Beruflich Dokumente
Kultur Dokumente
Skid Steer
Serial No. ( 100100 - )
TECHNICAL
MANUAL
John Deere
Commercial Worksite Products
TM1747 (Nov00)
Replaces TM1747 (July99)
Litho in U.S.A
240 and 250 TM1747 (Nov2000)
Skid Steer
INTRODUCTION
Specifications and
Information
Power Train
Power Train
(Hydrostatic)
Each section will be identified with a symbol rather than a
number. The groups and pages within a section will be Steering
consecutively numbered.
Brakes
COPYRIGHT© 2000
JOHN DEERE COMMERICAL WORKSITE PRODUCTS
Knoxville, Tennessee
All rights reserved
Previous Editions
Copyright© 1999 Deere & Company
11/22/00 1-1
SAFETY
1-2 11/22/00
SAFETY
• If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.
11/22/00 1-3
SAFETY
1-4 11/22/00
SAFETY
11/22/00 1-5
SAFETY
1-6 11/22/00
SAFETY
A Material Safety Data Sheet (MSDS) provides specific Before returning machine to customer, make sure
details on chemical products: physical and health machine is functioning properly, especially the safety
hazards, safety procedures, and emergency response systems. Install all guards and shields.
techniques. Check the MSDS before you start any job
using a hazardous chemical. That way you will know
exactly what the risks are and how to do the job safely.
Then follow procedures and recommended equipment.
11/22/00 1-7
SAFETY
1-8 11/22/00
SPECIFICATIONS AND INFORMATION CONTENTS
CONTENTS
SPECIFICATIONS AND INFORMATION
Page
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ELECTRICAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HYDRAULICS AND HYDROSTATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIMENSIONS—240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIMENSIONS—250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RECOMENDED LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
METRIC FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . 5
METRIC FASTENER TORQUE VALUES—GRADE 7 . . . . . . . . . . . . . . . 6
INCH FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
O-RING SEAL SERVICE RECOMMENDATIONS . . . . . . . . . . . . . . . . . . 8
FACE SEAL FITTINGS WITH INCH STUD ENDS TORQUE . . . . . . . . . . . . . . . . . . . 8
FACE SEAL FITTINGS WITH METRIC STUD ENDS TORQUE . . . . . . . . . . . . . . . . . 9
O-RING FACE SEAL FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
O-RING BOSS FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIESEL FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
LUBRICITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ENGINE OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-CYCLE DIESEL ENGINE OIL—NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . 12
BREAK-IN DIESEL ENGINE OIL—NORTH AMERICA. . . . . . . . . . . . . . . . . . . . . . . 13
HYDROSTATIC TRANSMISSION AND HYDRAULIC OIL—NORTH AMERICA. . . . 13
CHAIN CASE OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHAIN CASE OIL—NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
GENERAL APPLICATION GREASE SPECIFICATIONS . . . . . . . . . . . . 15
GREASE—NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
COOLANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIESEL AND GASOLINE ENGINE COOLANT—NORTH AMERICA . . . . . . . . . . . . 15
SUPPLEMENTAL COOLANT ADDITIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIESEL AND GASOLINE ENGINE COOLANT DRAIN INTERVAL—NORTH
AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SKID STEER PRODUCT IDENTIFICATION NUMBER. . . . . . . . . . . . . . . . . . . . . . . 17
ENGINE SERIAL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
11/22/00 2-1
SPECIFICATIONS SPECIFICATIONS AND INFORMATION
SPECIFICATIONS
ENGINE
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .John Deere
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel
Engine Model Number
• 240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3029D
• 250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3029T
Net Horsepower at rated engine RPM (2400 RPM)
• 240 (S/N -240852). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.3 kW (46 hp)
• 240 (S/N 240853- ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 kW (51 hp)
• 250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.5 kW (61 hp)
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 mm (4.17 in.)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 mm (4.33 in.)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 L (179 cu in.)
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.8:1
Rated Engine RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2400
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Full pressure
Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full flow (replaceable)
Air Cleaner . . . . . . . . . . . . . . .Dry paper with primary and secondary elements
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid-cooled
FUEL SYSTEM
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel #2
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In-line replaceable filter
Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric
Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rotary injection
ELECTRICAL SYSTEM
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-volt, electric start
Charging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator, 55 amp
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .750 CCA (cold cranking amps)
CAPACITIES
Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.7 L (15 gal)
Hydraulic Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6 L (4.1 gal)
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 L (6 gal)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 L (10 qt)
Engine Oil (with Filter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 L (6.9 qt)
Chain Case (per Side). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4 L (3 gal)
2-2 11/22/00
SPECIFICATIONS AND INFORMATION SPECIFICATIONS
DIMENSIONS—240
(See note below.)
NOTE: Standard tires (10 x 16.5) and 66 in. foundry bucket used in
determining dimensions.
11/22/00 2-3
SPECIFICATIONS SPECIFICATIONS AND INFORMATION
DIMENSIONS—250
(See note below.)
NOTE: Standard tires (12 x 16.5) and 72 in. foundry bucket used in
determining dimensions.
TIRES
240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 x 16.5
250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 x 16.5
RECOMENDED LUBRICANTS
Engine Oil . . . . . . . . . . . . . . . . . . . . . John Deere TORQ-GARD SUPREME® or
PLUS-50®
(See ENGINE OIL in the ENGINE section for cold weather oil)
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere COOL-GARD™
Hydraulic Oil and Hydrostatic Oil . . . . . . . . . . . . . . . . . John Deere HY-GARD®
John Deere Low Viscosity HY-GARD® (cold weather operation)
Grease . . . . . . . . . . . . . . . . . John Deere HIGH TEMPERATURE EP GREASE
John Deere MOLY HIGH TEMPERATURE EP GREASE (non-clay)
Chain Case Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere HY-GARD®
John Deere Low Viscosity HY-GARD® (cold weather operation)
John Deere TORQ-GARD SUPREME® or PLUS-50®
HY-GARD, TORQ-GARD SUPREME and PLUS-50 are is a registered trademarks of Deere & Company.
2-4 11/22/00
SPECIFICATIONS AND INFORMATION METRIC FASTENER TORQUE VALUES
Property 5 10 10 12
Class
and
10
10
12
5
Nut 5 10 10 12
Markings
TS1163
SIZE N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft
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
M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 109
M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300
M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410
M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580
M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800
M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000
M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500
M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000
M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500
DO NOT use these hand torque values if a different torque value or tightening procedure is given for a specific
application. Torque values listed are for general use only and include a ±10% variance factor. Check tightness of
fasteners periodically. DO NOT use air powered wrenches.
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same class. Make sure fastener threads are clean and that you properly
start thread engagement. This will prevent them from failing when tightening.
When bolt and nut combination fasteners are used, torque values should be applied to the NUT instead of the bolt
head.
Tighten toothed or serrated-type lock nuts to the full torque value.
a. “Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry”
means plain or zinc plated (yellow dichromate - Specification JDS117) without any lubrication.
Reference: JDS—G200.
11/22/00 2-5
METRIC FASTENER TORQUE VALUES—GRADE 7 SPECIFICATIONS AND INFORMATION
M6 11 8 8 6
M8 24 18 19 14
M10 52 38 41 30
M12 88 65 70 52
2-6 11/22/00
SPECIFICATIONS AND INFORMATION INCH FASTENER TORQUE VALUES
2 5 8
SAE
Grade No Marks
and Nut
Markings
TS1162
SIZE N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft
1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5
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
5/8 67 50 85 62 105 78 135 100 170 125 215 160 215 160 300 225
3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400
7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650
1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975
1-1/8 470 300 510 375 470 300 510 375 900 675 1150 850 1450 1075 1850 1350
1-1/4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550
1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
DO NOT use these hand torque values if a different torque value or tightening procedure is given for a specific
application. Torque values listed are for general use only and include a ±10% variance factor. Check tightness of
fasteners periodically. DO NOT use air powered wrenches.
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same grade. Make sure fastener threads are clean and that you properly
start thread engagement. This will prevent them from failing when tightening.
When bolt and nut combination fasteners are used, torque values should be applied to the NUT instead of the bolt
head.
Tighten toothed or serrated-type lock nuts to the full torque value.
a. “Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry”
means plain or zinc plated (yellow dichromate - Specification JDS117) without any lubrication.
b. “Grade 2” applies for hex cap screws (not hex bolts) up to 152 mm (6-in.) long. “Grade 1” applies for hex
cap screws over 152 mm (6-in.) long, and for all other types of bolts and screws of any length.
Reference: JDS—G200.
11/22/00 2-7
O-RING SEAL SERVICE RECOMMENDATIONS SPECIFICATIONS AND INFORMATION
Nominal Tube OD/Hose ID Face Seal Tube/Hose End O-Ring Stud Ends
Dash
mm in. mm in. N•m lb-ft N•m lb-ft in. N•m lb-ft
Size
-3 0.188 4.76 3/8-24 8 6
6 -4 0.250 6.35 9/16-18 16 12 12 9 7/16-20 12 9
8 -5 0.312 7.94 1/2-20 16 12
10 -6 0.375 9.52 11/16-16 24 18 24 18 9/16-18 24 18
12 -8 0.500 12.70 13/16-16 50 37 46 34 3/4-16 46 34
16 -10 0.625 15.88 1-14 69 51 62 46 7/8-14 62 46
-12 0.750 19.05 1-3/16-12 102 75 102 75 1-1/16-12 102 75
22 -14 0.875 22.22 1-3/16-12 102 75 102 75 1-3/16-12 122 90
25 -16 1.000 25.40 1-7/16-12 142 105 142 105 1-5/16-12 142 105
32 -20 1.25 31.75 1-11/16-12 190 140 190 140 1-5/8-12 190 140
38 -24 1.50 38.10 2-12 217 160 217 160 1-7/8-12 217 160
2-8 11/22/00
SPECIFICATIONS AND INFORMATION O-RING SEAL SERVICE RECOMMENDATIONS
Tube Nut/
Metric Bulkhead Steel or
Thread Hex Swivel Thread Hex Aluminum
Tube Inch Tube OD Lock Nut Gray Iron
Size Size Nut Size Size Torque
OD Torque Torque
Torque
Dash
mm in. mm in. mm N•m lb-ft N•m lb-ft mm mm N•m lb-ft N•m lb-ft
Size
6 -4 0.250 6.35 9/16-18 17 16 12 12 9 M12X1.5 17 21 15.5 9 6.6
8 -5 0.312 7.94
M14X1.5 19 33 24 15 11
10 -6 0.375 9.52 11/16-16 22 24 18 24 18 M16X1.5 22 41 30 18 13
12 -8 0.500 12.70 13/16-16 24 50 37 46 34 M18X1.5 24 50 37 21 15
16 -10 0.625 15.88 1-14 30 69 51 62 46 M22X1.5 27 69 51 28 21
-12 0.750 19.05 1-3/16-12 36 102 75 102 75 M27X2 32 102 75 46 34
22 -14 0.875 22.22 1-3/16-12 36 102 75 102 75 M30X2 36
25 -16 1.000 25.40 1-7/16-12 41 142 105 142 105 M33X2 41 158 116 71 52
28 M38X2 46 176 130 79 58
32 -20 1.25 31.75 1-11/16-12 50 190 140 190 140 M42X2 50 190 140 85 63
38 -24 1.50 38.10 2-12 60 217 160 217 160 M48X2 55 217 160 98 72
11/22/00 2-9
O-RING SEAL SERVICE RECOMMENDATIONS SPECIFICATIONS AND INFORMATION
Sealing Surface
Special Nut
O-Ring
Sealing Surface
3. For angle fittings, loosen special nut and push
special washer against threads so O-ring can be
installed into the groove of fitting.
1. Inspect the fitting sealing surfaces. They must be 4. Turn fitting into the boss by hand until special
free of dirt or defects. washer or washer face (straight fitting) contacts
2. Inspect the O-ring. It must be free of damage or boss face and O-ring is squeezed into its seat.
defects. 5. To position angle fittings, turn the fitting counter-
3. Lubricate O-rings and install into groove using clockwise a maximum of one turn.
petroleum jelly to hold in place. 6. Tighten straight fittings to torque value shown on
4. Push O-ring into the groove with plenty of chart. For angle fittings, tighten the special nut to
petroleum jelly so O-ring is not displaced during value shown in the chart while holding body of
assembly. fitting with a wrench.
5. Index angle fittings and tighten by hand pressing
joint together to insure O-ring remains in place. STRAIGHT FITTING OR SPECIAL NUT TORQUE
6. Tighten fitting or nut to torque value shown on the
chart per dash size stamped on the fitting. Do not Torquea
allow hoses to twist when tightening fittings. Thread Number
Size of Flatsb
N•m lb-ft
O-RING BOSS FITTINGS 3/8-24 UNF 8 (6) 2
1. Inspect boss O-ring boss seat. It must be free of dirt
and defects. If repeated leaks occur, inspect for 7/16-20 UNF 12 (9) 2
defects with a magnifying glass. Some raised
1/2-20 UNF 16 (12) 2
defects can be removed with a slip stone.
9/16-18 UNF 24 (18) 2
Groove
O-Ring 3/4-16 UNF 46 (34) 2
2. Put hydraulic oil or petroleum jelly on the O-ring. 1-7/8-12 UN 217 (160) 1/2
Place electrical tape over the threads to protect O- a. Torque tolerance is ± 10%.
ring from nicks. Slide O-ring over the tape and into b. To be used if a torque wrench cannot be used.
the groove of fitting. Remove tape. After tightening fitting by hand, put a mark on nut or
boss; then tighten special nut or straight fitting the
number of flats shown.
2 - 10 11/22/00
SPECIFICATIONS AND INFORMATION DIESEL FUEL SPECIFICATIONS
In general, diesel fuels are blended to satisfy the low air IMPORTANT: DO NOT USE GALVANIZED
temperature requirements of the geographical area in CONTAINERS—diesel fuel stored in galvanized
which they are sold. containers reacts with zinc coating in the
• Use Grade No. 2-D fuel at temperatures above 4°C container to form zinc flakes. If fuel contains
(40°F). water, a zinc gel will also form. The gel and
flakes will quickly plug fuel filters and damage
• For maximum filter life, sediment and water should fuel injectors and injection pumps.
not be more than 0.10%.
• The cetane number should be 45 minimum. If you
operate your machine where air temperatures are It is recommended that diesel fuel be stored ONLY in a
normally low or in high altitudes, you may need fuel clean, approved POLYETHYLENE PLASTIC container
with a higher cetane number. WITHOUT any metal screen or filter. This will help
• Cloud Point - For cold weather operation, cloud prevent any accidental sparks from occurring. Store
point should be 6°C (10°F) below lowest normal air fuel in an area that is well ventilated to prevent possible
temperature. igniting of fumes by an open flame or spark, this
• In winter use special winter fuel or add an anti- includes any appliance with a pilot light.
gelling compound to fuel to maintain its proper
viscosity.
IMPORTANT: Keep all dirt, scale, water or other
If diesel fuel being used has a sulfur content foreign material out of fuel.
greater than 0.5%, reduce the service interval
for engine oil and filter by 50%. Keep fuel in a safe, protected area and in a clean,
properly marked (“DIESEL FUEL”) container. DO NOT
Bio-Diesel Fuels with bio-degradable properties that use de-icers to attempt to remove water from fuel. DO
meet specification DIN 51606 or equivalent may be
NOT depend on fuel filters to remove water from fuel. It
used.
is recommended that a water separator be installed in
the storage tank outlet. BE SURE to properly discard
Consult your local diesel fuel distributor for properties
unstable or contaminated diesel fuel and/or their
of the diesel fuel available in your area.
containers when necessary.
c WARNING
California Proposition 65 Warning: Diesel engine
exhaust and some of its elements from this
product are known to the State of California to
cause cancer, birth defects, or other
reproductive harm.
LUBRICITY
Diesel fuel must have adequate lubricity to ensure
proper operation and durability of fuel injection system
components. Fuel lubricity should pass a minimum of
3300 gram load level as measured by the BOCLE
scuffing test.
11/22/00 2 - 11
ENGINE OIL SPECIFICATIONS SPECIFICATIONS AND INFORMATION
SAE 30
air temperature range during the period between
SAE 15W-40
recommended oil changes. Operating outside of these
recommended oil air temperature ranges may cause
premature engine failure.
SAE10W-30
The following oil is preferred AFTER first 100 hours of
SAE 5W-30
break-in oil is used:
• John Deere TORQ-GARD SUPREME or John
Deere PLUS-50
2 - 12 11/22/00
SPECIFICATIONS AND INFORMATION ENGINE OIL SPECIFICATIONS
11/22/00 2 - 13
CHAIN CASE OIL SPECIFICATIONS SPECIFICATIONS AND INFORMATION
SAE 30
temperature range. Operating outside of the
SAE 15W-40
recommended oil air temperature range may cause
premature chain case failure.
SAE 10W-40
SAE 5W-30
IMPORTANT: DO NOT use BIO-HY-GARD® in this
SAE 5W-30
chain case.
Other oils may be used if above preferred John Deere AIR TEMPERATURE
oils are not available, provided they meet the following
specification: M58275
2 - 14 11/22/00
SPECIFICATIONS AND INFORMATION GENERAL APPLICATION GREASE SPECIFICATIONS
The following John Deere greases are PREFERRED: These coolants satisfy specifications for “Automobile
and Light Duty Engine Service” and are safe for use in
• John Deere MOLY HIGH TEMPERATURE EP John Deere Lawn and Grounds Care/Golf and Turf
GREASE Division equipment, including aluminum block gasoline
• John Deere HIGH TEMPERATURE EP GREASE engines and cooling systems.
(Non-Clay)
Other greases may be used if they meet one of the The above preferred pre-diluted coolants provide:
following:
• adequate heat transfer
• SAE Multipurpose EP Grease with a maximum of • corrosion-resistant chemicals for the cooling
5% molybdenum disulfide system
• SAE Multipurpose EP Grease • compatibility with cooling system hose and seal
material
Greases meeting Military Specification MIL-G-10924F
• protection during extreme cold and extreme hot
may be used as arctic grease.
weather operations
• chemically pure water for better service life
• compliance with ASTM D4656 (JDM H24C2)
specifications
11/22/00 2 - 15
COOLANT SPECIFICATIONS SPECIFICATIONS AND INFORMATION
IMPORTANT: To prevent engine damage, DO NOT The use of non-recommended supplemental coolant
use pure anti-freeze or less than a 50% anti- additives may result in additive drop-out and gelation
freeze mixture in the cooling system. Water of the coolant.
used to dilute engine coolant concentrate must Add the manufacturer’s recommended concentration
be of high quality—clean, clear, potable water of supplemental coolant additive. DO NOT add more
(low in chloride and hardness—see table below) than the recommended amount.
is generally acceptable. DO NOT use salt water.
Deionized or distilled water is ideal to use.
Coolant that is not mixed to these specified
levels and water purity can cause excessive
DIESEL AND GASOLINE ENGINE
scale, sludge deposits, and increased corrosion COOLANT DRAIN INTERVAL—
potential. NORTH AMERICA
When using John Deere Concentrate (TY16034)
Water Quality Automobile and Light Duty Engine Service coolants,
drain and flush the cooling system and refill with fresh
Property Requirements coolant mixture every 24 months or 2,000 hours of
operation, whichever comes first.
Total Solids, Maximum 340 ppm (20 grns/gal)
If above John Deere Automobile and Light Duty Engine
Total Hardness, Max. 170 ppm (10 grns/gal) Service coolants are not being used, drain, flush, and
Chloride (as Cl), Max. 40 ppm (2.5 grns/gal) refill the cooling system according to instructions found
on product container or in equipment operator’s manual
Sulfate (as SO4), Max. 100 ppm (5.8 grns/gal) or technical manual.
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.
2 - 16 11/22/00
SPECIFICATIONS AND INFORMATION SERIAL NUMBER LOCATION
KV18593
11/22/00 2 - 17
SERIAL NUMBER LOCATION SPECIFICATIONS AND INFORMATION
2 - 18 11/22/00
DIESEL ENGINE CONTENTS
CONTENTS
DIESEL ENGINE
Page
56SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CYLINDER HEAD AND VALVES SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 7
CYLINDER BLOCK, LINERS, PISTONS, AND RODS SPECIFICATIONS . . . . . . . . . 9
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONS . . . . . . . . 11
CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS . . . . . . . . . . . . . . . . . . 12
LUBRICATION SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
COOLING SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FUEL SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ENGINE SYSTEM—DIAGNOSIS AND TESTS SPECIFICATIONS . . . . . . . . . . . . . 15
FUEL SYSTEM—OPERATION AND TESTS SPECIFICATIONS . . . . . . . . . . . . . . . 15
CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SEALANT APPLICATION GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . 18
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PRELIMINARY ENGINE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
GENERAL TUNE-UP RECOMMENDATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TEST THERMOSTAT OPENING TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CHECK ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
MEASURE ENGINE BLOW-BY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CYLINDER COMPRESSION PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FUEL SUPPLY PUMP PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FAST AND SLOW IDLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FUEL INJECTION PUMP TIMING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CHECK AND ADJUST VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
ENGINE REPAIR STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
MOUNT ENGINE ON REPAIR STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ENGINE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
RADIATOR REMOVAL, INSPECTION, and INSTALLATION. . . . . . . . . . . . . . . . . . . 41
CLEAN ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
ENGINE DISASSEMBLY SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
ENGINE ASSEMBLY SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
CYLINDER HEAD–EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
CHECK VALVE LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
REMOVE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
CLEAN INJECTION NOZZLE BORES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
VALVE ACTUATING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
REMOVE VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
CHECKING CYLINDER HEAD FLATNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
CLEAN VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
MEASURE VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
11/22/00 3-1
CONTENTS DIESEL ENGINE
Page
3-2 11/22/00
DIESEL ENGINE CONTENTS
Page
11/22/00 3-3
CONTENTS DIESEL ENGINE
Page
3-4 11/22/00
DIESEL ENGINE CONTENTS
Page
11/22/00 3-5
CONTENTS DIESEL ENGINE
3-6 11/22/00
DIESEL ENGINE
SPECIFICATIONS
11/22/00 3-7
SPECIFICATIONS DIESEL ENGINE
3-8 11/22/00
DIESEL ENGINE SPECIFICATIONS
11/22/00 3-9
SPECIFICATIONS DIESEL ENGINE
Some piston pin bores are elliptical, the width being 0.038 mm (0.0015 in.) wider than specification given.
3 - 10 11/22/00
DIESEL ENGINE SPECIFICATIONS
11/22/00 3 - 11
SPECIFICATIONS DIESEL ENGINE
Hub width of idler gear . . . . . . . . . . . . . 21.975—22.025 mm (0.865—0.867 in.). . . 21.93 mm (0.863 in.)
Width of idler shaft . . . . . . . . . . . . . . . . . . 22.17—22.27 mm (0.873—0.877 in.)
End play of idler gear . . . . . . . . . . . . . . . . . . 0.14—0.29 mm (0.006—0.012 in.). . . . 0.40 mm (0.016 in.)
3 - 12 11/22/00
DIESEL ENGINE SPECIFICATIONS
11/22/00 3 - 13
SPECIFICATIONS DIESEL ENGINE
Rated Speed
Model Pump Part # Dynamic Timing
(rpm)
3 - 14 11/22/00
DIESEL ENGINE SPECIFICATIONS
Engine blow-by at crankcase vent tube, maximum at full load rated speed:
• Model 3029D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 m3/h (141 cu-ft/h)
• Model 3029T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 m3/h (225 cu-ft/h)
CAPACITIES
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.7 L (15 gal)
Hydraulic reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6 L (4.1 gal)
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.7 L (6 gal)
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 L (10 qt)
Engine oil (with filter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 L (6.9 qt)
Chain case (per side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4 L (3 gal)
11/22/00 3 - 15
SPECIAL OR ESSENTIAL TOOLS DIESEL ENGINE
3 - 16 11/22/00
DIESEL ENGINE SPECIAL OR ESSENTIAL TOOLS
11/22/00 3 - 17
SEALANT APPLICATION GUIDELINES DIESEL ENGINE
JOHN DEERE
CONTENT PRODUCT EXAMPLE OF USE
PART NUMBER
3 - 18 11/22/00
DIESEL ENGINE TROUBLESHOOTING
TROUBLESHOOTING
Problem or
under load
under load
Solution
Fuel in oil
Improper intake/exhaust valve
● ● ● ●
clearance
11/22/00 3 - 19
TROUBLESHOOTING DIESEL ENGINE
Problem or
under load
under load
Solution
Fuel in oil
Engine oil leaking ● ●
Water in fuel ● ● ● ● ● ●
No fuel ● ●
High altitude/temperature
● ● ● ●
operation
Inspect alternator ●
Electrical system
●
troubleshooting
3 - 20 11/22/00
DIESEL ENGINE DIAGNOSIS
DIAGNOSIS
Conditions:
• Machine parked on level surface.
• Park brake engaged.
• Key switch off unless indicated otherwise.
Test/Check Point Normal If Not Normal
Engine Oil Check
Engine dipstick and Oil level between “L” and “H” marks. Oil Change oil and inspect for source of
exterior engine surface. not burnt, or contaminated with metal contamination. Check gaskets, seals,
particles, fuel, or coolant. No external plugs, cylinder head, block and intake
leakage, filter clean. manifold and breather. Change oil filter.
Cooling System Check
Coolant tank and Coolant level between marks on tank Add proper coolant mix.
radiator. when engine is warm.
Coolant in radiator full to top.
Coolant not contaminated with oil, fuel, Drain and flush system. Check for
or discolored brown. source of contamination.
Radiator screen free of debris. Clean or replace.
Water pump not leaking. Inspect water pump. (See WATER
PUMP.)
Hoses not cracked or leaking, clamps Pressure test radiator and cap. (See
and radiator cap tight. COOLING SYSTEM PRESURE TEST.)
Fan belt tight, not glazed or cracked. Replace and adjust belt tension. (See
FAN/ALTERNATOR DRIVE BELT
ADJUSTMENT.)
Fan blades not damaged or warped. Replace fan.
Fuel System Check
Fuel tank, pump, lines, Fuel level correct, not contaminated, Drain and clean fuel tank. Add fresh fuel.
filter and filter shutoff correct grade of fuel, no water. Replace filters.
valve. Fuel pump in-line filter free of debris.
Fuel hoses not cracked or leaking. Replace.
Fuel hose clamps tight. Replace or tighten.
Air Intake System
Check
Air filter and air intake. Air filter hose not cracked, clamps tight. Replace and tighten clamps.
Element not plugged. Air filter housing Replace element or housing.
sealed, no dirt tracking inside filter
element.
Fuel Pump Check
Fuel filter and fuel pump. Fuel level increases in filter. See FUEL PUMP POWER CIRCUIT
(Key switch in RUN Fuel pump operating - listen for DIAGNOSIS in ELECTRICAL section.
position.) humming sound. Test fuel pump pressure. (See FUEL
Fuel present in return hose at fuel pump. SUPPLY PUMP PRESSURE TEST.)
Replace fuel filter.
11/22/00 3 - 21
DIAGNOSIS DIESEL ENGINE
DIAGNOSIS (CONTINUED)
Valve Check
Intake and exhaust Cold engine. Valve clearance within Check and adjust. (See VALVE
valves. specification. CLEARANCE CHECK AND
Valves not sticking. ADJUSTMENT.)
Check valve guides and stems.
Fuel Injector Check
Fuel at injectors. (Key in Crack fuel injection lines at injectors. Check spray pattern and cracking
START position - engine Fuel shutoff solenoid pulled in. pressure. (See FUEL INJECTION
cranking.) NOZZLE TEST.) Replace injectors. (See
Engine must crank. CRANKING CIRCUIT DIAGNOSIS in
ELECTRICAL section.)
Cylinder Compression
Check
Injector ports. (Key in Cylinder compression within Perform cylinder compression test. (See
START position.) specification. Pressure difference CYLINDER COMPRESSION
between cylinders within specification. PRESSURE TEST.)
Starter Check
Flywheel and starter. Minimum cranking rpm within See STARTER AMP DRAW TEST in
specification. ELECTRICAL section.
Injection Pump Check
Injection pump timing Timing should be correct. Remove pump Perform injection pump static timing
inspection. (Key OFF.) as the LAST possible solution. adjustment. (See INJECTION PUMP
STATIC TIMING ADJUSTMENT.) Have
pump tested by an EPA certified Service
Repair Shop.
Fast and Slow Idle
Check
Injection pump idle Engine runs smooth under load. Engine See SLOW IDLE ADJUSTMENT and
settings. (Engine rpm to specification. FAST IDLE ADJUSTMENT.
running).
Oil Pressure Check
Oil pressure sender port. Oil pressure in specification. Test engine oil pressure. (See ENGINE
OIL PRESSURE TEST.)
Thermostat Check
Thermostat. (Engine at Clean from corrosion, rust, or debris. Replace thermostat.
operating temperature.) Opening temperature within Perform thermostat opening test. (See
specification. THERMOSTAT OPENING TEST.)
Muffler Check
Muffler. Not restricted. Replace muffler.
3 - 22 11/22/00
DIESEL ENGINE TESTS AND ADJUSTMENTS
GENERAL TUNE-UP
RECOMMENDATIONS
As a general rule, an engine tune-up is not necessary
if all recommended Operator’s Manual hourly service
procedure are performed on schedule. If your engine
performance is not within the rated application
guidelines and if engine condition does not require
overhaul, the following service procedures are
recommended to help restore engine to normal
operating efficiency.
1. Change engine oil and filter. RG5971
11/22/00 3 - 23
TESTS AND ADJUSTMENTS DIESEL ENGINE
Procedure:
Thermostat Test Specifications
NOTE: Use gauge from FKM10002 or JT05470
Rating Initial Opening Full Open Universal Pressure Test Kit if available.
(Range) (Nominal)
Otherwise, use gauge with a reading range of
71°C (160°F) 69-72°C (156-162°F) 84°C (182°F) 0–600 kPa (0–87 psi) minimum.
Specifications:
3029D. . . . . . . . . . . . . . . . . . . . . . 4 m3/h (141 cu ft/h)
3029T . . . . . . . . . . . . . . . . . . . . . . 6 m3/h (225 cu ft/h)
If blow-by is lower, there is no excessive wear
between piston rings and liners. For a further check,
carry out cylinder compression pressure test. If blow-
by is higher, there is excessive wear between piston
rings and liners, resulting in loss of engine power.
Overhaul the engine.
CD30686
3 - 24 11/22/00
DIESEL ENGINE TESTS AND ADJUSTMENTS
CYLINDER COMPRESSION
PRESSURE TEST
Reason:
To determine the condition of the pistons, rings,
cylinder walls and valves.
Equipment:
FKM10021 Compression Test Kit
Procedure:
A
A
B
B
C
C
CD30432
C
C D
D
11/22/00 3 - 25
TESTS AND ADJUSTMENTS DIESEL ENGINE
Test Gauge
Inlet
A
Outlet
CD30681
KV18011
1. Disconnect speed control rod at fuel injection pump.
2. Move pump throttle lever against pump fast idle
Procedure: adjusting screw (A). Check engine speed and
compare with specifications.
1. Remove plug from auxiliary outlet port on fuel filter
base. Specification:
2. Install test gauge as shown.
240 Fast Idle Speed . . . . . . . . . . . . . . . 2450±50 rpm
3. Start engine. Fuel pump should maintain positive
minimum pressure of 15–30 kPa (0.15–0.30 bar) 250 Fast Idle Speed . . . . . . . . . . . . . . . 2400±50 rpm
(2–4.5 psi). A low pressure can be due to a
NOTE: Fast idle is set by the factory, then the fast idle
clogged filter element or a defective supply pump.
adjusting screw (A) is sealed to prevent
Replace filter element then check pressure again.
tampering. Fast idle adjustment can only be
If reading is still below specification, replace
performed by an authorized EPA certified
supply pump.
service center.
NOTE: The fuel pump is not repairable and therefore
3. Move pump throttle lever in slow idle position
should be replaced when defective.
against slow idle adjusting screw (B). Check
engine speed and adjust to specifications.
FAST AND SLOW IDLE Specifications:
ADJUSTMENT 240 Slow Idle Speed. . . . . . . . . . . . . . . 1175±50 rpm
250 Slow Idle Speed. . . . . . . . . . . . . . . 1175±50 rpm
Reason: 4. Turn screw (B) clockwise to increase and counter-
clockwise to decrease engine speed.
To ensure an adequate slow idle rpm that will allow the
engine to run smoothly without stalling and to ensure
specified fast idle speed setting.
Equipment:
JT05801 Clamp-on Electronic Tachometer.
3 - 26 11/22/00
DIESEL ENGINE TESTS AND ADJUSTMENTS
Dynamic Timing
Reason:
To make sure injection pump timing is set to
specification.
Equipment:
JT07158 Time-Trac. CD30195
Install FKM10429-6 timing sensor (E) between No. 1
nozzle and high pressure fuel line.
Using two wrenches, tighten sensor and fuel pressure
line to 30 N•m (22 lb-ft).
D
H
C
J I
K E
B
CD30441
A. Meter C
B. Sensor Clamp
C. 6 mm Clamp-On Transducer CD30673
D. Instruction Manuals
E. Timing Sensor NOTE: If clearance does not allow proper installation
F. Timing Pin of the timing sensor (E), FKM10429-5 or
G. Magnetic Probe FKM10465-3 clamp-on transducer (C) can be
H. Transducer Cable installed close to injection nozzle. Remove
I. 1/4" Clamp-On Transducer paint on injection line before installation.
J. Magnetic Probe Adapter
K. Magnetic Probe Adapter
11/22/00 3 - 27
TESTS AND ADJUSTMENTS DIESEL ENGINE
CD30442
KV18568
KV18075
G. Magnetic Probe
H. Timing Sensor
I. Sensor Clamp
CD30443
3 - 28 11/22/00
DIESEL ENGINE TESTS AND ADJUSTMENTS
E
F
CD30447
CD30205
CD30202 7. Once 1300 rpm is displayed, press "ENTER" key.
"Calibrating..." will then appear on the display for a
1. Press the "ON/CLEAR" key. The display will show
short period of time.
"Time-Trac", then "Model TT1000", then "R = 0".
11/22/00 3 - 29
TESTS AND ADJUSTMENTS DIESEL ENGINE
CD30449
CD30198
3 - 30 11/22/00
DIESEL ENGINE TESTS AND ADJUSTMENTS
CD30549
A. Front of Engine
B. No. 1 Piston at TDC Compression Stroke
C. No. 1 Piston at TDC Exhaust Stroke
D. Intake Valve
CD30544
E. Exhaust Valve
Using JDE83 or JDG820 Flywheel Turning Tool (A),
rotate engine flywheel in running direction (clockwise 1. Using JDE81-4 Timing Pin, lock No. 1 piston at
viewed from water pump) until No.1 piston (front) has TDC compression stroke (B).
reached top dead center (TDC) on compression 2. Adjust valve clearance on No. 1 and 2 exhaust
stroke. Insert timing pin JDE81-4 (B) into flywheel valves and No. 1 and 3 intake valves.
bore. 3. Turn crankshaft 360° and reinsert timing pin.
4. Adjust valve clearance on No. 3 exhaust valve and
No. 2 intake valve.
CD30545
11/22/00 3 - 31
REPAIR DIESEL ENGINE
REPAIR
c CAUTION
This repair stand should be used only by
qualified service technicians familiar with this
equipment.
3 - 32 11/22/00
DIESEL ENGINE REPAIR
Equipment:
Engine Repair Stand
Engine Hoist - 1000 kg (2200 lb.) capacity
Engine Removal:
1. Remove bucket or any other attachments
CD30527
2. Park skid steer on flat level surface. Place blocks in
front of and behind tires.
1. Use a 73 mm spacer at hole (A) and a 79 mm 3. Start engine and raise boom arms to the fully raised
spacer at hole (B). position, and engage boom locks.
2. Mount engine to adapter using the cap screws
4. Disconnect battery, negative (–) cable first then
listed below at the hole locations as shown:
positive (+) cable.
Holes A and B . . . . 14 mm (9/16-12 x 4-1/2 in.) 5. Raise ROPS and ensure ROPS is locked in
Hole C . . . . . . . . . 38 mm (9/16-12 x 1-1/12 in.) position.
3. Drain all engine oil and coolant. 6. Remove top, rear, and side engine panels.
D
NOTE: Approximate cooling system capacity is 9.5 L
(10 qt).
CD30528
Radiator Drain Valve
4. Disconnect oil inlet line at turbocharger (D) to
prevent hydraulic lock. Drain Hose
KV13939
11/22/00 3 - 33
REPAIR DIESEL ENGINE
KV13940
KV13964
Inlet
Lower Radiator Hose
KV13941
KV18010
KV13058
3 - 34 11/22/00
DIESEL ENGINE REPAIR
Latch Bracket
Filler Tube
Cap Screw
Intake Hose
Air Cleaner
KV18841 KV13948
15. Remove filler tube-to-radiator support cap screw. 22. Disconnect intake hose from intake manifold or
16. Remove engine cover latch bracket. Repeat for turbocharger if equipped.
opposite side of radiator. 23. Disconnect air filter restriction sensor connector.
24. Remove air cleaner/intake hose assembly from
mounting bracket.
Recovery Bottle
NOTE: Close all openings using caps or plugs to
prevent contamination.
KV18012
Cap Screws
Fuel Leak-Off Line
KV13064
Mounting Bracket
KV13950
NOTE: Tag or label all wires and connectors to aid
during installation.
27. Remove four cap screws and mounting bracket.
20. Disconnect coolant temperature sensor wiring Move bracket with hydraulic oil filter and filter
connector. manifold forward away from engine.
21. Disconnect fuel leak-off line.
11/22/00 3 - 35
REPAIR DIESEL ENGINE
Wiring Lead
28. Disconnect wiring lead from fuel shut-off solenoid. 33. Bend wire harness retainer back and move harness
29. Disconnect throttle linkage from bracket and fuel away from engine.
injection pump. 34. Disconnect cylinder block heater connector (if
equipped).
Preheat Relay
Front Engine
Mounting Bolt
KV31115
Alternator
Manifold Preheater
Rear Engine
Mounting Bolts
Starter KV13957
KV18842
3 - 36 11/22/00
DIESEL ENGINE REPAIR
B
KV15160
F
c CAUTION
Boom lock pins must remain in place. Be sure
that boom is adequately supported by boom lock
KV13985
pins.
43. Install lifting sling around hydrostatic pump and
mounting plate. Attach hoist and take up slack in
36. Remove boom lock linkage mounting plate (A) cap sling.
screws. Disconnect boom lock linkage (B) from
44. Remove pump flange-to-engine flywheel cover cap
levers (C) and (D). Remove mounting plate,
screws. Remove mounting plate cap screws,
leaving boom lock pins and levers in place.
washers, and nuts.
45. Remove remaining flywheel cover cap screws.
Remove flywheel cover.
KV13976
Cap Screw
37. Install JD244 lifting brackets to engine. Attach
JDG23 lifting sling to bracket.
38. Attach a suitable hoist to engine and take out the Coupling
slack on lifting chain.
39. Label and remove hoses from hydrostatic pump KV31121
assembly.
40. Disconnect steering linkage from hydrostatic pump 46. Remove eight coupling-to-flywheel cap screws.
arms. Remove coupling.
47. Install engine on repair stand. (See MOUNT
ENGINE ON REPAIR STAND.)
NOTE: Make sure all lines, hoses, and electrical wiring
are removed and do not entangle with engine
during removal. Engine Installation:
41. Remove engine/hydrostatic pump assembly. IMPORTANT: Before installing engine make sure
42. Lower engine to floor and block. all electrical wiring, lines, and hoses are moved
away from engine.
11/22/00 3 - 37
REPAIR DIESEL ENGINE
Torque Specification:
Pump Flange-to-flywheel . . . . . . 140 N•m (105 lb-ft)
cover cap screw
Mounting bracket cap screw . . . . 140 N•m (105 lb-ft)
Mounting bracket . . . . . . . . . . . . . 305 N•m (225 lb-ft)
cap screw and nut
Washer
Grommet
Cap Screw Nut
Bushing 140 N•m (105 lb-ft)
Grommet
Washer
KV13987
Rear Engine Mount
Cap Screw
Coupling
KV31121
KV13976
1. Place coupling on flywheel and install eight 4. Install engine/pump assembly. Remove hoist and
coupling-to-flywheel cap screws. Tighten to lifting brackets.
63 N•m (46 lb-ft).
3 - 38 11/22/00
DIESEL ENGINE REPAIR
Block Heater Connector 12. Connect fuel shut-off solenoid wiring lead.
13. Connect throttle linkage to fuel injection pump and
bracket.
Preheat Relay
Mounting Bracket
KV13950
KV13949
11/22/00 3 - 39
REPAIR DIESEL ENGINE
Latch Bracket
Filler Tube
Coolant Temperature
Sender
Cap Screw
Fuel Leak-Off Line
KV18841
KV13058
KV18012
21. Install radiator/hydraulic oil cooler assembly. NOTE: Replace all O-rings and seals. Used or
22. Install coolant recovery bottle and connect hose to damaged O-rings and seals will leak.
radiator filler neck.
23. Check for fan tip clearance. Fan shroud should
have tip clearance of 10 ± 1.0 mm 27. Install new O-ring seals and connect hydraulic oil
(0.40 ± 0.04 in.) to shroud cutout. cooler hoses. Tighten hoses securely.
3 - 40 11/22/00
DIESEL ENGINE REPAIR
KV13941
28. Install cooling fan finger guard. Tighten cap screws
to 26 N•m (19 lb-ft).
29. Install upper and lower radiator hoses. Tighten all
hose clamps securely.
30. Connect cab heater hoses to engine (if equipped).
Inlet
TS281
c CAUTION
Outlet Explosive release of fluids from pressurized
cooling system can cause serious burns. Shut
KV18010 off engine. Only remove filler cap when cool
enough to touch with bare hands. Slowly loosen
31. Install fuel filter base with filter. Connect inlet line to
cap to first stop to relieve pressure before
filter base.
removing cap completely.
32. Install hydraulic oil reservoir drain plugs and tighten
securely.
Removal:
NOTE: Approximate hydraulic oil reservoir capacity is
1. Open top and rear panels and remove side engine
15.6 L (4.1 gal.).
panels.
2. Disconnect battery, negative (-) cable first.
33. Fill hydraulic oil reservoir with clean hydraulic oil.
34. Install bottom engine access cover. NOTE: Approximate cooling system capacity is 9.5 L
(10 qt).
NOTE: Approximate cooling system capacity is 9.5 L
(10 qt).
11/22/00 3 - 41
REPAIR DIESEL ENGINE
Latch Bracket
Filler Tube
Cap Screw
Radiator Drain Valve
Finger
Guard
Drain Hose
KV13939 KV18841
3. Route radiator drain hose out of access panel on 6. Remove cooling fan finger guard.
left side of frame. 7. Remove cap screw, retaining hydraulic filler tube to
4. Open radiator drain valve and drain coolant. support.
8. Remove engine access cover latch bracket. Repeat
Finger procedure on opposite side of radiator.
Guard
Upper Radiator
Hose
Cap Screws
KV13940
KV13992
9. Remove four cap screws securing fan shroud. Move
fan shroud away from fan and towards engine,
away from radiator.
10. Disconnect coolant recovery hose from filler neck
and remove coolant recovery bottle.
Cap Screws
KV13941
KV18010
3 - 42 11/22/00
DIESEL ENGINE REPAIR
Installation:
Cap Screw
Cap Screw
KV13993
KV13993
NOTE: Some models have a spacer washer between 1. Install radiator in support brackets. Apply medium
the support bracket and radiator mounting strength threadlock to both cap screws. Install and
flange. Retain for reuse. tighten only left side cap screw to 29 N•m
(21 lb-ft).
13. Remove one cap screw on each side of radiator
support and remove radiator. Shroud does not
need to be removed with radiator.
Washer
c CAUTION
Reduce compressed air to less than 210 kPa
(30 psi) when using for cleaning purposes. Clear
area of bystanders, guard against flying chips,
and wear personal protection equipment
including eye protection.
Latch Bracket
Filler Tube
11/22/00 3 - 43
REPAIR DIESEL ENGINE
Cap screws
KV13992
6. Install coolant recovery bottle and connect recovery
hose to filler neck.
7. Install fuel filter assembly.
Finger
Guard
Upper Radiator
Hose
KV13940
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.
3 - 44 11/22/00
DIESEL ENGINE REPAIR
11/22/00 3 - 45
REPAIR DIESEL ENGINE
E
D
CD30531
3 - 46 11/22/00
DIESEL ENGINE REPAIR
C
A
CD30532
D
NOTE: Measuring valve lift can give an indication of E CD30533
wear on cam lobes.
NOTE: A generic PowerTech 2.9 L engine is shown.
1. Rotate engine and determine valve locations as Skid steer engine is similar.
indicated under VALVE CLEARANCE in this
section. Before removal, mark all parts so that they can
2. Adjust valve to zero clearance. be installed in their original positions.
3. Position dial indicator on valve rotator and adjust
indicator to "0".
1. Drain engine coolant.
4. Rotate engine and observe indicator reading as
2. Remove muffler.
valve moves to the fully open position. Compare
readings with specifications. 3. Remove exhaust manifold (A). On turbocharged
engine, disconnect oil inlet line (B) and oil return
5. Repeat above procedure for all valves and readjust
line (C), then remove the exhaust manifold,
valves to specified clearance after this operation.
turbocharger, and crossover pipe.
6. If valve lift is not within specification, remove and
4. Remove thermostat housing (D), bypass tube (E),
inspect camshaft.
and thermostat.
11/22/00 3 - 47
REPAIR DIESEL ENGINE
KV18570 CD30537
NOTE: A generic PowerTech 2.9 L engine is shown. 14. Lift cylinder head from block. If cylinder head sticks,
Skid steer engine is similar. use a soft hammer to tap cylinder head. Do not
use screwdriver or pry-bar which can damage the
7. Remove air inlet adapter (I). sealing surface.
8. Remove crankcase vent hose (J).
9. Remove rocker arm cover (K). NOTE: Do not turn crankshaft after removal of cylinder
head until each liner has been secured with
washer and cap screw.
KV18571
10. Remove rocker arm assembly (L).
11. Remove all push rods.
CD30538
3 - 48 11/22/00
DIESEL ENGINE REPAIR
D
C
G
F
A I
L
K
CD30379
A. Cam Follower D. Support G. Keepers J. Metering Seal
B. Push Rod E. Shaft H. Rotator K. Valve Seat Insert
C. Rocker Arm F. Plug I. Spring L. Valve
L103629
L30699
1. Using JDE138 Valve Spring Compressor, compress
the valve springs far enough to remove keepers. Maximum permissible flatness is 0.08 mm (0.003 in.).
2. Release spring tension and remove valve rotator Machined surface of cylinder head must be re-faced if
and valve spring. Mark each part so that it can be flatness is more than specified maximum.
assembled in the same position it was removed
from.
3. Remove valves, marking them for assembly. NOTE: Maximum permissible amount to be machined
4. Remove valve stem seals from valve guide tower. from cylinder head is 0.76 mm (0.03 in.).
After any head machining, always recheck
valve recesses.
11/22/00 3 - 49
REPAIR DIESEL ENGINE
CLEAN VALVE GUIDES If valve guide-to-stem oil clearance exceeds the wear
limit, oversize valve stems 0.38 mm (0.015 in.) and
0.76 mm (0.030 in.) are available. Have valve guides
reamed by a qualified workshop to assure a proper
guide-to-stem clearance.
CD30539
CD30550
Maximum permissible
clearance. . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
3 - 50 11/22/00
DIESEL ENGINE REPAIR
LAPPING VALVE SEATS After lapping valve seat or machining combustion face,
install re-faced or new valves in cylinder head and
check valve recess (A).
RG7761
RG4756
RG7813
2. Protect the cylinder head surface with a non-
CD30541 flammable welder’s cloth (A). Apply a thin bead of
weld (B) around internal diameter of valve seat
insert.
11/22/00 3 - 51
REPAIR DIESEL ENGINE
RG7763
Machining Valve Seat Insert 1. Freeze the valve seat inserts to –30° C (–22° F).
2. Using JDG676 Pilot Driver (A) and JDG675 Valve
Seat Insert Installing Adapter (B), install valve seat
inserts.
3. Lap valve seats to maintain correct valve recess
and valve to valve seat sealing. (See LAPPING
VALVE SEATS.)
3 - 52 11/22/00
DIESEL ENGINE REPAIR
RG4234
T91224
11/22/00 3 - 53
REPAIR DIESEL ENGINE
INSTALL VALVES
1. Apply engine oil to valve stems and guides.
2. Insert valves in head (in same location as found
during removal).
CD30233
RG5654
RG4718
RG5655
IMPORTANT: Ensure that cam followers (A) are
4. Install valve springs and rotators. present before installing cylinder head.
5. Compress valve springs using JDE138 Valve
Spring Compressor and install new keepers on
valves.
CD30693
3 - 54 11/22/00
DIESEL ENGINE REPAIR
9 5 10
4 6 14
12 3 1 11
8 2 7
B B KV15177
11/22/00 3 - 55
REPAIR DIESEL ENGINE
CD30381
INSTALL ROCKER ARM ASSEMBLY
D C
CD30382
A. Plug CD30536
B. Bowed Washer
1. Install push rods in same location from which they
C. Oil Supply Hole in Rocker Arm Shaft
were removed.
D. Oil Supply Hole in Cylinder Head
3 - 56 11/22/00
DIESEL ENGINE REPAIR
CD30546
1. Install rocker arm cover with built-in sealing ring
(without sealant).
2. Install cap screws (A) by hand and tighten to
10 N•m (89 lb-in.), starting from center and
moving towards both front and rear ends of the
cover. DO NOT OVERTIGHTEN.
KV14267
11/22/00 3 - 57
REPAIR DIESEL ENGINE
D
C
E
F
H
A
J I
CD30551
A. Cylinder Block D. Piston Rings G. Liner Seals
B. Cylinder Liner E. Piston Pin H. Oil Pressure Regulating Valve Seat
C. Piston F. Snap Ring I. Oil Bypass Valve
J. Connecting Rod
3 - 58 11/22/00
DIESEL ENGINE REPAIR
CD30554
A
B
RG7464
11/22/00 3 - 59
REPAIR DIESEL ENGINE
CD30556
3 - 60 11/22/00
DIESEL ENGINE REPAIR
R26164 RG6426
1. Place cylinder liners in a suitable clamping device. 1. Check each piston cooling jet (A) for plugging or
2. Use D17004BR Flex-Hone to de-glaze liner. Follow damage.
instructions supplied with tool to obtain 45°
crosshatch pattern.
NOTE: A cooling jet failure could cause damage to
pistons, piston pins, rod pin bushings and
NOTE: After de-glazing, clean cylinder liner bore with liners.
a mixture of warm water and soap. Rinse with
clear water until rinse water is clear. Dry with
clean towels and coat bore with clean engine 2. Reinstall jets and tighten to 10 N•m (7.5 lb-ft).
oil.
CAM FOLLOWER BORE MEASURE
IMPORTANT: Do NOT use gasoline, kerosene, or :
commercial solvents to clean liners.
T81656
11/22/00 3 - 61
REPAIR DIESEL ENGINE
CD30340
CD30389
CD30388
Extract camshaft bushing using JDG739B tool as 2. Slide bushing onto driver so notched end (A) of
follows: bushing will be toward front end of engine when
installed.
1. Assemble threaded spacers (A) and forcing plate
(B) to cylinder block (C).
2. Insert bushing puller (D) into camshaft bushing IMPORTANT: Bushing must be installed so oil
bore. supply hole (arrow) aligns with oil drilling in
block bore.
3 - 62 11/22/00
DIESEL ENGINE REPAIR
CD7271
CD30559
2. After having positioned block on a boring machine,
bore new bearing caps to 84.46—84.48 mm
(3.325—3.326 in.) diameter. Take care to remain
within the specified dimension (A) (crankshaft bore
center line to block top face).
Distance (A) . . . . . . . . . . . . . . . . 301.98—302.11mm
(11.889—11.894 in.)
IMPORTANT: Make sure all crankshaft bearing
bores are in alignment.
11/22/00 3 - 63
REPAIR DIESEL ENGINE
CD30199
CD30563
3 - 64 11/22/00
DIESEL ENGINE REPAIR
A A
B
B
C D CD30565
CD7134
2. Seat liners using KCD10001 special tool.
A. Cylinder Liner 3. Secure liners by means of large washers and cap
B. Packing screws.
C. Improper Installation
D. Proper Installation MEASURE CONNECTING ROD
BEARING
LINER O-RING INSTALLATION
Apply lubricating soap to new O-rings. Install O-rings NOTE: Before measuring, connecting rod cap screws
in respective grooves. must be tightened according to specifications.
CD7135
CD7120
A. Rectangular Section Packing
B. Red or White O-Ring
C. Black O-Ring
D. Cylinder Liner
E. Cylinder Block
CD7121
Measure OD of rod journal on crankshaft. Tighten rod
cap screws to specification and measure ID of rod
bearing. Subtract journal dimension from rod bearing
dimension. The result is clearance.
11/22/00 3 - 65
REPAIR DIESEL ENGINE
CD30567
3 - 66 11/22/00
DIESEL ENGINE REPAIR
RG7132
RG7131
11/22/00 3 - 67
REPAIR DIESEL ENGINE
T81604 RG6283
If diameter is less or clearance is more than specified, PISTON TOP RING GROOVE
replace pin/bushing assembly for the 3029T engines
and replace connecting rod/piston pin assembly for the
3029D engines.
c CAUTION
RG4746
Follow manufacturer’s instruction exactly. DO A. Piston Can Be Used Again
NOT ALLOW CHEMICAL TO COME IN CONTACT B. Discard Piston and Replace
WITH SKIN OR EYES; chemical contains
creosotes which can be very harmful. C. JDG957 Gauge
D. Tool Shoulder-to-Ring Land Clearance
3 - 68 11/22/00
DIESEL ENGINE REPAIR
RG5625
CD30569
CD30391
11/22/00 3 - 69
REPAIR DIESEL ENGINE
1. Install oil control ring (C) in bottom ring groove over PISTON/LINER SET INFORMATION
ring expander. Be sure that the ring expander and
the wire are correctly fitted.
2. Install second ring (B) in center ring groove. Second
ring can be identified by a yellow paint mark (F).
Proper installation is obtained when this mark is to
the left of end gap.
3. Install top ring (A) in top ring groove. Top ring can
be identified by a blue paint mark (E). Proper
installation is obtained when this mark is directly
above yellow mark (F).
F
CD30579
A A. Liner
E
B B. Piston
C. Piston Ring Set
D. Liner Seal Set
C D
IMPORTANT: Do not intermix assemblies having
tongue-and-groove rod with assemblies having
PRECISION JOINT™ rod on the same engine.
Check parts catalog for correct application.
3 - 70 11/22/00
DIESEL ENGINE REPAIR
ASSEMBLE PISTON AND 2. Coat piston pin (B) with engine oil and insert it
through piston and connecting rod bores. Install
CONNECTING ROD NEW piston pin retaining rings (C) with sharp edge
of ring facing away from piston pin. Make sure
retaining rings are seated correctly in their
B grooves.
C
A
INSTALL PISTON AND
CONNECTING ROD
CD30571
11/22/00 3 - 71
REPAIR DIESEL ENGINE
B
A
CD30574
CD30573
KV18573
3 - 72 11/22/00
DIESEL ENGINE REPAIR
9. Check for proper side clearance in all rods. Each 7. If protrusion is out of specifications, check all
rod must have a slight side-to-side movement. concerned parts to determine the cause.
CD30575
B
A
CD30005
11/22/00 3 - 73
REPAIR DIESEL ENGINE
COMPLETE FINAL ASSEMBLY 2. Cylinder block has some orifices which are in
relation either with the lubrication or coolant
system. When assembling an engine, be sure that
coolant lines are connected to corresponding
coolant ports and oil lines to oil ports. Apply
torques as indicated.
3. Be sure that piston cooling jets (H) and oil gallery
steel caps (J) are installed.
CD30577
KV18077
Rear Left View 4. Service cylinder block may have additional side
mounting bosses (K). If these bosses interfere with
the chassis or other machine components, grind
concerned area.
CD30576
Front Right View
KV18078
Torques/Specifications:
A. Coolant drain (1/4 in.) . . . . . . . . . 17 N•m (13 lb-ft) 5. Oil gallery ball (M) is provided with service cylinder
B. Turbocharger oil return (1/2 in.) . 45 N•m (33 lb-ft) block, but may not be installed. In this case,
C. 1/2 cyl. for dipstick tube . . . . . . . 67 N•m (50 lb-ft) proceed as follows:
D. Oil galleries (1/8 in.). . . . . . . . . . . 17 N•m (13 lb-ft) • Put ball (M) in oil passage (N).
E. Coolant gallery (side) (1/4 in.) . . 17 N•m (13 lb-ft) • Drive in ball using an appropriate driver (O) until
F. Rear coolant gallery (1 in.) . . . . . 45 N•m (33 lb-ft) ball bottoms.
G. Oil gallery (3/8 in.) . . . . . . . . . . . . 45 N•m (33 lb-ft) • Check for proper installation. The distance
between pan rail and top of ball should be
1. Install all components previously removed. Apply approximately 54 mm (2.16 in.).
following recommendations then perform engine
test.
3 - 74 11/22/00
DIESEL ENGINE REPAIR
c CAUTION
Flywheel is heavy. Plan a proper lifting
procedure to avoid personal injury.
CD30580
A
1. Remove pulley attaching cap screw.
2. Using JDG410 Puller or any other suitable puller,
remove pulley from crankshaft.
11/22/00 3 - 75
REPAIR DIESEL ENGINE
E C
B
T90596 RG6345
INSTALL FLYWHEEL
IMPORTANT: If flame is used to heat ring gear, be
sure gear is heated uniformly around
circumference.
CD7140
3 - 76 11/22/00
DIESEL ENGINE REPAIR
Removal:
B
RG5639
Using JDG645E
CD30584
The crankshaft rear oil seal (A) and the wear sleeve
(B) composes a non-separable part. To remove this oil
seal/wear sleeve assembly, the two following
procedures can be used depending on special tool
availability:
Using JDG698
CD30243
RG5638
11/22/00 3 - 77
REPAIR DIESEL ENGINE
Installation:
CD30586
CD30397
CD30247
3 - 78 11/22/00
DIESEL ENGINE REPAIR
B
B
A A B CD7144
B
CD7141 Check crankshaft end play using a dial indicator and
compare with specifications.
2. Remove four 5/8 in. cap screws (B) and eight 3/8 in.
cap screws (A). Remove flywheel housing.
A
CD30220
11/22/00 3 - 79
REPAIR DIESEL ENGINE
CD30587
CD7149
CD7147
2. Install main bearing inserts and caps then tighten
2. Check crankshaft for cracks or signs of load stress
cap screws to 135 N•m (100 lb-ft), then measure
(see illustration for critical areas of load stress in a
ID of main bearing (assembled) and compare with
crankshaft.).
specifications.
3. Inspect both shoulders of thrust bearing journal for
Main Bearings (Assembled) ID Specifications:
scores or unevenness.
Main bearings assembled
ID (standard) . . . . . . . . . . . . . . 79.396—79.440 mm
(3.126—3.127 in.)
Clearance . . . . . . . . . . . . . . . . . . 0.046—0.116 mm
(0.0018—0.0046 in.)
Maximum wear . . . . . . . . . . . . 0.15 mm (0.006 in.)
3 - 80 11/22/00
DIESEL ENGINE REPAIR
11/22/00 3 - 81
REPAIR DIESEL ENGINE
The following specifications are required when cast NOTE: Gear can be replaced without removing the
iron crankshafts have to be ground: crankshaft.
Center Line Average (C.L.A) . . . . . . . . . . 0.2 micron
(8 micro-in.)
or better
0.64 micron (25.6 micro-in.) depth . . . Tp more than A. No. 1123 Pulling Attachment
90% B. Disc
C. D01200AA Push Puller
Final journal finishing operation must be done in
clockwise direction (as viewed from forward end of 1. Pull gear using D01200AA Push Puller or any
crankshaft.). suitable puller.
2. Remove woodruff key from crankshaft and remove
any burrs from gear journal.
IMPORTANT: DO NOT attempt to grind cast iron
3. Install a new woodruff key in crankshaft keyway.
crankshafts if above specifications cannot be
obtained. 4. Heat new gear to 180°C (360°F).
c CAUTION
Oil fumes or oil can ignite above 190°C (380°F).
Use a thermometer to ensure that a temperature
of 180°C (360°F) is not exceeded. Do not allow a
flame or heating element to come into direct
contact with the oil. Heat the oil in a well-
ventilated area. Plan a safe handling procedure
to avoid burns.
JDG794
CD30398
3 - 82 11/22/00
DIESEL ENGINE REPAIR
CD30589
A
A
T88557
CD30590
CD30250
3. Install all bearing caps (B) according to the
identification marks stamped on them, and so that
tabs (A) of both bearing halves are on the same
side. Install all cap screws finger-tight.
4. Apply an initial torque not exceeding 20 N•m
(14 lb-ft).
11/22/00 3 - 83
REPAIR DIESEL ENGINE
MEASURE TIMING GEAR Using a dial indicator, check camshaft end play.
BACKLASH Camshaft end play . . . . . . . . . . . . . . . 0.08—0.23 mm
(0.003—0.009 in.)
Measure backlash between gears using a dial Maximum wear . . . . . . . . . . . . . . 0.38 mm (0.015 in.)
indicator and compare with specifications.
Thrust plate thickness . . . . . . . . . . 3.935—3.985 mm
If backlash is not correct, install new gears. (0.155—0.157 in.)
Maximum wear . . . . . . . . . . . . . . . . 3.8 mm (0.15 in.)
REMOVE CAMSHAFT
C
D
CD30591
A. Camshaft/Upper Idler Gear CD30593
B. Injection Pump/Upper Idler Gear
C. Upper Idler/Crankshaft Gear NOTE: Camshaft can be removed from engine without
D. Crankshaft/Lower Idler Gear removing cylinder head by holding cam
E. Oil Pump/Lower Idler Gear followers away from camshaft lobes with
D15001NU Magnetic Holding Set.
Camshaft End Play Measure
NOTE: Mark parts so that they can be installed in their
original positions.
3 - 84 11/22/00
DIESEL ENGINE REPAIR
CD30592
11/22/00 3 - 85
REPAIR DIESEL ENGINE
RG6324
CD30200
Measure cam follower OD and compare with
1. Drill and tap an extraction hole of approx. 6 mm
specifications.
(0.250 in.) diameter and 12 mm (0.500 in.) depth in
center of pin. Cam Follower Specifications:
2. Using a self-made puller (spacer, washer, screw), Cam follower OD . . . . . . . . . . . . . . 31.62—31.64 mm
pull out the tachometer pick-up pin. (1.124—1.246 in.)
CD30596
3 - 86 11/22/00
DIESEL ENGINE REPAIR
CD30186
CD7160
11/22/00 3 - 87
REPAIR DIESEL ENGINE
A
B
RG6459
CD7161
D
NOTE: Bushing for spur upper idler gear is not
available separately. Install a new idler gear/
bushing assembly.
CD30599
3 - 88 11/22/00
DIESEL ENGINE REPAIR
A
B
C
D
A
G
E
CD30255
F CD30600
A. Upper Idler Shaft
A. T23442 Stud (Qty 3)
B. AT21191 Plug (5/16") (6 used)
C. R79854 Bushing
D. AT22919 Plug (3/8") (2 used)
E. Front Plate
F. Countersunk Screw (5 used)
G. Gasket
CD30256
H
B. Lower Idler Shaft
H
IMPORTANT: Oil hole in upper idler shaft must be
properly indexed to provide adequate
lubrication to idler gear bushing. H
NOTE: Idler shaft is secured to front plate when gear 2. On standard front plate only, install the 5/16" plugs
bolt or nut are tightened. (B) and the 3/8" plugs (D) as shown. Bushing (C)
is not required for this application.
11/22/00 3 - 89
REPAIR DIESEL ENGINE
CD30598
CD30697
KV18079
3 - 90 11/22/00
DIESEL ENGINE REPAIR
CD30604
9 15 12
11 14
13
10
24
2
A 6
1
CD30605 5 8
7 4
1. Install oil pump and lower idler gear.
2. Install new bolt with washer (A) from oil pump side. 3
17
Install washer, with sharp edge toward timing
cover, and new nut on gear side then tighten to 16
110 N•m (80 lb-ft).
19
NOTE: Engine may be equipped with a self-locking oil 23 21
20 18 22
pump nut. In this case, tighten to 85 N•m
(63 lb-ft). Do not apply any punch marks. CD30609
3. Install oil pump gear on pump shaft, tighten hex nut 1. Install new gasket on front plate.
to 75 N•m (55 lb-ft) and secure with three center 2. Install cover on engine and apply the following
punch marks. torques in sequence:
Cover cap screws (1—17) . . . . . . . . 50 N•m (35 lb-ft)
Oil pan cap screws (18—23) . . . . . . 50 N•m (35 lb-ft)
A. Magnetic pick-up . . . . . . . . . . . . . 15 N•m (11 lb-ft)
B. Injection pump gear plug . . . . . . 30 N•m (22 lb-ft)
C. Oil pressure valve plug . . . . . . . . 95 N•m (70 lb-ft)
11/22/00 3 - 91
REPAIR DIESEL ENGINE
KV18577
B CD30271
CD30698
3 - 92 11/22/00
DIESEL ENGINE REPAIR
CD30275
CD30620
1. Remove oil cooler nipple (A). Remove oil pressure regulating valve plug. Check
2. Press in new nipple so that threaded end faces valve cone for excessive wear and damaged sealing
outward. face.
Spring tension at a length
of 42.5 mm (1.68 in.). . . . 60 to 75 N (13.5 to 16.5 lb).
INSTALL OIL COOLER
REPLACE OIL PRESSURE
REGULATING VALVE SEAT
JD-248A
813
CD30617
11/22/00 3 - 93
REPAIR DIESEL ENGINE
A CD30622
CD30413 1. Remove timing gear cover and front plate.
2. Remove oil bypass valve and spring (A). Inspect
valve and spring for damage.
NOTE: One or several shims (A) may be used to
adjust the oil pressure. 3. Check spring calibration:
79 to 96.5 N (18 to 22 lb) when spring is
compressed at 29 mm (1.14 in.) length.
1. Install valve, spring, shims, washer, and plug in 4. Install oil bypass valve and spring.
timing gear cover.
5. Install front plate and timing gear cover.
2. Tighten plug to 95 N•m (70 lb-ft).
CD30623
3 - 94 11/22/00
DIESEL ENGINE REPAIR
C
CD7178
CD7176
Radial clearance between
gear and pump housing . . . . . . . . . 0.10 to 0.16 mm
1. Remove oil pan and timing gear cover. (0.004 to 0.006 in.)
2. Remove nut (A) from pump shaft. Max. permissible radial
3. Pull gear (B) from conical shaft of pump, using a clearance. . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
suitable puller.
4. Remove the 3 cap screws (C) attaching pump
housing to front plate. OIL PUMP SPECIFICATIONS
T81953
T81781
11/22/00 3 - 95
REPAIR DIESEL ENGINE
L
C
E
A
D
H
M
N
J
B
K
I
F
G
CD30416
KV18080
CD30624
1. Install new seal (A) in cylinder block. NOTE: Service oil pump kit has two outlet tubes.
2. Install O-rings in pump cover (for outlet tube) and Install tube (I) without paint mark.
on oil strainer tube.
3. Install drive shaft with gear and idler gear in pump
housing. Both gears must turn freely.
4. Install outlet tube, strainer, and pump cover.
KV18578
5. Attach oil pump assembly to front plate, tightening
cap screws (L) to 50 N•m (35 lb-ft).
3 - 96 11/22/00
DIESEL ENGINE REPAIR
6. Rotate pump shaft, again making sure that pump 2. Select and install the correct gasket for the oil pan
gears turn freely. being used.
7. Install pump drive gear (M) and a new nut (N).
Tighten to 75 N•m (55 lb-ft).
CD30627
T81782
NOTE: A generic PowerTech 2.9 L engine is shown.
Skid steer engine is similar.
NOTE: Engine may be equipped with a self-lock nut. In
this case, tighten to 85 N•m (63 lb-ft). Do not
apply any punch marks. 3. Install oil pan and tighten cap screws as follows:
Oil pan (all types) to timing
8. Secure the nut by applying three center punch gear cover . . . . . . . . . . . . . . . . . . . 50 N•m (35 lb-ft)
marks. Sheet metal oil pan to block
and flywheel housing. . . . . . . . . . 50 N•m (35 lb-ft)
Aluminum oil pan to block
INSTALL OIL PAN and flywheel housing. . . . . . . . . . 50 N•m (35 lb-ft)
Cast iron pan to block and flywheel housing:
SAE 5 screws (3 dashes) . . . . . . . 50 N•m (35 lb-ft)
SAE 8 screws (6 dashes) . . . . . . . 70 N•m (50 lb-ft)
CD30626
11/22/00 3 - 97
REPAIR DIESEL ENGINE
CD30628
B
A
C CD30629
2. Disconnect water pump hoses (A).
3. Remove attaching screws (B) and nut (C). Lift out
water pump.
3 - 98 11/22/00
DIESEL ENGINE REPAIR
DISASSEMBLE WATER PUMP 3. Using a suitable puller, remove pulley (B) or hub
from bearing shaft (C).
4. Support pulley end of housing, then using a 13 mm
(0.5 in.) driver, simultaneously remove impeller (D)
from bearing shaft and bearing shaft from pump
housing (E). Discard bearing and impeller.
5. Using a suitable driver, remove seal (F) from pump
housing and discard.
E D
CD30630
CD30631
6. Inspect water pump housing, cover, and pulley for
wear, debris, cracks or other damage. Replace as
necessary.
A. Rear Cover
B. Pulley
C. Bearing Shaft
D. Impeller
E. Pump Housing
F. Seal
G. Weep Hole
CD30632
NOTE: When water pump operation is abnormal or
when coolant drains from weep hole (G), H. Pre-Assembled Water Pump
disassemble water pump as follows.
1. Remove rear cover (A) and discard gasket NOTE: Complete or pre-assembled (H) water pumps
. are available for service as well as a seal kit
including bearing shaft (C), impeller (D), seal
(F), and gasket set.
CD30662
2. Measure dimension (X) as shown and retain for use
in pump assembly.
11/22/00 3 - 99
REPAIR DIESEL ENGINE
A B
CD30636
CD30637
KV18554
CD30635
3 - 100 11/22/00
DIESEL ENGINE REPAIR
X
D
E
KV18081
7. Install pulley or hub to dimension (X) obtained step G
2 of water pump disassembly.
F
INSTALL WATER PUMP
1. Attach pump rear cover to pump housing using a
new gasket and tighten cap screws to 45 N•m
(33 lb-ft).
D
CD30641
REMOVE/INSTALL THERMOSTAT
CD30682
11/22/00 3 - 101
REPAIR DIESEL ENGINE
C
CD30645
CD30642
B D
CD30643
CD30644
3 - 102 11/22/00
DIESEL ENGINE REPAIR
INSTALL FAN
1. Inspect fan blades for damage. Damaged blades
reduce cooling system efficiency and throw the fan
out of balance. Replace if necessary.
Wire
Connector
KV31112
CD30649
Blower Fan (Top View)
Heating
BLOCK HEATER (OPTIONAL) Jam Nut Element
KV31111
Removal:
1. Park skid steer safely.
2. Raise ROPS. (See RAISING ROPS in the IMPORTANT: Heater element is bent to avoid
MISCELLANEOUS Section) interference with cylinder block walls. DO NOT
TURN the heater element. Doing so will damage
3. Remove any attachment from skid steer Quik-Tatch.
the heater element.
4. Raise boom and engage boom locks.
5. Drain radiator.
7. Hold heating elment in place and loosen jam nut.
8. Remove jam nut.
11/22/00 3 - 103
REPAIR DIESEL ENGINE
Mark
Toward
Outside
of Block
Fitting
Fitting Heating
Element Mark
KV31108 KV31110
NOTE: If heating element will be reused, make a mark IMPORTANT: Note where the offset in the heating
on the element to determine position for element. Offset must go to the out side of block
reassembly. (right side of engine).
9. Keep heating element from rotating and unscrew 3. Install element into engine, making sure offset is
fitting from block. Remove fitting and heating towards the outside of the block. Holding element
element from block. from rotating, tighten fitting into block.
4. Hold element in place and install jam nut and
tighten.
Installation:
5. Connect wire connector and install knurled nut.
6. Fill radiator.
7. Lower ROPS.
8. Operate engine and check for leaks.
Heating
B
Element
O-Ring
A
Fitting
KV31109
3 - 104 11/22/00
DIESEL ENGINE REPAIR
1. Remove muffler.
2. On engines with turbocharger, remove
turbocharger. C
CD30661
A
CD30654
CHECK RADIAL BEARING
CLEARANCE
NOTE: A generic PowerTech 2.9 L engine is shown.
Skid steer engine is similar.
11/22/00 3 - 105
REPAIR DIESEL ENGINE
B
CD30659
E
1. Using a dial indicator with indicator rod against A
shaft, measure axial end play.
CD30661
2. Move shaft axially back and forth by hand. Indicator
reading should not exceed 0.14 mm (0.005 in.). 1. Install turbocharger on exhaust manifold (A) with a
If axial end play is not within specifications, replace new gasket (B). Tighten cap screws (C) to 30 N•m
turbocharger. (20 lb-ft).
2. If not done previously, prelube turbocharger, then
connect the oil supply line (D). Tighten to 25 N•m
REPAIR TURBOCHARGER (18 lb-ft).
Due to special tooling and highly specialized personnel 3. Connect the oil return tube (E). Tighten to 80 N•m
required, turbochargers can be serviced only by an (60 lb-ft).
authorized workshop. 4. Connect exhaust system and air hoses.
Complete turbochargers are available through service
parts channel. Individual components for repair are not IMPORTANT: Be sure that the air hose connections
available. are tight to prevent entry of dirt into engine.
PRELUBE TURBOCHARGER
CD30660
Fill oil inlet or drain port with clean engine oil and spin
rotating assembly (by hand) to properly lubricate
bearings.
3 - 106 11/22/00
DIESEL ENGINE REPAIR
LV2112
TURBOCHARGER CD30665
RECOMMENDATIONS A. Retaining Ring
In most cases, turbocharger damage is caused by B. Filter Element
improper start-up and shutdown procedure. Always C. Sediment Glass Bowl (Optional)
idle the engine for at least 30 seconds (no load) after D. Bleed Screw
start-up and before shutdown. E. Drain Screw (2 used)
IMPORTANT: Should the engine stall when 1. Unfasten filter retaining ring (A) and remove filter
operating under load, IMMEDIATELY restart the element (B).
engine to prevent overheating of turbocharger
parts.
NOTE: For a cleaner service, seal the old element with
the plug provided with the new element.
11/22/00 3 - 107
REPAIR DIESEL ENGINE
CD30667
Y RG6293
3. Install dust seal (F) as shown.
4. Position new element in proper location then tighten
about 1/3 turn until retaining ring fits into the IMPORTANT: Never steam clean or pour cold water
detent. DO NOT overtighten. on a fuel injection pump while the pump is
5. To ensure that the fuel system is primed, turn the running or while it is warm. Seizure of internal
key switch to the RUN position and wait 20 components can occur.
seconds before starting the engine.
1. Clean fuel injection pump, lines, and area around
pump with cleaning solvent or a steam cleaner.
REPLACE FUEL PUMP 2. Check for the presence of timing marks on front
plate (X) and injection pump flange (Y). If
necessary, mark both the pump and the front plate.
B
B C E
G
B
A
C A
KV31120
3 - 108 11/22/00
DIESEL ENGINE REPAIR
KV18581
JDG670A
CD30317
11/22/00 3 - 109
REPAIR DIESEL ENGINE
H
J
G
F
K
A
B
D I
C
L
E
CD30670
1. Using a new O-ring (C), slide housing onto the 3. Push drive gear firmly onto shaft taper. Install
three studs (D), inserting shaft in drive gear. washer and nut (M) then tighten to 200 N•m
(150 lb-ft). Install mounting plug onto timing gear
cover.
NOTE: Make sure that the Woodruff key (F) is seated
properly.
Y RG6293
3 - 110 11/22/00
DIESEL ENGINE REPAIR
11/22/00 3 - 111
REPAIR DIESEL ENGINE
FUEL INJECTION NOZZLE TEST 4. Deviations from the regular spray pattern or angle
may be due to the complete or partial clogging of a
nozzle orifice. In this case the fuel issues in a jet
rather than in a fine spray.
A Chatter Test
Make sure nozzle orifices are free. When working
pump of fuel injection nozzle tester at 60 strokes per
minute (gauge shut-off valve closed), a definite
characteristic "chatter" should be heard. If this is not
the case, the nozzle valve may be bent or tight in its
guide because of the lacquer deposits which have
B accumulated. This can be corrected only by
disassembling the nozzle.
3 - 112 11/22/00
DIESEL ENGINE REPAIR
Checking Valve Seat 2. Loosen lock nut (B) of pressure adjusting screw (C).
1. Connect the nozzle to tester in horizontal position. 3. Connect nozzle to tester, then using JDG949
Operate the pump lever rapidly to bleed the nozzle Special Wrench, adjust opening pressure by
and allow the valve to seat. turning the pressure adjusting screw (C).
2. Dry the tip of the nozzle thoroughly. Now operate 4. Tighten lock nut (B) to 10 N•m (7 lb-ft), then check
the pump lever slowly until the indicated pressure opening pressure.
is approximately 2800 to 3500 kPa (28 to 35 bar) 5. Carefully screw lift adjusting screw (D) until it
(400 to 500 psi) below opening pressure (see bottoms on spring seat (E).
opening pressure above). 6. Unscrew lift adjusting screw with the number of
3. Keep watching the nozzle. The nozzle tip must stay turns as specified.
dry (visual check) after a period of 5 seconds. 7. Tighten lock nut of lift adjusting screw to 5 N•m
4. Work the pump lever quickly several times in (3.5 lb-ft).
succession to make the nozzle spray in the normal 8. Check opening pressure.
way. After the last stroke of the pump, observe
again. If the nozzle is not quite leakproof,
disassemble for servicing.
CD30674
A. Lock Nut
B. Lock Nut
C. Adjusting Screw
D. Adjusting Screw
E. Spring Seat
1. Loosen and remove lock nut (A) of lift adjusting
screw (D).
11/22/00 3 - 113
REPAIR DIESEL ENGINE
A I
A
F
G B
H
C B
C CD30323
E C
H
CD30675
CD30676
A. Tee Fitting
2. Install nozzle in cylinder head. Install and hand
B. Cap Screw tighten cap screw (B). Do not tighten at this time.
C. Fuel Injection Line 3. Connect fuel injection line (C) to nozzle. Tighten to
D. Carbon Stop Seal 30 N•m (23 lb-ft) using two wrenches as shown.
E. Seal Washer 4. Tighten cap screw (B) to 37 N•m (27 lb-ft).
F. Seal 5. Install leak-off lines (I) and tee fittings (A) as an
G. Tube Nut assembly. Connect leak-off fuel lines to ends of
H. Protective Caps leak-off line assembly. Tighten all leak-off line nuts
to 5 N•m (44 lb-in.).
3 - 114 11/22/00
DIESEL ENGINE REPAIR
10 minutes 1/4 load 2,000 to rated speed Check oil pressure and
coolant temperature.
15 minutes 1/2 load 2,000 to rated speed Check for fluid leakage.
15 minutes 1/2 to 3/4 load 2,000 to rated speed
After break-in, run the engine for 1 or 2 minutes at After engine overhaul, fill the engine with John Deere
mid-throttle, no load, before shutting it off. Check and ENGINE BREAK-IN OIL.
reset the valve clearances.
If John Deere ENGINE BREAK-IN OIL is not available,
use a diesel engine oil meeting one of the following
NOTE: It is not necessary to retorque the cylinder during the first 100 hours of operation:
head cap screws once the engine is broken in. • API Service Classification CE
• ACEA Specification
After the break-in period, use John Deere PLUS-50• or
During the first 100 hours of operation, avoid
other diesel engine oil as recommended in this
overloading, excessive idling, and no-load operation.
manual.
After 100 hours, drain the crankcase oil and change
the oil filter. Fill the crankcase with oil of the specified
viscosity. IMPORTANT: Do not use PLUS-50 oil or engine oils
meeting API CG4, API CF4, ACEA E3, or ACEA
E2 performance levels during the first 100 hours
ENGINE BREAK-IN OIL of operation of a new or rebuilt engine. These
New engines are filled at the factory with John Deere oils will not allow the engine to break-in
ENGINE BREAK-IN OIL. During the break-in period, properly.
add John Deere ENGINE BREAK-IN OIL as needed to
maintain the specified oil level.
Change the oil and filter after the first 100 hours of
operation of a new or rebuilt engine.
11/22/00 3 - 115
REPAIR DIESEL ENGINE
F B
A
A
C
E
B C A
D
L30869
CD30206
A. Shaft
A. Clamp-On Transducer FKM10429-5 B. Turbine Housing
B. Cable FKM10429-3 C. Turbine Wheel
C. Timing Meter FKM10429-1 D. Center Housing
E. Compressor Wheel
F. Compressor Housing
Operating Instructions
1. Remove paint and thoroughly clean the area of the
high-pressure line to which the clamp-on
transducer is to be attached.
2. Install transducer (A) and connect cable
FKM10429-3 (B) between transducer and timing
meter (C). Also connect ground wire.
3. Switch the meter ON by pressing the "ON/CLEAR"
key and start the engine.
3 - 116 11/22/00
DIESEL ENGINE REPAIR
11/22/00 3 - 117
REPAIR DIESEL ENGINE
COLD START ADVANCE SYSTEM The engine utilizes a cold start advance system to aid
in starting and operating a cold engine.
OPERATION (IF EQUIPPED)
The cold advance system is a solenoid assembly (A)
in relation with the advance piston (E), and connected
through the wires (B) to a thermo-switch (F) located in
thermostat cover.
When coolant temperature is below 50°C (122°F), the
solenoid valve (C) is activated and opens the cold
advance circuit. This directs transfer pump pressure to
the cold advance piston (D), forcing the advance
piston to the fully advanced position.
When coolant temperature reaches 50°C (122°F), the
solenoid valve (C) is no longer activated and due to
the spring action, closes the cold advance circuit.
CD30696
The normal advance is now running and is controlled
by the speed and load advance mechanism.
The cold advance system is connected to the fuel
shut-off terminals as follows:
• Red wire to positive terminal (G)
• Black wire to negative (ground) terminal (H)
CD30692
CD30691
3 - 118 11/22/00
DIESEL ENGINE REPAIR
FUEL INJECTION NOZZLES— Fuel injection nozzles are of the multi-orifice type.
GENERAL INFORMATION The nozzle spray tip (1) forms an integral unit with
nozzle body (4) from which it cannot be separated.
The injection nozzle is secured in the cylinder head by
three superimposed spring clamps which press on a
location clamp and a cap screw. The contact pressure
is limited by a spacer ring. The nozzle is sealed in the
cylinder head at its lower end with a carbon stop seal
(2). The top end is sealed with seal washer (5).
Location clamp (19) ensures correct position of the
complete fuel injection nozzle in the cylinder head. The
leak-off line is connected by tee fitting (14), which is
fitted on the nozzle body and secured with grommet
(18) and hex nut (17).
The fuel injection nozzle works basically in the same
way as a normal spray type nozzle. Its opening
pressure is adjusted by the pressure adjusting screw
(16). The valve lift of nozzle valve (3) is adjusted by lift
adjusting screw (12) located in pressure adjusting
screw (16).
The carbon stop seal (2) prevents carbon from
collecting around nozzle in cylinder head. The fuel
injection nozzles have four orifices.
11/22/00 3 - 119
REPAIR DIESEL ENGINE
3 - 120 11/22/00
DIESEL ENGINE STARTING MOTOR
THEORY OF OPERATION
A C D
F E
B
G J
H I
RG1313
11/22/00 3 - 121
STARTING MOTOR DIESEL ENGINE
THEORY OF OPERATION—CONTINUED
B
J
C
D
H
E
G F CD30450
When solenoid (A) engages, it pulls engaging lever (J). The two windings cancel each other, and solenoid is
Lever pushes overrunning clutch drive (H) to engage released.
pinion in starter gear on flywheel. As armature (F)
A spring pushes solenoid back to disengaged position.
turns, it cranks engine.
This opens main contacts and shuts off current to field
When engine starts, overrunning clutch spins freely on windings and armature.
shaft. This prevents overspeeding of armature by
Shift lever retracts overrunning clutch drive,
flywheel.
disengaging pinion from flywheel.
When key switch is released, current to solenoid hold-
In this reduction-type starter, the speed of armature
in winding is shut off. Current can feed through both
rotation is reduced by the gear reduction assembly
pull-in and hold-in windings from main contacts, but
(G).
direction of current is reversed in pull-in winding.
3 - 122 11/22/00
DIESEL ENGINE STARTING MOTOR
KV18083
11/22/00 3 - 123
STARTING MOTOR DIESEL ENGINE
STARTING MOTOR
SPECIFICATIONS
Weight . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 kg (10.6 lb)
Brush length:
New . . . . . . . . . . . . . . . . . . . . . . . . . 14 mm (0.55 in.)
Worn (mimimum) . . . . . . . . . . . . . . 8.5 mm (0.22 in.)
Pinion:
Number of teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.54
DISASSEMBLY OF STARTING
MOTOR
KV18086
CD30452
1. Disconnect field winding cable (A).
2. Unscrew the two through-bolts (B).
KV18087
3 - 124 11/22/00
DIESEL ENGINE STARTING MOTOR
KV18088 KV18091
10. Remove two screws (N) retaining contactor. 14. Position and push the disassembly sleeve (U) on
the shaft to hold brushes in their housing and
remove the armature.
KV18089
15. Slide carbon brush plate away from the field frame.
16. Loosen and remove the four brush clips from the
plate. Take care to avoid losing the four springs.
17. Remove the disassembly sleeve.
KV18090
11/22/00 3 - 125
STARTING MOTOR DIESEL ENGINE
CD30463 CD30465
TESTING BRUSHES
CD30466
3 - 126 11/22/00
DIESEL ENGINE STARTING MOTOR
CD30467
CD30468
1. Check insulation by connecting an ohmmeter
between brush (A) and field frame (B). If 1. Check for pinion tooth condition. Slight damage on
ohmmeter indicator swings toward zero, a teeth can be eliminated by grinding.
grounded circuit is indicated.
2. Connect ohmmeter between brush (A) and terminal
(C). Resistance should be below 1 ohm. NOTE: Damage on teeth can be caused by a
3. If defective, replace the complete starting motor. malfunction of electrical system. Check also
electrical circuit for proper operation (switch,
relay, etc.).
11/22/00 3 - 127
STARTING MOTOR DIESEL ENGINE
CD30469
3 - 128 11/22/00
DIESEL ENGINE ALTERNATOR
ALTERNATOR
J
W G
Y B+
A I H
B X Z D+
C
B-
F
REG. E
D KV15183
The alternator is a synchronous three-phase NOTE: Order tools according to information given in
generator. The current coil is located in the stator, and the U.S. SERVICE-GARD Catalog or in
the exiting current is supplied by the diode trio (I) European Microfiche Tool Catalog (MTC).
through the regulator (D+ circuit), two carbon brushes
and slip rings to the exiting coil in the rotor.
The alternator is normally driven by the fan belt from
the engine crankshaft. The rotor is supported by two
permanently lubricated bearings.
The alternator generates alternating current which is
then transformed into direct current by the rectifier
diode bridge (J).
The alternating windings are delta-connected. The coil
ends X, Y, and Z are connected to the rectifier diode
as shown. Alternating current is generated in each
stator coil (B) of the alternator. During one revolution
of the rotor (C), the voltage in the stator coil rises from RW11274
0 to the positive maximum, drops to 0, rises to the
negative maximum and again drops to 0. The current Digital Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . JT05791
then flows through the diode and terminal B+ directly
to the positive pole of the battery. Test electrical components for voltage, resistance, or
current flow. It is especially good for measuring low
A sealed electronic regulator is used to regulate voltage or high resistance circuits.
alternator voltage. This regulator, which cannot be
adjusted, limits the alternator voltage to approximately
14 volts.
A protection device (H), including a Zener diode and a
capacitor, protects diode from voltage surges and
suppresses radio interference.
11/22/00 3 - 129
ALTERNATOR DIESEL ENGINE
ALTERNATOR SPECIFICATIONS:
Rotor winding resistance . . . . . . . . . . . . 2.95 ohms
Stator resistance . . . . . . . . . . . . . . . . . . . 0.00 ohms
Alternator output voltage . . . . . . . . 13.5–14.2 volts
Alternator rated amps . . . . . . . . . . . . . . . . . 55 amps
Working temperature range . . . . . . –40°C to +90°C
(–104°F to +194°F)
Maximum D+ terminal current load . . . . . . 0.5 amp
Maximum continuous alternator speed 13 000 rpm
Nominal alternator speed . . . . . . . . . . . . . .6000 rpm
Minimum brush length . . . . . . . . . . 7 mm (0.28 in.)
Single groove pulley diameter . . . 85 mm (3.35 in.)
Torque Specifications:
Alternator pulley nut . . . . . . . . . . . 40 N•m (29 lb–ft)
B+ terminal nut . . . . . . . . . . . . . . . 4 N•m (35 lb-in.)
B– terminal nut . . . . . . . . . . . . . . . 3 N•m (27 lb-in.)
Through-bolts . . . . . . . . . . . . . . . . 3 N•m (27 lb-in.)
3 - 130 11/22/00
DIESEL ENGINE ALTERNATOR
ALTERNATOR—EXPLODED VIEW
G
F
E
D
H
C
B
I
A
M
K
KV15184
11/22/00 3 - 131
ALTERNATOR DIESEL ENGINE
TROUBLESHOOTING
Problem or
Alternator indicator
Alternator indicator
Alternator indicator
engine not running
light stays off with
(alternator is not
(alternator is not
charging) at any
charging) at low
engine running
engine running
ignition on and
overcharging
Check or
Battery
speed
speed
Loose connection
Check wiring leads
z
Regulator failure
Replace brush/regulator z
assembly
Loose connection
Check wiring leads
z
Brush/regulator or capacitor
failure z
Replace parts
Diode failure
Replace complete rectifier z
bridge
Stator failure
Replace complete alternator
z
Rotor failure
Replace complete alternator
z
Regulator failure
Replace regulator
z
3 - 132 11/22/00
DIESEL ENGINE ALTERNATOR
ALTERNATOR—IDENTIFICATION
CD30471
4. Disconnect wire (D) from terminal. Remove two
CD30470 screws and washers (E). Remove brush/regulator
The information for parts identification is stamped on assembly by tilting top of regulator up and away
the body of the alternator. from alternator.
DISASSEMBLE—ALTERNATOR
ZT10613
ZT10614
11/22/00 3 - 133
ALTERNATOR DIESEL ENGINE
KV18094
7. Remove rotor/front housing assembly (I) from
stator/rear housing assembly (H).
CD30476
KV18095
CD30475
3 - 134 11/22/00
DIESEL ENGINE ALTERNATOR
CD30477
CD30479
1. Inspect slip rings (A) of rotor for scoring or rough
surface. Polish slip rings sparingly with No. 00 1. Inspect stator winding (A) for discoloration or a
sand paper. burned odor indicating a short circuit.
2. Check stator for grounds by connecting an
ohmmeter between each stator lead (B) and stator
frame (C). Resistance should be infinity.
Replace complete alternator if any defect is noted.
CD30478
2. Connect ohmmeter between both slip rings of the
rotor. Resistance should be 2.95 ohms.
3. Check the rotor for insulation by connecting an
ohmmeter between each slip ring and shaft (B). CD30480
Resistance should be infinity. 3. Check positive diodes by connecting an ohmmeter
If insulation, resistance, or slip ring are defective, between each phase terminal (D) and the “B+”
replace complete alternator. plate (E), then reverse the polarity.
4. Check negative diodes by connecting an ohmmeter
between each phase terminal (D) and the “B–”
plate (F) or ground, then reverse the polarity.
5. Check the diode trio by connecting an ohmmeter
between each phase terminal (D) and the “D+”
terminal (G), then reverse the polarity.
A diode with a high reading in one direction and a low
reading in the other direction is good. A diode with the
same reading in both directions is bad. If any diode
fails the test, replace the entire rectifier bridge.
11/22/00 3 - 135
ALTERNATOR DIESEL ENGINE
CD30484
5. Hand press rotor/front housing assembly into rear
CD30481 housing using alignment marks.
1. To replace the rectifier bridge, un-solder the leads 6. Install the three mounting bolts (F) with washers.
of phase winding (A) and “W” terminal (B) using a Tighten to 3 N•m (27 lb-in.).
soldering iron.
2. Position the replacement rectifier bridge and solder
phase winding leads. Solder “W” terminal at the
proper location.
ASSEMBLE ALTERNATOR
CD30485
7. Install brush/regulator assembly with care. Tilt it so
that the brushes contact the rotor slip rings.
Secure brush/regulator with the two screws and
washers (G). Attach wire to terminal (H).
CD30482
1. Install stator and rectifier bridge into rear housing
using alignment mark.
CD30486
8. Install shaft key (J), spacer (K) and fan (L).
CD30483
2. Secure rectifier bridge to rear housing by the two
nuts and washers (A). Install capacitor (B) with nut
and washer (C). Tighten nuts (A) and (C) to 3 N•m
(27 lb-in.).
3. Install insulated washer, flat washer, capacitor wire,
lock washer, and nut on “B+” terminal (D). Tighten
to 4 N•m (35 lb-in.). CD30487
4. Install insulated washer, flat washer, spade 9. Install pulley (M) with lock washer and nut (N).
terminal, lock washer, and nut on “W” terminal (E). Tighten to 40 N•m (29 lb–ft).
Tighten to 3 N•m (27 lb-in.). 10. Install alternator on engine and connect wiring
connectors.
3 - 136 11/22/00
ELECTRICAL CONTENTS
CONTENTS
ELECTRICAL
Page
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ELECTRICAL DIAGNOSTIC INFORMATION . . . . . . . . . . . . . . . . . . . . . 7
READING ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
THEORY OF OPERATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
COMMON CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WIRE COLOR ABBREVIATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LEGEND FOR ELECTRICAL COMPONENTS. . . . . . . . . . . . . . . . . . . . . 9
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MAIN SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ELECTRICAL WIRE HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ENGINE WIRE HARNESS (W1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ROPS WIRE HARNESS (W2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DUAL FLASHER WIRE HARNESS (W3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
COLD START WIRE HARNESS (W4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CAB HEATER/DEFROSTER WIRE HARNESS (W5, W6, W7). . . . . . . . . . . . . . . . . 25
BACKUP ALARM WIRE HARNESS (W8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
WIPER/WASHER WIRE HARNESS (W9). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
TROUBLESHOOTING CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
THEORY OF OPERATION AND DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 29
POWER AND CRANKING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 29
POWER AND CRANKING CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . 31
POWER AND CRANKING CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 32
POWER AND CRANKING CIRCUIT TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . 35
FUEL AND PREHEAT CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
FUEL AND PREHEAT CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
FUEL CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
FUEL CIRCUIT TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
PREHEAT CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
PREHEAT CIRCUIT TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
CHARGING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
CHARGING CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
CHARGING CIRCUIT DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
CHARGING CIRCUIT TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT OPERATION . . . . 49
BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT SCHEMATIC . . . . 50
BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT DIAGNOSIS. . . . . 51
BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT TEST POINTS . . . 55
GAUGES AND WARNING LIGHTS CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . 56
GAUGES AND WARNING LIGHTS CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . 59
SEAT BELT WARNING LIGHT CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 60
SEAT BELT WARNING LIGHT CIRCUIT TEST POINTS . . . . . . . . . . . . . . . . . . . . . 62
PARK BRAKE SWITCH AND WARNING LIGHT CIRCUIT DIAGNOSIS . . . . . . . . . 63
11/22/00 4-1
CONTENTS ELECTRICAL
Page
4-2 11/22/00
ELECTRICAL CONTENTS
Page
11/22/00 4-3
CONTENTS ELECTRICAL
Page
4-4 11/22/00
ELECTRICAL CONTENTS
11/22/00 4-5
SPECIFICATIONS ELECTRICAL
SPECIFICATIONS
Battery
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BCI Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Cold Cranking Amps at –18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750
Reserve Capacity at 27°C (80°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180 minutes
Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.225 or above
Electrolyte Required Fill (Approx.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt)
Load Test (Minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 amp for 15 seconds
Alternator
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 amps
Regulated Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 amps (min)
Unregulated Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 amps (min)
Regulated Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.5—14.2 volts
Resistor at 25°C (77°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47—53 ohms
Rotor Winding Resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.95 ohms
Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 mm (0.28 in.)
Alternator Torques
Alternator Pulley Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (29 lb-ft)
B+ Terminal Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (35 lb-in.)
B– Terminal Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 N•m (26 lb-in.)
Through-Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 N•m (26 lb-in.)
Starter
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetic solenoid shift
Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 kW
Loaded (on Vehicle) Draw . . . . . . . . . . . . . . . . . . . . . . . 350 amps (max), 8.5 volts (min)
No-load (Free-Spinning) Draw. . . . . . . . . . . . . . . . . . . . . . . 90 amps (max) at 3500 rpm
Pre-Heater
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.70—1.65 ohms
Lighting
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 W, halogen type
Rear, Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.5 W, incandescent type 1156
Rear, Running (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . .10 W, incandescent type R19/10
4-6 11/22/00
ELECTRICAL ELECTRICAL DIAGNOSTIC INFORMATION
M46311
11/22/00 4-7
ELECTRICAL DIAGNOSTIC INFORMATION ELECTRICAL
4-8 11/22/00
ELECTRICAL LEGEND FOR ELECTRICAL COMPONENTS
K5—Dual Flasher Relay (SE8, W3) X7—Instrument Cluster Connector (SE6, W2)
K6—High Flow Relay (SE9, W1) X8—Instrument Cluster Connector (SE6, W2)
K7—Cab Heater Relay (SE10, W7) X9—Shutdown Module Connector (SE6, W2)
R3—Cab Heater Thermostat (SE10, W5) X15—Right Front Work Light Connector (SE7, W2)
S1—Key Switch (SE1, W2) X16—High Flow Valve Diode Connector (SE9, W1)
11/22/00 4-9
LEGEND FOR ELECTRICAL COMPONENTS ELECTRICAL
4 - 10 11/22/00
ELECTRICAL COMPONENT LOCATION
COMPONENT LOCATION
X13 12-Volt
Accessory
Connector
X12 Accessory
X2 Engine/ROPS Harness X15 Right Front Work
Ground
Connector Light Connector
Connector
X20 Left Tail Light X99 Interlock
Connector Connector
B1 Air Filter
B3 Hydraulic Oil Filter Restriction Switch
Restriction Switch
G2 Alternator
Terminal B (-)
K3 Fuel
G2 Alternator Relay
Terminal B (+) K1 Start
Relay
K4 Accessory
Relay
B2 Hydraulic
G1 Battery Overtemp Switch
M2 Fuel Pump X11 12-Volt Accessory
B6 Engine Low Oil Connector
Pressure Switch and Pressure Sender
Cold Start KV13044
Fuel Injection Y1 Fuel Shutoff
Sender
Pump Solenoid
11/22/00 4 - 11
COMPONENT LOCATION ELECTRICAL
S9 Blower Switch
S12 Wiper/Washer Switch
R3 Cab Heater Temperature
Control Thermostat M4 Wiper Motor
A1 Heater Control
Circuit Board Y7 Cab Heater
Temperature Control
Valve
H2 Backup Alarm X25 Cab Heater Engine
Harness-to-ROPS
Harness Connector
F5 Cab Heater Fuse (15A) M5 Washer Pump
X22 Accessory
Ground Connector
4 - 12 11/22/00
ELECTRICAL ELECTRICAL SCHEMATIC
ELECTRICAL SCHEMATIC
MAIN SCHEMATIC
F1 Accessories Fuse
25 Amp
445 Yel 445 Yel
550 Yel/Wht 550 Yel/Wht
15 Amp 226 Red 226 Red
720 Pur 720 Pur
725 Pur/Wht 725 Pur/Wht
F3 708 Pur 708 Pur
Key Switch Fuse 706 Pur 706 Pur
231 Red 231 Red
550 Yel/Wht 500 Yel/Red 502 Yel 502 Yel
5 Amp
505 Yel 501 Yel 501 Yel (A1)
X2 503 Yel 503 Yel
F2 (C1) 725 Pur/Wht 508 Yel
720 Pur
Seat Switch Fuse S1 5 Amp
X1 (C2)
Key 721 Pur 721 Pur 722 Pur
225 Red 1 2
Park 4
Brake On Off 802 Dk Grn
3 7
705 Pur Switch X3 813 Grn (1) X4
709 Pur 5
3 560 Yel/Blk To Auto Preheat 508 Yel (2)
220 Red (Optional) 995 (3) 990
X1 (A3) 931 Gry
701 Dk Blu Gry/Blk Wht
(1)
X2 To Shutdown
K1 30 86 B7
(2) (C5) Module
Start Cold Start
(Optional)
Relay 87a 87 85 930 Switch
(3) 995 Gry/Blk
Gry (250 Only)
X2 (C4) K3 30 86
(4)
930 Gry Fuel
700 Pur t Relay 87a 87 85
SE1 - POWER AND CRANKING CIRCUIT SE2 - PREHEAT CIRCUIT SE3 - FUEL CIRCUIT
KV31050
11/22/00 4 - 13
ELECTRICAL SCHEMATIC ELECTRICAL
(C1) (C2)
SE4 - CHARGING CIRCUIT SE5 - BOOM/BUCKET LOCKOUT AND PARK BRAKE CIRCUIT SE6 - GAUGES AND WARNING LIGHTS CIRCUIT
KV31051
4 - 14 11/22/00
ELECTRICAL ELECTRICAL SCHEMATIC
(B2) (B3)
(C2) (C3)
KV31052
11/22/00 4 - 15
ELECTRICAL SCHEMATIC ELECTRICAL
101 Blk
(B3)
(C3) (C3)
001C Red
SE9 - HIGH FLOW CIRCUIT SE10 - CAB HEATER/DEFROSTER CIRCUIT SE11 - BACKUP ALARM CIRCUIT
KV31053
4 - 16 11/22/00
ELECTRICAL ELECTRICAL SCHEMATICS
460 Yel
460 Yel
S12
Wiper/Washer Switch
A Off
B Wiper
C Washer
Back
7 Light 111 Blk
5B
6 463 Yel/Blk
1 465 Yel/Red
2B Indicator
466 Yel 10 Light
462
Yel
461
Yel/Wht
463
Yel/Blk
465 Yel/Red
4
466 Yel 5 M M4
6 Wiper Motor
461 2
Yel/Wht
110
Blk
B
M5 W
Washer Pump
A
111
Blk 101
112 Blk
Blk
(C3)
KV31054
11/22/00 4 - 17
ELECTRICAL SCHEMATICS ELECTRICAL
4 - 18 11/22/00
ELECTRICAL ELECTRICAL WIRE HARNESSES
B A
118
109
117 0.8 Blk V1 (A), Splice 1 452 451
103
118 0.8 Blk M2 (B), Splice 1 Splice 3 104
711 713 711
450
454 117 Splice 6
119 0.8 Blk K6 (85), Splice 1
B A
119 715 722
200 5.0 Red M1, G2 741
104 B4 741 742 Y2
220 5.0 Red K1 (30), Splice 8 Fuel Level Bucket Lock
740 Splice 5
225 2.0 Red F3, X1 (A2) 900 Sender Solenoid
A
X2
B
226 0.8 Red F3, X10 (A)
Harness 705 Splice 4
231 0.8 Red F2, X1 (A1) Connector X22
708 709
240 8.0 Red K2, Splice 7 Accessory
Ground
241 3.0 Red Fuse M1, Splice 7 103 (Frame)
Link
5 1 A
250 5.0 Red F2, Splice 8
5 1 B
251 2.0 Red Fuse M1, Splice 8 5 1 C 454
Link Plug
300 0.8 Org/Wht B5, X2 (A1) X11
A1 = 300 B1 = 600 C1 = 721 12-Volt Accessory
320 0.8 Org B5, X2 (A2)
A2 = 320 B2 = 620 C2 = 750 (Frame)
325 0.8 Dk Grn/Wht B2 (A), X2 (A3) 445 110 220 112 515 114 511 119
A3 = 325 B3 = 625 C3 = 900
335 0.8 Dk Grn B3, X2 (A4) A4 = 335 B4 = 730 C4 = 930
A5 = 345 B5 = 740 C5 = 995 Plug Plug Plug Plug
345 0.8 Pink B1 (A), X2 (A5)
445 2.0 Yel F1, K4 (30) 450 700 813
550 709 995 655 811
450 2.0 Yel/Wht K4 (87), Splice 3
722 231 K4 K1 K3 K6
451 2.0 Yel/Wht X1 (B2), Splice 3 445 225/226
Accessory Start Fuel High Flow
452 0.8 Yel X5 (1), Splice 3 D C B A
Relay Relay Relay Relay
454 2.0 Yel X11, Splice 3 Fuse Block 721 250 (Optional)
F1 = Accessories Fuse
25
15
226
5
11/22/00 4 - 19
ELECTRICAL WIRE HARNESSES ELECTRICAL
M1 Ground Wire
100 Circuit
Starting Motor 700 Size Color Termination Points
Number
Terminal B M1 mm2
K2
108 Starting Motor 501 2.0 Yel X1 (C2), Splice 2
Preheat Terminal S G2
510 0.8 Yel X10 (B), Splice 2
Relay Alternator
100/101
Terminal B (–) 511 0.8 Yel Splice 2, K6 (87)
930 241
251 512 0.8 Yel M2 (A), Splice 2
Splice 7
515 1.0 Yel K3 (87), Splice 2
Splice 8 G2
200 Alternator 550 0.8 Yel/Wht K4 (86), X1 (C1)
K2 920
Preheat 250 240
Terminal B (+) 600 0.8 Brn X2 (B1), X5 (2)
Relay 220 200 620 0.8 Tan B6 (WK), X2 (B2)
240 920 625 0.8 Tan/Wht B6 (G), X2 (B3)
R1
Manifold 655 1.0 Wht K3 (87), Y1 (S)
Preheater 700 3.0 Pur K1 (87), M1
705 0.8 Pur X1 (A3), Splice 4
708 0.8 Pur X10 (C), Splice 4
709 0.8 Pur K1 (86), Splice 6
711 0.8 Pur Y2 (B), Splice 6
713 0.8 Pur Y3 (B), Splice 6
715 0.8 Pur Y4 (A), Splice 6
X5
721 0.8 Pur X2 (C1), F4
Alternator Resistor
Connector 722 0.8 Pur F4, Splice 6
452 730 0.8 PurWht Y4 (B), X2 (B4)
1
740 0.8 Pur/Blk X2 (B5), Splice 5
2
741 0.8 Pur/Blk Y2 (A), Splice 5
600
335 106 742 0.8 Pur/Blk Y3 (A), Splice 5
B3
750 0.8 Pur/Blk X2 (C2), X10 (D)
Hydraulic Oil A B
Filter Restriction 811 0.8 Pink X1 (A4), K6 (86)
Switch 812 0.8 Dk Grn X1 (A5), Splice 9
813 0.8 Dk Grn K6 (87), Splice 9
102 A B A B A B Y4
325
814 0.8 Dk Grn V1 (B), Splice 9
Park Brake Solenoid
B2
815 0.8 Dk Grn Y5 (A), Splice 9
Hydraulic
Overtemp 900 0.8 Blk/Wht B4 (B), X2 (C3)
Switch 345 105 815 109 715 730
920 8.0 Red/Wht K2, R1
B1 Y5
High Flow 930 0.8 Gry K2, X2 (C4)
Air Filter
Restriction Valve 995 0.8 Gry/Blk K3 (86), X2 (C5)
Switch (Optional)
KV18017B
4 - 20 11/22/00
ELECTRICAL ELECTRICAL WIRE HARNESSES
990
KV18018A
11/22/00 4 - 21
ELECTRICAL WIRE HARNESSES ELECTRICAL
Wire
Circuit
Size Color Termination Points
Number
5 1 A
A1 = 231 B1 = Plug C1 = 550 (mm2)
5 1 B A2 = 225 B2 = 451 C2 = 501
5 1 C A3 = 705 B3 = Plug C3 = Plug 501 2.0 Yel X1 (C2), Splice 1
A4 = 811 B4 = Plug C4 = Plug 502 0.8 Yel S8 (5B), Splice 1
A5 = 812 B5 = Plug C5 = 116
503 0.8 Yel X8 (D), Splice 1
504 0.8 Yel X3 (4), Splice 1
X1 505 0.8 Yel S2 (5B), Splice 1
Engine/ROPS 506 0.8 Yel S3 (2B), Splice 1
Harness Connector X18
Right Tail Light 508 0.8 Yel X4 (2), Splice 1
451/
124
A 476 550 0.8 Yel/Wht S1 (4), X1 (C1)
453 B 106
560 0.8 Yel/Blk S1(3), S2 (6)
X19
600 0.8 Brn X2 (B1), X7 (D)
Rear Work Light
X13 620 0.8 Tan X2 (B2), X7 (F)
X12 A 475
12-Volt
Accessory B 105 625 0.8 Tan/Wht X2 (B3), X6 (A)
Accessory
Ground Connector
Connector X20 701 0.8 Dk Blu S3 (4), X3 (1)
(ROPS)
(ROPS) Left Tail Light
705 0.8 Pur S1 (5), X1 (A3)
A 477
B 107 706 0.8 Pur S1 (5), X9 (2)
707 0.8 Pur X8 (F), X9 (2)
720 0.8 Pur S2 (4), X6 (G)
721 0.8 Pur S2 (4), X2 (C1)
725 0.8 Pur/Wht S2 (1), X6 (D)
730 0.8 Pur X2 (B4), X7 (G)
X2 740 0.8 Pur/Blk X2 (B5), X7 (H)
Engine/ROPS
Harness Connector 750 0.8 Pur/Blk X2 (C2), X6 (B)
800 0.8 Pink X21 (B), X6 (F)
801 0.8 Pink X21 (B), S4 (2)
4 - 22 11/22/00
ELECTRICAL ELECTRICAL WIRE HARNESSES
460 126
X13
12-Volt
Accessory X12
(ROPS) Accessory
Ground
(ROPS)
Switch Connector
Terminal Numbering
7 9
4 1
5B 2B
6 3
8 10
126
K5 127
Dual Flasher
Relay 480
481
482
129 481
X24B X23A
Right Hazard Left Hazard
Light Connectors Light Connectors
X24A X23B
127
482 128
S7
Dual Flasher 128
Switch 129
460
480
KV18014
11/22/00 4 - 23
ELECTRICAL WIRE HARNESSES ELECTRICAL
B7
Cold Start
Switch
(Model 250)
373 372
372 010
Y1
Fuel Shutoff
Solenoid
373 010
Y6
Cold Start Advance
Solenoid
(Model 250)
KV18533
4 - 24 11/22/00
ELECTRICAL WIRE HARNESSES
A1
012 Heater Control
009 Circuit Board ABCDEFGH
Empty
Empty 6 1 013B
004 5 2
001B 001 4 3 010B
A B 001C A F
001C Y7
B E
C D
011 Heater Valve
X28
F5 005 000A/
Starter B+ 000B
Heater Fuse (15A) X27
Main Connector
ROPS-to-Heater M3
001A X25 Blower
000A
Harness Connector X29
X30
Engine Harness (W7) Engine Ground
A Heater Unit Harness (W6)
B 000A 17 20 004
11/22/00 4 - 25
ELECTRICAL WIRE HARNESSES
450
A
B
456
455/456
F6
Backup Alarm
Fuse
X11 10 amp
12-Volt 455
Accessory
(Frame)
101
–
H2
Backup Alarm
100
+
458
X22
Accessory Ground
(Frame)
100/101
B A
457 Wire
450 Circuit Termination
Size Color
Number Points
S10 (mm2)
Backup Alarm
Switch (Rear) 100 2.0 Blk X22, X22
101 0.8 Blk X22, H2(–)
450 0.8 Yel F6(A), S10(A)
B A 455 2.0 Yel X11, F6(B)
458 457 456 2.0 Yel X11, F6(B)
457 0.8 Yel S10(B), S11(A)
S11 458 0.8 Yel S11(B), H2(+)
Backup Alarm
Switch (Front)
KV31080
4 - 26 11/22/00
ELECTRICAL ELECTRICAL WIRE HARNESSES
460 472
100 100/101
X99 470
Interlock
Connector
X12
Accessory Ground
Switch Connector
Terminal Numbering
7 9
4 1
5B 2B
6 3
8 10
465
111 X33
461/462 Door Switch
460/466 Harness Connector
470
463
462 472
S12 466
465 461
Wiper/Washer
Switch
4 5 6 M4
1 2 3 Wiper Motor
Wire
Circuit Termination
Size Color
Number Points
(mm2)
100 2.0 Blk X12, X12
101 0.8 Blk X12, Splice 1
110 0.8 Blk Splice 1, M4(2)
111 0.8 Blk Splice 1, S12(7)
112 0.8 Blk Splice 1, M5(A)
460 0.8 Yel X99(C), S12(5B)
461 0.8 Yel/wht S12(2B), M4(6)
462 0.8 Yel/wht S12(2B), S12(10)
463 0.8 Yel/blk S12(6), M5(B)
465 0.8 Yel/red M4(4), S12(1)
466 0.8 Yel S12(5B), M4(5) M5
Washer Pump
470 0.8 Dk Grn X99(B), X33(B)
463 B A
472 0.8 Dk Grn X99(A), X33(A) 112
KV31081
11/22/00 4 - 27
TROUBLESHOOTING CHART ELECTRICAL
TROUBLESHOOTING CHART
properly
properly
See cranking circuit diagnosis z
4 - 28 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
NOTE: Beginning in 2001, all wires will be solid colors Operating Conditions:
and will no longer include stripes. Each wire Voltage must be present at terminal 1 of the key switch
will have a circuit number stamped into the (S1).
insulation to aid in circuit tracing. The color on
the schematics, text and wiring diagrams in this
manual will be correct less the stripe color; i.e. Theory of Operation:
wire 425 yel/blk will become wire 425 yel. This
will be a running change not associated with With the key switch (S1) in the RUN position, voltage is
any serial number or model change. present at the following components:
• Terminal 86 (coil) of the accessory relay (K4)
• Terminal 23 of manual preheat switch (S3)
POWER AND CRANKING CIRCUIT • Terminal 5B of the park brake switch (S2)
OPERATION • Terminal 30 of the fuel relay (K3)
• Fuel pump (M2
UNSWITCHED POWER CIRCUITS • Terminal B of service plug (X10)
• Terminal 4 of auto preheat connector (X3)
• Terminal 5B of high-flow switch (S8)
Function: • Terminal 30 of high-flow relay (K6)
Provide power to the primary machine components • Terminal G of instrument cluster connector (X6)
whenever the battery is connected. • Terminal 2 of shutdown module( X4)
Operating Conditions: With the key switch (S1) in the ACCESSORY position,
Voltage must be present at the following components voltage is present at terminal 86 (coil) of the accessory
with the key switch in the OFF position: relay (K4).
• Terminal B of starting motor (M1)
• Terminal 30 of start relay (K1) CRANKING CIRCUIT
• Terminal 30 of accessory relay (K4)
• Terminal 1 of the seat switch (S4) Function:
• Terminal 2 of seat belt switch (S5)
To energize the starting motor (M1) and crank the
• Terminal A of the service plug (X10)
engine.
• Terminal 1 of the key switch (S1)
• Terminal V1 of the preheat relay (K2)
• Terminal B+ of Alternator (G2) Operating Conditions:
To crank the engine, the park brake switch (S2) must
be in the ENGAGE position and the key switch (S1)
Theory of Operation: must be in the START position.
The positive battery cable (red) connects to terminal B
of the starting motor (M1). Power is routed through wire
251 red which acts as a fuse link in case of excessive Theory of Operation:
current drain and is then routed through wire 250 red to With the key switch (S1) in the START position, current
fuses F1, F2, and F3. From fuse F3, power goes to from terminal 1 flows out terminal 2 through wire 500
terminal 1 of the key switch (S1). yel/red to terminal 5B of the park brake switch (S2).
With the park brake switch in the ENGAGE position,
current flows from terminal 6 through wire 560 yel/blk
SWITCHED POWER CIRCUIT back to terminal 3 of the key switch. From the key
switch, current flows from terminal 5 through wires 705
pur and 709 pur to the coil of the start relay (K1). The
Function:
start relay energizes and current flows through its
Provides power to primary components depending on contacts to the solenoid of the starting motor (M1) and
the position of the key switch (S1). the starting motor cranks.
11/22/00 4 - 29
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
4 - 30 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
140
Blk
705 Pur 5 3
To Preheat
Relay 560 Yel/Blk
X1
706
(A3) Pur X9 Shutdown
(2) Module Connector To X8 (F)
707 Pur on
705
240 Pur H1 Instrument
Red
708 Pur
X10 (C) Cluster
709
Service
220 Red Plug
Pur
G1 Ground Circuit
M1
Battery Starting
Motor
M
Engine
Ground KV15154
11/22/00 4 - 31
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
1. Battery positive (+) post. 11.8—13.2 volts Test battery. (See BATTERY TEST in this
section.)
2. Red wire on starting motor. Battery voltage. Test red wire from battery to starting motor.
3. Wire 220 red at terminal 30 on (K1) Battery voltage. Test wire 220 red and 251 red to (K1) start
start relay. relay.
4. Wire 250 red on (F3) key switch fuse. Battery voltage. Test wires 250 red and 251 red between (F3)
key switch fuse and B terminal of starting
motor.
5. Accessory fuse (F1) (25-amp). Battery voltage. Test accessory fuse (F1) and replace as
necessary.
6. Seat switch/seat belt fuse (F2) (5-amp). Battery voltage. Test seat switch/seat belt fuse (F2) and replace
as necessary.
7. Key switch fuse (F3) (15-amp). Battery voltage. Test key switch fuse (F3) and replace as
necessary.
8. Wire 225 red at terminal A2 on (X1) Battery voltage. Test wire 225 red between (F3) key switch fuse
engine/ROPS harness connector. and (X1) engine/ROPS harness connector.
9. Wire 225 red at terminal A2 on (X1) Battery voltage. Test connector (X1) engine/ROPS harness
engine/ROPS harness connector. connector. Make sure wires are properly
crimped in the terminals.
10. Wire 225 red at terminal 1 on (S1) key Battery voltage. Test wire 225 red between (X1) engine/ROPS
switch. harness connector and (S1) key switch.
4 - 32 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
Test Conditions:
• Park Brake Switch in ENGAGE position.
• Key switch in RUN position.
11. Wire 500 yel/red at terminal 2 on (S1) Battery voltage. Replace (S1) key switch.
key switch.
12. Wire 550 yel/wht at terminal 4 on (S1) Battery voltage. Replace (S1) key switch.
key switch.
13. Wire 505 yel at terminal 5B on (S2) Battery voltage. If battery voltage is not present, test wires 500
park brake switch. Park brake yel/red and 505 yel between (S1) key switch
switch back and (S2) park brake switch.
lighting is on.
If back lighting is not on, test ground circuit wire
140 blk from (S2) park brake Switch to ground.
If Ground circuit is good, replace (S2) park
brake switch.
14. Wire 560 yel/blk at terminal 3 on (S1) Battery voltage. Test wire 560 yel/blk from (S1) key switch to
key switch. (S2) park brake switch.
15. Wire 560 yel/blk wire at terminal 6 on Battery voltage. Replace (S2) park brake switch.
(S2) park brake switch.
11/22/00 4 - 33
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
Test Conditions:
16. Wire 705 pur at terminal 5 on Battery voltage. Replace (S1) key switch.
(S1) key switch.
17. Wire 705 pur at terminal A3 on Battery voltage. Test wire 705 pur from (S1) key switch to (X1)
(X1) engine/ROPS harness engine/ROPS harness connector.
connector.
18. Wire 705 pur at terminal A3 on Battery voltage. Test connector (X1) engine/ROPS harness
(X1) engine/ROPS harness connector. Make sure wires are properly
connector crimped in the terminals.
19. Wire 709 pur at terminal 86 on Battery voltage. Test wires 709 pur and 705 pur between (X1)
(K1) start relay. engine/ROPS harness connector and (K1) start
relay.
20. Wire 700 pur at terminal 87 on Battery voltage. Test (K1) start relay. If relay is good, test ground
(K1) start relay. circuit wire 112 blk from (K1) start relay to
ground.
21. Wire 700 pur at terminal S on Battery voltage. (M1) If battery voltage is not present, test wire 700
(M1) starting motor. starting motor cranks. pur.
If battery voltage is present and (M1) starting
motor does not crank, check starting motor-to-
engine block ground. If starting motor-to-engine
block ground is good, test starting motor.
Repair or replace starting motor as necessary.
4 - 34 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
13
To Accessory
Relay
550 Yel/Wht 14
S1
Key Switch 505 Yel G2
500 Yel/Red
Alternator
11
140 Blk
560 Yel/Blk
12
100 Blk
16
10
705 Pur 17
9
15
225 Red
8
18 101 Blk
X1
Engine/ROPS
Harness Connector
225 Red
K1
Start Relay 220 Red
5
19 709 Pur
6
250 Red
3 20 7
112 Blk F4
700 Pur F1
4 F2
251 Red
F3
Fuse Link
Red
21
M1
Starting Motor
KV31061
11/22/00 4 - 35
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
Function: Function:
To energize the fuel shutoff solenoid which allows fuel To provide current to the manifold preheater (R1).
flow through the fuel injector pump.
Operating Conditions:
Operating Conditions: Voltage must be present at one terminal of the preheat
Voltage must be present at the fuel pump (M2), relay (K2), regardless of the position of the key switch
terminal 86 of the fuel relay (K3), and at fuel shut-off (S1). Voltage must be present at terminal 2B of the
solenoid (Y1) when the key switch is in the START or manual preheat switch (S3) when the key switch is in
RUN position. the START or RUN position.
4 - 36 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
500
To Key Yel/Red
Switch
506
Yel
S3
Manual
Preheat
To Switch 501
Starting 2B Yel 508
Motor Yel
504
4 On Off Yel
3 7
141
241 Blk
Red X4
Fuse 931 2 990 Wht
Link Gry
701 Dk Blu
X3 515
(1) Yel
512 3
(2) Auto Yel
Preheat 995
(3) Gry/Blk
(Option)
(4) X2
(C5)
995
240 Red
930 Gry/Blk
Gry
130 30 86
K2 M2 M K3
Blk Fuel Fuel
Preheat 87 85
Relay Pump Relay
118 Blk 114
Blk
108 Blk
920
Red/Wht 655
Wht
Y1
Fuel
Shutoff
R1 Solenoid
Manifold
Preheater
Unswitched Power
Preheat Circuit
Ground Circuit
KV15155
11/22/00 4 - 37
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
1. Battery positive (+) post. 11.8—13.2 volts Test battery. (See BATTERY TEST in this
section.)
2. Red wire on (M1) starting motor. Battery voltage. Test red wire from battery to starting motor.
3. Wire 250 red on (F3) key switch fuse. Battery voltage. Test wires 250 red and 251 red between (M1)
starting motor and (F3) key switch fuse.
4. Wire 225 red on (F3) key switch fuse. Battery voltage. Test (F3) key switch fuse and replace as
necessary.
5. Wire 225 red at terminal A2 on (X1) Battery voltage. Test wire 225 red between (F3) key switch fuse
engine/ROPS harness connector. and (X1) engine/ROPS harness connector.
6. Wire 225 red at terminal A2 on (X1) Battery voltage. Test connector (X1) engine/ROPS harness
engine/ROPS harness connector. connector. Make sure wires are properly
crimped in the terminals.
7. Wire 225 red at terminal 1 on (S1) key Battery voltage. Test wire 225 red between (X1) engine/ROPS
switch. harness connector and (S1) key switch.
Test Conditions:
8. Wire 500 yel/red at terminal 2 on (S1) Battery voltage. Replace (S1) key switch.
key switch.
4 - 38 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
Test Conditions:
• Engine stopped.
• Key switch in RUN position.
9. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.
10. Wire 508 yel at terminal 2 on Battery voltage. Test wires 508 yel and 500 yel/red between
(X4) shutdown module connector. (S1) key switch and (X4) shutdown module
connector.
11. Wire 995 gry/blk at terminal 3 Battery voltage. Test (X4) shutdown module connector and wire
on (X4) shutdown module 990 wht. Make sure wires are properly crimped
connector. in terminals. Repair wire and/or replace
connector as necessary.
12. Wire 995 gry/blk at terminal Battery voltage. Test wire 995 gry/blk between (X4) Shutdown
C5 on (X2) engine/ROPS harness module connector and (X2) engine/ROPS
connector. harness connector.
13. Wire 995 gry/blk at terminal Battery voltage. Test (X2) engine/ROPS harness connector.
C5 on (X2) engine/ROPS harness Make sure wires are properly crimped in the
connector. terminals.
14. Wire 995 gry/blk at terminal 86 Battery voltage. Test wire 995 gry/blk between (X2) engine/
on (K3) fuel relay. ROPS harness connector and (K3) fuel relay.
15. Wire 501 yel at terminal C2 on Battery voltage. Test wires 501 yel and 500 yel/red between
(X1) engine/ROPS harness (X1) engine/ROPS harness connector and (s1)
connector. key switch.
16. Wire 501 yel at terminal C2 on Battery voltage. Test connector (X1) engine/ROPS harness
(X1) engine/ROPS harness connector. Make sure wires are properly
connector. crimped in the terminals.
17. Wire 515 yel at terminal 30 on Battery voltage. Test wire 515 yel between (X1) engine/ROPS
(K3) fuel relay. harness connector and (K3) fuel relay.
18. Wire 655 wht at terminal 87 on Battery voltage. Test ground circuit wire 114 blk to ground. If
(K3) fuel relay. ground circuit is good, test (K3) fuel relay.
Replace relay as necessary.
19. Wire 655 wht at (Y1) fuel Battery voltage. If battery voltage is not present, test wire 655
shutoff solenoid. Solenoid clicks when wht between (Y1) fuel shutoff solenoid and (K3)
wire is removed and fuel relay. If battery voltage is present and
connected. solenoid does not click, replace (Y1) fuel
shutoff solenoid.
20. Wire 512 yel at (M2) fuel Battery voltage. Fuel If battery voltage is not present, test wires 512
pump. pump running (listen). yel and 501 yel between (M2) fuel pump and
(X1) engine/ROPS harness connector.
If battery voltage is present and pump is not
running, test ground circuit wire 118 blk from
(M2) Fuel Pump to ground. If ground is good
replace (M2) Fuel Pump.
11/22/00 4 - 39
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
S1
Key Switch
8 9
500 Yel/Red
225 Red M2
7 Fuel Pump
508 Yel 6 X1
501 Yel Engine/ROPS
10
Harness Connector
990 Wht
5 512 Yel
X4 15 20
Shutdown Module 995 Gry/Blk 12 501 Yel
Connector 118 Blk
11 X2
Engine/ROPS
Harness Connector
16
225 Red
13 4
515 Yel F4
995 Gry/Blk 19 F1
Y1
655 Wht Fuel Shutoff F2
Solenoid F3
14
250 Red
17 118 Blk
3
K3
Fuel Relay
101 Blk 100 Blk
114 Blk 18
G2
Alternator
251 Red
Fuse Link
Red
1
M1
Starting Motor
KV31062
4 - 40 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
1. Battery positive (+) post. 11.8—13.2 volts Test battery. (See BATTERY TEST in this
section.)
2. Red wire on (M1) starting motor. Battery voltage. Test red wire from battery to starting motor.
3. Wire 240 red on (K2) preheat relay. Battery voltage. Test wires 240 red and 241 red between (K2)
preheat relay and (M1) starting motor.
4. Wire 250 red on (F3) key switch fuse. Battery voltage. Test wires 250 red and 251 red between (M1)
starting motor and (F3) key switch fuse.
5. Wire 225 red on (F3) key switch fuse. Battery voltage. Test (F3) key switch fuse and replace as
necessary.
6. Wire 225 red at terminal A2 on (X1) Battery voltage. Test wire 225 red between (F3) key switch fuse
engine/ROPS harness connector. and (X1) engine/ROPS harness connector.
7. Wire 225 red at terminal A2 on (X1) Battery voltage. Test connector (X1) engine/ROPS harness
engine/ROPS harness connector. connector. Make sure wires are properly
crimped in the terminals.
8. Wire 225 red at terminal 1 on (S1) key Battery voltage. Test wire 225 red between (X1) engine/ROPS
switch. harness connector and (s1) key switch.
Test Conditions:
9. Wire 500 yel/red at terminal 2 on (S1) Battery voltage. Replace (S1) key switch.
key switch.
11/22/00 4 - 41
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
Test Conditions:
• Engine stopped.
• Key switch in RUN position.
10. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.
11. Wire 506 yel at terminal 2B on Battery voltage. Manual If battery voltage is not present, test wires 500
(S3) manual preheat switch. preheat switch back yel/red and 506 yel between (S1) key switch
lighting is on. and (S3) manual preheat switch.
If back lighting is not on, test ground circuit wire
141 blk from (S3) manual preheat switch to
ground. If Ground circuit is good, replace (S3)
manual preheat switch.
Test Conditions:
• Key switch in RUN position.
• Manual preheat switch in ON position.
12. Wire 931 gry at terminal 3 on Battery voltage. Replace (S3) manual preheat switch.
(S3) manual preheat switch.
13. Wire 931gry at terminal 3 on Battery voltage. Test wire 931 gry between (S3) manual preheat
(X3) auto preheat connector. switch and (X3) auto preheat connector.
14. Wire 930 gry at terminal C4 on Battery voltage. Test wire 930 gry between (X3) auto preheat
(X2) engine/ROPS harness connector and (X2) engine/ROPS harness
connector. connector.
15. Wire 930 gry at terminal C4 on Battery voltage. Test connector (X2) engine/ROPS harness
(X2) engine/ROPS harness connector. Make sure wires are properly
connector. crimped in the terminals.
16. Wire 930 gry on (K2) preheat Battery voltage. Test wire 930 gry between (X2) engine/ROPS
relay. harness connector and (K2) preheat relay.
17. Wire 920 red/wht on (K2) Battery voltage. Test ground circuit wire 108 blk from (K2)
preheat relay. preheat relay to ground. If ground circuit is
good, test (K2) preheat relay. Replace relay as
necessary.
18. Wire 920 red/wht at (R1) Battery voltage. If battery voltage is not present, test wire 920
manifold preheater. Manifold preheater gets red/wht between (R1) manifold preheater and
hot. (K2) preheat relay. If battery voltage is present
and manifold preheater does not get hot,
replace (R1) manifold preheater.
4 - 42 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
S1
Key Switch
S3 9 10
Manual Preheat
Switch
8
500 Yel/Red
506 Yel
X1
225 Red Engine/ROPS
11 100 Blk G2
7 Harness Connector
12 141 Blk Alternator
116 Blk
931 Gry 6
X2
130 Blk
Engine/ROPS
14 Harness Connector 101 Blk
930 Gry
116 Blk
13 R1
Manifold 225 Red
Preheater
F4
15 F1
18
X3 F2
Auto Preheat 920 Red/Wht F3
Connector
17
3 5
4
930 Gry
240 Red
108 Blk
K2 250 Red
Preheat Relay
16
Red
M1
Starting Motor
2
KV31063
11/22/00 4 - 43
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
4 - 44 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
To F3
Key Switch To F1
Fuse S1 Accessories
Key Switch Fuse
0 Accessory
1 Off
2 Run
3 Start
0, 1, 2
4 550 Yel/Wht
445 Yel
225 Red 1 2
5 3
K4 86 30
Accessory
Relay 85 87
87a
G2
Alternator R2 452 Yel
Alternator
200 Red B+
G
D+
Resistor X5 (1)
3
U 47 Ohm
B- To Instrument
Red X5 (2) Panel
100 Blk
B S
Unswitched Power
G1 M1
Battery Starting
Motor M Switched Power
Ground Circuit
KV15226
11/22/00 4 - 45
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
1. Battery positive (+) post. 11.8—13.2 volts Test battery. (See BATTERY TEST in this
section.)
2. Red wire on (M1) starting motor. Battery voltage. Test red wire from battery to starting motor.
3. Wire 200 red at B+ terminal on (G2) Battery voltage. Test wire 200 red from (M1) starting motor to
alternator. (G2) alternator.
Test Conditions:
• Test meter set to read resistance (ohms).
4. B– terminal on (G2) alternator. Maximum 0.1 Test wire 100 blk between (G2) alternator and
ohm. ground and battery negative (–) cable between
(G1) battery and ground.
Test Conditions:
• Test meter set to read DC voltage.
5. Wire 250 red on (F3) key switch fuse. Battery voltage. Test wires 250 red and 251 red between (M1)
starting motor and (F3) key switch fuse.
6. Wire 225 red on (F3) key switch fuse. Battery voltage. Test (F3) key switch fuse and replace as
necessary.
7. Wire 225 red at terminal A2 on (X1) Battery voltage. Test wire 225 red between (F3) key switch fuse
engine/ROPS harness connector. and (X1) engine/ROPS harness connector.
8. Wire 225 red at terminal A2 on (X1) Battery voltage. Test connector (X1) engine/ROPS harness
engine/ROPS harness connector. connector. Make sure wires are properly
crimped in the terminals.
9. Wire 225 red at terminal 1 on (S1) key Battery voltage. Test wire 225 red between (X1) engine/ROPS
switch. harness connector and (S1) key switch.
Test Conditions:
• Key switch in RUN position.
10. Wire 550 yel/wht at terminal 4 on (S1) Battery voltage. Replace (S1) key switch.
key switch.
4 - 46 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
Test Conditions:
• Key switch in ACCESSORY position.
11. Wire 550 yel/wht at terminal 4 on (S1) Battery voltage. Replace (S1) key switch.
key switch.
12. Wire 550 yel/wht at terminal C1 on Battery voltage. Test wire 550 yel/wht between (S1) key switch
(X1) engine/ROPS harness connector. and (X1) engine/ROPS harness connector.
13. Wire 550 yel/wht at terminal C1 on Battery voltage. Test (X1) engine/ROPS harness connector and
(X1) engine/ROPS harness connector. make sure wires are properly crimped in the
terminals.
14. Wire 550 yel/wht at terminal 86 on (K4) Battery voltage. Test wire 550 yel/wht between (K4) accessory
accessory relay. relay and (X1) engine/ROPS harness
connector.
15. Wire 445 yel on (F1) accessories fuse. Battery voltage. Test (F1) accessories fuse and replace as
necessary.
16. Wire 445 yel at terminal 30 on (K4) Battery voltage. Test wire 445 yel between (F1) accessories
accessory relay. fuse and (K4) accessory relay.
17. Wire 450 yel/wht at terminal 87 on (K4) Battery voltage. Test ground circuit wire 110 blk from (K4)
accessory relay. accessory relay to ground. If ground circuit is
good, test (K4) accessory relay. Replace relay
as necessary.
18. Wire 452 yel at (X5) alternator resistor Battery voltage. Test wires 452 yel and 450 yel/wht between
connector. (X5) alternator resistor connector and (K4)
accessory relay.
Test Conditions:
• Key switch in OFF position.
• (X5) Alternator Resistor Connector disconnected.
• Test meter set to measure resistance (ohms).
19. (R2) alternator resistor. 47 ± 0.5 ohm. Replace (R2) alternator resistor.
Test Conditions:
• Connect (X5) Alternator Resistor Connector.
• Key switch in OFF position.
• Alternator belt must not be worn or slipping.
• Perform REGULATED AMPERAGE AND VOLTAGE
TEST in this section.
11/22/00 4 - 47
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
S1
Key Switch
225 Red 9
8 10 11
550 Yel/Wht
12
X1 7
Engine/ROPS
Harness Connector
13
225 Red
445 Yel
K4
Accessory 550 Yel/Wht 445 Yel
Relay
14
16 X5
19
Alternator Resistor
Connector
15
18 F4
450 Yel/Wht
F1
17 19
110 Blk 452 Yel F2
F3
Red 6
101 Blk
4 5
600 Brn
G2
Alternator
To 100 Blk
Discharge 250 Red
Light
3
200 Red
251 Red
Fuse Link
1
Red
M1
Starting Motor
KV31064
4 - 48 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
Function: Function:
To disable and enable boom and bucket functions. To engage and release the park brake.
Theory of Operation:
Theory of Operation: The seat belt switch (S5) receives current from the seat
The seat belt switch (S5) receives current from the seat switch/seat belt fuse (F2) through wire 231 red. Current
switch/seat belt fuse (F2) through wire 231 red. Current is also supplied to the seat switch (S4) through wires
is also supplied to the seat switch (S4) through wires 232 red and 230 red. When the operator sits on the
232 red and 230 red. When the operator sits on the seat, the seat switch closes and current flows to the
seat, the seat switch closes and current flows to the instrument cluster through wires 801 pnk and 800 pnk.
instrument cluster through wires 800 pnk and 801 pnk. When the operator fastens the seat belt, the seat belt
When the operator fastens the seat belt, the seat belt switch closes and current flows to the instrument
switch closes and current flows to the instrument cluster through wire 810 dk grn, 991 wht, 813 dk grn,
cluster through wire 810 dk grn, 991 wht, 813 dk grn, and 802 dk grn. If the machine has a cab door, door
and 802 dk grn. If the machine has a cab door, cab switch (S13) is connected in place of wire 991 wht.
door switch (S13) is connected in place of wire 991
On models with a cab door switch (S13) mounted in the
wht.
front, the cab door switch (S13) is a normally open
On models with a cab door switch (S13) mounted in the switch that is activated when the door is closed. Unless
front, the cab door switch (S13) is a normally open the door is fully closed and latched, the circuit will be
switch that is activated when the door is closed. Unless open causing the brake solenoid switch to remain
the door is fully closed and latched, the circuit will be deactivated (brake engaged).
open and the boom and bucket lockout will remain
On models with a cab door switch (S13) mounted in the
activated.
rear, the cab door switch (S13) is a normally closed
On models with a cab door switch (S13) mounted in the switch. When the door is fully open, it contacts the door
rear, the cab door switch (S13) is a normally closed switch (S13) and opens the circuit causing the brake
switch. When the door is fully open, it contacts the door solenoid to remain deactivated (brake engaged).
switch (S13) and opens the circuit causing the boom
When the key switch (S1) is in the RUN or START
and bucket lockout to remain activated.
position and the park brake switch (S2) is in the RUN
When the key switch (S1) is in the RUN or START (middle detent) position after being pushed to the
position and the park brake switch (S2) is in the RUN RELEASED (momentary) position, the instrument
(middle detent) position, the instrument cluster cluster provides ground for the park brake solenoid
provides ground for the bucket lock solenoid (Y2) and (Y4) through wire 730 pur. The ground circuit is
boom lock solenoid (Y3) through wires 740 pur/blk, 741 completed through the instrument cluster wire 128 blk,
pur/blk, and 742 pur/blk to the instrument cluster. The thus allowing the solenoid to energize.
ground circuit is completed through the instrument
cluster wire 128 blk allowing the solenoids to energize.
11/22/00 4 - 49
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
715
Pur
Y2 Y3 Y4
Bucket Boom Park Brake
Lock Lock Solenoid
Solenoid Solenoid
730 Pur
741 742
Pur/Blk Pur/Blk
740 Pur/Blk
KV15157
4 - 50 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
1. Battery positive (+) post. 11.8—13.2 volts Test battery. (See BATTERY TEST in this
section.)
2. Red wire on (M1) starting motor. Battery voltage. Test red wire from battery to starting motor.
3. Wire 250 red on (F3) key switch fuse. Battery voltage. Test wires 250 red and 251 red between (F3)
key switch fuse and B terminal of starting
motor.
4. Wire 225 red on (F3) key switch fuse. Battery voltage. Test (F3) key switch fuse. Replace if necessary.
5. Wire 225 red at terminal A2 on (X1) Battery voltage. Test wire 225 red between (F3) key switch fuse
engine/ROPS harness connector. and (X1) engine/ROPS harness connector.
6. Wire 225 red at terminal A2 on (X1) Battery voltage. Test connector (X1) engine/ROPS harness
engine/ROPS harness connector. connector. Make sure wires are properly
crimped in the terminals.
7. Wire 225 red at terminal 1 on (S1) key Battery voltage. Test wire 225 red between (S1) key switch and
switch. (X1) engine/ROPS harness connector.
Test Conditions:
• Test meter set to read resistance (ohms).
8. Wire 128 blk at terminal C on (X8) Maximum Test wire 128 blk from (X8) instrument cluster
instrument cluster connector. 0.1 Ohm. connector to ground.
11/22/00 4 - 51
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
Test Conditions:
• Engine stopped and key switch in RUN position.
9. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.
10. Wire 505 yel at terminal 5B on Battery voltage. (S2) If battery voltage not present, test wires 500
(S2) park brake switch. park brake switch back yel/red and 505 yel between (S1) key switch
lighting is on. and (S2) park brake switch.
If back lighting is not on, test ground circuit wire
140 blk from (S2) park brake switch to ground.
If Ground circuit is good, replace (S2) park
brake switch.
11. Wire 503 yel at terminal D on Battery voltage. Test wires 503 yel/red and 500 yel between
(X8) instrument cluster connector. (X8) Instrument cluster connector and (S1) key
switch.
12. Wire 231 red at (F2) seat Battery voltage. Test (F2) seat switch/seat belt fuse. Replace if
switch/seat belt fuse. necessary.
13. Wire 231 red at terminal A1 on Battery voltage. Test wire 231 red between (F2) Seat Switch/
(X1) engine/ROPS harness seat belt fuse and (X1) engine/ROPS harness
connector. connector.
14. Wire 231 red at terminal A1 on Battery voltage. Test connector (X1) Engine/ROPS harness
(X1) engine/ROPS harness connector. Make sure wires are properly
connector. crimped in the terminals.
15. Wire 231 red on (S5) seat belt Battery voltage. Test wire 231 red between (S5) seat belt switch
switch. and (X1) engine/ROPS harness connector.
16. Wire 230 red on (S4) seat Battery voltage. Test wires 230 red and 232 red between (S5)
switch. seat belt switch and (S4) seat switch.
4 - 52 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
Test Conditions:
• Sit in seat or place a weight in seat to close the seat
switch.
• Fasten seat belt.
• Cab door closed and latched (if equipped).
17. Wire 801 pnk at terminal 2 on (S4) Battery voltage. Replace (S4) seat switch.
seat switch.
18. Wire 800 pnk at terminal F on (X6) Battery voltage. Test wire 800 pnk and 801 pnk between (S4)
instrument cluster connector. seat switch and (X6) instrument cluster
connector.
19. Wire 810 dk grn at terminal 1 on (S5) Battery voltage. Replace (S5) seat belt switch.
seat belt switch.
20. Wire 810 dk grn at terminal A on (X99) Battery voltage. Test wire 810 dk grn between (X99) interlock
interlock connector. connector and (S5) seat belt switch.
21. Wire 813 dk grn at terminal B on (X99) Battery voltage. Replace 991 wht jumper.
interlock connector. If equipped with cab door, test wires 470 Dk
Grn and 472 Dk Grn from (X99) interlock
connector to (S13) cab door switch. If good,
replace (S13) cab door switch.
22. Wire 813 dk grn at terminal 1 on (X4) Battery voltage. Test wire 813 dk grn between (X4) shutdown
shutdown module connector. module connector and (X99) interlock
connector.
23. Wire 802 dk grn at terminal E on (X6) Battery voltage. Test wire 802 dk grn between (X4) shutdown
instrument cluster connector. module connector and (X6) instrument cluster
connector.
Test Conditions:
• Press and hold the park brake switch in the
RELEASE position.
24. Wire 725 pur/wht at terminal 1 on (S2) Battery voltage. If battery voltage is present at terminal 5B on
park brake switch. (S2) park brake switch, replace switch.
25. Wire 725 pur/wht at terminal D on (X6) Battery voltage. Test wire 725 pur/wht between (S2) park brake
instrument cluster connector. switch and (X6) instrument cluster connector.
11/22/00 4 - 53
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
Test Conditions:
• Release the park brake switch to the RUN position.
26. Wire 721 pur at terminal 4 on (S2) park Battery voltage. If battery voltage is present at terminal 5B on
brake switch. (S2) park brake switch, replace switch.
27. Wire 721 pur at terminal C1 on (X2) Battery voltage. Test wire 721 pur from (S2) park brake switch to
engine/ROPS harness connector. (X2) engine/ROPS harness connector.
28. Wire 721 pur at terminal C1 on (X2) Battery voltage. Test connector (X2) Engine/ROPS Harness
Engine/ROPS Harness Connector. Connector. Make sure wires are properly
crimped in the terminals.
29. Wire 721 pur on (F4) interlock fuse. Battery voltage. Test wire 721 pur between (F4) interlock fuse
and (X2) engine/ROPS harness connector.
30. Wire 722 pur on (F4) interlock fuse. Battery voltage. Test (F4) interlock fuse. Replace if necessary.
31. Wire 711 pur on (Y2) bucket lock Battery voltage. Test wires 711 pur and 722 pur between (Y2)
solenoid. bucket lock solenoid and (F4) interlock fuse.
32. Wire 713 pur on (Y3) boom lock Battery voltage. Test wires 713 pur and 722 pur between (Y3)
solenoid. boom lock solenoid and (F4) interlock fuse.
33. Wire 715 pur on (Y4) park brake Battery voltage. Test wires 715 pur and 722 pur between (Y4)
solenoid. park brake solenoid and (F4) interlock fuse.
Test Conditions:
• Key switch in OFF position.
• Disconnect (Y2) bucket lock solenoid, (Y3) boom
lock solenoid, and (Y4) park brake solenoid.
• Disconnect (X7) instrument cluster connector.
Set meter to read resistance (ohms). Connect one lead
to one of the numbered test points and the other lead to
the other numbered test point (two test points
numbered the same on the diagram).
34. Wires 741 pur/blk on (Y2) bucket lock Maximum If no continuity in wire, repair or replace engine/
solenoid and 740 pur/blk at terminal H on 0.1 ohms. ROPS harness.
(X7) instrument cluster connector. If continuity in wire, test and replace solenoid.
If continuity in wire and solenoid is OK, replace
(H1) instrument cluster.
35. Wires 742 pur/blk on (Y3) boom lock Maximum If no continuity in wire, repair or replace engine/
solenoid and 740 pur/blk at terminal H on 0.1 ohms. ROPS harness.
(X7) instrument cluster connector. If continuity in wire, test and replace solenoid.
If continuity in wire and solenoid is OK, replace
(H1) instrument cluster.
36. Wire 730 pur on (Y4) park brake Maximum If no continuity in wire, repair or replace engine/
solenoid and at terminal G on (X7) 0.1 ohms. ROPS harness.
instrument cluster connector. If continuity in wire, test and replace solenoid.
If continuity in wire and solenoid is OK, replace
(H1) instrument cluster.
4 - 54 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT TEST POINTS
S1
Key Switch
S4
H1 Seat Switch 9
Instrument Cluster
S5 16
230
Seat Belt Switch 7
Red
S2 17
801 Pnk
Park Brake Switch 15 232
Red 500 Yel/Red
19 810 Dk Grn
X99
26 Interlock 225 Red
10 800 Pnk Connector
36
M1
Starting Motor
2
KV31065
11/22/00 4 - 55
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
Theory of Operation: The fuel sender resistance will be 29—33 ohms when
fuel tank is full and 244—250 ohms when fuel tank is
When the key switch (S1) is in the RUN or START empty.
position, current flows to the instrument cluster (H1) on
wire 503 yel to provide power for operation. Ground to Engine Coolant Temperature – The engine
the instrument cluster is provided by wire 128 blk. The overtemperature switch and coolant temperature
gauges and warning lights theory of operation are as sender (B5) houses two components and controls both
follows: the engine coolant temperature gauge and
overtemperature light. It is grounded directly to the
Battery Voltage - The battery voltage as measured on engine block. The coolant temperature sender portion
connector X8 pin D is displayed by the battery is a variable resistor that varies with the engine coolant
voltmeter on the instrument cluster. temperature and is connected to the instrument cluster
Battery Discharge - Battery discharge is detected on (H1) using wire 320 org.
wire 600 brn at connector X7 pin D and turns on the
battery discharge warning light.
4 - 56 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
Engine Overtemperature – The engine Engine Low Oil Pressure – The low oil pressure
overtemperature switch and coolant temperature switch and oil pressure sender (B6) is grounded
sender (B5) houses two components and controls both directly to the engine block. The switch portion is a
the engine coolant temperature gauge and normally closed switch and uses oil pressure to open,
overtemperature light. It is grounded directly to the causing the engine oil pressure warning light to not
engine block. When the engine overheats, the switch light. If the oil pressure becomes too low, the switch
closes and connects the instrument cluster (H1) to closes and connects the instrument cluster (H1) to
ground using wire 300 org/wht. When this ground is ground using wire 620 tan, and the engine oil pressure
completed, the engine overtemperature warning light warning light comes on.
comes on.
The oil pressure switch closes when pressure
The engine overtemperature switch closes when decreases to 80 kPa ± 30.4 kPa (11.6 psi ± 4.4 psi)
coolant temperature rises to 116.2°C (241°F). during normal operating temperature [–25°C—100°C
(–13°F—212°F)].
Engine Oil Pressure – The low oil pressure switch and
oil pressure sender (B6) is grounded directly to the
engine block. The oil gauge sender portion is
connected to the instrument cluster (H1) using wire 625
tan/wht. The oil pressure sender is a variable resistor
that varies with the engine oil pressure.
Oil Pressure Sender
Pressure/Resistance
Resistance
Pressure
(ohms)
11/22/00 4 - 57
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
4 - 58 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
15 Amp
503 Yel
X9 (2)
720 Pur Shutdown Module
505 Yel Connector
5 Amp 725 Pur/Wht
F2
Seat Switch/
Seat Belt Fuse 706 707
Engage Pur Pur
225 Red Run
706 Pur
Release
B,C
7
8
5B 140 Blk
4
X1
X8 X8
(A2) 1 X6 X6
S2 (D) (F)
(D) (G)
Park 706 Pur
Brake 500 Yel/Red
X6 (F)
231 Red Switch 800 Pnk
H1
0 Acc Instrument
X6 (E)
X1 S1 1 Off Cluster
(A1) Key X8 (C)
Switch 2 Run
600 Brn
0,1,2 3 Start
X7 (D)
225 Red X7 X7 X7 X8 X7 X8 X7 X8
4
(A) (C) (B) (E) (E) (B) (F) (A) 128 Blk
345 Pnk 325 335 Dk Grn 900 Blk/Wht 300 320 Org 620 Tan 625 Tan/Wht
1 2 Dk Grn/Wht Org/Wht
231 Red
To Alternator
5 D+ Terminal X2 X2 X2 X2 X2 X2 X2 X2
3
X21 (A5) (A3) (A4) (C3) (A1) (A2) (B2) (B3)
345 Pnk 325 335 Dk Grn 900 Blk/Wht 300 320 Org 620 Tan 625 Tan/Wht
Dk Grn/Wht Org/Wht
802
Off P
Dk Grn P t° P Q t° t° P
S4
On
Seat Switch B1
1 Air Filter B2 B3 B4
2 801 Pnk
Restriction Hydraulic Hydraulic Fuel B5 B6
105 Blk
Switch Over Temp- Oil Filter Level Engine Over Temperature Engine Low Oil Pressure
230 Red erature Restriction Sender Switch and Coolant Switch and Oil
Off Temperature Sender
102 Blk Switch 106 Blk Switch 104 Blk Pressure Sender
S5
On X21
Seat Belt
Switch 1 232 Red
2 802 Dk Grn
Unswitched Power Alternator Input Circuit
813 Dk Grn
810 Dk Grn
X4 (1) Switched Power Sensor Circuit
11/22/00 4 - 59
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
NOTE: If wire 500 yel/red has not voltage, neither will instrument cluster or any warning lights.
Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–) terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose terminals when testing.
1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.
2. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.
3. Wire 503 yel at terminal D on Battery voltage. Test wires 503 yel and 500 yel/red between
(X8) instrument cluster connector. (X8) instrument cluster connector and (S1) key
switch.
Test Conditions:
• Key switch in OFF position.
• Test meter set to read resistance (ohms).
4. Wire 128 blk at terminal C on Maximum 0.1 ohms. Test wire 128 blk from (X8) instrument cluster
(X8) instrument cluster connector. connector to ground.
Test Conditions:
• Test meter set to read DC voltage.
5. Wire 231 red on (F2) seat Battery voltage. Test (F2) seat switch/seat belt fuse. Replace if
switch/seat belt fuse. necessary.
If fuse is good, see POWER AND CRANKING
CIRCUIT DIAGNOSIS in this section.
6. Wire 231 red at terminal A1 on Battery voltage. Test wire 231 red between (F2) seat switch/seat
(X1) engine/ROPS harness belt fuse and (X1) engine/ROPS harness
connector. connector.
7. Wire 231 red at terminal A1 on Battery voltage. Test connector (X1) engine/ROPS harness
(X1) engine/ROPS harness connector. Make sure wires are properly
connector. crimped in the terminals.
8. Wire 231 red at terminal 2 on Battery voltage. Test wire 231 red between (X1) engine/ROPS
(S5) seat belt switch. harness connector and (S5) seat belt switch.
9. Wire 230 red at terminal 1 on Battery voltage. Test wire 230 red and 232 red between (S4)
(S4) seat switch. seat switch and (S5) seat belt switch, including
terminals at X21 seat switch pigtail connector.
4 - 60 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
Test Conditions:
• Key switch in RUN position.
• Operator sitting in seat with seat belt fastened.
• Cab door closed (if equipped).
10. Wire 801 pnk at terminal 2 on Battery voltage. Replace (S4) seat switch.
(S4) seat switch.
11. Wire 800 pnk at terminal F on Battery voltage. Test wire 800 pnk and 801 pnk between (X6)
(X6) instrument cluster connector. instrument cluster connector and (S4) seat
switch.
12. Wire 810 dk grn at terminal 1 Battery voltage. Replace (S5) seat belt switch.
on (S5) seat belt switch.
13. Wire 810 dk grn at terminal A Battery voltage. Test wire 810 dk grn between (X99) interlock
on (X99) interlock connector. connector and (S5) seat belt switch.
14. Wire 813 dk grn at (X99) Battery voltage. Replace 991 wht jumper.
interlock connector. If equipped with cab door, test wires 470 Dk
Grn and 472 Dk Grn from (X99) interlock
connector to (S13) cab door switch. If good,
replace (S13) cab door switch.
15. Wire 813 dk grn at terminal 1 Battery voltage. Test wire 813 dk grn between (X4) shutdown
on (X4) shutdown module module connector and (X99) interlock
connector. connector.
16. Wire 802 dk grn at terminal E Battery voltage. Test wire 802 dk grn between (X6) instrument
on (X6) instrument cluster cluster connector and (X4) shutdown module
connector. connector including the terminals on X99
interlock connector.
11/22/00 4 - 61
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
S4 S1
X33 Seat Switch Key Switch 2
S13 472 Door Switch
Cab Grn Harness Connector
Door Switch
470 10
Grn
9
801 Pnk
8
230 Red
S5 1
H1 232 Red
Instrument Cluster 472 Seat Belt Switch
Grn 991
470 Wht 13 12 500
Grn
Yel/Red
X99 810
Interlock Dk Grn
Connector 14
X4
Shutdown Module 813
Connector Dk Grn
X8
15
3 800 Pnk
X7
231 Red
100 Blk
11 4
503 Yel
X6 4
802 7
Dk Grn X1
128 Blk Engine/ROPS
Harness Connector
Instrument Cluster G2
Connectors 16 6 101 Blk Alternator
116 Blk
231 Red
116 Blk 5
F4
F1
F2
F3
KV31066
4 - 62 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
NOTE: If wire 500 yel/red has not voltage, neither will instrument cluster or any warning lights.
Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.
1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.
2. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.
3. Wire 503 yel at terminal D on Battery voltage. Test wires 503 yel and 500 yel/red between
(X8) instrument cluster connector. (X8) instrument cluster connector and (S1) key
switch.
Test Conditions:
• Key switch in OFF position.
• Test meter set to read resistance (ohms).
4. Wire 128 blk at terminal C on Maximum 0.1 ohms. Test wire 128 blk from (X8) instrument cluster
(X8) instrument cluster connector. connector to ground.
Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Park brake switch in the RUN position.
5. Wire 505 yel at terminal 5B on Battery voltage. If battery voltage is not present, test wires 505
(S2) park brake switch. Park switch light is on. yel and 500 yel/red between (S2) park brake
Park brake light is on. switch and (S1) key switch.
If battery voltage is present but park switch light
is not on, test 140 blk ground. If ground wire is
good, replace park brake switch.
If park brake light is on, check for voltage at 725
pur on (S2) Park Brake Switch.
If voltage on 725 pur, replace park brake switch
or check for short in harness.
If no voltage at 725 pur, replace (H1)
instrument cluster.
11/22/00 4 - 63
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
Test Conditions:
• Operator in seat.
• Seat belt fastened.
• Hold park brake switch in RELEASE position.
6. Wire 725 pur/wht at terminal 1 Battery voltage. If battery voltage is present at terminal 5B on
on (S2) park brake switch. (S2) park brake switch, replace switch.
7. Wire 725 pur/wht at terminal D Battery voltage. Test wire 725 pur/wht between (X6) instrument
on (X6) instrument cluster Park brake warning light cluster connector and (S2) park brake switch.
connector. goes out.
If battery voltage is present and park brake
warning light does not go out, replace (H1)
instrument cluster.
Test Conditions:
• Release park brake switch to the RUN position.
8. Wire 720 pur at terminal 4 on Battery voltage. Replace (S2) park brake switch.
(S2) park brake switch.
9. Wire 720 pur at terminal G on Battery voltage. If battery voltage is not present, test wire 720
(X6) instrument cluster connector. pur between (X6) instrument cluster connector
and (S2) park brake switch.
4 - 64 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
S1
Key Switch
2
H1
Instrument Cluster 1
S2
Park Brake Switch
8
6
5 500 Yel/Red
X8 3 505 Yel
725 Pur/Wht
X7
9
X6 503 Yel
4
Instrument Cluster
Connectors
140 Blk
128 Blk
720 Pur X1
7 Engine/ROPS
Harness Connector
116 Blk
116 Blk
101 Blk
G2
Alternator
100 Blk
KV15192
11/22/00 4 - 65
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
NOTE: If wire 500 yel/red has not voltage, neither will instrument cluster or any warning lights.
Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.
1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.
2. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.
3. Wire 503 yel at terminal D on Battery voltage. Test wires 503 yel and 500 yel/red between
(X8) instrument cluster connector. (X8) instrument cluster connector and (S1) key
switch.
Test Conditions:
• Key switch in OFF position.
• Test meter set to read resistance (ohms).
4. Wire 128 blk at terminal C on Maximum 0.1 ohms. Test wire 128 blk from (X8) instrument cluster
(X8) instrument cluster connector. connector to ground.
5. Wire 105 blk on harness side Maximum 0.1 ohms. Test wire 105 blk from (B1) air filter restriction
of connector to (B1) air filter switch to ground.
restriction switch.
Test Conditions:
• Disconnect (B1) air filter restriction switch.
• Connect a jumper wire across the terminals at 345
pnk and 105 blk on harness side of the air filter
restriction switch connector.
• Key switch in RUN position.
6. Air filter restriction warning Warning light comes on. If warning light comes on, test (B1) air filter
light. restriction switch.
4 - 66 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
6
S1
Key Switch
2
H1
Instrument Cluster
X8 3
500 Yel/Red
X7
4 503 Yel
X6
B1
Air Filter
Restriction
Switch 116 Blk
345 Pnk
105 Blk 101 Blk
5
G2
Alternator
100 Blk
4
5
KV15193
11/22/00 4 - 67
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
NOTE: If wire 500 yel/red has not voltage, neither will instrument cluster or any warning lights.
Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.
1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.
2. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.
3. Wire 503 yel at terminal D on Battery voltage. Test wires 503 yel and 500 yel/red between
(X8) instrument cluster connector. (X8) instrument cluster connector and (S1) key
switch.
Test Conditions:
• Key switch in OFF position.
• Test meter set to read resistance (ohms).
4. Wire 128 blk at terminal C on Maximum 0.1 ohms. Test wire 128 blk from (X8) instrument cluster
(X8) instrument cluster connector. connector to ground.
5. Wire 102 blk on harness side Maximum 0.1 ohms. Test wire 102 blk from (B2) hydraulic
of connector to (B2) hydraulic overtemperature switch to ground.
overtemperature switch.
Test Conditions:
• Disconnect (B2) Hydraulic Overtemperature
Switch.
• Connect a jumper wire across the terminals at 325
dk grn/wht and 102 blk on harness side of
hydraulic overtemperature switch connector.
• Key switch in RUN position.
6. Hydraulic overtemperature Warning light comes on. If warning light comes on, test (B2) hydraulic
warning light. overtemperature switch.
If hydraulic overtemperature warning light does
not come on, test wires 325 dk grn/wht between
(B2) hydraulic overtemperature switch and
terminal C on (X7) instrument cluster
connector.
If wires are good, replace (H1) instrument
cluster.
4 - 68 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
6
S1
Key Switch
2
H1
Instrument Cluster
3 1
X8
500 Yel/Red
X7
4 503 Yel
X6
128 Blk
325 Dk Grn/Wht
Instrument Cluster X1
Connectors Engine/ROPS
116 Blk Harness Connector
X2
Engine/ROPS
Harness Connector
B2
Hydraulic Oil
Overtemperature
Switch 116 Blk
325 Dk Grn/Wht
100 Blk
4
5
KV15194
11/22/00 4 - 69
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
NOTE: If wire 500 yel/red has not voltage, neither will instrument cluster or any warning lights.
Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.
1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.
2. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.
3. Wire 503 yel at terminal D on Battery voltage. Test wires 503 yel and 500 yel/red between
(X8) instrument cluster connector. (X8) instrument cluster connector and (S1) key
switch.
Test Conditions:
• Key switch in OFF position.
• Test meter set to read resistance (ohms).
4. Wire 128 blk at terminal C on Maximum 0.1 ohms. Test wire 128 blk from (X8) instrument cluster
(X8) instrument cluster connector. connector to ground.
5. Wire 106 blk at ring terminal on Maximum 0.1 ohms. Test wire 106 blk from (B3) hydraulic oil filter
hydraulic filter housing ground. restriction switch to ground.
Test Conditions:
• Key switch in RUN position.
• Disconnect 335 dk grn wire from (B3) hydraulic oil
filter restriction switch and connect to wire 106 blk
with jumper wire.
6. Hydraulic filter restriction Warning light comes on. If warning light comes on, test (B3) hydraulic oil
warning light. filter restriction switch.
If hydraulic filter restriction warning light does
not come on, test wires 335 dk grn between
(B3) hydraulic oil filter restriction switch and
terminal B on (X7) instrument cluster
connector.
If wires are good, replace (H1) instrument
cluster.
4 - 70 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
6
S1
Key Switch
2
H1
Instrument Cluster
1
X8 3
500 Yel/Red
X7
4 503 Yel
X6
128 Blk
335 Dk Grn
Instrument Cluster X1
Connectors Engine/ROPS
116 Blk Harness Connector
X2
Engine/ROPS
B3 Harness Connector
Hydraulic Oil Filter
Restriction Switch
5
116 Blk
335 Dk Grn
106 Blk 101 Blk
G2
Alternator
100 Blk
4
5
KV15195
11/22/00 4 - 71
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
NOTE: If wire 500 yel/red has not voltage, neither will instrument cluster or any warning lights.
Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.
1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.
2. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.
3. Wire 503 yel at terminal D on Battery voltage. Test wires 503 yel and 500 yel/red between
(X8) instrument cluster connector. (X8) instrument cluster connector and (S1) key
switch.
Test Conditions:
• Key switch in OFF position.
• Test meter set to read resistance (ohms).
4. Wire 128 blk at terminal C on Maximum 0.1 ohms. Repair or replace wire 128 blk from (X8)
(X8) instrument cluster connector. instrument cluster connector to ground.
5. Wire 104 blk at connector of Maximum 0.1 ohms. Repair or replace wire 104 blk from (B4) fuel
(B4) fuel level sender. level sender to ground.
6. Wire 900 blk/wht between (B4) Maximum 0.1 ohms. Repair or replace wire 900 blk/wht between
fuel level sender and terminal C3 (B4) fuel level sender and (X2) engine/ROPS
at (X2) engine/ROPS harness harness connector.
connector.
7. Wire 900 blk/wht between C3 Maximum 0.1 ohms. Repair or replace wire 900 blk/wht between
on (X2) engine/ROPS harness (X2) engine/ROPS harness connector and
connector and terminal E on (X8) terminal E on (X8) instrument cluster
instrument cluster connector. connector.
Test Conditions:
• Key switch in OFF position.
• Test meter set to read resistance (ohms)
• Disconnect the wire harness from (B4) Fuel Level
Sender.
4 - 72 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
Test Conditions:
• Disconnect the wire harness from the fuel level
sender.
• Key switch in RUN position.
Test Conditions:
• Disconnect the wire harness from the fuel level
sender.
• Install a jumper wire between wire 900 blk/wht and
wire 104 blk.
• Key switch in RUN position.
10. Fuel gauge. Gauge indicates full. Replace (H1) instrument cluster.
11/22/00 4 - 73
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
9 10
S1
Key Switch
2
H1
Instrument Cluster
1
X8 3
4 500 Yel/Red
X7
X6 503 Yel
Instrument Cluster 7
Connectors 128 Blk
X1
6 Engine/ROPS
900 Blk/Wht 7 116 Blk Harness Connector
X2
5 Engine/ROPS
B4 104 Blk Harness Connector
Fuel Level
Sender
6
9
8
8 900 Blk/Wht
116 Blk
101 Blk
G2
Alternator
100 Blk
4
5
KV15197
4 - 74 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
NOTE: If wire 500 yel/red has not voltage, neither will instrument cluster or any warning lights.
Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.
1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.
2. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.
3. Wire 503 yel at terminal D on Battery voltage. Test wires 503 yel and 500 yel/red between
(X8) instrument cluster connector. (X8) instrument cluster connector and (S1) key
switch.
Test Conditions:
• Key switch in OFF position.
• Test meter set to read resistance (ohms).
4. Wire 128 blk at terminal C on Maximum 0.1 ohms. Test wire 128 blk from (X8) instrument cluster
(X8) instrument cluster connector. connector to ground.
Test Conditions:
• Key switch in RUN position.
• Connect wire 300 org/wht from (B5) Engine
overtemperature switch and coolant temperature
sender to ground.
5. Engine overtemperature Warning light comes on. If warning light comes on, test (B5) engine
warning light. overtemperature switch and coolant
temperature sender.
If engine overtemperature warning light does
not come on, test wires 300 org/wht between
terminal E on (X7) instrument cluster connector
and (B5) engine overtemperature switch and
coolant temperature sender.
If wires are good, replace (H1) instrument
cluster.
11/22/00 4 - 75
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
5
S1
Key Switch
H1 2
Instrument Cluster
X8 1
500 Yel/Red
X7
4
503 Yel
X6
Instrument Cluster
Connectors
128 Blk
X1
320 Org Engine/ROPS
116 Blk Harness Connector
X2
Engine/ROPS
Harness Connector
300 Org/Wht
B5 116 Blk
Engine Overtemperature
Switch and Coolant 300 Org/Wht
101 Blk
Temperature Sender
320 Org G2
Alternator
5 100 Blk
KV15196
4 - 76 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
NOTE: If wire 500 yel/red has not voltage, neither will instrument cluster or any warning lights.
Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.
1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.
2. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.
3. Wire 503 yel at terminal D on Battery voltage. Test wires 503 yel and 500 yel/red between
(X8) instrument cluster connector. (X8) Instrument cluster connector and (S1) key
switch.
Test Conditions:
• Test meter set to read resistance (ohms).
• Key switch in OFF position.
4. Wire 128 blk at terminal C on Maximum 0.1 ohms. Test wire 128 blk from (X8) instrument cluster
(X8) instrument cluster connector. connector to ground.
11/22/00 4 - 77
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
5. Wire 320 org at terminal B on Battery voltage. Replace (H1) instrument cluster.
(X8) instrument cluster connector.
6. Wire 320 org at terminal A2 on Battery voltage. Test wire 320 org between (H1) instrument
(X2) engine/ROPS harness cluster and (X2) engine/ROPS harness
connector. connector.
7. Wire 320 org at terminal A2 on Battery voltage. Test (X2) engine/ROPS harness connector.
(X2) engine/ROPS harness Make sure wires are properly crimped in the
connector. terminals.
8. Wire 320 org at (B5) engine Battery voltage. Test wire 320 org between (X2) engine/ROPS
overtemperature switch and harness connector and (B5) engine
coolant temperature sender. overtemperature switch and coolant
temperature sender.
Test Conditions:
• Connect wire 320 org from (B5) Engine
overtemperature switch and coolant temperature
sender to ground.
9. Engine temperature gauge. Gauge indicates HOT. If gauge does not indicate HOT, replace (H1)
instrument cluster.
If gauge indicates HOT, test (B5) engine
overtemperature switch and coolant
temperature sender. (See ENGINE COOLANT
TEMPERATURE SENDER/SWITCH TEST in
this section.)
4 - 78 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
S1
Key Switch
H1 2
Instrument Cluster
X8 1
500 Yel/Red
X7
4
503 Yel
X6 5
Instrument Cluster
Connectors
128 Blk
X1
320 Org 6 Engine/ROPS
116 Blk Harness Connector
X2
Engine/ROPS
Harness Connector
300 Org/Wht
116 Blk
B5
Engine Overtemperature
300 Org/Wht
Switch and Coolant 101 Blk
Temperature Sender
320 Org G2
Alternator
100 Blk
9 8
4
KV15196
11/22/00 4 - 79
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.
2. Wire 500 yel/red at terminal 2 on Battery voltage. Replace (S1) key switch.
(S1) key switch.
3. Wire 503 yel at terminal D on (X8) Battery voltage. Test wires 503 yel and 500 yel/red between
instrument cluster connector. (X8) instrument cluster connector and (S1) key
switch.
Test Conditions:
• Key switch in OFF position.
• Test meter set to read resistance (ohms).
4. Wire 128 blk at terminal C on (X8) Maximum 0.1 ohms. Test wire 128 blk from (X8) instrument cluster
Instrument cluster connector. connector to ground.
Test Conditions:
• Key switch in RUN position.
• Disconnect wire 620 tan from (B6) engine low oil
pressure switch and oil pressure sender.
5. Engine oil pressure warning light. Light is not on. Test wire 620 tan between (B6) engine low oil
pressure switch and oil pressure sender and
(X7) instrument cluster connector.
If wire 620 tan tests good, replace (H1)
instrument cluster.
Test Conditions:
• Key switch in RUN position.
• Connect wire 620 tan to ground.
6. Engine oil pressure warning light. Warning light comes Test (B6) engine low oil pressure switch and oil
on. pressure sender. (See ENGINE OIL
PRESSURE SWITCH/SENDER TEST in this
section.)
If engine oil pressure warning light does not
come on, test wire 620 tan between (X7)
Instrument cluster connector and (B6) engine
low oil pressure switch and oil pressure sender.
If wires are good, replace (H1) instrument
cluster.
4 - 80 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
S1
Key Switch
5 6
2
H1
Instrument Cluster 1
500 Yel/Red
3
X8
503 Yel
X7
4
X6 128 Blk
Instrument Cluster X1
Connectors Engine/ROPS
Harness Connector
620 Tan 116 Blk
625 Tan/Wht
X2
Engine/ROPS
Harness Connector
116 Blk
101 Blk
G2
625 Tan/Wht Alternator
B6 100 Blk
Engine Low Oil 620 Tan
Pressure Switch
and Oil Pressure Sender 5
KV15198
11/22/00 4 - 81
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
NOTE: If wire 500 yel/red has not voltage, neither will instrument cluster or any warning lights.
Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.
1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS.
2. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.
3. Wire 503 yel at terminal D on Battery voltage. Test wires 503 yel and 500 yel/red between
(X8) instrument cluster connector. (X8) instrument cluster connector and (S1) key
switch.
Test Conditions:
• Key switch in OFF position.
• Test meter set to read resistance (ohms).
4. Wire 128 blk at terminal C on Maximum 0.1 ohm. Test wire 128 blk from (X8) instrument cluster
(X8) instrument cluster connector. connector to ground.
Test Conditions:
• Key switch in RUN position.
• Test meter set to read DC voltage.
5. Wire 625 tan/wht at terminal A Approximately 6 volts. Replace (H1) instrument cluster.
on (X8) instrument cluster
connector.
6. Wire 625 tan/wht at terminal Approximately 6 volts. Test wire 625 tan/wht between (H1) instrument
B3 on (X2) engine/ROPS harness cluster and (X2) engine/ROPS harness
connector. connector.
7. Wire 625 tan/wht at terminal Approximately 6 volts. Test (X2) engine/ROPS harness connector.
B3 on (X2) engine/ROPS harness Make sure wires are properly crimped in the
connector. terminals.
8. Wire 625 tan/wht at (B6) Approximately 6 volts. Test wire 625 tan/wht between (X2) engine/
engine low oil pressure switch and ROPS harness connector and (B6) engine low
oil pressure sender. oil pressure switch and oil pressure sender.
4 - 82 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
Test Conditions:
• Key switch in RUN position.
• Connect wire 625 tan/wht from (B6) engine low oil
pressure switch and oil pressure sender to ground.
9. Engine oil pressure gauge. Gauge indicates LOW If gauge does not indicate LOW pressure,
pressure. replace (H1) instrument cluster.
11/22/00 4 - 83
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
S1
9
Key Switch
H1
Instrument Cluster 1
500 Yel/Red
3
X8
503 Yel
X7
4
X6 128 Blk
Instrument Cluster 5 X1
Connectors Engine/ROPS
Harness Connector
620 Tan 116 Blk
625 Tan/Wht
6
X2
Engine/ROPS
Harness Connector
116 Blk
7 101 Blk
G2
625 Tan/Wht Alternator
B6 100 Blk
Engine Low Oil 620 Tan
Pressure Switch
and Oil Pressure Sender
8
9
KV15198
4 - 84 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
11/22/00 4 - 85
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
4 - 86 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
1. Wire 142 blk at harness Maximum 0.1 ohms. Test ground circuit wire 142 blk from (S8) high
connector from (S8) high flow flow switch to ground.
switch.
Test Conditions:
• Connect harness to (S8) High Flow Switch.
• Key switch in RUN position.
• Test meter set to read DC voltage.
2. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.
3. Wire 500 yel/red at terminal 2 Battery voltage. Replace (S1) key switch.
on (S1) key switch.
4. Wire 502 yel at terminal 5B on Battery voltage. If voltage is not present, test wires 502 yel and
(S8) high flow switch. 500 yel/red between (S1) key switch and (S8)
High flow switch back
high flow switch.
lighting is on.
If voltage is present and back lighting does not
come on, check 142 blk ground.
If good, replace switch.
5. Wire 501 yel at terminal C2 on Battery voltage. Test wires 500 yel/red and 501 yel between
(X1) engine/ROPS harness (S1) key switch and (X1) engine/ROPS harness
connector (ROPS side). connector.
6. Wire 501 yel at terminal C2 on Battery voltage. Test (X1) engine/ROPS harness connector.
(X1) engine/ROPS harness Make sure wires are properly crimped in the
connector (engine side). terminals.
7. Wire 511 yel at terminal 30 on Battery voltage. Test wires 501 yel and 511 yel between (K6)
(K6) high flow relay. high flow relay and (X1) engine/ROPS harness
connector.
11/22/00 4 - 87
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
Test Conditions:
• Hold the high flow switch in the ON position.
• Key switch in RUN position.
8. Wire 811 pnk at terminal 3 on Battery voltage. Replace (S8) high flow switch.
(S8) high flow switch.
High flow switch
indicator light is on.
9. Wire 811 pnk at terminal A4 on Battery voltage. Test wire 811 pnk between (S8) high flow
(X1) engine/ROPS harness switch and (X1) engine/ROPS harness
connector (ROPS side). connector.
10. Wire 811 pnk at terminal A4 Battery voltage. Test (X1) engine/ROPS harness connector.
on (X1) engine/ROPS harness Make sure wires are properly crimped in the
connector (engine side). terminals.
11. Wire 811 pnk at terminal 86 on Battery voltage. Test wire 811 pnk between (K6) high flow relay
(K6) high flow relay. and (X1) engine/ROPS harness connector.
Test Conditions:
• Release the high flow switch to the RUN position.
• Key switch in RUN position.
12. Wire 813 dk grn at terminal 87 Battery voltage. Test ground circuit wire 119 blk from (K6) high
on (K6) high flow relay. flow relay to ground. If ground circuit is good,
replace relay.
13. Wire 812 dk grn at terminal A5 Battery voltage. Test wires 812 dk grn and 813 dk grn between
on (X1) engine/ROPS harness (X1) engine/ROPS harness connector and (K6)
connector (engine side). high flow relay.
14. Wire 812 dk grn at terminal A5 Battery voltage. Test (X1) engine/ROPS harness connector and
on (X1) engine/ROPS harness make sure wires are properly crimped in the
connector (ROPS side). terminals.
15. Wire 812 dk grn at terminal 2B Battery voltage. Test wire 812 dk grn between (X1) engine/
on (S8) high flow switch. ROPS harness connector and (S8) high flow
switch.
16. Wire 811 pnk at terminal 3 on Battery voltage. Replace (S8) high flow switch.
(S8) high flow switch.
17. Wire 815 dk grn at (Y5) high Battery voltage. If voltage is not present, test wires 815 dk grn
flow valve solenoid. and 813 dk grn between (Y5) high flow valve
Valve is energized. (Test
solenoid and (K6) high flow relay.
by holding a metal
screwdriver next to it. If If voltage is present and valve is not energized,
energized, the test ground circuit wire 109 blk from (Y5) high
screwdriver will be flow valve solenoid to ground. If ground circuit is
pulled toward it.) good, replace valve.
4 - 88 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
Test Conditions:
• Key switch in OFF position.
• Disconnect (V1) high flow valve diode.
• Test meter set to read continuity.
• Meter positive (+) lead connected to (V1) high flow
valve diode where wire 814 dk grn connects.
• Meter negative (–) lead connected to (V1) high flow
valve diode where wire 117 blk connects.
18. (V1) high flow valve diode. Continuity or no Replace (V1) high flow valve diode.
continuity.
Test Conditions:
• Reverse the test meter leads.
19. (V1) high flow valve diode. Opposite of step 18. Replace (V1) high flow valve diode.
11/22/00 4 - 89
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
S1
Key Switch 3
500 Yel/Red
S8
High Flow Switch 2
1
4 502 Yel
9
812 Dk Grn 5
15
501 Yel
142 Blk 811 Pnk
8 10 X1
16 Engine/ROPS
Harness Connector
116 Blk
6
14
13
K6
High Flow 11
Relay 812 Dk Grn
V1 811 Pnk
19
18 High Flow 501 Yel
Valve Diode
7
511 Yel
814 Dk Grn
Y5 119 Blk 116 Blk
High Flow 12
Valve Solenoid 117 Blk
813 Dk Grn 4
100 Blk
101 Blk G2
815 Dk Grn Alternator
109 Blk
17
KV15188
4 - 90 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
11/22/00 4 - 91
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
4 - 92 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
Test Conditions:
• Key switch in ACCESSORIES position.
3. Wire 550 yel/wht at terminal 4 on (S1) Battery voltage. Replace (S1) key switch.
key switch.
4. Wire 550 yel/wht at terminal C1 on (X1) Battery voltage. Test wire 550 yel/wht between (S1) key switch
engine/ROPS harness connector (ROPS and (X1) engine/ROPS harness connector.
side).
5. Wire 550 yel/wht at terminal C1 on (X1) Battery voltage. Test connector (X1) engine/ROPS harness
engine/ROPS harness connector (engine connector and make sure wires are properly
side). crimped in the terminals.
6. Wire 550 yel/wht at terminal 86 on (K4) Battery voltage. Test wire 550 yel/wht between (K4) accessory
accessory relay. relay and (X1) engine/ROPS harness
connector.
7. Terminal 30 on (K4) accessory relay. Battery voltage. Check wire 445 yel to (F1) key switch fuse.
8. Wire 450 yel/wht at terminal 87 on (K4) Battery voltage. Test ground circuit wire 110 blk from (K4)
accessory relay. accessory relay to ground. If ground circuit is
good, replace relay.
9. Wire 451 yel/wht at terminal B2 on (X1) Battery voltage. Test wires 450 yel/wht and 451 yel/wht between
engine/ROPS harness connector (engine (X1) engine/ROPS harness connector and (K4)
side). accessory relay.
10. Wire 451 yel/wht at terminal B2 on (X1) Battery voltage. Test connector (X1) engine/ROPS harness
engine/ROPS harness connector (ROPS connector. Make sure wires are properly
side). crimped in the terminals.
11. Wire 451 yel/wht and 453 yel/wht at Battery voltage. Test wire 451 yel/wht between (X1) engine/
(X13) 12-volt accessory connector. ROPS harness connector and (X13) 12-volt
accessory connector.
12. Wire 453 yel/wht at terminal C on (X99) Battery voltage. Test wire 453 yel/wht between (X99) Interlock
interlock connector. connector and (X13) 12-volt accessory
connector.
13. Wire 450 yel/red at terminal 5B on (S6) Battery voltage. If voltage is not present, test wire 450 yel/red
work lights switch. between (X99) interlock connector and (S6)
Work lights
work lights switch.
switch back
If voltage is present and back lighting is not on,
lighting is on.
check 103 blk ground. If good, replace switch.
14. Wire 452 yel at terminal 2B on (S6) Battery voltage. Test wire 452 yel/red between terminals 2B and
work lights switch. 5B on (S6) work lights switch.
11/22/00 4 - 93
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
Test Conditions:
• Work lights switch in FRONT WORK/TAIL LIGHT
(middle) position.
• Key switch in ACCESSORY position.
15. Wire 473 brn at terminal 3 on Battery voltage. Replace (S6) work lights switch.
(S6) work lights switch. If indicator light is not on, check ground 103 blk.
Work lights switch
If good, replace switch.
indicator is on.
Test Conditions:
• Work lights switch in FRONT/REAR WORK/TAIL
LIGHTS (up) position.
• Key switch in ACCESSORY position.
16. Wire 473 brn at terminal 3 on Battery voltage. Replace (S6) work lights switch.
(S6) work lights switch. If indicator light is not on, check ground 103 blk.
Work lights switch
If good, replace switch.
indicator is on.
17. Wire 475 brn/wht at terminal 6 Battery voltage. Replace (S6) work lights switch.
on (S6) work lights switch. If indicator light is not on, check ground 103 blk.
If good, replace switch.
Test Conditions:
• Remove sockets from (E1) left front work light and
(E2) right front work light, then remove bulbs from
sockets.
• Test meter set to read DC voltage.
• Key switch in ACCESSORY position.
• Work lights switch in FRONT WORK/TAIL LIGHTS
(middle) position.
18. Center terminal of bulb socket Battery voltage. Check for loose or corroded connections
on (E1) left front work light. between harness connector and socket.
Test wires 470 brn and 473 brn between (E1)
left front work light and (S6) work lights switch.
19. Center terminal bulb socket on Battery voltage. Check for loose or corroded connections
(E2) right front work light. between harness connector and socket.
Test wires 471 brn and 473 brn between (E2)
right front work light and (S6) work lights switch.
4 - 94 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
Test Conditions:
• Key switch in OFF position.
• Work lights switch in OFF (down) position.
• Test meter set to read resistance (ohms).
20. Outer contact of bulb socket Maximum 0.1 ohms. Check for loose or corroded connections
on (E1) left front work light. between harness connector and socket.
Test wire 101 blk from (E1) left front work light
to ground.
21. Outer contact of bulb socket Maximum 0.1 ohms. Check for loose or corroded connections
on (E2) right front work light. between harness connector and socket.
est wire 102 blk from (E1) left front work light to
ground.
Test Conditions:
• Replace light bulb and socket previously removed.
• Test meter set to read DC voltage.
• Key switch in RUN or ACCESSORY position.
• Work lights switch in FRONT WORK/TAIL LIGHTS
(middle) position.
• Remove sockets from (E3) left tail light and (E4)
right tail light. Remove bulbs from sockets.
22. Center terminal of bulb socket Battery voltage. Check for loose or corroded connections
on (E3) left tail light. between harness connector and socket.
Test wires 477 brn and 473 brn between (E3)
left tail light and (S6) work light switch.
23. Center terminal of bulb socket Battery voltage. Check for loose or corroded connections
on (E4) right tail light. between harness connector and socket.
Test wires 476 brn and 473 brn between (E4)
right tail light and (S6) work light switch.
Test Conditions:
• Key switch in OFF position.
• Work lights switch in OFF (down) position.
• Test meter set to read resistance (ohms).
24. Outer contact of bulb socket Maximum 0.1 ohms. Check for loose or corroded connections
on (E3) left tail light. between harness connector and socket.
Test wire 107 blk from (E3) left tail light to
ground.
25. Outer contact of bulb socket Maximum 0.1 ohms. Check for loose or corroded connections
on (E4) right tail light. between harness connector and socket.
Test wire 106 blk from (E4) right tail light to
ground.
11/22/00 4 - 95
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
Test Conditions:
• Replace light bulbs and sockets previously
removed.
• Test meter set to read DC voltage.
• Key switch in RUN or ACCESSORY position.
• Work lights switch in FRONT/REAR WORK/TAIL
LIGHTS (up) position.
• Remove socket from (E5) rear work light and then
remove bulb from socket.
26. Center terminal of bulb socket Battery voltage. Check for loose or corroded connections
on (E5) rear work light. between harness connector and socket.
Test wire 475 brn/wht between (E5) rear work
light and (S6) work lights switch.
Test Conditions:
• Key switch in OFF position.
• Work lights switch in OFF (down) position.
• Test meter set to read resistance (ohms).
27. Outer contact of bulb socket Maximum 0.1 ohms. Check for loose or corroded connections
on (E5) rear work light. between harness connector and socket.
Test wire 105 blk from (E5) rear work light to
ground.
4 - 96 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
E1
Left Front
S6 Work Light
Work Lights Switch 20 18
E2
Right Front
Work Light
13
470 Brn
452 Yel
17 471 Brn
X13
Accessory 12 Volt
Connector 102 Blk
14
15 16
450 Yel/Red 3
473 Brn S1 2
24 22 12 X99 Key Switch
Interlock
11 Connector
107 Blk 453 Yel/Wht
104 Blk 1
477 Brn 475 451 Yel/Wht
124 Blk
Brn/Wht
10 4
105 Blk 103 Blk 550 Yel/Wht
116 Blk
9
X12
E3 26 27 Accessory
Left Tail Ground Connector X1 5
Light 106 Blk Engine/ROPS
476 Brn
Harness Connector
E5 23 25 K4 6
Rear Work Accessory
Light Relay
116 Blk
E4 450
Yel/Wht 451 Yel/Wht
Right Tail
Light
550 Yel/Wht
101 Blk 7
110 Blk
8
100 Blk
G2 445 Yel
Alternator
To F1
Accessories
Fuse
KV18053
11/22/00 4 - 97
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
Function:
To provide flashing lights to warn others of a potential
hazard.
Operating Conditions:
The key switch (S1) must be in the RUN or
ACCESSORY position and the dual flasher switch (S7)
must be in the ON position.
Theory of Operation:
When the key switch (S1) is in the RUN or
ACCESSORY position, the accessory relay (K4) is
energized, and current flows from the accessories fuse
(F1) through the accessory relay contacts to the
common terminal of the dual flasher switch (S7). The
back lighting in the lights switch is connected to the
common terminal and is grounded by wire 128 blk. The
back lighting is on regardless of the position of the dual
flasher lights switch.
When the dual flasher switch is in the OFF position, no
current flows from pin 3, the dual flasher relay (K5)
remains off and all dual flasher lights remain off.
When the dual flasher switch is in the ON position,
current flows from pin 3 through wire 480 yel/red to the
dual flasher relay and all hazard lights flash on and off.
4 - 98 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
To K4
Accessory Relay
451/453 Yel/Wht A - Off
X13
S7 C - On
460 Dual A,C
Yel/Wht Flasher Back
Switch Light
3
2B
480
Yel/Red
Indicator
Light
K5
Dual
Flasher
Relay
126 Blk
128
Blk
482
Yel/Blk
481
Yel/Blk
127
Blk
E6 E7
Left Right
Hazard Hazard
Light Light
129 Blk
124 Blk
X12
Ground Circuit
KV31068
11/22/00 4 - 99
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
1. Terminal 1 on (S1) key switch. Battery voltage. See POWER AND CRANKING CIRCUIT
DIAGNOSIS in this section.
2. Wire 550 yel/wht at terminal 4 Battery voltage. Replace (S1) key switch.
on (S1) key switch.
Test Conditions:
• Key switch in ACCESSORY position.
3. Wire 550 yel/wht at terminal 4 Battery voltage. Replace (S1) key switch.
on (S1) key switch.
4. Wire 550 yel/wht at terminal C1 Battery voltage. Test wire 550 yel/wht between (S1) key switch
on (X1) engine/ROPS harness and (X1) engine/ROPS harness connector.
connector (ROPS side).
5. Wire 550 yel/wht at terminal C1 Battery voltage. Test (X1) engine/ROPS harness connector.
on (X1) engine/ROPS harness Make sure wires are properly crimped in the
connector (engine side). terminals.
6. Wire 550 yel/wht at terminal 86 Battery voltage. Test wire 550 yel/wht between (K4) accessory
on (K4) accessory relay. relay and (X1) engine/ROPS harness
connector.
7. Wire 445 yel at terminal 30 on Battery voltage. Test wire 445 yel between (K4) accessory relay
(K4) accessory relay. and (F1) accessories fuse. Check fuse.
8. Wire 450 yel/wht at terminal 87 Battery voltage. Test ground circuit wire 110 blk from (K4)
on (K4) accessory relay. accessory relay to ground. If ground circuit is
good, replace relay.
9. Wire 451 yel/wht at terminal B2 Battery voltage. Test wires 451 yel/wht and 450 yel/wht between
on (X1) engine/ROPS harness (X1) engine/ROPS harness connector and (K4)
connector (engine side). accessory relay.
10. Wire 451 yel/wht at terminal Battery voltage. Test (X1) engine/ROPS harness connector.
B2 on (X1) engine/ROPS harness Make sure wires are properly crimped in the
connector (ROPS side). terminals.
11. Wire 451 yel/wht on (X13) Battery voltage. Test wire 451 yel/wht between (X13) 12-volt
12-volt accessory connector. accessory connector and (X1) engine/ROPS
harness connector.
12. Wire 460 yel/wht on (X13) Battery voltage. Test (X13) 12-volt accessory connector. Make
12-volt accessory connector. sure wires are properly crimped in the
terminals.
4 - 100 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
13. Wire 460 yel/wht at terminal Battery voltage. If voltage is not present, test wire 460 yel/wht
2B on (S7) dual flasher switch. between (X13) 12-volt accessory connector
Dual flasher switch back and (S7) dual flasher switch.
lighting is on. If voltage is present and back lighting is not on,
check wire 128 blk to ground. If good, replace
switch.
Test Conditions:
• Key switch in ACCESSORY position
• Dual flasher switch in ON position.
14. Wire 480 yel/red at terminal 3 Battery voltage. Replace (S7) dual flasher switch.
on (S7) dual flasher switch.
Dual flash switch
indicator light is on.
15. Wire 480 yel/red on (K5) dual Battery voltage. Test wire 480 yel/red between (S7) dual flasher
flasher relay. switch and (K5) dual flasher relay.
16. Wire 481 yel/blk and 482 yel/ Battery voltage cycling Test wire 126 blk from (K5) dual flasher relay to
blk at (K5) dual flasher relay. ON and OFF. ground. If ground is good, replace (K5) dual
flasher relay.
Test Conditions:
• Remove sockets from (E6) left hazard light and (E7)
right hazard light, then remove bulbs from sockets.
• Test meter set to read DC voltage.
• Key switch in ACCESSORY position.
• Dual flasher switch in ON position.
17. Center terminal of bulb socket Battery voltage cycling Check for loose or corroded connections
on (E6) left hazard light. ON and OFF. between harness connector and socket.
18. Center terminal of bulb socket Battery voltage cycling Check for loose or corroded connections
on (E7) right hazard light. ON and OFF. between harness connector and socket.
11/22/00 4 - 101
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
Test Conditions:
• Key switch in OFF position.
• Dual flasher switch in OFF position.
• Test meter set to read resistance (ohms).
19. Outer contact of bulb socket Maximum 0.1 ohms. Check for loose or corroded connections
on (E6) left hazard light. between harness connector and socket.
20. Outer contact of bulb socket Maximum 0.1 ohms. Check for loose or corroded connections
on (E7) right hazard light. between harness connector and socket.
4 - 102 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
S7
Dual Flasher Switch
13
14
124 Blk
K5
Dual Flasher
Relay 480 Yel/Red
15
126
Blk 126 Blk
128 Blk 3
S1
460 Yel/Wht Key Switch 2
16
127 Blk
481
19 Yel/Blk 129 Blk 12
128 Blk
17 11 1
482
Yel/Blk 453 124 Blk
To
20 X13 Yel/Wht 550 Yel/Wht
12-Volt
X99
Accessory 451
E6 Connector Yel/Wht
Left Hazard 18 4
Light
10
116 Blk
5
X1
E7 Engine/ROPS
Right Hazard Harness Connector
Light 550 Yel/Wht
450 Yel/Wht
101 Blk
445 Yel
110 Blk
100 Blk
G2
8
Alternator
From F1
Accessories
Fuse
KV18054
11/22/00 4 - 103
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
Theory of Operation:
When the key switch (S1) is in the RUN or
ACCESSORY position, the accessory relay (K4) is
energized, and the current flows from the 25A
accessories fuse (F1), through the accessory relay
contacts to terminal 86 of the cab heater relay (K7),
energizing the cab heater relay (K7). Current flows
from the battery terminal of the starting motor (M1),
through the 15A in-line cab heater fuse (F5) (located
near the hydraulic filter), to terminal 30, through the
closed contacts of the cab heater relay (K7) to terminal
87. Current is provided by the cab heater relay (K7)
terminal 87 to the blower switch (S9) and cab heater
heater control circuit board (A1). Back lighting in the
blower switch (S9) is connected to the common
terminal and is grounded by wire 000B blk. The back
lighting is on regardless of the position of the blower
switch (S9).
When the blower switch (S9) is in the LOW speed
position, current flows through 004 yel wire to the
resistor on the blower (M3), through the resistor and to
the blower (M3) motor. When the blower switch (S9) is
in the HIGH speed position, current flows through 005
org, directly to the blower (M3) motor, bypassing the
resistor. When the blower switch (S9) is in the OFF
position, no current flows to the blower motor (M3). The
blower pulls air through the recirculating air vents and
the air inlet filter of the heater housing, through the
heater core, and blows into the ductwork within the cab.
The recirculating vents provide air to the heater should
the air inlet filter become plugged with debris. The
heater core is a heat exchanger that uses the heat from
the engine coolant to heat the air that passes through
it.
The cab heater thermostat (R3), mounted in the cab,
controls the current flow of the heater control circuit
board (A1). The heater control circuit board (A1)
controls the position of the cab heater control valve
(Y7). The position of the cab heater temperature
control valve (Y7) controls the amount of heated engine
coolant that passes through the heater core. When the
cab heater thermostat (R3) is set to a particular
position (i.e. 1/2), current flows from 001 red into the
heater control circuit board (A1). Current flows from the
heater control circuit board (A1) through 011 org and
012 red to the cab heater temperature control valve
(Y7) causing the valve to open or close. The polarity of
4 - 104 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
To K4 Accessory Relay
454 Yel
002 Red
A Off
010A Wht
B Low 008 Blu
013A Yel
S9 A, B, C C High
Blower X26
Back
Switch 9
(20)
Light
R3 X26
2B 3 Cab (17)
7 6 Indicator Heater Thermostat X26
Light (18)
005 Org 001B Red
003 Yel F5
87a
K7 Cab
X27 86 87 008 Blu
Cab Heater Heater
(C) Fuse
000B Blk 85 30 Relay
013A Yel
001A X25 X27 010A Wht
Red (A) (E)
001 Red
012 Red
004 Yel 004 Yel
011 Org
X27
X25 (B)
(B) X27
(D) 001C Red
000B Blk
005 Org
000A Blk
A B C D E F G H
000A Blk M A1
Heater Control
M3 Circuit Board 010B Wht
To Accessory Ground Blower
000B Blk 009 Grn 013B Yel
6 5 4 3 2 1
Y7
Cab Heater
From Battery Terminal of Starting Motor Temperature Control Valve
Thermostat Circuit
Control Circuit
Blower Circuit
Ground Circuit
KV31084
11/22/00 4 - 105
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
Test Conditions:
• Fully charged battery.
• Key switch in ACC position.
• Digital test meter set to read DC voltage.
• Meter negative (–) lead on battery negative (–)
terminal.
• Meter positive (+) lead on numbered test point.
• Check connections for corrosion and loose
terminals when testing.
1. Wire 003 yel on terminal 86 of Battery voltage. Test 003 yel wire between (K4) accessory
(K7) cab heater relay. relay and (K7) cab heater relay.
2. Wire 001C red on starter side Battery voltage. Test 001C red between (M1) starting motor
of (F5) cab heater fuse. and (F5) cab heater fuse.
3. Wire 001B red on (K7) cab Battery voltage. Replace (F5) cab heater fuse.
heater relay side of (F5) cab
heater fuse.
4. Wire 001B at terminal 87 on Battery voltage. Test 001B red between (F5) cab heater fuse
(K7) cab heater relay. and (K7) cab heater relay.
5. Wire 001A red at terminal 30 Battery voltage. Test ground circuit wire 000B blk from (K7) cab
on (K7) cab heater relay. heater relay to ground. If good, replace relay.
6. Wire 001A red at terminal 2B Battery voltage. Test Wire 001A red from (K7) cab heater relay
on (S9) blower switch. to (S9) blower switch including terminals in
X25 cab heater engine harness-to-ROPS
harness connector.
Test Conditions:
• Blower switch in HIGH position.
7. Wire 005 org at terminal 6 on Battery voltage. Replace (S9) blower switch.
(S9) blower switch.
8. Wire 005 org on (M3) blower. Battery voltage. Test wire 005 org from (S9) blower switch to
Blower operating at high (M3) blower including terminals in X27 cab
speed. heater ROPS harness-to-heater harness main
connector.
If blower is not operating, test ground circuit
wire 000A from blower to ground. If good,
replace blower.
4 - 106 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
Test Conditions:
• Blower switch in LOW position.
9. Wire 004 yel at terminal 3 on Battery voltage. Replace (S9) blower switch.
(S9) blower switch.
10. Wire 004 yel on (M3) blower. Battery voltage. Test wire 004 yel from (S9) blower switch to
Blower operating at low (M3) blower including terminals in X27 cab
speed. heater ROPS harness-to-heater harness main
connector.
If blower is not operating, test 000A blk ground
circuit from blower to ground. If good, replace
blower.
Test Conditions:
• Blower Switch in OFF position.
• Negative (–) test lead at terminal A (blk) on (A1)
heater control circuit board.
• Positive (+) test lead on numbered test point.
11. Wire 001 red at terminal D on Battery voltage. Test wire 001 red and 001A red from (A1)
(A1) heater control circuit board. heater control circuit board to terminal 87 on
(K7) cab heater relay including terminals in
connectors X25 and X27.
12. Wire 013B yel at terminal C Minimum 8.2 V. Test ground wire 000B blk from terminal A on
on (A1) heater control circuit (A1) heater control circuit board to ground. If
board. good replace heater control circuit board.
13. Wire 013B yel at terminal 2 Same reading as step 12. Test wire 013B yel from (A1) heater control
on (Y7) cab heater temperature circuit board to (Y7) cab heater temperature
control valve. control valve.
Test Conditions:
• Negative (–) test lead at wire 010A wht on (R3) cab
heater thermostat.
• Positive (+) test lead on numbered test point.
14. Wire 013A yel at (R3) cab Minimum 8.2 V. Test 013A yel from (R3) cab heater thermostat
heater thermostat connector. to (A1) heater control circuit board. If good,
replace (A1) heater control circuit board.
15. Wire 002 red at (R3) cab Battery voltage. Test wire 002 red from (R3) cab heater
heater thermostat connector. thermostat to (S9) blower switch. If good,
replace (S9) blower switch.
16. Wire 008 blu at (R3) cab Reading should smoothly Replace (R3) cab heater thermostat.
heater thermostat connector. decrease from 8.5 V to
Slowly rotate thermostat from 0 V (approx).
HOTTEST to COLDEST setting.
11/22/00 4 - 107
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
Test Conditions:
• Negative (–) test lead at terminal B (wht) on (A1)
heater control circuit board.
• Positive (+) test lead on numbered test point.
17. Wire 008 blu at terminal H on Same reading as step 16. Test wire 008 blu from (R3) cab heater
(A1) heater control circuit board. thermostat to (A1) heater control circuit board.
Test Conditions:
• Cab thermostat set to medium temperature.
• Positive (+) test lead at terminal 6 (red) and
negative (–) lead at terminal 4 (org) on the cab
heater temperature control valve.
18. Set (R3) cab heater Minus (–) 10.5 V Replace (A1) heater control circuit board.
thermostat to COLDEST setting (approximately)
and observe meter.
19. Set (R3) cab heater Plus (+) 10.5 V Replace (A1) heater control circuit board.
thermostat to HOTTEST setting (approximately)
and observe meter.
20. Rotate (R3) cab heater Minus (–) 10.5 V (approx.) Go to step 24.
thermostat from HOTTEST to 1/4 until (Y7) cab heater
COLDEST setting and observe temperature control valve
meter. reaches position, then to
0 V (approx).
21. Rotate (R3) cab heater Plus (+) 10.5 V (approx.) Go to step 24.
thermostat to 3/4 HOTTEST until (Y7) cab heater
setting and observe meter. temperature control valve
reaches position, then to
0 V (approx).
Test Conditions:
• Negative (–) test lead at terminal A (blk) on (A1)
heater control circuit board.
• Positive (+) test lead on numbered test point.
22. Wire 009 grn at terminal 1 on Reading should smoothly Replace (Y7) cab heater temperature control
(Y7) cab heater temperature decrease to 0.5 V valve.
control valve. Rotate (R3) cab (approx). Listen for (Y7)
heater thermostat to COLDEST cab heater temperature
setting. control valve motor
running.
23. Wire 009 grn at terminal 1 on Reading should smoothly Replace (Y7) cab heater temperature control
(Y7) cab heater temperature increase to 8 V (approx). valve.
control valve. Rotate (R3) cab Listen for (Y7) cab heater
heater thermostat to HOTTEST temperature control valve
setting. motor running.
KV31058
4 - 108 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
Test Conditions:
• Failure of steps 20 or 21.
• Jumper wire connected to 009 grn at terminal G on
(A1) heater control circuit board.
24. Connect jumper first to 013B Listen. (Y7) Cab heater temperature If valve motor runs, replace (Y7) cab
yel (terminal C), then to 010B wht control valve motor should run. heater temperature control valve
(terminal B) on (A1) heater assy.
control circuit board. If valve motor does not run, replace
(A1) heater control circuit board.
Repeat steps 18—23 after repair.
11/22/00 4 - 109
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
10 18 19 20 21
8
M3
Blower 45
6 22
1
Y7
32 23
Cab Heater
Temperature
Control Valve
13
12 11 17
011 Org
012 Red
009 Grn 013B Yel
H 010B Wht
A1 DE
FG
C
Heater Control A
B
Circuit Board 24
7 15
6
9
14
004 Yel
X27
A
Cab Heater ROPS F B
E C
Harness-to-Heater D
005 Org
Harness Main 001A Red
Connector
000B Blk
001A Red
F5
Cab Heater Fuse
001B Red 15 A
5
4 M1
Starting Motor
001C Red
000B Blk
000A Blk 3 2 KV31046
4 - 110 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
Function:
To provide an audible warning when the machine is
operating in reverse.
Operating Conditions:
The key switch (S1) must be in the RUN or
ACCESSORY position and both steering control levers
must be in reverse.
Theory of Operation:
Power is supplied by the closed contacts of the
accessory relay to the accessory connector (X11).
When the steering control levers are both placed in
REVERSE position, linkages move the corresponding
hydrostatic pump control levers, and close the contacts
in both backup alarm switches (S10) and (S11). With
both switches closed, current flows from X11 through
the 10 Amp backup alarm fuse (F6) (located near the
accessory connector) through backup alarm switch
(rear) (S10), through backup alarm switch (front) (S11),
and to the positive (+) terminal on the warning horn.
The negative terminal of the warning horn is connected
to ground through the accessory ground connector
(X22). The backup alarm (H2) is mounted on the cover
just behind the cab rear window.
Each switch is mounted to a centering plate bracket;
one on the front pump and one on the rear pump.
When the hydrostatic control lever is moved into the
REVERSE position, the plunger of the switch is
depressed and the contacts are closed.
The switches are connected in series, meaning that
both switches must be closed for current to pass. When
both hydrostatic control levers are in the REVERSE
position, current passes through both switches and to
the warning horn, causing the horn to sound. Circuitry
within the horn causes the sound to be interrupted in a
BEEP BEEP manner.
11/22/00 4 - 111
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
458 Yel
H2
Backup Alarm
101 Blk
S11
Backup Alarm
Switch (Front)
457 Yel
S10
Backup Alarm
Switch (Rear)
450 Yel
F6
X11 Backup
12-Volt Alarm Fuse
Accessory 10 Amp
(Frame)
454 Yel 455 Yel
X22 Accessory
Ground Connector (Frame)
KV31057
4 - 112 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
1. Wire 455 yel on X11 side of Battery voltage. Check accessory relay circuit.
(F6) backup alarm fuse.
2. Wire 450 yel on reverse horn Battery voltage. Replace (F6) backup alarm fuse.
side of (F6) backup alarm fuse.
3. Wire 450 yel at (S10) backup Battery voltage. Test wire 450 yel between (F6) backup alarm
alarm switch (rear). fuse and (S10) backup alarm switch (rear).
Test Conditions:
• Depress plunger on (S10) backup alarm switch
(rear).
4. Wire 457 yel at (S10) backup Battery voltage. Replace (S10) backup alarm switch (rear).
alarm switch (rear).
5. Wire 457 yel on (S11) backup Battery voltage. Test wire 457 yel between (S10) backup alarm
alarm switch (front). switch (rear) and (S11) backup alarm switch
(front). If good, replace (S10) backup alarm
switch (rear).
Test Conditions:
• Depress plunger on (S11) backup alarm switch
(front) and on (S10) backup alarm switch (rear).
6. Wire 458 yel on (S11) backup Battery voltage. Replace (S11) backup alarm switch (front).
alarm switch (front).
7. Wire 458 yel on Backup Alarm Battery voltage, Backup Test 458 yel between (S11) backup alarm
(H2). Alarm sounding. switch (front) and (H1) backup alarm. If alarm
is not sounding, test wire 101 blk from (H1)
backup alarm to ground. If good, replace (H1)
backup alarm.
11/22/00 4 - 113
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
H2
7 Backup Alarm
458
Yel
6 S11
101 Blk Backup Alarm
Switch (Front)
5
457
X22 4 Yel
S10
Accessory
Backup Alarm
Ground Connector
Switch (Rear)
2
3
1
450
116 Blk Yel
455 F6
K4 Yel Backup Alarm Fuse
Accessory
Relay 450
Yel/Wht X11
101 Blk Accessory
110 Blk
12 V Connector
454
Yel
100 Blk
From S1
Key Switch
From F1
G2 Alternator Accessories Fuse
4 - 114 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
Function:
To provide a means of cleaning the windshield of cab
door. It incorporates both wiper and wiper/washer
functions.
Operating Conditions:
The key switch (S1) must be in the RUN or
ACCESSORY position and the wiper/washer switch
(S12) must be in the WIPER or WASHER position for
the wiper to operate. Wiper/washer switch (S12) must
be in the momentary WASHER position for the washer
to operate.
Theory of Operation:
Power is supplied by the closed contacts of the
accessory relay (K4), through wires 450, 451, and 453
yel/wht to terminal C of the interlock connector (X99).
Wire 460 yel connects from terminal C of the interlock
connector (X99) to terminal 5B of the wiper/washer
switch (S12). Wire 466 yel connects from terminal 5B
of the wiper/washer switch (S12) to terminal 5 on the
wiper motor (M4) to provide power for the self-parking
feature.
When wiper/washer switch (S12) is in the WIPER
(center) position, current flows through S12 from
terminal 5B to 2B, through wire 461 yel/wht to the ’run
terminal’ 6 on the wiper motor (M4). Current then flows
through the wiper motor (M4), through terminal 2, and
through wires 110 blk and 101 blk to the accessory
ground connector (X22) of the main ROPS harness.
When wiper/washer switch (S12) is turned OFF, power
continues to flow through wire 466 yel to ’park terminal’
5 on the wiper motor (M4), through the parking disk to
’park terminal’ 4, through wire 465 yel/red to terminal 1
of the wiper washer switch. Terminal 1 is internally
connected to terminal 2B, which is in turn connected
through wire 461 yel/wht to the ’run terminal’ 6 on the
wiper motor (M4). The parking disk is a rotating contact
with a gap in the contact surface. When the gap is
reached, current stops flowing and the wiper motor
(M4) stops.
The washer pump (M5) is activated by the momentary
WASHER (top) position of the wiper/washer switch
(S12). When the washer function is activated on wiper/
washer switch (S12), terminals 5B and 6 are connected
and current flows through wire 463 yel/blk to washer
pump (M5) terminal B. The ground circuit is provided
by wires 112 blk and 101 blk to the accessory ground
connector (X22) on the main ROPS harness. The
washer pump (M5) pushes fluid through a small hose
to the wiper arm until the wiper/washer switch (S12) is
released.
11/22/00 4 - 115
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
A Off
S12 B Wiper
Wiper/Washer Back
C Washer
Swith Light
7 111 Blk
From K4 460 Yel 5B
AccessoryRelay 6 463 Yel/Blk
1 465 Yel/Red
2B
10
462
Yel
466 Yel Indicator
461 Light
Yel/Wht
463
Yel/Blk
M4
465 Yel/Red Wiper Motor
4
466 Yel 5 M
6
461 2
Yel/Wht
110
Blk
B
M5 W
Washer Pump
A
111
Blk 101
112 Blk
Blk
To X12
101 Blk
Accessory
Ground Connector
Park Circuit
Washer Circuit
Ground Circuit
KV31057
4 - 116 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
1. Wire 460 yel at terminal C on Battery voltage. Check accessory relay circuit to
(X99) interlock connector. (X99) interlock connector.
2. Wire 460 yel at terminal 5B on Battery voltage. Test wire 460 yel.
(S12) wiper/washer switch.
3. Wire 466 yel at terminal 5 on Battery voltage. Test wire 466 yel from (S12) wiper/
(M4) wiper motor. washer switch to (M4) wiper motor.
Test Conditions:
• Turn (S12) wiper/washer switch (12) to WIPER
(center) position.
4. Wire 461 yel/wht at terminal Battery voltage. Replace (S12) wiper/washer switch.
2B on (S12) wiper/washer switch.
5. Wire 461 yel/wht at terminal 6 Battery voltage. Test wire 461 yel/wht between (S12)
on (M4) wiper motor. Wiper motor should be operating. wiper/washer switch and (M4) wiper
motor. If good, Test wires 110 blk
and 101 blk to verify ground circuit.
If good, replace (M4) wiper motor.
11/22/00 4 - 117
THEORY OF OPERATION AND DIAGNOSIS ELECTRICAL
Test Conditions:
• Turn (S12) wiper/washer switch to the WASHER
(top) position.
6. Wire 463 yel/blk at terminal 6 Battery voltage. Replace (S12) wiper/washer switch.
on (S12) wiper/washer switch.
7. Wire 463 yel/blk at terminal B Battery voltage. If no voltage is present, test wire
on washer pump. (M5) washer pump should be 463 yel/blk.
running. If voltage is present but (M5)
Fluid should be discharging at wiper. washer pump is not running, test
wires 112 blk and 101 blk to verify
ground circuit. If good, replace (M5)
washer pump.
If (M5) washer pump runs but no
fluid discharges at wiper:
• Verify that reservoir has fluid.
• Verify that hose and fittings are not
plugged or broken.
• If both are good, replace (M5)
washer pump.
Test Conditions:
• Turn (S12) wiper/washer switch to the OFF
position.
8. Wire 465 yel/red at terminal 4 Battery voltage (while motor is If no voltage is present and motor
on (M4) wiper motor. operating). Motor should run until stops immediately, replace (M4)
wiper is in parked position. wiper motor.
If wiper parks in the wrong position, If voltage is present and wiper
adjust location of wiper arm on (M4) motor stops immediately, go to step
wiper motor shaft. 9.
9. Wire 465 yel/red at terminal 1 Battery voltage (while motor is Test wire 465 yel/red between (M4)
on (S12) wiper/washer switch. operating). Motor should run until wiper motor and (S12) wiper/
wiper is in parked position. washer switch. If good, go to step
10.
10. Wire 461 yel/wht at terminal Battery voltage (while motor is If no voltage is present, replace
2B on (S12) wiper/washer switch. operating). Motor should run until (S12) wiper/washer switch.
wiper is in parked position.
4 - 118 11/22/00
ELECTRICAL THEORY OF OPERATION AND DIAGNOSIS
M4
Wiper Motor
461 Yel/Wht
466 Yel
465 Yel/Red 8 3
S12
466 Yel
Wiper/Washer
Switch
9
465 Yel/Red
110 Blk
4 10
461 Yel/Wht X33
Door Switch
2 Harness Connector
111 Blk
6 466 Yel
463
Yel/Blk
112 Blk
470 Dk Grn
101 Blk
X99
Interlock Connector
1 7
M5
Washer
Pump
From K4
Accessory Relay
X12
Accessory Ground
Connector
11/22/00 4 - 119
TESTS AND ADJUSTMENTS ELECTRICAL
BATTERY TEST
Reason:
To check condition of battery and determine battery
voltage.
Equipment:
• Hydrometer
• Voltmeter or JT05685 Battery Tester
Procedure:
1. Remove any attachments.
2. Park machine on level surface. Raise boom fully
and ENGAGE the boom lock.
3. Turn key OFF and ENGAGE park brake. M49596
4. Open engine rear cover and remove left engine side 11. Use a hydrometer to check for a minimum specific
panel. gravity of 1.225 with less than 50 point
5. Disconnect negative (–) and positive (+) cable variation in each cell:
clamps from battery. Remove battery hold-down
clamp.
6. Remove battery from machine. Results:
7. Clean battery terminals and case. • If all cells are less than 1.175, charge battery at 10
8. Inspect battery terminals and case for breakage or amp rate. (See CHARGE BATTERY in this
cracks. section.)
9. Check electrolyte level in each battery cell. Add • If all cells are less than 1.225 with less than 50
clean, distilled water as needed. If water was point variation, charge battery at 10 amp rate. (See
added, charge battery for 20 minutes at 10 amps. CHARGE BATTERY in this section.)
(See CHARGE BATTERY in this section.) • If cells are above 1.225 with less than 50 point
10. Remove surface charge by placing a small load on variation, load test battery. (See BATTERY LOAD
the battery for 15 seconds. TEST in this section.)
• If more than 50 point variation, replace battery.
12. Use a voltmeter or JT05685 Battery Tester to check
for a minimum battery voltage of 12.4 volts:
• If battery voltage is less than 12.4 VDC, charge
battery. (See CHARGE BATTERY in this section.)
• If voltage is above 12.4 VDC, test specific gravity.
(See step 9.)
13. Install battery.
14. Install left engine side panel and close engine
cover.
4 - 120 11/22/00
ELECTRICAL TESTS AND ADJUSTMENTS
CHARGE BATTERY
11/22/00 4 - 121
TESTS AND ADJUSTMENTS ELECTRICAL
Results:
• If battery DOES NOT pass test and has NOT been
charged, charge battery and retest. (See CHARGE
BATTERY in this section.)
• If battery DOES NOT pass test and HAS been
charged, replace the battery.
13. Install left engine side panel and close engine
cover.
M49597
4 - 122 11/22/00
ELECTRICAL TESTS AND ADJUSTMENTS
Procedure:
10. Turn load knob off (fully counterclockwise).
1. Park machine on level surface. Lower boom to the
at-rest position. Turn key to OFF position and 11. Let engine run and watch when current gun reading
ENGAGE park brake. is 10 amps or less.
2. Be sure battery is fully charged and all accessories 12. Read and record meter voltage.
are off.
3. Open engine rear cover and remove left engine side Results:
panel.
4. Turn load knob of battery tester off (fully • If alternator current output or regulated voltage is
counterclockwise). not to specifications, repair or replace alternator.
(See ALTERNATOR in ENGINE section.)
5. Connect red battery tester clamp to positive (+) post
of battery. 13. Install left engine side panel and close engine
cover.
6. Connect black battery tester clamp to negative (–)
post of battery.
11/22/00 4 - 123
TESTS AND ADJUSTMENTS ELECTRICAL
KV15226
Reason: Procedure:
To determine the amperage required to crank the 1. Remove any attachments.
engine and check starting motor operation under load. 2. Park machine on level surface. Raise boom fully
and ENGAGE the boom lock.
3. Turn key to OFF position and ENGAGE park brake.
Equipment:
4. Open engine rear cover and remove both engine
• JT05685 Load Tester side panels.
• JT05719 Tachometer 5. Turn load knob fully counterclockwise.
6. Connect load tester red cable to positive (+)
terminal on battery.
Specification:
7. Connect load tester black cable to negative (–)
Starting Motor Loaded (on Vehicle) terminal.
Draw/Voltage. . . . . . . . . . . . . . . . . 350 amps (max) 8. Disconnect fuel shut-off solenoid wire from pump.
8.5 volts (min) @ 0°C (32°F) 9. Check system ground connections. Be sure battery
is fully charged.
10. Crank engine. Read and record voltage at meter.
c CAUTION 11. Use tachometer to read and record cranking rpm.
12. Turn key switch to OFF position. Adjust load knob
until battery voltage is the same as when engine is
Disconnect fuel shutoff solenoid wiring to cranking. Read and record amperage on meter.
prevent engine from starting. 13. Turn load knob fully counterclockwise.
4 - 124 11/22/00
ELECTRICAL TESTS AND ADJUSTMENTS
11/22/00 4 - 125
TESTS AND ADJUSTMENTS ELECTRICAL
STARTING MOTOR SOLENOID TEST 11. Disconnect one of the jumper wires.
Results:
Reason: The solenoid drive gear should move back.
To determine if starting motor solenoid is defective.
Equipment:
• Two jumper wires
c CAUTION
• 12-volt battery Ensure all power is disconnected from starting
motor. Drive gear could move suddenly, causing
injury.
Procedure:
1. Remove any attachments. 12. If drive gear does not move, make sure jumper
2. Park machine on level surface. Raise boom fully wires are disconnected and try to pull drive gear
and engage the boom lock. out by hand by rotating counterclockwise.
3. Turn key to OFF position and engage park brake. 13. If drive gear cannot be pulled out, check solenoid
4. Open engine rear cover and remove left engine side plunger and shaft for binding.
panels. 14. If drive gear moves out freely but solenoid does not
5. Disconnect negative (–) battery cable clamp from energize, check resistance between solenoid
battery. terminal and metal housing of solenoid.
6. Remove and tag all wires to the starting motor.
7. Remove starting motor from engine and mount on Results:
bench. (See STARTING MOTOR REMOVAL/ Maximum resistance should be 1.0 ohm through
INSTALLATION.) solenoid coil. Replace solenoid if open circuit is
indicated.
A
15. Connect starting motor lead (A) to terminal (B).
16. Remove jumper wire from starting motor housing
B and negative (–) terminal post on battery.
17. Install starting motor.
C 18. Install left engine side panel and close engine
cover.
CD30452A
Results:
The solenoid should pull in freely with a loud click,
causing the starting motor drive gear to move fully out
to the end of shaft and stay there.
4 - 126 1/3/01
ELECTRICAL TESTS AND ADJUSTMENTS
Reason: Reason:
To determine if air filter restriction switch is detecting air To check operation of coolant temperature sender/
flow resistance through air filter. overheat switch.
Procedure: Equipment:
1. Park skid steer on flat level surface and engage • JT05791 Digital Multimeter
park brake switch.
2. Start and operate engine at low idle.
Procedure:
3. Open engine rear cover.
1. Park machine on level surface. Lower boom to the
at-rest position. Turn key to OFF position and
ENGAGE park brake.
2. Open engine rear cover.
KV15246
KV15200
11/22/00 4 - 127
TESTS AND ADJUSTMENTS ELECTRICAL
KV15201
Results:
• If continuity is indicated, replace cold weather start
switch.
• If no continuity is indicated, switch is good.
8. Install cold weather start switch into thermostat
housing. Tighten switch to 5 N•m (42 lb-in.).
9. Connect cold weather start switch wire connector.
4 - 128 11/22/00
ELECTRICAL TESTS AND ADJUSTMENTS
A
A
B
B
C KV15202
KV15211
5. Disconnect battery, negative (–) cable first.
5. Disconnect battery, negative (–) cable first. 6. Remove nut and washer (A) and wire lead (B) from
6. Remove wire leads (A and B) from oil pressure pre-heater (C).
switch (C). 7. Check resistance between terminal and engine
7. Check for resistance between terminal marked “G” block. Reading should be 0.70—1.65 ohms
and the engine block. Value should be 5—13 ohms
at 0 kPa (0 psi). Results:
8. Check for resistance (maximum 0.1 ohms) between • Replace manifold pre-heater if reading is incorrect.
terminal “WK” and engine block.
8. Install pre-heater and tighten to 60 N•m (44 lb-ft).
NOTE: Resistance will change if there is pressure. 9. Connect wire lead and install washer and nut.
10. Connect battery.
Results:
• Replace oil pressure switch if resistance readings
are incorrect.
11/22/00 4 - 129
TESTS AND ADJUSTMENTS ELECTRICAL
MANIFOLD PREHEATER RELAY 8. Connect a jumper wire from battery positive (+) post
to one small terminal. Connect a jumper wire from
TEST the other small terminal to negative (–) post.
Continuity should now exist between the two large
terminals (F).
Reason:
To check operation of manifold pre-heater relay.
Results:
• If continuity is not correct, replace manifold pre-
Equipment: heater relay.
• JT05791 Digital Multimeter 9. Connect leads, cap screws, and washers.
10. Connect battery, positive (+) cable first.
Procedure: 11. Lower ROPS. Tighten ROPS retaining nuts to
105 N•m (77 lb-ft).
C
B
C A
D KV15203
KV15247
E
4 - 130 11/22/00
ELECTRICAL TESTS AND ADJUSTMENTS
Reason: Reason:
To check operation of ignition key switch. To check operation of park brake switch.
Equipment: Equipment:
• JT05791 Digital Multimeter • JT05791 Digital Multimeter
Procedure: Procedure:
A
B 3 2B
6 1
C
D 9
5B
E
7
KV15248 KV15248
1. Disconnect battery, negative (–) cable first. 1. Disconnect battery, negative (–) cable first.
2. Remove key switch from control panel. 2. Remove park brake switch from control panel.
3. Use multimeter to check continuity between switch 3. Use multimeter to check continuity between switch
terminals (A—E) in the ACCESSORY, OFF, RUN terminals in the positions as shown in the table.
and START positions.
Results:
Results:
• If continuity is not correct, replace park brake
• If continuity is not present between terminals listed switch.
for each key switch position, replace key switch.
• If continuity exists between terminals not listed for
each switch position, replace key switch.
11/22/00 4 - 131
TESTS AND ADJUSTMENTS ELECTRICAL
Reason: Reason:
To check operation of cold start switch. To check operation of light switch.
Equipment: Equipment:
• JT05791 Digital Multimeter • JT05791 Digital Multimeter
Procedure: Procedure:
7 4
9 5B
7 9 6
8
1
2B
2B
KV1550 3
1. Disconnect battery, negative (–) cable first. 1. Disconnect battery, negative (–) cable first.
2. Remove cold start switch from control panel. 2. Remove light switch from control panel.
3. Use multimeter to check continuity between switch 3. Use multimeter to check continuity between switch
terminals in the positions as shown in the table. terminals in the positions as shown in the table.
4 - 132 11/22/00
ELECTRICAL TESTS AND ADJUSTMENTS
Reason: Reason:
To check operation of cab door switch. To check operation of dual flasher switch.
Equipment: Equipment:
• JT05791 Digital Multimeter • JT05791 Digital Multimeter
Procedure: Procedure:
7
9
Plunger
8
KV31131 2B
3
Out YES
In NO
Results:
• If continuity is not correct, replace switch.
11/22/00 4 - 133
TESTS AND ADJUSTMENTS ELECTRICAL
Reason: Reason:
To check operation of high-flow switch. To check operation of blower switch.
Equipment: Equipment:
• JT05791 Digital Multimeter • JT05791 Digital Multimeter
Procedure: Procedure:
7 4 7 4 5B
5B 9 6
9 6 8
8
1
1
2B
2B 3
3 KV31133 KV31134
1. Disconnect battery, negative (–) cable first. 1. Disconnect battery, negative (–) cable first.
2. Remove high-flow switch from control panel. 2. Remove blower switch from control panel.
3. Use multimeter to check continuity between switch 3. Use multimeter to check continuity between switch
terminals in the positions as shown in the table. terminals in the positions as shown in the table.
Results: Results:
• If continuity is not correct, replace switch. • If continuity is not correct, replace switch.
4 - 134 11/22/00
ELECTRICAL TESTS AND ADJUSTMENTS
Reason: Reason:
To check operation of wiper/washer switch. To determine if fuel level sender is changing resistance
as float is raised and lowered.
Equipment:
• JT05791 Digital Multimeter Equipment:
• JT05791 Digital Multimeter
Procedure:
Procedure:
7 4
5B
9 6
B
8
1
A
2B 10
3
KV31135
Results: E
• If continuity is not correct, replace switch. KV15213
11/22/00 4 - 135
TESTS AND ADJUSTMENTS ELECTRICAL
Equipment:
• JT05791 Digital Multimeter
Procedure:
KV15252
A
5. Connect leads from JT05791 Digital Multimeter to
posts on sender. Set meter to read ohms.
B
6. Hold fuel sender upright so float arm is resting on
KV15253
bottom stop (empty tank position). Note meter
reading.
1. Remove seat safety switch from under seat and
7. Holding fuel sender upright, lift float arm up against disconnect wiring connector.
upper stop (full tank position). Note meter reading.
2. Check continuity between terminals (A and B) with
switch released and depressed.
Results:
• The resistance of the fuel level sender is as follows: SEAT SAFETY SWITCH CONTINUITY
Continuity Between
FUEL LEVEL SENDER Switch Position
Terminals
Resistance Released No
Tank Fuel Level
(Ohms)
Depressed Yes
Full 30.0 ± 3
1/2 89.3 ± 3
Results:
Empty 248.2 ± 3 • If continuity is not correct, replace switch.
4 - 136 11/22/00
ELECTRICAL TESTS AND ADJUSTMENTS
Procedure:
Equipment:
• JT05791 Digital Multimeter
Procedure:
Unlatched
A
B
KV15219
11/22/00 4 - 137
TESTS AND ADJUSTMENTS ELECTRICAL
6. Install hydraulic oil overtemperature switch and BOOM LOCKOUT SOLENOID TEST
connect wiring connector.
Reason: Procedure:
A
A B
KV31136
4 - 138 11/22/00
ELECTRICAL TESTS AND ADJUSTMENTS
Reason: Reason:
To check operation of park brake solenoid. To check operation of hydraulic oil filter restriction
switch.
Equipment:
• Two jumper wires Equipment:
• JT05791 Digital Multimeter
(set to read continuity)
Procedure:
1. Remove any attachments.
Procedure:
2. Park machine on level surface. Raise boom fully
and ENGAGE the boom lock.
3. Turn key to OFF position and ENGAGE park brake.
4. Raise ROPS and ensure ROPS is safely in the
locked position. (See RAISING ROPS A
[ROLLOVER PROTECTION STRUCTURE] in the
MISCELLANEOUS section.)
5. Remove cover plates. (See COVER PLATE
REMOVAL/INSTALLATION in the B
MISCELLANEOUS section.)
C
KV15221
Results: Results:
• If solenoid does not “click”, replace solenoid. • If continuity is indicated at any time as pressure
rises to 248.2 kPa (36 psi), replace switch.
10. Install cover plates. (See COVER PLATE • Continuity should be indicated above 248.2 kPa
REMOVAL/INSTALLATION in the (36 psi). If no continuity is indicated, replace
MISCELLANEOUS section.) switch.
11. Lower ROPS. Tighten ROPS retaining nuts to 105 8. Lower ROPS. Tighten ROPS retaining nuts to 105
N•m (77 lb-ft). N•m (77 lb-ft).
11/22/00 4 - 139
COMPONENT REPLACEMENT ELECTRICAL
COMPONENT REPLACEMENT
COOLANT TEMPERATURE
SENDER/SWITCH
Replace:
1. Park machine on a level surface. Turn key to OFF A
position and ENGAGE park brake.
2. Raise ROPS and ensure ROPS is safely in the
locked position. (See RAISING ROPS KV15201
[ROLLOVER PROTECTION STRUCTURE] in the
MISCELLANEOUS section.) 4. Disconnect wiring connector (A) and remove cold
3. Disconnect battery, negative (–) cable first. weather start switch (B) located on side of
thermostat housing.
5. Apply pipe sealant with TEFLON to threads of
switch before installation.
4 - 140 11/22/00
ELECTRICAL COMPONENT REPLACEMENT
KV15211
MANIFOLD PREHEATER
Replace:
1. Park machine on a level surface. Turn key to OFF
position and ENGAGE park brake.
2. Raise ROPS and ensure ROPS is safely in the
locked position. (See RAISING ROPS
[ROLLOVER PROTECTION STRUCTURE] in the
MISCELLANEOUS section.)
3. Disconnect battery, negative (–) cable first.
11/22/00 4 - 141
COMPONENT REPLACEMENT ELECTRICAL
C
B
C A
D KV15203
4 - 142 11/22/00
ELECTRICAL COMPONENT REPLACEMENT
A B C D E F G H I J
KV18865
A. Heater Blower (Optional) F. Work Lights
B. Air Conditioner (Optional) G. Instrument Cluster
C. Windshield Wiper/Washer (Optional) H. Cold Start
D. Dual Flasher (Optional) I. Park Brake
E. High-Flow (Optional) J. Key Switch
KEY SWITCH
Replace:
1. Park skid steer on flat level surface. Lower boom to
the at-rest ground position, engage park brake
switch and turn engine off.
2. Disconnect battery, negative (–) cable first. C
B
B KV15204
KV15205
11/22/00 4 - 143
COMPONENT REPLACEMENT ELECTRICAL
A A
KV15204
3. Remove six screws (A) and pull bezel away from KV18862
headliner.
C KV15206
KV18863
4 - 144 11/22/00
ELECTRICAL COMPONENT REPLACEMENT
D D
B B
C
KV15209
KV15210
Replace:
1. Park machine on a level surface. Turn key to OFF FUEL LEVEL SENDER
position and ENGAGE park brake.
2. Disconnect battery, negative (–) cable first.
Replace:
1. Park machine on a level surface. Turn key to OFF
position and ENGAGE park brake.
2. Raise ROPS and ensure ROPS is safely in the
locked position. (See RAISING ROPS
[ROLLOVER PROTECTION STRUCTURE] in the
MISCELLANEOUS section.)
3. Disconnect battery, negative (–) cable first.
A A
KV15204
11/22/00 4 - 145
COMPONENT REPLACEMENT ELECTRICAL
KV15212
KV15214
4. Access fuel level sender on top of fuel tank.
3. Remove two nuts (A) on each side of seat support.
NOTE: Tag fuel lines to aid during installation. 4. Lift seat and support upward off adjustment rails to
access seat safety switch.
D C
KV15215
Replace:
1. Park machine on a level surface. Turn key to OFF
position and ENGAGE park brake.
2. Disconnect battery, negative (–) cable first.
4 - 146 11/22/00
ELECTRICAL COMPONENT REPLACEMENT
Replace: Remove/Install:
1. Park machine on a level surface. Turn key to OFF 1. Park machine on a level surface. Turn key to OFF
position and ENGAGE park brake. position and ENGAGE park brake.
2. Disconnect battery, negative (–) cable first. 2. Raise ROPS and ensure ROPS is safely in the
locked position. (See RAISING ROPS
[ROLLOVER PROTECTION STRUCTURE] in the
MISCELLANEOUS section.)
3. Remove left side engine panel.
4. Disconnect battery, negative (–) cable first.
B
KV15214
3. Remove the cap screw and nut (A) securing the KV15216
seat belt latch to the ROPS.
5. Remove nut (A) and cover (B) to access starter
4. Disconnect electrical connector.
wiring leads.
5. Connect electrical connector of new seat belt latch. .
C KV15217
11/22/00 4 - 147
COMPONENT REPLACEMENT ELECTRICAL
D B
C
KV15218
KV15219
NOTE: Tag or label wiring leads on alternator to aid
during installation.
4. Access hydraulic oil temperature sender (B) located
4. Disconnect wiring leads (A). Tag or label wiring on front of hydraulic reservoir.
leads to aid during installation.
5. Loosen nuts (B and C). NOTE: Hydraulic reservoir capacity is approximately
6. Move alternator (D) toward engine and lift belt off 15.6 L (4.1 gal).
pulley.
7. Remove alternator adjustment and pivot mounting
hardware. 5. Drain hydraulic oil from reservoir.
8. Remove alternator. Make repairs to alternator as 6. Disconnect wiring connector (A) and remove switch
necessary. (See ALTERNATOR in DIESEL (B).
ENGINE section). 7. Apply pipe sealant with TEFLON to threads of
9. Install alternator pivot and adjustment mounting switch before installation.
hardware. Do not tighten hardware at this time. 8. Install hydraulic oil temperature switch and connect
10. Adjust belt tension. (See CHECK FAN/ wiring connector.
ALTERNATOR BELT TENSION in DIESEL
ENGINE section.)
NOTE: Make sure hydraulic reservoir drain plug is
11. Connect wiring leads to alternator. installed.
12. Connect battery, positive (+) cable first.
13. Install left engine side panel.
9. Fill reservoir with proper hydraulic oil and check
level.
10. Connect battery, positive (+) cable first.
11. Lower ROPS. Tighten ROPS retaining nuts to 105
N•m (77 lb-ft).
4 - 148 11/22/00
ELECTRICAL COMPONENT REPLACEMENT
B
A
A B
KV15220
11/22/00 4 - 149
COMPONENT REPLACEMENT ELECTRICAL
Replace:
1. Park machine on level surface. Lower boom to the C
at-rest position. Turn key to OFF position and
E
ENGAGE park brake.
A
KV31077
KV31079
SWITCH
Replace:
1. Park machine on level surface. Lower boom to the 5. Remove screws (2 used) and lock nuts retaining
at-rest position. Turn key to OFF position and switch to bracket. Install new switch on original
ENGAGE park brake. bracket and tighten screws securely.
2. Raise ROPS and ensure ROPS is safely in the
locked position. (See RAISING ROPS
[ROLLOVER PROTECTION STRUCTURE] in the
MISCELLANEOUS section.)
4 - 150 11/22/00
ELECTRICAL COMPONENT REPLACEMENT
G
F
11/22/00 4 - 151
COMPONENT REPLACEMENT ELECTRICAL
4 - 152 11/22/00
POWER TRAIN (CHAINCASE AND AXLES) CONTENTS
CONTENTS
POWER TRAIN (CHAINCASE AND AXLES)
Page
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
POWER TRAIN COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHAIN CASE OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHAIN CASE ACCESS PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DRIVE CHAIN TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AXLE HOUSING REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AXLE HOUSING DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DRIVE CHAIN AND SPROCKET REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . 12
11/22/00 5-1
SPECIFICATIONS POWER TRAIN (CHAIN CASE AND AXLES)
SPECIFICATIONS
Drive Axles:
Wheel Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 N•m (175 lb-ft)
Mounting Nut Torque (Axle Housing to Chain Case) . . . . . . . . . . . . . 305 N•m (225 lb-ft)
Axle Spanner Lock Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . .340-408 N•m (250-300 lb-ft)
Axle Housing Lubrication (Before Installation)
John Deere TORQ-GARD SUPREME® or PLUS 50® . . . . . . . . . . . . . . 237 mL (8 oz)
Chain Case:
Access Plate Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . 70—80 N•m (52—59 lb-ft)
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4 L (3 gal) (Each Side)
Drive Chain:
Chain Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #80
Front Chain Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Links
Rear Chain Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Links
Chain Free Play Movement (Up and Down) . . . . . . . . . . . . . . . . . . . . . . 5 mm (0.197 in.)
Chain Tension (Movement at Tire Tread) . . . . . . . . . . . . . . . .0—6.35 mm (0—0.250 in.)
OTHER MATERIALS
SPECIAL TOOLS
HY-GARD, TORQ-GARD SUPREME and PLUS-50 are registered trademarks of Deere & Company.
5-2 1/3/01
POWER TRAIN (CHAIN CASE AND AXLES) POWER TRAIN COMPONENT LOCATION
Hydrostatic Motors
Chain Case
Front Axle Sprocket
Chain Case
Chain Case Access Plate
Rear Axle Sprocket
Level/Fill Plug
11/22/00 5-3
OPERATION POWER TRAIN (CHAIN CASE AND AXLES)
OPERATION
Drive Axles
Chain Case
KV13152
KV13157
The drive axles are attached to the chain case on eight
The chain case is also the skid steer side frame slotted mounting holes. The axle housing slides to
member. It is completely sealed from the other provide tension to the roller drive chain inside the chain
components of the skid steer and from the case. The splined axle shaft extends into the chain
environment. Left and right chain cases are identical. case where it is driven by a large roller chain sprocket.
Chain cases contain front and rear drive chains and The sprocket is allowed to slide freely on the splines of
sprockets. Each chain case has its own oil bath the axle shaft. The axle housing contains two tapered
lubrication system with an oil level/fill plug on the chain roller bearings in replaceable races. The axle bearings
case side access plate. All service to the components are lubricated by the oil bath in the chain case.
of each chain case may be accomplished through the
removable chain case side access plates.
5-4 11/22/00
POWER TRAIN (CHAIN CASE AND AXLES) TROUBLESHOOTING
TROUBLESHOOTING
Problem or
powered
housing
Inspect O-ring at chain case drain
●
plug
1/3/01 5-5
DIAGNOSIS POWER TRAIN (CHAIN CASE AND AXLES)
DIAGNOSIS
Test Conditions:
• Operator on seat, seat belt fastened.
• Engine running at fast idle.
• Park brake OFF.
1. Push both steering Skid steer moves forward in a straight Engine stalls, wheels locked or dragging:
control levers line with all wheels turning. See BRAKES section.
forward at an equal Slow or no power: go to step 4.
rate. One side of skid steer drags: go to step
2.
2. Pull both steering Skid steer moves backward in a straight Engine stalls, wheels locked or dragging:
control levers back at line with all wheels turning. See BRAKES section.
an equal rate. Slow or no power: go to step 4.
One side of skid steer drags: go to step
3.
Test Conditions:
• Roll bucket back.
• Lower boom to ground.
• Set park brake.
• Stop engine.
• Raise and block skid steer. (See RAISING AND BLOCKING SKID STEER in MISCELLANEOUS section.).
3. Rotate each tire by Tires move less than 6.35 mm Tires move more than 6.35 mm
hand. (0.250 in.) at tire tread. (0.250 in.): check chain tension for that
axle.
If normal, but skid steer continues to pull One tire rotates freely: drive chain or
to one side, go to step 4. sprocket broken for that axle or splines
stripped from sprocket.
Both tires on one side rotate together
freely: inspect hydrostatic motor, chain,
and brake/sprocket spline.
Test Conditions:
• Roll bucket back.
• Lower boom to ground.
• Raise and block skid steer. (See RAISING AND BLOCKING SKID STEER in MISCELLANEOUS section.)
• Start engine and run at a fast idle.
4. Move steering control Wheels and tires are driven smoothly for Chain noise: inspect drive chain.
levers forward and that steering control lever, and run at Slow on one side: see STEERING
reverse for each same rpm (use photo tachometer). section for steering control lever
side. adjustment; see HYDROSTATIC
POWER TRAIN section for hydrostatic
motor diagnostics.
5-6 1/3/01
POWER TRAIN (CHAIN CASE AND AXLES) DIAGNOSIS
Right Steering
Left Steering Control Lever
Control Lever
Front Axle
Sprocket
Front Drive
Chain
Right Drive
Shaft
Rear Drive
Chain
KV13934
1/3/01 5-7
REPAIR POWER TRAIN (CHAIN CASE AND AXLES)
REPAIR
KV13152
NOTE: The left and right side chain cases are not Chain Case
connected. Service each chain case Access Plate
individually.
KV13042
IMPORTANT: DO NOT use John Deere
4. Remove twelve cap screws holding the side access
BIO-HY-GARDTM in chain case.
plate to the chain case. Remove access plate.
5. Remove sealant from access plate and chain case.
3. Fill chain case with proper lubricant. The following
oils are PREFERRED:
Chain Case Side Access Plate Installation
• John Deere HY-GARD
• John Deere Low Viscosity HY-GARD 1. Clean mating surfaces of side access plate and
(cold weather operation) chain case.
• John Deere TORQ-GARD SUPREME 2. Install access plate using PM20166 John Deere
• John Deere PLUS-50 5900 RTV Silicone.
• Other Oil: API Service Classification SG or Higher 3. Tighten twelve chain case access plate cap screws
to 70—80 N•m (52—59 lb-ft).
4. Install all chain case fill and drain plugs.
CHAIN CASE ACCESS PLATE
It is necessary to remove the chain case access plate IMPORTANT: DO NOT use John Deere
to service drive chains, sprockets and drive shaft, and BIO-HY-GARDTM in chain case.
to access brake assembly mounting cap screws.
Chain Case Access Plate Removal 5. Fill chain case with proper lubricant. The following
oils are PREFERRED:
1. Park skid steer on flat level surface.
• John Deere HY-GARD
2. With boom and bucket lowered to the ground,
engage park brake switch, and turn engine off. • John Deere Low Viscosity HY-GARD
(cold weather operation)
• John Deere TORQ-GARD SUPREME
• John Deere PLUS-50
• Other Oil: API Service Classification SG or Higher
5-8 1/3/01
POWER TRAIN (CHAIN CASE AND AXLES) REPAIR
KV18785
Right Side of Skid Steer Shown. KV13157
6. Install a suitable lifting strap and hoist to aid during
removal of axle housing.
NOTE: Chain free play movement up and down should 7. Remove eight axle housing mounting nuts.
be 5 mm (0.197 in.).
1/3/01 5-9
REPAIR POWER TRAIN (CHAIN CASE AND AXLES)
Axle Housing Installation 11. Install wheels and tighten nuts to 237 N•m
(175 lb-ft).
1. Clean mating surfaces of axle housing and chain
case before installation. 12. Check chain case oil level after skid steer has been
driven and fill as necessary.
O-Ring
Pre-lubricate
AXLE HOUSING DISASSEMBLY/
Through ASSEMBLY
Bearing
Axle Disassembly
1. Remove axle housing to be serviced from skid
steer. (See AXLE HOUSING REMOVAL/
INSTALLATION.)
Tab KV15147
KV13155
5 - 10 1/3/01
POWER TRAIN (CHAIN CASE AND AXLES) REPAIR
KVP13933
Assembly:
1. If removed, install a new outer axle bearing over
axle with taper facing up.
2. Slide a piece of tubing over axle shaft and install
axle in arbor press. Support axle under center of 11. Press bearing on until it is 1—2 mm
hub so wheel bolts will not be pressed out when (0.039—0.079 in.) above shoulder on shaft.
pressure is applied. Use press to seat outer
bearing onto shoulder of axle shaft.
Washer
Seal
Tab Washer
KVP13935
KV13139
3. Inspect axle housing seal. If required, pry seal from
axle housing. 12. Install washer, tab washer, and lock nut.
13. Using a spanner wrench, tighten lock nut until
washer seats bearing and bottoms out on shoulder
NOTE: Always replace bearings as cone/outer-race of axle shaft. Tighten to a final torque of 340-408
sets. N•m (250-300 lb-ft)
14. Align tab slot with tab washer. Bend tab on tab
4. If outer bearing was removed, remove outer bearing washer into slot on lock nut.
race with a hammer and a punch. Install new outer 15. Install axle housing. (See AXLE HOUSING
bearing race in housing using a 4.4-in. (OD) driver. REMOVAL/INSTALLATION.)
1/3/01 5 - 11
REPAIR POWER TRAIN (CHAIN CASE AND AXLES)
DRIVE CHAIN AND SPROCKET 4. To remove rear axle sprocket, lift sprocket to top of
chain case. Pull bottom of sprocket out over
REMOVAL/INSTALLATION bottom lip of chain case and remove rear axle
1. Drain oil from chain case being serviced and sprocket.
remove chain case access plate. (See CHAIN
CASE ACCESS PLATE.)
NOTE: Front and rear drive chains are not repairable.
Replace chains if necessary.
NOTE: It is necessary to remove rear axle housing
Front Drive Chain
and rear drive chain from the drive shaft before
removing front drive chain.
Rear Drive 5. Slide front axle sprocket rearward and remove front
Front Drive
Chain Chain
drive chain from drive shaft and front sprocket.
6. If removal of drive shaft or front axle sprocket is
necessary, park brake must be loosened and
sprocket pushed toward center of machine to allow
clearance. (See BRAKE REMOVAL and
DISASSEMBLY in the BRAKES section.)
Drive Shaft 7. Installation is done in the reverse order of removal.
5 - 12 1/3/01
HYDROSTATIC POWER TRAIN CONTENTS
CONTENTS
HYDROSTATIC POWER TRAIN
Page
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TESTS AND ADJUSTMENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE PARTS KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HYDROSTATIC SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HYDROSTATIC COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . 6
HYDROSTATIC SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HYDRAULIC/CHARGE PUMP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HYDRAULIC/CHARGE PUMP FLOW TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
HYDROSTATIC PUMP HIGH PRESSURE RELIEF TEST . . . . . . . . . . . . . . . . . . . . 12
WHEEL SPEED TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HYDROSTATIC PUMP FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
HYDROSTATIC PUMP CASE DRAIN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HYDROSTATIC CASE DRAIN PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
START-UP PROCEDURE AFTER COMPONENT REPLACEMENT. . . . . . . . . . . . . 20
HYDROSTATIC PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FRONT HYDROSTATIC PUMP EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . 23
CENTER MANIFOLD EXPLODED VIEW (EARLY MODELS). . . . . . . . . . . . . . . . . . 24
CENTER MANIFOLD EXPLODED VIEW (LATE and CONVERTED MODELS) . . . . 25
REAR HYDROSTATIC PUMP EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
HYDROSTATIC PUMP DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
HYDROSTATIC PUMP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
HYDROSTATIC PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
HYDROSTATIC PUMP INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
HYDROSTATIC MOTOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 37
HYDROSTATIC MOTOR EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
HYDROSTATIC MOTOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
HYDROSTATIC MOTOR INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
HYDROSTATIC MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11/22/00 6-1
CONTENTS HYDROSTATIC POWER TRAIN
6-2 11/22/00
HYDROSTATIC POWER TRAIN SPECIFICATIONS
SPECIFICATIONS
TORQUE SPECIFICATIONS
Hydrostatic High Pressure Relief Valves. . . . . . . . . . . . . . . . . . . . . . 135 N•m (100 lb-ft)
Hydraulic/Charge Pump Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . 35 N•m (26 lb-ft)
Hydrostatic Pump-to-Center Manifold Cap Screws. . . . . . . . . . . . . . . . 56 N•m (41 lb-ft)
Hydrostatic Pump Mounting Flange-to-Flywheel Housing . . . . . . . . . 118 N•m (87 lb-ft)
Hydrostatic Pump Mounting Bracket-to-Hydrostatic Pump . . . . . . . . . 39 N•m (29 lb-ft)
Hydrostatic Pump Drive Hub Set Screws . . . . . . . . . . . . . . . . . . . . . . . 37 N•m (27 lb-ft)
Hydrostatic Pump Cover Plate Cap Screws . . . . . . . . . . . . . . . . . . . . . 41 N•m (30 lb-ft)
Centering Plate Mount Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 N•m (30 lb-ft)
Centering Plate Spring Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 N•m (50 lb-ft)
Centering Plate Guide Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft)
Control Rod Cap Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Hydrostatic Motor Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . 118 N•m (87 lb-ft)
Hydrostatic Motor Flange Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . 82 N•m (60 lb-ft)
Hydrostatic Motor Relief Valve Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)
Hydrostatic Motor Shuttle Valve Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 41 N•m (30 lb-ft)
REPAIR SPECIFICATIONS
Reservoir Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6 L (4.1 gal)
System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 L (6 gal)
11/22/00 6-3
SPECIFICATIONS HYDROSTATIC POWER TRAIN
OTHER MATERIALS
LOCTITE®
PRODUCTS
U.S./
Canadian/
LOCTITE No.
TY9370/ Thread Lock & Sealer Apply to hydrostatic pump drive hub set
TY9477 (Medium Strength) screws.
242
6-4 11/22/00
HYDROSTATIC POWER TRAIN HYDROSTATIC SYSTEM OPERATION
11/22/00 6-5
HYDROSTATIC COMPONENT LOCATION HYDROSTATIC POWER TRAIN
Center Manifold
KV15143
6-6 11/22/00
HYDROSTATIC POWER TRAIN HYDROSTATIC SYSTEM SCHEMATIC
Charge Flow
Brake Valve
B A
To
Main
Control
Valve
Drive Motor
Brake
Hydraulic/Charge
Pump
Hydrostatic High Flow
Pumps Valve (Optional)
Engine
Oil
Cooler
High Flow
Pump 3300 psi
(Optional)
To
Main
Control
Valve
Brake
Drive Motor
From
Main
Control
Valve
M18535
11/22/00 6-7
TROUBLESHOOTING HYDROSTATIC POWER TRAIN
TROUBLESHOOTING
Problem or
Sluggish response to
Noisy pump or motor
changes in speed
either direction
Low power
Check or
Solution
not
Hydraulic oil level low in
reservoir ● ● ●
Check and top off oil level
Air in system
● ● ●
Purge
6-8 11/22/00
HYDROSTATIC POWER TRAIN DIAGNOSIS
DIAGNOSIS
Test Conditions:
• Operator in seat.
• Seat belt fastened.
1. Steering levers. Levers should move freely. Check linkage from levers to pump.
Test Conditions:
• Start engine and run at low idle.
• Release Park Brake.
1. Steering levers are in neutral. Machine should not creep forward or Perform steering system
backward or in circles. adjustments.
2. Move levers smoothly forward Machine should accelerate smoothly Check oil reservoir for proper oil
or backward from center. forward or backward. level.
Check hydrostatic hoses, tubing,
and connections for leaks.
Perform case drain flow and
hydrostatic pressure and flow tests
to verify proper operation of
hydrostatic pumps.
3. Steering levers in full forward Machine should move forward in a Perform steering system
position. straight line. adjustments.
Perform hydrostatic pump tests.
11/22/00 6-9
TESTS AND ADJUSTMENTS HYDROSTATIC POWER TRAIN
Specifications:
• Charge pressure must be 1379—1551 kPa
(200—225 psi)
Results:
1. If charge pressure does not meet specifications,
test pump flow.
2. If pump flow meets specifications, replace complete
hydraulic oil filter manifold.
3. If pump flow does not meet specifications, replace
or rebuild hydraulic/charge pump.
KV18853
6 - 10 11/22/00
HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS
HYDRAULIC/CHARGE PUMP FLOW IMPORTANT: Make sure skid steer male connector
is routed to tester inlet.
TEST
Reason: Female Auxiliary Connector
To ensure that the hydraulic/charge pump is delivering
sufficient oil flow to operate the hydraulic system
properly.
Equipment:
• D01074AA In-Line Hydraulic Tester
• KV13885 Quick Disconnect, Male
• KV13884 Quick Disconnect, Female Male Auxiliary Connector
• JT03377 Hose, 2 required
• JT03012 Connector, 2 required KV18562
• JT05690 Connector, 2 required 6. Attach quick disconnects to auxiliary hydraulic ports
located on left boom arm.
Procedure:
7. Operate hydraulic system until oil reaches normal
1. Lower boom and bucket to normal ground position. operating temperature of 43°C (110°F).
Stop engine and relieve hydraulic pressure.
8. Set engine speed to full throttle position.
2. Raise and block skid steer. (See RAISING AND
9. Actuate auxiliary hydraulics control handle into
BLOCKING SKID STEER in the
detent (down toward seat) position.
MISCELLANEOUS section.)
10. Turn load valve knob to increase resistance until
pressure reads 10 340 kPa (1500 psi).
Specifications:
KV13885
JT03012 JT03377 Minimum Pump Flow (Standard)
JT05690 240 . . . . . . . . . . . . . . . . . . . . . 49.1 L/min (13 gpm)
KV13884 250 . . . . . . . . . . . . . . . . . . . . . .56.7 L/min (15 gpm)
D01074AA
In-Line
Hydraulic
Tester KV15136
5. Connect JT03377 Hose to D01074AA In-Line
Hydraulic Tester.
11/22/00 6 - 11
TESTS AND ADJUSTMENTS HYDROSTATIC POWER TRAIN
Right
Forward Right Forward
Port Relief Valve
Left Forward
Relief Valve Left Forward
Port
JT03340
Right Reverse Port Quick Coupler
Left
Reverse JT03362
Port Test Gauge
Right Reverse
Relief Valve JT03364
Test Hose
38H1035 RE60700
Tee Fitting Diagnostic
Receptacle
KV18036
240 Models above serial number: KV0240A142337– or if PIP 00KV010 has been performed
250 Models above serial number: KV0250A152709– or if PIP 00KV010 has been performed
Right JT03340
Forward Quick Coupler
Relief Valve
JT05489
Connector
Left
JT03364
Reverse Left
Test Hose
Relief Valve Reverse
Port 38H1035
Tee Fitting
RE60700
Diagnostic
Receptacle
KV31049
6 - 12 11/22/00
HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS
Reason:
c CAUTION
To ensure that hydrostatic pump high pressure relief
valves are operating properly.
Procedure:
11/22/00 6 - 13
TESTS AND ADJUSTMENTS HYDROSTATIC POWER TRAIN
c CAUTION
• Perform Hydraulic/Charge Pump Pressure test.
(See HYDRAULIC/CHARGE PUMP PRESSURE
TEST in this section.)
To help prevent injury from moving tires when • Hydrostatic Pump Case Drain test. (See
performing the wheel speed test, have an HYDROSTATIC PUMP CASE DRAIN test in this
assistant operate the controls while seated in section.)
the machine. • Perform Hydraulic/Charge Pump Flow Test. (See
HYDRAULIC/CHARGE PUMP FLOW TEST in this
section.)
IMPORTANT: Make sure that the hydraulic fluid in • Hydostatic Case Drain Pressure Test. (See
the reservoir is at the full mark. Insufficient HYDROSTATIC CASE DRAIN PRESSURE TEST
hydraulic fluid could cause the system to run in this section)
dry and damage pumps and motors. If wheel speed varies more than 1 rpm from side to side,
perform tracking adjustment. (See CONTROL LEVER
STOPS ADJUSTMENT–TRACKING in the steering
4. Start and operate engine at 3/4 throttle until
SECTION.)
hydraulic oil reaches 43°C (110°F).
5. Increase engine rpm to high idle. Verify rpm is
correct. (See FAST AND SLOW IDLE
ADJUSTMENT in the ENGINE section.)
HYDROSTATIC PUMP FLOW TEST
6. With hydrostatic control (steering) lever moved fully
to forward position, measure and record rotations Reason:
in one minute of corresponding wheel that has the
reflective tape. To ensure that the hydrostatic pumps are delivering
7. Move hydrostatic control lever fully rearward. sufficient oil flow to the hydrostatic motors.
Measure and record rotations in one minute of
same wheel.
Equipment:
8. Repeat steps 6 and 7 for opposite side.
9. Stop engine. • D01074AA -In-Line Hydraulic Tester
• JT03377 - 2- 365cm (10 ft) hoses, ¾ M NPT x ¾ M
NPT
Specifications (Optimal): • JT03012 – ¾ F NPT x 1-1/16 F 37° Flare (2 used)
Wheel Rotations • JT05690 – 1-3/16-12 F ORFS Sw x 1-1/16-12 37°
Model 240 WOT RPM in One Minute M Flare (2 used)
• 38H1272 – 1-3/16-12 M ORFS x 1-3/16-12 M
Serial Number Forward Reverse ORFS
–242579 (2400 minimum) 80—85 65—70
242580– (2400 minimum) 80—85 80—85
Procedure:
Wheel Rotations
1. Park skid steer safely.
Model 250 WOT RPM in One Minute
2. Raise boom and place on boom locks.
Serial Number Forward Reverse 3. Stop engine. Turn key to ON position and operate
–252793 (2400 minimum) 70—75 60—65 all hydraulic controls to relieve hydraulic pressure.
252794– (2400 minimum) 70—75 70—75 4. Raise and block skid steer. (See RAISING AND
BLOCKING SKID STEER in the
MISCELLANEOUS section.)
IMPORTANT: Left and right sides must be within 1 5. Remove cover plates to access hydrostatic pumps.
rpm to provide proper steering control. (See COVER PLATE REMOVAL/INSTALLATION in
the MISCELLANEOUS section.)
6 - 14 11/22/00
HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS
c CAUTION
To help prevent injury from escaping hydraulic
oil under pressure, relieve the pressure in the
system before removing hydraulic lines.
Line to Motor
KV31087
NOTE: Left side pump is shown. Test for the right side
pump is similar.
9. Disconnect hydraulic line from elbow fitting on
pump.
11/22/00 6 - 15
TESTS AND ADJUSTMENTS HYDROSTATIC POWER TRAIN
JT03012
JT05690 Inlet
JT03377 Outlet
Connect to Pump
6 - 16 11/22/00
HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS
Tee Fitting
KV18070
Procedure: c CAUTION
1. Park skid steer safely.
2. Raise and block skid steer. (See RAISING AND To help prevent injury from escaping hydraulic
BLOCKING SKID STEER in the oil under pressure, relieve the pressure in the
MISCELLANEOUS section.) system before removing hydraulic lines.
3. Remove cover plates to access the hydrostatic
pumps. (See REMOVING COVER PLATES in the
MISCELLANEOUS section.)
c CAUTION
c CAUTION To help prevent injury from escaping hot oil, use
suitable protection when disconnecting the
Avoid possible injury from moving tires when hydraulic lines.
using remote start box. Keep tire area clear of
bystanders. Do NOT use remote start box 8. Disconnect return drain hose and left drive motor
without raising and blocking skid steer. drain hose from tee fitting at left side of rear
hydrostatic pump.
4. Install remote start box. (See USING REMOTE 9. Disconnect right motor drain hose from fitting at
START BOX in the MISCELLANEOUS section.) right side of front hydrostatic pump.
11/22/00 6 - 17
TESTS AND ADJUSTMENTS HYDROSTATIC POWER TRAIN
38H1415
Cap Assembly
38H1416
Cap Assembly
10. Connect the left drive motor drain hose and the NOTE: To ensure accurate readings, outlet of test
return drain hose to 38H1206 Union Tee. hose should be above hydraulic reservoir full
11. Connect the right drive motor drain hose to line.
38H1206 Union Tee using 8-6 TRLO-S Adapter.
12. Install 38H1416 Cap Assembly to rear port on tee 19. Transfer hose from container to graduated beaker.
fitting at left side of rear hydrostatic pump.
20. Capture fluid for a 10-second period of time. Return
13. Install 38H1415 Cap Assembly to fitting on right hose to container.
side of front hydrostatic pump.
14. Connect 9.5 mm (3/8 in.) ID test hose of
appropriate length to tee fitting at left side of rear IMPORTANT: Complete this test within 20 seconds
pump. Fasten using a hose clamp. to avoid overheating hydraulic oil.
15. Put end of test hose in a suitable container.
16. Start engine and disengage park brake.
21. Stop engine.
17. Run engine at 3/4 throttle until hydraulic oil reaches
22. Record volume of oil in graduated beaker.
normal operating temperature of 43°C (110°F).
Specifications:
IMPORTANT: Move only the corresponding
steering lever of pump being tested. If both • Volume in graduated beaker should not exceed
steering levers are moved during the test, an 0.95 L (2 pt) in 10 seconds.
inaccurate reading will result.
Results:
18. Move corresponding steering lever of pump being If volume exceeds specifications, repair or replace
tested slowly forward or backward until fluid flows pump.
from end of hose.
Repeat steps 14—20 for the other hydrostatic pump.
6 - 18 11/22/00
HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS
Equipment:
• JT0KV12444 Remote Start Box
KV18022
• 38H1161 Adapter
• JT03457 Adapter 6. Remove plug from right side of rear hydrostatic
• JT05498* Hose pump housing.
• JT05472* Gauge 0—400 kPa (0—60 psi) 7. Install 38H1161 Adapter in port.
8. Install JT03457 Adapter on 38H1161 Adapter.
*Part of JT05470 Universal Pressure Test Kit 9. Install gauge and hose assembly.
10. Start and operate engine at 3/4 throttle until
Procedure: hydraulic oil reaches normal operating temperature
of 43°C (110°F).
1. Park skid steer safely.
11. Disengage park brake. Move both steering levers
2. Raise and block skid steer. (See RAISING AND slowly forward or backward.
BLOCKING SKID STEER in the
MISCELLANEOUS section.) 12. Record gauge reading.
3. Remove cover plates to access the hydrostatic 13. Stop engine.
pump. (See REMOVING COVER PLATES in the
MISCELLANEOUS section.) Specifications:
• Case drain pressure should not exceed 172 kPa
c CAUTION
(25 psi).
Results:
Avoid possible injury from moving tires when If case drain pressure is over specifications:
using remote start box. Keep tire area clear of
bystanders. Do NOT use remote start box 1. Check for restriction in return drain hose
without raising and blocking skid steer. 2. Repair or replace pump or motor.
c CAUTION
To help prevent injury from escaping hydraulic
oil under pressure, relieve the pressure in the
system before removing hydraulic lines.
11/22/00 6 - 19
REPAIR HYDROSTATIC POWER TRAIN
REPAIR
START-UP PROCEDURE AFTER 38H5069
COMPONENT REPLACEMENT JT03457
6 - 20 11/22/00
HYDROSTATIC POWER TRAIN REPAIR
E
Control Rods
KV18872
A. Hydrostatic Pump Center Manifold Port-to-
KV18869 Hydraulic Oil Filter Manifold Hose
B. Hydrostatic Pump Rear Port-to-Left Drive
4. Remove steering control rods from control levers. Motor Case Drain Hose
5. Drain hydraulic reservoir. C. Hydrostatic Pump Rear Port-to-Hydraulic/
Charge Pump Hose
D. Hydraulic/Charge Pump-to-Hydraulic Oil
Reservoir Hose
E. Hydrostatic Pump Bottom Left Center Manifold
Port-to-Left Drive Motor Top Rear Port Hose
Hydraulic F. Hydrostatic Pump Top Left Center Manifold
Fitting Port-to-Left Drive Motor Top Front Port Hose
Hydraulic
Line
KV18870
11/22/00 6 - 21
REPAIR HYDROSTATIC POWER TRAIN
I Cap Screws
(2 used)
Hydrostatic Pump
Assembly
Flywheel
Spacer Adapter Plate
Hydrostatic Pump
Mounting Bracket
KV18871
G. Through serial number:
Spacers
–KV0240A142337 or –KV0250A152709: (See Note)
Hydrostatic Pump Top Right Center Manifold
Port-to-Right Drive Motor Top Front Port Hose
Cap Screws
Cap Screws (See Note)
Above serial number:
KV0240A142337– or KV0250A152709– (or if (See Note)
KV18496
PIP 00KV010 has been performed):
Hydrostatic Pump Top Right Center Manifold
Port-to-Right Drive Motor Top Rear Port Hose NOTE: The quantity of screws and spacers have
changed throughout production. Your machine
H. Through serial number: may have five or six screws and four or five
–KV0240A142337 or –KV0250A152709: spacers. Refer to the appropriate parts catalog
Hydrostatic Pump Bottom Right Center for correct quantities for your machine.
Manifold Port-to-Right Drive Motor Top Rear
Port Hose
8. Remove six cap screws and four spacers from
Above serial number: mounting bracket.
KV0240A142337– or KV0250A152709– (or if 9. Remove two cap screws from pump assembly
PIP 00KV010 has been performed): flange.
Hydrostatic Pump Bottom Right Center 10. Slide pump assembly forward to remove from
Manifold Port-to-Right Drive Motor Top Front flywheel adapter plate.
Port Hose 11. Attach a sling and hoist to pump assembly and
remove from machine.
I. Hydrostatic Pump Front Port-to-Right Drive
Motor Case Drain Hose
J. Hydraulic/Charge Pump-to-Hydraulic Control
Valve Hose
6 - 22 11/22/00
HYDROSTATIC POWER TRAIN REPAIR
A
B
C
R D
N
E
M
F
L O
K
J Q
I
P
H
F
Front of Machine
D
B
A
S
KV31095
11/22/00 6 - 23
REPAIR HYDROSTATIC POWER TRAIN
D
C
A
M B
E
M
F
J G
H
T I
U K
N
J
L
S
R N
Q P M
Front of Machine
O
KV31106
6 - 24 11/22/00
HYDROSTATIC POWER TRAIN REPAIR
D
C
A
L B
E
L
F
J G
H
S I
T K
M
J
R M
P O L
Front of Machine
N
KV31094
11/22/00 6 - 25
REPAIR HYDROSTATIC POWER TRAIN
A
I J
B C
D E H
F
K
E L
D G
M
N
W Q
R
S
V T
M
L
H
U Front of Machine
I
KV31096
6 - 26 11/22/00
HYDROSTATIC POWER TRAIN REPAIR
HYDROSTATIC PUMP .
DISASSEMBLY c CAUTION
IMPORTANT: Clean hydrostatic and hydraulic/
charge pump cases before separating pumps to Use proper lifting equipment. Approximate
prevent contamination of hydraulic system. weight of pumps is 45 kg (100 lb).
Coupler
Set Screws
Input Shaft
KV18503
Mounts
KV18504 KV18873
5. Remove eight cap screws and remove hydraulic/
3. Remove control levers and front and rear centering
charge pump. (Refer to the HYDRAULICS section
plate mounts.
for disassembly and inspection procedures for the
hydraulic/charge pump.)
11/22/00 6 - 27
REPAIR HYDROSTATIC POWER TRAIN
c CAUTION
Note location and orientation of hydrostatic Relief
pump components. Components are not Valves
interchangeable between front and rear
hydrostatic pumps.
Front Pump
Housing
Cap
Screws NOTE: Rotating assembly might "stick" to center
manifold due to hydraulic oil adhesion. Be
KV18507 careful not to let rotating assembly fall
6. Remove four cap screws securing front pump unexpectedly.
housing to center manifold.
7. Lift front pump housing straight up and off from
center manifold. 14. Remove rear valve plate from center manifold.
Rotating Assembly
Center Manifold
Rotating
Valve Assembly
Housing
Plate
KV18508
6 - 28 11/22/00
HYDROSTATIC POWER TRAIN REPAIR
Cover Plates
Snap Ring
Cam Plate
(Swash Plate)
KV18511
Trunnion
17. Remove snap ring holding seal and shaft. Housing Shaft KV18513
Housing
NOTE: Rear pump housing shown. The procedure is
Shaft the same for the front pump housing.
KV18512
11/22/00 6 - 29
REPAIR HYDROSTATIC POWER TRAIN
Metering Slots
Metering Slots
Insert
O-Rings KV18516
6 - 30 11/22/00
HYDROSTATIC POWER TRAIN REPAIR
KV18518
Bearings
Bearing Surfaces 2. Install bearings and shims onto cam plate (swash
Thrust plate). Install the same thickness of shims taken off
Bearing of each side (if crush washer was removed, install
equivalent thickness shims). When new bearings
are being installed, add or subtract shims to obtain
proper bearing preload. Preload will be determined
when cover plates are installed.
3. Install cam plate (swash plate) insert onto cam plate
(swash plate). Use petroleum jelly to hold in place
Spacer during assembly.
Thrust
Washers KV18519
11. Inspect rear pump input shaft bearing surfaces and
spline areas.
12. Inspect thrust bearings and thrust washers.
Bearing Surfaces
Splines Internal
Splines KV18520
11/22/00 6 - 31
REPAIR HYDROSTATIC POWER TRAIN
Cam Plate
(Swash Plate)
Spacer
Trunnion
Housing KV18521
Shaft KV18513
10. Apply petroleum jelly to needle bearings in housing
4. Install cam plate (swash plate) assembly into and install shaft assembly in housing by tapping
housing with trunnion shaft through the previously lightly with a soft-faced hammer.
noted or marked side of the housing. 11. Install spacer over shaft and into housing.
5. Install new seal in cover plate for trunnion shaft
side.
6. Install cover plates to housing. Tighten cap screws
to 41 N•m (30 lb-ft).
7. Install torque wrench on the square of the trunnion
shaft. Rolling torque should be 2.3-3.4 N•m
(20-30 lb-in.). Add or remove shims to obtain the
correct adjustment.
Bearing Surfaces
Thrust
Bearing
Seal
KV18522
12. Using a piece of pipe of appropriate diameter,
lightly tap new seal into housing until it bottoms out
on spacer.
Spacer Snap
Thrust
Ring
Washers
Snap Ring
Snap Rings KV18519
KV18523
13. Install snap ring.
6 - 32 11/22/00
HYDROSTATIC POWER TRAIN REPAIR
Holding
Fixture
Rotating
Assembly Cap Screws
Housing
KV18509
Valve Plate KV18525 20. Install new O-rings on relief valves and install into
center manifold. Tighten to 135 N•m (100 lb-ft).
21. Apply a light coat of petroleum jelly to needle
IMPORTANT: Valve plates are not interchangeable. bearing and back side of valve plate. Install valve
plate on center manifold.
16. Apply petroleum jelly to back side of valve plate to
hold in place during assembly. Drive Shaft
17. Apply a light coat of petroleum jelly to needle
bearing. Install valve plate on center manifold.
Rotating Assembly
Center Manifold
Valve
Plate
KV18508
11/22/00 6 - 33
REPAIR HYDROSTATIC POWER TRAIN
Front Pump
Housing
Cap Screws
Passages
KV18507
25. Install new gasket and lower front pump housing
over rotating group onto center manifold.
26. Install four cap screws and tighten to 56 N•m
(41 lb-ft).
Cap Screws
KV31116
KV18873
27. Install hydraulic/charge pump onto front pump.
28. Tighten the eight screws to 35 N•m (26 lb-ft).
c CAUTION
Use proper lifting equipment. Approximate
KV31113 weight of pumps is 45 kg (100 lb).
24. Looking at the pump as it would be mounted in the 29. Remove pump assembly from holding fixture.
machine, look for passages in the two round oil
ports. The oil port at the 3 o’clock position will
always have passages. If there are passages in the
port at the 9 o’clock position, a plug must be
installed or the pump will not prime. If there are no
passages in the port at the 9 o’clock position, no
plug is required.
6 - 34 11/22/00
HYDROSTATIC POWER TRAIN REPAIR
HYDROSTATIC PUMP
Control Control INSTALLATION
Lever Mounts Lever
1. Install pump assembly into machine using a hoist
and sling.
2. Remove sling and hoist and slide assembly to the
rear through the flywheel adapter plate and
engage into hub.
Cap Screws
(2 used)
6 mm (0.025 in.)
Flywheel
Spacer Adapter Plate
Coupler
Hydrostatic Pump
Mounting Bracket
Set Screws
Spacer
KV31117 (See Note)
31. Install coupler on input shaft. Adjust the gap
between the pump and coupler to 6 mm (0.250 in.). Cap Screw
32. Apply thread lock and sealer (medium strength) to Cap Screws (See Note)
set screws. Tighten set screws to 37 N•m (See Note) KV18496
(27 lb-ft).
11/22/00 6 - 35
REPAIR HYDROSTATIC POWER TRAIN
B G
C
A H
KV18872
A. Hydrostatic Pump Center Manifold Port-to-
Hydraulic Oil Filter Manifold Hose
KV18871
B. Hydrostatic Pump Rear Port-to-Left Drive
Motor Case Drain Hose G. Through serial number:
C. Hydrostatic Pump Rear Port-to-Hydraulic/ –KV0240A142337 or –KV0250A152709:
Charge Pump Hose Hydrostatic Pump Top Right Center Manifold
Port-to-Right Drive Motor Top Front Port Hose
D. Hydraulic/Charge Pump-to-Hydraulic Oil
Reservoir Hose
Above serial number:
E. Hydrostatic Pump Bottom Left Center Manifold KV0240A142337– or KV0250A152709– (or if
Port-to-Left Drive Motor Top Rear Port Hose PIP 00KV010 has been performed):
F. Hydrostatic Pump Top Left Center Manifold Hydrostatic Pump Top Right Center Manifold
Port-to-Left Drive Motor Top Front Port Hose Port-to-Right Drive Motor Top Rear Port Hose
6 - 36 11/22/00
HYDROSTATIC POWER TRAIN REPAIR
Cap Screws
KV13914
NOTE: Left motor shown. Right motor is similar.
Installation:
1. Install new O-ring in brake assembly housing.
2. Align pump motor to brake assembly. Fasten with
four cap screws. Tighten to 118 N•m (87 lb-ft).
3. Install hydrostatic lines removed during pump
removal.
11/22/00 6 - 37
REPAIR HYDROSTATIC POWER TRAIN
X
G
V
W U
Align Shuttle Flow Holes
T
S R
KV31123
A. End Cap G. Steel Ball (2 used) M. O-Ring S. Flange
B. O-Ring H. Drive Shaft N. Plug T. Backup Ring
C. Seal, Square Cut I. Seal, Square Cut O. O-Ring U. Seal
D. Valve Plate J. Balance Plate P. Relief Valve Assy. V. Plug, Shuttle Valve
E. Seal, Square Cut K. Seal, Square Cut Q. Cap Screw (9 used) W. O-Ring
F. GEROLER® L. Backup Ring R. Shaft Face Seal X. Shuttle Valve
Assembly
6 - 38 11/22/00
HYDROSTATIC POWER TRAIN REPAIR
HYDROSTATIC MOTOR
DISASSEMBLY
Shuttle Valve
1. Scribe two lines 25 mm (1 in.) apart down body of Assembly
motor to aid in assembly.
12-Point
Cap Screws
(9 used)
Shims
Relief Valve
Assembly KV18879
4. Remove relief valve and shuttle valve assemblies
from end cap.
5. Remove and discard all O-rings and seals.
KV18886
11/22/00 6 - 39
REPAIR HYDROSTATIC POWER TRAIN
X
G
V
W
U
Align Shuttle Flow Holes
T
S R
KV31123
A. End Cap G. Steel Ball (2 used) M. O-Ring S. Flange
B. O-Ring H. Drive Shaft N. Plug T. Backup Ring
C. Seal, Square Cut I. Seal, Square Cut O. O-Ring U. Seal
D. Valve Plate J. Balance Plate P. Relief Valve Assy. V. Plug, Shuttle Valve
E. Seal, Square Cut K. Seal, Square Cut Q. Cap Screw (9 used) W. O-Ring
F. GEROLER® L. Backup Ring R. Shaft Face Seal X. Shuttle Valve
Assembly
6 - 40 11/22/00
HYDROSTATIC POWER TRAIN REPAIR
Valve Plate
Shuttle
Piston Dash Pots
(2 used)
Springs
(2 used)
Poppets
(2 used) Shims
KV18881
Shuttle Valve Plug O-Ring KV18879
6. Place valve plate on end cap. Align bolt holes and
shuttle flow hole with end cap.
IMPORTANT: Install poppets with tapers facing
each other in port.
Square Cut Seal
Shuttle Flow
1. Coat shuttle valve parts with petroleum jelly and Hole
install one poppet, spring and dash pot into shuttle
valve bore from valve plate side of end cap.
2. Install poppet, spring and dash pot onto the shuttle
piston. Install assembly into valve bore from
opposite side of end cap.
3. Install shuttle valve plug, with a new O-ring, and
tighten to 41 N•m (30 lb-ft).
4. Place original shims (if used) in recess of relief
valve poppet. Install relief valve assembly and
tighten relief valve plug to 27 N•m (20 lb-ft).
KV18882
KV18880
7. Coat both sides of GEROLER with petroleum jelly
5. Place end cap on workbench, name tag side down, and install square cut seal on each side. Place
seal groove side up. Coat surfaces and grooves GEROLER over valve plate, valve side of rotor
with petroleum jelly and install O-ring and square down and spline side up. Align bolt holes and
cut seal. shuttle flow hole.
11/22/00 6 - 41
REPAIR HYDROSTATIC POWER TRAIN
Check Balls 9 1
4
6
7
3
KV18883 2
8
8. Place two check balls in rotor and retain with 5
petroleum jelly. Install drive shaft.
KV18588
9. Place balance plate on GEROLER. Align bolt holes
and shuttle flow holes. 13. Install nine 12-point cap screws lubricated with
HY-GARD hydraulic oil. Tighten cap screws to an
initial setting of 41 N•m (30 lb-ft) in a criss-cross
NOTE: Backup ring for O-ring is contoured on one side pattern as shown. Finish tightening to 82 N•m
to properly sit over O-ring. (60 lb-ft) in the same criss-cross pattern.
Backup
Ring
Seal
Backup
Ring
KV18885
O-Ring
14. Install shaft face seal with the cupped side down.
Backup Hold in place with petroleum jelly.
Ring
Installation:
1. Install motor assembly (see HYDROSTATIC
MOTOR REMOVAL/INSTALLATION in this
Shuttle section.)
Flow
2. Perform start-up procedure. (See START-UP
Hole
O-Ring PROCEDURE AFTER COMPONENT
Flange REPLACEMENT in this section.)
KV18587
6 - 42 11/22/00
STEERING CONTENTS
CONTENTS
STEERING
Page
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TESTS AND ADJUSTMENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STEERING COMPONENT LOCATION—SINGLE PLATE MODELS. . . . 5
STEERING COMPONENT LOCATION—DUAL PLATE MODELS . . . . . 6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CENTERING PLATE ADJUSTMENT—SINGLE PLATE MODELS . . . . . . . . . . . . . . . 9
CENTERING PLATE ADJUSTMENT—DUAL PLATE MODELS . . . . . . . . . . . . . . . . 12
STEERING CONTROL LEVER ADJUSTMENT—CENTERING . . . . . . . . . . . . . . . . 14
STEERING DETENT ADJUSTMENT - DUAL PLATE MODELS . . . . . . . . . . . . . . . . 15
STEERING CONTROL LEVER STOPS ADJUSTMENT—TRACKING. . . . . . . . . . . 16
AUXILIARY HYDRAULIC CONTROL HANDLE ADJUSTMENT . . . . . . . . . . . . . . . . 17
HYDRAULIC CONTROL HANDLE ADJUSTMENT – HANDS ONLY MACHINES . . 17
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CENTERING PLATE REMOVAL—SINGLE PLATE MODELS . . . . . . . . . . . . . . . . . 18
CENTERING PLATE REMOVAL—DUAL PLATE MODELS . . . . . . . . . . . . . . . . . . . 19
CENTERING PLATE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CENTERING PLATE INSTALLATION—SINGLE PLATE MODELS. . . . . . . . . . . . . . 21
CENTERING PLATE INSTALLATION—DUAL PLATE MODELS. . . . . . . . . . . . . . . . 21
STEERING DAMPENER REMOVAL/INSPECTION/INSTALLATION . . . . . . . . . . . . 22
STEERING CONTROL LEVER REMOVAL/INSPECTION/INSTALLATION . . . . . . . 23
STEERING CROSS SHAFT ASSEMBLY REMOVAL/INSTALLATION —
SINGLE PLATE MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
STEERING CROSS SHAFT ASSEMBLY REMOVAL/INSTALLATION —
DUAL PLATE MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
STEERING CROSS SHAFT ASSEMBLY REPAIR—DUAL PLATE MODELS. . . . . . 25
STEERING CONTROL LEVER HANDLE DISASSEMBLY/ASSEMBLY . . . . . . . . . . 26
11/22/00 7-1
CONTENTS STEERING
7-2 11/22/00
STEERING SPECIFICATIONS
SPECIFICATIONS
TORQUE SPECIFICATIONS
Centering Plate Spring Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 N•m (50 lb-ft)
Auxiliary Cable Jam Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)
Guide Pin Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft)
Pivot Bearing Block Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Dampener Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Link Rod Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Control Rod Cap Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Centering Block Mounting Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Control Lever Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Steering Control Lever Handle Set Screw Lock Nut . . . . . . . . . . . . 13.5 N•m (120 lb-in.)
Steering Control Lever Handle Set Screw. . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.)
Detent Ring Set Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Detent Spring Screw Jam Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.9 N•m (25 lb-ft)
Number Name
11/22/00 7-3
THEORY OF OPERATION STEERING
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.
Centering Plate
Early models incorporate a single centering plate that is
located on top of the hydrostatic pumps. This assembly
spans both pumps and consists of a spring-loaded
centering plate and two pairs of adjustment screws.
Each pair of adjustment screws contact a pump lever
and provide the ability to adjust the neutral position.
Late models incorporate two spring loaded centering
plate assemblies with one pair of adjusting screws
each. One centering plate is mounted to each pump.
The steering control levers are connected by control
rods to the hydrostatic pump control levers. Operating
the steering levers move the corresponding control rod
which acts against the spring-loaded centering plate.
7-4 11/22/00
STEERING STEERING COMPONENT LOCATION—SINGLE PLATE MODELS
Right Steering
Lever
Left Steering
Lever
Link Rod
Spring Bolt
Assembly
Control Centering
Rod Plate
Centering Screws
11/22/00 7-5
STEERING COMPONENT LOCATION—DUAL PLATE MODELS STEERING
Right Steering
Lever
Pivot Bearing
Left Wheel
Centering Plate
Right Wheel
Centering Plate
Right Wheel
Control Rod
Detent Ring
Detent Screw
Guide Pins and Bushings
KV18848
7-6 11/22/00
STEERING TROUBLESHOOTING
TROUBLESHOOTING
vibrate excessively.
Hydrostatic system
reverse position.
Vehicle tracks to
in full forward or
loose or sloppy.
Machine creeps
Levers pulse or
noisy while in
with levers in
to move.
Check or
neutral.
neutral.
Solution
11/22/00 7-7
DIAGNOSTICS STEERING
DIAGNOSTICS
Test Conditions:
• Operator in seat.
1. Steering control levers. Levers should move freely with slight Check linkage from levers to pump.
resistance. Check steering dampeners.
Test Conditions:
1. Steering control levers are in Pumps should be quiet. Engine Adjust centering plate(s).
neutral, park brake switch should not sound labored.
disengaged.
2. Steering control levers are in Machine should not creep forward or Adjust centering plate(s).
neutral, park brake switch backward or in circles.
disengaged.
3. Steering control levers in full Machine should move forward, or Adjust steering control lever stop
forward or full reverse position, backward, in a straight line. screws.
park brake switch disengaged.
4. Dual steering plate models only Lever should remain in position and Adjust or repair steering detent.
- Steering control levers in full machine should continue in a
forward or full reverse position, straight line.
park brake switch disengaged.
Release one lever.
7-8 11/22/00
STEERING TESTS AND ADJUSTMENTS
Pump Control
CENTERING PLATE Lever
ADJUSTMENT—SINGLE PLATE
MODELS
Control Rod
Reason:
To prevent the skid steer from creeping when control
levers are in neutral. Rear Front
Centering Screws Centering Screws
KV13980
11/22/00 7-9
TESTS AND ADJUSTMENTS STEERING
Right Wheels
Right Wheels Rearward Movement
D
Forward Movement C
Left Wheels
Rearward Movement B A Left Wheels
Forward Movement
No Gap
IMPORTANT: A 3.2—6.4 mm (1/8 in.—1/4 in.) IMPORTANT: Adjusting any centering screw will
horizontal gap between upper centering plate affect the clearance between the centering
and lower front centering bracket must be screws and bearings for the wheels on the other
maintained when adjusting screws (A—D). side of the machine.
11. Verify that the gap between the upper centering 14. Verify that there is no gap between all four
plate and lower front centering bracket is between centering screws and all four bearings. Adjust as
3.2 mm and 6.4 mm (1/8 in. and 1/4 in.). necessary being careful not to change the neutral
12. Start skid steer and set engine rpm to 3/4 throttle. position of the pump control lever.
Turn parking brake OFF. Wheels should not rotate. 15. Verify that the gap between the upper centering
13. If wheels rotate, adjust centering screws as plate and lower front centering bracket is between
indicated: 3.2 mm and 6.4 mm (1/8 in. and 1/4 in.).
• The machine will not center consistently with a gap
• To adjust the left side wheels forward movement: less than 3.2 mm (1/8 in.).
Loosen jam nut and turn centering screw (A) in • Steering effort will be increased with a gap greater
(clockwise) until the left wheels start to turn than 6.4 mm (1/4 in.).
rearward. Slowly turn the centering screw out until • If not within specified gap, adjust all four screws
the left wheels stop turning. Tighten the jam nut. equally to obtain gap and repeat STEPS 11-15.
• To adjust the left side wheels rearward movement: 16. Connect control rods to pump control levers.
Loosen jam nut and turn centering screw (B) in Tighten cap screws to 40 N•m (30 lb-ft).
(clockwise) until the left wheels start to turn 17. Test left wheel adjustment by moving left control
forward. Slowly turn the centering screw out until lever to full forward and releasing handle. The
the left wheels stop turning. Tighten the jam nut. wheels should stop turning. Perform the same test
• To adjust the right side wheels forward movement: by pulling rearward on the left control lever.
Loosen jam nut and turn centering screw (C) in • If motion does not stop, adjust the left wheel
(clockwise) until the right wheels start to turn centering screws (A)-(B) so that both screws touch
rearward. Slowly turn the centering screw out until the bearings in the neutral position and repeat
the right wheels stop turning. Tighten the jam nut. STEPS 9-17.
• To adjust the right side wheels rearward movement: • Repeat test using the right control lever. Adjust the
Loosen jam nut and turn centering screw (D) in right wheel centering screws (C)-(D) so that both
(clockwise) until the right wheels start to turn screws touch the bearings in the neutral position
forward. Slowly turn the centering screw out until and repeat STEPS 9-17.
the right wheels stop turning. Tighten the jam nut.
18. Center left and right steering control levers. (See
STEERING CONTROL LEVER ADJUSTMENT—
CENTERING in this section.)
7 - 10 11/22/00
STEERING TESTS AND ADJUSTMENTS
11/22/00 7 - 11
TESTS AND ADJUSTMENTS STEERING
CENTERING PLATE
ADJUSTMENT—DUAL PLATE Pump Control
Levers
MODELS
Control Rod
Reason:
To prevent the skid steer from creeping when control
levers are in neutral.
Control Rod
Equipment:
• JT0KV12444 Remote Start Box
Procedure:
1. Park skid steer safely. Detent Ring
Set Screws
2. Raise and block skid steer. (See RAISING AND
BLOCKING SKID STEER in MISCELLANEOUS KV18845
section.)
3. Raise boom and engage boom locks.
7. Check pivot points of all the steering linkage for
4. Raise ROPS and ensure ROPS is safely in the wear and damage. Repair linkage components
locked position. prior to performing these adjustments.
5. Remove cover plates to gain access to the
hydrostatic pump assembly. (See REMOVING
c CAUTION
COVER PLATES in MISCELLANEOUS section.)
Rear
Centering Screws
KV13980 Front
Centering Screws
7 - 12 11/22/00
STEERING TESTS AND ADJUSTMENTS
Right Wheels
Right Wheels
C Forward Movement
Rearward Movement D
Left Wheels
Rearward Movement B A Left Wheels
Forward Movement
No Gap
KV18847
IMPORTANT: A 3.2—6.4 mm (1/8 in.—1/4 in.) 15. Verify that the gap between the upper centering
horizontal gap between upper centering plate plates and lower centering brackets is between 3.2
and lower centering bracket must be maintained mm and 6.4 mm (1/8 in. and 1/4 in.) and that
when adjusting screws (A—D). there is no gap between all four centering screws
and all four bearings. Adjust as necessary being
careful not to change the neutral position of the
12. Verify that the gap between the upper centering pump control lever.
plates and lower centering brackets is between 3.2 • The machine will not center consistently with a gap
mm and 6.4 mm (1/8 in. and 1/4 in.). less than 3.2 mm (1/8 in.).
13. Start skid steer and set engine rpm to 3/4 throttle. • Steering effort will be increased with a gap greater
Turn parking brake OFF. Wheels should not rotate. than 6.4 mm (1/4 in.).
14. If wheels rotate, adjust centering screws as • If not within specified gap, adjust screws equally to
indicated: obtain gap and repeat STEPS 12-15.
16. Connect control rods to pump control levers.
• To adjust the left side wheels forward movement: Tighten cap screws to 40 N•m (30 lb-ft).
Loosen jam nut and turn centering screw (A) in
(clockwise) until the left wheels start to turn 17. Test left wheel adjustment by moving left control
rearward. Slowly turn the centering screw out until lever to full forward and releasing handle. The
the left wheels stop turning. Tighten the jam nut. wheels should stop turning. Perform the same test
by pulling rearward on the left control lever.
• To adjust the left side wheels rearward movement:
Loosen jam nut and turn centering screw (B) in • If motion doesn’t stop, adjust the left wheel
(clockwise) until the left wheels start to turn centering screws (A)-(B) so that both screws touch
forward. Slowly turn the centering screw out until the bearings in the neutral position and repeat
the left wheels stop turning. Tighten the jam nut. STEPS 9-17.
• To adjust the right side wheels forward movement: • Repeat test using the right control lever. Adjust the
Loosen jam nut and turn centering screw (C) in right wheel centering screws (C)-(D) so that both
(clockwise) until the right wheels start to turn screws touch the bearings in the neutral position
rearward. Slowly turn the centering screw out until and repeat STEPS 9-17.
the right wheels stop turning. Tighten the jam nut. 18. Center left and right steering control levers. (See
• To adjust the right side wheels rearward movement: STEERING CONTROL LEVER ADJUSTMENT—
Loosen jam nut and turn centering screw (D) in CENTERING in this section.)
(clockwise) until the right wheels start to turn 19. Adjust steering control lever stops. (See
forward. Slowly turn the centering screw out until STEERING CONTROL LEVER STOPS
the right wheels stop turning. Tighten the jam nut. ADJUSTMENT—TRACKING in this section.)
20. Verify detent ball is in detent groove of detent ring.
Tighten set screws to 40 N•m (30 lb-ft).
11/22/00 7 - 13
TESTS AND ADJUSTMENTS STEERING
21. Pull both steering control levers to the full foward 8. Tighten both jam nuts on left and right link rods.
postion. Verify detent ball is in detent groove of
detent ring. If not, repeat Steps 18-21.
22. Remove one M10 x 30 cap screw from each IMPORTANT: The steering control lever stops must
steering lever yoke. be adjusted properly to prevent damage to the
linkage and internal hydrostatic components.
23. Remove remote start box.
24. Install cover plates. (See REMOVING COVER
PLATES in MISCELLANEOUS section.) 9. Adjust steering control lever stops. (See
25. Lower ROPS. STEERING CONTROL LEVER STOPS
26. Raise and remove skid steer jacking blocks. ADJUSTMENT—TRACKING in this section.)
10. Remove M10 x 30 cap screw from each steering
lever yoke.
STEERING CONTROL LEVER 11. Install cover plates. (See REMOVING COVER
ADJUSTMENT—CENTERING PLATES in MISCELLANEOUS section.)
12. Lower ROPS.
Reason:
To center the steering control levers.
Procedure:
1. Park skid steer on flat level surface.
2. Raise boom and engage boom locks.
3. Raise ROPS and ensure ROPS is safely in the
locked position.
4. Remove cover plates to gain access to the steering
linkage. (See REMOVING COVER PLATES in
MISCELLANEOUS section.)
M10 x 30 Cap Screw
Jam Nuts
Align
KV15260
7 - 14 11/22/00
STEERING TESTS AND ADJUSTMENTS
Jam Nut
Procedure:
1. Park skid steer on flat level surface. Detent Spring Screw
2. Raise boom and engage boom locks. KV31011
3. Raise ROPS and ensure ROPS is safely in the 7. Loosen detent ring set screws and rotate ring to
locked position. verify detent ball is in groove on ring. Tighten set
4. Remove cover plates to gain access to the steering screws to 40 N•m (30 lb-ft).
linkage. (See REMOVING COVER PLATES in
MISCELLANEOUS section.)
Dampener
Left Bellcrank
Jam Nut
KV31012 Detent Spring Screw
11/22/00 7 - 15
TESTS AND ADJUSTMENTS STEERING
Reason:
To ensure machine tracks straight and to protect
hydrostatic pumps from damage.
KV13984
Equipment: 11. Adjust stop screw to act as the primary stop just
before the hydrostatic pump control lever stops due
• JT0KV12444 Remote Start Box
to mechanical motion inside the pump.
• JT05719 Photo Tachometer
12. Move left steering control lever to full rearward
position.
Procedure: 13. Adjust stop screw to act as the primary stop just
before the hydrostatic pump control lever stops due
1. Park skid steer safely.
to mechanical motion inside the pump.
2. Raise and block skid steer. (See RAISING AND
14. Repeat procedure for the right steering control lever
BLOCKING SKID STEER in MISCELLANEOUS
stops.
section.)
15. Start engine and run at fast idle.
3. Raise boom and engage boom locks.
16. While simultaneously holding both levers in the full
4. Raise ROPS and ensure ROPS is safely in the
forward position, measure and record the full
locked position.
forward wheel speed (revolutions per minute) of
5. Remove cover plates to gain access to the steering the left and right wheels using a JT05719 Photo
linkage. (See REMOVING COVER PLATES in Tachometer.
MISCELLANEOUS section.)
• Left and right wheel speed should be within one
revolution per minute of each other.
c CAUTION • If left and right wheels are not within one revolution
per minute of each other, adjust the faster wheel to
equal the slower wheel speed by turning the stop
Avoid possible injury from moving tires when screw out (counterclockwise).
using remote start box. Do NOT use remote start 17. Tighten jam nuts on the steering control lever stop
box without raising and blocking skid steer. screws.
18. Repeat procedure for left and right full reverse.
6. Install remote start box. (See USING REMOTE
START BOX in MISCELLANEOUS section.) NOTE: Due to variations such as tire size, tracking
7. Install an M10 x 30 cap screw in tab at the rear of must be verified by driving the skid steer. If
both yokes to secure steering assembly during mistracking is more than the width of the
adjustment. machine per 30.5 m (100 ft) of travel,
8. Loosen jam nuts on the steering control lever stop readjustment of the stop screws are required.
screws.
9. Turn stop screws in (clockwise).
19. Remove one M10 x 30 cap screw from each
10. Move left steering control lever to full forward steering lever yoke.
position.
20. Remove remote start box.
21. Install cover plates. (See REMOVING COVER
PLATES in MISCELLANEOUS section.)
22. Lower ROPS.
23. Raise and remove skid steer jacking blocks.
7 - 16 11/22/00
STEERING TESTS AND ADJUSTMENTS
Procedure: Procedure:
1. Park skid steer safely. 1. Park skid steer safely.
2. Raise ROPS and ensure ROPS is safely in the 2. Raise the boom and place on the boom locks.
locked position. 3. Raise ROPS and ensure ROPS is safely in the
3. Remove cover plates to gain access to the control locked position.
valve. (See REMOVING COVER PLATES in 4. Remove cover plates to gain access to the control
MISCELLANEOUS section.) valve. (See REMOVING COVER PLATES in
MISCELLANEOUS section.)
KV0575
5. Move each handle all the way down and all the way
up. Ensure that the boom control valve locks into
KV15239 detent.
6. Confirm that when the handles are returned to
4. Lock handle in the middle (neutral) position by neutral position, they are in the center of the
turning key to the left. operating range.
Cable
Jam Nuts
Cable
Auxiliary Cable
Jam Nuts
Jam Nuts
KV13989 KV0582a
5. Loosen both auxiliary cable jam nuts. 7. If necessary to adjust, loosen both cable jam nuts.
6. Center spool in control valve. 8. Adjust nuts until handle is centered.
7. Tighten both auxiliary cable jam nuts finger tight 9. Tighten both cable jam nuts finger tight against
against cable saddle, then tighten to 27 N•m cable saddle, then tighten to 27 N•m
(20 lb-ft). (20 lb-ft).
11/22/00 7 - 17
REPAIR STEERING
REPAIR
KV14333
Spring Bolt Assembly
7. Remove centering plate by prying it from right guide
pin.
Control Lever
Jam Nut
KV13981
Control Rod
Bracket
KV14338
Left Guide Pin Nut NOTE: Removal of the bracket retaining cap screws
can allow the cover to dislodge and might
cause difficulty in reassembly. Put at least one
screw back into place once guide pin has been
removed.
7 - 18 11/22/00
STEERING REPAIR
KV18837
NOTE: Rear plate shown; front is similar.
Bracket
Control Rod
Bracket
Left Guide Pin Nut
KV14338
11/22/00 7 - 19
REPAIR STEERING
Bushing Spacer
KV14337
Bearing Surface
KV14335
7 - 20 11/22/00
STEERING REPAIR
CENTERING PLATE 8. Install and tighten centering plate guide pin nuts to
54 N•m (40 lb-ft).
INSTALLATION—SINGLE PLATE
MODELS
Spring Bolt Assembly
KV13981
3.2 mm (1/8 in.)
9. Install spring bolt assembly onto centering plate
KV18846 assembly. Tighten spring bolt to 67 N•m (50 lb-ft).
1. Loosen jam nuts. Adjust centering screws until each 10. Perform centering plate adjustment. (See
bearing surface protrudes approximately 3.2 mm CENTERING PLATE ADJUSTMENT—SINGLE
(1/8 in.). PLATE MODELS in this section.)
KV14333
Bracket
M44227
11/22/00 7 - 21
REPAIR STEERING
Centering Plate
STEERING DAMPENER REMOVAL/
Right Guide Pin
Bushing INSPECTION/INSTALLATION
Left Guide Pin Nut 1. Remove cap screws (early models) or push nuts
(late models) securing dampener to bracket and
cap screws retaining dampener to cross shaft.
2. Stroke dampener through full range of motion.
Dampeners should operate smoothly with some
resistance to movement. If no resistance is noted,
or if unit is leaking, replace unit.
3. Test dampener as follows:
• With dampener in its installed position, fully extend
Bracket rod-end.
KV18839
• Apply a 9 kg (20 lb) force to rod-end. Time how long
6. Install left guide pin into bushing. it takes for rod-end to fully retract; should be
7. Install left side of centering plate on lower centering between 1-5 seconds.
bracket. • With dampener in its installed position and rod-end
8. Install and torque centering plate guide pin nuts to fully retracted, apply a 9 kg (20 lb) pull to rod-end.
54 N•m (40 lb-ft). • Time how long it takes for rod-end to fully extend;
should be between 1-5 seconds.
Spring Bolt Assembly Replace damener if results vary.
KV13981 NOTE: Verify that dampener does not reach its travel
limit before the steering control lever contacts
9. Install spring bolt assembly onto centering plate
the stop screws in both forward and reverse.
assembly. Torque spring bolt to 67 N•m (50 lb-ft).
Install or remove shim washer(s) as required.
10. Repeat STEPS 2-9 for front centering plate.
11. Perform centering plate adjustment. (See
CENTERING PLATE ADJUSTMENT—DUAL 6. Tighten dampener mounting cap screws to
PLATE MODELS in this section.) 40 N•m (30 lb-ft).
7 - 22 11/22/00
STEERING REPAIR
STEERING CONTROL LEVER 4. Remove steering control lever assembly with spring
bracket attached.
REMOVAL/INSPECTION/
INSTALLATION
Inspection:
1. Inspect steering control levers for damage.
Removal:
2. Inspect pivot bearing for looseness or damage.
Replace if required.
Cap Screw
Installation:
Spring Bracket
KV13984
KV14341
Cap Screw
KV14341
KV13984
KV15261
11/22/00 7 - 23
REPAIR STEERING
Cross Shaft
Assembly
Cross Shaft
Assembly
Dampeners
KV18003 Dampeners KV18845
NOTE: Cross shaft assembly shown is for left-side NOTE: Cross shaft assembly shown is for right-side
mounting. Some models may use right-side mounting. Some models may use left-side
mounting. Other components are the same. mounting. Other components are the same.
Removal: Removal:
1. Park skid steer safely. 1. Park skid steer safely.
2. Raise and block skid steer. (See RAISING AND 2. Raise and block skid steer. (See RAISING AND
BLOCKING SKID STEER in MISCELLANEOUS BLOCKING SKID STEER in MISCELLANEOUS
section.) section.)
3. Raise boom and engage boom locks. 3. Raise boom and engage boom locks.
4. Raise ROPS and ensure ROPS is safely in the 4. Raise ROPS and ensure ROPS is safely in the
locked position. locked position.
5. Remove cover plates to gain access to the cross 5. Remove cover plates to gain access to the cross
shaft. (See REMOVING COVER PLATES in shaft assembly. (See REMOVING COVER
MISCELLANEOUS section.) PLATES in MISCELLANEOUS section.)
6. Remove cap screws and nuts holding dampeners, 6. Remove cap screws and nuts holding dampeners,
link rods, and control rods to cross shaft assembly. link rods, and control rods to cross shaft assembly.
7. Lift control rods from assembly and move to side. 7. Push control rods to rear and remove from
8. Remove cap screws and nuts holding cross shaft assembly.
assembly to right support bracket. 8. Remove cap screws and nuts holding cross shaft
9. Lift right side of cross shaft assembly and slide out assembly to right support bracket.
from left support bracket. 9. Lift right side of cross shaft assembly and slide out
10. Repair or replace as required. from left support bracket.
10. Repair or replace as required.
Installation:
1. Slide cross shaft assembly into left support bracket. Installation:
2. Secure cross shaft assembly to right support 1. Slide cross shaft assembly into left support bracket.
bracket using cap screws and nuts. Tighten cap 2. Secure cross shaft assembly to right support
screws to 40 N•m (30 lb-ft). bracket using cap screws and nuts. Tighten cap
3. Attach control rods to cross shaft and tighten cap screws to 40 N•m (30 lb-ft).
screws to 40 N•m (30 lb-ft). 3. Attach right control rod to cross shaft assembly and
4. Attach link rods and dampeners to cross shaft tighten cap screws to 40 N•m (30 lb-ft).
assembly. Tighten cap screws to 40 N•m (30 lb-ft).
7 - 24 11/22/00
STEERING REPAIR
4. Attach right link rod and dampener to cross shaft 6. Inspect cross shaft (J) and bellcrank bushings for
assembly. Tighten cap screws to 40 N•m (30 lb-ft). wear or damage. Replace as necessary.
5. Adjust detent ring. (See STEERING DETENT
ADJUSTMENT - DUAL PLATE MODELS in this
section.) Assembly:
6. Attach left control rod, link rod and dampener. 1. Install snap ring (K) on flange end of cross shaft (J).
Tighten cap screws to 40 N•m (30 lb-ft). 2. Place detent ring (I) on left bellcrank (G) and finger
7. Check and adjust link rods. (See STEERING tighten set screws.
CONTROL LEVER ADJUSTMENT—CENTERING 3. Place all components on cross shaft (J) in order
in this section.) shown.
8. Check and adjust steering control lever stops. (See 4. Install detent ball (D) and pack detent ball cavity
STEERING CONTROL LEVER STOPS with TY24416 Multi-Purpose HD Lithium Complex
ADJUSTMENT—TRACKING in this section.) grease.
5. Install spring (C) and screw/jam nut (A-B) assembly
in detent cavity.
STEERING CROSS SHAFT 6. Install cross shaft assembly in machine. (See
ASSEMBLY REPAIR—DUAL PLATE STEERING CROSS SHAFT REMOVAL/
MODELS INSTALLATION—DUAL PLATE MODELS in this
section.)
C
D B
I A
F
T G
ON E
FR KV18849
Disassembly:
1. Remove cross shaft assembly. (See STEERING
CROSS SHAFT REMOVAL/INSTALLATION in this
section.)
2. Remove detent screw/jam nut (A-B), spring (C) and
ball (D).
3. Remove snap ring (E) and nylon washer (F) from
left end.
4. Remove both bellcranks (G-H) and both nylon
washers from shaft.
5. If it is necessary to remove the detent ring (I), mark
its locaton on the left bellcrank (G). Loosen both
set screws and remove.
11/22/00 7 - 25
REPAIR STEERING
STEERING CONTROL LEVER NOTE: Models having optional 8-Button Handle will
require disconnecting a harness near the
HANDLE DISASSEMBLY/ASSEMBLY bottom of the lever.
Spring Pin
Cable Assembly
KV14343
Set Screw
Lock Nut
KV14345
7 - 26 11/22/00
BRAKES CONTENTS
CONTENTS
BRAKES
Page
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OTHER MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BRAKE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
BRAKE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
BRAKE DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BRAKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BRAKE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BRAKE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
BURNISH BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BRAKE ACTUATOR CYLINDER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . 12
11/22/00 8-1
CONTENTS BRAKES
8-2 11/22/00
BRAKES SPECIFICATIONS
SPECIFICATIONS
BRAKE LINER
Thickness (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.76 mm (3/16 in.)
Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.9 cm (9 in.)
TORQUE SPECIFICATIONS
Hydrostatic Motor-to-Brake Assembly Socket Head Screws. . . . . . . . 118 N•m (87 lb-ft)
Brake Assembly-to-Frame Mount Screws . . . . . . . . . . . . . . . . . . . . . . 109 N•m (80 lb-ft)
Cover Plate-to-Brake Housing Cap Screws . . . . . . . . . . . . . . . . . . . . 109 N•m (80 lb-ft)
Chain Case Cover Cap Screws. . . . . . . . . . . . . . . . . . . . . . . . 70—80 N•m (52—59 lb-ft)
CHAIN CASE
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4 L (3 gal) (Each Side)
OTHER MATERIALS
HY-GARD®, LOW VIS HY-GARD® (cold weather Fill hydraulic reservoir and chain
operation), John Deere TORQ-GARD SUPREME® case.
or PLUS-50®
PM20166 John Deere 5900 RTV Silicone Seal chain case covers.
TORQ-GARD SUPREME and PLUS-50 are registered trademarks of Deere & Company.
11/22/00 8-3
THEORY OF OPERATION BRAKES
THEORY OF OPERATION
The brake system is electrically controlled and pressure inside cylinder pushes actuator lever up
hydraulically activated. Hydraulic pressure holds the causing it to rotate in a clockwise direction in the left
park brakes disengaged. The left and right side brakes side and counterclockwise in the right side. Hydraulic
are separate units. The brake assembly is mounted pressure on the spring side of the cylinder assists
between the axle and the hydrostatic motor. Each engagement of the brake when the engine is running.
brake assembly is actuated by a cylinder assembly. The actuator rises up on steel balls, applying pressure
The brakes are designed to hold the skid steer in place to the thrust bearing, stator, and brake liner. The brake
to prevent rolling or creeping when parked on a grade. liner is splined to the driver. The driver is keyed to the
The brake is to be used as a parking brake and a drive shaft. When the actuator rotates up, the brake
secondary brake in the event of loss of dynamic liner is held in place, preventing the drive shaft from
(hydrostatic) braking. All braking under power is rotating.
achieved by returning the hydrostatic steering control When the park brake switch is disengaged, the
levers to the center position. solenoid allows hydraulic pressure to flow to the
The cylinder assembly is spring loaded and requires cylinder assembly. Hydraulic pressure overcomes the
hydraulic pressure to retract the spring for brake spring in the cylinder assembly, thus releasing the
disengagement. The cylinder acts on the actuator brake.
lever. When the brake is engaged, hydraulic pressure is Electrical power and hydraulic pressure are required to
removed from the release side of the cylinder. Spring release the park brake.
Brake
Actuator Lever
Cylinder
Actuator
KV15125
8-4 11/22/00
BRAKES BRAKE EXPLODED VIEW
1
2
3
4
5 6
7
8
9 10
33 11
35
32 12
34 13
14
15
31 30 16
29 17
18
28
19 20
27
26 21
24 22
26 23
25
24
11/22/00 8-5
DIAGNOSIS AND TROUBLESHOOTING BRAKES
Test Conditions:
1. Park brake switch Skid steer moves forward and Wheels locked or locked on one side:
disengaged. Move steering backward for the appropriate
control levers forward and Check to see if brake lever is moving
hydrostatic lever.
backward, one at a time. during actuation.
Check lining material.
Troubleshoot park brake solenoid. (See
procedure in the ELECTRICAL section.)
Troubleshoot park brake switch. (See
procedure in the ELECTRICAL section.)
Check charge pump hydraulic pressure.
2. Park brake switch engaged. Skid steer remains stationary One or both sides of skid steer move:
Move steering control levers and engine pulls down or
Troubleshoot park brake solenoid. (See
forward and backward, one stalls (even at full throttle).
procedure in the ELECTRICAL section.)
at a time.
Troubleshoot park brake switch. (See
procedure in the ELECTRICAL section.)
TROUBLESHOOTING
Problem or
Grinding noise while operating
Symptom
Brakes not holding.
Check or
Solution
skid steer.
8-6 11/22/00
BRAKES REPAIR
REPAIR
Cylinder Actuator
BRAKE REMOVAL
1. Park skid steer safely.
2. Raise and block skid steer. (See RAISING AND
BLOCKING SKID STEER in the
MISCELLANEOUS section.)
Hoses
3. Remove cover plates to access the brake assembly.
(See REMOVING COVER PLATES in the
MISCELLANEOUS section.) Hoses
4. Remove steering mechanism and steering cross
shaft. (See procedures in the STEERING section.)
Early Models KV13156
5. Remove the front and rear wheels on the side to be
serviced.
6. Drain the oil from chain case into a suitable
container. The approximate capacity of each chain
case is 11.4 L (3 gal).
Chain Case Cover
Nut
Hose
Hoses
Drive Shaft
11/22/00 8-7
REPAIR BRAKES
Screw
(4 used)
Cap Screws
Boot Plate
Boot
KV18537
BRAKE DISASSEMBLY
Retaining Ring
KV18874
KV13134
6. Install two fully-threaded M10 cap screws 102 mm
(4 in.) long into threaded holes. Thread cap screws
Retaining Pin in evenly and remove housing cover and inner
(2 used) bearing.
Mounting Pin 7. Remove brake lining, stator, cylinder arm, and
(2 used) gasket from brake housing.
KV18536
2. Remove retainer pins, mounting pins, and brake
actuator. Slowly back off C-clamp to relieve brake
actuator pressure and remove clamp.
8-8 11/22/00
BRAKES REPAIR
Detents
Ball Actuator (5 used)
(5 used) Bearing
KV18543 KV18538
Housing
Retaining Ring
Shaft
Cover
Key KV18878
(2 used)
12. Remove seals in brake cover and housing.
KV18540
10. Remove keys from shaft and remove shaft from
housing.
11/22/00 8-9
REPAIR BRAKES
KV18543
Indexing Tabs
KV18545
BRAKE ASSEMBLY
NOTE: Stator is positioned by locating indexing tabs
into half rounds of housing.
IMPORTANT: Do not get oil, grease, or solvents on
brake linings.
6. Install gasket, stator, and lining into housing.
Position stator indexing tabs into half rounds of
NOTE: Install seals with lips of seals facing away from housing.
center of brake assembly.
KV13134
8 - 10 11/22/00
BRAKES REPAIR
KV18877
Drive Shaft
KV18563
Rear Drive Chain Front Drive Chain
9. Determining shim thickness:
a. Install snap ring to top surface of groove. KV13157
b. Measure depth from top of snap ring to top of 3. Install drive chains to shaft.
bearing inner race. 4. Install front and rear axle shafts. (See AXLE
c. Remove and measure snap ring thickness. HOUSING REMOVAL/INSTALLATION in the
d. Subtract snap ring thickness from depth POWER TRAIN [CHAIN CASE AND AXLES]
measurement to determine required shim section.)
thickness. 5. Apply a bead of PM20166 RTV SILICONE
10. Install shims required and snap ring. SEALANT to chain case cover and install with
11. Install boot, boot plate. nuts. Tighten nuts to
70—80 N•m (52—59 lb-ft).
12. Install actuator cylinder.
6. Fill chain case with John Deere HY-GARD, LOW
13. Install O-ring and hydrostatic motor with four socket VIS HY-GARD, TORQ-GARD SUPREME or
head screws. Tighten screws to 118 N•m (87 lb- PLUS-50 hydraulic fluid to bottom of check plug
ft). opening.
7. Install front and rear wheels.
BRAKE INSTALLATION 8. Install cross shaft and steering control lever
assembly. (See procedures in the STEERING
1. Attach hoist and strap to wheel motor/brake section.)
assembly. 9. Install cover plates. (See COVER PLATE
REMOVAL/INSTALLATION in the
MISCELLANEOUS section.)
10. Burnish brakes. (See BURNISH BRAKES in this
section.)
11/22/00 8 - 11
REPAIR BRAKES
Removal:
1. Park skid steer safely.
2. Raise and block skid steer. (See RAISING AND
BLOCKING SKID STEER in the
MISCELLANEOUS section.)
3. Remove cover plates. (See REMOVING COVER
PLATES in the MISCELLANEOUS section.)
c CAUTION
Avoid possible injury from moving tires when
using remote start box. Keep tire area clear of
bystanders. Do NOT use remote start box
without raising and blocking skid steer.
8 - 12 11/22/00
BRAKES REPAIR
Installation:
Hoses Hoses
Early Models KV18015
Hose
Hoses
Cylinder Arm
Retaining Pin
KV18016
9. Using a hooked type tool, remove retaining pin or
cotter pin from lower pivot pin.
11/22/00 8 - 13
REPAIR BRAKES
8 - 14 11/22/00
HYDRAULICS CONTENTS
CONTENTS
HYDRAULICS
Page
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE PARTS KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SYSTEM COMPONENTS AND OPERATION . . . . . . . . . . . . . . . . . . . . . 5
SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SYSTEM COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CONTROL VALVE COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HYDRAULIC/CHARGE PUMP COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . 11
BUCKET CYLINDER COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BOOM CYLINDER COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BOOM AND BUCKET LOCKOUT SOLENOIDS CHECK . . . . . . . . . . . . . . . . . . . . . 15
SYSTEM RELIEF VALVE PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
HYDRAULIC/CHARGE PUMP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HYDRAULIC/CHARGE PUMP FLOW TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CIRCUIT RELIEF VALVE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BOOM DRIFT DOWN CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BOOM LIFT CHECK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BOOM DRIFT UP CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BUCKET DRIFT DUMP POSITION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BUCKET DRIFT ROLLBACK POSITION CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BUCKET LIFT CHECK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
BUCKET SELF-LEVELING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HYDRAULIC/CHARGE PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HYDRAULIC/CHARGE PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HYDRAULIC/CHARGE PUMP COMPONENT INSPECTION . . . . . . . . . . . . . . . . . . 23
HYDRAULIC/CHARGE PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
HYDRAULIC/CHARGE PUMP INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
HIGH-FLOW PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
HIGH-FLOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CONTROL VALVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CONTROL VALVE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CONTROL VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
CONTROL VALVE CROSS SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
11/22/00 9-1
CONTENTS HYDRAULICS
Page
9-2 11/22/00
HYDRAULICS SPECIFICATIONS
SPECIFICATIONS
HYDRAULIC/CHARGE PUMP
Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High pressure gear pump
Pump Flow (Minimum):
(Standard):
240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.1 L/min (13 gpm)
250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.7 L/min (15 gpm)
(High-Flow Option):
240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.8 L/min (22.4 gpm)
250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98.1 L/min (25.9 gpm)
Hydraulic System Relief Pressure. . . . . . . . . . . . . . . . 21 374±1034 kPa (3100±150 psi)
Hydraulic Circuit Relief Pressure . . . . . . . . . . . . . . . . 22 753±1379 kPa (3300±200 psi)
Charge Circuit Pressure . . . . . . . . . . . . . . . . . . . . . . . . 1379—1551 kPa (200—225 psi)
Gear Shaft OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 mm (0.748 in.)
Gear Shaft Bushing ID (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . 19.2 mm (0.755 in.)
End Plate Scoring (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0381 mm (0.0015 in.)
Pump Body Gear Pocket ID (Maximum) . . . . . . . . . . . . . . . . . . . . . . 43.7 mm (1.719 in.)
CONTROL VALVE
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9110
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 spool, open center
SYSTEM
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spin-on canister
System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 L (6 gal)
Reservoir Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6 L (4.1 gal)
11/22/00 9-3
SPECIFICATIONS HYDRAULICS
TORQUE SPECIFICATIONS
Hydraulic/Charge Pump Body Cap Screws. . . . . . . . . . . . . . . . . . . . . . 35 N•m (26 lb-ft)
Boom Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 N•m (33 lb-ft)
Bucket Circuit Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft)
System Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 N•m (34 lb-ft)
Anti-Cavitation Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 N•m (33 lb-ft)
Spool Cover Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 N•m (84 lb-in.)
Spool Retainer Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 N•m (84 lb-in.)
Valve Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (18 lb-ft)
Bucket Cylinder Upper Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 N•m (54 lb-ft)
Boom Cylinder Lower Pivot Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624 N•m (460 lb-ft)
Work Port Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft)
Lift Check Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 N•m (48 lb-ft)
Valve Body Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft)
Upper Cylinder Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624 N•m (460 lb-ft)
Lower Cylinder Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 N•m (54 lb-ft)
Boom and Bucket Cylinder Lock Nut. . . . . . . . . . . . . . . . . . . . . . . . . 136 N•m (100 lb-ft)
High-Flow Pump Gear Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.1 N•m (30 lb-ft)
High-Flow Pump Retaing Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . 50 N•m (35 lb-ft)
Self-Leveling Valve Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N•m (20 lb-ft)
OTHER MATERIALS
9-4 11/22/00
SYSTEM COMPONENTS AND OPERATION HYDRAULICS
SYSTEM COMPONENTS AND locked in the neutral or actuated position by turning the
lock located on the handle.(On hands only machines
OPERATION the right foot pedal controls the auxiliary hydraulics.
Pushing the “toe” on the pedal sends oil to the quick
Function: couplers. Pushing the pedal into the detent position will
hold it in place.)
The hydraulic system provides fluid power to charge
the hydrostatic system and operate the bucket and The system relief valve, located in the control valve,
boom cylinders and optional auxiliary hydraulic protects the hydraulic system and hydraulic/charge
attachments. pump from excessive pressure. The system relief valve
limits system pressure to 21 374 ± 1034 kPa
(3100 ± 150 psi) and is not adjustable.
Theory of Operation:
The boom circuit relief valve, located in the control
The hydraulic system is an "open center series" type
valve, protects the boom cylinder circuit from excessive
system. In this system, the hydraulic/charge pump
pressure resulting from shock loading when the spool
provides a continuous flow of oil through a main circuit
that connects all of the controlling valves. If the valves is in the neutral position. The circuit relief valves limit
are not operated, the flow of oil passes through the cylinder circuit pressure to 22 753 ± 1379 kPa
open center passage of each valve, then through the oil (3300 ± 200 psi) and is not adjustable.
cooler and oil filter, and returns to the hydraulic The bucket and boom circuits each incorporate a
reservoir. Also, in this type of circuit, the first controlling solenoid valve that hydraulically locks movement of the
valve takes priority over the next valve downstream bucket and boom should any of the following conditions
from the circuit. occur:
• If the operator engages the park brake switch
• Hydraulic/Charge Pump • If the operator turns the engine off or if the engine
The hydraulic/charge pump is a direct drive, positive stalls
displacement gear pump. The pump is mounted and • If the operator releases the seat belt
driven off the end of the front hydrostatic pump. The • If the operator is not sitting in the seat
hydraulic/charge pump draws oil from the reservoir and
supplies a constant flow of oil to the control valve.
• Oil Cooler and Filter
• Control Valve Return oil from the control valve flows to the oil cooler,
located at the rear of the machine. This location allows
The control valve integrates three spool valves and the cooler and radiator to be cooled by the engine fan.
three pressure relief valves into one housing.
Oil from the oil cooler flows to the hydraulic oil filter and
The first valve in the series, and therefore first priority, the charge pressure relief valve before entering the
controls the boom cylinder circuit. When this valve is hydraulic reservoir. The oil filter is a canister-type
actuated by the left foot pedal (toe—lower, heel— screw-on filter.
raise), [On hands only machines the left foot pedal is
non-functional. The left steering control lever has a The charge pressure relief valve maintains charge
“wrist” mechanism built into it. To raise the boom pull pressure at 1448 kPa (210 psi) and is not adjustable.
“wrist” up toward ROPS. To lower the boom push “wrist Solenoid lockout valves are located in both the boom
down towards seat.] the open center port is blocked and bucket circuits. In the boom circuit it is located
and oil is directed to the appropriate side of the boom before the tee connection to the base end of the
cylinders. Cylinder return oil flows through the control cylinders. The lockout valve is located before the tee
valve to the oil cooler, filter and reservoir. connection to the rod end of the bucket cylinders. The
The second valve in the series controls the bucket function of the lockout valve is to prevent flow to or from
cylinder circuit. When this valve is actuated by the right the cylinders.
foot pedal (toe—dump, heel—roll back), [On hands
only machines the right foot pedal is the auxiliary • High Flow Pump (Optional)
hydraulics control. The right steering control lever has a
The high flow option is for attachments that require a
“wrist” mechanism built into it. To roll the bucket back
high flow rate to operate. The high flow pump is a
push “wrist” down towards seat. To dump the bucket
positive displacement gear pump. The pump draws oil
pull “wrist up towards ROPS.] the open center port is
from the reservoir and supplies a constant flow of oil to
blocked and oil is directed to the appropriate side of the
the high flow solenoid valve which is mounted on the
bucket cylinders. Cylinder return oil flows through the
reservoir. When the high flow switch is off the pump will
control valve to the oil cooler, filter and reservoir.
pump oil through the valve and back to the reservoir.
The third valve in the series provides power to operate When the switch is turned on it energizes the solenoud
optional auxiliary hydraulic attachments. This spool is valve and the oil is diverted to the auxiliary spool of the
controlled by a special "wrist" mechanism built into the control valve.
right steering control lever. The auxiliary handle can be
9-5 11/22/00
HYDRAULICS SYSTEM COMPONENTS AND OPERATION
• Self-Leveling (Optional)
Self-leveling automatically levels attachments as the
boom is raised by routing oil from the rod ends of the
boom cylinders to the piston ends of the bucket
cylinders.
As the boom cylinders extend, oil from the rod ports is
directed through a variable orifice and a fixed orifice at
the flow divider valve. The proportion of the oil flow is
determined by the size of the variable orifice. Oil from
the variable orifice flows to the head ports of the bucket
cylinders and the remainder of the oil goes through the
fixed orifice to return. Resistance to movement of the
bucket cylinders creates a pressure high enough to
open the unloading spool in the self-level valve. As the
bucket cylinders extend, oil from the rod ports flows
past the open unloading valve and goes to return. The
purpose of the unloading valve is to prevent the bucket
cylinders from dumping during the self-level cycle.
Self-leveling does not operate during boom lowering.
11/22/00 9-6
HYDRAULICS SYSTEM SCHEMATIC
SYSTEM SCHEMATIC
Charge Flow
Brake Valve
B A Lockout
Solenoid
Drive Motor
3100 psi
Brake
Self-Leveling
A A Valve (Optional)
B B
Hydraulic/Charge
Pump
Hydrostatic High-Flow
Pumps Valve (Optional)
Bucket
Engine Lockout
Solenoid
Oil C D
Cooler
High-Flow A
Pump 3000 psi
(Optional) B
Anticavitation
Check Tilt Cylinders
A
Aux Auxiliary
B
Couplers
Brake
Drive Motor
KV31129
11/22/00 9-7
SYSTEM COMPONENT LOCATION HYDRAULICS
9-8 11/22/00
HYDRAULICS SYSTEM COMPONENT LOCATION
Oil Cooler
Self-Leveling
High Flow Valve Valve (Optional)
(Optional)
Hydraulic Vent
Reservoir
Hydraulic Oil
Temperature
Sender (late
models)
Hydraulic Oil
Temperature
Drain Plugs Sender (Early
Models)
Hydraulic
Suction Line
Hydraulic
Pressure Line
Hydraulic/
Charge Pump
Line to Boom
Cylinders
Hydraulic
Return Line
Lines to
Bucket Control Valve
Cylinders
Foot Pedal
Assembly
KV31097
11/22/00 9-9
SYSTEM COMPONENT LOCATION HYDRAULICS
3
8
4 10
3
25
3
21
24
8
3 10
22
8
20 3
10
12
11
9
2
15
19
14
18
16
17
13
KV31130
18
1. Plug 14. Bucket Spool Valve
2. Spring 15. Boom Spool Valve
3. O-Ring 16. Centering Pin
4. Lift Check Valve 17. Bucket Spool Cover
5. System Relief Valve 18. Auxiliary/Boom Spool Cover
6. Bushing 19. Detent Ball
7. Washer 20. Spacer Block
8. Cover Plate 21. Boom Relief Valve
9. Screw 22. Plug
10. Backup Washer 23. Anti-Cavitation Valve
11. Spacer 24. Screw
12. Control Valve Body 25. Spacer
13. Auxiliary Spool Valve
9 - 10 11/22/00
HYDRAULICS SYSTEM COMPONENT LOCATION
O-Ring
End Plate
(250 Shown)
Screw (8)
45 N•m (33 lb-ft)
Idler Gear
O-Ring
Backup Gasket
Seal
Wear Plate
Drive Gear
Body
KV13951
11/22/00 9 - 11
SYSTEM COMPONENT LOCATION HYDRAULICS
KV13266
N
M
KV13267
9 - 12 11/22/00
HYDRAULICS TROUBLESHOOTING
TROUBLESHOOTING
Bucket overloaded ● ● ● ● ●
High system pressure
Check system relief valve ● ● ●
pressure setting
Hydraulic oil cooler restricted ●
11/22/00 9 - 13
DIAGNOSIS HYDRAULICS
DIAGNOSIS
Test Conditions:
• Hydraulic reservoir oil at proper level.
• Operator in seat.
• Seat belt fastened.
• Key switch in RUN position.
1. Foot pedals. Pedals should move freely. Check linkage from pedals to valve.
Check for bent spools in valve.
Test Conditions:
• Engine running at slow idle.
1. Instrument panel. Hydraulic oil temperature and filter Filter restriction light on—replace
restriction warning lights should be filter.
off. Hydraulic oil temperature light on—
check oil cooler for restriction.
2. Boom operation. Boom should move freely through Check that park brake switch is in
range of motion when left pedal is the center or run position.
depressed forward or backward. Perform system flow and pressure
Perform following boom checks: checks to verify proper operation of
• Boom operation. hydraulic/charge pump.
• Boom drift down. Check boom cylinders for bent rod
or damaged cylinder wall.
• Boom lift check test.
Check hydraulic hoses, tubing, and
• Boom drift up. connections for leaks.
3. Bucket operation. Bucket should move freely through Check that park brake switch is in
range of motion when right pedal is the center or run position.
depressed forward or backward. Perform system flow and pressure
Perform following bucket checks: checks to verify proper operation of
• Bucket operation. hydraulic/charge pump.
• Bucket drift dump position. Check bucket cylinders for bent rod
or damaged cylinder wall.
• Bucket drift rollback position.
Check hydraulic hoses, tubing, and
• Bucket lift check test. connections for leaks.
9 - 14 11/22/00
HYDRAULICS TESTS AND ADJUSTMENTS
Procedure:
Equipment:
IMPORTANT: If lockout solenoids are not working • D01074AA In-Line Hydraulic Tester
properly, boom and bucket will not move. • KV13885 Quick Disconnect, Male
• KV13884 Quick Disconnect, Female
1. Sit in seat.
• JT03377 Hose, 2 required
2. Fasten seat belt.
• JT03012 Connector, 2 required
3. Start the engine.
• JT05690 Connector, 2 required
4. Release the park brake switch by holding all the
way down and releasing to the RUN position.
5. Move the bucket and boom pedals. Bucket and Procedure:
boom should move freely. 1. Lower boom and bucket to normal ground position.
6. Disconnect seat belt. Boom and bucket should lock Stop engine and relieve hydraulic pressure.
as soon as the seat belt is released.
Results:
If function is not correct, check boom and bucket
lockout solenoid circuit.
KV13885
JT05690 JT03012 JT03377
KV13884
KV15257
2. Install JT03012 and JT05690 Connectors on one
end of both JT03377 Hoses.
3. Install KV13885 and KV13884 Quick Disconnects
on connectors.
Inlet
D01074AA
In-Line
Hydraulic
Tester KV15136
4. Connect JT03377 Hose to D01074AA In-Line
Hydraulic Tester.
11/22/00 9 - 15
TESTS AND ADJUSTMENTS HYDRAULICS
KV18562 c CAUTION
5. Attach quick disconnects to auxiliary hydraulic
connectors. To help prevent injury from escaping hydraulic
6. Operate hydraulic system until oil reaches normal oil under pressure, relieve the pressure in the
operating temperature of 43°C (110°F). system before removing hydraulic lines.
7. Set engine speed to full throttle position.
8. Actuate auxiliary hydraulic control lever into detent Procedure:
position. 1. Raise and block skid steer. (See RAISING AND
9. Slowly turn load valve knob on hydraulic tester to BLOCKING SKID STEER in the
the right (clockwise) until pressure relief valve MISCELLANEOUS section.)
releases. 2. Raise boom fully and engage the boom lock. Stop
engine and relieve hydraulic pressure.
Specifications: 3. Remove cover plates to access the hydrostatic
pumps. (See COVER PLATE REMOVAL/
INSTALLATION in the MISCELLANEOUS section.)
NOTE: Add 1379 kPa (200 psi) for system charge
pressure when checking pressure on machine.
9 - 16 11/22/00
HYDRAULICS TESTS AND ADJUSTMENTS
Hydraulic Oil
Filter Manifold
KV18853
7. Follow charge flow line from filter manifold and
disconnect at left side of hydrostatic pump center
manifold.
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.
Specifications:
• Charge pressure must be 1379—1551 kPa
(200—225 psi).
Results:
1. If charge pressure does not meet specifications,
test pump flow.
2. If pump flow meets specifications, replace complete
hydraulic oil filter manifold.
11/22/00 9 - 17
TESTS AND ADJUSTMENTS HYDRAULICS
Reason:
To ensure that the hydraulic/charge pump is delivering
sufficient oil flow to operate the hydraulic system
properly.
Equipment:
• D01074AA In-Line Hydraulic Tester
Male Auxiliary Connector
• KV13885 Quick Disconnect, Male
• KV13884 Quick Disconnect, Female KV18562
• JT03377 Hose, 2 required
6. Attach quick disconnects to auxiliary hydraulic ports
• JT03012 Connector, 2 required located on left boom arm.
• JT05690 Connector, 2 required 7. Operate hydraulic system until oil reaches normal
Procedure: operating temperature of 43°C (110°F).
1. Raise and block skid steer. (See RAISING AND 8. Set engine speed to wide open throttle (WOT)
BLOCKING SKID STEER in the position (2400 rpm).
MISCELLANEOUS section.) 9. Actuate auxiliary hydraulics control handle into
2. Lower boom and bucket to normal ground position. detent (down toward seat) position.
Stop engine and relieve hydraulic pressure. 10. Turn load valve knob to increase resistance until
pressure reads 10 340kPa (1500 psi).
Specifications:
KV13885 Minimum Pump Flow
JT03012 JT03377 (Standard):
JT05690
240 . . . . . . . . . . . . . . . . . . . . . .49.1 L/min (13 gpm)
KV13884 250 . . . . . . . . . . . . . . . . . . . . . 56.7 L/min (15 gpm)
(High-Flow Option):
240 . . . . . . . . . . . . . . . . . . . . 84.8 L/min (22.4 gpm)
250 . . . . . . . . . . . . . . . . . . . . 98.1 L/min (25.9 gpm)
KV15257
3. Install JT03012 and JT05690 Connectors on one
end of both JT03377 Hoses. Results:
4. Install KV13885 and KV13884 Quick Disconnects 1. Check auxiliary hydraulic control valve spool travel
on connectors. and control handle pivot and linkage to make sure
mechanical systems are operating properly.
Male Quick Outlet 2. If flow is low, verify proper engine speed at full
Disconnect- throttle. If engine speed is OK, rebuild or replace
to-Inlet Hose charge pump.
Outlet-to-Female
Quick Disconnect 3. If machine is equipped with high-flow option and
Hose has low flow or is overheating, check to make sure
lift check valve assemblies have been removed
from control valve. (See CONTROL VALVE
ASSEMBLY in this section.)
Inlet
D01074AA
In-Line
Hydraulic
Tester KV15136
5. Connect JT03377 Hose to D01074AA In-Line
Hydraulic Tester.
9 - 18 11/22/00
HYDRAULICS TESTS AND ADJUSTMENTS
CIRCUIT RELIEF VALVE TEST 6. Start remote pump to pressurize boom raise port.
Take reading when pressure on gauge starts to
decrease. The point at which pressure decreases
NOTE: If machine is equipped with a bucket circuit is the opening pressure of the boom circuit relief
relief valve perform mandatory PIP 00KV010 to valve.
remove bucket circuit relief valve.
Reason: Specifications:
To check boom and bucket circuit relief valves. Boom
Circuit Relief Pressure. . . . . . . . . 22 753 ± 1379 kPa
Equipment: (3300 ± 200 psi)
• 38H1417 Cap
• JT03494 Adapter Fitting Results:
• JT07192 Electric/Hydraulic Pump If pressure is not within specification, replace circuit
• 0—35 000 kPa (0—5000 psi) Gauge relief valve.
Procedure:
NOTE: Relief valve is factory set and not adjustable.
1. Park skid steer safely. Replace relief valve if pressure readings are
2. Raise boom and place on boom locks. not within specification.
3. Gain access to the hydraulic control valve. (See
COVER PLATE REMOVAL/INSTALLATION in the
MISCELLANEOUS section.) BOOM DRIFT DOWN CHECK
Reason:
To ensure that boom raise circuit does not have internal
leaks.
Procedure:
Boom Raise
Port Start engine and raise boom halfway. Shut off engine.
KV18008 Specifications:
4. Disconnect boom raise line at both ends and set • Slight boom drift is permissible.
aside. Cap fitting at boom lockout solenoid.
Electric/Hydraulic Results:
Pump If boom drifts down, check for:
Hose-to-Valve
• Leaking port lock solenoid valve. Replace valve.
• Leaking circuit relief valve. Replace valve.
• Leaking cylinder packing. Rebuild or replace
cylinder.
• Leaking control valve spool. Replace valve.
Gauge
KV18009
11/22/00 9 - 19
TESTS AND ADJUSTMENTS HYDRAULICS
Specifications: Results:
• Slight boom drift is permissible. If bucket drifts:
Results: • Check for leaks in cylinder packing. Rebuild or
replace cylinder.
If boom drifts upward:
• Check for leaks in control valve spool. Replace
• Check for leaking cylinder packing. Rebuild or valve.
replace cylinder.
• Check for leaking control valve spool. Replace
valve.
9 - 20 11/22/00
HYDRAULICS TESTS AND ADJUSTMENTS
Reason:
To ensure that bucket lift check does not have internal
leak.
Procedure:
1. Start engine and use bucket dump function to raise
machine a few inches off ground. Self-Leveling
2. Turn engine off. Valve
3. Turn key on and push park brake switch to center Adjusting
position. Screw
4. Press bucket pedal to dump position.
KV31141
11/22/00 9 - 21
REPAIR HYDRAULICS
REPAIR
Drive Gear
Idler Gear
Hydraulic/Charge
Pump Body
Pump
KV14291
6. Disconnect inlet and high pressure hydraulic lines
from charge pump.
KV14305
Mark Case
2. Remove idler gear and drive gear from pump body.
KV14304
9 - 22 11/22/00
HYDRAULICS REPAIR
Pump Body
End Plate
O-Ring
KV14306 KV14307
3. Remove pump body from end plate. 6. Inspect inside diameter of bushings in end plate
4. Remove and discard O-ring. and front hydrostatic pump. Replace if greater than
19.2 mm (0.755 in.).
Cover Plate
O-Ring
KV14308
KV14309
5. Remove cover plate and discard O-ring.
7. Inspect end plate and front hydrostatic pump for
scoring and wear. Replace if wear or scoring
HYDRAULIC/CHARGE PUMP exceeds 0.0381 mm (0.0015 in.).
COMPONENT INSPECTION
1. Clean all parts in suitable solvent. Dry all parts.
2. Remove all nicks and burrs using emery cloth.
3. Inspect drive gear splines for twisted, broken, or
worn teeth.
4. Inspect gear shafts at bushing area and seal area
for rough surfaces and excessive wear.
KV14312
8. Inspect pump body gear pockets. Replace body if
ID of gear pockets exceeds 43.7 mm (1.719 in.).
KV14299
11/22/00 9 - 23
REPAIR HYDRAULICS
Pump Body
End Plate
KV14310
5. Install new wear plate assembly in pump body.
Drive Gear
Idler Gear
Pump Body
KV14305
KV14294
4. Install new seal and backup gasket in new wear
plate. Step in middle of backup gasket must nest in
seal step.
9 - 24 11/22/00
HYDRAULICS REPAIR
HYDRAULIC/CHARGE PUMP
INSTALLATION
O-Ring
Hydraulic
Inlet Line
Passages
Hydraulic/Charge
Pump
Hydraulic High
Pressure Line
KV14291
3. Install hydraulic/charge pump assembly onto front
KV31116 hydrostatic pump using eight screws and washers.
KV31113
1/4/01 9 - 25
REPAIR HYDRAULICS
Removal:
1. Remove left side engine cover.
Output Line
O-Ring
Nut
Suction Line
1. Loosen nut and unthread until flush with end of
shaft. Leave nut on end of shaft to protect the
threads.
2. Using a small gear puller, put tension on gear. Tap
the end of puller to loosen the taper.
2. Disconnect suction line and output line from pump. 3. Remove nut and gear.
Installation:
1. Install new O-ring and position pump on engine.
2. Install cap screws and nuts. Tighten to 50 N•m
3. Remove cap screws and nuts. (35 lb-ft).
4. Remove pump from machine. 3. Connect output and suction lines to pump.
4. Install left side engine cover.
9 - 26 11/22/00
HYDRAULICS REPAIR
Jam Nuts
Line from High- Bracket
Flow Pump
11/22/00 9 - 27
REPAIR HYDRAULICS
Clamp
Boom Lower
Line Fittings
Bucket Dump
Line Fittings
Boom Raise Bucket Rollback
Line Fittings Line Fittings
KV31071 KV31073
14. Remove clamp.
c CAUTION
15. Disconnect bucket dump line fittings and remove
line.
16. Disconnect bucket rollback fittings and remove line.
To help prevent injury from escaping hydraulic
oil under pressure, relieve the pressure in the
system before removing hydraulic lines.
Clamp
KV31074
Isolator Plate 17. Remove clamp.
18. Disconnect auxiliary line fittings and remove lines.
Cotter
Pins Clevis
Clamp
Pins
KV31072
12. Remove cap screws and isolator plate from both High Pressure
left and right sides. Line KV31075
13. Remove clamp (left side only). 19. Remove cotter pins and clevis pins from spools.
20. Disconnect high pressure line and return line.
9 - 28 11/22/00
HYDRAULICS REPAIR
Cap Screws
and Nuts
KV31076 Auxiliary
Spool
21. Remove three cap screws and nuts and remove Bucket Spool
control valve. KV31014
Boom, Bucket
and Auxiliary
Fittings
Hydraulic
Return
KV31014
11/22/00 9 - 29
REPAIR HYDRAULICS
O-Ring
KV14317
Wiper
NOTE: Boom and auxiliary spool valves have detent
balls that are retained by the spool cover. Be
careful not to lose them during disassembly.
KV31018
Wiper
KV31017
9 - 30 11/22/00
HYDRAULICS REPAIR
O-Ring
Cap
Detent Sleeve
KV31018
7. Remove spiral ring that retains the cap in spool
cover. Remove cap and detent sleeve from cover. Retainer
KV31020A
Sleeves
12. Remove auxiliary spool retainer, wiper and O-ring
Retainers from opposite end of valve housing. Place all
auxiliary spool parts together.
Screws
KV31027
Bucket Spool
Spacer
O-Ring
KV31030
Backup
Washer 13. Remove cover from bucket spool.
Wiper
KV31028
9. Remove wiper, backup washer, O-ring, and spacer
from housing.
10. Place all boom valve parts together to avoid mixing
parts.
11. Repeat steps 3—7 for auxiliary spool.
11/22/00 9 - 31
REPAIR HYDRAULICS
O-Ring
O-Ring
Retainer
Wiper
Wiper
Spacer Retainer
KV31029 KV31031
14. Pull bucket spool from housing. Remove O-ring, 15. Remove the retainer, wiper and O-ring from the
wiper, retainer plate and spacer from spool. opposite end of the valve housing. Place all bucket
valve parts together.
Boom Relief
Valve Assy.
Plug
O-Ring
KV31023
16. Remove the boom relief valve.
17. Remove plug. If bucket relief valve is present,
update machine per mandatory PIP 00KV010.
9 - 32 11/22/00
HYDRAULICS REPAIR
System Relief
Valve Assy.
Anti-Cavitation
Check Valve Assy.
O-Ring
O-Ring
Spring
Poppet
KV31024 Boom Raise Lift Check Assy.
Fitting
18. Remove the system relief valve.
19. Remove anti-cavitation check valve.
Auxiliary
Port
KV31025
O-Ring
KV14322
21. Remove valve body plug.
11/22/00 9 - 33
REPAIR HYDRAULICS
KV14318
Pintle
Poppet
KV31033
Seat
KV31035
6. Inspect system relief valve. Verify pintle moves
freely.
KV31032
9 - 34 11/22/00
HYDRAULICS REPAIR
11/22/00 9 - 35
REPAIR HYDRAULICS
KV31010
9 - 36 11/22/00
HYDRAULICS REPAIR
1. Boom Spool 19. Spiral Snap Ring 33. O-Ring (3 used) 51. Retaining Plate
2. Cap Screw (2 used) 20. Ball (Large) 34. Spool Seal 52. Spool Wiper
3. Retaining Plate 21. Plate 35. Retaining Plate 53. Spacer
4. Spool Wiper 22. End Cap 36. Spool Wiper 54. Spring
5. Backup Ring 23. Ball (Small) 37. Spacer 55. Spring Collar
6. Spool Seal (4 used) 38. Spring Collar 56. Washer
7. Seal Extender 24. Spring 39. Spring 57. Detent Spring
8. O-Ring 25. Bucket Spool 40. Spring Collar 58. Spool End
9. Spool Seal 26. Spool Wiper 41. End Cap 59. Detent Sleeve
10. Retaining Plate 27. Cap Screw (2 used) 42. Spool End 60. Spiral Snap Ring
11. Spool Wiper 28. Retaining Plate 43. Cap Screw (2 used) 61. Ball (Large)
12. Spacer 29. Spool Seal 44. Auxiliary Spool 62. Plate
13. Cap Screw (2 used) 30. Load Check 45. Spool Wiper 63. End Cap
14. Spring Collar (3 used) 46. Cap Screw (2 used) 64. Ball (Small)
15. Washer 31. Load Check Plug 47. Retaining Plate (4 used)
(3 used) 65. Cap Screw (2 used)
16. Detent Sleeve 48. Spool Seal
32. Load Check Spring
17. Spool End (3 used) 49. Valve Body
18. Detent Sleeve 50. Spool Seal
11/22/00 9 - 37
REPAIR HYDRAULICS
Poppet
1. Thoroughly clean and dry all parts.
Boom Raise Lift Check Assy.
Fitting
O-Ring
KV14322 Auxiliary
Port
2. Install new O-ring on valve body plug and install into
control valve. Tighten to 38 N•m (28 lb-ft).
KV31026
9 - 38 11/22/00
HYDRAULICS REPAIR
Bucket
Auxiliary Boom
Boom Relief
Valve Assy.
Plug
O-Ring
O-Ring
Wiper
Retainer
KV31031
10. Install O-ring, wiper, and retainer for auxiliary and
bucket spools. Tighten to 9.5 N•m (84 lb-in.).
KV31023
6. Replace boom relief valve O-ring and install relief Spacer Retainer
valve. Tighten to 45 N•m (33 lb-ft).
7. Install bucket circuit plug. Tighten to 38 N•m O-Ring
(28 lb-ft). If control valve has a bucket relief valve
perform mandatory PIP 00KV010.
System Relief
Valve Assy.
Anti-Cavitation
Check Valve Assy.
Wiper
KV31017
O-ring
11. Place spacer, retainer, new wiper, and O-ring on
each spool.
12. Use protective jaws and place housing in vise with
boom relief valve up.
13. Thoroughly coat spools and body passages with
oil.
KV31024
8. Replace system relief valve O-ring and install valve. NOTE: All three spools are different. Be careful not to
Tighten to 51 N•m (34 lb-ft). mix spool and spring assemblies when
9. Replace anti-cavitation check valve O-ring and assembling valve.
install. Tighten to 45 N•m (30 lb-ft).
11/22/00 9 - 39
REPAIR HYDRAULICS
Detent Sleeve
KV31039
15. Use petroleum jelly to retain balls in boom spool. KV31040
Place four small balls and one large ball in spool. 17. While holding detent sleeve just above end of
cover, use a punch to depress the large ball. While
depressing ball, slide detent sleeve down into
cover.
Cover
Cap Screw
KV31038 KV31041
16. Install spool covers and press on cover to seat O- 18. Install cap in end of cover and retain with spiral
rings in control valve housing. Install cap screws ring.
finger-tight. 19. Repeat process for auxiliary spool.
20. Tighten spool cover cap screws to 9.5 N•m
(84 lb-in.).
9 - 40 11/22/00
HYDRAULICS REPAIR
21. Move spools in and out to verify operation. 24. Install retainers, sleeves and screws. Tighten
screws to 9.5 N•m (84 lb-in.).
KV31037
Spacer
KV31076
Return Line
Backup Washer
Wiper
Cotter
KV31019 Pins Clevis
Pins
23. Install spacer, O-ring, back-up washer and
retainers for boom spool.
Sleeves
High Pressure
Retainers Line KV31075
Screws
KV31027
11/22/00 9 - 41
REPAIR HYDRAULICS
Boom Lower
Line Fittings
Clamp
Auxiliary Line
Fittings
Boom Raise
Line Fittings
KV31074 KV31071
4. Connect auxiliary line fittings. 10. Connect boom line fittings to control valve.
5. Install clamp.
Clamp
Jam Nuts
Bracket
Cable
KV31070
KV31073 11. Install auxiliary cable to bracket and tighten jam
6. Connect bucket dump line fittings and bucket nuts securely.
rollback fittings. 12. Connect rod end to bellcrank.
7. Install clamp. 13. Connect boom lockout harness connector. Install
wire ties as needed.
14. Connect battery negative (–) cable to battery.
Isolator Plate
15. Run machine and operate all hydraulic controls to
check operation and leaks.
16. Install cover plates. (See COVER PLATE
Cap Screws REMOVAL/INSTALLATION in the
MISCELLANEOUS section.)
17. Lower and secure the ROPS. (See RAISING ROPS
[ROLL OVER PROTECTION STRUCTURE] in the
MISCELLANEOUS section.)
Clamp
KV31072
9 - 42 11/22/00
HYDRAULICS REPAIR
c CAUTION
PROTECTION STRUCTURE] in the
MISCELLANEOUS Section)
C
Boom Lower Line
Boom Cylinder
Cap Screw
Installation:
7. Install cap screws and tighten to 28 N•m (20 lb-ft).
11/22/00 9 - 43
REPAIR HYDRAULICS
Boom
Retract Cylinder
Hydraulic Line
Cap Screw
Spacer Block
KV14330
5. Loosen lower pivot cap screw.
KV14329
2. Install upper pivot pin. Tighten cap screw to 73 N•m
(54 lb-ft).
9 - 44 11/22/00
HYDRAULICS REPAIR
NOTE: Right-side bucket cylinder shown in photo. Left- IMPORTANT: DO NOT remove nut until cylinder
side cylinder is the same. pivot is loose.
Tapered Pin
Hydraulic Lines
Cap Screw
KV14269
9. Rock cylinder back and forth perpendicular to
normal rotation until tapered pin becomes loose.
10. Remove nut, cap screw, tapered pin and bucket
cylinder. Make repairs as necessary.
KV13997
4. Tag or label bucket cylinder hydraulic lines to aid
during installation. BUCKET CYLINDER INSTALLATION
5. Disconnect hydraulic lines from bucket cylinder.
Tapered Pin
Cap Screw
Pivot Pin
Cap Screw
Nut KV14269
KV13998 1. Install bucket cylinder, tapered pin and cap screw.
6. Remove nut and cap screw retaining lower cylinder
pivot pin.
7. Remove lower cylinder pivot pin using a brass
punch and hammer.
Nut
Nut KV14268
2. Install nut and tighten to draw tapered pin into upper
cylinder pivot. Tighten nut to 624 N•m (460 lb-ft).
KV14268
11/22/00 9 - 45
REPAIR HYDRAULICS
Pivot Pin
Cylinder Rod
Remove Paint
Nut
KV13998
3. Position cylinder and install lower pivot pin. Install
cap screw and nut. Tighten cap screw to 73 N•m
(54 lb-ft). Cylinder Barrel
Snap Ring
KV18854
3. Pull cylinder rod out slowly to the full extended limit
to remove trapped oil or air between rod piston and
rod guide.
4. Push cylinder rod back in cylinder barrel
approximately 50 mm (2.0 in.).
5. Remove external snap ring.
6. Remove paint from flange of rod guide. Thoroughly
Hydraulic Lines
clean all debris from rod guide.
Rod Guide
KV13997
KV18851
4. Inspect hydraulic fitting O-rings for wear or damage.
7. Using a wooden dowel or brass drift, drive rod guide
Replace if necessary. Connect hydraulic lines.
into cylinder past internal snap ring groove.
KV18855
9 - 46 11/22/00
HYDRAULICS REPAIR
Filler Ring
14. Install new seals and O-rings.
15. Install rod guide, piston and lock nut on cylinder
rod.
KV18852
30°
8. Make sure there is no debris in internal snap ring
groove. Install filler ring supplied with cylinder seal
kit into internal snap ring groove.
Cylinder Rod
KV14276
16. Tighten lock nut to 136 N•m (100 lb-ft).
Internal
Cylinder Rod
Snap Ring Piston
Hose Clamp
Lock Nut
Rod Guide
Rod Guide
KV14276 Rod Guide Flange
10. Install rod end in a soft-jawed vise. Cylinder Bore KV14285
11. Remove lock nut, piston, and rod guide from
cylinder rod. 18. Install a hose clamp over snap ring on rod guide.
12. Clean and inspect all parts. Remove any nicks or 19. Tighten hose clamp until snap ring is seated in
burrs with emery cloth. groove on rod guide, then loosen one turn.
13. Carefully inspect cylinder bore and piston for deep
grooves or scratches. Replace entire cylinder if
either is damaged.
11/22/00 9 - 47
REPAIR HYDRAULICS
KV14272
21. Install external snap ring.
22. Perform start-up procedure. (See START-UP
PROCEDURE AFTER COMPONENT
REPLACEMENT in the HYDROSTATIC POWER
TRAIN section.)
9 - 48 1/4/01
MISCELLANEOUS CONTENTS
CONTENTS
MISCELLANEOUS
Page
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RAISING ROPS (ROLLOVER PROTECTION STRUCTURE). . . . . . . . . . . . . . . . . . . 4
BOOM LOCK REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RAISING AND BLOCKING SKID STEER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COVER PLATE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
USING REMOTE START BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ROPS REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LOWER BOOM LINK REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 10
UPPER BOOM LINK REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 12
QUIK-TATCH® HITCH COUPLING REMOVAL/INSTALLATION. . . . . . . . . . . . 13
QUIK-TATCH® REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BOOM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CAB HEATER/DEFROSTER (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HEATER CORE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
BLOWER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CONTROL VALVE REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . 20
CAB HEATER DEAERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CAB DOOR (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
WINDSHIELD WIPER/WASHER (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
WASHER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
11/22/00 10 - 1
CONTENTS MISCELLANEOUS
10 - 2 11/22/00
MISCELLANEOUS SPECIFICATIONS
SPECIFICATIONS
TORQUE SPECIFICATIONS
ROPS-to-Side Frame Retaining Nuts Torque . . . . . . . . . . . . . . . . . . . 105 N•m (77 lb-ft)
ROPS-to-Rear Weldment Post Cap Screws Torque . . . . . . . . . . . . . . 105 N•m (77 lb-ft)
Lower Boom Link-to-Frame Pin Retaining Cap Screw Torque . . . . . . . 73 N•m (54 lb-ft)
Upper Boom Link, Lower Boom Link,
and Boom Pivot-Pin Cap Screws Torque . . . . . . . . . . . . . . . . . . . 275 N•m (200 lb-ft)
Cylinder Upper Pivot-Pin Retaining Cap Screw . . . . . . . . . . . . . . . . . . 73 N•m (54 lb-ft)
Wiper Arm Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 N•m (92 lb-in.)
OTHER MATERIALS
TY6333 or Moly High Temperature EP Grease Apply to boom lock and QUIK-TATCH™.
TY6347
PT–569 Never–Seez Lubricant Apply to upper boom link, lower boom link and
boom pivot pins.
NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or in the
European Microfiche Tool Catalog (MTC).
11/22/00 10 - 3
REPAIR MISCELLANEOUS
Lock Nut
(2 Used)
KV15169
Cylinder Tube
KV18531
10 - 4 11/22/00
MISCELLANEOUS REPAIR
I
H
F H
E
A D G
C I
J
L
A
E D
KV15160
Removal: Installation:
1. Lower boom to the at-rest ground position. Engage
park brake switch and turn engine off. NOTE: Apply Moly High Temperature EP Grease to all
2. Raise ROPS and ensure ROPS is safely in the moving boom lock parts before installation.
locked position. (See RAISING ROPS
[ROLLOVER PROTECTION STRUCTURE].)
3. Remove two cap screws (A), guide bracket (B), and 1. Installation is the reverse of removal.
spring (G).
4. Remove cotter pins (D), washers (E), pins (F and
K), and linkage (L).
5. Remove levers (C and J) with spring pins (I) and
boom lock pins (H) as an assembly.
11/22/00 10 - 5
REPAIR MISCELLANEOUS
c CAUTION
should not contact ground.
Removal:
NOTE: Skid steer shown with boom in raised position. 1. Park skid steer safely.
If access to engine compartment is needed or 2. Raise boom and engage boom locks.
if ROPS will be raised, raise boom to top of
travel and lower onto boom locks. For all other 3. Raise ROPS and ensure ROPS is safely in the
repairs, lower boom to bottom of travel. locked position. (See RAISING ROPS
[ROLLOVER PROTECTION STRUCTURE].)
3. Place a suitable floor jack under front of skid steer Toe Guard
in line with front axle, centering jack between tires Cap Screw
on flat spot of frame. (2 Used)
4. Jack up front end until tires are approximately
51 mm (2 in.) from the ground.
KV18096
10 - 6 11/22/00
MISCELLANEOUS REPAIR
Retaining
Pin
Boot Plate
KV18097 KV18052
5. Remove six cap screws securing center kick plate 8. Remove retaining pins and pivot pins.
to cover plate and skid steer frame. Remove center 9. To remove boot plates, remove control lever
kick plate. handles. (See CONTROL LEVER HANDLE
DISASSEMBLY/ASSEMBLY in the STEERING
section.)
Cap Screw
(2 Used) 10. Make repairs to components as necessary.
Side Plate
Installation:
1. Installation is the reverse of removal.
KV18098
Reason:
6. Remove two cap screws securing side plate to To allow the engine to be started with the ROPS raised
cover plate and skid steer frame. Remove side and in the locked position.
plate. Repeat procedure for opposite side.
Procedure:
1. Park skid steer safely.
c CAUTION
Boot Plates
11/22/00 10 - 7
REPAIR MISCELLANEOUS
c CAUTION
Prevent personal injury! DO NOT operate boom
and bucket functions when using remote start
box. Boom and bucket hydraulics are enabled
when engine is running and park brake switch is
disengaged by the remote start box.
10. Use remote start box ignition to start and shut off
engine with ROPS raised and in the locked
KV18038 position.
11. Use the remote start box park brake switch to
7. Install an M10 x 30 cap screw in tab at the rear of engage or disengage park brake.
both yokes to secure steering assembly during
adjustment.
IMPORTANT: Remove cap screws securing
steering assembly. Lowering ROPS with cap
screws in position may damage yoke
assemblies.
ROPS REMOVAL/INSTALLATION
Removal:
1. Park skid steer on flat level surface. Lower boom to
the at-rest ground position, engage park brake
switch and turn engine off.
KV15239
KV15239 2. Disconnect negative (–) battery cable.
8. Lock auxiliary hydraulic control handle in the neutral Wire Connector Rear Light Bracket
position.
Ignition
Right Tail Light
Rear Work Light
Left Tail Light
Electrical
Connector
KV18030
3. Push rear tail and work lights to left and pull from
rear light bracket.
4. Disconnect rear tail and work light wire connectors.
Tag or label connectors to aid during installation.
5. Remove cap screws and remove rear light bracket.
KV18004
10 - 8 11/22/00
MISCELLANEOUS REPAIR
c CAUTION
Make sure ROPS is supported properly with
suitable lifting strap and hoist before
proceeding.
Rear Light
Connectors
KV18031 12. Raise hoist and lifting strap to remove weight from
6. Remove tie bands securing bulkhead connectors. ROPS cylinders.
7. Disconnect ROPS-to-engine bulkhead connectors. 13. Remove retaining pins and pivot pins to disconnect
left and right ROPS cylinders from skid steer
frame.
Washer
(2 used) Pivot Bushings
Cap Screw
Bulkhead
Connectors
Lock Nut
(2 used)
KV15169
KV18033
ROPS
ROPS
Cylinder
Cylinder
Pivot Pin
KV18032
11/22/00 10 - 9
REPAIR MISCELLANEOUS
Installation: BOOM
Pivot Bushings
Cap Screw LOWER BOOM LINK REMOVAL/
Bulkhead
INSTALLATION
Connectors
Removal:
1. Park skid steer on flat level surface. Lower boom to
the at-rest ground position, engage park brake
switch and turn engine off.
2. Turn key switch ON and operate all hydraulic
controls to relieve system pressure. Turn key
Rear Light switch OFF.
Connectors
KV18033
Washer
(2 Used)
KV31005
10 - 10 11/22/00
MISCELLANEOUS REPAIR
KV31001
Hydraulic
Pivot Pin Hoses
KV31003
KV31006
7. Disconnect both hydraulic hoses from lines under
boom. Tag hoses for ease of installation.
IMPORTANT: Use a non-metallic hammer to
prevent damaging lower link.
Hose
Retainers
4. Strike the lower link with a 5.2 kg (11.5 lb) non-
metallic deadblow hammer to loosen taper of pivot
pin.
KV31004
11/22/00 10 - 11
REPAIR MISCELLANEOUS
KV31002
Installation:
1. Coat front pivot pin with Never–Seez compound. Upper Cap
Put link in place in machine and install front pivot Screws
pin. Secure pin with cap screw and nut. Tighten to
73 N•m (54 lb-ft).
2. Lower and secure ROPS. (See RAISING ROPS
[ROLLOVER PROTECTION STRUCTURE] in this
section.) Lower Cap
3. Coat taper of new pivot pin with Never–Seez Screws and Nuts KV31007
compound. Install pivot pin through lower link and
into boom.
5. Loosen both lower pivot-pin cap screws and nuts.
4. Install pivot pin cap screw and nut. Tighten to
Do not remove nuts. Loosen nuts to the end of the
275 N•m (200 lb-ft.)
cap screw.
5. Route hydraulic hoses through loops on link and
connect to hydraulic lines under boom. Install hose
Cap Screw
retainers.
6. Install wiring harness (eight button or 12-volt) if
equipped.
7. Remove blocking and lubricate pivot points.
Removal:
1. Park skid steer on flat level surface. Lower boom to
the at-rest ground position, engage park brake
KV31008
switch and turn engine off.
2. Turn key switch ON and move all hydraulic controls NOTE: Left Side Shown
to remove system pressure. Turn key switch OFF.
6. Loosen both upper pivot-pin cap screws
approximately six turns.
10 - 12 11/22/00
MISCELLANEOUS REPAIR
Removal:
1. Remove any attachments. (See QUIK-TATCH
REMOVAL/INSTALLATION in this section.)
2. Park skid steer on flat level surface.
KV31007
KV31125
11/22/00 10 - 13
REPAIR MISCELLANEOUS
Pivot Pin
Shoulder
KV31139
KV31126
Remove KV31127
Threads
9. Strike the driver sharply to loosen the taper and
remove the pivot pin
19.6 mm
KV31138
10 - 14 11/22/00
MISCELLANEOUS REPAIR
Boom Cylinder
Pivot Pins
KV31128
QUIK-TATCH® REPAIR
Removal:
1. Remove any attachments from skid steer.
2. Lower boom to the at-rest ground position and turn
engine off.
B A
KV15163
11/22/00 10 - 15
REPAIR MISCELLANEOUS
2. Install QUIK-TATCH assembly into implement frame 2. Park skid steer on flat level surface. Lower boom
with end of pin (A) located in upper corner of and block the front near the at-rest ground position.
weldment frame as shown above. Engage park brake switch and turn engine off.
c CAUTION
B
BOOM REMOVAL/INSTALLATION
Blocking
KV31003
10 - 16 11/22/00
MISCELLANEOUS REPAIR
KV31044
CAB HEATER/DEFROSTER
(OPTIONAL)
KV31045
FILTER REPLACEMENT
1. Park skid steer on flat level surface. Lower boom to 2. Remove heater cover. Disconnect lights.
the at-rest ground position, engage park brake
switch and turn engine off.
11/22/00 10 - 17
REPAIR MISCELLANEOUS
Remove Screws
TS281
c CAUTION KV18856
Foam Seals
Remove Hoses
Vent Valve
KV18861
10 - 18 11/22/00
MISCELLANEOUS REPAIR
BLOWER REMOVAL/INSTALLATION
Remove Cap Screws
Removal:
1. Park skid steer on flat level surface. Lower boom to
the at-rest ground position, engage park brake
switch and turn engine off.
Heater KV18860
Cover
5. Remove four cap screws retaining blower to main
housing.
6. Lift blower from housing.
KV31045
Installation:
2. Remove heater cover.
1. Place blower in housing.
2. Loosely install four cap screws to retain blower in
housing.
Disconnect Wires
Install Screws
KV18858
KV18859
3. Disconnect wires from speed controller and ground. 3. Install and tighten three screws retaining blower
Tag wires for ease of installation. from bottom of housing.
4. Tighten cap screws.
Remove Screws
KV18859
11/22/00 10 - 19
REPAIR MISCELLANEOUS
Connect Wires
TS281
KV18858
c CAUTION
5. Connect wires to speed controller and ground. Explosive release of fluids from pressurized
6. Install heater cover. cooling system can cause serious burns. Shut
off engine. Remove filler cap only when cool
enough to touch with bare hands. Slowly loosen
CONTROL VALVE REMOVAL/ cap to first stop to relieve pressure before
INSTALLATION removing cap completely.
Removal:
1. Park skid steer on flat level surface. Lower boom to Remove Hoses
the at-rest ground position, engage park brake
switch and turn engine off. Vent Valve Cap Screw
Connector
Cap Screw
Heater
Cover
KV18857
Installation:
1. Install valve. Tighten cap screws and nuts securely.
10 - 20 11/22/00
MISCELLANEOUS REPAIR
KV31043
11/22/00 10 - 21
REPAIR MISCELLANEOUS
Vent Valve
KV18857 KV18867
Removal:
KV18868
1. Park skid steer on flat level surface. Lower boom to
the at-rest ground position, engage park brake 6. Loosen upper cap screws and lower nuts that retain
switch and turn engine off. left door roller brackets to door.
Installation:
1. One person enter skid steer.
2. With second person assisting from outside cab, tilt
the door so the right side is lower. Slide door into
cab.
3. Insert top-right roller into door track.
10 - 22 11/22/00
MISCELLANEOUS REPAIR
Removal:
Thumb Nut
Small Nut
KV31099
Cup Large Nut
Seal
1. Disconnect wiring harness from motor.
KV31103
Installation:
1. Place motor in machine. Install small nut and flat
washer.
2. Install seal, cup and large nut on motor shaft.
11/22/00 10 - 23
REPAIR MISCELLANEOUS
WASHER PUMP
O-Ring
Removal:
1. Disconnect wiring harness and hose from pump.
KV31102
Screws KV31104
Tapered Spline
KV31101B
10 - 24 11/22/00
INDEX
11/22/00 INDEX - 1
INDEX
INDEX - 2 11/22/00
INDEX
11/22/00 INDEX - 3
INDEX
Engine (Cont.) G
Speed Adjustment . . . . . . . . . . . . . . . . . . . . 3-115
Grease Specifications . . . . . . . . . . . . . . . . . . . . . . 2-15
Tests and Adjustments . . . . . . . . . . . . . . . . . . 3-23
Engine Oil Pressure Switch/Sender Test . . . . . . 4-129 H
Exhaust Manifold, Inspection . . . . . . . . . . . . . . . 3-105 High-Flow
Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . 4-85
F Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-134
Face Seal Hydraulic
Fittings with Inch Stud Ends Torque . . . . . . . . . 2-8 Auxiliary Control Handle Adjustment . . . . . . . 7-17
Fittings with Metric Stud Ends Torque . . . . . . . 2-9 Boom and Bucket Cylinder Repair . . . . . . . . . 9-46
Fan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103 Boom and Bucket Lockout Solenoids Check . 9-15
Boom Cylinder
Fan/Alternator Belt Tension . . . . . . . . . . . . . . . . 3-102
Component Location . . . . . . . . . . . . . . . . 9-12
Flywheel Replace . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
Ball Bearing Installation . . . . . . . . . . . . . . . . . 3-76 Boom Drift Down Check . . . . . . . . . . . . . . . . . 9-19
Housing, Replacement . . . . . . . . . . . . . . . . . . 3-79 Boom Drift Up Check . . . . . . . . . . . . . . . . . . . 9-20
Hydrostatic Drive Coupling . . . . . . . . . . . . . . . 3-38 Boom Lift Check Test . . . . . . . . . . . . . . . . . . . 9-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76 Boom Lockout Solenoid Check . . . . . . . . . . . 9-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75 Bucket Cylinder
Ring Gear Replacement . . . . . . . . . . . . . . . . . 3-76 Component Location . . . . . . . . . . . . . . . . 9-12
Four-Way Flasher . . . . . . . . . . . . . . . . . . . . . . . . . 4-98 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
Front Plate Bucket Drift Dump Position Check . . . . . . . . . 9-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89 Bucket Drift Rollback Position Check . . . . . . . 9-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86 Bucket Lift Check Test . . . . . . . . . . . . . . . . . . 9-21
Bucket Lockout Solenoid Check . . . . . . . . . . . 9-15
Fuel and Preheat Circuit . . . . . . . . . . . . . . . . . . . . 4-36 Bucket Self-Leveling Adjustment . . . . . . . . . . 9-21
Fuel Filter, Replace Element . . . . . . . . . . . . . . . . 3-107 Charge Pump Pressure Test . . . . . . . . . . . . . 9-16
Fuel Injection Nozzle Circuit Relief Valve Test . . . . . . . . . . . . . . . . . 9-19
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113 Component Location . . . . . . . . . . . . . . . . . . . . 9-9
Chatter Test . . . . . . . . . . . . . . . . . . . . . . . . . 3-112 Control Handle Adjustment
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111 Hands Only . . . . . . . . . . . . . . . . . . . . . . . 7-17
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-113 Control Valve
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
Opening Pressure Test . . . . . . . . . . . . . . . . . 3-112 Component Location . . . . . . . . . . . . . . . . 9-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111 Cross Section . . . . . . . . . . . . . . . . . . . . . . 9-36
Running Test . . . . . . . . . . . . . . . . . . . . . . . . 3-120 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 9-29
Spray Pattern Test . . . . . . . . . . . . . . . . . . . . 3-112 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112 Installation . . . . . . . . . . . . . . . . . . . . . . . . 9-41
Valve Seat Checking . . . . . . . . . . . . . . . . . . 3-113 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Valve Stem/Guide Wear Checking . . . . . . . . 3-112 Fitting Information . . . . . . . . . . . . . . . . . . . . . . . 2-8
High-Flow Pump
Fuel Injection Pump Remove/Inspect/Install . . . . . . . . . . . . . . . 9-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110
High-Flow Valve Replace . . . . . . . . . . . . . . . . 9-27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
Hydraulic/Charge Pump
Timing Adjustment . . . . . . . . . . . . . . . . . . . . . 3-27
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . 3-101
Component Location . . . . . . . . . . . . . . . . 9-11
Fuel Level Sender Disassembly . . . . . . . . . . . . . . . . . . . . . . . 9-22
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-145 Flow Test . . . . . . . . . . . . . . . . . . . . 6-11, 9-18
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-135 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Fuel Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Measure Supply Pressure . . . . . . . . . . . . . . . 3-26 Pressure Test . . . . . . . . . . . . . . . . . . . . . . 6-10
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 3-108 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Fuel System Oil Filter Restriction Switch
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114 Replacement . . . . . . . . . . . . . . . . . . . . . 4-149
Cold Start Advance System . . . . . . . . . . . . . 3-118 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-139
Fuel Injection Nozzles, General Information . 3-119 Oil Overtemperature Switch
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . 3-117 Replacement . . . . . . . . . . . . . . . . . . . . . 4-148
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-137
Self-Leveling Valve - Replace . . . . . . . . . . . . 9-43
System Component Location . . . . . . . . . . . . . . 9-8
INDEX - 4 11/22/00
INDEX
Hydraulic (Cont.) M
System Components and Operation . . . . . . . . 9-5
Manifold Preheat Relay Replacement . . . . . . . . 4-142
System Relief Valve Pressure Test . . . . . . . . 9-15
System Schematic . . . . . . . . . . . . . . . . . . . . . . 9-7 Metric Fastener Torque Values . . . . . . . . . . . . . . . . 2-5
Hydrostatic Drive Coupling, Install . . . . . . . . . . . . 3-38 N
Hydrostatic Motor Nozzle Bores, Injection, Cleaning . . . . . . . . . . . . . 3-48
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 O
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Removal/Installation . . . . . . . . . . . . . . . . . . . . 6-37 Oil Bypass Valve Replacement . . . . . . . . . . . . . . . 3-94
Oil Cooler
Hydrostatic Power Train
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
Component Location . . . . . . . . . . . . . . . . . . . . 6-6
Nipple Replacement . . . . . . . . . . . . . . . . . . . . 3-93
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . 6-20
System Operation . . . . . . . . . . . . . . . . . . . . . . . 6-5 Oil Deflector Installation . . . . . . . . . . . . . . . . . . . . 3-91
Test and Adjustments . . . . . . . . . . . . . . . . . . . 6-10 Oil Dipstick Guide Adapter Replacement . . . . . . . 3-94
Troubleshooting and Diagnosis . . . . . . . . 6-8, 6-9
Oil Pan Installation . . . . . . . . . . . . . . . . . . . . . . . . 3-97
Hydrostatic Pump
Oil Pressure Regulating Valve
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
Case Drain Pressure Test . . . . . . . . . . . . . . . 6-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
Case Drain Test . . . . . . . . . . . . . . . . . . . . . . . 6-17
Valve Seat Replacement . . . . . . . . . . . . . . . . 3-93
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Exploded View Oil Pressure Switch/Sender
Center Manifold . . . . . . . . . . . . . . . 6-24, 6-25 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 4-141
Front Pump . . . . . . . . . . . . . . . . . . . . . . . 6-23 Oil Pressure, Engine, Checking . . . . . . . . . . . . . . 3-24
Rear Pump . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Oil Pump
Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Gear Axial Clearance . . . . . . . . . . . . . . . . . . . 3-95
High Pressure Relief Test . . . . . . . . . . . . . . . . 6-12 Gear Radial Clearance . . . . . . . . . . . . . . . . . . 3-95
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3-95
Hydrostatic Transmission and Hydraulic Oil . . . . . 2-13 Strainer Replacement . . . . . . . . . . . . . . . . . . . 3-94
O-Ring Face Seal Fittings
I Service Recommendations . . . . . . . . . . . . . . . . 2-10
Idler Gear
Bushing and Shaft, Measure . . . . . . . . . . . . . 3-87 P
Bushing Replacement . . . . . . . . . . . . . . . . . . 3-88 Park Brake
End Play, Measure . . . . . . . . . . . . . . . . . . . . . 3-86 Actuator Cylinder
Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . 3-89 Removal/Installation . . . . . . . . . . . . . . . . . 8-12
Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-88 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Spring Pin Installation . . . . . . . . . . . . . . . . . . . 3-88 Burnish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Ignition Switch Test . . . . . . . . . . . . . . . . . . . . . . . 4-131 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Inch Fastener Torque Values . . . . . . . . . . . . . . . . . 2-7 Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Injection Nozzle Bores, Cleaning . . . . . . . . . . . . . 3-48 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Instrument Cluster Replacement . . . . . . . . . . . . 4-145 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Instrument Panel Component Location . . . . . . . . 4-143 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Solenoid Replacement . . . . . . . . . . . . . . . . . 4-149
K Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . 4-138
Key Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . 4-131 Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-131
Theory of Operation . . . . . . . . . . . . . . . . . . . . . 8-4
L Park Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Legend, Electrical Components . . . . . . . . . . . . . . . 4-9 Piston
Levers, Steering - See Steering Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . 3-68
Light Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . 4-132 Cooling Jets, Checking . . . . . . . . . . . . . . . . . . 3-61
Lights Circuit Operation . . . . . . . . . . . . . . . . . . . . 4-91 Head and Skirt Checking . . . . . . . . . . . . . . . . 3-69
Lock, Boom Removal/Installation . . . . . . . . . . . . . 10-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
11/22/00 INDEX - 5
INDEX
INDEX - 6 11/22/00
INDEX
Troubleshooting (Cont.)
Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Turbocharger
Axial Bearing End Play . . . . . . . . . . . . . . . . . 3-106
Boost Pressure, Checking . . . . . . . . . . . . . . 3-117
Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116
Pre-Lubrication . . . . . . . . . . . . . . . . . . . . . . . 3-106
Radial Bearing Clearance . . . . . . . . . . . . . . . 3-105
Recommendations . . . . . . . . . . . . . . . . . . . . 3-107
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106
V
Valve
Assembly, Actuating Parts . . . . . . . . . . . . . . . 3-49
Checking Recess . . . . . . . . . . . . . . . . . . . . . . 3-51
Clearance, Adjusting . . . . . . . . . . . . . . . . . . . 3-31
Grind Face Angle . . . . . . . . . . . . . . . . . . . . . . 3-53
Guides
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Measuring . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Inspect and Measure . . . . . . . . . . . . . . . . . . . 3-52
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Lift, Checking . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Rocker Arm, Valve Clearance Adjustment . . . 3-31
Rotators, Inspect . . . . . . . . . . . . . . . . . . . . . . 3-53
Seats
Clean and Inspect . . . . . . . . . . . . . . . . . . 3-50
Installing Inserts . . . . . . . . . . . . . . . . . . . . 3-52
Lapping . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Machining . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
Removing Inserts . . . . . . . . . . . . . . . . . . . 3-51
Springs
Inspect and Measure . . . . . . . . . . . . . . . . 3-53
Removing . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
W
Water Pump
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . 3-98
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-101
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
Wear Ring, Installation . . . . . . . . . . . . . . . . . . . . . 3-92
Wheel Speed Test . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Windshield Wiper/Washer
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-115
Circuit Schematic . . . . . . . . . . . . . . . . . . . . . 4-116
Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-135
Washer Pump Replacement . . . . . . . . . . . . . 10-24
Wiper Motor Replacement . . . . . . . . . . . . . . 10-23
11/22/00 INDEX - 7
INDEX
INDEX - 8 11/22/00