Technical Manual: John Deere Agriculture

John Deere Agriculture
1023E, 1025R and 1026R Compact Utility Tractor
TECHNICAL MANUAL
Compact Utility models 1025R, 1023E, 1026R,
1025R
TM126919, January 2013

TM126919-TECHNICAL MANUAL (g) by Belgreen
Table of contents
FOREWORD
Section 10 - GENERAL INFORMATION
Group 05 - Safety
Group 10 - General Specifications
Group 15 - Fuel and Lubricants
Group 20 - Serial Number Locations
Group 25 - Features and Accessories
Section 20 - ENGINE REPAIR
Group 05 - Engine
Group 10 - Cooling System
Section 30 - FUEL AND AIR REPAIR
Group 05 - Fuel System
Group 10 - Air Intake and Exhaust Systems
Group 15 - Speed Control Linkage
Section 40 - ELECTRICAL REPAIR
Group 05 - Battery, Starter and Alternator
Group 10 - Electrical System Components
Group 15 - Wiring Harness
Section 50 - POWER TRAIN REPAIR
Group 15 - Transmission
Group 20 - Rear PTO Driveshaft
Group 25 - Differential
Group 30 - Final Drives
Group 35 - Mechanical Front Wheel Drive
Section 60 - STEERING AND BRAKE REPAIR
Group 05 - Steering Repair
Group 10 - Brake Repair
Section 70 - HYDRAULICS REPAIR
Group 05 - Hydraulic Pump and Filter
Group 10 - Rockshaft
Group 15 - Selective Control Valve
Section 80 - MISCELLANEOUS REPAIR
Group 10 - Wheels
Group 15 - 3-Point Hitch
Group 20 - Hood
Group 25 - Mid-Mount Lift
Section 90 - OPERATOR′S STATION REPAIR
Group 05 - Seat and Support
Group 10 - ROLL-GARD
Group 15 - Operator Platform
Group 20 - Fenders
Section 210 - OPERATIONAL CHECKOUT PROCEDURES
Group 05 - Operational Checkout Procedures
Section 220 - ENGINE OPERATION, TESTS, AND ADJUSTMENTS
Group 05 - Component Location
Group 10 - Theory of Operation
Group 15 - Diagnosis, Tests, and Adjustments
Section 230 - FUEL AND AIR OPERATION, TESTS, AND ADJUSTMENTS
<- Go to Global Table of contents TM126919-TECHNICAL MANUAL


Group 15 - Diagnosis, Test and Adjustments
Section 240 - ELECTRICAL SYSTEM OPERATION, TESTS, AND ADJUSTMENTS
Group 20 - Wiring Schematics
Group 25 - Connector Information
Section 250 - POWER TRAIN OPERATION, TESTS, AND ADJUSTMENTS
Section 260 - STEERING AND BRAKE OPERATION, TESTS, AND ADJUSTMENTS
Section 270 - HYDRAULIC SYSTEM OPERATION, TESTS, AND ADJUSTMENTS
Group 15 - Diagnosis
Group 20 - Hydraulic Tests
Group 25 - Adjustments
Group 30 - Hydraulic Schematics
Section 299 - SERVICE TOOLS
Group 05 - Dealer Fabricated Tools
Group 10 - Service Tools and Kits

GENERAL INFORMATION (g) by Belgreen
Foreword
This manual is written for an experienced technician. Essential tools required in performing
certain service work are identified in this manual and are recommended for use.
Live with safety: Read the safety messages in the introduction of this manual and the
cautions presented throughout the text of the manual.
CAUTION:
This is the safety-alert symbol. When you see this symbol on the machine or in this manual,
be alert to the potential for personal injury.
Technical manuals are divided in two parts: repair and operation and tests. Repair sections
tell how to repair the components. Operation and tests sections help you identify the majority
of routine failures quickly.
Information is organized in groups for the various components requiring service instruction.
At the beginning of each group are summary listings of all applicable essential tools, service
equipment and tools, other materials needed to do the job, service parts kits, specifications,
wear tolerances, and torque values.
Technical Manuals are concise guides for specific machines. They are on-the-job guides
containing only the vital information needed for diagnosis, analysis, testing, and repair.
Fundamental service information is available from other sources covering basic theory of
operation, fundamentals of troubleshooting, general maintenance, and basic type of failures
and their causes.
<- Go to Section TOC Section 10 page 2 TM126919-TECHNICAL MANUAL

Section 10 - GENERAL INFORMATION
Table of contents
Group 05 - Safety ...................................................................................................................... 2
Recognize Safety Information ................................................................................................ 2
Handle Fuel Safely—Avoid Fires ............................................................................................. 2
Prevent Battery Explosions .................................................................................................... 3
Prepare for Emergencies ........................................................................................................ 4
Prevent Acid Burns ................................................................................................................. 6
Service and Operate Chemical Sprayers Safely ..................................................................... 8
Handle Chemical Products Safely ........................................................................................... 9
Avoid High-Pressure Fluids ................................................................................................... 11
Park Machine Safely ............................................................................................................. 11
Support Machine Properly .................................................................................................... 12
Wear Protective Clothing ..................................................................................................... 13
Work in Clean Area .............................................................................................................. 14
Service Machines Safely ....................................................................................................... 15
Work In Ventilated Area ....................................................................................................... 16
Illuminate Work Area Safely ................................................................................................. 17
Replace Safety Signs ............................................................................................................ 18
Use Proper Lifting Equipment ............................................................................................... 19
Remove Paint Before Welding or Heating ............................................................................ 20
Avoid Heating Near Pressurized Fluid Lines ......................................................................... 21
Keep ROPS Installed Properly ............................................................................................... 22
Service Tires Safely .............................................................................................................. 23
Avoid Harmful Asbestos Dust ............................................................................................... 25
Practice Safe Maintenance ................................................................................................... 26
Use Proper Tools .................................................................................................................. 28
Dispose of Waste Properly ................................................................................................... 29
Prevent Machine Runaway ................................................................................................... 30
Handle Starting Fluid Safely ................................................................................................. 30
Service Cooling System Safely ............................................................................................. 31
Stay Clear of Rotating Drivelines ......................................................................................... 33
Protect Against High Pressure Spray .................................................................................... 35
Construct Dealer-Made Tools Safely .................................................................................... 35
Clean Vehicle of Hazardous Pesticides ................................................................................. 36
Servicing Electronic Control Units ........................................................................................ 38
Welding Near Electronic Control Units ................................................................................. 39
Keep Electronic Control Unit Connectors Clean .................................................................... 41
Live With Safety ................................................................................................................... 41
Group 10 - General Specifications ........................................................................................ 43
Machine Specifications 1023E, 1025R, and 1026R EEC ....................................................... 43
Service Recommendations for O-Ring Boss Fittings ............................................................. 46
Service Recommendations For Flat Face O-Ring Seal Fittings ............................................. 49
Metric Cap Screw Torque Values—Grade 7 .......................................................................... 51
Metric Bolt and Screw Torque Values ................................................................................... 52
Unified Inch Bolt and Screw Torque Values .......................................................................... 53
Group 15 - Fuel and Lubricants ............................................................................................. 55

Diesel Fuel ........................................................................................................................... 55

Handling and Storing Diesel Fuel ......................................................................................... 56
Do Not Use Galvanized Containers ...................................................................................... 57
Lubricity of Diesel Fuel ......................................................................................................... 58
Testing Diesel Fuel ............................................................................................................... 58
Biodiesel Fuel ....................................................................................................................... 59
Filling Fuel Tank ................................................................................................................... 61
Diesel Engine Break-In Oil .................................................................................................... 63
Diesel Engine Oil .................................................................................................................. 64
Oil Filters .............................................................................................................................. 65
Heavy Duty Diesel Engine Coolant ....................................................................................... 66
Operating in Warm Temperature Climates .......................................................................... 67
Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT
CONDITIONER ............................................................................................................... 68
Testing Diesel Engine Coolant .............................................................................................. 70
Transmission and Hydraulic Oil ............................................................................................ 71
Use Correct Transmission/Hydraulic Filter Element ............................................................. 72
MFWD Axle Housing and Wheel Hub Oil ............................................................................... 73
Grease .................................................................................................................................. 74
Grease (Specific Application) ............................................................................................... 76
Mixing of Lubricants ............................................................................................................. 76
Alternative and Synthetic Lubricants ................................................................................... 76
Lubricant Storage ................................................................................................................. 77
Group 20 - Serial Number Locations .................................................................................... 78
Serial Numbers ..................................................................................................................... 78
Product Identification Number Location ............................................................................... 78
Engine Serial Number Location ............................................................................................ 78
Group 25 - Features and Accessories ................................................................................... 80
Features and Accessories ..................................................................................................... 80

Section 10 - GENERAL INFORMATION Group 05: Safety
Group 05 - Safety
Recognize Safety Information
Safety-alert symbol
This is a safety-alert symbol. When you see this symbol on your machine or in this manual,
be alert to the potential for personal injury.
Follow recommended precautions and safe operating practices.
Handle Fuel Safely—Avoid Fires

Avoid Fires
Handle fuel with care: it is highly flammable. Do not refuel the machine while smoking or
when near open flame or sparks.
Always stop engine before refueling machine. Fill fuel tank outdoors.
Prevent fires by keeping machine clean of accumulated trash, grease, and debris. Always
clean up spilled fuel.
Use only an approved fuel container for transporting flammable liquids.
Never fill fuel container in pickup truck with plastic bed liner. Always place fuel container on
ground before refueling. Touch fuel container with fuel dispenser nozzle before removing can
lid. Keep fuel dispenser nozzle in contact with fuel container inlet when filling.
Do not store fuel container where there is an open flame, spark, or pilot light such as within a
water heater or other appliance.
Prevent Battery Explosions

Battery Explosions
Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can
explode.
Never check battery charge by placing a metal object across the posts. Use a volt-meter or
hydrometer.
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
Prepare for Emergencies

First Aid Kit
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near
your telephone.

Prevent Acid Burns
Acid Burns
Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).
3. Get medical attention immediately.

Service and Operate Chemical Sprayers Safely
Safety
Safety

Chemicals used in agricultural sprayers can be harmful to your health or the environment if
not used carefully.
Always follow all label directions for effective, safe, and legal use of agricultural chemicals.
Reduce risk of exposure and injury:
Wear appropriate personal protective equipment as recommended by the

manufacturer. (See ‘Handle agricultural chemicals safely’ found in the Safety Section.)
Fill, flush, calibrate, and decontaminate sprayer in an area where runoff will not reach
ponds, lakes or streams, livestock areas, or gardens, or near other people.
Keep children away from the chemicals, chemical solutions, and rinsates.
If spray or chemical concentrate contacts skin, hands, or face, wash immediately with
soap and water.
If spray or chemical concentrate gets into eyes, flush immediately with water.
If nozzle clogs or system malfunctions, stop engine and relieve spray pressure from
system.
Do not place nozzle tips or other components to the mouth to clear obstructions. Keep
spare tips on hand for replacement.
Minimize risk of spray drift.
Use large nozzle tips operated at lower pressures
Do not operate solution delivery system at pressures exceeding 345kPa (3.5 bar)
(50 psi).
Do not spray when winds exceed 16 km/h (10 mph).
Do not spray when wind is blowing towards a nearby sensitive crop, garden, or
populated area.
Properly dispose of unused chemicals, flushing solution, and empty chemical
containers.
Decontaminate equipment used in mixing, transferring, and applying chemicals after
use.
Handle Chemical Products Safely

Material Safety Data Sheet
Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous
chemicals used with John Deere equipment include such items as lubricants, coolants, paints,
and adhesives.
A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical
and health hazards, safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a hazardous chemical. That way you will know
exactly what the risks are and how to do the job safely. Then follow procedures and
recommended equipment.
(See your John Deere dealer for MSDS’s on chemical products used with John Deere
equipment.)

Avoid High-Pressure Fluids
High Pressure
Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts,
cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or
damage.
Replace worn or damaged hose assemblies immediately with John Deere approved
replacement parts.
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be
surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this
type of injury should reference a knowledgeable medical source. Such information is
available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by
calling 1-800-822-8262 or +1 309-748-5636.

Park Machine Safely
Remove the Key
Before working on the machine:
Lower all equipment to the ground.

Stop the engine and remove the key.
Disconnect the battery ground strap.
Hang a "DO NOT OPERATE" tag in operator station.
Support Machine Properly

Support Properly
Always lower the attachment or implement to the ground before you work on the machine. If
the work requires that the machine or attachment be lifted, provide secure support for them.
If left in a raised position, hydraulically supported devices can settle or leak down.
Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under
continuous load. Do not work under a machine that is supported solely by a jack. Follow
recommended procedures in this manual.
When implements or attachments are used with a machine, always follow safety precautions
listed in the implement or attachment operator′s manual.
Wear Protective Clothing

Protective Clothing
Wear close fitting clothing and safety equipment appropriate to the job.
Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear a suitable hearing protective device such as earmuffs or earplugs to protect against
objectionable or uncomfortable loud noises.
Operating equipment safely requires the full attention of the operator. Do not wear radio or
music headphones while operating machine.
Work in Clean Area

Clean Work Area
Before starting a job:
Clean work area and machine.

Make sure you have all necessary tools to do your job.
Have the right parts on hand.
Read all instructions thoroughly; do not attempt shortcuts.
Service Machines Safely

Moving Parts
Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when
you work near machine tools or moving parts. If these items were to get caught, severe injury
could result.
Remove rings and other jewelry to prevent electrical shorts and entanglement in moving
parts.
Work In Ventilated Area

Engine exhaust fumes
Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an
enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.
If you do not have an exhaust pipe extension, open the doors and get outside air into the
area.
Illuminate Work Area Safely

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

Safety Signs
Replace missing or damaged safety signs. See the machine operator’s manual for correct
safety sign placement.
Use Proper Lifting Equipment

Proper Lifting Equipment
Lifting heavy components incorrectly can cause severe injury or machine damage.
Follow recommended procedure for removal and installation of components in the manual.
Remove Paint Before Welding or Heating

Toxic Fumes
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated by welding, soldering, or using a
torch.
Remove paint before heating:
Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint
cannot be removed, wear an approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with soap and water before
welding. Remove solvent or paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes before welding or heating.
Do not use a chlorinated solvent in areas where welding will take place.
Do all work in an area that is well ventilated to carry toxic fumes and dust away.
Dispose of paint and solvent properly.

Avoid Heating Near Pressurized Fluid Lines
Flammable Spray
Flammable spray can be generated by heating near pressurized fluid lines, resulting in
severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch
near pressurized fluid lines or other flammable materials. Pressurized lines can accidentally
burst when heat goes beyond the immediate flame area.
Keep ROPS Installed Properly

Roll-Over Protective Structure
Make certain all parts are reinstalled correctly if the roll-over protective structure (ROPS) is
loosened or removed for any reason. Tighten mounting bolts to proper torque.
The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is
involved in an overturn incident, or is in any way altered by welding, bending, drilling, or
cutting. A damaged ROPS should be replaced, not reused.
The seat is part of the ROPS safety zone. Replace only with John Deere seat approved for
your tractor.
Any alteration of the ROPS must be approved by the manufacturer.
Service Tires Safely

Explosive Tire and Rim Parts

Explosive separation of a tire and rim parts can cause serious injury or death.
Do not attempt to mount a tire unless you have the proper equipment and experience to
perform the job.
Always maintain the correct tire pressure. Do not inflate the tires above the recommended
pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in
air pressure resulting in a tire explosion. Welding can structurally weaken or deform the
wheel.
When inflating tires, use a clip-on chuck and extension hose long enough to allow you to
stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
Avoid Harmful Asbestos Dust
Asbestos Dust
Avoid breathing dust that may be generated when handling components containing asbestos
fibers. Inhaled asbestos fibers may cause lung cancer.
Components in products that may contain asbestos fibers are brake pads, brake band and
lining assemblies, clutch plates, and some gaskets. The asbestos used in these components
is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as

airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding
material containing asbestos. When servicing, wear an approved respirator. A special vacuum
cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the
material containing asbestos.
Keep bystanders away from the area.
Practice Safe Maintenance

Keep Area Clean

Understand service procedure before doing work. Keep area clean and dry.
Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing
from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower
equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.
Securely support any machine elements that must be raised for service work.
Keep all parts in good condition and properly installed. Fix damage immediately. Replace
worn or broken parts. Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground cable (-) before making adjustments
on electrical systems or welding on machine.
On towed implements, disconnect wiring harnesses from tractor before servicing electrical
system components or welding on machine.
Use Proper Tools
Proper Tools
Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.
Use power tools only to loosen threaded parts and fasteners.

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S.
measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.
Use only service parts meeting John Deere specifications.
Dispose of Waste Properly
Recycle Waste
Improperly disposing of waste can threaten the environment and ecology. Potentially harmful
waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid,
filters, and batteries.
Use leakproof containers when draining fluids. Do not use food or beverage containers that
may mislead someone into drinking from them.
Do not pour waste onto the ground, down a drain, or into any water source.
Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere.
Government regulations may require a certified air conditioning service center to recover and
recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste from your local environmental or
recycling center, or from your John Deere dealer.

Prevent Machine Runaway
Machinery Runaway
Avoid possible injury or death from machinery runaway.
Do not start engine by shorting across starter terminals. Machine will start in gear if normal
circuitry is bypassed.
NEVER start engine while standing on ground. Start engine only from operator’s seat, with
transmission in neutral or park.
Handle Starting Fluid Safely

Store Safely
Starting fluid is highly flammable.
Keep all sparks and flame away when using it. Keep starting fluid away from batteries and
cables.
To prevent accidental discharge when storing the pressurized can, keep the cap on the
container, and store in a cool, protected location.
Do not incinerate or puncture a starting fluid container.
Service Cooling System Safely

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

Stay Clear of Rotating Drivelines
Rotating Drivelines

Drivelines
Entanglement in rotating driveline can cause serious injury or death.
Keep tractor master shield and driveline shields in place at all times. Make sure rotating
shields turn freely.
Wear close fitting clothing. Stop the engine and be sure that PTO driveline is stopped before
making adjustments, connections, or cleaning out PTO driven equipment.
Do not install any adapter device between the tractor and the primary implement PTO drive
shaft that will allow a 1000 rpm tractor shaft to power a 540 rpm implement at speeds higher
than 540 rpm.
Do not install any adapter device that results in a portion of the rotating implement shaft,
tractor shaft, or the adapter to be unguarded. The tractor master shield shall overlap the end
of the splined shaft and the added adaptor device as outlined in the table.
PTO Type Diameter Splines n ± 5 mm (0.20 in.)
1 35 mm (1.378 in.) 6 85 mm (3.35 in.)
2 35 mm (1.378 in.) 21 85 mm (3.35 in.)

PTO Type Diameter Splines n ± 5 mm (0.20 in.)
3 45 mm (1.772 in.) 20 100 mm (4.00 in.)
Protect Against High Pressure Spray
High Pressure Spray
Spray from high pressure nozzles can penetrate the skin and cause serious injury. Keep spray
from contacting hands or body.
If an accident occurs, see a doctor immediately. Any high pressure spray injected into the
skin must be surgically removed within a few hours or gangrene may result. Doctors
unfamiliar with this type of injury should reference a knowledgeable medical source. Such
information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
Construct Dealer-Made Tools Safely

Construct Dealer-Made Tools Safely
Faulty or broken tools can result in serious injury. When constructing tools, use proper,
quality materials, and good workmanship.
Do not weld tools unless you have the proper equipment and experience to perform the job.
Clean Vehicle of Hazardous Pesticides
CAUTION:
During application of hazardous pesticides, pesticide residue can build up

on the inside or outside of the vehicle. Clean vehicle according to use
instructions of hazardous pesticides.
When exposed to hazardous pesticides, clean exterior and interior of vehicle daily to keep
free of the accumulation of visible dirt and contamination.
[1] - Sweep or vacuum the floor of cab.

[2] - Clean headliners and inside cowlings of cab.
[3] - Wash entire exterior of vehicle.
[4] - Dispose of any wash water with hazardous concentrations of active or non-active
ingredients according to published regulations or directives.

Servicing Electronic Control Units
Electronic Control Unit
[1] -
IMPORTANT:
Do not open control unit and do not clean with a high pressure spray.
Moisture, dirt and other contaminants may cause permanent damage.
Control units are not repairable; replace only if indicated in the diagnostic procedure.
[2] - Since control units are the components LEAST likely to fail, isolate failure before
replacing by completing the diagnostic procedure.
[3] - The wiring harness terminals and connectors for electronic control units are repairable.

[4] -
IMPORTANT:
Misleading diagnostic messages and poor performance may occur if an

electronic control unit is not programmed identical to the original
controller.
Before putting back into service, verify the control unit is programmed identical to the
original controller.
Welding Near Electronic Control Units
Welding Graphic
[1] -
IMPORTANT:
Do not jump-start engines with arc welding equipment. Currents and

voltages are too high and may cause permanent damage.
Disconnect the negative (-) battery cable(s).

[2] - Disconnect the positive (+) battery cable(s).
[3] - Connect the positive and negative cables together. Do not attach to vehicle frame.
[4] - Clear or move any wiring harness sections away from welding area.
[5] - Connect welder ground close to welding point and away from control units.
[6] - After welding, reverse Steps 1—5.

Keep Electronic Control Unit Connectors Clean
[1] -
IMPORTANT:
Keep terminals clean and free of foreign debris. Moisture, dirt and other
contaminants may cause the terminals to erode over time and not make a
good electrical connection.
If a connector is not in use, put on the proper dust cap or an appropriate seal to protect it
from foreign debris and moisture.
[2] -
IMPORTANT:
Do not probe through the wire insulation or through the back of the
connector. Do not insert items such as paper clips or wires into connector
terminals.
Make measurements on a connector terminal using JDG10466 Flex Probe Kit in

SERVICEGARD.
[3] - Observe the locking mechanism of the connector when disconnecting and reconnecting.
[4] - Do not pull on wires to disconnect.
[5] - Before reconnecting:
Look for bent terminals; do not force connectors into each other.
Replace any terminal where corrosion exists.
Clean the connector of any foreign debris.
Dry the connector of any moisture.
[6] - When reconnecting, make sure seals around the connector pairs are functional.

Section 10 - GENERAL INFORMATION Group 10: General Specifications
Live With Safety
Safety Systems
Before returning machine to customer, make sure machine is functioning properly, especially
the safety systems. Install all guards and shields.

Group 10 - General Specifications
Machine Specifications 1023E, 1025R, and 1026R EEC
→NOTE:
Specifications and design subject to change without notice.
1023E 1025R 1026R EEC
Ground Speed:
Forward and Reverse - Range Low 0—6.6 km/h (0—4.1 mph)
Forward and Reverse - Range High 0—14.6 km/h (0—9.1 mph)
Engine:
Make Yanmar
Type Diesel
Model 3TNM74 3TNV80 3TNV76
Rated Speed 3200 rpm
Slow Idle Speed 1575 ± 50 rpm 1575 ± 50 rpm 1575 ± 50 rpm
Fast Idle Speed 3370 ± 50 rpm 3370 ± 50 rpm 3370 ± 50 rpm
Cylinders In-line 3
Displacement 0.993L (60.59 in. 3 ) 1.267L (77 in. 3 ) 1.115L (68 in. 3 )
Bore 74 mm (2.83 in.) 80 mm (2.99 in.) 76 mm (2.99 in.)
Stroke 77 mm (2.91 in.) 84 mm (3.23 in.) 82 mm (3.23 in.)
Firing Order 1-3-2
Timing 19° BTDC 20° BTDC
Lubrication Pressurized
Cooling Liquid Cooled
Start Aid Air Heater (Optional)
Air Cleaner Dry Type with Primary/Secondary Elements
Engine Shut Off Key Switch
Fuel System:
Type Indirect Injection
Injection Pump Type Mechanical Rotary w/Electric Shutoff
Electrical System:
Type 12 Volt Negative Ground

1023E 1025R 1026R EEC
Alternator 40 amp 55 amp
Batteries 12-volt
Cold Cranking Amps 500
Transmission:
Transmission Hydrostatic
Final Drive 2 Range Gear
Power Take Off:
Type Fully Independent
Speed 540 rpm
Steering:
Type Hydrostatic Power
Brakes:
Type Internal Wet Disk
Hydraulic System:
System Type Open Center
Pump Type Gear Pump
Rated Pump Flow:
.. Displacment (Gear Pump) 8 cm 3 /rev
.. Working Pressure 138 ± 10 bar (2000 ± 150 psi)
.. Charge Pressure 4.9 +3/-0 bar (71 +43/-0 psi)
Capacities:
Fuel Tank 21.2 L (5.6 gal)
Crankcase - 3TNM74 (with Filter) 2.7 L (2.9 qt.)
Crankcase - 3TNV80 (with Filter) 2.7 L (2.9 qt.)
Crankcase - 3TNV76 (with Filter) 2.7 L (2.9 qt.)
Cooling System 3.7 L (3.9 qt.)
Transmission—Hydraulic System: 12.3 L (3.25 gal)
MFWD Axle:
MFWD Axle Housing 2.8 L (3.0 qt.)
Dimensions:
Wheelbase 1450 mm (57.1 in.)
Overall Length with 3-Point Hitch 2605 mm (102.6 in.)
Overall Width 1202 mm (47.3 in.)

Ground Clearance - Front Axle 195 mm (7.7 in.)
Turning Radius MFWD Off 2256 mm (88.8 in.)

Service Recommendations for O-Ring Boss Fittings
Straight Fitting
Straight Fitting
[1] - Inspect O-ring boss seat for dirt or defects.
[2] - Lubricate O-ring with petroleum jelly. Place electrical tape over threads to protect O-
ring. Slide O-ring over tape and into O-ring groove of fitting. Remove tape.
[3] - Tighten fitting to torque value shown on chart.
Angle Fitting

Angle Fitting
[1] - Back-off lock nut (A) and back-up washer (B) completely to head-end (C) of fitting.
[2] - Turn fitting into threaded boss until back-up washer contacts face of boss.
[3] - Turn fitting head-end counterclockwise to proper index (maximum of one turn).
[4] -
→NOTE:
Do not allow hoses to twist when tightening fittings.
Hold fitting head-end with a wrench and tighten locknut and back-up washer to proper torque
value.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
Thread Size N˙m lb-ft
3/8-24 UNF 8 6
7/16-20 UNF 12 9

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
Thread Size N˙m lb-ft
1/2-20 UNF 16 12
9/16-18 UNF 24 18
3/4-16 UNF 46 34
7/8-14 UNF 62 46
1-1/16-12 UN 102 75
1-3/16-12 UN 122 90
1-5/16-12 UN 142 105
1-5/8-12 UN 190 140
1-7/8-12 UN 217 160

Service Recommendations For Flat Face O-Ring Seal

Fittings
[1] - Inspect the fitting sealing surfaces and O-ring. They must be free of dirt or defects.
[2] - Lubricate O-rings and install into grove using petroleum jelly to hold in place.
[3] - Index angle fittings and tighten by hand pressing joint together to insure O-ring remains
in place.
[4] - Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist
when tightening fittings, use backup wrench on straight hose couplings.
IMPORTANT:
Tighten fittings to 150% of listed torque value if indexing is necessary or if

fitting is attached to an actuating device.
Tighten fittings to 50% of listed torque value if used in aluminum housing.
FLAT FACE O-RING SEAL FITTING TORQUE*
Nomial Tube O.D. Thread Size Swivel Nut Bulkhead Nut
mm in. in. N˙m lb-ft N˙m lb-ft
6.35 0.250 9/16-18 16 12 12 9
9.52 0.375 11/16-16 24 18 24 18
12.70 0.500 13/16-16 50 37 46 34
15.88 0.625 1-14 69 51 62 46
19.05 0.750 1 3/16-12 102 75 102 75
22.22 0.875 1 3/16-12 102 75 102 75
25.40 1.000 1 7/16-12 142 105 142 105
31.75 1.250 1 11/16-12 190 140 190 140
38.10 1.500 2-12 217 160 217 160
*Torque tolerance is +15 -20% unless otherwise specified.
Stud End O-ring Seal Torque for Straight and Adjustable Fittings*
Thread Size Straight Hex Size Locknut Hex Size Straight Fitting or Locknut Toque
Inch Inch Inch N˙m lb-ft
3/8-24 5/8 9/16 12 9

7/16-20 5/8 5/8 21 15
1/2-20 3/4 11/16 26 19
9/16-18 3/4 3/4 34 25
3/4-16 7/8 15/16 73 55
7/8-14 1 1/16 1 1/16 104 76
1 1/16-12 1 1/4 1 3/8 176 130
1 3/16-12 1 3/8 1 1/2 230 170
1 5/16-12 1 1/2 1 5/8 285 210
*Torque tolerance is +15 -20% unless otherwise specified.

Metric Cap Screw Torque Values—Grade 7
→NOTE:
When bolting aluminum parts, tighten to 80% of torque specified in table.
Size N˙m (lb-ft)
M6 9.5—12.2 (7—9)
M8 20.3—27.1 (15—20)
M10 47.5—54.2 (35—40)
M12 81.4—94.9 (60—70)
M14 128.8—146.4 (95—108)
M16 210.2—240 (155—177)

Metric Bolt and Screw Torque Values
Metric Bolt and Screw
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Lubricated Lubricated Lubricated Lubricated

[ “Lubricated” [ “Lubricated” [ “Lubricated” [ “Lubricated”
means coated Dry means coated Dry means coated Dry means coated Dry
with a lubricant [ “Dry” means with a lubricant [ “Dry” means with a lubricant [ “Dry” means with a lubricant [ “Dry” means
Bolt such as engine plain or zinc such as engine plain or zinc such as engine plain or zinc such as engine plain or zinc
or oil, fasteners plated without oil, fasteners plated without oil, fasteners plated without oil, fasteners plated without
Screw with phosphate any lubrication, with phosphate any lubrication, with phosphate any lubrication, with phosphate any lubrication,
Size and oil coatings, or M6 to M18 and oil coatings, or M6 to M18 and oil coatings, or M6 to M18 and oil coatings, or M6 to M18
or M20 and fasteners with or M20 and fasteners with or M20 and fasteners with or M20 and fasteners with
larger fasteners JDM F13B, F13E larger fasteners JDM F13B, F13E larger fasteners JDM F13B, F13E larger fasteners JDM F13B, F13E
with JDM F13C, or F13H zinc with JDM F13C, or F13H zinc with JDM F13C, or F13H zinc with JDM F13C, or F13H zinc
F13F or F13J flake coating. ] F13F or F13J flake coating. ] F13F or F13J flake coating. ] F13F or F13J flake coating. ]
zinc flake zinc flake zinc flake zinc flake
coating. ] coating. ] coating. ] coating. ]
N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in.
M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172
N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft.
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft.
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
N˙m lb.-ft.
M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190
M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300
M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410
M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580
M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800
M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000
M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475
M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000
M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500
Torque values listed are for general use only, based on the
Shear bolts are designed to fail under predetermined loads. Always
strength of the bolt or screw. DO NOT use these values if a
replace shear bolts with identical property class. Replace fasteners
different torque value or tightening procedure is given for a
with the same or higher property class. If higher property class
specific application. For stainless steel fasteners or for nuts
fasteners are used, tighten these to the strength of the original. Make
on U-bolts, see the tightening instructions for the specific
sure fastener threads are clean and that you properly start thread
application. Tighten plastic insert or crimped steel type lock
engagement. When possible, lubricate plain or zinc plated fasteners
nuts by turning the nut to the dry torque shown in the chart,
other than lock nuts, wheel bolts or wheel nuts, unless different
unless different instructions are given for the specific
instructions are given for the specific application.
application.

Unified Inch Bolt and Screw Torque Values
Unified Inch Bolt and Screw
SAE Grade 2
[ Grade 2 applies for hex cap
screws (not hex bolts) up to 6 in.
SAE Grade 1 (152 mm) long. Grade 1 applies for SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
hex cap screws over 6 in. (152
mm) long, and for all other types
of bolts and screws of any length. ]

Bolt [ “Lubricated” [ “Lubricated” [ “Lubricated” [ “Lubricated”
or means coated Dry means coated Dry means coated Dry means coated Dry
Screw with a lubricant [ “Dry” means with a lubricant [ “Dry” means with a lubricant [ “Dry” means with a lubricant [ “Dry” means
Size such as engine plain or zinc such as engine plain or zinc such as engine plain or zinc such as engine plain or zinc
oil, fasteners plated without oil, fasteners plated without oil, fasteners plated without oil, fasteners plated without
with phosphate any lubrication, with phosphate any lubrication, with phosphate any lubrication, with phosphate any lubrication,
and oil or 1/4 to 3/4 in. and oil or 1/4 to 3/4 in. and oil coatings, or 1/4 to 3/4 in. and oil coatings, or 1/4 to 3/4 in.
coatings, or 7/8 fasteners with coatings, or 7/8 fasteners with or 7/8 in. and fasteners with or 7/8 in. and fasteners with
in. and larger JDM F13B, F13E in. and larger JDM F13B, F13E larger fasteners JDM F13B, F13E larger fasteners JDM F13B, F13E
fasteners with or F13H zinc fasteners with or F13H zinc with JDM F13C, or F13H zinc with JDM F13C, or F13H zinc
JDM F13C, F13F flake coating. ] JDM F13C, F13F flake coating. ] F13F or F13J flake coating. ] F13F or F13J flake coating. ]
or F13J zinc or F13J zinc zinc flake zinc flake
flake coating. ] flake coating. ] coating. ] coating. ]
N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in.
1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150
N˙m lb.-ft. N˙m lb.-ft.
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
N˙m lb.-ft. N˙m lb.-ft.
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft.
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
N˙m lb.-ft.
1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350

Section 10 - GENERAL INFORMATION Group 15: Fuel and Lubricants
SAE Grade 2
[ Grade 2 applies for hex cap
screws (not hex bolts) up to 6 in.
SAE Grade 1 (152 mm) long. Grade 1 applies for SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
hex cap screws over 6 in. (152
mm) long, and for all other types
of bolts and screws of any length. ]

Bolt [ “Lubricated” [ “Lubricated” [ “Lubricated” [ “Lubricated”
or means coated Dry means coated Dry means coated Dry means coated Dry
Screw with a lubricant [ “Dry” means with a lubricant [ “Dry” means with a lubricant [ “Dry” means with a lubricant [ “Dry” means
Size such as engine plain or zinc such as engine plain or zinc such as engine plain or zinc such as engine plain or zinc
oil, fasteners plated without oil, fasteners plated without oil, fasteners plated without oil, fasteners plated without
with phosphate any lubrication, with phosphate any lubrication, with phosphate any lubrication, with phosphate any lubrication,
and oil or 1/4 to 3/4 in. and oil or 1/4 to 3/4 in. and oil coatings, or 1/4 to 3/4 in. and oil coatings, or 1/4 to 3/4 in.
coatings, or 7/8 fasteners with coatings, or 7/8 fasteners with or 7/8 in. and fasteners with or 7/8 in. and fasteners with
in. and larger JDM F13B, F13E in. and larger JDM F13B, F13E larger fasteners JDM F13B, F13E larger fasteners JDM F13B, F13E
fasteners with or F13H zinc fasteners with or F13H zinc with JDM F13C, or F13H zinc with JDM F13C, or F13H zinc
JDM F13C, F13F flake coating. ] JDM F13C, F13F flake coating. ] F13F or F13J flake coating. ] F13F or F13J flake coating. ]
or F13J zinc or F13J zinc zinc flake zinc flake
flake coating. ] flake coating. ] coating. ] coating. ]
Torque values listed are for general use only, based on the strength
Replace fasteners with the same or higher grade. If higher
of the bolt or screw. DO NOT use these values if a different torque
grade fasteners are used, tighten these to the strength of the
value or tightening procedure is given for a specific application. For
original. Make sure fastener threads are clean and that you
plastic insert or crimped steel type lock nuts, for stainless steel
properly start thread engagement. When possible, lubricate
fasteners, or for nuts on U-bolts, see the tightening instructions for
plain or zinc plated fasteners other than lock nuts, wheel
the specific application. Shear bolts are designed to fail under
bolts or wheel nuts, unless different instructions are given for
predetermined loads. Always replace shear bolts with identical
the specific application.
grade.

Group 15 - Fuel and Lubricants
Diesel Fuel
Consult your local fuel distributor for properties of the diesel fuel available in your area.
In general, diesel fuels are blended to satisfy the low temperature requirements of the
geographical area in which they are marketed.
Diesel fuels specified to EN 590 or ASTM D975 are recommended. Renewable diesel fuel
produced by hydrotreating animal fats and vegetable oils is basically identical to petroleum
diesel fuel. Renewable diesel that meets EN 590 or ASTM D975 is acceptable for use at all
percentage mixture levels.
Required Fuel Properties
In all cases, the fuel shall meet the following properties:
Cetane number of 43 minimum. Cetane number greater than 47 is preferred, especially

for temperatures below –20°C (–4°F) or elevations above 1500 m (5000 ft.).
Cold Filter Plugging Point (CFPP) should be at least 5°C (9°F) below the expected lowest
temperature or Cloud Point below the expected lowest ambient temperature.
Fuel lubricity should pass a maximum scar diameter of 0.45 mm as measured by ASTM
D6079 or ISO 12156-1.
Diesel fuel quality and sulfur content must comply with all existing emissions regulations
for the area in which the engine operates. DO NOT use diesel fuel with sulfur content greater
than 10 000 mg/kg (10 000 ppm).
Sulfur content for Interim Tier 4 and Stage III B engines
Use ONLY ultra low sulfur diesel (ULSD) fuel with a maximum of 15 mg/kg (15 ppm)
sulfur content.

Sulfur Content for Tier 3 and Stage III A Engines
Use of diesel fuel with sulfur content less than 1000 mg/kg (1000 ppm) is
RECOMMENDED
Use of diesel fuel with sulfur content 1000–5000 mg/kg (1000–5000 ppm) REDUCES oil
and filter change intervals.
BEFORE using diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm),
contact your John Deere dealer
Sulfur Content for Tier 2 and Stage II Engines
Use of diesel fuel with sulfur content less than 500 mg/kg (500 ppm) is RECOMMENDED.
Use of diesel fuel with sulfur content 500–5000 mg/kg (500–5000 ppm) REDUCES the oil
and filter change interval
BEFORE using diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm),
contact your John Deere dealer
Sulfur Content for Other Engines
Use of diesel fuel with sulfur content less than 5000 mg/kg (5000 ppm) is
recommended.
Use of diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm) REDUCES
the oil and filter change intervals.
IMPORTANT:
Do not mix used diesel engine oil or any other type of lubricating oil with
diesel fuel.
IMPORTANT:
Improper fuel additive usage may cause damage on fuel injection

equipment of diesel engines.

Handling and Storing Diesel Fuel
CAUTION:
Reduce the risk of fire. Handle fuel carefully. DO NOT fill the fuel tank
when engine is running. DO NOT smoke while you fill the fuel tank or
service the fuel system.
Fill the fuel tank at the end of each day′s operation to prevent water condensation and
freezing during cold weather.
Keep all storage tanks as full as practicable to minimize condensation.
Ensure that all fuel tank caps and covers are installed properly to prevent moisture from
entering. Monitor water content of the fuel regularly.
When using biodiesel fuel, the fuel filter may require more frequent replacement due to
premature plugging.
Check engine oil level daily prior to starting engine. A rising oil level may indicate fuel dilution
of the engine oil.
IMPORTANT:
The fuel tank is vented through the filler cap. If a new filler cap is required,
always replace it with an original vented cap.
When fuel is stored for an extended period or if there is a slow turnover of fuel, add a fuel
conditioner to stabilize the fuel and prevent water condensation. Contact your fuel supplier
for recommendations.
Do Not Use Galvanized Containers
IMPORTANT:
Diesel fuel stored in galvanized containers reacts with zinc coating on the
container to form zinc flakes. If fuel contains water, a zinc gel will also
form. The gel and flakes will quickly plug fuel filters and damage fuel
injectors and fuel pumps.

DO NOT use a galvanized container to store diesel fuel.
Store fuel in:
plastic containers.
aluminum containers.
specially coated steel containers made for diesel fuel.
DO NOT use brass-coated containers: brass is an alloy of copper and zinc.
Lubricity of Diesel Fuel

Most diesel fuels manufactured in the United States, Canada, and the European Union have
adequate lubricity to ensure proper operation and durability of fuel injection system
components. However, diesel fuels manufactured in some areas of the world may lack the
necessary lubricity.
IMPORTANT:
Make sure the diesel fuel used in your machine demonstrates good lubricity
characteristics.
Fuel lubricity should pass a maximum scar diameter of 0.45 mm as measured by ASTM
D6079 or ISO 12156-1.
If fuel of low or unknown lubricity is used, add John Deere Fuel-Protect Diesel Fuel Conditioner
(or equivalent) at the specified concentration.
Lubricity of Biodiesel Fuel
Fuel lubricity can improve significantly with biodiesel blends up to B20 (20% biodiesel).
Further increase in lubricity is limited for biodiesel blends greater than B20.
Testing Diesel Fuel

A fuel analysis program can help to monitor the quality of diesel fuel. The fuel analysis can
provide critical data such as cetane number, fuel type, sulfur content, water content,
appearance, suitability for cold weather operations, bacteria, cloud point, acid number,
particulate contamination, and whether the fuel meets specification.
Contact your John Deere dealer for more information on diesel fuel analysis.

Biodiesel Fuel
Biodiesel fuel is comprised of mono-alkyl esters of long chain fatty acids derived from
vegetable oils or animal fats. Biodiesel blends are biodiesel mixed with petroleum diesel fuel
on a volume basis.
Before using fuel containing biodiesel, review the Biodiesel Use Requirements and
Recommendations in this Operator’s Manual.
Environmental laws and regulations can encourage or prohibit the use of biofuels. Operators
should consult with appropriate governmental authorities prior to using biofuels.
All John Deere Engines with Exhaust Filter (Released 2011 and After)
While 5% blends (B5) are preferred, biodiesel concentrations up to a 20% blend (B20) in
petroleum diesel fuel can be used. Biodiesel blends up to B20 can be used ONLY if the
biodiesel (100% biodiesel or B100) meets ASTM D6751, EN 14214, or equivalent
specification. Expect a 2% reduction in power and a 3% reduction in fuel economy when
using B20.
Biodiesel concentrations above B20 can harm the engine’s emission control systems and
should not be used. Risks include, but are not limited to, more frequent stationary
regeneration, soot accumulation, and increased intervals for ash removal.
John Deere approved fuel conditioners, which contain detergent and dispersant additives, are
required when using B20, and are recommended when using lower biodiesel blends.
All John Deere Engines Excluding Exhaust Filter (Primarily Released Prior to 2012)
While 5% blends (B5) are preferred, biodiesel concentrations up to a 20% blend (B20) in
petroleum diesel fuel can be used. Biodiesel blends up to B20 can be used ONLY if the
biodiesel (100% biodiesel or B100) meets ASTM D6751, EN 14214, or equivalent
specification. Expect a 2% reduction in power and a 3% reduction in fuel economy when
using B20.
These John Deere engines can operate on biodiesel blends above B20 (up to 100% biodiesel).
Operate at levels above B20 ONLY if the biodiesel is permitted by law and meets the EN
14214 specification (primarily available in Europe). Engines operating on biodiesel blends
above B20 might not fully comply with or be permitted by all applicable emissions
regulations. Expect up to a 12% reduction in power and an 18% reduction in fuel economy
when using 100% biodiesel.
John Deere approved fuel conditioners, which contain detergent and dispersant additives, are
required when using B20, and are recommended when using lower biodiesel blends.
Biodiesel Use Requirements and Recommendations

The petroleum diesel portion of all biodiesel blends must meet the requirements of ASTM
D975 (US) or EN 590 (EU) commercial standards.
Biodiesel users in the U.S. are strongly encouraged to purchase biodiesel blends from a
BQ-9000 Certified Marketer and sourced from a BQ-9000 Accredited Producer (as certified by
the National Biodiesel Board). Certified Marketers and Accredited Producers can be found at
the following website: http://www.bq9000.org .
Biodiesel contains residual ash. Ash levels exceeding the maximums allowed in either ASTM
D6751 or EN14214 can result in more rapid ash loading and require more frequent cleaning
of the Exhaust Filter (if present).
The fuel filter can require more frequent replacement, when using biodiesel fuel, particularly
if switching from diesel. Check engine oil level daily prior to starting engine. A rising oil level
can indicate fuel dilution of the engine oil. Biodiesel blends up to B20 must be used within 90
days of the date of biodiesel manufacture. If used, biodiesel blends above B20 must be used
within 45 days from the date of biodiesel manufacture.
When using biodiesel blends up to B20, the following must be considered:
Cold weather flow degradation

Stability and storage issues (moisture absorption, microbial growth)
Possible filter restriction and plugging (usually a problem when first switching to
biodiesel on used engines.)
Possible fuel leakage through seals and hoses (primarily an issue with older engines)
Possible reduction of service life of engine components
Request a certificate of analysis from your fuel distributor to ensure that the fuel is compliant
with the specifications provided in this Operator’s Manual.
Consult your John Deere dealer for approved fuel conditioners to improve storage and
performance with biodiesel fuels.
The following must also be considered if using biodiesel blends above B20:
Possible coking or blocked injector nozzles, resulting in power loss and engine misfire if
John Deere approved fuel conditioners are not used
Possible crankcase oil dilution (requiring more frequent oil changes)
Possible lacquering or seizure of internal components
Possible formation of sludge and sediments
Possible thermal oxidation of fuel at elevated temperatures
Possible compatibility issues with other materials (including copper, lead, zinc, tin,
brass, and bronze) used in fuel handling equipment

Possible reduction in water separator efficiency

Possible damage to paint if exposed to biodiesel
Possible corrosion of fuel injection equipment
Possible elastomeric seal and gasket material degradation (primarily an issue with older
engines)
Possible high acid levels within fuel system
Because biodiesel blends above B20 contain more ash, using blends above B20 can
result in more rapid ash loading and require more frequent cleaning of the Exhaust
Filter (if present)
IMPORTANT:
Raw pressed vegetable oils are NOT acceptable for use as fuel in any
concentration in John Deere engines. Their use could cause engine failure.
Filling Fuel Tank

CAUTION:
Fill Fuel Tank Safely
Handle fuel with care: It is highly flammable. DO NOT refuel the machine
while smoking or when near open flame or sparks.
Prevent fires by keeping machine clean of accumulated trash, grease, and

debris. Always clean up spilled fuel.
Fill fuel tank at the end of each day of operation. This action prevents condensation in tank as
moist air cools.
IMPORTANT:
The fuel tank use a vented filler cap. If a new filler cap is required, always
replace it with a vented cap.
→NOTE:
John Deere Fuel Flow Improver, or equivalent, can be added to fuel or bulk
storage tank during cold weather to reduce gelling and control wax
separation.

Diesel Engine Break-In Oil

New engines are filled at the factory with John Deere ENGINE BREAK-IN OIL. During the break-
in period, add John Deere ENGINE BREAK-IN OIL as needed to maintain the specified oil level.
Change the oil and filter after the first 100 hours of operation of a new or rebuilt engine.
After engine overhaul, fill the engine with John Deere ENGINE BREAK-IN OIL.
If John Deere ENGINE BREAK-IN OIL is not available, use a diesel engine oil meeting one of the
following during the first 100 hours of operation:
API Service Classification CE

API Service Classification CD
API Service Classification CC
ACEA Oil Sequence E2
After the break-in period, use John Deere Plus-50 ™ or other diesel engine oil as
recommended in this manual.
IMPORTANT:
Do not use Plus-50 oil or engine oils meeting any of the following during
the first 100 hours of operation of a new or rebuilt engine:
API CI-4 API CF
API CH-4 ACEA E5
API CG-4 ACEA E4
API CF-4 ACEA E3
API CF-2
These oils will not allow the engine to break-in properly.

Diesel Engine Oil
Oil Viscosities for Air Temperature Ranges
Use oil viscosity based on the expected air temperature range during the period between oil
changes.
John Deere Plus-50 ™ II oil is preferred.
John Deere Plus-50 ™ is also recommended.
Other oils may be used if they meet one or more of the following:
John Deere Torq-Gard ™

API Service Category CJ-4
API Service Category CI-4 PLUS
API Service Category CI-4

API Service Category CH-4

API Service Category CG-4
API Service Category CF-4
If oils meeting API CG-4, API CF-4, or ACEA E2 are used, reduce the service interval by 50%.
Multi-viscosity diesel engine oils are preferred.
Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations
for the area in which the engine operates.
If diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm) is used, reduce the
service interval by 50%.
DO NOT use diesel fuel with sulfur content greater than 10 000 mg/kg (10 000 ppm).
Oil Filters
Filtration of oils is critical to proper operation and lubrication.
Always change filters regularly as specified in this manual.
Use filters meeting John Deere performance specifications.

Heavy Duty Diesel Engine Coolant

The engine cooling system is filled to provide year-round protection against corrosion and
cylinder liner pitting, and winter freeze protection to -37°C (-34°F). If protection at lower
temperatures is required, consult your John Deere dealer for recommendations.
The following engine coolants are preferred:
John Deere COOL-GARD ™ II Premix

John Deere COOL-GARD II PG Premix
Use John Deere COOL-GARD II PG Premix when a non-toxic coolant formulation is required.
Additional Recommended Coolants
The following engine coolant is also recommended:
John Deere COOL-GARD II Concentrate in a 40–60% mixture of concentrate with quality

water.
John Deere COOL-GARD II Premix, COOL-GARD II PG Premix, and COOL-GARD II Concentrate

coolants do not require use of supplemental coolant additives.
Other Coolants
John Deere COOL-GARD II and COOL-GARD II PG coolants might not be available in the
geographical area where service is performed.
If these coolants are unavailable, use a coolant concentrate or prediluted coolant intended for
use with heavy duty diesel engines and with a minimum of the following chemical and
physical properties:
Is formulated with a quality nitrite-free additive package.

Provides cylinder liner cavitation protection according to either the John Deere
Cavitation Test Method or a fleet study run at or above 60% load capacity
Protects the cooling system metals (cast iron, aluminum alloys, and copper alloys such
as brass) from corrosion
The additive package must be part of one of the following coolant mixtures:
ethylene glycol or propylene glycol base prediluted (40—60%) heavy duty coolant
ethylene glycol or propylene glycol base heavy duty coolant concentrate in a 40—60%
mixture of concentrate with quality water
Water Quality
Water quality is important to the performance of the cooling system. Distilled, deionized, or
demineralized water is recommended for mixing with ethylene glycol and propylene glycol
base engine coolant concentrate.
IMPORTANT:
Do not use cooling system sealing additives or antifreeze that contains

sealing additives.
Do not mix ethylene glycol and propylene glycol base coolants.
Do not use coolants that contain nitrites.
Operating in Warm Temperature Climates

John Deere engines are designed to operate using glycol base engine coolants.
Always use a recommended glycol base engine coolant, even when operating in geographical
areas where freeze protection is not required.
John Deere COOL-GARD ™ II Premix is available in a concentration of 50% ethylene glycol.

However, there are situations in warm temperature climates where a coolant with lower
glycol concentration (approximately 20% ethylene glycol) has been approved. In these cases,
the low glycol formulation has been modified to provide the same level of corrosion inhibitor
as John Deere COOL-GARD II Premix (50/50).
IMPORTANT:
Water may be used as coolant in emergency situations only.
Foaming, hot surface aluminum and iron corrosion, scaling, and cavitation
will occur when water is used as the coolant, even when coolant
conditioners are added.
Drain cooling system and refill with recommended glycol base engine
coolant as soon as possible.

Additional Information About Diesel Engine Coolants

and John Deere LIQUID COOLANT CONDITIONER
Engine coolants are a combination of three chemical components: ethylene glycol or
propylene glycol antifreeze, inhibiting coolant additives, and quality water.
Coolant Specifications
Some products, including John Deere COOL-GARD ™ Premix coolant, are fully formulated
coolants that contain all three components in their correct concentrations. Do not add an
initial charge of supplemental coolant additives or water to John Deere COOL-GARD Premix.
John Deere COOL-GARD Concentrate contains both ethylene glycol and inhibiting coolant
additives. Mix COOL-GARD Concentrate with quality water, but do not add an initial charge of
supplemental coolant additives.
Replenish Coolant Additives
Some coolant additives will gradually deplete during engine operation. Periodic
replenishment of inhibitors is required, even when John Deere COOL-GARD Premix, COOL-
GARD Concentrate, or COOL-GARD PG Premix is used. Follow the recommendations in this
manual for the use of supplemental coolant additives.
Why use John Deere LIQUID COOLANT CONDITIONER?
Operating without proper coolant additives will result in increased corrosion, cylinder liner
erosion and pitting, and other damage to the engine and cooling system. A simple mixture of
ethylene glycol or propylene glycol and water will not give adequate protection.
John Deere LIQUID COOLANT CONDITIONER is an additive system designed to reduce

corrosion, erosion, and pitting when used with nitrite-containing diesel engine coolants such
as John Deere COOL-GARD Premix, COOL-GARD Concentrate, and COOL-GARD PG Premix.
Maintaining John Deere COOL-GARD coolants with John Deere LIQUID COOLANT CONDITIONER
provides optimum protection for up to 5 years or 5000 hours of operation.
Avoid Automotive-type Coolants
Never use automotive-type coolants (such as those meeting ASTM D3306). These coolants do
not contain the correct additives to protect heavy-duty diesel engines. They often contain a
high concentration of silicates and may damage the engine or cooling system. Do not treat
an automotive engine coolant with a supplemental coolant additive because the high
concentration of additives can result in additive fallout.

Water Quality
Water quality is important to the performance of the cooling system. Distilled, deionized, or
demineralized water is recommended for mixing with ethylene glycol and propylene glycol
base engine coolant concentrate. All water used in the cooling system should meet the
following minimum specifications for quality:
Chlorides <40 mg/L
Sulfates <100 mg/L
Total dissolved solids <340 mg/L
Total hardness <170 mg/L
pH 5.5 to 9.0
Freeze Protection
The relative concentrations of glycol and water in the engine coolant determine its freeze
protection limit.
Ethylene Glycol Freeze Protection Limit
40% -24°C (-12°F)
50% -37°C (-34°F)
60% -52°C (-62°F)
Propylene Glycol Freeze Protection Limit
40% -21°C (-6°F)
50% -33°C (-27°F)
60% -49°C (-56°F)
DO NOT use a coolant-water mixture greater than 60% ethylene glycol or 60% propylene
glycol.

Testing Diesel Engine Coolant

Maintaining adequate concentrations of glycol and inhibiting additives in the coolant is
critical to protect the engine and cooling system against freezing, corrosion, and cylinder
liner erosion and pitting.
Test the coolant solution at intervals of 12 months or less and whenever excessive coolant is
lost through leaks or overheating.
Coolant Test Strips
Coolant test strips are available from your John Deere dealer. These test strips provide a
simple, effective method to check the freeze point and additive levels of your engine coolant.
When Using John Deere COOL-GARD II
John Deere COOL-GARD II Premix ™ , COOL-GARD II PG Premix and COOL-GARD II

Concentrate are maintenance free coolants for up to six years or 6000 hours of operation,
provided that the cooling system is topped off using only John Deere COOL-GARD II Premix or
COOL-GARD II PG premix. Test the coolant condition annually with coolant test strips
designed for use with John Deere COOL-GARD II coolants. If the test strip chart indicates that
additive is required, add John Deere COOL-GARD II Coolant Extender as directed.
Add only the recommended concentration of John Deere COOL-GARD II Coolant Extender. DO
NOT add more than the recommended amount.
When Using Nitrite-Containing Coolants
Compare the test strip results to the supplemental coolant additive (SCA) chart to determine
the amount of inhibiting additives in your coolant and whether more John Deere Liquid
Coolant Conditioner should be added.
Add only the recommended concentration of John Deere Liquid Coolant Conditioner. DO NOT
add more than the recommended amount.
Coolant Analysis
For a more thorough evaluation of your coolant, perform a coolant analysis. The coolant
analysis can provide critical data such as freezing point, antifreeze level, pH, alkalinity, nitrite
content (cavitation control additive), molybdate content (rust inhibitor additive), silicate
content, corrosion metals, and visual assessment.
Contact your John Deere dealer for more information on coolant analysis.

Transmission and Hydraulic Oil
Transmission and Hydraulic Oil

changes.
The following oils are preferred:
John Deere HY-GARD ™

John Deere Low Viscosity HY-GARD ™
Other oils may be used if they meet one of the following:
John Deere Standard JDM J20C

John Deere Standard JDM J20D
Use John Deere BIO-HY-GARD ™ oil when a biodegradable fluid is required.
[ BIO-HY-GARD meets or exceeds the minimum biodegradability of 80% within 21 days according to CEC-L-33-T-82 test method. BIO-HY-GARD should
not be mixed with mineral oils, because this reduces the biodegradability and makes proper oil recycling impossible. ]
Use Correct Transmission/Hydraulic Filter Element

To protect systems, replace transmission-hydraulic oil filter with a John Deere service filter
element.
See Maintenance and Service Intervals section for recommended filter change intervals.

MFWD Axle Housing and Wheel Hub Oil
MFWD Axle Housing & Wheel Hub Oil

changes.
The following oils are preferred:
John Deere Hy-Gard ™

John Deere Low Viscosity Hy-Gard ™
Other oils may be used if they meet one of the following:
John Deere Standard JDM J20C

John Deere Standard JDM J20D
Use John Deere Bio Hy-Gard ™ oil when a biodegradable fluid is required.
[ Bio Hy-Gard meets or exceeds the minimum biodegradability of 80% within 21 days according to CEC-L-33-T-82 test method. Bio Hy-Gard should not
be mixed with mineral oils, because this reduces the biodegradability and makes proper oil recycling impossible. ]
Grease

Greases for Air Temperature Ranges
Use grease based on NLGI consistency numbers and the expected air temperature range
during the service interval.
John Deere SD Polyurea Grease is preferred.

The following greases are also recommended:
John Deere HD Lithium Complex Grease

John Deere HD Water Resistant Grease
John Deere GREASE-GARD ™
Other greases may be used if they meet the following:
NLGI Performance Classification GC-LB
IMPORTANT:
Some types of grease thickeners are not compatible with others. Consult
your grease supplier before mixing different types of grease.
Grease (Specific Application)

Lithium Grease with Molybdenum Disulphide is recommended for use on internal components
of transmission.
TY6333 John Deere Moly High Temperature EP Grease is recommended for use on the
traction clutch and PTO clutch splines.
Mixing of Lubricants
In general, avoid mixing different brands or types of oil. Oil manufacturers blend additives in
their oils to meet certain specifications and performance requirements.
Mixing different oils can interfere with the proper functioning of these additives and degrade
lubricant performance.
Consult your John Deere dealer to obtain specific information and recommendations.
Alternative and Synthetic Lubricants

Conditions in certain geographical areas may require lubricant recommendations different
from those printed in this manual.
Some John Deere brand coolants and lubricants may not be available in your location.
Consult your John Deere dealer to obtain information and recommendations.

Section 10 - GENERAL INFORMATION Group 20: Serial Number Locations
Synthetic lubricants may be used if they meet the performance requirements as shown in
this manual.
The temperature limits and service intervals shown in this manual apply to both conventional
and synthetic lubricants.
Re-refined base stock products may be used if the finished lubricant meets the performance
requirements.
Lubricant Storage
Your equipment can operate at top efficiency only when clean lubricants are used.
Use clean containers to handle all lubricants.
Store lubricants and containers in an area protected from dust, moisture, and other
contamination. Store containers on their side to avoid water and dirt accumulation.
Make certain that all containers are properly marked to identify their contents.
Properly dispose of all old containers and any residual lubricant they may contain.

Section 10 - GENERAL INFORMATION Group 20: Serial Number Locations
Group 20 - Serial Number Locations
Serial Numbers
When working on machines or components that are covered by warranty, it is IMPORTANT
that you include the machine′s Product Identification Number and the component serial
number on the warranty claim form.
The location of component serial number plates are shown below.
Product Identification Number Location
Product Identification Number Plate
LEGEND:
A Product Identification Number Plate
Product identification number (A), also called tractor serial number or chassis number, is
located on the right side of the frame.

Section 10 - GENERAL INFORMATION Group 25: Features and Accessories
Engine Serial Number Location
Engine Serial Number Plate
LEGEND:
A Engine Serial Number Plate
The engine serial number plate (A) is located on the top of the valve cover.

ENGINE REPAIR (g) by Belgreen
Group 25 - Features and Accessories
Features and Accessories

Section 20 - ENGINE REPAIR
Table of contents
Group 05 - Engine ...................................................................................................................... 2
Summary of References ......................................................................................................... 2
Specifications ......................................................................................................................... 4
Other Material ...................................................................................................................... 13
Service Equipment and Tools ............................................................................................... 13
Essential or Recommended Tools ........................................................................................ 14
Remove Engine .................................................................................................................... 15
Install Engine ....................................................................................................................... 25
Remove and Install Valve Cover .......................................................................................... 36
Remove and Install Rocker Arm Assembly and Push Rods ................................................... 38
Disassemble, Inspect, and Assemble Rocker Arm Assembly and Push Rods ....................... 39
Remove and Install Exhaust Manifold .................................................................................. 44
Remove and Install Cylinder Head ....................................................................................... 46
Disassemble and Assemble Cylinder Head .......................................................................... 50
Recondition Cylinder Head ................................................................................................... 53
Replace Crankshaft Rear Oil Seal: 3TNM74 .......................................................................... 72
Replace Crankshaft Rear Oil Seal: 3TNV76 and 3TNV80 ...................................................... 73
Remove and Install Crankshaft Rear Oil Seal Case: 3TNV76 and 3TNV80 ........................... 75
Replace Crankshaft Front Oil Seal ........................................................................................ 77
Remove and Install Timing Gear Cover ................................................................................ 80
Remove, Inspect, and Install Idler Gear ............................................................................... 84
Remove, Inspect, and Install Camshaft Followers ................................................................ 90
Remove and Install Camshaft .............................................................................................. 93
Inspect Camshaft, Gear, Bushing and Bores ........................................................................ 97
Remove and Install Oil Pan and Strainer: 3TNM74 ............................................................. 107
Remove and Install Oil Pan and Strainer: 3TNV76 and 3TNV80 ......................................... 110
Check Connecting Rod Side Play ........................................................................................ 113
Check Crankshaft End Play ................................................................................................ 115
Check Connecting Rod Bearing Clearance ......................................................................... 117
Check Crankshaft Main Bearing Clearance ........................................................................ 120
Remove Piston and Connecting Rod .................................................................................. 124
Install Piston and Connecting Rod ...................................................................................... 125
Disassemble and Inspect Piston and Connecting Rod ........................................................ 129
Assemble Piston and Connecting Rod ................................................................................ 141
Inspect Cylinder Bore ......................................................................................................... 147
Rebore Cylinder ................................................................................................................. 152
Remove Crankshaft and Main Bearings: 3TNM74 .............................................................. 156
Install Crankshaft and Main Bearings: 3TNM74 .................................................................. 157
Remove Crankshaft and Main Bearings: 3TNV76 and 3TNV80 ........................................... 167
Install Crankshaft and Main Bearings: 3TNV76 and 3TNV80 .............................................. 169
Remove and Install Flywheel .............................................................................................. 172
Remove and Install Engine Back Plate ............................................................................... 173
Inspect Oil Pump: 3TNM74 ................................................................................................. 175
Inspect Oil Pump: 3TNV76 and 3TNV80 ............................................................................. 181
Group 10 - Cooling System .................................................................................................. 188

Summary of References ..................................................................................................... 188

Specifications ..................................................................................................................... 189
Remove and Install Fan and Alternator Belt ....................................................................... 190
Remove and Install Radiator .............................................................................................. 192
Remove and Install Water Pump ........................................................................................ 198
Remove and Install Thermostat ......................................................................................... 209
Remove and Install Coolant Temperature Sensor .............................................................. 214
Install Block Heater: 3TNM74 ............................................................................................. 218
Install Block Heater: 3TNV76 and 3TNV80 ......................................................................... 225

Section 20 - ENGINE REPAIR Group 05: Engine
Group 05 - Engine
Summary of References
Specifications
Other Material
Service Equipment and Tools
Essential or Recommended Tools
Remove Engine
Install Engine
Remove and Install Valve Cover
Remove and Install Rocker Arm Assembly and Push Rods
Disassemble, Inspect, and Assemble Rocker Arm Assembly and Push Rods
Remove and Install Exhaust Manifold
Remove and Install Cylinder Head
Disassemble and Assemble Cylinder Head
Recondition Cylinder Head
Replace Crankshaft Rear Oil Seal: 3TNM74
Replace Crankshaft Rear Oil Seal: 3TNV76 and 3TNV80
Remove and Install Crankshaft Rear Oil Seal Case: 3TNV76 and 3TNV80
Replace Crankshaft Front Oil Seal
Remove and Install Timing Gear Cover
Remove, Inspect, and Install Idler Gear
Remove, Inspect, and Install Camshaft Followers
Remove and Install Camshaft
Inspect Camshaft, Gear, Bushing and Bores
Remove and Install Oil Pan and Strainer: 3TNM74
Remove and Install Oil Pan and Strainer: 3TNV76 and 3TNV80
Check Connecting Rod Side Play
Check Crankshaft End Play
Check Connecting Rod Bearing Clearance
Check Crankshaft Main Bearing Clearance

Remove Piston and Connecting Rod

Install Piston and Connecting Rod
Disassemble and Inspect Piston and Connecting Rod
Assemble Piston and Connecting Rod
Inspect Cylinder Bore
Rebore Cylinder
Remove Crankshaft and Main Bearings: 3TNM74
Install Crankshaft and Main Bearings: 3TNM74
Remove Crankshaft and Main Bearings: 3TNV76 and 3TNV80
Install Crankshaft and Main Bearings: 3TNV76 and 3TNV80
Remove and Install Flywheel
Remove and Install Engine Back Plate
Inspect Oil Pump: 3TNM74
Inspect Oil Pump: 3TNV76 and 3TNV80

Specifications
Item Measurement Specification
M10 Engine Isolator Mount Bolts and Nuts Torque 73 ± 14.6 N·m
(53.8 ± 10.8 lb.-ft.)
(27.3 ± 5.5 lb.-ft.)
Driveshaft Coupling Bolts Torque 27 N·m
(20 lb.-ft.)
Valve Cover-to-Cylinder Head Cap Screws Torque 11 N·m
(97 lb.-in.)
Rocker Arm Assembly-to-Head Cap Screws Torque 26 N·m
(226 lb.-in.)
Rocker Arm Shaft Diameter

Standard Diameter 11.97—11.98 mm
(0.471—0.472 in.)
Wear Limit Diameter 11.95 mm
(0.470 in.)
Rocker Arm and Shaft Support ID

(0.472—0.473 in.)
(0.476 in.)
(0.005 in.)
Push Rod Clearance 0—0.03 mm
(0.0—0.001 in.)
Exhaust Manifold-to-Cylinder Head Cap Screws Torque 22.5—28.4 N·m
(17—21 lb.-ft.)
Initial Torque 27 N·m
(20 lb.-ft.)
Final Torque 54—58 N·m
(40—43 lb.-ft.)
Cylinder Head Distortion

Standard Clearance 0—0.05 mm
(0—0.002 in.)
Wear Limit Clearance 0.15 mm
(0.006 in.)
Valve Grinding
Face Margin (A) 3TNM74 Intake and Exhaust Standard 0.4—0.6 mm

(0.015—0.023 in.)
3TNM74 Wear Limit 0.4 mm
(0.015 in.)
Face Margin (A) 3TNV76 and 3TNV80 Intake Standard 0.9—1.1 mm
(0.035—0.043 in.)
3TNV76 and 3TNV80 Wear Limit 0.5 mm
(0.02 in.)
Face Margin (A) 3TNV76 and 3TNV80 Exhaust Standard 1.0—1.2 mm
(0.039—0.047 in.)
(0.02 in.)
Face Angle (B) Intake Valve 30°
Exhaust Valve 45°
Valve Stem Diameter

Intake Valve Standard Diameter 5.96—5.98 mm
(0.234—0.2355 in.)
Exhaust Valve Standard Diameter 5.95—5.97 mm
(0.234—0.235 in.)
Both Valves Wear Limit 5.90 mm
(0.232 in.)
Valve Recession
Both Valves Standard 0.40—0.60 mm
(0.016—0.024 in.)
Intake Valve Wear Limit 0.09 mm
(0.04 in.)
Exhaust Valve Wear Limit 0.08 mm
(0.03 in.)
Valve Guide Inside Diameter

(0.236— 0.237 in.)
Wear Limit 6.08 mm
(0.239 in.)
Valve Guide-to-Valve Stem Oil Clearance

Intake Valve Standard Clearance 0.03—0.05 mm
(0.001—0.002 in.)
Exhaust Valve Standard Clearance 0.04—0.07 mm
(0.002—0.003 in.)
(0.007 in.)

Valve Guide Height 9.8—10 mm
(0.386—0.394 in.)
3TNM74 Valve Stem Seal Height 13.8 mm
(0.543 in.)
3TNV76 and 3TNV80 Valve Stem Seal Height 11.2—11.9 mm
(0.441—0.429 in.)
Valve Spring Free Length 37.8 mm
(1.488 in.)
Valve Spring Maximum Inclination 1.3 mm
(0.051 in.)
Oil Seal Case-to-Engine Block Cap Screws Torque 11 N·m
(97 lb.-in.)
Crankshaft Pulley-to-Crankshaft Cap Screw Torque 113—123 N·m
(83—90 lb.-ft.)
3TNM74 Timing Gear Cover-to-Housing Cap Screws Torque 22.5—28.4 N·m
(200—250 lb.-in.)
3TNV76 and 3TNV80 Timing Gear Cover-to-Housing Cap

Torque 9 N·m
Screws
(79 lb.-in.)
Idler Gear Shaft Outside Diameter

3TNM74 Standard OD 29.95—29.98 mm
(1.179—1.180 in.)
3TNM74 Wear Limit OD 29.91 mm
(1.177 in.)
3TNV76 and 3TNV80 Standard OD 45.95—45.98 mm
(1.809—1.810 in.)
3TNV76 and 3TNV80 Wear Limit OD 45.90 mm
(1.807 in.)
Idler Gear Bushing Inside Diameter

3TNM74 Standard ID 30.0—30.02 mm
(1.181—1.182 in.)
3TNM74 Oil Clearance 0.02—0.06 mm
(0.001—0.003 in.)
3TNM74 Wear Limit ID 0.14 mm
(0.005 in.)
3TNV76 and 3TNV80 Standard ID 46.0—46.08 mm
(1.811—1.813 in.)
3TNV76 and 3TNV80 Oil Clearance 0.03—0.08 mm
(0.001—0.003 in.)

3TNV76 and 3TNV80 Wear Limit ID 0.18 mm
(0.007 in.)
Idler Gear Shaft-to-Engine Torque 10 N·m
(88 lb.-in.)
Cam Follower Outside Diameter

Standard OD 20.93—20.96 mm
(0.824—0.825 in.)
Wear Limit OD 20.90 mm
(0.823 in.)
Cam Follower Bore Inside Diameter

Standard ID 21.00—21.02 mm
(0.827—0.828 in.)
Wear Limit ID 21.04 mm
(0.828 in.)
Cam Follower-to-Bore Oil Clearance

Standard Clearance 0.04—0.09 mm
(0.002—0.004 in.)
(0.005 in.)
Camshaft-to-Engine cap Screws Torque 11 N·m
(97 lb.-in.)
Thrust Plate-to-Front Side of Camshaft Bearing Journal Standard Side Gap 0.05—0.15 mm
(0.002—0.006 in.)
Camshaft Standard Axial Runout (Wobble) 0.00—0.02 mm
(0.00—0.001 in.)
Wear Limit Axial Runout (Wobble) 0.05 mm
(0.002 in.)
3TNM74 Camshaft Lobe Standard Height 34.53—34.66 mm
(1.359—1.364 in.)
Wear Limit Height 34.28 mm
(1.349 in.)
3TNV76 and 3TNV80 Camshaft Lobe Standard Height 34.14—34.27 mm
(1.343—1.349 in.)
(1.334 in.)
Camshaft Bearing Journal

Gear Side and Flywheel-End Journals Standard OD 39.94—35.96 mm
(1.572—1.573 in.)

(1.571 in.)
Intermediate Journals Standard OD 39.91—39.94 mm
(1.571—1.572 in.)
(1.569 in.)
Camshaft Bushing Standard ID 40.0—40.03 mm
(1.575—1.578 in.)
(1.579 in.)
Oil Clearance 0.04—0.14 mm
(0.002—0.005 in.)
Camshaft Bearing Bores

Flywheel-End Bore Standard ID 40.0—40.03 mm
(1.575—1.576 in.)
(1.579 in.)
(0.002—0.003 in.)
Intermediate Bores Standard ID 40.0—40.03 mm
(1.575—1.576 in.)
(1.579 in.)
Oil Clearance (0.07—0.12 mm)
(0.003—0.005 in.)
Oil Pan-to-Engine Cap Screws Torque 10 N·m
(88 lb.-in.)
Oil Pan-to-Engine Cap Screws Torque 22.5—28.4 N·m
(200—250 lb.-in.)
Connecting Rod Side Play 0.2—0.4 mm
(0.008—0.016 in.)
Crankshaft End Play 0.11—0.25 mm
(0.004—0.010 in.)
Connecting Rod Cap Screws Torque 22.6—27.5 N·m
(16.6—20.2 lb.-ft.)
Clearance Specifications
Connecting Rod Bearing Clearance 0.02—0.06 mm
(0.001—0.002 in.)
(0.005 in.)

Ladder Frame Cap Screws Torque 45 N·m
(33 lb.-ft.)
Clearance Specifications
Crankshaft Main Bearing Clearance 0.03—0.06 mm
(0.001—0.002 in.)
(0.005 in.)
Connecting Rod Cap Bolts Torque 22.6—27.5 N·m
(200—243 lb.-in.)
Connecting Rod Big End Bearing specifications

3TNM74 Connecting Rod Bearing ID 37.98—38.01 mm
(1.495—1.496 in.)
3TNV76 and 3TNV80 Connecting Rod Bearing ID 41.98—42.00 mm
(1.653—1.654 in.)
Bearing Thickness 1.50—1.51 mm
(0.059 in.)
Oil Clearance 0.02—-.05 mm
(0.002—0.002 in.)
Oil Clearance Wear Limit Clearance 0.11 mm
(0.004 in.)
Piston Ring Groove Side Clearance

3TNM74 Top Piston Ring Clearance 0.06—0.10 mm
(0.002—0.004 in.)
3TNM74 Second Piston Ring Clearance 0.09—0.12 mm
(0.004—0.005 in.)
3TNM74 Oil Control Ring Clearance 0.02—0.06 mm
(0.001—0.002 in.)
3TNV76 and 3TNV80 Top Piston Ring Clearance 0.15—0.30 mm
(0.006—0.012 in.)
3TNV76 and 3TNV80 Second Piston Ring Clearance 0.18—0.33 mm
(0.007—0.013 in.)
3TNV76 and 3TNV80 Oil Control Ring Clearance 0.02—0.06 mm
(0.001—0.002 in.)
3TNM74 Piston Ring End Gap

Top Piston Ring Gap 0.10—0.30 mm
(0.004—0.012 in.)
Second Piston Ring Gap 0.25—0.40 mm
(0.010—0.016 in.)
Oil Control Ring Gap 0.20—0.45 mm

(0.008—0.018 in.)
3TNV76 and 3TNV80 Piston Ring End Gap

(0.006—0.012 in.)
(0.004—0.007 in.)
(0.008—0.018 in.)
Piston Pin Outside Diameter

Standard OD 22.00 mm
(0.866 in.)
(0.865 in.)
Piston Pin Bore Inside Diameter

(0.866—0.867 in.)
(0.868 in.)
(0.000—0.001 in.)
(0.003 in.)
Piston Pin Bushing Inside Diameter

(0.867—0.868 in.)
(0.869 in.)
3TNM74 Piston Outside Diameter

Distance (A) 22—25 mm
(0.866—0.984 in.)
Standard Piston OD 73.96—73.99 mm
(2.912—2.913 in.)
(2.910 in.)
3TNV76 Piston Outside Diameter

(0.866—0.984 in.)

(2.991—2.992 in.)
(2.989 in.)

(0.866—0.984 in.)
(3.148—3.149 in.)
(3.146 in.)
Cylinder Bore Specifications

(2.913 in.)
3TNM74 Standard Wear Limit ID 74.20 mm
(2.921 in.)
3TNM74 Oversize ID 74.25—74.28 mm
(2.923—2.924 in.)
3TNM74 Oversize Wear Limit ID 74.45 mm
(2.931 in.)
3TNM74 Piston to Cylinder Clearance 0.01—0.07 mm
(0.001—0.002 in.)
3TNV76 Standard ID 76.01—76.03 mm
(2.993 in.)
3TNV76 Standard Wear Limit ID 76.20 mm
(2.999 in.)
3TNV76 Oversize ID 76.25—76.28 mm
(3.002—3.003 in.)
3TNV76 Oversize Wear Limit ID 76.45 mm
(3.010 in.)
3TNV76 Piston to Cylinder Clearance 0.01—0.07 mm
(0.001—0.002 in.)
(3.15 in.)
(3.157 in.)
(3.159—3.161 in.)
(3.167 in.)

(0.001—0.002 in.)
All Models Cylinder Roundness and Taper

Cylinder Roundness 0.00—0.01 mm
(0.000—0.001 in.)
Wear Limit Roundness 0.03 mm
(0.001 in.)
Cylinder Taper 0.00—0.01 mm
(0.000—0.001 in.)
Wear Limit Taper 0.03 mm
(0.001 in.)
Ladder Frame-to-Engine Cap Screws Torque 45 N·m
(33 lb.-ft.)
Main Bearing Cap Screws Torque 76—81 N·m
(56—60 lb.-ft.)
Flywheel Cap Screws Torque 80.4—86.4 N·m
(59—64 lb.-ft.)
Cap Screws Torque 49 N·m
(36 lb.-ft.)
Outer Rotor to Bore Clearance 0.05—0.10 mm
(0.002—0.004 in.)
(0.010 in.)
Outer Rotor Side Clearance 0.05—0.10 mm
(0.002—0.004 in.)
(0.006 in.)
Outer-to-Inner Rotor Clearance 0.05—0.10 mm
(0.002—0.004 in.)
Mounting Cap Screws Torque 11 N·m
(97 lb.-in.)
Outer Rotor to Cover Clearance 0.12—0.21 mm
(0.005—0.008 in.)
(0.012 in.)
Rotor-to-Rotor Clearance 0.02—0.07 mm
(0.001—0.003 in.)
(0.005 in.)

Rotor Side Clearance 0.02—0.07 mm
(0.001—0.003 in.)
Other Material
Number Name Use
• PM38609 (us)
• PM37469 (canadian) Form-in-Place Gasket Apply to seal surfaces as indicated.
• 59630 Loctite ™ (loctite)
• TY16285 (us)
• CXTY16285 (canadian) Clean and Cure Primer Clean mating surfaces.
→NOTE:
Order tools according to information given in the SERVICEGARD ™ Catalog.

Some tools may be available from a local supplier.

→NOTE:
Order tools from the SERVICEGARD ™ Catalog.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable only
from the SERVICEGARD ™ Catalog.
RECOMMENDED TOOLS, as noted, are suggested to perform the job correctly. Some tools
may be available from local suppliers or may be fabricated.

Remove Engine
[1] - Park machine safely. (See procedure in Section 10, Group 05.)
Air Intake Removal
LEGEND:
A Clamp
B Cap Screws
[2] - Allow engine to cool.
[3] - Remove hood and side panels.
[4] - Shut off fuel valve on fuel filter. Disconnect and plug fuel lines.
[5] - Disconnect negative cable from battery.

[6] - Loosen clamp (A) on air intake hose. Remove cap screws (B). Remove air cleaner and
hose as an assembly.
[7] - Drain coolant and remove upper and lower radiator hoses.
[8] - Remove two cap screws (C) on each side securing nose piece to frame.
Nose Piece Cap Screws
LEGEND:
C Cap Screws

[9] - Remove flange nut (D), and cap screws and nuts (E) from support. Remove support.
Support Removal
LEGEND:
D Nut and Lockwasher
E Nuts

[10] - Tilt radiator and nose piece forward a few inches (do not use excessive force) for
access to fan bolts.
Tilt Radiator Forward
[11] - Remove four bolts securing fan and spacer to water pump. Remove fan and spacer.
[12] - Disconnect battery cable and positive connectors (F) and solenoid exciter wire (G)
from starting motor.

Engine Electrical Connections Left-Hand Side
LEGEND:
F Battery Cable Positive Connectors
G Solenoid Exciter Wire
H Alternator Connectors
H Harness Clamps
[13] - Disconnect alternator connectors (H). Remove bolt securing harness clamps (I).

[14] - Remove exhaust pipe clamp (J) and support bolt (K). Remove exhaust pipe.
Exhaust Pipe
LEGEND:
J Pipe Clamp
K Support Bolt
[15] - Disconnect wire from coolant temperature sensor (L).

Engine Connections Right Hand Side
LEGEND:
L Coolant Temperature Sensor
M Cap Screw
N Glow Plug Harness Connector
O Fuel Shutoff Solenoid Connector
P Throttle Cable Jam Nuts
Q Oil Pressure Switch
[16] - Remove cap screw (M) securing ground strap and wires to engine.
[17] - Disconnect glow plug harness connector (N).
[18] - Disconnect fuel shutoff solenoid connector (O).
[19] - Loosen jam nuts (P) on throttle cable and disconnect throttle cable from throttle
control lever.

[20] - Disconnect oil pressure switch (Q).
[21] - Remove three bolts (R) connecting driveshaft coupling to flywheel.
Driveshaft Coupling Bolts
LEGEND:
R Bolts
[22] - Install lift rings to engine. Install lift sling or chain to lift rings, ensuring that no damage
is done to rear fuel injector and high-pressure fuel line.

[23] - Remove engine mounting bolts, washers, and nuts (S) on both sides of engine.
Engine Mount Bolts
LEGEND:
S Engine Mount Nuts
[24] - Lift engine slightly and check that flywheel coupling disconnects from flywheel.
[25] -
→NOTE:
Have an assistant help maneuver engine out of machine.
Simultaneously hoist engine and turn front of engine to right to clear radiator. Hoist engine
out of frame.

[26] - Lower engine onto wood blocks to prevent damage to oil pan or front cover.

Install Engine
[1] - Install lift rings or bolts to cylinder head cover into threaded holes. Install lift sling or
chain to lift rings or bolts, ensuring that no damage is done to rear fuel injector and fuel line.
Engine Mounting Hardware
LEGEND:
A Nuts
[2] -
→NOTE:
Obtain assistance to maneuver engine into machine.
Lift engine using sling and hoist. Do not damage high-pressure fuel line on rear fuel injector.

[3] - Install engine from right side of machine, starting with engine perpendicular to machine
frame with flywheel going in first.
[4] - Carefully lower and turn engine onto engine supports on frame. Pay special attention
not to damage fan blades.
[5] - Install M10 bolts, washers, and nuts (A) to engine mounts and tighten to specification.
(53.8 ± 10.8 lb.-ft.)
(27.3 ± 5.5 lb.-ft.)

[6] - Install three bolts (B) connecting driveshaft coupling to flywheel.
Driveshaft Coupling Bolts
LEGEND:
B Bolts
Driveshaft Coupling Bolts Torque 27 N·m
(20 lb.-ft.)

[7] - Connect coolant temperature sensor (C).
Engine Connectors Right Hand Side
LEGEND:
C Coolant Temperature Sensor
D Cap Screw
E Glow Plug Harness Connector
F Fuel Shutoff Solenoid Connector
G Jam Nuts
H Oil Pressure Switch
[8] - Install cap screw (D) securing ground strap and wires to engine.
[9] - Connect glow plug harness connector (E).
[10] - Connect fuel shutoff solenoid connector (F).

[11] - Connect throttle cable to control lever on injection pump. Adjust throttle cable and
tighten jam nuts (G) on throttle cable. (See Adjust Throttle Cable in Section 220, Group 15.)
[12] - Connect oil pressure switch (H).
[13] - Install exhaust pipe. Install support bolt (I) and tighten clamp (J).
Exhaust Pipe
LEGEND:
I Clamp
J Bolt

[14] - Connect battery cable and positive connectors (K) and solenoid exciter wire (L) to
starting motor. Connect alternator wires (M). Install harness clamps (N).
Engine connectors Left Hand Side
LEGEND:
K Battery Positive Cables
L Solenoid Exciter Wire
M Alternator Wires
N Harness Clamps
[15] - Connect alternator wires (M). Install harness clamps (N).

[16] - Slide nose piece back to original location.
Nose Piece and Radiator Assembly
[17] - Align holes and install two cap screws (O) on each side securing nose piece to frame.

Nose Piece Cap Screws
LEGEND:
O Cap Screws
[18] - Connect radiator hoses and tighten clamps.

[19] - Install support rod (P) with flange nut (Q), and cap screws and nuts (R).
Support Rod
LEGEND:
P Support Rod
Q Locknut and Washer
R Nuts

[20] - Install air cleaner and secure with cap screws (S). Tighten clamp (T) on air intake hose.
Air Cleaner
LEGEND:
S Cap Screws
T Clamp
[21] - Connect fuel supply and return hoses from fuel filter and water separator to fuel
injection pump. Secure hoses with spring clamps.
[22] - Fill engine with proper oil. (See Section 10, Group 15.). Engine oil capacity (with filter)
is approximately 2.9 L (3.1 qt.).
[23] - Fill radiator with recommended coolant.
[24] - Make sure that ignition switch is in OFF position. Install battery and connect positive
(+) battery cable to battery first, then negative (–) cable.

[25] - Install engine hood. (See procedure in Section 80, Group 20.)

Remove and Install Valve Cover
Valve Cover Components Exploded
LEGEND:
A Cap Screw, Long (6 used)
B Cap Screw, Short (3 used)
C Intake Cover
D Gasket
E Gasket
F Breather Baffle

G Diaphragm Cover
H Spring
I Center Plate
J Diaphragm
[1] - Remove muffler. (See procedure in this group.)
[2] - Loosen hose clamps from air cleaner hose and remove air cleaner.
[3] - Remove cap screws (A and B).
[4] - Remove valve cover.
[5] - Remove intake cover (C) and clean off mating surfaces and replace gasket (D).
[6] - Remove and disassemble breather baffle (F) and clean or replace mesh media.
[7] - Remove diaphragm cover (G), spring (H), center plate (I), and diaphragm (J).
[8] - Inspect diaphragm, spring, and center plate for wear or damage. Diaphragm must not
have any cracks or tears and must not leak. Replace parts showing any wear.
a. Clean all parts.

b. Reassemble valve cover using new gaskets.
c. Use John Deere Form in Place Gasket between breather baffle and valve cover.
Number Name Use
⚬ PM38609 (us)
⚬ PM37469 (canadian) Apply between breather baffle
Form-in-Place Gasket
⚬ 59630 Loctite ™ and valve cover.
(loctite)
d. Tighten valve cover cap screws to specification.

Valve Cover-to-Cylinder Head Cap Screws Torque 11 N·m
(97 lb.-in.)

Remove and Install Rocker Arm Assembly and Push

Rods
[1] - Remove valve cover. (See Remove and Install Valve Cover in this group.)
[2] - Remove 3 rocker arm mounting cap screws.
[3] - Pull rocker arm assembly straight up off cylinder head.
[4] - Remove push rods.
[5] - Inspect all parts for wear or damage. (See Disassemble, Inspect, and Assemble Rocker
Arm Assembly and Push Rods in this group.)
[6] -
IMPORTANT:
Avoid Damage! Be sure valve caps are in place on end of valve stems
before installing rocker arms.
Align rocker arm supports with holes in cylinder head. Align rockers with valve stems.
[7] - Install push rods in block and align into rocker arms.
[8] - Install 3 cap screws and tighten evenly to pull rocker arm assembly to head. Tighten to
specification.
Rocker Arm Assembly-to-Head Cap Screws Torque 26 N·m
(226 lb.-in.)
[9] - Adjust valve clearance. (See Adjust Valve Clearance in Section 220, Group 15.)

Disassemble, Inspect, and Assemble Rocker Arm

Assembly and Push Rods
Rocker Arm Assembly
LEGEND:
A Retaining Ring (2 used)
B Rocker Arm (3 intake and 3 exhaust)
C Set Screw
[ Set screw located in end rocker arm support for 3TNM74, located in middle support for 3TNV76 and 3TNV80. ]
D Rocker Arm Shaft Spring (2 used)
E Nut (6 used)
F Adjusting Screw (6 used)
G Rocker Arm Shaft
H Push Rod
I Valve Caps (6 used)
J Rocker Arm Support (3 used)
K Mounting Cap Screw (3 used)
[1] - Before disassembly mark all parts for location to aid reassembly.
[2] - Remove end retaining rings (A) and slide components off rocker arm shaft (G).

[3] - Remove Adjusting screw (F) from center support. Remove rocker arm shaft from center
support.
[4] - Clean all parts of varnish and oil.
[5] -
Rocker Arm Shaft
Measure outer diameter of rocker arm shaft.
Rocker Arm Shaft Diameter

(0.471—0.472 in.)
(0.470 in.)
Replace rocker arm shaft if less than wear limit.
[6] -

Rocker Arm ID

Measure inside diameter of rocker arms and rocker shaft supports.
Rocker Arm and Shaft Support ID

(0.472—0.473 in.)
(0.476 in.)
(0.005 in.)
Replace rocker arms or supports if ID is more than wear limit.
[7] - If shaft, support, and arm clearance (support or arm ID minus shaft OD) exceed wear
limit, replace all parts.
[8] -

Inspect Push Rod
Lay push rod on flat surface and roll while checking for a gap under center of rod. Use feeler
gauge to check dimension.
Push Rod Clearance 0—0.03 mm
(0.0—0.001 in.)
Replace push rod if not within specifications.
[9] - Check the surface of the adjusting screw that contacts the push rod for wear. Replace
push rod or adjusting screw if worn.
[10] - Check the rocker arm-to-valve stem cap contact surface for wear. Replace rocker arm
if worn.
[11] - Assemble rocker arm assembly.
a. Be sure oil holes (A) are oriented as shown when assembling rocker arm shaft
components. Assemble rocker shaft aligning Adjusting screw hole in shaft with
Adjusting screw in number one cylinder shaft support (flywheel end).
Rocker Arm Oil Hole Alignment

LEGEND:
A Oil Holes
b. Be sure that rocker arms are installed in same order as removed.
[12] - Install rocker arm assembly. (See Remove and Install Rocker Arm Assembly and Push
Rods in this section.)
Remove and Install Exhaust Manifold
[1] - Remove muffler. (See Remove and Install Muffler in Section 30, Group 10.)
[2] - Remove six cap screws holding exhaust manifold to cylinder head.
[3] - Inspect all parts for wear or damage. Replace as necessary.

[4] - Install exhaust manifold and tighten cap screws to specification.
Exhaust Manifold-to-Cylinder Head Cap Screws Torque 22.5—28.4 N·m
(17—21 lb.-ft.)
[5] - Install muffler.

Remove and Install Cylinder Head
[1] - Remove air cleaner and air cleaner mounting bracket.
[2] - Remove rocker arm assembly. (See Remove and Install Rocker Arm Assembly and Push
Rods in this group.)
[3] - Remove exhaust manifold. (See Remove and Install Exhaust Manifold in this group.)
[4] - Remove water pump. (See Remove and Install Water Pump in Section 20, Group 10.)
[5] - Remove coolant recovery tank and mounting bracket from cylinder head.
[6] - Remove coolant temperature sensor wire from sensor.
[7] - Shut off fuel valve on fuel filter.
[8] - Remove high-pressure fuel lines and fuel leak-off line running from fuel injection pump
to nozzles.
[9] - Disconnect glow plug wiring harness from engine harness.
[10] - Remove cylinder head cap screws.

Cylinder Head
[11] - Using lift brackets and hoist, pull head straight up from block.
[12] - Remove and discard gasket.

[13] - Disassemble and inspect cylinder head and valves. (See Recondition Cylinder Head in
this group.)
[14] -
Cylinder Head Bolt Torque Sequence
Clean all threads in top of cylinder block with a flat bottom tap, and blow debris from hole.
[15] - Clean top of cylinder block and check for flatness.
[16] -
IMPORTANT:
Avoid Damage! Oil passage in gasket must be located over oil passage in
cylinder block.
Place a new cylinder head gasket on cylinder block with locating pins on front and rear of
block inside holes in gasket. Align oil port on left rear of block with oil port in gasket.
[17] - Install cylinder head.
[18] - Clean threads of cylinder head cap screws and dip in clean oil. Install all cap screws
finger tight.

[19] - Tighten cap screws in sequence shown according to specifications.
Initial Torque 27 N·m
(20 lb.-ft.)
Final Torque 54—58 N·m
(40—43 lb.-ft.)
IMPORTANT:
Avoid Damage! Cylinder head mounting cap screws must be checked for
proper torque after 50 hours of engine operation.
[20] - Remove lift brackets.
[21] - Connect glow plug wiring harness to engine harness.
[22] - Install high-pressure fuel lines and fuel leak-off line running from fuel injection pump to
nozzles.
[23] - Open fuel valve on fuel filter.
[24] - Install coolant temperature sensor wire to sensor
[25] - Install coolant recovery tank and mounting bracket.
[26] - Install water pump. (See Remove and Install Water Pump in Section 20, Group 10.)
[27] - Install exhaust manifold. (See Remove and Install Exhaust Manifold in this group.)
[28] - Install rocker arm assembly. (See Remove and Install Rocker Arm Assembly and Push
Rods in this group.)
[29] - Install air cleaner and air cleaner mounting bracket.

Disassemble and Assemble Cylinder Head
Cylinder Head Valve Assemblies
LEGEND:
A Valve Spring
B Collet Halves
C Retainer
D Stem Seal

E Valve Guide
F Seat
G Valve
[1] - Compress valve springs (A) using JDE138 Valve Spring Compressor.
[2] -
→NOTE:
It may be necessary to tap on valve spring retainer while initially operating

compressor to break retainer free from collet halves.
Remove collet halves (B) from retainer (C).
[3] - Slowly release compressor and valve spring.
[4] - Remove valve spring, stem seal (D), and valve (G) from head.
[5] - Intake and exhaust valve guides (E) and seats (F) are press fit. Remove only if
replacement is necessary.
[6] - Inspect all parts for wear or damage. Clean all carbon deposits and measure all parts for
proper clearances. (See Recondition Cylinder Head in this group.)
[7] -
IMPORTANT:
Avoid Damage! Do not reuse stem seals if removed. Used seals will leak.
Apply clean engine oil on intake and exhaust valve stems during assembly.
[8] - Install springs with smaller pitch end or paint mark toward cylinder head.

[9] -
→NOTE:
If new valves are installed, measure valve recession. (See procedure in this
group.)
Use valve spring compressor to compress spring and retainer, and install collet as removed.
[10] - After each valve has been assembled, tap on top of valve stem with a plastic hammer
to seat retainer.

Recondition Cylinder Head
Cylinder Head
Measure Cylinder Head Flatness
Measure cylinder head flatness. Place a straight-edge along each of the four sides and each
diagonal. Measure clearance between straight edge and combustion surface with a feeler
gauge. If distortion exceeds the wear limit replace cylinder head.
Cylinder Head Distortion

Standard Clearance 0—0.05 mm
(0—0.002 in.)
(0.006 in.)

Intake and Exhaust Valves
Check Valve for Out-of-Round
[1] - Check valve for out-of-round, bent or warped condition using a valve inspection center
and dial indicator. Replace valve if necessary.
[2] -

Valve Face Angle and Margin
LEGEND:
A Valve Face Margin
B Valve Face Angle
If valve faces are worn, burned or pitted, grind valves to proper face angle. If valve face
margin (A) is less than specification after grinding, replace valve.
Valve Grinding
Face Margin (A) 3TNM74 Intake and Exhaust Standard 0.4—0.6 mm
(0.015—0.023 in.)
3TNM74 Wear Limit 0.4 mm
(0.015 in.)
Face Margin (A) 3TNV76 and 3TNV80 Intake Standard 0.9—1.1 mm
(0.035—0.043 in.)
(0.02 in.)
Face Margin (A) 3TNV76 and 3TNV80 Exhaust Standard 1.0—1.2 mm
(0.039—0.047 in.)

(0.02 in.)
Face Angle (B) Intake Valve 30°
Exhaust Valve 45°
[3] -
Valve Stem Diameter
Measure valve stem diameter at the two locations shown. Replace valve if measurement
exceeds wear limit.
Valve Stem Diameter

Intake Valve Standard Diameter 5.96—5.98 mm
(0.234—0.2355 in.)
Exhaust Valve Standard Diameter 5.95—5.97 mm
(0.234—0.235 in.)
(0.232 in.)
[4] -


Measure Valve Recession
LEGEND:
C Valve Recession
Measure valve recession (C) using a depth gauge. Replace valve or cylinder head if
measurement exceeds wear limit.
Valve Recession
(0.016—0.024 in.)
Intake Valve Wear Limit 0.09 mm
(0.04 in.)
Exhaust Valve Wear Limit 0.08 mm
(0.03 in.)
Valve Guides
[1] - Clean valve guides using a valve guide brush.

[2] - Measure valve guide inside diameter using a ball or telescoping snap gauge.
If valve guide inside diameter exceeds wear limit, replace guide.

Valve Guide Inside Diameter

(0.236—0.237 in.)
Wear Limit 6.08 mm
(0.239 in.)
If valve guide inside diameter is less than wear limit, determine guide-to-stem
clearance (Valve guide diameter minus valve stem diameter). If clearance exceeds wear
limit specification, replace valve guides.
Valve Guide-to-Valve Stem Oil Clearance

Intake Valve Standard Clearance 0.03—0.05 mm
(0.001—0.002 in.)
Exhaust Valve Standard Clearance 0.04—0.07 mm
(0.002—0.003 in.)
(0.007 in.)
[3] -

Valve Guide in Cylinder Head
LEGEND:
A Height
Valve Stem Seal Height

LEGEND:
B Distance
If necessary, replace valve guides using JDE504 Valve Guide Driver. Install valve guides with
tapered ends down. Push valve guides down until top of valve guides are projecting the
specified height (A) from the valve spring seat in the cylinder head.
Valve Guide Height 9.8—10 mm
(0.386—0.394 in.)
3TNM74 Valve Stem Seal Height 13.8 mm
(0.543 in.)
3TNV76 and 3TNV80 Valve Stem Seal Height 11.2—11.9 mm
(0.441—0.429 in.)
a. Ream inside diameter of valve guides using a 6 mm Valve Guide Reamer.

→NOTE:
The intake and exhaust valve stem seals on the 3TNM74 are different
and can be identified by markings on the seals. The intake valve stem
seals have a white spring and the exhaust valve stem seals have a
white mark on the body of the seal.
Measure the distance (B) between the cylinder head and the valve stem seal to ensure
proper clearance between valve stem seal and valve guide. Compare to specification.
Valve Springs

Measure Spring Free Length

Measure Spring Inclination
LEGEND:
C Spring Free Length
D Spring Inclination

[1] - Measure spring free length (C). Replace spring if measurement exceeds specification.
Valve Spring Free Length 37.8 mm
(1.488 in.)
[2] - Measure spring inclination (D). Replace spring if measurement exceeds specification.
Valve Spring Maximum Inclination 1.3 mm
(0.051 in.)
Grinding Valve Seats

Grinding Valve Seats

[1] -
→NOTE:
LIGHTLY grind valve seats only for a few seconds to avoid excessive valve
seat width. If valve guide is to be replaced, always replace guide before
grinding valve seat, as seat grinder pilot is centered by guide.
Grind intake valve seat using a 30° seat grinder, and exhaust valve seat using a 45° seat
grinder. Follow tool manufacturers instructions.

[2] -
Valve Seat Measurements
LEGEND:
E Valve Seat Width
F Lower Seat Surface
G Upper Seat Surface
H Valve Seat
Measure valve seat width (E) after grinding.
[3] - If seat is too wide after grinding, grind lower seat surface (F) using a 70° seat grinder
until seat width is close to specifications.

[4] - Grind upper seat surface (G) using a 15° seat grinder until seat width is narrowed to
specifications.
[5] - If valve seats (H) are ground, measure valve recession and check contact pattern
between the seat and valve with bluing dye.
[6] - Lap valves. (See procedure in this group.)
→NOTE:
If valve recession exceeds maximum specifications or seats cannot be

reconditioned, replace cylinder head.
Lapping Valves


Lapping Valves
Valve Face
LEGEND:
I Valve Face
→NOTE:
Use a rubber type lapping tool for valves without a lapping tool groove slit.
If seat does not make proper contact, lap the valve into the seat.
[1] - Apply small amount of fine lapping compound to face of valve.
[2] - Turn valve to lap valve to seat.
[3] - Lift valve from seat every 8 to 10 strokes. Lap until a uniform ring appears around the
surface of the valve face (I).
[4] - Wash all parts in solvent to remove lapping compound. Dry parts.

[5] - Check position of lap mark on valve face. Lap mark must be on or near center of valve
face.
Replace Crankshaft Rear Oil Seal: 3TNM74
Crankshaft Rear Oil Seal
LEGEND:
A Oil Seal
B Engine Block
[1] - Remove flywheel. (See Remove and Install Flywheel in this group.)
[2] - Carefully pry oil seal (A) from engine block (B).
[3] - Replace oil seal using a driver set. Install seal with lip toward cylinder block. Install seal
flush with surface of engine block.
[4] - Install flywheel.

Replace Crankshaft Rear Oil Seal: 3TNV76 and 3TNV80
[1] - Remove flywheel. (See Remove and Install Flywheel in this group.)
[2] -
→NOTE:
Oil Seal
LEGEND:
A Oil Seal
B Seal Case
It is not necessary to remove oil seal case (B) to remove oil seal.
Carefully pry oil seal (A) from oil seal case.

[3] - Replace oil seal (A) using a driver set. Install seal with lip toward cylinder block. Install
seal flush with surface of oil seal case.
→NOTE:
If oil seal has worn a groove in crankshaft at oil seal contact point, seal can
be installed 3 mm (0.120 in.) deeper into oil seal case.
[4] - Install flywheel.

Remove and Install Crankshaft Rear Oil Seal Case:

3TNV76 and 3TNV80
Oil Seal Case and Seal
LEGEND:
A Cap Screw (10 used)
B Alignment Pin (2 used)
C Gasket Sealer

[1] -
→NOTE:
It is not necessary to remove oil seal case to remove oil seal. It is not
necessary to remove oil seal to remove seal case.
Remove ten oil seal case-to-cylinder block cap screws (A).
[2] - Pry oil seal case from engine block. Note positions of two alignment pins (B).
[3] - Clean all old gasket material from oil seal case and engine block.
Number Name Use

• TY16285 (us)
Clean mating surfaces of oil seal case and engine
• CXTY16285 (canadian) Cure Primer
block.
[4] - Apply form-in-place gasket sealer (C) on mating surfaces of oil seal case-to-engine
block.
Number Name Use

• PM38609 (us)
• PM37469 (canadian) Apply on mating surfaces of oil seal case-
• 59630 Loctite ™ to-engine block.
(loctite)
[5] - Install seal case with ten cap screws. Tighten to specification.
Oil Seal Case-to-Engine Block Cap Screws Torque 11 N·m
(97 lb.-in.)
[6] - Install new oil seal after oil seal case is installed. (See procedure in this group.)

Replace Crankshaft Front Oil Seal
Remove Crankshaft Sheave with Puller

Oil Seal Removed from Timing Cover
[1] - Remove engine. (See procedure in this group.)
[2] - Remove alternator. (See Remove and Install Alternator in Section 40, Group 05.)
[3] - Remove fan, fan spacer, sheave, and belt.
[4] - Remove crankshaft sheave cap screw and washer. Install puller to crankshaft sheave
and remove sheave.
[5] - Carefully pry oil seal from timing cover.
[6] - Install new oil seal using a driver set. Install seal with lip toward engine. Install seal flush
with surface of cover.
[7] - Coat lip of seal with clean engine oil.

[8] - Install crankshaft pulley to crankshaft, lining up key in crankshaft with keyway in
crankshaft pulley.
[9] - Install new O-ring on flat washer. Install cap screw and washer. Tighten to specification.
(83—90 lb.-ft.)
[10] - Install fan, spacer, and sheave.
[11] - Install alternator.
[12] - Install fan and alternator belt. (See Adjust Fan and Alternator Belt in Section 20, Group
10.)

Remove and Install Timing Gear Cover
Remove Sheave with Puller
[1] - Remove alternator. (See Remove and Install Alternator in Section 40, Group 05.)
[2] - Remove fan, spacer, and sheave from water pump.
[3] - Remove crankshaft pulley mounting bolt and washer.
[4] - Install puller to crankshaft sheave and remove sheave.
[5] - Remove timing cover mounting cap screws (A).

Timing Gear Cover Parts 3TNM74

Timing Gear Cover Parts 3TNV76 and 3TNV80
LEGEND:
A Cap Screws
B Timing Gear Cover
C Injection Pump Gear Cover
[6] - Remove timing gear cover (B).
[7] - Remove injection pump gear cover (C).

[8] - Clean all old gasket material from timing gear cover, and timing gear housing on block.
Number Name Use

• TY16285 (us)
Clean mating surfaces of timing gear cover and
housing.
[9] - Apply a thin bead of John Deere Form-In-Place Gasket Sealer to timing gear cover before
installation.
Number Name Use

• PM38609 (us)
Apply on mating surfaces of timing gear
• PM37469 (canadian) Form-in-Place Gasket
cover and engine block.
[10] - Install timing gear cover and cap screws. Tighten to specification.
3TNM74 Timing Gear Cover-to-Housing Cap Screws Torque 22.5—28.4 N·m
(200—250 lb.-in.)
3TNV76 and 3TNV80 Timing Gear Cover-to-Housing Cap Screws Torque 9 N·m
(79 lb.-in.)
[11] - Install crankshaft pulley, carefully lining up keyway with key on crankshaft. Install flat
washer with new O-ring. Tighten to specification.
(83—90 lb.-ft.)
[12] - Install water pump sheave and fan.
[13] - Install alternator and drive belt. (See Adjust Fan and Alternator Belt in Section 40,
Group 05.)

Remove, Inspect, and Install Idler Gear
[1] - Check backlash of timing gears. (See Check Timing Gear Backlash in Section 220, Group
15.)
[2] -
→NOTE:
Idler Gear 3TNM74

Idler Gear 3TNV76 and 3TNV80
LEGEND:
A Cap Screws
B Shaft
C Idler Gear
Due to the odd number of teeth on the idler gear, timing marks align
periodically. When all timing marks on gears align, the piston closest to the
water pump (No. 3) is at TDC on compression stroke. (No. 1 cylinder is
closest to the flywheel.)
Rotate crankshaft and align timing marks.
[3] -
→NOTE:
Mark position of idler gear shaft (B) to make sure it is installed in the exact
same position.

Remove three cap screws (A), shaft (B) and idler gear (C).
[4] - Inspect all parts for wear or damage.
a. Inspect gear for chipped or broken teeth. Replace if necessary.
b.
Idler Gear Shaft
LEGEND:
A Gear Shaft OD
Measure idler gear shaft diameter. If shaft diameter is damaged or less than wear limit,
replace idler gear shaft.
Idler Gear Shaft Outside Diameter

3TNM74 Standard OD 29.95—29.98 mm
(1.179—1.180 in.)
3TNM74 Wear Limit OD 29.91 mm
(1.177 in.)
3TNV76 and 3TNV80 Standard OD 45.95—45.98 mm
(1.809—1.810 in.)
3TNV76 and 3TNV80 Wear Limit OD 45.90 mm
(1.807 in.)

c.
Idler Gear Bushing

Idler Gear Shaft Oil Holes - 3TNM74

LEGEND:
B Idler Gear Bushing
C Oil Holes
Measure idler gear bushing diameter. If bushing diameter exceeds wear limit, replace
bushing. If bushing oil clearance (bushing ID minus shaft OD) exceeds specification,
replace bushing, shaft or both.
Idler Gear Bushing Inside Diameter

(1.181—1.182 in.)
3TNM74 Oil Clearance 0.02—0.06 mm
(0.001—0.003 in.)
3TNM74 Wear Limit ID 0.14 mm
(0.005 in.)
3TNV76 and 3TNV80 Standard ID 46.0—46.08 mm
(1.811—1.813 in.)
3TNV76 and 3TNV80 Oil Clearance 0.03—0.08 mm
(0.001—0.003 in.)
3TNV76 and 3TNV80 Wear Limit ID 0.18 mm

(0.007 in.)
d. If necessary, replace bushing using a driver set. Align oil holes in bushing and idler
gear. Install bushing flush with surface of idler gear.
[5] - Install idler gear in the reverse order of removal.
a. Install idler gear with all timing Marks aligned.

b. Make sure idler gear shaft Marks align to oil holes (C) when shaft is installed.
c. Tighten cap screws to specifications.
Idler Gear Shaft-to-Engine Torque 10 N·m
(88 lb.-in.)

Remove, Inspect, and Install Camshaft Followers
IMPORTANT:
Avoid Damage! Always replace all camshaft followers when installing a new
camshaft. The components wear as a set and replacing only one of the
components will accelerate wear on the other.
[1] - Remove cylinder head. (See procedure in this group.)
[2] - Remove cam followers from cylinder block with magnetic pick-up tool.
a.
Cam Follower Contact Surface
LEGEND:
A Abnormal Wear
B Normal Wear
Check cam follower contact surface for abnormal (A) or normal wear (B).

b.
Measure Cam Follower Diameter
Measure cam follower diameter. If outside diameter is less than wear limit, replace cam
follower.
Cam Follower Outside Diameter

Standard OD 20.93—20.96 mm
(0.824—0.825 in.)
(0.823 in.)
c. Measure cam follower bore diameter in cylinder block. If cam follower bore diameter
exceeds wear limit, replace cylinder block.
Cam Follower Bore Inside Diameter

(0.827—0.828 in.)
(0.828 in.)
d. If follower-to-bore oil clearance (bore ID minus follower OD) exceeds specification,

replace cam follower, cylinder block or both.
Cam Follower-to-Bore Oil Clearance

Standard Clearance 0.04—0.09 mm

(0.002—0.004 in.)
(0.005 in.)
[4] - Apply clean engine oil on all parts during installation.
[5] - Install cam followers after camshaft is installed. Installation is done in the reverse order
of removal.

Remove and Install Camshaft
IMPORTANT:
Avoid Damage! Always replace all camshaft followers when installing a new
camshaft. The components wear as a set and replacing only one of the
components accelerates wear on the other.
[1] - Remove rocker arm assembly and push rods. (See Remove and Install Rocker Arm
Assembly and Push Rods in this group.)
[2] - Remove timing gear cover. (See Remove and Install Timing Gear Cover in this group.)
[3] - Check camshaft end play. (See Check Camshaft End Play in Section 220, Group 15.)
[4] - Check backlash of timing gears. (See Check Timing Gear Backlash in Section 220, Group
15.)
[5] -
→NOTE:
If camshaft is being removed with cylinder head installed, use a magnetic

follower holder tool, or turn engine until oil pan is upward, to hold cam
followers away from camshaft.
Hold cam followers away from camshaft using a magnetic follower holder kit such as
D15001NU.
[6] -
→NOTE:

Timing Marks Aligned 3TNM74

Timing Marks Aligned 3TNV76 and 3TNV80
LEGEND:
A Timing Marks
B Cap Screws
C Camshaft
Due to the odd number of teeth on the idler gear, timing marks only align
periodically.
Rotate crankshaft and align timing marks (A).
[7] -
IMPORTANT:
Avoid Damage! DO NOT allow camshaft lobes to hit bearing surfaces while
removing camshaft. Machined surfaces will be damaged.
Remove two cap screws (B) and camshaft (C).

[8] - Inspect camshaft, gear, and bearings for wear or damage. (See procedure in this
group.)
[9] - Apply clean engine oil on all parts during installation.
[10] - Rotate crankshaft to align timing marks and install camshaft into cylinder block, being
careful not to allow camshaft lobes to scratch camshaft bushings. Align camshaft gear timing
marks with timing marks on idler gear.
[11] - Install two cap screws and tighten to specification.
Camshaft-to-Engine Cap Screws Torque 11 N·m
(97 lb.-in.)
[12] - Install timing gear cover.
[13] - If cam followers were removed, replace into same holes as removed.
[14] - Install push rods and rocker arm assembly.

Inspect Camshaft, Gear, Bushing and Bores


Camshaft Side Gap Measurement
LEGEND:
A Thrust Plate
B Camshaft Bearing Journal
C Side Gap
[1] - Check camshaft end play while camshaft is installed in cylinder block. (See Check
Camshaft End Play in Section 220, Group 15.)
[2] - Check camshaft side gap (C) with camshaft removed from cylinder block using a feeler
gauge between camshaft thrust plate (A) and front side of first camshaft bearing journal (B).
If side gap is excessive, remove gear and replace thrust plate.
Thrust Plate-to-Front Side of Camshaft Bearing Journal Standard Side Gap 0.05—0.15 mm
(0.002—0.006 in.)
[3] -
Replace Gear and Thrust Plate

LEGEND:
A Thrust Plate
D Key
E Stepped Shoulder
Inspect gear for chipped or broken teeth. Replace if necessary.
a. Remove gear using a knife-edge puller and an arbor press. Place flat side of puller
against camshaft gear.
CAUTION:
Avoid Injury! Plan a safe handling procedure to avoid burns. DO NOT
heat oil over 182 °C (360 °F). Oil fumes or oil can ignite above 193 °C
(380 °F). Use a thermometer. Do not allow a flame or heating element
to come in direct contact with the oil. Heat the oil in a well ventilated
area.
Heat new gear to approximately 150 °C (300 °F) .
c. Install key (D) into slot of camshaft.

d. Install thrust plate (A) onto camshaft, centering onto stepped shoulder (E).
IMPORTANT:
Avoid Damage! Be sure αthat thrust plate is not trapped between
camshaft gear and stepped shoulder while gear is being pressed on.
Install heated camshaft gear with longer hub of camshaft gear facing camshaft. Align
slot in gear with key in shaft. Press camshaft into gear until hub of gear is tight against
camshaft shoulder.
[4] -

Inspect Camshaft for Bend
Inspect camshaft for bend by using a pair of V-blocks and a dial indicator. Turn camshaft
slowly and read variation on indicator. If variation is greater than wear limit, replace
camshaft.
Camshaft Standard Axial Runout (Wobble) 0.00—0.02 mm
(0.00—0.001 in.)
Wear Limit Axial Runout (Wobble) 0.05 mm
(0.002 in.)

[5] -
Camshaft Lobe Height
LEGEND:
F Camshaft Lobe Height
Measure camshaft lobe height (F) using a micrometer. If lobe height is less than wear limit, or
if there are chips or scratches in lobes or bearing journals, replace camshaft.
3TNM74 Camshaft Lobe Standard Height 34.53—34.66 mm
(1.359—1.364 in.)
(1.349 in.)
3TNV76 and 3TNV80 Camshaft Lobe Standard Height 34.14—34.27 mm
(1.343—1.349 in.)
(1.334 in.)
[6] -

Measure Camshaft Journals
LEGEND:
G End Journals
H Intermediate Journals
Measure camshaft end journals (G) and intermediate journals (H) outside diameters. If journal
diameters are less than wear limit, replace camshaft.
Camshaft Bearing Journal

Gear Side and Flywheel-End Journals Standard OD 39.94—35.96 mm
(1.572—1.573 in.)
(1.571 in.)
Intermediate Journals Standard OD 39.91—39.94 mm
(1.571—1.572 in.)
(1.569 in.)

[7] -
Camshaft Bore Measurement (3TNM74 Shown)
LEGEND:
I Camshaft Bore
Measure front camshaft bore (I) diameter at gear housing end.
Camshaft Bushing Standard ID 40.0—40.03 mm
(1.575—1.578 in.)
(1.579 in.)
(0.002—0.005 in.)
a. If inside diameter exceeds wear limit, replace engine block on 3TNM74.

b. If inside diameter exceeds wear limit, replace bushing on 3TNV76 and 3TNV80.
[8] -

→NOTE:
Plug at Flywheel-End (3TNM74 Shown)
Camshaft Bore—Flywheel-End (3TNV76 and 3TNV80 Shown)

LEGEND:
J Plug
K Intermediate Camshaft Bores
L Flywheel-End Camshaft Bore
Engine back plate must be removed to measure camshaft intermediate and
flywheel end bearing diameters.
Measure intermediate and flywheel end camshaft bore diameters using the following
procedures:
a. Remove engine back plate. (See Remove and Install Engine Back Plate in this group.)
b. Remove plug (J) using a long wooden dowel. Insert a long wooden dowel through gear
housing side and drive plug out.
c. Measure intermediate (K) and flywheel-end camshaft bore (L) diameters. If bore
diameter exceeds wear limit, replace cylinder block. If bore clearance (bore ID minus
camshaft journal OD) exceeds specification, replace camshaft, cylinder block or both.
Camshaft Bearing Bores

Flywheel-End Bore Standard ID 40.0—40.03 mm
(1.575—1.576 in.)
(1.579 in.)
(0.002—0.003 in.)
Intermediate Bores Standard ID 40.0—40.03 mm
(1.575—1.576 in.)
(1.579 in.)
Oil Clearance (0.07—0.12 mm)
(0.003—0.005 in.)
d. Apply John Deere Form-In Place Gasket, or an equivalent, on outer edge of plug. Install
plug until edge of plug is slightly below edge of engine block.
Number Name Use
⚬ PM38609 (us)
⚬ PM37469 (canadian) Apply to outer edge of camshaft
⚬ 59630 Loctite ™ plug at flywheel-end.
(loctite)
e. Install engine back plate.

Remove and Install Oil Pan and Strainer: 3TNM74
Oil Pan and Strainer Components
LEGEND:

A Oil Strainer
B O-Ring (replace)
C Cap Screws
D Oil Pan
E Drain Plug
F Washer (replace)
G Cap Screws
[1] -
→NOTE:
Approximate oil pan capacity is 2.9 L (3.1 qt.).
Drain oil.
[2] - Remove cap screws (G) from oil pan (D) and remove pan.
[3] - Remove cap screws (C) from strainer (A) and remove strainer and O-ring (B).
[4] - Clean and inspect all parts. Make sure that all gasket material has been removed from
mating surfaces.
Number Name Use

• TY16285 (us)
• CXTY16285 (canadian) Cure Primer Clean oil pan and spacer mating surfaces.
[5] - Install new O-ring (B) on strainer tube and install strainer (A).
[6] - Apply a thin bead of John Deere Form-in-Place Gasket to ladder frame.
Number Name Use

• TY15130 (us)
• NA (canadian) Form-in-Place Gasket Apply to oil pan and spacer mating surfaces.
• NA Loctite ™ (loctite)
[7] - Install pan (D), and cap screws (G). Tighten to specifications.
Oil Pan-to-Engine Cap Screws Torque 10 N·m
(88 lb.-in.)

[8] - Fill engine with correct engine oil. (See Section 10, Group 15.)

Remove and Install Oil Pan and Strainer: 3TNV76 and

3TNV80


Oil Pan and Strainer Components
LEGEND:
A Oil Strainer
B O-Ring (replace)
C Cap Screw
D Oil Pan Spacer
E Drain Plug
F Washer (replace)
G Oil Pan
H Cap Screw
I Cap Screw
[1] -
→NOTE:
Approximate oil pan capacity is 2.6 L (2.75 qt.).
Drain oil.
[2] - Remove cap screws from oil pan (G) and remove pan.
[3] - Remove cap screws (C) from strainer (A) and remove strainer and O-ring.
mating surfaces.
Number Name Use

• TY16285 (us)
[5] - Install new O-ring on strainer tube and install strainer.
[6] - Apply a thin bead of John Deere Form-in-Place Gasket to engine block and install oil pan
spacer.
Number Name Use

• PM38609 (us)
Apply to oil pan and spacer mating
surfaces.

[7] - Apply a thin bead of John Deere Form-in-Place Gasket to spacer.
[8] - Install pan, and cap screws. Tighten to specifications.
Oil Pan-to-Engine Cap Screws Torque 22.5—28.4 N·m
(200—250 lb.-in.)
[9] - Fill engine with correct engine oil. (See Section 10, Group 15.)
Check Connecting Rod Side Play

Check Side Play
LEGEND:
A Feeler Gauge
Insert a feeler gauge (A), according to specifications, between connecting rod cap and
crankshaft. If side play exceeds specification, replace connecting rod.
Connecting Rod Side Play 0.2—0.4 mm
(0.008—0.016 in.)

Check Crankshaft End Play
Dial Indicator on End of Crankshaft
LEGEND:
A Dial Indicator
B Crankshaft
→NOTE:
Crankshaft end play can be measured at either end of crankshaft.

Procedure shown is performed from the rear end. The flywheel is removed
to show detail.
[1] - Fasten dial indicator (A) to engine and position indicator tip on end of crankshaft (B).

[2] - Zero the dial indicator.
[3] -
IMPORTANT:
Do not use excessive force when moving crankshaft to avoid damaging

bearings
Using a bar, gently pry the crankshaft as far forward as possible.
[4] - Check reading on dial indicator. If end play exceeds specification, replace thrust
bearings.
Crankshaft End Play 0.11—0.25 mm
(0.004—0.010 in.)

Check Connecting Rod Bearing Clearance
[1] - Remove connecting rod cap.
[2] - Wipe oil from bearing insert and crankshaft journal.
[3] - Put a piece of Plastigage ™ (A), or an equivalent, along the full length of the bearing
insert approximately 6 mm (0.25 in.) off center.
Plastigage Placement
LEGEND:
H Plastigage®
[4] - Turn crankshaft approximately 30° from bottom dead center.
[5] -
IMPORTANT:
Connecting rod caps must be installed on the same connecting rod and in
the same direction to prevent crankshaft and connecting rod damage.

Install connecting rod end cap and original cap screws. Tighten cap screws to specification.
Connecting Rod Cap Screws Torque 22.6—27.5 N·m
(16.6—20.2 lb.-ft.)
[6] - Remove cap screws and connecting rod cap.

[7] - Use the graduation marks on the envelope to compare the width of the flattened
Plastigage® at its widest point.
Connecting Rod Bearing Clearance

Connecting Rod Bearing Clearance 0.02—0.06 mm
(0.001—0.002 in.)
(0.005 in.)
Plastigage Measurement
[8] - Determine bearing clearance. The number within the graduation marks indicates the
bearing clearance in inches or millimeters depending on which side of the envelope is used.
[9] - Remove Plastigage®.

Check Crankshaft Main Bearing Clearance
[1] -
→NOTE:
The engine must be removed from the machine to perform this test.
Remove the flywheel from the crankshaft. (See Remove and Install Flywheel in this Group.)
Ladder Frame Cap Screws
LEGEND:
A Cap Screws
B Ladder Frame
[2] - Remove bolts from the flywheel housing. Remove the flywheel housing from the engine.

[3] - Before removing the main bearing, measure the crankshaft end play.
[4] - Install a dial indicator on the engine block. Move the crankshaft in and out to measure
end play. Record the measurement.
[5] - Remove the 16 cap screws (A) and ladder frame (B). Do not remove the bearing inserts
at this time.
[6] - Wipe oil from bearing insert and crankshaft journal.
[7] - Put a piece of Plastigage ™ (C), or an equivalent, on each of the four crankshaft main
bearing journals as shown.
Plastigage®
LEGEND:
C Plastigage® Placement

[8] - Reinstall the ladder frame. Tighten cap screws to specification in the sequence shown.
Ladder Frame Cap Screws Torque 45 N·m
(33 lb.-ft.)
Ladder Frame Cap Screw Torque Sequence
[9] - Remove the ladder frame.
[10] -
→NOTE:
The flattened Plastigage® may be found on either the bearing insert or

crankshaft journal.
Use the graduation marks on the envelope (B) to compare the width of the flattened
Plastigage® (C) at its widest point.

Bearing Clearance
Crankshaft Main Bearing Clearance 0.03—0.06 mm
(0.001—0.002 in.)
(0.005 in.)
Plastigage Measurement
LEGEND:
C Plastigage® Placement
D Envelope MARKS
[11] - Determine bearing clearance on each main bearing. The number within the graduation
marks indicates the bearing clearance in inches or millimeters depending on which side of
the envelope is used.
[12] - Remove Plastigage®.

Remove Piston and Connecting Rod
[1] - Remove oil pan and oil pickup tube.
[2] - Remove cylinder head.
[3] - Check cylinder bore for ridges. These ridges can damage piston and rings if ridge is not
removed. If necessary, remove ridge from top of cylinder bore using a ridge reamer.
[4] - Measure connecting rod side play. (See Check Connecting Rod Side Play in this Group.)
[5] - Measure connecting rod bearing clearance.
[6] - Remove two cap screws, connecting rod cap, and bearing inserts.
[7] - Note connecting rod alignment mark in relation to the cylinders. Starting at flywheel
end with cylinder number one, then two, etc.
[8] - Push piston and connecting rod out of cylinder bore using a wooden dowel.
[9] - Disassemble and inspect all parts for wear or damage.

Install Piston and Connecting Rod


Piston and Piston Rod Cap
Piston Alignment Marks
LEGEND:
A Bearing Inserts
B Connecting Rod Bolt
C Connecting Rod Cap
D Connecting Rod
E Piston Size Mark
Apply clean engine oil on all parts during installation.

Do not reuse connecting rod bolts, replace with new bolts.
[1] -
IMPORTANT:
Pistons must be installed in cylinders from which they were removed and in
the same direction. Be careful not to damage crankshaft rod journal while
installing piston.
If new piston rings are being installed, deglaze cylinder bore.

[2] - Install a bearing insert (A) onto connecting rod (D).
[3] - Install piston and connecting rod (D) into the cylinder from which it was removed. Install
with the embossed mark on connecting rod (D) facing toward the flywheel; with piston size
mark (E) on top of piston toward the camshaft side of engine.
[4] -
IMPORTANT:
Do not touch bearing insert surfaces. Oil and acid from your finger will
corrode the bearing surface.
Install second bearing insert on connecting rod cap (C).
[5] -
IMPORTANT:
Connecting rod caps must be installed on the same connecting rods they
were removed from.
Match the connecting rods to caps using alignment marks, install caps.
[6] - Dip entire new connecting rod bolt (B) in clean engine oil.
[7] - Install bolts and tighten to specification.
Connecting Rod Cap Bolts Torque 22.6—27.5 N·m
(200—243 lb.-in.)
[8] - If a new piston and connecting rod are installed, stamp a number corresponding to the
cylinder number on the connecting rod cap and connecting rod.
[9] - Install cylinder head. (See Remove and Install Cylinder Head in this Group.
[10] - Install oil pan and strainer tube. (See Remove and Install Oil Pan and Strainer: 3TNM74
or Remove and Install Oil Pan and Strainer: 3TNV76 and 3TNV80 in this Group.)

Disassemble and Inspect Piston and Connecting Rod
[2] - Measure crankshaft connecting rod journal diameter.
[3] - Install connecting rod cap and bearing inserts on connecting rod. Install old connecting
rod cap screws and tighten to 22.6—27.5 N·m (200—243 lb.-in.).
[4] - Measure connecting rod bearing diameter.
Connecting Rod Big End Bearing

3TNM74 Connecting Rod Bearing ID 37.98—38.01 mm
(1.495—1.496 in.)
3TNV76 and 3TNV80 Connecting Rod Bearing ID 41.98—42.00 mm
(1.653—1.654 in.)
Bearing Thickness 1.50—1.51 mm
(0.059 in.)
Oil Clearance 0.02—-.05 mm
(0.002—0.002 in.)
(0.004 in.)
If bearing diameter exceeds wear limit, replace bearing inserts.

If bearing clearance (bearing ID minus crankshaft journal OD) exceeds specification,
grind crankshaft connecting rod journals and install undersized bearing inserts, or
replace bearing inserts and crankshaft.
[5] - With rings installed on piston, measure piston ring groove clearance. Measure several
places around each piston.

Piston Ring Groove Clearance
Piston Ring Groove Side Clearance

3TNM74 Top Piston Ring Clearance 0.06—0.10 mm
(0.002—0.004 in.)
3TNM74 Second Piston Ring Clearance 0.09—0.12 mm
(0.004—0.005 in.)
3TNM74 Oil Control Ring Clearance 0.02—0.06 mm
(0.001—0.002 in.)
3TNV76 and 3TNV80 Top Piston Ring Clearance 0.15—0.30 mm
(0.006—0.012 in.)
3TNV76 and 3TNV80 Second Piston Ring Clearance 0.18—0.33 mm
(0.007—0.013 in.)
3TNV76 and 3TNV80 Oil Control Ring Clearance 0.02—0.06 mm
(0.001—0.002 in.)

If clearance exceeds maximum limit, replace rings or piston.
[6] - Measure piston ring end gap (A). Push ring into cylinder bore, using a piston, until ring is
approximately 30 mm (1.2 in.) from bottom of cylinder bore (B).


Piston ring End Gap Measurement
LEGEND:
A Piston Ring End Gap
B 30 mm (1.2 in.)
3TNM74 Piston Ring End Gap

(0.004—0.012 in.)
(0.010—0.016 in.)
(0.008—0.018 in.)
3TNV76 and 3TNV80 Piston Ring End Gap

(0.006—0.012 in.)
(0.004—0.007 in.)
(0.008—0.018 in.)
If end gap exceeds wear limit, replace rings.
[7] - Measure piston pin diameter. Measure diameter at six places.

Piston Pin Diameter Measurement
Piston Pin Outside Diameter

Standard OD 22.00 mm
(0.866 in.)
(0.865 in.)

If pin diameter is less than wear limit, replace pin.
[8] - Measure piston pin bore diameter in piston.
Piston Pin Bore Measurement
Piston Pin Bore Inside Diameter

(0.866—0.867 in.)

(0.868 in.)
(0.000—0.001 in.)
(0.003 in.)
If piston pin bore exceeds wear limit, replace piston.

If bore clearance (bore ID minus pin OD) exceeds specification, replace piston, piston
pin or both.
[9] - Measure piston pin bushing diameter in connecting rod.

Piston Pin Bushing Diameter Measurement
Piston Pin Bushing Inside Diameter

(0.867—0.868 in.)
(0.869 in.)
If bushing diameter exceeds wear limit, replace bushing.

If bushing clearance (bushing ID minus pin OD) exceeds specification, replace bushing,
piston pin or both.
Piston pin bushing is press fit. Replace bushing using a driver set. When installing
bushing, make sure to align oil hole in bushing with hole in connecting rod.
[10] -
→NOTE:
If engine has had a previous major overhaul, oversize pistons and rings
may have been installed. Oversize pistons are available in 0.25 mm (0.010
in.).
Measure piston diameter perpendicular to piston pin bore at distance (A).
Piston Diameter Measurement Location

Piston Diameter Measurement Location
LEGEND:
A Distance From Skirt Bottom
3TNM74 Piston Outside Diameter

(0.866—0.984 in.)
(2.912—2.913 in.)
(2.910 in.)

(0.866—0.984 in.)
(2.991—2.992 in.)
(2.989 in.)

(0.866—0.984 in.)
(3.148—3.149 in.)
(3.146 in.)
If piston diameter is less than wear limit, install a new piston.
[11] - Measure cylinder bore diameter. (See Inspect Cylinder Bore in this Group.)

Assemble Piston and Connecting Rod


Piston and Connecting Rod Components
LEGEND:
A Piston Size MARK
B Top Compression Ring
C Second Compression Ring
D Oil Ring
E Piston
F Piston Pin
G Retaining Snap Ring (2 used)
H Connecting Rod
[1] -
IMPORTANT:
Pistons must be installed on the same connecting rod they were removed
from.
→NOTE:
Apply clean engine oil to all parts during assembly.
Assemble piston to connecting rod with piston size mark (A) on opposite side of connecting
rod “punched” alignment mark.
[2] - Install piston pin (F) and retaining snap rings (G).

[3] - Install oil ring expander in bottom ring groove of piston.
Oil Ring and Expander
[4] - Install oil ring over expander with ring gap opposite (180°) of expander ends.
[5] - Install top two piston rings with punch mark or letter facing up.

Piston Ring Install
a. Install second compression ring. Turn ring until gap is 120° away from oil ring gap.
b. Install first compression ring in top groove. Turn ring until gap is 120° away from
second ring gap and from oil ring gap.

Inspect Cylinder Bore


Cylinder Bore Measurement
Inspection
Measure cylinder bore diameter at three positions; top, middle, and bottom. At these three
positions, measure in both directions; along crankshaft center line and direction of crankshaft
rotation.
Cylinder Bore
(2.913 in.)
(2.921 in.)
(2.923—2.924 in.)
(2.931 in.)
(0.001—0.002 in.)
(2.993 in.)
3TNV76 Standard Wear Limit ID 76.20
(2.999 in.)
(3.002—3.003 in.)
(3.010 in.)
(0.001—0.002 in.)
(3.15 in.)
(3.157 in.)
(3.159—3.161 in.)
(3.167 in.)
(0.001—0.002 in.)
All Models Cylinder Roundness and Taper

Cylinder Roundness 0.00—0.01 mm
(0.000—0.001 in.)
Wear Limit Roundness 0.03 mm
(0.001 in.)
Cylinder Taper 0.00—0.01 mm
(0.000—0.001 in.)
Wear Limit Taper 0.03 mm
(0.001 in.)
→NOTE:
If engine has had a previous major overhaul, oversize pistons and rings
may have been installed.
If cylinder bore exceeds wear limit, replace cylinder block or have cylinder rebored.
(See Rebore Cylinder in this Group.)
If cylinder is rebored, oversize pistons and rings must be installed. Pistons and rings are
available in 0.25 mm (0.010 in.) oversize.
If clearance (cylinder bore ID minus piston OD) exceeds specification, replace cylinder
block, piston or both; or rebore cylinder and install oversize piston and rings.
Deglazing
IMPORTANT:
If cylinder bores are deglazed with crankshaft installed in engine, put clean
shop towels over crankshaft to protect journal and bearing surfaces from
any abrasives.

Cylinder Deglazing
Deglaze cylinder bores using a flex-hone with 180 grit stones.

Use flex-hone as instructed by manufacturer to obtain a 30—40° crosshatch pattern as
shown.
IMPORTANT:
Do not use gasoline, kerosene, or commercial solvents to clean
cylinder bores. Solvents do not remove all abrasives from cylinder
walls.
Remove excess abrasive residue from cylinder walls using a clean dry rag. Clean
cylinder walls using clean white rags and warm soapy water. Continue to clean cylinder
until white rags show no discoloration.
Rebore Cylinder
Cylinder Hone
[1] -
→NOTE:
The cylinder block can be rebored to use oversize pistons and rings. Pistons
and rings are available in 0.25 mm (0.010 in.) oversize.
Align center of bore to drill press center.
[2] - Adjust hone so lower end is even with lower end of cylinder bore.

[3] - Adjust rigid hone stones until they contact narrowest point of cylinder.
[4] - Coat cylinder with honing oil. Hone should turn by hand. Adjust if too tight.
[5] - Run drill press at about 250 rpm Move hone up and down in order to obtain a 30—40°
crosshatch pattern.
[6] -
→NOTE:
Measure bore when cylinder is cool. Finish should not be smooth and have
a 30—40° crosshatch pattern.
Remove rigid hone when cylinder is within 0.03 mm (0.001 in.) of desired size.
[7] - Use a flex hone with 180 grit stones for honing to final size.

[8] - Check bore for size, taper, and out-of-round. (See Inspect Cylinder Bore in this Group.)
Cylinder Bore
(2.913 in.)
(2.921 in.)
(2.923—2.924 in.)
(2.931 in.)
(0.001—0.002 in.)
(2.993 in.)
(2.999 in.)
(3.002—3.003 in.)
(3.010 in.)
(0.001—0.002 in.)
(3.15 in.)
(3.157 in.)
(3.159—3.161 in.)
(3.167 in.)
(0.001—0.002 in.)
[9] -
IMPORTANT:
Do not use gasoline, kerosene, or commercial solvents to clean cylinder

bores. Solvents do not remove all abrasives from cylinder walls.

Clean cylinder thoroughly using warm soapy water until clean white rags show no
discoloration.
[10] - Dry cylinder and apply engine oil.

Remove Crankshaft and Main Bearings: 3TNM74
[1] - Check crankshaft end play. (See Check Crankshaft End Play in this Group.)
[2] - Remove flywheel. (See Remove and Install Flywheel in this Group.)
[3] - Remove timing gear cover. (See Remove and Install Timing Gear Cover in this Group.)
[4] - Remove ladder frame and check crankshaft bearing clearance. (See Check Crankshaft
Main Bearing Clearance in this Group.)
[5] -
IMPORTANT:
Connecting rod end caps must be installed on the same connecting rods
they were removed from. Note alignment marks on caps and rods.
Remove connecting rod cap screws and end caps.
[6] - Push pistons and connecting rods away from crankshaft.
[7] - Remove crankshaft.
[8] - Remove thrust bearings and main bearing inserts.

Install Crankshaft and Main Bearings: 3TNM74


Crankshaft and Main Bearing Components
LEGEND:
A Upper Main Bearing Inserts
B Lower Main Bearing Inserts
C Plain Thrust Bearings
D Tabbed Thrust Bearings
mating surfaces.
Number Name Use

• TY16285 (us)
[2] - Install upper main bearing inserts (A) drilled with oil passage in cylinder block bearing
bores, aligning tangs with slots in bores.
[3] - Lubricate bearing shells and install crankshaft into engine block.

[4] - Lubricate and install plain thrust bearing halves (C) into engine block with oil grooves
facing crankshaft. Turn bearing into engine block until ends of bearing are flush with engine
block.
Crankshaft Thrust Bearing Halves
LEGEND:
C Thrust Bearing Halves

[5] - Lubricate and install tabbed bearing halves with oil grooves (E) toward crankshaft.
Crankshaft Thrust Bearing Oil Grooves
LEGEND:
E Oil Grooves

[6] - Turn the inside bearing assembly clockwise until tab (F) is against engine block in the 3
o’clock position as shown.
Crankshaft Thrust Bearing Tab Position
LEGEND:
G Thrust Bearing Tab
[7] - Turn the outside bearing counterclockwise until the tab (F) is against the engine block in
the nine o’clock position as shown.

[8] - Install the lower main bearing inserts into the ladder frame aligning tab (G) on bearing
with cutout in ladder frame.
Crankshaft Lower Main Bearing
LEGEND:
G Lower Main Bearing Tab

[9] - Place a bead of John Deere form-in-place gasket (H) on each side of ladder frame
assembly as shown. Make sure that sealant is applied to edge of oil seal bore. Wipe excess
sealant out of oil seal bore after tightening ladder frame bolts.
Number Name Use

• TY15130 (us)
• NA (canadian) Form-in-Place Gasket Apply to oil pan and spacer mating surfaces.
Ladder Frame Gasket Compound
LEGEND:
H Form-in-Place Gasket

[10] - Install new O-ring (I) on engine block.
Engine Block O-ring
[11] - Lubricate bearings and crankshaft journals and carefully lower the ladder frame on to
the engine block. Lubricate cap screws and tighten to specification in the sequence shown.
Ladder Frame-to-Engine Cap Screws Torque 45 N·m
(33 lb.-ft.)

Ladder Frame Torque Sequence

Remove Crankshaft and Main Bearings: 3TNV76 and

3TNV80
[1] - Check crankshaft end play. (See Check Crankshaft End Play in this Group.)
[3] - Remove rear oil seal case. (See Remove and Install Crankshaft Rear Oil Seal Case:
3TNV76 and 3TNV80 in this Group.)
[5] - Check crankshaft bearing clearance.
[6] -
IMPORTANT:
Connecting rod end caps must be installed on the same connecting rods
they were removed from. Note alignment marks on caps and rods.
Remove connecting rod cap screws and end caps.
[7] - Push pistons and connecting rods away from crankshaft.
[8] -
IMPORTANT:
Main bearing caps must be installed on the same main bearing and in the
same direction to prevent crankshaft and main bearing damage.
Remove main bearing cap screws, caps, and thrust bearings.
[9] - Remove crankshaft.
[10] - Remove thrust bearings and main bearing inserts.


Install Crankshaft and Main Bearings: 3TNV76 and

3TNV80
Crankshaft and Main Bearings
LEGEND:
A Inserts
B Thrust Bearings
C Bearing Caps
D Inserts

E Thrust Bearings
mating surfaces.
[2] - Install upper main bearing inserts (A) drilled with oil passage in cylinder block bearing
bores, aligning tangs with slots in bores.
[3] - Install block thrust bearings (B) with oil grooves facing away from engine block.
[4] -
→NOTE:
Main bearing caps (C) have raised arrows that are stamped with numbers.
Both correspond to their location on the engine block. The number 1 main
bearing bore is at flywheel end. Install bearing caps beginning with number
1, then 2 and 3. The main bearing cap at gear train end does not have a
number. Also install bearing caps with the arrow toward the flywheel end.
Install crankshaft.
[5] - Install smooth bearing inserts (D) in main bearing caps, aligning tangs with slots in
caps.
[6] - Install cap thrust bearings (E), with oil grooves facing away from cap, in the number 1
main bearing cap.
[7] - Install main bearing caps in their original locations with arrows pointing toward flywheel
side of engine.
[8] -
IMPORTANT:
DO NOT use high speed power tools or air wrenches to tighten main
bearing cap screws.
Dip entire main bearing cap screws in clean engine oil. Install cap screws and tighten. DO

NOT tighten to specifications.
[9] - Using a soft-faced hammer, tap the front end of the crankshaft then the rear end of the
crankshaft to align the thrust bearings.
[10] - Tighten main bearing cap screws to specifications. When tightening, start at center
main bearing cap and work out, alternating to the ends. Turn crankshaft by hand. If it does
not turn easily, disassemble the parts and find the cause.
Main Bearing Cap Screws Torque 76—81 N·m
(56—60 lb.-ft.)

Remove and Install Flywheel
Flywheel
LEGEND:
A Flywheel Mounting Cap Screws
[1] - Remove engine. (See Remove Engine in this Group.)
[2] -
IMPORTANT:
FLYWHEEL IS HEAVY! Do not remove flywheel mounting bolts unless

flywheel is secure. Use a hoist and lift rings, or get help to lift flywheel
from crankshaft.
Remove five flywheel mounting cap screws (A).

[3] - Pull flywheel from crankshaft alignment pin.
[4] - Inspect flywheel ring gear teeth for wear or chips.
[5] -
IMPORTANT:
Always install new flywheel mounting cap screws.
Install flywheel:
a. Align flywheel on alignment pin and install five new flywheel mounting cap screws.
b. Tighten cap screws to specification.
Flywheel Cap Screws Torque 80.4—86.4 N·m
(59—64 lb.-ft.)
Remove and Install Engine Back Plate

Engine Back Plate
[2] - Remove mounting cap screws, and pry engine back plate from cylinder block.
[3] - Tighten mounting cap screws to specification when installing back plate.
(36 lb.-ft.)

Inspect Oil Pump: 3TNM74
Idler Shaft and Gear

Oil Pump Cap Screws
LEGEND:
A Timing MARK
B Timing MARK
C Timing MARK
D Idle Gear Shaft
E Cap Screws
[2] - Align all timing marks (A), (B), and (C).
[3] - Remove three cap screws securing idler gear shaft (D) and remove idler gear and shaft.
[4] - Remove three cap screws (E) securing oil pump and remove oil pump.

[5] - Measure the clearance between the OD of the outer rotor and the pump bore with a
feeler gauge (F).
Oil Pump Rotor Clearance
LEGEND:
F Feeler Gauge
[6] - Compare measurement to specification. If measurement is larger than specification

replace oil pump.
Outer Rotor to Bore Clearance 0.05—0.10 mm
(0.002—0.004 in.)
(0.010 in.)

[7] - Place a straight edge (G) across pump body and use a feeler gauge (I) to determine side
clearance between outer rotor (H) and straight edge.
Outer Rotor Side Clearance 0.05—0.10 mm
(0.002—0.004 in.)
(0.006 in.)
Oil Pump Rotor Side Clearance
LEGEND:
G Straight Edge
H Outer Rotor
I Feeler Gauge
[8] - Compare reading to specification. If reading is more than specification replace oil pump.

[9] - Measure between high spots of inner and outer rotors (J) with a feeler gage. Compare
measurement to specification. If measurement is larger than specification replace oil pump.
Outer-to-Inner Rotor Clearance 0.05—0.10 mm
(0.002—0.004 in.)
(0.006 in.)
Oil Pump Inner Rotor Clearance
LEGEND:
J Inner and Outer Rotor Clearance

[10] - Remove relief valve cap (K). Inspect spring (L), valve plunger (M), and valve seat
inside pump body. If any parts show wear or damage replace oil pump.
Oil Pump Relief Valve
LEGEND:
K Relief Valve Cap
L Spring
M Valve Plunger
[11] - Install pump in reverse order of removal. Tighten Mounting cap screws to specification.
Mounting Cap Screws Torque 11 N·m
(97 lb.-in.)

Inspect Oil Pump: 3TNV76 and 3TNV80
Oil Pump Timing Gear Cover
LEGEND:
A Screws
B Cover
[2] - Remove the eight screws (A) from oil pump cover (B) and remove cover.

[3] - Remove inner rotor (C) and outer rotor (D) and check for wear or damage. Check inside
of cover for wear or deep scratches. Replace any worn or damaged parts.
Oil Pump Inner and Outer Rotors
LEGEND:
C Inner Rotor
D Outer Rotor

[4] - Inspect inside of oil pump cover for grooves or deep scratches. Replace cover if worn or
damaged.
Oil Pump Cover

[5] - Remove relief valve cap (E), spring (F), and valve (G). Inspect all parts for wear or
damage. Replace any worn or damaged parts.
Oil Pump Relief Valve
LEGEND:
E Cap
F Spring
G Valve
[6] - Measure clearance between outer rotor (H) and timing cover (I) with a feeler gauge (J).
If clearance exceeds wear limit, replace timing cover and both rotors.
Outer Rotor to Cover Clearance 0.12—0.21 mm
(0.005—0.008 in.)
(0.012 in.)

Oil Pump Outer Rotor Clearance
LEGEND:
H Outer Rotor
I Timing Cover
J Feeler Gauge

[7] - Measure between high spots of inner and outer rotors with a feeler gage. If clearance
exceeds specification replace rotors.
Rotor-to-Rotor Clearance 0.02—0.07 mm
(0.001—0.003 in.)
(0.005 in.)
Oil Pump Rotors Inspect

Section 20 - ENGINE REPAIR Group 10: Cooling System
[8] - Place a straight edge (K) across timing gear cover bosses. Measure gap between edge
of timing gear cover and the rotors with a feeler gauge (L). If clearance exceeds wear limit
replace timing gear cover and rotors.
Rotor Side Clearance 0.02—0.07 mm
(0.001—0.003 in.)
(0.005 in.)
Oil Pump Rotor Side Clearance
LEGEND:
K Straight Edge
L Feeler Gauge
[9] - Assemble in the reverse order of disassembly.
[10] - Apply medium strength thread locking compound to oil pump cover screws and relief
valve cap when installing.

Group 10 - Cooling System
Specifications
Remove and Install Fan and Alternator Belt
Remove and Install Radiator
Remove and Install Water Pump
Remove and Install Thermostat
Remove and Install Coolant Temperature Sensor
Install Block Heater: 3TNM74
Install Block Heater: 3TNV76 and 3TNV80

Specifications
Belt
Belt Applied Force 98 N
(22 lb.-force)
Belt Deflection 10—15 mm
(0.400—0.600 in.)
(30 lb.-ft.)
Water Pump Cap Screw Torque 25 N·m
(221 lb.-in.)
Housing-to-Engine Cap Screws Torque 18 N·m
(160 lb.-in.)
Coolant Temperature Sensor Torque 24 ±3 N·m
(212 ±27 lb.-in.)
Block Heater Adaptor Bolts Torque 27 N·m
(240 lb.-in.)
Block Heater Element Torque 27 N·m
(240 lb.-in.)

Remove and Install Fan and Alternator Belt
[1] - Park machine safely.
Replace Fan and Radiator Belt
LEGEND:
A Adjusting Cap Screw
B Alternator Cap Screws
[3] - Loosen adjusting cap screw (A).
[4] - Loosen alternator cap screws (B).
[5] - Push alternator inward to loosen belt.

[6] - Remove belt from engine sheave, and alternator and fan pulleys. Pull belt over fan.
[7] - Install new belt loosely around sheave and pulleys.
[8] - Check belt tension. Adjust as needed.
Belt
(22 lb.-force)
(0.400—0.600 in.)
(30 lb.-ft.)

Remove and Install Radiator
CAUTION:
Radiator Cap—Safety
Avoid Injury! When the engine is hot, the explosive release of fluids from
the pressurized cooling system can cause serious burns. Do not remove
the radiator cap unless the engine is cool. Slowly loosen cap to the first
step.
[2] - Remove hood and side panels.
[3] - Disconnect negative battery cable.
[4] -
→NOTE:
Cooling system capacity is approximately 3.7 L (3.9 qt.).

Place a suitable container under radiator drain hose. Open radiator drain valve (A) and drain
the coolant.
Radiator Drain Valve
LEGEND:
A Radiator Drain Valve
[5] - Disconnect upper and lower radiator hoses.

[6] - Disconnect radiator overflow tube (B).
Radiator Overflow Tube and Top Bracket Bolts
LEGEND:
B Overflow Tube
C Carriage Bolts
[7] - Remove nuts and carriage bolts (C) securing oil cooler to radiator brackets.

[8] - Remove radiator drain hose (D).
Radiator Support Rod
LEGEND:
D Drain Hose
E Nut
[9] - Remove nut (E) from oil cooler support rod.

[10] - Remove four bolts (F) securing radiator to shroud/support assembly.
Radiator Shroud Removal
LEGEND:
F Bolts
[11] - Pull the oil cooler up and forward and secure with a rubber strap or plastic tie.
[12] - Carefully lift radiator lower right corner up untill drain nipple on bottom of radiator
clears opening and then pull forward. Do not use excessive force. When lower radiator outlet
clears shroud/support assembly, lift radiator out of machine.

[13] -
CAUTION:
Reduce compressed air to less than 210 kPa (2.1 bar) (30 psi) when using
for cleaning purposes. Clear area of bystanders, guard against flying chips,
and wear personal protection equipment including eye protection.
Check radiator for debris lodged in fins. Clean radiator using compressed air or pressure
washer.
[14] - Inspect radiator for bent fins, cracks, and damaged seams. Repair as necessary.
[15] - Install radiator in the reverse order of removal.
a. Fill radiator with proper coolant to top of filler neck.

b. Fill coolant reservoir between the full cold and full hot marks.
c. Start engine and allow it to reach proper operating temperature. Check radiator, hoses,
and connections for leaks. Allow engine to cool, then check and adjust coolant level in
recovery tank as needed.

Remove and Install Water Pump
CAUTION:
step.
[2] - Allow engine to cool before servicing cooling system.
[3] - Open radiator cap.

[4] -
→NOTE:
LEGEND:
A Drain Valve
the coolant.

[5] - Place a suitable container under engine block drain plug (B) and remove plug.
Engine Block Drain Plug
LEGEND:
B Drain Plug

[6] - Loosen clamp (C). Remove cap screws (D) and remove air cleaner and intake hose
assembly.
Air Cleaner Removal
LEGEND:
C Clamp
D Cap Screws

[7] - Loosen hose clamps (E) and (F) and disconnect radiator hoses from water pump.
Disconnect temperature sensor wire (G).
Water Pump Hoses
LEGEND:
E Hose Clamp
F Hose Clamp
G Sensor Wire

[8] - Remove nut and washer (H) and cap screws and nuts (I). Remove radiator support rod.
Radiator Support Rod
LEGEND:
H Nut and Washer
I Nuts

[9] - Remove clamp (J) and cap screw (K) Remove exhaust pipe.
Exhaust and Alternator
LEGEND:
J Clamp
K Cap Screw
L Alternator Bracket
[10] - Remove alternator bracket (L). Pivot alternator clear of the water pump.

[11] - Remove two cap screws (M) from left side of water pump.
Water Pump - Left Side
LEGEND:
M Cap Screws

[12] - Remove the remaining water pump mounting cap screw (N) from the right side.
Water Pump - Right Side
LEGEND:
N Cap Screw

[13] - Use care not to damage fan blades. Pull water pump assembly out toward right side of
machine.
Water Pump Removal
[14] - Clean cylinder block mating surfaces of all old gasket material.
[15] - Inspect the water pump for coolant leakage.
a. If coolant is leaking at the bottom of the shaft housing the shaft seal is defective.
Replace the water pump.
b. If coolant is leaking between the cylinder head and the pump housing the gasket
between the head and the pump is defective. Replace the gasket.
[16] - Inspect the water pump for a worn bearing shaft. Check for side to side movement of
the shaft. If shaft can be moved replace the water pump.

[17] - Install the water pump.
a. Make sure all sealing areas are clean and free of any old gasket material.
b. Install new gasket and O-ring on water pump.
c. Install water pump and tighten cap screws to specification.
Water Pump Cap Screw Torque 25 N·m
(221 lb.-in.)
d. Install alternator bracket and install belt. Adjust belt tension.

e. Install support rod, air cleaner assembly, and exhaust pipe.
f. Install block drain plug.
g. Close drain valves. Fill radiator to top of filler neck with proper coolant.
h. Fill coolant reservoir between the full cold and full hot marks.
i. Start engine. Allow it to reach proper operating temperature. Check radiator, hoses and
connections for leaks. Allow engine to cool, then check and adjust coolant level in

Remove and Install Thermostat
CAUTION:
step.
[2] - Allow engine to cool before servicing the cooling system.
[3] - Open radiator cap.

[4] -
→NOTE:
LEGEND:
A Drain Valve
the coolant.
[5] - Disconnect crankcase ventilation hose from tee in intake air hose. Disconnect air intake
hose from turbocharger and remove air cleaner assembly.
[6] - Loosen clamp. Remove upper radiator hose from thermostat housing.

[7] - Remove two cap screws (B) holding thermostat housing to water pump. Remove
housing (C) and gasket.
Thermostat
LEGEND:
B Cap Screws
[8] - Remove thermostat.

Thermostat and Gasket
→NOTE:
Thermostat is offset and only fits in one direction. Make sure that it is
installed as shown and fits down in recess.
[9] - Test or replace thermostat. Install thermostat with spring facing down.
[10] - Install new gasket.

[11] - Install housing. Tighten cap screws to specifications.
Housing-to-Engine Cap Screws Torque 18 N·m
(160 lb.-in.)
[12] - Close drain valve. Fill radiator with proper coolant to top of filler neck.
[13] - Fill coolant reservoir between the full cold and full hot marks.
[14] - Start engine. Allow it to reach proper operating temperature. Check radiator, hoses,
and connections for leaks. Allow engine to cool, then check and adjust coolant level in

Remove and Install Coolant Temperature Sensor
CAUTION:
step.


Coolant Temperature Sensor
LEGEND:
A Drain Valve
B Wire Lead
C Sensor
[3] -
→NOTE:
the coolant to lower thancoolant sensor level.

[4] - Disconnect wiring lead (B).
[5] - Remove sensor (C) and copper washer.
[6] - Install sensor in reverse order of removal.
a. Replace copper washer.

b. Tighten sensor to specification.
Coolant Temperature Sensor Torque 24 ±3 N·m
(212 ±27 lb.-in.)
c. Refill radiator and recovery tank with approved coolant.

Install Block Heater: 3TNM74
CAUTION:
step.

[3] -
→NOTE:
LEGEND:
A Drain Valve
the coolant.

[4] - Place clean container under engine and remove engine coolant drain plug (B).
Engine Block Drain Plug
LEGEND:
B Drain Plug
[5] - When all coolant has drained, remove freeze plug (C) from back of cylinder head.

Freeze Plug
LEGEND:
C Freeze Plug
[6] - Clean cylinder head and threaded holes where block heater adapter is installed.
[7] - Install gasket (D) between adapter (E) and cylinder head.

Block Heater Adaptor
LEGEND:
D Gasket
E Adaptor
F Cap Screws
(240 lb.-in.)
[8] - Install cap screws (F) with wiring harness P-clamp under lower cap screw. Tighten cap
screws to specification.

[9] - Apply thread sealant to threads of heating element and thread heating element (G) into
adapter. Tighten element to specification.
Block Heating Element
LEGEND:
G Heating Element
(240 lb.-in.)

[10] - Connect 115 VAC cord (H) to block heater. Route cord to accessible location and
secure with plastic tie.
Block Heater Power Cord
LEGEND:
H 115 VAC Cord
[11] - Install block drain plug and close drain valve on radiator. Fill cooling system with good
clean antifreeze.

Install Block Heater: 3TNV76 and 3TNV80
CAUTION:
step.

[3] -
→NOTE:
LEGEND:
A Drain Valve
the coolant.

[4] - Place clean container under engine and remove engine coolant drain plug (B).
Engine Drain Plug and Freeze Plug
LEGEND:
B Drain Plug
C Freeze Plug
[5] - When all coolant has drained, remove freeze plug (C) from engine block.
[6] - Clean cylinder head and threaded holes where block heater adapter is installed.
[7] - Install gasket (D) between adapter (E) and cylinder block. Install cap screws (F) and
tighten to specification.

Block Heater Adaptor
LEGEND:
D Gasket
E Adaptor
F Cap Screws
(240 lb.-in.)

[8] - Apply thread sealant to threads of heating element and thread heating element (G) into
adapter. Tighten element to specification.
Block Heating Element
LEGEND:
G Heating Element
(240 lb.-in.)

FUEL AND AIR REPAIR (g) by Belgreen
[9] - Connect 115 VAC cord (H) to block heater. Route cord to accessible location and secure
with plastic tie.
Block Heater Power Cord
LEGEND:
H 115 VAC Cord
[10] - Install block drain plug and close drain valve on radiator. Fill cooling system with good
clean antifreeze.

Section 30 - FUEL AND AIR REPAIR
Table of contents
Group 05 - Fuel System ............................................................................................................ 2
Specifications ......................................................................................................................... 3
Other Material ........................................................................................................................ 3
Service Equipment and Tools ................................................................................................. 3
Bleed Fuel System ................................................................................................................. 4
Remove and Install Fuel Transfer Pump ................................................................................. 6
Remove and Install Fuel Injection Nozzle ............................................................................... 8
Clean and Inspect Fuel Injection Nozzle ............................................................................... 13
Remove Fuel Injection Pump: 3TNM74 ................................................................................. 17
Install Fuel Injection Pump: 3TNM74 .................................................................................... 23
Remove Fuel Injection Pump: 3TNV76 and 3TNV80 ............................................................. 27
Install Fuel Injection Pump: 3TNV76 and 3TNV80 ................................................................ 33
Remove and Install Fuel Shutoff Solenoid ............................................................................ 35
Remove and Install Fuel Filter Assembly .............................................................................. 37
Disassemble and Assemble Fuel Filter and Water Separator ............................................... 39
Remove and Install Inline Fuel Filter .................................................................................... 43
Group 10 - Air Intake and Exhaust Systems ....................................................................... 45
Summary of References ....................................................................................................... 45
Remove and Install Muffler .................................................................................................. 46
Group 15 - Speed Control Linkage ........................................................................................ 49
Replace Throttle Cable ......................................................................................................... 50

Section 30 - FUEL AND AIR REPAIR Group 05: Fuel System
Group 05 - Fuel System
Specifications
Other Material
Bleed Fuel System
Remove and Install Fuel Transfer Pump
Remove and Install Fuel Injection Nozzle
Clean and Inspect Fuel Injection Nozzle
Remove Fuel Injection Pump: 3TNM74
Install Fuel Injection Pump: 3TNM74
Remove Fuel Injection Pump: 3TNV76 and 3TNV80
Install Fuel Injection Pump: 3TNV76 and 3TNV80
Remove and Install Fuel Shutoff Solenoid
Remove and Install Fuel Filter Assembly
Disassemble and Assemble Fuel Filter and Water Separator
Remove and Install Inline Fuel Filter

Specifications
Injector Nozzles Torque 50 N·m
(37 lb.-ft.)
Nuts Torque 29.4—34.3 N·m
(22—25 lb.-ft.)
Injection Pump Mounting Bolts Torque 22.5—28.4 N·m
(17—21 lb.-ft.)
Injection Pump Drive Gear Nut Torque 58—68 N·m
(43—51 lb.-ft.)
Gear Cover Bolts Torque 22.5—28.4 N·m
(17—21 lb.-ft.)
Injection Line Nuts Torque 29—34 N·m
(22—25 lb.-ft.)
Injection Pump Mounting Nuts Torque 22.5—28.4 N·m
(17—21 lb.-ft.)
Gear Cover Cap Screws Torque 11 N·m
(97 lb.-in.)
Other Material
Number Name Use
• PM38609 (us)
• PM37469 (canadian) Form-in-Place Gasket Apply to injection pump mating surfaces.
→NOTE:


Bleed Fuel System

The machine incorporates a self bleeding fuel system which forces air out of the fuel filter,
injection pump, and injection nozzles, and vents it back to the fuel tank. Fuel system bleeding
is usually not necessary after a repair. If the system is completely drained and will not self-
prime without overheating the starter, proceed as follows.
Fuel Injection High Pressure Line Nuts
LEGEND:
A High Pressure Line Nuts
[2] - Be sure fuel tank is not empty, and fuel valve on fuel filter is in OPEN (O) position.
[3] - Turn key switch to on position and listen for clicking noise indicating fuel transfer pump
is running. Allow to run to for at least 30 seconds.

[4] - Try to start engine. If engine will not start after two or three attempts, continue steps
six to nine.
[5] - Remove air filter and intake if necessary to access high-pressure line nuts.
[6] - Using a 17 mm open-end wrench, loosen high-pressure line nuts (A) on top of fuel
injector nozzles 1/4 turn.
[7] - Crank engine until fuel is seen seeping from all three injector fittings.
[8] - Tighten fittings.
[9] - Install air filter and intake if removed.

Remove and Install Fuel Transfer Pump
CAUTION:
Handle fuel with care: it is highly flammable. Do not refuel the machine

Fuel Transfer Pump
LEGEND:
A Hose Clamps
B Connector
C Cap Screws

[3] - Close fuel shutoff valve at the fuel filter and water separator.
[4] -
→NOTE:
Clamp or pinch inlet hose end to prevent draining from tank due to gravity.
Remove inlet and outlet hose clamps (A) at fuel transfer pump and disconnect hoses.
[5] - Disconnect wiring harness at connector (B).
[6] - Remove two fuel pump mounting cap screws (C).
[7] - Install pump in the reverse order of removal.
Turn on fuel shutoff valve and turn key switch to ON position for 20 or 30 seconds to
bleed air from system.

Remove and Install Fuel Injection Nozzle
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious
injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or

other lines. Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from
high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the
skin must be surgically removed within a few hours or gangrene may
result. Doctors unfamiliar with this type of injury should reference a
knowledgeable medical source. Such information is available in English
from Deere & Company Medical Department in Moline, Illinois, U.S.A., by
calling 1-800-822-8262 or +1 309-748-5636.
CAUTION:


Fuel Lines to Injectors
LEGEND:
A Fuel Line Connectors
B Delivery Valves
C Fuel Line Nuts
D Leakoff Hoses
[2] - Allow engine to cool
[3] - Clean the injection pump lines and area around the pump using a parts cleaning solvent
or steam cleaner.
[4] - Slowly loosen fuel line connectors (A) at injection pump to release pressure in the fuel
system. When loosening connectors, use a backup wrench to prevent delivery valves (B) from
turning.
[5] - Loosen fuel line nuts (C) at fuel injector nozzle.

[6] - Remove injector line nuts at the injection pump and the injector nozzles and remove
injector lines.
[7] - Disconnect the leakoff hose (D).
[8] - Remove nuts (E) and leakoff line assembly (F).

Fuel Leakoff Line Components
LEGEND:
E Nuts
F Leakoff Line Assembly
G Washers

H Injector Nozzle Assembly
[9] - Remove bronze washers (G).
[10] - Remove injector nozzle assembly (H).
[11] - Test injector nozzles. (See Test Fuel Injection Nozzle in Section 230, Group 15.)
[12] - Install injector nozzles in the reverse order of removal.
a. Replace bronze washers.

b. Replace heat protectors.
c. Tighten injector nozzles to specification.
Injector Nozzles Torque 50 N·m
(37 lb.-ft.)
d. Tighten nuts (E) to specification.

Nuts Torque 29.4—34.3 N·m
(22—25 lb.-ft.)

Clean and Inspect Fuel Injection Nozzle
Injector Nozzle Components


Injector Nozzle Cross Section
LEGEND:
A Nozzle Cast Nut
B Nozzle Body
C Nozzle Valve
D Valve Stop Spacer
E Nozzle Holder
F Pressure Adjustment Shims
G Nozzle Spring
H Nozzle Spring Seat
IMPORTANT:
If injection nozzles are disassembled to be cleaned, the same number and

thickness of shims must be installed.
→NOTE:
If servicing more than one nozzle, keep parts for each nozzle separate from
one another.
[1] - Remove anticorrosive grease from new or reconditioned nozzles by washing them
thoroughly in diesel fuel.
[2] -
IMPORTANT:
Never use a steel brush to clean nozzles. Use of a steel brush distorts the
spray hole.
→NOTE:
To clean nozzles properly, JDF13 Nozzle Cleaning Kit is recommended. The

Cleaning Kit is available through the John Deere SERVICEGARD? Catalog.
Remove carbon from used nozzles, and clean by washing in diesel fuel. If parts are coated
with hardened carbon or lacquer, it may be necessary to use a brass wire brush (supplied in
Nozzle Cleaning Kit).
[3] - After removing carbon or lacquer from the exterior of nozzle, inspect sealing surfaces
between separator plate and nozzle body for nicks or scratches.

[4] - Inspect condition of separator plate and nozzle body. Contact area of separator plate
(both parts) must not be scored or pitted. Use an inspection magnifier (No. 16487 or
equivalent) to aid in making the inspection.
[5] - Inspect the piston (large) part of nozzle valve to see that it is not scratched or scored
and that lower (tip) end of valve is not broken. If any of these conditions are present, replace
the nozzle assembly.
[6] - Further inspect the nozzle assembly by performing a slide test. Use the following
procedure:
Injector Nozzle Slide Test
a. Dip the nozzle valve in clean diesel fuel. Insert valve in nozzle body.
b. Hold nozzle vertical, and pull valve out about 1/3 of its engaged length.
c. Release valve. Valve should slide down to its seat by its own weight.
d. Replace nozzle assembly if the valve does not slide freely to its seat.
[7] - Test injector nozzles after assembly is complete. (See Test Fuel Injection Nozzle in
Section 230, Group 15.)

Remove Fuel Injection Pump: 3TNM74
CAUTION:

IMPORTANT:
DO NOT attempt to remove or install the fuel injection pump unless you are
an EPA Authorized Diesel Service (ADS) Center technician with
authorization to service fuel injection engines.
[3] - Turn the fuel shutoff valve on the fuel filter and water separator to the CLOSED position.
[4] -
IMPORTANT:
Never steam clean or pour cold water on injection pump while the pump is
running, or engine is warm. Doing so can damage the pump.
When removing injection lines, DO NOT turn pump delivery valve fittings.
Turning fittings can damage pump internally. Always use a backup wrench
when removing lines.
Clean the injection pump lines and area around the pump using a parts cleaning solvent or
steam cleaner.
[5] - Remove the air cleaner assembly.

turning.
turning.
LEGEND:
A Fuel Line Connections
B Delivery Valves
C Fuel Line Nuts
D Fuel Leakoff Hose
E Fuel Input Hose
F Fuel Shutoff Solenoid
G Throttle Cable

[9] - Remove fuel line connector nuts at the injection pump and the injector nozzles and
remove fuel lines.
[10] - Cover ends of injectors, delivery valves, and fuel lines with plastic caps to prevent dirt
from entering system.
[11] - Disconnect fuel leakoff hoses (D).
[12] - Disconnect the fuel input hose (E).
[13] - Disconnect the fuel shutoff solenoid (F) and throttle cable (G).
[14] - Remove injection pump gear cover on front of timing gear cover.
[15] -
IMPORTANT:
DO NOT loosen four cap screws attaching gear to hub. This gear and hub
assembly times the injection pump camshaft in relation to the crankshaft
for precise timing of EPA engines. This procedure is done at the pump
manufacturing plant and CAN NOT be duplicated in the field.
Rotate crankshaft and align timing marks (H) on injection pump gear and idler gear.

Injector Pump Gear
LEGEND:
H Timing MARKS
I Nut
[16] - Remove nut (I) and lock washer.
[17] -
→NOTE:
Do NOT turn engine crankshaft after injection pump gear has been
removed. The idler gear has an odd number of teeth and timing marks only
align periodically. If crankshaft is turned, timing cover must be removed to
align MARKS. (See Remove and Install Timing Gear Cover in Section 20,
Group 5.)
Use a gear puller as shown and remove injection pump gear.

Injector Pump Gear Removal

Injector Pump to Engine Block
LEGEND:
J Socket Head Cap Screws
K Metal Gasket
[18] - Remove the four socket head cap screws (J) and metal gasket (K) securing the
injection pump to the engine block and remove the injection pump.

Install Fuel Injection Pump: 3TNM74
Injection Pump Gasket
LEGEND:
A Gasket
B Oil Hole
[1] - Install a new gasket (A) between injection pump and engine. Make sure oil hole (B) is
correctly lined up with oil hole on injection pump and engine block.

[2] - Install the injection pump, the metal gasket (C), and the four socket head cap screws
(D). Tighten the cap screws to specification.
Injection Pump Mounting Bolts Torque 22.5—28.4 N·m
(17—21 lb.-ft.)
Injection Pump to Engine Block
LEGEND:
C Metal Gasket
D Socket Head Cap Screws

[3] - Carefully install the injection pump drive gear and hub assembly while aligning the shaft
key with keyway in hub and the timing gear marks. Install lock washer and nut and tighten to
specification.
(43—51 lb.-ft.)
[4] - Check fuel injection timing and adjust if necessary. (See Adjust Fuel Injection Timing:
3TNM74 in Section 230, Group 15.)
[5] - Install injection pump gear cover.
Gear Cover Bolts Torque 22.5—28.4 N·m
(17—21 lb.-ft.)
[6] - Install the inlet and outlet hoses to the fuel transfer pump.
[7] - Install the fuel input hose and injector nozzle leakoff hose to the injection pump.
[8] - Install fuel lines at the injection pump and the injector nozzles and tighten the
connector nuts to specification. When tightening connectors, use a backup wrench to prevent
delivery valves from turning.
(22—25 lb.-ft.)
[9] -
IMPORTANT:
Avoid Damage! After installing an injection pump it is important to add

engine oil to the injection pump to provide lubrication for initial start up.
Add 150—200 cc (5—7 oz.) of clean engine oil to the injection pump through
the fill plug (E) in the top of the governor housing.
Remove fill plug (E) in the top of the governor housing and add 150—200 cc (5—7 oz.) of
clean engine oil to the injection pump.

Governor Housing Oil Fill Plug
LEGEND:
E Fill Plug
[10] - Install the air cleaner assembly.

Remove Fuel Injection Pump: 3TNV76 and 3TNV80
CAUTION:

IMPORTANT:
DO NOT attempt to remove or install the fuel injection pump unless you are
an EPA Authorized Diesel Service (ADS) Center technician with
authorization to service fuel injection engines.
[4] -
IMPORTANT:
Never steam clean or pour cold water on injection pump while the pump is
running, or engine is warm. Doing so can damage the pump.
When removing injection lines, DO NOT turn pump delivery valve fittings.
Turning fittings can damage pump internally. Always use a backup wrench
when removing lines.
Clean the injection pump lines and area around the pump using a parts cleaning solvent or
steam cleaner.
[5] - Remove the air cleaner assembly.

turning.

LEGEND:
A Fuel Line Connections
B Delivery Valves
C Fuel Line Nuts
D Leakoff Hose
E Fuel Input Hose
F Fuel Shutoff Solenoid
G Throttle Cable
[8] - Remove fuel line connector nuts at the injection pump and the injector nozzles and
remove fuel lines.
[9] - Cover ends of injectors, delivery valves, and fuel lines with plastic caps to prevent dirt
from entering system.

[10] - Disconnect fuel leakoff hose (D).
[11] - Disconnect the fuel input hose (E).
[12] - Disconnect the fuel shutoff solenoid (F) and throttle cable (G).
[13] - Remove injection pump gear cover on front of timing gear cover.
[14] -
IMPORTANT:
DO NOT loosen four cap screws attaching gear to hub. This gear and hub
assembly times the injection pump camshaft in relation to the crankshaft
for precise timing of EPA engines. This procedure is done at the pump
manufacturing plant and CAN NOT be duplicated in the field.
Rotate crankshaft and align “C” timing marks (H) on injection pump gear and idler gear.

Injection Pump Gear
LEGEND:
H Timing MARKS
I Nut
[15] - Remove nut (I) and lock washer.
[16] -
→NOTE:
Do NOT turn engine crankshaft after injection pump gear has been
removed. The idler gear has an odd number of teeth and timing marks only
align periodically. If crankshaft is turned, timing cover must be removed to
align MARKS. (See Remove and Install Timing Gear Cover in Section 20,
Group 5.)
Use a gear puller and remove injection pump gear.
[17] - Note the location of the injection pump timing mark (J) as related to the timing gear
housing timing marks (K). The replacement pump will need to be installed in the exact same
location.

Injection Pump Timing Mark
LEGEND:
J Injection Pump Timing Mark
K Housing Timing Marks
L Mounting Nut
[18] - Remove the three mounting nuts (L) securing the injector pump to the crank case and
remove the injection pump.

Install Fuel Injection Pump: 3TNV76 and 3TNV80
[1] - Apply John Deere form-in-place gasket to injection pump mating surfaces.
Number Name Use

• PM38609 (us)
• PM37469 (canadian) Form-in-Place Gasket Apply to injection pump mating surfaces.
[2] - Install and tighten injector pump, aligning the timing mark to the same mark on the
timing gear housing as noted during removal.
[3] - Install and tighten the three mounting nuts to specification.
(17—21 lb.-ft.)
[4] - Align the timing gear marks and install injector pump gear and lock nut and tighten to
specification.
(43—51 lb.-ft.)
[5] - Apply John Deere form-in-place gasket to injection pump gear cover and install cover.
Tighten cover cap screws to specification.
Gear Cover Cap Screws Torque 11 N·m
(97 lb.-in.)
[6] - Install the inlet and outlet hoses to the fuel transfer pump.
[7] - Install the injector lubrication line and secure with banjo bolts.
[8] - Install the fuel input hose and injector nozzle leakoff hose to the injection pump.

[9] - Install fuel lines at the injection pump and the injector nozzles and tighten the
connector nuts to specification. When tightening connectors, use a backup wrench to prevent
delivery valves from turning.
(22—25 lb.-ft.)
[10] - Install and connect the fuel shutoff solenoid.
[11] - Install the air cleaner assembly.

Remove and Install Fuel Shutoff Solenoid
CAUTION:

Fuel Shutoff Solenoid
LEGEND:
A Connector
B Cap Screws
C Solenoid

[4] - Clean around the fuel shutoff solenoid using a parts cleaning solvent or steam cleaner.
[5] - Disconnect the electrical connector (A) to the fuel shutoff solenoid.
[6] - Remove the two solenoid mounting cap screws (B) and remove solenoid (C) from
governor housing.
[7] - Test fuel solenoid.
[8] - Installation is in reverse of removal. Check condition of O-ring on solenoid before

installing.

Remove and Install Fuel Filter Assembly
CAUTION:

Fuel Filter Assembly
LEGEND:
A Shutoff Valve

B Hose Clamps
C Bolts
[1] - Park machine safely
[3] - Turn fuel shutoff valve (A) to off position.
[4] - Remove lower cowling for access to rear fittings.
[5] -
→NOTE:
When disconnecting hoses (B) from fuel filter assembly, be sure to cap
hoses or catch draining fuel in a clean container.
Mark hoses (B) for proper reassembly and disconnect hoses after removing mounting cap
screw and nut (C).
[6] - Remove fuel filter assembly.
[7] - Install new filter assembly in reverse order of removal.
[8] - Install lower cowling.

Disassemble and Assemble Fuel Filter and Water

Separator


Fuel Filter Components
LEGEND:
A Mounting Base
B O-ring
C Filter Element
D Spring
E O-ring
F Filter Cover
G Retaining Ring
[1] -
→NOTE:
This procedure does not require removing the filter and water separator
base or fuel hoses.
Remove the retaining ring (G) from the mounting base (A) while holding on to the filter cover
(F).
[2] - Remove the filter cover from the mounting base.
[3] - Remove and replace the O-rings (B and E) and filter element (C).
[4] - Be sure the spring (D) is in the filter cover and place the filter element in the filter
cover.
[5] - Before installing the filter cover and element in the mounting base, verify that the O-
ring is in the groove inside the mounting base.
[6] - Install the filter cover and the element in the mounting base.
[7] -
IMPORTANT:
Tighten retaining ring only enough to keep the filter assembly from
leaking. Overtightening will damage the filter cover or retaining ring.
Place the retaining ring over filter cover and screw on the mounting base to retain filter cover

to mounting base.

Remove and Install Inline Fuel Filter
CAUTION:

Inline Fuel Filter Located Under Footrest
LEGEND:
A Fuel Filter
B Hose Clamps
[2] - Check fuel hoses for damage or deterioration. Replace hoses as necessary.

Section 30 - FUEL AND AIR REPAIR Group 10: Air Intake and Exhaust Systems
[3] -
→NOTE:
Leave enough room to slide hose clamps off of fuel filter ends.
Pinch fuel supply hoses on each side of fuel filter (A) to prevent fuel flow.
[4] - Slide hose clamps (B) away from fuel filter. Remove filter.
[5] - Install new filter with fuel flow indicator arrow pointing toward engine.
[6] - Secure fuel filter with hose clamps.

Group 10 - Air Intake and Exhaust Systems
Remove and Install Muffler

Remove and Install Muffler
Hot—Safety

Exhaust System
LEGEND:
A Mounting Nuts (4 used)
B Cap Screw
[1] -
CAUTION:
Avoid Injury! Muffler may be hot. Allow muffler to cool before removing.
Park machine safely. (See procedure in Section 10, Group 05.)
[2] - Remove hood.

Section 30 - FUEL AND AIR REPAIR Group 15: Speed Control Linkage
[3] - Remove four mounting nuts (A).
[4] - Remove exhaust pipe support cap screw (B).
[5] - Remove muffler.
Installation is done in the reverse order of removal.
Clean off old gasket material and install new gasket and muffler.
Install muffler on exhaust manifold studs and tighten four mounting nuts (A) to
specification.
Muffler-to-Manifold Nuts Torque 28 N·m
(248 lb.-in.)
Install and tighten exhaust pipe support cap screw (B).

Group 15 - Speed Control Linkage
Replace Throttle Cable

Replace Throttle Cable
Throttle Cable End
LEGEND:
A Nuts
B Cable End
[2] - Loosen lock nuts (A) and lift cable out of bracket.
[3] - Disconnect cable end (B).

[4] - Pinch tabs (C) together with a pliers and pull cable housing out of holder.
Throttle Cable End
LEGEND:
C Tabs
D Cable End
[5] - Disconnect cable end (D) from throttle lever.

ELECTRICAL REPAIR (g) by Belgreen
[6] - Pull cable through grommet (E).
Throttle Cable Grommet
LEGEND:
E Grommet
[7] - Install cable in reverse order of removal.
a. Route cable through grommet (E).

b. Attach cable end (D) to throttle lever.
c. Feed cable through slot in holder and snap cable housing tabs (C) into holder.
d. Attach throttle cable end (B) to injector pump lever.
e. Insert cable housing and nuts (A) into bracket.
[8] - Adjust throttle cable. (See Adjust Throttle Cable in Section 220, Group 15.)

Section 40 - ELECTRICAL REPAIR
Table of contents
Group 05 - Battery, Starter and Alternator ........................................................................... 2
Specifications ......................................................................................................................... 3
Essential or Recommended Tools .......................................................................................... 3
Remove and Install Battery .................................................................................................... 4
Remove and Install Starting Motor ......................................................................................... 7
Remove and Install Alternator .............................................................................................. 10
Disassemble and Inspect Alternator ..................................................................................... 12
Assemble Alternator ............................................................................................................. 24
Group 10 - Electrical System Components .......................................................................... 35
Electrical System Components ............................................................................................. 36
Electrical Components - EEC ................................................................................................ 38
Group 15 - Wiring Harness ..................................................................................................... 40
1023E Wiring Harness .......................................................................................................... 40
1025R Wiring Harness .......................................................................................................... 44
1026R EEC Wiring Harness .................................................................................................. 48

Section 40 - ELECTRICAL REPAIR Group 05: Battery, Starter and Alternator
Group 05 - Battery, Starter and Alternator
Specifications
Remove and Install Battery
Remove and Install Starting Motor
Remove and Install Alternator
Disassemble and Inspect Alternator
Assemble Alternator

Specifications
(65 lb.-ft.)
(30 lb.-ft.)
Belt
(22 lb.-force)
(0.400—0.600 in.)
Slip Ring Minimum Diameter 14.0 mm
(0.55 in.)
Brush Length specifications

Minimum Length 4.5 mm
(0.17 in.)
Maximum Length 10.5 mm
(0.41 in.)
Alternator Sheave Nut Torque 54 N·m
(40 lb.-ft.)
→NOTE:

Remove and Install Battery
CAUTION:
Battery Safety

Battery
Keep all sparks and flames away from batteries, as gas given off by
electrolyte is explosive. To avoid sparks, connect ground cable last and
disconnect it first.
To avoid shocks and burns, disconnect battery ground cable before

servicing any part of electrical system.
[1] - Raise hood.
[2] - Disconnect headlights from wiring harness.
[3] -
→NOTE:
One headlight needs to be removed so there is clearance to remove the

battery.
Disconnect negative (—) battery cable first, then positive (+) battery cable.
[4] - Remove battery hold-down strap, freeing the battery.
[5] -
Lift the battery from the battery tray.
[6] - Remove battery. Clean and service as necessary.
[7] - Install battery.
[8] - Install battery hold down strap.
[9] - Connect positive (+) battery cable first, then negative (—) battery cable.

[10] - Apply petroleum jelly on battery terminals.
[11] - Connect wiring harness to headlights.

Remove and Install Starting Motor
Starting Motor

Starting Motor Electric Connections
LEGEND:
A Tie Wrap
B Nut
C Exciter Wire
D Nuts
E Cap Screws
[1] - Disconnect negative (—) battey cable and then positive (+) battery cable.
[2] - Remove tie wrap (A) from cable boot, slide boot back.
[3] - Remove nut (B) and disconnect the positive battery cable and wires from the starter
solenoid.
[4] - Disconnect the solenoid exciter wire (C).

[5] -
→NOTE:
On some models the engine mounting bracket must be removed to remove

lower cap screw (E).
Remove the two nuts (D) and cap screws (E) securing the starting motor to the engine
backplate. Remove the starting motor.
[6] -
IMPORTANT:
Do not overtighten cap screws.
Install the starting motor in the reverse order of removal. Tighten starting motor cap screws
to specification.
(65 lb.-ft.)

Remove and Install Alternator
Alternator
LEGEND:
A Adjusting Cap Screw
B Alternator Cap Screws
[3] - Disconnect electrical harness connectors from alternator.
[4] - Loosen adjusting cap screw (A).
[5] - Loosen alternator cap screws (B).

[6] - Push alternator inward to loosen belt.
[7] - Remove belt from alternator.
[8] - Remove cap screws (A and B), remove alternator.
[9] - Install alternator in reverse order of removal.
a. Tighten cap screws to specification.

(30 lb.-ft.)
b. Check belt tension. Adjust as needed. (See Remove and Install Fan and Alternator Belt
in Section 20, Group 10.)
Belt
(22 lb.-force)
(0.400—0.600 in.)

Disassemble and Inspect Alternator
Alternator Sheave Nut
LEGEND:
A Nut
B Sheave
[1] -
→NOTE:
Clamp sheave in soft jaw vise and use an impact wrench to remove pulley
nut. Do not overtighten vise.
Remove sheave nut (A).
[2] - Use a puller to remove sheave (B).

[3] - Remove three screws (C) securing alternator rear cover to alternator.
Alternator Rear Cover
LEGEND:
C Screws
[4] - Loosen positive post flange nut (D) enough to pull insulator (E) clear of rear cover.
Remove rear cover.

Alternator Insulator and Cover
LEGEND:
D Flange Nut
E Insulator

[5] - Remove four voltage regulator screws (F) and black brush screw (G).
Alternator Voltage Regulator
LEGEND:
F Screws
G Brush Screw
[6] - Remove regulator and brush assemblies.

[7] - Remove four screws (H) retaining rectifier to alternator body.
Alternator Rectifier Remove
LEGEND:
H Screws

[8] - Straighten the four wire leads (I) to allow removal of the rear half of alternator case.
Alternator Wire Leads
LEGEND:
I Wire Leads
[9] - Separate the two alternator case halves.
[10] - Remove retainer plate (J).

Alternator Case retainer Plate and Bearing
LEGEND:
J Plate
K Bearing
[11] - Press bearing (K) from case.

[12] - Inspect bearing (L) for smooth rotation. Replace if necessary.
Alternator Rotor
LEGEND:
L Bearing
M Slip Rings
N Rotor Core
[13] - Inspect slip rings (M) for dirt or rough spots. If necessary, use No. 00 sandpaper or
400-grit silicon carbide paper to polish rings.
[14] - Measure outer diameter of slip rings (M). Replace rotor if less than specification.
Slip Ring Minimum Diameter 14.0 mm
(0.55 in.)
[15] - Check continuity between slip rings (M) using ohmmeter or multimeter. Replace rotor
assembly if there is no continuity.
[16] -
→NOTE:
Use an ohmmeter that is sensitive to 0—1 ohm.

Check continuity between slip rings and rotor core (N). Replace rotor assembly if there is
continuity.
[17] - Inspect stator for defective insulation, discoloration, or burned odor.
[18] -
→NOTE:
Set ohmmeter to the K Ohm range.
Check for continuity between each stator lead and body. Replace stator if there is continuity.

[19] - Check continuity between lead (O) and each diode lead (P). Reverse ohmmeter leads
and recheck. There should be continuity in one direction, but not the other. Replace diodes or
rectifier plate if bad.
Alternator Diode Assembly
LEGEND:
O Lead
P Diode Leads
[20] - Measure length of brush (Q) protruding from holder. Dimension should be within
specification. Replace brushes if length is less than minimum.
Brush Length specifications

Minimum Length 4.5 mm
(0.17 in.)
Maximum Length 10.5 mm
(0.41 in.)

Alternator Brush
LEGEND:
Q Brush Length

[21] - Check continuity between brush (R) and terminal (S). There should be continuity only
at these points. Repeat procedure for other brush and terminal. There should be continuity
only at these points.
Alternator Brush
LEGEND:
R Brush
S Terminal

Assemble Alternator
Alternator Case and Bearing
LEGEND:
A Bearing
B Retainer Plate
C Screws
[1] - Press new bearing (A) into case and install retainer plate (B).
[2] - Install four screws (C).

[3] - Route stator leads (D) through holes in rear case (E).
Alternator Stator Leads
LEGEND:
D Leads
E Rear Case
[4] -
→NOTE:
Check that rotor fan does not contact case and that rotor assembly turns
smoothly in bearing.
Press rotor shaft (F) into rear case.

Alternator Rotor and Rear Case
LEGEND:
F Rotor Shaft
[5] - Route stator leads (G) through holes in rectifier (H) and install rectifier.

Alternator Stator Leads and Rectifier
LEGEND:
G Leads
H Rectifier
[6] - Using a needle nose pliers, form a loop (I) in each stator wire lead and install screws
through the loops.

Alternator Stator Leads Connection
LEGEND:
I Loop
[7] -
IMPORTANT:
Check that short, black, screw is installed in regulator tab. Longer screw
will contact frame and damage the charging system.
Install regulator (J).

Alternator Regulator and Brush Holder
LEGEND:
J Regulator
K Brush holder
[8] - Using a small screwdriver to hold brushes, install brush holder (K).

[9] - Install brush holder screws as shown; black screw (L) and gold screws (M).
Alternator Brush Holder Screws
LEGEND:
L Black Screw
M Gold Screws
[10] - Install regulator cover (N) and screws (O).

Alternator Regulator Cover
LEGEND:
N Cover
O Screws
P Insulator
[11] - Install insulator (P) and nut.
[12] - Install sheave.

[13] - Secure sheave in soft jaw vise. Install nut (Q) and tighten to specification.
Alternator Sheave Nut Torque 54 N·m
(40 lb.-ft.)
Alternator Sheave Nut
LEGEND:
Q Sheave Nut

Alternator Components
LEGEND:
A Nut
B Sheave
C Bushing (40 Amp alternator only)
D Front Case
E Stator
F Stud (2 used)
G Bearing
H Cover
I Screw (4 used)
J Rotor
K Bearing
L Cover
M Thrust Washer (40 Amp alternator only)
N Nut (2 used)
O Flange Nut
P Insulator Bushing

Section 40 - ELECTRICAL REPAIR Group 10: Electrical System Components
Q Screw (2 Gold, 1 Black)

R Rear Case
S Cap Screw
T Diode Assembly
U Regulator
V Screw (2 used)
W Brush Assembly
X Screw
Y Cover
Z Cap Screw (3 used)

Group 10 - Electrical System Components
Electrical System Components

Electrical System Components
Electrical System Component Location
LEGEND:
A G01 Battery
B H2 Horn
C E02 Right Hand Headlight
D E01 Left Hand Headlight
E G01 Alternator
F T08 to B02 Coolant Sensor
G T09 to B04 Oil Pressure Switch
H Load Center
I Instrument Control Cluster (ICC)
J S05 PTO/RIO Switch
K S01 Key Switch
L S03 Turn signal Switch
M S11 Horn Switch
N S02 Light Switch

O S38 Seat Switch Connector

P E04 Right Hand Work Light Connector
Q S08 MBR PTO Switch Connector
R E07 Left Hand Work Light Connector
S Y03 Rear PTO Solenoid Connector
T E07 Left Hand Work Light
U E04 Right Hand Lights
V E18 License Plate Light
W E03 Left Hand Lights
X S04 Neutral Switch Connector
Y Y02 and M02 Engine Fuel Connectors
Z S42 Brake Switch Connector
AA T06 Fuselinks Connector
AB X-M01 Start Solenoid Connector
AC X-40 Front Hitch Detection
AD X-S10 Mower Lift Switch
AE X-S60 Reverse Pedal Sense Switch

Electrical Components - EEC
Electrical System Component Location, EEC
LEGEND:
A G01 Battery
B H2 Horn
E G02 Alternator
H Y02, M02 Engine Fuel, and Glow Plug Connectors
I K07 Flasher Connector
J X56 Cab Connector
K Load Center
L Instrument Control Cluster (ICC)
M S05 PTO Switch
N S13 Hazard Switch

Section 40 - ELECTRICAL REPAIR Group 15: Wiring Harness
O S01 Key Switch

P S03 Turn signal Switch
Q S11 Horn Switch
R S02 Light Switch
S X09 Connector to S10 Mower Lift Switch option
T S41 Park Brake Switch
U S38 Seat Switch Connector
V X54 to Right Hand Fender Harness
W S08 MBR PTO Switch Connector
X X12 to Trailer Connector
Y E18 License Plate Light
Z E06—E08 Right Hand Lights
AA E04 Right Hand Work Light
AB X03 Power Port
AC E12—E14 Left Hand Lights
AD X12 Trailer Connector
AE X55 to Left Fender Harness
AF Y03 Rear PTO Solenoid Connector
AG E07 Left Hand Work Light
AH S04 Neutral Switch Connector
AI S42 Brake Switch Connector
AJ T06 Fuselinks Connector
AK X-M01 Start Solenoid Connector
AL X-40 Front Hitch Detection
AM X-S10 Mower Lift Switch
AN X-S60 Reverse Pedal Sense Switch

Group 15 - Wiring Harness
1023E Wiring Harness
1025R Wiring Harness
1026R EEC Wiring Harness
1023E Wiring Harness
Wiring Harness (1 of 3)




1025R Wiring Harness




1026R EEC Wiring Harness
1026R EEC Wiring Harness (1 of 6)





POWER TRAIN REPAIR (g) by Belgreen

Section 50 - POWER TRAIN REPAIR
Table of contents
Group 15 - Transmission .......................................................................................................... 2
Specifications ......................................................................................................................... 3
Other Material ........................................................................................................................ 3
Remove Transmission ............................................................................................................ 4
Install Transmission ............................................................................................................. 19
Remove and Install Hydrostatic Drive .................................................................................. 35
Disassemble and Inspect Hydrostatic Drive ......................................................................... 38
Assemble Hydrostatic Drive ................................................................................................. 47
Remove and Install Range Transmission .............................................................................. 55
Group 20 - Rear PTO Driveshaft ............................................................................................ 65
Specifications ....................................................................................................................... 66
Other Material ...................................................................................................................... 66
Remove PTO Clutch ............................................................................................................. 68
Disassemble and Inspect PTO Clutch ................................................................................... 74
Assemble PTO Clutch ........................................................................................................... 79
Install PTO Clutch ................................................................................................................. 85
Remove and Inspect Rear PTO Driveshaft and Gears .......................................................... 93
Install Rear PTO Driveshaft and Gears ............................................................................... 103
Remove and Inspect Mid PTO Driveshaft and Gears .......................................................... 106
Install Mid PTO Driveshaft and Gears ................................................................................. 119
Group 25 - Differential .......................................................................................................... 137
Specifications ..................................................................................................................... 137
Other Material .................................................................................................................... 137
Remove and Install Differential .......................................................................................... 138
Disassemble and Inspect Differential ................................................................................. 145
Assemble Differential ......................................................................................................... 153
Group 30 - Final Drives ......................................................................................................... 156
Essential or Recommended Tools ...................................................................................... 156
Remove and Install Rear Axle ............................................................................................ 157
Group 35 - Mechanical Front Wheel Drive ......................................................................... 171
Specifications ..................................................................................................................... 171
Remove Front Axle ............................................................................................................. 172
Install Front Axle ................................................................................................................ 175
Disassemble Front Axle ...................................................................................................... 179
Assemble Front Axle .......................................................................................................... 191
Disassemble Front Outer Axle ............................................................................................ 198
Assemble Front Outer Axle ................................................................................................ 212
Disassemble MFWD Differential ......................................................................................... 224
Assemble MFWD Differential .............................................................................................. 228

Section 50 - POWER TRAIN REPAIR Group 15: Transmission
Group 15 - Transmission
Specifications
Other Material
Remove Transmission
Install Transmission
Remove and Install Hydrostatic Drive
Disassemble and Inspect Hydrostatic Drive
Assemble Hydrostatic Drive
Remove and Install Range Transmission

Specifications
Torque Specifications
5/8x1-3/8 Bolt Torque 175 N·m
(129 lb.-ft.)
M12x40 Bolt Torque 70 N·m
(52 lb.-ft.)
(129 lb.-ft.)
Hydrostatic Drive-to-Gear Case Cap Screws Torque 26 N·m
(19 lb.-ft.)
Trunnion Bearing-to-Housing Socket-Head Bolts Torque 18 N·m
(159 lb.-in.)
Valve Block-to-Housing Socket-Head Bolts Torque 26 N·m
(19 lb.-ft.)
Front Cover-to-Transmission Cap Screws Torque 26 N·m
(19 lb.-ft.)
Pinion Nut-to-Shaft Torque 112 N·m
(83 lb.-ft.)
Other Material
Number Name Use
• T43512 (us)
Thread Lock and Sealer
• TY9473 (canadian) Apply to threads as indicated.
(Medium Strength)
• PM37465 (us)
• PM38628 (canadian) Seal transmission front cover -to-
Form-in-Place gasket
• RTV Blue Loctite ™ transmission case.
(loctite)

Remove Transmission
Shift Knob
LEGEND:
A Hex Nut
[1] - Remove any front or mid-mount PTO driven attachments. Remove mid-mount quick-
attach PTO shaft from transmission, if installed.
[3] - Raise and safely support machine frame on jack stands installed in front of rear axle.
[4] - Remove rear wheel assemblies.
[5] - Remove three point hitch draft arms and links.

[6] -
→NOTE:
The transmission holds approximately 12.3 L (3.25 gal.) of oil.
Drain transmission to a suitable container.
[7] - Remove MFWD front driveshaft.
[8] - Remove front PTO driveshaft (if installed).
[9] - Remove center closeout panel. (See Remove and Install Center Closeout Panel in
[10] - Remove seat assembly. (See Remove Seat and Remove Seat Base Section 90, Group
05.)
[11] - Remove range selector shift knob cap and retaining hex nut (A). Remove shift knob.
[12] - Remove left and right closeout panels (1025R only).

[13] - Remove bolts (B) securing fuel tank support bracket.
Seat Support and Tank Support
LEGEND:
B Bolts
C Bolts
[14] - Remove fenders and fuel tank. (See Section 90, Group 20.)
[15] - Remove bolts (C) securing controls quadrant to seat mounting bracket. Remove
quadrant.

[16] - Remove wiring harness retainers (D) from seat mounting bracket.
Seat Mount Bracket and Harness Retainers
LEGEND:
D Harness Retainers
E Bolts
F Harness Retainer
[17] - Remove two bolts (E) securing set mounting bracket and wiring harness retainer (F).
Remove bracket.

[18] - Remove four screws (G) and washers securing steering pedestal cowl. Remove cowl.
Screws
LEGEND:
G Screws

[19] - Release fuel hoses from retaining slot (H).
Left Foot Rest and Fuel Hoses
LEGEND:
H Retaining Slot
I Bolts
[20] - Remove ten bolts (I) securing footrest. Remove foot rest.
[21] - Remove ROPS. (See Remove ROPS in Section 90, Group 10.)

[22] - Remove two hex bolts (J) securing right side wire harness retainers.
Right Side Harness Retainers
LEGEND:
J Hex Bolts
[23] - Note wire harness routing for later reinstallation.

[24] - Separate wire harness connectors (K), and remove hex bolt securing left side wire
harness retainer (L).
Left Side Harness Retainers
LEGEND:
K Harness Connectors
L Harness Retainers

[26] - Remove wiring harness connector (M) and retainers (N) from transmission.
Harness and Shift Rod
LEGEND:
M Harness Connectors
N Harness Retainers
O Locking Pin
[28] - Remove locking pin (O) and washer securing shift rod. Remove shift rod from
transmission shift arm.

[29] - Disconnect brake control rod (P) from transmission arm.
Brake Control rod
LEGEND:
P Brake Control Rod
Q Hex Bolt
[30] - Remove hex bolt (Q), washers, and hex nut securing outer brake arm to inner arm.
Mark bolt locations for reassembly and remove outer arm.

[31] - Remove cotter pin and washer securing differential lock rod (R). Remove control rod
from transmission arm (S).
Differential Lock Rod
LEGEND:
R Differential Lock Rod
S Transmission Arm

[32] - Disconnect hydraulic pipes (T) from transmission fittings.
Hydraulic Pipes
LEGEND:
T Hydraulics Pipes

[33] - Disconnect hydraulic pipes (U) from SCV fittings.
Hydraulic Pipes
LEGEND:
U Hydraulic Pipes
V Hydraulic Pipe
[34] - Remove hydraulic pipe (V) installed between transmission and outer SCV port.

[35] - Remove M8 hex nut (W) and washer securing transmission shift control damper to
mounting stud. Remove damper from stud.
Shift Control Damper
LEGEND:
W Hex Nut
[36] - Support transmission.

[37] - Remove eight hex bolts (X) at left and right sides securing frame to transmission.
Frame-to-Transmission Bolts
LEGEND:
X Hex Bolts
[38] - Remove transmission from frame, guiding transmission past hydraulic pipes and wiring
harness.

Install Transmission
[1] - Guide transmission into place between frame members.
a. Pass hydraulic pipes between motion control arm and centering damper.
b. Lubricate transmission input splines. Align and install driveshaft yoke to input shaft.
[2] - Align transmission to frame attachment holes. Loosely install bolts securing each side of
transmission.
Transmission-to-Frame Bolts
LEGEND:
A 5/8x1-3/8 in. Bolts
B M12x40 hex Bolts
C 5/8x1-5/8 in. Bolts
a. Install two 5/8x1-3/8 in. bolts (A).

b. Install four M12x40 hex bolts (B).
c. Install two 5/8x1-5/8 in. bolts (C) through hitch pivot pin reinforcing plate.

[3] - Install ROPS. (See Install ROPS in Section 90, Group 10.)
[4] - Tighten bolts (A, B, and C) on left and right sides to specification.
(129 lb.-ft.)
M12x40 Bolt Torque 70 N·m
(52 lb.-ft.)
(129 lb.-ft.)
[5] - Connect brake and differential lock control linkage.
Brake Control Rod

Differential Control Rod
LEGEND:
D Brake Control Rod
E Right Side Differential Lock Control Rod
F Left Side Differential Lock Control Rod
a. Install brake control rod (D) to brake arm. Secure brake rod with washer and locking
pin.
b. Attach brake rod to round hole in brake arm for domestic models.
c. Attach brake rod to slotted hole in brake arm for export models.
d. Connect right side differential lock control rod (E) to brake arm.
e. Connect left side differential lock control rod (F) to left side differential lock arm. Install
trunnion to linkage arm and secure with washer and cotter pin.
[6] - Adjust brake and differential lock linkage. (See Adjust Differential Lock in Section 250,
Group 15.)
[7] - Connect transmission control linkage.

Shift Arm Eccentric
LEGEND:
G M8 Lock Nut
a. Install damper to shift arm eccentric and secure with M8 lock nut (G).
b. Install motion control rod to shift arm and secure with washer and locking pin (H).

Motion Control Rod

LEGEND:
H Locking Pin
[8] - Install hydraulic pipes to rockshaft (I), SCV (J), and PTO valve (K) connections.

Hydraulic Lines

Hydraulic Lines
LEGEND:
I Rockshaft
J SCV
K PTO Valve
[9] - Install wire harness to transmission connectors. Route and secure wire harness as
originally installed.
a. Install ROPS lighting connectors (L).
Wiring Harness Connectors

LEGEND:
L Lighting Connectors
M Retainers
b. Bundle wire harness and secure to ROPS upright with tie wrap.
c. Secure wire harness with retainers (M).
d. Install PTO solenoid connector (N), PTO selector connector (O), and ROPS lighting
connectors (P).


LEGEND:
N Solenoid Connector
O PTO Selector Connector
P ROPS Lighting Connectors
Q Retainer
e. Bundle lighting wire harness and secure to ROPS upright with tie wrap.
f. Secure wire harness with retainer (Q).
g. Install neutral switch connector (R). Secure connector halves with tie wrap over release
tab.


LEGEND:
R Switch Connector
S Retainers
h. Secure wire harness with two retainers (S).
[10] - Install foot rest. Ensure that fuel hoses (T) are captured in foot rest retaining slot and
through relief notch in firewall.

Fuel Lines Routing Footrest and Firewall
LEGEND:
T Fuel Hoses
[11] - Install steering pedestal cowl (U). Secure cowl with four screws.

Pedestal Cowl
LEGEND:
U Cowl
[12] - Verify that fuel lines are securely routed and not forcing cowl toward brake pedal.

[13] - Install front seat mounting bracket to transmission. Secure bracket with two M10x30
hex bolts (V). Secure wire harness retainer (W) with right bolt.
LEGEND:
V Hex Bolts
W Retainer
X Retainers
[14] - Secure wire harness with two retainers (X).

[15] - Install shift gate over PTO selector, transmission range selector, and height of cut
adjuster shafts. Secure gate to seat support with two M8x20 hex bolts (Y) and hex nuts.
Shift Gate and Controls
LEGEND:
Y Hex Bolts
Z Hex Nut
aa Return Spring
[16] - Secure fender support with M10 hex nut (Z).
[17] - Install end hook of differential lock lever return spring (aa) to shift gate.
[18] - Install left and right closeout panels.

[19] - Install center closeout panel.
Closeout Panel
LEGEND:
ab Phillips Head Screws
ac Shoulder Bolts
ad Adjuster Shaft
a. Loosely install two M6x30 Phillips head screws (ab).

b. Loosely install two M8x27 shoulder bolts (ac) and flat washers.
c. Adjust panel position so height of cut adjuster shaft (ad) is centered in control opening,
and tighten fasteners.
d. Align height of cut adjuster knob to shaft flat and install knob.

[20] - Install range selector shift knob. Secure knob with retaining hex nut (ae). Install shift
knob cap.
Range Selector Shifter
LEGEND:
ae Hex Nut
[21] - Install right fender.
[22] - Install seat base assembly. (See Install Seat Base in Section 90, Group 05.)
[23] - Lubricate transmission splines. Align and install front PTO driveshaft (if used).
[24] - Lubricate and install MFWD front driveshaft.
[25] - Fill transmission with specified type and amount of fluid.
[26] - Install three point hitch draft arms and links.

[27] - Install rear wheels.
[28] - Lower machine to floor.

Remove and Install Hydrostatic Drive
Hydrostatic Drive Location
LEGEND:
A Cap Screws, M8 x 50 (2 used)
B Cap Screws, M8 x 150 (2 used)
C Cap Screw, M8 x 70
[1] - Clean outside of unit thoroughly before removal and disassembly. Avoid contamination
of system ports.
[2] - Protect all component bearing and seal surfaces during removal and when setting aside
for installation.
[3] - Remove cap screws (A—C).

[4] - Remove hydrostatic drive and O-rings (A—C).
Remove Hydrostatic Drive
LEGEND:
A O-Ring
B O-Ring
C O-Ring
D Through Shaft
[6] - Ensure that mating surfaces of gear case front cover and hydrostatic unit are clean
before assembly.
[7] - Lubricate and install new O-rings (A—C).
[8] - Install PTO through shaft (D), if removed. Rotate shaft to index splines to internal PTO
clutch drive gear and rear pump coupling.

[9] - Index hydrostatic motor shaft splines to gear case shaft couplings and install drive to
gear case.
[10] - Install cap screws and tighten to specification.
Hydrostatic Drive-to-Gear Case Cap Screws Torque 26 N·m
(19 lb.-ft.)

Disassemble and Inspect Hydrostatic Drive
→NOTE:
Components of the hydrostatic drive unit are not serviceable except for the
seals.
[1] - Remove lever from control shaft. Clean shaft of any dirt or burrs.
[2] - Remove socket-head bolts (A and B). Separate valve block from housing.
Separate Valve from Housing
LEGEND:
A Socket-Head Bolts, M8 x 35 (2 used)
B Socket-Head Bolts, M8 x 40 (5 used)

[3] -
→NOTE:
Keep hydrostatic pump and motor rotating assemblies on shafts. Be careful

to not scratch mating surfaces of rotating assemblies and plates.
Inspect motor (c) and pump plates (D) for wear.
Valve Block—Exploded
LEGEND:
C Motor Plate
D Pump Plate
E Valve
F Reverse Valve
G Forward Valve
H Gasket
[4] - Remove and inspect valve (E).

[5] - Remove and inspect reverse valve (F).
[6] - Remove and inspect forward valve (G).
[7] - Remove gasket (H). Ensure that all gasket material is removed from block passages and
bearing surfaces.
[8] -
→NOTE:
Keep hydrostatic pump and motor rotating assemblies and components

separated for later reassembly to proper location.
Position housing on its side to remove pump and motor rotating assemblies.
Housing with Pump and Motor Rotating Assemblies

[9] - Remove pump and motor rotating assemblies. Inspect plungers for wear or damage.
[10] - Inspect mating surface for scratches.
Rotating Assembly Face and Spring

Rotating Assembly Spring
LEGEND:
I Snap Ring
J Washer (2 used)
K Spring
[11] - Inspect spring inside of rotating assemblies.
[12] - If disassembly is required, press in washer with appropriate sized socket and remove
snap ring (I), washers (J), and spring (K).
[13] - Remove pump outer race (L) and thrust bearing (M).

Remove Thrust Bearings and Output Shaft
LEGEND:
L Pump Outer Race
M Thrust Bearing
N Motor Race
O Thrust Bearing
P Motor Output Shaft
[14] - Remove motor race (N), thrust bearing (O) and motor output shaft (P).
[15] - Inspect thrust bearings, races, and shaft surfaces for damage.

[16] - Remove snap ring (Q) securing through shaft assembly to housing.
Shaft Assembly in Housing
LEGEND:
Q Snap Ring
[17] - Tap shaft with seal, spacer, and bearing from housing. Inspect bearing for damage.

[18] - Remove socket-head bolts from trunnion bearing housings (R). Hold swash plate (S),
and remove housings with care to protect swash plate trunnion bearing surfaces.
Remove Trunnion Bearing Housings
LEGEND:
R Trunnion Bearing Housings
S Swash Plate

[19] - Remove swash plate, exercising care to protect bearing surfaces.
Remove Swash Plate
[20] - Inspect trunnion bearings and bearing surfaces for wear or scratches.
[21] - If damage to any bearings or bearing surfaces are found, replace complete hydrostatic
drive unit.

Assemble Hydrostatic Drive

Install new seals and O-rings at all locations when assembling the hydrostatic drive unit.
Ensure that all components are free of dirt or other contamination. Protect bearing and
sealing surfaces during reassembly.
[1] - Protect bearing surfaces (A) of swash plate trunnions.
Install Swash Plate
LEGEND:
A Bearing Surfaces
B Swash Plate
[2] - Install swash plate (B) to transaxle housing.

[3] - Lubricate and install new O-rings (C) to left and right trunnion bearing housings.
Install Trunnion Bearing Housings
LEGEND:
C O-Rings
D Control Shaft Seal
[4] - Lubricate and install new control shaft seal (D) to bearing housing.
[5] - Lubricate trunnion bearing surfaces and install bearing housings to transaxle housing.

[6] - Apply thread lock and sealer (medium strength) to threads of socket-head bolts (E).
Install and tighten to specification.
Bearing Housing Socket-Head Bolts
LEGEND:
E Socket-Head Bolts (3 used)
Number Name Use

• T43512 (us)
Thread Lock and Sealer Apply to threads of trunnion
• TY9473 (canadian)
(Medium Strength) bearing socket-head bolts.
Trunnion Bearing-to-Housing Socket-Head Bolts Torque 18 N·m
(159 lb.-in.)

[7] - Install input shaft (F) with bearing to housing. Press against outer race of bearing to
fully install bearing to housing bore.
Shaft in Housing
LEGEND:
F Input Shaft
G Spacer
H Seal
I Snap Ring
[8] - Install spacer (G).
[9] - Lubricate input shaft and new seal (H). Install seal flush with housing surface.
[10] - Install snap ring (I).

[11] - Install output shaft (J).
Install Thrust Bearings and Output Shaft
LEGEND:
J Motor Output Shaft
K Ball Thrust Bearing
L Grooved Outer Race
M Roller Thrust Bearing
N Flat Outer Race
[12] - Install ball thrust bearing (K) and grooved outer race (L).
[13] - Install roller thrust bearing (M) and flat outer race (N).

[14] -
→NOTE:
Positioning the hydrostatic motor housing on its side at a slight angle

keeps thrust bearing components and pump and motor components in
place as they are installed.
Carefully install pump (O) and motor (P) rotating assemblies to housing shafts, ensuring that
pistons remain in cylinder blocks.
Housing with Pump and Motor Rotating Assemblies
LEGEND:
O Pump Rotating Assembly
P Motor Rotating Assembly

[15] - Ensure that pump and motor wear plates are correctly installed to valve block locating
pins (R). Pump wear plate tapered grooves (Q) must face pump rotating assembly.
Valve Block—Bearings
LEGEND:
Q Tapered Grooves
R Locating Pin
S Gasket
[16] - Install new gasket (S) to valve block. Ensure to align holes in gasket with locating pins
in block.
[17] - Lubricate check valve seal rings. Install check valves.
[18] - Lubricate and install new O-rings to relief valve. Install valve to block.

[19] - Apply thread lock and sealer (medium strength) to threads of socket-head bolts (T and
U). Install and tighten to specification.
Assemble Valve to Housing
LEGEND:
T Socket-Head Bolts, M8 x 35 (2 used)
U Socket-Head Bolts, M8 x 40 (5 used)
Number Name Use

• T43512 (us)
Thread Lock and Sealer Apply to threads of valve block
(Medium Strength) socket-head bolts.
Valve Block-to-Housing Socket-Head Bolts Torque 26 N·m
(19 lb.-ft.)

Remove and Install Range Transmission
Remove Front Cover
LEGEND:
A Bevel Pinion Shaft Hole
B Nut
C Front Cover
D Detent Plug
[1] - Remove plug covering bevel pinion shaft hole (A).
[2] - Rotate brake arm clockwise to apply resistance to the bevel pinion shaft and loosen nut
(B) from pinion.
[3] - Remove cap screws from front cover (C) and remove cover.
[4] - Remove detent plug (D) while disengaging it from the MFWD shift arm.

[5] - Simultaneously pull out shaft assemblies (E and F) while disconnecting shifter (G) from
shift fork.
Shaft Assemblies in Front Cover
LEGEND:
E Shaft Assembly
F Shaft Assembly
G Shifter
H MFWD Output Shaft
[6] - Pull MFWD output shaft (H).

[7] - Remove nut (B) from pinion.
Cover and Pinion Nut
LEGEND:
B Nut
[8] - Pull pinion shaft assembly (I) from housing.

Pinion Shaft Assembly in Front Cover
LEGEND:
I Pinion Shaft Assembly

[9] - Remove snap ring (J) from other side of housing and remove bearing.
Remove Pinion Shaft Assembly Bearing
LEGEND:
J Snap Ring

[10] - Remove bolt and keeper plate (K).
Shifter Assembly in Cover
LEGEND:
K Keeper Plate
L Shifter Assembly
M MFWD Shifter Assembly
[11] - Slide shifter assembly (L) out of housing.
[12] - Repeat procedure for MFWD shifter assembly (M).
[13] - Inspect all MFWD shift assembly parts for any wear or damage. Replace any worn or
broken parts.

MFWD Shift Assembly—Exploded
LEGEND:
N Snap Ring
O MFWD Gear
P Shift Arm
Q O-Ring
R Spring
a. Remove snap ring (N).

b. Remove MFWD gear (O) from shaft. Check for wear at the bearing surface.
c. Check shift arm (P) for wear. Replace O-ring (Q).
d. Check spring (R) in detent assembly.

[14] - Inspect all gearshift assembly parts for any wear or damage. Replace any worn or
broken parts.
Gear Shift Assembly—Exploded
LEGEND:
S Spring and Ball
T Shift Arm
U O-Ring
V Pinion Nut
a. Check spring and ball (S) in detent assembly.

b. Remove gears and check for wear at the bearing surfaces.
c. Check shift arm (T) for wear. Replace O-ring (U).
d. Always replace pinion nut (V).
[15] - Install in reverse order of removal.

Brake Bellcrank
LEGEND:
A Bolt
B Brake Bell Crank
Refer to exploded view for correct orientation of the pinion nut.

Use thread lock and sealer on pinion nut during installation. Snug pinion nut after
installing range gear assembly in front cover.
Number Name Use
⚬ T43512 (us)
Thread Lock and Sealer Apply to threads of
⚬ TY9473 (canadian)
(Medium Strength) pinion nut.
⚬ 242 Loctite ™ (loctite)
Use form-in-place gasket on front cover. Install front cover.

Number Name Use
⚬ PM37465 (us)
⚬ PM38628 (canadian) Seal front cover to
⚬ RTV Blue Loctite ™ transmission.
(loctite)

Section 50 - POWER TRAIN REPAIR Group 20: Rear PTO Driveshaft
Tighten front cover to transmission cap screws to specification.

Front Cover-to-Transmission Cap Screws Torque 26 N·m
(19 lb.-ft.)
After assembly is complete, hold brake bell crank in an engaged position to keep brake
disks engaged and tighten pinion nut to specification.
Pinion Nut-to-Shaft Torque 112 N·m
(83 lb.-ft.)
Install a bolt (A) for this procedure.

Install the external bellcrank .
Turn brake bell crank (B) clockwise until tight and place a tie wrap between end of
external bellcrank and installed bolt (A) to keep pressure on brake disks.

Group 20 - Rear PTO Driveshaft
Specifications
Other Material
Remove PTO Clutch
Disassemble and Inspect PTO Clutch
Assemble PTO Clutch
Install PTO Clutch
Remove and Inspect Rear PTO Driveshaft and Gears
Install Rear PTO Driveshaft and Gears
Remove and Inspect Mid PTO Driveshaft and Gears
Install Mid PTO Driveshaft and Gears

Specifications
PTO Clutch
Clutch Plate Minimum Thickness 2.21 mm
(0.09 in.)
Friction Disks Minimum Thickness 2.5 mm
(0.098 in.)
Clutch and Brake

Brake Friction Disk Minimum Thickness 2.5 mm
(0.098 in.)
Brake Outer Plate (I) Minimum Thickness 3.02 mm
(0.12 in.)
Brake Inner Plate (K) Minimum Thickness 4.37 mm
(0.17 in.)
Clutch Friction Disk Minimum Thickness 2.5 mm
(0.098 in.)
(0.09 in.)
Clutch Drum-to-Clutch Cylinder Socket Head Bolts Torque 29 N·m
(21 lb.-ft.)
Rear Cover-to-Gear Case Cap Screw Torque 26 N·m
(19 lb.-ft.)
Rockshaft Housing-to-Gear Case Cap Screw Torque 52 N·m
(38 lb.-ft.)
Transmission Oil
Oil Type J20D
Oil Capacity 12.3 L
(3.25 gal.)
Drain Plug Torque 26 ± 6 N·m
(19 ± 4.4 lb.-ft.)
Shaft Seal Recess Depth 3.0 ±0.5 mm
(0.12 ± 0.02 in.)
Rear Cover-to-Transmission Cap Screws Torque 26 N·m
(19 lb.-ft.)
Rockshaft Housing-to-Transmission Cap Screws Torque 55 N·m
(40 lb.-ft.)

Other Material
Number Name Use
• T43512 (us)
Thread Lock and Sealer Apply to clutch cylinder-to-clutch
(Medium Strength) drum socket head bolts.
• TY16285 (us)
Clean mating surfaces; helps speed
curing.
• PM37465 (us)
• PM38628 (canadian)
Form-In-Place Gasket Apply as indicated.
• RTV Blue Loctite ™
(loctite)
→NOTE:

Remove PTO Clutch
[1] - Clean external surfaces of the hydrostatic drive and final drive gear case.
Hydrostatic Drive Assembly
LEGEND:
A Hydrostatic Drive Assembly
B PTO Drive Shaft
[2] - Remove hydrostatic drive assembly (A).
[3] - Remove PTO drive shaft (B) through front of gear case.

[4] - Shift M-B-R PTO selector (C) to REAR position.
Remove Hoses and Pipes
LEGEND:
C M-B-R PTO Selector
D Clamps
E Elbow
F Suction Pipe
G Fitting
[5] - Release clamps (D) and remove hose from elbow (E).
[6] - Drain oil to a suitable container.
[7] - Remove suction pipe (F) from hydraulic pump.

[8] - Disconnect fitting securing pipe (G) at pump outlet and at rock shaft, remove pipe.
[9] - Remove eight cap screws (H) and rock shaft housing.
Remove Rockshaft Housing
LEGEND:
H Cap Screws (8 used)

[10] - Remove nine cap screws securing rear cover (I) to transmission.
Remove Rear Cover
LEGEND:
I Rear Cover
J PTO Pinion Gear Shaft Assembly
K Idler Gear Assembly
[11] - Remove rear cover, retaining pump drive coupler.
[12] - Remove PTO pinion gear shaft assembly (J) with idler gear assembly (K).

[13] - Support PTO shift gear and collar with Phillips screwdriver (L) or similar tool that allows
shift gear movement to disengage from clutch gear.
Disengage PTO Shift Gear from Clutch Gear
LEGEND:
L Phillips Screwdriver
[14] - Remove PTO clutch assembly from transmission case:

Brake Reaction Tang
LEGEND:
M Brake Reaction Tang
N Clutch Housing Notch
a. Rotate PTO clutch assembly so that brake reaction tang (M) is on dipstick side of
housing.
b. Align clutch housing notch (N) with PTO M-B-R shift shaft.
c. Move clutch assembly rearward to remove front end from gear case.
d. Rotate clutch assembly front end upward and remove assembly through top of gear
case.
[15] - Inspect bearings for roughness or damage.
[16] - Disassemble and inspect PTO clutch assembly. (See procedure in this group.)
[17] - Remove sealer from rear cover, rock shaft housing, and gear case sealing surfaces.
Ensure that all sealing material is removed from gear case internal areas.

Disassemble and Inspect PTO Clutch
→NOTE:
PTO clutch service requires a special spring compression tool with cutouts
allowing access for spring retention snap ring removal or installation.
[1] - Loosen and then remove six socket-head bolts (A).
Clutch Assembly

Clutch Cylinder and Drum
LEGEND:
A Socket-Head Bolt (6 used)
B Cylinder
C Drum
D Bearing
[2] - Separate PTO clutch cylinder (B) and clutch drum (C).
[3] - Remove and save three interlock pins.
[4] - Remove clutch plates, friction disks, and drive hub from clutch cylinder.
[5] - Inspect clutch plates for damage. Replace any plates that are not flat or that show
abnormal wear or discoloration.

[6] - Inspect friction disks for wear or damage. Replace if near or under minimum specified
thickness, or if friction material is worn to bottom of grooves.
PTO Clutch
(0.09 in.)
Friction Disks Minimum Thickness 2.5 mm
(0.098 in.)
[7] - Check bearing (D) for wear or damage. Press bearing from shaft to replace if damaged.
[8] -
→NOTE:
A PTO Clutch Spring Compression Tool can be fabricated. (See PTO Clutch
Spring Compression Tool in Section 299, Group 05.)
Compress spring with PTO clutch spring compression tool (E) and remove snap ring (F).
Clutch Service Tool
LEGEND:
E PTO Clutch Spring Compression Tool

F Snap Ring
G Piston
[9] - Remove spring retainer, spring, and piston (G).
[10] - Remove snap ring (H) and outer brake plate (I).
Brake Plate Assembly
LEGEND:
H Snap Ring
I Outer Brake Plate
J Friction Disk
K Inner PTO Brake Actuator Plate
[11] - Remove friction disk (J) and inner PTO brake actuator plate (K).

[12] - Inspect friction disk for wear or damage. Replace if near or under minimum specified
[13] - Inspect brake plate and retainer for damage. Replace any parts that are not flat or that
show abnormal wear or discoloration.
Clutch and Brake

Brake Friction Disk Minimum Thickness 2.5 mm
(0.098 in.)
Brake Outer Plate (I) Minimum Thickness 3.02 mm
(0.12 in.)
Brake Inner Plate (K) Minimum Thickness 4.37 mm
(0.17 in.)
Clutch Friction Disk Minimum Thickness 2.5 mm
(0.098 in.)
(0.09 in.)

Assemble PTO Clutch
IMPORTANT:
Avoid Damage! Soak new clutch or brake friction disks in hydraulic oil for 1
hour before assembling clutch or brake packs. Failure to complete this step
results in premature clutch failure.
→NOTE:
Lubricate O-rings and seals prior installation.
[1] - Lubricate piston internal O-ring (A) and external O-ring (B). Install O-rings to clutch
piston.
Exploded Assembly
LEGEND:
A Internal O-Ring
B External O-Ring
C Clutch Drum
D Solid Flange Sections
E Oil Seals

[2] - Lubricate bore and center shaft of clutch drum (C). Install piston to cylinder with piston
tabs centered between bolt holes and over solid flange sections (D).
[3] - Lubricate and install two oil seals (E).
[4] - Install three interlock pins.
[5] - Install inner PTO brake actuator plate (F) with tabs located over interlock pin holes.
Brake Plate Assembly
LEGEND:
F Inner PTO Brake Actuator Plate
G Friction Disk
H Outer Brake Plate
I Snap Ring
[6] - Install friction disk (G) with tang located over an interlock pin hole.
[7] - Install outer brake plate (H) and secure with snap ring (I). Ensure that snap ring is
located in groove.
[8] -
→NOTE:
Install flat side of PTO brake spring retainer toward spring.
Install spring and retainer to clutch piston. Compress spring with PTO clutch spring
compression tool (J) and install snap ring (K).
Clutch Service Tool
LEGEND:
J PTO Clutch Spring Compression Tool
K Snap Ring

[9] - Install four clutch brake plates (L) separated by three friction disks (M) to drive hub (N).
Brake Plates and Disks to Clutch Cylinder
LEGEND:
L Clutch Brake Plates (4 used)
M Friction Disks (3 used)
N Drive Hub
O Clutch Cylinder
[10] - Install drive hub with clutch pack to clutch cylinder (O).

[11] - Grease three interlock pins (P) to hold them in place and install into clutch cylinder.
Clutch Assembly
LEGEND:
P Interlock Pins (3 used)
Q Socket-Head Bolt (6 used)
[12] - Assemble clutch drum to clutch cylinder with flange indentations aligned.
[13] - Apply thread lock and sealer (medium strength) to six socket-head bolts (Q).
Number Name Use

• T43512 (us)
• TY9473 (canadian) Thread Lock and Sealer Apply to clutch cylinder-to-clutch drum
• 242 Loctite ™ (Medium Strength) socket head bolts.
(loctite)
[14] - Install bolts and tighten incrementally in a cross pattern to specification.
Clutch Drum-to-Clutch Cylinder Socket Head Bolts Torque 29 N·m
(21 lb.-ft.)

[15] - Lubricate seal rings and install clutch assembly to gear case. (See Install PTO Clutch in
this Group.)

Install PTO Clutch
Assembly In Gear Case Bore

PTO Clutch Tang Position
LEGEND:
A Gear Case Bore
B PTO Brake Reaction Tang
C Gear Case Housing Stop
IMPORTANT:
Avoid Damage! Use liberal amounts of transmission oil to lubricate

components as they are assembled. DO NOT use grease or other heavy
lubricants unless they are called for.
[1] - Lubricate PTO clutch assembly bearings, seals, and bearing bores.
[2] - Install clutch assembly through top of gear case.
[3] - Insert front of assembly fully into gear case bore (A).

[4] -
IMPORTANT:
Make sure tang rests on gear case housing to avoid interference damage
when installing rockshaft.
Rotate installed clutch assembly so that PTO brake reaction tang (B) rests on gear case
housing stop (C).
[5] - Hold PTO shift gear and collar in position as temporary support tool (D) is removed.
Remove Support Tool
LEGEND:
D Support Tool
[6] -
→NOTE:
Ensure that the M-B-R shift fork is engaged in the shift collar as the pinion
gear shaft assembly is installed.

Index shift gear to PTO clutch drive gear and install pinion gear shaft assembly (E) and idler
gear assembly (F).
Pinion Gear Shaft and Idler Gear
LEGEND:
E Pinion Gear Shaft Assembly
F Idler Gear Assembly
G Sealing Surface
[7] - Apply form-in-place gasket compound to gear case rear cover sealing surface (G).
Number Name Use

• TY16285 (us)
curing.
• PM37465 (us)
• PM38628 (canadian) Sealing flange assemblies. Apply to front
Form-In-Place Gasket
• RTV Blue Loctite ™ cover, rear cover, and axle housing.
(loctite)

[8] - Install rear cover and nine M8 x 30 cap screws. Tighten in a cross pattern to
specification.
Rear Cover-to-Gear Case Cap Screw Torque 26 N·m
(19 lb.-ft.)
[9] - Install new O-rings (H) to grooves in gear case front cover.
O-Rings in Front Cover
LEGEND:
H O-rings
I Bearing Surface
[10] - Lubricate bearing surface (I) of PTO through shaft.

[11] -
→NOTE:
Rotate the PTO through shaft while installing it to the gear case in order to
index shaft splines to the internal PTO drive gear and the rear pump
coupling.
Install shaft through front of gear case, exercising care to not damage PTO clutch pilot
bushing.
[12] - Index hydrostatic drive unit input and motor shafts to gear case couplings. Install unit
to gear case and secure with five cap screws.
[13] - Apply form-in-place gasket compound to rockshaft bottom sealing surface.
Number Name Use

• TY16285 (us)
curing.
• PM37465 (us)
• PM38628 (canadian) Sealing flange assemblies. Apply to front
Form-In-Place Gasket
• RTV Blue Loctite ™ cover, rear cover, and axle housing.
(loctite)
[14] - Install rock shaft housing to gear case with six M10 x 50 cap screws (J) and two M10 x
70 cap screws (K). Tighten in a cross pattern to specification.

Rockshaft Housing on Gear Case
LEGEND:
J Cap Screws, M10 x 50 (6 used)
K Cap Screws, M10 x 70 (2 used)
Rockshaft Housing-to-Gear Case Cap Screw Torque 52 N·m
(38 lb.-ft.)
[15] - Install hydraulic pipe from hydraulic pump to rockshaft and tighten fittings.
[16] - Fill gear case with specified amount and type of oil.
Transmission Oil
Oil Type J20D
Oil Capacity 12.3 L
(3.25 gal.)
[17] - Install suction pipe and hose from suction filter fitting to hydraulic pump. (See Remove
and Install Oil Suction Screen in Section 70, Group 05.)

[18] - Install drain plug.
Drain Plug Torque 26 ±6 N·m
(19 ±4.4 lb.-ft.)

Remove and Inspect Rear PTO Driveshaft and Gears
Remove Rear Cover
LEGEND:
A Hose Clamps
B Elbow
C Suction Pipe
D Pipe
E Cap Screws (4 used)
[2] - Remove center lift link, draft arms, and adjustable draft links.

[3] -
→NOTE:
Oil capacity is approximately 12.3 L (3.25 gal.).
Drain hydraulic oil from transaxle.
[4] - Release clamps (A) and remove hose from elbow (B).
[5] - Remove suction pipe (C) from hydraulic pump.
[6] - Disconnect fitting securing pipe (D) at pump outlet and at rock shaft, remove pipe.
[7] - Remove four cap screws (E) and hydraulic pump.
[8] - Remove nine cap screws fastening rear cover to transmission.
[9] - Remove rear PTO cover assembly (F). Retain hydraulic pump drive coupler.

Rear PTO Cover Assembly
LEGEND:
F Rear PTO Cover Assembly
[10] -
→NOTE:
Make sure that the M—B—R shift arm is in “BOTH” position.
Simultaneously pull idler gear assembly (G) and rear PTO pinion shaft (H) out far enough to
remove idler assembly.

Idler Gear Assembly and Rear PTO Pinion Shaft
LEGEND:
G Idler Gear Assembly
H Rear PTO Pinion Shaft
I Hydraulic Pump Drive Coupling
[11] - Inspect hydraulic pump drive coupling (I). Replace if worn or damaged.

[12] - Remove rear PTO pinion shaft (J).
Rear PTO Pinion Shaft
LEGEND:
J Rear PTO Pinion Shaft

[13] - Inspect ball bearings (K), splines and gear teeth on shaft. Replace any worn or broken
parts.
Bearings and Shaft
LEGEND:
K Ball Bearings
[14] - Remove PTO gear and shaft assembly (L) from rear cover. Inspect all gears for missing
or damaged teeth.

PTO Gear and Shaft Assembly—Exploded
LEGEND:
L PTO Gear and Shaft Assembly
M Bearing
N Bearings
O Bearing
P Oil Seal
[15] - Inspect bearings (M, N, and O). Replace any worn or damaged parts.

[16] -
IMPORTANT:

lubricants unless they are specifically called for in the assembly story.
Mid and rear PTO shaft seals have grass cutter lips that require a special
driver. Use only seal drivers with a recessed drive face designed for this
type of seal. Flat-faced seal drivers will damage these seals.
→NOTE:
Install new seals when assembling PTO drive. Lubricate seals, bearings,
bearing bores, and shafts with clean oil before assembly. Prevent damage
to seals by covering splined shafts with tape or thin plastic before
assembly.
Replace oil seal (P). Install new oil seal using JDG11236 Rear PTO Seal Driver. Recess seal to
specification.


Rear PTO Seal Install
(0.12 ±0.02 in.)

Install Rear PTO Driveshaft and Gears
Rear PTO Pinion Shaft
LEGEND:
A Rear PTO Pinion Shaft
[1] - Assemble shafts and idler in the reverse order of disassembly. Lubricate bearings and
bearing bores with clean oil.
[2] - Install bearing to rear PTO pinion shaft (A). Install snap ring.
[3] - Simultaneously install idler gear assembly (B) and rear PTO pinion shaft (C).

All Shaft Assemblies in Transmission Case
LEGEND:
B Idler Gear Assembly
C Rear PTO Pinion Shaft
D Hydraulic Pump Drive Coupling
[4] - Install hydraulic pump drive coupling (D).
[5] - Thoroughly clean mating surfaces of rear cover and differential housing to remove all
traces of old sealant.
[6] - Install PTO output shaft and new seal in rear cover.

[7] - Apply a bead of John Deere Form-in-Place gasket maker to mating surfaces and install
rear cover.
Assemble Rear Cover to Transmission
Number Name Use

• PM37465 (us)
• PM38628 (canadian) Apply to mating surfaces of rear cover
• RTV Blue Loctite ™ and transmission.
(loctite)
[8] - Tighten rear cover cap screws to specification.
(19 lb.-ft.)

Remove and Inspect Mid PTO Driveshaft and Gears
Remove Hydrostatic Drive Assembly
LEGEND:
A Hydrostatic Drive Assembly
B PTO Drive Shaft
[2] - Remove center lift link. Disconnect draft links from rockshaft arms.
[3] -
→NOTE:
Oil capacity is approximately 12.3 L (3.25 gal.).
Drain hydraulic oil from gear case.

[4] - Remove hydrostatic drive assembly (A) from front of gear case.
[5] - Remove PTO drive shaft (B) through front of gear case.
[6] - Remove rear PTO shield assembly.
[7] - Shift M-B-R PTO selector (C) to REAR position.
Rear of Transmission
LEGEND:
C M-B-R PTO Selector
D Hose Clamps
E Elbow
F Suction Pipe
G Pipe

[8] - Release clamps (D) and remove hose from elbow (E).
[9] - Drain oil.
[10] - Remove suction pipe (F) from hydraulic pump.
[11] - Disconnect fitting securing pipe (G) at pump outlet and at rock shaft, remove pipe.
[12] - Remove cap screws (H) fastening rockshaft housing to gear case. Remove rockshaft
housing.
Rockshaft Housing
LEGEND:
H Cap Screws

[13] - Remove nine cap screws and rear cover (I).
Remove Rear Cover
LEGEND:
I Rear Cover
J PTO Pinion Gear Shaft Assembly
K Idler Gear Assembly
[14] - Remove PTO pinion gear shaft assembly (J) with idler gear assembly (K).

[15] - Support PTO shift gear and collar with Phillips screwdriver or similar tool (L) that allows
shift gear to move to disengage from clutch gear.
Support PTO Shift Gear and Collar
LEGEND:
L Collar Removal Tool
[16] - Remove PTO clutch assembly from transmission case.

PTO Clutch Assembly in Case
LEGEND:
M Brake Reaction Tang
N Clutch Housing Notch
a. Rotate PTO clutch assembly so that brake reaction tang (M) is on dipstick side of
housing.
b. Align clutch housing notch (N) with PTO M-B-R shift shaft.
c. Move clutch assembly rearward to remove front end from gear case.
d. Rotate clutch assembly front end upward and remove assembly through top of gear
case.

[17] - Remove tool supporting drive gear (O).
Remove Drive Gear and Shift Collar
LEGEND:
O Drive Gear
P Shift Collar
Q Gear Hub
R Needle Bearing
[18] - Remove drive gear, along with shift collar (P) and gear hub (Q).
[19] - Needle bearing (R) which supports the front of the rear PTO pinion stays in mid PTO
shaft. Remove and inspect needle bearing for damage or discoloration.

[20] - Remove ten cap screws (S and T) and cover.
Remove Front Cover
LEGEND:
S Cap Screws, M8 x 65 (6 used)
T Cap Screws, M8 x 30 (4 used)

[21] - Remove snap ring (U) from pinion shaft (V). Remove front PTO drive gear.
Remove Drive Gear
LEGEND:
U Snap Ring
V Pinion Shaft

[22] - Remove snap ring (W), pinion shaft and bearing.
Remove Pinion Shaft and Bearing
LEGEND:
W Snap Ring

[23] - Remove Mid-PTO idler gear (X) and shaft with range shift fork.
Remove Mid-PTO Idler Gear Assembly
LEGEND:
X Mid-PTO Idler Gear

[24] - Remove roll pin (Y), idler gear and bearing from shaft.
Idler Gear Bearing and Shaft
LEGEND:
Y Roll Pin
Z Snap Ring
[25] - Remove snap ring (Z) and bearing.

[26] - Tap mid PTO shaft with bearings and gear from gear case front cover.
Remove Shaft Assembly from Cove
[27] - Clean gasket material from front cover and gear case sealing surfaces.
Number Name Use

• TY16285 (us)
Clean gasket material from front cover and gear
case sealing surfaces.
[28] - Inspect bearings, gears, and shafts for wear or damage. Remove bearings from shafts
for replacement if damage is apparent.
[29] - Replace components as required.

Install Mid PTO Driveshaft and Gears
IMPORTANT:

lubricants unless they are specifically called for in the assembly story.
Mid and rear PTO shaft seals have grass cutter lips that require a special
driver. Use only seal drivers with a recessed drive face designed for this
type of seal. Flat-faced seal drivers will damage these seals.
→NOTE:
Install new seals when assembling PTO drive. Lubricate seals, bearings,
bearing bores, and shafts with clean oil before assembly. Prevent damage
to seals by covering splined shafts with tape or thin plastic before
assembly.
[1] - Lubricate and install new mid PTO shaft seal to front gear case cover using JDG11235
Seal Driver. Recess seal to specification.


Mid-PTO Shaft Seal Install
(0.12 ±0.02 in.)
[2] - Cover mid PTO shaft splines (A) to protect seal and install shaft assembly to front gear
case cover.
Shaft Assembly in Cover
LEGEND:
A Mid PTO Shaft Splines

[3] - Secure bearing in idler gear with snap ring (B), and install to idler gear shaft.
Idler Gear Bearing and Shaft
LEGEND:
B Snap Ring
C Roll Pin
[4] -
→NOTE:
The roll pin installed to the mid PTO idler gear shaft extends from the shaft
to properly index the range gearshift fork. The pin fits the shaft from one
side only.
Install roll pin (C) to bore in idler shaft.

[5] - Install mid PTO idler gear assembly to gear case front cover. Ensure that range shift
lever (D) is installed between lugs on range shift, with range shift fork (E) engaged in range
gearshift collar.
Mid-PTO Idler Gear Assembly
LEGEND:
D Range Shift Lever
E Range Shift Fork

[6] - Lubricate and install new seal (F) to mid PTO pinion shaft.
Seal on Mid PTO Pinion Shaft
LEGEND:
F Seal
[7] - Lubricate and install new O-ring to M-B-R shifter and install shifter to gear case.
[8] - Install pinion shaft bearing (G) to gear case and fasten with snap ring.

Pinion Shaft and Bearing
LEGEND:
G Pinion Shaft Bearing
[9] -
→NOTE:
The mid PTO drive gear is installed to the pinion shaft with the gear hub
facing the shaft bearing.
Install mid PTO input gear (H) to shaft with gear hub facing bearing. Fasten gear to shaft with
snap ring.

Mid PTO Input Gear
LEGEND:
H Mid PTO Input Gear

[10] - Install needle bearing (I) to mid PTO pinion shaft. Place grease on needle bearing to
hold it in pinion shaft.
Needle Bearing on Mid PTO Pinion Shaft
LEGEND:
I Needle Bearing
[11] -
→NOTE:
Install the gear hub to the shift collar with the hub outer spline beveled
ends facing the mid PTO pinion shaft.
Install drive gear (J) with shift collar (K) and gear hub (L) installed. Ensure that shifter fork
engages shift collar flange.

Install Drive Gear, Shift Collar and Gear Hub
LEGEND:
J Drive Gear
K Shift Collar
L Gear Hub
[12] - Hold drive gear assembly in position with temporary support tool through gear case
and mid PTO pinion shaft.

[13] - Lubricate seals (M) and install PTO clutch and brake assembly to gear case.
Install PTO Clutch and Brake Assembly
LEGEND:
M Seals
N PTO Brake Plate Tangs
[14] - Make sure that the PTO brake plate tangs (N) are rotated against the stop in the
housing.

[15] - Support PTO drive gear and withdraw support tool (O).
Support PTO Drive Gear
LEGEND:
O Support Tool
[16] - Lubricate shaft and bearing of rear PTO pinion (P) and partially install pinion through
drive gear spindle and gear hub.

Install Pinion Through Drive Gear Spindle and Gear Hub
LEGEND:
P Rear PTO Pinion

[17] - Lubricate bearing and partially install rear PTO idler gear assembly (Q) to gear case.
Install Rear PTO Idler Gear Assembly
LEGEND:
Q Rear PTO Idler Gear Assembly
[18] - Complete installation of rear PTO pinion and idler gear assemblies.

[19] - Ensure that locating pins (R) are installed to gear case.
Install Rear Cover
LEGEND:
R Locating Pins
[20] - Apply a bead of John Deere Form-in-Place gasket maker to mating surfaces of rear
cover.
Number Name Use

• PM37465 (us)
• PM38628 (canadian) Apply to mating surfaces of rear cover
• RTV Blue Loctite ™ and transmission.
(loctite)
[21] - Install drive coupler to hydraulic pump input shaft.
[22] - Lubricate bearings and install rear cover to gear case.

[23] - Install nine cap screws (S). Tighten cap screws in a cross pattern to specification.
Rear of Transmission
LEGEND:
S Cap Screws, M8 x 30 (9 used)
T Suction Pipe
(19 lb.-ft.)
[24] - Install hose and suction pipe (T) to pump inlet. Secure hose with clamps. Tighten pipe
to pump cap screws. (See Remove and Install Oil Suction Screen in Section 70, Group 05.)

[25] - Apply Form-in Place gasket maker to sealing surface of transmission case and install
rockshaft housing (U).
Rockshaft Housing
LEGEND:
U Rockshaft Housing
V Cap Screw, M10 x 50 (6 used)
W Cap Screw, M10 x 70 (2 used)
Number Name Use

• PM37465 (us)
• PM38628 (canadian) Apply to mating surfaces of rockshaft
• RTV Blue Loctite ™ housing and transmission.
(loctite)
[26] - Fasten rockshaft housing to transmission with cap screws (V and W). Tighten cap
screws in a cross pattern to specification.
Rockshaft Housing-to-Transmission Cap Screws Torque 55 N·m
(40 lb.-ft.)

Section 50 - POWER TRAIN REPAIR Group 25: Differential
[27] - Install hydraulic pipe to pump, rockshaft housing, and right-hand axle housing and
tighten fittings.
[28] - Refill gear case with specified amount and type of oil.
Transmission Oil
Oil Type J20D
Oil Capacity 12.3 L
(3.25 gal.)

Group 25 - Differential
Specifications
Other Material
Remove and Install Differential
Disassemble and Inspect Differential
Assemble Differential
Specifications
Axle Housing-to-Gear Case Cap Screws Torque 52 N·m
(38 lb.-ft.)
Ring Gear-to-Housing Bolts Torque 102 N·m
(75 lb.-ft.)
Other Material
Number Name Use
• PM37465 (us)
• PM38628 (canadian) Apply to axle housing
• RTV Blue Loctite ™ mating surfaces.
(loctite)
• T43513 (us)
Thread Lock and Sealer (High
• TY9474 (canadian) Apply to ring gear bolts.
Strength)

Remove and Install Differential
Bell Crank
LEGEND:
A Bolt
B Bell Crank
[1] - Remove bell cranks from both sides of differential lock shaft.
[2] - Hold brake bell crank in an engaged position to keep brake disks in position for easier
assembly.
a. Install a bolt (A) for this procedure.

b. Install the external bell crank.
c. Turn brake bell crank (B) clockwise until tight and place a tie wrap between end of
external bell crank and installed bolt (A) to keep pressure on brake disks.
[3] - Remove suction manifold and suction screen from case.
[4] - Remove right axle and axle housing assembly.

[5] -
→NOTE:
Bevel ring gear and bearing may remain in side cover or stay on pinion
shaft.
Remove differential pinion shaft and bevel gear assembly (B).
Bevel Gear Assembly
LEGEND:
B Bevel Gear Assembly

[6] - Simultaneously pull out differential assembly (C) with differential lock shaft and fork
assembly (D).
Differential Removal
LEGEND:
C Differential Assembly
D Fork Assembly
[7] - Remove differential lock shaft assembly from the differential assembly.

[9] -
→NOTE:
Protect differential lock shaft oil seals during assembly if they are still in
the housings.
Place differential lock shift fork (A) on collar (B) and simultaneously install differential
assembly (C) with differential lock shaft and fork assembly.
Differential Shift Assemble
LEGEND:
A Lock Shift Fork
B Collar

[10] - Temporarily insert bevel gear pinion shaft (D) to center and align brake friction disks.
Pinion Shaft
LEGEND:
D Bevel Gear Pinion Shaft
[11] - Install bevel gear and bearing assembly to bevel gear shaft and insert into bearing
housing and brake disks.
[12] - Rotate brake cam shaft to move brake disks to applied position. Check for brake hold
with bevel gear shaft assembly.
[13] - Fasten outer hex of brake cam shaft in applied position with Vice-Grip or wrench to
hold brake disks in alignment. Remove bevel gear assembly and install to gear case.

[14] - Ensure that two locating dowels (E) are installed to housing.
Housing
LEGEND:
E Locating Dowels
F Housing Mounting Flange
[15] - Apply grease to bearing housing bore surface to retain backlash shim. Install backlash
shim removed at disassembly.
[16] - Apply Form-in-Place gasket maker to housing mounting flange (F).
Number Name Use

• PM37465 (us)
• PM38628 (canadian) Form-in-Place Gasket Apply to axle housing mating surfaces.
• RTV Blue Loctite ™ (loctite)
[17] -
→NOTE:
If necessary, rotate the bevel gear pinion shaft to align it to the brake disk
splines when installing the axle housing to the gear case.
Install housing to gear case. Install and tighten cap screws to specification.
(38 lb.-ft.)
[18] -
IMPORTANT:
Make sure that the free end of the suction screen is aligned and fitted to
the socket in the transmission right side cover during assembly. Improper
installation could result in crushing of the suction screen and subsequent
hydraulic pump failure.
Install suction manifold and suction screen. Make sure the oil suction screen is properly
aligned to the side cover during installation. (See Remove and Install Oil Suction Screen in

Disassemble and Inspect Differential
[1] - Remove bearing (A) from differential carrier.
Bearing
LEGEND:
A Bearing

[2] - Remove differential lock collar (B).
Lock Collar
LEGEND:
B Lock Collar

[3] - Remove bolts from the ring gear and remove ring gear from differential carrier.
Ring Gear

[4] - Using a pin punch (C) from the ring gear side of the differential carrier, drive roll pin (D)
out of pinion shaft (E).
Differential Carrier
LEGEND:
C Pin Punch
D Roll Pin
E Pinion Shaft
[5] - Remove pinion shaft.

[6] - Rotate gears to open spot in differential carrier (F) and remove all gears and thrust
washers from case.
Differential Carrier
LEGEND:
F Differential Carrier

[7] - Inspect all gear teeth and thrust washers for wear and damage. Check back side of
gears at thrust washer contact area (G) for wear or damage.
Differential Gears
LEGEND:
G Contact Area

[8] - Check differential lock notches (H) for wear, damage, or rounded off corners. Check
differential lock pins (I) for wear, damage, or rounded off corners. Replace any worn or
damaged parts.
Differential Lock
LEGEND:
H Lock Notches
I Lock Pins

[9] - Inspect differential lock shaft (J), fork (K), spring (L), and pin (M) for wear or damage.
Replace any worn or damaged parts.
Differential Lock
LEGEND:
J Lock Shaft
K Fork
L Spring
M Pin
[10] -
IMPORTANT:
Avoid Damage! DO NOT spin bearing using compressed air. Damage to

bearing balls, cage, and races could result.
Clean bearings in a suitable solvent. Dry with compressed air.
[11] - Inspect bearings for discolored, burned, balls, and races. Check balls and races for
spalling or cracking. Roll bearing by hand to check for rough turning or excessive looseness
or play between balls and races. Replace bearings as required.

Assemble Differential
Assembly of the differential is the reverse of disassembly.
[1] - Clean old thread lock compound from ring gear bolt threads and differential housing
holes.
[2] - Apply a small amount of lithium grease to thrust washers to hold them in place while
assembling.
[3] - Install gears in differential housing. Make sure that differential lock gear is on correct
side of housing. Install pinion shaft. Make sure all gears rotate freely.

[4] - Align holes in differential housing and pinion shaft and drive roll pin (A) through pinion
shaft and into differential housing.
Pinion Shaft Install
LEGEND:
A Roll Pin

Section 50 - POWER TRAIN REPAIR Group 30: Final Drives
[5] - Apply thread lock and sealer (high strength) to ring gear bolts and install ring gear with
the machined (flat) side against differential.
Differential Components
Number Name Use

• T43513 (us)
• TY9474 (canadian) Thread Lock and Sealer (High Strength) Apply to ring gear bolts.
[6] - Tighten ring gear bolts to specification in a cross pattern.
Ring Gear-to-Housing Bolts Torque 102 N·m
(75 lb.-ft.)
[7] - Install differential lock collar. Make sure collar seats fully into differential side gear.
[8] - Install bearings.

Group 30 - Final Drives
Remove and Install Rear Axle
→NOTE:

Remove and Install Rear Axle
Axle Housing Snap Ring
LEGEND:
A Snap Ring
→NOTE:
Procedure is the same for either side.
Oil capacity of transaxle is 12.3 L (3.25 gal.).
[1] - Drain oil from transmission.
[2] - Remove rear wheel(s). (See procedure in Section 80, Group 10.)

[3] - Remove snap ring (A).
[4] -
Axle Shaft Remove - JDG11405
LEGEND:
B JDG11405 Plate Fixture Tool
C Bolts (19M9991 or equivalent)
Using a JDG11405 plate fixture tool (B) and two long bolts (C) push out the axle shaft.

[5] - Alternate Method: Using a standard bearing separator (B) and two long bolts (C) push
out the axle shaft.
Axle Shaft Remove
LEGEND:
B Bearing Separator
C Bolts (19M9991 or equivalent)

[6] - The axle shaft should come out with the outer snap ring (D), axle seal (E), ball bearing
(F) and inner snap ring (G).
Axle Shaft Components
LEGEND:
D Outer Snap Ring
E Axle Seal
F Ball Bearing
G Inner Snap Ring
[7] - Remove snap ring (A).
Axle Snap Ring
LEGEND:
A Inner Snap Ring

[8] -
IMPORTANT:
Support the inner race of the bearing. Be certain the force of the press
does not pass through the balls of the bearing.
Support the bearing on the inner race (C).


Axle Bearing Removal
LEGEND:
B Axle Shaft
C Axle Bearing Inner Race
[9] - Push the axle shaft (B) through the bearing.
[10] - Remove axle seal and discard.
[11] -
→NOTE:
Always use a new axle seal.
Install the new axle seal being certain the seal stays on the ground sealing diameter (D) and
does not get pushed beyond the sealing diameter limit (E).
Axle Shaft Seal Install
LEGEND:

D Ground Sealing Diameter

E Sealing Diameter Limit
[12] -
IMPORTANT:
Be certain the force of the press does not pass through the balls of the
bearing.
Press the ball bearing (F) on to the axle shaft using a tube (G) as shown.


Axle Shaft Bearing Install
LEGEND:
F Ball Bearing
G Tube
[13] - Install snap ring (H) next to bearing.
Axle Shaft Inner Snap Ring
LEGEND:
H Snap Ring
[14] -
→NOTE:
Make sure outer snap ring is stays to the outside and not between the split
cylinder tool and axle seal.
Install JDG11404 split cylinder tool (I) as shown.

JDG11404 Split Cylinder Tool Use
LEGEND:
I JDG11404 Split Cylinder Tool
[15] - Insert the axle shaft (J) into the axle housing (K) until the ball bearing is completely
inside the housing and resistance is felt.

Axle Shaft Install
LEGEND:
J Axle Shaft
K Axle Housing
[16] -
IMPORTANT:
Do not hit hard on the shaft before ensuring that the inside splines are
lined up and engaged. The spline engagement can be verified by turning
the axle shaft and verifying that the axle shaft on the other side is rotating
in the opposite direction.
Lightly tap on the axle shaft face (L) with a soft face hammer while rotating it until you feel
the axle splines (N) are lined up and engaged with the differential splines as shown, and the
seal (M) is recessed 3—4 mm (0.12—0.16 in.).

Axle Shaft Install - Depth
LEGEND:
L Axle Shaft Face
M Seal Recess
N Splines
[17] - Remove the split cylinder tool and install outer snap ring (O) in groove in main
housing.

Section 50 - POWER TRAIN REPAIR Group 35: Mechanical Front Wheel Drive
Axle Shaft Outer Snap Ring
LEGEND:
O Outer Snap Ring

Group 35 - Mechanical Front Wheel Drive
Specifications
Remove Front Axle
Install Front Axle
Disassemble Front Axle
Assemble Front Axle
Disassemble Front Outer Axle
Assemble Front Outer Axle
Disassemble MFWD Differential
Assemble MFWD Differential
Specifications
Pivot Bolt Lock Nut Torque Turn 370 N·m
(275 lb.-ft.)
Outer Axle End to Axle Bolt Torque 80 N·m
(60 lb.-ft.)
Tie Rod End Nut Torque 55 N·m
(40 lb.-ft.)
Steering Cylinder End Nut Torque 150 N·m
(110 lb.-ft.)
Axle Housing Cover Bolt Torque 28 N·m
(20 lb.-ft.)

Remove Front Axle
Support Front End of Machine
LEGEND:
A Supports
[2] - Remove any front mounted attachments and attachment mounting brackets.
[3] - Raise front of machine and place secure supports (A) under frame behind front axle.
[4] - Remove front wheel assemblies.
[5] - Clean axle assembly to remove any accumulated dirt or debris.
[6] - Clean steering cylinder hose fittings (B) at pipe connections.

Front Axle Connections

Front Axle Pivot Bolt
LEGEND:
B Hose Fittings
C Lock Nut
D Pivot Bolt
[7] - Remove and cap steering cylinder hose fittings.
[8] - Remove hex lock nut (C) and washers securing axle pivot bolt.
[9] - Support axle with floor jack centered under axle.
[10] - Remove axle pivot bolt (D).
[11] - Lower axle to clear axle mount.
[12] - Remove axle from under machine.
[13] - Securely support axle on work surface.

Install Front Axle
Front Axle Pivot Bolt
LEGEND:
A Pivot Bolt
[1] - Install axle assembly to machine if removed. Grease axle pivot bolt (A) and install
through frame mounts and axle.
[2] - Grease splines and install front axle driveshaft to transmission MFWD output shaft.
[3] - Install shield to front drive shaft. Slide shield part way down shaft.
[4] - Grease front axle input shaft splines.
[5] - Align holes in drive shaft yoke and axle input shaft. Slide drive shaft forward to install to
axle.

[6] - Drive spring pin (B) through yoke and input shaft. Install snap ring (C) to yoke groove to
secure spring pin. Ensure that snap ring covers both ends of spring pin.
Drive Shaft to Front Axle
LEGEND:
B Spring Pin
C Snap Ring

[7] - Install shield to axle, and tighten hose clamp (D) to secure shield.
Front Axle Drive Shaft Shield
LEGEND:
D Hose Clamp
[8] - Install two washers and hex lock nut (E) to axle pivot bolt. Tighten nut to specification.
Pivot Bolt Lock Nut Torque Turn 370 N·m
(275 lb.-ft.)

Front Axle Connections
LEGEND:
E Lock Nut
F Hoses
[9] - Connect steering cylinder hoses (F) to hydraulic pipes. Install cylinder hose near axle
pivot to pipe nearest frame.
[10] - Install wheel assemblies and lower machine from supports.

Disassemble Front Axle

Service procedures are the same for the left and right side outer axle assemblies. Only the
right side outer axle assembly must be removed to service the differential.
MFWD Input Shield
Driveshaft-to-MFWD Input Shaft

LEGEND:
A Clamp
B Input Shield
C Snap Ring
D Spring Pin
[1] - Loosen clamp (A), and remove axle input shield (B).
[2] - Remove snap ring (C) from driveshaft yoke groove. Drive spring pin (D) through yoke
until drive shaft can be removed from axle input shaft.
[3] - Slide drive shaft rearward to remove from axle input shaft splines.

[4] - Clean area around fill plug and dipstick (E) and outer axle end plug (F).
MFWD Fill and Drain Plugs
LEGEND:
E Fill Plug and Dipstick
F Plug
[5] - Remove plugs and drain lubricant to a suitable container.

[6] - Remove hex nut (G) securing steering cylinder end to left bevel gear housing if left
outer end is removed. Remove cylinder end from housing.
MFWD Steering Cylinder Rod Connection
LEGEND:
G Hex Nut

[7] - Remove cotter pin and hex nut (H) securing tie rod end to axle outer end being
removed. Remove tie rod end from ring gear housing arm.
MFWD Tie Rod Connection
LEGEND:
H Hex Nut
[8] - Remove eight hex flange bolts (I) securing cover to bevel gear housing.

MFWD Bevel Gear Housing Cover
LEGEND:
I Hex Flange Bolts
J Pry Points
[9] - Use pry points (J) provided to separate cover from housing. Remove cover.

[10] - Remove five hex bolts (K) securing outer end assembly to axle tube. Tap spindle
housing at knock points (L) to separate housing from axle.
MFWD Axle Outer End Housing
LEGEND:
K Hex Bolts
L Knock Points
[11] - Remove outer end assembly from axle.

[12] - Remove axle shaft (M) from differential.
MFWD Axle Shaft
LEGEND:
M Axle Shaft
[13] - Remove snap ring (N) securing differential assembly in axle housing.

MFWD Differential Snap Ring
LEGEND:
N Snap Ring
O Differential Assembly
[14] - Remove differential assembly (O) from axle housing.
[15] - Rotate the axle input pinion shaft with the differential assembly removed to check
bearing condition. If any roughness is felt, remove the pinion assembly and replace the
bearings.
a. Clean area around front axle input shaft.

MFWD Input Shaft Seal

LEGEND:
A Seal
b. Remove input shaft seal (A).

c. Remove snap ring (B) securing input shaft outer bearing to housing.

MFWD Input Shaft Snap Ring

LEGEND:
B Snap Ring
d. Remove input shaft assembly from housing.

e. Remove snap ring (C).
MFWD Input Shaft Snap Ring

LEGEND:
C Snap ring
f. Support outer pinion bearing (D), and press pinion shaft from bearing.

MFWD Press Out Pinion Shaft

LEGEND:
D Outer Bearing
E Inner Bearing
g. Remove spacer and inner pinion bearing (E).

Assemble Front Axle
MFWD Input Shaft Assembly and Snap Ring

MFWD Input Shaft Seal
LEGEND:
A Snap Ring
B Seal
[1] - Lubricate bearings with clean hydraulic oil and install input shaft assembly to axle
housing.
[2] - Install snap ring (A) securing input shaft assembly to housing.
[3] - Lubricate input shaft, and housing bore with clean hydraulic oil.
[4] - Lubricate seal with lithium grease and install shaft seal (B) to bottom of housing bore.

[5] - Install differential assembly (C) to axle tube. Rotate input shaft to align gears and
opposite side axle shaft splines.
MFWD Differential Assembly and Snap Ring
LEGEND:
D Snap ring
[6] - Install snap ring (D) to secure differential assembly.
[7] -
→NOTE:
Install the longer splined section of axle shafts to the differential side
gears.
Align splines and install axle shaft (E) to differential. Rotate shaft to align splines.

MFWD Axle Shaft
LEGEND:
E Axle Shaft
[8] -
→NOTE:
Rotate axle flange to align inner axle to spindle gear.
Align bolt holes and locating pin, and install outer axle assembly to axle tube.

[9] - Secure outer axle assembly with five M10x25 hex bolts (F). Tighten bolts to
specification in a cross pattern.
Outer Axle End to Axle Bolt Torque 80 N·m
(60 lb.-ft.)
MFWD Axle-to-Outer Axle Bolts
LEGEND:
F Bolts

[10] - Install tie rod end to ring gear housing arm. Install hex castle nut (G) and tighten to
specification. Loosen nut as required to insert cotter pin to secure nut.
Tie Rod End Nut Torque 55 N·m
(40 lb.-ft.)
MFWD Tie Rod End Nut
LEGEND:
G Castle Nut

[11] - Install steering cylinder end to left gear housing if removed. Install hex castle nut (H)
and tighten to specification. Loosen nut as required to insert cotter pin to secure nut.
Steering Cylinder End Nut Torque 150 N·m
(110 lb.-ft.)
MFWD Steering Cylinder Castle Nut
LEGEND:
H Castle Nut

Disassemble Front Outer Axle
Spindle Housing Seal
LEGEND:
A Seal
Service procedures are the same for the left and right side outer axle assemblies.
Rotate outer axle end bearings to check bearing condition. Inspect gears, shafts, and seals
for wear or damage. Replace components as needed.
[1] - Remove seal (A) from spindle housing.

[2] - Remove snap ring (B) securing bevel gear bearing.
Spindle Bevel Gear
LEGEND:
B Snap Ring
C Bearing Assembly
[3] - Remove axle bevel gear and bearing assembly (C) from spindle housing.

[4] - Remove spindle bevel gear (D) from drive spindle splines. Remove gear from spindle
housing.
Spindle Bevel Gear
LEGEND:
D Bevel Gear

[5] - Remove snap ring (E) and spacer from drive spindle lower end.
Spindle Snap ring
LEGEND:
E Snap Ring

[6] - Separate spindle housing (F) from ring gear housing.
Spindle Housing and Ring Gear Housing Separation
LEGEND:
F Spindle Housing
[7] - Push drive spindle upper bearing (G) from housing bore with drive spindle. Remove
bearing and spindle from housing.

Spindle Housing Upper Bearing
LEGEND:
G Bearing
[8] - Remove pinion and bearing assembly (H) from ring gear housing.

Ring Gear Housing Pinion and Bearing
LEGEND:
H Pinion and Bearing Assembly
[9] - Remove seal (I) from ring gear housing.

Ring Gear Housing Upper Seal
LEGEND:
I Seal

[10] - Remove upper spindle bearing (J) from housing.
Ring Gear Housing Upper Bearing
LEGEND:
J Bearing

[11] - Remove snap ring (K) securing lower spindle bearing (L). Remove bearing from
housing.
Ring Gear Housing Lower Bearing
LEGEND:
K Snap Ring
L Bearing
[12] -
IMPORTANT:
Do not attempt to press the axle shaft from the bevel gear and inner axle
bearing. A snap ring secures the axle shaft and outer bearing to the
housing cover. Pull the inner bearing and bevel gear from the shaft to
avoid damage.
Pull inner axle bearing (M) and bevel gear (N) from axle shaft.

Spindle Housing Bevel Gear and Bearing
LEGEND:
M Bearing
N Bevel Gear
[13] - Remove snap ring (O) from axle shaft.

Spindle Housing Axle Shaft
LEGEND:
O Snap Ring
P Axle
[14] - Support housing cover and press axle (P) from outer bearing.

[15] - Remove outer bearing (Q) from housing cover.
Spindle Housing Outer Bearing
LEGEND:
Q Bearing

[16] - Remove seal (R) from housing cover.
Spindle Housing Cover Seal
LEGEND:
R Seal
[17] - Clean all parts and check for wear or damage.

Assemble Front Outer Axle
Bevel Gear Housing Seal
LEGEND:
A Seal
[1] - Install new seal (A) to bottom of bevel gear housing bore.
[2] - Lubricate seal and axle stub shaft with lithium grease. Install shaft to housing cover.

[3] - Lubricate shaft outer bearing (B) and housing bore with clean hydraulic oil. Install
bearing to axle and housing.
MFWD Bevel Gear Housing
LEGEND:
B Bearing
C Snap Ring
[4] - Secure axle with snap ring (C).

[5] - Install bevel gear (D) to axle shaft splines.
MFWD Bevel Gear and Housing
LEGEND:
D Bevel Gear
E Bearing
F Gasket
[6] - Lubricate axle and inner bearing (E) with clean hydraulic oil. Press bearing on to axle.
[7] - Install new gasket (F) to housing cover.

[8] - Lubricate housing bore and lower spindle bearing (G) with clean hydraulic oil. Install
bearing to housing and secure with snap ring (H).
Lower Spindle Bearing and Snap Ring
LEGEND:
G Bearing
H Snap Ring

[9] - Lubricate housing bore and upper spindle bearing (I) with clean hydraulic oil. Install
bearing to housing.
Spindle Bearing
LEGEND:
I Bearing

[10] - Lubricate new spindle seal (J) with lithium grease and install to housing. Install seal
slightly below surface of housing.
Spindle Housing Seal
LEGEND:
J Seal

[11] - Install lower drive spindle bearing (K) with drive gear to housing.
Lower Drive Spindle Bearing
LEGEND:
K Bearing
[12] - Lubricate spindle bearings, seal, and spindle with clean hydraulic oil. Install spindle
housing to bevel gear housing.

[13] - Install spacer and snap ring (L) to end of spindle housing.
Spindle Housing Snap Ring
LEGEND:
L Snap Ring

[14] - Install drive spindle (M) to assembled housings. Rotate spindle to mesh with installed
drive gear.
Drive Spindle and Bearing
LEGEND:
M Spindle
N Bearing
[15] - Lubricate upper drive spindle bearing (N) with clean hydraulic oil and install to
housing.

[16] - Install drive spindle input gear (O) to drive spindle.
Spindle Input Gear Install
LEGEND:
O Input Gear
[17] - Lubricate bearing, drive gear (P) with clean hydraulic oil and install with bearing to
spindle. Rotate drive gear to mesh with spindle gear.

Spindle Housing Drive Gear Install
LEGEND:
P Drive Gear
Q Snap Ring
R Seal
S O-ring
T Pin
[18] - Secure drive gear bearing to spindle housing with snap ring (Q).
[19] - Lubricate housing seal (R) with lithium grease and install to spindle housing.
[20] - Install new O-ring (S) to spindle housing.
[21] - Ensure that locating pin (T) is installed to housing.

[22] - Align bolt holes and loosely install cover to bevel gear housing. Rotate axle flange to
mesh gears.
Bevel Gear Housing Cover Install
LEGEND:
U Hex Bolts
[23] - Install eight M8x25 hex bolts (U) and draw cover to housing in a cross pattern. Tighten
bolts to specification.
Axle Housing Cover Bolt Torque 28 N·m
(20 lb.-ft.)

Disassemble MFWD Differential
MFWD Differential Gear Assemblies
LEGEND:
A Side Gear Assemblies
B Cupped Washers
Rotate the differential case bearings to check bearing condition. Inspect the differential gear
condition. Replace components as needed.
[1] - Rotate side gear assemblies (A) around pinion gears. Remove side gears with cupped
washers (B) from differential case.

[2] - Remove bevel gear (C) from differential case splines.
MFWD Differential Bevel Gear and Bearings
LEGEND:
C Bevel Gear
D Bearings
[3] - Remove bearings (D) from differential case.
[4] - Insert drift pin (E) through smaller differential case hole, and drive spring pin (F) from
pinion gear shaft.

MFWD Differential Spring Pin
LEGEND:
E Drift Pin
F Spring Pin
[5] - Remove pinion gear shaft (G) and pinion gears (H) with cupped washers from
differential case.

MFWD Differential Pinion Shaft and Gears
LEGEND:
G Shaft
H Gears
[6] - Clean all parts and check for wear or damage.

Assemble MFWD Differential
MFWD Differential Pinion Gears and Shaft
LEGEND:
A Pinion Gears
B Cupped Washers
[1] - Install pinion gears (A) and cupped washers (B) to partially installed pinion shaft.
[2] - Install pinion shaft to carrier, aligning carrier and shaft holes.

[3] - Hold hole alignment with punch, and drive spring pin (C) through carrier into shaft.
MFWD Differential Spring Pin
LEGEND:
C Spring Pin

[4] - Install bearings (D) to differential carrier.
MFWD Differential Bearings and Bevel Gear
LEGEND:
D Bearings
E Bevel Gear
[5] - Align splines and install driven gear (E) to carrier.
[6] -
→NOTE:
It may be necessary to use a small amount of lithium grease to hold cupped

washers to side gears during installation.
Install side gears (F) and cupped washers (G) through openings in differential housing. Rotate
gears into position.

STEERING AND BRAKE REPAIR (g) by Belgreen
MFWD Differential Side Gears
LEGEND:
F Side Gears
G Cupped Washers
[7] - Make sure pinion gears and side gears rotate freely and do not bind.

Section 60 - STEERING AND BRAKE REPAIR
Table of contents
Group 05 - Steering Repair ...................................................................................................... 2
Specifications ......................................................................................................................... 3
Remove and Install Steering Wheel ....................................................................................... 3
Remove and Install Steering Cylinder .................................................................................... 5
Remove and Install Tilt Steering Assembly ............................................................................ 7
Disassemble Tilt Steering Assembly .................................................................................... 10
Assemble Tilt Steering Assembly ......................................................................................... 19
Remove Steering Control Unit (SCU) .................................................................................... 28
Install Steering Control Unit (SCU) ....................................................................................... 30
Remove and Install Tie Rod .................................................................................................. 31
Group 10 - Brake Repair ......................................................................................................... 33
Specifications ....................................................................................................................... 33
Other Material ...................................................................................................................... 33
Disassemble and Inspect Brakes .......................................................................................... 34
Assemble Brakes .................................................................................................................. 38

Section 60 - STEERING AND BRAKE REPAIR Group 05: Steering Repair
Group 05 - Steering Repair
Specifications
Remove and Install Steering Wheel
Remove and Install Steering Cylinder
Remove and Install Tilt Steering Assembly
Disassemble Tilt Steering Assembly
Assemble Tilt Steering Assembly
Remove Steering Control Unit (SCU)
Install Steering Control Unit (SCU)
Remove and Install Tie Rod

Specifications
Steering Wheel Nut Torque 35 ± 7 N·m
(25.8 ± 5.1 lb.-ft.)
Castle Nuts Torque 25—32 N·m
(18—24 lb.-ft.)
Hose Ends Torque 17 N·m
(150 lb.-in.)
Bracket-to-Support Cap Screws Torque 30 ± 7 N·m
(22.1 ± 5.1 lb.-ft.)
SCU Mounting Cap Scerws Torque 15 N·m
(133 lb.-in.)
Specifications
SCU Adaptor Fittings Torque 14—19 N·m
(124—168 lb.-in.)
Hydraulic Lines to SCU (size -4) Torque 16 N·m
(142 lb.-in.)
(27.3 lb.-ft.)
Tie Rod Castle Nuts Torque 25—32 N·m
(18—24 lb.-ft.)
Remove and Install Steering Wheel
[1] - Disengage three locking tabs at underside of steering wheel and remove steering wheel
cover.
[2] - Remove nut securing steering wheel.
[3] - Remove steering wheel. If necessary, use a suitable puller.
[4] -
→NOTE:
Lightly coat the steering shaft splines with NEVER-SEEZ ™ or general

purpose grease before installing steering wheel to allow easy removal.

Install steering wheel and retain with nut. Tighten steering wheel nut to specification.
Steering Wheel Nut Torque 35 ± 7 N·m
(25.8 ± 5.1 lb.-ft.)
[5] - Install center cover to steering wheel.

Remove and Install Steering Cylinder
Steering Cylinder
LEGEND:
A Hoses
B Nylock
[1] -
→NOTE:
Cylinder ball end studs are tapered. Use a tie rod end removal tool to avoid
damaging threads if cylinder is to be re used.
Mark hoses (A) and disconnect from cylinder.
[2] - Remove and discard nylocks (B).
[3] - Remove cylinder.

[4] - Inspect rubber boots on ends of cylinder. Replace boots if necessary.
[5] - Install cylinder with new nylocks. Tighten nylocks to specification.
Nylock Torque 64— 95 N·m
(47—70 lb.-ft.)
[6] - Connect hoses to cylinder.
Hose Ends Torque 17 N·m
(150 lb.-in.)

Remove and Install Tilt Steering Assembly
Tilt Steering Assembly Remove and Install

Tilt Steering Assembly Remove and Install
LEGEND:
A Cap Screws
B Tilt Steering Assembly
C Nuts
D Cap Screws
[1] - Remove steering wheel and control panel. (See Remove Control Panel in Section 90,
Group 15.)
[2] - Remove two cap screws (A) on each side securing tilt steering wheel bracket to steering
support.
[3] - Lift tilt assembly (B) out of steering supports. If nuts (C) do not clear steering support,
loosen cap screws (D) and gently pry steering support out enough to remove tilt assembly.

[4] - Install tilt steering assembly.
a. Slide tilt steering assembly down between steering supports. If nuts (C) interfere, loosen
cap screws (D) and slightly spread steering supports apart to clear nuts. Be sure to
retighten cap screws (D) after unit is in place.
b. Align holes and install cap screws (D) on each side of tilt assembly.
c. Tighten cap screws to specification.
Bracket-to-Support Cap Screws Torque 30 ± 7 N·m
(22.1 ± 5.1 lb.-ft.)
d. Install control panel.

Disassemble Tilt Steering Assembly
Tilt Steering Assembly
LEGEND:
A Snap Ring
B Washer
[1] - Remove tilt steering assembly. (See Remove and Install Tilt Steering Assembly in this
Group.)
[2] - Remove snap ring (A) and backet (B).

[3] - Remove steering shaft (C) from bottom of tilt assembly.
Steering Shaft
LEGEND:
C Shaft

[4] - Remove spring (D). Remove two nuts (E), one on each side of bracket.
Tilt Steering Spring
LEGEND:
D Spring
E Nuts

[5] - Remove spring (F).
Tilt Steering Spring
LEGEND:
F Spring
G Lever
[6] - Slide lever (G) off tilt assembly.

[7] - Remove two pivot bolts (H) from tilt assembly.
Tilt Steering Pivot Bolt
LEGEND:
H Pivot Bolt

[8] - Pull back on pawl (I) and turn tilt steering assembly (J) up and out of bracket.
Tilt Steering Pawl
LEGEND:
I Pawl
J Assembly

[9] - Remove and inspect pawl (K). Replace pawl if teeth are worn or damaged.
Tilt Steering Pawl
LEGEND:
K Pawl
[10] - Inspect teeth on sector (L). If teeth are worn or broken remove nut (M) and replace
sector.

Tilt Steering Pawl Teeth
LEGEND:
L Sector Teeth
M Nut

[11] - Inspect two steering shaft bushings (N) in each end of the housing. If worn, replace
bushings.
Steering shaft Bushings
LEGEND:
N Bushings
[12] - Check threads (O) and splines on steering wheel end of shaft for wear or damage.
Check hex drive end (P) for any wear or damage. Inspect snap ring grooves for wear or
damage. Check shaft for straightness. Replace shaft if any defects are found.
Steering Shaft
LEGEND:
O Threads
P Drive End

Assemble Tilt Steering Assembly
Steering Shaft Bushing
LEGEND:
A Bushings
[1] - Install bushings (A) into housing.
[2] - Install sector gear into bracket making sure raised area (B) is properly engaged in hole.
Install cap screw and tighten nut (C).

Tilt Steering Bracket
LEGEND:
B Raised Area
C Nut
[3] - Install the pawl (D) with the offset (E) toward the housing.

Tile Steering Pawl Install
LEGEND:
D Pawl
E Offset
[4] - Hold pawl (F) out and install tilt assembly (G) into bracket.

Tilt Steering Assembly Insert Into Bracket
LEGEND:
F Pawl
G Tilt Assembly
[5] -
IMPORTANT:
Square shoulder on pivot bolt needs to be fully engaged in mating hole in

bracket.
Install a pivot bolt (H) in each side and secure with flange nut.

Tilt Steering Pivot Bolt
LEGEND:
H Pivot Bolt
[6] - Snap lever (I) into place and install spring (J).

Tilt Steering Lever and Spring
LEGEND:
I Lever
J Spring

[7] - Install spring (K).
LEGEND:
K Spring

[8] - Install steering shaft (L).
Steering Shaft
LEGEND:
L Shaft

[9] - Install bracket (M) and snap ring (N).
LEGEND:
M Bracket
N Snap Ring
[10] -
IMPORTANT:
Verify function of mechanism prior to install. Tilt lever must seat on its own
when released.
Install tilt steering assembly. (See Remove and Install Tilt Steering Assembly in this Group.)

Remove Steering Control Unit (SCU)
Steering Control Unit Hydraulic Lines

Steering Control Unit Bolts
LEGEND:
A Hydraulic Lines
B Cap Screws
[1] - Remove the steering wheel. (See Remove and Install Steering Wheel in this Group.)
[2] - Remove the control panel. (See Remove Control Panel in Section 90, Group 15.)
[3] - Place clean shop rags around the hydraulic lines under the SCU to absorb hydraulic fluid
that may escape when lines are disconnected. Label and remove the four hydraulic lines (A).
[4] - Remove four cap screws (B) and remove the SCU from the machine.

Install Steering Control Unit (SCU)
[1] - Check that O-rings are installed on port fittings. Replace any missing or damaged O-
rings.
[2] -
→NOTE:
Unevenly or improperly torquing cap screws attaching SCU to machine can

result in distortion of the valve body, and premature failure of the SCU.
Install the SCU to the machine, securing with four cap screws, removed earlier. Tighten to
specification.
SCU Mounting Cap Scerws Torque 15 N·m
(133 lb.-in.)
[3] - Install the hydraulic lines to the adapter fittings and tighten to specification.
Specifications
SCU Adaptor Fittings Torque 14—19 N·m
(124—168 lb.-in.)
(142 lb.-in.)
(27.3 lb.-ft.)
[4] - Install the control panel.
[5] - Install steering wheel. (See Remove and Install Steering Wheel in this Group.)
[6] - Fill the hydraulic system to the proper level; bleed the system if required.

Remove and Install Tie Rod
Tie Rod Ends
LEGEND:
A Castle Nuts
[1] - Remove cotter pins from castle nuts (A) and remove castle nuts.
[2] - Using a tie rod end separator, remove tie rod ends from spindles.
[3] - Inspect tie rod end boots. If necessary, replace boots.

Section 60 - STEERING AND BRAKE REPAIR Group 10: Brake Repair
[4] - Install tie rods:
a. Install two castle nuts to rod ends.

b. Tighten castle nuts (A) to specification.
Tie Rod Castle Nuts Torque 25—32 N·m
(18—24 lb.-ft.)
c. Install the cotter pins. If slots in castle nuts don’t align with holes after tightening,
tighten nuts until next slot aligns.
[5] - Lubricate tie rod ends using general purpose grease.

Group 10 - Brake Repair
Specifications
Other Material
Disassemble and Inspect Brakes
Assemble Brakes
Specifications
Friction Disk Minimum Thickness 3.22 mm
(0.13 in.)
Brake Disk Minimum Thickness 2.21 mm
(0.09 in.)
Bearing Housing-to-Axle Housing cap Screws Torque 52 N·m
(38 lb.-in.)
(38 lb.-ft.)
Other Material
Number Name Use
• TY16285 (us)
• CXTY16285 (canadian) Cure Primer Remove sealant from side plate.
• PM37465 (us)
Apply to axle housing mating
surfaces.

Disassemble and Inspect Brakes
Bearing Housing
LEGEND:
A Shim Washer
B Bearing Housing
C Flange-Head Cap Screws, M10 x 35 (3 used)
[1] - Remove right-hand rear axle housing and side plate assembly. (See procedure in

[2] -
→NOTE:
A shim washer is installed between the bevel ring gear pinion bearing and
the bearing housing. Retain and set aside the shim for installation at
reassembly to maintain proper gear backlash.
Remove and set aside shim washer (A) between bevel ring gear and bearing housing (B).
[3] - Remove flange-head cap screws (C) and bearing housing.
[4] -
Brake Disks

Brake Actuating Plate
LEGEND:
D Friction Disks
E Brake Disks
F Actuating Plate
G Balls
H Brake Cam
I Snap Ring
Remove three pairs of friction disks (D) and brake disks (E).
[5] - Measure friction disk thickness. Replace disks if near or under minimum specified
Friction Disk Minimum Thickness 3.22 mm
(0.13 in.)

[6] - Inspect brake disk and actuating plate (F) for damage. Replace any plates that are not
flat or that show abnormal wear or discoloration.
Brake Disk Minimum Thickness 2.21 mm
(0.09 in.)
[7] - Remove brake actuating plate. Inspect balls (G) and ball ramps in plate for wear or
damage.
[8] - Inspect contact area on brake cam (H) and actuating arm for excessive wear.
[9] - Remove snap ring (I), washer and cam shaft.
[10] - Remove sealant from side plate.
Number Name Use

• TY16285 (us)
• CXTY16285 (canadian) Cure Primer Remove sealant from side plate.
[11] - Replace parts as necessary.

Assemble Brakes
[1] -
Brake Cam Shaft
LEGEND:
A Cam Shaft
B Actuator Balls (3 used)
Lubricate new O-ring with clean hydraulic oil and install to brake cam shaft (A).
[2] - Lubricate housing bore with clean hydraulic oil and install cam shaft to axle housing
side cover. Fasten with washer and snap ring.
[3] - Install three brake actuator balls (B) to side plate.

[4] -
Brake Actuator Plate
LEGEND:
C Actuator Plate
D Friction Disk
E Brake Disk
Install brake actuator plate (C), with actuator arm contacting and parallel to cam (brake
released position).
[5] - Install friction disk (D) centered on actuator plate.
[6] - Install brake disk (E) to notches in brake housing.
[7] - Install two additional pairs of friction and brake disks.

[8] -
Gear Pinion Shaft
LEGEND:
F Bevel Gear Pinion Shaft
Temporarily insert bevel gear pinion shaft (F) to center and align brake friction disks.
[9] -

Bevel Gear Bearing Housing
LEGEND:
G Bearing Housing
H Cap Screw, M10 x 35 (3 used)
I Bearing Assembly
Install bevel gear bearing housing (G) and three M10 x 35 cap screws (H). Leave loose.
[10] - Install bevel gear and bearing assembly (I) to bevel gear shaft and insert into bearing
housing and brake disks.
[11] - Tighten bearing housing cap screws (H) to specification.
Bearing Housing-to-Axle Housing cap Screws Torque 52 N·m
(38 lb.-in.)

[12] - Rotate brake cam shaft to move brake disks to applied position. Check for brake hold
with bevel gear shaft assembly.
[13] - Hold outer hex of brake cam shaft in applied position with wrench to hold brake disks
in alignment. Remove bevel gear assembly and reinstall to gear case.
[14] -
Housing
LEGEND:
J Dowels
K Bore Surface
L Mounting Flange
Ensure that two locating dowels (J) are installed to housing.
[15] - Apply grease to bearing housing bore surface (K) to retain backlash shim.

HYDRAULICS REPAIR (g) by Belgreen
[16] - Apply Form-in-Place gasket maker to housing mounting flange (L).
Number Name Use

• PM37465 (us)
Apply to axle housing mating
surfaces.
[17] -
→NOTE:
If necessary, rotate the bevel gear pinion shaft to align it to the brake disk
splines when installing the axle housing to the gear case.
Install housing to gear case. Install and tighten cap screws to specification.
(38 lb.-ft.)
[18] -
IMPORTANT:
Install suction manifold and suction screen. Make sure the oil suction screen is properly
aligned to the side cover during installation. (See Remove and Install Oil Suction Screen in

Section 70 - HYDRAULICS REPAIR
Table of contents
Group 05 - Hydraulic Pump and Filter .................................................................................... 2
Specifications ......................................................................................................................... 2
Remove and Install Hydraulic Pump ....................................................................................... 3
Disassemble and Inspect Hydraulic Pump .............................................................................. 7
Assemble Hydraulic Pump .................................................................................................... 15
Remove and Install Oil Suction Screen ................................................................................. 19
Remove PTO Valve ............................................................................................................... 26
Install PTO Valve .................................................................................................................. 28
Group 10 - Rockshaft .............................................................................................................. 30
Specifications ....................................................................................................................... 31
Other Material ...................................................................................................................... 31
Remove Rockshaft Housing ................................................................................................. 32
Install Rockshaft Housing ..................................................................................................... 36
Disassemble Rockshaft ........................................................................................................ 44
Assemble Rockshaft ............................................................................................................. 52
1025R Disassemble Rockshaft Position Feedback ............................................................... 63
1025R Assemble Rockshaft Position Feedback .................................................................... 68
Group 15 - Selective Control Valve ....................................................................................... 75
Specifications ....................................................................................................................... 75
Remove and Install Selective Control Valve (SCV) ............................................................... 76
Inspect Selective Control Valve (SCV) .................................................................................. 79

Section 70 - HYDRAULICS REPAIR Group 05: Hydraulic Pump and Filter
Group 05 - Hydraulic Pump and Filter
Specifications
Remove and Install Hydraulic Pump
Disassemble and Inspect Hydraulic Pump
Assemble Hydraulic Pump
Remove and Install Oil Suction Screen
Remove PTO Valve
Install PTO Valve
Specifications
Hydraulic Pump to Cover Bolts Torque 28 N·m
(20 lb.-ft.)
Suction Pipe-to-Pump Bolts Torque 11 N·m
(97 lb.-in.)
Hydraulic Line Nuts Torque 50 N·m
(37 lb.-ft.)
Hydraulic Pump Cover Cap Screws Torque 15 N·m
(133 lb.-in.)
Suction Manifold Bolt Torque 28 N·m
(248 lb.-in.)
Wheel Bolts Torque 120 N·m
(89 lb.-ft.)
Pipe Nuts Torque 24 N·m
(160 lb.-in.)

Remove and Install Hydraulic Pump
Suction Pipe and Hydraulic Pump
LEGEND:
A Hex Bolts
[2] -
→NOTE:
Drain transmission oil into a suitable container.
[3] - Remove three hex bolts (A) securing oil suction pipe to pump.

[4] - Disconnect fittings (B) securing pipe at pump outlet and at PTO valve body.
Hydraulic Line Nuts
LEGEND:
B Fittings

[5] - Remove two M8x80 hex bolts (C).
Hydraulic Pump Bolts
LEGEND:
C M8x80 Hex Bolts
D M8x30 Hex Bolts
[6] - Remove two M8x30 hex bolts (D) securing hydraulic pump. Remove pump being careful
to retain splined coupler.

[7] - Install hydraulic pump in reverse order of removal.
a. Tighten hydraulic pump bolts to specification.

Hydraulic Pump to Cover Bolts Torque 28 N·m
(20 lb.-ft.)
b. Tighten suction pipe to pump bolts to specification.

(97 lb.-in.)
c. Tighten hydraulic line nuts to specification.

Hydraulic Line Nuts Torque 50 N·m
(37 lb.-ft.)

Disassemble and Inspect Hydraulic Pump
→NOTE:
Repair parts are not available separately for the hydraulic pump. If any
wear or damage is found during inspection, replace hydraulic pump.
Hydraulic Pump Cover Cap Screws
LEGEND:
A Cap Screws
[1] - Remove pump from transmission. (See Remove and Install Hydraulic Pump in this
Group.)
[2] - Mark front and rear covers as well as pump body, to aid in reassembly

[3] - Remove four remaining cap screws (A) securing pump cover to pump body.
[4] -
→NOTE:
O-rings may stay in housing or stick to covers.
Remove rear pump cover (B).
Hydraulic Pump Rear Cover
LEGEND:
B Cover
C Formed O-ring
[5] - Remove formed O-ring (C).

[6] - Remove front cover (D) and formed O-ring (E).
Hydraulic Pump Front Cover
LEGEND:
D Cover
E Formed O-ring
[7] - If O-ring (F) is still in housing, remove O-ring. Remove seals (G) from bushing assembly.

Hydraulic Pump Housing and Seals
LEGEND:
F O-ring
G Seals

[8] - Remove bushing assembly (H).
Hydraulic Pump Bushing Assembly
LEGEND:
H Bushing Assembly

[9] - Remove pump drive gear (I) and idler gear (J).
Hydraulic Pump Gears
LEGEND:
I Drive Gear
J Idler Gear
K Shaft Splines
[10] - Inspect gear faces for wear.
[11] - Inspect drive gear shaft splines (K).
[12] - Inspect idler gear and drive gear shaft bearing surfaces.

[13] - Inspect all bushings (L) in both bushing assemblies.
Hydraulic Pump Bushings
LEGEND:
L Bushings
M Internal Surfaces
[14] - Inspect pump body internal surfaces (M) for scoring or excessive scratching.

[15] - Inspect seal (N) for wear.
Hydraulic Pump Seal
LEGEND:
N Seal
[16] - If any parts are worn or damaged, replace hydraulic pump.

Assemble Hydraulic Pump
LEGEND:
A Bushing Assembly
B Idler Gear
C Drive Gear
[1] - Install bushing assembly (A) into pump body.
[2] - Install idler gear (B) and drive gear (C) into pump body.

[3] - Install bushing assembly (D).
LEGEND:
D Bushing Assembly
[4] - Install seals (E) and O-ring (F) into both bushing assemblies.

Hydraulic Pump Seals and O-ring
LEGEND:
E Seals
F O-ring

[5] - Install front and rear pump covers on pump body. Secure with four cap screws (G).
Tighten to specification.
Hydraulic Pump Cover Cap Screws Torque 15 N·m
(133 lb.-in.)
Hydraulic Pump Cover Cap Screws
LEGEND:
G Cap Screws

Remove and Install Oil Suction Screen
Rear Tire Removal
LEGEND:
A Transmission
[2] -
CAUTION:
The machine can fall or slip from an unsafe lifting device or supports. Use
a safe lifting device rated for the load to be lifted. Lower machine onto
jack stands or other stable supports and block wheels before servicing.

Raise rear of machine and remove left rear tire.
[3] - Lower machine onto jack stand under left side of transmission (A)
[4] -
→NOTE:
Place a drain pan under left side of transmission. Drain transmission.

[5] - Raise bottom hose clamp (B), and lower top hose clamp (C) onto hose (D).
Suction Filter Removal
LEGEND:
B Lower Hose Clamp
C Upper Hose Clamp
D Hose
E Suction Pipe
F Lower Manifold
[6] - Remove hose (D) from suction pipe (E) and lower manifold (F).

[7] - Remove bolt (G) securing lower manifold to transmission case.
Suction Screen Removal
LEGEND:
F Lower Manifold
G Bolt
H Suction Screen
[8] -
→NOTE:
If suction screen does not come out with the lower manifold, reach in and
remove screen from transmission. Be certain all O-rings remain on
assemblies. Inspect O-rings and replace as necessary.
Remove lower manifold (F) and suction screen (H).

[9] - Clean the suction screen (H).
Suction Screen and Magnets
LEGEND:
H Suction Screen
I Magnets
[10] -
→NOTE:
Depending upon your machine, you may have one, two, or four magnets in
screen.
Remove the magnet(s) (I) from the screen. Clean magnet(s) and install into screen.

[11] - Lubricate and install suction screen to lower manifold. Make sure that screen is fitted
straight into elbow to aide proper alignment to transmission opposite side cover.
Suction Screen Proper Alignment
[12] -
IMPORTANT:
Install screen assembly to transmission. Make sure that end of screen fits into socket inside
transmission right side cover.
[13] -
→NOTE:
If upper suction pipe (E) was removed from hydraulic pump replace O-ring
and before installing pipe. Tighten bolts to specification.

Install bolt (G). Tighten bolt to specification.
Suction Manifold Bolt Torque 28 N·m
(248 lb.-in.)
(97 lb.-in.)
[14] - Install hose (D) onto suction pipe (E) and lower manifold (F). Secure hose with upper
clamp (C) and lower clamp (B).
[15] - Install left wheel onto machine. Tighten wheel bolts to specification.
Wheel Bolts Torque 120 N·m
(89 lb.-ft.)
[16] - Raise machine and remove jack stand. Lower machine.
[17] - Fill transmission with oil. Check for proper oil level.

Remove PTO Valve
PTO Valve Remove
LEGEND:
A Harness connector
B PTO Selector
C Nut
D Nuts
E Bolts
[2] - Raise and safely support rear axle.
[3] - Remove left rear wheel.
[4] - Remove wire harness connector (A) from PTO valve solenoid.
[5] - Shift MBR PTO selector (B) to rearmost position.

[6] - Remove nut (C) securing pipe to valve body elbow.
[7] - Remove nuts (D) securing pipes to valve body fittings.
[8] - Remove two bolts (E) securing valve body to transmission case.
[9] - Remove PTO valve.

Install PTO Valve
PTO Valve Install
LEGEND:
A Bolts
B Nuts
C Nut
D Harness Connector
[1] -
→NOTE:
Make sure that all O-rings are in place when installing the valve body and
hydraulic pipes.
Install O-rings at transmission case PTO passages.
[2] - Install PTO valve and secure with two bolts (A).
[3] - Make sure that O-rings are in place at valve fittings.

Section 70 - HYDRAULICS REPAIR Group 10: Rockshaft
[4] - Install hydraulic pipe nuts (B) to valve fittings. Tighten to specification.
Pipe Nuts Torque 24 N·m
(160 lb.-in.)
[5] - Install hydraulic pipe nut (C) to valve elbow fitting. Tighten to specification.
Pipe Nut Torque 24 N·m
(160 lb.-in.)
[6] - Install wire harness connector (D) to solenoid.
[7] - Install rear wheel. (See “Remove and Install Rear Wheels” in Section 80, Group 10.)

Group 10 - Rockshaft
Specifications
Other Material
Install Rockshaft Housing
Disassemble Rockshaft
Assemble Rockshaft
1025R Disassemble Rockshaft Position Feedback
1025R Assemble Rockshaft Position Feedback

Specifications
Rockshaft Housing-to-Transmission Bolts Torque 55 N·m
(40 lb.-ft.)
Hydraulic Pipe Fittings Torque 50 N·m
(37 lb.-ft.)
Rockshaft Cross-Brace Bolts Torque 80 N·m
(60 lb.-ft.)
Rockshaft Bushing Insertion Depth 6.4 mm
(0.25 in.)
Rockshaft Relief Valves Torque 37 N·m
(27 lb.-ft.)
Valve Stem Nut Torque 55 N·m
(40 lb.-ft.)
Feedback Housing-to-Rockshaft Housing Torque 47 N·m
(39 lb.-ft.)
Feedback Valve-to-Housing Torque 40 N·m
(30 lb.-ft.)
Feedback Housing Cover Bolts Torque 28 N·m
(20 lb.-ft.)
Control Arm Lock Nut Torque 55 N·m
(40 lb.-ft.)
Seat Mounting Bracket Front Bolts Torque 55 ±11 N·m
(40.5 ± 8 lb.-ft.)
Clearance Specification
Rockshaft Lift Arms to ROPS Cross-Brace Clearance (minimum) 25 mm
(1 in.)
Other Material
Number Name Use
• PM37465 (us)
• PM38628 Apply to mating surfaces of rockshaft housing
(canadian) Form-in-Place Gasket and transmission, and rockshaft housing and
• RTV Blue Loctite ™ feedback position housing.
(loctite)

Seat Base Rear Bolts
LEGEND:
A Bolts
[2] - Remove seat. (See Remove Seat in Section 90, Group 05.)
[3] - Remove left and right closeout panels.
[4] - Remove right fender. (See Remove Right Fender in Section 90, Group 20.)
[5] - Remove left fender, fuel tank, and support. (See Remove Left Fender and Fuel Tank in
[6] - Remove lift links from rockshaft arms.

[7] - Remove two front bolts, and two bolts (A) securing rear seat base. Remove seat base.
(See Remove Seat Base in Section 90, Group 05.)
[8] - Remove two hex bolts (B) and two hex bolts (C) with lock washers and hex nuts
securing ROPS brace. Remove brace.
ROPS Brace
LEGEND:
B Hex Bolts
C Hex Bolts

[9] - Disconnect hydraulic supply pipe fittings (D) from pump and PTO valve. Disconnect
hydraulic return pipe fitting (E).
Hydraulic Supply Pipe
LEGEND:
D Supply Pipe Fittings
E Return Pipe Fitting
[10] - Clean area around rockshaft housing to prevent entry of debris into transmission.

[11] - Remove eight hex bolts (F) securing rockshaft housing to transmission.
Rockshaft Bolts
LEGEND:
F Hex Bolts
[12] -
IMPORTANT:
Avoid damage to rockshaft. Lift rockshaft straight up to clear dowel pins.

Do not pry or rock to either side to remove.
Use a suitable lifting device to lift rockshaft housing from transmission.

Install Rockshaft Housing
PTO Clutch Tang Position
LEGEND:
A PTO Clutch Tang
B Case Housing Stop
IMPORTANT:
To avoid interference damage make sure tang rests on housing stop.
Before starting rockshaft installation rotate installed clutch assembly so that PTO brake
reaction tang (A) rests on gear case housing stop (B).

[1] - Clean transmission mating surface and apply a bead of form-in-place gasket.
Number Name Use

• PM37465 (us)
• PM38628 (canadian) Apply to mating surfaces of rockshaft
• RTV Blue Loctite ™ housing and transmission.
(loctite)
Rockshaft Mounting Bolts
LEGEND:
A Hex Bolts
B Hex Bolts
[2] - Align rockshaft housing and transmission dowel pins. Install housing to transmission.
[3] - Install M10x85 hex bolts (A) and M10x50 hex bolts (B) securing housing to transmission.
Tighten bolts in a cross pattern from center to specification.
Rockshaft Housing-to-Transmission Bolts Torque 55 N·m
(40 lb.-ft.)

[4] - Install hydraulic pipe nut (C) to rockshaft housing fitting and tighten to specification.
Hydraulic Supply Pipe
LEGEND:
C Pipe Nut
D Pipe Fittings
[5] - Install hydraulic supply pipe fittings (D) to pump and PTO valve and tighten to
specification.
Hydraulic Pipe Fittings Torque 50 N·m
(37 lb.-ft.)

[6] - Install ROPS cross-brace and bracket to rockshaft housing and secure with two M16x40
hex bolts (E) and two M10x70 hex bolts (F) with hex flange nuts.
ROPS Cross Brace Bolts
LEGEND:
E Hex Bolts
F Hex Bolts
Rockshaft Cross-Brace Bolts Torque 80 N·m
(60 lb.-ft.)
[7] -
IMPORTANT:
Minimum clearance must be present.
Raise rockshaft lift arms and check clearance between lift arms and cross-brace. If minimum
clearance is not present, loosen cross-brace hardware and adjust until clearance is achieved.
Tighten hardware to specification.

Rockshaft Lift Arm to Cross-Brace Clearance (minimum) 25 mm
(1 in.)
[8] - Install rear seat mounting bracket to rockshaft housing and secure with two M8x25 hex
bolts (G).
Seat Mounting Rear Bracket
LEGEND:
G Hex Bolts

[9] - Install front seat mounting bracket and secure with two M10x30 hex bolts (H). Secure
wire harness clamp (I) with right bolt.
Seat Mounting Front Bracket Bolts Torque 55 ±11 N·m
(40.5 ± 8 lb.-ft.)
Seat Mounting Front Bracket
LEGEND:
H Hex Bolts
I Harness Clamp

[10] - Install left fender and fuel tank support bracket to front seat bracket and secure with
two M8x20 hex bolts (J) and hex nuts. (See Install Left Fender and Fuel Tank in Section 90,
Group 20.)
Hex Bolts
LEGEND:
J Hex Bolts
K Hex Nut
[11] - Install fuel tank. Insert mounting stud through support bracket and secure with M10
hex nut (K).
[12] - Install right fender. (See Install Right Fender in Section 90, Group 20.)
[13] - Install seat base and seat. (See Install Seat Base ” and “ Install Seat in Section 90,
Group 05.)
[14] - Install center closeout panel. (See Remove and Install Center Closeout Panel in Section
90, Group 15.)
[15] - Install left and right closeout panels (Model 1025R).

[16] -
→NOTE:
1023E does not have removable knob.
Install rate of drop/stop valve handle to shaft and secure with set screw. Adjust control to
slow setting.
[17] - Install lift links to rockshaft arms.

Disassemble Rockshaft
Rockshaft Lift Arms
LEGEND:
A Snap Rings
B Locking Pin
[1] - Remove snap rings (A) securing lift arms to rockshaft.
[2] - Remove locking pin (B) and flat washer securing position feedback rod (if so equipped).
[3] - Remove lift arms from rockshaft.

[4] - Ensure that right side rockshaft is clean. Hold internal arm (C) and tap rockshaft from
housing.
Rockshaft Internal Arm
LEGEND:
C Internal Arm
[5] - Remove arm and attached pushrod from housing.
[6] -
CAUTION:
Use low-pressure air and loosely seal the air nozzle to the port when
removing the rockshaft piston. Do not place your hand in the rockshaft
housing while low-pressure air is applied.
Remove pressure relief valve from housing port (D). Loosely seal air nozzle to relief port, and
inject low-pressure air to remove piston (E) from housing.

Rockshaft Piston Removal
LEGEND:
D Port
E Piston
[7] - Inspect piston and cylinder surfaces for damage.

[8] - Inspect rockshaft bushings (F) for wear or damage. Remove bushings if replacement is
needed.
Rockshaft Bushings
LEGEND:
F Bushings

[9] - Remove nut (G) and rate of drop/stop valve control shaft.
Model 1026R Shown (1023E Similar)
LEGEND:
G Nut

[10] - Thread a M4 screw (H) with washer into rate of drop/stop valve. Remove valve from
bore.
Rockshaft Load Control Valve
LEGEND:
H Screw

[11] - Inspect valve seals. Replace O-ring (I) and seals (J) and (K).
Rockshaft Load Control Valve Components
LEGEND:
I O-ring
J Seal
K Seal

[12] - Remove relief valves (L and M).
1026R Rockshaft Relief Valves (1023E Similar)
LEGEND:
L Relief Valve
M Relief Valve
[13] - Inspect relief valves for damaged components.

Assemble Rockshaft
Rockshaft Bushing Depth
LEGEND:
A Bushings
B Depth
[1] - Insert new rockshaft bushing(s) (A) if removed. Press bushings to a depth (B) of 6.4 mm
(0.25 in.) below outer edge of rockshaft bores.
Rockshaft Bushing Insertion Depth 6.4 mm
(0.25 in.)

[2] - Install new O-ring (C) and seal (D) to piston .
Rockshaft Piston, O-ring, and Seal
LEGEND:
C O-ring
D Seal
[3] -
→NOTE:
Fully open the rate of drop/stop valve or remove the pressure relief valve
to allow air trapped behind the piston to escape.
Lubricate piston assembly (E) and rockshaft housing bore. Install piston to bore, pushing
piston below bottom of bore.

Rockshaft Piston Install
LEGEND:
E Piston assembly
[4] - Lubricate end of cylinder rod (F). Place rod and arm inside rockshaft housing, with rod
inserted into piston.

Rockshaft Cylinder Rod
LEGEND:
F Cylinder Rod
G Alignment Marks
[5] - Lubricate rockshaft and housing bushings.
[6] - Partially install rockshaft through left side of housing and into internal arm.
[7] - Match alignment marks (G) to index arm and rockshaft. Install shaft through arm and
opposite shaft bushing.
[8] - Reinstall relief valve if removed for piston installation.

[9] - Install O-ring (H) to left and right sides of shaft. Press O-rings into housing bores.
Rockshaft Lift Arm O-ring
LEGEND:
H O-Ring

[10] - Install flat washers (I) to left and right side of rockshaft.
Rockshaft Lift Arm Install
LEGEND:
I Flat Washers
J Alignment Marks
K Snap Rings
[11] - Install left and right rockshaft arms to shaft with alignment marks (J) matched.
[12] - Secure arms with snap rings (K). Install left snap ring to inner rockshaft groove.

[13] - 1025R Only: Install position feedback rod (L) to feedback control linkage if so
equipped. Secure rod with washer and secure pin.
1025R Rockshaft Feedback Rod
LEGEND:
L Feedback Rod
[14] - Install relief valves (M and N). Tighten to specification.

1025R Rockshaft Relief Valves (1023E Similar)
LEGEND:
M Relief Valve
N Relief Valve
Rockshaft Relief Valves Torque 37 N·m
(27 lb.-ft.)

[15] - Lubricate Rockshaft control valve (O) with hydraulic oil and insert valve into bore.
Rockshaft Control Valve Install
LEGEND:
O Rockshaft Control Valve

[16] - Install new O-ring (P) to rate of drop/stop valve stem nut.
Rockshaft Control Valve Stem (1025R Shown)
LEGEND:
P O-Ring
Q Stop
[17] - Hold nut and turn valve stem until nut is located next to stop (Q).
[18] - Install Rockshaft Control valve stem to housing and tighten valve nut to specification.

Rockshaft Control Valve Stem
Valve Stem Nut Torque 55 N·m
(40 lb.-ft.)

1025R Disassemble Rockshaft Position Feedback
Rockshaft Feedback Link
LEGEND:
A Pin
B Lock Nut
[2] - Raise rear of machine and remove right rear wheel assembly. Safely support rear axle.
[3] - Remove right fender cover and fender.
[4] - Remove secure pin (A) and washer securing rockshaft feedback link to housing arm.
Remove link from arm.
[5] - Remove hex lock nut (B) securing rockshaft control lever and arm from shaft. Remove
arm from shaft. Reinstall nut to shaft to retain washers.

[6] - Remove seven hex bolts (C) securing feedback valve cover. Remove cover.
Feedback Valve Cover
LEGEND:
C Hex Bolts

[7] - Remove three hex socket bolts (D) securing feedback valve to housing. Remove valve.
Feedback Valve Bolts
LEGEND:
D Socket Bolts

[8] - Remove five hex socket head bolts (E) securing housing to transmission. Remove
housing.
Feedback Valve Housing Bolts
LEGEND:
E Socket Head Bolts

[9] - Remove two O-rings (F).
Feedback Valve O-rings
LEGEND:
F O-rings
[10] - Remove sealant from valve and rockshaft housing surfaces.

1025R Assemble Rockshaft Position Feedback
Feedback Housing O-rings
LEGEND:
A O-rings
B Surface
[1] - Replace two O-rings (A).
[2] - Apply a thin bead of Form-in-Place gasket maker to joining surface (B).
Number Name Use

• TY15130 (us)
Apply to mating surfaces of feedback
• NA (canadian) Form-in-Place Gasket
position housing and rockshaft housing.

[3] - Install feedback valve housing and secure with five M8x25 hex socket head bolts (C).
Tighten bolts to specification.
Feedback Valve Housing Bolts
LEGEND:
C Socket Head Bolts
D O-Rings
Feedback Housing-to-Rockshaft Housing Torque 47 N·m
(39 lb.-ft.)
[4] - Install two new O-rings (D).

[5] - Install new O-ring (E) on feedback valve.
Feedback Valve O-ring
LEGEND:
E O-Ring
[6] - Install feedback valve and secure with three M8x20 hex socket bolts (F). Tighten bolts
to specification.

Feedback Valve Mounting Bolts
LEGEND:
F Hex Socket Bolts
G Dowel Pins (2 used)
Feedback Valve-to-Housing Torque 40 N·m
(30 lb.-ft.)
[7] - Install dowel pins (G) to two housing locations.
[8] - Install new gasket over dowel pins.

[9] - Install feedback housing cover and secure with two M8x50 hex bolts (H) and five M8x65
hex bolts (I). Tighten bolts to specification.
Feedback Housing Cover
LEGEND:
H Hex Bolts
I Hex Bolts
Feedback Housing Cover Bolts Torque 28 N·m
(20 lb.-ft.)
[10] - Install control arm stop (J) to shaft, aligning control shaft key to arm hub.

Rockshaft feedback Control Arm
Friction Washer Stack
LEGEND:
J Stop
K Friction Washers
L Control Arm Marks

Section 70 - HYDRAULICS REPAIR Group 15: Selective Control Valve
[11] - Install four friction washers (K) to shaft in a double opposed stack.
[12] - Align feedback shaft and control arm marks (L) and install arm to shaft splines.
[13] - Secure rockshaft control arm with hex lock nut (M) and tighten to specification. Check
that the control arm operates smoothly, and maintains its setting when traveling over rough
terrain. Adjust the nut as necessary.
Rockshaft Control Arm
LEGEND:
M Lock Nut
N Spring Pin
Control Arm Lock Nut Torque 55 N·m
(40 lb.-ft.)
[14] - Install feedback link to control arm and secure with washer and spring pin (N).

Group 15 - Selective Control Valve
Specifications
Remove and Install Selective Control Valve (SCV)
Inspect Selective Control Valve (SCV)
Specifications
SCV-to-Bracket Cap Screws Torque 27 N·m
(240 lb.-in.)

Remove and Install Selective Control Valve (SCV)
SCV Front Hydraulic Lines
LEGEND:
A Hydraulic Lines
[2] - Operate SCV lever in all positions to relieve any hydraulic pressure. Lower any
suspended attachments to ground so that no hydraulic pressure is released when
disconnecting hydraulic lines.
[3] - Remove right fender. (See Remove Right Fender in Group 90, Section 20.)
[4] - Disconnect four hydraulic lines (A) from front of SCV.

[5] - Disconnect three hydraulic lines (B) from back of SCV.
SCV Rear Hydraulic Lines
LEGEND:
B Hydraulic Lines

[6] - Remove three cap screws (C) securing SCV to bracket.
SCV Cap Screws
LEGEND:
C Cap Screws
[7] - Remove SCV with control linkage as an assembly.
[8] - Installation is the reverse of removal.
a. Replace all O-rings on SCV fittings.

b. Tighten cap screws securing SCV to bracket to specification.
SCV-to-Bracket Cap Screws Torque 27 N·m
(240 lb.-in.)

Inspect Selective Control Valve (SCV)
SCV Body and Check Valves
LEGEND:
A Check Valves
→NOTE:
The SCV valve is serviced as a complete assembly. Inspection consists of

removing check valves and relief valve to check for debris or damage. Any
other problems require SCV valve replacement.
[1] - Remove two check valve caps (A).

[2] - Remove check valves. Inspect each check valve face (B) and seat (C) inside valve body
for debris or deep scratches.
SCV Check Valve
LEGEND:
B Check Valve Face
C Seat
D Spring
E O-ring
[3] - Inspect spring (D).
[4] - Replace O-ring (E).
[5] - Remove relief valve (F) from body.

SCV Relief Valve
SCV Relief Valve Components
LEGEND:
F Relief Valve
G Cap
H Spring
I Plunger
J Seat

MISCELLANEOUS REPAIR (g) by Belgreen
[6] - Clean cap (G), spring (H), plunger (I), and seat (J) components in suitable solvent.
[7] - Inspect all components for wear, deep scratches, or breakage. Replace SCV as required.

Section 80 - MISCELLANEOUS REPAIR
Table of contents
Group 10 - Wheels ..................................................................................................................... 2
Specifications ......................................................................................................................... 2
Remove and Install Front Wheels ........................................................................................... 3
Remove and Install Rear Wheels ............................................................................................ 3
Group 15 - 3-Point Hitch ........................................................................................................... 5
Adjust 3-Point Hitch ................................................................................................................ 6
Remove and Install 3-Point Hitch ........................................................................................... 9
Group 20 - Hood ....................................................................................................................... 12
Remove and Install Hood ..................................................................................................... 13
Group 25 - Mid-Mount Lift ...................................................................................................... 16
Specifications ....................................................................................................................... 17
Remove Mid Mount Mower Draft Arm .................................................................................. 18
Install Mid Mount Mower Draft Arm ...................................................................................... 20
Remove Mid Mount Rockshaft and Lift Arm ......................................................................... 24
Install Mid Mount Rockshaft and Lift Arm ............................................................................. 31
Install Mid Mount Lift Actuator, Mechanical .......................................................................... 40
Install Mid Mount Lift Actuator, Hydraulic ............................................................................ 46
Remove Mid Mount Mower Lift Hydraulic Hose and Cylinder ............................................... 53
Install Mid Mount Mower Lift Hydraulic Cylinder and Hose ................................................... 60
Adjust Mid Mount Lift - Mechanical Lift ................................................................................. 72

Section 80 - MISCELLANEOUS REPAIR Group 10: Wheels
Group 10 - Wheels
Specifications
Remove and Install Front Wheels
Remove and Install Rear Wheels
Specifications
Lug Bolts Torque 120 N·m
(89 lb.-ft.)

Section 80 - MISCELLANEOUS REPAIR Group 10: Wheels
Remove and Install Front Wheels
[2] -
→NOTE:
If wheels are being removed to perform work on the front axle, lower
machine onto suitable stands so that machine is supported by the frame.
Loosen lug nuts before raising front axle.
[3] - Raise front of machine and lower onto support stands so that machine is supported by
the front axle.
[4] - Remove wheel lug nuts and wheel.
[5] - Install wheels in reverse order of removal.
a. Install wheels onto axle, insert and lightly tighten lug nuts.
b. Raise front of machine, remove supports and lower machine to the floor.
c. Tighten lug bolts to specification.
(89 lb.-ft.)
Remove and Install Rear Wheels
[2] -
Loosen lug nuts before raising front axle.

Section 80 - MISCELLANEOUS REPAIR Group 15: 3-Point Hitch
[3] - Raise rear of machine and lower onto support stands so that machine is supported by
the rear axle.
[4] - Remove wheel lug nuts and wheel.
[5] - Install wheels in reverse order of removal.
a. Install wheels onto axle, insert and lightly tighten lug nuts.
b. Raise rear of machine, remove supports and lower machine to the floor.
c. Tighten lug bolts to specification.
Lug Bolts Torque 120 N·m·
(89 lb.-ft.)

Group 15 - 3-Point Hitch
Adjust 3-Point Hitch
Remove and Install 3-Point Hitch

Adjust 3-Point Hitch
3-Point Hitch Center Link
LEGEND:
A Lock Nut
B Center Link
Adjust 3-point hitch links and stabilizers to position draft arms for most efficient attachment
operation or to prevent excessive lateral movement. Stabilizers should be adjusted to
position left and right draft arms the same distance from the machine centerline for PTO
operation.
[2] -
→NOTE:
There are grooves in the threaded shanks that should become visible when
they are at the end of their adjustment.

Loosen lock nut (A) and adjust center link length as required to level attachment front to rear.
Rotate center link (B) to lengthen or shorten link. Tighten lock nut.
[3] - Loosen lock nut (C) and turn right side lift link (D) as required to adjust draft arm side to
side level. Tighten lock nut.
3-Point Hitch Lift Links

3-Point Hitch Turnbuckle
LEGEND:
C Lock Nut
D Lift Link
E Stabilizers
F Ring
G Turnbuckle
[4] - Adjust left and right draft arm stabilizers (E) to limit sway when attachments is raised
for transport or to center PTO driven attachments. Adjust stabilizers to allow more movement
of draft arms for ground engaging attachments requiring greater scope of movement.
a. Remove ring (F) from drilled link.

b. Rotate turnbuckle (G) to adjust angle of draft arm.
c. Reinstall ring to link to secure stabilizer setting.

Remove and Install 3-Point Hitch
3-Point Hitch Center Link

3-Point Hitch Right Lift Link
LEGEND:
A Lock Pin
B Center Link
C Lock Pin
D Lock Pin
E Lock Pin
[2] - Remove lock pin (A) and pivot pin securing center link (B) to rockshaft housing mast.
Remove center link.
[3] - Remove lock pin (C) and remove stabilizer from pivot pin.
[4] - Rotate PTO shaft guard upward and remove lock pin (D) from pivot pin. Remove draft
arm from pin.
[5] - Support draft arm assembly. Remove lock pin (E) and pin securing lift link to rockshaft
arm. Remove assembly.

Section 80 - MISCELLANEOUS REPAIR Group 20: Hood
[6] - Remove opposite side draft arm assembly.
[7] - Return PTO shaft guard to lowered position.
[8] - Install 3-point hitch in reverse order of removal.
a. Insert pin through adjustable lift link and right side rockshaft arm. Secure pin with lock
pin (E).
b. Rotate PTO shaft guard upward. Install draft arm to inside frame pin and secure with
quick lock pin (D).
c. Install stabilizer to outside frame pin and secure with lock pin (C).
d. Install pivot pin through rockshaft housing mast and center link eye, and secure with
lock pin (A).
e. Install left side draft arm assembly.
f. Return PTO shaft guard to lowered position.

Group 20 - Hood
Remove and Install Hood

Remove and Install Hood
Hood Support Pin

Hood Hinge Rods
LEGEND:
A Support Pin
B Hinge Rod Bolts
[2] - Raise hood.
[3] - Remove spring locking clip and washer from bottom support pin (A).
[4] - Hold up hood and remove pin.
[5] - Remove bolts (B).
[6] - Raise hood while pulling hood forward until hinge rods release from hinge, remove
hood.

Section 80 - MISCELLANEOUS REPAIR Group 25: Mid-Mount Lift
[7] - Install hood:
a. Insert hood hinge rods into hinges and rotate hood up or down until flats on hinge and
hinge rods align and slide into place.
b. Install bolts (B).
c. Align holes in hood support and firewall mounted bracket, insert pin (A).
d. Install washer and spring locking clip.

Group 25 - Mid-Mount Lift
Specifications
Remove Mid Mount Mower Draft Arm
Install Mid Mount Mower Draft Arm
Remove Mid Mount Rockshaft and Lift Arm
Install Mid Mount Rockshaft and Lift Arm
Install Mid Mount Lift Actuator, Mechanical
Install Mid Mount Lift Actuator, Hydraulic
Remove Mid Mount Mower Lift Hydraulic Hose and Cylinder
Install Mid Mount Mower Lift Hydraulic Cylinder and Hose
Adjust Mid Mount Lift - Mechanical Lift

Specifications
Arm to Draft Arm Bolt Torque 37 N•m
(27 lb-ft)
Lift Strap to Lift Arm Nut Torque 140 N•m
(103 lb-ft)
Fuel Hose Retainer Nut Torque 28 N•m
(20 lb-ft)
Lift Cylinder Bracket Nut Torque 55 N•m
(40 lb-ft)
Lift Bracket Support Nut Torque 28 N•m
(20 lb-ft)
Elbow to Cylinder Nut Torque 20-28 N•m
(15-21 lb-ft)
Hydraulic Hose Support Nut Torque 55 N•m
(40 lb-ft)
Hose Retainer Nut Torque 28 N•m
(20 lb-ft)
Quick Connect to Elbow Nut Torque 20-28 N•m
(15-21 lb-ft)
Elbow to Hose End Nut Torque 20-28 N•m
(15-21 lb-ft)
Hose to Cylinder Elbow Nut Torque 20-28 N•m
(15-21 lb-ft)
Lift Strap to Lift Link Bolt Torque 40 N•m
(29.5 lb-ft)

Remove Mid Mount Mower Draft Arm
[2] - Remove mid-mount mower deck, if installed.
[3] - Disconnect AutoConnect driveshaft coupler from transmission mid PTO shaft if machine
is so equipped.
Pins
LEGEND:
A Pins
B Draft Arms
C Lift Links
[4] - Remove spring pins securing drilled pins (A). Support draft arms (B) and remove pins.
Lower draft arms.
[5] - Remove lift links (C) from rockshaft lift arms.

[6] - Remove spring locking pins and drilled pins (D) securing draft arms to frame mounting
brackets. Remove draft arm assembly.
Arms
LEGEND:
D Pins

Install Mid Mount Mower Draft Arm
→NOTE:
Orient lift link eye bolts so that bend in yoke rod is facing front of machine.
[1] - Install draft arm (A) to left side frame bracket. Secure draft arm with clevis pin (B) and
locking clip (C).
Frame
LEGEND:
A Draft Arm
B Clevis Pin
C Locking Pin
D Yoke
E Stud
F Drilled Pin
G Spring Locking Pin

[2] - Thread lift link eye bolt midway into yoke (D). Install lift link assembly to lift arm stud
(E). Secure yoke to draft arm with drilled pin (F) and spring locking pin (G).
[3] - Insert draft arm rod (H) into left draft arm with stop plate (I) positioned near draft arm.
Insert index pin (J) into draft arm hole.
Draft Arm
LEGEND:
H Draft Arm Rod
I Stop Plate
J Index Pin

[4] - Install right draft arm to frame bracket. Secure draft arm with clevis pin and locking clip.
Draft Arm Rods
LEGEND:
K Locknuts
[5] - Insert draft arm rod and index pin into right draft arm.
[6] - Secure left and right ends of draft arm rod with M12 hex locknuts (K). Tighten securely,
then loosen 1/4 turn.
[7] - Thread lift link eye bolt midway into yoke. Install lift link assembly to lift arm stud.
[8] - Insert drilled pin through yoke and draft arm. Check draft arm rod height at each end.
Remove pin and adjust eyebolt position in yoke as needed until draft arm rod is level.
[9] - Secure yoke to draft arm with drilled pin and spring locking pin.

[10] - Install AutoConnect driveshaft if so equipped.

Remove Mid Mount Rockshaft and Lift Arm
Cowl
LEGEND:
A Fasteners
[3] - Remove four fasteners (A) securing steering pedestal cowl. Remove cowl.
[4] - Raise rockshaft to unload height of cut adjuster.

[5] - Rotate height of cut adjustment control (B) to install position.
Height of Cut Adjustment
LEGEND:
B Control
C Panel
D Shoulder Bolts and Washers
[6] - Lower rockshaft to stop.
[7] - Remove draft arms. (See Remove Mid Mount Mower Draft Arm in this Section.)
[8] - Remove center closeout panel (C). (See Remove and Install Center Closeout Panel in
Group 90, Section 15.)
[9] - Remove ten hex shoulder bolts (D) and washers securing foot rest. Remove foot rest.
[10] - Remove rockshaft actuator.
a. Mechanical lift: Remove locking pin and drilled pin (E) securing lift link to rockshaft
arms. Secure lift link away from rockshaft arms
Rockshaft Arms
LEGEND:
E Pin
.
CAUTION:
Avoid Injury! Components are installed under spring tension. Wear
eye protection and use proper tools when installing and removing
components with spring tension.
Hydraulic Lift: Remove locking pin and drilled pin (F) securing hydraulic shaft to left
rockshaft lift arm. Secure hydraulic cylinder away from rockshaft lift arm.

Lift Arm
LEGEND:
F Pin

[11] - Remove snap ring (G) and washer securing left side rockshaft arm to rockshaft.
Snap Ring
LEGEND:
G Snap Ring

[12] - Move rockshaft (H) to right side, and remove left rockshaft arm. Retain shaft key.
Rockshaft
LEGEND:
H Rockshaft
[13] - Remove snap ring and washer securing right side rockshaft arm to rockshaft.
[14] - Remove right rockshaft arm. Retain shaft key.

[15] - Remove rockshaft bushings (I) from machine frame.
Bushing
LEGEND:
I Bushing
J Shaft Brackets
[16] - Rotate rockshaft so that shaft brackets (J) clear obstructions. Move rockshaft to right
side of frame until left end clears frame. Remove rockshaft from frame.

Install Mid Mount Rockshaft and Lift Arm
Pedestal
LEGEND:
A Fasteners

[3] - Rotate height of cut adjuster control (B) to lowest (install) position. Remove control
knob.
Cut Adjuster
LEGEND:
B Control
C Panel
D Shoulder Bolts

[6] - Insert rockshaft long end through right frame hole (E).
Hole
LEGEND:
E Hole
[7] - Rotate rockshaft upward so that arms (F) clear obstructions. Insert rockshaft short end
(G) through left side frame hole.

Rockshaft
LEGEND:
F Arms
G Rockshaft End
H Bushing
[8] - Install bushings (H) over left and right rockshaft ends. Seat bushings fully in frame
openings.
[9] - Rotate shaft to place brackets in near vertical position.
CAUTION:
Avoid Injury! Components are installed under spring tension. Wear eye
protection and use proper tools when installing and removing components
with spring tension.

[10] -
→NOTE:
Install drop assist spring to foot rest bracket with long hook end down.
For hydraulic lift: install drop assist spring (I) to left mower lift arm and footrest support
bracket.
Lift
LEGEND:
I Spring
[11] - Install left mower lift arm to rockshaft.

[12] - Align arm and shaft keyway. Install key (J).
Keyway
LEGEND:
J Key

[13] - Install 38.1 mm (OD) washer (K) and snap ring (L) to shaft.
Side Lift Arm
LEGEND:
K Washer
L Snap-Ring
[14] - Install right side lift arm and key. Secure key with washer and snap ring.
[15] - Install rockshaft actuator.

Mechanical Lift
LEGEND:
M Pin
a. Mechanical lift: Insert drilled pin (M) through rockshaft arms and lift link. Secure with
locking pin.
b. Hydraulic Lift: Insert drilled pin (N) through left rockshaft lift arm and hydraulic shaft.
Secure with locking pin (O).

Hydraulic Lift
LEGEND:
N Drilled Pin
O Locking Pin
[16] - Install foot rest and secure with ten hex shoulder bolts and washers.
[17] - Install and secure steering pedestal cowl.
[18] - Install center closeout panel. (See Remove and Install Center Closeout Panel in Group
90, Section 15.)

Install Mid Mount Lift Actuator, Mechanical
[2] - Rotate height of cut adjuster to lowest (install) position.
[3] - Remove center closeout panel. (See Remove and Install Center Closeout Panel in Group
90, Section 15.)
[4] - Remove four fasteners securing steering pedestal cowl. Remove cowl.
[5] - Remove ten hex shoulder bolts securing foot rest. Remove foot rest.
[6] - Remove left fender and fuel tank. (See Remove Left Fender and Fuel Tank in Group 90,
Section 20.)

[7] - Install lift link (A) to rockshaft arms and secure with drilled pin (B) and spring locking
pin.
Brackets
LEGEND:
A Lift Link
B Drilled Pin
[8] - Position lift strap (C) to lift link and loosely secure using three 30 mm (OD) washers,
three 25.4 mm (OD) washers, and three M10x25 bolts (D).

Lift Strap
LEGEND:
C Lift Strap
D Bolts
E Snap Ring
F Dowel Pin
[9] - Remove snap ring (E) from left end of three point lift rockshaft. Retain snap ring.
[10] - Install dowel pin (F) to rockshaft lift arm.

[11] - Align dowel pin and install mid mount lift arm (G) to rockshaft. Secure arm with snap
ring.
Lift Arm
LEGEND:
G Lift Arm
H Bolt
[12] - Install a M8x30 bolt (H) securing arm to draft arm. Tighten to specification.
Arm to Draft Arm Bolt Torque 37 N•m
(27 lb-ft)
→NOTE:
Bolt must be installed in orientation shown.

[13] - Install 37 mm OD washer (I) and spacer (J) to M12x50 bolt. Install bolt through lift strap
and lift arm and secure with M12 nut (K). Tighten to specification
Lift Strap
LEGEND:
I Washer
J Spacer
K Nut
.
Lift Strap to Lift Arm Nut Torque 140 N•m
(103 lb-ft)
[14] - Ensure that wiring harness is secured away from linkage.
[15] - Adjust lift strap to lift link position. (See Adjust Mid Mount Lift - Mechanical Lift in this
Group.)

[16] - Reinstall left fender and fuel tank. (See Install Left Fender and Fuel Tank in Group 90,
Section 20.)
[17] - Reinstall foot rest, steering pedestal cowl, and center closeout panel.

Install Mid Mount Lift Actuator, Hydraulic
Cowl
LEGEND:
A Fasteners

knob.
height control
LEGEND:
B Control Adjuster
C Closeout Panel
D Bolts

[6] - Remove two M10 hex nuts and bolts (E) from left side frame.
Side Frame
LEGEND:
E Nuts

[7] - Install M8x15 carriage bolt (F) to lift cylinder bracket and secure with M8 hex nut.
Bracket
LEGEND:
F Carriage Bolt
[8] - Install lift cylinder bracket to frame with two M10x35 carriage bolts and loosely secure
with M10 hex nuts (G).

Frame
LEGEND:
G Nuts
H Nut and Carriage Bolt
[9] - Remove hex nut and carriage bolt (H) securing fuel hose retainer. Move fuel hoses
aside.

[10] - Install lift cylinder (I) to frame bracket with inlet fitting at bottom.
Lift Cylinder
LEGEND:
I Lift Cylinder
J Drilled Pin
K Drilled Pin
[11] - Install M12x100 drilled pin (J) through footrest bracket, frame bracket, and cylinder.
Secure with locking pin.
[12] - Secure fuel hose retainer to footrest bracket with carriage bolt and hex nut.
Fuel Hose Retainer Nut Torque 28 N•m
(20 lb-ft)
[13] - Secure cylinder rod to rockshaft bracket with M12x60 drilled pin (K) and locking pin.
Lift Cylinder Bracket Nut Torque 55 N•m
(40 lb-ft)

[14] - Tighten hex nuts securing lift cylinder bracket to frame.
Lift Bracket Support Nut Torque 28 N•m
(20 lb-ft)
[15] - Reinstall foot rest, steering pedestal cowl, and center closeout panel.

Remove Mid Mount Mower Lift Hydraulic Hose and

Cylinder
[2] - Adjust height of cut control to install position, and fully lower mid mount rockshaft.
Cowl
LEGEND:
A Fasteners

knob.
Adjuster Control
LEGEND:
B Height of Cut Adjuster Control
C Panel
D Bolts
[8] - Place suitable container below hydraulic lift cylinder to contain lost fluid.

[9] - Remove three tie wraps (E) securing hose to support bracket.
Support Bracket
LEGEND:
E Tie Wraps
F Fitting
[10] - Remove hose end fitting (F) from hydraulic cylinder elbow.

[11] - Retain orifice (G) installed to hose end fitting. Cover fitting to prevent entry of dirt.
Orifice
LEGEND:
G Orifice
[12] - Remove hose from foot rest bracket.

[13] - Remove two hex nuts (H) securing hose retainers to front seat rail bolts. Remove
retainers from hose.
Seat Rails
LEGEND:
H Nuts
I Opening
[14] - Withdraw hose through opening (I) between fender and SCV support bracket.

[15] - Remove fasteners (J) from two hose retainers securing hose to hydraulic pipe. Remove
hose from retainers.
Fasteners
LEGEND:
J Fasteners
[16] - Remove hose fitting from quick-connect coupler.
[17] - Remove hose.

[18] - Remove locking pin and drilled pin (K) securing cylinder rod to rockshaft arm.
Pin
LEGEND:
K Pin
L Nut
M Pin
[19] - Remove hex nut (L) securing fuel hose retainer.
[20] - Remove locking pin and drilled pin (M) securing cylinder to bracket.
[21] - Remove cylinder.

Install Mid Mount Mower Lift Hydraulic Cylinder and

Hose
[1] - Install and secure elbow fitting (A) to lift cylinder
Lift Cylinder
LEGEND:
A Elbow Fitting
.
Elbow to Cylinder Nut Torque 20-28 N•m
(15-21 lb-ft)
[2] - Push rod fully into cylinder.

[3] - Remove hex nut and carriage bolt (B) securing fuel hose retainer. Move fuel hoses
aside.
Retainer
LEGEND:
B Nut and Bolt
[4] - Install hose support to footrest bracket and frame. Secure bracket with hex stop nut (C).
Tighten nut to specification

Footrest
LEGEND:
C Stop Nut
D Lift Cylinder
E Drilled Pin
F Drilled Pin
.
Hydraulic Hose Support Nut Torque 55 N•m
(40 lb-ft)
[5] - Install lift cylinder (D) to frame brackets with inlet fitting at bottom.
[6] - Install M12x100 drilled pin (E) through footrest bracket, frame bracket, and cylinder.
Secure with locking pin.

[7] - Secure fuel hose retainer to footrest bracket with carriage bolt and hex nut.
Hose Retainer Nut Torque . 28 N•m
(20 lb-ft)
[8] - Secure cylinder rod to rockshaft bracket with M12x60 drilled pin (F) and locking pin.

[9] - Assemble fittings to 90 degree hose end. Ensure that fitting O-rings are in place.
Fitting
LEGEND:
G Quick Connect Fitting
H 90 Degree End
I Fitting Cap
a. Install quick connect fitting (G) to 90 degree elbow. Tighten fitting nut to specification.
Quick Connect to Elbow Nut Torque 20-28 N•m
(15-21 lb-ft)
b. Install elbow assembly to 90 degree hose end (H). Position elbow assembly parallel to
hose end and tighten hose end nut to specification.
Elbow to Hose End Nut Torque 20-28 N•m
(15-21 lb-ft)
[10] - Install fitting cap (I) to hose end assembly.

[11] - Install hose end fitting to bottom inside quick-connect coupler (J).
Coupler
LEGEND:
J Quick Coupler
K Retainer
[12] - Cap or otherwise cover straight hose end to prevent entry of dirt.
[13] - Install retainer (K) securing hose at bend in horizontal pipe behind quick connect
bracket. Secure retainer with M8x15 hex bolt and nut.

[14] - Install retainer securing hose to bottom of vertical pipe section (L). Secure retainer
with M8x15 hex bolt and nut.
Retainer
LEGEND:
L Vertical Pipe
[15] - Pass hose through opening (M) between inner and outer fenders and SCV support
bracket.

Pass Opening
LEGEND:
M Opening
N Retainers
[16] - Secure hose with two retainers (N) and M8 hex nuts to forward seat track bolts.

[17] - Secure hose to top of support rod with tie wraps (O) at support rod bends (three
locations).
Support Rods
LEGEND:
O Tie Wraps
P Foot Rest
Q Support Bracket
[18] - Route hose under foot rest (P) and over foot rest support bracket (Q).

[19] - Install orifice (R) to hose end fitting with O-ring facing hose.
Orifice
LEGEND:
R Orifice
→NOTE:
Ensure that O-rings are installed to the orifice and elbow fitting before
assembling the hose to the cylinder.
[20] - Form loop in hose (S). Install hose to cylinder elbow fitting, with fitting nut snug but
not tight.

Hose
LEGEND:
S Hose
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious
injury. Avoid the hazard by relieving pressure before disconnecting
hydraulic or other lines. Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from
high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the
skin must be surgically removed within a few hours or gangrene may
result. Doctors unfamiliar with this type of injury should reference a
knowledgeable medical source. Such information is available from Deere &
Company Medical Department in Moline, Illinois, U.S.A.

[21] - Bleed deck lift hydraulic system.
a. Place catch pan under cylinder hose fitting.

b. Start engine, and run at slow idle speed. Move SCV lever to fully extend cylinder rod.
c. Release SCV lever to center position when air bubbles stop and only oil flows from
fitting.
d. Stop engine, and remove key.
e. Tighten hose fitting to specification.
Hose to Cylinder Elbow Nut Torque 20-28 N•m
(15-21 lb-ft)
22.Check system for leaks.

Adjust Mid Mount Lift - Mechanical Lift
Draft Arms
LEGEND:
A Drilled Pins
B Draft Arms
[3] - Remove locking pins securing drilled pins (A). Support draft arms (B) and remove pins.
Lower draft arms.
[4] - Start engine, and raise rear rockshaft to highest position. Close rate of drop control to
hold rockshaft in raised position. Shut off engine and remove key.
[5] - Rotate height of cut adjustment control to highest position.

[6] - Remove left rear wheel. (See Remove and Install Rear Wheels in this Section.)
[7] - Loosen three hex bolts (C) securing lift strap (D) to lift link (E).
Lift Link
LEGEND:
C Hex Bolts
D Lift Strap
E Lift Link
→NOTE:
The height of cut cam must be set at the highest cut position for this
adjustment procedure.

[8] - Rotate mid mount rockshaft (F) forward so that lift arm stop (G) contacts height of cut
cam.
Rockshaft
LEGEND:
F Rockshaft
G Lift Arm Stop
[9] - Move lift strap forward to end of travel slot.
[10] - Tighten three hex bolts (C) securing lift strap to lift link to specification.
Lift Strap to Lift Link Bolt Torque 40 N·m
(29.5 lb-ft)
[11] - Secure mid mount lift links to draft arms.
[12] - Reinstall wheel.

OPERATOR′S STATION REPAIR (g) by Belgreen
[13] - Tighten lug bolts to specification.
(89 lb.-ft.)

Section 90 - OPERATOR′S STATION REPAIR
Table of contents
Group 05 - Seat and Support ................................................................................................... 2
Specifications ......................................................................................................................... 2
Remove Seat .......................................................................................................................... 2
Install Seat ............................................................................................................................. 4
Remove Seat Base ................................................................................................................. 7
Install Seat Base .................................................................................................................. 10
Group 10 - ROLL-GARD ........................................................................................................... 13
Specifications ....................................................................................................................... 13
Remove ROPS ...................................................................................................................... 14
Install ROPS .......................................................................................................................... 18
Group 15 - Operator Platform ................................................................................................ 22
Specifications ....................................................................................................................... 22
Remove Control Panel .......................................................................................................... 23
Install Control Panel ............................................................................................................. 32
Remove and Install Center Closeout Panel .......................................................................... 39
Group 20 - Fenders .................................................................................................................. 41
Remove Right Fender ........................................................................................................... 42
Install Right Fender .............................................................................................................. 47
Remove Left Fender and Fuel Tank ...................................................................................... 51
Install Left Fender and Fuel Tank ......................................................................................... 56

Section 90 - OPERATOR′S STATION REPAIR Group 05: Seat and Support
Group 05 - Seat and Support
Specifications
Remove Seat
Install Seat
Remove Seat Base
Install Seat Base
Specifications
Seat Track Mounting Hardware Torque 27 N·m
(20 lb.-ft.)
Remove Seat
Seat Switch Connector

1025R Shown, 1023E Similar
LEGEND:
A Harness Connector
B Locking Pin
[2] - Tip seat forward. Remove wire harness connector (A) from seat switch.
[3] - Pass wire harness through openings in seat platform.
[4] - Remove locking pin (B) and flat washer securing seat hinge pin. Remove hinge pin.
[5] - Remove seat assembly.

Install Seat
Seat Hinge Pin

Seat Switch Harness Connections
LEGEND:
A Hinge Pin
B Locking Pin
C Harness Connector
[1] - Position seat over seat base.
[2] - Insert hinge pin (A) through mounting tabs on seat and base.
[3] - Secure hinge pin with washer and locking pin (B).
[4] - Install wire harness connector (C) to seat switch.
[5] -
IMPORTANT:
Verify wiring harness is not damaged or hitting rockshaft casting.

Make sure that wire harness is routed so as to avoid damage during full range of motion
(forward, reverse, tipped forward).

Remove Seat Base
1025R with Suspension Shown, 1023E Similar
LEGEND:
A Hex Socket Bolts
[2] - Slide seat fully rearward, and remove two hex socket bolts (A) and nuts securing seat
tracks to front mounting bracket.

[3] - Slide seat base fully forward, and remove two hex socket bolts (B) and nuts securing
seat tracks to rear seat mounting bracket.
Hex Bolts
LEGEND:
B Socket Bolts

[4] - Remove seat mount assembly, passing seat switch wire harness through openings in
seat base.
Seat Switch Wire Connector

Install Seat Base
Seat Switch Wire Connector
[1] - Install seat switch wire harness through openings in seat base.
[2] - Align seat track mounting holes with front and rear mounting brackets.

[3] - Install two hex socket bolts (A) and nuts securing seat tracks to front mounting bracket.
Install socket head bolts far enough to allow seat to slide forward.
Seat Base Mounting Bracket
LEGEND:
A Hex Socket Bolts
[4] - Slide seat fully forward.

Section 90 - OPERATOR′S STATION REPAIR Group 10: ROLL-GARD
[5] - Install two M8x20 hex socket bolts (B) securing rear seat tracks to mounting brackets.
Seat Base Mounting Bracket
LEGEND:
B Socket Bolts
[6] - Tighten all socket head bolts and nuts to specification.
Seat Track Mounting Hardware Torque 27 N·m
(20 lb.-ft.)
90, Group 15.)

Group 10 - ROLL-GARD
Specifications
Remove ROPS
Install ROPS
Specifications
Draft Arm Pivot Pin Nut Torque 203 N·m
(150 lb.-ft.)
M12 Nuts Torque 110 N·m
(80 lb.-ft.)
M12 Bolt Torque 96 N·m
(70 lb.-ft.)
Clearance Specification
Rockshaft Lift Arms to ROPS Crossbar Clearance 25 mm
(1 in.)

Remove ROPS
CAUTION:
To maintain operator protection and ROPS certification:
Do not repair or revise the ROPS.

Discard removed ROPS hardware and replace with new hardware.
ROPS Harness

ROPS Wire Harness Connectors
LEGEND:
A Tie Wraps
B Harness Connectors
The roll-over protective structure (ROPS) should only be removed as required for machine
repair procedures. The ROPS must be reinstalled before the machine is put back into service.
[1] - Remove three point hitch draft arms and support links.
[2] - Cut tie wraps (A) securing ROPS wiring harness at bottom of left and right ROPS
uprights.
[3] - Separate ROPS wire harness connectors (B) at left and right sides. Secure ROPS wire
harness.
[4] - Safely support ROPS.

[5] - Remove hex nut (C) and draft arm pivot pin at left and right sides.
ROPS Hardware
LEGEND:
C Hex Nut
D Hex Bolts
[6] - Remove one M12 hex bolt, and three hex nuts and carriage bolts (D) securing ROPS at
left and right sides.

[7] - Remove M12 hex nuts and bolts (E) securing ROPS cross brace to rockshaft bracket.
ROPS Cross Brace
LEGEND:
E Hex Bolts
[8] - Remove ROPS from machine.

Install ROPS
ROPS Cross Brace

ROPS Hardware
LEGEND:
A Hex Bolts
B Draft Arm Pivot Pin
C Hex Bolts
CAUTION:
To maintain operator protection and ROPS certification:
Do not repair or revise the ROPS.

Discard removed ROPS hardware and replace with new hardware.
[1] - Install the ROPS to the machine frame, aligning all mounting holes.
[2] - Install two M12x35 hex bolts (A) through ROPS crossbar bracket, and loosely secure
with hex nuts.

[3] - Align flat on draft arm pivot pins (B) to ROPS mounting plate. Install pins through left
and right ROPS mounting plates, machine frame, and outside plates. Loosely secure pins with
hex nuts.
[4] - Install M12 hex bolt and three carriage bolts (C) through machine frame and ROPS
mounting plates at each side. Secure carriage bolts with nuts.
[5] - Raise rockshaft lift arms and check clearance between lift arm and crossbar.
Lift Arm Clearance
[6] - If minimum clearance is not present, adjust ROPS to attain clearance.
Rockshaft Arm to Crossbar Clearance (minimum) 25 mm
(1 in.)

Section 90 - OPERATOR′S STATION REPAIR Group 15: Operator Platform
[7] - Tighten fasteners to specification.
Draft Arm Torque

Draft Arm Pivot Pin Nut Torque 203 N·m
(150 lb.-ft.)
M12 Nuts Torque 110 N·m
(80 lb.-ft.)
M12 Bolt Torque 96 N·m
(70 lb.-ft.)

Group 15 - Operator Platform
Specifications
Remove Control Panel
Install Control Panel
Remove and Install Center Closeout Panel
Specifications
Steering Wheel Nut Torque 39—49 N·m
(29—36 lb.-ft.)

Remove Control Panel
Steering Wheel
[1] - Remove cap from steering wheel.
[2] - Remove nut securing steering wheel.
[3] - Remove steering wheel using an appropriate puller if necessary.

[4] - Remove two cap screws (A) securing instrument panel to firewall.
Instrument Panel Firewall Screws
LEGEND:
A Cap Screws
[5] - Remove four screws (B), one from each side of cowl panel and two in center.

Cowl Screws
LEGEND:
B Screws

[6] - Remove two screws (C).
Cowl Screws
LEGEND:
C Cap Screw

[7] - Pull instrument panel back 2.5-5 cm (1-2 in.) from firewall and disconnect park brake
rod (D) from handle.
Park Brake Rod
LEGEND:
D Park Brake Rod
[8] -
→NOTE:
The current model has two connectors at top and one at bottom.
Disconnect three connectors (E) from display module.

Connectors
LEGEND:
E Connectors
[9] - On right side of instrument panel, disconnect PTO switch (F) and key switch (G).

Instrument Panel Right Side Switches
LEGEND:
F PTO Switch
G Key Switch

[10] - On left side, disconnect turn signal connector (H) and headlight switch (I).
Instrument Panel Left Side Switches
LEGEND:
H Turn Signal Switch
I Headlight Switch
[11] - Lift control panel carefully, guiding throttle lever through opening.

[12] - If removing display module, remove eight screws (J).
Screws
LEGEND:
J Screws

Install Control Panel
SN —209999 shown, SN 210000— is similar
LEGEND:
A Screws
[1] - Install display module with eight screws (A).

[2] - Connect wiring harness connectors to turn signal switch (B), and light switch (C) on left
side of panel.
Switch Connectors
LEGEND:
B Turn Signal Switch
C Light Switch

[3] - Connect wiring harness connectors to PTO switch (D) and key switch (E) on right side of
panel.
Switch Connectors
LEGEND:
D PTO Switch
E Key Switch
[4] -
→NOTE:
SN 210000— has two connectors at top and one at bottom.
Connects plugs (F) to display module.

SN —209999 shown, SN 210000— is similar
LEGEND:
F Plugs
[5] - Slide park brake rod (G) into park brake handle (H).

Park Brake Rod and Handle
LEGEND:
G Rod
H Handle
[6] - Fit control panel to cowl and firewall and install screws (I).

Cowl Panel Front Screws
Cowl Panel Side Screw
LEGEND:
I Screws
J Screw

[7] - Install one screw (J) on each side of cowl.
[8] - Install screws (K) securing top of control panel to firewall.
Control Panel-to-Firewall Screws
LEGEND:
K Screws
[9] - Install steering wheel and tighten steering wheel nut to specification. Install steering
wheel cover. (See Remove and Install Steering Wheel in Section 60, Group 5.)
Steering Wheel Nut Torque 39—49 N·m
(29—36 lb.-ft.)

Remove and Install Center Closeout Panel
Center Closeout Panel
LEGEND:
A Phillips Head Screws
B Shoulder Bolts
C Height of Cut Adjustment Knob
[1] - Remove two Phillips head screws (A).
[2] - Remove two hex shoulder bolts (B).
[3] - Remove height of cut adjustment knob (C).
[4] - Remove closeout panel.

Section 90 - OPERATOR′S STATION REPAIR Group 20: Fenders
[5] - Install closeout panel.
a. Install closeout panel over rate of drop knob shaft and height of cut control shafts.
b. Loosely install two shoulder bolts (B) and two Phillips head screws (A).
c. Hold differential lock lever down and adjust closeout panel to center height of cut
adjuster shaft in control opening. Tighten fasteners (A and B) to secure panel.
d. Align height of cut adjuster knob (C) to shaft flat and install knob.

Group 20 - Fenders
Remove Right Fender
Install Right Fender
Remove Left Fender and Fuel Tank
Install Left Fender and Fuel Tank

Remove Right Fender
Right Fender Handle

Right Fender Controls Console
LEGEND:
A Shoulder Bolts
B Hex Nuts (hidden)
C Harness Connector
D Rockshaft Control Lever
Remove the right side controls console and fender for access to the SCV and right side of the
transmission.
[2] - Remove rear wheel weight(s) (if installed).
[3] - Remove right wheel. (See procedure in section 80-10.)
[4] - Remove two hex shoulder bolts (A) and flat washers securing fender to bottom bracket.
[5] - From under fender, remove two hex nuts (B) securing handle to fender bracket.
[6] - Remove wire harness connector (C) from work light (if installed).
[7] - Move rockshaft control lever (D) to middle of control slot.
[8] - Lift controls console from fender, passing rockshaft lever knob through slot.

[9] - Remove wire harness connector (E) from power port.
Power Port Connector
LEGEND:
E Harness Connector
[10] - Set controls console aside.

[11] - Remove knob (F) from SCV control lock.
SCV Control Lock
LEGEND:
F Knob

[12] - Remove five hex flange shoulder bolts (G) and flat washers securing foot rest.
Foot Rest Hardware
LEGEND:
G Shoulder Bolts
H Foot Rest
[13] - Lift fender, passing rockshaft lever and SCV lock shaft through fender slots.
[14] - Raise outer edge of foot rest (H), releasing base of fender. Remove fender.

Install Right Fender
Right Fender Controls
LEGEND:
A Wire Harness
[1] - Install fender over SCV, SCV lock, and rockshaft controls.
[2] - Arrange fender wire harness (A) along top of fender.

[3] - Lift edge of foot rest to fit fender flange under foot rest.
Right Foot Rest Bolts
LEGEND:
B Bolts
[4] - Loosely install foot rest bolts (B) and washers.

[5] - Install console cover to fender over SCV and rockshaft controls.
Right Fender Console Install
LEGEND:
C Accessory Outlet
D Notches
[6] - Connect wire harness connectors to worklight and accessory outlet (C).
[7] - Lower console cover to fender, fitting wire harness into notches (D) in underside of
cover.

[8] - Install handle (E) to fender, fitting studs through cover, fender, and support bracket.
Install and tighten two hex lock nuts.
Right Fender Console Install
LEGEND:
E Handle
F Hex Bolts
G Knob
[9] - Install two hex bolts (F) with flat washers securing fender to bottom bracket.
[10] - Install knob (G) to SCV lock shaft.
[11] - Tighten foot rest bolts until shoulder is seated. Do not overtighten.

Remove Left Fender and Fuel Tank
Fuel Filter
LEGEND:
A Fuel Shutoff Valve
Remove the left side fender and fuel tank for access to the left side of the transmission or for
repairs to the fuel tank.
[1] - Place engine fuel shutoff valve (A) in closed position.
[2] -
→NOTE:
Fuel tank capacity is 22.2 L (5.6 gal.).
Loosen hose clamp (B) at tank filter. Remove hose and drain fuel to a suitable container.

Left Fender and Fuel Lines
LEGEND:
B Hose Clamp
C Hose Clamp
[3] - Loosen hose clamp (C) and remove fuel return hose from tank fitting.
[4] - Plug fuel hoses to prevent leakage.

[5] - Separate wire harness connector (D) (if installed) and remove from retainers (E).
Harness Connectors, Left ROPS
LEGEND:
D Harness Connectors
E Retainers

[6] - Remove shoulder bolt (F) securing fender.
Remove Left Fender
LEGEND:
F Shoulder Bolt
G Bolts and Nuts
[7] - Remove two bolts (G) and nuts securing fender support bracket to quadrant.

[8] - Remove five bolts (H) and washers securing foot rest.
Foot Rest, Left Side
LEGEND:
H Hex Flange Bolts
Foot Rest
[9] - Lift outer edge of foot rest (I) and remove fender with fuel tank.

Install Left Fender and Fuel Tank
[1] - Lift foot rest outer edge (A) and insert fender flange under foot rest.
Lift Foot Rest
LEGEND:
A Edge

[2] - Insert fuel tank support bracket (B) into controls quadrant.
Bracket
LEGEND:
B Support Bracket
C Bolts
D Bolt
[3] - Align attachment holes in foot rest and fender flange.
[4] -
IMPORTANT:
Front bolt should be installed with assembly off of tractor if possible to

ease alignment and prevent possible cross-threading.
Install two hex bolts (C) and nuts securing fuel tank bracket and tighten to specification.
[5] - Install five hex bolts (D) with washers through footrest and tighten to specification.

[6] - Install hex shoulder bolts (E) with washers through footrest and tighten to specification.
Step
LEGEND:
E Bolts

[7] - Install fuel hoses to tank and filter fittings (F) and secure with clamps.
Fuel Hoses Fittings, Left Fender
LEGEND:
F Fittings

OPERATIONAL CHECKOUT PROCEDURES (g) by Belgreen
[8] - Join wire harness connectors (G), and secure harness with retainers (H).
Harness Connection, Left Side of ROPS
LEGEND:
G Connectors
H Retainers

Section 210 - OPERATIONAL CHECKOUT

PROCEDURES
Table of contents
Group 05 - Operational Checkout Procedures ...................................................................... 2
Reference ............................................................................................................................... 3
Reference ............................................................................................................................... 5
Reference ............................................................................................................................... 6
Reference ............................................................................................................................... 8
Reference ............................................................................................................................. 10
Reference ............................................................................................................................. 12
Reference ............................................................................................................................. 12
Reference ............................................................................................................................. 14
Reference ............................................................................................................................. 16

Section 210 - OPERATIONAL CHECKOUT PROCEDURES Group 05: Operational Checkout Procedures
Group 05 - Operational Checkout Procedures
System Checks
Rear Differential Lock Operational Check
PTO Operational Checks
PTO and Seat Switch Interface Check
Brakes Operational Check
Steering Preliminary Check
Steering Operational Check
Hydraulic System Operational Checks

System Checks
Reference
( 1 ) Preliminary Checks
Action:
Make the following checks before installing test equipment:
[1] - Ask Operator:
How is machine performing?

When does it malfunction?
In what applications?
[2] - Check maintenance records for:
Proper service intervals

Unusual, frequent or similar failures
[3] - If performing MFWD Preliminary Checks, check for:
Damaged or missing MFWD driveline

Other mechanical failures

[4] - Check hydraulic oil condition:
Is oil reservoir level low?
Possible causes:
Improper service intervals

External leaks
Is oil milky or dirty?
Possible causes:
Water in oil (milky)

Filter failure (dirty)
Metal particles (mechanical failure)
Is oil discolored or does it have burned odor (overheated oil)?
Possible causes:
Kinked pipes
Crushed hoses
Plugged oil cooler
Wrong oil viscosity
Internal leaks
Mechanical failure
[5] -
CAUTION:
See CAUTION about oil leak checks in Observe Safety Precautions.
Check for external oil leaks, with engine stopped and again with engine running.

Result:
YES: Go to next check.
NO: Repair as needed and return to diagnosis in process.
Rear Differential Lock Operational Check
Reference
( 1 ) Perform Rear Differential Lock Operational Check
Action:
Set engine speed to low idle. Drive tractor straight forward at slow or moderate speed.
Engage differential lock pedal and turn steering sharply in either direction.
Tractor should have tendency to go straight forward, or cause inside rear tire to slip.
Release differential lock pedal and tap brake pedal or stop and reverse direction briefly, if
necessary, to release differential lock.
Test steering again by steering sharply in either direction. Steering should return to normal.
Result:
YES: Rear differential lock is operating properly. Go to next check.
NO: Return to diagnosis in progress.

PTO Operational Checks
Reference
( 1 ) PTO Indicator Light Check
Action:
Observe PTO indicator light on instrument panel when key switch is turned to On position.
Light should come on and go off after light check cycle. Light should remain off if the PTO
switch is in the off position. It should come on if the PTO switch is placed in any other
position.
Result:
YES: Go to step 2.

( 2 ) PTO Operational Check
Action:
IMPORTANT:
Damage may occur if PTO is shifted with PTO switch in On position,

especially with implement connected.
Remove any mid or rear implements.
Start vehicle.
With engine at low idle and PTO switch in OFF position, PTO and PTO indicator light on
instrument panel should be off.
IMPORTANT:
There should be no creep of the PTO shaft.
There should be a solid detent feel when shifting PTO lever between
positions.
Place PTO lever in the REAR position.
Place PTO switch in the ON position.
PTO shaft should start rotating and PTO indicator light should be on.
Turn PTO switch Off and shift PTO lever to the MID-AND-REAR position. Place PTO switch in
ON position. The mid PTO and rear PTO shafts should start rotating.
Shift PTO lever to the MID position. The rear PTO should stop within 7 seconds and the PTO
indicator light should remain on.
Result:
YES: PTO is operating properly. Go to next check.

RIO Operational Check
Reference
( 1 ) RIO Operational Check
Action:
IMPORTANT:
Damage may occur if PTO is shifted with PTO switch in On position,

especially with implement connected.
Vehicle must have mid implement installed.
Start vehicle.
With engine at low idle and PTO switch in OFF position, PTO and PTO indicator light on
instrument panel should be off.
IMPORTANT:
There should be a solid detent feel when shifting PTO lever between
positions.
Place PTO lever in the MID position.
Place PTO switch in the ON position.
The mid PTO shaft should start rotating and PTO indicator light should be on.
Hold PTO switch in up position.
IMPORTANT:
Observe PTO indicator light on instrument panel. Light should flash while in
reverse motion.
→NOTE:
If front hitch drive shaft rotation is detected, RIO feature is allowed.

Begin reverse motion and release PTO switch.
MID implement remains engaged while in reverse motion.
Result:
YES: RIO is operating properly. Go to next check.

PTO and Seat Switch Interface Check
Reference
( 1 ) PTO Switch Check
Action:
1. Sit on operator′s seat.

2. Lock park brake.
3. Move the transmission range lever to neutral.
4. Pull the PTO switch to the ON position.
5. Turn key switch to START position.
→NOTE:
Engine must not crank
6. Push the PTO switch to the OFF position.

7. Turn key switch to the OFF position.
Result:
YES: Go to step 2.
NO: Return to diagnosis in progress. (See PTO circuit operation, Section 240, Group 10.)

( 2 ) Seat Switch Interface Check
Action:
1. Sit on operator′s seat.

2. Lock park brake.
3. Move the transmission range lever to neutral.
4. Move PTO selection lever to MID or MID-AND-REAR position.
→NOTE:
This test is invalid if PTO selection lever is in the REAR only position.

6. Start the engine and set the engine speed to slow idle.
7. Pull the PTO switch to the ON position.
→NOTE:
The engine must continue to run if the PTO selection lever is in the
REAR position.
8. Raise up from the operator′s seat, do not dismount machine.

→NOTE:
Engine must stop.

10. Turn key switch to the OFF position.
Result:
YES: PTO and seat interface are operating properly. Go to next check.

Brakes Operational Check
Reference
( 1 ) Rear Brake Operational Check
Action:
→NOTE:
Perform this test in an open area, free of obstructions that could cause
damage to the tractor or other property.
Power brake checks:
1. Start engine and allow hydraulic oil to warm up to a normal operating temperature, if
needed.
2. Make sure the brake pedal is free of obstructions.
3. Run engine at 1500 rpm and put tractor in appropriate forward gear to run at 8 km/h (5
mph).
4. Driving the tractor straight forward, firmly press on the brake pedal.
The tractor should stop in a straight line. The engine should labor but not stall.
5. Stop tractor, put transmission in gear, and shut engine off.
Manual brake checks:
1. With engine OFF, apply the brake. The pedal should not bottom out.
2. With the brake pedal pressed, latch the park brake. The brake pedal should remain
down.
Result:
YES: Brakes operate properly. Go to next check.
NO: Brakes did not operate properly. Note results. Return to diagnosis in process.

Steering Preliminary Check
Reference
( 1 ) Preliminary Check
Action:
With the tractor engine OFF, perform the following checks:
Inspect the front tires for wear and correct tire pressure for application.
Inspect the front axle for wear or loose parts such as tie rod, spindles, tires and rims.
Inspect all steering lines, fittings and cylinders for leaks and/or damage.
Check to ensure that tractor has the correct type and quantity of hydraulic oil.
Inspect oil for excessive amounts of air, moisture, or other contaminants.
Inspect exterior of steering valve for damage, leaks, or loose fittings.
Result:
YES: Steering operates properly. Go to next check.
NO: Make any necessary repairs. Return to diagnosis in process.

Steering Operational Check
Reference

( 1 ) Operational Check
Action:
IMPORTANT:
Perform this test in an open area, free of obstructions that could cause
damage to the tractor or other property.
Start engine and allow oil to warm to operating temperature if needed.
Conduct the following checks with the tractor parked safely and the engine ON.
1. Set engine to 2000 rpm.

2. Turn the steering wheel CCW (left) and then CW (right)
The front wheels should turn easily and in time with the steering wheel.
Conduct the following checks with the tractor in motion.
1. Put tractor in proper forward gear to operate at 8—14 km/h (5—8.7 mph).
2. Set front wheels in a straight forward direction.
3. Release the steering wheel and note how far the tractor travels in a straight direction.
The tractor should drive in a straight path. Conditions such as potholes, bumps or a crowned
path may affect the direction of the tractor.
Conduct a manual steering operational check with the tractor parked safely and the engine
OFF.
1. Turn the steering wheel CCW (left) and then CW (right).
The wheels should turn with a considerable amount of effort.
Result:
YES: Steering operates properly. Go to next check.
NO: Note results. Return to diagnosis in process.

Hydraulic System Operational Checks
Reference
( 1 ) Basic Hydraulic Function Checks
Action:
Do the following checks. Record details or repair obvious problems before proceeding to the
hydraulic diagnostics.
Ask operator:
How is machine performing?
When does it malfunction?
In what application?
Check maintenance records for:
Correct service intervals
Unusual, frequent or similar features
Check for:
Disconnected, broken or binding operating linkage and wiring
Kinked or dented oil lines
Other mechanical failures
Check hydraulic oil condition:
Oil reservoir level low?
Possible causes:
Improper service intervals
External leaks
Is oil milky or dirty?
Possible causes:
Water in oil (milky)
Filter failure (dirty)
Is oil discolored or burned odor? (overheated oil)
Possible causes:
Kinked pipes
Crushed hoses

ENGINE OPERATION, TESTS, AND ADJUSTMENTS (g) by Belgreen
Plugged oil cooler

Wrong oil viscosity
Internal leaks
Mechanical failure
Check for external oil leaks, with engine stopped and again with engine running. Review
safety precautions.
IMPORTANT:
With engine running, if sound of hydraulic system seems to be under
load or at high pressure, STOP ENGINE. Return to diagnosis in
progress.
Cycle all hydraulic control levers, pedals and switches while running at slow idle.
Possible causes:
Broken pipes, hoses or loose connections

Leaking O-rings
Cracked housing
Check for internal oil leaks with engine at slow idle:

Listen for unusual noises in oil lines, passages, and control valves as hydraulic and
power train functions are operated.
Check for hot oil lines and passages.
At slow idle, feel return lines and passages for excessive heat due to internal oil
leaks.
Turn steering full right and full left.
Apply brakes.
Move SCV lever forward and rearward (without cylinders). Repeat check with
cylinder in each SCV coupler.
Operate hitch with only an implement quick coupler installed using the position
control lever.
Result:
YES: Go to next check.

Section 220 - ENGINE OPERATION, TESTS, AND

ADJUSTMENTS
Table of contents
Group 05 - Component Location ............................................................................................. 2
3TNM74 Engine Component Locations ................................................................................... 2
3TNV76 and 3TNV80 Engine Component Locations ............................................................... 3
Group 10 - Theory of Operation .............................................................................................. 4
Cooling System Theory of Operation ...................................................................................... 5
Lubrication System Theory of Operation ................................................................................ 7
Group 15 - Diagnosis, Tests, and Adjustments .................................................................... 9
Specifications ....................................................................................................................... 10
Other Material ...................................................................................................................... 10
Adjust Throttle Cable ........................................................................................................... 13
Adjust Slow Idle .................................................................................................................... 15
Adjust Fast Idle .................................................................................................................... 17
Adjust Valve Clearance ........................................................................................................ 18
Check Camshaft End Play .................................................................................................... 26
Check Timing Gear Backlash ................................................................................................ 28
Cylinder Compression Test—3TNM74 .................................................................................. 31
Cylinder Compression Test—3TNV76 and 3TNV80 ............................................................... 34
Pressure Test Cooling System .............................................................................................. 37
Test Thermostat ................................................................................................................... 39
Pressure Test Radiator Cap .................................................................................................. 42
Test Oil Pressure .................................................................................................................. 44
Adjust Fan and Alternator Belt ............................................................................................. 46

Group 05: Component Location
ADJUSTMENTS
3TNM74 Engine Component Locations
3TNV76 and 3TNV80 Engine Component Locations
3TNM74 Engine Component Locations
Component Location 3TNM74 Engine
LEGEND:
A Fuel Transfer Pump
B Fuel Return Line
C Fuel Injector
D Coolant Temperature Sensor
E Fuel Injector Pump
F Oil Pan
G Engine Block Coolant Drain
H Oil Pressure Sender
I Fuel Line
J Fuel Filter and Water Separator
K Coolant Reservoir
L Starting Motor Solenoid shift
M Flywheel
N Starting Motor
O Ladder Frame
P Alternator

Group 10: Theory of Operation
ADJUSTMENTS
3TNV76 and 3TNV80 Engine Component Locations
Component Location 3TNV76 and 3TNV80 Engine
LEGEND:
A Fuel Transfer Pump
B Fuel Line
C Fuel Injector
D Coolant Temperature Sensor
E Fuel Injector Timing MARKS
F Oil Pan
G Oil Pressure Sender
H Engine Block Coolant Drain
I Fuel Return Line
J Fuel Filter and Water Separator
K Coolant Reservoir
L Starting Motor Solenoid Shift
M Flywheel
N Starting Motor
O Ladder Frame
P Alternator

ADJUSTMENTS
Cooling System Theory of Operation
Lubrication System Theory of Operation

ADJUSTMENTS
Cooling System Theory of Operation
Cooling System
LEGEND:
A Coolant Pump
B Cylinder Block
C Cylinder Head
D Thermostat
E Bypass Tube
F Upper Radiator Hose
G Pressure Cap
H Coolant Recovery Tank
I Radiator
J Lower Radiator Hose
Function
The cooling system allows the engine to rise to full operating temperature when engine is
started cold, but keeps the engine from overheating once engine reaches operating
temperature. The thermostat opens when operating temperature has been reached,
circulating coolant from the hot engine to the radiator to prevent engine overheating. The
cooling system is pressurized, which raises the boiling point of the coolant, and allows more
heat to be carried away from the engine.

ADJUSTMENTS
Theory of Operation
The cooling system includes the following components: radiator, radiator cap, upper and
lower radiator hoses, coolant pump, fan, thermostat, coolant recovery tank, drain hoses and
drain valve.
When the engine is started cold, the thermostat is closed. The impeller type coolant pump
pulls coolant from the cylinder head and through the bypass tube inside the water pump
housing. The water pump then pushes the coolant into the cylinder block water jacket. The
coolant absorbs heat from the cylinder walls, and is then pushed up into the cylinder head,
and sucked back into the water pump. This provides a fast warmup period, as engine heat is
retained and evenly distributed throughout the engine.
As the engine reaches operating temperature, 69.5—72.5°C (157—163°F), the thermostat

opens, and the hot coolant from the cylinder head passes through the thermostat and into
the top tank of the radiator. As coolant flows down through the tubes of the radiator core,
heat is transferred from the coolant to the air stream being drawn through the core by the
engine fan. When the coolant reaches the bottom radiator tank, it is sucked through the
lower radiator hose and into the water pump, and pushed back into the cylinder block.
When coolant system pressure exceeds 88.3 ± 14.7 kPa (12.8 ± 2.2 psi), the spring in the
radiator cap pushes open to allow coolant to discharge into the coolant recovery tank. As the
engine cools after shutdown, a vacuum is produced in the cooling system, and coolant is
drawn back out of the coolant recovery tank through a small valve in the bottom of the
radiator cap.
Air is pulled by the engine fan through a removable debris guard on the front of the radiator,
through the radiator and fan, and back over engine block. The engine fan belt drives both the
water pump and the cooling fan.
An electrical coolant temperature switch is located in the thermostat housing. When the
coolant temperature reaches 107—113°C (225—235°F), the coolant temperature switch
closes, lighting the coolant warning light on the instrument panel. The light informs the
operator of the high temperature condition.
The radiator can be drained with a drain valve on the lower right corner of the radiator. The
engine block can be drained through the drain port on the left side of the engine near the
front, next to the oil pressure switch. The coolant recovery tank can be removed and drained.

ADJUSTMENTS
Lubrication System Theory of Operation
Lubrication Oil Flow Chart
LEGEND:
A Oil Suction Pipe (strainer)
B Oil Pump
C Regulator Valve
D Bypass Valve
E Oil Filter
F Cylinder Body Main Galley
G Pressure Switch
H Idler Gear Shaft
I Fuel Injection Pump
J Crank Journal
K Crank Pin
L Camshaft Bearing
M Rocker Arm Bearings
N Rocker Arm
O Tappet Cam Face

Group 15: Diagnosis, Tests, and Adjustments
ADJUSTMENTS
Theory of Operation
The pressure lubrication system consists of an oil strainer, positive displacement oil pump, oil
pressure regulating valve, full flow oil filter, and an electrical pressure warning switch.
The oil pump draws lubrication oil from the oil pan through a strainer and a suction tube. The
oil is then pumped through an oil passage to the oil filter and through the engine block main
oil galley.
From the main oil galley, oil is forwarded under pressure to the intermediate gear shaft and
crankshaft main bearing journals. Drilled cross-passages in the crankshaft distribute the oil
from the main bearings to connecting rod bearings.
Lube oil holes in main bearing oil grooves direct oil to the camshaft bearings.
A drilled passage from the rear camshaft bearing through the cylinder block and cylinder
head supplies lubricating oil to the rocker arm bearings. The hollow shaft distributes oil to the
rocker arms, cam followers and valves.
Lubrication oil is supplied to the fuel injection pump from the main oil galley.
An oil pressure switch activates an indicator light to alert the operator if oil pressure drops
below specification.

ADJUSTMENTS
Group 15 - Diagnosis, Tests, and Adjustments
Specifications
Other Material
Adjust Throttle Cable
Adjust Slow Idle
Adjust Fast Idle
Adjust Valve Clearance
Check Camshaft End Play
Check Timing Gear Backlash
Pressure Test Cooling System
Test Thermostat
Pressure Test Radiator Cap
Test Oil Pressure
Adjust Fan and Alternator Belt

ADJUSTMENTS
Specifications
Slow Idle Speed Rotation 1575 ±25 rpm
Fast Idle Speed Rotation 3415 ±50 rpm
Valve Clearance Clearance 0.15—0.25 mm
(0.006—0.010 in.)
Rocker Cover Bolt Torque 11 N·m
(97 lb.-in.)
Camshaft End Play 0.05—0.25 mm
(0.002—0.010 in.)
All Timing Gears

Standard Backlash 0.06—0.12 mm
(0.002—0.005 in.)
Wear Limit Backlash 0.14 mm
(0.0055 in.)
Pressurize System Pressure 100 kPa
(15 psi)
Begin Thermostat Opening Temperature 69.65—72.5°C
(157—163°F)
Thermostat Fully Open Temperature 85°C
(185°F)
Relief Valve Opening Pressure Pressure 83—93 kPa
(12—14 psi)
Oil Pressure at:

Fast Idle: 3TNM74 Pressure 282—380 kPa
(41—55 psi)
Fast Idle: 3TNV76 and 3TNV80 Pressure 241—338 kPa
(35—49 psi)
Slow Idle (minimum) Pressure 60 kPa
(9 psi)
Other Material
Number Name Use
• Loctite ™ 592 (us) Pipe Sealant with TEFLON ™ Seal pressure switch threads.

ADJUSTMENTS
→NOTE:


ADJUSTMENTS
→NOTE:

ADJUSTMENTS
Adjust Throttle Cable
Throttle Cable Adjustment
LEGEND:
A High Speed Stop Screw
B Jam Nuts
[2] - Place throttle in fast idle position.
[3] - Check if tab on throttle lever touches high speed throttle screw (A).
[4] - If tab on throttle lever is not touching high speed throttle screw loosen jam nuts (B).
Adjust nuts so throttle lever tab contacts screw. Tighten jam nuts.

ADJUSTMENTS
[5] - Move throttle control to slow idle position. Check that the tab on throttle lever (C)
travels all the way to the stop screw (D).
Throttle Stop Screw
LEGEND:
B Jam Nuts
C Throttle Lever
D Stop Screw
[6] - If tab on throttle lever is not touching stop screw loosen jam nuts (B). Adjust nuts so
throttle lever tab contacts screw. Tighten jam nuts.
[7] - Recheck steps and adjust jam nuts until proper high and low speed travel is obtained.

ADJUSTMENTS
Adjust Slow Idle
Throttle Lever
LEGEND:
A Governor Throttle Lever
B Jam Nuts
[2] - Place a small piece of reflective tape on the outside edge of crankshaft pulley.
[3] - Start engine and run for 5 minutes to obtain normal operating temperature.
[4] - Move throttle lever to slow idle position.

ADJUSTMENTS
[5] - Check that governor throttle lever (A) is against slow idle stop screw. If the lever does
not contact stop screw adjust the throttle cable.
[6] - Use tachometer to measure engine speed at front crankshaft pulley.
Slow Idle Speed Rotation 1575 ±25 rpm

ADJUSTMENTS
Adjust Fast Idle
IMPORTANT:
The fast idle adjustment is preset by the engine manufacturer to comply

with emissions requirements and is not adjustable. Tampering with the fast
idle adjustment may result in fines or penalties.
IMPORTANT:
If it is determined that either the fuel injection pump or governor assembly

need repair, they must be replaced only as complete assemblies. Only an
authorized factory trained technician is allowed to remove and install these
assemblies. If replacement is necessary, remove and install the fuel
injection pump or governor assembly as complete, individual assemblies.
Because the fast idle is not adjustable, the throttle cable adjustment becomes critical to
proper engine operation. Therefore, first make sure that the throttle cable obtains its full
range of motion, stop-to-stop, before performing any diagnostic procedure.
[1] - Place a small piece of tape on the flywheel
[2] - Start engine and run for 5 minutes to obtain normal operating temperature.
[3] - Move throttle lever to fast idle position.
[4] - Use digital tachometer to measure engine speed at flywheel.
Fast Idle Speed Rotation 3415 ±50 rpm
If engine speed does not meet specification carefully check throttle cable adjustment.
If engine speed still does not meet specification, have governor inspected by an EPA
authorized diesel service (ADS) center.

ADJUSTMENTS
Adjust Valve Clearance
CAUTION:
Engine must be cool (room temperature) before valve clearance is

checked.
[2] - Be sure that ignition key is OFF before attempting to turn engine by hand.
[3] - Remove valve cover.
[4] -
→NOTE:
?Top Dead Center (TDC)? is when the piston is at it?s highest point of travel
in the cylinder on the compression stroke. Number one cylinder is closest
cylinder to flywheel. There is a timing grid for each cylinder on the
flywheel. Each top dead center mark has the cylinder number next to it.

ADJUSTMENTS
Top Dead Center Timing Mark
LEGEND:
A Timing Mark (TDC)
From underside of machine, locate number one cylinder top dead center timing mark (A) on
engine flywheel. Highlight mark with paint or similar light-colored mark.
[5] -
→NOTE:
When top dead center is reached, the rocker arms for that cylinder will be
motionless as the crankshaft is rotated. If rocker arms are still moving
when TDC is approached, rotate crankshaft one full revolution and try
again.

ADJUSTMENTS
Timing Mark Window (3TNM74 shown)
LEGEND:
A Timing Mark (TDC)
B Window
Turn the flywheel while watching for the number 1 cylinder TDC mark (A) to appear in the
1023E window (B) for 3TNM74 engines, the 1025R lower window for the 3TNV80 and 3TNV76
engines. Align the number 1 TDC mark (A) on the flywheel in the center of the window.
[6] - Try to move rocker arms push rods for No. 1 cylinder:
If rocker arm and push rod are loose, the piston is at TDC on the compression stroke.
Proceed to next step.
If rocker arms or push rods are not loose, rotate flywheel one revolution and align mark
as in previous step again. Recheck rocker arm and push rods.

ADJUSTMENTS
[7] -
Valve Clearance and Rocker Arms
LEGEND:
A Cylinder Numbers
B Flywheel Side
Measure and adjust valve clearance only on the four valves indicated with arrows while
number 1 piston is at TDC on compression stroke.
[8] -

ADJUSTMENTS
Valve Clearance Side View
LEGEND:
C Clearance Gap
D Lock Nut
E Adjustment Screw
Slide feeler gauge between valve cap and rocker arm to measure clearance (C). Valve
clearance should be to specification. Adjust as necessary.
Valve Clearance Clearance 0.15—0.25 mm
(0.006—0.010 in.)

ADJUSTMENTS
[9] -
Valve Clearance Adjustment
To adjust valves, loosen lock nut (D) and turn adjusting screw (E) until blade of feeler gauge
can be inserted between rocker arm and valve cap. Turn adjustment screw to obtain a slight
drag on feeler gage. Hold adjustment screw while tightening lock nut.
[10] - Recheck valve clearance after tightening lock nut.

ADJUSTMENTS
[11] -
Normal Valve Cap - Not Normal Valve Cap
Check that valve cap on end of valve stem remained seated on valve and inside valve spring
retainer.
[12] - Turn crankshaft pulley one revolution (360°) to the number 1 TDC mark again. This
rotation puts the piston in number 1 cylinder at TDC on the exhaust stroke.

ADJUSTMENTS
[13] -
Valve Clearance and Rocker Arms
LEGEND:
A Cylinder Numbers
B Flywheel Side
Measure and adjust valve clearance on the last two valves (arrows) with number 1 piston at
TDC of exhaust stroke.
[14] - Install rocker arm cover and tighten bolts to specification.
Rocker Cover Bolt Torque 11 N·m
(97 lb.-in.)

ADJUSTMENTS
Check Camshaft End Play
[1] - Remove timing gear cover. (See Remove and Install Timing Gear Cover in Section 20,
Group 05.)
[2] -
Camshaft End Play
Fasten dial indicator base to cylinder block and position indicator tip on end of camshaft.
[3] - Push camshaft toward the rear as far as possible.
[4] - Zero the dial indicator.

ADJUSTMENTS
[5] - Pull camshaft forward as far as possible. If camshaft end play exceeds specification,
remove camshaft and replace thrust plate.
Camshaft End Play 0.05—0.25 mm
(0.002—0.010 in.)

ADJUSTMENTS
Check Timing Gear Backlash
[1] - Remove timing gear cover. (See Remove and Install Timing Gear Cover in Section 20,
Group 05.)
[2] -
Engine Gears 3TNM74

ADJUSTMENTS
Engine Gears 3TNV76 and 3TNV80
LEGEND:
A Fuel Injection Pump Drive Gear
B Idler Gear
C Camshaft Gear
D Crankshaft Gear
E Oil Pump Gear (3TNM74 only)
Place dial indicator magnetic base on cylinder block with tip of indicator on tooth of gear
being measured.

ADJUSTMENTS
[3] - Holding opposite gear stationary, move measured gear back and forth while measuring
backlash between meshing gears. If backlash exceeds specifications, replace worn gears as a
complete set: Idler Gear, Camshaft Gear, Crankshaft Gear, Fuel Injection Pump Drive Gear.
All Timing Gears

Standard Backlash 0.06—0.12 mm
(0.002—0.005 in.)
Wear Limit Backlash 0.14 mm
(0.0055 in.)

ADJUSTMENTS
Cylinder Compression Test—3TNM74
Reason:
To determine the condition of the pistons, rings, cylinder walls and valves.
Equipment:
JT01682 Compression Gauge Assembly

JDG472 Adapter
Procedure:
[1] - Run engine for 5 minutes to bring to operating temperature. Shut off engine.
[2] - Remove injection nozzles.
[3] -

ADJUSTMENTS
Compression Gauge Installed
Remove heat protector from end of fuel injection nozzle, and install on JDG472 adapter.
[4] - Install JT01682 Compression Gauge Assembly and JDG472 Adapter in injection port.
[5] - Disconnect fuel shutoff solenoid electrical connector on rear of governor.
[6] -
IMPORTANT:
Avoid Damage! DO NOT overheat starting motor during test.
Crank engine for three seconds with starting motor.

ADJUSTMENTS
[7] - Record pressure reading for each cylinder. Compare readings to specifications.
Cylinder Compression @ 250 rpm Cranking Speed Pressure 3240 kPa (470 psi)
Cylinder Compression (Minimum) Pressure 2551 kPa (370 psi)
Difference Between Cylinders (Maximum) Pressure 200 to 296 kPa (29 to 43 psi)
→NOTE:
Pressure listed is for 300 meters (1000 ft) above sea level. Reduce
specification an additional 4% for each 300 meters (1000 ft) of altitude
above this level.
Results:
If pressure reading is below specification, squirt clean engine oil into cylinders through
injector ports and repeat test.
If pressure increases significantly, check piston, rings, and cylinder walls for wear or
damage.
If pressure does not increase significantly after retest, check for leaking valves, valve
seats or cylinder head gasket.

ADJUSTMENTS
Cylinder Compression Test—3TNV76 and 3TNV80
Reason:
To determine the condition of the pistons, rings, cylinder walls and valves.
Equipment:
JT01682 Compression Gauge Assembly

JDG472 Adapter
Procedure:
[1] - Run engine for 5 minutes to bring to operating temperature. Shut off engine.
[2] - Remove injection nozzles.
[3] -

ADJUSTMENTS
Compression Gauge Installed
Remove heat protector from end of fuel injection nozzle, and install on JDG472 adapter.
[4] - Install JT01682 Compression Gauge Assembly and JDG472 Adapter in injection port.
[5] - Disconnect fuel shutoff solenoid electrical connector on rear of governor.
[6] -
IMPORTANT:
Avoid Damage! DO NOT overheat starting motor during test.
Crank engine for three seconds with starting motor.

ADJUSTMENTS
[7] - Record pressure reading for each cylinder. Compare readings to specifications.
Cylinder Compression @ 250 rpm Cranking Speed Pressure 3432 kPa (498 psi)
Cylinder Compression (Minimum) Pressure 2746 kPa (398 psi)
Difference Between Cylinders (Maximum) Pressure 245 kPa (36 psi)
→NOTE:
Pressure listed is for 300 meters (1000 ft) above sea level. Reduce
specification an additional 4% for each 300 meters (1000 ft) of altitude
above this level.
Results:
If pressure reading is below specification, squirt clean engine oil into cylinders through
injector ports and repeat test.
If pressure increases significantly, check piston, rings, and cylinder walls for wear or
damage.
If pressure does not increase significantly after retest, check for leaking valves, valve
seats or cylinder head gasket.

ADJUSTMENTS
Pressure Test Cooling System
[1] -
CAUTION:
Explosive release of fluids from pressurized cooling system can cause

serious burns.
Shut off engine. Only remove filler cap when cool enough to touch with
bare hands. Slowly loosen cap to first stop to relieve pressure before
removing completely.
Check that cooling system is cool and squeeze top radiator hose to check that system
pressure has dropped.
[2] -
Coolant System Pressure Test
Remove cap. Top off coolant if low. Attach D05104ST pressure pump to hose.

ADJUSTMENTS
[3] - Pressurize system with tester to specification.
Pressurize System Pressure 100 kPa
(15 psi)
[4] - Check for leaks throughout cooling system.
Results
Pressure should hold to specifications. If pressure decreases, check for leaks. Repair
leaks or replace parts as necessary.
If leakage continues after all external leaks have been stopped, a defective head
gasket, cracked block, or cylinder head may be the cause.

ADJUSTMENTS
Test Thermostat
[3] -
CAUTION:

serious burns.
[4] - Remove thermostat. (See Remove and Install Thermostat in Section 20, Group 10.)
[5] - Suspend thermostat and a thermometer in a container of water.

ADJUSTMENTS
Thermostat Test
[6] - Heat and stir the water. Observe opening action of thermostat and compare
temperatures with specifications.

ADJUSTMENTS
[7] - Remove thermostat and observe its closing action as it cools.
Begin Thermostat Opening Temperature 69.65—72.5 ° C
(157—163 ° F)
Thermostat Fully Open Temperature 85 ° C
(185 ° F)
If thermostat does not open according to specifications, replace thermostat.

If closing action is not smooth and slow, replace thermostat.

ADJUSTMENTS
Pressure Test Radiator Cap
[2] -
CAUTION:

serious burns.
[3] - Remove radiator cap.

ADJUSTMENTS
[4] - Install radiator cap on appropriate adapter.
Radiator Cap Pressure Test
[5] - Attach adapter to D05104ST pressure pump.
[6] - Apply pressure. Pressure valve in cap should open according to specifications.
Relief Valve Opening Pressure Pressure 83—93 kPa
(12—14 psi)
If cap leaks, relieve pressure and retighten cap. Test again. Replace cap if pressure is not
within specification.

ADJUSTMENTS
Test Oil Pressure
[3] - Remove wire to oil pressure switch. The oil pressure switch is located on the left side of
the engine near the oil filter.
[4] - Unscrew oil pressure switch from block.
[5] - Install connector tool into block.
[6] - Connect hose assembly and pressure gauge.
[7] -
IMPORTANT:
Stop running engine if no oil pressure present.
Start engine. If pressure reading is below 69 kPa (10 psi), STOP engine.
[8] - Run engine approximately 5 minutes to heat oil, then check oil pressure at fast idle.
Oil Pressure at:

Fast Idle: 3TNM74 Pressure 282—380 kPa
(41—55 psi)
Fast Idle: 3TNV76 and 3TNV80 Pressure 241—338 kPa
(35—49 psi)
Slow Idle (minimum) Pressure 60 kPa
(9 psi)

ADJUSTMENTS
[9] - When test is complete:
a. STOP engine and allow engine to cool.

b. Remove hose assembly and gauge.
c. Remove connector from engine.
d. Install oil pressure switch and switch wiring lead. Use pipe sealant on switch threads.
Number Name Use
⚬ Loctite ™ 592 (us) Pipe Sealant with TEFLON ™ Seal pressure switch threads.
Results
If oil pressure is not within specifications, inspect oil pressure regulating valve parts for
wear or damage.
If oil pressure does not increase, engine may be worn beyond specifications.

ADJUSTMENTS
Adjust Fan and Alternator Belt
[1] -
Fan and Alternator Belt Tension Check
LEGEND:
A Mid-point - Water Pump, and Alternator
B Mid-point - Alternator, and Crankshaft Pulley
Park machine safely.
[3] - Apply a force of 98 N (22 lb.-force) to the belt midway between water pump and
alternator (A), or between crankshaft pulley and alternator (B), using a belt tension gauge
and a straight edge.
[4] - Adjust belt if the deflection is not to specification.

ADJUSTMENTS
Belt Deflection Specifications - Used Belt
A 10—14 mm (0.40—0.55 in.)
B 7—10 mm (0.28—0.40 in.)
Belt Deflection Specifications - New Belt
A 8—12 mm (0.32—0.47 in.)
B 5—8 mm (0.20—0.32 in.)

FUEL AND AIR OPERATION, TESTS, AND (g) by Belgreen
ADJUSTMENTS
Adjust Belt Tension
Fan and Alternator Belt Adjustment
LEGEND:
A Adjustment Bolt
B Pivot Bolt
[1] - Loosen adjustment bolt (A).
[2] - Loosen alternator pivot bolt (B).
[3] - Push alternator inward to loosen belt, and outward to tighten belt.
[4] - Tighten bolts.
[5] - Check belt tension.

Section 230 - FUEL AND AIR OPERATION, TESTS, AND

ADJUSTMENTS
Table of contents
Fuel System ........................................................................................................................... 2
Air Intake System Theory of Operation .................................................................................. 4
Fuel System Theory of Operation ........................................................................................... 5
Group 15 - Diagnosis, Test and Adjustments ....................................................................... 7
Specifications ......................................................................................................................... 8
Other Material ........................................................................................................................ 8
Service Equipment and Tools ................................................................................................. 8
Test Fuel Injection System ................................................................................................... 11
Test Fuel Injection Nozzle .................................................................................................... 14
Injection Pump Timing (EPA Engines) ................................................................................... 18
Check Injection Pump Static Timing ..................................................................................... 19
Adjust Fuel Injection Timing: 3TNM74 .................................................................................. 27
Adjust Fuel Injection Timing: 3TNV76 and 3TNV80 .............................................................. 31
Test Fuel Supply Pressure and Flow ..................................................................................... 33
Test Air Filter Restriction Indicator ....................................................................................... 35

ADJUSTMENTS
Fuel System
Fuel System
View from Right Rear
LEGEND:
A Fuel Tank
B Fuel Filter
C Throttle Assembly
D Fuel Transfer Pump
E Fuel Shutoff Solenoid
F Fuel Injector
G Glow Plug
H High Pressure Fuel Injector Pump
I Fuel Injector Pump
J Injection Pump Fuel Supply Line
K Fuel Injection Leak-Off Line
L Fuel Filter and Water Separator
M Fuel Supply Hose
N Fuel Return Hose

ADJUSTMENTS
Air Intake System Theory of Operation
Fuel System Theory of Operation

ADJUSTMENTS
Air Intake System Theory of Operation

The air intake system filters air needed for combustion. The system components include:
Air inlet tube

Air cleaner housing and cover
Unloader valve (and rubber cleanout valve)
Primary air filter element
Secondary (or safety) air cleaner element
Air filter restriction indicator
outlet tube
Air enters the air cleaner inlet tube and into the air cleaner housing, and is directed into the
side of a shield. This starts a high-speed centrifugal motion of air which continues around the
element until it reaches the far end of the air cleaner housing, to an unloader valve.
Most of the dust is separated from the air by centrifugal force that causes heavy dust
particles to enter the opening at the top of the unloader valve. The air flows through the
primary air filter element. The primary filter element filters the larger dirt particles before the
air enters the secondary air filter element. The finer dirt particles are filtered out by the
secondary air filter before the air enters the intake manifold.
The dirt that is deposited in the unloader valve is removed through the rubber diaphragm at
the base of the air cleaner. When the engine is running, a pulsing action is created in the
intake system by each intake stroke of the engine. This pulsing action causes the rubber
diaphragm to open and close, thus emptying the unloader valve. The operator can squeeze
the valve to let out the large particles.
The difference in pressure between the intake manifold and air cleaner is monitored by the
Air Filter Restriction Indicator. As the air filters become clogged, and intake manifold vacuum
increases, the restriction indicator piston is pulled down against spring tension, and is shows
when it’s time to change air cleaner.

ADJUSTMENTS
Fuel System Theory of Operation
Fuel System Theory of Operation Diagram
LEGEND:
A Fuel Tank
B Supply Hose
C Inline Fuel Filter
D Fuel Transfer Pump
E Fuel Filter and Water Separator with Shutoff Valve
F Fuel Injection Pump
G Fuel Injectors
H Fuel Return Hose
The fuel system supplies clean fuel to injection pump and nozzles, and circulates unused fuel
back to the tank.
An electric fuel transfer pump pumps low-pressure fuel to the fuel filter/water separator and
then to the fuel injection pump inlet. Fuel from the transfer pump flows to the fuel shutoff
valve in the top of the fuel filter/water separator. The injection pump then directs high-
pressure fuel through the injector lines to the fuel injector nozzles for combustion. Excess fuel
from the injection pump is combined with leak off fuel from the injectors, through a junction
fitting and is routed through the top of the secondary filter base, back to the fuel tank. An air
bleed hole in the return line automatically purges air from the return line.
If the machine runs out of fuel, or after servicing fuel strainer and water separator, air must
be bled from the fuel strainer and water separator. Make sure that fuel shutoff valve is ON.
Turn the key switch ON. Let the electric fuel transfer pump run (you should hear clicking
sound) for 30 seconds to purge the air from the fuel system.
Group 15: Diagnosis, Test and Adjustments
ADJUSTMENTS
The engine speed is controlled by the throttle lever. The throttle rod is connected to the
injection pump governor control lever. The fuel shutoff solenoid controls the injection pump
shutoff shaft. When the solenoid is retracted (key in the START or ON position), the engine
can run. When the key is turned off, return springs on the shutoff shaft, extend the solenoid,
moving the shutoff linkage to the shutoff position. The solenoid also closes if the machine is
operated in an unsafe condition.
The injection pump meters fuel as determined by the governor and delivers it at high
pressure to the injectors.
The injection nozzle prevents flow until high pressure is reached, then opening the valve and
spraying atomized fuel into the combustion chamber. Injection lines contain trapped fuel
whenever injection is not taking place.
A small amount of fuel leaks past the nozzle valve to lubricate the fuel injection nozzle. This
leakage combines with excess fuel from the injection pump and is returned to tank. Any air in
the fuel system is bled out with return fuel to the fuel tank.

ADJUSTMENTS
Specifications
Other Material
Test Fuel Injection System
Test Fuel Injection Nozzle
Injection Pump Timing (EPA Engines)
Check Injection Pump Static Timing
Adjust Fuel Injection Timing: 3TNM74
Adjust Fuel Injection Timing: 3TNV76 and 3TNV80
Test Fuel Supply Pressure and Flow
Test Air Filter Restriction Indicator

ADJUSTMENTS
Specifications
Injection Nozzle Specification

3TNM74 Nozzle Opening Pressure Pressure 12 300—13 300 kPa
(1785—1930 psi)
3TNV76 and 3TNV80 Nozzle Opening Pressure Pressure 11 800—12 800 kPa
(1712—1856 psi)
Nozzle Pressure for Leak Test Pressure 11 032 kPa
(1600 psi)
(1785—1930 psi)
(1712—1856 psi)
Injection Nozzle Test Results

Slow Hand Lever Movement Quantity Chatter Sound
Slow Hand Lever Movement Quantity Fine Stream Spray Pattern
Fast Hand Lever Movement Quantity Fine Atomized Spray
Injection Timing Angle 19° ±1°
Drive Gear Cap Screws Torque 32—36 N·m
(24—27 lb.-ft.)
Gear Cover Cap Screws Torque 23—29 N·m
(17—22 lb.-ft.)
(17—21 lb.-ft.)
(22—25 lb.-ft.)
Fuel Flow in 15 seconds (minimum) Flow Rate 100 mL
(3.4 oz.)
Fuel Pressure (maximum) Pressure 37.3 kPa
(5.4 psi)
Other Material
Number Name Use
• Loctite ™ (us) 587 Form-in-Place Gasket Seal injection pump timing gear cover.

ADJUSTMENTS
→NOTE:


ADJUSTMENTS
→NOTE:

ADJUSTMENTS
Test Fuel Injection System
CAUTION:
Escaping fluid under high pressure can penetrate the skin and cause
serious injury. Avoid the hazard by relieving pressure before disconnecting
hydraulic or other lines. Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body
from high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into
the skin must be surgically removed within a few hours or gangrene
may result. Doctors unfamiliar with this type of injury should
reference a knowledgeable medical source. Such information is
available from Deere & Company Medical Department in Moline,
Illinois, U.S.A. In the United States and Canada only, this information
may be obtained by calling 1-800- 822-8262.
The purpose of this test is stop fuel flow to the cylinders (one at a time), while engine is
running, to determine what effect that cylinder has on overall engine performance.
[2] - Remove air cleaner.
[3] -
CAUTION:
This test causes diesel fuel to be released from fuel system. The injection
pump is capable of producing high pressure.
Wear eye protection.

Do not open fuel injector connectors more than 1/8 of a turn.
Do not place hands near injectors during test.
Do not allow any debris to enter intake manifold during test.
Do not smoke.

ADJUSTMENTS
Start engine and run at slow idle.
[4] -
Fuel Injector Lines
LEGEND:
A High Pressure Fuel Line - Injector Nozzle End
B High Pressure Fuel Line - Fuel Pump End
Using two 17 mm open-end wrenches, loosen nut on one high-pressure fuel injector line,
either at the injector nozzle (A), or at injection pump (B), while holding lower nut stationary
with second wrench. Only loosen nut 1/8 of a turn (45°).
[5] - Listen for engine speed to drop and exhaust noise to change.
[6] - Tighten nut and allow engine to return to original speed before loosening next cylinder
fuel line nut.
[7] - Compare sound and speed of each cylinder as it is disabled.

ADJUSTMENTS
[8] - Tighten fuel line nuts and stop engine.
Results
When fuel flow is stopped to a cylinder, engine rpm should drop, engine should begin to
vibrate and run rough, and exhaust noise will be uneven until fuel flow is restored.
If test produces the results described, but engine performance remains poor, test the
following:
Clogged air cleaner elements, leaking air filter outlet hoses or clamps.
Restriction in exhaust system.
Presence of coolant or diesel in crankcase oil.
If defeating a single cylinder has no effect on overall engine performance, test the following:
Fuel injector nozzle opening pressure, spray pattern, and leakage and for that cylinder.
See nozzle test.
Cylinder compression or cylinder leakage test.
Fuel supply pump pressure.
Fuel shutoff solenoid is opening fully
Fuel control and governor linkage flyweights allowing full fuel flow to injection pump.
Injection pump timing correct.
If the test results are within specifications, remove injection pump and have tested at an
Authorized Diesel Service (ADS) Center.

ADJUSTMENTS
Test Fuel Injection Nozzle
[1] - Connect fuel injection nozzle to D01109AA Diesel Fuel Injection Nozzle Tester using
parts from D01110AA Adapter Set and 23622 Straight Adapter.

ADJUSTMENTS
Injection Nozzle Test Equipment
[2] -
IMPORTANT:
Use clean, filtered diesel fuel when testing injection nozzles for best
results.
Test fuel injection nozzle opening pressure following the Nozzle Tester manufacturer′s
instructions.
Injection Nozzle Specification

(1785—1930 psi)
(1712—1856 psi)
Results:
If pressure reading does not meet specification, disassemble injection nozzle and inspect
nozzle assembly for contamination or stuck valve. If necessary, add or remove shims to
change opening pressure.
Procedure 2:
Test fuel injection nozzle leakage following the Nozzle Tester manufacturer′s instructions.
1. Dry nozzle completely using a lint-free cloth.

2. Pressurize nozzle to 11 032 kPa (1600 psi).
Nozzle Pressure for Leak Test Pressure 11 032 kPa
(1600 psi)
3. Watch for leakage from nozzle spray orifice. Leakage time should be a minimum of 10
seconds.

ADJUSTMENTS
Results:
If leakage time does not meet specification, disassemble injection nozzle and inspect nozzle
assembly for contamination. Inspect valve seating surface. Replace nozzle assembly if
necessary.
Procedure 3:
Test fuel injection nozzle chatter and spray pattern following the Nozzle Tester
manufacturer′s instructions.
1. Pressurize nozzle to opening pressure.

(1785—1930 psi)
(1712—1856 psi)
Correct Injection Angle

ADJUSTMENTS
Incorrect Injection Angle
2. Listen for “chatter” sound and watch spray pattern.

Injection Nozzle Test Results

Slow Hand Lever Movement Quantity Chatter Sound
Slow Hand Lever Movement Quantity Fine Stream Spray Pattern
Fast Hand Lever Movement Quantity Fine Atomized Spray

ADJUSTMENTS
Results:
If nozzle chatter or spray pattern does not meet specifications, disassemble injection
nozzle and inspect nozzle assembly for contamination. Inspect valve seating surface.
Replace nozzle assembly if necessary.
If there is excessive difference in spray angle or injection angle, incomplete atomizing
or sluggish starting and stopping of injection, disassemble injection nozzle and inspect
assembly for contamination. Replace nozzle assembly if necessary.
Injection Pump Timing (EPA Engines)

EPA engines have EPA compliance sticker on rocker arm cover.
IMPORTANT:
DO NOT attempt to adjust the fuel injection pump timing. For most engine
problems, the fuel injection pump timing does not have to be adjusted. If
the engine performed well at one time, then performance dropped, the fuel
injection timing is NOT the problem. Fuel injection timing, once set by the
engine manufacturer, should NOT change during the life of the engine.
IMPORTANT:
Fuel injection pump timing should NOT change during the life of the engine
unless the pump has been altered illegally, or there is excessive wear to
the camshaft injection pump cam lobes and lifters.
First check the fuel quality, fuel supply, fuel injectors, air intake system,
and engine compression in all cylinders before considering fuel injection
timing problems.
If all other possibilities have been ruled out and it is determined that the
fuel injection pump and governor assembly are in need of repair, they must
be replaced ONLY as complete assemblies.
Only an authorized factory trained technician is allowed to remove and

install these assemblies.

ADJUSTMENTS
Check Injection Pump Static Timing
[2] - Remove air cleaner assembly.
[3] -
CAUTION:
Fuel vapors are explosive and flammable:
Do not smoke while handling fuel.

Keep fuel away from flames or sparks.
Shut off engine before servicing.
Allow engine to cool before servicing.
Work in a well-ventilated area.
Clean up spilled fuel immediately.
→NOTE:
Normal rotation, as viewed from the flywheel end, is counterclockwise. The

number one fuel injection line is closest to flywheel.

ADJUSTMENTS
Fuel Injector
Clean areas around injectors and top of injection pump and remove the fuel injector lines as
an assembly.
[4] - Cover openings on injectors and the two delivery valves that do not have the test tool in
them to keep dirt from entering system.
[5] -
Install the timing tool (A) and clear straw (B) on the number one delivery valve (closest to
flywheel) of injection pump.

ADJUSTMENTS

ADJUSTMENTS
Fuel Injection Timing Tool Install
LEGEND:
A Timing Tool
B Clear Straw
[6] - Place key is run position for 30 seconds to make sure transfer pump runs to fill injector
pump with fuel. Place key in off position.
[7] -
→NOTE:
Highlight TDC and fuel injection timing marks with different color markers.
This mark eliminates confusion as to which mark is in the timing window.

ADJUSTMENTS
Flywheel Timing Marks
LEGEND:
C TDC Timing Mark
D Timing Mark
Turn the flywheel while watching for the number 1 cylinder TDC mark (C).
[8] - Locate fuel injection timing marks near the TDC mark.
[9] - Highlight the 19° mark (D) with a different color highlight than the TDC mark.
ADJUSTMENTS
[10] -
→NOTE:
In order for test to work, fuel shutoff solenoid must be energized. If engine
is out of machine, or if for some other reason the fuel shutoff solenoid
cannot be energized, remove the fuel shutoff solenoid.
Set the throttle lever to the fast idle position. Turn ignition switch to ON position and listen for
fuel shutoff solenoid to click. Fuel shutoff solenoid must be on and stay on during test.
[11] - Slowly turn the flywheel counterclockwise (as viewed from the flywheel end) until the
timing tool straw shows fuel movement.

ADJUSTMENTS
[12] -
Timing Window
LEGEND:
D Timing Mark
E Timing Window
Turn the flywheel clockwise (back) until the No. 1 cylinder top dead center (TDC) mark (C),
and pump timing marks (D) have gone past the flywheel cover timing window (E) by at least
50 mm (2 in.).
[13] - Snap the straw with your finger until the level of the fuel, or a bubble, is set part way
up the straw. This level is the point to watch for fuel movement.
[14] -
→NOTE:
If there is no fuel movement, engine may be on exhaust stroke. Rotate

flywheel 360° and repeat test.
Slowly turn the flywheel counterclockwise (as viewed from the flywheel end) until the fuel in

ADJUSTMENTS
the straw just starts to move. Stop rotating the flywheel the instant the fuel begins to move.
[15] - Check the injection pump timing marks on the flywheel. The 19° mark (D) on the
flywheel must line up in the center of the timing window (E) ±1°.
Injection Timing Angle 19° ±1°
Results
If the timing is not within specifications, timing must be adjusted. Record the number of
degrees, advanced or retarded, to use for a reference when adjusting timing.
If the timing is correct, remove timing tool, install injector lines, install air cleaner
assembly and hood.

ADJUSTMENTS
Adjust Fuel Injection Timing: 3TNM74
Injection Pump Timing Gear Cover
[1] - Remove five cap screws from injection pump timing gear cover and remove cover.
[2] -
→NOTE:
A new injection pump comes with a timing grid sticker. Each line represents
one degree.

ADJUSTMENTS
Fuel Injection Pump Timing Gear Sticker
LEGEND:
A Timing Sticker
Clean off the oil from the timing gear under the pointer in the timing gear cover. Install the
sticker (A) on the gear with the center of the grid under the pointer.
[3] -

ADJUSTMENTS
Fuel Injection Pump Timing Gear Cap Screws
LEGEND:
B Cap Screws
Loosen the four cap screws (B) securing the injection pump drive gear to the hub. Make sure
that the cap screws are loose enough that there is no drag on the injection pump hub. The
object is to have the gear move while turning the engine and the injection pump hub remain
stationary.

ADJUSTMENTS
[4] - If the injection pump timing was a lower number than the timing specification, the
injection timing is retarded and needs to be advanced.
The following references to direction of rotation are made facing the front of the engine
(timing gear end) and turning the crankshaft.
a. To Advance timing rotate the crankshaft counterclockwise.

b. If the injection pump timing was a higher number than the timing specification, the
injection timing is advanced and will need to be retarded.
c. To Retard timing rotate the crankshaft clockwise.
[5] - Slowly rotate the crankshaft while watching the pointer on the timing cover and the
timing grid sticker on the injection pump gear. Turn it the number of degrees and the
direction determined earlier when observing the flywheel grid.
[6] - Tighten the drive gear mounting cap screws to specification.
Drive Gear Cap Screws Torque 32—36 N·m
(24—27 lb.-ft.)
[7] - Recheck the fuel injection timing. Repeat the check and adjustment procedures until
the timing is correct.
[8] - Remove the sticker from the injection pump gear.
[9] - Clean old sealant from injection pump gear cover and timing gear cover.
[10] - Apply small bead of Form-in-Place gasket to injection pump gear cover. Install cover
and tighten cap screws to specification.
Number Name Use

• Loctite ™ (us) 587 Form-in-Place Gasket Seal injection pump timing gear cover.
Gear Cover Cap Screws Torque 23—29 N·m
(17—22 lb.-ft.)

ADJUSTMENTS
Adjust Fuel Injection Timing: 3TNV76 and 3TNV80
Injection Pump Timing Marks
LEGEND:
A Nut
[1] - Check injection pump static timing. (See Check Injection Pump Static Timing in this
Group.)
[2] - If the timing is not to specification, loosen the three injection pump mounting nuts (A).
Tighten nuts to specification.
(17—21 lb.-ft.)
[3] - Turn the pump toward engine block to retard the timing or away to advance the timing.
Recheck the static timing.

ADJUSTMENTS
[4] - If the timing did not change remove the injection pump and have it tested by an
authorized diesel injection service shop.
[5] - If the timing is correct, remove the static timing tool, and install injection lines. Tighten
line nuts to specification.
(22—25 lb.-ft.)

ADJUSTMENTS
Test Fuel Supply Pressure and Flow
[3] - Raise hood and remove right side panel.
[4] - Disconnect fuel supply pump outlet hose (A) from fuel filter and place end of hose into a
clean graduated container.
Fuel Supply Hose
LEGEND:
A Fuel Pump Outlet Hose
[5] - Collect fuel in graduated container as key switch is turned ON for 15 seconds.

ADJUSTMENTS
[6] - Compare fuel amount to specification.
Fuel Flow in 15 seconds (minimum) Flow Rate 100 mL
(3.4 oz.)
[7] - Install the gauge to end of outlet hose (A).
[8] - Place key switch in ON position.
[9] - Record fuel pressure reading on gauge and compare to specification.
Fuel Pressure (maximum) Pressure 37.3 kPa
(5.4 psi)

ADJUSTMENTS
Test Air Filter Restriction Indicator
Air Filter Restriction Indicator
LEGEND:
A Air Restriction Indicator
B Window
C Release Button
[2] - Remove side panels.
[3] -
→NOTE:
Indicator does not function correctly when plastic indicator housing is

damaged.
Locate and check air filter restriction indicator (A).

ADJUSTMENTS
a. If window (B) is clear or yellow, no air cleaner service is required.

b. If window (B) shows fully red, air cleaner requires immediate service.
[4] -
→NOTE:
The air filter restriction indicator operation can be checked by unscrewing

indicator from air filter outlet tube and sucking on the indicator′s vacuum
port with your mouth. The indicator window (B) should show easy
movement of indicator moving into the red zone and hold there until the
release button (C), on top of indicator, is depressed.
Service air cleaner elements if needed.
[5] - Push reset button on top of air filter restriction indicator
Results:
Momentarily run engine at full throttle. If red indicator still moves and into the window after
resetting button:
Replace primary (large) filter element.

Reset air filter restriction indicator button, and retest. If red indicator is still visible after
retest:
Replace secondary (small) filter element.
Reset air filter restriction indicator button, and retest. If red indicator is still visible after
retest:
Check air filter housing, outlet and inlet tubes, unloader valve diaphragm.
Run with both filter elements removed and recheck.

ADJUSTMENTS
Procedure (Simulated Excess Restriction):
1. Make sure that park brake is ON. Start and run engine at SLOW idle.
Air Restriction Indicator Test

LEGEND:
A Air Cleaner Intake Tube
2. Cover the air cleaner intake tube (A) with a piece of cardboard.
3. Watch air filter restriction indicator (B). The indicator should move into the red area.
4. Remove cardboard and stop engine.
5. Push indicator reset button, indicator should clear.
Results:
If restriction indicator DID NOT move, or moved little, check for:
Loose or damaged hose clamps.

Air leaks in air filter to intake manifold hose.
Air leaks in intake manifold.

ELECTRICAL SYSTEM OPERATION, TESTS, AND (g) by Belgreen
ADJUSTMENTS
Air leaks at indicator mounting threads.

Cracked indicator housing or diaphragm.
Clogged screen inside indicator mounting nipple.

Section 240 - ELECTRICAL SYSTEM OPERATION,

TESTS, AND ADJUSTMENTS
Table of contents
Electrical Components ........................................................................................................... 3
Electrical Components - EEC .................................................................................................. 5
Load Center - Domestic .......................................................................................................... 6
Load Center - EEC .................................................................................................................. 9
Group 10 - Theory of Operation ............................................................................................ 11
Charging Circuit - 1023E ...................................................................................................... 12
Cranking and Starting Circuit - 1023E .................................................................................. 14
Instrument Control Cluster (ICC) - 1023E ............................................................................. 18
Power Circuit - 1023E ........................................................................................................... 23
PTO Circuit - 1023E .............................................................................................................. 27
Lighting Circuit - 1023E ........................................................................................................ 30
Charging Circuit - 1025R ...................................................................................................... 34
Cranking and Starting Circuit - 1025R .................................................................................. 36
Instrument Control Cluster (ICC) - 1025R ............................................................................. 40
Power Circuit - 1025R ........................................................................................................... 45
PTO Circuit - 1025R .............................................................................................................. 49
Lighting Circuit - 1025R ....................................................................................................... 52
Group 15 - Diagnosis, Test and Adjustments ..................................................................... 56
Specifications ....................................................................................................................... 57
Power Circuit Diagnosis 1023E and 1025R ........................................................................... 58
Charge Circuit Diagnosis 1023E and 1025R ......................................................................... 61
Crank Circuit Diagnosis 1023E and 1025R ........................................................................... 62
Fuel Shutoff Circuit Diagnosis 1023E and 1025R ................................................................. 64
Glow Plug Circuit Diagnosis 1023E and 1025R ..................................................................... 66
PTO Circuit Diagnosis 1023E and 1025R .............................................................................. 67
Lighting Circuit Diagnosis 1023E .......................................................................................... 69
Lighting Circuit Diagnosis 1025R ......................................................................................... 71
Instrument Control Cluster (ICC) Diagnosis .......................................................................... 73
Key Switch Test .................................................................................................................... 75
PTO Switch Test ................................................................................................................... 77
Park Brake Switch Test ........................................................................................................ 79
Reverse Pedal Switch Test ................................................................................................... 81
Reverse Pedal Switch Adjustment ........................................................................................ 83
Seat Switch Test .................................................................................................................. 87
Light Switch Test .................................................................................................................. 89
Turn Signal Switch Test ........................................................................................................ 91
Hazard Switch Test .............................................................................................................. 92
PTO MBR Switch Test ........................................................................................................... 94
PTO Solenoid Test ................................................................................................................ 96

Neutral Switch Test .............................................................................................................. 99
Horn Switch Test ................................................................................................................ 101
Relay Test .......................................................................................................................... 102
Oil Pressure Switch Test ..................................................................................................... 105
Coolant Temperature Sensor Test ...................................................................................... 107
Fuel Shutoff Solenoid Test .................................................................................................. 109
Regulated Voltage Output Test .......................................................................................... 111
Group 20 - Wiring Schematics ............................................................................................. 112
Schematic Information ....................................................................................................... 112
1023E Schematic Legend ................................................................................................... 113
1023E Schematic ............................................................................................................... 115
1025R Schematic Legend .................................................................................................. 123
1025R Schematic ............................................................................................................... 125
1026R EEC Schematic Legend ........................................................................................... 133
1026R EEC Schematic ........................................................................................................ 135
Group 25 - Connector Information ...................................................................................... 145
K01— K04 Relay Connector ............................................................................................... 147
K05— K06 Relay Connector ............................................................................................... 149
X03 Power Port Connector ................................................................................................. 151
X09 Mow Lift Solenoid Connector ....................................................................................... 153
X54 RH Fender Light Connector ......................................................................................... 155
X55 LH Fender Light Connector ......................................................................................... 157
X—E01 and X—E02 Headlight Connector ........................................................................... 159
X—E01 and X—E02 EEC Headlight Connector .................................................................... 161
X—G02 Alternator Connector ............................................................................................. 163
X—ICC—J1 Display Connector ............................................................................................ 165
X—ICC—J1 Display EEC Connector ..................................................................................... 167
X—ICC—J2 Display EEC Connector ..................................................................................... 171
X—K07 Flasher Connector .................................................................................................. 175
X—M01 Start Motor Connector ........................................................................................... 177
X—M02 Fuel Pump Connector ............................................................................................ 179
X—R01 Glow Plug Connector ............................................................................................. 181
X—S01 Key Switch Connector ............................................................................................ 183
X—S02 (X—S08 EEC) Light Switch Connector .................................................................... 185
X—S03 Turn Signal Switch Connector ................................................................................ 187
X—S04 Neutral Start Switch Connector ............................................................................. 189
X—S05 (X—S02 EEC) PTO Switch Connector ...................................................................... 191
X—S08 (X—X07) MBR Switch Connector ............................................................................ 192
X—S10 Mow Lift Switch Connector ..................................................................................... 194
X—S13 Hazard Switch Connector ....................................................................................... 196
X—S38 Seat Switch Connector ........................................................................................... 198
X—S40 Front Hitch Detection Connector ........................................................................... 200
X—S41 Park Brake Switch Connector ................................................................................. 202
X—S41 Park Brake Switch Connector — EEC ..................................................................... 204
X—S42 Brake Switch Connector ......................................................................................... 206

X—S60 Reverse Pedal Sense Connector ............................................................................ 208

X—Y02 Fuel Shutoff Solenoid Connector ............................................................................ 210
X—Y03 PTO Solenoid Connector ........................................................................................ 212

Electrical Components
Load Center - Domestic
Load Center - EEC

Electrical Components
Electrical System Component Location
LEGEND:
A G01 Battery
B H2 Horn
E G01 Alternator
H Load Center
I Instrument Control Cluster (ICC)
J S05 PTO/RIO Switch
K S01 Key Switch
L S03 Turn signal Switch
M S11 Horn Switch
N S02 Light Switch

O S38 Seat Switch Connector

P E04 Right Hand Work Light Connector
Q S08 MBR PTO Switch Connector
R E07 Left Hand Work Light Connector
S Y03 Rear PTO Solenoid Connector
T E07 Left Hand Work Light
U E04 Right Hand Lights
V E18 License Plate Light
W E03 Left Hand Lights
X S04 Neutral Switch Connector
Y Y02 and M02 Engine Fuel Connectors
Z S42 Brake Switch Connector
AA T06 Fuselinks Connector
AB X-M01 Start Solenoid Connector
AC Front Hitch Detection
AD Mower Lift Switch
AE Reverse Pedal Sense Switch

Electrical System Component Location, EEC
LEGEND:
A G01 Battery
B H2 Horn
E G02 Alternator
H Y02, M02 Engine Fuel, and Glow Plug Connectors
I K07 Flasher Connector
J X56 Cab Connector
K Load Center
L Instrument Control Cluster (ICC)
M S05 PTO Switch
N S13 Hazard Switch

O S01 Key Switch

P S03 Turn signal Switch
Q S11 Horn Switch
R S02 Light Switch
S X09 Connector to S10 Mower Lift Switch option
T S41 Park Brake Switch
U S38 Seat Switch Connector
V X54 to Right Hand Fender Harness
W S08 MBR PTO Switch Connector
X X12 to Trailer Connector
Y E18 License Plate Light
Z E06—E08 Right Hand Lights
AA E04 Right Hand Work Light
AB X03 Power Port
AC E12—E14 Left Hand Lights
AD X12 Trailer Connector
AE X55 to Left Fender Harness
AF Y03 Rear PTO Solenoid Connector
AG E07 Left Hand Work Light
AH S04 Neutral Switch Connector
AI S42 Brake Switch Connector
AJ T06 Fuselinks Connector
AK X-M01 Start Solenoid Connector
AL Front Hitch Detection
AM Mower Lift Switch
AN Reverse Pedal Sense Switch
Load Center - Domestic

Load Center Components - Domestic

LEGEND:
A K03 Glow Plug Relay
B K02 Starter Relay
C K01 Fuel Solenoid Relay
D F01 Fuse, 10 amp Tailights
E F02 Fuse, 10 amp Headlights
F F06 Fuse, 20 amp Fender Lights or Worklights
G F08 Fuse, 10 amp Ignition Run Power
H F09 Fuse, 20 amp Key Switch
I F10 Fuse, 30 amp Light Switch
J F11 Fuse, 15 amp Power Outlet

Load Center - EEC

Load Center Components - EEC
LEGEND:
A K04 Marker Lights Relay
B K03 Glow Plug Relay
C K02 Starter Relay
D K01 Fuel Solenoid Relay
E K05 Trailer Relay
F K06 Brake Relay
G F01 Fuse, 10 amp Marker Lights and License Plate Lights
H F02 Fuse, 10 amp Marker Lights
I F03 Fuse, 20 amp Trailer Relay, Horn, and Turn Signals
J F04 Fuse, 20 amp Fender and Work Lights
K F05 Fuse, 20 amp Headlights
L F06 Fuse, 15 amp Power Outlet
M F07 Fuse, 30 amp Cab Power
N F09 Fuse, 20 amp Key Switch
O F10 Fuse, 20 amp Trailer Power
P F11 Fuse, 20 amp Light Switch and Marker Lights
Q F12 Fuse, 20 amp Brake and Hazard Lights

Charging Circuit - 1023E
Cranking and Starting Circuit - 1023E
Instrument Control Cluster (ICC) - 1023E
Power Circuit - 1023E
PTO Circuit - 1023E
Lighting Circuit - 1023E
Charging Circuit - 1025R
Cranking and Starting Circuit - 1025R
Instrument Control Cluster (ICC) - 1025R
Power Circuit - 1025R
PTO Circuit - 1025R
Lighting Circuit - 1025R

Charging Circuit

Function
To charge the battery and maintain electrical system levels at 12.6—14.2 volts.
Operating Conditions
Key switch in RUN position

Engine running
Theory of Operation
The charging system consists of an alternator with an internal rectifier/voltage regulator. An

indicator light on the display panel alerts the operator of charging system problems.
Battery status is monitored by the voltage regulator sense circuit. When lower-than-normal
system voltage is detected, the regulator energizes the rotating field windings in the
alternator armature. The rotating magnetic field induces an alternating current in the fixed
stator coils. Rectifiers convert this alternating current into the direct current needed to
charge the battery. Upon reaching a full charge, the regulator switches off current to the field
windings.
Should the output of the alternator become insufficient, the battery discharge indicator is
activated through a regulator-switched ground connection.
The starting motor main terminal functions as the power tie point for the battery, alternator
output, and electrical supply system. Alternator grounding is with the engine and frame
ground circuit.
A harness connector with two wires plugs into the back of the alternator:
Red - voltage regulator power (switched +12 V)

Green - pulse output (for tachometer/hour meter)

Cranking and Starting Circuit - 1023E
Cranking and Starting Circuit (Sheet 1)

Cranking and Starting Circuit (sheet 2)
Cranking Circuit Function
To energize the starting motor solenoid and engage the starting motor.

Cranking Circuit Operating Conditions
PTO switch OFF

Transmission in NEUTRAL
Key switch in the START position
Cranking Circuit Theory of Operation
Engine operation is monitored and managed by the instrument control cluster. Moving the
key switch to RUN supplies the switched power circuit and activates the cluster.
The START position of the key switch, along with the neutral, brake, seat, and PTO switches,
supply input signals to the control cluster logic circuits. If all conditions are met, the cluster
energizes the start relay coil. The relay connects the power at the key switch START terminal
to the starting motor solenoid. As the solenoid plunger retracts, the starter pinion gear
engages the flywheel, allowing the starting motor to crank the engine.
Pulses from the alternator, normally used by the tachometer to display engine speed, are
also used by the control cluster logic to protect the starting motor. The cranking process can
occur only if the sensed engine speed is <400 rpm (perceived by the cluster as a non-running
engine). An engine speed of >800 rpm for 3 seconds, or a cranking attempt exceeding 20
seconds, ends the cranking sequence, even if the key switch is held in the START position.
Fuel Supply Function
To supply and regulate the flow of fuel to the engine.
Fuel Supply Operating Conditions
Key switch in the START or RUN position
Fuel Supply Theory of Operation
The instrument control cluster, fuel pump, and fuel shutoff solenoid work together in
regulating the flow of fuel to the engine. Moving the key switch to RUN supplies the switched
power circuits, activating the fuel pump and control cluster. After confirming that the
conditions required to crank the engine are present, the control cluster then briefly (≈1 sec.)
triggers the fuel shutoff relay. This permits the relay to apply a pulse of current to the pull-in
coil of the fuel shutoff solenoid, opening the fuel passage. The solenoid hold-in coil, powered
by the cluster, keeps the fuel passage open.

Glow Plug Function
To provide an added source of heat for the combustion chamber during startup.
Glow Plug Operating Conditions
Glow Plug Circuit Theory of Operation
High levels of battery current are required to heat the glow plugs. To switch these heavy
currents, the instrument control cluster employs a glow plug relay. A dedicated wire and fuse
link connects the battery to the relay.
When power from the key switch first activates the control cluster, the glow plugs (via the
relay) and glow plug indicator light are initially powered for five seconds. The glow plugs will
also be energized as long as the engine is in crank mode.

Instrument Control Cluster (ICC) - 1023E
1023E Instrument Control Cluster 1 of 2

Instrument Control Cluster 2 of 2
1023E Instrument Control Cluster 2 of 2

Function
To inform the operator of various machine operating conditions as well as controlling certain
lighting operations. The display panel provides the logic to operate the various machine
safety interlocks in addition to offering limited diagnostic functions.
Theory of Operation - Display Panel
There are three modes of operation, key switch, hazard, and back light mode.
When the key switch is in the run position:
Tell tale indicators are on for one second.

The LCD display icons are activated for one second.
The analog gauges are moved from the zero position to full deflection and return to the
operation position based on gauge inputs. This occurs within three seconds.
When the key switch is in the off position and the light switch is in the hazard position, the
hazard lights operate and the hour meter is displayed.
When the key switch is in the off position and the light switch is in the on position, the LCD
display backlights operate and the hour meter is displayed.
Interlock circuits are active within 0.2 seconds of key switch ON when conditions are met.
Needle sweep and light check conclude within 5 seconds. Needle sweep and light check may
continue or be temporarily suspended while the Crank input is active.
Power for the module is supplied through (1) switched and (1) unswitched connection to the
battery; a single point grounding wire completes the circuit.
The module turns off all outputs if the electrical system exceeds 20 volts, and selected
outputs below 9 volts. This is done to prevent damage to electrical components and possible
inadvertent operation.
Engine Oil Pressure Light
The engine oil pressure light is controlled by the oil pressure switch. Whenever oil pressure
drops to unsafe levels, the switch contacts close and completes the ground path that
illuminates the warning light. The oil pressure switch also influences hour meter logic.

Tachometer
The tachometer display is driven by pulses from the alternator while the engine is running.
An engine speed of 3000 rpm correlates to an input frequency of 465 Hz.
Engine Temperature Gauge and Indicator Light
Changes in engine coolant temperature are sensed by a variable-resistance temperature

sender. The module translates that resistance value into a temperature reading. A colored
scale on the temperature gauge indicates the safe (green) and unsafe (red) zones of
operation.
Should engine heating become excessive (red zone), the overheat indicator light glows and
stays lit until the temperature drops sufficiently to safe (green zone) levels. PTO operation is
suspended for the duration of the overheat condition.
Hour Meter
The hour meter records the hours of engine operation. Time is measured to within ±5% and
displayed to the nearest 0.1 hour. Accumulation of time occurs when the key is on, AND
(tachometer is above 450 rpm OR [EOP Initial State is close to the previously recorded value,
AND engine oil pressure input is open, AND seat switch is active]). While accumulating, the
hour glass icon flashes at the rate of once per second.
Diagnostic Trouble Codes
The error codes are displayed on the LCD panel to indicate a problem on certain outputs and
the reasons for not being able to turn on the fuel solenoid. The error codes will be displayed
for 2 seconds every 10 seconds as long as the fault persists, except for Fuel Solenoid OFF
codes. Fuel Solenoid can be OFF, if during initial power-up, PTO switch is ON or Neutral switch
is OFF.
→NOTE:
Fault will have to be active for at least 0.5 seconds before the error is
displayed to avoid nuisance errors.
Description Code Notes
SHIFt to NEut Neutral Switch OFF

Fuel Solenoid OFF
SHUt Pto OFF PTO ON (front, mid or rear)
Pull-in Coil Output Fault Pull CoIL FAuLt Coil Open or short to Gnd
Hold-in Coil Output Fault HoLd CoIL FAuLt Coil Open or short to Gnd

Starter Coil Output Fault StArt CoIL FAuLt Starter coil open or short to Gnd
Only display when attempts to crank. Code shall continue to

No Crank When Engine is running EnGInE run
display twice after crank attempt has ceased.
Tractor mid PTO is disabled. Error code needs to be displayed

RIO feature is active RIO_ON
twice whenever cluster enters Engine_OFF/RIO state.
RPEdAL SEnSE Sensor Inputs NC and NO both at 12V.

Reverse Pedal Sensor
RPEdAL SEnSE Sensor inputs NC and NO both at Gnd.
PTO coil output Fault PtO CoIL FAULt PTO coil open or short to Gnd.
Right Turn or Hazard RIGht Bulb Error Bulb open.
Left Turn or Hazard LEFt Bulb Error Bulb open.
Engine Overheat EnGInE Error HEAt Engine coolant above 112°C (234°F).

Power Circuit - 1023E
1023E Power Circuit 1 of 2

Power Circuit 2 of 2
1023E Power Circuit 2 of 2

Power Circuit Function
To provide unswitched power to primary components and switched power to secondary

components whenever the battery is connected.
The power circuits are divided among the unswitched power circuits, switched power circuits
(key switch in RUN or START position), and secondary power circuits. The secondary power
circuits become active when switched power circuits energize those components that in turn
provide current paths for the secondary circuits. A majority of the secondary power circuits
are governed by the logic contained within the instrument control cluster.
Power Circuit Operating Conditions, Unswitched Circuits
Voltage must be present at the following components with the key switch in the OFF position:
Battery Positive Terminal

Starting Motor Battery Terminal
Key Switch, Terminal B
Alternator, Terminal B
Glow Plug Relay, Terminal 30
Fuel Shutoff Relay, Terminal 30
Light Switch, Terminal B
Power Port, Center Terminal (if equipped)
Instrument Control Cluster, Terminal J1-B
The positive battery cable connects the battery to the starting motor. The starting motor bolt
is used as the 12 VDC tie point for the rest of the electrical system.
Protection of the unswitched circuits is provided by two fuse links and three fuses.
Open, loose, or corroded connections compromise the integrity of the entire electrical
system. Ground cable connections are as equally important as their positive cable
counterparts.
counterparts.

Power Circuit Operating Conditions, Switched Circuits
In addition to the unswitched circuits, voltage must be present at the following components
with the key switch in the RUN position, transmission in neutral, and PTO switch OFF:
Key switch terminal L to Fuse F8
From Fuse F8, the 562 Red-series of switched power wires lead to the:
MBR Switch
Neutral Switch
Park Brake Switch
PTO Switch
Turn Signal Switch
Seat Switch
Fuel Pump
Alternator, Connector pin 2
Instrument Control Cluster, Terminal J1-A

PTO Circuit - 1023E
PTO Circuit

PTO Circuit Function
To energize the PTO solenoid and allow safe operation of the PTO system.
PTO Circuit Operating Conditions
Engine running
Operator ON seat
PTO switch ON
or
Engine running
Operator OFF seat
Transmission in neutral
Park brake engaged
PTO switch ON (Rear PTO Only)

PTO Circuit Theory of Operation
Signals from the coolant temperature sensor and seven switches (neutral, seat, park brake,
MBR, PTO, reverse pedal sense, and front hitch detection) are read by the control cluster.
Logic inside the cluster determines if the inputs meet the requirements for energizing the
PTO solenoid in a safe manner. Any disallowed state immediately turns off the fuel shutoff
solenoid and disables engine cranking.
The display panel PTO light glows when the PTO switch is ON. A shift lever selects which PTO
output shafts engage. The REAR PTO ONLY position closes the contacts of the MBR (mid-both-
rear) switch.
The seat switch must remain closed while the machine is in motion. However, the operator
can leave the seat and operate the rear PTO when the transmission is in neutral and the park
brake is locked. The mid PTO cannot be used while the operator is off-seat.
The RIO position of the PTO switch allows the operator to operate mid mount implement
while the tractor is traveling in the reverse direction. This function must be selected before
each time the tractor is placed in reverse.
To prevent shock loads when engaging the PTO, the control cluster first ramps up the current
to the PTO solenoid over a two-second period. Current is then maintained at 1100 mA ±50
mA by using pulse width modulation at a frequency of 100~200 Hz.
The PTO solenoid de-energizes when any of these conditions occur:
Key switch is OFF

The PTO switch is OFF
Electrical system measures < 9 or > 20 volts
Solenoid current cannot be maintained for at least 4 seconds
The temperature gauge enters the red zone (≥112 °C). Power remains off until the
temperature drops below 98 °C and the PTO switch is cycled OFF and ON
A disallowed off seat state is encountered

Lighting Circuit - 1023E
1023E Lighting Circuit 1 of 2

Lighting Circuit 2 of 2
1023E Lighting Circuit 2 of 2

Lighting Circuit Function
To energize the lighting system in individual, or combined circuits.
Lighting Circuit Operating Conditions
Key switch in OFF or ON position

All lights except turn signals (See Turn Lights Operation below.)
Headlight Operation
A dedicated fuse provides unswitched battery current to the light switch. Moving the light
switch to either the Road or Field position makes this power available to the headlights. A
separate fuse protects the headlight circuit wiring.
Marker Lights Operation
The same light switch connection that provides power for the headlight circuit also powers
the marker lights. A separate fuse protects the marker lights wiring.
Hazard Lights Operation
Both the Hazard and Road positions of the light switch activate a single input on the control
cluster. The cluster powers up (without regard to the key switch) and simultaneously flash
the outputs for the left and right turn signal lights. The display panel turn signal indicators
flash in unison with the turn signal outputs.
Turn Lights Operation
The turn signal switch common terminal is wired into the machine’s switched power circuit.
Moving the switch to the RIGHT or LEFT position lets the switch send a positive signal to the
corresponding input of the control cluster. Logic in the cluster flashes the output of the
selected turn signal light and keeps ON the opposite turn light. The display panel turn signal
indicators flash in unison with the respective turn signal outputs.
Turn signal switch inputs override the hazard input when the key switch is ON.

Work Lights Operation
Machine lighting varies according to model. Work lights and fender lights are standard on
deluxe machines. Base-level machines require an optional wiring kit that allows up to two
work lights to be installed.
A light switch contact, made active in the Field position, is the power source for the work
lights. The work lights connect to this power via the wiring circuit fuse.

1025R Charging Circuit

Function
To charge the battery and maintain electrical system levels at 12.6—14.2 volts.
Key switch in RUN position

Engine running
Theory of Operation
The charging system consists of an alternator with an internal rectifier/voltage regulator. An

indicator light on the display panel alerts the operator of charging system problems.
Battery status is monitored by the voltage regulator sense circuit. When lower-than-normal
system voltage is detected, the regulator energizes the rotating field windings in the
alternator armature. The rotating magnetic field induces an alternating current in the fixed
stator coils. Rectifiers convert this alternating current into the direct current needed to
charge the battery. Upon reaching a full charge, the regulator switches off current to the field
windings.
Should the output of the alternator become insufficient, the battery discharge indicator is
activated through a regulator-switched ground connection.
The starting motor main terminal functions as the power tie point for the battery, alternator
output, and electrical supply system. Alternator grounding is with the engine and frame
ground circuit.
A harness connector with two wires plugs into the back of the alternator:
Red - voltage regulator power (switched +12 V)

Green - pulse output (for tachometer/hour meter)

Cranking and Starting Circuit - 1025R
1025R Cranking and Starting Circuit 1 of 2

1025R Cranking and Starting Circuit 2 of 2
Cranking Circuit Function
To energize the starting motor solenoid and engage the starting motor.

PTO switch OFF

Key switch in the START position
Theory of Operation
Engine operation is monitored and managed by the instrument control cluster. Moving the
key switch to RUN supplies the switched power circuit and activates the cluster.
The START position of the key switch, along with the neutral, brake, seat, and PTO switches,
supply input signals to the control cluster logic circuits. If all conditions are met, the cluster
energizes the start relay coil. The relay connects the power at the key switch START terminal
to the starting motor solenoid. As the solenoid plunger retracts, the starter pinion gear
engages the flywheel, allowing the starting motor to crank the engine.
Pulses from the alternator, normally used by the tachometer to display engine speed, are
also used by the control cluster logic to protect the starting motor. The cranking process can
occur only if the sensed engine speed is <400 rpm (perceived by the cluster as a non-running
engine). An engine speed of >800 rpm for 3 seconds, or a cranking attempt exceeding 20
seconds, ends the cranking sequence, even if the key switch is held in the START position.
Fuel Supply Function
To supply and regulate the flow of fuel to the engine.
Fuel Supply Operating Conditions

Fuel Supply Theory of Operation
The instrument control cluster, fuel pump, and fuel shutoff solenoid work together in
The instrument control cluster, fuel pump and fuel shutoff solenoid work together in
Glow Plug Function
To provide an added source of heat for the combustion chamber during startup.
Glow Plug Operating Conditions
Glow Plug Circuit Theory of Operation
High levels of battery current are required to heat the glow plugs. To switch these heavy
currents, the instrument control cluster employs a glow plug relay. A dedicated wire and fuse
link connects the battery to the relay.
When power from the key switch first activates the control cluster, the glow plugs (via the
relay) and glow plug indicator light are initially powered for five seconds. The glow plugs will
also be energized as long as the engine is in crank mode.

Instrument Control Cluster (ICC) - 1025R
1025R Instrument Control Cluster 1 of 2

Instrument Control Cluster 2 of 2
1025R Instrument Control Cluster 2 of 2

Function
To inform the operator of various machine operating conditions as well as controlling certain
lighting operations. The display panel provides the logic to operate the various machine
safety interlocks in addition to offering limited diagnostic functions.
Theory of Operation - Display Panel
There are three modes of operation, key switch, hazard, and back light mode.
When the key switch is in the run position:
Tell tale indicators are on for one second.

The LCD display icons are activated for one second.
The analog gauges are moved from the zero position to full deflection and return to the
operation position based on gauge inputs. This occurs within three seconds.
When the key switch is in the off position and the light switch is in the hazard position, the
hazard lights operate and the hour meter is displayed.
When the key switch is in the off position and the light switch is in the on position, the LCD
display backlights operate and the hour meter is displayed.
Interlock circuits are active within 0.2 seconds of key switch ON when conditions are met.
Needle sweep and light check conclude within 5 seconds. Needle sweep and light check may
continue or be temporarily suspended while the Crank input is active.
Power for the module is supplied through (1) switched and (1) unswitched connection to the
battery; a single point grounding wire completes the circuit.
The module turns off all outputs if the electrical system exceeds 20 volts, and selected
outputs below 9 volts. This is done to prevent damage to electrical components and possible
inadvertent operation.
Engine Oil Pressure Light
The engine oil pressure light is controlled by the oil pressure switch. Whenever oil pressure
drops to unsafe levels, the switch contacts close and completes the ground path that
illuminates the warning light. The oil pressure switch also influences hour meter logic.

Tachometer
The tachometer display is driven by pulses from the alternator while the engine is running.
An engine speed of 3000 rpm correlates to an input frequency of 465 Hz.
Engine Temperature Gauge and Indicator Light
Changes in engine coolant temperature are sensed by a variable-resistance temperature

sender. The module translates that resistance value into a temperature reading. A colored
scale on the temperature gauge indicates the safe (green) and unsafe (red) zones of
operation.
Should engine heating become excessive (red zone), the overheat indicator light glows and
stays lit until the temperature drops sufficiently to safe (green zone) levels. PTO operation is
suspended for the duration of the overheat condition.
Hour Meter
The hour meter records the hours of engine operation. Time is measured to within ±5% and
displayed to the nearest 0.1 hour. Accumulation of time occurs when the key is on, AND
(tachometer is above 450 rpm OR [EOP Initial State is close to the previously recorded value,
AND engine oil pressure input is open, AND seat switch is active]). While accumulating, the
hour glass icon flashes at the rate of once per second.
Diagnostic Trouble Codes
The error codes are displayed on the LCD panel to indicate a problem on certain outputs and
the reasons for not being able to turn on the fuel solenoid. The error codes will be displayed
for 2 seconds every 10 seconds as long as the fault persists, except for Fuel Solenoid OFF
codes. Fuel Solenoid can be OFF, if during initial power-up, PTO switch is ON or Neutral switch
is OFF.
→NOTE:
Fault will have to be active for at least 0.5 seconds before the error is
displayed to avoid nuisance errors.
SHIFt to NEut Neutral Switch OFF

Fuel Solenoid OFF
SHUt Pto OFF PTO ON (front, mid or rear)
Pull-in Coil Output Fault Pull CoIL FAuLt Coil Open or short to Gnd
Hold-in Coil Output Fault HoLd CoIL FAuLt Coil Open or short to Gnd

Starter Coil Output Fault StArt CoIL FAuLt Starter coil open or short to Gnd
Only display when attempts to crank. Code shall continue to

No Crank When Engine is running EnGInE run
display twice after crank attempt has ceased.
Tractor mid PTO is disabled. Error code needs to be displayed

RIO feature is active RIO_ON
twice whenever cluster enters Engine_OFF/RIO state.
RPEdAL SEnSE Sensor Inputs NC and NO both at 12V.

Reverse Pedal Sensor
RPEdAL SEnSE Sensor inputs NC and NO both at Gnd.
PTO coil output Fault PtO CoIL FAULt PTO coil open or short to Gnd.
Right Turn or Hazrd RIGht Bulb Error Bulb open.
Left Turn or Hazard LEFt Bulb Error Bulb open.
Engine Overheat EnGInE Error HEAt Engine coolant above 112°C (234°F).

Power Circuit - 1025R
1025R Power Circuit 1 of 2

Power Circuit 2 of 2
1025R Power Circuit 2 of 2

Power Circuit Function
To provide unswitched power to primary components and switched power to secondary

components whenever the battery is connected.
The power circuits are divided among the unswitched power circuits, switched power circuits
(key switch in RUN or START position), and secondary power circuits. The secondary power
circuits become active when switched power circuits energize those components that in turn
provide current paths for the secondary circuits. A majority of the secondary power circuits
are governed by the logic contained within the instrument control cluster.
Power Circuit Operating Conditions, Unswitched Circuits
Voltage must be present at the following components with the key switch in the OFF position:
Battery Positive Terminal

Starting Motor Battery Terminal
Key Switch, Terminal B
Alternator, Terminal B
Glow Plug Relay, Terminal 30
Fuel Shutoff Relay, Terminal 30
Light Switch, Terminal B
Power Port, Center Terminal (if equipped)
Instrument Control Cluster, Terminal J1-B
The positive battery cable connects the battery to the starting motor. The starting motor bolt
is used as the 12 VDC tie point for the rest of the electrical system.
Protection of the unswitched circuits is provided by two fuse links and three fuses.
counterparts.
counterparts.

Power Circuit Operating Conditions, Switched Circuits
In addition to the unswitched circuits, voltage must be present at the following components
with the key switch in the RUN position, transmission in neutral, and PTO switch OFF:
Key switch terminal L to Fuse F8
From Fuse F8, the 562 Red-series of switched power wires lead to the:
MBR Switch
Neutral Switch
Park Brake Switch
PTO Switch
Turn Signal Switch
Seat Switch
Fuel Pump
Alternator, Connector pin 2
Instrument Control Cluster, Terminal J1-A

PTO Circuit - 1025R
1025R PTO Circuit

PTO Circuit Function
To energize the PTO solenoid and allow safe operation of the PTO system.
PTO Circuit Operating Conditions
Engine running
Operator ON seat
PTO switch ON
or
Engine running
Operator OFF seat
Transmission in neutral
Park brake engaged
PTO switch ON (Rear PTO Only)

PTO Circuit Theory of Operation
Signals from the coolant temperature sensor and seven switches (neutral, seat, park brake,
MBR, PTO, reverse pedal sense, and front hitch detection) are read by the control cluster.
Logic inside the cluster determines if the inputs meet the requirements for energizing the
PTO solenoid in a safe manner. Any disallowed state immediately turns off the fuel shutoff
solenoid and disables engine cranking.
The display panel PTO light glows when the PTO switch is ON. A shift lever selects which PTO
output shafts engage. The REAR PTO ONLY position closes the contacts of the MBR (mid-both-
rear) switch.
The seat switch must remain closed while the machine is in motion. However, the operator
can leave the seat and operate the rear PTO when the transmission is in neutral and the park
brake is locked. The mid PTO cannot be used while the operator is off-seat.
The RIO position of the PTO switch allows the operator to operate mid mount implement
while the tractor is traveling in the reverse direction. This function must be selected before
each time the tractor is placed in reverse.
To prevent shock loads when engaging the PTO, the control cluster first ramps up the current
to the PTO solenoid over a two-second period. Current is then maintained at 1100 mA ±50
mA by using pulse width modulation at a frequency of 100~200 Hz.
The PTO solenoid de-energizes when any of these conditions occur:
Key switch is OFF

The PTO switch is OFF
Electrical system measures < 9 or > 20 volts
Solenoid current cannot be maintained for at least 4 seconds
The temperature gauge enters the red zone (≥112 °C). Power remains off until the
temperature drops below 98 °C and the PTO switch is cycled OFF and ON
A disallowed off seat state is encountered

Lighting Circuit - 1025R
1025R Lighting Circuit 1 of 2

Lighting Circuit 2 of 2
1025R Lighting Circuit 2 of 2

Lighting Circuit Function
To energize the lighting system in individual, or combined circuits.
Lighting Circuit Operating Conditions
Key switch in OFF or ON position

All lights except turn signals (See Turn Lights Operation below.)
Headlight Operation
A dedicated fuse provides unswitched battery current to the light switch. Moving the light
switch to either the Road or Field position makes this power available to the headlights. A
separate fuse protects the headlight circuit wiring.
Marker Lights Operation
The same light switch connection that provides power for the headlight circuit also powers
the marker lights. A separate fuse protects the marker lights wiring.
Hazard Lights Operation
Both the Hazard and Road positions of the light switch activate a single input on the control
cluster. The cluster powers up (without regard to the key switch) and simultaneously flash
the outputs for the left and right turn signal lights. The display panel turn signal indicators
flash in unison with the turn signal outputs.
Turn Lights Operation
The turn signal switch common terminal is wired into the machine’s switched power circuit.
Moving the switch to the RIGHT or LEFT position lets the switch send a positive signal to the
corresponding input of the control cluster. Logic in the cluster flashes the output of the
selected turn signal light and keeps ON the opposite turn light. The display panel turn signal
indicators flash in unison with the respective turn signal outputs.
Turn signal switch inputs override the hazard input when the key switch is ON.

Work Lights Operation
Machine lighting varies according to model. Work lights and fender lights are standard on
deluxe machines. Base-level machines require an optional wiring kit that allows up to two
work lights to be installed.
A light switch contact, made active in the Field position, is the power source for the work
lights. The work lights connect to this power via the wiring circuit fuse.

Specifications
Power Circuit Diagnosis 1023E and 1025R
Charge Circuit Diagnosis 1023E and 1025R
Crank Circuit Diagnosis 1023E and 1025R
Fuel Shutoff Circuit Diagnosis 1023E and 1025R
Glow Plug Circuit Diagnosis 1023E and 1025R
PTO Circuit Diagnosis 1023E and 1025R
Lighting Circuit Diagnosis 1023E
Lighting Circuit Diagnosis 1025R
Instrument Control Cluster (ICC) Diagnosis
Key Switch Test
PTO Switch Test
Park Brake Switch Test
Reverse Pedal Switch Test
Reverse Pedal Switch Adjustment
Seat Switch Test
Light Switch Test
Turn Signal Switch Test
Hazard Switch Test
PTO MBR Switch Test
PTO Solenoid Test
Neutral Switch Test
Horn Switch Test
Relay Test
Oil Pressure Switch Test
Coolant Temperature Sensor Test

Fuel Shutoff Solenoid Test

Regulated Voltage Output Test
Specifications
Coolant Temperature Sensor Torque 24 ± 3 N·m
(212 ± 27 lb.-in.)
PTO Solenoid Coil Resistance Resistance 5.5 ohms (approximate)
Regulated Output Voltage 13.9—14.6 VDC
→NOTE:

→NOTE:

Power Circuit Diagnosis 1023E and 1025R
Unswitched Power Circuit
CONDITIONS:
Machine parked, park brake locked

PTO disengaged
Key switch to OFF
Voltmeter (—) lead to battery negative post
Voltmeter (+) lead to designated test point
Refer to, Power Circuit - 1023E , or Power Circuit - 1025R for circuit schematics.
Test Point or Action Normal If Not Normal
1. Battery positive test. Minimum 11.8 VDC Test or charge battery; replace if needed.
Check for loose, corroded, or broken wire

2. Starter motor battery terminal. Battery voltage
between battery and starter motor.
3. Alternator battery terminal

Check for loose, corroded, or broken wire
(See X—G02 Alternator Connector in this Battery voltage
between starter motor and alternator.
Section).
4. Remove K03 relay from fuse block. Battery voltage. Reinstall

Check 002B fuse link and 002D Red wire.
Meter to terminal 30, 002D Red wire. K03 relay.
5. Remove K01 relay from fuse block. Battery voltage. Reinstall Check 002C fuse link and 002E and 002F Red
Meter to terminal 30, 002F Red wire. K01 relay. wires.
6. Light Switch, 122 Red wire.

(See X—S02 (X—S08 EEC) Light Switch Battery voltage Check F10 fuse and 002K and 122 Red wires.
Connector in this Section).
7. Power Port RH fender, 262B Red wire

(1025R only). Check F11 fuse, 262A, 262B and 002H Red
Battery voltage
(See X03 Power Port Connector in this wires, and connector X54.
Section.)
Check F09 fuse and 012A, 012B and 002G Red

8. Key Switch, 012A Red wire. Battery voltage
wires.
9. Display Panel connector: J1-B

(unplugged), (See or J1-A, B, C
Check F09 fuse and 012A, 012B and 002G Red
(unplugged), 012C, D, E Red wire. (See Battery voltage
wires.
X—ICC—J1 Display Connector in this
Section.)
No more than 0.1 ohm

10. Set meter to OHMS. Display Panel Check 050 Blk wire, battery negative cable, and
over the meter’s residual
connector J1-D (unplugged), 050 Blk connections.
“zero” resistance.
11. Power Port RH fender, 010AA Blk wire No more than 0.1 ohm Check 010AA, 010Y, 010S, 010C Blk wires;
(1025R only). over the meter’s residual connector X54, and battery negative cable and
(See X03 Power Port Connector .) “zero” resistance. connections.

No more than 0.1 ohm Check alternator mounting, negative battery

12. Alternator case over the meter’s residual cable and connections, and frame-to-engine
“zero” resistance. bonding jumper.
Switched Power Circuit
CONDITIONS:

PTO disengaged
Unswitched Power Circuit tested and functional
Key switch to ON, engine not running
Voltmeter (—) lead to battery negative post
Test key switch. (See Key Switch

1. Key Switch, 072B Red wire. Battery voltage
Test in this Group.)
2. Alternator connector (unplugged), 562E Red wire. Battery voltage, confirm Check F08 fuse and 072B, 072C,
(See X—G02 Alternator Connector in this Section. before proceeding with test. 562H, and 562E Red wires.
3. Fuel Pump, 562N Red wire.

Battery voltage Check 562N Red wire.
(See X—M02 Fuel Pump Connector in this Section.)
4. PTO On—Off Switch 562R and 562D Red wire (See

X—S05 (X—S02 EEC) PTO Switch Connector in this Battery voltage Check 562D Red wire.
Section.)
5. Turn Signal Switch, 562K Red wire.

(See X—S03 Turn Signal Switch Connector in this Battery voltage Check 562K Red wire.
Section.)
6. Mower Lift Switch, 562P Red wire.

(See X—S10 Mow Lift Switch Connector in this Battery voltage Check 562P Red wire.
Section.)
7. Display Panel connector J1-F (unplugged), 562C Red

wire (See X—ICC—J1 Display Connector in this Battery voltage Check 562C Red wire.
Section.)
8. Park Brake Switch, 562B Red wire.

Battery voltage, confirm
(See X—S41 Park Brake Switch Connector in this Check 562A and 562B Red wires.
before proceeding with test.
Section.)
9. Seat Switch, 562F Red wire.

Battery voltage Check 562F Red wire.
(See X—S38 Seat Switch Connector in this Section.)
10. MBR PTO Switch (unplugged), 562J Red wire.

(See X—S08 (X—X07) MBR Switch Connector in this Battery voltage Check 562J Red wire.
Section.)
10. Neutral Switch (unplugged), 562G Red wire.

(See X—S04 Neutral Start Switch Connector in this Battery voltage Check 562G Red wire.
Section.)

No more than 0.1 ohm over

10. Key switch OFF. Set meter to OHMS. Fuel Pump, Check 010AF and 010B Blk wires,
the meter’s residual “zero”
010AF Blk wire. and connections.
resistance.

Charge Circuit Diagnosis 1023E and 1025R

CONDITIONS:

PTO disengaged
Harness connector unplugged from alternator
Voltmeter (–) lead to battery negative post
Key switch to RUN
Refer to Charging Circuit - 1023E or Charging Circuit - 1025R for circuit schematics.
1. Battery positive test. Minimum 11.8 VDC Test or charge battery; replace if needed.
Check alternator mounting, negative battery cable

2. Alternator case Less than 0.1 volt
connections, frame-to-engine bonding jumper.
Check for loose, corroded, or broken wire between

3. Starter motor battery terminal Battery voltage
battery and starter motor.
Check for loose, corroded, or broken wire between

4. Alternator battery terminal Battery voltage
starter motor and alternator.
5. Alternator connector (unplugged),

562E Red wire Check 562E Red wire. Test power circuit. (See Power
Battery voltage
(See X—G02 Alternator Connector in Circuit Diagnosis 1023E and 1025R in this Group.)
this Section.)
Approximately 1.5 VDC less

6.Alternator connector (unplugged), than battery voltage Check 334 Yel wire. (ICC connector JS—F). (See
334 Yel wire Battery discharge light is X—ICC—J3 Display Connector .)
off.
7. Use jumper wire from ground to Battery discharge light is

If previous steps test OK, replace ICC.
Alternator connector, 334 Yel wire. on.
8. Reattach Alternator connector.

14.2 - 14.8 VDC Check belt tension. Test alternator.
Voltmeter to Alternator battery
Battery discharge light is →NOTE:
terminal. Start engine, run at fast
off. ICC will shut down if system exceeds 20 VDC.
idle.

Crank Circuit Diagnosis 1023E and 1025R

CONDITIONS:

Battery charged, Power Circuit tested and functioning
Transmission in NEUTRAL or as directed
PTO switch OFF or as directed
Digital voltmeter (–) lead to battery negative post
Digital voltmeter (+) lead to designated test point
Key switch position as directed
Refer to Cranking and Starting Circuit - 1023E or Cranking and Starting Circuit - 1025R for
circuit schematics.
→NOTE:
In rare cases, the instrument cluster may be faulty. Test all applicable
power, grounds, wires, connectors and components before replacing ICC.
1. Remove K02 relay from fuse block. (See

Meter shows battery voltage and Perform key switch test. (See Key
K01— K04 Relay Connector .)
glow plug light is on while key is in Switch Test in this Group.)
Meter to terminal 30, 572A Red wire. Turn
START position. Check 572A and 572B Red wires.
key to START. Note display panel.
2. Key to RUN. Move shift lever to Perform Neutral Switch test. (See
Display panel readout shows
Forward, then to Reverse, and return to Neutral Switch Test in this Group.)
“NeutOF” when not in Neutral.
Neutral. Note display panel. Check 514 Yel wire.
PTO light goes on/off with switch. Perform PTO switch test. (See PTO
3. Pull PTO switch ON, then press back to
Display panel readout shows Switch Test in this Group.)
OFF. Note display panel.
“PTOON” when switch is activated. Check 574 Yel wire.
Adjust switch bracket. Test Park

4. Release, then lock, Park Brake. Note Brake light is on with brake locked, Brake switch. (See Park Brake Switch
display panel. and off when brake is released. Test in this Group.)
Check 586 Blu wire.
5. Shift lever to Neutral. PTO switch OFF.

Meter shows battery voltage while Confirm position of PTO switch and
K02 relay socket terminal 86, 369 Wht
key is in START position. shift lever. Check 369 Wht wire.
wire. Turn key to START.
6. Key OFF. Meter to OHMS. K02 relay No more than 0.1 ohm over the Check 010V, 010B Blk wires, and
socket terminal 85, 010V Blk wire. meter’s residual “zero” resistance. connections.
7. Reinstall K02 relay. Starter solenoid Battery voltage present. starter Test K02 relay. Check 309A Wht wire.
terminal, 309A Wht wire. Key to START. motor cranks engine. Repair starter motor.
7. Reinstall K02 relay. Starter solenoid

Battery voltage present. Test K02 relay. Check 309A Wht wire.
terminal, 309A Wht wire. Key to START.

8.Key to START. Starter motor cranks engine. Repair starter motor.

Fuel Shutoff Circuit Diagnosis 1023E and 1025R

CONDITIONS:

Battery fully charged
Power and Crank Circuits tested and functioning
PTO switch OFF
circuit schematics.
→NOTE:
1. Key OFF. Remove K01 relay. Unplug

Fuel Shutoff solenoid and perform Fuel
Per specifications. Reconnect Fuel
Shutoff solenoid test. Replace solenoid.
Shutoff solenoid.
(See Fuel Shutoff Solenoid Test in the
Group.)
2. Meter to OHMS. Fuel Shutoff solenoid

connector, 010D Blk wire. No more than 0.1 ohm over the Check 010D and 010B Blk wires and
(See X—Y02 Fuel Shutoff Solenoid meter’s residual “zero” resistance. connections.
Connector in this Section.)
3. K01 relay socket terminal 85, 010U Blk

No more than 0.1 ohm over the Check 010U, 010E, and 010B Blk
wire. (See K01— K04 Relay Connector in
meter’s residual “zero” resistance. wires and connections.
this Section.)
4. K01 relay socket terminal 87, 329 Wht Resistance of Fuel Shutoff solenoid
Check 329 Wht wire.
wire. pull-in coil.
5. Meter to VOLTS. K01 relay socket

Battery voltage. Check 002F Red wire.
terminal 30, 002F Red wire.
6. K01 relay socket terminal 86, 522 Red Battery voltage for approximately 1 Confirm position of PTO switch and
wire. Move key from OFF to RUN. second, then dropping to a low value. shift lever. Check 522 Red wire.
7. Fuel Shutoff solenoid connector, 302 Confirm position of PTO switch and
Battery voltage.
Red wire. shift lever. Check 302 Red wire.

8. Reinstall K01 relay. Fuel Shutoff Confirm position of PTO switch and
Battery voltage for approximately 1
solenoid connector, 329 Wht wire. shift lever. Test K01 relay.
second.
Move key switch from OFF to RUN. (See Relay Test in this Group.)
Readout does not display HCFT

A wiring error or component fault
9. Observe display panel readout. (hold—in coil fault) or PCFT (pull—in
still exists in those circuits; recheck.
coil fault).

Glow Plug Circuit Diagnosis 1023E and 1025R

CONDITIONS:

Crank Circuit tested and functioning
PTO switch OFF
circuit schematics.
→NOTE:
1. Key OFF. Remove K03 relay from fuse block. K03 relay
Check 002B fuse link and
socket terminal 30, 002D Red wire. (See K01— K04 Relay Battery voltage.
002D Red wire.
Connector in this Section.)
Check 383 Org wire to glow

2. Meter to OHMS. K03 relay socket terminal 87, 383 Org
Less than 1 ohm. plug connector. Test glow
wire. (See K01— K04 Relay Connector in this Section.)
plug(s).
No more than 0.1 ohm over

3. K03 relay socket terminal 85, 010E Blk wire. (See K01— Check 010E and 010B Blk
the meter’s residual “zero”
K04 Relay Connector in this Section.) wires, and connections.
resistance.
4. Meter to VOLTS. K03 relay socket terminal 86, 385 Grn

Battery voltage for
wire. Move key switch from OFF to RUN. (See K01— K04 Check 385 Grn wire.
approximately 5 seconds.
Relay Connector in this Section.)
5. Reinstall K03 relay. 383 Org wire at glow plug

Test K03 relay.
connector. (See X—R01 Glow Plug Connector in this Battery voltage for
(See Relay Test in this
Section.) approximately 5 seconds.
Group.)
Move key switch from OFF to RUN.

PTO Circuit Diagnosis 1023E and 1025R

CONDITIONS:

Power Circuit tested and functioning
Transmission in NEUTRAL or as directed
PTO On-Off switch OFF
Key switch OFF or as directed
Refer to , PTO Circuit - 1023E , or PTO Circuit - 1025R for circuit schematics.
→NOTE:
No more than 0.1 ohm over Check 010R and 010C Blk wires and
1. Key switch OFF. Meter to OHMS. PTO
the meter’s residual “zero” connections. (See X—Y03 PTO Solenoid
solenoid connector (unplugged), 010R wire.
resistance. Connector .)
2. Perform PTO solenoid test. (See PTO

Meets specifications Replace solenoid
Solenoid Test .)
3. Key switch to RUN. Voltmeter to PTO Review test conditions. Check 747 Pur wire
solenoid connector (unplugged), 747 Pur Approximately 0.17 VDC (ICC connector J1-G). (See X—ICC—J1
wire. (See X—Y03 PTO Solenoid Connector .) Display Connector .)
Adjust switch bracket. (See Adjust Park

Brake Engagement or Adjust Park Brake
4. Release, then lock, park brake. Observe Brake locked = light on.
Engagement EEC in Section 260, Group 15.)
the park brake indicator light icon. Brake released = light off.
Test park brake switch. (See Park Brake
Switch Test .)
Needle stays within green Refer to ICC diagnostics. (See Instrument

5. Start engine; run at slow idle. Observe
zone of dial. Over Control Cluster (ICC) Diagnosis .)
temperature gauge.
temperature light off. Check PTO attachments for excessive load.

•
Check 521 Brn wire ICC connector J3—K
X—ICC—J3 Display Connector ). Test seat
switch. (See Seat Switch Test .)
•
6. Perform “PTO and Seat Switch Interface
Engine operation meets Check ICC connector J3—B X—ICC—J1
Check”. (See PTO and Seat Switch Interface
check results. Display Connector ). Test PTO MBR switch.
Check in Section 210, Group 05.)
(See PTO MBR Switch Test .)
•
Check ICC connector J1—H X—ICC—J1
Display Connector ). Test PTO switch. (See
PTO Switch Test .)
7. Perform the “PTO Operational Checks” Confirm previous diagnostic steps and
procedure. (See PTO Operational Checks in Meets check results. circuit operation. Adjust or repair applicable
Section 210, Group 05.) mechanical and hydraulic systems.

Lighting Circuit Diagnosis 1023E

CONDITIONS:

PTO switch OFF
Key switch position OFF or as directed
Light switch and Turn Signal switch position as directed
Refer to Lighting Circuit - 1023E for circuit schematic.
→NOTE:
Check fuse F10. Test Light switch. (See

1. Move Turn Signal switch to OFF. Light Switch Test in this Group.)
Battery voltage present. Display panel
Move Light switch to HAZARD Check ICC connector J2—C, 103 Org
Left and Right Turn indicators flashing.
position. Light switch, 103 Org wire. wire. (See X—ICC—J2 Display Connector
)
Battery voltage cycles on-off. Left and (Output is open circuit or shorted) - Test
2. ROPS lamps, 135B and 135C Grn Right Turn lamps flashing. Display panel bulbs; check lamp ground wires 010J,
wires and 145B and 145C Grn wires. readout does not show LTFT (left turn 010K and 010C Blk. Check 135B, 135C,
fault) or RTFT (right turn fault). 145B and 145C Grn wires.
3. Move Light switch to ROAD

Battery voltage. Left and Right Turn Test Light switch. (See Light Switch Test
position. Light switch, 138B Gry
lamps remain flashing. in this Group.)
wire.
(No voltage) - Check fuse F02. Check all

4. Headlight sockets, 119-Wht 119-Wht wires, 138A and 138B Gray
Wires. Battery voltage. Left and Right wires.
(See X—E01 and X—E02 Headlight headlights on. (Voltage OK) - Test bulbs; check lamp
Connector .) ground wires 010G, 010H, 010X, and
010B Blk.
(No voltage) - Check fuse F01. Check

Battery voltage. Left and Right Marker
5. ROPS lamps, 118-Gry wires. 138C, 138B, and (all) 118 Gry wires.
lights on.
(Voltage OK) - Test bulbs and grounds.

Headlights and Marker lights remain on.

Test Light switch. (See Light Switch Test
6. Light switch in FIELD position. Turn Signal indicators and Turn lamps
in this Group.)
are off.
7. (With optional Work Light Kit

Test Light switch. (See Light Switch Test
installed). Light switch, 137A Pur Battery voltage.
in this Group.)
wire.
(No voltage) - Check fuse F06. Check

8. (With optional Work Light Kit 137A and (all) 147 Pur wires.
installed). Work lights, 147-Pur Battery voltage. Work lights on. (Voltage OK) - Test bulbs; check lamp
wires. ground wires 010AC, 010AD, and 010AE
Blk.
9. Light switch OFF. Key switch to

Battery voltage. Right Turn indicator Test Turn Signal switch. (See Turn Signal
RUN. Press Turn Signal switch to
and Right Turn lamp flashing. Left Turn Switch Test in this Group.)
RIGHT. Turn Signal switch, 125 Grn
indicator and Left Turn lamp on steady. Check 125 Grn wire.
wire.
Battery voltage. Left Turn indicator and

Test Turn Signal switch. (See Turn Signal
10. Press Turn Signal switch to LEFT, Left Turn lamp flashing. Right Turn
Switch Test in this Group.)
115 Grn wire. indicator and Right Turn lamp on
Check 115 Grn wire.
steady.

Lighting Circuit Diagnosis 1025R

CONDITIONS:

PTO switch OFF
Key switch position OFF or as directed
Light switch and Turn Signal switch position as directed
Refer to or Lighting Circuit - 1025R for circuit schematic.
→NOTE:
Check fuse F10. Test Light switch. (See

1. Move Turn Signal switch to OFF. Light Switch Test in this Group.)
Move Light switch to HAZARD Battery voltage present. Display panel Check 122 and 002K Red wires. Check for
position. Light switch, 103 Org Left and Right Turn indicators flashing. battery voltage at: ICC connector J2—C, 103
wire. Org wire. See X—ICC—J2 Display Connector
)
Battery voltage cycles on-off. Left and (Output is open circuit or shorted) - Test
2. ROPS lamps, 135B and 135C
Right Turn lamps flashing. Display bulbs; check lamp ground wires 010J, 010K,
Grn wires and 145B and 145C Grn
panel readout does not show LTFT (left and 010C Blk. Check
wires.
turn fault) or RTFT (right turn fault). 135B, 135C, 145B and 145C Grn wires.
3. Move Light switch to ROAD

Battery voltage. Left and Right Turn Test Light switch. (See Light Switch Test in
position. Light switch, 138B Gry
lamps remain flashing. this Group.)
wire.
(No voltage) - Check fuse F02. Check all

4. Headlight sockets, 119-Wht
119-Wht wires, 138A and 138B Gray wires.
Wires. Battery voltage. Left and Right
(Voltage OK) - Test bulbs; check lamp
(See X—E01 and X—E02 Headlight headlights on.
ground wires 010G, 010H, 010X, and 010B
Connector .)
Blk.
(No voltage) - Check fuse F01. Check 138C,

Battery voltage. Left and Right Marker
5. ROPS lamps, 118-Gry wires. 138B, and (all) 118 Gry wires.
lights on.
(Voltage OK) - Test bulbs and grounds.

Headlights and Marker lights remain

Test Light switch. (See Light Switch Test in
6. Light switch in FIELD position. on. Turn Signal indicators and Turn
this Group.)
lamps are off.
Test Light switch. (See Light Switch Test in

7. Light switch, 137A Pur wire. Battery voltage.
this Group.)
(No voltage) - Check fuse F06. Check 137A,

8. Work lights, 147A and 147B Pur 147A, 147B, and 147C Pur wires.
Battery voltage. Work lights on.
wires. (Voltage OK) - Test bulbs; check lamp
ground wires 010L, 010M, and 010C Blk.
(No voltage) - Check fuse F06. Check 137A,

9. Fender lights, 147F and 147G
147A, 147D, 147E, 147F, and 147G Pur
Pur wires at lamps; 147D and 147E
wires.
at X54 and X55.
Battery voltage. Fender lights on. (Voltage OK) - Test bulbs; check lamp
(See X54 RH Fender Light
ground wires 010AB, 010F, 010Y, 010N,
Connector and X55 LH Fender
010S and 010C Blk. Check connectors X54
Light Connector .)
and X55.
10. Light switch OFF. Key switch to Battery voltage. Right Turn indicator
RUN. Press Turn Signal switch to and Right Turn lamp flashing. Left Turn
RIGHT. Turn Signal switch, 125 Grn indicator and Left Turn lamp on
Check 125 Grn wire.
wire. steady.
Battery voltage. Left Turn indicator

11. Press Turn Signal switch to and Left Turn lamp flashing. Right Turn
LEFT, 115 Grn wire. indicator and Right Turn lamp on
Check 115 Grn wire.
steady.

Instrument Control Cluster (ICC) Diagnosis
ICC Circuit — Test Procedure A:
CONDITIONS:

The following circuits tested:
Power
Charging
Cranking
PTO
Lighting
PTO On—Off switch to OFF
Key switch to RUN, engine off
Refer to , Instrument Control Cluster (ICC) - 1023E , or Instrument Control Cluster (ICC) -
1025R for circuit schematics.
Display back lights on. All LCD readout

In rare cases, the instrument cluster
1. Cycle key switch from OFF to RUN. segments active for 1 second,
may be faulty. Test all applicable
Observe the instrument cluster “Power reverting to hour meter function.
power, grounds, wires, connectors
On Self Test” (POST) — typically 5 Needle sweep and indicator light check
and components before replacing
seconds in length. within 5 seconds, reverting to normal
ICC.
operation.

Test the controlling switch. check

2. Key switch to RUN; the ICC powered wire between switch and ICC for an
and active. All switch controlled inputs, With input OFF (switch open or open circuit or short to voltage
that when activated, connect to the disconnected): 0.025—0.10 VDC source; a ground short typically blows
battery positive supply. typical. a fuse.
• With input ON (switch connected and Controlling switch wires
PTO On-Off switch connector closed): 11—14 VDC typical. •
• (See Instrument Control Cluster (ICC) - 574 Yel wire (ICC J1—H)
Seat switch connector 1023E , or Instrument Control Cluster •
• (ICC) - 1025R in the Section.) 521 Brn wire (ICC J3—K)
Neutral switch connector (See X—ICC—J1 Display EEC Connector •
• , X—ICC—J2 Display Connector and 514 Yel wire (ICC J3—P)
PTO MBR switch conector X—ICC—J3 Display Connector for ICC •
• connectors.) 594 Yel wire (ICC J3—B)
Park brake switch connector •
586 Blu wire (ICC J3—C)
3. Coolant Temperature sensor Check 359 Wht wire , ICC connector

Approximately 8.5 VDC
connector (unplugged), 359 Wht wire. J2—F.
4. Oil Pressure switch connector Check 347 Pur wire , ICC connector
Approximately 10.3 VDC
(unplugged), 347 Pur wire. J2—L.
ICC Circuit — Test Procedure B:
CONDITIONS:

ICC Circuit — Test Procedure A completed
All switches and components connected
PTO On—Off switch to OFF
Start engine and run at slow idle
Test oil pressure switch. (See Oil Pressure

1. Observe display panel, Light goes off shortly after engine has
Switch Test .)
engine oil pressure light started (oil pressure switch opens).
Check engine oil pressure.
Check 325 Grn wire from alternator connector to

ICC connector J2—J. (See X—G02 Alternator
Gauge displays current engine idle speed
2. Observe tachometer connector and X—ICC—J2 Display EEC Connector
(slow idle = 1575 ±25 rpm)
.)
Inspect alternator.
Needle slowly climbs to green zone as Check engine coolant system.

3. Observe temperature
engine warms up. Over temperature light Test engine coolant sensor. (See Coolant
gauge
off. Temperature Sensor Test .)
Review test conditions. Confirm that engine oil

Hour glass icon flashes once per second.
4. Observe hour meter pressure light is off and tachometer reads >450
Counter increments time every 6 minutes.
rpm.

Key Switch Test
Key Switch
LEGEND:
B Battery Terminal
G Ground Terminal
L Load Terminal
M M Terminal
S Start Terminal
[1] - Disconnect switch.
[2] - Use ohmmeter to check continuity across switch terminals.
a. If continuity is not present between terminals listed for each switch position, replace
switch
b. If continuity exists between terminals not listed for each switch position, replace switch.

Switch Continuity
Off G—M
Run B—L
Start B—L—S

PTO Switch Test
PTO Switch
LEGEND:
1 Common Terminal
4 Normally Open
3 Common Terminal
6 Momentary
7 Normally Closed
switch.

Switch Continuity
Off 1—7
On 1—4
RIO 3—6

Park Brake Switch Test
Park Brake Switch
LEGEND:
A Common
B Common
C Normally Open
D Normally Open
[2] - Access the switch on the left side of the machine.
[3] - Disconnect switch from wiring harness.
switch

Switch Continuity
Released A—C
Pressed B—D

Reverse Pedal Switch Test
[1] -
Reverse Pedal Switch
LEGEND:
A Common
B Common
C Normally Open
D Normally Open
[3] - Disconnect wiring harness from reverse pedal switch.
[4] - Use hydro pedals to move bell crank away from reverse pedal switch plunger.

switch.
Switch Continuity
Released A—C
Pressed B—D
[6] - Connect wiring harness to reverse pedal switch.
90, Group 15.)

[1] -
LEGEND:
A Reverse Pedal Switch
B Bracket
C Nut
D Screw
E Boot
F Bell Crank
G Nut
H Setscrew

[3] - Remove seat base. (See Remove Seat Base in Section 90, Group 15.)
[4] -
→NOTE:
The top edge of the switch flange should be in line with the top edge of the
bracket.
Confirm that the top edge of reverse pedal switch (A) mounting flange is in line with the top
edge of bracket (B).
[5] - If adjustment is necessary, loosen nuts (C) on screws (D).
[6] - Align top of reverse pedal switch (A) mounting flange with top of bracket (B). Tighten
nuts (C) on screws (D) to specification.
Reverse pedal switch mounting nut on screw. Torque 2.4—1.6 N·m (21.2—14.1 lb.-in.)
[7] - Using hydro pedals move bell crank (F) away from reverse pedal switch (A) plunger.
[8] -

Reverse Pedal Setscrew Offset
LEGEND:
F Bell Crank
G Nut
H Setscrew
I Setscrew Offset
Measure the setscrew offset (I) from the face of the bell crank (F). Compare measurement to
specification.
Setscrew Offset Measurement 4.26—4.06 mm (0.17—0.16 in.)
[9] - If adjustment is necessary, loosen nut (G) and adjust setscrew (H) to correct dimension.
[10] - Maintain the position of setscrew (H) and tighten nut (G) to specification.
Nut Torque 3.84—2.56 N·m (34—22.7 lb.-ft.)

[11] - Perform reverse pedal switch test. (See Reverse Pedal Switch Test in Section 240,
Group 15.)
[12] - Install seat base. (See Install Seat Base in Section 90, Group 15.)
90, Group 15.)

Seat Switch Test
Seat Switch

Seat Switch
LEGEND:
A Terminals
switch
Switch Continuity
Plunger Released None
Plunger Pressed Continuity

Light Switch Test
Light Switch
LEGEND:
B Common
1 All Positions Out
2 Hazard and Road Out
3 Road and Field Out
4 Field Out
[2] - Remove left side engine panel to gain access to switch.
[3] - Disconnect switch from wiring harness and remove switch from machine.

switch
Switch Continuity
Off B—1
Hazard B — 1 and B — 2
Road B — 1 and B — 2 and B — 3
Field B — 1 and B — 3 and B — 4

Turn Signal Switch Test
Turn Signal Switch
LEGEND:
A Common Terminal
B Normally Open
C Normally Open
switch
Switch Continuity
Off None
On (both directions) A — B or A — C

Hazard Switch Test
Hazard Switch
LEGEND:
1 Normally Closed
2 Common
3 Normally Open
5 Common
10 LED Indicator Light
17 Normally Open
18 LED Indicator Light
[2] - Remove side panel to gain access to switch.
[3] - Disconnect switch from wiring harness and remove switch from machine.

[4] -
→NOTE:
Pins 10 and 18 are for the LED indicator light.
Use ohmmeter to check continuity across switch terminals.
switch
Switch Continuity
Off 1—2
On 2 — 3 and 5 — 17 and 5 — 18

PTO MBR Switch Test
PTO MBR Switch
LEGEND:
A Terminals
[2] - Unplug connector from MBR switch.
[3] - Attach ohmmeter leads across the switch terminals (A).
[4] - Shift the PTO lever as directed and note meter readings.
Mid PTO and Mid+REAR PTO positions: no continuity

REAR PTO position: continuity
[5] - If continuity is not correct, remove switch from the transmission.

[6] - Test switch continuity in OPEN and CLOSED positions.
OPEN (plunger released): no continuity

CLOSED (plunger depressed): continuity
Results
If any continuity is NOT correct, replace switch.

If continuity is correct with switch removed, but not with switch installed in
transmission, see the power train repair Section 50.

PTO Solenoid Test
PTO Solenoid

PTO Solenoid and Connector
LEGEND:
A Terminal
B Terminal
[1] - Disconnect Y03 solenoid connector.
[2] - Use ohmmeter to check continuity across terminals.
a. If continuity is not present between terminals listed, replace solenoid

b. If continuity exists between terminals and housing, replace solenoid.
[3] -
IMPORTANT:
Check solenoid for secure connection.
Reconnect solenoid. Confirm connector seal is not damaged. Verify that locking tabs are fully
engaged into solenoid body retaining slots.

Continuity
A—B Approximately 5.5 Ohms
A — Housing None
B — Housing None

Neutral Switch Test
Neutral Switch
LEGEND:
A Terminals
[2] - Disconnect wiring harness from switch.
[3] - Attach ohmmeter leads across the switch terminals (A).
[4] - Shift the transmission range to high or low.
Range in gear position: no continuity

Neutral position: continuity
[5] - If continuity is not correct, drain the transmission and remove switch.
[6] - Test switch continuity in OPEN and CLOSED positions.
OPEN (plunger released): no continuity

CLOSED (plunger depressed): continuity
Results
If any continuity is NOT correct, replace switch.

If continuity is correct with switch removed, but not with switch installed in
transmission, see the power train repair Section 50.

Horn Switch Test
Horn Switch
LEGEND:
A Terminals
switch
Switch Continuity
Plunger Released None
Plunger Pressed Continuity

Relay Test
Relay - LVA13729

Relay - LVA17565
LEGEND:
A Terminal 85
B Terminal 86
C Terminal 30
D Terminal 87a
E Terminal 87
[1] - Remove relay from load center.
[2] - Use ohmmeter to check continuity between relay terminals 87A and 30 (D and C).
[3] - Check for no continuity between terminals 30 and 87 (C and E).
[4] - Measure resistance between 85 and 86 (A and B).

[5] - Connect a jumper wire from battery positive (+) post to relay terminal 85 (A). Connect a
jumper wire from relay terminal 86 (B) to ground (–). Continuity should now exist between
terminals 30 and 87 (C and E); no continuity between 30 and 87A (C and D).
Results:
If continuity is not correct, replace relay.

If resistance is approximately 680 ohms the relay coil is open, replace relay.
If resistance between terminals 85 and 86 (A and B) does not meet specification,
replace relay.
Relay Coil Resistance
Large Relay 80 Ω ±10%
Small Relay 105 Ω ±10%

Oil Pressure Switch Test
Oil Pressure Switch
LEGEND:
A Wire
B Body Ground
C Switch Terminal
→NOTE:
Perform test with engine at room temperature.
[1] - Park machine safely with park brake locked.
[2] - Disconnect wire (A) from switch.

[3] - Use ohmmeter to check continuity between switch terminal and ground.
→NOTE:
Be sure to apply Pipe Sealant with TEFLON ™ to threads of switch
anytime it is installed.
If continuity is present between terminal and ground with engine off, replace switch.
b. If continuity is present, proceed to next step.
[4] - Start engine.
[5] - Measure resistance between terminal and engine block.
a. If continuity is present between terminal and ground, switch is good.

b. If continuity is not present between terminal and ground, test oil pressure. If oil
pressure is greater than 55 kPa (8 psi), replace switch.
Switch Continuity
Engine Off B—C
Engine Running None

Coolant Temperature Sensor Test
CAUTION:
step.
Temperature Sensor
LEGEND:
A Temperature Sensor
[3] - Remove coolant temperature sensor. (See Remove and Install Coolant Temperature
Sensor in Section 20, Group 10.)
[4] -
CAUTION:
DO NOT allow sensor or thermometer to rest against the side or bottom of

glass container when heating water. Either may rupture if overheated.
Suspend sensor (A) in water and coolant mixture.
[5] - Bring water and coolant mixture to specified temperatures while measuring resistance
of sensor. Use ohmmeter to check resistance across solenoid terminals.
[6] - If resistance does not meet specification, replace coolant temperature sensor.
[7] - Install sensor.
a. Replace copper washer.

b. Tighten sensor to specification.
Coolant Temperature Sensor Torque 24 ± 3 N·m
(212 ± 27 lb.-in.)
c. Refill radiator and recovery tank with approved coolant.
Coolant Temperature Sensor Specifications
Resistance at 60 °C (140 °F) 251 Ohms

Fuel Shutoff Solenoid Test
Fuel Shutoff Solenoid
LEGEND:
A Black Terminal
B White Terminal
C Red Terminal
[3] - Disconnect wiring harness from solenoid.

[4] - Use ohmmeter to check resistance across solenoid terminals.
a. Hold-in coil terminals A to C.

b. Pull-in coil terminals A to B.
c. Combined coils B to C.
[5] - Check for grounds or shorts between solenoid terminals (A, B, and C) and solenoid
housing. There must be no continuity between any terminal and the solenoid housing.
[6] - If resistance does not meet specification, replace solenoid.
Specifications
Terminals A — C 22.6 Ohms
Terminals A — B 0.4 Ohms
Terminals B — C 23 Ohms

Group 20: Wiring Schematics
Regulated Voltage Output Test
[1] - Park machine safely. Key switch OFF.
[2] - Remove surface charge from battery by turning on the headlights for 1 minute.
[3] - Set multimeter to measure DC voltage.
[4] - Connect meter black lead to battery negative (–) terminal.
[5] - Connect meter red lead to battery positive (+) terminal.
[6] - Start and run engine at FAST idle.
[7] - Read meter several times during 5 minutes of fast idling. Voltage should remain at
specification.
Regulated Output Voltage 13.9—14.6 VDC
a. If the DC voltage remains below the minimum specification: Check belt tension. Test
power cables between alternator and battery. Check for power at the regulator
connector Red wire. Inspect alternator for worn or damaged brushes, slip rings, shorted
diodes, or burnt wires. If all appears OK, replace voltage regulator.
b. If the DC voltage goes above the maximum specification, replace the voltage regulator.
→NOTE:
Alternator outputs exceeding 20 VDC shuts down all instrument control

cluster outputs and stops machine operation.

Group 20 - Wiring Schematics
Schematic Information
1023E Schematic Legend
1023E Schematic
1025R Schematic Legend
1025R Schematic
1026R EEC Schematic Legend
1026R EEC Schematic
Schematic Information
The wiring schematics are drawn with the battery positive circuit across the top and the
ground, or battery negative, circuit across the bottom. The flow is then, as much as possible,
from top to bottom through each circuit and component. All components are shown in their
normal (de-energized) position.
The circuit numbers used in the schematics represent entire circuit sections using the same
number. Actual circuits may have letter suffixes added to indicate specific portions of the
circuit. For the exact designation, refer to the tractor wiring harness.

1023E Schematic Legend
Components
DEFINITIONS:
B02 Coolant Temperature Sensor
B04 Oil Pressure Switch
E01 Left Headlamp
E02 Right Headlamp
E03 LH ROPS Lamp
E04 RH ROPS Lamp
E05 Left Fender Light
E06 Right Fender Light
E07 LH Work Light
E08 RH Work Light
F01 10A Fuse
F02 10A Fuse
F06 20A Fuse
F08 10A Fuse
F09 20A Fuse
F10 30A Fuse
G01 Battery
G02 Alternator
K01 Fuel Shutoff Relay
K02 Start Relay
K03 Glow Plug Relay
M01 Start Motor
M02 Fuel Pump
R01 Glow Plug
R02 Glow Plug
R03 Glow Plug
S01 Key Switch
S02 Light Switch
S03 Turn Signal Switch
S04 Neutral Switch
S05 PTO On/Off Switch
S08 MBR PTO Switch
S10 Mower Lift Switch
S11 Horn Switch
S38 Seat Switch
S41 Park Brake Switch
S60 Reverse Pedal Sense
W01 Ground
X40 Front Hitch Detection
Y01 Start Solenoid
Y02 Fuel Shutoff Solenoid
Y03 PTO Solenoid
Y04 Mower Lift Solenoid

Schematic Sections
DEFINITIONS:
SE01 Operator Station - Key Switch, Alternator and Starting
SE02A Lighting and Turn Signal
SE02B Work Lights Option
SE03 Operator Station Instrumentation
SE03A Instrument Cluster
SE04 Seat, Brake, Park Brake, Neutral Switches and PTO
SE05 not used
SE06 Mower Lift Kit Option

1023E Schematic
1023E Schematic Sheet 1 of 8

1023E Schematic Sheet 2







1025R Schematic Legend
Components
DEFINITIONS:
B02 Coolant Temperature Sensor
E01 Left Headlamp
E02 Right Headlamp
E03 LH ROPS Lamp
E04 RH ROPS Lamp
E07 LH Work Light
E08 RH Work Light
F01 10A Fuse
F02 10A Fuse
F06 20A Fuse
F08 10A Fuse
F09 20A Fuse
F10 30A Fuse
G01 Battery
G02 Alternator
K02 Start Relay
K03 Glow Plug Relay
M01 Start Motor
M02 Fuel Pump
R01 Glow Plug
R02 Glow Plug
R03 Glow Plug
S01 Key Switch
S02 Light Switch
S04 Neutral Switch
S08 MBR PTO Switch
S38 Seat Switch
X03 Power Port
W01 Ground
Y01 Start Solenoid
Y03 PTO Solenoid

Schematic Sections
DEFINITIONS:
SE01 Operator Station: Key Switch, Alternator and Starting
SE02A Lighting and Turn Signal
SE02B Work Lights Option
SE05 Power Port

1025R Schematic
1025R Schematic Sheet 1 of 8

1025R Schematic Sheet 2







1026R EEC Schematic Legend
Components
DEFINITIONS:
B02 Coolant Temperature Sender
E01 Left Headlamp
E02 Right Headlamp
E03 LH Work Light
E04 RH Work Light
E05 RH Front Turn/Hazard Light
E06 RH Front Marker Light
E07 RH Rear Turn/Hazard Light
E08 RH Brake and Rear Marker Lights
E11 LH Front Turn/Hazard Light
E12 LH Front Marker Light
E13 LH Rear Turn/Hazard Light
E14 LH Brake and Rear Marker Lights
E18 License Plate Light
F01 10A Fuse
F02 10A Fuse
F03 20A Fuse
F04 20A Fuse
F06 15A Fuse
F07 30A Fuse
F09 20A Fuse
F10 20A Fuse
F11 20A Fuse
F12 20A Fuse
H2 Horn
G01 Battery
G02 Alternator
K02 Start Relay
K03 Glow Plug/Cab Relay
K04 Marker Lights Relay
K05 Trailer Relay
K06 Brake Relay
M01 Start Motor
M02 Fuel Pump
R01 Glow Plug
R02 Glow Plug
R03 Glow Plug
S01 Key Switch
S02 Light Switch
S04 Neutral Switch


S08 MBR PTO Switch
S11 Horn Switch
S13 Hazard Light Switch
S38 Seat Switch
S42 Brake Switch
W01 Ground
X03 Power Port
Y01 Start Solenoid
Y03 PTO Solenoid
Schematic Sections
DEFINITIONS:
SE01 Operator Station - Key Switch, Alternator and Starting
SE01A Operator Station - Key Switch, Alternator and Starting
SE02 Lighting, Turn Signal and Horn
SE02A Lighting, Turn Signal and Horn
SE02B Lighting, Turn Signal and Horn
SE05 Power Port

1026R EEC Schematic
1026R EEC Schematic Sheet 1 of 10

1026R EEC Schematic Sheet 2








Group 25: Connector Information

Group 25 - Connector Information
K01— K04 Relay Connector
X03 Power Port Connector
X09 Mow Lift Solenoid Connector
X54 RH Fender Light Connector
X55 LH Fender Light Connector
X—E01 and X—E02 Headlight Connector
X—E01 and X—E02 EEC Headlight Connector
X—G02 Alternator Connector
X—ICC—J1 Display Connector
X—K07 Flasher Connector
X—M01 Start Motor Connector
X—M02 Fuel Pump Connector
X—R01 Glow Plug Connector
X—S01 Key Switch Connector
X—S02 (X—S08 EEC) Light Switch Connector
X—S03 Turn Signal Switch Connector
X—S04 Neutral Start Switch Connector
X—S05 (X—S02 EEC) PTO Switch Connector
X—S08 (X—X07) MBR Switch Connector
X—S10 Mow Lift Switch Connector
X—S13 Hazard Switch Connector
X—S38 Seat Switch Connector
X—S41 Park Brake Switch Connector
X—S42 Brake Switch Connector
X—S41 Park Brake Switch Connector — EEC

X—Y02 Fuel Shutoff Solenoid Connector

X—Y03 PTO Solenoid Connector

K01—K04 Relay Socket
K01 Fuel Solenoid Relay Connector
Schematic: —
Wiring Harnesses: 1023E, 1025R, 1026R EEC
Terminal Circuit Number
30 002F (1023E and 1025R), 002L (1026R EEC)
85 010U (1023E and 1025R), 010AA (1026R EEC)
86 522
87 329
87a —
K02 Start Relay Connector
Schematic: —

30 572A
85 010V (1023E and 1025R), 010F (1026R EEC)
86 369
87 309A (1023E), 309B (1025R), 309 (1026R EEC)
87a —
K03 Glow Plug Relay Connector
Schematic: —
Wiring Harnesses: 1023E, 1025R
30 020D
85 010U, 010E
86 385
87 383
87a —
K03 Glow Plug and Cab Power Relay Connector
Schematic: —
Wiring Harnesses: 1026R EEC
30 002B
85 010L, 010P
86 385
87 383
87a 002H (to fuse F07)
K04 Marker Lights Relay Connector
Schematic: —
30 133C
85 010M, 010N
86 137B
87 122B
87a 103

K05--K06 Relay Socket
K05 Trailer Relay Connector
Schematic: —
30 (3) 252
85 (1) 010N, 010P
86 (2) 072E
87 (5) 222
87a (4) —
K06 Brake Relay Connector
Schematic: —

30 (3) 042D
85 (1) 010P, 010AA
86 (2) 116
87 (5) 136A
87a (4) —

X03 Component Location
Schematic: —
Wiring Harnesses: 1025R, 1026R EEC
1 262B

2 010AA

Schematic: —

A 706A
B 010AG (010AM 1026R EEC)

X54 RH Light Connector
Schematic: —

A 262A
B 010AF
C 147D

X55 LH Light Connector
Schematic: —

A 147E
B 010AG

X-E01 and X-E02 Headlight Connector
X-E01 and X-E02 Component Location
Schematic: —

A 119B (Left), 119C (Right)
B 010G (Left), 010H (Right)

X—E01 and X—E02 EEC Headlight Connector
X-E01 and X-E02 EEC Headlight Connector

X-E01 and X-E02 Component Location
Schematic: —
A not used
B 119B (Left), 119C (Right)
C 010D (Left), 010C (Right)

X-G02 Alternator Connector
X-G02 Component Location

Schematic: —
1 (L) 334
2 (IG) 562E
3 (P) 325

X-ICC-J1 Display Connector
J1 Connector Location
Schematic: —
A 012C
B 012D
C 012E
F 562C
G 747

H 574
K 115
L 125
M 050A

X—ICC—J1 Display EEC Connector
X-ICC-J1 Display EEC Connector
J1 Connector EEC Location
Schematic: —
A 012C
B 012D
C 012E
D 102B
F 562C
G 747

H 574
K 115A
L 125A
M 050B

X-ICC-J2 Component Location
Schematic: —
C 103
D 118D
F 359
G 145A

H 135A
J 325
L 347

X-ICC-J2 Display EEC Connector
X-ICC-J2 Component EEC Location
Schematic: —
C 113
D 118F
F 359
G 145A

H 135A
J 325
L 347
N 165
P 155

X-ICC-J3 Component Location
Schematic: —
A 302
B 594
C 586
D 572B
E 573
F 576
G 564

H 565
K 521
L 385
M 522
N 369
P 514

X—K07 Flasher Connector
X-K07 Flasher Connector
X-K07 Component Location
X-K07 Flasher Connector
Schematic: —

49A 127C
C 148
49 102A
31 010K
C2 146
C3 not used

X-M01 Start Motor Connector
X-M01 Component Location
Schematic: —

309A — 1023E
1 309B — 1025R
309 — 1026R EEC

X—M02 Fuel Pump Connector
X-M02 Fuel Pump Connector

X-M02 Component Location
X—M02 Alternator Connector
Schematic: —
1 (L) 562N
2 (IG) 010AF

X-R01 Glow Plug Connector

X-R01 Component Location
Schematic: —
1 383

X-S01 Key switch Connector
X-S01 Component Location
Schematic: —

1 (Bat) 012A
2 (S) 0572A, 0572B
3 (M) —
4 (L) 072B
5 (G) —

X—S02 (X—S08 EEC) Light Switch Connector
X-S02 Light Switch Connector (Rear View)
X—S02 Light Switch Connector
Schematic: —
Wiring Harnesses: 1023E

1 —
2 103
3 138B
4 —
B 122
Schematic: —
Wiring Harnesses: 1025R
1 —
2 103
3 138B
4 137A
B 122
Schematic: —
1 —
2 103
3 138
4 137A
B 122A

X-S03 Turn Signal Switch Connector

Schematic: —
1 115
2 562K
3 115
Schematic: —
1 125A
2 127A
3 115A

X-S04 Neutral Start Switch Connector
Schematic: —

A 562G
B 514

X—S05 (X—S02 EEC) PTO Switch Connector
X-S05 (X—S02 EEC) PTO Switch Connector
X—S05 PTO Switch Connector
Schematic: —
1 562D
3 562R
4 574
6 573

X—S08 (X—X07) MBR Switch Connector
X-S08 MBR Switch Connector
X—S08 MBR Switch Connector
Schematic: —

A 562J
B 594

X-S10 Mow Lift Switch Connector

Schematic: —
2 562P
3 706A
Schematic: —
2 562K
3 706A

X—S13 Hazard Switch Connector
X-S13 Hazard Switch Connector

X-S13 Hazard Switch Connector
Schematic: —
1 072A
2 102A, 102B
3 042B
5 127B
10 010J
17 115C
18 125C

X-S38 Seat Switch Connector
Schematic: —
A 562F

B 521

X—S40 Front Hitch Detection Connector
X-S40 Front Hitch Detection Connector
Schematic: —
A 562T
B 565

C 050B
Schematic: —
A 562N
B 565
C 050C

X-S41 Park Brake Switch Connector

Schematic: —
B 562B
D 586

X—S41 Park Brake Switch Connector — EEC
X-S41 Park Brake Switch Connector
Schematic: —

B 562B
D 586

X-S42 Brake Switch Connector
Schematic: —

A 042A
C 116

X—S60 Reverse Pedal Sense Connector
X-S60 Reverse Pedal Sense Connector
Schematic: —
A 562L
B 562M
C 564

D 576
Schematic: —
A 562N
B 562P
C 564
D 576

X-Y02 Fuel Shutoff Solenoid Connector

X-Y02 Component Location
Schematic: —
A 302
B 329
010D — 1023E, 1025R

C
010H — 1026R EEC

X-Y03 PTO Solenoid Connector
X-Y03 Component Location
Schematic: —

POWER TRAIN OPERATION, TESTS, AND (g) by Belgreen
ADJUSTMENTS
1 747
2 010R

Section 250 - POWER TRAIN OPERATION, TESTS, AND

ADJUSTMENTS
Table of contents
Transmission Sub-Assemblies ................................................................................................ 2
Driveshaft .............................................................................................................................. 3
Hydraulic Transmission .......................................................................................................... 6
Gear Transmission Sub-Assemblies ....................................................................................... 7
Transmission Housing ............................................................................................................ 9
Range Gears, Pinion, and Bevel Gear ................................................................................... 11
Differential ........................................................................................................................... 12
Brakes .................................................................................................................................. 14
Axles .................................................................................................................................... 15
Mechanical Front Wheel Drive (MFWD) ................................................................................ 16
PTO Clutch ........................................................................................................................... 18
PTO Drive ............................................................................................................................. 20
Rockshaft - 1023E ................................................................................................................ 22
Rockshaft With Feedback - 1025R ....................................................................................... 24
Hydraulic Pump and PTO Valve ............................................................................................ 27
Front Axle Input Gear and Differential ................................................................................. 29
Front Axle Case and Tie Rod ................................................................................................ 30
Front Axle Final Drive Gears ................................................................................................. 33
Group 10 - Theory of Operation ............................................................................................ 35
Gear Train Operation ........................................................................................................... 36
Range Gear Operation ......................................................................................................... 38
MFWD Operation .................................................................................................................. 40
PTO Operation ...................................................................................................................... 42
Group 15 - Diagnosis, Test and Adjustments ..................................................................... 46
Specifications ....................................................................................................................... 47
MFWD Diagnosis .................................................................................................................. 49
Adjust Neutral Creep ............................................................................................................ 50
Adjust Differential Lock ........................................................................................................ 55
Adjust Forward and Reverse Pedals ..................................................................................... 57
Cone Point and Backlash Setting ......................................................................................... 66

ADJUSTMENTS
Transmission Sub-Assemblies
Driveshaft
Hydraulic Transmission
Gear Transmission Sub-Assemblies
Transmission Housing
Range Gears, Pinion, and Bevel Gear
Differential
Brakes
Axles
Mechanical Front Wheel Drive (MFWD)
PTO Clutch
PTO Drive
Rockshaft - 1023E
Rockshaft With Feedback - 1025R
Hydraulic Pump and PTO Valve
Front Axle Input Gear and Differential
Front Axle Case and Tie Rod
Front Axle Final Drive Gears

ADJUSTMENTS
LEGEND:
A Hydraulic Transmission
B Gear Transmission
C Rockshaft (Basic Assembly Shown)
D Hydraulic Implement Pump
E Hydraulic Valve Assembly
Driveshaft

ADJUSTMENTS
Driveshaft, Engine-to-Transmission
LEGEND:
A Bolt M8x50 (3 used)
B Washer (6 used)
C Hub
D Dampener
E Bolt M8x60 (3 uesd)
F Bearing

ADJUSTMENTS
G Hub
H Snap Ring
I Roll Pin
J Driveshaft Assembly

ADJUSTMENTS
Hydraulic Transmission
Hydraulic Transmission Components
LEGEND:
A Snap Ring
B Seal
C Spacer
D Clip

ADJUSTMENTS
E Bearing
F Plug
G O-ring
H O-ring (2 used)
I Housing
J Screw (6 used)
K Seal
L Swash Plate
M Bushing (2 used)
N Thrust Washer, Thin
O Thrust Bearing, Roller
P Thrust Washer, Thick
Q Drive Shaft, Pump
R Piston (14 used)
S Spring and Retainer (14 used)
T Cylinder (2 used)
U Washer (4 used)
V Spring (2 used)
W Snap Ring (2 used)
X Plate, Pump
Y Bearing (2 used)
Z Locator Pin (2 used)
AA Valve, Forward
AB Valve, Reverse
AC Bolt (2 used)
AD Plug
AE O-ring
AF Spring, Relief
AG Valve, Charge
AH Bolt (5 used)
AI Bolt (2 used)
AJ O-ring
AK O-ring
AL O-ring
AM Housing
AN Gasket
AO Plate, Motor
AP Bearing Race
AQ Thrust Bearing, Ball
AR Bearing Race
AS Output Shaft, Motor
AT Bearing
AU Housing
AV Bolt (2 used)
AW Plate
AX Bolt (2 used)

ADJUSTMENTS
Gear Transmission Sub-Assemblies
Gear Transmission
LEGEND:
A Right-hand Axle and Housing
B Brake Assembly
C Pinion and Bevel Gear
D Ring Gear and Differential
E PTO Clutch
F PTO and MFWD Gear Assembly
G Left-Hand Axle
H Range Gears Assembly
I MFWD

ADJUSTMENTS
Transmission Housing
Transmission Housing Components
LEGEND:
A Transmission Front Cover
B O-ring
C Plug
D Transmission Housing
E Locating Pin (8 used)
F Dipstick, Oil Level
G Transmission Rear Cover
H Bolt, Hex Flanged, M8 x 30 (9 used)
I Bracket, Frame Attachment (4 used)
J Bolt, Hex Flanged, M14 x 55 (10 used)
K Shift Detent Assembly (Plug, O-ring, Spring, Plunger)
L Relief Valve Assembly (Plug, O-ring, Spring, Ball)
M Filter

ADJUSTMENTS
N Magnet (2 used - located inside filter)

O O-ring
P O-ring
Q Elbow, Hose Fitting
R Bolt, M6
S Snap Ring
T Seal, Axle Shaft
U Bearing, Axle Shaft
V Seal, Shift Shaft
W Bolt, Hex Flanged, M8 x 30 (4 used)
X Filter, Oil
Y Plug, Oil Seal
Z Bolt, Hex Flanged, M8 x 65 (6 used)

ADJUSTMENTS
LEGEND:
A Backlash Shim
[ Cone point and backlash shims used from the respective kits vary for pinion and backlash adjustment. ]
B Bearing
C Bevel Gear
D Pinion

ADJUSTMENTS
E Bearing
F Range Output Gear
G Cone Point Shim (2 used)
H Bearing
I Snap Ring
J Nut (note orientation)
K Bearing
L Input Shaft
M Range Sliding Gear
N Bearing
O Shift Arm
P O-ring
Q Keeper
R Bolt
S Pin
T Shaft, Detent
U Shift Fork
V Spring
W Ball, Detent
Differential

ADJUSTMENTS
Differential Component Location
LEGEND:
A Final Drive Pinion Shaft
B Bearing
C Washer, Differential (2 used)
D Pinion Gear (2 used)
E Pinion Shaft
F Pin
G Differential Lock
H Bearing
I Bolt (12 used)
J Final Drive Ring Gear
K Bearing
ADJUSTMENTS
L Washer
M Differential Side Gear
N Differential Housing
O Differential Side Gear, Locking
P Arm (2 used)
Q Seal (2 used)
R Spring
S Differential Lock Fork Shaft
T Differential Lock Fork
Brakes
Brakes Component Location

ADJUSTMENTS
LEGEND:
A Axle Housing, Right
B Hex Flange Bolt, M10 x 35 (13 used)
C Locating Dowel (2 used)
D Ball Bearing
E Actuator, Brake
F Disk, Brake Friction (3 used)
G Brake Separator Plate (3 used)
H Brake Quill
I Bolt, Hex Flange, M10 x 35 (3 used)
J Plug, Drain
K Shim
L Bearing
M Bevel Gear
N Final Drive Pinion Shaft
O Bearing
P Cam Shaft, Brake
Q O-Ring
R Washer
S Snap Ring
Axles

ADJUSTMENTS
Axle Components
LEGEND:
A Axle Shaft, Right-Hand
B Snap Ring
C Seal
D Bearing
E Snap Ring
F Bolt
G Axle Housing
H Bracket
I Bolt
J Seal
K Plug
L Axle Shaft, Left-Hand

ADJUSTMENTS
Mechanical Front Wheel Drive (MFWD)
MFWD Drive Components
LEGEND:
A O-Ring
B Shift Lever
C Bolt
D Keeper
E Plug, Detent
F O-Ring
G Spring
H Pin, Detent
I Seal
J Bearing
K MFWD Output Shaft
L Shift Collar
M Circlip
N Bearing

ADJUSTMENTS
PTO Clutch
PTO Clutch Components
LEGEND:
A Coupler
B Circlip
C Snap Ring
D Bearing
E Split Seal (2 used)
F Snap Ring
G Clutch Shaft
H Brake Plate
I Brake Disk
J Plate
K Pin (3 used)
L Bearing
M PTO Cylinder
N Socket Head Bolt (6 used)
O O-Ring

ADJUSTMENTS
P O-Ring
Q Piston
R Spring
S Thrust Washer
T Circlip
U Plate (4 used)
V Disc (3 used)
W Splined Hub
X PTO Drum
Y Bearing
Z Splined Collar

ADJUSTMENTS
PTO Drive
PTO Drive Components
LEGEND:
A Snap Ring
B Mid PTO Input Gear
C Snap Ring
D Bearing
E Seal Ring
F Mid PTO Pinion Shaft
G Needle Bearing
H Shift Collar
ADJUSTMENTS
I Hub
J Gear, PTO Select
K Bearing
L Snap Ring
M Bearing
N Pinion, Rear PTO
O Bearing
P Bearing
Q Idler Gear, Rear PTO
R PTO Shift Clip
S PTO Shift Arm
T O-Ring
U Plate, Retainer
V Bolt
W Detent Pin
X Spring
Y O-Ring
Z Plug
AA Bearing
AB Shaft, PTO Output AC
AC Bearing
AD Seal
AE Mid PTO Idler Gear
AF Bearing
AG Snap Ring
AH Seal
AI Bearing
AJ Mid PTO Shaft
AK Bearing

ADJUSTMENTS
Rockshaft - 1023E
Rockshaft Components
LEGEND:
A Arm (2 used)
B Washer (2 used)
C O-Ring (2 used)
D Sleeve (2 used)
E Rockshaft Housing
F O-Ring
G Cap
H Bolt, M10 x 50 (6 used)
I Fitting
J Bolt, M10,x,70 (2 used)
K Shaft
L Snap Ring (2 used)

ADJUSTMENTS
M Arm, Crank
N Pin
O Rod
P O-Ring
Q Slip Ring
R O-Ring
S Piston
T Relief Valve
U Arm
V Valve Assembly
W Screw, M6 x 25 (3 used)
X Pin, Locating
Y Plate, Keeper
Z Arm
AA Rate-of-Drop Valve Assembly

ADJUSTMENTS
Rockshaft With Feedback - 1025R
Rockshaft Arms and Rate of Drop Valve Assembly
LEGEND:
A Arm (2 used)
B Washer (2 used)
C O-Ring (2 used)
D Arm, Crank
E Sleeve (2 used)
F Shaft
G Rockshaft Housing
H O-Ring
I Cap
J Snap Ring (2 used)
K Relief Valve Assembly
L Valve Assembly
M Rate of Drop Valve Assembly
N Rod
O O-Ring
P Slip Ring
Q O-Ring
R Piston
ADJUSTMENTS
S Pin
T Pin
U Washer
V Pin
Rockshaft Raise/Lower Valve Assembly
LEGEND:
A Pin
B Washer
C Feedback Arm
D Nut, Jam (2 used)
E Bracket
F Pin
G Arm
H Washer
I Clip
J Screw, Socket Head, M8 x 20
K Valve Assembly, Raise/Lower
ADJUSTMENTS
L O-Ring (2 used)
M Housing
N O-Ring (2 used)
O Screw, Socket Head, M8 x 25
P Pin, Locating (2 used)
Q Link Bracket
R Washer
S Snap Ring (4 used)
T Cam Shaft
U Washer
V O-Ring
W Cam Shaft
X Gasket
Y Housing
Z Bolt, M8 x 50 (2 used)
AA Bolt, M8 x 65 (2 used)
AB Washer
AC Cam
AD Key
AE Washer, Friction (AR)
AF Arm, Lift Control
AG Flange Nut, M10

ADJUSTMENTS
Hydraulic Pump and PTO Valve
Hydraulic Pump and PTO Valve Components
LEGEND:
A O-Ring (2 used)
B Fitting (2 used)
C O-Ring (2 used)
D Relief Valve
E Divider Valve
F O-Ring (2 used)
G Valve Body, PTO
H Bolt, M8 x 30 (2 used)
I Valve, Solenoid
J Screw (2 used)
K Elbow, Hose Fitting
L Bolt, M6
M O-Ring
N Bolt, M6 x 16 (3 used)

ADJUSTMENTS
O Gasket
P O-Ring
Q Fitting, Elbow
R O-Ring
S Pipe Assembly
T O-Ring
U Fitting
V O-Ring
W Bolt, M8 x 90 (2 used)
X Pump, Implement
Y Bolt, M8 x 35 (2 used)
Z O-Ring
AA O-Ring
AB Pipe, Suction
AC Clamp
AD Hose, Suction
AE Clamp

ADJUSTMENTS
Front Axle Input Gear and Differential
Front Axle Input Gear and Differential Components
LEGEND:
A Pinion Gear, 12T
ADJUSTMENTS
B Bearing
C Snap Ring
D Shaft, Right
E Snap Ring
F Bearing (2 used)
G Differential Case
H Thrust Washer (2 used)
I Gear (2 used)
J Thrust Washer (2 used)
K Pinion, Differential (2 used)
L Shaft, Differential Pinion (2 used)
M Pin
N Gear, 23T
O Input Gear, 12T
P Bearing (2 used)
Q Collar
R Snap Ring
S Washer
T Snap Ring
U Seal
V Front Axle Case
W Shaft, Left
Front Axle Case and Tie Rod

ADJUSTMENTS
Front Axle Case and Tie Rod Components
LEGEND:
A Dipstick
B O-ring
C Bolt M10x25 (10 used)
D Bushing (2 used)
E Washer (2 used)
F Lock Nut
G Front Axle Case
H Packing (2 used)
I Pinion 10x20 (2 used)
J Nut (2 used)
K Pin (2 used)
L Tie Rod
M Bolt

ADJUSTMENTS
N Bolt M12x12
O Gasket

ADJUSTMENTS
Front Axle Final Drive Gears
Front Axle Final Drive Gears and Case Components
LEGEND:
A Cap (2 used)
B Gear, 16T (2 used)
C Bearing (2 used)
D Front Gear Case (2 used)

ADJUSTMENTS
E Shaft, 2nd (2 used)

F Pinion Gear, 9T (2 used)
G Bearing (2 used)
H Seal (2 used)
I Bearing (2 used)
J Collar (2 used)
K Snap Ring (2 used)
L Snap Ring (2 used)
M Bearing (2 used)
N Plug (2 used)
O Front Gear Case (Left Shown)
P Gasket (2 used)
Q Bolt M12x12 (2 used)
R Bearing (2 used)
S Final Drive Gear, 39T (2 used)
T Snap Ring (2 used)
U Bearing (2 used)
V Gasket (2 used)
W Bearing Case (2 used)
X Seal (2 used)
Y Spindle (2 used)
Z Bolt M8x25 (16 used)

ADJUSTMENTS
Gear Train Operation
Range Gear Operation
MFWD Operation
PTO Operation

ADJUSTMENTS
Gear Train Operation
Gear Train
LEGEND:
A Input Shaft
B PTO Input Shaft
C MFWD Shaft
D Front PTO Shaft
E Rear PTO
F Pinion Shaft
Inputs
There are two drive inputs from the hydraulic transmission to the gear transmission; the
variable (forward and reverse swash plate) input to the gear drive input shaft (A), and the
relatively constant (engine rpm) input to the PTO input shaft (B).
The gear input shaft is splined to the range sliding gear which can be shifted and engage the
high range gear, not engage a gear (neutral), or engage the low range gear. See Range Gear
Operation .
The PTO input shaft drives the PTO gears when the PTO clutch is engaged driving the PTO

ADJUSTMENTS
clutch drum and the PTO selection gear. See PTO Operation .
Outputs
There are four outputs; the MFWD shaft (C) to the front axle, the front PTO shaft (D), the rear
PTO (E), and the final drive pinion shaft (F) which drive the differential and rear wheels.

ADJUSTMENTS
LEGEND:
A Input Shaft
B Sliding Gear
C Gear, Small
D Gear, Large
E Pinion Gear
F Bevel Gear
The gear input shaft (A) is splined to the range sliding gear (B). The range sliding gear is
shifted forward or rearward with the range shift fork, controlled by the range shift lever. The
sliding gear contains a spring and ball which holds the gear in one of three detent positions;
forward - high range, middle - neutral, and rearward - low range.
The sliding gear is a double gear with that engages with the range output gear. The range
output gear is also a double gear and is splined to the bevel gear.
When the sliding gear is shifted forward its larger gear engages the smaller gear (C) on the
range output gear causing the range output gear to rotate at a higher rpm An internal ball
and spring in the shift fork holds the range sliding gear in the forward detent position.
When the sliding gear is shifted rearward it moves into a neutral position where the range
sliding gears are between the gears of the range output gear. No gears are engaged and the
transmission is in neural. The shift fork can maintain that position with the detent ball.
When the sliding gear is shifted rearward its smaller gear engages the larger gear (D) of the

ADJUSTMENTS
range output gear causing the range output gear to rotate at a lower rpm. The internal ball
and spring in the shift fork again hold the range sliding gear in a detent position.
When the range output gear is being driven it rotates the splined pinion gear (E) which is
engaged to the bevel gear (F). This turns the axis of rotation 90 degrees. The final drive
pinion shaft is splined to the inside of the bevel gear and engaged to the final drive ring gear.
Whenever the pinion gear is being driven the bevel gear, final drive pinion shaft, final drive
ring gear, differential, and rear axles rotates.

ADJUSTMENTS
MFWD Operation
MFWD Shift Operation
LEGEND:
A Shift Collar
B Rear Gear
C Output Shaft Splines
When the range output gear is being driven its gearset rotates to drive the rear wheels. See
Range Gear Operation . The front wheels can be driven by engaging the MFWD shift collar (A)
with the rear gear (B) of the range output gear and the MFWD output shaft (C).
When the shift collar (A) is in the forward position it does not engage the range output gear
and the internal splines of the shift collar do not engage the splines (C) of the MFWD output
shaft. The machine operates in a rear drive mode.
When the shift collar is moved rearward it engages the range output gear and the shift collar
engages the splined MFWD output shaft which rotates and drives the front wheels through
ADJUSTMENTS
the MFWD shaft and front axle gears.

ADJUSTMENTS
PTO Operation
PTO Shift Operation
LEGEND:
A Clutch Shaft
B PTO Clutch
C Drum Gear
D Gear
E Pinion
F Shift Collar
G Internal Splines
H Internal Splines
I Gear Splines
J Hub
K Idler Gear
L Output Shaft
M Pinion Splines
N Input Gear
O Idler Gear
P Output Shaft
The PTO clutch shaft (A) is splined to the pump drive shaft of the hydrostatic transmission. It
ties directly to the engine and rotates any time the engine is running. The clutch shaft is
splined to the PTO hub and clutch disks.
When the PTO clutch (B) is engaged the clutch piston presses the clutch disks to the clutch
plates and transfers power the PTO drum gear (C). The PTO drum gear is engaged to the PTO
select gear (D) and drives it any time the PTO clutch is engaged.

ADJUSTMENTS
The PTO select gear (D) is splined to the shift collar (F) The shift collar is internally splined in
the front and rear and can be shifted to engage the rear PTO, the front PTO or centered to
engage both.
Rear PTO Engaged
LEGEND:
F Shift Collar (Cut-Away)
G Internal Splines
H Internal Splines
I Select Gear Splines
J Hub
When the shift collar (F) is shifted rearward the internal splines (G) and (H) engage the select
gear splines (I) and the hub splines (J). The hub (J) has internal splines that connect to the
rear PTO pinion (E). The rear PTO pinion engages the rear PTO idler gear (K) which engages
the rear PTO output shaft (L).

ADJUSTMENTS
Mid PTO Engaged
LEGEND:
F Shift Collar (Cut-Away)
G Internal Splines
H Internal Splines
I Gear Splines
M Mid PTO Pinion Splines
When the shift collar (F) is shifted forward the internal splines (G) and (H) engage the select
gear splines (I) and the mid PTO pinion splines (M). The mid PTO pinion is splined to the mid
PTO input gear (N) which engages the mid PTO idler gear (O) which engages the mid PTO
output shaft (P).

ADJUSTMENTS
Mid PTO and Rear PTO Engaged
LEGEND:
G Internal Splines
H Internal Splines
I Gear Splines
J Hub Splines
M Mid PTO Pinion Splines
When the shift collar is centered the internal splines (H) engage the select gear splines (I).
The internal splines (G) engage both hub splines (J) and the mid PTO pinion splines (M). Both
the rear PTO and mid PTO are driven through their respective gears.

ADJUSTMENTS
Specifications
MFWD Diagnosis
Adjust Neutral Creep
Adjust Differential Lock
Adjust Forward and Reverse Pedals
Cone Point and Backlash Setting

ADJUSTMENTS
Specifications
Spring Length Length 65 mm
(2.56 in.)
Motion Control Rod Center-to-Center Length 413.3 ±0.8
(16.27 ±0.03 in.)
M8 Locknut Torque 25 ±5 N·m
(221 ±44 lb.-in.)
Ground Speed Specifications

Forward Maximum Speed 14.6 km/h
(9.1 mph)
Reverse Maximum Speed 6.6 km/h
(4.1 mph)
Front Cover Bolts Torque 15 N·m
(133 lb.-in.)
Side Cover Bolts Torque 15 N·m
(133 lb.-in.)
Axial Play 0.15 mm
(0.006 in.)
Pinion Nut Torque 112.5 ±12.5 N·m
(83 ±9.2 lb.-ft.)
Backlash (one reading) Backlash 0.16—0.2 mm
(0.006—0.008 in.)
Remaining Readings Backlash 0.10—0.26 mm
(0.004—0.0010 in.)
Maximum Variation Backlash 0.1 mm
(0.004 in.)
Front Cover Plug Recess 3 ±0.5 mm
(0.12 ±0.02 in.)
→NOTE:

ADJUSTMENTS

ADJUSTMENTS
MFWD Diagnosis
MFWD Lever Hard to Engage
Refer to Section 50, Group 35.
Test Location Normal If Not Normal
Lever operates smoothly. No evidence of wear, damage or

1. MFWD shift lever Repair or replace lever.
bent condition.
2. Shift fork No evidence of wear, damage or bent condition. Replace shift fork.
Clean and lubricate, or replace

3. Shift collar Collar slides smoothly. No wear or damage to splines.
collar.
4. MFWD shaft No wear or damage to splines. Replace shaft.
MFWD Lever Will Not Stay ON
Refer to Section 50, Group 35.
1. MFWD shift lever No evidence of wear, damage, or bent condition. Repair or replace lever.
2. Shift fork No evidence of wear, damage, or bent condition. Replace shift fork.

ADJUSTMENTS
Adjust Neutral Creep

Make adjustment to the hydrostatic pump control neutral position eccentric if creep is
evident with the machine on a level surface with the engine running, brakes released, and no
movement of the transmission control pedals.
→NOTE:
If creep is intermittent, inspect the transmission control linkage for binding

or damage. Repair linkage before making adjustment to the transmission
neutral position.
CAUTION:
The machine can fall or slip from an unsafe lifting device or supports.
Use a safe lifting device rated for the load.

Lower machine onto jack stands or other stable supports.
CAUTION:
Wheels rotate during adjustment if transaxle is out of adjustment. Always

support machine frame or rear axles with jack stands. Make sure that
MFWD is not engaged. Be cautious of rotating wheels.
[2] - Block front wheels securely, disengage MFWD and release park brake lock.
[3] - Raise rear of machine and support frame with jack stands.

ADJUSTMENTS
[4] - Remove center closeout panel for access to transmission motion control eccentric
adjuster.
Remove Transmission Cover
LEGEND:
A Screws
B Hex Bolts
C Knob
a. Remove two Phillips head screws (A).

b. Remove two hex bolts (B).
c. Lift height of cut adjuster knob (C) from control shaft.
d. Remove closeout panel.
[5] - Have an assistant occupy seat, or temporarily bypass seat safety switch.

ADJUSTMENTS
[6] -
CAUTION:
Use caution when adjusting for neutral creep. Drive wheels are free to spin
when machine is raised off the floor and the engine is started.
Start and run engine at high idle.
[7] - Release park brake.
[8] - Place transmission in low range.
[9] - Slightly loosen hex lock nut (D) securing adjuster eccentric.
Adjuster Eccentric Marks
LEGEND:
D Lock Nut
E Eccentric Position Marks

ADJUSTMENTS
[10] - Rotate eccentric forward or backward until wheels stop turning. Mark eccentric
position (E) on adjuster hex and arm.
[11] - Continue eccentric rotation until wheels begin to rotate in opposite direction. Rotate
eccentric in opposite direction until wheels stop turning, and mark eccentric position on arm.
[12] - Position eccentric adjuster between marks on arm. Tighten lock nut while holding
eccentric position.
[13] - Press, and then release both forward and reverse motion control pedals to verify
adjustment. Readjust eccentric as necessary.
[14] - Check for worn or binding travel pedal control linkage if eccentric adjustment does not
prevent creep. Disconnect linkage and repeat eccentric adjustment.
[15] - Check for wear in hydrostatic pump if eccentric adjustment is not effective with control
linkage disconnected. Check for binding or wear of swash plate shaft bushing, pump or motor
valve plate wear, and neutral return spring condition.

ADJUSTMENTS
[16] - Remove seat switch connector bypass, and reinstall connector to seat switch.
Install Transmission Cover
LEGEND:
C Knob
F Differential Lock Lever
[17] - Reinstall center closeout panel, and loosely secure with two shoulder bolts and two
Phillips head screws.
[18] - Hold differential lock lever (F) down, and adjust closeout panel position to center
height of cut adjuster shaft (C) in control opening. Tighten fasteners to secure cover.
[19] - Align height of cut adjuster knob to shaft flat and reinstall knob.

ADJUSTMENTS
Adjust Differential Lock
Differential Lock Rod Adjust
LEGEND:
A Length of Spring
The differential lock linkage must be properly adjusted in order to fully engage the differential
lock within the range of movement of the operator control.
CAUTION:

Lower machine onto jack stands or other stable supports and block
wheels before servicing.

ADJUSTMENTS
[2] - Block front wheels securely, disengage MFWD and release park brake lock.
[3] - Raise rear of machine and support on jack stands. Remove left rear wheel.
[4] - Check length of spring (A) on differential lock rod. Adjust spring compressed length to
specification if needed.
Spring Length Length 65 mm
(2.56 in.)

ADJUSTMENTS
Adjust Forward and Reverse Pedals
Motion Control Rod

ADJUSTMENTS
Motion Control Rod-to-Cam Bolt
LEGEND:
A Locking Pin
B Hex Bolt
C Washers
Adjust the forward and reverse motion control pedal stops to assure full travel of the
hydrostatic transmission control without overtravel loads on control linkage.
[2] - Raise rear of machine and safely support frame.
[3] - Remove center closeout panel for access to transmission motion control eccentric
adjuster. (See Remove and Install Center Closeout Panel in Section 90, Group 15.)
[4] - Remove locking pin (A) and washer securing motion control rod to hydrostatic
transmission trunnion lever.

ADJUSTMENTS
[5] - Remove hex bolt (B) securing rod to motion control cam. Retain washers (C) between
rod end and cam.
[6] - Measure rod length (D) between rod end centers. Adjust rod length to specification if
needed.
Motion Control Rod Center-to-Center Length 413.3 ± 0.8
(16.27 ± 0.03 in.)
Motion control Rod Length Measurement
LEGEND:
D Length Center-to-Center
[7] - Install control rod to cam and secure with hex bolt through rod end, washers, and cam
to nut.
[8] - Install control rod to transmission lever and secure with washer and locking pin.
[9] - Test for neutral creep and adjust as needed. (See Adjust Neutral Creep in this Group.)

ADJUSTMENTS
[10] - Turn stop bolts (E) out until flush with end of captive nuts (F).
Forward and Reverse Pedal Travel Adjust
LEGEND:
E Stop Bolts
F Captive Nuts

ADJUSTMENTS
[11] - Remove M8 locknut (G) securing damper (H) to control arm. Remove damper from
arm.
Damper-to-Control Arm
LEGEND:
G Locknut
H Damper

ADJUSTMENTS
[12] - Rotate hydrostatic motion control arm rearward to limit of travel when shoulder bolt (I)
contacts end of arm slot.
Control Arm Limit, Reverse
LEGEND:
I Shoulder Bolt
[13] - Hold control arm in full rearward position. Turn in reverse pedal stop bolt until bolt end
contacts reverse pedal arm (J).

ADJUSTMENTS
Reverse Pedal-to-Stop Bolt
LEGEND:
J Reverse Pedal Arm

ADJUSTMENTS
[14] - Rotate hydrostatic motion control arm forward to limit of travel when shoulder bolt (I)
contacts end of arm slot.
Control Arm Limit, Forward
LEGEND:
I Shoulder Bolt
[15] - Hold control arm in full forward position. Turn in forward pedal stop bolt until bolt end
contacts forward pedal arm.
[16] - Install control arm damper and secure with M8 locknut (J). Tighten locknut to
specification.
M8 Locknut Torque 25 ±5 N·m
(221 ±44 lb.-in.)

ADJUSTMENTS
[18] -
→NOTE:
Ground speed based on fast idle at 3200 rpm, and 26x12:00-12 tires
installed.
Check machine ground travel speed to make sure that transmission control arm has full
range of motion.
Ground Speed
Forward Maximum Speed 14.6 km/h
(9.1 mph)
Reverse Maximum Speed 6.6 km/h
(4.1 mph)

ADJUSTMENTS
Cone Point and Backlash Setting

The purpose of this procedure is to select correct shims to set the cone point and backlash.
If any of the following components in the transmission is replaced, the procedure is

performed:
1. Bevel Pinion
2. Bevel Ring Gear
3. Main Case
4. Front Cover
5. Side Cover or Rear Axle Housing
6. Brake Quill
If none of the components has been replaced, the existing shims can be used to reassemble
the transmission.

ADJUSTMENTS
[1] -
Press bevel pinion head bearing (A) on to the bevel pinion shaft and install gear set (B).
Pinion Shaft
LEGEND:
A Pinion Head Bearing
B Gear Set
[2] - Complete sub-assembly of range and PTO components to main case.
[3] - Complete the sub-assembly of range components and PTO components to front cover.

ADJUSTMENTS
[4] -
Install nominal size shim, 2.0 mm thick (LVU21956), at location (C).
Pinion Bearing
LEGEND:
C Shim
D Shim
E Bearing
F Nut
[5] - Install bevel pinion tail bearing (E) and a second nominal size shim, 2.0 mm thick
(LVU21956), at location (D).
[6] - Install a used lock nut (F), with no thread lock on the threads, on to the bevel pinion
shaft through the opening in the front cover. Tighten the nut only up to 20 N·m (14 lb.-ft.). Do
not install the end plug.

ADJUSTMENTS
[7] -
Install the front cover sub-assembly on to the main case. However, do not apply sealant to
the front cover-to-main case interface at this point. Install the front cover sub-assembly on to
the main case using only four bolts (G) at corners. Tighten bolts to specification.
Front Cover Bolts Torque 15 N·m
(133 lb.-in.)
Front Cover
LEGEND:
G Bolts

ADJUSTMENTS
[8] -
Complete sub-assembly of brake, final drive pinion, ring gear, and side cover. However, do
not install the backlash shim (H) shown in figure inset.
Backlash Shim
LEGEND:
H Shim
[9] -
IMPORTANT:
Make sure the oil suction screen is properly aligned to the side cover before cover

ADJUSTMENTS
installation. (See Remove and Install Oil Suction Screen in Section 70, Group 05.)
[10] -
Install the side cover sub-assembly on to the main case using four bolts (I) on corners of the
side cover. Tighten the bolts to specification. At this point, do not install differential or
differential lock components. Do not apply sealant to the side-cover and main case interface.
(133 lb.-in.)
Side Cover Bolts
LEGEND:
I Bolts
[11] - Put the transmission in the top-side up orientation (same as it would be in the tractor.)

ADJUSTMENTS
[12] - Reach through the rock-shaft opening and push the bevel ring gear as far to the right,
away from the bevel pinion head, as possible. Tap on the ring gear with a rubber mallet to
check that it is as far to the right as possible.
[13] -
Insert the “GO NO-GO” gauge block tool (J) in the gap between the head of the bevel pinion
and the final drive pinion.

ADJUSTMENTS

ADJUSTMENTS
JDG11251 Go No-Go Gauge
Gauge Block Insert
LEGEND:
J Gauge Block
[14] - Push the gauge block to right side such that its one side touches the bevel ring gear
(arrows).

ADJUSTMENTS
[15] -
If the GO portion (K) of the gauge fits in the gap as show, but the NO-GO portion does not fit
in the gap, the cone point setting is correct. Skip steps 17 and 18 and proceed to step 19.
Gauge Block - GO Portion
LEGEND:
K GO Portion of Gauge Block

ADJUSTMENTS
[16] - If the GO portion of the gauge does not fit in the gap then:
a. Remove the front cover assembly.

b. Install one size thicker shim in location (C) and one size thinner shim in location (D).
Table 1 lists the sizes of shims available.
Pinion Shim Location

LEGEND:
C Shim
D Shim
c. Reinstall the front cover assembly using four bolts. Go back to step 14.
[17] - If the NO-GO portion of the gauge fits in the gap then:
a. Remove the front cover assembly.

b. Install one size thinner shim in location (C) and one size thicker shim in location (D).
c. Reinstall the front cover assembly using four bolts. Go back to step 14.

ADJUSTMENTS
[18] - Part Number Dimension Number of Shims
LVU21954 1.8 mm 1
LVU21955 1.9 mm 1
LVU21956 2.0 mm 1
LVU21957 2.1 mm 1
LVU21958 2.2 mm 1
Arrange a dial indicator (L), at the end of the bevel pinion shaft through the opening in the
front cover as shown in picture.

ADJUSTMENTS
Pinion Shaft Axial Play
LEGEND:
E Shim
L Dial Indicator

ADJUSTMENTS
[19] -
→NOTE:
You can temporarily install an M8 bolt at the end of the bevel pinion shaft
to hold as you try to move the pinion shaft fore and aft.
Check the axial play of the bevel pinion gear. The axial play measured at the front end of the
bevel pinion shaft should be less than specification. If the axial play is less than specification,
then skip steps 21 and 22 and proceed to step 23.
Axial Play 0.15 mm
(0.006 in.)
[20] - If the axial play is more than specification, then remove the front cover assembly and
install one size thicker shim in location (E).
[21] - Reinstall the front cover assembly using 4 bolts, and go back to step 19.
[22] -
→NOTE:
Apply Loctite ™ thread lock to the pinion nut.
Remove the front cover assembly. Install a new undisturbed torque preserving lock nut (F).
Do not tighten nut fully. Complete the reassembly of front cover sub-assembly.
[23] - Apply sealant to the walls of the front cover and install the front cover sub-assembly
on to the main case. Install all the cap-screws for front cover-to-main case joint and tighten
them appropriately.
[24] - Make sure that the MFWD is in shift arm engaged position, hold the MFWD output shaft
stationary using a Vise Grip and tighten the pinion nut (F) to specification.
Pinion Nut Torque 112.5 ±12.5 N·m
(83 ±9.2 lb.-ft.)
[25] - Remove side-cover sub-assembly.

ADJUSTMENTS
[26] - Remove final drive pinion & bevel gear from the side cover and install a 2.3 mm thick
shim, reinstall final drive gear and bevel bearing.
[27] - Reinstall side cover sub-assembly on to the main case. Do not apply sealant at this
point. Install the brake and side cover on to the main case using only four bolts on corners of
the side cover. Tighten the bolts to only specification. (At this point, do not install differential
or differential lock components.)
(133 lb.-in.)
[28] - Clamp the bevel pinion shaft through the opening in the front cover using a Vice Grip
and block to prevent it movement.
[29] -
Set up a dial indicator through the rockshaft opening. Make sure that the indicator registers
closest to the outer diameter of the bevel ring gear and rests on a tooth that is horizontal at
that point.

ADJUSTMENTS
Bevel Gear Backlash
[30] - Measure backlash in 3 places 120° apart on bevel gear.
a. Backlash measurements should be to specification with at least one measurement

reading between 0.16—0.2 mm (0.0063—0.0078 in.).
Backlash (one reading) Backlash 0.16—0.2 mm
(0.006—0.008 in.)
Remaining Readings Backlash 0.10—0.26 mm
(0.004—0.0010 in.)
b. Maximum allowable variation between measurements is 0.1 mm.

Maximum Variation Backlash 0.1 mm
(0.004 in.)

ADJUSTMENTS
[31] - If the backlash measurements are with in the specifications and proceed to step 34.
[32] - If it was found to be outside of the specifications, change the shim to change the
backlash.
a. Increasing the thickness of the shim decreases the backlash, while decreasing the
thickness of the shim increases the backlash.
b. Shims are available in 0.1 mm (0.0039 in.) increments 2.0—2.6 mm.
[33] - Reinstall side cover sub-assembly and repeat steps 27 through 31.
[34] - Once the correct backlash shim is identified and installed:
a. Remove side cover sub-assembly;

b. install differential or differential lock components;
c. apply sealant to side cover-to-main case joint;
d. reinstall the sub-assembly;
e. tighten all cap screws appropriately.
[35] -
Install plug (M) to cover the opening in the front cover. Recess plug to specification.
Front Cover Plug Recess 3 ±0.5 mm
(0.12 ±0.02 in.)

STEERING AND BRAKE OPERATION, TESTS, AND (g) by Belgreen
ADJUSTMENTS
Front Cover Plug

Section 260 - STEERING AND BRAKE OPERATION,

Table of contents
Steering Components ............................................................................................................. 2
Tilt Steering Components ....................................................................................................... 3
Brake Components ................................................................................................................. 4
Park Brake Components - Export ........................................................................................... 5
Steering System Operation .................................................................................................... 8
Group 15 - Diagnosis, Test and Adjustments ....................................................................... 9
Specifications ......................................................................................................................... 9
Adjust Brakes ....................................................................................................................... 10
Adjust Park Brake Engagement ............................................................................................ 17
Adjust Park Brake Engagement EEC ..................................................................................... 20
Check Toe-in ........................................................................................................................ 22

Steering Components
Tilt Steering Components
Brake Components
Park Brake Components - Export
Steering Components
Steering Components
LEGEND:
A Oil Cooler
B Steering Control Unit (SCU)
C Pressure Tube
D Oil Return Tube

E Right and Left Steering Hoses

F Steering Cylinder
G Tie Rod
H Final Drive Housing

LEGEND:
A Snap Ring (2 used)
B Bushing (2 used)
C Spring
D Stud (2 used)
E Steering Column
F Washer
G Pawl
H Sector
I Lever
J Spring
K Support (2 used)
L Bolt, M10x40 (12 used)
M Shaft
N Bracket
O Shaft, Steering
P Lock Nut, M8 (2 used)
Q Bracket
Brake Components
Brakes Component Location
LEGEND:
A Park Brake Handle
[ North American Models ]
B Park Brake Rod

C Bellcrank
D Brake Pedal
E Brake Cross-Shaft
F Spring, Extension
G Brake Rod
H Turnbuckle
I Yoke
J Outer Brake Arm
K Differential Link, Right Hand
(For internal brakes components, see “Brakes” in Section 250, Group 05.)
Park Brake Components - Export
Park Brake Components, Export
LEGEND:
A Handle
B Cable

C Nuts, Adjustment
D Arm
E Rod
F Outer Brake Arm
G Spring, Compression
H spring, Extension

Steering System Operation

Steering System Operation

The hydraulic pump above the rear PTO shaft supplies hydraulic pressure to the PTO solenoid
valve. The solenoid valve has a pressure relief valve that opens at a minimum pressure of
2068 kPa (300 psi). The PTO valve contains a divider valve that sends 50% of the oil to the
loader selective control valve (SCV), and 50% to the steering control valve (SCU).
The SCU utilizes an open center control valve to operate the steering cylinder. When the
steering wheel is turned, the SCU directs hydraulic pressure to the appropriate steering
cylinder hose. The pressure pushes the cylinder ram, which pivots the front spindles and
wheels. The SCU contains a 75 bar (1087 psi) relief valve.
The SCU and steering cylinder cannot be rebuilt, and must be replaced as complete units.
Excess oil from the SCU is sent to the oil cooler, mounted in the front of the machine. After
the oil is cooled, it passes through an in-line filter and goes to the hydrostatic transmission.
The hydrostatic transmission is a combination motor and pump, and operates as a closed-
loop. Most of the hydraulic oil delivered to this unit passes through the charge pressure relief
valve and returns to the reservoir.
A small amount of oil flows through the hydrostatic unit, providing makeup oil and internal
lubrication, and then returns to the reservoir.

Specifications
Adjust Brakes
Adjust Park Brake Engagement
Adjust Park Brake Engagement EEC
Check Toe-in
Specifications
Differential Lock Rod Springs Length 65 mm
(2.56 in.)
Brake Input Shaft Torque 5—15N·m
(44—133 lb.-in.)
Bellcrank Hardware Torque 50 N·m
(37 lb.-ft.)
Brake Rod Yoke-to-Roll Pin Gap 4—7 mm
(0.16—0.28 in.)
Rear Wheel Lug Bolt Torque 120 N·m
(89 lb.-ft.)
Toe-in Distance 0—3 mm
(0—0.12 in.)

Adjust Brakes
CAUTION:

Lower machine onto jack stands or other stable supports and block
wheels before servicing.
Brake control linkage must be properly adjusted in order to provide effective brake operation
within the required arc of movement of the brake pedal.
The differential lock is engaged when brakes are applied in order to apply braking force
equally to both rear wheels. Differential lock engagement may be affected by brake wear and
brake linkage adjustment.
[2] - Block front tires to prevent machine movement. Release park brake.
[3] - Raise rear of machine and support on jack stands. Remove right rear wheel.

[4] - Remove locking pin (A), washer and pin securing brake yoke to outer brake arm.
Remove yoke from brake arm.
Brake Yoke and Brake Arm
LEGEND:
A Locking Pin
B Bolt
[5] - Remove hex bolt (B), two washers, and hex nut securing outer brake arm to inner arm.
Do not remove outer arm.
[6] - Check length of springs (D) on left and right differential lock rods (C). Adjust spring
compressed length to specification if needed.

Differential Lock Rod Spring Compression
LEGEND:
C Differential Lock Rods
D Spring Length
E Differential Lock Bellcrank
Differential Lock Rod Springs Length 65 mm
(2.56 in.)
[7] -
→NOTE:
Rotate the axle shaft while rotating the differential lock bellcrank to ensure
differential lock engagement.
Engage differential lock control to rotate differential lock bellcrank (E) downward. Ensure that
differential lock is fully engaged.

[8] - Hold differential lock control down to maintain differential lock engagement.
[9] - With the differential lock fully engaged, use a 17 mm socket on the transmission brake
brake shaft (F) to apply and hold torque to specification.
Brake Input Shaft Torque 5—15N·m
(44—133 lb.-in.)
Brake Shaft Torque
LEGEND:
F Brake Shaft
G Holes
[10] - Determine which set of holes (G) in outer and inner brake arms are best aligned.
[11] - Install M10x30 hex bolt with washers through aligned brake arm holes. Secure bolt
with hex nut and tighten to specification.
Bellcrank Hardware Torque 50 N·m
(37 lb.-ft.)

[12] - Release differential lock control and rotate axle (if needed) to disengage differential
lock. Ensure that differential lock shaft returns to fully released position.
[13] - Loosen hex nut (H) securing brake rod adjuster (I).
Brake Rod Adjustment
LEGEND:
H Turnbuckle Locknut
I Turnbuckle
[14] - Turn adjuster several turns to lengthen brake rod.
[15] - Reattach brake rod yoke to outer brake arm with drilled pin.
a. Attach brake rod to round hole in brake arm for domestic models.
b. Attach brake rod to slotted hole in brake arm for export models.
c. Secure pin with washer and locking pin.

[16] -
→NOTE:
Gear contact will be heard (and felt in the axle) when the differential lock
begins to engage.
Rotate axle while turning adjuster nut to shorten brake rod until differential lock just begins
to engage.
[17] - Rotate axle while turning adjuster nut to lengthen brake rod just until clicking is no
longer heard (or felt in axle hub).
[18] - Tighten lock nut to secure adjuster.
[19] - Rotate the hub to ensure that it turns freely, without brake drag or partial differential
lock engagement.
a. If brake drag is noted, repeat steps 5 through 19.

b. If partial differential lock engagement is noted, repeat steps 13 through 19.
[20] - Lock the park brake.
[21] - Check compression of brake rod spring (J). Spring should be partially, but not fully
compressed.

Brake Spring Compression Measurement
LEGEND:
J Brake Rod Spring
K Space
[22] - Check brake rod extension to see if space (K) between brake rod yoke and roll pin is
within specification. If the gap is not to specification, repeat steps 5 through 21.
Brake Rod Yoke-to-Roll Pin Gap 4—7 mm
(0.16—0.28 in.)
[23] - Install rear wheels and tighten lug bolts to specification.
Rear Wheel Lug Bolt Torque 120 N·m
(89 lb.-ft.)
[24] - Lower machine and check operation of brakes and differential lock.

Adjust Park Brake Engagement

Adjust park brake engagement after the service brake adjustment procedure has been
completed. (See Adjust Brakes in this Group.)
Cowl

Bellcrank Pivot
LEGEND:
A Phillips Head Screws
B Pivot Nut
C Eccentric Nut
[2] - Adjust service brake linkage. (See Adjust Brakes in this Group 15.)
[3] - Press brake pedal and lift park brake control to set park brake. If park brake cannot be
set, or if park brake does not hold, adjust park brake linkage.
[4] - Remove left and right engine side panels.
[5] - Remove two hex and two Phillips head screws (A) securing steering pedestal cowl.
Remove cowl.
[6] - Loosen bell crank pivot nut (B).

[7] - Rotate eccentric nut (C) to adjust engagement point of park brake pawl.
[8] - Rotate adjuster eccentric so that park brake engagement pawl (D) just clears lobe (E) of
brake cam with brake pedal fully depressed.
Park Brake Eccentric Adjust
LEGEND:
D Pawl
E Lobe
[9] - Tighten pivot nut on adjusting eccentric.
[10] - Check park brake engagement.
[11] - Install cowl and secure with two hex and two Phillips head screws.

Adjust Park Brake Engagement EEC

Adjust park brake engagement after the service brake adjustment procedure has been
completed. (See Adjust Brakes in this Group.)
Park Brake Adjust - EEC
LEGEND:
A Jam Nuts
B Brake Cable
C Bell Crank
D Nut
E Yoke
F Bolts
G Switch

[2] - Adjust service brake linkage. (See Adjust Brakes in this Group.)
[3] - Place park brake handle in fully lowered position. Adjust jam nuts (A) on brake cable (B)
so that intermediate bell crank (C) is rotated as far forward at the top as it will go.
[4] - Be certain that there is no slack in brake cable and tighten jam nuts.
[5] - Loosen nut (D), and adjust the brake rod yoke (E) at the intermediate bell crank (C) so
that there is no free play. Tighten nut (D).
[6] - Loosen two bolts (F), and adjust the park brake switch (G) position so that it is not
engaged when the park brake handle is in the fully lowered position and so that it engages
within 2-4 clicks of raising park brake handle.
[7] - Check park brake engagement. Verify the engine stalls with the transmission in high
range when the park brake handle is in the fully engaged (raised) position.

Check Toe-in
Support Front of Tractor
LEGEND:
A Supports
Check toe-in to make sure of proper wheel tracking when turning, and to prevent tire scrub
and premature tire wear.
The tie rod is not adjustable.
[2] - Raise front of machine and place secure supports (A) under frame behind front axle.
[3] - Rotate tire by hand and scribe a line near the center of each of the front tires.

HYDRAULIC SYSTEM OPERATION, TESTS, AND (g) by Belgreen
ADJUSTMENTS
[4] - Measure and record the distance between the lines at the front and the rear of the tire
at about axle height. The front measurement should be 0 - 3 mm (0 - 0.12 in.) less than the
rear measurement.
Toe-in Distance 0—3 mm
(0—0.12 in.)
[5] - If measurement is not correct, replace tie rod.

Section 270 - HYDRAULIC SYSTEM OPERATION,

Table of contents
Hydraulic Pump ...................................................................................................................... 2
PTO Solenoid .......................................................................................................................... 5
Surge Relief Valve Operation ................................................................................................. 8
Group 15 - Diagnosis ............................................................................................................... 10
Diagnostic Information ......................................................................................................... 11
Preliminary Hydraulic System Inspection ............................................................................. 12
Entire Hydraulic System Fails to Function/No Hydraulic Pump Output ................................. 13
Insufficient Pump Delivery ................................................................................................... 14
Hydraulic Functions Too Slow .............................................................................................. 15
Excessive Pump Pressure ..................................................................................................... 16
Slow Hydraulic Pump Response ........................................................................................... 17
Excessive Pump Noise During Operation ............................................................................. 18
Rockshaft Does Not Lift or Lifts Slowly ................................................................................. 19
Rockshaft Does Not Lower or Lowers Slowly ........................................................................ 20
Neutral Position Unstable, Rockshaft Drops after Engine Shut Down ................................... 21
Mid-Mount Joystick Does Not Return to Neutral Position—Mid-Mount SCV ........................... 22
Mid-Mount Joystick Does Not Remain in Detent Position—Mid-Mount SCV ........................... 23
Remote Cylinder Does Not Extend or Retract ...................................................................... 24
Remote Cylinder Settles Under Load ................................................................................... 25
Remote Cylinder Operates Too Fast or Too Slow ................................................................. 26
Group 20 - Hydraulic Tests .................................................................................................... 27
Specifications ....................................................................................................................... 28
Hydraulic Oil Warm-up Procedure ........................................................................................ 29
Test SCV Implement Relief Pressure .................................................................................... 30
Test PTO Cluch Pressure ...................................................................................................... 32
Test HST Charge Pressure .................................................................................................... 34
Check Rate of Drop/Stop Valve ............................................................................................ 36
Reference ............................................................................................................................. 38
Reference ............................................................................................................................. 40
Reference ............................................................................................................................. 42
Reference ............................................................................................................................. 44
Reference ............................................................................................................................. 46
Group 25 - Adjustments .......................................................................................................... 50
Specifications ....................................................................................................................... 50
Adjust Rockshaft Position Feedback ..................................................................................... 51
Adjust Rockshaft Feedback Friction Washers ....................................................................... 52
Group 30 - Hydraulic Schematics .......................................................................................... 53

Hydraulic Circuit Symbols .................................................................................................... 53
1023E Hydraulic Schematic ................................................................................................. 55
1025R Hydraulic Schematic ................................................................................................. 56

Hydraulic Pump
PTO Solenoid
Hydraulic Pump

Hydraulic Pump Components
LEGEND:
A O-ring
B Fitting, Elbow
C O-ring (2 used)
D Pipe Assembly
E Fitting
F O-ring
G Pump, Implement
H Bolt M8x90 (2 used)

I Bolt M8x35 (2 used)

J Gasket
K O-ring
L O-ring
M Bolt M6x16 (3 used)
N Pipe, Suction
O Clamp
P Hose, Suction
Q Clamp
R Elbow, Hose Fitting
S Bolt
T O-ring
U O-ring
V Filter
W Magnet (1 large, or 2 or 4 small)

PTO Solenoid
PTO Solenoid Valve Components
LEGEND:
A O-ring (2 used)
B Valve Body
C Seals
D Seals
E O-ring
F Pressure ReliefValve

G Divider Valve
H O-ring
I Seals
J Seals
K Seals
L O-ring
M Fitting, Elbow
N O-ring
O Pipe Assembly
P O-ring
Q Fitting
R O-ring
S Pump, Implement
T Screw (2 used)
U Valve, Solenoid
V Bolt M8x30 (2 used)
W O-ring (2 used)
X Fitting (2 used)
Y O-ring (2 used)
Z Cap (2 used)

Surge Relief Valve Operation

LEGEND:
A From Rockshaft Cylinder
B Rockshaft Cylinder Casting
Group 15: Diagnosis
C Surge Relief Valve Cartridge

D Relief Spring
E Relief Ball
F To Sump
G Pressure Oil
H Return Oil
FUNCTION:
The surge relief valve threads into a passage of the rockshaft cylinder. The valve protects the
cylinder and its related parts from damage due to excessive pressure.
MAJOR COMPONENTS:
Surge Relief Valve

Rockshaft Cylinder
Rockshaft Piston
THEORY OF OPERATION:
As long as pressure inside the rockshaft cylinder is less than 17200 kPa (172 bar) (2494 psi),
tension from relief spring (D) holds relief ball (E) closed. If pressure increases suddenly and
exceeds spring pressure, relief ball unseats, allowing oil back to sump. This condition can
occur when the rockshaft encounters a sudden increase in implement load.

Group 15: Diagnosis
Group 15 - Diagnosis
Diagnostic Information
Preliminary Hydraulic System Inspection
Entire Hydraulic System Fails to Function/No Hydraulic Pump Output
Insufficient Pump Delivery
Hydraulic Functions Too Slow
Excessive Pump Pressure
Slow Hydraulic Pump Response
Excessive Pump Noise During Operation
Rockshaft Does Not Lift or Lifts Slowly
Rockshaft Does Not Lower or Lowers Slowly
Neutral Position Unstable, Rockshaft Drops after Engine Shut Down
Mid-Mount Joystick Does Not Return to Neutral Position—Mid-Mount SCV
Mid-Mount Joystick Does Not Remain in Detent Position—Mid-Mount SCV
Remote Cylinder Does Not Extend or Retract
Remote Cylinder Settles Under Load
Remote Cylinder Operates Too Fast or Too Slow

Group 15: Diagnosis
Diagnostic Information
The diagnostic information in this group is used to test components related to a specific
problem or symptom. Select a symptom from the list and follow the test procedures under
the heading.
The symptom headings are:
Entire Hydraulic System Fails to Function/No Hydraulic Pump Output

Neutral Position Unstable, Rockshaft Drops after Engine Shut Down
Mid-Mount Joystick Does Not Return to Neutral Position—Mid-Mount SCV
Mid-Mount Joystick Does Not Remain in Detent Position—Mid-Mount SCV
The diagnostic procedure lists:
Test conditions
Test sequence
Test location
Normal reading
Check or test to perform if reading is not normal
When performing the test or check, be sure to set your machine up to the test conditions
listed and follow the sequence carefully. The middle (Normal) column gives the reading or
condition that should be obtained when performing the test or check. If the results of the test
or check are not normal, perform the test, check, or adjustment listed in the third (If Not
Normal) column to repair the malfunction.

Group 15: Diagnosis
Preliminary Hydraulic System Inspection

CONDITIONS:
Operate the tractor and make checks with the hydraulic oil warm.
1. Check entire machine for

No leaks. Repair cause of leakage.
hydraulic oil leakage.
Level between marks on site

2. Check oil level. Add oil if low.
gauge
3. Check oil condition. Clear. Milky—check for water in oil.
Clean. Dirty—change oil and filter.
No metal particles. Change oil, filter and check for mechanical failure.
Not discolored. Check for causes of oil overheating.
4. Operate all hydraulic All functions operate equally

Change filter.
functions. smooth and quick.
Check mesh filter.
Make sure oil is correct type.
→NOTE:
If the tractor is equipped with SCV, operate each valve to determine if the
problem affects complete system or only one valve.

Group 15: Diagnosis
Entire Hydraulic System Fails to Function/No Hydraulic

Pump Output
CONDITIONS:
Machine parked on level surface.

Key switch in OFF position.
Hydraulic tests and adjustments in this section.
1. Hydraulic dipstick. Oil clean and up to proper level. Add or change oil.
2. Suction hose and pipe. Free of restrictions. Replace components.
3. Mesh filter. Free of debris. Clean filter.
4. Pump drive. Drive pump in good condition. Repair or replace pump.

Group 15: Diagnosis

CONDITIONS:

Engine at 2400 rpm.
1. Suction hose and pipe. Free of restrictions, no air leaks. Repair or replace.
System pressure within specifications. Relief Adjust relief valve. Repair or replace as
3. Main relief valve.
valve not leaking. needed.
Perform Pump Flow Test (Tractors With

Flow output within specifications. Good
4. Hydraulic pump. SCV) in Section 270, Group 20. Repair or
condition with minimal wear.
replace as needed.

Group 15: Diagnosis

CONDITIONS:

Engine adjustments in Section 220, Group 15.
2. Suction hose and pipe. Free of restrictions. Repair or replace.
3. Tachometer. Reads rated rpm at 2400 at full load. Check and adjust fast idle.
4. Relief valve. System pressure within specifications. Adjust relief valve.
Perform Pump Flow Test (Tractors With SCV) in

5. Hydraulic pump. Flow output within specifications
Section 270, Group 20. Repair or replace as needed.
Move control lever into neutral position. Inspect

6. SCV, if equipped. In neutral position.
linkage. Repair or replace parts as necessary.

Group 15: Diagnosis

CONDITIONS:

1. Relief valve. Pressure within specifications. Replace relief valve.
2. Outlet line. Free of kinks and restrictions. Replace line.
3. Rockshaft feedback linkage. Proper hitch free-play. Adjust linkage.
Operate SCV levers. Check for pressure change.

4. SCV, if equipped. Free to return to neutral position.
Repair or replace SCV valve.

Group 15: Diagnosis

CONDITIONS:

1. Suction hose and pipe. Free of restrictions. Repair or replace.
3. Hydraulic dipstick. Oil of the proper type and viscosity. Drain and refill with correct oil.
Free to return to neutral position. Not Operate SCV levers. Check for pressure
4. SCV, if equipped.
leaking internally. change. Repair or replace SCV valve.
6. Main relief valve. Pressure within specifications. Not leaking. Replace relief valve.
Perform Pump Flow Test (Tractors With SCV) in

7. Hydraulic pump. Flow output within specifications. Section 270, Group 20. Repair or replace as
needed.
8. Surge relief valve. Not leaking. . Replace valve.

Group 15: Diagnosis

CONDITIONS:

1. Hydraulic dipstick. Oil level up to marks. Add oil as needed.
Oil of the proper type. Drain and refill with correct oil.
2. Suction hose and pipe. Secure and free of air leaks. Tighten suction line clamps. Repair or replace as needed.
3. Main relief valve. Pressure within specifications. Adjust. Replace if necessary.
4. SCV, if equipped. Free to return to neutral position. Operate SCV levers. Repair or replace valve.
Perform Rockshaft Lift Cycle Test in section 270, Group

5. Rockshaft valve. Neutralizing.
20.

Group 15: Diagnosis

CONDITIONS:

Perform rockshaft lift cycle test. (See Rockshaft Lift

1. Rockshaft lift arms. Rockshaft lift cycle within specifications.
Cycle Test in Section 270, Group 20.)
2. Hydraulic dipstick. Oil of proper type and viscosity. Drain and refill hydraulic system.
3. Filter/Manifold. Free of restrictions. Replace filter.
Perform Pump Flow Test (Tractors With SCV) in Section

5. Hydraulic pump. Flow within specifications.
270, Group 20. Repair or replace as needed.
6. Relief valve. System pressure within specifications. Replace relief valve.
Check rate of drop-stop valve. (See Check Rate of

7. Rockshaft. Leakage within specifications.
Drop/Stop Valve in Section 270, Group 20.).
8. SCV, if equipped. Free to return to neutral position. Operate SCV levers. Repair or replace valve.

Group 15: Diagnosis

CONDITIONS:

1. Rate-of-drop valve. Backed-out (open). Open valve.
Valve and passages clean. Clean, repair, or replace valve as needed.
2. Rockshaft linkage. Linkage connected and not binding, bent, or worn. Repair or replace as needed.
3. Draft control linkage. Linkage connected and not binding, bent, or worn. Repair, replace, or adjust as needed.

Group 15: Diagnosis
Neutral Position Unstable, Rockshaft Drops after

Engine Shut Down
CONDITIONS:

Replace rockshaft piston O-ring. Check cylinder for scoring and

1. Rockshaft. Leakage within specifications.
other damage, replace if necessary.
Check rate of drop-stop valve. (See Check Rate of Drop/Stop

Leakage within specifications.
Valve in Section 270, Group 20.).
Install as instructed by Operator′s Manual or Installation

Attachment installed correctly.
Instruction.
2. Rate-of-drop valve. Closes completely without leaks. Repair or replace valve as needed.
3. Surge relief valve. Not leaking. Replace valve.

Group 15: Diagnosis
Mid-Mount Joystick Does Not Return to Neutral

Position—Mid-Mount SCV
CONDITIONS:

1. Joystick. Free from binding. Repair or replace as needed.
2. Cables. Free and properly lubricated. Lubricate or replace cables as needed.
Spool slides back and forth through Replace SCV assembly. (See Remove and Install Selective
3. Mid-Mount SCV.
housing without binding. Control Valve (SCV) in Section 70, Group 15.)
→NOTE:
The mid-mount SCV employs a detent that engages when the joystick nears
the end of its travel in the forward direction. This is normal. The above
diagnostic routines apply when the joystick binds in the non-detent
positions.

Group 15: Diagnosis
Mid-Mount Joystick Does Not Remain in Detent

Position—Mid-Mount SCV
CONDITIONS:

1. Joystick. Full range of travel without binding. Repair or replace as needed.
2. Cables. Properly connected and free from binding. Repair or replace as needed.
Replace SCV assembly. (See Remove and Install

Detent locks in when valve nears end of travel
Mid-Mount SCV. Selective Control Valve (SCV) in Section 70, Group
in forward direction.
15.)

Group 15: Diagnosis

CONDITIONS:

1. Remote cylinder. Cylinder piston in good condition. Replace cylinder if scored or leaking.

Group 15: Diagnosis

CONDITIONS:

Cylinder piston in good

1. Remote cylinder. Replace cylinder if scored or leaking.
condition.
Excessive leakage at SCV, replace SCV. (See Remove and Install

SCV not leaking.
Selective Control Valve (SCV) in Section 70, Group 15.)

Group 20: Hydraulic Tests

CONDITIONS:

1. Remote cylinder. Stop valve free. Repair or replace stop valve.
2. SCV levers. Free and movable throughout range of travel. Repair, replace, or lubricate levers and linkage.

Group 20 - Hydraulic Tests
Specifications
Hydraulic Oil Warm-up Procedure
Test SCV Implement Relief Pressure
Test PTO Cluch Pressure
Test HST Charge Pressure
Check Rate of Drop/Stop Valve
Pump Flow Test (Tractors With SCV)
Main Relief Valve Test (Tractors With SCV)
SCV Leakage Test
Rockshaft Lift Cycle Test
Rockshaft Leakdown Test

Specifications
Operational Oil Temperature Temperature 38—49 ° C
(100—120 ° F)
SCV Pressure Relief Pressure 137 bar
(1986 psi)
PTO Clutch Pressure Pressure 1380—1480 kPa
(200—215 psi)
HST Charge Pressure Pressure 500—800 kPa
(72—116 psi)
Rockshaft Drop Cycle Time 2-1/2—3 seconds
Hydraulic Pump Flow Rate 2400 rpm 64.3—69.6 Lpm (17.0—18.4 gpm)
Hydraulic Pump Flow Rate 2000 rpm 53.3—57.9 Lpm (14.1—15.3 gpm)
18 995—19 685 kPa (190—197 bar) (2755—2855

Main Relief Valve Test Outlet Pressure
psi)
Time to Drop Below 3 450 kPa (34.5 bar) (500

Time At Least 5 Seconds
psi)
Hitch Raise Time Time Less than 3 Seconds
Drop in 10 minutes Distance 51 mm (2 in.)

→NOTE:
Hydraulic Oil Warm-up Procedure

When performing hydraulic tests the hydraulic oil must be heated to normal operating
temperature for the tests to be accurate.
[1] - Install JDG282 Temperature Gauge on transmission oil filter.
[2] - Apply brake, start engine and run at high idle.
[3] - Periodically cycle all hydraulic functions to distribute heated oil.
[4] - Heat oil to operational temperature.
Operational Oil Temperature Temperature 38—49 ° C
(100—120 ° F)

Test SCV Implement Relief Pressure
SCV Port for Test Pressure
LEGEND:
A Pressure Port
Perform this test to check condition of the hydraulic SCV relief valve setting (implement
operation pressure). This determines if there is sufficient oil pressure to operate implements.
[2] - Install pressure gauge as follows:
Assemble AM105467 coupler, JTO5486 connector, JTO3017 hose, and JTO3345 pressure
gauge in pressure port (A).
[3] - Start engine and set throttle at fast idle.

[4] - Check pressure on gauge by activating SCV control handle, read gauge, and release.
SCV Pressure Relief Pressure 137 bar
(1986 psi)
Results
Pressure should be to specification.

If there is no pressure, repeat test using different coupler. If pressure exists, replace
coupler and repeat test.
If pressure is below specification, the relief valve may be malfunctioning or hydraulic
pump may have damaged or have worn parts.

Test PTO Cluch Pressure
PTO Valve
LEGEND:
A Test Port
Perform this test to check PTO clutch hydraulic pressure. This determines if there is sufficient
oil pressure to engage PTO clutch.
[2] - Raise and safely support rear axle.
[3] - Lock park brake.
[4] - Remove left rear wheel.
[5] - Remove plug from pressure test port (A).

Assemble JTO3366 elbow connector, JTO3017 hose, and JTO3344 pressure gauge in test
port.
[7] - Start engine and set throttle at low idle.
[8] - Check and record PTO clutch pressure.
PTO Clutch Pressure Pressure 1380—1480 kPa
(200—215 psi)
[9] - Stop engine and cycle valves to relieve any pressure.
[10] - Install new O-ring on plug.
[11] - Remove gauge assembly from port. Install plug.
Results
Pressure should be to specification.

If pressure is below specification, check PTO clutch seals and PTO clutch pack condition.

Test HST Charge Pressure
HST Charge Pressure Test Port
LEGEND:
A Test Port
Perform this test to check HST charge pressure. This determines if there is sufficient oil
pressure to transmission.
[2] - Lock park brake.
[3] - Remove center closeout panel. See Remove and Install Center Closeout Panel in Section
90, Group 15.
[4] - Remove plug from pressure test port (A).

Assemble appropriate fitting, JTO3017 hose, and JTO3344 pressure gauge in test port.
[6] - Start engine and set throttle at low idle.
[7] - Check and record charge pressure.
[8] - Increase engine to high idle.
[9] - Check and record charge pressure.
HST Charge Pressure Pressure 500—800 kPa
(72—116 psi)
[10] - Stop engine and cycle valves to relieve any pressure.
[11] - Install new O-ring on plug.
[12] - Remove gauge assembly from port. Install plug.
Results
Pressure should be to specification and increase as engine speed is increased.

If pressure is below specification, check charge pressure relief valve for debris or
damage.

Check Rate of Drop/Stop Valve
Reason:
To ensure that lift arms lower rear attachment completely and lower it at a safe rate of
speed.
Equipment:
BW15073 Ballast Box
Procedure:
[1] - Park machine on a level surface and set park brake.
[2] - Shift transmission to NEUTRAL.
[3] - Install BW15073 ballast box, or approximately 227 kg (500 lb) , on the three point
hitch.
[4] - Start engine and run at fast idle.
[5] - Put lift control lever in full UP position.
[6] - Raise weight as high as it will go.
[7] - Close rate of drop/stop valve.
[8] - Put lift control lever in full DOWN position.
[9] - Open rate of drop/stop valve 1-1/2—2 turns.
[10] - Time duration of drop cycle from full up to full down.
Rockshaft Drop Cycle Time 2-1/2—3 seconds

Results:
If the weight lowers slower than specified time, open rockshaft rate of drop/stop valve until
specification is met. If weight drop time will not meet specification, the rate of drop/stop
valve may be clogged or faulty.

Pump Flow Test (Tractors With SCV)
Reference
→NOTE:
The following tools may be required for proper diagnosis:
1. JT03051 (Part of JT05418—Industrial Flow Test Kit)

2. JT03042 (Part of JT05418—Industrial Flow Test Kit)
3. AR94522 (Internal Half)
4. JT07148
5. Hydraulic Hose 1-1/16 F 37° x 1-1/16 M 37° (2 used)
( 1 ) Install Test Equipment
Action:
[1] - Assemble test equipment and connect flowmeter inlet hose to one of the SCV couplers.
[2] - Secure flow block return hose into transmission/hydraulic fill hole.
Result:
YES: Go to Procedure 2.

( 2 ) Pump Flow Test (With SCV)
Action:
[1] - Warm hydraulic oil. (See Hydraulic Oil Warm-up Procedure in this Group.)
[2] - Fully open JT07148 Digital Hydraulic Tester control valve.
[3] - Start tractor and run at 3200 rpm.
[4] - Slowly close JT07148 Digital Hydraulic Tester control valve until 10 345 kPa (103.5 bar)
(1500 psi) shows on the gauge.
[5] - Record flow, then open JT07148 Digital Hydraulic Tester control valve to release
pressure.
[6] - Compare recorded flow with specification below.
Hydraulic Pump Flow Rate 3200 rpm 13.25 Lpm (3.5 gpm)
Result:
YES: Return to diagnosis in progress.
NO: The mesh filter may be restricted.
NO: Filter/manifold may be restricted.
NO: The suction line may be restricted.
NO: The suction line may be leaking air. Check clamps, hose, and O-ring on suction line.
NO: Relief valve may be leaking.
NO: Control lever or cables not allowing full open valve.
NO: Coupler damaged. Repair.
NO: SCV valve spool scored or leaking.
NO: Mechanical hitch valve spool scored or leaking.
NO: The pump may be worn or damaged, requiring repair or replacement.

Main Relief Valve Test (Tractors With SCV)
Reference
→NOTE:
1. JT05473
2. JT03364
4. JT05494
Action:
[1] - Assemble gauge, hose, and adapter.
[2] - Connect test equipment into any SCV outlet.
Result:
YES: Go To 2.

( 2 ) Main Relief Valve Test (With SCV)
Action:
CAUTION:
To prevent hydraulic oil from overheating, DO NOT hold the SCV or

multifunction control handle in the EXTEND or RETRACT position for an
extended period of time. Overheating of hydraulic oil will cause
malfunction of hydraulic components and possible personal injury.
[2] - Run engine at slow idle.
[3] - Move SCV lever to pressurize test outlet. Hold until you hear system go into relief.
[4] - Record pressure reading on gauge and compare with specification.
Main Relief Valve Test Outlet Pressure 18 995—19 685 kPa (190—197 bar) (2755—2855 psi)
Result:
NO: Pressure high or low: adjust relief valve.
NO: Pressure high or low: replace relief valve.

SCV Leakage Test
Reference
→NOTE:
1. JT05473
2. JT03364
4. JT05494
Action:
[1] - Assemble gauge, hose, and adapter.
[2] - Connect test equipment into any SCV outlet.
Result:
YES: Go To 2.

( 2 ) Perform SCV Leakage Test
Action:
CAUTION:
To prevent hydraulic oil from overheating, DO NOT hold the SCV or

multifunction control handle in the EXTEND or RETRACT position for an
extended period of time. Overheating of hydraulic oil will cause
malfunction of hydraulic components and possible personal injury.
[2] - Run engine at fast idle.
[3] - Move SCV lever to pressurize test outlet. Hold until system goes into relief.
[4] - Release lever and record the time it takes for pressure to drop below 3459 kPa (34.5
bar) (500 psi).
[5] - Repeat for remaining valves and outlets.
[6] - Compare recorded time with specification below.
Time to Drop Below 3 450 kPa (34.5 bar) (500 psi) Time At Least 5 Seconds
Result:
NO: Service SCV(s).

Reference
( 1 ) Perform Lift Cycle Test
Action:
→NOTE:
Make sure all SCV spool valves are in neutral.
[2] - Attach approximately 227 kg (500 lb) rear weight or implement.
→NOTE:
BW15073 Ballast Box may be used.

[3] - Open rate-of-drop valve completely.
[4] - Lower 3-point hitch completely.
[5] - Run engine at fast idle.
[6] - Record the time it takes to completely raise the 3-point hitch arms after you pull the
position lever all the way back.
[7] - Compare recorded hitch raise time with specification below.
Hitch Raise Time Time Less than 3 Seconds
Result:
NO: See Rockshaft Leakdown Test .
NO: See Pump Flow Test (Tractors With SCV) .
NO: Service rockshaft valve.
NO: Repair leaking seal or O-ring.

Reference
→NOTE:
1. BW15073 Ballast Block

2. Digital Thermometer; GT07253 Temperature Measurement Gun; or
equivalent
3. Stop Watch or Timer
( 1 ) Test Conditions
Action:
[1] - DO NOT use I-Match attachment on machine during this test.
[2] - Park machine on flat surface for measurement.
[3] - Install ballast box or equivalent weight of 227 kg ±13.6 kg (500 lb. ±30 lb.)
→NOTE:
BW15073 Ballast Box may be used.
[4] - Raise hydraulic oil system to target temperature of 49° C ±3° C (120° F ±5° F). (See
Hydraulic Oil Warm-up Procedure in this Group.)
[5] - Ensure that ballast box has been cycled up and down 10 times to circulate heated oil
through system.
Result:
YES: Go to 2.
( 2 ) Open Rate of Drop Test

Action:
→NOTE:
Make sure all SCV spool valves are in neutral.
[1] - Engage park brake, and place machine in neutral range.
[2] - Open rate-of-drop valve completely.
[3] - Run engine at fast idle. Raise hydraulic temperature to 49° C ±3° C (120° F ±5° F).
[4] - Ensure that ballast box has been cycled up and down 10 times before proceeding.
[5] - Final rockshaft position shall be full powered lift height with throttle set to slow idle.
Shut off engine and wait 30 seconds before beginning measurement.
[6] - Measure vertical distance from floor to rockshaft ball joint center at end of right arm (as
determined from seat of tractor) and record measurement.

[7] - Time unit for 5 minutes. Measure distance from floor to rockshaft ball joints (at end of
lift arm) and record measurement.
Result:
( 3 ) Closed Rate of Drop Test
Action:
[1] - Run engine at fast idle. Raise hydraulic temperature to 49° C ±3° C (120° F ±5° F).
[2] - Ensure that ballast box has been cycled up and down 10 times before proceeding.
[3] - Close rate of drop valve fully and back off 1/4 turn.
[4] - Raise rockshaft to full height.
[5] - Shut off engine.
[6] - Close rockshaft rate of drop fully, by hand, before proceeding.
[7] - Pull rockshaft control lever forward and retain in forward position with bungee cord or
similar means and wait 30 seconds before beginning measurement.
[8] -
→NOTE:
Initial height measurement should be taken after lever is pulled forward.

Group 25: Adjustments
Measure vertical distance from floor to rockshaft ball joint center at end of left arm and
record measurement.
Result:

Group 25 - Adjustments
Specifications
Adjust Rockshaft Position Feedback
Adjust Rockshaft Feedback Friction Washers
Specifications
Height Difference Controlled by Lever Height 22.3 cm
(8.75 in.)
Manual Lift Height Difference Height 24.1 cm
(9.5 in.)

Adjust Rockshaft Position Feedback
Reason:
To ensure that rockshaft arms raise to maximum lift height without engaging relief valve.
Procedure:
[1] - Position machine on a level surface and set park brake.
[2] - Shift transmission to NEUTRAL position.
[3] - Position lift control lever at full forward (down) position and provide enough weight on
lift arms to allow self lowering.
[4] - Start engine.
[5] - Move lift control lever to full raise position.
[6] -
→NOTE:
Difference in height from fully down to fully up (measured at center of lift

arm pins) should be approximately 22.2 cm (8.75 in.).
Lift arm should raise fully without engaging the relief valve.
[7] - Shorten the lift arm position feedback rod to increase, or lengthen to reduce the
maximum height. The relief valve should not engage at maximum height.
Height Difference Controlled by Lever Height 22.3 cm
(8.75 in.)

Group 30: Hydraulic Schematics
[8] - Manually check full range of lift arm movement.
Manual Lift Height Difference Height 24.1 cm
(9.5 in.)
a. Stop engine.
b. Fully open load control valve to allow ease of lift arm motion.
c. Manually lift arms and measure difference from lower to full height.
Adjust Rockshaft Feedback Friction Washers
[1] - Loosen jam nut (A).
[2] - Turn adjusting cap screws (B) clockwise to increase friction and counterclockwise to
decrease friction. Turn cap screws equal number of times.
[3] - Retighten jam nut (A) when adjustment is complete.

Group 30 - Hydraulic Schematics
Hydraulic Circuit Symbols
1023E Hydraulic Schematic
1025R Hydraulic Schematic



LEGEND:
1 PTO Solenoid Valve
2 Steering Valve
3 Hydrostatic Transmission (HST)
4 Loader Selective Control Valve (SCV)
5 Rockshaft Valve


SERVICE TOOLS (g) by Belgreen
LEGEND:
1 PTO Solenoid Valve
2 Steering Valve
3 Hydrostatic Transmission (HST)
4 Loader Selective Control Valve (SCV)
5 Rockshaft Valve

Section 299 - SERVICE TOOLS
Table of contents
Group 05 - Dealer Fabricated Tools ........................................................................................ 2
PTO Clutch Spring Compression Tool ..................................................................................... 2
Group 10 - Service Tools and Kits ........................................................................................... 3
Essential or Recommended Tools .......................................................................................... 3

Section 299 - SERVICE TOOLS Group 10: Service Tools and Kits
Group 05 - Dealer Fabricated Tools
PTO Clutch Spring Compression Tool
LEGEND:
A ID 35 mm (1.38 in.)
[ OD 45 mm (or 1.75in) (Choose wall thickness adequate for use in bearing press) ]
B 65 mm (2.56 in.)
C 20 mm (0.787 in.)
D 40 mm (1.575 in.)
Tool can be fabricated from 1.75 in.OD iron pipe 2.6 in. long with two sides cut away.

Section 299 - SERVICE TOOLS Group 10: Service Tools and Kits
Group 10 - Service Tools and Kits
→NOTE:

Technical Manual: John Deere Agriculture

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John Deere Agriculture

1023E, 1025R and 1026R Compact Utility Tractor

TM126919, January 2013

<- Go to Global Table of contents TM126919-TECHNICAL MANUAL

Group 10 - Theory of Operation

<- Go to Global Table of contents TM126919-TECHNICAL MANUAL

<- Go to Section TOC Section 10 page 2 TM126919-TECHNICAL MANUAL

Section 10 - GENERAL INFORMATION

<- Go to Global Table of contents TM126919-TECHNICAL MANUAL

Diesel Fuel ........................................................................................................................... 55

<- Go to Global Table of contents TM126919-TECHNICAL MANUAL

Recognize Safety Information

Follow recommended precautions and safe operating practices.

Handle Fuel Safely—Avoid Fires

<- Go to Section TOC Section 10 page 2 TM126919-TECHNICAL MANUAL

Use only an approved fuel container for transporting ﬂammable liquids.

Prevent Battery Explosions

<- Go to Section TOC Section 10 page 3 TM126919-TECHNICAL MANUAL

Prepare for Emergencies

<- Go to Section TOC Section 10 page 4 TM126919-TECHNICAL MANUAL

First Aid Kit

Be prepared if a ﬁre starts.

Keep a ﬁrst aid kit and ﬁre extinguisher handy.

<- Go to Section TOC Section 10 page 5 TM126919-TECHNICAL MANUAL

Prevent Acid Burns

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

If you spill acid on yourself:

1. Flush your skin with water.

1. Do not induce vomiting.

<- Go to Section TOC Section 10 page 7 TM126919-TECHNICAL MANUAL

Service and Operate Chemical Sprayers Safely

<- Go to Section TOC Section 10 page 8 TM126919-TECHNICAL MANUAL

Reduce risk of exposure and injury:

Wear appropriate personal protective equipment as recommended by the

Handle Chemical Products Safely

<- Go to Section TOC Section 10 page 9 TM126919-TECHNICAL MANUAL

Material Safety Data Sheet

<- Go to Section TOC Section 10 page 10 TM126919-TECHNICAL MANUAL

Avoid High-Pressure Fluids

<- Go to Section TOC Section 10 page 11 TM126919-TECHNICAL MANUAL

Park Machine Safely

Remove the Key

Before working on the machine:

Lower all equipment to the ground.

Support Machine Properly

<- Go to Section TOC Section 10 page 12 TM126919-TECHNICAL MANUAL

Wear Protective Clothing

<- Go to Section TOC Section 10 page 13 TM126919-TECHNICAL MANUAL

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Work in Clean Area

<- Go to Section TOC Section 10 page 14 TM126919-TECHNICAL MANUAL

Clean Work Area

Before starting a job:

Clean work area and machine.

Service Machines Safely

<- Go to Section TOC Section 10 page 15 TM126919-TECHNICAL MANUAL

Work In Ventilated Area

<- Go to Section TOC Section 10 page 16 TM126919-TECHNICAL MANUAL

Engine exhaust fumes

Illuminate Work Area Safely

<- Go to Section TOC Section 10 page 17 TM126919-TECHNICAL MANUAL

Work Area Safely