John Deere 240 & 250 Skid Steer Technical Manual TM1747 - PDF DOWNLOAD by www.heydownloads.com

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 Skid Steer

TM1747 (Nov2000)

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 program.

Safety 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 • Troubleshooting Diagram • Diagnostics • Tests & Adjustments • Repair

Note:

Depending on the particular section or system being covered, not all of the above groups may be used.

Engine (Diesel) Electrical Power Train (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 consecutively numbered.

Steering 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 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.

Hydraulics

Miscellaneous

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 CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.

REPLACE SAFETY SIGNS

When you work around fuel, do not smoke or work near heaters or other fire hazards. Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. 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 SERVICING BATTERIES

USE CARE AROUND HIGHPRESSURE 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. • Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. • Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

Prevent Acid Burns • Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid injury from escaping fluid under pressure by stopping the engine and relieving pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

• Avoid acid burns by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Using proper jump start procedure. • If you spill acid on yourself:

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A., (1-800-822-8262 U.S.A. or 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 Fluid Lines

Service Machines Safely

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.

USE SAFE SERVICE PROCEDURES Wear Protective Clothing

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

Use Proper Tools Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards. Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping 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 impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

1-4

M55689

Before working on the machine: 1. Lower all equipment to the ground. 2. Relieve hydraulic pressure. 3. Stop the engine and remove the key. 4. Disconnect the battery ground strap. 5. Hang a “DO NOT OPERATE” tag in operator station.

11/22/00

SAFETY

Support Machine Properly and Use Proper Lifting Equipment

Work In Ventilated Area

If you must work on a lifted machine or attachment, securely support the machine or attachment.

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust duct system.

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.

If you do not have an exhaust duct system, open the doors and get outside air into the area.

Lifting heavy components incorrectly can cause severe injury or machine damage. Follow recommended procedure for removal and installation of components in the manual.

Work In Clean Area Before starting a job: 1. Clean work area and machine. 2. Make sure you have all necessary tools to do your job. 3. Have the right parts on hand. 4. Read all instructions thoroughly; do not attempt shortcuts.

Using High Pressure Washers Directing pressurized water at electronic/electrical components or connectors, bearings, hydraulic seals, 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.

WARNING: California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well-ventilated area. Dispose of paint and solvent properly. Remove paint before welding or heating. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

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 proper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel.

Shut off machine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

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 SAFELY

LIVE WITH SAFETY

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 details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

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

CONTENTS

SPECIFICATIONS AND INFORMATION

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

METRIC FASTENER TORQUE VALUES

SPECIFICATIONS AND INFORMATION

METRIC FASTENER TORQUE VALUES 4.8

9.8

10.9

4.8

8.8

9.8

10.9

12.9

4.8

8.8

9.8

10.9

12.9

5 5

12.9 12

Property Class and Nut Markings

12.9

8.8

Property Class and Head Markings

TS1163

Class 4.8

Class 8.8 or 9.8

Lubricateda

Drya

SIZE

N•m

lb-ft

N•m

4.8

3.5

M10

Class 10.9

Lubricateda

Drya

lb-ft

N•m

lb-ft

N•m

4.5

6.5

8.5

M12

M14

M16

100

M18

Class 12.9

Lubricateda

Drya

Lubricateda

Drya

lb-ft

N•m

lb-ft

N•m

lb-ft

N•m

lb-ft

N•m

lb-ft

8.5

9.5

11.5

14.5

110

140

105

130

165

120

150

110

175

130

225

165

205

150

260

109

125

190

140

240

175

275

200

350

225

320

240

400

300

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 Iron Torque

Aluminum Torque

N•m

lb-ft

N•m

lb-ft

M10

M12

M14

138

102

111

M16

224

165

179

132

Size

2-6

11/22/00

INCH FASTENER TORQUE VALUES

SPECIFICATIONS AND INFORMATION

INCH FASTENER TORQUE VALUES 5.1

1 or 2b

SAE Grade and Head Markings

5.2

8.2

No Marks

2 SAE Grade and Nut Markings

No Marks TS1162

Grade 2b

Grade 1 Lubricateda

Drya

SIZE

N•m

lb-ft

N•m

1/4

3.7

2.8

5/16

7.7

3/8

Grade 5, 5.1 or 5.2

Grade 8 or 8.2

Lubricateda

Drya

Lubricateda

Drya

Lubricateda

Drya

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

4.7

3.5

4.5

7.5

5.5

9.5

13.5

12.5

5.5

7/16

100

1/2

110

120

150

115

9/16

125

155

115

175

130

225

160

5/8

105

135

100

170

125

215

160

215

160

300

225

3/4

120

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

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 Metric Tube OD

Inch Tube OD

Face Seal Tube/Hose End Thread Size

Tube Nut/ Swivel Nut Torque

Bulkhead Lock Nut Torque

N•m

Dash Size

in.

-3

0.188

4.76

-4

0.250

6.35

-5

0.312

7.94

-6

0.375

9.52

11/16-16

-8

0.500

12.70

13/16-16

-10

0.625

15.88

1-14

-12

0.750

19.05

1-3/16-12

-14

0.875

22.22

-16

1.000

-20

-24

in.

O-Ring Stud Ends

N•m

lb-ft

3/8-24

7/16-20

1/2-20

9/16-18

3/4-16

7/8-14

102

1-1/16-12

102

1-3/16-12

102

1-3/16-12

122

25.40

1-7/16-12

142

105

142

105

1-5/16-12

142

105

1.25

31.75

1-11/16-12

190

140

190

140

1-5/8-12

190

140

1.50

38.10

2-12

217

160

217

160

1-7/8-12

217

160

lb-ft

Straight Fitting or Lock Nut Torque

in.

9/16-18

lb-ft

Thread Size

NOTE: Torque tolerance is plus 15 minus 20%.

2-8

11/22/00

O-RING SEAL SERVICE RECOMMENDATIONS

SPECIFICATIONS AND INFORMATION

FACE SEAL FITTINGS WITH METRIC STUD ENDS TORQUE Stud End

Tube Nut

Groove For Metric Identification Stud Straight and Tube Nut

Swivel 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

Nominal Tube OD/Hose ID Metric Tube OD

Inch Tube OD

O-Ring Stud Ends, Straight Fitting or Lock Nut

Face Seal Tube/Hose End

Thread Size

Dash Size

in.

-4

0.250

6.35

9/16-18

-5

0.312

7.94

Hex Size

Tube Nut/ Bulkhead Swivel Lock Nut Nut Torque Torque

mm N•m lb-ft N•m lb-ft 17

Thread Size

Steel or Hex Aluminum Gray Iron Size Torque Torque

mm N•m lb-ft N•m lb-ft

M12X1.5

15.5

6.6

M14X1.5

-6

0.375

9.52

11/16-16

M16X1.5

-8

0.500 12.70

13/16-16

M18X1.5

-10

0.625 15.88

1-14

M22X1.5

-12

0.750 19.05 1-3/16-12

102

M27X2

102

-14

0.875 22.22 1-3/16-12

102

M30X2

-16

1.000 25.40 1-7/16-12

142 105 142 105

M33X2

158

116

M38X2

176

130

28 32

-20

1.25

31.75 1-11/16-12

190 140 190 140

M42X2

190

140

-24

1.50

38.10

217 160 217 160

M48X2

217

160

2-12

NOTE: Torque tolerance is plus 15 minus 20%.

11/22/00

2-9

O-RING SEAL SERVICE RECOMMENDATIONS

O-RING FACE SEAL FITTINGS

SPECIFICATIONS AND INFORMATION

Sealing Surface

Special Nut

Angle Fitting

Special Washer

O-Ring Sealing Surface

1. Inspect the fitting sealing surfaces. They must be free of dirt or defects. 2. Inspect the O-ring. It must be free of damage or defects. 3. Lubricate O-rings and install into groove using petroleum jelly to hold in place. 4. Push O-ring into the groove with plenty of petroleum jelly so O-ring is not displaced during assembly. 5. Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place. 6. Tighten fitting or nut to torque value shown on the chart per dash size stamped on the fitting. Do not allow hoses to twist when tightening fittings.

O-RING BOSS FITTINGS 1. Inspect boss O-ring boss seat. It must be free of dirt and defects. If repeated leaks occur, inspect for defects with a magnifying glass. Some raised defects can be removed with a slip stone. Groove

O-Ring

2. Put hydraulic oil or petroleum jelly on the O-ring. Place electrical tape over the threads to protect Oring from nicks. Slide O-ring over the tape and into the groove of fitting. Remove tape.

2 - 10

3. For angle fittings, loosen special nut and push special washer against threads so O-ring can be installed into the groove of fitting. 4. Turn fitting into the boss by hand until special washer or washer face (straight fitting) contacts boss face and O-ring is squeezed into its seat. 5. To position angle fittings, turn the fitting counterclockwise a maximum of one turn. 6. Tighten straight fittings to torque value shown on chart. For angle fittings, tighten the special nut to value shown in the chart while holding body of fitting with a wrench. STRAIGHT FITTING OR SPECIAL NUT TORQUE

Thread Size

Torquea

Number of Flatsb

N•m

lb-ft

3/8-24 UNF

(6)

7/16-20 UNF

(9)

1/2-20 UNF

(12)

9/16-18 UNF

(18)

3/4-16 UNF

(34)

7/8-14 UNF

(46)

1-1/2

1-1/16-12 UN

102

(75)

1-3/16-12 UN

122

(90)

1-5/16-12 UN

142

(105)

3/4

1-5/8-12 UN

190

(140)

3/4

1-7/8-12 UN

217

(160)

1/2

a. Torque tolerance is ± 10%. b. To be used if a torque wrench cannot be used. After tightening fitting by hand, put a mark on nut or boss; then tighten special nut or straight fitting the number of flats shown.

11/22/00

SPECIFICATIONS AND INFORMATION

DIESEL FUEL SPECIFICATIONS

STORAGE

In general, diesel fuels are blended to satisfy the low air temperature requirements of the geographical area in which they are sold.

IMPORTANT: DO NOT USE GALVANIZED CONTAINERS—diesel fuel stored in galvanized containers reacts with zinc coating in the container to form zinc flakes. If fuel contains water, a zinc gel will also form. The gel and flakes will quickly plug fuel filters and damage fuel injectors and injection pumps.

• Use Grade No. 2-D fuel at temperatures above 4°C (40°F). • For maximum filter life, sediment and water should not be more than 0.10%. • The cetane number should be 45 minimum. If you operate your machine where air temperatures are normally low or in high altitudes, you may need fuel with a higher cetane number. • Cloud Point - For cold weather operation, cloud point should be 6°C (10°F) below lowest normal air temperature. • In winter use special winter fuel or add an antigelling compound to fuel to maintain its proper viscosity. If diesel fuel being used has a sulfur content greater than 0.5%, reduce the service interval for engine oil and filter by 50%. Bio-Diesel Fuels with bio-degradable properties that meet specification DIN 51606 or equivalent may be used. Consult your local diesel fuel distributor for properties of the diesel fuel available in your area.

It is recommended that diesel fuel be stored ONLY in a clean, approved POLYETHYLENE PLASTIC container WITHOUT any metal screen or filter. This will help prevent any accidental sparks from occurring. Store fuel in an area that is well ventilated to prevent possible igniting of fumes by an open flame or spark, this includes any appliance with a pilot light. IMPORTANT: Keep all dirt, scale, water or other foreign material out of fuel. Keep fuel in a safe, protected area and in a clean, properly marked (“DIESEL FUEL”) container. DO NOT use de-icers to attempt to remove water from fuel. DO NOT depend on fuel filters to remove water from fuel. It is recommended that a water separator be installed in the storage tank outlet. BE SURE to properly discard unstable or contaminated diesel fuel and/or their 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

• John Deere TORQ-GARD SUPREME or John Deere PLUS-50

SAE 30

SAE10W-30

The following oil is preferred AFTER first 100 hours of break-in oil is used:

SAE 5W-30

Use the appropriate oil viscosity based on the expected air temperature range during the period between recommended oil changes. Operating outside of these recommended oil air temperature ranges may cause premature engine failure.

SAE 15W-40

4-CYCLE DIESEL ENGINE OIL— NORTH AMERICA

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

ENGINE OIL SPECIFICATIONS

SPECIFICATIONS AND INFORMATION

BREAK-IN DIESEL ENGINE OIL— NORTH AMERICA IMPORTANT: ONLY use this specified break-in oil in rebuilt or remanufactured engines for the first 100 hours (maximum) of operation. DO NOT use PLUS-50®, SAE 15W40 oil or oils meeting specifications API CG-4 or API CF-4, these oils will not allow rebuilt or remanufactured engines to break in properly. The following John Deere oil is PREFERRED: • BREAK-IN ENGINE OIL. John Deere BREAK-IN ENGINE OIL is formulated with special additives for aluminum and cast iron type engines to allow the power cylinder components (pistons, rings, and liners as well) to “wear in” while 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.

HYDROSTATIC TRANSMISSION AND HYDRAULIC OIL—NORTH AMERICA Use the following oil viscosity based on the air temperature range. Operating outside of the recommended oil air temperature range may cause premature hydrostatic transmission or hydraulic system failures. IMPORTANT: DO NOT use BIO-HY-GARD® in this system. The following PREFERRED:

John

Deere

engine

oils

are

• John Deere HY-GARD®. • John Deere low viscosity HY-GARD® (cold weather operation only).

• API Service Classification CE or higher. IMPORTANT: After the break-in period, use the John Deere oil that is recommended for this engine.

BREAK-IN OIL

AIR TEMPERATURE

11/22/00

LOW VIS JD HY-GARD

If this preferred John Deere oil is not available, use a break-in engine oil meeting the following specification during the first 100 hours of operation:

JD HY-GARD

John Deere BREAK-IN ENGINE OIL is also recommended for non-John Deere engines, both aluminum and cast iron types.

M58275

2 - 13

CHAIN CASE OIL SPECIFICATIONS

SPECIFICATIONS AND INFORMATION

CHAIN CASE OIL SPECIFICATIONS

The following John Deere oils are PREFERRED:

SAE 30 SAE 5W-30

SAE 5W-30

IMPORTANT: DO NOT use BIO-HY-GARD® in this chain case.

SAE 10W-40

Use the following oil viscosity based on the air temperature range. Operating outside of the recommended oil air temperature range may cause premature chain case failure.

SAE 15W-40

CHAIN CASE OIL—NORTH AMERICA

• 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 oils are not available, provided they meet the following specification:

AIR TEMPERATURE M58275

LOW VIS JD HY-GARD

JD HY-GARD

• API Service Classification SG or higher.

AIR TEMPERATURE

2 - 14

M58275

11/22/00

GENERAL APPLICATION GREASE SPECIFICATIONS

SPECIFICATIONS AND INFORMATION

GENERAL APPLICATION GREASE SPECIFICATIONS

DIESEL AND GASOLINE ENGINE COOLANT—NORTH AMERICA

GREASE—NORTH AMERICA Use the following grease based on the air temperature range. Operating outside of the recommended grease air temperature range may cause premature failures. IMPORTANT: ONLY use a quality grease in this application. DO NOT mix any other greases in this application. DO NOT use any BIO-GREASE in this application. The following John Deere greases are PREFERRED: • John Deere MOLY HIGH TEMPERATURE EP GREASE • John Deere HIGH TEMPERATURE EP GREASE (Non-Clay) Other greases may be used if they meet one of the following: • SAE Multipurpose EP Grease with a maximum of 5% molybdenum disulfide • SAE Multipurpose EP Grease Greases meeting Military Specification MIL-G-10924F may be used as arctic grease.

The engine cooling system, when filled with a proper dilution mixture of anti-freeze and deionized or distilled water, provides year-round protection against corrosion, cylinder or liner pitting, and winter freeze protection down to –37°C (–34°F). The following John Deere coolants are PREFERRED: • John Deere COOL-GARD • John Deere ANTIFREEZE/SUMMER COOLANT These coolants satisfy specifications for “Automobile and Light Duty Engine Service” and are safe for use in John Deere Lawn and Grounds Care/Golf and Turf Division equipment, including aluminum block gasoline engines and cooling systems. The above preferred pre-diluted coolants provide: • adequate heat transfer • corrosion-resistant chemicals for the cooling system • compatibility with cooling system hose and seal material • protection during extreme cold and extreme hot 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: • DIESEL ENGINE ANTI-FREEZE/SUMMER COOLANT CONCENTRATE™ (TY16034).

NLGI Grade 2

JD High Temp EP

JD Moly High Temp EP

COOLANT SPECIFICATIONS

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

11/22/00

M58275

2 - 15

COOLANT SPECIFICATIONS IMPORTANT: To prevent engine damage, DO NOT use pure anti-freeze or less than a 50% antifreeze mixture in the cooling system. Water used to dilute engine coolant concentrate must be of high quality—clean, clear, potable water (low in chloride and hardness—see table below) 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 scale, sludge deposits, and increased corrosion potential.

Water Quality Property

Requirements

Total Solids, Maximum

340 ppm (20 grns/gal)

Total Hardness, Max.

170 ppm (10 grns/gal)

Chloride (as Cl), Max.

40 ppm (2.5 grns/gal)

Sulfate (as SO4), Max.

100 ppm (5.8 grns/gal)

SPECIFICATIONS AND INFORMATION

The use of non-recommended supplemental coolant additives may result in additive drop-out and gelation of the coolant. Add the manufacturer’s recommended concentration of supplemental coolant additive. DO NOT add more than the recommended amount.

DIESEL AND GASOLINE ENGINE COOLANT DRAIN INTERVAL— NORTH AMERICA When using John Deere Concentrate (TY16034) Automobile and Light Duty Engine Service coolants, drain and flush the cooling system and refill with fresh coolant mixture every 24 months or 2,000 hours of operation, whichever comes first. If above John Deere Automobile and Light Duty Engine Service coolants are not being used, drain, flush, and refill the cooling system according to instructions found on product container or in equipment operator’s manual or technical manual.

Mix 50 percent anti-freeze concentrate with 50 percent distilled or deionized water. This mixture and the prediluted 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 antifreeze 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 COOLGARD. 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

SERIAL NUMBER LOCATION

SPECIFICATIONS AND INFORMATION

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

CONTENTS

DIESEL ENGINE

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

SPECIFICATIONS

DIESEL ENGINE

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

SPECIFICATIONS

DIESEL ENGINE

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

SPECIFICATIONS

DIESEL ENGINE

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:

Model

Pump Part #

Dynamic Timing

Rated Speed (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 PART NUMBER

CONTENT

PRODUCT

EXAMPLE OF USE

TY9370

6 ml tube

LOCTITE 242 Thread Lock & Sealer Medium Strength (blue)

Cap screws: Crankshaft pulley Flywheel

TY9371

6 ml tube

LOCTITE 271 Thread Lock & Sealer High Strength (clear)

Studs: Water pump-to-cylinder block Injection pump-to-front plate Exhaust manifold-to-turbocharger Oil filter nipple

T43514

50 ml tube

LOCTITE 277 Plastic Gasket High Strength (red)

Steel cap plugs: Cylinder block, cylinder head Water pump

DD15664 or TY6304

25 ml tube 50 ml bottle

LOCTITE 515 Flexible Sealant General Purpose (purple)

Flywheel housing-to-cylinder block Front plate/Timing gear-to-oil pan

TY9374 or TY9375

6 ml tube 50 ml bottle

LOCTITE 592 Pipe Sealant with Teflon (white)

Pipe plugs: Cylinder block, water pump Dipstick tube threads Temperature sending unit

TY15969

50 ml bottle

LOCTITE 609 Retaining Compound (green)

Wear ring sleeve-to-crankshaft

3 - 18

11/22/00

TROUBLESHOOTING

DIESEL ENGINE

Intake/exhaust valve leaking Intake/exhaust valve seized

●

Piston ring, piston, or cylinder worn

●

Crankshaft pin or bearing seized

●

● ●

●

● ●

●

● ●

●

● ●

Excessive timing gear backlash Intake/exhaust valve guide worn

●

Governor not functioning properly ●

● ●

●

● ●

Engine running too hot

●

Coolant level low

●

Engine running too cool

●

● ●

●

Cracked water jacket ●

Fan belt loose Improper engine oil viscosity/ type 11/22/00

●

Connecting rod bolt loose

Improper injection timing, intake/exhaust valves

Air intake pressure rise

●

Crankshaft pin or bearing worn

Foreign matter trapped in combustion chamber

Air intake pressure drop

●

Improper piston ring placement

Low oil pressure

●

Broken or seized piston ring

Ring gaps not positioned properly

Fuel in oil

●

Cylinder head gasket leaking

Coolant in oil/oil in coolant

High oil consumption

●

High fuel consumption

●

Engine surges under load

Low engine output

●

Engine surges at idle

Engine starts but does not continue to run

Improper intake/exhaust valve clearance

Exhaust smoke black when under load

Check or Solution

Engine will not start

Problem or Symptom

Exhaust smoke white when under load

TROUBLESHOOTING

●

3 - 19

TROUBLESHOOTING

●

Engine oil leaking

●

Oil filter clogged

●

Pressure control valve worn

●

Oil quantity low

● ●

●

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

●

● ●

●

High altitude/temperature operation

●

Exhaust system restricted

●

Air filter clogged

Inspect starter motor

●

Inspect alternator

●

Electrical system troubleshooting

●

3 - 20

●

Incorrect spray pattern at fuel injection nozzle

Air intake pressure rise

●

Oil pump worn

Advanced injection pump timing

Air intake pressure drop

Low oil pressure

Fuel in oil

Coolant in oil/oil in coolant

High oil consumption

High fuel consumption

Engine surges under load

Engine surges at idle

Exhaust smoke black when under load

Exhaust smoke white when under load

Low engine output

Check or Solution

Engine will not start

Problem or Symptom

Engine starts but does not continue to run

DIESEL ENGINE

● ●

●

● ● ●

● ●

11/22/00

DIAGNOSIS

DIESEL ENGINE

DIAGNOSIS Conditions: • Machine parked on level surface. • Park brake engaged. • Key switch off unless indicated otherwise. Test/Check Point

Normal

If Not Normal

Oil level between “L” and “H” marks. Oil not burnt, or contaminated with metal particles, fuel, or coolant. No external leakage, filter clean.

Change oil and inspect for source of contamination. Check gaskets, seals, plugs, cylinder head, block and intake manifold and breather. Change oil filter.

Coolant level between marks on tank when engine is warm. Coolant in radiator full to top. Coolant not contaminated with oil, fuel, or discolored brown.

Add proper coolant mix.

Radiator screen free of debris.

Clean or replace.

Water pump not leaking.

Inspect water pump. (See WATER PUMP.)

Hoses not cracked or leaking, clamps and radiator cap tight.

Pressure test radiator and cap. (See 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 level correct, not contaminated, correct grade of fuel, no water. Fuel pump in-line filter free of debris.

Drain and clean fuel tank. Add fresh fuel. Replace filters.

Fuel hoses not cracked or leaking.

Replace.

Fuel hose clamps tight.

Replace or tighten.

Air filter hose not cracked, clamps tight.

Replace and tighten clamps.

Element not plugged. Air filter housing sealed, no dirt tracking inside filter element.

Replace element or housing.

Fuel level increases in filter. Fuel pump operating - listen for humming sound. Fuel present in return hose at fuel pump.

See FUEL PUMP POWER CIRCUIT DIAGNOSIS in ELECTRICAL section. Test fuel pump pressure. (See FUEL SUPPLY PUMP PRESSURE TEST.) Replace fuel filter.

Engine Oil Check Engine dipstick and exterior engine surface.

Cooling System Check Coolant tank and radiator.

Drain and flush system. Check for source of contamination.

Fuel System Check Fuel tank, pump, lines, filter and filter shutoff valve.

Air Intake System Check Air filter and air intake.

Fuel Pump Check Fuel filter and fuel pump. (Key switch in RUN position.)

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 correctly.

Repair, replace, or adjust cable. (See THROTTLE CONTROL ADJUSTMENT.)

Cold engine. Valve clearance within specification. Valves not sticking.

Check and adjust. (See VALVE CLEARANCE CHECK AND ADJUSTMENT.) Check valve guides and stems.

Crack fuel injection lines at injectors. Fuel shutoff solenoid pulled in.

Check spray pattern and cracking pressure. (See FUEL INJECTION NOZZLE TEST.) Replace injectors. (See CRANKING CIRCUIT DIAGNOSIS in ELECTRICAL section.)

Valve Check Intake and exhaust valves.

Fuel Injector Check Fuel at injectors. (Key in START position - engine cranking.)

Engine must crank. Cylinder Compression Check Injector ports. (Key in START position.)

Cylinder compression within specification. Pressure difference between cylinders within specification.

Perform cylinder compression test. (See CYLINDER COMPRESSION PRESSURE TEST.)

Minimum cranking rpm within specification.

See STARTER AMP DRAW TEST in ELECTRICAL section.

Timing should be correct. Remove pump as the LAST possible solution.

Perform injection pump static timing adjustment. (See INJECTION PUMP STATIC TIMING ADJUSTMENT.) Have pump tested by an EPA certified Service Repair Shop.

Engine runs smooth under load. Engine rpm to specification.

See SLOW IDLE ADJUSTMENT and FAST IDLE ADJUSTMENT.

Oil pressure in specification.

Test engine oil pressure. (See ENGINE OIL PRESSURE TEST.)

Clean from corrosion, rust, or debris. Opening temperature within specification.

Replace thermostat. Perform thermostat opening test. (See THERMOSTAT OPENING TEST.)

Not restricted.

Replace muffler.

Starter Check Flywheel and starter. Injection Pump Check Injection pump timing inspection. (Key OFF.)

Fast and Check

Slow

Idle

Injection pump idle settings. (Engine running). Oil Pressure Check Oil pressure sender port. Thermostat Check Thermostat. (Engine at operating temperature.) Muffler Check Muffler.

3 - 22

11/22/00

TESTS AND ADJUSTMENTS

DIESEL ENGINE

TESTS AND ADJUSTMENTS PRELIMINARY ENGINE TESTING

TEST THERMOSTAT OPENING TEMPERATURE

The following preliminary tests will help determine if the engine can be tuned-up to restore operating efficiency, or if engine overhaul is required.

Reason:

• After engine has stopped for several hours, loosen crankcase drain plug and watch for any water to drain out. A few drops due to condensation is normal, but more than this would indicate problems which require engine repair. • 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.

To determine opening temperature of thermostat. Equipment: • Thermometer • Glass Container • Heating Plate

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. 2. Replace fuel filter and water separator. 3. Clean crankcase vent tube. 4. Clean and flush cooling system. 5. Test thermostat and pressure cap. 6. Check condition of coolant hoses and fan belt. 7. Check air intake system. Replace air cleaner elements. 8. Check exhaust system. 9. Inspect turbocharger and check boost pressure. 10. Check fuel injection system: • Have injection pump checked by your Authorized Stanadyne workshop. • Clean injection nozzles and adjust opening pressure. • Adjust slow idle speed and perform a dynamic timing. 11. Check engine oil pressure. 12. Check engine valve clearance. 13. Check electrical system.

RG5971

Procedure: Visually inspect thermostat for corrosion or damage. Replace as necessary.

c CAUTION DO NOT allow thermostat or thermometer to rest against the side or bottom of container when heating water. Either may rupture if overheated. 1. Remove thermostat. (See REMOVE THERMOSTAT.) 2. Suspend thermostat and a thermometer in a container of water. 3. Stir the water as it heats. Observe opening action of thermostat and compare temperatures with specification given in chart below.

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 Rating

Initial Opening (Range)

Full Open (Nominal)

71°C (160°F)

69-72°C (156-162°F)

84°C (182°F)

77°C (170°F)

74-78°C (166-172°F)

89°C (192°F)

82°C (180°F)

80-84°C (175-182°F)

94°C (202°F)

89°C (192°F)

86-90°C (187-194°F)

101°C (214°F)

90°C (195°F)

89-93°C (193-200°F)

103°C (218°F)

92°C (197°F)

89-93°C (193-200°F)

100°C (213°F)

96°C (205°F)

94-97°C (201-207°F)

105°C (221°F)

99°C (210°F)

96-100°C (205-212°F)

111°C (232°F)

4. Remove thermostat and observe its closing action as it cools. In ambient air the thermostat should close completely. Closing action should be smooth and slow. 5. If thermostat is defective, replace thermostat.

CHECK ENGINE OIL PRESSURE

NOTE: Use gauge from FKM10002 or JT05470 Universal Pressure Test Kit if available. Otherwise, use gauge with a reading range of 0–600 kPa (0–87 psi) minimum. 1. Before checking oil pressure, warm up engine to allow the lubricating oil to reach operating temperature. 2. Attach pressure gauge. 3. At 93°C (200°F) operating temperature, gauge should show a minimum pressure of: • 279 kPa (40 psi) at 1000 rpm • 350 kPa (50 psi) at rated speed

MEASURE ENGINE BLOW-BY Reason: To determine the condition of piston, rings and cylinder walls. Equipment: • Standard Gas Gauge • Hose

Reason: To determine if engine bearings or lubrication system components are worn.

Procedure: 1. Place a hose with a standard gas gauge over end of crankcase vent tube. 2. Run engine at rated speed (engine at operating temperature and run-in, with at least 100 operating hours), full load. 3. Measure blow-by over a period of 5 minutes. Multiply figure obtained by 12 (hourly rate) and then compare with specifications.

Equipment: • JT03017 Hose Assembly • JT05577 Pressure Gauge (100 psi) • JT03349 Connector

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 blowby 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

TESTS AND ADJUSTMENTS

DIESEL ENGINE

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 fully charged and injection nozzle area is thoroughly cleaned. 1. Start engine and run at slow idle for 10 to 15 minutes. 2. Remove fuel injection nozzles.

CD30685

Compression pressure must be 2400 kPa (350 psi) minimum. The difference between the highest and lowest cylinder must be less than 350 kPa (50 psi). This test must be performed at a minimum cranking speed of 150 rpm.

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 temperature.

To determine supply pump operating pressure.

All indicated speeds apply to an engine not under load. The maximum permissible speed variation is ± 50 rpm for slow idle speed and ± 50 rpm for fast idle speed.

Equipment: JT03115 Gauge (0—150 psi) with Male Quick Coupler. JT01609 Female Quick Coupler Adapter.

Test Gauge Inlet A B

Outlet CD30681 KV18011

Procedure: 1. Remove plug from auxiliary outlet port on fuel filter base. 2. Install test gauge as shown. 3. Start engine. Fuel pump should maintain positive minimum pressure of 15–30 kPa (0.15–0.30 bar) (2–4.5 psi). A low pressure can be due to a clogged filter element or a defective supply pump. Replace filter element then check pressure again. If reading is still below specification, replace supply pump.

NOTE: The fuel pump is not repairable and therefore should be replaced when defective.

FAST AND SLOW IDLE ADJUSTMENT Reason: 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.

1. Disconnect speed control rod at fuel injection pump. 2. Move pump throttle lever against pump fast idle adjusting screw (A). Check engine speed and compare with specifications. Specification: 240 Fast Idle Speed . . . . . . . . . . . . . . . 2450±50 rpm 250 Fast Idle Speed . . . . . . . . . . . . . . . 2400±50 rpm

NOTE: Fast idle is set by the factory, then the fast idle adjusting screw (A) is sealed to prevent tampering. Fast idle adjustment can only be performed by an authorized EPA certified service center. 3. Move pump throttle lever in slow idle position against slow idle adjusting screw (B). Check engine speed and adjust to specifications. Specifications: 240 Slow Idle Speed. . . . . . . . . . . . . . . 1175±50 rpm 250 Slow Idle Speed. . . . . . . . . . . . . . . 1175±50 rpm 4. Turn screw (B) clockwise to increase and counterclockwise to decrease engine speed.

Equipment: JT05801 Clamp-on Electronic Tachometer.

3 - 26

11/22/00

TESTS AND ADJUSTMENTS

DIESEL ENGINE

FUEL INJECTION PUMP TIMING ADJUSTMENT

Install Timing Sensor

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).

IMPORTANT: Timing sensor must be installed at nozzle end of No. 1 fuel injection line. Sensor MUST BE installed on No.1 injection line of all 3-cylinder engines.

A H

C F

I CD30441

A. Meter B. Sensor Clamp C. 6 mm Clamp-On Transducer D. Instruction Manuals E. Timing Sensor F. Timing Pin G. Magnetic Probe H. Transducer Cable I. 1/4" Clamp-On Transducer J. Magnetic Probe Adapter K. Magnetic Probe Adapter

C CD30673

NOTE: If clearance does not allow proper installation of the timing sensor (E), FKM10429-5 or FKM10465-3 clamp-on transducer (C) can be installed close to injection nozzle. Remove paint on injection line before installation.

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 flywheel housing timing hole (B) to ensure engine is NOT stopped at No. 1 TOP DEAD CENTER. At No. 1 TDC, flywheel timing hole will align with flywheel housing timing hole (B). The magnetic probe (D) would be damaged when engine is started.

Installation of flywheel housing with smooth timing hole: 1. Install JDG821 magnetic probe adapter (F) into flywheel housing smooth hole (B). Lightly tap adapter to lock into position. 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

TESTS AND ADJUSTMENTS

DIESEL ENGINE

Timing Sensor and Magnetic Probe Connection

E F CD30447

3. Press "MAG PROBE" key. A default "trig level" 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. Type in 0.0 to enter a 0.0° "Offset" value and press the "ENTER" key.

B 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. 2. Connect magnetic probe (E) to meter socket "MP" (F). Check Fuel Injection Pump Timing

CD30204

5. The display will now show "Calibrate?". The meter is now ready to accept a timing sensor signal for calibration. 6. Press "ENTER" to perform calibration. Run engine at 1,300 rpm. The display will automatically show the engine speed.

CD30205 CD30202

1. Press the "ON/CLEAR" key. The display will show "Time-Trac", then "Model TT1000", then "R = 0".

NOTE: At this point, meter can be used as tachometer. 2. Start the engine and run for 10 minutes to bring to operating temperature.

11/22/00

7. Once 1300 rpm is displayed, press "ENTER" key. "Calibrating..." will then appear on the display for a short period of time.

NOTE: If the meter loses the engine speed signal or the engine is not running, the display will show "Eng. not running". This message flashes three times before the meter returns to tachometer mode. To restart the procedure, press "MAG PROBE" key (step 3).

3 - 29

TESTS AND ADJUSTMENTS

DIESEL ENGINE

CD30449

CD30448

8. Run engine at fast idle speed then load engine down gradually to rated speed (see SPECIFICATIONS) using dynamometer or any other system allowing to load engine. 9. Record engine speed rpm and timing degrees.

Pump Timing Specifications

Model

Pump Part #

Dynamic Timing

Rated Speed (rpm)

240

RE500441

6°

2400

240

RE501933

17°

2400

240

RE505093

14.5°

2400

250

RE500442

7°

2400

250

RE504984

7°

2400

NOTE: If display shows "R + 1,500 No Probe", the magnetic probe has not been installed properly, air gap exceeds 0.65 mm (0.025") or there is debris on the back of the flywheel. Check for proper air gap or clean the back side of the flywheel.

IMPORTANT: Stop engine prior to making timing adjustments. Injection pump can seize if adjustment is made with engine running. 10. Stop engine and, if necessary, rotate injection pump as follows: • If below specification, rotate pump towards engine block. • If above specification, rotate pump away from engine block.

NOTE: 1 mm (0.039 in.) offset on the injection pump flange corresponds approximately to 2° on the meter display. 11. Recheck timing until specified timing is obtained. 12. After adjustment, grind the engine front plate mark to avoid any confusion with the original timing adjustment.

NOTE: If the injection pump has to be removed from engine and reinstalled without any change, mark both the front plate and the injection pump flange to allow the installation of injection pump at the same location. In case of repair or replacement of injection pump, perform dynamic timing.

CD30198

3 - 30

11/22/00

TESTS AND ADJUSTMENTS

DIESEL ENGINE

CHECK AND ADJUST VALVE CLEARANCE

Adjust valve clearance as ADJUSTMENT SEQUENCE.

directed

VALVE

VALVE ADJUSTMENT SEQUENCE Firing order is 1-2-3.

Reason: To achieve correct engine operation.

Equipment:

Feeler Gauge B

Procedure: The valve clearance must be adjusted when engine is cold. E

CD30549

CD30544

Using JDE83 or JDG820 Flywheel Turning Tool (A), rotate engine flywheel in running direction (clockwise viewed from water pump) until No.1 piston (front) has reached top dead center (TDC) on compression stroke. Insert timing pin JDE81-4 (B) into flywheel bore.

A. Front of Engine B. No. 1 Piston at TDC Compression Stroke C. No. 1 Piston at TDC Exhaust Stroke D. Intake Valve E. Exhaust Valve 1. Using JDE81-4 Timing Pin, lock No. 1 piston at TDC compression stroke (B). 2. Adjust valve clearance on No. 1 and 2 exhaust valves and No. 1 and 3 intake valves. 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 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.

D05225ST Adapter

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

D01003AA Repair Stand To facilitate engine repair, the D01003AA repair stand can be used in conjunction with D05225ST adapter.

3 - 32

Never permit any part of the body to be positioned under a load being lifted or suspended. Accidental slippage may result in personal injury.

11/22/00

REPAIR

DIESEL ENGINE

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:

CD30527

1. Use a 73 mm spacer at hole (A) and a 79 mm spacer at hole (B). 2. Mount engine to adapter using the cap screws listed below at the hole locations as shown: Holes A and B . . . . 14 mm (9/16-12 x 4-1/2 in.) Hole C . . . . . . . . . 38 mm (9/16-12 x 1-1/12 in.) 3. Drain all engine oil and coolant. IMPORTANT: Hydraulic lock occurs when trapped oil in the oil filter housing drains through the turbocharger, the exhaust and intake manifolds, and then into the cylinder head. After starting the engine, the trapped oil in the manifold and head is released into the cylinders filling them with oil causing hydraulic lock and severe engine damage.

1. Remove bucket or any other attachments 2. Park skid steer on flat level surface. Place blocks in front of and behind tires. 3. Start engine and raise boom arms to the fully raised position, and engage boom locks. 4. Disconnect battery, negative (–) cable first then positive (+) cable. 5. Raise ROPS and ensure ROPS is locked in position. 6. Remove top, rear, and side engine panels.

c CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing cap completely.

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

CD30528

4. Disconnect oil inlet line at turbocharger (D) to prevent hydraulic lock.

Radiator Drain Valve 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). 9. Remove bottom engine access cover located under rear of skid steer.

Finger Guard

Upper Radiator Hose

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 prevent contamination of hydraulic oil.

Outlet KV18010

11. Disconnect inlet line from fuel filter. Close all openings using caps or plugs to prevent contamination of fuel system. Remove filter base and attach to engine using wire or plastic tie.

Hydraulic Oil Cooler Hoses

KV13058

14. Disconnect hydraulic oil cooler hoses. Use caps or plugs to cover openings to prevent contamination.

3 - 34

11/22/00

REPAIR

DIESEL ENGINE

Latch Bracket Filler Tube Cap Screw Intake Hose

Air Cleaner

KV18841

15. Remove filler tube-to-radiator support cap screw. 16. Remove engine cover latch bracket. Repeat for opposite side of radiator.

KV13948

22. Disconnect intake hose from intake manifold or turbocharger if equipped. 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. 19. Remove radiator and oil cooler assembly using a lifting strap and suitable hoist.

Wiring Connector

Harness Connector KV13949

25. Remove hydraulic oil hose from filter manifold. Close all openings using caps or plugs. 26. Disconnect brake solenoid harness connector. Cap Screws

Fuel Leak-Off Line

KV13064

Mounting Bracket

NOTE: Tag or label all wires and connectors to aid during installation. 20. Disconnect coolant temperature sensor wiring connector. 21. Disconnect fuel leak-off line.

11/22/00

KV13950

27. Remove four cap screws and mounting bracket. Move bracket with hydraulic oil filter and filter manifold forward away from engine.

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. 29. Disconnect throttle linkage from bracket and fuel injection pump.

33. Bend wire harness retainer back and move harness away from engine. 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 KV13957

Starter

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

REPAIR

DIESEL ENGINE

A D

KV15160

c CAUTION Boom lock pins must remain in place. Be sure that boom is adequately supported by boom lock pins. 36. Remove boom lock linkage mounting plate (A) cap screws. Disconnect boom lock linkage (B) from levers (C) and (D). Remove mounting plate, leaving boom lock pins and levers in place.

KV13985

43. Install lifting sling around hydrostatic pump and mounting plate. Attach hoist and take up slack in sling. 44. Remove pump flange-to-engine flywheel cover cap screws. Remove mounting plate cap screws, washers, and nuts. 45. Remove remaining flywheel cover cap screws. Remove flywheel cover.

KV13976

37. Install JD244 lifting brackets to engine. Attach JDG23 lifting sling to bracket. 38. Attach a suitable hoist to engine and take out the slack on lifting chain. 39. Label and remove hoses from hydrostatic pump assembly. 40. Disconnect steering linkage from hydrostatic pump arms.

NOTE: Make sure all lines, hoses, and electrical wiring are removed and do not entangle with engine during removal. 41. Remove engine/hydrostatic pump assembly. 42. Lower engine to floor and block.

11/22/00

Cap Screw Coupling

KV31121

46. Remove eight coupling-to-flywheel cap screws. Remove coupling. 47. Install engine on repair stand. (See MOUNT ENGINE ON REPAIR STAND.) Engine Installation: IMPORTANT: Before installing engine make sure all electrical wiring, lines, and hoses are moved away from engine.

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 140 N•m (105 lb-ft)

Bushing

Nut

Grommet Washer KV13987

Rear Engine Mount IMPORTANT: If bushings have flat sides, flat side should be parallel to machine sides.

Cap Screw 140 N•m (105 lb-ft)

Cap Screw 305 N•m (225 lb-ft)

KV13985

Install Coupling and Flywheel Cover:

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

1. Place coupling on flywheel and install eight coupling-to-flywheel cap screws. Tighten to 63 N•m (46 lb-ft).

KV13976

4. Install engine/pump assembly. Remove hoist and lifting brackets.

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. 2. If removed, install two pump flange-to-engine flywheel cover cap screws. Tighten cap screws to 140 N•m (105 lb-ft).

Rear Engine Mounting Bolts

KV13957

3 - 38

11/22/00

REPAIR

DIESEL ENGINE

IMPORTANT: If bushings have flat sides, flat side should be parallel to machine sides. DO NOT ROTATE while tightening mount hardware.

removal. 11. Install wire ties as necessary.

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 KV18842

10. Connect all wire leads, cables, and connectors to the preheat relay, manifold preheater, starter, and alternator using the tags or labels installed during 11/22/00

16. Connect hydraulic oil hose and tighten clamp. 17. Connect harness connector to solenoid connector on filter manifold. 18. Install air cleaner and intake hose. Connect harness to air filter restriction sensor.

3 - 39

REPAIR

DIESEL ENGINE

Latch Bracket Filler Tube

Coolant Temperature Sender Cap Screw Fuel Leak-Off Line

KV18841 KV13064

19. Connect fuel leak off line and tighten clamp. 20. Connect harness to coolant temperature sender. Ground Cable

25. Install engine cover latch bracket on both sides of radiator support. 26. Install and tighten hydraulic oil fill hose cap screw.

Hydraulic Oil Cooler Hoses

Recovery Tank

KV13058 KV18012

21. Install radiator/hydraulic oil cooler assembly. 22. Install coolant recovery bottle and connect hose to radiator filler neck. 23. Check for fan tip clearance. Fan shroud should have tip clearance of 10 ± 1.0 mm (0.40 ± 0.04 in.) to shroud cutout.

NOTE: Replace all O-rings and seals. Used or damaged O-rings and seals will leak. 27. Install new O-ring seals and connect hydraulic oil 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

REPAIR

DIESEL ENGINE

Finger Guard

Upper Radiator Hose

KV13940

35. Close drain valve and fill radiator with proper coolant to top of filler neck. 36. Connect backup alarm harness if equipped. 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 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 KV18010

31. Install fuel filter base with filter. Connect inlet line to filter base. 32. Install hydraulic oil reservoir drain plugs and tighten securely.

Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing cap completely.

Removal:

NOTE: Approximate hydraulic oil reservoir capacity is 15.6 L (4.1 gal.). 33. Fill hydraulic oil reservoir with clean hydraulic oil. 34. Install bottom engine access cover.

1. Open top and rear panels and remove side engine panels. 2. Disconnect battery, negative (-) cable first.

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 Drain Hose

Finger Guard

KV13939

3. Route radiator drain hose out of access panel on left side of frame. 4. Open radiator drain valve and drain coolant. Finger Guard

KV18841

6. Remove cooling fan finger guard. 7. Remove cap screw, retaining hydraulic filler tube to support. 8. Remove engine access cover latch bracket. Repeat procedure on opposite side of radiator.

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

REPAIR

DIESEL ENGINE

Installation:

Cap Screw Cap Screw KV13993 KV13993

NOTE: Some models have a spacer washer between the support bracket and radiator mounting flange. Retain for reuse.

1. Install radiator in support brackets. Apply medium strength threadlock to both cap screws. Install and 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 radiator using compressed air or pressure washer. 15. Inspect radiator for bent fins, cracks, and damaged seams. Repair or replace radiator as necessary.

Notch

Fan Shroud

KV31119

2. Inspect clearance between right radiator mounting flange and support bracket. If it is in excess of 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 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 disassembly for overhaul is required.

The following assembly sequence is suggested when engine has been completely disassembled. Be sure to check run-out specifications, clearance tolerances, torques, etc. as engine is assembled. Refer to the appropriate repair section when assembling engine components.

1. Drain engine oil. Check engine oil for metal contaminates. 2. Remove fan belts, fan, alternator, and muffler. 3. Remove turbocharger (if equipped) and exhaust manifold. 4. Remove rocker arm cover with vent tube. On engines having an Option Code label on rocker arm cover, be careful not to damage label. 5. Remove rocker arm assembly and push rods. Keep rods in sequence. Check for bent push rods and condition of wear pad contact surfaces on rockers. 6. Remove thermostat housing and bypass tube. 7. Remove high-flow pump (if equipped). 8. Remove oil cooler piping and water pump. 9. Remove dipstick, oil filter, and engine oil cooler. Discard standard-flow oil cooler if oil contained metal particles. 10. Remove starting motor. 11. Remove fuel lines. 12. Remove injection lines, injection pump, and injection nozzles. 13. Remove cylinder head. 14. Remove cam followers. Keep in same sequence as removed. 15. Remove oil pan. 16. Remove crankshaft pulley. 17. Remove oil pressure regulating valve assembly. 18. Remove timing gear cover. 19. Remove oil pump drive gear, outlet tube (and its Oring in block), and pump body. 20. Remove oil deflector, timing gears, and camshaft. Perform wear checks. 21. Remove engine front plate. 22. Remove oil system bypass valve. 23. Remove flywheel and flywheel housing. 24. Stamp cylinder number on rod (if required). Remove pistons and rods. Perform wear checks with Plastigage™. 25. Remove main bearings and crankshaft. Perform wear checks with Plastigage™. 26. Remove cylinder liners and mark each one with cylinder number from which removed. 27. Remove piston cooling orifices. 28. Remove balancer shaft and camshaft bushings (if equipped). 29. Remove cylinder block plugs and serial number plate (as required) when block is to be put in a "hot tank". 30. Clean out liner bores (upper and lower areas) with nylon brush. 31. Measure cylinder block.

1. Install all plugs (and serial number plates) in cylinder block that were removed to service block. 2. Install clean piston cooling orifices and new camshaft bushings. 3. Install cylinder liners without O-rings and measure protrusion. Install liners with O-rings. 4. Install crankshaft and main bearings. 5. Install flywheel housing, rear oil seal, and flywheel. 6. Install pistons and rods. Check for piston protrusion. 7. Install oil system bypass valve. 8. Install front plate. 9. Install oil outlet tube, O-ring in block, and oil pump. 10. Install injection pump on front plate. 11. Install high-flow pump (if equipped). 12. Install camshaft, timing gears, and oil deflector. 13. Time all gears to TDC, No. 1 cylinder on compression stroke. 14. Install timing gear cover (with new front seal). 15. Install oil pan. 16. Install oil pressure regulating valve (if equipped). 17. Install cam follower in the same sequence as removed. 18. Install cylinder head gasket, cylinder head, push rods, and rocker arm assembly. 19. Install injection nozzles (with new seals) and injection lines. 20. Install fuel lines. 21. Install starting motor. 22. Install engine oil cooler, new oil filter, and dipstick. Never clean or reuse a contaminated standardflow oil cooler, install a new one. 23. Install thermostat housing with thermostat. 24. Install exhaust manifold and turbocharger. Pre-lube the turbocharger. 25. Install water pump and hoses. 26. Install crankshaft pulley. 27. Install alternator, fan, and fan belts. 28. Adjust valves and install rocker arm cover. 29. Install vent tube. 30. Install muffler. 31. Fill engine with clean oil and proper coolant. 32. Perform engine break-in and perform normal standard performance checks.

Plastigage is a trademark of DANA Corp. 11/22/00

3 - 45

REPAIR

DIESEL ENGINE

CYLINDER HEAD–EXPLODED VIEW

F E D

C B

CD30531

A. Cylinder Head B. Valve Seat

3 - 46

C. Cylinder Head Gasket D. Cylinder Head Bolt (1/2-13 UNC x 112 mm[4.41 in.])

E. Rocker Arm Cover F. Vent Tube

11/22/00

REPAIR

DIESEL ENGINE

CHECK VALVE LIFT

REMOVE CYLINDER HEAD B

C A

CD30532

NOTE: Measuring valve lift can give an indication of wear on cam lobes. 1. Rotate engine and determine valve locations as indicated under VALVE CLEARANCE in this section. 2. Adjust valve to zero clearance. 3. Position dial indicator on valve rotator and adjust indicator to "0". 4. Rotate engine and observe indicator reading as valve moves to the fully open position. Compare readings with specifications. 5. Repeat above procedure for all valves and readjust valves to specified clearance after this operation. 6. If valve lift is not within specification, remove and inspect camshaft.

CD30533

NOTE: A generic PowerTech 2.9 L engine is shown. Skid steer engine is similar. Before removal, mark all parts so that they can be installed in their original positions. 1. Drain engine coolant. 2. Remove muffler. 3. Remove exhaust manifold (A). On turbocharged engine, disconnect oil inlet line (B) and oil return line (C), then remove the exhaust manifold, turbocharger, and crossover pipe. 4. Remove thermostat housing (D), bypass tube (E), 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

NOTE: A generic PowerTech 2.9 L engine is shown. Skid steer engine is similar. 7. Remove air inlet adapter (I). 8. Remove crankcase vent hose (J). 9. Remove rocker arm cover (K).

CD30537

14. Lift cylinder head from block. If cylinder head sticks, use a soft hammer to tap cylinder head. Do not use screwdriver or pry-bar which can damage the sealing surface.

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

REPAIR

DIESEL ENGINE

VALVE ACTUATING PARTS

D C

B G

CD30379

A. Cam Follower B. Push Rod C. Rocker Arm

D. Support E. Shaft F. Plug

REMOVE VALVES AND VALVE SPRINGS

G. Keepers H. Rotator I. Spring

J. Metering Seal K. Valve Seat Insert L. Valve

CHECKING CYLINDER HEAD FLATNESS

L103629

1. Using JDE138 Valve Spring Compressor, compress the valve springs far enough to remove keepers. 2. Release spring tension and remove valve rotator and valve spring. Mark each part so that it can be assembled in the same position it was removed from. 3. Remove valves, marking them for assembly. 4. Remove valve stem seals from valve guide tower.

11/22/00

L30699

Maximum permissible flatness is 0.08 mm (0.003 in.). Machined surface of cylinder head must be re-faced if flatness is more than specified maximum.

NOTE: Maximum permissible amount to be machined from cylinder head is 0.76 mm (0.03 in.). After any head machining, always recheck valve recesses.

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 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.

MEASURE VALVE GUIDES

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 cylinder head . . 7.912—7.938 mm (0.312—0.313 in.) New guide-to-valve stem clearance. . . . . . . . 0.05—0.10 mm (0.002—0.004 in.)

1. Use an electric hand drill with D17024BR End Brush to remove all carbon on valve seats. 2. Inspect seats for excessive wear, cracks, or damage.

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

3 - 50

11/22/00

REPAIR

DIESEL ENGINE

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

Check seat width and contact pattern between seat and valve with blueing. If necessary lap the valve onto its seat using a lapping tool and lapping compound. IMPORTANT: Always check valve recess in cylinder head after lapping, as described in this section.

REMOVE VALVE SEAT INSERTS Valve seat inserts are made of sintered metal. The following method, performed by experienced personnel or specialized workshop, can be used to remove inserts. Using an Arc Welder 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 CD30541

11/22/00

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

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

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.)

Machining Valve Seat Insert

INSPECT AND MEASURE VALVES RG5606

Thoroughly clean and inspect valves to help determine if they can be reused. Replace valves that are burned, 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.) Exhaust Valve Seat Insert Bore Specifications: A. . . . . . . . 42.987—43.013 mm (1.6924—1.6934 in.) B. . . . . . . . . . . . . . . . 3.82 mm (0.150 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.) Replacement Valve Seat Insert OD:

T82053

1. Measure valve stem diameter and compare with corresponding valve guide diameter to check clearance. (See MEASURE VALVE GUIDES.) Valve Stem Diameter Specifications: Intake Valve. . . . . . . . . . . . . . . . . . 7.864—7.884 mm (0.3096—0.3104 in.) Exhaust Valve . . . . . . . . . . . . . . . . . 7.848—7.874 mm (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

REPAIR

DIESEL ENGINE

INSPECT AND MEASURE VALVE SPRINGS

RG4234

2. Check for valve face run-out and bent valves. Maximum permissible run-out of valve face:. . . . . . . 0.038 mm (0.0015 in.)

GRIND VALVES

T82054

Valve Spring Specifications: 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

4. Install valve springs and rotators. 5. Compress valve springs using JDE138 Valve Spring Compressor and install new keepers on valves.

IMPORTANT: Ensure that cam followers (A) are present before installing cylinder head.

CD30693

2. Install new cylinder head gasket dry (without sealant).

3 - 54

11/22/00

REPAIR

DIESEL ENGINE

TORQUE TURN TIGHTENING METHOD

12 8

5 4

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) could be damaged when positioning cylinder head on engine block to align cap screw holes. 5. Position cylinder head over guide studs and lower into place on cylinder block. 6. Dip cap screws entirely in clean engine oil. 7. Remove guide studs and install cap screws in all open bores. 8. Tighten cap screws in sequence to the torque specified, beginning with No. 1. Use JD-307 Torque Wrench Adapter if necessary. Step 1. Tighten all cap screws to . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 N•m (75 lb-ft) Step 2. Tighten all cap screws to . . . . . . . . . . . . . . . . . . . . . . . . . . 150 N•m (110 lb-ft) Step 3. Wait 5 minutes and tighten all cap screws to . . . . . . . . . . . . . . . . . . . . . . . . 150 N•m (110 lb-ft) Step 4. Tighten each cap screw an additional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60° ± 10°

11/22/00

KV31107

A. Reference Mark B. 60° Mark To ensure that the full 60° angle is reached (Step C.), the following procedure can be used: Step A. Make a mark (A) on socket and make a second mark (B) 60° counterclockwise from the first. Step B. Place socket on cap screw and transfer mark (A) to cylinder head. Step C. Tighten (in sequence) all cap screws until second mark on socket aligns with mark on cylinder head.

NOTE: The torque turn method eliminates the need to re-torque the cylinder head bolts after the first hours of engine operation. However, valve clearance adjustment is still required.

3 - 55

REPAIR

DIESEL ENGINE

CHECKING ROCKER ARM SHAFT

Assembling 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.

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

B CD30381

IMPORTANT: The oil supply hole (C) in the shaft must be in line with the oil supply hole (D) of cylinder head.

INSTALL ROCKER ARM ASSEMBLY

CD30382

A. Plug B. Bowed Washer C. Oil Supply Hole in Rocker Arm Shaft D. Oil Supply Hole in Cylinder Head Disassembling and Checking 1. Remove plugs (A) and bowed washers (B) from rocker arm shaft. 2. Slide springs, rocker arms, and supports off rocker arm shaft, identifying their sequence for reassembly in the same order. 3. Clean all parts with solvent and dry with compressed air. 4. Check all parts for good condition (See SPECIFICATIONS for part dimensions). 5. Replace parts as necessary.

CD30536

1. Install push rods in same location from which they were removed.

NOTE: Valve stem tips are specially hardened, wear caps are not required. 2. Position rocker arm assembly (A) on engine. 3. Lubricate the rocker arms with engine oil. 4. Tighten attaching cap screws to 50 N•m (35 lb-ft). 5. Adjust valve clearance. (See CHECK AND ADJUST VALVE CLEARANCE.)

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

REPAIR

DIESEL ENGINE

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

RG6322

The sealing ring (B) is reusable. In case of leak, proceed as follows: 1. Remove sealing ring. 2. Clean cover sealing ring groove with acetone and dry with compressed air. 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

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 rpm) or perform break-in if engine has been overhauled. 5. Check valve clearances and adjust when necessary.

NOTE: Re-torquing cylinder head bolts is not required.

3 - 57

REPAIR

DIESEL ENGINE

CYLINDER BLOCK EXPLODED VIEW

C E

B G

H A

CD30551

A. Cylinder Block B. Cylinder Liner C. Piston

3 - 58

D. Piston Rings E. Piston Pin F. Snap Ring

G. Liner Seals H. Oil Pressure Regulating Valve Seat I. Oil Bypass Valve J. Connecting Rod

11/22/00

REPAIR

DIESEL ENGINE

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. Cylinder Liner Bore Specifications:

CD30384

1. Mark liners and cylinder block then pull liners out of 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: Clearance (measured . . . . . . . . . . . . 0.09—0.14 mm at bottom of skirt). . . . . . . . . . (0.0035—0.0055 in.)

RG4745

2. Remove O-rings (A) from groove in cylinder block (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

REPAIR

DIESEL ENGINE

CYLINDER LINER DEGLAZING

CHECK PISTON COOLING JETS

RG6426

R26164

1. Place cylinder liners in a suitable clamping device. 2. Use D17004BR Flex-Hone to de-glaze liner. Follow instructions supplied with tool to obtain 45° crosshatch pattern.

NOTE: After de-glazing, clean cylinder liner bore with 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 oil.

1. Check each piston cooling jet (A) for plugging or damage.

NOTE: A cooling jet failure could cause damage to pistons, piston pins, rod pin bushings and liners. 2. Reinstall jets and tighten to 10 N•m (7.5 lb-ft).

CAM FOLLOWER BORE MEASURE IMPORTANT: Do NOT use gasoline, kerosene, or commercial solvents to clean liners.

CYLINDER BLOCK CLEANING

T81656

Cam Follower Bore Specifications: R26166

1. Remove liner O-rings from cylinder block. Clean block with cleaning solvent or pressure steam. 2. Make sure all passages and openings are free from sludge, rust, and grease. 3. Use D17015BR Cleaning Brush to clean liner Oring grooves.

11/22/00

Cam follower bore ID . . . . . . . . . . . 31.70—31.75 mm (1.248—1.250 in.) Maximum clearance . . . . . . . . . . 0.13 mm (0.005 in.) If diameter is more than specified, install a new cylinder block. Service bushings are not available through service parts.

3 - 61

REPAIR

DIESEL ENGINE

MEASURE CAMSHAFT BORE

CD30340 CD30557

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

INSTALL CAMSHAFT BUSHING

Camshaft Bore Specifications: 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 cases, install a new cylinder block.

REMOVE CAMSHAFT BUSHING

CD30388

Extract camshaft bushing using JDG739B tool as follows: 1. Assemble threaded spacers (A) and forcing plate (B) to cylinder block (C). 2. Insert bushing puller (D) into camshaft bushing bore.

CD30558

Install camshaft bushing using JDG739B as follows: 1. Apply TY6333 grease to internal diameter and outside diameter of bushing.

CD30389

2. Slide bushing onto driver so notched end (A) of bushing will be toward front end of engine when installed. IMPORTANT: Bushing must be installed so oil 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

REPAIR

DIESEL ENGINE

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.]). 1. Install replacement caps in block and tighten cap screws to 135 N•m (100 lb-ft).

CD30561

Top deck out-of-flat . . . . . . . . . . 0.08 mm (0.003 in.) Top deck surface finish (CLA) . . . . 0.8—3.2 micron (32—128 micro-in) Maximum wave deep . . . . . 8 micron (320 micro-in.) Crankshaft bore centerlineto-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

RG6439

A. Liner protrusion

4. If liner protrusion or permissible difference is above specifications, apply lapping compound to liner flange shoulder in the block. Install liner then, 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 not rotate smoothly by hand, remove liner and polish lower pilot bore in block with emery cloth or D17015BR brush. 2. Align liner and cylinder block marks, then secure at four points with cap screws and thick washers (approx. 3 mm—0.118 in.). Tighten to 100 N•m (74 lb-ft). 3. Using KJD10123 Gauge, measure liner protrusion (A) at four points.

CD30564

5. If protrusion is below specifications, install one liner shim (A) under liner flange. Two sizes of shims are available: 0.05 mm (0.002 in.) and 0.10 mm (0.004 in.). IMPORTANT: ONLY ONE SHIM IS ALLOWED PER CYLINDER. If liner requires more than one shim, 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

REPAIR

DIESEL ENGINE

LINER PACKING INSTALLATION Apply lubricating soap to new packing and install over liner until it contacts liner shoulder. Liner packing must be compressed to a minimum of 0.13 mm (0.005 in.).

A B

INSTALL CYLINDER LINERS 1. Slide liner together with shim and packing into its bore in cylinder block.

CD30565 CD7134

2. Seat liners using KCD10001 special tool. 3. Secure liners by means of large washers and cap screws.

A. Cylinder Liner B. Packing C. Improper Installation D. Proper Installation

MEASURE CONNECTING ROD BEARING

LINER O-RING INSTALLATION Apply lubricating soap to new O-rings. Install O-rings in respective grooves.

NOTE: Before measuring, connecting rod cap screws 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

CONNECTING ROD BUSHING

Specifications: 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 (0.01 in.) under standard size.

CD30566

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)

RG6405

1. Remove connecting rod cap. Place a piece of Plastigage™ in the center of the bearing. Install cap and tighten cap screws according to specifications. 2. Remove cap and compare the width of Plastigage™ with scale provided on the side of package to determine clearance. Max. permissible clearance. . . . 0.16 mm (0.006 in.)

3 - 66

NOTE: 3029D engines are equipped with straight pinend connecting rods while 3029T engines receive the tapered pin-end connecting rods. If diameter or clearance are more than specified, replace connecting rod bushing for the 3029T engines and replace connecting rod/piston pin assembly for the 3029D engines. Specifications: Connecting rod bushing ID 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.)

11/22/00

REPAIR

DIESEL ENGINE

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

RG7132

RG7130

4. Slide bushing (A) onto JDG738-1 driver (B) and install JDG738-2 pilot ring (C) onto O-ring end of driver. 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 matches up with taper on bushing. 2. Install receiver cup JDG738-3 onto opposite side of rod bushing.

NOTE: Stud in cup keeps rod properly located on the cup. Use JDG738-2 pilot ring (B) as a hollow spacer when pressing bushing out of rod. 3. Using hydraulic press, push bushing out of rod until driver and bushing fall into receiver cup.

RG7236

6. Insert driver into rod pin bore so pilot ring pilots in 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). 7. Install JDG738-3 receiver cup (F) onto opposite side of rod so taper on rod aligns with taper on receiver cup. 8. Press bushing into rod until edge of bushing is flush machined surface on connecting rod face. 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

Piston Pin OD Specifications: 3029D . . . . . . . . . . . . . . . . . . . . . . . 31.994—32.000m (1.2596—1.2598 in.) 3029T . . . . . . . . . . . . . . . . . . . . . . . . 41.27—41.28 mm (1.6248—1.6252 in.) Wear tolerance . . . . . . . . . . . . . 0.013 mm (0.005 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.) If diameter is less or clearance is more than specified, replace pin/bushing assembly for the 3029T engines and replace connecting rod/piston pin assembly for the 3029D engines.

RG6283

Specifications: 3029D. . . . . . . . . . . . . . . . . . . . . . . . 32.003—32.013m (1.356—1.560 in.) 3029T . . . . . . . . . . . . . . . . . . . . . . 41.285—41.295mm (1.6254—1.6258 in.)

NOTE: Some piston pin bores are elliptical, the width being 0.038 mm (0.0015 in.) larger than the bore specifications. If bore is not within specifications, replace piston/liner set.

PISTON TOP RING GROOVE

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

c CAUTION Follow manufacturer’s instruction exactly. DO NOT ALLOW CHEMICAL TO COME IN CONTACT WITH SKIN OR EYES; chemical contains creosotes which can be very harmful.

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

RG4746

A. Piston Can Be Used Again B. Discard Piston and Replace C. JDG957 Gauge D. Tool Shoulder-to-Ring Land Clearance Use JDG957 wear gauge to check wear of top compression ring groove.

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

REPAIR

DIESEL ENGINE

PISTON SECOND AND THIRD RING GROOVES

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

CD30568

PISTON HEAD AND SKIRT CHECKING

CD30569

A CD30391

1. Check piston for scuffing, scoring, or signs of overheating. 2. Measure piston diameter 19 mm (0.74 in.) from bottom of skirt and 90° from piston pin.

E C F

KV18888

Specifications: Piston OD at 19 mm (0.74 in.) from bottom of skirt and measured 90° from piston pin . . . . . . . . . . . . . . . . . . . . . . . . . 106.381—106.399 mm (4.1882—4.1890 in.)

11/22/00

A. Top Ring B. Second Ring C. Oil Control Ring D. KJD10140 Piston Ring Expander E. Blue Mark F. Yellow Mark

3 - 69

REPAIR

DIESEL ENGINE

1. Install oil control ring (C) in bottom ring groove over 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/LINER SET INFORMATION

PISTON RINGS STAGGERING F CD30579

A. Piston Head B. Top Compression Ring Gap C. Oil Control Ring Gap D. Expander Ring Gap E. Bottom Compression Ring Gap F. Front of Engine Stagger piston rings as shown.

A. Liner B. Piston C. Piston Ring Set D. Liner Seal Set 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. Service piston is available only as an assembly and includes items listed above.

NOTE: Liner, piston ring set and liner seal set are available separately. Piston/Liner sets may be packaged in an anticorrosion 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

REPAIR

DIESEL ENGINE

ASSEMBLE PISTON AND CONNECTING ROD

2. Coat piston pin (B) with engine oil and insert it through piston and connecting rod bores. Install 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 grooves.

B 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-andgroove 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 E. Centerline of Liner Bore F. Combustion Chamber Offset

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.

IMPORTANT: Different style rods MUST NOT be intermixed on the same engine.

NOTE: Pistons must be installed in the cylinder liner from which they were removed.

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 side of engine. The long side of the connecting rod should face camshaft side of block.

11/22/00

CD30572

1. Coat pistons and rings with clean engine oil. Install pistons in liners, using JDE84 piston ring compressor.

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. C

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 each. One groove (C) will remain unused. 4. Apply clean engine oil on insert and crankshaft journal. Carefully place connecting rod against crankshaft journal. 5. Install bearing insert in connecting rod cap with tab in groove. IMPORTANT: On PRECISION JOINT rod assemblies, be sure cap is oriented properly and that it is correctly aligned on rod, with edges flush and interlocking surfaces sealed tightly.

3 - 72

KV18574

IMPORTANT: Never use connecting rod cap screws more than once for final engine assembly. Cap screws used on PRECISION JOINT style rod and cap are 3 mm (0.120 in.)shorter than those used on tongue-and-groove style rod and cap. 7. Apply clean oil to NEW connecting rod cap screws and tighten alternately to 56 N•m (40 lb-ft). 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).

11/22/00

REPAIR

DIESEL ENGINE

9. Check for proper side clearance in all rods. Each rod must have a slight side-to-side movement.

7. If protrusion is out of specifications, check all 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.

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

CD30577

Rear Left View

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.

KV18077

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) B. Turbocharger oil return (1/2 in.) . 45 N•m (33 lb-ft) C. 1/2 cyl. for dipstick tube . . . . . . . 67 N•m (50 lb-ft) D. Oil galleries (1/8 in.). . . . . . . . . . . 17 N•m (13 lb-ft) E. Coolant gallery (side) (1/4 in.) . . 17 N•m (13 lb-ft) F. Rear coolant gallery (1 in.) . . . . . 45 N•m (33 lb-ft) G. Oil gallery (3/8 in.) . . . . . . . . . . . . 45 N•m (33 lb-ft) 1. Install all components previously removed. Apply following recommendations then perform engine test.

3 - 74

5. Oil gallery ball (M) is provided with service cylinder block, but may not be installed. In this case, proceed as follows: • Put ball (M) in oil passage (N). • Drive in ball using an appropriate driver (O) until ball bottoms. • Check for proper installation. The distance between pan rail and top of ball should be approximately 54 mm (2.16 in.).

11/22/00

REPAIR

DIESEL ENGINE

REMOVE CRANKSHAFT PULLEY

FLYWHEEL REMOVAL

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

lifting

CD30580

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.

CD30581

1. Install shaft key (A). 2. Position pulley on crankshaft with washer (B) and cap screw (C). 3. Tighten to 150 N•m (110 lb-ft).

11/22/00

NOTE: If the flywheel does not have the threaded holes (A), install two cap screws (for handling flywheel) into clutch system threaded holes then, using a soft hammer, gently tap on flywheel to un-stick it.

3 - 75

REPAIR

DIESEL ENGINE

FLYWHEEL RING GEAR REPLACEMENT

INSTALL BALL BEARING A E

RG6345

T90596

1. Drive ring gear off with a brass drift and hammer.

A. 27487 Driver B. 27508 Disk

2. Heat new ring gear to 150°C (300°F) using either heated oil, oven heat, or flame heat.

C. 27493 Disk D. Ball Bearing E. Flywheel

NOTE: Some flywheels have a ball bearing (D) which needs to be installed with flywheel removed from engine.

c CAUTION Oil fumes or oil can ignite above 190° C (380°F). When heating ring gear, use a thermometer and do not exceed 180°C (360°F). Heat the oil in a well ventilated area. Plan a safe handling procedure to avoid burns.

Drive new ball bearing into engine side of flywheel using 27487 driver (A), 27508 disk (B) and 27493 disk (C) from D01045AA or other bearing driver set, until bearing bottoms in bore. Check bearing for smooth operation.

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

CD7140

RG3838

3. Tap heated ring gear into place against flywheel shoulder. Chamfered edge of teeth (A) must be toward engine.

NOTE: Be sure complete ring gear circumference is flush against shoulder of flywheel.

3 - 76

1. Install two guide studs in crankshaft. 2. Place flywheel on studs and slide into position against crankshaft. IMPORTANT: Always replace flywheel cap screws when flywheel has been removed. 3. Install cap screws and tighten crosswise to 160 N•m (120 lb-ft).

11/22/00

REPAIR

DIESEL ENGINE

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. 3. Drill a 3/16 in. hole through wear sleeve lip and seal casing at the three marked locations.

11/22/00

CD30244

2. Secure the assembly with a clamp then gradually tighten the screw until wear sleeve is extracted.

3 - 77

REPAIR

DIESEL ENGINE

Installation:

CD30586 CD30396

3. Cut the rubber lip now accessible and remove it.

1. The oil seal/wear sleeve assembly can be installed using JT30040 or KCD10002A tools. Due to a 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 pivots.

T81204

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 case.

3 - 78

T81205

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.

11/22/00

REPAIR

DIESEL ENGINE

FLYWHEEL HOUSING REPLACEMENT

MEASURING CRANKSHAFT END PLAY

1. Remove flywheel and oil pan.

NOTE: It is recommended to measure crankshaft end play prior to removing crankshaft to determine condition of thrust bearings.

c CAUTION AVOID INJURY. Flywheel housing weighs approximately 20 to 40 kg (43 to 86 lbs.). B B A

B CD7141

2. Remove four 5/8 in. cap screws (B) and eight 3/8 in. cap screws (A). Remove flywheel housing.

CD7144

Check crankshaft end play using a dial indicator and compare with specifications.

A CD30220

CD30585

3. Clean mating surfaces and install new gasket (C).

NOTE: On certain applications, the open holes need to be sealed. Apply TY6304 Flexible Sealant to threads of cap screws.

A. Oversized Thrust Washers B. Front of Engine C. Rear Bearing Cap Side 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: 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 placement during reassembly. 2. Attach nylon slings (or other suitable lifting slings) to crankshaft. 3. Carefully lift crankshaft out of cylinder block.

CRANKSHAFT INSPECTION 1. Clean crankshaft thoroughly, especially oil passages from crankshaft bearings to connecting rod bearings.

CD30588

1. Measure diameter of all crankshaft journals at several points around journal and compare with specifications. Crankshaft Journal Specifications: Main journal diameter (std.) . . . . . 79.324—79.350 mm (3.123—3.124 in.) Maximum wear Taper . . . . . . . . . . . . . . . . . . . 0.03 mm (0.0012 in.) Out-of-roundness . . . . . . . . . 0.075 mm (0.003 in.)

CD7149 CD7147

2. Check crankshaft for cracks or signs of load stress (see illustration for critical areas of load stress in a crankshaft.). 3. Inspect both shoulders of thrust bearing journal for scores or unevenness.

2. Install main bearing inserts and caps then tighten cap screws to 135 N•m (100 lb-ft), then measure ID of main bearing (assembled) and compare with specifications. Main Bearings (Assembled) ID Specifications: 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

REPAIR

DIESEL ENGINE

3. If crankshaft journal diameter or clearance are not within specifications, replace crankshaft or grind journals to match under-size bearings. Under-size bearings are only available in 0.25 mm (0.01 in.) under standard size.

NOTE: Under-size crankshafts may be also available through regular service parts channel.

DETERMINE CRANKSHAFT MAIN BEARING CLEARANCE

RG7528

1. Place a strip of Plastigage™ in the center of the bearing. 2. Install cap and tighten cap screws to 135 N•m (100 lb-ft). 3. Remove cap and compare the width of Plastigage™ with scale provided on side of package to determine clearance.

REGRINDING CRANKSHAFT IMPORTANT: Crankshaft grinding should be carried out ONLY by experienced personnel on equipment capable of maintaining crankshaft size and finish specifications.

CRANKSHAFT REGRINDING GUIDELINES If the crankshaft is to be ground, use the following recommended guidelines: 1. Determine the size to which the journals are to be ground according to the measures taken during inspections. 2. If one or more main or connecting rod journals require grinding, then grind all of the main journals or all of the connecting rod journals to the same 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 oversize washer is used, crankshaft end play specification must be maintained. 5. If the thrust surfaces of the crankshaft are worn or grooved excessively, they must be ground and polished. An oversize thrust washer set is available. 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.). 7. After grinding has been completed, inspect the crankshaft by the fluorescent magnetic particle method, or other similar method to determine if cracks have originated due to the grinding operation. 8. De-magnetize the crankshaft. 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 iron crankshafts have to be ground:

NOTE: Gear can be replaced without removing the 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

0.22 micron (8.8 micro-in.) depth . . . . Tp more than 20%

0.38 micron (15.2 micro-in.) depth . . . Tp more than 80% 0.64 micron (25.6 micro-in.) depth . . . Tp more than 90% Final journal finishing operation must be done in clockwise direction (as viewed from forward end of crankshaft.). IMPORTANT: DO NOT attempt to grind cast iron crankshafts if above specifications cannot be obtained.

RG7238

A. No. 1123 Pulling Attachment B. Disc C. D01200AA Push Puller 1. Pull gear using D01200AA Push Puller or any suitable puller. 2. Remove woodruff key from crankshaft and remove any burrs from gear journal. 3. Install a new woodruff key in crankshaft keyway. 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 wellventilated 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

REPAIR

DIESEL ENGINE

INSTALL MAIN BEARING INSERTS

INSTALL 6-PIECE THRUST BEARING

CD30589 CD30399

A. Bearing Insert Tab B. Cylinder Block Slot Install main bearing inserts, making sure that tab (A) 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.

Install two thrust washers in the block and two on bearing cap. The oil grooves (A) must face towards crankshaft thrust surfaces.

CRANKSHAFT INSTALLATION 1. Apply a liberal coating of clean engine oil to bearing surfaces and crankshaft journals and install crankshaft. 2. Dip all main bearing cap screws in clean engine oil and position them with washers in the bearing caps.

INSTALL 2-PIECE THRUST BEARING

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

Using a dial indicator, check camshaft end play.

MEASURE TIMING GEAR BACKLASH Measure backlash between gears using a dial indicator and compare with specifications. If backlash is not correct, install new gears.

Camshaft end play . . . . . . . . . . . . . . . 0.08—0.23 mm (0.003—0.009 in.) Maximum wear . . . . . . . . . . . . . . 0.38 mm (0.015 in.) Thrust plate thickness . . . . . . . . . . 3.935—3.985 mm (0.155—0.157 in.) Maximum wear . . . . . . . . . . . . . . . . 3.8 mm (0.15 in.)

NOTE: If end play exceeds specifications, check thickness of thrust plate as this determines end play.

REMOVE CAMSHAFT

C D E

CD30591

A. Camshaft/Upper Idler Gear B. Injection Pump/Upper Idler Gear C. Upper Idler/Crankshaft Gear D. Crankshaft/Lower Idler Gear E. Oil Pump/Lower Idler Gear

CD30593

NOTE: Camshaft can be removed from engine without removing cylinder head by holding cam 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

REPAIR

DIESEL ENGINE

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. 1. Remove cylinder head, cam followers and fuel pump. 2. Remove cap screws (A) and pull camshaft straight out.

MEASURE CAMSHAFT JOURNAL

CD30594

Camshaft Lobe Height Specifications: Intake lobe . . . . . . 6.93—7.42 mm (0.273—0.292 in.) Maximum wear . . . . . . . . . . . . . . 6.68 mm (0.263 in.) Exhaust lobe. . . . . 6.76—7.26 mm (0.266—0.286 in.) 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: 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. IMPORTANT: To keep the initial working condition between cam lobes and cam followers, always replace cam followers when installing a new camshaft.

11/22/00

3. Install gear with timing mark (A) away from camshaft. 4. Press gear on shaft until flush with shoulder on camshaft.

3 - 85

REPAIR

DIESEL ENGINE

TACHOMETER PICK-UP PIN REMOVAL

MEASURE CAM FOLLOWER

RG6324 CD30200

1. Drill and tap an extraction hole of approx. 6 mm (0.250 in.) diameter and 12 mm (0.500 in.) depth in center of pin. 2. Using a self-made puller (spacer, washer, screw), pull out the tachometer pick-up pin.

Measure cam specifications.

follower

and

compare

with

Cam Follower Specifications: Cam follower OD . . . . . . . . . . . . . . 31.62—31.64 mm (1.124—1.246 in.) Cam follower to bore clearance . . . . 0.06—0.13 mm (0.002—0.005 in.)

INSTALL CAMSHAFT

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 with camshaft bushing, lubricate the inner circumference of bushing with TY6333 grease. 3. Install camshaft and thrust plate (C) in cylinder block. 4. Install cap screws (D) and tighten to 50 N•m (35 lb-ft).

CD7155

Using a dial indicator, check end play of upper and lower idler gears: End play . . . . . . . . 0.14—0.29 mm (0.006—0.012 in.) Maximum wear . . . . . . . . . . . . . . 0.40 mm (0.016 in.)

REMOVE FRONT PLATE IMPORTANT: To keep the initial working condition between cam lobes and cam followers, always replace cam followers (E) when installing a new camshaft.

3 - 86

1. Proceed as follows in case of front plate replacement: 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. 11/22/00

REPAIR

DIESEL ENGINE

IDLER GEAR BUSHING AND SHAFT MEASURE

CD30186

• Build a template as shown. • Attach template to previous front plate using three 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.

CD7159

CD7160

If clearance is more than specified, replace worn parts with new ones.

KV18575

4. Remove five countersunk screws (D) and lift off front plate.

KV18576

5. Remove oil bypass valve and spring (E).

11/22/00

Idler Gear Specifications: 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.) 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 (0.002—0.0038 in.) Maximum wear . . . . . . . . . . . . 0.15 mm (0.006 in.)

3 - 87

REPAIR

DIESEL ENGINE

IDLER GEAR BUSHING REPLACEMENT

INSTALL IDLER SHAFT SPRING PIN A B

RG6459 CD7161

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 gear is specified with a lube-groove fitted bushing. 2. Press in new bushing with JD-252 Driver and JDG537 Handle so that it is flush with one side of the gear.

NOTE: The upper idler shaft for engine with auxiliary drive (spur gear) has a spring pin to allow a proper orientation of the shaft oil holes (C) and of the thrust washer ears (A) to clear space around countersunk front plate screw (B). 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

REPAIR

DIESEL ENGINE

INSTALL IDLER SHAFTS

INSTALL FRONT PLATE A B C D

A G E

CD30255

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 1. Install injection pump studs (A) on front plate using Loctite 271.

CD30256

B. Lower Idler Shaft H

IMPORTANT: Oil hole in upper idler shaft must be properly indexed to provide adequate lubrication to idler gear bushing. 1. Install thrust washers (A and B) with sharp edge toward front plate. 2. Place idler shaft in front plate bore with oil hole oriented approximately 45° to the left of top center. On engine with auxiliary drive, make sure that spring pin of upper shaft is in line with thrust washer and front plate holes. 3. Press shaft into front plate until thrust washer is fully seated.

NOTE: Idler shaft is secured to front plate when gear bolt or nut are tightened.

11/22/00

CD30695

H. Injection Pump Stud Locations

NOTE: Standard front plate (without auxiliary drive extension) have several injection pump stud locations. Use holes marked (H). 2. On standard front plate only, install the 5/16" plugs (B) and the 3/8" plugs (D) as shown. Bushing (C) is not required for this application.

3 - 89

REPAIR

DIESEL ENGINE

INSTALL UPPER TIMING GEAR 1. Adjust No. 1 piston to TDC using JDE83 or JDG820 (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 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 only after timing gear cover has been tightened.

3. Install fuel injection pump. 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

REPAIR

DIESEL ENGINE

INSTALL OIL DEFLECTOR

CD30604

7. Install washer, with sharp edge toward timing cover, and bolt (B). Tighten to 110 N•m (80 lb-ft). 8. Recheck gear timing to make sure it is correct.

INSTALL LOWER TIMING GEAR

CD30608

Install oil deflector (A) and O-ring (B) when equipped, on forward end of crankshaft.

INSTALL TIMING GEAR COVER

15 14

13 10

1. Install oil pump and lower idler gear. 2. Install new bolt with washer (A) from oil pump side. Install washer, with sharp edge toward timing cover, and new nut on gear side then tighten to 110 N•m (80 lb-ft).

NOTE: Engine may be equipped with a self-locking oil pump nut. In this case, tighten to 85 N•m (63 lb-ft). Do not apply any punch marks. 3. Install oil pump gear on pump shaft, tighten hex nut to 75 N•m (55 lb-ft) and secure with three center punch marks.

11/22/00

CD30605

8 4

3 16 19 20

21 CD30609

1. Install new gasket on front plate. 2. Install cover on engine and apply the following 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)

3 - 91

REPAIR

DIESEL ENGINE

INSTALL WEAR RING

KV18577

NOTE: A generic PowerTech 2.9 L engine is shown. Skid steer engine is similar. 3. Install oil filler neck or block-off plate then tighten cap screws (F) to: Aluminum neck . . . . . . . . . . . . . . . . 50 N•m (35 lb-ft) Composite neck . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Block-off plate . . . . . . . . . . . . . . . . . 50 N•m (35 lb-ft) 4. Cut off protruding edge of gasket.

CD30612

1. When equipped, install the wear ring with chamfered side (A) toward engine. Be sure that the O-ring is in place against the oil deflector. 2. Install shaft key.

REMOVE OIL COOLER

INSTALL CRANKSHAFT FRONT OIL SEAL A

CD30271

CD30611

1. Place new seal onto KJD10164 Seal Installer (A) with open side toward engine, then slide the assembly onto crankshaft end. 2. Install pulley cap screw with washer (B), then tighten until driver bottoms.

A. Inlet Line from Water Pump B. Outlet Line to Water Pump C. Nipple 1. Disconnect inlet line (A) and outlet line (B) at oil cooler. 2. Remove nipple (C) and lift out oil cooler. 3. Discard packing.

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

REPAIR

DIESEL ENGINE

REPLACE OIL COOLER NIPPLE

REMOVE OIL PRESSURE REGULATING VALVE

CD30275 CD30620

1. Remove oil cooler nipple (A). 2. Press in new nipple so that threaded end faces outward.

Remove oil pressure regulating valve plug. Check valve cone for excessive wear and damaged sealing 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 (25 lb-ft). 3. Connect coolant lines to oil cooler. 4. Install oil filter.

CD7175A

1. Remove valve seat bushing, using a suitable puller. 2. Drive in new bushing, using special tools JD-248A 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 REGULATING VALVE

REPLACE OIL BYPASS VALVE

CD30622 CD30413

NOTE: One or several shims (A) may be used to adjust the oil pressure. 1. Install valve, spring, shims, washer, and plug in timing gear cover. 2. Tighten plug to 95 N•m (70 lb-ft).

REPLACE OIL DIPSTICK GUIDE ADAPTER

1. Remove timing gear cover and front plate. 2. Remove oil bypass valve and spring (A). Inspect valve and spring for damage. 3. Check spring calibration: 79 to 96.5 N (18 to 22 lb) when spring is compressed at 29 mm (1.14 in.) length. 4. Install oil bypass valve and spring. 5. Install front plate and timing gear cover.

REPLACE OIL PUMP STRAINER

CD30623

KV18013

1. Loosen jam nut and unscrew dipstick guide adapter. 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

1. Remove oil pan. 2. Loosen the two lower cap screws (A) and remove oil strainer. 3. Install new strainer with new O-ring and tighten cap screws to 50 N•m (35 lb-ft). 4. Install oil pan.

11/22/00

REPAIR

DIESEL ENGINE

REMOVE OIL PUMP

GEAR RADIAL CLEARANCE

B A

C CD7178 CD7176

1. Remove oil pan and timing gear cover. 2. Remove nut (A) from pump shaft. 3. Pull gear (B) from conical shaft of pump, using a suitable puller. 4. Remove the 3 cap screws (C) attaching pump housing to front plate.

Radial clearance between gear and pump housing . . . . . . . . . 0.10 to 0.16 mm (0.004 to 0.006 in.) Max. permissible radial clearance. . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)

OIL PUMP SPECIFICATIONS

GEAR AXIAL CLEARANCE

T81953

CD7177

Thickness of gears . . . . . . . . . . . 41.15 to 41.20 mm (1.62 to 1.622 in.) Axial clearance . . . . . . . . . . . . . . . . . 0.05 to 0.17 mm (0.002 to 0.007 in.) Max. permissible axial clearance. . . . . . . . . . . . . . . . . . 0.22 mm (0.0085 in.)

Bore of drive shaft in pump housing . . . . . . . . . . . . . . . 16.05 to 16.08 mm (0.632 to 0.633 in.) Max. permissible wear . . . . . . . . 0.08 mm (0.003 in.) Drive shaft O.D. . . . . . . . . . . . . . . . 16.02—16.03 mm (0.630—0.631 in.) Max. permissible wear . . . . . . . 0.025 mm (0.001 in.) Idler shaft O.D. . . . . . . . . . . . . . . . 12.32 to 12.34 mm (0.485 to 0.486 in.) Max. permissible wear . . . . . . 0.013 mm (0.0005 in.)

T81781

11/22/00

3 - 95

REPAIR

DIESEL ENGINE

OIL PUMP INSTALLATION

L C

H M N

B I

K F G CD30416

H. Housing I. Outlet Tube J. Strainer K. Cover L. Cap Screws (3 or 4 used) M. Drive Gear N. Nut

A. Cylinder Block Seal B. O-Ring (Outlet Tube) C. O-Ring (Oil Strainer Tube) D. Drive Shaft E. Spring Pin F. Gears G. Shaft

KV18080 CD30624

1. Install new seal (A) in cylinder block. 2. Install O-rings in pump cover (for outlet tube) and 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.

NOTE: Service oil pump kit has two outlet tubes. Install tube (I) without paint mark.

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

REPAIR

DIESEL ENGINE

6. Rotate pump shaft, again making sure that pump gears turn freely. 7. Install pump drive gear (M) and a new nut (N). Tighten to 75 N•m (55 lb-ft).

2. Select and install the correct gasket for the oil pan being used.

CD30627 T81782

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. 8. Secure the nut by applying three center punch marks.

INSTALL OIL PAN

NOTE: A generic PowerTech 2.9 L engine is shown. Skid steer engine is similar. 3. Install oil pan and tighten cap screws as follows: Oil pan (all types) to timing gear cover . . . . . . . . . . . . . . . . . . . 50 N•m (35 lb-ft) Sheet metal oil pan to block and flywheel housing. . . . . . . . . . 50 N•m (35 lb-ft) Aluminum oil pan to block 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 B. Bearing Shaft

C. Seal D. Impeller

E. Gasket F. Rear Cover G. Hub (or Pulley)

REMOVE WATER PUMP 1. Remove fan and sheet metal pulley when equipped.

B A

CD30629

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

3 - 98

11/22/00

REPAIR

DIESEL ENGINE

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

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), disassemble water pump as follows. 1. Remove rear cover (A) and discard gasket .

H. Pre-Assembled Water Pump

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

CD30636 CD30633

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.

4. Place pump housing under a press and support on pulley end of shaft.

CD30637

KV18579

5. Using special tool JD-262A, press impeller onto pump shaft until recess of 0.25 mm (0.5 in.) is 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

REPAIR

DIESEL ENGINE

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

KV18081

7. Install pulley or hub to dimension (X) obtained step 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. 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 (35 lb-ft). 9. Install bypass tube into thermostat cover. Tighten clamp. 10. Fill cooling system and check for leaks.

B A

CD30629

2. Install water pump, placing a new gasket between the pump cover and cylinder block. Tighten cap screws (B) to 50 N•m (35 lb-ft) and nut (C) to 40 N•m (30 lb-ft). 3. Connect coolant hoses (A).

COLD START ADVANCE WIRE HARNESS (IF EQUIPPED)

REMOVE/INSTALL THERMOSTAT

CD30682

CD30640

The cold start advance wire harness allows easy startup when the engine is cold. The temperature signal is supplied by switch (A) located in thermostat cover. 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

B 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.).

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

CHECK FAN/ALTERNATOR BELT TENSION 1. Check belt tension using one of following methods:

CD30646

2. If adjustment is necessary, loosen alternator nuts (D) and (E). Pull alternator frame outward until belt tension is correct. IMPORTANT: Do not pry against the alternator rear frame. Do not tighten or loosen belts while they are hot.

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

REPAIR

DIESEL ENGINE

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 improperly. Fan is not reversible. Refer to illustration.

Knurled Nut

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)

BLOCK HEATER (OPTIONAL)

Jam Nut

Heating Element KV31111

Removal: 1. Park skid steer safely. 2. Raise ROPS. (See RAISING ROPS in the MISCELLANEOUS Section) 3. Remove any attachment from skid steer Quik-Tatch. 4. Raise boom and engage boom locks. 5. Drain radiator.

IMPORTANT: Heater element is bent to avoid interference with cylinder block walls. DO NOT TURN the heater element. Doing so will damage the heater element. 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

Heating Element

Mark

KV31108

KV31110

NOTE: If heating element will be reused, make a mark on the element to determine position for reassembly.

IMPORTANT: Note where the offset in the heating element. Offset must go to the out side of block (right side of engine).

9. Keep heating element from rotating and unscrew fitting from block. Remove fitting and heating element from block.

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

Installation:

CHECK AIR INLET PIPE

Heating Element

O-Ring A

Fitting KV31109

1. Install new O-ring on heating element. 2. Apply TY9374 Pipe Sealant with Teflon to the threads of the fitting.

C CD30653

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

REPAIR

DIESEL ENGINE

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 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 D

EXHAUST MANIFOLD INSPECTION 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. 6. Tighten exhaust manifold attaching cap screws to 50 N•m (35 lb-ft).

REMOVE TURBOCHARGER 1. Thoroughly clean exterior of turbocharger and surrounding area.

11/22/00

CD30658

1. Remove compressor cover. 2. Install a dial indicator against shaft end. 3. Move shaft alternately toward and away from indicator. Range of travel should not exceed 0.51 mm (0.20 in.). 4. If radial clearance is not within specifications, replace turbocharger.

3 - 105

REPAIR

DIESEL ENGINE

CHECK AXIAL BEARING END PLAY

INSTALL TURBOCHARGER D

C B CD30659

1. Using a dial indicator with indicator rod against shaft, measure axial end play. 2. Move shaft axially back and forth by hand. Indicator reading should not exceed 0.14 mm (0.005 in.). If axial end play is not within specifications, replace turbocharger.

A CD30661

Due to special tooling and highly specialized personnel required, turbochargers can be serviced only by an authorized workshop.

1. Install turbocharger on exhaust manifold (A) with a new gasket (B). Tighten cap screws (C) to 30 N•m (20 lb-ft). 2. If not done previously, prelube turbocharger, then connect the oil supply line (D). Tighten to 25 N•m (18 lb-ft). 3. Connect the oil return tube (E). Tighten to 80 N•m (60 lb-ft). 4. Connect exhaust system and air hoses.

Complete turbochargers are available through service parts channel. Individual components for repair are not available.

IMPORTANT: Be sure that the air hose connections are tight to prevent entry of dirt into engine.

REPAIR TURBOCHARGER

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

REPAIR

DIESEL ENGINE

TURBOCHARGER BREAK-IN IMPORTANT: A new or repaired turbocharger does not have adequate oil supply. Perform the following steps to prevent damage to turbocharger.

REPLACE FUEL/WATER SEPARATOR FILTER

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 RECOMMENDATIONS In most cases, turbocharger damage is caused by improper start-up and shutdown procedure. Always idle the engine for at least 30 seconds (no load) after start-up and before shutdown. IMPORTANT: Should the engine stall when operating under load, IMMEDIATELY restart the engine to prevent overheating of turbocharger parts.

CD30665

A. Retaining Ring B. Filter Element C. Sediment Glass Bowl (Optional) D. Bleed Screw E. Drain Screw (2 used) 1. Unfasten filter retaining ring (A) and remove filter element (B).

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

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 detent. DO NOT overtighten. 5. To ensure that the fuel system is primed, turn the key switch to the RUN position and wait 20 seconds before starting the engine.

RG6293

IMPORTANT: Never steam clean or pour cold water on a fuel injection pump while the pump is running or while it is warm. Seizure of internal components can occur. 1. Clean fuel injection pump, lines, and area around pump with cleaning solvent or a steam cleaner. 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.

REPLACE FUEL PUMP

B C

E G

B A

D C

A KV31120

1. Disconnect battery negative (–) cable. 2. Disconnect harness plug (A) at fuel pump. 3. Disconnect and plug both fuel lines (B). 4. Remove two screws (C) securing fuel pump to fuel tank.

NOTE: Fuel pump is not repairable, Replace if nonoperational.

KV18082

3. Disconnect the following elements: A. Cold start advance connector(if equipped) B. Fuel shut-off ground terminal C. Fuel shut-off positive terminal D. Speed control linkage E. Fuel return line 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

REPAIR

DIESEL ENGINE

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

L E CD30670

A. Front Plate B. Pump Flange C. O-Ring

D. Stud (3 used) E. Nut (3 used) F. Woodruff Key

1. Using a new O-ring (C), slide housing onto the three studs (D), inserting shaft in drive gear.

NOTE: Make sure that the Woodruff key (F) is seated properly.

G. Return Line H. Injection Line No. 1 I. Pump Outlet

J. Injection Line No. 2 K. Injection Line No. 3 L. Supply Line

3. Push drive gear firmly onto shaft taper. Install washer and nut (M) then tighten to 200 N•m (150 lb-ft). Install mounting plug onto timing gear cover.

2. Screw the three nuts (E) onto studs and handtighten at this time. X

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 CD30671

NOTE: In case of replacement of injection pump, 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

REPAIR

DIESEL ENGINE

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. 6. Connect: • Fuel supply line (L) and tighten to 30 N•m (23 lbft) • 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) • Throttle cable bracket

REMOVE FUEL INJECTION NOZZLE IMPORTANT: Before removal, carefully remove all dirt from the cylinder head around fuel injection nozzles and blow clean with compressed air in 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 to the nozzles when handling them. Do not bend the fuel pressure lines, as this may affect their durability and breakdowns may occur. When loosening the fuel pressure lines, hold male union of nozzle line.

CD30676

2. Using two wrenches as shown, disconnect fuel injection line (E) from nozzle to be removed. 3. Remove cap screw (F).

JDG716

CD30324

IMPORTANT: Do not use screwdrivers or similar tools for removal, as they may cause irreparable damage to the injection nozzles. 4. Pull injection nozzle out of cylinder head, using JDE38B Injection Nozzle Puller.

Removal:

CLEAN FUEL INJECTION NOZZLE D

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

Remove the carbon stop seal from groove in nozzle body using suitable pliers. Pull seal washer from the nozzle body and discard carbon stop seal and seal washer.

B C

A B F

KV31118

1. Loosen end fuel lines (A) and tube nuts (B). Remove leak-off lines (C) and tee fittings (D) as an assembly. Immediately cap or plug all openings.

11/22/00

Place fuel injection nozzle in solvent or clean Diesel fuel until accumulated deposits are saturated. Clean body and tip with brass wire brush. NEVER use a steel wire brush or scraper for this purpose. 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.

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. 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 accumulated. This can be corrected only by disassembling the nozzle.

Checking Valve Stem and Guide Wear L30741

NOTE: Testing the performance of a nozzle while the engine is running is not an accurate test. To obtain a true check of nozzle performance, use a nozzle tester JT25510 (A) and pressure line KJD10109 (B), as shown under Special Tools. IMPORTANT: Use only carefully filtered diesel fuel for testing the injection nozzles, dirty fuel will severely damage the precision parts of a nozzle.

c CAUTION The nozzle tip must always point away from the operator. The fuel issuing from an orifice can penetrate clothes and skin and thus cause severe infection. 1. Connect the nozzle to the tester so that the axis of the nozzle forms an angle of approx. 30° to the vertical and the spray of fuel is directed downwards. 2. Check all connections for leaks. Close the gauge shut-off valve and flush (bleed) the nozzle by operating test pump rapidly. Spray Pattern Test 1. Close gauge shut-off valve and operate the pump lever at 60 strokes per minute. 2. If the fuel injection nozzle is working properly, the fuel should issue through all nozzle orifices in a fine, evenly shaped spray cone. This spray cone is inclined from the centerline of the nozzle body, but should be distributed. 3. For a better check, place a piece of paper or cardboard at a suitable distance below the nozzle and check the appearance of the damp circular spots made by the fuel.

3 - 112

1. Connect fuel injection nozzle to the nozzle tester with the tip raised a little higher than its opposite end. 2. Cover the tip and pump the tester to a pressure of 10 300 kPa (1500 psi). Keep the pressure constant and observe how much fuel leaks out of the nozzle return end. After the first drop has formed, count the drops for 30 seconds; there should be 3 to 10 drops. Opening Pressure Test

NOTE: Absolute opening pressure is less important than equal opening pressure of all nozzles. Max. permissible variation is 700 kPa (100 psi). 1. Close gauge shut-off valve and actuate the pump several times to allow the nozzle valve to seat properly. 2. Open gauge shut-off valve. Pump the pressure up to the point where the pressure gauge needle falls rapidly. This point (take reading) is the nozzle valve opening pressure. Minimum opening pressure should be: 3029D: New or Reconditioned . . . . . . . . . . . . . . . 25 235 kPa (3660 psi) Minimum Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 856 kPa (3170 psi) Minimum 3029T: New or Reconditioned . . . . . . . . . . . . . . . 23 166 kPa (3360 psi) Minimum Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 960 kPa (3330 psi) Minimum 3. If spray pattern and valve seat test (see below) are good but the opening pressure test is unsatisfactory, adjust opening pressure. (See ADJUST FUEL INJECTION NOZZLE.)

11/22/00

REPAIR

DIESEL ENGINE

Checking Valve Seat 1. Connect the nozzle to tester in horizontal position. Operate the pump lever rapidly to bleed the nozzle and allow the valve to seat. 2. Dry the tip of the nozzle thoroughly. Now operate the pump lever slowly until the indicated pressure is approximately 2800 to 3500 kPa (28 to 35 bar) (400 to 500 psi) below opening pressure (see opening pressure above). 3. Keep watching the nozzle. The nozzle tip must stay dry (visual check) after a period of 5 seconds. 4. Work the pump lever quickly several times in succession to make the nozzle spray in the normal way. After the last stroke of the pump, observe again. If the nozzle is not quite leakproof, disassemble for servicing.

2. Loosen lock nut (B) of pressure adjusting screw (C). 3. Connect nozzle to tester, then using JDG949 Special Wrench, adjust opening pressure by turning the pressure adjusting screw (C). 4. Tighten lock nut (B) to 10 N•m (7 lb-ft), then check opening pressure. 5. Carefully screw lift adjusting screw (D) until it bottoms on spring seat (E). 6. Unscrew lift adjusting screw with the number of turns as specified. 7. Tighten lock nut of lift adjusting screw to 5 N•m (3.5 lb-ft). 8. Check opening pressure.

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 I

F G

B CD30323

D H

CD30675 CD30676

A. Tee Fitting B. Cap Screw C. Fuel Injection Line D. Carbon Stop Seal E. Seal Washer F. Seal G. Tube Nut H. Protective Caps IMPORTANT: Before installation, be sure nozzle is clean and free from oil and grease.

2. Install nozzle in cylinder head. Install and hand tighten cap screw (B). Do not tighten at this time. 3. Connect fuel injection line (C) to nozzle. Tighten to 30 N•m (23 lb-ft) using two wrenches as shown. 4. Tighten cap screw (B) to 37 N•m (27 lb-ft). 5. Install leak-off lines (I) and tee fittings (A) as an assembly. Connect leak-off fuel lines to ends of leak-off line assembly. Tighten all leak-off line nuts to 5 N•m (44 lb-in.).

BLEED FUEL SYSTEM The fuel system utilizes an automatic priming system.

IMPORTANT: Each time an injection nozzle is removed from cylinder head, replace the carbon stop seal (D).

To ensure that the fuel system is primed, turn the key switch to the RUN position and wait 20 seconds before starting the engine.

1. Slide seal washer (E) onto nozzle body. Using JD258 Pilot Tool, slide the new carbon stop seal until it fits properly into the groove.

3 - 114

11/22/00

REPAIR

DIESEL ENGINE

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

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

15 minutes

1/2 load

2,000 to rated speed

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 mid-throttle, no load, before shutting it off. Check and reset the valve clearances.

NOTE: It is not necessary to retorque the cylinder head cap screws once the engine is broken in. During the first 100 hours of operation, avoid overloading, excessive idling, and no-load operation. After 100 hours, drain the crankcase oil and change the oil filter. Fill the crankcase with oil of the specified viscosity.

ENGINE BREAK-IN OIL New engines are filled at the factory with John Deere ENGINE BREAK-IN OIL. During the break-in period, add John Deere ENGINE BREAK-IN OIL as needed to maintain the specified oil level.

Remarks

Check oil pressure and coolant temperature. Check for fluid leakage.

After engine overhaul, fill the engine with John Deere ENGINE BREAK-IN OIL. If John Deere ENGINE BREAK-IN OIL is not available, use a diesel engine oil meeting one of the following during the first 100 hours of operation: • API Service Classification CE • ACEA Specification After the break-in period, use John Deere PLUS-50• or other diesel engine oil as recommended in this manual. 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 of operation of a new or rebuilt engine. These oils will not allow the engine to break-in properly.

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" AS TACHOMETER

TURBOCHARGER OPERATION

F A A

E B

D CD30206

A. Clamp-On Transducer FKM10429-5 B. Cable FKM10429-3 C. Timing Meter FKM10429-1

L30869

A. Shaft B. Turbine Housing C. Turbine Wheel D. Center Housing E. Compressor Wheel F. Compressor Housing 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 where it is then delivered to engine cylinders.

B CD30207

The STANADYNE "TIME-TRAC" meter can be used as a tachometer by using clamp-on transducer FKM10429-5 (A) on any high-pressure line.

Engine oil under pressure from the engine lubrication system is forced through passages in center housing (D) to the bearings.

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

REPAIR

DIESEL ENGINE

CHECK TURBOCHARGER BOOST PRESSURE

Oil on Compressor Wheel or in Compressor Housing (Oil Being Forced Through Center Housing) • Excessive crankcase pressure • Air intake restriction Oil Dripping from Housing in Intake or Exhaust Manifold

A CD30687

• 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 • Bearing wear • 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 Attach pressure gauge (A) to any air inlet port. Before checking boost pressure, warm up engine to allow the lubricating oil to reach operating temperature. Observe pressure reading on gauge. Reading should be at least 60 kPa (9 psi) when engine is developing rated horsepower at full load speed. If the reading is lower, check the following: • Restriction in the air cleaner • Leak in air intake system between turbocharger and cylinder head • Defective turbocharger

DIAGNOSING TURBOCHARGER MALFUNCTIONS Lack of Engine Power • Clogged manifold system • Foreign material lodged in compressor, impeller, or turbine • Excessive dirt build-up in compressor • Leak in engine intake or exhaust manifold • Rotating assembly bearing failure

(Do not confuse the whine heard during rundown with noise which indicates a bearing failure). • Bearings not lubricated (insufficient oil pressure) • Air leak in engine intake or exhaust manifold • Improper clearance between turbine wheel and turbine housing • Broken blades (or other wheel failures) Drag in Turbine Wheel • Carbon build-up behind turbine wheel caused by coked oil or combustion deposits • Dirt build-up behind compressor wheel caused by air intake leaks • Bearing seizure or dirty or worn bearings caused by excessive temperatures, unbalanced wheel, dirty oil, oil starvation, or insufficient lubrication

FUEL INJECTION PUMP The fuel injection pump is a sealed unit and is not serviceable. The pump must be returned to an authorized service center for repair.

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 OPERATION (IF EQUIPPED)

The engine utilizes a cold start advance system to aid in starting and operating a cold engine. 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

REPAIR

DIESEL ENGINE

FUEL INJECTION NOZZLES— GENERAL INFORMATION

Fuel injection nozzles are of the multi-orifice type. 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

1. Spray Tip 2. Carbon Stop Seal 3. Nozzle Valve 4. Nozzle Body 5. Seal Washer 6. Connection for Injection Line 7. Nozzle Valve Guide 8. Union Nut 9. Spring Seat 10. Adjustable Pressure Spring 11. Spacer Washer 12. Lift Adjusting Screw 13. Lock Nut 14. Tee Fitting 15. Lock Nut 16. Pressure Adjusting Screw 17. Hex Nut 18. Grommet 19. Location Clamp 20. Nipple 21. Filter Screen 22. Fuel Pressure Line

11/22/00

Fuel Not Reaching Fuel Injection Nozzles • Fuel filter clogged • Fuel line clogged or restricted • Fuel transfer pump pressure too low • Air in fuel system • Fuel return line restricted • Loss of fuel through leakage Engine Hard to Start or Will Not Start • Water, dirt or air in fuel system • Fuel filter clogged • Shut-off knob stuck • Fuel lines clogged or restricted • Fuel injection nozzles dirty or faulty • Fuel injection pump faulty • Fuel transfer pump faulty incorrect timing • Fuel injection pump metering valve stuck in closed position (check speed-control linkage) Engine Starts and Stops • Water in fuel • Filter clogged • Air in fuel system • Fuel lines clogged or restricted • Fuel injection pump return line damaged

3 - 119

REPAIR Engine Runs Irregularly or Stalls Frequently • Filter clogged • Air in fuel system • Fuel injection nozzles faulty or dirty • Fuel lines clogged or restricted • Incorrect timing • Water in fuel • Fuel injection pump return line restricted • Fuel injection nozzle leak-off line clogged Poor Engine Idling • Air in fuel system • Fuel injection nozzles dirty or faulty • Incorrect timing • Automatic advance of fuel injection pump faulty or not operating • Fuel lines clogged or restricted • Water in fuel • Fuel injection pump return line restricted • Fuel injection nozzle leak-off line clogged

DIESEL ENGINE

• Excessive wear in valve guides

TESTING FUEL INJECTION NOZZLES ON A RUNNING ENGINE Run engine at intermediate speed under no load. Slowly loosen fuel pressure line at one of the injection nozzles so that the fuel escapes at the line connection and is not forced through the nozzle (nozzle not 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. Repeat test consecutively at each of the remaining nozzles. When a faulty fuel injection nozzle is found, remove it and check thoroughly. (See FUEL INJECTION NOZZLE TEST.)

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

STARTING MOTOR

DIESEL ENGINE

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 than 30 seconds. Allow at least 2 minutes for cooling and battery recovery before operating again. Overheating caused by excessive operation will seriously damage starting motor.

Strong magnetic fields are set up by current flow through field windings and armature windings. Windings are arranged so that magnetic fields constantly repel each other, rotating armature.

THEORY OF OPERATION C

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 A

D H E G

A. Solenoid B. Field Winding C. Rear Bearing D. Brush

E. Commutator F. Armature G. Gear Reduction Assembly H. Overrunning Clutch

When solenoid (A) engages, it pulls engaging lever (J). Lever pushes overrunning clutch drive (H) to engage pinion in starter gear on flywheel. As armature (F) turns, it cranks engine. When engine starts, overrunning clutch spins freely on shaft. This prevents overspeeding of armature by flywheel. When key switch is released, current to solenoid holdin winding is shut off. Current can feed through both pull-in and hold-in windings from main contacts, but direction of current is reversed in pull-in winding.

3 - 122

CD30450

I. Pinion J. Engaging Lever

The two windings cancel each other, and solenoid is released. A spring pushes solenoid back to disengaged position. This opens main contacts and shuts off current to field windings and armature. Shift lever retracts overrunning disengaging pinion from flywheel.

clutch

drive,

In this reduction-type starter, the speed of armature rotation is reduced by the gear reduction assembly (G).

11/22/00

STARTING MOTOR

DIESEL ENGINE

EXPLODED VIEW OF STARTING MOTOR

KV18083

A. Pivot Pin B. Engaging Lever/Plunger C. Solenoid Spring D. Gear Reduction Assembly E. Solenoid Body F. Cover G. Overrunning Clutch H. Pinion Stop I. Retaining Ring

11/22/00

J. Bushing K. Armature L. Field Frame M. Brush Plate N. Shim (2 used) O. Rear Bearing P. Clip Q. Plastic Cap R. Through-Bolt (2 used)

S. Brush (4 used) T. Brush Spring U. Clip V. Field Winding W. Pole Shoe Screw X. Field Winding Terminal Y. Solenoid Attaching Screw

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 SPECIFICATIONS

KV18085

Starting motor-to-engine . . . . . . . . 50 N•m (37 lb-ft) Solenoid attaching screw . . . . . . . 3 N•m (27 lb-in.) Field winding terminal nut. . . . . . 10 N•m (88 lb-in.) Through-bolts. . . . . . . . . . . . . . . . . 7 N•m (62 lb-in.)

5. Separate gear reduction/solenoid/overrunning clutch assembly (G) from drive end housing (H). 6. Push pinion stop (I) toward pinion to have access to the retaining ring (J). 7. Remove retaining ring and slide pinion stop off 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

KV18084

9. Separate overrunning clutch/engaging lever/mobile 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

STARTING MOTOR

DIESEL ENGINE

KV18088

10. Remove two screws (N) retaining contactor.

KV18091

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

CD30465

CD30463

1. Check for continuity between terminals (A) and (B). If there is no continuity, replace the solenoid switch. 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 terminal (A) and ground. Connect the ohmmeter between terminals (B) and (C). Replace the solenoid switch if the resistance is not infinity.

NOTE: This operation requires specialized soldering tools. If not available, have the brushes replaced by a local electrical repair station. 1. Cut off old brush at end of brush strand (A). 2. Solder new brush using a 40—60% tin-lead mixing. Heat to 230°C (446°F).

TESTING ARMATURE

NOTE: Solenoid switch is available as a John Deere service part.

TESTING BRUSHES

CD30466

CD30464

1. Check positive brushes (A) by connecting an ohmmeter between brushes and plate. The resistance should be infinity. 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.

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. 2. Check for armature condition. Space between bars must be clean and of even depth. Small defects can be eliminated using sandpaper and a lathe. 3. If insulation is defective or armature is quite worn, replace the complete starting motor.

NOTE: Brush plate assembly is available as a John Deere Service part.

3 - 126

11/22/00

STARTING MOTOR

DIESEL ENGINE

TESTING FIELD WINDING

CHECKING OVERRUNNING CLUTCH PINION

CD30467

1. Check insulation by connecting an ohmmeter between brush (A) and field frame (B). If ohmmeter indicator swings toward zero, a grounded circuit is indicated. 2. Connect ohmmeter between brush (A) and terminal (C). Resistance should be below 1 ohm. 3. If defective, replace the complete starting motor.

CD30468

1. Check for pinion tooth condition. Slight damage on teeth can be eliminated by grinding.

NOTE: Damage on teeth can be caused by a 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 disassembly procedure. Use petroleum-base grease to lightly coat mechanical part assemblies such as shaft in nose bushing, gear reduction train, overrunning clutch pinion on shaft and shaft rear bearing.

TORQUE SPECIFICATIONS: Starting motor-to-engine . . . . . . . . . 50 N•m (35 lb-ft) Solenoid attaching screw . . . . . . . . 3 N•m (27 lb-in.) Field winding terminal screw . . . . 10 N•m (88 lb-in.) Through-bolts. . . . . . . . . . . . . . . . . . 7 N•m (62 lb-in.)

(See STARTER in the ELECTRICAL section.)

3 - 128

11/22/00

ALTERNATOR

DIESEL ENGINE

ALTERNATOR J

W B+

Y I

A B

D+

REG.

A. Alternator B. Current Coil (Stator) C. Exiting Coil (Rotor)

KV15183

D. Regulator E. Battery F. Indicator Light G. Ignition Switch

H. Protection Device I. Diode Trio J. Rectifier Diode Bridge

THEORY OF OPERATION

Equipment:

The alternator is a synchronous three-phase generator. The current coil is located in the stator, and the exiting current is supplied by the diode trio (I) through the regulator (D+ circuit), two carbon brushes and slip rings to the exiting coil in the rotor.

NOTE: Order tools according to information given in the U.S. SERVICE-GARD Catalog or in European Microfiche Tool Catalog (MTC).

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 0 to the positive maximum, drops to 0, rises to the negative maximum and again drops to 0. The current then flows through the diode and terminal B+ directly to the positive pole of the battery. A sealed electronic regulator is used to regulate alternator voltage. This regulator, which cannot be adjusted, limits the alternator voltage to approximately 14 volts.

RW11274 Digital Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or current flow. It is especially good for measuring low voltage or high resistance circuits.

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

ALTERNATOR

DIESEL ENGINE

ALTERNATOR—EXPLODED VIEW G F E

D H C B

M K

KV15184

A. Pulley Nut (M14 x 1.5) B. Lock Washer C. Pulley D. Fan E. Rotor F. Rear Bearing

11/22/00

G. Spring Coil H. Stator I. Front Bearing J. Front Housing K. Regulator and Brush Assembly L. Rectifier Bridge Assembly M. Capacitor N. Rear Housing

3 - 131

ALTERNATOR

DIESEL ENGINE

Loose connection Check wiring leads

Regulator failure Replace brush/regulator assembly

Stator failure (short-circuit)

Drive belt loose or broken Adjust tension or replace

Loose connection Check wiring leads

Brush/regulator or capacitor failure Replace parts

Diode failure Replace complete rectifier bridge

Stator failure Replace complete alternator

Rotor failure Replace complete alternator

Alternator speed too low Use smaller alternator pulley

Battery overcharging

Alternator indicator light stays on with engine running (alternator is not charging) at low speed

Check or

Alternator indicator light stays on with engine running (alternator is not charging) at any speed

Problem or Symptom

Alternator indicator light stays off with ignition on and engine not running

TROUBLESHOOTING

Low electrical consumption Use regulator with narrower regulation range (RE69380)

Regulator failure Replace regulator

3 - 132

11/22/00

ALTERNATOR

DIESEL ENGINE

ALTERNATOR—IDENTIFICATION

CD30471 CD30470

The information for parts identification is stamped on the body of the alternator.

4. Disconnect wire (D) from terminal. Remove two screws and washers (E). Remove brush/regulator assembly by tilting top of regulator up and away 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 from shaft.

KV18093

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

ALTERNATOR

DIESEL ENGINE

TESTING ALTERNATOR ROTOR

TESTING ALTERNATOR STATOR/ RECTIFIER BRIDGE ASSEMBLY

CD30477

1. Inspect slip rings (A) of rotor for scoring or rough surface. Polish slip rings sparingly with No. 00 sand paper.

CD30479

1. Inspect stator winding (A) for discoloration or a 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). Resistance should be infinity. If insulation, resistance, or slip ring are defective, replace complete alternator.

11/22/00

CD30480

3. Check positive diodes by connecting an ohmmeter between each phase terminal (D) and the “B+” 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.

3 - 135

ALTERNATOR

DIESEL ENGINE

REPLACE RECTIFIER BRIDGE

CD30484 CD30481

1. To replace the rectifier bridge, un-solder the leads of phase winding (A) and “W” terminal (B) using a soldering iron. 2. Position the replacement rectifier bridge and solder phase winding leads. Solder “W” terminal at the proper location.

5. Hand press rotor/front housing assembly into rear housing using alignment marks. 6. Install the three mounting bolts (F) with washers. Tighten to 3 N•m (27 lb-in.).

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.). 4. Install insulated washer, flat washer, spade terminal, lock washer, and nut on “W” terminal (E). Tighten to 3 N•m (27 lb-in.).

3 - 136

CD30487

9. Install pulley (M) with lock washer and nut (N). Tighten to 40 N•m (29 lb–ft). 10. Install alternator on engine and connect wiring connectors. 11/22/00

CONTENTS

ELECTRICAL

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

CONTENTS

ELECTRICAL

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 INFORMATION

WIRE COLOR ABBREVIATION CHART

The theory of operation divides the electrical system into individual circuits by function. Each circuit is isolated from the main wiring schematic and only shows the components that are used in it. The story contains information on function, operating conditions, and theory of operation. The circuit schematics are drawn with the components in the operating position, with the power, or battery positive, into them across the top and the ground, or battery negative, across the bottom.

Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green Gry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gray Org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange Pnk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tan Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow Blk/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . Black/White Blu/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue/White Dk Blu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dark Blue Dk Brn/Lt Grn . . . . . . . . . . . . . Dark Brown/Light Green Dk Brn/Red. . . . . . . . . . . . . . . . . . . . . Dark Brown/Red Dk Brn/Yel . . . . . . . . . . . . . . . . . . . Dark Brown/Yellow Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Green Lt Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Green Org/Wht . . . . . . . . . . . . . . . . . . . . . . . . . Orange/White Pnk/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink/Black Pur/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . Purple/White Red/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black Red/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/White Wht/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Black Wht/Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red Yel/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Black Yel/Red . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Red Yel/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/White

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

4-8

NOTE: Beginning in 2001, all wires will be solid colors 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 the schematics, text and wiring diagrams in this manual will be correct less the stripe color; i.e. wire 425 yel/blk will become wire 425 yel. This will be a running change not associated with any serial number or model change.

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 Temperature Sender (SE6, W1)

S7—Dual Flasher Switch (SE8, W3)

B6—Engine Low Oil Pressure Switch and Oil Pressure Sender (SE6, W1) B7—Cold Start Switch (Model 250) (SE3, W4) E1—Left Front Work Light (SE7) E2—Right Front Work Light (SE7) E3—Left Tail Light (SE7) E4—Right Tail Light (SE7) E5—Rear Work Light (SE7) E6—Left Hazard Light (SE8) E7—Right Hazard Light (SE8) F1—Accessories Fuse (SE1, W1) F2—Seat Switch/Seat Belt Fuse (SE1, W1) F3—Key Switch Fuse (SE1, W1) F4—Interlock Fuse (SE3, W1) F5—Cab Heater Fuse (SE10, W7) F6—Backup Alarm Fuse (SE11, W8) G1—Battery (SE1) G2—Alternator (SE4, W1) H1—Instrument Cluster (SE6) H2—Backup Alarm (SE11, W8) K1—Start Relay (SE1, W1)

S8—High Flow Switch (SE9, W2) S9—Blower Switch (SE10, W5) S10—Backup Alarm Switch (Rear) (SE11, W8) S11—Backup Alarm Switch (Front) (SE11, W8) S12—Wiper/Washer Switch (SE12, W9) S13—Cab Door Switch (SE5) V1—High Flow Valve Diode (SE9, W1) W1—Engine Harness (with High Flow Option) W2—ROPS Harness (with High Flow Option) W3—Dual Flasher Harness (Optional) W4—Cold Start Wire Harness (Model 250) W5—Cab Heater/Defroster ROPS Harness (Optional) W6—Cab Heater/Defroster (Optional)

Heater

Unit

Harness

W7—Cab Heater/Defroster Engine Harness (Optional) W8—Backup Alarm Harness (Optional) W9—Wiper/Washer Harness (Optional) X1—Engine Harness-to-ROPS Harness Connector (SE1, SE2, SE3, SE4, SE7, SE9, W1, W2) X2—Engine Harness-to-ROPS Harness Connector (SE3, SE5, SE6, W1, W2) X3—Auto Preheat Connector (Optional) (SE2, W2)

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) M4—Wiper Motor (SE12, W9) M5—Washer Pump (SE12, W9)

X12—Accessory Ground Connector (SE8, W2, W3, W9)

R1—Manifold Preheater (SE2, W1)

X13—(12-Volt) Accessory Connector (ROPS) (SE7, 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

COMPONENT LOCATION

ELECTRICAL

COMPONENT LOCATION X17 Left Front Work Light Connector

X13 12-Volt Accessory Connector X12 Accessory Ground Connector

X2 Engine/ROPS Harness Connector

X15 Right Front Work Light Connector

X99 Interlock Connector

X20 Left Tail Light Connector X19 Rear Work Light Connector

X1 Engine/ROPS Harness Connector

X18 Right Tail Light Connector

B3 Hydraulic Oil Filter Restriction Switch

B1 Air Filter Restriction Switch

Ground

Y3 Boom Lock Solenoid

Y4 Park Brake Solenoid B5 Coolant Over Temperature Switch and Coolant Temperature Sender

K2 Preheat Relay

Y2 Bucket Lock Solenoid

Fuse Block

G2 Alternator Terminal B (-) K3 Fuel Relay

G2 Alternator Terminal B (+)

K1 Start Relay K4 Accessory Relay B4 Fuel Level Sender

M1 Starting Motor

B2 Hydraulic Overtemp Switch

G1 Battery

M2 Fuel Pump B6 Engine Low Oil Pressure Switch and Pressure Sender Cold Start Sender

11/22/00

X22 Accessory Ground Connector

Fuel Injection Pump

X11 12-Volt Accessory Connector KV13044

Y1 Fuel Shutoff Solenoid

4 - 11

COMPONENT LOCATION

ELECTRICAL

COMPONENT LOCATION (CONT) X12 Accessory Ground Connector

X99 Interlock Connector

S9 Blower Switch

S12 Wiper/Washer Switch

R3 Cab Heater Temperature Control Thermostat

M3 Blower

M4 Wiper Motor

X33 Door Switch Harness Connector

X27 Cab Heater ROPS Harness-to-Heater Harness Main Connector

X26 Cab Heater ROPS Harness-to-Heater Harness Thermostat Connector

S13 Cab Door Switch A1 Heater Control Circuit Board

H2 Backup Alarm

Y7 Cab Heater Temperature Control Valve X25 Cab Heater Engine Harness-to-ROPS Harness Connector

M5 Washer Pump

F5 Cab Heater Fuse (15A)

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 SCHEMATIC

ELECTRICAL

ELECTRICAL SCHEMATIC MAIN SCHEMATIC F1 Accessories Fuse 25 Amp 445 Yel

445 Yel 550 Yel/Wht 226 Red 720 Pur 725 Pur/Wht 708 Pur 706 Pur 231 Red 502 Yel

550 Yel/Wht 15 Amp

226 Red 720 Pur

F3 Key Switch Fuse

725 Pur/Wht

708 Pur 706 Pur 231 Red 550 Yel/Wht

5 Amp

500 Yel/Red

X2 (C1)

F2 Seat Switch Fuse

S1 Key Switch

225 Red

708 Pur

X1 (A2)

0,1,2

720 Pur

0 Acc

Engage

1 Off

Run B,C

7 5B

705 Pur 709 Pur

220 Red

S2 Park Brake Switch

140 Blk

512 Yel 515 Yel

813 Grn

1 4 3

802 Dk Grn

On Off

X3 To Auto Preheat (Optional)

560 Yel/Blk 931 Gry 701 Dk Blu

(2) 930 Gry

(3)

X2 (C5)

B7 Cold Start Switch (250 Only)

(3) 990 Wht

To Shutdown Module (Optional)

995 Gry/Blk 30 K3 Fuel 87 Relay 87a

(4) 700 Pur

(1) (2) 995 Gry/Blk

(1)

86 85

813 Grn 508 Yel

930 Gry

86 85

112 Blk

Fuse Link

130 Blk 200 Red 241 Red

Red B

240 Red

K2 Preheat Relay

141 Blk

R1 Manifold Preheater

Y6 Cold Start Advance Solenoid (250 Only)

372 Red

010 Blk

140 Blk

920 Red/Wht

M1 Starting Motor

373 Org

200 Red

Fuse Link

G1 Battery (12V)

722 Pur

504 Yel

S3 Manual Preheat Switch

X2 (C4)

251 Red

5 Amp

X1 (C2)

F4 Interlock Fuse

506 Yel

6 4

(A1)

503 Yel

X2 (C1)

X1 (A3) K1 30 Start Relay 87a 87

501 Yel

721 Pur

Release

3 Start

250 Red

225 Red

725 Pur/Wht 721 Pur

2 Run

706 Pur

502 Yel 501 Yel 503 Yel 508 Yel

505 Yel

116 Blk

200 Red

Y1 Fuel Shutoff Solenoid

M 114 Blk

X1 (C5) 108 Blk

655 Wht

M2 Fuel Pump

118 Blk

116 Blk

(B1)

Engine Ground

(C1)

001C Red

SE2 - PREHEAT CIRCUIT

SE1 - POWER AND CRANKING CIRCUIT

SE3 - FUEL CIRCUIT

KV31050

11/22/00

4 - 13

ELECTRICAL SCHEMATIC

ELECTRICAL

445 Yel 550 Yel/Wht

445 Yel 550 Yel/Wht 226 Red 720 Pur 725 Pur/Wht 708 Pur 706 Pur 231 Red 502 Yel

226 Red 720 Pur 725 Pur/Wht

708 Pur 511 Yel

706 Pur 452 Yel

452 Yel 502 Yel

502 Yel 501 Yel 503 Yel

(A1)

503 Yel

713 Pur

X1 (A1)

725 Pur/Wht 720 Pur

722 Pur

S5 Seat Belt Switch

Off

231 Red

711 Pur

Y2 Bucket Lock Solenoid

810 Dk Grn 2

232 Red

S4 Seat Switch

Off

X21

801 Pnk

Y4 Park Brake Solenoid

810Grn

X99 (A) Interlock Connector

991 Wht

X99 (B)

730 Pur/Wht

X2 (B4) 600 Brn

730 Pur 600 Brn

600 Brn

B–

708 Pur 750 Pur/Blk

(1)

X8 (D)

X6 (H)

X8 (F)

X10 Service Plug

750 (D) Pur/Blk

X6 (C)

X6 (D)

X6 (G)

X6 (B)

452 Yel

X6 (F)

H1 Instrument Cluster

X7 (G) X8 (C)

X7 (D)

X7 (A)

On Off

X7 (C) 325 Dk Grn/Wht

345 Pnk

X2 (A5)

452 Yel

X2 (A3) 325 Dk Grn/Wht

345 Pnk

126 Blk

X5 (1) R2 Alternator Resistor

X7 (B)

X8 (E)

335 Dk Grn

900 Blk/Wht

X2 (A4)

X2 (C3)

335 Dk Grn

900 Blk/Wht

X7 (E)

X7 (F)

X8 (B)

X8 (A)

620 Tan

625 Tan/Wht

X2 (A2)

X2 (B2)

X2 (B3)

300 Org/Wht 320 Org

620 Tan

625 Tan/Wht

300 Org/Wht 320 Org

X2 (A1)

P B1 Air Filter Restriction Switch

B2 Hydraulic Overtemperature Switch 105 Blk

102 Blk

106 Blk

(B1)

B3 Hydraulic Oil Filter Restriction Switch

t B4 Fuel Level Sender 104 Blk

B5 Engine Overtemperature Switch and Coolant Temperature Sender

(C1)

128 Blk

B6 Engine Low Oil Pressure Switch and Oil Pressure Sender

(B2)

(C2)

001C Red

SE4 - CHARGING CIRCUIT

(A) (B) (C)

510 Yel

X2 (B1)

100 Blk 101 Blk

X7 (H)

With Cab Door

47 Ohm

226 Red

X9 To Shutdown Module

X6 (E)

802 Dk Grn

X33 Door Switch (B) Harness Connector

X5 (2)

D+

740 Pur/Blk 800 Pnk

(A)

S13 Door Switch

Without Cab Door

G2 Alternator B+ 3

472 Dk Grn 470 Dk Grn

813 Grn

200 Red

X2 (B5) 740 Pur/Blk

802 Dk Grn

(3) (4)

X2 (C2)

715 Pur

(2) 960 Wht/Blk 970 Wht/Blu 126 Blk

741 Pur/Blk

230 Red

707 Pur

503 Yel

742 Pur/Blk

X21

Y3 Boom Lock Solenoid

001C Red

SE6 - GAUGES AND WARNING LIGHTS CIRCUIT

SE5 - BOOM/BUCKET LOCKOUT AND PARK BRAKE CIRCUIT

KV31051

4 - 14

11/22/00

ELECTRICAL SCHEMATIC

ELECTRICAL

460 Yel

445 Yel 550 Yel/Wht

460 Yel 455 Yel

455 Yel 003 Yel

003 Yel

000A Blk

000A Blk 511 Yel

511 Yel

502 Yel

460 Yel/Wht 86

S7 Dual Flasher Switch

X13 K4 85 Accessory Relay

87a 451 Yel/Wht

A Off

453 Yel/Wht

B Front Work/Tail Lights C Front/Rear Work/Tail Lights

A, B, C

A Off C On A, C

129 Blk

Indicator Light

Back Light

450 Yel/Wht

X1 (B2) 452 Yel

451 Yel/Wht

X99 (C)

7 450 Yel/Red 452 Yel

454 Yel

103 Blk 475 Brn/Wht

X22

X14

128 Blk

X11

12-Volt Accessory (Frame)

480 Yel/Red

K5 Dual Flasher Relay

473 Brn

S6 Work Lights Switch

X14

Accessory Ground (Frame)

482 Yel/Blk 481 Yel/Blk

476 Brn

470 Brn 471 Brn

126 Blk

477 Brn

127 Blk

X23A

X24A

110 Blk 103 Blk

E1 Left Front Work Light

E2 Right Front Work Light

X17

X15

E3 Left Tail Light

X15

X20 E4 Right Tail Light X20

X18 E5 Rear Work Light X18

X19 E6 Left Hazard Light

X19

E7 Right Hazard Light 129 Blk

101 Blk

X12 103 Blk

X23B

X24B

124 Blk 102 Blk

107 Blk

106 Blk

105 Blk 128 Blk

101 Blk

(B3)

(B2)

(C3)

(C2)

001C Red

SE7 - LIGHTS CIRCUIT

SE8 - DUAL FLASHER CIRCUIT KV31052

11/22/00

4 - 15

ELECTRICAL SCHEMATIC

ELECTRICAL

460 Yel

455 Yel 003 Yel 000A Blk 002 Red

511 Yel 502 Yel

A, B, C

Off

Run

S9 A, B, C Blower Switch

Off

Low

High 9

Back Light 2B

811 Pnk

5B 7

S8 High Flow Switch

812 Grn

Indicator Light

X1 (A4)

X26 (20)

812 Grn

000B Blk

87 87a 30

X25 (A)

K7 Cab Heater Relay

004 Yel

X25 (B)

X27 (D)

815 Grn

F6 Backup Alarm Fuse

F5 Cab Heater Fuse 15 Amp

008 Blu 013A Yel

S11 Backup Alarm Switch (Front)

010A Wht 450 Yel

011 Org

X27 (B)

013B Yel

001C Red

S10 Backup Alarm Switch (Rear)

000B Blk

814 Grn

V1 High Flow Valve Diode

005 Org

Off

M 119 Blk

Y5 High Flow Valve Solenoid

On 457 Yel

000A Blk A

142 Blk

A1 Heater Control Circuit Board

M3 Blower 000B Blk

109 Blk

101 Blk

On 458 Yel

001 Red

012 Red

004 Yel

H2 Backup Alarm

Off

X27 (E)

000A Blk

X1 (A5)

X16

85 001A Red

87a 813 Grn

455 Yel

X26 (18) 001B Red

X27 (C)

X26 (17)

R3 Cab Heater Indicator Thermostat Light

005 Org 003 Yel

Back Light

811 Pnk

K6 High Flow Relay

010A Wht 008 Blu 013A Yel 3 4

010B Wht

6 5 4 3 2 1

009 Grn

Y7 Cab Heater Temperature Control Valve

117 Blk

101 Blk

(B3)

(C3)

001C Red

SE9 - HIGH FLOW CIRCUIT

SE10 - CAB HEATER/DEFROSTER CIRCUIT

SE11 - BACKUP ALARM CIRCUIT

KV31053

4 - 16

11/22/00

ELECTRICAL SCHEMATICS

ELECTRICAL

460 Yel

S12 Wiper/Washer Switch A

Off

Wiper

Washer

Back 7 Light 5B

6 463 Yel/Blk 1 465 Yel/Red

2B 466 Yel

111 Blk

Indicator

10 Light

462 Yel 461 Yel/Wht 463 Yel/Blk

465 Yel/Red 4 466 Yel

M4 Wiper Motor

461 Yel/Wht

110 Blk B

M5 Washer Pump

W A

112 Blk

111 Blk

101 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 WIRE HARNESSES

ELECTRICAL

ELECTRICAL WIRE HARNESSES ENGINE WIRE HARNESS (W1) Termination Points

5.0 3.0

A3 = 705

B3 = Plug C3 = Plug

A4 = 811

B4 = Plug C4 = Plug

A5 = 812

B5 = Plug C5 = 116

M2 Fuel Pump

C2 = 501 814

B B

Blk Blk

102

0.8

Blk

B2 (B), Splice 1

103

2.0

Blk

X22, Splice 1

104

0.8

Blk

B4 (A), Splice 1

0.8

Blk

B1 (B), Splice 1

106

0.8

Blk

B3, Splice 1

108

0.8

Blk

K2, Splice 1

109

0.8

Blk

Y5 (B), Splice 1

110

0.8

Blk

K4 (85), Splice 1

112

0.8

Blk

K1 (85), Splice 1

114

0.8

Blk

K3 (85), Splice 1

116

2.0

Blk

X1 (C4), Splice 1

0.8

Blk

V1 (A), Splice 1

118

0.8

Blk

M2 (B), Splice 1

119

0.8

Blk

K6 (85), Splice 1

200

5.0

Red

M1, G2

220

5.0

Red

K1 (30), Splice 8

225

2.0

Red

F3, X1 (A2)

226

0.8

Red

F3, X10 (A)

231

0.8

Red

F2, X1 (A1)

240

8.0

Red

K2, Splice 7

241

3.0

Red Fuse Link

M1, Splice 7

250

5.0

Red

F2, Splice 8

251

2.0

Red Fuse Link

M1, Splice 8

Y1 Fuel Shutoff Solenoid

625

620

300

X16 High Flow Valve Diode Connector

X1 Harness Connector

320

B5 Engine Over Temperature Switch and Coolant Temperature Sender

Splice 1 512

110

501

112

Splice 2 515

511

114

510

116 118 452

451

812 813 814

101 102 105 106 108 109

711 713

117

454

119

X2 Harness Connector

713

742

104 450

711

Splice 6

722

Splice 5

Y2 Bucket Lock Solenoid

715

741

B4 Fuel Level Sender

900

Y3 Boom Lock Solenoid

Splice 9

103

Splice 3

104

815

741

742 740

X22 Accessory Ground (Frame)

103 5 5 5

1 A 1 B 1 C

705

Splice 4

708

709

454

Plug

300

0.8

Org/Wht

B5, X2 (A1)

320

0.8

Org

B5, X2 (A2)

A1 = 300

B1 = 600

C1 = 721

A2 = 320

B2 = 620

C2 = 750

A3 = 325

B3 = 625

C3 = 900

325

0.8

Dk Grn/Wht B2 (A), X2 (A3)

335

0.8

Dk Grn

B3, X2 (A4)

A4 = 335

B4 = 730

C4 = 930

345

0.8

Pink

B1 (A), X2 (A5)

A5 = 345

B5 = 740

C5 = 995

445

2.0

Yel

F1, K4 (30)

450

2.0

Yel/Wht

K4 (87), Splice 3

451

2.0

Yel/Wht

X1 (B2), Splice 3

452

0.8

Yel

X5 (1), Splice 3

454

2.0

Yel

X11, Splice 3

X11 12-Volt Accessory (Frame) 445

110

220

112

Plug

550 722

445

Fuse Block

4 - 19

250

721

F4 F1 F2 F3

750

708

510

X10 Service Plug

450

K4 Accessory Relay

231 225/226 D C B A

F1 = Accessories Fuse F2 = Seat Switch Fuse F3 = Key Switch Fuse F4 = Interlock Fuse

11/22/00

655

B A

117

B A

105

C 1 1 B 1 A

V1 High Flow Valve Diode

G2, Ground G2, Splice 1

B6 Engine Low Oil Pressure Switch and Pressure Sender

512

118

117

5 25 5 15

101

Color

(mm2)

B2 = 451

100

Wire Size

B1 = Plug C1 = 550

A2 = 225

Circuit Number

A1 = 231

114

515

Plug 700

709

K1 Start Relay

511

Plug

Plug 655

995

K3 Fuel Relay

119

811

813

K6 High Flow Relay (Optional)

226

KV18017A

ELECTRICAL WIRE HARNESSES

Ground

M1 Starting Motor Terminal B K2 Preheat Relay

100

700

M1 Starting Motor Terminal S

108

G2 Alternator Terminal B (–)

100/101

930

241

251

Splice 7

Splice 8 200

K2 920 Preheat Relay

250

240 220

G2 Alternator Terminal B (+)

200

240

920

R1 Manifold Preheater

X5 Alternator Resistor Connector 452 1 2 600 335

106

B3 Hydraulic Oil Filter Restriction Switch

A B

325

B2 Hydraulic Overtemp Switch

A B

102

345

105

B1 Air Filter Restriction Switch

815

A B

109

715

Y4 Park Brake Solenoid

730

Y5 High Flow Valve (Optional)

ELECTRICAL

Circuit Number

Wire Size mm2

Color

Termination Points

501

2.0

Yel

X1 (C2), Splice 2

510

0.8

Yel

X10 (B), Splice 2

511

0.8

Yel

Splice 2, K6 (87)

512

0.8

Yel

M2 (A), Splice 2

515

1.0

Yel

K3 (87), Splice 2

550

0.8

Yel/Wht

K4 (86), X1 (C1)

600

0.8

Brn

X2 (B1), X5 (2)

620

0.8

Tan

B6 (WK), X2 (B2)

625

0.8

Tan/Wht

B6 (G), X2 (B3)

655

1.0

Wht

K3 (87), Y1 (S)

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

721

0.8

Pur

X2 (C1), F4

722

0.8

Pur

F4, Splice 6

730

0.8

PurWht

Y4 (B), X2 (B4)

740

0.8

Pur/Blk

X2 (B5), Splice 5

741

0.8

Pur/Blk

Y2 (A), Splice 5

742

0.8

Pur/Blk

Y3 (A), Splice 5

750

0.8

Pur/Blk

X2 (C2), X10 (D)

811

0.8

Pink

X1 (A4), K6 (86)

812

0.8

Dk Grn

X1 (A5), Splice 9

813

0.8

Dk Grn

K6 (87), Splice 9

814

0.8

Dk Grn

V1 (B), Splice 9

815

0.8

Dk Grn

Y5 (A), Splice 9

900

0.8

Blk/Wht

B4 (B), X2 (C3)

920

8.0

Red/Wht

K2, R1

930

0.8

Gry

K2, X2 (C4)

995

0.8

Gry/Blk

K3 (86), X2 (C5)

KV18017B

4 - 20

11/22/00

ELECTRICAL WIRE HARNESSES

ELECTRICAL

ROPS WIRE HARNESS (W2) Circuit Number 101

Wire Size

Color

Termination Points

Switch Connector Terminal Numbering

(mm2) 1.0

Blk

X17 (B), Splice 2

7 4 5B

9 1 2B 3 10

102

1.0

Blk

X15 (B), Splice 2

103

1.0

Blk

S6, (7), Splice 2

105

1.0

Blk

X19 (B), Splice 2

106

1.0

Blk

X18 (B), Splice 2

107

1.0

Blk

X20 (B), Splice 2

116

2.0

Blk

X1 (C5), Splice 2

124

2.0

Blk

X12, Splice 2

126

0.8

Blk

X9 (1), Splice 2

128

0.8

Blk

X8 (C), Splice 2

130

0.8

Blk

X3 (2), Splice 2

140

0.8

Blk

S2 (7), Splice 2

141

0.8

Blk

S3 (7), Splice 2

142

0.8

Blk

S8, Splice 2

225

2.0

Red

S1, X1 (A2)

230

0.8

Red

X21 (A), S4 (1)

231

0.8

Red

S5 (2), X1 (A1)

232

0.8

Red

S5 (2), X21

300

0.8

Org/Wht

X2 (A1), X7 (E)

0.8

Org

325

0.8

Dk Grn/Wht X2 (A3), X7 (C)

335

0.8

Dk Grn

X2 (A4), X7 (B)

345

0.8

Pink

X2 (A5), X7 (A)

2.0

Yel/Red

S6 (5B), X99 (1)

451

2.0

Yel/Wht

X1 (B2), X13

452

1.0

Yel

S6 (2B), S6 (5B)

453

2.0

Yel/Wht

X13, X99 (1)

470

1.0

Brn

X17 (A), Splice 3 X15 (A), Splice 3

505

H J K

A = 345 B = 335 C = 325 D = 600 E = 300 F = 620 G = 730 H = 740

X7 Instrument Cluster Connector

A = 625 B = 320 C = 128 D = 503 E = 900 F = 707

X8 Instrument Cluster Connector

140 D C B A

S2 Park Brake Switch

725 141

G H

701

S3 Manual Preheat Switch

506

D E

C B A

931

500 225

S1 Key Switch 705/706

X2 (A2), X8 (B)

450

F G

X6 Instrument Cluster Connector

720/721 560

550

320

E D C B A

A = Plug B = 750 C = 970 D = 725 E = 802 F = 800 G = 720 H = 960 J = Plug K = Plug

Splice 1

560

471

500

501

504 505

503 502

128 140 141 126 130

506 508

A B

Splice 3

Splice 2

142

470 471 473

116 101 124 105 106 107

476 477

452

103

102 X15 Right Front Work Light Connector 802/813

126

142

502

706/707 130

701

S8 High Flow Switch (Optional)

S6 450/452 Work 103 Lights 475 Switch

508

X4 Shutdown Module Connector

811 995

471

1.0

Brn

473

1.0

Brn

S6 (3), Splice 3

475

1.0

Brn/Wht

S6 (6), X19 (A)

990

476

1.0

Brn

X18 (A), Splice 3

990

477

1.0

Brn

X20 (A), Splice 3

500

2.0

Yel/Red

S1 (2), Splice 1

960

970

X9 Shutdown Module Connector

930/931

812

473

452

470

X17 left Work Light Connector 101

504

X3 Auto Preheat Connector (Optional)

990

KV18018A

11/22/00

4 - 21

ELECTRICAL WIRE HARNESSES

5 5 5

1 A 1 B 1 C

5 5

X18 Right Tail Light

C 1 1 B 1 A

813

AB 232

800

503

0.8

Yel

X8 (D), Splice 1

504

0.8

Yel

X3 (4), Splice 1

505

0.8

Yel

S2 (5B), Splice 1

506

0.8

Yel

S3 (2B), Splice 1

(mm2)

508

0.8

Yel

X4 (2), Splice 1

476

550

0.8

Yel/Wht

S1 (4), X1 (C1)

106

560

0.8

Yel/Blk

S1(3), S2 (6)

600

0.8

Brn

X2 (B1), X7 (D)

475

620

0.8

Tan

X2 (B2), X7 (F)

105

625

0.8

Tan/Wht

X2 (B3), X6 (A)

701

0.8

Dk Blu

S3 (4), X3 (1)

705

0.8

Pur

S1 (5), X1 (A3)

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)

477

107

730

0.8

Pur

X2 (B4), X7 (G)

740

0.8

Pur/Blk

X2 (B5), X7 (H)

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)

802

0.8

Dk Grn

X4 (1), X6 (E)

810

0.8

Dk Grn

S5, X99 (2)

811

0.8

Pink

S8 (3), X1 (A4)

812

0.8

Dk Grn

X1 (A5), S8 (2B)

813

0.8

Dk Grn

X4 (1), X99 (3)

900

0.8

Blk/Wht

X2 (C3), X8 (E)

A1 = 300

B1 = 600

C1 = 721

A2 = 320

B2 = 620

C2 = 750

A3 = 325

B3 = 625

C3 = 900

930

0.8

Gry

X2 (C4), X3 (3)

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)

970

0.8

Wht/Blu

X6 (C), X9 (4)

990

0.8

Wht

X4 (2), X4 (3)

991

0.8

Wht

X99 (2), X99 (3)

995

0.8

Gry/Blk

X2 (C5), X4 (3)

810

X21 Seat Switch Pigtail Connector

S8 (5B), Splice 1

B5 = Plug C5 = 116

X99 Interlock Connector

991

Yel

B4 = Plug C4 = Plug

A5 = 812

450/453

232/231

0.8

A4 = 811

X2 Engine/ROPS Harness Connector

S5 Seat Belt Switch

502

501

X20 Left Tail Light

991

X1 (C2), Splice 1

B3 = Plug C3 = Plug

X12 Accessory Ground Connector (ROPS)

991

Yel

B2 = 451

A3 = 705

X19 Rear Work Light

810

2.0

A2 = 225

124

X13 12-Volt Accessory Connector (ROPS)

Termination Points

B1 = Plug C1 = 550 C2 = 501

Wire Size

Color

A1 = 231

X1 Engine/ROPS Harness Connector 451/ 453

Circuit Number

ELECTRICAL

S4 Seat Switch

801

230

801

230

KV18018B

4 - 22

11/22/00

ELECTRICAL WIRE HARNESSES

ELECTRICAL

DUAL FLASHER WIRE HARNESS (W3) 126

460

X13 12-Volt Accessory (ROPS)

X12 Accessory Ground (ROPS)

Switch Connector Terminal Numbering 7 4

9 1

K5 Dual Flasher Relay 480

126 127

481 482

481

129

Right Hazard Light Connectors

X24B

X23A

X24A

X23B

Left Hazard Light Connectors

127 128

482

S7 Dual Flasher Switch

128 129

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

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 Terminal Numbering

000B 001B

002

7 4 5B

S9 Blower Switch

9 1 2B 3

001B F

E D

B C

X26 Thermostat Connector ROPS-to-Heater

013A

008 Empty 010A

010A

013A

Wire Size

Color

Termination Points

Blk

X25(B), X27(D)

(mm2) 3.0

000B

0.8

Blk

X27(D), S9(7)

001A

3.0

Red

X25(A), S9(2B)

001B

3.0

Red

S9(5B), X27(E)

002

0.8

Red

R3(C), S9(9)

004

2.0

Yel

S9(3), X27(B)

005

3.0

Org

S9(6), X27(C)

008

0.8

Blu

R3(B), X26(17)

010A

0.8

Wht

R3(A), X26(18)

013A

0.8

Yel

R3(D), X26(20)

013A/013B

012 011

X25 Harness Connector

A B C D

002

000A

ROPS Harness (W5)

004

008

004

X27 Main Connector ROPS-to-Heater

005

000A/000B

001A

005

Circuit Number

Empty

010A/010B

R3 Cab Thermostat

001A

A B 000A

009

001

000B

008

A1 012 Empty Empty

004 001B

A B

001C

001C X28 Starter B+

F5 Heater Fuse (15A)

001A

005

Engine Harness (W7)

000A Engine Harness (W7)

Color

Termination Points

(mm2)

000A

3.0

Blk

X25(A), X29

000B

0.8

Blk

X22, K7(85)

001A

3.0

Red

K7(30), X25(A)

001B

3.0

Red

F5(A), K7(87)

001C

3.0

Red

X28, F5(B)

003

0.8

Yel

X11, K7(86)

X11 12-Volt Accessory (Frame)

X22 Accessory Ground (Frame) 001A K7 Cab Heater Relay

000B 85 87A

003

11/22/00

011

Empty

001B

4 - 25

ABCDEFGH

000A/ 000B

M3 Blower

000A X30

Heater Unit Harness (W6) 17

013A Empty 010A

Circuit Number 000A

004

008

003

Wire Size

001

009 013B 010B Y7 Heater Valve

X29 Engine Ground

A B

Circuit Number

F E D

1 2 3

X27 Main Connector ROPS-to-Heater

X25 Harness Connector

000A

A B C

6 5 4

Heater Control Circuit Board

Wire Size

X26 Thermostat Connector ROPS-to-Heater

Color

(mm2) 3.0

Blk

X31 X32

Termination Points

Circuit Number

X27(D), X30

010A

Wire Size

Color

Termination Points

0.8

Wht

X26(18), A1(B)

(mm2)

000B

0.8

Blk

X27(D), A1(A)

010B

0.8

Wht

A1(B), Y7(3)

001

1.0

Red

X27(E), A1(D)

011

0.8

Org

A1(F), Y7(4)

004

2.0

Yel

X27(B), X31

012

0.8

Red

A1(E), Y7(6)

005

3.0

Org

X27(C), X32

013A

0.8

Yel

X26(20), A1(C)

008

0.8

Blu

X26(17), A1(H)

013B

0.8

Yel

A1(C), Y7(2)

009

0.8

Blu

A1(G), Y7(1)

005

KV31055

ELECTRICAL WIRE HARNESSES

BACKUP ALARM WIRE HARNESS (W8)

450 A B

456

X11 12-Volt Accessory (Frame)

455/456 F6 Backup Alarm Fuse 10 amp

455

101 – H2 Backup Alarm 100 + 458

X22 Accessory Ground (Frame)

100/101

457

Circuit Number

450 S10 Backup Alarm Switch (Rear)

B 458

A 457

S11 Backup Alarm Switch (Front)

Wire Size

Color

Termination Points

(mm2)

100

2.0

Blk

X22, X22

101

0.8

Blk

X22, H2(–)

450

0.8

Yel

F6(A), S10(A)

455

2.0

Yel

X11, F6(B)

456

2.0

Yel

X11, F6(B)

457

0.8

Yel

S10(B), S11(A)

458

0.8

Yel

S11(B), H2(+)

KV31080

4 - 26

11/22/00

ELECTRICAL WIRE HARNESSES

ELECTRICAL

WIPER/WASHER WIRE HARNESS (W9) 460

472

X99 Interlock Connector

470

100

100/101

X12 Accessory Ground

Switch Connector Terminal Numbering 7 4

9 1

465 111

461/462

460/466

470

X33 Door Switch Harness Connector

463

S12 Wiper/Washer Switch

472

462

465

466

4 1

461

5 6 2 3

M4 Wiper Motor

Blank Blank 110

101 110 111 Splice 1 112

Circuit Number

Wire Size

Color

Termination 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)

470

0.8

Dk Grn

X99(B), X33(B)

472

0.8

Dk Grn

X99(A), X33(A)

11/22/00

M5 Washer Pump 463

B A 112

KV31081

4 - 27

TROUBLESHOOTING CHART

ELECTRICAL

Test battery and connections

See charging circuit diagnosis

See lights circuit diagnosis See hydraulic boom and bucket lockout circuit diagnosis

See preheat circuit diagnosis

Check fuel shutoff solenoid circuit See fuel circuit diagnosis

See power circuit diagnosis

Check fuel pump ground circuit

See appropriate circuit diagnosis indicated by warning light that is on

4 - 28

Boom/bucket control not working properly

Fuel shutoff solenoid not working properly

Road/work lights do not operate

Hour meter does not operate

Fuel pump will not run

Engine will not shut off

Preheater not working properly

Warning lamps or fuel gauge stay on or will not light

See cranking circuit diagnosis

Engine will not start

Check or Solution

Engine will not crank

Problem or Symptom

Battery not charging or overcharging

TROUBLESHOOTING CHART

z z z

z z

11/22/00

ELECTRICAL

THEORY OF OPERATION AND DIAGNOSIS

THEORY OF OPERATION AND DIAGNOSIS NOTE: Beginning in 2001, all wires will be solid colors 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 the schematics, text and wiring diagrams in this manual will be correct less the stripe color; i.e. wire 425 yel/blk will become wire 425 yel. This will be a running change not associated with any serial number or model change.

POWER AND CRANKING CIRCUIT OPERATION UNSWITCHED POWER CIRCUITS Function: Provide power to the primary machine components whenever the battery is connected. Operating Conditions: Voltage must be present at the following components with the key switch in the OFF position: • Terminal B of starting motor (M1) • Terminal 30 of start relay (K1) • Terminal 30 of accessory relay (K4) • Terminal 1 of the seat switch (S4) • Terminal 2 of seat belt switch (S5) • Terminal A of the service plug (X10) • Terminal 1 of the key switch (S1) • Terminal V1 of the preheat relay (K2) • Terminal B+ of Alternator (G2) Theory of Operation: 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 current drain and is then routed through wire 250 red to fuses F1, F2, and F3. From fuse F3, power goes to terminal 1 of the key switch (S1). SWITCHED POWER CIRCUIT Function: Provides power to primary components depending on the position of the key switch (S1).

11/22/00

Operating Conditions: Voltage must be present at terminal 1 of the key switch (S1). Theory of Operation: With the key switch (S1) in the RUN position, voltage is present at the following components: • Terminal 86 (coil) of the accessory relay (K4) • Terminal 23 of manual preheat switch (S3) • Terminal 5B of the park brake switch (S2) • Terminal 30 of the fuel relay (K3) • Fuel pump (M2 • Terminal B of service plug (X10) • Terminal 4 of auto preheat connector (X3) • Terminal 5B of high-flow switch (S8) • Terminal 30 of high-flow relay (K6) • Terminal G of instrument cluster connector (X6) • Terminal 2 of shutdown module( X4) With the key switch (S1) in the ACCESSORY position, voltage is present at terminal 86 (coil) of the accessory relay (K4). CRANKING CIRCUIT Function: To energize the starting motor (M1) and crank the engine. Operating Conditions: To crank the engine, the park brake switch (S2) must be in the ENGAGE position and the key switch (S1) must be in the START position. Theory of Operation: With the key switch (S1) in the START position, current from terminal 1 flows out terminal 2 through wire 500 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 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 start relay energizes and current flows through its contacts to the solenoid of the starting motor (M1) and the starting motor cranks.

4 - 29

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

This page intentionally left blank.

4 - 30

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

POWER AND CRANKING CIRCUIT SCHEMATIC

To Accessory Relay Contacts

445 Yel

F1 Accessory Fuse 231 Red

To Seat Belt and Seat Switches

F2 Seat Switch Fuse 226 Red

To Service Plug

F3 Key Switch Fuse

S1 Key Switch

550 Yel/Wht

225 Red

To Accessory Relay Coil

0 Accessory 1 Off

C Engage

2 Run

X1 (A2)

3 Start

S2 Park Brake Switch

0,1,2 4

B Run B,C

250 Red

A Release

7 225 Red

500 Yel/Red

505 Yel

6 5B 140 Blk

705 Pur

To Preheat Relay

3 560 Yel/Blk

X1 (A3)

706 Pur

X9 (2)

Shutdown Module Connector 707 Pur

705 Pur

240 Red

708 Pur 709 Pur

220 Red

251 Red Fuse Link

241 Red Fuse Link

700 Pur

Red B

G1 Battery

M Engine Ground

11/22/00

K1 Start Relay

M1 Starting Motor

Service Plug

Unswitched Power 87

85 112 Blk

X10 (C)

To X8 (F) on H1 Instrument Cluster

Switched Power Ground Circuit

KV15154

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) start relay.

Battery voltage.

Test wire 220 red and 251 red to (K1) start 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) engine/ROPS harness connector.

Battery voltage.

Test wire 225 red between (F3) key switch fuse and (X1) engine/ROPS harness connector.

9. Wire 225 red at terminal A2 on (X1) engine/ROPS harness connector.

Battery voltage.

Test connector (X1) engine/ROPS harness connector. Make sure wires are properly crimped in the terminals.

10. Wire 225 red at terminal 1 on (S1) key switch.

Battery voltage.

Test wire 225 red between (X1) engine/ROPS harness connector and (S1) key switch.

4 - 32

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL Test Conditions: • Park Brake Switch in ENGAGE position. • Key switch in RUN position. Test/Check Point

Normal

11. Wire 500 yel/red at terminal 2 on (S1) key switch.

Battery voltage.

Replace (S1) key switch.

12. Wire 550 yel/wht at terminal 4 on (S1) key switch.

Battery voltage.

Replace (S1) key switch.

13. Wire 505 yel at terminal 5B on (S2) park brake switch.

Battery voltage. Park brake switch back lighting is on.

If battery voltage is not present, test wires 500 yel/red and 505 yel between (S1) key switch and (S2) park brake switch.

14. Wire 560 yel/blk at terminal 3 on (S1) key switch.

Battery voltage.

Test wire 560 yel/blk from (S1) key switch to (S2) park brake switch.

15. Wire 560 yel/blk wire at terminal 6 on (S2) park brake switch.

Battery voltage.

Replace (S2) park brake switch.

11/22/00

If Not Normal

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.

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 (S1) key switch.

Battery voltage.

Replace (S1) key switch.

17. Wire 705 pur at terminal A3 on (X1) engine/ROPS harness connector.

Battery voltage.

Test wire 705 pur from (S1) key switch to (X1) engine/ROPS harness connector.

18. Wire 705 pur at terminal A3 on (X1) engine/ROPS harness connector

Battery voltage.

Test connector (X1) engine/ROPS harness connector. Make sure wires are properly crimped in the terminals.

19. Wire 709 pur at terminal 86 on (K1) start relay.

Battery voltage.

Test wires 709 pur and 705 pur between (X1) engine/ROPS harness connector and (K1) start relay.

20. Wire 700 pur at terminal 87 on (K1) start relay.

Battery voltage.

Test (K1) start relay. If relay is good, test ground circuit wire 112 blk from (K1) start relay to ground.

21. Wire 700 pur at terminal S on (M1) starting motor.

Battery voltage. (M1) starting motor cranks.

If battery voltage is not present, test wire 700 pur. If battery voltage is present and (M1) starting motor does not crank, check starting motor-toengine 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

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

POWER AND CRANKING CIRCUIT TEST POINTS S2 Park Brake Switch

13 To Accessory Relay 550 Yel/Wht S1 Key Switch

14 500 Yel/Red

505 Yel

G2 Alternator

140 Blk

560 Yel/Blk

100 Blk

16 10 17

705 Pur

15 225 Red

8 101 Blk

18 X1 Engine/ROPS Harness Connector 225 Red 116 Blk

705 Pur K1 Start Relay

220 Red

709 Pur

6 250 Red

20 112 Blk

F4 F1

700 Pur

4 251 Red Fuse Link

F2 F3

1 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:

To energize the fuel shutoff solenoid which allows fuel flow through the fuel injector pump.

To provide current to the manifold preheater (R1). Operating Conditions:

Operating Conditions: Voltage must be present at the fuel pump (M2), terminal 86 of the fuel relay (K3), and at fuel shut-off solenoid (Y1) when the key switch is in the START or RUN position.

Voltage must be present at one terminal of the preheat relay (K2), regardless of the position of the key switch (S1). Voltage must be present at terminal 2B of the manual preheat switch (S3) when the key switch is in the START or RUN position.

Theory of Operation:

Current to terminal 30 of the fuel relay (K3) is supplied by wires 515 yel. With the key switch (S1) in the START or RUN position, current flows to the fuel pump (M2) and terminal 86 (coil) of the fuel relay (K3) energizing the fuel pump and coil of the fuel relay. With the fuel relay energized, current flows to the fuel shutoff solenoid (Y1) which allows fuel to flow through the fuel injection pump.

While holding the manual preheat switch (S3) in the ON position, current flows to the primary terminal (coil) of the preheat relay (K2). The preheat relay energizes and current flows to the manifold preheater (R1) and heats the air entering the engine to make starting easier.

4 - 36

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

FUEL AND PREHEAT CIRCUIT SCHEMATIC 500 Yel/Red

To Key Switch

506 Yel

S3 Manual Preheat Switch

To Starting Motor

501 Yel

2B 4 3

504 Yel

On Off

508 Yel

141 Blk

241 Red Fuse Link

931 Gry

701 Dk Blu

(1) (2) (3)

Auto Preheat (Option)

515 Yel

512 Yel

990 Wht

3 995 Gry/Blk

X2 (C5)

(4)

240 Red

995 Gry/Blk

930 Gry

K2 Preheat Relay

130 Blk

M2 Fuel Pump

K3 Fuel Relay

118 Blk

114 Blk

108 Blk 920 Red/Wht

R1 Manifold Preheater

655 Wht

Y1 Fuel Shutoff Solenoid

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) engine/ROPS harness connector.

Battery voltage.

Test wire 225 red between (F3) key switch fuse and (X1) engine/ROPS harness connector.

6. Wire 225 red at terminal A2 on (X1) engine/ROPS harness connector.

Battery voltage.

Test connector (X1) engine/ROPS harness connector. Make sure wires are properly crimped in the terminals.

7. Wire 225 red at terminal 1 on (S1) key switch.

Battery voltage.

Test wire 225 red between (X1) engine/ROPS 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

8. Wire 500 yel/red at terminal 2 on (S1) key switch.

Battery voltage.

4 - 38

If Not Normal Replace (S1) key switch.

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL Test Conditions: • Engine stopped. • Key switch in RUN position. Test/Check Point

Normal

If Not Normal

9. Wire 500 yel/red at terminal 2 on (S1) key switch.

Battery voltage.

Replace (S1) key switch.

10. Wire 508 yel at terminal 2 on (X4) shutdown module connector.

Battery voltage.

Test wires 508 yel and 500 yel/red between (S1) key switch and (X4) shutdown module connector.

11. Wire 995 gry/blk at terminal 3 on (X4) shutdown module connector.

Battery voltage.

Test (X4) shutdown module connector and wire 990 wht. Make sure wires are properly crimped in terminals. Repair wire and/or replace connector as necessary.

12. Wire 995 gry/blk at terminal C5 on (X2) engine/ROPS harness connector.

Battery voltage.

Test wire 995 gry/blk between (X4) Shutdown module connector and (X2) engine/ROPS harness connector.

13. Wire 995 gry/blk at terminal C5 on (X2) engine/ROPS harness connector.

Battery voltage.

Test (X2) engine/ROPS harness connector. Make sure wires are properly crimped in the terminals.

14. Wire 995 gry/blk at terminal 86 on (K3) fuel relay.

Battery voltage.

Test wire 995 gry/blk between (X2) engine/ ROPS harness connector and (K3) fuel relay.

15. Wire 501 yel at terminal C2 on (X1) engine/ROPS harness connector.

Battery voltage.

Test wires 501 yel and 500 yel/red between (X1) engine/ROPS harness connector and (s1) key switch.

16. Wire 501 yel at terminal C2 on (X1) engine/ROPS harness connector.

Battery voltage.

Test connector (X1) engine/ROPS harness connector. Make sure wires are properly crimped in the terminals.

17. Wire 515 yel at terminal 30 on (K3) fuel relay.

Battery voltage.

Test wire 515 yel between (X1) engine/ROPS harness connector and (K3) fuel relay.

18. Wire 655 wht at terminal 87 on (K3) fuel relay.

Battery voltage.

Test ground circuit wire 114 blk to ground. If ground circuit is good, test (K3) fuel relay. Replace relay as necessary.

19. Wire 655 wht at (Y1) fuel shutoff solenoid.

Battery voltage. Solenoid clicks when wire is removed and connected.

If battery voltage is not present, test wire 655 wht between (Y1) fuel shutoff solenoid and (K3) fuel relay. If battery voltage is present and solenoid does not click, replace (Y1) fuel shutoff solenoid.

20. Wire 512 yel at (M2) fuel pump.

Battery voltage. Fuel pump running (listen).

If battery voltage is not present, test wires 512 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

500 Yel/Red

7 508 Yel

X1 Engine/ROPS Harness Connector

501 Yel

M2 Fuel Pump

225 Red

990 Wht

512 Yel

X4 Shutdown Module Connector

995 Gry/Blk

501 Yel X2 Engine/ROPS Harness Connector

118 Blk

16 225 Red

515 Yel

995 Gry/Blk

19 655 Wht

14 17

114 Blk

101 Blk

F2 F3 250 Red

118 Blk

K3 Fuel Relay

Y1 Fuel Shutoff Solenoid

100 Blk

18 G2 Alternator

251 Red Fuse Link

Red

M1 Starting Motor

KV31062

4 - 40

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

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) engine/ROPS harness connector.

Battery voltage.

Test wire 225 red between (F3) key switch fuse and (X1) engine/ROPS harness connector.

7. Wire 225 red at terminal A2 on (X1) engine/ROPS harness connector.

Battery voltage.

Test connector (X1) engine/ROPS harness connector. Make sure wires are properly crimped in the terminals.

8. Wire 225 red at terminal 1 on (S1) key switch.

Battery voltage.

Test wire 225 red between (X1) engine/ROPS harness connector and (s1) key switch.

Test Conditions:

Normal

9. Wire 500 yel/red at terminal 2 on (S1) key switch.

Battery voltage.

11/22/00

If Not Normal Replace (S1) key switch.

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 on (S1) key switch.

Battery voltage.

Replace (S1) key switch.

11. Wire 506 yel at terminal 2B on (S3) manual preheat switch.

Battery voltage. Manual preheat switch back lighting is on.

If battery voltage is not present, test wires 500 yel/red and 506 yel between (S1) key switch 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 (S3) manual preheat switch.

Battery voltage.

Replace (S3) manual preheat switch.

13. Wire 931gry at terminal 3 on (X3) auto preheat connector.

Battery voltage.

Test wire 931 gry between (S3) manual preheat switch and (X3) auto preheat connector.

14. Wire 930 gry at terminal C4 on (X2) engine/ROPS harness connector.

Battery voltage.

Test wire 930 gry between (X3) auto preheat connector and (X2) engine/ROPS harness connector.

15. Wire 930 gry at terminal C4 on (X2) engine/ROPS harness connector.

Battery voltage.

Test connector (X2) engine/ROPS harness connector. Make sure wires are properly crimped in the terminals.

16. Wire 930 gry on (K2) preheat relay.

Battery voltage.

Test wire 930 gry between (X2) engine/ROPS harness connector and (K2) preheat relay.

17. Wire 920 red/wht on (K2) preheat relay.

Battery voltage.

Test ground circuit wire 108 blk from (K2) preheat relay to ground. If ground circuit is good, test (K2) preheat relay. Replace relay as necessary.

18. Wire 920 red/wht at (R1) manifold preheater.

Battery voltage. Manifold preheater gets hot.

If battery voltage is not present, test wire 920 red/wht between (R1) manifold preheater and (K2) preheat relay. If battery voltage is present and manifold preheater does not get hot, replace (R1) manifold preheater.

4 - 42

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

PREHEAT CIRCUIT TEST POINTS

S1 Key Switch

9 10

S3 Manual Preheat Switch

8 500 Yel/Red 506 Yel

225 Red

141 Blk

X1 Engine/ROPS Harness Connector

100 Blk

G2 Alternator

116 Blk 931 Gry

X2 Engine/ROPS 14 Harness Connector

130 Blk

101 Blk

930 Gry 116 Blk

R1 Manifold Preheater

225 Red F4

F1 F2

X3 Auto Preheat Connector

920 Red/Wht

930 Gry 240 Red

108 Blk

K2 Preheat Relay

250 Red

251 Red Fuse Link

241 Red Fuse Link

Red

M1 Starting Motor

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— 14.2 volts (while charging).

When the key switch (S1) is in the RUN position, the 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+ of the alternator to the common tie point on the starting motor (M1) and then to the positive terminal of the battery (G1). The charge rate is regulated by an external regulator on the alternator.

Operating Conditions: The engine must be running for the charging circuit to charge the battery.

4 - 44

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

CHARGING CIRCUIT SCHEMATIC

To F3 Key Switch Fuse

To F1 Accessories Fuse

S1 Key Switch

0 Accessory 1 Off 2 Run 3 Start 0, 1, 2 550 Yel/Wht

225 Red

445 Yel

K4 Accessory Relay

86 85

30 87 87a 451 Yel/Wht

110 Blk 450 Yel/Wht

200 Red

G2 Alternator R2 Alternator G Resistor X5 (1) D+ B+ 47 Ohm

BRed

X5 (2)

G1 Battery

M1 Starting Motor

452 Yel

454 Yel

To Lights and Accessories

To Instrument Panel

100 Blk

Unswitched Power

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) alternator.

Battery voltage.

Test wire 200 red from (M1) starting motor to (G2) alternator.

Normal

If Not Normal

Maximum 0.1 ohm.

Test wire 100 blk between (G2) alternator and ground and battery negative (–) cable between (G1) battery and ground.

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) engine/ROPS harness connector.

Battery voltage.

Test wire 225 red between (F3) key switch fuse and (X1) engine/ROPS harness connector.

8. Wire 225 red at terminal A2 on (X1) engine/ROPS harness connector.

Battery voltage.

Test connector (X1) engine/ROPS harness connector. Make sure wires are properly crimped in the terminals.

9. Wire 225 red at terminal 1 on (S1) key switch.

Battery voltage.

Test wire 225 red between (X1) engine/ROPS harness connector and (S1) key switch.

Test/Check Point

Normal

If Not Normal

10. Wire 550 yel/wht at terminal 4 on (S1) key switch.

Battery voltage.

Test Conditions: • Test meter set to read resistance (ohms). Test/Check Point 4. B– terminal on (G2) alternator.

Test Conditions: • Test meter set to read DC voltage.

Test Conditions: • Key switch in RUN position.

4 - 46

Replace (S1) key switch.

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL Test Conditions: • Key switch in ACCESSORY position. Test/Check Point

Normal

If Not Normal

11. Wire 550 yel/wht at terminal 4 on (S1) key switch.

Battery voltage.

Replace (S1) key switch.

12. Wire 550 yel/wht at terminal C1 on (X1) engine/ROPS harness connector.

Battery voltage.

Test wire 550 yel/wht between (S1) key switch and (X1) engine/ROPS harness connector.

13. Wire 550 yel/wht at terminal C1 on (X1) engine/ROPS harness connector.

Battery voltage.

Test (X1) engine/ROPS harness connector and make sure wires are properly crimped in the terminals.

14. Wire 550 yel/wht at terminal 86 on (K4) accessory relay.

Battery voltage.

Test wire 550 yel/wht between (K4) accessory 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) accessory relay.

Battery voltage.

Test wire 445 yel between (F1) accessories fuse and (K4) accessory relay.

17. Wire 450 yel/wht at terminal 87 on (K4) accessory relay.

Battery voltage.

Test ground circuit wire 110 blk from (K4) 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 connector.

Battery voltage.

Test wires 452 yel and 450 yel/wht between (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 19. (R2) alternator resistor.

Normal 47 ± 0.5 ohm.

If Not Normal 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

10 11

550 Yel/Wht

12 7

X1 Engine/ROPS Harness Connector

225 Red 445 Yel

K4 Accessory Relay

550 Yel/Wht

445 Yel

14 16

450 Yel/Wht

15 F4

452 Yel

110 Blk

X5 Alternator Resistor Connector

F2 F3

Red

101 Blk

600 Brn

To Discharge Light

G2 Alternator

100 Blk

250 Red

200 Red

251 Red Fuse Link

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:

To disable and enable boom and bucket functions.

To engage and release the park brake.

Operating Conditions:

The operator must sit on the seat, fasten the seat belt, and release the park brake switch in order for the boom and bucket circuit to operate.

The operator must first sit on the seat and then fasten the seat belt in order for the park brake to release. Theory of Operation:

Theory of Operation: The seat belt switch (S5) receives current from the seat switch/seat belt fuse (F2) through wire 231 red. Current is also supplied to the seat switch (S4) through wires 232 red and 230 red. When the operator sits on the seat, the seat switch closes and current flows to the instrument cluster through wires 800 pnk and 801 pnk. When the operator fastens the seat belt, the seat belt switch closes and current flows to the instrument cluster through wire 810 dk grn, 991 wht, 813 dk grn, and 802 dk grn. If the machine has a cab door, cab door switch (S13) is connected in place of wire 991 wht. On models with a cab door switch (S13) mounted in the front, the cab door switch (S13) is a normally open switch that is activated when the door is closed. Unless the door is fully closed and latched, the circuit will be open and the boom and bucket lockout will remain activated. On models with a cab door switch (S13) mounted in the rear, the cab door switch (S13) is a normally closed switch. When the door is fully open, it contacts the door switch (S13) and opens the circuit causing the boom and bucket lockout to remain activated. When the key switch (S1) is in the RUN or START position and the park brake switch (S2) is in the RUN (middle detent) position, the instrument cluster provides ground for the bucket lock solenoid (Y2) and boom lock solenoid (Y3) through wires 740 pur/blk, 741 pur/blk, and 742 pur/blk to the instrument cluster. The ground circuit is completed through the instrument cluster wire 128 blk allowing the solenoids to energize.

11/22/00

The seat belt switch (S5) receives current from the seat switch/seat belt fuse (F2) through wire 231 red. Current is also supplied to the seat switch (S4) through wires 232 red and 230 red. When the operator sits on the seat, the seat switch closes and current flows to the instrument cluster through wires 801 pnk and 800 pnk. When the operator fastens the seat belt, the seat belt switch closes and current flows to the instrument cluster through wire 810 dk grn, 991 wht, 813 dk grn, and 802 dk grn. If the machine has a cab door, door switch (S13) is connected in place of wire 991 wht. On models with a cab door switch (S13) mounted in the front, the cab door switch (S13) is a normally open switch that is activated when the door is closed. Unless the door is fully closed and latched, the circuit will be open causing the brake solenoid switch to remain deactivated (brake engaged). On models with a cab door switch (S13) mounted in the rear, the cab door switch (S13) is a normally closed switch. When the door is fully open, it contacts the door switch (S13) and opens the circuit causing the brake solenoid to remain deactivated (brake engaged). When the key switch (S1) is in the RUN or START position and the park brake switch (S2) is in the RUN (middle detent) position after being pushed to the RELEASED (momentary) position, the instrument cluster provides ground for the park brake solenoid (Y4) through wire 730 pur. The ground circuit is completed through the instrument cluster wire 128 blk, thus allowing the solenoid to energize.

4 - 49

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT SCHEMATIC F2 Seat Switch/ Seat Belt Fuse

X33 Door Switch Harness Connector 231 Red

S13 Cab Door Switch

S4 Seat Switch

801 Pnk

Off

F3 Key Switch Fuse

1 472 Dk Grn 470 Dk Grn

With Cab Door

225 Red

S5 Seat Belt Switch

991 Wht

232 Red

810 Dk Grn

S1 Key Switch

X4 (1) Shutdown Module Connector

813 Dk Grn

X99 Interlock Connector

Without Cab Door

X21 Seat Switch Pigtail Connector

230 Red

800 Pnk

503 Yel 802 Dk Grn

0 Accessories 1 Off 2 Run 3 Start

S2 Park Brake B,C Switch

0,1,2 4

1 5

500 Yel/Red

505 Yel

C Engage B Run A Release

X8 (D)

7 6 4

140 Blk 725 Pur/Wht

1 3

X6 (D)

721 Pur

F4 Interlock Fuse

X6 (E)

X6 (F)

Instrument Cluster X8 (C)

X7 (G)

X7 (H)

128 Blk

711 Pur

722 Pur

713 Pur 715 Pur

Y2 Bucket Lock Solenoid 741 Pur/Blk

Y3 Boom Lock Solenoid

Y4 Park Brake Solenoid 730 Pur

742 Pur/Blk 740 Pur/Blk

Unswitched Power Switched Power Input to Instrument Panel from Seat, Seat Belt and Door Switches Input to Instrument Panel from Park Brake Switch

Boom and Bucket Lock Solenoids and Park Brake Solenoid Power Boom and Bucket Lock Solenoids Ground from Instrument Panel Park Brake Solenoid Ground from Instrument Panel Ground Circuit KV15157

4 - 50

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

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) engine/ROPS harness connector.

Battery voltage.

Test wire 225 red between (F3) key switch fuse and (X1) engine/ROPS harness connector.

6. Wire 225 red at terminal A2 on (X1) engine/ROPS harness connector.

Battery voltage.

Test connector (X1) engine/ROPS harness connector. Make sure wires are properly crimped in the terminals.

7. Wire 225 red at terminal 1 on (S1) key switch.

Battery voltage.

Test wire 225 red between (S1) key switch and (X1) engine/ROPS harness connector.

Normal

If Not Normal

Test Conditions: • Test meter set to read resistance (ohms). Test/Check Point 8. Wire 128 blk at terminal C on (X8) instrument cluster connector.

11/22/00

Maximum 0.1 Ohm.

Test wire 128 blk from (X8) instrument cluster connector to ground.

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 on (S1) key switch.

Battery voltage.

Replace (S1) key switch.

10. Wire 505 yel at terminal 5B on (S2) park brake switch.

Battery voltage. (S2) park brake switch back lighting is on.

If battery voltage not present, test wires 500 yel/red and 505 yel between (S1) key switch 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 (X8) instrument cluster connector.

Battery voltage.

Test wires 503 yel/red and 500 yel between (X8) Instrument cluster connector and (S1) key switch.

12. Wire 231 red at (F2) seat switch/seat belt fuse.

Battery voltage.

Test (F2) seat switch/seat belt fuse. Replace if necessary.

13. Wire 231 red at terminal A1 on (X1) engine/ROPS harness connector.

Battery voltage.

Test wire 231 red between (F2) Seat Switch/ seat belt fuse and (X1) engine/ROPS harness connector.

14. Wire 231 red at terminal A1 on (X1) engine/ROPS harness connector.

Battery voltage.

Test connector (X1) Engine/ROPS harness connector. Make sure wires are properly crimped in the terminals.

15. Wire 231 red on (S5) seat belt switch.

Battery voltage.

Test wire 231 red between (S5) seat belt switch and (X1) engine/ROPS harness connector.

16. Wire 230 red on (S4) seat switch.

Battery voltage.

Test wires 230 red and 232 red between (S5) seat belt switch and (S4) seat switch.

4 - 52

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL 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) seat switch.

Battery voltage.

Replace (S4) seat switch.

18. Wire 800 pnk at terminal F on (X6) instrument cluster connector.

Battery voltage.

Test wire 800 pnk and 801 pnk between (S4) seat switch and (X6) instrument cluster connector.

19. Wire 810 dk grn at terminal 1 on (S5) seat belt switch.

Battery voltage.

Replace (S5) seat belt switch.

20. Wire 810 dk grn at terminal A on (X99) interlock connector.

Battery voltage.

Test wire 810 dk grn between (X99) interlock connector and (S5) seat belt switch.

21. Wire 813 dk grn at terminal B on (X99) interlock connector.

Battery voltage.

Replace 991 wht jumper. 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) shutdown module connector.

Battery voltage.

Test wire 813 dk grn between (X4) shutdown module connector and (X99) interlock connector.

23. Wire 802 dk grn at terminal E on (X6) instrument cluster connector.

Battery voltage.

Test wire 802 dk grn between (X4) shutdown 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) park brake switch.

Battery voltage.

If battery voltage is present at terminal 5B on (S2) park brake switch, replace switch.

25. Wire 725 pur/wht at terminal D on (X6) instrument cluster connector.

Battery voltage.

Test wire 725 pur/wht between (S2) park brake 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 brake switch.

Battery voltage.

If battery voltage is present at terminal 5B on (S2) park brake switch, replace switch.

27. Wire 721 pur at terminal C1 on (X2) engine/ROPS harness connector.

Battery voltage.

Test wire 721 pur from (S2) park brake switch to (X2) engine/ROPS harness connector.

28. Wire 721 pur at terminal C1 on (X2) Engine/ROPS Harness Connector.

Battery voltage.

Test connector (X2) Engine/ROPS Harness 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 solenoid.

Battery voltage.

Test wires 711 pur and 722 pur between (Y2) bucket lock solenoid and (F4) interlock fuse.

32. Wire 713 pur on (Y3) boom lock solenoid.

Battery voltage.

Test wires 713 pur and 722 pur between (Y3) boom lock solenoid and (F4) interlock fuse.

33. Wire 715 pur on (Y4) park brake solenoid.

Battery voltage.

Test wires 715 pur and 722 pur between (Y4) 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 34. Wires 741 pur/blk on (Y2) bucket lock solenoid and 740 pur/blk at terminal H on (X7) instrument cluster connector.

Normal Maximum 0.1 ohms.

If Not Normal If no continuity in wire, repair or replace engine/ ROPS harness. 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 solenoid and 740 pur/blk at terminal H on (X7) instrument cluster connector.

Maximum 0.1 ohms.

If no continuity in wire, repair or replace engine/ ROPS harness. 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 solenoid and at terminal G on (X7) instrument cluster connector.

Maximum 0.1 ohms.

If no continuity in wire, repair or replace engine/ ROPS harness. 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

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT TEST POINTS

S1 Key Switch

S4 Seat Switch

H1 Instrument Cluster

S5 Seat Belt Switch

230 Red

S2 Park Brake Switch

801 Pnk

15 232

Red

500 Yel/Red 810 Dk Grn

X99 Interlock Connector

26 10

Instrument Cluster Connectors

725 Pur/Wht 503 Yel

36 721 Pur

21 20 813 Dk Grn

470 Dk Grn

730 Pur

14 5

22 X4 Shutdown Module Connector

802 Dk Grn 740 Pur/Blk

116 Blk

G2 Alternator

231 Red

29 30

116 Blk

721 Pur

741 Pur/Blk

S13 Cab Door Switch

225 Red

Y2 Bucket Lock Solenoid

740 Pur/Blk

X1 Engine/ROPS Harness Connector

100 Blk

X2 Engine/ROPS Harness Connector

X33 Door Switch Harness Connector

470 Dk Grn 472 Dk Grn

128 Blk

25 23

231 Red 472 Dk Grn

35 34

225 Red

991 Wht

505 Yel

800 Pnk

140 Blk

24 11

250 Red

721 Pur

F1 101 Blk

742 Pur/Blk

Y3 Boom Lock Solenoid

730 Pur

711 Pur

32 Y4 Park Brake Solenoid

4 251 Red Fuse Link

Red

713 Pur 715 Pur

F3 722 Pur

M1 Starting Motor

KV31065

11/22/00

4 - 55

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

GAUGES AND WARNING LIGHTS CIRCUIT OPERATION Function: To provide the total time of machine operation (hour meter), monitor and provide a visual indication (warning lights and gauges) of vital machine functions. The functions that are monitored are: * Battery voltage * Battery discharge * Air filter restriction * Hydraulic overtemperature * Hydraulic oil filter restriction * Fuel level * Engine overtemperature * Oil pressure * Low oil pressure * Engine coolant temperature * Machine hours * Occupancy * Brake

Air Filter Restriction – When the engine air filter becomes restricted, air filter restriction switch (B1) closes and completes a ground, using wires 345 pnk and 105 blk and the air filter restriction warning light comes on. Hydraulic Overtemperature – When the hydraulic oil overheats, hydraulic overtemperature switch (B2) closes and completes a ground using wires 325 dk grn/ wht and 102 blk and the hydraulic oil overtemperature warning light comes on. The overtemp switch closes when temperature rises to 104.5°C ± 2.8°C (220°F ± 5°F). The overtemperature switch opens when temperature lowers to 87.9°C ± 2.8°C (190°F ± 5°F). Hydraulic Oil Filter Restriction – When the hydraulic oil filter becomes restricted, hydraulic oil filter restriction switch (B3) closes and completes a ground using wires 335 dk grn and 106 blk and the hydraulic filter restriction warning light comes on. The restriction switch closes when oil pressure increases to 275.8 ± 27.6 kPa (40 ± 4 psi). The restriction switch opens when oil pressure decreases to 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 position for the instrument cluster (H1) to monitor the above functions.

NOTE: The engine must be running for time to accumulate on the hour meter. Theory of Operation: When the key switch (S1) is in the RUN or START position, current flows to the instrument cluster (H1) on wire 503 yel to provide power for operation. Ground to the instrument cluster is provided by wire 128 blk. The gauges and warning lights theory of operation are as follows: Battery Voltage - The battery voltage as measured on connector X8 pin D is displayed by the battery voltmeter on the instrument cluster. Battery Discharge - Battery discharge is detected on wire 600 brn at connector X7 pin D and turns on the battery discharge warning light.

4 - 56

NOTE: Fuel Level – The fuel level sender (B4) is a variable resistor that varies with the fuel level in the fuel tank and is used to control the fuel gauge. The fuel level sender is connected to the instrument cluster (H1), using wire 900 blk/wht and is grounded by wire 104 blk. The fuel sender resistance will be 29—33 ohms when fuel tank is full and 244—250 ohms when fuel tank is empty. Engine Coolant Temperature – The engine overtemperature switch and coolant temperature sender (B5) houses two components and controls both the engine coolant temperature gauge and overtemperature light. It is grounded directly to the engine block. The coolant temperature sender portion is a variable resistor that varies with the engine coolant temperature and is connected to the instrument cluster (H1) using wire 320 org.

11/22/00

ELECTRICAL

THEORY OF OPERATION AND DIAGNOSIS

The engine Engine Overtemperature – overtemperature switch and coolant temperature sender (B5) houses two components and controls both the engine coolant temperature gauge and overtemperature light. It is grounded directly to the engine block. When the engine overheats, the switch closes and connects the instrument cluster (H1) to ground using wire 300 org/wht. When this ground is completed, the engine overtemperature warning light comes on.

Engine Low Oil Pressure – The low oil pressure switch and oil pressure sender (B6) is grounded directly to the engine block. The switch portion is a normally closed switch and uses oil pressure to open, causing the engine oil pressure warning light to not light. If the oil pressure becomes too low, the switch closes and connects the instrument cluster (H1) to ground using wire 620 tan, and the engine oil pressure warning light comes on.

The engine overtemperature switch closes when coolant temperature rises to 116.2°C (241°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.

The oil pressure switch closes when pressure decreases to 80 kPa ± 30.4 kPa (11.6 psi ± 4.4 psi) during normal operating temperature [–25°C—100°C (–13°F—212°F)].

Oil Pressure Sender Pressure/Resistance

11/22/00

Pressure

Resistance (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

4 - 57

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

This page intentionally left blank.

4 - 58

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

GAUGES AND WARNING LIGHTS CIRCUIT SCHEMATIC F3 Key Switch Fuse 15 Amp

503 Yel

X9 (2) Shutdown Module Connector

720 Pur 505 Yel

5 Amp F2 Seat Switch/ Seat Belt Fuse

725 Pur/Wht 706 Pur

Engage

707 Pur

Run

225 Red

706 Pur

Release B,C 7 5B

X1 (A2) S2 Park Brake Switch

231 Red

8 4

140 Blk

X8 (D)

X6 (F)

800 Pnk

S1 Key Switch

H1 Instrument Cluster

X6 (E)

1 Off

X8 (C)

2 Run 0,1,2

225 Red

600 Brn

3 Start

X7 (D)

X7 (A)

1 231 Red 5

X7 (C)

345 Pnk

To Alternator D+ Terminal

X2 (A5)

X2 (A3)

345 Pnk 802 Dk Grn

Off

S4 Seat Switch

801 Pnk

Off

S5 Seat Belt Switch

On 1 2

t°

105 Blk

230 Red 102 Blk

X8 (E)

335 Dk Grn

X2 (A4) 325 Dk Grn/Wht

P B1 Air Filter Restriction Switch

X7 (B)

325 Dk Grn/Wht

X21

X8 (F)

X6 (G)

706 Pur 500 Yel/Red

0 Acc

X1 (A1)

X6 (D)

900 Blk/Wht

X2 (C3) 335 Dk Grn

P B2 Hydraulic Over Temperature Switch 106 Blk

X8 (B)

X7 (F)

300 Org/Wht

320 Org

620 Tan

X2 (A2)

X2 (A1) 900 Blk/Wht

300 Org/Wht

t°

Q B3 Hydraulic Oil Filter Restriction 104 Blk Switch

X7 (E)

B4 Fuel Level Sender

X2 (B2)

B5 Engine Over Temperature Switch and Coolant Temperature Sender

128 Blk

625 Tan/Wht

X2 (B3) 620 Tan

320 Org

t°

X8 (A)

625 Tan/Wht

B6 Engine Low Oil Pressure Switch and Oil Pressure Sender

X21 232 Red

802 Dk Grn

813 Dk Grn 810 Dk Grn

X4 (1)

X99

Unswitched Power

Alternator Input Circuit

Switched Power

Sensor Circuit

Seat and Seat Belt

Park Brake Switch Circuit

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 on (S1) key switch.

Battery voltage.

Replace (S1) key switch.

3. Wire 503 yel at terminal D on (X8) instrument cluster connector.

Battery voltage.

Test wires 503 yel and 500 yel/red between (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 4. Wire 128 blk at terminal C on (X8) instrument cluster connector.

Normal Maximum 0.1 ohms.

If Not Normal Test wire 128 blk from (X8) instrument cluster connector to ground.

Test Conditions: • Test meter set to read DC voltage. Test/Check Point 5. Wire 231 red on (F2) seat switch/seat belt fuse.

Normal Battery voltage.

If Not Normal Test (F2) seat switch/seat belt fuse. Replace if necessary. If fuse is good, see POWER AND CRANKING CIRCUIT DIAGNOSIS in this section.

6. Wire 231 red at terminal A1 on (X1) engine/ROPS harness connector.

Battery voltage.

Test wire 231 red between (F2) seat switch/seat belt fuse and (X1) engine/ROPS harness connector.

7. Wire 231 red at terminal A1 on (X1) engine/ROPS harness connector.

Battery voltage.

Test connector (X1) engine/ROPS harness connector. Make sure wires are properly crimped in the terminals.

8. Wire 231 red at terminal 2 on (S5) seat belt switch.

Battery voltage.

Test wire 231 red between (X1) engine/ROPS harness connector and (S5) seat belt switch.

9. Wire 230 red at terminal 1 on (S4) seat switch.

Battery voltage.

Test wire 230 red and 232 red between (S4) seat switch and (S5) seat belt switch, including terminals at X21 seat switch pigtail connector.

4 - 60

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL 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 (S4) seat switch.

Battery voltage.

Replace (S4) seat switch.

11. Wire 800 pnk at terminal F on (X6) instrument cluster connector.

Battery voltage.

Test wire 800 pnk and 801 pnk between (X6) instrument cluster connector and (S4) seat switch.

12. Wire 810 dk grn at terminal 1 on (S5) seat belt switch.

Battery voltage.

Replace (S5) seat belt switch.

13. Wire 810 dk grn at terminal A on (X99) interlock connector.

Battery voltage.

Test wire 810 dk grn between (X99) interlock connector and (S5) seat belt switch.

14. Wire 813 dk grn at (X99) interlock connector.

Battery voltage.

Replace 991 wht jumper. 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 on (X4) shutdown module connector.

Battery voltage.

Test wire 813 dk grn between (X4) shutdown module connector and (X99) interlock connector.

16. Wire 802 dk grn at terminal E on (X6) instrument cluster connector.

Battery voltage.

Test wire 802 dk grn between (X6) instrument cluster connector and (X4) shutdown module 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

S13 Cab Door Switch

472 Grn

S4 Seat Switch

X33 Door Switch Harness Connector

9 801 Pnk

8 H1 Instrument Cluster

S5 Seat Belt Switch

472 Grn

X99 Interlock Connector 14 X4 Shutdown Module Connector

230 Red

232 Red

991 Wht 13

470 Grn

500 Yel/Red

810 Dk Grn 813 Dk Grn

15 3

800 Pnk

231 Red

11 X6

470 Grn

S1 Key Switch

503 Yel

100 Blk

4 7

802 Dk Grn

X1 Engine/ROPS Harness Connector

128 Blk Instrument Cluster Connectors 16

101 Blk

G2 Alternator

116 Blk 231 Red 116 Blk

5 F4 F1 F2 F3

KV31066

4 - 62

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

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 on (S1) key switch.

Battery voltage.

Replace (S1) key switch.

3. Wire 503 yel at terminal D on (X8) instrument cluster connector.

Battery voltage.

Test wires 503 yel and 500 yel/red between (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 4. Wire 128 blk at terminal C on (X8) instrument cluster connector.

Normal Maximum 0.1 ohms.

If Not Normal Test wire 128 blk from (X8) instrument cluster 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 (S2) park brake switch.

Battery voltage. Park switch light is on. Park brake light is on.

If battery voltage is not present, test wires 505 yel and 500 yel/red between (S2) park brake 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 on (S2) park brake switch.

Battery voltage.

If battery voltage is present at terminal 5B on (S2) park brake switch, replace switch.

7. Wire 725 pur/wht at terminal D on (X6) instrument cluster connector.

Battery voltage. Park brake warning light goes out.

Test wire 725 pur/wht between (X6) instrument cluster connector and (S2) park brake switch. 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 (S2) park brake switch.

Battery voltage.

Replace (S2) park brake switch.

9. Wire 720 pur at terminal G on (X6) instrument cluster connector.

Battery voltage.

If battery voltage is not present, test wire 720 pur between (X6) instrument cluster connector and (S2) park brake switch.

4 - 64

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

PARK BRAKE SWITCH AND WARNING LIGHT CIRCUIT TEST POINTS

S1 Key Switch

H1 Instrument Cluster

1 S2 Park Brake Switch

8 500 Yel/Red

5 3

725 Pur/Wht

505 Yel

503 Yel

Instrument Cluster Connectors

140 Blk 128 Blk

720 Pur

X1 Engine/ROPS Harness Connector

7 116 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 on (S1) key switch.

Battery voltage.

Replace (S1) key switch.

3. Wire 503 yel at terminal D on (X8) instrument cluster connector.

Battery voltage.

Test wires 503 yel and 500 yel/red between (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) instrument cluster connector.

Maximum 0.1 ohms.

Test wire 128 blk from (X8) instrument cluster connector to ground.

5. Wire 105 blk on harness side of connector to (B1) air filter restriction switch.

Maximum 0.1 ohms.

Test wire 105 blk from (B1) air filter restriction switch to ground.

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 6. Air filter restriction warning light.

Normal Warning light comes on.

If Not Normal If warning light comes on, test (B1) air filter 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

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

AIR FILTER RESTRICTION WARNING LIGHT CIRCUIT TEST POINTS

S1 Key Switch

H1 Instrument Cluster

1 3

500 Yel/Red X7

503 Yel

128 Blk

345 Pnk Instrument Cluster Connectors

X1 Engine/ROPS Harness Connector

116 Blk X2 Engine/ROPS Harness Connector

B1 Air Filter Restriction Switch

116 Blk 345 Pnk 105 Blk

101 Blk 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 on (S1) key switch.

Battery voltage.

Replace (S1) key switch.

3. Wire 503 yel at terminal D on (X8) instrument cluster connector.

Battery voltage.

Test wires 503 yel and 500 yel/red between (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) instrument cluster connector.

Maximum 0.1 ohms.

Test wire 128 blk from (X8) instrument cluster connector to ground.

5. Wire 102 blk on harness side of connector to (B2) hydraulic overtemperature switch.

Maximum 0.1 ohms.

Test wire 102 blk from (B2) hydraulic overtemperature switch to ground.

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 6. Hydraulic overtemperature warning light.

4 - 68

Normal

If Not Normal

Warning light comes on.

If warning light comes on, test (B2) hydraulic 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. 11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

HYDRAULIC OIL OVERTEMPERATURE WARNING LIGHT CIRCUIT TEST POINTS

6 S1 Key Switch

2 H1 Instrument Cluster

500 Yel/Red X7

503 Yel

128 Blk 325 Dk Grn/Wht Instrument Cluster Connectors X2 Engine/ROPS Harness Connector

B2 Hydraulic Oil Overtemperature Switch

116 Blk

X1 Engine/ROPS Harness Connector

116 Blk 325 Dk Grn/Wht

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 on (S1) key switch.

Battery voltage.

Replace (S1) key switch.

3. Wire 503 yel at terminal D on (X8) instrument cluster connector.

Battery voltage.

Test wires 503 yel and 500 yel/red between (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) instrument cluster connector.

Maximum 0.1 ohms.

Test wire 128 blk from (X8) instrument cluster connector to ground.

5. Wire 106 blk at ring terminal on hydraulic filter housing ground.

Maximum 0.1 ohms.

Test wire 106 blk from (B3) hydraulic oil filter 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 6. Hydraulic filter restriction warning light.

Normal

If Not Normal

Warning light comes on.

If warning light comes on, test (B3) hydraulic oil 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

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

HYDRAULIC FILTER RESTRICTION WARNING LIGHT CIRCUIT TEST POINTS

6 S1 Key Switch

2 H1 Instrument Cluster

500 Yel/Red X7

503 Yel

128 Blk Instrument Cluster Connectors

335 Dk Grn 116 Blk X2 Engine/ROPS Harness Connector

B3 Hydraulic Oil Filter Restriction Switch

X1 Engine/ROPS Harness Connector

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 on (S1) key switch.

Battery voltage.

Replace (S1) key switch.

3. Wire 503 yel at terminal D on (X8) instrument cluster connector.

Battery voltage.

Test wires 503 yel and 500 yel/red between (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) instrument cluster connector.

Maximum 0.1 ohms.

Repair or replace wire 128 blk from (X8) instrument cluster connector to ground.

5. Wire 104 blk at connector of (B4) fuel level sender.

Maximum 0.1 ohms.

Repair or replace wire 104 blk from (B4) fuel level sender to ground.

6. Wire 900 blk/wht between (B4) fuel level sender and terminal C3 at (X2) engine/ROPS harness connector.

Maximum 0.1 ohms.

Repair or replace wire 900 blk/wht between (B4) fuel level sender and (X2) engine/ROPS harness connector.

7. Wire 900 blk/wht between C3 on (X2) engine/ROPS harness connector and terminal E on (X8) instrument cluster connector.

Maximum 0.1 ohms.

Repair or replace wire 900 blk/wht between (X2) engine/ROPS harness connector and terminal E on (X8) instrument cluster 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 8. Terminal A to Terminal B of (B4) fuel level sender.

4 - 72

Normal Between 33—240 ohms.

If Not Normal Replace (B4) fuel level sender.

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL Test Conditions: • Disconnect the wire harness from the fuel level sender. • Key switch in RUN position. Test/Check Point 9. Fuel gauge.

Normal Gauge indicates empty.

If Not Normal 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 10. Fuel gauge.

11/22/00

Normal Gauge indicates full.

If Not Normal Replace (H1) instrument cluster.

4 - 73

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

FUEL GAUGE CIRCUIT TEST POINTS

9 10

S1 Key Switch

2 H1 Instrument Cluster

Instrument Cluster Connectors

500 Yel/Red

503 Yel

7 128 Blk

900 Blk/Wht

5 104 Blk

B4 Fuel Level Sender

7 X2 Engine/ROPS Harness Connector

116 Blk

X1 Engine/ROPS Harness Connector

6 9

8 8

900 Blk/Wht 116 Blk

101 Blk G2 Alternator 100 Blk

4 5

KV15197

4 - 74

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

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 on (S1) key switch.

Battery voltage.

Replace (S1) key switch.

3. Wire 503 yel at terminal D on (X8) instrument cluster connector.

Battery voltage.

Test wires 503 yel and 500 yel/red between (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 4. Wire 128 blk at terminal C on (X8) instrument cluster connector.

Normal Maximum 0.1 ohms.

If Not Normal Test wire 128 blk from (X8) instrument cluster 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 5. Engine overtemperature warning light.

Normal Warning light comes on.

If Not Normal If warning light comes on, test (B5) engine 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 Instrument Cluster

2 3 1

500 Yel/Red X7

4 503 Yel

X6 Instrument Cluster Connectors

128 Blk X1 Engine/ROPS Harness Connector

320 Org 116 Blk X2 Engine/ROPS Harness Connector 300 Org/Wht

B5 Engine Overtemperature Switch and Coolant Temperature Sender

116 Blk 300 Org/Wht 101 Blk 320 Org

G2 Alternator 100 Blk

KV15196

4 - 76

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

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 on (S1) key switch.

Battery voltage.

Replace (S1) key switch.

3. Wire 503 yel at terminal D on (X8) instrument cluster connector.

Battery voltage.

Test wires 503 yel and 500 yel/red between (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 4. Wire 128 blk at terminal C on (X8) instrument cluster connector.

11/22/00

Normal Maximum 0.1 ohms.

If Not Normal Test wire 128 blk from (X8) instrument cluster connector to ground.

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 (X8) instrument cluster connector.

Battery voltage.

Replace (H1) instrument cluster.

6. Wire 320 org at terminal A2 on (X2) engine/ROPS harness connector.

Battery voltage.

Test wire 320 org between (H1) instrument cluster and (X2) engine/ROPS harness connector.

7. Wire 320 org at terminal A2 on (X2) engine/ROPS harness connector.

Battery voltage.

Test (X2) engine/ROPS harness connector. Make sure wires are properly crimped in the terminals.

8. Wire 320 org at (B5) engine overtemperature switch and coolant temperature sender.

Battery voltage.

Test wire 320 org between (X2) engine/ROPS harness connector and (B5) engine 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

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

COOLANT TEMPERATURE GAUGE CIRCUIT TEST POINTS

S1 Key Switch H1 Instrument Cluster

2 3 1

500 Yel/Red X7

4 503 Yel

Instrument Cluster Connectors

128 Blk X1 Engine/ROPS Harness Connector

320 Org

116 Blk X2 Engine/ROPS Harness Connector 300 Org/Wht

116 Blk

B5 Engine Overtemperature Switch and Coolant Temperature Sender

300 Org/Wht 101 Blk 320 Org

G2 Alternator 100 Blk

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. • 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

NOTE: If wire 500 yel/red has not voltage, neither will instrument cluster or any warning lights.

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 (S1) key switch.

Battery voltage.

Replace (S1) key switch.

3. Wire 503 yel at terminal D on (X8) instrument cluster connector.

Battery voltage.

Test wires 503 yel and 500 yel/red between (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) Instrument cluster connector.

Maximum 0.1 ohms.

Test wire 128 blk from (X8) instrument cluster 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 5. Engine oil pressure warning light.

Normal Light is not on.

If Not Normal 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 on.

Test (B6) engine low oil pressure switch and oil 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

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

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

X1 Engine/ROPS Harness Connector

Instrument Cluster Connectors 116 Blk

620 Tan 625 Tan/Wht

X2 Engine/ROPS Harness Connector 116 Blk 101 Blk

G2 Alternator

625 Tan/Wht B6 Engine Low Oil Pressure Switch and Oil Pressure Sender

100 Blk 620 Tan

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 on (S1) key switch.

Battery voltage.

Replace (S1) key switch.

3. Wire 503 yel at terminal D on (X8) instrument cluster connector.

Battery voltage.

Test wires 503 yel and 500 yel/red between (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 4. Wire 128 blk at terminal C on (X8) instrument cluster connector.

Normal Maximum 0.1 ohm.

If Not Normal Test wire 128 blk from (X8) instrument cluster connector to ground.

Test Conditions: • Key switch in RUN position. • Test meter set to read DC voltage. Test/Check Point

Normal

5. Wire 625 tan/wht at terminal A on (X8) instrument cluster connector.

Approximately 6 volts.

Replace (H1) instrument cluster.

6. Wire 625 tan/wht at terminal B3 on (X2) engine/ROPS harness connector.

Approximately 6 volts.

Test wire 625 tan/wht between (H1) instrument cluster and (X2) engine/ROPS harness connector.

7. Wire 625 tan/wht at terminal B3 on (X2) engine/ROPS harness connector.

Approximately 6 volts.

Test (X2) engine/ROPS harness connector. Make sure wires are properly crimped in the terminals.

8. Wire 625 tan/wht at (B6) engine low oil pressure switch and oil pressure sender.

Approximately 6 volts.

Test wire 625 tan/wht between (X2) engine/ ROPS harness connector and (B6) engine low oil pressure switch and oil pressure sender.

4 - 82

If Not Normal

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL 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

9. Engine oil pressure gauge.

Gauge indicates LOW pressure.

If Not Normal If gauge does not indicate LOW 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 Key Switch

2 H1 Instrument Cluster

1 500 Yel/Red

3 X8 503 Yel X7

4 X6

128 Blk X1 Engine/ROPS Harness Connector

Instrument Cluster Connectors

116 Blk

620 Tan 625 Tan/Wht

6 X2 Engine/ROPS Harness Connector

116 Blk 101 Blk

G2 Alternator

625 Tan/Wht 100 Blk

B6 Engine Low Oil Pressure Switch and Oil Pressure Sender

620 Tan

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

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

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 1. Wire 142 blk at harness connector from (S8) high flow switch.

Normal Maximum 0.1 ohms.

If Not Normal Test ground circuit wire 142 blk from (S8) high flow switch to ground.

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 on (S1) key switch.

Battery voltage.

Replace (S1) key switch.

4. Wire 502 yel at terminal 5B on (S8) high flow switch.

Battery voltage.

If voltage is not present, test wires 502 yel and 500 yel/red between (S1) key switch and (S8) high flow switch.

High flow switch back 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 (X1) engine/ROPS harness connector (ROPS side).

Battery voltage.

Test wires 500 yel/red and 501 yel between (S1) key switch and (X1) engine/ROPS harness connector.

6. Wire 501 yel at terminal C2 on (X1) engine/ROPS harness connector (engine side).

Battery voltage.

Test (X1) engine/ROPS harness connector. Make sure wires are properly crimped in the terminals.

7. Wire 511 yel at terminal 30 on (K6) high flow relay.

Battery voltage.

Test wires 501 yel and 511 yel between (K6) 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 (S8) high flow switch.

Battery voltage.

Replace (S8) high flow switch.

9. Wire 811 pnk at terminal A4 on (X1) engine/ROPS harness connector (ROPS side).

Battery voltage.

Test wire 811 pnk between (S8) high flow switch and (X1) engine/ROPS harness connector.

10. Wire 811 pnk at terminal A4 on (X1) engine/ROPS harness connector (engine side).

Battery voltage.

Test (X1) engine/ROPS harness connector. Make sure wires are properly crimped in the terminals.

11. Wire 811 pnk at terminal 86 on (K6) high flow relay.

Battery voltage.

Test wire 811 pnk between (K6) high flow relay and (X1) engine/ROPS harness connector.

High flow switch indicator light is on.

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 on (K6) high flow relay.

Battery voltage.

Test ground circuit wire 119 blk from (K6) high flow relay to ground. If ground circuit is good, replace relay.

13. Wire 812 dk grn at terminal A5 on (X1) engine/ROPS harness connector (engine side).

Battery voltage.

Test wires 812 dk grn and 813 dk grn between (X1) engine/ROPS harness connector and (K6) high flow relay.

14. Wire 812 dk grn at terminal A5 on (X1) engine/ROPS harness connector (ROPS side).

Battery voltage.

Test (X1) engine/ROPS harness connector and make sure wires are properly crimped in the terminals.

15. Wire 812 dk grn at terminal 2B on (S8) high flow switch.

Battery voltage.

Test wire 812 dk grn between (X1) engine/ ROPS harness connector and (S8) high flow switch.

16. Wire 811 pnk at terminal 3 on (S8) high flow switch.

Battery voltage.

Replace (S8) high flow switch.

17. Wire 815 dk grn at (Y5) high flow valve solenoid.

Battery voltage.

If voltage is not present, test wires 815 dk grn and 813 dk grn between (Y5) high flow valve solenoid and (K6) high flow relay.

4 - 88

Valve is energized. (Test by holding a metal screwdriver next to it. If energized, the screwdriver will be pulled toward it.)

If voltage is present and valve is not energized, test ground circuit wire 109 blk from (Y5) high flow valve solenoid to ground. If ground circuit is good, replace valve.

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL 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 18. (V1) high flow valve diode.

Normal Continuity or no continuity.

If Not Normal Replace (V1) high flow valve diode.

Test Conditions: • Reverse the test meter leads. Test/Check Point 19. (V1) high flow valve diode.

11/22/00

Normal Opposite of step 18.

If Not Normal Replace (V1) high flow valve diode.

4 - 89

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

HIGH FLOW CIRCUIT TEST POINTS

S1 Key Switch

500 Yel/Red S8 High Flow Switch

502 Yel

9 812 Dk Grn

5 501 Yel 811 Pnk

142 Blk

8 16

X1 Engine/ROPS Harness Connector

116 Blk

6 14 13

K6 High Flow Relay

V1 High Flow Valve Diode

11 501 Yel

7 Y5 High Flow Valve Solenoid

812 Dk Grn

811 Pnk

511 Yel

814 Dk Grn

12 117 Blk

119 Blk

116 Blk

813 Dk Grn

4 100 Blk 101 Blk

815 Dk Grn

G2 Alternator

109 Blk

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

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

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) key switch.

Battery voltage.

Replace (S1) key switch.

3. Wire 550 yel/wht at terminal 4 on (S1) key switch.

Battery voltage.

Replace (S1) key switch.

4. Wire 550 yel/wht at terminal C1 on (X1) engine/ROPS harness connector (ROPS side).

Battery voltage.

Test wire 550 yel/wht between (S1) key switch and (X1) engine/ROPS harness connector.

5. Wire 550 yel/wht at terminal C1 on (X1) engine/ROPS harness connector (engine side).

Battery voltage.

Test connector (X1) engine/ROPS harness connector and make sure wires are properly crimped in the terminals.

6. Wire 550 yel/wht at terminal 86 on (K4) accessory relay.

Battery voltage.

Test wire 550 yel/wht between (K4) accessory 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) accessory relay.

Battery voltage.

Test ground circuit wire 110 blk from (K4) accessory relay to ground. If ground circuit is good, replace relay.

9. Wire 451 yel/wht at terminal B2 on (X1) engine/ROPS harness connector (engine side).

Battery voltage.

Test wires 450 yel/wht and 451 yel/wht between (X1) engine/ROPS harness connector and (K4) accessory relay.

10. Wire 451 yel/wht at terminal B2 on (X1) engine/ROPS harness connector (ROPS side).

Battery voltage.

Test connector (X1) engine/ROPS harness connector. Make sure wires are properly crimped in the terminals.

11. Wire 451 yel/wht and 453 yel/wht at (X13) 12-volt accessory connector.

Battery voltage.

Test wire 451 yel/wht between (X1) engine/ ROPS harness connector and (X13) 12-volt accessory connector.

12. Wire 453 yel/wht at terminal C on (X99) interlock connector.

Battery voltage.

Test wire 453 yel/wht between (X99) Interlock connector and (X13) 12-volt accessory connector.

13. Wire 450 yel/red at terminal 5B on (S6) work lights switch.

Battery voltage.

If voltage is not present, test wire 450 yel/red between (X99) interlock connector and (S6) work lights switch. If voltage is present and back lighting is not on, check 103 blk ground. If good, replace switch.

14. Wire 452 yel at terminal 2B on (S6) work lights switch.

Battery voltage.

Test Conditions: • Key switch in ACCESSORIES position.

11/22/00

Work lights switch back lighting is on.

Test wire 452 yel/red between terminals 2B and 5B on (S6) work lights switch.

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 15. Wire 473 brn at terminal 3 on (S6) work lights switch.

Normal Battery voltage. Work lights switch indicator is on.

If Not Normal Replace (S6) work lights switch. If indicator light is not on, check ground 103 blk. If good, replace switch.

Test Conditions: • Work lights switch in FRONT/REAR WORK/TAIL LIGHTS (up) position. • Key switch in ACCESSORY position. Test/Check Point

Normal

16. Wire 473 brn at terminal 3 on (S6) work lights switch.

Battery voltage.

17. Wire 475 brn/wht at terminal 6 on (S6) work lights switch.

Battery voltage.

Work lights switch indicator is on.

If Not Normal Replace (S6) work lights switch. If indicator light is not on, check ground 103 blk. If good, replace switch. Replace (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 on (E1) left front work light.

Battery voltage.

Check for loose or corroded connections 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 (E2) right front work light.

Battery voltage.

Check for loose or corroded connections 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

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL 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 on (E1) left front work light.

Maximum 0.1 ohms.

Check for loose or corroded connections between harness connector and socket. Test wire 101 blk from (E1) left front work light to ground.

21. Outer contact of bulb socket on (E2) right front work light.

Maximum 0.1 ohms.

Check for loose or corroded connections 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 on (E3) left tail light.

Battery voltage.

Check for loose or corroded connections 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 on (E4) right tail light.

Battery voltage.

Check for loose or corroded connections 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 on (E3) left tail light.

Maximum 0.1 ohms.

Check for loose or corroded connections between harness connector and socket. Test wire 107 blk from (E3) left tail light to ground.

25. Outer contact of bulb socket on (E4) right tail light.

Maximum 0.1 ohms.

Check for loose or corroded connections 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 26. Center terminal of bulb socket on (E5) rear work light.

Normal Battery voltage.

If Not Normal Check for loose or corroded connections 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 27. Outer contact of bulb socket on (E5) rear work light.

4 - 96

Normal Maximum 0.1 ohms.

If Not Normal Check for loose or corroded connections between harness connector and socket. Test wire 105 blk from (E5) rear work light to ground.

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

LIGHT CIRCUIT TEST POINTS

E1 Left Front Work Light

S6 Work Lights Switch

20 18

E2 Right Front Work Light

470 Brn 101 Blk

103 Blk

21 19

452 Yel

17 14

471 Brn

X13 Accessory 12 Volt Connector

15 16

102 Blk

450 Yel/Red

24 22

S1 Key Switch

473 Brn X99 Interlock Connector

12 11

3 2

453 Yel/Wht

107 Blk 104 Blk 477 Brn

1 475 Brn/Wht

105 Blk

550 Yel/Wht

103 Blk X12 Accessory Ground Connector

26 27

E3 Left Tail Light

451 Yel/Wht

124 Blk

106 Blk E5 Rear Work Light

X1 Engine/ROPS Harness Connector

476 Brn

23 25

116 Blk

K4 Accessory Relay

116 Blk 450 Yel/Wht

E4 Right Tail Light

550 Yel/Wht

101 Blk 110 Blk

451 Yel/Wht

100 Blk G2 Alternator

445 Yel

To F1 Accessories Fuse

11/22/00

KV18053

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

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

DUAL FLASHER CIRCUIT SCHEMATIC

To K4 Accessory Relay 451/453 Yel/Wht

A - Off

X13

S7 A,C Dual Flasher Switch

460 Yel/Wht

C - On

Back Light 3

2B 480 Yel/Red

Indicator Light K5 Dual Flasher Relay

128 Blk

126 Blk 482 Yel/Blk 481 Yel/Blk 127 Blk

E6 Left Hazard Light

E7 Right Hazard 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 on (S1) key switch.

Battery voltage.

Replace (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 on (S1) key switch.

Battery voltage.

Replace (S1) key switch.

4. Wire 550 yel/wht at terminal C1 on (X1) engine/ROPS harness connector (ROPS side).

Battery voltage.

Test wire 550 yel/wht between (S1) key switch and (X1) engine/ROPS harness connector.

5. Wire 550 yel/wht at terminal C1 on (X1) engine/ROPS harness connector (engine side).

Battery voltage.

Test (X1) engine/ROPS harness connector. Make sure wires are properly crimped in the terminals.

6. Wire 550 yel/wht at terminal 86 on (K4) accessory relay.

Battery voltage.

Test wire 550 yel/wht between (K4) accessory relay and (X1) engine/ROPS harness connector.

7. Wire 445 yel at terminal 30 on (K4) accessory relay.

Battery voltage.

Test wire 445 yel between (K4) accessory relay and (F1) accessories fuse. Check fuse.

8. Wire 450 yel/wht at terminal 87 on (K4) accessory relay.

Battery voltage.

Test ground circuit wire 110 blk from (K4) accessory relay to ground. If ground circuit is good, replace relay.

9. Wire 451 yel/wht at terminal B2 on (X1) engine/ROPS harness connector (engine side).

Battery voltage.

Test wires 451 yel/wht and 450 yel/wht between (X1) engine/ROPS harness connector and (K4) accessory relay.

10. Wire 451 yel/wht at terminal B2 on (X1) engine/ROPS harness connector (ROPS side).

Battery voltage.

Test (X1) engine/ROPS harness connector. Make sure wires are properly crimped in the terminals.

11. Wire 451 yel/wht on (X13) 12-volt accessory connector.

Battery voltage.

Test wire 451 yel/wht between (X13) 12-volt accessory connector and (X1) engine/ROPS harness connector.

12. Wire 460 yel/wht on (X13) 12-volt accessory connector.

Battery voltage.

Test (X13) 12-volt accessory connector. Make sure wires are properly crimped in the terminals.

4 - 100

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

Test/Check Point 13. Wire 460 yel/wht at terminal 2B on (S7) dual flasher switch.

Normal Battery voltage. Dual flasher switch back lighting is on.

If Not Normal If voltage is not present, test wire 460 yel/wht between (X13) 12-volt accessory connector and (S7) dual flasher switch. 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 14. Wire 480 yel/red at terminal 3 on (S7) dual flasher switch.

Normal Battery voltage.

If Not Normal Replace (S7) dual flasher switch.

Dual flash switch indicator light is on. 15. Wire 480 yel/red on (K5) dual flasher relay.

Battery voltage.

Test wire 480 yel/red between (S7) dual flasher switch and (K5) dual flasher relay.

16. Wire 481 yel/blk and 482 yel/ blk at (K5) dual flasher relay.

Battery voltage cycling ON and OFF.

Test wire 126 blk from (K5) dual flasher relay to 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

17. Center terminal of bulb socket on (E6) left hazard light.

Battery voltage cycling ON and OFF.

If Not Normal Check for loose or corroded connections 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 on (E7) right hazard light.

Battery voltage cycling ON and OFF.

Check for loose or corroded connections 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 19. Outer contact of bulb socket on (E6) left hazard light.

Normal Maximum 0.1 ohms.

If Not Normal Check for loose or corroded connections between harness connector and socket. Test wire 127 blk from (E6) left hazard light to ground.

20. Outer contact of bulb socket on (E7) right hazard light.

Maximum 0.1 ohms.

Check for loose or corroded connections between harness connector and socket. Test wire 129 blk from (E7) right hazard light to ground.

4 - 102

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

DUAL FLASHER CIRCUIT TEST POINTS

S7 Dual Flasher Switch

13 14 124 Blk K5 Dual Flasher Relay

480 Yel/Red 126 Blk

126 Blk 128 Blk

S1 Key Switch

460 Yel/Wht

16 127 Blk

481 Yel/Blk

129 Blk

12 128 Blk

482 Yel/Blk X13 12-Volt Accessory Connector

20 E6 Left Hazard Light

124 Blk

453 To Yel/Wht

550 Yel/Wht

X99

451 Yel/Wht

116 Blk

4 10 5

X1 Engine/ROPS Harness Connector

E7 Right Hazard Light

550 Yel/Wht

K4 Accessory Relay

116 Blk

451 Yel/Wht

450 Yel/Wht

101 Blk

445 Yel 110 Blk 100 Blk G2 Alternator

From F1 Accessories Fuse KV18054

11/22/00

4 - 103

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

CAB HEATER/DEFROSTER CIRCUIT (OPTIONAL) OPERATION Function: To heat cab air for operator comfort. Operating Conditions: The key switch (S1) must be in the RUN or ACCESSORY position and the thermostat must be set to a warm setting. The blower switch must be set to LOW or HIGH speed.

011 org and 012 red will change, depending on 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 positive. When the valve is closing, 011 org is positive. A potentiometer within the cab heater temperature control valve (Y7) feeds current back through 009 grn into the heater control circuit board (A1) and causes the cab heater temperature control valve (Y7) to stop 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

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

CAB HEATER/DEFROSTER CIRCUIT SCHEMATIC

To K4 Accessory Relay 454 Yel

002 Red

S9 A, B, C Blower Switch

Off

Low

High 9

010A Wht 008 Blu 013A Yel

Back Light

X26 (20)

R3 Cab Indicator Heater Thermostat Light

X26 (17)

005 Org 003 Yel

001B Red 87a 86

X27 (C)

000B Blk

85 001A Red

004 Yel

X25 (B)

X27 (D)

X26 (18)

87 30

F5 Cab Heater Fuse

K7 008 Blu Cab Heater Relay

013A Yel

X25 (A)

X27 (E)

010A Wht

001 Red

012 Red

004 Yel

011 Org

X27 (B)

001C Red 000B Blk

005 Org

000A Blk A

000A Blk

To Accessory Ground

A1 Heater Control Circuit Board

M3 Blower 000B Blk

From Battery Terminal of Starting Motor 001C Red

010B Wht

6 5 4 3 2 1

009 Grn

013B Yel

Y7 Cab Heater Temperature Control Valve 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 (K7) cab heater relay.

Battery voltage.

Test 003 yel wire between (K4) accessory relay and (K7) cab heater relay.

2. Wire 001C red on starter side of (F5) cab heater fuse.

Battery voltage.

Test 001C red between (M1) starting motor and (F5) cab heater fuse.

3. Wire 001B red on (K7) cab heater relay side of (F5) cab heater fuse.

Battery voltage.

Replace (F5) cab heater fuse.

4. Wire 001B at terminal 87 on (K7) cab heater relay.

Battery voltage.

Test 001B red between (F5) cab heater fuse and (K7) cab heater relay.

5. Wire 001A red at terminal 30 on (K7) cab heater relay.

Battery voltage.

Test ground circuit wire 000B blk from (K7) cab heater relay to ground. If good, replace relay.

6. Wire 001A red at terminal 2B on (S9) blower switch.

Battery voltage.

Test Wire 001A red from (K7) cab heater relay 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 (S9) blower switch.

Battery voltage.

Replace (S9) blower switch.

8. Wire 005 org on (M3) blower.

Battery voltage. Blower operating at high speed.

Test wire 005 org from (S9) blower switch to (M3) blower including terminals in X27 cab 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

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL Test Conditions: • Blower switch in LOW position. Test/Check Point

Normal

If Not Normal

9. Wire 004 yel at terminal 3 on (S9) blower switch.

Battery voltage.

Replace (S9) blower switch.

10. Wire 004 yel on (M3) blower.

Battery voltage. Blower operating at low speed.

Test wire 004 yel from (S9) blower switch to (M3) blower including terminals in X27 cab 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 (A1) heater control circuit board.

Battery voltage.

Test wire 001 red and 001A red from (A1) 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 on (A1) heater control circuit board.

Minimum 8.2 V.

Test ground wire 000B blk from terminal A on (A1) heater control circuit board to ground. If good replace heater control circuit board.

13. Wire 013B yel at terminal 2 on (Y7) cab heater temperature control valve.

Same reading as step 12.

Test wire 013B yel from (A1) heater control circuit board to (Y7) cab heater temperature 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 heater thermostat connector.

Minimum 8.2 V.

Test 013A yel from (R3) cab heater thermostat to (A1) heater control circuit board. If good, replace (A1) heater control circuit board.

15. Wire 002 red at (R3) cab heater thermostat connector.

Battery voltage.

Test wire 002 red from (R3) cab heater thermostat to (S9) blower switch. If good, replace (S9) blower switch.

16. Wire 008 blu at (R3) cab heater thermostat connector. Slowly rotate thermostat from HOTTEST to COLDEST setting.

Reading should smoothly decrease from 8.5 V to 0 V (approx).

Replace (R3) cab heater thermostat.

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 (A1) heater control circuit board.

Same reading as step 16.

Test wire 008 blu from (R3) cab heater 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 thermostat to COLDEST setting and observe meter.

Minus (–) 10.5 V (approximately)

Replace (A1) heater control circuit board.

19. Set (R3) cab heater thermostat to HOTTEST setting and observe meter.

Plus (+) 10.5 V (approximately)

Replace (A1) heater control circuit board.

20. Rotate (R3) cab heater thermostat from HOTTEST to 1/4 COLDEST setting and observe meter.

Minus (–) 10.5 V (approx.) until (Y7) cab heater temperature control valve reaches position, then to 0 V (approx).

Go to step 24.

21. Rotate (R3) cab heater thermostat to 3/4 HOTTEST setting and observe meter.

Plus (+) 10.5 V (approx.) until (Y7) cab heater temperature control valve reaches position, then to 0 V (approx).

Go to step 24.

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 (Y7) cab heater temperature control valve. Rotate (R3) cab heater thermostat to COLDEST setting.

Reading should smoothly decrease to 0.5 V (approx). Listen for (Y7) cab heater temperature control valve motor running.

Replace (Y7) cab heater temperature control valve.

23. Wire 009 grn at terminal 1 on (Y7) cab heater temperature control valve. Rotate (R3) cab heater thermostat to HOTTEST setting.

Reading should smoothly increase to 8 V (approx). Listen for (Y7) cab heater temperature control valve motor running.

Replace (Y7) cab heater temperature control valve.

4 - 108

KV31058

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL 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 yel (terminal C), then to 010B wht (terminal B) on (A1) heater control circuit board.

Listen. (Y7) Cab heater temperature control valve motor should run.

If valve motor runs, replace (Y7) cab heater temperature control valve assy. 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 18 19 20 21

8 M3 Blower

1 32

Y7 Cab Heater Temperature Control Valve

22 23

17 011 Org 012 Red 013B Yel 010B Wht

009 Grn A1 Heater Control Circuit Board 005 Org

000B Blk

008 Blu

010A Wht

013A Yel X26 Cab Heater ROPS Harness-to-Heater Harness Thermostat Connector

008 Blu

001 Red

004 Yel

000A Blk

013A Yel 010A Wht S9 Blower Switch

002 Red

R3 Cab Thermostat

004 Yel X27 Cab Heater ROPS Harness-to-Heater Harness Main Connector

F E D

A B C

005 Org 001A Red 000B Blk

000A Blk X25 Cab Heater Engine Harness-to-ROPS Harness Connector K7 Cab Heater Relay

1 From K4 Accessory Relay B

003 Yel

001A Red

F5 Cab Heater Fuse 15 A

001B Red

4 000B Blk

4 - 110

001A Red

M1 Starting Motor 001C Red 000A Blk

KV31046

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

X11 12-Volt Accessory (Frame) 454 Yel

103 Blk

F6 Backup Alarm Fuse 10 Amp 455 Yel

101 Blk

X22 Accessory Ground Connector (Frame)

Power from Accessory Relay Switched Power Ground Circuit

KV31057

4 - 112

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

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 (F6) backup alarm fuse.

Battery voltage.

Check accessory relay circuit.

2. Wire 450 yel on reverse horn side of (F6) backup alarm fuse.

Battery voltage.

Replace (F6) backup alarm fuse.

3. Wire 450 yel at (S10) backup alarm switch (rear).

Battery voltage.

Test wire 450 yel between (F6) backup alarm 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 alarm switch (rear).

Battery voltage.

Replace (S10) backup alarm switch (rear).

5. Wire 457 yel on (S11) backup alarm switch (front).

Battery voltage.

Test wire 457 yel between (S10) backup alarm 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 alarm switch (front).

Battery voltage.

Replace (S11) backup alarm switch (front).

7. Wire 458 yel on Backup Alarm (H2).

Battery voltage, Backup Alarm sounding.

Test 458 yel between (S11) backup alarm 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 Backup Alarm

458 Yel

6 101 Blk

S11 Backup Alarm Switch (Front)

5 4

X22 Accessory Ground Connector

450 Yel

116 Blk K4 Accessory Relay 101 Blk

455 Yel 450 Yel/Wht

110 Blk 454 Yel

457 Yel S10 Backup Alarm Switch (Rear)

F6 Backup Alarm Fuse X11 Accessory 12 V Connector

100 Blk From S1 Key Switch

G2 Alternator

4 - 114

From F1 Accessories Fuse

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

S12 Wiper/Washer Swith

Off

Wiper

Washer

Back Light 111 Blk

From K4 AccessoryRelay

460 Yel

6 463 Yel/Blk 1 465 Yel/Red

462 Yel

466 Yel 461 Yel/Wht

Indicator Light 463 Yel/Blk

M4 Wiper Motor

465 Yel/Red 4 466 Yel

6 2

461 Yel/Wht

110 Blk B

M5 Washer Pump

W A

112 Blk

111 Blk

101 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

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

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 (X99) interlock connector.

Battery voltage.

Check accessory relay circuit to (X99) interlock connector.

2. Wire 460 yel at terminal 5B on (S12) wiper/washer switch.

Battery voltage.

Test wire 460 yel.

3. Wire 466 yel at terminal 5 on (M4) wiper motor.

Battery voltage.

Test wire 466 yel from (S12) wiper/ 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 2B on (S12) wiper/washer switch.

Battery voltage.

Replace (S12) wiper/washer switch.

5. Wire 461 yel/wht at terminal 6 on (M4) wiper motor.

Battery voltage. Wiper motor should be operating.

Test wire 461 yel/wht between (S12) 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 on (S12) wiper/washer switch.

Battery voltage.

Replace (S12) wiper/washer switch.

7. Wire 463 yel/blk at terminal B on washer pump.

Battery voltage. (M5) washer pump should be running. Fluid should be discharging at wiper.

If no voltage is present, test wire 463 yel/blk. If voltage is present but (M5) 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 on (M4) wiper motor.

Battery voltage (while motor is operating). Motor should run until wiper is in parked position. If wiper parks in the wrong position, adjust location of wiper arm on (M4) wiper motor shaft.

If no voltage is present and motor stops immediately, replace (M4) wiper motor. If voltage is present and wiper motor stops immediately, go to step 9.

9. Wire 465 yel/red at terminal 1 on (S12) wiper/washer switch.

Battery voltage (while motor is operating). Motor should run until wiper is in parked position.

Test wire 465 yel/red between (M4) wiper motor and (S12) wiper/ washer switch. If good, go to step 10.

10. Wire 461 yel/wht at terminal 2B on (S12) wiper/washer switch.

Battery voltage (while motor is operating). Motor should run until wiper is in parked position.

If no voltage is present, replace (S12) wiper/washer switch.

4 - 118

11/22/00

THEORY OF OPERATION AND DIAGNOSIS

ELECTRICAL

WIPER/WASHER CIRCUIT TEST POINTS

M4 Wiper Motor

5 461 Yel/Wht 466 Yel 465 Yel/Red

S12 Wiper/Washer Switch

466 Yel

465 Yel/Red 110 Blk

4 10 X33 Door Switch Harness Connector

461 Yel/Wht

2 111 Blk

466 Yel 463 Yel/Blk 112 Blk

460 Yel

463 Yel/Blk

472 Dk Grn 470 Dk Grn 101 Blk

X99 Interlock Connector

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. 4. Open engine rear cover and remove left engine side panel. 5. Disconnect negative (–) and positive (+) cable clamps from battery. Remove battery hold-down clamp. 6. Remove battery from machine. 7. Clean battery terminals and case. 8. Inspect battery terminals and case for breakage or cracks. 9. Check electrolyte level in each battery cell. Add clean, distilled water as needed. If water was added, charge battery for 20 minutes at 10 amps. (See CHARGE BATTERY in this section.) 10. Remove surface charge by placing a small load on the battery for 15 seconds.

M49596

11. Use a hydrometer to check for a minimum specific gravity of 1.225 with less than 50 point variation in each cell: Results: • If all cells are less than 1.175, charge battery at 10 amp rate. (See CHARGE BATTERY in this section.) • If all cells are less than 1.225 with less than 50 point variation, charge battery at 10 amp rate. (See CHARGE BATTERY in this section.) • If cells are above 1.225 with less than 50 point variation, load test battery. (See BATTERY LOAD 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

TESTS AND ADJUSTMENTS

ELECTRICAL

CHARGE BATTERY Reason: To increase battery charge after battery has been discharged.

10. Check if battery is accepting a 10 amp charge after 10 minutes at boost setting: Results:

Equipment: • Battery charger (variable rate) (use according to manufacturer’s instructions). Procedure:

NOTE: See BATTERY TEST in this section before charging battery. 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. 4. Open engine rear cover and REMOVE left engine side panel. 5. Disconnect negative (–) and positive (+) battery cable clamps. Remove battery hold-down clamp. 6. Remove battery from machine. 7. Clean battery terminals and case.

• If battery WILL NOT accept 10 amp charge after 10 minutes at boost setting, replace battery. • If battery is accepting 10 amp charge after 10 minutes at boost setting, and battery did NOT need water, go to steps 11 and 12. • 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 11and 12. 11. Set charger at 15—25 amps. IMPORTANT: Decrease charge rate if battery gases or bubbles excessively or becomes too warm to touch. 12. Check specific gravity after 30 minutes: Results: • If MORE THAN 50 point variation between cells, 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.

M49598

8. Connect variable rate charger to battery.

NOTE: Maximum charge time at boost is 10 minutes. Allow additional 5 minutes for each 10°F (5.5°C) below 70°F (21°C). 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

13. Continue to charge battery until specific gravity is 1.230—1.265 points. 14. Load test battery. (See BATTERY LOAD TEST, in this section.) 15. Install battery. 16. Install left engine side panel and close engine cover.

4 - 121

TESTS AND ADJUSTMENTS

ELECTRICAL

BATTERY LOAD TEST 8. Connect tester positive cable (red) to battery positive (+) terminal (B). 9. Connect tester negative cable (black) to battery negative (–) terminal (C).

Reason: To check condition of battery under load. Equipment: •

JT05685 Battery Tester (use manufacturer’s instructions).

according

IMPORTANT: Perform this test quickly to prevent damage to battery tester. DO NOT apply full load to battery for more than 5—10 seconds

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. 4. OPEN engine rear cover and REMOVE left engine side panel. 5. Disconnect negative (–) and positive (+) battery cable clamps. Remove battery hold-down clamp. 6. Remove battery from machine. 7. Clean battery terminals and case.

10. Turn load knob (A) on DC amps scale of tester clockwise (in) until amperage reading (D) is equal to: • cold cranking amperage rating of battery (use blue scale). —or— • three times ampere hour rating (use black scale). 11. Hold for 15 seconds and turn load knob (A) of tester counterclockwise (out) to OFF position. 12. Repeat steps 10 and 11 above and read condition of battery at DC volts scale (E).

Procedure:

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 B. Battery Positive (+) Terminal C. Battery Negative (–) Terminal

D. DC Amps Scale E. DC Volts Scale

IMPORTANT: Turn load knob on battery tester fully out (counterclockwise) BEFORE making any test connections.

4 - 122

11/22/00

TESTS AND ADJUSTMENTS

ELECTRICAL

REGULATED AMPERAGE AND VOLTAGE TEST

Reason: To determine regulated charging output of the alternator. Equipment: • JT05685 Load Tester • JT02153 DC Current Gun or Equivalent Specifications: Current Output . . . . . . . . . . Approximately 50 amps (min) @full rpm Regulated Voltage . . . . . 13.5—14.2 VDC @ full rpm

7. Put current gun over large red cable between alternator and starter. 8. Start and operate engine at full rpm. IMPORTANT: Perform this test as quickly as possible to prevent damage to the electrical system components. 9. Slowly turn load knob clockwise until current gun displays maximum current output. Record reading. IMPORTANT: Load system only as necessary to obtain maximum current output. Do not reduce system voltage any lower than 11 volts.

Procedure: 1. Park machine on level surface. Lower boom to the at-rest position. Turn key to OFF position and ENGAGE park brake. 2. Be sure battery is fully charged and all accessories are off. 3. Open engine rear cover and remove left engine side panel. 4. Turn load knob of battery tester off (fully counterclockwise). 5. Connect red battery tester clamp to positive (+) post of battery. 6. Connect black battery tester clamp to negative (–) post of battery.

11/22/00

10. Turn load knob off (fully counterclockwise). 11. Let engine run and watch when current gun reading is 10 amps or less. 12. Read and record meter voltage. Results: • If alternator current output or regulated voltage is not to specifications, repair or replace alternator. (See ALTERNATOR in ENGINE section.) 13. Install left engine side panel and close engine cover.

4 - 123

TESTS AND ADJUSTMENTS

ELECTRICAL

STARTING MOTOR LOADED AMPERAGE DRAW TEST

KV15226

Reason:

Procedure:

To determine the amperage required to crank the engine and check starting motor operation under load.

1. Remove any attachments. 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. Open engine rear cover and remove both engine side panels. 5. Turn load knob fully counterclockwise. 6. Connect load tester red cable to positive (+) terminal on battery. 7. Connect load tester black cable to negative (–) terminal. 8. Disconnect fuel shut-off solenoid wire from pump. 9. Check system ground connections. Be sure battery is fully charged. 10. Crank engine. Read and record voltage at meter. 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 cranking. Read and record amperage on meter. 13. Turn load knob fully counterclockwise.

Equipment: • JT05685 Load Tester • JT05719 Tachometer Specification: Starting Motor Loaded (on Vehicle) Draw/Voltage. . . . . . . . . . . . . . . . . 350 amps (max) 8.5 volts (min) @ 0°C (32°F)

c CAUTION Disconnect fuel shutoff solenoid wiring to prevent engine from starting. IMPORTANT: Turn load knob fully counterclockwise before making connections.

NOTE: Engine should be at normal operating temperature when performing this test.

4 - 124

Results: • If amp reading is not to specification, or is to specification but rpm is low, remove starter and perform STARTING MOTOR NO-LOAD AMPERAGE AND RPM TESTS in this section. 14. Install left and right engine side panels and close engine cover.

11/22/00

TESTS AND ADJUSTMENTS

ELECTRICAL

STARTING MOTOR NO-LOAD AMPERAGE AND RPM TESTS

Reason: To determine if starting motor is binding or has excessive amperage draw under no-load. Equipment: • JT02153 DC Current Gun or Equivalent • JT05719 Tachometer

9. Connect jumper cables to battery. 10. Attach current gun to positive cable. IMPORTANT: Complete this test in 20 seconds or less to prevent starter damage. 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) Draw . . . . . . . . . . . . . . 90 amp (max) at 3,500 rpm

Results:

Procedure:

• If starting motor amps or rpm are not to specification, repair or replace starter. 13. Install starting motor. 14. Install left engine side panel and close engine cover.

1. Remove any attachments. 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. 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.

c CAUTION

Equipment: • Two jumper wires • 12-volt battery

Ensure all power is disconnected from starting motor. Drive gear could move suddenly, causing injury.

Procedure: 1. Remove any attachments. 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. Open engine rear cover and remove left engine side panels. 5. Disconnect negative (–) battery cable clamp from battery. 6. Remove and tag all wires to the starting motor. 7. Remove starting motor from engine and mount on bench. (See STARTING MOTOR REMOVAL/ INSTALLATION.)

12. If drive gear does not move, make sure jumper wires are disconnected and try to pull drive gear out by hand by rotating counterclockwise. 13. If drive gear cannot be pulled out, check solenoid plunger and shaft for binding. 14. If drive gear moves out freely but solenoid does not energize, check resistance between solenoid terminal and metal housing of solenoid. Results: Maximum resistance should be 1.0 ohm through solenoid coil. Replace solenoid if open circuit is indicated. 15. Connect starting motor lead (A) to terminal (B). 16. Remove jumper wire from starting motor housing and negative (–) terminal post on battery. 17. Install starting motor. 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

TESTS AND ADJUSTMENTS

ELECTRICAL

AIR FILTER RESTRICTION SWITCH TEST

ENGINE COOLANT TEMPERATURE SENDER/SWITCH TEST

Reason:

To determine if air filter restriction switch is detecting air flow resistance through air filter.

To check operation of coolant temperature sender/ overheat switch.

Procedure:

Equipment:

1. Park skid steer on flat level surface and engage park brake switch. 2. Start and operate engine at low idle. 3. Open engine rear cover.

• JT05791 Digital Multimeter Procedure: 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

c CAUTION

3. Disconnect wiring connectors (A) from coolant 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 cardboard or plywood. 5. Observe on the instrument panel that the air filter restriction light comes on. Results: • If indicator light will not come on, check wiring and light. • If wiring circuit and light are good, replace air filter restriction switch.

• Replace coolant temperature sender if continuity is indicated. 5. Check resistance between sender large (org) spade terminal and engine block. Reading should be as follows: • 2.21K—2.69K ohms @ 20°C (68°F) • 1.65K—5.88K ohms @ 0°—30°C (32°—86°F) 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 Results: • Replace coolant temperature sender if continuity is indicated. 7. Remove engine coolant temerature sender/switch from engine. 8. Connect continuity meter between sender small (org/wht) spade terminal and sender housing.

ELECTRICAL

COLD WEATHER START SWITCH TEST (MODEL 250 ONLY) Reason: To check operation of cold start switch.

NOTE: Do not submerge wire harness connector end of sender in oil. Submerge only to the bottom of the hexagon of the sender.

Equipment:

9. Submerge in oil. Heat oil and monitor meter reading. Meter should show continuity at 116°C (241°F).

Procedure:

Results: • Replace engine coolant temperature sender/switch if results vary.

• JT05791 Digital Multimeter

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

TESTS AND ADJUSTMENTS

ELECTRICAL

ENGINE OIL PRESSURE SWITCH/ SENDER TEST

MANIFOLD PREHEATER 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. 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. Open engine rear cover and remove right engine side panels.

C C

KV15202 KV15211

5. Disconnect battery, negative (–) cable first. 6. Remove wire leads (A and B) from oil pressure switch (C). 7. Check for resistance between terminal marked “G” and the engine block. Value should be 5—13 ohms at 0 kPa (0 psi). 8. Check for resistance (maximum 0.1 ohms) between terminal “WK” and engine block.

NOTE: Resistance will change if there is pressure.

5. Disconnect battery, negative (–) cable first. 6. Remove nut and washer (A) and wire lead (B) from pre-heater (C). 7. Check resistance between terminal and engine block. Reading should be 0.70—1.65 ohms Results: • Replace manifold pre-heater if reading is incorrect. 8. Install pre-heater and tighten to 60 N•m (44 lb-ft). 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 TEST Reason: To check operation of manifold pre-heater relay.

8. Connect a jumper wire from battery positive (+) post to one small terminal. Connect a jumper wire from the other small terminal to negative (–) post. Continuity should now exist between the two large terminals (F). Results: • If continuity is not correct, replace manifold preheater relay. 9. Connect leads, cap screws, and washers. 10. Connect battery, positive (+) cable first. 11. Lower ROPS. Tighten ROPS retaining nuts to 105 N•m (77 lb-ft).

Equipment: • JT05791 Digital Multimeter Procedure: C B

A 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.

KV15247

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

TESTS AND ADJUSTMENTS

ELECTRICAL

KEY SWITCH TEST

PARK BRAKE SWITCH TEST

Reason:

To check operation of ignition key switch.

To check operation of park brake switch.

Equipment:

• JT05791 Digital Multimeter

Procedure:

Procedure: 3

1 9

4 7

KV15248

1. Disconnect battery, negative (–) cable first. 2. Remove key switch from control panel. 3. Use multimeter to check continuity between switch terminals (A—E) in the ACCESSORY, OFF, RUN and START positions.

KV15248

1. Disconnect battery, negative (–) cable first. 2. Remove park brake switch from control panel. 3. Use multimeter to check continuity between switch terminals in the positions as shown in the table. PARK BRAKE SWITCH CONTINUITY

KEY SWITCH CONTINUITY Switch Position

Continuity (<1 ohm) Between Terminals

Accessory

A, D

Off

None

Run

A, D, E

Start

B, C and D, E

Results: • If continuity is not present between terminals listed 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

Switch Position

Continuity (<1 ohm) Between Terminals

Engage

2B, 3, 9, 5B, 6

Run

2B, 3, 9, 5B, 4

Release

2B, 1, 9, 5B, 4

All positions

2B, 9, 5B, 7

Results: • If continuity is not correct, replace park brake switch.

4 - 131

TESTS AND ADJUSTMENTS

ELECTRICAL

PRE-HEATER SWITCH TEST

LIGHT SWITCH TEST

Reason:

To check operation of cold start switch.

To check operation of light switch.

Equipment:

• JT05791 Digital Multimeter

Procedure:

Procedure: 4

7 9

6 8

1 2B 2B

KV1550

1. Disconnect battery, negative (–) cable first. 2. Remove cold start switch from control panel. 3. Use multimeter to check continuity between switch terminals in the positions as shown in the table.

1. Disconnect battery, negative (–) cable first. 2. Remove light switch from control panel. 3. Use multimeter to check continuity between switch terminals in the positions as shown in the table.

COLD START SWITCH CONTINUITY

LIGHT SWITCH CONTINUITY

Switch Position

Continuity (<1 ohm) Between Terminals

Switch Position

Continuity (<1 ohm) 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 Lights

2B, 3, 9and 5B, 6

All positions

7, 8 and 9, 2B

Results: • If continuity is not correct, replace pre-heater switch.

Results: • If continuity is not correct, replace light switch.

4 - 132

11/22/00

TESTS AND ADJUSTMENTS

ELECTRICAL

CAB DOOR SWITCH TEST

DUAL FLASHER SWITCH TEST

Reason:

To check operation of cab door switch.

To check operation of dual flasher switch.

Equipment:

• JT05791 Digital Multimeter

Procedure:

Procedure: 7 9

Plunger

KV31131

1. Disconnect battery, negative (–) cable first. 2. Remove cab door switch from machine. 3. Use multimeter to check continuity between switch terminals in the positions as shown in the table.

CAB DOOR SWITCH CONTINUITY FRONT MOUNTED VERSION

3 KV31132

1. Disconnect battery, negative (–) cable first. 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. DUAL FLASHER SWITCH CONTINUITY

Plunger Position

Continuity (<1 ohm) Between Terminals

Out

YES

CAB DOOR SWITCH CONTINUITY REAR MOUNTED VERSION Plunger Position

Continuity Between Terminals

Out

YES

Switch Position

Continuity (<1 ohm) Between Terminals

Off

7, 8 and 9, 2B

2B, 3, 9 and 7, 8

All positions

7, 8 and 9, 2B

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:

To check operation of high-flow switch.

To check operation of blower switch.

Equipment:

• JT05791 Digital Multimeter

Procedure:

Procedure: 4

7 5B

8 8

1 1 2B 2B

KV31133

KV31134

1. Disconnect battery, negative (–) cable first. 2. Remove high-flow switch from control panel. 3. Use multimeter to check continuity between switch terminals in the positions as shown in the table.

1. Disconnect battery, negative (–) cable first. 2. Remove blower switch from control panel. 3. Use multimeter to check continuity between switch terminals in the positions as shown in the table.

HIGH-FLOW SWITCH CONTINUITY

BLOWER SWITCH CONTINUITY

Switch Position

Continuity (<1 ohm) Between Terminals

Switch Position

Continuity (<1 ohm) Between Terminals

Off

2B, 1 and 5B, 4, 9

Off

5B, 4, 2B, 1, 9

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: • If continuity is not correct, replace switch.

4 - 134

Results: • If continuity is not correct, replace switch.

11/22/00

TESTS AND ADJUSTMENTS

ELECTRICAL

WIPER/WASHER SWITCH TEST

FUEL LEVEL SENDER TEST

Reason:

To check operation of wiper/washer switch.

To determine if fuel level sender is changing resistance as float is raised and lowered.

Equipment: Equipment:

• JT05791 Digital Multimeter

• JT05791 Digital Multimeter Procedure: Procedure: 7

KV31135

1. Disconnect battery, negative (–) cable first. 2. Remove wiper/washer switch from control panel. 3. Use multimeter to check continuity between switch terminals in the positions as shown in the table. WIPER/WASHER SWITCH CONTINUITY Switch Position

Continuity (<1 ohm) Between Terminals

Off

1, 2B and 5B, 4, 3, 9

Wiper

9, 2B, 3, 5B, 4

Washer (Momentary)

9, 2B, 3, 5B, 6

All positions

7, 8 and 3, 5B, 9

KV15212

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 fuel level sender on top of fuel tank. 3. Disconnect wire harness connector (A). Remove two fuel lines (B).

Results: • If continuity is not correct, replace switch.

E 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. 6. Hold fuel sender upright so float arm is resting on bottom stop (empty tank position). Note meter reading. 7. Holding fuel sender upright, lift float arm up against upper stop (full tank position). Note meter reading.

B KV15253

1. Remove seat safety switch from under seat and disconnect wiring connector. 2. Check continuity between terminals (A and B) with switch released and depressed.

Results: • The resistance of the fuel level sender is as follows: FUEL LEVEL SENDER Tank Fuel Level

Resistance (Ohms)

Full

30.0 ± 3

1/2

89.3 ± 3

Empty

248.2 ± 3

SEAT SAFETY SWITCH CONTINUITY Switch Position

Continuity Between Terminals

Released

Depressed

Yes

Results: • 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

TESTS AND ADJUSTMENTS

ELECTRICAL

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 switch.

• JT05791 Digital Multimeter Procedure:

Equipment: • JT05791 Digital Multimeter Procedure:

Unlatched A B 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. Remove seat belt latch from skid steer and disconnect wiring connector. 2. Check continuity between terminals (A) and (B).

1. Drain hydraulic oil from reservoir. 2. Disconnect wiring connector (B) and remove switch (A).

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 Switch Position

Continuity Between Terminals

Unlatched

Latched

Yes

3. Submerge switch in 108°C (226°F) oil for a few minutes. 4. Remove from oil and check for continuity across connector terminals. Results:

Results: • If continuity is not correct, replace switch.

11/22/00

• If no continuity is indicated, replace hydraulic oil overtemperature switch, then go to step 5. • If continuity is indicated, switch is good. Go to step 5. 5. Apply pipe sealant with TEFLON to threads of switch before installing.

4 - 137

TESTS AND ADJUSTMENTS

ELECTRICAL

6. Install hydraulic oil overtemperature switch and connect wiring connector.

NOTE: Make sure hydraulic reservoir drain plug is installed.

BOOM LOCKOUT SOLENOID TEST Reason: To check operation of boom lockout solenoid.

7. Fill reservoir with proper hydraulic oil. Check level. Equipment:

PARK BRAKE SOLENOID TEST

• Two jumper wires Procedure:

Reason: To check operation of park brake solenoid. Equipment: • Two jumper wires Procedure: 1. Remove any attachments. 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. Open engine rear cover and remove left engine side panel.

1. Remove any attachments. 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 [ROLLOVER PROTECTION STRUCTURE] in the MISCELLANEOUS section.) 5. Remove cover plates. (See COVER PLATE REMOVAL/INSTALLATION in the MISCELLANEOUS section.)

A B

KV31136 KV15220

5. Remove connector (A) from solenoid (B). 6. Connect a jumper wire between one terminal of park brake solenoid and ground. 7. Connect one end of another jumper wire to battery positive (+) terminal. Touch other end of jumper wire to open terminal on solenoid (B). Listen for solenoid to “click”. 8. Remove jumper wire from solenoid. Listen for solenoid to “click” again. Results: • If solenoid does not “click”, replace park brake solenoid.

4 - 138

6. Separate connector (A). 7. Connect a jumper wire between one terminal of boom lockout solenoid connector and ground. 8. Connect one end of another jumper wire to battery positive (+) terminal. Touch other end of jumper wire to open terminal on boom lockout solenoid connector. Listen for solenoid to “click”. 9. Remove jumper wire. Listen for solenoid to “click” again. Results: • If solenoid does not “click”, replace solenoid. 10. Install cover plates. (See COVER PLATE REMOVAL/INSTALLATION in the MISCELLANEOUS section.) 11. Lower ROPS. Tighten ROPS retaining nuts to 105 N•m (77 lb-ft).

11/22/00

TESTS AND ADJUSTMENTS

ELECTRICAL

BUCKET LOCKOUT SOLENOID TEST

HYDRAULIC OIL FILTER RESTRICTION SWITCH TEST

Reason:

To check operation of park brake solenoid.

To check operation of hydraulic oil filter restriction switch.

Equipment: Equipment:

• Two jumper wires

• JT05791 Digital Multimeter (set to read continuity)

Procedure: 1. Remove any attachments. 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 [ROLLOVER PROTECTION STRUCTURE] in the MISCELLANEOUS section.) 5. Remove cover plates. (See COVER PLATE REMOVAL/INSTALLATION in the MISCELLANEOUS section.)

B 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). 4. Remove switch (A).

KV31137

6. Separate connector (A). 7. Connect a jumper wire between one terminal of bucket lockout solenoid connector and ground. 8. Connect one end of another jumper wire to battery positive (+) terminal. Touch other end of jumper wire to open terminal on bucket lockout solenoid connector. Listen for solenoid to “click”. 9. Remove jumper wire. Listen for solenoid to “click” again. Results: • If solenoid does not “click”, replace solenoid. 10. Install cover plates. (See COVER PLATE REMOVAL/INSTALLATION in the MISCELLANEOUS section.) 11. Lower ROPS. Tighten ROPS retaining nuts to 105 N•m (77 lb-ft). 11/22/00

Procedure:

NOTE: The restriction switch closes when oil pressure increases to 275.8 ± 27.6 kPa (40 ± 4 psi). The restriction switch opens when oil pressure decreases to 206.8 kPa (30 psi) minimum. The normal operating pressure is 41.4—206.8 kPa (6—30 psi) 5. Attach an external (regulated) source of air or oil pressure to oil filter restriction switch. 6. Attach one test lead of multimeter to center terminal of switch and other test lead to switch body. 7. While observing multimeter, slowly increase supply pressure to 275.8 ± 27.6 kPa (40 ± 4 psi). Results: • If continuity is indicated at any time as pressure rises to 248.2 kPa (36 psi), replace switch. • Continuity should be indicated above 248.2 kPa (36 psi). If no continuity is indicated, replace switch. 8. Lower ROPS. Tighten ROPS retaining nuts to 105 N•m (77 lb-ft).

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 locked position. (See RAISING ROPS [ROLLOVER PROTECTION STRUCTURE] in the MISCELLANEOUS section.) 3. Disconnect battery, negative (–) cable first. B

A B

KV15200

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 N•m (77 lb-ft).

KV15199

4. Access air filter restriction switch (B). 5. Disconnect wiring connector (A) and remove switch (B), located behind air cleaner. 6. Apply pipe sealant with TEFLON to threads of switch before installation. 7. Install air filter restriction switch (B). 8. Connect wiring connector (A). 9. Connect battery, positive (+) cable first. 10. Lower ROPS. Tighten ROPS retaining nuts to 105 N•m (77 lb-ft).

COLD WEATHER START SWITCH (MODEL 250 ONLY) Replace: 1. Park machine on a level surface. Turn key to OFF position and ENGAGE park brake. 2. Open engine rear cover. Remove right engine side panel. 3. Disconnect battery, negative (–) cable first. B

COOLANT TEMPERATURE SENDER/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 locked position. (See RAISING ROPS [ROLLOVER PROTECTION STRUCTURE] in the MISCELLANEOUS section.) 3. Disconnect battery, negative (–) cable first.

4 - 140

KV15201

4. Disconnect wiring connector (A) and remove cold weather start switch (B) located on side of thermostat housing. 5. Apply pipe sealant with TEFLON to threads of switch before installation.

11/22/00

COMPONENT REPLACEMENT

ELECTRICAL

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.

ENGINE OIL PRESSURE SWITCH/ SENDER Replace:

1. Park machine on a level surface. Turn key to OFF position and ENGAGE park brake. 2. Open rear engine cover and remove right engine side panel. 3. Disconnect battery, negative (–) cable first.

KV15202

4. Remove nut and lock washer (A). 5. Remove wire lead (B) and remove manifold preheater (C). 6. Install manifold pre-heater (C). Tighten to 60 N•m (44 lb-ft). Connect wire lead (B) and install lock washer and nut (A). 7. Connect battery, positive (+) cable first. 8. Lower ROPS. Tighten ROPS retaining nuts to 105 N•m (77 lb-ft).

C 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

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

COMPONENT REPLACEMENT

ELECTRICAL

INSTRUMENT PANEL COMPONENT LOCATION

J KV18865

F. Work Lights G. Instrument Cluster H. Cold Start I. Park Brake J. Key Switch

A. Heater Blower (Optional) B. Air Conditioner (Optional) C. Windshield Wiper/Washer (Optional) D. Dual Flasher (Optional) E. High-Flow (Optional)

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.

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 NOTE: Park brake switch shown. Other switch replacement is similar. 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.

CAB HEATER THERMOSTAT (IF EQUIPPED) 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 (–) terminal.

Remove Screws

KV15204 KV18862

3. Remove six screws (A) and pull bezel away from headliner.

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.

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

COMPONENT REPLACEMENT

ELECTRICAL

3. Remove six screws (A) and pull bezel away from headliner. D

B C

KV18864

KV15209

4. Remove two cap screws (B) and mounting clips (D). Pull instrument cluster (C) away from headliner.

6. Push connector forward through hole (D) in frame.

KV15210

KV18862

7. Install controller and secure with screws. 8. Connect battery.

INSTRUMENT CLUSTER

5. Disconnect three wiring harness connectors (E) and remove instrument cluster. 6. Install instrument cluster and connect wiring harness connectors (E). 7. Install instrument cluster and clips into headliner using two cap screws. 8. Install bezel using six screws. 9. Connect battery, positive (+) cable first.

Replace: 1. Park machine on a level surface. Turn key to OFF position and ENGAGE park brake. 2. Disconnect battery, negative (–) cable first.

FUEL LEVEL SENDER 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 KV15204

11/22/00

4 - 145

COMPONENT REPLACEMENT

ELECTRICAL

KV15212 KV15214

4. Access fuel level sender on top of fuel tank.

NOTE: Tag fuel lines to aid during installation.

3. Remove two nuts (A) on each side of seat support. 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 installation.

D C

E KV15213

6. Remove five screws (C), fuel level sender (D) and gasket (E). 7. Inspect gasket (E) for damage. Replace if necessary. 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).

KV15215

5. Disconnect wire harness connector (B). 6. Remove two screws (C) and seat safety switch (D). 7. Install seat switch and install screws (C). 8. Connect wire harness connector and install seat and support on adjustment rails. Tighten nuts to 28 N•m (20 lb-ft). 9. Connect battery, positive (+) cable first.

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

COMPONENT REPLACEMENT

ELECTRICAL

SEAT BELT SWITCH

STARTER

Replace:

Remove/Install:

1. Park machine on a level surface. Turn key to OFF position and ENGAGE park brake. 2. Disconnect battery, negative (–) cable first.

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. Remove left side engine panel. 4. Disconnect battery, negative (–) cable first.

A A

B KV15214

3. Remove the cap screw and nut (A) securing the seat belt latch to the ROPS. 4. Disconnect electrical connector. 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 (40 lb-ft). 7. Connect battery, positive (+) cable first.

KV15216

5. Remove nut (A) and cover (B) to access starter wiring leads. .

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 at-rest position. Turn key to OFF position and ENGAGE park brake. 2. Disconnect battery, negative (–) cable first. 3. Remove left engine side panel.

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 D

C KV15218

NOTE: Tag or label wiring leads on alternator to aid during installation. 4. Disconnect wiring leads (A). Tag or label wiring leads to aid during installation. 5. Loosen nuts (B and C). 6. Move alternator (D) toward engine and lift belt off pulley. 7. Remove alternator adjustment and pivot mounting hardware. 8. Remove alternator. Make repairs to alternator as necessary. (See ALTERNATOR in DIESEL ENGINE section). 9. Install alternator pivot and adjustment mounting hardware. Do not tighten hardware at this time. 10. Adjust belt tension. (See CHECK FAN/ ALTERNATOR BELT TENSION in DIESEL ENGINE section.) 11. Connect wiring leads to alternator. 12. Connect battery, positive (+) cable first. 13. Install left engine side panel.

4 - 148

KV15219

4. Access hydraulic oil temperature sender (B) located on front of hydraulic reservoir.

NOTE: Hydraulic reservoir capacity is approximately 15.6 L (4.1 gal). 5. Drain hydraulic oil from reservoir. 6. Disconnect wiring connector (A) and remove switch (B). 7. Apply pipe sealant with TEFLON to threads of switch before installation. 8. Install hydraulic oil temperature switch and connect wiring connector.

NOTE: Make sure hydraulic reservoir drain plug is installed. 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).

11/22/00

COMPONENT REPLACEMENT

ELECTRICAL

PARK BRAKE SOLENOID

HYDRAULIC OIL FILTER RESTRICTION SWITCH

Replace: Replace:

c CAUTION To help prevent injury from escaping hydraulic oil under pressure, relieve the pressure in the system. 1. Park machine on level surface. Lower boom to the at-rest position. Turn key to OFF position and ENGAGE park brake. 2. Relieve all hydraulic pressure in system by sitting in the operator seat with seat belt fastened. Turn key switch to the ON position but do not start engine. Press the park brake switch in the RELEASE position and operate the hydraulic foot control 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.

1. Park machine on level surface. Lower boom to the at-rest position. Turn key to OFF position and ENGAGE park brake. 2. Relieve all hydraulic pressure in system by sitting in the operator seat with seat belt fastened. Turn key switch to the ON position but do not start engine. Press the park brake switch in the RELEASE position and operate the hydraulic foot control pedals. ENGAGE the park brake switch and turn key switch to OFF position. 3. Raise ROPS and ensure ROPS is safely in the locked position. (See RAISING ROPS [ROLLOVER PROTECTION STRUCTURE] in the MISCELLANEOUS section.) 4. Access hydraulic oil filter restriction switch located on front of hydraulic oil filter manifold.

C B A A

B KV15220

5. Disconnect wiring connectors (A). Remove nut (B) and park brake solenoid (C). 6. Install park brake solenoid and connect wiring connectors. 7. Install nut and tighten to 5.4 N•m (48 lb-in.). 8. Connect battery, positive (+) cable first. 9. Start engine and check for oil leaks. 10. Install engine side panel.

KV15221

5. Remove nut and washer (A). 6. Remove wire lead (B). 7. Remove switch and O-ring (C).

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 at-rest position. Turn key to OFF position and ENGAGE park brake.

C E D

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 at-rest position. 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.)

4 - 150

5. Remove screws (2 used) and lock nuts retaining switch to bracket. Install new switch on original bracket and tighten screws securely.

11/22/00

COMPONENT REPLACEMENT

ELECTRICAL

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

CONTENTS

POWER TRAIN (CHAINCASE AND AXLES)

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® (Cold Weather Operation)

Axle housing and chain case lubrication.

TY22073

John Deere TORQ-GARD SUPREME®

Axle housing and chain case lubrication.

TY6390

Axle housing and chain case John Deere PLUS-50® Other Oil: API Service Classification SG or Higher lubrication.

TY6333/ TY6347

Moly High Temperature EP Grease

Axle housing to chain case O-ring.

PM20166

John Deere 5900 RTV Silicone

Seal chain case covers.

SPECIAL TOOLS Number

Name

JDG666

Spanner Wrench

Use 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 COMPONENT LOCATION

POWER TRAIN (CHAIN CASE AND AXLES)

POWER TRAIN COMPONENT LOCATION

Hydrostatic Motors

Chain Case Front Axle Sprocket

Front Drive Chain

Park Brake Assembly

Right Drive Shaft

Chain Case Level/Fill Plug

Rear Axle Sprocket

Chain Case Access Plate

Rear Drive Chain

Front Axle Housing

Chain Case Drain Plug Rear Axle Housing

11/22/00

5-3

KV13158

OPERATION

POWER TRAIN (CHAIN CASE AND AXLES)

OPERATION Theory of Operation

Drive Chains

The gear power train transmits power from the hydrostatic motor to the drive chains in the chain case. The drive chains turn large sprockets splined to the axles. Each hydrostatic motor is mounted onto the park brake assembly. The hydrostatic motor is splined to the machined shaft assembly through the park brake assembly. The left and right side gear power trains are completely separate units. The drive system is the same for forward or reverse; the drive motor is reversed through the hydrostatic system.

The skid steer uses four endless drive chains, one for each axle, running in an oil bath inside the chain case. The chain is driven by a double sprocket drive shaft from the hydrostatic motor. Each chain then drives a large chain sprocket splined onto the axle shaft. The large chain sprocket slides freely on the axle shaft spline. The chain can be tightened by sliding individual axle housings on slots; there are no chain tensioners or idler springs to adjust. Drive Axles

Chain Case

KV13152 KV13157

The chain case is also the skid steer side frame member. It is completely sealed from the other components of the skid steer and from the environment. Left and right chain cases are identical. Chain cases contain front and rear drive chains and sprockets. Each chain case has its own oil bath lubrication system with an oil level/fill plug on the chain case side access plate. All service to the components of each chain case may be accomplished through the removable chain case side access plates.

5-4

The drive axles are attached to the chain case on eight slotted mounting holes. The axle housing slides to provide tension to the roller drive chain inside the chain case. The splined axle shaft extends into the chain case where it is driven by a large roller chain sprocket. The sprocket is allowed to slide freely on the splines of the axle shaft. The axle housing contains two tapered roller bearings in replaceable races. The axle bearings are lubricated by the oil bath in the chain case.

11/22/00

TROUBLESHOOTING

POWER TRAIN (CHAIN CASE AND AXLES)

●

Check drive chain and sprockets

●

See DRIVE CHAIN TENSION ADJUSTMENT

●

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

See AXLE HOUSING DISASSEMBLY/ASSEMBLY

1/3/01

Both drive wheels on one side not powered

Grinding noise

Check chain case oil level

Check or Solution

One drive wheel not powered

Chain noise

Excessive axle play

Oil leak from axle or axle housing

Problem or Symptom

Oil leak from chain case

TROUBLESHOOTING

●

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 control levers forward at an equal rate.

Skid steer moves forward in a straight line with all wheels turning.

Engine stalls, wheels locked or dragging: See BRAKES section. Slow or no power: go to step 4. One side of skid steer drags: go to step 2.

2. Pull both steering control levers back at an equal rate.

Skid steer moves backward in a straight line with all wheels turning.

Engine stalls, wheels locked or dragging: See BRAKES section. 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 hand.

Tires move less than 6.35 mm (0.250 in.) at tire tread.

Tires move more than 6.35 mm (0.250 in.): check chain tension for that axle. One tire rotates freely: drive chain or 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.

If normal, but skid steer continues to pull to one side, go to step 4.

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 levers forward and reverse for each side.

Wheels and tires are driven smoothly for that steering control lever, and run at same rpm (use photo tachometer).

Chain noise: inspect drive chain. Slow on one side: see STEERING section for steering control lever adjustment; see HYDROSTATIC POWER TRAIN section for hydrostatic motor diagnostics.

5-6

1/3/01

DIAGNOSIS

POWER TRAIN (CHAIN CASE AND AXLES)

Right Steering Control Lever

Left Steering Control Lever

Front Axle Sprocket

Front Drive Chain

Rear Drive Chain

Right Drive Shaft 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. Drain oil into a suitable container.

KV13040 .

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. 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 connected. Service each chain case individually.

Cap Screw

Chain Case Access Plate KV13042

IMPORTANT: DO NOT use John Deere BIO-HY-GARDTM in chain case. 3. Fill chain case with proper lubricant. The following oils are PREFERRED: • John Deere HY-GARD • 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

4. Remove twelve cap screws holding the side access plate to the chain case. Remove access plate. 5. Remove sealant from access plate and chain case. Chain Case Side Access Plate Installation 1. Clean mating surfaces of side access plate and chain case. 2. Install access plate using PM20166 John Deere 5900 RTV Silicone. 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 to service drive chains, sprockets and drive shaft, and to access brake assembly mounting cap screws. Chain Case Access Plate Removal 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.

5-8

IMPORTANT: DO NOT use John Deere BIO-HY-GARDTM in chain case. 5. Fill chain case with proper lubricant. The following oils are PREFERRED: • John Deere HY-GARD • 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

1/3/01

REPAIR

POWER TRAIN (CHAIN CASE AND AXLES)

DRIVE CHAIN TENSION ADJUSTMENT

4. To tighten drive chain: • Push rear axle housing rearward. • Push front axle housing forward. 5. Tighten axle housing nuts to 305 N•m (225 lb-ft).

Check Chain Tension 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 BLOCKING SKID STEER in MISCELLANEOUS section.)

AXLE HOUSING REMOVAL/ INSTALLATION Axle Housing Removal

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.

KV15158

4. Check chain tension by rotating each tire by hand forward and rearward. Maximum tire movement at tire tread should be 6.35 mm (0.250 in.). If not within specification, adjust chain tension, see CHAIN TENSION ADJUSTMENT.

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 BLOCKING SKID STEER in MISCELLANEOUS section.) 4. Remove wheel from axle being serviced. 5. Clean around axle housing to prevent debris from entering chain case oil reservoir. Axle Housing Nuts

Chain Tension Adjustment Rear Drive Chain

Front Drive Chain

Axle Housing

KV18785

Right Side of Skid Steer Shown.

KV13157

NOTE: Chain free play movement up and down should be 5 mm (0.197 in.). 1. Drain chain case oil and remove chain case access plate. See CHAIN CASE ACCESS PLATE. 2. Loosen eight axle housing mounting nuts. 3. To loosen drive chain: • Push rear axle housing forward. • Push front axle housing rearward.

1/3/01

6. Install a suitable lifting strap and hoist to aid during removal of axle housing. 7. Remove eight axle housing mounting nuts.

NOTE: The inner and outer axle bearings are lubricated by the oil bath in the chain case. The axle housing will be half full of oil, and will drain when tipped. 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.)

5-9

REPAIR

POWER TRAIN (CHAIN CASE AND AXLES)

Axle Housing Installation 1. Clean mating surfaces of axle housing and chain case before installation.

11. Install wheels and tighten nuts to 237 N•m (175 lb-ft). 12. Check chain case oil level after skid steer has been driven and fill as necessary.

O-Ring

AXLE HOUSING DISASSEMBLY/ ASSEMBLY

Pre-lubricate Through 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 axle bearing to pre-lubricate. Notch

Tab Washer O-Ring

Lock Nut

Chain Sprocket Hub KV13139

Chain Case

2. Remove O-ring from axle housing. 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 inside chain case. (See DRIVE CHAIN TENSION ADJUSTMENT.) 10. Tighten eight axle housing mounting nuts to 305 N•m (225 lb-ft).

5 - 10

KV13140

5. Place axle housing in press with support under housing mounting flanges that will allow the axle shaft to drop two inches. 6. Press axle shaft down until axle shaft drops free of housing. 1/3/01

REPAIR

POWER TRAIN (CHAIN CASE AND AXLES)

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 hub so wheel bolts will not be pressed out when pressure is applied. Use press to seat outer bearing onto shoulder of axle shaft.

11. Press bearing on until it is 1—2 mm (0.039—0.079 in.) above shoulder on shaft.

Washer Seal Tab Washer Outer Bearing Race

O-Ring

Lock Nut

KVP13935

3. Inspect axle housing seal. If required, pry seal from axle housing.

NOTE: Always replace bearings as cone/outer-race sets. 4. If outer bearing was removed, remove outer bearing race with a hammer and a punch. Install new outer bearing race in housing using a 4.4-in. (OD) driver. 1/3/01

KV13139

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 of axle shaft. Tighten to a final torque of 340-408 N•m (250-300 lb-ft) 14. Align tab slot with tab washer. Bend tab on tab washer into slot on lock nut. 15. Install axle housing. (See AXLE HOUSING REMOVAL/INSTALLATION.)

5 - 11

REPAIR

POWER TRAIN (CHAIN CASE AND AXLES)

DRIVE CHAIN AND SPROCKET REMOVAL/INSTALLATION 1. Drain oil from chain case being serviced and remove chain case access plate. (See CHAIN CASE ACCESS PLATE.)

NOTE: It is necessary to remove rear axle housing and rear drive chain from the drive shaft before removing front drive chain.

4. To remove rear axle sprocket, lift sprocket to top of chain case. Pull bottom of sprocket out over bottom lip of chain case and remove rear axle sprocket.

NOTE: Front and rear drive chains are not repairable. Replace chains if necessary. 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.

Rear Drive Chain

Front Drive Chain

Drive Shaft

Right Side of Skid Steer Shown.

KV13155

5. Slide front axle sprocket rearward and remove front 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.) 7. Installation is done in the reverse order of removal.

KV13157

3. Slide rear axle sprocket forward and remove rear drive chain from drive shaft and rear axle sprocket.

5 - 12

1/3/01

CONTENTS

HYDROSTATIC POWER TRAIN

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 Reverse Min Reverse Model 250 Forward 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

TY6238

Name

Use

Petroleum Jelly

Apply to components of hydrostatic pump during assembly

John Deere HY-GARD®

Apply to internal surfaces of hydrostatic pump and hydrostatic motor during assembly.

Thread Lock & Sealer (Medium Strength)

Apply to hydrostatic pump drive hub set screws.

LOCTITE® PRODUCTS U.S./ Canadian/ LOCTITE No. TY9370/ TY9477 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: The Hydrostatic System provides a means to transfer power from the engine to the hydrostatic motors that drive the wheels. It also provides infinitely variable speed and steering. Theory of Operation: The hydrostatic system is a closed loop fluid power system that consists of two tandem mounted piston pumps and two GEROLER® motors. Charge pressure is provided by a gear pump located on the front of the hydrostatic pump assembly. Steering is controlled by two hand levers located in the operator’s cab. These hand levers control direction (forward, reverse) and speed (oil flow) of the vehicle by pivoting the cam plates (or swash plates) in the hydrostatic pumps. (See STEERING section.) • Hydrostatic Pump: The hydrostatic pumps are tandem mounted, manually variable displacement, axial piston pumps. They are mounted as an assembly to the flywheel housing. Power is transferred directly from the engine to the hydrostatic pump assembly by a hub coupler splined on the hydrostatic pump shaft.

Oil flow is controlled by changing the angle of the cam plate (swash plate). The position from center of the cam plate (swash plate) controls the distance the pistons travel inside the piston bore of the rotating assembly. 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 plate) is deflected determines how much oil will be displaced (speed). The hydrostatic pumps provide oil to the hydrostatic motors through hydrostatic lines and fittings. Oil in the hydrostatic system circulates in a closed loop. Oil leaves the hydrostatic pumps and flows through the hydrostatic motors and is returned to the hydrostatic pump, not the reservoir. Oil that leaves this closed loop circuit, such as case drain, is replenished by oil from the gear pump. (See HYDRAULICS section). The rear hydrostatic pump drives the right hydrostatic motor and the front hydrostatic pump drives the left hydrostatic motor. • Hydrostatic Motors: The hydrostatic motors are GEROLER® motors. There are two hydrostatic motors on each machine and are mounted on brake assemblies which are located on the 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 SYSTEM SCHEMATIC

HYDROSTATIC POWER TRAIN

HYDROSTATIC SYSTEM SCHEMATIC

Charge Flow

Brake Valve 210 psi

75 psi

Spin-On Filter

Hydraulic Reservoir B

To Main Control Valve Drive Motor

Brake

Hydraulic/Charge Pump High Flow Valve (Optional)

Hydrostatic Pumps

Engine Oil Cooler High Flow Pump (Optional)

3300 psi

To Main Control Valve

Brake

Drive Motor

From Main Control Valve

M18535

11/22/00

6-7

TROUBLESHOOTING

HYDROSTATIC POWER TRAIN

●

Hydrostatic pump not running Check engine coupling

●

Low charge pressure Check charge pump

●

Oil too heavy Cold weather

●

Shuttle valve stuck open Check valve

●

One side drives, other does not

●

Low power

●

Hydraulic oil level low in reservoir Check and top off oil level

Sluggish response to changes in speed

Check or Solution

Noisy pump or motor

Problem or Symptom

Machine will not move in either direction

TROUBLESHOOTING

●

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

●

6-8

●

Broken drive chain Linkages loose or broken

●

11/22/00

DIAGNOSIS

HYDROSTATIC POWER TRAIN

DIAGNOSIS Test Conditions: • Operator in seat. • Seat belt fastened. Test/Check Point 1. Steering levers.

Normal Levers should move freely.

If Not Normal 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 backward or in circles.

Perform steering system adjustments.

2. Move levers smoothly forward or backward from center.

Machine should accelerate smoothly forward or backward.

Check oil reservoir for proper oil 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 position.

Machine should move forward in a straight line.

Perform steering system adjustments. Perform hydrostatic pump tests.

11/22/00

6-9

TESTS AND ADJUSTMENTS

HYDROSTATIC POWER TRAIN

TESTS AND ADJUSTMENTS HYDRAULIC/CHARGE PUMP PRESSURE TEST

4. Disconnect charge flow line at left side of hydrostatic pump center manifold.

Reason: To ensure there is sufficient oil pressure to charge the hydrostatic systems properly and supply oil to the hydraulic system.

38H5069

Equipment:

JT03344

JT03457 JT03017

• 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) • JT0KV12444 Remote Start Box

c CAUTION To help prevent injury from escaping hydraulic oil under pressure, relieve the pressure in the system before removing hydraulic lines. Procedure: 1. Raise and block skid steer. (See RAISING AND BLOCKING SKID STEER in the MISCELLANEOUS section.) 2. Raise boom fully and engage the boom lock. Stop engine and relieve hydraulic pressure. 3. Remove cover plates to access the hydrostatic pumps. (See REMOVING COVER PLATES in MISCELLANEOUS section.)

Hydraulic Oil Filter Manifold

KV15134

5. Connect JT03017 Hose to JT03457 Adapter. 6. Attach JT03344 Gauge to quick disconnect on hose.

NOTE: Make sure all O-rings used between connections are in good condition to prevent leakage during test. 7. Connect 38H5069 Tee Fitting to adapter and tighten all connections. 8. Connect 38H5069 Tee Fitting to center manifold fitting and attach charge flow line to opposite end of Tee Fitting.

Charge Flow Line

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

TESTS AND ADJUSTMENTS

HYDROSTATIC POWER TRAIN

HYDRAULIC/CHARGE PUMP FLOW TEST

IMPORTANT: Make sure skid steer male connector is routed to tester inlet. 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 • KV13885 Quick Disconnect, Male • KV13884 Quick Disconnect, Female • JT03377 Hose, 2 required • JT03012 Connector, 2 required • JT05690 Connector, 2 required

Male Auxiliary Connector KV18562

Procedure: 1. Lower boom and bucket to normal ground position. Stop engine and relieve hydraulic pressure. 2. Raise and block skid steer. (See RAISING AND BLOCKING SKID STEER in the MISCELLANEOUS section.)

Specifications:

KV13885 JT05690

JT03012

JT03377

KV13884

KV15257

3. Install JT03012 and JT05690 Connectors on one end of both JT03377 Hoses. 4. Install KV13885 and KV13884 Quick Disconnects on connectors. Male Quick Disconnectto-Inlet Hose

6. Attach quick disconnects to auxiliary hydraulic ports located on left boom arm. 7. Operate hydraulic system until oil reaches normal operating temperature of 43°C (110°F). 8. Set engine speed to full throttle position. 9. Actuate auxiliary hydraulics control handle into detent (down toward seat) position. 10. Turn load valve knob to increase resistance until pressure reads 10 340 kPa (1500 psi).

Outlet Outlet-to-Female Quick Disconnect Hose

Minimum Pump Flow (Standard) 240 . . . . . . . . . . . . . . . . . . . . . 49.1 L/min (13 gpm) 250 . . . . . . . . . . . . . . . . . . . . . .56.7 L/min (15 gpm) Minimum Pump Flow (High-Flow Option) 240 . . . . . . . . . . . . . . . . . . . . 84.8 L/min (22.4 gpm) 250 . . . . . . . . . . . . . . . . . . . . 98.1 L/min (25.9 gpm) Results: 1. Check auxiliary hydraulic control valve spool travel and control handle pivot and linkage to make sure mechanical systems are operating properly. 2. If flow is low, verify proper engine speed at full throttle. If engine speed is OK, rebuild or replace charge pump. 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 Port

Left Forward Relief Valve

Right Forward Relief Valve Left Forward Port JT03340 Quick Coupler

Right Reverse Port Left Reverse Port

JT03362 Test Gauge

Left Reverse Relief Valve

JT05489 Connector

Right Reverse Relief Valve

JT03364 Test Hose 38H1035 Tee Fitting

RE60700 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 Right Forward Port

Left Forward Port

Right Reverse Port

JT03362 Test Gauge

Right Forward Relief Valve

Left Reverse Relief Valve

Left Reverse Port

JT03340 Quick Coupler JT05489 Connector JT03364 Test Hose

38H1035 Tee Fitting RE60700 Diagnostic Receptacle KV31049

6 - 12

11/22/00

TESTS AND ADJUSTMENTS

HYDROSTATIC POWER TRAIN

Reason:

c CAUTION

To ensure that hydrostatic pump high pressure relief valves are operating properly. Equipment: • 38H1035 Tee Fitting • JT05489** Connector (7/16-20M 37°x1/2-20M ORB) • JT03340** Quick Coupler • JT03364* Hose • JT03362* Gauge 0—70 000 kPa (0—10,000 psi) • JT0KV12444 Remote Start Box • RE60700 Diagnostic Receptacle

To help prevent injury from escaping hydraulic oil under pressure, relieve the pressure in the system before removing hydraulic lines. 6. Install 38H1035 Tee Fitting in the hydrostatic closed loop circuit at the hydrostatic pump center manifold port locations as indicated in HYDROSTATIC PUMP HIGH PRESSURE RELIEF TEST diagram: Left Forward Relief Valve—Right Top Port 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

Procedure: 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 to access the hydrostatic pumps. (See REMOVING COVER PLATES in the MISCELLANEOUS section.)

c CAUTION

7. Connect test hose, fittings, and gauge to tee fitting. 8. Start and operate engine at 3/4 throttle until hydraulic oil reaches 43°C (110°F). 9. Slowly move corresponding steering lever in appropriate direction for relief valve being tested. 10. Record gauge reading. 11. Perform steps 6—10 for all four relief valves as necessary. Specifications: • 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 bystanders. Do not use remote start box without raising and blocking skid steer.

Results:

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.

WHEEL SPEED TEST

If pressure is not within specifications, replace the corresponding relief valve.

Reason: 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 pumps and motors.

To use as an initial test to verify if hydrostatic system is operating normally. Equipment:

NOTE: Illustration shows gauge connection for testing the left reverse relief valve.

• JT05719 Hand Held Digital Tachometer • 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. 2. Raise and block skid steer. (See RAISING AND BLOCKING SKID STEER in the MISCELLANEOUS section.) 3. Apply reflective tape to one wheel at both sides of machine.

c CAUTION To help prevent injury from moving tires when performing the wheel speed test, have an assistant operate the controls while seated in the machine. 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 pumps and motors. 4. Start and operate engine at 3/4 throttle until 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.) 6. With hydrostatic control (steering) lever moved fully to forward position, measure and record rotations in one minute of corresponding wheel that has the reflective tape. 7. Move hydrostatic control lever fully rearward. Measure and record rotations in one minute of same wheel. 8. Repeat steps 6 and 7 for opposite side. 9. Stop engine. Specifications (Optimal): Model 240

WOT RPM

Wheel Rotations in One Minute

Serial Number

Forward

Reverse

–242579 242580–

80—85 80—85

65—70 80—85

Model 250

(2400 minimum) (2400 minimum) WOT RPM

Wheel Rotations in One Minute

Serial Number

Forward

Reverse

–252793 252794–

70—75 70—75

60—65 70—75

(2400 minimum) (2400 minimum)

IMPORTANT: Left and right sides must be within 1 rpm to provide proper steering control.

6 - 14

Results: If wheel speed is significantly outside of the listed ranges: • Perform Engine Fast and Slow Idle test. (See FAST AND SLOW IDLE ADJUSTMENT in the ENGINE section.) • Inspect brakes for dragging • Perform Hydraulic/Charge Pump Pressure test. (See HYDRAULIC/CHARGE PUMP PRESSURE TEST in this section.) • Hydrostatic Pump Case Drain test. (See HYDROSTATIC PUMP CASE DRAIN test in this section.) • Perform Hydraulic/Charge Pump Flow Test. (See HYDRAULIC/CHARGE PUMP FLOW TEST in this section.) • Hydostatic Case Drain Pressure Test. (See HYDROSTATIC CASE DRAIN PRESSURE TEST in this section) If wheel speed varies more than 1 rpm from side to side, perform tracking adjustment. (See CONTROL LEVER STOPS ADJUSTMENT–TRACKING in the steering SECTION.)

HYDROSTATIC PUMP FLOW TEST Reason: To ensure that the hydrostatic pumps are delivering sufficient oil flow to the hydrostatic motors. Equipment: • D01074AA -In-Line Hydraulic Tester • JT03377 - 2- 365cm (10 ft) hoses, ¾ M NPT x ¾ M NPT • JT03012 – ¾ F NPT x 1-1/16 F 37° Flare (2 used) • JT05690 – 1-3/16-12 F ORFS Sw x 1-1/16-12 37° M Flare (2 used) • 38H1272 – 1-3/16-12 M ORFS x 1-3/16-12 M ORFS Procedure: 1. Park skid steer safely. 2. Raise boom and place on boom locks. 3. Stop engine. Turn key to ON position and operate all hydraulic controls to relieve hydraulic pressure. 4. Raise and block skid steer. (See RAISING AND BLOCKING SKID STEER in the MISCELLANEOUS section.) 5. Remove cover plates to access hydrostatic pumps. (See COVER PLATE REMOVAL/INSTALLATION in the MISCELLANEOUS section.)

11/22/00

TESTS AND ADJUSTMENTS

HYDROSTATIC POWER TRAIN

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 B. Above serial numbers: KV0240A142337– KV0250A152709– or if P.I.P. 00KV010 has been performed on earlier model.

M10 x 30 Cap Screw

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

38H1272

HYDROSTATIC POWER TRAIN

Line to Motor

Connect to Hose JT03012 Inlet

JT05690 JT03377

Outlet

Connect to Pump Line from Pump Load Valve KV31085 KV31089

10. Install fittings on JT03377 hydraulic lines as shown. Elbow

13. Connect line from pump to inlet port on in-line tester. 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 Tester Inlet Port

Line to Motor Line from Tester Outlet Port KV31086

11. Connect hydraulic line with 38H1272 ORFS union to hydraulic line disconnected from pump. 12. Connect the other hydraulic line to the elbow fitting on pump.

Specifications: Minimum Pump Flow (approximate): 240 . . . . . . . . . . . . . . . . . . . . . . . 90.8 L/min (24 gpm) 250 . . . . . . . . . . . . . . . . . . . . . . . 90.8 L/min (24 gpm) 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

TESTS AND ADJUSTMENTS

HYDROSTATIC POWER TRAIN

HYDROSTATIC PUMP CASE DRAIN TEST

Tee Fitting

Left Drive Motor Drain Hose Right Drive Motor Drain Hose Return Drain Hose

KV18070

Reason: To ensure that hydrostatic pump is not bypassing excessive hydraulic oil. Equipment: • 38H1415 Cap Assembly • 38H1416 Cap Assembly • 38H1206 Union Tee • 8-6 TRLO-5 (Parker) Adapter • 3/8 ID x 24" Long Hose with Hose Clamp • JT0KV12444 Remote Start Box • Graduated Breaker Procedure: 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 to access the hydrostatic pumps. (See REMOVING COVER PLATES in the MISCELLANEOUS section.)

11/22/00

5. Install a M10x30 cap screw in both steering control arms to secure them to the frame. 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 pumps and motors. 6. Start and operate engine at 3/4 throttle until hydraulic oil reaches normal operating temperature of 43°C (110°F). 7. Stop engine.

c CAUTION To help prevent injury from escaping hydraulic oil under pressure, relieve the pressure in the system before removing hydraulic lines.

c CAUTION To help prevent injury from escaping hot oil, use suitable protection when disconnecting the hydraulic lines. 8. Disconnect return drain hose and left drive motor drain hose from tee fitting at left side of rear hydrostatic pump. 9. Disconnect right motor drain hose from fitting at right side of front hydrostatic pump.

6 - 17

TESTS AND ADJUSTMENTS

HYDROSTATIC POWER TRAIN

38H1415 Cap Assembly

38H1416 Cap Assembly Return Drain Hose Hose Clamp

9.5 mm (3/8 in.) ID Test Hose

Right Drive Motor Drain Hose 8-6 TRLO-S Adapter

38H1206 Union Tee Left Drive Motor Drain Hose KV18071

10. Connect the left drive motor drain hose and the return drain hose to 38H1206 Union Tee. 11. Connect the right drive motor drain hose to 38H1206 Union Tee using 8-6 TRLO-S Adapter. 12. Install 38H1416 Cap Assembly to rear port on tee fitting at left side of rear hydrostatic pump. 13. Install 38H1415 Cap Assembly to fitting on right 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 pump. Fasten using a hose clamp. 15. Put end of test hose in a suitable container. 16. Start engine and disengage park brake. 17. Run engine at 3/4 throttle until hydraulic oil reaches normal operating temperature of 43°C (110°F).

NOTE: To ensure accurate readings, outlet of test hose should be above hydraulic reservoir full line. 19. Transfer hose from container to graduated beaker. 20. Capture fluid for a 10-second period of time. Return hose to container. IMPORTANT: Complete this test within 20 seconds to avoid overheating hydraulic oil. 21. Stop engine. 22. Record volume of oil in graduated beaker. Specifications:

IMPORTANT: Move only the corresponding steering lever of pump being tested. If both steering levers are moved during the test, an inaccurate reading will result.

• Volume in graduated beaker should not exceed 0.95 L (2 pt) in 10 seconds. Results:

18. Move corresponding steering lever of pump being tested slowly forward or backward until fluid flows from end of hose.

6 - 18

If volume exceeds specifications, repair or replace pump. Repeat steps 14—20 for the other hydrostatic pump.

11/22/00

TESTS AND ADJUSTMENTS

HYDROSTATIC POWER TRAIN

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 • 38H1161 Adapter • JT03457 Adapter • JT05498* Hose • JT05472* Gauge 0—400 kPa (0—60 psi) *Part of JT05470 Universal Pressure Test Kit

Procedure: 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 to access the hydrostatic pump. (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.

KV18022

6. Remove plug from right side of rear hydrostatic pump housing. 7. Install 38H1161 Adapter in port. 8. Install JT03457 Adapter on 38H1161 Adapter. 9. Install gauge and hose assembly. 10. Start and operate engine at 3/4 throttle until hydraulic oil reaches normal operating temperature of 43°C (110°F). 11. Disengage park brake. Move both steering levers slowly forward or backward. 12. Record gauge reading. 13. Stop engine. Specifications: • Case drain pressure should not exceed 172 kPa (25 psi). Results: If case drain pressure is over specifications: 1. Check for restriction in return drain hose 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 COMPONENT REPLACEMENT 1. Park skid steer safely. 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.

38H5069 JT03457 JT03017 JT03344

KV15134

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. 4. Install remote start box. (See USING REMOTE START BOX in the MISCELLANEOUS section.) 5. Change hydraulic system filter. 6. Remove hydraulic breather assembly on top of reservoir. Clean filter in solvent and dry before installation. IMPORTANT: If contamination is found in hydraulic system or component, flush entire hydraulic system. If the hydraulic oil is being reused, make sure it is filtered through a 10-micron filter before putting into reservoir. 7. Fill reservoir with HY-GARD or LOW VIS HY-GARD (cold weather operation) to the proper level. Approximate capacity of reservoir is 15.6 L (4.1 gal). 8. Disconnect wires to fuel shut-off solenoid. 9. Turn remote start box key to START and crank engine for 10 seconds. 10. Connect wires to fuel shut-off solenoid.

6 - 20

11. Install gauge as described in HYDRAULIC/ CHARGE PUMP PRESSURE TEST. (See HYDRAULIC/CHARGE PUMP PRESSURE TEST.) 12. Put steering levers in neutral position. Start engine using remote start box and operate at low idle. Charge pressure should read 550—830 kPa (80—120 psi) within 5 to 10 seconds. IMPORTANT: If charge pressure remains below 350 kPa (50 psi) for more than 10 seconds, stop engine and check for cause of low pressure. Failure to stop engine when charge pressure is low will cause severe damage to pumps and motors.

c CAUTION To help prevent injury from escaping hydraulic oil under pressure, relieve the pressure in the system before removing hydraulic lines. 13. Stop engine after proper charge pressure has been indicated, and relieve all hydraulic pressure in system. 14. Remove gauge and install hydraulic lines. 15. Remove remote start box and lower ROPS. 16. Disengage boom lock and lower boom with boom and bucket cylinders fully retracted. 17. Start engine and operate at half throttle for 20 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. 11/22/00

REPAIR

HYDROSTATIC POWER TRAIN

HYDROSTATIC PUMP REMOVAL 1. Remove cover plates. (See COVER PLATE REMOVAL/INSTALLATION in the MISCELLANEOUS section.) 2. Remove steering cross shaft. (See STEERING CROSS SHAFT REMOVAL/INSTALLATION in the STEERING section.) 3. Remove centering plate(s). (See CENTERING PLATE REMOVAL/INSTALLATION in the STEERING section.)

B C A

F E

Control Rods

KV18872 KV18869

4. Remove steering control rods from control levers. 5. Drain hydraulic reservoir.

Hydraulic Fitting

A. Hydrostatic Pump Center Manifold Port-toHydraulic Oil Filter Manifold Hose B. Hydrostatic Pump Rear Port-to-Left Drive Motor Case Drain Hose 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 F. Hydrostatic Pump Top Left Center Manifold 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.

7. Mark and disconnect hoses (A–J) from hydrostatic pump assembly.

Cap Screws (2 used)

Hydrostatic Pump Assembly J

Spacer

Flywheel Adapter Plate

Hydrostatic Pump Mounting Bracket KV18871

G. Through serial number: –KV0240A142337 or –KV0250A152709: Hydrostatic Pump Top Right Center Manifold Port-to-Right Drive Motor Top Front Port Hose Above serial number: KV0240A142337– or KV0250A152709– (or if PIP 00KV010 has been performed): Hydrostatic Pump Top Right Center Manifold 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

6 - 22

Spacers (See Note)

Cap Screws (See Note)

Cap Screws (See Note) KV18496

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. 8. Remove six cap screws and four spacers from mounting bracket. 9. Remove two cap screws from pump assembly flange. 10. Slide pump assembly forward to remove from flywheel adapter plate. 11. Attach a sling and hoist to pump assembly and remove from machine.

11/22/00

REPAIR

HYDROSTATIC POWER TRAIN

FRONT HYDROSTATIC PUMP EXPLODED VIEW A B

D E

M F O

L K J

Q I P

H G

Front of Machine

E D B A S KV31095

A. Screw (6 used) B. Washer (6 used) C. Cover Plate D. O-Ring E. Bearing Race

F. Bearing Cone G. Front Pump Housing H. Ring I. Needle Bearing

J. Drive Shaft K. Cam Plate (or Swash Plate) L. Insert M. Rotating Assembly

N. Valve Plate O. Shim(s) P. O-Ring Q. Plug 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

Through serial numbers:

250

–KV0240A142337

–KV0250A152709

D C A

H I

T U

K J

R Q Front of Machine

P O

KV31106

A. Center Manifold B. Washer (8 used) C. Cap Screw (8 used) D. Right Forward High Pressure Relief Valve E. O-Ring F. Left Forward Port G. Plug H. O-Ring

I. Left Reverse Port J. Dowel Pin (2 used) K. Front Gasket (early models) L. Front Gasket (late models) M. Needle Bearing N. Roll Pin (2 used) O. Right Reverse High Pressure Relief Valve

P. Left Reverse High Pressure Relief Valve Q. Left Forward High Pressure Relief Valve R. Right Reverse Port S. Right Forward Port T. Bushing U. Rear Gasket

NOTE: Early models have different front and rear gaskets. Later models use same gasket (oval with cutout).

6 - 24

11/22/00

REPAIR

HYDROSTATIC POWER TRAIN

CENTER MANIFOLD EXPLODED VIEW (LATE and CONVERTED MODELS) Model

240

After serial numbers:

250

KV0240A142337– KV0250A152709– and early models after PIP 00KV010 has been performed. D C A

H I

S T

K J

R P

Front of Machine N KV31094

A. Center Manifold B. Washer (8 used) C. Cap Screw (8 used) D. Right Reverse High Pressure Relief Valve E. O-Ring F. Left Forward Port G. Plug

11/22/00

H. O-Ring I. Left Reverse Port J. Dowel Pin (2 used) K. Front Gasket L. Needle Bearing M. Roll Pin (2 used) N. Right Forward High Pressure Relief Valve

O. Left Reverse High Pressure Relief Valve P. Left Forward High Pressure Relief Valve Q. Right Reverse Port R. Right Forward Port S. Bushing T. Rear Gasket

6 - 25

REPAIR

HYDROSTATIC POWER TRAIN

REAR HYDROSTATIC PUMP EXPLODED VIEW A B

C D

H K L

E G

M N O P

Q R S T

V M L K

H I

Front of Machine KV31096

A. Retaining Ring B. Shaft Seal C. Washer D. Snap Ring E. Bearing Race F. Thrust Bearing

G. Drive Shaft H. Washer (6 used) I. Cap Screw (6 used) J. Cover Plate K. Seal L. O-Ring

M. Bearing Race N. Bearing Cone O. Plug P. O-Ring Q. Cam Plate (or Swash Plate)

R. Insert S. Rotating Assembly T. Valve Plate U. Cover Plate V. Shims 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

REPAIR

HYDROSTATIC POWER TRAIN

HYDROSTATIC PUMP DISASSEMBLY

c CAUTION

IMPORTANT: Clean hydrostatic and hydraulic/ charge pump cases before separating pumps to prevent contamination of hydraulic system.

Use proper lifting equipment. weight of pumps is 45 kg (100 lb).

Approximate

Cap Screws and Nuts

KV18505

Coupler

Input Shaft

Set Screws KV18503

1. Measure or mark position of coupler on pump input shaft to aid in assembly. 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

3. Remove control levers and front and rear centering plate mounts.

11/22/00

KV18873

5. Remove eight cap screws and remove hydraulic/ charge pump. (Refer to the HYDRAULICS section for disassembly and inspection procedures for the hydraulic/charge pump.)

6 - 27

REPAIR

HYDROSTATIC POWER TRAIN

c CAUTION Note location and orientation of hydrostatic pump components. Components are not interchangeable between front and rear hydrostatic pumps.

Relief Valves

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 KV18507

6. Remove four cap screws securing front pump housing to center manifold. 7. Lift front pump housing straight up and off from center manifold.

14. Remove rear valve plate from center manifold. Holding Fixture

Drive Shaft

Center Manifold

NOTE: Rotating assembly might "stick" to center manifold due to hydraulic oil adhesion. Be careful not to let rotating assembly fall unexpectedly.

Rotating Assembly

Valve Plate

Housing

Rotating Assembly

KV18508

8. Pull out drive shaft from center manifold and rotating assembly. 9. Lift rotating assembly from valve plate. IMPORTANT: Valve plates are not interchangeable. Note location of each valve plate.

KV18510

15. Using your hand, hold rotating assembly in housing. 16. Rotate holding fixture 180 degrees and slowly slide out rotating assembly.

10. Remove front valve plate from center manifold.

6 - 28

11/22/00

REPAIR

HYDROSTATIC POWER TRAIN

Cover Plates

Snap Ring

Cam Plate (Swash Plate) KV18511

17. Remove snap ring holding seal and shaft.

Housing

Trunnion Shaft KV18513

Housing

NOTE: Rear pump housing shown. The procedure is the same for the front pump housing.

Shaft

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 Bearing

Cam Plate (Swash Plate)

Bearing Outer Race

Outer Race

Needle Bearings

KV18514

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 bearing cage, are discolored, broken, pitted, or are not free to move. Relief Valves

Seal

Insert O-Rings

KV18516

4. Inspect cam plate (swash plate) and cam plate insert. Surfaces should be smooth and free of deep scratches. 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

KV18515

Relief Valves

2. Inspect four relief valves in center manifold. Bearing

Cam Plate (Swash Plate)

Outer Race

Bearing Outer Race KV18517

Seal

Front Pump Valve Plate Metering Slots

Insert O-Rings

KV18516

NOTE: Early models ( S/N –KV0240A140201; S/N –KV0250A150192) have factory-installed shims under bearings. Shims and bearings must be kept on the same side of the cam plate (swash plate) they were taken from. Later models use a crush washer. The crush washer is not a serviced part and must be replaced with shims from an available shim kit.

KV18809

Rear Pump Valve Plate 6. Inspect bronze side of valve plate for wear. Replace 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

REPAIR

HYDROSTATIC POWER TRAIN

NOTE: Rotating assembly is not serviceable. Replace assembly if any components are damaged.

Slipper

HYDROSTATIC PUMP ASSEMBLY 1. Clean all parts in a suitable solvent and dry using compressed air or a lint-free rag. 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 NOT use John Deere BIO HY-GARD®.

Piston Block Piston

Bearings

KV18518

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. Bearing Surfaces

Spacer

Thrust Washers

Thrust Bearing

Insert

Shims

KV18524

2. Install bearings and shims onto cam plate (swash plate). Install the same thickness of shims taken off 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 during assembly.

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

Shaft Assembly

Cover Plates

Cam Plate (Swash Plate) Spacer Housing

Trunnion Shaft KV18513

4. Install cam plate (swash plate) assembly into housing with trunnion shaft through the previously noted or marked side of the 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 Seal

KV18521

10. Apply petroleum jelly to needle bearings in housing and install shaft assembly in housing by tapping lightly with a soft-faced hammer. 11. Install spacer over shaft and into housing.

Thrust Bearing

KV18522

Spacer

Snap Rings

Thrust Washers

Snap Ring

12. Using a piece of pipe of appropriate diameter, lightly tap new seal into housing until it bottoms out on spacer.

Snap Ring 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

REPAIR

HYDROSTATIC POWER TRAIN

Holding Fixture

Housing

Rotating Assembly

Cap Screws KV18509

KV18510

14. Push rotating assembly onto shaft and into housing. Align splines on shaft and rotating assembly as assembly is inserted into housing. 15. Hold rotating assembly in housing and rotate holding fixture 180 degrees. Needle Bearing

18. Install new gasket and install center manifold onto pump housing. 19. Install four cap screws and tighten to 56 N•m (41 lb-ft). Valve Plate

Relief Valves

Center Manifold

Relief Valves

Needle Bearing KV18709

Valve Plate

KV18525

IMPORTANT: Valve plates are not interchangeable.

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 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. 17. Apply a light coat of petroleum jelly to needle bearing. Install valve plate on center manifold.

Drive Shaft

Center Manifold

Rotating Assembly

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 with Plug Installed

Port at 3 O’Clock Position

KV18873

27. Install hydraulic/charge pump onto front pump. 28. Tighten the eight screws to 35 N•m (26 lb-ft).

c CAUTION KV31113

24. Looking at the pump as it would be 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.

6 - 34

Use proper lifting equipment. weight of pumps is 45 kg (100 lb).

Approximate

29. Remove pump assembly from holding fixture.

11/22/00

REPAIR

HYDROSTATIC POWER TRAIN

Control Lever

Mounts

HYDROSTATIC PUMP INSTALLATION

Control 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 KV18504

Hydrostatic Pump Assembly

30. Install centering plate mounts. Tighten cap screws to 41 N•m (30 lb-ft). 6 mm (0.025 in.)

Spacer

Flywheel Adapter Plate

Coupler

Hydrostatic Pump Mounting Bracket

Set Screws Spacer (See Note)

KV31117

31. Install coupler on input shaft. Adjust the gap between the pump and coupler to 6 mm (0.250 in.). 32. Apply thread lock and sealer (medium strength) to set screws. Tighten set screws to 37 N•m (27 lb-ft).

Cap Screws (See Note)

Cap Screw (See Note) KV18496

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

G C H

F E J

KV18872

KV18871

6 - 36

11/22/00

REPAIR

HYDROSTATIC POWER TRAIN

6. Install steering control rods to control levers. Tighten to 40 N•m (30 lb-ft). 7. Install centering plate(s). (See CENTERING PLATE REMOVAL/INSTALLATION in the STEERING section.) 8. Install steering cross shaft. (See STEERING CROSS SHAFT REMOVAL/INSTALLATION in the STEERING section.) 9. Install cover plates. (See COVER PLATE REMOVAL/INSTALLATION in the MISCELLANEOUS section.) 10. Fill hydraulic reservoir to proper level. 11. Perform start-up procedure. (See START-UP PROCEDURE AFTER COMPONENT REPLACEMENT.)

HYDROSTATIC MOTOR REMOVAL/ INSTALLATION Removal: 1. Remove covers to access the hydrostatic motors. (See REMOVING COVERS in the MISCELLANEOUS section.) 2. Remove steering cross shaft (see STEERING CROSS SHAFT REMOVAL/INSTALLATION in the STEERING section.) A

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

F G

P H

I J K L

V W Align Shuttle Flow Holes

U T S

R KV31123

A. End Cap B. O-Ring C. Seal, Square Cut D. Valve Plate E. Seal, Square Cut F. GEROLER®

6 - 38

G. Steel Ball (2 used) H. Drive Shaft I. Seal, Square Cut J. Balance Plate K. Seal, Square Cut L. Backup Ring

M. O-Ring N. Plug O. O-Ring P. Relief Valve Assy. Q. Cap Screw (9 used) R. Shaft Face Seal

S. Flange T. Backup Ring U. Seal V. Plug, Shuttle Valve W. O-Ring X. Shuttle Valve Assembly

11/22/00

REPAIR

HYDROSTATIC POWER TRAIN

HYDROSTATIC MOTOR DISASSEMBLY 1. Scribe two lines 25 mm (1 in.) apart down body of motor to aid in assembly.

Shuttle Valve 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

2. Place motor in a vertical position and remove nine 12-point cap screws.

NOTE: There are two small check balls underneath balance plate in GEROLER that can fall out when taking motor apart.

Check Balls

NOTE: Relief valve may have shims in recess of poppet. Use care not to lose them while cleaning parts. 1. Clean all parts in a suitable solvent and dry with 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 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

F G

P H

I J K L

X G V W Align Shuttle Flow Holes

U T S

R KV31123

A. End Cap B. O-Ring C. Seal, Square Cut D. Valve Plate E. Seal, Square Cut F. GEROLER®

G. Steel Ball (2 used) H. Drive Shaft I. Seal, Square Cut J. Balance Plate K. Seal, Square Cut L. Backup Ring

M. O-Ring N. Plug O. O-Ring P. Relief Valve Assy. Q. Cap Screw (9 used) R. Shaft Face Seal

S. Flange T. Backup Ring U. Seal V. Plug, Shuttle Valve W. O-Ring 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

REPAIR

HYDROSTATIC POWER TRAIN

Valve Plate Shuttle Piston

Dash Pots (2 used)

Springs (2 used) O-Ring

Relief Valve Plug Poppets (2 used)

Shuttle Valve Plug

Shims O-Ring

KV18881

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. 1. Coat shuttle valve parts with petroleum jelly and 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

Square Cut Seal Shuttle Flow Hole

O-Ring Valve Side of GEROLER

KV18882 KV18880

5. Place end cap on workbench, name tag side down, seal groove side up. Coat surfaces and grooves with petroleum jelly and install O-ring and square cut seal.

11/22/00

7. Coat both sides of GEROLER with petroleum jelly and install square cut seal on each side. Place GEROLER over valve plate, valve side of rotor down and spline side up. Align bolt holes and shuttle flow hole.

6 - 41

REPAIR

HYDROSTATIC POWER TRAIN

12. Install flange on balance plate being careful not to displace seals and O-rings.

Balance Plate

Check Balls

KV18883

8. Place two check balls in rotor and retain with petroleum jelly. Install drive shaft. 9. Place balance plate on GEROLER. Align bolt holes and shuttle flow holes.

NOTE: Backup ring for O-ring is contoured on one side to properly sit over O-ring.

8 5

KV18588

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 pattern as shown. Finish tightening to 82 N•m (60 lb-ft) in the same criss-cross pattern. Shaft Face Seal

Square Cut Seal

Backup Ring

Seal

Backup Ring KV18885

O-Ring Backup Ring

14. Install shaft face seal with the cupped side down. Hold in place with petroleum jelly. Installation:

Shuttle Flow Hole

O-Ring

Flange KV18587

1. Install motor assembly (see HYDROSTATIC MOTOR REMOVAL/INSTALLATION in this section.) 2. Perform start-up procedure. (See START-UP PROCEDURE AFTER COMPONENT REPLACEMENT in this section.)

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

CONTENTS

STEERING

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

SPECIFICATIONS

STEERING

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

Function

One dampener is attached to each steering control lever. The steering dampeners eliminate hydrostatic pulses and torque feedback into the steering control levers. The steering dampeners provide a slight resistance in movement of the steering control levers.

The steering system provides a means of controlling the direction and speed of the skid steer by controlling the 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

Right Steering Lever

Cross Shaft Bellcranks

Pivot Bearing

Left Steering Lever Spring Bolt Assembly

Link Rod

Centering Plate

Control Rod

Centering Screws

Guide Pins and Bushings

11/22/00

KV15159

7-5

STEERING COMPONENT LOCATION—DUAL PLATE MODELS

STEERING

STEERING COMPONENT LOCATION—DUAL PLATE MODELS

Right Steering Lever

Pivot Bearing Left Steering Lever

Cross Shaft Spring Bolt Bellcranks Assemblies

Link Rod

Left Wheel Centering Plate

Right Wheel Centering Plate

Detent Ring

Right Wheel Control Rod Left Wheel Control Rod

Detent Screw

7-6

Centering Screws

Guide Pins and Bushings

KV18848

11/22/00

TROUBLESHOOTING

STEERING

●

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

●

11/22/00

●

● ●

●

Steering lever travel incorrectly adjusted ROPS not secured

Levers pulse or vibrate excessively.

Steering levers feel loose or sloppy.

●

Centering plate(s) improperly adjusted

Check or Solution

Vehicle tracks to one side with levers in full forward or reverse position.

Steering levers hard to move.

●

Machine creeps with levers in neutral.

Problem or Symptom

Hydrostatic system noisy while in neutral.

TROUBLESHOOTING

● ●

●

7-7

DIAGNOSTICS

STEERING

DIAGNOSTICS Test Conditions: • Operator in seat. • Seat belt fastened. Test/Check Point 1. Steering control levers.

Normal

If Not Normal

Levers should move freely with slight resistance.

Check linkage from levers to pump. Check steering dampeners.

Test Conditions: • Engine running at slow idle. Test/Check Point

Normal

If Not Normal

1. Steering control levers are in neutral, park brake switch disengaged.

Pumps should be quiet. Engine should not sound labored.

Adjust centering plate(s).

2. Steering control levers are in neutral, park brake switch disengaged.

Machine should not creep forward or backward or in circles.

Adjust centering plate(s).

3. Steering control levers in full forward or full reverse position, park brake switch disengaged.

Machine should move forward, or backward, in a straight line.

Adjust steering control lever stop screws.

4. Dual steering plate models only - Steering control levers in full forward or full reverse position, park brake switch disengaged. Release one lever.

Lever should remain in position and machine should continue in a straight line.

Adjust or repair steering detent.

7-8

11/22/00

TESTS AND ADJUSTMENTS

STEERING

TESTS AND ADJUSTMENTS Pump Control Lever

CENTERING PLATE ADJUSTMENT—SINGLE PLATE MODELS

Control Rod

Reason: To prevent the skid steer from creeping when control levers are in neutral.

Rear Centering Screws

Equipment:

Front Centering Screws Pump Control Lever

• JT0KV12444 Remote Start Box Procedure: 1. Park skid steer safely. 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. 5. Remove cover plates to gain access to the hydrostatic pump assembly. (See REMOVING COVER PLATES in MISCELLANEOUS section.)

Spring Bolt Assembly

Control Rod

KV13927 .

c CAUTION

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 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

Right Wheels Forward Movement

Left Wheels Rearward Movement

STEERING

Right Wheels Rearward Movement

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.) horizontal gap between upper centering plate and lower front centering bracket must be maintained when adjusting screws (A—D).

IMPORTANT: Adjusting any centering screw will affect the clearance between the centering screws and bearings for the wheels on the other side of the machine.

11. Verify that the gap between the upper centering plate and lower front centering bracket is between 3.2 mm and 6.4 mm (1/8 in. and 1/4 in.). 12. Start skid steer and set engine rpm to 3/4 throttle. Turn parking brake OFF. Wheels should not rotate. 13. If wheels rotate, adjust centering screws as indicated:

14. Verify that 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 pump control lever. 15. Verify that the gap between the upper centering plate and lower front centering bracket is between 3.2 mm and 6.4 mm (1/8 in. and 1/4 in.). • The machine will not center consistently with a gap less than 3.2 mm (1/8 in.). • Steering effort will be increased with a gap greater than 6.4 mm (1/4 in.). • If not within specified gap, adjust all four screws equally to obtain gap and repeat STEPS 11-15. 16. Connect control rods to pump control levers. Tighten cap screws to 40 N•m (30 lb-ft). 17. Test left wheel adjustment by moving left control lever to full forward and releasing handle. The wheels should stop turning. Perform the same test by pulling rearward on the left control lever. • If motion does not stop, adjust the left wheel centering screws (A)-(B) so that both screws touch the bearings in the neutral position and repeat STEPS 9-17. • Repeat test using the right control lever. Adjust the right wheel centering screws (C)-(D) so that both screws touch the bearings in the neutral position and repeat STEPS 9-17. 18. Center left and right steering control levers. (See STEERING CONTROL LEVER ADJUSTMENT— CENTERING in this section.)

• To adjust the left side wheels forward movement: Loosen jam nut and turn centering screw (A) in (clockwise) until the left wheels start to turn rearward. Slowly turn the centering screw out until the left wheels stop turning. Tighten the jam nut. • To adjust the left side wheels rearward movement: Loosen jam nut and turn centering screw (B) in (clockwise) until the left wheels start to turn forward. Slowly turn the centering screw out until the left wheels stop turning. Tighten the jam nut. • To adjust the right side wheels forward movement: Loosen jam nut and turn centering screw (C) in (clockwise) until the right wheels start to turn rearward. Slowly turn the centering screw out until the right wheels stop turning. Tighten the jam nut. • To adjust the right side wheels rearward movement: Loosen jam nut and turn centering screw (D) in (clockwise) until the right wheels start to turn forward. Slowly turn the centering screw out until the right wheels stop turning. Tighten the jam nut.

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 MODELS

Pump Control Levers 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. 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. 5. Remove cover plates to gain access to the hydrostatic pump assembly. (See REMOVING COVER PLATES in MISCELLANEOUS section.)

M10 x 30 Cap Screw

Detent Ring Set Screws KV18845

7. Check pivot points of all the steering linkage for wear and damage. Repair linkage components prior to performing these adjustments.

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 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 both steering lever yokes to secure steering assembly during adjustment.

Spring Bolt Assembly KV18845

11. Check that the spring bolt assemblies are tightened to 67 N•m (50 lb-ft).

7 - 12

11/22/00

TESTS AND ADJUSTMENTS

STEERING

Right Wheels C Forward Movement

Right Wheels Rearward Movement D

Left Wheels Rearward Movement

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.) horizontal gap between upper centering plate and lower centering bracket must be maintained when adjusting screws (A—D). 12. Verify that the gap between the upper centering plates and lower centering brackets is between 3.2 mm and 6.4 mm (1/8 in. and 1/4 in.). 13. Start skid steer and set engine rpm to 3/4 throttle. Turn parking brake OFF. Wheels should not rotate. 14. If wheels rotate, adjust centering screws as indicated: • To adjust the left side wheels forward movement: Loosen jam nut and turn centering screw (A) in (clockwise) until the left wheels start to turn rearward. Slowly turn the centering screw out until the left wheels stop turning. Tighten the jam nut. • To adjust the left side wheels rearward movement: Loosen jam nut and turn centering screw (B) in (clockwise) until the left wheels start to turn forward. Slowly turn the centering screw out until the left wheels stop turning. Tighten the jam nut. • To adjust the right side wheels forward movement: Loosen jam nut and turn centering screw (C) in (clockwise) until the right wheels start to turn rearward. Slowly turn the centering screw out until the right wheels stop turning. Tighten the jam nut. • To adjust the right side wheels rearward movement: Loosen jam nut and turn centering screw (D) in (clockwise) until the right wheels start to turn forward. Slowly turn the centering screw out until the right wheels stop turning. Tighten the jam nut.

11/22/00

15. Verify that the gap between the upper centering plates and lower centering brackets is between 3.2 mm and 6.4 mm (1/8 in. and 1/4 in.) and that 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 pump control lever. • The machine will not center consistently with a gap less than 3.2 mm (1/8 in.). • Steering effort will be increased with a gap greater than 6.4 mm (1/4 in.). • If not within specified gap, adjust screws equally to obtain gap and repeat STEPS 12-15. 16. Connect control rods to pump control levers. Tighten cap screws to 40 N•m (30 lb-ft). 17. Test left wheel adjustment by moving left control lever to full forward and releasing handle. The wheels should stop turning. Perform the same test by pulling rearward on the left control lever. • If motion doesn’t stop, adjust the left wheel centering screws (A)-(B) so that both screws touch the bearings in the neutral position and repeat STEPS 9-17. • Repeat test using the right control lever. Adjust the right wheel centering screws (C)-(D) so that both screws touch the bearings in the neutral position and repeat STEPS 9-17. 18. Center left and right steering control levers. (See STEERING CONTROL LEVER ADJUSTMENT— CENTERING in this section.) 19. Adjust steering control lever stops. (See STEERING CONTROL LEVER STOPS 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).

7 - 13

TESTS AND ADJUSTMENTS

STEERING

21. Pull both steering control levers to the full foward 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 steering lever yoke. 23. Remove remote start box. 24. Install cover plates. (See REMOVING COVER PLATES in MISCELLANEOUS section.) 25. Lower ROPS. 26. Raise and remove skid steer jacking blocks.

STEERING CONTROL LEVER ADJUSTMENT—CENTERING

8. Tighten both jam nuts on left and right link rods. IMPORTANT: The steering control lever stops must be adjusted properly to prevent damage to the linkage and internal hydrostatic components. 9. Adjust steering control lever stops. (See STEERING CONTROL LEVER STOPS ADJUSTMENT—TRACKING in this section.) 10. Remove M10 x 30 cap screw from each steering lever yoke. 11. Install cover plates. (See REMOVING COVER 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

Align

Jam Nuts

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

TESTS AND ADJUSTMENTS

STEERING

STEERING DETENT ADJUSTMENT DUAL PLATE MODELS IMPORTANT: Proper adjustment is required to allow for momentary one-hand operation. Centering plate adjustment must be correct to perform this procedure.

Dealer Installed Cap Screw

Right Bellcrank

Detent Ring

Reason: To correctly adjust and pre-load detent.

Jam Nut

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.)

Control Rod

Detent Spring Screw KV31011

7. Loosen detent ring set screws and rotate ring to verify detent ball is in groove on ring. Tighten set screws to 40 N•m (30 lb-ft).

Link Rod

Dampener

Left Bellcrank Jam Nut KV31012

5. Remove left steering control rod, link rod and dampener from cross shaft bellcrank. Dealer Installed Cap Screw and Nut

KV31011a

Detent Spring Screw KV31013

8. Using the cap screw installed earlier, check the torque required to rotate the left bellcrank ‘out of detent’ while holding the right bellcrank stationary. 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.) 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 been made for any reason, the steering control lever stops must be adjusted.

Rear Stop

The steering control lever stops must be adjusted properly to prevent damage to the linkage and internal hydrostatic components. Stop Screw

Forward Stop

Jam Nuts

Stop Screw

Reason: To ensure machine tracks straight and to protect hydrostatic pumps from damage. KV13984

Equipment: • JT0KV12444 Remote Start Box • JT05719 Photo Tachometer Procedure: 1. Park skid steer safely. 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. 5. Remove cover plates to gain access to the steering linkage. (See REMOVING COVER PLATES in MISCELLANEOUS section.)

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. 6. Install remote start box. (See USING REMOTE START BOX in MISCELLANEOUS section.) 7. Install an M10 x 30 cap screw in tab at the rear of both yokes to secure steering assembly during adjustment. 8. Loosen jam nuts on the steering control lever stop screws. 9. Turn stop screws in (clockwise). 10. Move left steering control lever to full forward position.

7 - 16

11. Adjust stop screw to act as the primary stop just before the hydrostatic pump control lever stops due to mechanical motion inside the pump. 12. Move left steering control lever to full rearward position. 13. Adjust stop screw to act as the primary stop just before the hydrostatic pump control lever stops due to mechanical motion inside the pump. 14. Repeat procedure for the right steering control lever stops. 15. Start engine and run at fast idle. 16. While simultaneously holding both levers in the full forward position, measure and record the full forward wheel speed (revolutions per minute) of the left and right wheels using a JT05719 Photo Tachometer. • Left and right wheel speed should be within one revolution per minute of each other. • 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 screw out (counterclockwise). 17. Tighten jam nuts on the steering control lever stop screws. 18. Repeat procedure for left and right full reverse.

NOTE: Due to variations such as tire size, tracking must be verified by driving the skid steer. If mistracking is more than the width of the machine per 30.5 m (100 ft) of travel, readjustment of the stop screws are required. 19. Remove one M10 x 30 cap screw from each steering lever yoke. 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.

11/22/00

TESTS AND ADJUSTMENTS

STEERING

AUXILIARY HYDRAULIC CONTROL HANDLE ADJUSTMENT

HYDRAULIC CONTROL HANDLE ADJUSTMENT – HANDS ONLY MACHINES

Reason: This procedure ensures that the auxiliary control handle is centered, giving equal hydraulic oil flow in all positions.

Reason:

Procedure:

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 control valve. (See REMOVING COVER PLATES in MISCELLANEOUS section.)

This procedure ensures that the control handles are centered, giving equal hydraulic oil flow in all positions.

1. Park skid steer safely. 2. Raise the boom and place on the boom locks. 3. Raise ROPS and ensure ROPS is safely in the locked position. 4. Remove cover plates to gain access to the control valve. (See REMOVING COVER PLATES in MISCELLANEOUS section.)

KV0575

KV15239

4. Lock handle in the middle (neutral) position by turning key to the left.

Cable Jam Nuts

Auxiliary Cable Jam Nuts

KV13989

5. Loosen both auxiliary cable jam nuts. 6. Center spool in control valve. 7. Tighten both auxiliary cable jam nuts finger tight against cable saddle, then tighten to 27 N•m (20 lb-ft). 11/22/00

5. Move each handle all the way down and all the way up. Ensure that the boom control valve locks into detent. 6. Confirm that when the handles are returned to neutral position, they are in the center of the operating range.

Cable Jam Nuts

KV0582a

7. If necessary to adjust, loosen both cable jam nuts. 8. Adjust nuts until handle is centered. 9. Tighten both cable jam nuts finger tight against cable saddle, then tighten to 27 N•m (20 lb-ft).

7 - 17

REPAIR

STEERING

REPAIR CENTERING PLATE REMOVAL— SINGLE PLATE MODELS

Right Guide Pin

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

Control Rod Bracket

Left Guide Pin Nut

Bracket KV14332

5. Remove left side guide pin nut. 6. Lift left side of centering plate from lower rear centering bracket slot.

7 - 18

KV14338

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 and remove bracket. • Rotate bracket and remove guide pin. • Install at least one cap screw to prevent dislodging of pump cover.

11/22/00

REPAIR

STEERING

CENTERING PLATE REMOVAL— DUAL 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.)

Right Guide Pin

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

Control Lever

KV13981

NOTE: Front centering plate must be removed to gain access to rear centering plate spring bolt assembly.

Cap Screw

Jam Nut

4. Remove spring bolt assembly.

Bracket Cap Screw Control Rod Left Guide Pin Nut

Cap Screw Bracket KV14338

NOTE: Rear components shown; front is similar.

KV18839

5. Remove left side guide pin nut. 6. Lift left side of centering plate from lower centering bracket slot.

11/22/00

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 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.

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. Guide Pin

Single Plate Models

KV14336

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

REPAIR

STEERING

CENTERING PLATE INSTALLATION—SINGLE PLATE MODELS

8. Install and tighten centering plate guide pin nuts to 54 N•m (40 lb-ft).

Spring Bolt Assembly

KV13981

3.2 mm (1/8 in.) KV18846

1. Loosen jam nuts. Adjust centering screws until each bearing surface protrudes approximately 3.2 mm (1/8 in.). Right Guide Pin Bushing

9. Install spring bolt assembly onto centering plate assembly. Tighten spring bolt to 67 N•m (50 lb-ft). 10. Perform centering plate adjustment. (See CENTERING PLATE ADJUSTMENT—SINGLE PLATE MODELS in this section.)

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

Right Guide Pin Bushing

Mounting Plate

STEERING DAMPENER REMOVAL/ INSPECTION/INSTALLATION

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 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.

Bracket

KV14340

Left Guide Pin Nut

Bracket KV18839

6. Install left guide pin into bushing. 7. Install left side of centering plate on lower centering bracket. 8. Install and torque centering plate guide pin nuts to 54 N•m (40 lb-ft). Spring Bolt Assembly

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 rod-end. • Apply a 9 kg (20 lb) force to rod-end. Time how long it takes for rod-end to fully retract; should be between 1-5 seconds. • With dampener in its installed position and rod-end fully retracted, apply a 9 kg (20 lb) pull to rod-end. • Time how long it takes for rod-end to fully extend; should be between 1-5 seconds. 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

9. Install spring bolt assembly onto centering plate assembly. Torque spring bolt to 67 N•m (50 lb-ft). 10. Repeat STEPS 2-9 for front centering plate. 11. Perform centering plate adjustment. (See CENTERING PLATE ADJUSTMENT—DUAL PLATE MODELS in this section.)

7 - 22

NOTE: Verify that dampener does not reach its travel limit before the steering control lever contacts the stop screws in both forward and reverse. Install or remove shim washer(s) as required. 6. Tighten dampener mounting cap screws to 40 N•m (30 lb-ft). 11/22/00

REPAIR

STEERING

STEERING CONTROL LEVER REMOVAL/INSPECTION/ INSTALLATION

4. Remove steering control lever assembly with spring bracket attached. 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 REMOVAL/INSTALLATION — SINGLE PLATE MODELS Right Control Rods Support Bracket Link Rod

STEERING CROSS SHAFT ASSEMBLY REMOVAL/INSTALLATION — DUAL PLATE MODELS Control Rods

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 mounting. Some models may use right-side mounting. Other components are the same.

NOTE: Cross shaft assembly shown is for right-side mounting. Some models may use left-side mounting. Other components are the same.

Removal:

1. Park skid steer safely. 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. 5. Remove cover plates to gain access to the cross shaft. (See REMOVING COVER PLATES in MISCELLANEOUS section.) 6. Remove cap screws and nuts holding dampeners, link rods, and control rods to cross shaft assembly. 7. Lift control rods from assembly and move to side. 8. Remove cap screws and nuts holding cross shaft assembly to right support bracket. 9. Lift right side of cross shaft assembly and slide out from left support bracket. 10. Repair or replace as required.

1. Park skid steer safely. 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. 5. Remove cover plates to gain access to the cross shaft assembly. (See REMOVING COVER PLATES in MISCELLANEOUS section.) 6. Remove cap screws and nuts holding dampeners, link rods, and control rods to cross shaft assembly. 7. Push control rods to rear and remove from assembly. 8. Remove cap screws and nuts holding cross shaft assembly to right support bracket. 9. Lift right side of cross shaft assembly and slide out from left support bracket. 10. Repair or replace as required.

Installation: 1. Slide cross shaft assembly into left support bracket. 2. Secure cross shaft assembly to right support bracket using cap screws and nuts. Tighten cap screws to 40 N•m (30 lb-ft). 3. Attach control rods to cross shaft and tighten cap screws to 40 N•m (30 lb-ft). 4. Attach link rods and dampeners to cross shaft assembly. Tighten cap screws to 40 N•m (30 lb-ft).

7 - 24

Installation: 1. Slide cross shaft assembly into left support bracket. 2. Secure cross shaft assembly to right support bracket using cap screws and nuts. Tighten cap screws to 40 N•m (30 lb-ft). 3. Attach right control rod to cross shaft assembly and tighten cap screws to 40 N•m (30 lb-ft).

11/22/00

REPAIR

STEERING

4. Attach right link rod and dampener to cross shaft assembly. Tighten cap screws to 40 N•m (30 lb-ft). 5. Adjust detent ring. (See STEERING DETENT ADJUSTMENT - DUAL PLATE MODELS in this section.) 6. Attach left control rod, link rod and dampener. Tighten cap screws to 40 N•m (30 lb-ft). 7. Check and adjust link rods. (See STEERING CONTROL LEVER ADJUSTMENT—CENTERING in this section.) 8. Check and adjust steering control lever stops. (See STEERING CONTROL LEVER STOPS ADJUSTMENT—TRACKING in this section.)

STEERING CROSS SHAFT ASSEMBLY REPAIR—DUAL PLATE MODELS

6. Inspect cross shaft (J) and bellcrank bushings for wear or damage. Replace as necessary. Assembly: 1. Install snap ring (K) on flange end of cross shaft (J). 2. Place detent ring (I) on left bellcrank (G) and finger tighten set screws. 3. Place all components on cross shaft (J) in order shown. 4. Install detent ball (D) and pack detent ball cavity with TY24416 Multi-Purpose HD Lithium Complex grease. 5. Install spring (C) and screw/jam nut (A-B) assembly in detent cavity. 6. Install cross shaft assembly in machine. (See STEERING CROSS SHAFT REMOVAL/ INSTALLATION—DUAL PLATE MODELS in this section.)

T ON FR

A G

F E 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 HANDLE DISASSEMBLY/ASSEMBLY

NOTE: Models having optional 8-Button Handle will require disconnecting a harness near the bottom of the lever. 3. Loosen lock nut. Loosen set screw and remove handle from steering control lever.

NOTE: Hands-only Machines: Follow steps 1—3 for left handle.

Cable Bracket

KV14344

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.).

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

CONTENTS

BRAKES

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

SPECIFICATIONS

BRAKES

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

PM20166

Name

Use

HY-GARD®, LOW VIS HY-GARD® (cold weather operation), John Deere TORQ-GARD SUPREME® or PLUS-50®

Fill hydraulic reservoir and chain case.

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 hydraulically activated. Hydraulic pressure holds the park brakes disengaged. The left and right side brakes are separate units. The brake assembly is mounted between the axle and the hydrostatic motor. Each brake assembly is actuated by a cylinder assembly. The brakes are designed to hold the skid steer in place to prevent rolling or creeping when parked on a grade. The brake is to be used as a parking brake and a secondary brake in the event of loss of dynamic (hydrostatic) braking. All braking under power is achieved by returning the hydrostatic steering control levers to the center position. The cylinder assembly is spring loaded and requires hydraulic pressure to retract the spring for brake disengagement. The cylinder acts on the actuator lever. When the brake is engaged, hydraulic pressure is removed from the release side of the cylinder. Spring

pressure inside cylinder pushes actuator lever up causing it to rotate in a clockwise direction in the left side and counterclockwise in the right side. Hydraulic pressure on the spring side of the cylinder assists engagement of the brake when the engine is running. The actuator rises up on steel balls, applying pressure to the thrust bearing, stator, and brake liner. The brake liner is splined to the driver. The driver is keyed to the drive shaft. When the actuator rotates up, the brake liner is held in place, preventing the drive shaft from rotating. When the park brake switch is disengaged, the solenoid allows hydraulic pressure to flow to the cylinder assembly. Hydraulic pressure overcomes the spring in the cylinder assembly, thus releasing the brake. Electrical power and hydraulic pressure are required to release the park brake.

Brake

Actuator Lever

Cylinder Actuator

KV15125

(Left Side Shown)

8-4

11/22/00

BRAKE EXPLODED VIEW

BRAKES

BRAKE EXPLODED VIEW 1 2

4 5

6 7 8

9 35

10 11 12

32 34

13 14

15 30

17 18 28 19

22 26

(Right Side Shown) 1. Plug 2. Retainer Ring 3. Shim(s) 4. Tapered Roller Bearing 5. Outer Race 6. Cap Screw 7. Cover Plate 8. Retainer Ring 9. Driver

11/22/00

10. Parallel Key (2 used) 11. Brake Liner 12. Stator 13. Thrust Bearing 14. Actuator Lever 15. Steel Balls (5 used) 16. Brake Housing 17. Gasket 18. Cap Screw

19. Seal 20. Outer Race 21. Tapered Roller Bearing 22. Drive Shaft 23. Cap Screw 24. Pivot Pin 25. Actuator Cylinder 26. Retaining Pin 27. Jam Nut

KV15124

28. Yoke 29. Dowel Pin 30. Cylinder Arm 31. Boot Plate 32. Boot 33. Screw 34. Cap Screw 35. Seal

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 disengaged. Move steering control levers forward and backward, one at a time.

Skid steer moves forward and backward for the appropriate hydrostatic lever.

Wheels locked or locked on one side: Check to see if brake lever is moving 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. Move steering control levers forward and backward, one at a time.

Skid steer remains stationary and engine pulls down or stalls (even at full throttle).

One or both sides of skid steer move: Troubleshoot park brake solenoid. (See procedure in the ELECTRICAL section.) Troubleshoot park brake switch. (See procedure in the ELECTRICAL section.)

TROUBLESHOOTING

Brakes not holding.

Brakes stay locked.

Grinding noise while operating skid steer.

Problem or Symptom

Check park brake solenoid.

Check park brake switch/circuit.

Check charge pump for proper pressure.

Inspect/replace brake lining.

Check or Solution

8-6

11/22/00

REPAIR

BRAKES

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.) 3. Remove cover plates to access the brake assembly. (See REMOVING COVER PLATES in the MISCELLANEOUS section.) 4. Remove steering mechanism and steering cross shaft. (See procedures in the STEERING section.) 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).

Hoses

Hoses Early Models

KV13156

Chain Case Cover

Nut

Hose

Hoses Late Models

KV18850

11. Disconnect hydraulic hoses from actuator cylinder. Strap

KV13152

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

Rear Drive Chain

Front Drive Chain

KV13153

12. Disconnect hydraulic lines from hydrostatic motor. Close all openings with caps or plugs. 13. Attach a strap around hydrostatic motor/brake 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 brake assembly. Remove motor.

Cap Screws

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

Mounting Pin (2 used)

Retaining Pin (2 used) KV18536

6. Install two fully-threaded M10 cap screws 102 mm (4 in.) long into threaded holes. Thread cap screws in evenly and remove housing cover and inner bearing. 7. Remove brake lining, stator, cylinder arm, and gasket from brake housing.

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

REPAIR

BRAKES

Ball (5 used)

Actuator

Detents (5 used) Bearing

KV18538

KV18543

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 bottom of gear and brake housing for removal. 9. Remove retaining ring and brake gear.

Seal KV18541

Seal

Shaft

Cover

Key (2 used)

KV18878

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 Ball (5 used)

Actuator

Detents (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.

NOTE: Install seals with lips of seals facing away from 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 ring.

6. Install gasket, stator, and lining into housing. Position stator indexing tabs into half rounds of housing.

Cylinder 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

REPAIR

BRAKES

KV18877

8. Press bearing into housing cover. Apply a preload force of 8006 N (1800 lb-force).

KV13154

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

9. Determining shim thickness: a. Install snap ring to top surface of groove. b. Measure depth from top of snap ring to top of bearing inner race. c. Remove and measure snap ring thickness. d. Subtract snap ring thickness from depth measurement to determine required shim thickness. 10. Install shims required and snap ring. 11. Install boot, boot plate. 12. Install actuator cylinder. 13. Install O-ring and hydrostatic motor with four socket head screws. Tighten screws to 118 N•m (87 lbft).

BRAKE INSTALLATION 1. Attach hoist and strap to wheel motor/brake assembly.

11/22/00

Rear Drive Chain

Front Drive Chain KV13157

3. Install drive chains to shaft. 4. Install front and rear axle shafts. (See AXLE HOUSING REMOVAL/INSTALLATION in the POWER TRAIN [CHAIN CASE AND AXLES] section.) 5. Apply a bead of PM20166 RTV SILICONE SEALANT to chain case cover and install with nuts. Tighten nuts to 70—80 N•m (52—59 lb-ft). 6. Fill chain case with John Deere HY-GARD, LOW VIS HY-GARD, TORQ-GARD SUPREME or PLUS-50 hydraulic fluid to bottom of check plug opening. 7. Install front and rear wheels. 8. Install cross shaft and steering control lever assembly. (See procedures in the STEERING section.) 9. Install cover plates. (See COVER PLATE REMOVAL/INSTALLATION in the MISCELLANEOUS section.) 10. Burnish brakes. (See BURNISH BRAKES in this section.)

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 BLOCKING SKID STEER in the MISCELLANEOUS section.)

Brake cylinder rod will move when the park brake is engaged or disengaged. Keep fingers away from cylinder rod.

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. 3. Install remote start box. (See USING REMOTE 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. 7. If machine drives through park brake(s): • Operate steering control lever(s) for 15 seconds in each direction. This burnishes lining material. • Let brake(s) cool and attempt drive-through again. • If machine still drives through park brake(s), repeat brake repair procedures in this section.

5. Start engine and disengage park brake using remote start box. Brake spring tension will be removed to loosen upper pivot pin.

Retaining Pin Actuator Lever Upper Pivot Pin Actuator Cylinder

KV18007

6. With engine running and park brake disengaged, remove retaining pin and upper pivot pin from cylinder rod yoke. 7. Turn engine off.

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

REPAIR

BRAKES

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

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

CONTENTS

HYDRAULICS

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

PT569/ TY6332

Name

Use

Petroleum Jelly

To lubricate O-rings. To retain components during assembly.

NEVER-SEEZ® Anti-Seize Compound

Apply to ID of cylinder bushings.

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

SYSTEM COMPONENTS AND OPERATION Function: The hydraulic system provides fluid power to charge the hydrostatic system and operate the bucket and boom cylinders and optional auxiliary hydraulic attachments. Theory of Operation: The hydraulic system is an "open center series" type system. In this system, the hydraulic/charge pump provides a continuous flow of oil through a main circuit that connects all of the controlling valves. If the valves are not operated, the flow of oil passes through the open center passage of each valve, then through the oil cooler and oil filter, and returns to the hydraulic reservoir. Also, in this type of circuit, the first controlling valve takes priority over the next valve downstream from the circuit. • Hydraulic/Charge Pump The hydraulic/charge pump is a direct drive, positive displacement gear pump. The pump is mounted and driven off the end of the front hydrostatic pump. The hydraulic/charge pump draws oil from the reservoir and supplies a constant flow of oil to the control valve. • Control Valve The control valve integrates three spool valves and three pressure relief valves into one housing. The first valve in the series, and therefore first priority, controls the boom cylinder circuit. When this valve is actuated by the left foot pedal (toe—lower, heel— raise), [On hands only machines the left foot pedal is non-functional. The left steering control lever has a “wrist” mechanism built into it. To raise the boom pull “wrist” up toward ROPS. To lower the boom push “wrist down towards seat.] the open center port is blocked and oil is directed to the appropriate side of the boom cylinders. Cylinder return oil flows through the control valve to the oil cooler, filter and reservoir. The second valve in the series controls the bucket cylinder circuit. When this valve is actuated by the right foot pedal (toe—dump, heel—roll back), [On hands only machines the right foot pedal is the auxiliary hydraulics control. The right steering control lever has a “wrist” mechanism built into it. To roll the bucket back push “wrist” down towards seat. To dump the bucket pull “wrist up towards ROPS.] the open center port is blocked and oil is directed to the appropriate side of the bucket cylinders. Cylinder return oil flows through the control valve to the oil cooler, filter and reservoir. The third valve in the series provides power to operate optional auxiliary hydraulic attachments. This spool is controlled by a special "wrist" mechanism built into the right steering control lever. The auxiliary handle can be

9-5

HYDRAULICS locked in the neutral or actuated position by turning the lock located on the handle.(On hands only machines the right foot pedal controls the auxiliary hydraulics. Pushing the “toe” on the pedal sends oil to the quick couplers. Pushing the pedal into the detent position will hold it in place.) The system relief valve, located in the control valve, protects the hydraulic system and hydraulic/charge pump from excessive pressure. The system relief valve limits system pressure to 21 374 ± 1034 kPa (3100 ± 150 psi) and is not adjustable. The boom circuit relief valve, located in the control valve, protects the boom cylinder circuit from excessive pressure resulting from shock loading when the spool is in the neutral position. The circuit relief valves limit cylinder circuit pressure to 22 753 ± 1379 kPa (3300 ± 200 psi) and is not adjustable. The bucket and boom circuits each incorporate a solenoid valve that hydraulically locks movement of the bucket and boom should any of the following conditions occur: • If the operator engages the park brake switch • If the operator turns the engine off or if the engine stalls • If the operator releases the seat belt • If the operator is not sitting in the seat • Oil Cooler and Filter Return oil from the control valve flows to the oil cooler, located at the rear of the machine. This location allows the cooler and radiator to be cooled by the engine fan. Oil from the oil cooler flows to the hydraulic oil filter and the charge pressure relief valve before entering the hydraulic reservoir. The oil filter is a canister-type screw-on filter. The charge pressure relief valve maintains charge pressure at 1448 kPa (210 psi) and is not adjustable. Solenoid lockout valves are located in both the boom and bucket circuits. In the boom circuit it is located before the tee connection to the base end of the cylinders. The lockout valve is located before the tee connection to the rod end of the bucket cylinders. The function of the lockout valve is to prevent flow to or from the cylinders. • High Flow Pump (Optional) The high flow option is for attachments that require a high flow rate to operate. The high flow pump is a positive displacement gear pump. The pump draws oil from the reservoir and supplies a constant flow of oil to the high flow solenoid valve which is mounted on the reservoir. When the high flow switch is off the pump will pump oil through the valve and back to the reservoir. When the switch is turned on it energizes the solenoud valve and the oil is diverted to the auxiliary spool of the control valve.

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

SYSTEM SCHEMATIC

HYDRAULICS

SYSTEM SCHEMATIC Charge Flow

Brake Valve 210 psi

75 psi

Spin On Filter

Hydraulic Reservoir B

Lift Cylinders

Lockout Solenoid

Main Control Valve Drive Motor 3100 psi 3300 psi

Boom

Brake A

Self-Leveling Valve (Optional)

Hydraulic/Charge Pump High-Flow Valve (Optional)

Hydrostatic Pumps

Bucket

Lockout Solenoid

Engine Oil Cooler

High-Flow Pump (Optional)

A 3000 psi B Anticavitation Check

Aux

Tilt Cylinders A B

Auxiliary 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

9-8

KV13043

11/22/00

SYSTEM COMPONENT LOCATION

HYDRAULICS

SYSTEM COMPONENT LOCATION Charge Pressure Relief Valve (Inside Oil Filter Head Housing) High Flow Pump (Optional)

Auxiliary Quick Coupler Case Drain Line

Hydraulic Oil Dipstick

Oil Cooler High Flow Valve (Optional)

Self-Leveling Valve (Optional)

Vent

Hydraulic Reservoir Hydraulic Oil Temperature Sender (late models)

Hydraulic Oil Temperature Sender (Early Models)

Drain Plugs

Hydraulic Suction Line

Hydraulic Pressure Line

Hydraulic/ Charge Pump Line to Boom Cylinders Hydraulic Return Line

Lines to Bucket Cylinders

Control Valve

Foot Pedal Assembly

KV31097

11/22/00

9-9

SYSTEM COMPONENT LOCATION

HYDRAULICS

CONTROL VALVE COMPONENT LOCATION 5

3 2

3 8 4

10 3

21 24 8 3

22 8

20 10

12 11

2 15

19 14 18 16 17

13 KV31130

1. Plug 2. Spring 3. O-Ring 4. Lift Check Valve 5. System Relief Valve 6. Bushing 7. Washer 8. Cover Plate 9. Screw 10. Backup Washer 11. Spacer 12. Control Valve Body 13. Auxiliary Spool Valve

9 - 10

14. Bucket Spool Valve 15. Boom Spool Valve 16. Centering Pin 17. Bucket Spool Cover 18. Auxiliary/Boom Spool Cover 19. Detent Ball 20. Spacer Block 21. Boom Relief Valve 22. Plug 23. Anti-Cavitation Valve 24. Screw 25. Spacer

11/22/00

SYSTEM COMPONENT LOCATION

HYDRAULICS

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 K

A J

O P

I H

F E D

KV13266

A. Cylinder Barrel B. Nut C. Piston D. Cylinder Rod Guide E. Seal F. O-Ring

G. Backup Ring H. Wear Ring I. Internal Snap Ring J. O-Ring K. External Snap Ring

L. Seal M. Wiper Seal N. Rod O. Seal P. Bushing

BOOM CYLINDER COMPONENT LOCATION D C L K

B J

I H G F E O

N M KV13267

A. Bushing B. Cylinder Barrel C. Nut D. Piston E. Cylinder Rod Guide

9 - 12

F. Seal G. Wear Ring H. O-Ring I. Backup Ring J. Internal Snap Ring

K. O-Ring L. External Snap Ring M. Seal N. Wiper Seal O. Rod

11/22/00

TROUBLESHOOTING

HYDRAULICS

Hydraulics slow, low power

Jerky or spongy movement

Hydraulic system noisy

Charge pressure low

Hydraulic system hot

●

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

●

Pedals will not move

Bucket will not roll back

●

Bucket drifts up or down

Bucket will not dump

●

Boom drifts up or down

Hydraulic oil level low in reservoir Check and add oil

Problem or Symptom

Boom will not lower

Check or Solution

Boom will not raise

TROUBLESHOOTING

●

● ●

●

● ●

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 1. Foot pedals.

Normal Pedals should move freely.

If Not Normal 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 restriction warning lights should be off.

Filter restriction light on—replace filter. Hydraulic oil temperature light on— check oil cooler for restriction.

2. Boom operation.

Boom should move freely through range of motion when left pedal is depressed forward or backward. Perform following boom checks: • Boom operation. • Boom drift down. • Boom lift check test. • Boom drift up.

Check that park brake switch is in the center or run position. Perform system flow and pressure checks to verify proper operation of hydraulic/charge pump. Check boom cylinders for bent rod or damaged cylinder wall. Check hydraulic hoses, tubing, and connections for leaks.

3. Bucket operation.

Bucket should move freely through range of motion when right pedal is depressed forward or backward. Perform following bucket checks: • Bucket operation. • Bucket drift dump position. • Bucket drift rollback position. • Bucket lift check test.

Check that park brake switch is in the center or run position. Perform system flow and pressure checks to verify proper operation of hydraulic/charge pump. Check bucket cylinders for bent rod or damaged cylinder wall. Check hydraulic hoses, tubing, and connections for leaks.

9 - 14

11/22/00

TESTS AND ADJUSTMENTS

HYDRAULICS

TESTS AND ADJUSTMENTS BOOM AND BUCKET LOCKOUT SOLENOIDS CHECK

SYSTEM RELIEF VALVE PRESSURE TEST

Reason: To ensure that the boom and bucket lockout solenoids are functioning properly. Procedure: IMPORTANT: If lockout solenoids are not working properly, boom and bucket will not move. 1. Sit in seat. 2. Fasten seat belt. 3. Start the engine. 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 boom should move freely. 6. Disconnect seat belt. Boom and bucket should lock as soon as the seat belt is released.

Reason: To check high pressure relief valve. Equipment: • D01074AA In-Line Hydraulic Tester • KV13885 Quick Disconnect, Male • KV13884 Quick Disconnect, Female • JT03377 Hose, 2 required • JT03012 Connector, 2 required • JT05690 Connector, 2 required Procedure: 1. Lower boom and bucket to normal ground position. Stop engine and relieve hydraulic pressure.

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 Disconnectto-Inlet Hose

Outlet 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 is routed to tester inlet.

Female Auxiliary Connector

HYDRAULIC/CHARGE PUMP PRESSURE TEST Reason: To ensure there is sufficient oil pressure to charge the hydrostatic systems and supply oil to the hydraulic system. 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) • JT0KV12444 Remote Start Box

Male Auxiliary Connector

c CAUTION

KV18562

5. Attach quick disconnects to auxiliary hydraulic connectors. 6. Operate hydraulic system until oil reaches normal operating temperature of 43°C (110°F). 7. Set engine speed to full throttle position. 8. Actuate auxiliary hydraulic control lever into detent position. 9. Slowly turn load valve knob on hydraulic tester to the right (clockwise) until pressure relief valve releases. Specifications:

To help prevent injury from escaping hydraulic oil under pressure, relieve the pressure in the system before removing hydraulic lines. Procedure: 1. Raise and block skid steer. (See RAISING AND BLOCKING SKID STEER in the MISCELLANEOUS section.) 2. Raise boom fully and engage the boom lock. Stop engine and relieve hydraulic pressure. 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 (3300 +/- 150 psi)

38H5069 JT03457 JT03017

Results:

JT03344

If pressure is not within specifications, replace system relief valve.

NOTE: Relief valve is factory set and not repairable. Replace relief valve if pressure readings are not within specifications.

KV15134

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

TESTS AND ADJUSTMENTS

HYDRAULICS

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

Male Auxiliary Connector KV18562

Procedure: 1. Raise and block skid steer. (See RAISING AND BLOCKING SKID STEER in the MISCELLANEOUS section.) 2. Lower boom and bucket to normal ground position. Stop engine and relieve hydraulic pressure.

6. Attach quick disconnects to auxiliary hydraulic ports located on left boom arm. 7. Operate hydraulic system until oil reaches normal operating temperature of 43°C (110°F). 8. Set engine speed to wide open throttle (WOT) position (2400 rpm). 9. Actuate auxiliary hydraulics control handle into detent (down toward seat) position. 10. Turn load valve knob to increase resistance until pressure reads 10 340kPa (1500 psi). Specifications:

KV13885 JT05690

JT03012

JT03377

KV13884

KV15257

3. Install JT03012 and JT05690 Connectors on one end of both JT03377 Hoses. 4. Install KV13885 and KV13884 Quick Disconnects on connectors. Male Quick Disconnectto-Inlet Hose

Outlet Outlet-to-Female Quick Disconnect Hose

Minimum 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) Results: 1. Check auxiliary hydraulic control valve spool travel and control handle pivot and linkage to make sure mechanical systems are operating properly. 2. If flow is low, verify proper engine speed at full throttle. If engine speed is OK, rebuild or replace charge pump. 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 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

TESTS AND ADJUSTMENTS

HYDRAULICS

CIRCUIT RELIEF VALVE TEST NOTE: If machine is equipped with a bucket circuit relief valve perform mandatory PIP 00KV010 to remove bucket circuit relief valve.

6. Start remote pump to pressurize boom raise port. Take reading when pressure on gauge starts to decrease. The point at which pressure decreases is the opening pressure of the boom circuit relief valve.

Reason:

Specifications:

To check boom and bucket circuit relief valves.

Boom Circuit Relief Pressure. . . . . . . . . 22 753 ± 1379 kPa (3300 ± 200 psi)

Equipment: • 38H1417 Cap • JT03494 Adapter Fitting • JT07192 Electric/Hydraulic Pump • 0—35 000 kPa (0—5000 psi) Gauge

Results: If pressure is not within specification, replace circuit relief valve.

Procedure: 1. Park skid steer safely. 2. Raise boom and place on boom locks. 3. Gain access to the hydraulic control valve. (See COVER PLATE REMOVAL/INSTALLATION in the MISCELLANEOUS section.)

NOTE: Relief valve is factory set and not adjustable. Replace relief valve if pressure readings are not within specification.

BOOM DRIFT DOWN CHECK Reason: To ensure that boom raise circuit does not have internal leaks.

Electric/Hydraulic Pump Hose

Boom Raise Port

KV18008

4. Disconnect boom raise line at both ends and set aside. Cap fitting at boom lockout solenoid. Electric/Hydraulic Pump Hose-to-Valve

IMPORTANT: The person raising the boom should remain in skid steer until test is compelte and boom is lowered to the ground or raised and resting on boom locks. Procedure: Start engine and raise boom halfway. Shut off engine. Specifications: • Slight boom drift is permissible. Results: If boom drifts down, check for: • 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

BOOM LIFT CHECK TEST

HYDRAULICS

BUCKET DRIFT DUMP POSITION CHECK

Reason: To ensure that boom lift check circuit does not have internal leaks. IMPORTANT: The person raising the boom should remain in skid steer until test is compelte and boom is lowered to the ground or raised and resting on boom locks. Procedure: 1. Raise boom halfway. 2. Turn engine OFF. 3. Turn key on and push park brake switch to center position. 4. Press boom pedal to raise position.

Reason: To ensure that bucket dump circuit does not have internal leaks. Procedure: 1. Raise boom halfway. 2. Rotate bucket all the way back and then roll to halfway position and shut off engine. Specifications: • Slight bucket drift is permissible. Results: If bucket drifts in dump position:

Specifications: • Slight boom drift is permissible. Results:

• Check port lock solenoid valve. Replace valve. • Check for leaks in cylinder packing. Rebuild or replace cylinder. • Check for leaks in control valve spool. Replace valve.

If boom drifts down: • Rebuild or replace lift check valve.

BOOM DRIFT UP CHECK

BUCKET DRIFT ROLLBACK POSITION CHECK Reason:

Reason: To ensure that boom lower circuit does not have internal leaks.

To ensure that bucket rollback circuit does not have internal leaks. Procedure:

Procedure: 1. Start engine and use boom to raise front of machine a few inches off ground. 2. Shut off engine.

1. Start engine and use bucket to raise machine a few inches off ground. 2. Shut off engine. Specifications:

NOTE: Bucket may have to be in dump position. Specifications: • Slight boom drift is permissible. Results: If boom drifts upward: • Check for leaking cylinder packing. Rebuild or replace cylinder. • Check for leaking control valve spool. Replace valve.

9 - 20

• Slight bucket drift is permissible. Results: If bucket drifts: • Check for leaks in cylinder packing. Rebuild or replace cylinder. • Check for leaks in control valve spool. Replace valve.

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. 2. Turn engine off. 3. Turn key on and push park brake switch to center position. 4. Press bucket pedal to dump position.

Self-Leveling Valve Adjusting Screw KV31141

Specifications:

3. Loosen jam nut.

• Bucket must not roll back.

NOTE: Make adjustments in 1/2 turn increments. Results: If bucket rolls back: • Replace lift check valve.

BUCKET SELF-LEVELING ADJUSTMENT

4. Adjust as follows: • To slow bucket cylinder extend, turn adjusting screw clockwise. • To speed bucket cylinder extend, turn adjusting screw counterclockwise. If unable to achieve adjustment:

Reason: To ensure that bucket remains level through the lift range of the boom.

• Remove adjusting screw and check that adjusting needle is free to move and not damaged. • Check for proper hose routing to and from self 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 REMOVAL 1. Park skid steer safely. 2. Raise boom and place on boom locks. 3. Shut off engine. 4. Gain access to the hydraulic/charge pump. (See COVER PLATE REMOVAL/INSTALLATION in MISCELLANEOUS section.) 5. Drain hydraulic reservoir.

c CAUTION

7. Mark pump case across front hydrostatic pump, pump body and end plate to ensure proper reassembly. 8. Remove eight cap screws securing charge pump to front hydrostatic pump. 9. Remove pump assembly.

NOTE: Wash pump in suitable solvent and dry before disassembling.

HYDRAULIC/CHARGE PUMP DISASSEMBLY

To help prevent injury from escaping hydraulic oil under pressure, relieve the pressure in the system before removing hydraulic lines.

Wear Plate

IMPORTANT: Clean hydrostatic and hydraulic/ charge pump cases before separating pumps to prevent contamination of hydraulic system. Hydraulic Inlet Lines

Wear Plate Seal Backup Gasket

Hydraulic High Pressure Line

KV14310

1. Remove and discard wear plate seal and backup gasket. Drive Gear Hydraulic/Charge Pump

Idler Gear

Pump Body

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

2. Remove idler gear and drive gear from pump body.

Mark Case

KV14304

9 - 22

11/22/00

REPAIR

HYDRAULICS

Pump Body End Plate

O-Ring KV14306

KV14307

6. Inspect inside diameter of bushings in end plate and front hydrostatic pump. Replace if greater than 19.2 mm (0.755 in.).

3. Remove pump body from end plate. 4. Remove and discard O-ring.

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 exceeds 0.0381 mm (0.0015 in.).

HYDRAULIC/CHARGE PUMP 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 ASSEMBLY

Wear Plate Assembly

NOTE: Pay special attention to orientation components during assembly.

Pump Body End Plate

KV14310

5. Install new wear plate assembly in pump body.

O-Ring

Cover Plate

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

REPAIR

HYDRAULICS

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

Port at 9 O’Clock Position with Plug Installed

KV31116

3. Install hydraulic/charge pump assembly onto front hydrostatic pump using eight screws and washers.

Port at 3 O’Clock Position

IMPORTANT: Use an alternating pattern and tighten hydraulic/charge pump screws to 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 hydraulic system, thoroughly clean fittings before disconnecting hydraulic lines.

NOTE: Gear is keyed on to a tapered shaft.

Removal: 1. Remove left side engine cover. Output Line

O-Ring Nut Suction Line

2. Disconnect suction line and output line from pump.

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. 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:

3. Remove cap screws and nuts. 4. Remove pump from machine.

9 - 26

1. Install new O-ring and position pump on engine. 2. Install cap screws and nuts. Tighten to 50 N•m (35 lb-ft). 3. Connect output and suction lines to pump. 4. Install left side engine cover.

11/22/00

REPAIR

HYDRAULICS

HIGH-FLOW VALVE

CONTROL VALVE REMOVAL

Replacement: 1. Disconnect wiring connector.

Jamb Nut Thumb Nut Solenoid Auxiliary Hydraulic Line

1. Park skid steer on a flat level surface. 2. Raise boom fully and place on boom locks. Shut engine OFF. 3. Turn key switch ON and operate all hydraulic controls to relieve system pressure. Turn key switch OFF. 4. Disconnect battery negative (–) cable. 5. Raise the ROPS. (See RAISING ROPS [ROLL OVER PROTECTION STRUCTURE] in the 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 Line from HighFlow Pump

2. Remove case drain line. 3. Remove auxiliary hydraulic line. 4. Remove high-flow pump line. 5. Loosen jam nut. 6. Unthread valve assembly from tank. 7. Remove thumb nut. Remove solenoid from valve assembly. 8. Repair or replace components as necessary. 9. Installation is done in reverse of removal.

Bracket

Jam Nuts

Cable Bellcrank

Wire Connector

Rod End

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 Bucket Rollback Line Fittings

Boom Raise Line Fittings

KV31071

KV31073

14. Remove clamp. 15. Disconnect bucket dump line fittings and remove line. 16. Disconnect bucket rollback fittings and remove line.

c CAUTION 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. Return Line

Cap Screws

Cotter Pins

Clamp

Clevis Pins

KV31072

NOTE: Left side shown. 12. Remove cap screws and isolator plate from both left and right sides. 13. Remove clamp (left side only).

9 - 28

High Pressure Line

KV31075

19. Remove cotter pins and clevis pins from spools. 20. Disconnect high pressure line and return line. 11/22/00

REPAIR

HYDRAULICS

CONTROL VALVE DISASSEMBLY Boom Relief Plug

Load Check Valves Anti-Cavitation Check Valve System Relief Valve

Cap Screws and Nuts Spool Detent Cover KV31076

Boom Spool Auxiliary Spool

21. Remove three cap screws and nuts and remove control valve.

Bucket Spool KV31014

Boom Raise Fitting

Hydraulic 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 detent balls (four small, one large) from cover. 3. Remove detent spring from cavity in end of spool.

Spacer

Retainer 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

REPAIR

HYDRAULICS

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 Retainers

12. Remove auxiliary spool retainer, wiper and O-ring 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

Retainer

Spacer

KV31029

14. Pull bucket spool from housing. Remove O-ring, wiper, retainer plate and spacer from spool.

KV31031

15. Remove the retainer, wiper and O-ring from the 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

REPAIR

HYDRAULICS

System Relief Valve Assy. Anti-Cavitation Check Valve Assy.

O-Ring

O-Ring Spring

Poppet KV31024

18. Remove the system relief valve. 19. Remove anti-cavitation check valve.

Boom Raise Fitting

Lift Check Assy.

Auxiliary Port KV31025

NOTE: The anti-cavitation check valve can be disassembled but is only serviced as an assembly. Large end of spring goes in cover.

KV31026

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. 2. Inspect each spool and spool bore for scratches, fretting, or burrs.

Pintle

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. Remove spools and place on clean work surface.

KV31034

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 entire relief valve if not functioning properly.

9 - 34

KV31025

7. Inspect anit-cavitation check valve for damage. Verify seat moves freely within cover.

11/22/00

REPAIR

HYDRAULICS

This page intentionally left blank.

11/22/00

9 - 35

REPAIR

HYDRAULICS

CONTROL VALVE CROSS SECTION

KV31010

9 - 36

11/22/00

REPAIR

HYDRAULICS

CONTROL VALVE CROSS SECTION 1. Boom Spool 2. Cap Screw (2 used) 3. Retaining Plate 4. Spool Wiper 5. Backup Ring 6. Spool Seal 7. Seal Extender 8. O-Ring 9. Spool Seal 10. Retaining Plate 11. Spool Wiper 12. Spacer 13. Cap Screw (2 used) 14. Spring Collar 15. Washer 16. Detent Sleeve 17. Spool End 18. Detent Sleeve

11/22/00

19. Spiral Snap Ring 20. Ball (Large) 21. Plate 22. End Cap 23. Ball (Small) (4 used) 24. Spring 25. Bucket Spool 26. Spool Wiper 27. Cap Screw (2 used) 28. Retaining Plate 29. Spool Seal 30. Load Check (3 used) 31. Load Check Plug (3 used) 32. Load Check Spring (3 used)

33. O-Ring (3 used) 34. Spool Seal 35. Retaining Plate 36. Spool Wiper 37. Spacer 38. Spring Collar 39. Spring 40. Spring Collar 41. End Cap 42. Spool End 43. Cap Screw (2 used) 44. Auxiliary Spool 45. Spool Wiper 46. Cap Screw (2 used) 47. Retaining Plate 48. Spool Seal 49. Valve Body 50. Spool Seal

51. Retaining Plate 52. Spool Wiper 53. Spacer 54. Spring 55. Spring Collar 56. Washer 57. Detent Spring 58. Spool End 59. Detent Sleeve 60. Spiral Snap Ring 61. Ball (Large) 62. Plate 63. End Cap 64. Ball (Small) (4 used) 65. Cap Screw (2 used)

9 - 37

REPAIR

HYDRAULICS

CONTROL VALVE ASSEMBLY IMPORTANT: Due to extremely tight tolerances and 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.

O-Ring

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 Fitting

Lift Check Assy.

O-Ring

KV14322

2. Install new O-ring on valve body plug and install into control valve. Tighten to 38 N•m (28 lb-ft).

Auxiliary Port

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

REPAIR

HYDRAULICS

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 valve. Tighten to 45 N•m (33 lb-ft). 7. Install bucket circuit plug. Tighten to 38 N•m (28 lb-ft). If control valve has a bucket relief valve perform mandatory PIP 00KV010.

Spacer

Retainer O-Ring

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. Tighten to 51 N•m (34 lb-ft). 9. Replace anti-cavitation check valve O-ring and install. Tighten to 45 N•m (30 lb-ft).

11/22/00

NOTE: All three spools are different. Be careful not to mix spool and spring assemblies when assembling valve.

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. Place four small balls and one large ball in spool.

Cover

KV31040

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.

Cap Screw

KV31038

16. Install spool covers and press on cover to seat Orings in control valve housing. Install cap screws finger-tight.

9 - 40

KV31041

18. Install cap in end of cover and retain with spiral ring. 19. Repeat process for auxiliary spool. 20. Tighten spool cover cap screws to 9.5 N•m (84 lb-in.).

11/22/00

REPAIR

HYDRAULICS

24. Install retainers, sleeves and screws. Tighten screws to 9.5 N•m (84 lb-in.).

21. Move spools in and out to verify operation.

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 mounting evenly to 24 N•m (18 lb-ft).

O-Ring

Return Line Backup Washer Wiper KV31019

Cotter Pins

Clevis Pins

23. Install spacer, O-ring, back-up washer and retainers for boom spool.

Sleeves Retainers

High Pressure 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

10. Connect boom line fittings to control valve.

4. Connect auxiliary line fittings. 5. Install clamp. Clamp

Bracket

Jam Nuts

Cable

Bucket Dump Line Fittings

Bellcrank

Wire Connector

Bucket Rollback Line Fittings Rod End

KV31070 KV31073

6. Connect bucket dump line fittings and bucket rollback fittings. 7. Install clamp. Isolator Plate

Cap Screws

11. Install auxiliary cable to bracket and tighten jam nuts securely. 12. Connect rod end to bellcrank. 13. Connect boom lockout harness connector. Install wire ties as needed. 14. Connect battery negative (–) cable to battery. 15. Run machine and operate all hydraulic controls to check operation and leaks. 16. Install cover plates. (See COVER PLATE 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

REPAIR

HYDRAULICS

SELF-LEVELING VALVE

BOOM CYLINDER REMOVAL

Removal:

NOTE: Boom arm cylinders can be safely removed while arms are supported on boom arm locks.

1. Park skid steer safely. 2. Turn key switch to ACCESSORY position, disengage park brake and operate all hydraulic controls to relieve pressure in the hydraulic system. Turn key switch OFF. 3. Raise ROPS. (See RAISING ROPS [ROLLOVER PROTECTION STRUCTURE] in the MISCELLANEOUS Section)

1. Park skid steer safely. Raise boom and place on boom locks.

c CAUTION To help prevent injury from escaping hydraulic oil under pressure, relieve the pressure in the system before removing hydraulic lines.

B A

Cap Screws

2. Sitting in operator’s seat with seat belt fastened, 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

A. Line to Control Valve B. Line to Boom Cylinders Rod End Lines C. Line to Bucket Cylinder Head End Lines D. Line to Bucket Cylinders Rod End Lines

Boom Cylinder

Boom Raise Line

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 openings. 5. Remove cap screws and remove valve. 6. Repair or replace as required.

3. Disconnect boom cylinder hydraulic lines at cylinder.

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 damaged O-rings will leak. 8. Connect lines (A—D). 9. Lower ROPS and secure.

Pivot Pin

KV14329

4. Remove cap screw on top cylinder pivot pin. Remove pin.

11/22/00

9 - 43

REPAIR

HYDRAULICS

Retract Hydraulic Line

Boom Cylinder

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 normal rotation to loosen lower pivot. 8. Remove lower pivot cap screw. Remove cylinder. 9. Repair or replace cylinder as necessary.

KV18000

3. Connect hydraulic lines. Install rubber spacer block and secure tube to cylinder with hose clamp. 4. Cycle cylinder and check for leaks. 5. Check hydraulic oil level and fill if necessary.

BOOM CYLINDER INSTALLATION BUCKET CYLINDER REMOVAL

c CAUTION

Pivot Cap Screw

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 system before removing hydraulic lines.

Cap Screw

Pivot Pin

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 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

REPAIR

HYDRAULICS

NOTE: Right-side bucket cylinder shown in photo. Leftside cylinder is the same.

IMPORTANT: DO NOT remove nut until cylinder 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. 5. Disconnect hydraulic lines from bucket cylinder.

BUCKET CYLINDER INSTALLATION Tapered Pin

Cap Screw

Pivot Pin

Cap Screw KV14269

Nut 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

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

Cap Screw

1. Place cylinder end in a soft-jawed vise. 2. Clean outside surface of cylinder with suitable solvent and dry to prevent dirt and debris from entering cylinder barrel.

Pivot Pin Remove Paint

Cylinder Rod

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

Hydraulic Lines

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 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. Replace if necessary. Connect hydraulic lines.

7. Using a wooden dowel or brass drift, drive rod guide 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

REPAIR

HYDRAULICS

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

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.

30°

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 cylinder rod from cylinder barrel. Inspect all parts for wear or damage and replace as necessary. Cylinder Rod

Internal Snap Ring

IMPORTANT: Make sure filler ring used during removal of cylinder rod is removed from snap ring groove in cylinder barrel.

Piston Hose Clamp

Lock Nut

Rod Guide

Rod Guide KV14276

10. Install rod end in a soft-jawed vise. 11. Remove lock nut, piston, and rod guide from cylinder rod. 12. Clean and inspect all parts. Remove any nicks or burrs with emery cloth. 13. Carefully inspect cylinder bore and piston for deep grooves or scratches. Replace entire cylinder if either is damaged.

11/22/00

Rod Guide Flange Cylinder Bore

KV14285

18. Install a hose clamp over snap ring on rod guide. 19. Tighten hose clamp until snap ring is seated in groove on rod guide, then loosen one turn.

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 softfaced 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

CONTENTS

MISCELLANEOUS

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

SPECIFICATIONS

MISCELLANEOUS

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 TY6347

Moly High Temperature EP Grease

Apply to boom lock and QUIK-TATCH™.

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.

Washer (2 Used)

KV18532

5. To lower ROPS, push right lower cylinder tube rearward to unlock cylinder. 6. Pull ROPS down until seated on mounting studs. 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

REPAIR

MISCELLANEOUS

BOOM LOCK REMOVAL/INSTALLATION H

F G I

C B

J L

K A

D KV15160

A. Cap Screw (2 used) B. Guide Bracket C. Lever D. Cotter Pin (3 used)

E. Washer (4 used) F. Pin G. Spring H. Boom Lock Pin (2 used)

Removal: 1. Lower boom to the at-rest ground position. Engage park brake switch and turn engine off. 2. Raise ROPS and ensure ROPS is safely in the locked position. (See RAISING ROPS [ROLLOVER PROTECTION STRUCTURE].) 3. Remove two cap screws (A), guide bracket (B), and 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.

I. Spring Pin (2 used) J. Lever K. Pin L. Linkage

Installation:

NOTE: Apply Moly High Temperature EP Grease to all moving boom lock parts before installation. 1. Installation is the reverse of removal.

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 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 the at-rest ground position, engage park brake, and turn engine off.

c CAUTION Avoid possible injury! Skid steer is heavy! The approximate weight of skid steer is 3693 kg (8140 lb). Use proper lifting device to raise skid steer.

KV18786

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 should not contact ground.

c CAUTION 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. If access to engine compartment is needed or if ROPS will be raised, raise boom to top of travel and lower onto boom locks. For all other repairs, lower boom to bottom of travel. 3. Place a suitable floor jack under front of skid steer in line with front axle, centering jack between tires on flat spot of frame.

1. Park skid steer safely. 2. Raise boom and engage boom locks. 3. Raise ROPS and ensure ROPS is safely in the locked position. (See RAISING ROPS [ROLLOVER PROTECTION STRUCTURE].) Toe Guard Cap Screw (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

REPAIR

MISCELLANEOUS

Cap Screw (6 Used)

Center Kick Plate

Pivot Pin

Retaining Pin Boot Plate KV18097

5. Remove six cap screws securing center kick plate to cover plate and skid steer frame. Remove center kick plate. Cap Screw (2 Used)

Side Plate

KV18052

8. Remove retaining pins and pivot pins. 9. To remove boot plates, remove control lever handles. (See CONTROL LEVER HANDLE DISASSEMBLY/ASSEMBLY in the STEERING section.) 10. Make repairs to components as necessary. Installation: 1. Installation is the reverse of removal.

USING REMOTE START BOX KV18098

6. Remove two cap screws securing side plate to cover plate and skid steer frame. Remove side plate. Repeat procedure for opposite side.

Reason: To allow the engine to be started with the ROPS raised and in the locked position. Procedure: 1. Park skid steer safely.

c CAUTION

Boot Plates

Cover Plate

KV18099

7. Lift boot plates out of cover plate. Pivot cover plate forward and lift out.

11/22/00

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 steer may override brake and move quickly. 2. Raise and block skid steer. (See RAISING AND BLOCKING SKID STEER.) 3. Raise boom and engage boom locks. 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].)

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.

KV18038

7. Install an M10 x 30 cap screw in tab at the rear of both yokes to secure steering assembly during adjustment.

10. Use remote start box ignition to start and shut off engine with ROPS raised and in the locked position. 11. Use the remote start box park brake switch to engage or disengage park brake. 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:

KV15239 KV15239

8. Lock auxiliary hydraulic control handle in the neutral position. Remote Start Box

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 negative (–) battery cable. Wire Connector

Rear Light Bracket

Park Brake Switch

Ignition

Right Tail Light Left Tail Light Electrical Connector

Rear Work Light

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

REPAIR

MISCELLANEOUS

11. Install a suitable lifting strap and hoist on ROPS as shown.

Bulkhead Connectors

c CAUTION Make sure ROPS is supported properly with suitable lifting strap and hoist before proceeding.

Rear Light Connectors

KV18031

6. Remove tie bands securing bulkhead connectors. 7. Disconnect ROPS-to-engine bulkhead connectors. Washer (2 used)

12. Raise hoist and lifting strap to remove weight from ROPS cylinders. 13. Remove retaining pins and pivot pins to disconnect left and right ROPS cylinders from skid steer frame. 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 out of upper skid steer frame. 15. Remove cap screw and nut from both sides of ROPS. 16. Remove ROPS. Make repairs as necessary. 17. Inspect ROPS pivot bushings for wear or damage. Remove only if replacement is necessary.

JT01748 Lifting Eyelet

ROPS Cylinder

ROPS 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

BOOM

Installation: Pivot Bushings Cap Screw Bulkhead Connectors

LOWER BOOM LINK 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. 2. Turn key switch ON and operate all hydraulic controls to relieve system pressure. Turn key switch OFF.

Rear Light 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 time.

Lock Nut (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

REPAIR

MISCELLANEOUS

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 Hoses

Pivot Pin

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) nonmetallic deadblow hammer to loosen taper of pivot pin.

KV31004

KV31002

11/22/00

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 equipped. 10. Remove lower link rear pivot pin. 11. Raise ROPS. (See RAISING ROPS [ROLLOVER PROTECTION STRUCTURE] in this section.)

10 - 11

REPAIR

MISCELLANEOUS

Front Pivot Pin

KV31002

12. Remove cap screw and lock nut retaining lower link front pivot pin. 13. Remove front pivot pin and remove lower link from machine. 14. Repair or replace link and bushings as required.

3. Securely block both sides of the rear of the boom. 4. Install a suitable lifting strap and hoist to upper link.

Installation: 1. Coat front pivot pin with Never–Seez compound. Put link in place in machine and install front pivot 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.) 3. Coat taper of new pivot pin with Never–Seez compound. Install pivot pin through lower link and into boom. 4. Install pivot pin cap screw and nut. Tighten to 275 N•m (200 lb-ft.) 5. Route hydraulic hoses through loops on link and connect to hydraulic lines under boom. Install hose retainers. 6. Install wiring harness (eight button or 12-volt) if equipped. 7. Remove blocking and lubricate pivot points.

Upper Cap Screws

Lower Cap Screws and Nuts

KV31007

5. Loosen both lower pivot-pin cap screws and nuts. Do not remove nuts. Loosen nuts to the end of the cap screw. Cap Screw

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 switch and turn engine off. 2. Turn key switch ON and move all hydraulic controls to remove system pressure. Turn key switch OFF.

KV31008

NOTE: Left Side Shown 6. Loosen both upper pivot-pin cap screws approximately six turns.

10 - 12

11/22/00

REPAIR

MISCELLANEOUS

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: 1. Lift into place using a suitable strap and hoist. 2. Coat tapered portion of upper pins with Never–Seez compound and install. Tighten cap screws to 275 N•m (200 lb-ft). 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). 4. Remove blocking. Lubricate bushings.

KV31124

3. Roll QUIK-TATCH® hitch coupling full forward and lower boom to within 1/4 in. of blocking as shown. 4. Engage park brake switch and turn engine off. Plug

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 Threads

KV31127

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

REPAIR

MISCELLANEOUS

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. 11. If required, remove components from hitch coupling. (See QUIK-TATCH REMOVAL/ INSTALLATION in this section.) Installation: 1. Place hitch coupling on blocking. 2. Install tapered pins in each side. Install and tighten cap screws and nuts to 350 N•m (225 lb-ft). 3. Position cylinders and install pivot pins through cylinders and into hitch coupling. Secure with cap 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.

KV15162

4. Remove QUIK-TATCH assembly from implement frame. 5. Inspect parts for wear or damage. Replace or repair as necessary. 6. Repeat this procedure for opposite side if necessary. Installation: 1. Apply Moly High Temperature EP Grease to all moving parts on QUIK-TATCH before installation.

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

KV15163

NOTE: Left rear of implement frame shown. A KV15161

11/22/00

IMPORTANT: During installation of QUIK-TATCH assembly into implement frame, make sure the end of pin (A) is located in upper corner of weldment frame as shown above.

10 - 15

REPAIR

MISCELLANEOUS

2. Install QUIK-TATCH assembly into implement frame with end of pin (A) located in upper corner of weldment frame as shown above.

2. Park skid steer on flat level surface. Lower boom and block the front near the at-rest ground position. Engage park brake switch and turn engine off.

c CAUTION

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 hitch coupling (see QUIK-TACH HITCH COUPLING REMOVAL/INSTALLATION in this section) and bucket cylinders (see BUCKET CYLINDER REMOVAL in HYDRAULICS section) prior to removing boom.

KV31002

4. Securely block both sides of the rear of the boom. Hydraulic Hoses Hose Retainer

Removal: 1. Remove any attachments. .

Blocking

KV31003

(Left Side Shown; Right Side Similar)

KV31128

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 equipped.

NOTE: Plug or cap all open hydraulic fittings to prevent contamination of the system.

10 - 16

11/22/00

REPAIR

MISCELLANEOUS

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

9. Remove lock nut and cap screw on top cylinder pivot pin. Remove pin. 10. Attach suitable lifting straps to each side of the boom. Using a suitable hoist, lift boom from machine. Installation: 1. Hoist boom into place on machine. 2. Install upper link lower pins. (See UPPER BOOM LINK REMOVAL/INSTALLATION in this section.) 3. Install lower link rear pins. (See LOWER BOOM LINK REMOVAL/INSTALLATION in this section.) 4. Install cylinder upper pivot pin, cap screw, and lock nut. Tighten cap screw and lock nut to 73 N•m (54 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.

NOTE: Boom is raised for the sake of clarity. 2. Remove two screws holding air inlet cover on left side of heater housing and remove cover. 3. Replace filter. 4. Install air inlet cover.

HEATER CORE 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.

Heater Cover

CAB HEATER/DEFROSTER (OPTIONAL) KV31045

FILTER REPLACEMENT 1. Park skid steer on flat level surface. Lower boom to the at-rest ground position, engage park brake switch and turn engine off.

11/22/00

2. Remove heater cover. Disconnect lights.

10 - 17

REPAIR

MISCELLANEOUS

Remove Screws

TS281

c CAUTION

KV18856

Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Remove filler cap only when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing cap completely.

5. Remove four screws retaining heater core. Remove core. Installation:

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

3. Drain approximately 2 L (0.53 gal) coolant from radiator. Loosen vent valve on heater core outlet tube to aid draining. 4. Remove hoses from heater core and control valve.

10 - 18

NOTE: Be careful not to over-tighten hose clamps or vent valve. 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.) 6. Run engine with heater control at maximum heat to verify operation. 7. Check for coolant leaks. 8. Install heater cover.

11/22/00

REPAIR

MISCELLANEOUS

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.

KV18860

Heater 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

3. Disconnect wires from speed controller and ground. Tag wires for ease of installation.

KV18859

3. Install and tighten three screws retaining blower 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

5. Connect wires to speed controller and ground. 6. Install heater cover.

CONTROL VALVE REMOVAL/ INSTALLATION

c CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Remove filler cap only when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing cap completely.

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.

Remove Hoses Vent Valve

Cap Screw

Connector Cap Screw

Heater Cover

KV18857 KV31045

2. Remove heater cover.

3. Drain approximately 2 L (0.53 gal) coolant from radiator. Loosen vent valve on heater core outlet tube to aid draining. 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

REPAIR

MISCELLANEOUS

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.) 6. Run engine with heater control set to maximum heat to verify operation. 7. Check for coolant leaks. 8. Install heater cover.

Fabricated Hose

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

2. Remove heater cover to gain access to vent valve. 3. Fill cooling system with the recommended coolant. Fill coolant recovery bottle to within 25 mm (1 in.) of the top. Tighten cover securely.

11/22/00

5. Verify that radiator cap is secured in its normal running position. 6. Adjust air pressure to a maximum of 69 kPa (10 psi). 7. Turn key switch ON and adjust cab heat control to maximum heat. 8. Apply regulated pressure to cooling system.

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. 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.

Lower Nuts

CAB DOOR (IF EQUIPPED) 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.

NOTE: This operation requires two people 2. One person enter skid steer. DO NOT close door. 3. Remove gas springs from ball studs on door handles. 4. Close door. 5. Unlock auxiliary hydraulic handle and place in detent position.

KV18868

6. Loosen upper cap screws and lower nuts that retain left door roller brackets to door.

c CAUTION Door weighs 21 kg (47 lb). Two people are required for door removal. 7. Open door halfway. With second person assisting 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

REPAIR

MISCELLANEOUS

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. 11. Test for proper operation of door safety interlock switch. Hydraulic lock and park brake should engage when door is open. Adjust as necessary.

Washer Hose

Arm Retaining Nut KV31100

WINDSHIELD WIPER/WASHER (OPTIONAL)

2. Remove cap covering wiper arm retaining nut. Remove nut. 3. Disconnect washer hose. Remove wiper arm from motor shaft.

WIPER MOTOR Removal:

Thumb Nut

Small Nut Large Nut

Harness Connector

KV31101

4. Remove thumb nut and O-ring. KV31099

Seal

Cup

Large Nut

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

4. Install wiper arm and nut. Tighten nut to 10.4 N•m (92 lb-in.). 5. Connect washer hose. 6. Connect wiring harness to motor. 7. Run wiper to verify operation.

KV31105

3. Carefully pry pump from grommet. 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 Air Filter Restriction Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-140 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-127 Air Inlet Pipe, Inspection . . . . . . . . . . . . . . . . . . . 3-104 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136 Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . 3-102 Disassembly and Testing . . . . . . . . . . . . . . . 3-133 Exploded View . . . . . . . . . . . . . . . . . . . . . . . 3-131 Identification . . . . . . . . . . . . . . . . . . . . . . . . . 3-133 Regulated Amperage/Voltage Test . . . . . . . 4-123 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-148 Axle Disassembly/Assembly . . . . . . . . . . . . . . . . . . 5-10 Housing Removal/Installation . . . . . . . . . . . . . . 5-9

B Backup Alarm Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-111 Circuit Schematic . . . . . . . . . . . . . . . . . . . . . 4-112 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-150 Switch Replacement . . . . . . . . . . . . . . . . . . . 4-150 Backup Alarm Circuit . . . . . . . . . . . . . . . . . . . . . 4-111 Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-121 Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-122 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-120 Belt Tension, Fan/Alternator . . . . . . . . . . . . . . . . 3-102 Blocking Skid Steer . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Blower Switch Test . . . . . . . . . . . . . . . . . . . . . . . 4-134 Boom Bucket Cylinder Replace . . . . . . . . . . . . . . . . 9-44 Cylinder Component Location . . . . . . . . . . . . 9-12 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . 9-46 Cylinder Replace . . . . . . . . . . . . . . . . . . . . . . 9-43 Drift Down Check . . . . . . . . . . . . . . . . . . . . . . 9-19 Drift Up Check . . . . . . . . . . . . . . . . . . . . . . . . 9-20 Lift Check Test . . . . . . . . . . . . . . . . . . . . . . . . 9-20 Lock Removal/Installation . . . . . . . . . . . . . . . . 10-5 Lockout Solenoid Check . . . . . . . . . . . . . . . . . 9-15 Lockout Solenoid Test . . . . . . . . . . . . . . . . . 4-138 Lower Link Removal/Installation . . . . . . . . . . 10-10 Operation Check . . . . . . . . . . . . . . . . . . . . . . . 9-15 QUIK-TATCH® Hitch Coupling Removal/Installation . . . . . . . . . . . . . . . . . 10-13 QUIK-TATCH® Repair . . . . . . . . . . . . . . . . . 10-15 Removal/Installation . . . . . . . . . . . . . . . . . . . 10-16 Upper Link Removal/Installation . . . . . . . . . . 10-12 Boom and Bucket Lockout Circuit . . . . . . . . . . . . . 4-49 Brakes - See Park Brake Break-In Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Bucket Cylinder Component Location . . . . . . . . . . . . 9-12 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . 9-46 Cylinder Replace . . . . . . . . . . . . . . . . . . . . . . 9-44 11/22/00

Drift Dump Position Check . . . . . . . . . . . . . . . 9-20 Drift Rollback Position Check . . . . . . . . . . . . . 9-20 Lift Check Test . . . . . . . . . . . . . . . . . . . . . . . . 9-21 Lockout Solenoid Check . . . . . . . . . . . . . . . . . 9-15 Lockout Solenoid Test . . . . . . . . . . . . . . . . . 4-139

C Cab Door Replacement . . . . . . . . . . . . . . . . . . . 10-22 Cab Door Switch Test . . . . . . . . . . . . . . . . . . . . . 4-133 Cab Heater/Defroster Blower Replacement . . . . . . . . . . . . . . . . . . 10-19 Blower Switch Test . . . . . . . . . . . . . . . . . . . . 4-134 Circuit Operation . . . . . . . . . . . . . . . . . . . . . . 4-104 Control Valve Replacement . . . . . . . . . . . . . 10-20 Deaeration . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21 Filter Replacement . . . . . . . . . . . . . . . . . . . . 10-17 Heater Core Replacement . . . . . . . . . . . . . . 10-17 Thermostat Replacement . . . . . . . . . . . . . . . 4-144 Cam Follower Bore, Measure . . . . . . . . . . . . . . . . 3-61 Camshaft Bore, Measure . . . . . . . . . . . . . . . . . . . . . . . . 3-62 Bushing Installation . . . . . . . . . . . . . . . . . . . . 3-62 Bushing Removal . . . . . . . . . . . . . . . . . . . . . . 3-62 Cam Follower, Measure . . . . . . . . . . . . . . . . . 3-86 Gear Replacement . . . . . . . . . . . . . . . . . . . . . 3-85 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86 Journal OD, Measure . . . . . . . . . . . . . . . . . . . 3-85 Lobe Height, Measure . . . . . . . . . . . . . . . . . . 3-85 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84 Tachometer Pick-Up Pin Removal . . . . . . . . . 3-86 Centering Plate Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 Removal . . . . . . . . . . . . . . . . . . . . . . . . 7-18, 7-19 Centering Plate Adjustment . . . . . . . . . . . . . . . . . 7-12 Centering, Steering Control Levers . . . . . . . . . . . . 7-14 Chain Drive Chain Tension Adjustment . . . . . . . . . . . 5-9 Chain Case Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Oil Specifications . . . . . . . . . . . . . . . . . . . . . . 2-14 Charging Battery . . . . . . . . . . . . . . . . . . . . . . . . . 4-121 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 Circuit Relief Valve Test . . . . . . . . . . . . . . . . . . . . 9-19 Cold Weather Start Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-140 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-128 Compression Test, Cylinder . . . . . . . . . . . . . . . . . 3-25 Connecting Rods Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71 Bearing Clearance . . . . . . . . . . . . . . . . . . . . . 3-66 Bearing Inspection . . . . . . . . . . . . . . . . . . . . . 3-65 Bushing ID . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66 Bushing Replacement . . . . . . . . . . . . . . . . . . 3-67 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

INDEX - 1

INDEX Control Lever Auxiliary Handle Adjust . . . . . . . . . . . . . . . . . . 7-17 Hydraulic Handle Adjust Hands Only . . . . . . . . . . . . . . . . . . . . . . . 7-17 Stops Adjustment, Tracking . . . . . . . . . . . . . . 7-16 Control Valve Component Location . . . . . . . . . . . 9-10 Coolant Drain Interval . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Temperature Sender/Switch Replacement . . . . . . . . . . . . . . . . . . . . . 4-140 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-127 Cooling System, Deaeration . . . . . . . . . . . . . . . . 3-102 Cover Plate Removal/Installation . . . . . . . . . . . . . 10-6 Crankshaft Bearing Cap Replacement . . . . . . . . . . . . . . . 3-63 Bearing Inserts Installation . . . . . . . . . . . . . . . 3-83 Bore, Measure . . . . . . . . . . . . . . . . . . . . . . . . 3-63 End Play, Measuring . . . . . . . . . . . . . . . . . . . 3-79 Front Oil Seal Installation . . . . . . . . . . . . . . . . 3-92 Gear Replacement . . . . . . . . . . . . . . . . . . . . . 3-82 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80 Install 2-Piece Thrust Bearing . . . . . . . . . . . . 3-83 Install 6-Piece Thrust Bearing . . . . . . . . . . . . 3-83 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83 Journal Diameter, Measure . . . . . . . . . . . . . . 3-80 Main Bearing Clearance, Determine . . . . . . . 3-81 Micro-Finishing Specifications . . . . . . . . . . . . 3-82 Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . 3-75 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75 Rear Oil Seal, Removal . . . . . . . . . . . . . . . . . 3-77 Regrinding . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81 Regrinding Guidelines . . . . . . . . . . . . . . . . . . 3-81 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80 Cross Shaft Detent Adjustment . . . . . . . . . . . . . . . . . . . . . 7-15 Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 Cylinder Block Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 Exploded View . . . . . . . . . . . . . . . . . . . . . . . . 3-58 Top Desk Flatness . . . . . . . . . . . . . . . . . . . . . 3-63 Cylinder Compression Test . . . . . . . . . . . . . . . . . . 3-25 Cylinder Head Check Valve Recess . . . . . . . . . . . . . . . . . . . 3-51 Checking Flatness . . . . . . . . . . . . . . . . . . . . . 3-49 Clean, Inspect Valve Seats . . . . . . . . . . . . . . 3-50 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54 Measure Valve Guide . . . . . . . . . . . . . . . . . . . 3-50 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 Remove Valve Seat Inserts . . . . . . . . . . . . . . 3-51 Torque Turn Tightening Method . . . . . . . . . . . 3-55 Cylinder Liners Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65 Measure Bore . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

INDEX - 2

O-Ring Installation . . . . . . . . . . . . . . . . . . . . . 3-65 Packing Installation . . . . . . . . . . . . . . . . . . . . . 3-65 Protrusion, Measure . . . . . . . . . . . . . . . . . . . . 3-64 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

D Diagnosis Chain Case and Axles . . . . . . . . . . . . . . . . . . . 5-6 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 3-119 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Diesel Fuel Lubricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Drive Chain Sprocket Removal/Installation . . . . . . . . . . . . 5-12 Tension Adjustment . . . . . . . . . . . . . . . . . . . . . 5-9 Dual Flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-98 Dual Flasher Switch Test . . . . . . . . . . . . . . . . . . 4-133

E Electrical Air Filter Restriction Switch Replacement . . 4-140 Alternator Replacement . . . . . . . . . . . . . . . . 4-148 Backup Alarm Circuit . . . . . . . . . . . . . . . . . . 4-111 Backup Alarm Circuit Schematic . . . . . . . . . 4-112 Backup Alarm Replacement . . . . . . . . . . . . . 4-150 Backup Alarm Switch Replacement . . . . . . . 4-150 Battery Charging . . . . . . . . . . . . . . . . . . . . . . 4-121 Boom and Bucket Lockout Circuit . . . . . . . . . 4-49 Boom and Bucket Lockout Circuit Schematic . 4-50 Cab Heater Thermostat Replacement . . . . . 4-144 Cab Heater/Defroster Circuit Operation . . . . 4-104 Cab Heater/Defroster Circuit Schematic . . . 4-105 Charging Circuit Operation . . . . . . . . . . . . . . . 4-44 Charging Circuit Schematic . . . . . . . . . . . . . . 4-45 Cold Weather Start Switch Replacement . . . 4-140 Common Circuit Tests . . . . . . . . . . . . . . . . . . . 4-8 Component Legend . . . . . . . . . . . . . . . . . . . . . 4-9 Component Location . . . . . . . . . . . . . . . . . . . 4-11 Component Replacement . . . . . . . . . . . . . . . 4-140 Coolant Temperature Sender/Switch Replacement . . . . . . . . . . . . . . . . . . . . . . 4-140 Diagnosis Air Filter Restriction Warning Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66 Backup Alarm Circuit . . . . . . . . . . . . . . . 4-113 Boom/Bucket Lockout and Park Brake Circuit . . . . . . . . . . . . . 4-51 Cab Heater/Defroster Circuit . . . . . . . . . 4-106 Charging Circuit . . . . . . . . . . . . . . . . . . . . 4-46 Coolant Temperature Gauge Circuit . . . . 4-77 Dual Flasher Circuit . . . . . . . . . . . . . . . . 4-100 Engine Oil Pressure Guage Circuit . . . . . 4-82 11/22/00

INDEX Electrical;Diagnosis (Cont.) Engine Oil Pressure Warning Light Circuit . . . . . . . . . . . . . . 4-80 Engine Overtemperature Warning Light Circuit . . . . . . . . . . . . . . 4-75 Fuel Circuit . . . . . . . . . . . . . . . . . . . . . . . . 4-38 Fuel Gauge Circuit . . . . . . . . . . . . . . . . . . 4-72 High Flow Circuit . . . . . . . . . . . . . . . . . . . 4-87 High-Flow Circuit . . . . . . . . . . . . . . . . . . . 4-87 Hydraulic Filter Restriction Warning Light Circuit . . . . . . . . . . . . . . 4-70 Hydraulic Oil Overtemperature Warning Light Circuit . . . . . . . . . . . . . . 4-68 Lights Circuit . . . . . . . . . . . . . . . . . . . . . . 4-93 Park Brake Switch Warning Light Circuit . . . . . . . . . . . . . . 4-63 Power and Cranking Circuit . . . . . . . . . . . 4-32 Preheat Circuit . . . . . . . . . . . . . . . . . . . . . 4-41 Seat Belt Warning Light Circuit . . . . . . . . 4-60 Wiper/Washer Circuit . . . . . . . . . . . . . . . 4-117 Dual Flasher Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-98 Circuit Schematic . . . . . . . . . . . . . . . . . . . 4-99 Engine Oil Pressure Switch/Sender Replacement . . . . . . . . . . . . . . . . . . . . . . 4-141 Fuel and Preheat Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 Circuit Schematic . . . . . . . . . . . . . . . . . . . 4-37 Fuel Level Sender Replacement . . . . . . . . . 4-145 Gauges and Warning Lights Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56 Circuit Schematic . . . . . . . . . . . . . . . . . . . 4-59 High-Flow Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85 Circuit Schematic . . . . . . . . . . . . . . . . . . . 4-86 Hydraulic Oil Filter Restriction Switch Replacement . . . . . . . . . . . . . . . . . . . . . . 4-149 Hydraulic Oil Temperature Switch Replacement . . . . . . . . . . . . . . . . . . . . . . 4-148 Instrument Panel Component Location . . . . . . . . . . . . . . . 4-143 Instrument Cluster Replacement . . . . . . 4-145 Key Switch Replacement . . . . . . . . . . . . 4-143 Switch Replacement . . . . . . . . . . . . . . . 4-144 Lights Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91 Circuit Schematic . . . . . . . . . . . . . . . . . . . 4-92 Main Schematic . . . . . . . . . . . . . . . . . . . . . . . 4-13 Manifold Preheat Relay Replacement . . . . . 4-142 Manifold Preheater Replacement . . . . . . . . . 4-141 Park Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49 Circuit Schematic . . . . . . . . . . . . . . . . . . . 4-50 Solenoid Replacement . . . . . . . . . . . . . . 4-149 Power and Cranking Circuit . . . . . . . . . . . . . . 4-29 Schematic . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Schematics, Reading . . . . . . . . . . . . . . . . . . . . 4-7 Seat Belt Switch Replacement . . . . . . . . . . . 4-147 Seat Safety Switch Replacement . . . . . . . . . 4-146 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

11/22/00

Starting Motor Replacement . . . . . . . . . . . . . . . . . . . . . 4-147 Solenoid Test . . . . . . . . . . . . . . . . . . . . . 4-126 Switched Power Circuit . . . . . . . . . . . . . . . . . . 4-29 Tests and Adjustments . . . . . . . . . . . . . . . . . 4-120 Air Filter Restriction Switch . . . . . . . . . . 4-127 Backup Alarm Switch Adjust . . . . . . . . . 4-151 Battery Testing and Charging . . . . . . . . 4-120 Blower Switch . . . . . . . . . . . . . . . . . . . . . 4-134 Boom Lockout Solenoid . . . . . . . . . . . . . 4-138 Bucket Lockout Solenoid . . . . . . . . . . . . 4-139 Cab Door Switch . . . . . . . . . . . . . . . . . . 4-133 Cold Weather Start Switch . . . . . . . . . . . 4-128 Coolant Temperature Sender . . . . . . . . . 4-127 Coolant Temperature Switch . . . . . . . . . 4-127 Dual Flasher Switch . . . . . . . . . . . . . . . . 4-133 Fuel Level Sender . . . . . . . . . . . . . . . . . 4-135 High-Flow Switch . . . . . . . . . . . . . . . . . . 4-134 Hydraulic Oil Filter Restriction Switch . . 4-139 Hydraulic Oil Overtemperature Switch . . 4-137 Key Switch . . . . . . . . . . . . . . . . . . . . . . . 4-131 Manifold Preheater . . . . . . . . . . . . . . . . . 4-129 Oil Pressure Switch/Sender, Engine . . . 4-129 Park Brake Solenoid . . . . . . . . . . . . . . . 4-138 Park Brake Switch . . . . . . . . . . . . . . . . . 4-131 Preheater Relay . . . . . . . . . . . . . . . . . . . 4-130 Preheater Switch . . . . . . . . . . . . . . . . . . 4-132 Regulated Amperage and Voltage Test . 4-123 Running Lights Switch . . . . . . . . . . . . . . 4-132 Seat Belt Switch . . . . . . . . . . . . . . . . . . . 4-137 Seat Switch . . . . . . . . . . . . . . . . . . . . . . 4-136 Starter Load Draw . . . . . . . . . . . . . . . . . 4-124 Wiper/Washer Switch . . . . . . . . . . . . . . . 4-135 Unswitched Power Circuits . . . . . . . . . . . . . . . 4-29 Wiper/Washer Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-115 Circuit Schematic . . . . . . . . . . . . . . . . . . 4-116 Wire Color Abbreviation Chart . . . . . . . . . . . . . 4-8 Wire Harness Diagram Backup Alarm . . . . . . . . . . . . . . . . . . . . . . 4-26 Cab Heater/Defroster . . . . . . . . . . . . . . . . 4-25 Cold Start . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Dual Flasher . . . . . . . . . . . . . . . . . . . . . . . 4-23 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Wiper/Washer . . . . . . . . . . . . . . . . . . . . . 4-27 Electrical Component Legend . . . . . . . . . . . . . . . . . 4-9 Engine Assembly Sequence . . . . . . . . . . . . . . . . . . . . 3-45 Blow-By, Measure . . . . . . . . . . . . . . . . . . . . . 3-24 Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115 Complete Final Assembly . . . . . . . . . . . . . . . . 3-74 Disassembly Sequence . . . . . . . . . . . . . . . . . 3-45 Final Work . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57 General Tune-Up Recommendations . . . . . . . 3-23 Oil Pressure, Checking . . . . . . . . . . . . . . . . . . 3-24 Oil Specifications . . . . . . . . . . . . . . . . . . . . . . 2-12 Oil, Break-In . . . . . . . . . . . . . . . . . . . . . . . . . 3-115 Preliminary Testing . . . . . . . . . . . . . . . . . . . . . 3-23 Removal/Installation . . . . . . . . . . . . . . . . . . . . 3-33

INDEX - 3

INDEX Engine (Cont.) Speed Adjustment . . . . . . . . . . . . . . . . . . . . 3-115 Tests and Adjustments . . . . . . . . . . . . . . . . . . 3-23

G Grease Specifications . . . . . . . . . . . . . . . . . . . . . . 2-15

Engine Oil Pressure Switch/Sender Test . . . . . . 4-129

Exhaust Manifold, Inspection . . . . . . . . . . . . . . . 3-105

High-Flow Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . 4-85 Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-134

F Face Seal Fittings with Inch Stud Ends Torque . . . . . . . . . 2-8 Fittings with Metric Stud Ends Torque . . . . . . . 2-9 Fan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103 Fan/Alternator Belt Tension . . . . . . . . . . . . . . . . 3-102 Flywheel Ball Bearing Installation . . . . . . . . . . . . . . . . . 3-76 Housing, Replacement . . . . . . . . . . . . . . . . . . 3-79 Hydrostatic Drive Coupling . . . . . . . . . . . . . . . 3-38 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75 Ring Gear Replacement . . . . . . . . . . . . . . . . . 3-76 Four-Way Flasher . . . . . . . . . . . . . . . . . . . . . . . . . 4-98 Front Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86 Fuel and Preheat Circuit . . . . . . . . . . . . . . . . . . . . 4-36 Fuel Filter, Replace Element . . . . . . . . . . . . . . . . 3-107 Fuel Injection Nozzle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113 Chatter Test . . . . . . . . . . . . . . . . . . . . . . . . . 3-112 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-113 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114 Opening Pressure Test . . . . . . . . . . . . . . . . . 3-112 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111 Running Test . . . . . . . . . . . . . . . . . . . . . . . . 3-120 Spray Pattern Test . . . . . . . . . . . . . . . . . . . . 3-112 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112 Valve Seat Checking . . . . . . . . . . . . . . . . . . 3-113 Valve Stem/Guide Wear Checking . . . . . . . . 3-112 Fuel Injection Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108 Timing Adjustment . . . . . . . . . . . . . . . . . . . . . 3-27 Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . 3-101 Fuel Level Sender Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-145 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-135 Fuel Pump Measure Supply Pressure . . . . . . . . . . . . . . . 3-26 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 3-108 Fuel System Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114 Cold Start Advance System . . . . . . . . . . . . . 3-118 Fuel Injection Nozzles, General Information . 3-119 Fuel Injection Pump . . . . . . . . . . . . . . . . . . . 3-117

INDEX - 4

Hydraulic Auxiliary Control Handle Adjustment . . . . . . . 7-17 Boom and Bucket Cylinder Repair . . . . . . . . . 9-46 Boom and Bucket Lockout Solenoids Check . 9-15 Boom Cylinder Component Location . . . . . . . . . . . . . . . . 9-12 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43 Boom Drift Down Check . . . . . . . . . . . . . . . . . 9-19 Boom Drift Up Check . . . . . . . . . . . . . . . . . . . 9-20 Boom Lift Check Test . . . . . . . . . . . . . . . . . . . 9-20 Boom Lockout Solenoid Check . . . . . . . . . . . 9-15 Bucket Cylinder Component Location . . . . . . . . . . . . . . . . 9-12 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44 Bucket Drift Dump Position Check . . . . . . . . . 9-20 Bucket Drift Rollback Position Check . . . . . . . 9-20 Bucket Lift Check Test . . . . . . . . . . . . . . . . . . 9-21 Bucket Lockout Solenoid Check . . . . . . . . . . . 9-15 Bucket Self-Leveling Adjustment . . . . . . . . . . 9-21 Charge Pump Pressure Test . . . . . . . . . . . . . 9-16 Circuit Relief Valve Test . . . . . . . . . . . . . . . . . 9-19 Component Location . . . . . . . . . . . . . . . . . . . . 9-9 Control Handle Adjustment Hands Only . . . . . . . . . . . . . . . . . . . . . . . 7-17 Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 9-38 Component Location . . . . . . . . . . . . . . . . 9-10 Cross Section . . . . . . . . . . . . . . . . . . . . . . 9-36 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 9-29 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 9-34 Installation . . . . . . . . . . . . . . . . . . . . . . . . 9-41 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27 Fitting Information . . . . . . . . . . . . . . . . . . . . . . . 2-8 High-Flow Pump Remove/Inspect/Install . . . . . . . . . . . . . . . 9-26 High-Flow Valve Replace . . . . . . . . . . . . . . . . 9-27 Hydraulic/Charge Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 9-24 Component Location . . . . . . . . . . . . . . . . 9-11 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 9-22 Flow Test . . . . . . . . . . . . . . . . . . . . 6-11, 9-18 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 9-23 Installation . . . . . . . . . . . . . . . . . . . . . . . . 9-25 Pressure Test . . . . . . . . . . . . . . . . . . . . . . 6-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22 Oil Filter Restriction Switch Replacement . . . . . . . . . . . . . . . . . . . . . 4-149 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-139 Oil Overtemperature Switch Replacement . . . . . . . . . . . . . . . . . . . . . 4-148 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-137 Self-Leveling Valve - Replace . . . . . . . . . . . . 9-43 System Component Location . . . . . . . . . . . . . . 9-8 11/22/00

INDEX Hydraulic (Cont.) System Components and Operation . . . . . . . . 9-5 System Relief Valve Pressure Test . . . . . . . . 9-15 System Schematic . . . . . . . . . . . . . . . . . . . . . . 9-7

M Manifold Preheat Relay Replacement . . . . . . . . 4-142 Metric Fastener Torque Values . . . . . . . . . . . . . . . . 2-5

Hydrostatic Drive Coupling, Install . . . . . . . . . . . . 3-38

Hydrostatic Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Removal/Installation . . . . . . . . . . . . . . . . . . . . 6-37

Nozzle Bores, Injection, Cleaning . . . . . . . . . . . . . 3-48

Hydrostatic Power Train Component Location . . . . . . . . . . . . . . . . . . . . 6-6 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . 6-20 System Operation . . . . . . . . . . . . . . . . . . . . . . . 6-5 Test and Adjustments . . . . . . . . . . . . . . . . . . . 6-10 Troubleshooting and Diagnosis . . . . . . . . 6-8, 6-9 Hydrostatic Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Case Drain Pressure Test . . . . . . . . . . . . . . . 6-19 Case Drain Test . . . . . . . . . . . . . . . . . . . . . . . 6-17 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27 Exploded View Center Manifold . . . . . . . . . . . . . . . 6-24, 6-25 Front Pump . . . . . . . . . . . . . . . . . . . . . . . 6-23 Rear Pump . . . . . . . . . . . . . . . . . . . . . . . . 6-26 Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 High Pressure Relief Test . . . . . . . . . . . . . . . . 6-12 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

O Oil Bypass Valve Replacement . . . . . . . . . . . . . . . 3-94 Oil Cooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93 Nipple Replacement . . . . . . . . . . . . . . . . . . . . 3-93 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92 Oil Deflector Installation . . . . . . . . . . . . . . . . . . . . 3-91 Oil Dipstick Guide Adapter Replacement . . . . . . . 3-94 Oil Pan Installation . . . . . . . . . . . . . . . . . . . . . . . . 3-97 Oil Pressure Regulating Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93 Valve Seat Replacement . . . . . . . . . . . . . . . . 3-93 Oil Pressure Switch/Sender Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 4-141 Oil Pressure, Engine, Checking . . . . . . . . . . . . . . 3-24

Hydrostatic Transmission and Hydraulic Oil . . . . . 2-13

Oil Pump Gear Axial Clearance . . . . . . . . . . . . . . . . . . . 3-95 Gear Radial Clearance . . . . . . . . . . . . . . . . . . 3-95 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3-95 Strainer Replacement . . . . . . . . . . . . . . . . . . . 3-94

O-Ring Face Seal Fittings Service Recommendations . . . . . . . . . . . . . . . . 2-10

Idler Gear Bushing and Shaft, Measure . . . . . . . . . . . . . 3-87 Bushing Replacement . . . . . . . . . . . . . . . . . . 3-88 End Play, Measure . . . . . . . . . . . . . . . . . . . . . 3-86 Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . 3-89 Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-88 Spring Pin Installation . . . . . . . . . . . . . . . . . . . 3-88 Ignition Switch Test . . . . . . . . . . . . . . . . . . . . . . . 4-131 Inch Fastener Torque Values . . . . . . . . . . . . . . . . . 2-7 Injection Nozzle Bores, Cleaning . . . . . . . . . . . . . 3-48 Instrument Cluster Replacement . . . . . . . . . . . . 4-145 Instrument Panel Component Location . . . . . . . . 4-143

K Key Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . 4-131

L Legend, Electrical Components . . . . . . . . . . . . . . . 4-9 Levers, Steering - See Steering Light Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . 4-132 Lights Circuit Operation . . . . . . . . . . . . . . . . . . . . 4-91 Lock, Boom Removal/Installation . . . . . . . . . . . . . 10-5 11/22/00

P Park Brake Actuator Cylinder Removal/Installation . . . . . . . . . . . . . . . . . 8-12 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Burnish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Solenoid Replacement . . . . . . . . . . . . . . . . . 4-149 Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . 4-138 Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-131 Theory of Operation . . . . . . . . . . . . . . . . . . . . . 8-4 Park Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 4-49 Piston Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71 Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . 3-68 Cooling Jets, Checking . . . . . . . . . . . . . . . . . . 3-61 Head and Skirt Checking . . . . . . . . . . . . . . . . 3-69 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

INDEX - 5

INDEX Piston (Cont.) Pin Bore, Measure . . . . . . . . . . . . . . . . . . . . . 3-68 Pin, OD Measure . . . . . . . . . . . . . . . . . . . . . . 3-68 Piston Rings Staggering . . . . . . . . . . . . . . . . . 3-70 Piston/Liner Set Information . . . . . . . . . . . . . . 3-70 Protrusion, Measure . . . . . . . . . . . . . . . . . . . . 3-73 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59 Ring Installation . . . . . . . . . . . . . . . . . . . . . . . 3-69 Second and Third Ring Grooves . . . . . . . . . . 3-69 Top Ring Groove . . . . . . . . . . . . . . . . . . . . . . 3-68 Plate, Cover, Removal/Installation . . . . . . . . . . . . 10-6 Power Train Component Location . . . . . . . . . . . . . . . . . . . . 5-3 Component Operation . . . . . . . . . . . . . . . . . . . 5-4 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Preheater Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-130 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-141 Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-132 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-129

Q QUIK-TATCH® - See Boom

R Radiator, Remove, Inspect, Install . . . . . . . . . . . . 3-41 Raising and Blocking Skid Steer . . . . . . . . . . . . . . 10-6 Remote Start Box, Using . . . . . . . . . . . . . . . . . . . 10-7 Rocker Arm Cover, Installing . . . . . . . . . . . . . . . . 3-57 Rocker Arm Shaft, Inspect . . . . . . . . . . . . . . . . . . 3-56 ROPS (Roll Over Protection Structure) Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Removal/Installation . . . . . . . . . . . . . . . . . . . . 10-8

Sprocket, Drive Chain, Removal/Installation . . . . . 5-12 Start Box, Remote, Using . . . . . . . . . . . . . . . . . . . 10-7 Starting Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-124 Exploded View . . . . . . . . . . . . . . . . . . . . . . . 3-123 Loaded Amperage Draw Test . . . . . . . . . . . . 4-124 No-Load Amperage/RPM Tests . . . . . . . . . . 4-125 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-147 Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . 4-126 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3-124 Steering Auxiliary Control Adjustment . . . . . . . . . . . . . 7-17 Centering Plate Inspection . . . . . . . . . . . . . . . 7-20 Centering Plate Installation Single Plate Models . . . . . . . . . . . . . . . . . 7-21 Centering Plate Removal Dual Plate Models . . . . . . . . . . . . . . . . . . 7-19 Single Plate Models . . . . . . . . . . . . . . . . . 7-18 Component Location . . . . . . . . . . . . . . . . 7-5, 7-6 Control Lever Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Handle Repair . . . . . . . . . . . . . . . . . . . . . 7-26 Removal/Installation . . . . . . . . . . . . . . . . . 7-23 Tracking - Stops Adjustment . . . . . . . . . . 7-16 Cross Shaft Detent Adjustment . . . . . . . . . . . . . . . . . . 7-15 Removal/Installation . . . . . . . . . . . . . . . . . 7-24 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 Dampener Inspection . . . . . . . . . . . . . . . . . . . 7-22 Dampener Removal/Installation . . . . . . . . . . . 7-22 Hydraulic Control Adjustment Hands Only . . . . . . . . . . . . . . . . . . . . . . . 7-17 Tests and Adjustment . . . . . . . . . . . . . . . . . . . . 7-9 Theory of Operation . . . . . . . . . . . . . . . . . . . . . 7-4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Schematics - See Component in Electrical Sealant, Application Guidelines, Engine . . . . . . . . 3-18

Tachometer, Using Stanadyne "Time-Trac" . . . . 3-116

Seat Belt Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-147 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-137

Thermostat Inspect and Test . . . . . . . . . . . . . . . . . . . . . . . 3-23 Remove/Install . . . . . . . . . . . . . . . . . . . . . . . 3-101

Seat Safety Switch Test . . . . . . . . . . . . . . . . . . . 4-136

Timing Gear Backlash, Measure . . . . . . . . . . . . . . . . . . . . . 3-84 Cover, Installation . . . . . . . . . . . . . . . . . . . . . . 3-91 Lower, Installation . . . . . . . . . . . . . . . . . . . . . . 3-91 Upper, Installation . . . . . . . . . . . . . . . . . . . . . . 3-90

Seat Switch Replacement . . . . . . . . . . . . . . . . . . 4-146 Self-Leveling Adjustment . . . . . . . . . . . . . . . . . . . 9-21 Serial Number Location . . . . . . . . . . . . . . . . . . . . 2-17 Skid Steer, Raising and Blocking . . . . . . . . . . . . . 10-6 Specifications Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Hydrostatic Power Train . . . . . . . . . . . . . . . . . . 6-3 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

INDEX - 6

Torque Values Face Seal Fittings with Inch Stud Ends . . . . . . 2-8 Face Seal Fittings with Metric Stud Ends . . . . . 2-9 Inch Fastener . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Metric Fastener . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Troubleshooting Chain Case and Axles . . . . . . . . . . . . . . . . . . . 5-5 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13 Hydrostatic Power Train . . . . . . . . . . . . . . 6-8, 6-9

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