery to starting motor.

3. Wire 240 red on (K2) preheat relay. Battery voltage. Test wires 240 red and 241 red between (K2)
preheat relay and (M1) starting motor.

4. Wire 250 red on (F3) key switch fuse. Battery voltage. Test wires 250 red and 251 red between (M1)
starting motor and (F3) key switch fuse.

5. Wire 225 red on (F3) key switch fuse. Battery voltage. Test (F3) key switch fuse and replace as
necessary.

6. Wire 225 red at terminal A2 on (X1) Battery voltage. Test wire 225 red between (F3) key switch fuse
engine/ROPS harness connector. and (X1) engine/ROPS harness connector.

7. Wire 225 red at terminal A2 on (X1) Battery voltage. Test connector (X1) engine/ROPS harness
engine/ROPS harness connector. connector. Make sure wires are properly
crimped in the terminals.

8. Wire 225 red at terminal 1 on (S1) key Battery voltage. Test wire 225 red between (X1) engine/ROPS
switch. harness connector and (s1) key switch.

Test Conditions:

NOTE: When performing tests, do not hold key switch


in START position for longer than 10 seconds
to avoid overheating starting motor and
discharging battery.

• Key switch in START position.

Test/Check Point Normal If Not Normal

9. Wire 500 yel/red at terminal 2 on (S1) Battery voltage. Replace (S1) key switch.
key switch.

11/22/00 4 - 41
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

Test Conditions:
• Engine stopped.
• Key switch in RUN position.

Test/Check Point Normal If Not Normal

10. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.

11. Wire 506 yel at terminal 2B on Battery voltage. Manual If battery voltage is not present, test wires 500
(S3) manual preheat switch. preheat switch back yel/red and 506 yel between (S1) key switch
lighting is on. and (S3) manual preheat switch.
If back lighting is not on, test ground circuit wire
141 blk from (S3) manual preheat switch to
ground. If Ground circuit is good, replace (S3)
manual preheat switch.

NOTE: When performing tests, do not hold manual


preheat switch in ON position for longer than
10 seconds to avoid discharging the battery.

Test Conditions:
• Key switch in RUN position.
• Manual preheat switch in ON position.

Test/Check Point Normal If Not Normal

12. Wire 931 gry at terminal 3 on Battery voltage. Replace (S3) manual preheat switch.
(S3) manual preheat switch.

13. Wire 931gry at terminal 3 on Battery voltage. Test wire 931 gry between (S3) manual preheat
(X3) auto preheat connector. switch and (X3) auto preheat connector.

14. Wire 930 gry at terminal C4 on Battery voltage. Test wire 930 gry between (X3) auto preheat
(X2) engine/ROPS harness connector and (X2) engine/ROPS harness
connector. connector.

15. Wire 930 gry at terminal C4 on Battery voltage. Test connector (X2) engine/ROPS harness
(X2) engine/ROPS harness connector. Make sure wires are properly
connector. crimped in the terminals.

16. Wire 930 gry on (K2) preheat Battery voltage. Test wire 930 gry between (X2) engine/ROPS
relay. harness connector and (K2) preheat relay.

17. Wire 920 red/wht on (K2) Battery voltage. Test ground circuit wire 108 blk from (K2)
preheat relay. preheat relay to ground. If ground circuit is
good, test (K2) preheat relay. Replace relay as
necessary.

18. Wire 920 red/wht at (R1) Battery voltage. If battery voltage is not present, test wire 920
manifold preheater. Manifold preheater gets red/wht between (R1) manifold preheater and
hot. (K2) preheat relay. If battery voltage is present
and manifold preheater does not get hot,
replace (R1) manifold preheater.

4 - 42 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

PREHEAT CIRCUIT TEST POINTS

S1
Key Switch
S3 9 10
Manual Preheat
Switch
8
500 Yel/Red

506 Yel

X1
225 Red Engine/ROPS
11 100 Blk G2
7 Harness Connector
12 141 Blk Alternator
116 Blk
931 Gry 6
X2
130 Blk
Engine/ROPS
14 Harness Connector 101 Blk
930 Gry

116 Blk
13 R1
Manifold 225 Red
Preheater
F4
15 F1
18
X3 F2
Auto Preheat 920 Red/Wht F3
Connector
17
3 5
4
930 Gry

240 Red
108 Blk

K2 250 Red
Preheat Relay

16

241 Red 251 Red


Fuse Link Fuse Link
1

Red

M1
Starting Motor
2

KV31063

11/22/00 4 - 43
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

CHARGING CIRCUIT OPERATION

Function: Theory of Operation:


To maintain battery voltage at approximately 13.5— When the key switch (S1) is in the RUN position, the
14.2 volts (while charging). alternator resistor (R2) on the alternator provides
exciter current to the field coils of the alternator (G2).
With the engine running, current flows from terminal B+
Operating Conditions: of the alternator to the common tie point on the starting
The engine must be running for the charging circuit to motor (M1) and then to the positive terminal of the
charge the battery. battery (G1). The charge rate is regulated by an
external regulator on the alternator.

4 - 44 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

CHARGING CIRCUIT SCHEMATIC

To F3
Key Switch To F1
Fuse S1 Accessories
Key Switch Fuse

0 Accessory
1 Off
2 Run
3 Start
0, 1, 2

4 550 Yel/Wht

445 Yel
225 Red 1 2

5 3

K4 86 30
Accessory
Relay 85 87
87a

110 Blk 451 Yel/Wht To Lights


450 Yel/Wht
and
454 Yel
Accessories

G2
Alternator R2 452 Yel
Alternator
200 Red B+
G
D+
Resistor X5 (1)
3
U 47 Ohm

B- To Instrument
Red X5 (2) Panel
100 Blk
B S
Unswitched Power
G1 M1
Battery Starting
Motor M Switched Power

Alternator Exciter Circuit

Battery Charging Circuit

Voltmeter and Battery


Indicator Light Circuit

Ground Circuit

KV15226

11/22/00 4 - 45
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

CHARGING CIRCUIT DIAGNOSIS


Test Conditions:
• Key switch in OFF position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.
• Battery must be fully charged.

Test/Check Point Normal If Not Normal

1. Battery positive (+) post. 11.8—13.2 volts Test battery. (See BATTERY TEST in this
section.)

2. Red wire on (M1) starting motor. Battery voltage. Test red wire from battery to starting motor.

3. Wire 200 red at B+ terminal on (G2) Battery voltage. Test wire 200 red from (M1) starting motor to
alternator. (G2) alternator.

Test Conditions:
• Test meter set to read resistance (ohms).

Test/Check Point Normal If Not Normal

4. B– terminal on (G2) alternator. Maximum 0.1 Test wire 100 blk between (G2) alternator and
ohm. ground and battery negative (–) cable between
(G1) battery and ground.

Test Conditions:
• Test meter set to read DC voltage.

Test/Check Point Normal If Not Normal

5. Wire 250 red on (F3) key switch fuse. Battery voltage. Test wires 250 red and 251 red between (M1)
starting motor and (F3) key switch fuse.

6. Wire 225 red on (F3) key switch fuse. Battery voltage. Test (F3) key switch fuse and replace as
necessary.

7. Wire 225 red at terminal A2 on (X1) Battery voltage. Test wire 225 red between (F3) key switch fuse
engine/ROPS harness connector. and (X1) engine/ROPS harness connector.

8. Wire 225 red at terminal A2 on (X1) Battery voltage. Test connector (X1) engine/ROPS harness
engine/ROPS harness connector. connector. Make sure wires are properly
crimped in the terminals.

9. Wire 225 red at terminal 1 on (S1) key Battery voltage. Test wire 225 red between (X1) engine/ROPS
switch. harness connector and (S1) key switch.

Test Conditions:
• Key switch in RUN position.

Test/Check Point Normal If Not Normal

10. Wire 550 yel/wht at terminal 4 on (S1) Battery voltage. Replace (S1) key switch.
key switch.

4 - 46 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

Test Conditions:
• Key switch in ACCESSORY position.

Test/Check Point Normal If Not Normal

11. Wire 550 yel/wht at terminal 4 on (S1) Battery voltage. Replace (S1) key switch.
key switch.
12. Wire 550 yel/wht at terminal C1 on Battery voltage. Test wire 550 yel/wht between (S1) key switch
(X1) engine/ROPS harness connector. and (X1) engine/ROPS harness connector.

13. Wire 550 yel/wht at terminal C1 on Battery voltage. Test (X1) engine/ROPS harness connector and
(X1) engine/ROPS harness connector. make sure wires are properly crimped in the
terminals.

14. Wire 550 yel/wht at terminal 86 on (K4) Battery voltage. Test wire 550 yel/wht between (K4) accessory
accessory relay. relay and (X1) engine/ROPS harness
connector.

15. Wire 445 yel on (F1) accessories fuse. Battery voltage. Test (F1) accessories fuse and replace as
necessary.

16. Wire 445 yel at terminal 30 on (K4) Battery voltage. Test wire 445 yel between (F1) accessories
accessory relay. fuse and (K4) accessory relay.

17. Wire 450 yel/wht at terminal 87 on (K4) Battery voltage. Test ground circuit wire 110 blk from (K4)
accessory relay. accessory relay to ground. If ground circuit is
good, test (K4) accessory relay. Replace relay
as necessary.

18. Wire 452 yel at (X5) alternator resistor Battery voltage. Test wires 452 yel and 450 yel/wht between
connector. (X5) alternator resistor connector and (K4)
accessory relay.

Test Conditions:
• Key switch in OFF position.
• (X5) Alternator Resistor Connector disconnected.
• Test meter set to measure resistance (ohms).

Test/Check Point Normal If Not Normal

19. (R2) alternator resistor. 47 ± 0.5 ohm. Replace (R2) alternator resistor.

Test Conditions:
• Connect (X5) Alternator Resistor Connector.
• Key switch in OFF position.
• Alternator belt must not be worn or slipping.
• Perform REGULATED AMPERAGE AND VOLTAGE
TEST in this section.

11/22/00 4 - 47
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

CHARGING CIRCUIT TEST POINTS

S1
Key Switch

225 Red 9
8 10 11
550 Yel/Wht

12

X1 7
Engine/ROPS
Harness Connector

13
225 Red
445 Yel
K4
Accessory 550 Yel/Wht 445 Yel
Relay
14

16 X5
19
Alternator Resistor
Connector
15
18 F4
450 Yel/Wht
F1
17 19
110 Blk 452 Yel F2
F3
Red 6
101 Blk
4 5

600 Brn
G2
Alternator
To 100 Blk
Discharge 250 Red
Light
3

200 Red

251 Red
Fuse Link
1

Red

M1
Starting Motor

KV31064

4 - 48 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT OPERATION

BOOM AND BUCKET LOCKOUT CIRCUIT PARK BRAKE CIRCUIT OPERATION

Function: Function:
To disable and enable boom and bucket functions. To engage and release the park brake.

Operating Conditions: Operating Conditions:


The operator must sit on the seat, fasten the seat belt, The operator must first sit on the seat and then fasten
and release the park brake switch in order for the boom the seat belt in order for the park brake to release.
and bucket circuit to operate.

Theory of Operation:
Theory of Operation: The seat belt switch (S5) receives current from the seat
The seat belt switch (S5) receives current from the seat switch/seat belt fuse (F2) through wire 231 red. Current
switch/seat belt fuse (F2) through wire 231 red. Current is also supplied to the seat switch (S4) through wires
is also supplied to the seat switch (S4) through wires 232 red and 230 red. When the operator sits on the
232 red and 230 red. When the operator sits on the seat, the seat switch closes and current flows to the
seat, the seat switch closes and current flows to the instrument cluster through wires 801 pnk and 800 pnk.
instrument cluster through wires 800 pnk and 801 pnk. When the operator fastens the seat belt, the seat belt
When the operator fastens the seat belt, the seat belt switch closes and current flows to the instrument
switch closes and current flows to the instrument cluster through wire 810 dk grn, 991 wht, 813 dk grn,
cluster through wire 810 dk grn, 991 wht, 813 dk grn, and 802 dk grn. If the machine has a cab door, door
and 802 dk grn. If the machine has a cab door, cab switch (S13) is connected in place of wire 991 wht.
door switch (S13) is connected in place of wire 991
On models with a cab door switch (S13) mounted in the
wht.
front, the cab door switch (S13) is a normally open
On models with a cab door switch (S13) mounted in the switch that is activated when the door is closed. Unless
front, the cab door switch (S13) is a normally open the door is fully closed and latched, the circuit will be
switch that is activated when the door is closed. Unless open causing the brake solenoid switch to remain
the door is fully closed and latched, the circuit will be deactivated (brake engaged).
open and the boom and bucket lockout will remain
On models with a cab door switch (S13) mounted in the
activated.
rear, the cab door switch (S13) is a normally closed
On models with a cab door switch (S13) mounted in the switch. When the door is fully open, it contacts the door
rear, the cab door switch (S13) is a normally closed switch (S13) and opens the circuit causing the brake
switch. When the door is fully open, it contacts the door solenoid to remain deactivated (brake engaged).
switch (S13) and opens the circuit causing the boom
When the key switch (S1) is in the RUN or START
and bucket lockout to remain activated.
position and the park brake switch (S2) is in the RUN
When the key switch (S1) is in the RUN or START (middle detent) position after being pushed to the
position and the park brake switch (S2) is in the RUN RELEASED (momentary) position, the instrument
(middle detent) position, the instrument cluster cluster provides ground for the park brake solenoid
provides ground for the bucket lock solenoid (Y2) and (Y4) through wire 730 pur. The ground circuit is
boom lock solenoid (Y3) through wires 740 pur/blk, 741 completed through the instrument cluster wire 128 blk,
pur/blk, and 742 pur/blk to the instrument cluster. The thus allowing the solenoid to energize.
ground circuit is completed through the instrument
cluster wire 128 blk allowing the solenoids to energize.

11/22/00 4 - 49
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT SCHEMATIC


F2 X33
Seat Switch/
Door Switch
Seat Belt
Harness Connector
Fuse 231 Red
S13 Cab
S4
Door Switch
Seat Switch
On
801 Pnk
Off
1 2
X21
F3 472
230 Red Seat Switch
Key Switch 1 2 Dk Grn
470 Pigtail
Fuse
With Dk Grn Connector
Cab Door S5
Seat Belt 232
Switch Red X4 (1) Shutdown
991 810 Dk Grn 1 2 Module Connector
Wht
225 Red
Without X99 813
Cab Door Dk Grn
S1 Interlock
Key Switch Connector
800
503 Yel Pnk
802
0 Accessories
1 Off Dk Grn
2 Run
3 Start
S2 C Engage
0,1,2 Park B Run
Brake B,C A Release X8
4 X6 X6
Switch (D) (E) (F)
7
6 140
1 2 500 Yel/Red 505 Yel 5B
4
Blk Instrument
1 725 Pur/Wht Cluster
5 3 X6
721 (D)
Pur X8 X7 X7
(C) (G) (H)
F4
Interlock
Fuse 128 Blk

711 Pur 722


713 Pur Pur

715
Pur
Y2 Y3 Y4
Bucket Boom Park Brake
Lock Lock Solenoid
Solenoid Solenoid
730 Pur
741 742
Pur/Blk Pur/Blk
740 Pur/Blk

Unswitched Power Boom and Bucket Lock Solenoids


and Park Brake Solenoid Power
Switched Power
Boom and Bucket Lock Solenoids
Input to Instrument Panel
Ground from Instrument Panel
from Seat, Seat Belt and
Door Switches Park Brake Solenoid Ground
from Instrument Panel
Input to Instrument Panel
from Park Brake Switch Ground Circuit

KV15157

4 - 50 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT DIAGNOSIS


Test Conditions:
• Key switch in OFF position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.

Test/Check Point Normal If Not Normal

1. Battery positive (+) post. 11.8—13.2 volts Test battery. (See BATTERY TEST in this
section.)

2. Red wire on (M1) starting motor. Battery voltage. Test red wire from battery to starting motor.

3. Wire 250 red on (F3) key switch fuse. Battery voltage. Test wires 250 red and 251 red between (F3)
key switch fuse and B terminal of starting
motor.

4. Wire 225 red on (F3) key switch fuse. Battery voltage. Test (F3) key switch fuse. Replace if necessary.

5. Wire 225 red at terminal A2 on (X1) Battery voltage. Test wire 225 red between (F3) key switch fuse
engine/ROPS harness connector. and (X1) engine/ROPS harness connector.

6. Wire 225 red at terminal A2 on (X1) Battery voltage. Test connector (X1) engine/ROPS harness
engine/ROPS harness connector. connector. Make sure wires are properly
crimped in the terminals.

7. Wire 225 red at terminal 1 on (S1) key Battery voltage. Test wire 225 red between (S1) key switch and
switch. (X1) engine/ROPS harness connector.

Test Conditions:
• Test meter set to read resistance (ohms).

Test/Check Point Normal If Not Normal

8. Wire 128 blk at terminal C on (X8) Maximum Test wire 128 blk from (X8) instrument cluster
instrument cluster connector. 0.1 Ohm. connector to ground.

11/22/00 4 - 51
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

Test Conditions:
• Engine stopped and key switch in RUN position.

Test/Check Point Normal If Not Normal

9. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.
10. Wire 505 yel at terminal 5B on Battery voltage. (S2) If battery voltage not present, test wires 500
(S2) park brake switch. park brake switch back yel/red and 505 yel between (S1) key switch
lighting is on. and (S2) park brake switch.
If back lighting is not on, test ground circuit wire
140 blk from (S2) park brake switch to ground.
If Ground circuit is good, replace (S2) park
brake switch.
11. Wire 503 yel at terminal D on Battery voltage. Test wires 503 yel/red and 500 yel between
(X8) instrument cluster connector. (X8) Instrument cluster connector and (S1) key
switch.
12. Wire 231 red at (F2) seat Battery voltage. Test (F2) seat switch/seat belt fuse. Replace if
switch/seat belt fuse. necessary.

13. Wire 231 red at terminal A1 on Battery voltage. Test wire 231 red between (F2) Seat Switch/
(X1) engine/ROPS harness seat belt fuse and (X1) engine/ROPS harness
connector. connector.

14. Wire 231 red at terminal A1 on Battery voltage. Test connector (X1) Engine/ROPS harness
(X1) engine/ROPS harness connector. Make sure wires are properly
connector. crimped in the terminals.

15. Wire 231 red on (S5) seat belt Battery voltage. Test wire 231 red between (S5) seat belt switch
switch. and (X1) engine/ROPS harness connector.

16. Wire 230 red on (S4) seat Battery voltage. Test wires 230 red and 232 red between (S5)
switch. seat belt switch and (S4) seat switch.

4 - 52 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

Test Conditions:
• Sit in seat or place a weight in seat to close the seat
switch.
• Fasten seat belt.
• Cab door closed and latched (if equipped).

Test/Check Point Normal If Not Normal

17. Wire 801 pnk at terminal 2 on (S4) Battery voltage. Replace (S4) seat switch.
seat switch.

18. Wire 800 pnk at terminal F on (X6) Battery voltage. Test wire 800 pnk and 801 pnk between (S4)
instrument cluster connector. seat switch and (X6) instrument cluster
connector.

19. Wire 810 dk grn at terminal 1 on (S5) Battery voltage. Replace (S5) seat belt switch.
seat belt switch.

20. Wire 810 dk grn at terminal A on (X99) Battery voltage. Test wire 810 dk grn between (X99) interlock
interlock connector. connector and (S5) seat belt switch.

21. Wire 813 dk grn at terminal B on (X99) Battery voltage. Replace 991 wht jumper.
interlock connector. If equipped with cab door, test wires 470 Dk
Grn and 472 Dk Grn from (X99) interlock
connector to (S13) cab door switch. If good,
replace (S13) cab door switch.

22. Wire 813 dk grn at terminal 1 on (X4) Battery voltage. Test wire 813 dk grn between (X4) shutdown
shutdown module connector. module connector and (X99) interlock
connector.

23. Wire 802 dk grn at terminal E on (X6) Battery voltage. Test wire 802 dk grn between (X4) shutdown
instrument cluster connector. module connector and (X6) instrument cluster
connector.

Test Conditions:
• Press and hold the park brake switch in the
RELEASE position.

Test/Check Point Normal If Not Normal

24. Wire 725 pur/wht at terminal 1 on (S2) Battery voltage. If battery voltage is present at terminal 5B on
park brake switch. (S2) park brake switch, replace switch.

25. Wire 725 pur/wht at terminal D on (X6) Battery voltage. Test wire 725 pur/wht between (S2) park brake
instrument cluster connector. switch and (X6) instrument cluster connector.

11/22/00 4 - 53
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

Test Conditions:
• Release the park brake switch to the RUN position.

Test/Check Point Normal If Not Normal

26. Wire 721 pur at terminal 4 on (S2) park Battery voltage. If battery voltage is present at terminal 5B on
brake switch. (S2) park brake switch, replace switch.

27. Wire 721 pur at terminal C1 on (X2) Battery voltage. Test wire 721 pur from (S2) park brake switch to
engine/ROPS harness connector. (X2) engine/ROPS harness connector.

28. Wire 721 pur at terminal C1 on (X2) Battery voltage. Test connector (X2) Engine/ROPS Harness
Engine/ROPS Harness Connector. Connector. Make sure wires are properly
crimped in the terminals.

29. Wire 721 pur on (F4) interlock fuse. Battery voltage. Test wire 721 pur between (F4) interlock fuse
and (X2) engine/ROPS harness connector.

30. Wire 722 pur on (F4) interlock fuse. Battery voltage. Test (F4) interlock fuse. Replace if necessary.

31. Wire 711 pur on (Y2) bucket lock Battery voltage. Test wires 711 pur and 722 pur between (Y2)
solenoid. bucket lock solenoid and (F4) interlock fuse.

32. Wire 713 pur on (Y3) boom lock Battery voltage. Test wires 713 pur and 722 pur between (Y3)
solenoid. boom lock solenoid and (F4) interlock fuse.

33. Wire 715 pur on (Y4) park brake Battery voltage. Test wires 715 pur and 722 pur between (Y4)
solenoid. park brake solenoid and (F4) interlock fuse.

Test Conditions:
• Key switch in OFF position.
• Disconnect (Y2) bucket lock solenoid, (Y3) boom
lock solenoid, and (Y4) park brake solenoid.
• Disconnect (X7) instrument cluster connector.
Set meter to read resistance (ohms). Connect one lead
to one of the numbered test points and the other lead to
the other numbered test point (two test points
numbered the same on the diagram).

Test/Check Point Normal If Not Normal

34. Wires 741 pur/blk on (Y2) bucket lock Maximum If no continuity in wire, repair or replace engine/
solenoid and 740 pur/blk at terminal H on 0.1 ohms. ROPS harness.
(X7) instrument cluster connector. If continuity in wire, test and replace solenoid.
If continuity in wire and solenoid is OK, replace
(H1) instrument cluster.

35. Wires 742 pur/blk on (Y3) boom lock Maximum If no continuity in wire, repair or replace engine/
solenoid and 740 pur/blk at terminal H on 0.1 ohms. ROPS harness.
(X7) instrument cluster connector. If continuity in wire, test and replace solenoid.
If continuity in wire and solenoid is OK, replace
(H1) instrument cluster.

36. Wire 730 pur on (Y4) park brake Maximum If no continuity in wire, repair or replace engine/
solenoid and at terminal G on (X7) 0.1 ohms. ROPS harness.
instrument cluster connector. If continuity in wire, test and replace solenoid.
If continuity in wire and solenoid is OK, replace
(H1) instrument cluster.

4 - 54 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT TEST POINTS

S1
Key Switch
S4
H1 Seat Switch 9
Instrument Cluster

S5 16
230
Seat Belt Switch 7
Red

S2 17
801 Pnk
Park Brake Switch 15 232
Red 500 Yel/Red

19 810 Dk Grn
X99
26 Interlock 225 Red
10 800 Pnk Connector

24 140 Blk 991 Wht


231 Red
725 472 Dk Grn
11 21
Pur/Wht X33
Instrument X8 505 Yel 20 Door Switch
Cluster 503 Yel
813 Harness
Connectors 36
Dk Grn 470 Dk Grn Connector
X7 721 Pur
8 470 Dk Grn
18 35 472 Dk Grn
X6 34
14 S13
128 Blk X1
Cab
X4 22 5 Engine/ROPS
25 23 802 Harness Connector
Door Switch
Dk Grn Shutdown Module 116 Blk 6
Connector
730 Pur 740 Pur/Blk 13 231 Red
100 Blk G2 225 Red
X2 Alternator
29
Engine/ROPS 30
Harness Connector Y2
27 721
Bucket Lock Pur
740 Pur/Blk Solenoid 116 Blk
12
741 Pur/Blk F4
250 Red
721 Pur F1
28 101 Blk
F2
742 Pur/Blk
Y3 F3
730 Pur 31
Boom Lock 722 Pur
Solenoid
711 Pur 4
34
32 251 Red 3
Fuse Link 1
Y4
Park Brake Red
33 713 Pur
Solenoid
715 Pur 35

36

M1
Starting Motor
2

KV31065

11/22/00 4 - 55
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

GAUGES AND WARNING LIGHTS CIRCUIT OPERATION

Function: Air Filter Restriction – When the engine air filter


To provide the total time of machine operation (hour becomes restricted, air filter restriction switch (B1)
meter), monitor and provide a visual indication closes and completes a ground, using wires 345 pnk
(warning lights and gauges) of vital machine functions. and 105 blk and the air filter restriction warning light
The functions that are monitored are: comes on.
Hydraulic Overtemperature – When the hydraulic oil
* Battery voltage
overheats, hydraulic overtemperature switch (B2)
* Battery discharge closes and completes a ground using wires 325 dk grn/
* Air filter restriction wht and 102 blk and the hydraulic oil overtemperature
warning light comes on.
* Hydraulic overtemperature
The overtemp switch closes when temperature rises to
* Hydraulic oil filter restriction 104.5°C ± 2.8°C (220°F ± 5°F). The overtemperature
* Fuel level switch opens when temperature lowers to 87.9°C ±
2.8°C (190°F ± 5°F).
* Engine overtemperature
Hydraulic Oil Filter Restriction – When the hydraulic
* Oil pressure oil filter becomes restricted, hydraulic oil filter restriction
* Low oil pressure switch (B3) closes and completes a ground using wires
335 dk grn and 106 blk and the hydraulic filter
* Engine coolant temperature restriction warning light comes on.
* Machine hours The restriction switch closes when oil pressure
* Occupancy increases to 275.8 ± 27.6 kPa (40 ± 4 psi). The
restriction switch opens when oil pressure decreases to
* Brake
206.8 kPa (30 psi) minimum. The normal operating
pressure is 41.4—206.8 kPa (6—30 psi).
Operating Conditions:
The key switch (S1) must be in the RUN or START NOTE:
position for the instrument cluster (H1) to monitor the
above functions.
Fuel Level – The fuel level sender (B4) is a variable
resistor that varies with the fuel level in the fuel tank
NOTE: The engine must be running for time to and is used to control the fuel gauge. The fuel level
accumulate on the hour meter. sender is connected to the instrument cluster (H1),
using wire 900 blk/wht and is grounded by wire 104 blk.

Theory of Operation: The fuel sender resistance will be 29—33 ohms when
fuel tank is full and 244—250 ohms when fuel tank is
When the key switch (S1) is in the RUN or START empty.
position, current flows to the instrument cluster (H1) on
wire 503 yel to provide power for operation. Ground to Engine Coolant Temperature – The engine
the instrument cluster is provided by wire 128 blk. The overtemperature switch and coolant temperature
gauges and warning lights theory of operation are as sender (B5) houses two components and controls both
follows: the engine coolant temperature gauge and
overtemperature light. It is grounded directly to the
Battery Voltage - The battery voltage as measured on engine block. The coolant temperature sender portion
connector X8 pin D is displayed by the battery is a variable resistor that varies with the engine coolant
voltmeter on the instrument cluster. temperature and is connected to the instrument cluster
Battery Discharge - Battery discharge is detected on (H1) using wire 320 org.
wire 600 brn at connector X7 pin D and turns on the
battery discharge warning light.

4 - 56 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

Engine Overtemperature – The engine Engine Low Oil Pressure – The low oil pressure
overtemperature switch and coolant temperature switch and oil pressure sender (B6) is grounded
sender (B5) houses two components and controls both directly to the engine block. The switch portion is a
the engine coolant temperature gauge and normally closed switch and uses oil pressure to open,
overtemperature light. It is grounded directly to the causing the engine oil pressure warning light to not
engine block. When the engine overheats, the switch light. If the oil pressure becomes too low, the switch
closes and connects the instrument cluster (H1) to closes and connects the instrument cluster (H1) to
ground using wire 300 org/wht. When this ground is ground using wire 620 tan, and the engine oil pressure
completed, the engine overtemperature warning light warning light comes on.
comes on.
The oil pressure switch closes when pressure
The engine overtemperature switch closes when decreases to 80 kPa ± 30.4 kPa (11.6 psi ± 4.4 psi)
coolant temperature rises to 116.2°C (241°F). during normal operating temperature [–25°C—100°C
(–13°F—212°F)].
Engine Oil Pressure – The low oil pressure switch and
oil pressure sender (B6) is grounded directly to the
engine block. The oil gauge sender portion is
connected to the instrument cluster (H1) using wire 625
tan/wht. The oil pressure sender is a variable resistor
that varies with the engine oil pressure.
Oil Pressure Sender
Pressure/Resistance

Resistance
Pressure
(ohms)

0 kPa (0 psi) 5—13

200 kPa (29 psi) 48—56

400 kPa (58 psi) 84—92

600 kPa (87 psi) 119—129

11/22/00 4 - 57
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

This page intentionally left blank.

4 - 58 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

GAUGES AND WARNING LIGHTS CIRCUIT SCHEMATIC


F3
Key Switch Fuse

15 Amp
503 Yel
X9 (2)
720 Pur Shutdown Module
505 Yel Connector
5 Amp 725 Pur/Wht
F2
Seat Switch/
Seat Belt Fuse 706 707
Engage Pur Pur
225 Red Run
706 Pur
Release
B,C
7
8
5B 140 Blk
4
X1
X8 X8
(A2) 1 X6 X6
S2 (D) (F)
(D) (G)
Park 706 Pur
Brake 500 Yel/Red
X6 (F)
231 Red Switch 800 Pnk

H1
0 Acc Instrument
X6 (E)
X1 S1 1 Off Cluster
(A1) Key X8 (C)
Switch 2 Run
600 Brn
0,1,2 3 Start
X7 (D)
225 Red X7 X7 X7 X8 X7 X8 X7 X8
4
(A) (C) (B) (E) (E) (B) (F) (A) 128 Blk

345 Pnk 325 335 Dk Grn 900 Blk/Wht 300 320 Org 620 Tan 625 Tan/Wht
1 2 Dk Grn/Wht Org/Wht
231 Red
To Alternator
5 D+ Terminal X2 X2 X2 X2 X2 X2 X2 X2
3
X21 (A5) (A3) (A4) (C3) (A1) (A2) (B2) (B3)
345 Pnk 325 335 Dk Grn 900 Blk/Wht 300 320 Org 620 Tan 625 Tan/Wht
Dk Grn/Wht Org/Wht

802
Off P
Dk Grn P t° P Q t° t° P
S4
On
Seat Switch B1
1 Air Filter B2 B3 B4
2 801 Pnk
Restriction Hydraulic Hydraulic Fuel B5 B6
105 Blk
Switch Over Temp- Oil Filter Level Engine Over Temperature Engine Low Oil Pressure
230 Red erature Restriction Sender Switch and Coolant Switch and Oil
Off Temperature Sender
102 Blk Switch 106 Blk Switch 104 Blk Pressure Sender
S5
On X21
Seat Belt
Switch 1 232 Red
2 802 Dk Grn
Unswitched Power Alternator Input Circuit
813 Dk Grn
810 Dk Grn
X4 (1) Switched Power Sensor Circuit

Seat and Seat Belt Park Brake Switch Circuit


X99 X99
Ground Circuit
991 Wht
KV31069

11/22/00 4 - 59
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

SEAT BELT WARNING LIGHT CIRCUIT DIAGNOSIS

NOTE: If wire 500 yel/red has not voltage, neither will instrument cluster or any warning lights.

Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–) terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose terminals when testing.

Test/Check Point Normal If Not Normal

1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.

2. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.

3. Wire 503 yel at terminal D on Battery voltage. Test wires 503 yel and 500 yel/red between
(X8) instrument cluster connector. (X8) instrument cluster connector and (S1) key
switch.

Test Conditions:
• Key switch in OFF position.
• Test meter set to read resistance (ohms).

Test/Check Point Normal If Not Normal

4. Wire 128 blk at terminal C on Maximum 0.1 ohms. Test wire 128 blk from (X8) instrument cluster
(X8) instrument cluster connector. connector to ground.

Test Conditions:
• Test meter set to read DC voltage.

Test/Check Point Normal If Not Normal

5. Wire 231 red on (F2) seat Battery voltage. Test (F2) seat switch/seat belt fuse. Replace if
switch/seat belt fuse. necessary.
If fuse is good, see POWER AND CRANKING
CIRCUIT DIAGNOSIS in this section.

6. Wire 231 red at terminal A1 on Battery voltage. Test wire 231 red between (F2) seat switch/seat
(X1) engine/ROPS harness belt fuse and (X1) engine/ROPS harness
connector. connector.

7. Wire 231 red at terminal A1 on Battery voltage. Test connector (X1) engine/ROPS harness
(X1) engine/ROPS harness connector. Make sure wires are properly
connector. crimped in the terminals.

8. Wire 231 red at terminal 2 on Battery voltage. Test wire 231 red between (X1) engine/ROPS
(S5) seat belt switch. harness connector and (S5) seat belt switch.

9. Wire 230 red at terminal 1 on Battery voltage. Test wire 230 red and 232 red between (S4)
(S4) seat switch. seat switch and (S5) seat belt switch, including
terminals at X21 seat switch pigtail connector.

4 - 60 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

Test Conditions:
• Key switch in RUN position.
• Operator sitting in seat with seat belt fastened.
• Cab door closed (if equipped).

Test/Check Point Normal If Not Normal

10. Wire 801 pnk at terminal 2 on Battery voltage. Replace (S4) seat switch.
(S4) seat switch.

11. Wire 800 pnk at terminal F on Battery voltage. Test wire 800 pnk and 801 pnk between (X6)
(X6) instrument cluster connector. instrument cluster connector and (S4) seat
switch.

12. Wire 810 dk grn at terminal 1 Battery voltage. Replace (S5) seat belt switch.
on (S5) seat belt switch.

13. Wire 810 dk grn at terminal A Battery voltage. Test wire 810 dk grn between (X99) interlock
on (X99) interlock connector. connector and (S5) seat belt switch.

14. Wire 813 dk grn at (X99) Battery voltage. Replace 991 wht jumper.
interlock connector. If equipped with cab door, test wires 470 Dk
Grn and 472 Dk Grn from (X99) interlock
connector to (S13) cab door switch. If good,
replace (S13) cab door switch.

15. Wire 813 dk grn at terminal 1 Battery voltage. Test wire 813 dk grn between (X4) shutdown
on (X4) shutdown module module connector and (X99) interlock
connector. connector.

16. Wire 802 dk grn at terminal E Battery voltage. Test wire 802 dk grn between (X6) instrument
on (X6) instrument cluster cluster connector and (X4) shutdown module
connector. connector including the terminals on X99
interlock connector.

11/22/00 4 - 61
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

SEAT BELT WARNING LIGHT CIRCUIT TEST POINTS

S4 S1
X33 Seat Switch Key Switch 2
S13 472 Door Switch
Cab Grn Harness Connector
Door Switch

470 10
Grn
9
801 Pnk
8
230 Red
S5 1
H1 232 Red
Instrument Cluster 472 Seat Belt Switch
Grn 991
470 Wht 13 12 500
Grn
Yel/Red
X99 810
Interlock Dk Grn
Connector 14
X4
Shutdown Module 813
Connector Dk Grn
X8
15
3 800 Pnk
X7
231 Red
100 Blk
11 4
503 Yel
X6 4
802 7
Dk Grn X1
128 Blk Engine/ROPS
Harness Connector
Instrument Cluster G2
Connectors 16 6 101 Blk Alternator

116 Blk
231 Red
116 Blk 5
F4
F1
F2
F3

KV31066

4 - 62 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

PARK BRAKE SWITCH AND WARNING LIGHT CIRCUIT DIAGNOSIS

NOTE: If wire 500 yel/red has not voltage, neither will instrument cluster or any warning lights.

Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.

Test/Check Point Normal If Not Normal

1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.

2. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.

3. Wire 503 yel at terminal D on Battery voltage. Test wires 503 yel and 500 yel/red between
(X8) instrument cluster connector. (X8) instrument cluster connector and (S1) key
switch.

Test Conditions:
• Key switch in OFF position.
• Test meter set to read resistance (ohms).

Test/Check Point Normal If Not Normal

4. Wire 128 blk at terminal C on Maximum 0.1 ohms. Test wire 128 blk from (X8) instrument cluster
(X8) instrument cluster connector. connector to ground.

Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Park brake switch in the RUN position.

Test/Check Point Normal If Not Normal

5. Wire 505 yel at terminal 5B on Battery voltage. If battery voltage is not present, test wires 505
(S2) park brake switch. Park switch light is on. yel and 500 yel/red between (S2) park brake
Park brake light is on. switch and (S1) key switch.
If battery voltage is present but park switch light
is not on, test 140 blk ground. If ground wire is
good, replace park brake switch.
If park brake light is on, check for voltage at 725
pur on (S2) Park Brake Switch.
If voltage on 725 pur, replace park brake switch
or check for short in harness.
If no voltage at 725 pur, replace (H1)
instrument cluster.

11/22/00 4 - 63
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

Test Conditions:
• Operator in seat.
• Seat belt fastened.
• Hold park brake switch in RELEASE position.

Test/Check Point Normal If Not Normal

6. Wire 725 pur/wht at terminal 1 Battery voltage. If battery voltage is present at terminal 5B on
on (S2) park brake switch. (S2) park brake switch, replace switch.

7. Wire 725 pur/wht at terminal D Battery voltage. Test wire 725 pur/wht between (X6) instrument
on (X6) instrument cluster Park brake warning light cluster connector and (S2) park brake switch.
connector. goes out.
If battery voltage is present and park brake
warning light does not go out, replace (H1)
instrument cluster.

Test Conditions:
• Release park brake switch to the RUN position.

Test/Check Point Normal If Not Normal

8. Wire 720 pur at terminal 4 on Battery voltage. Replace (S2) park brake switch.
(S2) park brake switch.

9. Wire 720 pur at terminal G on Battery voltage. If battery voltage is not present, test wire 720
(X6) instrument cluster connector. pur between (X6) instrument cluster connector
and (S2) park brake switch.

4 - 64 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

PARK BRAKE SWITCH AND WARNING LIGHT CIRCUIT TEST POINTS

S1
Key Switch
2

H1
Instrument Cluster 1
S2
Park Brake Switch
8
6
5 500 Yel/Red

X8 3 505 Yel

725 Pur/Wht
X7

9
X6 503 Yel
4
Instrument Cluster
Connectors
140 Blk
128 Blk
720 Pur X1
7 Engine/ROPS
Harness Connector
116 Blk

116 Blk
101 Blk

G2
Alternator

100 Blk

KV15192

11/22/00 4 - 65
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

AIR FILTER RESTRICTION WARNING LIGHT CIRCUIT DIAGNOSIS

NOTE: If wire 500 yel/red has not voltage, neither will instrument cluster or any warning lights.

Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.

Test/Check Point Normal If Not Normal

1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.

2. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.
3. Wire 503 yel at terminal D on Battery voltage. Test wires 503 yel and 500 yel/red between
(X8) instrument cluster connector. (X8) instrument cluster connector and (S1) key
switch.

Test Conditions:
• Key switch in OFF position.
• Test meter set to read resistance (ohms).

Test/Check Point Normal If Not Normal

4. Wire 128 blk at terminal C on Maximum 0.1 ohms. Test wire 128 blk from (X8) instrument cluster
(X8) instrument cluster connector. connector to ground.

5. Wire 105 blk on harness side Maximum 0.1 ohms. Test wire 105 blk from (B1) air filter restriction
of connector to (B1) air filter switch to ground.
restriction switch.

Test Conditions:
• Disconnect (B1) air filter restriction switch.
• Connect a jumper wire across the terminals at 345
pnk and 105 blk on harness side of the air filter
restriction switch connector.
• Key switch in RUN position.

Test/Check Point Normal If Not Normal

6. Air filter restriction warning Warning light comes on. If warning light comes on, test (B1) air filter
light. restriction switch.

If air filter restriction warning light does not


come on, test wires 345 pnk between (B1) air
filter restriction switch and terminal A on (X7)
instrument cluster connector.

If wires are good, replace (H1) instrument


cluster.

4 - 66 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

AIR FILTER RESTRICTION WARNING LIGHT CIRCUIT TEST POINTS

6
S1
Key Switch
2

H1
Instrument Cluster

X8 3
500 Yel/Red
X7

4 503 Yel
X6

345 Pnk 128 Blk


X1
Instrument Cluster Engine/ROPS
Connectors Harness Connector
116 Blk
X2
Engine/ROPS
Harness Connector

B1
Air Filter
Restriction
Switch 116 Blk
345 Pnk
105 Blk 101 Blk
5
G2
Alternator

100 Blk

4
5

KV15193

11/22/00 4 - 67
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

HYDRAULIC OIL OVERTEMPERATURE WARNING LIGHT CIRCUIT


DIAGNOSIS

NOTE: If wire 500 yel/red has not voltage, neither will instrument cluster or any warning lights.

Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.

Test/Check Point Normal If Not Normal

1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.

2. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.

3. Wire 503 yel at terminal D on Battery voltage. Test wires 503 yel and 500 yel/red between
(X8) instrument cluster connector. (X8) instrument cluster connector and (S1) key
switch.

Test Conditions:
• Key switch in OFF position.
• Test meter set to read resistance (ohms).

Test/Check Point Normal If Not Normal

4. Wire 128 blk at terminal C on Maximum 0.1 ohms. Test wire 128 blk from (X8) instrument cluster
(X8) instrument cluster connector. connector to ground.

5. Wire 102 blk on harness side Maximum 0.1 ohms. Test wire 102 blk from (B2) hydraulic
of connector to (B2) hydraulic overtemperature switch to ground.
overtemperature switch.

Test Conditions:
• Disconnect (B2) Hydraulic Overtemperature
Switch.
• Connect a jumper wire across the terminals at 325
dk grn/wht and 102 blk on harness side of
hydraulic overtemperature switch connector.
• Key switch in RUN position.

Test/Check Point Normal If Not Normal

6. Hydraulic overtemperature Warning light comes on. If warning light comes on, test (B2) hydraulic
warning light. overtemperature switch.
If hydraulic overtemperature warning light does
not come on, test wires 325 dk grn/wht between
(B2) hydraulic overtemperature switch and
terminal C on (X7) instrument cluster
connector.
If wires are good, replace (H1) instrument
cluster.

4 - 68 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

HYDRAULIC OIL OVERTEMPERATURE WARNING LIGHT CIRCUIT TEST


POINTS

6
S1
Key Switch
2
H1
Instrument Cluster

3 1
X8
500 Yel/Red
X7

4 503 Yel
X6
128 Blk
325 Dk Grn/Wht
Instrument Cluster X1
Connectors Engine/ROPS
116 Blk Harness Connector
X2
Engine/ROPS
Harness Connector

B2
Hydraulic Oil
Overtemperature
Switch 116 Blk
325 Dk Grn/Wht

5 102 Blk 101 Blk


G2
Alternator

100 Blk

4
5

KV15194

11/22/00 4 - 69
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

HYDRAULIC FILTER RESTRICTION WARNING LIGHT CIRCUIT DIAGNOSIS

NOTE: If wire 500 yel/red has not voltage, neither will instrument cluster or any warning lights.

Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.

Test/Check Point Normal If Not Normal

1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.

2. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.

3. Wire 503 yel at terminal D on Battery voltage. Test wires 503 yel and 500 yel/red between
(X8) instrument cluster connector. (X8) instrument cluster connector and (S1) key
switch.

Test Conditions:
• Key switch in OFF position.
• Test meter set to read resistance (ohms).

Test/Check Point Normal If Not Normal

4. Wire 128 blk at terminal C on Maximum 0.1 ohms. Test wire 128 blk from (X8) instrument cluster
(X8) instrument cluster connector. connector to ground.

5. Wire 106 blk at ring terminal on Maximum 0.1 ohms. Test wire 106 blk from (B3) hydraulic oil filter
hydraulic filter housing ground. restriction switch to ground.

Test Conditions:
• Key switch in RUN position.
• Disconnect 335 dk grn wire from (B3) hydraulic oil
filter restriction switch and connect to wire 106 blk
with jumper wire.

Test/Check Point Normal If Not Normal

6. Hydraulic filter restriction Warning light comes on. If warning light comes on, test (B3) hydraulic oil
warning light. filter restriction switch.
If hydraulic filter restriction warning light does
not come on, test wires 335 dk grn between
(B3) hydraulic oil filter restriction switch and
terminal B on (X7) instrument cluster
connector.
If wires are good, replace (H1) instrument
cluster.

4 - 70 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

HYDRAULIC FILTER RESTRICTION WARNING LIGHT CIRCUIT TEST POINTS

6
S1
Key Switch
2
H1
Instrument Cluster

1
X8 3
500 Yel/Red
X7

4 503 Yel
X6

128 Blk

335 Dk Grn
Instrument Cluster X1
Connectors Engine/ROPS
116 Blk Harness Connector
X2
Engine/ROPS
B3 Harness Connector
Hydraulic Oil Filter
Restriction Switch
5

116 Blk

335 Dk Grn
106 Blk 101 Blk
G2
Alternator

100 Blk

4
5

KV15195

11/22/00 4 - 71
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

FUEL GAUGE CIRCUIT DIAGNOSIS

NOTE: If wire 500 yel/red has not voltage, neither will instrument cluster or any warning lights.

Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.

Test/Check Point Normal If Not Normal

1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.

2. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.

3. Wire 503 yel at terminal D on Battery voltage. Test wires 503 yel and 500 yel/red between
(X8) instrument cluster connector. (X8) instrument cluster connector and (S1) key
switch.

Test Conditions:
• Key switch in OFF position.
• Test meter set to read resistance (ohms).

Test/Check Point Normal If Not Normal

4. Wire 128 blk at terminal C on Maximum 0.1 ohms. Repair or replace wire 128 blk from (X8)
(X8) instrument cluster connector. instrument cluster connector to ground.

5. Wire 104 blk at connector of Maximum 0.1 ohms. Repair or replace wire 104 blk from (B4) fuel
(B4) fuel level sender. level sender to ground.

6. Wire 900 blk/wht between (B4) Maximum 0.1 ohms. Repair or replace wire 900 blk/wht between
fuel level sender and terminal C3 (B4) fuel level sender and (X2) engine/ROPS
at (X2) engine/ROPS harness harness connector.
connector.

7. Wire 900 blk/wht between C3 Maximum 0.1 ohms. Repair or replace wire 900 blk/wht between
on (X2) engine/ROPS harness (X2) engine/ROPS harness connector and
connector and terminal E on (X8) terminal E on (X8) instrument cluster
instrument cluster connector. connector.

Test Conditions:
• Key switch in OFF position.
• Test meter set to read resistance (ohms)
• Disconnect the wire harness from (B4) Fuel Level
Sender.

Test/Check Point Normal If Not Normal

8. Terminal A to Terminal B of Between 33—240 Replace (B4) fuel level sender.


(B4) fuel level sender. ohms.

4 - 72 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

Test Conditions:
• Disconnect the wire harness from the fuel level
sender.
• Key switch in RUN position.

Test/Check Point Normal If Not Normal

9. Fuel gauge. Gauge indicates empty. Replace (H1) instrument cluster.

Test Conditions:
• Disconnect the wire harness from the fuel level
sender.
• Install a jumper wire between wire 900 blk/wht and
wire 104 blk.
• Key switch in RUN position.

Test/Check Point Normal If Not Normal

10. Fuel gauge. Gauge indicates full. Replace (H1) instrument cluster.

11/22/00 4 - 73
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

FUEL GAUGE CIRCUIT TEST POINTS

9 10

S1
Key Switch
2
H1
Instrument Cluster

1
X8 3
4 500 Yel/Red
X7

X6 503 Yel
Instrument Cluster 7
Connectors 128 Blk

X1
6 Engine/ROPS
900 Blk/Wht 7 116 Blk Harness Connector
X2
5 Engine/ROPS
B4 104 Blk Harness Connector
Fuel Level
Sender
6
9
8
8 900 Blk/Wht
116 Blk

101 Blk
G2
Alternator

100 Blk

4
5

KV15197

4 - 74 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

ENGINE OVERTEMPERATURE WARNING LIGHT CIRCUIT DIAGNOSIS

NOTE: If wire 500 yel/red has not voltage, neither will instrument cluster or any warning lights.

Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.

Test/Check Point Normal If Not Normal

1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.

2. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.

3. Wire 503 yel at terminal D on Battery voltage. Test wires 503 yel and 500 yel/red between
(X8) instrument cluster connector. (X8) instrument cluster connector and (S1) key
switch.

Test Conditions:
• Key switch in OFF position.
• Test meter set to read resistance (ohms).

Test/Check Point Normal If Not Normal

4. Wire 128 blk at terminal C on Maximum 0.1 ohms. Test wire 128 blk from (X8) instrument cluster
(X8) instrument cluster connector. connector to ground.

Test Conditions:
• Key switch in RUN position.
• Connect wire 300 org/wht from (B5) Engine
overtemperature switch and coolant temperature
sender to ground.

Test/Check Point Normal If Not Normal

5. Engine overtemperature Warning light comes on. If warning light comes on, test (B5) engine
warning light. overtemperature switch and coolant
temperature sender.
If engine overtemperature warning light does
not come on, test wires 300 org/wht between
terminal E on (X7) instrument cluster connector
and (B5) engine overtemperature switch and
coolant temperature sender.
If wires are good, replace (H1) instrument
cluster.

11/22/00 4 - 75
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

ENGINE OVERTEMPERATURE WARNING LIGHT CIRCUIT TEST POINTS

5
S1
Key Switch

H1 2
Instrument Cluster

X8 1
500 Yel/Red
X7
4
503 Yel

X6
Instrument Cluster
Connectors
128 Blk
X1
320 Org Engine/ROPS
116 Blk Harness Connector
X2
Engine/ROPS
Harness Connector
300 Org/Wht

B5 116 Blk
Engine Overtemperature
Switch and Coolant 300 Org/Wht
101 Blk
Temperature Sender
320 Org G2
Alternator
5 100 Blk

KV15196

4 - 76 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

COOLANT TEMPERATURE GAUGE CIRCUIT DIAGNOSIS

NOTE: If wire 500 yel/red has not voltage, neither will instrument cluster or any warning lights.

Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.

Test/Check Point Normal If Not Normal

1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.

2. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.

3. Wire 503 yel at terminal D on Battery voltage. Test wires 503 yel and 500 yel/red between
(X8) instrument cluster connector. (X8) Instrument cluster connector and (S1) key
switch.

Test Conditions:
• Test meter set to read resistance (ohms).
• Key switch in OFF position.

Test/Check Point Normal If Not Normal

4. Wire 128 blk at terminal C on Maximum 0.1 ohms. Test wire 128 blk from (X8) instrument cluster
(X8) instrument cluster connector. connector to ground.

11/22/00 4 - 77
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.

Test/Check Point Normal If Not Normal

5. Wire 320 org at terminal B on Battery voltage. Replace (H1) instrument cluster.
(X8) instrument cluster connector.

6. Wire 320 org at terminal A2 on Battery voltage. Test wire 320 org between (H1) instrument
(X2) engine/ROPS harness cluster and (X2) engine/ROPS harness
connector. connector.

7. Wire 320 org at terminal A2 on Battery voltage. Test (X2) engine/ROPS harness connector.
(X2) engine/ROPS harness Make sure wires are properly crimped in the
connector. terminals.

8. Wire 320 org at (B5) engine Battery voltage. Test wire 320 org between (X2) engine/ROPS
overtemperature switch and harness connector and (B5) engine
coolant temperature sender. overtemperature switch and coolant
temperature sender.

Test Conditions:
• Connect wire 320 org from (B5) Engine
overtemperature switch and coolant temperature
sender to ground.

Test/Check Point Normal If Not Normal

9. Engine temperature gauge. Gauge indicates HOT. If gauge does not indicate HOT, replace (H1)
instrument cluster.
If gauge indicates HOT, test (B5) engine
overtemperature switch and coolant
temperature sender. (See ENGINE COOLANT
TEMPERATURE SENDER/SWITCH TEST in
this section.)

4 - 78 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

COOLANT TEMPERATURE GAUGE CIRCUIT TEST POINTS

S1
Key Switch

H1 2
Instrument Cluster

X8 1
500 Yel/Red
X7
4
503 Yel

X6 5
Instrument Cluster
Connectors
128 Blk
X1
320 Org 6 Engine/ROPS
116 Blk Harness Connector
X2
Engine/ROPS
Harness Connector
300 Org/Wht

116 Blk
B5
Engine Overtemperature
300 Org/Wht
Switch and Coolant 101 Blk
Temperature Sender
320 Org G2
Alternator

100 Blk
9 8
4

KV15196

11/22/00 4 - 79
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

ENGINE OIL PRESSURE WARNING LIGHT CIRCUIT DIAGNOSIS


Test Conditions:
• Key switch in RUN position. NOTE: If wire 500 yel/red has not voltage, neither will
• Test meter set to read DC voltage. instrument cluster or any warning lights.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.

Test/Check Point Normal If Not Normal

1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.

2. Wire 500 yel/red at terminal 2 on Battery voltage. Replace (S1) key switch.
(S1) key switch.

3. Wire 503 yel at terminal D on (X8) Battery voltage. Test wires 503 yel and 500 yel/red between
instrument cluster connector. (X8) instrument cluster connector and (S1) key
switch.

Test Conditions:
• Key switch in OFF position.
• Test meter set to read resistance (ohms).

Test/Check Point Normal If Not Normal

4. Wire 128 blk at terminal C on (X8) Maximum 0.1 ohms. Test wire 128 blk from (X8) instrument cluster
Instrument cluster connector. connector to ground.

Test Conditions:
• Key switch in RUN position.
• Disconnect wire 620 tan from (B6) engine low oil
pressure switch and oil pressure sender.

Test/Check Point Normal If Not Normal

5. Engine oil pressure warning light. Light is not on. Test wire 620 tan between (B6) engine low oil
pressure switch and oil pressure sender and
(X7) instrument cluster connector.
If wire 620 tan tests good, replace (H1)
instrument cluster.

Test Conditions:
• Key switch in RUN position.
• Connect wire 620 tan to ground.

Test/Check Point Normal If Not Normal

6. Engine oil pressure warning light. Warning light comes Test (B6) engine low oil pressure switch and oil
on. pressure sender. (See ENGINE OIL
PRESSURE SWITCH/SENDER TEST in this
section.)
If engine oil pressure warning light does not
come on, test wire 620 tan between (X7)
Instrument cluster connector and (B6) engine
low oil pressure switch and oil pressure sender.
If wires are good, replace (H1) instrument
cluster.

4 - 80 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

ENGINE OIL PRESSURE WARNING LIGHT CIRCUIT TEST POINTS

S1
Key Switch
5 6
2

H1
Instrument Cluster 1

500 Yel/Red
3
X8
503 Yel
X7

4
X6 128 Blk
Instrument Cluster X1
Connectors Engine/ROPS
Harness Connector
620 Tan 116 Blk
625 Tan/Wht

X2
Engine/ROPS
Harness Connector
116 Blk
101 Blk

G2
625 Tan/Wht Alternator
B6 100 Blk
Engine Low Oil 620 Tan
Pressure Switch
and Oil Pressure Sender 5

KV15198

11/22/00 4 - 81
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

ENGINE OIL PRESSURE GAUGE CIRCUIT DIAGNOSIS

NOTE: If wire 500 yel/red has not voltage, neither will instrument cluster or any warning lights.

Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.

Test/Check Point Normal If Not Normal

1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS.

2. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.

3. Wire 503 yel at terminal D on Battery voltage. Test wires 503 yel and 500 yel/red between
(X8) instrument cluster connector. (X8) instrument cluster connector and (S1) key
switch.

Test Conditions:
• Key switch in OFF position.
• Test meter set to read resistance (ohms).

Test/Check Point Normal If Not Normal

4. Wire 128 blk at terminal C on Maximum 0.1 ohm. Test wire 128 blk from (X8) instrument cluster
(X8) instrument cluster connector. connector to ground.

Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.

Test/Check Point Normal If Not Normal

5. Wire 625 tan/wht at terminal A Approximately 6 volts. Replace (H1) instrument cluster.
on (X8) instrument cluster
connector.

6. Wire 625 tan/wht at terminal Approximately 6 volts. Test wire 625 tan/wht between (H1) instrument
B3 on (X2) engine/ROPS harness cluster and (X2) engine/ROPS harness
connector. connector.

7. Wire 625 tan/wht at terminal Approximately 6 volts. Test (X2) engine/ROPS harness connector.
B3 on (X2) engine/ROPS harness Make sure wires are properly crimped in the
connector. terminals.

8. Wire 625 tan/wht at (B6) Approximately 6 volts. Test wire 625 tan/wht between (X2) engine/
engine low oil pressure switch and ROPS harness connector and (B6) engine low
oil pressure sender. oil pressure switch and oil pressure sender.

4 - 82 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

Test Conditions:
• Key switch in RUN position.
• Connect wire 625 tan/wht from (B6) engine low oil
pressure switch and oil pressure sender to ground.

Test/Check Point Normal If Not Normal

9. Engine oil pressure gauge. Gauge indicates LOW If gauge does not indicate LOW pressure,
pressure. replace (H1) instrument cluster.

If gauge indicates LOW pressure, test (B6)


engine low oil pressure switch and oil pressure
sender.

11/22/00 4 - 83
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

ENGINE OIL PRESSURE GAUGE CIRCUIT TEST POINTS

S1
9
Key Switch

H1
Instrument Cluster 1

500 Yel/Red
3
X8
503 Yel
X7

4
X6 128 Blk
Instrument Cluster 5 X1
Connectors Engine/ROPS
Harness Connector
620 Tan 116 Blk
625 Tan/Wht
6
X2
Engine/ROPS
Harness Connector
116 Blk
7 101 Blk

G2
625 Tan/Wht Alternator
B6 100 Blk
Engine Low Oil 620 Tan
Pressure Switch
and Oil Pressure Sender

8
9

KV15198

4 - 84 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

HIGH-FLOW CIRCUIT (OPTIONAL) OPERATION


Replace this page with color page, filename—
4L_elec1C.fm, page 1 of 2.

11/22/00 4 - 85
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

HIGH-FLOW CIRCUIT SCHEMATIC


Replace this page with color page, filename—
4L_elec1C.fm, page 2 of 2.

4 - 86 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

HIGH-FLOW CIRCUIT DIAGNOSIS


Test Conditions:
• Key switch in OFF position.
• High flow switch in OFF position.
• Disconnect harness from (S8) High Flow Switch.
• Test meter set to read resistance (ohms).
• Meter positive (+) lead on numbered test point.
• Meter negative (–) lead on battery negative (–)
terminal.
• Check connections for corrosion and loose
terminals when testing.

Test/Check Point Normal If Not Normal

1. Wire 142 blk at harness Maximum 0.1 ohms. Test ground circuit wire 142 blk from (S8) high
connector from (S8) high flow flow switch to ground.
switch.

Test Conditions:
• Connect harness to (S8) High Flow Switch.
• Key switch in RUN position.
• Test meter set to read DC voltage.

Test/Check Point Normal If Not Normal

2. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.

3. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.
4. Wire 502 yel at terminal 5B on Battery voltage. If voltage is not present, test wires 502 yel and
(S8) high flow switch. 500 yel/red between (S1) key switch and (S8)
High flow switch back
high flow switch.
lighting is on.
If voltage is present and back lighting does not
come on, check 142 blk ground.
If good, replace switch.

5. Wire 501 yel at terminal C2 on Battery voltage. Test wires 500 yel/red and 501 yel between
(X1) engine/ROPS harness (S1) key switch and (X1) engine/ROPS harness
connector (ROPS side). connector.

6. Wire 501 yel at terminal C2 on Battery voltage. Test (X1) engine/ROPS harness connector.
(X1) engine/ROPS harness Make sure wires are properly crimped in the
connector (engine side). terminals.

7. Wire 511 yel at terminal 30 on Battery voltage. Test wires 501 yel and 511 yel between (K6)
(K6) high flow relay. high flow relay and (X1) engine/ROPS harness
connector.

11/22/00 4 - 87
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

Test Conditions:
• Hold the high flow switch in the ON position.
• Key switch in RUN position.

Test/Check Point Normal If Not Normal

8. Wire 811 pnk at terminal 3 on Battery voltage. Replace (S8) high flow switch.
(S8) high flow switch.
High flow switch
indicator light is on.

9. Wire 811 pnk at terminal A4 on Battery voltage. Test wire 811 pnk between (S8) high flow
(X1) engine/ROPS harness switch and (X1) engine/ROPS harness
connector (ROPS side). connector.

10. Wire 811 pnk at terminal A4 Battery voltage. Test (X1) engine/ROPS harness connector.
on (X1) engine/ROPS harness Make sure wires are properly crimped in the
connector (engine side). terminals.

11. Wire 811 pnk at terminal 86 on Battery voltage. Test wire 811 pnk between (K6) high flow relay
(K6) high flow relay. and (X1) engine/ROPS harness connector.

Test Conditions:
• Release the high flow switch to the RUN position.
• Key switch in RUN position.

Test/Check Point Normal If Not Normal

12. Wire 813 dk grn at terminal 87 Battery voltage. Test ground circuit wire 119 blk from (K6) high
on (K6) high flow relay. flow relay to ground. If ground circuit is good,
replace relay.

13. Wire 812 dk grn at terminal A5 Battery voltage. Test wires 812 dk grn and 813 dk grn between
on (X1) engine/ROPS harness (X1) engine/ROPS harness connector and (K6)
connector (engine side). high flow relay.

14. Wire 812 dk grn at terminal A5 Battery voltage. Test (X1) engine/ROPS harness connector and
on (X1) engine/ROPS harness make sure wires are properly crimped in the
connector (ROPS side). terminals.

15. Wire 812 dk grn at terminal 2B Battery voltage. Test wire 812 dk grn between (X1) engine/
on (S8) high flow switch. ROPS harness connector and (S8) high flow
switch.

16. Wire 811 pnk at terminal 3 on Battery voltage. Replace (S8) high flow switch.
(S8) high flow switch.
17. Wire 815 dk grn at (Y5) high Battery voltage. If voltage is not present, test wires 815 dk grn
flow valve solenoid. and 813 dk grn between (Y5) high flow valve
Valve is energized. (Test
solenoid and (K6) high flow relay.
by holding a metal
screwdriver next to it. If If voltage is present and valve is not energized,
energized, the test ground circuit wire 109 blk from (Y5) high
screwdriver will be flow valve solenoid to ground. If ground circuit is
pulled toward it.) good, replace valve.

4 - 88 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

Test Conditions:
• Key switch in OFF position.
• Disconnect (V1) high flow valve diode.
• Test meter set to read continuity.
• Meter positive (+) lead connected to (V1) high flow
valve diode where wire 814 dk grn connects.
• Meter negative (–) lead connected to (V1) high flow
valve diode where wire 117 blk connects.

Test/Check Point Normal If Not Normal

18. (V1) high flow valve diode. Continuity or no Replace (V1) high flow valve diode.
continuity.

Test Conditions:
• Reverse the test meter leads.

Test/Check Point Normal If Not Normal

19. (V1) high flow valve diode. Opposite of step 18. Replace (V1) high flow valve diode.

11/22/00 4 - 89
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

HIGH FLOW CIRCUIT TEST POINTS

S1
Key Switch 3

500 Yel/Red
S8
High Flow Switch 2
1

4 502 Yel

9
812 Dk Grn 5
15
501 Yel
142 Blk 811 Pnk
8 10 X1
16 Engine/ROPS
Harness Connector
116 Blk
6
14
13
K6
High Flow 11
Relay 812 Dk Grn
V1 811 Pnk
19
18 High Flow 501 Yel
Valve Diode
7
511 Yel

814 Dk Grn
Y5 119 Blk 116 Blk
High Flow 12
Valve Solenoid 117 Blk
813 Dk Grn 4
100 Blk

101 Blk G2
815 Dk Grn Alternator

109 Blk

17

KV15188

4 - 90 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

LIGHTS CIRCUIT OPERATION


Replace this page with color page, filename—
4m_elec1C.fm, page 1 of 2.

11/22/00 4 - 91
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

LIGHTS CIRCUIT SCHEMATIC


Replace this page with color page, filename—
4m_elec1C.fm, page 2 of 2.

4 - 92 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

LIGHTS CIRCUIT DIAGNOSIS


Test Conditions:
• Key switch in RUN or ACCESSORY position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.
Test/Check Point Normal If Not Normal
1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.
2. Wire 550 yel/wht at terminal 4 on (S1) Battery voltage. Replace (S1) key switch.
key switch.

Test Conditions:
• Key switch in ACCESSORIES position.
3. Wire 550 yel/wht at terminal 4 on (S1) Battery voltage. Replace (S1) key switch.
key switch.
4. Wire 550 yel/wht at terminal C1 on (X1) Battery voltage. Test wire 550 yel/wht between (S1) key switch
engine/ROPS harness connector (ROPS and (X1) engine/ROPS harness connector.
side).
5. Wire 550 yel/wht at terminal C1 on (X1) Battery voltage. Test connector (X1) engine/ROPS harness
engine/ROPS harness connector (engine connector and make sure wires are properly
side). crimped in the terminals.
6. Wire 550 yel/wht at terminal 86 on (K4) Battery voltage. Test wire 550 yel/wht between (K4) accessory
accessory relay. relay and (X1) engine/ROPS harness
connector.
7. Terminal 30 on (K4) accessory relay. Battery voltage. Check wire 445 yel to (F1) key switch fuse.
8. Wire 450 yel/wht at terminal 87 on (K4) Battery voltage. Test ground circuit wire 110 blk from (K4)
accessory relay. accessory relay to ground. If ground circuit is
good, replace relay.
9. Wire 451 yel/wht at terminal B2 on (X1) Battery voltage. Test wires 450 yel/wht and 451 yel/wht between
engine/ROPS harness connector (engine (X1) engine/ROPS harness connector and (K4)
side). accessory relay.
10. Wire 451 yel/wht at terminal B2 on (X1) Battery voltage. Test connector (X1) engine/ROPS harness
engine/ROPS harness connector (ROPS connector. Make sure wires are properly
side). crimped in the terminals.
11. Wire 451 yel/wht and 453 yel/wht at Battery voltage. Test wire 451 yel/wht between (X1) engine/
(X13) 12-volt accessory connector. ROPS harness connector and (X13) 12-volt
accessory connector.
12. Wire 453 yel/wht at terminal C on (X99) Battery voltage. Test wire 453 yel/wht between (X99) Interlock
interlock connector. connector and (X13) 12-volt accessory
connector.
13. Wire 450 yel/red at terminal 5B on (S6) Battery voltage. If voltage is not present, test wire 450 yel/red
work lights switch. between (X99) interlock connector and (S6)
Work lights
work lights switch.
switch back
If voltage is present and back lighting is not on,
lighting is on.
check 103 blk ground. If good, replace switch.
14. Wire 452 yel at terminal 2B on (S6) Battery voltage. Test wire 452 yel/red between terminals 2B and
work lights switch. 5B on (S6) work lights switch.

11/22/00 4 - 93
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

Test Conditions:
• Work lights switch in FRONT WORK/TAIL LIGHT
(middle) position.
• Key switch in ACCESSORY position.

Test/Check Point Normal If Not Normal

15. Wire 473 brn at terminal 3 on Battery voltage. Replace (S6) work lights switch.
(S6) work lights switch. If indicator light is not on, check ground 103 blk.
Work lights switch
If good, replace switch.
indicator is on.

Test Conditions:
• Work lights switch in FRONT/REAR WORK/TAIL
LIGHTS (up) position.
• Key switch in ACCESSORY position.

Test/Check Point Normal If Not Normal

16. Wire 473 brn at terminal 3 on Battery voltage. Replace (S6) work lights switch.
(S6) work lights switch. If indicator light is not on, check ground 103 blk.
Work lights switch
If good, replace switch.
indicator is on.

17. Wire 475 brn/wht at terminal 6 Battery voltage. Replace (S6) work lights switch.
on (S6) work lights switch. If indicator light is not on, check ground 103 blk.
If good, replace switch.

Test Conditions:
• Remove sockets from (E1) left front work light and
(E2) right front work light, then remove bulbs from
sockets.
• Test meter set to read DC voltage.
• Key switch in ACCESSORY position.
• Work lights switch in FRONT WORK/TAIL LIGHTS
(middle) position.

Test/Check Point Normal If Not Normal

18. Center terminal of bulb socket Battery voltage. Check for loose or corroded connections
on (E1) left front work light. between harness connector and socket.
Test wires 470 brn and 473 brn between (E1)
left front work light and (S6) work lights switch.

19. Center terminal bulb socket on Battery voltage. Check for loose or corroded connections
(E2) right front work light. between harness connector and socket.
Test wires 471 brn and 473 brn between (E2)
right front work light and (S6) work lights switch.

4 - 94 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

Test Conditions:
• Key switch in OFF position.
• Work lights switch in OFF (down) position.
• Test meter set to read resistance (ohms).

Test/Check Point Normal If Not Normal

20. Outer contact of bulb socket Maximum 0.1 ohms. Check for loose or corroded connections
on (E1) left front work light. between harness connector and socket.
Test wire 101 blk from (E1) left front work light
to ground.

21. Outer contact of bulb socket Maximum 0.1 ohms. Check for loose or corroded connections
on (E2) right front work light. between harness connector and socket.
est wire 102 blk from (E1) left front work light to
ground.

Test Conditions:
• Replace light bulb and socket previously removed.
• Test meter set to read DC voltage.
• Key switch in RUN or ACCESSORY position.
• Work lights switch in FRONT WORK/TAIL LIGHTS
(middle) position.
• Remove sockets from (E3) left tail light and (E4)
right tail light. Remove bulbs from sockets.

Test/Check Point Normal If Not Normal

22. Center terminal of bulb socket Battery voltage. Check for loose or corroded connections
on (E3) left tail light. between harness connector and socket.
Test wires 477 brn and 473 brn between (E3)
left tail light and (S6) work light switch.

23. Center terminal of bulb socket Battery voltage. Check for loose or corroded connections
on (E4) right tail light. between harness connector and socket.
Test wires 476 brn and 473 brn between (E4)
right tail light and (S6) work light switch.

Test Conditions:
• Key switch in OFF position.
• Work lights switch in OFF (down) position.
• Test meter set to read resistance (ohms).

Test/Check Point Normal If Not Normal

24. Outer contact of bulb socket Maximum 0.1 ohms. Check for loose or corroded connections
on (E3) left tail light. between harness connector and socket.
Test wire 107 blk from (E3) left tail light to
ground.

25. Outer contact of bulb socket Maximum 0.1 ohms. Check for loose or corroded connections
on (E4) right tail light. between harness connector and socket.
Test wire 106 blk from (E4) right tail light to
ground.

11/22/00 4 - 95
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

Test Conditions:
• Replace light bulbs and sockets previously
removed.
• Test meter set to read DC voltage.
• Key switch in RUN or ACCESSORY position.
• Work lights switch in FRONT/REAR WORK/TAIL
LIGHTS (up) position.
• Remove socket from (E5) rear work light and then
remove bulb from socket.

Test/Check Point Normal If Not Normal

26. Center terminal of bulb socket Battery voltage. Check for loose or corroded connections
on (E5) rear work light. between harness connector and socket.
Test wire 475 brn/wht between (E5) rear work
light and (S6) work lights switch.

Test Conditions:
• Key switch in OFF position.
• Work lights switch in OFF (down) position.
• Test meter set to read resistance (ohms).

Test/Check Point Normal If Not Normal

27. Outer contact of bulb socket Maximum 0.1 ohms. Check for loose or corroded connections
on (E5) rear work light. between harness connector and socket.
Test wire 105 blk from (E5) rear work light to
ground.

4 - 96 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

LIGHT CIRCUIT TEST POINTS

E1
Left Front
S6 Work Light
Work Lights Switch 20 18

E2
Right Front
Work Light
13
470 Brn

103 Blk 101 Blk


21 19

452 Yel

17 471 Brn
X13
Accessory 12 Volt
Connector 102 Blk
14
15 16
450 Yel/Red 3
473 Brn S1 2
24 22 12 X99 Key Switch
Interlock
11 Connector
107 Blk 453 Yel/Wht
104 Blk 1
477 Brn 475 451 Yel/Wht
124 Blk
Brn/Wht
10 4
105 Blk 103 Blk 550 Yel/Wht

116 Blk
9
X12
E3 26 27 Accessory
Left Tail Ground Connector X1 5
Light 106 Blk Engine/ROPS
476 Brn
Harness Connector
E5 23 25 K4 6
Rear Work Accessory
Light Relay

116 Blk
E4 450
Yel/Wht 451 Yel/Wht
Right Tail
Light
550 Yel/Wht
101 Blk 7

110 Blk
8

100 Blk
G2 445 Yel
Alternator

To F1
Accessories
Fuse
KV18053

11/22/00 4 - 97
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

DUAL FLASHER CIRCUIT (OPTIONAL) OPERATION

DUAL FLASHER (OPTIONAL) CIRCUIT

Function:
To provide flashing lights to warn others of a potential
hazard.

Operating Conditions:
The key switch (S1) must be in the RUN or
ACCESSORY position and the dual flasher switch (S7)
must be in the ON position.

Theory of Operation:
When the key switch (S1) is in the RUN or
ACCESSORY position, the accessory relay (K4) is
energized, and current flows from the accessories fuse
(F1) through the accessory relay contacts to the
common terminal of the dual flasher switch (S7). The
back lighting in the lights switch is connected to the
common terminal and is grounded by wire 128 blk. The
back lighting is on regardless of the position of the dual
flasher lights switch.
When the dual flasher switch is in the OFF position, no
current flows from pin 3, the dual flasher relay (K5)
remains off and all dual flasher lights remain off.
When the dual flasher switch is in the ON position,
current flows from pin 3 through wire 480 yel/red to the
dual flasher relay and all hazard lights flash on and off.

4 - 98 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

DUAL FLASHER CIRCUIT SCHEMATIC

To K4
Accessory Relay
451/453 Yel/Wht A - Off
X13
S7 C - On
460 Dual A,C
Yel/Wht Flasher Back
Switch Light
3
2B
480
Yel/Red

Indicator
Light
K5
Dual
Flasher
Relay

126 Blk
128
Blk
482
Yel/Blk
481
Yel/Blk

127
Blk

E6 E7
Left Right
Hazard Hazard
Light Light

129 Blk

124 Blk

X12

Power from Accessory Relay

Dual Flasher Circuit

Ground Circuit

KV31068

11/22/00 4 - 99
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

DUAL FLASHER CIRCUIT DIAGNOSIS


Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.

Test/Check Point Normal If Not Normal

1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.

2. Wire 550 yel/wht at terminal 4 Battery voltage. Replace (S1) key switch.
on (S1) key switch.

Test Conditions:
• Key switch in ACCESSORY position.

Test/Check Point Normal If Not Normal

3. Wire 550 yel/wht at terminal 4 Battery voltage. Replace (S1) key switch.
on (S1) key switch.

4. Wire 550 yel/wht at terminal C1 Battery voltage. Test wire 550 yel/wht between (S1) key switch
on (X1) engine/ROPS harness and (X1) engine/ROPS harness connector.
connector (ROPS side).

5. Wire 550 yel/wht at terminal C1 Battery voltage. Test (X1) engine/ROPS harness connector.
on (X1) engine/ROPS harness Make sure wires are properly crimped in the
connector (engine side). terminals.

6. Wire 550 yel/wht at terminal 86 Battery voltage. Test wire 550 yel/wht between (K4) accessory
on (K4) accessory relay. relay and (X1) engine/ROPS harness
connector.

7. Wire 445 yel at terminal 30 on Battery voltage. Test wire 445 yel between (K4) accessory relay
(K4) accessory relay. and (F1) accessories fuse. Check fuse.

8. Wire 450 yel/wht at terminal 87 Battery voltage. Test ground circuit wire 110 blk from (K4)
on (K4) accessory relay. accessory relay to ground. If ground circuit is
good, replace relay.

9. Wire 451 yel/wht at terminal B2 Battery voltage. Test wires 451 yel/wht and 450 yel/wht between
on (X1) engine/ROPS harness (X1) engine/ROPS harness connector and (K4)
connector (engine side). accessory relay.

10. Wire 451 yel/wht at terminal Battery voltage. Test (X1) engine/ROPS harness connector.
B2 on (X1) engine/ROPS harness Make sure wires are properly crimped in the
connector (ROPS side). terminals.

11. Wire 451 yel/wht on (X13) Battery voltage. Test wire 451 yel/wht between (X13) 12-volt
12-volt accessory connector. accessory connector and (X1) engine/ROPS
harness connector.

12. Wire 460 yel/wht on (X13) Battery voltage. Test (X13) 12-volt accessory connector. Make
12-volt accessory connector. sure wires are properly crimped in the
terminals.

4 - 100 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

Test/Check Point Normal If Not Normal

13. Wire 460 yel/wht at terminal Battery voltage. If voltage is not present, test wire 460 yel/wht
2B on (S7) dual flasher switch. between (X13) 12-volt accessory connector
Dual flasher switch back and (S7) dual flasher switch.
lighting is on. If voltage is present and back lighting is not on,
check wire 128 blk to ground. If good, replace
switch.

Test Conditions:
• Key switch in ACCESSORY position
• Dual flasher switch in ON position.

Test/Check Point Normal If Not Normal

14. Wire 480 yel/red at terminal 3 Battery voltage. Replace (S7) dual flasher switch.
on (S7) dual flasher switch.
Dual flash switch
indicator light is on.

15. Wire 480 yel/red on (K5) dual Battery voltage. Test wire 480 yel/red between (S7) dual flasher
flasher relay. switch and (K5) dual flasher relay.

16. Wire 481 yel/blk and 482 yel/ Battery voltage cycling Test wire 126 blk from (K5) dual flasher relay to
blk at (K5) dual flasher relay. ON and OFF. ground. If ground is good, replace (K5) dual
flasher relay.

Test Conditions:
• Remove sockets from (E6) left hazard light and (E7)
right hazard light, then remove bulbs from sockets.
• Test meter set to read DC voltage.
• Key switch in ACCESSORY position.
• Dual flasher switch in ON position.

Test/Check Point Normal If Not Normal

17. Center terminal of bulb socket Battery voltage cycling Check for loose or corroded connections
on (E6) left hazard light. ON and OFF. between harness connector and socket.

Test wire 481 yel/blk between (K5) dual flasher


relay and (E6) left hazard light.

18. Center terminal of bulb socket Battery voltage cycling Check for loose or corroded connections
on (E7) right hazard light. ON and OFF. between harness connector and socket.

Test wire 482 yel/blk between (K5) dual flasher


relay and (E7) right hazard light.

11/22/00 4 - 101
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

Test Conditions:
• Key switch in OFF position.
• Dual flasher switch in OFF position.
• Test meter set to read resistance (ohms).

Test/Check Point Normal If Not Normal

19. Outer contact of bulb socket Maximum 0.1 ohms. Check for loose or corroded connections
on (E6) left hazard light. between harness connector and socket.

Test wire 127 blk from (E6) left hazard light to


ground.

20. Outer contact of bulb socket Maximum 0.1 ohms. Check for loose or corroded connections
on (E7) right hazard light. between harness connector and socket.

Test wire 129 blk from (E7) right hazard light to


ground.

4 - 102 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

DUAL FLASHER CIRCUIT TEST POINTS

S7
Dual Flasher Switch

13
14

124 Blk
K5
Dual Flasher
Relay 480 Yel/Red
15
126
Blk 126 Blk
128 Blk 3
S1
460 Yel/Wht Key Switch 2

16
127 Blk
481
19 Yel/Blk 129 Blk 12
128 Blk
17 11 1
482
Yel/Blk 453 124 Blk
To
20 X13 Yel/Wht 550 Yel/Wht
12-Volt
X99
Accessory 451
E6 Connector Yel/Wht
Left Hazard 18 4
Light
10
116 Blk

5
X1
E7 Engine/ROPS
Right Hazard Harness Connector
Light 550 Yel/Wht

116 Blk 9 451 Yel/Wht


K4
Accessory
Relay 7 6

450 Yel/Wht
101 Blk

445 Yel
110 Blk
100 Blk
G2
8
Alternator
From F1
Accessories
Fuse

KV18054

11/22/00 4 - 103
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

CAB HEATER/DEFROSTER CIRCUIT (OPTIONAL) OPERATION

Function: 011 org and 012 red will change, depending on


To heat cab air for operator comfort. whether the cab heater temperature control valve (Y7)
is opening or closing. When the cab heater
temperature control valve (Y7) is opening, 012 red is
Operating Conditions: positive. When the valve is closing, 011 org is positive.
A potentiometer within the cab heater temperature
The key switch (S1) must be in the RUN or control valve (Y7) feeds current back through 009 grn
ACCESSORY position and the thermostat must be set into the heater control circuit board (A1) and causes
to a warm setting. The blower switch must be set to the cab heater temperature control valve (Y7) to stop
LOW or HIGH speed. moving when it has rotated to the appropriate position.

Theory of Operation:
When the key switch (S1) is in the RUN or
ACCESSORY position, the accessory relay (K4) is
energized, and the current flows from the 25A
accessories fuse (F1), through the accessory relay
contacts to terminal 86 of the cab heater relay (K7),
energizing the cab heater relay (K7). Current flows
from the battery terminal of the starting motor (M1),
through the 15A in-line cab heater fuse (F5) (located
near the hydraulic filter), to terminal 30, through the
closed contacts of the cab heater relay (K7) to terminal
87. Current is provided by the cab heater relay (K7)
terminal 87 to the blower switch (S9) and cab heater
heater control circuit board (A1). Back lighting in the
blower switch (S9) is connected to the common
terminal and is grounded by wire 000B blk. The back
lighting is on regardless of the position of the blower
switch (S9).
When the blower switch (S9) is in the LOW speed
position, current flows through 004 yel wire to the
resistor on the blower (M3), through the resistor and to
the blower (M3) motor. When the blower switch (S9) is
in the HIGH speed position, current flows through 005
org, directly to the blower (M3) motor, bypassing the
resistor. When the blower switch (S9) is in the OFF
position, no current flows to the blower motor (M3). The
blower pulls air through the recirculating air vents and
the air inlet filter of the heater housing, through the
heater core, and blows into the ductwork within the cab.
The recirculating vents provide air to the heater should
the air inlet filter become plugged with debris. The
heater core is a heat exchanger that uses the heat from
the engine coolant to heat the air that passes through
it.
The cab heater thermostat (R3), mounted in the cab,
controls the current flow of the heater control circuit
board (A1). The heater control circuit board (A1)
controls the position of the cab heater control valve
(Y7). The position of the cab heater temperature
control valve (Y7) controls the amount of heated engine
coolant that passes through the heater core. When the
cab heater thermostat (R3) is set to a particular
position (i.e. 1/2), current flows from 001 red into the
heater control circuit board (A1). Current flows from the
heater control circuit board (A1) through 011 org and
012 red to the cab heater temperature control valve
(Y7) causing the valve to open or close. The polarity of

4 - 104 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

CAB HEATER/DEFROSTER CIRCUIT SCHEMATIC

To K4 Accessory Relay
454 Yel

002 Red

A Off
010A Wht
B Low 008 Blu
013A Yel
S9 A, B, C C High
Blower X26
Back
Switch 9
(20)
Light
R3 X26
2B 3 Cab (17)
7 6 Indicator Heater Thermostat X26
Light (18)
005 Org 001B Red
003 Yel F5
87a
K7 Cab
X27 86 87 008 Blu
Cab Heater Heater
(C) Fuse
000B Blk 85 30 Relay
013A Yel
001A X25 X27 010A Wht
Red (A) (E)
001 Red
012 Red
004 Yel 004 Yel
011 Org
X27
X25 (B)
(B) X27
(D) 001C Red
000B Blk
005 Org
000A Blk
A B C D E F G H
000A Blk M A1
Heater Control
M3 Circuit Board 010B Wht
To Accessory Ground Blower
000B Blk 009 Grn 013B Yel
6 5 4 3 2 1

Y7
Cab Heater
From Battery Terminal of Starting Motor Temperature Control Valve

001C Red 001C Red

Heater Main Power


Power from Accessory Relay

Thermostat Circuit
Control Circuit

Blower Circuit
Ground Circuit

KV31084

11/22/00 4 - 105
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

CAB HEATER/DEFROSTER CIRCUIT DIAGNOSIS

NOTE: Proper cab heater/defroster operation is


dependent on engine temperature and coolant
level. Verify that both are correct.

Test Conditions:
• Fully charged battery.
• Key switch in ACC position.
• Digital test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.

Test/Check Point Normal If Not Normal

1. Wire 003 yel on terminal 86 of Battery voltage. Test 003 yel wire between (K4) accessory
(K7) cab heater relay. relay and (K7) cab heater relay.

2. Wire 001C red on starter side Battery voltage. Test 001C red between (M1) starting motor
of (F5) cab heater fuse. and (F5) cab heater fuse.

3. Wire 001B red on (K7) cab Battery voltage. Replace (F5) cab heater fuse.
heater relay side of (F5) cab
heater fuse.

4. Wire 001B at terminal 87 on Battery voltage. Test 001B red between (F5) cab heater fuse
(K7) cab heater relay. and (K7) cab heater relay.

5. Wire 001A red at terminal 30 Battery voltage. Test ground circuit wire 000B blk from (K7) cab
on (K7) cab heater relay. heater relay to ground. If good, replace relay.

6. Wire 001A red at terminal 2B Battery voltage. Test Wire 001A red from (K7) cab heater relay
on (S9) blower switch. to (S9) blower switch including terminals in
X25 cab heater engine harness-to-ROPS
harness connector.

Test Conditions:
• Blower switch in HIGH position.

Test/Check Point Normal If Not Normal

7. Wire 005 org at terminal 6 on Battery voltage. Replace (S9) blower switch.
(S9) blower switch.

8. Wire 005 org on (M3) blower. Battery voltage. Test wire 005 org from (S9) blower switch to
Blower operating at high (M3) blower including terminals in X27 cab
speed. heater ROPS harness-to-heater harness main
connector.
If blower is not operating, test ground circuit
wire 000A from blower to ground. If good,
replace blower.

4 - 106 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

Test Conditions:
• Blower switch in LOW position.

Test/Check Point Normal If Not Normal

9. Wire 004 yel at terminal 3 on Battery voltage. Replace (S9) blower switch.
(S9) blower switch.

10. Wire 004 yel on (M3) blower. Battery voltage. Test wire 004 yel from (S9) blower switch to
Blower operating at low (M3) blower including terminals in X27 cab
speed. heater ROPS harness-to-heater harness main
connector.
If blower is not operating, test 000A blk ground
circuit from blower to ground. If good, replace
blower.

Test Conditions:
• Blower Switch in OFF position.
• Negative (–) test lead at terminal A (blk) on (A1)
heater control circuit board.
• Positive (+) test lead on numbered test point.

Test/Check Point Normal If Not Normal

11. Wire 001 red at terminal D on Battery voltage. Test wire 001 red and 001A red from (A1)
(A1) heater control circuit board. heater control circuit board to terminal 87 on
(K7) cab heater relay including terminals in
connectors X25 and X27.

12. Wire 013B yel at terminal C Minimum 8.2 V. Test ground wire 000B blk from terminal A on
on (A1) heater control circuit (A1) heater control circuit board to ground. If
board. good replace heater control circuit board.

13. Wire 013B yel at terminal 2 Same reading as step 12. Test wire 013B yel from (A1) heater control
on (Y7) cab heater temperature circuit board to (Y7) cab heater temperature
control valve. control valve.

Test Conditions:
• Negative (–) test lead at wire 010A wht on (R3) cab
heater thermostat.
• Positive (+) test lead on numbered test point.

Test/Check Point Normal If Not Normal

14. Wire 013A yel at (R3) cab Minimum 8.2 V. Test 013A yel from (R3) cab heater thermostat
heater thermostat connector. to (A1) heater control circuit board. If good,
replace (A1) heater control circuit board.

15. Wire 002 red at (R3) cab Battery voltage. Test wire 002 red from (R3) cab heater
heater thermostat connector. thermostat to (S9) blower switch. If good,
replace (S9) blower switch.

16. Wire 008 blu at (R3) cab Reading should smoothly Replace (R3) cab heater thermostat.
heater thermostat connector. decrease from 8.5 V to
Slowly rotate thermostat from 0 V (approx).
HOTTEST to COLDEST setting.

11/22/00 4 - 107
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

Test Conditions:
• Negative (–) test lead at terminal B (wht) on (A1)
heater control circuit board.
• Positive (+) test lead on numbered test point.

Test/Check Point Normal If Not Normal

17. Wire 008 blu at terminal H on Same reading as step 16. Test wire 008 blu from (R3) cab heater
(A1) heater control circuit board. thermostat to (A1) heater control circuit board.

Test Conditions:
• Cab thermostat set to medium temperature.
• Positive (+) test lead at terminal 6 (red) and
negative (–) lead at terminal 4 (org) on the cab
heater temperature control valve.

Test/Check Point Normal If Not Normal

18. Set (R3) cab heater Minus (–) 10.5 V Replace (A1) heater control circuit board.
thermostat to COLDEST setting (approximately)
and observe meter.
19. Set (R3) cab heater Plus (+) 10.5 V Replace (A1) heater control circuit board.
thermostat to HOTTEST setting (approximately)
and observe meter.

20. Rotate (R3) cab heater Minus (–) 10.5 V (approx.) Go to step 24.
thermostat from HOTTEST to 1/4 until (Y7) cab heater
COLDEST setting and observe temperature control valve
meter. reaches position, then to
0 V (approx).

21. Rotate (R3) cab heater Plus (+) 10.5 V (approx.) Go to step 24.
thermostat to 3/4 HOTTEST until (Y7) cab heater
setting and observe meter. temperature control valve
reaches position, then to
0 V (approx).

Test Conditions:
• Negative (–) test lead at terminal A (blk) on (A1)
heater control circuit board.
• Positive (+) test lead on numbered test point.

Test/Check Point Normal If Not Normal

22. Wire 009 grn at terminal 1 on Reading should smoothly Replace (Y7) cab heater temperature control
(Y7) cab heater temperature decrease to 0.5 V valve.
control valve. Rotate (R3) cab (approx). Listen for (Y7)
heater thermostat to COLDEST cab heater temperature
setting. control valve motor
running.

23. Wire 009 grn at terminal 1 on Reading should smoothly Replace (Y7) cab heater temperature control
(Y7) cab heater temperature increase to 8 V (approx). valve.
control valve. Rotate (R3) cab Listen for (Y7) cab heater
heater thermostat to HOTTEST temperature control valve
setting. motor running.
KV31058

4 - 108 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

Test Conditions:
• Failure of steps 20 or 21.
• Jumper wire connected to 009 grn at terminal G on
(A1) heater control circuit board.

Test/Check Point Normal If Not Normal

24. Connect jumper first to 013B Listen. (Y7) Cab heater temperature If valve motor runs, replace (Y7) cab
yel (terminal C), then to 010B wht control valve motor should run. heater temperature control valve
(terminal B) on (A1) heater assy.
control circuit board. If valve motor does not run, replace
(A1) heater control circuit board.
Repeat steps 18—23 after repair.

11/22/00 4 - 109
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

CAB HEATER/DEFROSTER CIRCUIT TEST POINTS

10 18 19 20 21
8

M3
Blower 45
6 22
1

Y7
32 23
Cab Heater
Temperature
Control Valve
13

12 11 17
011 Org
012 Red
009 Grn 013B Yel
H 010B Wht
A1 DE
FG
C
Heater Control A
B

Circuit Board 24

005 Org 008 Blu


000B Blk 010A Wht
013A Yel
X26
004 Yel
Cab Heater ROPS
Harness-to-Heater
Harness Thermostat
Connector
001 Red 008 Blu
000A Blk
013A Yel
010A Wht R3
S9 Cab
16
Blower Switch 002 Red Thermostat

7 15
6

9
14
004 Yel
X27
A
Cab Heater ROPS F B
E C
Harness-to-Heater D
005 Org
Harness Main 001A Red
Connector
000B Blk

X25 000A Blk


Cab Heater Engine
Harness-to-ROPS 001A Red
Harness Connector
K7 1
Cab From K4
Heater Relay Accessory Relay
B
003 Yel A

001A Red
F5
Cab Heater Fuse
001B Red 15 A
5
4 M1
Starting Motor
001C Red
000B Blk
000A Blk 3 2 KV31046

4 - 110 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

BACKUP ALARM CIRCUIT (OPTIONAL) OPERATION

Function:
To provide an audible warning when the machine is
operating in reverse.

Operating Conditions:
The key switch (S1) must be in the RUN or
ACCESSORY position and both steering control levers
must be in reverse.

Theory of Operation:
Power is supplied by the closed contacts of the
accessory relay to the accessory connector (X11).
When the steering control levers are both placed in
REVERSE position, linkages move the corresponding
hydrostatic pump control levers, and close the contacts
in both backup alarm switches (S10) and (S11). With
both switches closed, current flows from X11 through
the 10 Amp backup alarm fuse (F6) (located near the
accessory connector) through backup alarm switch
(rear) (S10), through backup alarm switch (front) (S11),
and to the positive (+) terminal on the warning horn.
The negative terminal of the warning horn is connected
to ground through the accessory ground connector
(X22). The backup alarm (H2) is mounted on the cover
just behind the cab rear window.
Each switch is mounted to a centering plate bracket;
one on the front pump and one on the rear pump.
When the hydrostatic control lever is moved into the
REVERSE position, the plunger of the switch is
depressed and the contacts are closed.
The switches are connected in series, meaning that
both switches must be closed for current to pass. When
both hydrostatic control levers are in the REVERSE
position, current passes through both switches and to
the warning horn, causing the horn to sound. Circuitry
within the horn causes the sound to be interrupted in a
BEEP BEEP manner.

11/22/00 4 - 111
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

BACKUP ALARM CIRCUIT SCHEMATIC (OPTIONAL)

458 Yel
H2
Backup Alarm

101 Blk

S11
Backup Alarm
Switch (Front)
457 Yel

S10
Backup Alarm
Switch (Rear)
450 Yel

F6
X11 Backup
12-Volt Alarm Fuse
Accessory 10 Amp
(Frame)
454 Yel 455 Yel

103 Blk 101 Blk

X22 Accessory
Ground Connector (Frame)

Power from Accessory Relay


Switched Power
Ground Circuit

KV31057

4 - 112 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

BACKUP ALARM CIRCUIT DIAGNOSIS


Test Conditions:
• Key switch in ACC position.
• Digital test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.

Test/Check Point Normal If Not Normal

1. Wire 455 yel on X11 side of Battery voltage. Check accessory relay circuit.
(F6) backup alarm fuse.
2. Wire 450 yel on reverse horn Battery voltage. Replace (F6) backup alarm fuse.
side of (F6) backup alarm fuse.

3. Wire 450 yel at (S10) backup Battery voltage. Test wire 450 yel between (F6) backup alarm
alarm switch (rear). fuse and (S10) backup alarm switch (rear).

Test Conditions:
• Depress plunger on (S10) backup alarm switch
(rear).

Test/Check Point Normal If Not Normal

4. Wire 457 yel at (S10) backup Battery voltage. Replace (S10) backup alarm switch (rear).
alarm switch (rear).

5. Wire 457 yel on (S11) backup Battery voltage. Test wire 457 yel between (S10) backup alarm
alarm switch (front). switch (rear) and (S11) backup alarm switch
(front). If good, replace (S10) backup alarm
switch (rear).

Test Conditions:
• Depress plunger on (S11) backup alarm switch
(front) and on (S10) backup alarm switch (rear).

Test/Check Point Normal If Not Normal

6. Wire 458 yel on (S11) backup Battery voltage. Replace (S11) backup alarm switch (front).
alarm switch (front).

7. Wire 458 yel on Backup Alarm Battery voltage, Backup Test 458 yel between (S11) backup alarm
(H2). Alarm sounding. switch (front) and (H1) backup alarm. If alarm
is not sounding, test wire 101 blk from (H1)
backup alarm to ground. If good, replace (H1)
backup alarm.

11/22/00 4 - 113
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

BACKUP ALARM CIRCUIT TEST POINTS

H2
7 Backup Alarm

458
Yel

6 S11
101 Blk Backup Alarm
Switch (Front)

5
457
X22 4 Yel
S10
Accessory
Backup Alarm
Ground Connector
Switch (Rear)
2
3
1
450
116 Blk Yel
455 F6
K4 Yel Backup Alarm Fuse
Accessory
Relay 450
Yel/Wht X11
101 Blk Accessory
110 Blk
12 V Connector
454
Yel

100 Blk

From S1
Key Switch

From F1
G2 Alternator Accessories Fuse

4 - 114 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

WIPER/WASHER CIRCUIT (OPTIONAL) OPERATION

Function:
To provide a means of cleaning the windshield of cab
door. It incorporates both wiper and wiper/washer
functions.

Operating Conditions:
The key switch (S1) must be in the RUN or
ACCESSORY position and the wiper/washer switch
(S12) must be in the WIPER or WASHER position for
the wiper to operate. Wiper/washer switch (S12) must
be in the momentary WASHER position for the washer
to operate.

Theory of Operation:
Power is supplied by the closed contacts of the
accessory relay (K4), through wires 450, 451, and 453
yel/wht to terminal C of the interlock connector (X99).
Wire 460 yel connects from terminal C of the interlock
connector (X99) to terminal 5B of the wiper/washer
switch (S12). Wire 466 yel connects from terminal 5B
of the wiper/washer switch (S12) to terminal 5 on the
wiper motor (M4) to provide power for the self-parking
feature.
When wiper/washer switch (S12) is in the WIPER
(center) position, current flows through S12 from
terminal 5B to 2B, through wire 461 yel/wht to the ’run
terminal’ 6 on the wiper motor (M4). Current then flows
through the wiper motor (M4), through terminal 2, and
through wires 110 blk and 101 blk to the accessory
ground connector (X22) of the main ROPS harness.
When wiper/washer switch (S12) is turned OFF, power
continues to flow through wire 466 yel to ’park terminal’
5 on the wiper motor (M4), through the parking disk to
’park terminal’ 4, through wire 465 yel/red to terminal 1
of the wiper washer switch. Terminal 1 is internally
connected to terminal 2B, which is in turn connected
through wire 461 yel/wht to the ’run terminal’ 6 on the
wiper motor (M4). The parking disk is a rotating contact
with a gap in the contact surface. When the gap is
reached, current stops flowing and the wiper motor
(M4) stops.
The washer pump (M5) is activated by the momentary
WASHER (top) position of the wiper/washer switch
(S12). When the washer function is activated on wiper/
washer switch (S12), terminals 5B and 6 are connected
and current flows through wire 463 yel/blk to washer
pump (M5) terminal B. The ground circuit is provided
by wires 112 blk and 101 blk to the accessory ground
connector (X22) on the main ROPS harness. The
washer pump (M5) pushes fluid through a small hose
to the wiper arm until the wiper/washer switch (S12) is
released.

11/22/00 4 - 115
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

WIPER/WASHER CIRCUIT SCHEMATIC

A Off
S12 B Wiper
Wiper/Washer Back
C Washer
Swith Light
7 111 Blk
From K4 460 Yel 5B
AccessoryRelay 6 463 Yel/Blk
1 465 Yel/Red
2B
10

462
Yel
466 Yel Indicator
461 Light
Yel/Wht

463
Yel/Blk

M4
465 Yel/Red Wiper Motor
4
466 Yel 5 M
6
461 2
Yel/Wht

110
Blk

B
M5 W
Washer Pump
A

111
Blk 101
112 Blk
Blk
To X12
101 Blk
Accessory
Ground Connector

Power from Accessory Relay


Switched Power

Park Circuit

Washer Circuit
Ground Circuit

KV31057

4 - 116 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

WIPER/WASHER CIRCUIT DIAGNOSIS


Test Conditions:
• Key switch in ON or ACC position.
• Digital test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (-)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.

Test/Check Point Normal If Not Normal

1. Wire 460 yel at terminal C on Battery voltage. Check accessory relay circuit to
(X99) interlock connector. (X99) interlock connector.

2. Wire 460 yel at terminal 5B on Battery voltage. Test wire 460 yel.
(S12) wiper/washer switch.

3. Wire 466 yel at terminal 5 on Battery voltage. Test wire 466 yel from (S12) wiper/
(M4) wiper motor. washer switch to (M4) wiper motor.

Test Conditions:
• Turn (S12) wiper/washer switch (12) to WIPER
(center) position.

Test/Check Point Normal If Not Normal

4. Wire 461 yel/wht at terminal Battery voltage. Replace (S12) wiper/washer switch.
2B on (S12) wiper/washer switch.

5. Wire 461 yel/wht at terminal 6 Battery voltage. Test wire 461 yel/wht between (S12)
on (M4) wiper motor. Wiper motor should be operating. wiper/washer switch and (M4) wiper
motor. If good, Test wires 110 blk
and 101 blk to verify ground circuit.
If good, replace (M4) wiper motor.

11/22/00 4 - 117
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL

Test Conditions:
• Turn (S12) wiper/washer switch to the WASHER
(top) position.

Test/Check Point Normal If Not Normal

6. Wire 463 yel/blk at terminal 6 Battery voltage. Replace (S12) wiper/washer switch.
on (S12) wiper/washer switch.

7. Wire 463 yel/blk at terminal B Battery voltage. If no voltage is present, test wire
on washer pump. (M5) washer pump should be 463 yel/blk.
running. If voltage is present but (M5)
Fluid should be discharging at wiper. washer pump is not running, test
wires 112 blk and 101 blk to verify
ground circuit. If good, replace (M5)
washer pump.
If (M5) washer pump runs but no
fluid discharges at wiper:
• Verify that reservoir has fluid.
• Verify that hose and fittings are not
plugged or broken.
• If both are good, replace (M5)
washer pump.

Test Conditions:
• Turn (S12) wiper/washer switch to the OFF
position.

Test/Check Point Normal If Not Normal

8. Wire 465 yel/red at terminal 4 Battery voltage (while motor is If no voltage is present and motor
on (M4) wiper motor. operating). Motor should run until stops immediately, replace (M4)
wiper is in parked position. wiper motor.
If wiper parks in the wrong position, If voltage is present and wiper
adjust location of wiper arm on (M4) motor stops immediately, go to step
wiper motor shaft. 9.

9. Wire 465 yel/red at terminal 1 Battery voltage (while motor is Test wire 465 yel/red between (M4)
on (S12) wiper/washer switch. operating). Motor should run until wiper motor and (S12) wiper/
wiper is in parked position. washer switch. If good, go to step
10.

10. Wire 461 yel/wht at terminal Battery voltage (while motor is If no voltage is present, replace
2B on (S12) wiper/washer switch. operating). Motor should run until (S12) wiper/washer switch.
wiper is in parked position.

4 - 118 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS

WIPER/WASHER CIRCUIT TEST POINTS

M4
Wiper Motor

461 Yel/Wht
466 Yel
465 Yel/Red 8 3

S12
466 Yel
Wiper/Washer
Switch
9
465 Yel/Red
110 Blk
4 10
461 Yel/Wht X33
Door Switch
2 Harness Connector

111 Blk
6 466 Yel
463
Yel/Blk

112 Blk

460 Yel 463


472 Dk Grn Yel/Blk

470 Dk Grn
101 Blk

X99
Interlock Connector
1 7

M5
Washer
Pump

From K4
Accessory Relay

X12
Accessory Ground
Connector

11/22/00 4 - 119
TESTS AND ADJUSTMENTS ELECTRICAL

TESTS AND ADJUSTMENTS

BATTERY TEST

Reason:
To check condition of battery and determine battery
voltage.

Equipment:
• Hydrometer
• Voltmeter or JT05685 Battery Tester

Procedure:
1. Remove any attachments.
2. Park machine on level surface. Raise boom fully
and ENGAGE the boom lock.
3. Turn key OFF and ENGAGE park brake. M49596
4. Open engine rear cover and remove left engine side 11. Use a hydrometer to check for a minimum specific
panel. gravity of 1.225 with less than 50 point
5. Disconnect negative (–) and positive (+) cable variation in each cell:
clamps from battery. Remove battery hold-down
clamp.
6. Remove battery from machine. Results:
7. Clean battery terminals and case. • If all cells are less than 1.175, charge battery at 10
8. Inspect battery terminals and case for breakage or amp rate. (See CHARGE BATTERY in this
cracks. section.)
9. Check electrolyte level in each battery cell. Add • If all cells are less than 1.225 with less than 50
clean, distilled water as needed. If water was point variation, charge battery at 10 amp rate. (See
added, charge battery for 20 minutes at 10 amps. CHARGE BATTERY in this section.)
(See CHARGE BATTERY in this section.) • If cells are above 1.225 with less than 50 point
10. Remove surface charge by placing a small load on variation, load test battery. (See BATTERY LOAD
the battery for 15 seconds. TEST in this section.)
• If more than 50 point variation, replace battery.
12. Use a voltmeter or JT05685 Battery Tester to check
for a minimum battery voltage of 12.4 volts:
• If battery voltage is less than 12.4 VDC, charge
battery. (See CHARGE BATTERY in this section.)
• If voltage is above 12.4 VDC, test specific gravity.
(See step 9.)
13. Install battery.
14. Install left engine side panel and close engine
cover.

4 - 120 11/22/00
ELECTRICAL TESTS AND ADJUSTMENTS

CHARGE BATTERY

Reason: 10. Check if battery is accepting a 10 amp charge after


To increase battery charge after battery has been 10 minutes at boost setting:
discharged.
Results:
Equipment: • If battery WILL NOT accept 10 amp charge after 10
minutes at boost setting, replace battery.
• Battery charger (variable rate) (use according to
• If battery is accepting 10 amp charge after 10
manufacturer’s instructions).
minutes at boost setting, and battery did NOT need
water, go to steps 11 and 12.
Procedure: • If battery is accepting 10 amp charge after 10
minutes at boost setting, but battery DID need
water or all cells were BELOW 1.175, go to steps
NOTE: See BATTERY TEST in this section before 11and 12.
charging battery. 11. Set charger at 15—25 amps.

1. Remove any attachments. IMPORTANT: Decrease charge rate if battery gases


2. Park machine on level surface. Raise boom fully or bubbles excessively or becomes too warm to
and ENGAGE the boom lock. touch.
3. Turn key OFF and ENGAGE park brake.
4. Open engine rear cover and REMOVE left engine
side panel. 12. Check specific gravity after 30 minutes:
5. Disconnect negative (–) and positive (+) battery
cable clamps. Remove battery hold-down clamp. Results:
6. Remove battery from machine.
• If MORE THAN 50 point variation between cells,
7. Clean battery terminals and case. replace battery.
• If LESS THAN 50 point variation between cells, go
to step 13.

NOTE: If battery was discharged at slow or unknown


rate, charge at 10—15 amps for 6—12 hours. If
battery was discharged at fast rate, charge at
20—25 amps for 2—4 hours.

13. Continue to charge battery until specific gravity is


1.230—1.265 points.
M49598
14. Load test battery. (See BATTERY LOAD TEST, in
8. Connect variable rate charger to battery. this section.)
NOTE: Maximum charge time at boost is 10 minutes. 15. Install battery.
Allow additional 5 minutes for each 10°F 16. Install left engine side panel and close engine
(5.5°C) below 70°F (21°C). cover.
9. Start charger at SLOW rate. Increase charge rate
ONE setting at a time. Check charger ammeter
after 1 minute at each setting. Maintain 10 amp
charge rate. Use boost setting as necessary.

11/22/00 4 - 121
TESTS AND ADJUSTMENTS ELECTRICAL

BATTERY LOAD TEST

Reason: 8. Connect tester positive cable (red) to battery


positive (+) terminal (B).
To check condition of battery under load.
9. Connect tester negative cable (black) to battery
negative (–) terminal (C).
Equipment:
• JT05685 Battery Tester (use according to IMPORTANT: Perform this test quickly to prevent
manufacturer’s instructions). damage to battery tester. DO NOT apply full load
to battery for more than 5—10 seconds
Procedure:
1. Remove any attachments. 10. Turn load knob (A) on DC amps scale of tester
2. Park machine on level surface. Raise boom fully clockwise (in) until amperage reading (D) is equal
and ENGAGE the boom lock. to:
3. Turn key OFF and ENGAGE park brake. • cold cranking amperage rating of battery (use blue
scale).
4. OPEN engine rear cover and REMOVE left engine
side panel. —or—
5. Disconnect negative (–) and positive (+) battery • three times ampere hour rating (use black scale).
cable clamps. Remove battery hold-down clamp. 11. Hold for 15 seconds and turn load knob (A) of tester
6. Remove battery from machine. counterclockwise (out) to OFF position.
7. Clean battery terminals and case. 12. Repeat steps 10 and 11 above and read condition
of battery at DC volts scale (E).

Results:
• If battery DOES NOT pass test and has NOT been
charged, charge battery and retest. (See CHARGE
BATTERY in this section.)
• If battery DOES NOT pass test and HAS been
charged, replace the battery.
13. Install left engine side panel and close engine
cover.
M49597

A. Load Knob D. DC Amps Scale


B. Battery Positive (+) E. DC Volts Scale
Terminal
C. Battery Negative
(–) Terminal

IMPORTANT: Turn load knob on battery tester fully


out (counterclockwise) BEFORE making any
test connections.

4 - 122 11/22/00
ELECTRICAL TESTS AND ADJUSTMENTS

REGULATED AMPERAGE AND VOLTAGE TEST

Reason: 7. Put current gun over large red cable between


To determine regulated charging output of the alternator and starter.
alternator. 8. Start and operate engine at full rpm.

IMPORTANT: Perform this test as quickly as


Equipment:
possible to prevent damage to the electrical
• JT05685 Load Tester system components.
• JT02153 DC Current Gun or Equivalent
9. Slowly turn load knob clockwise until current gun
Specifications: displays maximum current output. Record reading.
Current Output . . . . . . . . . . Approximately 50 amps
(min) @full rpm IMPORTANT: Load system only as necessary to
Regulated Voltage . . . . . 13.5—14.2 VDC @ full rpm obtain maximum current output. Do not reduce
system voltage any lower than 11 volts.

Procedure:
10. Turn load knob off (fully counterclockwise).
1. Park machine on level surface. Lower boom to the
at-rest position. Turn key to OFF position and 11. Let engine run and watch when current gun reading
ENGAGE park brake. is 10 amps or less.
2. Be sure battery is fully charged and all accessories 12. Read and record meter voltage.
are off.
3. Open engine rear cover and remove left engine side Results:
panel.
4. Turn load knob of battery tester off (fully • If alternator current output or regulated voltage is
counterclockwise). not to specifications, repair or replace alternator.
(See ALTERNATOR in ENGINE section.)
5. Connect red battery tester clamp to positive (+) post
of battery. 13. Install left engine side panel and close engine
cover.
6. Connect black battery tester clamp to negative (–)
post of battery.

11/22/00 4 - 123
TESTS AND ADJUSTMENTS ELECTRICAL

STARTING MOTOR LOADED AMPERAGE DRAW TEST

KV15226

Reason: Procedure:
To determine the amperage required to crank the 1. Remove any attachments.
engine and check starting motor operation under load. 2. Park machine on level surface. Raise boom fully
and ENGAGE the boom lock.
3. Turn key to OFF position and ENGAGE park brake.
Equipment:
4. Open engine rear cover and remove both engine
• JT05685 Load Tester side panels.
• JT05719 Tachometer 5. Turn load knob fully counterclockwise.
6. Connect load tester red cable to positive (+)
terminal on battery.
Specification:
7. Connect load tester black cable to negative (–)
Starting Motor Loaded (on Vehicle) terminal.
Draw/Voltage. . . . . . . . . . . . . . . . . 350 amps (max) 8. Disconnect fuel shut-off solenoid wire from pump.
8.5 volts (min) @ 0°C (32°F) 9. Check system ground connections. Be sure battery
is fully charged.
10. Crank engine. Read and record voltage at meter.
c CAUTION 11. Use tachometer to read and record cranking rpm.
12. Turn key switch to OFF position. Adjust load knob
until battery voltage is the same as when engine is
Disconnect fuel shutoff solenoid wiring to cranking. Read and record amperage on meter.
prevent engine from starting. 13. Turn load knob fully counterclockwise.

IMPORTANT: Turn load knob fully counter- Results:


clockwise before making connections.
• If amp reading is not to specification, or is to
specification but rpm is low, remove starter and
NOTE: Engine should be at normal operating perform STARTING MOTOR NO-LOAD
temperature when performing this test. AMPERAGE AND RPM TESTS in this section.
14. Install left and right engine side panels and close
engine cover.

4 - 124 11/22/00
ELECTRICAL TESTS AND ADJUSTMENTS

STARTING MOTOR NO-LOAD AMPERAGE AND RPM TESTS

Reason: 9. Connect jumper cables to battery.


To determine if starting motor is binding or has 10. Attach current gun to positive cable.
excessive amperage draw under no-load.
IMPORTANT: Complete this test in 20 seconds or
Equipment: less to prevent starter damage.

• JT02153 DC Current Gun or Equivalent


• JT05719 Tachometer 11. Use jumper wire (A) to briefly connect positive (+)
starter terminal to solenoid terminal “S”.
12. Read and record starter amperage and rpm.
Specification:
Starting Motor No-Load (Free-spinning)
Results:
Draw . . . . . . . . . . . . . . 90 amp (max) at 3,500 rpm
• If starting motor amps or rpm are not to
specification, repair or replace starter.
Procedure: 13. Install starting motor.
1. Remove any attachments. 14. Install left engine side panel and close engine
2. Park machine on level surface. Raise boom fully cover.
and ENGAGE the boom lock.
3. Turn key to OFF position and ENGAGE park brake.
4. Open engine rear cover and remove left engine side
panels.
5. Disconnect battery negative (–) cable and remove
starter from engine.
6. Attach starter to a work surface.

NOTE: Check that battery is fully charged to ensure


accuracy of test.

7. Connect positive (+) cable to positive (battery)


terminal on starter.
8. Connect negative (–) cable to starter body.

11/22/00 4 - 125
TESTS AND ADJUSTMENTS ELECTRICAL

STARTING MOTOR SOLENOID TEST 11. Disconnect one of the jumper wires.

Results:
Reason: The solenoid drive gear should move back.
To determine if starting motor solenoid is defective.

Equipment:
• Two jumper wires
c CAUTION
• 12-volt battery Ensure all power is disconnected from starting
motor. Drive gear could move suddenly, causing
injury.
Procedure:
1. Remove any attachments. 12. If drive gear does not move, make sure jumper
2. Park machine on level surface. Raise boom fully wires are disconnected and try to pull drive gear
and engage the boom lock. out by hand by rotating counterclockwise.
3. Turn key to OFF position and engage park brake. 13. If drive gear cannot be pulled out, check solenoid
4. Open engine rear cover and remove left engine side plunger and shaft for binding.
panels. 14. If drive gear moves out freely but solenoid does not
5. Disconnect negative (–) battery cable clamp from energize, check resistance between solenoid
battery. terminal and metal housing of solenoid.
6. Remove and tag all wires to the starting motor.
7. Remove starting motor from engine and mount on Results:
bench. (See STARTING MOTOR REMOVAL/ Maximum resistance should be 1.0 ohm through
INSTALLATION.) solenoid coil. Replace solenoid if open circuit is
indicated.

A
15. Connect starting motor lead (A) to terminal (B).
16. Remove jumper wire from starting motor housing
B and negative (–) terminal post on battery.
17. Install starting motor.
C 18. Install left engine side panel and close engine
cover.

CD30452A

8. Disconnect starting motor lead (A) from solenoid


terminal.
9. Connect one end of a jumper wire to the positive (+)
post on the battery and other end to the small
solenoid terminal (C).
10. Connect one end of another jumper wire to the
starting motor housing and other end to negative
(–) post on battery.

Results:
The solenoid should pull in freely with a loud click,
causing the starting motor drive gear to move fully out
to the end of shaft and stay there.

4 - 126 1/3/01
ELECTRICAL TESTS AND ADJUSTMENTS

AIR FILTER RESTRICTION SWITCH ENGINE COOLANT TEMPERATURE


TEST SENDER/SWITCH TEST

Reason: Reason:
To determine if air filter restriction switch is detecting air To check operation of coolant temperature sender/
flow resistance through air filter. overheat switch.

Procedure: Equipment:
1. Park skid steer on flat level surface and engage • JT05791 Digital Multimeter
park brake switch.
2. Start and operate engine at low idle.
Procedure:
3. Open engine rear cover.
1. Park machine on level surface. Lower boom to the
at-rest position. Turn key to OFF position and
ENGAGE park brake.
2. Open engine rear cover.

KV15246
KV15200

3. Disconnect wiring connectors (A) from coolant


c CAUTION temperature switch and sender assembly.
4. Check for continuity between both spade
connectors on sender.
Exhaust system can be hot. Avoid the hazard of
serious injury from burns.
Results:
4. Cover the air cleaner intake tube with a piece of • Replace coolant temperature sender if continuity is
cardboard or plywood. indicated.
5. Observe on the instrument panel that the air filter
restriction light comes on. 5. Check resistance between sender large (org) spade
terminal and engine block. Reading should be as
follows:
Results: • 2.21K—2.69K ohms @ 20°C (68°F)
• If indicator light will not come on, check wiring and • 1.65K—5.88K ohms @ 0°—30°C (32°—86°F)
light.
• If wiring circuit and light are good, replace air filter
restriction switch. Results:
• Replace coolant temperature sender if readings are
incorrect.

6. Check for continuity between sender small (org/wht)


spade terminal and engine block.

11/22/00 4 - 127
TESTS AND ADJUSTMENTS ELECTRICAL

Results: COLD WEATHER START SWITCH


• Replace coolant temperature sender if continuity is TEST (MODEL 250 ONLY)
indicated.
7. Remove engine coolant temerature sender/switch
from engine. Reason:
8. Connect continuity meter between sender small To check operation of cold start switch.
(org/wht) spade terminal and sender housing.

NOTE: Do not submerge wire harness connector end Equipment:


of sender in oil. Submerge only to the bottom • JT05791 Digital Multimeter
of the hexagon of the sender.

9. Submerge in oil. Heat oil and monitor meter Procedure:


reading. Meter should show continuity at 116°C
(241°F). 1. Remove any attachments.
2. Park machine on level surface. Raise boom fully
and ENGAGE the boom lock.
Results: 3. Turn key to OFF position and ENGAGE park brake.
• Replace engine coolant temperature sender/switch 4. Open engine rear cover and remove right engine
if results vary. side panels.

KV15201

5. Disconnect wire harness connector (A) and remove


cold weather start switch (B) from thermostat
housing.

NOTE: Do not submerge wire harness connector end


of switch in water. Submerge only the switch.

6. Submerge switch in water at 60°C (140°F) for a few


minutes.
7. Remove switch from water and check for continuity
between terminals.

Results:
• If continuity is indicated, replace cold weather start
switch.
• If no continuity is indicated, switch is good.
8. Install cold weather start switch into thermostat
housing. Tighten switch to 5 N•m (42 lb-in.).
9. Connect cold weather start switch wire connector.

4 - 128 11/22/00
ELECTRICAL TESTS AND ADJUSTMENTS

ENGINE OIL PRESSURE SWITCH/ MANIFOLD PREHEATER TEST


SENDER TEST
Reason:
Reason: To check operation of engine manifold pre-heater.
To check operation of engine oil pressure switch.
Equipment:
Equipment: • JT05791 Digital Multimeter
• JT05791 Digital Multimeter
Procedure:
Procedure: 1. Remove any attachments.
1. Remove any attachments. 2. Park machine on level surface. Raise boom fully
2. Park machine on level surface. Raise boom fully and ENGAGE the boom lock.
and ENGAGE the boom lock. 3. Turn key to OFF position and ENGAGE park brake.
3. Turn key to OFF position and ENGAGE park brake. 4. Open engine rear cover and remove left engine side
4. Open engine rear cover and remove right engine panel.
side panels.

A
A

B
B

C KV15202
KV15211
5. Disconnect battery, negative (–) cable first.
5. Disconnect battery, negative (–) cable first. 6. Remove nut and washer (A) and wire lead (B) from
6. Remove wire leads (A and B) from oil pressure pre-heater (C).
switch (C). 7. Check resistance between terminal and engine
7. Check for resistance between terminal marked “G” block. Reading should be 0.70—1.65 ohms
and the engine block. Value should be 5—13 ohms
at 0 kPa (0 psi). Results:
8. Check for resistance (maximum 0.1 ohms) between • Replace manifold pre-heater if reading is incorrect.
terminal “WK” and engine block.
8. Install pre-heater and tighten to 60 N•m (44 lb-ft).
NOTE: Resistance will change if there is pressure. 9. Connect wire lead and install washer and nut.
10. Connect battery.

Results:
• Replace oil pressure switch if resistance readings
are incorrect.

11/22/00 4 - 129
TESTS AND ADJUSTMENTS ELECTRICAL

MANIFOLD PREHEATER RELAY 8. Connect a jumper wire from battery positive (+) post
to one small terminal. Connect a jumper wire from
TEST the other small terminal to negative (–) post.
Continuity should now exist between the two large
terminals (F).
Reason:
To check operation of manifold pre-heater relay.
Results:
• If continuity is not correct, replace manifold pre-
Equipment: heater relay.
• JT05791 Digital Multimeter 9. Connect leads, cap screws, and washers.
10. Connect battery, positive (+) cable first.
Procedure: 11. Lower ROPS. Tighten ROPS retaining nuts to
105 N•m (77 lb-ft).
C
B

C A

D KV15203

1. Park machine on level surface. Lower boom to the


at-rest position. Turn key to OFF position and
ENGAGE park brake.
2. Raise ROPS and secure safely
3. Disconnect battery, negative (–) cable first.

NOTE: Tag or label wiring leads on relay to aid during


installation.

4. Disconnect wiring leads (A and B) from relay (D).


Tag or label wiring leads to aid during installation.
5. Remove two cap screws and washers (C) and
remove manifold pre-heater relay (D).

KV15247
E

6. Check for continuity between the two small


terminals (E).
7. Check for no continuity between the two large
terminals (F).

4 - 130 11/22/00
ELECTRICAL TESTS AND ADJUSTMENTS

KEY SWITCH TEST PARK BRAKE SWITCH TEST

Reason: Reason:
To check operation of ignition key switch. To check operation of park brake switch.

Equipment: Equipment:
• JT05791 Digital Multimeter • JT05791 Digital Multimeter

Procedure: Procedure:

A
B 3 2B
6 1
C

D 9
5B
E

7
KV15248 KV15248

1. Disconnect battery, negative (–) cable first. 1. Disconnect battery, negative (–) cable first.
2. Remove key switch from control panel. 2. Remove park brake switch from control panel.
3. Use multimeter to check continuity between switch 3. Use multimeter to check continuity between switch
terminals (A—E) in the ACCESSORY, OFF, RUN terminals in the positions as shown in the table.
and START positions.

PARK BRAKE SWITCH CONTINUITY


KEY SWITCH CONTINUITY
Continuity (<1 ohm)
Continuity (<1 ohm) Switch Position
Switch Position Between Terminals
Between Terminals
Engage 2B, 3, 9, 5B, 6
Accessory A, D
Run 2B, 3, 9, 5B, 4
Off None
Release 2B, 1, 9, 5B, 4
Run A, D, E
All positions 2B, 9, 5B, 7
Start B, C and D, E

Results:
Results:
• If continuity is not correct, replace park brake
• If continuity is not present between terminals listed switch.
for each key switch position, replace key switch.
• If continuity exists between terminals not listed for
each switch position, replace key switch.

11/22/00 4 - 131
TESTS AND ADJUSTMENTS ELECTRICAL

PRE-HEATER SWITCH TEST LIGHT SWITCH TEST

Reason: Reason:
To check operation of cold start switch. To check operation of light switch.

Equipment: Equipment:
• JT05791 Digital Multimeter • JT05791 Digital Multimeter

Procedure: Procedure:

7 4
9 5B
7 9 6
8

1
2B
2B
KV1550 3

1. Disconnect battery, negative (–) cable first. 1. Disconnect battery, negative (–) cable first.
2. Remove cold start switch from control panel. 2. Remove light switch from control panel.
3. Use multimeter to check continuity between switch 3. Use multimeter to check continuity between switch
terminals in the positions as shown in the table. terminals in the positions as shown in the table.

COLD START SWITCH CONTINUITY LIGHT SWITCH CONTINUITY


Continuity (<1 ohm) Continuity (<1 ohm)
Switch Position Switch Position
Between Terminals Between Terminals
Off 9, 2B Off 2B, 1, 9and 5B, 4
Momentary 9, 2B, 3 Front Work/Tail Lights 2B, 3, 9and 5B, 4
All positions 9, 2B, 7 Front/Rear Work/Tail 2B, 3, 9and 5B, 6
Lights

Results: All positions 7, 8 and 9, 2B


• If continuity is not correct, replace pre-heater
switch.
Results:
• If continuity is not correct, replace light switch.

4 - 132 11/22/00
ELECTRICAL TESTS AND ADJUSTMENTS

CAB DOOR SWITCH TEST DUAL FLASHER SWITCH TEST

Reason: Reason:
To check operation of cab door switch. To check operation of dual flasher switch.

Equipment: Equipment:
• JT05791 Digital Multimeter • JT05791 Digital Multimeter

Procedure: Procedure:

7
9
Plunger
8

KV31131 2B
3

1. Disconnect battery, negative (–) cable first.


KV31132
2. Remove cab door switch from machine.
3. Use multimeter to check continuity between switch 1. Disconnect battery, negative (–) cable first.
terminals in the positions as shown in the table.
2. Remove dual flasher switch from control panel.
3. Use multimeter to check continuity between switch
terminals in the positions as shown in the table.
CAB DOOR SWITCH CONTINUITY
FRONT MOUNTED VERSION
DUAL FLASHER SWITCH CONTINUITY
Continuity (<1 ohm)
Plunger Position
Between Terminals Continuity (<1 ohm)
Switch Position
Between Terminals
Out NO
Off 7, 8 and 9, 2B
In YES
On 2B, 3, 9 and 7, 8

All positions 7, 8 and 9, 2B


CAB DOOR SWITCH CONTINUITY
REAR MOUNTED VERSION
Results:
Continuity Between • If continuity is not correct, replace switch.
Plunger Position
Terminals

Out YES

In NO

Results:
• If continuity is not correct, replace switch.

11/22/00 4 - 133
TESTS AND ADJUSTMENTS ELECTRICAL

HIGH-FLOW SWITCH TEST BLOWER SWITCH TEST

Reason: Reason:
To check operation of high-flow switch. To check operation of blower switch.

Equipment: Equipment:
• JT05791 Digital Multimeter • JT05791 Digital Multimeter

Procedure: Procedure:

7 4 7 4 5B
5B 9 6
9 6 8
8

1
1
2B
2B 3
3 KV31133 KV31134

1. Disconnect battery, negative (–) cable first. 1. Disconnect battery, negative (–) cable first.
2. Remove high-flow switch from control panel. 2. Remove blower switch from control panel.
3. Use multimeter to check continuity between switch 3. Use multimeter to check continuity between switch
terminals in the positions as shown in the table. terminals in the positions as shown in the table.

HIGH-FLOW SWITCH CONTINUITY BLOWER SWITCH CONTINUITY

Continuity (<1 ohm) Continuity (<1 ohm)


Switch Position Switch Position
Between Terminals Between Terminals

Off 2B, 1 and 5B, 4, 9 Off 5B, 4, 2B, 1, 9

On 2B, 3, 6and 5B, 4, 9 Low 2B, 3, 5B, 4, 9

Momentary 2B, 3, 5B, 6, 9 High 5B, 6, 2B, 3, 9

All positions 7, 8 and 5B, 9 and 3, 6 All positions 9, 2B, 5B

Results: Results:
• If continuity is not correct, replace switch. • If continuity is not correct, replace switch.

4 - 134 11/22/00
ELECTRICAL TESTS AND ADJUSTMENTS

WIPER/WASHER SWITCH TEST FUEL LEVEL SENDER TEST

Reason: Reason:
To check operation of wiper/washer switch. To determine if fuel level sender is changing resistance
as float is raised and lowered.

Equipment:
• JT05791 Digital Multimeter Equipment:
• JT05791 Digital Multimeter
Procedure:
Procedure:
7 4
5B
9 6
B
8

1
A

2B 10
3
KV31135

1. Disconnect battery, negative (–) cable first.


KV15212
2. Remove wiper/washer switch from control panel.
3. Use multimeter to check continuity between switch 1. Park machine on level surface. Lower boom to the
terminals in the positions as shown in the table. at-rest position. Turn key to OFF position and
ENGAGE park brake.
WIPER/WASHER SWITCH CONTINUITY 2. Raise ROPS and secure safely. Access fuel level
sender on top of fuel tank.
Continuity (<1 ohm) 3. Disconnect wire harness connector (A). Remove
Switch Position two fuel lines (B).
Between Terminals

Off 1, 2B and 5B, 4, 3, 9


C
Wiper 9, 2B, 3, 5B, 4

Washer (Momentary) 9, 2B, 3, 5B, 6

All positions 7, 8 and 3, 5B, 9


D

Results: E
• If continuity is not correct, replace switch. KV15213

4. Remove five screws (C), fuel level sender (D) and


gasket (E). Use care not to tear gasket.

11/22/00 4 - 135
TESTS AND ADJUSTMENTS ELECTRICAL

SEAT SAFETY SWITCH TEST


Reason:
To check operation of seat switch.

Equipment:
• JT05791 Digital Multimeter

Procedure:

KV15252
A
5. Connect leads from JT05791 Digital Multimeter to
posts on sender. Set meter to read ohms.
B
6. Hold fuel sender upright so float arm is resting on
KV15253
bottom stop (empty tank position). Note meter
reading.
1. Remove seat safety switch from under seat and
7. Holding fuel sender upright, lift float arm up against disconnect wiring connector.
upper stop (full tank position). Note meter reading.
2. Check continuity between terminals (A and B) with
switch released and depressed.
Results:
• The resistance of the fuel level sender is as follows: SEAT SAFETY SWITCH CONTINUITY

Continuity Between
FUEL LEVEL SENDER Switch Position
Terminals
Resistance Released No
Tank Fuel Level
(Ohms)
Depressed Yes
Full 30.0 ± 3

1/2 89.3 ± 3
Results:
Empty 248.2 ± 3 • If continuity is not correct, replace switch.

• If the resistance of the fuel level sender is not within


specifications at the prescribed fuel levels, replace
fuel level sender.
8. Lower ROPS. Tighten ROPS retaining nuts to 105
N•m (77 lb-ft).

4 - 136 11/22/00
ELECTRICAL TESTS AND ADJUSTMENTS

SEAT BELT SWITCH TEST HYDRAULIC OIL


OVERTEMPERATURE SWITCH TEST
Reason:
To check operation of seat belt switch.
Reason:
Equipment: To check operation of hydraulic oil overtemperature
• JT05791 Digital Multimeter switch.

Procedure:
Equipment:
• JT05791 Digital Multimeter

Procedure:

Unlatched

A
B

KV15219

NOTE: Hydraulic oil temperature switch (A) is located


on side of hydraulic reservoir and can be
accessed from under rear of machine.

Hydraulic reservoir capacity is approximately


15.6 L (4.1 gal).
Latched
KV15255 1. Drain hydraulic oil from reservoir.
2. Disconnect wiring connector (B) and remove switch
1. Remove seat belt latch from skid steer and (A).
disconnect wiring connector.
2. Check continuity between terminals (A) and (B). NOTE: Do not submerge wire harness connector end
of switch in oil. Submerge only to the bottom of
the hexagon of the switch.
SEAT BELT SWITCH CONTINUITY
3. Submerge switch in 108°C (226°F) oil for a few
Continuity Between minutes.
Switch Position
Terminals 4. Remove from oil and check for continuity across
connector terminals.
Unlatched No
Results:
Latched Yes • If no continuity is indicated, replace hydraulic oil
overtemperature switch, then go to step 5.
• If continuity is indicated, switch is good. Go to
Results: step 5.
• If continuity is not correct, replace switch.
5. Apply pipe sealant with TEFLON to threads of
switch before installing.

11/22/00 4 - 137
TESTS AND ADJUSTMENTS ELECTRICAL

6. Install hydraulic oil overtemperature switch and BOOM LOCKOUT SOLENOID TEST
connect wiring connector.

NOTE: Make sure hydraulic reservoir drain plug is Reason:


installed.
To check operation of boom lockout solenoid.
7. Fill reservoir with proper hydraulic oil. Check level.
Equipment:
PARK BRAKE SOLENOID TEST • Two jumper wires

Reason: Procedure:

To check operation of park brake solenoid. 1. Remove any attachments.


2. Park machine on level surface. Raise boom fully
and ENGAGE the boom lock.
Equipment: 3. Turn key to OFF position and ENGAGE park brake.
• Two jumper wires 4. Raise ROPS and ensure ROPS is safely in the
locked position. (See RAISING ROPS
[ROLLOVER PROTECTION STRUCTURE] in the
Procedure: MISCELLANEOUS section.)
1. Remove any attachments. 5. Remove cover plates. (See COVER PLATE
2. Park machine on level surface. Raise boom fully REMOVAL/INSTALLATION in the
and ENGAGE the boom lock. MISCELLANEOUS section.)
3. Turn key to OFF position and ENGAGE park brake.
4. Open engine rear cover and remove left engine side
panel.

A
A B

KV31136

KV15220 6. Separate connector (A).


7. Connect a jumper wire between one terminal of
5. Remove connector (A) from solenoid (B). boom lockout solenoid connector and ground.
6. Connect a jumper wire between one terminal of 8. Connect one end of another jumper wire to battery
park brake solenoid and ground. positive (+) terminal. Touch other end of jumper
7. Connect one end of another jumper wire to battery wire to open terminal on boom lockout solenoid
positive (+) terminal. Touch other end of jumper connector. Listen for solenoid to “click”.
wire to open terminal on solenoid (B). Listen for 9. Remove jumper wire. Listen for solenoid to “click”
solenoid to “click”. again.
8. Remove jumper wire from solenoid. Listen for
solenoid to “click” again.
Results:
• If solenoid does not “click”, replace solenoid.
Results:
• If solenoid does not “click”, replace park brake 10. Install cover plates. (See COVER PLATE
solenoid. REMOVAL/INSTALLATION in the
MISCELLANEOUS section.)
11. Lower ROPS. Tighten ROPS retaining nuts to 105
N•m (77 lb-ft).

4 - 138 11/22/00
ELECTRICAL TESTS AND ADJUSTMENTS

BUCKET LOCKOUT SOLENOID HYDRAULIC OIL FILTER


TEST RESTRICTION SWITCH TEST

Reason: Reason:
To check operation of park brake solenoid. To check operation of hydraulic oil filter restriction
switch.

Equipment:
• Two jumper wires Equipment:
• JT05791 Digital Multimeter
(set to read continuity)
Procedure:
1. Remove any attachments.
Procedure:
2. Park machine on level surface. Raise boom fully
and ENGAGE the boom lock.
3. Turn key to OFF position and ENGAGE park brake.
4. Raise ROPS and ensure ROPS is safely in the
locked position. (See RAISING ROPS A
[ROLLOVER PROTECTION STRUCTURE] in the
MISCELLANEOUS section.)
5. Remove cover plates. (See COVER PLATE
REMOVAL/INSTALLATION in the B
MISCELLANEOUS section.)
C
KV15221

1. Park machine on level surface. Lower boom to the


at-rest position. Turn key to OFF position and
ENGAGE park brake.
2. Raise ROPS and secure safely. Access hydraulic oil
filter restriction switch located on front of hydraulic
oil filter manifold.
3. Remove nut and washer (B) and wire lead (C).
A 4. Remove switch (A).

NOTE: The restriction switch closes when oil pressure


increases to 275.8 ± 27.6 kPa (40 ± 4 psi). The
KV31137 restriction switch opens when oil pressure
decreases to 206.8 kPa (30 psi) minimum. The
6. Separate connector (A). normal operating pressure is 41.4—206.8 kPa
7. Connect a jumper wire between one terminal of (6—30 psi)
bucket lockout solenoid connector and ground.
8. Connect one end of another jumper wire to battery
positive (+) terminal. Touch other end of jumper 5. Attach an external (regulated) source of air or oil
wire to open terminal on bucket lockout solenoid pressure to oil filter restriction switch.
connector. Listen for solenoid to “click”. 6. Attach one test lead of multimeter to center terminal
9. Remove jumper wire. Listen for solenoid to “click” of switch and other test lead to switch body.
again. 7. While observing multimeter, slowly increase supply
pressure to 275.8 ± 27.6 kPa (40 ± 4 psi).

Results: Results:
• If solenoid does not “click”, replace solenoid. • If continuity is indicated at any time as pressure
rises to 248.2 kPa (36 psi), replace switch.
10. Install cover plates. (See COVER PLATE • Continuity should be indicated above 248.2 kPa
REMOVAL/INSTALLATION in the (36 psi). If no continuity is indicated, replace
MISCELLANEOUS section.) switch.
11. Lower ROPS. Tighten ROPS retaining nuts to 105 8. Lower ROPS. Tighten ROPS retaining nuts to 105
N•m (77 lb-ft). N•m (77 lb-ft).

11/22/00 4 - 139
COMPONENT REPLACEMENT ELECTRICAL

COMPONENT REPLACEMENT

AIR FILTER RESTRICTION SWITCH


Replace:
1. Park machine on a level surface. Turn key to OFF
position and ENGAGE park brake.
2. Raise ROPS and ensure ROPS is safely in the A
locked position. (See RAISING ROPS
B
[ROLLOVER PROTECTION STRUCTURE] in the
MISCELLANEOUS section.)
3. Disconnect battery, negative (–) cable first. KV15200

B 4. Disconnect wiring connectors (A) and remove


temperature sender (B), located on top of engine
block.
5. Apply pipe sealant with TEFLON to threads of
sender before installation.
6. Install coolant temperature sender (B) and connect
wiring connectors (A).
7. Connect battery, positive (+) cable first.
8. Lower ROPS. Tighten ROPS retaining nuts to 105
A
N•m (77 lb-ft).

COLD WEATHER START SWITCH


KV15199
(MODEL 250 ONLY)
4. Access air filter restriction switch (B). Replace:
5. Disconnect wiring connector (A) and remove switch
(B), located behind air cleaner. 1. Park machine on a level surface. Turn key to OFF
position and ENGAGE park brake.
6. Apply pipe sealant with TEFLON to threads of
switch before installation. 2. Open engine rear cover. Remove right engine side
panel.
7. Install air filter restriction switch (B).
3. Disconnect battery, negative (–) cable first.
8. Connect wiring connector (A).
9. Connect battery, positive (+) cable first.
B
10. Lower ROPS. Tighten ROPS retaining nuts to 105
N•m (77 lb-ft).

COOLANT TEMPERATURE
SENDER/SWITCH
Replace:
1. Park machine on a level surface. Turn key to OFF A
position and ENGAGE park brake.
2. Raise ROPS and ensure ROPS is safely in the
locked position. (See RAISING ROPS KV15201
[ROLLOVER PROTECTION STRUCTURE] in the
MISCELLANEOUS section.) 4. Disconnect wiring connector (A) and remove cold
3. Disconnect battery, negative (–) cable first. weather start switch (B) located on side of
thermostat housing.
5. Apply pipe sealant with TEFLON to threads of
switch before installation.

4 - 140 11/22/00
ELECTRICAL COMPONENT REPLACEMENT

6. Install cold weather start switch (B) and tighten to 5


N•m (42 lb-in.).
7. Connect battery, positive (+) cable first.
8. Connect wiring connector (A) and install engine
side panel. A

ENGINE OIL PRESSURE SWITCH/


B
SENDER
Replace: C

1. Park machine on a level surface. Turn key to OFF KV15202


position and ENGAGE park brake.
2. Open rear engine cover and remove right engine 4. Remove nut and lock washer (A).
side panel. 5. Remove wire lead (B) and remove manifold pre-
3. Disconnect battery, negative (–) cable first. heater (C).
6. Install manifold pre-heater (C). Tighten to
60 N•m (44 lb-ft). Connect wire lead (B) and
A
install lock washer and nut (A).
7. Connect battery, positive (+) cable first.
8. Lower ROPS. Tighten ROPS retaining nuts to 105
B N•m (77 lb-ft).

KV15211

NOTE: Tag or label wiring leads on oil pressure switch


to aid during installation.

4. Disconnect wiring leads (A and B) from engine oil


pressure switch (C). Tag or label wiring leads to aid
during installation.
5. Install engine oil pressure switch (C) and connect
wiring leads (A) tan/wht to terminal marked “G” and
(B) tan to terminal marked “WK”.
6. Connect battery, positive (+) cable first.
7. Install engine side panel and close engine rear
cover.

MANIFOLD PREHEATER
Replace:
1. Park machine on a level surface. Turn key to OFF
position and ENGAGE park brake.
2. Raise ROPS and ensure ROPS is safely in the
locked position. (See RAISING ROPS
[ROLLOVER PROTECTION STRUCTURE] in the
MISCELLANEOUS section.)
3. Disconnect battery, negative (–) cable first.

11/22/00 4 - 141
COMPONENT REPLACEMENT ELECTRICAL

MANIFOLD PREHEAT RELAY


Replace:
1. Park machine on a level surface. Turn key to OFF
position and ENGAGE park brake.
2. Raise ROPS and ensure ROPS is safely in the
locked position. (See RAISING ROPS
[ROLLOVER PROTECTION STRUCTURE] in the
MISCELLANEOUS section.)
3. Disconnect battery, negative (–) cable first.

C
B

C A

D KV15203

NOTE: Tag or label wiring leads on relay to aid during


installation.

4. Disconnect wiring leads (A and B) from relay (D).


Tag or label wiring leads to aid during installation.
5. Remove two cap screws and washers (C) and
remove manifold preheat relay (D).
6. Install relay. Install two cap screws and washers
(C).
7. Connect wiring leads (A and B).
8. Connect battery, positive (+) cable first.
9. lower ROPS. Tighten ROPS retaining nuts to 105
N•m (77 lb-ft).

4 - 142 11/22/00
ELECTRICAL COMPONENT REPLACEMENT

INSTRUMENT PANEL COMPONENT LOCATION

A B C D E F G H I J
KV18865
A. Heater Blower (Optional) F. Work Lights
B. Air Conditioner (Optional) G. Instrument Cluster
C. Windshield Wiper/Washer (Optional) H. Cold Start
D. Dual Flasher (Optional) I. Park Brake
E. High-Flow (Optional) J. Key Switch

KEY SWITCH

Replace:
1. Park skid steer on flat level surface. Lower boom to
the at-rest ground position, engage park brake
switch and turn engine off.
2. Disconnect battery, negative (–) cable first. C

B
B KV15204

3. Remove six screws (B) and pull bezel away from


headliner.
KV15206

5. Remove wiring harness connector (C) and remove


ignition key switch from bezel.
6. Install key switch and connect wiring harness
connector (C).
7. Install key switch bezel nut.
8. Install bezel using six screws.
9. Connect battery, positive (+) cable first.
A

KV15205

4. Remove key switch bezel nut (A).

11/22/00 4 - 143
COMPONENT REPLACEMENT ELECTRICAL

INSTRUMENT PANEL SWITCHES CAB HEATER THERMOSTAT (IF


EQUIPPED)
NOTE: Park brake switch shown. Other switch
replacement is similar. Replace:
1. Park skid steer on flat level surface. Lower boom to
Replace: the at-rest ground position, engage park brake
1. Park skid steer on flat level surface. Lower boom to switch and turn engine off.
the at-rest ground position, engage park brake 2. Disconnect battery negative (–) terminal.
switch and turn engine off.
2. Disconnect battery, negative (–) cable first.
Remove Screws

A A

KV15204

3. Remove six screws (A) and pull bezel away from KV18862
headliner.

B IMPORTANT: Only remove two screws as shown.


Damage to the thermostat could occur if the
other two screws are removed.

3. Remove two screws shown.

C KV15206

4. Disconnect wiring harness connector (B) and


remove park brake switch (C).
5. Install park brake switch and connect wiring
harness connector (B).
6. Install bezel using six screws.
7. Connect battery, positive (+) cable first.

KV18863

4. Pull connector through headliner and disconnect.


5. Connect new heater control

4 - 144 11/22/00
ELECTRICAL COMPONENT REPLACEMENT

3. Remove six screws (A) and pull bezel away from


headliner.

D D

B B

C
KV15209

4. Remove two cap screws (B) and mounting clips (D).


KV18864 Pull instrument cluster (C) away from headliner.

6. Push connector forward through hole (D) in frame.

KV15210

5. Disconnect three wiring harness connectors (E)


KV18862
and remove instrument cluster.
7. Install controller and secure with screws. 6. Install instrument cluster and connect wiring
8. Connect battery. harness connectors (E).
7. Install instrument cluster and clips into headliner
using two cap screws.
INSTRUMENT CLUSTER 8. Install bezel using six screws.
9. Connect battery, positive (+) cable first.

Replace:
1. Park machine on a level surface. Turn key to OFF FUEL LEVEL SENDER
position and ENGAGE park brake.
2. Disconnect battery, negative (–) cable first.
Replace:
1. Park machine on a level surface. Turn key to OFF
position and ENGAGE park brake.
2. Raise ROPS and ensure ROPS is safely in the
locked position. (See RAISING ROPS
[ROLLOVER PROTECTION STRUCTURE] in the
MISCELLANEOUS section.)
3. Disconnect battery, negative (–) cable first.

A A

KV15204

11/22/00 4 - 145
COMPONENT REPLACEMENT ELECTRICAL

KV15212
KV15214
4. Access fuel level sender on top of fuel tank.
3. Remove two nuts (A) on each side of seat support.
NOTE: Tag fuel lines to aid during installation. 4. Lift seat and support upward off adjustment rails to
access seat safety switch.

5. Disconnect wire harness connector (A) and remove


two fuel lines (B). Tag fuel lines to aid in proper B
installation.
D
C

D C
KV15215

E 5. Disconnect wire harness connector (B).


6. Remove two screws (C) and seat safety switch (D).
KV15213
7. Install seat switch and install screws (C).
6. Remove five screws (C), fuel level sender (D) and 8. Connect wire harness connector and install seat
gasket (E). and support on adjustment rails. Tighten nuts to
28 N•m (20 lb-ft).
7. Inspect gasket (E) for damage. Replace if
necessary. 9. Connect battery, positive (+) cable first.
8. Install gasket and install new fuel level sender into
tank.
9. Install five screws and tighten securely.
10. Connect two fuel lines and wire harness connector.
11. Connect battery, positive (+) cable first.
12. Lower ROPS. Tighten ROPS retaining nuts to 105
N•m (77 lb-ft).

SEAT SAFETY SWITCH

Replace:
1. Park machine on a level surface. Turn key to OFF
position and ENGAGE park brake.
2. Disconnect battery, negative (–) cable first.

4 - 146 11/22/00
ELECTRICAL COMPONENT REPLACEMENT

SEAT BELT SWITCH STARTER

Replace: Remove/Install:
1. Park machine on a level surface. Turn key to OFF 1. Park machine on a level surface. Turn key to OFF
position and ENGAGE park brake. position and ENGAGE park brake.
2. Disconnect battery, negative (–) cable first. 2. Raise ROPS and ensure ROPS is safely in the
locked position. (See RAISING ROPS
[ROLLOVER PROTECTION STRUCTURE] in the
MISCELLANEOUS section.)
3. Remove left side engine panel.
4. Disconnect battery, negative (–) cable first.

B
KV15214

3. Remove the cap screw and nut (A) securing the KV15216
seat belt latch to the ROPS.
5. Remove nut (A) and cover (B) to access starter
4. Disconnect electrical connector.
wiring leads.
5. Connect electrical connector of new seat belt latch. .

6. Install seat belt latch to ROPS using cap screw and


nut retained from disassembly. Tighten to 54 N•m D
(40 lb-ft).
7. Connect battery, positive (+) cable first.
D

C KV15217

NOTE: Tag or label wiring leads on starter to aid


during installation.

6. Disconnect wiring leads (C).


7. Remove two cap screws (D) and remove starter.
Make repairs to starter as necessary. (See
STARTING MOTOR in DIESEL ENGINE section.)
8. Install starter and cap screws.
9. Connect wiring leads.
10. Install cover and nut.
11. Connect battery, positive (+) cable first.
12. Install left engine side panel.
13. Lower ROPS. Tighten ROPS retaining nuts to 105
N•m (77 lb-ft).

11/22/00 4 - 147
COMPONENT REPLACEMENT ELECTRICAL

ALTERNATOR HYDRAULIC OIL


OVERTEMPERATURE SWITCH
Remove/Install:
1. Park machine on a level surface. Lower boom to the Replace:
at-rest position. Turn key to OFF position and 1. Park machine on a level surface. Turn key to OFF
ENGAGE park brake. position and ENGAGE park brake.
2. Disconnect battery, negative (–) cable first. 2. Raise ROPS and ensure ROPS is safely in the
3. Remove left engine side panel. locked position. (See RAISING ROPS
[ROLLOVER PROTECTION STRUCTURE] in the
MISCELLANEOUS section.)
B 3. Disconnect battery, negative (–) cable first.

D B

C
KV15218

KV15219
NOTE: Tag or label wiring leads on alternator to aid
during installation.
4. Access hydraulic oil temperature sender (B) located
4. Disconnect wiring leads (A). Tag or label wiring on front of hydraulic reservoir.
leads to aid during installation.
5. Loosen nuts (B and C). NOTE: Hydraulic reservoir capacity is approximately
6. Move alternator (D) toward engine and lift belt off 15.6 L (4.1 gal).
pulley.
7. Remove alternator adjustment and pivot mounting
hardware. 5. Drain hydraulic oil from reservoir.
8. Remove alternator. Make repairs to alternator as 6. Disconnect wiring connector (A) and remove switch
necessary. (See ALTERNATOR in DIESEL (B).
ENGINE section). 7. Apply pipe sealant with TEFLON to threads of
9. Install alternator pivot and adjustment mounting switch before installation.
hardware. Do not tighten hardware at this time. 8. Install hydraulic oil temperature switch and connect
10. Adjust belt tension. (See CHECK FAN/ wiring connector.
ALTERNATOR BELT TENSION in DIESEL
ENGINE section.)
NOTE: Make sure hydraulic reservoir drain plug is
11. Connect wiring leads to alternator. installed.
12. Connect battery, positive (+) cable first.
13. Install left engine side panel.
9. Fill reservoir with proper hydraulic oil and check
level.
10. Connect battery, positive (+) cable first.
11. Lower ROPS. Tighten ROPS retaining nuts to 105
N•m (77 lb-ft).

4 - 148 11/22/00
ELECTRICAL COMPONENT REPLACEMENT

PARK BRAKE SOLENOID HYDRAULIC OIL FILTER


RESTRICTION SWITCH
Replace:
Replace:

1. Park machine on level surface. Lower boom to the


c CAUTION at-rest position. Turn key to OFF position and
ENGAGE park brake.
2. Relieve all hydraulic pressure in system by sitting in
To help prevent injury from escaping hydraulic the operator seat with seat belt fastened. Turn key
oil under pressure, relieve the pressure in the switch to the ON position but do not start engine.
system. Press the park brake switch in the RELEASE
position and operate the hydraulic foot control
1. Park machine on level surface. Lower boom to the pedals. ENGAGE the park brake switch and turn
at-rest position. Turn key to OFF position and key switch to OFF position.
ENGAGE park brake. 3. Raise ROPS and ensure ROPS is safely in the
2. Relieve all hydraulic pressure in system by sitting in locked position. (See RAISING ROPS
the operator seat with seat belt fastened. Turn key [ROLLOVER PROTECTION STRUCTURE] in the
switch to the ON position but do not start engine. MISCELLANEOUS section.)
Press the park brake switch in the RELEASE 4. Access hydraulic oil filter restriction switch located
position and operate the hydraulic foot control on front of hydraulic oil filter manifold.
pedals. ENGAGE the park brake switch and turn
key switch to OFF position.
3. Disconnect battery, negative (–) cable first.
4. Remove left engine side panel.

B
A
A B

KV15220

5. Disconnect wiring connectors (A). Remove nut (B)


and park brake solenoid (C). KV15221
6. Install park brake solenoid and connect wiring
connectors. 5. Remove nut and washer (A).
7. Install nut and tighten to 5.4 N•m (48 lb-in.). 6. Remove wire lead (B).
8. Connect battery, positive (+) cable first. 7. Remove switch and O-ring (C).
9. Start engine and check for oil leaks.
10. Install engine side panel. NOTE: Make sure O-ring is installed on oil filter
restriction switch before installing new switch
into manifold.

8. Install hydraulic oil filter restriction switch and


O-ring.
9. Connect wire lead and install washer and nut.
10. Lower ROPS. Tighten ROPS retaining nuts to
105 N•m (77 lb-ft).

11/22/00 4 - 149
COMPONENT REPLACEMENT ELECTRICAL

BACKUP ALARM (OPTIONAL)


ALARM

Replace:
1. Park machine on level surface. Lower boom to the C
at-rest position. Turn key to OFF position and
E
ENGAGE park brake.

A
KV31077

3. Disconnect harness (C) from switch.


4. Remove single screw (D) that retains switch bracket
to plate (E). Remove switch and bracket assembly.
B

KV31079

2. Disconnect wires (A and B) from alarm.


3. Remove cap screws (2 used) and lock nuts that
attach alarm to boom lock plate.
4. Install new alarm using original cap screws and lock
nuts.
5. Attach yellow wire (A) to upper terminal. Attach
black wire (B) to lower terminal.

SWITCH

Replace:
1. Park machine on level surface. Lower boom to the 5. Remove screws (2 used) and lock nuts retaining
at-rest position. Turn key to OFF position and switch to bracket. Install new switch on original
ENGAGE park brake. bracket and tighten screws securely.
2. Raise ROPS and ensure ROPS is safely in the
locked position. (See RAISING ROPS
[ROLLOVER PROTECTION STRUCTURE] in the
MISCELLANEOUS section.)

4 - 150 11/22/00
ELECTRICAL COMPONENT REPLACEMENT

G
F

6. Install switch and bracket assembly on plate. DO


NOT tighten screw completely.
7. Be sure control arm (F) is in NEUTRAL position.
8. Position switch so plunger (G) just touches control
arm. Carefully tighten screw.
9. Check adjustment by connecting an ohmmeter to
the switch terminals. Reading should be infinity. If
continuity is indicated, the switch must be adjusted.
10. Connect harness connector.
11. Verify operation by operating the machine. Both
control handles must be in REVERSE for alarm to
sound. Alarm must stop when control handles are
returned to NEUTRAL.

11/22/00 4 - 151
COMPONENT REPLACEMENT ELECTRICAL

This page intentionally left blank.

4 - 152 11/22/00
POWER TRAIN (CHAINCASE AND AXLES) CONTENTS

CONTENTS
POWER TRAIN (CHAINCASE AND AXLES)
Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
POWER TRAIN COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHAIN CASE OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHAIN CASE ACCESS PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DRIVE CHAIN TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AXLE HOUSING REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AXLE HOUSING DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DRIVE CHAIN AND SPROCKET REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . 12

11/22/00 5-1
SPECIFICATIONS POWER TRAIN (CHAIN CASE AND AXLES)

SPECIFICATIONS
Drive Axles:
Wheel Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 N•m (175 lb-ft)
Mounting Nut Torque (Axle Housing to Chain Case) . . . . . . . . . . . . . 305 N•m (225 lb-ft)
Axle Spanner Lock Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . .340-408 N•m (250-300 lb-ft)
Axle Housing Lubrication (Before Installation)
John Deere TORQ-GARD SUPREME® or PLUS 50® . . . . . . . . . . . . . . 237 mL (8 oz)

Chain Case:
Access Plate Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . 70—80 N•m (52—59 lb-ft)
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4 L (3 gal) (Each Side)

Drive Chain:
Chain Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #80
Front Chain Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Links
Rear Chain Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Links
Chain Free Play Movement (Up and Down) . . . . . . . . . . . . . . . . . . . . . . 5 mm (0.197 in.)
Chain Tension (Movement at Tire Tread) . . . . . . . . . . . . . . . .0—6.35 mm (0—0.250 in.)

OTHER MATERIALS

Number Name Use


U.S./
Canadian
TY6238 John Deere HY-GARD® Axle housing and chain case
lubrication
TY6342 John Deere Low Viscosity HY-GARD® Axle housing and chain case
(Cold Weather Operation) lubrication.
TY22073 John Deere TORQ-GARD SUPREME® Axle housing and chain case
lubrication.
TY6390 John Deere PLUS-50® Axle housing and chain case
Other Oil: API Service Classification SG or Higher lubrication.
TY6333/ Moly High Temperature EP Grease Axle housing to chain case
TY6347 O-ring.
PM20166 John Deere 5900 RTV Silicone Seal chain case covers.

SPECIAL TOOLS

Number Name Use


JDG666 Spanner Wrench Axle bearing lock nut.

HY-GARD, TORQ-GARD SUPREME and PLUS-50 are registered trademarks of Deere & Company.

5-2 1/3/01
POWER TRAIN (CHAIN CASE AND AXLES) POWER TRAIN COMPONENT LOCATION

POWER TRAIN COMPONENT LOCATION

Hydrostatic Motors

Chain Case
Front Axle Sprocket

Front Drive Chain


Park Brake Assembly

Right Drive Shaft

Chain Case
Chain Case Access Plate
Rear Axle Sprocket
Level/Fill Plug

Front Axle Housing


Rear Drive Chain

Chain Case Drain Plug

Rear Axle Housing KV13158

11/22/00 5-3
OPERATION POWER TRAIN (CHAIN CASE AND AXLES)

OPERATION

Theory of Operation Drive Chains


The gear power train transmits power from the The skid steer uses four endless drive chains, one for
hydrostatic motor to the drive chains in the chain case. each axle, running in an oil bath inside the chain case.
The drive chains turn large sprockets splined to the The chain is driven by a double sprocket drive shaft
axles. Each hydrostatic motor is mounted onto the park from the hydrostatic motor. Each chain then drives a
brake assembly. The hydrostatic motor is splined to the large chain sprocket splined onto the axle shaft. The
machined shaft assembly through the park brake large chain sprocket slides freely on the axle shaft
assembly. The left and right side gear power trains are spline. The chain can be tightened by sliding individual
completely separate units. The drive system is the axle housings on slots; there are no chain tensioners or
same for forward or reverse; the drive motor is reversed idler springs to adjust.
through the hydrostatic system.

Drive Axles
Chain Case

KV13152
KV13157
The drive axles are attached to the chain case on eight
The chain case is also the skid steer side frame slotted mounting holes. The axle housing slides to
member. It is completely sealed from the other provide tension to the roller drive chain inside the chain
components of the skid steer and from the case. The splined axle shaft extends into the chain
environment. Left and right chain cases are identical. case where it is driven by a large roller chain sprocket.
Chain cases contain front and rear drive chains and The sprocket is allowed to slide freely on the splines of
sprockets. Each chain case has its own oil bath the axle shaft. The axle housing contains two tapered
lubrication system with an oil level/fill plug on the chain roller bearings in replaceable races. The axle bearings
case side access plate. All service to the components are lubricated by the oil bath in the chain case.
of each chain case may be accomplished through the
removable chain case side access plates.

5-4 11/22/00
POWER TRAIN (CHAIN CASE AND AXLES) TROUBLESHOOTING

TROUBLESHOOTING

Problem or

Both drive wheels on one


Oil leak from axle or axle
Symptom

Oil leak from chain case

One drive wheel not


Excessive axle play

side not powered


Grinding noise
Chain noise
Check or
Solution

powered
housing
Inspect O-ring at chain case drain

plug

Inspect/replace sealant on chain



case access plate

Inspect O-ring at chain case fill



plug

Inspect O-ring on axle housing ● ●

Inspect oil seal at axle ● ●

Inspect axle bearings ●

Check chain case oil level ● ●

Check drive chain and sprockets ● ● ● ●

See DRIVE CHAIN TENSION


● ●
ADJUSTMENT

See AXLE HOUSING


● ● ●
DISASSEMBLY/ASSEMBLY

1/3/01 5-5
DIAGNOSIS POWER TRAIN (CHAIN CASE AND AXLES)

DIAGNOSIS
Test Conditions:
• Operator on seat, seat belt fastened.
• Engine running at fast idle.
• Park brake OFF.

Test/Check Point Normal If Not Normal

1. Push both steering Skid steer moves forward in a straight Engine stalls, wheels locked or dragging:
control levers line with all wheels turning. See BRAKES section.
forward at an equal Slow or no power: go to step 4.
rate. One side of skid steer drags: go to step
2.

2. Pull both steering Skid steer moves backward in a straight Engine stalls, wheels locked or dragging:
control levers back at line with all wheels turning. See BRAKES section.
an equal rate. Slow or no power: go to step 4.
One side of skid steer drags: go to step
3.

Test Conditions:
• Roll bucket back.
• Lower boom to ground.
• Set park brake.
• Stop engine.
• Raise and block skid steer. (See RAISING AND BLOCKING SKID STEER in MISCELLANEOUS section.).

Test/Check Point Normal If Not Normal

3. Rotate each tire by Tires move less than 6.35 mm Tires move more than 6.35 mm
hand. (0.250 in.) at tire tread. (0.250 in.): check chain tension for that
axle.
If normal, but skid steer continues to pull One tire rotates freely: drive chain or
to one side, go to step 4. sprocket broken for that axle or splines
stripped from sprocket.
Both tires on one side rotate together
freely: inspect hydrostatic motor, chain,
and brake/sprocket spline.

Test Conditions:
• Roll bucket back.
• Lower boom to ground.
• Raise and block skid steer. (See RAISING AND BLOCKING SKID STEER in MISCELLANEOUS section.)
• Start engine and run at a fast idle.

Test/Check Point Normal If Not Normal

4. Move steering control Wheels and tires are driven smoothly for Chain noise: inspect drive chain.
levers forward and that steering control lever, and run at Slow on one side: see STEERING
reverse for each same rpm (use photo tachometer). section for steering control lever
side. adjustment; see HYDROSTATIC
POWER TRAIN section for hydrostatic
motor diagnostics.

5-6 1/3/01
POWER TRAIN (CHAIN CASE AND AXLES) DIAGNOSIS

Right Steering
Left Steering Control Lever
Control Lever

Front Axle
Sprocket

Front Drive
Chain

Right Drive
Shaft
Rear Drive
Chain
KV13934

1/3/01 5-7
REPAIR POWER TRAIN (CHAIN CASE AND AXLES)

REPAIR

CHAIN CASE OIL LEVEL CHECK


Chain Case
Access Plate

Oil Level/Fill Plug

Chain Case Drain Plug

KV13152

3. Remove chain case oil drain plug behind rear tire.


KV13040 Drain oil into a suitable container.
.

1. The fluid level is checked and filled through the oil


level/fill check plug located on the left and right
chain case access plates. Cap Screw
2. Remove oil level/fill plug. Insert a finger into the
hole. If your finger can touch oil, the level is
sufficient.

NOTE: The left and right side chain cases are not Chain Case
connected. Service each chain case Access Plate
individually.
KV13042
IMPORTANT: DO NOT use John Deere
4. Remove twelve cap screws holding the side access
BIO-HY-GARDTM in chain case.
plate to the chain case. Remove access plate.
5. Remove sealant from access plate and chain case.
3. Fill chain case with proper lubricant. The following
oils are PREFERRED:
Chain Case Side Access Plate Installation
• John Deere HY-GARD
• John Deere Low Viscosity HY-GARD 1. Clean mating surfaces of side access plate and
(cold weather operation) chain case.
• John Deere TORQ-GARD SUPREME 2. Install access plate using PM20166 John Deere
• John Deere PLUS-50 5900 RTV Silicone.
• Other Oil: API Service Classification SG or Higher 3. Tighten twelve chain case access plate cap screws
to 70—80 N•m (52—59 lb-ft).
4. Install all chain case fill and drain plugs.
CHAIN CASE ACCESS PLATE
It is necessary to remove the chain case access plate IMPORTANT: DO NOT use John Deere
to service drive chains, sprockets and drive shaft, and BIO-HY-GARDTM in chain case.
to access brake assembly mounting cap screws.

Chain Case Access Plate Removal 5. Fill chain case with proper lubricant. The following
oils are PREFERRED:
1. Park skid steer on flat level surface.
• John Deere HY-GARD
2. With boom and bucket lowered to the ground,
engage park brake switch, and turn engine off. • John Deere Low Viscosity HY-GARD
(cold weather operation)
• John Deere TORQ-GARD SUPREME
• John Deere PLUS-50
• Other Oil: API Service Classification SG or Higher

5-8 1/3/01
POWER TRAIN (CHAIN CASE AND AXLES) REPAIR

DRIVE CHAIN TENSION 4. To tighten drive chain:


ADJUSTMENT • Push rear axle housing rearward.
• Push front axle housing forward.
Check Chain Tension 5. Tighten axle housing nuts to 305 N•m (225 lb-ft).
1. Park skid steer on flat level surface.
2. With boom and bucket lowered to the ground, AXLE HOUSING REMOVAL/
engage park brake switch, and turn engine off.
3. Raise and block skid steer. (See RAISING AND
INSTALLATION
BLOCKING SKID STEER in MISCELLANEOUS Axle Housing Removal
section.)
NOTE: The axle housing may be removed without
removing the chain case access plate or
draining the chain case oil.

The axle housing must be removed to service the axle


bearings, axle seals, drive chains and sprockets, and to
remove the brake assembly mounting cap screws.
1. Park skid steer on flat level surface.
2. With boom and bucket lowered to the ground,
engage park brake switch, and turn engine off.
3. Raise and block skid steer. (See RAISING AND
KV15158 BLOCKING SKID STEER in MISCELLANEOUS
section.)
4. Check chain tension by rotating each tire by hand 4. Remove wheel from axle being serviced.
forward and rearward. Maximum tire movement at
5. Clean around axle housing to prevent debris from
tire tread should be 6.35 mm (0.250 in.). If not
entering chain case oil reservoir.
within specification, adjust chain tension, see
CHAIN TENSION ADJUSTMENT. Axle Housing Nuts
Chain Tension Adjustment
Rear Drive Front Drive Axle Housing
Chain Chain

KV18785
Right Side of Skid Steer Shown. KV13157
6. Install a suitable lifting strap and hoist to aid during
removal of axle housing.
NOTE: Chain free play movement up and down should 7. Remove eight axle housing mounting nuts.
be 5 mm (0.197 in.).

NOTE: The inner and outer axle bearings are


1. Drain chain case oil and remove chain case access
lubricated by the oil bath in the chain case. The
plate. See CHAIN CASE ACCESS PLATE.
axle housing will be half full of oil, and will drain
2. Loosen eight axle housing mounting nuts. when tipped.
3. To loosen drive chain:
• Push rear axle housing forward.
• Push front axle housing rearward. 8. Pull the axle housing slowly from the chain case,
letting the large chain sprocket drop off of the axle
spline.
9. Inspect axle housing for wear or damage. Repair as
necessary. (See AXLE HOUSING DISASSEMBLY/
ASSEMBLY.)

1/3/01 5-9
REPAIR POWER TRAIN (CHAIN CASE AND AXLES)

Axle Housing Installation 11. Install wheels and tighten nuts to 237 N•m
(175 lb-ft).
1. Clean mating surfaces of axle housing and chain
case before installation. 12. Check chain case oil level after skid steer has been
driven and fill as necessary.
O-Ring

Pre-lubricate
AXLE HOUSING DISASSEMBLY/
Through ASSEMBLY
Bearing

Axle Disassembly
1. Remove axle housing to be serviced from skid
steer. (See AXLE HOUSING REMOVAL/
INSTALLATION.)

NOTE: An arbor press is required to remove the axle


shaft from the axle housing.

Tab KV15147

IMPORTANT: Replace all O-rings. Damaged or


used O-rings will leak.
Washer
2. Install new O-ring in groove of machined surface on
axle housing.
3. Tip axle housing up and pour 237 mL (8 oz) of
John Deere HY-GARD into axle housing through Tab Washer
axle bearing to pre-lubricate.
O-Ring
Lock Nut
Notch Chain Sprocket Hub
KV13139
2. Remove O-ring from axle housing.
Chain Case 3. Bend tabs on tab washer away from lock nut.
4. Using JDG666, Spanner Wrench, remove lock nut.
Remove tab washer, and washer.

KV13155

4. Position chain sprocket so splined hub is visible


through axle hole in chain case.
5. Be sure axle shaft and chain sprocket splines are
clean with no burrs.
6. Install axle housing with tab on back of housing
aligned with notch on mating surface of chain
case.
7. Engage axle shaft splines into chain sprocket
splines.
8. Slide axle housing mounting flange over mounting
studs and install eight nuts loosely in place.
9. Slide axle housing outward to tighten drive chain KV13140
inside chain case. (See DRIVE CHAIN TENSION 5. Place axle housing in press with support under
ADJUSTMENT.) housing mounting flanges that will allow the axle
10. Tighten eight axle housing mounting nuts to shaft to drop two inches.
305 N•m (225 lb-ft). 6. Press axle shaft down until axle shaft drops free of
housing.

5 - 10 1/3/01
POWER TRAIN (CHAIN CASE AND AXLES) REPAIR

5. If required, install new seal using a seal driver or


soft mallet.
6. Remove inner bearing race with a hammer and
punch. Inspect inner bearing race. Install a new
inner bearing race using a 4.4-in. (OD) driver.
7. Install axle housing over axle shaft.
8. Install inner bearing over axle shaft.
9. Place axle and housing in press with support under
center of hub so wheel bolts will not be pressed
out as pressure is applied.
10. Install a 2-in. (ID) driver over axle and onto inner
bearing. Install inner bearing over axle shaft.

KVP13933

NOTE: Outer axle bearing will be destroyed when


removed. Remove bearing only if replacement
is necessary.

7. Remove outer bearing only if necessary, using a


suitable bearing separator/puller as shown. Do not
reuse bearing.
8. Inspect axle shaft for wear or damage. Repair or
replace as necessary.

Assembly:
1. If removed, install a new outer axle bearing over
axle with taper facing up.
2. Slide a piece of tubing over axle shaft and install
axle in arbor press. Support axle under center of 11. Press bearing on until it is 1—2 mm
hub so wheel bolts will not be pressed out when (0.039—0.079 in.) above shoulder on shaft.
pressure is applied. Use press to seat outer
bearing onto shoulder of axle shaft.

Washer

Seal
Tab Washer

Outer Bearing Race O-Ring


Lock Nut

KVP13935
KV13139
3. Inspect axle housing seal. If required, pry seal from
axle housing. 12. Install washer, tab washer, and lock nut.
13. Using a spanner wrench, tighten lock nut until
washer seats bearing and bottoms out on shoulder
NOTE: Always replace bearings as cone/outer-race of axle shaft. Tighten to a final torque of 340-408
sets. N•m (250-300 lb-ft)
14. Align tab slot with tab washer. Bend tab on tab
4. If outer bearing was removed, remove outer bearing washer into slot on lock nut.
race with a hammer and a punch. Install new outer 15. Install axle housing. (See AXLE HOUSING
bearing race in housing using a 4.4-in. (OD) driver. REMOVAL/INSTALLATION.)

1/3/01 5 - 11
REPAIR POWER TRAIN (CHAIN CASE AND AXLES)

DRIVE CHAIN AND SPROCKET 4. To remove rear axle sprocket, lift sprocket to top of
chain case. Pull bottom of sprocket out over
REMOVAL/INSTALLATION bottom lip of chain case and remove rear axle
1. Drain oil from chain case being serviced and sprocket.
remove chain case access plate. (See CHAIN
CASE ACCESS PLATE.)
NOTE: Front and rear drive chains are not repairable.
Replace chains if necessary.
NOTE: It is necessary to remove rear axle housing
Front Drive Chain
and rear drive chain from the drive shaft before
removing front drive chain.

2. Remove wheel and axle housing for each drive


chain being serviced. (See AXLE HOUSING
REMOVAL/INSTALLATION.)

IMPORTANT: Be sure to follow all jacking and


cleaning instructions. KV13155

Rear Drive 5. Slide front axle sprocket rearward and remove front
Front Drive
Chain Chain
drive chain from drive shaft and front sprocket.
6. If removal of drive shaft or front axle sprocket is
necessary, park brake must be loosened and
sprocket pushed toward center of machine to allow
clearance. (See BRAKE REMOVAL and
DISASSEMBLY in the BRAKES section.)
Drive Shaft 7. Installation is done in the reverse order of removal.

Right Side of Skid Steer Shown. KV13157

3. Slide rear axle sprocket forward and remove rear


drive chain from drive shaft and rear axle sprocket.

5 - 12 1/3/01
HYDROSTATIC POWER TRAIN CONTENTS

CONTENTS
HYDROSTATIC POWER TRAIN

Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TESTS AND ADJUSTMENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE PARTS KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HYDROSTATIC SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HYDROSTATIC COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . 6
HYDROSTATIC SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HYDRAULIC/CHARGE PUMP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HYDRAULIC/CHARGE PUMP FLOW TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
HYDROSTATIC PUMP HIGH PRESSURE RELIEF TEST . . . . . . . . . . . . . . . . . . . . 12
WHEEL SPEED TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HYDROSTATIC PUMP FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
HYDROSTATIC PUMP CASE DRAIN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HYDROSTATIC CASE DRAIN PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
START-UP PROCEDURE AFTER COMPONENT REPLACEMENT. . . . . . . . . . . . . 20
HYDROSTATIC PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FRONT HYDROSTATIC PUMP EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . 23
CENTER MANIFOLD EXPLODED VIEW (EARLY MODELS). . . . . . . . . . . . . . . . . . 24
CENTER MANIFOLD EXPLODED VIEW (LATE and CONVERTED MODELS) . . . . 25
REAR HYDROSTATIC PUMP EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
HYDROSTATIC PUMP DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
HYDROSTATIC PUMP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
HYDROSTATIC PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
HYDROSTATIC PUMP INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
HYDROSTATIC MOTOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 37
HYDROSTATIC MOTOR EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
HYDROSTATIC MOTOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
HYDROSTATIC MOTOR INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
HYDROSTATIC MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

11/22/00 6-1
CONTENTS HYDROSTATIC POWER TRAIN

This page intentionally left blank

6-2 11/22/00
HYDROSTATIC POWER TRAIN SPECIFICATIONS

SPECIFICATIONS

TESTS AND ADJUSTMENTS SPECIFICATIONS


Hydraulic Oil Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43°C (110°F)
Charge Circuit Pressure . . . . . . . . . . . . . . . . . . . . . . . . 1379—1551 kPa (200—225 psi)
Hydrostatic Pump Flow (approximate) . . . . . . . . . . . . . . . . . . . . . . 90.8 L/min (24 gpm)
Hydrostatic Pressure Relief Setting . . . . . .34 474 kPa ± 1379 kPa (5000 psi ± 200 psi)
Wheel Speed (Optimal) at WOT (2400 minimum) Engine RPM (within 1 rpm each side)
Model 240 Forward Reverse Min Reverse
Through serial number –242579 80—85 rpm 65—70 rpm 60 rpm
After serial number 242579– 80—85 rpm 80—85 rpm 60 rpm

Model 250 Forward Reverse Min Reverse


Through serial number –252793 70—75 rpm 60—65 rpm 52 rpm
After serial number 252793– 70—75 rpm 70—75 rpm 52 rpm
Maximum Pump Case Drain Flow (Single Pump) . . . . . . . . . 0.95 L (2 pt) in 10 seconds
Maximum Pump Case Drain Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 172 kPa (25 psi)
Hydraulic/Charge Pump Flow:
(Standard):
240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.1 L/min (13 gpm)
250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.7 L/min (15 gpm)
(High-Flow Option):
240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.8 L/min (22.4 gpm)
250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98.1 L/min (25.9 gpm)

SERVICE PARTS KITS


Refer to the Parts Catalog for the Following Available Service Parts Kits:
Hydrostatic Pump Seal Kit (Front or Rear)
Hydrostatic Motor Seal Kit

TORQUE SPECIFICATIONS
Hydrostatic High Pressure Relief Valves. . . . . . . . . . . . . . . . . . . . . . 135 N•m (100 lb-ft)
Hydraulic/Charge Pump Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . 35 N•m (26 lb-ft)
Hydrostatic Pump-to-Center Manifold Cap Screws. . . . . . . . . . . . . . . . 56 N•m (41 lb-ft)
Hydrostatic Pump Mounting Flange-to-Flywheel Housing . . . . . . . . . 118 N•m (87 lb-ft)
Hydrostatic Pump Mounting Bracket-to-Hydrostatic Pump . . . . . . . . . 39 N•m (29 lb-ft)
Hydrostatic Pump Drive Hub Set Screws . . . . . . . . . . . . . . . . . . . . . . . 37 N•m (27 lb-ft)
Hydrostatic Pump Cover Plate Cap Screws . . . . . . . . . . . . . . . . . . . . . 41 N•m (30 lb-ft)
Centering Plate Mount Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 N•m (30 lb-ft)
Centering Plate Spring Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 N•m (50 lb-ft)
Centering Plate Guide Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft)
Control Rod Cap Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Hydrostatic Motor Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . 118 N•m (87 lb-ft)
Hydrostatic Motor Flange Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . 82 N•m (60 lb-ft)
Hydrostatic Motor Relief Valve Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)
Hydrostatic Motor Shuttle Valve Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 41 N•m (30 lb-ft)

REPAIR SPECIFICATIONS
Reservoir Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6 L (4.1 gal)
System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 L (6 gal)

11/22/00 6-3
SPECIFICATIONS HYDROSTATIC POWER TRAIN

SPECIAL OR ESSENTIAL TOOLS


Bench-Mounted Holding Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D01006AA

OTHER MATERIALS

Number Name Use

Petroleum Jelly Apply to components of hydrostatic pump


during assembly

TY6238 John Deere HY-GARD® Apply to internal surfaces of hydrostatic pump


and hydrostatic motor during assembly.

LOCTITE®
PRODUCTS
U.S./
Canadian/
LOCTITE No.

TY9370/ Thread Lock & Sealer Apply to hydrostatic pump drive hub set
TY9477 (Medium Strength) screws.
242

LOCTITE is a registered trademark of Loctite Corp.


HY-GARD is a registered trademark of Deere & Company.

6-4 11/22/00
HYDROSTATIC POWER TRAIN HYDROSTATIC SYSTEM OPERATION

HYDROSTATIC SYSTEM OPERATION

Function: Oil flow is controlled by changing the angle of the cam


The Hydrostatic System provides a means to transfer plate (swash plate). The position from center of the cam
power from the engine to the hydrostatic motors that plate (swash plate) controls the distance the pistons
drive the wheels. It also provides infinitely variable travel inside the piston bore of the rotating assembly.
speed and steering. The direction the cam plate (swash plate) is pivoted
from center determines the direction of oil flow (forward
or reverse). The amount of angle the cam plate (swash
Theory of Operation: plate) is deflected determines how much oil will be
The hydrostatic system is a closed loop fluid power displaced (speed).
system that consists of two tandem mounted piston The hydrostatic pumps provide oil to the hydrostatic
pumps and two GEROLER® motors. Charge pressure motors through hydrostatic lines and fittings. Oil in the
is provided by a gear pump located on the front of the hydrostatic system circulates in a closed loop. Oil
hydrostatic pump assembly. leaves the hydrostatic pumps and flows through the
Steering is controlled by two hand levers located in the hydrostatic motors and is returned to the hydrostatic
operator’s cab. These hand levers control direction pump, not the reservoir. Oil that leaves this closed loop
(forward, reverse) and speed (oil flow) of the vehicle by circuit, such as case drain, is replenished by oil from the
pivoting the cam plates (or swash plates) in the gear pump. (See HYDRAULICS section).
hydrostatic pumps. (See STEERING section.) The rear hydrostatic pump drives the right hydrostatic
motor and the front hydrostatic pump drives the left
• Hydrostatic Pump: hydrostatic motor.
The hydrostatic pumps are tandem mounted, manually
variable displacement, axial piston pumps. They are • Hydrostatic Motors:
mounted as an assembly to the flywheel housing. The hydrostatic motors are GEROLER® motors. There
Power is transferred directly from the engine to the are two hydrostatic motors on each machine and are
hydrostatic pump assembly by a hub coupler splined on mounted on brake assemblies which are located on the
the hydrostatic pump shaft. right and left chain cases under the operator’s seat.
Each motor drives a sprocket/chain system which
transfers power to the wheels. [See POWER TRAIN
(CHAIN CASE AND AXLES) section.] The right-hand
motor drives the right wheels, the left-hand motor drives
the left wheels.

GEROLER is a registered trademark of Eaton Corporation.

11/22/00 6-5
HYDROSTATIC COMPONENT LOCATION HYDROSTATIC POWER TRAIN

HYDROSTATIC COMPONENT LOCATION

Center Manifold

Right Brake Assembly

Rear Hydrostatic Pump


(For Right Wheels)

Front Hydrostatic Pump


(For Left Wheels)
Hydraulic/Charge Pump

Left Brake Assembly

Right Hydrostatic Motor

Left Hydrostatic Motor

KV15143

6-6 11/22/00
HYDROSTATIC POWER TRAIN HYDROSTATIC SYSTEM SCHEMATIC

HYDROSTATIC SYSTEM SCHEMATIC

Charge Flow
Brake Valve

210 psi 75 psi


Spin-On
Hydraulic Filter
Reservoir

B A

To
Main
Control
Valve

Drive Motor

Brake

Hydraulic/Charge
Pump
Hydrostatic High Flow
Pumps Valve (Optional)

Engine
Oil
Cooler
High Flow
Pump 3300 psi
(Optional)

To
Main
Control
Valve

Brake

Drive Motor
From
Main
Control
Valve

M18535

11/22/00 6-7
TROUBLESHOOTING HYDROSTATIC POWER TRAIN

TROUBLESHOOTING

Problem or

One side drives, other does


Symptom

Machine will not move in

Sluggish response to
Noisy pump or motor

changes in speed
either direction

Low power
Check or
Solution

not
Hydraulic oil level low in
reservoir ● ● ●
Check and top off oil level

Hydrostatic pump not running



Check engine coupling

Low charge pressure


● ● ●
Check charge pump

Oil too heavy


● ● ●
Cold weather

Shuttle valve stuck open


● ● ●
Check valve

Air in system
● ● ●
Purge

Output pressure too low


● ● ● ●
Check output pressure

Internal pump or motor damage ● ● ● ●

Park brake engaged or


● ● ● ●
dragging

Pump linkage not centered for


● ●
neutral on one or both pumps

Broken drive chain ●

Linkages loose or broken ● ● ●

6-8 11/22/00
HYDROSTATIC POWER TRAIN DIAGNOSIS

DIAGNOSIS

Test Conditions:
• Operator in seat.
• Seat belt fastened.

Test/Check Point Normal If Not Normal

1. Steering levers. Levers should move freely. Check linkage from levers to pump.

Test Conditions:
• Start engine and run at low idle.
• Release Park Brake.

Test/Check Point Normal If Not Normal

1. Steering levers are in neutral. Machine should not creep forward or Perform steering system
backward or in circles. adjustments.

2. Move levers smoothly forward Machine should accelerate smoothly Check oil reservoir for proper oil
or backward from center. forward or backward. level.
Check hydrostatic hoses, tubing,
and connections for leaks.
Perform case drain flow and
hydrostatic pressure and flow tests
to verify proper operation of
hydrostatic pumps.

3. Steering levers in full forward Machine should move forward in a Perform steering system
position. straight line. adjustments.
Perform hydrostatic pump tests.

11/22/00 6-9
TESTS AND ADJUSTMENTS HYDROSTATIC POWER TRAIN

TESTS AND ADJUSTMENTS 4. Disconnect charge flow line at left side of


hydrostatic pump center manifold.
HYDRAULIC/CHARGE PUMP
PRESSURE TEST
Reason:
To ensure there is sufficient oil pressure to charge the
hydrostatic systems properly and supply oil to the 38H5069
JT03457
hydraulic system.
JT03017
Equipment: JT03344
• JT03344 — 2068 kPa (300 psi) Gauge
• JT03017 Hose with quick disconnect
• 38H5069 Tee Fitting (Parker #8 R6LO-S) 13/16-16
Female Swivel ORFS x 13/16-16 Male ORFS x
13/16-16 Male ORFS
KV15134
• JT03457 Adapter (in Kit #JT05412)
• JT0KV12444 Remote Start Box 5. Connect JT03017 Hose to JT03457 Adapter.
6. Attach JT03344 Gauge to quick disconnect on
hose.

c CAUTION NOTE: Make sure all O-rings used between


connections are in good condition to prevent
To help prevent injury from escaping hydraulic leakage during test.
oil under pressure, relieve the pressure in the
system before removing hydraulic lines. 7. Connect 38H5069 Tee Fitting to adapter and tighten
all connections.

Procedure: 8. Connect 38H5069 Tee Fitting to center manifold


fitting and attach charge flow line to opposite end
1. Raise and block skid steer. (See RAISING AND of Tee Fitting.
BLOCKING SKID STEER in the
MISCELLANEOUS section.)
2. Raise boom fully and engage the boom lock. Stop
engine and relieve hydraulic pressure.
c CAUTION
3. Remove cover plates to access the hydrostatic
pumps. (See REMOVING COVER PLATES in Avoid possible injury from moving tires when
MISCELLANEOUS section.) using remote start box. Keep tire area clear of
bystanders. Do NOT use remote start box
without raising and blocking skid steer.
Hydraulic Oil
9. Install remote start box. (See USING REMOTE
Filter Manifold
START BOX in the MISCELLANEOUS section.)
10. Use remote start box to start engine.
11. Operate hydraulic controls until oil reaches normal
operating temperature of 43°C (110°F).
Charge Flow Line 12. Set throttle to full advance.

Specifications:
• Charge pressure must be 1379—1551 kPa
(200—225 psi)

Results:
1. If charge pressure does not meet specifications,
test pump flow.
2. If pump flow meets specifications, replace complete
hydraulic oil filter manifold.
3. If pump flow does not meet specifications, replace
or rebuild hydraulic/charge pump.
KV18853

6 - 10 11/22/00
HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS

HYDRAULIC/CHARGE PUMP FLOW IMPORTANT: Make sure skid steer male connector
is routed to tester inlet.
TEST
Reason: Female Auxiliary Connector
To ensure that the hydraulic/charge pump is delivering
sufficient oil flow to operate the hydraulic system
properly.

Equipment:
• D01074AA In-Line Hydraulic Tester
• KV13885 Quick Disconnect, Male
• KV13884 Quick Disconnect, Female Male Auxiliary Connector
• JT03377 Hose, 2 required
• JT03012 Connector, 2 required KV18562
• JT05690 Connector, 2 required 6. Attach quick disconnects to auxiliary hydraulic ports
located on left boom arm.
Procedure:
7. Operate hydraulic system until oil reaches normal
1. Lower boom and bucket to normal ground position. operating temperature of 43°C (110°F).
Stop engine and relieve hydraulic pressure.
8. Set engine speed to full throttle position.
2. Raise and block skid steer. (See RAISING AND
9. Actuate auxiliary hydraulics control handle into
BLOCKING SKID STEER in the
detent (down toward seat) position.
MISCELLANEOUS section.)
10. Turn load valve knob to increase resistance until
pressure reads 10 340 kPa (1500 psi).

Specifications:
KV13885
JT03012 JT03377 Minimum Pump Flow (Standard)
JT05690 240 . . . . . . . . . . . . . . . . . . . . . 49.1 L/min (13 gpm)
KV13884 250 . . . . . . . . . . . . . . . . . . . . . .56.7 L/min (15 gpm)

Minimum Pump Flow (High-Flow Option)


KV15257
240 . . . . . . . . . . . . . . . . . . . . 84.8 L/min (22.4 gpm)
250 . . . . . . . . . . . . . . . . . . . . 98.1 L/min (25.9 gpm)
3. Install JT03012 and JT05690 Connectors on one
end of both JT03377 Hoses.
4. Install KV13885 and KV13884 Quick Disconnects Results:
on connectors. 1. Check auxiliary hydraulic control valve spool travel
and control handle pivot and linkage to make sure
Male Quick Outlet mechanical systems are operating properly.
Disconnect-
2. If flow is low, verify proper engine speed at full
to-Inlet Hose
Outlet-to-Female throttle. If engine speed is OK, rebuild or replace
Quick Disconnect charge pump.
Hose 3. If machine is equipped with High-Flow option and
has low flow or is overheating, check to make sure
lift check valve assemblies have been removed
from control valve. (See CONTROL VALVE
ASSEMBLY in HYDRAULIC section.)
Inlet

D01074AA
In-Line
Hydraulic
Tester KV15136
5. Connect JT03377 Hose to D01074AA In-Line
Hydraulic Tester.

11/22/00 6 - 11
TESTS AND ADJUSTMENTS HYDROSTATIC POWER TRAIN

HYDROSTATIC PUMP HIGH


PRESSURE RELIEF TEST
240 Models through serial number: –KV0240A142337
250 Models through serial number: –KV0250A152709

Right
Forward Right Forward
Port Relief Valve
Left Forward
Relief Valve Left Forward
Port

JT03340
Right Reverse Port Quick Coupler
Left
Reverse JT03362
Port Test Gauge

Left Reverse JT05489


Relief Valve Connector

Right Reverse
Relief Valve JT03364
Test Hose
38H1035 RE60700
Tee Fitting Diagnostic
Receptacle

KV18036

240 Models above serial number: KV0240A142337– or if PIP 00KV010 has been performed
250 Models above serial number: KV0250A152709– or if PIP 00KV010 has been performed

Right Reverse Relief Valve


Left Forward
Relief Valve Left Forward
Right Reverse Port Port
Right Forward Port
JT03362
Test Gauge

Right JT03340
Forward Quick Coupler
Relief Valve
JT05489
Connector
Left
JT03364
Reverse Left
Test Hose
Relief Valve Reverse
Port 38H1035
Tee Fitting

RE60700
Diagnostic
Receptacle

KV31049

6 - 12 11/22/00
HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS

Reason:

c CAUTION
To ensure that hydrostatic pump high pressure relief
valves are operating properly.

Equipment: To help prevent injury from escaping hydraulic


oil under pressure, relieve the pressure in the
• 38H1035 Tee Fitting system before removing hydraulic lines.
• JT05489** Connector (7/16-20M 37°x1/2-20M
ORB) 6. Install 38H1035 Tee Fitting in the hydrostatic closed
• JT03340** Quick Coupler loop circuit at the hydrostatic pump center manifold
• JT03364* Hose port locations as indicated in HYDROSTATIC
• JT03362* Gauge 0—70 000 kPa (0—10,000 psi) PUMP HIGH PRESSURE RELIEF TEST diagram:
• JT0KV12444 Remote Start Box Left Forward Relief Valve—Right Top Port
• RE60700 Diagnostic Receptacle Left Reverse Relief Valve—Right Bottom Port
* Part of JT05738 Compact Utility Tractor Hydraulic Fitting Kit Right Forward Relief Valve—Left Top Port
** Part of JT01765 Kit Application Right Reverse Relief Valve—Left Bottom Port
7. Connect test hose, fittings, and gauge to tee fitting.
Procedure: 8. Start and operate engine at 3/4 throttle until
hydraulic oil reaches 43°C (110°F).
1. Park skid steer safely.
9. Slowly move corresponding steering lever in
2. Raise and block skid steer. (See RAISING AND
appropriate direction for relief valve being tested.
BLOCKING SKID STEER in the
MISCELLANEOUS section.) 10. Record gauge reading.
3. Remove cover plates to access the hydrostatic 11. Perform steps 6—10 for all four relief valves as
pumps. (See REMOVING COVER PLATES in the necessary.
MISCELLANEOUS section.)
Specifications:
c CAUTION • Pump pressure should be 34 474 ± 1379 kPa
(5000 ± 200 psi).
Avoid possible injury from moving tires when
using remote start box. Keep tire area clear of Results:
bystanders. Do not use remote start box without
raising and blocking skid steer. If pressure is not within specifications, replace the
corresponding relief valve.
4. Install remote start box. (See USING REMOTE
START BOX in the MISCELLANEOUS section.)
WHEEL SPEED TEST
5. Install a M10x30 cap screw in both steering control
arms to secure them to the frame.
Reason:
IMPORTANT: Make sure that the hydraulic fluid in To use as an initial test to verify if hydrostatic system is
the reservoir is at the full mark. Insufficient operating normally.
hydraulic fluid could cause the system to run
dry and damage pumps and motors.
Equipment:
• JT05719 Hand Held Digital Tachometer
NOTE: Illustration shows gauge connection for testing
the left reverse relief valve. • JT05709 Reflective Tape

Procedure:

IMPORTANT: Before performing this procedure,


make sure engine high idle is to specification.
(See FAST AND SLOW IDLE ADJUSTMENT in
the DIESEL ENGINE section.)

11/22/00 6 - 13
TESTS AND ADJUSTMENTS HYDROSTATIC POWER TRAIN

1. Park skid steer safely. Results:


2. Raise and block skid steer. (See RAISING AND If wheel speed is significantly outside of the listed
BLOCKING SKID STEER in the ranges:
MISCELLANEOUS section.)
3. Apply reflective tape to one wheel at both sides of • Perform Engine Fast and Slow Idle test. (See FAST
machine. AND SLOW IDLE ADJUSTMENT in the ENGINE
section.)
• Inspect brakes for dragging

c CAUTION
• Perform Hydraulic/Charge Pump Pressure test.
(See HYDRAULIC/CHARGE PUMP PRESSURE
TEST in this section.)
To help prevent injury from moving tires when • Hydrostatic Pump Case Drain test. (See
performing the wheel speed test, have an HYDROSTATIC PUMP CASE DRAIN test in this
assistant operate the controls while seated in section.)
the machine. • Perform Hydraulic/Charge Pump Flow Test. (See
HYDRAULIC/CHARGE PUMP FLOW TEST in this
section.)
IMPORTANT: Make sure that the hydraulic fluid in • Hydostatic Case Drain Pressure Test. (See
the reservoir is at the full mark. Insufficient HYDROSTATIC CASE DRAIN PRESSURE TEST
hydraulic fluid could cause the system to run in this section)
dry and damage pumps and motors. If wheel speed varies more than 1 rpm from side to side,
perform tracking adjustment. (See CONTROL LEVER
STOPS ADJUSTMENT–TRACKING in the steering
4. Start and operate engine at 3/4 throttle until
SECTION.)
hydraulic oil reaches 43°C (110°F).
5. Increase engine rpm to high idle. Verify rpm is
correct. (See FAST AND SLOW IDLE
ADJUSTMENT in the ENGINE section.)
HYDROSTATIC PUMP FLOW TEST
6. With hydrostatic control (steering) lever moved fully
to forward position, measure and record rotations Reason:
in one minute of corresponding wheel that has the
reflective tape. To ensure that the hydrostatic pumps are delivering
7. Move hydrostatic control lever fully rearward. sufficient oil flow to the hydrostatic motors.
Measure and record rotations in one minute of
same wheel.
Equipment:
8. Repeat steps 6 and 7 for opposite side.
9. Stop engine. • D01074AA -In-Line Hydraulic Tester
• JT03377 - 2- 365cm (10 ft) hoses, ¾ M NPT x ¾ M
NPT
Specifications (Optimal): • JT03012 – ¾ F NPT x 1-1/16 F 37° Flare (2 used)
Wheel Rotations • JT05690 – 1-3/16-12 F ORFS Sw x 1-1/16-12 37°
Model 240 WOT RPM in One Minute M Flare (2 used)
• 38H1272 – 1-3/16-12 M ORFS x 1-3/16-12 M
Serial Number Forward Reverse ORFS
–242579 (2400 minimum) 80—85 65—70
242580– (2400 minimum) 80—85 80—85
Procedure:
Wheel Rotations
1. Park skid steer safely.
Model 250 WOT RPM in One Minute
2. Raise boom and place on boom locks.
Serial Number Forward Reverse 3. Stop engine. Turn key to ON position and operate
–252793 (2400 minimum) 70—75 60—65 all hydraulic controls to relieve hydraulic pressure.
252794– (2400 minimum) 70—75 70—75 4. Raise and block skid steer. (See RAISING AND
BLOCKING SKID STEER in the
MISCELLANEOUS section.)
IMPORTANT: Left and right sides must be within 1 5. Remove cover plates to access hydrostatic pumps.
rpm to provide proper steering control. (See COVER PLATE REMOVAL/INSTALLATION in
the MISCELLANEOUS section.)

6 - 14 11/22/00
HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS

c CAUTION Right Forward Port (A)

Right Forward Port (B)


Avoid possible injury from moving tires when
using remote start box. Keep tire area clear of
bystanders. Do not use remote start box without
raising and blocking skid steer.

6. Install remote start box. (See USING REMOTE


START BOX in the MISCELLANEOUS section.)
Left Forward Port
IMPORTANT: Make sure that the hydraulic fluid in
the reservoir is at the full mark. Insufficient
hydraulic fluid could cause the system to run
dry and damage the pumps and motors. KV31088

A. Through serial numbers: –KV0240A142337


–KV0250A152709
M10 x 30 Cap Screw B. Above serial numbers: KV0240A142337–
KV0250A152709–
or if P.I.P. 00KV010 has been
performed on earlier model.

8. Identify correct port on center manifold to determine


which pump will be tested.
.

c CAUTION
To help prevent injury from escaping hydraulic
oil under pressure, relieve the pressure in the
system before removing hydraulic lines.

IMPORTANT: Clean all hydraulic connections to


prevent contamination of hydraulic system.
KV13980
NOTE: It is not necessary to remove steering control
handle boots. Boots have been removed for
clarity only. Left Forward Port
7. Install a M10 X 30 cap screw in both steering
control arms to secure them to the frame.

Line to Motor

KV31087

NOTE: Left side pump is shown. Test for the right side
pump is similar.
9. Disconnect hydraulic line from elbow fitting on
pump.

11/22/00 6 - 15
TESTS AND ADJUSTMENTS HYDROSTATIC POWER TRAIN

38H1272 Connect to Hose Line to Motor

JT03012
JT05690 Inlet
JT03377 Outlet

Connect to Pump

Line from Pump


Load Valve
KV31085
KV31089
10. Install fittings on JT03377 hydraulic lines as shown.
13. Connect line from pump to inlet port on in-line
tester.
Elbow
Line to Tester Inlet Port 14. Connect other line to the outlet side of tester.
15. Turn load valve all the way open.
16. Start skid steer and operate steering controls to
heat oil up to normal operating temperature of
43°C (110°F).
17. Run at fast idle and push left steering control arm
all the way forward.
18. Slowly turn load valve knob IN to increase pressure
to 13790 kPa (2000 psi)
19. Check flow through meter.
Line to Motor
Line from Tester
Outlet Port Specifications:
KV31086 Minimum Pump Flow (approximate):
240 . . . . . . . . . . . . . . . . . . . . . . . 90.8 L/min (24 gpm)
11. Connect hydraulic line with 38H1272 ORFS union
250 . . . . . . . . . . . . . . . . . . . . . . . 90.8 L/min (24 gpm)
to hydraulic line disconnected from pump.
12. Connect the other hydraulic line to the elbow fitting
on pump. Results:
If flow is low:
• Verify proper engine speed at full throttle.
• Verify proper control lever travel.(See CONTROL
LEVER STOPS ADJUSTMENT-TRACKING in the
STEERING section.)
• Inspect steering linkage. Should not be sloppy.
Repair or replace pump.

6 - 16 11/22/00
HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS

HYDROSTATIC PUMP CASE DRAIN TEST

Tee Fitting

Left Drive Motor


Drain Hose

Right Drive Motor


Drain Hose

Return Drain Hose

KV18070

Reason: 5. Install a M10x30 cap screw in both steering control


arms to secure them to the frame.
To ensure that hydrostatic pump is not bypassing
excessive hydraulic oil.
IMPORTANT: Make sure that the hydraulic fluid in
Equipment: the reservoir is at the full mark. Insufficient
hydraulic fluid could cause the system to run
• 38H1415 Cap Assembly dry and damage pumps and motors.
• 38H1416 Cap Assembly
• 38H1206 Union Tee 6. Start and operate engine at 3/4 throttle until
• 8-6 TRLO-5 (Parker) Adapter hydraulic oil reaches normal operating temperature
• 3/8 ID x 24" Long Hose with Hose Clamp of 43°C (110°F).
• JT0KV12444 Remote Start Box 7. Stop engine.
• Graduated Breaker

Procedure: c CAUTION
1. Park skid steer safely.
2. Raise and block skid steer. (See RAISING AND To help prevent injury from escaping hydraulic
BLOCKING SKID STEER in the oil under pressure, relieve the pressure in the
MISCELLANEOUS section.) system before removing hydraulic lines.
3. Remove cover plates to access the hydrostatic
pumps. (See REMOVING COVER PLATES in the
MISCELLANEOUS section.)
c CAUTION
c CAUTION To help prevent injury from escaping hot oil, use
suitable protection when disconnecting the
Avoid possible injury from moving tires when hydraulic lines.
using remote start box. Keep tire area clear of
bystanders. Do NOT use remote start box 8. Disconnect return drain hose and left drive motor
without raising and blocking skid steer. drain hose from tee fitting at left side of rear
hydrostatic pump.
4. Install remote start box. (See USING REMOTE 9. Disconnect right motor drain hose from fitting at
START BOX in the MISCELLANEOUS section.) right side of front hydrostatic pump.

11/22/00 6 - 17
TESTS AND ADJUSTMENTS HYDROSTATIC POWER TRAIN

38H1415
Cap Assembly

38H1416
Cap Assembly

Return Drain Hose 9.5 mm (3/8 in.) ID


Hose
Test Hose
Clamp

Right Drive Motor


Drain Hose
8-6 TRLO-S 38H1206
Adapter Union Tee

Left Drive Motor


Drain Hose
KV18071

10. Connect the left drive motor drain hose and the NOTE: To ensure accurate readings, outlet of test
return drain hose to 38H1206 Union Tee. hose should be above hydraulic reservoir full
11. Connect the right drive motor drain hose to line.
38H1206 Union Tee using 8-6 TRLO-S Adapter.
12. Install 38H1416 Cap Assembly to rear port on tee 19. Transfer hose from container to graduated beaker.
fitting at left side of rear hydrostatic pump.
20. Capture fluid for a 10-second period of time. Return
13. Install 38H1415 Cap Assembly to fitting on right hose to container.
side of front hydrostatic pump.
14. Connect 9.5 mm (3/8 in.) ID test hose of
appropriate length to tee fitting at left side of rear IMPORTANT: Complete this test within 20 seconds
pump. Fasten using a hose clamp. to avoid overheating hydraulic oil.
15. Put end of test hose in a suitable container.
16. Start engine and disengage park brake.
21. Stop engine.
17. Run engine at 3/4 throttle until hydraulic oil reaches
22. Record volume of oil in graduated beaker.
normal operating temperature of 43°C (110°F).

Specifications:
IMPORTANT: Move only the corresponding
steering lever of pump being tested. If both • Volume in graduated beaker should not exceed
steering levers are moved during the test, an 0.95 L (2 pt) in 10 seconds.
inaccurate reading will result.
Results:
18. Move corresponding steering lever of pump being If volume exceeds specifications, repair or replace
tested slowly forward or backward until fluid flows pump.
from end of hose.
Repeat steps 14—20 for the other hydrostatic pump.

6 - 18 11/22/00
HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS

HYDROSTATIC CASE DRAIN


PRESSURE TEST
Reason: Plug
To check if there is excessive pressure in the
hydrostatic pump case.

IMPORTANT: Excessive drain pressure may cause


the pump case to rupture.

Equipment:
• JT0KV12444 Remote Start Box
KV18022
• 38H1161 Adapter
• JT03457 Adapter 6. Remove plug from right side of rear hydrostatic
• JT05498* Hose pump housing.
• JT05472* Gauge 0—400 kPa (0—60 psi) 7. Install 38H1161 Adapter in port.
8. Install JT03457 Adapter on 38H1161 Adapter.
*Part of JT05470 Universal Pressure Test Kit 9. Install gauge and hose assembly.
10. Start and operate engine at 3/4 throttle until
Procedure: hydraulic oil reaches normal operating temperature
of 43°C (110°F).
1. Park skid steer safely.
11. Disengage park brake. Move both steering levers
2. Raise and block skid steer. (See RAISING AND slowly forward or backward.
BLOCKING SKID STEER in the
MISCELLANEOUS section.) 12. Record gauge reading.
3. Remove cover plates to access the hydrostatic 13. Stop engine.
pump. (See REMOVING COVER PLATES in the
MISCELLANEOUS section.) Specifications:
• Case drain pressure should not exceed 172 kPa

c CAUTION
(25 psi).

Results:
Avoid possible injury from moving tires when If case drain pressure is over specifications:
using remote start box. Keep tire area clear of
bystanders. Do NOT use remote start box 1. Check for restriction in return drain hose
without raising and blocking skid steer. 2. Repair or replace pump or motor.

4. Install remote start box. (See USING REMOTE


START BOX in the MISCELLANEOUS section.)
5. Install a M10x30 cap screw in both steering control
arms to secure them to the frame.

c CAUTION
To help prevent injury from escaping hydraulic
oil under pressure, relieve the pressure in the
system before removing hydraulic lines.

IMPORTANT: Make sure that the hydraulic fluid in


the reservoir is at the full mark. Insufficient
hydraulic fluid could cause the system to run
dry and damage the pumps and motors.

11/22/00 6 - 19
REPAIR HYDROSTATIC POWER TRAIN

REPAIR
START-UP PROCEDURE AFTER 38H5069
COMPONENT REPLACEMENT JT03457

1. Park skid steer safely. JT03017


JT03344
2. Raise and block skid steer. (SEE RAISING AND
BLOCKING SKID STEER in the
MISCELLAENOUS section.)
3. Raise ROPS and ensure ROPS is safely in the
locked position.
KV15134
11. Install gauge as described in HYDRAULIC/

c CAUTION CHARGE PUMP PRESSURE TEST. (See


HYDRAULIC/CHARGE PUMP PRESSURE
TEST.)
Avoid possible injury from moving tires when 12. Put steering levers in neutral position. Start engine
using remote start box. Keep tire area clear of using remote start box and operate at low idle.
bystanders. Do NOT use remote start box Charge pressure should read 550—830 kPa
without raising and blocking skid steer. (80—120 psi) within 5 to 10 seconds.
IMPORTANT: If charge pressure remains below
4. Install remote start box. (See USING REMOTE 350 kPa (50 psi) for more than 10 seconds, stop
START BOX in the MISCELLANEOUS section.) engine and check for cause of low pressure.
5. Change hydraulic system filter. Failure to stop engine when charge pressure is
6. Remove hydraulic breather assembly on top of low will cause severe damage to pumps and
reservoir. Clean filter in solvent and dry before motors.
installation.

IMPORTANT: If contamination is found in hydraulic


system or component, flush entire hydraulic
c CAUTION
system.
To help prevent injury from escaping hydraulic
If the hydraulic oil is being reused, make sure it oil under pressure, relieve the pressure in the
is filtered through a 10-micron filter before system before removing hydraulic lines.
putting into reservoir.
13. Stop engine after proper charge pressure has been
7. Fill reservoir with HY-GARD or LOW VIS HY-GARD indicated, and relieve all hydraulic pressure in
(cold weather operation) to the proper level. system.
Approximate capacity of reservoir is 15.6 L 14. Remove gauge and install hydraulic lines.
(4.1 gal). 15. Remove remote start box and lower ROPS.
8. Disconnect wires to fuel shut-off solenoid. 16. Disengage boom lock and lower boom with boom
9. Turn remote start box key to START and crank and bucket cylinders fully retracted.
engine for 10 seconds. 17. Start engine and operate at half throttle for 20
10. Connect wires to fuel shut-off solenoid. minutes. Stop engine and check hydraulic oil level.
Fill as needed.
18. Start engine and operate at half throttle. Move boom
arm and bucket pedals for 3 minutes to remove air
from system and to progressively load charge
pump.
19. Slowly move steering levers with no load on wheels
to eliminate trapped air.
20. Stop engine and check hydraulic reservoir oil level.
Check all line connections for leaks and tighten if
necessary.
21. Adjust steering. (See STEERING section.)
22. Operate engine for an additional 30 minutes to
circulate oil through the filter. Stop engine. Change
hydraulic filter.
23. Lower skid steer to the ground.

6 - 20 11/22/00
HYDROSTATIC POWER TRAIN REPAIR

HYDROSTATIC PUMP REMOVAL


1. Remove cover plates. (See COVER PLATE
REMOVAL/INSTALLATION in the
MISCELLANEOUS section.) B

2. Remove steering cross shaft. (See STEERING C


CROSS SHAFT REMOVAL/INSTALLATION in the A
STEERING section.)
3. Remove centering plate(s). (See CENTERING
PLATE REMOVAL/INSTALLATION in the
STEERING section.)
F

E
Control Rods

KV18872
A. Hydrostatic Pump Center Manifold Port-to-
KV18869 Hydraulic Oil Filter Manifold Hose
B. Hydrostatic Pump Rear Port-to-Left Drive
4. Remove steering control rods from control levers. Motor Case Drain Hose
5. Drain hydraulic reservoir. C. Hydrostatic Pump Rear Port-to-Hydraulic/
Charge Pump Hose
D. Hydraulic/Charge Pump-to-Hydraulic Oil
Reservoir Hose
E. Hydrostatic Pump Bottom Left Center Manifold
Port-to-Left Drive Motor Top Rear Port Hose
Hydraulic F. Hydrostatic Pump Top Left Center Manifold
Fitting Port-to-Left Drive Motor Top Front Port Hose

Hydraulic
Line

KV18870

6. Remove rear hydraulic line from left drive motor.


Remove fitting from motor to provide clearance for
hydrostatic pump removal. Cap and plug openings.

11/22/00 6 - 21
REPAIR HYDROSTATIC POWER TRAIN

NOTE: Mark or tag all hydrostatic pump hoses to aid in


assembly.

Close all openings using caps and plugs.


G
7. Mark and disconnect hoses (A–J) from hydrostatic
H pump assembly.

I Cap Screws
(2 used)

Hydrostatic Pump
Assembly

Flywheel
Spacer Adapter Plate

Hydrostatic Pump
Mounting Bracket

KV18871
G. Through serial number:
Spacers
–KV0240A142337 or –KV0250A152709: (See Note)
Hydrostatic Pump Top Right Center Manifold
Port-to-Right Drive Motor Top Front Port Hose
Cap Screws
Cap Screws (See Note)
Above serial number:
KV0240A142337– or KV0250A152709– (or if (See Note)
KV18496
PIP 00KV010 has been performed):
Hydrostatic Pump Top Right Center Manifold
Port-to-Right Drive Motor Top Rear Port Hose NOTE: The quantity of screws and spacers have
changed throughout production. Your machine
H. Through serial number: may have five or six screws and four or five
–KV0240A142337 or –KV0250A152709: spacers. Refer to the appropriate parts catalog
Hydrostatic Pump Bottom Right Center for correct quantities for your machine.
Manifold Port-to-Right Drive Motor Top Rear
Port Hose
8. Remove six cap screws and four spacers from
Above serial number: mounting bracket.
KV0240A142337– or KV0250A152709– (or if 9. Remove two cap screws from pump assembly
PIP 00KV010 has been performed): flange.
Hydrostatic Pump Bottom Right Center 10. Slide pump assembly forward to remove from
Manifold Port-to-Right Drive Motor Top Front flywheel adapter plate.
Port Hose 11. Attach a sling and hoist to pump assembly and
remove from machine.
I. Hydrostatic Pump Front Port-to-Right Drive
Motor Case Drain Hose
J. Hydraulic/Charge Pump-to-Hydraulic Control
Valve Hose

6 - 22 11/22/00
HYDROSTATIC POWER TRAIN REPAIR

FRONT HYDROSTATIC PUMP EXPLODED VIEW

A
B
C

R D
N
E

M
F
L O

K
J Q
I
P
H

F
Front of Machine

D
B

A
S
KV31095

A. Screw (6 used) F. Bearing Cone J. Drive Shaft N. Valve Plate


B. Washer (6 used) G. Front Pump K. Cam Plate O. Shim(s)
C. Cover Plate Housing (or Swash Plate) P. O-Ring
D. O-Ring H. Ring L. Insert Q. Plug
E. Bearing Race I. Needle Bearing M. Rotating Assembly R. Seal
S. Cover Plate

NOTE: The front hydrostatic pump drives the left


hydrostatic motor.

Early models have factory installed shims (O).


Later models use a crush washer. The crush
washer is not a serviced part and must be
replaced by shims from a shim kit if pump
repair is necessary.

11/22/00 6 - 23
REPAIR HYDROSTATIC POWER TRAIN

CENTER MANIFOLD EXPLODED VIEW (EARLY MODELS)


Model 240 250
Through serial numbers: –KV0240A142337 –KV0250A152709

D
C
A
M B
E
M
F
J G

H
T I
U K
N
J
L
S

R N
Q P M

Front of Machine
O

KV31106

A. Center Manifold I. Left Reverse Port P. Left Reverse High Pressure


B. Washer (8 used) J. Dowel Pin (2 used) Relief Valve
C. Cap Screw (8 used) K. Front Gasket (early models) Q. Left Forward High Pressure
D. Right Forward High L. Front Gasket (late models) Relief Valve
Pressure Relief Valve M. Needle Bearing R. Right Reverse Port
E. O-Ring N. Roll Pin (2 used) S. Right Forward Port
F. Left Forward Port O. Right Reverse High T. Bushing
G. Plug Pressure Relief Valve U. Rear Gasket
H. O-Ring

NOTE: Early models have different front and rear


gaskets. Later models use same gasket (oval
with cutout).

6 - 24 11/22/00
HYDROSTATIC POWER TRAIN REPAIR

CENTER MANIFOLD EXPLODED VIEW (LATE and CONVERTED MODELS)


Model 240 250
After serial numbers: KV0240A142337– KV0250A152709–
and early models after PIP 00KV010 has been performed.

D
C
A
L B
E
L
F
J G

H
S I
T K
M
J

R M
P O L
Front of Machine
N

KV31094

A. Center Manifold H. O-Ring O. Left Reverse High Pressure


B. Washer (8 used) I. Left Reverse Port Relief Valve
C. Cap Screw (8 used) J. Dowel Pin (2 used) P. Left Forward High Pressure
D. Right Reverse High K. Front Gasket Relief Valve
Pressure Relief Valve L. Needle Bearing Q. Right Reverse Port
E. O-Ring M. Roll Pin (2 used) R. Right Forward Port
F. Left Forward Port N. Right Forward High S. Bushing
G. Plug Pressure Relief Valve T. Rear Gasket

11/22/00 6 - 25
REPAIR HYDROSTATIC POWER TRAIN

REAR HYDROSTATIC PUMP EXPLODED VIEW

A
I J
B C
D E H
F
K
E L

D G
M
N

W Q
R
S

V T

M
L

H
U Front of Machine
I
KV31096

A. Retaining Ring G. Drive Shaft M. Bearing Race R. Insert


B. Shaft Seal H. Washer (6 used) N. Bearing Cone S. Rotating Assembly
C. Washer I. Cap Screw (6 used) O. Plug T. Valve Plate
D. Snap Ring J. Cover Plate P. O-Ring U. Cover Plate
E. Bearing Race K. Seal Q. Cam Plate V. Shims
F. Thrust Bearing L. O-Ring (or Swash Plate) W. Needle Bearing

NOTE: The rear hydrostatic pump drives the right


hydrostatic motor.

Early models have factory installed shims (V).


Later models use a crush washer. The crush
washer is not a serviced part and must be
replaced by shims from a shim kit if pump
repair is necessary.

6 - 26 11/22/00
HYDROSTATIC POWER TRAIN REPAIR

HYDROSTATIC PUMP .

DISASSEMBLY c CAUTION
IMPORTANT: Clean hydrostatic and hydraulic/
charge pump cases before separating pumps to Use proper lifting equipment. Approximate
prevent contamination of hydraulic system. weight of pumps is 45 kg (100 lb).

Coupler

Set Screws
Input Shaft
KV18503

1. Measure or mark position of coupler on pump input


shaft to aid in assembly. Cap Screws and Nuts KV18505
2. Loosen two set screws and remove coupler from
input shaft. 4. Mount pumps on D01006AA Bench-Mounted
Holding Fixture using two cap screws and nuts.
Control Levers
Cap Screws

Mounts
KV18504 KV18873
5. Remove eight cap screws and remove hydraulic/
3. Remove control levers and front and rear centering
charge pump. (Refer to the HYDRAULICS section
plate mounts.
for disassembly and inspection procedures for the
hydraulic/charge pump.)

11/22/00 6 - 27
REPAIR HYDROSTATIC POWER TRAIN

c CAUTION
Note location and orientation of hydrostatic Relief
pump components. Components are not Valves
interchangeable between front and rear
hydrostatic pumps.

Front Pump
Housing

Cap Screws KV18509

11. Loosen four relief valves for ease of removal later.


12. Remove four cap screws holding center manifold to
rear pump
13. Lift center manifold off from rear pump.

Cap
Screws NOTE: Rotating assembly might "stick" to center
manifold due to hydraulic oil adhesion. Be
KV18507 careful not to let rotating assembly fall
6. Remove four cap screws securing front pump unexpectedly.
housing to center manifold.
7. Lift front pump housing straight up and off from
center manifold. 14. Remove rear valve plate from center manifold.

Drive Shaft Holding


Fixture

Rotating Assembly
Center Manifold

Rotating
Valve Assembly
Housing
Plate
KV18508

8. Pull out drive shaft from center manifold and KV18510


rotating assembly. 15. Using your hand, hold rotating assembly in
9. Lift rotating assembly from valve plate. housing.
16. Rotate holding fixture 180 degrees and slowly slide
out rotating assembly.
IMPORTANT: Valve plates are not interchangeable.
Note location of each valve plate.

10. Remove front valve plate from center manifold.

6 - 28 11/22/00
HYDROSTATIC POWER TRAIN REPAIR

Cover Plates

Snap Ring

Cam Plate
(Swash Plate)
KV18511
Trunnion
17. Remove snap ring holding seal and shaft. Housing Shaft KV18513

Housing
NOTE: Rear pump housing shown. The procedure is
Shaft the same for the front pump housing.

19. To aid in assembly, mark the side of the housing


where the trunnion shaft is.
20. Remove cover plates from pump housing.
21. Remove cam plate (swash plate) from housing.

KV18512

18. Using a soft-faced hammer, tap shaft from housing.

11/22/00 6 - 29
REPAIR HYDROSTATIC POWER TRAIN

HYDROSTATIC PUMP INSPECTION Cam Plate Bearing


Bearing (Swash Plate)
Outer Race
Outer
Race Seal

Needle Bearings KV18514


Insert
1. Inspect the needle bearings in the center manifold
and the front and rear pump housings. Replace the
needle bearing if needles do not remain in the O-Rings KV18516
bearing cage, are discolored, broken, pitted, or are 4. Inspect cam plate (swash plate) and cam plate
not free to move. insert. Surfaces should be smooth and free of
deep scratches.
Relief Valves
5. Discard O-rings and seal in cover plates.

IMPORTANT: Valve plates are not interchangeable.


Pump input rotation should always turn into the
metering slots. The two pumps are assembled
back-to-back, so the front pump will have a
different rotation valve plate than the rear pump.

Metering Slots

Relief Valves KV18515

2. Inspect four relief valves in center manifold.


Cam Plate Bearing
Bearing (Swash Plate)
Outer Race
Outer KV18517
Race Seal

Front Pump Valve Plate

Metering Slots

Insert

O-Rings KV18516

NOTE: Early models ( S/N –KV0240A140201;


S/N –KV0250A150192) have factory-installed KV18809
shims under bearings. Shims and bearings
must be kept on the same side of the cam plate
(swash plate) they were taken from. Later Rear Pump Valve Plate
models use a crush washer. The crush washer
is not a serviced part and must be replaced 6. Inspect bronze side of valve plate for wear. Replace
with shims from an available shim kit. valve plate if any scoring or scratches are present.

3. Inspect cam plate (swash plate) bearings and


bearing outer races in cover plates.

6 - 30 11/22/00
HYDROSTATIC POWER TRAIN REPAIR

NOTE: Rotating assembly is not serviceable. Replace HYDROSTATIC PUMP ASSEMBLY


assembly if any components are damaged.
1. Clean all parts in a suitable solvent and dry using
compressed air or a lint-free rag.
Slipper IMPORTANT: Due to extremely tight tolerances and
surface finish of pump internal surfaces, it is
very important to maintain absolute cleanliness
during the assembly of the pump.

Apply clean HY-GARD hydraulic oil to all


internal surfaces during pump assembly. DO
Piston Block NOT use John Deere BIO HY-GARD®.
Piston

KV18518
Bearings

7. Inspect piston block surface that makes contact with


valve plate. Surface should be smooth and free of
deep scratches.
8. Check piston movement in block bore. If pistons do
not move freely in bore, examine bore for scoring
or contamination.
9. Examine the OD of the pistons for finish condition.
Pistons should not show wear or deep scratches.
10. Inspect the slippers for a snug fit on the ball end of
the pistons. Check the face of the slippers for a flat,
smooth surface. Insert Shims KV18524

Bearing Surfaces 2. Install bearings and shims onto cam plate (swash
Thrust plate). Install the same thickness of shims taken off
Bearing of each side (if crush washer was removed, install
equivalent thickness shims). When new bearings
are being installed, add or subtract shims to obtain
proper bearing preload. Preload will be determined
when cover plates are installed.
3. Install cam plate (swash plate) insert onto cam plate
(swash plate). Use petroleum jelly to hold in place
Spacer during assembly.
Thrust
Washers KV18519
11. Inspect rear pump input shaft bearing surfaces and
spline areas.
12. Inspect thrust bearings and thrust washers.
Bearing Surfaces

Splines Internal
Splines KV18520

13. Inspect forward pump input shaft bearing surfaces.


14. Inspect external spline areas and internal splines
which drive hydraulic/charge pump.

BIO HY-GARD is a registered trademark of Deere &


Company.

11/22/00 6 - 31
REPAIR HYDROSTATIC POWER TRAIN

Cover Plates Shaft Assembly

Cam Plate
(Swash Plate)
Spacer
Trunnion
Housing KV18521
Shaft KV18513
10. Apply petroleum jelly to needle bearings in housing
4. Install cam plate (swash plate) assembly into and install shaft assembly in housing by tapping
housing with trunnion shaft through the previously lightly with a soft-faced hammer.
noted or marked side of the housing. 11. Install spacer over shaft and into housing.
5. Install new seal in cover plate for trunnion shaft
side.
6. Install cover plates to housing. Tighten cap screws
to 41 N•m (30 lb-ft).
7. Install torque wrench on the square of the trunnion
shaft. Rolling torque should be 2.3-3.4 N•m
(20-30 lb-in.). Add or remove shims to obtain the
correct adjustment.

Bearing Surfaces
Thrust
Bearing
Seal

KV18522
12. Using a piece of pipe of appropriate diameter,
lightly tap new seal into housing until it bottoms out
on spacer.
Spacer Snap
Thrust
Ring
Washers
Snap Ring
Snap Rings KV18519

8. Apply petroleum jelly to thrust bearing and thrust


washers.
9. Install thrust bearing, thrust washers, and snap
rings on rear pump input shaft. Remove and
discard old seal.

KV18523
13. Install snap ring.

6 - 32 11/22/00
HYDROSTATIC POWER TRAIN REPAIR

Holding
Fixture

Rotating
Assembly Cap Screws
Housing
KV18509

18. Install new gasket and install center manifold onto


KV18510 pump housing.
14. Push rotating assembly onto shaft and into 19. Install four cap screws and tighten to 56 N•m
housing. Align splines on shaft and rotating (41 lb-ft).
assembly as assembly is inserted into housing. Valve Plate Relief
15. Hold rotating assembly in housing and rotate Valves
holding fixture 180 degrees.

Needle Center Manifold


Bearing

Relief Needle Bearing


Valves
KV18709

Valve Plate KV18525 20. Install new O-rings on relief valves and install into
center manifold. Tighten to 135 N•m (100 lb-ft).
21. Apply a light coat of petroleum jelly to needle
IMPORTANT: Valve plates are not interchangeable. bearing and back side of valve plate. Install valve
plate on center manifold.
16. Apply petroleum jelly to back side of valve plate to
hold in place during assembly. Drive Shaft
17. Apply a light coat of petroleum jelly to needle
bearing. Install valve plate on center manifold.
Rotating Assembly
Center Manifold

Valve
Plate
KV18508

22. Install rotating assembly onto valve plate.


23. Align splines on drive shaft with rotating assembly
and install into center manifold.

11/22/00 6 - 33
REPAIR HYDROSTATIC POWER TRAIN

Front Pump
Housing

Port at 9 O’Clock Position Port at 3 O’Clock Position

Cap Screws

Passages
KV18507
25. Install new gasket and lower front pump housing
over rotating group onto center manifold.
26. Install four cap screws and tighten to 56 N•m
(41 lb-ft).

Cap Screws

KV31116

Port at 9 O’Clock Position


Port at 3 O’Clock Position
with Plug Installed

KV18873
27. Install hydraulic/charge pump onto front pump.
28. Tighten the eight screws to 35 N•m (26 lb-ft).

c CAUTION
Use proper lifting equipment. Approximate
KV31113 weight of pumps is 45 kg (100 lb).

24. Looking at the pump as it would be mounted in the 29. Remove pump assembly from holding fixture.
machine, look for passages in the two round oil
ports. The oil port at the 3 o’clock position will
always have passages. If there are passages in the
port at the 9 o’clock position, a plug must be
installed or the pump will not prime. If there are no
passages in the port at the 9 o’clock position, no
plug is required.

6 - 34 11/22/00
HYDROSTATIC POWER TRAIN REPAIR

HYDROSTATIC PUMP
Control Control INSTALLATION
Lever Mounts Lever
1. Install pump assembly into machine using a hoist
and sling.
2. Remove sling and hoist and slide assembly to the
rear through the flywheel adapter plate and
engage into hub.
Cap Screws
(2 used)

Cap Screws Hydrostatic Pump


KV18504 Assembly
30. Install centering plate mounts. Tighten cap screws
to 41 N•m (30 lb-ft).

6 mm (0.025 in.)

Flywheel
Spacer Adapter Plate
Coupler

Hydrostatic Pump
Mounting Bracket

Set Screws
Spacer
KV31117 (See Note)
31. Install coupler on input shaft. Adjust the gap
between the pump and coupler to 6 mm (0.250 in.). Cap Screw
32. Apply thread lock and sealer (medium strength) to Cap Screws (See Note)
set screws. Tighten set screws to 37 N•m (See Note) KV18496
(27 lb-ft).

NOTE: The quantity of screws and spacers have


changed throughout production. Your machine
may have five or six screws and four or five
spacers. Refer to the appropriate parts catalog
for correct quantities for your machine.

3. Install two flange-to-flywheel housing cap screws.


Tighten to 118 N•m (87 lb-ft).
4. Install six mounting bracket-to-pump assembly cap
screws and four spacers. Tighten to 39 N•m
(29 lb-ft).

11/22/00 6 - 35
REPAIR HYDROSTATIC POWER TRAIN

B G

C
A H

KV18872
A. Hydrostatic Pump Center Manifold Port-to-
Hydraulic Oil Filter Manifold Hose
KV18871
B. Hydrostatic Pump Rear Port-to-Left Drive
Motor Case Drain Hose G. Through serial number:
C. Hydrostatic Pump Rear Port-to-Hydraulic/ –KV0240A142337 or –KV0250A152709:
Charge Pump Hose Hydrostatic Pump Top Right Center Manifold
Port-to-Right Drive Motor Top Front Port Hose
D. Hydraulic/Charge Pump-to-Hydraulic Oil
Reservoir Hose
Above serial number:
E. Hydrostatic Pump Bottom Left Center Manifold KV0240A142337– or KV0250A152709– (or if
Port-to-Left Drive Motor Top Rear Port Hose PIP 00KV010 has been performed):
F. Hydrostatic Pump Top Left Center Manifold Hydrostatic Pump Top Right Center Manifold
Port-to-Left Drive Motor Top Front Port Hose Port-to-Right Drive Motor Top Rear Port Hose

H. Through serial number:


–KV0240A142337 or –KV0250A152709:
Hydrostatic Pump Bottom Right Center
Manifold Port-to-Right Drive Motor Top Rear
Port Hose

Above serial number:


KV0240A142337– or KV0250A152709– (or if
PIP 00KV010 has been performed):
Hydrostatic Pump Bottom Right Center
Manifold Port-to-Right Drive Motor Top Front
Port Hose

I. Hydrostatic Pump Front Port-to-Right Drive


Motor Case Drain Hose
J. Hydraulic/Charge Pump-to-Hydraulic Control
Valve Hose

5. Connect hoses (A–J) to hydrostatic pump assembly


as marked or tagged during disassembly.

6 - 36 11/22/00
HYDROSTATIC POWER TRAIN REPAIR

6. Install steering control rods to control levers. HYDROSTATIC MOTOR REMOVAL/


Tighten to 40 N•m (30 lb-ft).
7. Install centering plate(s). (See CENTERING PLATE
INSTALLATION
REMOVAL/INSTALLATION in the STEERING
section.) Removal:
8. Install steering cross shaft. (See STEERING 1. Remove covers to access the hydrostatic motors.
CROSS SHAFT REMOVAL/INSTALLATION in the (See REMOVING COVERS in the
STEERING section.) MISCELLANEOUS section.)
9. Install cover plates. (See COVER PLATE 2. Remove steering cross shaft (see STEERING
REMOVAL/INSTALLATION in the CROSS SHAFT REMOVAL/INSTALLATION in the
MISCELLANEOUS section.) STEERING section.)
10. Fill hydraulic reservoir to proper level.
11. Perform start-up procedure. (See START-UP A
PROCEDURE AFTER COMPONENT
REPLACEMENT.)
Brake Assembly
C

Cap Screws
KV13914
NOTE: Left motor shown. Right motor is similar.

A. Hydrostatic Pump Rear Port-to-Left Drive


Motor Case Drain Hose
B. Hydrostatic Pump Bottom Left Center Manifold
Port-to-Left Drive Motor Top Rear Port Hose
C. Hydrostatic Pump Top Left Center Manifold
Port-to-Left Drive Motor Top Front Port Hose

3. Disconnect hydrostatic lines to hydrostatic motor


being serviced.

IMPORTANT: Motor must be handled with drive


end up. DO NOT carry motor by drive shaft or
with drive shaft hanging down. Damage to
internal parts will occur.

4. Remove four cap screws securing hydrostatic motor


to brake assembly. Remove motor.

Installation:
1. Install new O-ring in brake assembly housing.
2. Align pump motor to brake assembly. Fasten with
four cap screws. Tighten to 118 N•m (87 lb-ft).
3. Install hydrostatic lines removed during pump
removal.

11/22/00 6 - 37
REPAIR HYDROSTATIC POWER TRAIN

HYDROSTATIC MOTOR EXPLODED VIEW


A
B C
D
N
E O
F
G
P
Q
H I
J
K
L
M

X
G

V
W U
Align Shuttle Flow Holes
T

S R
KV31123
A. End Cap G. Steel Ball (2 used) M. O-Ring S. Flange
B. O-Ring H. Drive Shaft N. Plug T. Backup Ring
C. Seal, Square Cut I. Seal, Square Cut O. O-Ring U. Seal
D. Valve Plate J. Balance Plate P. Relief Valve Assy. V. Plug, Shuttle Valve
E. Seal, Square Cut K. Seal, Square Cut Q. Cap Screw (9 used) W. O-Ring
F. GEROLER® L. Backup Ring R. Shaft Face Seal X. Shuttle Valve
Assembly

6 - 38 11/22/00
HYDROSTATIC POWER TRAIN REPAIR

HYDROSTATIC MOTOR
DISASSEMBLY
Shuttle Valve
1. Scribe two lines 25 mm (1 in.) apart down body of Assembly
motor to aid in assembly.

12-Point
Cap Screws
(9 used)

Shims

Relief Valve
Assembly KV18879
4. Remove relief valve and shuttle valve assemblies
from end cap.
5. Remove and discard all O-rings and seals.

HYDROSTATIC MOTOR INSPECTION


KV18874
NOTE: Relief valve may have shims in recess of
2. Place motor in a vertical position and remove nine poppet. Use care not to lose them while
12-point cap screws. cleaning parts.
NOTE: There are two small check balls underneath
balance plate in GEROLER that can fall out 1. Clean all parts in a suitable solvent and dry with
when taking motor apart. compressed air. Do not wipe parts with paper towel
or rag. Lint in hydraulic system will cause damage.
2. Inspect valve plate and balance plate for scoring or
Check Balls wear.
3. Inspect GEROLER for scoring or wear.

KV18886

3. Disassemble motor, being careful not to lose check


balls in GEROLER.

11/22/00 6 - 39
REPAIR HYDROSTATIC POWER TRAIN

HYDROSTATIC MOTOR ASSEMBLY


A
B C
D
N
E O
F
G
P
Q
H I
J
K
L
M

X
G

V
W
U
Align Shuttle Flow Holes
T

S R
KV31123
A. End Cap G. Steel Ball (2 used) M. O-Ring S. Flange
B. O-Ring H. Drive Shaft N. Plug T. Backup Ring
C. Seal, Square Cut I. Seal, Square Cut O. O-Ring U. Seal
D. Valve Plate J. Balance Plate P. Relief Valve Assy. V. Plug, Shuttle Valve
E. Seal, Square Cut K. Seal, Square Cut Q. Cap Screw (9 used) W. O-Ring
F. GEROLER® L. Backup Ring R. Shaft Face Seal X. Shuttle Valve
Assembly

NOTE: Use petroleum jelly to hold seals and O-rings in


place during assembly.

IMPORTANT: Due to extremely tight tolerances and


surface finish of motor internal surfaces it is
very important to maintain absolute cleanliness
during assembly of the motor.

Apply clean HY-GARD hydraulic oil to all


internal surfaces during motor assembly. DO
NOT use John Deere BIO HY-GARD.

NOTE: Always use new seals and O-rings when


assembling motor. Used O-rings and seals will
leak

IMPORTANT: Make sure shuttle flow holes align


throughout assembly.

6 - 40 11/22/00
HYDROSTATIC POWER TRAIN REPAIR

Valve Plate

Shuttle
Piston Dash Pots
(2 used)
Springs
(2 used)

O-Ring Relief Valve


Plug

Poppets
(2 used) Shims
KV18881
Shuttle Valve Plug O-Ring KV18879
6. Place valve plate on end cap. Align bolt holes and
shuttle flow hole with end cap.
IMPORTANT: Install poppets with tapers facing
each other in port.
Square Cut Seal
Shuttle Flow
1. Coat shuttle valve parts with petroleum jelly and Hole
install one poppet, spring and dash pot into shuttle
valve bore from valve plate side of end cap.
2. Install poppet, spring and dash pot onto the shuttle
piston. Install assembly into valve bore from
opposite side of end cap.
3. Install shuttle valve plug, with a new O-ring, and
tighten to 41 N•m (30 lb-ft).
4. Place original shims (if used) in recess of relief
valve poppet. Install relief valve assembly and
tighten relief valve plug to 27 N•m (20 lb-ft).

Square Cut Seal O-Ring


Valve Side of
GEROLER

KV18882
KV18880
7. Coat both sides of GEROLER with petroleum jelly
5. Place end cap on workbench, name tag side down, and install square cut seal on each side. Place
seal groove side up. Coat surfaces and grooves GEROLER over valve plate, valve side of rotor
with petroleum jelly and install O-ring and square down and spline side up. Align bolt holes and
cut seal. shuttle flow hole.

11/22/00 6 - 41
REPAIR HYDROSTATIC POWER TRAIN

12. Install flange on balance plate being careful not to


Balance Plate displace seals and O-rings.

Check Balls 9 1

4
6

7
3

KV18883 2
8
8. Place two check balls in rotor and retain with 5
petroleum jelly. Install drive shaft.
KV18588
9. Place balance plate on GEROLER. Align bolt holes
and shuttle flow holes. 13. Install nine 12-point cap screws lubricated with
HY-GARD hydraulic oil. Tighten cap screws to an
initial setting of 41 N•m (30 lb-ft) in a criss-cross
NOTE: Backup ring for O-ring is contoured on one side pattern as shown. Finish tightening to 82 N•m
to properly sit over O-ring. (60 lb-ft) in the same criss-cross pattern.

Shaft Face Seal


Square Cut Seal

Backup
Ring

Seal

Backup
Ring
KV18885
O-Ring
14. Install shaft face seal with the cupped side down.
Backup Hold in place with petroleum jelly.
Ring
Installation:
1. Install motor assembly (see HYDROSTATIC
MOTOR REMOVAL/INSTALLATION in this
Shuttle section.)
Flow
2. Perform start-up procedure. (See START-UP
Hole
O-Ring PROCEDURE AFTER COMPONENT
Flange REPLACEMENT in this section.)
KV18587

10. Position flange on workbench with seal grooves up.


11. Coat surface and grooves with petroleum jelly and
install square cut seal, backup ring and seal and
align with bolt holes. Install O-ring and backup ring.

6 - 42 11/22/00
STEERING CONTENTS

CONTENTS
STEERING
Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TESTS AND ADJUSTMENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STEERING COMPONENT LOCATION—SINGLE PLATE MODELS. . . . 5
STEERING COMPONENT LOCATION—DUAL PLATE MODELS . . . . . 6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CENTERING PLATE ADJUSTMENT—SINGLE PLATE MODELS . . . . . . . . . . . . . . . 9
CENTERING PLATE ADJUSTMENT—DUAL PLATE MODELS . . . . . . . . . . . . . . . . 12
STEERING CONTROL LEVER ADJUSTMENT—CENTERING . . . . . . . . . . . . . . . . 14
STEERING DETENT ADJUSTMENT - DUAL PLATE MODELS . . . . . . . . . . . . . . . . 15
STEERING CONTROL LEVER STOPS ADJUSTMENT—TRACKING. . . . . . . . . . . 16
AUXILIARY HYDRAULIC CONTROL HANDLE ADJUSTMENT . . . . . . . . . . . . . . . . 17
HYDRAULIC CONTROL HANDLE ADJUSTMENT – HANDS ONLY MACHINES . . 17
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CENTERING PLATE REMOVAL—SINGLE PLATE MODELS . . . . . . . . . . . . . . . . . 18
CENTERING PLATE REMOVAL—DUAL PLATE MODELS . . . . . . . . . . . . . . . . . . . 19
CENTERING PLATE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CENTERING PLATE INSTALLATION—SINGLE PLATE MODELS. . . . . . . . . . . . . . 21
CENTERING PLATE INSTALLATION—DUAL PLATE MODELS. . . . . . . . . . . . . . . . 21
STEERING DAMPENER REMOVAL/INSPECTION/INSTALLATION . . . . . . . . . . . . 22
STEERING CONTROL LEVER REMOVAL/INSPECTION/INSTALLATION . . . . . . . 23
STEERING CROSS SHAFT ASSEMBLY REMOVAL/INSTALLATION —
SINGLE PLATE MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
STEERING CROSS SHAFT ASSEMBLY REMOVAL/INSTALLATION —
DUAL PLATE MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
STEERING CROSS SHAFT ASSEMBLY REPAIR—DUAL PLATE MODELS. . . . . . 25
STEERING CONTROL LEVER HANDLE DISASSEMBLY/ASSEMBLY . . . . . . . . . . 26

11/22/00 7-1
CONTENTS STEERING

This page intentionally left blank

7-2 11/22/00
STEERING SPECIFICATIONS

SPECIFICATIONS

TESTS AND ADJUSTMENTS SPECIFICATIONS


Gap between Upper Centering Plate
and Lower Centering Bracket . . . . . . . . . . . . . . . . . . . . . . . . 3.2—6.4 mm (1/8—1/4 in.)
Wheel Tracking (Left and Right Wheel Speed Difference) . . . . . . . . . . .Less than 1 rpm

TORQUE SPECIFICATIONS
Centering Plate Spring Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 N•m (50 lb-ft)
Auxiliary Cable Jam Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)
Guide Pin Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft)
Pivot Bearing Block Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Dampener Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Link Rod Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Control Rod Cap Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Centering Block Mounting Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Control Lever Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Steering Control Lever Handle Set Screw Lock Nut . . . . . . . . . . . . 13.5 N•m (120 lb-in.)
Steering Control Lever Handle Set Screw. . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.)
Detent Ring Set Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Detent Spring Screw Jam Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.9 N•m (25 lb-ft)

SPECIAL OR ESSENTIAL TOOLS


NOTE: Order tools according to information given in the U.S. SERVICE-GARDTM Catalog or in the
European Microfiche Tool Catalog (MTC).

Number Name

JT0KV12444 Remote Start Box

JT05719 Photo Tachometer

SERVICE-GARD is a registered trademark of Deere and Company.

11/22/00 7-3
THEORY OF OPERATION STEERING

THEORY OF OPERATION Steering Dampeners


One dampener is attached to each steering control
lever. The steering dampeners eliminate hydrostatic
Function pulses and torque feedback into the steering control
The steering system provides a means of controlling the levers. The steering dampeners provide a slight
direction and speed of the skid steer by controlling the resistance in movement of the steering control levers.
location of the cam plates (or swash plates) in the
hydrostatic pumps. Displacement and orientation of the
cam plates control fluid flow and direction of flow to the
hydrostatic motors.

Theory
The steering system consists of two steering control
levers mounted on either side of the operator and
centering plate, or plates (2) on later models, mounted
directly on the hydrostatic pump assembly. Pushing or
pulling the steering control levers rotates the cam plates
in the hydrostatic pumps causing the pumps to displace
hydraulic fluid. This in turn operates the hydrostatic
motors moving the skid steer forward or backward,
respectively. The centering plate, or plates (2) on later
models, ensure a positive center and neutral location of
the steering levers. Twin dampeners absorb hydrostatic
pulses and torque feedback into the steering control
levers.

Steering Control Levers


The two steering control levers are mounted on either
side of the operator. Each lever operates independently
to control the appropriate hydrostatic pump. The levers
incorporate an ergonomically designed angle and a soft
grip to prevent operator wrist fatigue. For hand/foot
machines, the right steering control lever also
incorporates a wrist control that controls the auxiliary
hydraulic system. This wrist control can be locked out or
engaged by rotating the lock knob located on the handle
socket.

Centering Plate
Early models incorporate a single centering plate that is
located on top of the hydrostatic pumps. This assembly
spans both pumps and consists of a spring-loaded
centering plate and two pairs of adjustment screws.
Each pair of adjustment screws contact a pump lever
and provide the ability to adjust the neutral position.
Late models incorporate two spring loaded centering
plate assemblies with one pair of adjusting screws
each. One centering plate is mounted to each pump.
The steering control levers are connected by control
rods to the hydrostatic pump control levers. Operating
the steering levers move the corresponding control rod
which acts against the spring-loaded centering plate.

7-4 11/22/00
STEERING STEERING COMPONENT LOCATION—SINGLE PLATE MODELS

STEERING COMPONENT LOCATION—SINGLE PLATE MODELS

Right Steering
Lever

Cross Shaft Pivot Bearing


Bellcranks

Left Steering
Lever
Link Rod
Spring Bolt
Assembly

Control Centering
Rod Plate

Centering Screws

Guide Pins and Bushings


KV15159

11/22/00 7-5
STEERING COMPONENT LOCATION—DUAL PLATE MODELS STEERING

STEERING COMPONENT LOCATION—DUAL PLATE MODELS

Right Steering
Lever

Pivot Bearing

Left Steering Cross Shaft


Lever Spring Bolt Link Rod
Bellcranks
Assemblies

Left Wheel
Centering Plate

Right Wheel
Centering Plate

Right Wheel
Control Rod
Detent Ring

Left Wheel Centering Screws


Control Rod

Detent Screw
Guide Pins and Bushings
KV18848

7-6 11/22/00
STEERING TROUBLESHOOTING

TROUBLESHOOTING

Steering levers hard


Problem or

one side with levers

vibrate excessively.
Hydrostatic system

Steering levers feel


Symptom

reverse position.
Vehicle tracks to

in full forward or
loose or sloppy.
Machine creeps

Levers pulse or
noisy while in
with levers in

to move.
Check or

neutral.

neutral.
Solution

Centering plate(s) improperly


● ● ● ●
adjusted

Bad pivot bearings on steering


control levers ● ● ● ●
Inspect and/or replace pivot bearings

Bent control rods ● ● ●

Damaged link rod ends ● ● ●

Worn rubber bushings in control rods ● ● ●

Faulty steering dampener ● ● ● ● ● ●

Steering lever travel incorrectly



adjusted

ROPS not secured ● ●

11/22/00 7-7
DIAGNOSTICS STEERING

DIAGNOSTICS

Test Conditions:

• Operator in seat.

• Seat belt fastened.

Test/Check Point Normal If Not Normal

1. Steering control levers. Levers should move freely with slight Check linkage from levers to pump.
resistance. Check steering dampeners.

Test Conditions:

• Engine running at slow idle.

Test/Check Point Normal If Not Normal

1. Steering control levers are in Pumps should be quiet. Engine Adjust centering plate(s).
neutral, park brake switch should not sound labored.
disengaged.

2. Steering control levers are in Machine should not creep forward or Adjust centering plate(s).
neutral, park brake switch backward or in circles.
disengaged.

3. Steering control levers in full Machine should move forward, or Adjust steering control lever stop
forward or full reverse position, backward, in a straight line. screws.
park brake switch disengaged.

4. Dual steering plate models only Lever should remain in position and Adjust or repair steering detent.
- Steering control levers in full machine should continue in a
forward or full reverse position, straight line.
park brake switch disengaged.
Release one lever.

7-8 11/22/00
STEERING TESTS AND ADJUSTMENTS

TESTS AND ADJUSTMENTS

Pump Control
CENTERING PLATE Lever
ADJUSTMENT—SINGLE PLATE
MODELS
Control Rod

Reason:
To prevent the skid steer from creeping when control
levers are in neutral. Rear Front
Centering Screws Centering Screws

Equipment: Pump Control


Lever
• JT0KV12444 Remote Start Box

Procedure: Spring Bolt Control Rod


1. Park skid steer safely. Assembly
2. Raise and block skid steer. (See RAISING AND
BLOCKING SKID STEER in MISCELLANEOUS
section.)
3. Raise boom and engage boom locks.
4. Raise ROPS and ensure ROPS is safely in the
locked position.
KV13927
5. Remove cover plates to gain access to the
hydrostatic pump assembly. (See REMOVING .

COVER PLATES in MISCELLANEOUS section.)

M10 x 30 Cap Screw


c CAUTION
Avoid possible injury from moving tires when
using remote start box. Do Not use remote start
box without raising and blocking skid steer.

8. Install remote start box. (See USING REMOTE


START BOX in MISCELLANEOUS section.)
9. Disconnect control rods from pump control levers.
10. Check that the spring bolt assembly is tightened to
67 N•m (50 lb-ft).

KV13980

NOTE: It is not necessary to remove the steering


control lever covers. Steering control lever
cover removed for clearity.

6. Check pivot points of all the steering linkage for


wear and damage. Repair linkage components
prior to performing these adjustments.
7. Install an M10 x 30 cap screw in tab at the rear of
both steering lever yokes to secure steering
assembly during adjustment.

11/22/00 7-9
TESTS AND ADJUSTMENTS STEERING

Right Wheels
Right Wheels Rearward Movement
D
Forward Movement C

Left Wheels
Rearward Movement B A Left Wheels
Forward Movement
No Gap

3.2—6.4 mm (1/8—1/4 in.) Gap KV13927

IMPORTANT: A 3.2—6.4 mm (1/8 in.—1/4 in.) IMPORTANT: Adjusting any centering screw will
horizontal gap between upper centering plate affect the clearance between the centering
and lower front centering bracket must be screws and bearings for the wheels on the other
maintained when adjusting screws (A—D). side of the machine.

11. Verify that the gap between the upper centering 14. Verify that there is no gap between all four
plate and lower front centering bracket is between centering screws and all four bearings. Adjust as
3.2 mm and 6.4 mm (1/8 in. and 1/4 in.). necessary being careful not to change the neutral
12. Start skid steer and set engine rpm to 3/4 throttle. position of the pump control lever.
Turn parking brake OFF. Wheels should not rotate. 15. Verify that the gap between the upper centering
13. If wheels rotate, adjust centering screws as plate and lower front centering bracket is between
indicated: 3.2 mm and 6.4 mm (1/8 in. and 1/4 in.).
• The machine will not center consistently with a gap
• To adjust the left side wheels forward movement: less than 3.2 mm (1/8 in.).
Loosen jam nut and turn centering screw (A) in • Steering effort will be increased with a gap greater
(clockwise) until the left wheels start to turn than 6.4 mm (1/4 in.).
rearward. Slowly turn the centering screw out until • If not within specified gap, adjust all four screws
the left wheels stop turning. Tighten the jam nut. equally to obtain gap and repeat STEPS 11-15.
• To adjust the left side wheels rearward movement: 16. Connect control rods to pump control levers.
Loosen jam nut and turn centering screw (B) in Tighten cap screws to 40 N•m (30 lb-ft).
(clockwise) until the left wheels start to turn 17. Test left wheel adjustment by moving left control
forward. Slowly turn the centering screw out until lever to full forward and releasing handle. The
the left wheels stop turning. Tighten the jam nut. wheels should stop turning. Perform the same test
• To adjust the right side wheels forward movement: by pulling rearward on the left control lever.
Loosen jam nut and turn centering screw (C) in • If motion does not stop, adjust the left wheel
(clockwise) until the right wheels start to turn centering screws (A)-(B) so that both screws touch
rearward. Slowly turn the centering screw out until the bearings in the neutral position and repeat
the right wheels stop turning. Tighten the jam nut. STEPS 9-17.
• To adjust the right side wheels rearward movement: • Repeat test using the right control lever. Adjust the
Loosen jam nut and turn centering screw (D) in right wheel centering screws (C)-(D) so that both
(clockwise) until the right wheels start to turn screws touch the bearings in the neutral position
forward. Slowly turn the centering screw out until and repeat STEPS 9-17.
the right wheels stop turning. Tighten the jam nut.
18. Center left and right steering control levers. (See
STEERING CONTROL LEVER ADJUSTMENT—
CENTERING in this section.)

7 - 10 11/22/00
STEERING TESTS AND ADJUSTMENTS

19. Adjust steering control lever stops. (See


STEERING CONTROL LEVER STOPS
ADJUSTMENT—TRACKING in this section.)
20. Remove M10 x 30 cap screws from each steering
lever yoke.
21. Remove remote start box.
22. Install cover plates. (See REMOVING COVER
PLATES in MISCELLANEOUS section.)
23. Lower ROPS.
24. Raise and remove skid steer jacking blocks.

11/22/00 7 - 11
TESTS AND ADJUSTMENTS STEERING

CENTERING PLATE
ADJUSTMENT—DUAL PLATE Pump Control
Levers
MODELS
Control Rod

Reason:
To prevent the skid steer from creeping when control
levers are in neutral.
Control Rod

Equipment:
• JT0KV12444 Remote Start Box

Procedure:
1. Park skid steer safely. Detent Ring
Set Screws
2. Raise and block skid steer. (See RAISING AND
BLOCKING SKID STEER in MISCELLANEOUS KV18845
section.)
3. Raise boom and engage boom locks.
7. Check pivot points of all the steering linkage for
4. Raise ROPS and ensure ROPS is safely in the wear and damage. Repair linkage components
locked position. prior to performing these adjustments.
5. Remove cover plates to gain access to the
hydrostatic pump assembly. (See REMOVING

c CAUTION
COVER PLATES in MISCELLANEOUS section.)

M10 x 30 Cap Screw


Avoid possible injury from moving tires when
using remote start box. Do Not use remote start
box without raising and blocking skid steer.

8. Install remote start box. (See USING REMOTE


START BOX in MISCELLANEOUS section.)
9. Disconnect both steering control rods from pump
control levers.
10. Loosen detent ring set screws.

Rear
Centering Screws
KV13980 Front
Centering Screws

NOTE: It is not necessary to remove the steering


control lever covers. Steering control lever
cover removed for clearity.

6. Install an M10 x 30 cap screw in tab at the rear of Spring Bolt


both steering lever yokes to secure steering Assembly
assembly during adjustment.
KV18845

11. Check that the spring bolt assemblies are tightened


to 67 N•m (50 lb-ft).

7 - 12 11/22/00
STEERING TESTS AND ADJUSTMENTS

Right Wheels
Right Wheels
C Forward Movement
Rearward Movement D

Left Wheels
Rearward Movement B A Left Wheels
Forward Movement
No Gap

KV18847

3.2—6.4 mm (1/8—1/4 in.) Gap

IMPORTANT: A 3.2—6.4 mm (1/8 in.—1/4 in.) 15. Verify that the gap between the upper centering
horizontal gap between upper centering plate plates and lower centering brackets is between 3.2
and lower centering bracket must be maintained mm and 6.4 mm (1/8 in. and 1/4 in.) and that
when adjusting screws (A—D). there is no gap between all four centering screws
and all four bearings. Adjust as necessary being
careful not to change the neutral position of the
12. Verify that the gap between the upper centering pump control lever.
plates and lower centering brackets is between 3.2 • The machine will not center consistently with a gap
mm and 6.4 mm (1/8 in. and 1/4 in.). less than 3.2 mm (1/8 in.).
13. Start skid steer and set engine rpm to 3/4 throttle. • Steering effort will be increased with a gap greater
Turn parking brake OFF. Wheels should not rotate. than 6.4 mm (1/4 in.).
14. If wheels rotate, adjust centering screws as • If not within specified gap, adjust screws equally to
indicated: obtain gap and repeat STEPS 12-15.
16. Connect control rods to pump control levers.
• To adjust the left side wheels forward movement: Tighten cap screws to 40 N•m (30 lb-ft).
Loosen jam nut and turn centering screw (A) in
(clockwise) until the left wheels start to turn 17. Test left wheel adjustment by moving left control
rearward. Slowly turn the centering screw out until lever to full forward and releasing handle. The
the left wheels stop turning. Tighten the jam nut. wheels should stop turning. Perform the same test
by pulling rearward on the left control lever.
• To adjust the left side wheels rearward movement:
Loosen jam nut and turn centering screw (B) in • If motion doesn’t stop, adjust the left wheel
(clockwise) until the left wheels start to turn centering screws (A)-(B) so that both screws touch
forward. Slowly turn the centering screw out until the bearings in the neutral position and repeat
the left wheels stop turning. Tighten the jam nut. STEPS 9-17.
• To adjust the right side wheels forward movement: • Repeat test using the right control lever. Adjust the
Loosen jam nut and turn centering screw (C) in right wheel centering screws (C)-(D) so that both
(clockwise) until the right wheels start to turn screws touch the bearings in the neutral position
rearward. Slowly turn the centering screw out until and repeat STEPS 9-17.
the right wheels stop turning. Tighten the jam nut. 18. Center left and right steering control levers. (See
• To adjust the right side wheels rearward movement: STEERING CONTROL LEVER ADJUSTMENT—
Loosen jam nut and turn centering screw (D) in CENTERING in this section.)
(clockwise) until the right wheels start to turn 19. Adjust steering control lever stops. (See
forward. Slowly turn the centering screw out until STEERING CONTROL LEVER STOPS
the right wheels stop turning. Tighten the jam nut. ADJUSTMENT—TRACKING in this section.)
20. Verify detent ball is in detent groove of detent ring.
Tighten set screws to 40 N•m (30 lb-ft).

11/22/00 7 - 13
TESTS AND ADJUSTMENTS STEERING

21. Pull both steering control levers to the full foward 8. Tighten both jam nuts on left and right link rods.
postion. Verify detent ball is in detent groove of
detent ring. If not, repeat Steps 18-21.
22. Remove one M10 x 30 cap screw from each IMPORTANT: The steering control lever stops must
steering lever yoke. be adjusted properly to prevent damage to the
linkage and internal hydrostatic components.
23. Remove remote start box.
24. Install cover plates. (See REMOVING COVER
PLATES in MISCELLANEOUS section.) 9. Adjust steering control lever stops. (See
25. Lower ROPS. STEERING CONTROL LEVER STOPS
26. Raise and remove skid steer jacking blocks. ADJUSTMENT—TRACKING in this section.)
10. Remove M10 x 30 cap screw from each steering
lever yoke.
STEERING CONTROL LEVER 11. Install cover plates. (See REMOVING COVER
ADJUSTMENT—CENTERING PLATES in MISCELLANEOUS section.)
12. Lower ROPS.

IMPORTANT: Centering plate(s) must be properly


adjusted to perform steering control lever
centering adjustment.

Reason:
To center the steering control levers.

Procedure:
1. Park skid steer on flat level surface.
2. Raise boom and engage boom locks.
3. Raise ROPS and ensure ROPS is safely in the
locked position.
4. Remove cover plates to gain access to the steering
linkage. (See REMOVING COVER PLATES in
MISCELLANEOUS section.)
M10 x 30 Cap Screw

Jam Nuts
Align

KV15260

NOTE: It is not necessary to remove the steering


control lever covers. Steering control lever
cover removed for clearity.

5. Install an M10 x 30 cap screw in tab at the rear of


both steering yokes to secure steering assembly
during adjustment.
6. Loosen both jam nuts on left and right link rods.
7. Adjust left and right link rods to align lever castings
with pivot bearings.

7 - 14 11/22/00
STEERING TESTS AND ADJUSTMENTS

STEERING DETENT ADJUSTMENT -


Dealer Installed
DUAL PLATE MODELS Cap Screw

IMPORTANT: Proper adjustment is required to


allow for momentary one-hand operation. Right Bellcrank
Centering plate adjustment must be correct to
perform this procedure.

Reason: Detent Ring

To correctly adjust and pre-load detent.

Jam Nut
Procedure:
1. Park skid steer on flat level surface. Detent Spring Screw
2. Raise boom and engage boom locks. KV31011

3. Raise ROPS and ensure ROPS is safely in the 7. Loosen detent ring set screws and rotate ring to
locked position. verify detent ball is in groove on ring. Tighten set
4. Remove cover plates to gain access to the steering screws to 40 N•m (30 lb-ft).
linkage. (See REMOVING COVER PLATES in
MISCELLANEOUS section.)

Control Rod Link Rod

Dampener

Left Bellcrank
Jam Nut
KV31012 Detent Spring Screw

5. Remove left steering control rod, link rod and KV31013


dampener from cross shaft bellcrank.
8. Using the cap screw installed earlier, check the
torque required to rotate the left bellcrank ‘out of
Dealer Installed detent’ while holding the right bellcrank stationary.
Cap Screw and Nut Reading should be 8.1—10.8 N•m (72—96 lb-in.).
Adjust the detent spring screw to achieve the
correct reading.
9. Tighten detent spring screw jam nut to 33.9 N•m
(25 lb-ft).
10. Attach left link rod, control rod and dampener.
Tighten cap screws to 40 N•m (30 lb-ft).
11. Remove M10 x 30 cap screw from each steering
lever yoke.
12. Install cover plates. (See REMOVING COVER
PLATES in MISCELLANEOUS section.)
KV31011a 13. Lower ROPS.
6. Install an M10 x 30 cap screw and nut in dampener
attaching hole. Tighten securely.

11/22/00 7 - 15
TESTS AND ADJUSTMENTS STEERING

STEERING CONTROL LEVER


STOPS ADJUSTMENT—TRACKING

IMPORTANT: If steering system adjustments have Rear Stop Forward Stop


been made for any reason, the steering control
lever stops must be adjusted.

The steering control lever stops must be


adjusted properly to prevent damage to the
linkage and internal hydrostatic components.
Jam Nuts Stop Screw
Stop Screw

Reason:
To ensure machine tracks straight and to protect
hydrostatic pumps from damage.
KV13984

Equipment: 11. Adjust stop screw to act as the primary stop just
before the hydrostatic pump control lever stops due
• JT0KV12444 Remote Start Box
to mechanical motion inside the pump.
• JT05719 Photo Tachometer
12. Move left steering control lever to full rearward
position.
Procedure: 13. Adjust stop screw to act as the primary stop just
before the hydrostatic pump control lever stops due
1. Park skid steer safely.
to mechanical motion inside the pump.
2. Raise and block skid steer. (See RAISING AND
14. Repeat procedure for the right steering control lever
BLOCKING SKID STEER in MISCELLANEOUS
stops.
section.)
15. Start engine and run at fast idle.
3. Raise boom and engage boom locks.
16. While simultaneously holding both levers in the full
4. Raise ROPS and ensure ROPS is safely in the
forward position, measure and record the full
locked position.
forward wheel speed (revolutions per minute) of
5. Remove cover plates to gain access to the steering the left and right wheels using a JT05719 Photo
linkage. (See REMOVING COVER PLATES in Tachometer.
MISCELLANEOUS section.)
• Left and right wheel speed should be within one
revolution per minute of each other.

c CAUTION • If left and right wheels are not within one revolution
per minute of each other, adjust the faster wheel to
equal the slower wheel speed by turning the stop
Avoid possible injury from moving tires when screw out (counterclockwise).
using remote start box. Do NOT use remote start 17. Tighten jam nuts on the steering control lever stop
box without raising and blocking skid steer. screws.
18. Repeat procedure for left and right full reverse.
6. Install remote start box. (See USING REMOTE
START BOX in MISCELLANEOUS section.) NOTE: Due to variations such as tire size, tracking
7. Install an M10 x 30 cap screw in tab at the rear of must be verified by driving the skid steer. If
both yokes to secure steering assembly during mistracking is more than the width of the
adjustment. machine per 30.5 m (100 ft) of travel,
8. Loosen jam nuts on the steering control lever stop readjustment of the stop screws are required.
screws.
9. Turn stop screws in (clockwise).
19. Remove one M10 x 30 cap screw from each
10. Move left steering control lever to full forward steering lever yoke.
position.
20. Remove remote start box.
21. Install cover plates. (See REMOVING COVER
PLATES in MISCELLANEOUS section.)
22. Lower ROPS.
23. Raise and remove skid steer jacking blocks.

7 - 16 11/22/00
STEERING TESTS AND ADJUSTMENTS

AUXILIARY HYDRAULIC CONTROL HYDRAULIC CONTROL HANDLE


HANDLE ADJUSTMENT ADJUSTMENT – HANDS ONLY
MACHINES
Reason:
This procedure ensures that the auxiliary control handle Reason:
is centered, giving equal hydraulic oil flow in all This procedure ensures that the control handles are
positions. centered, giving equal hydraulic oil flow in all positions.

Procedure: Procedure:
1. Park skid steer safely. 1. Park skid steer safely.
2. Raise ROPS and ensure ROPS is safely in the 2. Raise the boom and place on the boom locks.
locked position. 3. Raise ROPS and ensure ROPS is safely in the
3. Remove cover plates to gain access to the control locked position.
valve. (See REMOVING COVER PLATES in 4. Remove cover plates to gain access to the control
MISCELLANEOUS section.) valve. (See REMOVING COVER PLATES in
MISCELLANEOUS section.)

KV0575

5. Move each handle all the way down and all the way
up. Ensure that the boom control valve locks into
KV15239 detent.
6. Confirm that when the handles are returned to
4. Lock handle in the middle (neutral) position by neutral position, they are in the center of the
turning key to the left. operating range.

Cable
Jam Nuts
Cable
Auxiliary Cable
Jam Nuts
Jam Nuts

KV13989 KV0582a

5. Loosen both auxiliary cable jam nuts. 7. If necessary to adjust, loosen both cable jam nuts.
6. Center spool in control valve. 8. Adjust nuts until handle is centered.
7. Tighten both auxiliary cable jam nuts finger tight 9. Tighten both cable jam nuts finger tight against
against cable saddle, then tighten to 27 N•m cable saddle, then tighten to 27 N•m
(20 lb-ft). (20 lb-ft).

11/22/00 7 - 17
REPAIR STEERING

REPAIR

CENTERING PLATE REMOVAL— Right Guide Pin


SINGLE PLATE MODELS
1. Park skid steer safely.
2. Raise ROPS and ensure ROPS is safely in the
locked position.
3. Remove cover plates to gain access to the steering
linkage. (See REMOVING COVER PLATES in
MISCELLANEOUS section.)

KV14333
Spring Bolt Assembly
7. Remove centering plate by prying it from right guide
pin.

Right Guide Pin Cap Screw

Control Lever

Jam Nut

KV13981

4. Remove spring bolt assembly.

NOTE: Spring bolt will be under a small amount of


tension when removed. Exercise care when
removing bolt. Cap Screw Cap Screw

Control Rod
Bracket
KV14338

Left Guide Pin Nut NOTE: Removal of the bracket retaining cap screws
can allow the cover to dislodge and might
cause difficulty in reassembly. Put at least one
screw back into place once guide pin has been
removed.

8. To remove right guide pin:


• Pull control rod forward to rotate control lever.
• Loosen guide pin jam nut.
• Remove cap screws (3) retaining bracket to pump
Bracket
and remove bracket.
KV14332
• Rotate bracket and remove guide pin.
5. Remove left side guide pin nut. • Install at least one cap screw to prevent dislodging
6. Lift left side of centering plate from lower rear of pump cover.
centering bracket slot.

7 - 18 11/22/00
STEERING REPAIR

CENTERING PLATE REMOVAL—


DUAL PLATE MODELS
1. Park skid steer safely. Right Guide Pin
2. Raise ROPS and ensure ROPS is safely in the
locked position.
3. Remove cover plates to gain access to the steering
linkage. (See REMOVING COVER PLATES in
MISCELLANEOUS section.)

Spring Bolt Assembly

KV18837
NOTE: Rear plate shown; front is similar.

7. Remove centering plate by prying it from right guide


pin bushing.

Right Guide Pin Cap Screw

KV13981 Control Lever

NOTE: Front centering plate must be removed to gain Jam Nut


access to rear centering plate spring bolt
assembly.

4. Remove spring bolt assembly.

Bracket

Cap Screw Cap Screw

Control Rod
Bracket
Left Guide Pin Nut
KV14338

NOTE: Rear components shown; front is similar.

NOTE: Removal of the bracket retaining cap screws


can allow the cover to dislodge and might
cause difficulty in reassembly. Put at least one
KV18839 screw back into place once guide pin has been
removed.
5. Remove left side guide pin nut.
6. Lift left side of centering plate from lower centering
bracket slot. 8. To remove right rear guide pin:
• Pull control rod forward to rotate control lever.
• Loosen guide pin jam nut.
• Remove cap screws (3) retaining bracket to pump
and remove bracket.
• Rotate bracket and remove guide pin.
• Install at least one cap screw to prevent dislodging
of pump cover.

11/22/00 7 - 19
REPAIR STEERING

CENTERING PLATE INSPECTION


Bearing Surface

Bushing Spacer
KV14337

1. Inspect bushing and spacer for wear and/or


breakage. Replace if required.
Single Plate Models KV14336
Guide Pin

Bearing Surface

Guide Pin Bushing


KV14334

2. Inspect guide pins and guide pin bushings for


breakage or wear.

Dual Plate Models


KV18843

4. Inspect centering screw bearing surface. Bearing


surface should be smooth and free of deep
scratches or wear. Replace as necessary.

Pump Control Lever

KV14335

3. Inspect pump control lever bearings for excessive


play in bearing race. Replace as necessary.

7 - 20 11/22/00
STEERING REPAIR

CENTERING PLATE 8. Install and tighten centering plate guide pin nuts to
54 N•m (40 lb-ft).
INSTALLATION—SINGLE PLATE
MODELS
Spring Bolt Assembly

KV13981
3.2 mm (1/8 in.)
9. Install spring bolt assembly onto centering plate
KV18846 assembly. Tighten spring bolt to 67 N•m (50 lb-ft).
1. Loosen jam nuts. Adjust centering screws until each 10. Perform centering plate adjustment. (See
bearing surface protrudes approximately 3.2 mm CENTERING PLATE ADJUSTMENT—SINGLE
(1/8 in.). PLATE MODELS in this section.)

Right Guide Pin


Bushing CENTERING PLATE
INSTALLATION—DUAL PLATE
MODELS

NOTE: Installation of front and rear plates is similar.


Rear centering plate must be installed first.
Mounting Plate

KV14333

2. Install right guide pin, bushing and nut in mounting


plate. Tighten nut to 54 N•m (40 lb-ft).
3. Rotate mounting plate into position and install cap
screws (3 used). Tighten mounting plate cap
screws to 41 N•m (30 lb-ft).
4. Install plastic bushing in left side of centering plate.
5. Slide centering plate onto right guide pin bushing.
3.2 mm (1/8 in.)
Left Guide Pin Nut
KV18844

1. Loosen jam nuts on each centering plate. Adjust


centering screws until each bearing surface
protrudes approximately 3.2 mm (1/8 in.).

Bracket
M44227

6. Install left guide pin into plastic bushing.


7. Install left side of centering plate on rear centering
bracket.

11/22/00 7 - 21
REPAIR STEERING

Centering Plate
STEERING DAMPENER REMOVAL/
Right Guide Pin
Bushing INSPECTION/INSTALLATION

Mounting Plate Cross Shaft

Dampener Shim Washer(s)


KV18837
NOTE: Rear plate shown; front plate is similar.
2. Install right guide pin, bushing and nut in mounting Bracket
plate. Tighten nut to 54 N•m (40 lb-ft).
3. Rotate mounting plate into position and install cap
screws (3 used). Tighten mounting plate cap
screws to 41 N•m (30 lb-ft).
4. Install plastic guide pin bushing in left side of
centering plate.
5. Slide centering plate onto right guide pin bushing.
KV14340

Left Guide Pin Nut 1. Remove cap screws (early models) or push nuts
(late models) securing dampener to bracket and
cap screws retaining dampener to cross shaft.
2. Stroke dampener through full range of motion.
Dampeners should operate smoothly with some
resistance to movement. If no resistance is noted,
or if unit is leaking, replace unit.
3. Test dampener as follows:
• With dampener in its installed position, fully extend
Bracket rod-end.
KV18839
• Apply a 9 kg (20 lb) force to rod-end. Time how long
6. Install left guide pin into bushing. it takes for rod-end to fully retract; should be
7. Install left side of centering plate on lower centering between 1-5 seconds.
bracket. • With dampener in its installed position and rod-end
8. Install and torque centering plate guide pin nuts to fully retracted, apply a 9 kg (20 lb) pull to rod-end.
54 N•m (40 lb-ft). • Time how long it takes for rod-end to fully extend;
should be between 1-5 seconds.
Spring Bolt Assembly Replace damener if results vary.

IMPORTANT: Always use a new push nut.

4. Installation is done in reverse order of removal.


Install cap screws, lock nuts, and new push nuts.
5. Tap push nut until fully seated.

KV13981 NOTE: Verify that dampener does not reach its travel
limit before the steering control lever contacts
9. Install spring bolt assembly onto centering plate
the stop screws in both forward and reverse.
assembly. Torque spring bolt to 67 N•m (50 lb-ft).
Install or remove shim washer(s) as required.
10. Repeat STEPS 2-9 for front centering plate.
11. Perform centering plate adjustment. (See
CENTERING PLATE ADJUSTMENT—DUAL 6. Tighten dampener mounting cap screws to
PLATE MODELS in this section.) 40 N•m (30 lb-ft).

7 - 22 11/22/00
STEERING REPAIR

STEERING CONTROL LEVER 4. Remove steering control lever assembly with spring
bracket attached.
REMOVAL/INSPECTION/
INSTALLATION
Inspection:
1. Inspect steering control levers for damage.
Removal:
2. Inspect pivot bearing for looseness or damage.
Replace if required.
Cap Screw

Installation:

Spring Bracket

KV13984

1. Remove cap screw from steering control lever link


rod.

Pivot Bearing Spring

KV14341

1. If removed, install spring bracket on steering control


lever assembly.
2. Install steering control lever assembly. Tighten
pivot bearing block mounting cap screws (4 used)
to 40 N•m (30 lb-ft).

Cap Screw

KV14341

2. Remove spring from steering control lever


assembly.

Pivot Bearing Block

KV13984

3. Install link rod on steering control lever. Tighten link


rod cap screw to 40 N•m (30 lb-ft).
4. Install spring.

KV15261

3. Remove four cap screws from pivot bearing block.

11/22/00 7 - 23
REPAIR STEERING

STEERING CROSS SHAFT ASSEMBLY STEERING CROSS SHAFT ASSEMBLY


REMOVAL/INSTALLATION — REMOVAL/INSTALLATION —
SINGLE PLATE MODELS DUAL PLATE MODELS
Right Control Rods
Support Control Rods
Bracket Link Rod
Link Rod Link Rod Link Rod
Right
Support
Bracket
Detent Ring

Cross Shaft
Assembly
Cross Shaft
Assembly
Dampeners
KV18003 Dampeners KV18845

NOTE: Cross shaft assembly shown is for left-side NOTE: Cross shaft assembly shown is for right-side
mounting. Some models may use right-side mounting. Some models may use left-side
mounting. Other components are the same. mounting. Other components are the same.

Removal: Removal:
1. Park skid steer safely. 1. Park skid steer safely.
2. Raise and block skid steer. (See RAISING AND 2. Raise and block skid steer. (See RAISING AND
BLOCKING SKID STEER in MISCELLANEOUS BLOCKING SKID STEER in MISCELLANEOUS
section.) section.)
3. Raise boom and engage boom locks. 3. Raise boom and engage boom locks.
4. Raise ROPS and ensure ROPS is safely in the 4. Raise ROPS and ensure ROPS is safely in the
locked position. locked position.
5. Remove cover plates to gain access to the cross 5. Remove cover plates to gain access to the cross
shaft. (See REMOVING COVER PLATES in shaft assembly. (See REMOVING COVER
MISCELLANEOUS section.) PLATES in MISCELLANEOUS section.)
6. Remove cap screws and nuts holding dampeners, 6. Remove cap screws and nuts holding dampeners,
link rods, and control rods to cross shaft assembly. link rods, and control rods to cross shaft assembly.
7. Lift control rods from assembly and move to side. 7. Push control rods to rear and remove from
8. Remove cap screws and nuts holding cross shaft assembly.
assembly to right support bracket. 8. Remove cap screws and nuts holding cross shaft
9. Lift right side of cross shaft assembly and slide out assembly to right support bracket.
from left support bracket. 9. Lift right side of cross shaft assembly and slide out
10. Repair or replace as required. from left support bracket.
10. Repair or replace as required.

Installation:
1. Slide cross shaft assembly into left support bracket. Installation:
2. Secure cross shaft assembly to right support 1. Slide cross shaft assembly into left support bracket.
bracket using cap screws and nuts. Tighten cap 2. Secure cross shaft assembly to right support
screws to 40 N•m (30 lb-ft). bracket using cap screws and nuts. Tighten cap
3. Attach control rods to cross shaft and tighten cap screws to 40 N•m (30 lb-ft).
screws to 40 N•m (30 lb-ft). 3. Attach right control rod to cross shaft assembly and
4. Attach link rods and dampeners to cross shaft tighten cap screws to 40 N•m (30 lb-ft).
assembly. Tighten cap screws to 40 N•m (30 lb-ft).

7 - 24 11/22/00
STEERING REPAIR

4. Attach right link rod and dampener to cross shaft 6. Inspect cross shaft (J) and bellcrank bushings for
assembly. Tighten cap screws to 40 N•m (30 lb-ft). wear or damage. Replace as necessary.
5. Adjust detent ring. (See STEERING DETENT
ADJUSTMENT - DUAL PLATE MODELS in this
section.) Assembly:
6. Attach left control rod, link rod and dampener. 1. Install snap ring (K) on flange end of cross shaft (J).
Tighten cap screws to 40 N•m (30 lb-ft). 2. Place detent ring (I) on left bellcrank (G) and finger
7. Check and adjust link rods. (See STEERING tighten set screws.
CONTROL LEVER ADJUSTMENT—CENTERING 3. Place all components on cross shaft (J) in order
in this section.) shown.
8. Check and adjust steering control lever stops. (See 4. Install detent ball (D) and pack detent ball cavity
STEERING CONTROL LEVER STOPS with TY24416 Multi-Purpose HD Lithium Complex
ADJUSTMENT—TRACKING in this section.) grease.
5. Install spring (C) and screw/jam nut (A-B) assembly
in detent cavity.
STEERING CROSS SHAFT 6. Install cross shaft assembly in machine. (See
ASSEMBLY REPAIR—DUAL PLATE STEERING CROSS SHAFT REMOVAL/
MODELS INSTALLATION—DUAL PLATE MODELS in this
section.)

C
D B

I A
F
T G
ON E
FR KV18849

NOTE: Cross shaft (J) is drawn for right-side


mounting. Some models may use left-side
mounting. Other components are the same.

Disassembly:
1. Remove cross shaft assembly. (See STEERING
CROSS SHAFT REMOVAL/INSTALLATION in this
section.)
2. Remove detent screw/jam nut (A-B), spring (C) and
ball (D).
3. Remove snap ring (E) and nylon washer (F) from
left end.
4. Remove both bellcranks (G-H) and both nylon
washers from shaft.
5. If it is necessary to remove the detent ring (I), mark
its locaton on the left bellcrank (G). Loosen both
set screws and remove.

11/22/00 7 - 25
REPAIR STEERING

STEERING CONTROL LEVER NOTE: Models having optional 8-Button Handle will
require disconnecting a harness near the
HANDLE DISASSEMBLY/ASSEMBLY bottom of the lever.

3. Loosen lock nut. Loosen set screw and remove


handle from steering control lever.
A

NOTE: Hands-only Machines: Follow steps 1—3 for


Cable Bracket left handle.

4. Assembly is done in reverse order of removal.


Tighten set screw to 9 N•m (80 lb-in.). Tighten lock
nut to 13.5 N•m (120 lb-in.).
KV14344

NOTE: Right side lever shown.

NOTE: Hands-only Machines: Lock knob (A) is not


used on hands-only machines.

1. Remove cable bracket on steering control lever.

Spring Pin

Cable Assembly

KV14343

2. Remove spring pin from handle. Remove cable


assembly from handle.

Set Screw
Lock Nut

KV14345

7 - 26 11/22/00
BRAKES CONTENTS

CONTENTS
BRAKES

Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OTHER MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BRAKE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
BRAKE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
BRAKE DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BRAKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BRAKE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BRAKE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
BURNISH BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BRAKE ACTUATOR CYLINDER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . 12

11/22/00 8-1
CONTENTS BRAKES

This page intentionally left blank

8-2 11/22/00
BRAKES SPECIFICATIONS

SPECIFICATIONS

BRAKE LINER
Thickness (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.76 mm (3/16 in.)
Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.9 cm (9 in.)

TORQUE SPECIFICATIONS
Hydrostatic Motor-to-Brake Assembly Socket Head Screws. . . . . . . . 118 N•m (87 lb-ft)
Brake Assembly-to-Frame Mount Screws . . . . . . . . . . . . . . . . . . . . . . 109 N•m (80 lb-ft)
Cover Plate-to-Brake Housing Cap Screws . . . . . . . . . . . . . . . . . . . . 109 N•m (80 lb-ft)
Chain Case Cover Cap Screws. . . . . . . . . . . . . . . . . . . . . . . . 70—80 N•m (52—59 lb-ft)

DRIVE SHAFT ASSEMBLY


Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8006 N (1800 lb)

CHAIN CASE
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4 L (3 gal) (Each Side)

OTHER MATERIALS

Number Name Use

HY-GARD®, LOW VIS HY-GARD® (cold weather Fill hydraulic reservoir and chain
operation), John Deere TORQ-GARD SUPREME® case.
or PLUS-50®

PM20166 John Deere 5900 RTV Silicone Seal chain case covers.

TORQ-GARD SUPREME and PLUS-50 are registered trademarks of Deere & Company.

11/22/00 8-3
THEORY OF OPERATION BRAKES

THEORY OF OPERATION
The brake system is electrically controlled and pressure inside cylinder pushes actuator lever up
hydraulically activated. Hydraulic pressure holds the causing it to rotate in a clockwise direction in the left
park brakes disengaged. The left and right side brakes side and counterclockwise in the right side. Hydraulic
are separate units. The brake assembly is mounted pressure on the spring side of the cylinder assists
between the axle and the hydrostatic motor. Each engagement of the brake when the engine is running.
brake assembly is actuated by a cylinder assembly. The actuator rises up on steel balls, applying pressure
The brakes are designed to hold the skid steer in place to the thrust bearing, stator, and brake liner. The brake
to prevent rolling or creeping when parked on a grade. liner is splined to the driver. The driver is keyed to the
The brake is to be used as a parking brake and a drive shaft. When the actuator rotates up, the brake
secondary brake in the event of loss of dynamic liner is held in place, preventing the drive shaft from
(hydrostatic) braking. All braking under power is rotating.
achieved by returning the hydrostatic steering control When the park brake switch is disengaged, the
levers to the center position. solenoid allows hydraulic pressure to flow to the
The cylinder assembly is spring loaded and requires cylinder assembly. Hydraulic pressure overcomes the
hydraulic pressure to retract the spring for brake spring in the cylinder assembly, thus releasing the
disengagement. The cylinder acts on the actuator brake.
lever. When the brake is engaged, hydraulic pressure is Electrical power and hydraulic pressure are required to
removed from the release side of the cylinder. Spring release the park brake.

Brake

Actuator Lever

Cylinder
Actuator

KV15125

(Left Side Shown)

8-4 11/22/00
BRAKES BRAKE EXPLODED VIEW

BRAKE EXPLODED VIEW

1
2
3
4
5 6
7

8
9 10
33 11
35
32 12
34 13
14
15
31 30 16

29 17
18

28
19 20
27
26 21
24 22

26 23
25
24

(Right Side Shown) KV15124

1. Plug 10. Parallel Key 19. Seal 28. Yoke


2. Retainer Ring (2 used) 20. Outer Race 29. Dowel Pin
3. Shim(s) 11. Brake Liner 21. Tapered Roller 30. Cylinder Arm
4. Tapered Roller 12. Stator Bearing 31. Boot Plate
Bearing 13. Thrust Bearing 22. Drive Shaft 32. Boot
5. Outer Race 14. Actuator Lever 23. Cap Screw 33. Screw
6. Cap Screw 15. Steel Balls (5 used) 24. Pivot Pin 34. Cap Screw
7. Cover Plate 16. Brake Housing 25. Actuator Cylinder 35. Seal
8. Retainer Ring 17. Gasket 26. Retaining Pin
9. Driver 18. Cap Screw 27. Jam Nut

11/22/00 8-5
DIAGNOSIS AND TROUBLESHOOTING BRAKES

DIAGNOSIS AND TROUBLESHOOTING


DIAGNOSIS

Test Conditions:

• Park machine on level surface.


• Bucket rolled back.
• Boom lowered.
• Engine running at half throttle.

Test/Check Point Normal If Not Normal

1. Park brake switch Skid steer moves forward and Wheels locked or locked on one side:
disengaged. Move steering backward for the appropriate
control levers forward and Check to see if brake lever is moving
hydrostatic lever.
backward, one at a time. during actuation.
Check lining material.
Troubleshoot park brake solenoid. (See
procedure in the ELECTRICAL section.)
Troubleshoot park brake switch. (See
procedure in the ELECTRICAL section.)
Check charge pump hydraulic pressure.

2. Park brake switch engaged. Skid steer remains stationary One or both sides of skid steer move:
Move steering control levers and engine pulls down or
Troubleshoot park brake solenoid. (See
forward and backward, one stalls (even at full throttle).
procedure in the ELECTRICAL section.)
at a time.
Troubleshoot park brake switch. (See
procedure in the ELECTRICAL section.)

TROUBLESHOOTING
Problem or
Grinding noise while operating

Symptom
Brakes not holding.

Brakes stay locked.

Check or
Solution
skid steer.

Check park brake solenoid. z z z

Check park brake switch/circuit. z z

Check charge pump for proper pressure. z z z

Inspect/replace brake lining. z z z

8-6 11/22/00
BRAKES REPAIR

REPAIR
Cylinder Actuator

BRAKE REMOVAL
1. Park skid steer safely.
2. Raise and block skid steer. (See RAISING AND
BLOCKING SKID STEER in the
MISCELLANEOUS section.)
Hoses
3. Remove cover plates to access the brake assembly.
(See REMOVING COVER PLATES in the
MISCELLANEOUS section.) Hoses
4. Remove steering mechanism and steering cross
shaft. (See procedures in the STEERING section.)
Early Models KV13156
5. Remove the front and rear wheels on the side to be
serviced.
6. Drain the oil from chain case into a suitable
container. The approximate capacity of each chain
case is 11.4 L (3 gal).
Chain Case Cover

Nut
Hose

Hoses

Late Models KV18850


11. Disconnect hydraulic hoses from actuator cylinder.
KV13152 Strap

7. Remove chain case cover plate.


8. Remove front and rear axles. (See REMOVE AND
INSTALL AXLES in POWER TRAIN [CHAIN CASE
AND AXLES] section.)

Drive Shaft

Hydraulic Lines KV13153


12. Disconnect hydraulic lines from hydrostatic motor.
Close all openings with caps or plugs.
13. Attach a strap around hydrostatic motor/brake
Rear Drive Chain Front Drive Chain assembly.
KV13157
9. Roll rear axle sprocket forward and remove rear
drive chain from drive shaft.
10. Roll front axle sprocket rearward and remove front
drive chain from drive shaft.

11/22/00 8-7
REPAIR BRAKES

Screw
(4 used)
Cap Screws
Boot Plate

Boot

KV18537

3. Remove four screws securing boot plate to brake


housing. Remove boot and plate.
KV13154
14. Remove ten cap screws securing brake assembly
to vehicle frame.
15. Remove hydrostatic motor/brake assembly from
machine.
16. Remove four socket head screws securing motor to Cap Screws
brake assembly. Remove motor.

BRAKE DISASSEMBLY
Retaining Ring

Actuator Cylinder KV13151A


C-Clamp
4. Remove retaining ring from drive shaft. Remove
shim(s).
5. Remove eight cap screws from brake housing.
M10
Cap Screws

KV18874

1. Install C-clamp around brake actuator mounting


points to relieve tension on pivot pins for removal.

KV13134
6. Install two fully-threaded M10 cap screws 102 mm
(4 in.) long into threaded holes. Thread cap screws
Retaining Pin in evenly and remove housing cover and inner
(2 used) bearing.
Mounting Pin 7. Remove brake lining, stator, cylinder arm, and
(2 used) gasket from brake housing.
KV18536
2. Remove retainer pins, mounting pins, and brake
actuator. Slowly back off C-clamp to relieve brake
actuator pressure and remove clamp.

8-8 11/22/00
BRAKES REPAIR

Detents
Ball Actuator (5 used)
(5 used) Bearing

KV18543 KV18538

8. Remove actuator plate and five balls.


NOTE: Bearing is a press fit.

11. Remove bearing from shaft.

Housing

Retaining Ring

Brake Gear KV18542

NOTE: Brake gear might require some prying between Seal


bottom of gear and brake housing for removal. KV18541

9. Remove retaining ring and brake gear. Seal

Shaft

Cover

Key KV18878
(2 used)
12. Remove seals in brake cover and housing.
KV18540
10. Remove keys from shaft and remove shaft from
housing.

11/22/00 8-9
REPAIR BRAKES

BRAKE INSPECTION Detents


Ball Actuator (5 used)
(5 used)
IMPORTANT: Do not get oil, grease, or solvents on
brake linings.

1. Clean all parts.


2. Inspect bearings and races for wear or scoring.
3. Inspect actuator plate, housing and balls for wear or
scoring.

KV18543

5. Lubricate five detents in housing and actuator and


five balls with multi-purpose grease. Install balls
and actuator into housing.

Indexing Tabs

KV18545

4. Inspect brake lining for wear, cracks, and


discoloration.
5. Measure brake lining for excessive wear. If linings
measure less than 4.76 mm (3/16 in.), replace
them.
KV18552

BRAKE ASSEMBLY
NOTE: Stator is positioned by locating indexing tabs
into half rounds of housing.
IMPORTANT: Do not get oil, grease, or solvents on
brake linings.
6. Install gasket, stator, and lining into housing.
Position stator indexing tabs into half rounds of
NOTE: Install seals with lips of seals facing away from housing.
center of brake assembly.

1. Install seals into housing and cover until bottomed


out on shoulder of bores. Apply a light coat of
hydraulic oil to seal lips.
2. Install bearing on shaft with cone facing away from
sprocket until bottomed out on shaft shoulder.
3. Install shaft assembly into brake housing.
4. Install keys into shaft and install gear and retaining Cylinder
ring. Arm

KV13134

NOTE: Install longer cap screws through cylinder arm.

7. Install housing cover with cap screws. Tighten cap


screws to 109 N•m (80 lb-ft).

8 - 10 11/22/00
BRAKES REPAIR

KV18877

8. Press bearing into housing cover. Apply a preload KV13154


force of 8006 N (1800 lb-force). 2. Install assembly into machine with a new gasket
and secure with ten cap screws and nuts. Tighten
cap screws to 109 N•m (80 lb-ft).

Drive Shaft

KV18563
Rear Drive Chain Front Drive Chain
9. Determining shim thickness:
a. Install snap ring to top surface of groove. KV13157
b. Measure depth from top of snap ring to top of 3. Install drive chains to shaft.
bearing inner race. 4. Install front and rear axle shafts. (See AXLE
c. Remove and measure snap ring thickness. HOUSING REMOVAL/INSTALLATION in the
d. Subtract snap ring thickness from depth POWER TRAIN [CHAIN CASE AND AXLES]
measurement to determine required shim section.)
thickness. 5. Apply a bead of PM20166 RTV SILICONE
10. Install shims required and snap ring. SEALANT to chain case cover and install with
11. Install boot, boot plate. nuts. Tighten nuts to
70—80 N•m (52—59 lb-ft).
12. Install actuator cylinder.
6. Fill chain case with John Deere HY-GARD, LOW
13. Install O-ring and hydrostatic motor with four socket VIS HY-GARD, TORQ-GARD SUPREME or
head screws. Tighten screws to 118 N•m (87 lb- PLUS-50 hydraulic fluid to bottom of check plug
ft). opening.
7. Install front and rear wheels.
BRAKE INSTALLATION 8. Install cross shaft and steering control lever
assembly. (See procedures in the STEERING
1. Attach hoist and strap to wheel motor/brake section.)
assembly. 9. Install cover plates. (See COVER PLATE
REMOVAL/INSTALLATION in the
MISCELLANEOUS section.)
10. Burnish brakes. (See BURNISH BRAKES in this
section.)

11/22/00 8 - 11
REPAIR BRAKES

BURNISH BRAKES 4. Install remote start box. (See USING REMOTE


START BOX in the MISCELLANEOUS section.)
Reason:
To ensure brakes were properly installed and to
burnish brake lining material. c CAUTION
1. Park skid steer safely.
2. Raise and block skid steer. (See RAISING AND Brake cylinder rod will move when the park
BLOCKING SKID STEER in the brake is engaged or disengaged. Keep fingers
MISCELLANEOUS section.) away from cylinder rod.

5. Start engine and disengage park brake using


remote start box. Brake spring tension will be

c CAUTION removed to loosen upper pivot pin.

Avoid possible injury from moving tires when Retaining Pin


using remote start box. Keep tire area clear of Actuator Lever
bystanders. Do NOT use remote start box
without raising and blocking skid steer. Upper Pivot Pin
Actuator
3. Install remote start box. (See USING REMOTE Cylinder
START BOX in the MISCELLANEOUS section.)
4. Start engine and engage park brake using remote
start box. (See USING REMOTE START BOX in
the MISCELLANEOUS section.)
5. Operate left and right steering control levers to
attempt to drive through park brake.
6. If machine does not drive through park brake, park
brakes are installed properly. KV18007
7. If machine drives through park brake(s):
6. With engine running and park brake disengaged,
• Operate steering control lever(s) for 15 seconds in
remove retaining pin and upper pivot pin from
each direction. This burnishes lining material.
cylinder rod yoke.
• Let brake(s) cool and attempt drive-through again.
7. Turn engine off.
• If machine still drives through park brake(s), repeat
brake repair procedures in this section.

BRAKE ACTUATOR CYLINDER


REMOVAL/INSTALLATION

Removal:
1. Park skid steer safely.
2. Raise and block skid steer. (See RAISING AND
BLOCKING SKID STEER in the
MISCELLANEOUS section.)
3. Remove cover plates. (See REMOVING COVER
PLATES in the MISCELLANEOUS section.)

c CAUTION
Avoid possible injury from moving tires when
using remote start box. Keep tire area clear of
bystanders. Do NOT use remote start box
without raising and blocking skid steer.

8 - 12 11/22/00
BRAKES REPAIR

10. Remove lower pivot pin from actuator cylinder


base. Remove actuator cylinder from cylinder arm.

Installation:

NOTE: Use a hair-pin type clamp to install brake


cylinder.

1. Installation is the reverse of removal.

Hoses Hoses
Early Models KV18015

Hose

Hoses

Late Models KV18887


8. Disconnect hydraulic hoses from cylinder. Close all
openings with caps or plugs.
.

Cylinder Arm

Retaining Pin

Lower Pivot Pin

KV18016
9. Using a hooked type tool, remove retaining pin or
cotter pin from lower pivot pin.

NOTE: If unable to remove pin, remove complete


brake assembly (see BRAKE REMOVAL in this
section.)

11/22/00 8 - 13
REPAIR BRAKES

This page intentionally left blank

8 - 14 11/22/00
HYDRAULICS CONTENTS

CONTENTS
HYDRAULICS
Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE PARTS KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SYSTEM COMPONENTS AND OPERATION . . . . . . . . . . . . . . . . . . . . . 5
SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SYSTEM COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CONTROL VALVE COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HYDRAULIC/CHARGE PUMP COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . 11
BUCKET CYLINDER COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BOOM CYLINDER COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BOOM AND BUCKET LOCKOUT SOLENOIDS CHECK . . . . . . . . . . . . . . . . . . . . . 15
SYSTEM RELIEF VALVE PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
HYDRAULIC/CHARGE PUMP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HYDRAULIC/CHARGE PUMP FLOW TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CIRCUIT RELIEF VALVE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BOOM DRIFT DOWN CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BOOM LIFT CHECK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BOOM DRIFT UP CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BUCKET DRIFT DUMP POSITION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BUCKET DRIFT ROLLBACK POSITION CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BUCKET LIFT CHECK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
BUCKET SELF-LEVELING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HYDRAULIC/CHARGE PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HYDRAULIC/CHARGE PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HYDRAULIC/CHARGE PUMP COMPONENT INSPECTION . . . . . . . . . . . . . . . . . . 23
HYDRAULIC/CHARGE PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
HYDRAULIC/CHARGE PUMP INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
HIGH-FLOW PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
HIGH-FLOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CONTROL VALVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CONTROL VALVE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CONTROL VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
CONTROL VALVE CROSS SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

11/22/00 9-1
CONTENTS HYDRAULICS

Page

CONTROL VALVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41


SELF-LEVELING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
BOOM CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
BOOM CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
BUCKET CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
BUCKET CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
BOOM AND BUCKET CYLINDER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

9-2 11/22/00
HYDRAULICS SPECIFICATIONS

SPECIFICATIONS

HYDRAULIC/CHARGE PUMP
Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High pressure gear pump
Pump Flow (Minimum):
(Standard):
240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.1 L/min (13 gpm)
250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.7 L/min (15 gpm)
(High-Flow Option):
240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.8 L/min (22.4 gpm)
250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98.1 L/min (25.9 gpm)
Hydraulic System Relief Pressure. . . . . . . . . . . . . . . . 21 374±1034 kPa (3100±150 psi)
Hydraulic Circuit Relief Pressure . . . . . . . . . . . . . . . . 22 753±1379 kPa (3300±200 psi)
Charge Circuit Pressure . . . . . . . . . . . . . . . . . . . . . . . . 1379—1551 kPa (200—225 psi)
Gear Shaft OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 mm (0.748 in.)
Gear Shaft Bushing ID (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . 19.2 mm (0.755 in.)
End Plate Scoring (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0381 mm (0.0015 in.)
Pump Body Gear Pocket ID (Maximum) . . . . . . . . . . . . . . . . . . . . . . 43.7 mm (1.719 in.)

CONTROL VALVE
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9110
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 spool, open center

SYSTEM
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spin-on canister
System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 L (6 gal)
Reservoir Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6 L (4.1 gal)

11/22/00 9-3
SPECIFICATIONS HYDRAULICS

TORQUE SPECIFICATIONS
Hydraulic/Charge Pump Body Cap Screws. . . . . . . . . . . . . . . . . . . . . . 35 N•m (26 lb-ft)
Boom Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 N•m (33 lb-ft)
Bucket Circuit Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft)
System Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 N•m (34 lb-ft)
Anti-Cavitation Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 N•m (33 lb-ft)
Spool Cover Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 N•m (84 lb-in.)
Spool Retainer Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 N•m (84 lb-in.)
Valve Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (18 lb-ft)
Bucket Cylinder Upper Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 N•m (54 lb-ft)
Boom Cylinder Lower Pivot Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624 N•m (460 lb-ft)
Work Port Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft)
Lift Check Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 N•m (48 lb-ft)
Valve Body Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft)
Upper Cylinder Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624 N•m (460 lb-ft)
Lower Cylinder Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 N•m (54 lb-ft)
Boom and Bucket Cylinder Lock Nut. . . . . . . . . . . . . . . . . . . . . . . . . 136 N•m (100 lb-ft)
High-Flow Pump Gear Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.1 N•m (30 lb-ft)
High-Flow Pump Retaing Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . 50 N•m (35 lb-ft)
Self-Leveling Valve Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N•m (20 lb-ft)

OTHER MATERIALS

Number Name Use

Petroleum Jelly To lubricate O-rings.


To retain components during assembly.

PT569/ NEVER-SEEZ® Anti-Seize Apply to ID of cylinder bushings.


TY6332 Compound

SERVICE PARTS KITS


The following kits are available through your parts catalog:
Boom Cylinder Kit
Bucket Cylinder Kit
Control Valve Seal Kit
Hydraulic/Charge Pump Kit

LOCTITE is a registered trademark of the Loctite Corp.


NEVER-SEEZ is a registered trademark of the Emhart Chemical Group.

9-4 11/22/00
SYSTEM COMPONENTS AND OPERATION HYDRAULICS

SYSTEM COMPONENTS AND locked in the neutral or actuated position by turning the
lock located on the handle.(On hands only machines
OPERATION the right foot pedal controls the auxiliary hydraulics.
Pushing the “toe” on the pedal sends oil to the quick
Function: couplers. Pushing the pedal into the detent position will
hold it in place.)
The hydraulic system provides fluid power to charge
the hydrostatic system and operate the bucket and The system relief valve, located in the control valve,
boom cylinders and optional auxiliary hydraulic protects the hydraulic system and hydraulic/charge
attachments. pump from excessive pressure. The system relief valve
limits system pressure to 21 374 ± 1034 kPa
(3100 ± 150 psi) and is not adjustable.
Theory of Operation:
The boom circuit relief valve, located in the control
The hydraulic system is an "open center series" type
valve, protects the boom cylinder circuit from excessive
system. In this system, the hydraulic/charge pump
pressure resulting from shock loading when the spool
provides a continuous flow of oil through a main circuit
that connects all of the controlling valves. If the valves is in the neutral position. The circuit relief valves limit
are not operated, the flow of oil passes through the cylinder circuit pressure to 22 753 ± 1379 kPa
open center passage of each valve, then through the oil (3300 ± 200 psi) and is not adjustable.
cooler and oil filter, and returns to the hydraulic The bucket and boom circuits each incorporate a
reservoir. Also, in this type of circuit, the first controlling solenoid valve that hydraulically locks movement of the
valve takes priority over the next valve downstream bucket and boom should any of the following conditions
from the circuit. occur:
• If the operator engages the park brake switch
• Hydraulic/Charge Pump • If the operator turns the engine off or if the engine
The hydraulic/charge pump is a direct drive, positive stalls
displacement gear pump. The pump is mounted and • If the operator releases the seat belt
driven off the end of the front hydrostatic pump. The • If the operator is not sitting in the seat
hydraulic/charge pump draws oil from the reservoir and
supplies a constant flow of oil to the control valve.
• Oil Cooler and Filter

• Control Valve Return oil from the control valve flows to the oil cooler,
located at the rear of the machine. This location allows
The control valve integrates three spool valves and the cooler and radiator to be cooled by the engine fan.
three pressure relief valves into one housing.
Oil from the oil cooler flows to the hydraulic oil filter and
The first valve in the series, and therefore first priority, the charge pressure relief valve before entering the
controls the boom cylinder circuit. When this valve is hydraulic reservoir. The oil filter is a canister-type
actuated by the left foot pedal (toe—lower, heel— screw-on filter.
raise), [On hands only machines the left foot pedal is
non-functional. The left steering control lever has a The charge pressure relief valve maintains charge
“wrist” mechanism built into it. To raise the boom pull pressure at 1448 kPa (210 psi) and is not adjustable.
“wrist” up toward ROPS. To lower the boom push “wrist Solenoid lockout valves are located in both the boom
down towards seat.] the open center port is blocked and bucket circuits. In the boom circuit it is located
and oil is directed to the appropriate side of the boom before the tee connection to the base end of the
cylinders. Cylinder return oil flows through the control cylinders. The lockout valve is located before the tee
valve to the oil cooler, filter and reservoir. connection to the rod end of the bucket cylinders. The
The second valve in the series controls the bucket function of the lockout valve is to prevent flow to or from
cylinder circuit. When this valve is actuated by the right the cylinders.
foot pedal (toe—dump, heel—roll back), [On hands
only machines the right foot pedal is the auxiliary • High Flow Pump (Optional)
hydraulics control. The right steering control lever has a
The high flow option is for attachments that require a
“wrist” mechanism built into it. To roll the bucket back
high flow rate to operate. The high flow pump is a
push “wrist” down towards seat. To dump the bucket
positive displacement gear pump. The pump draws oil
pull “wrist up towards ROPS.] the open center port is
from the reservoir and supplies a constant flow of oil to
blocked and oil is directed to the appropriate side of the
the high flow solenoid valve which is mounted on the
bucket cylinders. Cylinder return oil flows through the
reservoir. When the high flow switch is off the pump will
control valve to the oil cooler, filter and reservoir.
pump oil through the valve and back to the reservoir.
The third valve in the series provides power to operate When the switch is turned on it energizes the solenoud
optional auxiliary hydraulic attachments. This spool is valve and the oil is diverted to the auxiliary spool of the
controlled by a special "wrist" mechanism built into the control valve.
right steering control lever. The auxiliary handle can be

9-5 11/22/00
HYDRAULICS SYSTEM COMPONENTS AND OPERATION

• Self-Leveling (Optional)
Self-leveling automatically levels attachments as the
boom is raised by routing oil from the rod ends of the
boom cylinders to the piston ends of the bucket
cylinders.
As the boom cylinders extend, oil from the rod ports is
directed through a variable orifice and a fixed orifice at
the flow divider valve. The proportion of the oil flow is
determined by the size of the variable orifice. Oil from
the variable orifice flows to the head ports of the bucket
cylinders and the remainder of the oil goes through the
fixed orifice to return. Resistance to movement of the
bucket cylinders creates a pressure high enough to
open the unloading spool in the self-level valve. As the
bucket cylinders extend, oil from the rod ports flows
past the open unloading valve and goes to return. The
purpose of the unloading valve is to prevent the bucket
cylinders from dumping during the self-level cycle.
Self-leveling does not operate during boom lowering.

11/22/00 9-6
HYDRAULICS SYSTEM SCHEMATIC

SYSTEM SCHEMATIC

Charge Flow
Brake Valve

210 psi 75 psi


Spin On
Hydraulic Lift Cylinders
Filter
Reservoir

B A Lockout
Solenoid

Main Control Valve

Drive Motor
3100 psi

Boom 3300 psi

Brake
Self-Leveling
A A Valve (Optional)

B B

Hydraulic/Charge
Pump
Hydrostatic High-Flow
Pumps Valve (Optional)

Bucket
Engine Lockout
Solenoid
Oil C D
Cooler
High-Flow A
Pump 3000 psi
(Optional) B

Anticavitation
Check Tilt Cylinders

A
Aux Auxiliary
B
Couplers

Brake

Drive Motor

KV31129

11/22/00 9-7
SYSTEM COMPONENT LOCATION HYDRAULICS

SYSTEM COMPONENT LOCATION

Auxiliary Couplers Left Bucket Cylinder

Auxiliary Hydraulic Lines

Bucket Cylinder Lines

Right Bucket Cylinder

Bucket Hydraulic Lines

Right Boom Cylinder

Boom Hydraulic Lines


KV13043

9-8 11/22/00
HYDRAULICS SYSTEM COMPONENT LOCATION

SYSTEM COMPONENT LOCATION

Charge Pressure Relief


Valve (Inside Oil Filter
Head Housing)

Hydraulic Oil Dipstick Auxiliary Quick


High Flow Pump Coupler Case
(Optional) Drain Line

Oil Cooler
Self-Leveling
High Flow Valve Valve (Optional)
(Optional)

Hydraulic Vent
Reservoir

Hydraulic Oil
Temperature
Sender (late
models)

Hydraulic Oil
Temperature
Drain Plugs Sender (Early
Models)

Hydraulic
Suction Line

Hydraulic
Pressure Line

Hydraulic/
Charge Pump

Line to Boom
Cylinders
Hydraulic
Return Line

Lines to
Bucket Control Valve
Cylinders

Foot Pedal
Assembly

KV31097

11/22/00 9-9
SYSTEM COMPONENT LOCATION HYDRAULICS

CONTROL VALVE COMPONENT LOCATION


5
1 7
3 6 9
2 23

3
8
4 10
3
25
3

21
24
8
3 10
22
8
20 3

10
12

11
9
2
15

19
14
18

16
17

13

KV31130

18
1. Plug 14. Bucket Spool Valve
2. Spring 15. Boom Spool Valve
3. O-Ring 16. Centering Pin
4. Lift Check Valve 17. Bucket Spool Cover
5. System Relief Valve 18. Auxiliary/Boom Spool Cover
6. Bushing 19. Detent Ball
7. Washer 20. Spacer Block
8. Cover Plate 21. Boom Relief Valve
9. Screw 22. Plug
10. Backup Washer 23. Anti-Cavitation Valve
11. Spacer 24. Screw
12. Control Valve Body 25. Spacer
13. Auxiliary Spool Valve

9 - 10 11/22/00
HYDRAULICS SYSTEM COMPONENT LOCATION

HYDRAULIC/CHARGE PUMP COMPONENT LOCATION

O-Ring
End Plate
(250 Shown)

Screw (8)
45 N•m (33 lb-ft)
Idler Gear

O-Ring

Backup Gasket
Seal
Wear Plate

Drive Gear

Body
KV13951

11/22/00 9 - 11
SYSTEM COMPONENT LOCATION HYDRAULICS

BUCKET CYLINDER COMPONENT LOCATION


C
B
M
L
A K
J O
P
I
H
G O
F
E
D
N

KV13266

A. Cylinder Barrel G. Backup Ring L. Seal


B. Nut H. Wear Ring M. Wiper Seal
C. Piston I. Internal Snap Ring N. Rod
D. Cylinder Rod Guide J. O-Ring O. Seal
E. Seal K. External Snap Ring P. Bushing
F. O-Ring

BOOM CYLINDER COMPONENT LOCATION


D
C
L
B K
J
A I
H
G
F
E

N
M

KV13267

A. Bushing F. Seal K. O-Ring


B. Cylinder Barrel G. Wear Ring L. External Snap Ring
C. Nut H. O-Ring M. Seal
D. Piston I. Backup Ring N. Wiper Seal
E. Cylinder Rod Guide J. Internal Snap Ring O. Rod

9 - 12 11/22/00
HYDRAULICS TROUBLESHOOTING

TROUBLESHOOTING

Hydraulics slow, low power

Jerky or spongy movement


Bucket drifts up or down
Bucket will not roll back
Boom drifts up or down
Problem or

Hydraulic system noisy

Hydraulic system hot


Symptom

Bucket will not dump

Charge pressure low


Pedals will not move
Boom will not lower
Boom will not raise
Check or
Solution

Hydraulic oil level low in reservoir


● ● ● ● ● ● ● ●
Check and add oil

Hydraulic/charge pump damaged


or worn ● ● ● ● ● ● ● ●
Check flow

Control valve linkage or spool


● ● ● ● ● ● ● ● ● ● ●
binding or damaged

Control valve not functioning


● ● ● ● ● ● ● ● ● ●
properly
Check cylinders for bent or
● ● ● ● ● ● ● ● ●
damaged rods
Stuck pivot pins ● ● ● ● ● ● ●

Leaking cylinder packing ● ● ● ● ● ● ● ●

Low system pressure


Check system relief valve ● ● ● ●
pressure setting

Air in hydraulic cylinders


Check fluid level and run ● ● ● ●
hydraulics to bleed system

Boom or bucket solenoid


● ● ● ● ●
malfunctioning

Bucket overloaded ● ● ● ● ●
High system pressure
Check system relief valve ● ● ●
pressure setting
Hydraulic oil cooler restricted ●

Charge pressure relief valve



damaged or setting incorrect

Hydrostatic pump damaged or


● ● ●
leaking

11/22/00 9 - 13
DIAGNOSIS HYDRAULICS

DIAGNOSIS
Test Conditions:
• Hydraulic reservoir oil at proper level.
• Operator in seat.
• Seat belt fastened.
• Key switch in RUN position.

Test/Check Point Normal If Not Normal

1. Foot pedals. Pedals should move freely. Check linkage from pedals to valve.
Check for bent spools in valve.

Test Conditions:
• Engine running at slow idle.

Test/Check Point Normal If Not Normal

1. Instrument panel. Hydraulic oil temperature and filter Filter restriction light on—replace
restriction warning lights should be filter.
off. Hydraulic oil temperature light on—
check oil cooler for restriction.

2. Boom operation. Boom should move freely through Check that park brake switch is in
range of motion when left pedal is the center or run position.
depressed forward or backward. Perform system flow and pressure
Perform following boom checks: checks to verify proper operation of
• Boom operation. hydraulic/charge pump.
• Boom drift down. Check boom cylinders for bent rod
or damaged cylinder wall.
• Boom lift check test.
Check hydraulic hoses, tubing, and
• Boom drift up. connections for leaks.

3. Bucket operation. Bucket should move freely through Check that park brake switch is in
range of motion when right pedal is the center or run position.
depressed forward or backward. Perform system flow and pressure
Perform following bucket checks: checks to verify proper operation of
• Bucket operation. hydraulic/charge pump.
• Bucket drift dump position. Check bucket cylinders for bent rod
or damaged cylinder wall.
• Bucket drift rollback position.
Check hydraulic hoses, tubing, and
• Bucket lift check test. connections for leaks.

9 - 14 11/22/00
HYDRAULICS TESTS AND ADJUSTMENTS

TESTS AND ADJUSTMENTS

BOOM AND BUCKET LOCKOUT SYSTEM RELIEF VALVE PRESSURE


SOLENOIDS CHECK TEST
Reason:
Reason:
To ensure that the boom and bucket lockout solenoids
are functioning properly. To check high pressure relief valve.

Procedure:
Equipment:
IMPORTANT: If lockout solenoids are not working • D01074AA In-Line Hydraulic Tester
properly, boom and bucket will not move. • KV13885 Quick Disconnect, Male
• KV13884 Quick Disconnect, Female
1. Sit in seat.
• JT03377 Hose, 2 required
2. Fasten seat belt.
• JT03012 Connector, 2 required
3. Start the engine.
• JT05690 Connector, 2 required
4. Release the park brake switch by holding all the
way down and releasing to the RUN position.
5. Move the bucket and boom pedals. Bucket and Procedure:
boom should move freely. 1. Lower boom and bucket to normal ground position.
6. Disconnect seat belt. Boom and bucket should lock Stop engine and relieve hydraulic pressure.
as soon as the seat belt is released.

Results:
If function is not correct, check boom and bucket
lockout solenoid circuit.
KV13885
JT05690 JT03012 JT03377
KV13884

KV15257
2. Install JT03012 and JT05690 Connectors on one
end of both JT03377 Hoses.
3. Install KV13885 and KV13884 Quick Disconnects
on connectors.

Male Quick Outlet


Disconnect-
to-Inlet Hose
Outlet-to-Female
Quick Disconnect
Hose

Inlet

D01074AA
In-Line
Hydraulic
Tester KV15136
4. Connect JT03377 Hose to D01074AA In-Line
Hydraulic Tester.

11/22/00 9 - 15
TESTS AND ADJUSTMENTS HYDRAULICS

IMPORTANT: Make sure skid steer male connector HYDRAULIC/CHARGE PUMP


is routed to tester inlet.
PRESSURE TEST
Reason:
To ensure there is sufficient oil pressure to charge the
Female Auxiliary Connector hydrostatic systems and supply oil to the hydraulic sys-
tem.
Equipment:
• JT03344 — 2068 kPa (300 psi) Gauge.
• JT03017 Hose with quick disconnect.
• 38H5069 Tee Fitting (Parker #8 R6LO-S) 13/16-16
Female Swivel ORFS x 13/16-16 Male ORFS x 13/
16-16 Male ORFS.
• JT03457 Adapter (in Kit #JT05412)
Male Auxiliary Connector
• JT0KV12444 Remote Start Box

KV18562 c CAUTION
5. Attach quick disconnects to auxiliary hydraulic
connectors. To help prevent injury from escaping hydraulic
6. Operate hydraulic system until oil reaches normal oil under pressure, relieve the pressure in the
operating temperature of 43°C (110°F). system before removing hydraulic lines.
7. Set engine speed to full throttle position.
8. Actuate auxiliary hydraulic control lever into detent Procedure:
position. 1. Raise and block skid steer. (See RAISING AND
9. Slowly turn load valve knob on hydraulic tester to BLOCKING SKID STEER in the
the right (clockwise) until pressure relief valve MISCELLANEOUS section.)
releases. 2. Raise boom fully and engage the boom lock. Stop
engine and relieve hydraulic pressure.
Specifications: 3. Remove cover plates to access the hydrostatic
pumps. (See COVER PLATE REMOVAL/
INSTALLATION in the MISCELLANEOUS section.)
NOTE: Add 1379 kPa (200 psi) for system charge
pressure when checking pressure on machine.

• Relief pressure of valve should be 21 374 ± 1034


kPa (3100 ± 150 psi). Reading in hydraulic
tester should be 22 753 +/- 1034 kPa 38H5069
(3300 +/- 150 psi) JT03457
JT03017
Results: JT03344

If pressure is not within specifications, replace system


relief valve.

NOTE: Relief valve is factory set and not repairable. KV15134


Replace relief valve if pressure readings are
not within specifications. 4. Connect JT03017 Hose to JT03457 Adapter.
5. Attach JT03344 Gauge to quick disconnect on
hose.

NOTE: Make sure O-rings used between connections


are in good condition to prevent leakage during
test.

6. Connect 38H5069 Tee Fitting to adapter and tighten


all connections.

9 - 16 11/22/00
HYDRAULICS TESTS AND ADJUSTMENTS

Hydraulic Oil
Filter Manifold

Charge Flow Line

KV18853
7. Follow charge flow line from filter manifold and
disconnect at left side of hydrostatic pump center
manifold.

8. Connect 38H5069 Tee Fitting to center manifold


fitting and attach charge flow line to opposite end
of Tee fitting.

c CAUTION
Avoid possible injury from moving tires when
using remote start box. Keep tire area clear of
bystanders. Do NOT use remote start box
without raising and blocking skid steer.

9. Install remote start box. (See USING REMOTE


START BOX in the MISCELLANEOUS section.)
10. Use remote start box to start engine.
11. Operate hydraulic controls until oil reaches normal
operating temperature of 43°C (110°F).
12. Set throttle to wide open throttle (WOT).

Specifications:
• Charge pressure must be 1379—1551 kPa
(200—225 psi).

Results:
1. If charge pressure does not meet specifications,
test pump flow.
2. If pump flow meets specifications, replace complete
hydraulic oil filter manifold.

11/22/00 9 - 17
TESTS AND ADJUSTMENTS HYDRAULICS

HYDRAULIC/CHARGE PUMP FLOW


TEST Female Auxiliary Connector

Reason:
To ensure that the hydraulic/charge pump is delivering
sufficient oil flow to operate the hydraulic system
properly.

Equipment:
• D01074AA In-Line Hydraulic Tester
Male Auxiliary Connector
• KV13885 Quick Disconnect, Male
• KV13884 Quick Disconnect, Female KV18562
• JT03377 Hose, 2 required
6. Attach quick disconnects to auxiliary hydraulic ports
• JT03012 Connector, 2 required located on left boom arm.
• JT05690 Connector, 2 required 7. Operate hydraulic system until oil reaches normal
Procedure: operating temperature of 43°C (110°F).
1. Raise and block skid steer. (See RAISING AND 8. Set engine speed to wide open throttle (WOT)
BLOCKING SKID STEER in the position (2400 rpm).
MISCELLANEOUS section.) 9. Actuate auxiliary hydraulics control handle into
2. Lower boom and bucket to normal ground position. detent (down toward seat) position.
Stop engine and relieve hydraulic pressure. 10. Turn load valve knob to increase resistance until
pressure reads 10 340kPa (1500 psi).

Specifications:
KV13885 Minimum Pump Flow
JT03012 JT03377 (Standard):
JT05690
240 . . . . . . . . . . . . . . . . . . . . . .49.1 L/min (13 gpm)
KV13884 250 . . . . . . . . . . . . . . . . . . . . . 56.7 L/min (15 gpm)
(High-Flow Option):
240 . . . . . . . . . . . . . . . . . . . . 84.8 L/min (22.4 gpm)
250 . . . . . . . . . . . . . . . . . . . . 98.1 L/min (25.9 gpm)
KV15257
3. Install JT03012 and JT05690 Connectors on one
end of both JT03377 Hoses. Results:
4. Install KV13885 and KV13884 Quick Disconnects 1. Check auxiliary hydraulic control valve spool travel
on connectors. and control handle pivot and linkage to make sure
mechanical systems are operating properly.
Male Quick Outlet 2. If flow is low, verify proper engine speed at full
Disconnect- throttle. If engine speed is OK, rebuild or replace
to-Inlet Hose charge pump.
Outlet-to-Female
Quick Disconnect 3. If machine is equipped with high-flow option and
Hose has low flow or is overheating, check to make sure
lift check valve assemblies have been removed
from control valve. (See CONTROL VALVE
ASSEMBLY in this section.)

Inlet

D01074AA
In-Line
Hydraulic
Tester KV15136
5. Connect JT03377 Hose to D01074AA In-Line
Hydraulic Tester.

IMPORTANT: Make sure skid steer male connector


is routed to tester inlet.

9 - 18 11/22/00
HYDRAULICS TESTS AND ADJUSTMENTS

CIRCUIT RELIEF VALVE TEST 6. Start remote pump to pressurize boom raise port.
Take reading when pressure on gauge starts to
decrease. The point at which pressure decreases
NOTE: If machine is equipped with a bucket circuit is the opening pressure of the boom circuit relief
relief valve perform mandatory PIP 00KV010 to valve.
remove bucket circuit relief valve.

Reason: Specifications:
To check boom and bucket circuit relief valves. Boom
Circuit Relief Pressure. . . . . . . . . 22 753 ± 1379 kPa
Equipment: (3300 ± 200 psi)
• 38H1417 Cap
• JT03494 Adapter Fitting Results:
• JT07192 Electric/Hydraulic Pump If pressure is not within specification, replace circuit
• 0—35 000 kPa (0—5000 psi) Gauge relief valve.

Procedure:
NOTE: Relief valve is factory set and not adjustable.
1. Park skid steer safely. Replace relief valve if pressure readings are
2. Raise boom and place on boom locks. not within specification.
3. Gain access to the hydraulic control valve. (See
COVER PLATE REMOVAL/INSTALLATION in the
MISCELLANEOUS section.) BOOM DRIFT DOWN CHECK
Reason:
To ensure that boom raise circuit does not have internal
leaks.

IMPORTANT: The person raising the boom should


remain in skid steer until test is compelte and
Electric/Hydraulic boom is lowered to the ground or raised and
Pump Hose resting on boom locks.

Procedure:
Boom Raise
Port Start engine and raise boom halfway. Shut off engine.

KV18008 Specifications:
4. Disconnect boom raise line at both ends and set • Slight boom drift is permissible.
aside. Cap fitting at boom lockout solenoid.

Electric/Hydraulic Results:
Pump If boom drifts down, check for:

Hose-to-Valve
• Leaking port lock solenoid valve. Replace valve.
• Leaking circuit relief valve. Replace valve.
• Leaking cylinder packing. Rebuild or replace
cylinder.
• Leaking control valve spool. Replace valve.

Gauge

KV18009

5. Connect electric/hydraulic pump hose with gauge to


boom raise port.

11/22/00 9 - 19
TESTS AND ADJUSTMENTS HYDRAULICS

BOOM LIFT CHECK TEST BUCKET DRIFT DUMP POSITION


CHECK
Reason:
To ensure that boom lift check circuit does not have Reason:
internal leaks. To ensure that bucket dump circuit does not have
internal leaks.
IMPORTANT: The person raising the boom should
remain in skid steer until test is compelte and Procedure:
boom is lowered to the ground or raised and
resting on boom locks. 1. Raise boom halfway.
2. Rotate bucket all the way back and then roll to half-
way position and shut off engine.
Procedure:
1. Raise boom halfway.
Specifications:
2. Turn engine OFF.
3. Turn key on and push park brake switch to center • Slight bucket drift is permissible.
position.
4. Press boom pedal to raise position. Results:
If bucket drifts in dump position:
Specifications: • Check port lock solenoid valve. Replace valve.
• Slight boom drift is permissible. • Check for leaks in cylinder packing. Rebuild or
replace cylinder.
• Check for leaks in control valve spool. Replace
Results:
valve.
If boom drifts down:
• Rebuild or replace lift check valve.
BUCKET DRIFT ROLLBACK
POSITION CHECK
BOOM DRIFT UP CHECK
Reason:
Reason: To ensure that bucket rollback circuit does not have
To ensure that boom lower circuit does not have internal leaks.
internal leaks.
Procedure:
Procedure: 1. Start engine and use bucket to raise machine a few
1. Start engine and use boom to raise front of machine inches off ground.
a few inches off ground. 2. Shut off engine.
2. Shut off engine.
Specifications:
NOTE: Bucket may have to be in dump position. • Slight bucket drift is permissible.

Specifications: Results:
• Slight boom drift is permissible. If bucket drifts:
Results: • Check for leaks in cylinder packing. Rebuild or
replace cylinder.
If boom drifts upward:
• Check for leaks in control valve spool. Replace
• Check for leaking cylinder packing. Rebuild or valve.
replace cylinder.
• Check for leaking control valve spool. Replace
valve.

9 - 20 11/22/00
HYDRAULICS TESTS AND ADJUSTMENTS

BUCKET LIFT CHECK TEST


Jam Nut

Reason:
To ensure that bucket lift check does not have internal
leak.

Procedure:
1. Start engine and use bucket dump function to raise
machine a few inches off ground. Self-Leveling
2. Turn engine off. Valve
3. Turn key on and push park brake switch to center Adjusting
position. Screw
4. Press bucket pedal to dump position.
KV31141

Specifications: 3. Loosen jam nut.


• Bucket must not roll back.
NOTE: Make adjustments in 1/2 turn increments.
Results:
If bucket rolls back: 4. Adjust as follows:
• To slow bucket cylinder extend, turn adjusting screw
• Replace lift check valve.
clockwise.
• To speed bucket cylinder extend, turn adjusting
BUCKET SELF-LEVELING screw counterclockwise.
ADJUSTMENT
If unable to achieve adjustment:

Reason: • Remove adjusting screw and check that adjusting


needle is free to move and not damaged.
To ensure that bucket remains level through the lift • Check for proper hose routing to and from self
range of the boom. leveling valve. (See REMOVE and INSTALL SELF
LEVELING VALVE in this section.)
Procedure:
1. Park skid steer safely.
2. Raise ROPS. [See RAISING ROPS(ROLL OVER
PROTECTION STRUCTURE) in the
MISCELLANEOUS section.]

11/22/00 9 - 21
REPAIR HYDRAULICS

REPAIR

HYDRAULIC/CHARGE PUMP 7. Mark pump case across front hydrostatic pump,


pump body and end plate to ensure proper
REMOVAL reassembly.
1. Park skid steer safely. 8. Remove eight cap screws securing charge pump to
2. Raise boom and place on boom locks. front hydrostatic pump.
3. Shut off engine. 9. Remove pump assembly.
4. Gain access to the hydraulic/charge pump. (See
COVER PLATE REMOVAL/INSTALLATION in
NOTE: Wash pump in suitable solvent and dry before
MISCELLANEOUS section.)
disassembling.
5. Drain hydraulic reservoir.

c CAUTION HYDRAULIC/CHARGE PUMP


DISASSEMBLY
To help prevent injury from escaping hydraulic
oil under pressure, relieve the pressure in the Wear Plate
system before removing hydraulic lines.

IMPORTANT: Clean hydrostatic and hydraulic/


charge pump cases before separating pumps to
prevent contamination of hydraulic system.

Hydraulic Wear Plate Seal


Inlet Lines
Backup Gasket
Hydraulic High KV14310
Pressure Line
1. Remove and discard wear plate seal and backup
gasket.

Drive Gear
Idler Gear

Hydraulic/Charge
Pump Body
Pump
KV14291
6. Disconnect inlet and high pressure hydraulic lines
from charge pump.

IMPORTANT: Plug pump openings and hose ends


to prevent contamination of hydraulic system.

KV14305

Mark Case
2. Remove idler gear and drive gear from pump body.

KV14304

9 - 22 11/22/00
HYDRAULICS REPAIR

Pump Body

End Plate

O-Ring
KV14306 KV14307

3. Remove pump body from end plate. 6. Inspect inside diameter of bushings in end plate
4. Remove and discard O-ring. and front hydrostatic pump. Replace if greater than
19.2 mm (0.755 in.).

Cover Plate

O-Ring
KV14308
KV14309
5. Remove cover plate and discard O-ring.
7. Inspect end plate and front hydrostatic pump for
scoring and wear. Replace if wear or scoring
HYDRAULIC/CHARGE PUMP exceeds 0.0381 mm (0.0015 in.).
COMPONENT INSPECTION
1. Clean all parts in suitable solvent. Dry all parts.
2. Remove all nicks and burrs using emery cloth.
3. Inspect drive gear splines for twisted, broken, or
worn teeth.
4. Inspect gear shafts at bushing area and seal area
for rough surfaces and excessive wear.

KV14312
8. Inspect pump body gear pockets. Replace body if
ID of gear pockets exceeds 43.7 mm (1.719 in.).

NOTE: A step worn in pump body at inlet port is


normal.

KV14299

5. Replace gear assembly if shaft measures less than


19 mm (0.748 in.) in bushing area.

11/22/00 9 - 23
REPAIR HYDRAULICS

HYDRAULIC/CHARGE PUMP Wear Plate Assembly


ASSEMBLY

NOTE: Pay special attention to orientation of


components during assembly.

Pump Body
End Plate
KV14310
5. Install new wear plate assembly in pump body.

Cover Plate O-Ring


KV14306

1. Using new O-ring, install pump body on end plate.


2. Using new O-ring install cover plate.

Drive Gear
Idler Gear

Pump Body

KV14305

3. Install idler and drive gears in pump body.

Wear Plate Seal Backup Gasket

KV14294
4. Install new seal and backup gasket in new wear
plate. Step in middle of backup gasket must nest in
seal step.

9 - 24 11/22/00
HYDRAULICS REPAIR

HYDRAULIC/CHARGE PUMP
INSTALLATION

O-Ring

Port at 9 O’Clock Position Port at 3 O’Clock Position


KV14313
2. Install new O-ring on front hydrostatic pump.

Hydraulic
Inlet Line
Passages

Hydraulic/Charge
Pump

Hydraulic High
Pressure Line

KV14291
3. Install hydraulic/charge pump assembly onto front
KV31116 hydrostatic pump using eight screws and washers.

Port at 9 O’Clock Position IMPORTANT: Use an alternating pattern and


Port at 3 O’Clock Position tighten hydraulic/charge pump screws to
with Plug Installed
35 N•m (26 lb-ft).

4. Connect inlet and high pressure hydraulic lines to


hydraulic/charge pump.
5. Perform start-up procedure before operating skid
steer. (See START-UP PROCEDURE AFTER
HYDRAULIC COMPONENT REPLACEMENT in
HYDROSTATIC POWER TRAIN section.)

KV31113

1. Looking at the front hydrostatic pump as it is


mounted in the machine, look for passages in the
two round oil ports. The oil port at the 3 o’clock
position will always have passages. If there are
passages in the port at the 9 o’clock position, a
plug must be installed or the pump will not prime. If
there are no passages in the port at the 9 o’clock
position, no plug is required.

1/4/01 9 - 25
REPAIR HYDRAULICS

HIGH-FLOW PUMP Disassembly:

IMPORTANT: To prevent contamination of the NOTE: Gear is keyed on to a tapered shaft.


hydraulic system, thoroughly clean fittings
before disconnecting hydraulic lines.

Removal:
1. Remove left side engine cover.

Output Line

O-Ring

Nut

Suction Line
1. Loosen nut and unthread until flush with end of
shaft. Leave nut on end of shaft to protect the
threads.
2. Using a small gear puller, put tension on gear. Tap
the end of puller to loosen the taper.
2. Disconnect suction line and output line from pump. 3. Remove nut and gear.

NOTE: Pump has no servicable components and must


be replaced as an assembly.

4. Inspect gear and shaft for wear. Replace or repair


as required.
Nuts
Cap Screw
Assembly:
1. Install gear and nut onto shaft. Tighten nut to
40.7 N•m (30 lb-ft).

Installation:
1. Install new O-ring and position pump on engine.
2. Install cap screws and nuts. Tighten to 50 N•m
3. Remove cap screws and nuts. (35 lb-ft).
4. Remove pump from machine. 3. Connect output and suction lines to pump.
4. Install left side engine cover.

9 - 26 11/22/00
HYDRAULICS REPAIR

HIGH-FLOW VALVE CONTROL VALVE REMOVAL


1. Park skid steer on a flat level surface.
Replacement: 2. Raise boom fully and place on boom locks. Shut
engine OFF.
1. Disconnect wiring connector.
3. Turn key switch ON and operate all hydraulic
controls to relieve system pressure. Turn key
switch OFF.
Jamb Nut
Thumb Nut 4. Disconnect battery negative (–) cable.
Solenoid 5. Raise the ROPS. (See RAISING ROPS [ROLL
Auxiliary Hydraulic OVER PROTECTION STRUCTURE] in the
Line MISCELLANEOUS section.)
6. Remove cover plates. (See COVER PLATE
REMOVAL/INSTALLATION in the
MISCELLANEOUS section.)
7. Lock auxiliary hydraulic handle in the OFF position.

Case Drain Line

Jam Nuts
Line from High- Bracket
Flow Pump

2. Remove case drain line. Cable


3. Remove auxiliary hydraulic line. Wire Connector
Bellcrank
4. Remove high-flow pump line.
5. Loosen jam nut.
6. Unthread valve assembly from tank.
7. Remove thumb nut. Remove solenoid from valve
Rod End
assembly.
8. Repair or replace components as necessary.
9. Installation is done in reverse of removal. KV31070
8. Disconnect rod end from bellcrank.
9. Loosen jam nuts and remove cable from bracket.
10. Disconnect boom lockout wire connection. Cut wire
ties as needed.

11/22/00 9 - 27
REPAIR HYDRAULICS

Clamp
Boom Lower
Line Fittings

Bucket Dump
Line Fittings
Boom Raise Bucket Rollback
Line Fittings Line Fittings

KV31071 KV31073
14. Remove clamp.

c CAUTION
15. Disconnect bucket dump line fittings and remove
line.
16. Disconnect bucket rollback fittings and remove line.
To help prevent injury from escaping hydraulic
oil under pressure, relieve the pressure in the
system before removing hydraulic lines.
Clamp

IMPORTANT: Cap and plug pump openings and


hose ends to prevent contamination of
hydraulic system. Auxiliary Line
Fittings
NOTE: Tag hydraulic lines to ease installation.

11. Disconnect boom line fittings and remove boom


lines from control valve.

KV31074
Isolator Plate 17. Remove clamp.
18. Disconnect auxiliary line fittings and remove lines.

Cap Screws Return Line

Cotter
Pins Clevis
Clamp
Pins

KV31072

NOTE: Left side shown.

12. Remove cap screws and isolator plate from both High Pressure
left and right sides. Line KV31075
13. Remove clamp (left side only). 19. Remove cotter pins and clevis pins from spools.
20. Disconnect high pressure line and return line.

9 - 28 11/22/00
HYDRAULICS REPAIR

CONTROL VALVE DISASSEMBLY

Boom Relief Load Check Valves


Anti-Cavitation
Plug Check Valve
System Relief
Valve

Cap Screws
and Nuts

Spool Detent Boom Spool


Cover

KV31076 Auxiliary
Spool
21. Remove three cap screws and nuts and remove Bucket Spool
control valve. KV31014

Boom Raise Hydraulic


Fitting Supply

Boom, Bucket
and Auxiliary
Fittings

Hydraulic
Return
KV31014

NOTE: Boom-raise hydraulic fitting has a smaller ID


than the other five fittings. The restricted size
helps control boom down speed.

IMPORTANT: Before removing valve spools, make


sure the exposed portion of spool is free of
paint or corrosion which could damage the
internal porting of the valve.

1. Thoroughly clean valve assembly before


disassembling. Place on clean work surface for
disassembly.

11/22/00 9 - 29
REPAIR HYDRAULICS

O-Ring

KV14317

Wiper
NOTE: Boom and auxiliary spool valves have detent
balls that are retained by the spool cover. Be
careful not to lose them during disassembly.

KV31018

4. Carefully pull spool from housing and place on


clean work surface.
KV31015
2. Slowly remove boom spool cover. Remove loose
Spacer Retainer
detent balls (four small, one large) from cover.
3. Remove detent spring from cavity in end of spool.
O-Ring

NOTE: Spools are a matched set within the control


valve. Test spools for freedom of rotation. If
spool binds in housing, rotate spools 180°. If
binding still occurs, replace complete control
valve assembly.

Wiper

KV31017

5. Remove O-ring and wiper from spool.


6. Remove retainer and spacer from spool.

9 - 30 11/22/00
HYDRAULICS REPAIR

O-Ring
Cap

Spiral Ring Wiper


Cover

Detent Sleeve
KV31018
7. Remove spiral ring that retains the cap in spool
cover. Remove cap and detent sleeve from cover. Retainer

KV31020A
Sleeves
12. Remove auxiliary spool retainer, wiper and O-ring
Retainers from opposite end of valve housing. Place all
auxiliary spool parts together.

Screws
KV31027

8. Remove screws, sleeves and retainers (2 used)


from opposite side of valve housing.

Bucket Spool

Spacer

O-Ring

KV31030
Backup
Washer 13. Remove cover from bucket spool.

Wiper

KV31028
9. Remove wiper, backup washer, O-ring, and spacer
from housing.
10. Place all boom valve parts together to avoid mixing
parts.
11. Repeat steps 3—7 for auxiliary spool.

11/22/00 9 - 31
REPAIR HYDRAULICS

O-Ring
O-Ring
Retainer
Wiper
Wiper

Spacer Retainer

KV31029 KV31031
14. Pull bucket spool from housing. Remove O-ring, 15. Remove the retainer, wiper and O-ring from the
wiper, retainer plate and spacer from spool. opposite end of the valve housing. Place all bucket
valve parts together.

NOTE: DO NOT disassemble the spool and spring


assemblies. There are no detail service parts.

Boom Relief
Valve Assy.

Plug

O-Ring

KV31023
16. Remove the boom relief valve.
17. Remove plug. If bucket relief valve is present,
update machine per mandatory PIP 00KV010.

9 - 32 11/22/00
HYDRAULICS REPAIR

System Relief
Valve Assy.
Anti-Cavitation
Check Valve Assy.
O-Ring

O-Ring
Spring

Poppet
KV31024 Boom Raise Lift Check Assy.
Fitting
18. Remove the system relief valve.
19. Remove anti-cavitation check valve.

Auxiliary
Port

KV31025

NOTE: The anti-cavitation check valve can be


disassembled but is only serviced as an KV31026
assembly. Large end of spring goes in cover.

NOTE: Machines having the high-flow option will not


have a lift check poppet and spring in the
auxiliary port.

20. Remove the three lift check assemblies.

O-Ring

KV14322
21. Remove valve body plug.

11/22/00 9 - 33
REPAIR HYDRAULICS

CONTROL VALVE INSPECTION


1. Thoroughly clean and dry all parts. Pintle
2. Inspect each spool and spool bore for scratches,
fretting, or burrs.

KV14318

IMPORTANT: Spools are a matched set within the


control valve. If excessively worn or damaged,
replace entire control valve.

3. Lightly oil each spool and insert in valve housing.


Move spools in and out to check for tight spots. KV31034
Remove spools and place on clean work surface. 5. Inspect boom and bucket (early models only) relief
valve. Verify pintle moves freely.

Pintle

Poppet
KV31033

Seat

KV31035
6. Inspect system relief valve. Verify pintle moves
freely.

KV31032

4. Inspect lift check poppets and seats for abnormal


wear or damage.

NOTE: Do not disassemble system or boom relief


valves. Valves are not serviceable. Replace KV31025
entire relief valve if not functioning properly. 7. Inspect anit-cavitation check valve for damage.
Verify seat moves freely within cover.

9 - 34 11/22/00
HYDRAULICS REPAIR

This page intentionally left blank.

11/22/00 9 - 35
REPAIR HYDRAULICS

CONTROL VALVE CROSS SECTION

KV31010

9 - 36 11/22/00
HYDRAULICS REPAIR

CONTROL VALVE CROSS SECTION

1. Boom Spool 19. Spiral Snap Ring 33. O-Ring (3 used) 51. Retaining Plate
2. Cap Screw (2 used) 20. Ball (Large) 34. Spool Seal 52. Spool Wiper
3. Retaining Plate 21. Plate 35. Retaining Plate 53. Spacer
4. Spool Wiper 22. End Cap 36. Spool Wiper 54. Spring
5. Backup Ring 23. Ball (Small) 37. Spacer 55. Spring Collar
6. Spool Seal (4 used) 38. Spring Collar 56. Washer
7. Seal Extender 24. Spring 39. Spring 57. Detent Spring
8. O-Ring 25. Bucket Spool 40. Spring Collar 58. Spool End
9. Spool Seal 26. Spool Wiper 41. End Cap 59. Detent Sleeve
10. Retaining Plate 27. Cap Screw (2 used) 42. Spool End 60. Spiral Snap Ring
11. Spool Wiper 28. Retaining Plate 43. Cap Screw (2 used) 61. Ball (Large)
12. Spacer 29. Spool Seal 44. Auxiliary Spool 62. Plate
13. Cap Screw (2 used) 30. Load Check 45. Spool Wiper 63. End Cap
14. Spring Collar (3 used) 46. Cap Screw (2 used) 64. Ball (Small)
15. Washer 31. Load Check Plug 47. Retaining Plate (4 used)
(3 used) 65. Cap Screw (2 used)
16. Detent Sleeve 48. Spool Seal
32. Load Check Spring
17. Spool End (3 used) 49. Valve Body
18. Detent Sleeve 50. Spool Seal

11/22/00 9 - 37
REPAIR HYDRAULICS

CONTROL VALVE ASSEMBLY

IMPORTANT: Due to extremely tight tolerances and O-Ring


finish of internal surfaces it is very important to
maintain absolute cleanliness during the
assembly of the valve. Apply clean hydraulic
fluid to all internal parts before assembling.
Spring

IMPORTANT: Replace all O-rings with new. Old or


damaged O-rings will leak.

Poppet
1. Thoroughly clean and dry all parts.
Boom Raise Lift Check Assy.
Fitting

O-Ring

KV14322 Auxiliary
Port
2. Install new O-ring on valve body plug and install into
control valve. Tighten to 38 N•m (28 lb-ft).

KV31026

IMPORTANT: Machines having the High-Flow


option will NOT have a lift check poppet and
spring in the auxiliary port. If they are
mistakenly installed, low flow and overheated
oil will result.

3. Install three lift check poppets and springs in


housing.
4. Install new O-rings on lift check plugs and install.
Tighten plug to 65 N•m (48 lb-ft).

NOTE: Boom-raise hydraulic fitting is an orificed fitting


and is located in left rear (boom raise) port next
to boom relief valve. The restricted size helps
control boom down speed. If the hydraulic
fittings are removed, be sure to install the
boom-down fitting in the correct place.

5. If the six hydraulic fittings were removed, install new


O-rings on fittings and install fittings in housing.
Tighten all fittings to 38 N•m (28 lb-ft).

9 - 38 11/22/00
HYDRAULICS REPAIR

Bucket
Auxiliary Boom

Boom Relief
Valve Assy.

Plug
O-Ring
O-Ring

Wiper

Retainer

KV31031
10. Install O-ring, wiper, and retainer for auxiliary and
bucket spools. Tighten to 9.5 N•m (84 lb-in.).

KV31023
6. Replace boom relief valve O-ring and install relief Spacer Retainer
valve. Tighten to 45 N•m (33 lb-ft).
7. Install bucket circuit plug. Tighten to 38 N•m O-Ring
(28 lb-ft). If control valve has a bucket relief valve
perform mandatory PIP 00KV010.

System Relief
Valve Assy.
Anti-Cavitation
Check Valve Assy.
Wiper

KV31017
O-ring
11. Place spacer, retainer, new wiper, and O-ring on
each spool.
12. Use protective jaws and place housing in vise with
boom relief valve up.
13. Thoroughly coat spools and body passages with
oil.
KV31024

8. Replace system relief valve O-ring and install valve. NOTE: All three spools are different. Be careful not to
Tighten to 51 N•m (34 lb-ft). mix spool and spring assemblies when
9. Replace anti-cavitation check valve O-ring and assembling valve.
install. Tighten to 45 N•m (30 lb-ft).

11/22/00 9 - 39
REPAIR HYDRAULICS

IMPORTANT: Be careful not to damage O-rings


when installing spools.

14. Carefully install spools in housing.

Detent Sleeve

KV31039
15. Use petroleum jelly to retain balls in boom spool. KV31040
Place four small balls and one large ball in spool. 17. While holding detent sleeve just above end of
cover, use a punch to depress the large ball. While
depressing ball, slide detent sleeve down into
cover.
Cover

Cap Screw

KV31038 KV31041

16. Install spool covers and press on cover to seat O- 18. Install cap in end of cover and retain with spiral
rings in control valve housing. Install cap screws ring.
finger-tight. 19. Repeat process for auxiliary spool.
20. Tighten spool cover cap screws to 9.5 N•m
(84 lb-in.).

9 - 40 11/22/00
HYDRAULICS REPAIR

21. Move spools in and out to verify operation. 24. Install retainers, sleeves and screws. Tighten
screws to 9.5 N•m (84 lb-in.).

CONTROL VALVE INSTALLATION


O-Ring
IMPORTANT: Do not overtighten valve mounting
screws. Excessive torque on valve mounting
screws may deform valve body and cause
malfunction and/or damage to valve.

KV31037

22. Replace O-ring on boom spool spacer.


Cap Screws
and Nuts

Spacer

KV31076

1. Install three cap screws and nuts and tighten


O-Ring mounting evenly to 24 N•m (18 lb-ft).

Return Line
Backup Washer

Wiper
Cotter
KV31019 Pins Clevis
Pins
23. Install spacer, O-ring, back-up washer and
retainers for boom spool.

Sleeves
High Pressure
Retainers Line KV31075

2. Install cotter pins and clevis pins to spools.


3. Connect high pressure line and return line.

Screws
KV31027

11/22/00 9 - 41
REPAIR HYDRAULICS

Boom Lower
Line Fittings
Clamp

Auxiliary Line
Fittings
Boom Raise
Line Fittings

KV31074 KV31071

4. Connect auxiliary line fittings. 10. Connect boom line fittings to control valve.
5. Install clamp.

Clamp
Jam Nuts
Bracket

Cable

Bellcrank Wire Connector


Bucket Dump
Line Fittings
Bucket Rollback
Line Fittings
Rod End

KV31070
KV31073 11. Install auxiliary cable to bracket and tighten jam
6. Connect bucket dump line fittings and bucket nuts securely.
rollback fittings. 12. Connect rod end to bellcrank.
7. Install clamp. 13. Connect boom lockout harness connector. Install
wire ties as needed.
14. Connect battery negative (–) cable to battery.
Isolator Plate
15. Run machine and operate all hydraulic controls to
check operation and leaks.
16. Install cover plates. (See COVER PLATE
Cap Screws REMOVAL/INSTALLATION in the
MISCELLANEOUS section.)
17. Lower and secure the ROPS. (See RAISING ROPS
[ROLL OVER PROTECTION STRUCTURE] in the
MISCELLANEOUS section.)
Clamp

KV31072

NOTE: Left side shown


8. Install isolator plate to both left and right sides.
9. Install left side clamp.

9 - 42 11/22/00
HYDRAULICS REPAIR

SELF-LEVELING VALVE BOOM CYLINDER REMOVAL

Removal: NOTE: Boom arm cylinders can be safely removed


1. Park skid steer safely. while arms are supported on boom arm locks.
2. Turn key switch to ACCESSORY position,
disengage park brake and operate all hydraulic 1. Park skid steer safely. Raise boom and place on
controls to relieve pressure in the hydraulic boom locks.
system. Turn key switch OFF.
3. Raise ROPS. (See RAISING ROPS [ROLLOVER

c CAUTION
PROTECTION STRUCTURE] in the
MISCELLANEOUS Section)

B To help prevent injury from escaping hydraulic


oil under pressure, relieve the pressure in the
system before removing hydraulic lines.
A

2. Sitting in operator’s seat with seat belt fastened,


Cap Screws turn ignition switch to the ON position. Push park
brake switch to middle position to release
hydraulics but engage park brake. Operate all
hydraulic controls to relieve hydraulic pressure in
the system.
D

C
Boom Lower Line
Boom Cylinder

A. Line to Control Valve


B. Line to Boom Cylinders Rod End Lines
C. Line to Bucket Cylinder Head End Lines
Boom Raise Line
D. Line to Bucket Cylinders Rod End Lines

IMPORTANT: To prevent contamination of the


hydraulic system, thoroughly clean fittings
before disconnecting hydraulic lines.
KV14328
4. Disconnect hydraulic lines (A—D). Cap and plug all 3. Disconnect boom cylinder hydraulic lines at
openings. cylinder.
5. Remove cap screws and remove valve.
6. Repair or replace as required.

Cap Screw
Installation:
7. Install cap screws and tighten to 28 N•m (20 lb-ft).

NOTE: Inspect O-rings on hydraulic fittings for wear or


damage. Replace if necessary. Used or Pivot Pin
damaged O-rings will leak.

8. Connect lines (A—D).


9. Lower ROPS and secure. KV14329

4. Remove cap screw on top cylinder pivot pin.


Remove pin.

11/22/00 9 - 43
REPAIR HYDRAULICS

Boom
Retract Cylinder
Hydraulic Line
Cap Screw

Extend Hydraulic Line

Spacer Block

KV14330
5. Loosen lower pivot cap screw.

IMPORTANT: DO NOT remove nut from lower cap


screw until cylinder pivot is loose.

6. Rotate cylinder to an upright position.


7. Rock cylinder back and forth perpendicular to KV18000
normal rotation to loosen lower pivot. 3. Connect hydraulic lines. Install rubber spacer block
8. Remove lower pivot cap screw. Remove cylinder. and secure tube to cylinder with hose clamp.
9. Repair or replace cylinder as necessary. 4. Cycle cylinder and check for leaks.
5. Check hydraulic oil level and fill if necessary.
BOOM CYLINDER INSTALLATION
BUCKET CYLINDER REMOVAL

Pivot Cap Screw c CAUTION


Bucket cylinders can be safely removed only
while lift arms are in completely lowered
position.

1. Park skid steer on flat level surface. Lower boom lift


arms completely and turn engine off.
KV14330
1. Install cylinder and lower pivot pin. Tighten nut to
624 N•m (460 lb-ft). c CAUTION
To help prevent injury from escaping hydraulic
oil under pressure, relieve the pressure in the
Cap Screw system before removing hydraulic lines.

2. Sitting in operator’s seat with seat belt fastened,


turn ignition switch to the ON position. Push park
brake switch in to disengage park brake and
operate all hydraulic controls to relieve hydraulic
Pivot Pin pressure in the system.
3. Engage park brake switch and turn ignition key to
the OFF position.

KV14329
2. Install upper pivot pin. Tighten cap screw to 73 N•m
(54 lb-ft).

9 - 44 11/22/00
HYDRAULICS REPAIR

NOTE: Right-side bucket cylinder shown in photo. Left- IMPORTANT: DO NOT remove nut until cylinder
side cylinder is the same. pivot is loose.

8. Loosen nut from upper bucket cylinder pivot.

Tapered Pin

Hydraulic Lines
Cap Screw

KV14269
9. Rock cylinder back and forth perpendicular to
normal rotation until tapered pin becomes loose.
10. Remove nut, cap screw, tapered pin and bucket
cylinder. Make repairs as necessary.
KV13997
4. Tag or label bucket cylinder hydraulic lines to aid
during installation. BUCKET CYLINDER INSTALLATION
5. Disconnect hydraulic lines from bucket cylinder.

Tapered Pin
Cap Screw

Pivot Pin

Cap Screw

Nut KV14269
KV13998 1. Install bucket cylinder, tapered pin and cap screw.
6. Remove nut and cap screw retaining lower cylinder
pivot pin.
7. Remove lower cylinder pivot pin using a brass
punch and hammer.

Nut

Nut KV14268
2. Install nut and tighten to draw tapered pin into upper
cylinder pivot. Tighten nut to 624 N•m (460 lb-ft).

KV14268

11/22/00 9 - 45
REPAIR HYDRAULICS

1. Place cylinder end in a soft-jawed vise.


2. Clean outside surface of cylinder with suitable
Cap Screw solvent and dry to prevent dirt and debris from
entering cylinder barrel.

Pivot Pin

Cylinder Rod
Remove Paint

Nut
KV13998
3. Position cylinder and install lower pivot pin. Install
cap screw and nut. Tighten cap screw to 73 N•m
(54 lb-ft). Cylinder Barrel

Snap Ring

KV18854
3. Pull cylinder rod out slowly to the full extended limit
to remove trapped oil or air between rod piston and
rod guide.
4. Push cylinder rod back in cylinder barrel
approximately 50 mm (2.0 in.).
5. Remove external snap ring.
6. Remove paint from flange of rod guide. Thoroughly
Hydraulic Lines
clean all debris from rod guide.

Rod Guide

KV13997

NOTE: Inspect O-rings on hydraulic fittings for wear or


damage. Replace if necessary. Used or
damaged O-rings will leak.

KV18851
4. Inspect hydraulic fitting O-rings for wear or damage.
7. Using a wooden dowel or brass drift, drive rod guide
Replace if necessary. Connect hydraulic lines.
into cylinder past internal snap ring groove.

BOOM AND BUCKET CYLINDER


REPAIR

IMPORTANT: Cylinder will distort if clamped on


barrel. Clamp cylinder only at pivot area.

KV18855

9 - 46 11/22/00
HYDRAULICS REPAIR

NOTE: Replace all seals and O-rings. Used or


damaged seals will leak.

Filler Ring
14. Install new seals and O-rings.
15. Install rod guide, piston and lock nut on cylinder
rod.

KV18852
30°
8. Make sure there is no debris in internal snap ring
groove. Install filler ring supplied with cylinder seal
kit into internal snap ring groove.

Cylinder Rod
KV14276
16. Tighten lock nut to 136 N•m (100 lb-ft).

NOTE: 30° equals 1/2 flat on nut.

17. After lock nut has been tightened to specification,


turn lock nut clockwise an additional 30°.
Cylinder Barrel
KV14275
9. With cylinder barrel secured in vise, remove IMPORTANT: Make sure filler ring used during
cylinder rod from cylinder barrel. Inspect all parts removal of cylinder rod is removed from snap
for wear or damage and replace as necessary. ring groove in cylinder barrel.

Internal
Cylinder Rod
Snap Ring Piston
Hose Clamp
Lock Nut
Rod Guide

Rod Guide
KV14276 Rod Guide Flange
10. Install rod end in a soft-jawed vise. Cylinder Bore KV14285
11. Remove lock nut, piston, and rod guide from
cylinder rod. 18. Install a hose clamp over snap ring on rod guide.
12. Clean and inspect all parts. Remove any nicks or 19. Tighten hose clamp until snap ring is seated in
burrs with emery cloth. groove on rod guide, then loosen one turn.
13. Carefully inspect cylinder bore and piston for deep
grooves or scratches. Replace entire cylinder if
either is damaged.

11/22/00 9 - 47
REPAIR HYDRAULICS

NOTE: With a soft-faced hammer, hit rod guide flange


firmly to install rod guide, and seat snap ring in
cylinder bore groove.

20. Install rod guide into cylinder bore using a soft-


faced hammer. Remove hose clamp once internal
snap ring has entered cylinder bore. Continue to
push rod guide into cylinder until internal snap ring
is in its groove. Pull firmly on rod to verify.

External Snap Ring

KV14272
21. Install external snap ring.
22. Perform start-up procedure. (See START-UP
PROCEDURE AFTER COMPONENT
REPLACEMENT in the HYDROSTATIC POWER
TRAIN section.)

9 - 48 1/4/01
MISCELLANEOUS CONTENTS

CONTENTS
MISCELLANEOUS
Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RAISING ROPS (ROLLOVER PROTECTION STRUCTURE). . . . . . . . . . . . . . . . . . . 4
BOOM LOCK REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RAISING AND BLOCKING SKID STEER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COVER PLATE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
USING REMOTE START BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ROPS REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LOWER BOOM LINK REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 10
UPPER BOOM LINK REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 12
QUIK-TATCH® HITCH COUPLING REMOVAL/INSTALLATION. . . . . . . . . . . . 13
QUIK-TATCH® REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BOOM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CAB HEATER/DEFROSTER (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HEATER CORE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
BLOWER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CONTROL VALVE REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . 20
CAB HEATER DEAERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CAB DOOR (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
WINDSHIELD WIPER/WASHER (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
WASHER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

11/22/00 10 - 1
CONTENTS MISCELLANEOUS

This page intentionally left blank

10 - 2 11/22/00
MISCELLANEOUS SPECIFICATIONS

SPECIFICATIONS

TORQUE SPECIFICATIONS
ROPS-to-Side Frame Retaining Nuts Torque . . . . . . . . . . . . . . . . . . . 105 N•m (77 lb-ft)
ROPS-to-Rear Weldment Post Cap Screws Torque . . . . . . . . . . . . . . 105 N•m (77 lb-ft)
Lower Boom Link-to-Frame Pin Retaining Cap Screw Torque . . . . . . . 73 N•m (54 lb-ft)
Upper Boom Link, Lower Boom Link,
and Boom Pivot-Pin Cap Screws Torque . . . . . . . . . . . . . . . . . . . 275 N•m (200 lb-ft)
Cylinder Upper Pivot-Pin Retaining Cap Screw . . . . . . . . . . . . . . . . . . 73 N•m (54 lb-ft)
Wiper Arm Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 N•m (92 lb-in.)

OTHER MATERIALS

Number Name Use

TY6333 or Moly High Temperature EP Grease Apply to boom lock and QUIK-TATCH™.
TY6347

PT–569 Never–Seez Lubricant Apply to upper boom link, lower boom link and
boom pivot pins.

SPECIAL OR ESSENTIAL TOOLS

NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or in the
European Microfiche Tool Catalog (MTC).

Remote Start Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JT0KV12444


Lifting Eyelets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JT01748

QUIK-TATCH and SERVICEGARD are trademarks of Deere & Company.

11/22/00 10 - 3
REPAIR MISCELLANEOUS

REPAIR Cylinder Tube

RAISING ROPS (ROLLOVER


PROTECTION STRUCTURE)
1. Park skid steer on flat level surface, lower boom to
the at-rest ground position, engage park brake,
and turn engine off.

NOTE: The ROPS can be raised with the boom resting


on the boom locks. KV18532

5. To lower ROPS, push right lower cylinder tube


rearward to unlock cylinder.
Washer 6. Pull ROPS down until seated on mounting studs.
(2 Used) 7. Install washer and nut on ROPS mounting stud (one
each side). Tighten cap screws to 105 N•m
(77 lb-ft).

Lock Nut
(2 Used)
KV15169

2. Remove lock nut and flat washer. Repeat this step


for opposite side of ROPS.
3. Use handholds to raise ROPS, making sure
steering levers fall forward. Continue raising ROPS
all the way up so that gas spring cylinder locks in
place.

Cylinder Tube

KV18531

NOTE: Early model cylinder lock shown. Late model is


similar.

4. Ensure ROPS cylinder is locked by pushing forward


on lower cylinder tube.

10 - 4 11/22/00
MISCELLANEOUS REPAIR

BOOM LOCK REMOVAL/INSTALLATION

I
H

F H
E
A D G
C I

J
L

A
E D

KV15160

A. Cap Screw (2 used) E. Washer (4 used) I. Spring Pin (2 used)


B. Guide Bracket F. Pin J. Lever
C. Lever G. Spring K. Pin
D. Cotter Pin (3 used) H. Boom Lock Pin (2 used) L. Linkage

Removal: Installation:
1. Lower boom to the at-rest ground position. Engage
park brake switch and turn engine off. NOTE: Apply Moly High Temperature EP Grease to all
2. Raise ROPS and ensure ROPS is safely in the moving boom lock parts before installation.
locked position. (See RAISING ROPS
[ROLLOVER PROTECTION STRUCTURE].)
3. Remove two cap screws (A), guide bracket (B), and 1. Installation is the reverse of removal.
spring (G).
4. Remove cotter pins (D), washers (E), pins (F and
K), and linkage (L).
5. Remove levers (C and J) with spring pins (I) and
boom lock pins (H) as an assembly.

NOTE: Remove spring pins (I) only if replacement of


lock pins (H) and levers (C and J) is necessary.

6. Inspect all parts for wear or damage. Replace if


necessary.

11/22/00 10 - 5
REPAIR MISCELLANEOUS

RAISING AND BLOCKING SKID


STEER

NOTE: Tires are removed from skid steer to show A B


block placement and jacking locations only. It is
not necessary to remove tires during raising
and blocking of the skid steer.

1. Remove all attachments and weights from skid


steer.
2. Park skid steer on flat level surface, lower boom to KV18786
the at-rest ground position, engage park brake,
and turn engine off. 5. Wooden blocks should be installed under right and
left sides of frame at (A and B). Skid steer must be
evenly supported by wooden blocks and wheels

c CAUTION
should not contact ground.

Avoid possible injury! Skid steer is heavy! The


approximate weight of skid steer is 3693 kg c CAUTION
(8140 lb). Use proper lifting device to raise skid
steer. To prevent personal injury, do not use floor
stands to support skid steer. Floor stands may
slip out from under skid steer while raising skid
steer.

6. Lower skid steer onto wooden blocks.


7. Repeat procedure for rear of skid steer.

COVER PLATE REMOVAL/


INSTALLATION
Reason:
To allow for easier access to some skid steer
components.
KV18068

Removal:
NOTE: Skid steer shown with boom in raised position. 1. Park skid steer safely.
If access to engine compartment is needed or 2. Raise boom and engage boom locks.
if ROPS will be raised, raise boom to top of
travel and lower onto boom locks. For all other 3. Raise ROPS and ensure ROPS is safely in the
repairs, lower boom to bottom of travel. locked position. (See RAISING ROPS
[ROLLOVER PROTECTION STRUCTURE].)

3. Place a suitable floor jack under front of skid steer Toe Guard
in line with front axle, centering jack between tires Cap Screw
on flat spot of frame. (2 Used)
4. Jack up front end until tires are approximately
51 mm (2 in.) from the ground.

KV18096

4. Remove cap screw on both sides of toe guard


shield and remove toe guard.

10 - 6 11/22/00
MISCELLANEOUS REPAIR

Center Kick Plate Cap Screw


(6 Used)
Pivot
Pin

Retaining
Pin
Boot Plate

KV18097 KV18052

5. Remove six cap screws securing center kick plate 8. Remove retaining pins and pivot pins.
to cover plate and skid steer frame. Remove center 9. To remove boot plates, remove control lever
kick plate. handles. (See CONTROL LEVER HANDLE
DISASSEMBLY/ASSEMBLY in the STEERING
section.)
Cap Screw
(2 Used) 10. Make repairs to components as necessary.
Side Plate
Installation:
1. Installation is the reverse of removal.

USING REMOTE START BOX

KV18098
Reason:
6. Remove two cap screws securing side plate to To allow the engine to be started with the ROPS raised
cover plate and skid steer frame. Remove side and in the locked position.
plate. Repeat procedure for opposite side.

Procedure:
1. Park skid steer safely.

c CAUTION
Boot Plates

Avoid possible injury from moving tires when


using remote start box. Keep tire area clear of
bystanders. Do NOT use remote start box
without raising and blocking skid steer. Skid
Cover Plate steer may override brake and move quickly.

2. Raise and block skid steer. (See RAISING AND


KV18099 BLOCKING SKID STEER.)
7. Lift boot plates out of cover plate. Pivot cover plate 3. Raise boom and engage boom locks.
forward and lift out. 4. Set park brake switch to OFF position.
5. Turn engine OFF.
6. Raise ROPS and ensure ROPS is safely in the
locked position. (See RAISING ROPS
[ROLLOVER PROTECTION STRUCTURE].)

11/22/00 10 - 7
REPAIR MISCELLANEOUS

9. Connect JT0KV12444 Remote Start Box to


electrical connector inside right frame.
M10 x 30 Cap Screw

c CAUTION
Prevent personal injury! DO NOT operate boom
and bucket functions when using remote start
box. Boom and bucket hydraulics are enabled
when engine is running and park brake switch is
disengaged by the remote start box.

10. Use remote start box ignition to start and shut off
engine with ROPS raised and in the locked
KV18038 position.
11. Use the remote start box park brake switch to
7. Install an M10 x 30 cap screw in tab at the rear of engage or disengage park brake.
both yokes to secure steering assembly during
adjustment.
IMPORTANT: Remove cap screws securing
steering assembly. Lowering ROPS with cap
screws in position may damage yoke
assemblies.

12. Remove start box and cap screws securing


steering assembly.
13. Lower ROPS. (See RAISING ROPS [ROLLOVER
PROTECTION STRUCTURE].)

ROPS REMOVAL/INSTALLATION
Removal:
1. Park skid steer on flat level surface. Lower boom to
the at-rest ground position, engage park brake
switch and turn engine off.
KV15239
KV15239 2. Disconnect negative (–) battery cable.

8. Lock auxiliary hydraulic control handle in the neutral Wire Connector Rear Light Bracket
position.

Remote Start Box Park Brake Switch

Ignition
Right Tail Light
Rear Work Light
Left Tail Light
Electrical
Connector
KV18030

3. Push rear tail and work lights to left and pull from
rear light bracket.
4. Disconnect rear tail and work light wire connectors.
Tag or label connectors to aid during installation.
5. Remove cap screws and remove rear light bracket.

KV18004

10 - 8 11/22/00
MISCELLANEOUS REPAIR

11. Install a suitable lifting strap and hoist on ROPS as


Bulkhead
Connectors
shown.

c CAUTION
Make sure ROPS is supported properly with
suitable lifting strap and hoist before
proceeding.
Rear Light
Connectors
KV18031 12. Raise hoist and lifting strap to remove weight from
6. Remove tie bands securing bulkhead connectors. ROPS cylinders.
7. Disconnect ROPS-to-engine bulkhead connectors. 13. Remove retaining pins and pivot pins to disconnect
left and right ROPS cylinders from skid steer
frame.
Washer
(2 used) Pivot Bushings
Cap Screw

Bulkhead
Connectors

Lock Nut
(2 used)
KV15169

8. Remove lock nut and flat washer. Repeat this step


for opposite side of ROPS. Rear Light
Connectors

KV18033

14. Pull bulkhead connectors and rear light connectors


JT01748 out of upper skid steer frame.
Lifting
15. Remove cap screw and nut from both sides of
Eyelet
ROPS.
16. Remove ROPS. Make repairs as necessary.
17. Inspect ROPS pivot bushings for wear or damage.
Remove only if replacement is necessary.

ROPS
ROPS
Cylinder
Cylinder

Pivot Pin

KV18032

9. Raise ROPS and ensure that it is safely in the


locked position. (See RAISING ROPS
[ROLLOVER PROTECTION STRUCTURE].)
10. Install JT01748 Lifting Eyelets in ROPS.

11/22/00 10 - 9
REPAIR MISCELLANEOUS

Installation: BOOM
Pivot Bushings
Cap Screw LOWER BOOM LINK REMOVAL/
Bulkhead
INSTALLATION
Connectors
Removal:
1. Park skid steer on flat level surface. Lower boom to
the at-rest ground position, engage park brake
switch and turn engine off.
2. Turn key switch ON and operate all hydraulic
controls to relieve system pressure. Turn key
Rear Light switch OFF.
Connectors

KV18033

1. Install ROPS and tighten cap screws to 105 N•m


(77 lb-ft).
2. Install right and left ROPS cylinders. Make sure
ROPS is in the locked position.
3. Remove lifting strap, hoist, and JT01748 Lifting
Eyelets.

Washer
(2 Used)

KV31005

3. Loosen lower link rear pin through-bolt and nut.


Loosen nut to end of bolt. DO NOT remove at this
Lock Nut time.
(2 Used)
KV15169

4. Lower ROPS into position. Install left and right flat


washers and nuts. Tighten lock nuts to 105 N•m
(77 lb-ft).
5. Push bulkhead connectors and rear light
connectors through upper skid steer frame.
6. Connect ROPS-to-engine bulkhead connectors.
Secure with tie bands as required.
7. Install rear tail and work light mounting bracket.
8. Connect wire connectors and install rear tail and
work lights.
9. Connect negative (–) battery cable.

10 - 10 11/22/00
MISCELLANEOUS REPAIR

5. Block rear of boom on side being serviced.

NOTE: Rear engine compartment door must be


removed to provide clearance to remove bolt
from left side.

6. Remove through-bolt and nut. Remove pivot pin.

IMPORTANT: Clean fittings before disconnecting


to prevent contamination of hydraulic system.

IMPORTANT: Plug or cap all openings to prevent


contamination of hydraulic system.

KV31001

Hydraulic
Pivot Pin Hoses

KV31003

KV31006
7. Disconnect both hydraulic hoses from lines under
boom. Tag hoses for ease of installation.
IMPORTANT: Use a non-metallic hammer to
prevent damaging lower link.
Hose
Retainers
4. Strike the lower link with a 5.2 kg (11.5 lb) non-
metallic deadblow hammer to loosen taper of pivot
pin.

KV31004

8. Remove hose retainers from lower link and boom.


Pull hydraulic hoses forward through loops and
place out of the way.
9. Remove wiring harness (eight button or 12-volt) if
KV31002 equipped.
10. Remove lower link rear pivot pin.
11. Raise ROPS. (See RAISING ROPS [ROLLOVER
PROTECTION STRUCTURE] in this section.)

11/22/00 10 - 11
REPAIR MISCELLANEOUS

Front Pivot Pin

KV31002

3. Securely block both sides of the rear of the boom.


12. Remove cap screw and lock nut retaining lower link
4. Install a suitable lifting strap and hoist to upper link.
front pivot pin.
13. Remove front pivot pin and remove lower link from
machine.
14. Repair or replace link and bushings as required.

Installation:
1. Coat front pivot pin with Never–Seez compound. Upper Cap
Put link in place in machine and install front pivot Screws
pin. Secure pin with cap screw and nut. Tighten to
73 N•m (54 lb-ft).
2. Lower and secure ROPS. (See RAISING ROPS
[ROLLOVER PROTECTION STRUCTURE] in this
section.) Lower Cap
3. Coat taper of new pivot pin with Never–Seez Screws and Nuts KV31007
compound. Install pivot pin through lower link and
into boom.
5. Loosen both lower pivot-pin cap screws and nuts.
4. Install pivot pin cap screw and nut. Tighten to
Do not remove nuts. Loosen nuts to the end of the
275 N•m (200 lb-ft.)
cap screw.
5. Route hydraulic hoses through loops on link and
connect to hydraulic lines under boom. Install hose
Cap Screw
retainers.
6. Install wiring harness (eight button or 12-volt) if
equipped.
7. Remove blocking and lubricate pivot points.

UPPER BOOM LINK REMOVAL/


INSTALLATION

Removal:
1. Park skid steer on flat level surface. Lower boom to
the at-rest ground position, engage park brake
KV31008
switch and turn engine off.
2. Turn key switch ON and move all hydraulic controls NOTE: Left Side Shown
to remove system pressure. Turn key switch OFF.
6. Loosen both upper pivot-pin cap screws
approximately six turns.

10 - 12 11/22/00
MISCELLANEOUS REPAIR

QUIK-TATCH® HITCH COUPLING


REMOVAL/INSTALLATION

Removal:
1. Remove any attachments. (See QUIK-TATCH
REMOVAL/INSTALLATION in this section.)
2. Park skid steer on flat level surface.

KV31007

7. Using a 5.2 kg (11.5 lb) non-metallic deadblow


hammer, strike in directions shown to loosen upper
pivot pins.
8. Repeat process on lower pins.
9. Remove cap screws and nuts. Remove upper link
from machine.
QUIK-TATCH
Hitch Coupling
Installation:
KV31124
1. Lift into place using a suitable strap and hoist.
2. Coat tapered portion of upper pins with Never–Seez 3. Roll QUIK-TATCH® hitch coupling full forward and
compound and install. Tighten cap screws to 275 lower boom to within 1/4 in. of blocking as shown.
N•m (200 lb-ft). 4. Engage park brake switch and turn engine off.
3. Coat tapered portion of lower pins with Never–Seez
compound and install. Tighten cap screws and
nuts to 275 N•m (200 lb-ft). Plug
4. Remove blocking. Lubricate bushings.

KV31125

5. Remove plugs from both sides.

11/22/00 10 - 13
REPAIR MISCELLANEOUS

Pivot Pin

Shoulder

KV31139

8. Insert the driver through the boom pivot boss until it


contacts the shoulder of the pivot pin.

KV31126

6. Loosen and remove cap screws and nuts at boom/


hitch coupling pivot points.

Remove KV31127
Threads
9. Strike the driver sharply to loosen the taper and
remove the pivot pin

19.6 mm

KV31138

7. Remove the threads from a 19.6 mm bolt, to


fabricate a driver as shown.

10 - 14 11/22/00
MISCELLANEOUS REPAIR

NOTE: It may be necessary to rotate pivot pins (B) to


remove spring pins (A).
Cap Screw
and Nut
3. Remove two spring pins (A) and pivot pins (B) using
a punch and hammer from side of implement
mounting frame being serviced.

Boom Cylinder
Pivot Pins

KV31128

10. Remove cap screw and nut from each bucket


cylinder pivot pin. Remove pivot pins from end of
cylinders and remove hitch coupling from boom.
KV15162
11. If required, remove components from hitch
coupling. (See QUIK-TATCH REMOVAL/ 4. Remove QUIK-TATCH assembly from implement
INSTALLATION in this section.) frame.
5. Inspect parts for wear or damage. Replace or repair
as necessary.
Installation: 6. Repeat this procedure for opposite side if
1. Place hitch coupling on blocking. necessary.
2. Install tapered pins in each side. Install and tighten Installation:
cap screws and nuts to 350 N•m (225 lb-ft).
3. Position cylinders and install pivot pins through 1. Apply Moly High Temperature EP Grease to all
cylinders and into hitch coupling. Secure with cap moving parts on QUIK-TATCH before installation.
screws and nuts. Tighten to 80 N•m (60 lb-ft).
4. Lubricate all pivot points. Roll hitch coupling fully
back and fully forward to verify operation. Install
attachments.

QUIK-TATCH® REPAIR
Removal:
1. Remove any attachments from skid steer.
2. Lower boom to the at-rest ground position and turn
engine off.

B A

KV15163

NOTE: Left rear of implement frame shown.

A IMPORTANT: During installation of QUIK-TATCH


assembly into implement frame, make sure the
KV15161 end of pin (A) is located in upper corner of
weldment frame as shown above.

11/22/00 10 - 15
REPAIR MISCELLANEOUS

2. Install QUIK-TATCH assembly into implement frame 2. Park skid steer on flat level surface. Lower boom
with end of pin (A) located in upper corner of and block the front near the at-rest ground position.
weldment frame as shown above. Engage park brake switch and turn engine off.

c CAUTION
B

To help prevent injury from escaping hydraulic


oil under pressure, relieve the pressure in the
system before removing hydraulic lines.

3. Turn key switch ON and move all hydraulic controls


to remove system pressure. Turn key switch OFF.

A KV15161 Upper Link


Lower Pivot Pin
NOTE: It may be necessary to use a C-clamp to align
pins.
Cylinder Upper Pivot Pin
3. Install pivot pins (B) and spring pins (A) using a
punch and hammer.
4. Engage and disengage QUIK-TATCH assembly to
ensure free movement without binding.
Lower Link Rear Pivot Pin

BOOM REMOVAL/INSTALLATION

NOTE: If boom is to be replaced, remove QUIK-TACH KV31002


hitch coupling (see QUIK-TACH HITCH
COUPLING REMOVAL/INSTALLATION in this 4. Securely block both sides of the rear of the boom.
section) and bucket cylinders (see BUCKET
CYLINDER REMOVAL in HYDRAULICS
section) prior to removing boom. Hydraulic Hoses
Hose Retainer
Removal:
1. Remove any attachments.
.

Blocking

KV31003

(Left Side Shown; Right Side Similar)

5. Disconnect bucket and auxiliary hydraulic hoses


from boom lines (both sides). Remove hose
retainers.
6. Remove wiring harness (eight button or 12-volt) if
KV31128 equipped.

NOTE: Plug or cap all open hydraulic fittings to prevent


contamination of the system.

10 - 16 11/22/00
MISCELLANEOUS REPAIR

7. Remove lower link rear pivot pins. (See LOWER


BOOM LINK REMOVAL/INSTALLATION in this
section.)
8. Remove upper link lower pivot pins. (See UPPER
BOOM LINK REMOVAL/INSTALLATION in this
section.)
Screws
Cap Screw

Upper Pivot Pin

KV31044

KV14329 NOTE: Boom is raised for the sake of clarity.


9. Remove lock nut and cap screw on top cylinder 2. Remove two screws holding air inlet cover on left
pivot pin. Remove pin. side of heater housing and remove cover.
10. Attach suitable lifting straps to each side of the 3. Replace filter.
boom. Using a suitable hoist, lift boom from
machine. 4. Install air inlet cover.

Installation: HEATER CORE REMOVAL/


1. Hoist boom into place on machine. INSTALLATION
2. Install upper link lower pins. (See UPPER BOOM
LINK REMOVAL/INSTALLATION in this section.)
Removal:
3. Install lower link rear pins. (See LOWER BOOM
LINK REMOVAL/INSTALLATION in this section.) 1. Park skid steer on flat level surface. Lower boom to
4. Install cylinder upper pivot pin, cap screw, and lock the at-rest ground position, engage park brake
nut. Tighten cap screw and lock nut to 73 N•m (54 switch and turn engine off.
lb-ft).
5. Connect hydraulic hoses. Install hose retainers on
boom.
6. Install wiring harness (eight button or 12-volt) if
equipped.
7. Start machine and operate hydraulics to check
operation. Check for leaks. Heater
Cover

CAB HEATER/DEFROSTER
(OPTIONAL)
KV31045
FILTER REPLACEMENT
1. Park skid steer on flat level surface. Lower boom to 2. Remove heater cover. Disconnect lights.
the at-rest ground position, engage park brake
switch and turn engine off.

11/22/00 10 - 17
REPAIR MISCELLANEOUS

Remove Screws

TS281

c CAUTION KV18856

5. Remove four screws retaining heater core. Remove


Explosive release of fluids from pressurized core.
cooling system can cause serious burns. Shut
off engine. Remove filler cap only when cool
enough to touch with bare hands. Slowly loosen Installation:
cap to first stop to relieve pressure before
removing cap completely.

Foam Seals

Remove Hoses

Vent Valve

KV18861

1. Inspect foam seals and replace if necessary.


2. Install heater core using four screws.
3. Connect hoses and close vent valve.
KV18857
NOTE: Be careful not to over-tighten hose clamps or
3. Drain approximately 2 L (0.53 gal) coolant from vent valve.
radiator. Loosen vent valve on heater core outlet
tube to aid draining.
4. Add approximately 2 L (0.53 gal) coolant to radiator.
4. Remove hoses from heater core and control valve. Install radiator cap.
5. Remove air from system (see CAB HEATER
DEAERATION in this section.)
6. Run engine with heater control at maximum heat to
verify operation.
7. Check for coolant leaks.
8. Install heater cover.

10 - 18 11/22/00
MISCELLANEOUS REPAIR

BLOWER REMOVAL/INSTALLATION
Remove Cap Screws

Removal:
1. Park skid steer on flat level surface. Lower boom to
the at-rest ground position, engage park brake
switch and turn engine off.

Heater KV18860
Cover
5. Remove four cap screws retaining blower to main
housing.
6. Lift blower from housing.
KV31045
Installation:
2. Remove heater cover.
1. Place blower in housing.
2. Loosely install four cap screws to retain blower in
housing.
Disconnect Wires

Install Screws

KV18858
KV18859

3. Disconnect wires from speed controller and ground. 3. Install and tighten three screws retaining blower
Tag wires for ease of installation. from bottom of housing.
4. Tighten cap screws.

Remove Screws

KV18859

4. Remove three screws retaining blower to housing


bottom.

11/22/00 10 - 19
REPAIR MISCELLANEOUS

Connect Wires

TS281

KV18858
c CAUTION
5. Connect wires to speed controller and ground. Explosive release of fluids from pressurized
6. Install heater cover. cooling system can cause serious burns. Shut
off engine. Remove filler cap only when cool
enough to touch with bare hands. Slowly loosen
CONTROL VALVE REMOVAL/ cap to first stop to relieve pressure before
INSTALLATION removing cap completely.

Removal:
1. Park skid steer on flat level surface. Lower boom to Remove Hoses
the at-rest ground position, engage park brake
switch and turn engine off. Vent Valve Cap Screw

Connector
Cap Screw

Heater
Cover

KV18857

KV31045 3. Drain approximately 2 L (0.53 gal) coolant from


radiator. Loosen vent valve on heater core outlet
tube to aid draining.
2. Remove heater cover.
4. Disconnect wiring connector from valve.
5. Remove hoses from control valve
6. Remove two cap screws, nuts and washers.
7. Remove valve.

Installation:
1. Install valve. Tighten cap screws and nuts securely.

NOTE: Be careful not to over-tighten hose clamps or


vent valve.

10 - 20 11/22/00
MISCELLANEOUS REPAIR

2. Install hoses and close vent valve.


3. Install wiring connector.
4. Add approximately 2 L (0.53 gal) coolant to radiator.
Install radiator cap.
5. Remove air from system. (See CAB HEATER
DEAERATION in this section.) Fabricated Hose
6. Run engine with heater control set to maximum
heat to verify operation.
7. Check for coolant leaks.
8. Install heater cover.

CAB HEATER DEAERATION

NOTE: Cooling system must be cool to the touch.

1. Park skid steer on flat level surface. Lower boom to


the at-rest ground position, engage park brake
switch and turn engine off.

KV31043

4. Fabricate a hose that will connect a regulated shop


air supply to the coolant recovery bottle overflow.
Connect and clamp hose securely.
Heater
Cover
IMPORTANT: Cooling system is designed for a
maximum pressure of 96—110 kPa (14—16 psi).
Exceeding this pressure could result in
component damage or personal injury.
KV31045

5. Verify that radiator cap is secured in its normal


2. Remove heater cover to gain access to vent valve. running position.
3. Fill cooling system with the recommended coolant. 6. Adjust air pressure to a maximum of 69 kPa
Fill coolant recovery bottle to within 25 mm (1 in.) (10 psi).
of the top. Tighten cover securely. 7. Turn key switch ON and adjust cab heat control to
maximum heat.
8. Apply regulated pressure to cooling system.

11/22/00 10 - 21
REPAIR MISCELLANEOUS

Vent Valve

Upper Cap Screws

KV18857 KV18867

9. Open vent valve, located near the heater control


valve, until coolant flows from vent valve. Close
vent valve. Lower Nuts
10. Disconnect air and remove adapter.
11. Fill coolant recovery bottle to correct level.
12. Turn cab heat control to coldest setting and turn key
switch OFF.
13. Start and run engine until engine is at normal
operating temperature. Operate Cab Heater at
various settings to verify operation.

CAB DOOR (IF EQUIPPED)

Removal:
KV18868
1. Park skid steer on flat level surface. Lower boom to
the at-rest ground position, engage park brake 6. Loosen upper cap screws and lower nuts that retain
switch and turn engine off. left door roller brackets to door.

NOTE: This operation requires two people


c CAUTION
2. One person enter skid steer. DO NOT close door.
3. Remove gas springs from ball studs on door Door weighs 21 kg (47 lb). Two people are
handles. required for door removal.
4. Close door.
5. Unlock auxiliary hydraulic handle and place in 7. Open door halfway. With second person assisting
detent position. from outside cab, slide left roller brackets inward to
disengage rollers from track. Move door to the left
to disengage right rollers from door track. Lower
(Drop) right side of door and remove door from
cab.

Installation:
1. One person enter skid steer.
2. With second person assisting from outside cab, tilt
the door so the right side is lower. Slide door into
cab.
3. Insert top-right roller into door track.

10 - 22 11/22/00
MISCELLANEOUS REPAIR

4. Insert bottom-right roller into door track.


5. Adjust left roller brackets outward to insert top and
bottom rollers into door track.
6. Adjust left rollers to provide maximum engagement
without binding. Tighten upper cap screws and
lower nuts.
7. Attach both gas springs to ball studs on door.
8. Open and close door several times to check
operation. Adjust as necessary.
9. Tighten cap screws and nuts completely.
10. Return auxiliary hydraulic handle to normal position
and lock. Washer Hose
11. Test for proper operation of door safety interlock
switch. Hydraulic lock and park brake should
engage when door is open. Adjust as necessary. Arm Retaining Nut
KV31100

WINDSHIELD WIPER/WASHER 2. Remove cap covering wiper arm retaining nut.


(OPTIONAL) Remove nut.
3. Disconnect washer hose. Remove wiper arm from
motor shaft.
WIPER MOTOR

Removal:

Thumb Nut

Small Nut

Harness Connector Large Nut


KV31101

4. Remove thumb nut and O-ring.

KV31099
Cup Large Nut
Seal
1. Disconnect wiring harness from motor.

KV31103

5. Remove large nut, cup and seal from motor shaft.


6. Hold motor and remove small nut and flat washer.
Remove motor from machine.

Installation:
1. Place motor in machine. Install small nut and flat
washer.
2. Install seal, cup and large nut on motor shaft.

11/22/00 10 - 23
REPAIR MISCELLANEOUS

WASHER PUMP
O-Ring
Removal:
1. Disconnect wiring harness and hose from pump.

KV31102

3. Install thumb nut and O-ring. DO NOT overtighten.

Screws KV31104

2. Remove screws holding fluid container to bracket.

Tapered Spline

KV31101B

NOTE: Wiper arm orientation is controlled by a


tapered spline. Be sure arm is in correct
orientation while installing nut.
Grommet
KV31105
4. Install wiper arm and nut. Tighten nut to 10.4 N•m
(92 lb-in.).
3. Carefully pry pump from grommet.
5. Connect washer hose.
6. Connect wiring harness to motor.
7. Run wiper to verify operation. Installation:
1. Push pump nipple into grommet on washer
container until seated.
2. Install washer container on bracket.
3. Connect wiring harness and washer hose.
4. Verify washer operation.

10 - 24 11/22/00
INDEX

A Drift Dump Position Check . . . . . . . . . . . . . . . 9-20


Drift Rollback Position Check . . . . . . . . . . . . . 9-20
Air Filter Restriction Switch
Lift Check Test . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-140
Lockout Solenoid Check . . . . . . . . . . . . . . . . . 9-15
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-127
Lockout Solenoid Test . . . . . . . . . . . . . . . . . 4-139
Air Inlet Pipe, Inspection . . . . . . . . . . . . . . . . . . . 3-104
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129 C
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136 Cab Door Replacement . . . . . . . . . . . . . . . . . . . 10-22
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . 3-102 Cab Door Switch Test . . . . . . . . . . . . . . . . . . . . . 4-133
Disassembly and Testing . . . . . . . . . . . . . . . 3-133
Exploded View . . . . . . . . . . . . . . . . . . . . . . . 3-131 Cab Heater/Defroster
Identification . . . . . . . . . . . . . . . . . . . . . . . . . 3-133 Blower Replacement . . . . . . . . . . . . . . . . . . 10-19
Regulated Amperage/Voltage Test . . . . . . . 4-123 Blower Switch Test . . . . . . . . . . . . . . . . . . . . 4-134
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-148 Circuit Operation . . . . . . . . . . . . . . . . . . . . . . 4-104
Control Valve Replacement . . . . . . . . . . . . . 10-20
Axle Deaeration . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Disassembly/Assembly . . . . . . . . . . . . . . . . . . 5-10 Filter Replacement . . . . . . . . . . . . . . . . . . . . 10-17
Housing Removal/Installation . . . . . . . . . . . . . . 5-9 Heater Core Replacement . . . . . . . . . . . . . . 10-17
Thermostat Replacement . . . . . . . . . . . . . . . 4-144
B
Cam Follower Bore, Measure . . . . . . . . . . . . . . . . 3-61
Backup Alarm
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-111 Camshaft
Circuit Schematic . . . . . . . . . . . . . . . . . . . . . 4-112 Bore, Measure . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-150 Bushing Installation . . . . . . . . . . . . . . . . . . . . 3-62
Switch Replacement . . . . . . . . . . . . . . . . . . . 4-150 Bushing Removal . . . . . . . . . . . . . . . . . . . . . . 3-62
Cam Follower, Measure . . . . . . . . . . . . . . . . . 3-86
Backup Alarm Circuit . . . . . . . . . . . . . . . . . . . . . 4-111
Gear Replacement . . . . . . . . . . . . . . . . . . . . . 3-85
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-121 Journal OD, Measure . . . . . . . . . . . . . . . . . . . 3-85
Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-122 Lobe Height, Measure . . . . . . . . . . . . . . . . . . 3-85
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-120 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
Belt Tension, Fan/Alternator . . . . . . . . . . . . . . . . 3-102 Tachometer Pick-Up Pin Removal . . . . . . . . . 3-86
Blocking Skid Steer . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Centering Plate
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Blower Switch Test . . . . . . . . . . . . . . . . . . . . . . . 4-134
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . 7-18, 7-19
Bucket Cylinder Replace . . . . . . . . . . . . . . . . 9-44
Cylinder Component Location . . . . . . . . . . . . 9-12 Centering Plate Adjustment . . . . . . . . . . . . . . . . . 7-12
Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . 9-46 Centering, Steering Control Levers . . . . . . . . . . . . 7-14
Cylinder Replace . . . . . . . . . . . . . . . . . . . . . . 9-43 Chain
Drift Down Check . . . . . . . . . . . . . . . . . . . . . . 9-19 Drive Chain Tension Adjustment . . . . . . . . . . . 5-9
Drift Up Check . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Chain Case
Lift Check Test . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Lock Removal/Installation . . . . . . . . . . . . . . . . 10-5
Oil Specifications . . . . . . . . . . . . . . . . . . . . . . 2-14
Lockout Solenoid Check . . . . . . . . . . . . . . . . . 9-15
Lockout Solenoid Test . . . . . . . . . . . . . . . . . 4-138 Charging Battery . . . . . . . . . . . . . . . . . . . . . . . . . 4-121
Lower Link Removal/Installation . . . . . . . . . . 10-10 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Operation Check . . . . . . . . . . . . . . . . . . . . . . . 9-15
Circuit Relief Valve Test . . . . . . . . . . . . . . . . . . . . 9-19
QUIK-TATCH® Hitch Coupling
Removal/Installation . . . . . . . . . . . . . . . . . 10-13 Cold Weather Start Switch
QUIK-TATCH® Repair . . . . . . . . . . . . . . . . . 10-15 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-140
Removal/Installation . . . . . . . . . . . . . . . . . . . 10-16 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-128
Upper Link Removal/Installation . . . . . . . . . . 10-12 Compression Test, Cylinder . . . . . . . . . . . . . . . . . 3-25
Boom and Bucket Lockout Circuit . . . . . . . . . . . . . 4-49 Connecting Rods
Brakes - See Park Brake Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Bearing Clearance . . . . . . . . . . . . . . . . . . . . . 3-66
Break-In Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Bearing Inspection . . . . . . . . . . . . . . . . . . . . . 3-65
Bucket Bushing ID . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Cylinder Component Location . . . . . . . . . . . . 9-12 Bushing Replacement . . . . . . . . . . . . . . . . . . 3-67
Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . 9-46 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Cylinder Replace . . . . . . . . . . . . . . . . . . . . . . 9-44 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

11/22/00 INDEX - 1
INDEX

Control Lever O-Ring Installation . . . . . . . . . . . . . . . . . . . . . 3-65


Auxiliary Handle Adjust . . . . . . . . . . . . . . . . . . 7-17 Packing Installation . . . . . . . . . . . . . . . . . . . . . 3-65
Hydraulic Handle Adjust Protrusion, Measure . . . . . . . . . . . . . . . . . . . . 3-64
Hands Only . . . . . . . . . . . . . . . . . . . . . . . 7-17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Stops Adjustment, Tracking . . . . . . . . . . . . . . 7-16
Control Valve Component Location . . . . . . . . . . . 9-10 D
Diagnosis
Coolant
Chain Case and Axles . . . . . . . . . . . . . . . . . . . 5-6
Drain Interval . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 3-119
Temperature Sender/Switch
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Replacement . . . . . . . . . . . . . . . . . . . . . 4-140
Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-127
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Cooling System, Deaeration . . . . . . . . . . . . . . . . 3-102
Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Cover Plate Removal/Installation . . . . . . . . . . . . . 10-6
Diesel Fuel
Crankshaft Lubricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Bearing Cap Replacement . . . . . . . . . . . . . . . 3-63 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Bearing Inserts Installation . . . . . . . . . . . . . . . 3-83 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Bore, Measure . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Drive Chain
End Play, Measuring . . . . . . . . . . . . . . . . . . . 3-79
Sprocket Removal/Installation . . . . . . . . . . . . 5-12
Front Oil Seal Installation . . . . . . . . . . . . . . . . 3-92
Tension Adjustment . . . . . . . . . . . . . . . . . . . . . 5-9
Gear Replacement . . . . . . . . . . . . . . . . . . . . . 3-82
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80 Dual Flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-98
Install 2-Piece Thrust Bearing . . . . . . . . . . . . 3-83 Dual Flasher Switch Test . . . . . . . . . . . . . . . . . . 4-133
Install 6-Piece Thrust Bearing . . . . . . . . . . . . 3-83
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83 E
Journal Diameter, Measure . . . . . . . . . . . . . . 3-80 Electrical
Main Bearing Clearance, Determine . . . . . . . 3-81 Air Filter Restriction Switch Replacement . . 4-140
Micro-Finishing Specifications . . . . . . . . . . . . 3-82 Alternator Replacement . . . . . . . . . . . . . . . . 4-148
Pulley Backup Alarm Circuit . . . . . . . . . . . . . . . . . . 4-111
Installation . . . . . . . . . . . . . . . . . . . . . . . . 3-75 Backup Alarm Circuit Schematic . . . . . . . . . 4-112
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75 Backup Alarm Replacement . . . . . . . . . . . . . 4-150
Rear Oil Seal, Removal . . . . . . . . . . . . . . . . . 3-77 Backup Alarm Switch Replacement . . . . . . . 4-150
Regrinding . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81 Battery Charging . . . . . . . . . . . . . . . . . . . . . . 4-121
Regrinding Guidelines . . . . . . . . . . . . . . . . . . 3-81 Boom and Bucket Lockout Circuit . . . . . . . . . 4-49
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80 Boom and Bucket Lockout Circuit Schematic . 4-50
Cross Shaft Cab Heater Thermostat Replacement . . . . . 4-144
Detent Adjustment . . . . . . . . . . . . . . . . . . . . . 7-15 Cab Heater/Defroster Circuit Operation . . . . 4-104
Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Cab Heater/Defroster Circuit Schematic . . . 4-105
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 Charging Circuit Operation . . . . . . . . . . . . . . . 4-44
Cylinder Block Charging Circuit Schematic . . . . . . . . . . . . . . 4-45
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 Cold Weather Start Switch Replacement . . . 4-140
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . 3-58 Common Circuit Tests . . . . . . . . . . . . . . . . . . . 4-8
Top Desk Flatness . . . . . . . . . . . . . . . . . . . . . 3-63 Component Legend . . . . . . . . . . . . . . . . . . . . . 4-9
Component Location . . . . . . . . . . . . . . . . . . . 4-11
Cylinder Compression Test . . . . . . . . . . . . . . . . . . 3-25 Component Replacement . . . . . . . . . . . . . . . 4-140
Cylinder Head Coolant Temperature Sender/Switch
Check Valve Recess . . . . . . . . . . . . . . . . . . . 3-51 Replacement . . . . . . . . . . . . . . . . . . . . . . 4-140
Checking Flatness . . . . . . . . . . . . . . . . . . . . . 3-49 Diagnosis
Clean, Inspect Valve Seats . . . . . . . . . . . . . . 3-50 Air Filter Restriction Warning Light
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54 Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
Measure Valve Guide . . . . . . . . . . . . . . . . . . . 3-50 Backup Alarm Circuit . . . . . . . . . . . . . . . 4-113
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 Boom/Bucket Lockout
Remove Valve Seat Inserts . . . . . . . . . . . . . . 3-51 and Park Brake Circuit . . . . . . . . . . . . . 4-51
Torque Turn Tightening Method . . . . . . . . . . . 3-55 Cab Heater/Defroster Circuit . . . . . . . . . 4-106
Cylinder Liners Charging Circuit . . . . . . . . . . . . . . . . . . . . 4-46
Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 Coolant Temperature Gauge Circuit . . . . 4-77
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65 Dual Flasher Circuit . . . . . . . . . . . . . . . . 4-100
Measure Bore . . . . . . . . . . . . . . . . . . . . . . . . . 3-60 Engine Oil Pressure Guage Circuit . . . . . 4-82

INDEX - 2 11/22/00
INDEX

Electrical;Diagnosis (Cont.) Starting Motor


Engine Oil Pressure Replacement . . . . . . . . . . . . . . . . . . . . . 4-147
Warning Light Circuit . . . . . . . . . . . . . . 4-80 Solenoid Test . . . . . . . . . . . . . . . . . . . . . 4-126
Engine Overtemperature Switched Power Circuit . . . . . . . . . . . . . . . . . . 4-29
Warning Light Circuit . . . . . . . . . . . . . . 4-75 Tests and Adjustments . . . . . . . . . . . . . . . . . 4-120
Fuel Circuit . . . . . . . . . . . . . . . . . . . . . . . . 4-38 Air Filter Restriction Switch . . . . . . . . . . 4-127
Fuel Gauge Circuit . . . . . . . . . . . . . . . . . . 4-72 Backup Alarm Switch Adjust . . . . . . . . . 4-151
High Flow Circuit . . . . . . . . . . . . . . . . . . . 4-87 Battery Testing and Charging . . . . . . . . 4-120
High-Flow Circuit . . . . . . . . . . . . . . . . . . . 4-87 Blower Switch . . . . . . . . . . . . . . . . . . . . . 4-134
Hydraulic Filter Restriction Boom Lockout Solenoid . . . . . . . . . . . . . 4-138
Warning Light Circuit . . . . . . . . . . . . . . 4-70 Bucket Lockout Solenoid . . . . . . . . . . . . 4-139
Hydraulic Oil Overtemperature Cab Door Switch . . . . . . . . . . . . . . . . . . 4-133
Warning Light Circuit . . . . . . . . . . . . . . 4-68 Cold Weather Start Switch . . . . . . . . . . . 4-128
Lights Circuit . . . . . . . . . . . . . . . . . . . . . . 4-93 Coolant Temperature Sender . . . . . . . . . 4-127
Park Brake Switch Coolant Temperature Switch . . . . . . . . . 4-127
Warning Light Circuit . . . . . . . . . . . . . . 4-63 Dual Flasher Switch . . . . . . . . . . . . . . . . 4-133
Power and Cranking Circuit . . . . . . . . . . . 4-32 Fuel Level Sender . . . . . . . . . . . . . . . . . 4-135
Preheat Circuit . . . . . . . . . . . . . . . . . . . . . 4-41 High-Flow Switch . . . . . . . . . . . . . . . . . . 4-134
Seat Belt Warning Light Circuit . . . . . . . . 4-60 Hydraulic Oil Filter Restriction Switch . . 4-139
Wiper/Washer Circuit . . . . . . . . . . . . . . . 4-117 Hydraulic Oil Overtemperature Switch . . 4-137
Dual Flasher Key Switch . . . . . . . . . . . . . . . . . . . . . . . 4-131
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-98 Manifold Preheater . . . . . . . . . . . . . . . . . 4-129
Circuit Schematic . . . . . . . . . . . . . . . . . . . 4-99 Oil Pressure Switch/Sender, Engine . . . 4-129
Engine Oil Pressure Switch/Sender Park Brake Solenoid . . . . . . . . . . . . . . . 4-138
Replacement . . . . . . . . . . . . . . . . . . . . . . 4-141 Park Brake Switch . . . . . . . . . . . . . . . . . 4-131
Fuel and Preheat Preheater Relay . . . . . . . . . . . . . . . . . . . 4-130
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 Preheater Switch . . . . . . . . . . . . . . . . . . 4-132
Circuit Schematic . . . . . . . . . . . . . . . . . . . 4-37 Regulated Amperage and Voltage Test . 4-123
Fuel Level Sender Replacement . . . . . . . . . 4-145 Running Lights Switch . . . . . . . . . . . . . . 4-132
Gauges and Warning Lights Seat Belt Switch . . . . . . . . . . . . . . . . . . . 4-137
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56 Seat Switch . . . . . . . . . . . . . . . . . . . . . . 4-136
Circuit Schematic . . . . . . . . . . . . . . . . . . . 4-59 Starter Load Draw . . . . . . . . . . . . . . . . . 4-124
High-Flow Wiper/Washer Switch . . . . . . . . . . . . . . . 4-135
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85 Unswitched Power Circuits . . . . . . . . . . . . . . . 4-29
Circuit Schematic . . . . . . . . . . . . . . . . . . . 4-86 Wiper/Washer
Hydraulic Oil Filter Restriction Switch Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-115
Replacement . . . . . . . . . . . . . . . . . . . . . . 4-149 Circuit Schematic . . . . . . . . . . . . . . . . . . 4-116
Hydraulic Oil Temperature Switch Wire Color Abbreviation Chart . . . . . . . . . . . . . 4-8
Replacement . . . . . . . . . . . . . . . . . . . . . . 4-148 Wire Harness Diagram
Instrument Panel Backup Alarm . . . . . . . . . . . . . . . . . . . . . . 4-26
Component Location . . . . . . . . . . . . . . . 4-143 Cab Heater/Defroster . . . . . . . . . . . . . . . . 4-25
Instrument Cluster Replacement . . . . . . 4-145 Cold Start . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Key Switch Replacement . . . . . . . . . . . . 4-143 Dual Flasher . . . . . . . . . . . . . . . . . . . . . . . 4-23
Switch Replacement . . . . . . . . . . . . . . . 4-144 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Lights ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91 Wiper/Washer . . . . . . . . . . . . . . . . . . . . . 4-27
Circuit Schematic . . . . . . . . . . . . . . . . . . . 4-92
Electrical Component Legend . . . . . . . . . . . . . . . . . 4-9
Main Schematic . . . . . . . . . . . . . . . . . . . . . . . 4-13
Manifold Preheat Relay Replacement . . . . . 4-142 Engine
Manifold Preheater Replacement . . . . . . . . . 4-141 Assembly Sequence . . . . . . . . . . . . . . . . . . . . 3-45
Park Brake Blow-By, Measure . . . . . . . . . . . . . . . . . . . . . 3-24
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49 Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115
Circuit Schematic . . . . . . . . . . . . . . . . . . . 4-50 Complete Final Assembly . . . . . . . . . . . . . . . . 3-74
Solenoid Replacement . . . . . . . . . . . . . . 4-149 Disassembly Sequence . . . . . . . . . . . . . . . . . 3-45
Power and Cranking Circuit . . . . . . . . . . . . . . 4-29 Final Work . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Schematic . . . . . . . . . . . . . . . . . . . . . . . . 4-31 General Tune-Up Recommendations . . . . . . . 3-23
Schematics, Reading . . . . . . . . . . . . . . . . . . . . 4-7 Oil Pressure, Checking . . . . . . . . . . . . . . . . . . 3-24
Seat Belt Switch Replacement . . . . . . . . . . . 4-147 Oil Specifications . . . . . . . . . . . . . . . . . . . . . . 2-12
Seat Safety Switch Replacement . . . . . . . . . 4-146 Oil, Break-In . . . . . . . . . . . . . . . . . . . . . . . . . 3-115
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Preliminary Testing . . . . . . . . . . . . . . . . . . . . . 3-23
Removal/Installation . . . . . . . . . . . . . . . . . . . . 3-33

11/22/00 INDEX - 3
INDEX

Engine (Cont.) G
Speed Adjustment . . . . . . . . . . . . . . . . . . . . 3-115
Grease Specifications . . . . . . . . . . . . . . . . . . . . . . 2-15
Tests and Adjustments . . . . . . . . . . . . . . . . . . 3-23
Engine Oil Pressure Switch/Sender Test . . . . . . 4-129 H
Exhaust Manifold, Inspection . . . . . . . . . . . . . . . 3-105 High-Flow
Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . 4-85
F Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-134
Face Seal Hydraulic
Fittings with Inch Stud Ends Torque . . . . . . . . . 2-8 Auxiliary Control Handle Adjustment . . . . . . . 7-17
Fittings with Metric Stud Ends Torque . . . . . . . 2-9 Boom and Bucket Cylinder Repair . . . . . . . . . 9-46
Fan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103 Boom and Bucket Lockout Solenoids Check . 9-15
Boom Cylinder
Fan/Alternator Belt Tension . . . . . . . . . . . . . . . . 3-102
Component Location . . . . . . . . . . . . . . . . 9-12
Flywheel Replace . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
Ball Bearing Installation . . . . . . . . . . . . . . . . . 3-76 Boom Drift Down Check . . . . . . . . . . . . . . . . . 9-19
Housing, Replacement . . . . . . . . . . . . . . . . . . 3-79 Boom Drift Up Check . . . . . . . . . . . . . . . . . . . 9-20
Hydrostatic Drive Coupling . . . . . . . . . . . . . . . 3-38 Boom Lift Check Test . . . . . . . . . . . . . . . . . . . 9-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76 Boom Lockout Solenoid Check . . . . . . . . . . . 9-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75 Bucket Cylinder
Ring Gear Replacement . . . . . . . . . . . . . . . . . 3-76 Component Location . . . . . . . . . . . . . . . . 9-12
Four-Way Flasher . . . . . . . . . . . . . . . . . . . . . . . . . 4-98 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
Front Plate Bucket Drift Dump Position Check . . . . . . . . . 9-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89 Bucket Drift Rollback Position Check . . . . . . . 9-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86 Bucket Lift Check Test . . . . . . . . . . . . . . . . . . 9-21
Bucket Lockout Solenoid Check . . . . . . . . . . . 9-15
Fuel and Preheat Circuit . . . . . . . . . . . . . . . . . . . . 4-36 Bucket Self-Leveling Adjustment . . . . . . . . . . 9-21
Fuel Filter, Replace Element . . . . . . . . . . . . . . . . 3-107 Charge Pump Pressure Test . . . . . . . . . . . . . 9-16
Fuel Injection Nozzle Circuit Relief Valve Test . . . . . . . . . . . . . . . . . 9-19
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113 Component Location . . . . . . . . . . . . . . . . . . . . 9-9
Chatter Test . . . . . . . . . . . . . . . . . . . . . . . . . 3-112 Control Handle Adjustment
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111 Hands Only . . . . . . . . . . . . . . . . . . . . . . . 7-17
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-113 Control Valve
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
Opening Pressure Test . . . . . . . . . . . . . . . . . 3-112 Component Location . . . . . . . . . . . . . . . . 9-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111 Cross Section . . . . . . . . . . . . . . . . . . . . . . 9-36
Running Test . . . . . . . . . . . . . . . . . . . . . . . . 3-120 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 9-29
Spray Pattern Test . . . . . . . . . . . . . . . . . . . . 3-112 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112 Installation . . . . . . . . . . . . . . . . . . . . . . . . 9-41
Valve Seat Checking . . . . . . . . . . . . . . . . . . 3-113 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Valve Stem/Guide Wear Checking . . . . . . . . 3-112 Fitting Information . . . . . . . . . . . . . . . . . . . . . . . 2-8
High-Flow Pump
Fuel Injection Pump Remove/Inspect/Install . . . . . . . . . . . . . . . 9-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110
High-Flow Valve Replace . . . . . . . . . . . . . . . . 9-27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
Hydraulic/Charge Pump
Timing Adjustment . . . . . . . . . . . . . . . . . . . . . 3-27
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . 3-101
Component Location . . . . . . . . . . . . . . . . 9-11
Fuel Level Sender Disassembly . . . . . . . . . . . . . . . . . . . . . . . 9-22
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-145 Flow Test . . . . . . . . . . . . . . . . . . . . 6-11, 9-18
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-135 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Fuel Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Measure Supply Pressure . . . . . . . . . . . . . . . 3-26 Pressure Test . . . . . . . . . . . . . . . . . . . . . . 6-10
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 3-108 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Fuel System Oil Filter Restriction Switch
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114 Replacement . . . . . . . . . . . . . . . . . . . . . 4-149
Cold Start Advance System . . . . . . . . . . . . . 3-118 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-139
Fuel Injection Nozzles, General Information . 3-119 Oil Overtemperature Switch
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . 3-117 Replacement . . . . . . . . . . . . . . . . . . . . . 4-148
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-137
Self-Leveling Valve - Replace . . . . . . . . . . . . 9-43
System Component Location . . . . . . . . . . . . . . 9-8

INDEX - 4 11/22/00
INDEX

Hydraulic (Cont.) M
System Components and Operation . . . . . . . . 9-5
Manifold Preheat Relay Replacement . . . . . . . . 4-142
System Relief Valve Pressure Test . . . . . . . . 9-15
System Schematic . . . . . . . . . . . . . . . . . . . . . . 9-7 Metric Fastener Torque Values . . . . . . . . . . . . . . . . 2-5
Hydrostatic Drive Coupling, Install . . . . . . . . . . . . 3-38 N
Hydrostatic Motor Nozzle Bores, Injection, Cleaning . . . . . . . . . . . . . 3-48
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 O
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Removal/Installation . . . . . . . . . . . . . . . . . . . . 6-37 Oil Bypass Valve Replacement . . . . . . . . . . . . . . . 3-94
Oil Cooler
Hydrostatic Power Train
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
Component Location . . . . . . . . . . . . . . . . . . . . 6-6
Nipple Replacement . . . . . . . . . . . . . . . . . . . . 3-93
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . 6-20
System Operation . . . . . . . . . . . . . . . . . . . . . . . 6-5 Oil Deflector Installation . . . . . . . . . . . . . . . . . . . . 3-91
Test and Adjustments . . . . . . . . . . . . . . . . . . . 6-10 Oil Dipstick Guide Adapter Replacement . . . . . . . 3-94
Troubleshooting and Diagnosis . . . . . . . . 6-8, 6-9
Oil Pan Installation . . . . . . . . . . . . . . . . . . . . . . . . 3-97
Hydrostatic Pump
Oil Pressure Regulating Valve
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
Case Drain Pressure Test . . . . . . . . . . . . . . . 6-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
Case Drain Test . . . . . . . . . . . . . . . . . . . . . . . 6-17
Valve Seat Replacement . . . . . . . . . . . . . . . . 3-93
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Exploded View Oil Pressure Switch/Sender
Center Manifold . . . . . . . . . . . . . . . 6-24, 6-25 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 4-141
Front Pump . . . . . . . . . . . . . . . . . . . . . . . 6-23 Oil Pressure, Engine, Checking . . . . . . . . . . . . . . 3-24
Rear Pump . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Oil Pump
Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Gear Axial Clearance . . . . . . . . . . . . . . . . . . . 3-95
High Pressure Relief Test . . . . . . . . . . . . . . . . 6-12 Gear Radial Clearance . . . . . . . . . . . . . . . . . . 3-95
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3-95
Hydrostatic Transmission and Hydraulic Oil . . . . . 2-13 Strainer Replacement . . . . . . . . . . . . . . . . . . . 3-94
O-Ring Face Seal Fittings
I Service Recommendations . . . . . . . . . . . . . . . . 2-10
Idler Gear
Bushing and Shaft, Measure . . . . . . . . . . . . . 3-87 P
Bushing Replacement . . . . . . . . . . . . . . . . . . 3-88 Park Brake
End Play, Measure . . . . . . . . . . . . . . . . . . . . . 3-86 Actuator Cylinder
Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . 3-89 Removal/Installation . . . . . . . . . . . . . . . . . 8-12
Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-88 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Spring Pin Installation . . . . . . . . . . . . . . . . . . . 3-88 Burnish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Ignition Switch Test . . . . . . . . . . . . . . . . . . . . . . . 4-131 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Inch Fastener Torque Values . . . . . . . . . . . . . . . . . 2-7 Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Injection Nozzle Bores, Cleaning . . . . . . . . . . . . . 3-48 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Instrument Cluster Replacement . . . . . . . . . . . . 4-145 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Instrument Panel Component Location . . . . . . . . 4-143 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Solenoid Replacement . . . . . . . . . . . . . . . . . 4-149
K Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . 4-138
Key Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . 4-131 Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-131
Theory of Operation . . . . . . . . . . . . . . . . . . . . . 8-4
L Park Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Legend, Electrical Components . . . . . . . . . . . . . . . 4-9 Piston
Levers, Steering - See Steering Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . 3-68
Light Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . 4-132 Cooling Jets, Checking . . . . . . . . . . . . . . . . . . 3-61
Lights Circuit Operation . . . . . . . . . . . . . . . . . . . . 4-91 Head and Skirt Checking . . . . . . . . . . . . . . . . 3-69
Lock, Boom Removal/Installation . . . . . . . . . . . . . 10-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

11/22/00 INDEX - 5
INDEX

Piston (Cont.) Sprocket, Drive Chain, Removal/Installation . . . . . 5-12


Pin Bore, Measure . . . . . . . . . . . . . . . . . . . . . 3-68 Start Box, Remote, Using . . . . . . . . . . . . . . . . . . . 10-7
Pin, OD Measure . . . . . . . . . . . . . . . . . . . . . . 3-68
Piston Rings Staggering . . . . . . . . . . . . . . . . . 3-70 Starting Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
Piston/Liner Set Information . . . . . . . . . . . . . . 3-70 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128
Protrusion, Measure . . . . . . . . . . . . . . . . . . . . 3-73 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59 Exploded View . . . . . . . . . . . . . . . . . . . . . . . 3-123
Ring Installation . . . . . . . . . . . . . . . . . . . . . . . 3-69 Loaded Amperage Draw Test . . . . . . . . . . . . 4-124
Second and Third Ring Grooves . . . . . . . . . . 3-69 No-Load Amperage/RPM Tests . . . . . . . . . . 4-125
Top Ring Groove . . . . . . . . . . . . . . . . . . . . . . 3-68 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-147
Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . 4-126
Plate, Cover, Removal/Installation . . . . . . . . . . . . 10-6 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3-124
Power Train Steering
Component Location . . . . . . . . . . . . . . . . . . . . 5-3 Auxiliary Control Adjustment . . . . . . . . . . . . . 7-17
Component Operation . . . . . . . . . . . . . . . . . . . 5-4 Centering Plate Inspection . . . . . . . . . . . . . . . 7-20
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Centering Plate Installation
Preheater Single Plate Models . . . . . . . . . . . . . . . . . 7-21
Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-130 Centering Plate Removal
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-141 Dual Plate Models . . . . . . . . . . . . . . . . . . 7-19
Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-132 Single Plate Models . . . . . . . . . . . . . . . . . 7-18
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-129 Component Location . . . . . . . . . . . . . . . . 7-5, 7-6
Control Lever
Q Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 7-14
QUIK-TATCH® - See Boom Handle Repair . . . . . . . . . . . . . . . . . . . . . 7-26
Removal/Installation . . . . . . . . . . . . . . . . . 7-23
R Tracking - Stops Adjustment . . . . . . . . . . 7-16
Radiator, Remove, Inspect, Install . . . . . . . . . . . . 3-41 Cross Shaft
Detent Adjustment . . . . . . . . . . . . . . . . . . 7-15
Raising and Blocking Skid Steer . . . . . . . . . . . . . . 10-6 Removal/Installation . . . . . . . . . . . . . . . . . 7-24
Remote Start Box, Using . . . . . . . . . . . . . . . . . . . 10-7 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Rocker Arm Cover, Installing . . . . . . . . . . . . . . . . 3-57 Dampener Inspection . . . . . . . . . . . . . . . . . . . 7-22
Dampener Removal/Installation . . . . . . . . . . . 7-22
Rocker Arm Shaft, Inspect . . . . . . . . . . . . . . . . . . 3-56
Hydraulic Control Adjustment
ROPS (Roll Over Protection Structure) Hands Only . . . . . . . . . . . . . . . . . . . . . . . 7-17
Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Tests and Adjustment . . . . . . . . . . . . . . . . . . . . 7-9
Removal/Installation . . . . . . . . . . . . . . . . . . . . 10-8 Theory of Operation . . . . . . . . . . . . . . . . . . . . . 7-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 7-7
S
Schematics - See Component in Electrical T
Sealant, Application Guidelines, Engine . . . . . . . . 3-18 Tachometer, Using Stanadyne "Time-Trac" . . . . 3-116
Seat Belt Switch Thermostat
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-147 Inspect and Test . . . . . . . . . . . . . . . . . . . . . . . 3-23
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-137 Remove/Install . . . . . . . . . . . . . . . . . . . . . . . 3-101
Seat Safety Switch Test . . . . . . . . . . . . . . . . . . . 4-136 Timing Gear
Backlash, Measure . . . . . . . . . . . . . . . . . . . . . 3-84
Seat Switch Replacement . . . . . . . . . . . . . . . . . . 4-146
Cover, Installation . . . . . . . . . . . . . . . . . . . . . . 3-91
Self-Leveling Adjustment . . . . . . . . . . . . . . . . . . . 9-21 Lower, Installation . . . . . . . . . . . . . . . . . . . . . . 3-91
Serial Number Location . . . . . . . . . . . . . . . . . . . . 2-17 Upper, Installation . . . . . . . . . . . . . . . . . . . . . . 3-90
Skid Steer, Raising and Blocking . . . . . . . . . . . . . 10-6 Torque Values
Face Seal Fittings with Inch Stud Ends . . . . . . 2-8
Specifications
Face Seal Fittings with Metric Stud Ends . . . . . 2-9
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Inch Fastener . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Metric Fastener . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Troubleshooting
Hydrostatic Power Train . . . . . . . . . . . . . . . . . . 6-3 Chain Case and Axles . . . . . . . . . . . . . . . . . . . 5-5
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Hydrostatic Power Train . . . . . . . . . . . . . . 6-8, 6-9

INDEX - 6 11/22/00
INDEX

Troubleshooting (Cont.)
Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Turbocharger
Axial Bearing End Play . . . . . . . . . . . . . . . . . 3-106
Boost Pressure, Checking . . . . . . . . . . . . . . 3-117
Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116
Pre-Lubrication . . . . . . . . . . . . . . . . . . . . . . . 3-106
Radial Bearing Clearance . . . . . . . . . . . . . . . 3-105
Recommendations . . . . . . . . . . . . . . . . . . . . 3-107
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106

V
Valve
Assembly, Actuating Parts . . . . . . . . . . . . . . . 3-49
Checking Recess . . . . . . . . . . . . . . . . . . . . . . 3-51
Clearance, Adjusting . . . . . . . . . . . . . . . . . . . 3-31
Grind Face Angle . . . . . . . . . . . . . . . . . . . . . . 3-53
Guides
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Measuring . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Inspect and Measure . . . . . . . . . . . . . . . . . . . 3-52
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Lift, Checking . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Rocker Arm, Valve Clearance Adjustment . . . 3-31
Rotators, Inspect . . . . . . . . . . . . . . . . . . . . . . 3-53
Seats
Clean and Inspect . . . . . . . . . . . . . . . . . . 3-50
Installing Inserts . . . . . . . . . . . . . . . . . . . . 3-52
Lapping . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Machining . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
Removing Inserts . . . . . . . . . . . . . . . . . . . 3-51
Springs
Inspect and Measure . . . . . . . . . . . . . . . . 3-53
Removing . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

W
Water Pump
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . 3-98
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-101
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
Wear Ring, Installation . . . . . . . . . . . . . . . . . . . . . 3-92
Wheel Speed Test . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Windshield Wiper/Washer
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-115
Circuit Schematic . . . . . . . . . . . . . . . . . . . . . 4-116
Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-135
Washer Pump Replacement . . . . . . . . . . . . . 10-24
Wiper Motor Replacement . . . . . . . . . . . . . . 10-23

11/22/00 INDEX - 7
INDEX

This page intentionally left blank.

INDEX - 8 11/22/00

You might also like