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TSE DPT40-B, Owner'S Manual

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Specific Parts List

Summary of Contents for DPT40-B

Page 1: ...www tse international com 5301 Shreveport Blanchard Hwy Shreveport Louisiana 71107 USA P 318 929 2368 F 318 929 4853 Owner s Manual Model DPT40 B Puller Tensioner Serial Number 1 01 ...

Page 2: ...e to be returned prepaid to TSE Items not returned within 30 days will result in the RGA closure and may result in a denial of the claim 3 Warranty submission must be on the standard TSE International Inc claim form Claims that are not will be classified as pending until proper forms are submitted All claims must have an estimated cost associated with each item under discrepancy 4 Major subcompone...

Page 3: ...dual application of the equipment described in this manual The contents of this manual are intended as a basis of for operation maintenance and parts listing of the unit in its intended and anticipated use as it stands alone in conjunction with other equipment The Equipment described in this manual is potentially dangerous if improperly or carelessly operated For the protection of personnel and eq...

Page 4: ...ts innovative products with Premium Customer Service Our comprehensive Service Department provides TSE customers with the service parts and technical assistance they need to maintain their equipment in top operating condition For Customer Service on Your Model Serial No PLEASE CALL 1 800 825 2402 Our People Care Our Equipment is the Proof DPT40 B 19 5201 01 ...

Page 5: ...der the replacement part locate the part from the drawings in this manual and give the following information 1 Unit Model No From the plates on the unit s frame 2 Unit Serial No From the plate on the unit s frame will contain numbers only 3 Part Number If available 4 Description If part no not available 5 Quantity Required On large components such as transmissions engines multiple pump drives etc ...

Page 6: ...y trained operators who are critically aware of the proper procedures operating parameters and limitations potential dangers and application of this equipment should be allowed to touch the controls at any time There is potential DANGER of ELECTRICAL SHOCK when operating this machine Ground the unit in accordance with the regulations of the using organization Various methods of bonding isolation a...

Page 7: ...which after shipment from the factory of TSE has not been altered changed repaired or treated in any manner whatsoever unless such alteration change repair or treatment has been previously authorized in writing by TSE or has been performed by the authorized service representative of TSE This Warranty to repair is the only Warranty either express implied or statutory upon which the said machinery i...

Page 8: ...THODS Grounding Equipment and Methods information is covered in the following publication IEEE GUIDE TO INSTALLATION OF OVERHEAD TRANSMISSION LINE CONDUCTORS IEEE STD 524 2003 The above publication is available through the following organization THE INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS INC 3 PARK AVENUE NEW YORK NY 10016 5997 USA ...

Page 9: ...hese decals be missing they could prevent the proper operation and or maintenance of the unit which may result in personal injury or property damage If any of these decals are missing please contact us for a replacement Order the decal s by stating the decal description number and quantity TSE INTERNATIONAL 5301 SHREVEPORT BLANCHARD HWY SHREVEPORT LA 71107 ATTENTION SERVICE MANAGER TELEPHONE 800 8...

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Page 12: ... ASSEMBLY 8602068 D HYDRAULIC SCHEMATIC 7601116 C LIGHTING DIAGRAM 7601128 CONTROL PANEL ASSEMBLY 8600484 A OVERHEAD LEVELWIND ASSEMBLY 760188 N LEVELWIND ASSEMBLY 7600250 E LEVELWIND PLUMBING 8602493 LEVELWIND OVER UNDER DPT40 B 860106 O OVERHEAD UNDERGROUND BOOM OPTIONAL 563016 C HIGH SPEED POLEMASTER OPTIONAL 860952 G POLEMASTER LEVELWIND ASSEMBLY OPTIONAL 880256 G BRAKE INSTALLATION SECTION V ...

Page 13: ...hydraulically powered post type levelwind WARNING CAUTION WHEN THIS SIGN APPEARS ON THESE PAGES IT INDICATES WHERE SPECIAL ATTENTION SHOULD BE PAID TO THE INSTRUCTIONS GIVEN PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT MAY OCCUR IF THE INSTRUCTIONS ARE NOT FOLLOWED DIMENSIONS Length 199 inches Width 89 inches Height 73 inches PERFORMANCE Continuous Torque 70 000 in lbs Intermittent Torque 80 000 in ...

Page 14: ...ed 3000 psi during the operation of the machine 2 Linepull Control The pressure in the hydraulic system is regulated with this control knob also shown in Figure 2 Clockwise rotation of the Linepull Control increases pressure and therefore increases the Linepull Counter clockwise rotation of the Linepull Control decreases pressure and therefore decreases the Linepull Once the system pressure is set...

Page 15: ...ERIFIED BEFORE THE UNIT IS PUT INTO SERVICE TO ENSURE SAFE OPERATION THIS IS PARTICULARLY IMPORTANT WHEN STRINGING IN THE VICINITY OF ENERGIZED LINES Figure 3 Brake Control 4 Direction Control The reel turning speed Linespeed and direction is controlled by a single lever that regulates the degree of pump stroke in both directions from the NEUTRAL Position also shown in Figure 4 Movement of the Dir...

Page 16: ...he Levelwind Speed Control knob 8 Charge Pressure Gauge This gauge indicates the system charge pressure and should be approximately 300 psi TOWING Before towing always check the following 1 Front and rear jacks are fully retracted 2 Operator protective screen is folded down 3 Wheel brakes are operational 4 Tires are inflated to proper pressure 5 Wheel chocks are removed and stored away properly 6 ...

Page 17: ...uired by IEEE and or the applicable standards in your area Use of a ground mat and a running ground on the conductor are highly recommended 6 Put a hazard barrier around the perimeter of the unit to keep unauthorized personnel away from the equipment 7 Perform daily inspection and preventive maintenance as required PRE START CHECKLIST 1 Ensure that the Direction Control is in the NEUTRAL position ...

Page 18: ... In extreme cold weather operations special low temperature hydraulic oil is recommended PULLING BEGINNING WITH SLACK ROPE The following procedure describes how to operate the DPT40 B when it is used as a puller and the rope is not under tension CAUTION DO NOT FOLLOW THIS PROCEDURE WHEN THERE IS TENSION ON THE PULLING ROPE 1 Increase the engine speed to full throttle An engine operated at idle spe...

Page 19: ...Control clockwise until the pulling rope or conductor starts to move TENSIONING BEGINNING WITH SLACK ROPE This procedure describes how to set the DPT40 B when it is used as a tensioner and the rope is not under tension WARNING DO NOT FOLLOW THIS PROCEDURE WHEN THERE IS TENSION ON THE CONDUCTOR 1 Increase the engine speed to full throttle An engine operated at idle speed does not sufficiently power...

Page 20: ...se the speed WARNING NEVER PUT THE DIRECTION CONTROL LEVER IN THE PAY OUT POSITION WHEN PULLING ROPE OR WHEN THE CONDUCTOR IS UNDER TENSION 6 To stop pull the Direction Control to the NEUTRAL position The Direction Lever Stop will fall back into place restricting movement into the PAY OUT direction once again PAYING OUT ROPE UNDER TENSION This procedure describes how to pay out or loosen a pulling...

Page 21: ...gure 6 WARNING THERE MUST BE NO TENSION ON THE LINE WHEN REMOVING THE LOCKING PIN Figure 6 Opening Drive Door 6 Pull off the conductor or rope as required using the drag brake to prevent reel overspin 7 When payout is complete reinsert the lock pin in the drive sprocket You may have to rotate the reel by hand to line up the lock pin hole PULLING UNDERGOUND OPTIONAL This procedure describes how to ...

Page 22: ...n Vertical Position 2 On the drive arm side pull the ball lock pin straight up and pull the reel shaft pin back enough to allow the reel shaft to be lifted up shown in Figure 8 Figure 8 Removing Reel Shaft Pin 3 On the lifting loop side open the locking latch and swing it back out of the way shown in Figure 9 Figure 9 Removing Locking Latch ...

Page 23: ...collar to 200 ft lbs ALWAYS MAKE SURE THAT THE REEL IS PUSHED TIGHT AGAINST THE DRIVE ARM AND HELD SECURELY BY LIFTING LOOP LOCKING COLLAR 7 Install the bronze bearing on end of the reel shaft 8 Attach lifting hooks to the drive arm and lifting loop making sure they are balanced so the reel remains level during lifting 9 Lower the reel in place engaging the reel shaft drive with its mating part an...

Page 24: ...cribed in Freewheeling Payout section This allows the Polemaster drum to turn without also turning the reel shaft 2 Remove the drive shaft extension cover from the drive door and store it on top of the door as shown in Figure 11 Figure 11 Extension Cover 3 Remove the Polemaster drive shaft from its storage pin located on the frame 4 Slide the Polemaster drive shaft onto the drive shaft extension w...

Page 25: ... Figure 13 Make sure the spring clip is installed correctly in order to keep the pin from falling out Figure 13 Polemaster Drum 7 Remove some rope from the Polemaster Drum and feed it around the guide sheaves of the Polemaster Levelwind as shown in Figure 14 Figure 14 Levelwind Reeving 8 The installation of the drum and rope should be as shown in Figure 15 The Polemaster System is now ready to pul...

Page 26: ...ute the pilot rope across the Polemaster Drum so it does not pile in one spot and get tangled 3 When the pulling rope for the first phase arrives at the Tensioner end it is removed from the end of the pilot rope and is attached to the end of the conductor 4 In preparation for tensioning the conductor remove the full Polemaster Drum from the DPT40 B 5 Remove the Polemaster drive shaft and store 6 I...

Page 27: ...iece of cardboard or other material as detector rather than your hand Pressurized hydraulic fluid escaping from a faulty component can penetrate the skin and cause serious injury 7 Do not change the pressure setting of any hydraulic valves unless authorized instruction has been obtained 8 Ensure that all tire and rim parts are undamaged and correctly assembled before inflating the tires 9 Use an i...

Page 28: ...light any occurrence of a potentially hazardous malfunction On a daily basis walk around the unit and look closely for any indication of the following 1 Loose threaded connections 2 Metal fatigue or excessive corrosion 3 Abraded hose surfaces 4 Hydraulic fluid leakage 5 Possible obstruction of moving parts especially in the drive train To ensure proper operation and long life of your TSE Internati...

Page 29: ...RAULIC FLUID IS USED IN YOUR MACHINE ISO 46 567851 HYDRAULIC SYSTEM FLUID UTILITY EP 2 GREASE MULTIPURPOSE GREASE BEARINGS SHAFTS FRICTION COMPONENTS LUBRIPLATE CHAIN CABLE FLUID PENETRATING FLUID SAE 10 ISO 32 CHAINS WIRE ROPES CABLES SPARTAN EP150 INDUSTRIAL GEAR OIL ISO 150 GEARBOXES REDUCERS SEE VENDOR LITERATURE FOR VARIATIONS AND AMOUNTS SUPER MPGO 80W90 PETROLEUM OIL BLEND PUMP DRIVES ...

Page 30: ...INTS X L CHAIN DRIVES O L LUBRICATE COUPLINGS X BOLTED CONNECTIONS X X INSPECT CORRECT HYDRAULIC PLUMBING X HYDRAULIC RESERVOIR 4 X O CLEAN LUBRICATE HYDRAULIC FILTERS 2 R 3 HYDRAULIC HOSES X F FLUSH CHANGE MISC COMPONENTS 1 L 1 Items such as engines pumps pump drives motors reducers brakes etc on your equipment should be serviced according to the manufacturer s maintenance schedule see outside ve...

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Page 48: ...ts are known to the State of California to cause cancer birth defects and other reproductive harm If this product contains a gasoline engine WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The State of California requires the above two warnings Additional Proposition 65 Warnings can be found i...

Page 49: ......

Page 50: ...m warranty Equipment operators can t afford downtime or unexpected repairs That s why we offer a 2 year 2 000 hour warranty with unlimited hours in the first year on our OEM industrial and marine engines This warranty takes effect the date that the engine is delivered to the first retail purchaser In addition extended warranties are available under certain conditions John Deere offers a variety of...

Page 51: ...in loss of warranty protection for this engine CERTAIN ENGINE ACCESSORIES such as radiator air cleaner and instruments are optional equipment on John Deere OEM Engines These accessories may be provided by the equipment manufacturer instead of John Deere This operator s manual applies only to the engine and those options available through the John Deere distribution network NOTE This operator s man...

Page 52: ...Introduction ZE59858 0000048 19 15SEP14 1 1 Identification Views RG25479 UN 11APR14 3029HFC03 Left Rear View RG25478 UN 11APR14 3029HFC03 Right Front View 032715 PN 5 ...

Page 53: ...Hy Gard Hy Gard is a trademark of Deere Company JDLink JDLink is a trademark of Deere Company JDParts JDParts is a trademark of Deere Company John Deere John Deere is a trademark of Deere Company Loctite Loctite is a trademark of Henkel Corporation Metri Pack Metri Pack is a trademark of Delphi Connection Systems OILSCAN PLUS OILSCAN PLUS is a trademark of Deere Company Oilscan Oilscan is a tradem...

Page 54: ...n ZE59858 0000006 19 13FEB14 2 2 Vari Cool Vari Cool is a trademark of Deere Company WEATHER PACK WEATHER PACK is a trademark of Packard Electric WINDOWS WINDOWS is a trademark of Microsoft Corporation 032715 PN 7 ...

Page 55: ...Introduction 032715 PN 8 ...

Page 56: ...uel 10 2 Handling and Storing Diesel Fuel 10 2 BioDiesel Fuel 10 3 Testing Diesel Fuel 10 4 Fuel Filters 10 4 Minimizing the Effect of Cold Weather on Diesel Engines 10 5 John Deere Break In Plus Engine Oil Interim Tier 4 Final Tier 4 Stage IIIB and Stage IV 10 6 Diesel Engine Oil Interim Tier 4 Final Tier 4 Stage IIIB and Stage IV 10 6 Engine Oil and Filter Service Intervals Interim Tier 4 Final ...

Page 57: ...ernator V Belt Tension 40 6 Checking Air Intake System 40 8 Checking Engine Ground Connection 40 8 Checking Cooling System 40 9 Page Pressure Testing Cooling System 40 10 Checking and Adjusting Engine Speeds 40 11 Lubrication Maintenance 1200 Hours Checking and Adjusting Valve Clearance 45 1 Lubrication Maintenance 1500 Hours 24 Months Changing Open Crankcase Ventilation OCV Filter 50 1 Lubricatio...

Page 58: ...75 4 Lubrication and Maintenance Records Using Lubrication and Maintenance Records 80 1 Daily Prestarting Service 80 1 250 Hours or 12 Months Service 80 1 500 Hours or 12 Months Service 80 2 1200 Hours 80 2 1500 Hours or 24 Months Service 80 3 6000 Hours or 72 Months Service 80 3 Service As Required 80 4 Warranty John Deere Warranty in OEM Applications 85 1 Emissions Control System Certification L...

Page 59: ...Contents iv 032715 PN 4 ...

Page 60: ... provided below This information is very important for repair parts or warranty information Use all 13 digits when providing engine serial number Engine Serial Number A Engine Model Number B NOTE On engine serial number A the seventh digit shows the emission level as follows U for Final Tier 4 Stage IV A Engine Serial Number B Engine Model Number C Serial Number Plate JOHN DEERE Engine Serial Numb...

Page 61: ...e 99 00 or XX The list on the next page shows only the first two digits of the code numbers For future reference such as ordering repair parts it is important to have these code numbers available To ensure this availability enter the third and fourth digits shown on your engine option code label in the spaces provided on the following page NOTE Your engine option code label may not contain all opt...

Page 62: ... Engine Hanger Straps Engine Base Code Record Aftertreatment Serial Numbers Record the numbers from your aftertreatment device as shown on DPF A B and DOC C D serial number plates Having these numbers recorded and kept in a safe location can aid in part ordering and assist in locating stolen items in case of theft DPF Part Number DPF Serial Number DOC Part Number DOC Serial Number A Diesel Particu...

Page 63: ...ial Number Record the part number and serial number information found on the serial number label A on the Engine Control Unit ECU mounted on or near the engine Part No Serial No A Serial Number Label RG24819 UN 04DEC13 Record Engine Control Unit ECU Serial Number 01 4 032715 PN 16 ...

Page 64: ...ssages in this manual TS187 19 30SEP88 Recognize Safety Information This is a safety alert symbol When you see this symbol on your machine or in this manual be alert to the potential for personal injury Follow recommended precautions and safe operating practices T81389 UN 28JUN13 Replace Safety Signs Replace missing or damaged safety signs Use this operator s manual for correct safety sign placeme...

Page 65: ...haust some of its constituents along with certain machine components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm In addition certain fluids contained in the machine and certain products of component wear contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm ...

Page 66: ...efrigerants escaping into the air can damage the Earth s atmosphere Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center or from your John Deere dealer TS1133 UN 15APR13 Prevent Machine Runaway Avoid possible ...

Page 67: ... work Keep all parts in good condition and properly installed Fix damage immediately Replace worn or broken parts Remove any buildup of grease oil or debris On self propelled equipment disconnect battery ground cable before making adjustments on electrical systems or welding on machine On towed implements disconnect wiring harnesses from tractor before servicing electrical system components or wel...

Page 68: ...n you work near machine tools or moving parts If these items were to get caught severe injury could result Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts TS228 UN 23AUG88 Use Proper Tools Use tools appropriate to the work Makeshift tools and procedures can create safety hazards Use power tools only to loosen threaded parts and fasteners For loosening a...

Page 69: ...s supported solely by a jack Follow recommended procedures in this manual When implements or attachments are used with a machine always follow safety precautions listed in the implement or attachment operator s manual TS229 UN 23AUG88 Use Proper Lifting Equipment Lifting heavy components incorrectly can cause severe injury or machine damage Follow recommended procedure for removal and installation...

Page 70: ...s in place at all times during engine operation Wear close fitting clothes Stop the engine and be sure fans belts pulleys and drives are stopped before making adjustments connections or cleaning near fans and their drive components TS677 UN 21SEP89 Stay Clear of Rotating Drivelines Entanglement in rotating driveline can cause serious injury or death Keep all shields in place at all times Make sure...

Page 71: ... Slowly loosen cap to first stop to relieve pressure before removing completely TS281 UN 15APR13 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 Remove paint before heating Remove paint a minimum of 100 mm 4 in from area to be affected by heating If paint cannot be removed wear...

Page 72: ...ing 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 Doctor...

Page 73: ... your fuel or fuel system supplier to ensure that the delivery system is in compliance with fueling standards for proper grounding and bonding practices RG22142 UN 17MAR14 RG21992 UN 21AUG13 Handle Fuel Safely Avoid Fires Handle fuel with care it is highly flammable Do not refuel the machine while smoking or when near open flame or sparks Always stop engine before refueling machine Fill fuel tank ...

Page 74: ... Handle Starting Fluid Safely Starting fluid is highly flammable Keep all sparks and flame away when using it Keep starting fluid away from batteries and cables To prevent accidental discharge when storing the pressurized can keep the cap on the container and store in a cool protected location Do not incinerate or puncture a starting fluid container Do not use starting fluid on an engine equipped ...

Page 75: ...ubber gloves Avoiding use of air pressure to clean batteries Avoiding breathing fumes when electrolyte is added Avoiding spilling or dripping electrolyte Using correct battery booster or charger procedure If acid is spilled on skin or in eyes 1 Flush skin with water 2 Apply baking soda or lime to help neutralize the acid 3 Flush eyes with water for 15 30 minutes Get medical attention immediately I...

Page 76: ...d on yourself 1 Flush your skin with water 2 Apply baking soda or lime to help neutralize the acid 3 Flush your eyes with water for 15 30 minutes Get medical attention immediately If acid is swallowed 1 Do not induce vomiting 2 Drink large amounts of water or milk but do not exceed 2 L 2 quarts 3 Get medical attention immediately TS203 UN 23AUG88 Prevent Battery Explosions Keep sparks lighted matc...

Page 77: ...LIVE 19 25SEP92 1 1 Live With Safety Before returning machine to customer make sure machine is functioning properly especially the safety systems Install all guards and shields TS231 19 07OCT88 05 14 032715 PN 30 ...

Page 78: ...hange interval BEFORE using diesel fuel with sulfur content greater than 2000 mg kg 2000 ppm contact your John Deere dealer Sulfur Content for Tier 2 and Stage II Engines Use of diesel fuel with sulfur content less than 2000 mg kg 2000 ppm is RECOMMENDED Use of diesel fuel with sulfur content 2000 5000 mg kg 2000 5000 ppm REDUCES the oil and filter change interval BEFORE using diesel fuel with sul...

Page 79: ...eater than B20 Handling and Storing Diesel Fuel CAUTION Reduce the risk of fire Handle fuel carefully DO NOT fill the fuel tank when engine is running DO NOT smoke while you fill the fuel tank or service the fuel system Fill the fuel tank at the end of each day s operation to prevent water condensation and freezing during cold weather Keep all storage tanks as full as practicable to minimize conde...

Page 80: ...etergent and dispersant additives are required when using BioDiesel blends from B10 B20 and are recommended when using lower BioDiesel blends BioDiesel Use Requirements and Recommendations The petroleum diesel portion of all BioDiesel blends must meet the requirements of ASTM D975 US or EN 590 EU commercial standard BioDiesel users in the U S are strongly encouraged to purchase BioDiesel blends fr...

Page 81: ...esel fuel The fuel analysis can provide critical data such as cetane number fuel type sulfur content water content appearance suitability for cold weather operations bacteria cloud point acid number particulate contamination and whether the fuel meets specification Contact your John Deere dealer for more information on diesel fuel analysis Fuel Filters The importance of fuel filtration cannot be o...

Page 82: ...n this section Diesel Fuel Flow Additive Use John Deere Fuel Protect Diesel Fuel Conditioner winter formula which contains anti gel chemistry or equivalent fuel conditioner to treat non winter grade fuel No 2 D in North America during the cold weather season This generally extends operability to about 10 C 18 F below the fuel cloud point For operability at even lower temperatures use winter grade ...

Page 83: ...s at all emission certification levels After the break in period use John Deere Plus 50 II or other diesel engine oil as recommended in this manual Break In Plus is a trademark of Deere Company Plus 50 is a trademark of Deere Company Diesel Engine Oil Interim Tier 4 Final Tier 4 Stage IIIB and Stage IV Use oil viscosity based on the expected air temperature range during the period between oil chan...

Page 84: ...l and filter service intervals Use of diesel fuel with sulfur content less than 15 mg kg 15 ppm is REQUIRED IMPORTANT To avoid engine damage Reduce oil and filter service intervals by 50 when using BioDiesel blends greater than B20 Oil analysis may allow longer service interval Use only approved oil types Approved Oil Types John Deere Plus 50 II Other Oils include API CJ 4 ACEA E9 and ACEA E6 NOTE...

Page 85: ...nge interval is only allowed if all the following conditions are met Engine equipped with an extended drain interval oil pan Use of diesel fuel with sulfur content less than 0 0015 15 ppm 15 mg kg maximum limit Use of John Deere Plus 50 II oil Use of an approved John Deere oil filter Oil Pan Option Codes Power Rating Fuel Sulfur Content 19GN 8 5 L kW hp Other Oils John Deere Plus 50 II 36 48 15 pp...

Page 86: ...l old containers and any residual lubricant they may contain Oil Filters Filtration of oils is critically important for proper operation and lubrication John Deere brand oil filters have been designed and produced specifically for John Deere applications John Deere filters adhere to engineering specifications for quality of the filter media filter efficiency rating strength of the bond between the...

Page 87: ...olant meeting ASTM D6210 requirements Coolant concentrate meeting ASTM D6210 requirements in a 40 60 mixture of concentrate with quality water If coolant meeting one of these specifications is unavailable use a coolant concentrate or pre mix coolant that has a minimum of the following chemical and physical properties Provides cylinder liner cavitation protection according to either the John Deere ...

Page 88: ...gher concentrations of total dissolved solids Freeze Protection The relative concentrations of glycol and water in the engine coolant determine its freeze protection limit Ethylene Glycol Freeze Protection Limit 40 24 C 12 F 50 37 C 34 F 60 52 C 62 F Propylene Glycol Freeze Protection Limit 40 21 C 6 F 50 33 C 27 F 60 49 C 56 F DO NOT use a coolant water mixture greater than 60 ethylene glycol or ...

Page 89: ...e refractometer place one drop of coolant on the window and close the lid 5 Look through the eyepiece and focus as necessary 6 Record the listed freeze point for the type of coolant ethylene glycol coolant or propylene glycol being tested TS1732 UN 04SEP13 SERVICEGARD Part Number 75240 TS1733 UN 04SEP13 Image with a Drop of 50 50 Coolant Placed on the Refractometer Window SERVICEGARD is a trademar...

Page 90: ...ight Q will illuminate when battery voltage is too low for proper operation of the fuel injection system D Audible Alarm Optional The audible alarm D will sound whenever low oil pressure high coolant temperature or water in fuel conditions exist This includes all signals that light up the amber warning indicator intermittent alarm or the red stop engine indicator steady alarm E Audible Alarm Overr...

Page 91: ...s to commit the new operating speed to memory If not done the engine s new speed will only be effective until the key switch is shut off Then the speed will revert back to the previous setting The fast idle speed is not adjustable It will always go back to the factory preset fast idle speed K Analog Throttle Control Optional The throttle control K is used to control engine speed This control is av...

Page 92: ...Engine Torque Engine Speed Total Engine Hours Trip Fuel RG13132 UN 09SEP03 Diagnostic Gauge A Diagnostic Gauge B Menu Key C Arrow Keys D Enter Key E Red STOP ENGINE Indicator Light F Amber WARNING Indicator Light Total Fuel Used Engine Coolant Temperature Fuel Temperature Ash NOTE Engine parameters which can be accessed will vary with the engine application Diagnostic gauge can be set to display r...

Page 93: ...ms of the Main Menu will be displayed RG13160 UN 02OCT03 Menu Display 3 Pressing the Arrow keys will scroll through the menu selections RG13161 UN 02OCT03 Main Menu Items 4 Pressing the right arrow key will scroll down to reveal the last items of Main Menu screen highlighting the next item down RG13162 UN 26SEP03 Last Items On Main Menu 15 4 032715 PN 46 ...

Page 94: ...guration data is a read only function NOTE The engine does not need to be running to navigate the diagnostic gauge screens If engine start up is desired See Starting The Engine All of the engine values illustrated on the diagnostic gauge indicate the engine is running 1 Turn the key switch to the ON position Starting at the single or four engine parameter display press the Menu key RG13159 UN 26SE...

Page 95: ...ine Config menu item has been highlighted press the Enter key to view the engine configuration data RG13165 UN 02OCT03 Enter Key 4 Use the Arrow keys to scroll through the engine configuration data RG13166 UN 29SEP03 Use Arrow Keys To Scroll 5 Press the Menu key to return to the main menu RG13167 UN 29SEP03 Return To Main Menu 15 6 032715 PN 48 ...

Page 96: ...nostic gauge screens If engine start up is desired See Starting The Engine All of the engine values illustrated on the diagnostic gauge indicate the engine is running For description of trouble codes see chart in Troubleshooting Section 1 Turn the key switch to the ON position Starting at the single or four engine parameter display press the Menu key RG13159 UN 26SEP03 Menu Key 2 The main menu wil...

Page 97: ...ighlighted press the Enter key to view the stored codes RG13169 UN 02OCT03 Enter Key 4 If the word Next appears above the Arrow keys there are more stored codes that may be viewed Use the Arrow key to scroll to the next stored code RG13245 UN 02OCT03 Use Arrow Keys To Scroll 5 Press the Menu key to return to the main menu RG13246 UN 02OCT03 Return To Main Menu 15 8 032715 PN 50 ...

Page 98: ...e codes see chart in Troubleshooting Section 1 During normal operation the single or four parameter screen will be displayed RG13172 UN 26SEP03 Normal Operation 2 When the diagnostic gauge receives a trouble code from an engine control unit the single or four parameter screen will be replaced with the Warning message The SPN and FMI number will be displayed along with a description of the problem ...

Page 99: ...single or four parameter display but the display will contain the warning icon Pressing the Enter key will redisplay the hidden trouble code RG13176 UN 26SEP03 Active Trouble Code Icon IMPORTANT Ignoring active trouble codes can result in severe engine damage 6 Pressing the Enter key once again will hide the trouble code and return the screen to the single or four parameter display RG13242 UN 30SE...

Page 100: ... the corrective action needed If the word Next appears above the arrow keys there are more trouble codes that can be viewed by using the arrow keys to scroll to the next trouble code RG13238 UN 29SEP03 Shutdown Message 3 To acknowledge and hide the trouble code and return to the single or four parameter display press the Enter key IMPORTANT Ignoring the shutdown message can result in severe engine...

Page 101: ...ur parameter screen will display the shutdown icon until the trouble code condition is corrected IMPORTANT Ignoring the shutdown message can result in severe engine damage RG13180 UN 26SEP03 Shutdown Icon Adjusting Backlighting 1 Turn the key switch to the ON position Starting at the single or four engine parameter display press the Menu key RG13159 UN 26SEP03 Menu Key 2 The main menu will be disp...

Page 102: ... Backlight menu item has been highlighted press the Enter key to activate the Adjust Backlight function RG13182 UN 02OCT03 Press Enter Key 4 Use the Arrow keys to select the desired backlight intensity RG13183 UN 29SEP03 Adjust Backlight Intensity 5 Press the Menu key to return to the main menu RG19048 UN 23AUG10 Return to Main Menu 15 13 032715 PN 55 ...

Page 103: ...sting Contrast 1 Turn the key switch to the ON position Starting at the single or four engine parameter display press the Menu key RG13159 UN 26SEP03 Menu Key 2 The main menu will be displayed Use the Arrow keys to scroll through the menu until Adjust Contrast is highlighted RG13161 UN 02OCT03 Select Adjust Contrast 3 Once the Adjust Contrast menu item has been highlighted press the Enter key to a...

Page 104: ...UN 29SEP03 Adjust Contrast Intensity 5 Press the Menu key to return to the main menu RG13187 UN 26SEP03 Return To Main Menu 6 Press the Menu key to exit the main menu and return to the engine parameter display RG13159 UN 26SEP03 Exit Main Menu Selecting Units Of Measurement 1 Turn the key switch to the ON position Starting at the single or four engine parameter display press the Menu key RG13159 U...

Page 105: ... been highlighted press the Enter key to access the Select Units function RG13189 UN 02OCT03 Press Enter Key 4 There are three choices for units of measurement English Metric kPa or Metric Bar English is for Imperial units with pressures displayed in PSI and temperatures in F Metric kPa and Metric bar are for IS units with pressures displayed in kPa and bar respectively and temperatures in C Use t...

Page 106: ...ted units RG13191 UN 30SEP03 Press Enter Key to Select 6 Press the Menu key to return to the main menu RG13192 UN 26SEP03 Return To Main Menu 7 Press the Menu key to return to the engine parameter display RG13159 UN 26SEP03 Press Menu Key Setup 1 Up Display 1 Turn the key switch to the ON position Starting at the single engine parameter display press the Menu key RG13159 UN 26SEP03 Menu Key 15 17 ...

Page 107: ...ation of the 1 Up Display a Use Defaults This option contains the following engine parameters for display Engine Hours Engine Speed Battery Voltage Load Coolant Temperature and Oil Pressure b Custom Setup This option contains a list of engine parameters Engine parameters from this list can be selected to replace any or all of the default parameters This option can be used to add parameters availab...

Page 108: ...e Arrow keys to scroll to and highlight Use Defaults in the menu display RG13195 UN 26SEP03 Select Defaults 6 Press the Enter key to activate the Use Defaults function RG13197 UN 29SEP03 Defaults Selected 7 The display parameters are reset to the factory defaults then the display will return to the Setup 1 Up Display menu RG13149 UN 24SEP03 Restored To Defaults 15 19 032715 PN 61 ...

Page 109: ...Up Display use the arrow buttons to scroll to and highlight Custom Setup on the display RG13198 UN 26SEP03 Select Custom Setup 9 Press the Enter key to display a list of engine parameters RG13199 UN 26SEP03 Engine Parameters 10 Use the Arrow keys to scroll to and highlight a selected parameter parameter with a number to right of it RG13150 UN 24SEP03 Select Parameters 15 20 032715 PN 62 ...

Page 110: ... Use the Arrow keys to scroll and highlight the desired parameter that has not been selected for display parameter without a number to right of it RG13151 UN 24SEP03 Select Desired Parameters 13 Press the Enter key to select the parameter for inclusion in the Single Engine Parameter Display 14 Continue to scroll through and select additional parameters for the custom 1 Up Display Press the Menu ke...

Page 111: ...1 Up Display to scroll through the selected set of parameters one at a time Use the Arrow keys to scroll to the Automatic Scan function RG13221 UN 26SEP03 Automatic Scan Off 16 Press the Enter key to toggle the Automatic Scan function on RG13222 UN 26SEP03 Automatic Scan On 17 Press the Enter key again to toggle the Automatic Scan function off RG13223 UN 26SEP03 Automatic Scan Off 15 22 032715 PN ...

Page 112: ... menu RG13224 UN 26SEP03 Menu Key 19 Press the Menu key to exit the main menu and return to the engine parameter display RG13159 UN 26SEP03 Exit Main Menu Setup 4 Up Display 1 Turn the key switch to the ON position From the single or four engine parameter display press the Menu key RG13159 UN 26SEP03 Menu Key 2 The main menu will be displayed Use the Arrow keys to scroll through the menu until Set...

Page 113: ...Speed Battery Voltage Coolant Temperature and Oil Pressure b Custom Setup This option contains a list of engine parameters Engine parameters from this list can be selected to replace any or all of the default parameters RG13244 UN 02OCT03 Select Factory Defaults 5 To reset the display parameters to the factory defaults scroll to and highlight Use Defaults Press the Enter key to activate the Use De...

Page 114: ...to and highlight Custom Setup on the display RG13227 UN 26SEP03 Custom Setup 7 The quadrant with the highlighted parameter value is the current selected parameter Use the Arrow keys to highlight the value in the quadrant you wish to change to a new parameter RG13228 UN 26SEP03 Select Parameters 8 Press the Enter key and a list of engine parameters will be displayed RG13229 UN 26SEP03 List Of Engin...

Page 115: ...light the new parameter to be placed in the 4 Up Display RG13230 UN 26SEP03 Select Desired Engine Parameter 10 Press the Enter key to change the selected parameter in the quadrant to the new parameter RG13231 UN 26SEP03 Enter Selected Parameter 11 Use the Menu keys to return to the 4 Up Custom Setup screen RG13232 UN 26SEP03 Return To 4 Up Custom Setup 12 The selected quadrant has now changed to t...

Page 116: ...hn Deere PowerSight is accessible from a laptop desktop or mobile device John Deere PowerSight works by combining a controller that includes cellular communication and GPS antennas Machine data is collected by the controller and wirelessly transferred to a data server where it is made available on a website John Deere PowerSight allows you to Stay informed on machine location and hours Protect ass...

Page 117: ... engine 6 During the initial operation of a new or rebuilt engine with Break In Plus change the oil and filter between a minimum of 100 hours and a maximum of up to 500 hours See Changing Engine Oil and Replacing Filter in the Lubrication Maintenance 500 Hours 12 Months Section Fill crankcase with seasonal viscosity grade oil See Diesel Engine Oil in the Fuels Lubricants and Coolants Section NOTE ...

Page 118: ...rough the John Deere Parts Distribution Network CAUTION Before starting engine in a confined building install proper outlet exhaust ventilation equipment Always use safety approved fuel storage and piping NOTE If temperature is below 0 C 32 F it may be necessary to use cold weather starting aids See Cold Weather Operation in the Engine Operation Section 1 Perform all prestarting checks See Daily P...

Page 119: ... is not normal stop the engine and RG13723 UN 11NOV04 Start And Idle Engine Controls On Instrument Panel A Key Start Switch B High Low Speed Select Rocker Switch C Bump Speed Enable Rocker Switch D Speed Select Rocker Switch E Analog Throttle Control Optional determine the cause For normal gauge pressures and temperatures see Break In Service in the Engine Operation Section Normal Engine Operation...

Page 120: ... Pressure 254 357 kPa 2 54 3 57 bar 37 52 psi 2 Watch coolant temperature gauge B Do not place engine under full load until it is properly warmed up The normal engine coolant temperature range is 83 95 C 181 203 F RG13724 UN 11NOV04 Oil Pressure and Coolant Temperature Gauges On Panel A Engine Oil Pressure Gauge B Engine Coolant Temperature Gauge NOTE It is a good practice to operate the engine un...

Page 121: ...tle symbol For fast speed press upper half of rocker switch indicated by rabbit symbol NOTE To adjust preset fast or slow speeds with adjustable High Low Speed Select Rocker Switch 1 Select middle position ADJ or slow turtle position on the optional Adjustable Three State Speed Select Rocker Switch A 2 Press and hold top or bottom half of Bump Speed Enable Rocker Switch B while using Speed Select ...

Page 122: ...ds are required below 0 C 32 F They will enhance starting performance above these temperatures and may be needed to start applications that have high parasitic loads during cranking and or start acceleration to idle Using correct grade oil per engine and machine operators manual is critical to achieving adequate cold weather cranking speed Synthetic oils have improved flow at low temperatures Othe...

Page 123: ...on the Exhaust Filter increase engine idle time to 10 minutes Panels with high low speed select rocker switch B only Set rpm using bump speed enable switch C with speed select rocker switch D Panels with optional analog throttle E Set either high low speed select switch B or analog throttle control E to slow idle and set desired speed with remaining control NOTE Engine control unit ECU reads the h...

Page 124: ... Always connect NEGATIVE cable last and disconnect this cable first WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling IMPORTANT Be sure that polarity is correct before making connections Reversed polarity damages electrical system Always connect positive ...

Page 125: ...s the Diesel Oxidation Catalyst DOC and Diesel Particulate Filter DPF is a critical component in the engine s emissions control system which is required to meet governmental emissions regulations The Exhaust Filter captures diesel particulate matter or soot to prevent its release into the atmosphere This soot must be eliminated from the DPF to keep it functioning properly The process of eliminatin...

Page 126: ...C The removal of DPF ash must be done by removing the DPF from the machine and placing it into specialized equipment Do not remove ash by using water or other chemicals Removing ash by these methods may damage the material securing the DPF in its canister resulting in the loosening of the DPF element in the canister and subjecting it to damage from vibration Failure to follow the approved ash remo...

Page 127: ...ds particulates remaining in the exhaust stream Trapped particles are eventually oxidized within the DPF through a process known as regeneration or exhaust filter cleaning Under normal machine operation and with the system in AUTO mode the exhaust filter system requires minimal operator interaction To avoid unnecessary buildup of diesel particulates or soot in the exhaust filter system 1 Utilize t...

Page 128: ... tank lacks the required fuel to complete the cleaning process The exhaust filter indicator C will illuminate when the exhaust filter is in need of cleaning and the operator has disabled auto exhaust filter cleaning DTC 3719 15 will be present on the diagnostic gauge see Listing of Diagnostic Trouble Codes in the Troubleshooting section for more information If conditions are safe the operator shou...

Page 129: ...the ECU to perform intelligent exhaust filter cleaning as required The Exhaust Filter Cleaning Indicator will illuminate when the system is actively performing an exhaust filter cleaning During this process the injector will inject small amounts of fuel into the exhaust stream to assist in cleaning the exhaust filter When the exhaust filter cleaning process has completed its cycle the cleaning ind...

Page 130: ...tions the engine will run at elevated idle and hot temperatures for approximately 20 50 minutes Exhaust gases and exhaust filter components reach temperatures hot enough to burn people ignite or melt common materials CAUTION Always park the machine in a safe location and check for adequate fuel level before beginning the exhaust filter cleaning process Any PTO driven devices if equipped should be ...

Page 131: ...rtain times during the exhaust filter cleaning cycle Disable exhaust filter cleaning in conditions where it may be unsafe for elevated exhaust temperatures To disable the auto exhaust filter cleaning mode 1 Press the Menu key on the diagnostic gauge 2 Press the Arrow keys to scroll up or down to select EXHAUST FILTER 3 Press the Enter key 4 Press the Arrow keys to scroll up or down and select DISA...

Page 132: ...and services performed using charts provided in Lubrication and Maintenance Records section IMPORTANT Recommended service intervals are for normal operating conditions Perform maintenance at interval which occurs first for example either at 500 hours of operation or every 12 months Service more often if engine operated under adverse conditions Neglecting maintenance can result in failures or perma...

Page 133: ... Wear Check Air Intake Hoses Connections System Check Engine Ground Connection Check Cooling System Pressure Test Cooling System Check Engine Speeds Check and Adjust Engine Valve Clearance Changing Open Crankcase Ventilation OCV Filter Flush and Refill Cooling System Test Thermostats Drain Water From Fuel Filters Bleed Fuel System Add Coolant Pre Start Cleaning Guide Replace Air Cleaner Elements C...

Page 134: ...ne cools down and parts contract If enough coolant weeps from the engine where coolant drips from the engine this may indicate the need to replace the coolant pump seal Contact your engine distributor or servicing dealer for repairs Check fan alternator and accessory drive belts for cracks breaks or other damage Loosen water drain valve on each fuel filter all the way so that the valve opens to dr...

Page 135: ...Fluids plugged fuel filters low fuel pressure If no alarm sounds during the 12 month service interval replace elements at that time or after 250 hours operation whichever comes first Remove and Install Primary Fuel Filter Element 1 Thoroughly clean filter header and surrounding area to prevent dirt and debris from entering fuel system 2 Connect a hose to filter drain valve A on bottom of filter an...

Page 136: ...chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling IMPORTANT Wear personal Protective Equipment while doing any type of Battery check or replacement 1 On regular batteries check electrolyte level Fill each cell to bottom of filler neck with distilled water NOTE Low maintenance or maintenance free batteries should require little additional ser...

Page 137: ...h your eyes with water for 10 15 minutes 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 In freezing weather run engine at least 30 minutes to ensure thorough mixing after adding water to battery Replacement battery ies must meet or exceed the following recom...

Page 138: ...le from your John Deere engine distributor or servicing dealer Oil samples should be taken prior to the oil change Refer to instructions provided with kit 1 Run engine approximately 5 minutes to warm up oil Shut engine off 2 Remove oil pan drain plug D NOTE Inspect copper washer for damage replace if necessary 3 Drain crankcase oil from engine while warm 4 Install drain plug D and copper washer E ...

Page 139: ...e engine oil through oil filler cap See Diesel Engine Oil Interim Tier 4 Final Tier 4 Stage IIIB and Stage IV in the Fuels Lubricants and Coolant Section for determining correct engine oil To determine the correct oil fill quantity for your engine see Engine Crankcase Oil Fill Quantities in the Specifications Section IMPORTANT Immediately after completing any oil change crank engine for 30 seconds...

Page 140: ... If bearing is loose repair or replace coolant pump RG25316 UN 25MAR14 Inspect Coolant Pump A Pulley B Weep Hole Checking Open Crankcase Vent OCV 1 Check all hoses A B C and D of open crankcase ventilation system for cracks damage and blockage 2 Check all constant tension clamps E F G and H for its appropriate tension on the hoses 3 Check filter housing for cracks and damage 4 Inspect duckbill val...

Page 141: ...akage High belt tension causes belt heating and excessive stretch as well as damage to drive components such as pulleys and shafts V belts should ride on the sides of standard pulleys not on the bottom of the groove Standard V belt tension can be checked with JDG529 Tension Gauge bold arrow or equivalent gauge Gauge is available from a John Deere Dealer or Distributor NOTE On engines with dual bel...

Page 142: ...22 lb ft Alternator Upper Bracket Torque 30 N m 22 lb ft IMPORTANT Do not pry against the alternator rear frame Do not tighten or loosen belts while they are hot 5 After a new or used belt has run for 10 minutes recheck belt tension STANDARD V BELTS New Belt Tension Used Belt Tensiona Single Belt 578 623 N 130 140 lb force 378 423 N 85 95 lb force Dual Belts 423 463 N 95 104 lb force 378 423 N 85 ...

Page 143: ...ottom of air cleaner for cracks or plugging Replace as necessary IMPORTANT ALWAYS REPLACE primary air cleaner element when air restriction indicator shows a vacuum of 625 mm 25 in H2O is torn or visibly dirty 4 Test air restriction indicator C for proper operation Replace indicator as necessary IMPORTANT If not equipped with air restriction indicator replace air cleaner elements at 500 Hours or at...

Page 144: ...cooling system when system is refilled Loosen temperature sending unit fitting at rear of cylinder head or plug in thermostat housing to allow air to escape when filling system Retighten fitting or plug when all the air has been expelled Cooling system must be free of air by time engine coolant temperature reaches 80 C 176 F 1 Check entire cooling system for leaks Tighten all clamps securely TS281...

Page 145: ...ate Test Cooling System for Leaks NOTE Engine should be warmed up to test overall cooling system for leaks 1 Allow engine to cool then carefully remove radiator cap 2 Fill radiator with coolant to the normal operating level IMPORTANT DO NOT apply excessive pressure to cooling system doing so may damage radiator and hoses 3 Connect gauge and adapter to radiator filler neck or expansion tank Pressur...

Page 146: ...gnostic gauge A to verify engine speeds See Engine Power and Speed Rating Specifications in the Specifications Section for engine speed specifications If engine speed adjustment is required see your authorized servicing dealer or engine distributor A Tachometer RG13728 UN 11NOV04 Using Tachometer to Check Engine Speeds 40 11 032715 PN 99 ...

Page 147: ...es of valve tips and rocker arm wear pads Check all parts for excessive wear breakage or cracks Replace parts that show visible damage Rocker arms that exhibit excessive valve clearance should be inspected more thoroughly to identify damaged parts 3 Rotate engine in operating direction with the flywheel turning tool until locking pin engages timing hole in flywheel RG20536 UN 03JUN11 Bores to Inse...

Page 148: ...justing screw with a 4 mm hex key wrench until feeler gauge slips with a slight drag Hold the adjusting screw from turning and tighten lock nut to specifications Specification Intake Valve Clearance Rocker Arm to Valve Tip With Engine Cold Clearance 0 35 mm 0 014 in Exhaust Valve Clearance Rocker Arm to Valve Tip With Engine Cold Clearance 0 45 mm 0 018 in Valve Adjusting Screw Lock Nut Torque 27 ...

Page 149: ...l Replace plug in flywheel housing 8 Lubricate valve components with a generous amount of engine oil 9 Install a new gasket C onto the cylinder head D Do not use sealant on gasket IMPORTANT Replace gasket C every time the rocker arm cover is removed 10 Install rocker arm cover B onto the cylinder head 11 Finger start cap screws A through the rocker arm cover and gasket into the cylinder head Tight...

Page 150: ...ecification Cap Screw Torque 11 N m 97 lb in 15 Install OCV inlet pipe Lubricate new O ring with engine oil and install OCV filter inlet tube into the rocker arm cover Tighten M6 cap screw to specification Specification M6 Cap Screw Torque 15 N m 133 lb in 16 Reconnect battery terminal A Cap Screw 2 used B Fuel Injector Heat Shield C External Groove RG25052 UN 12FEB14 Fuel Injector Heat Shield 45 ...

Page 151: ...tension clamps C on the OCV filter oil drain hose K with suitable tool and position clamp 50 mm 2 0 in from the end of the hose Remove the OCV filter oil drain hose K from the OCV filter assembly J inspect for damage 3 Squeeze constant tension clamps C on both ends of OCV filter inlet hose D with suitable tool and position clamps onto the OCV filter inlet tube A Remove the OCV filter inlet hose D ...

Page 152: ...m the end of the hose 8 Lubricate ID of both ends of OCV filter outlet hose E 9 Insert one end of OCV filter outlet hose E onto the OCV filter outlet hose barb 10 Install two constant tension clamps C onto the OCV filter outlet tube F 11 Install the OCV filter outlet hose E onto the OCV filter outlet tube F 12 Squeeze constant tension clamps C with suitable tool and position clamps 2 5 mm 0 08 0 2...

Page 153: ...he entire cooling system test thermostats and fill with recommended clean coolant per the following procedure 1 Pressure test entire cooling system and pressure cap if not previously done See Pressure Testing Cooling System in the Lubrication Maintenance 500 Hours 12 Months Section 2 Slowly open the engine cooling system filler cap or radiator cap A to relieve pressure and allow coolant to drain f...

Page 154: ...2 Remove radiator cap and engine coolant drain plugs as stated in steps 3 and 4 13 Install drain plug on engine block Close drain valve on radiator Tighten plugs to specification Specification Cylinder Block Coolant Drain Plug Torque 17 N m 13 lb ft 14 Install thermostat and thermostat housing with new gasket Tighten cap screws G to specification Reinstall the coolant pump bypass tube Specificatio...

Page 155: ...il it has cooled below operating temperature Always loosen radiator pressure cap or drain valve slowly to relieve pressure 2 Remove radiator pressure cap and partially drain cooling system TS281 UN 15APR13 High Pressure Fluids 3 Remove coolant pump bypass tube from the thermostat housing H Remove cap screws G and thermostat housing H Clean and check housing for cracks or damage 4 Remove thermostat...

Page 156: ...pening Temperature 5 Replace thermostat if defective Installing Thermostat 1 If necessary install seal F into the thermostat housing 2 Remove gasket material from cylinder head K and thermostat housing H surfaces 3 Place thermostat I into recess in thermostat housing with jiggle pin on top for proper deaeration 4 Apply Loctite fast drying black weather strip adhesive to the thermostat housing side...

Page 157: ...can perform repairs See your John Deere dealer IMPORTANT Never steam clean or pour cold water on a high pressure fuel pump while it is still warm To do so may cause seizure of pump parts Modification or alteration of the high pressure fuel pump A the injection timing or the fuel injectors in ways not recommended by the manufacturer will terminate the warranty obligation to the purchaser In additio...

Page 158: ...from pinholes and nozzles which eject fluids under high pressure Use a piece of cardboard or paper to search for leaks Do not use your hand 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 Illino...

Page 159: ...stem at the high pressure fuel pump A Fuel Supply Pump Primer Lever B Air Bleed Screw RG25136 UN 19FEB14 Air Bleed Screw and Fuel Supply Pump Primer Lever 6 Disconnect high pressure pump fuel inlet line A 7 Attach a fuel line to the fuel inlet line A and place other end in a 3 8 L 1 0 gal or larger container 8 Manually prime the mechanical transfer pump until discharge stream of fuel into bucket i...

Page 160: ...ant surge tank loosen the temperature sending unit fitting rear of cylinder head or a plug in thermostat housing to allow air to escape when filling the system Retighten fitting or plug when all the air has been expelled Coolant level should be maintained to the bottom of the surge tank filler neck or radiator filler neck A If needed add coolant as follows 1 Loosen temperature sending unit fitting...

Page 161: ...ible buildup of residue that blocks airflow may degrade machine performance and requires more frequent cleaning depending on environmental conditions Inspect difficult to observe areas daily as conditions may require additional cleaning care to remove debris Check for oil and fuel leaks daily Replace or repair any sources of leaks including gaskets seals breather tubes fittings and fluid lines Mai...

Page 162: ... Cleaner Neck to Engine Intake Overlap 38 mm 1 5 in 5 Tighten neck clamp A to specification below Specification Air Cleaner Neck Clamp Torque 6 8 N m 60 lb in IMPORTANT Do NOT overtighten body clamp Overtightening may cause crushing of air cleaner body Tighten body clamp only until snug 6 If equipped tighten body clamp until snug RG11319A UN 06SEP00 Single Stage Air Filter RG11320 UN 07SEP00 Insta...

Page 163: ...imary air cleaner element when air restriction indicator A shows a vacuum of 625 mm 25 in H2O is torn or visibly dirty NOTE This procedure applies to John Deere 2 stage axial seal air cleaner kits Refer to manufacturers instructions for servicing air cleaners not supplied by John Deere RG8719B UN 03SEP99 Air restriction Indicator 60 7 032715 PN 116 ...

Page 164: ...D and secondary element E Immediately replace secondary element with new element to prevent dust from entering air intake system Specification Retaining Nut Torque 20 N m 177 lb in 5 Install new primary element and tighten wing nut securely Install cover assembly and tighten retaining wing nut securely IMPORTANT Whenever the air cleaner has been serviced or had cover removed ALWAYS fully depress t...

Page 165: ...s usually necessary ONLY when primary element has a hole in it 5 To replace secondary element C pull filter element out gently Immediately replace secondary element with new element to prevent dust from entering air intake system 6 Install new primary filter element Apply pressure by hand at outer rim of filter IMPORTANT Do NOT use latches on cover to force filter into air cleaner Using cover to f...

Page 166: ...re information on the operator interface icons or exhaust filter cleaning procedures please see the Aftertreatment System Section of this Manual or the corresponding Component Technical Manual CTM RG16860 UN 01APR10 Exhaust Filter Cleaning is Needed RG16861 UN 01APR10 Exhaust Filter Cleaning is Disabled RG16862 UN 01APR10 Emission System Temperature is High or Exhaust Fil ter Cleaning is Underway ...

Page 167: ... offered as options with John Deere OEM engines to provide compressed air to operate air powered devices like vehicle air brakes Air compressors are engine driven piston types They are either air cooled or cooled with engine coolant The compressors are lubricated with engine oil The compressor runs continuously as gear or spline driven by the auxiliary drive of the engine but has loaded and unload...

Page 168: ...e following basic diagnostic thought process Know the engine and all related systems Study the problem thoroughly Relate the symptoms to your knowledge of engine and systems Diagnose the problem starting with the easiest things first Double check before beginning the disassembly Determine cause and make a thorough repair After making repairs operate the engine under normal conditions to verify tha...

Page 169: ...ult 14 Incorrect Message 15 Slightly High 16 Moderately High 17 Slightly Low 18 Moderately Low 19 Communication Error 31 Condition Exists SPN Code SPN Name 28 Digital Throttle Signal 29 Secondary Analog Throttle Signal 91 Primary Analog Throttle Signal 94 Low Pressure Fuel Signal 97 Water in fuel Signal 100 Engine Oil Pressure Signal 101 Crankcase Pressure Signal 102 Manifold Air Pressure Signal 1...

Page 170: ... instrument panel may also display text for communication faults such as CAN Bus FAILURE Contact your servicing dealer Diagnostic Trouble Codes DTCs Operation SPN FMI CODES Stored and active diagnostic trouble codes are output on the diagnostic gauge on the Deere electronic instrument panel according to the J1939 standard as a two part code as shown on the tables on the following pages The first p...

Page 171: ...ed splices and terminals Look for broken wires damaged splices and wire to wire shorts Use good judgment if component replacement is thought to be required NOTE The engine control unit ECU is the component LEAST likely to fail Suggestions for diagnosing intermittent faults If diagnostic charts on preceding pages indicate that the problem is intermittent try to reproduce the operating conditions th...

Page 172: ...ter Starter Cranks Slowly Low battery output voltage or discharged battery Charge or replace batteries Too high viscosity crankcase oil Drain crankcase oil and replace with correct viscosity oil Loose or corroded connections Clean and tighten connections Hard to Start or Will Not Start Engine starting under load Disengage PTO Improper starting procedure Review starting procedure Exhaust restricted...

Page 173: ...Deere engine distributor or servicing dealer Electronic fuel system problem See your authorized John Deere engine distributor or servicing dealer Electronic Control System problem or basic engine problem See your authorized John Deere engine distributor or servicing dealer Lack of Engine Power Intake air restriction Service air cleaner Exhaust restricted Check and correct exhaust restriction Poor ...

Page 174: ... John Deere engine distributor or servicing dealer Excessive Fuel Consumption Engine overloaded Reduce engine load Air cleaner restricted or dirty Replace air cleaner element as required Compression too low Determine cause of low compression and repair as required Leaks in fuel supply system Locate source of leak and repair as required Improper type of fuel Drain fuel and replace with proper grade...

Page 175: ... pump repair replace pump as required See your authorized John Deere engine distributor or servicing dealer Abnormal Engine Noise Worn main or connecting rod bearings Determine bearing clearance See your authorized John Deere engine distributor or servicing dealer Excessive crankshaft end play Check crankshaft end play See your authorized John Deere engine distributor or servicing dealer Loose mai...

Page 176: ...Loose or worn rocker arms Inspect rocker arms for wear See your authorized John Deere engine distributor or servicing dealer Bent pushrods Inspect pushrods for straightness and check contact ends for wear and damage See your authorized John Deere engine distributor or servicing dealer Broken valve springs Inspect valve springs See your authorized John Deere engine distributor or servicing dealer B...

Page 177: ... Check intake and exhaust manifold gaskets and manifolds repair as required See your authorized John Deere engine distributor or servicing dealer Improper clearance between turbine wheel and turbine housing Inspect turbocharger repair replace as required See your authorized John Deere engine distributor or servicing dealer Broken blades or other wheel failures Inspect turbocharger repair replace a...

Page 178: ...ctive fuel injectors See your authorized John Deere engine distributor or servicing dealer Engine Emits Black Gray or Blue Smoke Engine overloaded Reduce engine load Engine burning oil See your authorized John Deere engine distributor or servicing dealer Air cleaner restricted or dirty Replace air cleaner element as required Electronic control system problem or basic engine problem See your author...

Page 179: ...emperature replace thermostat as required Damaged cylinder head gasket Replace cylinder head gasket See your authorized John Deere engine distributor or servicing dealer Leak at cylinder head gasket Replace cylinder head gasket See your authorized John Deere engine distributor or servicing dealer Defective coolant pump Replace coolant pump See your authorized John Deere engine distributor or servi...

Page 180: ...il level Faulty pressure sensor Replace sensor See your authorized John Deere engine distributor or servicing dealer Restricted oil cooler or filter Remove and inspect oil cooler See your authorized John Deere engine distributor or servicing dealer Excessive oil temperature Remove and inspect oil cooler See your authorized John Deere engine distributor or servicing dealer Defective oil pump Remove...

Page 181: ...eere engine distributor or servicing dealer Excessive Oil Consumption Too low viscosity crankcase oil Drain crankcase and refill with correct viscosity oil Crankcase oil level too high Drain oil until oil level is correct External oil leak s Determine source of oil leak s and repair as required Excessive oil pressure See High Oil Pressure Oil control rings not seated See your authorized John Deere...

Page 182: ...ankshaft oil seal faulty Replace oil seals See your authorized John Deere engine distributor or servicing dealer Undercharged Electrical System Excessive electrical load from added accessories Remove accessories or install higher output alternator See your authorized John Deere engine distributor or servicing dealer Excessive engine idling Increase engine rpm when heavy electrical load is used Poo...

Page 183: ...ace fuse Entire Electrical System Does Not Function Faulty battery connection Clean and tighten connections Sulfated or worn out batteries Replace batteries Blown fuse Replace fuse Precautions for Electrical System When Steam Cleaning Engine IMPORTANT Do not steam clean any electrical or electronic components while steam cleaning the engine as it could damage sensitive parts 65 16 032715 PN 136 ...

Page 184: ...1 5 Engine Wiring Harness Layout NOTE Location of some sensors may change depending upon the application RG25292 UN 20MAR14 A Exhaust Throttle Actuator B Manifold Air Temperature MAT Sensor C Manifold Air Pressure MAP Sensor D Cold Start Aid Relay 65 17 032715 PN 137 ...

Page 185: ...Troubleshooting Continued on next page ZE59858 000006A 19 17APR14 2 5 RG25294 UN 20MAR14 A Fuel Injector Harness Connector B Suction Control Valve 65 18 032715 PN 138 ...

Page 186: ...ing Continued on next page ZE59858 000006A 19 17APR14 3 5 RG25291 UN 20MAR14 A Engine Oil Pressure Sensor B Exhaust Manifold Pressure Sensor C Fuel Rail Pressure Sensor D Fuel Temperature Sensor 65 19 032715 PN 139 ...

Page 187: ... Continued on next page ZE59858 000006A 19 17APR14 4 5 RG25293 UN 16SEP14 A Intake Air Temperature Sensor B Engine Coolant Temperature Sensor C Camshaft Position Sensor D Crankshaft Position Sensor 65 20 032715 PN 140 ...

Page 188: ...oting ZE59858 000006A 19 17APR14 5 5 RG25295 UN 20MAR14 A Air Filter Restriction Indicator Connector B Exhaust Filter Temperature Module Connector C DPF Differential Pressure Sensor Connector 65 21 032715 PN 141 ...

Page 189: ...erial from area before welding Allow fumes to disperse at least 15 minutes before welding or heating IMPORTANT Welding on the engine is NOT ALLOWED If welding must be performed on the machine follow these precautions IMPORTANT High currents or electrostatic discharge into electronic components from welding may cause permanent damage 1 Remove paint from the area to be welded and ground cable clamp ...

Page 190: ...02 Suction Control Valve Y5021 Fuel Injector Harness Connector 1 5424 2 5419 1 2 1 2 A 5493 B A B 5491 C01 Injector 1 A B A 5494 B 5491 C02 Injector 2 A B A 5495 B 5491 C03 Injector 3 2 5494 4 5491 3 5495 1 5493 4 5491 2 5494 3 5495 1 5493 1 2 3 4 1 3 2 4 12 5030 17 5443 30 5448 51 5447 53 5445 B5301 Crankshaft Position Sensor 2 5447 1 5448 2 5447 1 5448 2 5447 1 5448 1 2 B5301A Crankshaft Positio...

Page 191: ...ay Crankshaft Position Sensor Return A5501 33 5494 Yellow Injector 2 Pulse A5501 34 5493 Orange Injector 1 Pulse A5501 35 5424 Yellow Suction Control Valve Drive Positive A5501 51 5447 Violet Crankshaft Position Sensor Signal A5501 53 5445 Green Camshaft Position Sensor Signal B5301 Crankshaft Position Sensor B5301A Crankshaft Position Sensor Interconnect If Equipped B5302 Camshaft Position Sensor...

Page 192: ... Air Temperature Sensor 1 5455 2 5658 1 2 1 2 1 2 1 2 RG25534 UN 16SEP14 A5502 ECU Connector 2 A5502 04 5468 Gray Manifold Air Pressure Sensor Signal A5502 19 5455 Green Intake Air Temperature Sensor Signal A5502 21 5010 Black Single Point Ground A5502 23 5456 Blue Manifold Air Temperature Sensor Signal A5502 25 5625 Green 5 V Sensor Supply 7 Return A5502 26 5643 Orange Sensor Return 1 A5502 28 56...

Page 193: ... 51 52 53 54 18 19 20 21 22 28 29 30 31 32 38 39 40 41 42 08 5415 22 5611 30 5613 B5100 Fuel Rail Pressure Sensor 3 5611 2 5415 1 5613 2 1 3 2 1 3 RG25535 UN 16SEP14 A5501 ECU Connector 1 A5501 27 5636 Blue 5 V Sensor Supply 8 Return A5501 42 5634 Yellow 5 V Sensor Supply 8 Positive A5502 ECU Connector 2 A5502 07 5467 Violet Engine Oil Pressure Sensor Signal A5502 08 5415 Green Fuel Rail Pressure ...

Page 194: ...5474 1 5437 4 5786 3 5783 2 5474 3 5785 1 5437 2 5474 1 5437 4 5786 3 5783 B5204 Exhaust Filter Temperature Module B5204A Exhaust Filter Temperature Module Interconnect 1 3 2 4 1 2 3 4 1 2 3 4 1 2 3 1 2 3 1 2 3 1 2 3 4 1 2 3 A5502 ECU Harness Connector 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 23 24 25 26 27 33 34 35 36 37 43 44 45 46 47 48 49 50 51 52 53 54 18 19 20 21 22 28 29 30 31 32 38 39 4...

Page 195: ...pply A5501 52 5631 Brown 5 V Sensor Supply 3 Positive A5502 ECU Connector 2 A5502 03 5785 Green DPF Differential Pressure Sensor Signal A5502 12 5509 White Exhaust Throttle Actuator Position Signal A5502 31 5474 Yellow 5 V Sensor Supply 6 Return A5502 41 5437 Violet 5 V Sensor Supply 6 Positive B5109 DPF Differential Pressure Sensor B5109A DPF Differential Pressure Sensor Interconnect B5204 Exhaus...

Page 196: ...Troubleshooting 65 29 032715 PN 149 ...

Page 197: ...2 5022 5332 5092 5002 5022 5332 F5004 JD Link Fuse 5082 5092 F5012 ECU Power Fuse 5082 5022 To Diagram 6 To Diagram 6 To Diagram 6 To Diagram 6 C E F To Diagram 7 G B 10 A 20 A 1 2 F5001 TVP Fuse 5082 5332 30 A 50 M 1 5412 1 5412 5412 5412 1 2 1 2 X5002 Alternator Excitation Interconnect X5009 Alternator Excitation To Diagram 6 A V5700 Transient Voltage Protection 5050 5332 B 5050 A 5332 A B A B A...

Page 198: ...er To 2 9 L Wiring Diagram 6 F 5002 Red Control Panel Unswitched Power To 2 9 L Wiring Diagram 6 F5000 Control Panel Fuse 30 Amp F5001 Transient Voltage Protection Fuse 30 Amp F5004 JD Link Fuse 10 Amp F5010 Cold Start Aid Fuse 50 Amp F5012 ECU Power Fuse 20 Amp G 5002 Red Control Panel Unswitched Power To 2 9 L Wiring Diagram 7 G5000 Battery G5000 Positive 5082 Red Battery Power Positive G5001 Al...

Page 199: ... R 5981 45 03 08 P 5937 N 5436 M 5948 47 20 31 W 5473 X 5050 U 5017 T 5024 05 46 V 5015 5971 5954 5714 5012 5911 5939 5917 5941 5027 5913 5039 5036 5981 5937 O 5943 12 5943 5436 5948 5473 5017 5024 5015 48 53 33 04 10 35 06 37 22 54 49 32 5814 5044 5915 5439 5916 5947 5918 5616 5955 5923 15 5018 18 5019 5936 A H G E D F B J C A B C D E K J H G F H 5002 To Diagram 8 For Mating Connector I To Diagra...

Page 200: ...5714 Yellow 5 V Sensor Supply 5 Return A5503 35 5439 White Tachometer A5503 36 5039 White Vehicle Speed Signal A5503 37 5497 Violet Multi State Throttle A5503 38 5917 Violet Cruise Remote Switch A5503 39 5971 Brown Cruise Cancel Resume Switch A5503 42 5939 White External Derate Switch A5503 45 5036 Blue Optional Sensor A5503 46 5017 Violet AC High Pressure Switch A5503 47 5937 Violet Isochronous G...

Page 201: ...plication Specific S5014 Aftertreatment Interface Switch From Diagram 6 From Diagram 5 5050 D 5002 G RG25539 UN 16SEP14 A5503 ECU Connector 3 A5503 16 5025 Green Exhaust Temperature High Lamp A5503 17 5026 Blue DPF Regeneration Required Lamp A5503 25 5028 Gray Spare Driver Positive A5503 26 5029 White DPF Regeneration Status Lamp Starter Relay Control Negative A5503 30 5034 Yellow Starter Relay Co...

Page 202: ...le Speed S5009 External Derate Switch S5005 External Shutdown Switch S5006 Cruise Remote Switch S5008 Isochronous Droop Governor Switch S5007 Cruise Brake Switch H5000 Stop Engine Lamp U5000 PWM Throttle Alternator Feedback S5100 AC High Pressure Switch S5004 Cruise On Switch 5012 5714 5039 5050 5027 5012 5954 5050 5971 5050 5939 5012 5941 5917 5911 5937 5943 5913 5714 5911 5017 5911 5981 5473 505...

Page 203: ...C 5714 Yellow 5 V Sensor Supply 5 Return X5020 D 5971 Brown Cruise Cancel Resume Switch X5020 E 5954 Yellow Cruise On Switch X5020 F 5913 Orange Secondary Throttle X5020 G 5027 Violet PTO Speed X5020 H 5039 White Vehicle Speed Signal X5020 J 5939 White External Derate Switch X5020 K 5941 Brown External Shutdown Switch X5020 L 5917 Violet Cruise Remote Switch X5020 M 5948 Gray Cruise External Overr...

Page 204: ...A 464 914 918 B A 947 414 914 B A 012 C 936 955 3 1 Data 4 Data 6 3 1 4 6 3 1 4 6 3 1 4 6 3 1 4 6 SPG V B A 915 C 911 914 C B A A B C B A B A B C A 1 1 4 4 2 5 2 5 3 6 3 6 ST BAT ACC RUN 1 2 3 1 2 3 6 5 4 6 5 4 1 2 3 6 5 4 1 2 3 6 5 4 3 Data 4 Data 6 SPG 1 3 4 6 1 3 4 6 1 3 4 6 1 3 4 V P5000 Tachometer Data Data SPG V 1 2 3 1 2 3 6 5 4 6 5 4 1 2 3 6 5 4 1 2 3 6 5 4 Data Data SPG V P5200 Coolant Te...

Page 205: ...nswitched Power X5021 C 914 White 5 V Sensor Supply 4 Return X5021 D 422 White Start X5021 E 050 White Battery Negative X5021 F 020 White Primary CAN Shield X5021 G 012 White Key Switch X5021 J 412 White Alternator Excitation X5021 L 915 White Primary Throttle X5021 M 911 White 5 V Sensor Supply 4 Positive X5021 N 918 White Shutdown Override Switch X5021 P 464 914 White 5 V Sensor Supply 5 Return ...

Page 206: ...oline or equivalent vapor corrosion inhibitor 2 Replace air cleaner 3 Draining and flushing of cooling system is not necessary if the engine is only stored for less than one year However for extended storage periods of a year or longer it is recommended that the cooling system be drained flushed and refilled Refill with appropriate coolant See Diesel Engine Coolant engine with wet sleeve cylinder ...

Page 207: ...erform all appropriate prestarting checks See Daily Prestarting Checks in the Lubrication Maintenance Daily Section for more information IMPORTANT DO NOT operate starter more than 30 seconds at a time Wait at least 2 minutes for starter to cool before trying again 7 Crank engine for 20 seconds with starter Do not allow the engine to start Wait 2 minutes and crank engine an additional 20 seconds to...

Page 208: ...peed Rating Specifications in the Specifications Section Lubrication System Crankcase Oil Fill Capacity See Engine Crankcase Oil Fill Quantities in the Specifications Section Oil Pressure At Rated Speed kPa Bar psi 357 3 57 52 Oil Pressure At Low Idle Minimum kPa Bar psi 254 2 54 37 Cooling System Thermostat Start To Open Temperature C F 83 181 Thermostat Fully Open Temperature C F 95 203 Recommen...

Page 209: ...8 64 48 64 1800 1500 3029HFG03 7APJ 12 55 74 48 64 1800 1500 Engine Crankcase Oil Fill Quantities 1111 4391 6901 1399 4607 72F3 1425 4702 7306 3029HMY43 1553 C 2 9 L 1524 4803 7703 1606 4903 7897 1708 5002 8422 1928 5103 8911 2002 5215 9805 2699 5407 2815 5511 2909 5615 3008 5709 3512 5927 3914 6543 4026 6801 JOHN DEERE Customer No OPTION CODES Number PY3029R000093 A RG24034 UN 06AUG13 A Engine Ba...

Page 210: ...3400 2500 1 1 2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350 Torque values listed are for general use only based on the strength of the bolt or screw DO NOT use these values if a different torque value or tightening procedure is given for a specific application For plastic insert or crimped steel type lock nuts for stainless steel fasteners or for nuts on U bolts see t...

Page 211: ...1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730 M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500 Torque values listed are for general use only based on the strength of the bolt or screw DO NOT use these values if a different torque value or tightening procedure is given for a specific application For stainless steel fasteners or for nuts on U bolts see...

Page 212: ...ems to be performed and the service intervals required refer to the quick reference chart near the front of the Lubrication and Maintenance Section IMPORTANT The service recommendations covered in this manual are for the accessories that are provided by John Deere Follow manufacturer s service recommendations for servicing engine driven equipment not supplied by Deere Daily Prestarting Service Che...

Page 213: ...ical ground connection Check cooling system Pressure test cooling system Check engine speeds Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date 1 Service intervals depend on sulfur content of the diesel fuel oil pan capacity and the oil and filter used See DIESEL ENGINE OIL AND FILTER SERVICE INTERVALS in Fuels Lubricants and Coolant Section 1200 Hours Check an...

Page 214: ...vice Changing Open Crankcase Ventilation OCV Filter Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date 6000 Hours or 72 Months Service Flush and refill cooling system Test thermostats Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date 80 3 032715 PN 167 ...

Page 215: ...er Bleed fuel system Add coolant Pre Start Cleaning Guide Service Replace air cleaner Clean exhaust filter Replace fan belt Check fuses Check electrical wiring and connections Check air compressor if equipped Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date 80 4 032715 PN 168 ...

Page 216: ...nd legal requirements and for marketing and promotional purposes Sometimes we may ask our John Deere affiliates dealers or business partners to do work for us which involves your information For complete details on your privacy rights and to obtain a copy of the John Deere Privacy Statement please visit our website at https www johndeere com Warranty Duration Unless otherwise provided in writing b...

Page 217: ...antable problems Services performed by a party other than an authorized John Deere service dealer Charges by dealers for initial start up and inspection deemed unnecessary by John Deere when an Operator s Manual is supplied with the product are followed Costs related to interpretation or translation services No Representations or Implied Warranty Where permitted by law neither John Deere nor any c...

Page 218: ... number 1 319 292 5844 or in Europe fax number 33 2 38 84 62 66 Local Warranty Requirements Warranties required by local statutes will be furnished by the seller Option Codes Engine Manufacturing Configuration When in need of engine replacement parts your authorized John Deere service dealer will need to know the corresponding Option Codes for your engine The option code label on the engine rocker...

Page 219: ... The presence of an EU number signifies that the engine has been certified with the European Union countries per Directive 97 68 EC The EPA and or CARB emissions warranties do not apply to the EU countries The emissions label has applicable US EPA and or CARB regulatory year The regulatory year determines which warranty statement is applicable to engine See EPA Non road Emissions Control Warranty ...

Page 220: ...ation whichever first occurs Where a warrantable condition exists John Deere will repair or replace as it elects any part or component with a defect in materials or workmanship that would increase the engine s emissions of any regulated pollutant within the stated warranty period at no cost to you including expenses related to diagnosing and repairing or replacing emission related parts Warranty c...

Page 221: ...Warranty DX EMISSIONS EPA 19 12DEC12 2 2 TS1721 UN 15JUL13 85 6 032715 PN 174 ...

Page 222: ...et the State s stringent anti smog standards John Deere must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the fuel injection system and the air induction system Also included may be hoses belts connectors and other emissio...

Page 223: ...cheduled replacement point for the part Any warranted emissions related part not scheduled for replacement as required maintenance or scheduled only for regular inspection is warranted by John Deere for the stated warranty period OWNER S WARRANTY RESPONSIBILITIES As the off road diesel engine owner you are responsible for the performance of the required maintenance listed in your Operator s Manual...

Page 224: ...Warranty Continued on next page DX EMISSIONS CARB 19 01AUG14 3 8 RG25841 UN 19MAY14 85 9 032715 PN 177 ...

Page 225: ...Warranty Continued on next page DX EMISSIONS CARB 19 01AUG14 4 8 TS1723 UN 15JUL13 85 10 032715 PN 178 ...

Page 226: ...andards John Deere must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the fuel injection system and the air induction system Also included may be hoses belts connectors and other emission related assemblies John Deere warra...

Page 227: ...cheduled replacement point for the part Any warranted emissions related part not scheduled for replacement as required maintenance or scheduled only for regular inspection is warranted by John Deere for the stated warranty period OWNER S WARRANTY RESPONSIBILITIES As the off road diesel engine owner you are responsible for the performance of the required maintenance listed in your Operator s Manual...

Page 228: ...Warranty Continued on next page DX EMISSIONS CARB 19 01AUG14 7 8 RG26035 UN 24JUN14 85 13 032715 PN 181 ...

Page 229: ...Warranty DX EMISSIONS CARB 19 01AUG14 8 8 RG26036 UN 24JUN14 85 14 032715 PN 182 ...

Page 230: ...es 10 11 Coolant pump Inspecting 40 5 Cooling system Adding coolant 60 4 Check 40 9 Page Flush 55 1 Pressure test 40 10 Refill 55 1 D Daily prestarting checks 35 1 Daily Service 80 1 Diagnostic Gauge Keys and Indicators 25 4 Diagnostic procedure Using diagnostic gauge 15 3 Diagnostic trouble codes DTCs Active engine service codes viewing 15 9 Intermittent fault code diagnostics 65 4 Listing 65 2 O...

Page 231: ...ng 25 5 Cleaning 25 1 60 10 Cleaning and maintenance 25 1 Disposal 25 2 Maintenance and service 25 2 Manual parked cleaning 25 6 Passive regeneration natural cleaning 25 5 Service required 25 7 System overview 25 3 Filters Oil Oil Filters 10 9 Page Fire extinguisher service 40 1 Fuel BioDiesel 10 3 Diesel 10 1 Handling and storing 10 2 Lubricity 10 2 Fuel filter Replace 37 1 Fuel Filter Drain wate...

Page 232: ... Break in 20 1 Changing speed 20 5 Cold weather 20 6 Page Idling 20 4 Normal operation 20 3 Warming engine 20 4 Option codes 01 2 Orientation View Engine 5 P Passive Regeneration 25 5 Power ratings 75 2 Pre start cleaning Guide 60 5 Prestarting Service Daily 80 1 Proposition 65 05 2 R Recordkeeping Engine Control Unit ECU serial number 01 4 Engine option codes 01 2 Fuel pump model number 01 3 Refu...

Page 233: ... oil fill 75 2 Fuel injection pump and power ratings 75 2 General OEM 75 1 Starting engine 20 2 Steam Cleaning Engine 65 16 Stopping engine 20 7 Storage Guidelines 70 1 Storing fuel 10 2 T Thermostat Install 55 3 Remove 55 3 Test opening temperature 55 3 Torque charts Metric 75 4 Unified inch 75 3 Trademarks 6 Troubleshooting DTC Operation 65 3 General information 65 1 General engine 65 5 Intermit...

Page 234: ... warranty Equipment operators can t afford downtime or unexpected repairs That s why we offer a 2 year 2 000 hour warranty with unlimited hours in the first year on our OEM industrial and marine engines This warranty takes effect the date that the engine is delivered to the first retail purchaser In addition extended warranties are available under certain conditions John Deere offers a variety of ...

Page 235: ...Engine Registration IBC 2 032715 PN 188 ...

Page 236: ...eet 10 Agriculture Earth Moving Forestry Generator Set Industrial Marine Industrial Moveable Marine Propulsion Material Handling Municipal Utility Commercial On Highway Road and Miscellaneous Construction Rail Maintenance Other Purchase s Signature PRODUCT AND EQUIPMENT INFORMATION Product Serial Number Date Delivered Amount of Use Hours Miles New or Used Use of Information All personal informatio...

Page 237: ...Engine Registration BL90236 0000029 19 19NOV13 1 1 Mail In Registration MAILING INFORMATION Return Address John Deere Power Systems P O Box 5100 Waterloo IA 50704 5100 USA IBC 4 032715 PN 190 ...

Page 238: ...Engine Registration IBC 5 032715 PN 191 ...

Page 239: ...Engine Registration IBC 6 032715 PN 192 ...

Page 240: ...saue Axial Piston Pumps and Motors Service Manual Series 90 CONTENTS ...

Page 241: ...Authorized Service Center for details A list of all Service Centers can be found in bulletin BLN 2 40527 or in brochure SAW Ident No 698266 1 1 Use of This Manual Loss of Hydrostatic Braking Ability WARNING When Series 90 units are used in vehicular hydrostatic drive systems the loss of hydro static drive line power in any mode of opera tion e g acceleration deceleration or neu tral mode may cause...

Page 242: ...lacement Control EDC 14 2 5 4 Automotive Control AC and AC II 14 2 5 5 3 Position FNR Electric Control 14 2 6 Motor Features 15 2 6 1 Motor Loop Flushing Valve and Charge Relief Valve 15 2 6 2 Variable Motor Displacement Limiters 15 2 7 Variable Motor Controls 16 2 7 1 Hydraulic 2 Position Control 16 2 7 2 Electric 2 Position Control 16 3 Technical Specifications 17 3 1 General Specifications 17 3...

Page 243: ... 9 2 4 Charge Pump 58 9 2 5 Auxiliary Pad Installation 62 9 2 6 Filtration Options 64 9 3 Pump Controls 65 9 3 1 Cover Plate 65 9 3 2 Manual Displacement Control MDC 66 9 3 3 Solenoid Override Valve for MDC 67 9 3 4 Solenoid Override Valve for MDC with Pressure Released Brake 67 9 3 5 Hydraulic and Electric Displacement Controls 68 9 3 6 Pressure Control Pilot PCP for Electric Displacement Control...

Page 244: ...ich imparts the input energyintothehydraulicfluid Thehighpressurefluid is then ported out to provide power to a remote function The swashplate angle can be varied by the control piston Altering the swashplate angle varies the dis placement of fluid in a given revolution of the input shaft A larger angle causes greater displacement which yields greater output torque for a given input A smaller angl...

Page 245: ... Series 90 MV Cross Section 90000190 Series 90 MF Cross Section Piston Roller Bearing Output Shaft Valve Plate Loop Flushing Valve Cylinder Block Fixed Swashplate In the Fixed Displacement Motor the swashplate is fixed so any variation in motor speed and torque must be made by the input mechanism i e the pump 2 1 3 Variable Displacement Motor The Variable Displacement Motor MV operates in the same...

Page 246: ...3 The Basic Closed Circuit Themainportsofthepumpareconnectedbyhydrau lic lines to the main ports of the motor Fluid flows in either direction from the pump to the motor then back to the pump in this closed circuit Either of the hydrau lic lines can be under high pressure The position of the pump swashplate determines which line is high pressure as well as the direction of fluid flow Case Drain and...

Page 247: ...d cap axial ports or both ports on one side twin ports See the Series 90 Technical Information manuals BLN 10029 and BLN 10030 or the Series 90 Price Book BLN 2 40588 for information on available options Removing the end cap will void the warranty on a Series 90 pump or motor 2 3 2 Speed Sensors An optional speed sensor can be installed on Series 90 pumps and motors to provide unit speed informa t...

Page 248: ...arge pressure at a designated level A direct acting poppet valve relieves charge pressure when ever it surpasses a certain level This level is nomi nally set referencing case pressure at 1775 rpm This nominal setting assumes the pump is in neutral zero flow in forward or reverse charge pressure will be lower The charge relief valve setting is specified on the model code of the pump Sec 8 1 1 For r...

Page 249: ...lude a pressure limiter valve 2 4 5 Pressure Limiter and High Pressure Relief Valves Series 90 pumps are designed with a sequenced pressure limiting system and high pressure relief valves When the preset pressure is reached the pressure limiter system acts to rapidly destroke the pump so as to limit the system pressure For unusu ally rapid load application the high pressure relief valve acts to im...

Page 250: ...egral or remote mounted to filter the fluid entering the charge circuit See Sec 6 for more information Suction Filtration The suction filter is placed in the circuit between the reservoir and the inlet to the charge pump When suction filtration is used a reducer fitting is placed in the charge pressure gauge port M3 Filtration de vices of this type are provided by the user Charge Pressure Filtrati...

Page 251: ...h the pump displacement control Control supply pressure is normally ported through the pressure override valve to the displacement control valve for controlling the pump s displacement If the system demands a pressure above the override setting the POR valve will override the control by reducing the control pres sure supplied to the displacement control As the control pressure reduces the internal...

Page 252: ... control input shaft is rotated toward its maximum displacement position For adjustments see Sec 8 2 2 for repairs see 9 3 2 Solenoid Override Valve A solenoid override valve option not shown here is available for MDC This safety feature will return the swashplate to zero displacement position when acti vated The valve may be set in either a normally open ornormallyclosedmode Forrepairssee9 3 3 9 ...

Page 253: ...d so the angular position of the swashplate is proportional to the EDC input For neutral adjustment see Sec 8 2 4 for repairs see Sec 9 3 5 9 3 6 and 9 3 8 2 5 4 Automotive Control AC and AC II Automotive Control AC allows a vehicle to be driven in a manner similar to an automobile with an auto matic transmission The AC control includes a three position electric control to provide direction contro...

Page 254: ... there is a pressure differen tial in the main loop The shuttle valve is spring centered to the closed position so that no high pres sure fluid is lost from the circuit when reversing pressures For charge relief valve adjustment see Sec 8 3 1 for repairs see Sec 9 4 1 MF showing location of Loop Flushing Valve 90000248 Charge Relief Valve Loop Flushing Shuttle Valve End Cap Top of Motor 90000238 M...

Page 255: ...tions of the hydraulic two position control are preset at the factory For repairs see Sec 9 5 2 and 9 5 4 2 7 2 Electric 2 Position Control This control utilizes an electric solenoid operated three way hydraulic valve to port system pressure to either of the motor displacement control pistons The motor is normally held at its maximum displacement Energizing the solenoid will cause the motor to go ...

Page 256: ...ith fixed dis placement fixed swashplate design Type of Mounting per SAE J744 SAE flange Size B mounting pad 2 bolts SAE flange Size C mounting pad 4 bolts Cartridge flange 2 bolts for motor only Port Connections See Sec 4 2 for exact specs Main pressure ports SAE flange Code 62 Remaining ports SAE straight thread O ring boss Direction of Rotation Clockwise or counterclockwise motors are bidi rect...

Page 257: ... i t n o C m u m i x a M r a b 3 i s p 4 4 t n e t t i m r e t n I m u m i x a M t r a t S d l o C r o r a b 5 i s p 3 7 t n e t t i m r e t n I m u m i n i M t r a t S d l o C r o 0 4 C 0 4 F s u o u n i t n o C m u m i x a M 4 0 1 C 0 2 2 F t n e t t i m r e t n I m u m i x a M 5 1 1 C 0 4 2 F t n e t t i m r e t n I m u m i n i M m m 5 2 s S U S 2 4 s u o u n i t n o C m u m i n i M m m 4 6 2 s...

Page 258: ... 7 5 6 3 6 9 2 4 4 7 1 1 4 3 2 2 6 6 9 2 8 7 r e w o p r e n r o c x a M W k p h 1 1 1 9 4 1 5 5 1 8 0 2 7 8 1 1 5 2 7 3 2 8 1 3 2 9 2 2 9 3 4 5 3 5 7 4 4 2 2 0 0 3 2 8 2 8 7 3 t h g i e W e g n a l F E A S g k b l 1 1 4 2 5 1 4 3 0 2 5 4 6 2 7 5 4 3 4 7 5 4 9 9 9 3 6 8 4 4 8 9 t h g i e W r o t o M e g d i r t r a C g k b l 7 1 7 3 6 2 7 5 3 3 2 7 0 4 8 8 6 4 1 0 1 n o i s n e m i D V P 0 3 0 V P...

Page 259: ...e r u s s e r P e g u a G i s p 0 0 5 r o r a b 0 5 g n i t t i F g n i R O 8 1 6 1 9 t r o P n o i t c n u F e z i S e g u a G d e d n e m m o c e R g n i t t i F d n a 1 L 2 L e s a C e r u s s e r P e g u a G i s p 0 0 1 r o r a b 0 1 g n i t t i F g n i R O E A S 2 4 0 0 3 0 4 1 8 7 5 7 0 5 5 0 0 0 1 2 1 6 1 1 1 0 3 1 2 1 6 1 5 1 0 5 2 0 8 1 2 1 8 5 1 1 X 2 X C D E C D H e r u s s e r P e g u ...

Page 260: ...1 Top View System Pressure Port B System Pressure Gauge Port M2 System Pressure Gauge Port M1 System Pressure Port A Case Drain Port L1 Case Drain Port L2 Left Side View System Pressure Port B Charge Pump Inlet Port S Charge Inlet Pressure External Control Pressure Supply Port X3 Charge Pressure Gauge Port M3 Right Side View Speed Sensor PV with Side Port End Cap and Manual Displacement Control 90...

Page 261: ...in Port L2 Left Side View System Pressure Port B Charge Pump Inlet Port S System Pressure Port A Servo Displacement Cylinder Pressure Gauge Port M5 External Control Pressure Supply Port X3 Servo Displacement Cylinder Pressure Gauge Port M4 Charge Pressure Gauge Port M3 Case Drain Port L1 Top View PV with Side Port End Cap and Remote Pressure Filtration PV with Side Port End Cap and Integral Pressu...

Page 262: ... i S e g u a G d e d n e m m o c e R g n i t t i F d n a 1 M m e t s y S e r u s s e r P A t r o P e g u a G i s p 0 0 0 0 1 r o r a b 0 0 0 1 g n i t t i F g n i R O 8 1 6 1 9 2 M m e t s y S e r u s s e r P B t r o P e g u a G i s p 0 0 0 0 1 r o r a b 0 0 0 1 g n i t t i F g n i R O 8 1 6 1 9 3 M e g r a h C e r u s s e r P 3 M t r o P e g u a G i s p 0 0 0 1 r o r a b 0 5 g n i t t i F g n i R...

Page 263: ... y S e r u s s e r P A t r o P e g u a G i s p 0 0 0 0 1 r o r a b 0 0 0 1 g n i t t i F g n i R O 8 1 6 1 9 2 M m e t s y S e r u s s e r P B t r o P e g u a G i s p 0 0 0 0 1 r o r a b 0 0 0 1 g n i t t i F g n i R O 8 1 6 1 9 3 M e g r a h C e r u s s e r P e g u a G i s p 0 0 0 1 r o r a b 0 5 g n i t t i F g n i R O 8 1 6 1 9 t r o P n o i t c n u F e z i S e g u a G d e d n e m m o c e R g n...

Page 264: ...to monitor the charge pressure during start up It is recommended that the external control input signal linkage for MDC hydraulic lines for HDC or electrical connections for EDC be disconnected at the pump control until after initial start up This will ensure that the pump remains in its neutral position WARNING Do not start prime mover unless pump is in neutral position 0 swashplate angle Take pr...

Page 265: ...mp Filter Hydraulic fluid reservoir Adjustable Charge pressure relief valve To pump case to low pressure side and control Mano Vacuummeter To pump case Charge pump Hydraulic fluid reservoir Filter to low pressure side and control Screen Adjustable Charge pressure relief valve Suction Filtration Schematic Charge Pressure Filtration Schematic Partial Flow P000797 E P000798 E It may be necessary to c...

Page 266: ...at exchanger Measure charge pressure 4 2 Inspect and adjust or replace charge relief valve 8 1 1 and 9 2 3 Or repair leaky charge pump 9 2 4 Check charge inlet vacuum 4 2 If high inspect inlet filter and replace as neces sary Check for adequate line size length or other restrictions Verify settings of pressure limiters and high pressure relief valves and adjust or replace multi function valves as ...

Page 267: ...l 3 Check pump displace ment control 4 Ensurebypassvalve s are closed 5 Checkchargepressure with pump in neutral 6 Checkchargepressure with pump in stroke 7 Inspect pump charge relief valve 8 Check charge pump inlet filter Insufficient hydraulic fluid to supply system loop Input to control module is operating improperly Control linkages are not secure con trol orifices are blocked etc If bypass va...

Page 268: ... affect output speed Incorrectoutputflowindicates the swashplate is out of position If variable motor displacement con trol is not functioning correctly vari able motor swashplate may be in wrong position Fill oil to proper level Measure charge pressure 8 1 1 adjust charge system as necessary 9 2 3 and 9 2 4 Measure pump output flow by teeing into outflowhose Checkforproperpumpspeed and see that t...

Page 269: ...surechargeandcontrolpressuresand correct if necessary 4 2 and others Check for leakage in O rings gaskets and other fittings 9 1 1 and others Replace pump and motor 7 7 Excessive Noise and or Vibration Item Description Action 1 Check oil in reservoir 2 Air in system 3 Check pump inlet vacuum 4 Inspectshaftcouplings 5 Inspect shaft align ment Insufficient hydraulic fluid will lead to cavitation Air...

Page 270: ...ressure gauge port M3 Also install a gauge to measure case pressure tee into L1 or L2 or use servo gauge port Operate the system with the pump in neu tral zero displacement when measuring pump charge pressure 2 The table on the following page shows the accept able pump charge pressure range for some nomi nalchargereliefvalvesettings seesamplemodel code at right These pressures assume 1775 pump rpm...

Page 271: ...alve Adjustment of the charge pressure is ac complished by loosening the lock nut with a 1 1 16 inch hex wrench for 030 through 100 units or a 1 5 8 inch hex wrench for 130 through 250 units and turning the adjustment plug with a large screwdriver or a 1 2 inch hex wrench Clock wise rotation of the plug increases the setting and counterclockwise rotation decreases the setting at a rate of approxim...

Page 272: ... wrench for earlier 042 through 100 frame size units a 19 mm wrench for 030 and later 042 through 100 frame size units or a 13 mm wrench for earlier 130 frame size units 4 Insert a 3 mm early 042 through 100 units 5 mm 030 and late 042 through 100 units or 4 mm earlier 130 units internal hex wrench into the pressure adjusting screw NOTE A plastic dust plug is installed in the adjusting screw on 03...

Page 273: ... the high pressure circuit to the newly adjusted pressure limiter pressure set ting and read the high pressure gauge Then allow the pump to return to its neutral position The pressure in the high pressure circuit should return to the charge pressure setting 8 While holding the pressure adjusting screw sta tionary tighten the pressure adjusting screw lock nut to 3 Nm 26 in lbf on early production u...

Page 274: ...prevent rotationofthecartridgeassembly rotatethemiddle hex three revolutions counterclockwise to open the bypass valve Do not rotate more than 3 1 2 revolutions as additional rotation will permit ex ternal leakage 2 For units with an MDC type control prior to mov ing the vehicle or otherwise causing the motor shaft to turn move the control handle of the manual displacement control on the pump to t...

Page 275: ...e work function and note the pressure as the POR valve operates pump dis placement reduces to zero 4 Adjustment of the pressure override setting is made by loosening the lock nut with a 9 16 inch hexwrenchandturningtheadjustmentscrewwith a 3 16 inch internal hex wrench The POR setting should be at least 50 bar 750 psi below the high pressure relief valve setting of the multi function valves for pr...

Page 276: ...he desired maximum displace ment setting tighten the lock nut on the adjusting screw as follows 90000267 90000268 Rotate Adjusting Screw Tighten Lock Nut 90000269 e z i S e m a r F r e p p s i D n i e g n a h C x o r p p A w e r c S g n i t s u j d A f o v e R 0 3 0 m c 8 2 3 n i 7 1 0 v e r 3 v e r 2 4 0 m c 4 3 3 n i 1 2 0 v e r 3 v e r 5 5 0 m c 0 4 3 n i 5 2 0 v e r 3 v e r 5 7 0 m c 0 5 3 n i...

Page 277: ...Adjustment There are no adjustable elements in the manual displacement control The control spool is held in its neutral position by centering springs and washers on each end of the spool Since there is no centering spring on the control input shaft the shaft will auto matically assume the appropriate position when the control is installed on the pump For a functional description see Sec 2 5 1 CONT...

Page 278: ... an equal amount on the other gauge Note the angular position of the wrench 5 Rotate the adjusting screw clockwise half the distance between the locations noted above The gauges should read the same pressure case pressure indicating that the control is in its neu tral position 6 Hold the adjusting screw stationary and tighten the lock nut to 13 6 Nm 10 in lbf Do not overtorque the nut 7 Once the n...

Page 279: ...Neutral Start Switch 8 2 3 MDC Neutral Start Switch NSS Adjustments The neutral start switch NSS provides a means to prevent the system prime mover from starting while the pump control handle and control input shaft are in a position which would command the pump to go in stroke in either the forward or reverse direction When the control input shaft is in its neutral position the inner end of the s...

Page 280: ...ed by normal operating clearances in the control linkage control shaft free play By setting the NSS to open outside this area the control spool springs or control shaft centering spring can always act to return the handle to neutral and re close the NSS iii The NSS deadband must be narrow enough so the NSS will open before the unit builds 7 bar 100 psi differential system pressure in either direc ...

Page 281: ...ntinuitycheckerattachedtotheswitch rotate the control handle or the control shaft in each direction to assure continuity is broken when the control is not in the neutral position 6 If continuity is obtained in neutral and satisfacto rily interrupted in each direction proceed to check the switch with the prime mover running The switch must open beforethe unit builds 7 bar 100 psi differential syste...

Page 282: ... the locknut Remove the neutral start switch CAUTION Do not start the prime mover while the neutral start switch is removed from the control Case pressure will force the pin out of the eccentric plug causing oil loss NSS Showing Eccentric Plug Eccentric Plug Adjustment Tool NSS Removed 12 7 O D 0 5 9 14 I D 0 36 3 175 0 125 1 52 0 06 25 4 1 Neutral Start Switch Switch Lock Nut Eccentric Plug Switc...

Page 283: ...nter the switch pin with the cam slot Only a small amount of adjustment in either direc tion should be needed to center the pin 6 While holding the eccentric plug in place tighten the eccentric plug lock nut to 27 Nm 20 ft lbf Reinstall and adjust the switch as outlined in the previous section NOTE The eccentric plug normally requires between 5 1 2 and 6 1 2 turns to install into the control housi...

Page 284: ...creases more than 0 9 bar 12 psi from the base pressure obtained at neutral 5 Slowly move the control handle in the opposite direction Again continuity must be broken before the gauge pressure increases more than 0 9 bar 12 psi from base pressure 6 Continuity must again be verified when the control is returned to neutral 7 If continuity is not broken at base pressure plus 0 to 0 9 bar 0 to 12 psi ...

Page 285: ...or a neutral adjusting screw HDCs and current produc tion EDCs WARNING The following procedure requires the vehicle machine to be disabled wheels raised off the ground work function disconnected etc in order to prevent injury to the technician and bystanders 1 Install two 50 bar or 1000 psi gauges in each of the two displacement control cylinder gauge ports M4 and M5 Disconnect the external contro...

Page 286: ... position of the wrench Then rotate the neutral adjusting shaftorscrewcounterclockwiseuntilthepressure increasesbyanequalamountontheothergauge Again note the angular position of the wrench 4 Rotate the neutral shaft or adjusting screw clock wisehalfthedistancebetweenthelocationsnoted above The gauges should read the same pres sure case pressure indicating that the control is in its neutral positio...

Page 287: ...he plug 7 8 inch hex and changing the shim thickness behind the spring The plug for this type charge relief port should be torqued to 68 Nm 50 ft lbf Later production Series 90 motors are equipped with an external screw adjustable charge relief valve Adjustment of charge pressure is accom plished by loosening the lock nut with a 1 1 16 inch hex wrench for 030 through 100 units or a 1 5 8 inch hex ...

Page 288: ...ing the desired displacement set ting tighten the lock nut on the adjusting screw to 54 Nm 40 ft lbf Install a new tamper resistant cap 4 One turn of the adjusting screw will change the maximum or minimum displacement according to the following chart 90000359 Rotate Adjusting Screw for Minimum Displacement Limiter 90000352 Maximum Displacement Limiter e m a r F e z i S f o v e R r e p p s i D n i ...

Page 289: ...rom the speed ring on the unit s cylinder To locate the position of the speed sensor on the unit see Sec 4 For a description see Sec 2 3 2 1 Loosen the sensor lock nut with an 11 16 inch hex wrench 2 Turn the sensor clockwise CW by hand until it contacts the speed ring 8 4 Speed Sensor Adjustment 3 Turn the sensor counterclockwise CCW 1 2 turn 180 to establish the nominal gap of 0 71 mm 0 028 in 4...

Page 290: ...w gaskets Lightly lubricate all O rings with clean petroleum jelly prior to assembly Minor repairs may be performed following the proce dures in this section without voiding the unit war ranty Although specific models are shown these procedures apply to all series and types of units in the Series 90 Family Cleanliness is a primary means of ensuring satisfac tory transmission life on either new or ...

Page 291: ...oop Flushing Valve Left Side View Shaft Seal Charge Pressure Relief Valve Minimum Angle Displacement Limiter Maximum Angle Displacement Limiter Loop Flushing Valve Control Control Orifices Minimum Angle Displacement Limiter Speed Sensor on Opposite Side of Housing Left Side View Charge Pressure Relief Valve Shaft Seal Maximum Angle Displacement Limiter Control Loop Flushing Valve Control Orifices ...

Page 292: ... c n i 8 3 m N 8 6 t f f b l 0 5 g n i R O 2 1 6 1 1 1 h c n e r W x e H h c n i 4 1 1 m N 3 6 1 t f f b l 0 2 1 g n i R O 2 1 6 1 1 1 h c n e r W x e H l a n r e t n I h c n i 6 1 9 m N 5 1 1 t f f b l 5 8 g n i R O 2 1 6 1 5 1 h c n e r W x e H h c n i 2 1 1 m N 0 9 1 t f f b l 0 4 1 g n i R O 2 1 6 1 5 1 h c n e r W x e H l a n r e t n I h c n i 8 5 m N 9 2 1 t f f b l 5 9 g n i R O 2 1 8 5 1 h...

Page 293: ...er plate NOTE Certain earlier production units use a one piece retainer plate and seal carrier 3 Afterremovingthescrews thespringforceonthe shaft may move the seal carrier out of its bore by approximately 5 mm 1 4 inch If the seal carrier does not move from its bore after removing the screws pry it from its bore as shown and or lightly tap the end of the shaft with a soft mallet 4 Remove the O rin...

Page 294: ...sembly lubricate the O ring on the O D ofthesealcarrierandtheI D ofthesealwith clean petroleum jelly 14 Assemble the seal carrier and seal over the shaft and into the housing bore Install the retainer plate if used 15 Install the screws and torque to 16 Nm 12 ft lbf for 030 through 100 pumps 32 Nm 24 ft lbf for 130 through 250 pumps 9 5 Nm 7 ft lbf for 055 through 100 motors and 22 5 Nm 16 6 ft lb...

Page 295: ...ain tain sufficient control to prevent the contents from flying loose 4 Remove pressure limiter lock nut and bypass actuator 5 Unscrew the pressure limiter adjustment screw from the bypass actuator 6 Clean and inspect all disassembled parts 7 Reassemble with new lightly lubricated O rings by reversing the above procedure For early versions assemble with the retaining ring For late versions place t...

Page 296: ... large screwdriver or 1 2 inch hex wrench 2 Remove the spring and relief valve poppet 3 Inspectthepoppetandmatingseatintheendcap for damage or foreign material When inspecting shim adjustable valves do not alter the shims or interchange parts with another valve 4 Install the poppet and spring For shim adjustable valves install the plug and torque to 68 Nm 50 ft lbf For screw adjustable valves inst...

Page 297: ...ot allow the force of the cylinder block spring and swashplate leveler springs to sepa rate the end cap from the pump housing Gas ket damage and external leakage may result 2 Using a 10 mm 030 through 100 pumps or a 13 mm 130 through 250 pumps hex wrench re move the six screws holding the charge pump cover retainer 3 Remove the retainer and the charge pump cover For pumps with an auxiliary mountin...

Page 298: ...ps orouterspacerplate s intermediateproductionpumps mustbereplaced together Ifdifferentthicknessportplatesareused in an early production charge pump assembly the thicker plate is the inner port plate installed next to the pump end cap Journal Bearing Cover Retainer Cover O ring Retainer Screw Shaft Key Standard End Cap Screw Thin Port Plate Charge Pump Assembly Alignment Pin Thick Port Plate Gerot...

Page 299: ...he charge pump in the proper orientation If unsure of charge pump rotation refer to the model code NOTE The charge pump rotation is determined by the orientation of the gerotor assembly outer eccentricringandthelocationofthealignmentpin in the end cap NOTE Do not mix charge pump piece parts from different production periods Always install as a complete assembly 1 Install the inner port plate and t...

Page 300: ...O ring is not used on the cover 11 Carefully remove the alignment pin from the charge pump parts Install the pin in its hole in the charge pump cover see previous page for cor rect orientation and retain with petroleum jelly Install the cover with alignment pin into the end cap and aligned charge pump parts Take care not to damage the cover O ring if used CAUTION In order to avoid loss of charge p...

Page 301: ...e production pumps may not have the smaller screws installed to secure the end cap to the pump housing when the large screws are removed On these pumps secure the end cap to the pump housing with a clamp to avoid gasket damage CAUTION Do not allow the force of the cylinder block spring and swashplate leveler springs to sepa rate the end cap from the pump housing Gas ket damage and external leakage...

Page 302: ...he same side of the end cap as the charge inlet port 7 Install the charge pump cover retainer and the six hex screws and torque the screws to 13 5 Nm 10 ft lbf for 030 through 100 pumps and 32 Nm 24 ft lbf for 130 through 250 pumps 8 Install O ring on end cap pilot 9 Install the auxiliary mounting pad adapter on external pilot on rear of end cap 10 Installfournewlargescrewsandwashersthrough the mo...

Page 303: ... manifold or head to the desired position CAUTION Failure to install the filter manifold or filter head to a sufficient depth in the end cap will result in insufficient engagement of the tube in the end cap bore This may allow unfiltered oil to bypass the filter and enter the charge sys tem 4 Whileholdingthefiltermanifoldorfilterheadinthe desired position tighten the swivel lock nut 5 After instal...

Page 304: ...he cover plate and gasket from housing CAUTION Protect exposed surfaces and cavities from damage and foreign material 3 In preparation for installing the cover plate place a new gasket on the housing Place the cover plate into position and install the screws Torque the screws to 16 Nm 12 ft lbf NOTE A sealing washer must be installed under theheadofanymountingscrewsthatareinstalled into thru holes...

Page 305: ...rol 4 While setting the control into position engage the pin on the control linkage into the mating hole in the link attached to the swashplate 5 With the control in position move control lever both directions to check proper engagement of control linkage pin Proper engagement will be indicatedbycenteringtorqueastheleverismoved from center Non engagement of control linkage pin is indicated by lack...

Page 306: ...e control housing align the gasket and install the screws Torque screws to 13 5 Nm 10 ft lbf 9 3 4 Solenoid Override Valve for MDC with Pressure Released Brake 1 Thoroughly clean external surfaces prior to re moval of valve 2 Using a 4 mm internal hex wrench remove the foursolenoidvalvemountingscrews Removethe solenoid valve with O rings from the adapter plate 3 Using a 4 mm internal hex wrench re...

Page 307: ...ng hole in the link attached to the swashplate 5 With the control in position move control assem bly left and right to check engagement of pin in the link Proper engagement will be indicated by an increasing resistance as the control is moved away from center position Non engagement of pin will be indicated by lack of spring force In case of non engagement remove control and repeat the above proce...

Page 308: ... 4 Inspect the orifice installed between the valve and adapter plate This orifice MUST be installed in the case drain passage for proper pressure limiter operation 5 In preparation for installing the adapter plate place a new gasket on the housing Place the adapter plate into position and install the screws Torque the screws to 16 Nm 12 ft lbf NOTE A sealing washer must be installed under theheado...

Page 309: ...at the surface of the pump housing face Remove the spring retainer and spring from the orifice check valve cavity and then remove the orifice check valve 3 Install the desired orifice check valve in the cavity and then install the spring and spring retainer to hold the orifice check valve in position 4 Assemble the control onto the pump Refer to the instructions for the specific control 9 3 2 9 3 ...

Page 310: ...030 through 100 motors or 68 Nm 50 ft lbf on 130 motors 9 4 1 2 Motor Charge Relief Valve 1 Remove the shim adjustable charge relief valve plug with a 7 8 inch hex wrench Before removing the screw adjustable relief valve plug mark the plug lock nut and housing so as to be able to maintain the original adjustment when assem bling Remove the screw adjustable charge relief valve plug by loosening the...

Page 311: ...the Loop Flushing Valve 1 Remove loop flushing valve components these parts will not be used 2 Install defeating spool into spool bore in end cap 3 Install hex plugs provided and torque to 41 Nm 30 ft lbf on 030 through 100 motors or 68 Nm 50 ft lbf on 130 motors 4 Remove charge relief valve components these parts are not necessary 5 Replace with the hex plug provided and torque to 41 Nm 30 ft lbf...

Page 312: ... or minimum angle position and turn the appropriate limiter screw clockwise until it contacts the swashplate Then turn the screw an additional 1 4 turn clock wise and torque the seal lock nut to 54 Nm 40 ft lbf 4 Final adjustment of the displacement limiters should be performed on a test stand Do not turn the limiter screws counterclockwise beyond their initial adjustment positions WARNING Care sh...

Page 313: ...ylinder if equipped 5 Remove the control valve from the motor housing 6 Remove O rings from the valve 7 Install new O rings on the control valve 8 Install the valve into the motor housing and torque to 47 Nm 35 ft lbf Do not overtorque the control valve Over torquing may result in the valve spool sticking 9 Install the solenoid onto the valve and torque the hex nut to 5 Nm 44 in lbf Do not overtor...

Page 314: ...kup washers Check that the filter screen is secure in the orifice body and that the screen and the orifice are not plugged 3 Install new backup washers and O rings onto the orifice body Install the orifice into the motor hous ing and torque to 37 Nm 27 ft lbf CAUTION Do not interchange the control supply orifice with the minimum displacement orifice next section 9 5 4 2 Minimum Displacement Cylind...

Page 315: ... Remove the maximum displacement cyl inder orifice check valve from the motor housing with a 1 4 inch end wrench Remove the O ring The check ball in the valve must be free 2 Reinstall the check valve and torque to 15 Nm 11 ft lbf Install a new O ring Install the seal lock nut with the seal toward the motor housing Hold the check valve from turning while torquing the seal lock nut to 34 Nm 25 ft lb...

Page 316: ...r is not installed the housing plug should be torqued as indicated in the accompany ing figure OR 11 16 in hex wrench Torque 13 Nm 10 lbf ft after adjustment Housing Plug 1 4 in int hex wrench Torque 23 Nm 17 lbf ft Speed Sensor 11 16 in hex wrench Torque 13 Nm 10 lbf ft after adjustment Housing Plug 1 4 in int hex wrench Torque 23 Nm 17 lbf ft OR Speed Sensor 11 16 in hex wrench Torque 13 Nm 10 l...

Page 317: ...G508 B90 B82 L70 L70 L60 L40 L50 L40 L35 Early Production 075 Frame Size L30 G64 CODE 61 OPTION B83 B83 OR Model Code Typ 90L055 EA 1 N 6 S 3 C6 C 03 HNN 35 35 24 Model No Ident Nr 687459 N 88 26 67890 Serial No Fabr Nr Ames Iowa U S A Neumünster Germany saue Model Code Place of Manufacture Name Plate German Production MADE IN GERMANY MADE IN U S A Model Code Typ 90L055 EA 1 N 6 S 3 C6 C 03 HNN 35...

Page 318: ...8M M77M M76M T301 THRU T309 T322 T350 T401 THRU T409 T422 T450 M95M M97M M96M M9ME M11M M87H OR M0HA M0HC M0HF M0HG M0HH M0HJ M0HK M0HL M0HM M0HN M90H M11H M880 OR M87E OR M95E M96E M880 M91E M1EA M1EF M1EP M0EA M0EF M0EP M98E M90E M97E M9EA M9EP M11E M87C M0CA M1CA M90C M11C OR MODC MODD M90D M11D M1DC M1DD T201 THRU T209 T222 T250 M1MA M1MB M1MC M1MD M1ME M1MF M1MG M1HA M1HC M1HF M1HG M1HH M1HJ ...

Page 319: ...5N J30 J40N H30 OR OR H40 H50 H60 H50 H50L J80N OR J92_ J10_ J70_ H80 H70 J95_ J90_ J60_ J50_ J15_ J15L OR J15R J30 J00_ JL0_ OR JR0_ J80_ H90L H30 H05 H30 H40 H50 H60 H05 H40 H50 H60 H05 H80 OR OR N25R N35S N10S N40P N40L N20R N15M N35R N00M N15R N25M N00R N10R N31R N30R N20M N10M N35M N35M REF N00S 90000863 90000862 CONTENTS ...

Page 320: ...er assembly 1 J30 Bushing 1 J50A V O ring 1 J60A T Flange adaptor 1 J60B V Flange adaptor 1 J60C Flange adaptor 1 J60D Flange adaptor 1 J70A V Washer 4 J80A V Screw 4 J80N Screw 4 J90A V O ring 1 J92A V Cover plate 1 J95A V Screw 2 4 K10 Plug Assembly 1 K50 O ring 1 K70 Spring 1 K80 Poppet 1 K90 Nut 1 L30 Seal carrier 1 L35 Seal carrier 1 L40 Lip seal 1 L50 O ring 1 L60 Retainer 1 L70 Screw 3 L8 K...

Page 321: ... 6 M0MD MDC w sol valve nss 1 M7M Control handle 1 M71M Washer 1 M72M Nut 1 M75M Control manifold 1 M76M Solenoid valve 1 M77M Manifold gasket 1 M78M Screw 2 M80 Control gasket 1 M87M Washer seal 042 1 M90M Screw 6 S40 Neutral start switch kit 1 M810 Adapter Plate Control 130 cc 1 M820 O ring 130 cc 1 M830 O ring 130 cc 1 M840 O ring 130 cc 2 M850 Plug 130 cc 1 M860 Screw 130 cc 6 M870 Plug 130 cc...

Page 322: ...3 B83 B80 B80 B83 B83 MADE IN U S A Model Code Typ 90M055 NC 0 N 8 N 0 C6 W 00 NNN 00 00 24 Model No Ident Nr Serial No Fabr Nr Ames Iowa U S A Neumünster Germany Model Code Typ Model No Ident Nr Serial No Fabr Nr Ames Iowa U S A Neumünster Germany MADE IN GERMANY 90M055 NC 0 N 8 N 0 C6 W 00 NNN 00 00 24 312918 N 91 26 67890 94 2029 A 91 26 67890 Model Code Place of Manufacture Model Code Place of...

Page 323: ...64 Screw Shipping Cover 4 H10N Loop flushing spool defeat 1 H50N Plug 2 H10W Shuttle valve spool 1 H20W Spring guide 2 H30W Spring 2 H40W O ring 2 H50W Special plug 2 H60W Charge relief valve plug 1 H62W O ring 1 H64W Spring 1 H66W Charge relief poppet 1 H68W Lock nut 1 L30 Seal carrier 1 L35 Seal carrier 1 L40 Lip seal 1 L50 O ring 1 L60 Retainer 1 L70 Metric screw 3 L8 Key 1 L9 Slotted nut 1 CON...

Page 324: ...75 Frame Size L30 P400 P401 P402 P403 E35 E25 E15 P800 H60N G50 G50 H50N H50N G70 B74 P700 P702 B80 P601 P603 M1PT M1NA M1NB M1NC M1ND Y70 Y80 Y71 Y72 B74 G63 B83 B83 B74 Y60 Y40 Y50 Y50 Y102 Y100 Y101 Name Plate U S A Production MADE IN U S A Model Code Typ 90S055 NB 2 0 8 N 4 S1 W 01 NNN 01 00 24 Model No Ident Nr Serial No Fabr Nr Ames Iowa U S A Neumünster Germany 94 4002 A 91 26 67890 Serial ...

Page 325: ...50W Special plug 2 H60W Charge relief valve plug 1 H62W O ring 1 H64W Spring 1 H66W Charge relief poppet 1 H68W Lock nut 1 L8 Key 1 L9 Slotted nut 1 L30 Seal carrier 1 L35 Seal carrier 1 L40 Lip seal 1 L50 O ring 1 L60 Retainer 1 L70 Screw 3 M1N Control valve electric 1 M1P Control valve hydraulic 1 P400 Plug 2 P600 Plug 1 P601 Press compensator valve 1 P700 Special plug 1 P800 O ring 1 T30 Filter...

Page 326: ...saue 87 Series 90 Exploded View Parts Drawings 10 Notes CONTENTS ...

Page 327: ... for its products through an extensive network of Authorized Service Centers strategically located in all parts of the world Look to SAUER SUNDSTRAND for the best in WORLDWIDE SERVICE Genuine Service Parts Gear Pumps and Motors Open Circuit Axial Piston Pumps Hydraulic Power Systems Cartridge Motors Compact Wheel Drives Heavy Duty Bent Axis Variable Motors Heavy Duty Axial Piston Pumps and Motors ...

Page 328: ...No 06 161 May 1999 Eaton Medium Duty Piston Motors Parts Information Model 74624 and 74644 82 6 cm3 r 5 04 in3 r Displacement design code B ...

Page 329: ...2 Model 74624 and 74644 ...

Page 330: ...sign Code Number A B C D Single Motor Product Number 7 4 6 2 4 D A H 0 1 Required Tools 1 2 in Socket w Ratchet Wrench External Retaining Ring Pliers straight 090 tip Internal Retaining Ring Pliers straight 090 tip O ring Pick Torque Wrench 54 N m 40 lbf ft capacity Hammer soft face Light Petroleum Jelly Seal Driver Testers Initials Day of Month two digits Month two digits Serial Number Code B 93 ...

Page 331: ...600 620 1 Pilot Refer to specific parts list 20 74600 104 1 Thrust Bearing 21 16241 D916 1 Bearing Race 22 16032 510 6 Cap Screws 5 16 18 25 4 mm 1 in Long Refer to specific parts list 22a 16032 514 4 Cap Screws 5 16 18 38 1 mm 1 5 in Long Refer to specific parts list 23 16077 26 1 Retaining Ring 24 74600 103 A R Trust Race 25 24500 628 1 Key 74624 204 74644 210 74644 215 26 16078 16 2 Retaining R...

Page 332: ...oth 16 32 Spline Tapered 1 8 with 375 16 UNC 2B Thread 18 3 72 Min Full Thread Shaft Ext 46 1 81 Rear 15 Tooth 16 32 Spline with 375 16 UNC 2B Thread 18 3 72 Min Full Thread Shaft Length from Mounting Flange 274 3 10 80 1k 74644 214 Front 15 Tooth 16 32 Spline Shaft Ext 46 1 81 Rear Straight Shaft Dia 22 22 875 Keyway 6 35 X 26 9 250 X 1 06 Shaft Length from Mounting Flange 271 5 10 69 Short Key I...

Page 333: ...6 Model 74624 Parts Drawing 23 15 3 1 16 7 17 11 4 2 32 32 22 22 22 22 6 13 12 9 19 8 18 36 37 38 5 1 33 25 10 2 1 21 24 21 20 8 14 3 2 22 22 22 22 22 22 6 ...

Page 334: ...X X X X X X X X X X X X 1 1 X X X X X X X X X X X X X 2 1 X X X X X X X X X X X X X 3 1 X X X X X X X X X X X X X 4 1 X X X X X X X X X X X X X 5 1 X X X X X X X X X X X X 6 1 X X X X X X X X X X X X X 7 1 X X X X X X X X X X X X X 8 1 8 1 b 8 1 b 8 1 a 8 1 b 8 1 b 8 1 b 8 1 b 8 1 8 1 8 1 b 8 1 b 8 1 9 1 9 1 9 1 9 1 a 9 1 9 1 9 1 9 1 9 1 a 9 1 a 9 1 9 1 9 1 0 2 X X X X X X X X X X X X X 1 2 X X X ...

Page 335: ...8 Model 74644 Parts Drawing Through Shaft 23 15 3 1 16 7 17 11 4 2 32 32 22 35 35 1 22 22 22 6 13 12 9 26 28 27 28 26 30 29 31 19 8 18 36 37 38 5 1 34 10 2 1 8 14 3 33 25 ...

Page 336: ... X X 3 1 X X X X X X X X X 4 1 X X X X X X X X X 5 1 X X X X X X 6 1 X X X X X X X X X 7 1 X X X X X X X X X 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 9 1 9 1 a 9 1 9 1 a 9 1 a 9 1 9 1 9 1 a 9 1 a 9 1 2 2 a 2 2 a 2 2 a 2 2 a 2 2 a 2 2 a 2 2 a 2 2 a 2 2 a 2 2 3 2 X X X X X 5 2 X 6 2 X X X X X X X X X 7 2 X X X X X X X X X 8 2 X X X X X X X X X 9 2 X X X X X X X X X 0 3 X X X X X X X X X 1 3 X X X X X...

Page 337: ...10 Model 74624 and 74644 Notes ...

Page 338: ...11 Model 74624 and 74644 Notes ...

Page 339: ... of China Telephone 86 21 5046 0758 Fax 86 21 5046 0767 Eaton B V Boeing Avenue 11 1119 PC Schiphol Rijk The Netherlands Telephone 31 0 20 655 6776 Fax 31 0 20 655 6800 Jining Eaton Hydraulic Co Ltd 6 Ji Da Road Jining City Shandong Province 272131 Peoples Republic of China Telephone 86 537 2221288 Fax 86 537 2221557 Sumitomo Eaton Hydraulic Co 8 Temasek Blvd 42 01 Suntec Tower Three Singapore 039...

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Page 344: ...300 A T E X INCLUDED MOBILE EQUIPMENT AND WIND ENERGY SOLUTIONS INDUSTRY PROCESS AND AUTOMATION SOLUTIONS Installation use and service manual ...

Page 345: ......

Page 346: ...GEAR UNIT 15 5 1 1 Flanged execution 15 5 1 2 Foot mounting 17 5 1 3 Shaft mounting 18 5 1 4 Installing accessories on solid input and output shafts 19 5 2 INSTALLING THE ELECTRIC MOTOR 21 5 3 INSTALLING THE HYDRAULIC MOTOR 22 5 4 CONNECTING THE HYDRAULIC BRAKE 23 5 5 LUBRICATION 28 6 0 TESTING THE GEAR UNIT 29 7 0 USING THE EQUIPMENT 29 8 0 MAINTENANCE 30 8 1 ROUTINE MAINTENANCE 31 8 2 OIL CHANGE...

Page 347: ...the code of this manual This manual reflects the state of the art at the time of commercialisation of the gear unit The Manufacturer reserves the right to modify supplement and improve the manual without the present pu blication being for that reason considered inadequate Particularly significant sections of the manual and important specifications are highlighted by symbols whose meanings are expl...

Page 348: ... Supplementary nameplate on ATEX specified gear units EC Cert No Gearbox compliant with ATEX Directive 94 9 EC GROUP II 2G CATEGORY T4 Temperature 2D CATEGORY 135 C Temperature EX9 04 07 53387 001 1 2 PRODUCT IDENTIFICATION The information identifying the product is shown on its nameplate Gearmotors are equipped with two name plates one on the gear unit which bears the gear unit data and one on th...

Page 349: ...S LIABILITY The Manufacturer declines all liability in the event of use of the gear unit in contravention of local safety at work legislation incorrect installation disregard or incorrect application of the instructions provided in this manual incorrect or defective electrical hydraulic power supply gearmotors modifications or tampering work done on the unit by unqualified or unsuitable persons Th...

Page 350: ...tionals to make their products as versati le as possible For further technical information and descriptions refer to the corresponding Sales Catalo gue The User is responsible for using the products recommended for installation and maintenance of 2 2 CONFORMITY All gear units or gearmotors when supplied with electric motor are designed in compliance with the provi sions of applicable Essential Hea...

Page 351: ...lth and safety The gear unit must only be used for the applications permitted by the Manufacturer Improper use can re sult in risks to personal health and safety and economic damages Keep the gear unit at its maximum efficiency by following the routine maintenance schedule Good mainte nance ensures the unit s maximum performance extended service life and continued compliance with sa fety regulatio...

Page 352: ...s taking all neces sary precautions against it being accidentally switched on again or its parts moving without warning Furthermore all additional environmental safety precautions must be taken e g elimination of residual gas or dust etc On receipt of the gear unit make sure the delivery corresponds to the purchase order and that it is not damaged or faulty in any way Report any nonconformity to y...

Page 353: ...The weight of the product to be lifted is given in the Sales Catalogue The following pages illustrate in detail the different attachment methods for the various product series sizes and configurations described in this Manual The most suitable solution for lifting and handling the product in safety is indicated for each Symbols Type of lifting Manual With mechanical equipment Symbol M A B Approxim...

Page 354: ...2 3 Snap hook use with rope Screw clamp use with harness Eyebolt already fitted on gear units 317 321 3 Open harness with eyelets 2 Rope and hooks 1 Ring harness Maximum permissible tilt during handling 15 MAX 1 5 1 5 Identify the attachment points for lifting the gear unit Refer to the diagrams given below ...

Page 355: ...1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 3 Open harness with eyelets 2 Rope and hooks 1 Ring harness Snap hook use with rope Screw clamp use with harness Eyebolt already fitted on gear units 317 321 Maximum permissible tilt during handling 15 MAX 1 5 1 5 ...

Page 356: ...1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 Maximum permissible tilt during handling 15 MAX 1 5 1 5 Snap hook use with rope Screw clamp use with harness Eyebolt already fitted on gear units 317 321 3 Open harness with eyelets 2 Rope and hooks 1 Ring harness 2 3 1 2 3 1 ...

Page 357: ... hook use with rope Screw clamp use with harness Eyebolt already fitted on gear units 317 321 3 Open harness with eyelets 2 Rope and hooks 1 Ring harness Maximum permissible tilt during handling 15 MAX 1 5 1 5 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 ...

Page 358: ...e Screw clamp use with harness Eyebolt already fitted on gear units 317 321 3 Open harness with eyelets 2 Rope and hooks 1 Ring harness Maximum permissible tilt during handling 15 MAX 1 5 1 5 2 3 2 3 P F H 2 3 1 2 3 1 3V 00 3V 21 P F H 2 3 2 3 2 3 2 3 1 2 3 ...

Page 359: ...ft the load very slowly to check that it is stable Move the gear unit to the unloading area and lower it gently into position taking care not to tip it suddenly in transit If the gear unit is already equipped with an electric motor do not use the eyebolts on the mo tor casing for lifting unless expressly specified 4 3 STORAGE The following recommendations should be followed when storing the gear u...

Page 360: ...onment is corrosive for the gear unit or any of its parts follow the special precautions re quired for aggressive environments In this case contact the BONFIGLIOLI TRASMITAL sales service 9 We recommend applying a protective paste to all gear unit motor mating surfaces and other parts Klüberpaste 46 MR 401 or other product with similar properties and application range to ensure optimal coupling an...

Page 361: ...it is instead required to transmit high torque or is subject to heavy shock loads and inversions in the direction of rotation the counterflange must be drilled to accept the spigots At the time of installation move the spigots mounted on the gear unit forward into the counterflange by an amount equal to their diameter See diagram below 0 07 B B R 0 15 B 0 1 100 B Æ f7 Æ f7 3 2 Æ H8 Æ H8 3 2 3 2 b ...

Page 362: ...2 15 24 30 20 30 24 32 30 36 Class 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 Tightening torque Nm 50 50 85 85 135 200 200 200 200 400 400 400 1400 700 1400 1400 5 1 2 Foot mounting Foot mounted motor execution Gear units of this type must be mounted on a suitably rigid base machined flat with a planarity error margin of no more than 0 2 mm 100 mm See diagram below C C 0 15 3 ...

Page 363: ... operation seve ral times until all bolts are tightened to the torque specified in chart 2 in accordance with the type of disk gear unit N B Do not tighten down diametrically opposed bolts in sequence Rt 16 µm C R 600 N mm2 Æ H7 Æ H7 Æ H6 Æ H6 C 1 C 1 3 2 3 2 3 2 3 2 300 321 Do not use molybdenum bisulphide or any other grease which could reduce the friction of the mating surfaces and affect the p...

Page 364: ...trical hubs use the configuration shown in diagram A below Proceed with the installation as follows 1 Place the gear unit in the vicinity of the installation area 2 Mount the gear unit and secure it to the structure at the points provided The gear unit should be secured to the structure at all the mounting points bores on the mount provided feet or flange 3 Tighten down the mounting bolts and chec...

Page 365: ...0 M20 M24 M24 M24 M24 M24 PC M12 M16 M20 M20 M20 M20 M24 M24 M24 M24 M24 VK M20 M20 M24 M24 M24 M24 M24 M30 M30 Shaft end threads DIN 332 30 6xM16 Ø 140 Ø 200 r6 26 4xM16 Ø 110 Ø 180 m6 40 12xM20 Ø 200 Ø 280 h6 40 12xM20 Ø 250 Ø 340 m6 41 4xM24 Ø 150 Ø 250 m6 316 317 319 321 318 300 315 HC PC HC PC HC PC HC PC HC PC ...

Page 366: ... and application range Provided all the above checks have been performed and passed and all other instruc tions in this manual have been strictly observed an electric motor with ATEX rating equal to or greater than that of the gear unit may be installed thus forming a gearmotor which itself complies with the provisions of Directive 94 9 EC If instead the assembly of the motor to the gear unit requ...

Page 367: ...or and gear unit taking care to fit it correctly in its seat without damaging it 8 8 b Version with gasket already mounted to the coupling In this case no special intervention is required to ensure an oil tight seal since this is already provided by the motor coupling Merely smear the motor shaft with grease In both cases clean the spigot and the coupling where the motor is to be fitted fit the mo...

Page 368: ...ar T T Technical data NOTE The static torque Mbs is the maximum torque the brake can exert Under dynamic loads the braking torque is reduced The actual Mbs values can vary from 5 to 15 of the rating given in the chart 4 5 6 A B D F H K L B C E G K B C E G K L Braking torque Mbs daNm 5 10 16 26 33 40 44 40 50 63 80 100 85 110 150 210 260 320 Minimum release pressure bar 10 20 30 20 25 30 33 20 27 2...

Page 369: ...tion refer instead to the two sample diagrams below These are gene ric only since each specific installation has its own special requirements which must be evaluated on a per case basis by the Manufacturer Drive with electric motor L1 L2 L3 W2 U2 V2 W1 V1 U1 L1 L2 L3 W2 U2 V2 W1 V1 U1 L1 L1 U1 U1 W2 W1 L2 L3 U2 V2 V1 U2 L3 L2 V1 W1 V2 W2 L3 L2 L1 W1 V1 U1 W2 U2 V2 L3 L2 L1 W1 V1 U1 W2 U2 V2 ...

Page 370: ... of either the closed cen tre or open type The circuit line corresponding to the hydraulic motor delivery port must always be equipped with a pressure relief valve calibrated to a pressure no greater than the motor s pmax Refer to the hydraulic circuit diagrams below A B RV Closed loop circuit Open loop circuit RV pressure relief valves calibrated to pRV pmax Drive with TRASMITAL MG orbital hydrau...

Page 371: ...nal drainage and drain hole T must be connected to the tank Refer to the diagrams below A B T c Brake control Gearmotors equipped with a brake are available in two motor executions B02P or P01S Brake control is internal on the B02P version and is controlled directly by the motor The brake control pressure must instead be supplied by an auxiliary line of the brake control circuit on the P01S versio...

Page 372: ...6 Drive with hydraulic motor All motors must be charged with hydraulic fluid before being operated and during installation Position the drain hole so that it is positioned uppermost for charging with fluid Make sure the hoses are routed in such a way as to prevent the motor casing from emptying and hence pre vent air pockets from forming which may affect pump suction during operation T A B A B T A...

Page 373: ...150 GOYA 220 EL GRECO 220 MOBIL MOBILGEAR 629 MOBILGEAR 630 SHC 630 MOBILUBE HD MOBILUBE HD SHELL OMALA EP150 OMALA EP220 TIVELA OIL SA SPIRAXHD SPIRAX HD TOTAL CARTER EP 150 CARTER EP 220 TRANSMISSION TM TRANSMISSION TM Synthetic oil Brake lubrication The hydraulic multi disk brakes are lubricated with the same oil as the gear unit Only synthetic lubricants may be used on gear units conforming to...

Page 374: ...r radia tion and is free of dust build ups greater than 5 mm in depth during operation the gear unit is sufficiently ventilated and is not subject to radiation from exter nal heat sources during operation the cooling air does not exceed 40 C the oil level check and filler plugs and the vent plugs are all easily accessible all accessories mounted to the gear unit are ATEX certified gear units with ...

Page 375: ... safe operation of the gear unit The Manufacturer declines all liability for injury to persons and damage to components due to the use of non original spare parts and non routine work that modifies the safety requirements without the Manufactu rer s express prior authorisation Refer to the specific spare parts catalogue when ordering spare parts for the gear unit Do not dump polluting liquids worn...

Page 376: ...500 hrs Lubricant Replace Replace with new lubricant 5000 hrs Gear unit seals and gaskets Inspect carefully for wear age ing of external seals Replace if aged worn For installations in zones 21 and 22 the User must schedule and implement a regular clea ning programme for all surfaces and recesses to avoid dust build ups of more than 5 mm in depth Every 1000 hrs of operation or after 6 months Measu...

Page 377: ... refilling with the new lubricant If a leak is found identify the cause of the fault and repair it before topping up the lubricant and operating the unit Lubricants solvents and detergents are toxic harmful to health they may cause irritation in direct contact with the skin they may cause intoxication if inhaled they may be fatal if swallowed Handle them with care using suitable individual safety ...

Page 378: ...nges and mating surfaces but proceed as illustrated below 1 Drill and thread the motor shaft fan side 2 Screw an impact extractor tool into the bore 3 Undo the bolts fixing the motor to the gear unit 4 Detach the motor by means of the inertial force of the extractor 9 2 DECOMMISSIONING THE GEAR UNIT The unit must only be taken out of service by operators trained in the observance of applicable law...

Page 379: ...ng noise Gears damaged Contact authorised workshop Bearing axial backlash too high Contact authorised workshop Bearings defective or worn Contact authorised workshop Excessive load applied Correct load to rated values given in Sales Catalogue Contaminant in oil Replace oil Abnormal noise at gear unit mounting Mounting bolts loose Tighten bolts to specified torque Mounting bolts worn Replace bolts ...

Page 380: ... a rod to check that the oil level is between the MIN and MAX marks then screw the plug back in If the level is more than 3 mm below the spill level top up and check the reason for the drop in oil level Gear units conforming to Directive 94 9 EC and designed for a vertical mounting position are normally equipped with an oil expansion chamber fitted with service plugs for filling checking the oil l...

Page 381: ...6 4 6 4 3 R4 5 1 6 1 5 9 L4 3 9 4 9 4 6 307 L1 3 5 5 0 4 5 307 R2 6 0 8 0 7 0 L2 4 5 6 0 5 5 R3 7 0 9 0 8 0 L3 5 0 6 5 6 0 R4 7 5 9 5 8 5 L4 5 3 6 8 6 3 309 L1 4 0 5 5 5 0 309 R2 6 5 8 5 7 5 L2 5 0 6 5 6 0 R3 7 5 9 5 8 5 L3 5 5 7 0 6 5 R4 8 0 10 9 L4 5 8 7 3 6 8 310 L1 5 0 6 5 6 0 310 L2 6 3 7 8 7 3 R3 11 13 12 L3 7 1 8 6 8 1 R4 12 14 13 L4 7 4 8 9 8 4 311 L1 7 0 12 10 311 R2 14 19 17 L2 9 0 14 12...

Page 382: ...13 18 16 3 V 09 L3 5 4 3 4 5 5 3 9 5 0 3 9 5 3 0 6 5 3 5 6 3 5 3 V 10 L3 6 3 6 3 6 3 6 3 7 8 7 3 3 V 15 L4 21 21 21 21 29 25 3 V 16 L4 24 24 24 24 32 28 3 V 11 L3 9 7 8 9 6 9 6 7 9 6 7 9 5 0 14 5 5 12 5 5 3 V 13 L3 12 12 12 12 17 15 3 V 17 L4 29 29 29 29 44 39 3 V 15 L3 19 11 15 19 8 9 19 9 4 19 7 5 27 9 5 23 9 5 3 V 16 L3 22 22 22 22 30 26 3 V 18 L4 40 40 40 40 55 50 3 V 19 L4 50 50 50 50 70 60 3...

Page 383: ...EVISIONS R We reserve the right to implement modifications without notice This catalogue cannot be reproduced even partially without prior consent R1 Amended section 8 1 Routine maintenance COD 7 998 3 3 01 7 R1 31 ...

Page 384: ......

Page 385: ...w w w b o n f i g l i o l i c o m 300 MOBILE EQUIPMENT AND WIND ENERGY SOLUTIONS INDUSTRY PROCESS AND AUTOMATION SOLUTIONS ...

Page 386: ...www dexteraxle com OPERATION MAINTENANCE SERVICE MANUAL 600 8 000 lb Axles Related Components ...

Page 387: ...nd have enabled us to maintain our position of leadership First we operate on the theory that there is always a better way for a product to operate to be manufactured and or to be serviced We are constantly striving to find that better way Secondly we maintain wall to wall production control so that all the major components of your running gear system are manufactured in Dexter facilities under ou...

Page 388: ...ge 20 How to Measure Amperage 20 Magnet Amperes Chart 21 Braking Systems Hydraulic Hydraulic Brakes 23 Hydraulic Brake Operation 24 Duo Servo 24 Uni Servo 24 Self Adjusting Mechanism for 121 4 Brakes 25 Hydraulic Parking Brake Option 25 Disc Brakes 27 Actuation Systems 28 Electrical Schematic 28 Troubleshooting Guide 29 General Maintenance Hydraulic Brakes 31 Drum Brake Adjustment Manual 31 Wheel ...

Page 389: ...5 Suspensions Suspension Systems 57 Double Eye Leaf Springs 57 Grease Lubricated Suspension Bushings 58 Slipper Leaf Springs 58 Inspection and Replacement 59 Suspension Fastener Torque Values 59 Torflex Suspension 61 Airflex Suspension 62 Wheels and Tires Wheels 66 Wheel Selection 66 Torque Requirements 67 Wheel Torque Requirements 68 Maximum Wheel Fastener Torque 69 Tires 70 Tire Wear Diagnostic ...

Page 390: ... instructions provided in this manual must first establish that they neither compromise their personal safety nor the vehicle integrity by their choice of methods tools or parts Refer to your vehicle manufacturer s owners manual for additional procedures techniques and warnings prior to performing any maintenance or repairs CAUTION This is the safety alert symbol It is used to alert you to potenti...

Page 391: ...e of the drums which moves the actuating levers in the direction that the drums are turning The resulting force causes the actuating cam block at the shoe end of the lever to push the primary shoe out against the inside surface of the brake drum The force generated by the primary shoe acting through the adjuster moves the secondary shoe out into contact with the brake drum Increasing the current f...

Page 392: ...applied to the parking lever creates a torque through the pivot pin and cam assembly Torque transferred to the parking cam results in a spreading force between the primary and secondary shoes The shoes in turn move towards the drum until contact is made Friction generated between the drum and lining contact surface keeps the drum from rotating under normal loading conditions Self Adjusting Feature...

Page 393: ...e lights to warn of an impending stop Most electric brake controllers provide a modulation function that varies the current to the electric brakes with the pressure on the brake pedal or amount of deceleration of the tow vehicle Electronic or timing controllers do not provide proportional modulation These controllers tend to be inexpensive but not the best choice for optimum braking It is importan...

Page 394: ...ems Electric Breakaway Battery Provides power to actuate trailer brakes in the event of trailer breakaway Dexter Electric Brakes Wired in parallel Breakaway Switch Switches battery power to brakes if breakaway occurs ...

Page 395: ...ler Electric brake controller provides power to the magnets to actuate the trailer brakes Battery Connect controller directly Connector Used to connect and disconnect trailer and tow vehicle Always ground trailer brakes through connector ...

Page 396: ...al 1 Orange Auxiliary Circuit Terminal 9 Batt Stop Right Turn Signal Terminal 6 Electric Brake Terminal 2 Blue Electric Brake Ground Terminal 1 White Double Filament Bulb Brown Yellow White Green Red Black Orange Brown Blue Grey 3 To Tail Running License Lights 5 Stop Left Turn 4 Battery Charge 7 Aux Circuit 9 Aux Circuit 6 Stop Right Turn 2 Electric Brake 8 Aux Circuit Clearance Tail Lights Stop ...

Page 397: ... road testing Brake lockup grabbiness or harshness is quite often due to the lack of synchronization between the tow vehicle and the trailer being towed too high of a threshold voltage over 2 volts or under adjusted brakes Before any synchronization adjustments are made your trailer brakes should be burnished in by applying the brakes 20 30 times with approximately a 20 m p h decrease in speed e g...

Page 398: ...e point of impending brake lockup and wheel skid Note Not all trailer brakes are capable of wheel lockup Loading conditions brake type wheel and tire size can all affect whether a brake can lock It is not generally considered desirable to lock up the brakes and slide the tires This can cause unwanted flat spotting of the tires and could also result in a loss of control If the controller is applyin...

Page 399: ...pension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury 2 Remove the adjusting hole cover from the adjusting slot on the bottom of the brake backing plate 3 With a screwdriver or standard adjusting tool rotate the starwheel of the adjuster assembly to exp...

Page 400: ...eformed springs and replace as necessary CAUTION POTENTIAL ASBESTOS DUST HAZARD Some older brake linings may contain asbestos dust which has been linked to serious or fatal illnesses Certain precautions need to be taken when servicing brakes 1 Avoid creating or breathing dust 2 Avoid machining filing or grinding the brake linings 3 Do not use compressed air or dry brushing for cleaning dust can be...

Page 401: ... results the magnet should be flat Even if wear is normal as indicated by your straightedge the magnets should be replaced if any part of the magnet coil has become visible through the friction material facing of the magnet It is also recommended that the drum armature surface be refaced when replacing magnets see section on Brake Drum Inspection Magnets should also be replaced in pairs both sides...

Page 402: ... linings may contain asbestos dust which has been linked to serious or fatal illnesses Certain precautions need to be taken when servicing brakes 1 Avoid creating or breathing dust 2 Avoid machining filing or grinding the brake linings 3 Do not use compressed air or dry brushing for cleaning dust can be removed with a damp brush After replacement of brake shoes and linings the brakes must be re bu...

Page 403: ... electrical system failure Voltmeters and ammeters are essential tools for proper troubleshooting of electric brakes Mechanical causes are ordinarily obvious i e bent or broken parts worn out linings or magnets seized lever arms or shoes scored drums loose parts etc Replace defective parts with genuine Dexter replacements Please consult the following troubleshooting charts to determine the causes ...

Page 404: ...ponents Out of Round Brake Drums Insufficient Wheel Load Faulty Controller Broken Wires Loose Connections Find Correct Adjust Brakes Test Correct Clean or Replace Clean Correct Cause of Corrosion Replace Machine or Replace Correct Adjust Brakes Reburnish or Replace Correct Adjust Correct Test Correct Replace Components Machine or Replace Adjust System Resistor and Synchronize Test Correct Repair o...

Page 405: ...ntroller Overadjustment Out of Round Brake Drums Incorrect Brake Components Loose Bent or Broken Brake Components Faulty Breakaway Switch Loose Wheel Bearing Adjustment Adjust Clean or Replace Find Repair Find Repair Adjust Correct Change Test Correct Adjust Lubricate Replace Component Correct Clean or Replace Machine or Replace Test Correct Readjust Machine or Replace Replace Replace Repair or Re...

Page 406: ...o the brakes when the controller first turns on Lower threshold voltage will provide for smoother braking If the threshold voltage is too high the brakes may feel grabby and harsh How to Measure Amperage System amperage is the current flowing in the system when all the magnets are energized The amperage will vary in proportion to the voltage The engine of the tow vehicle should be running with the...

Page 407: ...mmeter in the line at the magnet you want to check Disconnect one of the magnet lead wire connectors and attach the ammeter between the two wires Make sure that the wires are properly reconnected and sealed after testing is completed The most common electrical problem is low or no voltage and amperage at the brakes Common causes of this condition are 1 Poor electrical connections 2 Open circuits 3...

Page 408: ...connected the short is in the trailer wiring All electrical troubleshooting procedures should start at the controller Most complaints regarding brake harshness or malfunction are traceable to improperly adjusted or non functioning controllers See your controller manufacturer s data for proper adjustment and testing procedures For best results all the connection points in the brake wiring should be...

Page 409: ...utomotive hydraulic brakes and hydraulic trailer brakes is the trailers actuation system These systems respond to the braking signal from the tow vehicle and supply the required brake fluid volume and pressure to the trailer brakes In the following pages you will find a more detailed description of the hydraulic brakes and actuation system used on your trailer CAUTION The operating pressure requir...

Page 410: ...brakes are applied while the vehicle is backing the shoes rotate in the direction of the drum rotation This causes the secondary shoe to leave the anchor and causes the primary shoe to move against the anchor Action of the brake is the same in reverse as forward Uni Servo This type of hydraulic brake utilizes a single acting cylinder Upon actuation the primary shoe is pressed against the brake dru...

Page 411: ...juster mechanism to rotate the screw assembly at the bottom of the brake That action expands the distance between the shoes and thus closes the gap to the drum surface Hydraulic Parking Brake Option Not Available on All Sizes The parking feature on Dexter hydraulic brakes is cable operated On the 10 and 12 brakes the parking cable body is mounted to the brake backing plate The cable end is attache...

Page 412: ...etween the primary and secondary shoes The shoes move toward the drum until contact is made Friction generated between the drum and lining contact surface results in parking brake capability The internal parking brake lever of Dexter 121 4 brakes transfers the applied cable force through a cam mechanism The cam mechanism generates a spreading force between the primary and secondary shoes The shoes...

Page 413: ...e outboard brake pad against the rotor surface As the lining material wears the caliper will automatically maintain the proper lining to rotor clearance The floating caliper design is used on Dexter 3 500 lb 10 000 lb and 12 000 lb axle models The fixed caliper method uses pistons situated on both sides of the rotor During actuation hydraulic pressure pushes against the pistons to apply the inboar...

Page 414: ...nsure that their in cab electronic controller is compatible with the Dexter E H actuator Dexter Axle attempts to provide compatibility with most controllers available but is unable to anticipate design changes that might be introduced by the various controller manufacturers The E H 1000 will supply 1000 psi for your drum brakes and the E H 1600 will generate 1600 psi for maximum performance from y...

Page 415: ... All other wires should be a minimum of 16 gauge 6 Slow response can be caused by improper adjustment of the brake controller On inertia based electronic brake controls adjust the pendulum inertia sensor to a more aggressive setting and or increase the gain setting Unit will not run when the ignition is on and the brake pedal is depressed 1 Verify that the trailer and tow vehicle are wired as deta...

Page 416: ...ctuator should be returned for repair 4 If the unit still does not run after the breakaway battery is fully charged verify that the voltage between the white wire and yellow wire is at least 12 volts 5 If the voltage is less than 12 volts either the breakaway switch or the breakaway wiring is defective 6 If the voltage is greater than 12 volts the E H unit should be returned for repair Trailer bra...

Page 417: ...under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury or death 2 Remove the adjusting hole cover from the adjusting slot on the bottom of the brake backing plate 3 With a screwdriver or standard adjusting tool rotate the starwheel of the adjuster assembly to expand the brake s...

Page 418: ...if they are usable Replacement is necessary if the lining is worn to within 1 16 or less contaminated with grease or oil or abnormally scored or gouged Hairline heat cracks are normal in bonded linings and should not be cause for concern When replacement is necessary it is important to replace both shoes on each brake and both brakes of the same axle This will help retain the balance of your brake...

Page 419: ...tice to Buyer It is recommended that all brakes be replaced at the same time to insure balanced braking performance Remove the old brake caliper 1 Jack up trailer and secure on adequate capacity jack stands Follow trailer manufacturers recommendations for lifting and supporting the unit CAUTION Do not lift or support the trailer on any part of the axle or suspension system Never go under any trail...

Page 420: ...re rotor against the hub face when reassembling the caliper After the caliper is assembled remove the lug nuts 4 Reconnect the hose to the elbow adapter on the back of the caliper and torque to 10 12 Ft Lbs 5 Reconnect the brake actuation system Refer to your actuation systems Operation Maintenance Service Manual for proper operation 6 Bleed and flush brake system per your actuation systems Operat...

Page 421: ...stalling the brake calipers Installing the new brake rotor 1 First inspect the brake assembly for grooves flaking cracks heat checking thickness variation insufficient rotor thickness and look to see that the mounting hardware is straight Replace any component as needed or desired per manufacturer recommendations 2 Install the new brake rotor by fitting it onto the hub flush with the hubface 3 Rem...

Page 422: ... the brake exposed 3 Disconnect the brake actuation system Check that the hydraulic system has zero pressure and that the hub and rotor rotates freely 4 Remove the four caliper mounting bolts Do not allow the caliper assembly to hang from the hose Do not disconnect the hose or allow air into the hydraulic system 5 With the caliper assembly out of the way remove the brake rotor Save the brake mount...

Page 423: ...r wheel nut torque procedures 7 Spin the wheel to ensure that there is enough clearance between the wheel crossover brake line and rotor Instructions for Brake Pad Kit 6K or 8K Disc Hydraulic Brakes Notice to Buyer It is recommended that all brakes be replaced at the same time to insure balanced braking performance Remove the old brake pads 1 Jack up trailer and secure on adequate capacity jack st...

Page 424: ...leaning dust can be removed with a damp brush Installing the new brake pads 1 First inspect the brake assembly for grooves flaking cracks heat checking thickness variation insufficient rotor thickness and look to see that the mounting hardware is straight Replace any component as needed or desired per manufacturer recommendations 2 Press the caliper pistons into the calipers until enough clearance...

Page 425: ... brake pads 1 Jack up trailer and secure on adequate capacity jack stands Follow trailer manufacturers recommendations for lifting and supporting the unit CAUTION Do not lift or support the trailer on any part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpecte...

Page 426: ...r brake line on the bottom sides of the piston boss on both calipers Note Make sure the crossover line fits snug around the calipers and rotor without touching the rotor Spin the rotor to ensure there is proper clearance Torque the crossover line to 12 15 Ft Lbs Torque the bleed screw and the hydraulic line fitting adapter to 60 76 Inch Lbs 5 Reassemble the brake pads into the disc brake Make sure...

Page 427: ... qualified mechanic Typical problems in a hydraulic braking system are Air or vacuum leaks Hydraulic system leaks Air in brake lines Water or other impurity in brake fluid Rusted or corroded master or wheel cylinders Actuation system malfunction Please consult the following troubleshooting charts to determine the causes and solutions for common problems found in trailer braking systems CAUTION The...

Page 428: ...g Thickness or Location Inflate Evenly on Both Sides to Req Pressures Match Tires on Axle Repair or Replace Install New Shoe and Lining Complete Axle Adjust Replace Rubber Parts Fill with DOT4 Fluid Open with Compressed Air or Replace Cylinder Free Cable and Lubricate Install New Shoes and Linings Pulls to One Side Improper Fluid Dragging Check for Stuck or Sluggish Pistons SYMPTOM CAUSES REMEDIES...

Page 429: ...Shoe and Lining Recondition or Replace All Cylinders Brake Fluid Reburnish or Replace Replace Bleed System Correct No Brakes Weak Brakes Frozen Master Cylinder or Wheel Cylinder Pistons Manual Adjust Brakes Automatic Make Several Reverse Stops SYMPTOM CAUSES REMEDIES Malfunctioning Actuating System Troubleshoot System Grease or Fluid on Linings Replace Shoes and Linings Manual Adjust Brakes Automa...

Page 430: ...sists of axle spindles that have been specially drilled and assembled with grease fittings in their ends When grease is pumped into the fitting it is channeled to the inner bearing and then flows back to the outer bearing and eventually back out the grease cap hole Nev R Lube option is the latest innovation from Dexter Nev R Lube bearings are comprised of opposed tapered roller bearing cones seale...

Page 431: ...r is used Gently pry off retainer from the nut and set aside 5 Unscrew the spindle nut counterclockwise and remove the spindle washer 6 Remove the hub from the spindle being careful not to allow the outer bearing cone to fall out The inner bearing cone will be retained by the seal 7 For 7 200 lb and 8 000 lb axles a hub puller may be necessary to assist in drum removal Brake Drum Inspection There ...

Page 432: ...never the armature surface is refaced and the armature surface should be refaced whenever the magnets are replaced Note It is important to protect the wheel bearing bores from metallic chips and contamination which result from drum turning or armature refacing operations Make certain that the wheel bearing cavities are clean and free of contamination before reinstalling bearing and seals The prese...

Page 433: ...ning the hub bore area replace the cup by tapping in with the brass drift punch Be sure the cup is seated all the way up against the retaining shoulder in the hub Bearing Lubrication Grease Along with bearing adjustment proper lubrication is essential to the proper function and reliability of your trailer axle Bearings should be lubricated every 12 months or 12 000 miles The method to repack beari...

Page 434: ...lug hole in the cap itself Recommended Wheel Bearing Lubrication Specifications Grease Thickener Type Lithium Complex Dropping Point 215O C 419O F Minimum Consistency NLGI No 2 Additives EP Corrosion Oxidation Inhibitors Viscosity Index 80 Minimum Approved Sources Mobil Oil Mobilgrease HP Mobilith AW2 Exxon Standard Ronex MP Kendall Refining Co Kendall L 427 Super Blu Ashland Oil Co Valvoline Mult...

Page 435: ...ing cavity If there is any question of condition replace the seal Use only the seals specified in the Seal Replacement Chart To replace the seal 1 Pry the seal out of the hub with a screwdriver Never drive the seal out with the inner bearing as you may damage the bearing 2 Apply a PERMATEX sealant to the outside of the new seal Note Permatex sealant should not be used on rubber encased seals 3 Tap...

Page 436: ...out slightly until the first castellation lines up with the cotter key hole and insert the cotter pin 5 Bend over the cotter pin legs to secure the nut 6 Nut should be free to move with only restraint being the cotter pin For E Z Lube axles using the new nut retainer 1 Finger tighten the nut until just snug align the retainer to the machined flat on the spindle and press the retainer onto the nut ...

Page 437: ...e grease gun wipe off any excess and replace the rubber plug in the cap 5 Rotate hub or drum while adding grease Note The E Z Lube feature is designed to allow immersion in water Axles not equipped with E Z Lube are not designed for immersion and bearings should be repacked after each immersion If hubs are removed from an axle with the E Z Lube feature it is imperative that the seals be replaced B...

Page 438: ...ement These bearings are designed with a small amount of axial end play This end play is essential to the longevity of the bearings service life Drum Removal Whenever the hub equipment on your axle must be removed for inspection or maintenance the following procedure should be utilized 1 Elevate and support the trailer unit per manufacturer s instructions Hubs Drums Bearings ...

Page 439: ... and remove the spindle washer 6 Carefully remove the hub from the spindle The Nev R Lube bearing cartridge will remain in the hub Note Do not remove cartridge bearing from the hub bore unless replacement of the bearing cartridge is intended Special tools and techniques are required for removal of the old bearing Bearing Inspection Important 1 Elevate and support the trailer unit per manufacturer ...

Page 440: ...bearings and the amount of tilt that can be expected Since there are a large number of wheel and tire combinations in use on trailers the tilt is expressed in inches per inch The movement as measured at the tire tread can be found by the following method Example if the tilt value is shown as 003 per inch and the tire measures 30 in diameter simply multiply 003 X 15 1 2 tire diameter 045 which is t...

Page 441: ...fitted with a hollow or stepped punch face to press only on the outer housing of the bearing Failure to follow procedure will damage the bearing and or seals during installation Press bearing until it seats against the backup shoulder machined into the hub 5 Install internal snap ring into hub 6 Clean and inspect spindle shaft Apply a light coating of anti seize lubricant to the spindle shaft prio...

Page 442: ...l bearing adjustment no other adjustments are to be made 10 Install torque instruction washer onto end of spindle 11 Install external snap ring onto end of spindle to retain washer 12 Inspect assembly for excessive end play noise and rotation restriction prior to mounting final wheel end hardware ...

Page 443: ...on bushings fitted for wear resistance The springs are held to the axle tube using a system of U bolts and clamp plates and are attached to the trailer as shown Center Hanger Equalizer Rear Hanger Front Hanger Tie Plate U Bolt Shackle Bolts Shackle Link Underslung Shown Articulation of this suspension occurs when the spring becomes loaded and consequently lengthens The double pivot action of the s...

Page 444: ...ngs have an eye formed in one end only with the other end formed into a reverse curve The attachment of these springs is as follows 1 The front eye is attached directly into the front hanger with a bolt and nut 2 The rear end of the spring is captured in the rear hanger or equalizer with a keeper bolt that prevents the spring from coming out when the trailer is jacked up for service The articulati...

Page 445: ...ff of the axle Loss of a wheel end while the trailer is moving can cause you to lose control and lead to an accident which can result in serious injury or death Suspension Fastener Torque Values Torque lbs ft Item Min Max 3 8 U Bolt 30 50 7 16 U Bolt 45 70 1 2 U Bolt 45 70 9 16 U Bolt 65 95 5 8 U Bolt 100 120 Non shoulder type with 9 16 threads Shackle Bolt Snug fit only Parts must rotate freely L...

Page 446: ...remove the spring and place on a suitable work surface 5 If the spring eye bushings are to be replaced drive out the old bushing using a suitable drift punch CAUTION Be sure to wear safety glasses when removing or installing force fitted parts Failure to comply may result in serious injury 6 Drive the new bushing into the spring eye using a piloted drift punch or a close fitting bolt inserted thro...

Page 447: ...ve been fitted with anti friction bearing materials which do not require routine lubrication When otherwise servicing the unit these pivot points may be lubricated if you so desire If your trailer has been fitted with the Heavy Duty Attaching Parts Kit you should lubricate periodically to ensure long component life Torflex Suspension The Torflex suspension system is a torsion arm type suspension w...

Page 448: ...ed in this manual CAUTION DO NOT WELD ON THE TORFLEX BEAM It has rubber cords inside and the heat generated by welding could damage the cords Airflex Suspension The Dexter Airflex suspension is a unique combination of Torflex axle and conventional air suspension technology This low maintenance suspension system carries the load on a cushion of air usually supplied by an on board compressor and sto...

Page 449: ...erly supported vehicles can fall unexpectedly and cause serious injury or death 2 Measure from king pin to spindle center on each side To simplify this process plumb lines may be dropped from the king pin and from the centerline of each spindle end Measurements A and B can then be taped on the floor to eliminate any miss measurement due to sagging of the tape long measurements Compare A and B meas...

Page 450: ... 64 Suspensions 4 Re measure A and B as before to assure that A and B dimensions are within 1 16 of each other If dimensions are not to specification then repeat adjustment procedure Figure 1 ...

Page 451: ... distances must be within 1 8 of each other 3 After alignment is completed make sure all nuts and bolts are tightened to their respective torque values 4 The limits of 1 16 and 1 8 appear very small in comparison to the overall dimensions of the vehicle but they are recognized as the maximum permissible limit of misalignment Also the relatively small size of those limits makes accurate measurement...

Page 452: ...ity Make sure that the wheels have enough load carrying capacity and pressure rating to match the rated load of the tire 3 Offset This refers to the relationship of the center line of the tire to the hub face of the axle Care should be taken to match any replacement wheel with the same offset wheel as originally equipped Failure to match offset can result in reducing the load carrying capacity of ...

Page 453: ...els However you must not exceed the limits of the wheel mounting studs on the axles It is extremely important to apply and maintain proper wheel mounting torque on your trailer axle Torque is a measure of the amount of tightening applied to a fastener nut or bolt and is expressed as length force For example a force of 90 pounds applied at the end of a wrench one foot long will yield 90 lbs ft of t...

Page 454: ... road use and after each wheel removal Check and re torque after the first 10 miles 25 miles and again at 50 miles Check periodically thereafter Wheel Torque Requirements For Dexter Steel Wheels Prior to June 2004 Wheel Torque Sequence Size 1st Stage 2nd Stage 3rd Stage 12 20 25 35 40 50 75 13 20 25 35 40 50 75 14 20 25 50 60 90 120 15 20 25 50 60 90 120 16 20 25 50 60 90 120 16 5 x 6 75 20 25 50 ...

Page 455: ...l that can be safely applied to these studs is listed in the following chart Stud Size Max Torque 1 2 20 UNF class 2A 120 lb ft 9 16 18 UNF class 2A 170 lb ft 5 8 18 UNF class 2A 325 lb ft CAUTION Exceeding the above listed torque limits can damage studs and or nuts and lead to eventual fractures and dangerous wheel separation Wheels and Tires ...

Page 456: ... Use the capacity rating molded into the tire sidewall divided by 1 10 for trailer use Use tire mounting procedures as outlined by the Rubber Manufacturer s Association or the tire manufacturers Tire inflation pressure is the most important factor in tire life Inflation pressure should be as recommended by the manufacturer for the load Pressure should be checked cold before operation Do not bleed ...

Page 457: ...correct toe in Out of balance Wheel lockup tire skidding Adjust pressure to particular load per tire catalog Adjust pressure to particular load per tire catalog Make sure load doesn t exceed axle rating Align at alignment shop Align at alignment shop Check bearing adjust ment and balance tires Avoid sudden stops when possible and adjust brakes Wear Pattern Cause Action g ...

Page 458: ...7 x 11 4 K71 045 00 N A 7 x 1 N A K71 466 00 10 x 21 4 K71 047 00 K71 267 00 Free Backing K71 393 00 Corrosion Resistant K71 423 00 12 x 2 5 2K K71 048 00 K71 268 00 12 x 2 7K K71 127 00 K71 269 00 LH K71 270 00 RH Free Backing K71 394 00 LH K71 395 00 RH Free Backing Corrosion Resistant K71 427 00 LH K71 428 00 RH 121 4 x 21 2 K71 497 00LH K71 496 00RH N A 121 4 x 33 8 K71 499 00LH K71 498 00RH K...

Page 459: ... K71 308 00 25520 25580 6K Outer K71 309 00 15245 15123 12 x 2 8 Bolt Inner K71 308 00 25520 25580 7K Outer K71 310 00 14145A 14276 121 4 x 21 2 8 Bolt Inner K71 308 00 25520 25580 7 2K Outer K71 415 00 02420 02475 121 4 x 33 8 8 Bolt Inner K71 308 00 25520 25580 8K Outer K71 415 00 02420 02475 Special Application Seal Replacement Reference Brake Hub Seal Part No Size Size Std E Z Lube Oil 7 x 11 ...

Page 460: ...part of the axle or suspension system Never go under any trailer unless it is properly supported on jack stands which have been rated for the load Improperly supported vehicles can fall unexpectedly and cause serious injury or death 3 Lubricate mechanical moving parts such as the hitch and suspension parts that are exposed to the weather 4 Boat trailer axles are subject to repeated immersion Befor...

Page 461: ...th an ohmmeter The magnets should check 3 2 ohms If shorted or worn excessively they must be replaced 6 Lubricate all brake moving parts using a high temperature brake lubricant LUBRIPLATE or Equivalent CAUTION Do not get grease or oil on brake linings or magnet face 7 Remove any rust from braking surface and armature surface of drums with fine emery paper or crocus cloth Protect bearings from con...

Page 462: ... breakaway battery is fully charged 4 Inspect towing hookup for secure attachment 5 Load your trailer so that approximately 10 of the trailers total weight is on the hitch For light trailers this should be increased to 15 6 Do Not Overload Stay within your gross vehicle rated capacity consult your trailers identification plate 7 Inflate tires according to manufacturer s specifications inspect tire...

Page 463: ...ines Inspect for cracks leaks kinks Trailer Brake Wiring Inspect wiring for bare spots fray etc Breakaway System Check battery charge and switch operation At Every Use Hub Drum Inspect for abnormal wear or scoring Wheel Bearings Cups Inspect for corrosion or wear Clean repack Seals Inspect for leakage Replace if removed Springs Inspect for wear loss of arch Suspension Parts Inspect for bending loo...

Page 464: ...rial and workmanship for a period of seven 7 years from the date of purchase EXCLUSIVE REMEDY Dexter Axle will at its option repair or replace the affected components of any defective axle repair or replace the entire defective axle or refund the then current list price of the axle In all cases a reasonable time period must be allowed for warranty repairs to be completed Allowance will only be mad...

Page 465: ... publication Operation Maintenance Service Manual including required maintenance after Prolonged Storage 12 Improper wheel nut torque 13 Cosmetic finish or corrosion LIMITATIONS 1 In all cases Dexter Axle reserves the right to fully satisfy its obligations under the Limited Warranties by refunding the then current list price of the defective axle or if the axle has been discontinued of the most ne...

Page 466: ...NTIAL DAMAGES INCLUDING LOSS OF TIME INCONVENIENCE LOSS OF USE TOWING FEES TELEPHONE CALLS OR COST OF MEALS FOR ANY BREACH OF ANY EXPRESS OR IMPLIED WARRANTY INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the a...

Page 467: ...ship within 24 hours direct to you from the factory With dedicated customer support quick turnaround and a 30 day money back guarantee the Dexter Online Parts Store helps keep your trailer going Hub Components Brake Components Suspension Components Complete Hub Kits Brake Assemblies Kits Brake Controllers Actuators Ready for Immediate Shipment Direct to Your Door Visit us online at www dexteraxle ...

Page 468: ...Service Record Date Service Performed Mileage ...

Page 469: ...Service Record Date Service Performed Mileage ...

Page 470: ...Service Record Date Service Performed Mileage ...

Page 471: ... 92408 Fax 909 799 6258 Ph 909 796 2908 Dexter Axle 500 S E 27th St El Reno OK 73036 Fax 405 262 9089 Ph 405 262 6700 Dexter Axle Road 75 East Albion IN 46701 Fax 260 636 3030 Ph 260 636 2195 Dexter Axle 11870 N 650 East N Manchester IN 46962 Fax 260 982 7511 Ph 260 982 4047 Company Headquarters 2900 Industrial Parkway East Elkhart IN 46516 Fax 574 295 8666 Ph 574 295 7888 Dexter Axle 1 Municipal ...

Page 472: ...www dexteraxle com 2900 Industrial Parkway East Elkhart IN 46516 Fax 574 295 8666 Ph 574 295 7888 2 07 Dexter Axle 2007 LIT 001 00 ...

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