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TSE DPT60, Owner'S Manual

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TSE DPT60 Owner'S Manual Download Page 232

3

Series 90

Contents

Contents

Introduction ......................................................................................................................................................................... 2

Use of this Manual ........................................................................................................................................................................................ 2
Safety Precautions ........................................................................................................................................................................................ 2

Functional Description ....................................................................................................................................................... 5

General Description and Cross Sectional Views ......................................................................................................................................... 5

Variable Displacement Pumps ................................................................................................................................................................ 5
Fixed Displacement Motor ..................................................................................................................................................................... 5
Variable Displacement Motor .................................................................................................................................................................. 6

The System Circuit ....................................................................................................................................................................................... 7

The Basic Closed Circuit ........................................................................................................................................................................ 7
Case Drain and Heat Exchanger ........................................................................................................................................................... 7

Common Features of Pumps and Motors .................................................................................................................................................... 8

End Caps and Shafts ............................................................................................................................................................................. 8
Speed Sensors ....................................................................................................................................................................................... 8

Pump Features ............................................................................................................................................................................................. 9

Charge Pump .......................................................................................................................................................................................... 9
Charge Relief Valve ................................................................................................................................................................................. 9
Multi-Function Valves .............................................................................................................................................................................. 9

Pressure Limiter and High Pressure Relief Valves ....................................................................................................................... 10
System Check Valves .................................................................................................................................................................... 10
Bypass Valves ................................................................................................................................................................................ 10

Displacement Limiters .......................................................................................................................................................................... 11
Auxiliary Mounting Pads ....................................................................................................................................................................... 11
Filtration Options ................................................................................................................................................................................... 11
Pressure Override (POR) - 180 Frame Size Only ............................................................................................................................. 12
Pump Control Options .......................................................................................................................................................................... 13

Manual Displacement Control (MDC) ........................................................................................................................................... 13
Hydraulic Displacement Control (HDC) ........................................................................................................................................ 13
Electric Displacement Control (EDC) ............................................................................................................................................ 14
Automotive Control (FBA II B) ....................................................................................................................................................... 14
3-Position (FNR) Electric Control .................................................................................................................................................. 14

Motor Features ........................................................................................................................................................................................... 15

Motor Loop Flushing Valve and Charge Relief Valve ........................................................................................................................... 15
Variable Motor Displacement Limiters .................................................................................................................................................. 15
Variable Motor Controls ........................................................................................................................................................................ 16

Hydraulic 2-Position Control .......................................................................................................................................................... 16
Electric 2-Position Control .............................................................................................................................................................. 16

Technical Specifications .................................................................................................................................................. 17

General Specifications ................................................................................................................................................................................ 17
Circuit Diagrams ......................................................................................................................................................................................... 17
Hydraulic Parameters ................................................................................................................................................................................. 18
Size Specific Data ....................................................................................................................................................................................... 19

Pressure Measurement ................................................................................................................................................... 20

Required Tools ............................................................................................................................................................................................ 20
Port Locations and Pressure Gauge Installation ....................................................................................................................................... 20

Variable Pump ....................................................................................................................................................................................... 20
Fixed Motor ........................................................................................................................................................................................... 23
Variable Motor ....................................................................................................................................................................................... 24

Initial Start-Up Procedure ................................................................................................................................................ 25

Fluid and Filter Maintenance ........................................................................................................................................... 26

Troubleshooting ................................................................................................................................................................ 27

"NEUTRAL" Difficult or Impossible to Find ................................................................................................................................................. 27
System Operating Hot ................................................................................................................................................................................ 27
Transmission Operates Normally in One Direction Only .......................................................................................................................... 28
System Will Not Operate in Either Direction .............................................................................................................................................. 28
Low Motor Output Torque ........................................................................................................................................................................... 29
Improper Motor Output Speed .................................................................................................................................................................... 29
Excessive Noise and/or Vibration .............................................................................................................................................................. 30
System Response is Sluggish .................................................................................................................................................................... 30

Summary of Contents for DPT60

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 DPT60 Puller Tensioner Serial Number 19 5230 01 ...

Page 2: ...tor controls include linepull linespeed holding brake levelwind and engine controls A freewheel disconnect and bronze overspin brake are available for controlled payout of the pulling rope OPTIONAL EQUIPMENT Hydraulic overhead levelwind 6052 Heavy duty pulling drum Hydraulic front jack Combination overhead underground levelwind Underground pulling drum BR 6030 Breakaway reel MODEL DPT 60 Continuou...

Page 3: ...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 4: ...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 5: ...its 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 DPT60 19 5230 01 ...

Page 6: ...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 7: ...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 8: ...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 9: ...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 10: ...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 13: ...8 GENERAL ASSEMBLY DPT60 7601256 A POWER UNIT AND PUMP ASSEMBLY 7600517 B DRIVE ASSEMBLY 7600516 REEL SHAFT ASSEMBLY 8602229 HYDRAULIC SCHEMATIC 7601116 C LIGHTING DIAGRAM LED 780298 E CONTROL PANEL ASSEMBLY 760188 N LEVELWIND ASSEMBLY 760097 I LEVELWIND HEAD ASSEMBLY 5602825 COOLER WIRING SCHEMATIC SECTION V VENDOR INFORMATION ENGINE PUMP MOTOR BRAKE GEARBOX AXLE ...

Page 14: ...ination lifting lug locking collar prevents any lateral movement of the reel on the reel shaft Another lifting lug is attached to the drive arm allowing reels to be loaded by crane 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 FOLLOW...

Page 15: ...000 lbs Reel Shaft Diameter 3 inch 4 Undercarriage Axle 16K Tandem with Leaf Springs Tires 9R17 5 HC Brakes 12 1 4 x 3 3 8 ELECTRIC Leveling Jacks 1 Front Manual Screw Type Hydraulic Option 2 Rear Manual or Hydraulic Optional WARNING CAUTION THESE VALUES ARE A MAXIMUM AND MUST NOT BE EXCEEDED ...

Page 16: ...S EQUIPMENT Figure 1 Control Panel 1 Hydraulic Gauge This gauge shows the hydraulic pressure in the system Do not continuously exceed 4500 PSI at any time during operation of the machine 2 Linepull Control The pressure in the hydraulic system is regulated with this control knob See Figure 2 Clockwise rotation of the Linepull Control increases pressure and therefore increases the Linepull Counter c...

Page 17: ...d released by hydraulic pressure See Figure 3 To hold the reel stationary turn the Reel Brake Lever to the APPLY position Turn to the RELEASE position before driving the reel THE BRAKE IS DESIGNED TO HOLD THE CONDUCTOR UNDER STATIC CONDITIONS ONLY THE HOLDING POWER OF THE BRAKES AND PROPER FUNCTIONING OF ALL MACHINE CONTROLS MUST BE VERIFIED BEFORE THE UNIT IS PUT INTO SERVICE TO ENSURE SAFE OPERA...

Page 18: ...l 5 Direction Lever Stop A Stop positioned in front of the Direction Control Lever 4 will not allow the Lever to be put in the Pay Out direction without the operator lifting the Stop handle to allow the Direction Control Lever to pass The Stop automatically falls back into place when the lever is returned to the NEUTRAL position or to the Pull In direction 6 Levelwind Direction Control Option Late...

Page 19: ... LIMITED TO A SPECIFIC MAXIMUM RPM AND CAN BE DAMAGED IF DRIVEN FASTER THAN THE GOVERNED ENGINE SPEED PRE START CHECKLIST Before starting the engine make sure 1 The Direction Control Lever 4 is in the NEUTRAL position 2 The Brake Control 3 should be in the APPLY position Engine Start Up Refer to the Engine Manufacturer s Operating Instructions in the APPENDIX Stopping the Engine 1 Move the Directi...

Page 20: ...ORTANT Anchor the unit using the anchoring lugs provided Use anchors that will hold three times the maximum pull of the unit Figure 5 Job Site Setup Anchoring 5 PROPER GROUNDING OF THE MACHINE IS VERY IMPORTANT The machine is equipped with a ground bar To protect against electrical hazards due to induction or electrical contact the system must be connected to a proper ground rod or the electrical ...

Page 21: ...read 1 000 PSI on the system Pressure Gauge 1 Allow system to run for a At least ten 10 minutes b Or until hydraulic oil reservoir feels warm to the touch c Or until the indicator gauge on the suction filter reads less than 5 inches vacuum In extreme cold weather operations special low temperature hydraulic oil is recommended Pulling Slack Pulling Rope The following procedure describes how to set ...

Page 22: ...g rope builds up on the pulling reel to maintain proper linepull and speed Always turn the Linepull Control in turn further than what is required to move the conductor and this will ensure the Puller will stall if a snag in the pulling rope or conductor occurs 10 To stop the pull move the Direction Control Lever 4 to the NEUTRAL position and then APPLY the brake 3 Pulling After Stopping during a P...

Page 23: ...position 6 Instruct the Puller operator to start pulling and as line starts moving adjust the Linepull Control 2 until the desired stringing tension is achieved on the Conductor to give the desired stringing sag You may have to adjust the Linepull Control 2 to increase or decrease tension in the conductor and maintain the correct stringing sag as the reel empties 7 To stop except in the case of an...

Page 24: ...ill fall back into place restricting movement into there PAY OUT direction once again Paying Out Rope or Conductor under Tension This procedure describes how to Pay Out or loosens a pulling rope or conductor when it is under tension This situation may occur for example when a conductor or pulling rope is to be backed into a grip Essentially the process is to tension out the rope or conductor at a ...

Page 25: ...e reel This procedure is usually used when the pulling rope is being pulled from the Puller end to the Tensioner end Figure 6 Opening Drive Door With the reel stationary 1 Place the Direction Control Lever 4 in the NEUTRAL position 2 Turn the Brake Control 3 to the APPLY position The engine can now be shut off See Engine section 3 Remove the Lock Pin from the drive sprocket THERE MUST BE NO TENSIO...

Page 26: ...denly DO NOT EXCEED RATING OF THE MACHINE Removing Reel 1 Turn the reel until Drive Arm and Lifting Loop are in vertical UP position 2 On the Drive Arm side pull Ball Lock Pin straight up and pull Reel Shaft Pin back enough to allow the reel shaft to be lifted up See Figure 7 8 3 On the Lifting Loop side open the Locking Latch and swing back out of the way See Figure 7 8 4 Attach lifting hooks to ...

Page 27: ...2 On the drive sprocket side pull Ball Lock Pin straight up and pull Reel Shaft Pin back enough to allow the reel shaft to be installed See Figure 7 8 3 On the Lifting Loop side open the Locking Latch and swing back out of the way See Figure 7 8 4 Put reel shaft in reel making sure the conductor or rope will wind on or off from the top of the reel in the correct direction 5 Make sure reel shaft Dr...

Page 28: ...gaging reel shaft drive with mating part and ensure Bronze Bearing is located in Bearing Support 10 Push reel shaft Pin into end of reel shaft at Drive Arm end and insert Ball Lock Pin to hold the Reel Shaft Pin in place 11 At Lifting Loop end swing Locking Latch into place over Bronze Bearing and insert Safety Pin CAUTION WARNING THE REEL MUST BE OVERWOUND WHEN PLACED IN THE MACHINE AS VIEWED FRO...

Page 29: ...ator protective screens are folded down 3 Wheel brakes are operational 4 Tires are inflated to proper pressure Check that wheel chocks are removed and stored away properly 5 Lights are operational 6 All reel shaft pins locking pins are properly engaged 7 Safety chains and breakaway switch connected ...

Page 30: ...shooting a hydraulic system for leaks use a piece 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 as...

Page 31: ...of consistent conditions which will tend to highlight 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 prop...

Page 32: ...RAULIC FLUID IS USED IN YOUR MACHINE ISO 46 56785 1 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 33: ...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...

Page 34: ...ch must be turn on for manual parked regen WARNING The Machine must not be operated while the engine is performing a manual parked regen See engine manual in vendor literature section of this manual for more detailed information on manual parked regen ...

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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 Continued on next page ZE59858 0000007 19 11MAR14 1 2 Identification Views RG25233 UN 10MAR14 4045HFC09 Left View RG25234 UN 10MAR14 4045HFC09 Right View 032015 PN 5 ...

Page 53: ...Introduction ZE59858 0000007 19 11MAR14 2 2 RG25231 UN 10MAR14 4045HFC04 Left View RG25232 UN 10MAR14 4045HFC04 Right View 032015 PN 6 ...

Page 54: ...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 55: ...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 032015 PN 8 ...

Page 56: ...uipped Engines 10 1 Storing Diesel Exhaust Fluid DEF 10 1 Refilling Diesel Exhaust Fluid DEF Tank 10 2 Testing Diesel Exhaust Fluid DEF 10 3 Disposal of Diesel Exhaust Fluid DEF 10 3 Diesel Fuel 10 4 Supplemental Diesel Fuel Additives 10 4 Lubricity of Diesel Fuel 10 5 Handling and Storing Diesel Fuel 10 5 BioDiesel Fuel 10 6 Testing Diesel Fuel 10 7 Fuel Filters 10 7 Minimizing the Effect of Cold...

Page 57: ...ar 40 7 Checking Tensioner Spring Tension 40 8 Checking Cooling System 40 8 Pressure Testing Cooling System 40 9 Page Checking and Adjusting Engine Speeds 40 10 Checking Engine Mounts 40 10 Checking Engine Ground Connection 40 10 Lubrication Maintenance 1500 Hours Changing Open Crankcase Ventilation OCV Filter 45 1 Lubrication Maintenance 3000 Hours 36 Months Checking Crankshaft Vibration Damper 5...

Page 58: ...ications 80 3 Engine Crankcase Oil Fill Quantities 80 4 Unified Inch Bolt and Screw Torque Values 80 4 Metric Bolt and Screw Torque Values 80 5 Lubrication and Maintenance Records Using Lubrication and Maintenance Records 85 1 Daily Prestarting Service 85 1 500 Hours of Operation or Every 12 Months Service 85 1 1500 Hours of Operation Service 85 2 3000 Hours of Operation or Every 36 Months Service...

Page 59: ...Contents iv 032015 PN 4 ...

Page 60: ... plate in the spaces provided below 3 This information is very important for repair parts or warranty information Engine Serial Number A Engine Model Number B NOTE On engine serial number A the seventh digit shows the emission level as follows L for Tier 3 Stage IIIA engines R for Interim Tier 4 Stage IIIB engines U for Final Tier 4 Stage IV JOHN DEERE Engine Serial Number PE4045U123456 4045HFC09 ...

Page 61: ...he 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 below Record engine base code A below as seen on your serial number plate Engine Option Codes Continued NOTE Your engine option code...

Page 62: ... Thermostat Housing 81 Primary Fuel Filter and Water Separator 40 Oil Dipstick 83 Electronic Software Vehicle Option 41 Belt Driven Front Auxiliary Drive 84 Electrical Wiring Harness 42 DEF Line 86 Fan Pulley 43 Starting Aid 87 Belt Tensioner 44 Timing Gear Cover with Gears 89 Exhaust Gas Recirculating EGR System 45 Balancer Shaft 90 Trim Options 46 Cylinder Block and Camshaft 91 Instrument Panel ...

Page 63: ...art Number SCR Serial Number A Diesel Particulate Filter Part Number B Diesel Particulate Filter Serial Number C Diesel Oxidation Catalyst Part Number D Diesel Oxidation Catalyst Serial Number E Selective Catalyst Reduction Part Number F Selective Catalyst Reduction Serial Number RG20010 UN 11FEB11 RG24024 UN 05AUG13 Serial Number Plates for Aftertreatment Record High Pressure Fuel Pump Model Numb...

Page 64: ...19 12AUG14 1 1 Record ECU Serial Number Record the part number and serial number information found on the serial number label on the Engine Control Unit ECU Part No Serial No A Serial Number Label RG26249 UN 30JUL14 01 5 032015 PN 17 ...

Page 65: ...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 66: ...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 67: ...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 68: ... 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 69: ...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 70: ...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 71: ...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 72: ... 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 73: ...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 74: ... 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 75: ... 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 76: ...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 77: ...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 78: ...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 032015 PN 31 ...

Page 79: ...y component of the aftertreatment system Do not use DEF that does not meet the required specifications or operate the engine with no DEF Never attempt to create DEF by mixing agricultural grade urea with water Agricultural grade urea does not meet the necessary specifications and can damage the aftertreatment system Do not add any chemicals or additives to DEF in an effort to prevent freezing Any ...

Page 80: ...DEF tank Ensure that the DEF tank cap area is free of debris before removing the cap Seal containers of DEF between use to prevent contamination and evaporation Avoid splashing DEF and do not allow DEF to come into contact with skin eyes or mouth DEF is not harmful to handle but DEF can be corrosive to materials such as steel iron zinc nickel copper TS1731 UN 23AUG13 aluminum and magnesium Use sui...

Page 81: ... if there is suspicion the engine or packaged DEF fluid has been contaminated with water Two approved tools are available through your John Deere dealer JDG11594 Digital DEF Refractometer A digital tool providing an easy to read concentration measurement JDG11684 DEF Refractometer Low cost alternative tool providing an analog reading Follow instructions included with either tool to obtain the meas...

Page 82: ...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 83: ...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 84: ...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 85: ...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 86: ...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 87: ...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 88: ... 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 89: ...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 1903 19BB 19AE 19BC 1923 19BA 1976 19AZ 19GK kW hp Other Oils John Deere Plus 50 II Other Oils John D...

Page 90: ...bricants are used Use clean containers to handle all lubricants Store lubricants and containers in an area protected from dust moisture and other contamination Store containers on their side to avoid water and dirt accumulation Make certain that all containers are properly marked to identify their contents Properly dispose of all old containers and any residual lubricant they may contain Oil Filte...

Page 91: ...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 92: ...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 93: ...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 94: ...nd to troubleshoot the engine systems when needed B Arrow Keys The arrow keys B allows the operator to select menu items C Menu Key The menu key C allow the operator to access the main menu of the diagnostic gauge D Select Key The select key D allows the operator to access menu items selected by the arrow keys B and confirm changes made by the operator E Exit Key The exit key E allows the operator...

Page 95: ...lly change from up and down to left and right depending on the menu item to be selected The menu key C allows the operator to access the main menu of the diagnostic gauge For more information see Diagnostic Gauge Main Menu The select key D allows the operator to access menu items selected by the arrow keys B and confirm changes made by the operator The exit key E allows the operator to cancel an o...

Page 96: ...t Key F Display Auto features Manual features Clock start Temperature start In Service Data list screens Engine hours Data logger Service reminders Harness diagnostics Component identification Emission system override if equipped In Utilities System settings Pressure governing ECU software update Advanced settings password protected John Deere PowerSight John Deere PowerSight is a web based servic...

Page 97: ... 500 Hours 12 Months Section Fill crankcase with seasonal viscosity grade oil See Diesel Engine Oil Interim Tier 4 Final Tier 4 Stage IIIB and Stage IV in the Fuels Lubricants and Coolants Section NOTE Some increase in oil consumption may be expected when low viscosity oils are used Check oil levels more frequently If temperature is below 0 C 32 F it may be necessary to use cold weather starting a...

Page 98: ...not start after four attempts see Engine Troubleshooting in the Troubleshooting Section 5 Turn the key start switch clockwise to the ON position Wait until the Engine Preheater Indicator light turns off then turn the key start switch F clockwise START position to crank the engine In cold weather preheater indicator light remains on longer while engine is warmed See Cold Weather Operation in the En...

Page 99: ...kly stop engine and determine cause before resuming operation Operate the engine under a lighter load and at slower than normal speed for first 15 minutes after start up DO NOT run engine at slow idle Stop engine immediately if there are any signs of part failure Symptoms that may be early signs of engine problems are Sudden drop in oil pressure Abnormal coolant temperatures Unusual noise or vibra...

Page 100: ...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 101: ...peeds than normal for the first few minutes after start up Idling Engine Avoid excessive engine idling Prolonged idling may cause the engine coolant temperature to fall below its normal range This in turn causes crankcase oil dilution due to incomplete fuel combustion and permits formation of gummy deposits on valves pistons and piston rings It also promotes rapid accumulation of engine sludge and...

Page 102: ...ON Gas given off by battery is explosive Keep sparks and flames away from battery Before connecting or disconnecting a battery charger turn off charger Make last connection and first disconnection at a point away from battery 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 ...

Page 103: ...n at front of engine power requirements of the accessory must be limited to values listed below IMPORTANT See OEM engine distributor for more information to prevent overloading the auxiliary drive Severe engine damage could result SAE Drive Continuous Power Maximum Intermittent Power Maximum A 30 kW 40 hp at 2500 rpm 37 kW 50 hp at 2500 rpm RG26299 UN 12AUG14 Auxiliary Gear Drive A Auxiliary Gear ...

Page 104: ...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 105: ...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 removal methods may violate U S federal state and local hazardous waste laws along with dam...

Page 106: ...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 107: ...ules are formed in the exhaust DEF is injected into the exhaust stream before the SCR catalyst Through a chemical reaction in the SCR NOx is converted into nitrogen and water Water vapor is a normal by product of combustion During cold weather operation at low exhaust temperatures this water vapor can condense and resemble white smoke from the exhaust This will dissipate as operating temperature i...

Page 108: ...ndicators you will see and use on the diagnostic gauge The diesel exhaust fluid indicator A engine emissions temperature indicator B exhaust filter indicator C auto cleaning disable indicator D engine emissions system malfunction indicator E and the caution indicator F provide the operator with visual notifications and aftertreatment system operations The Arrow keys G are used to scroll up or down...

Page 109: ...enable the auto exhaust filter clean function If conditions are not safe the operator should move the machine to a safe location and engage the auto exhaust filter cleaning mode Perform manual service regeneration or follow DTC procedure When the exhaust filter indicator is combined with the stop engine indicator engine performance is further reduced by the ECU because there is an aftertreatment s...

Page 110: ...ing 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 indicator will automatically turn off CAUTION Servicing machine or attachments during exhaust filter cleaning can result in serious personal injury Avoid exposure and skin contact with h...

Page 111: ...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 112: ...up or down to DISABLE EXH FLT CLEAN 5 Press Select key to disable exhaust filter cleaning Exhaust Filter Service Required The exhaust filter cleaning procedures listed earlier in this section clean the soot from your exhaust filter The exhaust filter also traps ash deposits over time which are not removed during an exhaust filter cleaning When the exhaust filter has run several thousand hours thes...

Page 113: ...ection 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 A RG22413 UN 27AUG13 Hour Meter On Instrument Panel A Hour Meter engine operated under adverse conditions Neglecting maintenance can result in failures or permanent damage to the e...

Page 114: ...ngine Ground Connection Change Open Crankcase Ventilation OCV Filterc Check Crankshaft Vibration Damper Adjust Engine Valve Clearance Test Glow Plugs for Continuity Change DEF Dosing Unit Filter Flush and Refill Cooling System Test Thermostats Drain Water From Fuel Filters When Alarm Sounds Add Coolant Clean DEF Tank Pre Start Cleaning Guide Service Air Cleaner Filter Elements Clean Diesel Particu...

Page 115: ...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 116: ...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 117: ...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 118: ...y engine power and the oil and filter used For more information see Diesel Engine Oil and Filter Service Intervals in the Fuels Lubricants and Coolants Section OILSCAN or OILSCAN PLUS is a John Deere sampling program to help you monitor machine performance and identify potential problems before they cause serious damage OILSCAN and OILSCAN PLUS kits are available from your John Deere engine distri...

Page 119: ...tage IV in 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 of this manual NOTE Crankcase oil capacity may vary slightly ALWAYS fill crankcase within crosshatch marks on dipstick DO NOT overfill 10 Start engine and run to check for possible leaks ...

Page 120: ...he skin causing serious injury Relieve pressure before disconnecting fuel or other lines Tighten all connections before applying pressure Keep hands and body away from pinholes and nozzles which eject fluids under high pressure To search for leaks use a piece of cardboard or paper Do not use your hand If any fluid is injected into the skin it must be surgically removed within a few hours by a doct...

Page 121: ...ose to filter drain valve F on bottom of filter and drain all fuel from filter canister 3 Disconnect water in fuel sensor connector E 4 Remove fuel filter element C 5 Place new O ring B on filter element 6 Apply a thin film of fuel on O ring IMPORTANT Do not fill the new filter with fuel before installing This could contaminate the fuel system with unfiltered fuel 7 Install new filter and tighten ...

Page 122: ...22 UN 13AUG14 Replace Secondary Fuel Filter Element A Secondary Fuel Filter Element B Secondary Fuel Filter Header C Bleed Vent Screw D Primer Lever screw pump primer lever until fuel flows out of bleed vent screw then tighten bleed vent screw securely Checking Belt Wear NOTE While belt is loosened inspect pulleys and bearings Rotate and feel for hard turning or any unusual sounds If pulleys or be...

Page 123: ...ioner assembly as required Specification Spring Tension 18 22 N m 13 16 lb ft A Mark B Mark RG24040 UN 07AUG13 Checking Belt Tensioner Spring Tension Checking Cooling System CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure b...

Page 124: ...rate 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 Pressu...

Page 125: ...urer Follow manufacturer s guidelines for mounting specifications IMPORTANT Use only Grade SAE 8 or higher grade of hardware for engine mounting 1 Check the engine mounting brackets A vibration isolators and mounting bolts on support frame and engine block for tightness Tighten as necessary 2 Inspect overall condition of vibration isolators if equipped Replace isolators as necessary if rubber has ...

Page 126: ... leaking or bulging hoses and for good clamp tension on all hose ends Expectation for minimal service interval will be at least 1500 hours or when the service indicator light comes on or as indicated by the diagnostic gauge 1 Remove cap A 2 Remove OCV filter from canister Discard old OCV filter 3 Install new OCV filter 4 Install cap A RG26250 UN 30JUL14 Changing OCV A Cap 45 1 032015 PN 79 ...

Page 127: ...h engine COLD 1 Remove rocker arm cover and crankcase ventilation tube 2 Remove plastic plug A from engine timing rotation hole B and timing pin hole C IMPORTANT Visually inspect contact surfaces of bridges 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...

Page 128: ...n adjusting screw with a 4 mm hex key 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 Bridge With Engine Cold Clearance 0 46 mm 0 018 in Exhaust Valve Clearance Rocker Arm to Valve Bridge With Engine Cold Clearance 0 53 mm 0 021 in Valve Adjusting Screw Lock Nut Torque ...

Page 129: ...Check and adjust valve clearance to the same specifications on for No 2 and 4 exhaust and No 3 and 4 intake valves 8 Install rocker arm cover gasket IMPORTANT When reinstalling rocker arm cover inspect gasket for damage prior to reusing 9 Tighten cap screws to specifications in the sequence shown Specification Rocker Arm Cover Cap Screws Torque 11 N m 97 lb in 10 Install vent tube to rocker arm co...

Page 130: ...inal 1 Remove glow plug wiring harness connector C 2 Using a multimeter check resistance from terminal B to the outer body of glow plug A If resistance is more than 10 Ohms the glow plug is damaged and must be replaced 3 If needed install new glow plugs and torque to specifications Specification Glow Plug Torque 15 N m 133 lb in RG26311 UN 13AUG14 Check Glow Plug A Glow Plug B Terminal C Harness C...

Page 131: ...r components See Access DEF Dosing Unit for location information 1 Remove DEF dosing unit filter cover A 2 Remove and discard DEF dosing unit filter equalizing element B 3 Insert Black end of DEF dosing unit filter tool C into DEF dosing unit filter D until CLICK is felt or heard indicating DEF dosing unit filter tool is fully engaged NOTE A tool such as a screwdriver can be inserted into DEF dosi...

Page 132: ...e pressure cap and allow pressure to relive before completely removing cap NOTE If COOL GARD II is not used the drain interval is reduced to 2000 hours or 24 months of operation 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 ca...

Page 133: ...eavy duty cooling system cleaner such as Restore or Restore Plus Follow manufacturer s directions on label 10 After cleaning the cooling system drain cleaner and fill with water to flush the system Run the engine about 7 minutes Stop engine remove radiator cap and drain water 11 Close all drain valves on engine and radiator 12 Perform Testing Thermostat Opening Temperature in the Lubrication Maint...

Page 134: ...ating temperature Always loosen radiator pressure cap or drain valve slowly to relieve pressure TS281 UN 15APR13 High Pressure Fluids 1 Visually inspect area around thermostat housing for leaks 2 Remove radiator pressure cap and partially drain cooling system 3 Remove three cap screws C and thermostat cover B clean and check cover for cracks or damage 4 Remove both thermostats A from the housing A...

Page 135: ...t and a thermometer in a container of water 3 Stir the water as it heats Observe opening action of thermostat and compare temperatures to specifications NOTE Due to varying tolerances of different suppliers initial opening and full open temperatures may vary slightly from specified temperatures Specification Thermostat Opening Temperature 85 C 97 C 185 F 207 F 4 Remove thermostat and observe its c...

Page 136: ...rmostat cover B and tighten thermostat cover cap screws C to specifications Specification Thermostat Cover Cap Screw Torque 73 N m 54 lb ft 4 Fill cooling system and check for leaks IMPORTANT Air must be expelled from cooling system when refilled A Thermostats B Thermostat Cover C Cap Screws 3 Used D Thermostat Housing RG20112 UN 18MAR11 RG25248 UN 12MAR14 Installing Thermostats 60 5 032015 PN 89 ...

Page 137: ...anufacturer will terminate the warranty obligation to the purchaser In addition tampering with fuel system which alters emission related equipment on engines may result in fines or other penalties per EPA regulations or other local emission laws Do not attempt to service fuel pump fuel rail or fuel injectors yourself Special training and special tools are required See your authorized servicing dea...

Page 138: ...l Filter B Drain Valve Adding Coolant CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to relieve pressure before removing completely IMPORTANT Never pour cold liquid into a hot engine as it may crack cylinder head or block DO NOT operate engine without cool...

Page 139: ...DEF should be crystal clear with a light ammonia smell If DEF appears cloudy has a colored tint or has a profound ammonia smell it is likely not within specification DEF in this condition should not be used 1 Remove drain plug if equipped and drain or siphon bad DEF from DEF tank NOTE Cleaning can take place with DEF tank installed or removed 2 Clean DEF tank with new DEF DEF must pass visual smel...

Page 140: ...sible 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 Ma...

Page 141: ...essary 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 force filter w...

Page 142: ...er gasket C is in good condition If gasket is damaged or missing replace element IMPORTANT Air cleaner MUST BE DRY before storing in plastic bag If the filter is to be stored for later use place it in a plastic bag to protect it from dust and damage RW4768 UN 15DEC88 Inspecting Primary Air Filter Element A Light B Outer Screen C Gasket Air Filter Element Storage IMPORTANT Air cleaner element MUST ...

Page 143: ...be located or moved to a suitable location with adequate ventilation To the right are symbols which may be seen on the operator interface IMPORTANT The area above and surrounding the engine during a manual exhaust filter cleaning should be free of any flammable objects as temperatures can reach as high as 550 C 1022 F NOTE For more information on the operator interface icons or exhaust filter clea...

Page 144: ...d turning or any unusual sounds If pulleys or bearings need replacement see your John Deere dealer 4 Install new belt making sure that belt is correctly seated in all pulley grooves Text on belt such as John Deere or part number should be readable when standing at the front of the engine looking back toward the rear Refer to belt routing at right for your application 5 Apply tension to belt with t...

Page 145: ...to turn the key off and on again to reprime the system before starting Checking Air Compressors If Equipped Air compressors are 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 engi...

Page 146: ...he 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 th...

Page 147: ... Incorrect Message 15 Slightly High 16 Moderately High 17 Slightly Low 18 Moderately Low 19 Communication Error 31 Condition Exists SPN Code SPN Name 27 EGR Valve Position Signal 51 Air Throttle Actuator Position Signal 94 Low Pressure Fuel Pressure Signal 97 Water in fuel Signal 100 Engine Oil Pressure Signal 101 Crankcase Pressure 102 Manifold Air Pressure Signal 103 VGT Speed Signal 105 Manifol...

Page 148: ...91 EGR Valve Drive Circuit 2795 VGT Calibration Version 2797 Injector High Voltage Supply 1 2798 Injector High Voltage Supply 2 3031 DEF Tank Fluid Temp Signal 3216 DPF Outlet NOx 3226 SCR Outlet NOx 3246 DPF Outlet Temperature 3251 DPF Differential Pressure Signal 3361 DEF Dosing Injector Signal 3464 Air Throttle Actuator Drive Circuit 3509 Sensor Supply 1 Voltage 3510 Sensor Supply 2 Voltage 351...

Page 149: ...e 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 part is a Suspect Parameter Number SPN followed by a Failure Mode Identifier FMI code In order to determine the exact failure both parts SPN and FMI of the code are needed The SPN identifies the system or the component that has the failure for exampl...

Page 150: ...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 151: ...anks 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 Check and cor...

Page 152: ...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 153: ... 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 154: ... 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 155: ...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 156: ...hn Deere engine distributor or servicing dealer Air leak in engine intake or exhaust manifold 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...

Page 157: ...ealer Improper type of fuel Drain fuel and replace with proper grade and quality of fuel for operating condition Poor fuel quality Drain fuel and replace with proper grade and quality of fuel for operating condition Low engine temperature Warm up engine to normal operating temperature Defective thermostat Remove and check thermostat Defective fuel injectors See your authorized John Deere engine di...

Page 158: ...aintenance 6000 Hours 72 Months Section Engine overloaded Reduce engine load Loose or defective fan belt Check automatic belt tensioner and belts Replace as required See Checking Tensioner Spring Tension in the Lubrication Maintenance 500 Hours 12 Months Section Defective or wrong type of thermostats Test thermostat opening temperature replace thermostats as required Damaged cylinder head gasket R...

Page 159: ... Deere engine distributor or servicing dealer Leaking oil cooler Pressure test oil cooler repair replace as required See your authorized John Deere engine distributor or servicing dealer Defective oil cooler O rings Remove and inspect oil cooler O rings replace as required See your authorized John Deere engine distributor or servicing dealer EGR cooler system leaking Pressure test EGR cooler syste...

Page 160: ...e engine distributor or servicing dealer Crankcase oil level too high Check engine oil level and drain as necessary High Oil Pressure Improper oil classification Drain crankcase and refill with correct oil Faulty pressure sensor Replace sensor See your authorized John Deere engine distributor or servicing dealer Oil pressure regulating valve failure Remove and inspect oil pressure regulating valve...

Page 161: ...easure valve stems and valve guides repair as required See your authorized John Deere engine distributor or servicing dealer Piston ring grooves excessively worn Remove and inspect pistons See your authorized John Deere engine distributor or servicing dealer Piston rings sticking in ring grooves Remove and inspect pistons See your authorized John Deere engine distributor or servicing dealer Insuff...

Page 162: ...st charging system Batteries Will Not Charge Loose or corroded connections Clean and tighten connections Sulfated or worn out batteries Replace batteries Stretched belt or defective belt tensioner Adjust belt tension or replace belts Starter and Hourmeter Functions Rest of Electrical System Does Not Function Blown fuse Replace fuse Entire Electrical System Does Not Function Faulty battery connecti...

Page 163: ...9858 0000027 19 30JUL14 1 4 Engine Wiring Harness Layout RG25766 UN 08MAY14 A Intake Air Sensor B Exhaust Manifold Pressure Sensor C Engine Coolant Temperature Sensor D Crankshaft Position Sensor E Engine Oil Pressure Sensor 70 18 032015 PN 116 ...

Page 164: ...d on next page ZE59858 0000027 19 30JUL14 2 4 RG25768 UN 08MAY14 A Exhaust Throttle Actuator B Fuel Rail Pressure Relief Valve C Fuel Rail Pressure Sensor D Suction Control Valve E Camshaft Position Sensor 70 19 032015 PN 117 ...

Page 165: ...nued on next page ZE59858 0000027 19 30JUL14 3 4 RG25769 UN 08MAY14 A EGR Valve B Charge Air Cooler Outlet Temperature Sensor C Cold Start Aid Relay D Water In Fuel WIF Sensor E Crankcase Pressure Sensor 70 20 032015 PN 118 ...

Page 166: ... 4 RG25770 UN 08MAY14 A Manifold Air Pressure Sensor B Fuel Injector Harness Connector C EGR Temperature Sensor D EGR Flow Sensor E Fuel Temperature Sensor F Low Pressure Fuel Pressure Sensor G Manifold Air Temperature Sensor 70 21 032015 PN 119 ...

Page 167: ...r flammable material 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 grou...

Page 168: ...04 03 6 5499 5498 5493 5495 5491 5496 5499 5 5498 4 5493 3 5495 8 5491 7 5496 6 5499 02 1 5 2 6 3 7 4 8 1 5 2 6 3 7 4 8 1 8 4 CYL 1 CYL 2 CYL 3 CYL 4 7 6 7 5 8 3 23 5410 2 3 4 To Diagram 5 A 14 5817 22 5003 Y5004 Electric Low Pressure Fuel Pump If Equipped 2 5003 1 5817 1 2 1 2 49 5826 24 50 5821 5658 39 5469 B5107 Low Pressure Fuel Pressure Sensor 3 5469 2 5658 1 5821 1 2 3 1 2 3 B5209 Fuel Tempe...

Page 169: ...r Supply 6b Positive A5501 33 5498 Gray Injector 3 Pulse A5501 39 5469 White Low Pressure Fuel Pressure Sensor Signal A5501 43 5495 Green Injector 4 Pulse A5501 44 5493 Orange Injector 1 Pulse A5501 48 5427 Violet Fuel Temperature Sensor Signal A5501 49 5826 Blue Sensor Return 10 A5501 50 5658 Gray Sensor Return 6 B To 4 5 L Wiring Diagram 5 or 4 5 L Wiring Diagram 7 B5107 Low Pressure Fuel Pressu...

Page 170: ... 3 5509 2 5633 6 5016 4 5018 1 5631 1 2 3 4 5 6 1 2 3 4 5 6 B5102 Exhaust Manifold Pressure Sensor 3 5465 2 5614 11 5465 1 5626 4 5423 3 5425 07 6 5421 08 52 2 5614 1 5626 5423 5425 5421 5614 5626 25 27 Y5400 EGR Valve 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 1 2 3 3 5646 2 5429 54 5429 1 5671 3 5646 1 2 5671 5429 3 5429 5 5332 5082 1 2 5643 5671 32 5671 21 5646 R5604 Cold Start Aid Interconnect K5803 Cold S...

Page 171: ...sure Sensor Signal A5501 27 5626 Blue 5 V Sensor Supply 6a Positive A5501 32 5671 Brown Cold Start Aid Drive Positive A5501 36 5509 White Exhaust Throttle Actuator Position Signal A5501 41 5633 Orange 5 V Sensor Supply 3 Return A5501 52 5425 Green EGR Valve Position Sensor Signal A5501 54 5429 White Cold Start Aid Signal C 5082 Red Battery Power Positive To 4 5 L Wiring Diagram 10 B5101 Engine Oil...

Page 172: ... 5623 1 3 2 18 5053 45 5621 1 1 2 2 3 3 To Diagram 5 or 7 D RG26329 UN 18AUG14 A5502 ECU Harness Connector 2 A5502 09 5456 Blue Manifold Air Temperature Sensor Signal A5502 14 5628 Gray Sensor Return 2 A5502 15 5623 Orange 5 V Sensor Supply 2 Return A5502 17 5125 Green Engine Coolant Level Alarm Switch Signal A5502 18 5053 Orange Crankcase Pressure Sensor Signal A5502 23 5126 Blue Sensor Return 7 ...

Page 173: ...24 5 5015 4 5818 53 5015 47 5818 Y5005 Variable Speed Fan B5303 Fan Speed Sensor Y5014 Fan Solenoid A5501 ECU Harness Connector 1 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 40 41 42 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 ...

Page 174: ...ply 7 Return A5502 27 5463 Orange EGR Temperature Sensor Signal A5502 32 5023 Orange Variable Speed Fan Drive Positive A5502 33 5647 Violet Variable Speed Fan Drive Negative A5502 36 5624 Yellow 5 V Sensor Supply 7 Positive A5502 37 5468 Gray Manifold Air Pressure Sensor Signal B5103 EGR Flow Sensor B5104 Manifold Air Pressure Sensor B5207 EGR Temperature Sensor B5303 Fan Speed Sensor E To 4 5 L W...

Page 175: ...9 5 5445 6 5410 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 B5302 Camshaft Position Sensor 2 5445 1 5443 1 2 1 2 1 2 1 2 Y5024 Fuel Rail Pressure Relief Valve Y5002 Suction Control Valve 2 5767 1 5756 2 5419 1 5424 1 2 2 1 B5113 Fuel Rail Pressure Sensor 3 5613 2 5415 1 5611 2 3 1 2 1 3 B5301 Crankshaft Position Sensor 2 5447 1 5448 1 2 1 2 To Diagram 9 From Diagram 1 G A B5208 Engine Co...

Page 176: ...01 38 5447 Violet Crankshaft Position Sensor Signal A5501 40 5419 White Suction Control Valve Drive Negative A5501 42 5424 Yellow Suction Control Valve Drive Positive A5501 45 5804 Yellow Engine CAN High A5501 46 5805 Green Engine CAN Low A5501 51 5415 Green Fuel Rail Pressure Sensor Signal B 5826 Blue Sensor Return 10 From 4 5 L Wiring Diagram 1 B5208 Engine Coolant Temperature Sensor B5113 Fuel ...

Page 177: ...5 4 5443 7 5613 1 5030 3 5447 2 5448 10 5756 11 5767 9 5415 8 5611 5445 5443 5613 5030 5756 5767 30 38 5447 5448 5415 5611 9 5415 7 5613 8 5611 10 5756 11 5767 3 5447 4 5443 1 5030 2 5448 5 5445 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 B5302 Camshaft Position Sensor 2 5445 1 5443 1 2 1 2 1 2 1 2 Y5024 Fuel Rail Pressure Relief Valve 2 5767 1 5756 B5113 Fuel Rail Pressure Sensor 3 5613...

Page 178: ...8 Gray Crankshaft Position Sensor Return A5501 34 5767 Violet Fuel Rail Pressure Relief Valve Drive Negative A5501 35 5030 Black Wiring Shield A5501 37 5611 Brown 5 V Sensor Supply 1 Positive A5501 38 5447 Violet Crankshaft Position Sensor Signal A5501 51 5415 Green Fuel Rail Pressure Sensor Signal B5113 Fuel Rail Pressure Sensor B5301 Crankshaft Position Sensor B5302 Camshaft Position Sensor G To...

Page 179: ... Diagram 1 B To Diagram 9 F 1 5 2 6 3 7 4 1 2 3 4 8 5 6 7 8 Wiring Diagram For Dual Turbocharged Engines With A Low Mount Fixed Turbocharger AA RG26333 UN 21AUG14 AA Wiring Diagram For Dual Turbocharged Engines With A Low Mount Fixed Turbocharger A5501 ECU Harness Connector 1 A5501 16 5461 Brown Engine Coolant Temperature Sensor Signal A5501 40 5419 White Suction Control Valve Drive Negative A5501...

Page 180: ...Troubleshooting 70 35 032015 PN 133 ...

Page 181: ...12 1 2 3 4 5 6 1 2 E5603 DEF Dosing Unit Return Line Heater 1 2 E5601 DEF Dosing Unit Pressure Line Heater 1 2 E5602 DEF Dosing Unit Supply Line Heater 1 2 3 4 5 6 B5501 DEF Dosing Unit X5037 DEF Dosing Unit Interconnect 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 40 41...

Page 182: ...ative A5502 41 5318 Gray DEF Dosing Unit Return Line Heater Negative A5502 42 5315 Green DEF Dosing Unit Supply Line Heater Negative A5502 43 5146 Blue Sensor Return 13 A5502 46 5309 White DEF Dosing Unit Pressure Sensor Signal A5502 48 5136 Blue Sensor Return 14 A5502 49 5329 White DEF Tank Fluid Level Sensor Signal A5502 51 5324 Yellow DEF Coolant Control Valve Drive Negative A5502 52 5303 Orang...

Page 183: ... 5605 10 5030 11 5604 3 5333 4 5625 1 5602 2 5331 5 5786 6 5783 47 5634 06 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 2 5625 3 5785 1 5634 B5109 DPF Differential Pressure Sensor Engines Equipped With A DPF Only 2 5625 1 5634 4 5786 3 5783 1 5602 5 5605 6 5604 4 5636 B5204 Aftertreatment Temperature Module 1 2 3 1 3 4 2 4 1 2 3 4 5 6 B5503 Aftertreatment Outlet NOx Sensor 1 2 3 1 2 3 R56...

Page 184: ...reatment CAN Low A5502 47 5785 Green DPF Differential Pressure Sensor Signal A5502 50 5602 Red Switched Power B5109 DPF Differential Pressure Sensor Engines Equipped With A DPF Only B5204 Aftertreatment Temperature Module B5502 Aftertreatment Inlet NOx Sensor B5503 Aftertreatment Outlet NOx Sensor E 5625 Green 5 V Sensor Supply 7 Return From 4 5 L Wiring Diagram 4 F 5783 Orange 12 V Sensor Supply ...

Page 185: ...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 40 41 42 Y5017 Starter Solenoid 2 3 4 30 1 X5800 Starter Relay Coil Power X5801 Starter Relay Coil Ground K5801 Starter Relay 5422 5050 G5000 Battery 5092 5092 5002 A B 5002 5222 5022 5332 5122 5092 5002 5222 5022 5332 5122 F5004 JD Link Fuse 5082 5092 F5005 ECU Pow...

Page 186: ...F5000 Control Panel Fuse 30 A F5004 JD Link Fuse 10 A F5005 ECU Power Fuse 25 A F5006 ECU Power Fuse 25 A F5007 ECU Power Fuse 25 A F5010 Transient Voltage Protection Fuse 30 A G5000 Battery G5001 Alternator H 5002 Red Control Panel Unswitched Power To 4 5 L Wiring Diagram 11 I 5002 Red Control Panel Unswitched Power To 4 5 L Wiring Diagram 11 J 5002 Red Control Panel Unswitched Power To 4 5 L Wir...

Page 187: ...3 B 5032 A 5002 B 5032 A 5002 A B A B A X J Q E N T S O R P W K V L M U G C B H D F Q 5816 R 5981 33 03 08 P 5937 N 5648 M 5773 46 34 40 W 5473 X 5050 U 5017 T 5024 47 22 V 5815 5971 5954 5714 5012 5911 5939 5917 5941 5027 5913 5039 5816 5981 5937 5648 5773 5473 5017 5024 5815 45 31 36 20 10 25 15 39 37 06 49 41 5814 5044 5915 5439 5916 5947 5918 5616 5956 5923 5936 A H G E D F B J C A B C D E K J...

Page 188: ...pply 4 Return A5503 37 5936 Blue Cruise Resume Bump Down Switch A5503 39 5947 Violet Digital Throttle A5503 40 5773 Orange Spare Driver Positive A5503 41 5956 Blue Set Accelerator Bump Up Switch A5503 45 5815 Green AC Compressor A5503 46 5937 Violet Isochronous Governor A5503 47 5473 Orange Stop Lamp A5503 48 5714 Yellow 5 V Sensor Supply 5 Return A5503 49 5616 Blue 5 V Sensor Supply 4 Positive A5...

Page 189: ...noid Application Specific S5014 Aftertreatment Interface Switch From Diagram 11 From Diagram 10 5050 N 5002 J RG26338 UN 18AUG14 A5503 ECU Harness Connector A5503 04 5798 Gray DPF Regeneration Required Lamp A5503 05 5025 Green Exhaust Temperature High Lamp A5503 26 5029 White Starter Relay Control Negative A5503 30 5034 Yellow Starter Relay Control Positive A5503 35 5796 Blue DPF Regeneration Stat...

Page 190: ... Filter Switch P5301 Vehicle 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 Y5016 AC Solenoid 5012 5714 5039 5050 5027 5012 5954 5050 5971 5050 5939 5012 5941 5917 5911 5937...

Page 191: ...20 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 Air Filter Switch X5020 H 5039 White Vehicle Speed Input X5020 J 5939 White External Derate Switch X5020 K 5941 Brown External Shutdown Switch X5020 L 5917 Violet Cruise Cancel Resume Switch X5020 M 5773 Orange Sp...

Page 192: ...Troubleshooting 70 47 032015 PN 145 ...

Page 193: ...CAN Auxiliary Connector S5000 Key Switch X5054 Remote Start Connector A5504 Diagnostic Gauge R5608 Diagnostic Gauge CAN Terminator 120 Ohm K5812 Control Panel Start Relay R5003 Digital Throttle S5012 Speed Select Switch S5010 Shutdown Override Switch S5013 Bump Enable Switch P Z Y Mating Connector Located On Diagram 11 B A 54 923 B A 464 914 918 B A 947 414 914 B A 55 C 936 955 B A 915 C 911 914 2...

Page 194: ...S5012 Speed Select Switch S5013 Bump Enable Switch X5021 Control Panel Connector X5021 B 28 White Fused Unswitched Power X5021 C 914 White 5 V Sensor Supply 4 Return X5021 D 30 White Start X5021 E 31 White Battery Negative X5021 F 32 White Primary CAN Shield X5021 G 33 White Key Switch X5021 J 36 White Accessory X5021 L 915 White Primary Throttle X5021 M 911 White 5 V Sensor Supply 4 Positive X502...

Page 195: ...or 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 liners in the Fuels Lubricants and Coolants...

Page 196: ...xhaust Fluid DEF Use in Selective Catalytic Reduction SCR Equipped Engines in the Fuels Lubricants and Coolants Section for more information 7 Perform 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 tryi...

Page 197: ...Section See Engine Power And Speed Rating Specifications in the Specifications Section Lubrication System Crankcase Oil Fill Capacity See Engine Crankcase Oil Fill Quantities in the Specifications Section See Engine Crankcase Oil Fill Quantities in the Specifications Section Oil Pressure At Rated Speed 2400 rpm Full Load With Oil Warmed to 97 C 207 F 15W40 Oil kPa Bar psi 385 3 85 56 370 3 70 54 O...

Page 198: ...28 19 19AUG14 2 2 ITEM UNIT OF MEASURE 4045HFC09 4045HFG09 4045HFC04 4045HFG04 Maximum Air Intake Restriction kPa Bar psi 12 3 0 0 44 12 3 0 0 44 Maximum Exhaust Back Pressure kPa Bar psi 30 7 5 1 09 30 7 5 1 09 80 2 032015 PN 151 ...

Page 199: ...AVEc 7AVFc 63 84 2200 800 2400 7AVG 7AVH 63 84 2200 800 2400 Industrial Units 4045HFC09 7ASP 7AST 129 173 2400 800 2600 7ASU 7ASV 129 173 2200 800 2400 7ASWc 7ASXc 116 155 2400 800 2600 7ASY 7ASZ 116 155 2400 800 2600 7ATAc 7ATBc 116 155 2200 800 2400 7ATC 7ATD 116 155 2200 800 2400 7ATEc 7ATFc 104 140 2400 800 2600 7ATG 7ATH 104 140 2400 800 2600 7ATJc 7ATKc 104 140 2200 800 2400 7ATL 7ATM 104 14...

Page 200: ...280 425 315 540 400 7 8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640 1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960 1 1 8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350 1 1 4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920 1 3 8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500 1 1 2 990 730 ...

Page 201: ...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 202: ...t supplied by Deere Daily Prestarting Service NOTE See Daily Prestarting Checks in the Lubrication Maintenance Daily Section for detailed procedures Check engine oil level Check coolant level Drain water from fuel filters Check air cleaner dust unloader valve and air filter restriction indicator if equipped Perform visual walk around inspection 500 Hours of Operation or Every 12 Months Service Ser...

Page 203: ...ation OCV filter Hours Date Hours Date Hours Date Hours Date 3000 Hours of Operation or Every 36 Months Service Check crankshaft vibration damper Adjust valve clearance Testing glow plugs for continuity Hours Date Hours Date Hours Date Hours Date 4500 Hours of Operation or Every 36 Months Service Change DEF dosing unit filter Hours Date Hours Date Hours Date Hours Date 85 2 032015 PN 156 ...

Page 204: ...Date Service as Required Drain water from fuel filters when alarm sounds Add coolant Clean DEF tank Pre Start Cleaning Guide Service air cleaner Clean exhaust filter Replace fan alternator belt Check fuses Check electrical wiring and connectors Check air compressor if equipped See your John Deere dealer Check Refrigerant A C compressor if equipped See your John Deere dealer Hours Date Hours Date H...

Page 205: ...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 206: ...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 207: ... 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 208: ... 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 209: ...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 210: ...Warranty DX EMISSIONS EPA 19 12DEC12 2 2 TS1721 UN 15JUL13 90 6 032015 PN 163 ...

Page 211: ...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 212: ...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 213: ...Warranty Continued on next page DX EMISSIONS CARB 19 01AUG14 3 8 RG25841 UN 19MAY14 90 9 032015 PN 166 ...

Page 214: ...Warranty Continued on next page DX EMISSIONS CARB 19 01AUG14 4 8 TS1723 UN 15JUL13 90 10 032015 PN 167 ...

Page 215: ...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 216: ...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 217: ...Warranty Continued on next page DX EMISSIONS CARB 19 01AUG14 7 8 RG26035 UN 24JUN14 90 13 032015 PN 170 ...

Page 218: ...Warranty DX EMISSIONS CARB 19 01AUG14 8 8 RG26036 UN 24JUN14 90 14 032015 PN 171 ...

Page 219: ...Warranty 90 15 032015 PN 172 ...

Page 220: ...40 8 Flush 60 1 Pressure test 40 9 Refill 60 1 Page Crankshaft vibration damper Checking 50 1 D Daily prestarting checks 35 1 DEF Disposal 10 3 Dosing unit filter changing 55 1 Storing 10 1 Tank cleaning 65 3 Tank refilling 10 2 Testing 10 3 Use in SCR equipped engines 10 1 DEF dosing unit Accessing 55 1 DEF dosing unit filter Changing 55 1 DEF tank Cleaning 65 3 Diagnostic Gauge Using 15 2 Diagno...

Page 221: ...ystem overview 25 3 F Fan belt 65 8 Checking belt wear 40 7 Checking spring tension 40 8 Filter replace Oil 40 3 Filters Exhaust Ash handling and disposal 25 2 Automatic cleaning 25 7 Cleaning 25 1 65 7 Cleaning and maintenance 25 1 Disable cleaning 25 9 Page Disposal 25 2 Indicators 25 5 Manual parked cleaning 25 8 Passive regeneration natural cleaning 25 7 Service required 25 9 System overview 2...

Page 222: ... DEF tank 65 3 Cleaning the exhaust filter 65 7 Drain water from fuel filters 65 2 Inspecting primary air filter element 65 6 Pre start cleaning guide 65 4 Replacing air filter element 65 5 Replacing fan belt 65 8 Daily Prestarting checks 35 1 Service interval chart 30 2 Lubrication and maintenance records 85 1 1500 hours 85 2 3000 hours or 36 months 85 2 4500 hours or 36 months 85 2 500 hours or ...

Page 223: ...and refilling cooling system 60 1 Testing thermostat opening temperature 60 3 As required 65 1 65 2 Adding coolant 65 2 Additional service information 65 1 Air filter element storage 65 6 Bleeding fuel system 65 9 Checking air compressors 65 9 Checking electrical wiring and connections 65 9 Checking fuses 65 9 Checking refrigerant A C compressor 65 9 Cleaning DEF tank 65 3 Cleaning the exhaust fil...

Page 224: ... 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 225: ...Engine Registration IBC 2 032015 PN 178 ...

Page 226: ...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 227: ...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 032015 PN 180 ...

Page 228: ...Engine Registration IBC 5 032015 PN 181 ...

Page 229: ...Engine Registration IBC 6 032015 PN 182 ...

Page 230: ...Axial Piston Pumps and Motors Service Manual Series 90 ...

Page 231: ...f SAUER SUNDSTRAND Autho rized Service Centers is available should repairs be needed Contact any SAUER SUNDSTRAND Autho rized Service Center for details A list of all Service Centers can be found in bulletin BLN 2 400527 or in brochure SAW Ident No 698266 Fluid under High Pressure Safety Precautions Observe the following safety precautions when using and servicing hydrostatic products Flammable Cl...

Page 232: ...lacement Control HDC 13 Electric Displacement Control EDC 14 Automotive Control FBA II B 14 3 Position FNR Electric Control 14 Motor Features 15 Motor Loop Flushing Valve and Charge Relief Valve 15 Variable Motor Displacement Limiters 15 Variable Motor Controls 16 Hydraulic 2 Position Control 16 Electric 2 Position Control 16 Technical Specifications 17 General Specifications 17 Circuit Diagrams 1...

Page 233: ...harge Relief Valve 57 Charge Pump Remove 58 Installing the Charge Pump 60 Auxiliary Pad Installation 62 Auxiliary Pad Conversion 63 Filtration Options 64 Pump controls 65 Cover Plate 65 Manual Displacement Control MDC 66 Solenoid Override Valve for MDC 67 Solenoid Override Valve for MDC with Pressure Released Brake 67 Hydraulic and Electric Displacement Controls 68 Pressure Control Pilot PCP for E...

Page 234: ...c fluid The high pressure fluid 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 displacement of fluid in a given revolution of the input shaft Fixed Displacement Motor The Fixed Displacement Motor MF is designed to convert an input of hydraulic power into an output torque It operates in the r...

Page 235: ...rates in the same manner as the fixed motor However its swashplate is not fixed it can be switched between minimum and maximum angle to amplify torque or speed like the Variable Displacement Pump Piston Roller Bearing Output Shaft Valve Plate Loop Flushing Valve Cylinder Block Fixed Swashplate End Cap A A Electric 2 Position Control optional Piston Roller Bearing Valve Plate Cradle Swashplate Outp...

Page 236: ...in can then be connected to the lower drain port on the pump housing and out the top most port A heat exchanger with a bypass valve is required to cool the case drain fluid before it returns to the reservoir Circuit Diagram for Series 90 PV and 90 MF 90000800E The System Circuit Control Handle Displacement Control Valve Orificed Check Valve Heat Exchanger Bypass Valve Heat Exchanger Reservoir Vacu...

Page 237: ...ce of the end 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 Speed Sensor 90000810 Speed Sensors An optional speed sensor can be installed on Series 90 pumps and motors to ...

Page 238: ...e pump serves to maintain charge pressure at a designated level A direct acting poppet valve relieves charge pressure whenever it sur passes a certain level This level is nominally set refer encing case pressure at 1500 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...

Page 239: ...imiter function may be de feated so that only the high pressure relief valve function remains System Check Valves The system check valves allow pressurized flow from the charge pump to enter the low pressure side of the loop whenever system pressure dips below a certain level This is needed as the pump will generally lose system pressure due to leakage and other factors Since the pump can operate ...

Page 240: ...ilable with provisions for either suction or charge pressure filtration integral or remote mounted to filter the fluid entering the charge circuit 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 devices of this type are pr...

Page 241: ...th the pump displacement control Control supply pressure is nor mally 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 pressure supplied to the displacement control As the control pressure reduces the interna...

Page 242: ...mover can be started only when the control is in a neutral position Hydraulic Displacement Control HDC The hydraulic displacement control uses a hydraulic input signal to operate a spring centered four way servo valve This valve ports hydraulic pressure to either side of a dual acting servo piston The servo piston rotates the cradle swashplate through an angular rotation of 17 thus varying the pum...

Page 243: ...ump s displacement from full displacement in one direction to full displacement in the opposite direction The control is designed so the angular position of the swashplate is proportional to the EDC input Automotive Control FBA II B Automotive Control allows a vehicle to be driven in a manner similar to an automobile with an automatic trans mission The Automotive Control includes a three position ...

Page 244: ...charge pres sure level only when there is a pressure differential in the main loop The shuttle valve is spring centered to the closed position so that no high pressure fluid is lost from the circuit when reversing pressures For charge relief valve adjustment see corresponding Section Variable Motor Displacement Limiters All Series 90 variable motors include mechanical dis placement stroke limiters...

Page 245: ...ment Supplying pilot hydraulic pressure to the valve will cause the motor to go to its minimum displacement 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 to i...

Page 246: ...hplate design Type of Mounting per SAE J744 SAE flange Size B 2 bolts SAE flange Size C and E 4 bolts Cartridge flange 2 bolts for motor only Port Connections for details see chapter Pressure Measurement Main pressure ports SAE flange Code 62 Remaining ports SAE straight thread O ring boss Direction of Rotation Clockwise or counterclockwise motors are bi directional Recommended Installation Positi...

Page 247: ... d e d n e m m o c e R e g n a r g n i t a r e p o 0 6 2 1 8 7 2 0 7 m u m i x a M 0 0 6 1 0 0 5 7 t n e t t i m r e t n i t r a t s d l o c E 0 1 0 2 0 0 T m u u c a V t e l n I p m u P e g r a h C y l n o s p m u p n o s b a r a b g H n i m u u c a V m u m i n i M s u o u n i t n o c 7 0 0 1 g n i r u d m u u c a V m u m i n i M t r a t S d l o C t n e t t i m r e t n I 2 0 5 2 E 3 5 2 2 0 0 T e...

Page 248: ... 5 5 0 V M 5 7 0 m u m i x a m t n e m e c a l p s i D m c 3 n i 3 0 3 3 8 1 2 4 6 5 2 5 5 5 3 3 5 7 7 5 4 0 0 1 0 1 6 0 3 1 3 9 7 5 5 5 3 3 5 7 7 5 4 m u m i n i m t n e m e c a l p s i D m c 3 n i 3 9 1 6 2 d e t a R d e e p s m u m i x a m t a t n e m e c a l p s i d n i m 1 m p r 0 0 2 4 0 0 2 4 0 0 9 3 0 0 6 3 0 0 3 3 0 0 1 3 0 0 9 3 0 0 6 3 m u m i n i m t a t n e m e c a l p s i d n i m 1 m...

Page 249: ...t i f g n i r O 8 1 6 1 9 3 M 6 M e r u s s e r P e g r a h C i s p 0 0 0 1 r o r a b 0 5 g n i r O 8 1 6 1 9 4 M 5 M e r u s s e r P o v r e S i s p 0 0 0 1 r o r a b 0 5 g n i r O 8 1 6 1 9 E 9 5 2 2 0 0 T Outline drawings showing port locations follow the tables below t r o P n o i t c n u F e z i S e g u a G d n a g n i t t i F 1 L 2 L e r u s s e r P e s a C i s p 0 0 1 r o r a b 0 1 0 3 0 2 ...

Page 250: ...Displacement Cylinder Pressure Gauge Port M4 Case Drain Port L1 Top View System Pressure Port B System Pressure Gauge Port M2 System Pressure Gauge Port M1 System Pressure Port A Case Drain Port L2 Left Side View System Pressure Port B Carge Pump Inlet Port S Charge Inlet Pressure External Control Pressure Supply Port X3 Charge Pressure Gauge Port M3 Right Side View Speed Sensor ...

Page 251: ... Port M2 System Pressure Gauge Port M1 Case Drain 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 Servo Displacement Cylinder Pressure Gauge Port M4 Case Drain Port L1 Top View Charge Pressure Gauge Port M3 after the filter Port E from filter Port D to filter Rear View Charge Pressure Gauge Port M3 aft...

Page 252: ...e Gauge Port M2 Fixed Motor MF with SAE Flange 90000821E MF with Cartridge Flange t r o P n o i t c n u F e z i S e g u a G d n a g n i t t i F 1 M e r u s s e r P m e t s y S A t r o P i s p 0 0 0 0 1 r o r a b 0 0 0 1 g n i r O 8 1 6 1 9 2 M e r u s s e r P m e t s y S B t r o P i s p 0 0 0 0 1 r o r a b 0 0 0 1 g n i r O 8 1 6 1 9 3 M e r u s s e r P e g r a h C i s p 0 0 0 1 r o r a b 0 5 g n ...

Page 253: ...ontrol SAE Flange Version Similar 90000823E t r o P n o i t c n u F e z i S e g u a G d n a g n i t t i F 4 M r e d b n i l y C l o r t n o C m u m i n i M e r u s s e r P t n e m e c a l p s i D i s p 0 0 0 0 1 r o r a b 0 0 0 1 g n i r O 0 2 6 1 7 5 M r e d b n i l y C l o r t n o C m u m i x a M e r u s s e r P t n e m e c a l p s i D i s p 0 0 0 0 1 r o r a b 0 0 0 1 g n i r O 0 2 6 1 7 1 L 2 ...

Page 254: ...ic lines for HDC or electrical Jog or slowly rotate prime mover until charge pressure starts to rise Start the prime mover and run at the lowest possible RPM until charge pressure has been estab lished Excess air may be bled from the high pressure lines through the high pressure system gauge port Once charge pressure has been established increase speed to normal operating RPM Charge pressure shoul...

Page 255: ...ility This should be done at latest half way between fluid changes It may be necessary to change the fluid more frequently than the above intervals if the fluid becomes contami nated with foreign matter dirt water grease etc or if the fluid has been subjected to temperature levels greater than the recommended maximum Never reuse fluid The filter should be changed whenever the fluid is changed or w...

Page 256: ...sufficiently cooling the system Low charge pressure will overwork sys tem High inlet vacuum will overwork sys tem A dirty filter will increase the inlet vacuum Inadequate line size will re strict flow If the system relief settings are too low the relief valves will be overworked Leakage will reduce low side system pressure and overwork the system High system pressure will overheat system Fill rese...

Page 257: ...harge pressure with pump in stroke 7 Pump charge relief valve 8 Charge pump inlet filter 9 Charge pump Insufficient hydraulic fluid to supply system loop Input to control module is operating improperly Control linkages are not secure control orifices are blocked etc If bypass valve s is open the system loop will be depressurized Low charge pressure insufficient to re charge system loop Low charge ...

Page 258: ...ontrol is not functioning correctly variable motor swashplate may be in wrong position Internal leakage will reduce system pressure Fill oil to proper level Measure pump output and check for proper pump speed and see that the pump is in full stroke See if variable motor displacement con trol is responding If not repair or re place control Check for leakage in O rings gaskets and other fittings Rep...

Page 259: ...and other fittings Excessive Noise and or Vibration Check Description Action 1 Oil in reservoir 2 Air in system 3 Pump inlet vacuum 4 Shaft couplings 5 Shaft alignment Insufficient hydraulic fluid will lead to cavitation Air bubbles will lead to cavitation High inlet vacuum will create noise A dirty filter will increase the inlet vacuum A loose shaft coupling will cause exces sive noise Unaligned ...

Page 260: ...re in order to prevent injury to the technician and bystanders Take necessary safety precautions before moving the vehicle machine S000007E 1 To measure pump charge pressure install a pres sure gauge in the pump charge pressure 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 neutral zero displace ment when me...

Page 261: ... Nm 50 lbf ft Later production Series 90 pumps are equipped with an external screw adjustable charge pressure relief valve Adjustment of the charge pressure is accom plished by loosening the lock nut e z i S e m a r F e z i S h c n e r W 0 0 1 0 3 0 h c n i 6 1 1 1 0 5 2 0 3 1 h c n i 8 5 1 E 7 6 2 2 0 0 T and turning the adjustment plug with a large screw driver or a 1 2 inch hex wrench Clockwise...

Page 262: ...i pressure gauge in the pump charge pressure gauge port M3 2 Start the prime mover and operate at normal speed 3 Loosen locking nut e z i S e m a r F e z i S h c n e r W y l r a e 0 0 1 2 4 0 m m 0 1 r e w e n 0 0 1 0 3 0 m m 9 1 0 3 1 y l r a e m m 3 1 0 5 2 0 3 1 m m 4 2 E 8 6 2 2 0 0 T 4 Insert a internal hex wrench into the pressure adjust ing screw e z i S e m a r F e z i S h c n e r W x e H ...

Page 263: ...e pressure as shown in the following table e z i S e m a r F e h t f o v e R r e p 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 y l r a e 0 0 1 2 4 0 v e R r e p i s p 7 5 1 1 r a b 0 8 r e w e n 0 0 1 0 3 0 r a b 0 9 v e R r e p i s p 0 0 3 1 0 5 2 0 3 1 r a b 0 8 v e R r e p i s p 7 5 1 1 E 0 7 2 2 0 0 T 7 To verify the actual pressure setting actuate or move the control input so that the...

Page 264: ...8 5 1 E 3 7 2 2 0 0 T wrench on the large hex to prevent rotation of the cartridge assembly rotate the middle hex three revolutions counterclockwise to open the bypass valve Do not rotate more than 3 1 2 revolutions as additional rotation will permit external leak age 2 For units with an MDC type control prior to moving the vehicle or otherwise causing the motor shaft to turn move the control hand...

Page 265: ...p operating at approximately 20 dis placement load the work function and note the pressure as the POR valve operates pump displace ment reduces to zero 4 Adjustment of the pressure override setting is made by loosening the lock nut with a 9 16 inch hex wrench and turning the adjustment screw with a 3 16 inch internal hex wrench The POR setting should be at least 50 bar 750 psi below the high press...

Page 266: ... setting tighten the lock nut on the adjusting screw as follows e z i S e m a r F e u q r o T 0 0 1 0 3 0 t f f b l 8 1 m N 4 2 0 3 1 m N 8 4 t f f b l 5 3 0 5 2 0 8 1 t f f b l 2 9 m N 5 2 1 E 8 7 2 2 0 0 T 4 One turn of the adjusting screw will change the maximum displacement approximately as follows e z i S e m a r F f o v e R 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 ...

Page 267: ...ment Control MDC Adjustment There are no adjustable elements in the manual dis placement 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 automatically assume the appro priate position when the control is installed on the pump ...

Page 268: ... prime mover and operate at normal speed 2 Loosen the lock nut on the neutral adjusting screw with a 13 mm hex wrench 3 Using a 4 mm internal hex wrench rotate the neutral adjustingscrewclockwiseuntilthepressureincreases on one of the pressure gauges Note the angular position of the wrench 4 Rotate the adjusting screw counterclockwise until the pressure increases by an equal amount on the other ga...

Page 269: ...NOT in its neutral position the eccentric cam moves the switch pin out of the slot This forces the NSS to open breaking the electrical starting circuit for the prime mover The neutral start switch is threaded into the special lock nut for the eccentric plug Turning the NSS clockwise CW into the special nut will move the NSS closer to the switch cam on the control shaft and will narrow the NSS dead...

Page 270: ...eadband cannot be adjusted the position of the NSS deadband must be adjusted to match it ii The NSS deadband must be wide enough so the NSS will not open within the loose area of control handle movement caused 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 alw...

Page 271: ... turn 90 after continuity has been obtained 5 Hold the switch in place and tighten the locknut to 27 Nm 20 lbf ft torque 6 With the continuity checker attached to the switch 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 7 If continuity is obtained in neutral and satisfactorily interrupted in each dire...

Page 272: ...ing drawing provides dimensions for an Eccentric Plug Adjustment Tool 1 Hold the switch and eccentric plug from turning and use two 1 1 8 inch wrenches to loosen the locknut Remove the neutral start switch 2 Note the slots on the eccentric plug for the adjust ment tool Hold the eccentric plug in place with the adjustment tool and loosen the lock nut with a 1 1 8 inch wrench continued WARNING Do no...

Page 273: ...ft an equal amount in either direction from neutral The switch pin should move out of the eccentric plug an equal distance when the control shaft is turned Turn the eccentric plug to center the switch pin with the cam slot Only a small amount of adjustment in either direction should be needed to center the pin 6 While holding the eccentric plug in place tighten the eccentric plug lock nut to 27 Nm...

Page 274: ...ction while observing the pressure gauges and the continuity checker Continuity must be broken before the pres sure on either gauge increases more than 1 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 thegaugepressureincreasesmorethan1 bar 12 psi from base pressure 6 Continuity must again be ve...

Page 275: ... a neutral adjusting shaft earlier production EDCs or a neutral adjusting screw HDCs and current production EDCs WARNING The following procedure may require the vehicle machinetobedisabled wheelsraisedofftheground work function disconnected etc while performing the procedure in order to prevent injury to the technician and bystanders Take necessary safety precautions before moving the vehicle mach...

Page 276: ... of the wrench Then rotate the neutral adjusting shaft or screw counterclockwise until the pressure increases by an equal amount on the other gauge Again note the angular position of the wrench 4 Rotate the neutral shaft or 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 neutr...

Page 277: ...n Series 90 motors are equipped with a shim adjustable charge relief valve Shim kits are available as service items Adjustment of the charge pressure is accomplished by removing the 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 lbf ft Later production Series 90 motors are equipped with an external screw a...

Page 278: ...ettings do not require adjusting Caution The displacement limiters act as travel stops for the swashplate Do not turn the limiter screws counterclockwise beyond the point of contact with the swashplate for either the maximum or minimum displacement position S000015E Caution Care should be taken in adjusting displacement limiters to avoid undesirable flow or speed conditions See corresponding secti...

Page 279: ...speed ring 3 Turn the sensor counterclockwise CCW 1 2 turn 180 to establish the nominal gap of 0 71 mm 0 028 inch 4 Then turn the sensor clockwise CW until the wrench flats on sensor body are positioned at a 22 angle to the pump shaft center line Note Many adjustable wrenches have a 22 handle offset 5 The final sensor position should be between 1 2 180 and1 4 turn 90 counterclockwise CCW from the ...

Page 280: ...ghtly 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 warranty 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 satisfactory transmission life on either new or repaired units...

Page 281: ...Right Side View Main Shaft Speed Sensor Left Side View Shaft Seal Charge Pressure Relief Valve Loop Flushing Valve Left Side View Shaft Seal Charge Pressure Relief Valve Loop Flushing Valve Speed Sensor Left Side View Charge Pressure Relief Valve Shaft Seal Maximum Angle Displacement Limiter Control Loop Flushing Valve Control Orifices Minimum Angle Displacement Limiter Left Side View Shaft Seal C...

Page 282: ...W x e H h c n i 8 7 m N 8 6 t f f b l 0 5 g n i r O 6 1 4 3 h c n e r W x e H l a n r e t n I h c n i 6 1 5 m N 8 6 t f f b l 0 5 g n i r O 4 1 8 7 h c n e r W x e H h c n i 1 m N 5 9 t f f b l 0 7 g n i r O 4 1 8 7 h c n e r W x e H l a n r e t n I h 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 ...

Page 283: ...ugh 100 units or a 6 mm internal hex wrench 130 through 250 units Remove the retainer plate Note Certain earlier production units use a one piece retainer plate and seal carrier 3 After removing the screws the spring force on the 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 b...

Page 284: ... seal with 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 like the tables Pumps e z i S e m a r F s p m u P e u q r o T 2 4 0 0 3 0 m N 2 1 t f f b l 9 0 0 1 5 5 0 m N 6 1 t f f b l 2 1 0 5 2 0 3 1 t f f b l 4 2 m N 2 3 E 2 8 2 2 0 0 T Motors e z i S e m a r F s r o t o M e u q...

Page 285: ...mbly is held by a retaining ring Remove retaining ring with a snap ring pliers On late versions the valve seat section is pressed over a lip Place the cartridge in a vise and pry the lower section off with an appropriate tool Maintain 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 f...

Page 286: ...0 5 2 0 3 1 h c n i 8 5 1 E 6 8 2 2 0 0 T Unscrew the plug with a large screwdriver or 1 2 inch hex wrench 2 Remove the spring and relief valve poppet 3 Inspect the poppet and mating seat in the end cap 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 insta...

Page 287: ...Assembly Inlet Discharge Left Hand Rotation Outside looking into pump Alignment Pin Caution Do not allow the force of the cylinder block spring and swashplate leveler springs to separate the end cap from the pump housing Gasket damage and external leakage may result S000019E 2 Remove the six screws holding the charge pump cover retainer e z i S e m a r F e z i S h c n e r W 0 0 1 0 3 0 m m 0 1 0 5...

Page 288: ...iner Cover O ring Retainer Screw Shaft Key Standard End Cap Screw Charge Pump Assembly Alignment Pin Port Plate Gerotor Assembly Eccentric Ring No Charge Pump Components Cover Journal Bearing O ring Shaft Spacer Plug Standard End Cap Screw Cover Retainer Retainer Screw Note If a different displacement charge pump is be ing installed the gerotor assembly gerotor outer eccentric ring and inner port ...

Page 289: ...production periods Always install as a com plete assembly 1 Install the inner port plate and the gerotor assembly outer ring 2 Install the alignment pin to properly orient the port plates and outer eccentric ring for corresponding pump rotation 3 Prior to installation apply a small quantity of petro leum jelly to the I D O D and side faces of the gerotor assembly to provide initial lubrication 4 I...

Page 290: ...ps with an auxiliary mounting pad install the auxiliary drive coupling 10 Install a new O ring onto the non auxiliary pad charge pump cover If an auxiliary pad is installed an 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 correct orienta tion and retain with petroleum jelly...

Page 291: ...1 5 7 0 m m 4 2 0 3 1 0 0 1 m m 4 1 0 5 2 0 8 1 m m 7 1 E 9 8 2 2 0 0 T Note At earlier production frame size 75 pumps with twin ports secure the end cap to the pump housing with a clamp to avoid gasket damage Remove Screws and Retainer Remove Charge Pump Cover Pad Cover Special Washer Cover Retainer Retainer Screw Screw O ring auxiliary Pad Typical O ring Cover Assembly Journal Bearing Auxiliary ...

Page 292: ...2 2 1 5 5 0 t f f b l 0 9 m N 2 2 1 0 0 1 5 7 0 t f f b l 9 8 1 m N 6 5 2 0 3 1 0 0 1 t f f b l 0 2 2 m N 8 9 2 0 5 2 0 8 1 t f f b l 9 2 4 m N 0 8 5 E 0 9 2 2 0 0 T 11 Install the O ring and flange cover or auxiliary pump Auxiliary Pad Conversion To convert an auxiliary mounting pad to a different size mounting pad use the above procedure with the following additions After removing the charge pum...

Page 293: ... of these two filtration devices as follows 1 Remove the reducer fitting located at charge pres sure gauge port from pump end cap this part will not be used 2 Install the filter manifold or filter head into the port The hydraulic tube should enter its mating bore in the pump end cap with a low force 3 After rotating the filter manifold or filter head clock wise so that the threads engage with the ...

Page 294: ...Remove the cover plate and gasket from housing 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 lbf ft Caution Protectexposedsurfacesandcavitiesfromdamage and foreign material S000022E NOTE Asealingwashermustbeinstalledundertheheadof any mounting screws that are installed into ...

Page 295: ...he housing Inspect to assure that the control orifice check valve and spring are in their proper position in the control 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 ...

Page 296: ...e the screws to 13 5 Nm 10 lbf ft Solenoid Override Valve for MDC with Pressure Released Brake 1 Thoroughly clean external surfaces prior to removal of valve 2 Using a 4 mm internal hex wrench remove the four solenoid valve mounting screws Remove the sole noid valve with O rings from the adapter plate 3 Using a 4 mm internal hex wrench remove the four adapter plate mounting screws Remove the adapt...

Page 297: ...al surfaces prior to removal of control 2 Using a 5 mm internal hex wrench remove the eight control mounting screws Remove the control with orifice check valve and spring and control gasket from housing Caution A sealing washer must be installed under the head of any mounting screws that are installed into thru holes in the housing S000 023E 3 In preparation for installing the control place a new ...

Page 298: ...ump housing face surface Remove the orifice plugs with a 4 mm internal hex wrench Note the location of each plug do not interchange plugs Torque the orifice plugs to 3 Nm 26 lbf in 3 Assemble the control onto the pump Refer to the instructions for the specific control NOTE Asealingwashermustbeinstalledundertheheadof any mounting screws that are installed into thru holes in the housing S000023E Cau...

Page 299: ...etainer to hold the orifice check valve in position 4 Assemble the control onto the pump Refer to the instructions for the specific control Displacement Control Adapter Plate Early produc tion 130 Pumps only The screws fastening the control adapter plate to the housing have retaining compound on the threads They are removed with a 6 mm internal hex wrench When installing the adapter plate ensure t...

Page 300: ...ulder washers with shoulders facing out and springs on each end of the spool Install the hex plugs with O rings and torque to 41 Nm 30 lbf ft on 030 through 100 motors or 68 Nm 50 lbf ft on 130 motors 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...

Page 301: ... ring defeat 4 Install the poppet and spring For shim adjustable valves install the plug and torque to 68 Nm 50 lbf ft For screw adjustable valves install the plug with its lock nut aligning the marks made at disassembly and torque the lock nut to 52 Nm 38 lbf ft 5 Check and adjust the charge pressure Defeating the Loop Flushing Valve 1 Remove loop flushing valve components these parts will not be...

Page 302: ...ounterclockwise beyond their initial adjustment positions One full turn of the displacement limiter adjustment screw will change the displacement as follows e z i S e m a r F f o v e R 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 5 5 0 m c 6 5 3 n i 4 3 0 v e R 3 v e R 5 7 0 m c 1 7 3 n i 3 4 0 v e R 3 v e R E 5 9 2 2 0 0 T 4 Following the final adjustment install new tamp...

Page 303: ...ve 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 lbf in Do not overtorque the nut 10 If previously removed reinstall the orifice check valve Reconnect the external signal connection Hydraulic 2 Position Control Type PT Follow the steps above except that in step 2 a hydraulic signal line will be disconnected and steps 3 ...

Page 304: ... orifice next section S000027E Variable Motor Control Orifices Control Supply Orifice 1 Remove the control supply orifice from the motor housing with an 1 1 16 inch hex wrench 2 Remove the O rings and the backup 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 Instal...

Page 305: ...e to 15 Nm 11 lbf ft 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 lbf ft 3 If no orifice check valve is installed the housing plug may be removed with a 9 16 inch hex wrench Always install a new O ring Reinstall the plug and torque to 20 Nm 15 lbf ft Orifice Check Valve Assembly ...

Page 306: ...ng Adjust the gap between the sensor and the magnetic speed ring as instructed in Section Speed Sensor Adjustment and torque the sensor lock nut 4 If a speed sensor is not installed the housing plug should be torqued as indicated in the accompanying figure 1 1 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 1 1 16 i...

Page 307: ...P06 G542 G546 P13 K018 bis K042 OR BOTH SIDES K90 K10 K50 G502 G506 B70 G172 G176 K70 K80 B70 B80 B80 G63 G64 G64 CODE 61 OPTION G63 CODE 61 OPTION B90 G522 G526 P30 G502 G506 B71 B90 B82 L70 L70 L60 L40 L50 L40 L35 Early Production 075 Frame Size L30 G501 G508 G521 G528 G63 G64 G63 CODE 61 OPTION G501 G508 G511 G518 G541 G548 G531 G538 K018 THRU K042 G501 G508 G64 CODE 61 OPTION B83 B83 OR ...

Page 308: ...g 3 G511 Plug 1 G512 Plug 1 G516 O ring 1 G518 O ring 1 G521 Plug 1 G522 Plug 1 G526 O ring 1 G528 O ring 1 G531 Plug 1 Item Description Qty Item Description Qty G532 Plug 1 G536 O ring 1 G538 O ring 1 G541 Plug 1 G542 Plug 1 G546 O ring 1 G548 O ring 1 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 Retaine...

Page 309: ...H M0HJ M0HK M0HL M0HM M0HN M90H M11H M880 M1HA M1HC M1HF M1HG M1HH M1HJ M1HK M1HL M1HM M1HN M880 M830 M840 M87M M74M T001 THRU T009 T022 T050 M75M M810 M840 REF M840 REF M820 M860 M870 M850 M92M M98M S40 M0MA M0ME M0MB M0MF M0MC M0MG M0MD M0M9 M90M M7MA M7MB M7MC M7MD M7ME M7MF M7MG M72M M71M M78M M77M M76M T301 THRU T309 T322 T350 T401 THRU T409 T422 T450 M97M M96M M9ME M11M T201 THRU T209 T222 T...

Page 310: ... neutral start switch 1 M7M Control handle 1 M71M Washer 1 M72M Nut 1 M80 Control gasket 1 M87M Washer seal 042 1 M90M Screw 6 M0MB Control MDC w neutral start switch 1 M7M Control handle 1 Item Description Qty Item Description Qty M71M Washer 1 M72M Nut 1 M80 Control gasket 1 M87M Washer seal 042 1 M90M Screw 6 S40 Neutral start switch kit 1 M0MC Control MDC w sol valve 1 M7M Control handle 1 M71...

Page 311: ... J40N H30 OR OR H40 H50 H60 H50 H50L J80N OR J92_ J10_ J70_ H80 H70 J95_ J90_ J60_ J50_ J15_ J30 J00_ 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 90000863E 90000862E ...

Page 312: ...4 J80N Screw 4 J90A V O ring 1 J92A V Cover plate 1 J95A V Screw 2 4 N00M Filtration manifold kit Int 1 N10M Manifold 1 N15M O ring 2 N20M Nut 1 N25M Tube 1 N35M Plug 2 N40L Filter 1 N40P Filter 1 N00R Filtration manifold kit Rmt 1 N10R Manifold 1 N15R O ring 1 N20R Nut 1 N25R Tube 1 N30R Plastic plug 2 N35R Plug 1 N00S Filtration kit Suction Flt 1 N10S Reducer fitting Suction Flt 1 N35S Plug 1 It...

Page 313: ...s G64 CODE 61 OPTION G64 G63 G63 CODE 61 OPTION G50 H20W H50W H40W H30W H10W H10N H50N G70 H50W H40W H20W H30W H50N G50 H60N H66W H64W H62W H60W H68W B80 B80 L70 L70 L60 L40 L50 L40 L35 Early Production 075 Frame Size L30 OR G63 CODE 61 OPTION G64 CODE 61 OPTION G64 G63 B83 B83 B80 B80 B83 B83 ...

Page 314: ...acture Name Plate German Production Name Plate U S A Production saue saue Model Number Serial Number Parts List Item Description Qty B80 Plug 2 B83 Plug 1 B83 Speed sensor 1 G50 Plug 2 G70 Plug 1 G63 Split flange screw 4 G64 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 Plug 2 H60W Charge relief ...

Page 315: ...66W H50W T100 T101 B74 T40 T50 T50 T60 B76 T30 P400 P401 P402 P403 E35 E26 E15 B80 L70 L70 L60 L40 L50 L40 L35 Early Production 075 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 Variable Motor Minor Repair Parts 90000865E ...

Page 316: ...l 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 PCOR Valve 1 P700 Special plug 1 P800 O ring 1 T30 Filter screen 1 T40 O ring 1 T50 Backup ring 2 T60 O ring 1 T100 Orifice plug 1 Y40 O ring 1 Y50 Backup ring 2 Y60 O ring 1 Y70 Orifice check valve 1 Y71 Nut Seal Lock 1 Y72 O...

Page 317: ...ostfach 2460 D 24531 Neumünster Krokamp 35 D 24539 Neumünster Germany Phone 04321 871 0 Fax 04321 871 122 SAUER DANFOSS is a world leader in the design and manufacture of Hydraulic Power Systems Research and development resources in both North America and Europe enable SAUER SUNDSTRAND to offer a wide range of design solutions utilizing hydraulic power system technology Heavy Duty Bent Axis Variab...

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Page 331: ...300 A T E X INCLUDED MOBILE EQUIPMENT AND WIND ENERGY SOLUTIONS INDUSTRY PROCESS AND AUTOMATION SOLUTIONS Installation use and service manual ...

Page 332: ......

Page 333: ...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 334: ...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 335: ... 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 336: ...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 337: ...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 338: ...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 339: ...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 340: ...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 341: ...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 342: ...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 343: ...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 344: ... 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 345: ...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 346: ...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 347: ...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 348: ...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 349: ...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 350: ... 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 351: ...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 352: ...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 353: ... 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 354: ...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 355: ...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 356: ...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 357: ... 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 358: ...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 359: ...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 360: ...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 361: ...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 362: ... 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 363: ...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 364: ... 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 365: ...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 366: ...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 367: ... 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 368: ...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 369: ...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 370: ...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 371: ......

Page 372: ...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 373: ...www dexteraxle com OPERATION MAINTENANCE SERVICE MANUAL 600 8 000 lb Axles Related Components ...

Page 374: ...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 375: ...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 376: ...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 377: ... 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 378: ...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 379: ...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 380: ...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 381: ...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 382: ...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 383: ...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 384: ... 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 385: ...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 386: ...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 387: ...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 388: ... 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 389: ... 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 390: ... 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 391: ...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 392: ...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 393: ...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 394: ...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 395: ...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 396: ...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 397: ...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 398: ...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 399: ...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 400: ...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 401: ...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 402: ... 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 403: ...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 404: ...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 405: ...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 406: ...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 407: ...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 408: ...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 409: ... 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 410: ...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 411: ...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 412: ... 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 413: ...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 414: ... 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 415: ...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 416: ...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 417: ...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 418: ...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 419: ...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 420: ...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 421: ...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 422: ...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 423: ...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 424: ...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 425: ...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 426: ... 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 427: ...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 428: ...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 429: ...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 430: ...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 431: ...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 432: ...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 433: ...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 434: ...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 435: ...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 436: ...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 437: ... 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 438: ... 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 439: ...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 440: ...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 441: ... 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 442: ...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 443: ... 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 444: ...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 445: ...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 446: ... 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 447: ...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 448: ...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 449: ... 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 450: ...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 451: ...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 452: ... 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 453: ...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 454: ...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 455: ...Service Record Date Service Performed Mileage ...

Page 456: ...Service Record Date Service Performed Mileage ...

Page 457: ...Service Record Date Service Performed Mileage ...

Page 458: ... 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 459: ...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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