8875 Skid-Steer Loader

TECHNICAL
MANUAL

John Deere
Lawn & Grounds Care Division
TM1566 (Feb 95)

Litho in U.S.A
 INTRODUCTION

This technical manual is written for an experienced

technician and contains sections that are specifically for
this product. It is a part of a total product support Safety
program.

Specifications and
Information

The manual is organized so that all the information on a

particular system is kept together. The order of grouping
is as follows:
• Table of Contents
• Specifications
• Theory of Operation
Engine (Diesel)
• Troubleshooting Diagram
• Diagnostics
• Tests & Adjustments Electrical
• Repair

Note: Depending on the particular section or system

being covered, not all of the above groups may be Power Train
used.

Power Train
Power Train
(Hydrostatic)
Each section will be identified with a symbol rather than a
number. The groups and pages within a section will be Steering
consecutively numbered.

Brakes

All information, illustrations and specifications in this

manual are based on the latest information available at
the time of publication. The right is reserved to make
Hydraulics
changes at any time without notice.

Backhoe

We appreciate your input on this manual. To help, there

are postage paid post cards included at the back. If you
find any errors or want to comment on the layout of the
manual please fill out one of the cards and mail it back to
us.
Miscellaneous

COPYRIGHT© 1995
JOHN DEERE HORICON WORKS
Horicon, Wisconsin
All rights reserved

2/8/95 1-1
SAFETY
HANDLE FLUIDS SAFELY-AVOID
FIRES
• BE PREPARED FOR EMERGENCIES
TS291
TS227
When you work around fuel, do not smoke or work near
heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and
debris.
Do not store oily rags; they can ignite and burn
spontaneously.
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your
telephone.
1-2
HANDLE CHEMICAL PRODUCTS
SAFELY
TS1132 TS1133
Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used
with John Deere equipment include such items as
lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques. Check the MSDS before you start any job
using a hazardous chemical. That way you will know
exactly what the risks are and how to do the job safely.
Then follow procedures and recommended equipment.
• DISPOSE OF WASTE PROPERLY
Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste
used with John Deere equipment include such items as
oil, fuel, coolant, brake fluid, filters, and batteries. Use
leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead
someone into drinking from them. Do not pour waste
onto the ground, down a drain, or into any water
source. Inquire on the proper way to recycle or dispose
of waste from your local environmental or recycling
center, or from your John Deere dealer.
4/13/95

USE CARE AROUND HIGH-
PRESSURE FLUID LINES
• AVOID HIGH-PRESSURE FLUIDS
X9811
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.
• AVOID HEATING NEAR PRESSURIZED FLUID
LINES
TS953
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines
or other flammable materials. Pressurized lines can be
accidentally cut when heat goes beyond the immediate
flame area.
4/13/95
SAFETY
USE CARE IN HANDLING AND
SERVICING BATTERIES
TS204 TS203
• PREVENT BATTERY EXPLOSIONS
• Keep sparks, lighted matches, and open flame
away from the top of battery. Battery gas can
explode.
• Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
• Do not charge a frozen battery; it may explode.
Warm battery to 16°C (60°F).
• PREVENT ACID BURNS
• Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, eat holes in clothing,
and cause blindness if splashed into eyes.
• Avoid acid burns by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. 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 10_15 minutes.
4. Get medical attention immediately.
• If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.
11 1 - 3
SAFETY

USE SAFE SERVICE PROCEDURES • PARK MACHINE SAFELY

• WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause
impairment or loss of hearing. Wear a suitable hearing
protective device such as earmuffs or earplugs to
protect against objectionable or uncomfortable loud
noises.
Operating equipment safely requires the full attention
of the operator. Do not wear radio or music
headphones while operating machine.
• Before working on the machine:
1. Lower all equipment to the ground.
2. Stop the engine and remove the key.
3. Disconnect the battery ground strap.
4. Hang a “DO NOT OPERATE” tag in operator station.

• SUPPORT MACHINE PROPERLY AND USE

TS206
PROPER LIFTING EQUIPMENT

TS229

TS228

• SERVICE MACHINES SAFELY

Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near If you must work on a lifted machine or attachment,
machine tools or moving parts. If these items were to securely support the machine or attachment.
get caught, severe injury could result. Do not support the machine on cinder blocks, hollow
Remove rings and other jewelry to prevent electrical tiles, or props that may crumble under continuous load.
shorts and entanglement in moving parts. Do not work under a machine that is supported solely
by a jack. Follow recommended procedures in this
manual.
Lifting heavy components incorrectly can cause severe
• USE PROPER TOOLS
injury or machine damage. Follow recommended
Use tools appropriate to the work. Makeshift tools and procedure for removal and installation of components
procedures can create safety hazards. Use power tools in the manual.
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.

1-4 4/13/95

• WORK IN CLEAN AREA
• BEFORE STARTING A JOB
1. Clean work area and machine:
2. Make sure you have all necessary tools to do your
job.
3. Have the right parts on hand.
4. Read all instructions thoroughly; do not attempt
shortcuts.
• ILLUMINATE WORK AREA SAFELY
Illuminate your work area adequately but safely. Use a
portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire
cage. The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
• WORK IN VENTILATED AREA
TS220
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.
• REMOVE PAINT BEFORE WELDING OR HEATING
Avoid potentially toxic fumes and dust. Hazardous
fumes can be generated when paint is heated by
welding, soldering, or using a torch. Do all work outside
or in a well ventilated area. Dispose of paint and
solvent properly. Remove paint before welding or
heating: If you sand or grind paint, avoid breathing the
dust. Wear an approved respirator. If you use solvent or
paint stripper, remove stripper with soap and water
before welding. Remove solvent or paint stripper
containers and other flammable material from area.
Allow fumes to disperse at least 15 minutes before
welding or heating.
4/13/95
SAFETY
• DISCONNECT ELECTRONIC INSTRUMENT
PANEL MODULE (EIPM) BEFORE WELDING OR
BATTERY CHARGING
Before welding, battery charging, or using any high
voltage equipment which attaches to the Skid Steer
Loader, always disconnect the Electronic Instrument
Panel Module connector from the back of the electronic
board. This will prevent high voltage surges which can
erase the memory stored in the electronic chips of the
EIPM.
• AVOID HARMFUL 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.
• SERVICE TIRES SAFELY
TS952
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.
11 1 - 5
SAFETY

• Check wheels for low pressure, cuts, bubbles, LIVE WITH SAFETY
damaged rims or missing lug bolts and nuts.

TS231

REPLACE SAFETY SIGNS

TS201

Before returning machine to customer, make sure

machine is functioning properly, especially the safety
Replace missing or damaged safety signs. See the
systems. Install all guards and shields.
machine operator's manual for correct safety sign
placement.

1-6 4/13/95
SPECIFICATIONS & INFORMATION CONTENTS

CONTENTS
Page

GENERAL VEHICLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 2

UNIFIED INCH TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
METRIC TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIESEL FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIESEL FUEL STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TRANSMISSION AND HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHAIN CASE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
GEARBOX OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ALTERNATIVE LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SYNTHETIC LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LUBRICANT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SKID STEER LOADER PRODUCT IDENTIFICATION NUMBER . . . . . . . . . . . . 10
ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4/13/95 2-1
SPECIFICATIONS & INFORMATION GENERAL VEHICLE SPECIFICATIONS

GENERAL VEHICLE SPECIFICATIONS

8875

ENGINE

Make John Deere

Model 3029T

Type Diesel

Cylinders 3

Bore 106.4 mm (4.19 in.)

Stroke 111.5 mm (4.39 in.)

Displacement 2.9 L (177 cu. in.)

Compression ratio 18:1

Net horsepower 45.5 kW (61)

RPM, slow (no load) 950

RPM, fast (no load) 2270

Lubrication Force-feed; Pressurized with flow filter.

Crankcase capacity (with filter) 8.5 L (9 qt.)

Cooling system Liquid

Coolant capacity 15.1 L (16 qt.)

Air filter type 2-Stage, replaceable paper element

ELECTRICAL

Type of starter Delco Remy 28MT

Battery voltage 12 V

Battery reserve capacity at 27°C (80° F) 160 minutes

Battery cold cranking amps at -18°C (0°F) 925 amps

Charging system 55 amp Magneton alternator

FUEL SYSTEM

Fuel Diesel # 1 or # 2

Capacity 71.2 L (18.8 gal)

Fuel delivery Inline direct injection

Fuel shut-off Internal Fuel shutoff solenoid in Injection Pump

POWER TRAIN

Type Hydrostatic

Charge pump Internal gerotor type in R/H Hydrostatic pump

Hydrostatic pumps Variable displacement axial piston

2-2 4/13/95
GENERAL VEHICLE SPECIFICATIONS SPECIFICATIONS & INFORMATION

8875

Hydrostatic pump relief pressure 34473 kPa (5000 psi)

Hydrostatic motor Variable displacement axial piston

Charge relief pressure 2068 kPa (300 psi)

Chain case capacity (each side) 7.6 L (2 gal.)

Gearbox capacity (each gearbox) 2.8 L (3 qt.)

Brakes Dual disks on hydrostatic motor shaft

STEERING

Type Power - hydrostatic

PERFORMANCE

Manufacturers operating load 568 kg (1250 lb.)

Hydraulic lift capacity 998 kg (2200 lb.)

Ground speed (low range—high range) 12.2—19.6 km/h (7.5—12.0 mph)

Operating weight 3025 kg (6670 lb.)

HYDRAULICS

Main system relief pressure 17927 kPa (2600 psi)

Circuit relief pressure 18961 kPa (2750 psi)

Hydraulic valve 3 spool open center

DIMENSIONS

Length less bucket 2845 mm (112 in.)

Length with bucket 3607 mm (142 in.)

Width less bucket 1753 (69 in.)

Height to ROPS 1829 mm (72 in.)

Height to hinge pin 3099 mm (122 in.)

Dump height 2464 mm (97 in.)

Dump reach 762 mm (30 in.)

Dump angle 45°

Bucket rollback 37°

Wheelbase 1219 mm (48 in.)

Ground clearance 203 mm (8 in.)

Angle of departure 28°

4/13/95 2-3
SPECIFICATIONS & INFORMATION UNIFIED INCH TORQUE VALUES

UNIFIED INCH TORQUE VALUES

1 or 2b 5 5.1 5.2 8 8.2

SAE
Grade
and Head No Marks
Markings

2 5 8
SAE
Grade No Marks
and Nut
Markings

Grade 1 Grade 2b Grade 5, 5.1 or 5.2 Grade 8 or 8.2

Lubricateda Drya Lubricateda Drya Lubricateda Drya Lubricateda Drya

SIZE Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft

1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5

5/16 7.7 5.5 10 7 12 9 15 11 20 15 25 18 28 21 35 26

3/8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46

7/16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75

1/2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115

9/16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160

5/8 67 50 85 62 105 78 135 100 170 125 215 160 215 160 300 225

3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400

7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650

1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975

1-1/8 470 300 510 375 470 300 510 375 900 675 1150 850 1450 1075 1850 1350

1-1/4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950

1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550

1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350

DO NOT use these values if a different torque value or
tightening procedure is given for a specific application.
Torque values listed are for general use only. Check
tightness of fasteners periodically.
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same or higher
grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original. Make
sure fasteners threads are clean and that you properly
start thread engagement. This will prevent them from
failing when tightening. Tighten plastic insert or
crimped steel-type lock nuts to approximately 50
percent of the dry torque shown in the chart, applied to
the nut, not to the bolt head.
Tighten toothed or serrated-type lock nuts to the full
torque value.
a “Lubricated” means coated with a lubricant such as
engine oil, or fasteners with phosphate and oil
coatings. “Dry” means plain or zinc plated without any
lubricationb
b
Grade 2 applies for hex cap screws (not hex bolts) up
to 152 mm (6-in.) long. Grade 1 applies for hex cap
screws over 152 mm (6-in.) long, and for all other types
of bolts and screws of any length.

2-4 4/13/95
METRIC TORQUE VALUES SPECIFICATIONS & INFORMATION

METRIC TORQUE VALUES

4.8 8.8 9.8 10.9 12.9
Property
Class
and 4.8 8.8 9.8 10.9 12.9
Head
Markings 4.8 8.8 9.8 10.9 12.9 12.9

Property 5 10 10 12
Class
and

10

10

12
5

Nut 5 10 10 12
Markings

Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

Lubricateda Drya Lubricateda Drya Lubricateda Drya Lubricateda Drya

SIZE Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft

M6 48 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5

M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35

M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70

M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120

M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 109

M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300

M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410

M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580

M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800

M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000

M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500

M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000

M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750

M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500

DO NOT use these values if a different torque value or
tightening procedure is given for a specific application.
Torque values listed are for general use only. Check
tightness of fasteners periodically.
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same or higher
grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original. Make
sure fasteners threads are clean and that you properly
start thread engagement. This will prevent them from
failing when tightening.
Tighten plastic insert or crimped steel-type lock nuts to
approximately 50 percent of the dry torque shown in
the chart, applied to the nut, not to the bolt head.
Tighten toothed or serrated-type lock nuts to the full
torque value.
a
“Lubricated” means coated with a lubricant such as
engine oil, or fasteners with phosphate and oil
coatings. “Dry” means plain or zinc plated without any
lubrication.
b
Grade 2 applies for hex cap screws (not hex bolts) up
to 152 mm (6-in.) long. Grade 1 applies for hex cap
screws over 152 mm (6-in.) long, and for all other types
of bolts and screws of any length.

4/13/95 2-5
SPECIFICATIONS & INFORMATION DIESEL FUEL SPECIFICATIONS

DIESEL FUEL SPECIFICATIONS DO NOT STORE DIESEL FUEL IN

Use only clean, high quality fuel. GALVANIZED CONTAINERS
Use Grade No. 2-D fuel at temperatures above 4°C
(40°F). IMPORTANT: Diesel fuel stored in galvanized
containers reacts with the zinc coating of the
Use Grade No. 1-D fuel at temperatures below 4°C container to form zinc flakes. If fuel contains
(40°F). any water, a zinc gel will also form. The gel and
Use Grade No. 1-D fuel for all air temperatures at flakes will quickly plug fuel filters and may
altitudes above 1500 m (5000 ft). damage fuel injectors and fuel pumps.

IMPORTANT: Use fuel with less than 1.0 per cent Store diesel fuel in:
sulfur. If possible, use fuel with less than 0.5 per • plastic containers
cent sulfur. If fuel sulfur is more than 0.5 per
• aluminum containers
cent, change engine oil and filter every 100
hours. • specially coated steel containers made for diesel fuel.

For maximum filter life, sediment and water should not DO NOT USE BRASS-COATED CONTAINERS: brass
be more than 0.10 per cent. is an alloy of copper and zinc.
The octane number should be 40 minimum. If you
operate your tractor where air temperatures are
normally low or where altitudes are high, you may need
fuel with a higher cetane number.
Cloud Point - For cold weather operation, cloud point
should be 10°F (6°C) below lowest normal air
temperature.

Fuel Tank Capacity

8875 . . . . . . . . . . . . . . . . . . . . . . . . 71.2 L (18.8 gal)

DIESEL FUEL STORAGE

NOTE: Diesel fuels stored for a long time may form
gum and plug filters.

Keep fuel in a clean container in a protected area.

Water and sediment must be removed before fuel gets
to the engine. Do not use de-icers to remove water
from fuel. Do not depend on fuel filters to remove
water. If possible, install a water separator at the
storage tank outlet. (See your John Deere dealer for
this part.)

IMPORTANT: Keep all dirt, scale, water or other

foreign material out of fuel.

Store fuel drum on its side with plug up.

2-6 4/13/95
LUBRICANT SPECIFICATIONS SPECIFICATIONS & INFORMATION

LUBRICANT SPECIFICATIONS GREASE

ENGINE OIL
Use oil viscosity based on the expected air
temperature range during the period between oil
changes.
The following oil is preferred:
• John Deere TORQ-GARD SUPREME PLUS-50 ™
Use grease based on the expected air temperature
range during the service interval.
The following greases are preferred:
• John Deere MOLY HIGH TEMPERATURE EP
GREASE
• John Deere HIGH TEMPERATURE EP GREASE
• John Deere GREASE-GARD TM

TS1412

The following oils are also recommended: TS1417

• John Deere TORQ-GARD SUPREME ®

• John Deere UNI-GARD ™
Other oils may be used if they meet one of the Other greases may be used if they meet one of the
following: following:

• API Service Classification CE • SAE Multipurpose EP Grease with a maximum of 5%

molybdenum disulfide.
• API Service Classification CD
• SAE Multipurpose EP Grease
• CCMC Specification D5
Greases meeting Military Specification MIL-G-10924F
• CCMC Specification D4 may be used as arctic grease.
• Oils meeting Military Specification MIL-L-46167B may
be used as arctic oils.
If John Deere TORQ-GARD SUPREME PLUS-50 ™
engine oil and a John Deere oil filter are used, the oil
and filter service interval may be extended by 50 hours.
If diesel fuel exceeding 0.5% sulphur content is used,
reduce the service interval for engine oil and filter by
50%.

4/13/95 2-7
SPECIFICATIONS & INFORMATION LUBRICANT SPECIFICATIONS

TRANSMISSION AND HYDRAULIC • Military Specification MIL-L-2105B.

OIL Oils meeting Military Specification MIL-L-10324A may
be used as arctic oils.
The following oil is preferred:
• John Deere PLUS-4 ® 10W-30
ALTERNATIVE LUBRICANTS
When adding small amounts of oil to top off the oil
reservoir, the following oil in descending order is Conditions in certain geographical areas outside the
permissible: United States and Canada may require different
lubricant recommendations than these printed in this
• John Deere TURF-GARD ® manual or the operator's manual. Consult with your
• 10W-30 oil equivalent to John Deere PLUS-4 ® John Deere Dealer, or Sales Branch to obtain the
• John Deere HY-GARD ® alternative lubricant recommendations.

CHAIN CASE OIL SYNTHETIC LUBRICANTS

The following oil is preferred:
• John Deere PLUS-4 ® 10W-30
When adding small amounts of oil to top off the oil
reservoir, the following oil in descending order is
permissible:
• John Deere TURF-GARD ®
• 10W-30 oil equivalent to John Deere PLUS-4 ®
• John Deere HY-GARD ®
GEARBOX OIL
Use oil viscosity based on the expected air
temperature range during the period between oil
changes.
John Deere GL-5 Gear Lubricant is recommended.
Synthetic lubricants may be used in John Deere
equipment if they meet the applicable performance
requirements (industry classification and/or military
specification) as shown in this group.
The recommended temperature limits and service or oil
change intervals should be maintained as shown in the
operator’s manual.
Avoid mixing different brands, grades, or types of oil.
Oil manufacturers blend additive 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.
OIL FILTERS
Filtration of oils is critical to proper lubrication. Always
change filters regularly.
Use filters meeting John Deere performance
specification.

LUBRICANT STORAGE
This machine can operate at top efficiency only if clean
lubricants are used.
Use clean containers to handle all lubricants. Store
them in an area protected from dust, moisture, and
other contamination. Store drums on their sides.

M74991
Other oils may be used if they meet one or more of the
following:
• API Service Classification GL-5.
• Military Specification MIL-L-2105D.
• Military Specification MIL-L-2105C.
ENGINE COOLANT
To meet cooling system protection requirements, the
coolant MUST consist of a 50/50 mixture of quality
water and ethylene glycol concentrate (antifreeze). Add
to the mixture 3% (by volume) supplemental coolant
additives (SCA’s). See ENGINE COOLANT
SPECIFICATIONS, later in this group, for further
definition.
Makeup of the coolant between changes MUST consist
of the same requirements as during a complete
change. Performing a COOLSCAN analysis is the
recommended method for determining the amount of

2-8 4/13/95
LUBRICANT SPECIFICATIONS
quality water, ethylene glycol concentrate, and
supplemental coolant additives that should be added.
IMPORTANT: Supplemental coolant additives
MUST be added to the coolant solution.
Ethylene glycol concentrate (antifreeze) DOES
NOT contain chemical inhibitors needed to
control liner pitting or erosion, rust, scale, and
acidity.
Coolant solutions of ethylene glycol concentrate
(antifreeze), quality water, and supplemental coolant
additives (SCA’s) MUST be used year-round to protect
against freezing, boil-over, liner erosion or pitting, and
to provide a stable, non-corrosive environment for
seals, hoses, and metal engine parts.
Water pump impellers and cylinder liner walls which
are in contact with engine coolant can be eroded or
pitted unless the proper concentration and type of
SCA’s are present in the coolant solution.
Generally, the most critical erosion occurs in the
cylinder liner area of wet-sleeve, heavy-duty diesel
engines. If coolant is allowed to enter the combustion
chamber, engine failure or other serious damage will
result.
Use of SCA’s will reduce the effects of erosion and
pitting. The chemicals in the additives form a protective
film on cylinder liner surface. This film acts as a barrier
against harmful erosion and pitting.
WATER QUALITY:
Distilled, de-ionized, or soft water is preferred for use in
cooling systems. Mineral (hard/tap) water should
NEVER be put in a cooling system unless first tested.
ETHYLENE GLYCOL CONCENTRATE
(ANTIFREEZE):
IMPORTANT: DO NOT use methyl alcohol or
methoxy propanol base concentrate. This
concentrate is not compatible with additives
used in supplemental coolant additives.
Damage can occur to rubber seals on cylinder
liners which are in contact with coolant.
DO NOT use ethylene glycol concentrate
containing sealer or stop-leak additives.
DO NOT use concentrate containing less than
10% ethylene glycol.
DO NOT use concentrate containing more than
0.1% anhydrous metasilicate. This type of
concentrate, which is intended for use in
aluminum engines, may cause a gel-like deposit
to form that reduces heat transfer and coolant
flow. Check container label or consult
withsupplier before using.
4/13/95
SPECIFICATIONS & INFORMATION
John Deere Low Silicate Antifreeze is the ethylene
glycol concentrate recommended for all John Deere
Diesel Engines. This product is concentrated and
should be mixed 50/50 with quality water. Add to the
mixture 3% (by volume) supplemental coolant additives
(SCA’s).
SUPPLEMENTAL COOLANT ADDITIVES (SCA’s):
IMPORTANT: Ethylene glycol concentrate DOES
NOT contain sufficient additives to prevent liner
erosion or pitting which could occur in wet
sleeve diesel engines. ALWAYS mix the coolant
solution with a supplemental coolant additive
such as John Deere Liquid Coolant Conditioner
or spin-on coolant filter conditioner element.
c
CAUTION:
John Deere Liquid coolant Conditioner
contains alkali. Avoid contact with eyes. Avoid
prolonged or repeated contact with skin. Do
not take internally. In case of contact,
immediately wash skin with soap and water.
For eyes, flush with large amounts of water for
at least 15 minutes. Call physician. KEEP OUT
OF REACH OF CHILDREN.
• John Deere Liquid Coolant Conditioner
IMPORTANT: ALWAYS mix the 50/50 solution of
ethylene glycol concentrate with quality water in
a separate container BEFORE adding the SCA’s.
Then add solution to the radiator. NEVER pour
cold water into a hot engine, as it may crack
cylinder block or head.
John Deere Liquid Coolant Conditioner MUST be
added at a rate of 3% (by volume) to the coolant
solution. When adding John Deere Liquid Coolant
Conditioner, follow the supplier’s recommendations
printed on the container.
IMPORTANT: John Deere Liquid Coolant
Conditioner does NOT protect against freezing.
DO NOT over-concentrate coolant solutions
with supplemental coolant additives, as this can
cause silicate-dropout. When this happens, a
gel-type deposit is created which retards heat
transfer and coolant flow. DO NOT use soluble
oil.
2-9
SPECIFICATIONS & INFORMATION SERIAL NUMBER LOCATION

DISPOSING OF COOLANT: SERIAL NUMBER LOCATION

When ordering parts or submitting a warranty claim, it
is IMPORTANT that you include the skid steer loader
product identification number and the component serial
numbers.
The location of skid steer loader product identification
number and component serial numbers are shown.

SKID STEER LOADER PRODUCT

IDENTIFICATION NUMBER

Improperly disposing of engine coolant can threaten

the environment and ecology.
Use leakproof containers when draining fluids. Do not
use food or beverage containers that may mislead
someone into drinking from them.
Do not pour waste onto the ground, down a drain, or
into any water source.
Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center, or from your John Deere dealer.

Product Identification Number

M71826

ENGINE SERIAL NUMBER

Engine Serial Number

2 - 10 4/13/95
CONTENTS DIESEL ENGINE

CONTENTS
Page

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GENERAL SPECIFICATIONS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REPAIR SPECIFICATIONS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SEALANT APPLICATION GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LUBRICATION SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FUEL SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSING ENGINE MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CYLINDER LINER, PISTON, AND CONNECTING ROD DIAGNOSIS . . . . . . . . 18
CYLINDER HEAD AND VALVE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CRANKSHAFT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FUEL SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FUEL SUPPLY PUMP DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
FUEL INJECTION NOZZLE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
FUEL INJECTION NOZZLE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
FUEL INJECTION PUMP DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
AIR INTAKE SYSTEM DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
VALVE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
VALVE LIFT MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
PRELIMINARY ENGINE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
ENGINE COMPRESSION PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . 27
ENGINE OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INTAKE MANIFOLD PRESSURE (TURBO BOOST) TEST . . . . . . . . . . . . . . . . 28
CRANKCASE VENTILATION SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . 28
AIR INTAKE SYSTEM INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CHECK EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
COOLING SYSTEM & RADIATOR CAP PRESSURE TEST. . . . . . . . . . . . . . . . 29
FUEL DRAIN BACK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CLEAN ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ENGINE REMOVAL (CAB TILTED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ENGINE LIFTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ENGINE REPAIR STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ENGINE DISASSEMBLY SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
ENGINE ASSEMBLY SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
CYLINDER HEAD REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ROCKER ARM DISASSEMBLY & INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 34
ROCKER ARM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
CAMSHAFT FOLLOWER REMOVAL & INSPECTION . . . . . . . . . . . . . . . . . . . . 35

2/24/95 3-1
DIESEL ENGINE CONTENTS

Page

VALVE RECESS CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

VALVE ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
VALVE SPRING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
VALVE ROTATOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
VALVE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
VALVE GRIND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
CYLINDER HEAD FLATNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
CYLINDER HEAD THICKNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INJECTOR BORE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
VALVE GUIDE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
VALVE GUIDE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
VALVE GUIDE KNURLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
VALVE SEAT CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 40
VALVE SEAT GRINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
VALVE SEAT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
VALVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
CYLINDER HEAD BOLT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
EXHAUST MANIFOLD INSPECTION & CLEANING . . . . . . . . . . . . . . . . . . . . . . 42
CYLINDER BLOCK TOP DECK CLEANING & INSPECTION . . . . . . . . . . . . . . . 42
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
TORQUE-TURN METHOD FOR PROPER TORQUE . . . . . . . . . . . . . . . . . . . . . 43
ROCKER ARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
ROCKER ARM COVER VENT CLEANING AND INSPECTION . . . . . . . . . . . . . 45
ROCKER ARM COVER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
COMPLETE FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
CYLINDER BLOCK REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
PISTON AND CONNECTING ROD REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . 46
CYLINDER LINER HEIGHT MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 47
CYLINDER LINER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
PISTON ROD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
PISTON CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
CYLINDER LINER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
CYLINDER LINER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
PISTON AND CYLINDER LINER MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . 51
CYLINDER LINER DEGAZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
PISTON AND LINER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
CONNECTING ROD BEARING INSPECTION & MEASUREMENT . . . . . . . . . . 53
CONNECTING ROD AND CAP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 54
PISTON PIN AND ROD BUSHING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 54
PISTON PIN BUSHING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
CONNECTING ROD PIN BORE CLEANING & INSPECTION . . . . . . . . . . . . . . 55

3-2 2/24/95
CONTENTS DIESEL ENGINE

Page

PISTON PIN BUSHING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

CYLINDER BLOCK CLEANING & INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 55
CYLINDER LINER O-RING BORE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . 56
CYLINDER BLOCK MAIN BEARING BORE MEASUREMENT . . . . . . . . . . . . . . 56
CAMSHAFT FOLLOWER BORE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . 56
CAMSHAFT BEARING BORE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . 57
CYLINDER BLOCK FLATNESS MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . 57
PISTON COOLING ORIFICE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
CYLINDER LINER FLANGE THICKNESS MEASUREMENT . . . . . . . . . . . . . . . 58
CYLINDER LINER HEIGHT MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 58
CYLINDER LINER O-RING & PACKING INSTALLATION . . . . . . . . . . . . . . . . . 59
CYLINDER LINER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
PISTON & CONNECTING ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
PISTON & CONNECTING ROD ASSEMBLY INSTALLATION . . . . . . . . . . . . . . 61
CRANKSHAFT ROTATION TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
PISTON PROTRUSION MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
COMPLETE FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
ENGINE BREAK-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL REPAIR . . . . . . 63
CRANKSHAFT PULLEY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
CRANKSHAFT PULLEY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
FLYWHEEL HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
HYDROSTATIC PUMP DRIVE SHAFT SEAL REPAIR . . . . . . . . . . . . . . . . . . . . 65
CRANKSHAFT END PLAY CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
FLYWHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
FLYWHEEL RING GEAR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
FLYWHEEL PILOT BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 66
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
CRANKSHAFT REAR OIL SEAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
CRANKSHAFT REAR OIL SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 68
ENGINE REAR PLATE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
REMOVE MAIN BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
CRANKSHAFT MAIN BEARING CLEARANCE CHECK (IN BLOCK) . . . . . . . . . 70
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
CRANKSHAFT GEAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
CRANKSHAFT MAIN BEARING MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . 71
CRANKSHAFT THRUST BEARING & JOURNAL MEASUREMENT . . . . . . . . . 72
CRANKSHAFT GRINDING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
CRANKSHAFT MAIN BEARING CAP MEASUREMENT . . . . . . . . . . . . . . . . . . 73
CRANKSHAFT GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
PISTON COOLING ORIFICES INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

2/24/95 3-3
DIESEL ENGINE CONTENTS

Page

MAIN BEARING AND CRANKSHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . 75

ENGINE REAR PLATE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
FLYWHEEL HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
HYDROSTATIC PUMP DRIVE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . 77
COMPLETE FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
CAMSHAFT AND TIMING GEAR REPAIR . . . . . . . . . . . . . . . . . . . . . . 78
VALVE LIFT MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
TIMING GEAR COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
CAMSHAFT END PLAY MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
IDLER GEAR END PLAY MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
TIMING GEAR BACKLASH MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 79
CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
CAMSHAFT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
CAMSHAFT THRUST PLATE CLEARANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
CAMSHAFT BEARING MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
CAMSHAFT LOBE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
CAMSHAFT GEAR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
CAMSHAFT FOLLOWER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
CAMSHAFT BUSHING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
FRONT PLATE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
MEASURE IDLER GEAR BUSHING AND SHAFT . . . . . . . . . . . . . . . . . . . . . . . 84
IDLER GEAR BUSHING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
IDLER GEAR SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
ENGINE FRONT PLATE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
IDLER SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
INSTALL ENGINE FRONT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
FUEL INJECTION PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
CAMSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
IDLER GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
TIMING GEAR COVER CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . 88
TIMING GEAR COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
CRANKSHAFT FRONT OIL SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 88
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
OIL COOLER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
OIL PRESSURE REGULATING VALVE & SEAT REPAIR . . . . . . . . . . . . . . . . . 90
OIL FILTER NIPPLE REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
DIPSTICK REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
OIL PUMP REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
OIL PAN INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
OIL PAN DRAIN PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
COOLING SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

3-4 2/24/95
CONTENTS DIESEL ENGINE

Page

THERMOSTAT REMOVAL & TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

WATER MANIFOLD REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 96
WATER PUMP REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
WATER PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
WATER PUMP DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
WATER PUMP CLEANING & INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
WATER PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
WATER PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
FAN BLADE INSPECTION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 99
TURBOCHARGER DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
TURBOCHARGER DIAGNOSIS (Cont.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
TURBOCHARGER DIAGNOSIS (Cont.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
TURBOCHARGER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
TURBOCHARGER FAILURE ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
TURBOCHARGER BEARING RADIAL CLEARANCE TEST . . . . . . . . . . . . . . 106
TURBOCHARGER BEARING AXIAL END PLAY TEST . . . . . . . . . . . . . . . . . . 107
TURBOCHARGER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
TURBOCHARGER DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . 107
TURBOCHARGER CENTER HOUSING & ROTATING ASSEMBLY
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
TURBOCHARGER PRE-LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
INSTALL TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
TURBOCHARGER BREAK-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
INTAKE MANIFOLD REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
EXHAUST MANIFOLD REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
RELIEVE FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
FUEL FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
FUEL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
FUEL PUMP TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
FUEL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
FUEL INJECTION PUMP TIMING MARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
FUEL INJECTION PUMP TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
INJECTION PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
INJECTION PUMP DRIVE GEAR & SHAFT INSPECTION. . . . . . . . . . . . . . . . 114
FUEL INJECTION PUMP REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
FUEL INJECTION PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
FUEL INJECTION NOZZLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
FUEL INJECTION NOZZLE BORE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . 117
INJECTION NOZZLE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
FUEL INJECTION NOZZLE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
FUEL INJECTION NOZZLE DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 119

2/24/95 3-5
DIESEL ENGINE CONTENTS

Page

FUEL INJECTION NOZZLE CLEANING & INSPECTION . . . . . . . . . . . . . . . . . 120

FUEL INJECTION NOZZLE VALVE SEAT INSPECTION & CLEANING . . . . . 120
FUEL INJECTION NOZZLE VALVE ADJUSTOR INSPECTION . . . . . . . . . . . . 121
FUEL INJECTION NOZZLE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
FUEL INJECTION NOZZLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
FUEL INJECTION NOZZLE SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . 123
FUEL INJECTION NOZZLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 123
ALTITUDE COMPENSATION GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

3-6 2/24/95
SPECIFICATIONS DIESEL ENGINE

SPECIFICATIONS

GENERAL SPECIFICATIONS:
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere Series 300 (Saran )
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CD 3029T
Number Of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinder Firing Order: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3
Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106.5 mm (4.19 in.)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 mm (4.33 in.)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 L (179 cu in.)
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.8:1
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3
Piston Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549.8 m/min (1804 ft/min )
Rated Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500 RPM
Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800-850

Bearings:
Number Of Mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Main Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.2 mm (3.12 in.)
Main Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.4 mm (1.12 in.)
Rod Journal Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.8 mm (2.75 in.)
Rod Journal Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.0 mm (1.18 in.)

Lubrication System:
Pump Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.88 L/s (14 gpm)
Normal Oil Pressure At Rated Speed, 30 W Oil At 105° C (220° F) . . . 380 kPa (55 psi)
Minimum Oil Pressure At Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 138 kPa (20 psi)
Bypass Pressure Relief In Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 kPa (22 psi)

REPAIR SPECIFICATIONS:
Cylinder Head
Thickness of New Cylinder Head . . . . . . . . . . . . . . 104.87-105.13 mm (4.129-4.139 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.25 mm (4.104 in.)
Maximum Material Removal for Resurfacing Head . . . . . . . . . . . . . . 0.76mm (0.030 in.)
Maximum Acceptable Head Out-of Flat :
For Entire Length of Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.)
For Every 150 mm (5.90 in.) Length or Width . . . . . . . . . . . . . . . 0.03 mm (90.001 in.)
Combustion Face Surface Finis h
(Surface Grind Only) (AA) . . . . . . . . . . . . . . . . . 0.0008-0.0032 mm (31-125 micro-in. )
Maximum Wave Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 mm (0.0005 in.)

Valves
Standard Valve Stem OD :
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.864-7.884 mm (0.3096-0.3104 in. )
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.848-7.874 mm (0.3090-0.3100 in. )
Oversize Valve Stems Available . . . . . . . . 0.38 mm (0.015 in.) and 0.76 mm (0.030 in. )
Valve Guide ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.912-7.938 mm (0.312-0.313 in. )
Valve Stem-to-Guide Clearance . . . . . . . . . . . . . . . . . . . 0.05-0.10 mm (0.002-0.004 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Valve Seat Angle (intake and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Valve Face Angle (intake and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.25° ± 0.25°

4/13/95 3-7
DIESEL ENGINE SPECIFICATIONS

Maximum Valve Seat Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.)

Maximum Valve Face Runout (Intake and Exhaust) . . . . . . . . . . . 0.038 mm (0.0015 in.)
Valve Recess in Cylinder Head :
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.61-1.11 mm (0.024-0.044 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.63 mm (0.064 in)
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22-1.72 mm (0.048-0.068 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 mm (0.089 in.)
Valve Seat Width (Intake And Exhaust) . . . . . . . . . . . . . 1.50-2.00 mm (0.059-0.079 in. )
Valve Head OD:
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.47-46.73 mm (1.830-1.840 in. )
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.37-42.63 mm (1.668-1.678 in. )
Cylinder Firing Order: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3
Valve Clearance (Rocker Arm-To-Valve Tip) :
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.)
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.018 in.)
Valve Lift At 0.00 mm (in.) Clearance :
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.56-12.37 mm (0.455-0.487 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13 mm (0.438 in.)
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.28-12.12 mm (0.444-0.477 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.85 mm (0.427 in.)
Rocker Arm Shaft OD . . . . . . . . . . . . . . . . . . . . . . . . . 19.99-20.02 mm (0.787-0.788 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.94 mm (0.785 in.)
Rocker Arm Bore ID . . . . . . . . . . . . . . . . . . . . . . . . . . 20.07-20.12 mm (0.790-0.792 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.17 mm (0.794 in.)
Rocker Arm Shaft Sprin g
Compressed Height . . . . . . . . . . . . . . . . . . 46 mm @ 18-27 N (1.81 in. @ 4-6 lb-force )
Valve Spring Compressed Height :
Valve Closed . . . . . . . . . . . . . . . . . . 46 mm @ 240-280 N (1.81 in. @ 54-62 lb-force )
Valve Open . . . . . . . . . . . . . . . . 34.5 mm @ 590-680 N (1.36 in. @ 133-153 lb-force )
Liner Height Above Block . . . . . . . . . . . . . . . . . . . . 0.030-0.100 mm (0.0010-0.0040 in. )
Maximum Permissible Height Differenc e
At Nearest Point Of Two Adjacent Liners . . . . . . . . . . . . . . . . . . . 0.051 mm (0.0020 in.)
Cam Follower OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.61-31.64 mm (1.245-1.246 in. )

Cylinder Block:
Main Bearing Bore in Cylinder Block . . . . . . . . . . . . . . 84.46-84.48 mm (3.325-3.326 in. )
Main Bearing Centerline to Top Deck of Block . . 302.00-302.08 mm (11.890-11.893 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301.98 mm (11.889 in.)
Maximum Acceptable Top Deck Out-of Flat :
For Entire Length of Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.)
For Every 150 mm (5.90 in.) Length or Width . . . . . . . . . . . . . . . 0.025 mm (0.001 in.)
Top Deck Surface Finis h
(Surface Grind Only) (AA) . . . . . . . . . . . . . . . . . 0.0008-0.0032 mm (31-125 micro-in. )
Maximum Wave Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 mm (0.0005 in.)
Cylinder Block Upper Counterbore Depth . . . . . . . . . . . . 5.95-5.99 mm (0.234-0.236 in. )
Camshaft Follower Bore ID . . . . . . . . . . . . . . . . . . . . . 31.70-31.75 mm (1.248-1.250 in. )
Camshaft Follower Bore OD . . . . . . . . . . . . . . . . . . . . 31.61-31.64 mm (1.245-1.246 in. )
Camshaft Follower Clearance . . . . . . . . . . . . . . . . . . . . . 0.06-0.13 mm (0.002-0.005 in. )
Camshaft Bore (Except No. 1) . . . . . . . . . . . . . . 55.986-56.012 mm (2.2042-2.2052 in. )
Camshaft Bore (No. 1 camshaft bore) . . . . . . . . 59.961-59.987 mm (2.3607-2.3617 in. )
No. 1 Camshaft Bushing ID . . . . . . . . . . . . . . . . . . . . . . . 55.948-56.000 (2.2026-2.2047 )
Camshaft Bearing Journal-to-Bearing Clearance :

3-8 4/13/95
SPECIFICATIONS DIESEL ENGINE

All except No. 1 Bearing . . . . . . . . . . . . . . . . . . . . . . . 0.08-0.13-mm (0.003-0.005 in. )

Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
No.1 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05-0.13 mm (0.002-0.005 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Lower Block Bore for Seating Liner . . . . . . . . . . . . . 115.75-115.80 mm (4.557-4.559 in. )
Upper Block Bore For Seating Liner . . . . . . . . . . . . 120.70-120.75 mm (4.752-4.754 in. )
OD of Liner at Upper Bore . . . . . . . . . . . . . . . . . . . 120.61-120.69 mm (4.748-4.751 in. )
Clearance Between Liner and Cylinder Block :
At Lower Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035-0.100 mm (0.001-0.004 in. )
At Upper Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10-0.14 mm (0.004-0.005 in. )
Liner Flange Thickness . . . . . . . . . . . . . . . . . . . . . . 6.022-6.058 mm (0.2371-0.2385 in. )
Liner Height Above Block . . . . . . . . . . . . . . . . . . . . 0.030-0.100 mm (0.0010-0.0040 in. )
Maximum Permissible Height Difference at Nearest Point of Tw o
Adjacent Cylinders or Within a Single Cylinder . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Thickness of Liner Shim CD15466 . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Minimum Liner Shim R65833 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)
Minimum Liner Packing Compression . . . . . . . . . . . . . . . . . . . . . . . . 0.13 mm (0.005 in.)
Desired Cylinder Finish (crosshatch pattern) . . . . . 0.0006-0.0011 mm (25-45 micro-in. )
Cylinder Liner ID . . . . . . . . . . . . . . . . . . . . . . . . . . . 106.48-106.52 mm (4.192-4.194 in. )
Maximum Permissible Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)
Maximum Permissible Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Maximum Permissible Out-of-Round . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Piston-to-Cylinder Liner Clearanc e
(Measured at Bottom of Skirt): . . . . . . . . . . . . . . . . . . 0.08-0.15 mm (0.003-0.006 in. )
Piston OD at 19 mm (0.74 in.) From Bottom of Skirt an d
Measured 90° to Piston Pin . . . . . . . . . . . . . . . . 106.38-106.40 mm (4.188-4.189 in. )
Piston Protrusion Above Block . . . . . . . . . . . . . . . . . . . . 0.08-0.30 mm (0.003-0.012 in. )
Piston Height (Measured From Center o f
Piston Pin Bore to top of Piston): . . . . . . . . . . . . . . 66.27-66.33 mm (2.609-2.611 in. )
Maximum Allowable Clearance Between
Second Piston Ring and Ring Groove . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.
Piston Ring End Gap:*
No. 1 Compression Ring . . . . . . . . . . . . . . . . . . . . . . . 0.33-0.58 mm (0.013-0.023 in. )
No. 2 Compression Ring . . . . . . . . . . . . . . . . . . . . . . . . .75-1.00 mm (0.030-0.039 in. )
No. 3 Oil Control Ring . . . . . . . . . . . . . . . . . . . . . . . . . 0.33-0.58 mm (0.013-0.023 in. )

*When measuring piston ring end gap, No. 2 compression

ring gap should be greater than the No. 1 compression ring

Piston Pin Bore ID . . . . . . . . . . . . . . . . . . . . . . . . 41.285-41.295 mm (1.6254-1.6258 in. )

Piston Pin OD . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.270-41.280 mm (1.6248-1.6252 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.257 mm (1.6243 in. )
Connecting Rod Pin Bushing ID (assembled) . . . 41.300-41.326 mm (1.6260-1.6270 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.376 mm (1.6290 in. )
Connecting Rod Pin Bore ID (without bushing) . . 46.025-46.051 mm (1.8120-1.8130 in. )
Piston Pin-to-Bushing Oil Clearance . . . . . . . . . . . . . . 0.02-0.06 mm (0.0008-0.0024 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)
Connecting Rod Bore ID (without bearings): . . . . 73.660-73.686 mm (2.9000-2.9010 in. )
Maximum Permissible Bore Out-of-Round: . . . . . . . . . . . . . . . . 0.038 mm (0.0015 in.)
Connecting Rod Bore-to-Pin Bushing Bor e
(Center-to-Center) Distance: . . . . . . . . . . . . . . . . 180.95-181.05 mm (7.124-7.128 in. )
Connecting Rod Bearing ID (assembled) . . . . . . . . . . 69.85-69.90 mm (2.750-2.752 in. )
Connecting Rod Bearing-to-Journal Clearance . . . . .0.03-0.10 mm (0.0012-0.0039 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)

4/13/95 3-9
DIESEL ENGINE SPECIFICATIONS

Crankshaft Rod Journal OD: . . . . . . . . . . . . . . . . . . . . 69.80-69.82 mm (2.748-2.749 in. )

Undersize Connecting Ro d
Bearings Available . . . . 0.05, 0.25, 0.51, and 0.76 mm (0.002, 0.01, 0.02, and 0.03 in. )
Engine Compression Pressure :
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2400 kPa (24 bar) (350 psi )
Maximum Difference between Cylinders . . . . . . . . . . . . . . . 350 kPa (3.5 bar) (50 psi )
Engine Oil Pressure @ 10 5° C (220° F) Sump Temperature*
Minimum at 850 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 kPa (1.4 bar) (20 psi )
Maximum at rated speed (2100 rpm) . . . . . . . . . . . . . . . . 483 kPa (4.83 bar) (70 psi )
Maximum Engine Blow-By at Crankcase Vent Tube . . . . . . . . . . . 6.0 m3 / h (225 cu ft/h)

* Gauge fluctuations and tolerance extremes can result ni

readings as high as 586 kPa (5.86 bar) (85 psi)

Camshaft and Timing Gear Train:

Camshaft Journal OD . . . . . . . . . . . . . . . . . . . . . 55.872-55.898 mm (2.1997-2.2007 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.85 mm (2.199 in.)
Camshaft Bore ID (Except No. 1 camshaft bore) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.986-56.012 mm (2.2042-2.2052 in. )
Camshaft Bushing ID (No. 1 with bushing installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.948-56.000 mm (2.2026-2.2047 in. )
Camshaft Bore (No. 1 bore with bushing removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.961-59.987 mm (2.3607-2.3617 in. )
Camshaft Bore-to-Journal Clearance . . . . . . . . . . . . . . . 0.10-0.15 mm (0.004-0.006 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Camshaft Bushing-to-Journal Clearance (No. 1 bore) . . 0.05-0.13 mm (0.002-0.005 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Camshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08-0.23 mm (0.003-0.009 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.38 mm (0.015 in.)
Camshaft Thrust Plate Thickness . . . . . . . . . . . . . . . . . . 3.96-4.01 mm (0.156-0.158 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.83 mm (0.151 in.)
Camshaft Follower OD . . . . . . . . . . . . . . . . . . . . . . . . 31.61-31.64 mm (1.245-1.246 in. )
Cam Follower Bore Diameter in Cylinder Block . . . . .31.70-31.75 mm (1.248-1.250 in. )
Valve Lift at 0.00 mm (in.) Clearance :
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.56-12.37 mm (0.455-0.487 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13 mm (0.438 in.)
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.28-12.12 mm (0.444-0.477 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.85 mm (0.427 in.)
Camshaft Lobe Height:
Intake Lobe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.93-7.42 mm (0.273-0.292 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.68 mm (0.263 in.)
Exhaust Lobe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.76-7.26 mm (0.266-0.286 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.50 mm (0.256 in.)
Upper Idler Gear Shaft OD . . . . . . . . . . . . . . . . . . . . . 44.43-44.46 mm (1.749-1.750 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.40 mm (1.748 in.)
Upper Idler Gear Bushing ID . . . . . . . . . . . . . . . . . . . . 44.48-44.53 mm (1.751-1.753 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.56 mm (1.754 in.)
Lower Idler Gear Shaft OD . . . . . . . . . . . . . . . . . . . . . 44.43-44.46 mm (1.749-1.750 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.40 mm (1.748 in.)
Lower Idler Gear Bushing ID . . . . . . . . . . . . . . . . . . . . 44.48-44.53 mm (1.751-1.753 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.56 mm (1.754 in.)
End Play of Idler Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14-0.29 mm (0.006-0.012 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)

3 - 10 4/13/95
SPECIFICATIONS DIESEL ENGINE

Hub Width of Idler Shaft . . . . . . . . . . . . . . . . . . . . . . . 22.17-22.27 mm (0.873-0.877 in. )

Hub Width of Idler Gear . . . . . . . . . . . . . . . . . . . . . . . 21.98-22.03 mm (0.865-0.867 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.93mm (0.863 in.)

Timing Gear Backlash:

Upper Idler Gear-to-Camshaft Gear . . . . . . . . . . . . . . . . 0.07-0.35 mm (0.003-0.014 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.51 mm (0.020 in.)
Upper Idler Gear-to-Injection Pump Gear . . . . . . . . . . . . 0.07-0.35 mm (0.003-0.014 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.51 mm (0.020 in.)
Upper Idler Gear-to-Crankshaft Gear . . . . . . . . . . . . . . . 0.07-0.30 mm (0.003-0.012 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
Lower Idler Gear-to-Crankshaft Gear . . . . . . . . . . . . . . . 0.07-0.35 mm (0.003-0.014 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.51 mm (0.020 in.)
Lower Idler Gear-to-Oil Pump Gear . . . . . . . . . . . . . . . 0.04-0.36 mm (0.0016-0.015 in. )
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)

Lubrication:
Oil Pressure Regulating Valve :
Free Length of Spring (approx.) . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 mm (4.72 in.)
Spring Tension at length of 42 mm (1.68 in.) . . . . . . . . . . 60-75 N (13.5-16.5 lb force )
Oil By-Pass Valve Spring :
Free Length of Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 mm (2.32 in.)
Spring Tension at length of 34 mm (1.34 in.) . . . . . . . . . . . . 92-112 N (21-25 lb force )
Minimum Oil Pressure at 850 rpm and engine oil at 9 3° C (200° F)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 kPa (1.4 bar) (20 psi )

Cooling:
Water Pump:
Pump Mounting Flange-to-Impeller Clearance . . . . . . . . . . 0.0-0.25 mm (0.0-0.01 in. )
Front Face of Pulley-to-Pump Mounting Flange . . . . . . . . . . . . . . . 137 mm (5.39 in.)
Impeller Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.85-15.88 mm (0.6242-0.6252 in. )
Bearing Shaft OD:
Impeller End . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.90-15.92 mm (0.6262-0.6267 in. )
Pulley End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.95-18.96 mm (0.7460-0.7465 in. )
Pulley/Hub Bore . . . . . . . . . . . . . . . . . . . . . . . . . 18.91-18.93 mm (0.7445-0.7455 in. )
Thermostat Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82° C (180° F)
Cooling System Leakage Test Pressure . . . . . . . . . . . . . . . . . 120 kPa (1.2 bar) (17 psi )
Fan Belt Tension:
Using JDG529 Gauge:
New Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578-622 N (130-140 lb force )
Used Belt* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378-423 N (85-94 lb force )
Using JDST28 Gauge and Straightedge :
19 mm (3/4 in.) deflection with 89 N (20 lb force) applied midway between pulley s
* Belts are considered used after 10 minutes of operation

Fuel, Air Intake, and Exhaust:

Intake Manifold Pressure (Turbo Boost) @ 2100 RPM . . . . . . . . 60 kPa (0.6 bar) (9 psi)
Turbocharger:
Radial Bearing Clearance (Maximum) . . . . . . . . . . . 0.06-0.13 mm (0.0024-0.005 in. )
Axial Bearing End Play (Maximum) . . . . . . . . . . . . . 0.025-0.09 mm (0.001-0.0035 in. )

4/13/95 3 - 11
DIESEL ENGINE SPECIFICATIONS

Fuel Injector:
Injector Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 mm (0.374 in.)
Nozzle Orifice Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.)
Opening Pressure of new or rebuilt nozzle :
For Setting . . . . . . . . . . . . . . . . . . 25100-25800 kPa (251-258 bar)(3650-3750 psi )
For Checking (min.) . . . . . . . . . . . . . . . . . . . . . . . . . 25200 kPa (252 bar)(3660 psi )
Min. Acceptable Opening Pressure Of Used Nozzle . . 22950 kPa (230 bar)(3330 psi )
Max. Opening Pressure Difference Between Cylinders . . . . 700 kPa (7 bar)(100 psi )
Nozzle Valve/Seat Tightness Condition at Pressure Test of
2800-3500 kPa (28-35 bar)(400-500 psi) . . . . . . . Nozzle tip still dry after 5 seconds *
(*A slight dampness is permissible on used nozzles)
Return leakage at pressure test o f
10300 kPa (103 bar)(1500 psi) . . . . . . . . . . . . . . . . . . . . . . . 3-10 Drops / 30 second s
Nozzle Valve Lift (Based on Zero Lift) . . . . . . . . . . . . . . . . . 3/4 turn counterclockwis e
Fuel Supply Pump:
Fuel Supply Pump Pressure . . . . . . . . . . . . 40-50 kPa (0.40-0.50 bar)(5.75-7.25 psi )
Min. static pressure at 850 rpm engine speed . . . . . . . . . .15 kPa (0.15 bar) (2.0 psi )
Min. flow at 2400 rpm engine speed . . . . . . . . . . . . . . . . . . . . . . 1.5 L/min (0.42 gpm)
Torques:
Piston Cooling Orifices Into Cylinder Block . . . . . . . . . . . . . . 10 Nm (7.5 lb-ft) (84 lb-in. )
Connecting Rod Cap Screw s
Initial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm (40 lb-ft)
Final (Do not reuse capscrews after being final torqued) . . . . . .Plus 90-100 Degrees
Crankshaft Main Bearing Cap Capscrews (Reusable after torqued) . 136 Nm (100 lb-ft)
Rocker Arm Shaft Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm (35 lb-ft)
Rocker Arm Adjusting Screw Jam Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Nm (20 lb-ft)
Cylinder Head Cap Screws: (Reusable after being torqued )
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm (75 lb-ft)
Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm (110 lb-ft)
Step 3 . . . . . . . . . . . . . . . . . . . . . . . . . . Wait 5 Minutes and verify 150 Nm (110 lb-ft )
Step 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten Additional 60° ± 10 °
Fuel Injection Nozzles-To-Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . 37 Nm (27 lb-ft)
Fuel Line Nuts (At Pump And Nozzles) . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Nm (20 lb-ft)
Intake Manifold-to-Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm (35 lb-ft)
Exhaust Manifold-To-Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm (35 lb-ft)
Rocker Arm Cover-to-Cylinder Head . . . . . . . . . . . . . . . . . . . . 11 Nm (8 lb-ft) (96 lb-in. )
Camshaft Thrust Plate-to-Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . 47 Nm (35 lb-ft.)
Oil Pump Drive Gear-to-Shaft, Retaining Nut (Staked) . . . . . . . . . . . . . 54 Nm (40 lb-ft.)
Upper Idler Gear Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm (75 lb-ft.)
Lower Idler Gear Hex Nut (Staked) . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm (75 lb-ft.)
Timing Gear Cover-to-Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm (35 lb-ft.)
Fuel Injection Pump Drive Gear-to-Shaft, Retaining Nut . . . . . . . . . 200 Nm (150 lb-ft.)
Injection Pump-to-Front Plate Hex. Nuts . . . . . . . . . . . . . . . . . . . . . . . . 27 Nm (20 lb-ft.)
Injection Pump Cover, Capscrews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Nm (17 lb-ft.)
Injection Pump Timing Gear Access Plug . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (22 lb-ft.)
Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm (110 lb-ft.)
Oil Pump-to-Front Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm (35 lb-ft.)
Oil Pan-to-Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Nm (27 lb-ft.)
Oil Pan-to-Timing Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Nm (27 lb-ft.)
Oil Pan-to-Rear Plate of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm (35 lb-ft.)
Oil Pan Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm (51 lb-ft.)
Oil Pressure Regulating Valve in Timing Gear Cover . . . . . . . . . . . . . . 95 Nm (70 lb-ft.)
Oil Filter Adapter to Oil Cooler Housing . . . . . . . . . . . . . . . . . . . . . . . . 37 Nm (27 lb-ft.)

3 - 12 4/13/95
SPECIFICATIONS DIESEL ENGINE

SEALANT APPLICATION GUIDELINE S

Listed below are sealants which have been tested and are used by the John Deere factory to control
leakage and assure hardware retention. ALWAYS use the following recommended sealants when
assembling your John Deere Diesel Engine to assure quality performance .
LOCTITE® products are designed to perform to sealing standards with machine oil residue present. If
excessive machine oil or poor cleanliness quality exists, clean with solvent. Refer to John Deere
Merchandise and Parts Sales Manual for ordering information .

Number Name Use

TY9370 6 mL tube LOCTITE® 242 Thread Plugs and fittings: fuel filter base, fuel transfer pump,
T43512 50 mL tube Lock & Sealer, Medium intake manifold, cylinder bloc k
Strength (Blue) Capscrews: crankshaft pulley, injection pump access
cover, oil filler inlet, flywheel cover, fuel transfer
pump, oil cooler housing-to-cylinder block (open
holes only). Oil pressure sending uni t

TY9371 6 mL tube LOCTITE® 271 Thread Studs: water pump-to-cylinder block, injection pump-
T43513 50 mL bottle Lock & Sealer, High to-front plate, exhaust manifold-to-turbocharger.
Strength (Clear) Mechanical tachometer drive gea r

T43514 50 mL bottle LOCTITE® 227 Plastic Steel cap plugs: cylinder block, cylinder head, and
Gasket. High strength water pump. O-ring adapter for oil pump outlet tub e
(Red)

TY6304 50 mL bottle LOCTITE® 515 Flexible Flywheel housing-to-cylinder bloc k

Sealant. General Purpose
(Purple)

TY9374 6 mL tube LOCTITE® 592 Pipe Pipe plugs: cylinder block (water manifold),
TY9375 50 mL tube Sealant with Teflon® thermostat housing, air intake manifold, water pump,
(White) flywheel housing (drain) .
Dipstick tube threads
Injection pump governor cover fittin g
Threaded nipples and elbows in water pump housin g
Temperature sending uni t
Oil pan (drain hose and drain valve )
Fittings: turbo oil supply line-to-block, turbo oil return
line-to-block.

T43515 50 mL bottle LOCTITE® 609 Retaining Wear ring sleeve-to-crankshaf t

Compound (Green)

TY6304 50 mL bottle LOCTITE® 515 Flexible Water pump and thermostat cover gasket s
Sealant. General Purpose
(Purple)

TY6299 8 oz. tube PERMATEX® AVIATION Front plate/timing gear cover-to oil pa n
(Form-A-Gasket No. 3) Flywheel housing-to-oil pa n
or or
DD14996 25 mL tube LOCTITE® 518 Flexible
Sealant (General
Purpose) (red)

PT569 Never-Seez® Compound Capscrews: Exhaust manifold and turbine housing-

to-center housing

4/13/95 3 - 13
DIESEL ENGINE SPECIFICATIONS

LUBRICATION SYSTEM OPERATIO N

E F

D
C
G
H
I

L
M
U

S
R
Q
P
O
N

A. Turbo Oil Supply H. Piston Cooling Orifice O. Oil Pickup Tube

B. Rear Camshaft Bearin g
C. Rocker Arm Shaft
D. Rocker Arm
E. Turbocharger Oil Supply Lin e
F. Turbocharger Oil Drain Lin e
G. Piston Pin Bushing
I. Cross-drilling P. Oil Outlet Line
J. Oil Passage-Upper Idler Bushin g Q. Turbo Oil Supply
K. Upper Idler Gear Bushin g R. Main Bearing
L. Oil Pressure Regulating Valv e S. Main Oil Gallery
M. Oil Pressure Bypass Valv e T. Connecting Rod Bearin g
N. Oil Pump U. Main-to-Rod Cross Drillin g

The engine lubrication system consists of a positive directly from pump to main oil gallery to prevent oil
displacement gear driven oil pump (N), full flow oil filter, starvation. Also, oil cooler and oil filter each have their
oil cooler, oil pressure regulating valve (L), and oil own bypass valve that opens if oil flow becomes
pressure bypass valve (M) . restricted.
The oil pump pulls oil from the oil pan sump through a If oil flow in main oil gallery exceeds a predetermined
strainer and a pickup tube (O). The pump forces oil factory safety factor, the pressure regulating valve (L)
through the outlet line (P) into the oil cooler and filter, opens and relieves excess pressure back to oil pan .
and on to the main oil gallery (S) .
If oil pressure from pump exceeds pressure in main oil
gallery (S) by more than 340 ± 34 kPa (3.38 ± 0.34 bar)
(49 ± 5 psi), oil pressure bypass valve (M) opens. This
allows oil to bypass oil cooler and filter, and flow

3 - 14 4/13/95
THEORY OF OPERATION DIESEL ENGINE

THEORY OF OPERATION

FUEL SYSTEM
Disposable Filter

Leak-Off Line
Filter/Water
Separator

Injectors

Pump Supply
Line
Return
Gauge Sender Line

Tank

Injector Pump
/Governor

M76244

Theory of Operation
Fuel is drawn from the fuel tank through a disposable
fuel filter, to a mechanical fuel pump driven by the
engine camshaft. The fuel pump then delivers fuel
under pressure to the water separator/filter, and on to
the injector pump/governor. The injection pump meters
fuel as determined by it’s internal governor and throttle
position, and delivers high pressure fuel to the injection
nozzles.
spraying finely atomized fuel into the combustion
chamber. Pressure fuel lines have trapped fuel
whenever injection is not taking place .
More fuel is routed through the system than is required
for injection. Excess fuel serves to cool and lubricate
the injection pump and nozzles. This excess is
returned to the fuel tank by the fuel leakoff line. The
returning fuel also warms the fuel in the tank .

Each injection nozzle prevents fuel flow until sufficient

high pressure is reached, opening the nozzle valve and

4/13/95 3 - 15
DIESEL ENGINE DIAGNOSIS

DIAGNOSIS Engine compression too lo w

Engine overheating
Worn camshaft lobes
DIAGNOSING ENGINE
MALFUNCTIONS
Fuel System Malfunction
• Will Not Crank Defective fuel injection pum p
Low fuel supply
Electrical System Malfunction Fuel injection nozzles defective or leakin g
Weak battery Fuel filter or fuel lines restricte d
Corroded or loose battery connection s Defective fuel transfer pum p
Defective main switch or start safety switc h Fuel injection pump incorrectly time d
Starter solenoid defectiv e
• Engine Misfiring
Starter defective

• Hard to Start or Will Not Start Service Problem

Electrical System Malfunction
Loose or corroded battery connection s
Weak battery
Excessive resistance in starter circui t
Fuel System Malfunction
Empty fuel tank
Improper fuel
Water, dirt or air in fuel syste m
Plugged fuel filter
Stuck throttle control
Dirty or faulty fuel injection nozzle s
Defective fuel injection pum p
Defective fuel transfer pum p
Fuel injection pump incorrectly time d
Service Problem
Too high viscosity crankcase oi l
• Engine Runs Irregularly or Stalls Frequently
Basic Engine Problem
Coolant temperature too lo w
Improper valve clearanc e
Cylinder head gasket leakin g
Worn or broken compression ring s
Valves sticking or burne d
Exhaust system restricte d
Water in fuel
Mixture of gasoline and diesel fue l
Fuel System Malfunction
Air in fuel system
Defective fuel injection nozzle s
Defective fuel injection pum p
Fuel injection nozzles improperly installe d
Leaking fuel injection nozzle seal s
Worn or defective fuel transfer pum p
Fuel injection pump incorrectly time d
Basic Engine Problem
Engine overheated
Lobes of camshaft worn
Weak valve springs
Preignition
Engine compression too lo w
Improper valve clearanc e
Burnt, damaged or stuck valve s
• Lack of Engine Power
Service Problem
Air cleaner restricted or dirt y
Excessive resistance in air intake syste m
Improper crankcase oil

3 - 16 4/13/95
DIAGNOSIS DIESEL ENGINE

Fuel System Malfunction Oil flow through oil passages restricte d

Fuel filter restricted Worn valve guides or stem s
Defective fuel transfer pum p Excessive oil pressure
Defective fuel injection pum p Piston ring grooves excessively wor n
Fuel injection pump incorrectly time d Piston rings sticking in ring groove s
Insufficient piston ring tensio n
Basic Engine Problem Piston ring gaps not staggere d
Engine overheated Excessive main or connecting rod bearing clearanc e
Defective cylinder head gaske t Front and/or rear crankshaft oil seal fault y
Lobes of camshaft worn Glazed cylinder liners (insufficient load during engine
Improper valve clearanc e break-in)

Improper valve timing

Burnt, damaged or stuck valve s Service Problem
Too low viscosity crankcase oi l
Weak valve springs
Crankcase oil level too hig h
Piston rings and cylinder liners excessively wor n
Engine compression too lo w External oil leaks

Improper coolant temperatur e

• Low Oil Pressure

• Engine Overheats
Service Problem
Low crankcase oil level
Service Problem
Improper crankcase oil
Lack of coolant in cooling syste m
Defective oil pressure warning switch or engine oil
Radiator and/or oil cooler cores dirt y
pressure indicator light
Cooling system limed up
Engine overloaded
Basic Engine Problem
Too low crankcase oil leve l
Leakage at internal oil passage s
Defective oil pump
Basic Engine Problem
Excessive main and connecting rod bearing clearanc e
Loose or defective fan bel t
Improper regulating valve adjustmen t
Defective thermostat
Piston cooling orifice missin g
Damaged cylinder head gaske t
Defective water pump • High Oil Pressure
Defective radiator cap
Basic Engine Problem
Fuel System Malfunction Oil pressure regulating valve bushing loose (wanders )
Fuel injection pump delivers too much fue l Improperly operating regulating valv e
Fuel injection pump incorrectly time d Stuck or damaged filter bypass valv e

• Excessive Oil Consumption • Excessive Fuel Consumption

Basic Engine Problem Service Problem

Oil control rings worn or broke n Engine overloaded
Scored cylinder liners or piston s Air cleaner restricted or dirt y
Excessive resistance in air intake syste m

4/13/95 3 - 17
DIESEL ENGINE DIAGNOSIS

Basic Engine Problem Worn connecting rod bushings and piston pin s
Compression too low Scored pistons
Worn timing gears
Fuel System Malfunction Excessive valve clearanc e
Leaks in fuel system Worn cam followers
Fuel injection nozzles dirty or fault y Bent push rods
Fuel injection pump defective (delivers too much fuel ) Worn camshaft
Fuel injection pump incorrectly time d Worn rocker arm shaft
Insufficient engine lubricatio n
• Black or Grey Exhaust Smoke
Worn turbocharger bearing s

Service Problem
Fuel System Malfunction
Excess fuel
Fuel injection pump incorrectly time d
Engine overloaded
Air cleaner restricted or dirt y • Detonation or Pre-Ignition
Defective muffler (causing back-pressure )
Basic Engine Problem
Fuel System Malfunction Oil picked up by intake air steam (intake manifold )
Fuel injection nozzles dirty or fault y
Incorrect engine timing Fuel System Malfunction
Dirty or faulty fuel injection nozzle s
• White Exhaust Smoke
Incorrect fuel injection pump timin g
Fuel injection nozzle tip holes enlarge d
Basic Engine Problem
Fuel injection nozzle tips broke n
Engine compression too lo w
Carbon buildup in compression chambe r
Defective thermostat (does not close )
• Water Pump Leaking
Fuel System Malfunction Seal ring or pump shaft wor n
Defective fuel injection nozzle s
Fuel injection pump incorrectly time d • Coolant Temperature Below Normal
Defective thermostat
• Coolant in Crankcase Coolant temperature gauge defectiv e

Basic Engine Problem • Engine Vibrating

Cylinder head gasket defectiv e Fan blades bent or broke n
Cylinder head or block cracke d Water pump shaft worn
Cylinder liner seals leakin g
CYLINDER LINER, PISTON, AND
• Abnormal Engine Noise CONNECTING ROD DIAGNOSIS
Basic Engine Problem
Scuffed or Scored Pistons:
Worn main or connecting rod bearing s
Overheating.
Excessive crankshaft end pla y
Overfueling.
Loose main bearing cap s
Insufficient lubrication.
Foreign material in combustion chambe r
Insufficient cooling.

3 - 18 4/13/95
DIAGNOSIS
Improper piston-to-liner clearance .
Coolant leakage into crankcase .
Misaligned or bent connecting rod .
Improperly installed piston .
Low oil level.
Improper operation.
Incorrect connecting rod bearing clearance .
Carbon buildup in ring groove .
Improper engine break-in .
Worn piston.
Contaminated oil.
Distorted cylinder liner.
Plugged piston cooling orifice .
Ingestion of dust through air intake .
Worn or Broken Compression Rings:
Insufficient lubrication.
Insufficient cooling.
Improper ring installation .
Improper combustion.
Improper timing.
Abrasives in combustion chamber .
Clogged Oil Control Ring:
Improper oil.
Excessive blowby.
Improper periodic service .
Low operating temperature .
Stuck Rings:
Improper oil classification .
Improper periodic service .
Poor operating conditions .
Coolant leakage into crankcase .
Excessive cylinder liner taper .
Cylinder Liner Wear and Distortion:
Incorrectly installed compression rings .
Insufficient lubrication.
Uneven cooling around liner .
Inadequate piston-to-liner clearance .
Liner bore damage.
4/13/95
DIESEL ENGINE
Warped Cylinder Block:
Insufficient cooling.
Broken Connecting Rod:
Inadequate piston-to-liner clearance .
Worn connecting road bearing .
Distorted cylinder liner.
Piston pin failure.
Piston Pin and Snap Ring Failure:
Misaligned connecting rod .
Excessive crankshaft end play .
Incorrect snap rings.
Mottled, Grayish or Pitted Compression Rings:
Internal coolant leaks.
Dull Satin Finish and Fine Vertical Scratches on
Rings:
Dirt and abrasive in air intake system .
CYLINDER HEAD AND VALVE
DIAGNOSIS
• Sticking Valves:
Carbon deposits on valve stem .
Worn Valve guides.
Scored valve stems.
Warped valve stems.
Cocked or broken valve springs .
Worn or distorted valve springs .
Worn or distorted valve seats .
Insufficient lubrication.
• Warped, Worn, or Distorted Valve Guides:
Lack of lubrication.
Cylinder head distortion .
Excessive heat.
Unevenly tightened cylinder head cap screws .
• Distorted Cylinder Head and Gasket Leakage:
Loss of cylinder head cap screw torque .
Broken cylinder head cap screw .
Overheating from low coolant level operation .
Insufficient Liner standout .
3 - 19
DIESEL ENGINE DIAGNOSIS

Coolant leakage into cylinder causing hydraulic failure CRANKSHAFT DIAGNOSIS

of gasket.
Crazed cylinder head.
Cracked cylinder liner.
Damaged or incorrect gasket .
Overpowering or Overfueling .
Damaged cylinder head or block surfaces .
Improper surface finish on cylinder head .
Improperly tighten cylinder head cap screws .
Faulty gasket installation (misaligned) .
• Worn or Broken Valve Seats:
Misaligned valves.
Distorted cylinder head.
Carbon deposits on seats due
combustion.
Valve spring tension too weak .
Excessive heat.
Improper valve clearance .
Improper valve timing.
• Scored Main Bearing:
(Diagnosis also applies to connecting rod bearing. )
Oil starvation.
Contaminated oil.
Engine parts failure.
Excessive heat.
Poor periodic service.
• Galled or “Wiped” Bearings:
Fuel in lubricating oil (incomplete combustion) .
Coolant in lubrication system (cracked block, liner seal
failure, or leaking water pump seal with plugged hole) .
Insufficient bearing oil clearance .
Parts not lubricated prior to engine operation .
to incomplete
Wrong bearing size.
• Inconsistent Wear Pattern:
Misaligned or bent connecting rod
Warped or bowed crankshaft .
Distorted cylinder block .

• Burned, Pitted, Worn, or Broken Valves: • Broken Main Bearing Caps:

Worn or distorted valve seats . Improper installation.
Loose Valve Seats. Dirt between bearing and crankshaft journal .
Low oil pressure.
Worn valve guides.
Oil pump failure.
Insufficient cooling.
Cocked or broken valve springs . • Cracked, Chipped or Broken Bearings:
Improper engine operation . Overspeeding.
Improper valve train timing . Excessive idling.
Lugging.
Faulty valve rotators.
Excessive oil clearance .
Warped or distorted valve stems . Improper installation.
“Stretched” valves due to excessive spring tension .
Warped cylinder head.
Bent push rods.
Carbon buildup on valve seats .
Rocker arm failure.

• Improper Valve Clearance:

Inefficient use of fuel.
Engine starts harder.
Maximum engine power will not be achieved .
Shorter service life of valve train .
Greater chance for engine to overheat .

3 - 20 4/13/95
DIAGNOSIS DIESEL ENGINE

FUEL SYSTEM DIAGNOSIS

Symptom Problem Solution

Engine Starts and Stop s
Erratic Engine Operation s
Excessive Black Smoke
Excessive Blue/White Smok e
Engine Idles Poorly
Air in system
Fuel filter restricted
Fuel lines restricted
Water in fuel
Injection pump return fuel line or
fittings restricted
Fuel filter restricted
Fuel too heavy at low temperature s
Injection nozzles faulty or stickin g
Fuel lines restricted
Incorrect timing
Governor faulty
Water in fuel
Injection pump return fuel line or
fittings restricted
Low cetane fuel
Injection nozzle return lines restricte d
Injection nozzles faulty or stickin g
Injection pump timing incorrec t
Low cetane fuel
Overfueling
Cranking speed too slo w
Injection pump timing incorrec t
Injection nozzles faulty or stickin g
Excessive wear in liners and/or
piston rings stuck
Incorrect cetane fuel for temperatur e
Engine running too “cold ”
Injection nozzles faulty or stickin g
Incorrect timing
Slow idle speed not correct .
Fuel lines restricted
Water in fuel
Injection pump return lines or fittings
restricted
Injection nozzle return lines clogge d
Low cetane fuel
Correct problem & bleed fuel system .
Replace fuel filter.
Clean lines as required.
Drain water in separator. Replace filter .
Clean lines as required.
Replace fuel filter.
Replace with correct grade of fuel .
Clean, adjust, or replace nozzles .
Clean as required.
Adjust injection pump timing .
Replace injection pump
Drain water in separator. Replace filter .
Clean lines as required.
Replace with correct grade of fuel .
Clean lines as required.
Clean, adjust, or replace nozzles .
Adjust injection pump timing .
Replace with correct grade of fuel .
Repair injection pump.
Check batteries and electrical system .
Adjust injection pump timing .
Clean, adjust, or replace nozzles .
See Engine Repair Section .
Replace with correct grade of fuel .
Check Thermostat.
Clean, adjust, or replace nozzles .
Adjust injection pump timing .
Adjust slow idle speed.
Clean as required.
Drain water in separator. Replace filter .
Clean as required.
Clean as required.
Replace with correct grade of fuel .

4/13/95 3 - 21
DIESEL ENGINE DIAGNOSIS

Symptom Problem Solution

Engine Does Not Develop Low cetane fuel
Full Power
Incorrect timing
Injection pump or governor fault y
Fuel filter clogged
Injection nozzles faulty or stickin g
Defective supply pump
Injection pump return fuel line or
fittings restricted
Water or gasoline in diesel fue l
Incorrect pump return fuel line or
fittings restricted
Water or gasoline in diesel fue l
Incorrect fast idle speed
Throttle control linkage incorrectly
adjusted
Replace with correct grade of fuel .
Adjust injection pump timing .
Replace injection pump .
Replace fuel filter.
Clean, adjust, or replace nozzles .
Test fuel supply pump.
Clean as required.
Drain water or replace with clean fuel.
Install new filters.
Clean as required.
Drain water or replace with clean fuel.
Install new filters.
Adjust injector pump high speed stop .
Adjust cable to allow full injector pump
arm travel.

FUEL SUPPLY PUMP DIAGNOSIS

Symptom Problem Solution

Low Supply Pump Out of fuel Add fuel to tank.

Pressure or Pump Not
Functioning Correctly

Restricted fuel line Clean as required.

Air leak in fuel line between pump Repair as required.

and tank

Hand primer lever left in upward Move lever toward engine block as
position far as it will go.

Punctured or leaking diaphrag m Replace pump.

Worn or damaged valve Replace pump.

assemblies

Broken valve spring(s) Replace pump.

Foreign material under diaphragm Replace pump.

(from vent holes)

Wear or damage to hand primer Replace pump.

linkage

3 - 22 4/13/95
DIAGNOSIS DIESEL ENGINE

FUEL INJECTION NOZZLE DIAGNOSIS

Symptom Problem Solution

Engine has Low Horsepowe r Nozzle orifices plugged Repair.

Incorrect nozzle valve opening Adjust.

pressure

Broken, worn or damaged parts : Repair as required.

-Broken nozzle valve sprin g
-Cracked or split nozzle ti p
-Cracked or split nozzle bod y
-Internal leak

Wrong nozzle assembly installe d Install correct nozzle assembly.

Nozzle loose in cylinder hea d Make sure nozzle assembly is

installed to specified torque.

Engine Emits Too Much Smok e Nozzle orifices plugged Repair.

Broken, worn or damaged parts : Repair as required.

-Broken nozzle valve sprin g
-Cracked or split nozzle ti p
-Cracked or split nozzle bod y
-Internal leak

Wrong nozzle assembly installe d Install correct nozzle assembly.

4/13/95 3 - 23
DIESEL ENGINE DIAGNOSIS

FUEL INJECTION NOZZLE DIAGNOSI S

Problem Possible Cause Suggested Remedy
Failed Carbon Stop Seal Nozzle replaced without using new Install new seal or washer .
Washer seal or washer.
Carbon stop seal groove not cleaned Clean groove. Install new seal .
when new seal was installed .
Incorrect Opening Pressur e Improper adjustment. Adjust opening pressure .
Broken spring. Replace spring.
Nozzle Will Not Open Plugged orifices. Clean.
Chipped orifices. Replace nozzle.
Bottomed lift screw. Adjust lift screw.
Poor Spray Pattern Plugged orifices. Clean.
Chipped orifices. Replace nozzle.
Cracked nozzle tip. Replace nozzle.
Poor Atomization Plugged orifice. Clean.
Chipped orifice. Replace nozzle.
Cracked nozzle tip. Replace nozzle.
Valve not free. See “Inconsistent Chatter” .
Inconsistent Chatter Spring components misaligned . Adjust opening pressure .
Varnish on valve. Clean guide area.
Deposits in seat area. Clean seat.
Bent valve. Replace nozzle.
Distorted body. Replace nozzle.
No Chatter Spring components misaligned . Adjust opening pressure .
Varnish on valve. Clean guide area.
Deposits in seat area. Clean seat.
Bent valve. Replace nozzle.
Valve seat eroded or pitted . Lap valve to seat. Replace nozzle as
necessary.
Seat interference angle worn . Replace nozzle.
Distorted body. Replace nozzle.
Seat Leakage Deposits in seat area. Clean seat.
Valve seat eroded or pitted . Lap valve to seat. Replace nozzle as
necessary.
Tip seat pitted. Lap tip to seat. Replace nozzle as
necessary.
Distorted body. Replace nozzle.
Cracked tip. Replace nozzle.
High Leak-Off Wear or Scratched at Guide . Lap valve to guide. Replace nozzle .
Low Leak-Off Varnish on valve. Clean guide area.
Insufficient clearance. Clean nozzle. Lap valve to guide.
Replace nozzle as necessary .

3 - 24 4/13/95
DIAGNOSIS DIESEL ENGINE

FUEL INJECTION PUMP DIAGNOSIS

Symptom Problem Solution

Engine Starts Hard or Won’t Star t Shut-off solenoid not functioning Test for voltage at injector pump
properly; or wiring lead loose or terminal. If present, test for fuel at
broken injectors.

Injection pump not correctly time d Adjust injection pump timing .

Defective injection pum p Remove pump from engine and

repair.

Automatic advance faulty or not Repair or replace injector pump .

operating

Slow Idle Speed Irregula r Nozzle faulty or sticking Clean, adjust, or replace nozzles .

Automatic advance faulty or not Repair or replace injector pump .

operating

Injection pump not properly time d Check pump timing.

Defective injection pum p Remove pump and repair .

Engine Horsepower Low Pump not properly time d Check timing.

Insufficient throttle arm trave l Inspect and adjust.

Automatic advance faulty or not Adjust or repair.

operating

Nozzle faulty or sticking Repair.

Defective injection pum p Remove pump and repair .

AIR INTAKE SYSTEM DIAGNOSIS

Symptom Problem Solution

Engine Starts Hard or Won’t Star t Air leak on suction side of syste m Check hose and pipe connections
for tightness; repair as required .

Erratic Engine Operation Air leak on suction side of syste m Check hose and pipe connections
for tightness; repair as required .

Engine Emits Excessive Black Air cleaner element restricte d Clean or replace elements (See
Smoke operator’s manual).

Engine Idles Poorly Air leak on suction side of syste m Check hose and pipe connections
for tightness; repair as required .

Engine Does Not Develop Full Air cleaner restricted Clean or replace elements (See
Power operator’s manual).

Air leak on suction side of syste m Check hose and pipe connections
for tightness; repair as required .

Turbocharger defective Repair or replace.

Turbocharger “Screams ” Air leak in manifold Check intake manifold gasket and
manifold; repair as required .

4/13/95 3 - 25
DIESEL ENGINE TESTS AND ADJUSTMENTS

TESTS AND ADJUSTMENTS

VALVE ADJUSTMENT
NOTE: Valve clearance can be checked with engine
cold or warm.

1. Remove rocker arm cover and ventilator tube .

A
RG4775

A. Front of Engine
B. No. 1 TDC Compression Strok e
C. No. 1 TDC Exhaust Strok e

4. Check valve clearance from rocker arm to valve tip

with feeler gauge on No. 1 and 2 exhaust valves,
and No. 1 and 3 intake valves. Adjust if necessary .

M76142 Intake Valve . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.)

Exhaust Valve . . . . . . . . . . . . . . . . 0.45 mm (0.018 in.)

2. Remove cover plug from engine timing holes (A) .
NOTE: Firing order is 1-2-3
3. Using engine rotation tool, rotate engine in running
direction (clockwise viewed from front of engine, or
rear of Skid-Steer Loader) until No. 1 cylinder is at 5. Remove timing pin and turn crankshaft 36 0°. Lock
top dead center of compression stroke . No. 1 piston at TDC exhaust stroke .
6. Check valve clearance from rocker arm to valve tip
NOTE: If No. 1 cylinder rocker arms are loose, the
with feeler gauge on No.3 exhaust valve, and No.
engine is at No. 1 “TDC-Compression”. If No. 1
2 intake valve. Adjust if necessary .
cylinder rocker arms are not loose, rotate
engine one full revolution (360°)
VALVE LIFT MEASUREMENT
4. Insert timing pin to lock flywheel at TDC for No. 1
cylinder NOTE: For a more accurate measurement, measure
valve lift at 0.00 mm (in.) rocker arm-to-valve
tip clearance.
T81224

1. Remove rocker arm cover .

2. Lock No. 1 piston at TDC compression stroke .
3. Set rocker arm-to-valve tip clearance to 0.00 mm
(in.) for No. 1 and 2 exhaust, and No. 1 and 3
intake valves.
(See Valve Adjustment section for valve locations)

3 - 26 4/13/95
TESTS AND ADJUSTMENTS DIESEL ENGINE

2. With engine stopped, inspect engine coolant for oil

RG6308 film. With engine running, inspect coolant for air
bubbles. Either condition would indicate problems
which require engine repairs rather than just a
tune-up.
3. Perform a dynamometer test and record power
output. Repeat dynamometer test after tune-up.
Compare power output before and after tune-up .
4. Perform compression test .

ENGINE COMPRESSION PRESSURE

TESTING
NOTE: Before beginning test, insure that batteries are
4. Place dial indicator tip on top of valve spring fully charged and injection nozzle area is
retainer or rotator. Preload indicator tip and set dial thoroughly cleaned. Adapters and test fittings
at 0.0 mm (in.) are part
5. Remove timing pin from flywheel and manually
rotate engine one full revolution (36 0°) in running 1. Run engine to bring up to normal operating
direction. temperature. (From a cold start, operate engine
6. Observe dial indicator reading as valve is moved to 10-15 minutes at slow idle. )
full open. Record maximum reading and compare 2. Remove fuel injection nozzles. (See Fuel Repair
with specifications given below . Section.)
Valve Lift Specification
(At 0.00 mm (in.) Valve Clearance)
Intake Valves . . . . . . 11.56-12.37 mm (0.455-0.487 in. )
Wear Limit . . . . . . . . . . . . . . . . 11.13 mm (0.438 in.)

Exhaust Valves. . . . . 11.28-12.12 mm (0.444-0.477 in. )

Wear Limit . . . . . . . . . . . . . . . . 10.85 mm (0.427 in.)

7. If valve lift is within specifications, adjust valve

clearance as specified in Valve Clearance
Adjustment Section.
8. If valve lift on one or more valves is not within
specification, remove and inspect entire valve train
and camshaft.
9. Rotate engine one full revolution (36 0°). Lock
engine at TDC of No. 1 exhaust stroke.
10. Set rocker arm-to-valve tip clearance to 0.0 mm
(in.) for No. 3 exhaust and No. 2 intake valves .
RG5646
11. Repeat steps 4-7.

3. Install JT01679 Adapter with O-ring in injection

PRELIMINARY ENGINE TESTING
The following preliminary tests will help determine if the
engine can be tuned-up to restore operating efficiency,
or if engine rebuilding is required .
1. After engine has stopped for several hours, loosen
crankcase drain plug and watch for any water to
seep out. A few drops due to condensation is
normal, but more than this would indicate
problems which require engine repair .
nozzle bore. Use JT02017 Holding Clamp to hold
JT01679 Adapter in position. Install hold down
screw in clamp and tighten screw to 37 Nm (27 lb
ft). Attach JT016582 Test Gauge to adapter .
4. Remove wire from connector on top of fuel injection
pump to prevent engine from starting. Turn
crankshaft for 10-15 seconds with starting motor
(minimum cranking speed—150 rpm cold/200 rpm
hot).
5. Compare readings from all cylinders .

4/13/95 3 - 27
DIESEL ENGINE
6. Compression pressure must be 2400 kPa (24 bar)
(350 psi) minimum. The difference between the
highest and lowest cylinder must be less than 350
kPa (3.5 bar) (50 psi).
7. If pressure is much lower than shown, remove
gauge and apply oil to ring area of piston through
injection nozzle bore. Do not use too much oil. Do
not get oil on the valves .
8. Test compression again. If pressure is high, worn or
stuck rings are indicated. If pressure is still low, it is
possible that valves are worn or sticking .
ENGINE OIL PRESSURE TEST
1. Remove oil pressure sender and install pressure
gauge capable of 0-100 psi from JTO5470
Pressure Test Kit.
IMPORTANT: Warm up engine to allow the
lubricating oil to reach operating temperature,
or high oil pressure readings will occur.
2. At 850 rpm engine speed and 9 3° C (200° F) oil
temperature, gauge should show a minimum
pressure of 140 kPa (1.4 bar) (210 psi) .
3. At 2100 rpm and 105° C (220° F) oil temperature,
gauge should show a pressure of 380 ± 103 kPa
(3.80 ± 1.03 bar) (55 ± 15 psi) on all engines .
NOTE: Tolerance extremes and gauge fluctuations
can result in a gauge reading of up to 582 kPa
(5.82 bar) (85 psi). This is not detrimental to
the engine.
INTAKE MANIFOLD PRESSURE
(TURBO BOOST) TEST
RG6356
1. Remove manifold heater from intake manifold and
install JT03470 fitting (A) from JDE147 Kit.
Connect gauge and test line to fitting .
2. Before checking boost pressure, warm up engine to
allow the lubricating oil to reach operating
temperature.
3 - 28
TESTS AND ADJUSTMENTS
IMPORTANT: Engine speed and load should be
stabilized before taking readings on gauge. Be
sure that gauge works properly.
Pressure checks are only a guide to determine if
there is an engine problem (valve leakage,
defective nozzles, etc.). Low readings are not a
valid reason for increasing injection pump fuel
delivery. Pump adjustment should be within
specification as established by an authorized
pump repair station.
3. Observe pressure reading on gauge. Reading
should be at least 60 kPa (0.6 bar) 9 psi) when
engine is developing rated power at full load rated
speed.
• If boost pressure is too high, remove and test fuel
injection pump for high fuel delivery .
• If boost pressure is too low, check for the following :
—Restricted air filter elements .
—Restricted fuel filter elements .
—Incorrect fast idle adjustment .
—Incorrect injection pump timing .
—Exhaust manifold leaks .
—Intake manifold leaks .
—Faulty fuel transfer pump .
—Low compression pressure .
—Faulty fuel injection nozzles .
—Carbon buildup in turbocharger .
—Turbocharger compressor or turbine wheel
rubbing housing.
—Low fuel injection pump fuel delivery .
—Restricted exhaust.
4. After testing, remove test gauge and fittings .
5. Install air manifold heater using thread sealant .
6. Install manifold heater electrical wire to terminal .
CRANKCASE VENTILATION
SYSTEM INSPECTION
1. Inspect crankcase ventilation system for
restrictions. Lack of ventilation causes sludge to
form in crankcase. This can lead to clogging of oil
passages, filters and screens, resulting in serious
engine damage.
2. Clean crankcase vent tube with solvent and
compressed air if restricted. Install and tighten
hose clamps securely.
4/13/95
REPAIR
AIR INTAKE SYSTEM INSPECTIO N
1. Replace air cleaner primary and secondary filter
elements.
2. Check condition of air intake hoses. Replace if
cracked, split or otherwise in poor condition .
3. Check hose clamps for tightness. Replace clamps
that cannot be properly tightened. This will prevent
dust from entering the air intake system and
causing serious engine damage .
CHECK EXHAUST SYSTEM
1. Inspect exhaust system for leaks or restrictions.
Check manifold for cracks. Repair or replace as
necessary.
2. Inspect gasket seals at turbocharger and cylinder
head for leakage.
3. Check torque of exhaust manifold capscrews .
4. Check clamp from to muffler to turbocharger to
make sure it is tight and not leaking. Correct as
necessary.
COOLING SYSTEM & RADIATOR
CAP PRESSURE TEST
1. Visually inspect radiator for leaks or damage .
c CAUTION
Remove radiator filler cap only when coolant
temperature is below operating temperature.
Always loosen cap slowly to the stop to relieve
pressure before removing cap.
2. Remove radiator cap .
3. Attach D05104ST Pressure Pump to radiator filler
neck, following manufacturers instructions .
4. Pressurize cooling system to 120 kPa (1.2 bar) (17
psi).
5. Check engine, radiator, and hoses for coolant
leaks.
6. Release pressure and repair system as necessary,
if it does not hold pressure .
7. Install radiator cap onto D05104ST tester .
8. Pressurize to 100-120 kPa (1.0-1.2 bar) (14-17 psi).
Replace cap if it does not hold pressure .
FUEL DRAIN BACK TEST
Fuel draining back through the fuel system may cause
hard starting. This procedure will determine if air is
entering the system at connections and allowing fuel to
siphon back to the fuel tank .
4/13/95
DIESEL ENGINE
1. Disconnect fuel supply line and fuel return line at
fuel tank.
2. Drain all fuel from the system, including the fuel
transfer pump, fuel injection pump, fuel filters, and
water separator.
3. Securely plug off the end of the fuel return pipe .
4. Using a low pressure air source, pressurize the fuel
system at the fuel supply line to 100 kPa (1 bar)
(15 psi).
c CAUTION
Maximum air pressure should be 100 kPa (1 bar)
(15 psi) when performing this test.
5. Apply liquid soap and water solution to all joints and
connections in the fuel system and inspect for
leaks.
NOTE: Connections may allow air to enter the system
without allowing fuel to leak out.
6. If any leaks are found, take necessary steps to
repair.
7. Reconnect supply and return lines and prime
system.
8. Start engine and run for approximately 10 minutes .
9. Allow engine to sit overnight and try starting the
following morning.
REPAIR
CLEAN ENGINE
1. Cap or plug all openings on engine. If electrical
components (starter, alternator, etc.) are not
removed prior to cleaning, cover with plastic and
tape securely to prevent moisture from entering .
2. Steam-clean engine thoroughly .
IMPORTANT: Never steam clean or pour cold water
on an injection pump while it is still warm. To do
so may cause seizure of pump parts.
ENGINE REMOVAL (CAB TILTED)
1. Park machine on level surface with bucket
removed, lock park brake, roll bucket attachment
plate back, lock boom in up position, stop engine .
2. Open engine cover and remove side panels .
3. Disconnect negative battery cable clamp from
battery post.
4. Jack and block up frame. Follow procedure for cab
and boom tilt using cab jack (see Cab Tilt section) .
3 - 29
DIESEL ENGINE
5. Remove muffler.
6. Disconnect positive battery cable clamp and battery
hold-down. Remove battery .
7. Remove muffler mounting capscrews and clamp to
turbo charger. Remove muffler .
8. Tag, label and remove wires to starter, alternator,
engine ground tie point, engine ground strap,
coolant temperature sender, manifold heater, oil
pressure switch, hydraulic reservoir temperature
sender, fuel injection pump, hydraulic filter and fuel
sender. Pull engine harness clear of engine .
9. Open rear access door and tip out radiator. Drain
coolant and remove upper and lower radiator
hoses from engine.
10. Loosen clamps on air inlet hose and disconnect
hose from air filter. Remove air filter mounting bolt.
Unlatch air filter mounting clamp and slide filter
housing out of mounting bracket .
11. Remove bolt holding throttle cable to fuel injector
pump.
12. Disconnect fuel hoses from fuel pump to tank .
13. Remove skid plate under engine. Drain hydraulic
reservoir into a drain pan by loosening hydraulic
line tee-fitting under battery .
14. Remove engine mounting bolts .
15. Remove access plate below hydrostatic
transmission on bottom of machine. Remove
transmission mounting bolt through access hole .
16. Disconnect pump control arm linkages where
attached to drive control rods .
17. Disconnect all hydraulic hoses from hydrostatic
transmission to chassis .
18. Attach suitable engine sling to engine lift brackets.
(See Engine Lifting Procedure Section) Lift engine
and hydrostatic transmission up keeping fan clear
of fan shroud.
ENGINE LIFTING PROCEDURE
M76268
3 - 30
REPAIR
1. Attach JDG23 Engine Lift Sling or equivalent to
engine lifting straps and overhead hoist or floor
crane.
NOTE: If engine does not have lifting straps, they can
be procured through service parts.
2. Adjust center of balance to equalize load of engine,
engine gearbox, and hydrostatic pumps .
IMPORTANT: Use overhead crane or floor hoist
rated to lift 907 kg (2000 lbs).
ENGINE REPAIR STAND
c CAUTION
Never mount engine on a repair stand not
capable of supporting engine weight.
Safety Precautions
• The engine repair stand should be used only by
qualified service technicians familiar with this
equipment.
• To maintain shear strength specifications, alloy
steel SAE grade 8 or higher socket head cap
screws must be used to mount adapters or engine .
• For full thread engagement, be certain that tapped
holes in adapters and engine blocks are clean and
not damaged. A thread length engagement equal
to 1-1/2 screw diameters minimum is required to
maintain strength requirements .
• To avoid structural or personal injury, do not exceed
the maximum capacity rating of the engine stand .
• To avoid an unsafe off-balanced load condition, the
center of balance of an engine must be located
within 51 mm (2in.) of the engine stand rotating
shaft. Engine center of balance is generally
located a few millimeters above the crankshaft .
• To prevent possible personal injury due to engine
slippage, recheck to make sure engine is solidly
mounted before releasing support from engine
lifting device.
• Never permit any part of the body to be positioned
under a load being lifted or suspended. Accidental
slippage may result in personal injury .
• The lifting jack is to be used when it is necessary to
lift the engine for rotation. When working on the
engine, the jack should be at its lowest position to
keep the center of gravity low and the possibility of
tipping low.
• To prevent possible personal injury due to sudden
engine movement, lower engine by operating jack
release valve slowly. Do not unscrew release valve
knob more than two turns from its closed position .
4/13/95
REPAIR DIESEL ENGINE

Installing Adapter Plate To Engine Stand
IMPORTANT: When servicing turbocharged engine
on rollover stand, disconnect turbocharger oil
inlet line before rolling engine over. Failure to
do so may cause severe engine damage from
hydraulic lock upon starting engine. Hydraulic
lock occurs when trapped oil in the oil filter
housing drains through the turbocharger, into
exhaust and intake manifolds, and cylinder
head. After starting the engine, trapped oil in the
manifold and head is released into the
cylinder(s) filling them with oil - causing
hydraulic lock and severe engine damage.

4. Disconnect turbocharger oil inlet line at

turbocharger.
RG4737

1. Attach the D05225ST Engine Adapter Plate to

mounting hub of the engine repair stand using four
5/8-11 x 2in. SAE Grade 8 cap screws. Tighten
screws to 135 N•m (100 lb-ft) .

Mounting Engine On Repair Stand

A B

B C A RG4739

1. Use No. 202557 Spacer (25mm O.D. x 73 mm long)

at hole (A) and No. 202558 Spacer (25mm O.D. x
79 mm long) at hole (B) .

NOTE: Spacers are furnished with the D05225ST

Engine Adapter.

2. Mount engine to adapter using the cap screws

listed below at the hole locations as shown :
Hole A . . . . . . . . . . . . . . . . . . . . . . . 9/16-12 x 4-1/2 in.

Hole B . . . . . . . . . . . . . . . . . . . . . . . 9/16-12 x 4-1/2 in.

Hole C . . . . . . . . . . . . . . . . . . . . . . . 9/16-12 x 1-1/2 in.

3. Drain all engine oil and coolant .

4/13/95 3 - 31
DIESEL ENGINE
ENGINE DISASSEMBLY SEQUENC E
The following sequence is suggested when complete
disassembly for overhaul is required. Refer to the
appropriate repair group when removing individual
engine components.
1. Drain coolant and oil. Check engine oil for metal
contaminates.
2. Remove fan belts, fan and alternator .
3. Remove turbocharger and exhaust manifold .
4. Remove rocker arm cover and vent tube .
5. Remove water manifold / thermostat housing.
6. Remove oil cooler piping, and water pump .
7. Remove dipstick, oil filter, oil cooler. Discard
standard-flow oil cooler if oil is contaminated .
8. Remove oil pressure regulating valve assembly .
9. Remove fuel filter, fuel supply pump, and fuel line .
10. Remove injection lines, injection pump, and
injection nozzles.
11. Remove starting motor .
12. Remove rocker arm assembly and push rods. Keep
rods in order. Check for bent push rods and
condition of wear pad contact surfaces on rockers .
13. Remove cylinder head. Check piston protrusion.
Verify piston height selection .
14. Remove cam followers. Keep followers in order.
15. Remove flywheel and flywheel housing .
16. Remove oil pan.
17. Remove crankshaft pulley .
18. Remove timing gear cover .
19. 19 Remove oil pump drive gear, outlet tube, and
pump body.
20. Remove oil slinger, timing gears, and camshaft.
Perform wear checks.
21. Remove balancer shafts .
22. Remove engine front plate .
23. Remove oil bypass valve .
24. Stamp cylinder number on connecting rod. Remove
pistons and rods. Perform wear checks with
PLASTIGAGE®.
25. Remove crankshaft and main bearings. Perform
wear checks with PLASTIGAG E®.
26. Remove cylinder liners and mark each one with
cylinder number and position in block .
27. Remove piston cooling orifices .
28. Remove camshaft bushing .
29. Remove cylinder block plugs and serial number
plate when block is to hot tanked.
30. Clean upper and lower liner bores with nylon brush .
31. Measure cylinder block .
3 - 32
REPAIR
ENGINE ASSEMBLY SEQUENCE
The following assembly sequence is suggested when
engine has been completely disassembled. Be sure to
check runout specifications, clearance tolerances,
torques, etc. as engine is assembled. Refer to the
appropriate repair group when assembling engine
components.
1. Install all plugs and serial number plate in cylinder
block (if removed).
2. Install piston cooling orifices .
3. Install new balancer shaft bushings and a new
camshaft bushing (if equipped) .
4. Install cylinder liners without O-rings. Measure liner
height. Install liners with O-rings .
5. Install main bearing and crankshaft. Plastigage
bearings.
6. Install flywheel housing, rear oil seal, and flywheel .
7. Install pistons and rods. Measure piston protrusion.
8. Install oil bypass valve.
9. Install front plate.
10. Install oil outlet tube, O-ring in block, and oil pump .
11. Install injection pump .
12. Install camshaft, timing gears, and oil slinger .
13. Time all gears with No. 1 cylinder at TDC
compression stroke.
14. Install timing gear cover. Install new front seal .
15. Install oil pan.
16. Install oil pressure regulating valve .
17. Install cam followers in same order as removed .
18. Install cylinder head gasket, cylinder head, push
rods, and rocker arm assembly .
19. Install starting motor .
20. Install injection nozzles (with new seals) and
injection lines.
21. Install fuel filter, fuel supply pump, and fuel lines .
22. Install oil cooler, new oil filter, and dipstick. (Never
clean or reuse a contaminated oil cooler. )
23. Install water manifold / thermostat housing, and
thermostat.
24. Install exhaust manifold and turbocharger. Prelube
the turbocharger.
25. Install water pump and hoses .
26. Install crankshaft pulley .
27. Install alternator, fan, and fan belts .
28. Adjust valves and install rocker arm cover .
29. Install vent tube.
30. Fill engine with clean oil and proper coolant.
31. Perform engine break-in and performance checks .
4/13/95
CYLINDER HEAD REPAIR DIESEL ENGINE

CYLINDER HEAD REPAIR

CYLINDER HEAD REMOVAL

In some applications, it may be necessary to remove
engine from machine to service cylinder head. Refer to
Engine Removal Section for procedure .

c CAUTION
T81241
Hot exhaust system components can cause
serious burns. After operating engine, allow
exhaust system to cool before working on 8. Remove rocker arm assembly .
engine. 9. Remove all push rods and identify for reassembly in
the same location.

Explosive release of fluids from pressurized

cooling system can cause serious burns. Shut
off engine. Remove radiator filler cap only when
the cap is cool enough to touch with bare hands.
Slowly loosen cap to first stop to relieve
pressure before removing completely.

1. Drain all engine oil and coolant .

2. Remove air inlet adapter and intake manifold .
3. Disconnect turbocharger oil inlet and outlet lines .
4. Remove turbocharger and exhaust manifold as an
assembly.
5. Remove thermostat housing/water manifol d RG6310
6. Remove air cleaner, fuel filter, and air cleaner
bracket assembly.
10. If a cylinder head gasket failure has occurred,
check and record torque on each cylinder head
cap screw before removing .
11. Make a reference mark (in-line) on socket (A) and
cylinder head surface (B). Loosen cap screw at
least 1/2 turn. Retighten cap screw (using a torque
wrench) until reference marks align and record
torque.
12. Remove all cylinder head cap screws .

IMPORTANT: Screwdrivers or prybars can damage

cylinder head and block gasket surfaces. DO
NOT use screwdrivers or prybars between
cylinder block and head to loosen head gasket
seal.

RG5658

7. Remove fuel leakoff line (A) and fuel delivery lines

(B) as an assembly. Remove fuel injection nozzles
(C). (See Fuel Repair Section.)

4/13/95 3 - 33
DIESEL ENGINE
RG5650
13. Lift cylinder head from block. If cylinder head sticks,
use a soft hammer to tap cylinder head .
14. Remove head gasket. Inspect possible oil, coolant,
or combustion chamber leaks. Also, check for
evidence of incorrect head gasket being used .
NOTE: Do not rotate crankshaft with cylinder head
removed unless cylinder liners are secured
with cap screws and large flat washers. (See
Cylinder Liner Height Measurement, later in
this group.)
ROCKER ARM DISASSEMBLY &
INSPECTION
T81234
1. Remove plugs and bowed washers from rocker arm
shaft.
3 - 34
CYLINDER HEAD REPAIR
T81235
2. Disassemble and inspect all parts for wear or
damage. Replace any parts that are damaged or
not within specifications .
Rocker Arm Specifications:
Spring Tension At 46 mm (1.81 In. )
Compressed Height) . . . . . . . . . . . . . . 18-27 N (4-6 lb)
Rocker Arm Shaft
Outside Diameter . . .19.99-20.02 mm (0.787-0.788 in. )
Wear Limit . . . . . . . . . . . . . . . . 19.94 mm (0.785 in.)
Rocker Arm Shaft
Support ID (max.) . . . . . . . . . . . . . . 20.17 mm (0.79 in.)
Rocker Arm ID . . . . .20.07-20.12 mm (0.790-0.792 in. )
Wear Limit . . . . . . . . . . . . . . . . 20.17 mm (0.794 in.)
ROCKER ARM ASSEMBLY
1. Lubricate shaft OD, rocker arm bores, and rocker
arm supports with clean engine oil .
RG6311
IMPORTANT: The oil supply hole (B) on the rocker
arm shaft must be toward the flywheel end of
the engine.
4/13/95
CYLINDER HEAD REPAIR DIESEL ENGINE

2. Assemble springs, rocker arms, and rocker arm

supports onto shaft in the same location as RG6312
removed from.
3. Install bowed washers and new end plugs (A) firmly
in end of shaft.

CAMSHAFT FOLLOWER REMOVAL

& INSPECTION

T90973

3. Check crown on follower face. If flat or concave,

replace follower and check camshaft lobes for
wear.

1. Remove and clean camshaft followers. Label for

reassembly in same location .

T81656

4. Measure camshaft follower bore in block and

determine if clearance is within specification .

Camshaft Follower Bore

Inside Diameter . . . . 31.70-31.75 mm (1.248-1.250 in )

Camshaft Follower Outsid e

Diameter (New) . . . . 31.61-31.64 mm (1.245-1.246 in )

T81239 Camshaft Follower-to-

Bore Clearance . . . . . . 0.06-0.13 mm (0.002-0.005 in )

2. Measure camshaft follower OD. If camshaft follower

OD is less than 31.61-31.64 mm (1.245-1.246 in.), If camshaft follower bore inside diameter and follower-
install a new follower. to-bore clearance exceed specified maximum. Install a
new cylinder block.

4/13/95 3 - 35
DIESEL ENGINE
VALVE RECESS CHECK
RG4756
1. Measure and record valve recess (A) using a depth
micrometer or magnetic base dial indicator.
T81869
2. Measurements must be made a maximum of 3.0
mm (0.12 in) in from edge of valve head .
Intake Valve . . . . . . . . . 0.61-1.11 mm (0.024-0.044 in. )
Worn Limit . . . . . . . . . . . . . . . . . 1.63 mm (0.064 in.)
Exhaust Valve . . . . . . . 1.22-1.72 mm (0.048-0.068 in. )
Worn Limit . . . . . . . . . . . . . . . . . 2.26 mm (0.089 in.)
Install new valves or inserts, as necessary, to obtain
proper valve recess. Grind valve seat inserts as
required.
3 - 36
CYLINDER HEAD REPAIR
VALVE ASSEMBLY REMOVAL
RG5655
1. Using JDG171 valve spring compressor, compress
valve springs far enough to remove keepers .
NOTE: Identify all parts for assembly in same location.
2. Release spring tension and remove valve rotator
and valve spring.
M76144
3. Remove valves from cylinder head .
4. Remove valve stem seals from valve guide tower .
VALVE SPRING INSPECTION
1. Inspect valve springs for alignment, wear, and
damage.
2. Using D01168AA Spring Compression Tester,
check valve spring tension. Compressed height
must be within specification given below .
Valve Spring Specifications
Compression Force Height
Free Length*
0.0 N (0.0 lb force) . . . . . . . . . . . . . 54.0 mm (2.125 in.)
240-280 N (54-62 lb force) . . . . . . . . 46.0 mm (1.81 in.)
590-680 N (133-153 lb force) . . . . . . 34.5 mm (1.36 in.)
NOTE: *Free length of spring may vary slightly
between springs.
4/13/95
CYLINDER HEAD REPAIR DIESEL ENGINE

VALVE ROTATOR INSPECTION

Valve rotators cannot be repaired. Replace valve 1. Clean and inspect valves, valve stems, stem tips,
rotators when valves are replaced or reground . and retainer lock groove (A). Replace valves that
are worn or damaged.

T82053

T91224

2. Measure valve stem OD. Record measurements

and compare with valve guide ID. (See Measure
1. Insure that valve rotators turn freely in both
Valve Guides, later in this group. )
directions. Replace if defective .

Valve Stem Specifications

VALVE CLEANING
Intake Valve . . . . .7.864-7.884 mm (0.3096-0.3100 in. )

IMPORTANT: Any carbon left on stem will affect Exhaust Valve . . .7.848-7.874 mm (0.3090-0.3100 in. )
alignment in valve refacer. DO NOT use a wire
wheel on plated portion of valve stem. Polish
the valve stems with steel wool or crocus cloth RG4234
to remove any scratch marks left by the wire
brush.

1. Remove all carbon from valve head, face, and

unplatted portion of stem by rotating the valve
firmly against a soft wire wheel on a bench grinder .
2. Polish plated portion of valve by locking stem in
chuck of drill press and spinning at high speed
while moving steel wool or crocus cloth against
valve.

VALVE INSPECTION
3. Use D05058ST Valve Inspection Center to
determine if valves are out of round, bent, or
warped.
A

Valve Face Runout Specifications

Valve face runout (max) . . . . . . . 0.038 mm (0.0015 in.)

M76143

4/13/95 3 - 37
DIESEL ENGINE CYLINDER HEAD REPAIR

VALVE GRIND CYLINDER HEAD FLATNESS

RG4755

T81872

1. Reface serviceable valves to specified angle (A).

Face angle on intake and exhaust valves is
29.25°± 0.25.
IMPORTANT: DO NOT nick valve head-to-stem
radius when grinding valves. A nick could cause
the valve to break. Break all sharp edges after
grinding.
1. Check cylinder head flatness using D05012ST
Precision Straightedge and feeler gauge. Check
lengthwise, crosswise, and diagonally in several
places.
Cylinder Head Flatness Specifications

Maximum Acceptable Out-of-Flat :

CYLINDER HEAD INSPECTION
1. Inspect combustion face for evidence of physical For Entire Length or Width . . . . . . . 0.08 mm (0.003 in.)
damage, oil or coolant leakage, or gasket failure
For Every 150 mm (5.90 in.) . . . . 0.025 mm (0.001 in.)
prior to cleaning the cylinder head. Repair or
replace cylinder head if there is evidence of
physical damage; such as cracking, abrasion,
distortion, or valve seat “torching”. Inspect all If Out-of-Flat exceeds specifications, measure cylinder
cylinder head passages for restrictions . head thickness to determine if cylinder head may be
2. Scrape gasket material, oil, carbon, and rust from reconditioned.
head. Use a powered wire brush to clean sealing
surfaces.
3. Clean cylinder head in a chemical hot tank, or with CYLINDER HEAD THICKNESS
solvent and a brush. Dry with compressed air and
blow out all passages.

RG5651

If cylinder head thickness is less than minimum

allowable thickness, install new cylinder head .

3 - 38 4/13/95
CYLINDER HEAD REPAIR DIESEL ENGINE

When resurfacing cylinder head, remove ONLY what is VALVE GUIDE CLEANING
necessary to restore flatness .

IMPORTANT: Measure and record valve recess in

cylinder head. (See Valve Recess In Cylinder
Head Check section)

Resurface to following specifications if necessary .

Cylinder Head Resurfacing Specifications

Thickness (New) . . . . 104.87-105.13 (4.129-4.139 in. )

Minimum Thickness . . . . . . . . . . 104.24 mm (4.104 in.)

Combustion Face Surface Finish-Surface Grind Only

(AA) . . . . . . . . 0.0008-0.0032 mm (31-125 micro-in ) T81874

Maximum Wave Depth . . . . . . . . 0.012 mm (0.0005 in.)

Clean valve guides before inspection or repair, with a
plastic brush.
INJECTOR BORE CLEANING
NOTE: A few drops of light oil or kerosene will help
clean the guides.

VALVE GUIDE MEASUREMENT

RG6317

1. Clean carbon deposits from nozzle bores with

JDE39 Nozzle Bore Cleaning Tool, Blow debris
from bore with compressed air .
RG5652

IMPORTANT: Always turn the tool clockwise

through the bore, even when pulling back, to 1. Using a telescopic gauge, measure valve guide
keep the tool from getting dull. wear.

Valve Guide Specifications

Bore I.D. (New) . . . . 7.912-7.938 mm (0.312-0.313 in )

Guide-to-Stem . . . . . . . 0.05-0.10 mm (0.002-0.004 in )

Wear Limit . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in)

If valve guide oil clearance exceeds the wear limit, but

is less than 0.20 mm (0.008 in.), valve guides can be
knurled.
If valve guide oil clearance is over 0.20 mm (0.008 in.),

4/13/95 3 - 39
DIESEL ENGINE CYLINDER HEAD REPAIR

install valves with oversize stems. Valve guides can be 1. Grind valve seat inserts to the following
knurled and then reamed to fit oversize valve stems . specifications:

NOTE: Valves are available with 0.38 mm (0.015 in.)

T88832
or 0.76 mm (0.030 in oversize stems.

VALVE GUIDE KNURLING

IMPORTANT: ALWAYS knurl valve guides before

reaming to assure proper valve guide-to-stem
clearance.

Valve Seat Grinding Specifications

Seat angle (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°

Seat Width (B) . . . . . . . 1.50-2.00 mm (0.059-0.079 in. )

Maximum Seat Runout (C) . . . . . . . . 0.8 mm (0.003 in.)

2. Use a vernier caliper or scale to measure seat

width. If valve seat is too wide, reduce the width
T81876
with a narrowing stone.

NOTE: A narrowing stone will change the top angle of

1. Use No. JT05949 (D20002WI) Knurling Tool Set to
knurl valve guides. Use tool set exactly as directed
by the manufacturer.
2. After knurling, hand ream valve guide to finish size
to provide specified stem-to-guide clearance. A
7.887 mm (0.3105 in.) OD pin must pass freely
through entire length of bore after reaming for a
standard size valve stem .
the seat and reduce the outer diameter of the
valve seating area. Varying the width changes
the fine contact between valve face and seat. If
seat width is too narrow, valve may burn or
erode.

VALVE SEAT CLEANING AND

INSPECTION
1. Use an electric hand drill with wire end brush to
remove all carbon on valve seats .
2. Inspect seats for excessive wear, cracks, or
damage.

VALVE SEAT GRINDING

IMPORTANT: ALWAYS keep valve guides and work

area clean when grinding valve seats to
RG6318
maintain valve guide bore-to-seat runout.
Grinding valve seats increases seat width and
valve recess in cylinder head. DO NOT grind
excessively. Only a few seconds are required to
recondition the average valve seat. Support the
weight of grinder to avoid excessive pressure
on the stone.

3 - 40 4/13/95
CYLINDER HEAD REPAIR DIESEL ENGINE

3. Use a new or refaced valve and blueing to check
contact between valve seat and face. If valve does
not seat properly use D11010KW Eccentrimeter
(D) to check valve seat runout. Replace valves
and inserts as necessary .
IMPORTANT: Blend or radius all sharp edges after
grinding valve seats for a more effective valve
face-to-seat seal.
Exhaust Seat Bore Specifications:
A. . . . . . . . . . . . 42.987-43.013 mm (1.6924-1.6934 in. )
B. . . . . . . . . . . . . . . . . . 3.82 mm (0.150 in.) Referenc e
C. . . . . . . . . . . . . 9.936-10.064 mm (0.3912-0.3962 in. )
D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-42°
E. . . . . . . . . . . . . Maximum Radius 0.5 mm (0.019 in. )

Surface finish of bore A . . . 0.00158 mm (0.000062 in. )

VALVE SEAT REPAIR
Intake Seat Bore Specifications:
VALVE SEAT INSERT REMOVAL A. . . . . . . . . . . . 47.104-47.130 mm (1.8545-1.8555 in. )

B. . . . . . . . . . . . . . . . . . 3.45 mm (0.136 in.) Referenc e

IMPORTANT: Be careful not to damage cylinder
head when removing valve seats.
C. . . . . . . . . . . . . 9.936-10.064 mm (0.3912-0.3962 in. )

D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-42°
Valve seat inserts are made of sintered (powdered)
metal. Remove inserts by one of the following
E. . . . . . . . . . . . . Maximum Radius 0.5 mm (0.019 in. )
methods:
• Use JDE41296 Valve Seat Puller . Surface finish of bore A . . . 0.00158 mm (0.000062.in. )
• Carefully heat insert with an oxyacetylene torch at
four opposite points until it becomes red hot. Use a
Replacement Seat Outside Diameter:
screwdriver or similar tool and carefully pry insert
from bore. Intake . . . . . . . . 47.155-47.181 mm (1.8565-1.8575 in. )
• Grind a used valve down to seat insert I.D. Install
valve and spot weld valve to insert. Drive valve Exhaust . . . . . . 43.038-43.064 mm (1.6944-1.6954 in.)
and seat out of cylinder head .
VALVE SEAT INSERT INSTALLATION
After removal of inserts, thoroughly clean area around
valve seat bore and inspect for damage or cracks.
Replace cylinder head as necessary .

VALVE SEAT BORE MEASUREMENT

1. If bore dimensions are not within specification,
machine head to the following specifications :

RG5606

RG5653

1. Use JDG676 Pilot Driver (A) and JDG675 Valve

Seat Installing Adapter (B) to install valve seats in
cylinder head. Use one end of JDG675 Adapter
(B) to install intake valve seats, and the other end
to install exhaust valve seats .
2. Install new or refaced valves and check valve
recess. (See Valve Recess Check section.)

4/13/95 3 - 41
DIESEL ENGINE CYLINDER HEAD REPAIR

3. Grind valve seats as required to maintain correct CYLINDER HEAD BOLT

valve recess and valve face-to-seat seal. (See
Valve Seat Grinding section.) INSPECTION

VALVE INSTALLATION
1. Lubricate valve stems and guides with AR44402
Valve Stem Lubricant or clean engine oil .

NOTE: Valves must move freely in guide and seat

properly in head to form an effective seal.

RG6319
2. Insert valves in head (if valves are reused, install in
same location from which removed) .
1. Clean entire length of cap screws. Use a wire brush
RG5654
and solvent to remove rust and scale. Dry cap
screws with compressed air .
2. Inspect cap screws for corrosion damage and
overall condition of threads. CAP SCREWS WITH
CORROSION OR OTHER IMPERFECTIONS
MUST BE REPLACED.

EXHAUST MANIFOLD INSPECTION

3. Use JDG678 Valve Stem Seal Installer (A) to slide
valve stem seals (B) over valve stems and onto
valve guide tower (C).
4. Install valve springs and rotators .
& CLEANING
1. Thoroughly clean all passages and gasket surfaces
in exhaust manifold and exhaust elbow .
2. Inspect entire exhaust manifold for cracks or
damage. Replace parts as necessary .
CYLINDER BLOCK TOP DECK
CLEANING & INSPECTION
1. Remove gasket material, rust, carbon, and other
foreign material from top deck. Gasket surface
must be clean.

RG4718

RG5655

5. Compress valve springs using JDE138 Valve

Spring Compressor and install keepers on valve
stems.
6. Strike end of each valve three or four times with a
soft mallet (nonmetallic) to insure proper
positioning of the keepers .
2. Clean threaded holes in cylinder block using
7. Recheck valve recess. (See Valve Recess in
JDG680 Tap or any 1/2-13 UNC-2A tap about 76
Cylinder Head Check section.)
mm (3.0 in.) long. Use compressed air to remove
debris and fluids from the cap screw holes.
Replace block if there is evidence of damage .

3 - 42 4/13/95
CYLINDER HEAD REPAIR DIESEL ENGINE

3. Use compressed air to remove all loose foreign

material from cylinders and top deck . RG6269

IMPORTANT: All debris must be cleaned from the 9 5 10

camshaft followers before assembling the 13 4 6 14
engine. A

12 3 1 11
8 2 7 B
B
T90973

6. Tighten all cap screws to specified torque in steps

as listed below. Be sure to start with bolt number
one and tighten in sequence :

• Step 1 - Tighten all capscrews to 100 Nm (75 lb-ft) .

• Step 2-Tighten all capscrews to 150 Nm (110 lb-ft) .

• Step 3 - Wait 5 minutes. Verify 150 Nm (110 lb-ft) .

• Step 4-Tighten all capscrews an additional 6 0° ±

4. If not previously done, remove camshaft followers
from block and wash in solvent. Lubricate with
clean engine oil and install in the same bore .
5. Inspect top deck for flatness and serviceability. (See
Cylinder Block Repair Section.)
6. Measure cylinder liner height above cylinder block.
(See Cylinder Liner Height Measurement section.)
CYLINDER HEAD INSTALLATION
1. Place new head gasket on cylinder block. Do not
use sealant; install dry.
10°. Use Torque-Turn Method (see next section) to
assure proper torque.
NOTE: Retorque of cylinder head cap screws after
engine break-in is not required when using the
recommended torque procedure along with
flanged-head cap screw.
TORQUE-TURN METHOD FOR
PROPER TORQUE

NOTE: Head gasket must have a minimum of 120 mm

(4.724 in.) combustion ring I.D.

2. Install two guide studs in cylinder block at locating

holes (B).

IMPORTANT: The O-ring seals in head gasket can

be damaged if head is repositioned while
resting on engine block. Use guide studs to RG5698
position cylinder head on block.

3. Position cylinder head over guide studs and lower
onto cylinder block.
4. Dip cap screw in clean engine oil. Remove excess
oil from screw.
5. Remove guide studs. Install flanged head cylinder
head cap screws.
1. After tightening cap screws to 150 Nm (110 lb-ft)
above in step two, use JT05993 Torque Angle
Gauge, or the line scribe method below, to tighten
each cap screw an additional 6 0° ± 10°.

4/13/95 3 - 43
DIESEL ENGINE CYLINDER HEAD REPAIR

Line scribe method:

RG5587D

RG5587A

4. Tighten (in sequence) all cap screws until second

1. Make two marks on 6 point socket wrench 1/6 turn mark on socket aligns with mark on cylinder head .
(60° ± 10°) apart (at points of socket) .

RG5587B NOTE: Retorque of cylinder head cap screws after

engine break-in is not required when using the
recommended torque procedure along with
flanged-head cap screws.

ROCKER ARM INSTALLATION

2. Make a mark on cylinder head in line with point of

hex of capscrew.

RG5587C

RG6321

1. Install push rods in same location from which

removed.

NOTE: Valve stem tips are specially hardened, wear

caps are not required.

3. Place socket on cap screw so first mark aligns with

mark on cylinder head.

3 - 44 4/13/95
CYLINDER HEAD REPAIR
T81240
2. Position rocker arm assembly on engine .
IMPORTANT: Oil supply hole in rocker arm shaft
must be positioned at the flywheel end of
engine and facing downward when rocker shaft
is installed.
3. Lubricate all rocker arms with engine oil and make
sure they move freely. Install rocker arm and shaft
assembly. Tighten cap screws to 47 Nm (35 lb-ft).
4. Adjust valve clearance. (See Valve Clearance
Check section)
5. Install rocker arm cover. (See Rocker Arm Cover
Installation.)
ROCKER ARM COVER VENT
CLEANING AND INSPECTION
1. Check vent outlet hose on rocker arm cover for bent
or damaged condition. Replace if necessary .
2. Clean vent hose and tube if they are restricted .
ROCKER ARM COVER
INSTALLATION
RG6322
4/13/95
DIESEL ENGINE
1. Install rocker arm cover with cover seal (B) in
bottom groove. Do not use sealant on cover seal .
2. Install all cap screws finger tight .
3. Tighten all cap screws to 11 Nm (8 lb-ft) (96 lb-in.),
starting at the center and alternate sides until
reaching the ends.
NOTE: The sealing ring is reusable if not damaged. If
the sealing ring leaks, the following procedure
should be used to install a new sealing ring:
Valve Cover Seal Replacement
1. Carefully remove the old sealing ring from rocker
arm cover. Do not use any cutting tool that could
damage the cover.
2. Clean the groove with acetone. Follow
manufacturer’s recommendations on label. Blow
dry with compressed air .
3. Lubricate sealing ring with grease to avoid
misalignment. Install in groove .
4. Cut sealing ring slightly longer than necessary .
5. Place the two ends of sealing ring end-to-end.
Press the sealing ring into the groove all the way
around the cover to ensure proper assembly .
COMPLETE FINAL ASSEMBLY
RG5658
1. Install injection nozzles (C).
2. Install injection lines (B) as an assembly .
3. Install fuel leakoff line (A) .
3 - 45
DIESEL ENGINE CYLINDER BLOCK REPAIR

NOTE: Do not rotate crankshaft with cylinder head

M76175 removed unless liners are fastened down.
B
D

4. Install exhaust manifold (A), and turbocharger (B )

5. Install water manifold . RG3932
6. Install fuel filter (C).
7. Install air intake adapter (D) . 7. Remove carbon from liner bore with a scraper or
8. If engine oil was drained from crankcase, install reamer. Use compressed air to remove loose
new oil filter and fill engine with clean oil of correct material from cylinders .
grade and viscosity. 8. Remove oil pan, oil pump, and outlet tube. (See
Lubrication Section.)
CYLINDER BLOCK REPAIR 9. Mark rods, pistons, and caps to insure correct
assembly in same location .

PISTON AND CONNECTING ROD IMPORTANT: Keep inserts with their respective
REMOVAL rods and caps. Do not stamp top of high ring
piston—piston may be damaged.
1. Remove engine from the machine (see Engine
Removal Section)
2. Perform steps 2 through 12 in Engine Disassembly 10. Remove connecting rod bolts, end caps and
Sequence bearing inserts.
3. Remove cylinder head. (See Cylinder Head 11. Place a piece of PLASTIGAGE across entire width
Removal section.) of bearing surface.
4. Remove camshaft followers and keep in order for
reassembly in same position . NOTE: Use PLASTIGAGE as directed by the
manufacturer. PLASTIGAGE will determine
5. Clean all foreign material from top of cylinder block bearing-to-journal oil clearance, but will not
deck. indicate the condition of either surface.

A B C

RG3819

6. Use short cap screws (A) and 3 mm (1/8 in.) thick

washers (B) to bolt down cylinder liners (C).
Fasten each liner in two locations. Tighten cap
screws to 68 Nm (50 lb-ft).

3 - 46 4/13/95
CYLINDER BLOCK REPAIR
T81615
12. Install correct rod cap bearing and torque to 55 Nm
(40 lb-ft) initially, then an additional 90-100
degrees.
13. Remove all rod caps with bearings .
RG6346
14. Measure rod bearing-to-journal oil clearance with
PLASTIGAGE Gauge strip. Record
measurements. (See Crankshaft Bearing
Inspection section for crankshaft and bearing wear
limits.)
IMPORTANT: Hold on to piston to prevent piston
from dropping. Piston will drop once piston
rings have cleared cylinder liner. If liners are to
be reused, be extremely careful not to let
connecting rod hit liner bore when removing
piston and rod assembly.
4/13/95
DIESEL ENGINE
RG3821
15. Gently tap piston through top of cylinder block from
the bottom.
CYLINDER LINER HEIGHT
MEASUREMENT
1. Secure liners using cap screws and flat washers.
Flat washers should be at least 3.18 mm (1/8 in.)
thick. Tighten cap screws to 68 Nm (50 lb-ft).
RG6439
2. Using JDG451 Gauge and D17526CL or D17527Cl
Dial indicator, measure liner height (A) at
approximately 1,5,7, and 11 O’clock positions as
viewed from flywheel end of engine. Record all
measurements.
Liner Height Specifications
Liner Height . . . . .0.030-0.100 mm (0.0010-0.0040 in. )
Maximum Height Difference At Nearest Point Of Two
Adjacent Liners . . . . . . . . . . . . 0.05 mm (0.002 in.)
3 - 47
DIESEL ENGINE CYLINDER BLOCK REPAIR

Maximum Height
Difference Across Liner . . . . . . . . . 0.05 mm (0.002 in.)

3. Remove cap screws and washers securing liners to

cylinder block.
A

IMPORTANT: Only one liner shim may be installed

under each liner flange.
B
4. Remove and shim cylinder liner. Replace any liner
that does not meet height specifications .

NOTE: Two sizes of shims are available: 0.05 mm

(0.002 in.) and 0.10 mm (0.004 in.).

CYLINDER LINER REMOVAL

1. Remove cap screws and washers securing liners to
cylinder block.
C

IMPORTANT: Do not stamp top of high ring piston. RG1179

Piston may be damaged.

3. Pull liners out of cylinder block with KCD10001 or

D01062AA (shown) Puller. If the KCD10001 Puller
is used, secure puller with two cylinder head cap
screws. When using the D01062AA (or
D01073AA) Cylinder Liner Puller (B) to remove
liners (A), be sure that jaw (C) of puller is correctly
positioned before attempting to remove liner. DO
NOT overtighten liner puller to remove liners.
Doing so could easily break liners .

M76150

2. Number cylinder liners and pistons. Stamp front of

liner to assure correct assembly. Do not stamp
liner flange; stamp on fire dam only .

IMPORTANT: Keep matched pistons and liners
together. Liners must be reinstalled in same
cylinder bore.
RG4745
4. Remove cylinder liner O-rings (A) from grooves in
cylinder block (B). Also remove packing (C) from
cylinder liner (D).
5. Complete the disassembly of the cylinder block (if
required) by removing:
• Crankshaft pulley. (see Crankshaft Removal
Section)
• Oil pressure regulating plug, valve, and spring in
timing gear cover (see Lubrication Section).

3 - 48 4/13/95
CYLINDER BLOCK REPAIR DIESEL ENGINE

• Timing gear cover, timing gears (see Timing Gear 3. Separate piston and rod. Keep these parts in place
Cover Removal Section). with their respective cylinder liner .
• Camshaft (see Camshaft Removal Section).
• Camshaft bushing (see Camshaft Bushing
Removal Section). PISTON CLEANING
• Front plate (see Cylinder Block Front Plate
Removal Section).

c CAUTION
• Oil-bypass valve (see Lubrication Section).
• Crankshaft and main bearings (see Crankshaft
Repair Section).
• Piston Cooling orifices (see Piston Cooling Orifice
Always follow manufacturer’s instructions, and
Inspection).
safety steps exactly.
• Remove water gallery plugs .
• If necessary to “Hot Tank” the block, also remove
screw-in type oil gallery plugs and the engine 1. Clean piston ring grooves using a piston ring
serial number plate. groove cleaning tool.

IMPORTANT: When washing pistons, always use a

PISTON ROD REMOVAL stiff bristle brush - NOT A WIRE BRUSH - to
loosen carbon residue. DO NOT bead blast ring
groove areas.
IMPORTANT: DO NOT reuse piston rings

2. Clean pistons by any of the following methods :

• Immersion-Solvent
• Hydra-Jet Rinse Gun
• Glass bead blasting machine (Do not blast ring
lands or grooves.)
• Hot water with liquid detergent soa p
If cleaning with hot water and liquid detergent, soak
pistons in a 50 percent solution of liquid household
detergent and hot water for 30 to 60 minutes. Use a
stiff bristle brush to loosen carbon residue. Dry with
compressed air.

RG5622 PISTON INSPECTION

1. Remove piston rings using the JDE85 or JDE135

Piston Ring Expander.

RG5623

2. Remove and discard piston pin snap rings .

RG3326

4/13/95 3 - 49
DIESEL ENGINE
1. Carefully inspect pistons under magnification.
Check for:
• signs of fatigue
• fine cracks in the piston head (A )
• bent or broken ring lands (B )
• cracks in the skirt at inner and outer ends of piston
pin bore (C)
• excessive piston skirt wear (Original machining
marks must be visible.)
2. Visually inspect piston pin. Pin must be in good
condition with no visible wear .
3. Dip piston pin in clean engine oil .
RG5626
4. Install pin (A) through piston. Pin should pass
through piston using only light thumb pressure .
RG4747
5. Insert pin from both sides. If pin enters freely, but
binds in the center, the bore could be tapered (B )
6. Insert pin to check for bore alignment (C). Pin
should not “click” or need to be forced into bore on
opposite side.
CYLINDER LINER CLEANING
1. Use a stiff bristle brush to remove all debris, rust,
and scale from O.D. of liners, under liner flange,
and in O-ring packing area. Make certain there are
no nicks or burrs in areas where packings will seat .
3 - 50
CYLINDER BLOCK REPAIR
IMPORTANT: Do not use gasoline, kerosene or
commercial solvents to clean liners. Solvents
will not remove all abrasives from liner walls.
2. Thoroughly clean liner I.D. with a 50 percent
solution of hot water and liquid detergent .
3. Rinse thoroughly and wipe dry with a clean rag .
4. Swab out liner as often as necessary with clean
SAE 10W oil. Clean liner until a clean, white rag
shows no discoloration.
CYLINDER LINER INSPECTION
IMPORTANT: If liner pitting has occurred, check
condition of coolant.
RG4643A RG4643B
1. Inspect exterior length of liner for pitting (A). Check
packing step for erosion (B). If pitting or erosion is
observed, measure depth of pits with a fine wire or
needle. Replace piston and liner if :
• Depth of any pit is one-half or more of liner
thickness (C).
• Depth of erosion is one-half or more of the packing
step (D).
4/13/95
CYLINDER BLOCK REPAIR DIESEL ENGINE

1. Use the JDE62 Ring Groove Wear Gauge to check

A
wear of keystone ring groove (top groove) .

RG4746

A-Piston With Good Keystone Ring Groov e

B-Piston With Worn Keystone Ring Groov e
C-JDE62 Gaug e
D-Tool Shoulder-to-Ring Land Clearanc e
RG1188
2. Gauge shoulders (C) should not contact ring land.
Clearance (D) between shoulders of tool and ring
land indicate ring groove is good .
2. Visually inspect liner ID. Replace piston and liner if :
3. If ring groove is worn, replace piston and liner as a
• The crosshatch honing pattern is not visible matched set. If ring groove is good, proceed to
immediately below the top ring turnaround area . next step.
• Liners are pitted or contain deep vertical scratches
that can be detected by the fingernail .
• Liner shows signs of fatigue, such as fine cracks in
the flange area (A) and cracks in the ring travel
area (B).

NOTE: Inspect block for cracks or erosion in the O-ring

packing area. (See Cylinder Block Inspection
Section.)

PISTON AND CYLINDER LINER

MEASUREMENT

RG5625

4. Check second and third ring grooves using a new

piston ring and a feeler gauge. Replace piston if
clearance exceeds 0.20 mm (0.008 in.)

RG5624

4/13/95 3 - 51
DIESEL ENGINE CYLINDER BLOCK REPAIR

2. Turn Piston 90° in liner. Measure clearance

between piston skirt and liner 90° to pin bore.
record the clearance.

RG6283

5. Measure piston pin bore. If bore is not within

specifications, replace piston and liner set .

Piston Pin Bore

Specifications . . . . . . 41.29-41.30 mm (1.625-1.626 in. )

NOTE: Piston pin bores are elliptical, the width being

0.038 mm (0.0015 in.) larger than the bore T71625
specifications.

3. Turn piston upside down in liner. Align marks made

Measure piston-to-liner clearance during disassembly on front of piston and front of
liner. Move piston so bottom edge of piston skirt is
25.4 mm (1.00 in.) below top of liner. Measure
clearance (A) between piston and skirt and liner at
90° to pin bore. Record the clearance .
4. Turn piston 90° in liner. Measure clearance
between piston skirt and liner 90° to pin bore.
Record the clearance.

Results:
The difference between clearances in Steps 1and 2 is
the amount liner is out-of-round at bottom of the liner .
The difference between clearances in Steps 3 and 4 is
the amount liner is out-of-round at top of the liner .
The difference between clearances in Steps 1 and 3 is
the amount liner is tapered .

PISTON AND CYLINDER LINER SPECIFICATIONS

Piston-to-liner Clearance (Measured at bottom of
T71624 A piston skirt . . . . . . . . 0.08-0.15 mm (0.003-0.006 in. )

Maximum Cylinder Out-Of-Round . . . . . . . . . . . . . . . .

1. Place piston (with rings removed) inside it’s (top or bottom) . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
matched liner. Align marks made during
disassembly on front of piston and front of liner. Maximum Cylinder Taper . . . . . . . . 0.05 mm (0.002 in.)
Move piston down until bottom edge of piston skirt
is 25.4 mm (1.00 in.) from bottom of liner. Use a If cylinder liner geometry is not within specifications,
feeler gauge to measure clearance (A) between replace piston and liner as a set .
piston skirt and liner 90° to pin bore. Record the
measured clearance.

3 - 52 4/13/95
CYLINDER BLOCK REPAIR DIESEL ENGINE

CYLINDER LINER DEGAZING

1. Secure cylinder liner in a secure holding fixture .
2. Use D17004BR Flexible Cylinder Hone at 300-500
rpm with 30-40 strokes per minute to deglaze
cylinder liner and obtain a 45° crosshatch pattern
on cylinder surface.

NOTE: Use honing oil along with flex hone when

deglazing liners.

Thoroughly clean liners after deglazing. (See Cylinder

Liner Cleaning Section.) T81598

PISTON AND LINER REPLACEMEN T
IMPORTANT: ALWAYS install a new (matched set)
liner when replacing a piston. Do not stamp top
high ring piston. Piston may be damaged.
5. Install correct rod cap bearing and torque to 55 N•m
(40 lb-ft) initially, then an additional 90-100
degrees.
6. Remove rod caps with bearings .

Mark matched piston and liner for placement in the

same cylinder location.

CONNECTING ROD BEARING

INSPECTION & MEASUREMENT
• Rod And Crankshaft Installed In Engine:
1. Inspect connecting rod bearings for damage or RG6346
wear.
2. Mark caps and rods to insure correct assembly in
same location. 7. Measure rod bearing-to-journal oil clearance with
PLASTIGAGE Gauge strip. Record measurement .

IMPORTANT: Keep inserts with their respective
rods and caps.
3. Remove connecting rod bolts, end caps and
bearing inserts.
4. Place a piece of PLASTIGAGE across entire width
of bearing surface.
• Rod and crankshaft removed from engine.
1. Measure crankshaft journal OD at several points .
2. Assemble connecting rod, cap, and bearings with
OLD cap screws. Tighten cap screws to 56 N•m
(49 lb-ft), then tighten an additional 90-100°. (See
Torque-Turn Method for Proper Torque Section.)

NOTE: Use PLASTIGAGE as directed by the

manufacturer. PLASTIGAGE will determine
bearing-to-journal oil clearance, but will not
indicate the condition of either surface.

T81599

4/13/95 3 - 53
DIESEL ENGINE CYLINDER BLOCK REPAIR

3. Measure assembled rod bearing ID . IMPORTANT: Do not attempt to polish or refinish

4. Subtact crankshaft journal OD from rod bearing ID
to determine oil clearance. Replace bearing if out
of specifications.
Connecting Rod Journal And Bearing
Specifications
Crankshaft
Journal OD . . . . . . . . 69.80-69.82 mm (2.748-2.749 in. )
Assembled Rod
Bearing ID . . . . . . . . . . . 69.85-69.90 (2.750-2.752 in. )
Oil Clearance
(new parts) . . . . . . . . . 0.03-0.10 mm (0.0012-0.004 in. )
Wear Limit . . . . . . . . . . . . . . . . 0.16 mm (0.0062 in.)
piston pin. Pin has a highly polished surface.
2. Measure pin OD. Replace if not within
specifications.
Piston Pin Specifications:
Pin OD . . . . . . . . . 41.270-41.280 mm (1.624-1.625 in. )
Wear Limit . . . . . . . . . . . . . . 41.257 mm (1.6235 in. )
Pin Length . . . . . . . .71.61-72.01 mm (2.819-2.835 in. )
3. Inspect piston pin bushing for damage or excessive
wear. Lubrication hole must be open .
T81605

CONNECTING ROD AND CAP

INSPECTION
1. Inspect rod and cap for wear or damage, such as
chips or cracks in the joint area .
2. Inspect in and around cap screw holes in cap. If any
defects are found, replace rod and cap .
3. Carefully clamp rod in soft-jawed vise (cap end
upward).
4. Install cap WITHOUT bearing inserts. Use old cap
screws.
5. Tighten cap screws to 55 N•m (40 lb-ft), then an
additional 90—100°. (See Torque-Turn Method for 4. Measure pin bushing ID and pin OD to determine oil
Proper Torque Section.) clearance.
6. Using an inside micrometer, measure rod bore at
center or bore and record measurements as
follows:

A. At right angle to rod-to-cap join t

B. At 45° to the left of measurement in step A
C. At 45° to the right of measurement in step A

Rod Bore Specifications (Without Bearing Inserts)

Rod Bore Id: . . .73.660-73.686 mm (2.9000-2.9010 in. ) RG5595

Maximum Permissible
Out-of-Round . . . . . . . . . . . . . . . 0.038 mm (0.0015 in.)
4. If difference between the largest and smallest
measurement exceeds Out-of-Round
specification, replace connecting rod .
5. Insert pin from either side of rod bushing. If pin is
free on one end, but tight on the other, the bore
could be tapered (A). If pin enters freely from both
sides, but is tight in the center, bore is bell
mouthed (B).

PISTON PIN AND ROD BUSHING Piston Pin Bushing Specifications

INSPECTION Bushing ID
1. Inspect piston pin for general overall condition. (Installed) . . . . .41.300-41.326 mm (1.6260-1.6270 in. )
Replace pin if it shows signs of fretting . Wear Limit . . . . . . . . . . . . . . 41.376 mm (1.6290 in. )

3 - 54 4/13/95
CYLINDER BLOCK REPAIR DIESEL ENGINE

Pin-to-Bushing
Clearance. . . . . . . . . 0.02-0.06 mm (0.0008-0.0024 in. ) T81608
Wear Limit . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)

PISTON PIN BUSHING REMOVAL

1. Use JDG738 Connecting Rod Bushing Service Set,
or arbor press, to remove connecting rod pin
bushing.

CONNECTING ROD PIN BORE

CLEANING & INSPECTION
1. Clean bore of rod with medium grit emery cloth .
2. Inspect for cracks or other damage. Make sure that
lube oil hole in top of rod is open .
1. Apply clean engine oil to new bushing OD and rod
bore ID.
2. Press bushing into connecting rod using JDG738
Connecting Rod Bushing Service Set, or arbor
press, to press pin bushing into connecting rod .
3. Push bushing into bore until oil hole in bushing
aligns with oil hole in connecting rod. Bushing
must be centered in the rod bore. Ends of bushing
must not protrude beyond edge of rod bore on
either side of rod.
4. Precision bore and hone bushing to the specified
dimensions.

RG6273 Connecting Rod and Pin Bushing Specifications

3. Measure bore diameter in two places, 90° apart.
Replace rod if not within 46.025-46.051 mm
(1.820-1.830 in.).
IMPORTANT: If bushing has spun in rod, replace
connecting rod.
PISTON PIN BUSHING
INSTALLATION
IMPORTANT: Make sure that lubrication oil hole in
bushing is aligned with bore in connecting rod.
Pin-to-Bushing
Clearance . . . . . . . . . . . . 0.02-0.06 (0.0008-0.0024 in. )
Bearing Bore-to-Pin Bushing Bore (Center-to-Center )
Length . . . . . . . . . 180.95-181.05 mm (7.124-7.128 in. )
CYLINDER BLOCK CLEANING &
INSPECTION
1. Remove all components (including piston cooling
orifices, soft plugs and oil gallery plugs) before
inspecting and cleaning cylinder block .
2. Clean block thoroughly using cleaning solvent,
pressure steam, or a hot tank .

IMPORTANT: If block is cleaned in a hot tank, be

sure to remove any aluminum parts (such as
nameplates). Aluminum parts can be damaged
or destroyed by hot tank solutions.

3. All passages and crevices must be clear of sludge,

and grease.
4. All coolant passages must be clear of lime deposits
and scale.

4/13/95 3 - 55
DIESEL ENGINE CYLINDER BLOCK REPAIR

5. Be sure liner support flange is free of any burrs. CYLINDER BLOCK MAIN BEARING
LIGHTLY file burrs with a small half-moon file. File
in a circular motion at approximately a 60° angle. BORE MEASUREMENT
DO NOT let file hit top of cylinder block while filing .

IMPORTANT: DO NOT file liner support flange

excessively. Excess filing can damage liner
support flange and allow an improper liner fit.
Thoroughly clean all fillings from cylinder block.

6. Inspect block for cracks or damage. If a cracked

block is suspected, pressure-test the block. A
procedure for pressure testing is outlined in FOS
(Fundamentals of Service) Manual-ENGINES.
Check for erosion or cracks in the liner O-ring/
packing area. Replace cracked or damaged T81655
blocks.

RG4718 1. Remove crankshaft. (See Crankshaft Removal

Section.)
2. Install cleaned main bearing caps in block (no
bearing inserts installed) and torque cap screws to
115 N•m (85 lb-ft).
3. Measure main bearing bore diameter and cylinder
block main thrust bearing width .

Cylinder Block Main Bearing Specifications

Main Bearing
Bore Diameter . . . . .84.46-84.48 mm (3.325-3.326 in. )

Cylinder Block Main Thrus t

Bearing Width. . . . . .33.62-33.72 mm (1.324-1.328 in. )
7. If cylinder block is serviceable, clean cylinder head 4. If bearing caps are damaged, or bore is not within
cap screw threads in block using JDG680 Tap or specification, replace caps and line bore to
equivalent 1/2-13 UNC-2A x 76 mm (3.0 in.) long specifications. (See Main Bearing Measurement
tap. Remove debris or fluid from tapped holes with Section.)
compressed air.

CAMSHAFT FOLLOWER BORE

CYLINDER LINER O-RING BORE
MEASUREMENT
CLEANING
1. Use D17015BR O-ring Bore Cleaning Brush to
clean lower liner O-ring bore in cylinder block .

NOTE: Use brush exactly as directed by the

manufacturer.

T81656

1. Measure camshaft follower bore diameter .

3 - 56 4/13/95
CYLINDER BLOCK REPAIR DIESEL ENGINE

Camshaft Follower Bore Specifications If bearing bore diameter in cylinder block is larger than
specified, install a new cylinder block. If bushing in No.
Camshaft Follower 1 bore is worn or damaged, install a new bushing. (See
Bore ID . . . . . . . . . . . 31.70-31.75 mm (1.248-1.250 in. ) Camshaft Bushing Removal and Installation Section.)

Camshaft Follower
OD (New) . . . . . . . . . 31.61-31.64 mm (1.245-1.246 in. ) CYLINDER BLOCK FLATNESS
MEASUREMENT
Camshaft Follower-to-Bor e
Clearance. . . . . . . . . . . 0.06-0.13 mm (0.002-0.005 in. )
T81658
2. If camshaft follower bore ID and follower-to-bore
clearance exceed specified maximum, install a
new cylinder block.

CAMSHAFT BEARING BORE

MEASUREMENT
NOTE: No. 1 camshaft bore has bushing installed.

T81657

1. Measure cylinder block top deck flatness using

D05012ST precision straightedge. If flatness is not
as specified, resurface cylinder block .

Cylinder Block Top Deck Maximum Acceptable

Out-of-Flat Specifications

Entire Length or Width (Used) . . . 0.088 mm (0.003 in.)

Any 150 mm (5.90 in.) Length . . . 0.025 mm (0.001 in.)

Top Deck Surface Finish (Surface Grin d

Only). . . . . . . . . . 0.0008-0.0032 mm (31-125 micro in. )

1. Measure camshaft bearing bore diameter . Maximum Wave Depth . . . . . . . . 0.012mm (0.0005 in.)

Main Bearing Bore Centerline-to-Cylinder Block Top

Camshaft Bearing Bore Specifications Deck Distance (minimum) . . 301.98 mm (11.889 in.)

No. 1 Camshaft Bearing Bore ID (Bushin g

Removed) . . . .59.961-59.987 mm (2.3607-2.3617 in. )

Camshaft Bearing Bore ID (Except No. 1

Bore) . . . . . . . . 55.986-56.012 mm (2.2042-2.2052 in. ) A

No. 1 Camshaft Bushing ID (Bushin g

Installed) . . . . . . 55.948-56.00 mm (2.2026-2.2047 in. )

Camshaft Journal-to Bearing Bore Clearance (Except

No. 1 Journal). . . . . . 0.08-0.13 mm (0.003-0.005 in. )
Wear Limit . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
RG4726
Camshaft Journal-to-Bushing Clearanc e

(No. 1 Journal) . . . . . . . 0.05-0.13 mm (0.002-0.005 in. ) 2. Measure cylinder block counterbore depth (A) using
Wear Limit . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.) D05012ST precision straightedge .

4/13/95 3 - 57
DIESEL ENGINE
Cylinder Block Counter
Bore Depth . . . . . . . . . . 5.95-5.99 mm (0.234-0.236 in. )
IMPORTANT: When cylinder block top deck or
main bearing bores are machined, the
dimension from crankshaft centerline to top
deck will be changed. Make sure this dimension
is within specifications, otherwise, piston may
contact cylinder head.
PISTON COOLING ORIFICE
INSPECTION
M76148
1. Remove and clean each piston cooling orifice (A) to
make sure it is not plugged or damaged. Replace if
questionable.
IMPORTANT: A piston cooling orifice failure could
cause damage to piston, piston pin, pin busing,
and liner. If a piston cooling orifice is left out,
low oil pressure will result.
2. Install and tighten orifices to 10 N•m (84 lb-in.).
3 - 58
CYLINDER BLOCK REPAIR
CYLINDER LINER FLANGE
THICKNESS MEASUREMENT
RG4727
Measure cylinder liner flange thickness at several
locations. If liner flange is not within specifications,
replace piston and liner set .
Cylinder Liner Flange Specifications
Flange
Thickness . . . . . . 6.022-6.058 mm (0.2371-0.2385 in. )
CYLINDER LINER HEIGHT
MEASUREMENT
1. Entire liner bore in cylinder block must be clean .
IMPORTANT: Liner should rotate smoothly by
hand when installed without O-rings or packing.
If not, remove liner and clean block.
2. Install liner without O-rings and packing. If liner
does not rotate smoothly by hand, remove liner
and polish lower pilot bore in block with emery
cloth or D17015BR Brush. Use a shop towel or
other suitable means to collect debris when
polishing bore.
3. Locate liner mark toward the front of the engine.
Secure with cap screws and washers
(approximately 3 mm (1/8 in.) thick). Tighten
screws to 68 N•m (50 lb-ft) .
4/13/95
CYLINDER BLOCK REPAIR DIESEL ENGINE

CYLINDER LINER O-RING &

PACKING INSTALLATION

IMPORTANT: DO NOT use oil or hand cleaner soap

on cylinder liner packing or O-rings. Petroleum
products will cause the red (or white) O-ring to
swell, which may result in O-ring damage during
liner installation.

1. Dip O-rings in AR54749 Soap Lubricant .

CD6371

RG6439

4. Using JDG451 Gauge and D17526Cl or D17527Cl

Dial Indicator, measure height (A) of liner at 1, 5, 7,
and 11 O’clock positions as viewed from flywheel
end of engine. RG3826

Linear Height Specifications 2. Install the black O-ring (A) in the lower O-ring
groove in the cylinder block (C) .
Liner Height . . . . . . 0.03-0.100 mm (0.0010-0.0040 in. )
3. Install the red (or white) O-ring (B) in the upper O-
Maximum Permissible Height Difference At Nearest ring groove in the cylinder block .
Point of Two Adjacent Liners, or Within a Single
Liner . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)

5. If liner height is above specification, check cylinder

block for burrs on liner support flange or incorrect
counterbore depth.

IMPORTANT: ONE LINER SHIM ONLY may be

installed under each liner flange. If liner requires
more than one shim, install a new liner or
cylinder block.

If liner height is no more than 0.08 mm (0.003 in.)

below top deck of block, install one liner shim under
RG4752
liner flange.

NOTE: Two shim sizes are available; 0.05 mm (0.002

in.) and 0.10 mm (0.004 in.). 4. Turn cylinder liner (B) upside-down. Dip square
packing (A) in soap and install over outside of liner .

4/13/95 3 - 59
DIESEL ENGINE
5. Slide packing down firmly against shoulder on liner.
Make sure packing is not twisted .
6. Coat the liner packing sealing area of the cylinder
liner and block O-rings with liquid soap .
CYLINDER LINER INSTALLATION
IMPORTANT: Do not scuff the liner packing across
the upper counterbore.
Pitted or eroded liners that meet reuse
guidelines should be rotated 90° from their
removed position. (See Cylinder Liner
Inspection Section.)
1. Install liner in block bore with mark toward front of
engine, unless liner OD is pitted or eroded .
2. If liner OD is pitted or eroded, but still within
acceptable service limits, rotate liner 90° from it’s
removed position. Pitted sections of the liner
should be facing the front or rear of engine .
M63273
3. A resistance will be felt when cylinder liner is
aligned in pilot bore. Seat liners with wood block
and hammer. KCD10001 Puller may also be used
to seat liners.
NOTE: Cylinder liner will protrude over top of cylinder
block more than normal due to uncompressed
packings and O-rings.
IMPORTANT: If you suspect a packing may have
sheared, or a displaced liner installation,
remove and examine the liner and packing
assembly. If no damage is found, check
packings for proper position, re-soap packings,
and reinstall liner assembly.
4. Hold liners in place with large flat washers and cap
screws. Turn cap screws snug but do not tighten .
3 - 60
CYLINDER BLOCK REPAIR
5. Clean inside of cylinder liner bores with waterless
hand cleaner after installation. Wipe dry with clean
towels.
6. Apply clean engine oil to liner bores immediately to
prevent corrosion.
PISTON & CONNECTING ROD
ASSEMBLY
IMPORTANT: If a new piston and liner assembly is
to be installed, DO NOT remove piston from
liner. Push piston out of liner bottom only far
enough to install piston pin.
1. Lubricate piston pin and bushing with clean engine
oil.
IMPORTANT: Pistons must be installed on
connecting rods from which they were removed.
Flat Boss
Stamp
M63270
2. Align the word “FRONT” cast on center of
connecting rod with flat on pin boss on underside
of piston. (Combustion bowl on top of piston
should be facing fuel injection pump side of
engine.)
3. Insert piston pin into piston pin bore. Install NEW
piston pin retaining rings with sharp edge of ring
facing away from piston pin. Make sure retaining
rings are seated in grooves of piston pin bore .
PISTON RING INSTALLATION
IMPORTANT: Piston rings can be damaged if
expanded too far. Expand piston rings only as
far as necessary to install rings on piston.
4/13/95
CYLINDER BLOCK REPAIR
T81600
1. When installing new piston rings, use JDE85 or
JDE135 Piston Ring Expander. Install oil ring
expander in bottom ring groove. Position end gap
toward front or rear of piston pin .
RG5628
2. Install oil control ring (A) in bottom ring groove over
ring expander. Install with end gap opposite end
gap of ring expander.
RG6400
3. Identify top side of compression rings. Top side of
rectangular and keystone compression rings will
be identified by one of the following :
• Depression marks on the top side of the ring .
• “TOP” marked on the top side of the ring .
• Yellow dye marks on the face of the ring. Dye
marks must be on the left side of ring gap as
shown.
4/13/95
DIESEL ENGINE
4. Install rectangular compression ring in center ring
groove with top of ring toward top of piston .
5. Position gap in rectangular compression ring on
opposite side of piston from oil control ring gap .
6. Install keystone compression ring in top ring groove
with top of ring toward top of piston .
7. Position gap in keystone compression ring on
opposite side of piston from rectangular
compression ring gap.
B E
A
D
C
CD5781
A. Piston Head D. Expander Ring Ga p
B. Top Compression Ring Ga p E. Bottom Compression Ring
C. Oil Control Ring Ga p Gap
F. Front of Engin e
7. Stagger ring gaps on pistons as shown .
PISTON & CONNECTING ROD
ASSEMBLY INSTALLATION
IMPORTANT: Do not damage cylinder walls or
crankshaft journals with connecting rod when
installing piston and rod in cylinder.
1. Coat pistons, liners and inside of JDE84 Ring
Compressor with clean engine oil .
2. Place piston assembly into ring compressor .
3. Place ring compressor and piston assembly over
cylinder liner with the word “FRONT” on
connecting rod facing the front of the engine .
NOTE: Combustion bowl in piston is offset toward fuel
injection pump side of engine, and the long
side of the connecting rod is toward camshaft
side of engine.
4. With piston centered in ring compressor and rings
staggered correctly, push piston into liner .
3 - 61
DIESEL ENGINE CYLINDER BLOCK REPAIR

IMPORTANT: NEVER use connecting rod cap

screws more than once for final engine
assembly. Once rod cap screws have been
tightened, they cannot be reused for final
assembly.

T88805

5. Install bearing insert in connecting rod with tang (A)

in groove (B).
6. Apply clean engine oil on insert and crankshaft
journal. Carefully pull connecting rod and insert
against crankshaft journal .

T81615

9. Dip NEW connecting rod cap screws in clean oil

and install. Tighten cap screws alternately to the
following torques:
• Initially tighten all cap screws to 55 Nm (40 lb-ft. )
• Tighten all cap screws an additional 90-10 0°. (See
Torque-Turn Method For Proper Torque.)

CRANKSHAFT ROTATION TORQUE

1. Rotate crankshaft several revolutions to be sure
engine rotates without excessive tightness .
T88806
2. Check liners for deep scratches caused by an
improperly installed or broken piston ring .
7. Install bearing insert in connecting rod cap with tang 3. Check side clearance of rods. Must have slight
(A) in groove (B). side-to-side movement.

PISTON PROTRUSION
MEASUREMENT
1. Press down on top of piston to remove oil
clearances before measuring piston protrusion .

Tangs
M76147

8. Apply clean engine oil to bearing insert. Install cap

on connecting rod with tangs to same side .

3 - 62 4/13/95
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL REPAIR
RG6440
2. Use JDG451 Gauge (or use a magnetic base dial
indicator) to measure piston protrusion. Place
gauge on top of cylinder block so dial indicator can
be set to “zero” with top of block .
L103012
3. Position gauge across piston. While pressing gauge
downward, rotate crankshaft until piston is at TDC.
Measure piston height at several positions around
the piston. If using JDG451 Gauge, piston height
must be checked at outer most diameter of piston .
4. Piston protrusion must be within the following
specifications to prevent piston-to-exhaust valve
contact.
Piston Protrusion Specifications
Piston Protrusion
(Above Block Deck) . . .0.08-0.30 mm (0.003-0.012 in.)
5. If protrusion does not meet specifications, check
dimensions of piston, connecting rod, cylinder
block, crankshaft, and bearings to determine the
cause.
4/13/95
DIESEL ENGINE
COMPLETE FINAL ASSEMBLY
1. Install oil pump outlet tube O-ring in cylinder block.
Install oil pump and outlet tube .
2. Install No. 1 camshaft bushing .
3. Install camshaft, timing gears, and timing gear
cover.
4. Install oil pressure regulator valve, spring, and plug
in timing gear cover.
5. Install oil pan.
6. Install crankshaft pulley .
7. Install camshaft followers .
8. Install cylinder head with new gasket .
9. Fill engine with clean oil and proper coolant .
10. Perform engine break-in .
ENGINE BREAK-IN PROCEDURE
1. Run engine at slow idle for 2 minutes. Check for
fluid leaks.
2. Increase RPM to fast idle, then load down to 2550
rpm for 20 minutes.
NOTE: Dynamometer is the preferred load control, but
a hydraulic load can be placed on the engine
through the auxiliary hydraulic ports by
attaching D01074AA Hydraulic Tester and
loading to required RPM.
3. Recheck valve clearances and adjust as necessary.
(See Valve Clearance Adjustment Section.)
4. Install rocker arm cover. Torque cap screws to 11
N•m (96 lb-in.). (See Rocker Arm Cover
Installation section.)
NOTE: Retorque of cylinder head cap screws after
engine break-in is not required.
CRANKSHAFT, MAIN BEARINGS,
AND FLYWHEEL REPAIR
CRANKSHAFT PULLEY REMOVAL
IMPORTANT: Do not hammer on or drop pulley.
3 - 63
DIESEL ENGINE CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL REPAIR

FLYWHEEL HOUSING REMOVAL

1. Support engine on engine stand. Do not have
weight of engine supported by flywheel housing or
rear engine flange.

A
M63274

1. Remove pulley cap screw (A) .

A M63275

2. Drain pump gear drive reservoir at drain plug (A).

Remove hydraulic pumps (if installed) from pump
mounting plate.

IMPORTANT: Pump mounting plate is heavy.

Attach hoist to plate before removing
capscrews to prevent injuries or damage.

3. Remove nine (9) capscrews (B) holding pump

mounting plate to flywheel cover. Pry plate from
flywheel cover.
M76122
4. Bolt lift sling to flywheel housing and attach to hoist
to prevent housing from dropping off alignment
dowel.
2. Using suitable puller, remove pulley from
crankshaft.

CRANKSHAFT PULLEY
INSTALLATION
A
1. Position pulley on crankshaft. Handle pulley with
care to avoid impact damage .

IMPORTANT: Pulley-to-Crankshaft cap screw must

be SAE grade 8. If replacing, use appropriate
SAE grade 8 cap screw and tighten to specified
torque.

2. Apply LOCTITE 242 (TY9370) Thread Lock & M63267

Sealer to cap screw threads. Install cap screw and
10 mm (0.39 in.) thick washer, and tighten to 150
N•m (110 lb-ft).
IMPORTANT: Flywheel housing is heavy. After
pump drive gear is removed, flywheel housing
is only supported by hoist and alignment
dowels on rear engine flange.

3 - 64 4/13/95
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL REPAIR DIESEL ENGINE

5. Remove six (6) Allen head capscrews (A) holding 2. Using a prybar, gently pry crankshaft as far to rear
pump drive gear in place . of engine as possible.
6. Pry housing off alignment dowels and remove from 3. Zero the dial indicator .
engine. 4. Gently pry the crankshaft as far forward as
possible. Note indicator reading. If end play is not
within specifications, install new thrust bearing .
HYDROSTATIC PUMP DRIVE SHAFT
SEAL REPAIR NOTE: If new thrust bearing does not restore proper
end play, install a five-piece thrust bearing with
oversize thrust washers.

Crankshaft End Play Specifications

New Parts

Two-Piece Thrust
Bearing. . . . . . . . . 0.05 mm-0.20 mm (0.002-0.008 in. )
Wear Limit . . . . . . . . . . . . . . . . . 0.38 mm (0.015 in.)

Five-Piece Thrust
Bearing. . . . . . . . . . . . 0.025-0.33 mm (0.001-0.013 in. )
Wear Limit . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.)

M63276 FLYWHEEL REMOVAL

1. Drive old pump drive shaft oil seal out of flywheel

housing.
2. Clean seal mating surface of housing . c CAUTION
3. Drive new seal into place using seal driver .
4. Coat lip of seal with gear oil prior to assembly . Flywheel is heavy. Plan a proper lifting
procedure to avoid personal injury.

CRANKSHAFT END PLAY CHECK

NOTE: Measure end play prior to removing crankshaft
to determine condition of thrust bearings.

T88331

M63268

1. Remove twelve (12) capscrews holding pump drive

plate to flywheel.

1. Position dial indicator on face of flywheel, or on

front crankshaft nose.

IMPORTANT: Do not apply too much pressure with

bar, as this could damage bearings.

4/13/95 3 - 65
DIESEL ENGINE CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL REPAIR

A
B

M76145

M63269

2. Remove ring gear with a brass drift and hammer .

2. Attach flywheel to overhead hoist with chain or
sling.
IMPORTANT: If flame heat is used, be sure gear is
3. Remove four (4) capscrews (A) holding flywheel to heated uniformly around circumference. DO
crankshaft. If flywheel will not release from NOT OVERHEAT. Overheating may destroy
crankshaft, install two capscrews into threaded original heat treatment of gear. SEE CAUTION.
holes (B) and turn in equal amounts until flywheel
is released.
3. Heat new ring gear to 14 8° C (300° F) using either
heated oil, oven heat, or flame heat .
FLYWHEEL INSPECTION
1. Inspect the flywheel face for scoring, overheating,
cracks. Replace flywheel if defective .
2. Examine flywheel ring gear for worn or broken
teeth. Replace ring gear if defective. (See
Flywheel Ring Gear Replacement Section.)

FLYWHEEL RING GEAR

REPLACEMENT
RG3838

c CAUTION 4. Install ring gear against shoulder of flywheel so

Oil fumes or oil can Ignite above 193°C (360°F).
Use a thermometer and do not exceed 182°C
(360°F). Do not allow a flame or heating element
to be in direct contact with the oil. Heat the oil in
a well ventilated area. Plan a safe handling
procedure to avoid burns.
1. Place flywheel on a solid flat surface .
chamfered side is on engine side of flywheel.
FLYWHEEL PILOT BEARING
REPLACEMENT
NOTE: Pilot Bearing is not under load in this
application and service is optional. Flywheel
must be removed from the engine to replace
this bearing.

1. With flywheel removed from engine, drive bearing

out toward engine side of flywheel. Discard
bearing.
2. Measure flywheel bore diameter. If bore is larger
than specifications, replace flywheel .

3 - 66 4/13/95
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL REPAIR DIESEL ENGINE

Flywheel Bearing Bore Specifications

Flywheel Bore
ID . . . . . . . . . . . 39.937-39.993 mm (1.5735-1.5745 in. )

IMPORTANT: Push on outer bearing race when

installing in flywheel. Bearing may be damaged
if force is applied to inner bearing race.

M63266

1. Install two guide studs in crankshaft cap screw

threaded holes. Place flywheel on studs with
dowel hole on flywheel lined up with crankshaft
dowel. Slide flywheel into position against
crankshaft.

IMPORTANT: ALWAYS install new flywheel cap

RG6345 screws when flywheel has been removed.

A. 27487 Driver Handl e

B. 27508 Disk 39.69 mm (1-9/16 in. )
2. Apply LOCTITE 242 (TY9370) to threads of all
C. 27493 Disk 15.86 mm (5/8 in. )
flywheel mounting cap screws. Start cap screws in
D. Ball Bearing
crankshaft. Do not tighten until guide studs are
E. Flywheel
removed and all cap screws are started .
3. Tighten cap screws to 163 N•m (120 lb-ft).

6. Drive new ball bearing into engine side of flywheel NOTE: Flywheels and front crankshaft pulleys are not
using 27487 Driver, 27508 Disk, and 27493 Disk, interchangeable with other engine models. 3-
until bearing bottoms in bore. Check bearing for cylinder engines are externally balanced.
smooth operation.

FLYWHEEL INSTALLATION

c CAUTION
Flywheel is heavy. Plan a proper handling
procedure to avoid injuries.

IMPORTANT: Flywheel MUST BE clean and free of

any oil, grease or debris.

M63268

4. Install pump drive plate to flywheel and torque

twelve capscrews to specifications .

4/13/95 3 - 67
DIESEL ENGINE CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL REPAIR

CRANKSHAFT REAR OIL SEAL

REMOVAL
NOTE: The oil seal MUST BE removed before
removing flywheel housing.

1. Remove flywheel. (See Flywheel Removal

Section.)

NOTE: The rear oil seal may be removed with JDG22

Puller slide hammer with sheet metal screw
mounted on end, or by using JDG698 Rear
Crankshaft Oil Seal And Wear Sleeve Removal T81200
Tool.

2. Use JDG22 Puller and a sheet metal screw to pull

Rear Oil Seal Removal (With JDG698 Removal Tool) seal from housing bore. Discard seal .
2. Adjust forcing screw on JDG698 Rear Crankshaft
Oil Seal And Wear Sleeve Removal Tool and
position screw so it centers tool on crankshaft
flange.
3. Use the slots in JDG698 Tool as a template, mark
three locations on oil seal casing where screws will
be installed. Remove tool from crankshaft flange .

IMPORTANT: Holes must be drilled at outer edge of

seal case. Screws will pull seal against wear
ring, thereby removing both pieces.

4. Drill a 3/16 in. hole through wear sleeve lip and seal
casing at the three marked locations.
5. Position JDG 698 Tool on end of crankshaft .
6. Install three 2-1/2 in. (approximate) sheet metal
screws with washers into slots of removal tool and
thread screws into holes in seal casing. Evenly
tighten screws until plate is flush with rear face of
crankshaft.
7. Tighten forcing screw (plate should pull evenly
against the three screws) until seal assembly is
removed from engine.
8. Clean OD of crankshaft flange with cleaning
solvent, acetone, or any other suitable cleaner that
will remove sealant.
T81202
3. Look for nicks or burrs on wear ring surface and
bore in flywheel housing. If necessary, use
polishing cloth to remove nicks or burrs .
4. Finish cleaning by wiping flange with a clean rag .
CRANKSHAFT REAR OIL SEAL
INSTALLATION
NOTE: Crankshaft and rear plate of engine must be
installed in block before rear oil seal.

IMPORTANT: No lubrication of any kind is to

Rear Oil Seal Removal (With Slide Hammer)
1. Drill a small hole through seal casing at three
locations (equally spaced) .
contact seal surface during installation. Use of a
lubricant may result in premature seal failure.
Install seal assembly immediately after removal
from plastic bag to avoid possible dirt
contamination.

3 - 68 4/13/95
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL REPAIR
RG5640
1. Clean OD of crankshaft flange with acetone or
equivalent solvent just prior to application of
sealant.
2. Make sure that OD of crankshaft flange and ID of
seal housing bore are free from nicks or burrs .
3. Apply a light coating of LOCTITE 609 Retaining
Compound completely around the leading edge of
crankshaft flange. Wipe away sealant that may
have gotten on engine rear plate seal bore .
ENGINE REAR PLATE REMOVAL
NOTE: Rear oil seal and wear sleeve must be
T88559
4. Install pilot (A) from the JT30040 Seal and Wear
Sleeve Installer Set on end of crankshaft using two
hex-head cap screws. Tighten both cap screws
securely. Make sure tool contacts face of
crankshaft.
T81204
4/13/95
DIESEL ENGINE
5. Carefully start oil seal and wear sleeve over pilot
and crankshaft flange with open side of seal
toward engine.
T81205
6. Attach driver and thrust washer to the guide with
capscrew. Tighten the capscrew until driver
bottoms on pilot.
7. Remove seal driver and pilot plate .
removed before Engine Rear Plate.
1. Remove flywheel. (See Flywheel Removal Section )
2. Remove dipstick, then starting motor .
3. Remove rear oil seal and wear sleeve. (See
Crankshaft Rear Oil Seal Removal Section.)
c CAUTION
The rear plate is heavy. Plan a proper handling
procedure to avoid injuries.
3 - 69
DIESEL ENGINE CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL REPAIR

T88558

M63266a
4. Check main bearing caps for arrows (A, cast in
main bearing cap) and numbers (B) stamped on
4. Remove eight rear plate-to-cylinder block cap cap and oil pan rail. Arrow points toward camshaft
screws (A), and rear plate-to-oil pan cap screws. side of engine and away from number stamped on
Remove rear plate from block . pan rail.

NOTE: If numbers are missing, stamp appropriate

numbers on cap and oil pan rail to assure
REMOVE MAIN BEARINGS correct placement of bearing caps during
1. Drain oil from engine crankcase . reassembly.
2. Remove oil pan.
5. Remove main bearing caps. Visually inspect
M76146 B A condition of bearing inserts as bearing caps are
removed. Keep caps and inserts together and in
correct order.

CRANKSHAFT MAIN BEARING

CLEARANCE CHECK (IN BLOCK )

3. Remove oil pump (A) and idler shaft cap screw (B) .

NOTE: When crankshaft is to be removed, leave front

and rear main bearing caps installed until all RG6346
connecting rod caps have been removed.

1. Place a strip of PLASTIGAGE in the center of the

main bearing cap about three-fourths of the width
of the bearing.
2. Use oil on PLASTIGAGE to prevent smearing .
3. Install cap and tighten cap screws to 135 N•m (100
lb-ft).
4. Remove cap and compare width of PLASTIGAGE
with scale provided to determine clearance .

3 - 70 4/13/95
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL REPAIR DIESEL ENGINE

Main Bearing Clearance Specifications
Main Bearing-to-Journa l
Clearance. . . . . . . . . . . 0.03-0.10 mm (0.001-0.004 in. )
Wear Limit . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
IMPORTANT: Small cracks may not be visible to
the eye. Use a method (such as the Fluorescent
Magnetic Particle Method) that is capable of
detecting small cracks. The crankshaft must be
demagnetized after the test.

CRANKSHAFT REMOVAL
1. Remove engine front plate .
2. Remove flywheel and crankshaft rear seal .
3. Remove flywheel housing .
4. Remove connecting rod caps .
5. Remove main bearing cap s

c CAUTION
Crankshaft is very heavy. Plan a proper handling
procedure to avoid injury.
CD7147

2. Inspect crankshaft for signs of load stress, cracks,

scoring, or journal scratches in critical areas
illustrated. Replace crankshaft if cracks are found .
3. Check each journal for evidence of excessive
overheating or discoloration. Replace crankshaft if
either condition exists.

CRANKSHAFT MAIN BEARING

MEASUREMENT
RG6347
1. With crankshaft removed from engine, assemble
main bearing caps and inserts .
6. Attach a lifting sling to crankshaft. Using proper 2. Tighten main bearing cap screws to 135 N•m (100
lifting equipment, carefully raise crankshaft out of lb-ft).
cylinder block.
7. Place crankshaft on a clean flat surface and support
journals with V-blocks.
8. If main bearings are to be replaced, remove inserts
from cylinder block. Otherwise, leave bearing
inserts in block until assembled ID has been
measured.

CRANKSHAFT GEAR REMOVAL

1. Remove Woodruff key, and oil slinger .
2. Pull gear with gear puller, legs, and H-bar, from the
T81186
DO1048AA Puller Set.

CRANKSHAFT INSPECTION 3. Measure and record main bearing ID .

1. Thoroughly clean crankshaft. Clear restrictions from

all oil passages.

4/13/95 3 - 71
DIESEL ENGINE CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL REPAIR

CRANKSHAFT THRUST BEARING &

T88550 JOURNAL MEASUREMENT

4. Measure and record crankshaft journal OD at

T81187
several points around each journal .

Main Bearing & Crankshaft Journal Specifications 1. Measure and record crankshaft main thrust journal
width.
Main Bearing ID
(standard). . . . . . . . . 79.39-79.44 mm (3.125-3.127 in. )
Main Thrust Journal & Thrust Bearing Specification
Crankshaft Journal OD
(standard). . . . . . . . . 79.34-79.36 mm (3.123-3.124 in. ) Thrust Journal
Width (new) . . . . . . .38.90-39.00 mm (1.531-1.535 in. )
Bearing-to-Journal Oil
Clearance. . . . . . . . 0.030-0.100 mm (0.0012-0.004 in. ) Thrust Bearing Width
Wear Limit . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) (standard) . . . . . . . . .38.80-38.85 mm (1.528-1.530 in. )
Maximum Journal Taper-Per-Inc h Thrust Bearing-to-Journal Oi l
Of Journal Length . . . . . . . . . . . 0.025 mm (0.0001 in.) Clearance . . . . . . . . . . . 0.05-0.20 mm (0.002-0.008 in. )
Wear Limit . . . . . . . . . . . . . . . . . 0.38 mm (0.015 in.)
Maximum Journal
Out-of-Round . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.) If crankshaft thrust journal width is not within
specifications, install a new or reconditioned
NOTE: Replace crankshaft if it does not fall within crankshaft, or oversize thrust washer set .
above specifications. This engine uses a
nodular iron crankshaft with undercut and
rolled fillets which cannot be reground except
by the factory. If a factory reconditioned
crankshaft has been installed, measured
dimensions will not meet above specifications.

T81188

2. Measure and record width of main thrust bearing.

Oil clearance between thrust bearing and thrust
journal must be within specifications .

3 - 72 4/13/95
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL REPAIR DIESEL ENGINE

In addition to the standard size main and connecting

rod bearings, 0.254 mm (0.010 in.) undersize bearings
are available.
Thrust bearings are available 0.05 mm (0.002 in.)
undersize and are used to compensate for slight even
wear on crankshaft. Regrinding is not usually
necessary when this size bearing is used .

RG5584

A. Thrust Washers
B. Front of engine
C. Toward Oil Pan RG6279

NOTE: Oversize thrust washer sets have thrust

washers (A) that are 0.18 mm (0.007 in.)
oversize.

CRANKSHAFT GRINDING
GUIDELINES

RG6274

To maintain the correct end play, the five-piece main

thrust bearing with individual thrust washers (D), can
be used to replace the two-piece flanged main thrust
bearing (C), if desired. (See Main Bearing and
Crankshaft Installation Section.)

RG6349
CRANKSHAFT MAIN BEARING CAP
MEASUREMENT
Saran-built 3029T engines are built with nodular iron
1. Remove bearing inserts from caps and cylinder
crankshafts that have undercut and rolled fillets (A), in
block. Keep inserts in correct order if they are to
place of ground fillets. These crankshafts also have
be reused.
micro-finished journal surfaces. Regrinding for
undersize bearings is not recommended for this 2. Clean and inspect caps for damage. Small burrs or
crankshaft. Replace crankshaft with a new or factory nicks on flat surfaces may be removed with a file.
reconditioned crankshaft if worn . Use a medium-grit polishing cloth to dress curved
bearing surfaces.
3. Install bearing caps (without bearings) in cylinder
IMPORTANT: If undersize bearings are installed, block. Tighten cap screws to 135 N•m (100 lb-ft) .
recheck bearing-to-journal clearance. If oil
clearance is not within specifications,
premature wear of bearings and journals will
result.

4/13/95 3 - 73
DIESEL ENGINE CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL REPAIR

CRANKSHAFT GEAR
INSTALLATION

c CAUTION
Oil Fumes or oil can ignite above 193°C (380°F).
Use a thermometer and do not exceed 182°C
(360°F). Do not allow a flame or heating element
to be in direct contact with the oil. Heat the oil in
T81655 a well-ventilated area. Plan a safe handling
procedure to avoid burns.

4. Measure ID of bearing cap bores .

Main Bearing Bore Specifications

Main Bearing Bore (Withou t

Bearings . . . . . . . . . . 84.45-84.48 mm (3.325-3.326 in. )

Main Bearing Bore Centerline-to-Top Dec k

Distance (Minimum): . . . . . . . . 301.98 mm (11.889 in.)

T81192

1. Heat new gear to 18 2°C (360°F).

2. Install Woodruff key in crankshaft. Drive gear onto
crankshaft using JDH7 Driver .

PISTON COOLING ORIFICES

INSPECTION

RG4788

IMPORTANT: When cylinder block is line bored,

the dimension from centerline of main bearing
bore to cylinder block top deck (A) will be
changed. Piston may contact cylinder head if
this dimension is less than specified above.
Main bearing line boring should be done ONLY
by experienced personnel on equipment
capable of maintaining bore specifications.
T88830

5. If bearing caps are damaged or bore is not within

specification, install a new cap and line bore to 1. Inspect and clean each cooling orifice to make sure
specified size. it is not plugged or damaged .
NOTE: Replacement bearing caps are supplied with
unfinished bearing bore.

3 - 74 4/13/95
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL REPAIR DIESEL ENGINE

IMPORTANT: If a five-piece main thrust is being

used, install one thrust washer onto rear side of
block web. Oil grooves on thrust washer must
face crankshaft thrust surface (away from the
block web).

NOTE: Some engines may have been built with two

thrust washers in the block and one on cap.
However, for service ALWAYS reassemble
engine with one thrust washer in the block and
two on the cap.

3. Apply a liberal coating of clean engine oil to bearing

surfaces and crankshaft journals .
4. Using proper lifting equipment, lower crankshaft
RG4943 onto main bearings.
5. Apply a liberal amount of clean oil to bearing insert.
Dip main bearing cap screws entirely in clean
2. Install orifices in block and tighten to 10 N•m (7 lb-
engine oil and position them in the main bearing
ft.) (84 lb-in.).
caps.

NOTE: Saran produced engines will have the arrow

MAIN BEARING AND CRANKSHAFT cast into the cap next to machined surface
INSTALLATION where cap number is stamped.

6. Make sure main bearing caps are installed in the

locations from which they were removed. The
numbers stamped on the caps should match the
number stamped on the pan rail of the block.
Arrow on cap must point toward camshaft side of
block.

T88555

1. Install main bearing inserts. Make sure that tang (A)

is engaged with slot (B) in the cylinder block and
main bearing caps. Also make sure oil holes line
up with oil passages in block .

IMPORTANT: If new thrust bearing inserts or thrust

washers are installed, they must be installed as
a set. T88557

7. Install main bearing caps so bearing tang (A) in cap

and cylinder block are together on same side of
cylinder block.

IMPORTANT: If a five-piece main thrust bearing is

being used, install a thrust washer on BOTH
SIDES to the main thrust bearing cap. Oil
T88556
grooves on thrust washers must face
crankshaft thrust surface (away from the
bearing cap).
2. Install main thrust bearing (A) in thrust web of
cylinder block.

4/13/95 3 - 75
DIESEL ENGINE CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL REPAIR
IMPORTANT: Do not use pneumatic wrench to
Install main bearing cap screws, as damage may
occur to the threads.
M76146
8. Tighten all main bearing cap screws to 135 N•m
(100 lb-ft) except rear main (thrust) bearing cap
screws. Tighten rear main (thrust) bearing cap
screw finger-tight.
IMPORTANT: DO NOT pry on thrust washer when
forcing crankshaft back and forth to align thrust
bearings.
9. Before tightening rear main (thrust) bearing cap
screws, align upper and lower thrust bearings.
Carefully force crankshaft and main thrust bearing
cap to the rear using a prybar between crank throw
and block web. Then, force crankshaft to the front
to line up thrust bearing surfaces .
10. Tighten rear main (thrust) bearing cap screws to
135 N•m (100 lb-ft).
11. Turn crankshaft by hand. If crankshaft does not turn
easily, disassemble main bearing caps and
determine the cause.
12. Install connecting rod caps and bearings. Install
new cap screws and tighten to specification .
IMPORTANT: Using pneumatic wrenches to install
cap screws may cause damage to the threads.
Never reuse connecting rod cap screws.
13. Check crankshaft for specified end play. (See
Crankshaft End Play Check Section)
3 - 76
ENGINE REAR PLATE
INSTALLATION
T81199
1. Drive old crankshaft rear oil seal out of rear plate (if
not previously removed) .
2. Inspect and clean cylinder block and rear plate
gasket surfaces.
3. Install a new rear plate gasket without sealant .
NOTE: Some engine overhaul gasket sets may
contain two gaskets: one with a silicone bead,
and one without. Use gasket without silicone
bead.
4. Dip threads of cap screws in clean engine oil before
installing.
5. Fit rear plate up to cylinder block. Install eight 5/16
in. capscrews and torque to 20 N•m (15 lb-ft).
6. Check flywheel housing seal bore runout. If runout
exceeds specification replace housing .
Flywheel Housing Run-Out Specifications
Maximum Permissible Run-Out of Flywheel Housing
Seal Bore . . . . . . . . . . . . . . . . 0.152 mm (0.006 in.).
7. Install crankshaft rear oil seal assembly. (See
Crankshaft Rear Oil Seal Installation Section.)
8. Install flywheel and pump drive plate. (See
Flywheel Installation Section.)
FLYWHEEL HOUSING
INSTALLATION
1. Replace pump drive shaft seal. (See Pump Drive
Shaft Seal Repair Section. .
2. Clean face of flywheel pump drive plate of old
sealant.
4/13/95
CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL REPAIR
M63264
3. Install flywheel housing on rear plate of engine
lining up locating dowels .
NOTE: Flywheel housing may be held in place
temporarily by installing a bolt through housing
to rear plate of engine.
4. Install pump drive shaft (See Pump Drive Shaft
Installation Section).
5. Clean mating surfaces of flywheel housing and
pump mounting plate.
6. Apply a bead of TY15443 Form-In-Place Gasket to
mating surface of pump mounting plate and
flywheel housing.
M63275
7. Install pump mounting plate. Line up mounting
holes and install five 3/8 x 1-1/4 in. capscrews, and
four 5/8 x 9-3/4 in. capscrews from rear of engine,
and two 5/8 x 2-3/4 in. capscrews from front of
engine. Torque to specifications .
4/13/95
DIESEL ENGINE
HYDROSTATIC PUMP DRIVE SHAFT
INSTALLATION
1. Inspect and/or replace pump drive shaft seal. (See
Pump Drive Shaft Seal Repair Section.)
2. Clean pump drive shaft mounting flange and
mounting bolt holes of old silicone sealer .
M63267
3. If center plug was removed, clean threads and
apply TY9375 Pipe Sealant before installing .
4. Apply TY15130 Form-In-Place Gasket Sealer to
heads of six 3/8 x 3 in. socket head capscrews and
insert into pump drive shaft .
5. Lubricate lip of pump drive shaft seal (mounted in
flywheel housing) with 90W gear oil .
6. Install pump drive shaft through oil seal until shaft is
seated into bore on pump drive plate. Line up
mounting bolts and torque to 68 N•m (50 lb-ft).
COMPLETE FINAL ASSEMBLY
1. Use new gaskets and O-rings during final engine
assembly. Clean all engine components as
necessary prior to assembly .
2. Install front plate, timing gear train, and camshaft .
3. Install oil pump assembly .
4. Install oil slinger.
5. Install timing gear cover gasket, timing gear cover,
oil pressure regulating valve assembly, and front
oil seal.
6. Install oil pan.
7. Install crankshaft pulley .
8. Install camshaft followers, push rods, and rocker
arm assembly.
9. Install fuel supply pump and injection pump .
10. Install starting motor and dipstick .
11. Adjust valve clearance .
12. Fill engine with clean oil and proper coolant .
13. Perform engine break-in .
3 - 77
DIESEL ENGINE CAMSHAFT AND TIMING GEAR REPAIR

CAMSHAFT AND TIMING GEAR 10. Set rocker arm-to-valve tip clearance to 0.0 mm
(in.) for No. 3 exhaust and No. 2 intake valves .
REPAIR 11. Repeat steps 4-7.

VALVE LIFT MEASUREMENT TIMING GEAR COVER REMOVAL

NOTE: For a more accurate measurement, measure 1. Drain oil from engine crankcase .
valve lift at 0.00 mm (in.) rocker arm-to-valve
tip clearance.

1. Remove rocker arm cover .

2. Lock No. 1 piston at TDC compression stroke .
3. Set rocker arm-to-valve tip clearance to 0.00 mm
(in.) for No. 1 and 2 exhaust, and No. 1 and 3
intake valves.
(See Valve Adjustment section for valve locations.)

RG6308

M63297

2. Remove fan, fan belt, and water pump. (See

Cooling Section.)
3. Remove alternator, and alternator mounting
bracket.
4. Remove crankshaft pulley .
5. Remove oil pan.

4. Place dial indicator tip on top of valve spring

retainer or rotator. Preload indicator tip and set dial M63298
at 0.0 mm (in.).
5. Remove timing pin from flywheel and manually
rotate engine one full revolution (36 0°) in running
direction.
6. Observe dial indicator reading as valve is moved to
full open. Record maximum reading and compare
with specifications given below .

Valve Lift Specification

(At 0.00 mm (in.) Valve Clearance)
Intake Valves . . . . . . 11.56-12.37 mm (0.455-0.487 in. )
Wear Limit . . . . . . . . . . . . . . . . 11.13 mm (0.438 in.)

Exhaust Valves. . . . . 11.28-12.12 mm (0.444-0.477 in. )

Wear Limit . . . . . . . . . . . . . . . . 10.85 mm (0.427 in.)
6. Unscrew oil pressure regulating valve plug and
7. If valve lift is within specifications, adjust valve remove spring and valve .
clearance as specified in Valve Clearance 7. Remove timing gear cover-to-cylinder block cap
Adjustment Section. screws and nuts. Remove cover .
8. If valve lift on one or more valves is not within
specification, remove and inspect entire valve train
and camshaft.
9. Rotate engine one full revolution (36 0°). Lock
engine at TDC of No. 1 exhaust stroke .

3 - 78 4/13/95
CAMSHAFT AND TIMING GEAR REPAIR DIESEL ENGINE

Idler Gear End Play Specifications

Idler Gear End Play . . .0.14-0.29 mm (0.006-0.012 in. )

Wear Limit . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)

2. If idler gear end play does not meet specifications,

check idler gear, idler shaft, and thrust washer for
wear. (See Idler Gear Bushing and Shaft
Measurement Section.)

TIMING GEAR BACKLASH

MEASUREMENT
RG6314 1. Rotate engine to remove any play in gear train .
2. Place magnetic dial indicator with tip at right angle
to helical gear being checked. Zero gauge .
8. Remove Woodruff key (C), and oil slinger (B) from
crankshaft.
A
B
CAMSHAFT END PLAY
MEASUREMENT
D

M76141

3. Measure timing gear backlash. Compare against

T90982 the following specifications :

Helical Timing Gear Backlash Specifications

1. Using magnetic dial indicator, measure idler gear
end play.
Camshaft End Play Specifications
Camshaft end play . . . .0.08-0.23 mm (0.003-0.009 in. )
Wear Limit . . . . . . . . . . . . . . . . . 0.38 mm (0.015 in.)
If end play is excessive, check thrust plate thickness
with camshaft removed. (See Camshaft Thrust Plate
Clearance Measurement Section.)
Camshaft-to-Upper
Idler (A) . . . . . . . . . . . . 0.07-0.35 mm (0.003-0.014 in. )
Wear Limit . . . . . . . . . . . . . . . . . 0.51 mm (0.020 in.)
Injection Pump-to-Uppe r
Idler (B) . . . . . . . . . . . . 0.07-0.35 mm (0.003-0.014 in. )
Wear Limit . . . . . . . . . . . . . . . . . 0.51 mm (0.020 In.)
Upper Idler-to-
Crankshaft (C) . . . . . . . 0.07-0.30 mm (0.003-0.012 in. )
Wear Limit . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)

IDLER GEAR END PLAY Crankshaft-to-Lower

MEASUREMENT Idler (D) . . . . . . . . . . . . 0.07-0.35 mm (0.003-0.014 in. )
Wear Limit . . . . . . . . . . . . . . . . . 0.51 mm (0.020 in.)
1. Using magnetic dial indicator, check end play of
upper and lower idler gears . Oil Pump-to-Lower
Idler (F). . . . . . . . . . . . 0.04-0.36 mm (0.0016-0.015 in. )
Wear Limit . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)

4/13/95 3 - 79
DIESEL ENGINE
CAMSHAFT REMOVAL
1. Measure valve lift. (See Valve Lift Measurement
Section.)
2. Remove rocker arm assembly and push rods .
NOTE: If camshaft lobes show excessive wear,
remove cylinder head so camshaft followers
can be removed. (See Cylinder Head Removal
Section.)
3. Remove timing gear cover. (See Remove timing
Gear Cover, earlier in this group. )
4. Remove camshaft activated fuel supply pump .
T90983
5. Turn crankshaft until cap screws (A) can be
removed.
6. Turn engine front side up and hold camshaft
followers away form camshaft lobes with
D15001NU Magnetic Holding Set .
IMPORTANT: DO NOT allow camshaft lobes to
drag on camshaft bushing or honed camshaft
bore surfaces.
T81258
7. Pull camshaft straight up, out of cylinder block.
Remove thrust plate.
3 - 80
CAMSHAFT AND TIMING GEAR REPAIR
NOTE: If camshaft lobes show excessive wear,
remove cylinder head so camshaft followers
can be removed. (See Cylinder Head Removal
Section.)
CAMSHAFT INSPECTION
1. Clean camshaft in solvent. Dry with compressed air .
A B A
RG3500
2. Inspect camshaft lobes (A) and journals (B) for
wear or damage. Replace as necessary. New
camshaft followers can be used with old camshaft.
DO NOT use old camshaft followers with a new
camshaft. (See Camshaft Follower Replacement
Section.)
NOTE: Very light score marks are acceptable if valve
lift is within specification. Pitting or galling is
unacceptable. (See Valve Lift Measurement
Section.)
CAMSHAFT THRUST PLATE
CLEARANCE
T81261
1. Clean camshaft thrust plate and check clearance
using a feeler gauge. Replace parts as necessary .
4/13/95
CAMSHAFT AND TIMING GEAR REPAIR DIESEL ENGINE

Camshaft Thrust Plate Clearance Specifications CAMSHAFT LOBE MEASUREMEN T

Camshaft Thrust Plate
Clearance. . . . . . . . . . . 0.08-0.23 mm (0.003-0.009 in. )
Wear Limit . . . . . . . . . . . . . . . . . 0.38 mm (0.015 in.)

NOTE: Thrust plate clearance determines camshaft

end play.

CAMSHAFT BEARING
MEASUREMENT

T81262

1. Measure each camshaft lobe at highest point and at

narrowest point. The difference between these
dimensions is camshaft lobe height. If height is not
correct on any lobe, install a new camshaft .

Camshaft Lobe Height Specifications

T81260 Intake Lobe Height . . . .6.93-7.42 mm (0.273-0.292 in. )

Wear Limit . . . . . . . . . . . . . . . . . 6.68mm (0.263 in.)

1. Measure camshaft journals. If a camshaft journal is Exhaust Lobe

damaged or does not meet specification, install a Height. . . . . . . . . . . . . . 6.76-7.26 mm (0.266-0.268 in. )
new camshaft. Wear Limit . . . . . . . . . . . . . . . . . 6.50 mm (0.256 in.)
2. Measure camshaft bore ID in cylinder block. If
camshaft bore is damaged or is not within
specification, install a new cylinder block or short CAMSHAFT GEAR REPLACEMEN T
block assembly.

NOTE: If No. 1 camshaft bushing ID does not meet IMPORTANT: Camshaft must be replaced if
specifications, replace camshaft bushing. (See dropped or damaged, do not allow camshaft to
Camshaft Bushing Replacement.) strike floor when removing gear.

Camshaft Bearing Bore and Journal Specifications

Camshaft Journal
OD . . . . . . . . . . 55.872-55.898 mm (2.1997-2.2007 in. )
Wear Limit . . . . . . . . . . . . . . . . 55.85 mm (2.199 in.)

Camshaft Cylinder Block Bore (Excep t

No.1 Bore) . . . . . . 55.986-56.012 mm (2.2042-2.2052 )

No. 1 Camshaft Bushing I D

(Installed) . . . . .55.948-56.000 mm (2.2026-2.2047 in. )

Camshaft Journal-to-Bore Clearance (Except No. 1 T88696

Camshaft Bore) . . . . . . 0.10-0.15 mm (0.004-0.006 in. )
Wear Limit . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
1. Press camshaft out of gear .
No. 1 Bushing-to-Camshaf t 2. Inspect cam journals for nicks and scratches.
Journal Clearance . . . .0.05-0.13 mm (0.002-0.005 in. ) Replace camshaft if damage is found .
Wear Limit . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)

4/13/95 3 - 81
DIESEL ENGINE CAMSHAFT AND TIMING GEAR REPAIR

3. Apply TY6333 grease to camshaft nose and gear ID Camshaft Follower and Bore Specifications
to ease installation.
4. Install Woodruff key in camshaft nose . Camshaft Follower
OD . . . . . . . . . . . . . . 31.61-31.64 mm (1.245-1.246 in. )

Camshaft Follower Bore I D

in Block. . . . . . . . . . . 31.70-31.75 mm (1.248-1.250 in. )

CAMSHAFT BUSHING
REPLACEMENT
Use JDG739 Camshaft Bushing Service Set to remove
and install camshaft bushing from No. 1 camshaft bore .

T88697 IMPORTANT: Block must be replaced if camshaft

bore is damaged. Be careful when removing or
installing bushing.
5. Install gear with timing mark (A) away from
camshaft (towards front timing gear cover). Press
gear onto camshaft with a tubular driver until gear
bottoms against camshaft shoulder .

CAMSHAFT FOLLOWER
INSPECTION
NOTE: Cylinder head must be removed before
camshaft followers can be removed from
engine.

RG6325

1. Assemble threaded spacers (A), and forcing plate

(B) to cylinder block so plate is centered over
camshaft bore. Tighten spacers and nuts securely .
2. Insert bushing puller (C) into camshaft bore so
puller pilots in bushing.

IMPORTANT: Cylinder block bore may be damaged

RG6324 if puller is not properly piloted in bushing. Be
sure puller is properly piloted before pulling
bushing.
1. Inspect followers for uneven wear or damage. Also
inspect corresponding camshaft lobe for wear or
damage. Replace as necessary .
2. Measure follower OD and follower bore ID in
cylinder block. Replace cam followers that are not
within specification. Replace cylinder block if any
one cam follower bore is not within specification .

3 - 82 4/13/95
CAMSHAFT AND TIMING GEAR REPAIR DIESEL ENGINE

RG6326
RG6328

3. Install thrust washer and hex nut. Tighten hex nut
until bushing is free of block bore. Remove puller
and discard bushing.
4. Clean and inspect bore in cylinder block. If bore is
damaged, replace the cylinder block .
8. Remove bushing tool from cylinder block and check
oil supply hole (F) for correct alignment. If holes
are not aligned, remove and discard bushing.
Install a new bushing.

IMPORTANT: Bushing must be installed so oil

FRONT PLATE REMOVAL
supply hole aligns with oil drilling in block bore. Before the front plate can be removed, the following
components must first be removed :

5. Mark orientation of oil supply hole on front face of -Oil pressure regulating valv e
block to help with bushing alignment during -Timing gear cover
installation. -Camshaft and gear
-Injection pump drive gea r
-Injection pump
-Oil pump drive gear
-Oil pump
-Idler gears

T90986

RG6327

6. Apply TY6333 grease to ID and OD of new bushing

(D), and ID of bushing bore. Slide bushing onto
driver (E) so notched end of bushing will be toward
front end of engine when installed .
7. Thread forcing screw into forcing plate. With
bushing started square in bore and oil hole
aligned, tighten forcing screw until flange of
bushing driver bottoms against face of block .
1. Remove five countersunk, flathead screws and
remove front plate.

4/13/95 3 - 83
DIESEL ENGINE CAMSHAFT AND TIMING GEAR REPAIR

Oil Clearance
T87436 Upper Idler . . . . . . . . . . 0.02-0.10 mm (0.001-0.004 in. )
Wear Limit . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)

Lower Idler . . . . . . . . . . 0.02-0.10 mm (0.001-0.004 in. )

Wear Limit . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)

Gear Hub Width . . . .21.98-22.03 mm (0.865-0.867 in. )

Wear Limit . . . . . . . . . . . . . . . . 21.93 mm (0.863 in.)

Shaft Hub Width . . . .22.17-22.27 mm (0.873-0.877 in. )

End Play . . . . . . . . . . . . 0.14-0.29 mm (0.006-0.012 in. )

Wear Limit . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)

2. If idler gear end play, measured earlier in this

2. Remove oil bypass valve and spring .
section, was out of specification, remove idler
shaft and thrust washer from front plate. (See Idler
Shaft Removal Section.)
MEASURE IDLER GEAR BUSHING
3. Check thrust washer for wear .
AND SHAFT 4. Measure idler gear hub width and shaft width.
Replace worn parts.
T81347

1. Measure Idler Gear Bushing ID And Shaft OD to

determine oil clearance. If oil clearance exceeds
specification, replace worn parts .

Idler Gear, Bushing, and

Shaft Specifications (New Parts)

Idler Bushing ID:

Upper Idler . . . . . . . . 44.49-44.54 mm (1.751-1.753 in. )
Wear Limit . . . . . . . . . . . . . . . . 44.56 mm (1.754 in.)
Lower Idler . . . . . . . . 44.49-44.54 mm (1.751-1.753 in. )
Wear Limit . . . . . . . . . . . . . . . . 44.56 mm (1.754 in.)

Idler Shaft OD:

Upper Idler . . . . . . . . 44.44-44.47 mm (1.750-1.751 in. )
Wear Limit . . . . . . . . . . . . . . . . 44.40 mm (1.748 in.)
Lower Idler . . . . . . . . 44.44-44.47 mm (1.750-1.751 in. )
Wear Limit . . . . . . . . . . . . . . . . 44.40 mm (1.748 in.)

3 - 84 4/13/95
CAMSHAFT AND TIMING GEAR REPAIR DIESEL ENGINE

IDLER GEAR BUSHING IDLER GEAR SHAFT REMOVAL

REPLACEMENT

T88704

T88701

1. Remove lower idler shaft and thrust washer by

1. Press worn idler gear bushing out of idler gear . driving or pressing on shaft from cylinder block
side of front plate.
2. Remove upper idler shaft and thrust washer by
IMPORTANT: Bushing failure will result if upper driving or pressing on shaft from cylinder block
and lower bushings are interchanged. Lower side of front plate.
idler gear bushings are splash lubricated and 3. Clean and inspect front plate for damage .
have a spiral oil groove; upper idler gear
bushings are pressure lubricated and DO NOT
have oil grooves.
ENGINE FRONT PLATE
REPLACEMENT
NOTE: Installing the wrong front plate will result in
inability to properly time the fuel injection
pump.

IMPORTANT: Replacement front plates do not have

a reference timing mark for the fuel injection
pump. The timing mark must be transferred
from existing front plate. See Fuel System
Section for instructions.

T88702 NOTE: Apply LOCTITE 242 (TY9370) Thread Lock

and Sealer to studs and set screw plugs before
installing in front plate.
2. Coat I.D. and O.D. of idler gear bushing and I.D. of
gear with TY6333 grease. Install bushing into idler
gear using JD252 Driver and JDG537 (OTC815)
Handle.

4/13/95 3 - 85
DIESEL ENGINE CAMSHAFT AND TIMING GEAR REPAIR

T88706

RG6265a
2. Press shaft into front plate until thrust washer is
fully seated. Spring pin (B) must be located in
1. Install injection pump mounting studs in front plate thrust washer notch (C) .
holes (A).
2. Install set screw plugs in ALL threaded holes not LOWER IDLER SHAFT INSTALLATION
used for mounting studs .
3. Accurately transfer injection pump timing mark from
original front plate onto replacement plate. (See IMPORTANT: ALWAYS discard and replace hex
Injection Pump Timing Mark Transfer in the Fuel head screw and lock nut whenever removed.
System Section.)
4. Install front plate. (See Engine Front Plate
Installation Section.)

IDLER SHAFT INSTALLATION

UPPER IDLER SHAFT INSTALLATION

IMPORTANT: Oil holes in idler shaft must be

properly indexed to provide adequate
lubrication to idler gear bushing.

RG5592

Install thrust washer (A) and lower idler shaft with

spring pin (B). Drive shaft into plate (C) until thrust
washer is fully seated.

RG6459

1. Install upper idler shaft into front plate so oil hole is

located at 12 O’clock position (toward top of front
plate).

3 - 86 4/13/95
CAMSHAFT AND TIMING GEAR REPAIR DIESEL ENGINE

INSTALL ENGINE FRONT PLATE

T88699
T87436

5. Check injection pump gear timing with JD 254

1. Install oil bypass valve and spring .
2. Apply LOCTITE 242 (TY9370) Thread Lock and
Sealer to cylinder block side of new gasket .
3. Install gasket and front plate .
Timing Tool resting on nose of crankshaft and
center of injection pump shaft. Timing mark (A),
with No. “3” beside it, must align with timing tool
(as shown).

T81348 IMPORTANT: The timing mark corresponds to the

number of cylinders. Injection pump cannot be
timed correctly unless No. 3 mark is used.

CAMSHAFT INSTALLATION
1. Lubricate camshaft bearing journals, lobes, and
followers with TY6333 high-temperature grease .

IMPORTANT: DO NOT allow camshaft lobes to

drag on camshaft bore or bushing surfaces
while installing camshaft. Bearing surfaces may
become scratched or scored. Rotate camshaft
during installation to avoid obstruction in any
bore.
4. Inspect external-tooth (star) washers. Replace as
necessary. Install washers on screws and tighten
screws to 34 N•m (25 lb-ft).

IMPORTANT: Do not cut off protruding edge of

gasket until timing gear cover has been
installed and tightened.

FUEL INJECTION PUMP

INSTALLATION
1. Lock engine with No. 1 piston at TDC compression
stroke.
2. Install fuel injection pump on front plate. Tighten
T94700
injection pump-to-front plate hex nuts to 27 N•m
(20 lb-ft).
3. Install fuel injection pump drive gear and new
retaining nut. Time injection pump to engine. (See 2. Install camshaft and thrust plate in cylinder block.
Injection Pump Timing in Fuel System Section.) Be careful not to damage bushing I.D. on No. 1
4. Tighten drive gear retaining nut to 200 N•m (150 lb- journal.
ft).

4/13/95 3 - 87
DIESEL ENGINE
3. Install thrust plate cap screws and tighten to 47
N•m (35 lb-ft).
T88698
4. With JD254 Timing Tool resting on nose of
crankshaft and center of camshaft (as shown), turn
camshaft until timing mark (A) aligns with timing
tool.
IDLER GEAR INSTALLATION
RG6348
1. Lubricate upper idler gear bushing I.D. and shaft
O.D. with TY6333 grease. Install idler gear without
turning camshaft gear or injection pump gear .
2. Recheck camshaft and injection pump gear timing
to make sure it did not change .
3 - 88
CAMSHAFT AND TIMING GEAR REPAIR
RG6333
3. Install thrust washer and cap screw. Tighten cap
screw to 100 N•m (75 lb-ft).
TIMING GEAR COVER CLEANING
AND INSPECTION
1. Drive crankshaft front oil seal out of cover .
2. Remove old sealant from cylinder block and timing
gear cover gasket surfaces. If necessary, remove
three small cover plates from front of timing gear
cover and remove old gasket. Clean bottom flange
of timing gear cover where it contacts oil pa n
3. Clean cover in solvent. Dry with compressed air .
4. Inspect cover for cracks or damage. Make sure seal
bore is clean and free of nicks .
TIMING GEAR COVER
INSTALLATION
1. Make sure gasket surfaces on timing gear cover
and front plate are clean .
RG4923
2. Install oil slinger (bold arrow) on crankshaft so
concave side faces away from crankshaft gear .
4/13/95
LUBRICATION SYSTEM DIESEL ENGINE

3. Install Woodruff Key in crankshaft slot . 9. Install rocker arm cover and new gasket .
4. Apply a light coating of TY15130 non-hardening 10. Perform engine break-in .
sealant to cylinder block side of new timing cover
gasket. Position gasket on front plate .
5. Install timing gear cover on engine . LUBRICATION SYSTEM
6. Install alternator mounting bracket, and oil cooler
coolant hose retaining clamp. Tighten screws to 47
N•m (35 lb-ft) on aluminum covers. OIL COOLER REPAIR

CRANKSHAFT FRONT OIL SEAL OIL COOLER REMOVAL

INSTALLATION
NOTE: Replacement seal housing is coated with dry A
sealant, DO NOT apply additional sealant.

M76110

1. Drain Coolant. (See Cooling System Section.)

2. Loosen hose clamps and disconnect coolant hoses
from oil cooler.
RG6341 3. Remove oil filter and adapter (A) to remove oil
cooler.

1. With timing gear cover installed, use KJD10164
Seal Installer to install front oil seal in timing gear
cover until seal bottoms in seal bore .
2. Remove tool and apply a light coating of engine oil
to inside lip of oil seal.
IMPORTANT: If engine oil was contaminated with
metallic particles, discard oil cooler (puncture
to prevent accidental reuse) and install a new
one.

4. Check coolant passage through oil cooler for

FINAL ASSEMBLY restrictions (use compressed air and blow through
coolant passage).
1. If a new front plate-to-engine block gasket was
installed, trim off protruding portion and apply
sealant.
2. Install oil pan. (See Oil Pan Installation Section in
Lubrication Group.)
3. Install pulley on crankshaft. Install oil pressure
regulating valve assembly .
4. Install fuel pump. (See Fuel System Section.)
5. Remove cam follower lifting tools (if used for
camshaft removal).
6. Install push rods and rocker arm assembly. (See
Cylinder Head Repair.)
7. Install alternator, fan belts, and fan .
8. Fill engine crankcase with clean oil having correct
viscosity and grade specifications.

4/13/95 3 - 89
DIESEL ENGINE LUBRICATION SYSTEM

2. Check free length of spring .

A
3. Check valve cone for excessive wear and damaged
sealing face.
4. Inspect valve seat in block for wear or damage. To
remove seat, pull out of cylinder block with
JT01727 Collet and JT01718 slide hammer from
D01061AA Blind-Hole Puller Set, or equivalent .

IMPORTANT: DO NOT drive against raised inner

rim of valve seat so that valve seat bore is not
damaged.

5. Drive new valve seat into cylinder block with

JD248A Oil Pressure Relief Valve Bushing Driver
M76107 and OTC813 Handle until the seat bottoms .
6. Install valve, spring, washer, and plug in timing gear
cover. Tighten plug to 95 N•m (70 lb-ft).
5. Remove and inspect oil cooler relief valve (A) .
6. Install relief valve. OIL FILTER NIPPLE REPAIR

OIL COOLER INSTALLATION OIL FILTER NIPPLE REMOVAL:

1. Install oil cooler on cylinder block using a new 1. Remove engine oil filter, oil filter adapter, and oil
packing. Tighten oil filter adaptor to 37 N•m (27 lb- cooler.
ft).
2. Inspect coolant hoses. Replace if cracked or
damaged.
3. Install hoses and clamps on oil cooler pipes .
4. Install a new oil filter.
5. Fill cooling system.
Install front plate and timing gear cover as described A
earlier in Camshaft and Timing Gear Repair Section.
B

OIL PRESSURE REGULATING

VALVE & SEAT REPAIR

M76106

2. Fill Holes (A) and (B) with grease to catch shavings .

3. Thread ID of nipple with appropriate size tap .
4. Install cap screw into tapped hole. Use slide
hammer to remove nipple .
5. Clean grease and shavings from both holes .
6. Put the new oil filter nipple over its bore in the
cylinder block so hole (B) is as close to hole (A) as
possible.

M63298

1. Remove oil pressure regulating valve assembly

from front timing cover of engine .

3 - 90 4/13/95
LUBRICATION SYSTEM DIESEL ENGINE

OIL PUMP REPAIR

OIL PUMP REMOVAL

1. Drain oil and disconnect turbocharger oil inlet line at
the turbocharger.
2. Remove oil pan. Remove gasket from oil pan and
pan rail.

T79808

7. Using a tubular driver (1), push the oil filter nipple

into the cylinder block until it is flush with the block
surface.
8. Install oil cooler (with new packing), and oil filter
adapter. Torque oil filter adapter to specification .
9. Install oil filter.
T81790

DIPSTICK REPAIR
3. Remove shaft nut and pull drive gear from oil pump
shaft.

NOTE: If a suitable puller is not available, loosen nut

several turns and apply force between the front
plate and gear on two sides of gear with small
pry bars. Strike the nut on end of shaft with a
lead hammer while applying force to gear until
gear is free of tapered shaft.

4. Remove the 3 oil pump-to-front plate Torx head

capscrews.

RG5599

1. Loosen lock nut (A) and screw dipstick nipple (B) B

out of cylinder block.
2. Replace dipstick nipple if damaged .
3. With lock nut installed on dipstick nipple, screw
nipple into block until nipple is at correct height.
Tighten lock nut.
4. Check dipstick calibration. Adjust nipple height as A
required.
5. Adjust dipstick nipple as follows :
• Drain crankcase and replace filter .
M76146
• Fill crankcase with 8 Liters (8.45 qts.) of new oil .
• Run engine to circulate oil .
• Stop engine and allow oil to drain back to oil pan . 5. Remove oil pump cover (A) and outlet tube (B) .
• Adjust dipstick nipple so oil level is at full mark on
dipstick.

4/13/95 3 - 91
DIESEL ENGINE
T92915
6. Remove O-ring from outlet tube bore in block .
7. Remove pump assembly from front plate .
OIL PUMP INSPECTION AND MEASUREMENT
1. Inspect oil pump components for excessive wear.
Replace parts or oil pump assembly, as necessary .
T81779
2. Check gear-to-pump cover axial clearance .
Oil Pump Axial Clearance Specifications
Thickness of
Rotors . . . . . . . 41.156-41.206 mm (1.6203-1.6223 in. )
Wear Limit . . . . . . . . . . . . . . 41.106 mm (1.6183 in.)
Axial Clearance . . 0.031-0.157 mm (0.0012-0.0062 in. )
Wear Limit . . . . . . . . . . . . . . . . 0.22 mm (0.0085 in.)
3 - 92
LUBRICATION SYSTEM
T81780
3. Check gear-to-pump housing radial clearance .
Oil Pump Radial Clearance Specifications
Radial Clearance . . . . .0.10-0.16 mm (0.004-0.006 in. )
Wear Limit . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
T81953
4. Check housing bore ID .
Oil Pump Housing Bore Specifications
Bore ID
(In Housing) . . .16.059-16.083 mm (0.6322-0.0332 in. )
Wear Limit . . . . . . . . . . . . . . 16.163 mm (0.6362 in. )
4/13/95
LUBRICATION SYSTEM DIESEL ENGINE

M76108
T91265

3. Remove O-ring (A) from pickup tube .

5. Check oil pump shaft OD .
Oil Pump Drive Shaft Specifications
Drive Shaft
OD . . . . . . . . . . 16.022-16.032 mm (0.6308-0.6312 in. )
Wear Limit . . . . . . . . . . . . . . 15.997 mm (0.6298 in.)
Idler Shaft
OD . . . . . . . . . . 12.319-12.329 mm (0.4850-0.4854 in. )
Wear Limit . . . . . . . . . . . . . . 12.306 mm (0.4845 in.)
4. Clean all oil pump parts in solvent. Use compressed
air to dry parts.
5. Inspect pickup tube. Check flange-to-tube weld for
cracks. If cracks or other defects are found,
replace pickup tube.
OIL PUMP ASSEMBLY
IMPORTANT: Lubricate oil pump rotors and shaft
with clean engine oil before assembling.

OIL PUMP DISASSEMBLY 1. Install new O-ring for outlet tube in oil pump cover .
2. Install drive rotor and driven rotor in pump housing .

NOTE: Rotors must turn freely in housing.

3. Install outlet tube in pump cover .

OIL PUMP INSTALLATION

NOTE: This procedure is for installing the oil pump

with timing gear cover installed. If timing gear
cover is removed from the engine, refer to
T81791 Timing Gear Installation Section.

1. Remove outlet tube from cover .

2. Remove and discard O-ring .

4/13/95 3 - 93
DIESEL ENGINE LUBRICATION SYSTEM

OIL PAN INSTALLATION

1. Clean all old sealant from oil pan and engine rail .
2. Apply Permatex Aviation (Form-a-Gasket No. 3) or
Loctite 518 Flexible Sealant on oil pan rail where
engine rear plate, front plate, and timing gear
cover attach to cylinder block .

T92915

1. Install a new O-ring in cylinder block for oil pump

outlet tube.
2. Install a new O-ring on oil intake pickup tube .
3. Install one end of pickup tube into block, and other M76121
end into oil pump housing .
4. Install pump housing on front plate (no rotors
installed) and adjust pickup tube length so housing 3. Select and install gasket shown above from engine
mounting holes line up with front plate holes . gasket kit.
5. Install oil pump drive gear so it meshes with idler
gear WITHOUT altering the position of the timing
gears.
6. While holding drive gear in place, install oil pump
drive shaft and rotor through pump housing and
into taper on drive gear hub .
7. Install driven oil pump rotor into housing .
8. Install pump cover with outlet tube and pickup tube .
9. Install the pump-to-front plate cap screws and
tighten to 47 N•m (35 lb-ft).
10. Rotate oil pump shaft by hand to be sure it turns
easily.
11. Install and tighten hex nut to 54 N•m (40 lb-ft).

RG6424

4. Install oil pan with bolt holes aligned. Install all

spacer washers, flat washers and capscrews hand
tight.

T81782

12. Stake nut to shaft by applying three center punch

marks near ID of the nut .

3 - 94 4/13/95
COOLING SYSTEM DIESEL ENGINE

COOLING SYSTEM
19

18
20 21 1 22 23 24 3 COOLING SYSTEM TESTING
4

17 5

16 6
c CAUTION
7 Explosive release of fluids from pressurized
15 cooling system can cause serious burns. Do not
13 12 2 11 10 9 8 drain coolant until coolant temperature is below
14
operating temperature. Always loosen radiator
cap and drain valve slowly to relieve pressure.
RG6424

5. Tightening oil pan bolts to specifications in
sequence shown.
IMPORTANT: Do not overtighten the oil pan-to-
timing gear cover cap screws.
Oil Pan Bolt Torques:
Oil Pan-to-Block . . . . . . . . . . . . . . . . . 47 N•m (35 lb-ft.)
Oil Pan-to-Rear Engine Plate . . . . . . . 47 N•m (35 lb-ft.)
Oil Pan-to-Timing Gear Cover . . . . . . 37 N•m (27 lb-ft.)
OIL PAN DRAIN PLUG
1. Visually inspect cooling system for leaks in areas
around water manifold, water pump, radiator,
expansion plugs, cylinder head gasket, oil cooler,
and coolant temperature sensor .
2. Check radiator hoses for spongy or cracked rubber,
loose clamps, or leakage .
3. Test cooling system using D05104ST Cooling
System Pressure Tester to determine source of
leaks while engine is cool .
4. Inspect water pump drive belt for glazing or wear.
Test tension with gauge or use ruler and
straightedge to check amount of deflection .
THERMOSTAT REMOVAL &
TESTING
1. Drain coolant from system only after system
pressure has been released. Remove radiator cap
slowly. Place 5 gallon container under radiator and
open drain valve.
2. Remove thermostat housing and thermostat .
3. Test thermostat by placing in hot water (with a
thermometer) and noting opening and closing
temperatures. Thermostat should begin opening at
82° C (181° F). Replace if defective .
4. Remove gasket material from gasket surfaces.
Clean and inspect housing for cracks or damage .

T81958

1. Install aluminum washer on drain plug with raised

center against plug. Install plug in oil pan. Tighten
to 70 N•m (50 lb-ft).
2. Fill engine crankcase with correct grade and
viscosity engine oil.

4/13/95 3 - 95
DIESEL ENGINE COOLING SYSTEM

2. Remove thermostat housing and thermostat. (See

Thermostat Removal & Testing Section.)
3. Remove water pump-to-water manifold bypass
hose.

A
M76175

4. Remove water manifold-to-cylinder head cap

screws (A).
5. Clean gasket face of block and water manifold .
6. Install housing with new gasket onto cylinder head.
Tighten cap screws to 47 N•m (35 lb-ft).
M76116 7. Install thermostat and thermostat housing. (See
Thermostat Removal & Testing Section.)
8. Connect upper radiator hose to thermostat housing .
5. Install thermostat in stepped seat of water neck with 9. Fill cooling system. Air must be expelled when
new gasket on top. Torque cover cap screws to 34 refilled. Loosen temperature sending unit fitting at
N•m (25 lb-ft). rear of cylinder head to allow air to escape when
filling system. Tighten plug when all the air has
been expelled.
IMPORTANT: Air must be expelled from cooling
10. Test system for leaks. (See Cooling System Testing
system when filling. Remove temperature
Section.)
sending unit fitting in cylinder head to allow air
to escape when filling system. Replace fitting
when all air has been expelled.
WATER PUMP REPAIR
WATER MANIFOLD REMOVAL &
INSTALLATION

c CAUTION
Explosive release of fluids from pressurized
cooling system can cause serious burns. Do not
drain coolant until coolant temperature is below
operating temperature. Always loosen cooling
system filler cap, radiator cap, or drain cock
slowly to relieve pressure.

M76209
1. Drain coolant at radiator drain valve. (See
Thermostat Removal & Testing Section.)

3 - 96 4/13/95
COOLING SYSTEM DIESEL ENGINE

The water pump used on the 8875 is a low flow type,

one-piece bearing and shaft assembly, with a pressed-
on pulley and hub.

WATER PUMP REMOVAL

c CAUTION
Explosive release of fluids from pressurized
cooling system can cause serious burns. Do not
drain coolant until coolant temperature is below
operating temperature. Always loosen cooling
system filler cap, radiator cap, or drain cock M76120
slowly to relieve pressure.

1. Drain coolant. 2. Using a suitable puller, remove water pump pulley

and hub from bearing shaft .
2. Remove fan.

NOTE: If engine is not removed from frame, it is

IMPORTANT: Pressing bearing out of housing in
necessary to first remove four fan shroud
the wrong direction may result in a broken
mounting bolts and pull shroud forward over
pump housing.
fan before removing fan mounting bolts.

3. Loosen alternator and remove water pump belt .

4. Remove four inlet and outlet hoses from water
pump.
5. Remove water pump .

WATER PUMP DISASSEMBLY

M76174

3. Support water pump on pulley end of housing.

Remove the bearing and shaft from the impeller
and pump housing by pressing on impeller end of
bearing shaft with a 13 mm (0.5 in.) x 76 mm (3.0
in.) driver. Discard bearing and impeller .

RG6372 NOTE: Plastic impellers are not reusable.

1. Remove rear cover (A) and discard gasket (B) . 4. Using a suitable driver, remove water seal from
pump housing and discard .

WATER PUMP CLEANING &

INSPECTION
1. Inspect water pump housing, cover, and pulley for
wear, debris, cracks, or damage. Replace as
necessary.

4/13/95 3 - 97
DIESEL ENGINE COOLING SYSTEM

Water Pump Specifications NOTE: Be sure shaft and seal are free of grease and
debris. Do not use sealant on any portion of
Impeller Bore . . . . 15.85-15.88 mm (0.6242-0.6252 in. ) unitized seal.

Bearing Shaft OD:

Impeller End . . . . . 15.90-15.92 mm (0.6262-0.6267 in. )
Pulley End . . . . . . 18.95-18.96 mm (0.7460-0.7465 in. )
Pulley/Hub Bore . . 18.91-18.93 mm (0.7445-0.7455 in. )
2. Clean parts with solvent, dry with compressed air .
3. Clean out weep hole. Remove gasket material from
water pump housing and cover .
10. Place pump housing in press with support under
WATER PUMP ASSEMBLY
1. Place pump housing with impeller side down on
arbor press.
7. Place seal (A) on pump shaft as shown. Place
installation tool (C), (included in seal kit), over
seal.
8. Support water pump on nose of pump housing (use
washer from step 2). Drive water pump seal onto
shaft until seal bottoms on shoulder (D) of
housing. (Installation tool installs seal to correct
height.)
9. Remove pump from press. Place impeller on end of
pump shaft.
pulley end of shaft.

NOTE: Bearing shaft is installed from pulley end of

pump housing.

2. Place a large flat washer over pulley end of new

bearing. Check washer to make sure it does not
contact protruding-type bearing seals. (Washer will
act as a stop on pump housing when pressing
bearing into housing.)
RG6282

IMPORTANT: Do not push against end of bearing

shaft. Push against outer race only. 11. Using special tool JD262A, press impeller onto
pump shaft until impeller rotor surface is 0.0-0.25
mm (0.0-0.1 in.) below face of pump mounting
3. Place JD262A driver over pump shaft and onto
flange (gasket removed) .
washer.
4. Press bearing into pump housing until washer
bottoms against nose of housing .
5. Remove pump from press .

137 mm

RG5596
RG6376

12. Place water pump pulley on base of press. Place

6. The water pump has a unitized (one-piece) water pump on pulley with shaft over pulley bore. Using
seal (A).
a 3/8 in. driver in arbor of press, drive on impeller

3 - 98 4/13/95
COOLING SYSTEM DIESEL ENGINE

end of pump shaft until face of pulley is 137 mm
(5.39 in.) from mounting flange of pump (rear plate
removed).
13. Turn pulley by hand to make sure shaft turns freely .
14. Install rear cover plate using a new gasket and
TY6304 flexible sealant .
15. Tighten rear plate-to-pump housing cap screws to
47 N•m (35 lb-ft).
16. Rotate pulley and hub by hand. If impeller drags on
rear cover plate, remove cover and recheck
impeller position.
17. Install hub on pulley by using fan mounting bolts
and washers to draw hub bore onto pulley .
FAN BLADE INSPECTION AND
INSTALLATION
The 8875 engine is equipped with a blower-type fan
which pulls air from the engine top cover and pushes it
out first through the hydraulic oil cooler and then
through the radiator, and out the back of the tractor.
This provides a cleaner source of air for the loader.
Debris that does enter the engine compartment may be
trapped on the front side of the oil cooler or the front
side of the radiator. Always inspect fan blades for bent
or damaged condition. Bent blades reduce cooling
system efficiency and throw the fan out of balance.
Replace fan if blades are bent or damaged .

NOTE: If engine is installed in loader, it will be

WATER PUMP INSTALLATION necessary to install fan shroud and fan into
loader at the same time. Mount fan to pulley
before attaching shroud to frame.

1. Install fan on pulley hub. Tighten cap screws (with

washers) to 27 N•m (20 lb-ft).

M76209

1. Clean gasket surfaces. Install new gasket between

rear pump plate and block and apply TY6304
sealer. Install water pump and capscrews into
block. Torque to specifications .
2. Install water manifold (see Water Manifold Removal
And Installation Section) and thermostat housing
(see Thermostat Removal and Installation
Section).
3. Install coolant supply and return hoses, and pump
mounted brackets.
4. Install alternator (if removed) and fan belt(s). Adjust
belt tension. (See Specifications at beginning of
this group.)
5. Fill cooling system with proper coolant.

IMPORTANT: Air must be expelled from cooling

system when refilled. Loosen temperature
sending unit fitting at rear of cylinder head to
allow air to escape while filling system. Tighten
fitting when all the air has been expelled.

4/13/95 3 - 99
DIESEL ENGINE TURBOCHARGER DIAGNOSIS

TURBOCHARGER DIAGNOSIS

Problem Possible Cause Suggested Remedy

Compressor Housing Inlet Defects

Foreign Object Damage Objects left in intake syste m Disassemble and inspect intake
system for foreign object s

Inspect engine for internal damag e

Leaking and/or defective intake Inspect air intake system

system connections including air filter;
repair as required

Inspect air intake related engine

components

Compressor Wheel is Rubbin g Bearing failure Determine if engine and/or

operator contributed to lack of
lubrication, contaminated
lubrication, excessive temperature,
or debris generating engine failure
in progress. Correct as required .

Manufacturing defects Correct as required

Compressor Housing Outlet Defects

Oil and/or Dirt in Housin g Restricted air intake syste m Inspect and clean air cleane r

Prolonged periods of low RPM Check with operator to confirm

engine idling conditions (See Operator’s Manual )

Defective oil seal ring Repair as required

Restricted oil drain line Inspect and clear oil drain lin e

Turbine Housing Inlet Defects

Oil in Housing Internal engine failure Inspect and repair engine as

required

Oil leaking from compressor housing Verify that oil is in compressor

seal housing and refer to “Compressor
Housing Outlet Defects” as listed
earlier in this chart.

Center Wall Deteriorate d Excessive operating temperatur e Check for restricted air intak e

Check engine for overfuelin g

Check injection pump timin g

3 - 100 4/13/95
TURBOCHARGER DIAGNOSIS DIESEL ENGINE

TURBOCHARGER DIAGNOSIS (Cont. )

Problem Possible Cause Suggested Remedy

Turbine Housing Outlet Defects

Turbine Wheel is Rubbin g Bearing failure Determine if engine and/or

operator contributed to lack of
lubrication, contaminated
lubrication, excessive temperature,
or debris generating engine failure
in progress. Correct as required .

Manufacturing defect Correct as required

Foreign Object Damage Internal engine failure Inspect and repair engine as
required

Objects left in intake syste m Disassemble and inspect air intake

system

Leaking air intake syste m Correct as required

Oil and/or Excessive Carbo n Internal engine failure Verified by oil in turbine housing.
Correct as required

Turbine seal failure Inspect for excessive heat from

overfueling and/or restricted air
intake

Prolonged periods of low RPM Verify with operator to run engine

engine idling under load or a higher RP M

Restricted oil drain line Inspect and clear oil drain lin e

External Defects on Center Housing and Housing Joints

Leaks from Casting Defective casting Replace turbocharger

Defective gasket Verify that leaks are not occurring at

gasket joints

Leaks from joints Loose attaching screws Tighten to Specification s

Defective gasket Inspect and repair as require d

Internal Center Housing Defects

Excessive Carbon Buildup in Hot engine shutdown Review proper operation with
Housing or on Shaft operator

Excessive operating temperatur e Restricted air intake; Overfueling or

Mistimed engine

Restricted oil drain line Inspect and clean oil drain lines as
required

Operating engine at high speeds Idle engine for a few minutes to

and loads immediately after start-u p allow oil to reach bearings before
applying heavy loads

4/13/95 3 - 101
DIESEL ENGINE
TURBOCHARGER DIAGNOSIS
(Cont.)
Turbochargers are designed to last the life of the
engine, but, because they operate at such high speeds
(100,000 rpm or more); a moment’s carelessness can
cause them to fail in seconds .
The major causes of turbocharger failures are
attributed to:
• Lack of lube oil (quick starts and hot shutdowns )
• Oil contamination
• Ingestion of foreign object s
• Restricted oil drainage
• Low oil level
• Operation on excessive side slope s
• Abnormally high exhaust temperature s
Lack of Lube Oil
Oil not only lubricates the turbo’s spinning shaft and
bearings, it also carries away heat. When oil flow stops
or is reduced, heat is immediately transferred from the
hot turbine wheel to the bearings, which are also
heating up because of the increased friction due to the
lack of oil. This combination causes the turbo shaft
temperature to increase rapidly .
If oil flow does not increase and the process continues,
bearings will fail. One the bearings fail, (which can
happen in just seconds), seals, shaft, turbine and
compressor wheels can also be damaged .
The principle causes of turbo bearing lubrication
problems are low oil pressure, a bent, plugged or
undersized oil lube supply line, plugged or restricted oil
galleries in the turbo, or improper machine start-up and
shutdown procedure.
Oil levels and pressure should always be closely
monitored and all worn hoses and lines should be
replaced. The turbo supply line should be checked
frequently to make sure it is not kinked or bent and it
should always be replaced with a line of equal size,
length and strength.
The easiest way to damage a turbo is through improper
start-up and shutdown procedures. Always idle the
engine for at least 30 seconds (no load) after start-up
and before shutdown. Warming the engine up before
applying a load allows oil pressure to build up and lines
to fill with oil.
Idling the engine before shutdown allows the engine
and turbo to cool. “Hot” shutdowns can cause the turbo
to fail because after high-speed operation the turbo will
continue to rotate long after the engine has been shut
off and oil pressure has dropped to zero. This will
cause heat to build up and possible bearing damage. It
can also cause carbon and varnish deposits to form .
Oil Contamination
A second cause of turbo failure is contaminated oil. It
3 - 102
TURBOCHARGER DIAGNOSIS
can be caused by a worn or damaged oil filter or not
changing the lube oil at recommended intervals.
Expecting the oil filter to remove dirt, sand, metal chips,
etc. from the oil before they reach the engine or
turbocharger can be a costly mistake because
contaminated oil may completely bypass the engine oil
filter if the oil filter or oil cooler is clogged, if the filter
element is improperly installed, or if the oil is thick
during cold weather.
Four good ways of avoiding oil contamination are :
• Always inspect the engine thoroughly during major
overhaul. Look especially for any sludge or debris
left in lube oil galleries.
• Change lube oil at recommended intervals.
Analysis of oil samples at filter change periods can
help identify potentially harmful contaminants in
the oil.
• Clean the area around the oil fill cap before adding
oil.
• Use a clean container when adding oil .
Injestion of Foreign Objects
The third cause of turbo damage is the ingestion of
foreign objects. Foreign objects or particles can be
ingested and cause damage to the turbo on both
compressor and turbine sides. This is easy to avoid .
On the compressor side, foreign objects usually take
the form of dust, sand, or shreds of air cleaner element
that enter through improperly installed air cleaner
elements, leaky air inlet piping (loose clamps or torn
rubber joints), or torn pleats in dry-type air cleaner
elements. The result is erosion of compressor blades
that can cause the delicately balanced wheel to
wobble.
Whenever an internal engine failure (valve, valve seat,
piston) occurs, a thorough inspection of the
turbocharger MUST BE performed before returning
engine to service.
Restricted Oil Drainage
A fourth cause of turbocharger damage is restricted oil
drainage. The lubricating oil carries away heat
generated by friction of the bearings and from the hot
exhaust gases. If drainage back to the sump is
impeded, the bearings will overheat with damage that
will ultimately lead to failure .
There are two primary reasons for restricted drainage :
• A blocked drain tube, due to either damage or a
build up of oil sludge.
• High crankcase pressure, which can be due to a
restricted crankcase breather or excessive engine
blowby.
• Periodically check both the turbocharger oil drain
tube and engine breather tube for damage or
restriction.
4/13/95
TURBOCHARGER DIAGNOSIS
Abnormally High Exhaust Temperatures
A fifth cause of turbocharger damage is abnormally
high exhaust temperatures, causing coking of oil which
can lead to bearing failure. Extreme over-temperature
operation can case the turbo wheel to burst .
There are two basic causes of over-temperature :
• Restricted air flow
• Overpowering the engine.
In either case the engine has more fuel than available
air for proper combustion, this overfueled condition
leads to elevated exhaust temperatures .
Causes of restricted air flow can include damaged inlet
piping, clogged air filters, excessive exhaust restriction,
or operation at extreme altitudes.
Overpowering generally is due to improper fuel delivery
or injection timing. If over-temperature, inlet and
exhaust systems inspection should be performed. Also,
check the fuel delivery and timing .
TURBOCHARGER REMOVAL
c CAUTION
After operating engine, allow exhaust system to
cool before removal.
IMPORTANT: When cleaning turbocharger, do not
spray directly into compressor cover or turbine
housing. If turbocharger inspection is required,
do not clean exterior prior to removal. Doing so
may wash away evidence of a potential cause of
failure. Clean exterior of turbocharger and
surrounding area only enough to prevent entry
of dirt into the air intake system during removal.
M76177
4/13/95
DIESEL ENGINE
1. Remove air intake hose, exhaust clamp, and
exhaust adapter. Loosen hose clamps .
2. Disconnect oil inlet line and oil return pipe from
turbocharger.
3. Remove mounting cap screws and nuts and lift
turbocharger from exhaust manifold. Remove
stainless steel gasket.
4. Place turbocharger on a clean flat surface. Cap or
plug all air intake and exhaust openings .
TURBOCHARGER FAILURE
ANALYSIS
The following is a guide for diagnosing the cause of
turbocharger failures after removal from the engine .
TURBOCHARGER SEVEN-STEP INSPECTION
The following inspection procedure is recommended
for systematic failure analysis of a suspected failed
turbocharger. This procedure will help find when a
turbocharger has failed, and why it has failed so the
primary cause of the failure can be corrected .
Proper diagnosis of a good turbocharger is important
for two reasons. First, it will lead to further investigation
and repair of the cause of a performance complaint .
Second, proper diagnosis eliminates the unnecessary
expense incurred when a non-failed turbocharger is
replaced.
The seven recommended inspection steps, which are
explained in detail on following pages, are :
• Compressor Housing Inlet and Compressor Wheel .
• Compressor Housing Outlet .
• Turbine Housing Inlet
• Turbine Housing Outlet and Turbine Wheel .
• External Center Housing and Joints .
• Internal Center Housing .
• Turbo Bench Test.
NOTE: To enhance the turbocharger inspection, an
inspection sheet (Form No. DS-2280 available
from Distribution Service Center) lists the
inspection steps in the proper order and shows
potential failure modes for each step. Check off
each step when complete and record any
problems observed during inspection. Retain
this with the work order for future reference.
3 - 103
DIESEL ENGINE TURBOCHARGER DIAGNOSIS

Compressor Housing Inlet and Compressor Wheel Compressor Housing Outlet

RG4525
RG4523

1. Check compressor housing outlet. The outlet

1. Check compressor inlet and compressor wheel for should be clean and free of dirt or oil .
foreign object damage.
2. Mark on your checklist if dirt or oil is found and
NOTE: Foreign object damage may be extensive or continue the inspection .
minor. In either case, the source of the foreign
object must be found and corrected to Turbine Housing Inlet
eliminate further damages.

2. Mark findings on your checklist and continue the

inspection.

NOTE: You will need a good light source for the next
check.

RG4526

1. Check the turbine housing inlet ports (arrow) for oil

in housing, excessive carbon deposit or erosion of
center walls.

NOTE: If the inlet is wet with oil, or has excessive

carbon deposits, an engine problem is likely.
Center wall erosion (cracking or missing
RG4524
pieces) indicate excessive exhaust
temperature.
3. Check compressor inlet for wheel rub on the
housing (arrow). Look very closely for any score
marks on the housing itself and check the tips of
the compressor wheel blades for damage .

3 - 104 4/13/95
TURBOCHARGER DIAGNOSIS DIESEL ENGINE

Turbine Housing Outlet and Turbine Wheel External Center Housing and Joints

RG4529

RG4527

1. Visually check the outside of the center housing, all

1. Use a flashlight to look up inside the turbine connections to the compressor, and turbine
housing outlet. Check blades for foreign object housing for oil.
damage.
NOTE: If oil is present, make sure it is not coming from
RG4528 a leak at the oil supply or return line.

Internal Center Housing

2. Inspect the wheel blades and housing for evidence

of wheel rub. Wheel rub can bend the tips of the
blades with the housing showing wear or damage . RG4530

1. Using a flashlight, look through the oil return hole to

check the condition of the shaft and/or bearings.
There should not be excess carbon deposits on
the shaft or in the housing .

4/13/95 3 - 105
DIESEL ENGINE TURBOCHARGER DIAGNOSIS

3. Next, pull up on the compressor end of the shaft

and press down on the turbine end while rotating
shaft. Neither the compressor wheel nor the
turbine wheel should contact the housing at any
point.

NOTE: There will be some “play” because the

bearings inside the center housing are free
floating.

RG4531

2. Excessive “blueing” or “coking” of oil along the

complete length of the shaft indicates a possible
lack of lubrication caused by an engine failure, or
improper operation, such as hot shutdowns .

Turbo Bench Test

RG4534

4. Next, check shaft end play by moving the shaft

back and forth while rotating. There will be some
end play but not to the extent that the wheels
contact the housings.

NOTE: These diagnostic procedures will allow you to

RG4532
1. Mount the turbocharger in a soft jaw vise .
2. Rotate the shaft, using both hands, to check
rotation and clearance. The shaft should turn
freely, however, there may be a slight amount of
drag.
determine the condition of the turbocharger. If
the turbocharger has failed, analysis of your
inspection notes should direct you to the
specific areas of the engine to correct the
problems causing the turbocharger failure.
(See DIAGNOSING TURBOCHARGER
MALFUNCTIONS, outlined earlier in this
group). It is not unusual to find that a
turbocharger has not failed. If your
turbocharger passes all the inspections, the
problem lies somewhere else.

IMPORTANT: Before you finalize your conclusion

that the turbocharger has not failed, it is
strongly recommended that the following
procedures of checking radial bearing clearance
and axial bearing end play with a dial indicator
be performed. These procedures are not
required if a failure mode has already been
identified.

TURBOCHARGER BEARING
RADIAL CLEARANCE TEST
RG4533
This test will give an indication of the condition of the
radial bearings within the center housing and rotating
assembly.

3 - 106 4/13/95
TURBOCHARGER REPAIR
M76227
1. Position dial indicator with extension adapter onto
center housing so that tip rests on shaft extending
through oil return cavity.
2. Grasp rotating shaft at both ends and move the
shaft toward the indicator then away from the
indicator (arrows).
3. Observe and record total indicator reading. Bearing
clearance specification is 0.025-0.09 mm (0.003-
0.007 in.)
4. If total indicator reading is not within specification,
replace center housing and rotating assembly .
TURBOCHARGER BEARING AXIAL
END PLAY TEST
This test will give and indication of the condition of the
thrust bearing within the center housing and rotating
assembly.
M76226
4/13/95
DIESEL ENGINE
1. Mount magnetic base dial indicator so that indicator
tip rests on end of shaft. Preload indicator tip and
zero dial on indicator.
2. Move shaft axially back and forth by hand .
3. Observe and record total dial indicator reading.
Bearing end play specification is 0.025-0.09 mm
(0.001-0.0035 in.).
4. If bearing end play is not within specification,
replace center housing and rotating assembly .
TURBOCHARGER REPAIR
The turbocharger used on the 8875 is available
through Service Parts as a complete remanufactured
assembly, or as a new center housing and rotating
assembly only. When a new center housing and
rotating assembly is being installed, the turbine and
compressor housings from existing turbocharger are
reused. Inspect the turbine and compressor housing
thoroughly before installation. New mounting hardware
MUST be used.
IMPORTANT: Repairing a turbocharger center
housing and rotating assembly requires
specialized tooling and trained personnel. It is
not recommended that the turbocharger be
disassembled completely.
TURBOCHARGER DISASSEMBLY
AND INSPECTION
RG5667
1. Scribe locating marks on turbine housing (C) and
compressor housing (A) in reference to any
location (e.g. oil inlet or return) on center housing
and rotating assembly (B) .
IMPORTANT: These reference marks are essential
for proper indexing during reassembly.
3 - 107
DIESEL ENGINE
2. Remove compressor housing and turbine housing
cap screws with lock plates and clamps .
NOTE: If necessary, gently tap the turbine housing and
compressor housing with a soft hammer and
carefully remove the turbine housing from the
center housing.
3. Thoroughly clean the compressor and turbine
housings using a commercially approved solvent
only. A caustic solution may damage housings.
Dry housings with compressed air. After a part is
cleaned, place it on a clean flat surface .
Inspect turbine housing for:
• Wheel rub damage within the contour area that
cannot be polished out with 60-grit silicone carbide
abrasive cloth.
• Nicks, dents, or warpage that could prevent proper
sealing between the turbine housing and center
housing.
Inspect compressor housing for:
• Wheel rub damage within the contour area that
cannot be polished out with 60-grit silicone carbide
abrasive cloth.
• Nicks, dents, or warpage that could prevent proper
sealing between the turbine housing and center
housing.
• Corroded or stripped center housing mounting
holes.
4. Replace either housing if any one of the above
defects are found.
TURBOCHARGER CENTER
HOUSING & ROTATING ASSEMBLY
REPLACEMENT
RG5667
3 - 108
TURBOCHARGER REPAIR
1. Carefully transfer the scribed marks from the
original center housing to the replacement
assembly, if necessary. Use the same procedure
for compressor and turbine housings, if they are
being replaced.
2. Attach compressor housing (A) to center housing
and rotating assembly (B) with cap screws, lock
plates, and clamps. Tighten cap screws to 10 N•m
(7 lb-ft) initially, then to a final torque of 17 N•m
(13 lb-ft).
3. Attach turbine housing (C) to center housing and
rotating assembly. Coat threads of cap screws with
PT569 NEVER-SEEZ. Install cap screws, lock
plates, and clamps. Initially, tighten cap screws,
lock plates, and clamps. Tighten cap screws
initially to 10 N•m (7 lb-ft), then to a final torque of
26 N•m (19 lb-ft).
4. After assembly, check the center housing and
rotating assembly for binding and wheel rub. If
either condition exists, disassemble turbocharger
and correct the cause.
5. Bend ears of lock plates against heads of cap
screws.
TURBOCHARGER PRE-
LUBRICATION
IMPORTANT: DO NOT spin the rotor assembly with
compressed air. Damage to bearing can occur.
RG6303
1. Fill oil inlet or drain port with clean oil and turn
rotating assembly (by hand) to properly lubricate
bearings. If turbocharger is to be stored, lubricate
internally and install protective covers on all
openings.
INSTALL TURBOCHARGER
If not done previously, prime the turbocharger
lubrication system prior to mounting turbocharger on
the engine. Fill the center housing with new engine oil
through the oil drain hole. Turn the rotating assembly
by hand to lubricate the bearings .
4/13/95
INTAKE MANIFOLD REPAIR
B with protective rubber boot .
A
E and electrical connector .
C
M76177
1. Position turbocharger (E) and stainless steel gasket
onto mounting studs on exhaust manifold. Tighten
stud nuts to 47 N•m (35 lb-ft).
2. Install oil return pipe (C) to turbocharger. Tighten
tube connector to 80 N•m (60 lb-ft). Connect
turbocharger oil inlet line (B) and tighten to 27 N•m
(20 lb-ft).
3. Connect air inlet hose to turbocharger compressor
housing. Tighten hose clamps (A) on air inlet line .
IMPORTANT: Tighten hose connections between
air cleaner and turbocharger securely to prevent
entry of dirt into system.
4. Fit muffler to turbine outlet with retaining clamp.
Install muffler mounting capscrews to cylinder
head and torque to 47 N•m (35 lb-ft).
TURBOCHARGER BREAK-IN
IMPORTANT: A new or repaired turbocharger does
not have an adequate oil supply for engine start-
up. Perform the steps below to prevent damage
to turbocharger bearings.
1. Disconnect electrical wire to injection pump to
prevent engine from starting. Do not let wire short
to ground while loose.
2. Remove oil pressure sender from engine and
attach pressure gauge to engine oil port .
3. Set Service/Run Switch to Service position .
4. Turn ignition key switch to START position and
crank engine for 30 seconds at a time until oil
pressure gauge reads above 138 kPa (20 psi) .
IMPORTANT: DO NOT crank engine longer than 30
seconds at a time to avoid damage to starting
motor.
4/13/95
DIESEL ENGINE
5. Install electrical wire to injection pump and cover
6. Remove oil gauge and install oil pressure sender
INTAKE MANIFOLD REPAIR
IMPORTANT: All intake manifold connections at
the turbocharger and engine cylinder head must
be tight to prevent loss of power resulting from
lower manifold pressure.
Intake manifold hose and cap screw connections
should be inspected periodically for tightness .
Whenever a tune-up has been performed, or
horsepower output is low, the intake manifold pressure
(turbo boost) should be checked. (See Intake Manifold
Pressure [Turbo-boost] Test Section. )
A
C B
M76177
1. Remove engine preheat element (C) from air inlet
elbow.
2. Loosen hose clamps (A) and remove hose from
inlet elbow.
3. Remove cap screws (B) attaching air inlet elbow to
intake manifold.
4. Inspect the air inlet elbow and intake manifold for
serviceability. Replace parts as needed if cracked
or damaged.
5. Inspect the machined mating surfaces of cylinder
head and air inlet elbow. Clean as required using a
scraper, wire brush, and compressed air .
6. Install air inlet manifold with new gasket. Tighten
capscrews to 47 N•m (35 lb-ft).
7. Make sure air intake hose is in good condition.
Tighten hose clamps securely .
8. Apply thread sealer to threads of engine preheat
element and install into air inlet elbow. Reconnect
electrical lead to element .
3 - 109
DIESEL ENGINE
EXHAUST MANIFOLD REPAIR
M76176
1. Remove muffler mounting clamp from turbocharger,
and muffler mounting bolts to cylinder head .
2. Remove turbocharger. (See Turbocharger Removal
Section.)
3. Remove exhaust manifold mounting bolts and
exhaust manifold.
4. Inspect exhaust manifold for cracks and warpage.
Replace if worn or badly corroded .
NOTE: When using gaskets with one steel-backed
side, the non-steel backed side must face
towards the cylinder head.
5. Install new gasket on manifold .
6. Coat exhaust manifold attaching capscrews with
PT569 NEVER-SEEZ Compound and tighten to 47
N•m (35 lb-ft).
7. Install turbocharger. (See Turbocharger Installation
Section.)
3 - 110
EXHAUST MANIFOLD REPAIR
FUEL SYSTEM
RELIEVE FUEL SYSTEM PRESSUR E
c CAUTION
Escaping diesel fuel under pressure can have
sufficient force to penetrate the skin, causing serious
injury. Before disconnecting lines, be sure to relieve
pressure. Before applying pressure to the system,
be sure ALL connections are tight and lines, pipes
and hoses are not damaged. Deep hands and body
away from pinholes and nozzles which eject fluid
under pressure. Use a piece of cardboard or wood,
rather than hands, to search for suspected leaks .
If ANY fluid is injected into the skin, it must be
surgically removed within a few hours by a doctor
familiar with this type injury or gangrene may result.
Doctors unfamiliar with this type of injury may call
the Deere & Company Medical Department in
Moline, Illinois, or other knowledgeable medical
source.
Any time the fuel system has been opened up for
service (lines disconnected or filters removed), it will be
necessary to bleed air from the system. (See Fuel
System Bleeding Section.)
FUEL FILTER REPLACEMENT
The 8875 has two fuel filters; one plastic in-line filter
between fuel tank and pump, and one filter/separator
unit mounted on left side of engine.
4/13/95
FUEL SYSTEM DIESEL ENGINE

Water Separator/Fuel Filter used when disconnecting fittings or fuel lines to

avoid damage to fittings.

A 1. Loosen hose clamps and disconnect fuel lines at

fuel pump. Cap off connections on fuel supply
pump and fuel lines to keep debris out of fuel
B system.
2. Remove two fuel pump mounting cap screws and
remove fuel supply pump assembly from cylinder
C block.
3. Cover opening on cylinder block to prevent dirt from
entering the engine.

FUEL PUMP TESTING

Vacuum/Pressure Test

NOTE: This test will give the condition of the inlet and
outlet valves, and diaphragm. The numerical
M76237 values obtained are not as important as the
gauge needle movement. That is, very slow for
a good pump; very fast or not at all for a
1. Relieve fuel system pressure by slowly turning out defective pump.
bleed screw (A) on side of fuel filter/water
separator.
2. Firmly grasp the filter retaining ring (B) and rotate it
counterclockwise (left) 1/3 turn. Remove retaining
ring and fuel filter (C).
3. Inspect filter mounting base for cleanliness. Clean
as required.

NOTE: The fuel filter must be indexed properly and the

key on canister must be orientated in slot of
mounting base for correct installation.

4. Install new filter element onto mounting base and

position element using a slight rocking motion. Be
sure element is properly indexed on mounting
base.
5. Install retaining ring onto mounting base and tighten
about 1/3 turn until ring “snaps” into the detent DO
NOT overtighten the retaining ring .
6. Bleed the fuel system. (See Fuel System Bleeding
Section.)
Plastic In-Line Fuel Filter
1. Remove two hose clamps holding fuel line to fuel
filter.
2. Check hoses for cracks or wear .
3. Install new filter with flow arrow towards pump .
FUEL PUMP REMOVAL
IMPORTANT: A backup wrench must always be
RG5167
1. Remove inlet and outlet hoses .
2. Install 0-200 kPa (0-30 psi) vacuum/pressure
gauge to inlet side of pump (B) .
3. Move primer lever (D) all the way upward. Release
lever and at the same time observe gauge :
• The gauge needle should read the same value
each time, and then very slowly return to “0”. This
indicates that the inlet valve and diaphragm are in
good condition. Proceed to next step .
• If the gauge needle does not move at all, or the
needle rapidly returns to “0”, the pump is defective
and must be replaced.
4. Remove vacuum/pressure gauge and install onto
outlet side of pump (C) .

4/13/95 3 - 111
DIESEL ENGINE FUEL SYSTEM

5. Move priming lever all the way to upward position.
Release lever and at same time observe gauge
reading:
• The gauge needle should initially read 28-41 kPa
(4-6 psi), then return to “0” very slowly. This
indicates that the outlet valve and diaphragm are
in good condition. Supply pump is operating
properly and should be reinstalled on engine .
• If the gauge needle initially reads same value as
above and then returns immediately back to “0”,
the pump is defective and must be replaced .
Leakage Test
IMPORTANT: ALWAYS use a backup wrench when
installing fuel fittings and lines to avoid damage
to fittings.
2. Connect fuel lines and tighten securely .
3. Bleed fuel system. (See Fuel System Bleeding
Section.)
FUEL INJECTION PUMP TIMING
MARK
IMPORTANT: Replacement front plates do not have
an injection pump timing mark. It is extremely
important that the timing be accurately
transferred from original front plate to the
replacement plate in the exact location for
correct injection pump timing. It is necessary to
create a template (DFRG2) to do this correctly.

RG5589

RG5167

The leakage test should be performed if a supply pump

suspected of leaking fuel externally, or internally into
the engine crankcase.
1. Install an air line on inlet side of pump (B) and apply
140 kPa ) (20 psi) pressure.
2. Hold finger over outlet side of pump (C) or install a
plug. Submerge pump into a container of clean
diesel fuel.
• If air bubbles occur around banded connection
holding the two halves of pump together (indicating
leakage), replace pump .
• If the diaphragm is bad, there will be leakage
through vent holes and around the rocker arm.
Replace pump as necessary .

FUEL PUMP INSTALLATION

IMPORTANT: Apply LOCTITE 242 Thread Lock and
Sealer (Deere Part No. TY9370) to threads of
supply pump mounting screws when
reinstalling supply pump. DO NOT allow sealant 1. Create DFRG2 template from above specifications
to get into fuel system. from sheet aluminum or other durable material
transfer timing mark from old plate to new .

1. Install the fuel supply pump on cylinder block using

a new gasket. Tighten cap screws to 30 N•m (22
lb-ft).

3 - 112 4/13/95
FUEL SYSTEM
RG5590
1. Position DFRG2 Aluminum Template (B) onto
original front plate (C) as shown. Install and tighten
three 3/8-16 cap screws securely .
2. Transfer injection pump timing mark (A) from
previous front plate onto template using a fine tip
marker and straightedge. Remove template from
front plate being replaced .
3. Attach template (with timing mark) to new
replacement front plate and tighten cap screws
securely.
4. Transfer timing mark from the template to the new
front plate using a scribe. Scribe deep enough so
mark becomes a permanent reference .
5. Remove template from front plate. Refer to Engine
Front Plate Installation procedure.
FUEL INJECTION PUMP TIMING
The fuel injection pump on John Deere 8875 Diesel
Engine is a Stanadyne model DB2. The pump is
dynamically timed at the factory by installing a sensor
within the No. 1 fuel line, and connected to a pulse-
activated timing meter to determine precisely at what
point injection occurs. The engine front plate is
stamped with a reference mark to allow the pump to be
static timed in the field. Internal pump timing markings
will still be present on most injection pumps, but are not
used for field timing. If the engine front plate must be
replaced, transfer factory mark to new plate before
installation.
INJECTION PUMP REMOVAL
IMPORTANT: Never steam clean or pour cold water
on a fuel injection pump while the pump is
running or while it is warm. Doing so may cause
seizure of internal rotating pump parts.
4/13/95
DIESEL ENGINE
1. Clean the fuel injection pump, lines and area
around the pump with cleaning solvent or a steam
cleaner.
A
B
C
M76250
2. Disconnect throttle control linkage. Disconnect
electrical connection to shut-off solenoid. Tag
electrical wire for correct reassembly .
IMPORTANT: ALWAYS use a backup wrench when
loosening or tightening fuel lines at injection
pump so that discharge fittings are not altered
to prevent possible internal pump damage.
3. Disconnect fuel return line (A) and fuel supply line
(C).
4. Disconnect all fuel delivery (pressure) lines (B) from
injection pump using a suitable 17 mm deep-well
crowsfoot socket.
5. Remove injection pump drive gear cover. Remove
drive gear retaining nut and washer from end of
pump shaft. Be careful not to let washer fall inside
timing gear cover.
NOTE: The injection pump drive gear fits snugly onto a
tapered drive shaft and is indexed by a
Woodruff Key installed in drive shaft. Do not let
woodruff key fall into timing cover as pump is
removed.
3 - 113
DIESEL ENGINE
RG6292
6. Attach JDG670A Drive Gear Puller (A) to injection
pump drive gear as shown .
7. Evenly tighten the two 6 mm, Grade 10.9 screws
(C, threaded in gear drive) and snugly tighten
center forcing screw (B) against end of pump
shaft.
8. Tighten center forcing screw until pump gear is free
from tapered shaft. Remove JDG670 Puller and
screws from drive gear.
RG6293
9. Check to make sure that timing marks on back side
of front plate (A) and injection pump flange (B) are
present and properly aligned. This assures that
repaired or replacement pump can be properly
timed to engine when installed .
NOTE: If timing mark is not clearly visible on front
plate, scribe a visible reference mark as
accurately as possible in-line with mark on
pump flange.
10. Remove three injection pump mounting stud nuts.
Remove injection pump from mounting studs.
Place pump on a clean flat surface and inspect
shaft O.D. and drive gear. (See Injection Pump
Drive Gear And Shaft Inspection Section.)
3 - 114
FUEL SYSTEM
INJECTION PUMP DRIVE GEAR &
SHAFT INSPECTION
IMPORTANT: Use a good light source to
thoroughly inspect gear I.D. and shaft O.D.
1. Inspect injection pump drive gear I.D. a full 36 0° for
metal transfer as a result of slippage on shaft .
2. Inspect injection pump drive shaft O.D. a full 36 0°
for presence of metal transfer from gear slippage.
Also, check to see that woodruff key on shaft is not
damaged, indicating gear slippage .
3. If there is clear evidence of slippage on pump shaft
or drive gear, or if woodruff key on pump shaft is
damaged, injection pump and drive gear MUST
BE replaced.
IMPORTANT: When replacing injection pump drive
gear or installing a new pump, the tapered
surfaces of the pump drive shaft O.D. and drive
gear I.D. MUST BE cleaned to remove protective
coatings and oily residue. Use a suitable cleaner
that does not leave a residue. Mating surfaces
MUST BE ASSEMBLED DRY and LUBRICANTS
MUST NOT BE USED.
FUEL INJECTION PUMP REPAIR
IMPORTANT: Do not disassemble the fuel injection
pump further than necessary for installing
available repair parts—not even for cleaning.
Be sure that injection serial number tag (A) is in place,
and that all identification numbers are legible so pump
will be set to the correct specification if sent out for
repair.
For injection pump repair and testing, have an
authorized ADS diesel injection repair station perform
the work. Unauthorized repairs made to fuel injection
pumps will void warranty .
FUEL INJECTION PUMP
INSTALLATION
Injection pump mounting flange timing mark and front
plate timing mark presence and alignment MUST BE
verified before removing pumps from engine. When
pump is reinstalled on engine, time pump by aligning
these two (external) marks. DO NOT reference internal
timing marks (on pump cam ring and governor weight
retainer) for accurate pump timing .
4/13/95
FUEL SYSTEM DIESEL ENGINE

1. Lubricate a new square sealing ring with clean

engine oil, install ring into groove on front face of
pump mounting flange. Slide injection pump onto
mounting studs while inserting pump shaft into
drive gear.
2. Check pump shaft and index pin for proper
alignment with pump drive gear key slot .

IMPORTANT: Shaft roll pin may be easily damaged

if improperly assembled. Pump drive gear
should not move when initially installing pump
index pin into drive gear key slot.
T95246
3. Install injection pump partially onto mounting studs
without engaging pump pilot hub into engine front
plate. 7. Push pump drive gear firmly onto shaft taper. Install
washer and retaining nut (A) onto end of shaft.
Tighten retaining nut to 200 N•m (150 lb-ft).
IMPORTANT: DO NOT tighten hex nuts more than 8. Install access cover plate using a new gasket, apply
three full turns on mounting studs. Pump drive LOCTITE 242 (TY9370) to cap screw threads and
shaft index pin may be damaged if pin is not tighten to 2 N•m (20 lb- in.).
properly aligned with drive gear key slot and
nuts are tightened more than three turns.

4. Install three flat washers, lock washers, and hex

nuts onto pump mounting studs. Tighten nuts
three turns only so that pump will not fall off
mounting studs.

NOTE: The pump drive gear should begin to move

forward (away from engine front plate) with the
pump when flange is approximately 3.2 mm (1/
8 in.) away from engine front plate.

5. Install pump mounting flange flush to engine front

plate with drive gear held flush against front side of
engine front plate. RG6278

IMPORTANT: DO NOT use tightening force of 9. Align timing mark on the pump flange (B) with
pump mounting stud nuts to pull pump shaft timing mark on the cylinder block front plate (A) .
into drive gear I.D. 10. Tighten the three hex nuts securing the pump to the
front plate to 27 N•m (20 lb-ft).
6. With the pump shaft index pin properly engaged in
the drive gear key slot, finger tighten mounting
stud nuts.

4/13/95 3 - 115
DIESEL ENGINE FUEL SYSTEM

• Do not bend the fuel delivery lines, as this may

affect their durability. When loosening the fuel
pressure lines, hold male union of nozzle line
stationary with a backup wrench .

RG5565

11. Connect injection pump pressure lines from

injectors as shown (number represents cylinder
number, others are capped off) .
RG6266
12. Tighten fuel delivery (pressure) lines at pump to 27
N•m (20 lb-ft), using a 17 mm deep-well tubing
socket and backup tubing wrench . A. Nozzle Assembly E. Cap Screw
B. Tube Nut F. Carbon Stop Seal
IMPORTANT: ALWAYS use a backup wrench when C. Packing G. Upper Sealing
loosening or tightening fuel delivery lines at fuel D. Leak-off T-fitting Washer
injection pump, so that the pump discharge
fittings are not altered. This prevents possible NOTE: When all fuel injection nozzles have to be
internal pump damage. removed, disconnect leak-off line and remove
as a complete assembly. For individual nozzle
13. Connect fuel supply line and fuel return line . removal, remove only the section of leak-off
line necessary for nozzle removal.
14. Connect throttle control linkage. Install and
securely tighten electrical connection to shut-off
solenoid.
15. Bleed air from fuel system. (See Fuel System
Bleeding Section.) Start engine, run for several
minutes and check entire fuel system for leaks .

FUEL INJECTION NOZZLE

REMOVAL

General Nozzle Service Precautions:

• Before removal, thoroughly remove all dirt from the
cylinder head around fuel injection nozzles. Clean RG6296
with compressed air to prevent dirt from entering
the cylinders. Plug the bore in the cylinder head
after each nozzle has been removed. Cap fuel line 1. Loosen tube nuts at each nozzle to remove leak-off
openings as soon as they are disconnected . lines and T-fittings as an assembly .
• Immediately fit protective caps over the nozzle tips
and the line connections to avoid getting debris in
fuel system and handling damage .

3 - 116 4/13/95
FUEL SYSTEM
RG6297
2. Disconnect fuel injection line from nozzle using a
backup wrench on nozzle connection as shown .
3. Remove cap screw securing nozzle in cylinder
head nozzle bore.
RG6298
4. Pull injection nozzle out of cylinder head using
JDE38B Injection Nozzle Puller Set or JDG716
Adapter and slide handle from JDE38 or JDE38A
Puller Set.
IMPORTANT: Do not use screwdrivers, pry bars or
similar tools for this as they might damage the
injection nozzle beyond repair.
FUEL INJECTION NOZZLE BORE
CLEANING
IMPORTANT: Always turn tool clockwise in bore to
prevent dulling of cutting edges, even when
removing tool from bore.
4/13/95
DIESEL ENGINE
RG6299
1. Clean injection nozzle using JDE-39 Nozzle Bore
Cleaning Tool. Blow debris from bore using
compressed air, and plug the bore to prevent entry
of foreign material.
INJECTION NOZZLE CLEANING
RG6300
1. Remove carbon stop seal (A) from groove in nozzle
body using needle nose pliers and remove upper
sealing washer (B). Discard seal and washer .
2. Place nozzle in solvent or clean diesel fuel, so
carbon stop seal groove is submerged, and soak
for a while.
IMPORTANT: Do not scrape or disturb the teflon
coating on the nozzle body above the carbon
stop seal groove. This coating will become
discolored during normal operation, but this is
not harmful. Do not use a motor-driven brush to
clean up nozzle body.
3. After soaking, clean nozzle tip with ROS16488
Brass Wire Brush. Never use a steel wire brush or
scraper.
3 - 117
DIESEL ENGINE
FUEL INJECTION NOZZLE TEST S
c CAUTION
The nozzle tip should always be directed away
from the operator. Fuel from the spray orifices
can penetrate clothing and skin causing serious
personal injury. Enclosing the nozzle in a clear
glass beaker is recommended.
Before applying pressure to the nozzle tester, be
sure that all connections are tight, and that the
fittings are not damaged. Fluid escaping from a
very small hole can be almost invisible. To
search for suspected leaks, use a piece of
cardboard or wood, rather than hands.
If injured by escaping fluid, 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 may call the Deere & Company
Medical Department in Moline, Illinois, or other
knowledgeable medical source.
B
C to chatter. Nozzle should chatter softly, and spray
A
RG1255
1. Use Y900-3, Y900-5 Adapters (C) and Y900-2 Fuel
Line (B) from D01110AA Adapter Set to connect
nozzles to D01109AA Nozzle Tester (A) .
2. Position tip of nozzle below top of beaker and back
out 30° from vertical. This is necessary to contain
all spray in beaker, as nozzle spray pattern is at an
angle to the nozzle centerline. Leave connections
slightly loose.
NOTE: Rapid operation of pump handle will result in
inaccurate cracking pressure readings and
cause undue wear on gauge.
3 - 118
FUEL SYSTEM
3. Pump handle several strokes to flush air from lines
and to determine the pumping rate required for
proper fuel atomization. Tighten all connections
securely after all air has been expelled from nozzle
and line.
IMPORTANT: Make sure that nozzle tester is in
good condition and that gauge works properly.
Service nozzle tester as recommended in the
operating instructions provided with tester.
OPENING PRESSURE TEST
NOTE: Actual nozzle opening pressure is less
important than equal opening pressure of all
nozzles. For maximum variation between
nozzles, see SPECIFICATIONS.
1. Actuate the nozzle tester rapidly several times to
allow the valve to seat rapidly .
2. Open gauge valve, actuate the tester and raise the
pressure to a point where the gauge needle falls
rapidly. This is the nozzle opening pressure, and
should be as specified for a new or used nozzle .
IMPORTANT: If any of the nozzle opening
pressures are not within specified range, reset
pressure and valve lift BEFORE checking
chatter and spray pattern. Otherwise, these
characteristics may be affected. (See Fuel
Injection Nozzle Adjustment Section.)
CHATTER TEST
1. Close gauge shut-off valve and operate nozzle
tester at a pumping rate that will cause the nozzle
pattern should be broad and finely atomized .
NOTE: Until the chattering range is reached, fuel will
emerge in non-atomized streams.
2. If nozzle fails to chatter, the nozzle valve may be
bent or tight in it’s guide due to accumulated
lacquer deposits. Disassemble nozzle and correct
as detailed later in this group .
3. Using the pumping rate for proper atomization,
operate tester for ten strokes. The nozzle must
atomize on at least eight of the ten strokes without
consecutive misses.
4. If the nozzle fails to meet this requirement, repeat
procedure. Nozzles which do not meet the
requirement after second test should be
considered unacceptable and should be either
repaired or replaced.
4/13/95
FUEL SYSTEM DIESEL ENGINE

SPRAY PATTERN TEST FUEL INJECTION NOZZLE

1. Close gauge shut-off valve and operate nozzle DISASSEMBLY
tester at a pumping rate that will cause the nozzle
to chatter.

NOTE: Partially clogged, chipped or eroded orifices A B C D E I J L M

will cause the spray to deviate from the correct
angle. Spray will be streaky, rather than finely
atomized.

2. Observe spray pattern and check for plugged

H K N O
orifices.
3. If nozzle fails to chatter or spray properly,
disassemble, clean and recondition as outlined F
later in this group.

LEAKAGE TEST
1. Check nozzle for fuel leakage past valve seat by
G
positioning nozzle on nozzle tester with nozzle tip RG2100
down.
2. Operate pump handle rapidly to firmly seat valve.
A. Nozzle Ti p I. Upper Sea l
Wipe the nozzle tip dry with a clean, lint-free cloth .
B. Carbon Stop Sea l J. Spring Sea t
3. Slowly raise pressure at nozzle to about 2800-3500
kPa (400-500 psi) under specified opening C. Nozzle Bod y K. Sprin g
pressure and hold at that pressure. Watch for an D. Nozzle Valv e L. Lift Adjusting Scre w
accumulation of fuel around the nozzle tip orifices . E. Upper Sealing Washe r M. Lock Nu t
4. If fuel drips from nozzle within 5 seconds, nozzle F. Edge Type Filte r N. Pressure Adjusting Scre w
must be lapped. G. Fuel Inle t O. Lock Nu t
H. Upper Guid e
• Valve Stem and Guide Wear Test
1. Position nozzle with tip slightly above the horizontal
GENERAL NOZZLE REPAIR NOTES:
plane.
NOTE: Disassembly of nozzles is not recommended

c CAUTION
unless servicing is indicated by nozzle
operation and testing.

Completely enclose spray zone in a glass beaker
to avoid possible personal injury from spray.
2. Slowly raise pressure to 10,300 kPa (1500 psi) on
test gauge.
NOTE: Leakage rate based on use of No. 2 diesel fuel
or an equivalent viscosity of test oil at 18°−
24°C (65°−75°F) ambient temperature.
3. Look for leakage from the return end of nozzle.
After one drop, leakage should be 3-10 drops in 30
seconds.
4. If nozzle leakage is not within specified range,
nozzle must be reconditioned as outlined later in
this group.
• Since dirt and water are the worst contaminants in
the fuel injection system, the working area, tools
and cleaning materials must be kept spotlessly
clean. Whenever possible, work in an isolated,
dust-free area.
• Cover the work bench with clean paper before
beginning disassembly of injection nozzles .
• As parts are disassembled, place them in a pan of
clean diesel fuel and leave there until needed. Do
not permit these parts to strike each other .
• Use a separate pan of clean fuel for washing parts
before assembly.

4/13/95 3 - 119
DIESEL ENGINE
3
2
RG1918
1. Place nozzle in ROS17787 Holding Fixture (1) and
secure fixture in a vise.
2. Loosen pressure adjusting screw lock nut (2) .
3. Back out pressure adjusting screw (3) and lift
assembly.
4. Invert nozzle and allow pressure adjusting spring
seat and adjusting assembly to fall into your hand.
Do not bend stem during removal .
5. If valve does not slide freely from body, use No.
16481 Retractor to remove valve .
6. Remove locating clamps and spacer from nozzle
body.
FUEL INJECTION NOZZLE
CLEANING & INSPECTION
NOTE: Unless otherwise indicated, all tools required
for nozzle cleaning can be found in the
ROS16494 Nozzle Cleaning Kit.
Clean carbon stop seal groove and nozzle tip with
ROS16488 Brass Wire Brush .
Inspect tip for cracks and spray orifices for chipping
and erosion using ROS16487 Inspection Magnifier .
To clean carbon from nozzle orifices :
1. Begin with a cleaning wire 0.07-0.10 mm (0.003--
0.004 in.) smaller than the nominal orifice size
given in specifications.
NOTE: Stoning the wire to provide a flat surface on
one side will help in reaming carbon from a
clogged hole.
2. Clamp the wire in ROS16483 Pin Vise. Wire should
not protrude from the vise more than 0.8 mm (1/32
in.).
3. Insert wire in orifice and rotate .
3 - 120
FUEL SYSTEM
4. 4. Use ROS17712 Scraper to clean deposits from
valve seating area.
RG1250
5. Grasp ROS16476 Sac Hole Drill with No. 16481
Valve Retractor.
6. For final cleaning, use a cleaning wire 0.03 mm
(0.001 in.) smaller than the nominal orifice size
and repeat Steps 2 and 3 .
FUEL INJECTION NOZZLE VALVE
SEAT INSPECTION & CLEANING
IMPORTANT: NEVER use a steel wire brush on
nozzle parts.
Use ROS16488 Brass Wire Brush to remove deposits
from seating area on tip of nozzle valve. Use a
ROS16544 Felt Pad to remove varnish deposits .
Inspect guide area of valve scratches which could
cause sticking. This area will generally be polished on
one side during operation. Visible vertical marks are
normal.
INCONSISTENT CHATTER OR NO CHATTER
A nozzle which during test had spotty chatter or
showed definite signs of sticking accompanied by low
return leakage, may be corrected by polishing the valve
guide area as follows:
1. Place a small amount of ROS16489 Lapping
Compound on the valve in guide area only. DO
NOT use any other compound for this purpose .
2. Slide valve into body.
3. Grip top of the valve with No. 16481 Retractor and
rotate valve in the guide by turning retractor. The
amount of lapping required can be accomplished
in 10-20 turns by hand. The valve should be raised
and lowered in the guide every 3-4 revolutions and
direction of rotation changed for best results .
4/13/95
FUEL SYSTEM DIESEL ENGINE

IMPORTANT: Never attempt to rotate the valve in a 6. Turn pressure adjusting screw down as far as
motor driven chuck for this purpose. possible by hand; usually about ten full turns.
Adjust nozzle as detailed later in this group .

4. Wash nozzle body and valve thoroughly in clean

fuel before reassembly. FUEL INJECTION NOZZLE
ADJUSTMENT
SEAT LEAKAGE
Seat leakage may be caused by dirt, carbon or fuel

c CAUTION
deposits in valve area. Inspect valve seat and clean as
follows:
1. Apply a small amount of ROS16489 Lapping
Compound to valve tip and insert valve in nozzle
Nozzle tip should always be directed away from
body.
operator. Fuel from spray orifices can penetrate
2. Gripping valve with No. 16481 Retractor, rotate clothing and skin causing serious personal
valve 3 to 5 turns to clean up seat . injury. Enclosing nozzle in a glass beaker is
3. Wash valve and nozzle body thoroughly in clean recommended.
fuel.

Before applying pressure to nozzle tester, be

FUEL INJECTION NOZZLE VALVE
ADJUSTOR INSPECTION
NOTE: Inspection steps refer to first illustration under
Disassemble Inspection Nozzles, earlier in this
group.
1. Inspect lift adjusting screw (L). Replace if bent or
otherwise damaged.
2. Inspect pressure adjusting screw (N). Replace if
worn or damaged.
3. Inspect pressure adjusting spring (K). Replace if
broken or distorted.
4. Inspect spring seat (J) for wear. Replace as
necessary.
5. Replace nozzle clamp if bent .
sure all connections are tight, and fittings are
not damaged. Fluid escaping from a very small
hole can be almost invisible. Use a piece of
cardboard or wood, rather than hands, to search
for suspected leaks.
If injured by escaping fluid, 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 may call the Deere & Company
Medical Department in Moline, Illinois, or other
knowledgeable medical source.
Connect nozzle to nozzle tester. (See Fuel Injection
Nozzle Testing Section.)

ADJUST NOZZLE OPENING PRESSURE

FUEL INJECTION NOZZLE
ASSEMBLY
1. Install nozzle spacer onto upper nozzle body.
Position nozzle locating clamp over upper nozzle
body with flanges pointing downward. Install three
remaining clamps onto nozzle body .
1. Close pressure gauge valve and flush nozzle by
operating pump rapidly.
2. Raise pressure on pump until nozzle opens (gauge
drops sharply).
3. Refer to nozzle opening pressure specification,
given in Fuel System Specifications at beginning
of this group.

IMPORTANT: Hands must be clean and kept wet

with clean fuel when assembling nozzles.

2. Dip valve in clean fuel and insert into nozzle body .

3. Thread lift adjusting screw into pressure adjusting
screw until top just enters screw .
4. Invert adjusting screw assembly and assemble
spring seat and spring to adjusting screw .
5. Tilt body. DO NOT allow valve to fall out, and install
spring adjusting screw to body. Be careful not to
dislodge spring or seat during initial assembly .

4/13/95 3 - 121
DIESEL ENGINE FUEL SYSTEM

RG4826
M76189

9. Remove nozzle from tester and secure in holding

4. If opening pressure is incorrect, remove nozzle fixture. While holding pressure adjusting screw,
from tester and install in ROS17787 Holding tighten pressure adjusting screw lock nut to 10
Fixture (A). N•m (7 lb-ft) using the ROS18958 (SAE), or No.
5. Loosen pressure adjusting screw lock nut (B) . 24374 (metric size) Torque Wrench Adapter .
6. Reconnect nozzle to tester with tip pointing
downward.
ADJUST NOZZLE VALVE LIFT:

RG4825

7. Back out lift adjusting screw locknut (E), and lift

adjusting screw (C), far enough (two or three
turns) to prevent bottoming when pressure
adjusting screw (D) is turned . RG4827
8. Turn pressure adjusting screw (D) in (clockwise) to
increase opening pressure, or out
(counterclockwise) to decrease opening pressure . 1. Reconnect nozzle to tester. While pumping fuel
through nozzle, hold pressure adjusting screw and
NOTE: It is desirable to set opening pressure to the slowly turn lift adjusting screw in (clockwise) until
high limit of specification. If required, repeat valve ceases to open.
procedure to obtain proper result.

IMPORTANT: DO NOT manually bottom the valve

with excessive force as bending of the valve
may result.

3 - 122 4/13/95
FUEL SYSTEM
2. Check for valve bottoming by raising pressure to
1380-3450 kPa (200-500 psi) above nozzle
opening pressure. Although some fuel may collect
at nozzle tip, a rapid dribble should not occur .
3. Remove nozzle from tester and install in holding
fixture.
4. Carefully turn lift adjusting screw out specified
amount. A tolerance of 1/8 turn is permissible.
(See Specifications at beginning of group. )
5. Hold pressure adjusting screw stationary while
tightening lock nut. Use ROS18958 Torque
Wrench Adapter (SAE) or No. 24374 (Metric) to
torque lock nuts.
6. Tighten pressure adjusting screw lock nut to 5 N•m
(3.5 lb-ft).
7. Recheck nozzle opening pressure .
8. If nozzle chatter is incorrect after servicing, valve
parts may be misaligned. To correct, screw
pressure adjusting screw through its range of
adjustment several times and reset valve lift.
Recheck nozzle for chatter .
9. Clean nozzle with ROS16488 Brass Wire Brush .
FUEL INJECTION NOZZLE SEAL
INSTALLATION
IMPORTANT: Each time an injection nozzle is
removed from the cylinder head, replace carbon
stop seal (C) with a new one.
RG6301
1. Position JD258 (ROS16477) Pilot Tool (A) over
nozzle tip.
2. Position a new carbon stop seal on pilot tool. Use a
new seal washer (B) to help slide the carbon seal
into place until it seats in it’s groove on nozzle
body.
3. Continue to slide upper sealing washer onto nozzle
body until it seats against inlet fitting .
4/13/95
DIESEL ENGINE
NOTE: If nozzle is not going to be installed at this time,
install a No. 16189 Nozzle Protector Cap over
nozzle tip. Plug all other openings in nozzle to
prevent contamination.
FUEL INJECTION NOZZLE
INSTALLATION
NOTE: If nozzle bore in cylinder head must be
cleaned, use JDE39 Nozzle Bore Cleaning
Tool. (See Remove Injection Nozzles, earlier in
this group.)
IMPORTANT: Before installing injection nozzles,
make sure nozzles are clean and free from oil or
grease.
1. Remove plug (if installed previously) from nozzle
bore in cylinder head and blow out bore with
compressed air.
NOTE: Make sure that the sealing surface of the
cylinder head (on which the seal washer will be
resting) is smooth and free of damage or dirt.
This could prevent proper sealing. Dirt and
roughness could also cause nozzle to be
distorted when the attaching screw is
tightened, making the valve stick.
RG6302
2. Install nozzle with spacer and clamps in cylinder
head using a slight twisting motion as nozzle is
seated in bore. Illustration shows relationship of
parts required for proper installation .
3. Align nozzle clamps and install cap screw. Do not
tighten cap screw at this stage .
3 - 123
DIESEL ENGINE FUEL SYSTEM

RG6297

4. Connect fuel pressure line to nozzle. Leave

connection slightly loose until air is bled from
system.
5. Tighten nozzle hold-down clamp cap screws to 37
N•m (27 lb-ft).
6. Install leak-off line assembly .
7. Bleed air from loose injection line connection.
Tighten connection using two wrenches. (See Fuel
System Bleeding Section.)

ALTITUDE COMPENSATION
GUIDELINES
High elevations may affect engine performance. These
guidelines will apply to the Turbocharged 3029 T
Engines:
One-half of one percent reduction in performance per
300 m (1000 ft) rise in elevation above sea level.
Engine may have to be defueled when a substantial
percentage of operating time occurs at 2250 m (7500
ft) or higher.
If engine required less fuel for acceptable performance
at higher elevation, contact your local authorized fuel
injection pump repair station for service .

3 - 124 4/13/95
CONTENTS ELECTRICAL

CONTENTS
Page

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ELECTRICAL DIAGNOSTIC INFORMATION . . . . . . . . . . . . . . . . . . . . . 4
READING ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
THEORY OF OPERATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSTIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
COMMON CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
WIRE COLOR ABBREVIATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ELECTRONIC INSTRUMENT PANEL MODULE OPERATION. . . . . . . . 6
TROUBLESHOOTING CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
WIRING HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
POWER CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CIRCUIT OPERATION AND DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 19
POWER CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
UNSWITCHED POWER CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SWITCHED POWER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
POWER CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
POWER CIRCUIT DIAGNOSIS (CONTINUED) . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CRANKING CIRCUIT OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CRANKING CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CRANKING CIRCUIT DIAGNOSIS (CONTINUED) . . . . . . . . . . . . . . . . . . . . . . . . 25
CHARGING CIRCUIT, VOLTMETER, AND BATTERY LIGHT OPERATION . . . . 26
TACHOMETER CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
HOURMETER CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CHARGING CIRCUIT, VOLTMETER, AND BATTERY LIGHT DIAGNOSIS. . . . . 28
CHARGING CIRCUIT, VOLTMETER, AND BATTERY LIGHT DIAGNOSIS. . . . . 29
TACHOMETER CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
TACHOMETER CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
FUEL SHUTOFF SOLENOID CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . 32
FUEL SHUTOFF SOLENOID CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 34
FUEL SHUTOFF SOLENOID CIRCUIT DIAGNOSIS (CONTINUED) . . . . . . . . . . 35
GLOW PLUG AND LIGHT CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 36
GLOW PLUG/MANIFOLD HEATER AND LIGHT CIRCUIT DIAGNOSIS . . . . . . . 38
MANUAL PREHEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
GLOW PLUG/MANIFOLD HEATER AND LIGHT CIRCUIT DIAGNOSIS . . . . . . . 39
GLOW PLUG/MANIFOLD HEATER AND LIGHT CIRCUIT DIAGNOSIS . . . . . . . 40
AUTOMATIC PREHEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
GLOW PLUG/MANIFOLD HEATER AND LIGHT CIRCUIT DIAGNOSIS . . . . . . . 41
HYDRAULIC CHARGE PRESSURE LIGHT CIRCUIT OPERATION . . . . . . . . . . 42
ENGINE OIL PRESSURE LIGHT CIRCUIT OPERATION. . . . . . . . . . . . . . . . . . . 42
HYDRAULIC CHARGE PRESSURE LIGHT CIRCUIT DIAGNOSIS . . . . . . . . . . . 44
HYDRAULIC CHARGE PRESSURE LIGHT CIRCUIT DIAGNOSIS . . . . . . . . . . . 45
ENGINE OIL PRESSURE LIGHT CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . 46
ENGINE OIL PRESSURE LIGHT CIRCUIT DIAGNOSIS (CONTINUED) . . . . . . . 47
ENGINE COOLANT TEMPERATURE LIGHT OPERATION . . . . . . . . . . . . . . . . . 48
HYDRAULIC OIL TEMPERATURE LIGHT CIRCUIT OPERATION . . . . . . . . . . . 48
ENGINE COOLANT TEMPERATURE LIGHT DIAGNOSIS . . . . . . . . . . . . . . . . . 50

2/9/95 4-1
ELECTRICAL CONTENTS

Page

ENGINE COOLANT TEMPERATURE LIGHT DIAGNOSIS (CONTINUED) . . . . . 51

HYDRAULIC OIL TEMPERATURE LIGHT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 52
HYDRAULIC OIL TEMPERATURE LIGHT DIAGNOSIS (CONTINUED) . . . . . . . 53
HYDRAULIC OIL FILTER RESTRICTION LIGHT CIRCUIT OPERATION . . . . . . 54
AIR FILTER RESTRICTION LIGHT CIRCUIT OPERATION . . . . . . . . . . . . . . . . . 54
FUEL LEVEL DISPLAY CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 54
HYDRAULIC OIL FILTER RESTRICTION LIGHT CIRCUIT DIAGNOSIS . . . . . . . 56
HYDRAULIC OIL FILTER RESTRICTION LIGHT CIRCUIT DIAGNOSIS . . . . . . . 57
AIR FILTER RESTRICTION LIGHT CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . 58
AIR FILTER RESTRICTION INDICATOR LIGHT CIRCUIT DIAGNOSIS . . . . . . . 59
FUEL LEVEL DISPLAY CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
FUEL LEVEL DISPLAY CIRCUIT DIAGNOSIS (CONTINUED) . . . . . . . . . . . . . . 61
HYDRAULIC BOOM AND BUCKET LOCKOUT CIRCUIT OPERATION . . . . . . . 62
HYDRAULIC BOOM AND BUCKET LOCKOUT CIRCUIT DIAGNOSIS . . . . . . . . 64
HYDRAULIC BOOM AND BUCKET LOCKOUT CIRCUIT DIAGNOSIS . . . . . . . . 65
ROAD/WORK LIGHT/ACCESSORY CIRCUIT OPERATION . . . . . . . . . . . . . . . . 66
ROAD/WORK LIGHT/ACCESSORY CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . 68
ROAD/WORK LIGHT/ACCESSORY CIRCUIT DIAGNOSIS (CONTINUED) . . . . 69
TESTS & ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
BATTERY TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
CHARGE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
REGULATED AMPERAGE AND VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . 72
STARTER LOADED AMPERAGE DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 72
STARTER NO-LOAD AMPERAGE AND RPM TESTS . . . . . . . . . . . . . . . . . . . . . 73
STARTER SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
FUEL GAUGE SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
BACKUP ALARM SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
ELECTRICAL SWITCH TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
ELECTRICAL SWITCH TESTS (CONTINUED). . . . . . . . . . . . . . . . . . . . . . . . . . . 77
ELECTRICAL RELAY / SOLENOID TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
ELECTRICAL RELAY TESTS (CONTINUED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
ELECTRONIC INSTRUMENT PANEL MODULE TEST . . . . . . . . . . . . . . . . . . . . 80
GROUND CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
BLOWN FUSE SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
STARTER—DELCO-REMY 2.5 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
STARTER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
STARTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
STARTER - INSPECTION/TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
STARTER GEAR TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
DISASSEMBLY/INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
VOLTAGE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
INSPECTION/TEST, ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
ALTERNATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

4-2 2/9/95
SPECIFICATIONS ELECTRICAL

SPECIFICATIONS
Battery
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CCA rating (Amps at 0o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 925
Reserve capacity (minutes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Specific gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.225 or above
Electrolyte required fill (Approx.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt)
Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Alternator
Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 amps
Regulated amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 amps (min)
Unregulated amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 amps (min)
Regulated voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2 - 14.8 volts
Resistor at 25°C (77°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 - 55 ohms
Tachometer output (“W” terminal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 volts (min)

Starter
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Shift
Loaded (on vehicle) draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 amps (max)
No load (free spinning) draw . . . . . . . . . .135-139 amps at 3600-5600 RPM (10.6 volts)

Fuel gauge sensor resistance

Full tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ohms
Empty tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 ohms

Fuel shutoff solenoid

Pull-in voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 volts
Hold voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 volts

Engine coolant temperature sensor resistance

At 20°C (68°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 - 2.69 K ohms
At 0 - 30°C (32 - 86°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.65 K - 5.88 K ohms

Hydraulic oil temperature sensor resistance

At 20°C (68°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 - 2.69 K ohms
At 0 - 30°C (32 - 86°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.65 - 5.88 K ohms

Glow Plug
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 - 0.5 ohms

Lighting
Road/Work lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.5 Watt Halogen Type 894
Electronic Instrument Panel Module Indicator Lamp . . . . . . . . . . . . . . . 0.080 amp C-2F

4/13/95 4-3
ELECTRICAL
ELECTRICAL DIAGNOSTIC
INFORMATION
READING ELECTRICAL
SCHEMATICS
The schematic is made up of individual circuits laid out
in a sequence of related functions. It is formatted with
all power wires (A) across the top and all ground wires
(B) across the bottom. Current flow is generally from
top to bottom through each circuit and component. All
components are shown in the OFF position. The
diagram does not list connector (C) information unless
needed to avoid confusion. If the connector is shown,
the number next to it is the terminal pin location (D) in
the connector.
Each component is shown by a symbol (E), its name
(F), and an identification code (G). The identification
4-4
ELECTRICAL DIAGNOSTIC INFORMATION
code contains a device identifying letter (H) and
number (I).
The identifying letter is always the same for a specific
component, but the identifying numbers are numbered
consecutively from upper left to lower right. The
terminal designation (J) is placed directly outside the
symbol next to the connecting wire path. Switch
positions (K) are also placed directly outside the
symbol. The solid line (L) shows the position the switch
is currently in and dash lines (M) represent other switch
positions.
Each circuit is identified at the bottom of the drawing by
a section number (N) and section name (O).
The circuit number (P) and wire color (Q) of the wires
are shown directly next to the wire path.
The same component name and identification code are
used consistently on all diagrams in this section.
Components can be easily cross-referenced.
M46311
4/13/95
ELECTRICAL DIAGNOSTIC INFORMATION
THEORY OF OPERATION
The theory of operation stories divide the electrical
system into individual circuits by function. Each circuit
is isolated from the main wiring schematic and only
shows the components that are used in it. The story
contains information on function, operating conditions,
and theory of operation. The circuit schematics are
drawn with the components in the operating position,
with the power, or battery positive, into them across the
top and the ground, or battery negative, across the
bottom.
DIAGNOSTIC INFORMATION
The diagnostic procedures is used to test the complete
circuit regardless of the problem or complaint. Select a
symptom or system from the quick check or
troubleshooting chart and follow the test procedures
under that heading.
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. The detailed tests or
adjustments referred to in the “IF NOT NORMAL”
column are located at the end of that group. The
system diagram that accompanies each test procedure
is drawn to resemble machine components. The key
number on the art matches the number in the “TEST
LOCATION” column and the leader line points to the
exact point the test is to be made.
COMMON CIRCUIT TESTS
Shorted Circuit:
A shorted circuit may result in the wrong component
operating (i.e. improper wire-to-wire contact). To test
for a shorted or improperly wired circuit:
1. Turn component switch ON.
2. Start at the controlling switch of the component that
should not be operating.
3. Follow the circuit and disconnect wires at connectors
until component stops operating.
4. Shorted or improper connections will be the last two
wires disconnected.
4/13/95
ELECTRICAL
High Resistance or Opened Circuit:
High resistance or open circuits usually result in slow,
dim or no component operation (i.e. poor, corroded, or
disconnected connections). Voltage at the component
will be low when the component is in operation. To test
for high resistance and open circuits:
1. Check all terminals and grounds of the circuit for
corrosion.
2. If terminals are not corroded or loose, the problem is
in the component or wiring.
Grounded Circuit:
Grounded circuits usually result in no component
operation or a blown fuse.
WIRE COLOR ABBREVIATION
CHART
Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black
Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue
Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown
Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green
Gry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gray
Org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange
Pnk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink
Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple
Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tan
Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White
Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow
Blk/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . Black/White
Blu/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue/White
Dk Blu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dark Blue
Dk Brn/Lt Grn . . . . . . . . . . . . . Dark Brown/Light Green
Dk Brn/Red. . . . . . . . . . . . . . . . . . . . . Dark Brown/Red
Dk Brn/Yel . . . . . . . . . . . . . . . . . . . Dark Brown/Yellow
Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Green
Lt Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue
Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Green
Org/Wht . . . . . . . . . . . . . . . . . . . . . . . . . Orange/White
Pnk/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink/Black
Pur/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . .Purple/white
Red/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black
Red/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/White
Wht/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Black
Wht/Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red
Yel/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Black
Yel/Red . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Red
Yel/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/White
4-5
ELECTRICAL ELECTRONIC INSTRUMENT PANEL MODULE OPERATION

ELECTRONIC INSTRUMENT PANEL MODULE OPERATION

H9 H8 P1 H6
H11 Engine
Tachometer Battery Digital
H15 Hydraulic Oil Coolant
Light Voltage Display/
Air Filter Light Temperature Temperature
H10 Hourmeter
S8 Restriction Light Light H7
Display Engine Hydraulic Oil
H17 Light
Select Coolant Temperature
Module Temperature
Alarm Switch Light
Light (Not Used)

H14
H5 H12
S10 Hydraulic
P2 Low H13 Battery
Diagnostic/ Oil Filter
Fuel Hydraulic Engine Voltage
Program Restriction H1 H3 Level Charge Coolant Light
Mode Light Engine Preheat Display Pressure Temperature
Switch Stop Light Light Light
Light H2
H16 H4 Seat
Parking Low Belt
Brake Engine Oil Light
Light Pressure
Light

Function: Operating Conditions:

The electronic instrument panel module performs the Vehicle operating conditions display - key switch
following: must be in the run position and display select switch
depressed to show condition selected by operator.
• Monitors and displays vehicle operating conditions
• Displays error codes when problem conditions Boom and bucket interlock - key switch must be in
occur during operation the run position and the operator must be on the seat
• Provides safety interlock for boom and bucket with the seat belt fastened.
hydraulic system Configuration mode - the service start switch must be
• Alerts operator of operating problems by audible in the service position, the display select switch and the
and visual alarms diagnostic/program mode switch depressed, and the
• Provides a configuration mode which allows the key switch turned to the run position.
display to be shown in Metric or English, and
allows selection of the engine code which matches
the module computer to the engine type
• Provides a diagnostic mode which lights the
symbols for a bulb check, displays the software
revision, and checks some vehicle sensor circuits
• Provides an anti-theft mode which uses a two digit
number to electrically “lock” the vehicle

4-6 4/13/95
ELECTRONIC INSTRUMENT PANEL MODULE OPERATION
Diagnostic mode - the service start switch must be in
the run position, the operator must be off the seat, the
diagnostic/program mode switch must be depressed
and the key switch turned to the run position.
Anti-theft mode - the operator must be off the seat,
the diagnostic/program mode switch must be
depressed, then the operator must be on the seat, and
the key switch must be in the run position.
Theory of Operation:
The electronic instrument panel module is a solid state
printed circuit board with an integrated computer that
uses an audible alarm, yellow or red symbols, LED
character display, and a segmented graph to monitor
and display vehicle operating conditions and modes.
The front of the electronic instrument panel module is
divided into six functional groups or components
consisting of; a module alarm (H17), display select
switch (S8) and digital display (P1), diagnostic/program
mode switch (S10), yellow warning symbols, fuel level
display (P2), and red fault symbols. When diagnosing a
machine problem using the electronic instrument panel
module, it is critical that you know how to interpret the
display codes and change modes. The following is an
explanation of the mode operation and what the display
codes or symbols mean.
Module alarm - the module alarm (H17) is energized
by the electronic instrument panel module if there is an
unusual condition in any of the monitored areas.
Display select switch and digital display - the
display select switch (S8) is used to:
• Change the operating condition monitored
• Put the electronic instrument panel module in the
configuration mode
• Turn the module alarm off
The digital display performs the following:
• Shows the numeric value of the operating condition
monitored
When the display select switch is depressed, the digital
display (P1) changes to show one of five operating
conditions that the operator selects and the monitored
operating condition symbol lights up. The operating
conditions that can be monitored are:
4/13/95
ELECTRICAL
• Engine rpm displayed to nearest 10 rpm, indicated
by the tachometer light (H9)
• Battery voltage displayed to nearest 0.1 volt,
indicated by the battery voltage light (H8)
• Engine hours displayed to nearest 0.1 hour,
indicated by the digital display/hourmeter (P1)
• Engine coolant temperature displayed to the
nearest degree, (expressed as Fahrenheit or
Celsius depending on configuration mode),
indicated by the engine coolant temperature light
(H6)
• Hydraulic oil temperature displayed to the nearest
degree, (expressed as Fahrenheit or Celsius
depending on configuration mode), indicated by
the hydraulic oil temperature light (H7)
Also when the display select switch is depressed, the
module alarm will “beep”, indicating that the display
condition has changed. If a problem occurs in one of
the monitored circuits and the module alarm beeps,
depressing the display select switch will turn the
module alarm off. At the same time the module alarm
beeps, the digital display shows an error code which
informs the operator which circuit has failed. The digital
display shows only one operating condition at a time.
After the engine is started, the display defaults to the
last operating condition viewed before the key switch
was turned off.
Diagnostic/program mode switch - the diagnostic/
program mode switch (S10) is used to:
• Put the electronic instrument panel module in the
configuration mode
• Put the electronic instrument panel module in the
diagnostic mode
• Put the electronic instrument panel module in the
anti-theft mode
The diagnostic/program mode switch has no function
during normal operation and will not “beep” when
depressed.
Yellow warning symbols - the yellow warning
symbols alert the operator of problems with the vehicle
operating conditions. The following conditions will
cause the yellow warning symbols to flash:
• Hydraulic oil filter plugged, indicated by hydraulic oil
filter restriction light (H14)
• Air filter plugged, indicated by air filter restriction
light (H15)
• Engine coolant temperature light (H10) NOT USED
• Operator on seat with key switch off, or operator on
seat with seat belt not fastened and engine
running; indicated by parking brake light (H16)
• Engine prestart conditions not satisfied or if either
the engine oil pressure or the hydraulic charge
pressure exceed the preset limits, indicated by
engine stop light (H1)
• Engine is preheating before starting, indicated by
preheat light (H3)
4-7
ELECTRICAL ELECTRONIC INSTRUMENT PANEL MODULE OPERATION

P1
H11
Digital
Hydraulic Oil H12
Display/
Temperature Battery
Hourmeter
Light Voltage
Light

P2 H13
H5 Engine
H1 Fuel Low
Engine Level Coolant
Hydraulic Temperature
Stop Display H4
Charge Light
Light Low
Pressure H2
Engine Oil
Light Seat
Pressure
Belt
Light
Light

Red fault symbols - the red fault symbols alert the
operator of problems with the vehicle operating
conditions. The following conditions will cause the red
fault symbols to flash and the module alarm to “beep”:
• Low hydraulic charge pressure, indicated by low
• hydraulic charge pressure light (H5)
• High hydraulic oil temperature, indicated by
hydraulic oil temperature light (H11)
• Low battery voltage, indicated by battery voltage
light (H12)
• Low engine oil pressure, indicated by low engine oil
pressure light (H4)
• High engine temperature, indicated by engine
coolant temperature light (H13)
• Seat belt not fastened, indicated by seat belt light
(H2)
The following vehicle operating conditions are
continuously monitored by the electronic instrument
panel module:
• Engine air filter
• Hydraulic oil filter
• Engine coolant temperature
• Battery voltage
• Hydraulic charge pressure
• Engine oil pressure
• Hydraulic oil temperature
If the electronic instrument panel module senses any
unusual condition in a monitored circuit, the symbol of
the problem circuit will flash and the module alarm will
“beep”. If either the engine oil pressure or the hydraulic
charge pressure exceed the preset limits, the electronic
instrument panel module will stop current flow to the
fuel shutoff solenoid after 30 seconds to stop the
engine. During the 30 second countdown, the engine
stop light (H1) will flash. If the problem condition is
caused by the engine coolant temperature, battery
voltage, or hydraulic oil temperature, the digital display
(P1) will show the numeric value of the problem
condition.
Fuel level display - fuel level is displayed as a vertical
10 segment green LED bar graph (P2). The 1st and
2nd bars will flash when the fuel level is low. At the
same time the bars flash, the module alarm will “beep”
for five seconds.

4-8 4/13/95
ELECTRONIC INSTRUMENT PANEL MODULE OPERATION
S8 Display
P1 Digital
Select Switch
Display/ Hourmeter
S10 Diagnostic/
Program Mode Switch
Configuration mode - allows the display to be shown
in Metric or English, and allows selection of the engine
code which matches the electronic instrument panel
module computer to the engine type. It is critical for the
engine code to be correct so the electronic instrument
panel module computer can calculate the preheat time
and display the engine rpm which is based on
alternator rpm.
To put the electronic instrument panel module into the
configuration mode, put the service start switch in the
service position, depress and hold both the display
select switch (S8) and the diagnostic/program mode
switch (S10), and turn the key switch to the run
position. Both switches must be held until the letter “C”
appears in the left side of the digital display, then
release the switches.
Depress the display select switch until the letter “F” for
English or “C” for Metric and 0 (left number of engine
code) appears in the digital display. Then depress the
diagnostic/program mode switch until the right number
is the number of the engine code that corresponds with
the engine model.
CODE ENGINE
02 3029T
4/13/95
ELECTRICAL
The configuration only has to be entered once if the
electronic instrument panel module is not replaced. If
the electronic instrument panel module is replaced,
the configuration must be entered for proper
machine operation. The configuration can be
changed at any time if desired by the operator. Turning
the key switch to the off position exits the configuration
mode and saves the configuration as displayed in the
electronic instrument panel module memory.
Disconnecting the electronic instrument panel module
connector or power will not lose the configuration
stored in the memory.
Error codes - the digital display (P1) displays error
codes and the module alarm “beeps” when problem
conditions occur during operation. The error code
informs the operator which circuit has failed. These
error codes cover circuits that do not have warning or
fault symbols. The following are the error codes and
their fault conditions:
Error Code Fault Condition
ERR01 Memory store error (engine
hours may not be accurate
ERR02 Output circuit to the fuel shutoff
solenoid has shorted/opened
ERR03 Output circuit to the hydraulic
boom and bucket solenoid has
shorted/opened
ERR04 Output circuit to the engine
preheat relay has shorted/
opened
An error code is canceled by depressing the display
select switch (S8). After the error code is cancelled, the
system will return to the normal start-up condition.
4-9
ELECTRICAL ELECTRONIC INSTRUMENT PANEL MODULE OPERATION
Diagnostic mode - this mode has a self diagnostic
program that lights the symbols for a bulb check,
displays the software revision, and checks some
vehicle sensor or switch circuits.
To put the electronic instrument panel module into the
diagnostic mode, put the service start switch in the run
position, raise off the seat, depress and hold the
diagnostic/program mode switch (S10), and turn the
key switch to the run position. The symbols will lite up
for a bulb check, and the digital display (P1) will show
“r0300”, indicating the software release level. Release
the diagnostic/program mode switch. The digital
display will show a “d” in the left side of the display
indicating the module is in the diagnostic mode.
4 - 10
To check the vehicle sensor circuits, disconnect and
ground the wire to the sensor or depress and release
the switch. When the sensor wire is disconnected and
grounded or the switch is depressed and released, the
electronic instrument panel module lights will flash and
the module alarm will “beep” indicating that the circuit
for that sensor or switch is functional. It does not
indicate that the sensor or switch is functional. The
following vehicle sensor or switch circuits can be
checked in the diagnostic mode:
• Engine air filter
• Engine oil pressure
• Engine coolant temperature
• Hydraulic oil filter
• Hydraulic charge pressure
• Hydraulic oil temperature
• Seat belt switch
• Seat switch
• Fuel gauge
Turning the key switch to the off position exits the
diagnostic mode.
4/13/95
ELECTRONIC INSTRUMENT PANEL MODULE OPERATION ELECTRICAL

Anti-theft mode - allows the operator to use a two digit
number to electrically “lock” and “unlock” the vehicle.
When the loader is “locked”, the engine will only start
and run while the key switch is held in the start
position. The boom and bucket will not operate at any
time. There is a “master key” number to unlock the
loader if the code is forgotten.
To put the electronic instrument panel module into the
anti-theft “lock” mode, perform the following:
• Put the boom and bucket on the ground such that
the bucket will prevent the loader from being
moved.
• Turn the key switch to the off position, unbuckle the
seat belt and get out of the seat.
S8 Display
P1 Digital
Select Switch
Display/ Hourmeter
To put the electronic instrument panel module into the
“unlock” mode, perform the following:
• Depress and hold the diagnostic/program mode
switch (S10), and sit on the seat. The digitial
display (P1) will show the letters “LOC”, indicating
the module is locked, and waiting for the unlocking
code. Release the diagnostic/program mode
switch.
• Turn the key switch to the run position.
• Depress the diagnostic/program mode switch and
the display select switch (S8) to enter the same
two digit number that was used in the locking code
to unlock the module.
• Turn the key switch to the off position. The
electronic instrument panel module will reset and
normal loader operation is now possible.
If the unlocking code is forgotten, contact the John
Deere Service Department to obtain a “master key”
number to unlock the loader.

S10 Diagnostic/
Program Mode Switch
• Depress and hold the diagnostic/program mode
switch (S10), and sit on the seat. The digital
display will show the letters “LOC”, indicating the
module is in the lock mode. Release the
diagnostic/program mode switch.
• Turn the key switch to the run position.
• Depress the diagnostic/program mode switch and
the display select switch (S8) to enter any two digit
number from 00 to 99.
• Turn the key switch to the off position. The digital
display will show the letters “LOC”, indicating the
loader is locked and prompting for the unlocking
code. With the loader locked, the boom, bucket,
and engine will not operate.

4/13/95 4 - 11
ELECTRICAL TROUBLESHOOTING CHART

TROUBLESHOOTING CHART

Fuel shutoff solenoid not working properly

Problem or

Warning lamps or fuel gauge stay on or will

Symptom

Tachometer does not operate properly

Battery not charging or overcharging,
Preheat light or manifold heater not

Boom / bucket control not working

Road / work lights do not operate
Hourmeter does not operate
voltage light stays on
Engine won’t shut off
Engine will not crank

Fuel pump won’t run

Engine will not start
Check or
Solution

working properly

properly
not light
See cranking circuit diagnosis ●

Test battery and connections ● ● ●

See charging, voltmeter, and

●
battery light circuit diagnosis

See electronic instrument panel

● ● ● ● ● ● ● ●
module circuits diagnosis

See road/work light and

●
accessory circuit diagnosis

See hydraulic boom and bucket

●
lockout circuit diagnosis

See glow plug/manifold heater

● ●
and light circuit diagnosis

See fuel shutoff solenoid circuit

● ● ●
diagnosis

See power circuit diagnosis ● ● ● ● ● ● ● ● ● ● ●

Check fuel pump ground circuit ● ●

See tachometer circuit

●
diagnosis

See appropriate circuit

diagnosis indicated by warning ● ● ● ●
light that is on.

Check configuration mode

● ● ●
engine code

Check digital display for error

● ● ●
code

4 - 12 4/13/95
 COMPONENT LOCATION ELECTRICAL

H9 H8 P1 H6 E4 Left Front Light

H11 Engine
Tachometer Battery Digital
H15 Hydraulic Oil Coolant
Light Voltage Display/ A4 Electronic Instrument
Air Filter Light Temperature Temperature
H10 Hourmeter Panel Module
S8 Restriction Light Light H7
Display Engine Hydraulic Oil
H17 Light E3 Right Front Light
Select Coolant Temperature
Module Temperature
Alarm Switch Light
Light (Not Used)

S11Light Switch
E2 Left Tail Light S3 Key Switch

E5 Rear Work Light

E1 Right Tail Light S7 Manual Preheat Switch
Y6 Two Speed Solenoid
S2 Service/Run Switch
K4 Accessory Relay
Accessory Fuse Panel
Engine Fuse Panel
F1 Preheat Circuit Breaker
K2 Start Interlock Relay
S22 Two Speed Transmission Switch
M57103 R1 Alternator Resistor
S4 Seat Switches
K1 Start Relay
H14
H5 H12
S10 Hydraulic B7 Air Filter Restriction Switch
P2 Low H13 Battery Y3 Hydraulic Boom Solenoid
Diagnostic/ Oil Filter
Fuel Hydraulic Engine Voltage B1 Manifold Heater
Program Restriction H1 H3 Y4 Hydraulic Bucket Solenoid
Level Charge Coolant Light
Mode Light Engine Preheat Display Pressure Temperature
Switch Stop Light Light Light
Light H2
H16 H4 Seat B3 Hydraulic Charge Pressure Switch
K3 Preheat Relay
Parking Low Belt
Brake Engine Oil Light
Light Pressure
Light B5 Hydraulic Oil Temperature Sender

G2 Alternator
Top Nearest Cab
B8 Fuel Level Sensor
Engine Fuse Panel Accessory Fuse Panel
F5 Electronics (Ign)
F4 Fuel Pump F8 Wiper M1 Starting Motor
F12 Heater F11 Turn Signal F7Road/Work Light
B6 Hydraulic Oil Filter Restriction Switch W1 Engine Ground
20A 10A
7.5A

F6 Accessory
15A

Spare Front X3 Engine to Main Harness Connector

5A
5A

7.5A 25A Outer B4 Engine Coolant Temperature Sensor

W3 Hydraulic Oil Filter Restriction Switch Ground Y1 Fuel Shutoff Solenoid
7.5A

Front
10A

15A 5A
F10 Attachment/ Inner B2 Engine Oil Pressure Switch
Horn/2-Speed 15A F3 Electronics (Bat)
5A
F9 Backup Alarm G1 Battery
F2 Key Switch
F13 Flashing Lights
F14 Beacon Light

M57104

M76097

4/17/95 4 - 13
ELECTRICAL ELECTRICAL SCHEMATIC

BUS

TO SE7 DOME
GRY/BLK LIGHT SWITCH F3 RED
0,1,2 1 0=ACC S3 ELECTRONICS
1=OFF
2=RUN KEY FUSE (BAT)
3=START SWITCH LT GRN/
RED RED/LT GRN
3 2 X1
1 0 ORG/LT BLU
ORG/LT BLU

LT GRN/BLK
BUS
LT GRN/BLK
ORG/
PUR LT GRN/
BLK
RED/ ORG/PUR BUS WHT
WHT
WHT
0=OFF SEAT LT GRN/
RED F4 F5
F2 0=SERVICE
1= ON SEAT
FUEL
KEY ELECTRONICS
X3 1=RUN S4 PUMP FUSE (IGN)
A FUSE S2 SEAT LT GRN/ S5
0,1 RED SEAT FUSE
TO SE7 - X8
SERVICE SWITCH PUR/
CONNECTOR START 0 SWITCH ORG H5 RED
1
SWITCH 0 (DELUXE ONLY) LOW H6
RED 1
TAN TAN A2
FUEL H4 HYDRAULIC H1 ENGINE H7 P1 H8
PUR/ LT H9
WHT/ GRN/ SHUTOFF LOW ENGINE CHARGE ENGINE COOLANT HYDRAULIC OIL DIGITAL BATTERY
RED X1 TAN A1 STOP TEMPERATURE TACHOMETER
DK BLU ORG
PREHEAT SOLENOID OIL PRESSURE PRESSURE TEMPERATURE DISPLAY/ VOLTAGE
X

0 X9 X9 X9 X9 X10 MODULE LIGHT LIGHT LIGHT LIGHT LIGHT X10 LIGHT LIGHT
RED WHT/ 1 LT
11 10 14 12 11 TIMER 4 HOURMETER
TAN 0=OFF SEAT GRN
LT GRN
1= ON SEAT
LT GRN/ F1 K2 WHT/ X30 WHT/
BLK PREHEAT ORG X2 X9
START ORG 0=SEAT BELT
DISENGAGED 4
CIRCUIT INTERLOCK 1=SEAT BELT STOP
BREAKER RED RELAY ENGAGED DK BLU
n/min
R1 WHT/ S6 A5 H2 H3
ALTERNATOR DK BLU SEAT BELT ENGINE SEAT BELT PREHEAT
RESISTOR X27 SWITCH START LIGHT LIGHT
BLK TO SE7 LT BLU/ 0 BLK MODULE
YEL/
K1 ACCES- ORG 1
PUR/ START X9 X9 X9 X10 X10 X10 X10
DK BLU SORY LT 13 5 8 YEL/ S8 3 A4
RED X1 2 7 YEL/ 2
X3 RELAY RELAY GRN X2
BLK GRY
DISPLAY ELECTRONIC
GROUND ORG PUR/
G X3 SELECT LT BLU INSTRUMENT
RED CLR LT BLU/ LT BLU/ X3
RED/ TO SE2 J PANEL MODULE
ORG ORG D SWITCH
YEL/ WHT X3 SERVICE PUR/
DK BLU BLK C TAN/WHT START LT GRN
YEL/ YEL/
BLK SWITCH GRY
BLK
G W S7 B3
D+ BLK
RED/ MANUAL HYDRAULIC B5
(EARLY UNITS ONLY) X3
3 B+
LT BLU PREHEAT p p CHARGE E HYDRAULIC OIL
RED/DK BLU o
U
BLK
SWITCH PRESSURE t TEMPERATURE
G2 PUR/ SWITCH SENSOR
B- ORG
ALTERNATOR B2
LT BLU/ ENGINE OIL BLK BLK
0 1 YEL PRESSURE
S
LT BLU/ 0=OFF LT BLU/ SWITCH
ORG 1= ON YEL PUR/
B X4 LT GRN

RED
to
M BLK
K3 Y2
M
PREHEAT FUEL
BLK RED Y1 RELAY B4
M1 FUEL PUMP BLK ENGINE
STARTING SHUTOFF COOLANT
MOTOR SOLENOID TEMPERATURE
LT BLU/ BLK SENSOR
BLK BLK
B1 TO SE4 FUEL LEVEL
SENSOR GROUND
GLOW
PLUGS OR
MANIFOLD BLK BLK TO SE9 BACKUP
+ ALARM GROUND
HEATER
G1 _
BATTERY
W2
FUEL PUMP BLK
GROUND

W1 STANDARD HARNESS
ENGINE
M57091
GROUND OPTIONAL EQUIPMENT HARNESS

SE1-POWER AND CHARGING CIRCUIT SE2-CRANKING AND FUEL SHUTOFF SOLENOID CIRCUIT SE3-PREHEAT AND FUEL PUMP CIRCUIT SE4-ELECTRONIC INSTRUMENT PANEL MODULE AND INDICATOR LIGHTS

4 - 14 4/17/95
 ELECTRICAL SCHEMATIC ELECTRICAL
BUS BUS BUS BUS

RED RED RED RED RED

F11
F6 TURN
ACCESSORY SIGNAL
FUSE FUSE
ORG/ ORG/
ORG/LT BLU ORG/LT BLU LT BLU LT BLU

LT GRN/ RED/ LT GRN/

LT GRN/BLK LT GRN/BLK BLK LT GRN/ LT GRN/ BLK BLK
TO SE1 BLK BLK
ALTERNATOR X8
RESISTOR F X22
RED/ LT GRN/
GRY BLK X19
LT GRN/
BLK RED/
BLK
K4 K5
ACCESSORY TURN
RELAY X8 CONNECTED TO X22 WITHOUT SIGNAL
TURN SIGNAL OPTION
RELAY
PNK

H10 BLK ORG/

H13 H14 P2 A3 A4 BLK DK BRN
ENGINE H12 ENGINE H15 H16 X8
H11 HYDRAULIC PARKING FUEL HYDRAULIC ELECTRONIC E
COOLANT HYDRAULIC OIL BATTERY COOLANT OIL FILTER AIR FILTER ORG/ TO SE2
RESTRICTION BRAKE LEVEL SOLENOID INSTRUMENT LT GRN START RELAY
TEMPERATURE TEMPERATURE VOLTAGE TEMPERATURE RESTRICTION DISPLAY MODULE X9
PANEL MODULE GROUND
LIGHT LIGHT LIGHT LIGHT 9 BLK BLK
LIGHT (NOT USED) LIGHT LIGHT
BLK
X22

G X13 ORG/ BUS X8 CONNECTED TO X22 WITHOUT

LT GRN TURN SIGNAL OPTION
P
X13 CONNECTED TO X14 WITHOUT ORG/
BACKUP ALARM FUSEBLOCK LT GRN
H17 ORG/
LT GRN H X14
MODULE F9
ALARM F7 BUS F10
ROAD/ BACKUP ATTACHMENT/HORN/
DK GRN/ X10 X10 X10 X10 X9 WORK F8 ALARM 2-SPEED FUSE DK GRN/
ORG 9 10 6 1 3 S10 LIGHT WIPER FUSE
PNK/ TO SE1 KEY SWITCH RED
PUR/
LT BLU
DIAGNOSTIC/ FUSE BATTERY TERMINAL
FUSE
X3 WHT GRY/BLK
B BLK/
YEL/ PNK/ PROGRAM DK GRN/
YEL LT GRN LT BLU MODE ORG/ X32 ORG/ RED
ORG/
BLK 0=OFF WHT
DK GRN/ SWITCH 1=ON
GRY
X17 CONNECTED TO X31 WITHOUT
ORG S1 X17
B6 X6 X15 HIGH FLOW HYDRAULICS OPTION WHT
X11
DOME
HYDRAULIC X3
LIGHT ORG/ X16
H DK GRN/ S22
OIL FILTER p ORG/ GRY RED DK GRN/
RESTRICTION BLK
0=WORK SWITCH 0 1
ORG/
RED TWO SPEED
NOT USED 1=OFF GRY X18
SWITCH 2=ROAD ORG/ S13 TRANSMISSION
Y3 E12 X31 ATTACHMENT 0=OFF
SWITCH
BLK/ HYDRAULIC S19 WHT LEFT 1=ON
X7 S11 DOME BACKUP POWER
BLK
YEL BOOM Y4 LIGHT WASHER CONNECTOR
SOLENOID LIGHT SWITCH S12 0=FORWARD SWITCH
HYDRAULIC 2 1 0 SWITCH WIPER 1=REVERSE DK GRN/
BUCKET RED DK GRN/
PNK DK BLU SWITCH RED 0 0 1
SOLENOID 1
W3 B8 BLK
HYDRAULIC OIL p S20
FUEL 0 1 X29
FILTER RESTRICTION Q LEVEL 0 1 HIGH FLOW WHT/
B7 BLK X12 DK BLU/ 0=OFF ORG/ TAN
SWITCH GROUND AIR FILTER SENSOR WHT 1=ON
0 1 WHT S14 HYDRAULICS
ORG/ 0=OFF WHT
RESTRICTION PNK/ DK BLU/ GRY 1=ON
SWITCH GRN
WHT 0=OFF RIGHT S15
PNK BLK
SWITCH PNK/ GRY/
1=ON
BACKUP HORN
BLK ORG
BLK E5 M SWITCH SWITCH
X7
E3 0
BLK RIGHT REAR 1
RED/
BLK X6 WORK M M2 0=FORWARD
0 1 BLK
E1 FRONT WIPER 1=REVERSE
GRY
RIGHT LIGHT LIGHT M4
WASHER MOTOR X29 Y5 Y6
TAIL H18 BLK HIGH FLOW
TO SE3 BLK LIGHT E4 MOTOR DK BLU/
TWO SPEED
BACKUP VALVE TRANSMISSION
FUEL E2 LEFT ALARM BLK
SOLENOID
PUMP LEFT FRONT BLK SOLENOID
GROUND BLK BLK BLK H19
TAIL BLK LIGHT BLK
BLK LIGHT HORN BLK
BLK BLK BLK BLK
TO SE3-W2 FUEL BLK
PUMP GROUND
BLK

BLK BLK BLK BLK

BLK
W4 W5
STANDARD HARNESS CAB LEFT CAB BLK
GROUND GROUND
M57092 OPTIONAL EQUIPMENT HARNESS

SE5- HYDRAULIC BOOM/ SE6- DIAGNOSTIC/PROGRAM SE8-WIPER/WASHER CIRCUIT

SE4-ELECTRONIC INSTRUMENT PANEL MODULE AND INDICATOR LIGHTS BUCKET LOCKOUT CIRCUIT MODE SWITCH AND ALARM CIRCUIT SE7-LIGHT CIRCUIT SE9-BACKUP ALARM CIRCUIT SE10-ATTACHMENT, HORN, HIGH FLOW, 2-SPEED CIRCUIT

4/17/95 4 - 15
ELECTRICAL ELECTRICAL SCHEMATIC

RED

F12
HEATER ORG/
FUSE DK BRN
ORG/
LT BLU BUS
X26
X24 CONNECTED TO B
X26 WITHOUT TURN
RED/ F14 SIGNAL OPTION - X24 A ORG/
ORG F13 BEACON TO X26 A DK BRN
FLASHING LIGHT
LIGHTS FUSE K7
LT GRN/
BLK FUSE FLASHER
X20 ORG/ ORG/
DK BRN YEL
RED/
ORG
X23 YEL/
X23 RED
K6
HEATER ORG/
DK BRN ORG/
POWER YEL
DK GRN/
RELAY BLK
X24 ORG/
B YEL/ X24
YEL
RED C
ORG/DK BRN S17
BEACON/
ORG/ HAZARD DK GRN/
DK BLU BLK
0=OFF SWITCH
1=ON 0=RIGHT
BLK X21
1=OFF
S21 2=LEFT
S18
BEACON TURN
SWITCH 0 1 SIGNAL
2 1 0
ORG/ 0=OFF CONNECTED TO X23 SWITCH
DK BLU 1=LOW AND X25 WITHOUT 0=BEACON 0 2
1
2=MEDIUM FLASHING LIGHTS 1=OFF
3=HIGH 2=HAZARD
YEL DK BRN/ DK GRN/
LT GRN YEL
X24
S16 D
BLOWER X25
K8
SWITCH TURN SIGNAL
3 0 X24 CONNECTED TO
2 1
X26 WITHOUT TURN X24 CONVERTER
LT GRN/
SIGNAL OPTION - X24 A A
WHT MODULE
TO X26 A
RED/ YEL
YEL
WHT E6 YEL/WHT
BLK
ORG
BEACON
LIGHT
X26
D
BLK DK BRN/ DK GRN BLK
R2 YEL
RESISTOR DK BRN/
ASSEMBLY LT GRN X26
A
DK BRN/
X25 LT GRN
DK BRN/ DK BRN/
LT GRN YEL DK BRN/
YEL
E9
TURN
E7 E8 SIGNAL
ORG
RIGHT RIGHT INDICATOR
REAR FRONT LIGHTS
DK BRN/
BLK
X28 YEL
FLASHING FLASHING
BLK LIGHT LIGHT E10
RED LEFT
BLK FRONT
M3 M BLK BLK FLASHING E11
BLOWER BLK LIGHT LEFT
MOTOR REAR
FLASHING
BLK
BLK LIGHT

BLK

STANDARD HARNESS

M57093 OPTIONAL EQUIPMENT HARNESS

SE11-HEATER CIRCUIT SE12- TURN SIGNAL AND HAZARD LIGHT CIRCUIT

4 - 16 4/17/95
ELECTRICAL WIRING HARNESS

WIRING HARNESS 100 K4

60/31 2 Speed 18 Accessory
Sw
70/78 78 Switch itc 69/68 Relay
60 101 h 21/29
Y3 Ha 37
15/21 Hydraulic rn
Y4 es 69
35 Boom Hydraulic s 8/29
S2 Solenoid Boom 97 18
Service X13 X8
Solenoid 96
Start S7 Manual 8/30 R1 Alternator Resistor
Switch 98 41/42
Preheat Switch K2 10
12
3 19 22 1 38/39 62
61 17/12
Cab Fuse Panel 99 So Start X19
35/54 2 33 6
11 40/41 53 l en Interlock F1 Preheat Circuit
4/1 44/45 o 7 14 Breaker
20 61 33/28 id Relay 64
S3 Key X30 94 Ha 16
Switch X15 To rn 10 Engine
Wiper Harness 54 32 6 2 Speed es
46 s 2 37 Fuse
48/56 62 67 B5 Hydraulic Oil 76 Solenoid
19 13/32 Panel
57 20 S6 Seat Belt 95 67
Bus Temperature 51 X14
Bus Switch Bus
Sensor 11 9
X12 To Light S11 X11 To
Harness W7 56 Light Harness 43 24 58 64 85 R1 Alternator Resistor
Light 76/77
36 Not Engine
Switch 68/65 39
Used Ground
K1 Start K3
45 77 Relay 65/66
Preheat
34 E4 Left 72/73
E3 Right W1 Engine 3/7 14 Relay
Front Light
Front Light 44 Ground
To X11 70/66 16
Light E1 Right
57 Fuse Tail Light

23 46
25/34 48/55 E5 Rear
5/25 Work Light
14 W4 Cab Ground
5 B8 Fuel
13 53
73 Level Sender
17 E2
4 28
36 W7 Light Harness Left 49
73/84
X9 Tail
40 23/43 Light
22
31
38 W4 Cab Ground Y2
1 Fuel
55
A4 Electronic Instrument Panel Module Pump
11 W8 Main Harness
15
63
47 B2 Engine Oil
2726
24
B6 Hydraulic Oil Filter
Pressure
X10 Restriction Switch
52 Switch W1 Engine 84
51 74
50 71 59 Ground
M57721AL 49 B3 Hydraulic
1 Y2 Fuel G2 Alternator
Charge Pressure Shutoff M1 Starting
Switch Solenoid B1 Manifold Motor 89 82
88 81
No. Gage Color No. Gage Color No. Gage Color No. Gage Color No. Gage Color 91 92 Heater 86 87 B4 Engine Coolant
74/75
1 16 Wht 22 18 Tan/Wht 43 18 Blk 64 18 Blk 85 18 Yel/Dk Blu
83 Temperature Sensor
80 79/75
2 16 Wht/Lt Grn 23 18 Blk 44 16 Dk Blu/Wht 65 18 Blk 86 12 Wht/Red 90
86 K1 Start
3 16 Wht/Dk Blu 24 18 Yel/Lt Grn 45 16 Dk Blu/Wht 66 18 Blk 87 6 Red Relay 87 58
4 18 Wht 25 18 BLK 46 16 Pnk/Blk 67 12 Org/Lt Grn 88 8 Red/Dk Blu
93
5 18 Blk 26 18 Yel/Gry 47 18 Dk Grn/Org 68 18 Blk 89 16 Pur/Red
X3
6 16 Wht/Org 27 18 Yel/Blk 48 16 Pnk/Blk 69 18 Blk 90 18 Pur/Lt Grn B7 Air Filter
7 16 Wht/Dk Blu 28 18 Lt Grn 49 18 Pur/Wht 70 16 Blk 91 18 Yel/Blk W6 Engine Harness Restriction
83
8 16 Lt Grn/Blk 29 16 Lt Grn/Blk 50 18 Pur/ Lt Grn 71 18 Yel/Gry 92 16 Lt Blu/Org 27 D 42 92 91 90 Switch
C 89
9 10 Red 30 16 Lt Grn/Blk 51 18 Pur/Lt Blu 72 18 Blk 93 18 Blk/Yel 50 FE 88
80
10 16 Red/Blk 31 18 Pnk/Lt Blu 52 18 Pur/Red 73 16 Blk 94 16 Lt Blu K3 Preheat Relay 30 A 79
81
11 10 Red/Wht 32 16 Lt Grn/Red 53 18 Pur/Org 74 18 Blk 95 16 Blk 52 G 59 M57721AR
12 16 Org 33 16 Wht/Org 54 16 Tan 75 18 Blk 96 16 Lt Blu H J B
85 47 71 93 82
13 18 Red/Lt Grn 34 18 BLK 55 16 Pnk/Blk 76 18 Blk 97 16 Blk 63 26
14 8 Red/Lt Blu 35 18 Lt Grn/Org 56 16 Pnk 77 18 Blk 98 16 Wht X3 Main to Engine Harness Connector
15 18 Lt Grn/Blk 36 18 Pnk 57 16 Org/Blk 78 16 Blk 99 16 Dk Grn/Red
16 8 Red 37 12 Red/Gry 58 16 Blk 79 18 Blk 100 16 Blk
17 18 Org 38 18 Lt Blu/Yel 59 18 Dk Grn/Org 80 8 Blk 101 16 Wht
18 12 Org/Lt Grn 39 18 Lt Blu/Yel 60 16 Pnk/Lt Blu 81 18 Lt Grn/Blk
19 16 Org/Pur 40 18 Lt Blu/Org 61 16 Org/Gry 82 18 Yel/Dk Blu
20 16 Org/Pur 41 16 Lt Blu/Org 62 16 Org/Blk 83 8 Lt Blu/Blk
21 16 Lt Grn/Blk 42 16 Lt Blu Org 63 18 Blk/Yel 84 16 Blk

4/17/95 4 - 17
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

POWER CIRCUIT OPERATION

BUS BUS

0=ACC
1=OFF F3
2=RUN
1,2 1 3=START ELECTRONICS
FUSE (BAT) F6 F11
S3 TURN
KEY
LT GRN/ RED/LT GRN ACCESSORY
3 2
RED
X1 FUSE SIGNAL
1 0 SWITCH FUSE
LT GRN/BLK RED/
LT GRN/BLK BLK
BUS LT GRN/
ORG/PUR ORG/PUR TO SE1 BLK
ALTERNATOR X8
WHT RESISTOR
RED/ RED/ F
WHT ORG/PUR BUS WHT
WHT GRY X19
LT GRN/
0=OFF SEAT F4 LT GRN/ BLK
F2 1= ON SEAT F5
0=SERVICE FUEL BLK
KEY ELECTRONICS
1=RUN S4 S5 PUMP
FUSE S2 SEAT LT GRN/ FUSE (IGN)
0,1 SEAT FUSE
SERVICE SWITCH
RED
0 SWITCH NOT
START 1 ORG
RED SWITCH 1 0 (DELUXE ONLY) USED K4
TO SE7-X8
CONNECTOR ACCESSORY
RELAY
X9 X9 X9 X10
X

1 0 10 14 12 11
ORG
F1 0= OFF SEAT
1= ON SEAT
PREHEAT
LT GRN/ CIRCUIT
BLK
BREAKER
RED A5 H2
R1 K2 ENGINE SEAT BELT
ALTERNATOR START LIGHT
START
RESISTOR INTERLOCK
MODULE
RELAY
A4
RED ELECTRONIC
X3 K1 INSTRUMENT
G
START PANEL MODULE
D+ RELAY
G
YEL/ B+ RED/
DK BLU 3 LT BLU
U RED/DK BLU

G2
ALTERNATOR
S

M K3
PREHEAT
RED
RELAY
M1
STARTING
MOTOR

+
G1 UNSWITCHED POWER
BATTERY -
SWITCHED POWER

OPTIONAL EQUIPMENT HARNESS

W1
ENGINE
M57095 GROUND

4 - 18 2/14/95
CIRCUIT OPERATION AND DIAGNOSIS
CIRCUIT OPERATION AND
DIAGNOSIS
POWER CIRCUIT OPERATION
UNSWITCHED POWER CIRCUITS
Function:
Provides power to the primary machine components
whenever the battery is connected.
Operating Conditions:
Voltage must be present at the following components
with the key switch in the “OFF” position:
• B+ terminal of Starting Motor
• Red/Dk Blu Wire at Alternator
• Red Wires at Start Relay
• Red Wires at Preheat Circuit Breaker
• Red Wires at Key Fuse
• Red/Lt Blu Wire at Preheat Relay
• Red/White Wire at Key Switch
• Light Green/Red Wire at Seat Switch
• Red/Light Green Wire at Pin 14 of Electronic
Instrument Panel Module
• Red/Gry Wire at Accessory Fuse
• Red/Gry Wire at Accessory Relay
• Red/Blk Wire at Turn Signal Fuse
The positive battery cable connects the battery to the
starter. The starter bolt is used as a tie point for the rest
of the electrical system.
The battery cables and starter tie point must be in good
condition to ensure trouble free operation of the vehicle
electrical system. Due to the starter’s high current
requirements, ground cable connections are equally
important.
4/13/95
ELECTRICAL
SWITCHED POWER CIRCUIT
Function:
Provides power to the primary components required to
operate the machine.
Operating Conditions:
Voltage must be present at the following components
with the key switch in the “RUN” position:
• Org/Pur Wire at Key Switch
• Org/Pur Wire at Electronics Fuse
• Org Wire at Electronic Instrument Panel Module
• Org/Pur Wire at Service Start Switch
• Org Wire at Starter Interlock Relay
• Lt Grn/Blk Wire at Key Switch
• Lt Grn/Blk Wire at Electronic Instrument Panel
Module
• Lt Grn/Blk wire at Accessory Relay
• Lt Grn/Blk Wire at Alternator Resistor
• Lt Grn/Blk Wire at Alternator
Operating Conditions:
Voltage must be present at the following components
with the key switch in the “ACC” position:
• Lt Grn/Blk Wire at Key Switch
• Lt Grn/Blk Wire at Electronic Instrument Panel
Module
• Lt Grn/Blk wire at Accessory Relay
• Lt Grn/Blk Wire at Alternator Resistor
• Lt Grn/Blk Wire at Alternator
4 - 19
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

POWER CIRCUIT DIAGNOSIS

Test Conditions:
• Key Switch “OFF”
• Meter negative (-) lead on battery negative (-) terminal
• Meter positive (+) lead on numbered test point
• Check connection for corrosion and loose terminals when testing

Test/Check Point Normal If Not Normal

1. Battery positive terminal 11.8-13.2 volts Test battery

2. Starter solenoid terminal B+ Battery voltage Check battery cables and clamps

3. Alternator terminal B+ Battery voltage Check red/dark blue wire (starter to alternator)

4. Start relay (Red wire) Battery voltage Check red wire (starter to starter relay)

5. Preheat circuit breaker Battery voltage Check red wire (starter relay to circuit breaker)

6. Right cavities of engine fuse panel Battery voltage Check red wire (preheat circuit breaker to
(fuse in place) fuses)

7. Left cavities of engine fuse panel Battery voltage Check for blown fuses
(fuse in place)

8. Red/lt blu wire at preheat relay Battery voltage Check preheat circuit breaker, if OK, check red/
lt blu wire

9. Red/gry wire at accessory relay Battery voltage Check red/gry wire

10. Depress seat switch, service start Dash lights up Check electronics fuse (bat), red/lt grn wire,
switch in run position seat and service start switch

Test Conditions:
• Key switch in “RUN” position

11. Right cavities of accessory fuses Battery voltage Check key fuse, key switch, and wiring

12. Left cavities of accessory fuses Battery voltage Check for blown fuses

13. Service start switch org/pur wire Battery volta ge Check org/pur wire from accessory fuse panel

14. Org wire at start interlock relay Battery voltage Check org wire from accessory fuse panel

15. Org wire at electronic instrument panel Battery voltage Check org wire from accessory fuse panel

16. Red/Lt grn wire electronic instrument Battery voltage Check red/lt grn wire from engine fuse panel
panel module

Test Conditions:
• Key switch in “ACC” position

17. Lt grn/blk wire at accessory relay Battery voltage Check lt grn/blk wire and key switch

18. Lt grn/blk wire at electronic instrument Battery voltage Check lt grn/blk wire
panel module

4 - 20 4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

POWER CIRCUIT DIAGNOSIS (CONTINUED)

ACCESSORY
RELAY 17 Red/Lt Grn
9
ELECTRONIC
16 INSTRUMENT
SEAT PANEL MODULE
SWITCH 10
18
Red/Gry
ENGINE Lt Grn/Red
FUSE PANEL
Lt Grn/Blk Lt Grn/Blk

SERVICE/
7 START SWITCH
8 15
6 13

Org
Red/Lt Blu
Red
5
Org/Pur
Red/Wht Org/Pur 11
12

4 ACCESSORY
FUSE PANEL Org

Red
2

Red 14

START
INTERLOCK
3
RELAY
Red/Dk Blu
1 M57722A

4/13/95 4 - 21
ELECTRICAL
CRANKING CIRCUIT OPERATION
Function:
To energize the starter solenoid, and engage starter
motor to crank engine.
Operating Conditions:
• To crank the engine with the service start switch in
the “RUN” position, the operator must be on the
seat with the seat belt fastened. The key switch
must be in the "START" position.
• With the service start switch in the “SERVICE”
position, the seat belt and seat switches are
bypassed, and the engine will crank anytime the
key switch is in the “START” position.
System Operation:
With the service start switch (S2) in the "RUN"
position:
With the key switch in the "START" position, current
flows from the key switch (S3), through the service
start switch (S2) (White wire), to energize the coil of the
start interlock relay (K2). One set of contacts on the
start interlock relay (K2) carries current from the seat
and seat belt switches (Wht/Org) to energize the start
relay (K1) (Wht/Dk Blu wire). With the start relay
contacts closed, current flows to the “S” terminal of the
starter solenoid (M1). When the starter solenoid
contacts close, the starter motor (M1) is energized
through the power circuit (Red wire).
4 - 22
CIRCUIT OPERATION AND DIAGNOSIS
The electronic instrument panel module is not used in
the cranking circuit but is helpful for diagnosing the
seat and seat belt switches. When the operator seats
on the seat, current from the seat switch flows to the
service start switch, electronic instrument panel
module and lights the module symbols. If the module
symbols light up, the seat switch is good. After the
module symbol lights go out, the seat belt light will flash
until the operator buckles the seat belt. When the seat
belt is buckled, current from the seat belt switch (Lt Grn
wire) flows to the electronic instrument panel and the
seat belt light goes out. If the seat belt light goes out,
the seat belt switch is good.
With the service start switch (S2) in the “SERVICE”
position:
With the key switch in the "START" position, current
flows from the key switch (S3), through the service
start switch (S2) (White wire), to energize the start
relay (K1) (Wht/Dk Blu wire). With the start relay
contacts closed, the starter and fuel shutoff solenoids
are energized. When the starter solenoid contacts
close, the starter motor (M1) is energized through the
power circuit (Red wire).
The service position of the service start switch is used
for diagnostics and adjustments. When the service
start switch is in the service position, the seat switch,
seat belt switch and start interlock relay are bypassed.
This allows the engine to crank and run with the
operator off the seat so the neutral adjustment can be
performed. For diagnostics purposes, if the engine will
not crank with the service start switch in the run
position, move the switch to the service position to
bypass the components and see if the engine will crank
now. If the engine cranks, the seat switch, seat belt
switch or start interlock relay are defective.
4/13/95
 CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

CRANKING CIRCUIT OPERATION

F3
0, 1, 2 1
0=ACC ELECTRONICS
1=OFF
2=RUN FUSE (BAT)
3=START LT GRN/
RED RED/LT GRN
3 0 X1
2 1
S3
KEY LT GRN/
RED
BUS
SWITCH ORG/
PUR

RED/ WHT
WHT
WHT 0= OFF SEAT
1= ON SEAT
F2 F5
0= SERVICE ELECTRONICS
KEY S4
S2 1= RUN S5 FUSE (IGN)
FUSE 0,1
LT GRN/
SEAT RED SEAT
SERVICE
SWITCH 0 SWITCH
START 1 ORG
RED SWITCH 1 0 (DELUXE ONLY)
TAN

F1 WHT/ X1
DK BLU TAN
PREHEAT X9 X9 X9 X9
X

0 11 10 14 12
CIRCUIT WHT/
TAN
1 LT
LT GRN 0= OFF SEAT GRN
BREAKER
WHT/ 1= ON SEAT
ORG X2
X9
K2 0=SEAT BELT 4
DISENGAGED
RED START 1=SEAT BELT DK BLU
ENGAGED
INTERLOCK S6 A5 H2
WHT/ RELAY ENGINE SEAT BELT
DK BLU SEAT BELT
START LIGHT
K1 0 BLK
SWITCH MODULE
BLK 1
START BLK X9
RELAY LT A4 13
X1 X2
GRN ELECTRONIC
RED INSTRUMENT
RED/ CLR
WHT PANEL MODULE
TAN/WHT

(EARLY UNITS ONLY)

BLK
POWER CIRCUIT

SEAT AND SEAT

BELT CIRCUIT
S START INTERLOCK
RELAY CIRCUIT
B
K3
PREHEAT START RELAY CIRCUIT
RELAY
M GROUND CIRCUIT

RED OPTIONAL EQUIPMENT

M1 HARNESS
STARTING
MOTOR

+
G1
BATTERY – BLK

W1 M57094
ENGINE
GROUND

2/15/95 4 - 23
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

CRANKING CIRCUIT DIAGNOSIS

Test Conditions:
• Battery fully charged and in good condition
• Service start switch in “SERVICE” position
• Seat switch depressed, or jumper wire installed in connector
• Seat belt switch activated, or jumper wire installed in connector
• Key switch in “START” position
• Meter negative (-) lead on battery negative (-) terminal
• Meter positive (+) lead on numbered test point
• Check connection for corrosion and loose terminals when testing

Test/Check Point Normal If Not Normal

1. Starting motor M1 Motor turns. Go to Go to step 2

step 10

2. Red/wht wire at key switch S3 Battery voltage Check power circuit

3. Wht wire at key switch S3 Battery voltage Replace key switch

4. Wht wire at service start switch S2 Battery voltage Check wht wire and connections

5. Wht/dk blu wire at service start switch S2 Battery voltage Check service start switch

6. Wht/dk blu wire at start relay K1 Battery voltage Check wht/dk blu wire and connections

7. Wht/Lt Grn wire at start interlock relay Maximum 0.1 ohms Check Wht/ Lt Grn wire and connections
K2 (Key switch in OFF position) resistance from start relay to preheat relay to engine
ground

8. Red/wht wire at start relay K1 (Key Battery voltage Replace start relay
switch in START position)

9. Red/wht wire at starting motor M1 Battery voltage Check red/wht wire and connections, if
OK, test starting motor

Test Conditions:
• Service start switch in “RUN” position
• Key switch in “START” position

10. Wht/lt grn wire at service start switch S2 Battery voltage Replace service start switch

11. Blk wire at start interlock relay K2 Battery voltage Check Blk wire

12. Lt grn/red wire at seat switch S4 Battery voltage Check power circuit

13. Tan wire at seat switch S4 Battery voltage Replace seat switch

14. Tan wire at seat belt switch connector S6 Battery voltage Check tan wire and connections

15. Lt grn wire at seat belt switch S6 Battery voltage Check seat belt switch

16. Lt grn wire at connector X1 Battery voltage Check lt grn wire and connections

17. Wht/org wire at start interlock relay K2 Battery voltage Check wht/org wire and connections

18. Wht/dk blu wire at start interlock relay K2 Battery voltage Replace start interlock relay

19. Wht/dk blu wire at start relay K1 Battery voltage Check wht/dk blu wire and connections

4 - 24 4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

CRANKING CIRCUIT DIAGNOSIS (CONTINUED)

SEAT
SWITCHES To EIPM
13 X9 Pin 11

To Electronic
12 (Bat) Fuse
Blk
Lt Grn Lt Grn/Red
/Red Tan Lt Grn
Tan
X1
CONNECTOR PREHEAT
15 RELAY
Wht/Org
X2
CONNECTOR 6 19
SEAT BELT 14 16 STARTER
SWITCH Lt Grn
RELAY
Wht/
Drk Blu
Tan
Wht/Org
8
18
STARTER Wht/
INTERLOCK Drk Blu
RELAY 11
17
7 Blk
SERVICE
START SWITCH 10 Wht/ Red
Lt Grn

IGNITION Red/Wht 9
SWITCH
4

5 STARTING
Wht MOTOR
2 1
3

Red/Wht

M57711A

4/13/95 4 - 25
ELECTRICAL
CHARGING CIRCUIT, VOLTMETER,
AND BATTERY LIGHT OPERATION
Function:
CHARGING CIRCUIT: To maintain battery voltage at
approximately 11.8 to 13.2 volts.
VOLTMETER AND BATTERY LIGHT: To monitor the
battery voltage through the Electronic Instrument Panel
Module and alert the operator of low voltage. The
battery voltage light (H12) will also flash if the key
switch is left in the “ACC” position to warn the operator
of battery discharge.
Operation Conditions:
CHARGING CIRCUIT: Engine running.
VOLTMETER: The key switch must be in the “RUN”
position, and the electronic instrument panel module
must be set to the voltmeter function indicated by the
battery voltage light (H8).
BATTERY LIGHT CIRCUIT: The key switch must be in
the “RUN” position.
System Operation:
CHARGING CIRCUIT: When the key switch is moved
to the “RUN” position, the external resistor on the
alternator is energized by the lt grn/blk wire, providing
excite current to the alternator field. With the engine
running, current flows from the large alternator “B+”
terminal to the common tie point on the starter, and
then to the positive terminal of the battery. The charge
rate is determined by an internal regulator in the
alternator.
VOLTMETER AND BATTERY LIGHT: The electronic
instrument panel module (A4) measures the voltage
present in the charging circuit at the orange wire
(connector X9 pin 12) and translates this into the
numerical value shown on the display (P1). If a low
voltage condition occurs (less than 11.2 volts), the
electronic instrument panel module lights the battery
voltage light (H12).
If the key switch is left in the “ACC” position, the
module senses voltage at the lt grn/blk wire (connector
X10 pin 11) and flashes the battery voltage light (H12)
to warn the operator of battery discharge.
4 - 26
CIRCUIT OPERATION AND DIAGNOSIS
TACHOMETER CIRCUIT
OPERATION
Function:
To inform the operator of the engine RPM’s.
Operating Conditions:
The engine must be running and the tachometer
function selected indicated by the tachometer light
(H9).
System Operation:
Pulsed current from the “W” terminal of the alternator
flows to the electronic instrument module (A4) at
connector X10 pin 4. The electronic instrument panel
module counts the pulses and translates this
information into the RPM value shown on the display
(P1). The engine code in the configuration mode of the
electronic instrument panel module must be set at “02”
for the tachometer to read correctly.
HOURMETER CIRCUIT OPERATION
Function:
To inform the operator of the engine hours.
Operating Conditions:
The engine must be running and the hourmeter
function selected indicated by the hourmeter digital
display (P1).
System Operation:
The hourmeter circuit is integrated into the electronic
instrument module (A4) and does not have any
external wiring. The hourmeter circuit operates only
when the engine is running. The hourmeter circuit uses
the engine oil pressure circuit to determine when the
engine is running. The engine oil pressure circuit must
be operating correctly for the hourmeter to add running
hours. If the hourmeter does not operate, or store new
running hours when the key switch is turned off, and
the engine oil pressure circuit is OK, the electronic
instrument panel module memory has been disrupted.
Contact DTAC to reset the module memory.
4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

CHARGING CIRCUIT, VOLTMETER, AND BATTERY LIGHT OPERATION

F3
1,2 1
ELECTRONICS
0= ACC FUSE (BAT)
1= OFF
2= RUN
3= START
3 2 1 0
S3 LT GRN/BLK
KEY
SWITCH
PUR/ BUS RED/
RED WHT
LT LT GRN/
GRN/ PUR/ RED
ORG/ BLK RED
PUR

F2 F5
X3 KEY ELECTRONICS
A FUSE FUSE (IGN) A4
ORG
ELECTRONIC
INSTRUMENT
RED X9 X10 X10 X9 PANEL MODULE
12 11 4 14
PUR/
RED
X

F1
r/min
PREHEAT P1
CIRCUIT H9 DIGITAL H8 H12
BREAKER TACHOMETER DISPLAY/ BATTERY BATTERY
LIGHT HOURMETER VOLTAGE VOLTAGE
RED LIGHT LIGHT
LT GRN/
R1 BLK X9-13
ALTERNATOR LT GRN/BLK
RESISTOR X27

X3 PUR/
G RED X8
F
RED

K1 K4
D+ W
START ACCESSORY
YEL/ G RELAY RELAY
DK BLU B+
3 REG
U RED/DK BLU

B-
G2
ALTERNATOR

RED
M1
STARTING
MOTOR

POWER CIRCUIT
+
G1 _
BATTERY CHARGING
BATTERY CIRCUIT

VOLTAGE REGULATOR
BLK
BLK CIRCUIT

W1 TACHOMETER CIRCUIT
ENGINE
GROUND
GROUND CIRCUIT
M57096

3/27/95 4 - 27
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

CHARGING CIRCUIT, VOLTMETER, AND BATTERY LIGHT DIAGNOSIS

Test Conditions:
• Key switch in "OFF" position
• Meter negative (-) lead on battery negative (-) terminal
• Meter positive (+) lead on numbered test point
• Check connection for corrosion and loose terminals when testing
• Battery must be fully charged before performing any tests

Test/Check Point Normal If Not Normal

1. Battery positive terminal 11.8 - 13.2 volts Test battery

2. Starting motor B terminal Battery voltage Check battery cables and clamps

3. Alternator B+ terminal Battery voltage Check red/dk blu wire and connections

4. Black wire at alternator Maximum 0.1 ohms Check battery negative cable, alternator ground
ground terminal resistance cable, connections, and engine ground.

• Alternator resistor (R1) disconnected

• Meter leads on resistor terminals

Test/Check Point Normal If Not Normal

5. Alternator resistor (R1) 45-55 ohms at 77°F (25°C) Replace alternator resistor

• Reconnect resistor leads

• Turn key switch to “RUN” position

Test/Check Point Normal If Not Normal

6. Yel/Dk Blu wire at alternator Battery voltage Check Yel/Dk Blu wires and key switch

7. Switch electronic instrument Voltmeter displays battery Check power circuit, if OK, check electronic
panel module to read voltage voltage instrument panel module

NOTE: Battery voltage light illuminates when battery voltage is below 11.2 or above 16.5 volts. The battery voltage
light is controlled by the electronic instrument panel module, and is not serviceable as a separate circuit. If
problems persist in the battery voltage light or voltmeter but battery voltage is within acceptable range, test
the electronic instrument panel module.

• Turn key switch to “OFF” position

• Battery must be in a fully charged state before performing charging test
• Alternator belt must not be worn or slipping
• Disconnect battery.
• Disconnect red/drk blu wire at alternator “B+” terminal
• Connect ammeter capable of reading 50 amps in-line from “B+” terminal to red/drk blu wire
• Reconnect battery, start engine and run at fast idle

Test/Check Point Normal If Not Normal

8. Ammeter reading 30 amps, steadily decreasing Replace alternator/regulator assembly

9. Instrument panel voltmeter Steadily increasing, to 14.8 Replace alternator/regulator assembly

4 - 28 4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

CHARGING CIRCUIT, VOLTMETER, AND BATTERY LIGHT DIAGNOSIS

7
9

Lt Grn To Accessory
Lt Grn /Blk Relay
/Blk
5
ALTERNATOR

EXTERNAL
ALTERNATOR
RESISTOR
Yel
/Dk Blu
3

TEST
AMMETER
6 8

Red
/Dk Blue
Blk 4

Red
1 2

STARTING
MOTOR

Blk

M57723A

4/13/95 4 - 29
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

TACHOMETER CIRCUIT DIAGNOSIS

Test Conditions:
• Service start switch in “RUN” position
• Operator on seat
• Engine running
• Electronic instrument panel module set to “TACHOMETER” mode (n/min)
• Check connections for corrosion and loose terminals when testing)

Test/Check Point Normal If Not Normal

1. Electronic instrument panel Engine rpm Check the engine code in the
module A4 configuration mode of the electronic
instrument panel module is set at
“02”, if OK, go to step 2

2. Pur/Red wire at alternator G2 At least 6.3 volts Replace alternator

3. Pur/Red wire at electronic Same voltage as found in step 2. If Check Pur/Red wire and
instrument panel module, pin 4, OK, test electronic instrument panel connections
connector X10 module

4. Electronic instrument panel All functions except tachometer Test electronic instrument panel
functioning correctly module

5. Electronic instrument panel Engine rpm Electronic instrument panel module

module A4 memory has been disrupted.
Contact DTAC to reset the module
memory.

4 - 30 4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

TACHOMETER CIRCUIT DIAGNOSIS

5
1

3
4
Pur/Red

2 Pur/Red

M57716A

4/13/95 4 - 31
ELECTRICAL
FUEL SHUTOFF SOLENOID CIRCUIT
OPERATION
Function:
To energize the fuel shutoff solenoid which allows fuel
flow to the fuel injector pump/governor by internally
moving the fuel pump/governor linkage.
The electronic instrument panel module will stop
current flow to the fuel shutoff solenoid to stop the
engine if engine oil pressure or hydraulic charge
pressure drop below acceptable levels for machine
operation.
Operation Conditions:
The fuel shutoff solenoid is energized when the key
switch is moved to the “RUN” position.
If the service start switch is in the “RUN” position, the
operator must be ON the seat and the seat belt must
be FASTENED.
If the service start switch is in the “SERVICE” position,
the operator may be off the seat.
System Operation:
Service start switch (S2) in "RUN" position:
With the seat switch (S4) closed (operator on seat)
current from the electronics fuse (F5) flows through
seat switch and service start switch to the engine start
module (A5) of the electronic instrument panel module
(A4). The electronic instrument panel module
4 - 32
CIRCUIT OPERATION AND DIAGNOSIS
energizes and initiates a bulb check. With the seat belt
switch (S6) closed (seat belt fastened), current from
the seat switch flows to the engine start module and
turns off the seat belt light. When the key switch (S3) is
turned to the “RUN” position, the fuel shutoff solenoid
module (A2) energizes the fuel shutoff solenoid (Y1).
The coil remains energized by the electronic
instrument panel module (A4) until the key switch is
turned to “OFF”.
If engine oil pressure or hydraulic charge pressure drop
below acceptable levels for machine operation, the
engine oil pressure switch (B2) or the hydraulic charge
pressure switch (B3) closes and current flows to
ground. The fuel shutoff solenoid module senses the
current flow and after 30 seconds will stop current flow
to the fuel shutoff solenoid coil, and the engine will
stop.
Service start switch (S2) in the “SERVICE”
position:
When the key switch is turned to the “RUN” position,
current from the fuel pump fuse (F4) flows through
service start switch (the electronic instrument panel
module is by-passed) and energizes the fuel shutoff
solenoid.
The coil remains energized until the key switch is
turned to “OFF”.
With the service start switch in the “SERVICE” position,
the electronic instrument panel module will NOT stop
current flow to the fuel shutoff solenoid if engine oil
pressure or hydraulic charge pressure drop below
acceptable levels for machine operation.
4/13/95
 CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

FUEL SHUTOFF SOLENOID CIRCUIT OPERATION

F3
1 0=ACC ELECTRONICS
1,2 1=OFF
2=RUN FUSE (BAT)
3=START LT GRN RED/LT GRN
RED
3 2 1 0
BUS
S3 X1
KEY
LT GRN
SWITCH RED
ORG/
PUR
RED/ BUS WHT
WHT
WHT ORG/PUR
0=OFF SEAT
F4 F5
F2 1= ON SEAT
FUEL
0=SERVICE ELECTRONICS
KEY S4 PUMP
1=RUN FUSE (IGN)
FUSE S2 SEAT LT GRN/ S5
0,1 RED SEAT FUSE
SERVICE SWITCH
START 0 1
SWITCH
SWITCH (DELUXE ONLY) ORG H5
1 0 A2 LOW
TAN
RED LT FUEL H4 HYDRAULIC
WHT/ X1 GRN/ SHUTOFF LOW ENGINE CHARGE
LT BLU/ORG TAN OIL PRESSURE
DK BLU ORG SOLENOID PRESSURE
X

1 0 LT
X9 X9 X9 X9 MODULE LIGHT LIGHT
WHT/ TAN 11 10 14 12
F1 LT GRN 0= OFF SEAT GRN
WHT/ 1= ON SEAT
PREHEAT WHT/
X30 ORG X2
ORG
CIRCUIT K2 X9
0=SEAT BELT 4
BREAKER START DISENGAGED
INTERLOCK 1=SEAT BELT DK BLU
ENGAGED
RED RELAY S6 A5 H2
WHT/ SEAT BELT ENGINE SEAT BELT
DK BLU START LIGHT
SWITCH
LT BLU/ 0 1
MODULE
BLK BLK
K1 BLK
ORG X10
X9 X9 X10 A4
START LT 13 5 7 8
RELAY X1 GRN X2 MODULE
ORG YEL/
LT BLU/ YEL/ PANEL
CLR ORG GRY
RED/ BLK INSTRUMENT
RED WHT X3 ELECTRONIC
TAN/WHT X3 J
D
LT BLU/ B3
(EARLY UNITS ONLY) ORG
P P HYDRAULIC
CHARGE
BLK PRESSURE
B2 SWITCH
ENGINE OIL
LT BLU/ PRESSURE
ORG SWITCH
S

B Y1
FUEL
SHUTOFF
SOLENOID
M K3 BLK
PREHEAT BLK
RED RELAY
M1
STARTING
MOTOR

+
G1 BLK
BATTERY –

W1
ENGINE POWER CIRCUIT HOLD-IN RELAY CIRCUIT GROUND CIRCUIT
GROUND
SEAT AND SEAT ENGINE OIL AND HYDRAULIC
CHARGE PRESSURE CIRCUIT OPTIONAL EQUIPMENT HARNESS M57097
BELT CIRCUIT

2/6/95 4 - 33
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

FUEL SHUTOFF SOLENOID CIRCUIT DIAGNOSIS

Test Conditions:
• Service start switch in “SERVICE” position
• Key switch in “RUN” position
• Meter negative (-) lead on battery negative (-) terminal
• Meter positive (+) lead on numbered test point
• Check connection for corrosion and loose terminals when testing

NOTE: When performing tests, do not hold key switch in “START” position for longer than 10 seconds to avoid
overheating starter and discharging battery.

1. Fuel shutoff solenoid Y1 Battery voltage present at Lt Blu/ Go to step 2

Org wire on fuel shutoff solenoid.
If battery voltage is present and
fuel solenoid is not allowing fuel
flow, replace fuel injection pump.

2. Start interlock relay K2 Battery voltage present at Lt Blu/ Go to step 3

Org wire on start interlock relay.

3. Service start switch S2 Battery voltage present at Lt Blu/ Go to step 4

Org wire on service start switch.

4. Key switch S3 Battery voltage present at Org/Pur Go to step 5

wire on key switch.

5. Key fuse F2 Battery voltage present at Red
wire on Key fuse F2. Replace key
fuse F2.
Check red wires at Preheat circuit
breaker F1, Start relay K1, Starting
motor M1, and Battery G1 for
battery voltage. Check wires and
connections.

Test Conditions:
• Seat Belt Fastened
• Service start switch in “RUN” position
• Turn key switch “START”

6. Fuel shutoff solenoid Y1 Battery voltage present at Lt Blu/ Go to step 7

Org wire on fuel shutoff solenoid.

7. Start interlock relay K2 Battery voltage present at Wht Lt/ Suspect faulty ignition switch. If
Grn wire on Start interlock relay. voltage is not present at Wht wire on
ignition switch replace switch.

8. Electronics fuse F5 Battery voltage at Org/Pur wire to Test Key switch fuse F2. Replace as
Electronics fuse. Replace fuse F5. necessary.

Test Conditions:
• Service start switch in “RUN” position-Check for error code “ERR02”-check lt blu/org wire
“ERR02” indicates an open or shorted circuit between electronic instrument panel and fuel shutoff solenoid.
• Operator on seat and seat belt fastened or jumper wires installed

9. Lt blu/org wire at connector X9, Battery voltage Test electronic instrument panel
pin 5, electronic instrument panel module

10. Lt blu/org wire at service start Battery voltage Check lt blu/org wire from service/
switch (S2) start switch to electronic instrument
panel module, pin 5, connector X9

4 - 34 4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

FUEL SHUTOFF SOLENOID CIRCUIT DIAGNOSIS (CONTINUED)

8
ELECTRONICS
FUSE F5
Org
/Pur
4
9
X9
KEY 5
Wht
SWITCH
S3
5
Red
To Battery /Wht
+ Terminal Red
KEY Lt Blu
FUSE /Org ELECTRONIC INSTRUMENT PANEL MODULE A4
F2

3 10
SERVICE
START
SWITCH
S2 Org

1 6

Wht
Lt Blu
/Org Lt Blu
/Org FUEL
START SHUTOFF
INTERLOCK SOLENOID
RELAY K2 2 Y1

Wht
/Lt Grn

7
M57726A

4/13/95 4 - 35
ELECTRICAL
GLOW PLUG AND LIGHT CIRCUIT
OPERATION
Function:
To provide current to the glow plugs or manifold heater
to preheat the engine for better starting performance.
Operation Conditions:
AUTO (TIMED): The operator must be on the seat and
the key switch must be in the run position.
MANUAL: The operator must be on the seat and the
manual preheat switch must be depressed.
System Operation:
AUTO (TIMED): When the key switch is turned to the
“RUN” position, the electronic instrument module (A4)
calculates the preheat time required based on voltage
input from the engine coolant temperature sensor (B4).
The engine code in the configuration mode of the
electronic instrument panel module must be set at “02”
4 - 36
CIRCUIT OPERATION AND DIAGNOSIS
for the preheat time to be calculated correctly. The
preheat timer (A1) energizes the coil of the preheat
relay (K3) and lights the preheat light (H3). The digital
display (P1) counts down the number of seconds the
preheat will remain on (based on coolant temperature).
When the counter reaches zero, the module alarm
(H17) beeps to alert the operator that preheat is
complete and the preheat light (H3) goes out.
Current flows from the preheat circuit breaker (F1)
through the contacts of the preheat relay (K3) to the
manifold heater or glow plugs (B1). The preheat circuit
will remain energized until the preheat timer in the
electronic instrument panel module stops current flow
to the coil of the preheat relay.
MANUAL: To manually operate the glow plugs or
manifold heater, the operator must be on the seat, but
the key switch may be in the “OFF” position. The
manual preheat switch (S7) energizes the coil of the
preheat relay (K3). The contacts of the preheat relay
close, and current flows to the glow plugs or manifold
heater (B1). When the manual preheat switch (S7) is
released, current flow to the coil of the preheat relay
stops. The contacts of the preheat relay open and
current flow to the glow plugs or manifold heater stops.
4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

GLOW PLUG CIRCUIT OPERATION

F3
1, 2 1 ELECTRONICS
0= ACC FUSE (BAT)
1= OFF
2= RUN RED/LT GRN
3= START
3 2 1 0 X1
S3
KEY LT GRN/
RED
BUS SWITCH
ORG/PUR

S4
RED/ SEAT
WHT SWITCH
0= OFF SEAT F5
F2 1= ON SEAT ELECTRONICS
KEY FUSE (IGN)
FUSE 0, 1
LT GRN/
0 1 RED
RED 1 0 ORG
TAN
S2 0= SERVICE
SERVICE 1= RUN
TAN
START X1
X

1 0
SWITCH S5
F1 SEAT 0= OFF SEAT
PREHEAT SWITCH 1= ON SEAT
(DELUXE ONLY) P1
CIRCUIT
BREAKER DIGITAL
RED LT GRN/ORG X9 X9 DISPLAY/
12 14 HOURMETER

A1
PREHEAT
TIMER
H3 H17
RED K1 PREHEAT MODULE
START LIGHT ALARM
RELAY S7
RED/LT BLU
MANUAL
PREHEAT X9 X9 X10 A4
2 13 2 ELECTRONIC
SWITCH
INSTRUMENT
PUR/ PANEL MODULE
LT GRN

X3
0 1 LT BLU/ E
S 0= OFF YEL
1= ON LT BLU/
B YEL
PUR/
LTGRN

M K3
RED
PREHEAT BLK
RELAY
M1
STARTING o
MOTOR LT BLU/ t
BLK
B1
G1 GLOW
BATTERY PLUGS OR B4
+ MANIFOLD
BLK ENGINE
HEATER COOLANT
– TEMPERATURE
SENSOR

W1
ENGINE
GROUND
POWER CIRCUIT PREHEAT RELAY CIRCUIT

PREHEAT TIMER CIRCUIT ENGINE COOLANT

SENSOR CIRCUIT
SEAT SWITCH CIRCUIT GROUND CIRCUIT

OPTIONAL EQUIPMENT HARNESS

M57098

2/9/95 4 - 37
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

GLOW PLUG/MANIFOLD HEATER AND LIGHT CIRCUIT DIAGNOSIS

MANUAL PREHEAT

Test Conditions:
• Seat switch depressed or jumper wire installed on connector
• Key switch in “OFF” position
• Meter negative (-) lead on battery negative (-) terminal
• Meter positive (+) on numbered test point
• Check connection for corrosion and loose terminals when testing

Test/Check Point Normal If Not Normal

1. Battery positive terminal (G1) 11.8 - 13.2 volts Test battery

2. Engine ground (W1) Maximum 0.1 ohms Check battery negative cable and
resistance harness ground connection

3. Preheat relay (K3) ground wire terminal Maximum 0.1 ohms Check black (ground) wire and
(blk) resistance connections

4. Tan wire at seat switch (S4) Battery voltage Check power circuit

5. Tan wire at service start switch (S2) Battery voltage Check tan wire

6. Lt grn/org wire at manual preheat switch Battery voltage Check lt grn/org wire
(S7)

7. Red wire at preheat circuit breaker (F1) Battery voltage Check power circuit

Test Conditions:
• Manual preheat switch (S7) depressed

NOTE: To avoid discharging the battery, do not depress the manual preheat switch for longer than a few seconds.

Test/Check Point Normal If Not Normal

8. Red/lt blu wire at preheat circuit breaker Battery voltage Check preheat circuit breaker

9. Red/lt blu wire at preheat relay (K3) Battery voltage Check red/lt blu wire

10. Lt blu/yel wire at manual preheat Battery voltage Replace manual preheat switch
switch

11. Lt blu/yel wire at preheat relay (K3) Battery voltage Check lt blu/yel wire

12. Preheat relay (K3) Relay clicks Relay does not click or cannot
hear go to step 13

13. Lt blu/blk wire at preheat relay Battery voltage Replace preheat relay (K3)

14. Lt blu/blk wire at glow plugs or manifold Battery voltage: if OK, test glow Check lt blu/blk wire
heater plugs or manifold heater

4 - 38 4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

GLOW PLUG/MANIFOLD HEATER AND LIGHT CIRCUIT DIAGNOSIS

SEAT
SWITCHES

PREHEAT 4
CIRCUIT Tan
BREAKER Blk

Tan MANIFOLD
HEATER
3 11
14
9
PREHEAT
8 RELAY
Lt Blu/Blk
Rd/Lt Blu
7 12

13
5
Lt Blu/Yel
10
MANUAL
PREHEAT
SWITCH
SERVICE Lt Grn/Org
START 6
SWITCH Lt Blu/Yel

ENGINE
STARTER GROUND
RELAY
2
X9
2

Red
STARTER
Red

ELECTRONIC INSTRUMENT
PANEL MODULE

BATTERY

M57724A

4/13/95 4 - 39
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

GLOW PLUG/MANIFOLD HEATER AND LIGHT CIRCUIT DIAGNOSIS

AUTOMATIC PREHEAT

Test Conditions
• Seat switch depressed or jumper wire installed on connector
• Key switch in “RUN” position
• Meter negative (-) lead on battery negative (-) terminal
• Meter positive (+) lead on numbered test point
• Check connection for corrosion and loose terminals when testing

NOTE: Turn key switch from “OFF” to “RUN” as often as necessary to ensure that electronic instrument module
timer is energizing preheat relay when performing test.

Test/Check Point Normal If Not Normal

1. Preheat light (H3) Illuminates for up to 45 seconds Check bulb

2. Electronic instrument panel Digital display counts down during Check engine code configuration
module (A4) and alarm (H17) preheat (up to 45 seconds), alarm mode is set at “02”, if OK, check
beeps when preheat is complete. No module. “ERR04” code-check lt blu/
“ERR04” in display. yel wire from module for open/short.

3. Preheat relay Listen for click when energized No click or cannot hear go to step 4

4. Pin 2, connector X9 at Battery voltage for up to 45 seconds Check electronic instrument module
electronic instrument panel
module (lt blu/yel wire)

5. Lt blu/yel wire at manual Battery voltage for up to 45 seconds Check lt blu/yel wire and
preheat switch connections

6. Lt blu/yel wire at preheat relay Battery voltage for up to 45 seconds Check lt blu/yel wire and
(K3) connections

7. Red wire at preheat circuit Battery voltage See POWER CIRCUIT diagnosis
breaker

8. Red/lt blu wire at preheat Battery voltage Replace preheat circuit breaker
circuit breaker

9. Red/lt blu wire at preheat relay Battery voltage Check red/lt blu wire

• Key switch in “OFF” position

10. Blk wire at preheat relay Maximum 0.1 ohm resistance Check blk wire and ground circuit

11. Lt Blu/Blk wire at glow plug or Maximum 0.5 ohm resistance Replace manifold heater
manifold heater

• Key switch in “RUN” position

12. Lt blu/blk wire at preheat Battery voltage Replace preheat relay

relay

13. Lt blu/blk wire at glow plug or Battery voltage: Check lt blu/blk wire
manifold heater Test glow plug or manifold heater

4 - 40 4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

GLOW PLUG/MANIFOLD HEATER AND LIGHT CIRCUIT DIAGNOSIS

SEAT
SWITCHES

PREHEAT
CIRCUIT Tan
BREAKER Blk
Tan MANIFOLD
10 HEATER
6
13 11
9
PREHEAT
8 RELAY
Lt Blu/Blk
Rd/Lt Blu
7 3

12

Lt Blu/Yel
5
MANUAL
PREHEAT
SWITCH
SERVICE
START Lt Grn/Org
SWITCH Lt Blu/Yel

ENGINE
STARTER GROUND
RELAY
4 X9 2
2

Red
Red STARTER

1
ELECTRONIC INSTRUMENT
PANEL MODULE

BATTERY

M57724A

4/13/95 4 - 41
ELECTRICAL
HYDRAULIC CHARGE PRESSURE
LIGHT CIRCUIT OPERATION
Function:
To warn the operator of a low charge pressure
condition in the hydraulic system by illuminating a
lamp, sounding an alarm, and shutting off the engine
after a brief period to prevent damage to the main
hydraulic pump.
Operating Conditions:
The service start switch (S2) must be in the “RUN”
position, the key switch (S3) must be in the “RUN”
position with the engine running, and the hydraulic
charge pressure switch (B3) must be closed.
System Operation:
NOTE: The hydraulic charge pressure switch will be
closed if the engine is not running or the
hydraulic charge pressure is below 345 kPa
(50 psi).
With the key switch in the “RUN” position and the
engine running, hydraulic charge oil pressure opens
the contacts on the hydraulic charge pressure switch.
When hydraulic pressure drops below 345 kPa (50
psi), the switch (B3) closes, and current from the yel/
gry wire flows to ground. The electronic instrument
panel module (A4) senses this current flow; sounds the
module alarm (H17) and flashes the low hydraulic
charge pressure light (H5) and the stop engine light
(H1). After 30 seconds, the electronic instrument panel
module stops the current flow to the fuel shutoff
solenoid (Y1), shutting off the engine.
NOTE: With the service start switch (S2) in the
“SERVICE” position, the electronic instrument
panel module will NOT stop current flow to the
fuel shutoff solenoid.
4 - 42
CIRCUIT OPERATION AND DIAGNOSIS
ENGINE OIL PRESSURE LIGHT
CIRCUIT OPERATION
Function:
To alert the operator of low engine oil pressure by
illuminating a lamp, sounding an alarm, and shutting off
the engine after a brief period to prevent engine
damage.
Operating Conditions:
The service start switch (S2) must be in the “RUN”
position, the key switch (S3) must be in the “RUN”
position with the engine running, and the oil pressure
switch (B2) must be closed.
System Operation:
NOTE: The engine oil pressure switch will be closed if
the engine is not running or the oil pressure is
below 28 kPa (4psi).
With the key switch in the “RUN” position and the
engine running, engine oil pressure opens the contacts
on the engine oil pressure switch. When engine oil
pressure drops below 28 kPa (4psi), the switch closes,
and the electronic instrument panel module (A4)
begins to flash the low engine oil pressure light (H4)
and stop engine light (H1). After approximately 10
seconds, the module alarm (H17) will sound to warn
the operator of the condition. If the service start switch
is in the “RUN” position, the electronic instrument panel
module will stop the engine after 30 seconds by
shutting off current to the fuel shutoff solenoid.
NOTE: The electronic instrument panel module will
monitor the engine coolant temperature and
prevent engine shutdown from low oil pressure
when oil is very thick from low ambient
temperatures.
4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

HYDRAULIC CHARGE / ENGINE OIL PRESSURE CIRCUIT OPERATION

BUS

1,2 1 F3
0=ACC
1=OFF ELECTRONICS
2=RUN
3=START FUSE (BAT)
3 2 1 0
S3
KEY
SWITCH
ORG/PUR LT GRN/
RED/ RED
WHT
ORG/PUR
S2 F4
SERVICE FUEL F5
F2 START PUMP ELECTRONICS
KEY SWITCH FUSE FUSE (IGN)
FUSE 0,1
H4
A2 LOW H5
1 0 ORG
RED FUEL ENGINE LOW
0= SERVICE HYDRAULIC
1= RUN SHUTOFF OIL
SOLENOID CHARGE
MODULE PRESSURE PRESSURE
X

X9 X9
K2 12 14 LIGHT LIGHT
F1 START LT BLU/
INTERLOCK ORG
PREHEAT
CIRCUIT RELAY
BREAKER STOP

RED H1
H17 ENGINE
MODULE STOP
LT BLU/ ALARM LIGHT
ORG
X9 X9 X10 X10 A4
X3 5 13 7 8
C ELECTRONIC
YEL/ INSTRUMENT
LT BLU/ORG GRY PANEL MODULE
RED YEL/
K1 BLK
START X3
RELAY X3 J
D
B3
p p
HYDRAULIC
CHARGE
B2 PRESSURE
ENGINE OIL SWITCH
PRESSURE
S
LTBLU/ SWITCH
ORG

Y1
FUEL
M
SHUTOFF
SOLENOID BLK
BLK
RED
M1
STARTING
MOTOR

+
G1
_ BATTERY

W1
ENGINE
GROUND

ENGINE OIL PRESSURE

POWER CIRCUIT SWITCH CIRCUIT
HOLD-IN RELAY CIRCUIT
HYDRAULIC CHARGE PRESSURE
GROUND CIRCUIT SWITCH CIRCUIT
M57100

2/27/95 4 - 43
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

HYDRAULIC CHARGE PRESSURE LIGHT CIRCUIT DIAGNOSIS

Test Conditions:
• Key switch in “OFF” position
• Hydraulic charge pressure switch leads disconnected
• Check connection for corrosion and loose terminals when testing

Test/Check Point Normal If Not Normal

1. Hydraulic charge pressure Continuity between two terminals of Replace switch

switch terminals switch (switch closed)

Test Conditions:
• Service start switch in the “SERVICE” position
• Start engine

2. Hydraulic charge pressure No continuity between two terminals Replace switch

switch terminals of switch (switch open)

Test Conditions:
• Key switch in “OFF” position
• Service start switch in the “RUN” position

Procedure:
• Raise off seat until electronic instrument panel module lights go OFF.
• Depress and hold diagnostic program mode switch (A), do not sit on seat.
• Turn key switch to “RUN” position
• Release diagnostic program mode switch
The digital display will show a “d” in the left side of the display (B) indicating the module is in the diagnostic mode.

3. Electronic instrument panel When yel/gry wire at hydraulic charge Check yel/gry wire and
module in diagnostic mode pressure switch is touched to ground, the connections
electronic instrument panel lights will flash
and module alarm will “beep”.

Test Conditions:
• Exit diagnostic mode by turning key switch to “OFF” position
• Jumper wire installed between yel/gry wire and blk wires at hydraulic charge pressure switch lead.
• Service start switch in “RUN” position
• Start engine

4. Electronic instrument module Low hydraulic charge pressure Test electronic instrument panel
lamp on, engine stop lamp on, module
module alarm sounds

5. Fuel shutoff solenoid After 30 seconds, no battery voltage. Test electronic instrument panel
Engine stops when fuel supply is module
shut off.

4 - 44 4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

HYDRAULIC CHARGE PRESSURE LIGHT CIRCUIT DIAGNOSIS

3
2
1

A
4

M57725A

4/13/95 4 - 45
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

ENGINE OIL PRESSURE LIGHT

CIRCUIT DIAGNOSIS

Test Conditions:
• Key switch in “OFF” position • Engine oil pressure switch lead disconnected
• Service start switch in the “RUN” position • Check connection for corrosion and loose terminals
when testing

Procedure:
1. Raise off seat until electronic instrument panel 3. Turn key switch to “RUN” position
module lights go OFF.
4. Release diagnostic program mode switch
2. Depress and hold diagnostic program mode switch
(A), do not sit on seat.

The digital display will show a “d” in the left side of the
display (B) indicating the module is in the diagnostic
mode.

Test/Check Point Normal If Not Normal

1. Yel/blk wire at engine oil When yel/blk wire is touched to Check yel/blk wire and engine
pressure switch B2 ground, the electronic instrument harness connector
panel lights will flash and module
alarm will “beep”

Test Conditions:
• Exit diagnostic mode by turning key switch to “OFF” • Short engine coolant temperature sensor wire to
position ground.
• Service start switch in “RUN” position • Engine oil pressure switch yel/blk lead jumped to
• Short hydraulic oil temperature sensor pur/lt blu ground
wire to ground. • Start engine

Test/Check Point Normal If Not Normal

2. Electronic instrument panel Engine oil pressure light (H4) and stop Test electronic instrument panel
module A4 engine light (H1) flashing, audible alarm module
sounds, fuel shutoff solenoid shuts engine
down after 30 seconds

Test Conditions:
• Engine oil pressure switch yel/blk lead disconnected from ground, engine running

3. Engine oil pressure switch No continuity to ground (maximum Check engine oil pressure, if
B2 resistance) OK, replace oil pressure switch

• Test Conditions:
• Key switch in “OFF” position

Test/Check Point Normal If Not Normal

4. Engine oil pressure switch B2 Maximum 0.1 ohms resistance to Check ground circuit, if OK, replace
ground oil pressure switch

4 - 46 4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

ENGINE OIL PRESSURE LIGHT CIRCUIT DIAGNOSIS (CONTINUED)

4 3
B
1 Yel/Blk
X10
7

2
A

M57719A

4/13/95 4 - 47
ELECTRICAL
ENGINE COOLANT TEMPERATURE
LIGHT OPERATION
Function:
To inform the operator of the engine coolant
temperature, and warn of a high temperature condition
by lighting a lamp, and sounding an alarm.
Operating Conditions:
The key switch must be in the “RUN” position and the
engine coolant temperature function selected,
indicated by the engine coolant temperature light (H6).
System Operation:
Current flows from the electronic instrument panel
module (A4) through the engine coolant temperature
sensor (B4) to ground. The sensor input voltage must
be a constant 5 volt current for the module computer to
process the sensor reading correctly. Current flow
through the sensor is controlled by a temperature
sensitive variable resistor. As the coolant temperature
increases, the amount of resistance in the sensor
decreases accordingly. This change in resistance is
sensed by the electronic instrument panel module
through the resulting change in voltage, and is
translated into the temperature value shown on the
digital display. When the coolant temperature reaches
216°F (102°C), the electronic instrument panel module
turns on the red engine coolant temperature light
(H13). After approximately 10 seconds, the electronic
instrument module sounds the module alarm (H17) to
warn the operator of the condition.
The amber engine coolant temperature light (H10) is
NOT used.
At engine start-up, the digital display will show “COLD”
instead of a numeric value until the engine coolant
temperature reaches 110°F (43°C).
4 - 48
CIRCUIT OPERATION AND DIAGNOSIS
HYDRAULIC OIL TEMPERATURE
LIGHT CIRCUIT OPERATION
Function:
To inform the operator of the hydraulic oil temperature,
and warn of a high temperature condition by lighting a
lamp.
Operating Conditions:
The key switch must be in the “RUN” position and the
hydraulic oil temperature function selected, indicated
by the hydraulic oil temperature light (H7).
System Operation:
Current flows from the electronic instrument panel
module (A4) through the hydraulic oil temperature
sensor (B5) to ground. The sensor input voltage must
be a constant 5 volt current for the module computer to
process the sensor reading correctly. Current flow
through the sensor is controlled by a temperature
sensitive variable resistor. As the oil temperature
increases, the amount of resistance in the sensor
decreases accordingly. This change in resistance is
sensed by the electronic instrument panel module
through the resulting change in voltage, and is
translated into the temperature value shown on the
digital display. When the hydraulic oil temperature
reaches about 200°F (93°C), the electronic instrument
panel module turns on the red hydraulic oil temperature
light (H11) to warn the operator of the condition.
At engine start-up, the digital display will show “COLD”
instead of a numeric value until the hydraulic oil
temperature reaches 110°F (43°C).
4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

ENGINE COOLANT / HYDRAULIC OIL TEMPERATURE LIGHT OPERATION

1,2 1 F3
ELECTRONICS
FUSE(BAT)
3 2 1 0
S3 0= ACC
1= OFF
KEY 2= RUN
BUS SWITCH ORG/ 3= START
PUR LTGRN/
RED

RED/
WHT
F5
F2 ELECTRONICS
KEY FUSE (IGN) H13
FUSE ORG H7 P1 ENGINE
HYDRAULIC OIL DIGITAL COOLANT
X9 X9 TEMPERATURE DISPLAY/ TEMPERATURE
RED 12 14 LIGHT HOURMETER LIGHT
X

F1
PREHEAT H11
CIRCUIT H17 HYDRAULIC OIL
BREAKER MODULE TEMPERATURE
ALARM LIGHT
RED
X9 S8 H6 X10 X10 A4
13 DISPLAY 2 3 ELECTRONIC
SELECT ENGINE PUR/
COOLANT PUR/ LT BLU INSTRUMENT
SWITCH LTGRN PANEL MODULE
TEMPERATURE
LIGHT
RED X3
E
K1 B5
START o
HYDRAULIC OIL
RELAY t TEMPERATURE
SENSOR
PUR/
LT GRN

S o
t
B BLK

B4
ENGINE
COOLANT
M
TEMPERATURE
SENSOR
RED
M1
STARTING
MOTOR

BLK
+
G1
_ BATTERY

HYDRAULIC OIL TEMPERATURE

POWER CIRCUIT
W1 SENSOR CIRCUIT
ENGINE ENGINE COOLANT TEMPERATURE
GROUND GROUND CIRCUIT
SENSOR CIRCUIT
M57099

12/15/94 4 - 49
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

ENGINE COOLANT TEMPERATURE LIGHT DIAGNOSIS

Test Conditions:
• Key switch in “OFF” position
• Service start switch in the “RUN” position
• Engine coolant temperature sensor lead disconnected
• Check connection for corrosion and loose terminals when testing

Procedure:
1. Raise off seat until electronic instrument panel module lights go OFF.
2. Depress and hold diagnostic program mode switch (A), do not sit on seat.
3. Turn key switch to “RUN” position.
4. Release diagnostic program mode switch.
The digital display will show a “d” in the left side of the display (B) indicating the module is in the diagnostic mode.

Test/Check Point Normal If Not Normal

1. Pur/lt grn wire at engine When wire is touched to ground, the Check pur/lt grn wire from sensor to
coolant temperature sensor electronic instrument panel lights will pin 2, connector X10 at electronic
flash and module alarm will “beep” instrument panel module

Test Conditions:
• Exit diagnostic mode by turning key switch to “OFF” position
• Key switch in “RUN” position
• Pur/lt grn wire at coolant temperature sensor jumped to ground

Test/Check Point Normal If Not Normal

2. Electronic instrument panel Temperature gauge reads Test electronic instrument panel
module approximately 250°F (120°C) module
Engine coolant temperature light
(H6, H13) flash

• Key switch “OFF”

Test/Check Point Normal If Not Normal

3. Engine coolant temperature Continuity to ground - (resistance Replace engine coolant

sensor will depend on engine temperature) temperature sensor
Sensor threads not corroded

• Engine coolant temperature sensor remains jumped to ground

• Start engine

Test/Check Point Normal If Not Normal

4. Electronic instrument panel Display reads greater than 220° Test electronic instrument module
module (104°C), engine coolant temperature
light illuminated, module alarm
sounds after 10 seconds.

4 - 50 4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

ENGINE COOLANT TEMPERATURE LIGHT DIAGNOSIS (CONTINUED)

Pur/Lt Grn

2 4
B

X3
D
X10
2

2 4

M57718A

4/13/95 4 - 51
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

HYDRAULIC OIL TEMPERATURE LIGHT DIAGNOSIS

Test Conditions:
• Key switch in “OFF” position
• Service start switch in the “RUN” position
• Hydraulic oil temperature sensor lead disconnected
• Check connection for corrosion and loose terminals when testing

Procedure:
1. Raise off seat until electronic instrument panel module lights go OFF.
2. Depress and hold diagnostic program mode switch (A), do not sit on seat.
3. Turn key switch to “RUN” position.
4. Release diagnostic program mode switch.
The digital display will show a “d” in the left side of the display (B) indicating the module is in the diagnostic mode.

Test/Check Point Normal If Not Normal

1. Pur/lt blu wire at hydraulic oil When wire is touched to ground, the Check pur/lt blu wire from sensor to
temperature sensor electronic instrument panel lights will pin 3, connector X10 electronic
flash and module alarm will “beep instrument panel module

Test Conditions:
• Exit diagnostic mode by turning key switch to “OFF” position

Test/Check Point Normal If Not Normal

2. Hydraulic oil temperature Maximum 0.1 ohms resistance to Check blk wire and engine ground
sensor blk wire ground connections

3. Hydraulic oil temperature Continuity to ground (resistance will Replace hydraulic oil temperature
sensor depend on oil temperature) sensor
Sensor threads not corroded.

Test Conditions:
• Key switch in “RUN” position
• Pur/lt blu wire jumped to ground

Test/Check Point Normal If Not Normal

4. Electronic instrument module Hydraulic oil temperature light Test electronic instrument module
flashing

5. Electronic instrument module Hydraulic temperature display reads Test electronic instrument module
approximately 250°F (120°C)

4 - 52 4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

HYDRAULIC OIL TEMPERATURE LIGHT DIAGNOSIS (CONTINUED)

Pur/Lt Blu

B 5 4

X10
3
A

M57717A

4/13/95 4 - 53
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

HYDRAULIC OIL FILTER FUEL LEVEL DISPLAY CIRCUIT

RESTRICTION LIGHT CIRCUIT OPERATION
OPERATION
Function:
Function: To inform the operator of the fuel level in the tank.
To inform the operator of a restriction in the hydraulic
oil filter, indicating that the filter is clogged and should
Operating Conditions:
be changed.
The operator must be on the seat.

Operating Conditions:
The key switch must be in the “RUN” position with the
engine running.
System Operation:
When the hydraulic oil filter becomes clogged,
pressure increases at the hydraulic oil filter restriction
switch (B6), opening the switch. Normally, current flows
from the electronic instrument panel module (A4)
through the switch (B6) to ground. If a restriction
occurs, the switch (B6) opens. The electronic
instrument panel module senses the open circuit,
lighting the hydraulic oil filter restriction light (H14).
AIR FILTER RESTRICTION LIGHT
CIRCUIT OPERATION
System Operation:
Current flows from the electronic instrument panel
module (A4) to the fuel gauge sensor (B8). The sensor
input voltage must be a constant 5 volt current for the
module computer to process the sensor reading
correctly. Current flow through the sensor is controlled
by a variable resistor. As the sensor float moves up in
response to the fuel level, the amount of resistance
decreases. This change in resistance is sensed at the
electronic instrument panel module which lights the
appropriate number of bars on the fuel level display
(P2) to indicate fuel level.
When the fuel level is at the 1st or 2nd bar, the bars will
flash indicating the fuel level is low. At the same time
the bars flash, the module alarm will “beep” for five
seconds.

Function:
To inform the operator of a restriction in the air filter,
indicating that the filter is clogged and should be
serviced.

Operating Conditions:
The key switch must be in the “RUN” position with the
engine running.

System Operation:
When the air filter becomes clogged, vacuum
increases at the air filter restriction switch (B7),
opening the switch. The electronic instrument panel
module (A4) senses this open switch, and turns on the
air filter restriction light (H15). The module alarm (H17)
will also beep for about 5 seconds.

4 - 54 4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

HYDRAULIC OIL RESTRICTION LIGHT, AIR FILTER RESTRICTION LIGHT,

AND FUEL LEVEL DISPLAY CIRCUIT OPERATION

1,2 1
F3
ELECTRONICS
FUSE (BAT)
3 2 1 0
S3 0=ACC
1=OFF
KEY 2=RUN
BUS SWITCH ORG/ 3=START
LT GRN/
PUR RED
A4
RED/ ELECTRONIC
WHT INSTRUMENT
F5
ELECTRONICS PANEL MODULE
F2
KEY FUSE (IGN) H14
HYDRAULIC H15 P2
FUSE ORG OIL FILTER AIR FILTER FUEL
RESTRICTION RESTRICTION LEVEL
X9 X9
RED 12 14 LIGHT LIGHT DISPLAY
X

F1
PREHEAT H17
CIRCUIT MODULE
BREAKER ALARM
RED X9 X10 X10 X10
13 9 10 1
BLK/ PUR/
DK GRN/
YEL WHT
ORG
X3
B X3
RED B6 H
HYDRAULIC
K1 OIL FILTER P

START RESTRICTION
SWITCH BLK/
RELAY YEL
BLK

B8
W3
P
FUEL
B7 Q LEVEL
BLK HYDRAULIC AIR FILTER
FILTER OIL SENSOR
S
RESTRICTION RESTRICTION
B3 SWITCH GROUND SWITCH
B
HYDRAULIC
CHARGE
PRESSURE
M SWITCH

RED
P BLK
M1 BLK
STARTING
MOTOR

BLK BLK
+
G1
BATTERY _

BLK

W1
ENGINE
GROUND
POWER CIRCUIT AIR FILTER RESTRICTION
LIGHT CIRCUIT
HYDRAULIC OIL FILTER
RESTRICTION LIGHT CIRCUIT FUEL LEVEL GROUND CIRCUIT
DISPLAY CIRCUIT
M57101

2/3/95 4- 55
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

HYDRAULIC OIL FILTER RESTRICTION LIGHT CIRCUIT DIAGNOSIS

Test Conditions:
• Key switch in “OFF” position
• Service start switch in the “RUN” position
• Check connection for corrosion and loose terminals when testing

Procedure:
1. Raise off seat until electronic instrument panel module lights go OFF.
2. Depress and hold diagnostic program mode switch (A), do not sit on seat.
3. Turn key switch to “RUN” position.
4. Release diagnostic program mode switch.

The digital display will show a “d” in the left side of the display (B) indicating the module is in the diagnostic mode.

Test/Check Point Normal If Not Normal

1. Dk Grn/Org wire at hydraulic When wire is removed from sensor and Check Dk Grn/Org wire to
oil filter restriction switch B6 shorted to ground, the electronic electronic instrument panel
instrument panel module lights will flash module connector X10, pin 9
and module alarm will “beep

Test Conditions:
• Exit diagnostic mode by turning key switch to “OFF” position
• Meter negative (-) lead on battery negative (-) terminal
• Meter positive (+) on numbered test point

Test/Check Point Normal If Not Normal

2. Hydraulic oil filter restriction Maximum 0.1 ohms resistance Check battery negative cable,
switch ground black wire, and engine ground
connection

3. Oil filter restriction switch B6 Continuity to ground Replace switch

Test Conditions:
• Key switch in “RUN” position
• Hydraulic oil temperature sensor shorted to ground
• Hydraulic oil filter restriction switch drk grn/org lead removed from sensor.

Test/Check Point Normal If Not Normal

4. Electronic instrument panel Hydraulic oil filter restriction light Test electronic instrument panel
module A4 flashes after 5 seconds module A4

4 - 56 4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

HYDRAULIC OIL FILTER RESTRICTION LIGHT CIRCUIT DIAGNOSIS

1
3

A 4 M57714A

4/13/95 4 - 57
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

AIR FILTER RESTRICTION LIGHT CIRCUIT DIAGNOSIS

Test Conditions:
• Key switch in “OFF” position
• Service start switch in the “RUN” position
• Check connection for corrosion and loose terminals when testing
Procedure:
1. Raise off seat until electronic instrument panel module lights go OFF.
2. Depress and hold diagnostic program mode switch (A), do not sit on seat.
3. Turn key switch to “RUN” position
4. Release diagnostic program mode switch
The digital display will show a “d” in the left side of the display (B) indicating the module is in the diagnostic mode.

Test/Check Point Normal If Not Normal

1. Blk/yel wire at air filter When Blk/Yel wire is removed from Check blk/yel wire from switch to
restriction switch B7 sensor, the electronic instrument pin 10, connector X10 electronic
panel module lights will flash and instrument panel module A4
module alarm will “beep”

Test Conditions:
• Exit diagnostic mode by turning key switch to “OFF” position
• Meter negative (-) lead on battery negative (-) terminal
• Meter positive (+) on numbered test point

Test/Check Point Normal If Not Normal

2. Blk wire at air filter restriction Maximum 0.1 ohms resistance Check black wire and engine
switch B7 ground

3. Air filter restriction switch Continuity to ground Replace switch

terminal (C)

Test Conditions:
• Key switch in “RUN” position
• Blk/yel wire removed from air filter restriction switch

Test/Check Point Normal If Not Normal

4. Electronic instrument panel Air filter restriction light flashes Test electronic instrument panel
module A4 module A4

4 - 58 4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

AIR FILTER RESTRICTION INDICATOR LIGHT CIRCUIT DIAGNOSIS

1
Blk
Yel/Blk

2
3

C B
4 ENGINE
CONNECTOR
X3

d
X3
B

X10
10

M57713A

4/13/95 4 - 59
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

FUEL LEVEL DISPLAY CIRCUIT DIAGNOSIS

Test Conditions:
• Key switch in “OFF” position
• Meter negative (-) lead on battery negative (-) terminal
• Meter positive (+) on numbered test point
• Check connection for corrosion and loose terminals when testing

Test/Check Point Normal If Not Normal

1. Blk wire at fuel gauge sender Maximum 0.1 ohms resistance Check black wire and connections to
B8 fuel pump Y2 ground

Test Conditions:
• Service start switch in the “RUN” position
• Pur/wht wire disconnected from fuel level sensor
Procedure:
• Raise off seat until electronic instrument panel module lights go OFF.
• Depress and hold diagnostic program mode switch (A), do not sit on seat.
• Turn key switch to “RUN” position.
• Release diagnostic program mode switch.
The digital display will show a “d” in the left side of the display (B) indicating the module is in the diagnostic mode.

2. Pur/wht wire at fuel level When wire is touched to ground, the Check pur/wht wire from sensor to
sensor B8 electronic instrument panel module pin 1, connector X10 electronic
lights will flash and module alarm will instrument panel module
“beep”

Test Conditions:
• Exit diagnostic mode by turning key switch to “OFF” position
• Pur/wht wire disconnected from fuel level sensor
• Operator on seat or jumper wire installed in connector
• Key switch in “RUN” position

3. Electronic instrument panel Bottom bar of fuel level display P2 Test electronic instrument panel
module A4 flashes (gauge reads “empty”) module A4

Test Conditions:
• Pur/wht wire jumped to ground

4. Electronic instrument panel All bars of fuel level display Test electronic instrument panel
module A4 illuminated (gauge reads “full”) module A4

Test Conditions:
• Pur/wht and blk wire connected to fuel level sensor
• Fuel level sensor removed from fuel tank

5. Fuel level display P2 Responds to float movement Replace fuel level sender

4 - 60 4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

FUEL LEVEL DISPLAY CIRCUIT DIAGNOSIS (CONTINUED)

A
Pur/Wht 3
Blk
4
2 5
1

FUEL
LEVEL
SENSOR
B8

M57712A

4/13/95 4 - 61
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

HYDRAULIC BOOM AND BUCKET Service start switch in “SERVICE” position:

LOCKOUT CIRCUIT OPERATION
Function:
To lock the boom and bucket controls when the
operator is out of the seat, or when the loader is started
in the “SERVICE” mode to prevent injury to the
operator.
When the service start switch is in the service position,
current from the seat switch is stopped at the service
start switch, bypassing the electronic instrument panel
module. The hydraulic solenoid module logic sequence
is not satisfied and the hydraulic solenoid module does
not energizes the boom solenoid valve and bucket
solenoid valve. This prevents boom and bucket valve
operation when the engine is running and the operator
is off the seat.

Operating Conditions:
To unlock the boom and bucket controls, the operator
must be on the seat, with the seat belt fastened, the
key switch must be in the “RUN” position, and the
service start switch must be in the “RUN” position.
The electronic instrument panel module requires
voltage input in a specific sequence to energize the
hydraulic solenoid module. The electronic instrument
panel module must receive seat switch voltage
(operator on seat) first and then receive seat belt
voltage (seat belt fastened). If the operator fastens the
seat belt first and then sits on the seat, the hydraulic
solenoid module will NOT energize.
If the service start switch is in the “SERVICE” position,
the hydraulic solenoid module will NOT energize.

System Operation:

Service start switch in “RUN” position:

With the seat switch (S4) closed (operator on seat)
current from the electronics fuse (F5) flows through
seat switch and service start switch to the engine start
module (A5) of the electronic instrument panel module
(A4). The electronic instrument panel module
energizes and initiates a bulb check and the hydraulic
solenoid module logic sequence. With the seat belt
switch (S6) closed (seat belt fastened), current from
the seat switch flows to the engine start module, turns
off the seat belt light and satisfies the logic sequence.
When the key switch is turned to the “RUN” position,
the hydraulic solenoid module (A3) energizes the boom
solenoid valve (Y3) and bucket solenoid valve (Y4),
allowing the operator to actuate the boom and bucket
control pedals.
If the operator unfastens the seat belt, or leaves the
seat, the electronic instrument module stops current
flow to the solenoids, locking the valves, preventing
boom and bucket valve operation.

4 - 62 4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

HYDRAULIC BOOM AND BUCKET LOCKOUT CIRCUIT

0= ACC
1= OFF
2= RUN F3
3= START
1,2 1 ELECTRONICS
FUSE (BAT)
RED/LT GRN

3 2 1 0 LT GRN/
S3 RED
KEY
SWITCH X1
ORG/
PUR

RED/
WHT F5
0= OFF SEAT
ELECTRONICS
F2 1= ON SEAT FUSE (IGN) A4
KEY S4 ELECTRONIC
FUSE SEAT LT GRN/ S5 INSTRUMENT
RED SEAT
BUS SWITCH PANEL MODULE
0 1 SWITCH ORG
(DELUXE ONLY)
RED A3
X1
HYDRAULIC
TAN SOLENOID
X

X9 X9 X9 MODULE
1 0 11 12 14
TAN
F1 0= OFF SEAT
PREHEAT 1= ON SEAT
TAN X9
CIRCUIT 0= SEAT BELT X2 4
BREAKER DISENGAGED
1= SEAT BELT LT
ENGAGED DK BLU GRN
RED
S6 A5 H2
SEATBELT ENGINE SEATBELT
SWITCH START LIGHT
K1 MODULE
START 0 1 BLK
X9 X9
RELAY LT 13 PNK/ 3
X1 X2 LT BLU
GRN
RED
0= SERVICE
1= RUN X6
PNK/
S2 0,1 LT BLU
SERVICE
START
SWITCH 1 0

TAN/WHT X7

S Y3
HYDRAULIC
B BOOM
SOLENOID

M Y4
HYDRAULIC X7
RED BUCKET
X6
M1 SOLENOID
STARTING
MOTOR BLK
BLK
BLK

+
G1
_ BATTERY

W1
ENGINE
GROUND

POWER CIRCUIT BOOM/BUCKET SOLENOID CIRCUIT

SEAT AND SEAT BELT

SWITCH CIRCUIT GROUND CIRCUIT

OPTIONAL EQUIPMENT HARNESS

M57102

12/15/94 4 - 63
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

HYDRAULIC BOOM AND BUCKET LOCKOUT CIRCUIT DIAGNOSIS

Test Conditions:
• Boom fully lowered
• Bucket on ground
• Service start switch in “RUN” position
• Operator on seat
• Seat belt fastened
• Key switch in “RUN” position
• Meter negative (-) lead on battery negative (-) terminal
• Meter positive (+) on numbered test point
• Check for corrosion and loose terminals when testing

Test/Check Point Normal If Not Normal

1. Electronic instrument panel Does not display error code Check pnk/lt blu wires between
module digital display (P1) “ERR03” electronic instrument panel module
connector X9, pin 3 and boom and
bucket solenoids for open or short.

2. Boom and bucket pedals Unlocked. If OK, check for Go to step 3

mechanical binding in SCV valve
and check hydraulic system.

3. Boom and bucket solenoid Solenoid clicks when connectors are No click or cannot hear: go to step 4
removed

4. Pnk/Lt Blu wire, pin 3, Battery voltage Test electronic instrument panel
connector X9, electronic module
instrument panel module

5. Pnk/Lt Blu wire at hydraulic Battery voltage Check pnk/lt blu wire and
boom and hydraulic bucket connections
solenoid

Test Conditions:
• Key switch in “OFF” position
• Hydraulic boom and bucket solenoid leads disconnected

Test/Check Point Normal If Not Normal

6. Blk wire at hydraulic boom and Maximum 0.1 ohms resistance to Check Blk wire and engine ground
bucket solenoid ground

7. Ohmmeter across boom and Continuity across terminals of Replace solenoid

bucket solenoid leads solenoid (maximum 30 ohms
resistance).

4 - 64 4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

HYDRAULIC BOOM AND BUCKET LOCKOUT CIRCUIT DIAGNOSIS

X9
3

Pnk/Lt Blu

7
Blk
5
Pnk/Lt Blu
6

3
7

Blk

M57715A

4/13/95 4 - 65
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

ROAD/WORK LIGHT/ACCESSORY System Operation:

CIRCUIT OPERATION When the key switch is turned to the “ACC” or “RUN”
position, the accessory relay (K4) is energized, and
current flows through the accessory fuse (F6) to the
Function: road/work light fuse (F7) and the light switch (S11).
To provide work/road illumination for operating in When the light switch is in the “WORK” position,
darkness. current flows to the front lights (E3, E4), rear work light
(E5), and the rear tail lights (E1, E2).

Operating Conditions:
The key switch must be in the “RUN” or “ACC” position,
and the work/road lights switch closed.
When the light switch is in the “ROAD” position, current
flows to the front lights (E3, E4) and rear tail lights (E1,
E2).
When the light switch is in either the “WORK” or
“ROAD” position, current also flows to the electronic
instrument panel module connector x9, pin 9 and the
module lights dim by 50% for night operation.

4 - 66 4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

ROAD/WORK LIGHT/ACCESSORY CIRCUIT OPERATION

BUS

0,1,2 1
0= ACC F6
1= OFF ACCESSORY
2= RUN
3= START FUSE
3 2 1 0
S3
KEY LT GRN/BLK
SWITCH
BUS

RED/ RED/
WHT GRY

F2
KEY K4
PNK
FUSE ACCESSORY
RELAY
X9
9
RED
A4
ELECTRONIC ORG/ BLK
INSTRUMENT LT GRN
PANEL MODULE
X

F1
PREHEAT
CIRCUIT
BREAKER
X13
RED

ORG/
LT GRN
F7
K1 ROAD/
START X12
WORK
RED RELAY LIGHT
FUSE
ORG/
PNK BLK

X11

ORG/ 0= WORK
BLK 1= OFF
2= ROAD S11
BLK LIGHT
SWITCH
K3 2 1 0
S
PREHEAT DK BLU
B
RELAY

DK BLU/
WHT
DK BLU/
M PNK/ WHT
BLK PNK/
BLK E3 E5
RED BLK
RIGHT REAR
M1 FRONT
STARTING E1 WORK
LIGHT LIGHT
MOTOR RIGHT
TAIL E4
LIGHT LEFT
E2
LEFT FRONT
TAIL LIGHT
BLK
+ BLK
LIGHT
G1 BLK BLK BLK
_ BATTERY

BLK BLK

W1 W4
ENGINE CAB
GROUND GROUND

POWER CIRCUIT LIGHT SWITCH CIRCUIT

ACCESSORY RELAY CIRCUIT GROUND CIRCUIT M57105

2/3/95 4 - 67
ELECTRICAL CIRCUIT OPERATION AND DIAGNOSIS

ROAD/WORK LIGHT/ACCESSORY CIRCUIT DIAGNOSIS

• Key switch in “ACC” position

Test/Check Point Normal If Not Normal

1. Light switch (S11) in Right front (E3), left front (E4), and rear One lamp out: go to step 3
“WORK” (up) position work (E5) lights on. Right (E1) and left All lights out: go to step 4
(E2) tail lights on. Rear tail lights out: go to step 15

2. Light switch (S11) in Right front (E3) and left front (E4) lights One lamp out: go to step 3
“ROAD” (down) position on. Right (E1) and left (E2) tail lights on. All lights out: go to step 5
Rear tail lights out: go to step 15

• Key switch in “OFF” position

• Test meter set to read continuity

3. Remove individual lamps and lamp Continuity through bulb and lamp Replace bulb or lamp holder.
holders holder. Go to step 4. Retest.

4. Blk ground wire at each lampholder Maximum 0.5 ohms resistance Check blk wire to ground

5. Key fuse (F2), accessory fuse (F6), Continuity through fuse Replace fuse
road/work light fuse (F7)

6. Blk wire at accessory relay (K4) Max. 0.1 ohms resistance Check Blk wire and engine
ground

• Negative lead (-) grounded to frame

• Positive lead (+) on numbered test point
• Light switch (S11) set to “WORK” (up) position
• Key switch in “ACC” position

7. Red/Gry wire at accessory relay (K4) Battery voltage Check Red/Gry wire to accessory
fuse

8. Lt Grn/blk wire at key switch (S3) Battery voltage Check key switch (S3)

9. Lt Grn/Blk wire at accessory relay Battery voltage Check lt Grn/Blk wire to key switch

10. Org/Lt Grn wire at accessory relay Battery voltage Replace accessory relay (K4)

11. Org/Lt Grn wire at road/work light fuse Battery voltage Check Org/Lt Grn wire

12. Org/Blk wire at road/work light fuse Battery voltage Check road/work light fuse (F7)

13. Org/Blk wire at light switch (S11) Battery voltage Check Org/Blk wire

14. Pnk wire at light switch (S11) Battery voltage. Electronic No voltage: replace light switch
instrument panel module Not dimming: check pnk wire
lights dim

15. Pnk/Blk wire at light switch Battery voltage. Right and No voltage: replace switch
left tail lights on No lights: check Pnk/Blk wire

16. Dk Blu/Wht wire at light switch Battery voltage. Left and No voltage: replace switch
right front lights on No lights: check Dk Blu/ Wht wire

17. Dk blu wire at light switch Battery voltage. Rear No voltage: replace switch
work light on No lights: check dk blu wire

4 - 68 4/13/95
CIRCUIT OPERATION AND DIAGNOSIS ELECTRICAL

ROAD/WORK LIGHT/ACCESSORY CIRCUIT DIAGNOSIS (CONTINUED)

E4
LEFT FRONT
LIGHT

S11 Dk Blu
/Wht
LIGHT
SWITCH E3
To Cab
15 Ground RIGHT FRONT
LIGHT
WORK 14
OFF
To EIPM 13 Blk
ROAD
X9 Pin 9

Pnk/Blk

Dk Blu/Wht
Dk
Blk Blu
Org/Blk

E2
LEFT TAIL
LIGHT To Cab
Ground Pnk/Blk
E5
REAR
12
WORK
LIGHT S3 F7
Key Switch Road/
Work
11 Fuse
E1
RIGHT TAIL Org/Grn
LIGHT
8 Red/Wht
Grn/Blk
F6
7 Accessory
K4 Fuse
9
ACCESSORY
RELAY
6 F2
10
Key
Red/Gry Fuse

M57716

4/13/95 4 - 69
ELECTRICAL
TESTS & ADJUSTMENTS
BATTERY TEST
Reason:
To check condition of battery and determine battery
voltage.
Equipment:
• Hydrometer
• JTO5685 Battery Tester
Procedure:
1. Park machine on level surface and LOCK boom in
up position with boom lock lever. Roll bucket back.
2. Turn key OFF and LOCK park brake.
3. Open engine cover and remove right engine side
cover.
4. Disconnect negative (-) and positive cable clamps
from battery. Remove battery hold-down clamp.
5. Remove battery from machine.
6. Clean battery terminals and case.
7. Inspect battery terminals and case for breakage or
cracks.
8. Check electrolyte level in each battery cell. Add
clean, soft water as needed. If water was added,
charge battery for 20 minutes at 10 amps.
9. Remove surface charge by placing a small load on
the battery for 15 seconds.
M49596
10. Use a hydrometer to check for a minimum
specific gravity of 1.225 with less than 50 point
variation in each cell:
• If all cells less than 1.175, charge battery at 10 amp
rate (see Charge Battery).
• If all cells are less than 1.225 with less than 50
point variation, charge battery at 10 amp rate (see
4 - 70
TESTS & ADJUSTMENTS
charge battery).
• If cells are above 1.225 with less than 50 point
variation, load test battery (see Battery Load Test).
• If more than 50 point variation, replace battery.
11. Use a voltmeter or JTO5685 Battery Tester to
check for a minimum battery voltage of 12.4
volts:
• If battery voltage less than 12.4 VDC, charge
battery.
• If voltage is above 12.4 VDC, test specific gravity
(see Step 9).
12. Install battery.
CHARGE BATTERY
Reason:
To increase battery charge after battery has been
discharged.
Equipment:
• Battery charger (variable rate) (use according to
manufacturer’s instructions).
Procedure:
NOTE: See BATTERY TEST in this group before
charging battery.
1. Park machine on level surface and LOCK boom in
up position with boom lock lever. Roll bucket back.
2. Turn key OFF and LOCK park brake.
3. OPEN engine cover and REMOVE right engine
side cover.
4. Disconnect negative (-) and positive (+) battery
cable clamps. Remove battery hold-down.
5. Remove battery from machine.
6. Clean battery terminals and case.
M49598
7. Connect variable rate charger to battery.
4/13/95
TESTS & ADJUSTMENTS
NOTE: Maximum charge time at boost is 10 minutes.
Allow additional 5 minutes for each 10° below
70°F.
8. Start charger at SLOW rate. Increase charge rate
ONE setting at a time. Check charger ampmeter
after 1 minute at each setting. Maintain 10 amp
charge rate. Use boost setting as necessary.
9. Check if battery is accepting a 10 amp charge after
10 minutes at boost setting:
• If battery WILL NOT accept 10 amp charge after 10
minutes at boost setting, replace battery;
• If battery is accepting 10 amp charge after 10
minutes at boost setting, and battery did NOT need
water, go to Steps 10 and 11;
• If battery is accepting 10 amp charge after 10
minutes at boost setting, but battery DID need
water or all cells were BELOW 1.175, go to Steps
9 and 10.
10. Set charger at 15-25 amps.
IMPORTANT: Decrease charge rate if battery gases
or bubbles excessively or becomes too warm to
touch.
11. Check specific gravity after 30 minutes:
• If MORE THAN 50 point variation between cells,
replace battery;
• If LESS THAN 50 point variation between cells, go
to steps 11 and 12.
NOTE: If battery was discharged at slow or unknown
rate, charge at 10-15 amps for 6-12 hours. If
battery was discharged at fast rate, charge at
20-25 amps for 2-4 hours.
12. Continue to charge battery until specific gravity is
1.230-1.265 points.
13. Load test battery (see Battery Load Test).
14. Install battery.
BATTERY LOAD TEST
Reason:
To check condition of battery under load.
Equipment:
• JTO5685 Battery Tester (use according to
manufacturers instructions).
Procedure:
1. Park machine on level surface and LOCK boom in
4/13/95
ELECTRICAL
up position with boom lock lever. Roll bucket back.
2. Turn key OFF and LOCK park brake.
3. OPEN engine cover and REMOVE right engine
side cover.
4. Disconnect negative (-) and positive (+) battery
cable clamps. Remove battery hold-down.
5. Remove battery from machine.
6. Clean battery terminals and case.
E
D
C B
A
M49597
IMPORTANT: Turn load knob on Battery Tester
fully out (counterclockwise) BEFORE making
any test connections.
7. Connect tester positive cable (red) to battery
positive (+) terminal (B).
8. Connect tester negative cable (black) to battery
negative (-) terminal (C).
IMPORTANT: Perform this test quickly to prevent
damage to battery tester. DO NOT apply full load
to battery for more than 5-10 seconds.
9. Turn load knob (A) of tester clockwise (in) until
amperage reading (D) is equal to:
• cold cranking amperage rating of battery (use blue
scale).
—or—
• three times ampere hour rating (use black scale).
10. Hold for 15 seconds and turn load knob (A) of
tester counterclockwise (out) into OFF position.
11. Repeat Steps 9 and 10 above and read condition
of battery at DC volts scale (E).
12. If battery DOES NOT pass test and has NOT been
charged, charge battery and retest (see Charge
Battery).
13. If battery DOES NOT pass test and HAS been
charged, replace the battery.
4 - 71
ELECTRICAL TESTS & ADJUSTMENTS

REGULATED AMPERAGE AND 9. Install JTO5792 Ammeter Shunt leads as follows:

VOLTAGE TEST • Red male plug to Volt/Ohm socket on JTO5791
Digital Multimeter.
• Black male plug to COM socket on JTO5791 Digital
Reason: Multimeter.
To determine regulated charging output of the • Shunt black clamp to the negative (-) battery post
(along with JTO5685 Battery tester ground clamp).
alternator.
• Shunt red clamp to the negative (-) battery cable
clamp.
Equipment: 10. Set JTO5791 Digital Multimeter to read 300 mV.
• JTO5791 Digital Multimeter 11. Set Electronic Instrument Panel Module to read
• JTO5792 Ammeter Shunt Assembly voltage.
• JTO5685 Battery Tester (use according to 12. Start and run engine at high idle. Read charging
manufacturers instructions). voltage from Electronic Instrument Panel Module.
Voltage should read between 12.2-14.7 volts DC
and be steadily rising.
Procedure: 13. Read amperage from JTO5791 Digital Multimeter
(set to 300 mV scale). Amperage should read 40
1. Park machine on level surface and LOCK boom in
amps and decrease as voltage approaches 14.8
up position with boom lock lever. Roll bucket back.
volts.
2. Turn key OFF and LOCK park brake.
14. If at anytime voltage exceeds 14.8 volts DC,
3. OPEN engine cover and REMOVE right engine replace alternator/regulator assembly.
side cover.
4. Remove negative battery cable clamp from battery.
STARTER LOADED AMPERAGE
DRAW TEST
B
D
A
Reason:
To determine the amperage required to crank the
engine and check starter motor operation under load.

Equipment:
• JTO5685 Battery Tester (use according to
C manufacturer’s instructions).
M76230

Procedure:
IMPORTANT: Turn load knob on battery tester fully 1. Park machine on level surface and LOCK boom in
out (counterclockwise) BEFORE making any up position with boom lock lever. Roll bucket back.
test connections. 2. Turn key OFF and LOCK park brake.
3. Open engine cover and remove right engine side
5. Connect tester positive cable (A) (red) to battery cover.
positive (+) terminal. 4. Test system ground connections (see Ground
6. Connect tester negative cable (B) (black) to battery Circuit Test).
negative (-) terminal. 5. Test battery (see Battery Load Test).

IMPORTANT: Perform this next step quickly to

prevent damage to battery tester. DO NOT apply
full load to battery for more than 5-10 seconds.

7. Turn load knob (C) clockwise (in) until voltage on

tester voltage scale (D) reads 11 volts for 10
seconds only to partially drain battery.
8. Quickly turn load knob completely
counterclockwise (out) into OFF position.

4 - 72 4/13/95
TESTS & ADJUSTMENTS ELECTRICAL

STARTER NO-LOAD AMPERAGE

A
AND RPM TESTS
D
Reason:
C
To determine if starter is binding or has excessive
amperage draw under no-load.

Equipment:
• JTO5791 Digital Multimeter
B
• JTO 5792 Ammeter Shunt
M76229 • JTO5719 Hand Held Digital Tachometer

IMPORTANT: Turn load knob (B) fully Procedure:

counterclockwise (out) into OFF position before
making any test connections.
NOTE: Check that battery is fully charged and of
proper size to ensure accuracy of test.
6. Disconnect fuel shutoff solenoid connector (A).
7. Connect JTO5685 Battery Tester to battery.
1. Park machine on level surface and LOCK boom in
8. Crank engine-read and record voltage on DC up position with boom lock lever. Roll bucket back.
voltage scale (D) of battery tester.
2. Turn key OFF and LOCK park brake.
9. Turn key switch to OFF position.
3. Open engine cover and remove right engine side
cover.
IMPORTANT: Perform the following step within 10 4. Disconnect negative (-) battery cable clamp from
seconds to prevent damage to tester and/or battery.
machine components. 5. Remove and tag all wires to the starter.
6. Remove starter from engine and mount to bench.
10. Turn load knob (B) clockwise (in) until DC voltage
(D) reads the same as when cranking.
11. Read and record DC amperage (C).
12. Turn load knob (B) completely counterclockwise
(out) into OFF position.

Results:
• Starter should have a amperage draw as follows:

Delco-Remy 28MT Model 1113271

300 amps

• If amperage is above specification, perform Starter

No-load Amperage and RPM Test to determine if
starter is binding or damaged.
• If starter passes No-load test but amperage draw
remains high, check internal engine components
for binding, wear, or damage.
M76228
7. Install JTO5792 Ammeter Shunt leads as follows:
• Red male plug to Volt/Ohm socket on JTO5791
Digital Multimeter.
• Black male plug to COM socket on JTO5791 Digital
Multimeter.
• Shunt black clamp to the negative (-) battery post.
• Shunt red clamp to starter case ground.
8. Set JTO5791 Digital Multimeter to read 300 mV.

4/13/95 4 - 73
ELECTRICAL TESTS & ADJUSTMENTS

9. Connect positive jumper cable between starter battery.

terminal “B” and positive battery post. 5. Remove and tag all wires to the starter.
6. Remove starter from engine and mount to bench.
IMPORTANT: Complete this test in 20 seconds or
less to prevent starter damage.

10. Momentarily connect a jumper lead from the B

positive battery post to the small solenoid terminal
“S”. The solenoid should pull-in and the drive gear
and shaft should move out and spin.
11. Record amperage from multimeter.
12. Place JTO5719 Digital Tachometer drive cone
against end of spinning starter drive gear, and
record RPM.
13. Remove jumper to solenoid.

Results: A
M76119
• No load starter specifications are as follows:

Delco-Remy 28MT Model 1113271
135-139 amps
3600-5600 RPM
10.6 Volts
• If amperage is above specification, check for
binding or seized bearings, sticky brushes, and
dirty or worn commutator. Repair or replace
starter.
• If starter passes No-load test but amperage draw
remains high when mounted on engine, check
internal engine components for binding, wear, or
damage.
STARTER SOLENOID TEST
Reason:
To determine if starter solenoid is defective. The
solenoid has a pull-in winding which grounds together
with the starter motor. This test requires two jumper
wires to test the solenoid winding.
7. Connect positive jumper wire (A) from solenoid “S”
terminal to positive battery post.
8. Momentarily connect negative jumper wire (B) from
starter case ground to negative battery post. The
solenoid should pull-in and the drive gear and shaft
should move out.
9. Remove the positive jumper wire to the solenoid
terminal. The solenoid drive gear and shaft should
move back.
Results:
• The solenoid should pull-in freely with a loud click
when energized. The starter drive gear and shaft
should be moved out.
• If solenoid does not move, disconnect jumper leads
and try to pull drive gear out by hand by rotating
counterclockwise.
• If drive gear will not turn by hand, check starter
motor for bad bearings, frozen armature, or
sticking brushes.
• If drive gear turns but will not pull out, check
solenoid plunger and shaft for binding.
• If drive gear turns and moves out freely, but
solenoid does not energize, replace solenoid.

Equipment:
• Two (2) jumper wires
• 12 volt battery

Procedure:
1. Park machine on level surface and LOCK boom in
up position with boom lock lever. Roll bucket back.
2. Turn key OFF and LOCK park brake.
3. Open engine cover and remove right engine side
cover.
4. Disconnect negative (-) battery cable clamp from

4 - 74 4/13/95
TESTS & ADJUSTMENTS ELECTRICAL

FUEL GAUGE SENDER 9. Hold Fuel Sender upright to slide float to bottom
(empty tank position). Note meter reading.
10. Turn sender upside down to slide float to top (full
REASON: tank position). Note meter reading.
To determine if fuel gauge sender is changing
resistance as float is raised and lowered. Results:
The resistance of the fuel gauge sender is as follows:
EQUIPMENT:
Tank Volume Resistance (Ohms)
• JTO5791 Digital Multimeter Full 33
7/8 49
3/4 65
PROCEDURE:
5/8 83
1. Park machine on level surface and lock boom in 1/2 103
UP position with boom lock lever. Roll bucket back. 3/8 125
2. Turn key OFF and LOCK park brake. 1/4 152
3. Open engine cover and remove left and right side 1/8 185
engine covers. Empty 239
4. Remove negative battery cable clamp from battery.
• If the above results are not found, replace fuel
gauge sender.

BACKUP ALARM SWITCHES

Front

M57740

5. Remove two nuts holding leads to terminal posts Nut Striker

on top of fuel level sensor.
6. Remove six machine screws holding fuel level
sensor to tank.
7. Remove sender from tank using care to not tear
gasket.

M76164
M76225

1. Raise seat and lock in up position.

2. Place key switch in run position.

NOTE: Both switches must be activated

simultaneously for alarm to sound.

M57741 3. With steering handles in neutral position, adjust

both strikers rearward until alarm sounds. Move
8. Connect leads from JTO5791 Digital Multimeter to strikers forward until alarm stops (approximately 1/
terminal posts on sender. Set meter to read Ohms. 8”) and tighten nuts.

4/13/95 4 - 75
ELECTRICAL TESTS & ADJUSTMENTS

ELECTRICAL SWITCH TESTS

Reason:
To determine if electrical switches are opening and closing as required:

Equipment:
• JTO5791 Digital Multimeter

Procedure:
1. Disconnect negative battery cable.
2. Tag and mark wires to switch and disconnect.
3. Remove switch from machine.
4. Set meter to read continuity or resistance (ohms).
5. Connect meter to listed test points, set switch to proper position, test for continuity.

Switch Switch Position Test Points Results

1. Seat Switch (S4, S5) Up A→ B No continuity

Down A→ B Continuity

2. Light Switch (S11) Centered (Off) C→ G Continuity

Down (Road lights) C→ G → D → E Continuity

Up (Work lights) C → G→ E → F Continuity

3. Service Start Switch (S2) Up (Service) I→ M, K → L Continuity

Down (Run) N→H, J→K Continuity

4. Manual Preheat Switch (S7) Out N→ O No continuity

In N→ O Continuity

5. Air Filter Restriction Switch No vacuum O→ P Continuity

Vacuum O→ P No continuity

6. Ignition Switch (S3) Off All terminals No continuity

On S→Q, S→R Continuity

Start S→ R, S→ P Continuity

Accessory S→ Q Continuity

7. Seat Belt Switch (S4,S5) No Belt latched T→ U No continuity

Belt latched T→ U Continuity

8. Two Speed Transmission Forward V→ W Continuity

Switch (S22)

Rearward V→ W No continuity

RESULTS:
• If switch shows no continuity or resistance higher than 0.05 ohms when contacts are closed, replace switch.

4 - 76 4/13/95
TESTS & ADJUSTMENTS ELECTRICAL

ELECTRICAL SWITCH TESTS (CONTINUED)

SEAT SWITCH (S4, S5) ROAD / WORK LIGHT SWITCH (S11)

C
E
A
B F

G
SERVICE

I
J
N
H
K

N O
RUN L
MANUAL PREHEAT SWITCH (S7)

SERVICE START SWITCH (S2)

TWO SPEED TRANSMISSION SWITCH (S22)

Q
Acc

P
Start

T
S R U
Bat Ign SEAT BELT SWITCH (S6)

IGNITION KEY SWITCH (S3)

M57732A

4/13/95 4 - 77
ELECTRICAL TESTS & ADJUSTMENTS

ELECTRICAL RELAY / SOLENOID TESTS

REASON:
To determine if electrical relay coils are actuating correctly, and resistance of relay contact points is correct.

EQUIPMENT:
• JTO5791 Digital Multimeter
• Jumper wires
• 12 volt battery

PROCEDURE-RELAY TEST:
1. Disconnect negative battery cable.
2. Tag and mark wires to relay and disconnect.
3. Remove relay from machine.
4. Test resistance through relay contacts with digital multimeter (no voltage applied to relay coil terminals).
5. Connect jumper wires from battery to relay or solenoid terminals listed in chart to actuate the relay coil.
6. Test resistance through relay contacts listed in chart with digital multimeter (relay coil pulled in).

Terminals used Contact test points:

Relay
to energize coil (Voltage applied)

1. Accessory Relay A→ C B→ D

2. Start Interlock Relay G→ J E→ F, H→ I

3. Starter or Preheat Relay K→ L M→ N

RESULTS:
• All of the relays have contacts which are normally open. Therefore, no continuity should exist through the
contacts when the coil is not energized.
• When the coil is energized, the resistance through the contacts should be no more than 0.05 ohms.
• If the above results are not found, replace relay.

PROCEDURE- SOLENOID TEST

1. Disconnect negative battery cable.
2. Tag and mark wires to solenoid and disconnect.
3. Remove solenoid from machine.
4. Connect jumper wires from battery to solenoid terminals listed in chart to actuate the relay coil).

Solenoid Contacts to energize Results

1. Boom / Bucket Lock solenoid Q→ R Plunger Rod Pulls-in

4 - 78 4/13/95
TESTS & ADJUSTMENTS ELECTRICAL

ELECTRICAL RELAY TESTS (CONTINUED)

C H
A I
E

ACCESSORY RELAY J
G

K L
START INTERLOCK RELAY

START RELAY
PREHEAT RELAY

O P

BOOM / BUCKET LOCK SOLENOID

Q
R

AIR FILTER RESTRICTION SWITCH M57733A

4/13/95 4 - 79
ELECTRICAL TESTS & ADJUSTMENTS

ELECTRONIC INSTRUMENT PANEL MODULE TEST

Reason:
To make sure the electronic instrument panel module has input and output voltage at the correct terminals for
proper operation. This test determines if the module is defective or the input circuit is defective.

Equipment:
• JTO5791 Digital Multimeter

Test Conditions:
• Park machine on level surface and lock boom in UP position with boom lock lever. Roll bucket back.
• Turn key OFF and LOCK park brake
• Service start switch in “RUN position
• Open engine cover and remove left and right side engine covers
• Connect meter negative (-) lead to battery negative (-) terminal
• Connect meter positive (+) lead on numbered test point
• Check connection for corrosion and loose terminals when testing

Test/Check Point Normal If Not Normal

1. Electronic instrument panel
module - operator on seat
All lights (H1-H15) on, fuel level
display (P2) bars all on and digital
display (P1) reads “8888” for 3
seconds. Then digital display shows
numeric value of the operating
condition monitored as indicated by
the light, fuel level display bars show
fuel level, parking brake (H16) and
seat belt (H2) lights flash.
No lights on - check key fuse (F2),
electronics (bat) fuse (F3), and
electronics (ign) fuse (F5). If OK, go
to step 5.
One light out - check bulb
Fuel level display not on or correct -
go to step 6.
Parking brake or seat belt light not
on - go to step 6.

2. Electronic instrument panel Seat belt light (H2) goes out Go to step 10
module - seat belt fastened

3. Electronic instrument panel
module - key switch in RUN
position
Parking brake light (H16) out.
Preheat light (H3) on, digital display
(P1) counts down seconds, module
alarm (H17) beeps and light goes
off. Low engine oil pressure (H4) and
low hydraulic charge pressure (H5)
lights flash. Digital display does not
show any error codes.
Digital display shows the following
error codes:
• ERR01-engine hours memory
store error-replace module or
reset hours
• ERR02-check output circuit to
fuel shutoff solenoid for open/
short
• ERR03-check output circuit to
hydraulic boom and bucket
solenoid for open/short
• ERR04-check output circuit to
preheat relay for open/short
No error codes - go to step 12

4. Electronic instrument panel Low engine oil pressure (H4) and Go to step 22
module - key switch in START low hydraulic charge pressure (H5)
position - engine running lights go out

4 - 80 4/13/95
TESTS & ADJUSTMENTS ELECTRICAL

H9 H8 P1 H6
H11 Engine
Tachometer Battery Digital
H15 Hydraulic Oil Coolant
Light Voltage Display/
Air Filter Light Temperature Temperature
H10 Hourmeter
S8 Restriction Light Light H7
Display Engine Hydraulic Oil
H17 Light
Select Coolant Temperature
Module Temperature
Switch Light
Alarm Light (Not Used)

H14
H5 H12
S10 Hydraulic
P2 Low H13 Battery
Diagnostic/ Oil Filter
Fuel Hydraulic Engine Voltage
Program Restriction H1 H3 Level Charge Coolant Light
Mode Light Engine Preheat Display Pressure Temperature
Switch Stop Light Light Light
Light H2
H16 H4 Seat
Parking Low Belt
Brake Engine Oil Light
Light Pressure
Light

4/13/95 4 - 81
ELECTRICAL TESTS & ADJUSTMENTS

Test/Check Point Normal If Not Normal

Test Conditions:
• Key switch in OFF position
• Disconnect battery negative cable
• Disconnect red/wht wire from starting motor to prevent engine from cranking
• Remove electronic instrument panel to provide access to connectors X9 and X10
• Connect battery negative cable

5. Blk wire at connector X9, pin Maximum 0.1 ohms resistance Check battery negative cable and
13 engine ground connection and
module ground circuit blk wires

Test Conditions:
• Operator on seat or jumper wire installed in connector
• Seat belt fastened or jumper wire installed in connector
• Key switch in RUN position

6. Red/lt grn wire at connector Battery voltage - input Check red/lt grn wire power circuit
X9, pin 14

7. Org wire at connector X9, pin Battery voltage - input Check org wire power circuit
12

8. Lt grn/blk wire at connector Battery voltage - input Check lt grn/blk wire power circuit
X10, pin 11

9. Tan/wht wire at connector X9, Battery voltage - input Check tan/wht wire, service start
pin 4 switch, tan wire, seat switch and lt
grn/red wire

10. Lt grn wire at connector X9, Battery voltage - input Check lt grn wires, seat belt switch
pin 11 and tan wires

Test Conditions:
• Key switch in START position

11. Wht wire at connector X9, pin Battery voltage - input Check wht wire and key switch
10

Test Conditions:
• Turn key switch to OFF and then to RUN position and check voltage quickly, repeat as needed

12. Lt blu/yel wire at connector
X9, pin 2
Battery voltage during preheat count
down when engine is cold - output
Check that engine code in
configuration mode is set at “02”
and check engine coolant
temperature sensor circuit. If OK,
replace electronic instrument panel
module

Test Conditions:
• Key switch in RUN position

13. Lt blu/org wire at connector Battery voltage - output Replace electronic instrument panel
X9, pin 5 module

14. Pnk/lt blu wire at connector Battery voltage - output Replace electronic instrument panel
X9, pin 3 module

4 - 82 4/13/95
TESTS & ADJUSTMENTS ELECTRICAL

X10

X9

8 Lt Grn/Blk
12 Lt Blu/Yel
14 Pnk/Lt Blu
9 Tan/Wht
13 Lt Blu/Org
11 Wht
10 Lt Grn
7 Org
5 Blk

6 Red/Lt Grn

M57108

4/13/95 4 - 83
ELECTRICAL TESTS & ADJUSTMENTS

Test/Check Point Normal If Not Normal

15. Pur/wht wire at connector 1 - 5 volts - output Replace electronic instrument panel
X10, pin 1 module

16. Pur/lt grn wire at connector 1 - 5 volts - output Replace electronic instrument panel
X10, pin 2 module

17. Pur/lt blu wire at connector 1 - 5 volts - output Replace electronic instrument panel
X10, pin 3 module

18. Dk grn/org wire at connector Battery voltage - output Replace electronic instrument panel
X10, pin 9 module

19. Blk/yel wire at connector X10, Battery voltage - output Replace electronic instrument panel
pin 10 module

20. Pnk/lt blu wire at connector Battery voltage - output Replace electronic instrument panel
X9, pin 3 module

Test Conditions:
• Key switch in OFF position
• Connect red/wht wire to starting motor
• Start engine and run at low idle

21. Yel/blk wire at connector X10, Battery voltage - output Replace electronic instrument panel
pin 7 module

22. Yel/gry wire at connector Battery voltage - output Replace electronic instrument panel
X10, pin 8 module

23. Pur/red wire at connector 6 - 12 volts - input Check pur/red wire and alternator
X10, pin 4 tachometer circuit

4 - 84 4/13/95
TESTS & ADJUSTMENTS ELECTRICAL

X10

15 Pur/Wht

16 Pur/Lt Grn

17 Pur/Lt Blu
X9

23 Pur/Red
21 Yel/Blk
22 Yel/Gry

18 Dk Grn/Org
19 Blk/Yel
20 Pnk/Lt Blu

M57108

4/13/95 4 - 85
ELECTRICAL TESTS & ADJUSTMENTS

GROUND CIRCUIT TEST Procedure:

OHMMETER METHOD:
Reason: 1. Park machine on level surface and LOCK boom in
up position with boom lock lever. Roll bucket back.
To check for opens, loose terminal wire crimps, poor
2. Turn key OFF and LOCK park brake.
connections, or corrosion in the ground circuit.
3. Open engine rear cover and remove left and right
engine side covers.
Equipment: 4. Connect ohmmeter negative (black) lead to
negative terminal of battery. Put meter positive (red)
• Ohmmeter or Voltmeter.
lead on negative terminal of battery and record
reading.
NOTE: The voltmeter method checks ground 5. Put meter red lead on ground terminal of circuit or
connections under load. component to be tested that is closest to the battery
negative terminal. Resistance reading must be
very close to or the same as the battery negative
terminal reading. Work backwards from the
Engine Ground battery on the ground side of the problem circuit
Battery Negative Cable until the resistance reading increases above 0.1
Ground
ohms. The problem is between the last two test
points. If a problem is indicated, disconnect the
wiring harness connector to isolate the wire or
component and check resistance again. Maximum
allowable resistance in the circuit is 0.1 ohms.
Check both sides of connectors closely as
disconnecting and connecting may temporarily
solve problem.

M57109 Wiring Harness Ground

VOLTMETER METHOD:
1. Park machine on level surface and LOCK boom in
up position with boom lock lever. Roll bucket back.
2. Turn key OFF and LOCK park brake.
Cab To Frame Ground
3. Open engine rear cover and remove left and right
engine side covers.
4. Connect voltmeter negative (black) lead to
negative terminal of battery.
5. Put meter positive (red) lead on ground terminal of
circuit or component to be tested. Be sure the
component circuit is activated (key on, switches
closed) so voltage will be present at the component.
Record voltage. Voltage must be greater than 0
but less than 1 volt. Some components will have a
M57111 M57110 very small voltage reading on the ground side and
still be operating correctly.

Results:
• If voltage is 0, the component is open.
• If voltage is greater than 1 volt, the ground circuit is
bad. Check for open wiring, loose terminal wire
crimps, poor connections, or corrosion in the
ground circuit.

Light Harness Cab Ground

M57112

4 - 86 4/13/95
TESTS & ADJUSTMENTS ELECTRICAL

BLOWN FUSE SYMPTOMS

Top Nearest Cab

Engine Fuse Panel
Accessory Fuse Panel
F5 Electronics (Ign)
F4 Fuel Pump F8 Wiper
F12 Heater F11 Turn Signal F7Road/Work Ligh
20A 10A
F6 Accessory

7.5A

15A
Spare Front

5A
5A
7.5A 25A Outer

7.5A
Front

10A
15A 5A Inner
F10 Attachment/Horn
F3 Electronics (Bat)
5A 15A
F9 Backup Alarm F2 Key Switch
F13 Flashing Lights
F14 Beacon Light
M57104

Blown 5 amp. Electronic Battery Fuse (F3)

1. When operator sits on the seat, the electronic instrument panel module lights will not light and the digital
display will not show any numeric values.
2. When the key switch is turned to the start position, the engine will not crank.
3. When the service start switch is in the service position, the engine will start.

Blown 5 amp. Electronic Ignition Fuse (F5)

1. When operator sits on the seat, the electronic instrument panel module lights will light and the digital display
will show “88888”.
2. With the key switch in the off position, the digital display will show 5.2 volts.
3. The seat belt and parking brake lights will flash.
4. When the seat belt is fastened, the seat belt light will go off.
5. When the key switch is turned to the run position, the digital display will show 5.2 volts and the preheat light will
not light.
6. When the key switch is turned to the start position, the engine will crank but not start.
7. When the service start switch is in the service position, the engine will start.

Blown 15 amp. Key Fuse (F2)

1. When operator sits on the seat, the electronic instrument panel module lights will light and the digital display
will show “88888”.
2. The seat belt and parking brake lights will flash.
3. When the seat belt is fastened, the seat belt light will go off.
4. When the key switch is turned to the run position, the digital display will show 5.2 volts and the preheat light will
not light.
5. When the key switch is turned to the start position, the engine will not crank.
6. When the service start switch is in the service position, the engine will not crank.

Remaining Fuses Blown

1. Component protected by that fuse will not operate.

4/13/95 4 - 87
ELECTRICAL REPAIR

REPAIR

STARTER—DELCO-REMY 2.5 kW
Field Coil Housing
Armature
STARTER DISASSEMBLY

Cap Screws

Cover
M36759A

8. Remove armature and field coil housing.

Solenoid 9. Remove o-ring.
10. Inspect and test brushes, holder, field coil and
Field Lead Screws armature. (See Inspection/Test procedures.)
M76130

STARTER ASSEMBLY
1. Disconnect field lead from solenoid.
2. Remove two screws securing solenoid to starter.
Remove solenoid by moving rear of solenoid toward
starter motor and pulling out.
3. Remove two cap screws and two screws that hold
cover to starter case.
4. Remove rear cover and o-ring.

Brush Holder

Front Bearing Housing M76133

NOTE: Apply multipurpose grease to bearing cup

Brush Spring inside rear cover and bearing cavity in front
M76131
bearing housing.

5. Pry brush springs away and pull negative brushes
up enough to allow spring to hold brush away from
rotor.
6. Remove two screws connecting brush leads to field
windings.
7. Remove brush holder.
1. Insure spacer shims are in place in the front
bearing housing. There should be a thick, thin, and
a nylon shim in the housing. The nylon shim should
be last one installed.

4 - 88 4/13/95
REPAIR
Field Coil Housing
Armature
M36759A
2. Install armature in field coil housing.
3. Place O-ring on field coil housing and install
assembly on front bearing housing. There are no
bolts to secure the field coil housing to the front
bearing housing at this time. The field coil housing
should have a snug fit and stay in place until rear
bearing cap is installed.
M76132A
Brush Housing M76131
4. Retract brushes into brush housing to allow brush
housing to fit over commutator. Springs will hold
brushes retracted until brush housing is installed.
5. Reconnect two field brush leads to field coil
housing inner diameter.
6. Push springs over brushes so springs apply
pressure to brushes to maintain contact with the
commutator.
4/13/95
ELECTRICAL
Grooves
M76131A
IMPORTANT: When installing rear cover, be sure
field coil brush wires do not touch cover. Turn
brush holder slightly to take up slack in brush
wires. Press wires inward to clear rear cover.
NOTE: Rear cover has indentations which must align
with the grooves in the brush holder assembly.
7. Install rear cover over brush holder assembly.
Secure brush holder to rear cover with two screws.
Solenoid
Field Coil Lead
Long Bolts M76130
8. Install two long bolts through rear cover and tighten
to specifications.
9. Install solenoid in starter case. Plunger on solenoid
must fit over shifter lever. Tighten two solenoid
mounting screws.
10. Attach field coil lead to solenoid.
11. Perform starter no-load tests after assembly.
4 - 89
ELECTRICAL REPAIR

STARTER - INSPECTION/TEST 4. Test for grounded field winding:

Touch one probe of tester to field coil brush terminal
and other probe to field coil housing. Be sure the
Min. 12.7 mm. (1/2 in.) brush lead is not touching the frame. If there is
Brush continuity, the coil is grounded and the field coil
housing assembly must be replaced.
5. Test for open field coil:
Touch one probe of tester to each field coil brush
terminal. If there is no continuity, the field coil is open
and the field coil housing assembly must be replaced.

Armature

M76132 Armature
Shaft

1. Measure holder and field coil brush lengths.

Minimum brush length is 12.7 mm. (1/2 in.). Replace
brush holder or field coil if brush length is below
minimum.
Commutator Bars
M82236A
NOTE: Test brush holder using an ohmmeter or test
light.
6. Inspect armature. Look for signs of dragging
against pole shoes.
2. Test brush holder:
7. Inspect commutator bars. Look for roughness,
Touch one probe of tester to negative brush holder
burned bars, or any material which might cause
and other probe to field brush holder. If there is
short circuits between bars. If necessary, clean and
continuity, replace the brush holder.
touch up with 400 sandpaper. NEVER use emery
3. Inspect springs for wear or damage. Replace if cloth. Clean all dust from armature when finished.
necessary.

NOTE: Test armature windings using an ohmmeter or

Field Coil Brush Terminals test light.

8. Test for grounded windings:

Touch probes on one commutator bar and armature
shaft. Armature windings are connected in series, so
only one commutator bar needs to be checked.
If test shows continuity, a winding is grounded and the
armature must be replaced.
9. Test for open circuited windings:
Field Coil Housing
Touch probes on two different commutator bars. If test
shows no continuity, there is an open circuit and the
armature must be replaced.
M82235A

NOTE: Test field coil using an ohmmeter or test light.

IMPORTANT: Do not clean armature with solvent.

Solvent can damage insulation on windings.
Use only mineral spirits and a brush.

4 - 90 4/13/95
REPAIR ELECTRICAL

Install new housing bearing tight against shoulder of

shaft using a piece of pipe.
Hacksaw Blade
Install new rear cover bearing tight against shoulder of
shaft using a driver set.

STARTER GEAR TRAIN

Armature

Disassembly/Inspection

Growler
M82125A
Front Bearing Housing

10. Test for short circuited windings using a growler.

Put armature in a growler and hold a hacksaw blade Shims
above each slot while slowly rotating armature.
Cap Screws
If coil is shorted, the blade will vibrate on the slot.

NOTE: A short circuit most often occurs because of

copper dust or filings between two commutator
segments. M76133

11. If test indicates short circuited windings, clean the

1. Remove two cap screws securing front bearing
commutator of dust and filings. Check the armature
housing to clutch housing. Do not loose the three
again. If the test still indicates a short circuit, replace
shims in the bearing cavity.
the armature.

Pivot Bolt

Cap Screws

Bearings
M82236A

12. Inspect armature bearings for wear or damage. M76134

Replace if necessary.
2. Remove the shift lever pivot bolt.
To replace bearings:
3. Remove two cap screws that retain the drive gear
Bearings are press fit. Remove bearings using a knife- assembly in the clutch housing.
edge puller set.

IMPORTANT: Install both bearings with sealed side

toward armature.

4/13/95 4 - 91
ELECTRICAL REPAIR

Shift Lever

Spring and Spring and

Clutch Assembly Clutch Assembly

M76135 M76135

4. Remove drive gear, spring and clutch assembly 4. Slide shift lever over clutch drive. Install spring and
from housing. clutch assembly in clutch housing.

Split Retaining Ring NOTE: When spring and clutch assembly is installed,
the shift lever tangs must remain in the groove
of the spring and clutch assembly.

Pivot Bolt
Clutch Drive Shaft Clutch Drive Pinion Stop
M76136

5. Remove pinion stop. Use a pipe coupling or other

metal cylinder to drive pinion stop toward pinion Bolt Holes
gear. Remove split retaining ring and slide pinion Shift Lever
stop off shaft.
6. Slide overrunning clutch drive off clutch drive shaft.
7. Inspect all parts for wear or damage. Replace as
necessary.

M76134
ASSEMBLY
5. Shift lever must protrude into the solenoid
IMPORTANT: Do not clean overrunning clutch mounting cavity. Install shift lever pivot bolt and
drive with solvent. Solvent would dissolve tighten.
lubricant in clutch mechanism. Clean only by
wiping with a clean cloth. Do not lubricate drive. 6. Associate clutch drive assembly bolt holes as
shown above. The bolts for the front bearing
housing will use the threads in the bolt holes.
1. Install clutch drive on clutch drive shaft. Place
pinion stop on clutch drive shaft with open end
toward end of shaft.
2. Install both halves of split retaining ring in groove of
clutch drive shaft. A small amount of grease may
help in holding both halves in place.
3. Force pinion stop over ring, using a washer and
two pairs of pliers. Remove washer.

4 - 92 4/13/95
REPAIR ELECTRICAL

ALTERNATOR—MAGNETRON 55A

DISASSEMBLY
Front Bearing Housing

Shims
Cap Screws

M76133

Pulley
7. Install front bearing housing on clutch drive
housing. The bolt holes in the clutch drive assembly Fan
will need to be aligned with the bolt holes in the front
bearing housing. Install cap screws.

M76195
VOLTAGE REGULATOR
REPLACEMENT
1. Remove pulley nut, washer, pulley, and fan from
alternator shaft using a three-jaw puller.
Voltage Regulator Electrical Connector

Spacer Key

M76196
M76197

2. Remove key and spacer from alternator shaft.

1. Remove two screws.
2. Unplug electrical connector from alternator.
3. Install in reverse order of removal. Torque screws
to 2.6—3.2 N•m (23—28 lb-in.).

4/13/95 4 - 93
ELECTRICAL REPAIR

Voltage Regulator
/Brush Holder

Stator Leads

M76197 M76199

3. Remove voltage regulator and brush holder

assembly. NOTE: Do not unsolder stator leads from rectifier if
neither of them is to be replaced. Rectifier and
stator assembly can be removed as a unit. To
remove rectifier and stator as a unit, go to step
Through Bolts 8.

6. Unsolder stator leads in commutator end bracket

assembly.

IMPORTANT: Clean rotor and stator with

compressed air only. Cleaning solvent will
damage insulation.

7. Remove stator assembly from commutator end

bracket assembly.

M76198
Suppressor

4. Remove through bolts.

5. Remove drive end bracket assembly with rotor in
such a way that stator assembly remains in
commutator end bracket assembly.
Nuts

M76200

8. Remove nuts securing rectifying unit to alternator

case. Suppressor must be removed. Set aside for
reassembly.
9. Remove rectifier from alternator case.
10. Inspect and test alternator components.

4 - 94 4/13/95
REPAIR
INSPECTION/TEST, ALTERNATOR
ROTOR
M82110A
• Inspect the rotor slip rings for dirt build-up, rough
spots, or out of roundness.
• If slip rings are rough or scored, turn them just
enough to eliminate roughness. Minimum diameter
of slip rings after turning is 29.5 mm (1.16 in.).
• Polish the surface of the slip rings using No. 00
sandpaper or 400-grit silicon carbide paper.
• Touch the probes of an ohmmeter to slip rings.
Replace rotor if test indicates no continuity (no
needle movement).
M82111A
• Touch the probes of the ohmmeter to the shaft and
one of the slip rings. Repeat for other slip ring.
Replace rotor if test shows continuity (needle
movement).
4/13/95
ELECTRICAL
BRUSHES
7 mm (0.28 in.) Min.
M76194
• Inspect brush holder and brushes for damage.
Brushes must slide freely and the springs must
hold the brushes firmly against the slip rings of the
rotor.
• Measure brushes for wear. Minimum length must
be 7 mm (0.28 in.) Replace brushes as necessary.
• To replace brushes, melt solder from connection.
Re-solder new brushes to brush holder.
NOTE: If additional solder is needed, use ONLY 60-40
rosin-core solder.
BEARINGS
Bearings
M76201
• Inspect bearings for damage and check that
bearings turn freely. Replace defective bearings.
Remove bearing on slip ring end of rotor with a
puller.
4 - 95
ELECTRICAL REPAIR

Rivets

M82114A

M76202 • Touch one probe of the ohmmeter to the bare metal

surface of stator and the other probe to a bare
stator lead wire. Repeat for each wire. Replace
• To remove bearing from drive end bracket stator if test indicates continuity.
assembly, cut rivets at flange and press bearing
out of drive end bracket. Inspect bearing surface in
drive end bracket. If bearing slippage is indicated, RECTIFIER
replace drive end bracket.
Ground Post
STATOR

Stator

Diodes

M76192

• Test the diodes by touching probes to the ground

Lead Wires M76193 post and the three upper terminals.
• Switch the probes and check each terminal again.
There should be continuity in only one combination
• Inspect stator for defective insulation, discoloration of each terminals and the ground post.
or a burned odor. If any of these defects are found, A shorted diode would have continuity in both
replace stator. directions. An open diode would have no continuity in
either direction. Replace the rectifier assembly if any of
the three diodes are defective.
NOTE: Use an ohmmeter that is sensitive to resistance
of 0 to 1 ohm. • To replace rectifier, melt solder from connections.

• Touch probes of an ohmmeter to lead wires of NOTE: If additional solder is needed, use ONLY 60-40
stator in three possible combinations. Continuity rosin-core solder.
should read approximately 0.1 ohms. If readings
are not equal, replace stator.

4 - 96 4/13/95
REPAIR ELECTRICAL

ALTERNATOR ASSEMBLY

Through Bolts

Rotor and Drive

End Bracket

Commutator
End Bracket

Lead Wires M76193

M76198

1. If rectifier or stator was de-soldered, re-solder
electrical leads.
NOTE: if additional solder is needed, use only 60-40
rosin-core solder.
3. Install spring collar in bearing cavity in commutator
end bracket assembly.
4. Assemble rotor and drive end bracket assembly to
commutator end bracket assembly. Install through
bolts with washers. Torque to 3 N•m (27 lb-in.).

Rotor Shaft Key

Suppressor
Spacer

M76196

Large Studs 5. Install key in key slot of rotor shaft.

6. Place spacer on rotor shaft and slide on until
spacer contacts front bearing.

Voltage Regulator
/Brush Holder

Stator M76200

2. Install rectifier and stator assembly in alternator M76197

case. Insulators must be installed on large studs.
Suppressor should be installed as shown above.
Install nuts on studs of rectifier. Torque small nuts to
7. Install regulator and brush holder assembly in
3 N•m (27 lb-in.) and large nuts to 4 N•m (35 lb-in.).
alternator case. Tighten mounting screws to 3 N•m
(27 lb-in.).
8. Plug wire from voltage regulator in to rectifier.
9. Install fan, pulley, washer and nut. Torque pulley
nut to 40 N•m (30 lb-ft.).
10. Install alternator on engine and adjust belt tension.
(See Engine section)

4/13/95 4 - 97
ELECTRICAL REPAIR

4 - 98 4/13/95
CONTENTS GEAR POWER TRAIN

CONTENTS
Page

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OTHER MATERIALS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHAIN CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DRIVE CHAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DRIVE AXLE ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
COMPONENT LOCATION - GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . 6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CHAIN CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2/10/95 5-1
GEAR POWER TRAIN CONTENTS

5-2 2/10/95
SPECIFICATIONS GEAR POWER TRAIN

SPECIFICATIONS

Drive Axle Assemblies:

Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 N•m (115 lb-ft)
Mounting Bolt Torque (Axle Housing To Chain Case) . . . . . . . . . . . . 190 N•m (140 lb-ft)
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Viscosity Lithium Grease

Chain Case:
Side Plate Bolt Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (132 lb-in.)
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Gallons (Each Side) 10W30 Motor Oil

Gear Box:
Gearbox Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 N•m (233 lb-ft)
Drive Motor Mounting Bolt Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 N•m (41 lb-ft)
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80w90 Multi Purpose Gear Lubricant

Drive Chain:
Front Chain Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #100 - Qty 64 - 1.25 in Links
Front Chain Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2032 mm (80 in)
Front Chain Maximum Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2035 mm (80.12 in)
Rear Chain Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #100 - Qty 58 - 1.25 in Links
Rear Chain Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1841.5 mm (72.5 in)
Rear Chain Maximum Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1844.3 mm (72.6 in)
Chain Tension . . . . . . . . . . . . . . . . . . 12.7-19.1 mm (0.5-0.75 in) Deflection At Midspan
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With Applied Force Of 4.5-6.8 Kg (10-15 lbs)

OTHER MATERIALS:

Number Name Use

TY15130 Form-In-Place Gasket Gearbox Mounting Bolts,

LOCTITE ® No. 395

TY9375 Pipe Sealant With Gearbox Drain Plug And Vent

LOCTITE No. 592 TEFLON ® Threads, Dipstick Tube Fitting
To Gearbox

TY15934 Gasket Maker Gearbox Cover, Gearbox To

Chain Case Wall, Chain Case
Cover

®LOCTITE is a registered trademark of the LOCTITE Corp.

®TEFLON is a registered trademark of the Du Pont Company

4/13/95 5-3
 GEAR DRIVE COMPONENT LOCATION GEAR POWER TRAIN

GEAR DRIVE COMPONENT LOCATION

M76092

Drive Chain

Hydrostatic Motor

Gearbox

Chain Case Fill

Double Chain Sprocket

Rear Axle Asssembly

Front Axle Assembly

Axle Sprocket

5-4 4/17/95
THEORY OF OPERATION GEAR POWER TRAIN

THEORY OF OPERATION components of the chain case may be accomplished

through the removable side plate.
The gear power train transmits power from the
hydrostatic drive motor, through a reduction gearbox, to
drive chains in the chain case. These chains turn DRIVE CHAINS
sprockets on the drive axles. The left and right side
gear power trains are completely separate units, and This machine uses four endless drive chains, one for
are sealed from the rest of the loader and the each axle, running in an oil bath inside the chain case.
environment. The drive system is the same for forward The chains are driven by a double sprocket shaft from
or reverse; the drive motor is reversed by reversing the the gearbox. Each chain then drives a large chain
flow of fluid from the pumps. sprocket spline connected to the axle shaft. The large
chain sprocket slides freely on the axle shaft spline, it’s
travel limited by a low friction bushing mounted on the
GEARBOX inside wall of the chain case. The chain is tightened by
sliding the entire axle assembly toward or away from
The entire gearbox and motor assembly are located on the drive sprocket. This is made possible by the
the inboard side of the chain case. The hydraulic drive presence of slots in the mounting holes of the axle
motor is mounted to the park brake chamber of the housing. There are no chain tensioners or idler springs
gear box. Within the Park brake chamber the output to adjust.
shaft of the motor is connected to the input or pinion
shaft of the gear box with a coupler that is splined both
externally and internally. The external splines of the DRIVE AXLE ASSEMBLIES
coupler mesh with the splines of the brake Discs. The
M57739
pinion shaft is a single piece, machined to be both a
shaft and a gear. This gear drives an idler that is
connected to the idler shaft. The idler shaft then drives
the final output shaft of the gearbox. The gear box is
sealed from the chain case, the drive motor, and the
environment, allowing use of different lubricants in
each system. The gearbox lubrication uses an oil bath
of 80W90 gear oil. The oil level in the gearbox is
maintained through a filler tube located at the front of
the gearbox. The filler tube is equipped with a dipstick
that has an indicated operating range.

CHAIN CASE
M76091

The axle housings are attached to the chain case on

eight slotted mounting holes. The splined axle shaft
extends into the chain case where it is driven by the
roller chain and sprocket. The axle housing contains
two tapered roller bearings in replaceable races, the
inside bearing being lubricated from the splash oil bath
in the chain case. The outside bearing and the
removable wear sleeve are lubricated by a grease
fitting on the side of the axle housing.

The chain case is also the skid steer side frame

member. It is completely sealed from the other
components of the loader and from the environment.
The left and right side chain cases are the same in
design. They both have front and rear drive chains and
sprockets, however, they are each an individual oil
reservoir and must be monitored separately. The oil
bath lubrication system is maintained through a oil fill/
level plug on the outboard side. All service to the

4/13/95 5-5
GEAR POWER TRAIN COMPONENT LOCATION - GEARBOX

COMPONENT LOCATION - GEARBOX

A
B

AE D
AF E

H
F I
G
AC
AB
AA
X Z
W Y K J
V
U
AD L
T
S

R
Q

P
O

M63277

A. Double Chain Sprocket/Output Shaft L. Park Brake Pad W. Idler Shaft Outer Bearing Race
B. Output Shaft Seal M. Hydrostatic Motor X. Idler Shaft Outer Bearing
C. Output Shaft Outer Bearing N. Park Brake Chamber Cover Y. Input Shaft Inner Bearing
D. Output Shaft Outer Bearing Race O. Park Brake Discs Z. Input Shaft Inner Bearing Race
E. Output Shaft Gear P. Fixed Friction Disc AA.Input Shaft
F. Output Shaft Inner Bearing Race Q. Splined Coupler AB. Input Shaft Outer Bearing Race
G. Output Shaft Inner Bearing R. Input Shaft Seal AC.Input Shaft Outer Bearing
H. Brake Screw S. Idler Shaft Inner Bearing AD. Filler Tube Assembly
I. Brake Screw Seal T. Idler Shaft Inner Bearing Race AE.Gearbox Housing
J. Gear Case Breather Assembly U. Idler Gear AF. Dipstick
K. Gearbox Cover V. Idler Shaft

5-6 4/13/95
TROUBLESHOOTING GEAR POWER TRAIN

TROUBLESHOOTING

Problem or

Grinding noise at gearbox

Symptom

One wheel not powered

Grease leaking at axle

Grinding noise at axle

Excessive axle play

Both drive wheels

Chain noise
Check or

inoperable
Solution

Oil leaks
Check gasket seal at gearbox cover

Check gasket seal between gearbox and chain case

Check O-ring seal between axle housing and chain case

Check that gearbox vent is clear

Check gearbox filler tube connection

Inspect inner axle seal

Check grease seal at axle

Check axle bearings for excessive wear

Check axle housing rolling torque (see Axle Assembly

And Disassembly)

Check chain case oil level

Check drive chain tension

Check drive chain for excessive wear or failure

Check axle housing for grease

Check gearbox oil level

Inspect gearbox components for wear or failure

See hydrostatic drive section

See brake section

4/13/95 5-7
GEAR POWER TRAIN
DIAGNOSIS
Test Conditions:
• Operator on seat, seat belt fastened.
• Engine running at high idle.
• Park brake off.
Test/Check Point
1. Push both drive handles
forward at an equal rate.
2. Pull both drive handles back
at an equal rate.
3. Operate drive handles in
forward and reverse individually.
Test Conditions:
• Roll bucket back.
• Lower boom to ground.
• Stop engine.
• Jack loader wheels off ground and support frame with suitable jack stands or hardwood cribbing.
• Release park brake.
4. Rotate each tire by hand.
Test Conditions:
• Set service/start switch to SERVICE position.
• Start engine and run at a high idle.
5. Move drive levers forward
and reverse for each side.
5-8
Normal
Loader moves forward in a
straight line with all wheels
turning.
Loader moves backward in a
straight line with all wheels
turning: go to step 3.
Loader rotates in one direction
with two wheels Turning
without grinding noises.
Tires present less than 1/4” of
rotational play.
If normal, but loader continues
to pull to one side, go to step
5.
Wheels and tires are driven
smoothly for that drive lever,
and run at same speed (use
digital tachometer).
DIAGNOSIS
If Not Normal
Engine stalls, loader rotates in one
direction, wheels locked or dragging,
Grinding noises in final drive area: Go to
step 2.
Slow or no power: See Hydrostatic
section.
Engine stalls, loader rotates in one
direction, wheels locked or dragging : Go
to step 3.
Slow or no power: See Hydrostatic
section.
Only one wheel is driven, excessive chain
noise: go to step 4.
Wheels not powered, engine doesn’t stall:
see step 4.
Engine stalls: Inspect gear box, see
hydrostatic section.
Tires present more than 1/4” of rotational
play.
Check chain tension for that axle.
One tire rotates freely:
Drive chain broken for that axle.
Both tires on one side rotate together
freely: Inspect gearbox, drive motor.
Chain noise: Inspect drive chain.
Slow on one side: See Steering section for
drive control handle adjustment. See
hydrostatic section for drive motor
diagnostics.
4/13/95
REPAIR GEAR POWER TRAIN

REPAIR 3. Remove both of the skid plates under the engine

compartment and the small one under the gearbox
to be removed.
GEARBOX 4. Drain the hydraulic system by disconnecting the filter
return line from the tee fitting located beneath the
battery.
GEARBOX OIL CHANGE AND LEVEL CHECK 5. Perform cab tilting procedure (see Cab And Boom
Tilting Procedure).
M63278
A
6. Remove kick plate.
7. Remove hydrostatic motor from gearbox to be
removed (see Hydrostatic section).
8. Remove wheels, tires and fenders from side of
loader being serviced.
9. Remove chain case side cover (see Chain Case
Side Cover Removal And Installation).
10. Remove the drive chains within chain case (see
Drive Chain and Sprocket Removal and Installation
in this section).

M76248

1. The gearbox gear oil level may be checked and filled

through a filler tube (A) located on the side of the
gearbox housing. The fluid level should be
maintained to the operating range on the dipstick
located in the filler tube. The gear oil is drained near
the bottom of the inboard side of the gearbox (B).
There is no hole in the bellypan beneath the gear
box for drainage. The fluid will need to be captured
as it escapes from other service openings in the
belly pan. The left and right side gearboxes are not
connected and require separate oil supplies.
2. The gearbox should be filled to operating level with
80W90 multi purpose gear lubricant.
3. Apply pipe sealant to plug threads before replacing.

NOTE: Be sure the gearbox vent cap remains

unclogged.

GEARBOX REMOVAL
1. Park machine on level surface. Raise boom and set
on boom stops. Stop engine and release hydraulic
pressure by operating hand and foot controls.

c CAUTION
Filler Tube

CAUTION: To avoid injury from escaping

hydraulic oil under pressure, relieve the
pressure in the system by stopping the engine
and operating all hydraulic control valves.
2. Jack machine and place on suitable jack stands.
Place at a height that allows servicing from
underneath.
11. Rig a suitable lifting device to the gear box as
shown.
12. Disconnect the filler tube at the gearbox.
13. Disconnect the lower mounting bracket that is
connected to the park brake chamber.

4/13/95 5-9
GEAR POWER TRAIN REPAIR

6. Inspect brake pucks for wear (see Brake Section).

7. Remove the seven (7) capscrews that fasten the
gearbox cover to the gearbox housing.

Pinion Shaft

Mounting bolts

Output Shaft

M76247

14. Remove the four (4) gearbox mounting bolts inside

the chain case.
15. Pry gearbox away from chain case to break silicone
seal at mating surfaces.
16. Pull gearbox away from side frame until double
chain sprocket will clear the side frame. Remove
gearbox from loader.
GEARBOX DISASSEMBLY AND REASSEMBLY
Idler Shaft M63282
8. With the gearbox supported on bench and the cover
facing up, gently tap the edge of the cover until the
silicone seal has been broken and the cover can be
removed. When removing cover, some of the shaft
bearings may stay on the end of the shaft or they
may separate from the shaft and stay in the cover.

M63281 Gearbox Bearing And Seal Replacement

Cover
1. Inspect the bearings on the cover side of the shaft. If
they appear to be warn, replace them.
Brake Chamber
Cover M63285

Gearbox
Housing

Gearbox Cover Removal

1. Remove gearbox from loader (see Gearbox Removal
And Installation).
2. Remove four (4) cap screws holding park brake
chamber cover to gearbox cover.
3. Gently tap park brake cover with a plastic or wood
mallet until it is loosened from the gearbox cover.
4. Remove the brake discs, friction disc, and coupler
from the end of the gearbox pinion shaft. NOTE: If puller is used to remove bearings, they will
likely be damaged in the process. Be prepared
5. Remove brake pucks from park brake cover and to replace them.
gearbox cover.

5 - 10 4/13/95
REPAIR
2. If bearings do not readily come out of cover, a slide
hammer type puller with inside jaws can be used as
shown.
IMPORTANT: Bearings and races should always be
replaced as a set.
3. To install bearings, apply a thin layer of 80W90 gear
lube to the outside of the bearing race.
4. Place the bearing into position in the cover or
housing. If necessary a plastic hammer can be used
to tap the race until it reaches the bottom of the
bore.
5. Inspect the pinion shaft seal in the gearbox cover.
6. To remove seal, pry out of cover from the outside.
7. Inspect and clean sealing surface in cover.
8. Install seal with the flat side out using the correct
size driver. Push seal in until flat side is flush with
housing.
NOTE: The output shaft seal can only be changed
after the output shaft has been removed from
the gear box (see Shaft Removal And
Disassembly).
Shaft Removal And Disassembly
1. Remove the retaining ring at the end of the output
shaft.
M63286
Supports
The gearbox output shaft must be removed before the
pinion or idler shaft can be removed.
4/13/95
GEAR POWER TRAIN
2. To remove the gearbox shaft, place it in a hydraulic
press in such a manner that will allow the shaft to be
pressed out the side of the housing as shown.
When pressing the shaft it is important to know that
the bearing races on both ends of the shaft will be
pressed off at the same time.
IMPORTANT: Make certain that when pressing the
output shaft, the side of the housing is properly
supported as close to the chain sprockets as
possible.
3. Press the output shaft until it releases and can be
removed out the side of the housing.
4. Remove the pinion shaft from the housing.
5. Remove the Idler shaft from the housing.
6. Examine the sealing surfaces of the output shaft and
the pinion. Check for wear or grooves.
7. Remove the thirty nine tooth output shaft gear from
the gearbox housing. Only after the output shaft and
output gear have been removed can the output shaft
seal be serviced.
8. Inspect the seal for damage.
9. If the output shaft bearing has been removed, the
seal can be driven out from the inside of the
gearbox. If not, it can be pried out from the outside
or removed with a slide hammer.
10. Drive the new seal in until the flat portion of the seal
is flush with the outside of the gearbox.
IMPORTANT: After removing the output shaft
examine the outer bearing to see that it was not
damaged during removal of the shaft.
11. Inspect the housing side bearings for wear or
damage. If necessary, replace (see Bearing And
Seal Replacement). If any of the pinion or idler
bearings were replaced, the associated races will
need to be pressed off the respective shaft.
5 - 11
GEAR POWER TRAIN
M63287
12. To press off the pinion shaft races, a bearing
separator will need to be used to grip the edge of
the race.
M63288
13. When installing the pinion races, press the races on
until they butt against the gear portion of the shaft.
14. On the idler shaft, the race on the chain case end of
the shaft can be pressed on until it butts against the
gear teeth on the shaft.
15. Before pressing the inboard race onto the idler
shaft, the idler gear must be installed. The race can
then be pressed until it meets the splines on the
shaft.
16. To install the output shaft begin by installing the
outboard bearing in the housing bore.
5 - 12
REPAIR
M63289
17. Position housing and output shaft in arbor press
such that the shaft is through housing bearing and is
supported under the double chain sprocket.
18. Press the race between the shaft and the bearing
until it reaches the next larger diameter of the shaft.
19. Simultaneously install the output gear and the idler
shaft.
20. Install the pinion shaft. This may require lifting the
Idler shaft and the output gear slightly out of position
and then allowing all three components to mesh.
M63290
21. With the housing in the press, and the output shaft
supported under the double chain sprocket, press
the race onto the output shaft until it reaches the
gear spline.
Gearbox Cover Installation
1. Apply a bead of sealant to the sealing surface of the
housing. Place gearbox cover on housing bearings
with respective races being positioned into
bearings.
4/13/95
REPAIR
2. Install five (5) of the seven (7) mounting screws and
torque to 41 N•m (30 lb-ft). Do not install the screws
that will later fasten the control arm mounting
bracket to the gear box (see Two Speed Cylinder
And Linkage Removal And Installation).
3. Install spacer and puck in brake chamber of gearbox
cover.
4. Install coupler on end of pinion shaft.
5. Install brake discs and friction plate.
6. Install brake puck into brake chamber cover.
7. Install brake chamber cover on gearbox cover
8. Install the two (2) upper mounting bolts finger tight.
The remaining two bolts will be installed when the
gearbox is installed in the machine.
GEAR BOX INSTALLATION
1. Thoroughly clean the mating surfaces of the gearbox
and the chain case. Be sure that these surfaces are
free of any old sealant.
2. Apply a 1/4” bead of silicone sealant to gearbox
surface that mates with the chain case.
M76249
3. Using a suitable lifting device, lower the gearbox into
position in the chassis.
4. Align the bolt holes in the gearbox with the holes in
the chain case and install the four mounting bolts.
Torque the mounting bolts to 311±7 N•m (230±5 lb-
ft).
5. Install the lower mounting bracket to the brake
chamber cover.
6. Connect the filler tube to the gear box.
7. Install the drive chains and the axle assemblies (see
Drive Chain And Sprocket Removal and Installation)
8. Install the hydrostatic motor, control arms, and
steering centering assembly, (see Hydrostatic
Section).
9. Install kick plate.
4/13/95
GEAR POWER TRAIN
10. Fill gear box to operating level with 80W90 multi
purpose gear lubricant.
11. Return cab to operating position (see Cab And
Boom Tilting Procedure).
12. Fill hydraulic reservoir to operating level with
10W30 motor oil.
13. Install wheels and fenders.
CHAIN CASE
CHAIN CASE OIL LEVEL CHECK
M63279 Fill Plug
1. The fluid level is checked and filled through a plug on
the side of the chain case, behind the front wheel.
Maintain oil level even with the bottom thread of the
fill plug. The left and right side chain cases are not
connected and require separate oil supplies.
2. Plug is sealed with an O-ring which should be
cleaned before installation.
CHAIN CASE OIL CHANGE
1. The chain case is not equipped with a bottom drain
plug. The oil can be removed through the side cover
using a suction pump or by absorbing with rags (see
Chain Case Side Cover Removal And Installation).
The left and right chain cases are not connected
and require separate servicing. Clean area around
drain plug before removing. Maintain oil level even
with the bottom of the fill hole. The fill plug is also
sealed with an O-ring which should be cleaned
before installation. Fill chain case with 10W30 motor
oil.
CHAIN CASE SIDE COVER REMOVAL AND
INSTALLATION
The chain case side cover can be removed to access
and service drive chains, sprockets, and the inside of
the chain case.
5 - 13
GEAR POWER TRAIN
Side Cover Removal
1. Park machine on level ground, boom and bucket
lowered to ground, park brake on, and engine off.
2. On the side from which the cover is to be removed,
Jack the loader until the wheels are off the ground
and support loader with suitable jack stands or
blocks.
3. Remove front and rear drive wheels.
4. Remove the mounting screws that fasten the plate to
the chain case.
5. Using a suitable pry bar, pry the cover away from the
case to break silicone seal on the cover.
Side Cover Installation
1. Clean all debris and used sealant from side cover,
chain case, and side cover mounting screws.
2. Apply 3/8” bead of form-in-place gasket sealant to
chain case opening.
3. Apply a spot of form-in-place gasket sealant to
outside edge of each hole in side cover where
machine screws pass.
4. Place side cover on chain case lining up bolt holes.
Install screws and tighten to 15 N•m (132 lb-in).
DRIVE CHAIN AND SPROCKET REMOVAL
1. Remove chain case cover (see Chain Case Side
cover removal And Installation).
NOTE: It is necessary to remove rear axle assembly
and rear drive chain from small sprocket before
removing front drive chain
2. Remove wheel and axle assembly for each drive
chain being serviced (See Axle Assembly Removal
And Installation, be sure to follow all jacking and
cleaning instructions)
3. Remove rear drive chain from center drive sprocket.
4. Pull drive chain and large sprocket to access hole
and remove.
5. Repeat steps 2-5 for front chain and sprocket if
necessary.
NOTE: Front drive chain is six (6) links longer than rear
chain. Label chains after removing from loader.
DRIVE CHAIN AND SPROCKET INSTALLATION
NOTE: Front axle sprocket is installed with the long
portion of the center hub facing outward while
the long portion of the rear center hub is
installed facing inward or towards the machine.
5 - 14
REPAIR
1. If front sprocket was removed, place chain around
front axle sprocket while it is still out of the machine.
2. Place the front sprocket and chain into the chain
case through the inspection hole as a unit.
3. Place the chain over the inside half of the double
drive sprocket and push the large sprocket as far
forward as possible
4. To install rear drive chain and sprocket, repeat steps
1-3, placing chain on outside of double gear
sprocket
5. Install axle assembly (see Axle Assembly Removal
And Installation).
DRIVE CHAIN TENSION ADJUSTMENT
Proper chain tension is achieved by sliding the axle
housings away from the double chain sprocket.
1. Jack the side of the loader and place on suitable
jackstands or cribbing.
2. Remove the wheel from the axle housing in need of
adjustment.
3. Remove the chain case cover (see Chain Case
Cover Removal And Installation).
M76094
NOTE: Do not loosen the axle housing mounting bolts
too much or the O-ring between the axle
housing and the chain case wall may become
dislodged. If this happens, the axle housing will
have to be removed to reset the O-ring.
4. Slightly loosen the axle housing mounting bolts until
the axle housing can be moved with a pry bar as
shown.
5. Pry against the mounting bolts at both the top and
bottom of the axle housing until there is
approximately 13-19 mm (0.5-0.75 in) of slack in
the chain at the center of the lower span.
6. Tighten the axle housing mounting bolts, torque to
190 N•m (140 lb-ft).
7. Install chain case cover (see Chain Case Cover
Removal And Installation).
8. Install wheels.
4/13/95
REPAIR
AXLE ASSEMBLY REMOVAL
NOTE: The axle assembly may be removed without
removing the chain case side cover or draining
the chain case oil.
The axle assembly must be removed from the machine
to service the axle bearings, axle seals, drive chains
and sprockets, low friction bushings, and axle housing
mounting bolts.
1. Park loader on level surface, boom and bucket
lowered to ground, park brake on, engine off.
2. Jack wheels off ground and support loader with
suitable jack stands or blocks.
3. Remove wheel and tire from axle being serviced.
4. Clean around and behind axle housing to prevent
debris from entering chain case oil reservoir.
Axle Housing M57739
Mounting Bolts
Large
Chain Sprocket
5. Loosen and remove eight (8) nuts and washers
holding axle housing to chain case
c CAUTION
Axle Assembly is heavy and may require the
efforts of more than one individual to move.
Consider using a proper lifting device.
6. Pull the axle assembly away from the chain case
letting the large chain sprocket drop off of the axle
spline.
NOTE: The inner axle bearing is lubricated by the
splash of oil in the chain case. The axle
housing will be full of oil, and will drain when
tipped down.
4/13/95
GEAR POWER TRAIN
AXLE ASSEMBLY INSTALLATION
M57746
Axle Housing
Mounting Bolts
Low Friction
Bushing
1. Before installing axle assembly to chain case, be
sure low friction bushing mounted on inner chain
case wall (behind large chain sprocket) is not worn
or missing.
2. Check axle housing mounting bolts for oil leakage
through wall of chain case.
3. If chain case is leaking at bolt hole, thoroughly
inspect bolt to see that it is not damaged or bent. If
bolt is damaged, replace ( see Axle Mounting Bolt
Removal And Installation). If bolt hole is leaking but
the bolt is tight and does not appear to be damaged,
clean the inside of the chain case wall around the
head of the bolt thoroughly. Apply a bead of silicone
sealant around the head of the bolt.
4. Position large chain sprocket so splined hub is
visible through axle hole in chain case.
5. Be sure axle shaft and chain sprocket splines are
clean with no burrs.
6. Place large O-ring in groove on inside face of axle
housing.
7. Thoroughly clean the outside of the chain case
where the O-ring meets chain case wall. When
clean, dry and apply a thin layer of grease.
8. Lift axle housing up to engage axle shaft splines into
chain sprocket splines.
9. Slide axle housing mounting flange over mounting
studs and install eight (8) washers and nuts loosely
in place.
10. Adjust chain tension (see Drive Chain Tension
Adjustment).
11. If chain case oil was removed to perform service,
check level after operating machine (see Chain
Case Oil Level Check).
5 - 15
GEAR POWER TRAIN REPAIR

AXLE HOUSING MOUNTING BOLT

REMOVAL AND INSTALLATION M63280

Axle housing mounting bolts should be replaced at any

sign of damage, as this may lead to oil leakage from
the chain case.
1. Remove axle assembly (see Axle Assembly
Removal And Installation).
2. Remove the mounting bolt with a hammer by driving
through the chain case wall and into the inside of
the chain case.

NOTE: If the mounting bolt is not to severely damaged,

it is good idea to thread a nut on the end of it
when striking it with a hammer . This will help
keep the bolt from mushrooming which may
prevent it from fitting through the hole.

3. Clean and wipe dry the inside of the chain case wall
around the bolt hole.
4. Apply sealant around the bolt hole where the head of
the bolt meets the chain case wall.
5. Insert the bolt into the back side of the hole
6. Place a stack of washers over the bolt leaving
enough threads to equal one thickness of the nut. Axle Flange
7. Thread the nut onto the bolt. Continue to thread the
nut using an impact wrench until the splined
shoulder of the bolt is drawn into the hole.
3. Use a puller to remove the inner bearing from the
8. Remove the nut and washers.
axle by puling both the housing and the bearing
9. Check the bolt to see that it is straight and securely from the axle.
seated in the hole.
10. Install axle assembly (see Axle Assembly Removal
And Installation). IMPORTANT: Support axle housing such that the
hub will be allowed to drop approximately two
inches after the bearing releases from the axle.
AXLE ASSEMBLY AND This will help prevent damage to axle seals
when the housing releases.
DISASSEMBLY
4. After the bearing releases from the axle, allow the
AXLE HOUSING REMOVAL housing to sit back down on the axle flange.
1. Remove O-ring from axle housing and external snap 5. Remove the inner bearing from the axle.
ring from the splined end of the axle shaft. 6. Clean the axle shaft around the snap ring groove
2. Remove and count shims under snap ring. and apply a single layer of plastic electrical tape
over the groove. This will permit the housing to be
pulled off of the axle without damaging the inner
seal.

5 - 16 4/13/95
REPAIR GEAR POWER TRAIN

BEARING AND SEAL REMOVAL 4. Inspect outer axle seal wear sleeve at the end of the
AND REPLACEMENT housing bore. If wear is present at the mating
surface between the sleeve and the seal, replace
the sleeve. The sleeve can be removed by gently
prying it from the axle housing. To install, use a seal
Outer Axle Seal
Wear Sleeve driver or a soft mallet.

Outer Axle
Bearing Race
Outer Axle Outer Axle
Grease Seal Bearing
Inner Axle
Oil Seal

M57748

1. The inner and outer axle bearing race may be M57747

removed from axle housing by hand. Remove and
inspect races. Replace bearing and race as a set if 5. The outer axle grease seal cannot be removed
worn. without removing the outer bearing.
2. With a seal driver or press, and the correct size seal
disk drive the inner axle seal out of the housing
NOTE: Both the outer axle bearing and the outer axle
pushing toward the outer end or “wheel” end of the
grease seal will be destroyed when removed.
housing.
Remove bearing only if replacement of bearing
or seal is necessary.
M57749

M57745

Seal Driver

6. Utilize a suitable bearing separator/puller as shown

3. When installing new inner axle oil seal, select seal
driver that will press only on outer metal edge of
seal, not on seal surface. Drive oil seal in place
using press or soft mallet until bottomed on axle
housing step. Do not distort seal with excess
pressure.
to remove outer axle bearing.
7. The outer axle grease seal can be removed in the
same manner as the outer bearing by mating the
pulling edge of the bearing separator with the lip
located on the inward edge of the seal.
8. Clean axle and housing thoroughly. Before installing
the new outer grease seal, apply a thin layer of
grease to the axle surface.
9. The new seal can be pressed on to the axle using a
cylindrical driver that will press on the steel portion
of the seal.

4/13/95 5 - 17
GEAR POWER TRAIN
10. Pack new outer bearing with grease before
installation.
M63284 Bearing Driver
Support
11. Place new bearing over axle with taper facing up.
12. Install the outer bearing in the same manner as the
outer grease seal (as shown). Be sure that the axle
is supported in the press under the center of the hub
and not by the lug bolts.
NOTE: This method may need to be altered depending
on the size and availability of equipment.
However, which ever method is used, be sure
that pressure is applied to the inner race of the
bearing and not the outer bearing cage.
13. Install outer bearing race over outer axle bearing on
axle shaft assembly.
14. Wrap a single layer of plastic tape over snap ring
groove on end of axle shaft to protect seal.
15. Fill the outer grooves of the grease seal with grease
before installing axle housing.
M57750
5 - 18
REPAIR
HOUSING INSTALLATION
1. Place axle housing over axle shaft as shown. Do not
use excessive force or inner axle oil seal will tear.
Check that outer bearing race seats in housing.
M63294
2. Place axle and housing in press with support under
center of hub so wheel bolts will not be pressed out
as pressure is applied.
3. Install inner bearing race into housing.
IMPORTANT: Do not press the inside roller bearing
tight against the race. The distance between the
tapered roller bearings determines the rolling
torque of the axle housing. If the bearing is
pressed on too far, the axle rolling torque will be
too tight and the bearing must be pressed off.
4. Place a cylindrical driver over the inside bearing. Be
sure that the driver will press on the inside race of
the bearing. Press bearing down onto axle shaft
until it is just about seated against the race.
M57753
5. Release pressure from press. Place JDT42 spring
gauge in outer axle mounting slot and pull
perpendicular to axle shaft. Note scale reading
when axle housing just begins to rotate on axle.
6. Press the tapered roller bearing down in increments,
while checking rolling torque, until 40 - 67 N (9 - 15
lbs) of pull is required to rotate housing on axle
shaft.
4/13/95
REPAIR GEAR POWER TRAIN

7. Release pressure on axle and remove from press.

8. Add shims to axle shaft to obtain 0.28 mm (0.011
in.) maximum endplay with snap ring in place.

NOTE: 0.010” and 0.020” axle shims are available.

9. Fill axle housing with recommended grease at fitting

until seeping at outer axle shaft seal

4/13/95 5 - 19
GEAR POWER TRAIN REPAIR

5 - 20 4/13/95
CONTENTS HYDROSTATIC POWER TRAIN

CONTENTS
Page

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
THEORY OF OPERATION HYDROSTATIC SYSTEM. . . . . . . . . . . . . . . 4
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TWO SPEED COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . 6
HYDROSTATIC SYSTEM SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . 7
COMPONENT LOCATION-HOSES AND LINES . . . . . . . . . . . . . . . . . . . 8
COMPONENT LOCATION-MAIN PUMP CASE. . . . . . . . . . . . . . . . . . . . 9
COMPONENT LOCATION- PUMP BACKPLATES . . . . . . . . . . . . . . . . 10
COMPONENT LOCATION-HYDROSTATIC MOTOR . . . . . . . . . . . . . . 11
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
HYDROSTATIC MOTOR CASE DRAIN FLOW TEST. . . . . . . . . . . . . . . . . . . . . 14
HYDROSTATIC PUMP CASE DRAIN FLOW TEST . . . . . . . . . . . . . . . . . . . . . . 16
HYDROSTATIC PUMP AND MOTOR CASE DRAIN PRESSURE TEST . . . . . . 18
HYDROSTATIC PUMP HIGH PRESSURE RELIEF TEST . . . . . . . . . . . . . . . . . 20
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HYDROSTATIC PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HYDROSTATIC PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
HYDROSTATIC PUMP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
HYDROSTATIC PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
HYDROSTATIC PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
TWO SPEED CYLINDER AND LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
HYDROSTATIC MOTOR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
HYDROSTATIC MOTOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
HYDROSTATIC MOTOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
HYDROSTATIC MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
HYDROSTATIC MOTOR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
START-UP PROCEDURE AFTER HYDRAULIC COMPONENT
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2/10/95 6-1
HYDROSTATIC POWER TRAIN CONTENTS

6-2 2/10/95
SPECIFICATIONS HYDROSTATIC POWER TRAIN

SPECIFICATIONS

HYDROSTATIC PUMPS
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EATON
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servo Controlled Piston Pump
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72400
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.47 GPM @ 2000 RPM
Pressure Relief Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34,400 kPa (5000 PSI)
Minimum Pump Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 percent
Maximum Pump Case Drain Flow . . . . . . . . . . . . . . . . . . . . . . . . . 13.2 LPM (3.5 GPM)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 L (4.5 pts.) in 10 seconds
Maximum Pump Case Drain Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 172 kPa (25 PSI)

HYDROSTATIC MOTORS
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EATON
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two Speed Piston Motor
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C71302-DAF
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.47 GPM @ 2000 RPM
Minimum Motor Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 percent
Maximum Motor Case Drain Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 LPM (1.5 GPM)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.95 L (2 pts) in 10 seconds
Maximum Motor Case Drain Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 172 kPa (25 PSI)

TORQUE SPECIFICATIONS
Pump Trunnion Cover Screws . . . . . . . . . . . . . . . . . . . . . . . . . 5 ± 0.5 N•m (44 ± 4 lb-in.)
Pump Main Drive Pressure Relief Valve . . . . . . . . . . . . . . . . 143 ± 6 N•m (105 ± 5 lb-ft.)
Pump And Motor Backplate Mounting Cap Screws . . . . . . . . . 40 ± 2 N•m (29 ± 2 lb-ft.)
Servo Cylinder Cover Mounting Screws . . . . . . . . . . . . . . . . . 5 ± 0.5 N•m (44 ± 4 lb-in.)
Servo Piston Screw Jam Nut. . . . . . . . . . . . . . . . . . . . . . . . . 17 ± 1 N•m (155 ± 5 lb-in.)
Servo Valve Mounting Screws. . . . . . . . . . . . . . . . . . . . . . . 5.0 ± 0.5 N•m (44 ± 4 lb-in.)
Wear Plate Retaining Screw . . . . . . . . . . . . . . . . . . . . . . . . 1.7 ± 0.1 N•m (15 ± 1 lb-in.)
Charge Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . 39 ± 2 N•m (29 ± 1 lb-ft.)
Hydraulic Pump Mounting Screw . . . . . . . . . . . . . . . . . . . . . . . 40 ± 2 N•m (29 ± 2 lb-ft.)
Two Speed Shaft To Linkage Retaining Screws . . . . . . . . . . . . 40 ± 2 N•m (30 ± 2 lb-ft.)
Gear Box Cover Mounting Screws . . . . . . . . . . . . . . . . . . . . . . 40 ± 2 N•m (30 ± 2 lb-ft.)
Hydrostatic Motor Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 N•m (75 lb-ft.)

OTHER MATERIALS
Petroleum Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pump And Motor Reassembly
JD Plus 4®, TurfGard®, HyGard® . . . . . . . . . . . . . . . . . . .Pump And Motor Reassembly

4/13/95 6-3
HYDROSTATIC POWER TRAIN
THEORY OF OPERATION
HYDROSTATIC SYSTEM
Function:
The hydrostatic system provides a means to transfer
power from the engine to the final drive for the wheels.
It also provides infinitely variable speed control, and
steering of the vehicle.
Principles of Operation:
The hydrostatic system is a closed loop fluid power
system that consists of two gear driven individually
mounted EATON piston pumps and two EATON piston
motors. Charge pressure is provided by a internal
charge pump located in the right hand hydrostatic
pump. An externally mounted gear pump mounted on
the end of the left hand hydrostatic pump provides
hydraulic pressure for operating the boom, bucket, and
auxiliary equipment (see Hydraulic section for
description of hydraulic pump).
Steering is controlled by two hand levers located in the
operators cab. These hand levers control direction
(forward, reverse) and flow (speed) of the vehicle by
rotating the camplate in the individual pumps. See
steering section for detailed description.
• Hydrostatic Pump
The hydrostatic pumps are gear driven EATON axial
piston, servo controlled, variable displacement piston
pumps. They are mounted to an adaptor plate which is
bolted on to the back of the engine. Power is
transferred by a gear drive system from the engine to
the two hydrostatic pumps.
Fluid flow is controlled by changing the angle of the
camplate. This angle is controlled by the servo control
spool valve and piston. Moving the respective steering
lever will move the spool off center which in turn will
provide hydraulic assist to the double acting piston
6-4
THEORY OF OPERATION HYDROSTATIC SYSTEM
which controls the position of the camplate.
The location, off center, of the camplate controls the
distance the pistons travel inside the piston bore of the
rotating assembly. The direction that the camplate is
rotated from center determines the direction of fluid
flow (forward or reverse). The number of degrees the
camplate is deflected, determines how much fluid will
be displaced (speed).
The hydrostatic pumps provide hydraulic fluid to the
hydrostatic motors through hydraulic lines and fittings.
Hydraulic fluid in the power train circulates in a closed
loop. Fluid leaves the hydrostatic pump and flows
through the hydrostatic motor and is returned to the
hydrostatic pump, not the reservoir. Fluid that leaves
this closed loop circuit, such as case drain, is
replenished by fluid from the charge pump.
• Charge Pump
The charge pump is a Gerotor type positive
displacement pump mounted internally in the right
hand hydrostatic pump.
This pump provides fluid under pressure to operate the
servo control, two speed control, and to provide
replacement fluid to the hydrostatic pumps.
• Hydrostatic Motors
The hydrostatic motors are EATON high torque axial
piston motors. There are two hydrostatic motors on
each machine. They are located on the right and left
gear boxes under the operators seat. Each hydrostatic
motors drives a gear reduction system which transfers
power to the wheels (see Final Drive Section). The
right hand hydrostatic motor and gear reduction system
drives the right wheels, the other drives the left hand
wheels.
The hydrostatic motors are also equipped with movable
camplates. These camplates can be set at either 7 or
19 degrees off of center. This allows the motors to be
operated at two speed ranges.
4/13/95
HYDROSTATIC POWER TRAIN HYDROSTATIC COMPONENT LOCATION

HYDROSTATIC COMPONENT LOCATION

Two Speed Left Hydrostatic
Charge Solenoid Valve
Pressure Motor
Sensor

Hydraulic
Pump

Left Hydrostatic Pump Right Hydrostatic

Motor

Right Hydrostatic Pump

Intake Line
r vo ir
e
Res
To

From Filter Hydrostatic Motor

Case Drain Cross Over
M76271

4/17/95 6-5
 TWO SPEED COMPONENT LOCATION HYDROSTATIC POWER TRAIN

TWO SPEED COMPONENT LOCATION

M76264

Control Linkage

Charge Supply Line

Solenoid Valve

Discharge Hose
Two Speed Cylinder

6- 6 4/17/95
 HYDROSTATIC SYSTEM SCHEMATIC HYDROSTATIC POWER TRAIN

HYDROSTATIC SYSTEM SCHEMATIC

Down

Gerotor Right Hydrostatic Pump

Engine Engine Left Hydrostatic Pump
Charge Pump

Up

Boom Cylinders
Bucket Cylinders
Bucket Spool
System Relief Valve Down
IN

A B
Boom Spool Left Servo
Main Control Control
Valve
Up
C Right Servo Charge Pump
D
Control

Circuit Relief
Valve
E
F

OUT Right Hydrostatic Left Hydrostatic

Motor Motor
BYD
Hydraulic Oil
Cooler
Two Speed
Control Solenoid P Pressure
Switch
Auxiliary Spool
Hydraulic Oil Filter High Pressure Oil
Two Speed Cylinder
P Return Oil - Low Pressure
Quick
Disconnect Filter
Auxiliary
Sensor Trapped Oil - Recirculating
Hydraulic Power
Hydraulic Oil
Reservoir
Charge Pressure Oil - Medium Pressure

2/27/95 6-7
 COMPONENT LOCATION - HOSES HYDROSTATIC POWER TRAIN

COMPONENT LOCATION - CASE DRAIN COMPONENT LOCATION - HOSES

6
5

11
10
27
11
17

11
25
10
10 22
12 14 11
29
2 3 17
9
7
9 16 24
8
7 23
11 20
9 1
4 26
10
15

19
2
9
10 21
9 10
10 10 11
11 18
11 5
13

12
10
11

8
M76185

1. Hose Assembly 5. O-Ring 9. Connector 1

2. Tube Assembly 6. Elbow 10. O-Ring 30
3. Tube Assembly 7. Tee Fitting 11. Elbow Fitting 3
28
4. Tube Assembly 8. T-Fitting 12. T-Fitting 4 M76184

1. O-Ring 11. O-Ring 21. Hose Assembly, 3/4"

2. Elbow Fitting 12. O-Ring 22. Connector
3. Elbow Fitting 13. Tube Assembly 23. Pressure Switch
4. Hose Assembly 14. Hose Assembly 24. Capscrew
5. Elbow Fitting 15. Elbow Fitting 25. Nut
6. Hose Assembly, 1/2" 16. Clamp 26. Tee-Fitting
7. Elbow Fitting 17. Connector 27. Elbow Fitting
8. Run Tee 18. Hose Assembly, 3/4" 28. Clamp
9. O-Ring 19. Hose Assembly, 3/4" 29. Hose Assembly
10. Elbow Fitting 20. Hose Assembly, 3/4" 30. Capscrew

6-8 4/17/95
COMPONENT LOCATION-MAIN PUMP CASE HYDROSTATIC POWER TRAIN

COMPONENT LOCATION-MAIN PUMP CASE

22 29
28
27 33
25 32
38 11 9
12
8

6
31
10
5
26 3
4
37 6
30
2
13 7
1 11
12
14
13
30
36
35 28
16
15 34

24 27
23
17 28
18 27
19 37
18
17 38
20 39
21
17

M76187

1. Main Pump Housing 11. O-ring 21. Seal 30. Plug

2. Cradle 12. Plug 22. Servo Valve 31. Gasket
3. Camplate 13. O-Ring 23. Cover 32. O-ring
4. Wear Plate 14. Needle Bearing 24. Gasket 33. Plug
5. Rotating Assembly 15. Shaft 25. Cover 34. Servo Piston
6. Cap Screw 16. Shaft 26. Gasket 35. Seal
7. Dowel Bushing 17. Retaining Ring 27. Cap Screws #10-24 36. Ring
8. Retaining Screw 18. Thrust Washer x 25.5 mm (1 in.) 37. Seal Washer
9. Servo Piston Follower 19. Thrust Bearing 28. Washer 38. Flat Washer
10. Gasket 20. Washer 29. Cap Screws 39. Jam Nut

4/13/95 6-9
HYDROSTATIC POWER TRAIN COMPONENT LOCATION- PUMP BACKPLATES

COMPONENT LOCATION- PUMP BACKPLATES

12
11 20
1 17
9
8
10

22 21
18 24
23

13

11 15
14
16
12

23 19
12
2
11

13
16 3
4
6
5
7

11
12
9 15
10
14

M76188

1. Backplate, Left Pump 7. Key 13. Washer 19. Cover

2. Backplate, Right Pump 8. Pin 14. Plug 20. Cap Screw
3. Gerotor Pump Housing 9. Needle Bearing 15. Retaining Ring 21. Cap Screw
4. Gerotor, Outer Ring 10. Valve Plate 16. O-ring 22. Washer
5. Gerotor, Inner Ring 11. O-ring 17. Cap Screw 23. Cap Screw
6. O-Ring, Shaped 12. Relief Valve 18. Coupler 24. O-Ring

6 - 10 4/13/95
COMPONENT LOCATION-HYDROSTATIC MOTOR HYDROSTATIC POWER TRAIN

COMPONENT LOCATION-HYDROSTATIC MOTOR

2
25
24
23
22
21 26
20
19
18
17
16
15
14
13
12
11

27
28
29
30
31
32
33
1

32
33
34
3 35
4 36
7 37
5 27
6
5
7
8
9
10

M76236

1. Motor Housing 14. Pivot 27. Screw

2. Motor Backplate 15. Spring Disk 28. Trunnion Cover
3. Needle Bearing 16. Piston Block 29. Trunnion Cover
4. Shaft 17. Pins 30. Lip Seal
5. Thrust Washer 18. Spring Clip 31. Washer
6. Thrust Bearing 19. Washer 32. Inner Race
7. Snap Ring 20. Spring 33. Needle Bearing
8. Spacer 21. Washer 34. O-Ring
9. Lip Seal 22. Retaining Ring 35. O-Ring Cover
10. Retaining Ring 23. Valve Plate 36. Trunnion Cover
11. Camplate 24. Gasket 37. Trunnion Cover
12. Pistons 25. Dowel
13. Spider 26. Cap Screw

4/13/95 6 - 11
HYDROSTATIC POWER TRAIN TROUBLESHOOTING

TROUBLESHOOTING

High or low speed will not

sides of machine will not
Problem or

Wheels on one or both

Sluggish response to
Noisy pump or motor
Symptom

Wheels rotate in one

changes in speed

direction only
Low power
Check or

operate
Solution

rotate
Check gear coupling between
●
engine and pump

Hydraulic level low in reservoir ● ● ●

Low charge pressure (see Tests

● ● ● ●
and Adjustments Section)

Main drive pressure relief valve

stuck open (see Tests & ● ● ● ●
Adjustments Section)

Air in system (see Start-Up

Procedure After Hydrostatic
● ● ●
Component Replacement
Section)

Hydrostatic motor output

pressure to low (see Tests and ● ●
Adjustments Section)

Internal pump or motor damage

● ● ● ●
or excessive wear

Parking brake engaged or

● ●
malfunctioning

Pump centering mechanism not

● ●
properly adjusted

Drive chain or gearbox

malfunction (see Gear Power ●
Train Section)

Steering linkages loose,

● ● ● ●
broken, or worn

Servo valve malfunctioning ● ● ●

Two speed control solenoid

●
not operating properly

6 - 12 4/13/95
DIAGNOSTICS HYDROSTATIC POWER TRAIN

DIAGNOSTICS
Test Conditions:
• Operator in seat
• Seat belt fastened
• Key switch in RUN position

Test/Check Point Normal If Not Normal

1. Control levers Levers should move freely Check lockout solenoid circuits.
Check linkage from levers to pump.

Test Conditions:

• Start engine and run at slow idle.

Test/Check Point Normal If Not Normal

2. Control levers are in neutral. Machine should not creep forward or Adjust centering of pump control
backward or in circles. levers.

3. Move levers smoothly forward
or backward from center.
Machine should accelerate smoothly
forward or backwards.
Check fluid reservoir for proper fluid
level.
Check hydraulic hoses, tubing, and
connections for leaks.
Perform system flow and pressure
checks to verify proper operation of
hydraulic pump.

4. Control levers in full forward Machine should move forward in a Reset stop plates on steering
position. straight line. mechanism.
Check Drive Pressure Relief valves.

4/13/95 6 - 13
HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS

TESTS AND ADJUSTMENTS

HYDROSTATIC MOTOR CASE DRAIN FLOW TEST

JTO3023

48" Long hoses

M76258

Reason:
To assure that hydrostatic motor is not bypassing

c CAUTION
excessive amount of hydraulic fluid.

Equipment:
Failure to block machine properly could result in
• Stop Watch movement of vehicle during test procedure
• Drain Pans (2), 3 Gallons Minimum causing severe injury to operators and damage
• JTO3391 Male Plug to equipment.
• JTO3023 Female Plug
• 1 Gallon Graduated Container
• JTO5719 Hand Held Digital Tachometer

c CAUTION
• 60" Long Hose W/9/16-18 37° Male Fitting
• 60" Long Hose W/9/16-18 37° Female Fitting

Procedure: CAUTION: Be sure that the seat support rod is

1. Park machine on level surface. Raise boom and set
on boom stops.
2. Turn key switch to off position.
3. Block machine off of the ground.
4. Apply parking brake.
securely locked in the service position so that
seat does not fall and cause injury.
5. Raise seat to service position.
6. Put service start switch in service position.
7. Start engine and allow to run until hydraulic oil is at
operating temperature of 40°C (110°F).

6 - 14 4/13/95
TESTS AND ADJUSTMENTS HYDROSTATIC POWER TRAIN

8. Set engine speed at 2000 RPM. Verify with
JTO5719 hand held digital tachometer.
9. Note position of throttle control.
10. Return to idle position and stop engine.
IMPORTANT: Make sure to relieve system pressure
before loosening any system lines or hoses.
11. Sit in seat and fasten seatbelt. Turn key to "ON"
position and cycle foot and hand controls to relieve
system pressure. Turn key to "OFF"
12. Disconnect case drain lines from tee fitting on right
hydrostatic motor.
13. Cap one male port of tee fitting with JTO3023
female plug as shown.
14. Cap hose from motor tee fitting to hydraulic pump
with JTO3391 male plug.
15. Connect 60" long hose with male fitting to LH
hydrostatic motor case drain line as shown.
16. Connect 60" long hose with female fitting to RH
hydrostatic motor tee fitting as shown.
19. For a period of ten (10) seconds, simultaneously
move the control lever of the motor being tested
forward while directing the drain hose for that
pump into the graduated container.
20. After 10 seconds return hose to original container
and return the control lever to the neutral position.
21. Return engine to idle and turn key to off position.
22. Record amount of fluid in graduated container.
23. If the other motor is to be tested, repeat steps 18
through 23.
Specifications:
• Volume in container should not exceed
approximately 0.95 L (2 pts.) in the ten (10) second
test. This calculates to 5.7 LPM (1.5 GPM).
Results:
• If volume is excessive, rebuild and/or replace
pumps.

IMPORTANT: Make sure that the hydraulic fluid

reservoir is topped off. Insufficient Hydraulic
fluid could cause system to run dry and damage
pumps and motors.

17. Place open ends of hoses in drain pans.

NOTE: The following portion of the test will require the

aid of a second technician.

IMPORTANT: Do not operate control lever for more

than 20 seconds with parking brake engaged or
hydraulic oil may overheat.

c CAUTION
If park brake fails to prevent wheels from
turning, CEASE TEST IMMEDIATELY. Repair or
adjust park brake as necessary before resuming
test (see Brake Section).

NOTE: Perform case drain test on one motor at a time.

18. Start engine and set operating speed to previously

noted throttle position.

4/13/95 6 - 15
HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS

HYDROSTATIC PUMP CASE DRAIN FLOW TEST

JTO3221

60" Hose
60" Hose

M76261

Reason:
To assure that hydrostatic pump is not bypassing

c CAUTION
excessive amount of hydraulic fluid.

Equipment:
Failure to block machine properly could result in
• Stop Watch movement of vehicle during test procedure
• Drain Pans (2), 3 Gallons Minimum causing severe injury to operators and damage
• JTO3221 Plug to equipment.
• 1 Gallon Graduated Container
• JTO5719 Hand Held Digital Tachometer
• 60" Long Hose W/ 3/4-16 37° Female Fitting (2)

Procedure:
1. Park machine on level surface. Raise boom and set
on boom stops.
2. Turn key switch to off position.
3. Block machine off of the ground.
4. Apply parking brake.
c CAUTION
CAUTION: Be sure that the seat support rod is
securely locked in the service position so that
seat does not fall and cause injury.
5. Raise seat to service position.
6. Put service start switch in service position.
7. Start engine and allow to run until hydraulic oil is at
operating temperature of 40°C (110°F).
8. Set engine speed at 2000 RPM. Verify with
JTO5719 hand held digital tachometer.

6 - 16 4/13/95
TESTS AND ADJUSTMENTS HYDROSTATIC POWER TRAIN

9. Note position of throttle control.
10. Return to idle position and stop engine.
IMPORTANT: Make sure to relieve system pressure
before loosening any system lines or hoses.
11. Sit in seat and fasten seatbelt. Turn key to "ON"
position and cycle foot and hand controls to relieve
system pressure. Turn key to "OFF"
NOTE: Both pumps have a common case drain.
12. Disconnect case drain line to hydraulic pump from
LH hydrostatic pump at tee fitting. Install JTO3221
drain plug in open end of line as shown.
13. Remove case drain line connecting case drains of
both hydrostatic pumps. Remove tee fitting from
LH hydrostatic pump.
14. Attach 60" long hoses to the left and right
hydrostatic pump case drains.
hose for that pump into the graduated container.
18. At end of 10 seconds return hose to original
container and return the control lever to the neutral
position.
19. Return engine to idle and turn key to off position.
20. Record amount of fluid in graduated container.
21. If the other pump is to be tested, repeat steps 16
through 20.
Specifications:
• Volume in container should not exceed
approximately 2.2 L (4.5 pt) in the ten (10) second
test. This calculates to 13.2 LPM (3.5 GPM).
Results:
• If volume is excessive, rebuild and/or replace
pumps.

IMPORTANT: Make sure that the hydraulic fluid

reservoir is topped off. Insufficient Hydraulic
fluid could cause system to run dry and damage
pumps and motors.

15. Place open ends of hoses in drain pans.

NOTE: The following portion of the test will require the

aid of a second technician.

IMPORTANT: Do not opertate control lever for

more than 20 seconds with parking brake
engaged or hydraulic oil may overheat.

c CAUTION
If park brake fails to prevent wheels from
turning, CEASE TEST IMMEDIATELY. Repair or
adjust park brake as necessary before resuming
test (see Brake Section).

NOTE: Perform case drain test on one pump at a time.

16. Start engine and set operating speed to previously

noted throttle position.
17. For a period of ten (10) seconds, simultaneously
move the control lever of the pump being tested to
the full forward position while directing the drain

4/13/95 6 - 17
HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS

HYDROSTATIC PUMP AND MOTOR CASE DRAIN PRESSURE TEST

JTO3344

JTO1609

JTO3017

JTO3386

M76259

Reason:
To assure that there is not excessive pressure in the
hydrostatic pump and motor cases.
c CAUTION
Equipment:
Failure to block machine properly could result in
• JTO3386 Tee Connector movement of vehicle during test procedure
• JTO3344 Gauge 2,000 kPa (300 PSI) causing severe injury to operators and damage
• JTO5719 Hand Held Digital Tachometer to equipment.
• JTO3017 Hose W/JTO1609 Quick Coupler
3. Block machine off of the ground.
Procedure:
1. Park machine on level surface. Raise boom and set
on boom stops.
2. Turn key switch to off position.
c CAUTION
CAUTION: Be sure that the seat support rod is
securely locked in the service position so that
seat does not fall and cause injury.

4. Raise seat.
5. Remove kick plate.
6. Put service start switch in service position.

6 - 18 4/13/95
TESTS AND ADJUSTMENTS HYDROSTATIC POWER TRAIN

7. Start engine and allow to run until hydraulic oil is at Results:

operating temperature of 40°C (110°F).
8. Set engine speed at 2000 RPM. Verify with
JTO5719 hand held digital tachometer.
9. Note position of throttle control.
10. Return to idle position.
11. Stop engine and release hydraulic pressure by
operating hand and foot controls.
• If case drain is over 172 kPa (25 PSI) pump and
motor case drains must be tested individually.
• If case drain is over 172 kPa (25 PSI) check for
blockage or pinched line in case drain system.
• If case pressure exceeds 172 kPa (25 PSI), the
pump case may rupture.

c CAUTION
CAUTION: To avoid injury from escaping
hydraulic oil under pressure, relieve the
pressure in the system by stopping the engine
and operating all hydraulic control valves.

NOTE: Both pumps and motors have a common case

drain.

12. Disconnect hose coming from RH hydrostatic motor

case drain at tee fitting on hydraulic pump.
13. Install JTO3386 tee connector in line and attach
hose to tee connector.
14. Install JTO3017 hose on open port of JTO3386 tee.
15. Attach JTO3344 gauge to hose with JTO1609 quick
coupler installed.
16. Engage parking brake.
17. Start engine. Set throttle to position noted earlier.

IMPORTANT: Do not operate control lever for more

than 20 seconds with parking brake engaged or
hydraulic oil may overheat.

c CAUTION
If park brake fails to prevent wheels from
turning, CEASE TEST IMMEDIATELY. Repair or
adjust park brake as necessary before resuming
test (see Brake Section).

18. Move drive levers slowly forward or backwards.

19. Record reading on gauge.

Specifications:
• Case drain pressure should not exceed 172 kPa (25
PSI).

4/13/95 6 - 19
HYDROSTATIC POWER TRAIN TESTS AND ADJUSTMENTS

HYDROSTATIC PUMP HIGH PRESSURE RELIEF TEST

JTO3362

JTO3364

JTO3103

JTO3058

M76260

Reason:
To assure that hydrostatic pump high pressure relief

c CAUTION
valves are operating properly.

Equipment:
• JTO3103 Adapter
• JTO3058 Tee Connector
• JTO5719 Hand Held Digital Tachometer
• JTO3364 Hose 70,000 kPa (10,000 PSI)
• JTO3362 Gauge 70,000 kPa (10,000 PSI)
Procedure
1. Park machine on level surface. Raise boom and set
on boom stops.
2. Turn key switch to off position.
CAUTION: Be sure that the seat support rod is
securely locked in the service position so that
seat does not fall and cause injury.
4. Raise seat.
5. Remove kick plate.
6. Put service start switch in service position.
7. Release hydraulic pressure by operating hand and
foot controls.

c CAUTION
Failure to block machine properly could result in
movement of vehicle during test procedure
causing severe injury to operators and damage
to equipment.
NOTE: Each pump has two high pressure relief valves.
3. Block machine off of the ground.
c CAUTION
CAUTION: To avoid injury from escaping
hydraulic oil under pressure, relieve the
pressure in the system by stopping the engine
and operating all hydraulic control valves.
One each for forward and reverse circuit. Each
valve must be tested independently.

8. Install JTO3058 tee connector between hydrostatic

pump fitting and hydraulic hose to the motor.

6 - 20 4/13/95
TESTS AND ADJUSTMENTS HYDROSTATIC POWER TRAIN

9. Attach JTO3103 adapter, JTO3364 hose and

JTO3362 gauge to tee fitting.
10. Engage parking brake.
11. Start engine and adjust speed to 2000 RPM. Verify
with JTO5719 hand held digital tachometer.

IMPORTANT: Do not operate control lever for more

than 20 seconds with parking brake engaged or
hydraulic oil may overheat.

c CAUTION
If park brake fails to prevent wheels from
turning, CEASE TEST IMMEDIATELY. Repair or
adjust park brake as necessary before resuming
test (see Brake Section).

12. If the gauge is hooked into the LH port on the

hydrostatic pump, slowly move control lever for that
pump backwards until gauge peaks.
13. If the gauge is hooked into the RH port on the
hydrostatic pump, slowly move control lever for that
pump forward until gauge peaks at highest reading.
14. Record reading.
15. Shut off engine.
16. Repeat process for all pressure ports on
hydrostatic pumps.

Specifications:
• Pump pressure should be approximately 34,473
kPa Max. (5000 PSI Max.).

Results:
• If pressure is low perform pump case drain flow test
or pump efficiency test. This will determine if the
valve is at fault or if the pump is in need of repair.

4/13/95 6 - 21
HYDROSTATIC POWER TRAIN REPAIR

REPAIR
6. If the left pump is being removed, disconnect the
main pressure hoses from both the left and right
HYDROSTATIC PUMP REMOVAL pumps. If the right pump is removed, the drive
hoses only need to be disconnect from the right
1. Park machine on level surface. Raise boom and set pump.
on boom stops. Stop engine and release hydraulic
pressure by operating hand and foot controls.
A M76232

c CAUTION B
C
H
CAUTION: To avoid injury from escaping
hydraulic oil under pressure, relieve the
pressure in the system by stopping the engine
E
and operating all hydraulic control valves.
F
2. Jack machine and place on suitable jack stands.
Place at a height that allows servicing from
underneath.
3. Remove both of the skid plates under the engine
compartment and the one under the hydrostatic
pumps. G D

4. Drain the hydraulic system by disconnecting the

filter return line from the tee fitting located beneath
the battery.
5. Raise seat to service position.
c CAUTION
CAUTION: Be sure that the seat support rod is
securely locked in the service position so that
seat does not fall and cause injury.
7. Remove the case drain (A) and charge pressure (B)
cross over lines.
8. If the left pump is being removed, disconnect the
following:
(C) Hose to charge pressure sensing unit
(D) Hydraulic pump suction line
(E) Hydrostatic motor case drain

(F) Hydraulic pump pressure line

NOTE: Illustrations are shown with cab raised for
(G) Two speed cylinder discharge line
clarity. It is not necessary to raise cab to
remove hydrostatic pumps.
9. If the right pump is being removed, disconnect the
Gerotor suction hose (H).

M76231

Drive Hoses

6 - 22 4/13/95
REPAIR HYDROSTATIC POWER TRAIN

the exception of the backplates. The RH pump is

equipped with a backplate that adapts to the Gerotor
Mounting Bolts charge pump. This Gerotor charge pump supplies the
charge pressure for the hydrostatic piston pumps as
well as the operating pressure for the servo controls
and the two speed cylinder. The LH pump is equipped
with a backplate that adapts to gear pump. This gear
pump supplies the high pressure charge for the
hydraulic operating system (boom and Bucket
cylinders).

Control Arm GEROTOR PUMP REMOVAL AND DISASSEMBLY

(RH PUMP ONLY)

M76139
Lower Linkage
M76234

10. Disconnect the lower linkage from the control arm

and then remove the control arm from the pump.
11. Secure a lifting strap to the center of the pump.
12. Remove the bolts that fasten the mounting flanges
to the engine plate. The bottom bolt will need to be
reached from underneath through the access hole
in the chassis.
13. Pull the pump away from plate while loosening the
bolts.
14. When the pump is free of the plate, lift and remove
from machine.

NOTE: Have a suitable drain container available as 1. Remove the flange cover and O-ring by removing
excess lube oil may drain from the engine gear the two mounting screws.
box after the pump is removed.

HYDROSTATIC PUMP Backplate

Gerotor Housing
DISASSEMBLY

RH Pump Machine LH Pump

Forward
Travel

Key
Rotors M76151

Hydraulic Gear Pump 2. Remove the four cap screws that hold the Gerotor
housing to the backplate.
Gerotor Charge Pump M76140 3. Pull the housing away from the backplate and
remove the O-ring.

The LH and RH hydrostatic pumps are identical with

4/13/95 6 - 23
HYDROSTATIC POWER TRAIN REPAIR

4. Remove the inner and outer rotors from the shaft.

The rotors are a loose fit on the shaft. However,
3. Remove the valve plate from the backplate. The
they may adhere slightly to the backplate due to oil
valve plate is not fastened to the backplate, but
between the machined surfaces. Be careful not to
may adhere slightly due to oil between machined
lose the key that is located between the shaft and
surfaces.
the inner gerotor ring.
4. In most cases it should not be necessary to remove
the spring pin that is used to keep the valve plate
M76152 properly located. If the pin is tight in the hole and is
not damaged, there is no need to replace it.
However, if the spring pin is damaged, it can be
removed. In doing so be extremely careful not to
scratch the machined surface of the backplate.

Relief valve
Shim Pack

5. Remove the charge pressure relief valve assembly

from the Gerotor housing.

IMPORTANT: Be sure to note the number of

washers in the shim pack. The same shim pack
must be installed when the pump is
reassembled.
BACKPLATE REMOVAL AND DISASSEMBLY (RH
PUMP ONLY).
1. Tap the backplate with a plastic mallet to loosen it
from the housing.
2. Remove the backplate and gasket from the
hydrostatic pump housing.
M76161
5. Remove the main drive pressure relief valves from
the backplate. Mark the valve as to which cavity
they came from and reassemble in the same
manner.
BACKPLATE REMOVAL AND DISASSEMBLY (LH
PUMP ONLY).

M76154

Spring Pin Valve Plate

6 - 24 4/13/95
REPAIR HYDROSTATIC POWER TRAIN

1. Remove the hydraulic gear pump by removing the 7. Remove the main drive pressure relief valves from
two cap screws that fasten it to the backplate. the backplate. Mark the valves as to which cavity
2. Remove the four cap screws that fasten the they came from and reassemble in the same
backplate to the pump housing. manner.
3. Tap the backplate with a plastic mallet to loosen it
from the housing.
ROTATING ASSEMBLY REMOVAL AND
4. Remove the backplate and gasket from the pump DISASSEMBLY (RH OR LH PUMP)
housing.

M76155
M76154

Spring Pin Valve Plate

1. Remove the rotating assembly from the housing.

5. Remove the valve plate from the backplate. The 2. If the pistons did not come out with the piston block,
valve plate is not fastened to the backplate, but remove the pistons along with the spider and pivot.
may adhere slightly due to oil between machined
surfaces.
Piston Block
6. In most cases it should not be necessary to remove
the spring pin that is used to keep the valve plate Pivot
properly located. If the pin is tight in the hole and is Spider
not damaged, there is no need to replace it.
However, if the spring pin is damaged, it can be
removed. In doing so be extremely careful not to
scratch the machined surface of the backplate.
Pins and Retainer

Pistons
M58106

Relief valve NOTE: Disassembling the piston block assembly is not

necessary unless the pins are damaged.

c CAUTION
The spring inside the piston block is
compressed and should not be removed without
M76214
compressing the spring first. Use the following
procedure to remove the spring safely.

4/13/95 6 - 25
HYDROSTATIC POWER TRAIN REPAIR

The following parts will be needed to disassemble the

piston block. Retaining Ring
2 ea. . . . . . . . . . . . . 3/8" ID x 1-1/4" O.D flat washers Spring
1 ea. . . . . . . . . . . . . . . . . . . . 3/8" x 5" N.C. cap screw Pin Retainer
1 ea. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8" N.C. nut
1 ea. . . . . . . . . . . . . 1/2" Drive Socket With 1-1/8" OD

Washers
M76099
Pins M56625

9. Remove washers, spring, pins, and pin retainer.

CAMPLATE AND SHAFT REMOVAL AND

DISASSEMBLY (LH AND RH PUMP)

M76156

Camplate

3. Place one of the flat washers over the 3/8" x 5" cap
screw. Install cap screw through spline end of
piston block so that the washer rests on the three
pins.

Nut
Washer Follower

Socket 1. Remove the camplate and follower from the

housing, this may require some maneuvering of the
camplate. When removing the camplate, be sure
Retaining Ring not to damage the shoe surface.

Retaining Screw
Wear Plate

M58132

4. Place the socket and then the washer over the end
of the cap screw.
5. Screw the nut on and slightly compress the spring
inside the piston block.
6. Use retaining ring pliers to remove the internal
retaining ring.
7. Carefully back off tension on nut until spring is M76158
slack.
8. Remove the nut, washer, and cap screw.
2. Remove the wear plate by removing the retaining
screw on the center tab.

6 - 26 4/13/95
REPAIR HYDROSTATIC POWER TRAIN

M76138 Main Shaft

Drive Gear

Thrust Washer

Washer
Retaining Ring
Seal Retaining Ring
Thrust Bearing
Drive gear
Retaining Ring
Retaining Ring

Seal
Retaining Ring
M57918

6. Remove the seal and washer.

3. Remove the drive gear and drive gear retaining
rings from the spline end of the shaft.
4. Remove the seal retaining ring.
M76138
7. Remove the retaining ring from the shaft and
remove the thrust washers and thrust bearing.
SERVO CONTROL DISASSEMBLY
(LH AND RH PUMPS)

M76159
Servo Valve

Servo Cylinder Cap

Gasket

1. Remove the servo valve and gasket by removing

the six socket head cap screws that fasten the
valve to the housing.
2. Remove the cylinder cap that does not have the
5. Press the shaft out of the housing as shown until screw and locknut through the center.
the rubber seal releases from the bore. Be sure
that the shaft is supported below so that it does not
drop and become damaged when it releases from
the housing.

4/13/95 6 - 27
HYDROSTATIC POWER TRAIN REPAIR

M76165 8. The cradle for the camplate can be removed by

taking out the two mounting screws and moving the
cradle back and forth to release the dowel
bushings that hold the cradle in place.

Piston
HYDROSTATIC PUMP INSPECTION

NOTE: Gerotor information applies to RH hydrostatic

pump only.

1. Inspect the needle bearing in the housing, needles

should be free spinning and not fall out of bearing
cage. If the bearing needs to be replaced, it can be
pressed out from the inside of the housing outward.
2. Inspect the needle bearings in the Gerotor housing,
the backplate, and the pump housing. If the
Piston Screw needles remain in the cage and spin freely, there is
no need to replace them.

M76153
3. Remove the locknut from the piston screw.
4. Remove the flat washer and rubber washer from
the piston screw.
5. Using a hex wrench (Allen wrench) in the end of the
piston screw, turn it clockwise until it threads
completely out of the cover.
6. Remove the cover with the piston screw hole
through the center.
7. Push the piston out of the piston bore.

NOTE: Do not disassemble the piston any further. The

piston spring tension is preset at the time of
manufacture. The service piston assembly is
only sold as an assembled unit.

3. If it is necessary to remove the bearing from the

Gerotor housing, it can be pressed from the inside
M76178
of the Gerotor housing to the outside as shown.

IMPORTANT: The Gerotor housing is aluminum

and the machined surfaces can be easily
damaged. Do not press the housing against
unprotected steel surfaces.

4. If the bearing in the backplate needs to be

replaced, it can be pressed out in the same fashion
as that of the Gerotor housing.

IMPORTANT: When removing bearing from

backplate, be extremely careful not to damage
machined surfaces.

6 - 28 4/13/95
REPAIR HYDROSTATIC POWER TRAIN

5. Inspect the inside of the Gerotor housing for

excessive wear particularly at the surfaces that
meet the Gerotor rotors.
Spider
6. Inspect the inner and outer rotors, check for nicks
or large scratches, particularly between the two
rotors.
7. Inspect the charge pressure check valve and the
check valve seat in the Gerotor housing. Be sure
that there are no burrs, excessive wear, or defects
on the check valve or the check valve seat.

Valve Plate Shoe Face

Pivot
M58088

11. Examine the OD of the pistons for finish condition.

They should not show wear or deep scratches.
12. Inspect the shoes for a snug fit on the ball end of
the pistons. Check the face of the shoes for a flat
smooth surface.
Piston Block
13. Examine the spider for wear in the pivot area.
M76105 14. Examine the pivot to insure smoothness and no
signs of wear.

8. Inspect the valve plate on the bronze side next to

the piston block for wear. Replace the valve plate if IMPORTANT: Piston face roll can be caused by
any wear, scoring, or scratches exists. towing unit, dry start-up, or loss of charge
pressure.
9. Inspect the piston block surface that makes contact
with the valve plate. This surface should be smooth
and free of deep scratches.

Piston Shoe
Piston Block

Piston

Relief valve

M56554

Check Valve
M76161

10. Check the piston movement in the block bore. If the

pistons are sticky in the bore examine the bore for
scoring or contamination.
15. Examine the main drive pressure relief valves and
seats. Inspect the check valve at the end of the of
the relief valve. The check valve at the end of the
relief valve should be loose and easily operated.
The seat for the check valve should be free of burrs
and defects.

4/13/95 6 - 29
HYDROSTATIC POWER TRAIN REPAIR

16. Examine the machined surfaces of the backplate,
particularly the Gerotor side.
M76156
IMPORTANT: Due to extremely tight tolerances and
finish of pump internal surfaces it is very
important to maintain absolute cleanliness
during the assembly of the pump. Coat all
internal surfaces with clean 10W30 motor oil
when assembling the pump.

Shoe Surface
HOUSING, SERVO CONTROL AND SHAFT
REASSEMBLY (LH AND RH PUMPS)
Cradle Surface

17. Examine the shoe surface of the camplate, be sure

that there are no scratches, grooves, or excessive
wear on the shoe surface. Check that the
lubrication holes in the camplate are open.
18. Inspect the cradle surface on the back side of the
camplate for excessive wear. M76181
19. Examine the wear plate, if the fiber surface of the
wear plate is worn, replace the wear plate.
1. If the needle bearing was removed from the
housing, the new one can be pressed from the
Bearing Surfaces M76112 outside inward until the bearing race is recessed in
the bore approximately 1.8 mm (1/16 in.). Be sure
that the numbers on the bearing race are facing to
the outside of the housing.

Thrust Bearing

Thrust Washers

20. Inspect the shaft for fretting in the bearing and

spline area.
21. Inspect thrust bearing and washers for wear.
22. Inspect the servo piston for scratches and wear.
23. Examine the servo piston cylinder in the pump
housing. If the seals in the cylinder are worn or
damaged, replace them. Piston Screw
M76182

HYDROSTATIC PUMP ASSEMBLY

2. Install the cylinder cover and gasket that has the
1. Clean all parts in a suitable solvent and dry with lint piston screw hole through the center. Torque the
free rag. mounting screws to 5 ± 0.5 N•m (44 ± 4 lb-in.).

6 - 30 4/13/95
REPAIR
3. Install the piston into the cylinder as indicated
above.
4. Insert a hex wrench (Allen wrench) into the end of
the piston screw and thread it through the cover
until the flat end of the piston is located 12.7 mm
(0.500 in.) from the edge of the cylinder.
5. Install the rubber washer, flat washer, and outside
jam nut onto the piston screw. Torque the jam nut
to 17.5 ± 1 N•m (155 ± 5 lb-in.).
Servo Valve
Cylinder Cap Gasket
M76159
6. Install the remaining cylinder cover and gasket.
Again, torque the mounting screws to 5 ± 0.5 N•m
(44 ± 4 lb-in.).
7. Install the servo valve and gasket onto the housing.
Be sure the servo valve feed back rod is positioned
into the narrow groove on the servo piston. Torque
the mounting screws to 5.0 ± 0.5 N•m (44 ± 4 lb-
in.).
4/13/95
HYDROSTATIC POWER TRAIN
8. Place the cradle into the housing being sure that
the dowel bushings are located in the holes in the
housing. Draw the cradle tight by evenly torquing
the two mounting screws to 36±2 N•m (26±2 lb-ft).
9. Install the wear plate onto the cradle and torque the
retaining screw to 1.7 ±0.1 N•m (15±1 lb-in.).
Retaining Ring Retaining Ring
Thrust Bearing
Thrust Washer Thrust Washer
M56557
10. the inside retaining ring, thrust washer, and thrust
bearing on the shaft. Install the outside thrust
washer and retaining ring.
11. Install the shaft into the housing. Install the washer
and a new shaft seal. Secure it with the retaining
ring.
12. Install the camplate follower onto the camplate.
13. Place the camplate over the shaft with the shoe
surface outward.
14. Use a long screw driver to guide the camplate
follower into the large groove in the servo piston.
ROTATING ASSEMBLY INSTALLATION
(LH AND RH PUMP)
1. If the piston block assembly was disassembled
complete the following. If not skip to step 8.
Retaining Ring
Spring
Pin Retainer
Washers
Pins
M56625
2. Install the three pins in oversize grooves in spline
end of piston block with the heads facing inside of
the block.
3. Install the pin retainer.
4. Install the washers and spring.
6 - 31
HYDROSTATIC POWER TRAIN REPAIR

5. Using same tools used to compress spring during 12. Slide the rotating unit up the shaft until it meshes
disassembly of block install washer, spring, second with the splines on the shaft.
washer, cap screw and nut in the piston block.
6. Compress spring.
BACKPLATE AND GEROTOR ASSEMBLY AND
7. Install retaining ring.
INSTALLATION (RH PUMP ONLY)
8. Remove spring compression tools from the piston
block.
9. Place the pivot such that the flat side rests on the M76203
Roll Pin
top of the three pins.

M76117

10. With the pistons in place in the spider, lower the

pistons into the piston block.

NOTE: It is not necessary to put the pistons in the

original positions, any piston can be installed in
any hole.
M76205

M76190 1. If the bearing was removed from the backplate,

press new one into position as shown. The
numbers on the bearing should be positioned
toward the inside of the pump housing. Press the
bearing in until 2.29 mm (0.090 in.) of the race
remains above the surface of the backplate.
2. Install the roll pin (if removed) that is used to
position the valve plate. Allow the pin to protrude
from the backplate approximately 4.39 mm (1.730
in.).

11. Tilt the pump housing so that the open end is facing
slightly downward, but not so much that the
camplate falls out of position.

6 - 32 4/13/95
REPAIR HYDROSTATIC POWER TRAIN

M76204 M76207

3. Apply a small amount of clear petroleum grease to

the steel side of valve plate to hold it in place for
installation.
4. Install the valve plate onto the backplate with the
steel side facing the backplate and the bronze side M76208
facing the inside of the housing.
5. Place a new gasket on the housing.
7. If necessary, press a new bearing into the Gerotor
housing. Press the bearing into the housing from
M76206 the outside inward with the numbered end of the
race facing outward. Press the top of the bearing
race until it is positioned 2.41 mm (0.095 in.) below
the top edge of the bore (as shown).

M76210
O-ring

Outer Gerotor Ring

6. Install the backplate assembly onto the housing Inner Gerotor Ring
assembly, making sure valve plate stays in
position. The backplate should rest approximately
1.5 mm (0.06 in.) off of the housing until it is 8. Install the key and inner Gerotor ring onto the shaft.
torqued down. This is due to the spring tension Lubricate the inner Gerotor ring.
within the rotating assembly.

4/13/95 6 - 33
HYDROSTATIC POWER TRAIN REPAIR

9. Install the O-ring and outer Gerotor ring into the BACKPLATE ASSEMBLY AND INSTALLATION
Gerotor housing. Use petroleum grease to (LH PUMP ONLY)
lubricate and hold the outer Gerotor ring and O-
ring in place in the housing.
M76203
Roll Pin
Cap Screws

Relief Valve M76211

10. Place the Gerotor housing over the shaft meshing

the inner and outer Gerotor rings. Insert the four
cap screws and torque evenly to 40±2 N•m (29±2
lb-ft).
11. After installing new O-rings, install the main drive
pressure relief valves in the same cavities in the
backplate from which they were removed. Torque
to 143±6 N•m (105±5 lb-ft.).

M76205

1. If the bearing was removed from the backplate,

press new one into position as shown. The
Relief Valve
numbers on the bearing should be positioned
toward the inside of the pump housing. Press the
bearing in until 2.29 mm (0.090 in.) of the race
remains above the surface of the backplate.
2. Install the roll pin (if removed) that is used to
position the valve plate. Allow the pin to protrude
Flange Cover from the backplate approximately 4.39 mm (1.73
in.).

M76212

12. Install the flange cover.

13. Install the charge pressure relief valve. Be sure to
install all of the shim washers. Torque capscrews to
39±2 N•m (29±1 lb-ft).
14. Install the drive gear and drive gear retaining rings.

6 - 34 4/13/95
REPAIR HYDROSTATIC POWER TRAIN

7. Insert the four (4) cap screws and torque evenly to

M76204 40±2 N•m (29±2 lb-ft).
8. After installing new O-rings, install the main drive
pressure relief valves in the same cavities in the
backplate from which they were removed. Torque
to 143±6 N•m (105±5 lb-ft).

3. Apply a small amount of clear petroleum grease to

the steel side of the valve plate to hold it in place
for installation. The backplate should rest
approximately 1.5 mm (0.06 in.) off of the housing
until it is torqued down. This is due to the spring
tension within the rotating assembly. 9. Using a new O-ring, install the hydraulic gear pump
4. Install the valve plate onto the backplate with the to the backplate. Torque the mounting screws to
steel side facing the backplate and the bronze side 40±2 N•m (29±2 lb-ft).
facing the inside of the housing.
5. Place a new gasket on the housing.
HYDROSTATIC PUMP
INSTALLATION
Cap Screws

NOTE: Illustrations are shown with the cab raised for

clarity. It is not necessary to raise the cab to
remove or install the hydrostatic pumps.

1. Be sure that the mounting area on the engine gear

box and the flange area on the pump are clean.
2. Install a new O-ring on the pump flange.

Relief Valve

6. Install the backplate assembly onto the housing

assembly, making sure the valve plate stays in
position.

4/13/95 6 - 35
HYDROSTATIC POWER TRAIN REPAIR

(E) Hydrostatic motor case drain

Mounting Bolts
(F) Hydraulic pump pressure line

(G) Two speed cylinder discharge line

9. If the right pump is being installed, connect the

Gerotor suction hose (H).
10. Install the case drain (A) and charge pressure (B)
cross over lines.

Control Arm M76231

Lower Linkage
M76234

3. With a lifting strap positioned at the center of the

pump, lower the pump into position.
4. Maneuver the drive gear on the pump into the hole
in the gear box meshing the drive gear with the
gear in the gear box.
Drive Hoses
5. Leave the mounting flange approximately 6 mm (1/
4 in.) away from the gear box until the mounting
bolts are threaded into the holes. Tighten the bolts
and draw the flange to the gear box. The bottom
11. Connect the main motor drive hoses.
bolt will need to be reached from underneath
through the access hole in the chassis. 12. Check the lubricant level in the engine gear box
with the dipstick located between the pumps.
6. Attach the control arm to the pump.
13. Fill the hydraulic reservoir to operating level.
7. Connect the lower linkage to the control arm.
14. Perform the start up procedures found at the end of
this section.
A M76232 15. Adjust control linkage (see Steering And Brake
Section).
B

H
TWO SPEED CYLINDER AND
C LINKAGE
E

c CAUTION
F

CAUTION: Do not start engine while two speed

linkage is removed. Two speed piston can
G D dislodge under pressure and cause serious
injury.

8. If the left pump is being installed, connect the

following:
(C) Hose to charge pressure sensing unit
(D) Hydraulic pump suction line
REMOVAL, INSPECTION, AND INSTALLATION
1. Park machine on level surface. Raise boom and set
on boom stops. Stop engine and release hydraulic
pressure by operating hand and foot controls.
2. Apply parking brake.

6 - 36 4/13/95
REPAIR
3. Raise seat to service position.
c CAUTION
CAUTION: Be sure that the seat support rod is
securely locked in the service position so that
seat does not fall and cause injury.
4. Remove kick plate.
5. Remove the right control arm assembly and
steering centering assembly (see Steering And
Brake Section).
M76239
Brake Spring
Mounting Bolts
Mounting Bracket
Tension Spring
Two Speed Cylinder
6. Disconnect the right brake linkage spring from the
brake control lever by removing the cotter key that
retains it to the lever.
7. Remove the two (2) cap screws that fasten the right
steering linkage mounting bracket to the right gear
box.
8. Disconnect the hydraulic hose at the back of the
cylinder.
9. Remove the two (2) mounting bolts that fasten the
cylinder to the two speed linkage and remove the
cylinder. Take note of the position of washers and
bushings in the cylinder mounting hardware so that
the cylinder can be reinstalled correctly.
10. Relieve the pressure of the tension spring by
backing off the nut on the eye bolt.
11. Remove the retaining bolts that fasten the two
speed linkage to the trunnion shafts of the motors.
12. The linkage is taper fit to the trunnion shafts. Use a
knife edge puller to remove the linkage from the
shafts. Do not pry the linkage off, prying may result
in internal motor damage.
4/13/95
HYDROSTATIC POWER TRAIN
M76243
13. To disassemble the cylinder pull the piston
completely out of the cylinder.
14. Examine the piston and the inside of the cylinder. If
either is damaged, replace.
15. Inspect the seals inside the cylinder, if the seals
appear to be worn or if the cylinder has been
leaking, install new seals.
16. To reassemble the cylinder, simply lubricate the
piston with oil and slide it into the cylinder.
Tie Bar
M76245
17. Examine the bushings in the tie bar, if worn, replace
the tie bar.
18. To install the linkage, place the linkage into the
machine such that the key ways in the linkage line
up with the keys on the ends of the trunnion shafts.
19. Install the retaining bolts in the ends of the shafts
and torque to 40±2 N•m (30±2 lb-ft).
20. Place the cylinder into position in the machine.
21. With the necessary washers and bushings in place,
place the rear cylinder mounting bolt through the
steering linkage mounting bracket, through the
cylinder, and into the stationary plate. Begin
threading the bolt, but do not tighten.
22. Fasten the steering linkage mounting bracket to the
gear box and torque the cap screws to 40±2 N•m
(30±2 lb-ft).
23. Install the front cylinder mounting bolt.
24. Tighten the rear cylinder mounting bolt.
6 - 37
HYDROSTATIC POWER TRAIN REPAIR

25. Connect the hydraulic line to the back of the

cylinder. M63255
26. Tighten the eye bolt until mild tension is created on
the linkage spring.
27. Connect the lower control linkage to the control
linkage mounting bracket.
28. Connect the right brake spring to the park brake
lever and install the cotter key.
29. Install the steering centering assembly and control
arm assembly (see Steering Section). Mounting Bolts

HYDROSTATIC MOTOR REMOVAL

NOTE: Illustrations are shown with the cab raised for

clarity. It is not necessary to raise the cab to
remove or install the hydrostatic motors.

1. Park machine on level a surface. Raise the boom

and set it on the boom stops. Stop the engine and
release the hydraulic pressure by operating the
hand and foot controls.
9. Remove the centering assembly mounting plate by

c CAUTION
removing the four (4) mounting bolts that fasten the
plate to the gear boxes.

CAUTION: To avoid injury from escaping M76246 Supply Hoses

hydraulic oil under pressure, relieve the
pressure in the system by stopping the engine
and operating all hydraulic control valves.

2. Jack the machine and place it on suitable jack

stands. Place the machine at a height that allows
servicing from underneath.
3. Remove both of the skid plates under the engine
compartment and the one under the hydrostatic
motor to be removed.
4. Drain the hydraulic system by disconnecting the
filter return line from the tee fitting located beneath
the battery.
5. Raise the seat to service position.

c CAUTION
CAUTION: Be sure that the seat support rod is Case Drain Mounting Bolts
securely locked in the service position so that
seat does not fall and cause injury.

10. Disconnect the main supply hoses from the back of

6. Remove the kick plate.
7. Remove the steering centering assembly (see
Steering And Brake Section).
8. Remove two speed cylinder and linkage (see Two
Speed Cylinder And Linkage Removal And
Installation Section).
the motor.
11. Disconnect the case drain lines to the motor.
12. Engage the parking brake to keep the brake discs
in place should the coupler come out when the
motor is removed.

6 - 38 4/13/95
REPAIR HYDROSTATIC POWER TRAIN

13. Remove the mounting bolts that fasten the motor to

the park brake chamber. The lower bolt will need to
be reached through the access hole in the chassis.
14. Pull the motor away from the park brake chamber
and lift and remove.

HYDROSTATIC MOTOR
DISASSEMBLY

BACKPLATE REMOVAL AND DISASSEMBLY

1. Wash the motor in suitable solvent and dry before
disassembling.

Cap Screws

M76096

3. Hit the backplate with a plastic mallet to loosen it

from the housing, then pull the backplate straight
up to remove.
M76095

2. Remove the four (4) cap screws that fasten the end
cap to the motor.

IMPORTANT: The motor body is aluminum and can

be easily damaged by steel tools. Be careful not
to damage machined surfaces. Do not use
screwdriver or other sharp objects to pry
backplate from body.

Valve Plate
M76098

4. Remove the gasket and valve plate. The valve plate

is not fastened to the backplate but may adhere
slightly to the backplate due to oil between the
machined surfaces.

4/13/95 6 - 39
HYDROSTATIC POWER TRAIN REPAIR

ROTATING UNIT REMOVAL AND DISASSEMBLY
The following parts will be needed to disassemble the
piston block.
2 ea. . . . . . . . . . . . . . 3/8" ID x 1-1/4" OD flat washers
1 ea. . . . . . . . . . . . . . . . . . . . 3/8" x 5" N.C. cap screw
1 ea. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8" N.C. nut
1 ea. . . . . . . . . . . . . 1/2" Drive Socket With 1-1/8" OD

M76099

Rotating Assembly

M56566

3. Place one of the flat washers over the 3/8" x 5" cap
1. Invert the motor and remove the rotating assembly screw. Install the cap screw through the spline end
from the housing. the of piston block so that the washer rests on the
2. If the pistons did not come out with piston block, three pins.
remove the pistons along with the spider and pivot.

Rotating Block Nut

Pivot Washer
Spider

Socket

Retaining Ring
Pins and Retainer

Pistons
M58106

M58132

NOTE: Disassembling the piston block assembly is not

necessary unless the pins are damaged.
4. Place the socket and then the washer over the end
of the cap screw.

c CAUTION
The spring inside the piston block is
compressed and should not be removed without
compressing the spring first. Use the following
procedure to remove the spring safely.
5. Screw the nut on and slightly compress the spring
inside the piston block.
6. Use a retaining ring pliers to remove the internal
retaining ring.
7. Carefully back off tension on nut until spring is slack
8. Remove the nut, washer, and cap screw.
9. Remove the washers, spring, pins, and pin retainer.

6 - 40 4/13/95
REPAIR HYDROSTATIC POWER TRAIN

Retaining Ring 3. Remove the seal and washer.

4. Remove the retaining ring from the shaft and
Spring remove the thrust washers and thrust bearing.
Pin Retainer

CAMPLATE AND SHAFT REMOVAL

Washers
Pins Trunnion Shaft
M56625 Inner Race
Bearing

MAIN SHAFT REMOVAL AND DISASSEMBLY O-ring Cover

Trunnion Covers
M76101

O-ring

M76102

1. To remove the bottom side trunnion shaft bearings,

remove the two trunnion cover mounting screws
and the two trunnion covers.
2. Remove the O-ring cover, O-ring, bearing, and
inner race.

M76103
Retaining Ring Trunnion Shaft

1. Remove the large retaining ring from the housing at

Seal
the spline end of the shaft.
Trunnion Covers
2. Gently tap the shaft with a plastic hammer as
shown until the rubber seal releases from the
housing.

Bearing
Main Shaft
Washer
Thrust Washer

Washer 3. To remove the top side trunnion shaft bearings,

again, remove the mounting screws and trunnion
Retaining Ring covers.
4. Remove the seal, washer, and bearing.
Thrust Bearing

Retaining Ring NOTE: Mark the pump case next to the trunnion shaft
to identify the shaft location on reassembly.
Seal
Retaining Ring
M57918 5. Remove the trunnion shaft.

4/13/95 6 - 41
HYDROSTATIC POWER TRAIN REPAIR

NOTE: The trunnion bearings are a loose fit into the

housing; Do not be concerned if they are not
tight.
Piston Shoe
Piston Block
6. Discard the shaft seals, gasket, and all O-rings. Piston
Replace with new items upon reassembly.

HYDROSTATIC MOTOR INSPECTION

Needle Bearings

M56554

4. Check the piston movement in the block bore. If the

pistons are sticky in the bore examine the bore for
scoring or contamination.

Spider
M76104

1. Inspect the needle bearings in the backplate and

the housing. If the needles remain in the bearing
cage and move freely, there is no need to replace
the bearing. If the bearing needs to be replaced, it
can be removed from the backplate using a slide
hammer. The housing bearing can be removed by
pressing it out from the inside of the housing. Shoe Face
Pivot
M58088
Valve Plate

5. Examine the O.D. of the pistons for finish condition.

They should not show wear or deep scratches.
6. Inspect the shoes for a snug fit on the ball end of
the pistons. Check the face of the shoes for a flat
smooth surface.
7. Examine the spider for wear in the pivot area.
8. Examine the pivot to insure smoothness and no
signs of wear.
Piston Block

M76105 IMPORTANT: Piston face roll can be caused by

towing unit, dry start-up, or loss of charge
pressure.
2. Inspect the valve plate on the bronze side next to
the piston block for wear. Replace the valve plate if
any wear, scoring, or scratches exist.
3. Inspect the piston block surface that makes contact
with the valve plate. This surface should be smooth
and free of deep scratches.

6 - 42 4/13/95
REPAIR HYDROSTATIC POWER TRAIN

HYDROSTATIC MOTOR ASSEMBLY

IMPORTANT: Due to extremely tight tolerances and

finish of internal surfaces it is very important to
maintain absolute cleanliness during the
assembly of the motor. Coat all internal surfaces
with clean 10W30 motor oil when assembling
the pump.

Pins MAIN SHAFT BEARING INSTALLATION

M56625

9. If the pins and the spring inside the piston block

were disassembled inspect the pins for straitness.

Bearing Surfaces M76112

Bearing Numbers
Thrust Bearing

1. If the needle bearings were removed from the

Thrust Washers
10. Inspect the shaft for fretting in the bearing and
spline area.
11. Inspect the thrust bearing and washers for wear.
backplate or the housing, new ones must be
installed. The bearings can be pressed in using the
correct size bearing driver. The housing bearing
should be driven from the outside of the housing
inward until the top is flush with the top of the
housing bore. Be sure that the bearing numbers
are facing outward. The backplate bearing can be
pressed in until 2.4 mm (3/32 in.) is left above the
bore.

Shoe Surface

Needle Bearings

M76113

12. Check the camplate shaft needle bearings and

races, make sure the needles remain in bearing
cage and move freely.
13. Inspect the camplate shoe surface. It should be
free of scratches and wear marks.

4/13/95 6 - 43
HYDROSTATIC POWER TRAIN REPAIR

CAMPLATE AND SHAFT INSTALLATION
4. Over the long end of the trunnion shaft, install the
bearing, washer, seal, and trunnion covers. Again,
the bearing numbers should be facing inward.
Torque the cover screws to 5±0.5 N•m (44±4 lb-
in.)

Snap Ring Snap Ring

Thrust Bearing

Thrust Washer Thrust Washer

M76115 M56557

5. Install the inside snap ring, thrust washer, and

1. Place the camplate into the housing with the long thrust bearing on shaft. Install the outside thrust
trunnion shaft toward boss marked during washer and snap ring.
disassembly.
6. Install the shaft into the housing. Install the washer
and the new shaft seal. Secure them with the
NOTE: The machined shoe surface of camplate retaining ring.
should face open end of pump case.
ROTATING UNIT ASSEMBLY AND INSTALLATION
1. If the piston block assembly was disassembled
M76102 complete the following. If not skip to step 8.

Retaining Ring

Spring
Pin Retainer

Washers
Pins
M56625

2. Install the three pins in the oversize grooves in the

2. After installing the camplate, insert the needle
bearings and the bearing inner race over the short
end of the trunnion shaft and slide them into the
housing. The numbered end of the bearing should
face inward.
3. Install the O-ring, O-ring cover, and trunnion
covers. Torque cover screws to 5±0.5 N•m (44±4
lb-in.).
spline end of piston block with the heads facing
inside of the block.
3. Install the pin retainer.
4. Install the washers and spring.
5. Using the same tools used to compress the spring
during disassembly of block, again compress the
spring.
6. Install the retaining ring.

6 - 44 4/13/95
REPAIR HYDROSTATIC POWER TRAIN

Crush Washer

M76118

IMPORTANT: The Crush washer must be replaced

every time the motor is disassembled.
M56566

7. Install a new crush washer over the three pins on

the piston block assembly. Align the pins with the
three slots in the I.D. of the disc.
8. Place the pivot such that the flat side rests on the
top of the three pins.
M76117
10. Invert the housing and install the rotating assembly
into the housing.
NOTE: The piston shoes must make contact with the
camplate. Be sure all parts are in their proper
position before proceeding. Clamp pump
assembly in a protected jaw vise with the open
end of the housing up.

BACKPLATE INSTALLATION
1. Install new dowel pins in the housing (if previously
removed).
2. place a new gasket on the housing.

M76098
Roll Pin

9. With the pistons in place in the spider, lower the

pistons into the piston block.

NOTE: It is not necessary to put the pistons in the

original positions, any piston can be installed in
any hole.

4/13/95 6 - 45
HYDROSTATIC POWER TRAIN
3. Install the roll pin (if removed) that is used to
position the valve plate. Allow the pin to protrude
from the backplate approximately 4 mm (5/16 in.).
4. Apply a small amount of petroleum grease to the
steel side of valve plate to hold it in place for
installation. Place the valve plate in position on the
backplate with steel side against backplate.
5. Install the backplate assembly onto the housing
assembly, making sure that the valve plate stays in
position.
Cap Screws
M76095
IMPORTANT: Tighten the cap screws evenly in
such a manner that the mating surfaces remain
parallel. Final torque to 40±2 N•m (29±2 lb-ft).
HYDROSTATIC MOTOR
INSTALLATION
If the coupler that joins the motor shaft and the gearbox
pinion shaft was dislodged when the motor was
removed, it will need to be installed.
1. Place the coupler into the hole in the brake
chamber cover. The spline on the inside of the
coupler must mesh with the pinion shaft of the
gearbox while the splines on the outside of the
coupler must mesh with the two brake plates. The
shaft can be pushed into the coupler until it
reaches the retaining ring in the center of the
coupler.
6 - 46
REPAIR
M76246 Supply Hoses
Case Drain Mounting Bolts
2. Place the motor onto the park brake chamber
engaging the shaft with the coupler.
3. Install the two (2) mounting bolts that fasten the
motor to the park brake chamber. Torque to 101
N•m (75 lb-ft).
4. Reconnect the case drain line
5. Install the steering centering device mounting plate.
6. Install the two speed cylinder and linkage (see Two
Speed Cylinder And Linkage Removal And
Installation).
7. Install the centering device and the steering control
arms (see Steering And Brakes Section).
START-UP PROCEDURE AFTER
HYDRAULIC COMPONENT
REPLACEMENT
1. Change the hydraulic system filter.
2. Remove the hydraulic breather assembly on top of
the reservoir. Clean the filter in solvent and dry
before installation.
IMPORTANT: If contamination is found in hydraulic
system filter or inside reservoir, flush entire
hydraulic system.
IMPORTANT: If the hydraulic oil is being reused,
make sure it is filtered through a 10 micron filter
before putting it into the reservoir.
3. Fill the reservoir with specified 10W-30 oil or an
equivalent oil to the proper level.
4/13/95
REPAIR
4. Loosen the hydraulic pump line fitting on the control
valve to bleed air from hydraulic system.
. should read 550-830 kPa (80-120 PSI) within 5 to
A below 350 kPa (50 PSI) for more than 10
M58135
5. Disconnect wire (A) to fuel shutoff solenoid.
c CAUTION
CAUTION: Make sure machine is securely
blocked before proceeding to the next step.
6. Turn the key to START and hold for 10 seconds or
until oil leaks from the loosened control valve
fitting. Turn the key to OFF.
7. Connect the wire to the fuel shutoff solenoid.
B any trapped air has been bled back to the reservoir.
C A
M76240
8. Disconnect the pressure sensor line at the tee
fitting (A).
9. Connect JTO1609 hose (B) to tee fitting (A).
Assemble JTO3344 gauge (C) to hose quick
coupler.
4/13/95
HYDROSTATIC POWER TRAIN
10. Put the steering levers in neutral position. Start the
engine and run at low idle. The hydraulic pressure
10 seconds.
IMPORTANT: If the hydraulic pressure remains
seconds, stop the engine and check for the
cause of low pressure. Failure to stop engine
when hydraulic pressure is low will cause
severe damage to pumps and motors.
c CAUTION
CAUTION: To help prevent injury from escaping
hydraulic oil under pressure, relieve the
pressure in the system. Stop the engine, turn the
ignition key to ON and operate all hydraulic
control valves. Turn key to OFF.
11. Relieve all hydraulic pressure in the system.
12. Disconnect the gauge and replace the hydraulic
pressure sensor after reaching proper hydraulic
pressure.
13. Start the engine and run at half throttle for 20
minutes. Stop the engine and check hydraulic the
oil level. Fill as needed.
14. Start the engine and run at half throttle. Move the
lift arm and bucket pedals for 3 minutes to remove
the air from the system and to progressively load
hydraulic pump.
15. Slowly move the steering levers with no load on
wheels until wheels turn smoothly indicating that
16. Stop the engine and check the hydraulic reservoir
oil level. Check all line connections for leaks and
tighten if necessary.
17. Adjust the steering centering device (see Steering
And Brake Section).
18. Run the engine for an additional 30 minutes to filter
the oil. Stop the engine, change the hydraulic filter.
19. Lower the machine to the ground.
6 - 47
HYDROSTATIC POWER TRAIN REPAIR

6 - 48 4/13/95
CONTENTS STEERING

CONTENTS
Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CONTROL LEVER CENTERING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 12
LINKAGE CENTERING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CONTROL LEVER STOP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
AUXILIARY CONTROL HANDLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 13
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CENTERING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
STEERING DAMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
STEERING CONTROL ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
AUXILIARY HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2/10/95 7-1
STEERING CONTENTS

7-2 2/10/95
SPECIFICATIONS STEERING

SPECIFICATIONS

TORQUE SPECIFICATIONS
Auxiliary Handle Set Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.)
Auxiliary Handle Set Screw Lock Nut. . . . . . . . . . . . . . . . . . . . . . . 13.5 N•m (120 lb-in.)
Pivot Bearing Mounting Carriage Bolts . . . . . . . . . . . . . . . . . . . . . . . . 13 N•m (10 lb-ft.)
Lower Rod End Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 N•m (10 lb-ft.)
Rod End Lock Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 N•m (10 lb-ft.)
Centering Mechanism Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . 44 N•m (33 lb-ft.)
Dampener Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (18 lb-ft.)
Linkage Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft.)

4/13/95 7-3
STEERING COMPONENT LOCATION

COMPONENT LOCATION

Left Hand Drive Lever

Auxiliary Control
Handle

Right Hand
Drive Lever

Steering Dampeners
Upper Linkage

Centering
Mechanism

Lower Linkage

M63299

7-4 4/13/95
COMPONENT LOCATION STEERING

Valve Spool

Forward Pivot Linkage

Auxiliary Control
Upper Linkage

Auxiliary Control
Lower Linkage

Rear Pivot Linkage

M76171

4/13/95 7-5
STEERING THEORY OF OPERATION

THEORY OF OPERATION Centering Mechanism

Function
The steering system provides a means of controlling
the direction and velocity of the vehicle by controlling
the location of the cam plates in the hydrostatic pumps.
Displacement and orientation of the cam plates
controls fluid flow and direction of flow to the
hydrostatic motors.

Theory
The steering system consists of two directional levers
mounted on either side of the operators cab and a
centering mechanism mounted directly in front of the
hydrostatic motors. Pushing, or pulling, the levers
results in rotation of the cam plates in the hydrostatic
pumps causing the pumps to displace hydraulic fluid
which in turn operates the drive motors, thus moving of
the vehicle forward or backwards, respectively. The
centering mechanism insures a positive center, or
neutral location of the drive levers. Twin hydraulic
dampeners helps absorb hydraulic pulses and
feedback from the hydraulic system.
Directional Levers
M76129
The centering mechanism is located in front of the
hydrostatic pumps and consists of two spring loaded
plates and two through-bolts and rod ends. The
directional levers are connected, by the control arms, to
the through-bolts. Moving one of the directional levers
moves the corresponding linkage which acts against
the spring loaded plates. Spring tension acts on the
linkage and control arm to center the directional lever
when released.

Steering Dampeners

M76172 M76124

The two directional levers are mounted on either side of
the operators cab. Each lever operates independently
to control the appropriate hydrostatic motor. The levers
incorporate a ergonomically designed angle to, in
combination with the soft grip, prevent operator wrist
fatigue.
The right side directional lever also incorporates a
“wrist” mechanism for the control of the auxiliary
hydraulic system. This mechanism can be locked out or
engaged by simply withdrawing the retaining pin
located on the bottom of the mechanism.
One hydraulic steering dampener is attached to each
control arm. These steering dampeners effectively
eliminate hydraulic pulse and torque feedback into the
steering levers. At the same time the steering
dampeners provide a slight resistance to movement of
the directional levers and thus provide a “feel” to the
operator.

7-6 4/13/95
TROUBLESHOOTING STEERING

TROUBLESHOOTING

feel loose or sloppy.

Problem or

vibrate excessively
Directional levers

Directional levers
Symptom

Hydraulic system

Vehicle tracks to
Machine creeps

Levers pulse or
noisy while in

hard to move.

one side with

with levers in
Check or
Solution

Steering Linkage Improperly

● ● ● ●
Adjusted. Adjust.

Bad Pivot Bearings On Steering

Control Lever Assembly. ● ● ●
Replace.

Bent Control Linkage. ● ●

Worn Rubber Bushings In

● ●
Centering Mechanism.

Faulty Hydraulic dampener. ● ●

Directional Lever Travel

●
Incorrectly Adjusted. Adjust

Auxiliary Hydraulics Control

Handle Improperly Adjusted. ●
Adjust.

4/13/95 7-7
STEERING DIAGNOSTICS

DIAGNOSTICS

Test Conditions:
• Operator in seat
• Seat belt fastened
• Key switch in run position

Test/Check Point Normal If Not Normal

1. Control levers Levers should move freely with slight Check linkage from levers to pump.
resistance. Check dampeners.

Levers should return to center when Check centering mechanism. Adjust

released. or repair as necessary.

Test Conditions:
• Engine running at slow idle

Test/Check Point Normal If Not Normal

2. Hydrostatic Pumps With control levers in neutral, brake Check linkage from control levers to
lever in PARK, pumps should be pump. Adjust centering of linkage.
quiet. Engine should not sound
strained.

3. Control levers are in neutral, Machine should not creep forward or Adjust centering of linkage.
brake disengaged. backward or in circles.

4. Control levers in full forward, or Machine should move forward, or Perform control lever centering and
full reverse, position. backwards, in a straight line. control lever stop adjustment.

7-8 4/13/95
DIAGNOSTICS STEERING

1 3 4

M63299

4/13/95 7-9
STEERING DIAGNOSTICS

Test Conditions:
• Kick plate removed

Test/Check Point Normal If Not Normal

1. Valve spool. Valve moves approx. 9.6 mm (3/8 Perform auxiliary control handle
in.) each way from center. adjustment.

2. Pivot linkages. Control handle moves without Inspect pivot bearings in rear pivot
binding. linkage. Check forward pivot linkage
for worn parts. Inspect rod ends for
wear and/or damage.

Test Conditions:
• Operator in seat
• Seat belt fastened
• Attachment installed on machine
• Engine running

Test/Check Point Normal If Not Normal

3. Auxiliary control handle. Rotate lever to the left until detent is If detent does not hold verify control
reached. Attachment should handle adjusted properly. If control
operate. handle properly adjusted go to
Hydraulics diagnostics section.

If attachment does not operate, go

to Hydraulics diagnostics section.

7 - 10 4/13/95
DIAGNOSTICS STEERING

M76171

4/13/95 7 - 11
STEERING TESTS AND ADJUSTMENTS

TESTS AND ADJUSTMENTS Reason:

To insure that control linkages are adjusted properly.
This will insure that machine tracks straight when
CONTROL LEVER CENTERING levers are at full forward and will protect the pumps
ADJUSTMENT from overstroking.

Equipment:
• Ruler

Procedure
1. Park skid steer safely.
2. Raise vehicle off ground and block.
3. Raise and lock seat in upright position.
4. Remove center kick plate.

9 1/2°
256 mm. (10-1/16”)

M76162

1. Using a protractor, verify control levers are 9 1/2°

forward of vertical. If this is correct, adjustment of
control levers is not required.
M76124

5. Disconnect one rod end, loosen both jam nuts and

Jam Nuts adjust upper linkages to a length of 256 mm. (10-1/
16 in.). The length is measured from center to
Bolt Heads center of the rod ends.
6. Reconnect rod end and tighten jam nuts.

M76124

145 mm. (5-11/16”)

2. Remove center kick plate.
3. Loosen jam nuts and adjust bolt heads to achieve
the 9 1/2° forward of vertical specification.
4. Tighten jam nuts.
5. Proceed with Linkage Centering Adjustment.

M76124
LINKAGE CENTERING
ADJUSTMENT
7. Disconnect one rod end on each lower linkage,
loosen both jam nuts and adjust lower linkages to a
IMPORTANT: CONTROL LEVER CENTERING length of 145 mm. (5-11/16 in.). The length is
ADJUSTMENT must be correct before control measured from center to center of the rod ends and
linkages are adjusted. is a preliminary setting.

7 - 12 4/13/95
TESTS AND ADJUSTMENTS STEERING

8. With the lower linkages disconnected from the

hydrostatic pump control arms, start the loader
engine. The hydrostatic controls will neutralize with
no tire rotation.
9. Rotate the arms of the hydrostatic pumps until the
tires start to rotate forward and then rotate the arms
back until tires just stop rotating. Now adjust the Drive Lever
length of the lower control links to allow the linkage
to be connected to the pump control arms. Adjust
both the left and right sides in this sequence. Kick Panel
10. Start the unit and check for neutral, no tire rotation.
If the tires rotate, repeat step 3.
Mounting Bolts
NOTE: If adjusted correctly, it will take the same
movement of the left and right hydrostatic M76125A
control levers to produce tire rotation.

5. Loosen four mounting bolts.

CONTROL LEVER STOP
ADJUSTMENT
IMPORTANT: The control lever stops must be
adjusted properly to prevent damage to the
linkage and internal transmission components.
NOTE: If the control lever location has been changed
for any reason the control lever stops will
require adjustment.
Reason:
To insure that control arm forward stops are adjusted
properly. This will insure that machine tracks straight
when levers are at full forward and will protect the
pumps from overstroking.
Procedure
1. Park skid steer safely.
2. Raise vehicle off ground and block.
3. Raise and lock seat in upright position.
4. Remove center kick plate.
6. Pull the control lever forward until the internal
transmission stop is felt and hold the linkage against
the internal stop.
7. Slide the boot stop assembly to the rear to contact
the control lever and then push the stop and lever to
the rear another 1/16 inch. This will insure that when
the control levers are fully stroked the lever will
contact the external stop and not the internal
transmission stop.
8. Tighten bolts securing adjuster plate to control lever
assembly.
9. Install center kick plate.
10. Return seat to the operating position.
11. Drive loader a long enough distance to determine if
one side is traveling faster than the other. If it is,
readjust the faster side by moving that boot stop
assembly to the rear.
AUXILIARY CONTROL HANDLE
ADJUSTMENT
Reason:
To insure that auxiliary control handle is properly
adjusted.

4/13/95 7 - 13
STEERING TESTS AND ADJUSTMENTS

Procedure NOTE: Valve spool is centered when pump is quiet

with engine running. Check for centering by
moving control handle slightly off center.

Valve Spool

L-Pin

Slot

M57906
M58124

4. Check spool travel. Spool should move

1. Lock handle in upright position by moving L-pin into approximately 9.6 mm (3/8 in.) each way from
slot in yoke casting. center.

Rod End
Align

Rod End
Bearings
Lock Nut M58125
M57888

5. Lock handle in center position and check bearing

2. Adjust rod ends until valve spool is centered. alignment with lower rod end.
3. Tighten lock nuts on rod ends.
NOTE: Another check for centering of rod end can be
made by moving the control handle back and
forth. If rod end is properly centered it will not
move up and down.

IMPORTANT: If pivot bearings and lower rod end

do not line up unnecessary wear and strain will
be put on auxiliary hydraulic components.

7 - 14 4/13/95
REPAIR STEERING

REPAIR Disassembly/Assembly

Center Shaft Rod Ends

CENTERING MECHANISM

Removal Spring

1. Park skid steer safely.

2. Raise boom and engage lock pins.
3. Raise and lock seat in upright position.
Plates

Bushings
M76129
Kick Plate

1. Use an open end wrench to prevent bolt from turning

while removing tie rod ends. Remove tie rod ends
from thru bolts.
2. Remove jam nuts and washers from bolts.
3. Remove bolts from centering mechanism and set
them aside.
4. Remove cap screw and washer from end of center
shaft.
M57889 5. Carefully remove center shaft, plates, spring and
bushings from centering mechanism assembly.
6. Inspect all parts for excessive wear. Replace as
4. Remove center kick plate. necessary.

NOTE: Center shaft must slide freely in plates with no

binding or roughness.
Rod Ends
Steering Dampeners

Bracket M76128

Center Shaft Plate

Bushings
Pivot Levers
M76124

5. Remove steering dampeners.

NOTE: Take note of the locations of the spacers and

washers for assembly.
6. Disconnect forward rod ends of steering mechanism
thru bolts from control arm pivot levers.
7. Remove mounting cap screws that secure centering
mechanism to mounting bracket.
7. Place center shaft in end of one plate. Slide spring
over assembled shaft and plate.
8. Install remaining plate on open end of shaft. Set this
sub-assembly aside.
9. Install four bushings into the outside holes of the
bracket.

4/13/95 7 - 15
STEERING REPAIR

NOTE: The grease holes in the plates must face up Installation

when installed.

Cap Screws

Bushings Pivot Shafts

M76124

M76127
10. Install the previously assembled shaft, spring and
plates to the bracket with two washers and cap
screws. The cap screws thread into the ends of the
center shaft.
1. Place centering mechanism assembly on support
bracket.
2. Install four cap screws to secure centering
mechanism to support bracket. Torque to 44 N•m
(33 lb-ft).
3. Connect rod ends to pivot shafts.
4. Perform control lever centering adjustment.
STEERING DAMPENERS

Steering Dampener Mount Removal

Dampeners

Tie Rods

M76126

Frame Bracket
M76125
11. Slide bolts through bracket, plates and bushings.
Bolt heads must be on the end with the bracket for
mounting the steering dampener.
1. Remove bolts holding steering dampeners to frame
12. Place a washer on the end of the bolts. Install three bracket and pivot shafts.
jam nuts on each bolt. Install large jam nut first.
Tighten first two nuts so all end play is removed. If IMPORTANT: Note the location of washers and
nuts are too tight or too loose on bolts, end play will bushings used for clearance spacing.
result.
13. Install tie rod on end of bolt but leave loose until
2. Stroke dampeners through full range of motion.
centering mechanism assembly is installed on
dampeners should operate smoothly with some
machine.
resistance to movement. If no resistance is noted, or
if unit is leaking, replace unit.

7 - 16 4/13/95
REPAIR STEERING

Installation 3. Remove capscrews securing steering mechanism to

frame.
1. Bolt steering dampeners to centering mechanism.
Install bolts with heads to the outside. Torque to 25
N•m (18 lb-ft).
NOTE: Steering mechanism, right and left, should be
2. Bolt steering dampener tie rod end to pivot shaft.
removed from vehicle as a complete sub
Install bolts with heads to the inside. Torque to 25
assembly for ease of inspection and
N•m (18 lb-ft). maintenance.
NOTE: One spacer should be installed between the tie
rod end and pivot shaft.
Inspection
1. Inspect control levers for damage.
STEERING CONTROL ARM 2. Inspect pivot bearings for looseness or damage.
ASSEMBLY Replace if necessary.
3. On right hand control assembly inspect rod ends for
looseness or damage. Replace is required.
Removal
1. Remove centering mechanism.
NOTE: Location of washers used for establishing
2. Remove steering linkage. proper clearance between frame and pivot
bearing.

Installation
1. Place assembled steering control assembly in
machine.
2. Install cap screws securing steering mechanism to
frame.

NOTE: Washers and bushings for clearance spacing

previously removed during removal must be
replaced in their original locations.
R/H Control

Dampeners

Steering Links
M58125
M58125

3. Install steering links.

NOTE: Check location of washers and bushings used 4. Install steering dampeners.
for clearance spacing. 5. Install centering mechanism.

4/13/95 7 - 17
STEERING REPAIR

AUXILIARY HANDLE Assembly

1. Inspect all parts for excessive wear. Replace if
necessary.
Disassembly

Lock Nut

Ball
Set Screw

Spring

M76166
L-Pin M57114A

1. Yoke can be removed from control arm by loosening

lock nut and backing off set screw and removing bolt
2. Install spring and ball in hole in handle yoke.
retaining rod end.
3. Compress spring and insert L-pin in place.

L-Pin
Yoke

C-Pin
M58124

C-Pin M58124 4. Drive C-pin in hole until it is flush with handle yoke.
5. Slide the handle assembly on to control arm.
6. Connect rod end to handle assembly.
2. Remove L-pin by driving C-pin from handle. 7. Install set screw and lock nut. Tighten set screw to 9
N•m (80 lb-in.). Tighten lock nut to 13.5 N•m (120
NOTE: Do not loose detent ball and spring located lb-in.).
behind L-pin.

7 - 18 4/13/95
CONTENTS BRAKES

CONTENTS
Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PARK BRAKE LINKAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PARK BRAKE HANDLE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PARK BRAKE HANDLE & LINKAGE REMOVAL & INSTALLATION . . . . . . . . . . 10
PARK BRAKE REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2/10/95 8-1
BRAKES CONTENTS

8-2 2/10/95
SPECIFICATIONS BRAKES

SPECIFICATIONS

Brake Discs
Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.76 mm (3/16 in.)
Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230.2 mm (9 in.)

Gear Case
Hydraulic Motor Mounting Plate Bolt Torque . . . . . . . . . . . . . . . . . . . . . 44 N•m (33 lb-ft)
Arm Setscrew Locknut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (9 lb-ft)

Brake Linkage
Spring Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 mm (6 in.)
Brake Handle Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 N•m (33 lb-ft)
Brake Rod Jam Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 N•m (33 lb-ft)

4/13/95 8-3
BRAKES THEORY OF OPERATION

THEORY OF OPERATION
The brake system is a mechanically activated disc brake located inside the gear boxes. The left and right side
brakes are separate units and are activated by a single hand lever located at the operator’s side. The brakes are
designed to hold the Skid Steer Loader in place to prevent rolling or creeping when parked on a grade.
The brake is only to be used as a parking brake and never to stop the machine when under power. All braking
under power can be achieved by returning the hydrostatic drive handles to the center position.
The dual brake discs are mounted inside the gear box on the the final drive, motor driven shaft. The two steel discs
slide freely on the splined shaft and are captured by a large rod threaded into the gear box. The discs are divided
by a stationary friction separator plate.
The gearbox contains two friction pads which are pressed onto the discs by an Acme threaded rod. The dual discs
are clamped between the friction pads when the Acme threaded rod is rotated. The caliper assembly is housed
internally on the hydraulic motor end of the final drive gear box. Removing the hydraulic motor mount housing
allows complete access to service the brake discs, friction pads, and remaining brake system components.
The brake linkage is accessible for adjustment and repair from under the operator’s seat. Dampener springs
prevent damage to the linkage from overtightening or mis-adjustment.
The function of the brake is simply to lock the hydrostatic motor and final drive assembly to prevent movement
while the Skid Steer Loader is parked.

M76160

8-4 4/13/95
COMPONENT LOCATION BRAKES

COMPONENT LOCATION

Acme Threaded
Rod
Seal
Actuating Lever

Set Screw

Plug Friction Pad

Motor Driven
Shaft

Brake Disk

Stationary Friction
Plate

Brake Disk
Friction Pad

Hydraulic Motor
Mounting Plate

Gearbox Mounting
Bracket

M63277

4/13/95 8-5
BRAKES DIAGNOSIS

DIAGNOSIS

Test Conditions:

• Park machine on level surface • Boom lowered

• Bucket rolled back • Engine running at half throttle

Test/Check Point Normal If Not Normal

1. Park brake lever off (down), Loader moves forward and Wheels locked: go to step 3
hydrostatic levers moved forward backward for the appropriate Wheels on one side locked: check brake
and backward, one at a time hydrostatic drive handle adjustment for that side

2. Park brake lever on (up), Loader remains stationary One side of loader moves: check brake
hydrostatic levers moved forward and engine stalls (even at full adjustment for that side
and backward, one at a time throttle) Both sides of loader move:readjust brakes

Test Conditions:

• Stop engine • Raise seat and lock in position

Test/Check Point Normal If Not Normal

3. Raise and lower brake handle while Handle moves smoothly up and down Handle frozen in place: check
holding lock button in handle pivot bolt and spacer

4. Raise brake handle and release Handle locks in raised position See brake handle repair
lock button

5. Linkage rod and pivots Move freely Check linkage bushings

6. Right Hand Brake arm Moves up when handle is raised, Brakes adjusted too tight,
down when handle is lowered readjust brake linkage and
dampener spring length

7. Left Hand Brake arm Moves forward when handle is raised, Brakes adjusted too tight,
rearward when handle is lowered readjust brake linkage and
dampener spring length

Test Conditions:

• Jack loader and support on suitable jack stands or • Start engine and run at half throttle
hardwood cribbing

Test/Check Point Normal If Not Normal

8. Park brake lever on (up), Tires remain stationary and Inspect friction pads (see Brake Pad
hydrostatic levers moved forward engine stalls (even at full throttle) Removal & Installation section)
and backward, one at a time

8-6 4/13/95
DIAGNOSIS BRAKES

DIAGNOSIS

7 1 2 8 3 4

M76160

4/13/95 8-7
BRAKES TROUBLESHOOTING

TROUBLESHOOTING

Problem or

Brake handle won’t

Brake handle won’t

Brake handle won’t

Brakes not holding
Symptom

Brakes locked on

while operating
Grinding noise
stay locked on
Check or
Solution

release
move
Adjust brake arm on caliper
● ● ●
shaft

Inspect handle ratchet assembly ● ● ● ●

Inspect linkage rods ●

Inspect linkage bushings ●

Inspect friction pads and discs ● ●

Inspect dampener springs

● ●
length

Check spacers on handle and

● ● ● ●
handle lock mounting bolts

8-8 4/13/95
TESTS AND ADJUSTMENTS BRAKES

TESTS AND ADJUSTMENTS

PARK BRAKE LINKAGE

ADJUSTMENT

Reason:
The brake linkage must be adjusted to compensate for
brake pad wear.

Conditions:
• Loader parked on level surface
• Boom lowered, bucket rolled forward
• Engine off Spring Link
• Park brake off (down)
Actuating Lever
• Seat raised and latched
Set Screw
M76160A
Procedure:

4. Loosen the set screw in actuating lever to allow the

c CAUTION lever to be removed from the Acme threaded rod.

5. Rotate the actuating lever to turn the Acme threaded
rod into the gearbox to remove any play in brake
Before adjusting the brake linkage, be sure that calipers. L/H lever has L/H threads on the Acme
the brake is disengaged and the loader is on threaded rod. When brake is applied the L/H
level ground to prevent the loader from rolling. actuating lever is move forward.
6. Slide the lever off the actuator shaft and rotate the
lever up on the splined shaft until the spring link can
NOTE: The fenders can be removed for more access be reconnected, while maintaining minimal play in
to brake linkage. brake calipers.
7. Slide the lever onto the shaft and reposition the lever
to prevent contact with hydraulic oil reservoir, hoses,
etc. and tighten the set screws.
8. Reinstall the cotter pin to retain spring link on the
actuating lever.

Adjustment Nut Results:

When the brake handle is pulled up to the locked
position, the calipers are fully applied and the
dampener spring will be compressed. As the friction
Spring Length pads wear, the dampener spring will compensate by
6” (152 mm) extending the length of the brake linkage.

Cotter Pin
Adjustment Nut
M58759

1. Remove cotter pin from spring link and lever at the

actuating lever on the gearbox.
2. Disconnect the spring link from actuating lever.
3. With the parking brake control lever in the released
position, adjust the spring assembly bolts equally to
obtain a spring length of 6” (152 mm).

4/13/95 8-9
BRAKES REPAIR

PARK BRAKE HANDLE REPAIR

ADJUSTMENT
PARK BRAKE HANDLE & LINKAGE
Reason: REMOVAL & INSTALLATION
To determine if brake handle pivots are operating
smoothly, and if handle lock is engaging correctly.
Removal:
1. Park loader on a level surface . Lower boom and roll
Conditions: bucket forward.
• Loader parked on level surface 2. Stop engine.
• Boom lowered, bucket rolled forward 3. Release park brake (down).
• Engine off 4. Raise and latch seat.
• Park brake down (off)
• Seat raised and latched

Procedure:
1. Remove cotter key from top dampener spring rods
on left and right side of loader.
2. Remove top dampener spring rods from arms to
brake handle linkage.
3. Press in lock button on while raising and lowering
handle.
4. Raise handle and release lock button.
5. Depress lock button and lower handle.

Results: M58769

The park brake handle should operate smoothly on the

pivot, and the linkage should pivot freely on the
bushings. The latch should hold the handle in the
raised position and release when the latch button is
depressed.
5. Remove cotter pins from top dampener spring rods.
6. Remove top dampener spring rods from brake arms
to brake handle.
7. Remove front mounting capscrew from brake
handle.
8. Remove latch and spacer from inside handle.
9. Pull latch button and hook, washer, and spring out
from end of handle.
10. Remove rear mounting capscrew from brake
handle.
11. Remove handle from frame. Be sure to catch
spacers as handle is pulled off.
12. Remove two capscrews holding linkage rod to
frame at left pivot bushing.
13. Pull linkage rod from right side bushing using care
to not damage leather washer at end of rod.

Installation:
1. Place bronze bushing for linkage rod into right side
frame bracket.
2. Crimp front leg of frame bracket around flat face of
bronze bushing.
3. Place leather washer on right end of linkage rod.
4. Insert right end of linkage rod into bronze bushing in
frame.

8 - 10 4/13/95
REPAIR
5. Install bronze bushing and bracket onto left end of
linkage rod and bolt bracket to frame.
6. Insert brake handle spacer into frame bracket slot.
7. Install brake handle over frame bracket.
8. Install rear mounting capscrew through brake arm,
handle, spacer, and slotted frame bracket.
9. Install handle latch button and hook, washer, and
spring into end of handle.
10. Place spacer into hole in latch.
11. Install latch into handle so that hole in latch lines up
with front hole in handle, and that top of latch is
caught inside hook of latch button and hook rod.
12. Install front mounting capscrew through handle and
spacer/latch assembly.
13. Torque handle mounting capscrews to 44 N•m (33
lb-ft).
PARK BRAKE REPAIR
DISASSEMBLY
1. Remove hydrostatic motor from gearbox. (See
Hydrostatic Repair Section.)
2. Remove gearbox mounting bracket and hydraulic
motor mounting plate to gain access to brake
assembly.
A mounting plate cavity.
B
C
G
M63277B
3. Remove friction pads (C) from gearbox. Pad in motor
mounting plate (D) may have a slight resistance.
Using a channel lock pliers, carefully pull friction pad
from motor mounting plate.
4. Remove brake disks (E) and stationary friction plate
(F) from motor driven shaft (G).
4/13/95
BRAKES
5. Remove plug (B) from between friction pad and
Acme threaded rod.
Inspection
6. Inspect friction pads for deterioration and obvious
damage. Replace as necessary.
7. Inspect seal for damage or deterioration. If seal
requires replacement, remove actuating lever from
Acme threaded rod and remove rod from gearbox.
Use a seal driver to drive seal from gearbox and
reinstall seal. Install with seal lip facing gearbox.
8. Inspect brake disks for damage to mating surfaces
and splines. Replace as necessary.
9. Inspect stationary friction plate for wear. Inspect tabs
on sides of friction plate for damage.
Assembly
10. Rotate Acme threaded rod outward to allow
maximum space in gearbox cavity for plug and
friction pad.
11. Install plug in gearbox cavity.
12. Install friction pad in same gearbox cavity.
13. Place one brake disk on motor driven shaft.
14. Place stationary friction plate over motor driven
shaft and place remaining brake disk on motor
driven shaft.
15. Install other friction pad in hydraulic motor
16. Tabs on friction plate must fit in recesses while
mating motor mounting plate and gear box. Install
motor mounting plate on gearbox. Install gearbox
mounting bracket and torque mounting cap screws
to 44 N•m (33 lb-ft).
17. Perform hydrostatic motor installation procedures.
(See Hydrostatic Repair Section.)
8 - 11
BRAKES

8 - 12 4/13/95
CONTENTS HYDRAULICS

CONTENTS
Page

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HYDRAULIC SYSTEM COMPONENT LOCATION . . . . . . . . . . . . . . . . . 6
HYDRAULIC SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
COMPONENT LOCATION - CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . 8
COMPONENT LOCATION - MISCELLANEOUS . . . . . . . . . . . . . . . . . . . 9
COMPONENT LOCATION - CONTROL VALVE . . . . . . . . . . . . . . . . . . 10
COMPONENT LOCATION - HYDRAULIC PUMP . . . . . . . . . . . . . . . . . 11
COMPONENT LOCATION - BUCKET CYLINDER . . . . . . . . . . . . . . . . 12
COMPONENT LOCATION - LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . 13
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
BOOM OPERATION CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
BUCKET OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
BOOM AND BUCKET LOCKOUT SOLENOID CHECK. . . . . . . . . . . . . . . . . . . . . 16
SYSTEM RELIEF VALVE PRESSURE TEST (with Aux. Hydraulics) . . . . . . . . . . 17
PUMP FLOW TEST (with Aux. Hydraulics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SYSTEM RELIEF VALVE PRESSURE TEST (w/o Aux. Hydraulics) . . . . . . . . . . 18
PUMP FLOW TEST (w/o Aux. Hydraulics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
BOOM DRIFT DOWN CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BOOM LIFT CHECK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BOOM DRIFT UP CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BUCKET DRIFT DUMP POSITION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BUCKET DRIFT ROLLBACK POSITION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . 20
BOOM LOCK CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2/10/95 9-1
HYDRAULICS CONTENTS

Page

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
HYDRAULIC PUMP REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
HYDRAULIC PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
HYDRAULIC PUMP COMPONENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 23
HYDRAULIC PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
HYDRAULIC PUMP INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
MAIN CONTROL VALVE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
MAIN CONTROL VALVE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
MAIN CONTROL VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
MAIN CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
MAIN CONTROL VALVE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
LIFT ARM CYLINDERS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
LIFT ARM CYLINDER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
LIFT ARM CYLINDERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
BUCKET CYLINDERS REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
BUCKET CYLINDER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
BUCKET CYLINDERS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
START-UP PROCEDURE AFTER
HYDRAULIC COMPONENT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 37

9-2 2/10/95
SPECIFICATIONS HYDRAULICS

SPECIFICATIONS

HYDRAULIC PUMP
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EATON
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25305, B2 Series
Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High pressure gear pump
Rated Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 L/min. (17 gpm)
Minimum Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 L/min. (14 gpm)
System Relief Pressure . . . . . . . . . . . . . . . . . . . . . 17926 ± 1379 kPa (2600 ± 200 psi)
Circuit Relief Pressure . . . . . . . . . . . . . . . . . . . . . . 18961 ± 1379 kPa (2750 ± 200 psi)
Hydraulic Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 758 ± 138 kPa (110 ± 20 psi)

MAIN CONTROL VALVE

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EATON
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34673-AAC
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Open Center, Series

HYDRAULIC CYLINDERS
Bore, Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.5 mm (2.5 in.)
Stroke, Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624.84 mm (24.6 in.)
Bore, Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.5 mm (2.5 in.)
Stroke, Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447.04 mm (17.6 in.)
Max Working Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18615 kPa (2700 psi)

HYDRAULIC CYCLE TIMES

Boom Raise Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . 10 seconds or less at slow idle
Boom Lower Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . 7 seconds or less at slow idle
Bucket Rollback Cycle Time . . . . . . . . . . . . . . . . . . . . . . . 5 seconds or less at slow idle
Bucket Roll down Cycle Time . . . . . . . . . . . . . . . . . . . . . . 7 seconds or less at slow idle

SYSTEM, GENERAL
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 micron (internal bypass)
Hydraulic System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24.6 L (6.5 gal)

SERVICE PARTS KITS

The following kits are available through your parts catalog:
Boom Cylinder Repair Kit
Bucket Cylinder Repair Kit
Bucket Cylinder Seal Kit
Control Valve Seal Kit
Spool Centering Kit
Spool Centering Kit
Hydraulic Pump Seal Kit

4/6/95 9-3
HYDRAULICS SPECIFICATIONS

TORQUE SPECIFICATIONS
Bearing Nut, Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 N•m (170 lb-ft.)
Piston Nut, Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 N•m (125 lb-ft.)
Cylinder Head, Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 N•m (210 lb-ft.)
Piston Nut, Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393 N•m (290 lb-ft.)
Bucket Cylinder Retainer Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 N•m (82 lb-ft.)
Hydraulic Pump Body Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 N•m (26 lb-ft.)
Hydraulic Pump Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft.)
Valve Housing Plugs (Large) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft.)
Valve Housing Plugs, (Small) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 N•m (23 lb-ft.)
Boom Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft.)
Spool Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (11 lb-ft.)
Solenoid Mounting Block Capscrews . . . . . . . . . . . . . . . . . . . . . . . . . . 16 N•m (12 lb-ft.)
System Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 N•m (38 lb-ft.)
Spool Cap Assembly Capscrews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 N•m (12 lb-ft.)
Plug, BYD Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft.)
Valve Mounting Capscrews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (18 lb-ft.)

OTHER MATERIALS

Number Name Use

T43512 John Deere LOCTITE® Thread Lock and Apply to threads of control valve spool detent
Sealer (medium strength) bolt and to bucket cylinder piston bolt.

Petroleum jelly To lubricate O-rings.

PT569 NEVER-SEEZ® Lubricant Apply to inside diameter of cylinder bushings.

9-4 4/6/95
THEORY OF OPERATION
THEORY OF OPERATION
Function:
The hydraulic system provides fluid power to operate
the bucket and boom cylinders, and any optional
auxiliary hydraulic attachments.
Theory of Operation:
The hydraulic system is a "open center series" type
system. In this system, the hydraulic pump provides a
continuous flow of oil through a main circuit that
connects all of the controlling valves. If the valve are
not operated, the flow of oil passes through the open
center passage of each valve, then through the oil
cooler, oil filter and returns to the hydraulic reservoir.
Also, in this type of circuit, the first controlling valve
takes priority over the next valve downstream the
circuit.
• Hydraulic Pump:
The hydraulic pump is an EATON® model 25300 B2
series direct drive, positive displacement gear pump.
The pump is mounted and driven off the end of the
hydrostatic pump. The hydraulic pump draws hydraulic
oil from the reservoir and supplies a constant flow of oil
to the main control valve.
• Main Control Valve
The main control valve integrates three spool valves,
two pressure relief valves, and two safety solenoids,
into one housing.
The first valve in the series, and therefore first priority,
controls the bucket cylinder circuit. When this valve is
actuated by the right foot pedal (toe-dump, heel-tilt
back) the open center port is blocked and oil is directed
to the appropriate side of the bucket cylinders. Cylinder
return oil flows through the main control valve to the oil
cooler, filter and reservoir.
The second valve in the series controls the boom
cylinder circuit. When this valve is actuated by the left
foot pedal (toe-lower heel-raise) the open center port is
blocked and oil is directed to the appropriate side of the
boom cylinders. Cylinder return oil flows through the
main control valve to the oil cooler, filter and reservoir.
4/6/95
HYDRAULICS
The third valve in the series provides power to operate
optional auxiliary hydraulic attachments. This spool is
controlled by a special "wrist" mechanism built into the
right steering control lever. The auxiliary handle can be
locked in the neutral or actuated position by a spring
loaded pin located under the hand lever.
The system relief valve located in the main control
valve, protects the hydraulic system and hydraulic
pump from excessive pressure. The system relief valve
limits system pressure to 17926 kPa (2600 psi) and is
not adjustable.
The circuit relief valve located in the main control valve,
protects the boom cylinder circuit from excessive
pressure resulting from shock loading when the boom
spool is in the neutral position. The circuit relief valve
limits boom cylinder circuit pressure to 18961 kPa
(2750 psi) and is not adjustable.
Both the bucket and boom spools are equipped with
solenoids that mechanically locks the spools in the
neutral (center) position. If the operator releases the
seat belt during loader operation, the solenoid pin will
engage the spool slots in the neutral position and stop
bucket or boom motion.
IMPORTANT: The spools must be returned to the
neutral position before the solenoid pins can
engage the spool slots.
The solenoid pins will keep the spools locked in the
neutral position until the operator sits in the seat,
fastens the seat belt, and turns the key switch to the
run position.
• Oil Cooler and Filter
Return oil from the main control valve flows to the oil
cooler located at the rear of the engine just before the
radiator. This location allows the cooler and radiator to
be cooled by the engine fan.
Oil from the oil cooler flows to the hydraulic oil filter
before entering the hydraulic reservoir. The oil filter is
an 10 micron canister type screw on filter.
9-5
 HYDRAULIC SYSTEM COMPONENT LOCATION HYDRAULICS

HYDRAULIC SYSTEM COMPONENT LOCATION

10

18

15 2 1 Return to Reservoir

2 Boom Control Pedal

3 Bucket Control Pedal

4 Main Control Valve

5 Pump Intake Hose

6 Hydraulic Oil Cooler

17
7 Hydraulic Oil Reservoir
3
8 Oil Filter Line
19
11 9 Control Valve ReturnTube
15
10 Auxillary Hydraulic Lines
4
14
11 Hydraulic Gear Pump
16
12 Return Tube
6 13 Hydraulic Oil Filter

14 Oil Filter Restriction

Sensor
5 15 Boom Hydraulic Lines

16 Control Valve Inlet Hose

8
7
17 Bucket Hydraulic Lines

18 Boom Lock Solenoid

19 Bucket Lock Solenoid

9

13

12

M76169

9- 6 4/17/95
 HYDRAULIC SYSTEM SCHEMATIC HYDRAULICS

HYDRAULIC SYSTEM SCHEMATIC

Down

Gerotor Right Hydrostatic Pump

Engine Engine Left Hydrostatic Pump
Charge Pump

Up

Boom Cylinders
Bucket Cylinders
Bucket Spool
System Relief Valve Down
IN

A B
Boom Spool Left Servo
Main Control Control
Valve
Up
C Right Servo Charge Pump
D
Control

Circuit Relief
Valve
E
F

OUT Right Hydrostatic Left Hydrostatic

Motor Motor
BYD
Hydraulic Oil
Cooler
Two Speed
Control Solenoid P Pressure
Switch
Auxiliary Spool
Hydraulic Oil Filter High Pressure Oil
Two Speed Cylinder
P Return Oil - Low Pressure
Quick
Disconnect Filter
Auxiliary
Sensor Trapped Oil - Recirculating
Hydraulic Power
Hydraulic Oil
Reservoir
Charge Pressure Oil - Medium Pressure

2/27/95 9-7
HYDRAULICS COMPONENT LOCATION - HYDRAULIC CYLINDERS

COMPONENT LOCATION - HYDRAULIC CYLINDERS

Left Bucket Cylinder

Auxiliary Couplers

Auxiliary Hydraulic Lines Right Bucket Cylinder

Bucket Cylinder Lines

Bucket Hydraulic Lines

Right Boom Cylinder

Boom Hydraulic Lines

M57924

9-8 4/6/95
COMPONENT LOCATION - MISCELLANEOUS HYDRAULICS

COMPONENT LOCATION - MISCELLANEOUS

19 22
18 23
24 26
25

13 5
27
5

13

12 11
15 17
4
9
6
3
8
20
21
2
9
16
5
7 8

14 28

10
5

1
5
13
15
M76179

1. Heat Exchanger 11. Hose, Intake 21. Capscrew

2. Tank 12. Tube 22. Screw
3. Filter 13. O-Ring 23. Cap
4. Block, Filter 14. Tube 24. Nut
5. O-Ring 15. Fitting 25. Bulkhead Fitting
6. Plugged Filter Sensor 16. Fitting 26. Screw
7. Fitting 17. Fitting 27. Bulkhead Flange
8. Capscrew 18. Fitting 28. Fitting
9. Hose Clamp, Large 19. Nut
10. Hose 20. Washer

4/6/95 9-9
HYDRAULICS COMPONENT LOCATION - CONTROL VALVE

COMPONENT LOCATION - CONTROL VALVE

12 35 34
39
6 10
33
2 6
38 8
6 36
39 37
6
32 6 7
6
8
7 14
6 16 11
10 18 12
30 31 13
15
17
41 19
40 20
21 22
54
55
23
49 24
47
25
51
8
7
5 6
50 1
49 9
4 6
44 44 39
43
29
51 28
43 27
26
45
53 3

42 42

48 M58548
47
52

1. Valve Housing 15. Orifice Plate 29. O-Ring 43. Spring Keeper, Tall
2. Solenoid Block 16. Screen Support Wire 30. O-Ring 44. Spring Keeper, Short
3. Bucket Spool 17. O-Ring 31. O-Ring 45. Spring
4. Boom Spool 18. Screen 32. Plug 46. Washer
5. Auxiliary Spool 19. Washer 33. Orifice Plate 47. Torx Head Bolt,
6. O-Ring 20. Snap Ring 34. Solenoid 1/4" x 1"
7. Back-up Washer 21. O-Ring 35. O-Ring 48. Shoulder Bolt
8. O-Ring 22. Plug Valve Body 36. Spool Seal 49. Special Shoulder Bolt
9. Boom Relief Valve 23. O-Ring 37. Torx Head Bolt, 1/4" x 2" 50. O-Ring
10. Housing Plug 24. Spring 38. Fitting, 1/2" Tube 51. Detent Spool Cover
11. Valve, System Relief 25. Plunger 39. Fitting, 3/8" Tube 52. Spool Cover
12. O-Ring 26. Clevis 40. Fitting, 5/8" Tube 53. Spacer
13. Pilot Body 27. Cotter Pin 41. O-Ring 54. Back-Up Washer
14. Spring 28. O-Ring Keeper 42. Spring Keeper 55. O-Ring

9 - 10 4/6/95
HYDRAULICS COMPONENT LOCATION - HYDRAULIC PUMP

COMPONENT LOCATION - HYDRAULIC PUMP

O
D
O

B
A
K
N
F

E
O

F
I
J
M

L
M57921

A. Back Plate Assembly F. Formed O-Ring K. Washer

B. Front Plate G. Wear Plate L. Shaft Seal
C. Body H. Back up Gasket M. Cap Screws
D. Idler Gear Assembly I. Bearing Seal N. O-Ring
E. Drive Gear Assembly J. Molded O-Ring O. Snap Ring

9 - 11 4/6/95
COMPONENT LOCATION - BUCKET CYLINDER HYDRAULICS

COMPONENT LOCATION - BUCKET CYLINDER

F
G
H

E
A

I
C
J

K
L

M
M57902

A. Cylinder Body F. Piston Wear Ring K. O-Ring

B. Rod G. Washer L. Shaft Seal
C. Head H. Capscrew M. Rod Wear Ring
D. Piston I. Rod Seal N. Zerk
E. Piston Seal J. Backup Washer

4/6/95 9 - 12
HYDRAULICS COMPONENT LOCATION - LIFT CYLINDER

COMPONENT LOCATION - LIFT CYLINDER

H
F

D
M
E L
K
J
C
I
O

M57922

A. Cylinder Body F. Piston Wear Ring K. O-Ring

B. Rod G. Bearing Nut L. Shaft Seal
C. Head H. Nut M. Rod Wear Ring
D. Piston I. Rod Seal N. Zerk
E. Piston Seal J. Backup Washer O. Retaining Ring

9 - 13 4/6/95
TROUBLESHOOTING HYDRAULICS

TROUBLESHOOTING

Hydraulics slow, low power

Jerky or spongy movement

Bucket will not roll forward

Hydraulic System Noisy

Problem or

Bucket drifts forward or

Boom drifts up or down

Bucket will not rollback

Hydraulic Pressure low

Symptom

Hydraulic system hot

Pedals will not move
Boom will not lower
Boom will not raise
Check or
Solution

back
Hydraulic pump not running or
● ● ● ● ● ● ●
pump worn. Check flow.

Hydraulic oil level low in

● ● ● ● ● ● ● ●
reservoir. Check and add oil.

Main control valve linkage or

● ● ● ● ● ● ● ● ● ● ●
spool binding or damaged.

Inspect lift check valve in main

control valve for weak or ● ●
broken springs.

Check cylinders for bent or

● ● ● ● ● ● ● ●
damaged rods.

Stuck pivot pins ● ● ● ● ● ● ●

Leaking cylinder packing ● ● ● ● ● ● ●

Low system pressure. Check

system relief valve pressure ● ● ● ● ● ●
setting.

Air in hydraulic cylinders.

● ● ●
Purge system

Boom or bucket solenoid

● ● ● ● ●
malfunctioning

Bucket overloaded ● ● ● ●

Bucket tilt control valve not

● ● ● ●
returning to center

High system pressure. Check

system relief valve pressure ● ●
setting.

Hydraulic oil filter restricted. ● ● ● ●

Hydraulic oil cooler restricted. ●

Hydraulic pressure relief valve

●
damaged or setting incorrect

Hydrostatic pump damaged or

● ● ●
leaking

4/6/95 9 - 14
HYDRAULICS DIAGNOSTICS

DIAGNOSTICS

Test Conditions:

• Hydraulic oil reservoir oil level at proper level

• Operator in seat

• Seat belt fastened

• Key switch in run position

Test/Check Point Normal If Not Normal

1. Foot pedals Pedals should move freely Check lockout solenoid circuits.
Check linkage from pedals to valve.
Check for bent spools in valve.

Test Conditions:

• Engine running at slow idle.

Test/Check Point Normal If Not Normal

2. Electronic instrument panel Hydraulic oil temperature, low
module hydraulic pressure and hydraulic oil
filter restriction lights should be off.
Hydraulic oil filter restriction light on
- replace hydraulic oil filter.
Low hydraulic pressure light on
- perform system flow and pressure
checks to verify proper operation of
hydraulic pump and check for
defective Hydraulic pressure relief
valve.
Hydraulic oil temperature light on
- check oil cooler for restriction

3. Boom operation Boom should move freely through
range of motion when left pedal is
depressed forward or back.
Perform following boom checks:
• Boom operation
• Boom drift down
• Boom lift check test
• Boom drift up
Perform system flow and pressure
checks to verify proper operation of
hydraulic pump.
Check boom cylinders for bent rod
or damaged cylinder wall.
Check hydraulic hoses, tubing, and
connections for leaks.

4. Bucket operation
Bucket should move freely through
range of motion when right pedal is
depressed forward or back.
Perform following bucket checks:
• Bucket operation
• Bucket drift dump position
• Bucket drift rollback position
Perform system flow and pressure
checks to verify proper operation of
hydraulic pump.
Check bucket cylinders for bent rod
or damaged cylinder wall.
Check hydraulic hoses, tubing, and
connections for leaks.

9 - 15 4/6/95
HYDRAULICS TEST AND ADJUSTMENT

TEST AND ADJUSTMENT Specifications:

• Bucket should dump and rollback smoothly
without hesitation.
BOOM OPERATION CHECK • Bucket should roll from full dump position to
full back position in 5 seconds or less.
• Bucket should roll from full back position to full
Reason:
dump position in 7 seconds or less.
To determine operating efficiency of boom systems.

Results:
Equipment:
1. If bucket cycle time is slow check:
• Stop watch • System pressure relief valve.
• Hydraulic pump flow.
Procedure: 2. If bucket tilts or jams check:
• Pivot points.
1. Run engine at slow idle.
• Boom and bucket frame for bending or twisting.
2. Time boom as it travels to full height from lowest
position.
BOOM AND BUCKET LOCKOUT
Specifications: SOLENOID CHECK
1. Boom should travel from full down to full up in
less than 10 seconds.
Reason:
2. Boom should travel from full up to full down in
less than 7 seconds. To insure that the Boom and Bucket Lockout Solenoids
3. Boom should travel to full height smoothly are functioning properly.
without hesitation.
4. Boom should not slow down or tilt sideways. Procedure:
1. Sit in seat.
Results: 2. Attempt to move pedals. Pedals should not move
1. If boom travel time is slow check: from centered location.
• System pressure relief valve. 3. Make sure that the service/run switch is in the run
position.
• hydraulic pump flow.
4. Fasten seat belt.
2. If boom tilts or jams check:
5. Turn key switch to run position.
• Pivot points.
• Boom frame for bending or twisting.
NOTE: It is not necessary to run the engine to perform
this test.
BUCKET OPERATION CHECK
6. Attempt to move pedals. Foot pedals should travel
Reason: freely through travel range.
To determine proper operating speed of bucket lilt 7. Disconnect seat belt.
forward and back. 8. Attempt to move foot pedals. Foot pedals should
not move past center position.
9. Attach seat belt with enough slack to allow operator
Equipment: to lift from seat.
• Stop watch. 10. Lift from seat slightly. Attempt to move foot pedals.
Foot pedals should not move past center position.

Procedure:
Results:
1. Run engine at slow idle.
2. Operate dump bucket fully down and rollback. • If foot pedal function is not correct, check linkage
for binding, if OK, check boom and bucket lockout
solenoid circuit.

9 - 16 4/6/95
TEST AND ADJUSTMENT HYDRAULICS

SYSTEM RELIEF VALVE PRESSURE Specifications:

TEST (For Units Equipped With • Relief pressure should be 17926 ± 1379 kPa
(2600 ± 200 psi).
Auxiliary Hydraulics)
Results:
Reason:
1. If pressure is high or low, replace system relief
To check high pressure relief valve. valve.

Equipment: NOTE: Relief valve is not serviceable. Relief pressure

• DO1074AA In-Line Hydraulic Tester. is factory set.
• JTO 3235 Connectors, 2 req.
• MG9801618 Quick Disconnect, Male
• MG256231 Quick Disconnect, Female.
PUMP FLOW TEST (For Units
• JTO3377 Hose, 2 req. Equipped With Auxiliary Hydraulics)

Procedure: Reason:
1. Lower boom and bucket into normal at rest ground To assure that pump is delivering sufficient volume to
position. Relieve hydraulic pressure. operate hydraulic system properly.

Equipment:
JTO3377
MG256231 • DO1074AA In-Line Hydraulic Tester.
• JTO 3235 Connectors, 2 req.
MG9801618
• MG9801618 Quick Disconnect, Male
DO1074AA
JTO3235 • MG256231 Quick Disconnect, Female.
• JTO3377 Hose, 2 req.

Procedure:
1. Lower boom and bucket into normal at rest ground
position. Stop engine and relieve hydraulic
pressure. Turn key switch off.

JTO3377
MG256231

MG9801618

M58134 JTO3235
DO1074AA

2. Install JTO3235 Connector on one end of both

JTO3377 Hoses.
3. Install JTO Quick Disconnects on Connectors.
4. Connect Hose JTO3377 to DO1074AA In-Line
Hydraulic Tester.
5. Attach Quick Disconnects to auxiliary hydraulic
ports located on left boom arm.
6. Operate hydraulic system until oil reaches normal
operating temperature of 43°C (110°).
7. Set throttle at 2500 rpm.
8. Actuate Auxiliary Hydraulics Control Lever. M58134
9. Slowly turn up valve on In-Line Hydraulic Tester
until Pressure relief valve releases.

4/6/95 9 - 17
HYDRAULICS TEST AND ADJUSTMENT

2. Install JTO3235 Connector on one end of both

JTO3377 Hoses.
3. Install JTO Quick Disconnects on Connectors. JTO3362
4. Connect Hose JTO3377 to DO1074AA In-Line
Hydraulic Tester.
5. Attach Quick Disconnects to auxiliary hydraulic
ports located on left boom arm.
6. Operate hydraulic system until oil reaches normal
operating temperature of 43°C (110°). JTO3386
7. Set throttle at 2500 rpm.
8. Actuate Auxiliary Hydraulics Control Lever.
9. Turn up resistance valve until pressure reads
13790 kPa (2000 psi).

Specifications:
Minimum Pump Flow . . . . . . . . . . 53 L/min. (14 gpm)
JTO1609
M57872

Results:
1. Check wrist and spool travel to make sure
mechanical systems are operating properly.
2. If flow is low rebuild and/or replace hydraulic pump.
SYSTEM RELIEF VALVE PRESSURE
TEST (For Units Not Equipped With
Auxiliary Hydraulics)
Reason:
To check high pressure relief valve.
2. Install JTO3386 "T" in one of the boom cylinder
lines.
3. Connect Hose JTO1609 to JTO3386 "T".
4. Attach Quick Disconnects to JTO3362 10000 psi
gauge.
5. Operate hydraulic system until oil reaches normal
operating temperature of 43°C (110°).
6. Set throttle at 2500 rpm.
7. Actuate and hold boom hydraulics control pedal in
the lower position until the system relief valve
opens.
8. Note reading on gauge.

Equipment: Specifications:
• JTO3362 10000 psi gauge.
• JTO1609 Hose with Quick disconnect • Relief pressure should be 17926 ± 1380 kPa (2600
• JTO 3386 "T". ± 200 psi).

Procedure: Results:

1. Raise boom and bucket and lock boom lock. Lower 1. If pressure is high/low replace relief valve.
boom onto boom lock pins.
NOTE: Relief valve is not serviceable. Relief pressure
is factory set.

PUMP FLOW TEST (For Units Not

Equipped With Auxiliary Hydraulics)

Reason:
To assure that pump is delivering sufficient volume to
operate hydraulic system properly.

9 - 18 4/6/95
TEST AND ADJUSTMENT HYDRAULICS

Equipment: BOOM DRIFT DOWN CHECK

• DO1074AA In-Line Hydraulic Tester.
• JTO 3235 Connectors, 2 req.
Reason:
• JTO3377 Hose, 2 req.
To insure that boom raise circuit does not have internal
leaks.
Procedure:
1. Lower boom and bucket into normal at rest ground Procedure:
position.
2. Install JTO3235 Connector on one end of both 1. Start engine and raise boom halfway. Shut off
JTO3377 Hoses. engine.
3. Connect Hose JTO3377 to DO1074AA In-Line
Hydraulic Tester. Specifications:
.
• Boom must not appreciably drift down in 5
minutes.

Results:
If boom drifts down, check for:
• Leaking circuit relief valve. Rebuild or replace
valve.
• Leaking control valve spool. Rebuild or replace
HIGH PRESSURE HOSE valve.
• Leaking cylinder packing. Rebuild or replace
cylinder.

M57888 BOOM LIFT CHECK TEST

Reason:
4. Disconnect high pressure hose from bottom of
hydraulic pump. To insure that boom lift check circuit does not have
5. Connect hoses in line with hydraulic pump. internal leaks.
6. Operate hydraulic system until oil reaches normal
operating temperature of 43°C (110°). Procedure:
7. Set throttle at 2500 rpm.
1. Raise boom halfway.
8. Turn up resistance valve until pressure reads 2000
2. Turn engine OFF.
psi.
3. Press boom pedal to raise position.

Specifications:
Specifications:
Minimum Pump Flow . . . . . . . . . . 53 L/min. (14 gpm)
• Boom must not move down.

Results:
Results:
• If flow is low rebuild and/or replace pump.
1. Rebuild or replace valve.

4/6/95 9 - 19
HYDRAULICS TEST AND ADJUSTMENT

BOOM DRIFT UP CHECK BUCKET DRIFT ROLLBACK

POSITION CHECK
Reason:
To insure that boom lower circuit does not have internal Reason:
leaks. To insure that bucket rollback circuit does not have
internal leaks.
Procedure:
1. Start engine and use boom to raise front of Procedure:
machine a few inches off ground. 1. Start engine and use bucket to raise machine a few
inches off ground.
NOTE: Bucket may have to be in dump position. Shut 2. Shut off engine.
off engine.
Specifications:
Specifications: • Bucket must not have excessive drift in up
• Boom must not have excessive drift in up direction.
direction.
Results:
Results: 1. If bucket drifts, check for leaks in control valve
• Check for leaking circuit relief valve. Rebuild or spool. Rebuild or replace valve.
replace valve. 2. Check for leaks in cylinder packing. Rebuild or
• Check for leaking control valve spool. Rebuild or replace cylinder.
replace valve.
• Check for leaking cylinder packing. Rebuild or
replace cylinder. BOOM LOCK CHECK

Reason:
BUCKET DRIFT DUMP POSITION
CHECK To insure the free and accurate activation of the Boom
Locking System.

Reason:
Procedure:
To insure that bucket dump circuit does not have
1. Start engine and raise boom.
internal leaks.
2. Activate mechanical boom lock.
3. Lower boom to rest on lock arms.
Procedure:
1. Raise boom halfway and shut off engine. Specifications:
2. Rotate bucket all the way back and then roll to half
way position. 1. Lock arms must move to lock position smoothly
with no binding.
2. Boom arms must rest solidly on both lock arms.
Specifications:
• Bucket must not drift an excessive amount in Results:
dump direction.
1. If lock arms do not move into position easily or fully
check linkage and pins for damage.
Results: 2. If boom does not rest on both pins, boom is twisted.
1. If bucket drifts, check for leaks in control valve Repair or replace boom.
spool. Rebuild or replace valve.
2. Check for leaks in cylinder packing. Rebuild or
replace cylinder.

9 - 20 4/6/95
REPAIR HYDRAULICS

REPAIR

HYDRAULIC PUMP REMOVAL

1. Park machine on level surface. Raise boom and set
on boom stops. Stop engine and release hydraulic
pressure by operating hand and foot controls.
A

c CAUTION C

CAUTION: To avoid injury from escaping

hydraulic oil under pressure, relieve the
pressure in the system by stopping the engine
B
and operating all hydraulic control valves. M76232

2. Jack machine and place on suitable jack stands.

Place at a height that allows servicing from 7. Disconnect high pressure line (A) and intake fittings
underneath. (B) from hydraulic pump.
3. Remove both of the skid plates under the engine
compartment and the one under the hydrostatic
IMPORTANT: Plug pump openings and hose ends
pumps.
to prevent contamination of hydraulic system.
4. Drain the hydraulic system by disconnecting the
filter return line from the tee fitting located beneath
the battery. 8. Remove two cap screws.(C)
5. Raise seat to service position. 9. Remove hydraulic pump.

c CAUTION HYDRAULIC PUMP DISASSEMBLY

CAUTION: Be sure that the seat support rod is NOTE: Wash pump in suitable solvent and dry before
securely locked in the service position so that disassembling.
seat does not fall and cause inury.

MARK

A M57885
M76231

1. Mark pump case across front plate, body and back

6. Disconnect four 3/4" hoses (A) on hydrostatic
plate to assure proper reassembly.
pumps. Cap and plug ends of fittings and hoses.
2. Remove fittings from suction port and high pressure
port.
3. Clamp pump in soft jaw vise, shaft end up.

4/6/95 9 - 21
HYDRAULICS REPAIR

Drive Gear
Idler Gear
A

M57886 M57901

4. Remove eight (8) bolts (A) from face end of pump.
5. Remove pump from vise.
IMPORTANT: Pump body is aluminum and can be
easily damaged by steel tools. Be careful not to
damage machined surfaces.
8. Remove drive gear assembly and idler gear
assembly from body.
9. To separate body from the plate it remained with
place drive gear assembly in bushing and tap
protruding end with plastic hammer or rawhide
mallet.

IMPORTANT: Do not use screwdriver or other hard,

sharp objects to pry body from plate.

C
M57887 B M57894

6. Hold pump in hands and bump shaft against
wooden block to separate front plate from back
plate. Body will remain with either front plate or
back plate.
7. If front plate separated first, remove wear plate
from body gear pockets.
10. Remove O-rings (A) from back plate and front
plate.
11. Remove back up gasket (B) from front plate by
prying carefully with sharp tool.
12. Remove bearing seal and molded O-ring (C) from
front plate.

9 - 22 4/6/95
REPAIR HYDRAULICS

Bearing Seal

M57891

M57902
13. Remove bearing seal (A) from front plate by prying
carefully with screwdriver.
7. Inspect gear assembly. Inspect shafts at bushing
points and seal area for rough surfaces and
HYDRAULIC PUMP COMPONENT excessive wear. Replace gear assembly if shaft
INSPECTION measures less than 19 mm (0.748 in.) in bushing
area.
1. Clean all parts in suitable solvent. Dry all parts.
2. Remove all nicks and burrs from parts with emery
cloth. NOTE: If necessary to replace a gear or shaft, each
gear and shaft assembly must be replaced as
a unit.
C C
M57885

C
A M57890

3. Check spline (A) on drive shaft for twisted or broken M57895

teeth.
4. Inspect gear faces (B) for scoring and excessive
wear. Replace gear assembly if gear width is less 8. Inspect front and back plates. Replace if scored or
than 19.35 mm (0.762 in.). worn, Wear on back plate, in gear contact area,
5. If edges of gears are sharp, break edge with emery should not exceed 0.381 mm (0.015 in.).
cloth.
6. Check snap rings (C) on either side of drive and
idler gears. Replace if bent, broken, or missing.

4/6/95 9 - 23
HYDRAULICS REPAIR

. referring to the location and orientation of half

moon ports in body and orientation of wear
plate.

M57893

9. Check inside diameter of bushings and replace

entire face plate or back plate if they exceed M57896
19.17 mm (0.755 in.).

NOTE: Bushings are not a field serviceable item. If
bushings are worn entire plate assembly must
be replaced as a unit.
10. Bushings in front plate should be flush with face of
front plate
1. Place spacer washer (A) in seal bore on face side
of body.
2. Install new drive shaft seal (B) in front plate with lip
of seal facing bearings in plate. Drive seal into front
plate until it is approximately 3 mm (1/8 in.) below
plate face.

M57892 M57897

11. Inspect body. Replace if machined surfaces are 3. Install new O-rings (A) in front plate and in back
scored or worn. plate.
12. Replace body if inside diameter of gear pockets 4. Install new molded ring (B) and bearing seal (C) in
exceeds 43.51 mm (1.713 in.). front plate.
5. Put back up gasket (D) into grove in front plate with
flat side of gasket facing out.
HYDRAULIC PUMP ASSEMBLY

NOTE: It is important that the relationship of the back

plate, body, wear plate and front plate is
correct. Pay special attention to section Notes

9 - 24 4/6/95
REPAIR
M57898
6. Apply a thin coat of petroleum jelly to both gear
pockets of body.
NOTE: Orientation of half cut pocket (A) on body.
B
M57900
7. Install body on to front plate.
NOTE: Make sure that the marks (B) on the outside of
the body, made during disassembly, and front
plate line up. The small half moon port (A)
must be on the pressure side of pump.
4/6/95
HYDRAULICS
Cut Away
M57899
8. Put wear plate in gear cavities with bronze face up.
NOTE: The side of the wear plate with the mid section
cut away must be on the suction side (large
port in back plate) of the pump.
.
M57901
9. Dip gear shaft assemblies in hydraulic oil.
10. Install drive gear and idler gear in body assembly.
Avoid damaging seal in drive gear bore.
11. Install body on face plate.
12. Install back plate on body taking care to match
alignment marks made during disassembly.
NOTE: Large port in back plate should line up with full
half moon port in body.
9 - 25
HYDRAULICS REPAIR

B O-RING

1 8
A
3 6

4
5
2
7
M57886

M57886 2. Place O-ring around boss on face of pump.

13. Install four unpainted cap screws (B) in drive cavity.

Install four painted cap screws (A) in remaining
holes. Tighten finger tight being careful not to cross
thread cap screws in aluminum body.

NOTE: Tighten cap screws evenly in the sequence

shown to avoid misaligning the plates and
possibly warping or breaking the pump
housing.

14. Fasten pump in soft jaw vise. Tighten cap screws to

35 N•m (26 lb-ft.).
M57904

HYDRAULIC PUMP INSTALLATION

3. Slide spline shaft on pump into mating spline on
end of hydrostatic pump.
SPECIAL ELBOW
"T" FITTING 4. Align mounting hole in pump housing with threaded
holes in hydrostatic pump housing. Install and
tighten two (2) 3/8" X 1" capscrews to 23 N•m (17
lb-ft.).
5. Connect high pressure line and intake hose to
hydraulic pump.
6. Reconnect any other lines that might have been
loosened or removed in order to remove the
O-RING x FLARE
90° ELBOW hydraulic pump.
7. Install center kick panel.
8. Perform start-up procedure before operating skid-
steer. (See Start-up Procedure at end of this
section.)

O-RING x FLARE
90° ELBOW

M76238

1. Install fittings in high pressure port and suction port.

Do not tighten lock nuts at this time.

9 - 26 4/6/95
REPAIR HYDRAULICS

MAIN CONTROL VALVE REMOVAL
1. Park machine on level surface. Raise boom and set
on boom stops. Stop engine and release hydraulic
pressure by operating hand and foot controls.
IMPORTANT: Plug pump openings and hose ends
to prevent contamination of hydraulic system.
10. Remove control valve.

c CAUTION MAIN CONTROL VALVE

DISASSEMBLY
CAUTION: To avoid injury from escaping .
hydraulic oil under pressure, relieve the 3/4" FITTING
1/2" FITTING
pressure in the system by stopping the engine
and operating all hydraulic control valves.

2. Jack machine and place on suitable jack stands.

Place at a height that allows servicing from
underneath.
3. Remove both of the skid plates under the engine
compartment and the one under the hydrostatic 3/8" FITTING
pumps.
4. Drain the hydraulic system by disconnecting the
filter return line from the tee fitting located beneath
the battery.
5. Raise seat to service position.
1/2" FITTING
M57907

c CAUTION 1. Remove hydraulic pump hose.

2. Remove fittings.
CAUTION: Be sure that the seat support rod is
securely locked in the service position so that
seat does not fall and cause injury. NOTE: Location and type of fitting to insure proper
placement on reassembly.

6. Remove center foot shield.

ELECTRICAL
CONNECTOR

COTTER PIN
SOLENOID
CLEVIS PIN

BLOCK

SOLENOID

SYSTEM RELIEF VALVE

M57906

M57907
7. Remove cotter pin and clevis pin connecting pedal
linkages to spool valves. 3. Remove solenoids.
8. Disconnect electrical connectors for solenoids. 4. Remove solenoid mounting blocks.
9. Mark hydraulic lines for proper reassembly. 5. Remove system relief valve.
Disconnect lines.

4/6/95 9 - 27
HYDRAULICS REPAIR

MAIN CONTROL VALVE

INSPECTION
1. Inspect each port in housing. Remove any burrs.
SPOOL COVER
AUXILIARY SPOOL

CIRCUIT RELIEF VALVE

BOOM SPOOL

SPOOL COVERS BUCKET SPOOL

M58089
M57907
M57907
2. Inspect spools. Spools should be free of deep
6. Mark spool covers for reassembly. Remove spool scratches or fretting.
covers.
7. Remove circuit relief valve.
8. Pull valve spools from housing from spool cover IMPORTANT: Spools are a matched set within the
end. control valve. If excessively worn or damaged,
9. Remove O-rings and cover washers from inside replace entire control valve.
spool openings.
NOTE: All three spools are different. Be careful not to
mix spools and spring assembly when re-
assembling valve.

SPECIAL BOLT

M58096

NOTE: Spools are a matched set within the control

valve. Test spools for freedom of rotation. If SHALLOW KEEPER
spool binds in housing, rotate spools 180°. If
binding still occurs, replace control valve DEEP KEEPER
assembly. SHOULDER BOLT
M58090

3. Remove spool screw, keepers and spring from

IMPORTANT: Before removing valve spools, make spools.
sure the exposed portion of spool is free of
paint or corrosion which could damage the
internal porting of the valve. NOTE: Bucket spool uses plain shoulder bolt to retain
spring. Other two spools use detent type
shoulder bolt.
10. Mark spools for future reassembly.

9 - 28 4/6/95
REPAIR HYDRAULICS

IMPORTANT: Spring keepers are not the same. Use

one deep keeper with large hole and one
PLUG VALVE
shallow keeper with small hole on special bolts.
Two deep keepers with small hole are used with
plain shoulder bolt.

SOLENOID

M58092

O-RING
9. Inspect plug valve. Replace if damaged or worn.

SEAL BACK-UP WASHER

M58094 O-RING

4. Inspect solenoid and mounting block.

5. Replace O-ring on solenoid.
6. Replace seal in face of mounting block.

BODY PLUG
NOTE: Seal for auxiliary spool is located in valve body.

M58093

O-RING 10. Replace O-rings on body plugs.

11. Inspect back-up washer. Replace if damaged.

SCREEN SCREEN
WASHER SUPPORT ORIFICE
O-RING WIRE PLATE
SNAP RING

O-RING
M58091
BACK-UP WASHER

7. Replace circuit relief valve O-rings.

8. Inspect back-up washer. Replace if damaged.
O-RING

PILOT BODY SYSTEM PRESSURE M58095

NOTE: Do not disassemble circuit relief valve. Valve is
not serviceable. Replace entire unit if not
functioning properly.
SEAT FACE RELIEF VALVE
12. Remove and disassemble system pressure relief
valve by removing internal snap ring from the relief
valve bore.
13. Remove and replace back-up washer and O-ring
(not shown above) located inside of main control
valve housing system relief valve bore.
14. Clean screen and replace O-rings.
15. Inspect Pilot Body tapered seat face for scoring.
Replace entire valve if damaged.

4/6/95 9 - 29
HYDRAULICS REPAIR

MAIN CONTROL VALVE ASSEMBLY

1/2" 37° FLARE HOUSING PLUG

7/8"-14 O-RING 1/2" 37° FLARE
CONNECTOR 7/8"-14 O-RING
CONNECTOR

ORIFICE

PLUG VALVE

PLUG VALVE

3/8" 37° FLARE

7/8"-14 O-RING
CONNECTOR

1/2" 37° FLARE

7/8"-14 O-RING
CONNECTOR M57907

IMPORTANT: Due to extremely tight tolerances and

finish of internal surfaces it is very important to
maintain absolute cleanliness during the
assembly of the valve. Use plenty of clean SPECIAL BOLT
hydraulic fluid when assembling the valve.
O-RING ON
BOOM BOLT ONLY
1. Thoroughly clean and dry all parts.
2. Install new O-ring on fittings.
3. Install fittings in housing. Tighten all fittings to 38
N•m (28 lb-ft.).

SHALLOW KEEPER
NOTE: Install orifice under boom fitting closest to
solenoid.
DEEP KEEPER
SHOULDER BOLT
M58090

PLUG VALVE

IMPORTANT: Spring keepers are not the same. Use

one deep keeper with large hole and one
shallow keeper with small hole on special bolts.
Two deep keepers with small hole are used with
shoulder bolt.
O-RING M58092
NOTE: Bucket spool uses a shoulder bolt to retain
spring. Other two spools use a detent type
4. Install new O-ring on plug valve. special bolt. Boom spool special bolt has a
5. Install spring and plunger in plug valves. small O-ring on threaded end.
6. Install three plug valves in center ports in top of
valve body.

9 - 30 4/6/95
REPAIR HYDRAULICS

7. Assemble keepers and spring on spools. Apply

threadlock and sealer (medium strength) on bolt
threads. Install proper shoulder or special bolts and
tighten to 8 N•m (7 lb-ft).

AUXILIARY SPOOL

BOOM SPOOL

WASHER
BUCKET SPOOL
O-RING
M58131

11. Install O-rings and retainer washers in outlet side of

M58089 valve.

8. Apply multipurpose grease to ends of special

detent shoulder bolts.

O-RING M58096

LIP SEAL

12. Oil spools and body passages thoroughly.

M58130

IMPORTANT: Be careful when installing spools not

9. Install three (3) new O-rings in inlet side of body to damage O-rings.
spool passages.
10. Install new lip seal in auxiliary spool passage. 13. Install spools.

4/6/95 9 - 31
HYDRAULICS REPAIR

STEP PLUGS

NOTE ORIENTATION
OF SOLENOIDS

CIRCUIT RELIEF VALVE M58097

M57907
14. Install circuit relief valve and tighten to 38 N•m (28
lb-ft).
15. Replace O-rings on step plugs and install step
plugs.Tighten step plugs to 38 N•m (28 lb-ft). 18. Place O-ring in groove on opposite side of solenoid
block from lip seal.

IMPORTANT: Be careful not to damage lip seals

when installing solenoid blocks over spools.

NOTE: Install solenoid block for boom spool with

solenoid hole towards top of body. Install
solenoid block for bucket spool with solenoid
LONG COVER
hole facing to side of body.

19. Install solenoid blocks on body. Tighten bolts to 15

N•m (11 lb-ft).
SHORT COVER 20. Install solenoids in solenoid blocks. Tighten to 15
N•m (11 lb-ft).

MAIN CONTROL VALVE

M57907 INSTALLATION

16. Install spool covers. Tighten bolts to 15 N•m (11 lb- IMPORTANT: Do not overtighten valve mounting
ft). bolts. Excessive torque on valve mounting bolts
may deform valve body and cause malfunction
17. Replace lip seal in solenoid block. and/or damage to valve.

1. Install main control valve assembly into vehicle

frame. Tighten two mounting bolts to 24 N•m (18
lb-ft).

9 - 32 4/6/95
REPAIR HYDRAULICS

c CAUTION
AUXILIARY FITTINGS
CAUTION: To help prevent injury from escaping
BOOM FITTINGS hydraulic oil under pressure, relieve the
pressure in the system. Stop the engine, turn the
ignition key to ON and operate all hydraulic
control valves. Turn key to OFF.

2. Relieve all hydraulic pressure in system.

3. Loosen fittings on hydraulic lines at cylinder.
BUCKET FITTINGS 4. Disconnect lines.

UPPER PIVOT
M58551

2. Connect hydraulic fittings. BOOM CYLINDER

3. Connect line to bottom of system pressure valve.
Tighten hose clamp a on tank end of line.
4. Connect high pressure line from hydraulic pump to
valve inlet. LOWER PIVOT
5. Connect linkages.
6. Hook up solenoids for boom and bucket safety M57873
interlock.
7. Install belly pan.
8. Install foot shields.
5. Remove retaining bolt on top cylinder pivot pin
9. Check oil level in hydraulic oil reservoir and add oil
plate, remove pin.
if needed.
10. Start engine and operate at one-half speed. Move
foot controls to cycle all hydraulic cylinders several
times.
11. Stop engine and inspect for leaks. Repair any
leaks.
12. Check hydraulic oil level again and add oil if
needed.

LIFT ARM CYLINDERS REMOVAL RETAINING BOLT

NOTE: Lift arm cylinders can be safely removed while

arms are supported on lift arm stops. M57875

1. Park skid steer safely. Raise lift arms and put arms
on lift arm stops. 6. Loosen lower bolt in center of cylinder pivot.

4/6/95 9 - 33
HYDRAULICS REPAIR

HEAD
BODY

M57874 M57877

4. Push cylinder head into cylinder body bore far

IMPORTANT: Do not remove nut from lower bolt
until cylinder pivot is loose.
7. Rotate cylinder to a upright position.
8. Rock cylinder back and forth to loosen lower pivot.
9. Remove lower pivot bolt, remove cylinder.
enough to remove retaining ring.
5. Pull piston rod and piston out of barrel.
6. Disassemble, clean and inspect parts. Remove any
nicks or burrs with emery cloth.
7. Carefully inspect cylinder bore and piston for deep
grooving or scratches. Replace entire cylinder if
either are damaged.

LIFT ARM CYLINDER REPAIR

1. Clean outside of cylinder with suitable solvent and
dry.
2. Pull piston rod out slowly to drain oil.

11/64" DRILL WEAR RING

SHAFT SEAL HEAD ROD SEAL
SPANNER M57879

NOTE: Shaft seal should be installed with the lip of the

seal facing the piston.

8. Replace shaft seal and wear ring on inside of head.

9. Drive new rod seal into head.
M57876

3. Install barrel in vise. Insert a 11/64" drill through

hole in cylinder body. Hole should align with
matching hole in cylinder head. Remove bearing
nut with DO5112ST adjustable hook spanner
wrench.

9 - 34 4/6/95
REPAIR HYDRAULICS

17. Insert 11/64 in. drill in hole in cylinder body. Hole

should align with matching hole in cylinder head.
I G F A C K 18. Tighten bearing nut (K) to 230 N•m (170 lb-ft) with
D
E DO5112ST adjustable hook spanner wrench.
19. Pack drill hole with grease.
20. Install hydraulic fittings if removed.

LIFT ARM CYLINDERS

INSTALLATION
J
H B M57878

SPACER

10. Replace O-ring (A) on outside of cylinder head (B). HEAVY WASHER
PIVOT

NOTE: Check location of back up washer (C). Washer

should be located toward threaded portion of
head.

11. Lubricate inside of cylinder head with hydraulic oil. WASHER

12. Lubricate piston rod (D) and install cylinder head
BOLT
assembly on rod being careful not to tear seal (E).
NUT
13. Install a new piston seal (F) and wear ring (G) on M57876
piston (H).

NOTE: Piston seal will stretch as it is installed. 1. Install cylinder and lower pivot pin. Tighten nut to
Compress seal after installation using hose 169 N•m (125 lb-ft).
clamp or ring compressor.

CAPSCREW
14. Install piston and locknut (I) on rod. Tighten locknut SPACER RING UPPER PIN
to 169 N•m (125 lb-ft.).
15. Apply hydraulic oil to piston seal and wear ring.
Insert piston and rod assembly into barrel. Be sure
to align hole in cylinder body with hole in cylinder
head.
16. Install retaining ring (J).
WASHER
NUT
M57881

2. Install upper pivot pin. Tighten capscrew to 38 N•m

(28 lb-ft).

M57876

4/6/95 9 - 35
HYDRAULICS REPAIR

HOSE CLAMP

TUBE SPACER
PIVOT PINS

M57910
M57873

3. Connect hydraulic lines and install rubber tube
spacer block and secure tube to cylinder with hose
clamp.
4. Cycle cylinder and check for leaks.
BUCKET CYLINDERS REMOVAL
1. Park skid steer safely. Lower lift arms completely
4. Remove pivot pins to remove cylinders.
BUCKET CYLINDER REPAIR
1. Clean outside of cylinder with suitable solvent and
dry.
2. Pull piston rod out slowly to drain oil.
3. Push rod back in.

HEAD CYLINDER

c CAUTION
CAUTION: Bucket cylinders can be safely
removed only while lift arms are in completely
lowered position.

ROD

c CAUTION M57913

CAUTION: To help prevent injury from escaping

hydraulic oil under pressure, relieve the
pressure in the system. Stop the engine, turn the 4. Unscrew cylinder head.
ignition key to ON and operate all hydraulic
control valves. Turn key to OFF

2. Relieve all hydraulic pressure in system.

3. Mark hydraulic lines for proper reassembly.
Disconnect lines.

M57911

9 - 36 4/6/95
REPAIR HYDRAULICS

5. Install barrel in vise and remove piston rod with

piston and head attached. HEAD CYLINDER
6. Disassemble, clean and inspect parts. Remove any
nicks or burrs with emery cloth.
7. Carefully inspect cylinder bore, rod, and piston for
deep grooving or scratches. Replace entire
cylinder if they are damaged.

K L I H E D C F G

ROD

M57913

J A B NOTE: The cylinder is threaded on the end. Be careful

not to damage piston seal on threads when
RECESSED END
M57912
installing.

14. Apply hydraulic fluid on piston assembly. Install rod

8. Replace O-ring (A) on outside of cylinder head (B). and piston assembly into cylinder. Tighten head to
285 N•m (210 lb-ft).
NOTE: Check location of back up washer (C). Washer
should be located away from threaded portion
of head.
BUCKET CYLINDERS
INSTALLATION
NOTE: Shaft seal should be installed with the lip of the 1. Install cylinders and pivot pins.
seal facing the piston. 2. Connect hydraulic lines.
3. Cycle cylinders and check for leaks.

9. Replace shaft seal (D) and wear ring (E) on inside

of head (B). START-UP PROCEDURE AFTER
10. Drive new rod seal (F) into head. HYDRAULIC COMPONENT
11. Lubricate inside of head with hydraulic fluid and
insert rod (G). REPLACEMENT
1. Change hydraulic system filter.
2. Remove hydraulic breather assembly on top of
NOTE: Piston seal will stretch as it is installed.
reservoir. Clean filter in solvent and dry before
Compress seal after installation using hose
installation.
clamp or ring compressor.

IMPORTANT: If contamination is found in hydraulic

12. Install new piston seal (H) and wear ring (I) on
system filter or inside reservoir, flush entire
piston (J).
hydraulic system.

NOTE: Piston has a flat and a recessed side. The flat

IMPORTANT: If the hydraulic oil is being reused,
side should be placed up against the rod.
make sure it is filtered through a 10 micron filter
Washer and capscrew go on recessed side.
before putting into reservoir.

13. Install piston on rod. Apply threadlock and sealer

3. Fill reservoir with specified oil to the proper level.
(medium strength) on capscrew (K) threads. Install
washer (L) and capscrew and tighten to 386 N•m
(285 lb-ft).

4/6/95 9 - 37
HYDRAULICS
4. Loosen hydraulic pump line fitting on control valve
to bleed air from hydraulic system.
A
M58135
5. Disconnect wire (A) to fuel shut-off solenoid.
c CAUTION
CAUTION: Make sure skid steer is securely
blocked before proceeding to the next step.
6. Turn key to START and hold for 10 seconds or until
oil leaks from loosened control valve fitting. Turn
key to OFF.
7. Connect wires to fuel shut-off solenoid.
B 18. Run engine for an additional 30 minutes to filter oil.
C A
M76240
8. Disconnect pressure sensor line at Tee fitting (A).
9. Connect JTO1609 hose (B) to Tee fitting (A).
Assemble JTO3262 gauge (C) to hose quick
coupler.
10. Put steering levers in neutral position. Start engine
and run at low idle. Hydraulic pressure should read
550-830 kPa (80-120 psi) within 5 to 10 seconds.
9 - 38
REPAIR
IMPORTANT: If hydraulic pressure remains below
350 kPa (50 psi) for more than 10 seconds, stop
engine and check for cause of low pressure.
Failure to stop engine when hydraulic pressure
is low will cause severe damage to pumps and
motors.
c CAUTION
CAUTION: To help prevent injury from escaping
hydraulic oil under pressure, relieve the
pressure in the system. Stop the engine, turn the
ignition key to ON and operate all hydraulic
control valves. Turn key to OFF.
11. Relieve all hydraulic pressure in system.
12. Disconnect gauge and replace test plug or
hydraulic pressure sensor after reaching proper
hydraulic pressure.
13. Start engine and run at half throttle for 20 minutes.
Stop engine and check hydraulic oil level. Fill as
needed.
14. Start engine and run at half throttle. Move lift arm
and bucket pedals for 3 minutes to remove air from
system and to progressively load hydraulic pump.
15. Slowly move steering levers with no load on wheels
until wheels turn smoothly indicating trapped air
has been bled back to reservoir.
16. Stop engine and check hydraulic reservoir oil level.
Check all line connections for leaks and tighten if
necessary.
17. Adjust steering neutralizer. (See steering section)
Stop engine, change hydraulic filter.
19. Lower skid-steer to ground.
4/6/95
CONTENTS BACKHOE

CONTENTS
Page

SPECIFICATIONS—900 AND 911 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HYDRAULIC SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BUCKET AND EXTENSION HYDRAULIC SYSTEM (911) . . . . . . . . . . . . . . . . . . . 6
BOOM AND DIPPERSTICK HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 7
BOOM SWING HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STABILIZER HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TROUBLESHOOTING CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TESTS & ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BUCKET CIRCUIT RELIEF VALVE PRESSURE TEST . . . . . . . . . . . . . . . . . . . . 14
DIPPERSTICK CIRCUIT RELIEF VALVE PRESSURE TEST. . . . . . . . . . . . . . . . 14
BOOM CIRCUIT RELIEF VALVE PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . 15
MAIN RELIEF VALVE PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SWING CROSSOVER RELIEF VALVE PRESSURE TEST . . . . . . . . . . . . . . . . . 16
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CONTROL VALVE REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
BOOM SWING CROSSOVER RELIEF VALVE REPAIR. . . . . . . . . . . . . . . . . . . . 21
HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DIPPERSTICK EXTENSION (911) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
O-RING BOSS FITTINGS SERVICE RECOMMENDATIONS . . . . . . . . . . . . . . . . 25

2/10/95 10 - 1
BACKHOE CONTENTS

10 - 2 2/10/95
SPECIFICATIONS—900 AND 911 BACKHOE

SPECIFICATIONS—900 AND 911

CONTROL VALVE:
Oil Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 - 43°C (100-110°F)
Main Relief Valve Pressure . . . . . . . . . . . . . . . . . . . . 14479-15513 kPa (2100-2250 psi)
Bucket Circuit Relief Valve Pressure . . . . . . . . . . . . . . . . . . . . . . . 17237 kPa (2500 psi)
Dipperstick Circuit Relief Valve Pressure . . . . . . . . . . . . . . . . . . . . 17237 kPa (2500 psi)
Boom Circuit Relief Valve Pressure . . . . . . . . . . . . . . . . . . . . . . . . 17237 kPa (2500 psi)
Main Relief Valve Housing Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)
Main Relief Valve Cap Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 N•m (14 lb-ft)
Load Check Valve Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)
Circuit Relief Valve Cartridge Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)
Circuit Relief Valve Cap Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 N•m (14 lb-ft)
Anti-Cavitation Check Valve Body Torque . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)
Spool Spring Retainer Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 N•m (10 lb-ft)
Spring Cover Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 N•m (10 lb-ft)
Control Valve Assembly Nuts Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 N•m (32 lb-ft)
Pivot Bracket To Valve Housing Screw Torque. . . . . . . . . . . . . . . . . . . . . 12 N•m (9 lb-ft)
Pivot Pin Nuts Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (18 lb-ft)
Control Handle Mounting Bracket Capscrew Torque . . . . . . . . . . . . . . . 25 N•m (18 lb-ft)
Control Valve Assembly Mounting Capscrews Torque . . . . . . . . . . . . . . 35 N•m (26 lb-ft)

CROSSOVER RELIEF VALVE:

Crossover Relief Valve Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 14824 kPa (2150 psi)

CONTROL VALVE PRESSURE RESTRICTORS:

Swing Valve Top (“A”) Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.575 mm (0.062 in.)
Swing Valve Bottom (“B”) Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.575 mm (0.062 in.)
Boom Valve Top (“A”) Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.880 mm (0.074 in.)
Left and Right Stabilizer Top (“A”) Port. . . . . . . . . . . . . . . . . . . . . . 1.575 mm (0.062 in.)

CYLINDERS:
Boom, Bucket and Dipperstick Piston Nut Torque . . . . . . . . . . . . . . . 407 N•m (300 lb-ft)
Stabilizer and Swing Piston Nut Torque . . . . . . . . . . . . . . . . . . . . . . . 339 N•m (250 lb-ft)

4/13/95 10 - 3
BACKHOE THEORY OF OPERATION

THEORY OF OPERATION DIPPERSTICK EXTENSION (911 MODEL ONLY)

BACKHOE
The backhoe attachment for the John Deere Skid Steer
Loader operates from the auxiliary hydraulic port on the
skid steer loader boom. It uses a open center control
valve which allows a continuous supply of oil to
circulate from the charge pump on the skid steer
loader, through the backhoe control spools, and return
to the loader. The backhoe has it’s own pressure relief
valve which will protect the backhoe hydraulic system
when the backhoe is forced beyond capacity.
The backhoe is attached to the skid steer loader boom
with the QuickTatch attachment system. In addition,
there are two mounting plates bolted to the front of the
skid steer loader which prevent the QuickTatch
mounting plate from rolling forward when the backhoe
is heavily loaded. The backhoe hydraulic system is
quickly detached from the skid steer loader by two
dripless quick disconnect fittings on the supply and
return hydraulic lines.
CONTROL VALVE
M60304
The model 911 Backhoe is equipped with an
extendable dipperstick. This is done with a hydraulic
cylinder located inside the dipperstick arm, and an
extra control valve section operated by a foot pedal.
Once the hydraulic cylinder is removed, repair is the
same as for other hydraulic cylinders.
HYDRAULIC CYLINDERS
There are two types of hydraulic cylinders used on the
backhoe: snap ring retained gland nut and threaded
gland nut. Although the sizes and appearance of
cylinders are different, the seal arrangement and
method of repair are the same.
All cylinders are dual acting, except for the swing
cylinders, which are single acting but vent into each
other to prevent debris from being pulled into the
system.
SWING CYLINDER CROSSOVER RELIEF VALVE
The crossover relief valve is located on the frame
below the control valve and connects the control valve
with the boom swing cylinder. It protects the boom
swing circuit from excessive hydraulic pressure by
opening a relief valve if the boom should be forced
sideways and high pressure builds up in one of the
swing cylinders. It contains two spring loaded relief
valves, one for left swing, and one for right swing. The
relief valves shunt the high pressure to the opposite
side of the crossover valve.

The hydraulic control valve consists of individual valve

sections stacked side-by-side with a continuous open
center supply of hydraulic pressure. All sections have a
self centering spool witch directs pressure to one of the
hydraulic cylinders. The first section is the main
pressure relief valve which protects the whole backhoe
hydraulic system from sharp pressure shocks. It is
adjustable by adding and removing shims from the
valve body. In addition, three of the individual hydraulic
circuits are protected from over pressure by circuit
relief valves. When a circuit relief valve is used, the
opposite side of that valve section will be fitted with an
anticavitaton valve, which will make up fluid lost out of
the circuit by pressure relief. Both the main and circuit
relief valves should be set to factory pressures to avoid
damage to the backhoe and skid steer loader.

10 - 4 4/13/95
 HYDRAULIC SYSTEM SCHEMATIC BACKHOE

HYDRAULIC SYSTEM SCHEMATIC

High Pressure Oil
Charge Pressure Oil

Trapped Oil

Dipperstick Right Stabilizer Left Stabilizer Left Swing Right Swing

Cylinder Cylinder Cylinder Cylinder Cylinder

Bucket Boom
Extension
Cylinder Cylinder Cylinder

• •
• • • • • •

• •

• • • • • •
• •
••
•
• •
Crossover
Relief Valve

Anti-Cavitation • •
Check Valve Lift Check Valve

• • • • • • •
• •
Backhoe
• • • • • Control Valve

• • IN
• • • •
• •
• • • •
Quick Disconnect
Restrictor Orifice •
• •
•

OUT

• • • • • • • • • • • • •

Bucket Circuit Right Stabilizer Spool Boom Spool System Relief Valve
Dipperstick Circuit Boom Circuit
Relief Valve Swing Spool
Relief Valve Extension Spool Left Stabilizer Spool Relief Valve
Dipperstick Spool Outlet Check Valve
Bucket Spool

1/17/97 10 - 5
 COMPONENT LOCATION BACKHOE

COMPONENT LOCATION

BUCKET AND EXTENSION (911 Model Only) HYDRAULIC SYSTEM

Extension Control Valve

Bucket Control Valve

Bucket Cylinder

Extension
Cylinder

10 - 6 4/17/95
HYDRAULIC SYSTEM SCHEMATIC BACKHOE

BOOM AND DIPPERSTICK HYDRAULIC SYSTEM

Boom Control Valve

Dipperstick Control Valve

Dipperstick Cylinder

Boom Cylinder

M60317

4/13/95 10 - 7
BACKHOE HYDRAULIC SYSTEM SCHEMATIC

BOOM SWING HYDRAULIC SYSTEM

Swing Control Valve

Crossover Relief Valve

Swing Cylinders

M60306

10 - 8 4/13/95
HYDRAULIC SYSTEM SCHEMATIC BACKHOE

STABILIZER HYDRAULIC SYSTEM

Right Stabilizer Valve

Skid Steer Auxiliary

Hydraulics

Left Stabilizer Valve

Right Stabilizer Cylinder

Left Stabilizer Cylinder

M60318

4/13/95 10 - 9
BACKHOE TROUBLESHOOTING CHART

TROUBLESHOOTING CHART

Problem or
Symptom

bucket, boom, or
Loss of power in

Loss of power in

Loss of power in
Backhoe will not

any one cylinder

Backhoe losses

swing cylinders

Spongy, jerking
Slow operation
Check or

dipperstick
Solution

operation
operate

power
Low oil level

Excessive back pressure

Loose or leaking connectors;

broken hoses

Restricted hoses

Cylinder malfunction

Spool not moved to full stroke

Worn valve section

System relief valve set too low

System relief valve malfunction

Skid steer loader hydraulic

system malfunction

Improper hose connection

Load check valve malfunction

Cold or wrong viscosity oil

Increase engine speed

Air in system

Circuit relief valve malfunction

Load check valve leaking

No oil to backhoe valve

Oil bypassing cylinder piston

Cross-over relief valve

malfunction

Anti-cavitation check valve ball

stuck or not seating properly

10 - 10 4/13/95
TROUBLESHOOTING CHART BACKHOE

TROUBLESHOOTING CHART

Problem or

can’t be pushed in

Full swing cannot

Symptom

or won’t return to
Boom, bucket or

when shifted to

Spool sticking,
cylinders drop

Load drops or
Check or

be obtained
dipperstick
Solution

Loose or leaking connectors;

broken hoses

Cylinder malfunction

Bent piston rod

Swing linkage interference

Load check valve poppet failure

Anti-cavitation check valve

failure

Worn valve section

Paint on spool or scored spool

Oil leakage passed spool seal

into spool cap

Broken return spring

Bent spool

Hydraulic oil contamination

Misaligned control valve

linkage

4/13/95 10 - 11
BACKHOE DIAGNOSTICS

DIAGNOSTICS

Test Conditions:

• Skid steer loader parked on level ground • Park brake on

• Engine running at half throttle • Skid steer auxiliary hydraulics on
• Hydraulic oil at operating temperature • Boom locks removed

Test/Check Point Normal If Not Normal

1. Lower stabilizers and cycle all Circuit operates smoothly with full Test auxiliary system input pressure
hydraulic control handles power at normal cycle times and flow from skid steer loader at
quick disconnect fittings (see
Hydrostatic Power Train section)

2. Left and right stabilizer control Stabilizers move down and raise Test for system pressure at top (“A”)
levers moved forward front of loader (cylinder extends) port of stabilizer valve sections.
Inspect anti-cavitation valve on top
of valve body

3. Left and right stabilizer control Stabilizers move up slowly to full up Inspect circuit restrictors in top (“A”)
levers moved rearward position (cylinder contracts) port of stabilizer valve section. Test
circuit pressure at bottom (“B”) port

4. Boom swing lever moved left Boom swings left Inspect circuit restrictor in top (“A”)
port of swing valve section. Test
circuit pressure at bottom (“B”) port

5. Boom swing lever moved right Boom swings right Inspect circuit restrictor in bottom
(“B”) port of swing valve section.
Test circuit pressure at top (“A”) port

6. Bucket control lever moved Bucket curls (cylinder extends) Inspect circuit relief valve on bottom
left of bucket control valve. Test circuit
pressure at bottom (“B”) port of
valve

7. Bucket control lever moved Bucket extends (cylinder retracts) Test circuit pressure at top (“A”) port
right of valve

8. Boom control lever moved Boom moves down (cylinder Test circuit pressure at top (“A”) port
forward extends) of valve

9. Boom control lever moved Boom moves up (cylinder retracts) Inspect circuit restrictor in top (“A”)
rearward port of boom valve section. Test
circuit pressure at bottom (“B”) port

10. Dipperstick control lever Dipperstick moves back (cylinder Inspect circuit relief valve on top of
moved rearward extends) dipperstick control valve. Test circuit
pressure at top (“A”) port of valve

10 - 12 4/13/95
DIAGNOSTICS BACKHOE

DIAGNOSTICS

4
6 5
7 2 8
10 3 9

4
5
8
9

1
2
6
7 3

1
2
3

M60315

4/13/95 10 - 13
BACKHOE
TESTS & ADJUSTMENTS
BUCKET CIRCUIT RELIEF VALVE
PRESSURE TEST
Reason:
To relieve excessive hydraulic pressure from the head
end of the bucket cylinder when the bucket is being
pulled by the boom, dipperstick, or extension (911
only).
Equipment:
• D01018AA Hydraulic Hand Pump
• JTO7045 Hydraulic Test Gauge 0-20684 kPa (0-
3000 psi)
Procedure:
1. Park machine on level surface, park brake on.
Install boom lock pins (swing and raise-lower).
Fully lower dipperstick extension (911 only), and
swing bucket to rest on ground.
2. Stop engine. Move all hydraulic controls to relieve
internal pressure. Lower stabilizers to ground.
(Note: If backhoe attachment is removed from skid
steer loader, make sure boom locks are installed
and frame of backhoe is resting directly on the
ground and not on stabilizer legs).
M60322
3. Remove lower hose (“B” port) from bucket control
valve section and attach test hose from pump and
gauge.
4. Pressurize control valve and note highest reading
on gauge.
10 - 14
TESTS & ADJUSTMENTS
Specifications:
• Bucket relief valve should begin opening at 17237
kPa (2500 psi).
Results:
If readings do not match specifications, inspect valve
(see Circuit Relief Valve Inspection section).
DIPPERSTICK CIRCUIT RELIEF
VALVE PRESSURE TEST
Reason:
To relieve excessive hydraulic pressure from the head
end of the dipperstick cylinder when the dipperstick is
being forced by the boom, bucket, or extension (911
only).
Equipment:
• D01018AA Hydraulic Hand Pump
• JTO7045 Hydraulic Test Gauge 0-20684 kPa (0-
3000 psi)
Procedure:
1. Park machine on level surface, park brake on.
Install boom lock pins (swing and raise-lower).
Fully lower dipperstick extension (911 only), and
swing bucket to rest on ground.
2. Stop engine. Move all hydraulic controls to relieve
internal pressure. Lower stabilizers to ground.
(Note: If backhoe attachment is removed from skid
steer loader, make sure boom locks are installed
and frame of backhoe is resting directly on the
ground and not on stabilizer legs).
M60321
4/13/95
TESTS & ADJUSTMENTS BACKHOE

3. Remove upper hose (“A” port) from dipperstick

control valve section and attach test hose from M60320
pump and gauge.
4. Pressurize control valve and note highest reading
on gauge.

Specifications:
• Dipperstick relief valve should begin opening at
17237 kPa (2500 psi).

Results:
If readings do not match specifications, inspect valve
(see Circuit Relief Valve Inspection section).

BOOM CIRCUIT RELIEF VALVE

PRESSURE TEST
3. Remove lower hose (“B” port) from boom control
Reason: valve section and attach test hose from pump and
gauge.
To relieve excessive hydraulic pressure from the head
end of the boom cylinder when the boom is being 4. Pressurize control valve and note highest reading
forced by the dipperstick, bucket, or extension (911 on gauge.
only).
Specifications:
Equipment:
• Boom relief valve should begin opening at 17237 kPa
• D01018AA Hydraulic Hand Pump
(2500 psi).
• JTO7045 Hydraulic Test Gauge 0-20684 kPa (0-
3000 psi)
Results:
Procedure: If readings do not match specifications, inspect valve
(see Circuit Relief Valve Inspection section).
1. Park machine on level surface, park brake on.
Install boom lock pins (swing and raise-lower).
Fully lower dipperstick extension (911 only), and MAIN RELIEF VALVE PRESSURE
swing bucket to rest on ground.
2. Stop engine. Move all hydraulic controls to relieve TEST
internal pressure. Lower stabilizers to ground.
(Note: If backhoe attachment is removed from skid
Reason:
steer loader, make sure boom locks are installed
and frame of backhoe is resting directly on the To protect the backhoe hydraulic system from
ground and not on stabilizer legs). excessive pressure caused by forcing the backhoe
against an immovable object, or beyond it’s range of
travel.

Equipment:
• JTO7045 Hydraulic Test Gauge 0-20684 kPa (0-
3000 psi)

Procedure:
1. Park machine on level surface, park brake on.
Install boom lock pins (swing and raise-lower).
Fully lower dipperstick extension (911 only), and
swing bucket to rest on ground. (Note: If backhoe
attachment is removed from skid steer loader,

4/13/95 10 - 15
BACKHOE REPAIR

make sure boom locks are installed and frame of Procedure:

backhoe is resting directly on the ground and not
on stabilizer legs).
2. Stop engine. Move all hydraulic controls to relieve
internal pressure. Lower stabilizers to ground.
3. Remove upper hose from control valve main relief
section and install test gauge in-line with tee fitting.
4. Start engine and run at half throttle. Raise boom
against boom lock pin and note highest reading on
gauge.
5. Stop engine.
Specifications:
• Main relief valve should open at 14479 kPa (2100
psi).
Results:
If readings do not match specifications, inspect valve
(see Main System Relief Valve Inspection section).
Specifications:
SWING CROSSOVER RELIEF VALVE
PRESSURE TEST
1. Park machine on level surface, park brake on.
Install boom lock pins (swing and raise-lower).
Fully lower dipperstick extension (911 only), and
swing bucket to rest on ground.
2. Stop engine. Move all hydraulic controls to relieve
internal pressure. Lower stabilizers to ground.
(Note: If backhoe attachment is removed from skid
steer loader, make sure boom locks are installed
and frame of backhoe is resting directly on the
ground and not on stabilizer legs).
3. Remove upper hose (“A” port) from boom swing
valve section and install hydraulic hand pump and
test gauge to hydraulic hose with tee fitting.
4. Pressurize swing cylinder against boom lock pin
and note highest reading on gauge.
5. Replace hydraulic hose to boom swing valve and
remove lower hose on boom swing control valve.
Connect hand pump and gauge as in step three.
Pressurize and note highest gauge reading.
• Boom swing crossover relief valve should open at
14824 kPa (2150 psi).

Reason: Results:

To test the crossover relief valve when the swing If readings do not match specifications, inspect valve
cylinder is loaded beyond it’s capacity. (See Boom Swing Crossover Relief Valve Inspection
section).
To Left Swing To Right Swing
Cylinder Cylinder
REPAIR

CONTROL VALVE REPAIR

CONTROL VALVE REMOVAL

Relief Valve 1. Park skid steer loader on level surface with parking
Opening brake on.
2. Raise and center boom. Insert lock pins into boom
locks (raise and swing) at base of boom.
3. Lower left and right stabilizers to ground without
Return To
putting weight of backhoe on stabilizer pads.
Pressure From
Control Valve Control Valve 4. Stop engine.

Equipment: NOTE: If backhoe attachment is removed from skid

steer loader, make sure boom locks are
• D01018AA Hydraulic Hand Pump installed and frame of backhoe is resting
• JTO7045 Hydraulic Test Gauge 0-20684.23 kPa (0- directly on the ground and not on stabilizer
3000 psi) legs.

5. Move all control valve handles to relieve all internal

pressure in all valve sections.

10 - 16 4/13/95
REPAIR BACKHOE

6. Disconnect supply and return lines to skid steer

loader by removing two quick disconnects on skid Control Lever
steer loader boom.
Lock Nut

Pivot Pin Allen Head

Retainer Mounting
Nut Screws

Pivot

Pivot Pin

Pivot Bracket

Base Bracket

M60303
t→
→
ke

6. Remove three Allen head mounting screws from

ck

→
c
Bu

r
n→
i

pivots.
r st

e
iliz

er →
e

s io

7. Loosen pivot pin retaining nuts and remove pivot

pp

m→
t ab
en

iliz

pins and spacers from valve spool.

Di

→
tS

o
t
t ab

in g
Ex

f→
Bo

8. Remove five 1/4” Allen head screws holding pivot

gh

ft S

lie
Sw

bracket and base bracket to control valve.

Ri

Re
Le

om

in
Bo

Ma

M60305 CONTROL VALVE DISASSEMBLY

1. Remove control valve from loader (see Control
7. Mark control valve sections and hoses for location Valve Removal section).
to aid assembly. 2. Remove control handle levers from control valve
8. Tag, label and remove all hydraulic hoses sections (see Control Valve Lever Removal
connected to control valve. section).
9. Remove mounting bolts holding control valve to
M60304
backhoe frame, and remove control valve.

CONTROL VALVE LEVER REMOVAL

1. Park skid steer loader on level surface with parking
brake on.
2. Raise and center boom. Insert lock pins into boom
locks (raise and swing) at base of boom.
3. Lower left and right stabilizers to ground without
putting weight of backhoe on stabilizer pads. Control Valve Retainer Bolt
4. Stop engine.
3. Remove control valve retainer bolt and separate
NOTE: If backhoe attachment is removed from skid valve sections. Note position of flat face seals
steer loader, make sure boom locks are between each section.
installed and frame of backhoe is resting
directly on the ground and not on stabilizer
legs. CONTROL VALVE SPOOL REMOVAL

5. Remove control valve cover by removing four NOTE: Spools in the six valve sections are identical,
capscrews from back of valve mounting plate. but each spool MUST be installed in the valve
section from which it was removed.

4/13/95 10 - 17
BACKHOE REPAIR

1. Remove control valve from backhoe (see Control SYSTEM RELIEF CHECK VALVE INSPECTION
Valve Removal section).
2. Remove control valve lever from slotted end of M60310
spool (see Control Valve Lever Removal section).
3. Remove two 1/4” Allen head capscrews holding
spring cover to bottom of valve section.
4. Carefully pull spool and centering spring out bottom
of valve section. Avoid scratching spool body. Cap
Spring
5. Remove top and bottom seal retainer plates, seal Relief Valve
Housing Shims
washers, and seals from valve body. Poppet

O-ring

O-ring

Valve Section

Short Spool Long Spool M60308

6. Carefully loosen spring retainer screw from spool
(spring will expand rapidly when released).
FLOW RESTRICTOR INSPECTION
1. Tag, label and remove hydraulic lines from control
valve.
2. Remove hydraulic flare fittings from control valve
ports by loosening retainer nut and turning fitting
out of valve.
3. Remove restrictor spring and restrictor from inside
control valve port.
1. Remove relief valve housing from valve section.
2. Remove cap from relief valve housing and
disassemble valve.
3. Check for broken spring or damaged poppet.
Replace valve if scratched or worn.
4. Use valve seal kit to replace all seals, washers, and
O-rings.
5. Install same number and size of shims that were
removed. Torque relief valve housing to 27 N•m
(20 lb-ft) and relief valve cap to 20 N•m (14 lb-ft).
6. Test system relief pressure. Add or subtract shims
to maintain 14479 kPa (2100 psi) relief pressure.
LOAD CHECK VALVE INSPECTION

.062 .074 .062 M60312

Spring Body

O-ring
Poppet

Body

Poppet
Spring

M60313 .062 O-ring

4. Check restrictor for wear by sizing opening with
shank of drill bit. Replace if worn.
5. Be sure restrictor spring is snapped over retainer
on restrictor body.
6. Replace restrictor and spring in port (restrictor in
first).
7. Replace flare fitting (see Service
Recommendations For O-ring Boss Fittings in
specifications section). Torque to 24 N•m (18 lb-
ft).
NOTE: All valve sections are equipped with load check
valves. Some valve sections may have
additional pressure relief valves.
1. Check poppets, springs and seats for damage.
Replace assembly as necessary.
2. Lubricate and assemble with new O-rings and
backup rings from seal kit.
3. Torque valve plug to 27 N•m (20 lb-ft).

10 - 18 4/13/95
REPAIR BACKHOE

CIRCUIT RELIEF VALVE INSPECTION 1. Thoroughly clean spool in solvent and air dry. Avoid
scratching spool body.
M60307 2. Lubricate valve section bore and spool with engine
oil.
Load Check 3. Carefully install spool into valve body. Avoid
Valve Spring scratching spool body.
I
Cartridge M60309
Spring
Cap Shims

Load Check
Valve Spring
Relief O-ring
Control Lever
O-ring Poppet Mounting Plate
Spool
Top Seal Screw
1. Check parts for damage and contaminates. Retainer Plate
Replace complete assembly if necessary. Top Seal
Top Seal
2. Lubricate and assemble with new O-rings and Washer
backup rings from seal kit.

IMPORTANT: Install the same number of shims

that were removed. DO NOT change relief valve
setting.

3. Torque cap to cartridge to 19 N•m (14 lb-ft).

4. Torque cartridge to valve body to 27 N•m (20 lb-ft).

ANTI-CAVITATION CHECK VALVE INSPECTION

M60319 Bottom Seal

Washer

Bottom Seal Bottom Seal

Load Check Valve Poppet O-ring
Load Check Valve Spring
Ball Retainer
Ball
Body
1. Be sure ball is free in retainer.
2. Lubricate and assemble with new O-rings and
backup rings from seal kit.
3. Be sure poppet is seated properly in valve body.
4. Torque body of valve to 27 N•m (20 lb-ft).
CONTROL VALVE SPOOL INSTALLATION
NOTE: Spools in the six valve sections are identical,
but each spool MUST be installed in the valve
section from which it was removed.
Retainer
Plate
Spring
Retainer Screw
Spring
Spring Cover
4. Install top and bottom spool seals over ends of
spools with lips of seals facing valve body. Push
seals down into recess in valve body.
5. Place bottom seal washer over bottom of spool with
raised lip facing away from seal.
6. Place bottom seal retainer plate over bottom of
spool and over raised lip on seal washer. Fit
retainer plate into recess in valve body.
7. Compress centering spring, spring retainers, and
retainer screw against bottom of valve body and
thread retainer screw into bottom of spool. Torque
to 13.5 N•m (10 lb-ft).
8. Install spring cover over spring. Install two 1/4”
Allen head cap screws into cover plate and torque
to 13.5 N•m (10 lb-ft).

4/13/95 10 - 19
BACKHOE REPAIR

9. Install top seal washer over top of spool with raised
lip facing away from seal.
10. Install top seal retainer plate over top of spool and
over top of raised lip on seal washer. Fit retainer
plate into recess in valve body.
CONTROL VALVE ASSEMBLY
CONTROL VALVE LEVER INSTALLATION
1. Place base bracket onto control valve housing
being sure spool seals are in place.
2. Place pivot bracket onto base bracket and install
five 1/4” Allen head screws through both brackets
and into control valve housing. Torque to 12 N•m (9
lb-ft).

1. Install three long tie rods through holes in end plate. M60303
2. Place two large and two small O-rings into
machined grooves on end plate.
3. Slide bucket control valve onto tie rods and down to Spacer
end plate. Be sure O-rings remain in place.
4. Install three large and one small O-ring into
machined grooves on bucket control valve section.
5. Slide dipperstick control valve onto tie rods and
down to bucket control valve section. Be sure O-
rings remain in place. Spacers

3. Install pivot pins into valve spools and pivot bracket.

Secure with 5/16” retainer nuts. Torque to 25 N•m
(18 lb-ft).
4. Install control handle mounting bracket onto pivots
with three 5/16” Allen head capscrews. Torque to
25 N•m (18 lb-ft).

CONTROL VALVE INSTALLATION

1. Place control valve on backhoe mounting bracket.
Line up mounting holes and install three 5/16” x 2-
1/2" mounting bolts and torque to 35 N•m (26 lb-
ft).
M60314
M60304

6. Continue to stack valve sections in order. Place

main relief valve on last and secure with three nuts.
A B C D E F G H

I J K L M N O P
)

A-Bucket Rod End I-Bucket Head End

B-Dipperstick Head End
M60311 C-Right Stabilizer Head End
D-Extension Rod End
E-Left Stabilizer Head End
7. Torque to 44 N•m (32 lb-ft). F-Boom Rod End
G-Right Swing Cylinder
H-Pressure Return
J-Dipperstick Rod End
K-Right Stabilizer Rod End
L-Extension Head End
M-Left Stabilizer Rod End
N-Boom Head End
O-Left Swing Cylinder
P-Pressure Inlet

10 - 20 4/13/95
REPAIR BACKHOE

2. Connect hydraulic cylinder hoses to control valve

as shown (see Service Recommendations For O-
ring Boss Fittings in specifications section). Torque
to 24 N•m (18 lb-ft).

BOOM SWING CROSSOVER

RELIEF VALVE REPAIR

REMOVAL
1. Park skid steer loader on level surface with parking
brake on.
2. Raise and center boom. Insert lock pins into boom
locks (raise and swing) at base of boom.
3. Lower left and right stabilizers to ground without
putting weight of backhoe on stabilizer pads.
4. Stop engine.

NOTE: If backhoe attachment is removed from skid
steer loader, make sure boom locks are
installed and frame of backhoe is resting
directly on the ground and not on stabilizer
legs.
5. Move all control valve handles to relieve all internal
pressure in all valve sections.
6. Disconnect supply and return lines to skid steer
loader by removing two quick disconnects on skid
steer loader boom.
7. Tag, label, and remove four hydraulic hoses to
crossover relief valve.
8. Remove two machine screws holding valve to
frame.
To Control
Valve Top Port
M60324
DISASSEMBLY
1. Remove valve caps and valve assemblies.
2. Clean all parts with solvent and air dry.
3. Check valve wear surfaces for scratches or scoring.
Replace whole valve assembly if scratched.
HYDRAULIC CYLINDERS
REMOVAL
1. Park skid steer loader on level surface with parking
brake on.
2. Raise and center boom. Insert lock pins into boom
locks (raise and swing) at base of boom.
3. Lower left and right stabilizers to ground without
putting weight of backhoe on stabilizer pads.
4. Stop engine.

To Control
Valve Bottom NOTE: If backhoe attachment is removed from skid
Port steer loader, make sure boom locks are
installed and frame of backhoe is resting
directly on the ground and not on stabilizer
legs. Do not remove dipperstick or bucket
hydraulic cylinders while weight of backhoe is
resting on arm. Do not remove backhoe from
skid steer loader while these cylinders are
removed or drained of oil.
M60325
5. Move all control valve handles to relieve all internal
pressure in all valve sections.
6. Disconnect supply and return lines to skid steer
loader by removing two quick disconnects on skid
steer loader boom.

4/13/95 10 - 21
BACKHOE REPAIR

7. Tag, label, and remove both hoses to hydraulic STABILIZER AND SWING CYLINDER
cylinder being serviced.

M60326
Mounting
Pin

Retainer
Bolt

8. Remove cylinder mounting pins by first removing

external snap ring or retaining bolt and nut holding
pin to frame.
9. Drive cylinder mounting pin out with suitable drift.
10. Remove cylinder from backhoe and drain out oil.

DISASSEMBLY
1. Remove gland nut from cylinder end by removing
internal snap ring (stabilizer and swing) or
unscrewing threaded gland with spanner wrench
(boom, bucket, dipperstick, and extension).
2. Pull rod from cylinder and place rod end in vise.
3. Remove seal retainer nut and seals. Lay out old
seals on bench in order of removal to aid
assembly. Do not reuse old seals. Clean all parts
with solvent and blow dry.

ASSEMBLY

M60327

Piston Nut
339 N•m (250 lb-ft)
1. Install new seals inside gland nut. Lubricate seals
and install gland on rod. Do not damage gland
seals by forcing over threads on end of rod.
2. Install piston spacers and seals on rod (dipperstick
extension cylinder shown).

M60331

10 - 22 4/13/95
REPAIR BACKHOE

BOOM, BUCKET, AND DIPPERSTICK CYLINDER

M60328
3. Install piston packing seals and rod guide bushing
(dipperstick extension cylinder shown).

M60329

4. Install rod nut (bucket cylinder shown).

5. Lubricate piston and install into cylinder.
6. Install snap ring or tighten gland nut.

DIPPERSTICK EXTENSION
(Model 911 Backhoe Only)

EXTENSION REMOVAL
1. Remove bucket from backhoe.
2. Park skid steer loader on level surface with parking
brake on.
3. Raise and center boom. Insert lock pins into boom
locks (raise and swing) at base of boom.
4. Lower left and right stabilizers to ground without
putting weight of backhoe on stabilizer pads.
5. Stop engine.

IMPORTANT: Do not remove dipperstick extension

while backhoe is removed from skid steer
Piston Nut loader. Do not remove backhoe from skid steer
407N•m( 300 lb-ft) loader while dipperstick extension is removed
from backhoe.
M60332

4/13/95 10 - 23
BACKHOE REPAIR

6. Move all control valve handles to relieve all internal

pressure in all valve sections.
7. Disconnect supply and return lines to skid steer
loader by removing two quick disconnects on skid
steer loader boom.
8. Tag, label, and remove two hoses to bucket
hydraulic cylinder. Plug end of hoses with flare end
plug.
9. Remove retainer strap holding hoses to bucket
cylinder body and pull hoses from retainer loop at
top of dipperstick.
10. Attach hoist to retainer loop at top of dipperstick.
11. Remove external snap ring from extension cylinder
bottom mounting pin located at bottom of
dipperstick just above bucket mounting pin.
12. Drive out extension cylinder mounting pin with
suitable drift. All of dipperstick weight will now be
on overhead hoist.
13. Lower hoist and slide dipperstick off of backhoe.

ANTI-FRICTION PAD REPLACEMENT

1. Remove dipperstick extension (see above).
2. Remove six self tapping screws holding anti-friction
pads to dipperstick.
3. Replace front and rear pads and apply thread
locking compound to screw threads before
installation.

CYLINDER REMOVAL
1. Tag, label and remove dipperstick extension
hydraulic lines to control valve.
2. Loosen clamps holding extension hydraulic lines
inside boom and pull excess hose to top of boom.

M60330

Cylinder
Mounting
Pin

Extension
Cylinder

3. Remove extension cylinder mounting pin from

dipperstick and slide cylinder out bottom of
dipperstick.

10 - 24 4/13/95
REPAIR BACKHOE

O-RING BOSS FITTINGS SERVICE

RECOMMENDATIONS
4. Inspect boss O-ring boss seat. It must be free of dirt
and defects. If repeated leaks occur, inspect for
defects with a magnifying glass. Some raised
defects can be removed with a slip stone.
5. Occasionally a lower durometer O-ring will seat
against a rough seat. If neither if these solutions
work, the component must be replaced. D
6. Put hydraulic oil. Petroleum jelly or soap on the O-
ring Put a thimble over the threads to protect O-
ring from nicks. Slide O-ring over the thimble and
into the turned down section of fitting (D).
7. For angle fittings (C), loosen special nut (A) and
push special washer (B) against threads so O-ring
can be installed into the turned down section of
fitting. A
8. Turn fitting into boss by hand until special washer
or washer face (straight fitting) contacts boss face B C
and O-ring is squeezed into its seat.
9. To position angle fittings, turn the fitting counter
clockwise a maximum of one turn.
10. Tighten straight fittings to torque value shown on
chart. For angle fittings, tighten the special nut to
value shown in the chart while holding body of
fitting with a wrench.

Table 1: Straight fitting or special nut torque (1)

Torque 1 Number
Thread size (lb-ft)
N-m of flats

3/8-24 UNF 8 6 2

7/16-20 UNF 12 9 2

1/2-20 UNF 16 12 2

9/16-18 UNF 24 18 2

3/4-16 UNF 46 34 2

7/8-14 UNF 62 46 1-1/2

1-1/16 UN 102 75 1

1-3/16-12 UN 122 90 1

1-5/16-12 UN 142 105 3/4

1-5/8-12 UN 190 140 3/4

1-7/8-12 UN 217 160 1/2

1
Torque tolerance is ± 10 percent.
2To be used if a torque wrench cannot be used.
Tighten fitting by hand, mark the nut or boss and then
tighten special nut or straight fitting the number of flats
shown.

4/13/95 10 - 25
BACKHOE REPAIR

10 - 26 4/13/95
CONTENTS MISCELLANEOUS

CONTENTS
Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CAB AND BOOM TILTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 3
CAB AND BOOM RETURN POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BOOM LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PARTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BOOM LOCK CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
QUICK-TACH ATTACHMENT MOUNTING SYSTEM . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
JACKING AND CRIBBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2/10/95 11 - 1
MISCELLANEOUS SPECIFICATIONS

SPECIFICATIONS

CAB TILTING
Rear Cab Support Bolts Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 N•m (80 lb-ft)
Front Cab Support Bolts Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 N•m (160 lb-ft)

QUICK-TACH ATTACHMENT MOUNTING SYSTEM

Pivot Handle Bolt Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (18 lb-ft)

ESSENTIAL TOOLS

Number Name

MG9862308 Cab Jack Kit

11 - 2 4/13/95
CAB AND BOOM TILTING PROCEDURE MISCELLANEOUS

CAB AND BOOM TILTING pressure in the hydraulic system and turn the key
switch to the OFF position.
PROCEDURE

c
CAUTION: NEVER attempt to tilt
the skid-steer loader cab without
proper instructions and using the
proper tool to insure a safe tilting
procedure and to prevent damage
to the loader frame, cab and boom
structure.

c
CAUTION: Never attempt to tilt the
cab with any attachment M57115

connected to the boom. 4. Jack up the loader and block it securely with all four
wheels off the ground. Position the front blocks to
the front of the final drive housings and the rear
blocks to the rear of the flat area of the final drive
housings.

c CAUTION: NEVER attempt to tilt

the skid-steer loader cab over
unless the loader is securely
supported.

B A
M57130
E

1. Remove any attachment from the boom Quick-Tach D

plate.

M57949

5. Open the rear door (A) raise the top engine shield
(B) and latch in raised position.
6. Remove engine side covers (C).
Boom Lock Pin 7. Remove fenders (D) right and left sides.
M57961
8. Remove foam material (E) from both sides.
9. Remove rear fenders supports (F) from right and left
sides.
2. Raise the boom, engage boom lock pins and lower
onto boom lock pins.
3. Stop the engine, actuate the footpedals to relieve

4/13/95 11 - 3
MISCELLANEOUS CAB AND BOOM TILTING PROCEDURE

Cotter Pin

Battery Negative Cable

Link Rod

M57950
M57953

10. Disconnect the battery negative (-) cable.

. 13. Remove the cotter pins from the parking brake
linkage. Disconnect link rod and raise the parking
brake lever to engaged position.

Spacer
Spacer

Capscrew

Seat Pan Latch

Wingnut

Lower Cab Jack Support M57962

Front Step Shield

M57952 14. Install the lower cab jack support. Hook the support
over the end of the front final drive housing and
attach with a 1/2 x 8 inch capscrew, two spacers,
one each side of housing and 1/2 inch wingnut.
11. Raise seat and lock in the up position. Make sure
the seat pan assembly is latched securely.
12. Remove the front step shield.

11 - 4 4/13/95
CAB AND BOOM TILTING PROCEDURE MISCELLANEOUS

D A

C
A B

E A

C
B
D
M57963 M57964

15. Install the upper cab jack support (A). The spacer
channel (B) is not used for the 8875 model. Pivot
the retaining plate (C) up behind the boom top link
and secure with 1/2 x 1-1/4 inch carriage bolt and 1/
2 inch wing nut at (D). Install 1/2 x 2-1/2 inch
17. Install the jack assembly (A) between the upper
and lower supports using two pins and retaining
clips.

c
retaining bolt (E) through side of cab with a large 1/2 CAUTION: Never loosen or
inch flat washer, 1/2 inch wing nut to the inside of remove any cab retaining
cab and tighten. hardware before the cab tilting
jack and brackets are installed.
Failure to do so may cause cab to
fall causing serious injury or
death.

18. Loosen the front cab mounting bolts (B) enough to

allow the bolt to rotate in the post and remove the
rear front cab bolts (C).
19. Remove the four rear cab post bolts (D).

M57968

16. Check spacer for correct position before installing

jack assembly.

Jack Stand M57969

4/13/95 11 - 5
MISCELLANEOUS CAB AND BOOM TILTING PROCEDURE

20. Be sure all wire harnesses, hydraulic hoses, and

throttle cable clear any obstructions during cab
tilting. Jack cab and boom assembly over with the
loader properly supported off the ground. B
21. After the cab is tilted, support the boom and cab
with a jack stand to prevent tipping of the loader
when heavy components, engine, hydrostatic
pumps etc. are removed from the lower frame. Jack
travel will limit the travel of the cab assembly to
prevent over travel.
A
C
CAB AND BOOM RETURN
POSITION D

M57966

5. Install front and rear cab support bolts and start

threads in bottom frame.
6. Lower cab to frame.
7. Tighten the rear bolts (A) to 108 N•m (80 lb-ft).
C
8. Connect the parking brake linkage (B).
9. Position the throttle cable (C) inside frame.
10. Install the rear fender supports (D).
A B

M57964

B
D
1. Pull the steering control handles forward and hold in
this position with rubber tie straps from the handle to E
the front post.
2. Watch the wire harnesses, hydraulic hoses, and
throttle cable position and carefully jack the cab and A
C
boom back down until within one inch of bottom
frame.
3. Keep the wire harness (A) and throttle cable (B) in
position to prevent damage from setting cab on
them. M57967
4. Pull the wire harness through the loop (C).

11. Tighten the front bolts (A) to 217 N•m (160 lb-ft).

c CAUTION: NEVER attempt to

operate or move the skid-steer
loader without first installing and
properly tightening all cab
retaining hardware.
12. Install foam (B), fenders (C) and front step shield
(D).
13. Remove cab jack and supports (E).
14. Connect the battery cable.
15. Install engine side covers.

11 - 6 4/13/95
BOOM LOCK MISCELLANEOUS

BOOM LOCK

PARTS LOCATION

A
K

L
C
F

N
O

M
N
J
P
E
G
P
H
E I
D
A

M58787

A. Pin I. Grommet
B. Rod J. Rod
C. Angle K. Sleeve
D. Cap Screw L. Cotter Pin
E. Nut M. Cap Screw
F. Spring N. Washer
G. Screw O. Lock nut
H. Washer P. Nut

4/13/95 11 - 7
MISCELLANEOUS BOOM LOCK

THEORY OF OPERATION

FUNCTION
The boom lock system is provided as a mechanical safety system to retain the boom in the up position.

THEORY
The boom lock consists of a pair of two inch solid steel pins, located in the rear cab uprights, connected by a
mechanical linkage and a lever located in the right hand side of the operators cab.
The boom lock is engaged by raising the boom to its uppermost extent and then rotating the lever in the operators
cab in a clock wise direction until the pins fully extend. Then the boom is lowered onto the pins.

CAB UPRIGHT

LEVER PINS

LINKAGE

CONNECTING ROD

M58783

11 - 8 4/13/95
BOOM LOCK MISCELLANEOUS

TROUBLESHOOTING

Locks Will Not Disengage

Boom Only Rests On One

Only One Lock Engages
Problem or
Symptom

Locks Will Not Move

Check or
Solution

Lock
Bent Or Broken Linkage Rod.
Repair and /or replace as ● ● ●
required.

Boom Resting On Locks. Raise

●
boom off locks.

Damaged Pins. Check pins

repair and /or replace as ●
required.

Bent Boom Arms. ●

Dirt In Pin Bushing.

Disassemble and clean Pins ● ● ●
And Bushings

DIAGNOSTICS
Test Conditions:

• 0perator in seat

• Seat belt fastened

• Engine running

• Boom in full up position

Test/Check Point Normal If Not Normal

1. Control lever
Lever should move freely. Pins Bent or broken linkage rod. Repair
should slide easily out to full and/or replace as required.
extension Damaged pins. Check pins repair
and/or replace as required.
Dirt in pin bushing. Disassemble
and clean pins and bushings

2. Boom resting on pins Boom should contact both pins Bent boom arms. Repair and/or
evenly replace as required.
Damaged pins. Check pins repair
and/or replace as required.

4/13/95 11 - 9
MISCELLANEOUS BOOM LOCK

BOOM LOCK CHECK PIN REMOVAL

Reason: IMPORTANT: Pins should only be removed when

the boom is in a lowered position.
To insure the free and accurate activation of the boom
locking system.

Procedure:
1. Start engine and raise boom.
2. Activate mechanical boom lock. PIN
3. Lower boom to rest on lock arms.

Specifications:
1. Lock pins must move to lock position smoothly and
with no binding.

M58788

1. Open and support engine cover.

LEFT SIDE

47.5 mm
(1-7/8 in)

M58785

2. Lock pins should extend a minimum of 47.5 mm (1- PUSH NUT

7/8 in) from sides of cab frame.
3. Boom arms must rest solidly on both lock arms.

Results: M58785

• If steps 1 and 2 are not met, repair and/or replace 2. Remove push nut from end of link.
pins and/or mechanism. 3. Remove link from pin.
• If step 3 is not met, replace and/or repair boom 4. Slide pin from bushing.
arms.

11 - 10 4/13/95
QUICK-TACH ATTACHMENT MOUNTING SYSTEM MISCELLANEOUS

When the lever handle is lowered, the striker spring

RIGHT SIDE and the striker are pushed down to the bottom of their
travel. When the handle is locked down, the striker
spring is compressed, keeping tension on the striker to
keep it engaged with the attachment.

NUT
REPAIR
BOLT
DISASSEMBLY
1. Remove attachment from skid steer loader.
2. Park machine on level surface, park brake on, boom
raised so Quick-Tach plate is at a comfortable
working height and rolled forward to a 45 degree
angle.
3. Raise handle of Quick-Tach to release tension on
striker spring.
4. Remove L shaped striker cover plate from the
outside edge of Quick-Tach housing by removing
two machine screws (one on side and one on rear of
housing).
M58786
5. Using a punch, drive out roll pin from slot in Quick-
5. Remove nut and bolt attaching pin to linkage. Tach plate. Remove striker by sliding out bottom of
Quick-Tach plate.
6. Slide pin from bushing.
6. Remove handle pivot bolt and spacers from Quick-
7. Reassembly is reverse of disassembly.
Tach plate. Pull handle and striker spring assembly
from Quick-Tach housing.
QUICK-TACH ATTACHMENT
MOUNTING SYSTEM Spacers

Handle
Handles
Pivot Bolt

Striker
Spring
Striker
Roll Pin

M57751 Striker

OPERATION
Striker Striker
The Quick-Tach attachment mounting system allows Roll Pin
fast attachment changes from the operator’s station.
M58777
When the handle is raised, the spring loaded striker pin
extended below the bottom of the Quick-Tach plate is
retracted into the housing. This allows the attachment
to be lowered to the ground by rolling the Quick-Tach ASSEMBLY
plate forward with the hydraulic system. 1. Place handle and striker spring assembly into Quick-

4/13/95 11 - 11
MISCELLANEOUS JACKING AND CRIBBING

Tach housing. Align handle pivot hole with pivot bolt

hole in housing. Install pivot bolt with spacers and
tighten to 25 N•m (18 lb-ft).
2. Install striker into Quick-Tach housing (with taper to
rear) and align roll pin hole with striker spring.
3. Install roll pin using a suitable punch or drift.
4. Install side cover plate.

JACKING AND CRIBBING

Reason:
M60301
To make the skid steer loader stable for repair with the 9. Build alternating rows of hardwood cribbing under
tires and wheels removed. This procedure must be left and right side frame rails in line with front axles.
followed when tilting the cab over for major repairs to 10. Lower skid steer loader onto cribbing.
the drive system.
11. Place floor jack under rear of loader in line with rear
axle. Be sure to center jack between tires and to
Procedure: jack on only the flat bottom of the frame.
1. Remove all attachments and weights from skid steer
loader.
2. Park skid steer loader on level surface.
3. Engage parking brake.
4. Roll back Quick-Tach plate.
5. Use the following to determine boom position:
• If access is needed to engine compartment or if cab
will be tilted over, raise boom to top of travel and
lower onto boom locks.
• For all other repair, lower boom to bottom of travel.
M58779
6. Stop engine.

NOTE: If chain cases are to be drained, do not block

chain case drain at bottom rear of frame side
member.

12. Build alternating rows of hardwood cribbing under

left and right side frame rails in line with rear axles.
Lower skid steer loader onto cribbing.
13. Remove wheels from loader.

M60300
7. Place floor jack under front of loader in line with front
axle. Be sure to center jack between tires.
8. Jack loader until front tires raise four to five inches
off ground.

11 - 12 4/13/95

A Camshaft Installation . . . . . . . . . . . . . . . . . . . . . .3 - 87
Air Filter Restriction Light Diagnosis . . . . . . . . . .4 - 58
Air Filter Restriction Light Operation . . . . . . . . . .4 - 54
Air Intake System Diagnosis . . . . . . . . . . . . . . . .3 - 25
Air Intake System Inspection . . . . . . . . . . . . . . . .3 - 29
Alternative Lubricants . . . . . . . . . . . . . . . . . . . . .2 - 8
Alternator - Inspection/test . . . . . . . . . . . . . . . . . .4 - 95
Alternator, Service . . . . . . . . . . . . . . . . . . . . . . .4 - 93
Altitude Compensation Guidelines . . . . . . . . . . . .3 - 124
Assembly - Alternator . . . . . . . . . . . . . . . . . . . . .4 - 97
Automatic Preheat . . . . . . . . . . . . . . . . . . . . . . . .4 - 40
Auxiliary Handle, Disassembly. . . . . . . . . . . . . . .7 - 18
Axle Assembly Installation . . . . . . . . . . . . . . . . . .5 - 15
Axle Assembly Removal . . . . . . . . . . . . . . . . . . .5 - 15
Axle Disassembly & Assembly. . . . . . . . . . . . . . .5 - 16
Axle Housing Mounting Bolt R & R . . . . . . . . . . .5 - 16
B Component Location - Hydro Hoses . . . . . . . . . .6 - 8
Battery Load Test . . . . . . . . . . . . . . . . . . . . . . . .4 - 71
Battery Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 70
Blown Fuse Symptoms . . . . . . . . . . . . . . . . . . . .4 - 87
Boom & Bucket Lock Solenoid Check . . . . . . . .9 - 16
Boom Relief Valve Test, Backhoe . . . . . . . . . . . .10 -15
Boom Drift Down Check. . . . . . . . . . . . . . . . . . . .9 - 19
Boom Drift Up Check . . . . . . . . . . . . . . . . . . . . . .9 - 20
Boom Lift Check Test. . . . . . . . . . . . . . . . . . . . . .9 - 19
Boom Lock Check . . . . . . . . . . . . . . . . . . . . . . . .10 -10
Boom Lock Check . . . . . . . . . . . . . . . . . .9 - 20, 10 -10
Boom Lock Pin Removal . . . . . . . . . . . . . . . . . . .10 -10
Boom Operation Check . . . . . . . . . . . . . . . . . . . .9 - 16
Boom Relief Valve Repair, Backhoe . . . . . . . . . .10 -21
Brakes, Component Location . . . . . . . . . . . . . . .8 -5
Brakes, Diagnosis . . . . . . . . . . . . . . . . . . . . . . . .8 - 6
Brakes, Repair . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 10
Brakes, Specifications . . . . . . . . . . . . . . . . . . . . .8 - 3
Brakes, Tests And Adjustments . . . . . . . . . . . . .8 - 9
Brakes, Troubleshooting . . . . . . . . . . . . . . . . . . .8 - 8
Brushes - Inspection/test . . . . . . . . . . . . . . . . . .4 - 95
Bucket Relief Valve Test, Backhoe . . . . . . . . . . .10 -14
Bucket Cylinder Location . . . . . . . . . . . . . . . . . .9 - 12
Bucket Cylinder Repair . . . . . . . . . . . . . . . . . . . .9 - 36
Bucket Cylinders Installation . . . . . . . . . . . . . . . .9 - 37
Bucket Cylinders Removal . . . . . . . . . . . . . . . . .9 - 36
Bucket Drift Dump Position Check . . . . . . . . . . .9 - 20
Bucket Drift Rollback Check . . . . . . . . . . . . . . . .9 - 20
Bucket Operation Check . . . . . . . . . . . . . . . . . . .9 - 16
C Control Valve, Component Location . . . . . . . . . .9 - 10
Cab & Boom Return . . . . . . . . . . . . . . . . . . . . . .10 -6
Cab & Boom Tilting Procedure . . . . . . . . . . . . . .10 -3
Camshaft And Timing Gear Repair . . . . . . . . . . .3 - 78
Camshaft Bearing Bore Measure. . . . . . . . . . . . .3 - 57
Camshaft Bearing Measurement . . . . . . . . . . . .3 - 81
Camshaft Bushing Replacement . . . . . . . . . . . .3 - 82
Camshaft End Play Measurement . . . . . . . . . . .3 - 79
Camshaft Follower Bore Measurement. . . . . . . .3 - 56
Camshaft Follower Inspection . . . . . . . . . . . . . . .3 - 82
Camshaft Follower Removal . . . . . . . . . . . . . . . .3 - 35
Camshaft Gear Replacement . . . . . . . . . . . . . . .3 - 81
Camshaft Inspection . . . . . . . . . . . . . . . . . . . . . .3 - 80
2/13/95
INDEX
Camshaft Removal . . . . . . . . . . . . . . . . . . . . . . .3 - 80
Camshaft Thrust Plate Clearance . . . . . . . . . . . .3 - 80
Centering Mechanism Removal . . . . . . . . . . . . .7 - 15
Chain Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 13
Chain Case Oil . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8
Chain Case Oil Change . . . . . . . . . . . . . . . . . . .5 - 13
Chain Case Oil Level Check . . . . . . . . . . . . . . . .5 - 13
Chain Case Side Cover Removal & Installation. .5 - 13
Charge Battery . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 70
Charge Pump System Pressure Test . . . . . . . . .9 - 17
Charge, Volt, & Battery Light Diagnosis. . . . . . . .4 - 28
Charge, Volt, And Battery Light Operation. . . . . .4 - 26
Clean Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 29
Common Circuit Tests . . . . . . . . . . . . . . . . . . . . .4 - 5
Complete Final Assembly . . . . . . . . . . . . . . . . . .3 - 45
Component Location - Hydro Pump. . . . . . . . . . .6 - 9
Component Location - Hydro Motor . . . . . . . . . .6 - 11
Component Location Backhoe, Boom
And Dipperstick Hydraulic System . . . . . . . . . .10 -7
Component Location Backhoe, Boom
Swing Hydraulic System . . . . . . . . . . . . . . . . .10 -8
Component Location Backhoe, Stabilizer
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . .10 -9
Component Location- Control Valve . . . . . . . . . .9 - 10
Component Location, Aux. Handle . . . . . . . . . . .7 - 5
Component Location, Backhoe Bucket And
Extension Hydraulic System . . . . . . . . . . . . . .10 -6
Component Location, Electrical . . . . . . . . . . . . .4 - 13
Component Location, Gearbox . . . . . . . . . . . . . .5 - 6
Component Location, Gear Power Train . . . . . . .5 - 4
Component Location, Hydraulic Pump. . . . . . . . .9 - 11
Component Location, Hydrostatic
Pump Backplates . . . . . . . . . . . . . . . . . . . . .6 - 10
Component Location, Lift Cylinder . . . . . . . . . . .9 - 13
Component Location, Steering . . . . . . . . . . . . . .7 - 4
Component Location-cylinders . . . . . . . . . . . . . .9 - 8
Component Location-miscellaneous . . . . . . . . . .9 - 9
Connecting Rod And Cap Inspection . . . . . . . . .3 - 54
Connecting Rod Pin Bore Cleaning . . . . . . . . . . .3 - 55
Control Arm Adjust - Centering . . . . . . . . . . . . . .7 - 12
Control Handle Adjustment . . . . . . . . . . . . . . . . .7 - 13
Control Lever Stop Adjustment . . . . . . . . . . . . . .7 - 13
Control Valve Repair, Backhoe . . . . . . . . . . . . . .10 -16
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 95
Cooling System Pressure Test . . . . . . . . . . . . . .3 - 29
Cooling System Testing . . . . . . . . . . . . . . . . . . .3 - 95
Crankcase Vent Inspection . . . . . . . . . . . . . . . . .3 - 28
Cranking Circuit Diagnosis . . . . . . . . . . . . . . . . .4 - 24
Cranking Circuit Operation . . . . . . . . . . . . . . . . .4 - 22
Crankshaft Diagnosis . . . . . . . . . . . . . . . . . . . . .3 - 20
Crankshaft End Play Check . . . . . . . . . . . . . . . .3 - 65
Crankshaft Front Oil Seal Install . . . . . . . . . . . . .3 - 88
Crankshaft Gear Removal . . . . . . . . . . . . . . . . . .3 - 71
Crankshaft Main Bearing Cap Measure . . . . . . . .3 - 73
INDEX - 1
INDEX
Crankshaft Main Bearing Clearance Check . . . . 3 - 70
Crankshaft Main Bearing Measurement . . . . . . . 3 - 71
Crankshaft Pulley Installation . . . . . . . . . . . . . . . 3 - 64
Crankshaft Pulley Removal . . . . . . . . . . . . . . . . 3 - 63
Crankshaft Rear Oil Seal Installation . . . . . . . . . 3 - 68
Crankshaft Rear Oil Seal Removal . . . . . . . . . . 3 - 68
Crankshaft Removal . . . . . . . . . . . . . . . . . . . . . . 3 - 71
Crankshaft Rotation Torque . . . . . . . . . . . . . . . . 3 - 62
Crankshaft Thrust Bearing & Journal Measure . 3 - 72
Crankshaft, Main Bearings, & Flywheel Repair. . 3 - 63
Crankshaft Grinding Guidelines . . . . . . . . . . . . . 3 - 73
Cylinder Block Cleaning & Inspection . . . . . . . . . 3 - 55
Cylinder Block Flatness Measure . . . . . . . . . . . . 3 - 57
Cylinder Block Main Bearing Bore Measurement 3 - 56
Cylinder Block Repair . . . . . . . . . . . . . . . . . . . . . 3 - 46
Cylinder Block Top Deck Cleaning & Inspection . 3 - 42
Cylinder Head And Valve Diagnosis . . . . . . . . . 3 - 19
Cylinder Head Bolt Inspection . . . . . . . . . . . . . . 3 - 42
Cylinder Head Flatness . . . . . . . . . . . . . . . . . . . 3 - 38
Cylinder Head Inspection . . . . . . . . . . . . . . . . . . 3 - 38
Cylinder Head Installation . . . . . . . . . . . . . . . . . 3 - 43
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . 3 - 33
Cylinder Head Repair . . . . . . . . . . . . . . . . . . . . . 3 - 33
Cylinder Head Thickness . . . . . . . . . . . . . . . . . . 3 - 38
Cylinder Liner Cleaning . . . . . . . . . . . . . . . . . . . 3 - 50
Cylinder Liner Degazing . . . . . . . . . . . . . . . . . . . 3 - 53
Cylinder Liner Flange Thickness Measurement . 3 - 58
Cylinder Liner Height Measurement . . . . . . . . . . 3 - 47
Cylinder Liner Height Measurement . . . . . . . . . . 3 - 58
Cylinder Liner Inspection . . . . . . . . . . . . . . . . . . 3 - 50
Cylinder Liner Installation . . . . . . . . . . . . . . . . . . 3 - 60
Cylinder Liner O-ring Installation . . . . . . . . . . . . . 3 - 59
Cylinder Liner Removal . . . . . . . . . . . . . . . . . . . 3 - 48
Cylinder Liner, Piston, And
Connecting Rod Diagnosis . . . . . . . . . . . 3 - 18
Cylinders, Component Location . . . . . . . . . . . . . 9 - 8
D Front Plate Removal . . . . . . . . . . . . . . . . . . . . . . 3 - 83
Diagnosing Engine Malfunctions . . . . . . . . . . . . 3 - 16
Diagnosis, Diesel Engine . . . . . . . . . . . . . . . . . . 3 - 16
Diagnosis, Gear Power Train . . . . . . . . . . . . . . . 5 - 8
Diagnostic Information . . . . . . . . . . . . . . . . . . . . 4 - 5
Diagnostics, Backhoe . . . . . . . . . . . . . . . . . . . . . 10 -12
Diagnostics, Boom Lock . . . . . . . . . . . . . . . . . . . 10 -9
Diagnostics, Hydraulics . . . . . . . . . . . . . . . . . . . 9 - 15
Diagnostics, Hydro Power Train . . . . . . . . . . . . . 6 - 13
Diagnostics, Steering . . . . . . . . . . . . . . . . . . . . . 7 - 8
Diesel Fuel Storage . . . . . . . . . . . . . . . . . . . . . . 2 - 6
Diesel Fuel Specifications . . . . . . . . . . . . . . . . . 2 - 6
Diesel Fuel Storage . . . . . . . . . . . . . . . . . . . . . . 2 - 6
Dipperstick Circuit Relief Valve
Pressure Test, Backhoe . . . . . . . . . . . . . 10 -14
Dipperstick Extension, Backhoe . . . . . . . . . . . . . 10 -23
Dipstick Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 91
Drive Chain And Sprocket Install. . . . . . . . . . . . . 5 - 14
Drive Chain And Sprocket Removal . . . . . . . . . . 5 - 14
Drive Chain Tension Adjustment . . . . . . . . . . . . 5 - 14
E Fuel Injection Pump Timing Mark . . . . . . . . . . . . 3 - 112
Electrical Relay / Solenoid Tests . . . . . . . . . . . . 4 - 78
INDEX - 2
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . 4 - 14
Electrical Switch Tests . . . . . . . . . . . . . . . . . . . . 4 - 76
Electronic Instrument Panel Module Operation . 4 - 6
Electronic Instrument Panel Test . . . . . . . . . . . . 4 - 80
Engine Assembly Sequence . . . . . . . . . . . . . . . 3 - 32
Engine Break-in Procedure . . . . . . . . . . . . . . . . 3 - 63
Engine Compression Testing . . . . . . . . . . . . . . . 3 - 27
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8
Engine Coolant Temperature Light Diagnosis . . 4 - 50
Engine Coolant Temperature Light Operation . . 4 - 48
Engine Disassembly Sequence . . . . . . . . . . . . . 3 - 32
Engine Final Assembly . . . . . . . . . . . . . . . . . . . . 3 - 77
Engine Front Plate Replacement . . . . . . . . . . . . 3 - 85
Engine Lifting Procedure . . . . . . . . . . . . . . . . . . 3 - 30
Engine Oil Pressure Light Diagnosis . . . . . . . . . 4 - 46
Engine Oil Pressure Light Circuit Operation . . . . 4 - 42
Engine Oil Pressure Test . . . . . . . . . . . . . . . . . . 3 - 28
Engine Oil Specifications . . . . . . . . . . . . . . . . . . 2 - 7
Engine Preliminary Testing . . . . . . . . . . . . . . . . 3 - 27
Engine Rear Plate Installation . . . . . . . . . . . . . . 3 - 76
Engine Rear Plate Removal . . . . . . . . . . . . . . . . 3 - 69
Engine Removal (Cab Tilted) . . . . . . . . . . . . . . . 3 - 29
Engine Repair Stand . . . . . . . . . . . . . . . . . . . . . 3 - 30
Engine Serial Number . . . . . . . . . . . . . . . . . . . . 2 - 10
Exhaust Manifold Inspection . . . . . . . . . . . . . . . . 3 - 42
Exhaust Manifold Repair . . . . . . . . . . . . . . . . . . 3 - 110
Exhaust System Check . . . . . . . . . . . . . . . . . . . 3 - 29
F
Fan Blade Inspection & Installation . . . . . . . . . . 3 - 99
Flywheel Housing Installation . . . . . . . . . . . . . . . 3 - 76
Flywheel Housing Removal . . . . . . . . . . . . . . . . 3 - 64
Flywheel Inspection . . . . . . . . . . . . . . . . . . . . . . 3 - 66
Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . 3 - 67
Flywheel Pilot Bearing Replacement . . . . . . . . . 3 - 66
Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . . 3 - 65
Flywheel Ring Gear Replacement . . . . . . . . . . . 3 - 66
Fuel Drain Back Test . . . . . . . . . . . . . . . . . . . . . 3 - 29
Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . 3 - 110
Fuel Gauge Sender . . . . . . . . . . . . . . . . . . . . . . 4 - 75
Fuel Injection Nozzle Adjustment . . . . . . . . . . . . 3 - 121
Fuel Injection Nozzle Assembly . . . . . . . . . . . . . 3 - 121
Fuel Injection Nozzle Bore Cleaning . . . . . . . . . 3 - 117
Fuel Injection Nozzle Cleaning . . . . . . . . . . . . . . 3 - 120
Fuel Injection Nozzle Diagnosis . . . . . . . 3 - 23, 3 - 24
Fuel Injection Nozzle Disassemble . . . . . . . . . . . 3 - 119
Fuel Injection Nozzle Installation . . . . . . . . . . . . 3 - 123
Fuel Injection Nozzle Removal . . . . . . . . . . . . . . 3 - 116
Fuel Injection Nozzle Seal Install . . . . . . . . . . . . 3 - 123
Fuel Injection Nozzle Tests . . . . . . . . . . . . . . . . 3 - 118
Fuel Injection Nozzle Valve Adjustor Inspection 3 - 121
Fuel Injection Nozzle Valve Seat Inspection . . . . 3 - 120
Fuel Injection Pump Diagnosis . . . . . . . . . . . . . . 3 - 25
Fuel Injection Pump Install . . . . . . . . . . . 3 - 87, 3 - 114
Fuel Injection Pump Repair 3 - 114
Fuel Injection Pump Timing . . . . . . . . . . . . . . . . 3 - 113
Fuel Level Display Circuit Diagnosis . . . . . . . . . 4 - 60
2/13/95

Fuel Level Display Circuit Operation . . . . . . . . . .4 - 54
Fuel Pump Installation . . . . . . . . . . . . . . . . . . . .3 - 112
Fuel Pump Removal . . . . . . . . . . . . . . . . . . . . . .3 - 111
Fuel Pump Testing . . . . . . . . . . . . . . . . . . . . . . .3 - 111
Fuel Shutoff Solenoid Diagnosis . . . . . . . . . . . . .4 - 34
Fuel Shutoff Solenoid Operation . . . . . . . . . . . . .4 - 32
Fuel Supply Pump Diagnosis . . . . . . . . . . . . . . .3 - 22
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 110
Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . .3 - 21
Fuel System, Theory Of Operation . . . . . . . . . . .3 - 15
G Hydrostatic Pump Rotating Assembly Install . . .6 - 31
Gear Box Installation . . . . . . . . . . . . . . . . . . . . . .5 - 13
Gear Power Train Repair . . . . . . . . . . . . . . . . . .5 - 9
Gearbox Bearing & Seal Replacement . . . . . . . .5 - 10
Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . .5 - 10
Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8
Gearbox Oil Level Check . . . . . . . . . . . . . . . . . .5 - 9
Gearbox Reassembly . . . . . . . . . . . . . . . . . . . . .5 - 10
Gearbox Removal . . . . . . . . . . . . . . . . . . . . . . . .5 - 9
Gearbox, Component Location . . . . . . . . . . . . . .5 - 6
General Specifications, Diesel Engine . . . . . . . .3 - 7
General Vehicle Specifications . . . . . . . . . . . . . .2 - 2
Gerotor Pump . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 23
Glow Plug And Light Operation . . . . . . . . . . . . . .4 - 36
Glow Plug/manifold Heater And Light Diagnosis .4 - 38
Grease Specifications . . . . . . . . . . . . . . . . . . . . .2 - 7
Ground Circuit Test . . . . . . . . . . . . . . . . . . . . . . .4 - 86
H Injection Nozzle Cleaning . . . . . . . . . . . . . . . . . .3 - 117
Handle Chemical Products Safely . . . . . . . . . . .1 - 2
Handle Fluids Safely . . . . . . . . . . . . . . . . . . . . . .1 - 2
Handling And Servicing Batteries . . . . . . . . . . . .1 - 3
High- Pressure Fluid Lines . . . . . . . . . . . . . . . . .1 - 3
Hoses & Lines Location, Hydrostatic . . . . . . . . .6 - 8
Hourmeter Circuit Operation . . . . . . . . . . . . . . . .4 - 26
Hydraulic Boom And Bucket Lockout Diagnosis .4 - 64
Hydraulic Boom And Bucket Lockout Operation .4 - 62
Hydraulic Charge Pressure Light Diagnosis . . . .4 - 44
Hydraulic Charge Pressure Light Operation . . . .4 - 42
Hydraulic Cylinders, Backhoe . . . . . . . . . . . . . . .10 -21
Hydraulic Oil Filter Restriction Light Diagnosis . .4 - 56
Hydraulic Oil Filter Restriction Light Operation . .4 - 54
Hydraulic Oil Temperature Light Operation . . . .4 - 48
Hydraulic Oil Temperature Light Diagnosis . . . . .4 - 52
Hydraulic Pump Assembly . . . . . . . . . . . . . . . . .9 - 24
Hydraulic Pump Component Inspect . . . . . . . . . .9 - 23
Hydraulic Pump Disassembly . . . . . . . . . . . . . . .9 - 21
Hydraulic Pump Installation . . . . . . . . . . . . . . . .9 - 26
Hydraulic Pump Removal . . . . . . . . . . . . . . . . . .9 - 21
Hydraulic Pump, Component Location . . . . . . . .9 - 11
Hydraulic Start-up Procedure . . . . . . . . . . . . . . .9 - 37
Hydraulic System Component Location . . . . . . . .9 - 6
Hydraulic System Schematic . . . . . . . . . . . . . . .9 - 7
Hydraulic System Schematic, Backhoe . . . . . . .10 -5
Hydro Case Drain Pressure Test . . . . . . . . . . . .6 - 18
Hydro Component Location . . . . . . . . . . . . . . . .6 - 5
Hydro High Pressure Relief Test . . . . . . . . . . . .6 - 20
Hydro Motor Case Drain Flow Test . . . . . . . . . . .6 - 14
Hydro Motor, Assembly . . . . . . . . . . . . . . . . . . . .6 - 43
2/13/95
INDEX
Hydro Motor, Component Location . . . . . . . . . . .6 - 11
Hydrostatic Motor, Disassembly . . . . . . . . . . . . .6 - 39
Hydrostatic Motor, Inspection . . . . . . . . . . . . . . .6 - 42
Hydrostatic Motor, Installation . . . . . . . . . . . . . . .6 - 46
Hydrostatic Motor, Removal . . . . . . . . . . . . . . . .6 - 38
Hydro Pump Case Drain Flow Test . . . . . . . . . . .6 - 16
Hydrostatic Pump Disassembly . . . . . . . . . . . . .6 - 23
Hydro Pump Drive Shaft Installation . . . . . . . . . .3 - 77
Hydro Pump Drive Shaft Seal Repair. . . . . . . . . .3 - 65
Hydrostatic Pump Removal . . . . . . . . . . . . . . . . .6 - 22
Hydrostatic Pump, Assembly . . . . . . . . . . . . . . .6 - 30
Hydrostatic Pump, Exploded View . . . . . . . . . . .6 - 9
Hydrostatic Pump, Exploded View
(Pump Backplates) . . . . . . . . . . . . . . . . .6 - 10
Hydrostatic Pump, Inspection . . . . . . . . . . . . . . .6 - 28
Hydrostatic Pumps Installation . . . . . . . . . . . . . .6 - 35
Hydrostatic System Schematic . . . . . . . . . . . . . .6 - 7
Hydro System, Troubleshooting . . . . . . . . . . . . .6 - 12
Hydrostatic Two Speed Component Location . . .6 - 6
I
Idler Gear Bushing Replacement . . . . . . . . . . . .3 - 85
Idler Gear End Play Measurement . . . . . . . . . . .3 - 79
Idler Gear Installation . . . . . . . . . . . . . . . . . . . . .3 - 88
Idler Gear Shaft Removal . . . . . . . . . . . . . . . . . .3 - 85
Idler Shaft Installation . . . . . . . . . . . . . . . . . . . . .3 - 86
Inch Torque Values . . . . . . . . . . . . . . . . . . . . . . .2 - 4
Injection Pump Drive Gear Inspect . . . . . . . . . . .3 - 114
Injection Pump Removal . . . . . . . . . . . . . . . . . . .3 - 113
Injector Bore Cleaning . . . . . . . . . . . . . . . . . . . . .3 - 39
Install Engine Front Plate . . . . . . . . . . . . . . . . . .3 - 86
Install Turbocharger . . . . . . . . . . . . . . . . . . . . . .3 - 108
Intake Manifold Pressure (Turbo Boost) Test . . .3 - 28
Intake Manifold Repair . . . . . . . . . . . . . . . . . . . .3 - 109
J
Jacking And Cribbing . . . . . . . . . . . . . . . . . . . . .10 -12
L
Lift Arm Cylinder Repair . . . . . . . . . . . . . . . . . . .9 - 34
Lift Arm Cylinders Installation . . . . . . . . . . . . . . .9 - 35
Lift Arm Cylinders Removal . . . . . . . . . . . . . . . . .9 - 33
Lift Cylinder, Component Location . . . . . . . . . . .9 - 13
Liner O-ring Bore Cleaning . . . . . . . . . . . . . . . . .3 - 56
Live With Safety . . . . . . . . . . . . . . . . . . . . . . . . .1 - 6
Lubricant Specifications . . . . . . . . . . . . . . . . . . .2 - 7
Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . . .2 - 8
Lubrication System . . . . . . . . . . . . . . . . . . . . . . .3 - 89
Lubrication System Operation . . . . . . . . . . . . . . .3 - 14
M
Main Bearing & Crankshaft Installation . . . . . . . .3 - 75
Main Control Valve Assembly . . . . . . . . . . . . . . .9 - 30
Main Control Valve Disassembly . . . . . . . . . . . .9 - 27
Main Control Valve Inspection . . . . . . . . . . . . . .9 - 28
Main Control Valve Installation . . . . . . . . . . . . . .9 - 32
Main Control Valve Removal . . . . . . . . . . . . . . . .9 - 27
Main Relief Valve Pressure Test, Backhoe . . . . .10 -15
Manual Preheat Manifold . . . . . . . . . . . . . . . . . . .4 - 38
Measure Idler Gear Bushing . . . . . . . . . . . . . . . .3 - 84
INDEX - 3
INDEX
Metric Torque Values . . . . . . . . . . . . . . . . . . . . . 2 - 5
O S
Oil Cooler Repair . . . . . . . . . . . . . . . . . . . . . . . . 3 - 89
Oil Filter Nipple Repair . . . . . . . . . . . . . . . . . . . . 3 - 90
Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8
Oil Pan Drain Plug . . . . . . . . . . . . . . . . . . . . . . . 3 - 95
Oil Pan Installation . . . . . . . . . . . . . . . . . . . . . . . 3 - 94
Oil Pressure Regulating Valve & Seat Repair . . 3 - 90
Oil Pump Disassembly . . . . . . . . . . . . . . . . . . . . 3 - 93
Oil Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 91
O-ring Boss Fittings Service Recommendations. 10 -25
P Specifications, Hydraulics . . . . . . . . . . . . . . . . . 9 - 3
Park Brake Assembly Repair . . . . . . . . . . . . . . . 8 - 11
Park Brake Handle & Linkage Replacement . . . 8 - 10
Park Brake Handle Adjustment . . . . . . . . . . . . . 8 - 10
Park Brake Linkage Adjustment . . . . . . . . . . . . . 8 - 9
Parking Brake Assembly . . . . . . . . . . . . . . . . . . 8 - 11
Parking Brake Disassembly . . . . . . . . . . . . . . . . 8 - 11
Parking Brake Inspection . . . . . . . . . . . . . . . . . . 8 - 11
Parts Location, Boom Lock . . . . . . . . . . . . . . . . 10 -7
Pin Removal, Boom Lock . . . . . . . . . . . . . . . . . . 10 -10
Piston & Connecting Rod Assembly . . . . . . . . . . 3 - 60
Piston & Connecting Rod Assembly Installation . 3 - 61
Piston And Cylinder Liner Measure. . . . . . . . . . . 3 - 51
Piston And Liner Replacement . . . . . . . . . . . . . . 3 - 53
Piston Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 49
Piston Cooling Orifice Inspection . . . . . . . . . . . . 3 - 58
Piston Cooling Orifices Inspection . . . . . . . . . . . 3 - 74
Piston Inspection . . . . . . . . . . . . . . . . . . . . . . . . 3 - 49
Piston Pin And Rod Bushing Inspect. . . . . . . . . . 3 - 54
Piston Pin Bushing Installation . . . . . . . . . . . . . . 3 - 55
Piston Pin Bushing Removal . . . . . . . . . . . . . . . 3 - 55
Piston Protrusion Measurement . . . . . . . . . . . . . 3 - 62
Piston Ring Installation . . . . . . . . . . . . . . . . . . . . 3 - 60
Piston Rod Removal . . . . . . . . . . . . . . . . . . . . . . 3 - 49
Power Circuit Diagnosis . . . . . . . . . . . . . . . . . . . 4 - 20
Power Circuit Operation . . . . . . . . . . . . . . . . . . . 4 - 18
Pump Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 17
Pump Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 18
Q Theory Of Operation, Backhoe . . . . . . . . . . . . . . 10 -4
Quick-attach Mounting System . . . . . . . . . . . . . 10 -11
R Theory Of Operation, Brakes . . . . . . . . . . . . . . . 8 - 4
Reading Electrical Schematics . . . . . . . . . . . . . . 4 - 4
Rectifier, Inspection/test . . . . . . . . . . . . . . . . . . . 4 - 96
Regulated Amp And Voltage Test . . . . . . . . . . . 4 - 72
Relieve Fuel System Pressure . . . . . . . . . . . . . . 3 - 110
Remove Main Bearings . . . . . . . . . . . . . . . . . . . 3 - 70
Repair Specifications, Diesel Engine . . . . . . . . . 3 - 7
Repair, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 29
Repair, Hydrostatic . . . . . . . . . . . . . . . . . . . . . . . 6 - 22
Replace Safety Signs . . . . . . . . . . . . . . . . . . . . . 1 - 6
Road/work Light/accessory Circuit Diagnosis . . 4 - 68
Road/work Light/accessory Circuit Operation . . 4 - 66
Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . 3 - 34
Rocker Arm Cover Installation . . . . . . . . . . . . . . 3 - 45
Rocker Arm Cover Vent Cleaning & Inspection . 3 - 45
Rocker Arm Disassembly & Cleaning . . . . . . . . . 3 - 34
Rocker Arm Installation . . . . . . . . . . . . . . . . . . . 3 - 44
INDEX - 4
Rotor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 95
Safe Service Procedures . . . . . . . . . . . . . . . . . . 1 - 4
Sealant Application Guidelines, Diesel Engine . 3 - 13
Serial Number Location . . . . . . . . . . . . . . . . . . . 2 - 10
Servo Control Assembly . . . . . . . . . . . . . . . . . . . 6 - 30
Servo Control Disassembly . . . . . . . . . . . . . . . . 6 - 27
Skid Steer Loader Product ID Number . . . . . . . . 2 - 10
Specifications, Diesel Engine . . . . . . . . . . . . . . . 3 - 7
Specifications, Electrical. . . . . . . . . . . . . . . . . . . 4 - 3
Specifications, Gear Power Train . . . . . . . . . . . . 5 - 3
Specifications, Hydro Power Train . . . . . . . . . . . 6 - 3
Specifications, Miscellaneous . . . . . . . . . . . . . . 10 -2
Specifications, Steering . . . . . . . . . . . . . . . . . . . 7 - 3
Specifications-900 And 911, Backhoe . . . . . . . . 10 -3
Start Up Procedure, Hydraulic . . . . . . . . . . . . . . 9 - 37
Starter - Inspection/test . . . . . . . . . . . . . . . . . . . 4 - 90
Starter Gear Train . . . . . . . . . . . . . . . . . . . . . . . 4 - 91
Starter Loaded Amperage Draw Test . . . . . . . . . 4 - 72
Starter No-load Amperage & Rpm Tests . . . . . . 4 - 73
Starter Solenoid Test . . . . . . . . . . . . . . . . . . . . . 4 - 74
Start-up Procedure, Hydrostatic/hydraulic . . . . . 6 - 46
Stator, Inspection/test . . . . . . . . . . . . . . . . . . . . . 4 - 96
Steering Arm Removal . . . . . . . . . . . . . . . . . . . . 7 - 17
Steering Assembly Inspection . . . . . . . . . . . . . . 7 - 17
Steering Damper Removal & Inspect . . . . . . . . . 7 - 16
Steering Linkage Adjustment . . . . . . . . . . . . . . . 7 - 12
Swing Crossover Relief Valve
Pressure Test, Backhoe . . . . . . . . . . . . . . . . . . 10 -16
Switched Power Circuit . . . . . . . . . . . . . . . . . . . 4 - 19
Synthetic Lubricants . . . . . . . . . . . . . . . . . . . . . . 2 - 8
System Relief Valve Pressure Test . . . . . . . . . . . 9 - 17
System Relief Valve Pressure Test . . . . . . . . . . 9 - 18
T
Tachometer Circuit Diagnosis . . . . . . . . . . . . . . 4 - 30
Tachometer Circuit Operation . . . . . . . . . . . . . . 4 - 26
Tests & Adjustments . . . . . . . . . . . . . . . . . . . . . 4 - 70
Tests And Adjustments, Engine . . . . . . . . . . . . . 3 - 26
Theory Of Operation, Boom Lock . . . . . . . . . . . . 10 -8
Theory Of Operation, Electrical . . . . . . . . . . . . . 4 - 5
Theory Of Operation, Gear Power Train . . . . . . 5 - 5
Theory Of Operation, Hydraulics . . . . . . . . . . . . 9 - 5
Theory Of Operation, Hydro System . . . . . . . . . 6 - 4
Theory Of Operation, Steering . . . . . . . . . . . . . . 7 - 6
Thermostat Removal & Testing . . . . . . . . . . . . . 3 - 95
Timing Gear Backlash Measurement . . . . . . . . . 3 - 79
Timing Gear Cover Cleaning & Inspection . . . . . 3 - 88
Timing Gear Cover Installation . . . . . . . . . . . . . . 3 - 88
Timing Gear Cover Removal . . . . . . . . . . . . . . . 3 - 78
Torque-turn Method Of Torque . . . . . . . . . . . . . 3 - 43
Transmission/hydraulic Oil Specifications . . . . . 2 - 8
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . 4 - 12
Troubleshooting Chart, Backhoe . . . . . . . . . . . . 10 -10
Troubleshooting, Boom Lock . . . . . . . . . . . . . . . 10 -9
Troubleshooting, Gear Power Train . . . . . . . . . . 5 - 7
2/13/95
 INDEX

Troubleshooting, Hydraulics . . . . . . . . . . . . . . . .9 - 14
Troubleshooting, Steering . . . . . . . . . . . . . . . . . .7 - 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 7
Turbocharger Bearing Axial End Play Test . . . . .3 - 107
Turbocharger Bearing Radial Clearance Test . .3 - 106
Turbocharger Break-in . . . . . . . . . . . . . . . . . . . .3 - 109
Turbocharger Center Housing Replacement . . .3 - 108
Turbocharger Diagnosis . . . . . . . . . . . . . . . . . . .3 - 100
Turbocharger Disassembly . . . . . . . . . . . . . . . . .3 - 107
Turbocharger Failure Analysis . . . . . . . . . . . . . .3 - 103
Turbocharger Pre-lubrication . . . . . . . . . . . . . . .3 - 108
Turbocharger Removal . . . . . . . . . . . . . . . . . . . .3 - 103
Turbocharger Repair . . . . . . . . . . . . . . . . . . . . . .3 - 107
Two Speed Component Location . . . . . . . . . . . .6 - 6
Two Speed Removal & Installation . . . . . . . . . . .6 - 36
U
Unswitched Power Circuits . . . . . . . . . . . . . . . . .4 - 19
V
Valve Adjustment, Engine . . . . . . . . . . . . . . . . . .3 - 26
Valve Assembly Removal . . . . . . . . . . . . . . . . . .3 - 36
Valve Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 37
Valve Grind . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 38
Valve Guide Cleaning . . . . . . . . . . . . . . . . . . . . .3 - 39
Valve Guide Knurling . . . . . . . . . . . . . . . . . . . . .3 - 40
Valve Guide Measurement . . . . . . . . . . . . . . . . .3 - 39
Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . .3 - 37
Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . .3 - 42
Valve Lift Measurement . . . . . . . . . . . . . 3 - 26, 3 - 78
Valve Lift Measurement . . . . . . . . . . . . . . . . . . .3 - 78
Valve Recess Check . . . . . . . . . . . . . . . . . . . . . .3 - 36
Valve Rotator Inspection . . . . . . . . . . . . . . . . . . .3 - 37
Valve Seat Cleaning And Inspection . . . . . . . . . .3 - 40
Valve Seat Grinding . . . . . . . . . . . . . . . . . . . . . .3 - 40
Valve Seat Insert Installation . . . . . . . . . . . . . . .3 - 41
Valve Seat Repair . . . . . . . . . . . . . . . . . . . . . . . .3 - 41
Valve Spring Inspection . . . . . . . . . . . . . . . . . . .3 - 36
Voltage Regulator, Replacement . . . . . . . . . . . .4 - 93
W
Water Manifold R & R . . . . . . . . . . . . . . . . . . . . .3 - 96
Water Pump Assembly . . . . . . . . . . . . . . . . . . . .3 - 97
Water Pump Cleaning & Inspection . . . . . . . . . .3 - 97
Water Pump Disassembly . . . . . . . . . . . . . . . . . .3 - 97
Water Pump Installation . . . . . . . . . . . . . . . . . . .3 - 98
Water Pump Removal . . . . . . . . . . . . . . . . . . . . .3 - 96
Water Pump Repair . . . . . . . . . . . . . . . . . . . . . .3 - 96
Wire Color Abbreviation Chart . . . . . . . . . . . . . .4 - 5
Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 17

2/13/95 INDEX - 5
INDEX

INDEX - 6 2/13/95