2254 LOADER

REPAIR MANUAL

INTRODUCTION REAR MOTOR REPAIR

TABLE OF CONTENTS MAIN HYDRAULIC SYSTEM

SAFETY RECOMMENDATIONS PUMP REPAIR

SPECIFICATIONS DIRECTIONAL CONTROL VALVE

CAPACITIES CYLINDER REPAIR

TORQUE SPECIFICATIONS RELIEF VALVE

FLUID RECOMMENDATIONS STEERING SYSTEM

GENERAL INFORMATION BRAKE SYSTEM

SERVICE POINTS OPERATOR’S STATION

HYDROSTATIC SYSTEM TRANSMISSION

HYDROSTATIC PUMP FOUR WHEEL TORQUE HUB

TWO WHEEL / FOUR WHEEL DRIVE

CONTROL VALVES ELECTRICAL SYSTEM

FWD/REV FOOT PEDAL INDEX

FRONT AXLE MOTOR

 SECTION 0001 SPECIFICATIONS

Engine ...................................................................................................... 0001-3

Transmission ............................................................................................ 0001-3
Final Drive (Front Axle) ............................................................................ 0001-3
Final Drive (Rear Axle) ............................................................................. 0001-3
Pump Drive ............................................................................................... 0001-3
Double Vane Pump ................................................................................... 0001-4
Single Vane Pump .................................................................................... 0001-4
Variable Displacement Pump (Hydrostatic Transmission) ..................... 0001-5
Variable Displacement Motor (Rear Axle) ............................................... 0001-5
Fixed Displacement Motor (Front Axle) .................................................. 0001-6
Steering Cylinders ................................................................................... 0001-7
Swing Cylinders ....................................................................................... 0001-7
Flex Cylinder ............................................................................................ 0001-7
Piler Lift Cylinders ................................................................................... 0001-7
Piler Motor Circuit .................................................................................... 0001-8
Grab Cylinders ......................................................................................... 0001-8
Lift Cylinder .............................................................................................. 0001-8
Loading System ....................................................................................... 0001-9
Control Valve—Boom Lift and Grab ........................................................ 0001-9
Traction System ....................................................................................... 0001-9
Front Axle Motor ...................................................................................... 0001-9
Steering System ....................................................................................... 0001-9
Piler Chain System .................................................................................. 0001-9
Grab and Lift ............................................................................................ 0001-10
Hydraulic Schematic ................................................................................ 0001-10
Steer, Swing Flex and Piler Lift ............................................................... 0001-11
Hydraulic Schematic ................................................................................ 0001-11
Piler .......................................................................................................... 0001-12
Hydraulic Schematic ................................................................................ 0001-12
Hydrostatic Transmission ........................................................................ 0001-13
Hydraulic Schematic ................................................................................ 0001-13
 SPECIFICATIONS

Engine
Type ........................................................................... JOHN DEERE 6068T
Cylinders .................................................................... 6 (In Line)
Displacement ............................................................. 8.3 L. (506 Cu. In.)
Horsepower ................................................................ 200 HP (149 Kw) At 2200 RPM
Peak Torque ................................................................ 585 Lb. Ft. (793 Nm) At 1500 RPM
Oil Pressure ............................................................... 50 PSI (345 kPa) (Normal)
Oil Temperature .......................................................... 248° F (120° C) In Pan (Normal)
Coolant Flow .............................................................. 67 GPM (253 L/M) At 2400 RPM
High Idle ..................................................................... 2400 RPM (Full Load) / 2550 RPM (No Load)

Transmission
Type ........................................................................... 3 Speed Manual
Gearing
1 ST ........................................................................................................................... 3.3077 : 1
2 ND .......................................................................................................................... 1.778 : 1
3 RD .......................................................................................................................... 0.875 : 1
Differential .................................................................. 3.1667 : 1

Final Drive (Front Axle)

Type ........................................................................... 9.5 : 1 High Clearance
Max Speed ................................................................. 940 RPM
Max Torque ................................................................. 34,000 In. Lb. (3,842 Nm)

Final Drive (Rear Axle)

Type ........................................................................... Planetary Gear Torque Hub
Reduction ................................................................... 26.28 : 1
Output Torque Rating
Max Continuous ................................................... 40,000 In. Lb.(4,519 Nm)
Max Intermittent .................................................. 80,000 In. Lb. (9,039 Nm)
Max Peak ............................................................ 100,000 In. Lb. (11,299 Nm)
Max Input Speed (Continuous) ................................... 3750 – 4500 RPM

Pump Drive
Type ........................................................................... Double
Reduction ................................................................... 1 : 1
Pump Rotation ........................................................... Enginewise

0001-3
 SPECIFICATIONS

Double Vane Pump

Displacement:
Shaft End Pump — .................................................... 4.12 Cu. In./Rev. (67.5 Cc/Rev)
Cover End Pump — ................................................... 1.67 Cu. In./Rev (27.4 Cc/Rev)
Speed:
Maximum ................................................................... 2700 RPM
Pressure:
Maximum At Max Speed ............................................ 3000 PSI (206.8 Bar)
Rotation:
Viewed From Shaft End .............................................. Left Hand
Typical Performance:
Shaft End Pump
Input Horsepower At 2250 PSI, 2400 RPM .......... 60 HP (45 kW)
Delivery At 2250 PSI, 2400 RPM ......................... 36 GPM (136 L/Min)
Cover End Pump
Input Horsepower At 2250 PSI, 2400 RPM .......... 22 HP (16 kW)
Delivery At 2250 PSI, 2400 RPM ......................... 15 GPM (57 L/Min)
Weight:
Normal ....................................................................... 45 Lb. (20.4 Kg)

Single Vane Pump

Displacement:
Maximum ................................................................... 2.78 Cu. In./Rev (45.5 Cc/Rev)
Speed:
Maximum ................................................................... 2700 RPM
Pressure:
Maximum At Max Speed ............................................ 3000 PSI (206.8 Bar)
Rotation:
Viewed From Shaft End .............................................. Right Hand
Typical Performance:
Input Horsepower At 2250 PSI, 2400 RPM ................. 42 HP (31 kW)
Delivery At 2250 PSI, 2400 RPM ............................... 23 GPM (87 L/Min)
Weight:
Normal ....................................................................... 32 Lb. (14.5 Kg)

0001-4
 SPECIFICATIONS

Variable Displacement Pump (Hydrostatic Transmission) (Eng.Ref. 0031352578)

Displacement:
Maximum ................................................................... 6.1 Cu. In./Rev (100 Cc/Rev)
Input Speed:
Maximum ................................................................... 4300 RPM
Continuous ................................................................. 3600 RPM
Minimum .................................................................... 500 RPM
Pressure:
Maximum ................................................................... 7000 PSI (480 Bar)
Continuous ................................................................. 6000 PSI (420 Bar)
Case Pressure:
Continuous ................................................................. 40 PSI (3 Bar)
Maximum (Cold Start) ................................................ 75 PSI (5 Bar)
Charge Inlet Vacuum at Sea Level:
Normal ....................................................................... 10 In. Hg (0.7 Bar [ABS])
Cold Start .................................................................. 25 In. Hg (0.2 Bar [ABS])
Weight:
Normal ....................................................................... 150 Lb. (68 Kg)

Variable Displacement Motor (Rear Axle) (Eng.Ref. 0331332747)

Displacement:
Maximum ................................................................... 4.92 Cu. In./Rev (80 Cc/Rev)
Rated Speed:
At Min Displacement .................................................. 5000 RPM
At Max Displacement ................................................. 3100 RPM
Maximum Speed:
At Min Displacement .................................................. 6250 RPM
At max Displacement ................................................. 4000 RPM
Theoretical Torque:
At Min Displacement .................................................. 156 Lb. In./1000 PSI
(0.26 Nm/Bar)
At Max Displacement ................................................. 784 Lb. In./1000 PSI
(1.28 Nm/Bar)
Pressure:
Maximum ................................................................... 6960 PSI (480 Bar)
Minimum .................................................................... 145 PSI (10 Bar)
Case Pressure:
Continuous ................................................................. 44 PSI (3 Bar)
Maximum (Cold Start) ................................................ 73 PSI (5 Bar)
Weight:
Normal ....................................................................... 72 Lb. (32 Kg)

0001-5
 SPECIFICATIONS

Fixed Displacement Motor (Front Axle)

Displacement:
Maximum ................................................................... 5.43 Cu. In./Rev (89 Cc/Rev)
Speed:
Maximum At Max Displacement ................................ 2900 RPM
Pressure:
Maximum At Max Speed, Max Displacement ............. 5000 PSI (345 Bar)
Charge Pressure:
Neutral ....................................................................... 190 - 210 PSI (13-15 Bar)
Forward or Reverse .................................................... 160 - 180 PSI (11-12.5 Bar)
Case Pressure:
Maximum ................................................................... 40 PSI (3 Bar)
Charge Inlet Vacuum at Sea Level:
Normal ....................................................................... 10 In. Hg (0.7 Bar [ABS])
Weight:
Normal ....................................................................... 108 Lb. (49 Kg)

0001-6
 SPECIFICATIONS

Steering Cylinders
Oil Supply ................................. Vane Piston Pump ........................... 15 GPM (57 L/M)
Cover End Pump
Relief Valve Priority Valve .................................................................... 1750 PSI (120 Bar)

Swing Cylinders
Oil Supply ................................. Vane Piston Pump ........................... 15 GPM (57 L/M)
Cover End Pump
Valve ......................................... 3 Bank Directional Control
3 Position / 4 Way
Pilot Operated
Cylinder Spool
Relief Valve ............................... Work Port Relief .............................. 1350 PSI (93 Bar) Left
1350 PSI (93 Bar) Right
Relief Valve ............................... Main Relief ...................................... 2250 PSI (155 Bar)

Flex Cylinder
Oil Supply ................................. Vane Piston Pump ........................... 15 GPM (57 L/M)
Cover End Pump
Valve ......................................... 3 Bank Directional Control
3 Position / 4 Way
Pilot Operated
Cylinder Spool
Relief Valve ............................... Work Port Relief .............................. 2000 PSI (138 Bar) Extd.
1000 PSI (69 Bar) Retract.
Relief Valve ............................... Main Relief ...................................... 2250 PSI (155 Bar)

Piler Lift Cylinders

Oil Supply ................................. Double Vane Piston Pump ............... 15 GPM (56.8 L/M)
Cover End Pump
Valve ......................................... 3 Bank Directional Control
3 Position / 4 Way
Pilot Operated
Cylinder Spool
Relief Valve ............................... Work Port Relief .............................. 1000 PSI (68 Bar) Close
500 PSI (34 Bar) Open
Relief Valve ............................... Main D.C. Valve Relief ...................... 2250 PSI (155 Bar)

0001-7
 SPECIFICATIONS

Piler Motor Circuit

Oil Supply ........................... Vane Piston Pump ................................. 25 GPM (94 L/M)
Single Pump
Valve ................................... Single Directional Control
3 Position / 4 Way
Manual Operated
Motor Spool
Relief Valve ......................... Main D.C. Valve Cartridge Relief ............. 2000 PSI (138 Bar) Extd.
Relief Valve ......................... Main Relief ............................................. 1750 PSI (138 Bar)

Grab Cylinders
Oil Supply ........................... Double Vane Piston Pump ...................... 36 GPM (136 L/M)
Shaft End Pump
Valve ................................... 2 Bank Directional Control
3 Position / 4 Way
Pilot Operated
Cylinder Spool
Relief Valve ......................... Work Port Relief ..................................... 2000 PSI (138 Bar) Close
1000PSI (69 Bar) Open
Relief Valve ......................... Main Relief ............................................. 2250 PSI (155 Bar)

Lift Cylinder
Oil Supply ........................... Double Vane Piston Pump ...................... 36 GPM (138 L/M)
Shaft End Pump
Valve ................................... 2 Bank Directional Control
3 Position / 4 Way
Pilot Operated
Cylinder Spool
Relief Valve ......................... Work Port Relief ..................................... 1800 PSI (124 Bar) Extd.
500 PSI (34 Bar) Retract.
Relief Valve ......................... Main Relief ............................................. 2250 PSI (155 Bar)

0001-8
 SPECIFICATIONS
Loading System
To check pressure, install gauges anywhere in the
lines that go from the pump to the respective control valve.
Run the engine at approximately 1000 RPM _.
Control Valve—Piler, Flex and Swing:
Main Relief .................... 2250 PSI (155 Bar)
Port Reliefs:
Boom Swing .................. 1350 PSI (93 Bar)
Boom Flex (Out) ............ 2000 PSI (138 Bar)
Boom Flex (In) .............. 1000 PSI (69 Bar)
Piler Lift (Raise) ............ 1000 PSI (69 Bar)
Piler Lift (Lower) ............ 500 PSI (34 Bar)
To check the pressure, actuate the piler or flex valve
until the cylinder bottoms out. Hold in this position while
observing pressure reading.
Control Valve—Boom Lift and Grab
Main Relief .................... 1800 PSI (124 Bar)
To check the main pressure, actuate the grab until
the cylinder bottoms out. Hold in this position while
observing pressure reading.
Port Reliefs:
Boom Lift (Raise) .......... 2250 PSI (155 Bar)
Boom Lift (Lower) .......... 500 PSI (34 Bar)
Grab (Both Ports) .......... 1350 PSI (93 Bar)
To check the pressure, lower boom until pressure
relief opens. Hold in this position while observing pressure
reading.
Throttle Valve—Lift:
The purpose of this valve is to slow the downward
movement of the boom in order to reduce pressure peaks.
It is fully open when the boom is lifting.
† In order to properly check your hydraulicpressure settings, you must first warm the system oil to at least 120°F (49°C).
0001-9
Traction System
Main System Pressure:
Main Relief ............. 5070 PSI (350 Bar)
NOTE: Multipurpose valve for high pressure
and relief and override.
Charge Pressure (Neutral) ..... 406 PSI (28 Bar)
Charge Pressure (For/Rev) .... 362 PSI (25 Bar)
To check the pressure, engage forth gear, lock the
wheels and fully stroke the pump at maximum engine
RPM. These readings are above the case drain pressure.
Vacuum:
Normal ................... 0-10" Hg (0-0.7 Bar ABS)
Cold Start .............. 25" Hg Max (0.2 Bar ABS)
Case Drain Pressure:
Normal ................... 0-40" PSI (0-3 Bar)
Cold Start .............. 75 PSI (5 Bar)
Front Axle Motor
High Pressure Relief5500 PSI (379.5 Bar)
Steering System
Relief Valve: Priority Steering Valve:
Relief Pressure ............. 2500 PSI (172 Bar)
Priority Valve: Steering Supply Valve:
Pressure Setting ........... 1750 PSI (121 Bar)
Piler Chain System
Relief Valve: Pump or Flow Control:
Pressure Setting ........... 1750 PSI (121 Bar)
Directional Valve: For/Rev Rotation:
Pressure Setting ........... 2000 PSI (138 Bar)
 SPECIFICATIONS

Grab and Lift

Hydraulic Schematic

0001-10
 SPECIFICATIONS

Steer, Swing Flex and Piler Lift

Hydraulic Schematic

0001-11
 SPECIFICATIONS

Piler
Hydraulic Schematic

0001-12
 SPECIFICATIONS

Hydrostatic Transmission
Hydraulic Schematic

0001-13
 FLUID CAPACITIES
Engine
Use an oil that meets the API Classification CF-4 or
CG-4, multi-grade 15W-40 Oil, CG preferred.†
6068T John Deere (200 HP) ....... 20 L (21 Qt)
Break-in oil, 100 hrs, followed by above CG-4
15W40 Multi Grade.
Change filter and completely drain after 100 hrs.
Radiator
Antifreeze (Ethylene Glycol) 7.6 L (2 Gal) min
Recommended 50% by volume.
Non-chromate Inhibitor ............... 3 - 6% by Volume
Clean Water ............................... Remainder
CAUTION
Do Not remove the radiator cap when it is hot!
Fill the radiator, operate the engine with the radiator
cap off and when the engine reaches normal operating
temperature, shut it off and check the coolant level. Top-
off the radiator with clean water, if necessary.
Transmission
SAE 85W140 (API-GL5) Oil ....... .10.5L (11 Qt)
Rear Steering Axle
SAE 85W140 (API-GL5) Oil or Equivalent††
Final Drive(s) ............................. 2.6 L (2.7 Qt)
Each Side
Front Rigid Axle
SAE 85W140 (API-GL5) Oil or Equivalent ††.
Large Final Drive(s) ................... 8 L (8½ Qt)
Small Final Drive(s) ................... 4.7 L (5 Qt)
Brake Fluid
J1703d or DOT3HD .................... ½-1 L (1-2 pt)
† In tropical conditions (ambient temperatures over 100° F [38° C]) use SAE 40W or SAE 15W40 oil in the engine.
†† Gear oil which meets AGMA (American Gear Manufacturers Association) Grade 5EP with a viscosity index of 95 min.
††† Adjust to conditions.
0002-3
Hydraulic Tank
SAE 30W Motor Oil ................... 320 L (85 Gal)
Which complies with one or more of the API
Classification CD/SF, CD/SD, CC/SF, CC/SD and MIL-
I-2104D.
Optional 15W30,CG-4Motor Oil ........ 320 L (85 Gal)
Fuel Tank
Standard Tank:
Clean Diesel Fuel ...................... 303 L (80 Gal)
Optional Tank:
Clean Diesel Fuel ...................... 340 L (90 Gal)
Tire Inflation Pressure †††
Front Tires
20.8 x 38 ................................... 1.38 bar (20 PSI)
23.1 x 34 ................................... 1.24 bar (18 PSI)
24.5 x 32 ................................... 1.10 bar (16 PSI)
30.5L32 ..................................... 1.10 bar (16 PSI)
Rear Tires
17.5L24 ..................................... 2.21 bar (32 PSI)
18.4 x 26 6PR ........................... 1.24 bar (18 PSI)
18.4 x 26 8PR ........................... 1.38 bar (20 PSI)
18.4 x 30 ................................... 1.24 bar (18 PSI)
Pump Drive
If the double pump drive is used, lubricate the pump
drive shafts and the splines with dry spline lubricant
whenever installing a pump or pump drive.
85W140 Gear Oil ...................................... 4.9L (1.3 Gal)