TM 1747

TECHNICAL
MANUAL
Litho in U.S.A
John Deere
Commercial Worksite Products
240 and 250
Skid Steer
Serial No. ( 100100 - )
TM1747 (Nov00)
Replaces TM1747 (July99)
240 and 250
Skid Steer
TM1747 (Nov2000)
INTRODUCTION
11/22/00 1 - 1
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.
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.
Each section will be identified with a symbol rather than a
number. The groups and pages within a section will be
consecutively numbered.
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.
COPYRIGHT

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

Information
Specifications and
Electrical
Power Train
Power Train
(Hydrostatic)
Steering
Brakes
Hydraulics
Engine (Diesel)
Safety
Miscellaneous
Power Train
(Chain Case and Axles)
SAFETY
1 - 2 11/22/00
RECOGNIZE SAFETY INFORMATION
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 wordDANGER, WARNING, or CAUTIONis
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
Replace missing or damaged safety signs. See the
machine operators manual for correct safety sign
placement.
HANDLE FLUIDS SAFELYAVOID
FIRES
Be Prepared For Emergencies
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.
SAFETY
11/22/00 1 - 3
USE CARE IN HANDLING AND
SERVICING BATTERIES
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 16C (60F).
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.
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:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the
acid.
3. Flush your eyes with water for 1015 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.
USE CARE AROUND HIGH-
PRESSURE FLUID LINES
Avoid High-Pressure Fluids
Escaping fluid under pressure can penetrate the skin
causing serious injury.
Avoid injury from escaping fluid under pressure by
stopping the engine and relieving pressure in the
system before disconnecting or connecting hydraulic or
other lines. Tighten all connections before applying
pressure.
Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any
fluid injected into the skin must be surgically removed
within a few hours or gangrene may result. Doctors
unfamiliar with this type of injury should reference a
knowledgeable medical source. Such information is
available from Deere & Company Medical Department
in Moline, Illinois, U.S.A., (1-800-822-8262 U.S.A. or
Canada).
SAFETY
1 - 4 11/22/00
Avoid Heating Near Pressurized
Fluid Lines

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
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.
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.
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
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.
M55689
SAFETY
11/22/00 1 - 5
Support Machine Properly and Use
Proper Lifting Equipment
If you must work on a lifted machine or attachment,
securely support the machine or attachment.
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.
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.
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.
Work In Ventilated Area
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.
If you do not have an exhaust duct system, open the
doors and get outside air into the area.
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.
SAFETY
1 - 6 11/22/00
SERVICE TIRES SAFELY
Explosive separation of a tire and rim parts can cause
serious injury or death.
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.
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.
SERVICE COOLING SYSTEM
SAFELY
Explosive release of fluids from pressurized cooling
system can cause serious burns.
Shut off machine. Only remove filler cap when cool
enough to touch with bare hands. Slowly loosen cap to
first stop to relieve pressure before removing
completely.
SAFETY
11/22/00 1 - 7
HANDLE CHEMICAL PRODUCTS
SAFELY
Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used
with John Deere equipment include such items as
lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques. Check the MSDS before you start any job
using a hazardous chemical. That way you will know
exactly what the risks are and how to do the job safely.
Then follow procedures and recommended equipment.
Dispose of Waste Properly
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.
LIVE WITH SAFETY
Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.
SAFETY
1 - 8 11/22/00
This page intentionally left blank.
SPECIFICATIONS AND INFORMATION CONTENTS
Page
CONTENTS
11/22/00 2 - 1
SPECIFICATIONS AND INFORMATION
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ELECTRICAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HYDRAULICS AND HYDROSTATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIMENSIONS240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIMENSIONS250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RECOMENDED LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
METRIC FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . 5
METRIC FASTENER TORQUE VALUESGRADE 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 OILNORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . 12
BREAK-IN DIESEL ENGINE OILNORTH AMERICA. . . . . . . . . . . . . . . . . . . . . . . 13
HYDROSTATIC TRANSMISSION AND HYDRAULIC OILNORTH AMERICA. . . . 13
CHAIN CASE OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHAIN CASE OILNORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
GENERAL APPLICATION GREASE SPECIFICATIONS. . . . . . . . . . . . 15
GREASENORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
COOLANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIESEL AND GASOLINE ENGINE COOLANTNORTH AMERICA. . . . . . . . . . . . 15
SUPPLEMENTAL COOLANT ADDITIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIESEL AND GASOLINE ENGINE COOLANT DRAIN INTERVALNORTH
AMERICA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SKID STEER PRODUCT IDENTIFICATION NUMBER. . . . . . . . . . . . . . . . . . . . . . . 17
ENGINE SERIAL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 - 2 11/22/00
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)
11/22/00 2 - 3
SPECIFICATIONS AND INFORMATION SPECIFICATIONS
HYDRAULICS AND HYDROSTATICS
Hydrostatic Pumps
Type. . . . . . . . . . . . . . . . . . . . . . . Tandem variable displacement piston pump
Displacement (Max) . . . . . . . . . . . . . . . . . . .40.6 cm
3
(2.48 in
3
) 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)
DIMENSIONS240
(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.
2 - 4 11/22/00
SPECIFICATIONS SPECIFICATIONS AND INFORMATION
DIMENSIONS250
(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 TORQ-GARD SUPREME
or PLUS-50
HY-GARD, TORQ-GARD SUPREME and PLUS-50 are is a registered trademarks of Deere & Company.
11/22/00 2 - 5
SPECIFICATIONS AND INFORMATION METRIC FASTENER TORQUE VALUES
METRIC FASTENER TORQUE VALUES
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: JDSG200.
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Lubricated
a
Dry
a
Lubricated
a
Dry
a
Lubricated
a
Dry
a
Lubricated
a
Dry
a
SIZE Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft
M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5
M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35
M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70
M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 109
M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300
M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410
M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580
M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800
M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000
M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500
M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000
M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500
TS1163
4.8
8.8 9.8
10.9
12.9
5 10
1
2
Property
Class
and
Head
Markings
Property
Class
and
Nut
Markings
4.8
4.8
5
5
8.8
8.8
9.8
9.8
10.9
10.9 12.9
12.9
12.9
12
12 10 10
10
1
0
1
0
METRIC FASTENER TORQUE VALUESGRADE 7 SPECIFICATIONS AND INFORMATION
2 - 6 11/22/00
METRIC FASTENER TORQUE VALUESGRADE 7
Size
Steel or Gray
Iron Torque
Aluminum
Torque
Nm lb-ft Nm lb-ft
M6 11 8 8 6
M8 24 18 19 14
M10 52 38 41 30
M12 88 65 70 52
M14 138 102 111 82
M16 224 165 179 132
11/22/00 2 - 7
SPECIFICATIONS AND INFORMATION INCH FASTENER TORQUE VALUES
INCH FASTENER TORQUE VALUES
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: JDSG200.
Grade 1 Grade 2
b
Grade 5, 5.1 or 5.2 Grade 8 or 8.2
Lubricated
a
Dry
a
Lubricated
a
Dry
a
Lubricated
a
Dry
a
Lubricated
a
Dry
a
SIZE Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft
1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5
5/16 7.7 5.5 10 7 12 9 15 11 20 15 25 18 28 21 35 26
3/8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46
7/16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75
1/2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115
9/16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160
5/8 67 50 85 62 105 78 135 100 170 125 215 160 215 160 300 225
3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400
7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650
1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975
1-1/8 470 300 510 375 470 300 510 375 900 675 1150 850 1450 1075 1850 1350
1-1/4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550
1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
TS1162
1 or 2
b
2
5 5.1 5.2
5
8 8.2
8
No Marks
No Marks
SAE
Grade
and Nut
Markings
SAE
Grade
and Head
Markings
O-RING SEAL SERVICE RECOMMENDATIONS SPECIFICATIONS AND INFORMATION
2 - 8 11/22/00
O-RING SEAL SERVICE RECOMMENDATIONS
FACE SEAL FITTINGS WITH INCH STUD ENDS TORQUE
NOTE: Torque tolerance is plus 15 minus 20%.
Nominal Tube OD/Hose ID Face Seal Tube/Hose End O-Ring Stud Ends
Metric
Tube
OD
Inch Tube OD Thread Size
Tube Nut/
Swivel Nut
Torque
Bulkhead
Lock Nut
Torque
Thread
Size
Straight Fitting or
Lock Nut Torque
mm
Dash
Size
in. mm in. Nm lb-ft Nm lb-ft in. Nm lb-ft
-3 0.188 4.76 3/8-24 8 6
6 -4 0.250 6.35 9/16-18 16 12 12 9 7/16-20 12 9
8 -5 0.312 7.94 1/2-20 16 12
10 -6 0.375 9.52 11/16-16 24 18 24 18 9/16-18 24 18
12 -8 0.500 12.70 13/16-16 50 37 46 34 3/4-16 46 34
16 -10 0.625 15.88 1-14 69 51 62 46 7/8-14 62 46
-12 0.750 19.05 1-3/16-12 102 75 102 75 1-1/16-12 102 75
22 -14 0.875 22.22 1-3/16-12 102 75 102 75 1-3/16-12 122 90
25 -16 1.000 25.40 1-7/16-12 142 105 142 105 1-5/16-12 142 105
32 -20 1.25 31.75 1-11/16-12 190 140 190 140 1-5/8-12 190 140
38 -24 1.50 38.10 2-12 217 160 217 160 1-7/8-12 217 160
Stud End
Tube Nut
Swivel Nut
Lock Nut
Tube Nut
Stud End
Stud Straight and Tube Nut
Bulkhead Union and Bulkhead Lock Nut
90Swivel Elbow and Tube Nut
90Adjustable Stud Elbow
11/22/00 2 - 9
SPECIFICATIONS AND INFORMATION O-RING SEAL SERVICE RECOMMENDATIONS
FACE SEAL FITTINGS WITH METRIC
STUD ENDS TORQUE
NOTE: Torque tolerance is plus 15 minus 20%.
Stud End
Tube Nut
Stud Straight and Tube Nut
Bulkhead Union and Bulkhead Lock Nut
Swivel Nut
Lock Nut
Tube Nut
Stud End
90Swivel Elbow and Tube Nut
90Adjustable Stud Elbow
Groove For Metric
Identification
Groove For Metric Identification
Nominal Tube OD/Hose ID Face Seal Tube/Hose End
O-Ring Stud Ends,
Straight Fitting or Lock Nut
Metric
Tube
OD
Inch Tube OD
Thread
Size
Hex
Size
Tube Nut/
Swivel
Nut
Torque
Bulkhead
Lock Nut
Torque
Thread
Size
Hex
Size
Steel or
Gray Iron
Torque
Aluminum
Torque
mm
Dash
Size
in. mm in. mm Nm lb-ft Nm lb-ft mm mm Nm lb-ft Nm lb-ft
6 -4 0.250 6.35 9/16-18 17 16 12 12 9 M12X1.5 17 21 15.5 9 6.6
8 -5 0.312 7.94
M14X1.5 19 33 24 15 11
10 -6 0.375 9.52 11/16-16 22 24 18 24 18 M16X1.5 22 41 30 18 13
12 -8 0.500 12.70 13/16-16 24 50 37 46 34 M18X1.5 24 50 37 21 15
16 -10 0.625 15.88 1-14 30 69 51 62 46 M22X1.5 27 69 51 28 21
-12 0.750 19.05 1-3/16-12 36 102 75 102 75 M27X2 32 102 75 46 34
22 -14 0.875 22.22 1-3/16-12 36 102 75 102 75 M30X2 36
25 -16 1.000 25.40 1-7/16-12 41 142 105 142 105 M33X2 41 158 116 71 52
28 M38X2 46 176 130 79 58
32 -20 1.25 31.75 1-11/16-12 50 190 140 190 140 M42X2 50 190 140 85 63
38 -24 1.50 38.10 2-12 60 217 160 217 160 M48X2 55 217 160 98 72
O-RING SEAL SERVICE RECOMMENDATIONS SPECIFICATIONS AND INFORMATION
2 - 10 11/22/00
O-RING FACE SEAL FITTINGS
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.
2. Put hydraulic oil or petroleum jelly on the O-ring.
Place electrical tape over the threads to protect O-
ring from nicks. Slide O-ring over the tape and into
the groove of fitting. Remove tape.
.
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 counter-
clockwise 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.
Sealing Surface
O-Ring
Sealing Surface
Groove
O-Ring
STRAIGHT FITTING OR SPECIAL NUT TORQUE
Thread
Size
Torque
a
a. Torque tolerance is 10%.
Number
of Flats
b
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.
Nm lb-ft
3/8-24 UNF 8 (6) 2
7/16-20 UNF 12 (9) 2
1/2-20 UNF 16 (12) 2
9/16-18 UNF 24 (18) 2
3/4-16 UNF 46 (34) 2
7/8-14 UNF 62 (46) 1-1/2
1-1/16-12 UN 102 (75) 1
1-3/16-12 UN 122 (90) 1
1-5/16-12 UN 142 (105) 3/4
1-5/8-12 UN 190 (140) 3/4
1-7/8-12 UN 217 (160) 1/2
Special Nut
Special Washer
Angle Fitting
11/22/00 2 - 11
SPECIFICATIONS AND INFORMATION DIESEL FUEL SPECIFICATIONS
DIESEL FUEL SPECIFICATIONS
In general, diesel fuels are blended to satisfy the low air
temperature requirements of the geographical area in
which they are sold.
Use Grade No. 2-D fuel at temperatures above 4C
(40F).
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 6C (10F) below lowest normal air
temperature.
In winter use special winter fuel or add an anti-
gelling 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.
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.
STORAGE
IMPORTANT: DO NOT USE GALVANIZED
CONTAINERSdiesel 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.
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.
ENGINE OIL SPECIFICATIONS SPECIFICATIONS AND INFORMATION
2 - 12 11/22/00
ENGINE OIL SPECIFICATIONS
4-CYCLE DIESEL ENGINE OIL
NORTH AMERICA
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.
The following oil is preferred AFTER first 100 hours of
break-in oil is used:
John Deere TORQ-GARD SUPREME or John
Deere PLUS-50
Other oils may be used if they meet one of the
following:
API Service Classification CE
API Service Classification CD
CCMC Specification D5
CCMC Specification D4
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.
AIR TEMPERATURE M58275
S
A
E

1
5
W
-
4
0
S
A
E

3
0
S
A
E
1
0
W
-
3
0
PREFERRED
S
A
E

5
W
-
3
0
11/22/00 2 - 13
SPECIFICATIONS AND INFORMATION ENGINE OIL SPECIFICATIONS
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.
John Deere BREAK-IN ENGINE OIL is also
recommended for non-John Deere engines, both
aluminum and cast iron types.
If this preferred John Deere oil is not available, use a
break-in engine oil meeting the following specification
during the first 100 hours of operation:
API Service Classification CE or higher.
IMPORTANT: After the break-in period, use the
John Deere oil that is recommended for this
engine.
HYDROSTATIC TRANSMISSION AND
HYDRAULIC OILNORTH 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 John Deere engine oils are
PREFERRED:
John Deere HY-GARD
.
John Deere low viscosity HY-GARD
(cold weather
operation only).
M58275
B
R
E
A
K
-
I
N

O
I
L
AIR TEMPERATURE
M58275
AIR TEMPERATURE
J
D

H
Y
-
G
A
R
D
L
O
W

V
I
S

J
D

H
Y
-
G
A
R
D
CHAIN CASE OIL SPECIFICATIONS SPECIFICATIONS AND INFORMATION
2 - 14 11/22/00
CHAIN CASE OIL SPECIFICATIONS
CHAIN CASE OILNORTH
AMERICA
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.
IMPORTANT: DO NOT use BIO-HY-GARD
in this
chain case.
The following John Deere oils are PREFERRED:
John Deere HY-GARD

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:
API Service Classification SG or higher.
M58275
AIR TEMPERATURE
J
D

H
Y
-
G
A
R
D
L
O
W

V
I
S

J
D

H
Y
-
G
A
R
D
M58275
AIR TEMPERATURE
S
A
E

1
5
W
-
4
0
S
A
E

1
0
W
-
4
0
S
A
E

5
W
-
3
0
S
A
E

5
W
-
3
0
S
A
E

3
0
11/22/00 2 - 15
SPECIFICATIONS AND INFORMATION GENERAL APPLICATION GREASE SPECIFICATIONS
GENERAL APPLICATION GREASE
SPECIFICATIONS
GREASENORTH 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.
COOLANT SPECIFICATIONS
DIESEL AND GASOLINE ENGINE
COOLANTNORTH AMERICA
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 37C (34F).
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).
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.
M58275
AIR TEMPERATURE
N
L
G
I

G
r
a
d
e

2
J
D

M
o
l
y

H
i
g
h

T
e
m
p

E
P
J
D

H
i
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T
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E
P
COOLANT SPECIFICATIONS SPECIFICATIONS AND INFORMATION
2 - 16 11/22/00
IMPORTANT: To prevent engine damage, DO NOT
use pure anti-freeze or less than a 50% anti-
freeze mixture in the cooling system. Water
used to dilute engine coolant concentrate must
be of high qualityclean, clear, potable water
(low in chloride and hardnesssee 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.
Mix 50 percent anti-freeze concentrate with 50 percent
distilled or deionized water. This mixture and the pre-
diluted mixture (TY16036) will protect the cooling
system down to 37C (34F) and up to 108C
(226F).
Certain geographical areas may require lower air
temperature protection. See the label on your anti-
freeze container or consult your John Deere dealer to
obtain the latest information and recommendations.
SUPPLEMENTAL COOLANT
ADDITIVES
The concentration of coolant additives is gradually
depleted during engine operation. For all
recommended coolants, replenish additives between
drain intervals by adding a supplemental coolant
additive every 12 months or as determined necessary
by coolant testing.
John Deere COOLANT CONDITIONER is
recommended as a supplemental coolant additive in
John Deere engines.
IMPORTANT: Do not add a supplemental coolant
additives when the cooling system is drained
and refilled with John Deere ANTIFREEZE/
SUMMER COOLANT or John Deere COOL-
GARD.
If other coolants are used, consult the coolant supplier
and follow the manufacturers recommendation for use
of supplemental coolant additives.
The use of non-recommended supplemental coolant
additives may result in additive drop-out and gelation
of the coolant.
Add the manufacturers 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 operators manual
or technical manual.
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 SO
4
), Max. 100 ppm (5.8 grns/gal)
11/22/00 2 - 17
SPECIFICATIONS AND INFORMATION SERIAL NUMBER LOCATION
SERIAL NUMBER LOCATION
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
KV18593
Product Identification Number
Engine Serial Number
KV18598
SERIAL NUMBER LOCATION SPECIFICATIONS AND INFORMATION
2 - 18 11/22/00
DIESEL ENGINE CONTENTS
Page
CONTENTS
11/22/00 3 - 1
DIESEL ENGINE
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 SYSTEMDIAGNOSIS AND TESTS SPECIFICATIONS . . . . . . . . . . . . . 15
FUEL SYSTEMOPERATION 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 HEADEXPLODED 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
3 - 2 11/22/00
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
11/22/00 3 - 3
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
3 - 4 11/22/00
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 PUMPEXPLODED 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
11/22/00 3 - 5
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 NOZZLESGENERAL 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
ALTERNATOREXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
ALTERNATORIDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
DISASSEMBLEALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
3 - 6 11/22/00
11/22/00 3 - 7
DIESEL ENGINE
SPECIFICATIONS
CYLINDER HEAD AND VALVES SPECIFICATIONS
DIMENSIONS OF NEW PARTS WEAR TOLERANCE
Thickness of new cylinder head . . . . . . . . . . . . . . . . . . . . . 104.87105.13 mm
(4.1294.139 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 . . . . . . . . . . . . . . . . . . . . 1.63.2 micron C.L.A.
(64128 micro-in)
Valve stem diameter (standard):
Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8647.884 mm
(0.30960.3104 in.)
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8487.874 mm
(0.30900.3100 in.)
Bore for valve stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9127.938 mm
(0.31150.3125 in.)
Clearance between bore and valve stem . . . . . . . . . . . . . . . . . . 0.050.10 mm. . . . . . . . . . . . 0.15 mm
(0.0020.004 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .611.11mm. . . . . . . . . . . . .1.63 mm
(0.0240.044 in.). . . . . . . . . . . (0.064 in.)
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.221.72 mm . . . . . . . . . . . . 2.26 mm
(0.0480.068 in.). . . . . . . . . . . (0.089 in.)
Valve seat width (intake and exhaust) . . . . . . . . . . . . . . . . . . . . . 1.502.00 mm
(0.0590.079 in.)
(Continued on next page)
C.L.A. (Center Line Average) corresponds to a measure of surface texture.
3 - 8 11/22/00
SPECIFICATIONS DIESEL ENGINE
Valve head diameter:
Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.4746.73 mm
(1.8301.840 in.)
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.3742.63 mm
(1.6681.678 in.)
Firing order3 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5612.37 mm. . . . . . . . . . . 11.13 mm
(0.4550.487 in.). . . . . . . . . . . (0.438 in.)
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2812.12 mm. . . . . . . . . . . 10.85 mm
(0.4440.477 in.). . . . . . . . . . . (0.427 in.)
Rocker arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.9920.02 mm. . . . . . . . . . . 19.94 mm
(0.7870.788 in.). . . . . . . . . . . (0.785 in.)
Rocker arm bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.0720.12 mm. . . . . . . . . . . 20.17 mm
(0.7900.792 in.). . . . . . . . . . . (0.794 in.)
Rocker arm shaft spring tension
at a length of 46 mm (1.81 in.) . . . . . . . . . . . . . . . . . . . . . 1827 N (46 lb)
Valve springs free height . . . . . . . . . . . . . . . . . . . . . . approx. 54 mm (2.125 in.)
Valve spring tension:
At a length of 46 mm (1.81 in.) . . . . . . . . . . . . . . . . . 240280 N (5462 lb)
At a length of 34.5 mm (1.36 in.) . . . . . . . . . . . . . . 590680 N (133153 lb)
11/22/00 3 - 9
DIESEL ENGINE SPECIFICATIONS
CYLINDER BLOCK, LINERS, PISTONS, AND RODS SPECIFICATIONS
Centerline of main bearing
bore-to-top deck of cyl. block. . . . . 301.98302.11 mm (11.88911.894 in.)
Maximum acceptable block out-of-flat . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.)
Cam follower bore ID. . . . . . . . . . . . . . . . . 31.7031.75 mm (1.2481.250 in.)
Cam followers OD. . . . . . . . . . . . . . . . . . . 31.6231.64 mm (1.2451.246 in)
Cam follower clearance. . . . . . . . . . . . . . . . . 0.060.13 mm (0.0020.005 in.)
Camshaft bore without bushing. . . . . . . . . 55.9856.01 mm (2.2042.205 in.)
Camshaft bore with bushing (No. 1 only)
Cyl. block bore for bushing installation . 59.9659.99 mm (2.3612.362 in.)
Bushing ID (installed) . . . . . . . . . . . . . . 55.9655.99 mm (2.2032.204 in.)
Crankshaft main bearing bores. . . . . . . . . 84.4684.48 mm (3.3253.326 in.)
Lower block bore for seating liner . . . . . 115.75115.80 mm (4.5574.559 in.)
Upper block bore for seating liner . . . . . 120.70120.75 mm (4.7524.754 in.)
OD of liner at upper bore. . . . . . . . . . . . 120.61120.69 mm (4.7484.751 in.)
OD of liner at lower bore
(measured 10 mm (0.39 in.)
below lower shoulder) . . . . . . . . . . 115.695115.735 mm (4.5554.556 in.)
Clearance between liner and cylinder
block at lower bore . . . . . . . . . . . . . . . 0.0150.105 mm (0.00060.004 in.)
Clearance between liner and cylinder
block at upper bore . . . . . . . . . . . . . . . . . . 0.100.14 mm (0.0040.005 in.)
Cylinder liner ID. . . . . . . . . . . . . . . . . 106.49106.52 mm (4.19254.1937 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. . . . . . . . . . 5.955.99 mm (0.2340.236 in.)
Liner height above block . . . . . . . . . . . . . . . 0.010.10 mm (0.00040.004 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
90to piston pin . . . . . . . . . . . . 106.381106.399 mm (4.18824.1890 in.)
Piston-to-cylinder liner clearance,
measured at bottom of skirt. . . . . . . . . . 0.090.14 mm (0.00350.0055 in.)
(Continued on next page)
3 - 10 11/22/00
Piston height:
Measured from center of piston
pin bore to top of piston . . . . . . . . . . . . . 66.2766.33 mm (2.6092.611 in.)
Piston protrusion above block . . . . . . . . . . . . 0.080.35 mm (0.0030.014 in.)
Piston pin bore:
(Straight rod end). . . . . . . . . . . . . . . . 32.00332.013 mm (1.2561.260 in.)
(Tapered rod end) . . . . . . . . . . . . . 41.28541.295 mm (1.62541.6258 in.)
Piston pin OD:
(Straight rod end). . . . . . . . . . . . . . 31.99432.000 mm (1.25961.2598 in.). . 0.013 mm (0.0005 in.)
(Tapered rod end) . . . . . . . . . . . . . . . 41.2741.28 mm (1.62481.6252 in.). . 0.013 mm (0.0005 in.)
Rod pin bushing ID:
(Straight rod end). . . . . . . . . . . . . . 32.01032.036 mm (1.26021.2612 in.). . . . 0.05 mm (0.002 in.)
(Tapered rod end) . . . . . . . . . . . . . . . 41.30041.326 mm (1.6261.627 in.). . . . 0.05 mm (0.002 in.)
Pin-to-bushing oil clearance:
(Straight rod end). . . . . . . . . . . . . . . . . 0.010.042 mm (0.00040.0016 in.). . . . 0.10 mm (0.004 in.)
(Tapered rod end) . . . . . . . . . . . . . . . . . 0.020.056 mm (0.00080.002 in.). . . . 0.10 mm (0.004 in.)
Connecting rod bearing
(assembled) ID . . . . . . . . . . . . . . . 69.84869.898 mm (2.74992.7519 in.)
Bearing-to-journal clearance. . . . . . . . . 0.0230.099 mm (0.00090.0039 in.). . . . 0.16 mm (0.006 in.)
Connecting rod bore for bearing . . . . . . 73.66073.686 mm (2.9002.901 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.
11/22/00 3 - 11
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONS
Crankshaft end play:
Engine with 6-piece thrust bearing . . . . . . 0.030.35 mm (0.0010.014 in.). . . . . 0.50 mm (0.02 in.)
Oversize thrust washers available . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Crankshaft main journals OD (std.). . . . 79.32479.350 mm (3.1233.124 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.) . . . . 79.39679.440 mm (3.1263.127 in.)
Crankshaft to main bearing clearance . 0.0460.116 mm (0.00180.0046 in.). . . . 0.15 mm (0.006 in.)
Undersize bearing available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 (0.01 in.)
Crankshaft conrod OD (std.) . . . . . . . . . 69.79969.825 mm (2.7482.749 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. . . . . . 37.98838.014 mm (1.49561.4966 in.)
Flywheel pilot bearing bore diameter 39.96739.993 mm (1.57351.5745 in.)
3 - 12 11/22/00
CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS
Camshaft journal OD. . . . . . . . . . . . . 55.87255.898 mm (2.19972.2007 in.). . . 55.85 mm (2.199 in.)
Camshaft bore to journal clearance . . . . . . . 0.100.15 mm (0.0040.006 in.). . . . 0.18 mm (0.007 in.)
Camshaft end play . . . . . . . . . . . . . . . . . . . . 0.080.23 mm (0.0030.009 in.). . . . 0.38 mm (0.015 in.)
Camshaft thrust plate thickness . . . . . . . . 3.9353.985 mm (0.1550.157 in.). . . . . . 3.8 mm (0.15 in.)
Cam follower OD. . . . . . . . . . . . . . . . . . . . 31.6231.64 mm (1.2451.246 in.)
Cam follower to bore clearance. . . . . . . . . . . 0.060.13 mm (0.0020.005 in.)
Camshaft lobe height:
Intake lobe . . . . . . . . . . . . . . . . . . . . . . . . . 6.937.42 mm (0.2730.292 in.). . . . 6.68 mm (0.263 in.)
Exhaust lobe . . . . . . . . . . . . . . . . . . . . . . . 6.767.26 mm (0.2660.286 in.). . . . 6.50 mm (0.256 in.)
Helical timing gear backlash between:
Upper idler/crankshaft gear . . . . . . . . . . . 0.070.30 mm (0.0030.012 in.). . . . 0.40 mm (0.016 in.)
Upper idler/camshaft gear . . . . . . . . . . . . 0.070.35 mm (0.0030.014 in.). . . . 0.51 mm (0.020 in.)
Upper idler/injection pump gear. . . . . . . . . 0.070.35 mm (0.0030.014 in.). . . . 0.51 mm (0.020 in.)
Lower idler/crankshaft gear . . . . . . . . . . . . 0.070.35 mm (0.0030.014 in.). . . . 0.51 mm (0.020 in.)
Lower idler/oil pump gear . . . . . . . . . . . . 0.040.38 mm (0.00160.015 in.). . . . 0.40 mm (0.016 in.)
Spur timing gear backlash between:
Upper idler/crankshaft gear . . . . . . . . . . . 0.040.35 mm (0.00160.014 in.). . . . 0.60 mm (0.024 in.)
Upper idler/camshaft gear . . . . . . . . . . . . . 0.080.45 mm (0.0030.018 in.). . . . 0.85 mm (0.033 in.)
Upper idler/injection pump gear. . . . . . . . . 0.080.45 mm (0.0030.018 in.). . . . 0.85 mm (0.033 in.)
Lower idler/crankshaft gear . . . . . . . . . . . 0.040.35 mm (0.00160.014 in.). . . . 0.65 mm (0.025 in.)
Lower idler/oil pump gear . . . . . . . . . . . . . 0.080.40 mm (0.0030.016 in.). . . . 0.75 mm (0.030 in.)
Idler gear shaft OD:
Upper with helical gear and lower
with helical or spur gear . . . . . . . . . 44.43744.463 mm (1.74951.7505 in.). . . 44.41 mm (1.748 in.)
Upper with spur gear . . . . . . . . . . . . 69.75969.775 mm (2.74642.747 in.)
Idler gear bushing ID:
with helical or spur gear . . . . . . . . . . . 44.50144.527 mm (1.7521.753 in.). . . 44.55 mm (1.754 in.)
Upper with spur gear . . . . . . . . . . . 69.82769.857 mm (2.74912.7503 in.)
Idler gear/bushing clearance:
with helical or spur gear . . . . . . . . . . . . 0.0380.09 mm (0.00150.0035 in.). . . . 0.15 mm (0.006 in.)
Upper with spur gear . . . . . . . . . . . . . . 0.0520.098 mm (0.0020.0038 in.)
Hub width of idler gear . . . . . . . . . . . . . 21.97522.025 mm (0.8650.867 in.). . . 21.93 mm (0.863 in.)
Width of idler shaft . . . . . . . . . . . . . . . . . . 22.1722.27 mm (0.8730.877 in.)
End play of idler gear . . . . . . . . . . . . . . . . . . 0.140.29 mm (0.0060.012 in.). . . . 0.40 mm (0.016 in.)
Spring pins protrude from shaft:
On lower idler gear . . . . . . . . . . . . . . . . . . . . . 6.57 mm (0.2560.275 in.)
On upper idler gear
Helical gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.5 mm (0.1570.177 in.)
Spur gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.58.5 mm (0.2950.335 in.)
11/22/00 3 - 13
LUBRICATION SYSTEM SPECIFICATIONS
Oil pump:
Bore of drive shaft in pump housing . . . . . . . . . . . . . . . . . . 16.0516.08 mm. . . . . . . . . . . . 0.08 mm
(0.6320.633 in.). . . . . . . . . . . (0.003 in.)
Diameter of idler shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3212.34 mm. . . . . . . . . . . 0.013 mm
(0.4850.486 in.). . . . . . . . . . (0.0005 in.)
Diameter of drive shaft journal. . . . . . . . . . . . . . . . . . . . . . . 16.0216.03 mm. . . . . . . . . . . 0.025 mm
(0.6300.631 in.). . . . . . . . . . . (0.001 in.)
Radial clearance between gear and pump housing. . . . . . . . . 0.100.16 mm. . . . . . . . . . . . 0.20 mm
(0.0040.006 in.). . . . . . . . . . . (0.008 in.)
Thickness of gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1541.20 mm. . . . . . . . . . . . 0.05 mm
(1.6201.622 in.). . . . . . . . . . . (0.002 in.)
Axial clearance between gears and pump cover . . . . . . . . . . . 0.050.17 mm. . . . . . . . . . . . 0.22 mm
(0.0020.007 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.) . . . . . . . . . . . . . . . . . . . . . . . . . . 6075 N (13.516.5 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.) . . . 7996.5 N (1822 lb)
COOLING SYSTEM SPECIFICATIONS
DIMENSIONS OF NEW PARTS WEAR LIMIT
Impeller recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.01 in.)
Thermostat opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82C (180F)
Fan belt tension (method 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578622 N. . . . . . . . . . 378423 N
(130140 lb) (8594 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.)
3 - 14 11/22/00
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:
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 40024 900 kPa. . . 25 50026 100 kPa
(35403620 psi). . . . . .(37003780 psi)
For checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 100 kPa min.. . . . . . 25 200 kPa min.
(3500 psi). . . . . . . . . . . (3660 psi)
Opening pressure of a used nozzle:
For setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 00023 600 kPa. . . 24 15024 700 kPa
(33403420 psi). . . . . .(35003580 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.
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
11/22/00 3 - 15
ENGINE SYSTEMDIAGNOSIS AND TESTS SPECIFICATIONS
Engine compression pressure at 150200 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 m
3
/h (141 cu-ft/h)
Model 3029T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 m
3
/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 SYSTEMOPERATION AND TESTS SPECIFICATIONS
Fuel supply pump:
Normal pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 2530 kPa (3.54.5 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)
3 - 16 11/22/00
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:
ARemover/Replacer Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG738-1
BInstaller Pilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG738-2
CReceiver Cup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG738-3
DRemover/Replacer Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG738-4
EInstaller Pilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG738-5
FReceiver Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG738-6
Camshaft Bushing Service Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG739B
NOTE: JDG739B consists of the following components:
ABushing Remover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG739-1
BFlat Bottom Legs (3/8-16) (3). . . . . . . . . . . . . . . . . . . . . . . . . JDG739-2
CRemoving/Installing Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG739-3
DBushing Installer Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG739-4
EBushing Installer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDB739-5B
FTapered Bottom Leg (3/8-16) . . . . . . . . . . . . . . . . . . . . . . . . . JDG739-6
GTapered Bottom Leg (M8 x 1.25). . . . . . . . . . . . . . . . . . . . . . JDG739-7
HFlat 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.
11/22/00 3 - 17
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-1/4Clamp-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
3 - 18 11/22/00
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
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
11/22/00 3 - 19
DIESEL ENGINE TROUBLESHOOTING
TROUBLESHOOTING
Problem or
Symptom
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Check or
Solution
Improper intake/exhaust valve
clearance
G G G G
Intake/exhaust valve leaking G G G G
Intake/exhaust valve seized G G G G G G
Cylinder head gasket leaking G G
Broken or seized piston ring G G G G G G G
Piston ring, piston, or cylinder
worn
G G G G G
Crankshaft pin or bearing seized G G G G
Ring gaps not positioned
properly
G G G
Improper piston ring placement G G G
Crankshaft pin or bearing worn G G G
Connecting rod bolt loose G
Foreign matter trapped in
combustion chamber
G G
Excessive timing gear backlash G G
Intake/exhaust valve guide
worn
G G G
Governor not functioning
properly
G G G
Improper injection timing,
intake/exhaust valves
G G G G
Engine running too cool G G
Engine running too hot G
Coolant level low G
Cracked water jacket G
Fan belt loose G
Improper engine oil viscosity/
type
G G G G G
3 - 20 11/22/00
TROUBLESHOOTING DIESEL ENGINE
Engine oil leaking G G
Oil pump worn G
Oil filter clogged G
Pressure control valve worn G
Oil quantity low G
Advanced injection pump timing G G
Retarded injection pump timing G G G G
Wrong type of fuel G G G
Water in fuel G G G G G G
Fuel filter clogged G G G
Air entering fuel system G G G
Clogged or cracked fuel line G G G
No fuel G G
Injection pump volume
insufficient
G G G G G
Injection pump volume
excessive
G G G G
Incorrect spray pattern at fuel
injection nozzle
G G G G G G
Air filter clogged G G G G
High altitude/temperature
operation
G G G G
Exhaust system restricted G G G
Inspect starter motor G
Inspect alternator G
Electrical system
troubleshooting
G
Problem or
Symptom
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Check or
Solution
11/22/00 3 - 21
DIESEL ENGINE DIAGNOSIS
DIAGNOSIS
Conditions:
Machine parked on level surface.
Park brake engaged.
Key switch off unless indicated otherwise.
Test/Check Point Normal If Not Normal
Engine Oil Check
Engine dipstick and
exterior engine surface.
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.
Cooling System Check
Coolant tank and
radiator.
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.
Drain and flush system. Check for
source of contamination.
Radiator screen free of debris. Clean or replace.
Water pump not leaking. Inspect water pump. (See WATER
PUMP.)
Hoses not cracked or leaking, clamps
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 System Check
Fuel tank, pump, lines,
filter and filter shutoff
valve.
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 Intake System
Check
Air filter and air intake.
Air filter hose not cracked, clamps tight. Replace and tighten clamps.
Element not plugged. Air filter housing
sealed, no dirt tracking inside filter
element.
Replace element or housing.
Fuel Pump Check
Fuel filter and fuel pump.
(Key switch in RUN
position.)
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.
3 - 22 11/22/00
DIAGNOSIS DIESEL ENGINE
DIAGNOSIS (CONTINUED)
Throttle Cable Check
Throttle lever and cable.
Linkage not binding and adjusted
correctly.
Repair, replace, or adjust cable. (See
THROTTLE CONTROL ADJUSTMENT.)
Valve Check
Intake and exhaust
valves.
Cold engine. Valve clearance within
specification.
Valves not sticking.
Check and adjust. (See VALVE
CLEARANCE CHECK AND
ADJUSTMENT.)
Check valve guides and stems.
Fuel Injector Check
Fuel at injectors. (Key in
START position - engine
cranking.)
Crack fuel injection lines at injectors.
Fuel shutoff solenoid pulled in.
Engine must crank.
Check spray pattern and cracking
pressure. (See FUEL INJECTION
NOZZLE TEST.) Replace injectors. (See
CRANKING CIRCUIT DIAGNOSIS in
ELECTRICAL section.)
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.)
Starter Check
Flywheel and starter. Minimum cranking rpm within
specification.
See STARTER AMP DRAW TEST in
ELECTRICAL section.
Injection Pump Check
Injection pump timing
inspection. (Key OFF.)
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.
Fast and Slow Idle
Check
Injection pump idle
settings. (Engine
running).
Engine runs smooth under load. Engine
rpm to specification.
See SLOW IDLE ADJUSTMENT and
FAST IDLE ADJUSTMENT.
Oil Pressure Check
Oil pressure sender port.
Oil pressure in specification. Test engine oil pressure. (See ENGINE
OIL PRESSURE TEST.)
Thermostat Check
Thermostat. (Engine at
operating temperature.)
Clean from corrosion, rust, or debris.
Opening temperature within
specification.
Replace thermostat.
Perform thermostat opening test. (See
THERMOSTAT OPENING TEST.)
Muffler Check
Muffler.
Not restricted. Replace muffler.
11/22/00 3 - 23
DIESEL ENGINE TESTS AND ADJUSTMENTS
TESTS AND ADJUSTMENTS
PRELIMINARY ENGINE TESTING
The following preliminary tests will help determine if
the engine can be tuned-up to restore operating
efficiency, or if engine overhaul is required.
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.
GENERAL TUNE-UP
RECOMMENDATIONS
As a general rule, an engine tune-up is not necessary
if all recommended Operators 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.
TEST THERMOSTAT OPENING
TEMPERATURE
Reason:
To determine opening temperature of thermostat.
Equipment:
Thermometer
Glass Container
Heating Plate
Procedure:
Visually inspect thermostat for corrosion or damage.
Replace as necessary.
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.
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.
RG5971
3 - 24 11/22/00
TESTS AND ADJUSTMENTS DIESEL ENGINE
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
Reason:
To determine if engine bearings or lubrication system
components are worn.
Equipment:
JT03017 Hose Assembly
JT05577 Pressure Gauge (100 psi)
JT03349 Connector
NOTE: A generic PowerTech 2.9 L engine is shown.
Skid steer engine is similar.
Procedure:
NOTE: Use gauge from FKM10002 or JT05470
Universal Pressure Test Kit if available.
Otherwise, use gauge with a reading range of
0600 kPa (087 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 93C (200F) 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
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.
Specifications:
3029D. . . . . . . . . . . . . . . . . . . . . . 4 m
3
/h (141 cu ft/h)
3029T. . . . . . . . . . . . . . . . . . . . . . 6 m
3
/h (225 cu ft/h)
If blow-by is lower, there is no excessive wear
between piston rings and liners. For a further check,
carry out cylinder compression pressure test. If blow-
by is higher, there is excessive wear between piston
rings and liners, resulting in loss of engine power.
Overhaul the engine.
Thermostat Test Specifications
Rating Initial Opening
(Range)
Full Open
(Nominal)
71C (160F) 69-72C (156-162F) 84C (182F)
77C (170F) 74-78C (166-172F) 89C (192F)
82C (180F) 80-84C (175-182F) 94C (202F)
89C (192F) 86-90C (187-194F) 101C (214F)
90C (195F) 89-93C (193-200F) 103C (218F)
92C (197F) 89-93C (193-200F) 100C (213F)
96C (205F) 94-97C (201-207F) 105C (221F)
99C (210F) 96-100C (205-212F) 111C (232F)
CD30686
11/22/00 3 - 25
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.
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.
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.
CD30432
A
B
C
C
D
A
B
C
C
D
CD30685
3 - 26 11/22/00
FUEL SUPPLY PUMP PRESSURE
Reason:
To determine supply pump operating pressure.
Equipment:
JT03115 Gauge (0150 psi) with Male Quick Coupler.
JT01609 Female Quick Coupler Adapter.
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 1530 kPa (0.150.30 bar)
(24.5 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.
Equipment:
JT05801 Clamp-on Electronic Tachometer.
Procedure:
NOTE: Before checking engine speed, make sure
engine has reached its normal operating
temperature.
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.
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 . . . . . . . . . . . . . . . 245050 rpm
250 Fast Idle Speed . . . . . . . . . . . . . . . 240050 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. . . . . . . . . . . . . . . 117550 rpm
250 Slow Idle Speed. . . . . . . . . . . . . . . 117550 rpm
4. Turn screw (B) clockwise to increase and counter-
clockwise to decrease engine speed.
KV18011
Inlet
Outlet
Test Gauge
CD30681
A
B
11/22/00 3 - 27
FUEL INJECTION PUMP TIMING
ADJUSTMENT
Dynamic Timing
Reason:
To make sure injection pump timing is set to
specification.
Equipment:
JT07158 Time-Trac.
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
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.
Install Timing Sensor
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 Nm (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.
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.
CD30441
A
B
C
D
E
F
G
H
I
J
K
CD30195
CD30673
C
3 - 28 11/22/00
Install Magnetic Probe
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 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.
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.
G. Magnetic Probe
H. Timing Sensor
I. Sensor Clamp
CD30442
CD30443
KV18568
KV18075
11/22/00 3 - 29
Timing Sensor and Magnetic Probe Connection
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
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.
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 20.0will now appear.
Type in 0.0 to enter a 0.0"Offset" value and press
the "ENTER" key.
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.
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).
A
C
B
F
E
D
CD30446
CD30202
CD30447
CD30204
CD30205
3 - 30 11/22/00
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
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 2on 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.
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
CD30448
CD30198
CD30449
11/22/00 3 - 31
CHECK AND ADJUST VALVE
CLEARANCE
Reason:
To achieve correct engine operation.
Equipment:
Feeler Gauge
Procedure:
The valve clearance must be adjusted when engine is
cold.
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.
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. . . . . . . . . . . . . . . . . . . . . 0.310.38 mm
(0.0120.015 in.)
Exhaust valve . . . . . . . . . . . . . . . . . . 0.410.048 mm
(0.0160.019 in.)
Adjust valve clearance as directed in VALVE
ADJUSTMENT SEQUENCE.
VALVE ADJUSTMENT SEQUENCE
Firing order is 1-2-3.
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 360and reinsert timing pin.
4. Adjust valve clearance on No. 3 exhaust valve and
No. 2 intake valve.
CD30544
CD30545
CD30549
B
C
A
D D D E E E
D D D E E E
3 - 32 11/22/00
REPAIR DIESEL ENGINE
REPAIR
ENGINE REPAIR STAND
D05225ST Adapter
D01003AA Repair Stand
To facilitate engine repair, the D01003AA repair stand
can be used in conjunction with D05225ST adapter.
D05225ST
R26420N
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.
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.
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.
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 3 - 33
DIESEL ENGINE REPAIR
MOUNT ENGINE ON REPAIR STAND
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.
4. Disconnect oil inlet line at turbocharger (D) to
prevent hydraulic lock.
ENGINE REMOVAL/INSTALLATION
NOTE: Engine and pumps weigh approximately 907
kg (2000 lb.) Be sure Engine Repair Stand and
Engine Hoist have adequate capacity.
Equipment:
Engine Repair Stand
Engine Hoist - 1000 kg (2200 lb.) capacity
Engine Removal:
1. Remove bucket or any other attachments
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.
NOTE: Approximate cooling system capacity is 9.5 L
(10 qt).
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.
CD30527
CD30528
D
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.
KV13939
Radiator Drain Valve
Drain Hose
3 - 34 11/22/00
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.
10. Remove front and rear hydraulic oil reservoir drain
plugs and drain hydraulic oil into proper container.
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.

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.
14. Disconnect hydraulic oil cooler hoses. Use caps or
plugs to cover openings to prevent contamination.
KV13964
Rear Drain Plug
KV18010
Outlet
Inlet
KV13940
Finger
Upper Radiator
Hose
Guard
KV13941
Lower Radiator Hose
KV13058
Hydraulic Oil Cooler Hoses
11/22/00 3 - 35
15. Remove filler tube-to-radiator support cap screw.
16. Remove engine cover latch bracket. Repeat for
opposite side of radiator.
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.
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.
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.
NOTE: Close all openings using caps or plugs to
prevent contamination.
25. Remove hydraulic oil hose from filter manifold.
Close all openings using caps or plugs.
26. Disconnect brake solenoid harness connector.
27. Remove four cap screws and mounting bracket.
Move bracket with hydraulic oil filter and filter
manifold forward away from engine.
KV18841
Latch Bracket
Filler Tube
Cap Screw
KV18012
Recovery Bottle
KV13064
Fuel Leak-Off Line
Wiring Connector
KV13948
Intake Hose
Air Cleaner
KV13949
Hydraulic Oil Hose
Harness Connector
KV13950
Mounting Bracket
Cap Screws
3 - 36 11/22/00
28. Disconnect wiring lead from fuel shut-off solenoid.
29. Disconnect throttle linkage from bracket and fuel
injection pump.
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.
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.
33. Bend wire harness retainer back and move harness
away from engine.
34. Disconnect cylinder block heater connector (if
equipped).
35. Remove front and rear engine mounting bolts.
KV18840
Throttle Linkage
Wiring Lead
KV18842
Alternator
Starter
Preheat Relay
Manifold Preheater
Wire Harness Retainer
KV18836
Cylinder Block Heater
KV31115
Front Engine
Mounting Bolt
KV13957
Rear Engine
Mounting Bolts
11/22/00 3 - 37
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.
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.
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.
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.
c
CAUTION
Boom lock pins must remain in place. Be sure
that boom is adequately supported by boom lock
pins.
F
A
B
C
D
KV15160
KV13976
KV13985
KV31121
Coupling
Cap Screw
3 - 38 11/22/00
IMPORTANT: If bushings have flat sides, flat side
should be parallel to machine sides.
Install Coupling and Flywheel Cover:
1. Place coupling on flywheel and install eight
coupling-to-flywheel cap screws. Tighten to
63 Nm (46 lb-ft).
Install Hydrostatic Pumps:
1. Install bushings, upper grommets, and upper
washers of front and rear engine mounting
hardware as shown above before lowering engine
into position.
2. If removed, install two pump flange-to-engine
flywheel cover cap screws. Tighten cap screws to
140 Nm (105 lb-ft).
Torque Specification:
Pump Flange-to-flywheel . . . . . . 140 Nm (105 lb-ft)
cover cap screw
Mounting bracket cap screw. . . . 140 Nm (105 lb-ft)
Mounting bracket . . . . . . . . . . . . . 305 Nm (225 lb-ft)
cap screw and nut
3. If removed, install cap screws, washers, and nuts
on both sides of hydrostatic pump mounting
bracket. Tighten cap screws to specification as
shown.
4. Install engine/pump assembly. Remove hoist and
lifting brackets.
KV13987
Washer
Grommet
Bushing
Grommet
Washer
Rear Engine Mount
KV31121
Coupling
Cap Screw
KV13985
Nut
Cap Screw
140 Nm (105 lb-ft)
Cap Screw
140 Nm (105 lb-ft)
Cap Screw
305 Nm (225 lb-ft)
KV13976
KV13957
Rear Engine
Mounting Bolts
11/22/00 3 - 39
IMPORTANT: If bushings have flat sides, flat side
should be parallel to machine sides. DO NOT
ROTATE while tightening mount hardware.
5. Install lower grommets, lower washers, nuts, and
bolts of front and rear engine mounting hardware.
Tighten to 305 Nm (225 lb-ft).
NOTE: Inspect hydraulic fittings and O-rings for
damage. Replace as necessary.
6. Connect hoses to hydrostatic pump assembly.
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.
10. Connect all wire leads, cables, and connectors to
the preheat relay, manifold preheater, starter, and
alternator using the tags or labels installed during
removal.
11. Install wire ties as necessary.
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.
15. Install hydraulic oil filter and air cleaner mounting
bracket using four cap screws. Tighten cap screws
securely.
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.
Wire Harness Retainer
KV18836
Block Heater Connector
KV18842
Alternator
Starter
Preheat Relay
Manifold Preheater
KV18840
Throttle Linkage
Wiring Lead
KV13950
Mounting Bracket
Cap Screws
KV13949
Hydraulic Oil Hose
Harness Connector
3 - 40 11/22/00
19. Connect fuel leak off line and tighten clamp.
20. Connect harness to coolant temperature sender.
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: 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 Nm
(21 lb-ft).
25. Install engine cover latch bracket on both sides of
radiator support.
26. Install and tighten hydraulic oil fill hose cap screw.
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.
KV13064
Fuel Leak-Off Line
Coolant Temperature
Sender
KV18012
Recovery Tank
Ground Cable
KV18841
Latch Bracket
Filler Tube
Cap Screw
KV13058
Hydraulic Oil Cooler Hoses
11/22/00 3 - 41
28. Install cooling fan finger guard. Tighten cap screws
to 26 Nm (19 lb-ft).
29. Install upper and lower radiator hoses. Tighten all
hose clamps securely.
30. Connect cab heater hoses to engine (if equipped).
31. Install fuel filter base with filter. Connect inlet line to
filter base.
32. Install hydraulic oil reservoir drain plugs and tighten
securely.
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.
(10 qt).
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
Removal:
1. Open top and rear panels and remove side engine
panels.
2. Disconnect battery, negative (-) cable first.
(10 qt).
KV13940
Finger
Upper Radiator
Hose
Guard
KV13941
Lower Radiator Hose
KV18010
Outlet
Inlet
c
CAUTION
off engine. Only remove filler cap when cool
TS281
3 - 42 11/22/00
3. Route radiator drain hose out of access panel on
left side of frame.
4. Open radiator drain valve and drain coolant.
5. Remove upper and lower radiator hoses.
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.
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.
11. Remove two cap screws and move fuel filter
assembly away from radiator support.
12. Attach a suitable lifting strap and hoist to radiator.
KV13939
Radiator Drain Valve
Drain Hose
KV13940
Finger
Upper Radiator
Hose
Guard
KV13941
Lower Radiator Hose
KV18841
Latch Bracket
Filler Tube
Cap Screw
Finger
Guard
KV13992
Coolant Recovery Hose
Cap Screws
KV18010
Cap Screws
11/22/00 3 - 43
NOTE: Some models have a spacer washer between
the support bracket and radiator mounting
flange. Retain for reuse.
13. Remove one cap screw on each side of radiator
support and remove radiator. Shroud does not
need to be removed with radiator.
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.
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.
Installation:
1. Install radiator in support brackets. Apply medium
strength threadlock to both cap screws. Install and
tighten only left side cap screw to 29 Nm
(21 lb-ft).
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 13mm
(0.0400.0120 in.). Install and tighten cap screw to
29 Nm (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.
5. Install engine cover latch brackets and hydraulic
filler tube cap screw.
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.
KV13993
Cap Screw
KV13059
Fan Shroud
Notch
KV13993
Cap Screw
Washer
KV31119
KV18841
Latch Bracket
Filler Tube
Cap Screw
3 - 44 11/22/00
6. Install coolant recovery bottle and connect recovery
hose to filler neck.
7. Install fuel filter assembly.
8. Connect upper and lower radiator hoses.
9. Install finger guard. Tighten cap screws to 26 Nm
(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
on an injection pump while it is still warm. To do
so may cause pump parts to seize.
KV13992
Coolant Recovery Hose
Cap screws
KV13940
Finger
Upper Radiator
Hose
Guard
KV13941
Lower Radiator Hose
11/22/00 3 - 45
ENGINE DISASSEMBLY SEQUENCE
The following sequence is suggested when complete
disassembly for overhaul is required.
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 O-
ring 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.
ENGINE ASSEMBLY SEQUENCE
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. 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 standard-
flow 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.
3 - 46 11/22/00
CYLINDER HEADEXPLODED VIEW
CD30531
A. Cylinder Head
B. Valve Seat
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
C
B
A
F
E
D
11/22/00 3 - 47
CHECK VALVE LIFT
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.
Valve Lift at 0.00 mm (0.00 in.) clearance:
Intake valves . . . . . . . . . . . . . . . . . 11.5612.37 mm
(0.4550.487 in.)
Wear tolerance . . . . . . . . . . . . . 11.13 mm (0.438 in.)
Exhaust valves . . . . . . . . . . . . . . . . 11.2812.12 mm
0.4440.477 in.)
REMOVE CYLINDER HEAD
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.
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.
CD30532
CD30533
A
B
C
D
E
KV18569
3 - 48 11/22/00
7. Remove air inlet adapter (I).
8. Remove crankcase vent hose (J).
9. Remove rocker arm cover (K).
10. Remove rocker arm assembly (L).
11. Remove all push rods.
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.
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
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.
KV18570
KV18571
KV18076
CD30537
CD30538
11/22/00 3 - 49
VALVE ACTUATING PARTS
REMOVE VALVES AND VALVE
SPRINGS
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.
CHECKING CYLINDER HEAD
FLATNESS
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.
C
B
A
L
K
J
I
H
G
F
E
D
CD30379
A. Cam Follower
B. Push Rod
C. Rocker Arm
D. Support
E. Shaft
F. Plug
G. Keepers
H. Rotator
I. Spring
J. Metering Seal
K. Valve Seat Insert
L. Valve
L103629
L30699
3 - 50 11/22/00
CLEAN VALVE GUIDES
Using a plastic brush, clean valve guides.
NOTE: A few drops of light oil or kerosene will make
cleaning of valve guides easier.
MEASURE VALVE GUIDES
Using a micrometer, measure valve guides then
Valve Guide Specifications:
Valve guide bore diameter in a new
cylinder head . . 7.9127.938 mm (0.3120.313 in.)
New guide-to-valve stem
clearance. . . . . . . . 0.050.10 mm (0.0020.004 in.)
Maximum permissible
clearance. . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
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.
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.
CLEAN AND INSPECT VALVE SEATS
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.
CD30539
CD30550
CD30548
CD30540
11/22/00 3 - 51
LAPPING VALVE SEATS
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.
CHECK VALVE RECESS
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. . . . . . . . . . . 0.611.11 mm (0.0240.044 in.)
Wear tolerance . . . . . . . . . . . . . . 1.63 mm (0.064 in.)
Exhaust . . . . . . . . . 1.221.72 mm (0.0480.068 in.)
Wear tolerance . . . . . . . . . . . . . . 2.26 mm (0.089 in.)
When maximum valve recess is reached, replace
valve seat inserts.
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.
2. Protect the cylinder head surface with a non-
flammable welders cloth (A). Apply a thin bead of
weld (B) around internal diameter of valve seat
insert.
CD30380
RG4756
CD30541
RG7761
RG7813
3 - 52 11/22/00
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.
Machining Valve Seat Insert
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. . . . . . . . 47.10447.130 mm (1.85451.8555 in.)
B. . . . . . . . . . . . . . . . 3.45 mm (0.136 in.) Reference
C. . . . . . . . . 9.93610.064 mm (0.39120.3962 in.)
D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3842
E. Maximum radius. . . . . . . . . . 0.5 mm (0.019 in.)
Exhaust Valve Seat Insert Bore Specifications:
A. . . . . . . . 42.98743.013 mm (1.69241.6934 in.)
B. . . . . . . . . . . . . . . . 3.82 mm (0.150 in.) Reference
C. . . . . . . . . 9.93610.064 mm (0.39120.3962 in.)
D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3842
E. Maximum radius. . . . . . . . . . 0.5 mm (0.019 in.)
Replacement Valve Seat Insert OD:
Intake. . . . . 47.15547.181 mm (1.85651.8575 in.)
Exhaust . . . 43.03843.064 mm (1.69441.6954 in.)
VALVE SEAT INSERT INSTALLATION
1. Freeze the valve seat inserts to 30C (22F).
2. Using JDG676 Pilot Driver (A) and JDG675 Valve
Seat Insert Installing Adapter (B), install valve seat
inserts.
3. Lap valve seats to maintain correct valve recess
and valve to valve seat sealing. (See LAPPING
VALVE SEATS.)
INSPECT AND MEASURE VALVES
Thoroughly clean and inspect valves to help determine
if they can be reused. Replace valves that are burned,
cracked, eroded, or chipped.
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. . . . . . . . . . . . . . . . . . 7.8647.884 mm
(0.30960.3104 in.)
Exhaust Valve. . . . . . . . . . . . . . . . . 7.8487.874 mm
(0.30900.3100 in.)
RG7763
RG5606
RG5653
T82053
11/22/00 3 - 53
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
Serviceable valves should be re-faced to specified
angle (A).
Valve Face Specification
Angle (A) . . . . . . . . . . . . . . . . . . . . . . . . 29.25 0.25
INSPECT AND MEASURE VALVE
SPRINGS
Valve Spring Specifications:
Spring Free Length 0 N (0 lb)
Height . . . . . . . . . . . . . . . . . . . . . 54.0 mm (2.125 in.)
Spring Compressed 240280 N (5462 lb)
Height . . . . . . . . . . . . . . . . . . . . . . 46.0 mm (1.81 in.)
Spring Compressed 590680 N (133153 lb)
Height . . . . . . . . . . . . . . . . . . . . . . 34.5 mm (1.36 in.)
INSPECT VALVE ROTATORS
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.
RG4234
RG4755
T82054
T91224
3 - 54 11/22/00
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.
3. Using JDG678 Valve Stem Seal Installer (A), slide
seal (B) over valve stem and onto valve guide
tower (C).
4. Install valve springs and rotators.
5. Compress valve springs using JDE138 Valve
Spring Compressor and install new keepers on
valves.
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
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.
IMPORTANT: Ensure that cam followers (A) are
present before installing cylinder head.
2. Install new cylinder head gasket dry (without
sealant).
RG5654
RG5655
CD30233
RG4718
CD30693
A
11/22/00 3 - 55
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 Nm (75 lb-ft)
Step 2. Tighten all cap screws to
. . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm (110 lb-ft)
Step 3. Wait 5 minutes and tighten all cap screws
to . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm (110 lb-ft)
Step 4. Tighten each cap screw an additional
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 10
TORQUE TURN TIGHTENING
METHOD

A. Reference Mark
B. 60Mark
To ensure that the full 60angle is reached (Step C.),
the following procedure can be used:
Step A. Make a mark (A) on socket and make a
second mark (B) 60counterclockwise 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.
KV15177
B
B
9
10
14
11 1 3
2 8
12
4 6
5
7
KV31107
3 - 56 11/22/00
CHECKING ROCKER ARM SHAFT
I
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.
NOTE: If the rocker arm has been damaged by a valve
failure, replace it together with the
corresponding push rod, valve rotator, and
keepers.
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.
IMPORTANT: The oil supply hole (C) in the shaft
must be in line with the oil supply hole (D) of
cylinder head.
3. Install bowed washers (B) and new plugs (A) on
shaft.
INSTALL ROCKER ARM ASSEMBLY
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 Nm (35 lb-ft).
5. Adjust valve clearance. (See CHECK AND ADJUST
VALVE CLEARANCE.)
CD30381
A
B
C
CD30382
D C
CD30536
11/22/00 3 - 57
INSTALL ROCKER ARM COVER
1. Install rocker arm cover with built-in sealing ring
(without sealant).
2. Install cap screws (A) by hand and tighten to
10 Nm (89 lb-in.), starting from center and
moving towards both front and rear ends of the
cover. DO NOT OVERTIGHTEN.
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.
FINAL WORK
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.
CD30546
RG6322
KV14267
A
3 - 58 11/22/00
CYLINDER BLOCK EXPLODED VIEW
CD30551
A. Cylinder Block
B. Cylinder Liner
C. Piston
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
J
I
H
G
F
E
D
C
B
A
11/22/00 3 - 59
REMOVE PISTONS AND
CONNECTING RODS
1. Remove cylinder head, oil pan, and oil pump.
2. Install large flat washers (A) with cap screws (B) to
hold cylinder liners down.
3. De-carbonize cylinder liners.
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).
6. Remove connecting rod and piston assembly
through the cylinder liner.
7. Remove and discard piston pin snap rings.
8. Press piston pin out of bore and separate piston
and rod.
CD30552
CD30553
B
A
PRECISION JOINT is a trademark of Deere & Company
CD30554
RG7464
3 - 60 11/22/00
MEASURE CYLINDER LINER BORE
1. Measure liner bore at four points of ring travel.
Cylinder Liner Bore Specifications:
Cylinder liner ID . . . . . . . . . . . . . 106.49106.52 mm
(4.19254.1937 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 . . . . . . . . . . . . 0.090.14 mm
at bottom of skirt). . . . . . . . . . (0.00350.0055 in.)
NOTE: Oversize liners do not exist. Install a complete
set including standard liner and piston.
REMOVE CYLINDER LINERS
1. Mark liners and cylinder block then pull liners out of
cylinder block using KCD10001 Puller.
2. Remove O-rings (A) from groove in cylinder block
(B). Also remove packing (C) from liner (D).
CD30556
CD30384
RG4745
11/22/00 3 - 61
CYLINDER LINER DEGLAZING
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.
IMPORTANT: Do NOT use gasoline, kerosene, or
commercial solvents to clean liners.
CYLINDER BLOCK CLEANING
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 O-
ring grooves.
CHECK PISTON COOLING JETS
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 Nm (7.5 lb-ft).
CAM FOLLOWER BORE MEASURE
:
Cam Follower Bore Specifications:
Cam follower bore ID . . . . . . . . . . . 31.7031.75 mm
(1.2481.250 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.
R26164
R26166
RG6426
T81656
3 - 62 11/22/00
MEASURE CAMSHAFT BORE
Camshaft Bore Specifications:
Camshaft bore without bushing . . 55.9856.01 mm
(2.2042.205 in.)
Camshaft bore with bushing (No. 1 only)
cylinder block bore for
bushing installation. . . . . . . . . . . . 59.9659.99 mm
(2.3612.362 in.)
Bushing ID (installed) . . . . . . . . . . 55.9655.99 mm
(2.2032.204 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
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.
3. Tighten nut until bushing is free of block bore.
INSTALL CAMSHAFT BUSHING
Install camshaft bushing using JDG739B as follows:
1. Apply TY6333 grease to internal diameter and
outside diameter of bushing.
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.
CD30557
CD30388
CD30340
CD30558
CD30389
11/22/00 3 - 63
MEASURE CRANKSHAFT BORE
Crankshaft Bore Specifications:
Crankshaft bore ID. . . . . . . . . . . . . 84.4684.48 mm
(3.3253.326 in.)
NOTE: Before measuring, the cap screws must be
tightened to 135 Nm (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 Nm (100 lb-ft).
2. After having positioned block on a boring machine,
bore new bearing caps to 84.4684.48 mm
(3.3253.326 in.) diameter. Take care to remain
within the specified dimension (A) (crankshaft bore
center line to block top face).
Distance (A) . . . . . . . . . . . . . . . . 301.98302.11mm
(11.88911.894 in.)
IMPORTANT: Make sure all crankshaft bearing
bores are in alignment.
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:
Top deck out-of-flat . . . . . . . . . . 0.08 mm (0.003 in.)
Top deck surface finish (CLA) . . . . 0.83.2 micron
(32128 micro-in)
Maximum wave deep . . . . . 8 micron (320 micro-in.)
Crankshaft bore centerline-
to-top deck. . . . . . . . . . . . . . . . . . 301.98302.11 mm
(11.88911.894 in.)
Liner counterbore depth (A) . . . . . . . 5.955.99 mm
(0.2340.236 in.)
CD7271
CD30559
CD30560
CD30561
3 - 64 11/22/00
MEASURE CYLINDER LINER
PROTRUSION
A. Liner protrusion
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 mm0.118 in.). Tighten to 100 Nm
(74 lb-ft).
3. Using KJD10123 Gauge, measure liner protrusion
(A) at four points.
Liner Protrusion Specifications:
Liner protrusion . . . . . . . . . . . . . . . . . 0.010.10 mm
(0.00040.004 in.)
Maximum permissible difference between
adjacent cylinders . . . . . . . . . . . 0.03 mm (0.001 in.)
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.
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.
RG6439
CD30563
CD30199
CD30564
11/22/00 3 - 65
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. Cylinder Liner
B. Packing
C. Improper Installation
D. Proper Installation
LINER O-RING INSTALLATION
Apply lubricating soap to new O-rings. Install O-rings
in respective grooves.
A. Rectangular Section Packing
B. Red or White O-Ring
C. Black O-Ring
D. Cylinder Liner
E. Cylinder Block
INSTALL CYLINDER LINERS
1. Slide liner together with shim and packing into its
bore in cylinder block.
2. Seat liners using KCD10001 special tool.
3. Secure liners by means of large washers and cap
screws.
MEASURE CONNECTING ROD
BEARING
NOTE: Before measuring, connecting rod cap screws
must be tightened according to specifications.
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.
CD7134
A
B
A
B
D C
CD7135
CD30565
CD7120
CD7121
3 - 66 11/22/00
Specifications:
Tightening torque
Initial . . . . . . . . . . . . . . . . . . . . . . . 56 Nm (40 lb-ft)
Final. . . . . . . . . . . . . . . . . . . . . . . . . Plus 90100
Bearing (assembled) ID. . . . . . . 69.84869.898 mm
(2.74992.7519 in.)
Crankshaft journal OD. . . . . . . . 69.79969.825 mm
(2.7482.749 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.
NOTE: Under size crankshafts may be also available
through the regular service parts channel.
ROD BEARING CLEARANCE
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.)
CONNECTING ROD BUSHING
Straight Pin-End (3029D)
Tapered Pin-End (3029T)
NOTE: 3029D engines are equipped with straight pin-
end connecting rods while 3029T engines
receive the tapered pin-end connecting rods.
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. . . . . . . . . . . . . . . . . . . . . . 32.01032.036 mm
(1.26021.2612 in.)
3029T. . . . . . . . . . . . . . . . . . . . . . 41.30041.326 mm
(1.6261.627 in.)
Pin-to-bushing clearance
3029D. . . . . . . . . . . . . . . . . . . . . . . . . 0.010.042 mm
(0.00040.0016 in.)
3029T. . . . . . . . . . . . . . . . . . . . . . . . . 0.020.056 mm
(0.00080.002 in.)
Maximum. . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)
RG6405
CD30566
CD30567
11/22/00 3 - 67
REPLACE CONNECTING ROD
BUSHING
Using JDG738 Connecting Rod Bushing Service Set,
proceed as follows:
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.
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
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.
RG7130
RG7131
RG7132
RG7236
3 - 68 11/22/00
MEASURE PISTON PIN
Piston Pin OD Specifications:
3029D . . . . . . . . . . . . . . . . . . . . . . . 31.99432.000m
(1.25961.2598 in.)
3029T. . . . . . . . . . . . . . . . . . . . . . . . 41.2741.28 mm
(1.62481.6252 in.)
Pin-to-bushing clearance:
3029D . . . . . . . . . . . . . . . . . . . . . . . . 0.010.042 mm
(0.00040.0016 in.)
3029T. . . . . . . . . . . . . . . . . . . . . . . . . 0.020.056 mm
(0.00080.002 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.
CLEAN AND INSPECT PISTONS
Clean pistons, using a commercial cleaner and a jet
rinse gun or glass bead blasting machine.
Check piston for cracks, excessive skirt wear, or any
other damages.
NOTE: Do not attempt to stamp top of piston. Distance
from top of piston and top of first ring is 4 mm
(0.16 in.) and therefore the top ring groove
inserted in piston may be damaged.
MEASURE PISTON PIN BORE
Specifications:
3029D. . . . . . . . . . . . . . . . . . . . . . . . 32.00332.013m
(1.3561.560 in.)
3029T. . . . . . . . . . . . . . . . . . . . . . 41.28541.295mm
(1.62541.6258 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
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.
c
CAUTION
Follow manufacturers instruction exactly. DO
NOT ALLOW CHEMICAL TO COME IN CONTACT
WITH SKIN OR EYES; chemical contains
creosotes which can be very harmful.
T81604
RG6283
RG4746
11/22/00 3 - 69
PISTON SECOND AND THIRD RING
GROOVES
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.
PISTON HEAD AND SKIRT
CHECKING
1. Check piston for scuffing, scoring, or signs of
overheating.
2. Measure piston diameter 19 mm (0.74 in.) from
bottom of skirt and 90from piston pin.
Specifications:
Piston OD at 19 mm (0.74 in.) from bottom of skirt
and measured 90from piston pin
. . . . . . . . . . . . . . . . . . . . . . . . . 106.381106.399 mm
(4.18824.1890 in.)
INSTALL PISTON RINGS
Use KJD10140 or any other suitable piston ring
expander for a proper installation and to prevent any
damage to the piston.
A. Top Ring
B. Second Ring
C. Oil Control Ring
D. KJD10140 Piston Ring Expander
E. Blue Mark
F. Yellow Mark
RG5625
CD30391
CD30568
CD30569
D
KV18888
C
B
A
F
E
3 - 70 11/22/00
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 RINGS STAGGERING
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.
PISTON/LINER SET INFORMATION
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 anti-
corrosion bag and therefore are not coated with oil or
grease. Before opening the bag, be sure that the parts
will be installed immediately to prevent any risk of
parts corroding.
C
D
E
B
A
F
CD30579
PRECISION JOINT is a trademark of Deere & Company
11/22/00 3 - 71
ASSEMBLE PISTON AND
CONNECTING ROD
A. FRONT Mark on Connection Rod
B. Piston Pin
C. Piston Pin Retaining Ring
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.
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.
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.
INSTALL PISTON AND
CONNECTING ROD
NOTE: Early engines have the traditional tongue-and-
groove between the connection rod and cap
(A). Later engines have the PRECISION
JOINT rod and cap (B). Installation of both
rods is similar, with differences noted.
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. Coat pistons and rings with clean engine oil. Install
pistons in liners, using JDE84 piston ring
compressor.
CD30571
A
B
C
KV18572
A. Tongue-and Groove Rod and Cap
B. PRECISION JOINT Rod and cap
CD30572
3 - 72 11/22/00
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.
3. Install bearing insert in connecting rod with tab (A)
in groove (B).
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.
6. Apply clean engine oil to bearing insert. Install cap
on connecting rod with tabs (C) to same side.
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 Nm (40 lb-ft).
8. Torque-turn all cap screws 90100as follows:
72Position the wrench parallel to engine axis (D).
Tighten until the wrench is perpendicular to engine
axis (E).
CD30573
A
B
PRECISION JOINT rod cap.
CD30574
C
KV18573
KV18574
11/22/00 3 - 73
9. Check for proper side clearance in all rods. Each
rod must have a slight side-to-side movement.
MEASURE PISTON PROTRUSION
NOTE: Press down on top of piston to remove
clearances before measuring piston
protrusion.
1. Place KJD10123 Gauge (with flat side up) on
cylinder block so that indicator point rests on block
surface.
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.).
7. If protrusion is out of specifications, check all
concerned parts to determine the cause.
CD30575
CD30005
A
B
3 - 74 11/22/00
COMPLETE FINAL ASSEMBLY
Torques/Specifications:
A. Coolant drain (1/4 in.) . . . . . . . . . 17 Nm (13 lb-ft)
B. Turbocharger oil return (1/2 in.) . 45 Nm (33 lb-ft)
C. 1/2 cyl. for dipstick tube . . . . . . . 67 Nm (50 lb-ft)
D. Oil galleries (1/8 in.). . . . . . . . . . . 17 Nm (13 lb-ft)
E. Coolant gallery (side) (1/4 in.) . . 17 Nm (13 lb-ft)
F. Rear coolant gallery (1 in.) . . . . . 45 Nm (33 lb-ft)
G. Oil gallery (3/8 in.) . . . . . . . . . . . . 45 Nm (33 lb-ft)
1. Install all components previously removed. Apply
following recommendations then perform engine
test.
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.
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).
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.).
CD30577
Rear Left View
Front Right View
CD30576
KV18077
KV18078
11/22/00 3 - 75
REMOVE CRANKSHAFT PULLEY
1. Remove pulley attaching cap screw.
2. Using JDG410 Puller or any other suitable puller,
remove pulley from crankshaft.
INSTALL CRANKSHAFT PULLEY
1. Install shaft key (A).
2. Position pulley on crankshaft with washer (B) and
cap screw (C).
3. Tighten to 150 Nm (110 lb-ft).
FLYWHEEL REMOVAL
1. Remove two cap screws and install guide studs in
their place (shown installed) then remove the other
cap screws.
2. Install two 1/2-13 UNC or M10 cap screws (length
100 mm/4 in.) into the threaded holes (A) to push
flywheel off crankshaft and to facilitate flywheel
handling.
NOTE: If the flywheel does not have the threaded
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.
CD30580
CD30581
c
CAUTION
Flywheel is heavy. Plan a proper lifting
procedure to avoid personal injury.
RG5632
A
3 - 76 11/22/00
FLYWHEEL RING GEAR
REPLACEMENT
1. Drive ring gear off with a brass drift and hammer.
2. Heat new ring gear to 150C (300F) using either
heated oil, oven heat, or flame heat.
IMPORTANT: If flame is used to heat ring gear, be
sure gear is heated uniformly around
circumference.
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.
INSTALL BALL BEARING
NOTE: Some flywheels have a ball bearing (D) which
needs to be installed with flywheel removed
from engine.
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
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
Nm (120 lb-ft).
c
CAUTION
Oil fumes or oil can ignite above 190C (380F).
When heating ring gear, use a thermometer and
do not exceed 180C (360F). Heat the oil in a
well ventilated area. Plan a safe handling
procedure to avoid burns.
T90596
RG3838
A
RG6345
A
B
D
E C
A. 27487 Driver
B. 27508 Disk
C. 27493 Disk
D. Ball Bearing
E. Flywheel
CD7140
11/22/00 3 - 77
CRANKSHAFT REAR OIL SEAL
Removal:
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
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.
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
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.
2. Secure the assembly with a clamp then gradually
tighten the screw until wear sleeve is extracted.
CD30584
A
B
RG5638
RG5639
CD30243
CD30244
3 - 78 11/22/00
3. Cut the rubber lip now accessible and remove it.
4. Using a punch and a hammer, tap the seal case
toward engine at any location until seal case
pivots.
5. Using JDG22 Slide Hammer Puller, extract seal
case.
Installation:
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.
2. Apply a light coating of LOCTITE 609 (TY15969)
completely around the leading edge of crankshaft
flange.
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.
CD30396
CD30397
CD30247
CD30586
T81204
T81205
11/22/00 3 - 79
FLYWHEEL HOUSING
REPLACEMENT
1. Remove flywheel and oil pan.
2. Remove four 5/8 in. cap screws (B) and eight 3/8 in.
cap screws (A). Remove flywheel housing.
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.
4. Install flywheel housing with the eight cap screws
(A).
5. Tighten 3/8 in. cap screws (A) initially to 30 Nm
(23 lb-ft). Finally, tighten screws to 50 Nm
(35 lb-ft).
6. Install the four 5/8 in. cap screws (B) and tighten to
230 Nm (170 lb-ft).
MEASURING CRANKSHAFT END
PLAY
NOTE: It is recommended to measure crankshaft end
play prior to removing crankshaft to determine
condition of thrust bearings.
Check crankshaft end play using a dial indicator and
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.
c
CAUTION
AVOID INJURY. Flywheel housing weighs
approximately 20 to 40 kg (43 to 86 lbs.).
CD7141
A
A A
B
B
B
B
CD30585
CD7144
CD30220
A
A
3 - 80 11/22/00
REMOVE CRANKSHAFT
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.
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.
MEASURE CRANKSHAFT JOURNAL
DIAMETER
1. Measure diameter of all crankshaft journals at
several points around journal and compare with
specifications.
Crankshaft Journal Specifications:
Main journal diameter
(std.) . . . . . 79.32479.350 mm (3.1233.124 in.)
Maximum wear
Taper . . . . . . . . . . . . . . . . . . . 0.03 mm (0.0012 in.)
Out-of-roundness. . . . . . . . . 0.075 mm (0.003 in.)
2. Install main bearing inserts and caps then tighten
cap screws to 135 Nm (100 lb-ft), then measure
ID of main bearing (assembled) and compare with
specifications.
Main Bearings (Assembled) ID Specifications:
Main bearings assembled
ID (standard) . . . . . . . . . . . . . . 79.39679.440 mm
(3.1263.127 in.)
Clearance . . . . . . . . . . . . . . . . . . 0.0460.116 mm
(0.00180.0046 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.
CD30587
CD7147
CD30588
CD7149
11/22/00 3 - 81
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
1. Place a strip of Plastigage in the center of the
bearing.
2. Install cap and tighten cap screws to 135 Nm
(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.
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.
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.
RG7528
3 - 82 11/22/00
MICRO-FINISHING SPECIFICATIONS
The following specifications are required when cast
iron crankshafts have to be ground:
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:
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.
REPLACE CRANKSHAFT GEAR
NOTE: Gear can be replaced without removing the
crankshaft.
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 180C (360F).
5. Drive gear, with chamfered side toward engine, onto
crankshaft using JDG794 driver.
c
CAUTION
Oil fumes or oil can ignite above 190C (380F).
Use a thermometer to ensure that a temperature
of 180C (360F) is not exceeded. Do not allow a
flame or heating element to come into direct
contact with the oil. Heat the oil in a well-
ventilated area. Plan a safe handling procedure
to avoid burns.
RG7238
A
B
C
CD30398
JDG794
11/22/00 3 - 83
INSTALL MAIN BEARING INSERTS
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 2-PIECE THRUST
BEARING
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.
INSTALL 6-PIECE THRUST
BEARING
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.
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 Nm
(14 lb-ft).
CD30589
A
B
CD30590
A
CD30399
T88557
A
CD30250
B
3 - 84 11/22/00
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 Nm (100 lb-ft).
7. Check for free rotation and end play of the
crankshaft.
MEASURE TIMING GEAR
BACKLASH
Measure backlash between gears using a dial
indicator and compare with specifications.
If backlash is not correct, install new gears.
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
Camshaft End Play Measure
Using a dial indicator, check camshaft end play.
Camshaft end play . . . . . . . . . . . . . . . 0.080.23 mm
(0.0030.009 in.)
Maximum wear . . . . . . . . . . . . . . 0.38 mm (0.015 in.)
Thrust plate thickness. . . . . . . . . . 3.9353.985 mm
(0.1550.157 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
NOTE: Camshaft can be removed from engine without
removing cylinder head by holding cam
followers away from camshaft lobes with
D15001NU Magnetic Holding Set.
NOTE: Mark parts so that they can be installed in their
original positions.
CD30591
A
B
C
D
E
CD7104
CD30593
11/22/00 3 - 85
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
Camshaft Journal Specifications:
Camshaft journal OD. . . . . . . . . 55.87255.898 mm
(2.19972.2007 in.)
Maximum wear . . . . . . . . . . . . . 55.85 mm (2.199 in.)
Max. clearance between bore
and camshaft journal . . . . . . . . . 0.18 mm (0.007 in.)
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.
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.
Camshaft Lobe Height Specifications:
Intake lobe . . . . . . 6.937.42 mm (0.2730.292 in.)
Exhaust lobe. . . . . 6.767.26 mm (0.2660.286 in.)
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.
3. Install gear with timing mark (A) away from
camshaft.
4. Press gear on shaft until flush with shoulder on
camshaft.
CD30592
A
CD30594
CD30594
CD30595
A
3 - 86 11/22/00
TACHOMETER PICK-UP PIN
REMOVAL
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.
INSTALL CAMSHAFT
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 12.8812.92 mm (0.50710.5087 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 Nm
(35 lb-ft).
replace cam followers (E) when installing a new
camshaft.
MEASURE CAM FOLLOWER
Measure cam follower OD and compare with
specifications.
Cam Follower Specifications:
Cam follower OD . . . . . . . . . . . . . . 31.6231.64 mm
(1.1241.246 in.)
Cam follower to bore clearance . . . . 0.060.13 mm
(0.0020.005 in.)
If diameter or clearance is not within specifications or if
the follower face is flat or concave, replace cam
follower.
MEASURE IDLER GEAR END PLAY
Using a dial indicator, check end play of upper and
lower idler gears:
End play . . . . . . . . 0.140.29 mm (0.0060.012 in.)
REMOVE FRONT PLATE
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.
CD30200
CD30596
RG6324
CD7155
11/22/00 3 - 87
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.
4. Remove five countersunk screws (D) and lift off
front plate.
5. Remove oil bypass valve and spring (E).
IDLER GEAR BUSHING AND SHAFT
MEASURE
If clearance is more than specified, replace worn parts
with new ones.
Idler Gear Specifications:
Idler gear shaft OD:
with helical or spur gear . . . . 44.43744.463 mm
(1.74951.7505 in.)
Upper with spur gear . . . . . . . 69.75969.775 mm
(2.74642.747 in.)
Idler gear bushing ID:
with helical or spur gear . . . . 44.50144.527 mm
(1.7521.753 in.)
Upper with spur gear . . . . . . . 69.82769.857 mm
(2.74912.7503 in.)
Idler gear/bushing clearance:
with helical or spur gear . . . . . . . 0.0380.09 mm
(0.00150.0035 in.)
Upper with spur gear . . . . . . . . . 0.0520.098 mm
(0.0020.0038 in.)
Maximum wear . . . . . . . . . . . . 0.15 mm (0.006 in.)
CD30186
KV18575
KV18576
CD7159
CD7160
3 - 88 11/22/00
IDLER GEAR BUSHING
REPLACEMENT
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.
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.
REMOVE IDLER SHAFT
Remove upper or lower idler shaft by driving shaft out
of the front plate. Remove thrust washer.
INSTALL IDLER SHAFT SPRING PIN
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.
Spring pin protrusion (D) . . . . . . . . . . . 7.58.5 mm
(0.2950.335 in.)
CD7161
CD30599
RG6459
A
B
C
CD30401
D
11/22/00 3 - 89
INSTALL IDLER SHAFTS
A. Upper Idler Shaft
B. Lower Idler Shaft
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 45to 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.
INSTALL FRONT PLATE
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.
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.
CD30255
A
CD30256
B
CD30600
A
B
C
D
E
F
G
CD30695
H
H
H
3 - 90 11/22/00
I. Oil Bypass Valve
3. Install oil bypass valve (I) and spring in cylinder
block.
4. Install gasket (G) and front plate. Place new
external tooth washers onto five countersunk
screws (F) then tighten to 35 Nm (25 lb-ft).
IMPORTANT: Cut off protruding edge of gasket
only after timing gear cover has been tightened.
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.
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.
3. Install fuel injection pump.
4. Using JD-254A Timing Tool, align the timing mark
"3" (for 3 cylinder engines) with the timing tool.
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.
CD30598
I
CD30697
F
CD30601
A
CD30602
KV18079
11/22/00 3 - 91
7. Install washer, with sharp edge toward timing cover,
and bolt (B). Tighten to 110 Nm (80 lb-ft).
8. Recheck gear timing to make sure it is correct.
INSTALL LOWER TIMING GEAR
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 Nm (80 lb-ft).
NOTE: Engine may be equipped with a self-locking oil
pump nut. In this case, tighten to 85 Nm
(63 lb-ft). Do not apply any punch marks.
3. Install oil pump gear on pump shaft, tighten hex nut
to 75 Nm (55 lb-ft) and secure with three center
punch marks.
INSTALL OIL DEFLECTOR
Install oil deflector (A) and O-ring (B) when equipped,
on forward end of crankshaft.
INSTALL TIMING GEAR COVER
1. Install new gasket on front plate.
2. Install cover on engine and apply the following
torques in sequence:
Cover cap screws (117) . . . . . . . . 50 Nm (35 lb-ft)
Oil pan cap screws (1823) . . . . . . 50 Nm (35 lb-ft)
A. Magnetic pick-up . . . . . . . . . . . . . 15 Nm (11 lb-ft)
B. Injection pump gear plug . . . . . . 30 Nm (22 lb-ft)
C. Oil pressure valve plug. . . . . . . . 95 Nm (70 lb-ft)
CD30604
B
CD30605
A
CD30608
CD30609
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
23
22
24
3 - 92 11/22/00
3. Install oil filler neck or block-off plate then tighten
cap screws (F) to:
Aluminum neck . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Composite neck . . . . . . . . . . . . . . . . 30 Nm (22 lb-ft)
Block-off plate . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
4. Cut off protruding edge of gasket.
INSTALL CRANKSHAFT FRONT OIL
SEAL
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.
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.).
INSTALL WEAR RING
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
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.
KV18577
CD30611
A
B
CD30698
CD30612
A
CD30271
11/22/00 3 - 93
REPLACE OIL COOLER NIPPLE
1. Remove oil cooler nipple (A).
2. Press in new nipple so that threaded end faces
outward.
INSTALL OIL COOLER
1. Install new packing between oil cooler and cylinder
block.
2. Attach oil cooler with nipple (A). Tighten to 35 Nm
(25 lb-ft).
3. Connect coolant lines to oil cooler.
4. Install oil filter.
REMOVE OIL PRESSURE
REGULATING VALVE
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).
REPLACE OIL PRESSURE
REGULATING VALVE SEAT
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.
CD30275
CD30617
CD30620
CD7175A
813
JD-248A
3 - 94 11/22/00
INSTALL OIL PRESSURE
REGULATING VALVE
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 Nm (70 lb-ft).
REPLACE OIL DIPSTICK GUIDE
ADAPTER
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.
REPLACE OIL BYPASS VALVE
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
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
4. Install oil pan.
CD30413
A
KV18013
CD30622
A
CD30623
A
11/22/00 3 - 95
REMOVE OIL PUMP
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.
GEAR AXIAL CLEARANCE
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.)
GEAR RADIAL CLEARANCE
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
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. . . . . . . . . . . . . . . . 16.0216.03 mm
(0.6300.631 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.)
CD7176
A
B
C
CD7177
CD7178
T81953
T81781
3 - 96 11/22/00
OIL PUMP INSTALLATION
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
H. Housing
I. Outlet Tube
J. Strainer
K. Cover
L. Cap Screws (3 or 4 used)
M. Drive Gear
N. Nut
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.
5. Attach oil pump assembly to front plate, tightening
cap screws (L) to 50 Nm (35 lb-ft).
CD30416
A
B
C
G
D
E
F
H
I
J
K
L
M
N
CD30624
KV18080
KV18578
11/22/00 3 - 97
6. Rotate pump shaft, again making sure that pump
gears turn freely.
7. Install pump drive gear (M) and a new nut (N).
NOTE: Engine may be equipped with a self-lock nut. In
this case, tighten to 85 Nm (63 lb-ft). Do not
apply any punch marks.
8. Secure the nut by applying three center punch
marks.
INSTALL OIL PAN
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.
2. Select and install the correct gasket for the oil pan
being used.
3. Install oil pan and tighten cap screws as follows:
Oil pan (all types) to timing
gear cover . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Sheet metal oil pan to block
and flywheel housing. . . . . . . . . . 50 Nm (35 lb-ft)
Aluminum oil pan to block
and flywheel housing. . . . . . . . . . 50 Nm (35 lb-ft)
Cast iron pan to block and flywheel housing:
SAE 5 screws (3 dashes) . . . . . . . 50 Nm (35 lb-ft)
SAE 8 screws (6 dashes) . . . . . . . 70 Nm (50 lb-ft)
4. Install a new seal on cylindrical drain plug. Tighten
as follows:
Cylindrical plug . . . . . . . . . . . . . . . . 70 Nm (50 lb-ft)
Conical plug . . . . . . . . . . . . . . . . . . . 55 Nm (40 lb-ft)
T81782
CD30626
CD30627
3 - 98 11/22/00
WATER PUMPEXPLODED VIEW
REMOVE WATER PUMP
1. Remove fan and sheet metal pulley when equipped.
2. Disconnect water pump hoses (A).
3. Remove attaching screws (B) and nut (C). Lift out
water pump.
CD30628
A. Housing
B. Bearing Shaft
C. Seal
D. Impeller
E. Gasket
F. Rear Cover
G. Hub (or Pulley)
CD30629
A
B
C
B
11/22/00 3 - 99
DISASSEMBLE WATER PUMP
A. Rear Cover
B. Pulley
C. Bearing Shaft
D. Impeller
E. Pump Housing
F. Seal
G. Weep Hole
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
.
2. Measure dimension (X) as shown and retain for use
in pump assembly.
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.
6. Inspect water pump housing, cover, and pulley for
wear, debris, cracks or other damage. Replace as
necessary.
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.
CD30630
CD30662
X
CD30631
E
D
CD30632
3 - 100 11/22/00
ASSEMBLE WATER PUMP
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.
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.
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.
4. Place pump housing under a press and support on
pulley end of shaft.
5. Using special tool JD-262A, press impeller onto
pump shaft until recess of 0.25 mm (0.5 in.) is
obtained.
6. Place pump housing under a press and support on
impeller end of shaft.
CD30633
A
B
KV18579
CD30635
CD30636
CD30637
KV18554
X
11/22/00 3 - 101
7. Install pulley or hub to dimension (X) obtained step
2 of water pump disassembly.
INSTALL WATER PUMP
1. Attach pump rear cover to pump housing using a
new gasket and tighten cap screws to 45 Nm
(33 lb-ft).
2. Install water pump, placing a new gasket between
the pump cover and cylinder block. Tighten cap
screws (B) to 50 Nm (35 lb-ft) and nut (C) to
40 Nm (30 lb-ft).
3. Connect coolant hoses (A).
REMOVE/INSTALL THERMOSTAT
1. Visually inspect area around thermostat cover (A)
for leaks. Partially drain coolant from system.
2. Remove bypass tube (B) from thermostat cover.
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.
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 Nm
(35 lb-ft).
9. Install bypass tube into thermostat cover. Tighten
clamp.
10. Fill cooling system and check for leaks.
COLD START ADVANCE WIRE
HARNESS (IF EQUIPPED)
The cold start advance wire harness allows easy start-
up when the engine is cold. The temperature signal is
supplied by switch (A) located in thermostat cover.
This switch must be tightened to 5 Nm (3.5 lb-ft).
KV18081
X
CD30629
A
B
C
B
CD30640
C
CD30641
D
E
F
D
G
CD30682
3 - 102 11/22/00
COOLING SYSTEM DEAERATION
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.
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.
CHECK FAN/ALTERNATOR BELT
TENSION
1. Check belt tension using one of following methods:
Using JDG529 Tension Gauge (A):
New Belt Tension:
Single belt . . . . . . . . . . . . . 578622 N (130140 lb)
Used Belt Tension:
Single belt . . . . . . . . . . . . . . . 378423 N (8594 lb)
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.).
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.
CD30642
CD30643
B
CD30644
A
CD30645
B
C
CD30646
E
D
11/22/00 3 - 103
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.
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 Nm (22 lb-ft)
3/8 in. cap screws. . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
BLOCK HEATER (OPTIONAL)
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.
6. Unscrew knurled nut and disconnect wire
connector.
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.
CD30649
Blower Fan (Top View)
KV31112
Knurled
Nut
Wire
Connector
KV31111
Heating
Element
Jam Nut
3 - 104 11/22/00
NOTE: If heating element will be reused, make a mark
on the element to determine position for
reassembly.
9. Keep heating element from rotating and unscrew
fitting from block. Remove fitting and heating
element from block.
Installation:
1. Install new O-ring on heating element.
2. Apply TY9374 Pipe Sealant with Teflon to the
threads of the fitting.
IMPORTANT: Note where the offset in the heating
element. Offset must go to the out side of block
(right side of engine).
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.
CHECK AIR INLET PIPE
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.
KV31108
Heating
Element
Fitting
Mark
KV31109
Heating
Element
Fitting
O-Ring
KV31110
Fitting
Mark
Toward
Outside
of Block
CD30653
A
B
C
11/22/00 3 - 105
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 Nm (35 lb-ft).
EXHAUST MANIFOLD INSPECTION
1. Remove muffler.
2. On engines with turbocharger, remove
turbocharger.
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 Nm (35 lb-ft).
REMOVE TURBOCHARGER
1. Thoroughly clean exterior of turbocharger and
surrounding area.
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.
CHECK RADIAL BEARING
CLEARANCE
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.
CD30654
A
CD30661
A
B
C
D
CD30658
3 - 106 11/22/00
CHECK AXIAL BEARING END PLAY
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.
REPAIR TURBOCHARGER
Due to special tooling and highly specialized personnel
required, turbochargers can be serviced only by an
authorized workshop.
Complete turbochargers are available through service
parts channel. Individual components for repair are not
available.
PRELUBE TURBOCHARGER
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.
INSTALL TURBOCHARGER
1. Install turbocharger on exhaust manifold (A) with a
new gasket (B). Tighten cap screws (C) to 30 Nm
(20 lb-ft).
2. If not done previously, prelube turbocharger, then
connect the oil supply line (D). Tighten to 25 Nm
(18 lb-ft).
3. Connect the oil return tube (E). Tighten to 80 Nm
(60 lb-ft).
4. Connect exhaust system and air hoses.
IMPORTANT: Be sure that the air hose connections
are tight to prevent entry of dirt into engine.
CD30659
CD30660
CD30661
A
B
C
D
E
11/22/00 3 - 107
TURBOCHARGER BREAK-IN
IMPORTANT: A new or repaired turbocharger does
not have adequate oil supply. Perform the
following steps to prevent damage to
turbocharger.
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.
REPLACE FUEL/WATER
SEPARATOR FILTER
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.
A
LV2112
CD30665
3 - 108 11/22/00
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.
REPLACE FUEL PUMP
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 non-
operational.
5. Installation is reverse order of removal.
REMOVE STANADYNE DB4 FUEL
INJECTION PUMP
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.
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
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.
CD30667
KV31120
B
A
C
B
RG6293
X
Y
KV18082
D
B
E
A
G
F
C
11/22/00 3 - 109
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.
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.
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
CD30317
JDG670A
3 - 110 11/22/00
INSTALL STANADYNE DB4 FUEL INJECTION PUMP
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.
2. Screw the three nuts (E) onto studs and hand-
tighten at this time.
NOTE: Use care when installing nut and washer. If
dropped, it will be necessary to remove the
engine front covers to retrieve them.
3. Push drive gear firmly onto shaft taper. Install
washer and nut (M) then tighten to 200 Nm
(150 lb-ft). Install mounting plug onto timing gear
cover.
4. Align timing mark on pump flange (X) with timing
mark on front plate (Y) then tighten nuts to 25 Nm
(18 lb-ft).
NOTE: In case of replacement of injection pump,
install injection pump with studs in middle of
flange slots. Then perform a dynamic timing.
CD30670
L
I
E
C
D
F
G
H
K
J
A. Front Plate
B. Pump Flange
C. O-Ring
D. Stud (3 used)
E. Nut (3 used)
F. Woodruff Key
G. Return Line
H. Injection Line No. 1
I. Pump Outlet
J. Injection Line No. 2
K. Injection Line No. 3
L. Supply Line
A
B
CD30671
M
RG6293
Y
X
11/22/00 3 - 111
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 Nm (18 lb-ft)
using JDF22 socket and a backup wrench.
6. Connect:
Fuel supply line (L) and tighten to 30 Nm (23 lb-
ft)
Fuel return line(G) and tighten to 15 Nm (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.
Removal:
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.
2. Using two wrenches as shown, disconnect fuel
injection line (E) from nozzle to be removed.
3. Remove cap screw (F).
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.
CLEAN FUEL INJECTION NOZZLE
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.
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.
KV31118
A
B
C
E
B
B
A
C
F
D
D
CD30676
C
CD30324
JDG716
3 - 112 11/22/00
FUEL INJECTION NOZZLE TEST
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.
1. Connect the nozzle to the tester so that the axis of
the nozzle forms an angle of approx. 30to 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.
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
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.)
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.
L30741
A
B
11/22/00 3 - 113
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.
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
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).
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 Nm (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 Nm
(3.5 lb-ft).
8. Check opening pressure.
CD30674
3 - 114 11/22/00
INSTALL FUEL INJECTION NOZZLE
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.
IMPORTANT: Each time an injection nozzle is
removed from cylinder head, replace the carbon
stop seal (D).
1. Slide seal washer (E) onto nozzle body. Using JD-
258 Pilot Tool, slide the new carbon stop seal until
it fits properly into the groove.
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 Nm (23 lb-ft) using two wrenches as shown.
4. Tighten cap screw (B) to 37 Nm (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 Nm (44 lb-in.).
BLEED FUEL SYSTEM
The fuel system utilizes an automatic priming system.
To ensure that the fuel system is primed, turn the key
switch to the RUN position and wait 20 seconds before
starting the engine.
CD30675
A
F
G
B
H
E
D
C
H
CD30323
I
A
B
C
CD30676
C
11/22/00 3 - 115
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".
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.
Change the oil and filter after the first 100 hours of
operation of a new or rebuilt engine.
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.
Time Load Engine Speed Remarks
5 minutes No load 800 rpm
Check oil pressure and
coolant temperature.
Check for fluid leakage.
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
3 - 116 11/22/00
USING STANADYNE "TIME-TRAC"
AS TACHOMETER
A. Clamp-On Transducer FKM10429-5
B. Cable FKM10429-3
C. Timing Meter FKM10429-1
The STANADYNE "TIME-TRAC" meter can be used
as a tachometer by using clamp-on transducer
FKM10429-5 (A) on any high-pressure line.
Operating Instructions
1. Remove paint and thoroughly clean the area of the
high-pressure line to which the clamp-on
transducer is to be attached.
2. Install transducer (A) and connect cable
FKM10429-3 (B) between transducer and timing
meter (C). Also connect ground wire.
3. Switch the meter ON by pressing the "ON/CLEAR"
key and start the engine.
TURBOCHARGER OPERATION
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.
Engine oil under pressure from the engine lubrication
system is forced through passages in center housing
(D) to the bearings.
CD30206
A B C
CD30207
B
A
L30869
F
A
B
C
D
E
A
11/22/00 3 - 117
CHECK TURBOCHARGER BOOST
PRESSURE
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
Engine Emits Black or Grey Smoke
Excessive build-up in compressor or turbine
Turbine housing cracked or attaching screws loose
Exhaust manifold gaskets blowing
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
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
Noise or Vibration
(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.
CD30687
A
3 - 118 11/22/00
COLD START ADVANCE SYSTEM
OPERATION (IF EQUIPPED)
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
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 50C (122F), 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 50C (122F), the
solenoid valve (C) is no longer activated and due to
the spring action, closes the cold advance circuit.
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)
CD30696
CD30692
CD30691
11/22/00 3 - 119
FUEL INJECTION NOZZLES
GENERAL INFORMATION
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
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
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 injection pump return line damaged
CD30040
3 - 120 11/22/00
Engine Runs Irregularly or Stalls Frequently
Filter clogged
Air in fuel system
Fuel injection nozzles faulty or dirty
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
Water in fuel
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 nozzles faulty or nozzle valve
sticking
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
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.)
11/22/00 3 - 121
DIESEL ENGINE STARTING MOTOR
STARTING MOTOR
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.
THEORY OF OPERATION
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.
From field windings, current flows through armature
windings (I) to ground, making contact through
commutator brushes (H).
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.
A
B
C
D
E
F
G
I
J
H
RG1313
3 - 122 11/22/00
STARTING MOTOR DIESEL ENGINE
THEORY OF OPERATIONCONTINUED
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 hold-
in 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.
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 clutch drive,
disengaging pinion from flywheel.
In this reduction-type starter, the speed of armature
rotation is reduced by the gear reduction assembly
(G).
A. Solenoid
B. Field Winding
C. Rear Bearing
D. Brush
E. Commutator
F. Armature
G. Gear Reduction Assembly
H. Overrunning Clutch
I. Pinion
J. Engaging Lever
CD30450
A
B
C
D
E
G
H
I
J
F
11/22/00 3 - 123
EXPLODED VIEW OF STARTING MOTOR
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
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
KV18083
3 - 124 11/22/00
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
Starting motor-to-engine. . . . . . . . 50 Nm (37 lb-ft)
Solenoid attaching screw . . . . . . . 3 Nm (27 lb-in.)
Field winding terminal nut. . . . . . 10 Nm (88 lb-in.)
Through-bolts. . . . . . . . . . . . . . . . . 7 Nm (62 lb-in.)
DISASSEMBLY OF STARTING
MOTOR
1. Disconnect field winding cable (A).
2. Unscrew the two through-bolts (B).
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.
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.
8. Remove pivot pin (K).
9. Separate overrunning clutch/engaging lever/mobile
core assembly (M) from gear reduction/solenoid
body assembly (L).
CD30452
KV18084
KV18085
KV18086
KV18087
11/22/00 3 - 125
10. Remove two screws (N) retaining contactor.
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).
13. Remove the rear bearing (S).
NOTE: Two shims (T) are located on each side of rear
bearing.
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.
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.
18. Push the two positive brushes inwards and remove
the brush plate from the field frame.
KV18088
KV18089
KV18090
KV18091
CD30461
CD30462
3 - 126 11/22/00
TESTING SOLENOID SWITCH
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: Solenoid switch is available as a John Deere
service part.
TESTING BRUSHES
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.
NOTE: Brush plate assembly is available as a John
Deere Service part.
POSITIVE BRUSH REPLACEMENT
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 4060% tin-lead mixing.
Heat to 230C (446F).
TESTING ARMATURE
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.
CD30463
CD30464
CD30465
CD30466
11/22/00 3 - 127
TESTING FIELD WINDING
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.
CHECKING OVERRUNNING
CLUTCH PINION
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.
CD30467
CD30468
3 - 128 11/22/00
ASSEMBLY OF STARTING MOTOR
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.
(See STARTER in the ELECTRICAL section.)
TORQUE SPECIFICATIONS:
Starting motor-to-engine. . . . . . . . . 50 Nm (35 lb-ft)
Solenoid attaching screw . . . . . . . . 3 Nm (27 lb-in.)
Field winding terminal screw . . . . 10 Nm (88 lb-in.)
Through-bolts. . . . . . . . . . . . . . . . . . 7 Nm (62 lb-in.)
CD30469
11/22/00 3 - 129
DIESEL ENGINE ALTERNATOR
ALTERNATOR
THEORY OF OPERATION
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.
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.
A protection device (H), including a Zener diode and a
capacitor, protects diode from voltage surges and
suppresses radio interference.
Equipment:
NOTE: Order tools according to information given in
the U.S. SERVICE-GARD

Catalog or in
Digital Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . JT05791
Test electrical components for voltage, resistance, or
current flow. It is especially good for measuring low
voltage or high resistance circuits.
KV15183
A
B
C
D
E
F
G
H
I
J
REG.
Y
Z X
W
B+
D+
B-
A. Alternator
B. Current Coil (Stator)
C. Exiting Coil (Rotor)
D. Regulator
E. Battery
F. Indicator Light
G. Ignition Switch
H. Protection Device
I. Diode Trio
J. Rectifier Diode Bridge
RW11274
3 - 130 11/22/00
ALTERNATOR DIESEL ENGINE
ALTERNATOR SPECIFICATIONS:
Rotor winding resistance . . . . . . . . . . . . 2.95 ohms
Stator resistance . . . . . . . . . . . . . . . . . . . 0.00 ohms
Alternator output voltage . . . . . . . . 13.514.2 volts
Alternator rated amps . . . . . . . . . . . . . . . . . 55 amps
Working temperature range . . . . . . 40C to +90C
(104F to +194F)
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 Nm (29 lbft)
B+ terminal nut . . . . . . . . . . . . . . . 4 Nm (35 lb-in.)
B terminal nut . . . . . . . . . . . . . . . 3 Nm (27 lb-in.)
Through-bolts . . . . . . . . . . . . . . . . 3 Nm (27 lb-in.)
11/22/00 3 - 131
ALTERNATOREXPLODED VIEW
A. Pulley Nut (M14 x 1.5)
B. Lock Washer
C. Pulley
D. Fan
E. Rotor
F. Rear Bearing
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
KV15184
A
B
C
D
E
F
G
I
H
J
K
M
N
L
3 - 132 11/22/00
TROUBLESHOOTING
Problem or
Symptom
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Check or
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

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

11/22/00 3 - 133
ALTERNATORIDENTIFICATION
The information for parts identification is stamped on
the body of the alternator.
DISASSEMBLEALTERNATOR
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.
2. Remove pulley nut (A), lock washer, pulley, and fan
from shaft.
3. Remove shaft key (B) and spacer (C) from shaft.
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.
5. Remove three bolts (F) from front housing side.
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.
CD30470
ZT10613
ZT10614
CD30471
KV18092
KV18093
3 - 134 11/22/00
7. Remove rotor/front housing assembly (I) from
stator/rear housing assembly (H).
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
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.
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.
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.
KV18094
KV18095
CD30475
CD30476
11/22/00 3 - 135
TESTING ALTERNATOR ROTOR
1. Inspect slip rings (A) of rotor for scoring or rough
surface. Polish slip rings sparingly with No. 00
sand paper.
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.
TESTING ALTERNATOR STATOR/
RECTIFIER BRIDGE ASSEMBLY
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.
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.
CD30477
CD30478
CD30479
CD30480
3 - 136 11/22/00
REPLACE RECTIFIER BRIDGE
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.
ASSEMBLE ALTERNATOR
1. Install stator and rectifier bridge into rear housing
using alignment mark.
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 Nm
(27 lb-in.).
3. Install insulated washer, flat washer, capacitor wire,
lock washer, and nut on B+ terminal (D). Tighten
to 4 Nm (35 lb-in.).
4. Install insulated washer, flat washer, spade
terminal, lock washer, and nut on W terminal (E).
Tighten to 3 Nm (27 lb-in.).
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 Nm (27 lb-in.).
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).
8. Install shaft key (J), spacer (K) and fan (L).
9. Install pulley (M) with lock washer and nut (N).
Tighten to 40 Nm (29 lbft).
10. Install alternator on engine and connect wiring
connectors.
CD30481
CD30482
CD30483
CD30484
CD30485
CD30486
CD30487
ELECTRICAL CONTENTS
Page
CONTENTS
11/22/00 4 - 1
ELECTRICAL
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
4 - 2 11/22/00
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
11/22/00 4 - 3
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
4 - 4 11/22/00
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
11/22/00 4 - 5
ELECTRICAL CONTENTS
SPECIFICATIONS ELECTRICAL
4 - 6 11/22/00
SPECIFICATIONS
Battery
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BCI Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Cold Cranking Amps at 18C (0F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750
Reserve Capacity at 27C (80F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.514.2 volts
Resistor at 25C (77F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4753 ohms
Rotor Winding Resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.95 ohms
Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 mm (0.28 in.)
Alternator Torques
Alternator Pulley Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm (29 lb-ft)
B+ Terminal Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Nm (35 lb-in.)
B Terminal Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Nm (26 lb-in.)
Through-Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Nm (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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.033.5 ohms
Empty Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244250 ohms
Fuel Shutoff Solenoid
Hold-In Amperage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 amp (max) continuous
Engine Coolant Temperature Sensor Resistance
At 20C (68F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.212.69 k-ohms
At 030C (3286F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.655.88 k-ohms
Engine Coolant Temperature Switch
Closing Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116C (241F)
Hydraulic Oil Overheat Switch
Close temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.4 2.8C (220 5F)
Open temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.8C (190F) minimum
Pre-Heater
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.701.65 ohms
Lighting
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 W, halogen type
Rear, Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.5 W, incandescent type 1156
Rear, Running (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . .10 W, incandescent type R19/10
ELECTRICAL ELECTRICAL DIAGNOSTIC INFORMATION
11/22/00 4 - 7
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
ELECTRICAL DIAGNOSTIC INFORMATION ELECTRICAL
4 - 8 11/22/00
THEORY OF OPERATION
INFORMATION
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.
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.
WIRE COLOR ABBREVIATION
CHART
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
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.
ELECTRICAL LEGEND FOR ELECTRICAL COMPONENTS
11/22/00 4 - 9
LEGEND FOR ELECTRICAL COMPONENTS
A1Heater Control Circuit Board (SE10, W5)
B1Air Filter Restriction Switch (SE6, W1)
B2Hydraulic Overtemperature Switch (SE6, W1)
B3Hydraulic Oil Filter Restriction Switch (SE6, W1)
B4Fuel Level Sender (SE6, W1)
B5Engine Overtemperature Switch and Coolant
Temperature Sender (SE6, W1)
B6Engine Low Oil Pressure Switch and Oil Pressure
Sender (SE6, W1)
B7Cold Start Switch (Model 250) (SE3, W4)
E1Left Front Work Light (SE7)
E2Right Front Work Light (SE7)
E3Left Tail Light (SE7)
E4Right Tail Light (SE7)
E5Rear Work Light (SE7)
E6Left Hazard Light (SE8)
E7Right Hazard Light (SE8)
F1Accessories Fuse (SE1, W1)
F2Seat Switch/Seat Belt Fuse (SE1, W1)
F3Key Switch Fuse (SE1, W1)
F4Interlock Fuse (SE3, W1)
F5Cab Heater Fuse (SE10, W7)
F6Backup Alarm Fuse (SE11, W8)
G1Battery (SE1)
G2Alternator (SE4, W1)
H1Instrument Cluster (SE6)
H2Backup Alarm (SE11, W8)
K1Start Relay (SE1, W1)
K2Preheat Relay (SE2, W1)
K3Fuel Relay (SE3, W1)
K4Accessory Relay (SE7, W1)
K5Dual Flasher Relay (SE8, W3)
K6High Flow Relay (SE9, W1)
K7Cab Heater Relay (SE10, W7)
M1Starting Motor (SE1, W1)
M2Fuel Pump (SE3, W1)
M3Blower (SE10, W6)
M4Wiper Motor (SE12, W9)
M5Washer Pump (SE12, W9)
R1Manifold Preheater (SE2, W1)
R2Alternator Resistor (SE4)
R3Cab Heater Thermostat (SE10, W5)
S1Key Switch (SE1, W2)
S2Park Brake Switch (SE1, W2)
S3Manual Preheat Switch (SE2, W2)
S4Seat Switch (SE4, W2)
S5Seat Belt Switch (SE4, W2)
S6Work Lights Switch (SE7, W2)
S7Dual Flasher Switch (SE8, W3)
S8High Flow Switch (SE9, W2)
S9Blower Switch (SE10, W5)
S10Backup Alarm Switch (Rear) (SE11, W8)
S11Backup Alarm Switch (Front) (SE11, W8)
S12Wiper/Washer Switch (SE12, W9)
S13Cab Door Switch (SE5)
V1High Flow Valve Diode (SE9, W1)
W1Engine Harness (with High Flow Option)
W2ROPS Harness (with High Flow Option)
W3Dual Flasher Harness (Optional)
W4Cold Start Wire Harness (Model 250)
W5Cab Heater/Defroster ROPS Harness (Optional)
W6Cab Heater/Defroster Heater Unit Harness
(Optional)
W7Cab Heater/Defroster Engine Harness (Optional)
W8Backup Alarm Harness (Optional)
W9Wiper/Washer Harness (Optional)
X1Engine Harness-to-ROPS Harness Connector
(SE1, SE2, SE3, SE4, SE7, SE9, W1, W2)
X2Engine Harness-to-ROPS Harness Connector
(SE3, SE5, SE6, W1, W2)
X3Auto Preheat Connector (Optional) (SE2, W2)
X4Shutdown Module Connector (SE3, W2)
X5Alternator Resistor Connector (SE5, W1)
X6Instrument Cluster Connector (SE6, W2)
X9Shutdown Module Connector (SE6, W2)
X10Service Plug Connector (SE6, W1)
X11(12-Volt) Accessory Connector (Frame) (SE7,
W1, W7, W8)
X12Accessory Ground Connector (SE8, W2, W3,
W9)
X13(12-Volt) Accessory Connector (ROPS) (SE7,
W2, W3)
X14Dual Flasher Relay Connectors (SE8, W3)
X15Right Front Work Light Connector (SE7, W2)
X16High Flow Valve Diode Connector (SE9, W1)
LEGEND FOR ELECTRICAL COMPONENTS ELECTRICAL
4 - 10 11/22/00
X17Left Front Work Light Connector (SE7, W2)
X18Right Tail Light Connector (SE7, W2)
X19Rear Work Light Connector (SE7, W2)
X20Left Tail Light Connector (SE7, W2)
X21Seat Switch Pigtail Connector (SE4, SE5, W2)
X22Accessory Ground Connector (Frame) (SE7,
W1, W7, W8)
X23Left Hazard Light Connectors (SE8, W3)
X24Right Hazard Light Connectors (SE8, W3)
X25Cab Heater Engine Harness-to-ROPS Harness
Connector (SE10, W5, W7)
X26Cab Heater ROPS Harness-to-Heater Harness
Thermostat Connector (SE10, W5, W6)
X27Cab Heater ROPS Harness-to-Heater Harness
Main Connector (SE10, W5, W6)
X28Cab Heater Engine Harness B+ to Starter (W7)
X29Cab Heater Engine Harness Ground (W7)
X30Cab Heater Unit Harness Blower Ground (W6)
X31Cab Heater Unit Harness Blower Low Speed
Connector (W6)
X32Cab Heater Unit Harness Blower High Speed
Connector (W6)
X33Door Switch Harness Connector (SE5, W9)
X99Interlock Connector (SE4, SE7, W2, W9)
Y1Fuel Shutoff Solenoid (SE3, W1, W4)
Y2Bucket Lock Solenoid (SE5, W1)
Y3Boom Lock Solenoid (SE5, W1)
Y4Park Brake Solenoid (SE5, W1)
Y5High Flow Valve Solenoid (SE9, W1)
Y6Cold Start Advance Solenoid (Model 250) (SE3,
W4)
Y7Cab Heater Temperature Control Valve (SE10,
W6)
ELECTRICAL COMPONENT LOCATION
11/22/00 4 - 11
COMPONENT LOCATION
Ground
B3 Hydraulic Oil Filter
Restriction Switch
Y4 Park Brake
Solenoid
K2 Preheat
Relay
G2 Alternator
M1 Starting
Motor
G1 Battery
Cold Start
Sender
Fuel Injection
Pump
Y1 Fuel Shutoff
Solenoid
B6 Engine Low Oil
Pressure Switch and Pressure Sender
B5 Coolant Over Temperature
Switch and Coolant
Temperature Sender
B2 Hydraulic
Overtemp Switch
Sender
K1 Start
Relay
K3 Fuel
Relay
B4 Fuel Level
Terminal B (-)
G2 Alternator
Terminal B (+)
B1 Air Filter
Restriction Switch
X1 Engine/ROPS Harness
Connector
X2 Engine/ROPS Harness
Connector
Y3 Boom Lock
Solenoid
Y2 Bucket Lock
Solenoid
K4 Accessory
Relay
X17 Left Front Work
X15 Right Front Work
X13 12-Volt
Accessory
X12 Accessory
Ground
X99 Interlock
Connector
X20 Left Tail Light
Connector
X19 Rear Work Light
Connector
X18 Right Tail Light
Connector
X22 Accessory
Ground Connector
X11 12-Volt Accessory
Connector
M2 Fuel Pump
Fuse
Block
KV13044
Light Connector
Light Connector
Connector
Connector
COMPONENT LOCATION ELECTRICAL
4 - 12 11/22/00
COMPONENT LOCATION (CONT)
X22 Accessory
Ground Connector
X11 12-Volt Accessory
Connector
X33 Door Switch
Harness Connector
M4 Wiper Motor
X99 Interlock Connector
X12 Accessory Ground
S12 Wiper/Washer Switch
S9 Blower Switch
R3 Cab Heater Temperature
Control Thermostat
S13 Cab Door Switch
X26 Cab Heater ROPS
Harness-to-Heater
Harness Thermostat
Connector
X27 Cab Heater ROPS
Harness-to-Heater
Harness Main
Connector
Y7 Cab Heater
Temperature Control
Valve
M3 Blower
A1 Heater Control
Circuit Board
H2 Backup Alarm
X29 Cab Heater Ground
F5 Cab Heater Fuse (15A)
K7 Cab Heater Relay
F6 Backup Alarm Fuse (10A)
M5 Washer Pump
S10 Backup Alarm Switch (rear)
X25 Cab Heater Engine
Harness-to-ROPS
Harness Connector
S11 Backup Alarm Switch (front)
Connector
KV31060
ELECTRICAL ELECTRICAL SCHEMATIC
11/22/00 4 - 13
ELECTRICAL SCHEMATIC
MAIN SCHEMATIC
KV31050
Park
SE1 - POWER AND CRANKING CIRCUIT
251 Red
Red
30
709 Pur
S1
250 Red
X1 (A2)
225 Red
F1 Accessories Fuse
5 Amp
15 Amp
25 Amp
231 Red
226 Red
445 Yel
S2
5B
7
B,C
Run
140 Blk
720 Pur
(C1)
550 Yel/Wht
X2
505 Yel
500 Yel/Red
550 Yel/Wht
725 Pur/Wht
SE2 - PREHEAT CIRCUIT
708 Pur
706 Pur
0,1,2
(C1)
(B1)
(A1)
SE3 - FUEL CIRCUIT
87a
F2
F3
Key Switch Fuse
Seat Switch Fuse
225 Red
708 Pur 706 Pur
Key
Switch
3 Start
0 Acc
1 Off
2 Run
Brake
6
4
1
Release
Engage
721 Pur
K1
Start
Relay
X1 (A3)
Fuse Link
220 Red
705 Pur
Fuse Link
M1
Starting
Motor
G1
Battery (12V)
Engine
Ground
87 85
86
700 Pur
112 Blk
200 Red
4
1 2
3
5
560 Yel/Blk
241 Red
B S
R1
200 Red
K2
Preheat
Relay
240 Red
Manifold
Preheater
920
Red/Wht
108
140
141
116 Blk
X1 (C5)
655 Wht
114 Blk
116 Blk
Y1
Fuel
Shutoff
Solenoid
X2 (C4)
930
Gry
930 Gry
931 Gry
130 Blk
(1)
(2)
(3)
(4)
701 Dk Blu
X3
To Auto Preheat
(Optional)
S3
Manual
Preheat
Switch
506 Yel
2B
3
4
7
On Off
504 Yel
720 Pur
725 Pur/Wht
721 Pur
X2 (C1)
501 Yel
508 Yel
X1 (C2)
445 Yel
550 Yel/Wht
226 Red
720 Pur
725 Pur/Wht
708 Pur
706 Pur
231 Red
501 Yel
To Shutdown
Module
X4
X2
(C5)
813 Grn
802 Dk Grn
512 Yel
990
Wht
508 Yel
995
Gry/Blk
813 Grn
995 Gry/Blk
(1)
(2)
(3)
M2
Fuel
Pump
200 Red
30 86
85 87 87a
K3
Fuel
Relay
118 Blk
722 Pur
Switch
5 Amp
F4
Interlock Fuse
515 Yel
502 Yel 502 Yel
503 Yel 503 Yel
372 Red
010 Blk
373 Org
Y6
Cold Start
Advance
Solenoid
(250 Only)
B7
Cold Start
Switch
(250 Only)
(Optional)
001C Red 001C Red
t
M
M
Blk
Blk
Blk
ELECTRICAL SCHEMATIC ELECTRICAL
4 - 14 11/22/00
KV31051
SE6 - GAUGES AND WARNING LIGHTS CIRCUIT SE4 - CHARGING CIRCUIT SE5 - BOOM/BUCKET LOCKOUT AND PARK BRAKE CIRCUIT
X8
(2)
(B2)
(C2)
(A1)
(C1)
(B1)
3
U
445 Yel
550 Yel/Wht
226 Red
720 Pur
725 Pur/Wht
708 Pur
706 Pur
231 Red
722 Pur
X1 (A1)
231 Red
Off
On
2 1
232 Red
Off
On
2 1
S4
Seat
Switch
S5
Seat Belt Switch
810 Dk Grn
802 Dk Grn
G2
Alternator
200 Red B+ D+
B
47 Ohm
X5 (2)
X5 (1)
100 Blk
101 Blk
600 Brn
Y4
Park Brake
Solenoid
715 Pur
713 Pur
711 Pur
741 Pur/Blk
Y2
Bucket
Lock
Solenoid
742 Pur/Blk
740
Pur/Blk
740
Pur/Blk
Y3
Boom Lock
Solenoid
X2 (B5)
800 Pnk
802 Dk Grn
730 Pur/Wht
600 Brn 600 Brn
730
X2 (B4)
X2 (B1)
503 Yel
X7 (H)
X6 (F)
X6 (E)
X7 (D)
X7 (G)
(D)
X8
(F)
X6
(H)
X6
(C)
707 Pur
960 Wht/Blk
970 Wht/Blu
126 Blk
(3)
(4)
(1)
X9
To Shutdown
Module
706 Pur
502 Yel
725 Pur/Wht
452 Yel
725 Pur/Wht
720 Pur
720 Pur
708 Pur
226 Red
226 Red
510 Yel
708 Pur
750
Pur/Blk
(A)
(B)
(C)
(D)
750
Pur/Blk
X6 X6 X6
X2 (C2)
(D) (G) (B)
X10
Service
Plug
452 Yel
445 Yel
550 Yel/Wht
511 Yel
502 Yel
452 Yel
128 Blk
H1
Instrument
Cluster
X8 (C)
X8
(A)
X7
(F)
X8
(B)
X7
(E)
620 Tan 625 Tan/Wht 320 Org
625 Tan/Wht 620 Tan 320 Org
X2
(B2)
X2
(B3)
X2
(A1)
X2
(A2)
300 Org/Wht
300 Org/Wht
X8
(E)
X7
(B)
X7
(C)
X7
(A)
335 Dk Grn 900 Blk/Wht 325 Dk Grn/Wht
335 Dk Grn 325 Dk Grn/Wht
X2
(A4)
X2
(C3)
X2
(A5)
X2
(A3)
345 Pnk
345 Pnk
126 Blk
105 Blk 102 Blk 106 Blk
B2
Hydraulic
Overtemper-
B1
Air Filter
Restriction
Switch
B4
Fuel Level
Sender
B3
Hydraulic
Oil Filter
Restriction
Switch 104 Blk
B5 B6
Engine Overtemperature
Switch and Coolant
Temperature Sender
Engine Low Oil Pressure
Switch and Oil
Pressure Sender
501 Yel
503 Yel
810Grn
813 Grn
991
900 Blk/Wht
X99 (A)
X99 (B)
502 Yel
503 Yel
X21
230
Red
Wht
801 Pnk
X21
R2
Alternator
Resistor
ature Switch
Interlock
001C Red 001C Red
Connector
452 Yel
Off
On S13
Door
Switch
2 1
Without
Door
With Cab Door
Cab
Q P P t t t P P
G
472
Dk Grn
470
Dk Grn
X33
Door Switch
Harness Connector
(A)
(B)
WK G
Pur
ELECTRICAL ELECTRICAL SCHEMATIC
11/22/00 4 - 15
KV31052
K4
511 Yel
(B3)
(C3)
445 Yel
(C2)
(B2)
X13
550 Yel/Wht
511 Yel
502 Yel
86 30
87a 87 85
Accessory
Relay
450 Yel/Wht
X11
451 Yel/Wht 452 Yel
454 Yel
X22
110 Blk
103 Blk
X1 (B2)
X99
451
453
450 Yel/Red
452
Yel
S6
Work Lights
Switch
5B
2B
7
6
103 Blk
473 Brn
Front/Rear Work/Tail Lights
Front Work/Tail Lights
Off A
B
C
A, B, C
475 Brn/Wht
S7
Dual
Flasher
Switch
Back
Light
Indicator
Light
K5
Dual
Flasher
Relay
A Off
C On
A, C
103 Blk
101 Blk
E1
Left
Front
Work
Light
E2
Right
Front
Work
Light
E3
Left
Tail
Light
102 Blk 107 Blk 106 Blk 105 Blk
470 Brn
471 Brn 477 Brn
E4
Right
Tail
Light
E5
Rear
Work
Light
E6
Left
Hazard
Light
E7
Right
Hazard
Light
511 Yel
502 Yel
SE7 - LIGHTS CIRCUIT SE8 - DUAL FLASHER CIRCUIT
3
Yel/Wht
476 Brn
460 Yel/Wht
128 Blk
126
128 Blk
129 Blk
129 Blk
481
482 Yel/Blk
127
12-Volt
Accessory
(Frame)
Accessory
Ground
480
Yel/Red
Blk Blk
X14
X14 X14
124 Blk
X17
X17
X15
X15
X20
X20
X18
X18
X19
X19
X23A X24A
X24B X23B
X12
Yel/Blk
(Frame)
2B
3
455 Yel
003 Yel
000A Blk
455 Yel
003 Yel
000A Blk
101 Blk
001C Red
101 Blk
001C Red
Yel/Wht
460 Yel 460 Yel
(C)
ELECTRICAL SCHEMATIC ELECTRICAL
4 - 16 11/22/00
SE9 - HIGH FLOW CIRCUIT
Back
(C3)
(B3)
142 Blk
812 Grn
511 Yel
502 Yel
A Off
B Run
C On A, B, C
Light
2B
5B
3
7
811 Pnk
811 Pnk
X1
(A4) Indicator
Light
S8
High
Flow
Switch
K6
High
Flow
Relay
86 30
87a 87 85
812 Grn
813 Grn
X1 (A5)
V1
High Flow
814 Grn
815 Grn
Y5
High Flow
Valve Solenoid
109 Blk
119 Blk
117 Blk
X16
M3
Blower
A1
Heater Control
Y7
Cab Heater Temperature
X25
(B)
X27
(D)
X27
(B)
X27
(E)
F5
X25
(A)
X27
(C)
S9
Blower
Switch
R3
K7
000A Blk
000A Blk
003 Yel
003 Yel
000B Blk
001C Red
001C Red
001B Red
001A
Red
001 Red
000B Blk
000A Blk
000B Blk
002 Red
013A Yel
008 Blu
010A Wht
X26
(18)
X26
(17)
X26
(20)
013A Yel
010A Wht
008 Blu
A B C D E F G H
6 5 4 3 2 1
012 Red
013B Yel
011 Org
010B Wht
009 Grn
86
30
87a 87
85
2B
6
7
005 Org
005 Org
004 Yel 004 Yel
3
9
F6
S11
Backup Alarm
Switch (Front)
S10
Backup Alarm
Switch (Rear)
H2
Backup Alarm
455 Yel
455 Yel
101 Blk
450 Yel
457 Yel
458 Yel
A
B
A
B
101 Blk
SE10 - CAB HEATER/DEFROSTER CIRCUIT SE11 - BACKUP ALARM CIRCUIT
A Off
B Low
C High A, B, C
Back
Light
Indicator
Light
KV31053
Off
On
Off
On
460 Yel 460 Yel
Valve Diode
Control Valve
Thermostat
Cab Heater
15 Amp
Cab Heater Fuse
Relay
Heater
Cab
Fuse
Backup
Alarm
(C3)
Circuit Board
3 4 2 1
M
ELECTRICAL ELECTRICAL SCHEMATICS
11/22/00 4 - 17
SE12 - WIPER/WASHER CIRCUIT
Back
Light
111 Blk
M4
Wiper Motor
Indicator
Light
460 Yel
M5
Washer Pump
461
Yel/Wht
466 Yel
466 Yel
461
Yel/Wht
462
Yel
463
Yel/Blk
465 Yel/Red
465 Yel/Red
463 Yel/Blk
2B
1
10
5B
7
6
111
112
101
110
6
5
4
2
B
A
W
M
460 Yel
A Off
B Wiper
C Washer
(C3)
Blk
Blk
Blk
Blk
S12
Wiper/Washer Switch
KV31054
ELECTRICAL SCHEMATICS ELECTRICAL
4 - 18 11/22/00
ELECTRICAL ELECTRICAL WIRE HARNESSES
11/22/00 4 - 19
ELECTRICAL WIRE HARNESSES
ENGINE WIRE HARNESS (W1)
Circuit
Number
Wire
Size
(mm
2
)
Color Termination Points
100 5.0 Blk G2, Ground
101 3.0 Blk G2, Splice 1
102 0.8 Blk B2 (B), Splice 1
103 2.0 Blk X22, Splice 1
104 0.8 Blk B4 (A), Splice 1
105 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
117 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
300 0.8 Org/Wht B5, X2 (A1)
320 0.8 Org B5, X2 (A2)
325 0.8 Dk Grn/Wht B2 (A), X2 (A3)
335 0.8 Dk Grn B3, X2 (A4)
345 0.8 Pink B1 (A), X2 (A5)
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
713 711
722 715
815
812
813
814
101
102
105
106
108
109
110
112
114
116
118
103
104
117
119
742 741
740
512
501
511
510
451
452
454
450
454
705
708 709
Fuse Block
X10
Accessory Start Fuel
Relay Relay Relay
High Flow
Relay
K4 K1 K3 K6
A
B
713
742
B
A
711
741
Plug
Service Plug
A B C D
445 110
Plug
450
550
Plug Plug
Plug
231
445
722
721
709
700
112 220
813
119 511
811 655
114 515
995
226
510 708
750
1 A
B
C 5
1
1
5
5
103
A1 = 300 B1 = 600 C1 = 721
A2 = 320 B2 = 620 C2 = 750
A3 = 325 B3 = 625 C3 = 900
A4 = 335 B4 = 730 C4 = 930
A5 = 345 B5 = 740 C5 = 995
A1 = 231 B1 = Plug C1 = 550
A2 = 225 B2 = 451 C2 = 501
A3 = 705 B3 = Plug C3 = Plug
A4 = 811 B4 = Plug C4 = Plug
A5 = 812 B5 = Plug C5 = 116
1
A
B
C
1
1 5
5
5
A
B
104
900
814 117
118
512
655
620
625
300
320
B A
B A
X2
X1
Harness
Connector
Harness
Connector
V1
High Flow
M2
Fuel Pump
B5
Y1
Fuel
B6
Y3
Boom Lock
Solenoid
Y2
Bucket Lock
Solenoid
B4
Fuel Level
Sender
5 5
2
5
Valve Diode
Shutoff
Solenoid
Low Oil
Pressure Switch
Engine
and Pressure Sender
Engine Over Temperature Switch
and Coolant Temperature Sender
X22
Accessory
X11
12-Volt Accessory
(Frame)
F2 F1 F4
F1 = Accessories Fuse
F2 = Seat Switch Fuse
F3 = Key Switch Fuse
Splice 2
Splice 1
Splice 4
Splice 5
Splice 6
Splice 9
Splice 3
515
225/226
250
F3
Ground
F4 = Interlock Fuse
1
5
X16
High Flow
Valve Diode
Connector
KV18017A
(Optional)
(Frame)
ELECTRICAL WIRE HARNESSES ELECTRICAL
4 - 20 11/22/00
100
X5
Alternator Resistor
Connector
100/101
700
241
251
250
220
240
200
108
930
920
240
200
920
730 715
105 345
102 325
106
335
452
600
A B
Y4
Park Brake Solenoid
M1
G2
Alternator
Terminal B ()
R1
Manifold
G2
Alternator
M1
Starting Motor
Terminal B
K2
Preheat
Relay
Preheat
Relay
Preheat
K2
Ground
Starting Motor
Filter Restriction
Hydraulic Oil
B3
Overtemp
Hydraulic
B2
Restriction
Air Filter
B1
Valve
High Flow
Y5
815 109
(Optional)
A B
Switch
A B
Switch
Switch

Circuit
Number
Wire
Size
mm
2
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)
Splice 8
Splice 7
Terminal S
Terminal B (+)
Preheater
1
2
A B
KV18017B
11/22/00 4 - 21
ROPS WIRE HARNESS (W2)
725
720/721
505 560
140
506
550
701
141
S2
Park Brake
Switch
S3
Preheat
Switch
S1
Key
Switch
S8
High Flow
Switch
X4
X9 X3
Shutdown
Module
Connector
Shutdown
Module
Connector
Auto Preheat Connector
(Optional)
500
225
560 705/706
931
508
802/813
995 960
970
706/707 126
701
930/931
130
504
502 142
812 811
A = Plug X6
B = 750
C = 970
D = 725
E = 802
F = 800
G = 720
H = 960
J = Plug
K = Plug
Instrument
A = 345
B = 335
C = 325
D = 600
E = 300
F = 620
G = 730
H = 740
A = 625
B = 320
C = 128
D = 503
E = 900
F = 707
F
G
H
J
K
E
D
C
B
A
D
C
B
A
E
F
G
H
C
B
A
D
E
F
128
140
141
126
130
142
116
101
124
500
504
505
506
508
501
503
502

Circuit
Number
Wire
Size
(mm
2
)
101 1.0 Blk X17 (B), Splice 2
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
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)
320 0.8 Org X2 (A2), X8 (B)
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)
450 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
471 1.0 Brn X15 (A), Splice 3
473 1.0 Brn S6 (3), Splice 3
475 1.0 Brn/Wht S6 (6), X19 (A)
476 1.0 Brn X18 (A), Splice 3
477 1.0 Brn X20 (A), Splice 3
500 2.0 Yel/Red S1 (2), Splice 1
Manual
Splice 1 Splice 2
990
Cluster
Connector
X7
Instrument
Cluster
Connector
X8
Instrument
Cluster
Connector
(Optional)
470
471
473
476
477
Splice 3
Work
Lights
103 475
473 452
450/452
9
1
2B
3
10
7
4
5B
6
8
Switch Connector
Terminal Numbering
990
990
A
B
102
471
X15
Right Front Work
Light Connector
105
106
107
103
452
S6
Switch
A B
470 101
X17
left Work
Light Connector
KV18018A
4 - 22 11/22/00
S5
Seat Belt
Switch
X21
Seat Switch
810
232/231
232 800
X13
451/
124
12-Volt
X12
Accessory
X99
Interlock Connector

Circuit
Number
Wire
Size
(mm
2
)
501 2.0 Yel X1 (C2), Splice 1
502 0.8 Yel S8 (5B), Splice 1
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
508 0.8 Yel X4 (2), Splice 1
550 0.8 Yel/Wht S1 (4), X1 (C1)
560 0.8 Yel/Blk S1(3), S2 (6)
600 0.8 Brn X2 (B1), X7 (D)
620 0.8 Tan X2 (B2), X7 (F)
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)
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)
930 0.8 Gry X2 (C4), X3 (3)
931 0.8 Gry S3 (3), X3 (3)
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)
A1 = 300 B1 = 600 C1 = 721
A2 = 320 B2 = 620 C2 = 750
A3 = 325 B3 = 625 C3 = 900
A4 = 335 B4 = 730 C4 = 930
A5 = 345 B5 = 740 C5 = 995
A1 = 231 B1 = Plug C1 = 550
A2 = 225 B2 = 451 C2 = 501
A3 = 705 B3 = Plug C3 = Plug
A4 = 811 B4 = Plug C4 = Plug
A5 = 812 B5 = Plug C5 = 116
1
A
B
C
1
1 5
5
5
1 A
B
C 5
1
1
5
5
X1
Engine/ROPS
X2
Engine/ROPS
Accessory
Connector
Ground Connector
810
450/453
813
991
Pigtail
991
991
Connector
S4
Seat
Switch
801
230 230 801
A 476
B 106
A 475
B 105
A 477
B 107
X18
Right Tail Light
X19
Rear Work Light
X20
Left Tail Light
(ROPS)
453
A B
KV18018B
Harness Connector
Harness Connector
(ROPS)
11/22/00 4 - 23
DUAL FLASHER WIRE HARNESS (W3)
460
126
Switch Connector
Terminal Numbering
9
1
2B
3
10
7
4
5B
6
8
126
127
480
481
482
X24B
X24A
128
129
S7
Dual Flasher
Switch
X23A
X23B
X13
12-Volt
Accessory
(ROPS)
X12
Accessory
Ground
(ROPS)
129
482
Right Hazard
Light Connectors
460
480
Left Hazard
Light Connectors
481
127
128
K5
Dual Flasher
Relay
KV18014
4 - 24 11/22/00
COLD START WIRE HARNESS (W4)
B7
Cold Start
Y6
Cold Start Advance
Solenoid
Y1
Fuel Shutoff
Solenoid
372 373
010 372
010 373
KV18533
Switch
(Model 250)
(Model 250)
11/22/00 4 - 25
CAB HEATER/DEFROSTER WIRE HARNESS (W5, W6, W7)
9
1
2B
3
10
7
4
5B
6
8
Switch Connector
Terminal Numbering
KV31055
X25
Harness Connector
X25
Harness Connector
X11
12-Volt
Accessory
(Frame)
Accessory Ground
(Frame)
X22
Cab Heater
Relay
K7
F5
Heater Fuse (15A)
A
B
001A
000A
001C
000A
000B
003
001A
001B
003
000A
001A
A B
S9
Blower Switch
R3
Cab Thermostat
X26
ROPS-to-Heater
Thermostat Connector
X27
ROPS-to-Heater
Main Connector
Heater Valve
Y7
M3
Heater Control
A1
Circuit Board
A
B
C
D
010A
000B
002
013A
008
004
001A
001B
002
005
001C
A B
001B
008 013A
010A
Empty
A
B
C D
E
F
004
005
000B
001B
000A/
Empty
A
B
C D
E
F
001
005
004
000A/
Empty
013A 008
010A
Empty
X26
ROPS-to-Heater
Thermostat Connector
X27
ROPS-to-Heater
Main Connector
A B C D E F G H
2
3
6
5
4
009
013B
010B
Empty
012
011
000B
010A/010B
013A/013B
001
012 011
009
008
000A
004
005
Heater Unit Harness (W6)
ROPS Harness (W5)
Engine Harness (W7)
Empty
1
000B

Circuit
Number
Wire
Size
(mm
2
)
Color
Termination
Points
000A 3.0 Blk X25(B), X27(D)
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)
Engine Harness (W7)

Circuit
Number
Wire
Size
(mm
2
)
Color
Termination
Points
000A 3.0 Blk X27(D), X30
000B 0.8 Blk X27(D), A1(A)
001 1.0 Red X27(E), A1(D)
004 2.0 Yel X27(B), X31
005 3.0 Org X27(C), X32
008 0.8 Blu X26(17), A1(H)
009 0.8 Blu A1(G), Y7(1)

Circuit
Number
Wire
Size
(mm
2
)
Color
Termination
Points
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)

Circuit
Number
Wire
Size
(mm
2
)
Color
Termination
Points
010A 0.8 Wht X26(18), A1(B)
010B 0.8 Wht A1(B), Y7(3)
011 0.8 Org A1(F), Y7(4)
012 0.8 Red A1(E), Y7(6)
013A 0.8 Yel X26(20), A1(C)
013B 0.8 Yel A1(C), Y7(2)
20 17
17 20
X30
X31
X32
X28
X29
Starter B+
Engine Ground
30 85
87 86
87A
Blower
4 - 26 11/22/00
BACKUP ALARM WIRE HARNESS (W8)
KV31080
101
458
457 458
A B
A B
450 457
A
B
456
450
455/456
455
100
100/101

Circuit
Number
Wire
Size
(mm
2
)
Color
Termination
Points
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(+)
X11
12-Volt
Accessory
(Frame)
S10
Backup Alarm
Accessory Ground
(Frame)
X22
F6
Backup Alarm
Fuse
10 amp
S11
Backup Alarm
H2
Backup Alarm
+
Switch (Rear)
Switch (Front)
11/22/00 4 - 27
WIPER/WASHER WIRE HARNESS (W9)
Switch Connector
Terminal Numbering
9
1
2B
3
10
7
4
5B
6
8

Circuit
Number
Wire
Size
(mm
2
)
Color
Termination
Points
100 2.0 Blk X12, X12
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)
Accessory Ground
X12
Interlock
Connector
X99
Door Switch
Harness Connector
X33
Wiper/Washer
S12
Wiper Motor
M4
Washer Pump
M5
Splice 1
112
111
112
110
101
100
100/101
472
470
460
470
472
465
466
461
Blank
110
Blank
463
A B
1 2 3
4 5 6
111
460/466
463
465
462
461/462
KV31081
Switch
TROUBLESHOOTING CHART ELECTRICAL
4 - 28 11/22/00
TROUBLESHOOTING CHART
Problem or
Symptom
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Check or
Solution
See cranking circuit diagnosis
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

ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
11/22/00 4 - 29
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).
Voltage must be present at terminal 1 of the key switch
(S1).
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.
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.
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.
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
4 - 30 11/22/00
11/22/00 4 - 31
POWER AND CRANKING CIRCUIT SCHEMATIC
M
S
445 Yel
250
Red
To Accessory
Relay Contacts
F1
Accessory
Fuse
F2
Seat Switch
Fuse
F3
Key
Switch
Fuse
231 Red
226 Red
To Seat Belt and Seat Switches
To Service Plug
225
Red
X1
(A2)
X1
(A3)
706
Pur
705
Pur
X10 (C)
Service
Plug
0,1,2
705 Pur
1
5
2
3
4
S1
Key Switch
To Accessory
Relay Coil
S2
Park
Brake
Switch
500 Yel/Red
560 Yel/Blk
505 Yel
C
B
A
B,C
7
6
550 Yel/Wht
225 Red
To Preheat
Relay
220 Red
240
Red
709
Pur
708 Pur
K1
Start
Relay
700 Pur
241
Red
Fuse
Link
112
Blk
B
251 Red
Fuse Link
Red
Ground Circuit
Switched Power
Unswitched Power
G1
Battery
M1
Starting
Motor
Accessory
Off
Run
Start
0
1
2
3
5B
140
Blk
30
87
86
85
Engine
Ground
KV15154
Engage
Run
Release
Shutdown
Module Connector
X9
(2) To X8 (F)
on
H1 Instrument
Cluster Cluster
707 Pur
4 - 32 11/22/00
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.
1. Battery positive (+) post. 11.813.2 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.
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.
11/22/00 4 - 33
Test Conditions:
Park Brake Switch in ENGAGE position.
Key switch in RUN position.
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.
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.
If back lighting is not on, test ground circuit wire
140 blk from (S2) park brake Switch to ground.
If Ground circuit is good, replace (S2) park
brake switch.
14. Wire 560 yel/blk at terminal 3 on (S1)
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
Battery voltage. Replace (S2) park brake switch.
4 - 34 11/22/00
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.
16. Wire 705 pur at terminal 5 on
(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)
18. Wire 705 pur at terminal A3 on
connector
(K1) start relay.
Battery voltage. Test wires 709 pur and 705 pur between (X1)
engine/ROPS harness connector and (K1) start
relay.
(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-to-
engine block ground. If starting motor-to-engine
block ground is good, test starting motor.
Repair or replace starting motor as necessary.
11/22/00 4 - 35
POWER AND CRANKING CIRCUIT TEST POINTS
140 Blk
13
14
11
16
10
15
12
18
17
9
8
19
20 3
21
1
2
560 Yel/Blk
500 Yel/Red
505 Yel
705 Pur
225 Red
225 Red
251 Red
116 Blk
705 Pur
709 Pur
700 Pur
112 Blk
Red
100 Blk
220 Red
Fuse Link
250 Red
101 Blk
S2
S1
X1
K1
Park Brake Switch
Key Switch
Engine/ROPS
Harness Connector
Start Relay
M1
Starting Motor
F1
F2
F3
F4
G2
Alternator
KV31061
4
5
6
7
550 Yel/Wht
To Accessory
Relay
4 - 36 11/22/00
FUEL AND PREHEAT CIRCUIT OPERATION
FUEL CIRCUIT
Function:
To energize the fuel shutoff solenoid which allows fuel
flow through the fuel injector pump.
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.
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.
PREHEAT CIRCUIT
Function:
To provide current to the manifold preheater (R1).
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.
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.
11/22/00 4 - 37
FUEL AND PREHEAT CIRCUIT SCHEMATIC
M
Preheat Circuit
Power from Key Switch
Unswitched Power
Ground Circuit
Fuel Shutoff Circuit
Y1
Fuel
Shutoff
Solenoid
K3
Fuel
Relay
M2
Fuel
Pump
To
Starting
Motor
S3
Manual
Preheat
Switch
To Key
Switch
990 Wht
508
Yel
501
Yel
504
Yel
512
Yel
995
Gry/Blk
995
Gry/Blk
114
Blk
655
Wht
K2
Preheat
Relay
108 Blk
118 Blk
130
Blk
920
Red/Wht
R1
Manifold
Preheater
240 Red
241
Red
Fuse
Link
931
Gry
141
Blk
701 Dk Blu
506
Yel
On Off
4
2B
3 7
X3
(1)
(2)
(3)
(4)
Auto
Preheat
(Option)
930
Gry
30 86
85
500
Yel/Red
2
3
X4
X2
(C5)
KV15155
515
Yel
87
4 - 38 11/22/00
FUEL CIRCUIT DIAGNOSIS
Test Conditions:
Key switch in OFF position.
terminal.
Test Conditions:
Key switch in START position.
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.
switch.
key switch.
11/22/00 4 - 39
Test Conditions:
Engine stopped.
9. Wire 500 yel/red at terminal 2
on (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
connector.
(X1) engine/ROPS harness connector and (s1)
key switch.
connector.
(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.
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).
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.
4 - 40 11/22/00
FUEL CIRCUIT TEST POINTS
118 Blk
20
7
9 8
6
15
16
5
10
11
12
13
18
14
17
19
1
2
500 Yel/Red
508 Yel
501 Yel
501 Yel
512 Yel
225 Red
655 Wht
250 Red
995 Gry/Blk
101 Blk
100 Blk
Red
251 Red
Fuse Link
118 Blk
225 Red
990 Wht
515 Yel
995 Gry/Blk
X4
S1
X1
K3
Shutdown Module
Key Switch
Engine/ROPS
Harness Connector
Fuel Relay
M1
Starting Motor
X2
Engine/ROPS
Harness Connector
Y1
Fuel Shutoff
M2
Fuel Pump
Solenoid
G2
Alternator
F1
F2
F3
F4
KV31062
3
4
114 Blk
Connector
11/22/00 4 - 41
PREHEAT CIRCUIT DIAGNOSIS
Test Conditions:
terminal.
Test Conditions:
Key switch in START position.
section.)
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.
necessary.
switch.
harness connector and (s1) key switch.
key switch.
4 - 42 11/22/00
Test Conditions:
Engine stopped.
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:
Manual preheat switch in ON position.
on (S1) key switch.
11. Wire 506 yel at terminal 2B on
(S3) manual preheat switch.
Battery voltage. Manual
preheat switch back
lighting is on.
and (S3) manual preheat switch.
141 blk from (S3) manual preheat switch to
ground. If Ground circuit is good, replace (S3)
manual preheat switch.
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
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
connector.
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.
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.
11/22/00 4 - 43
PREHEAT CIRCUIT TEST POINTS
500 Yel/Red
9 10
8
11
12
6
7
14
15
13
1
2
16
3
17
18
225 Red
116 Blk
506 Yel
931 Gry
130 Blk
930 Gry
141 Blk
920 Red/Wht
240 Red
241 Red
Fuse Link
251 Red
Fuse Link
Red
250 Red
108 Blk
930 Gry
100 Blk
101 Blk
225 Red
116 Blk
S3
S1
X1
R1
Manual Preheat
Key Switch
Engine/ROPS
Harness Connector
Manifold
M1
Starting Motor
X2
Engine/ROPS
Harness Connector
X3
Auto Preheat
K2
Preheat Relay
Connector
G2
Alternator
Switch
Preheater
F1
F2
F3
F4
KV31063
4
5
4 - 44 11/22/00
CHARGING CIRCUIT OPERATION
Function:
To maintain battery voltage at approximately 13.5
14.2 volts (while charging).
The engine must be running for the charging circuit to
charge the battery.
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.
11/22/00 4 - 45
CHARGING CIRCUIT SCHEMATIC
To F3
Key Switch
Fuse
To F1
Accessories
Fuse
0 Accessory
1 Off
2 Run
3 Start
550 Yel/Wht 4
2
3
1
5
225 Red
K4
Accessory
Relay
445 Yel
86 30
87 85
110 Blk
47 Ohm
G
3
U
450 Yel/Wht
451 Yel/Wht
454 Yel
200 Red B+ D+
B -
100 Blk
To Lights
and
Accessories
Unswitched Power
Switched Power
Alternator Exciter Circuit
Battery Charging Circuit
Voltmeter and Battery
Indicator Light Circuit
Ground Circuit
X5 (1)
X5 (2)
To Instrument
Panel
G1
Battery
M1
Starting
Motor
Red
M
B S
0, 1, 2
KV15226
452 Yel
G2
Alternator
R2
Alternator
Resistor
S1
Key Switch
87a
4 - 46 11/22/00
CHARGING CIRCUIT DIAGNOSIS
Test Conditions:
terminal.
Battery must be fully charged.
Test Conditions:
Test meter set to read resistance (ohms).
Test Conditions:
Test Conditions:
section.)
3. Wire 200 red at B+ terminal on (G2)
alternator.
Battery voltage. Test wire 200 red from (M1) starting motor to
(G2) alternator.
4. B terminal on (G2) alternator. Maximum 0.1
ohm.
Test wire 100 blk between (G2) alternator and
ground and battery negative () cable between
(G1) battery and ground.
necessary.
switch.
key switch.
11/22/00 4 - 47
Test Conditions:
Key switch in ACCESSORY position.
Test Conditions:
(X5) Alternator Resistor Connector disconnected.
Test meter set to measure resistance (ohms).
Test Conditions:
Connect (X5) Alternator Resistor Connector.
Alternator belt must not be worn or slipping.
Perform REGULATED AMPERAGE AND VOLTAGE
TEST in this section.
key switch.
12. Wire 550 yel/wht at terminal C1 on
Battery voltage. Test wire 550 yel/wht between (S1) key switch
13. Wire 550 yel/wht at terminal C1 on
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.
accessory relay.
accessory relay to ground. If ground circuit is
good, test (K4) accessory relay. Replace relay
as necessary.
18. Wire 452 yel at (X5) alternator resistor
connector.
Battery voltage. Test wires 452 yel and 450 yel/wht between
(X5) alternator resistor connector and (K4)
accessory relay.
19. (R2) alternator resistor. 47 0.5 ohm. Replace (R2) alternator resistor.
4 - 48 11/22/00
CHARGING CIRCUIT TEST POINTS
225 Red 9
11 10
12
8
13
7
17
14
16
18
19
19
3
4
1
2
550 Yel/Wht
225 Red
550 Yel/Wht
445 Yel
450 Yel/Wht
110 Blk
101 Blk
452 Yel
Red
200 Red
250 Red
251 Red
Fuse Link
Red
600 Brn
To
Discharge
Light
100 Blk
F1
F2
F3
F4
445 Yel
S1
X1
X5
Key Switch
Engine/ROPS
Harness Connector
Alternator Resistor
M1
Starting Motor
K4
Accessory
Relay
G2
Alternator
Connector
KV31064
15
5
6
11/22/00 4 - 49
BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT OPERATION
BOOM AND BUCKET LOCKOUT CIRCUIT
Function:
To disable and enable boom and bucket functions.
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 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.
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.
PARK BRAKE CIRCUIT OPERATION
Function:
To engage and release the park brake.
The operator must first sit on the seat and then fasten
the seat belt in order for the park brake to release.
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.
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).
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).
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 - 50 11/22/00
BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT SCHEMATIC
0,1,2
1 2
3
4
S1
Key Switch
225 Red
F3
Key Switch
Fuse
231 Red
F2
Seat Switch/
A
B,C
7
6
Instrument
Cluster
B
C
4
1
5B
X99
S5
Seat Belt
Switch
S2
Park
Brake
Switch
Y2
Bucket
Lock
Solenoid
Y3
Boom
Lock
Solenoid
Y4
Park Brake
Solenoid
2 1
2 1
500 Yel/Red 505 Yel
721
Pur
140
Blk
128 Blk
725 Pur/Wht
503 Yel
810 Dk Grn
801 Pnk
802
Dk Grn
713 Pur
711 Pur
740 Pur/Blk
730 Pur
742
Pur/Blk
741
Pur/Blk
715
Pur
230 Red
Input to Instrument Panel
from Seat, Seat Belt and
Switched Power
Unswitched Power
Input to Instrument Panel
from Park Brake Switch
Park Brake Solenoid Ground
from Instrument Panel
Boom and Bucket Lock Solenoids
Ground from Instrument Panel
Ground Circuit
Boom and Bucket Lock Solenoids
and Park Brake Solenoid Power
Accessories
Off
Run
Start
0
1
2
3
S4
Seat Switch
5
KV15157
F4
Interlock
Fuse
722
Pur
Engage
Run
Release
X21
Seat Switch
Pigtail
Connector
232
Red
Interlock
Connector
800
Pnk
991
Wht
813
Dk Grn
X4 (1) Shutdown
Module Connector
Without
Cab Door
With
Cab Door
2 1
470
Dk Grn
472
Dk Grn
S13 Cab
Door Switch
Door Switches
On
Off
X33
Door Switch
Harness Connector
Fuse
Seat Belt
X8
(D)
X6
(E)
X6
(F)
X7
(G)
X8
(C)
X6
(D)
X7
(H)
11/22/00 4 - 51
BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT DIAGNOSIS
Test Conditions:
terminal.
Test Conditions:
section.)
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.
switch.
Battery voltage. Test wire 225 red between (S1) key switch and
8. Wire 128 blk at terminal C on (X8)
instrument cluster connector.
Maximum
0.1 Ohm.
Test wire 128 blk from (X8) instrument cluster
connector to ground.
4 - 52 11/22/00
Test Conditions:
Engine stopped and key switch in RUN position.
on (S1) key switch.
Battery voltage. (S2)
park brake switch back
lighting is on.
If battery voltage not present, test wires 500
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
connector.
Battery voltage. Test wire 231 red between (F2) Seat Switch/
seat belt fuse and (X1) engine/ROPS harness
connector.
connector.
Battery voltage. Test connector (X1) Engine/ROPS harness
15. Wire 231 red on (S5) seat belt
switch.
Battery voltage. Test wire 231 red between (S5) seat belt switch
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.
11/22/00 4 - 53
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 Conditions:
Press and hold the park brake switch in the
RELEASE position.
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)
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)
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)
module connector and (X6) instrument cluster
connector.
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)
Battery voltage. Test wire 725 pur/wht between (S2) park brake
switch and (X6) instrument cluster connector.
4 - 54 11/22/00
Test Conditions:
Release the park brake switch to the RUN position.
Test Conditions:
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).
26. Wire 721 pur at terminal 4 on (S2) park
brake switch.
27. Wire 721 pur at terminal C1 on (X2)
Battery voltage. Test wire 721 pur from (S2) park brake switch to
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
29. Wire 721 pur on (F4) interlock fuse. Battery voltage. Test wire 721 pur between (F4) interlock fuse
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.
boom lock solenoid and (F4) interlock fuse.
33. Wire 715 pur on (Y4) park brake
solenoid.
park brake solenoid and (F4) interlock fuse.
34. Wires 741 pur/blk on (Y2) bucket lock
solenoid and 740 pur/blk at terminal H on
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.
35. Wires 742 pur/blk on (Y3) boom lock
solenoid and 740 pur/blk at terminal H on
Maximum
0.1 ohms.
ROPS harness.
36. Wire 730 pur on (Y4) park brake
solenoid and at terminal G on (X7)
Maximum
0.1 ohms.
ROPS harness.
11/22/00 4 - 55
BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT TEST POINTS
KV31065
801 Pnk
9
7
17
16
19
15
26
10
24
11
8
36
34
35
23
25
18
22
31
34
32
35
33
36
2
1
5
28
13
27
14
230
500 Yel/Red
810 Dk Grn
225 Red
503 Yel
505 Yel
725
Pur/Wht
730 Pur
740 Pur/Blk
740 Pur/Blk
741 Pur/Blk
730 Pur
742 Pur/Blk
715 Pur
711 Pur
116 Blk
101 Blk
100 Blk
Red
251 Red
Fuse Link
250 Red
231 Red
225 Red
721 Pur
128 Blk
116 Blk
802
Dk Grn
140 Blk
722 Pur
991 Wht
813
Dk Grn
713 Pur
6
20
21
721
Pur
S1
X1
X6
Key Switch
Engine/ROPS
Harness Connector
Instrument
M1
Starting Motor
G2
Alternator X2
Engine/ROPS
Harness Connector
S4
Seat Switch
S5
Seat Belt Switch
F1
F2
F3
F4
S2
Park Brake Switch
X7
X8
X4
Shutdown Module
Connector
Y2
Bucket Lock
Solenoid
Y3
Boom Lock
Solenoid
Y4
Park Brake
Solenoid
X99
Interlock
H1
Instrument Cluster
3
29
30
12
Connector
472 Dk Grn
470 Dk Grn
470 Dk Grn
X33
Door Switch
Harness
Connector
472 Dk Grn
231 Red
4
S13
Cab
Connectors
Cluster
800 Pnk
Red
232
Red
Door Switch
721 Pur
4 - 56 11/22/00
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
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.
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.
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
104.5C 2.8C (220F 5F). The overtemperature
switch opens when temperature lowers to 87.9C
2.8C (190F 5F).
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 41.4206.8 kPa (630 psi).
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 2933 ohms when
fuel tank is full and 244250 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 4 - 57
Engine Overtemperature The engine
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.
The engine overtemperature switch closes when
coolant temperature rises to 116.2C (241F).
Engine Oil Pressure The low oil pressure switch and
oil pressure sender (B6) is grounded directly to the
engine block. The oil gauge sender portion is
connected to the instrument cluster (H1) using wire 625
tan/wht. The oil pressure sender is a variable resistor
that varies with the engine oil pressure.
Oil Pressure Sender
Pressure/Resistance
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 oil pressure switch closes when pressure
decreases to 80 kPa 30.4 kPa (11.6 psi 4.4 psi)
during normal operating temperature [25C100C
(13F212F)].
Pressure
Resistance
(ohms)
0 kPa (0 psi) 513
200 kPa (29 psi) 4856
400 kPa (58 psi) 8492
600 kPa (87 psi) 119129
4 - 58 11/22/00
11/22/00 4 - 59
GAUGES AND WARNING LIGHTS CIRCUIT SCHEMATIC
F3
Switched Power
Unswitched Power
Seat and Seat Belt
Ground Circuit
Alternator Input Circuit
Sensor Circuit
Park Brake Switch Circuit
Key Switch Fuse
F2
Seat Switch/
15 Amp
231 Red
225 Red
225 Red
X1
(A2)
S1
Key
Switch
S2
Park
Brake
Switch
Off
Off
On
On
1
1
2
2
5 Amp
505 Yel
Release
Engage
Run
B,C
7
8
4
1
5B
0 Acc
1 Off
2 Run
3 Start 0,1,2
500 Yel/Red
140 Blk
4
2
3
1
5
S4
Seat Switch
S5
Seat Belt
Switch
To Alternator
D+ Terminal
Q t t P
P P P t
720 Pur
725 Pur/Wht
X6
(D)
X6
(G)
H1
Instrument
Cluster
X8 (C)
X7
(A)
X7
(C)
X7
(B)
X8
(E)
X7
(E)
X8
(A)
X7
(F)
X8
(B)
X2 X2 X2 X2 X2 X2
(A5) (A3) (A4) (C3) (A1) (B2)
X2 X2
(B3) (A2)
X8
(D)
X6 (F)
X6 (E)
X7 (D)
345 Pnk
345 Pnk
325
Dk Grn/Wht
325
Dk Grn/Wht
335 Dk Grn
335 Dk Grn
900 Blk/Wht
900 Blk/Wht
300
300
625 Tan/Wht
625 Tan/Wht
Org/Wht
Org/Wht
620 Tan
620 Tan
320 Org
320 Org
801 Pnk
102 Blk 106 Blk 104 Blk
813 Dk Grn
802 Dk Grn
600 Brn
230 Red
105 Blk
128 Blk
503 Yel
B1
Air Filter
Restriction
Switch
B2
Hydraulic
Over Temp-
erature
B3
Hydraulic
Oil Filter
Restriction
Switch
B4
Fuel
Level
Sender
B5
Engine Over Temperature
Switch and Coolant
Temperature Sender
B6
Engine Low Oil Pressure
Switch and Oil
Pressure Sender
X8
(F)
X1
(A1)
231 Red
X21
232 Red
810 Dk Grn
X99
991 Wht
802
Dk Grn
706 Pur
706 Pur
X9 (2)
Shutdown Module
Connector
706
Pur
707
Pur
X99
X4 (1)
800 Pnk
X21
Switch
KV31069
Seat Belt Fuse
4 - 60 11/22/00
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:
Meter negative () lead on battery negative () terminal.
Check connections for corrosion and loose terminals when testing.
Test Conditions:
Test Conditions:
1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.
on (S1) key switch.
(X8) instrument cluster connector and (S1) key
switch.
4. Wire 128 blk at terminal C on
Maximum 0.1 ohms. Test wire 128 blk from (X8) instrument cluster
5. Wire 231 red on (F2) seat
switch/seat belt fuse.
Battery voltage. Test (F2) seat switch/seat belt fuse. Replace if
necessary.
If fuse is good, see POWER AND CRANKING
CIRCUIT DIAGNOSIS in this section.
connector.
Battery voltage. Test wire 231 red between (F2) seat switch/seat
belt fuse and (X1) engine/ROPS harness
connector.
connector.
8. Wire 231 red at terminal 2 on
(S5) seat belt switch.
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.
11/22/00 4 - 61
Test Conditions:
Operator sitting in seat with seat belt fastened.
Cab door closed (if equipped).
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
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)
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.
on (X4) shutdown module
connector.
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
4 - 62 11/22/00
SEAT BELT WARNING LIGHT CIRCUIT TEST POINTS
KV31066
232 Red
1
2
8
10
12
15
16
3
4
7
6
500
810
800 Pnk
802
128 Blk
116 Blk
116 Blk
101 Blk
231 Red
100 Blk
813
231 Red
991
Dk Grn
Yel/Red
Dk Grn
Dk Grn
503 Yel
14
11
230 Red
9
801 Pnk
S1
X1
Key Switch
Engine/ROPS
Harness Connector
Instrument Cluster
G2
Alternator
Connectors
X4
Shutdown Module
Connector
H1
Instrument Cluster
X6
X7
X8
S4
Seat Switch
S5
Seat Belt Switch
X99
Interlock
Connector
4
5
Wht
13
472
Grn
472
Grn
470
Grn
470
Grn
X33
Door Switch
Harness Connector
S13
F1
F2
F3
F4
Door Switch
Cab
11/22/00 4 - 63
PARK BRAKE SWITCH AND WARNING LIGHT CIRCUIT DIAGNOSIS
Test Conditions:
terminal.
Test Conditions:
Test Conditions:
Park brake switch in the RUN position.
on (S1) key switch.
switch.
Battery voltage.
Park switch light is on.
Park brake light is on.
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.
4 - 64 11/22/00
Test Conditions:
Operator in seat.
Seat belt fastened.
Hold park brake switch in RELEASE position.
Test Conditions:
Release park brake switch to the RUN position.
6. Wire 725 pur/wht at terminal 1
on (S2) park brake switch.
7. Wire 725 pur/wht at terminal D
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.
Battery voltage. Replace (S2) park brake switch.
9. Wire 720 pur at terminal G on
Battery voltage. If battery voltage is not present, test wire 720
pur between (X6) instrument cluster connector
11/22/00 4 - 65
PARK BRAKE SWITCH AND WARNING LIGHT CIRCUIT TEST POINTS
500 Yel/Red
1
2
3
4
5
7
9
140 Blk
128 Blk
503 Yel
116 Blk
116 Blk
101 Blk
100 Blk
725 Pur/Wht
720 Pur
505 Yel
KV15192
6
8
S1
X1
X6
Key Switch
Engine/ROPS
Harness Connector
Instrument Cluster
G2
Alternator
Connectors
S2
Park Brake Switch
X7
X8
H1
Instrument Cluster
4
4 - 66 11/22/00
AIR FILTER RESTRICTION WARNING LIGHT CIRCUIT DIAGNOSIS
Test Conditions:
terminal.
Test Conditions:
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.
on (S1) key switch.
switch.
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.
6. Air filter restriction warning
light.
Warning light comes on. 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)
If wires are good, replace (H1) instrument
cluster.
11/22/00 4 - 67
AIR FILTER RESTRICTION WARNING LIGHT CIRCUIT TEST POINTS
500 Yel/Red
1
2
503 Yel
3
4
5
6
128 Blk
116 Blk
345 Pnk
345 Pnk
105 Blk 101 Blk
116 Blk
100 Blk
KV15193
S1
X1
X6
Key Switch
Engine/ROPS
Harness Connector
Instrument Cluster
G2
Alternator
Connectors
X7
X8
H1
Instrument Cluster
X2
Engine/ROPS
Harness Connector
B1
Air Filter
Switch
Restriction
4
5
4 - 68 11/22/00
HYDRAULIC OIL OVERTEMPERATURE WARNING LIGHT CIRCUIT
DIAGNOSIS
Test Conditions:
terminal.
Test Conditions:
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.
on (S1) key switch.
switch.
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.
6. Hydraulic overtemperature
warning light.
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.
cluster.
11/22/00 4 - 69
HYDRAULIC OIL OVERTEMPERATURE WARNING LIGHT CIRCUIT TEST
POINTS
500 Yel/Red
503 Yel
6
1
2
3
4
5
128 Blk
116 Blk
116 Blk
101 Blk
100 Blk
325 Dk Grn/Wht
102 Blk
325 Dk Grn/Wht
KV15194
S1
X1
X6
Key Switch
Engine/ROPS
Harness Connector
Instrument Cluster
G2
Alternator
Connectors
X7
X8
H1
Instrument Cluster
B2
Hydraulic Oil
Overtemperature
X2
Engine/ROPS
Harness Connector
5
4
Switch
4 - 70 11/22/00
HYDRAULIC FILTER RESTRICTION WARNING LIGHT CIRCUIT DIAGNOSIS
Test Conditions:
terminal.
Test Conditions:
Test Conditions:
Disconnect 335 dk grn wire from (B3) hydraulic oil
filter restriction switch and connect to wire 106 blk
with jumper wire.
on (S1) key switch.
switch.
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.
6. Hydraulic filter restriction
warning light.
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.
cluster.
11/22/00 4 - 71
HYDRAULIC FILTER RESTRICTION WARNING LIGHT CIRCUIT TEST POINTS
500 Yel/Red
503 Yel
6
1
2
128 Blk
116 Blk
116 Blk
101 Blk
100 Blk
335 Dk Grn
106 Blk
335 Dk Grn
5
3
4
KV15195
S1
X1
X6
Key Switch
Engine/ROPS
Harness Connector
Instrument Cluster
G2
Alternator
Connectors
X7
X8
H1
Instrument Cluster
B3
Hydraulic Oil Filter
Restriction Switch
X2
Engine/ROPS
Harness Connector
5
4
4 - 72 11/22/00
FUEL GAUGE CIRCUIT DIAGNOSIS
Test Conditions:
terminal.
Test Conditions:
Test Conditions:
Test meter set to read resistance (ohms)
Disconnect the wire harness from (B4) Fuel Level
Sender.
on (S1) key switch.
switch.
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)
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.
8. Terminal A to Terminal B of
(B4) fuel level sender.
Between 33240
ohms.
Replace (B4) fuel level sender.
11/22/00 4 - 73
Test Conditions:
Disconnect the wire harness from the fuel level
sender.
Test Conditions:
Disconnect the wire harness from the fuel level
sender.
Install a jumper wire between wire 900 blk/wht and
wire 104 blk.
9. Fuel gauge. Gauge indicates empty. Replace (H1) instrument cluster.
10. Fuel gauge. Gauge indicates full. Replace (H1) instrument cluster.
4 - 74 11/22/00
FUEL GAUGE CIRCUIT TEST POINTS
500 Yel/Red
503 Yel
116 Blk
101 Blk
100 Blk
1
2
10
128 Blk
900 Blk/Wht
3
7
116 Blk
7
6
104 Blk
900 Blk/Wht
5
6
KV15197
S1
X1
X6
Key Switch
Engine/ROPS
Harness Connector
Instrument Cluster
G2
Alternator
Connectors
X7
X8
H1
Instrument Cluster
B4
Fuel Level
Sender
X2
Engine/ROPS
Harness Connector
5
4
8
8
9
4
9
11/22/00 4 - 75
ENGINE OVERTEMPERATURE WARNING LIGHT CIRCUIT DIAGNOSIS
Test Conditions:
terminal.
Test Conditions:
Test Conditions:
Connect wire 300 org/wht from (B5) Engine
sender to ground.
on (S1) key switch.
switch.
5. Engine overtemperature
warning light.
Warning light comes on. 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.
cluster.
4 - 76 11/22/00
ENGINE OVERTEMPERATURE WARNING LIGHT CIRCUIT TEST POINTS
3
4
5
503 Yel
500 Yel/Red
128 Blk
116 Blk
320 Org
300 Org/Wht
300 Org/Wht
320 Org
100 Blk
101 Blk
116 Blk
2
1
KV15196
S1
X1
X6
Key Switch
Engine/ROPS
Harness Connector
Instrument Cluster
G2
Alternator
Connectors
X7
X8
H1
Instrument Cluster
B5
Switch and Coolant
X2
Engine/ROPS
Harness Connector
4
5
Temperature Sender
11/22/00 4 - 77
COOLANT TEMPERATURE GAUGE CIRCUIT DIAGNOSIS
Test Conditions:
terminal.
Test Conditions:
on (S1) key switch.
(X8) Instrument cluster connector and (S1) key
switch.
4 - 78 11/22/00
Test Conditions:
Test Conditions:
Connect wire 320 org from (B5) Engine
sender to ground.
5. Wire 320 org at terminal B on
Battery voltage. Replace (H1) instrument cluster.
6. Wire 320 org at terminal A2 on
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
connector.
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
temperature sender.
9. Engine temperature gauge. Gauge indicates HOT. If gauge does not indicate HOT, replace (H1)
instrument cluster.
If gauge indicates HOT, test (B5) engine
temperature sender. (See ENGINE COOLANT
TEMPERATURE SENDER/SWITCH TEST in
this section.)
11/22/00 4 - 79
COOLANT TEMPERATURE GAUGE CIRCUIT TEST POINTS
3
4
5
6
7
8
9
503 Yel
500 Yel/Red
128 Blk
116 Blk
320 Org
300 Org/Wht
300 Org/Wht
320 Org
100 Blk
101 Blk
116 Blk
2
1
S1
X1
X6
Key Switch
Engine/ROPS
Harness Connector
Instrument Cluster
G2
Alternator
Connectors
X7
X8
H1
Instrument Cluster
X2
Engine/ROPS
Harness Connector
4
9
KV15196
B5
Switch and Coolant
Temperature Sender
4 - 80 11/22/00
ENGINE OIL PRESSURE WARNING LIGHT CIRCUIT DIAGNOSIS
Test Conditions:
terminal.
NOTE: If wire 500 yel/red has not voltage, neither will
instrument cluster or any warning lights.
Test Conditions:
Test Conditions:
Disconnect wire 620 tan from (B6) engine low oil
pressure switch and oil pressure sender.
Test Conditions:
Connect wire 620 tan to ground.
2. Wire 500 yel/red at terminal 2 on
(S1) key switch.
3. Wire 503 yel at terminal D on (X8)
switch.
4. Wire 128 blk at terminal C on (X8)
Instrument cluster connector.
5. Engine oil pressure warning light. Light is not on. Test wire 620 tan between (B6) engine low oil
pressure switch and oil pressure sender and
If wire 620 tan tests good, replace (H1)
instrument cluster.
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.
cluster.
11/22/00 4 - 81
ENGINE OIL PRESSURE WARNING LIGHT CIRCUIT TEST POINTS
1
503 Yel
2
3
4
5
500 Yel/Red
620 Tan
625 Tan/Wht
620 Tan
100 Blk
101 Blk
116 Blk
116 Blk
625 Tan/Wht
128 Blk
S1
X1
X6
Key Switch
Engine/ROPS
Harness Connector
Instrument Cluster
G2
Alternator
Connectors
X7
X8
H1
Instrument Cluster
B6
Engine Low Oil
Pressure Switch
X2
Engine/ROPS
Harness Connector
and Oil Pressure Sender
6
6
5
KV15198
4 - 82 11/22/00
ENGINE OIL PRESSURE GAUGE CIRCUIT DIAGNOSIS
Test Conditions:
terminal.
Test Conditions:
Test Conditions:
DIAGNOSIS.
on (S1) key switch.
switch.
Maximum 0.1 ohm. Test wire 128 blk from (X8) instrument cluster
5. Wire 625 tan/wht at terminal A
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
connector.
Approximately 6 volts. Test (X2) engine/ROPS harness connector.
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.
11/22/00 4 - 83
Test Conditions:
Connect wire 625 tan/wht from (B6) engine low oil
pressure switch and oil pressure sender to ground.
9. Engine oil pressure gauge. Gauge indicates LOW
pressure.
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.
4 - 84 11/22/00
ENGINE OIL PRESSURE GAUGE CIRCUIT TEST POINTS
1
503 Yel
2
3
4
500 Yel/Red
620 Tan
625 Tan/Wht
620 Tan
100 Blk
101 Blk
116 Blk
116 Blk
625 Tan/Wht
128 Blk
9
5
S1
X1
X6
Key Switch
Engine/ROPS
Harness Connector
Instrument Cluster
G2
Alternator
Connectors
X7
X8
H1
Instrument Cluster
X2
Engine/ROPS
Harness Connector
9
8
B6
Engine Low Oil
Pressure Switch
and Oil Pressure Sender
6
7
KV15198
11/22/00 4 - 85
HIGH-FLOW CIRCUIT (OPTIONAL) OPERATION
Replace this page with color page, filename
4L_elec1C.fm, page 1 of 2.
4 - 86 11/22/00
HIGH-FLOW CIRCUIT SCHEMATIC
4L_elec1C.fm, page 2 of 2.
11/22/00 4 - 87
HIGH-FLOW CIRCUIT DIAGNOSIS
Test Conditions:
High flow switch in OFF position.
Disconnect harness from (S8) High Flow Switch.
terminal.
Test Conditions:
Connect harness to (S8) High Flow Switch.
1. Wire 142 blk at harness
connector from (S8) high flow
switch.
Maximum 0.1 ohms. Test ground circuit wire 142 blk from (S8) high
flow switch to ground.
on (S1) key switch.
(S8) high flow switch.
Battery voltage.
High flow switch back
lighting is on.
If voltage is not present, test wires 502 yel and
500 yel/red between (S1) key switch and (S8)
high flow switch.
If voltage is present and back lighting does not
come on, check 142 blk ground.
If good, replace switch.
connector (ROPS side).
Battery voltage. Test wires 500 yel/red and 501 yel between
(S1) key switch and (X1) engine/ROPS harness
connector.
connector (engine side).
terminals.
(K6) high flow relay.
Battery voltage. Test wires 501 yel and 511 yel between (K6)
high flow relay and (X1) engine/ROPS harness
connector.
4 - 88 11/22/00
Test Conditions:
Hold the high flow switch in the ON position.
Test Conditions:
Release the high flow switch to the RUN position.
Battery voltage.
High flow switch
indicator light is on.
Replace (S8) high flow switch.
9. Wire 811 pnk at terminal A4 on
Battery voltage. Test wire 811 pnk between (S8) high flow
switch and (X1) engine/ROPS harness
connector.
10. Wire 811 pnk at terminal A4
terminals.
(K6) high flow relay.
Battery voltage. Test wire 811 pnk between (K6) high flow relay
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
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
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.
Battery voltage. Replace (S8) high flow switch.
17. Wire 815 dk grn at (Y5) high
flow valve solenoid.
Battery voltage.
Valve is energized. (Test
by holding a metal
screwdriver next to it. If
energized, the
screwdriver will be
pulled toward it.)
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.
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 4 - 89
Test Conditions:
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 Conditions:
Reverse the test meter leads.
18. (V1) high flow valve diode. Continuity or no
continuity.
Replace (V1) high flow valve diode.
19. (V1) high flow valve diode. Opposite of step 18. Replace (V1) high flow valve diode.
4 - 90 11/22/00
HIGH FLOW CIRCUIT TEST POINTS
502 Yel
1
2
3
4
5
6
7
16
8
9
10
11
12
13
14
15
17
19
18
500 Yel/Red
811 Pnk 142 Blk
116 Blk
812 Dk Grn
501 Yel
811 Pnk
501 Yel
511 Yel
812 Dk Grn
116 Blk
100 Blk
101 Blk
109 Blk
815 Dk Grn
813 Dk Grn
119 Blk
117 Blk
814 Dk Grn
S1
X1
Key Switch
Engine/ROPS
Harness Connector
G2
Alternator
S8
High Flow Switch
K6
High Flow
Relay
Y5
High Flow
Valve Solenoid
V1
High Flow
Valve Diode
4
KV15188
11/22/00 4 - 91
LIGHTS CIRCUIT OPERATION
4m_elec1C.fm, page 1 of 2.
4 - 92 11/22/00
LIGHTS CIRCUIT SCHEMATIC
4m_elec1C.fm, page 2 of 2.
11/22/00 4 - 93
LIGHTS CIRCUIT DIAGNOSIS
Test Conditions:
Key switch in RUN or ACCESSORY position.
terminal.
Test Conditions:
Key switch in ACCESSORIES position.
key switch.
key switch.
4. Wire 550 yel/wht at terminal C1 on (X1)
engine/ROPS harness connector (ROPS
side).
5. Wire 550 yel/wht at terminal C1 on (X1)
engine/ROPS harness connector (engine
side).
connector and make sure wires are properly
accessory relay.
connector.
7. Terminal 30 on (K4) accessory relay. Battery voltage. Check wire 445 yel to (F1) key switch fuse.
accessory relay.
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
accessory relay.
10. Wire 451 yel/wht at terminal B2 on (X1)
engine/ROPS harness connector (ROPS
side).
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)
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.
Work lights
switch back
lighting is on.
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 wire 452 yel/red between terminals 2B and
5B on (S6) work lights switch.
4 - 94 11/22/00
Test Conditions:
Work lights switch in FRONT WORK/TAIL LIGHT
(middle) position.
Test Conditions:
Work lights switch in FRONT/REAR WORK/TAIL
LIGHTS (up) position.
Test Conditions:
Remove sockets from (E1) left front work light and
(E2) right front work light, then remove bulbs from
sockets.
Work lights switch in FRONT WORK/TAIL LIGHTS
(middle) position.
15. Wire 473 brn at terminal 3 on
(S6) work lights switch.
Battery voltage.
Work lights switch
indicator is on.
Replace (S6) work lights switch.
If indicator light is not on, check ground 103 blk.
16. Wire 473 brn at terminal 3 on
(S6) work lights switch.
Battery voltage.
Work lights switch
indicator is on.
Replace (S6) work lights switch.
17. Wire 475 brn/wht at terminal 6
on (S6) work lights switch.
Battery voltage. Replace (S6) work lights switch.
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.
right front work light and (S6) work lights switch.
11/22/00 4 - 95
Test Conditions:
Work lights switch in OFF (down) position.
Test Conditions:
Replace light bulb and socket previously removed.
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 Conditions:
20. Outer contact of bulb socket
on (E1) left front work light.
Maximum 0.1 ohms. Check for loose or corroded connections
Test wire 101 blk from (E1) left front work light
to ground.
on (E2) right front work light.
est wire 102 blk from (E1) left front work light to
ground.
on (E3) left tail light.
left tail light and (S6) work light switch.
on (E4) right tail light.
right tail light and (S6) work light switch.
on (E3) left tail light.
Test wire 107 blk from (E3) left tail light to
ground.
on (E4) right tail light.
Test wire 106 blk from (E4) right tail light to
ground.
4 - 96 11/22/00
Test Conditions:
Replace light bulbs and sockets previously
removed.
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 Conditions:
on (E5) rear work light.
Test wire 475 brn/wht between (E5) rear work
light and (S6) work lights switch.
on (E5) rear work light.
Test wire 105 blk from (E5) rear work light to
ground.
11/22/00 4 - 97
LIGHT CIRCUIT TEST POINTS
KV18053
103 Blk
1
2
3
4
5
6
7
8
To F1
Accessories
Fuse
9
10
11
14
15 16
17
18 20
Left Front
Work Light
Right Front
Work Light
19 21
22 24
Left Tail
Light
Rear Work
Light
Light
25 23
27 26
452 Yel
473 Brn
107 Blk
477 Brn
105 Blk
475
106 Blk
476 Brn
104 Blk
100 Blk
101 Blk
110 Blk
116 Blk
550 Yel/Wht
450
451 Yel/Wht
550 Yel/Wht
451 Yel/Wht
116 Blk
124 Blk
450 Yel/Red
102 Blk
101 Blk
471 Brn
470 Brn
445 Yel
13
Brn/Wht
103 Blk
453 Yel/Wht
12
Yel/Wht
S1
X1
Key Switch
Engine/ROPS
Harness Connector
G2
Alternator
K4
Accessory
Relay
X99
Interlock
Connector
X13
Accessory 12 Volt
Connector
Right Tail
E5
E3
E4
E2
E1
S6
Work Lights Switch
X12
Accessory
Ground Connector
4 - 98 11/22/00
DUAL FLASHER CIRCUIT (OPTIONAL) OPERATION
DUAL FLASHER (OPTIONAL) CIRCUIT
Function:
To provide flashing lights to warn others of a potential
hazard.
The key switch (S1) must be in the RUN or
ACCESSORY position and the dual flasher switch (S7)
must be in the ON position.
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.
11/22/00 4 - 99
DUAL FLASHER CIRCUIT SCHEMATIC
E7
Right
Hazard
Light
E6
Left
Hazard
Light
Dual Flasher Circuit
Power from Accessory Relay
Ground Circuit
To K4
Accessory Relay
X13
S7
Dual
Flasher
Switch
Back
Light
Indicator
Light
K5
Dual
Flasher
Relay
X12
A - Off
C - On
A,C
124 Blk
451/453 Yel/Wht
3
460
Yel/Wht
480
Yel/Red
126 Blk
127
Blk
128
Blk
481
Yel/Blk
482
Yel/Blk
129 Blk
2B
KV31068
4 - 100 11/22/00
DUAL FLASHER CIRCUIT DIAGNOSIS
Test Conditions:
terminal.
Test Conditions:
2. Wire 550 yel/wht at terminal 4
on (S1) key switch.
on (S1) key switch.
4. Wire 550 yel/wht at terminal C1
5. Wire 550 yel/wht at terminal C1
terminals.
on (K4) accessory relay.
connector.
(K4) accessory relay.
Battery voltage. Test wire 445 yel between (K4) accessory relay
and (F1) accessories fuse. Check fuse.
on (K4) accessory relay.
good, replace relay.
9. Wire 451 yel/wht at terminal B2
Battery voltage. Test wires 451 yel/wht and 450 yel/wht between
accessory relay.
10. Wire 451 yel/wht at terminal
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.
11/22/00 4 - 101
Test Conditions:
Key switch in ACCESSORY position
Dual flasher switch in ON position.
Test Conditions:
Remove sockets from (E6) left hazard light and (E7)
right hazard light, then remove bulbs from sockets.
Dual flasher switch in ON position.
2B on (S7) dual flasher switch.
Battery voltage.
Dual flasher switch back
lighting is on.
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.
on (S7) dual flasher switch.
Battery voltage.
Dual flash switch
indicator light is on.
Replace (S7) dual flasher switch.
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.
on (E6) left hazard light.
ON and OFF.
Check for loose or corroded connections
Test wire 481 yel/blk between (K5) dual flasher
relay and (E6) left hazard light.
on (E7) right hazard light.
ON and OFF.
Check for loose or corroded connections
Test wire 482 yel/blk between (K5) dual flasher
relay and (E7) right hazard light.
4 - 102 11/22/00
Test Conditions:
Dual flasher switch in OFF position.
on (E6) left hazard light.
Test wire 127 blk from (E6) left hazard light to
ground.
on (E7) right hazard light.
Test wire 129 blk from (E7) right hazard light to
ground.
11/22/00 4 - 103
DUAL FLASHER CIRCUIT TEST POINTS
KV18054
128 Blk
1
2
3
4
5
6
7
8
10
11
550 Yel/Wht
453
451
116 Blk
451 Yel/Wht
116 Blk
450 Yel/Wht
445 Yel
110 Blk
101 Blk
100 Blk
From F1
Accessories
Fuse
12
9
Yel/Wht
Yel/Wht
550 Yel/Wht
To
18
17
16
15
13
14
124 Blk
127 Blk
460 Yel/Wht
129 Blk
482
480 Yel/Red
126
Blk
128 Blk
Yel/Blk
481
Yel/Blk
126 Blk
124 Blk
X99
20
19
S1
X1
Key Switch
Engine/ROPS
Harness Connector
G2
Alternator
K4
Accessory
Relay
X13
S7
Dual Flasher Switch
K5
Dual Flasher
Relay
E6
Left Hazard
Light
E7
Right Hazard
Light
Connector
Accessory
12-Volt
4 - 104 11/22/00
CAB HEATER/DEFROSTER CIRCUIT (OPTIONAL) OPERATION
Function:
To heat cab air for operator comfort.
ACCESSORY position and the thermostat must be set
to a warm setting. The blower switch must be set to
LOW or HIGH speed.
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
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.
11/22/00 4 - 105
CAB HEATER/DEFROSTER CIRCUIT SCHEMATIC
M
Heater Main Power
Thermostat Circuit
Control Circuit
Blower Circuit
Ground Circuit
M3
Blower
A1
Heater Control
Y7
Cab Heater
X25
(B)
X27
(D)
X27
(B)
X27
(E)
F5
Cab
X25
(A)
X27
(C)
S9
Blower
Switch
R3
K7
Cab Heater
Relay
000A Blk
003 Yel
000B Blk
001C Red
001B Red
001A
Red
001 Red
000B Blk
000A Blk
000B Blk
002 Red
013A Yel
008 Blu
010A Wht
X26
(18)
X26
(17)
X26
(20)
013A Yel
010A Wht
008 Blu
A B C D E F G H
6 5 4 3 2 1
012 Red
013B Yel
011 Org
010B Wht
009 Grn
86
30
87a
87
85
2B
6
7
005 Org
005 Org
004 Yel 004 Yel
3
9
A Off
B Low
C High A, B, C
Back
Light
Indicator
Light
454 Yel
To K4 Accessory Relay
To Accessory Ground
Cab
Heater Thermostat
Temperature Control Valve
Heater
Fuse
Circuit Board
KV31084
From Battery Terminal of Starting Motor
001C Red 001C Red
4 - 106 11/22/00
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.
terminal.
Test Conditions:
Blower switch in HIGH position.
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.
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.
11/22/00 4 - 107
Test Conditions:
Blower switch in LOW position.
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 Conditions:
Negative () test lead at wire 010A wht on (R3) cab
heater thermostat.
(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.
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.
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
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
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.
4 - 108 11/22/00
Test Conditions:
Negative () test lead at terminal B (wht) on (A1)
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 Conditions:
Negative () test lead at terminal A (blk) on (A1)
17. Wire 008 blu at terminal H on
Same reading as step 16. Test wire 008 blu from (R3) cab heater
thermostat to (A1) heater control circuit board.
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
reaches position, then to
0 V (approx).
Go to step 24.
22. Wire 009 grn at terminal 1 on
(Y7) cab heater temperature
control valve. Rotate (R3) cab
heater thermostat to COLDEST
setting.
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.
increase to 8 V (approx).
Listen for (Y7) cab heater
motor running.
Replace (Y7) cab heater temperature control
valve.
KV31058
11/22/00 4 - 109
Test Conditions:
Failure of steps 20 or 21.
Jumper wire connected to 009 grn at terminal G on
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
Repeat steps 1823 after repair.
4 - 110 11/22/00
CAB HEATER/DEFROSTER CIRCUIT TEST POINTS
1
000A Blk
R3
M1
Starting Motor
F5
Cab Heater Fuse
15 A
K7
X25
X26
Cab Heater ROPS
Harness-to-Heater
Harness Thermostat
Connector
X27
Cab Heater ROPS
Harness-to-Heater
Harness Main
Connector
S9
Blower Switch
M3
Blower
A1
Heater Control
Circuit Board
Y7
From K4
Accessory Relay
4
2
3
5
6
9
7
16
15
14
17 11 12
24
13
A
1
2
3
6
5
4
B
C
D
E
F
G
H
23
22
20 21 18 19
8
001B Red
001C Red
003 Yel
000B Blk
001A Red
B
A
C
F
E
D
004 Yel
005 Org
001A Red
000A Blk
000B Blk
001A Red
002 Red
013A Yel
008 Blu
010A Wht
008 Blu
000B Blk
010B Wht
013A Yel
013B Yel
001 Red
010A Wht
012 Red
011 Org
009 Grn
000A Blk
004 Yel
005 Org
10
B
A
Control Valve
Temperature
Cab Heater
Cab
Thermostat
Harness Connector
Harness-to-ROPS
Cab Heater Engine
Heater Relay
Cab
KV31046
11/22/00 4 - 111
BACKUP ALARM CIRCUIT (OPTIONAL) OPERATION
Function:
To provide an audible warning when the machine is
operating in reverse.
ACCESSORY position and both steering control levers
must be in reverse.
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.
4 - 112 11/22/00
BACKUP ALARM CIRCUIT SCHEMATIC (OPTIONAL)
Switched Power
Ground Circuit
KV31057
X11
X22
12-Volt
Accessory
(Frame)
Accessory
Ground Connector (Frame)
F6
S11
Switch (Front)
S10
Backup Alarm
Backup Alarm
Switch (Rear)
H2
Backup Alarm
101 Blk
454 Yel 455 Yel
450 Yel
101 Blk 103 Blk
457 Yel
458 Yel
10 Amp
Backup
Alarm Fuse
11/22/00 4 - 113
BACKUP ALARM CIRCUIT DIAGNOSIS
Test Conditions:
Key switch in ACC position.
terminal.
Test Conditions:
Depress plunger on (S10) backup alarm switch
(rear).
Test Conditions:
Depress plunger on (S11) backup alarm switch
(front) and on (S10) backup alarm switch (rear).
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).
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).
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.
4 - 114 11/22/00
BACKUP ALARM CIRCUIT TEST POINTS
G2 Alternator
110 Blk
1
2
3
4
5
6
7
X11
K4
Relay
Accessory
12 V Connector
Accessory
F6
Backup Alarm Fuse
S10
Backup Alarm
S11
Backup Alarm
H2
Backup Alarm
X22
Ground Connector
Accessory
101 Blk
100 Blk
116 Blk
450
Yel/Wht
From F1
Key Switch
From S1
Accessories Fuse
455
Yel
454
Yel
450
Yel
457
Yel
458
Yel
101 Blk
Switch (Front)
Switch (Rear)
11/22/00 4 - 115
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.
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.
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.
4 - 116 11/22/00
WIPER/WASHER CIRCUIT SCHEMATIC
KV31057
W
M
Back
Light
111 Blk
M4
Wiper Motor
Indicator
Light
460 Yel
M5
Washer Pump
461
Yel/Wht
466 Yel
466 Yel
461
Yel/Wht
462
Yel
463
Yel/Blk
465 Yel/Red
465 Yel/Red
463 Yel/Blk
2B
1
10
5B
7
6
111
112
101
110
6
5
4
2
B
A
A Off
B Wiper
C Washer
101 Blk
Switched Power
Park Circuit
Washer Circuit
Ground Circuit
S12
Wiper/Washer
Swith
From K4
AccessoryRelay
To X12
Accessory
Ground Connector
Blk
Blk
Blk
Blk
11/22/00 4 - 117
WIPER/WASHER CIRCUIT DIAGNOSIS
Test Conditions:
Key switch in ON or ACC position.
Meter negative () lead on battery negative (-)
terminal.
Test Conditions:
Turn (S12) wiper/washer switch (12) to WIPER
(center) position.
1. Wire 460 yel at terminal C on
(X99) interlock connector.
Battery voltage. Check accessory relay circuit to
(X99) interlock connector.
(S12) wiper/washer switch.
Battery voltage. Test wire 460 yel.
(M4) wiper motor.
Battery voltage. Test wire 466 yel from (S12) wiper/
washer switch to (M4) wiper motor.
2B on (S12) wiper/washer switch.
Battery voltage. Replace (S12) wiper/washer switch.
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.
4 - 118 11/22/00
Test Conditions:
Turn (S12) wiper/washer switch to the WASHER
(top) position.
Test Conditions:
Turn (S12) wiper/washer switch to the OFF
position.
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.
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.
on (S12) wiper/washer switch.
Test wire 465 yel/red between (M4)
wiper motor and (S12) wiper/
washer switch. If good, go to step
10.
2B on (S12) wiper/washer switch.
If no voltage is present, replace
(S12) wiper/washer switch.
11/22/00 4 - 119
WIPER/WASHER CIRCUIT TEST POINTS
101 Blk
From K4
Accessory Relay
2
1
6
9
4 10
5
3
8
7
X12
Accessory Ground
M5
Washer
Pump
X99
Interlock Connector
X33
Door Switch
Harness Connector
S12
Wiper/Washer
Switch
M4
Wiper Motor
460 Yel
472 Dk Grn
470 Dk Grn
112 Blk
463
463
465 Yel/Red
461 Yel/Wht
466 Yel
110 Blk
111 Blk
465 Yel/Red
461 Yel/Wht
466 Yel
466 Yel
Yel/Blk
Connector
Yel/Blk
TESTS AND ADJUSTMENTS ELECTRICAL
4 - 120 11/22/00
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.
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.
M49596
ELECTRICAL TESTS AND ADJUSTMENTS
11/22/00 4 - 121
CHARGE BATTERY
Reason:
To increase battery charge after battery has been
discharged.
Equipment:
Battery charger (variable rate) (use according to
manufacturers instructions).
Procedure:
NOTE: See BATTERY TEST in this section before
charging battery.
4. Open engine rear cover and REMOVE left engine
side panel.
5. Disconnect negative () and positive (+) battery
cable clamps. Remove battery hold-down clamp.
8. Connect variable rate charger to battery.
NOTE: Maximum charge time at boost is 10 minutes.
Allow additional 5 minutes for each 10F
(5.5C) below 70F (21C).
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.
10. Check if battery is accepting a 10 amp charge after
10 minutes at boost setting:
Results:
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 1525 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 1015 amps for 612 hours. If
battery was discharged at fast rate, charge at
2025 amps for 24 hours.
13. Continue to charge battery until specific gravity is
1.2301.265 points.
14. Load test battery. (See BATTERY LOAD TEST, in
this section.)
15. Install battery.
cover.
M49598
4 - 122 11/22/00
BATTERY LOAD TEST
Reason:
To check condition of battery under load.
Equipment:
JT05685 Battery Tester (use according to
manufacturers instructions).
Procedure:
4. OPEN engine rear cover and REMOVE left engine
side panel.
5. Disconnect negative () and positive (+) battery
cable clamps. Remove battery hold-down clamp.
IMPORTANT: Turn load knob on battery tester fully
out (counterclockwise) BEFORE making any
test connections.
8. Connect tester positive cable (red) to battery
positive (+) terminal (B).
9. Connect tester negative cable (black) to battery
negative () terminal (C).
IMPORTANT: Perform this test quickly to prevent
damage to battery tester. DO NOT apply full load
to battery for more than 510 seconds
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).
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.
cover.
M49597
A. Load Knob
B. Battery Positive (+)
Terminal
C. Battery Negative
() Terminal
D. DC Amps Scale
E. DC Volts Scale
11/22/00 4 - 123
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 . . . . . 13.514.2 VDC @ full rpm
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.
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.
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.
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.)
cover.
4 - 124 11/22/00
STARTING MOTOR LOADED AMPERAGE DRAW TEST
Reason:
To determine the amperage required to crank the
engine and check starting motor operation under load.
Equipment:
JT05685 Load Tester
JT05719 Tachometer
Specification:
Starting Motor Loaded (on Vehicle)
Draw/Voltage. . . . . . . . . . . . . . . . . 350 amps (max)
8.5 volts (min) @ 0C (32F)
IMPORTANT: Turn load knob fully counter-
clockwise before making connections.
NOTE: Engine should be at normal operating
temperature when performing this test.
Procedure:
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.
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.
KV15226
c
CAUTION
Disconnect fuel shutoff solenoid wiring to
prevent engine from starting.
11/22/00 4 - 125
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
Specification:
Starting Motor No-Load (Free-spinning)
Draw . . . . . . . . . . . . . . 90 amp (max) at 3,500 rpm
Procedure:
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.
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.
Results:
If starting motor amps or rpm are not to
specification, repair or replace starter.
cover.
4 - 126 1/3/01
STARTING MOTOR SOLENOID TEST
Reason:
To determine if starting motor solenoid is defective.
Equipment:
Two jumper wires
12-volt battery
Procedure:
and engage the boom lock.
3. Turn key to OFF position and engage park brake.
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.)
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.
11. Disconnect one of the jumper wires.
Results:
The solenoid drive gear should move back.
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.
cover.

CD30452A
A
B
C
c
CAUTION
Ensure all power is disconnected from starting
motor. Drive gear could move suddenly, causing
injury.
11/22/00 4 - 127
AIR FILTER RESTRICTION SWITCH
TEST
Reason:
To determine if air filter restriction switch is detecting air
flow resistance through air filter.
Procedure:
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.
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.
ENGINE COOLANT TEMPERATURE
SENDER/SWITCH TEST
Reason:
To check operation of coolant temperature sender/
overheat switch.
Equipment:
JT05791 Digital Multimeter
Procedure:
ENGAGE park brake.
2. Open engine rear cover.
3. Disconnect wiring connectors (A) from coolant
temperature switch and sender assembly.
4. Check for continuity between both spade
connectors on sender.
Results:
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:
2.21K2.69K ohms @ 20C (68F)
1.65K5.88K ohms @ 030C (3286F)
Results:
Replace coolant temperature sender if readings are
incorrect.
6. Check for continuity between sender small (org/wht)
spade terminal and engine block.
c
CAUTION
Exhaust system can be hot. Avoid the hazard of
serious injury from burns.
KV15246
KV15200
A
4 - 128 11/22/00
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.
NOTE: Do not submerge wire harness connector end
of sender in oil. Submerge only to the bottom
of the hexagon of the sender.
9. Submerge in oil. Heat oil and monitor meter
reading. Meter should show continuity at 116C
(241F).
Results:
Replace engine coolant temperature sender/switch
if results vary.
COLD WEATHER START SWITCH
TEST (MODEL 250 ONLY)
Reason:
To check operation of cold start switch.
Equipment:
Procedure:
4. Open engine rear cover and remove right engine
side panels.
5. Disconnect wire harness connector (A) and remove
cold weather start switch (B) from thermostat
housing.
of switch in water. Submerge only the switch.
6. Submerge switch in water at 60C (140F) 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 Nm (42 lb-in.).
9. Connect cold weather start switch wire connector.
KV15201
A
B
11/22/00 4 - 129
ENGINE OIL PRESSURE SWITCH/
SENDER TEST
Reason:
To check operation of engine oil pressure switch.
Equipment:
Procedure:
4. Open engine rear cover and remove right engine
side panels.
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 513 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.
Results:
Replace oil pressure switch if resistance readings
are incorrect.
MANIFOLD PREHEATER TEST
Reason:
To check operation of engine manifold pre-heater.
Equipment:
Procedure:
panel.
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 0.701.65 ohms
Results:
Replace manifold pre-heater if reading is incorrect.
8. Install pre-heater and tighten to 60 Nm (44 lb-ft).
9. Connect wire lead and install washer and nut.
10. Connect battery.
KV15211
A
B
C
KV15202
A
B
C
4 - 130 11/22/00
MANIFOLD PREHEATER RELAY
TEST
Reason:
To check operation of manifold pre-heater relay.
Equipment:
Procedure:
ENGAGE park brake.
2. Raise ROPS and secure safely
NOTE: Tag or label wiring leads on relay to aid during
installation.
4. Disconnect wiring leads (A and B) from relay (D).
Tag or label wiring leads to aid during installation.
5. Remove two cap screws and washers (C) and
remove manifold pre-heater relay (D).
6. Check for continuity between the two small
terminals (E).
7. Check for no continuity between the two large
terminals (F).
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 pre-
heater relay.
9. Connect leads, cap screws, and washers.
11. Lower ROPS. Tighten ROPS retaining nuts to
105 Nm (77 lb-ft).
KV15203
B
A
C
C
D
KV15247
F
E
11/22/00 4 - 131
KEY SWITCH TEST
Reason:
To check operation of ignition key switch.
Equipment:
Procedure:
2. Remove key switch from control panel.
3. Use multimeter to check continuity between switch
terminals (AE) in the ACCESSORY, OFF, RUN
and START positions.
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.
PARK BRAKE SWITCH TEST
Reason:
To check operation of park brake switch.
Equipment:
Procedure:
2. Remove park brake switch from control panel.
terminals in the positions as shown in the table.
Results:
If continuity is not correct, replace park brake
switch.
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
KV15248
A
B
C
D
E
PARK BRAKE SWITCH CONTINUITY
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
KV15248
6
5B
4
3 2B
1
9
7
4 - 132 11/22/00
PRE-HEATER SWITCH TEST
Reason:
To check operation of cold start switch.
Equipment:
Procedure:
2. Remove cold start switch from control panel.
Results:
If continuity is not correct, replace pre-heater
switch.
LIGHT SWITCH TEST
Reason:
To check operation of light switch.
Equipment:
Procedure:
2. Remove light switch from control panel.
Results:
If continuity is not correct, replace light switch.
COLD START SWITCH CONTINUITY
Switch Position
Continuity (<1 ohm)
Between Terminals
Off 9, 2B
Momentary 9, 2B, 3
All positions 9, 2B, 7
KV1550
9
2B
7
3
LIGHT SWITCH CONTINUITY
Switch Position
Continuity (<1 ohm)
Between Terminals
Off 2B, 1, 9and 5B, 4
Front Work/Tail Lights 2B, 3, 9and 5B, 4
Front/Rear Work/Tail
Lights
2B, 3, 9and 5B, 6
All positions 7, 8 and 9, 2B
6
5B
4
3
2B
1
9
8
7
11/22/00 4 - 133
CAB DOOR SWITCH TEST
Reason:
To check operation of cab door switch.
Equipment:
Procedure:
2. Remove cab door switch from machine.
Results:
If continuity is not correct, replace switch.
DUAL FLASHER SWITCH TEST
Reason:
To check operation of dual flasher switch.
Equipment:
Procedure:
2. Remove dual flasher switch from control panel.
Results:
CAB DOOR SWITCH CONTINUITY
FRONT MOUNTED VERSION
Plunger Position
Continuity (<1 ohm)
Between Terminals
Out NO
In YES
CAB DOOR SWITCH CONTINUITY
REAR MOUNTED VERSION
Plunger Position
Continuity Between
Terminals
Out YES
In NO
KV31131
Plunger
DUAL FLASHER SWITCH CONTINUITY
Switch Position
Continuity (<1 ohm)
Between Terminals
Off 7, 8 and 9, 2B
On 2B, 3, 9 and 7, 8
All positions 7, 8 and 9, 2B
KV31132
3
2B
9
8
7
4 - 134 11/22/00
HIGH-FLOW SWITCH TEST
Reason:
To check operation of high-flow switch.
Equipment:
Procedure:
2. Remove high-flow switch from control panel.
Results:
BLOWER SWITCH TEST
Reason:
To check operation of blower switch.
Equipment:
Procedure:
2. Remove blower switch from control panel.
Results:
HIGH-FLOW SWITCH CONTINUITY
Switch Position
Continuity (<1 ohm)
Between Terminals
Off 2B, 1 and 5B, 4, 9
On 2B, 3, 6and 5B, 4, 9
Momentary 2B, 3, 5B, 6, 9
All positions 7, 8 and 5B, 9 and 3, 6
KV31133
6
5B
4
3
2B
1
9
8
7
BLOWER SWITCH CONTINUITY
Switch Position
Continuity (<1 ohm)
Between Terminals
Off 5B, 4, 2B, 1, 9
Low 2B, 3, 5B, 4, 9
High 5B, 6, 2B, 3, 9
All positions 9, 2B, 5B
KV31134
6
5B 4
3
2B
1
9
8
7
11/22/00 4 - 135
WIPER/WASHER SWITCH TEST
Reason:
To check operation of wiper/washer switch.
Equipment:
Procedure:
2. Remove wiper/washer switch from control panel.
Results:
FUEL LEVEL SENDER TEST
Reason:
To determine if fuel level sender is changing resistance
as float is raised and lowered.
Equipment:
Procedure:
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).
4. Remove five screws (C), fuel level sender (D) and
gasket (E). Use care not to tear gasket.
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
KV31135
6
5B
4
3
2B
1
9
8
7
10
KV15212
A
B
KV15213
C
D
E
4 - 136 11/22/00
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.
Results:
The resistance of the fuel level sender is as follows:
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
Nm (77 lb-ft).
SEAT SAFETY SWITCH TEST
Reason:
To check operation of seat switch.
Equipment:
Procedure:
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:
FUEL LEVEL SENDER
Tank Fuel Level
Resistance
(Ohms)
Full 30.0 3
1/2 89.3 3
Empty 248.2 3
KV15252
SEAT SAFETY SWITCH CONTINUITY
Switch Position
Continuity Between
Terminals
Released No
Depressed Yes
KV15253
A
B
11/22/00 4 - 137
SEAT BELT SWITCH TEST
Reason:
To check operation of seat belt switch.
Equipment:
Procedure:
1. Remove seat belt latch from skid steer and
disconnect wiring connector.
2. Check continuity between terminals (A) and (B).
Results:
HYDRAULIC OIL
OVERTEMPERATURE SWITCH TEST
Reason:
To check operation of hydraulic oil overtemperature
switch.
Equipment:
Procedure:
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).
1. Drain hydraulic oil from reservoir.
2. Disconnect wiring connector (B) and remove switch
(A).
of switch in oil. Submerge only to the bottom of
the hexagon of the switch.
3. Submerge switch in 108C (226F) oil for a few
minutes.
4. Remove from oil and check for continuity across
connector terminals.
Results:
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.
SEAT BELT SWITCH CONTINUITY
Switch Position
Continuity Between
Terminals
Unlatched No
Latched Yes
KV15255
A
B
Latched
Unlatched
KV15219
A
B
4 - 138 11/22/00
6. Install hydraulic oil overtemperature switch and
connect wiring connector.
NOTE: Make sure hydraulic reservoir drain plug is
installed.
7. Fill reservoir with proper hydraulic oil. Check level.
PARK BRAKE SOLENOID TEST
Reason:
To check operation of park brake solenoid.
Equipment:
Two jumper wires
Procedure:
panel.
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.
BOOM LOCKOUT SOLENOID TEST
Reason:
To check operation of boom lockout solenoid.
Equipment:
Two jumper wires
Procedure:
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
6. Separate connector (A).
boom lockout solenoid connector and ground.
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
Nm (77 lb-ft).
KV15220
A
B
KV31136
A
11/22/00 4 - 139
BUCKET LOCKOUT SOLENOID
TEST
Reason:
To check operation of park brake solenoid.
Equipment:
Two jumper wires
Procedure:
6. Separate connector (A).
bucket lockout solenoid connector and ground.
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.
Nm (77 lb-ft).
HYDRAULIC OIL FILTER
RESTRICTION SWITCH TEST
Reason:
To check operation of hydraulic oil filter restriction
switch.
Equipment:
(set to read continuity)
Procedure:
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).
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 41.4206.8 kPa
(630 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.
Nm (77 lb-ft).
KV31137
A
KV15221
B
C
A
COMPONENT REPLACEMENT ELECTRICAL
4 - 140 11/22/00
COMPONENT REPLACEMENT
AIR FILTER RESTRICTION SWITCH
Replace:
1. Park machine on a level surface. Turn key to OFF
position and ENGAGE park brake.
4. Access air filter restriction switch (B).
5. Disconnect wiring connector (A) and remove switch
(B), located behind air cleaner.
switch before installation.
7. Install air filter restriction switch (B).
8. Connect wiring connector (A).
Nm (77 lb-ft).
COOLANT TEMPERATURE
SENDER/SWITCH
Replace:
4. Disconnect wiring connectors (A) and remove
temperature sender (B), located on top of engine
block.
sender before installation.
6. Install coolant temperature sender (B) and connect
wiring connectors (A).
Nm (77 lb-ft).
COLD WEATHER START SWITCH
(MODEL 250 ONLY)
Replace:
2. Open engine rear cover. Remove right engine side
panel.
4. Disconnect wiring connector (A) and remove cold
weather start switch (B) located on side of
thermostat housing.
A
KV15199
B
KV15200
A
B
KV15201
A
B
ELECTRICAL COMPONENT REPLACEMENT
11/22/00 4 - 141
6. Install cold weather start switch (B) and tighten to 5
Nm (42 lb-in.).
8. Connect wiring connector (A) and install engine
side panel.
ENGINE OIL PRESSURE SWITCH/
SENDER
Replace:
2. Open rear engine cover and remove right engine
side panel.
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
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.
7. Install engine side panel and close engine rear
cover.
MANIFOLD PREHEATER
Replace:
4. Remove nut and lock washer (A).
5. Remove wire lead (B) and remove manifold pre-
heater (C).
6. Install manifold pre-heater (C). Tighten to
60 Nm (44 lb-ft). Connect wire lead (B) and
install lock washer and nut (A).
Nm (77 lb-ft).
KV15211
A
B
C
KV15202
A
B
C
4 - 142 11/22/00
MANIFOLD PREHEAT RELAY
Replace:
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).
9. lower ROPS. Tighten ROPS retaining nuts to 105
Nm (77 lb-ft).
KV15203
B
A
C
C
D
11/22/00 4 - 143
INSTRUMENT PANEL COMPONENT LOCATION
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.
3. Remove six screws (B) and pull bezel away from
headliner.
4. Remove key switch bezel nut (A).
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.
A. Heater Blower (Optional)
B. Air Conditioner (Optional)
C. Windshield Wiper/Washer (Optional)
D. Dual Flasher (Optional)
E. High-Flow (Optional)
F. Work Lights
G. Instrument Cluster
H. Cold Start
I. Park Brake
J. Key Switch
A B C D E F G H I J
KV18865
KV15204
B
B
KV15205
A
KV15206
C
4 - 144 11/22/00
INSTRUMENT PANEL SWITCHES
NOTE: Park brake switch shown. Other switch
replacement is similar.
Replace:
3. Remove six screws (A) and pull bezel away from
headliner.
4. Disconnect wiring harness connector (B) and
remove park brake switch (C).
5. Install park brake switch and connect wiring
harness connector (B).
CAB HEATER THERMOSTAT (IF
EQUIPPED)
Replace:
2. Disconnect battery negative () terminal.
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.
4. Pull connector through headliner and disconnect.
5. Connect new heater control
KV15204
A
A
KV15206
B
C
KV18862
Remove Screws
KV18863
11/22/00 4 - 145
6. Push connector forward through hole (D) in frame.
7. Install controller and secure with screws.
8. Connect battery.
INSTRUMENT CLUSTER
Replace:
3. Remove six screws (A) and pull bezel away from
headliner.
4. Remove two cap screws (B) and mounting clips (D).
Pull instrument cluster (C) away from headliner.
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.
FUEL LEVEL SENDER
Replace:
KV18864
D
KV18862
KV15204
A
A
B
C
KV15209
B
D
D
KV15210
E
4 - 146 11/22/00
4. Access fuel level sender on top of fuel tank.
NOTE: Tag fuel lines to aid during installation.
5. Disconnect wire harness connector (A) and remove
two fuel lines (B). Tag fuel lines to aid in proper
installation.
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.
Nm (77 lb-ft).
SEAT SAFETY SWITCH
Replace:
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 (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 Nm (20 lb-ft).
KV15212
A
B
KV15213
C
D
E
KV15214
A
KV15215
B
C
D
11/22/00 4 - 147
SEAT BELT SWITCH
Replace:
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 Nm
(40 lb-ft).
STARTER
Remove/Install:
3. Remove left side engine panel.
5. Remove nut (A) and cover (B) to access starter
wiring leads.
.
NOTE: Tag or label wiring leads on starter to aid
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.
12. Install left engine side panel.
Nm (77 lb-ft).
KV15214
A
KV15216
A
B
KV15217
C
D
D
4 - 148 11/22/00
ALTERNATOR
Remove/Install:
1. Park machine on a level surface. Lower boom to the
ENGAGE park brake.
3. Remove left engine side panel.
NOTE: Tag or label wiring leads on alternator to aid
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.
13. Install left engine side panel.
HYDRAULIC OIL
OVERTEMPERATURE SWITCH
Replace:
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).
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.
Nm (77 lb-ft).
KV15218
A
C
B
D
KV15219
A
B
11/22/00 4 - 149
PARK BRAKE SOLENOID
Replace:
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.
4. Remove left engine side panel.
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 Nm (48 lb-in.).
9. Start engine and check for oil leaks.
10. Install engine side panel.
HYDRAULIC OIL FILTER
RESTRICTION SWITCH
Replace:
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.
4. Access hydraulic oil filter restriction switch located
on front of hydraulic oil filter manifold.
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 Nm (77 lb-ft).
c
CAUTION
To help prevent injury from escaping hydraulic
oil under pressure, relieve the pressure in the
system.
KV15220
A
B
C
KV15221
A
B
C
4 - 150 11/22/00
BACKUP ALARM (OPTIONAL)
ALARM
Replace:
ENGAGE park brake.
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:
ENGAGE park brake.
3. Disconnect harness (C) from switch.
4. Remove single screw (D) that retains switch bracket
to plate (E). Remove switch and bracket assembly.
5. Remove screws (2 used) and lock nuts retaining
switch to bracket. Install new switch on original
bracket and tighten screws securely.
A
B
KV31079
KV31077
C
D
E
11/22/00 4 - 151
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.
F
G
4 - 152 11/22/00
POWER TRAIN (CHAINCASE AND AXLES) CONTENTS
Page
CONTENTS
11/22/00 5 - 1
POWER TRAIN (CHAINCASE AND AXLES)
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
SPECIFICATIONS POWER TRAIN (CHAIN CASE AND AXLES)
5 - 2 1/3/01
SPECIFICATIONS
Drive Axles:
Wheel Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 Nm (175 lb-ft)
Mounting Nut Torque (Axle Housing to Chain Case) . . . . . . . . . . . . . 305 Nm (225 lb-ft)
Axle Spanner Lock Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . .340-408 Nm (250-300 lb-ft)
Axle Housing Lubrication (Before Installation)
or PLUS 50
. . . . . . . . . . . . . . 237 mL (8 oz)
Chain Case:
Access Plate Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . 7080 Nm (5259 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) . . . . . . . . . . . . . . . .06.35 mm (00.250 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) lubrication.
TY22073 John Deere TORQ-GARD SUPREME

lubrication.
TY6390 John Deere PLUS-50

Other Oil: API Service Classification SG or Higher lubrication.
TY6333/ Moly High Temperature EP Grease Axle housing to chain case
TY6347 O-ring.
PM20166 John Deere 5900 RTV Silicone Seal chain case covers.
SPECIAL TOOLS
Number Name Use
JDG666 Spanner Wrench Axle bearing lock nut.
HY-GARD, TORQ-GARD SUPREME and PLUS-50 are registered trademarks of Deere & Company.
POWER TRAIN (CHAIN CASE AND AXLES) POWER TRAIN COMPONENT LOCATION
11/22/00 5 - 3
POWER TRAIN COMPONENT LOCATION
Chain Case
Rear Drive Chain
Right Drive Shaft
Front Drive Chain
Hydrostatic Motors
Chain Case
Level/Fill Plug
Chain Case
Access Plate
KV13158
Front Axle Housing
Rear Axle Housing
Rear Axle Sprocket
Park Brake Assembly
Front Axle Sprocket
Chain Case Drain Plug
OPERATION POWER TRAIN (CHAIN CASE AND AXLES)
5 - 4 11/22/00
OPERATION
Theory of Operation
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.
Chain Case
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.
Drive Chains
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
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.
KV13157
KV13152
POWER TRAIN (CHAIN CASE AND AXLES) TROUBLESHOOTING
1/3/01 5 - 5
TROUBLESHOOTING
Problem or
Symptom
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Check or
Solution
Inspect O-ring at chain case drain
plug
G
Inspect/replace sealant on chain
case access plate
G
Inspect O-ring at chain case fill
plug
G
Inspect O-ring on axle housing G G
Inspect oil seal at axle G G
Inspect axle bearings G
Check chain case oil level G G
Check drive chain and sprockets G G G G
See DRIVE CHAIN TENSION
ADJUSTMENT
G G
See AXLE HOUSING
DISASSEMBLY/ASSEMBLY
G G G
DIAGNOSIS POWER TRAIN (CHAIN CASE AND AXLES)
5 - 6 1/3/01
DIAGNOSIS
Test Conditions:
Operator on seat, seat belt fastened.
Engine running at fast idle.
Park brake OFF.
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 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.
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.
3. Rotate each tire by
hand.
Tires move less than 6.35 mm
(0.250 in.) at tire tread.
If normal, but skid steer continues to pull
to one side, go to step 4.
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.
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.
POWER TRAIN (CHAIN CASE AND AXLES) DIAGNOSIS
1/3/01 5 - 7
Front Axle
Sprocket
Right Drive
Shaft
Rear Drive
Chain
KV13934
Front Drive
Chain
Right Steering
Control Lever
Left Steering
Control Lever
REPAIR POWER TRAIN (CHAIN CASE AND AXLES)
5 - 8 1/3/01
REPAIR
CHAIN CASE OIL LEVEL CHECK
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.
IMPORTANT: DO NOT use John Deere
BIO-HY-GARD
TM
in chain case.
3. Fill chain case with proper lubricant. The following
oils are PREFERRED:
John Deere HY-GARD
John Deere PLUS-50
Other Oil: API Service Classification SG or Higher
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.
3. Remove chain case oil drain plug behind rear tire.
Drain oil into a suitable container.
.
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 7080 Nm (5259 lb-ft).
4. Install all chain case fill and drain plugs.
IMPORTANT: DO NOT use John Deere
BIO-HY-GARD
TM
in chain case.
5. Fill chain case with proper lubricant. The following
oils are PREFERRED:
John Deere HY-GARD
John Deere PLUS-50
Other Oil: API Service Classification SG or Higher
KV13040
Oil Level/Fill Plug
Chain Case
Access Plate
KV13152
Chain Case Drain Plug
KV13042
Cap Screw
Chain Case
Access Plate
POWER TRAIN (CHAIN CASE AND AXLES) REPAIR
1/3/01 5 - 9
DRIVE CHAIN TENSION
ADJUSTMENT
Check Chain Tension
3. Raise and block skid steer. (See RAISING AND
BLOCKING SKID STEER in MISCELLANEOUS
section.)
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.
Chain Tension Adjustment
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.
4. To tighten drive chain:
Push rear axle housing rearward.
Push front axle housing forward.
5. Tighten axle housing nuts to 305 Nm (225 lb-ft).
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.
section.)
4. Remove wheel from axle being serviced.
5. Clean around axle housing to prevent debris from
entering chain case oil reservoir.
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.)
KV15158
Right Side of Skid Steer Shown.
KV13157
Rear Drive
Chain
Front Drive
Chain
KV18785
Axle Housing Nuts
Axle Housing
5 - 10 1/3/01
Axle Housing Installation
1. Clean mating surfaces of axle housing and chain
case before installation.
IMPORTANT: Replace all O-rings. Damaged or
used O-rings will leak.
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.
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 Nm (225 lb-ft).
11. Install wheels and tighten nuts to 237 Nm
(175 lb-ft).
12. Check chain case oil level after skid steer has been
driven and fill as necessary.
AXLE HOUSING DISASSEMBLY/
ASSEMBLY
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.
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.
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.
O-Ring
Pre-lubricate
Through
Bearing
KV15147
Tab
Chain Sprocket Hub
Chain Case
KV13155
Notch
KV13139
Tab Washer
Lock Nut
Washer
O-Ring
KV13140
POWER TRAIN (CHAIN CASE AND AXLES) REPAIR
1/3/01 5 - 11
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.
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.
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.
11. Press bearing on until it is 12 mm
(0.0390.079 in.) above shoulder on shaft.
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
Nm (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.)
KVP13933
KVP13935
Seal
Outer Bearing Race
KV13139
Tab Washer
Lock Nut
Washer
O-Ring
5 - 12 1/3/01
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.
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.
3. Slide rear axle sprocket forward and remove rear
drive chain from drive shaft and rear axle sprocket.
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.
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
Rear Drive
Chain
Front Drive
Chain
Right Side of Skid Steer Shown.
Drive Shaft
KV13155
Front Drive Chain
HYDROSTATIC POWER TRAIN CONTENTS
Page
CONTENTS
11/22/00 6 - 1
HYDROSTATIC POWER TRAIN
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
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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
6 - 2 11/22/00
CONTENTS HYDROSTATIC POWER TRAIN
This page intentionally left blank
11/22/00 6 - 3
HYDROSTATIC POWER TRAIN SPECIFICATIONS
SPECIFICATIONS
TESTS AND ADJUSTMENTS SPECIFICATIONS
Hydraulic Oil Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43C (110F)
Charge Circuit Pressure . . . . . . . . . . . . . . . . . . . . . . . . 13791551 kPa (200225 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 8085 rpm 6570 rpm 60 rpm
After serial number 242579 8085 rpm 8085 rpm 60 rpm
Model 250 Forward Reverse Min Reverse
Through serial number 252793 7075 rpm 6065 rpm 52 rpm
After serial number 252793 7075 rpm 7075 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 Nm (100 lb-ft)
Hydraulic/Charge Pump Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm (26 lb-ft)
Hydrostatic Pump-to-Center Manifold Cap Screws. . . . . . . . . . . . . . . . 56 Nm (41 lb-ft)
Hydrostatic Pump Mounting Flange-to-Flywheel Housing . . . . . . . . . 118 Nm (87 lb-ft)
Hydrostatic Pump Mounting Bracket-to-Hydrostatic Pump . . . . . . . . . 39 Nm (29 lb-ft)
Hydrostatic Pump Drive Hub Set Screws . . . . . . . . . . . . . . . . . . . . . . . 37 Nm (27 lb-ft)
Hydrostatic Pump Cover Plate Cap Screws . . . . . . . . . . . . . . . . . . . . . 41 Nm (30 lb-ft)
Centering Plate Mount Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Nm (30 lb-ft)
Centering Plate Spring Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Nm (50 lb-ft)
Centering Plate Guide Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Nm (40 lb-ft)
Control Rod Cap Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm (30 lb-ft)
Hydrostatic Motor Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . 118 Nm (87 lb-ft)
Hydrostatic Motor Flange Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . 82 Nm (60 lb-ft)
Hydrostatic Motor Relief Valve Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Nm (20 lb-ft)
Hydrostatic Motor Shuttle Valve Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Nm (30 lb-ft)
REPAIR SPECIFICATIONS
Reservoir Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6 L (4.1 gal)
System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 L (6 gal)
6 - 4 11/22/00
SPECIFICATIONS HYDROSTATIC POWER TRAIN
Bench-Mounted Holding Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D01006AA
OTHER MATERIALS
Number Name Use
Petroleum Jelly Apply to components of hydrostatic pump
during assembly
TY6238 John Deere HY-GARD
Apply to internal surfaces of hydrostatic pump

and hydrostatic motor during assembly.
LOCTITE
PRODUCTS
U.S./
Canadian/
LOCTITE No.
TY9370/
TY9477
242
(Medium Strength)
Apply to hydrostatic pump drive hub set
screws.
LOCTITE is a registered trademark of Loctite Corp.
HY-GARD is a registered trademark of Deere & Company.
11/22/00 6 - 5
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.
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
operators 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 operators 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.
6 - 6 11/22/00
HYDROSTATIC COMPONENT LOCATION HYDROSTATIC POWER TRAIN
HYDROSTATIC COMPONENT LOCATION
KV15143
Hydraulic/Charge Pump
Right Brake Assembly
Center Manifold
Left Hydrostatic Motor
Right Hydrostatic Motor
Front Hydrostatic Pump
Left Brake Assembly
Rear Hydrostatic Pump
(For Right Wheels)
(For Left Wheels)
11/22/00 6 - 7
HYDROSTATIC POWER TRAIN HYDROSTATIC SYSTEM SCHEMATIC
HYDROSTATIC SYSTEM SCHEMATIC
Hydraulic
Reservoir
Spin-On
Filter
Charge Flow
210 psi
Brake Valve
A B
Drive Motor
Brake
High Flow
Valve (Optional)
High Flow
Pump
(Optional)
Hydrostatic
Pumps
3300 psi
Drive Motor
Brake
Engine
Oil
Cooler
Hydraulic/Charge
Pump
75 psi
To
Main
Control
Valve
To
Main
Control
Valve
From
Main
Control
Valve
M18535
6 - 8 11/22/00
TROUBLESHOOTING HYDROSTATIC POWER TRAIN
TROUBLESHOOTING
Problem or
Symptom
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Check or
Solution
Hydraulic oil level low in
reservoir
Check and top off oil level
G G G
Hydrostatic pump not running
Check engine coupling
G
Low charge pressure
Check charge pump
G G G
Oil too heavy
Cold weather
G G G
Shuttle valve stuck open
Check valve
G G G
Air in system
Purge
G G G
Output pressure too low
Check output pressure
G G G G
Internal pump or motor damage G G G G
Park brake engaged or
dragging
G G G G
Pump linkage not centered for
neutral on one or both pumps
G G
Broken drive chain G
Linkages loose or broken G G G
11/22/00 6 - 9
HYDROSTATIC POWER TRAIN DIAGNOSIS
DIAGNOSIS
Test Conditions:
Operator in seat.
Seat belt fastened.
Test Conditions:
Start engine and run at low idle.
Release Park Brake.
1. Steering levers. Levers should move freely. Check linkage from levers to pump.
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.
6 - 10 11/22/00
TESTS AND ADJUSTMENTS HYDROSTATIC POWER TRAIN
HYDRAULIC/CHARGE PUMP
PRESSURE TEST
Reason:
To ensure there is sufficient oil pressure to charge the
hydrostatic systems properly 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
Procedure:
BLOCKING SKID STEER in the
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
4. Disconnect charge flow line at left side of
hydrostatic pump center manifold.
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.
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 43C (110F).
12. Set throttle to full advance.
Specifications:
Charge pressure must be 13791551 kPa
(200225 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.
c
CAUTION
system before removing hydraulic lines.
KV18853
Hydraulic Oil
Filter Manifold
Charge Flow Line
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.
KV15134
38H5069
JT03457
JT03017
JT03344
11/22/00 6 - 11
HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS
HYDRAULIC/CHARGE PUMP FLOW
TEST
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
Procedure:
1. Lower boom and bucket to normal ground position.
Stop engine and relieve hydraulic pressure.
3. Install JT03012 and JT05690 Connectors on one
end of both JT03377 Hoses.
4. Install KV13885 and KV13884 Quick Disconnects
on connectors.
5. Connect JT03377 Hose to D01074AA In-Line
Hydraulic Tester.
IMPORTANT: Make sure skid steer male connector
is routed to tester inlet.
6. Attach quick disconnects to auxiliary hydraulic ports
located on left boom arm.
7. Operate hydraulic system until oil reaches normal
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).
Specifications:
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.)
JT03377 JT03012
JT05690
KV13885
KV13884
KV15257
KV15136
Male Quick
D01074AA
In-Line
Hydraulic
Tester
Disconnect-
to-Inlet Hose
Outlet-to-Female
Quick Disconnect
Hose
Outlet
Inlet
KV18562
Female Auxiliary Connector
Male Auxiliary Connector
6 - 12 11/22/00
HYDROSTATIC PUMP HIGH
PRESSURE RELIEF TEST
Left Forward
Relief Valve
Right Forward
Relief Valve
Left Forward
Port
Right
Forward
Port
Right Reverse Port
Left Reverse
Relief Valve
Right Reverse
Relief Valve
RE60700
Diagnostic
Receptacle
38H1035
Tee Fitting
JT03364
Test Hose
JT05489
Connector
JT03362
Test Gauge
KV18036
JT03340
Quick Coupler
Left
Reverse
Port
240 Models through serial number: KV0240A142337
250 Models through serial number: KV0250A152709
KV31049
Right Forward Port
Right Reverse Port
Right
Right Reverse Relief Valve
Forward
Relief Valve
RE60700
Diagnostic
Receptacle
38H1035
Tee Fitting
JT03364
Test Hose
JT05489
Connector
JT03340
Quick Coupler
JT03362
Test Gauge
Left
Reverse
Port
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
Left Forward
Relief Valve
Left Forward
Port
Left
Reverse
Relief Valve
11/22/00 6 - 13
Reason:
To ensure that hydrostatic pump high pressure relief
valves are operating properly.
Equipment:
38H1035 Tee Fitting
JT05489** Connector (7/16-20M 37x1/2-20M
ORB)
JT03340** Quick Coupler
JT03364* Hose
JT03362* Gauge 070 000 kPa (010,000 psi)
RE60700 Diagnostic Receptacle
* Part of JT05738 Compact Utility Tractor Hydraulic Fitting Kit
** Part of JT01765 Kit Application
Procedure:
pumps. (See REMOVING COVER PLATES in the
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.
NOTE: Illustration shows gauge connection for testing
the left reverse relief valve.
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 ValveRight Top Port
Left Reverse Relief ValveRight Bottom Port
Right Forward Relief ValveLeft Top Port
Right Reverse Relief ValveLeft Bottom Port
7. Connect test hose, fittings, and gauge to tee fitting.
8. Start and operate engine at 3/4 throttle until
hydraulic oil reaches 43C (110F).
9. Slowly move corresponding steering lever in
appropriate direction for relief valve being tested.
10. Record gauge reading.
11. Perform steps 610 for all four relief valves as
necessary.
Specifications:
Pump pressure should be 34 474 1379 kPa
(5000 200 psi).
Results:
If pressure is not within specifications, replace the
corresponding relief valve.
WHEEL SPEED TEST
Reason:
To use as an initial test to verify if hydrostatic system is
operating normally.
Equipment:
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.)
c
CAUTION
bystanders. Do not use remote start box without
raising and blocking skid steer.
c
CAUTION
6 - 14 11/22/00
3. Apply reflective tape to one wheel at both sides of
machine.
hydraulic oil reaches 43C (110F).
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):
Wheel Rotations
Model 240 WOT RPM in One Minute
Serial Number Forward Reverse
242579 (2400 minimum) 8085 6570
242580 (2400 minimum) 8085 8085
Wheel Rotations
Model 250 WOT RPM in One Minute
Serial Number Forward Reverse
252793 (2400 minimum) 7075 6065
252794 (2400 minimum) 7075 7075
IMPORTANT: Left and right sides must be within 1
rpm to provide proper steering control.
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 ADJUSTMENTTRACKING 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, M NPT x M
NPT
JT03012 F NPT x 1-1/16 F 37Flare (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:
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.
5. Remove cover plates to access hydrostatic pumps.
(See COVER PLATE REMOVAL/INSTALLATION in
the MISCELLANEOUS section.)
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.
11/22/00 6 - 15
dry and damage the pumps and motors.
7. Install a M10 X 30 cap screw in both steering
control arms to secure them to the frame.
8. Identify correct port on center manifold to determine
which pump will be tested.
.
IMPORTANT: Clean all hydraulic connections to
prevent contamination of hydraulic system.
9. Disconnect hydraulic line from elbow fitting on
pump.
c
CAUTION
bystanders. Do not use remote start box without
raising and blocking skid steer.
KV13980
M10 x 30 Cap Screw
NOTE: It is not necessary to remove steering control
handle boots. Boots have been removed for
clarity only.
c
CAUTION
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.
Right Forward Port (A)
Left Forward Port
Right Forward Port (B)
NOTE: Left side pump is shown. Test for the right side
pump is similar.
KV31087
Left Forward Port
Line to Motor
6 - 16 11/22/00
10. Install fittings on JT03377 hydraulic lines as shown.
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.
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
43C (110F).
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.
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.
KV31085
Connect to Hose 38H1272
JT05690
JT03012
JT03377
Connect to Pump
KV31086
Elbow
Line to Tester Inlet Port
Line from Tester
Line to Motor
Outlet Port
KV31089
Inlet
Load Valve
Line from Pump
Outlet
Line to Motor
11/22/00 6 - 17
HYDROSTATIC PUMP CASE DRAIN TEST
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
Graduated Breaker
Procedure:
pumps. (See REMOVING COVER PLATES in the
hydraulic oil reaches normal operating temperature
of 43C (110F).
7. Stop engine.
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.
KV18070
Right Drive Motor
Drain Hose
Return Drain Hose
Left Drive Motor
Drain Hose
Tee Fitting
c
CAUTION
c
CAUTION
c
CAUTION
To help prevent injury from escaping hot oil, use
suitable protection when disconnecting the
hydraulic lines.
6 - 18 11/22/00
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 43C (110F).
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.
18. Move corresponding steering lever of pump being
tested slowly forward or backward until fluid flows
from end of hose.
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:
Volume in graduated beaker should not exceed
0.95 L (2 pt) in 10 seconds.
Results:
If volume exceeds specifications, repair or replace
pump.
Repeat steps 1420 for the other hydrostatic pump.
KV18071
Left Drive Motor
Drain Hose
38H1206
Union Tee
8-6 TRLO-S
Right Drive Motor
Drain Hose
Return Drain Hose
38H1415
Cap Assembly
38H1416
Cap Assembly
9.5 mm (3/8 in.) ID
Test Hose
Hose
Clamp
Adapter
11/22/00 6 - 19
HYDROSTATIC CASE DRAIN
PRESSURE TEST
Reason:
To check if there is excessive pressure in the
hydrostatic pump case.
IMPORTANT: Excessive drain pressure may cause
the pump case to rupture.
Equipment:
38H1161 Adapter
JT03457 Adapter
JT05498* Hose
JT05472* Gauge 0400 kPa (060 psi)
*Part of JT05470 Universal Pressure Test Kit
Procedure:
pump. (See REMOVING COVER PLATES in the
dry and damage the pumps and motors.
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.
hydraulic oil reaches normal operating temperature
of 43C (110F).
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.
c
CAUTION
c
CAUTION
Plug
KV18022
6 - 20 11/22/00
REPAIR HYDROSTATIC POWER TRAIN
REPAIR
START-UP PROCEDURE AFTER
COMPONENT REPLACEMENT
2. Raise and block skid steer. (SEE RAISING AND
MISCELLAENOUS section.)
locked position.
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.
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 550830 kPa
(80120 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.
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.
c
CAUTION
c
CAUTION
KV15134
38H5069
JT03457
JT03017
JT03344
11/22/00 6 - 21
HYDROSTATIC POWER TRAIN REPAIR
HYDROSTATIC PUMP REMOVAL
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.)
4. Remove steering control rods from control levers.
5. Drain hydraulic reservoir.
6. Remove rear hydraulic line from left drive motor.
Remove fitting from motor to provide clearance for
hydrostatic pump removal. Cap and plug openings.
A. Hydrostatic Pump Center Manifold Port-to-
Hydraulic 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
KV18869
Control Rods
KV18870
Hydraulic
Line
Hydraulic
Fitting
KV18872
A
B
C
D
E
F
6 - 22 11/22/00
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):
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
KV0240A142337 or KV0250A152709 (or if
Manifold Port-to-Right Drive Motor Top Front
Port Hose
I. Hydrostatic Pump Front Port-to-Right Drive
J. Hydraulic/Charge Pump-to-Hydraulic Control
Valve Hose
NOTE: Mark or tag all hydrostatic pump hoses to aid in
assembly.
Close all openings using caps and plugs.
7. Mark and disconnect hoses (AJ) from hydrostatic
pump assembly.
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.
KV18871
G
H
I
J
Hydrostatic Pump
Assembly
KV18496
Cap Screws
(2 used)
Flywheel
Adapter Plate
Hydrostatic Pump
Mounting Bracket
Cap Screws
(See Note)
Spacers
(See Note)
Spacer
Cap Screws
(See Note)
11/22/00 6 - 23
FRONT HYDROSTATIC PUMP EXPLODED VIEW

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.
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
A
C
D
E
F
G
H
I
J
K
L
M
N
A
B
S
R
D
E
F
O
P
B
Q
KV31095
Front of Machine
6 - 24 11/22/00
CENTER MANIFOLD EXPLODED VIEW (EARLY MODELS)

NOTE: Early models have different front and rear
gaskets. Later models use same gasket (oval
with cutout).
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
B
T
U
O
P M
K
J
L
F
G
E
C
H
N
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
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
D
I
S
Q
N
J
M
M
A
R
Model 240 250
Through serial numbers: KV0240A142337 KV0250A152709
Front of Machine
11/22/00 6 - 25
CENTER MANIFOLD EXPLODED VIEW (LATE and CONVERTED MODELS)

KV31094
A. Center Manifold
B. Washer (8 used)
C. Cap Screw (8 used)
D. Right Reverse High
E. O-Ring
F. Left Forward Port
G. Plug
B
S
T
N
O L
K
J
F
G
E
C
H
M
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
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
D
I
Q
P
M
J
L
L
A
R
Model 240 250
After serial numbers: KV0240A142337 KV0250A152709
and early models after PIP 00KV010 has been performed.
Front of Machine
6 - 26 11/22/00
REAR HYDROSTATIC PUMP EXPLODED VIEW

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.
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
A
C
D
E
D
G
I
J
K
H
M
V
Q
KV31096
B
L
R
S
K
L
T
H
I
W
U
P
F
E
M
N
O
Front of Machine
11/22/00 6 - 27
HYDROSTATIC PUMP
DISASSEMBLY
IMPORTANT: Clean hydrostatic and hydraulic/
charge pump cases before separating pumps to
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.
3. Remove control levers and front and rear centering
plate mounts.
.
4. Mount pumps on D01006AA Bench-Mounted
Holding Fixture using two cap screws and nuts.
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.)
KV18503
Input Shaft
Coupler
Set Screws
KV18504
Control Levers
Mounts
c
CAUTION
Use proper lifting equipment. Approximate
weight of pumps is 45 kg (100 lb).
KV18505
Cap Screws and Nuts
KV18873
Cap Screws
6 - 28 11/22/00
6. Remove four cap screws securing front pump
housing to center manifold.
7. Lift front pump housing straight up and off from
center manifold.
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.
10. Remove front valve plate from center manifold.
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.
NOTE: Rotating assembly might "stick" to center
manifold due to hydraulic oil adhesion. Be
careful not to let rotating assembly fall
unexpectedly.
14. Remove rear valve plate from center manifold.
15. Using your hand, hold rotating assembly in
housing.
16. Rotate holding fixture 180 degrees and slowly slide
out rotating assembly.
c
CAUTION
Note location and orientation of hydrostatic
pump components. Components are not
interchangeable between front and rear
hydrostatic pumps.
KV18507
Cap
Screws
Front Pump
Housing
KV18508
Drive Shaft
Rotating Assembly
Valve
Plate
Center Manifold
KV18509
Cap Screws
Relief
Valves
KV18510
Rotating
Assembly
Holding
Fixture
Housing
11/22/00 6 - 29
17. Remove snap ring holding seal and shaft.
18. Using a soft-faced hammer, tap shaft from housing.
NOTE: Rear pump housing shown. The procedure is
the same for the front pump housing.
19. To aid in assembly, mark the side of the housing
where the trunnion shaft is.
20. Remove cover plates from pump housing.
21. Remove cam plate (swash plate) from housing.
KV18511
Snap Ring
KV18512
Housing
Shaft
Cover Plates
Cam Plate
Housing
Trunnion
Shaft
KV18513
(Swash Plate)
6 - 30 11/22/00
HYDROSTATIC PUMP INSPECTION
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.
2. Inspect four relief valves in center manifold.
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.
3. Inspect cam plate (swash plate) bearings and
bearing outer races in cover plates.
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.
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.
Front Pump Valve Plate
Rear Pump Valve Plate
6. Inspect bronze side of valve plate for wear. Replace
valve plate if any scoring or scratches are present.
KV18514
Needle Bearings
KV18515
Relief Valves
Relief Valves
KV18516
Bearing
Cam Plate Bearing
Insert
Outer Race
Outer
Race
Seal
O-Rings
(Swash Plate)
KV18516
Bearing
Cam Plate Bearing
Insert
Outer Race
Outer
Race
Seal
O-Rings
(Swash Plate)
KV18517
Metering Slots
KV18809
Metering Slots
11/22/00 6 - 31
NOTE: Rotating assembly is not serviceable. Replace
assembly if any components are damaged.
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.
11. Inspect rear pump input shaft bearing surfaces and
spline areas.
12. Inspect thrust bearings and thrust washers.
13. Inspect forward pump input shaft bearing surfaces.
14. Inspect external spline areas and internal splines
which drive hydraulic/charge pump.
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
.
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.
KV18518
Piston
Piston Block
Slipper
KV18519
Bearing Surfaces
Thrust
Bearing
Thrust
Washers
Spacer
KV18520
Bearing Surfaces
Splines Internal
Splines
BIO HY-GARD is a registered trademark of Deere &
Company.
KV18524
Bearings
Insert Shims
6 - 32 11/22/00
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
7. Install torque wrench on the square of the trunnion
shaft. Rolling torque should be 2.3-3.4 Nm
(20-30 lb-in.). Add or remove shims to obtain the
correct adjustment.
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.
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.
12. Using a piece of pipe of appropriate diameter,
lightly tap new seal into housing until it bottoms out
on spacer.
13. Install snap ring.
KV18513
Cover Plates
Cam Plate
Housing
Trunnion
Shaft
(Swash Plate)
KV18519
Bearing Surfaces
Thrust
Bearing
Thrust
Washers
Snap Rings
Spacer
Seal
Snap
Ring
KV18521
Shaft Assembly
Spacer
KV18522
KV18523
Snap Ring
11/22/00 6 - 33
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.
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.
18. Install new gasket and install center manifold onto
pump housing.
19. Install four cap screws and tighten to 56 Nm
(41 lb-ft).
20. Install new O-rings on relief valves and install into
center manifold. Tighten to 135 Nm (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.
22. Install rotating assembly onto valve plate.
23. Align splines on drive shaft with rotating assembly
and install into center manifold.
KV18510
Rotating
Assembly
Holding
Fixture
Housing
KV18525
Center Manifold Needle
Bearing
Valve Plate
KV18509
Cap Screws
KV18709
Needle Bearing
Relief
Valves
Valve Plate
Relief
Valves
KV18508
Drive Shaft
Rotating Assembly
Valve
Plate
Center Manifold
6 - 34 11/22/00
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 oclock position will
always have passages. If there are passages in the
port at the 9 oclock position, a plug must be
installed or the pump will not prime. If there are no
passages in the port at the 9 oclock position, no
plug is required.
25. Install new gasket and lower front pump housing
over rotating group onto center manifold.
26. Install four cap screws and tighten to 56 Nm
(41 lb-ft).
27. Install hydraulic/charge pump onto front pump.
28. Tighten the eight screws to 35 Nm (26 lb-ft).
29. Remove pump assembly from holding fixture.
Passages
Port at 3 OClock Position Port at 9 OClock Position
KV31116
Port at 3 OClock Position
with Plug Installed
KV31113
c
CAUTION
Use proper lifting equipment. Approximate
weight of pumps is 45 kg (100 lb).
KV18507
Cap Screws
Front Pump
Housing
KV18873
Cap Screws
11/22/00 6 - 35
30. Install centering plate mounts. Tighten cap screws
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 Nm
(27 lb-ft).
HYDROSTATIC PUMP
INSTALLATION
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.
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.
4. Install six mounting bracket-to-pump assembly cap
screws and four spacers. Tighten to 39 Nm
(29 lb-ft).
KV18504
Cap Screws
Mounts
Control
Lever
Control
Lever
KV31117
6 mm (0.025 in.)
Coupler
Set Screws
Hydrostatic Pump
Assembly
Cap Screws
(2 used)
Flywheel
Adapter Plate
Hydrostatic Pump
Mounting Bracket
Cap Screw
(See Note)
Spacer
(See Note)
Spacer
Cap Screws
(See Note) KV18496
6 - 36 11/22/00
A. Hydrostatic Pump Center Manifold Port-to-
Hydraulic Oil Filter Manifold Hose
B. Hydrostatic Pump Rear Port-to-Left Drive
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
F. Hydrostatic Pump Top Left Center Manifold
G. Through serial number:
KV0240A142337 or KV0250A152709:
Port-to-Right Drive Motor Top Front Port Hose
KV0240A142337 or KV0250A152709 (or if
Port-to-Right Drive Motor Top Rear Port Hose
H. Through serial number:
KV0240A142337 or KV0250A152709:
Manifold Port-to-Right Drive Motor Top Rear
Port Hose
KV0240A142337 or KV0250A152709 (or if
Manifold Port-to-Right Drive Motor Top Front
Port Hose
I. Hydrostatic Pump Front Port-to-Right Drive
J. Hydraulic/Charge Pump-to-Hydraulic Control
Valve Hose
5. Connect hoses (AJ) to hydrostatic pump assembly
as marked or tagged during disassembly.
KV18872
A
B
C
D
E
F
KV18871
G
H
I
J
11/22/00 6 - 37
6. Install steering control rods to control levers.
7. Install centering plate(s). (See CENTERING PLATE
REMOVAL/INSTALLATION in the STEERING
section.)
8. Install steering cross shaft. (See STEERING
STEERING 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
2. Remove steering cross shaft (see STEERING
STEERING section.)
NOTE: Left motor shown. Right motor is similar.
A. Hydrostatic Pump Rear Port-to-Left Drive
B. Hydrostatic Pump Bottom Left Center Manifold
C. Hydrostatic Pump Top Left Center Manifold
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 Nm (87 lb-ft).
3. Install hydrostatic lines removed during pump
removal.
KV13914
Brake Assembly
Cap Screws
A
C
B
6 - 38 11/22/00
HYDROSTATIC MOTOR EXPLODED VIEW
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
A
B
U
D
E
F
G
H I
J
K
L
M
P
Q
S
T
G
N
O
C
KV31123
R
Align Shuttle Flow Holes
V
W
X
11/22/00 6 - 39
HYDROSTATIC MOTOR
DISASSEMBLY
1. Scribe two lines 25 mm (1 in.) apart down body of
motor to aid in assembly.
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.
3. Disassemble motor, being careful not to lose check
balls in GEROLER.
4. Remove relief valve and shuttle valve assemblies
from end cap.
5. Remove and discard all O-rings and seals.
HYDROSTATIC MOTOR INSPECTION
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.
KV18874
12-Point
Cap Screws
(9 used)
KV18886
Check Balls
KV18879
Shuttle Valve
Relief Valve
Assembly
Assembly
Shims
6 - 40 11/22/00
HYDROSTATIC MOTOR ASSEMBLY
NOTE: Use petroleum jelly to hold seals and O-rings in
place during assembly.
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.
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
A
B
U
D
E
F
G
H I
J
K
L
M
P
Q
S
T
G
N
O
C
KV31123
R
Align Shuttle Flow Holes
V
W
X
11/22/00 6 - 41
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 Nm (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 Nm (20 lb-ft).
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.
6. Place valve plate on end cap. Align bolt holes and
shuttle flow hole with end cap.
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.
KV18879 Shuttle Valve Plug
Poppets
(2 used)
Shuttle
Piston
Dash Pots
(2 used)
Springs
(2 used)
O-Ring
O-Ring
Shims
Relief Valve
Plug
KV18880
Square Cut Seal O-Ring
KV18881
Valve Plate
Valve Side of
GEROLER
Square Cut Seal
KV18882
Shuttle Flow
Hole
6 - 42 11/22/00
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.
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.
12. Install flange on balance plate being careful not to
displace seals and O-rings.
13. Install nine 12-point cap screws lubricated with
HY-GARD hydraulic oil. Tighten cap screws to an
initial setting of 41 Nm (30 lb-ft) in a criss-cross
pattern as shown. Finish tightening to 82 Nm
(60 lb-ft) in the same criss-cross pattern.
14. Install shaft face seal with the cupped side down.
Hold in place with petroleum jelly.
Installation:
1. Install motor assembly (see HYDROSTATIC
MOTOR REMOVAL/INSTALLATION in this
section.)
REPLACEMENT in this section.)
KV18883
Check Balls
Balance Plate
KV18587
Square Cut Seal
Backup
Ring
Seal
Backup
Ring
O-Ring
Flange
Shuttle
Flow
Hole
O-Ring
Backup
Ring
KV18588
5
8
3
6
9
1
4
7
2
Shaft Face Seal
KV18885
STEERING CONTENTS
Page
CONTENTS
11/22/00 7 - 1
STEERING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TESTS AND ADJUSTMENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STEERING COMPONENT LOCATIONSINGLE PLATE MODELS. . . . 5
STEERING COMPONENT LOCATIONDUAL PLATE MODELS . . . . . 6
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CENTERING PLATE ADJUSTMENTSINGLE PLATE MODELS . . . . . . . . . . . . . . . 9
CENTERING PLATE ADJUSTMENTDUAL PLATE MODELS. . . . . . . . . . . . . . . . 12
STEERING CONTROL LEVER ADJUSTMENTCENTERING. . . . . . . . . . . . . . . . 14
STEERING DETENT ADJUSTMENT - DUAL PLATE MODELS. . . . . . . . . . . . . . . . 15
STEERING CONTROL LEVER STOPS ADJUSTMENTTRACKING. . . . . . . . . . . 16
AUXILIARY HYDRAULIC CONTROL HANDLE ADJUSTMENT . . . . . . . . . . . . . . . . 17
HYDRAULIC CONTROL HANDLE ADJUSTMENT HANDS ONLY MACHINES . . 17
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CENTERING PLATE REMOVALSINGLE PLATE MODELS . . . . . . . . . . . . . . . . . 18
CENTERING PLATE REMOVALDUAL PLATE MODELS . . . . . . . . . . . . . . . . . . . 19
CENTERING PLATE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CENTERING PLATE INSTALLATIONSINGLE PLATE MODELS. . . . . . . . . . . . . . 21
CENTERING PLATE INSTALLATIONDUAL 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 REPAIRDUAL PLATE MODELS. . . . . . 25
STEERING CONTROL LEVER HANDLE DISASSEMBLY/ASSEMBLY . . . . . . . . . . 26
7 - 2 11/22/00
CONTENTS STEERING
11/22/00 7 - 3
STEERING SPECIFICATIONS
SPECIFICATIONS
TESTS AND ADJUSTMENTS SPECIFICATIONS
Gap between Upper Centering Plate
and Lower Centering Bracket . . . . . . . . . . . . . . . . . . . . . . . . 3.26.4 mm (1/81/4 in.)
Wheel Tracking (Left and Right Wheel Speed Difference) . . . . . . . . . . .Less than 1 rpm
Centering Plate Spring Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Nm (50 lb-ft)
Auxiliary Cable Jam Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Nm (20 lb-ft)
Guide Pin Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Nm (40 lb-ft)
Pivot Bearing Block Mounting Cap Screws. . . . . . . . . . . . . . . . . . . . . . 40 Nm (30 lb-ft)
Dampener Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm (30 lb-ft)
Link Rod Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm (30 lb-ft)
Control Rod Cap Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm (30 lb-ft)
Centering Block Mounting Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm (30 lb-ft)
Control Lever Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm (30 lb-ft)
Steering Control Lever Handle Set Screw Lock Nut . . . . . . . . . . . . 13.5 Nm (120 lb-in.)
Steering Control Lever Handle Set Screw. . . . . . . . . . . . . . . . . . . . . . . 9 Nm (80 lb-in.)
Detent Ring Set Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm (30 lb-ft)
Detent Spring Screw Jam Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.9 Nm (25 lb-ft)
NOTE: Order tools according to information given in the U.S. SERVICE-GARD
TM
Catalog or in the
Number Name
JT05719 Photo Tachometer
SERVICE-GARD is a registered trademark of Deere and Company.
7 - 4 11/22/00
THEORY OF OPERATION STEERING
THEORY OF OPERATION
Function
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.
Steering Dampeners
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.
11/22/00 7 - 5
STEERING STEERING COMPONENT LOCATIONSINGLE PLATE MODELS
STEERING COMPONENT LOCATIONSINGLE PLATE MODELS
Bellcranks
Right Steering
Lever
Pivot Bearing
Centering
Guide Pins and Bushings
Cross Shaft
Spring Bolt
Centering Screws
Left Steering
Lever
KV15159
Control
Rod
Assembly
Plate
Link Rod
7 - 6 11/22/00
STEERING COMPONENT LOCATIONDUAL PLATE MODELS STEERING
STEERING COMPONENT LOCATIONDUAL PLATE MODELS
Right Steering
Lever
Pivot Bearing
Right Wheel
Guide Pins and Bushings
Cross Shaft
Spring Bolt
Left Steering
Lever
KV18848
Right Wheel
Assemblies
Centering Plate
Link Rod
Left Wheel
Centering Plate
Detent Ring
Detent Screw
Control Rod
Bellcranks
Left Wheel
Control Rod
Centering Screws
11/22/00 7 - 7
STEERING TROUBLESHOOTING
TROUBLESHOOTING
Problem or
Symptom
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Check or
Solution
Centering plate(s) improperly
adjusted
G G G G
Bad pivot bearings on steering
control levers
Inspect and/or replace pivot bearings
G G G G
Bent control rods G G G
Damaged link rod ends G G G
Worn rubber bushings in control rods G G G
Faulty steering dampener G G G G G G
Steering lever travel incorrectly
adjusted
G
ROPS not secured G G
7 - 8 11/22/00
DIAGNOSTICS STEERING
DIAGNOSTICS
Test Conditions:
Operator in seat.
Seat belt fastened.
1. Steering control levers. Levers should move freely with slight
resistance.
Check linkage from levers to pump.
Check steering dampeners.
Test Conditions:
Engine running at slow idle.
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.
11/22/00 7 - 9
STEERING TESTS AND ADJUSTMENTS
CENTERING PLATE
ADJUSTMENTSINGLE PLATE
MODELS
Reason:
To prevent the skid steer from creeping when control
levers are in neutral.
Equipment:
Procedure:
section.)
locked position.
5. Remove cover plates to gain access to the
hydrostatic pump assembly. (See REMOVING
COVER PLATES in MISCELLANEOUS section.)
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.
.
START BOX in MISCELLANEOUS section.)
9. Disconnect control rods from pump control levers.
10. Check that the spring bolt assembly is tightened to
67 Nm (50 lb-ft).
KV13980
M10 x 30 Cap Screw
c
CAUTION
using remote start box. Do Not use remote start
box without raising and blocking skid steer.
KV13927
Centering Screws
Centering Screws
Rear
Front
Assembly
Spring Bolt
Lever
Pump Control
Control Rod
Control Rod
Lever
Pump Control
7 - 10 11/22/00
TESTS AND ADJUSTMENTS STEERING
IMPORTANT: A 3.26.4 mm (1/8 in.1/4 in.)
horizontal gap between upper centering plate
and lower front centering bracket must be
maintained when adjusting screws (AD).
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:
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
forward. Slowly turn the centering screw out until
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
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
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.
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.
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 Nm (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.)
Left Wheels
Forward Movement
Left Wheels
Rearward Movement
Right Wheels
Right Wheels
Forward Movement
Rearward Movement
KV13927
C
D
B A
3.26.4 mm (1/81/4 in.) Gap
No Gap
11/22/00 7 - 11
19. Adjust steering control lever stops. (See
STEERING CONTROL LEVER STOPS
ADJUSTMENTTRACKING 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.
7 - 12 11/22/00
CENTERING PLATE
ADJUSTMENTDUAL PLATE
MODELS
Reason:
To prevent the skid steer from creeping when control
levers are in neutral.
Equipment:
Procedure:
section.)
locked position.
5. Remove cover plates to gain access to the
hydrostatic pump assembly. (See REMOVING
COVER PLATES in MISCELLANEOUS section.)
both steering lever yokes to secure steering
assembly during adjustment.
7. Check pivot points of all the steering linkage for
wear and damage. Repair linkage components
prior to performing these adjustments.
9. Disconnect both steering control rods from pump
control levers.
10. Loosen detent ring set screws.
11. Check that the spring bolt assemblies are tightened
KV13980
M10 x 30 Cap Screw
c
CAUTION
using remote start box. Do Not use remote start
Control Rod
Control Rod
Set Screws
Detent Ring
Levers
Pump Control
KV18845
Centering Screws
Rear
Centering Screws
Front
Assembly
Spring Bolt
KV18845
11/22/00 7 - 13
IMPORTANT: A 3.26.4 mm (1/8 in.1/4 in.)
horizontal gap between upper centering plate
and lower centering bracket must be maintained
when adjusting screws (AD).
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
To adjust the left side wheels rearward movement:
Loosen jam nut and turn centering screw (B) in
To adjust the right side wheels forward movement:
Loosen jam nut and turn centering screw (C) in
To adjust the right side wheels rearward movement:
Loosen jam nut and turn centering screw (D) in
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.
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 doesnt 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.)
20. Verify detent ball is in detent groove of detent ring.
Tighten set screws to 40 Nm (30 lb-ft).
Left Wheels
Forward Movement
Left Wheels
Rearward Movement
Right Wheels
Right Wheels
Rearward Movement
Forward Movement
KV18847
D
C
B A
3.26.4 mm (1/81/4 in.) Gap
No Gap
7 - 14 11/22/00
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.
25. Lower ROPS.
STEERING CONTROL LEVER
ADJUSTMENTCENTERING
IMPORTANT: Centering plate(s) must be properly
adjusted to perform steering control lever
centering adjustment.
Reason:
To center the steering control levers.
Procedure:
locked position.
4. Remove cover plates to gain access to the steering
linkage. (See REMOVING COVER PLATES in
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.
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.
10. Remove M10 x 30 cap screw from each steering
lever yoke.
12. Lower ROPS.
Jam Nuts
KV15260
M10 x 30 Cap Screw
Align
11/22/00 7 - 15
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.
Reason:
To correctly adjust and pre-load detent.
Procedure:
locked position.
5. Remove left steering control rod, link rod and
dampener from cross shaft bellcrank.
6. Install an M10 x 30 cap screw and nut in dampener
attaching hole. Tighten securely.
7. Loosen detent ring set screws and rotate ring to
verify detent ball is in groove on ring. Tighten set
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 8.110.8 Nm (7296 lb-in.).
Adjust the detent spring screw to achieve the
correct reading.
9. Tighten detent spring screw jam nut to 33.9 Nm
(25 lb-ft).
10. Attach left link rod, control rod and dampener.
11. Remove M10 x 30 cap screw from each steering
lever yoke.
13. Lower ROPS.
KV31012
Link Rod
Control Rod
Left Bellcrank
Dampener
Dealer Installed
Cap Screw and Nut
KV31011a
Dealer Installed
Cap Screw
Detent Spring Screw
Right Bellcrank
Detent Ring
KV31011
Jam Nut
KV31013
Detent Spring Screw
Jam Nut
7 - 16 11/22/00
STOPS ADJUSTMENTTRACKING
IMPORTANT: If steering system adjustments have
been made for any reason, the steering control
lever stops must be adjusted.
The steering control lever stops must be
adjusted properly to prevent damage to the
linkage and internal hydrostatic components.
Reason:
To ensure machine tracks straight and to protect
hydrostatic pumps from damage.
Equipment:
JT05719 Photo Tachometer
Procedure:
section.)
locked position.
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.
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.
22. Lower ROPS.
c
CAUTION
using remote start box. Do NOT use remote start
Forward Stop
Rear Stop
KV13984
Stop Screw
Stop Screw
Jam Nuts
11/22/00 7 - 17
AUXILIARY HYDRAULIC CONTROL
HANDLE ADJUSTMENT
Reason:
This procedure ensures that the auxiliary control handle
is centered, giving equal hydraulic oil flow in all
positions.
Procedure:
locked position.
3. Remove cover plates to gain access to the control
valve. (See REMOVING COVER PLATES in
4. Lock handle in the middle (neutral) position by
turning key to the left.
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 Nm
(20 lb-ft).
HYDRAULIC CONTROL HANDLE
ADJUSTMENT HANDS ONLY
MACHINES
Reason:
This procedure ensures that the control handles are
centered, giving equal hydraulic oil flow in all positions.
Procedure:
2. Raise the boom and place on the boom locks.
locked position.
4. Remove cover plates to gain access to the control
valve. (See REMOVING COVER PLATES in
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.
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 Nm
(20 lb-ft).
KV15239
KV13989
Auxiliary Cable
Jam Nuts
KV0575
KV0582a
Cable
Jam Nuts
Cable
Jam Nuts
7 - 18 11/22/00
REPAIR STEERING
REPAIR
CENTERING PLATE REMOVAL
SINGLE PLATE MODELS
locked position.
4. Remove spring bolt assembly.
NOTE: Spring bolt will be under a small amount of
tension when removed. Exercise care when
removing bolt.
5. Remove left side guide pin nut.
6. Lift left side of centering plate from lower rear
centering bracket slot.
7. Remove centering plate by prying it from right guide
pin.
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.
KV13981
Spring Bolt Assembly
KV14332
Left Guide Pin Nut
Bracket
KV14333
Right Guide Pin
Bracket
KV14338
Right Guide Pin
Control Lever
Jam Nut
Control Rod
Cap Screw Cap Screw
Cap Screw
11/22/00 7 - 19
STEERING REPAIR
CENTERING PLATE REMOVAL
DUAL PLATE MODELS
locked position.
NOTE: Front centering plate must be removed to gain
access to rear centering plate spring bolt
assembly.
4. Remove spring bolt assembly.
5. Remove left side guide pin nut.
6. Lift left side of centering plate from lower centering
bracket slot.
7. Remove centering plate by prying it from right guide
pin bushing.
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.
KV13981
KV18839
Left Guide Pin Nut
Bracket
KV18837
Right Guide Pin
Bracket
KV14338
Right Guide Pin
Control Lever
Jam Nut
Control Rod
NOTE: Rear components shown; front is similar.
Cap Screw Cap Screw
Cap Screw
NOTE: Rear plate shown; front is similar.
7 - 20 11/22/00
REPAIR STEERING
CENTERING PLATE INSPECTION
1. Inspect bushing and spacer for wear and/or
breakage. Replace if required.
2. Inspect guide pins and guide pin bushings for
breakage or wear.
3. Inspect pump control lever bearings for excessive
play in bearing race. Replace as necessary.
4. Inspect centering screw bearing surface. Bearing
surface should be smooth and free of deep
scratches or wear. Replace as necessary.
KV14337
Bushing Spacer
KV14334
Guide Pin
Guide Pin Bushing
KV14335
Pump Control Lever
KV14336
Bearing Surface
Single Plate Models
KV18843
Bearing Surface
Dual Plate Models
11/22/00 7 - 21
STEERING REPAIR
CENTERING PLATE
INSTALLATIONSINGLE PLATE
MODELS
1. Loosen jam nuts. Adjust centering screws until each
bearing surface protrudes approximately 3.2 mm
(1/8 in.).
2. Install right guide pin, bushing and nut in mounting
plate. Tighten nut to 54 Nm (40 lb-ft).
3. Rotate mounting plate into position and install cap
screws (3 used). Tighten mounting plate cap
4. Install plastic bushing in left side of centering plate.
5. Slide centering plate onto right guide pin bushing.
6. Install left guide pin into plastic bushing.
7. Install left side of centering plate on rear centering
bracket.
8. Install and tighten centering plate guide pin nuts to
54 Nm (40 lb-ft).
9. Install spring bolt assembly onto centering plate
assembly. Tighten spring bolt to 67 Nm (50 lb-ft).
10. Perform centering plate adjustment. (See
CENTERING PLATE ADJUSTMENTSINGLE
PLATE MODELS in this section.)
CENTERING PLATE
INSTALLATIONDUAL PLATE
MODELS
NOTE: Installation of front and rear plates is similar.
Rear centering plate must be installed first.
1. Loosen jam nuts on each centering plate. Adjust
centering screws until each bearing surface
protrudes approximately 3.2 mm (1/8 in.).
3.2 mm (1/8 in.)
KV18846
KV14333
Mounting Plate
Right Guide Pin
Bushing
Left Guide Pin Nut
Bracket
M44227
KV13981
3.2 mm (1/8 in.)
KV18844
7 - 22 11/22/00
REPAIR STEERING
2. Install right guide pin, bushing and nut in mounting
plate. Tighten nut to 54 Nm (40 lb-ft).
3. Rotate mounting plate into position and install cap
screws (3 used). Tighten mounting plate cap
4. Install plastic guide pin bushing in left side of
centering plate.
5. Slide centering plate onto right guide pin bushing.
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 Nm (40 lb-ft).
9. Install spring bolt assembly onto centering plate
assembly. Torque spring bolt to 67 Nm (50 lb-ft).
10. Repeat STEPS 2-9 for front centering plate.
11. Perform centering plate adjustment. (See
CENTERING PLATE ADJUSTMENTDUAL
PLATE MODELS in this section.)
STEERING DAMPENER REMOVAL/
INSPECTION/INSTALLATION
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.
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 Nm (30 lb-ft).
KV18837
Centering Plate
Right Guide Pin
Bushing
Mounting Plate
NOTE: Rear plate shown; front plate is similar.
KV18839
Bracket
Left Guide Pin Nut
KV13981
KV14340
Bracket
Dampener
Cross Shaft
Shim Washer(s)
11/22/00 7 - 23
STEERING REPAIR
REMOVAL/INSPECTION/
INSTALLATION
Removal:
1. Remove cap screw from steering control lever link
rod.
2. Remove spring from steering control lever
assembly.
3. Remove four cap screws from pivot bearing block.
4. Remove steering control lever assembly with spring
bracket attached.
Inspection:
1. Inspect steering control levers for damage.
2. Inspect pivot bearing for looseness or damage.
Replace if required.
Installation:
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)
3. Install link rod on steering control lever. Tighten link
rod cap screw to 40 Nm (30 lb-ft).
4. Install spring.
KV13984
Cap Screw
KV14341
Spring
Pivot Bearing
KV15261
Pivot Bearing Block
KV14341
Spring Bracket
KV13984
Cap Screw
7 - 24 11/22/00
REPAIR STEERING
STEERING CROSS SHAFT ASSEMBLY
SINGLE PLATE MODELS
NOTE: Cross shaft assembly shown is for left-side
mounting. Some models may use right-side
mounting. Other components are the same.
Removal:
section.)
locked position.
5. Remove cover plates to gain access to the cross
shaft. (See REMOVING COVER PLATES in
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.
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
3. Attach control rods to cross shaft and tighten cap
4. Attach link rods and dampeners to cross shaft
assembly. Tighten cap screws to 40 Nm (30 lb-ft).
STEERING CROSS SHAFT ASSEMBLY
DUAL PLATE MODELS
NOTE: Cross shaft assembly shown is for right-side
mounting. Some models may use left-side
Removal:
section.)
locked position.
5. Remove cover plates to gain access to the cross
shaft assembly. (See REMOVING COVER
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.
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
3. Attach right control rod to cross shaft assembly and
tighten cap screws to 40 Nm (30 lb-ft).
Link Rod
Cross Shaft
Dampeners
Link Rod
Right
Support
Bracket
KV18003
Control Rods
Assembly
Link Rod
Dampeners
Link Rod
Control Rods
Detent Ring
KV18845
Right
Support
Bracket
Cross Shaft
Assembly
11/22/00 7 - 25
STEERING REPAIR
4. Attach right link rod and dampener to cross shaft
assembly. Tighten cap screws to 40 Nm (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.
7. Check and adjust link rods. (See STEERING
CONTROL LEVER ADJUSTMENTCENTERING
in this section.)
8. Check and adjust steering control lever stops. (See
STEERING CROSS SHAFT
ASSEMBLY REPAIRDUAL PLATE
MODELS
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.
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/
INSTALLATIONDUAL PLATE MODELS in this
section.)
KV18849
A
D
B
C
E
F
G
I
H
J
K
F
R
O
N
T
NOTE: Cross shaft (J) is drawn for right-side
mounting. Some models may use left-side
7 - 26 11/22/00
REPAIR STEERING
HANDLE DISASSEMBLY/ASSEMBLY
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.
2. Remove spring pin from handle. Remove cable
assembly from handle.
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 13 for
left handle.
4. Assembly is done in reverse order of removal.
Tighten set screw to 9 Nm (80 lb-in.). Tighten lock
nut to 13.5 Nm (120 lb-in.).
KV14344
Cable Bracket
A
KV14343
Spring Pin
Cable Assembly
KV14345
Lock Nut
Set Screw
BRAKES CONTENTS
Page
CONTENTS
11/22/00 8 - 1
BRAKES
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
8 - 2 11/22/00
CONTENTS BRAKES
BRAKES SPECIFICATIONS
11/22/00 8 - 3
SPECIFICATIONS
BRAKE LINER
Thickness (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.76 mm (3/16 in.)
Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.9 cm (9 in.)
Hydrostatic Motor-to-Brake Assembly Socket Head Screws. . . . . . . . 118 Nm (87 lb-ft)
Brake Assembly-to-Frame Mount Screws . . . . . . . . . . . . . . . . . . . . . . 109 Nm (80 lb-ft)
Cover Plate-to-Brake Housing Cap Screws . . . . . . . . . . . . . . . . . . . . 109 Nm (80 lb-ft)
Chain Case Cover Cap Screws. . . . . . . . . . . . . . . . . . . . . . . . 7080 Nm (5259 lb-ft)
DRIVE SHAFT ASSEMBLY
Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8006 N (1800 lb)
CHAIN CASE
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4 L (3 gal) (Each Side)
OTHER MATERIALS
Number Name Use
HY-GARD
, LOW VIS HY-GARD
(cold weather
operation), John Deere TORQ-GARD SUPREME

or PLUS-50
Fill hydraulic reservoir and chain

case.
PM20166 John Deere 5900 RTV Silicone Seal chain case covers.
TORQ-GARD SUPREME and PLUS-50 are registered trademarks of Deere & Company.
THEORY OF OPERATION BRAKES
8 - 4 11/22/00
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.
KV15125
Actuator Lever
Cylinder
Actuator
Brake
(Left Side Shown)
BRAKES BRAKE EXPLODED VIEW
11/22/00 8 - 5
BRAKE EXPLODED VIEW
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
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
28. Yoke
29. Dowel Pin
30. Cylinder Arm
31. Boot Plate
32. Boot
33. Screw
34. Cap Screw
35. Seal
KV15124
1
2
3
5
6
7
9
11
14
15
16
18
19
23
24
25
26
27
28
29
30
32
33
34
35
26
4
8
12
13
17
20
21
22 24
31
10
(Right Side Shown)
DIAGNOSIS AND TROUBLESHOOTING BRAKES
8 - 6 11/22/00
DIAGNOSIS AND TROUBLESHOOTING
DIAGNOSIS
TROUBLESHOOTING
Test Conditions:
Park machine on level surface.
Bucket rolled back.
Boom lowered.
Engine running at half throttle.
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
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
Troubleshoot park brake switch. (See
Problem or
Symptom
B
r
a
k
e
s

n
o
t

h
o
l
d
i
n
g
.
B
r
a
k
e
s

s
t
a
y

l
o
c
k
e
d
.
G
r
i
n
d
i
n
g

n
o
i
s
e

w
h
i
l
e

o
p
e
r
a
t
i
n
g

s
k
i
d

s
t
e
e
r
.
Check or
Solution
Check park brake solenoid.
Check park brake switch/circuit.
Check charge pump for proper pressure.
Inspect/replace brake lining.
BRAKES REPAIR
11/22/00 8 - 7
REPAIR
BRAKE REMOVAL
3. Remove cover plates to access the brake assembly.
(See REMOVING COVER PLATES in the
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).
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.)
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. Disconnect hydraulic hoses from actuator cylinder.
12. Disconnect hydraulic lines from hydrostatic motor.
Close all openings with caps or plugs.
13. Attach a strap around hydrostatic motor/brake
assembly.
Chain Case Cover
KV13152
Nut
KV13157
Drive Shaft
Rear Drive Chain
Front Drive Chain
KV13156
Cylinder Actuator
Early Models
Hoses
Hoses
KV18850
Hose
Late Models
Hoses
Hydraulic Lines
Strap
KV13153
REPAIR BRAKES
8 - 8 11/22/00
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.
BRAKE DISASSEMBLY
1. Install C-clamp around brake actuator mounting
points to relieve tension on pivot pins for removal.
2. Remove retainer pins, mounting pins, and brake
actuator. Slowly back off C-clamp to relieve brake
actuator pressure and remove clamp.
3. Remove four screws securing boot plate to brake
housing. Remove boot and plate.
4. Remove retaining ring from drive shaft. Remove
shim(s).
5. Remove eight cap screws from brake housing.
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.
KV13154
Cap Screws
KV18874
Actuator Cylinder
C-Clamp
KV18536
Mounting Pin
(2 used)
Retaining Pin
(2 used)
KV18537
Screw
(4 used)
Boot Plate
Boot
KV13151A
Retaining Ring
Cap Screws
KV13134
M10
Cap Screws
BRAKES REPAIR
11/22/00 8 - 9
8. Remove actuator plate and five balls.
NOTE: Brake gear might require some prying between
bottom of gear and brake housing for removal.
9. Remove retaining ring and brake gear.
10. Remove keys from shaft and remove shaft from
housing.
NOTE: Bearing is a press fit.
11. Remove bearing from shaft.
12. Remove seals in brake cover and housing.
KV18543
Ball
(5 used)
Actuator
Detents
(5 used)
KV18542
Retaining Ring
Brake Gear
KV18540
Key
(2 used)
Shaft
KV18538
Bearing
Seal
Housing
KV18541
KV18878
Seal
Cover
REPAIR BRAKES
8 - 10 11/22/00
BRAKE INSPECTION
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.
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.
BRAKE ASSEMBLY
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.
5. Lubricate five detents in housing and actuator and
five balls with multi-purpose grease. Install balls
and actuator into housing.
NOTE: Stator is positioned by locating indexing tabs
into half rounds of housing.
6. Install gasket, stator, and lining into housing.
Position stator indexing tabs into half rounds of
housing.
NOTE: Install longer cap screws through cylinder arm.
7. Install housing cover with cap screws. Tighten cap
KV18545
KV18543
Ball
(5 used)
Actuator
Detents
(5 used)
Indexing Tabs
KV18552
Arm
KV13134
Cylinder
BRAKES REPAIR
11/22/00 8 - 11
8. Press bearing into housing cover. Apply a preload
force of 8006 N (1800 lb-force).
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 Nm (87 lb-
ft).
BRAKE INSTALLATION
1. Attach hoist and strap to wheel motor/brake
assembly.
2. Install assembly into machine with a new gasket
and secure with ten cap screws and nuts. Tighten
cap screws to 109 Nm (80 lb-ft).
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
7080 Nm (5259 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.)
10. Burnish brakes. (See BURNISH BRAKES in this
section.)
KV18877
KV18563
KV13154
KV13157
Drive Shaft
Rear Drive Chain
Front Drive Chain
REPAIR BRAKES
8 - 12 11/22/00
BURNISH BRAKES
Reason:
To ensure brakes were properly installed and to
burnish brake lining material.
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.
BRAKE ACTUATOR CYLINDER
Removal:
3. Remove cover plates. (See REMOVING COVER
PLATES in the MISCELLANEOUS section.)
5. Start engine and disengage park brake using
remote start box. Brake spring tension will be
removed to loosen upper pivot pin.
6. With engine running and park brake disengaged,
remove retaining pin and upper pivot pin from
cylinder rod yoke.
7. Turn engine off.
c
CAUTION
c
CAUTION
c
CAUTION
Brake cylinder rod will move when the park
brake is engaged or disengaged. Keep fingers
away from cylinder rod.
Actuator
Cylinder
Retaining Pin
Actuator Lever
Upper Pivot Pin
KV18007
BRAKES REPAIR
11/22/00 8 - 13
8. Disconnect hydraulic hoses from cylinder. Close all
openings with caps or plugs.
.
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.)
10. Remove lower pivot pin from actuator cylinder
base. Remove actuator cylinder from cylinder arm.
Installation:
NOTE: Use a hair-pin type clamp to install brake
cylinder.
1. Installation is the reverse of removal.
Hoses Hoses
KV18015
Early Models
KV18887
Hose
Late Models
Hoses
Lower Pivot Pin
Retaining Pin
Cylinder Arm
KV18016
REPAIR BRAKES
8 - 14 11/22/00
HYDRAULICS CONTENTS
Page
CONTENTS
11/22/00 9 - 1
HYDRAULICS
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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
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
Page
9 - 2 11/22/00
CONTENTS HYDRAULICS
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
HYDRAULICS SPECIFICATIONS
11/22/00 9 - 3
SPECIFICATIONS
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 3741034 kPa (3100150 psi)
Hydraulic Circuit Relief Pressure . . . . . . . . . . . . . . . . 22 7531379 kPa (3300200 psi)
Charge Circuit Pressure . . . . . . . . . . . . . . . . . . . . . . . . 13791551 kPa (200225 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)
SPECIFICATIONS HYDRAULICS
9 - 4 11/22/00
Hydraulic/Charge Pump Body Cap Screws. . . . . . . . . . . . . . . . . . . . . . 35 Nm (26 lb-ft)
Boom Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm (33 lb-ft)
Bucket Circuit Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Nm (28 lb-ft)
System Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Nm (34 lb-ft)
Anti-Cavitation Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm (33 lb-ft)
Spool Cover Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 Nm (84 lb-in.)
Spool Retainer Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 Nm (84 lb-in.)
Valve Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Nm (18 lb-ft)
Bucket Cylinder Upper Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Nm (54 lb-ft)
Boom Cylinder Lower Pivot Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624 Nm (460 lb-ft)
Work Port Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Nm (28 lb-ft)
Lift Check Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Nm (48 lb-ft)
Valve Body Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Nm (28 lb-ft)
Upper Cylinder Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624 Nm (460 lb-ft)
Lower Cylinder Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Nm (54 lb-ft)
Boom and Bucket Cylinder Lock Nut. . . . . . . . . . . . . . . . . . . . . . . . . 136 Nm (100 lb-ft)
High-Flow Pump Gear Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.1 Nm (30 lb-ft)
High-Flow Pump Retaing Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Self-Leveling Valve Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Nm (20 lb-ft)
OTHER MATERIALS
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
Number Name Use
Petroleum Jelly To lubricate O-rings.
To retain components during assembly.
PT569/
TY6332
NEVER-SEEZ
Anti-Seize
Compound
Apply to ID of cylinder bushings.
LOCTITE is a registered trademark of the Loctite Corp.
NEVER-SEEZ is a registered trademark of the Emhart Chemical Group.
SYSTEM COMPONENTS AND OPERATION HYDRAULICS
9 - 5 11/22/00
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.
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.
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 (toelower, 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 (toedump, heelroll 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
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.
HYDRAULICS SYSTEM COMPONENTS AND OPERATION
11/22/00 9 - 6
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.
HYDRAULICS SYSTEM SCHEMATIC
11/22/00 9 - 7
SYSTEM SCHEMATIC
KV31129
Hydraulic
Reservoir
Spin On
Filter
Charge Flow
210 psi
Brake Valve
A B
Drive Motor
Brake
High-Flow
Valve (Optional)
High-Flow
Pump
(Optional)
Hydrostatic
Pumps
3000 psi
Drive Motor
Brake
Engine
Oil
Cooler
Main Control Valve
3100 psi
3300 psi
Boom
Bucket
Aux
Anticavitation
Check
A
B
A
B
A
B
Lockout
Solenoid
Lockout
Solenoid
Lift Cylinders
Tilt Cylinders
Auxiliary
Couplers
Self-Leveling
Valve (Optional)
A
B
C D
Hydraulic/Charge
Pump
75 psi
SYSTEM COMPONENT LOCATION HYDRAULICS
9 - 8 11/22/00
SYSTEM COMPONENT LOCATION
Right Bucket Cylinder
Left Bucket Cylinder Auxiliary Couplers
Auxiliary Hydraulic Lines
Bucket Hydraulic Lines
Bucket Cylinder Lines
Right Boom Cylinder
Boom Hydraulic Lines
KV13043
HYDRAULICS SYSTEM COMPONENT LOCATION
11/22/00 9 - 9
SYSTEM COMPONENT LOCATION
Hydraulic
Return Line
Hydraulic
Suction Line
Control Valve
Hydraulic
Pressure Line
Hydraulic/
Charge Pump
Drain Plugs
Hydraulic
Reservoir
Hydraulic Oil
Temperature
Sender (Early
Models)
High Flow Pump
(Optional)
Hydraulic Oil Dipstick
Self-Leveling
Valve (Optional)
Oil Cooler
Foot Pedal
Assembly
KV31097
High Flow Valve
(Optional)
Charge Pressure Relief
Valve (Inside Oil Filter
Head Housing)
Vent
Hydraulic Oil
Temperature
Sender (late
models)
Line to Boom
Cylinders
Auxiliary Quick
Coupler Case
Drain Line
Lines to
Bucket
Cylinders
9 - 10 11/22/00
CONTROL VALVE COMPONENT LOCATION
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
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
1
2
3
4
6
7
9
10
3
10
8
24
3
14
12
13
15
16
17
11
9
18
19
2
8
3
10
20
5
25
21
8
KV31130
22
3
3
23
18
HYDRAULICS SYSTEM COMPONENT LOCATION
11/22/00 9 - 11
HYDRAULIC/CHARGE PUMP COMPONENT LOCATION
KV13951
Screw (8)
45 Nm (33 lb-ft)
End Plate
O-Ring
Body
Drive Gear
Idler Gear
Wear Plate
Seal
Backup Gasket
O-Ring
(250 Shown)
9 - 12 11/22/00
BUCKET CYLINDER COMPONENT LOCATION
BOOM CYLINDER COMPONENT LOCATION
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
A. Bushing
B. Cylinder Barrel
C. Nut
D. Piston
E. Cylinder Rod Guide
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
KV13266
B
C
M
N
O
P
O
K
I
L
F
D
G
H
J
E
A
KV13267
A
B
D
C
E
G
H
F
J
K
I
L
O
N
M
HYDRAULICS TROUBLESHOOTING
11/22/00 9 - 13
TROUBLESHOOTING
Problem or
Symptom
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Check or
Solution
Hydraulic oil level low in reservoir
Check and add oil
G G G G G G G G
Hydraulic/charge pump damaged
or worn
Check flow
G G G G G G G G
Control valve linkage or spool
binding or damaged
G G G G G G G G G G G
Control valve not functioning
properly
G G G G G G G G G G
Check cylinders for bent or
damaged rods
G G G G G G G G G
Stuck pivot pins G G G G G G G
Leaking cylinder packing G G G G G G G G
Low system pressure
Check system relief valve
pressure setting
G G G G
Air in hydraulic cylinders
Check fluid level and run
hydraulics to bleed system
G G G G
Boom or bucket solenoid
malfunctioning
G G G G G
Bucket overloaded G G G G G
High system pressure
Check system relief valve
pressure setting
G G G
Hydraulic oil cooler restricted G
Charge pressure relief valve
damaged or setting incorrect
G
Hydrostatic pump damaged or
leaking
G G G
DIAGNOSIS HYDRAULICS
9 - 14 11/22/00
DIAGNOSIS
Test Conditions:
Hydraulic reservoir oil at proper level.
Operator in seat.
Seat belt fastened.
Test Conditions:
Engine running at slow idle.
1. Foot pedals. Pedals should move freely. Check linkage from pedals to valve.
Check for bent spools in valve.
1. Instrument panel. Hydraulic oil temperature and filter
restriction warning lights should be
off.
Filter restriction light onreplace
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
Check bucket cylinders for bent rod
or damaged cylinder wall.
Check hydraulic hoses, tubing, and
connections for leaks.
HYDRAULICS TESTS AND ADJUSTMENTS
11/22/00 9 - 15
BOOM AND BUCKET LOCKOUT
SOLENOIDS CHECK
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.
Results:
If function is not correct, check boom and bucket
lockout solenoid circuit.
SYSTEM RELIEF VALVE PRESSURE
TEST
Reason:
To check high pressure relief valve.
Equipment:
Procedure:
on connectors.
Hydraulic Tester.
JT03377 JT03012
JT05690
KV13885
KV13884
KV15257
KV15136
Male Quick
D01074AA
In-Line
Hydraulic
Tester
Disconnect-
to-Inlet Hose
Outlet-to-Female
Quick Disconnect
Hose
Outlet
Inlet
TESTS AND ADJUSTMENTS HYDRAULICS
9 - 16 11/22/00
5. Attach quick disconnects to auxiliary hydraulic
connectors.
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:
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)
Results:
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.
PRESSURE TEST
Reason:
To ensure there is sufficient oil pressure to charge the
hydrostatic systems and supply oil to the hydraulic sys-
tem.
Equipment:
JT03344 2068 kPa (300 psi) Gauge.
JT03017 Hose with quick disconnect.
38H5069 Tee Fitting (Parker #8 R6LO-S) 13/16-16
Female Swivel ORFS x 13/16-16 Male ORFS x 13/
16-16 Male ORFS.
JT03457 Adapter (in Kit #JT05412)
Procedure:
2. Raise boom fully and engage the boom lock. Stop
engine and relieve hydraulic pressure.
pumps. (See COVER PLATE REMOVAL/
INSTALLATION in the MISCELLANEOUS section.)
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.
KV18562
c
CAUTION
KV15134
38H5069
JT03457
JT03017
JT03344
11/22/00 9 - 17
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.
10. Use remote start box to start engine.
11. Operate hydraulic controls until oil reaches normal
12. Set throttle to wide open throttle (WOT).
Specifications:
Charge pressure must be 13791551 kPa
(200225 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.
c
CAUTION
KV18853
Hydraulic Oil
Filter Manifold
Charge Flow Line
9 - 18 11/22/00
HYDRAULIC/CHARGE PUMP FLOW
TEST
Reason:
To ensure that the hydraulic/charge pump is delivering
sufficient oil flow to operate the hydraulic system
properly.
Equipment:
Procedure:
on connectors.
Hydraulic Tester.
6. Attach quick disconnects to auxiliary hydraulic ports
located on left boom arm.
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:
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.)
JT03377 JT03012
JT05690
KV13885
KV13884
KV15257
KV15136
Male Quick
D01074AA
In-Line
Hydraulic
Tester
Disconnect-
to-Inlet Hose
Outlet-to-Female
Quick Disconnect
Hose
Outlet
Inlet
KV18562
11/22/00 9 - 19
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.
Reason:
To check boom and bucket circuit relief valves.
Equipment:
38H1417 Cap
JT03494 Adapter Fitting
JT07192 Electric/Hydraulic Pump
035 000 kPa (05000 psi) Gauge
Procedure:
3. Gain access to the hydraulic control valve. (See
COVER PLATE REMOVAL/INSTALLATION in the
4. Disconnect boom raise line at both ends and set
aside. Cap fitting at boom lockout solenoid.
5. Connect electric/hydraulic pump hose with gauge to
boom raise port.
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.
Specifications:
Boom
Circuit Relief Pressure. . . . . . . . . 22 753 1379 kPa
(3300 200 psi)
Results:
If pressure is not within specification, replace circuit
relief valve.
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.
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.
KV18008
Boom Raise
Port
Electric/Hydraulic
Pump Hose
KV18009
Electric/Hydraulic
Pump
Hose-to-Valve
Gauge
9 - 20 11/22/00
BOOM LIFT CHECK TEST
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.
Specifications:
Results:
If boom drifts down:
Rebuild or replace lift check valve.
BOOM DRIFT UP CHECK
Reason:
To ensure that boom lower circuit does not have
internal leaks.
Procedure:
1. Start engine and use boom to raise front of machine
a few inches off ground.
2. Shut off engine.
NOTE: Bucket may have to be in dump position.
Specifications:
Results:
If boom drifts upward:
Check for leaking cylinder packing. Rebuild or
replace cylinder.
Check for leaking control valve spool. Replace
valve.
BUCKET DRIFT DUMP POSITION
CHECK
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 half-
way position and shut off engine.
Specifications:
Slight bucket drift is permissible.
Results:
If bucket drifts in dump position:
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.
BUCKET DRIFT ROLLBACK
POSITION CHECK
Reason:
To ensure that bucket rollback circuit does not have
internal leaks.
Procedure:
1. Start engine and use bucket to raise machine a few
inches off ground.
2. Shut off engine.
Specifications:
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 9 - 21
BUCKET LIFT CHECK TEST
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.
Specifications:
Bucket must not roll back.
Results:
If bucket rolls back:
Replace lift check valve.
BUCKET SELF-LEVELING
ADJUSTMENT
Reason:
To ensure that bucket remains level through the lift
range of the boom.
Procedure:
2. Raise ROPS. [See RAISING ROPS(ROLL OVER
PROTECTION STRUCTURE) in the
MISCELLANEOUS section.]
3. Loosen jam nut.
NOTE: Make adjustments in 1/2 turn increments.
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:
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.)
KV31141
Jam Nut
Adjusting
Screw
Self-Leveling
Valve
REPAIR HYDRAULICS
9 - 22 11/22/00
REPAIR
REMOVAL
3. Shut off engine.
4. Gain access to the hydraulic/charge pump. (See
COVER PLATE REMOVAL/INSTALLATION in
5. Drain hydraulic reservoir.
IMPORTANT: Clean hydrostatic and hydraulic/
charge pump cases before separating pumps to
6. Disconnect inlet and high pressure hydraulic lines
from charge pump.
IMPORTANT: Plug pump openings and hose ends
to prevent contamination of hydraulic system.
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.
DISASSEMBLY
1. Remove and discard wear plate seal and backup
gasket.
2. Remove idler gear and drive gear from pump body.
c
CAUTION
KV14291
Hydraulic/Charge
Pump
Hydraulic High
Pressure Line
Hydraulic
Inlet Lines
KV14304
Mark Case
KV14310
Wear Plate
Wear Plate Seal
Backup Gasket
KV14305
Pump Body
Drive Gear
Idler Gear
HYDRAULICS REPAIR
11/22/00 9 - 23
3. Remove pump body from end plate.
4. Remove and discard O-ring.
5. Remove cover plate and discard O-ring.
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.
5. Replace gear assembly if shaft measures less than
19 mm (0.748 in.) in bushing area.
6. Inspect inside diameter of bushings in end plate
and front hydrostatic pump. Replace if greater than
19.2 mm (0.755 in.).
7. Inspect end plate and front hydrostatic pump for
scoring and wear. Replace if wear or scoring
exceeds 0.0381 mm (0.0015 in.).
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.
KV14306
O-Ring
End Plate
Pump Body
KV14308
O-Ring
Cover Plate
KV14299
KV14307
KV14309
KV14312
REPAIR HYDRAULICS
9 - 24 11/22/00
ASSEMBLY
NOTE: Pay special attention to orientation of
components during assembly.
1. Using new O-ring, install pump body on end plate.
2. Using new O-ring install cover plate.
3. Install idler and drive gears in pump body.
4. Install new seal and backup gasket in new wear
plate. Step in middle of backup gasket must nest in
seal step.
5. Install new wear plate assembly in pump body.
KV14306
O-Ring
End Plate
Pump Body
Cover Plate
KV14305
Pump Body
Drive Gear
Idler Gear
KV14294
Wear Plate Seal
Backup Gasket
KV14310
Wear Plate Assembly
HYDRAULICS REPAIR
1/4/01 9 - 25
INSTALLATION
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 oclock
position will always have passages. If there are
passages in the port at the 9 oclock position, a
plug must be installed or the pump will not prime. If
there are no passages in the port at the 9 oclock
position, no plug is required.
2. Install new O-ring on front hydrostatic pump.
3. Install hydraulic/charge pump assembly onto front
hydrostatic pump using eight screws and washers.
IMPORTANT: Use an alternating pattern and
tighten hydraulic/charge pump screws to
35 Nm (26 lb-ft).
4. Connect inlet and high pressure hydraulic lines to
5. Perform start-up procedure before operating skid
steer. (See START-UP PROCEDURE AFTER
HYDRAULIC COMPONENT REPLACEMENT in
HYDROSTATIC POWER TRAIN section.)
Passages
Port at 3 OClock Position Port at 9 OClock Position
KV31116
with Plug Installed
KV31113
KV14313
O-Ring
KV14291
Hydraulic/Charge
Pump
Hydraulic High
Pressure Line
Hydraulic
Inlet Line
REPAIR HYDRAULICS
9 - 26 11/22/00
HIGH-FLOW PUMP
IMPORTANT: To prevent contamination of the
hydraulic system, thoroughly clean fittings
before disconnecting hydraulic lines.
Removal:
1. Remove left side engine cover.
2. Disconnect suction line and output line from pump.
3. Remove cap screws and nuts.
4. Remove pump from machine.
Disassembly:
NOTE: Gear is keyed on to a tapered shaft.
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.
Assembly:
1. Install gear and nut onto shaft. Tighten nut to
40.7 Nm (30 lb-ft).
Installation:
1. Install new O-ring and position pump on engine.
2. Install cap screws and nuts. Tighten to 50 Nm
(35 lb-ft).
3. Connect output and suction lines to pump.
4. Install left side engine cover.
Output Line
Suction Line
Cap Screw
Nuts
Nut
O-Ring
HYDRAULICS REPAIR
11/22/00 9 - 27
HIGH-FLOW VALVE
Replacement:
1. Disconnect wiring connector.
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.
CONTROL VALVE REMOVAL
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
7. Lock auxiliary hydraulic handle in the OFF position.
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.
Case Drain Line
Auxiliary Hydraulic
Line
Line from High-
Flow Pump
Thumb Nut
Solenoid
Jamb Nut
KV31070
Wire Connector
Bracket
Jam Nuts
Bellcrank
Cable
Rod End
REPAIR HYDRAULICS
9 - 28 11/22/00
IMPORTANT: Cap and plug pump openings and
hose ends to prevent contamination of
hydraulic system.
NOTE: Tag hydraulic lines to ease installation.
11. Disconnect boom line fittings and remove boom
lines from control valve.
12. Remove cap screws and isolator plate from both
left and right sides.
13. Remove clamp (left side only).
14. Remove clamp.
15. Disconnect bucket dump line fittings and remove
line.
16. Disconnect bucket rollback fittings and remove line.
17. Remove clamp.
18. Disconnect auxiliary line fittings and remove lines.
19. Remove cotter pins and clevis pins from spools.
20. Disconnect high pressure line and return line.
c
CAUTION
KV31071
Boom Lower
Line Fittings
Boom Raise
Line Fittings
KV31072
Isolator Plate
Clamp
Cap Screws
NOTE: Left side shown.
KV31073
Bucket Rollback
Line Fittings
Bucket Dump
Line Fittings
Clamp
KV31074
Clamp
Auxiliary Line
Fittings
KV31075
Return Line
Cotter
Pins
High Pressure
Line
Clevis
Pins
HYDRAULICS REPAIR
11/22/00 9 - 29
21. Remove three cap screws and nuts and remove
control valve.
CONTROL VALVE DISASSEMBLY
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.
Cap Screws
and Nuts
KV31076
KV31014
Load Check Valves
Boom Spool
Plug
System Relief
Valve
Anti-Cavitation
Check Valve
Boom Relief
Bucket Spool
Auxiliary
Spool
Spool Detent
Cover
KV31014
Boom Raise
Fitting
Hydraulic
Supply
Hydraulic
Return
Boom, Bucket
and Auxiliary
Fittings
REPAIR HYDRAULICS
9 - 30 11/22/00
NOTE: Boom and auxiliary spool valves have detent
balls that are retained by the spool cover. Be
careful not to lose them during disassembly.
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.
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.
4. Carefully pull spool from housing and place on
clean work surface.
5. Remove O-ring and wiper from spool.
6. Remove retainer and spacer from spool.
KV14317
KV31015
KV31018
O-Ring
Wiper
KV31017
Wiper
O-Ring
Retainer Spacer
HYDRAULICS REPAIR
11/22/00 9 - 31
7. Remove spiral ring that retains the cap in spool
cover. Remove cap and detent sleeve from cover.
8. Remove screws, sleeves and retainers (2 used)
from opposite side of valve housing.
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 37 for auxiliary spool.
12. Remove auxiliary spool retainer, wiper and O-ring
from opposite end of valve housing. Place all
auxiliary spool parts together.
13. Remove cover from bucket spool.
KV31018
Cover
Detent Sleeve
Cap
Spiral Ring
Retainers
Screws
Sleeves
KV31027
KV31028
Spacer
O-Ring
Wiper
Backup
Washer
KV31020A
O-Ring
Wiper
Retainer
KV31030
Bucket Spool
REPAIR HYDRAULICS
9 - 32 11/22/00
14. Pull bucket spool from housing. Remove O-ring,
wiper, retainer plate and spacer from spool.
NOTE: DO NOT disassemble the spool and spring
assemblies. There are no detail service parts.
15. Remove the retainer, wiper and O-ring from the
opposite end of the valve housing. Place all bucket
valve parts together.
16. Remove the boom relief valve.
17. Remove plug. If bucket relief valve is present,
update machine per mandatory PIP 00KV010.
KV31029
O-Ring
Wiper
Retainer
Spacer
KV31031
O-Ring
Wiper
Retainer
KV31023
Boom Relief
Valve Assy.
Plug
O-Ring
HYDRAULICS REPAIR
11/22/00 9 - 33
18. Remove the system relief valve.
19. Remove anti-cavitation check valve.
NOTE: The anti-cavitation check valve can be
disassembled but is only serviced as an
assembly. Large end of spring goes in cover.
NOTE: Machines having the high-flow option will not
have a lift check poppet and spring in the
auxiliary port.
20. Remove the three lift check assemblies.
21. Remove valve body plug.
KV31024
System Relief
Valve Assy.
O-Ring
Anti-Cavitation
Check Valve Assy.
KV31025
KV31026
O-Ring
Spring
Poppet
Lift Check Assy.
Boom Raise
Fitting
Auxiliary
Port
KV14322
O-Ring
REPAIR HYDRAULICS
9 - 34 11/22/00
CONTROL VALVE INSPECTION
1. Thoroughly clean and dry all parts.
2. Inspect each spool and spool bore for scratches,
fretting, or burrs.
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.
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.
5. Inspect boom and bucket (early models only) relief
valve. Verify pintle moves freely.
6. Inspect system relief valve. Verify pintle moves
freely.
7. Inspect anit-cavitation check valve for damage.
Verify seat moves freely within cover.
KV14318
Poppet
KV31033
KV31032
Seat
KV31034
Pintle
Pintle
KV31035
KV31025
HYDRAULICS REPAIR
11/22/00 9 - 35
REPAIR HYDRAULICS
9 - 36 11/22/00
CONTROL VALVE CROSS SECTION
KV31010
HYDRAULICS REPAIR
11/22/00 9 - 37
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
14. Spring Collar
15. Washer
16. Detent Sleeve
17. Spool End
18. Detent Sleeve
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
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
44. Auxiliary Spool
45. Spool Wiper
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)
REPAIR HYDRAULICS
9 - 38 11/22/00
CONTROL VALVE ASSEMBLY
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.
IMPORTANT: Replace all O-rings with new. Old or
damaged O-rings will leak.
1. Thoroughly clean and dry all parts.
2. Install new O-ring on valve body plug and install into
control valve. Tighten to 38 Nm (28 lb-ft).
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 Nm (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 Nm (28 lb-ft).
KV14322
O-Ring
KV31026
O-Ring
Spring
Poppet
Lift Check Assy.
Boom Raise
Fitting
Auxiliary
Port
HYDRAULICS REPAIR
11/22/00 9 - 39
6. Replace boom relief valve O-ring and install relief
valve. Tighten to 45 Nm (33 lb-ft).
7. Install bucket circuit plug. Tighten to 38 Nm
(28 lb-ft). If control valve has a bucket relief valve
perform mandatory PIP 00KV010.
8. Replace system relief valve O-ring and install valve.
9. Replace anti-cavitation check valve O-ring and
install. Tighten to 45 Nm (30 lb-ft).
10. Install O-ring, wiper, and retainer for auxiliary and
bucket spools. Tighten to 9.5 Nm (84 lb-in.).
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.
NOTE: All three spools are different. Be careful not to
mix spool and spring assemblies when
assembling valve.
KV31023
Boom Relief
Valve Assy.
Plug
O-Ring
KV31024
System Relief
Valve Assy.
O-ring
Anti-Cavitation
Check Valve Assy.
KV31031
O-Ring
Wiper
Retainer
Auxiliary
Bucket
Boom
KV31017
Wiper
O-Ring
Retainer Spacer
REPAIR HYDRAULICS
9 - 40 11/22/00
IMPORTANT: Be careful not to damage O-rings
when installing spools.
14. Carefully install spools in housing.
15. Use petroleum jelly to retain balls in boom spool.
Place four small balls and one large ball in spool.
16. Install spool covers and press on cover to seat O-
rings in control valve housing. Install cap screws
finger-tight.
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.
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 Nm
(84 lb-in.).
KV31039
KV31038
Cap Screw
Cover
KV31040
Detent Sleeve
KV31041
HYDRAULICS REPAIR
11/22/00 9 - 41
21. Move spools in and out to verify operation.
22. Replace O-ring on boom spool spacer.
23. Install spacer, O-ring, back-up washer and
retainers for boom spool.
24. Install retainers, sleeves and screws. Tighten
screws to 9.5 Nm (84 lb-in.).
CONTROL VALVE INSTALLATION
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.
1. Install three cap screws and nuts and tighten
mounting evenly to 24 Nm (18 lb-ft).
2. Install cotter pins and clevis pins to spools.
3. Connect high pressure line and return line.
KV31037
O-Ring
KV31019
Backup Washer
Wiper
Spacer
O-Ring
Retainers
Screws
Sleeves
KV31027
Cap Screws
and Nuts
KV31076
KV31075
Return Line
Cotter
Pins
High Pressure
Line
Clevis
Pins
REPAIR HYDRAULICS
9 - 42 11/22/00
4. Connect auxiliary line fittings.
5. Install clamp.
6. Connect bucket dump line fittings and bucket
rollback fittings.
7. Install clamp.
8. Install isolator plate to both left and right sides.
9. Install left side clamp.
10. Connect boom line fittings to control valve.
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.
17. Lower and secure the ROPS. (See RAISING ROPS
[ROLL OVER PROTECTION STRUCTURE] in the
KV31074
Clamp
Auxiliary Line
Fittings
KV31073
Bucket Rollback
Line Fittings
Bucket Dump
Line Fittings
Clamp
KV31072
Isolator Plate
Clamp
Cap Screws
NOTE: Left side shown
KV31071
Boom Lower
Line Fittings
Boom Raise
Line Fittings
KV31070
Wire Connector
Bracket
Jam Nuts
Bellcrank
Cable
Rod End
HYDRAULICS REPAIR
11/22/00 9 - 43
SELF-LEVELING VALVE
Removal:
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)
IMPORTANT: To prevent contamination of the
hydraulic system, thoroughly clean fittings
before disconnecting hydraulic lines.
4. Disconnect hydraulic lines (AD). Cap and plug all
openings.
5. Remove cap screws and remove valve.
Installation:
7. Install cap screws and tighten to 28 Nm (20 lb-ft).
NOTE: Inspect O-rings on hydraulic fittings for wear or
damage. Replace if necessary. Used or
8. Connect lines (AD).
9. Lower ROPS and secure.
BOOM CYLINDER REMOVAL
NOTE: Boom arm cylinders can be safely removed
while arms are supported on boom arm locks.
1. Park skid steer safely. Raise boom and place on
boom locks.
2. Sitting in operators 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.
3. Disconnect boom cylinder hydraulic lines at
cylinder.
4. Remove cap screw on top cylinder pivot pin.
Remove pin.
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
A
D
B
C
Cap Screws
c
CAUTION
KV14328
Boom Cylinder
Boom Lower Line
Boom Raise Line
Cap Screw
Pivot Pin
KV14329
REPAIR HYDRAULICS
9 - 44 11/22/00
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.
BOOM CYLINDER INSTALLATION
1. Install cylinder and lower pivot pin. Tighten nut to
624 Nm (460 lb-ft).
2. Install upper pivot pin. Tighten cap screw to 73 Nm
(54 lb-ft).
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.
BUCKET CYLINDER REMOVAL
1. Park skid steer on flat level surface. Lower boom lift
arms completely and turn engine off.
2. Sitting in operators 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.
KV14330
Cap Screw
KV14330
Pivot Cap Screw
KV14329
Cap Screw
Pivot Pin
c
CAUTION
Bucket cylinders can be safely removed only
while lift arms are in completely lowered
position.
c
CAUTION
KV18000
Boom
Cylinder
Retract
Hydraulic Line
Extend Hydraulic Line
Spacer Block
HYDRAULICS REPAIR
11/22/00 9 - 45
NOTE: Right-side bucket cylinder shown in photo. Left-
side cylinder is the same.
4. Tag or label bucket cylinder hydraulic lines to aid
5. Disconnect hydraulic lines from bucket cylinder.
6. Remove nut and cap screw retaining lower cylinder
pivot pin.
7. Remove lower cylinder pivot pin using a brass
punch and hammer.
IMPORTANT: DO NOT remove nut until cylinder
pivot is loose.
8. Loosen nut from upper bucket cylinder pivot.
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.
BUCKET CYLINDER INSTALLATION
1. Install bucket cylinder, tapered pin and cap screw.
2. Install nut and tighten to draw tapered pin into upper
cylinder pivot. Tighten nut to 624 Nm (460 lb-ft).
KV13997
Hydraulic Lines
KV13998
Cap Screw
Nut
Pivot Pin
KV14268
Nut
KV14269
Tapered Pin
Cap Screw
KV14269
Tapered Pin
Cap Screw
KV14268
Nut
REPAIR HYDRAULICS
9 - 46 11/22/00
3. Position cylinder and install lower pivot pin. Install
cap screw and nut. Tighten cap screw to 73 Nm
(54 lb-ft).
NOTE: Inspect O-rings on hydraulic fittings for wear or
damage. Replace if necessary. Used or
4. Inspect hydraulic fitting O-rings for wear or damage.
Replace if necessary. Connect hydraulic lines.
BOOM AND BUCKET CYLINDER
REPAIR
IMPORTANT: Cylinder will distort if clamped on
barrel. Clamp cylinder only at pivot area.
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.
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.
7. Using a wooden dowel or brass drift, drive rod guide
into cylinder past internal snap ring groove.
KV13998
Cap Screw
Nut
Pivot Pin
KV13997
Hydraulic Lines
KV18855
KV18854
Snap Ring
Cylinder Rod
Cylinder Barrel
Remove Paint
KV18851
Rod Guide
HYDRAULICS REPAIR
11/22/00 9 - 47
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.
9. With cylinder barrel secured in vise, remove
cylinder rod from cylinder barrel. Inspect all parts
for wear or damage and replace as necessary.
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.
NOTE: Replace all seals and O-rings. Used or
damaged seals will leak.
14. Install new seals and O-rings.
15. Install rod guide, piston and lock nut on cylinder
rod.
16. Tighten lock nut to 136 Nm (100 lb-ft).
NOTE: 30equals 1/2 flat on nut.
17. After lock nut has been tightened to specification,
turn lock nut clockwise an additional 30.
IMPORTANT: Make sure filler ring used during
removal of cylinder rod is removed from snap
ring groove in cylinder barrel.
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.
KV18852
Filler Ring
KV14275
Cylinder Rod
Cylinder Barrel
KV14276
Piston
Rod Guide
Cylinder Rod
Lock Nut
Internal
Snap Ring
KV14276
30
KV14285
Rod Guide
Hose Clamp
Rod Guide Flange
Cylinder Bore
REPAIR HYDRAULICS
9 - 48 1/4/01
NOTE: With a soft-faced hammer, hit rod guide flange
firmly to install rod guide, and seat snap ring in
cylinder bore groove.
20. Install rod guide into cylinder bore using a soft-
faced hammer. Remove hose clamp once internal
snap ring has entered cylinder bore. Continue to
push rod guide into cylinder until internal snap ring
is in its groove. Pull firmly on rod to verify.
21. Install external snap ring.
REPLACEMENT in the HYDROSTATIC POWER
TRAIN section.)
External Snap Ring
KV14272
MISCELLANEOUS CONTENTS
Page
CONTENTS
11/22/00 10 - 1
MISCELLANEOUS
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
10 - 2 11/22/00
CONTENTS MISCELLANEOUS
11/22/00 10 - 3
MISCELLANEOUS SPECIFICATIONS
SPECIFICATIONS
ROPS-to-Side Frame Retaining Nuts Torque . . . . . . . . . . . . . . . . . . . 105 Nm (77 lb-ft)
ROPS-to-Rear Weldment Post Cap Screws Torque . . . . . . . . . . . . . . 105 Nm (77 lb-ft)
Lower Boom Link-to-Frame Pin Retaining Cap Screw Torque . . . . . . . 73 Nm (54 lb-ft)
Upper Boom Link, Lower Boom Link,
and Boom Pivot-Pin Cap Screws Torque . . . . . . . . . . . . . . . . . . . 275 Nm (200 lb-ft)
Cylinder Upper Pivot-Pin Retaining Cap Screw . . . . . . . . . . . . . . . . . . 73 Nm (54 lb-ft)
Wiper Arm Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 Nm (92 lb-in.)
OTHER MATERIALS
NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or in the
Remote Start Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JT0KV12444
Lifting Eyelets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JT01748
Number Name Use
TY6333 or
TY6347
Moly High Temperature EP Grease Apply to boom lock and QUIK-TATCH
.
PT569 NeverSeez Lubricant Apply to upper boom link, lower boom link and
boom pivot pins.
QUIK-TATCH and SERVICEGARD are trademarks of Deere & Company.
10 - 4 11/22/00
REPAIR MISCELLANEOUS
REPAIR
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.
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.
NOTE: Early model cylinder lock shown. Late model is
similar.
4. Ensure ROPS cylinder is locked by pushing forward
on lower cylinder tube.
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 Nm
(77 lb-ft).
KV15169
Lock Nut
(2 Used)
Washer
(2 Used)
KV18531
Cylinder Tube
KV18532
Cylinder Tube
11/22/00 10 - 5
MISCELLANEOUS REPAIR
BOOM LOCK REMOVAL/INSTALLATION
Removal:
1. Lower boom to the at-rest ground position. Engage
park brake switch and turn engine off.
[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.
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.
Installation:
NOTE: Apply Moly High Temperature EP Grease to all
moving boom lock parts before installation.
KV15160
H
F
G
A
I
B
C
D
D
E
E
I
H
J
K
L
A
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)
I. Spring Pin (2 used)
J. Lever
K. Pin
L. Linkage
10 - 6 11/22/00
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.
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.
4. Jack up front end until tires are approximately
51 mm (2 in.) from the ground.
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.
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.
Removal:
4. Remove cap screw on both sides of toe guard
shield and remove toe guard.
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.
KV18068
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.
KV18786
A B
KV18096
Toe Guard
Cap Screw
(2 Used)
11/22/00 10 - 7
5. Remove six cap screws securing center kick plate
to cover plate and skid steer frame. Remove center
kick plate.
6. Remove two cap screws securing side plate to
cover plate and skid steer frame. Remove side
plate. Repeat procedure for opposite side.
7. Lift boot plates out of cover plate. Pivot cover plate
forward and lift out.
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:
USING REMOTE START BOX
Reason:
To allow the engine to be started with the ROPS raised
and in the locked position.
Procedure:
BLOCKING SKID STEER.)
4. Set park brake switch to OFF position.
5. Turn engine OFF.
KV18097
Center Kick Plate Cap Screw
(6 Used)
KV18098
Cap Screw
(2 Used)
Side Plate
KV18099
Boot Plates
Cover Plate
c
CAUTION
without raising and blocking skid steer. Skid
steer may override brake and move quickly.
Boot Plate
KV18052
Pivot
Pin
Retaining
Pin
10 - 8 11/22/00
both yokes to secure steering assembly during
adjustment.
8. Lock auxiliary hydraulic control handle in the neutral
position.
9. Connect JT0KV12444 Remote Start Box to
electrical connector inside right frame.
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:
2. Disconnect negative () battery cable.
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.
KV18038
M10 x 30 Cap Screw
KV15239
KV15239
Park Brake Switch
Ignition
Electrical
Connector
KV18004
Remote Start Box
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.
Left Tail Light
Wire Connector
KV18030
Rear Light Bracket
Right Tail Light
Rear Work Light
11/22/00 10 - 9
6. Remove tie bands securing bulkhead connectors.
7. Disconnect ROPS-to-engine bulkhead connectors.
8. Remove lock nut and flat washer. Repeat this step
for opposite side of ROPS.
9. Raise ROPS and ensure that it is safely in the
10. Install JT01748 Lifting Eyelets in ROPS.
11. Install a suitable lifting strap and hoist on ROPS as
shown.
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.
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.
KV18031
Bulkhead
Connectors
Rear Light
Connectors
KV15169
Lock Nut
(2 used)
Washer
(2 used)
JT01748
Lifting
Eyelet
ROPS
Cylinder
ROPS
Cylinder
Pivot Pin
KV18032
c
CAUTION
Make sure ROPS is supported properly with
suitable lifting strap and hoist before
proceeding.
Cap Screw
Bulkhead
Connectors
Rear Light
Connectors
Pivot Bushings
KV18033
10 - 10 11/22/00
Installation:
1. Install ROPS and tighten cap screws to 105 Nm
(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.
4. Lower ROPS into position. Install left and right flat
washers and nuts. Tighten lock nuts to 105 Nm
(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.
BOOM
LOWER BOOM LINK REMOVAL/
INSTALLATION
Removal:
2. Turn key switch ON and operate all hydraulic
controls to relieve system pressure. Turn key
switch OFF.
3. Loosen lower link rear pin through-bolt and nut.
Loosen nut to end of bolt. DO NOT remove at this
time.
Cap Screw
Bulkhead
Connectors
Rear Light
Connectors
Pivot Bushings
KV18033
KV15169
Lock Nut
(2 Used)
Washer
(2 Used)
KV31005
11/22/00 10 - 11
IMPORTANT: Use a non-metallic hammer to
prevent damaging lower link.
4. Strike the lower link with a 5.2 kg (11.5 lb) non-
metallic deadblow hammer to loosen taper of pivot
pin.
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.
7. Disconnect both hydraulic hoses from lines under
boom. Tag hoses for ease of installation.
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.)
KV31001
KV31006
Pivot Pin
KV31002
KV31003
Hydraulic
Hoses
KV31004
Hose
Retainers
10 - 12 11/22/00
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.
Installation:
1. Coat front pivot pin with NeverSeez compound.
Put link in place in machine and install front pivot
pin. Secure pin with cap screw and nut. Tighten to
73 Nm (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 NeverSeez
compound. Install pivot pin through lower link and
into boom.
4. Install pivot pin cap screw and nut. Tighten to
275 Nm (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 BOOM LINK REMOVAL/
INSTALLATION
Removal:
2. Turn key switch ON and move all hydraulic controls
to remove system pressure. Turn key switch OFF.
3. Securely block both sides of the rear of the boom.
4. Install a suitable lifting strap and hoist to upper link.
5. Loosen both lower pivot-pin cap screws and nuts.
Do not remove nuts. Loosen nuts to the end of the
cap screw.
6. Loosen both upper pivot-pin cap screws
approximately six turns.
Front Pivot Pin
KV31002
Lower Cap
Screws and Nuts
Upper Cap
Screws
KV31007
Cap Screw
KV31008
NOTE: Left Side Shown
11/22/00 10 - 13
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.
Installation:
1. Lift into place using a suitable strap and hoist.
2. Coat tapered portion of upper pins with NeverSeez
compound and install. Tighten cap screws to 275
Nm (200 lb-ft).
3. Coat tapered portion of lower pins with NeverSeez
compound and install. Tighten cap screws and
nuts to 275 Nm (200 lb-ft).
4. Remove blocking. Lubricate bushings.
QUIK-TATCH
HITCH COUPLING
Removal:
1. Remove any attachments. (See QUIK-TATCH
REMOVAL/INSTALLATION in this section.)
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.
5. Remove plugs from both sides.
KV31007
KV31124
QUIK-TATCH
Hitch Coupling
Plug
KV31125
10 - 14 11/22/00
6. Loosen and remove cap screws and nuts at boom/
hitch coupling pivot points.
7. Remove the threads from a 19.6 mm bolt, to
fabricate a driver as shown.
8. Insert the driver through the boom pivot boss until it
contacts the shoulder of the pivot pin.
9. Strike the driver sharply to loosen the taper and
remove the pivot pin
KV31126
KV31138
19.6 mm
Remove
Threads
Shoulder
Pivot Pin
KV31139
KV31127
11/22/00 10 - 15
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 Nm (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 Nm (60 lb-ft).
4. Lubricate all pivot points. Roll hitch coupling fully
back and fully forward to verify operation. Install
attachments.
QUIK-TATCH
REPAIR
Removal:
1. Remove any attachments from skid steer.
2. Lower boom to the at-rest ground position and turn
engine off.
NOTE: It may be necessary to rotate pivot pins (B) to
remove spring pins (A).
3. Remove two spring pins (A) and pivot pins (B) using
a punch and hammer from side of implement
mounting frame being serviced.
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.
NOTE: Left rear of implement frame shown.
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.
KV31128
Cap Screw
and Nut
Boom Cylinder
Pivot Pins
KV15161
A
B
KV15162
KV15163
A
10 - 16 11/22/00
2. Install QUIK-TATCH

assembly into implement frame
with end of pin (A) located in upper corner of
weldment frame as shown above.
NOTE: It may be necessary to use a C-clamp to align
pins.
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.
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.
Removal:
.
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.
3. Turn key switch ON and move all hydraulic controls
to remove system pressure. Turn key switch OFF.
4. Securely block both sides of the rear of the boom.
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.
B
A
KV15161
KV31128
Blocking
c
CAUTION
KV31002
Upper Link
Lower Pivot Pin
Cylinder Upper Pivot Pin
Lower Link Rear Pivot Pin
KV31003
Hose Retainer
(Left Side Shown; Right Side Similar)
Hydraulic Hoses
11/22/00 10 - 17
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.)
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 Nm (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.
CAB HEATER/DEFROSTER
(OPTIONAL)
FILTER REPLACEMENT
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:
2. Remove heater cover. Disconnect lights.
Cap Screw
Upper Pivot Pin
KV14329
KV31044
Screws
NOTE: Boom is raised for the sake of clarity.
KV31045
Heater
Cover
10 - 18 11/22/00
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.
5. Remove four screws retaining heater core. Remove
core.
Installation:
1. Inspect foam seals and replace if necessary.
2. Install heater core using four screws.
3. Connect hoses and close vent valve.
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.
c
CAUTION
off engine. Remove filler cap only when cool
TS281
KV18857
Vent Valve
Remove Hoses
KV18856
Remove Screws
Foam Seals
KV18861
11/22/00 10 - 19
BLOWER REMOVAL/INSTALLATION
Removal:
2. Remove heater cover.
3. Disconnect wires from speed controller and ground.
Tag wires for ease of installation.
4. Remove three screws retaining blower to housing
bottom.
5. Remove four cap screws retaining blower to main
housing.
6. Lift blower from housing.
Installation:
1. Place blower in housing.
2. Loosely install four cap screws to retain blower in
housing.
3. Install and tighten three screws retaining blower
from bottom of housing.
4. Tighten cap screws.
KV31045
Heater
Cover
Disconnect Wires
KV18858
Remove Screws
KV18859
Remove Cap Screws
KV18860
Install Screws
KV18859
10 - 20 11/22/00
5. Connect wires to speed controller and ground.
CONTROL VALVE REMOVAL/
INSTALLATION
Removal:
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.
Connect Wires
KV18858
KV31045
Heater
Cover
c
CAUTION
off engine. Remove filler cap only when cool
TS281
KV18857
Remove Hoses
Cap Screw
Connector
Cap Screw
Vent Valve
11/22/00 10 - 21
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.
CAB HEATER DEAERATION
NOTE: Cooling system must be cool to the touch.
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.
4. Fabricate a hose that will connect a regulated shop
air supply to the coolant recovery bottle overflow.
Connect and clamp hose securely.
IMPORTANT: Cooling system is designed for a
maximum pressure of 96110 kPa (1416 psi).
Exceeding this pressure could result in
component damage or personal injury.
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.
KV31045
Heater
Cover
KV31043
Fabricated Hose
10 - 22 11/22/00
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.
CAB DOOR (IF EQUIPPED)
Removal:
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.
6. Loosen upper cap screws and lower nuts that retain
left door roller brackets to door.
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.
KV18857
Vent Valve
c
CAUTION
Door weighs 21 kg (47 lb). Two people are
required for door removal.
Upper Cap Screws
KV18867
Lower Nuts
KV18868
11/22/00 10 - 23
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.
WINDSHIELD WIPER/WASHER
(OPTIONAL)
WIPER MOTOR
Removal:
1. Disconnect wiring harness from motor.
2. Remove cap covering wiper arm retaining nut.
Remove nut.
3. Disconnect washer hose. Remove wiper arm from
motor shaft.
4. Remove thumb nut and O-ring.
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.
Harness Connector
KV31099
Arm Retaining Nut
Washer Hose
KV31100
Small Nut
Large Nut
Thumb Nut
KV31101
KV31103
Cup
Seal
Large Nut
10 - 24 11/22/00
3. Install thumb nut and O-ring. DO NOT overtighten.
NOTE: Wiper arm orientation is controlled by a
tapered spline. Be sure arm is in correct
orientation while installing nut.
4. Install wiper arm and nut. Tighten nut to 10.4 Nm
(92 lb-in.).
5. Connect washer hose.
6. Connect wiring harness to motor.
7. Run wiper to verify operation.
WASHER PUMP
Removal:
1. Disconnect wiring harness and hose from pump.
2. Remove screws holding fluid container to bracket.
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.
KV31102
O-Ring
Tapered Spline
KV31101B
KV31104
Screws
KV31105
Grommet
INDEX
11/22/00 INDEX - 1
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
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
INDEX - 2 11/22/00
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
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
INDEX
11/22/00 INDEX - 3
Electrical;Diagnosis (Cont.)
Engine Oil Pressure
Warning Light Circuit . . . . . . . . . . . . . . 4-80
Fuel Circuit . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Fuel Gauge Circuit . . . . . . . . . . . . . . . . . . 4-72
High Flow Circuit . . . . . . . . . . . . . . . . . . . 4-87
High-Flow Circuit . . . . . . . . . . . . . . . . . . . 4-87
Hydraulic Filter Restriction
Hydraulic Oil Overtemperature
Lights Circuit . . . . . . . . . . . . . . . . . . . . . . 4-93
Park Brake Switch
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
Fuel Level Sender Replacement . . . . . . . . . 4-145
Gauges and Warning Lights
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
High-Flow
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
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
Main Schematic . . . . . . . . . . . . . . . . . . . . . . . 4-13
Manifold Preheat Relay Replacement . . . . . 4-142
Manifold Preheater Replacement . . . . . . . . . 4-141
Park Brake
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
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
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
INDEX - 4 11/22/00
Engine (Cont.)
Speed Adjustment . . . . . . . . . . . . . . . . . . . . 3-115
Tests and Adjustments . . . . . . . . . . . . . . . . . . 3-23
Engine Oil Pressure Switch/Sender Test . . . . . . 4-129
Exhaust Manifold, Inspection . . . . . . . . . . . . . . . 3-105
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
G
Grease Specifications . . . . . . . . . . . . . . . . . . . . . . 2-15
H
High-Flow
Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . 4-85
Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-134
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
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
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
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
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
INDEX
11/22/00 INDEX - 5
Hydraulic (Cont.)
System Components and Operation . . . . . . . . 9-5
System Relief Valve Pressure Test . . . . . . . . 9-15
System Schematic . . . . . . . . . . . . . . . . . . . . . . 9-7
Hydrostatic Drive Coupling, Install . . . . . . . . . . . . 3-38
Hydrostatic Motor
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Hydrostatic Power Train
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
Hydrostatic Transmission and Hydraulic Oil . . . . . 2-13
I
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
M
Manifold Preheat Relay Replacement . . . . . . . . 4-142
Metric Fastener Torque Values . . . . . . . . . . . . . . . . 2-5
N
Nozzle Bores, Injection, Cleaning . . . . . . . . . . . . . 3-48
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
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
P
Park Brake
Actuator Cylinder
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
INDEX - 6 11/22/00
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 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
S
Schematics - See Component in Electrical
Sealant, Application Guidelines, Engine . . . . . . . . 3-18
Seat Belt Switch
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-147
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-137
Seat Safety Switch Test . . . . . . . . . . . . . . . . . . . 4-136
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
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
Tracking - Stops Adjustment . . . . . . . . . . 7-16
Cross Shaft
Detent Adjustment . . . . . . . . . . . . . . . . . . 7-15
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
T
Tachometer, Using Stanadyne "Time-Trac" . . . . 3-116
Thermostat
Inspect and Test . . . . . . . . . . . . . . . . . . . . . . . 3-23
Remove/Install . . . . . . . . . . . . . . . . . . . . . . . 3-101
Timing Gear
Backlash, Measure . . . . . . . . . . . . . . . . . . . . . 3-84
Cover, Installation . . . . . . . . . . . . . . . . . . . . . . 3-91
Lower, Installation . . . . . . . . . . . . . . . . . . . . . . 3-91
Upper, Installation . . . . . . . . . . . . . . . . . . . . . . 3-90
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
INDEX
11/22/00 INDEX - 7
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
INDEX
INDEX - 8 11/22/00

TM 1747

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TM 1747

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TECHNICAL

1999 Deere & Company

fixed displacement 30 series

John Deere Low Viscosity HY-GARD

(cold weather operation)

John Deere Low Viscosity HY-GARD

(cold weather operation)

, SAE 15W40 oil or oils meeting

John Deere Low Viscosity HY-GARD

(cold weather operation)

Stator failure (short-circuit)

Axle housing and chain case

Axle housing and chain case

Axle housing and chain case

Axle housing and chain case

Apply to internal surfaces of hydrostatic pump

motors. Charge pressure

, LOW VIS HY-GARD

Fill hydraulic reservoir and chain

hitch coupling full forward and

Vous aimerez peut-être aussi