TECHNICAL MANUAL M–GATOR Utility Vehicle

™
M–GATOR
Utility Vehicle
TECHNICAL
MANUAL
John Deere
Worldwide Commercial and
Consumer Equipment Division
TM1804 (9Feb00)
Litho in U.S.A
INTRODUCTION
This technical manual is written for an experienced
technician and contains sections that are specifically
for this product. It is a part of a total product support
program.
Safety
Specifications and
Information
The manual is organized so that all the information on
a particular system is kept together. The order of
grouping is as follows:
•
•
•
•
•
•
•
•
•
Note:
Table of Contents
Specifications
Component Location
System Schematic
Theory of Operation
Troubleshooting Chart
Diagnostics
Tests & Adjustments
Repair
Depending on the particular section or system
being covered, not all of the above groups may
be used.
Each section will be identified with a symbol rather than
a number. The groups and pages within a section will
be consecutively numbered.
We appreciate your input on this manual. To help, there
are postage paid post cards included at the back. If you
find any errors or want to comment on the layout of the
manual please fill out one of the cards and mail it back
to us.
All information, illustrations and
specifications in this manual are based on
the latest information available at the time of
publication. The right is reserved to make
changes at any time without notice.
Engine
Electrical
Power Train
Steering
Brakes
Miscellaneous
COPYRIGHT© 2000
Deere & Co.
John Deere Worldwide Commercial and
Consumer Equipment Division
Horicon, WI
All rights reserved
2/9/00
1-1
SAFETY
RECOGNIZE SAFETY INFORMATION
HANDLE FLUIDS SAFELY-AVOID
FIRES
Be Prepared For Emergencies
This is the 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 servicing
practices.
Understand Signal Words
A signal word—DANGER, WARNING, or CAUTION—
is used with the safety-alert symbol. DANGER
identifies the most serious hazards.
DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention
to safety messages in this manual.
REPLACE SAFETY SIGNS
When you work around fuel, do not smoke or work near
heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and
debris.
Do not store oily rags; they can ignite and burn
spontaneously.
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your
telephone.
Replace missing or damaged safety signs. See the
machine operator’s manual for correct safety sign
placement.
1-2
2/9/00
SAFETY
USE CARE IN HANDLING AND
SERVICING BATTERIES
USE CARE AROUND HIGHPRESSURE FLUID LINES
Avoid High-pressure Fluids
Prevent Battery Explosions
• Keep sparks, lighted matches, and open flame
away from the top of battery. Battery gas can
explode.
• Never check battery charge by placing a metal
object across the posts. Use a volt-meter or
hydrometer.
• Do not charge a frozen battery; it may explode.
Warm battery to 16°C (60°F).
Prevent Acid Burns
• Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, eat holes in clothing,
and cause blindness if splashed into eyes.
• Avoid acid burns by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
Escaping fluid under pressure can penetrate the skin
causing serious injury.
Avoid injury from escaping fluid under pressure by
stopping the engine and relieving pressure in the
system before disconnecting or connecting hydraulic or
other lines. Tighten all connections before applying
pressure.
Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any
fluid injected into the skin must be surgically removed
within a few hours or gangrene may result. Doctors
unfamiliar with this type of injury should reference a
knowledgeable medical source. Such information is
available from Deere & Company Medical Department
in Moline, Illinois, U.S.A.
Avoid Heating Near Pressurized
Fluid Lines
• If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the
acid.
3. Flush your eyes with water for 10 – 15 minutes.
4. Get medical attention immediately.
• If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.
2/9/00
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines
or other flammable materials. Pressurized lines can be
accidentally cut when heat goes beyond the immediate
flame area.
1-3
SAFETY
USE SAFE SERVICE PROCEDURES
Park Machine Safely
Wear Protective Clothing
Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause
impairment or loss of hearing. Wear a suitable hearing
protective device such as earmuffs or earplugs to
protect against objectionable or uncomfortable loud
noises.
Operating equipment safely requires the full attention
of the operator. Do not wear radio or music
headphones while operating machine.
Before working on the machine:
1. Lower all equipment to the ground.
2. Stop the engine and remove the key.
3. Disconnect the battery ground strap.
4. Hang a “DO NOT OPERATE” tag in operator
station.
Support Machine Properly And Use
Proper Lifting Equipment
Service Machines Safely
Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to
get caught, severe injury could result.
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
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 and tightening hardware, use the correct size
tools. DO NOT use U.S. measurement tools on metric
fasteners. Avoid bodily injury caused by slipping
wrenches. Use only service parts meeting John Deere
specifications.
1-4
If you must work on a lifted machine or attachment,
securely support the machine or attachment.
Do not support the machine on cinder blocks, hollow
tiles, or props that may crumble under continuous load.
Do not work under a machine that is supported solely
by a jack. Follow recommended procedures in this
manual.
Lifting heavy components incorrectly can cause severe
injury or machine damage. Follow recommended
procedure for removal and installation of components
in the manual.
Work In Clean Area
Before starting a job:
1. Clean work area and machine.
2. Make sure you have all necessary tools to do your
job.
3. Have the right parts on hand.
4. Read all instructions thoroughly; do not attempt
shortcuts.
2/9/00
SAFETY
Using High Pressure Washers
Avoid Harmful Asbestos Dust
Directing pressurized water at electronic/electrical
components or connectors, bearings, hydraulic seals,
fuel injection pumps or other sensitive parts and
components may cause product malfunctions. Reduce
pressure and spray at a 45 to 90 degree angle.
Avoid breathing dust that may be generated when
handling components containing asbestos fibers.
Inhaled asbestos fibers may cause lung cancer.
Illuminate Work Area Safely
Illuminate your work area adequately but safely. Use a
portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire
cage. The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
Work In Ventilated Area
Components in products that may contain asbestos
fibers are brake pads, brake band and lining
assemblies, clutch plates, and some gaskets. The
asbestos used in these components is usually found in
a resin or sealed in some way. Normal handling is not
hazardous as long as airborne dust containing
asbestos is not generated.
Avoid creating dust. Never use compressed air for
cleaning. Avoid brushing or grinding material
containing asbestos. When servicing, wear an
approved respirator. A special vacuum cleaner is
recommended to clean asbestos. If not available, apply
a mist of oil or water on the material containing
asbestos. Keep bystanders away from the area.
SERVICE TIRES SAFELY
Engine exhaust fumes can cause sickness or death. If
it is necessary to run an engine in an enclosed area,
remove the exhaust fumes from the area with an
exhaust pipe extension.
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.
WARNING: California Proposition 65
Warning:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
Gasoline engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
Remove Paint Before Welding Or
Heating
Avoid potentially toxic fumes and dust. Hazardous
fumes can be generated when paint is heated by
welding, soldering, or using a torch. Do all work outside
or in a well ventilated area. Dispose of paint and
solvent properly. Remove paint before welding or
heating: If you sand or grind paint, avoid breathing the
dust. Wear an approved respirator. If you use solvent or
paint stripper, remove stripper with soap and water
before welding. Remove solvent or paint stripper
containers and other flammable material from area.
Allow fumes to disperse at least 15 minutes before
welding or heating.
2/9/00
Explosive separation of a tire and rim parts can cause
serious injury or death.
Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate
the tires above the recommended pressure. Never weld
or heat a wheel and tire assembly. The heat can cause
an increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension
hose long enough to allow you to stand to one side and
NOT in front of or over the tire assembly. Use a safety
cage if available.
Check wheels for low pressure, cuts, bubbles,
damaged rims or missing lug bolts and nuts.
1-5
SAFETY
AVOID INJURY FROM ROTATING
BLADES, AUGERS AND PTO
SHAFTS
HANDLE CHEMICAL PRODUCTS
SAFELY
Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used
with John Deere equipment include such items as
lubricants, coolants, paints, and adhesives.
Keep hands and feet away while machine is running.
Shut off power to service, lubricate or remove mower
blades, augers or PTO shafts.
SERVICE COOLING SYSTEM
SAFELY
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques. Check the MSDS before you start any job
using a hazardous chemical. That way you will know
exactly what the risks are and how to do the job safely.
Then follow procedures and recommended equipment.
Dispose of Waste Properly
Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste
used with John Deere equipment include such items as
oil, fuel, coolant, brake fluid, filters, and batteries. Use
leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead
someone into drinking from them. Do not pour waste
onto the ground, down a drain, or into any water
source. Inquire on the proper way to recycle or dispose
of waste from your local environmental or recycling
center, or from your John Deere dealer.
Explosive release of fluids from pressurized cooling
system can cause serious burns.
LIVE WITH SAFETY
Shut off machine. Only remove filler cap when cool
enough to touch with bare hands. Slowly loosen cap to
first stop to relieve pressure before removing
completely.
Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.
1-6
2/9/00
CONTENTS
SPECIFICATIONS AND INFORMATION
CONTENTS
Page
GENERAL VEHICLE SPECIFICATIONS1 . . . . . . . . . . . . . . . . . . . . . . . .
INCH FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . .
METRIC FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . .
DIESEL FUEL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
5
6
7
DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIESEL FUEL LUBRICITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIESEL FUEL STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BREAK–IN ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HYDROSTATIC TRANSMISSION AND HYDRAULIC OIL . . . . . . . . . . . . 9
CHASSIS GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ALTERNATIVE LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SYNTHETIC LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LUBRICANT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
MIXING OF LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
COOLANT DRAIN INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PRODUCT IDENTIFICATION LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2/9/00
2-1
NOTES
2-2
SPECIFICATIONS AND INFORMATION
2/9/00
SPECIFICATIONS & INFORMATION
GENERAL VEHICLE SPECIFICATIONS1
GENERAL VEHICLE SPECIFICATIONS1
ENGINE:
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yanmar
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN66C-JUV
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-cycle diesel
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead valves
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (658 cm 3) 40.2 cu. in.
Power (SAE J1940) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(13.4 kW) 18 hp
Maximum torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.9 lb-ft @ 2700 rpm
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full pressure
Slow Idle Speed (no load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 ± 50 rpm
Fast Idle Speed (no load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3550 ± 25 rpm
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liquid
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . Dry replaceable dual element w/ remote intake
Battery Cold Cranking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 cold cranking amps
ELECTRICAL:
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VDC
Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct inject diesel
Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.5 watt halogen
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 amp/hr
Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 amp regulated
FUEL SYSTEM:
Fuel Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel
Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 L (5.3 U.S. gal)
Fuel Consumption (Approximately) . . . . . . . . . . . . . . . . . . . 0.961 L/hr (0.25 U.S. gal/hr)
TRANSMISSION:
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Continuous variable
Differential Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard; hand operated
Ground Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0–25 km/h (0–15.5 mph)
Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 50 industrial roller chain
Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fully enclosed; oil bath
Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Forward, neutral, reverse
Overall Reduction Ratio
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70.8 : 1
High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3 : 1
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet disk in transaxle
2/9/00
2-3
GENERAL VEHICLE SPECIFICATIONS1
SPECIFICATIONS & INFORMATION
STEERING:
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rack and pinion Ackerman-type
GROUND PRESSURE (maximum):
With 200 lb Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.49 kg cm 2 (6.9 psi)
Fully Loaded Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.51 kg cm 2 (7.3 psi)
DIMENSIONS:
Length (with bumper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2810 mm (110.63 in.)
Width (overall with heavy duty tires) . . . . . . . . . . . . . . . . . . . . . . . . 1545 mm (60.83 in.)
Front Tread Centers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1270 mm (50.0 in.)
Rear Tread Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1220 mm (48.0 in.)
Height (overall with heavy duty tires). . . . . . . . . . . . . . . . . . . . . . . . . 1107 mm (43.6 in.)
Wheelbase (front/rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2006 mm (79.0 in.)
Weight (includes fuel/fluids) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .645 kg (1422 lbs)
Turn Clearance Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 m (24.8 ft)
GROUND CLEARANCE:
Under Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 mm (6.7 in.)
Under Foot Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 mm (8.5 in.)
CAPACITIES:
Payload Capacity (total)2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636 kg (1400 lb)
Towing Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636 kg (1400 lb)
Seating Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CARGO BOX:
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 gauge roll formed steel
Capacity
Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.32 m 3 (11.2 cu-ft)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 kg (1000 lb)
1. Specifications and design subject to change without notice.
2. Includes 200 lb. operator, 200 lb. passenger and maximum box capacity.
2-4
2/9/00
INCH FASTENER TORQUE VALUES
SPECIFICATIONS & INFORMATION
INCH FASTENER TORQUE VALUES
5.1
5
1 or 2b
SAE
Grade
and Head
Markings
8
5.2
8.2
No Marks
5
2
SAE
Grade
and Nut
Markings
8
No Marks
TS1162
Grade 2b
Grade 1
Lubricateda
Drya
SIZE
N•m
lb-ft
N•m
1/4
3.7
2.8
5/16
7.7
3/8
Grade 5, 5.1 or 5.2
Grade 8 or 8.2
Lubricateda
Drya
Lubricateda
Drya
Lubricateda
Drya
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
4.7
3.5
6
4.5
7.5
5.5
9.5
7
12
9
13.5
10
17
12.5
5.5
10
7
12
9
15
11
20
15
25
18
28
21
35
26
14
10
17
13
22
16
27
20
35
26
44
33
50
36
63
46
7/16
22
16
28
20
35
26
44
32
55
41
70
52
80
58
100
75
1/2
33
25
42
31
53
39
67
50
85
63
110
80
120
90
150
115
9/16
48
36
60
45
75
56
95
70
125
90
155
115
175
130
225
160
5/8
67
50
85
62
105
78
135
100
170
125
215
160
215
160
300
225
3/4
120
87
150
110
190
140
240
175
300
225
375
280
425
310
550
400
7/8
190
140
240
175
190
140
240
175
490
360
625
450
700
500
875
650
1
290
210
360
270
290
210
360
270
725
540
925
675
1050
750
1300
975
1-1/8
470
300
510
375
470
300
510
375
900
675
1150
850
1450
1075
1850
1350
1-1/4
570
425
725
530
570
425
725
530
1300
950
1650
1200
2050
1500
2600
1950
1-3/8
750
550
950
700
750
550
950
700
1700
1250
2150
1550
2700
2000
3400
2550
1-1/2
1000
725
1250
925
990
725
1250
930
2250
1650
2850
2100
3600
2650
4550
3350
DO NOT use these hand torque values if a different
torque value or tightening procedure is given for a
specific application. Torque values listed are for general
use only and include a ±10% variance factor. Check
tightness of fasteners periodically. DO NOT use air
powered wrenches.
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same grade.
Make sure fastener threads are clean and that you
properly start thread engagement. This will prevent
them from failing when tightening.
When bolt and nut combination fasteners are used,
torque values should be applied to the NUT instead of
the bolt head.
2/9/00
Tighten toothed or serrated-type lock nuts to the full
torque value.
a
“Lubricated” means coated with a lubricant
such as engine oil, or fasteners with phosphate
and oil coatings. “Dry” means plain or zinc
plated (yellow dichromate - Specification
JDS117) without any lubrication.
b
“Grade 2” applies for hex cap screws (not hex
bolts) up to 152 mm (6-in.) long. “Grade 1”
applies for hex cap screws over 152 mm (6-in.)
long, and for all other types of bolts and screws
of any length.
Reference: JDS—G200.
2-5
METRIC FASTENER TORQUE VALUES
SPECIFICATIONS & INFORMATION
METRIC FASTENER TORQUE VALUES
4.8
9.8
10.9
4.8
8.8
9.8
10.9
12.9
4.8
8.8
9.8
10.9
12.9
10
10
5
5
10
10
12.9
12
10
10
5
Property
Class
and
Nut
Markings
12.9
8.8
12
Property
Class
and
Head
Markings
12
TS1163
Class 4.8
Class 8.8 or 9.8
Lubricateda
Drya
SIZE
N•m
lb-ft
N•m
M6
48
3.5
M8
12
M10
Class 10.9
Lubricateda
Drya
lb-ft
N•m
lb-ft
N•m
6
4.5
9
6.5
8.5
15
11
22
23
17
29
21
M12
40
29
50
M14
63
47
M16
100
M18
Class 12.9
Lubricateda
Drya
Lubricateda
Drya
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
11
8.5
13
9.5
17
12
15
11.5
19
14.5
16
28
20
32
24
40
30
37
28
47
35
43
32
55
40
63
47
80
60
75
55
95
70
37
75
55
95
70
110
80
140
105
130
95
165
120
80
60
120
88
150
110
175
130
225
165
205
150
260
109
73
125
92
190
140
240
175
275
200
350
225
320
240
400
300
135
100
175
125
260
195
330
250
375
275
475
350
440
325
560
410
M20
190
140
240
180
375
275
475
350
530
400
675
500
625
460
800
580
M22
260
190
330
250
510
375
650
475
725
540
925
675
850
625
1075
800
M24
330
250
425
310
650
475
825
600
925
675
1150
850
1075
800
1350
1000
M27
490
360
625
450
950
700
1200
875
1350
1000
1700
1250
1600
1150
2000
1500
M30
675
490
850
625
1300
950
1650
1200
1850
1350
2300
1700
2150
1600
2700
2000
M33
900
675
1150
850
1750
1300
2200
1650
2500
1850
3150
2350
2900
2150
3700
2750
M36
1150
850
1450
1075
2250
1650
2850
2100
3200
2350
4050
3000
3750
2750
4750
3500
DO NOT use these hand torque values if a different
torque value or tightening procedure is given for a
specific application. Torque values listed are for
general use only and include a ±10% variance factor.
Check tightness of fasteners periodically. DO NOT use
air powered wrenches.
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same grade.
Make sure fastener threads are clean and that you
properly start thread engagement. This will prevent
them from failing when tightening.
torque values should be applied to the NUT instead of
the bolt head.
Tighten toothed or serrated-type lock nuts to the full
torque value.
a
“Lubricated” means coated with a lubricant
such as engine oil, or fasteners with phosphate
and oil coatings. “Dry” means plain or zinc
plated (yellow dichromate - Specification
JDS117) without any lubrication.
Reference: JDS—G200.
When bolt and nut combination fasteners are used,
2-6
2/9/00
SPECIFICATIONS & INFORMATION
DIESEL FUEL SPECIFICATIONS
DIESEL FUEL SPECIFICATIONS
DIESEL FUEL STORAGE
DIESEL FUEL
IMPORTANT:
DO NOT USE GALVANIZED
CONTAINERS—diesel fuel stored in galvanized
containers reacts with zinc coating in the
container to form zinc flakes. If fuel contains
water, a zinc gel will also form. The gel and
flakes will quickly plug fuel filters and damage
fuel injectors and fuel pumps.
In general, diesel fuels are blended to satisfy the low air
temperature requirements of the geographical area in
which they are sold.
In North America, diesel fuel is usually specified to
ASTM D975 and sold as either Grade 1 for cold air
temperatures or Grade 2 for warm air temperatures.
If diesel fuels being supplied in your area DO NOT
meet any of the above specifications, use diesel fuels
with the following equivalent properties:
• Cetane Number 40 (minimum)
A cetane number greater than 50 is preferred,
especially for air temperatures below –20 °C
(–4 °F) or elevations above 1500 m (5000 ft).
• Cold Filter Plugging Point (CFPP)
The temperature at which diesel fuel begins to
cloud or jell. Use diesel fuels with a CFPP which
is at least 5 °C (9 °F) below the expected low air
temperature.
• Sulfur Content of 0.05% (maximum)
Diesel fuels for highway use in the United States
now require sulfur content to be less than 0.05%.
If diesel fuel being used has a sulfur content
greater than 0.5%, reduce the service interval
for engine oil and filter by 50%.
It is recommended that diesel fuel be stored ONLY in a
clean, approved POLYETHYLENE PLASTIC container
WITHOUT any metal screen or filter. This will help
prevent any accidental sparks from occurring. Store
fuel in an area that is well ventilated to prevent possible
igniting of fumes by an open flame or spark, this
includes any appliance with a pilot light.
IMPORTANT: Keep all dirt, scale, water or other
foreign material out of fuel.
Keep fuel in a safe, protected area and in a clean,
properly marked (“DIESEL FUEL”) container. DO NOT
use deicers to attempt to remove water from fuel. DO
NOT depend on fuel filters to remove water from fuel. It
is recommended that a water separator be installed in
the storage tank outlet. BE SURE to properly discard
unstable or contaminated diesel fuel and/or their
containers when necessary.
Consult your local diesel fuel distributor for properties
of the diesel fuel available in your area.
c
WARNING
California Proposition 65 Warning: Diesel engine
exhaust and some of its elements from this
product are known to the State of California to
cause cancer, birth defects, or other
reproductive harm.
DIESEL FUEL LUBRICITY
Diesel fuel must have adequate lubricity to ensure
proper operation and durability of fuel injection system
components. Fuel lubricity should pass a minimum of
3300 gram load level as measured by the BOCLE
scuffing test.
2/9/00
2-7
ENGINE OIL
SPECIFICATIONS & INFORMATION
ENGINE OIL
interval for oil and filter by 50%.
Use the appropriate oil viscosity based on the expected
air temperature range during the period between
recommended oil changes. Operating outside of these
recommended oil air temperature ranges may cause
premature engine failure.
The following John Deere oils are PREFERRED:
• PLUS–50®—SAE 15W-40;
• UNI–GARD™—SAE 15W-40;
• TORQ–GARD SUPREME®—SAE 5W-30.
• UNI–GARD™—SAE 5W-30.
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper oil
for your customers:
• Module DX,ENOIL in JDS–G135;
• Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide;
• Lubrication Sales Manual PI7032.
OIL FILTERS
The following John Deere oils are also recommended,
based on their specified temperature range:
• TURF–GARD®—SAE 10W-30;
• PLUS–4®—SAE 10W-30;
• TORQ–GARD SUPREME®—SAE 30.
IMPORTANT: Filtration of oils is critical to proper
lubrication performance. Always change filters
regularly.
The following John Deere oil filters are PREFERRED:
Other oils may be used if above John Deere oils are not
available, provided they meet one of the following
specifications:
• SAE 15W-40—API Service Classification CF–4 or
higher;
• SAE 5W-30—API Service Classification CC or
higher;
• SAE 10W-30—API Service Classification CF or
higher;
• SAE 30—API Service Classification CF or higher.
• AUTOMOTIVE AND LIGHT TRUCK ENGINE OIL
FILTERS.
Most John Deere filters contain pressure relief and
anti-drainback valves for better engine protection.
Other oil filters may be used if above recommended
John Deere oil filters are not available, provided they
meet the following specification:
• ASTB Tested In Accordance With SAE J806.
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper oil
filter for your customers:
BREAK–IN ENGINE OIL
SAE10W-30
SAE 30
SAE 5W-30
SAE 15W-40
• Module DX,FILT in JDS–G135;
• Section 540, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide;
• Lawn & Grounds Care Tune-Up Guide PI672.
IMPORTANT: ONLY use this specified break-in oil
in rebuilt or remanufactured engines for the first
100 hours (maximum) of operation. DO NOT use
PLUS–50®, SAE 15W40 oil or oils meeting
specifications API CG–4 or API CF–4, these oils
will not allow rebuilt or remanufactured engines
to break-in properly.
The following John Deere oil is PREFERRED:
• BREAK–IN ENGINE OIL.
PREFERRED
AIR TEMPERATURE
M58275
IMPORTANT: If diesel fuel with sulfur content
greater than 0.5% is used, reduce the service
2-8
John Deere BREAK–IN ENGINE OIL is formulated
with special additives for aluminum and cast iron type
engines to allow the power cylinder components
(pistons, rings, and liners as well) to “wear-in” while
protecting other engine components, valve train and
gears, from abnormal wear. Engine rebuild instructions
should be followed closely to determine if special
requirements are necessary.
John Deere
BREAK–IN
ENGINE
OIL
is
also
2/9/00
HYDROSTATIC TRANSMISSION AND HYDRAULIC OIL
recommended for non-John Deere engines, both
aluminum and cast iron types.
If this preferred John Deere oil is not available, use a
break-in engine oil meeting the following specification
during the first 100 hours of operation:
Transmission Fluid in this transmission.
The following John Deere transmission and hydraulic
oil is PREFERRED:
• HY–GARD®—JDM J20C.
Other oils may be used if above recommended John
Deere oils are not available, provided they meet one of
the following specifications:
• API Service Classification CE or higher.
• CCMC Specification D4 or higher.
• John Deere Standard JDM J20C;
• John Deere Standard JDM D.
BREAK-IN OIL
JDM J20D
IMPORTANT: After the break-in period, use the
John Deere oil that is recommended for this
engine.
JDM J20C
SPECIFICATIONS & INFORMATION
PREFERRED
AIR TEMPERATURE
M58275
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper oil
for your customers:
• Module DX,ENOIL4 in JDS–G135;
• Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide;
• Lubrication Sales Manual PI7032.
AIR TEMPERATURE
M58275
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper oil
for your customers:
• Module DX,ANTI in JDS–G135;
• Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide;
• Lubrication Sales Manual PI7032.
HYDROSTATIC TRANSMISSION AND
HYDRAULIC OIL
Use the appropriate oil viscosity based on these air
temperature ranges. Operating outside of these
recommended oil air temperature ranges may cause
premature hydrostatic transmission or hydraulic system
failures.
IMPORTANT: Mixing of HY–GARD® and LOW
VISCOSITY HY–GARD® oils is permitted. DO
NOT mix any other oils in this transmission. DO
NOT use engine oil or “Type F” (Red) Automatic
2/9/00
2-9
CHASSIS GREASE
SPECIFICATIONS & INFORMATION
CHASSIS GREASE
ALTERNATIVE LUBRICANTS
IMPORTANT: ONLY use a quality grease in this
application. DO NOT mix any other greases in
this application. DO NOT use any BIO–GREASE
in this application.
The following John Deere greases are PREFERRED:
• MOLY HIGH-TEMPERATURE EP GREASE®—
JDM J25C, NLGI Grade 2;
• HIGH-TEMPERATURE EP GREASE®—JDM
J13E4, NLGI Grade 2.
• GREASE–GARD™—JDM J25C, NLGI Grade 2.
Other greases may be used if above preferred John
Deere greases are not available, provided they meet
one of the following specifications:
• John Deere Standard JDM J25C, NLGI Grade 2;
• John Deere Standard JDM J13E4, NLGI Grade 2.
IMPORTANT: If minimum air temperature should
fall below -20 °C (-4 °F), the grease must be
heated to at least five degrees above the lower
limit before start-up or components may be
damaged.
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper
grease for your customers:
• Module DX,GREA1 in JDS–G135;
• Section 530, Lubricants & Hydraulics, of the
John Deere Merchandise Sales Guide;
• the Lubrication Sales Manual PI7032.
2 - 10
IMPORTANT: Use of alternative lubricants could
cause reduced life of the component.
If alternative lubricants are to be used, it is
recommended that the factory fill be thoroughly
removed before switching to any alternative lubricant.
SYNTHETIC LUBRICANTS
Synthetic lubricants may be used in John Deere
equipment if they meet the applicable performance
requirements (industry classification and/or military
specification) as shown in this manual.
The recommended temperature limits and service or
lubricant change intervals should be maintained as
shown in the operator’s manual, unless otherwise
stated on lubricant label.
Avoid mixing different brands, grades, or types of oil.
Oil manufacturers blend additives in their oils to meet
certain specifications and performance requirements.
Mixing different oils can interfere with the proper
functioning of these additives and degrade lubricant
performance.
LUBRICANT STORAGE
All machines operate at top efficiency only when clean
lubricants are used. Use clean storage containers to
handle all lubricants. Store them in an area protected
from dust, moisture, and other contamination. Store
drums on their sides. Make sure all containers are
properly marked as to their contents. Dispose of all old,
used containers and their contents properly.
JDM J13E4
NLGI Grade 2
JDM J25C
NLGI Grade 2
AIR TEMPERATURE
Conditions in certain geographical areas outside the
United States and Canada may require different
lubricant recommendations than the ones printed in
this technical manual or the operator's manual. Consult
with your John Deere Dealer, or Sales Branch, to
obtain the alternative lubricant recommendations.
MIXING OF LUBRICANTS
In general, avoid mixing different brands or types of
lubricants. Manufacturers blend additives in their
lubricants to meet certain specifications and
performance requirements. Mixing different lubricants
can interfere with the proper functioning of these
additives and lubricant properties which will downgrade
their intended specified performance.
M58275
2/9/00
COOLANT
SPECIFICATIONS & INFORMATION
COOLANT
The engine cooling system when filled with a proper
dilution mixture of antifreeze and deionized or distilled
water provides year-round protection against corrosion,
cylinder or liner pitting, and winter freeze protection
down to –37 °C (–34 °F).
The following John Deere coolant is PREFERRED:
• PRE-DILUTED DIESEL ENGINE ANTIFREEZE/
SUMMER COOLANT™ (TY16036).
• COOL–GARD COOLANT CONCENTRATE™.
This coolant satisfies specifications for “Automobile
and Light Duty Engine Service” and is safe for use in
John Deere Lawn and Grounds Care/Golf and Turf
Division equipment, including aluminum block gasoline
engines and cooling systems.
The above preferred pre-diluted antifreeze provides:
• adequate heat transfer
• corrosion-resistant chemicals for the cooling
system
• compatibility with cooling system hose and
seal material
• protection during extreme cold and extreme hot
weather operations
• chemically pure water for better service life
• compliance with ASTM D4656 (JDM H24C2)
specifications
Table 1: Water Quality
Property
Requirements
Total Solids, Maximum
340 ppm (20 grns/gal)
Total Hardness, Max.
170 ppm (10 grns/gal)
Chloride (as Cl), Max.
40 ppm (2.5 grns/gal)
Sulfate (as SO4), Max.
100 ppm (5.8 grns/gal)
Mix 50 percent antifreeze concentrate with 50 percent
distilled or deionized water. This mixture and the prediluted mixture (TY16036) will protect the cooling
system down to –37 °C (–34 °F) and up to 108 °C
(226 °F).
Certain geographical areas may require lower air
temperature protection. See the label on your
antifreeze container or consult your John Deere dealer
to obtain the latest information and recommendations.
If above preferred pre-diluted coolant is not available,
the
following
John
Deere
concentrate
is
recommended:
• DIESEL ENGINE ANTIFREEZE/SUMMER
COOLANT CONCENTRATE™ (TY16034).
If either of above recommended engine coolants are
available use any Automobile and Light Duty Engine
Service ethylene glycol base coolant, meeting the
following specification:
• ASTM D3306 (JDM H24C1).
Read container label completely before using and
follow instructions as stated.
IMPORTANT: To prevent engine damage, DO NOT
use pure antifreeze or less than a 50% antifreeze
mixture in the cooling system. DO NOT mix or
add any additives/conditioners to the cooling
system in Lawn and Grounds Care/Golf and Turf
Division equipment. Water used to dilute engine
coolant concentrate must be of high quality—
clean, clear, potable water (low in chloride and
hardness–Table 1) is generally acceptable. DO
NOT use salt water. Deionized or distilled water
is ideal to use. Coolant that is not mixed to
these specified levels and water purity can
cause excessive scale, sludge deposits, and
increased corrosion potential.
2/9/00
2 - 11
COOLANT DRAIN INTERVAL
SPECIFICATIONS & INFORMATION
COOLANT DRAIN INTERVAL
ENGINE PRODUCT IDENTIFICATION NUMBER
When using John Deere Pre-Diluted (TY16036)
Automobile and Light Duty Engine Service coolants,
drain and flush the cooling system and refill with fresh
coolant mixture every 36 months or 3,000 hours of
operation, whichever comes first.
When using John Deere Concentrate (TY16034)
Automobile and Light Duty Engine Service coolants,
drain and flush the cooling system and refill with fresh
coolant mixture every 24 months or 2,000 hours of
operation, whichever comes first.
If above John Deere Automobile and Light Duty Engine
Service coolants are not being used; drain, flush, and
refill the cooling system according to instructions found
on product container or in equipment operator’s manual
or technical manual.
M76678
TRANSMISSION
NUMBER
PRODUCT IDENTIFICATION
LOCATIONS
PRODUCT
IDENTIFICATION
When ordering parts or submitting a warranty claim, it
is IMPORTANT that you include the product
identification number, and the component product
identification numbers.
The location of the product identification numbers and
component product identification numbers are shown.
PRODUCT IDENTIFICATION NUMBER
M55707
M55706
2 - 12
2/9/00
CONTENTS
DIESEL ENGINE
CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL OR REQUIRED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
LUBRICATION SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
AIR SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FUEL SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FUEL SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CYLINDER COMPRESSION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
THROTTLE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SLOW IDLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
FAST IDLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
VALVE CLEARANCE, CHECK AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . 23
VALVE LIFT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
FUEL INJECTION NOZZLE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FUEL INJECTION PUMP STATIC TIMING ADJUSTMENT. . . . . . . . . . . . . . . . . . . . 26
WATER PUMP/ALTERNATOR DRIVE BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . 28
THERMOSTAT TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
RADIATOR BUBBLE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
COOLING SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
RADIATOR CAP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ENGINE OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
FUEL TRANSFER PUMP PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
FUEL DRAIN BACK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
FUEL SYSTEM BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
AIR INTAKE SYSTEM LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
AIR FILTER/AIR RESTRICTION INDICATOR TESTS. . . . . . . . . . . . . . . . . . . . . . . . 32
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ENGINE REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
MUFFLER REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
ROCKER ARM COVER REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . 36
ROCKER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
CYLINDER HEAD REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
INTAKE MANIFOLD REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 39
EXHAUST MANIFOLD REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . 40
CYLINDER HEAD RECONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
CRANKSHAFT REAR OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
CRANKSHAFT FRONT OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2/9/00
3-1
CONTENTS CONTIUED
TIMING GEAR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT END PLAY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMING GEAR BACKLASH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IDLER GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAM FOLLOWERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PAN AND STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING ROD SIDE PLAY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT END PLAY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING ROD BEARING CLEARANCE CHECK. . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT MAIN BEARING CLEARANCE CHECK . . . . . . . . . . . . . . . . . . . . .
PISTON-TO-CYLINDER HEAD CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING ROD REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT AND MAIN BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLYWHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLYWHEEL PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMING GEAR HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PRESSURE REGULATING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLANT TEMPERATURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLANT FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL TRANSFER PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL INJECTION PUMP CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL CONTROL AND GOVERNOR LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING MOTOR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2
DIESEL ENGINE
46
46
47
47
48
49
52
52
53
53
54
55
55
56
60
62
64
64
65
65
66
67
67
68
68
69
70
70
71
73
75
77
80
80
83
2/9/00
DIESEL ENGINE
SPECIFICATIONS
SPECIFICATIONS
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yanmar
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN66C-JUV
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vertical, 4-cycle Diesel
Output Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.42 kW (18 HP)
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 mm (2.6 in.)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.2 mm (2.53 in.)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.658 L (40.2 cu. in. )
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1—3—2
Direction of Rotation . . . . . . . . . . . . . . . . . . . . Counterclockwise (viewed from flywheel)
Combustion System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indirect Injection Type
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.4 to 1
Oil Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approximately 2.0 L (2.1 qt)
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liquid
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 L (4.8 qt)
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal
Slow Idle (no-load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 ± 50 rpm
High Idle (no-load). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3550 ± 25 rpm
Rated RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3150
REPAIR SPECIFICATIONS
Rocker Arm Cover:
Special Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 N•m (160 lb-in.)
Rocker Arm Assembly:
Mounting Cap Screw and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.)
Rocker Arm Shaft OD
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.97 - 9.99 mm (0.3925 - 0.3933 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.95 mm (0.3920 in.)
Rocker Arm and Shaft Support ID's
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 mm (0.005 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.00 - 10.02 mm (0.3937 - 0.3945 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.09 mm (0.3972 in.)
Push Rod Length (Standard) . . . . . . . . . . . . . . . . . . . .114 - 115 mm (4.488 - 4.528 in.)
Push Rod Bend Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.)
Cylinder Head:
Mounting Cap Screw Torque
First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (97 lb-in.)
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.)
Final. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 N•m (25 lb-ft)
Piston-to-Cylinder Head Clearance. . . . . . . . . . . . . . .0.59 - 0.74 mm (0.023 - 0.029 in.)
Cylinder Head Distortion
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) or less
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Maximum Amount of Metal to be Removed . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
2/9/00
3-3
REPAIR SPECIFICATIONS
DIESEL ENGINE
Intake and Exhaust Valves:
Intake Valve Seat Width
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 mm (0.045 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.65 mm (0.065 in.)
Exhaust Valve Seat Width
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 mm (0.056 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.91 mm (0.075 in.)
Valve Seat Surface Angles
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Lower Seat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70°
Upper Seat Surface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15°
Valve Faces
Minimum Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.51 mm (0.020 in.)
Exhaust Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Intake Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Valve Stem OD
Distance A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 mm (0.787 in.)
Distance B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 mm (1.575 in.)
Intake Valve
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.46 - 5.48 mm (0.2149 - 0.2157 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40 mm (0.2126 in.)
Exhaust Valve
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.44 - 5.46 mm (0.2142 - 0.2149 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40 mm (0.2126 in.)
Valve Recession
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.85 mm (0.033 in.)
Valve Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 mm (0.300 in.)
Valve Guides:
Valve Guide ID
Maximum Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.50 - 5.52 mm (0.216 - 0.217 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.58 mm (0.220 in.)
Valve Guide Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 mm (0.276 in.)
Valve Springs:
Spring Free Length
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 mm (1.102 in.)
Maximum Spring Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.032 in.)
Exhaust Manifold:
Mounting Cap Screw and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (97 lb-in.)
Intake Manifold:
Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (97 lb-in.)
Connecting Rod Bearing ID:
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 - 36.042 mm (1.417 - 1.419 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.07 mm (1.459 in.)
Piston and Connecting Rod Cap Screw Torque . . . . . . . . . . . . . . . . 23 N•m (203 lb-in.)
3-4
2/9/00
DIESEL ENGINE
REPAIR SPECIFICATIONS
Piston Ring Groove Clearance:
First Compression Ring
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.065 - 0.100 mm (0.0026 - 0.0039 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Second Compression Ring
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.030 - 0.065 mm (0.0012 - 0.0026 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Oil Ring
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.020 - 0.055 mm (0.0008 - 0.0022 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Piston End Ring Gap:
First Compression Ring and Oil Ring . . . . . . . . . . . . .0.15 - 0.35 mm (0.006 - 0.014 in.)
Second Compression Ring . . . . . . . . . . . . . . . . . . . . .0.25 - 0.40 mm (0.010 - 0.016 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.059 in.)
Piston Pin:
Pin OD
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19.991 - 20.00 mm (0.787 - 0.788 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.975 mm (0.786 in.)
Bore ID
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.045 mm (0.0018 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20.00 - 20.008 mm (0.787 - 0.788 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.02 mm (0.788 in.)
Bushing ID
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.110 mm (0.0043 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20.025 - 20.038 mm (0.788 - 0.789 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.10 mm (0.781 in.)
Piston OD:
Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm (0.197 in.)
Standard Size Piston
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65.927 - 65.957 mm (2.596 - 2.597 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.85 mm (2.593 in.)
0.25 mm (0.010 in.) Oversize Piston
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66.18 - 66.21 mm (2.606 - 2.607 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.10 mm (2.602 in.)
0.50 mm (0.020 in.) Oversize Piston
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66.43 - 66.46 mm (2.615 - 2.616 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.35 mm (2.612 in.)
Cylinder Bore ID:
Standard Size Bore
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66.00 - 66.03 mm (2.599 - 2.600 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.20 mm (2.606 in.)
0.25 mm (0.010 in.) Oversize Bore
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66.25 - 66.28 mm (2.609 - 2.610 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.45 mm (2.616 in.)
0.50 mm (0.020 in.) Oversize Bore
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66.50 - 66.53 mm (2.619 - 2.620 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.70 mm (2.626 in.)
Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° cross-hatch pattern
Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° cross-hatch pattern
2/9/00
3-5
REPAIR SPECIFICATIONS
DIESEL ENGINE
Crankshaft Rear Oil Seal:
Seal Case-to-Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Oil Pan-to-Seal Case Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Crankshaft and Main Bearings:
Main Bearing Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft)
Crankshaft Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0007 in.)
Connecting Rod Journal OD
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35.97 - 35.98 mm (1.4161 - 1.4165 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.92 mm (1.414 in.)
Main Bearing Journal OD
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39.97 - 39.98 mm (1.5736 - 1.5740 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.92 mm (1.572 in.)
Main Bearing ID
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40.00 - 40.042 mm (1.575 - 1.577 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.07 mm (1.578 in.)
Stub Shaft:
Stub Shaft-to-Flywheel Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . 59 N•m (44 lb-ft)
Flywheel:
Maximum Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0008 in.)
Flywheel Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . 83 N•m (61 lb-ft)
Engine Back Plate Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft)
Camshaft:
Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Camshaft Side Gap
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.05 - 0.15 mm (0.0020 - 0.0060 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
Maximum Camshaft Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.001 in.)
Lobe Height
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29.97 - 30.03 mm (1.180 - 1.182 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.75 mm (1.171 in.)
Journal OD
Gear Housing and Flywheel Ends
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35.94 - 35.96 mm (1.4150 - 1.4157 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.85 mm (1.4114 in.)
Intermediate
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35.91 - 35.94 mm (1.4138 - 1.4150 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.85 mm (1.4114 in.)
Bushing ID
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36.00 - 36.065 mm (1.417 - 1.420 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.10 mm (1.421 in.)
Bore ID
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36.00 - 36.025 mm (1.417 - 1.418 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.10 mm (1.421 in.)
3-6
2/9/00
DIESEL ENGINE
REPAIR SPECIFICATIONS
Cam Followers:
OD
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . .17.950 - 17.968 mm (0.7067 - 0.7074 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.93 mm (0.706 in.)
Bore ID
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.032 - 0.068 mm (0.0013 - 0.0027 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . .18.00 - 18.018 mm (0.7087 - 0.7094 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.05 mm (0.711 in.)
Timing Gear Cover:
Fan Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Cover Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Crankshaft Pulley Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . 115 N•m (85 lb-ft)
Idler Gear:
Shaft OD
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19.959 - 19.980 mm (0.786 - 0.787 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.93 mm (0.785 in.)
Bushing ID
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20.00 - 20.021 mm (0.787 - 0.788 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.08 mm (0.791 in.)
Timing Gear Housing Cap Screw Torque:
Aluminum Housing-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Cast Iron Housing-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Oil Pan and Strainer Mounting Cap Screw Torque:
Oil Pan-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Oil Pan-to-Seal Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Oil Pan-to-Timing Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Oil Strainer-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Oil Pump:
Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (18 lb-ft)
Rotor Shaft OD-to-Backing Plate ID Clearance
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.015 - 0.048 mm (0.0006 - 0.0035 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0078 in.)
Rotor Recess Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Outer Rotor-to-Pump Body Clearance
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.03 - 0.09 mm (0.0011 - 0.0035 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 mm (0.0057 in.)
Inner-to-Outer Rotor Clearance Wear Limit . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Oil Pressure Regulating Valve:
Spring
Compressed Length . . . . . . . . . . . . . . . . . 14.70 mm (0.580 in.) @12 N (2.7 lb-force)
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21.90 - 24.50 mm (0.860 - 0.960 in.)
Housing-to-Valve Body Retaining Nut Torque . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)
2/9/00
3-7
REPAIR SPECIFICATIONS
DIESEL ENGINE
Fuel Injection Pump:
Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.)
Fuel Injection Pump Camshaft:
Bearing Retaining Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.)
Minimum Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.90 mm (1.217 in.)
Fuel Control and Governor Linkage:
Governor Shaft OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 mm (0.311 in.)
Governor Shaft Bore ID
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15 mm (0.321 in.)
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Sleeve ID (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20 mm (0.323 in.)
Injection Pump Camshaft OD
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 mm (0.311 in.)
Fuel Injection Nozzles:
Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Nozzle Fitting Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Nozzle Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 N•m (37 lb-ft)
Separator Plate Nozzle Contact Surface Maximum Wear. . . . . . . . 0.10 mm (0.0039 in.)
Starting Motor - Hitachi 0.8 kW:
Cover Bushing (Reamed Out) . . . . . . . . . . . . . . . . .12.50 - 12.53 mm (0.492 - 0.493 in.)
Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.70 mm (0.303 in.)
Alternator - Nipondenso 40 Amp:
Flywheel Assembly-to-Coil Plate Assembly Nut Torque . . . . . . . . . . . . 27 N•m (20 lb-ft)
Checks, Tests and Adjustments:
Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 mm (0.008 in.)
Connecting Rod Side Play
Standard Clearance . . . . . . . . . . . . . . . . . . . . . .0.20 - 0.40 mm (0.0079 - 0.0157 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.55 mm (0.0217 in.)
Connecting Rod Bearing Clearance
Standard Clearance . . . . . . . . . . . . . . . . . . . .0.020 - 0.072 mm (0.0008 - 0.0028 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Crankshaft End Play
Standard Clearance . . . . . . . . . . . . . . . . . . . . . .0.090 - 0.271 mm (0.004 - 0.011 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.33 mm (0.0129 in.)
Crankshaft Main Bearing Clearance
Main Bearing Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft)
Standard Clearance . . . . . . . . . . . . . . . . . . . .0.020 - 0.072 mm (0.0008 - 0.0028 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Valve Lift (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 mm (0.300 in.)
Camshaft End Play
Standard Clearance . . . . . . . . . . . . . . . . . . . . . .0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
3-8
2/9/00
DIESEL ENGINE
REPAIR SPECIFICATIONS
Timing Gear Backlash
Standard Backlash
All Except Crankshaft Gear-to-Oil
Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.04 - 0.12 mm (0.0016 - 0.0047 in.)
Crankshaft Gear-to-Oil Pump Gear. . . . . . . . . . . . .0.11 - 0.19 mm (0.0043 - 0.0075 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Fuel Injection Nozzle:
Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11722 ± 480 kPa (1700 ± 70 psi)
Leakage at 11032 kPa (1600 psi) . . . . . . . . . . . . . . . . . . . . . . . Minimum of 10 Seconds
Chatter and Spray Pattern at 11722 ± 480 kPa . . . . . . . . . . . . . . . . . . . (1700 ± 70 psi)
Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chatter Sound
Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . Fine Stream Spray Pattern
Fast Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . .Fine Atomized Spray Pattern
Thermostat:
Begin Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71° C (160°F)
Fully Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85° C (184° F)
Minimum Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 mm (0.310 in.)
Coolant Temperature Switch (On Engine):
Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109° ± 1° C (228° ± 2° F)
Radiator Core Temperature Switch (Operates Fan Motor):
Continuity (Closes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 - 75° C (153 - 167° F)
No Continuity (Opens). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 - 63° C (135 - 145° F)
Starter No-Load Amp Draw/RPM:
Maximum Starter Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Amps at 7000 rpm
Minimum Starter RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7000
Fuel Injection Pump Static Timing:
Injection Pump Timing. . . . . . . . . . . . . . . . . . . . . . 14° BTDC (Before Top Dead Center)
Distance on Outer Surface of Crankshaft Pulley for
Every 0.1 mm (0.004 in.) of Shim Thickness. . . . . . . . . . . . . . . . 1° or 1 mm (3/64 in.)
Engine Crankshaft Position . . . . . . . . . . . . . No. 1 Cylinder on TDC Compression Stroke
Total Shim Pack Thickness (New Shims) . . . . . . . . . . . . . . . . . . . . . . 0.5 mm (0.020 in.)
Delivery Valve Fitting Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 N•m (31 lb-ft)
Water Pump/Alternator Drive Belt Tension:
Applied Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98 N (22 lb-force)
Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 - 15 mm (0.400 - 0.600 in.)
Operational Tests:
Radiator Bubble Test
Maximum Air Pressure Into Cylinder. . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi)
Cooling System
Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 kPa (17 psi)
Minimum Pressure after 15 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . 90 kPa (13 psi)
2/9/00
3-9
SPECIAL OR REQUIRED TOOLS
DIESEL ENGINE
Radiator Cap
Valve Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 - 96 kPa (12 - 14 psi)
Cylinder Compression Pressure
Compression Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi)
Maximum Difference Between Cylinders. . . . . . . . . . . . . . . . . . . . . . 490 kPa (71 psi)
Engine Idle Speed
Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3550 ± 25 rpm
Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 ± 50 rpm
Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 - 392 kPa (43 - 57 psi)
Air Intake System Holding Pressure . . . . . . . . . . . . . . . . . . . . . . 34 - 69 kPa (5 - 10 psi)
SPECIAL OR REQUIRED TOOLS
Tool
Purpose
JTO5719 Digital Tachometer or,
JTO Digital Pulse Tachometer
Used to set slow idle engine rpm and check fast
idle rpm
D01109AA Diesel Fuel Injection Nozzle Tester
D01110AA Adapter Set
23622 Straight Adapter
Used for fuel injection nozzle test
JDF13 Nozzle Cleaning Kit
Used to clean fuel injection nozzles
JDG356 Fuel Pump Pressure Test Kit
Used for fuel transfer pump pressure test
JTO1682 Compression Gauge Assembly
JDG472 Adaptor
Used for cylinder compression check
JDG529 Belt Tension Gauge or,
JDST28 Belt Tension Gauge
Used to adjust the water pump/alternator drive
belt tension
JDG472 Adaptor
Used for radiator bubble test
DO5104ST Cooling System Pressure Pump
JDG692 Radiator Pressure Test Kit Adapters
Used for cooling system pressure test
JTO3017 Hose Assembly
JTO5577 Pressure Gauge (100 psi)
JTO3349 Connector
Used for engine oil pressure test
JDG813-1 Clutch Removal Tool
Used to remove clutch from flywheel
JDG1175-2 Center Distance Gauge
Used to determine isolator spacers for engine
mount
PLASTIGAGE®
Used for clearance measurements
Dial Indicator
Used for valve lift check
OTHER MATERIALS
Number
Name
Use
TY15130 LOCTITE®
No. 395
John Deere Form-InPlace Gasket
Seals crankcase extension housing, rear oil seal
case and flywheel housing to engine block.
Seals oil pan to timing gear housing and engine
block.
PLASTIGAGE® is a registered trademark of the DANA Corp.
LOCTITE® is a registered trademark of the Loctite Corp.
3 - 10
2/9/00
THEORY OF OPERATION
DIESEL ENGINE
THEORY OF OPERATION
COOLING SYSTEM
Remote Fill/
Pressure Cap
Thermostat
Cylinder Head
Bypass Tube
Coolant
Recovery
Tank
Cylinder Block
Coolant
Pump
Radiator
Function:
The cooling system allows the engine to rise to full
operating temperature when engine is started cold.
Once engine reaches operating temperature,
coolant is circulated from the hot engine to the
radiator to prevent engine overheating. The cooling
system is pressurized, which raises the boiling
point of the coolant and allows coolant to carry
away more heat from the engine.
Theory of Operation:
The pressurized cooling system includes the radiator,
water pump, fan and thermostat.
During the warm-up period, the thermostat remains
closed and the impeller type coolant pump draws
coolant from the bypass tube. Coolant from the pump
flows to the cylinder block water jacket and up through
the cylinder head providing a fast warm-up period.
where it is circulated to dissipate heat.
When coolant system pressure exceeds 90 kPa (13
psi), a valve in the radiator cap opens to allow coolant
to discharge into the coolant recovery tank.
When temperature is reduced, a vacuum is produced in
the radiator and coolant is drawn back out of the
coolant recovery tank through a valve in the radiator
cap.
A coolant temperature switch informs the operator of
the engine coolant temperature and warns of a high
temperature condition by lighting a lamp when the
coolant temperature reaches approximately 109°±1°C
(228°±2°F).
The radiator is equipped with a core temperature
sensor which will activate an electric cooling fan
mounted on the inside of the radiator. Air is pulled by
the fan through a grate under the right passenger seat,
through a removable debris guard, through the radiator
and fan, and out to the engine compartment.
Once the engine has reached operating temperature,
the thermostat opens and coolant is pumped from the
bottom of the radiator via the lower radiator hose into
the cylinder block. Here it circulates through the block
and around the cylinders.
From the block, coolant is then directed through the
cylinder head, and into thermostat housing. With the
thermostat open, 85° C (184° F), warm engine coolant
passes through the housing into the top of the radiator
2/9/00
3 - 11
LUBRICATION SYSTEM OPERATION
DIESEL ENGINE
LUBRICATION SYSTEM OPERATION
By-Pass Valve
Fuel Injection Pump
Oil Pressure
Regulating Valve
Oil Filter
Engine Block Main Oil Galley
Oil Pump
Idler
Gear Shaft
Camshaft Bearing
Oil Strainer
Idler
Gear Face
Valve Rocker
Arm Shaft
Crank Journal
Crank Pin
Valve
Rocker Arm
Tappet
Valve
Oil Pan
A full pressure system lubricates engine parts with
clean oil.
A drilled passage from the rear camshaft bearing
through the cylinder block and cylinder head supplies
lubricating oil to the rocker arm shaft. The hollow shaft
distributes oil to the rocker arms, tappets and valves.
Theory of Operation:
Oil passages route lubricating oil directly from the main
oil galley through external oil lines to the fuel injection
pump.
Function:
The pressure lubrication system consists of a positive
displacement gear-driven pump, oil strainer, full flow oil
filter, oil pressure regulating valve and an electrical
pressure warning switch.
An oil pressure switch activates an indicator light to
alert the operator to shut down the engine if oil
pressure drops below a specification.
The pump draws lubrication oil from the oil pan through
a strainer and a suction tube. The oil is then pumped
through an oil passage to the oil filter and through the
engine block main oil galley.
From the main oil galley, oil is forwarded under
pressure to the crankshaft main bearing journals and
idler gear shaft. Drilled cross-passages in the
crankshaft distribute the oil from the main bearings to
connecting rod bearings.
Lube oil holes in main bearing oil grooves are provided
to direct oil to the camshaft bearings.
3 - 12
2/9/00
AIR SYSTEM OPERATION
DIESEL ENGINE
AIR SYSTEM OPERATION
Function:
The air intake system filters air needed for combustion.
Theory of Operation:
Air enters the air cleaner inlet and is directed into the
side of a shield. This starts a high-speed centrifugal
motion of air which continues around the element until
it reaches the far end of the air cleaner housing, to an
unloader valve.
Most of the dust is separated from the air by centrifugal
force that causes heavy dust particles to enter the
opening at the top of the unloader valve. The remaining
air enters the filter element. The filter element filters the
air before entering the intake manifold.
The dirt that is deposited in the unloader valve is
removed by the rubber diaphragm at the base of the air
cleaner. When the engine is running, a pulsing action is
created in the intake system by each intake stroke of
the engine. This pulsing action causes the rubber
diaphragm to open and close, thus emptying the
unloader valve. The operator can squeeze the valve to
let the large particles out.
The difference in pressure between the intake manifold
and air cleaner is monitored by the Air Cleaner
Restriction Indicator. As the air cleaner becomes
clogged, and intake manifold increases, the restriction
indicator piston is pulled down against spring tension,
and is calibrated to show when it’s time to change air
cleaner.
To Intake Manifold
Air Cleaner
Rubber Diaphragm
Air Cleaner
Restriction
Indicator
Air Inlet
M76783
2/9/00
3 - 13
FUEL SYSTEM OPERATION
DIESEL ENGINE
FUEL SYSTEM OPERATION
Function:
Fuel Gauge
Fuel system supplies fuel to injection nozzles.
Theory of Operation:
The engine driven mechanical fuel transfer pump
draws fuel from the vented fuel tank, through the fuel
tank shutoff valve, through the fuel supply line (D), to
the transfer pump (on the back of the engine).
Pressurized fuel is then sent from the fuel transfer
pump to the glass bowl fuel filter/water separator
mounted on the right side of the frame, then on to the
fuel injection pump. After the injection pump galley is
full, excess fuel is returned, along with excess leak-off
fuel from the injectors, through the return line (B) to the
fuel tank.
If the unit ever runs out of fuel, there is a priming lever
on the side of the mechanical fuel transfer pump, which
allows fuel to be manually pumped from the tank to the
injector pump/governor assembly if air has entered the
fuel system. (See Checks, Tests and Adjustments)
The engine speed is controlled by the throttle pedal
and mechanical linkage. The linkage is connected to
the injection pump/governor control lever. The fuel
shutoff solenoid controls the injection pump shutoff
shaft. When the solenoid is retracted (key ON), the
engine can be started. When the key is turned off,
return springs on the shutoff shaft, extend the solenoid,
moving the shutoff linkage to the shutoff position.
Fuel Shutoff
Valve
Fuel Tank
Fuel Cap
M76679
Fuel Filter
The injection pump meters fuel as determined by the
governor and delivers it at high pressure to the injection
nozzles.
The injection nozzle prevents flow until high pressure is
reached, opening the valve and spraying atomized fuel
into the combustion chamber. Injection lines have
trapped fuel inside whenever injection is not taking
place.
A small amount of fuel leaks past the nozzle valve to
lubricate the fuel injection nozzle. This leakage
combines with excess fuel from the injection pump and
is returned to tank. Any air in the fuel system is bled out
with return fuel to the fuel tank.
M76680
A float-type fuel level sensor mounted on the top of the
tank informs the operator of the fuel level.
The fuel shutoff solenoid stops the flow of fuel inside
the fuel injector pump by forcing the governor rack
linkage to a no fuel position, causing the fuel injector
pump to stop suppling fuel to the injectors.
The fuel shutoff solenoid has two coils inside; one pullin and one hold-in coil. The hold-in coil is energized
whenever the key switch is in the on or start position.
The pull-in coil is energized only when in the start
position and oil pressure switch closed.
3 - 14
2/9/00
FUEL SYSTEM OPERATION
DIESEL ENGINE
FUEL SYSTEM OPERATION
Injection Nozzles
Injection Pump and Governor
Fuel Shutoff Solenoid
Fuel Transfer Pump
A
B
C
D
D
A
B
C
Fuel Filter &
Shutoff Valve
Fuel Return
Fuel Supply
Fuel Gauge
Fuel Tank Vent
(Inside Frame)
Tank Shutoff
Valve
Fuel Tank
Fuel Cap
2/9/00
MX0550
3 - 15
FUEL SYSTEM OPERATION
DIESEL ENGINE
NOTES:
3 - 16
2/9/00
TROUBLESHOOTING
DIESEL ENGINE
TROUBLESHOOTING
TROUBLESHOOTING CHART
Remove this page and insert two page foldout
3-17_2pg.fm
2/9/00
3 - 17
TROUBLESHOOTING CHART
DIESEL ENGINE
Remove this page and insert two page foldout
3-17_2pg.fm
3 - 18
2/9/00
DIAGNOSIS
DIESEL ENGINE
DIAGNOSIS
Conditions:
• Machine parked on level surface.
• Park brake engaged.
• Key switch off unless indicated otherwise.
Test/Check Point
Normal
If Not Normal
1. Engine dipstick and
exterior engine
surface - Engine Oil
Check
Oil level between “L” and “H” marks. Oil
not burnt, or contaminated with metal
particles, fuel, or coolant. No external
leakage, filter clean.
Change oil and inspect for source of
contamination. Check gaskets, seals,
plugs, cylinder head, block, and intake
manifold and breather. Change oil filter.
2. Coolant tank and
radiator - Cooling
System Check
Coolant level between marks on tank
when engine is warm.
Coolant in radiator full to top.
Coolant not contaminated with oil, fuel or
discolored brown.
Radiator screen free of debris.
Hoses not cracked or leaking, clamps
and radiator cap tight.
Water pump/alternator belt tight, not
glazed or cracked.
Fan blades not damaged or warped.
Add proper coolant mix.
3. Fuel tank, pump,
lines, filter, filter
shutoff valve - Fuel
System Check
Fuel level correct, not contaminated,
correct grade of fuel, no water or debris
in filter bowl/water separator.
Fuel tank and filter shutoff valves both in
“ON” position.
Fuel hoses not cracked or leaking.
Fuel hose clamps tight.
Fuel tank does not have vacuum.
Drain and clean fuel tank. Add fresh fuel.
Replace filters.
Air filter hose not cracked, clamps tight.
Element not plugged. Air filter housing
sealed, no dirt tracking inside filter
element.
Air filter restriction indicator not leaking
Replace and tighten clamps.
5. Fuel shutoff solenoid.
(Key in RUN
position.)
Fuel shutoff solenoid must pull in and
stay in. Listen for clicking as key is
cycled
If solenoid will not pull in and hold in, see
Fuel Shutoff Solenoid Circuit Diagnosis
in ELECTRICAL section.
6. Engine Coolant
Temperature Light
(Key in RUN
position.)
Indicator light should come on up to 30
seconds depending on air temperature.
See Indicator Light Diagnosis in 6x4
ELECTRICAL section.
7. Fuel filter/water
separator.
Fuel level visible in filter bowl.
Fuel bowl not full of water.
Fuel present at injector pump inlet hose
Pump lever on side of fuel transfer pump
to prime pump and fuel bowl.
Drain water from bowl.
Replace fuel filter. Recheck.
Test fuel pump.
8. Throttle cable and
pedal stop.
Cable not binding and pedal stop
adjusted correctly.
Repair, replace or adjust cable.
9. Intake and exhaust
valves
Valve clearance within specification
(engine cold).
Valves not sticking.
Adjust valves. (See Tests & Adjustments
in this section.)
Check valve guides and stems.
4. Air filter and air intake
- Air Intake System
Check
2/9/00
Drain and flush system. Check for
source of contamination.
Clean or replace.
Pressure test radiator and cap.
Replace and adjust belt tension.
Replace fan.
Move to “ON” position.
Replace.
Replace or tighten.
Replace fuel tank vent hose.
Replace element or housing.
Replace indicator
3 - 19
DIAGNOSIS
DIESEL ENGINE
10. Fuel is reaching
injectors.
Crack fuel injection lines at injectors.
Crank engine. ( Be sure fuel shutoff
solenoid has pulled in.). Fuel leaks out.
No fuel present: Check both fuel shutoff
valves are open, fuel level, inspect filter/
separator element. Test fuel pump.
11. Injectors are working
properly
Injector spray pattern is normal and
cracking pressure is within
specifications.
Check spray pattern and cracking
pressure. (See Tests and Adjustments in
this section.) Replace injectors.
12. Engine compression
tested at fuel injector
ports.
Cylinder compression within
specification. Pressure difference
between cylinders within specification.
Perform cylinder compression test. (See
Tests and Adjustments in this section.)
13. Flywheel and
starting motor
Minimum cranking rpm within
specification.
See Starter Amp Draw Test in Electrical
section.
14. Injection pump
timing inspection
(Key ON, Engine
OFF)
Timing should be correct.
(Remove pump as the LAST possible
solution.)
Have injection pump static timing
adjustment performed by a qualified
Service Repair Shop. (See Tests and
Adjustments in this section.)
15. Injection pump slow
idle speed (Engine
running)
Engine runs at 1000 ± 50 rpm.
See Slow Idle Adjustment in this section.
16. Injection pump fast
idle speed (Engine
running)
Engine runs at 3550 ± 25 rpm.
See Fast Idle Speed Adjustment in this
section.
17. Governor
Engine runs smooth throughout rpm
range with low smoke and good power
Have governor torque capsule adjusted
by a certified CARB/EPA service center.
18. Oil pressure sender
port
Oil pressure in specification.
Test engine oil pressure. (See Tests and
Adjustments in this section.)
19. Thermostat
Opening temperature within
specification.
Perform thermostat opening test. (See
Tests and Adjustments in this section.)
20. Muffler
Not restricted.
Replace muffler.
3 - 20
2/9/00
TESTS AND ADJUSTMENTS
DIESEL ENGINE
TESTS AND ADJUSTMENTS
CYLINDER COMPRESSION TEST
NOTE: Pressure listed is for 300m (1000 ft) above sea
level. For naturally aspirated engines, reduce
specification an additional 4% for each 300m
(1000 ft) of altitude.
Results:
Reason:
To determine the condition of the pistons, rings,
cylinder walls and valves.
Equipment:
• JT01682 Compression Gauge Assembly
• JDG472 Adapter
Procedure:
1. Run engine for 5 minutes to bring to operating
temperature. Shut off engine.
2. Remove injection nozzles.
• If pressure reading is below specification, squirt
clean engine oil into cylinders through injector
ports and repeat test.
• If pressure increases significantly, check piston,
rings, and cylinder walls for wear or damage.
• If pressure does not increase significantly after
retest, check for leaking valves, valve seats or
cylinder head gasket.
THROTTLE CABLE ADJUSTMENT
Reason:
To ensure that throttle pedal and cable adjustment is
allowing throttle lever on governor to reach full high idle
and slow idle positions, and that enough slack is in
throttle cable to prevent unnecessary wear.
Equipment:
• Two 1/2” Open End Wrenches
Procedure:
A
T6333EU
B
3. Install heat protector from end of injector and install
on JDG472 adapter (A).
4. Install JT01682 Compression Gauge Assembly (B)
and JDG472 Adapter in injection port.
5. Disconnect fuel shutoff solenoid electrical connector
on top of engine.
1. Park machine on level surface, turn key switch OFF,
shift transmission to NEUTRAL, and LOCK park
brake.
2. Loosen jam nut on cable end at engine and turn
adjuster until an equal amount of threads are
showing on front and rear of cable ferrule. Tighten
jam nut.
IMPORTANT: DO NOT move engine throttle control
arm by hand, this will kink the wire cable and
damage it. Use throttle pedal only.
IMPORTANT: DO NOT overheat starting motor
during test.
F
6. Crank engine for three seconds with starting motor.
7. Record pressure reading for each cylinder.
G
H
Specifications:
Compression Pressure . . . . . . . . 2448 kPa (355 psi)
Maximum difference
between cylinders . . . . . . . . . . . . . . 490 kPa (71 psi)
Minimum cranking speed . . . . . . . . . . . . . . 250 rpm
2/9/00
I
M56359
3 - 21
SLOW IDLE ADJUSTMENT
DIESEL ENGINE
3. Check that throttle pedal rod is resting against front
panel at (I).
4. Pull rubber boot (H) down.
5. Loosen jam nut (F).
6. Turn adjusting nut (G) until there is enough slack in
cable so that when throttle pedal is depressed there
is a 2 mm gap between pedal rod and front panel
at (I) before throttle lever arm on governor begins to
move.
7. Tighten jam nut (F).
8. With throttle pedal released, throttle lever arm on
governor should be resting against slow idle stop
screw.
SLOW IDLE ADJUSTMENT
FAST IDLE ADJUSTMENT
ATTENTION!
Fast idle is adjusted to comply with EPA
emissions
requirements
by
the
engine
manufacturer. Fast idle can only be adjusted by
an EPA authorized diesel service center.
Tampering with the fast idle adjustment by
unauthorized personnel will void the engine
warranty and result in fines.
Reason:
Reason:
To achieve proper slow idle rpm setting. Provides
adequate rpm to keep engine running smoothly without
stalling.
To verify proper fast idle speed setting. This checks that
the engine is running at proper rpm’s for peak
performance.
Equipment:
• JT05719 Digital Tachometer or JT07270 Digital
Pulse Tachometer
Equipment:
• JT05719 Hand Held Digital Tachometer or JT07270
Digital Pulse Tachometer.
Procedure:
1. Place a small piece of reflective tape on crankshaft
pulley.
Procedure:
1. Start engine and run for 5 minutes.
2. Visually check that injection pump throttle lever is
against slow idle stop screw. If not against slow idle
stop screw, adjust throttle cable (see Throttle Cable
Adjustment in this section).
3. Use JT05719 Hand Held Digital Tachometer or
JT07270 Digital Pulse Tachometer to check engine
speed at flywheel.
Specifications:
Slow Idle Speed . . . . . . . . . . . . . . . . . 1000 ± 50 rpm
:
NOTE:
Make sure air cleaner is clean and not
restricted. Replace air cleaner element as
needed.
2. Start engine and run for 5 minutes to obtain normal
operating temperature.
3. Move throttle lever to fast idle position.
4. Use JT05719 Digital Tachometer or JT07270 Digital
Pulse Tachometer to check engine speed at
crankshaft pulley.
Specifications:
Fast Idle Speed. . . . . . . . . . . . . . . . . . 3550 ± 25 rpm
A
B
Results:
M76724
• If fast idle speed does not meet specifications,
adjust throttle cable as needed. See “THROTTLE
CABLE ADJUSTMENT” on page 21.
• If engine still does not meet fast idle speed
specifications, have injection pump inspected by
an EPA authorized diesel service (ADS) center.
• If slow idle rpm is not according to specifications,
loosen nut (A) and turn slow idle stop screw (B).
After adjustment, tighten nut.
3 - 22
2/9/00
VALVE CLEARANCE, CHECK AND ADJUSTMENT
DIESEL ENGINE
VALVE CLEARANCE, CHECK AND
ADJUSTMENT
Reason:
To be sure valves are fully opening at the correct time,
but not remaining open too long or wearing valve train
unnecessarily.
3. Rotate flywheel counterclockwise (turn towards front
of vehicle) until No. 1 cylinder TDC mark (B) on
flywheel is visible in notch of flywheel guard.
NOTE: There are two marks on flywheel for each cylinder, approximately 30 mm (1.2 in.) apart. The
mark with the cylinder number stamped next to
it is the mark for finding TDC for that cylinder.
4. Try to move intake and exhaust rocker arms and/or
push rods for No. 1 cylinder:
• If rocker arm and push rod are loose, the piston is
at TDC on the compression stroke and you may
proceed to step 5.
• If rocker arms and/or push rods are not loose,
rotate flywheel one revolution (360°), and recheck
rocker arm and push rods.
Equipment:
• Feeler Gauge
• Open End Wrench
• Flat Blade Screwdriver
Procedure:
1. Remove rocker arm cover.
Cylinder Number
NOTE: “Top Dead Center (TDC)” is when the piston is
at it’s highest point of travel in the cylinder on
either the compression or exhaust stroke.
No. 1 cylinder is the closest to the flywheel.
A
E
1
Left Side
(Clutch End)
I
E
2
I
No. 1 Piston at TDC
Compression Stroke
E
3
I
Right Side
M82327A
5. Measure and adjust valve clearance only on the four
valves indicated above with black arrows while No.
1 piston is at TDC on compression stroke.
B
MX0552
D
2. Locate the notched out area (A) on the flywheel
guard near left rear engine mount isolator bracket.
C
A
MX0553
1
B
2/9/00
3 - 23
VALVE LIFT CHECK
DIESEL ENGINE
VALVE LIFT CHECK
Reason:
To test for excessive wear on camshaft lobes, cam
followers, bent push rods, worn rocker arms, or worn
valve stems.
Equipment:
• Dial Indicator
T6105BF
6. To adjust valves, loosen lock nut (C) and turn
adjusting screw (D) until 0.20 mm (0.008 in.) feeler
gauge can be inserted between rocker arm and
valve cap. Hold adjusting screw while tightening
lock nut.
7. Recheck valve clearance after tightening lock nut.
Procedure:
1. Adjust valve clearance. See “VALVE CLEARANCE,
CHECK AND ADJUSTMENT” on page 23.
2. Remove rocker arm cover. See “ROCKER ARM
COVER REMOVAL AND INSTALLATION” on
page 36.
MX0554
Normal
Not Normal
8. Check that valve cap on end of valve stem remained
seated on valve and inside valve spring retainer.
9. Turn crankshaft pulley one revolution (360°). This
puts the piston in No. 1 cylinder at TDC on the
exhaust stroke.
Cylinder Number
E
1
I
E
2
I
E
3
I
T6333DT
3. Fasten dial indicator to engine and position indicator
tip on valve retainer. Valve must be fully closed and
rocker arm must move freely.
4. Zero the dial indicator.
5. Rotate crankshaft towards front of vehicle while
observing dial indicator as valve is moved to the full
open (down) position. Valve lift (intake and exhaust)
should be 7.5 mm (0.300 in.).
6. Repeat for each valve.
Results:
Left Side
(Clutch End)
No. 1 Piston at TDC
Exhaust Stroke
Right Side
M82327A
• If valve lift is less than specification, remove and
inspect camshaft, camshaft followers, push rods,
and/or rocker arms for wear or damage.
10. Measure and adjust valve clearance on the last two
valves (black arrows) with No. 1 piston at TDC of
exhaust stroke.
3 - 24
2/9/00
FUEL INJECTION NOZZLE TEST
DIESEL ENGINE
FUEL INJECTION NOZZLE TEST
c
CAUTION
Escaping fluid under pressure can penetrate the
skin causing serious injury. Avoid the hazard by
relieving
pressure
before
disconnecting
hydraulic or other lines. Tighten all connections
before applying pressure. Search for leaks with a
piece of cardboard. Protect hands and body from
high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury should reference a
knowledgable source. Such information is
available from the Deere & Company Medical
Department in Moline, Illinois, U.S.A.
Fuel Injection Nozzle Tester using parts from
D01110AA Adapter Set and 23622 Straight
Adapter.
IMPORTANT: Use clean filtered diesel fuel when
testing injection nozzles to get best test results.
Procedure 1:
Test fuel injection nozzle opening pressure following
the Nozzle Tester manufacturer's instructions.
Specifications:
Fuel Injection Nozzle Opening
Pressure . . . . . . . 11722 ± 480 kPa (1700 ± 70 psi)
Results:
• If pressure reading does not meet specification,
disassemble injection nozzle and inspect nozzle
assembly for contamination or stuck valve. If
necessary, add or remove shims to change
opening pressure.
Reason:
To determine opening pressure, leakage, chatter and
spray pattern of the fuel injection nozzle.
Equipment:
• D01109AA Diesel Fuel Injection Nozzle Tester
• D01110AA Adapter Set
• 23622 Straight Adapter
• Container
Procedure 2:
Test fuel injection nozzle leakage following the Nozzle
Tester manufacturer's instructions.
1. Dry nozzle completely using a lint-free cloth.
2. Pressurize nozzle to 11032 kPa (1600 psi).
3. Watch for leakage from nozzle spray orifice.
Leakage time should be a minimum of 10 seconds.
Results:
Connections:
• If leakage time does not meet specification,
disassemble injection nozzle and inspect nozzle
assembly for contamination. Inspect valve seating
surface. Replace nozzle assembly if necessary.
Procedure 3:
Test fuel injection nozzle chatter and spray pattern
following the Nozzle Tester manufacturer's instructions.
1. Pressurize nozzle to 11722 ± 480 kPa (1700 ± 70
psi).
2. Listen for “chatter” sound and watch spray pattern.
Specifications:
Slow Hand
Lever Movement . . . . . . . . . . . . . . . Chatter Sound
Slow Hand
Lever Movement . . . . . Fine Stream Spray Pattern
Fast Hand Lever
Movement . . . . . . . . Fine Atomized Spray Pattern
1. Connect fuel injection nozzle to D01109AA Diesel
2/9/00
3 - 25
FUEL INJECTION PUMP STATIC TIMING ADJUSTMENT
DIESEL ENGINE
FUEL INJECTION PUMP STATIC
TIMING ADJUSTMENT
Reason:
To make sure that injection pump timing is set so fuel is
delivered to the injector nozzles and combustion
cylinders at the correct time of combustion cycle.
Correct
Equipment:
• End Wrenches
Procedure:
ATTENTION!
Poor
M82121A
Results:
• If nozzle chatter or spray pattern does not meet
specifications, disassemble injection nozzle and
inspect nozzle assembly for contamination. See
“Repair:” on page 72. Inspect valve seating
surface. Replace nozzle assembly if necessary.
• If there is excessive difference in spray angle or
injection angle, incomplete atomization or sluggish
starting/stopping of injection, disassemble injection
nozzle and inspect nozzle assembly for
contamination. See Fuel Injection Nozzle Repair
section. Replace nozzle assembly if necessary.
DO NOT attempt to adjust the fuel injection timing
unless you are a factory trained technician with
authorization to service CARB/EPA Certified
Emissions engines.
IMPORTANT: Injection pump timing will remain
correct unless a major engine failure occurs.
Once timing is set, it will normally not change
during the life of the engine, unless it was
tampered with. Check and adjust timing only as
the last option. Check fuel, fuel supply system,
injectors, air intake system and cylinder
compression before continuing.
1. Park vehicle on level surface, lock park brake,
transmission in neutral, stop engine, key switch in
OFF position.
2. Remove cargo box to allow access to fuel injection
pump.
3. Remove muffler from exhaust manifold. See
“MUFFLER REMOVAL AND INSTALLATION” on
page 36.
4. Remove air cleaner assembly.
A
M76727
3 - 26
2/9/00
FUEL INJECTION PUMP STATIC TIMING ADJUSTMENT
DIESEL ENGINE
5. Locate the index mark (A) stamped into the engine
back plate.
NOTE: Reflective tape is not needed using JT07270
Digital Pulse Tachometer.
9. Alternatively, timing mark can be scribed into
flywheel in line with 14° BTDC mark so it can be
seen as it passes under index mark on guard.
Engine Back Plate
Timing Fuel Injection Pump:
A
Extend
Mark
To Edge
B
View From Top Of Flywheel
6. Extend the index mark from it’s location on the
engine back plate to the outside edge of the
flywheel guard (B) using a square or similar tool.
10. The timing procedure must be performed with the
fuel shutoff solenoid pulled in and holding open so
a steady supply of fuel may be available to the
injection pump. The key switch must be left ON
during test to hold-in fuel solenoid. To pull solenoid
in, the key switch must be momentary turned to the
START position and an audible click heard from
governor housing. DO NOT start engine during
test.
11. Turn crankshaft (by hand) until the No. 3 cylinder
14° BTDC timing mark is about 1 inch to the rear of
the index mark on the flywheel guard.
NOTE:
3
14° BTDC
TDC
7. Rotate flywheel until the No. 3 timing mark is
located. (The marks are not visible except where
flywheel guard is notched on rear of engine, and
between starting motor and guard.) There are two
marks side-by-side. One is stamped with the
number 3 and is top-dead-center (TDC) for cylinder
No.3. The other mark is 14° before top-dead-center
(BTDC) and is the mark to be used to set the timing
of the injection pump.
• Use the No. 3 timing mark to set timing of No. 1
cylinder.
No. 3 Timing Mark
12. Remove the number one fuel injection line from the
injector pump to injector.
13. Use manual pump lever located on fuel transfer
pump to keep a continuous supply of fuel to
injection pump while performing timing procedure.
14. While fuel transfer pump lever is being pumped,
slowly turn flywheel counterclockwise until timing
mark on flywheel approaches index mark on
flywheel guard. Watch fuel level in fitting on top of
injection pump where No. 1 injector line was
removed. At exact moment when fuel level begins
to rise in fitting, flywheel timing mark should be
lined up with index mark on flywheel guard.
NOTE: If the fuel level does not change, the number
one piston may be on TDC of the exhaust
stroke instead of compression stroke. Turn flywheel one revolution and repeat Steps 8 & 9.
Check that fuel shutoff solenoid is pulled in and
battery is up to full charge.
A
Reflective
Tape
The crankshaft turns counterclockwise (as
viewed from the transmission drive belt/clutch
end). The number one cylinder is closest to the
drive belt/clutch on the left side of the vehicle.
M76789
15. Turn key switch OFF.
8. Attach reflective tape to flywheel with edge of tape
aligned with 14° before top dead center (BTDC)
mark. Place tape so it can be seen on flywheel as it
passes extended index mark (A) on flywheel guard.
2/9/00
3 - 27
WATER PUMP/ALTERNATOR DRIVE BELT ADJUSTMENT
Specifications:
Injection Pump Timing . . . . . . . . . . . . . . . 14° BTDC
Engine Crankshaft Position . . . . . . . . No.1 Cylinder
Distance Outer Surface Of Flywheel Travels
Per 1° Of Rotation . . . . . . . . . 2.62 mm (0.100 in.)
Timing Change per 0.1 mm Shim Thickness. . . . . 2°
DIESEL ENGINE
WATER PUMP/ALTERNATOR DRIVE
BELT ADJUSTMENT
Reason:
To keep proper tension on belt to drive water pump and
alternator. To prevent shortened belt and bearing life.
Results:
Equipment:
• If Timing Is Not According To Specifications:
• Remove injection pump and shims.
• Increase shim pack thickness to retard injector
timing, decrease thickness to advance timing.
• Install injection pump and tighten nuts to 20 N•m
(180 lb-in.)
• Recheck timing.
• JDG529 or JDST28 Belt Tension Gauge
• Straight Edge
Procedure:
• If Engine Performance Is Poor:
• Check air cleaners, fuel filter, fuel supply, injectors
and cylinder compression before removing pump
for service. Check all timing gears for wear. Retest
performance.
• If Performance Did Not Change:
• Have pump tested by an Authorized Diesel Service
(ADS) Center. When reinstalling injection pump,
use same thickness of shim pack removed. If shim
pack thickness is unknown or new pump is
installed, replace with 0.8 mm (0.031 in.) shim
pack thickness.
M54014
1. Remove belt cover.
2. Check belt tension between water pump and
alternator using Belt Tension Gauge and a straight
edge.
• If Timing Is Ok:
• Install number one injection line.
• Install muffler, air cleaner assembly, and cargo box.
Specifications:
Applied Force . . . . . . . . . . . . . . . . . 98 N (22 lb-force)
Deflection . . . . . . . . . . . . . . 10 - 15 mm (0.4 - 0.6 in.)
Results:
• If deflection is not within specifications:
• Loosen top and bottom alternator mounting cap
screws/nuts.
• Apply force only to right side of alternator housing
(near the belt) until tension is correct.
• Tighten alternator mounting hardware.
• Replace belt cover.
3 - 28
2/9/00
THERMOSTAT TEST
DIESEL ENGINE
THERMOSTAT TEST
• If closing action is not smooth and slow, replace
thermostat.
• Install thermostat in block with air bleed screw at 12
o’clock (top) position.
Reason:
To determine opening temperature of thermostat.
RADIATOR BUBBLE TEST
Equipment:
• Thermometer
• Glass Container
• Heating Unit
Reason:
To determine if compression pressure is leaking from
combustion cylinder into water jacket of cylinder block.
Procedure:
c
Equipment:
• JDG472 Adapter
CAUTION
Procedure:
DO NOT allow thermostat or thermometer to rest
against the side or bottom of glass container
when heating water. Either may rupture if
overheated.
1. Suspend thermostat and a thermometer in a
container of water.
2. Heat and stir the water. Observe opening action of
thermometer and compare temperatures with
specifications.
3. Remove thermostat and observe its closing action
as it cools.
1. With coolant at proper level and radiator cap tight,
run engine for 5 minutes to bring to operating
temperature.
2. Remove cap from recovery tank.
3. Check for bubbles coming from overflow hose at
bottom of tank.
If bubbles are present, isolate source of compression
leak:
• Remove injection nozzles.
• Install JDG472 Adapter in injection port of cylinder
to be tested.
• Move piston to bottom of stroke with intake and
exhaust valves closed.
• Connect hose from compressed air source to
adapter. Do not exceed rated pressure of hoses
and tools being used. Do not exceed 355 psi
pressure cylinder pressure.
• Check for bubbles in coolant recovery tank, or air
escaping from muffler, air cleaner or oil fill opening.
• Repeat for each cylinder.
Results:
• If bubbles are present:
M82122A
• Check for cracks in cylinder head and block. Check
for damaged head gasket.
• If air escapes from muffler:
Specifications:
• Check for worn exhaust valve.
Begin Opening . . . . . . . . . . . . . . . . . . . 71° C (160° F)
Fully Open. . . . . . . . . . . . . . . . . . . . . . . 85° C (184° F)
Minimum Lift Height. . . . . . . . . . . . . 8 mm (0.310 in.)
• If air escapes from air cleaner:
Results:
• If air escapes from engine oil fill:
• If thermostat does not open according to
specifications, replace.
2/9/00
• Check for worn intake valve.
• Check for worn piston rings.
3 - 29
COOLING SYSTEM PRESSURE TEST
COOLING SYSTEM PRESSURE
TEST
Reason:
DIESEL ENGINE
• If leakage continues after all external leaks have
been stopped, a defective head gasket, cracked
block, or cylinder head may be the cause.
RADIATOR CAP PRESSURE TEST
To inspect cooling system for leaks.
Reason:
Equipment:
• D05104ST Cooling System Pressure Pump
• JDG692 Radiator Pressure Test Kit (Adapters)
To test radiator cap spring and seal for correct opening
pressure range.
Equipment:
Procedure:
c
• D05104ST Cooling System Pressure Pump
• JDG692 Radiator Pressure Test Kit (Adapters)
CAUTION
Procedure:
Coolant may be above boiling temperature and
under pressure in cooling system. DO NOT
remove pressure cap when system is hot.
Escaping steam will burn unprotected skin.
Always wear protective clothing and goggles
when servicing cooling system.
1. Install radiator cap on appropriate adapter
2. Attach adapter to D05104ST pressure pump.
3. Apply pressure. Pressure valve in cap should open
according to specifications.
T6333AX
T6333AW
Specifications:
1. Check cooling system is cool and squeeze top
radiator hose to check system pressure has
dropped.
2. Remove cap. Top off coolant if low. Attach cooling
system pressure pump to hose.
3. Pressurize system with tester to 15 psi.
4. Check for leaks throughout cooling system.
Valve Opening Pressure . . . 83 - 96 kPa (12 - 14 psi)
Results:
• If cap leaks, relieve pressure and re-tighten cap.
Test again. Replace cap if pressure is not within
specification.
Specifications:
Maximum Pressure . . . . . . . . . . . . . 117 kPa (17 psi)
Minimum Pressure
after 15 Seconds . . . . . . . . . . . . . . 90 kPa (13 psi)
Results:
• Pressure should hold to specifications. If pressure
decreases, check for leaks. Repair leaks or
replace parts as necessary.
3 - 30
2/9/00
ENGINE OIL PRESSURE TEST
DIESEL ENGINE
ENGINE OIL PRESSURE TEST
FUEL TRANSFER PUMP PRESSURE
TEST
Reason:
To determine if engine bearings or lubrication system
components are worn.
Reason:
Equipment:
Equipment:
• JT03017 Hose Assembly
• JT05577 Pressure Gauge (100 psi)
• JT03349 Connector
To determine transfer pump operating pressure.
• JDG356 Fuel Pump Pressure Test Kit
Procedure:
1. Park vehicle in neutral, engine OFF, and park brake
ON.
A
A
M76710
2. Remove wire to oil pressure switch.
3. Unscrew oil pressure switch (A) from block.
4. Install JT03349 Connector into block.
5. Connect Hose Assembly and Pressure Gauge.
IMPORTANT:
Stop running engine if no oil
pressure present.
Fuel Filter
M82145B
M76723
Procedure:
1. Disconnect transfer pump-to-filter hose (A).
2. Install hose coupler on gauge to transfer pump hose.
3. Use manual pump lever located on fuel transfer
pump to pressurize test gauge.
Specifications:
Minimum Fuel Pressure. . . . . . . . . . 29 kPa (4.3 psi).
6. Start engine. If pressure reading is below 69 kPa (10
psi), STOP ENGINE.
7. Run engine approximately five minutes to heat oil,
then check oil pressure at fast idle.
Results:
• If pressure is below specification, replace fuel
transfer pump.
Specifications:
Fast Idle Speed. . . . . . . . . . . . . . . . . . 3550 ± 25 rpm
Engine Oil Pressure . . . . . . 343 ± 49 kPa (50 ± 7 psi)
Results:
• If oil pressure is not within specifications, inspect oil
pressure regulating valve parts for wear or
damage. Add or remove shims as necessary. (See
Lubrication System in this section.)
• If oil pressure does not increase, see “Engine Has
Low Oil Pressure” in Diagnosis group.
2/9/00
3 - 31
FUEL DRAIN BACK TEST
DIESEL ENGINE
FUEL DRAIN BACK TEST
Reason:
Determines if air is entering the fuel system at
connections, allowing fuel to siphon back to tank.
Procedure:
1. Disconnect fuel supply line and return line at fuel
tank.
2. Drain all fuel from the system, including fuel transfer
pump, injection pump and filters.
3. Plug end of fuel return hose.
4. Pressurize fuel system at fuel supply line, to a
maximum pressure of 103 kPa (15 psi).
5. Apply liquid soap and water solution to all joints and
connections in the fuel system and inspect for
leaks.
Results:
• Find leaks and repair or replace parts as
necessary.
M82124
3. Put large plastic bag into and over end of primary
filter element. Install primary filter element and
cover.
NOTE:
Do not start engine with plastic bag in air
cleaner.
4. Pressurize the air intake system between 34 - 69
kPa (5 - 10 psi). If air intake system cannot be
pressurized, turn engine slightly to close valves.
5. Spray soap solution over all connections from air
cleaner to intake manifold and check for leaks.
FUEL SYSTEM BLEEDING
The diesel engine incorporates a self bleeding fuel
system. Manually bleeding the fuel system is usually
not necessary after opening the fuel system. A primer
lever is provided on the fuel transfer pump to fill the fuel
bowl should the system be completely drained and will
not self-prime.
Results:
• Find leaks and repair or replace parts as
necessary.
AIR FILTER/AIR RESTRICTION
INDICATOR TESTS
AIR INTAKE SYSTEM LEAKAGE
TEST
Reason:
Reason:
Check operation of indicator and check air intake
system for leaks, restrictions, or obstructions.
To check for leaks in air intake system which allow
unfiltered air to bypass air cleaner.
Procedure (Normal Operation):
Equipment:
• Air Pressure Regulator
1. Park machine on level surface, shift transmission to
NEUTRAL, and LOCK park brake.
2. Run engine at FAST idle.
Procedure:
B
1. Connect air pressure regulator to manifold using
hose and fitting from air cleaner.
2. Remove air cleaner cover and primary filter element.
C
A
M76782
3 - 32
2/9/00
AIR FILTER/AIR RESTRICTION INDICATOR TESTS
DIESEL ENGINE
3. Check air restriction indicator yellow marker (A).
4. Press reset button (C) and recheck.
5. Stop engine.
7. Remove primary filter and STOP engine.
8. Push indicator reset button (C), indicator should
drop to bottom of scale.
Results:
Specifications:
• Normal maximum vacuum 2.5 kPa (10 in. H2O)
vacuum (with clean filters).
NOTE: Normal vacuum is between 2.5 – 6.25 kPa (10
– 25 in. H2O), and indicates a partially dirty air
filter. DO NOT change air filter under this condition.
If yellow marker DID NOT move or moved very little,
check for:
• loose or damaged hose clamps
• air leaks in air filter to intake manifold hose
• air leaks where air filter seals primary filter
• air leaks in intake manifold
• air leaks at indicator mounting threads
• cracked indicator housing or diaphragm.
Results:
If vacuum is 6.25 kPa (25 in. H2O) or higher:
N
• replace primary filter
• reset air restrictor (C)
If vacuum is still greater than 6.25 kPa (25 in. H2O):
M
• replace secondary filter
Procedure (Simulated Excess Restriction)
M76784
1. Unsnap spring clips (D) and remove filter cover (E)
from filter housing.
9. While air filter assembly is disconnected, remove
seats and plastic shroud (M) to check frame air
intake channel (N) for debris or obstructions.
O
P
D
P
O
M76785
E
M76783
2. Remove large secondary filter and set aside.
3. Remove smaller primary filter and keep nearby the
air filter housing.
4. Set park brake and start and run engine at SLOW
idle.
5. Turn primary filter so closed rubber end is inserted
first into the air filter housing (opposite normal
installation).
6. Watch air restriction indicator yellow marker (A) and
(B). It should move into the red area — 4.75 kPa
(19 in. H2O) vacuum.
2/9/00
10. Be sure shipping cap screws (O) and black plugs
(P) are installed in frame.
NOTE: Use compressed air to remove dust and debris
from inside channel. Always remove air
cleaner-to-frame hose and cover air inlet to air
cleaner before using compressed air to blow
channel clear.
3 - 33
REPAIR
DIESEL ENGINE
REPAIR
FRONT
Q
ENGINE REMOVAL AND
INSTALLATION
AIR FLOW
Removal:
R
S
T
(TOP VIEW)
M55741A
11. Install frame hose (Q) so angled edge (R) faces to
front of machine and tip (S) just touches inside
edge of frame (T) without being bent.
1. Disconnect battery negative (–) cable.
2. Disconnect battery positive (+) cable.
3. Remove cargo box.
4. Remove air cleaner assembly.
5. Remove drive belt.
6. Drain cooling system, lower block, and hose.
7. Remove coolant hose clamps and remove radiator
hoses.
8. Shut off fuel valve at tank (A).
A
M76722
9. Mark and remove fuel lines.
A
B
C
D
D
B
A
C
M76682
10. Mark and remove wiring harness connections.
3 - 34
2/9/00
ENGINE REMOVAL AND INSTALLATION
DIESEL ENGINE
11. Remove grounding wire lead cap screw, remove
battery negative cable and ground wire lead.
12. Remove throttle cable.
13. Remove mounting cap screws and lock nuts from
motor mounts.
14. Remove engine with safe lifting device and lifting
straps.
15. Remove drive clutch.
Installation:
Installation is done in reverse order of removal.
1. Place engine in frame, loosely install four main
mounting cap screws through main isolators and
engine mounting brackets.
2. Lift engine 5 - 10 mm (0.2 - 0.4 in.) to release strain
on isolators.
3. Lower engine fully onto isolators (A). Tighten four
main mounting cap screws to 50 N•m (37 lb-ft)
MX0768
• Make sure closed end is seated completely over
bushing end at secondary clutch.
.
NOTE: The engine may need to be pushed toward the
driven clutch to allow the gauge to drop onto
the drive clutch shaft.
A
G
E
Fifth Isolator Bracket
M76746
F
4. Inspect spacer(s) removed with fifth isolator parts. If
spacers removed are good proceed to Step 8. If
spacer(s) are damaged or missing:
.
E
B
C
D
6. Insert snubber step gauge (E) into opening between
front surface of engine isolator bracket (F) and the
rear surface of the frame bracket (G).
• Identify which step on gauge is inserted into
opening to determine the number of spacer
washers to install.
7. Remove gauges from machine.
5. Place the closed end (B) of clutch center distance
gauge (C) over the end of the secondary clutch.
Position the open end (D) over the center shaft of
the primary clutch.
2/9/00
3 - 35
MUFFLER REMOVAL AND INSTALLATION
Metal Cup
DIESEL ENGINE
MUFFLER REMOVAL AND
INSTALLATION
Rubber Mount
Removal:
M76748
Bushing
8. Install fifth isolator parts in order shown.
• Assemble bushings and rubber mounts onto frame
bracket. The spacer(s), metal cup and one rubber
mounting are installed between the frame
mounting bracket and engine mounting bracket.
Install correct number spacer(s) as determined
using snubber gauge.
• Install fifth isolation mounting cap screw and nut.
Tighten fifth isolation mounting cap screw (I) to
37±7 N•m (27±5 lb-ft)
1. Allow muffler to cool, or wear protective gloves
before working on muffler.
2. Remove three nuts and lock washers holding muffler
flange to exhaust manifold.
3. Remove cap screw holding muffler to cylinder block
and remove muffler.
4. Inspect studs on exhaust manifold. Replace if worn.
Installation:
• Clean sealing surfaces of muffler flange and
exhaust manifold and replace gasket before
installation.
• Tighten mounting nuts to 28 N•m (240 lb-in.).
ROCKER ARM COVER REMOVAL
AND INSTALLATION
Removal:
Rubber Mount
B
Oil Filler Cap
H
O-Ring
O-Ring
B
Metal Cup
A
E
Rubber Mount
I
Spacer(s)
Gasket
M76770
Lock Washer
9. Connect all electrical wires.
10. Connect coolant hoses and fill cooling system. See
“COOLANT FILLING” on page 68.
11. If drained, fill engine with proper oil. Refer to
Specifications section. Engine oil capacity is
approximately 2.0 L (2.1 qt).
12. Install air cleaner assembly.
13. Install drive belt onto primary clutch. Install belt to
secondary clutch by rotating belt and clutch slowly
until belt slides onto clutch.
14. Prime fuel system by pumping lever on fuel transfer
pump until fuel filter bowl is full.
15. Adjust throttle cable. See “THROTTLE CABLE
ADJUSTMENT” on page 21.
16. Connect battery positive (+) cable and then
negative (–) cable.
17. Install cargo box.
3 - 36
Cap screw
Baffle Breather
Deflector
O-RIng Seal
M82004A
1. Remove crankcase breather tube from breather
fitting (A) on rocker cover.
2. Remove two special nuts (B) securing cover to
cylinder head.
3. Remove rocker cover.
NOTE: If cover has not been removed recently, it may
be necessary to lightly tap side of cover with
soft faced hammer.
2/9/00
ROCKER ARM
DIESEL ENGINE
4. Inspect O-ring seals for wear or damage. Replace if
necessary.
5. Disassemble breather baffle and clean all parts
thoroughly.
4. Install mounting nuts on rocker arm supports and
evenly tighten nuts to pull rocker assembly to head.
Tighten mounting nuts and cap screw to 26 N•m
(226 lb-in.).
5. Adjust valve clearance. See “VALVE CLEARANCE,
CHECK AND ADJUSTMENT” on page 23.
6. Install rocker arm cover. See “ROCKER ARM
COVER REMOVAL AND INSTALLATION” on
page 36.
Installation:
Installation is done in the reverse order of removal.
• Tighten nuts (B) to 18 N•m (160 lb-in.).
Inspection:
ROCKER ARM
1. Remove rocker arm cover and rocker arm.
2. Mark all parts before tear-down to aid assembly.
3. Remove end retaining rings and slide components
off of rocker shaft.
4. Remove set screw from center support. Remove
rocker shaft from center support.
Removal:
1. Remove rocker arm cover. See “ROCKER ARM
COVER REMOVAL AND INSTALLATION” on
page 36.
2. Remove two M8 rocker arm mounting nuts (end arm
supports) and one M8 cap screw (center support).
3. Pull rocker arm assembly straight up off of mounting
studs on cylinder head.
4. Inspect all parts for wear. See “Inspection:” on
page 37.
Measure Outer Diameter Of Rocker Arm Shaft:
Installation:
1. Be sure valve caps are in place on end of valve
stems before installing rocker arms
2. Align rocker arm supports with studs on cylinder
head. Align rockers with valve stems.
3. Install push rods in block and align into rocker arms.
M35262
Retaining
Ring
Rocker Arm Shaft
Mounting Nut
Nut
Adjusting Screw
Intake Valve Rocker Arm
Exhaust Valve Rocker Arm
Set Screw
Rocker Arm
Shaft Spring
Mounting
Nut
Rocker Arm Support (3)
Cap Screw
Valve Caps
M82257A
2/9/00
Push Rod
3 - 37
CYLINDER HEAD REMOVAL AND INSTALLATION
DIESEL ENGINE
Rocker Arm Shaft OD:
Push Rod Length:
Standard . . . . . . . 9.97 – 9.99 mm (0.392 – 0.393 in.)
Wear Limit. . . . . . . . . . . . . . . . . . 9.95 mm (0.392 in.)
Standard . . . . . . . . . 114 - 115 mm (4.488 - 4.528 in.)
Push Rod Bend:
Replace rocker arm shaft if diameter is less than wear
limit.
Measure Inside Diameter Of Rocker Arms &
Supports:
Wear Limit . . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.)
Replace push rod if not within specifications.
• Check the surface of the adjusting screw that
contacts the push rod for wear, replace push rod or
adjusting screw if worn.
• Check the rocker arm to valve stem cap contact
surface for wear. Replace rocker arm if worn.
Rocker Arm Assembly:
1. Clean all parts of varnish and oil.
2. Assemble rocker shaft into center support, aligning
set screw hole in support with hole in rocker shaft.
3. Be sure rocker arms are installed in same order as
removed.
CYLINDER HEAD REMOVAL AND
INSTALLATION
M82022A
Removal:
Rocker Arm and Shaft Support ID’s:
Standard . . . . . . 10.00 - 10.02 mm (0.394 - 0.395 in.)
Wear Limit. . . . . . . . . . . . . . . . . 10.09 mm (0.397 in.)
Clearance . . . . . . . . . . . . . . . . . . 0.14 mm (0.005 in.)
Replace rocker arms or supports if ID is more than
wear limit.
If shaft and support/arm clearance (support/arm ID
minus shaft OD) exceed wear limit, replace all parts.
Length
Measure Push Rod Length & Straightness:
Feeler
Gauge
M82023A
3 - 38
NOTE: Cylinder head may be removed with engine
installed in vehicle chassis. Engine removal will
allow easier access to cylinder head.
1. Park machine on level surface, transmission in
NEUTRAL, park brake ON, engine OFF.
2. Disconnect negative battery cable from battery.
3. Remove cargo box from chassis.
4. Remove air cleaner.
5. Remove engine if needed (see note above). See
“ENGINE REMOVAL AND INSTALLATION” on
page 34.
6. Remove muffler, rocker arm cover, rocker arm
assembly, push rods and valve caps.
7. Drain cooling system, cylinder block, and hoses.
8. Remove water pump.
9. Shut off fuel valve at tank and fuel filter.
10. Remove fuel injector lines from injection pump to
nozzles.
11. Remove fuel injection nozzles from cylinder head.
12. Remove glow plug wires and glow plugs from
cylinder head.
13. Remove electrical leads to coolant temperature
switch, fuel shutoff solenoid, engine ground, oil
pressure switch, battery positive cable, and any
alternator leads across top of cylinder head.
14. Loosen and remove cylinder head bolts.
2/9/00
DIESEL ENGINE
INTAKE MANIFOLD REMOVAL AND INSTALLATION
Exhaust Manifold Side
Cylinder Head Bolt
3
13
Flywheel
Side
9
11
6
1
7
2
5
12
10
8
4
14
Intake Manifold Side
M82260A
5. Tighten cylinder head bolts in the sequence shown,
in three stages of gradually-increasing torque.
Torque Sequence Specifications:
First . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (97 lb-in.)
Second . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.)
Final. . . . . . . . . . . . . . . . . . . . . . . . . . 34 N•m (25 lb-ft)
IMPORTANT: Cylinder head mounting bolts must
be checked for proper torque after 50 hours of
engine operation.
Oil Passage
M82259A
INTAKE MANIFOLD REMOVAL AND
INSTALLATION
Removal:
15. Using lift brackets and hoist, pull head straight up
from block.
16. Remove exhaust and intake manifolds. See
“INTAKE MANIFOLD REMOVAL AND
INSTALLATION” on page 39.
17. Disassemble and inspect cylinder head and valves.
See “CYLINDER HEAD RECONDITION” on
page 40.
Installation:
1. Clean top of cylinder block and check for flatness.
2. Place new cylinder head gasket on block with oil
passage lined up with oil port in block.
IMPORTANT:
Oil passage in gasket must be
located over oil passage in cylinder block.
3. Set cylinder head on gasket.
NOTE: Dip cylinder head bolt in clean oil before installing.
Gasket
Cap Screw
M82269A
1. Remove cylinder head. See “CYLINDER HEAD
REMOVAL AND INSTALLATION” on page 38.
2. Remove four M6 x 20 intake manifold mounting cap
screws.
3. Remove gasket and clean mating surfaces. Check
flange for flatness with straight edge.
Installation:
• Install new gasket.
• Tighten mounting cap screws to 11 N•m (97 lb-in.).
• Tighten muffler mounting nuts to 28 N•m (240 lbin.).
4. Install all cylinder head bolts and start all threads
before tightening any one bolt.
2/9/00
3 - 39
EXHAUST MANIFOLD REMOVAL AND INSTALLATION
DIESEL ENGINE
EXHAUST MANIFOLD REMOVAL
AND INSTALLATION
Collet Halves (12)
Valve Spring (6)
Removal:
1. Remove muffler and gasket. See “MUFFLER
REMOVAL AND INSTALLATION” on page 36.
2. Remove four cap screws and two flange nuts holding
manifold to cylinder head.
Rocker Arm
Assembly &
Cover
Mounting Stud
Valve
Guides (6)
Retainer (6)
Stem Seal (6)
Exhaust
Mounting
Stud (2)
Mounting Nuts
Cap Screw
M6 x 70
Flange Nut
M6
Lifting
Bracket
Lifting
Bracket
Gasket
Valve Seat
Exhaust Valve
Intake Valve
M82261A
M76798
Cap Screw
M6 x 40
Installation:
• Tighten all cap screws to 11 N•m (97 lb-in.)
• Tighten muffler mounting nuts to 28 N•m (240 lbin.)
CYLINDER HEAD RECONDITION
Special Or Essential Tools
NOTE: Order tools according to information given in
the U.S. SERVICE-GARD™ Catalog or in the
European Microfiche Tool Catalog (MTC).
1. Compress valve springs using JDE138 valve spring
compressor
NOTE: It may be necessary to tap on valve spring
retainer while initially operating compressor to
break retainer free from valve stem.
2. Remove collet halves from retainer.
3. Slowly release compressor and valve spring.
4. Remove valve spring, stem seal, and valve from
head.
5. Valve guides and seats are press fit. Remove guides
only if replacement is necessary.
6. Inspect all parts for wear or damage. Clean all
carbon deposits and measure all parts for proper
clearances.
Assembly:
• JDE138 Valve Spring Compressor
• JDE504 Valve Guide Driver
IMPORTANT: Do not reuse stem seals if removed.
Used seals will leak.
Disassembly:
1. Apply clean engine oil on intake and exhaust valve
stems during assembly.
2. Install springs with smaller pitch end or paint mark
toward cylinder head.
NOTE:
3 - 40
If new valves are installed, measure valve
recession. See “Valve Recession Specifications:” on page 42.
2/9/00
CYLINDER HEAD RECONDITION
DIESEL ENGINE
3. Use valve spring compressor to compress spring
and retainer, and install collet as removed.
4. After each valve has been assembled, tap on top of
valve stem with a plastic hammer to seat retainer.
Inspection/Replacement:
Valve Seat Width
Before inspection, thoroughly clean all components of
carbon or dirt.
Cylinder Head:
• Measure cylinder head flatness. Place a straightedge along each of the four sides and each
diagonal. Measure clearance between straight
edge and combustion surface with a feeler gauge.
M82029A
Valve Seat Width Specifications:
Straight-Edge
Feeler Gauge
Intake Valve
Standard . . . . . . . . . . . . . . . . .
Wear Limit . . . . . . . . . . . . . . . .
Exhaust Valve
Standard . . . . . . . . . . . . . . . . .
Wear Limit . . . . . . . . . . . . . . . .
1.15 mm (0.045 in.)
1.65 mm (0.065 in.)
1.41 mm (0.056 in.)
1.91 mm (0.075 in.)
If necessary, grind valve seats to meet specifications.
See GRIND VALVE SEATS procedure.
M82028A
Intake and Exhaust Valves:
Cylinder Head Distortion:
Standard . . . . . . . . . . . . . 0.05 mm (0.002 in.) or less
Wear Limit. . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
If distortion exceeds the wear limit, resurface or replace
cylinder head. Remove only enough metal to make
cylinder head flat; but do not remove more than 0.20
mm (0.008 in.).
If Cylinder Head Was Resurfaced:
• Measure piston-to-cylinder head clearance. See
“PISTON-TO-CYLINDER HEAD CLEARANCE” on
page 55.
• Measure valve recession. See procedure in this
group.
• Measure valve seat width. See procedure in this
group.
M35307
1. Check valve for out-of-round, bent or warped
condition using a valve inspection center. Replace
valve if necessary.
Valve
Face
Margin
Valve Face
Angle
Exhaust 45°
Intake 30°
M82030A
2/9/00
3 - 41
CYLINDER HEAD RECONDITION
DIESEL ENGINE
• If valve faces are worn, burned or pitted, grind
valves to proper face angle. If valve face margin is
less than 0.51 mm (0.020 in.) after grinding,
replace valve.
Valve Recession
Cylinder Head
A
B
Depth Gauge
M82031A
2. Measure valve stem diameter at two locations
shown. Replace valve if measurement is less than
wear limit.
Valve Stem Specifications:
Valve Stem OD Measurement Locations
Location Distance A. . . . . . . . . . 20 mm (0.787 in.)
Location Distance B. . . . . . . . . . 40 mm (1.575 in.)
Intake Valve Stem OD . . . . . . . . . . . . . . . . . . . . . . . .
Standard . . . . 5.46 - 5.48 mm (0.2149 - 0.2157 in.)
Wear Limit . . . . . . . . . . . . . . . 5.40 mm (0.2126 in.)
Exhaust Valve Stem OD
Standard . . . . 5.44 - 5.46 mm (0.2142 - 0.2149 in.)
Wear Limit . . . . . . . . . . . . . . . 5.40 mm (0.2126 in.)
M82032A
3. Measure valve recession using a depth gauge.
Replace valve or cylinder head if measurement
exceeds specifications.
Valve Recession Specifications:
Intake Valve. . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
Exhaust Valve . . . . . . . . . . . . . . . 0.85 mm (0.033 in.)
Valve Guides:
1. Clean valve guides using a valve guide brush.
2. Measure valve guide inside diameter.
Valve Guide ID:
Standard . . . . . . . . 5.50 - 5.52 mm (0.216 - 0.217 in.)
Wear Limit . . . . . . . . . . . . . . . . . . 5.58 mm (0.220 in.)
• If diameter exceeds wear limit, knurl or replace
guide.
• If diameter is less than wear limit, determine guideto-stem clearance (guide diameter minus stem
diameter).
• If clearance exceeds 0.15 mm (0.006 in.) but is
less than 0.20 mm (0.008 in.), knurl valve guides
using a 5.50 mm Valve Guide Knurler.
• If clearance exceeds 0.20 mm (0.008 in.), replace
valve guide.
Valve Guide Replacement:
• Use JDG504 Valve Guide Driver.
3 - 42
2/9/00
CYLINDER HEAD RECONDITION
DIESEL ENGINE
Intake and exhaust valve guides are different. The
exhaust valve guide has one groove and the intake
valve guide has none.
1. Install valve guides with tapered ends down. Push
valve guides down until top of valve guides are set
to distance (A) from top of cylinder head.
A
Spring Inclination
Square Gauge
Free Length
M82193A
Valve Guide Height “A”: . . . . . . . . . 7 mm (0.276 in.)
2. Ream inside diameter of valve guides using 5.50
mm Valve Guide Reamer
M82035A
Spring Specifications:
Spring Free Length . . . . . . . . . . . . 28 mm (1.102 in.)
Maximum Spring Inclination . . . 0.80 mm (0.032 in.)
Valve Seat Grinding:
Valve Springs:
1. Measure spring free length. Replace spring if
measurement exceeds specification.
IMPORTANT: Valve seats should never be cut.
Cutting a valve seat can damage its sealing
surface, which may result in leaks or valve/seat
failure. Valve seats should be ground and
lapped.
NOTE: LIGHTLY grind valve seats for a few seconds
only to avoid excessive valve seat width.
1. Grind Intake valve seat using a 30° seat grinder, and
exhaust valve seat using a 45° seat grinder. Follow
tool manufacturers instructions.
M82034A
2. Measure spring inclination. Replace spring if
measurement exceeds specification.
Seat Grinder
M82039A
2/9/00
3 - 43
CRANKSHAFT REAR OIL SEAL
DIESEL ENGINE
2. Measure valve seat width after grinding.
Lower Seat
Surface 70°
1. Apply small amount of fine lapping compound to
face of valve.
Seat Width
Valve Face
Upper
Seat
Surface
Valve
Seat
M82030B
15°
Cylinder Head
M82040A
3. If seat is too wide after grinding, grind lower seat
surface using a 70° seat grinder until seat width is
close to specifications.
4. Grind upper seat surface using a 15° seat grinder
until seat width is narrowed to specifications.
5. If valve seats are ground, measure valve recession
and check contact pattern between the seat and
valve with bluing dye.
6. Lap valves. (See procedure in this group.)
NOTE: If valve recession exceeds maximum specifications or seats cannot be reconditioned, replace
valves and/or cylinder head.
Valve Lapping:
NOTE: Use a rubber type lapping tool for valves without a lapping tool groove slit.
2. Turn valve to lap valve to seat.
3. Lift valve from seat every 8 to 10 strokes. Lap until a
uniform ring appears around the surface of the
valve face.
4. Wash all parts in solvent to remove lapping
compound. Dry parts.
5. Check position of lap mark on valve face. Lap mark
must be on or near center of valve face.
CRANKSHAFT REAR OIL SEAL
NOTE: The crankshaft rear oil seal (on left side of vehicle) may be replaced with engine in chassis.
Engine In Chassis:
1. Remove muffler from exhaust manifold.
2. Remove drive belt from front transaxle pulley and
engine clutch.
3. Remove left rear axle chain master link and pull
chain from axle sprocket. Set chain out of way of
engine clutch.
4. Remove plastic plug from left side of engine drive
clutch.
5. Remove clutch retaining cap screw and remove
clutch with JDG813-1 clutch removal tool.
A
Lapping Tool
M76891
M82041A
If seat does not make proper contact, lap the valve into
the seat.
3 - 44
6. Remove four cap screws holding clutch stub shaft
(A) to flywheel. Remove stub shaft.
7. Remove five cap screws holding flywheel to
crankshaft.
2/9/00
CRANKSHAFT FRONT OIL SEAL
DIESEL ENGINE
8. Remove flywheel from alignment pin on crankshaft.
9. Carefully pry oil seal from oil seal case.
10. Replace oil seal using a driver set. Install seal with
lip toward cylinder block. Install seal flush with
surface of oil seal case.
NOTE: If oil seal has worn a groove in crankshaft at oil
seal contact point, seal can be installed 3 mm
(0.120 in.) farther into oil seal case.
14. Install seal case with form-in-place gasket sealer
on mating surfaces to block and to oil pan. Tighten
cap screws to specification.
15. Install new oil seal after oil seal case is installed.
16. Install flywheel and tighten five cap screws to
specification.
17. Install clutch stub shaft to flywheel and tighten four
cap screws to specification.
18. Install clutch on stub shaft and tighten clutch
mounting bolt to specification.
19. Replace clutch dust cap and drive chain master
link.
Oil Seal Case
Torque Specifications:
Seal Case-to-Block Cap Screws . . 11 N•m (96 lb-in.)
Flywheel Cap Screws. . . . . . . . . . . . 83 N•m (61 lb-ft)
Stub Shaft-to-Flywheel Cap Screws59 N•m (44 lb-ft)
Clutch Mounting Bolts. . . . . . . . . . . 55 N•m (40 lb-ft)
CRANKSHAFT FRONT OIL SEAL
Rear Oil Seal
M82279B
NOTE: The crankshaft front oil seal (on RH side) may
be replaced with engine in chassis.
Engine In Chassis:
Rear Oil Seal Case:
NOTE: It is not necessary to remove oil seal case to
remove oil seal.
Rear Oil Seal
Oil Seal Case
1. Remove alternator/water pump belt guard from front
of engine.
2. Loosen alternator mounts and remove belt.
3. Remove right rear axle chain master link and
remove chain from axle shaft sprocket. Set chain
out of the way of crankshaft pulley.
4. Remove crankshaft pulley mounting bolt and
washer.
5. Using a puller and two 7 x 40 mm cap screws
installed into tapped holes on crankshaft pulley,
remove crankshaft pulley from crankshaft.
Cap Screw (6)
M6 x 20
Cap Screw (2)
M82279A
11. Remove oil seat case-to-block cap screws, and two
oil pan-to-seal case cap screws.
12. Pry oil seal case from block and oil pan.
13. Clean all old gasket material from seal case and oil
pan.
2/9/00
Crankshaft
Front
Oil Seal
M82281A
3 - 45
TIMING GEAR COVER
DIESEL ENGINE
6. Carefully pry oil seal from timing cover.
7. Install new oil seal using a driver set. Install seal with
lip toward engine. Install seal flush with surface of
cover.
8. Coat lip of seal with clean engine oil.
9. Install crankshaft pulley on crankshaft, lining up pin
on crankshaft timing gear with hole in crankshaft
pulley. Tighten cap screw to 88 N•m (65 lb-ft).
10. Install alternator/water pump belt, belt cover, and
drive chain as removed.
10. Install crankshaft pulley and tighten cap screw to 88
N•m (65 lb-in.)
11. Adjust alternator drive belt tension. See “WATER
PUMP/ALTERNATOR DRIVE BELT
ADJUSTMENT” on page 28.
CAMSHAFT END PLAY CHECK
Reason:
TIMING GEAR COVER
To determine proper side clearance between camshaft
gear end journal and thrust plate.
Removal/Installation
Equipment:
1. Remove battery negative (–) cable.
2. Remove alternator/water pump belt cover.
3. Loosen alternator mounting screws and remove
alternator/water pump belt.
M6x50 (4)
• Dial Indicator
Procedure:
1. Remove timing gear cover. See “TIMING GEAR
COVER” on page 46.
M6x30 (5)
M6x18 (2)
M37512
M6x65 (6)
M6x40 (3)
4. Remove crankshaft pulley mounting bolt and
washer.
5. Using a puller and two 7 x 40 mm cap screws
installed into tapped holes on crankshaft pulley,
remove crankshaft pulley from crankshaft.
NOTE: It is not necessary to remove end cover or end
cover o-ring to remove timing gear cover.
2. Fasten dial indicator to engine and position indicator
tip on end of camshaft.
3. Push camshaft toward the rear as far as possible.
4. Zero the dial indicator.
5. Pull camshaft forward as far as possible.
Clearance Specifications:
Standard . . . . . . . . 0.05 - 0.20 mm (0.002 - 0.008 in.)
Wear Limit . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
Results:
6. Remove mounting cap screws and timing gear
cover.
7. Clean all old gasket material from timing cover and
timing cover housing on block.
8. Apply John Deere Form-In-Place Gasket Sealer to
timing cover prior to installation
9. Tighten all cover mounting cap screws to 9 N•m
(78 lb-in.)
3 - 46
• If end play exceeds specification, remove camshaft
and replace thrust plate. See “CAMSHAFT” on
page 49.
2/9/00
DIESEL ENGINE
TIMING GEAR BACKLASH CHECK
TIMING GEAR BACKLASH CHECK
Inspection/Replacement procedures.)
Reason:
Installation:
To check for wear between meshing gears, resulting in
excessive noise and poor engine performance.
Installation is done in the reverse order of removal.
Equipment:
Snap Ring
• Dial Indicator
Procedure:
1. Place dial indicator magnetic base on cylinder block
with tip of indicator on tooth of gear being
measured.
2. Holding opposite gear stationary, move measured
gear back and forth while measuring backlash
between meshing gears.
Washer
M37516
Specifications:
Standard Backlash For All Gears
(Except Crankshaft Gear-to-Oil Pump Gear):
Standard . . . . . . . . . . 0.04-0.12 mm (0.002-0.005 in.)
Crankshaft Gear-to-Oil
Pump Gear . . . . . 0.11-0.19 mm (0.004-0.0075 in.)
Wear Limit. . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Results:
Inspection/Replacement:
1. Inspect gear for chipped or broken teeth. Replace if
necessary.
2. Measure idler gear shaft diameter.
Idler Gear Shaft
Cap Screw
• If backlash exceeds specifications, replace
meshing gears as a set:
Idler Gear, Camshaft Gear, Crankshaft Gear, Oil Pump
Gear and/or Idler Gear, Fuel Injection Pump Gear.
IDLER GEAR
M37834
Removal:
1. Remove timing gear cover. See “TIMING GEAR
COVER” on page 46.
2. Check backlash of timing gears. See “TIMING
GEAR BACKLASH CHECK” on page 47.
NOTE: Due to the odd number of teeth on the idler
gear, timing marks will only align periodically.
When all timing marks on gears align, the piston closest to the water pump (No. 3) is at TDC
on compression stroke.
(No. 1 cylinder is closest to the flywheel.)
Idler Gear Shaft OD:
Standard . . . . . . . 19.96 - 19.98 mm (0.786–0.787 in.)
Wear Limit . . . . . . . . . . . . . . . . . 19.93 mm (0.785 in.)
• If shaft diameter is less than wear limit, replace idler
gear shaft.
3. Measure idler gear bushing diameter.
3. Rotate crankshaft and align timing marks.
4. Remove snap ring, washer and gear.
5. Inspect all parts for wear or damage. (See
2/9/00
3 - 47
CAM FOLLOWERS
DIESEL ENGINE
2. Install cam followers after camshaft is installed.
Inspection:
1. Inspect cam follower contact surface for abnormal
wear. Replace if necessary.
M35492
Idler Gear Bushing ID:
Standard . . . . . . 20.00 - 20.021 mm (0.787 - 0.788in.)
Wear Limit . . . . . . . . . . . . . . . 20.08 mm (0.791 in.)
Clearance . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Abnormal Contact
Normal Contact
M82293A
2. Measure cam follower diameter.
• If bushing diameter exceeds wear limit, replace
bushing.
To replace bushing:
• Replace bushing using a driver set.
• Align oil holes in bushing and idler gear. Install
bushing flush with surface of idler gear.
• If bushing clearance (bushing ID minus shaft OD)
exceeds specification, replace bushing, shaft or
both.
M35268
CAM FOLLOWERS
Cam Follower OD Specifications:
Removal:
1. Remove cylinder head. See “CYLINDER HEAD
REMOVAL AND INSTALLATION” on page 38.
IMPORTANT: Cam followers must be installed in
the same bores from which they were removed.
2. Put a mark on each cam follower and cylinder block
bore to aid in installation.
3. Remove cam followers from cylinder block with
magnetic pick-up tool.
4. Inspect all parts for wear or damage. (See
Inspection procedures.)
Installation:
Installation is done in the reverse order of removal.
1. Apply clean engine oil on all parts during installation.
3 - 48
Standard . . . . . . 17.95 - 17.97 mm (0.707 – 0.708 in.)
Wear Limit . . . . . . . . . . . . . . . . . 17.93 mm (0.706 in.)
• If stem diameter is less than wear limit, replace cam
follower.
3. Measure cam follower bore diameter in cylinder
block.
Cam Follower Bore ID Specifications:
Standard . 18.000 – 18.018 mm (0.7087 – 0.7094 in.)
Wear Limit . . . . . . . . . . . . . . . . . 18.05 mm (0.711 in.)
Clearance . . 0.032 – 0.068 mm (0.0013 – 0.0027 in.)
• If cam follower bore diameter exceeds wear limit,
replace cylinder block.
• If bore clearance (bore ID minus follower stem OD)
exceeds specification, replace cam follower,
cylinder block or both.
2/9/00
CAMSHAFT
DIESEL ENGINE
CAMSHAFT
Installation:
• Apply clean engine oil on all parts during
installation.
Removal:
1. Remove rocker arm assembly and push rods. See
“ROCKER ARM” on page 37.
2. Remove timing gear cover. See “TIMING GEAR
COVER” on page 46.
3. Check camshaft end play. See “CAMSHAFT END
PLAY CHECK” on page 46.
4. Check backlash of timing gears. See “TIMING
GEAR BACKLASH CHECK” on page 47.
NOTE:
If camshaft is being removed with cylinder
head installed, use a magnetic follower holder
tool, or turn engine until oil pan is upward, to
hold cam followers away from camshaft.
5. Hold cam followers away from camshaft using a
magnetic follower holder kit such as D15001NU.
IMPORTANT: DO NOT allow camshaft lobes to hit
bearing surfaces while installing camshaft.
Machined surfaces can be damaged.
1. Rotate crankshaft to align timing marks.
2. Install camshaft.
3. Install and tighten mounting cap screws to 11 N•m
(96 lb-in.).
4. Install timing gear cover. See “TIMING GEAR
COVER” on page 46.
5. Install push rods and rocker arm assembly. See
“ROCKER ARM” on page 37.
Inspection/Replacement:
1. Check camshaft side gap using a feeler gauge.
NOTE: Due to the odd number of teeth on the idler
gear, timing marks will only align periodically.
Camshaft Gear
Thrust Plate
6. Rotate crankshaft and align timing marks.
IMPORTANT: DO NOT allow camshaft lobes to hit
bearing surfaces while removing camshaft.
Machined surfaces can be damaged.
7. Remove two cap screws holding camshaft mounting
flange to block (through holes in camshaft gear).
8. Inspect all parts for wear or damage. (See
Inspection/Replacement procedures.)
M82067A
Mounting
Cap Screws
Side Gap
Camshaft Side Gap:
Standard . . . . . . 0.05 - 0.15 mm (0.0020 - 0.0060 in.)
Wear Limit . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
Timing
Marks
Camshaft
• If side gap is at wear limit, remove gear and replace
thrust plate.
2. Inspect gear for chipped or broken teeth. Replace if
necessary.
To Remove/Replace Gear:
1. Remove gear from camshaft using a knife-edge
puller and a press.
M37832
2/9/00
3 - 49
CAMSHAFT
DIESEL ENGINE
c CAUTION
Dial Indicator
DO NOT heat oil over 182° C (360° F). Oil fumes
or oil can ignite above 193° C (380° F). Use a
thermometer. Do not allow a flame or heating
element to come in direct contact with the oil.
Heat the oil in a well-ventilated area. Plan a safe
handling procedure to avoid burns.
V-Block
Camshaft Central
Bearing Areas
2. Heat gear to approximately 150oC (300oF).
M82291A
IMPORTANT: Be sure thrust plate is not between
camshaft gear and camshaft shoulder while
installing gear.
6. Measure camshaft lobe height.
3. Install thrust plate if removed. Install gear with timing
mark “C” side toward press table.
4. Align slot in gear with key in shaft. Press camshaft
into gear until gear is tight against camshaft
shoulder.
Lobe
Height
M82070A
NOTE: Thrust plate must spin freely on camshaft.
Lobe Height Specifications:
Standard . . . . . . 29.97 - 30.03 mm (1.180 - 1.182 in.)
Wear Limit . . . . . . . . . . . . . . . . . 29.75 mm (1.171 in.)
Key
Camshaft Gear
• If lobe height is less than wear limit, replace
camshaft.
7. Measure camshaft end and intermediate journal
diameters.
Flywheel End Journal
Thrust Plate
Gear Housing
End Journal
M82068A
5. Inspect camshaft for bend using V-blocks and a dial
indicator. Turn camshaft slowly and read variation
on indicator. If variation is greater than 0.02 mm
(0.001 in.), replace camshaft.
M82292A
Intermediate
Journal
Camshaft Journal OD Specifications:
Gear Housing and Flywheel Ends
Standard . . . . 35.94 - 35.96 mm (1.415 - 1.416 in.)
Wear Limit . . . . . . . . . . . . . . . 35.85 mm (1.411 in.)
Intermediate Journal OD
Standard . . . . 35.91 - 35.94 mm (1.414 - 1.415 in.)
Wear Limit . . . . . . . . . . . . . . . 35.85 mm (1.411 in.)
If journal diameters are less than wear limit, replace
camshaft.
3 - 50
2/9/00
CAMSHAFT
DIESEL ENGINE
• Measure intermediate and flywheel end camshaft
bore diameters.
Camshaft Bushing
Intermediate
Bores
Oil Holes
M82072
Flywheel
End Bore
M82073
8. Measure camshaft bushing diameter at gear housing
end.
Camshaft Bore ID Specifications:
Camshaft Bushing ID Specifications:
Standard . . . . . 36.00 - 36.065 mm (1.417 - 1.420 in.)
Wear Limit. . . . . . . . . . . . . . . . . 36.10 mm (1.421 in.)
Clearance . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
• If bushing diameter exceeds wear limit, replace
bushing.
• If bushing clearance (bushing ID minus camshaft
journal OD) exceeds specification, replace
bushing, camshaft or both.
To Replace Bushing:
Standard . . . . . 36.00 - 36.025 mm (1.417 - 1.418 in.)
Wear Limit . . . . . . . . . . . . . . . . . 36.10 mm (1.421 in.)
Clearance . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
• If bore diameter exceeds wear limit, replace
cylinder block.
• If bore clearance (bore ID minus camshaft journal
OD) exceeds specification, replace camshaft,
cylinder block or both.
3. Apply John Deere Form-In Place Gasket, or an
equivalent, on outer edge of plug. Install plug until it
bottoms in bore.
4. Install engine back plate.
1. Remove and replace bushing using a bushing driver.
Be careful not to push bushing inside of engine.
Align oil holes in new bushing and cylinder block.
NOTE: Engine back plate must be removed to measure camshaft intermediate and flywheel end
bearing diameters.
2. Measure intermediate and flywheel end camshaft
bore diameters using the following procedures:
• Remove engine back plate.
• Remove plug using a long wooden dowel. Insert
wooden dowel through gear housing side.
Plug
M35287
2/9/00
3 - 51
OIL PAN AND STRAINER
DIESEL ENGINE
OIL PAN AND STRAINER
Removal:
1. Drain engine oil.
2. Remove cap screws securing oil pan. Remove oil
pan and remove old gasket material.
3. Remove cap screws securing oil strainer. Remove
oil strainer.
Cap Screw (2)
M6 x 12
5. Install drain plug with new washer.
6. Fill crankcase with oil.
• Crankcase oil capacity is 2.0 L (2.1 qt).
• Fill engine with proper engine oil. (See
Specifications section.)
CONNECTING ROD SIDE PLAY
CHECK
Reason:
To determine proper side
crankshaft and connecting rod.
John Deere Form-In-Place Gasket
(RTV rubber silicone sealant)
Oil Strainer
clearance
between
Equipment:
O-Ring
• Feeler Gauge
Procedure:
Cap Screw (12)
M6 x 8
Feeler Gauge
Oil Pan-toOil Seal Case
Cap Screw (2)
M6 x 12
M82302B
M82116A
Drain Washer
Plug Replace.
Oil Pan-to-Timing Gear
Housing Cap Screw (4)
M6 x 12
1. Insert a feeler gauge, according to specifications,
between connecting rod cap and crankshaft.
Specifications:
Installation:
1. Install oil strainer with new O-ring.
2. Tighten cap screws to 11 N•m (96 lb-in.).
3. Cover oil pan mounting flange with a thin layer of
sealant.
4. Install oil pan and tighten cap screws to
specification.
Standard
Clearance . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.)
Wear Limit . . . . . . . . . . . . . . . . 0.55 mm (0.022 in.)
Results:
• If side play exceeds wear limit, replace connecting
rod and connecting rod cap.
Oil Pan Torque Specifications:
Pan-to-Engine. . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Pan-to-Oil Seal Case . . . . . . . . . . . . 9 N•m (78 lb-in.)
Pan-to-Timing Gear Housing . . . . . 9 N•m (78 lb-in.)
3 - 52
2/9/00
CRANKSHAFT END PLAY CHECK
DIESEL ENGINE
CRANKSHAFT END PLAY CHECK
CONNECTING ROD BEARING
CLEARANCE CHECK
Reason:
To determine proper side
crankshaft and engine block.
clearance
between
Reason:
To measure oil clearance between connecting rod
bearing and crankshaft journal.
Equipment:
Equipment:
• Dial Indicator
• PLASTIGAGE®
Procedure:
Procedure:
NOTE: Crankshaft end play can be measured at front
end or rear end of crankshaft. Procedure is
performed from the rear end. The flywheel is
removed to show detail.
1. Fasten dial indicator to engine and position indicator
tip on end of crankshaft.
IMPORTANT:
Connecting rod caps must be
installed on the same connecting rod and in the
same direction to prevent crankshaft and
connecting rod damage.
1. Remove connecting rod cap.
2. Wipe oil from bearing insert and crankshaft journal.
IMPORTANT: Do not use excessive force when
moving crankshaft to avoid damaging bearings.
2. Push crankshaft toward rear as far as possible.
3. Zero the dial indicator.
4. Using a bar, gently pry the crankshaft as far forward
as possible.
PLASTIGAGE
M35351
Dial Indicator
3. Put a piece of PLASTIGAGE®, or an equivalent,
along the full length of the bearing insert
approximately 6 mm (0.25 in.) off center.
4. Turn crankshaft approximately 30° from bottom dead
center.
5. Install connecting rod end cap and original cap
screws. Tighten cap screws to 23 N•m (203 lb-in.).
6. Remove cap screws and connecting rod cap.
Crankshaft
M82118A
NOTE: The flattened PLASTIGAGE® will be found on
either the bearing insert or crankshaft journal.
Clearance Specifications:
Standard . . . . . . 0.090 - 0.271 mm (0.004 - 0.011 in.)
Wear Limit. . . . . . . . . . . . . . . . . 0.33 mm (0.0129 in.)
Results:
If end play exceeds wear limit, replace thrust bearings.
2/9/00
3 - 53
CRANKSHAFT MAIN BEARING CLEARANCE CHECK
Graduation Marks
on Envelope
Flattened
PLASTIGAGE
PLASTIGAGE
M82117A
7. Use the graduation marks on the envelope to
compare the width of the flattened PLASTIGAGE®
at its widest point.
8. Determine bearing clearance. The number within the
graduation marks indicates the bearing clearance
in inches or millimeters depending on which side of
the envelope is used.
9. Remove PLASTIGAGE®.
Clearance Specifications:
DIESEL ENGINE
M35382
3. Place a piece of PLASTIGAGE®, or an equivalent,
along the full length of the bearing insert
approximately 6 mm (0.250 in.) off center.
4. Install main bearing cap and cap screws. Tighten
cap screws to 54 N•m (40 lb-ft).
5. Remove cap screws and main bearing cap.
NOTE: The flattened PLASTIGAGE® will be found on
either the bearing insert or crankshaft journal.
Standard . . . . 0.020 - 0.072 mm (0.0008 - 0.0028 in.)
Wear Limit. . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Results:
Graduated Marks
on Envelope
• If clearance exceeds specification, replace bearing
inserts.
CRANKSHAFT MAIN BEARING
CLEARANCE CHECK
Flattened
PLASTIGAGE
M82119AE
Reason:
To measure oil clearance between main bearing and
crankshaft journal.
Equipment:
• PLASTIGAGE®
6. Use the graduated marks on the envelope to
compare the width of the flattened PLASTIGAGE®
at its widest point.
7. Determine main bearing clearance. The number
within the graduation marks indicates the bearing
clearance in inches or millimeters depending on
which side of the envelope is used.
8. Remove PLASTIGAGE®.
Procedure:
Specifications:
IMPORTANT: Main bearing caps must be installed
on the same main bearing and in the same
direction to prevent crankshaft and main
bearing damage.
1. Remove main bearing cap.
2. Wipe oil from bearing insert and crankshaft journal.
3 - 54
Standard
Clearance . 0.020 - 0.072 mm (0.0008 - 0.0028 in.)
Wear Limit . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Results:
• If clearance exceeds specification, replace bearing
inserts.
2/9/00
DIESEL ENGINE
PISTON-TO-CYLINDER HEAD
CLEARANCE
1. Place small pieces of solder in three positions on the
flat part of the piston head.
2. Install cylinder head and old gasket. Install cylinder
head cap screws and tighten in proper sequence to
specified torque. See “CYLINDER HEAD
REMOVAL AND INSTALLATION” on page 38.
3. Slowly turn crankshaft one complete revolution.
4. Remove cylinder head and gasket.
5. Measure thickness of flattened pieces of solder.
Calculate average thickness of solder pieces to
obtain piston-to-cylinder head clearance
specification.
PISTON-TO-CYLINDER HEAD CLEARANCE
9. Push piston and connecting rod out of cylinder bore
using a wooden dowel.
10. Disassemble and inspect all parts for wear or
damage. (See Disassembly and Inspection/
Replacement procedures.)
Piston and
Connecting Rod
Piston-to-Cylinder Head Specification:
Clearance . . . . . . . 0.59 - 0.74 mm (0.023 - 0.029 in.)
• If clearance is less than specifications, replace
cylinder head.
CONNECTING ROD REPAIR
Bearing Inserts
Removal:
1. Remove oil pan and strainer tube. See “OIL PAN
AND STRAINER” on page 52.
2. Remove cylinder head. See “CYLINDER HEAD
REMOVAL AND INSTALLATION” on page 38.
3. Check cylinder bore for ridges. These ridges can
cause damage to piston if ridge is not removed.
4. If necessary, remove ridge from top of cylinder bore
using a ridge reamer.
5. Measure connecting rod side play. See
“CONNECTING ROD SIDE PLAY CHECK” on
page 52.
6. Measure connecting rod bearing clearance. See
“CONNECTING ROD BEARING CLEARANCE
CHECK” on page 53.
IMPORTANT: Keep connecting rods and caps
together. Rods and caps are a matched set.
Note alignment marks on each part.
7. Remove two cap screws, connecting rod cap and
bearing inserts.
IMPORTANT: Pistons and cylinders are matched.
Pistons must be installed in the cylinders from
which they are removed.
8. Note connecting rod alignment mark in relation to
the cylinders. Starting at flywheel end with cylinder
number one, then two, etc.
2/9/00
Connecting Rod Cap
Connecting Rod
Cap Screw
M82273A
Installation:
Installation is done in reverse order of removal.
• Apply clean engine oil on all parts during
installation.
• Never reuse connecting rod cap screws, replace
with new cap screws.
IMPORTANT:
Pistons must be installed in
cylinders from which they were removed and in
the same direction. Be careful not to damage
crankshaft rod journal while installing piston.
1. If new piston rings were installed, deglaze cylinder
bore. See “Deglazing:” on page 61.
2. Install piston and connecting rod into the cylinder
from which it was removed, with alignment mark on
connecting rod and/or with piston size mark on top
of piston toward fuel injection pump.
3. Install bearing inserts on connecting rod and rod
cap, aligning tangs with grooves.
3 - 55
PISTONS
DIESEL ENGINE
IMPORTANT:
Connecting rod caps must be
installed on the same connecting rods they
were removed from.
PISTONS
Disassembly:
4. Match the connecting rods to caps using alignment
marks. Install caps.
5. Dip entire connecting rod cap screws in clean engine
oil. Install new cap screws and tighten to
specifications.
Torque Specification:
Connecting Rod Cap Screw . . . . 23 N•m (203 lb-in.)
• If a new piston and connecting rod were installed,
stamp a number corresponding to the cylinder
number on the connecting rod cap and connecting
rod.
IMPORTANT: Pistons must be installed on the
same connecting rod they were removed from.
• Put a mark on each piston and connecting rod to
aid in assembly.
• Piston pin bushing is press fit in connecting rod.
Remove bushing only if replacement is necessary.
(See Inspection/Replacement procedures.)
• Inspect all parts for wear or damage. Replace as
necessary.
1st Compression Ring
Piston Recess
2nd Compression Ring
Fuel
Injection
Pump Side
Oil Ring with
Coil Expander
Flywheel
Side
Piston
Groove
Piston Pin
Tangs
Connecting Rod
Cap Alignment
Mark (Number)
Piston
Pin
Bushing
Groove
Connecting Rod
Cap Screw
Retaining Ring
Connecting Rod
M82273A
M82274A
6. Install cylinder head. See “CYLINDER HEAD
REMOVAL AND INSTALLATION” on page 38.
7. Install oil pan and strainer tube.
Assembly:
1. Apply clean engine oil to all parts during assembly.
IMPORTANT: Pistons must be installed on the
same connecting rod they were removed from.
3 - 56
2/9/00
PISTONS
DIESEL ENGINE
2. Assemble piston to connecting rod with piston size
mark on same side as connecting rod “punched”
alignment mark. If a new connecting rod is used,
assemble piston to connecting rod with piston size
mark opposite connecting rod bearing insert
groove.
6. Install second compression ring, with small diameter
of taper toward top of piston, in middle groove. Turn
ring until gap is 120o away from oil ring gap.
1st Compression Ring
Piston Recess
Piston
2nd
Compression
Ring
1st Compression Ring
Piston Pin
2nd
Compression
Ring
Oil Ring
Retaining Ring
Connecting
Rod
M82276A
Alignment Mark
(Number)
M82275A
Bearing Insert Groove
3. Install piston pin and retaining/snap rings.
4. Install oil ring expander in bottom ring groove of
piston with ends above either end of piston pin.
5. Install oil ring over expander with ring gap opposite
(180o) of expander ends.
Oil Ring
Expander
Oil
Ring
Gap
7. Install first compression ring (chrome plated), with
manufacturer's mark “R”, “T” or “RN” (near ring
gap) toward top of piston, in top groove. Turn ring
until gap is 120o away from second ring gap.
Inspection/Replacement:
1. Inspect all parts for wear or damage. Replace as
necessary.
2. Measure crankshaft connecting rod journal
diameter. (See Crankshaft, Main Bearings and
Flywheel in this section.)
3. Install connecting rod cap and bearing inserts on
connecting rod. Install old connecting rod cap
screws and tighten to specification.
Torque Specification:
Oil Ring
Expander
Ends
Connecting Rod Cap Screw . . . . 23 N•m (203 lb-in.)
4. Measure connecting rod bearing diameter.
Oil Ring
Piston Pin
2/9/00
M82046A
3 - 57
PISTONS
DIESEL ENGINE
Oil Ring
Standard . . 0.020 - 0.055 mm (0.0008 - 0.0022 in.)
• If clearance exceeds maximum limit, replace rings
or piston.
6. Measure piston ring end gap. Push ring into cylinder
bore, using a piston, until ring is approximately 30
mm (1.18 in.) from bottom of cylinder bore.
End Gap
M82048A
Cylinder Bore
Connecting Rod Bearing ID:
Standard . . . . . . . . 36 - 36.042 mm (1.417 - 1.419 in.)
Wear Limit. . . . . . . . . . . . . . . . . 37.07 mm (1.459 in.)
Clearance . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
• If bearing diameter exceeds wear limit, replace
bearing inserts.
• If bearing clearance (bearing ID minus crankshaft
journal OD) exceeds specification, grind
crankshaft connecting rod journals and install
undersized bearing inserts, or replace bearing
inserts and crankshaft.
5. With rings installed on piston, measure piston ring
groove clearance. Measure several places around
each piston.
Piston Ring
Approx.
30 mm
(1.18 in.)
End Gap
M82049A
Standard Piston Ring End Gap:
First Compression Ring and Oil Ring
. . . . . . . . . . . . . . 0.15 - 0.35 mm (0.006 - 0.014 in.)
Second Compression Ring
. . . . . . . . . . . . . . 0.25 - 0.40 mm (0.010 - 0.016 in.)
Wear Limit . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.)
• If end gap exceeds wear limit, replace rings.
M35360
Piston Ring Groove Clearance:
First Compression Ring
Standard . . 0.065 - 0.100 mm (0.0026 - 0.0039 in.)
Wear Limit . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Second Compression Ring
Standard . . 0.030 - 0.065 mm (0.0012 - 0.0026 in.)
Wear Limit . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
3 - 58
2/9/00
PISTONS
DIESEL ENGINE
Measuring Position
M82050A
7. Measure piston pin diameter. Measure diameter at
six places.
Piston Pin OD Diameter Specifications:
Standard . . . 19.991 - 20.00 mm (0.787 - 0.788 in.)
Wear Limit . . . . . . . . . . . . . . 19.975 mm (0.786 in.)
M82051A
9. Measure piston pin bushing diameter in connecting
rod.
Piston Pin Bushing ID Specifications:
Standard . . 20.025 - 20.038 mm (0.788 - 0.789 in.)
Wear Limit . . . . . . . . . . . . . . . 20.10 mm (0.781 in.)
Clearance . . . . . . . . . . . . . . . . . . . 0.11 (0.0043 in.)
• If bushing diameter exceeds wear limit, replace
bushing.
• If bushing clearance (bushing ID minus pin OD)
exceeds specification, replace bushing, piston pin
or both.
• If pin diameter is less than wear limit, replace pin.
NOTE: Piston pin bushing is press fit. Replace bushing
using a driver set. When installing bushing,
make sure to align oil hole in bushing with hole
in connecting rod.
10. Measure piston diameter perpendicular to piston
pin bore at distance A.
M37683
NOTE: If engine has had a previous major overhaul,
oversize pistons and rings may have been
installed. Pistons and rings are available in
0.25 mm (0.010 in.) and 0.50 mm (0.020 in.)
oversize.
8. Measure piston pin bore diameter in piston.
Piston Pin Bore ID Specifications:
Standard . . . 20.00 - 20.008 mm (0.787 - 0.788 in.)
Wear Limit . . . . . . . . . . . . . . . 20.02 mm (0.788 in.)
Clearance . . . . . . . . . . . . . . 0.045 mm (0.0018 in.)
• If piston pin bore exceeds wear limit, replace piston.
• If bore clearance (bore ID minus pin OD) exceeds
specification, replace piston, piston pin or both.
2/9/00
3 - 59
CYLINDER BORE
DIESEL ENGINE
CYLINDER BORE
Inspection:
1. Measure cylinder bore diameter at three positions;
top, middle and bottom. At these three positions,
measure in both directions; along crankshaft center
line and direction of crankshaft rotation.
NOTE: If engine has had a previous major overhaul,
oversize pistons and rings may have been
installed.
A
M82200A
Top Position
Middle Position
Bottom Position
M82052A
Specifications:
Piston OD Distance A) . . . . . . . . . . . 5 mm (0.197 in.)
Standard Size Piston
Standard . . 65.927 - 65.957 mm (2.596 - 2.597 in.)
Wear Limit . . . . . . . . . . . . . . . 65.85 mm (2.593 in.)
Oversize Piston – 0.25 mm (0.010 in.)
Standard . . . . 66.18 - 66.21 mm (2.606 - 2.607 in.)
Wear Limit . . . . . . . . . . . . . . . 66.10 mm (2.602 in.)
Oversize Piston – 0.50 mm (0.020 in.)
Standard . . . . 66.43 - 66.46 mm (2.615 - 2.616 in.)
Wear Limit . . . . . . . . . . . . . . . 66.35 mm (2.612 in.)
Direction of
Crankshaft Rotation
Direction of
Crankshaft
Centerline
M82053A
Cylinder Bore ID Specifications:
• If piston diameter is less than wear limit, install a
new piston.
11. Measure cylinder bore diameter. (See procedure in
this group.)
3 - 60
Standard Size Bore
Standard . . . . 66.00 - 66.03 mm (2.599 - 2.600 in.)
Wear Limit . . . . . . . . . . . . . . 66.20 mm (2.606 in.)
Piston to Cylinder Clearance . . 0.25 mm (0.010 in.)
Cylinder Roundness . . . . . . . . . 0.25 mm (0.010 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm
First Oversize Bore
Standard . . . . 66.25 - 66.28 mm (2.609 - 2.610 in.)
Wear Limit . . . . . . . . . . . . . . . 66.45 mm (2.616 in.)
Second Oversize Bore
Standard . . . . 66.50 - 66.53 mm (2.619 - 2.620 in.)
Wear Limit . . . . . . . . . . . . . . . 66.70 mm (2.626 in.)
• If cylinder bore exceeds wear limit, replace cylinder
block or have cylinder rebored. (See Reboring
procedure.)
• If cylinder is rebored, oversize pistons and rings
must be installed. Pistons and rings are available
2/9/00
CYLINDER BORE
DIESEL ENGINE
in 0.25 mm (0.010 in.) and 0.50 mm (0.020 in.)
oversize.
• If clearance (cylinder bore ID minus piston OD)
exceeds specification, replace cylinder block,
piston or both; or rebore cylinder and install
oversize piston and rings.
Deglazing:
IMPORTANT: Check stone for wear or damage. Use
a rigid hone with 300 grit stones.
2. Adjust hone so lower end is even with lower end of
cylinder bore.
3. Adjust rigid hone stones until they contact narrowest
point of cylinder.
4. Coat cylinder with honing oil. Hone should turn by
hand. Adjust if too tight.
IMPORTANT: If cylinder bores are to be deglazed
with crankshaft installed in engine, put clean
shop towels over crankshaft to protect journal
and bearing surfaces from any abrasives.
30 - 40°
1. Deglaze cylinder bores using a flex-hone with 180
grit stones.
2. Use flex-hone as instructed by manufacturer to
obtain a 30 - 40° cross-hatch pattern as shown.
M52959
M82054A
IMPORTANT: Do not use gasoline, kerosene or
commercial solvents to clean cylinder bores.
Solvents will not remove all abrasives from
cylinder walls.
5. Run drill press at about 250 RPM. Move hone up
and down in order to obtain a 30 - 40°crosshatch
pattern.
NOTE: Measure bore when cylinder is cool.
6. Stop press and check cylinder diameter.
3. Remove excess abrasive residue from cylinder walls
using a clean dry rag. Clean cylinder walls using
clean white rags and warm soapy water. Continue
to clean cylinder until white rags show no
discoloration.
Reboring:
NOTE: The cylinder block can be rebored to use oversize pistons and rings. Pistons and rings are
available in 0.25 mm (0.010 in.) and 0.50 mm
(0.020 in.) oversize. (See this group for cylinder
bore I D specifications.)
1. Align center of bore to drill press center.
2/9/00
NOTE: Finish should not be smooth. It should have a
30 - 40o crosshatch pattern.
7. Remove rigid hone when cylinder is within 0.03 mm
(0.001 in.) of desired size.
8. Use a flex hone with 180 grit stones for honing to
final size.
9. Check bore for size, taper and out-of-round. (See
Inspection procedures.)
IMPORTANT: Do not use solvents to clean cylinder
bore. Solvents will not remove all metal
particles and abrasives produced during
honing.
3 - 61
CRANKSHAFT AND MAIN BEARINGS
DIESEL ENGINE
10. Clean cylinder thoroughly using warm soapy water
until clean white rags show no discoloration.
11. Dry cylinder and apply engine oil.
Crankshaft
CRANKSHAFT AND MAIN
BEARINGS
Removal:
1. Check crankshaft end play. See “CRANKSHAFT
END PLAY CHECK” on page 53.
2. Remove flywheel. See “FLYWHEEL” on page 64.
3. Remove rear oil seal case. See “CRANKSHAFT
REAR OIL SEAL” on page 44.
4. Remove timing gear cover, timing gears, timing gear
housing, and flywheel of engine.
5. Check crankshaft bearing clearance. See
“CRANKSHAFT MAIN BEARING CLEARANCE
CHECK” on page 54.
IMPORTANT: Connecting rod end caps must be
installed on the same connecting rods from
which they were removed. Note alignment
marks on caps and rods.
6. Remove connecting rod cap screws and end caps.
7. Push pistons and connecting rods away from
crankshaft.
IMPORTANT: Main bearing caps must be installed
on the same main bearings from which they
were removed.
8. Remove main bearing cap screws, caps and cap
thrust bearings.
9. Remove crankshaft.
10. Remove block thrust bearings and main bearing
inserts.
11. Inspect all parts for wear or damage. (See
Inspection/Replacement procedure.)
Flywheel
End
Block
Thrust Bearing
Main Bearing Inserts
Cap
Thrust
Bearing
Main Bearing Cap
M82283A
Main Bearing Cap
Screw (8)
3. Install block thrust bearings with oil grooves facing
away from engine block.
NOTE: Main bearing caps have “raised arrows” that
are stamped with numbers. Both correspond to
their location on the engine block. The number
“1” main bearing bore is at flywheel end. Install
bearing caps beginning with number 1, then 2,
etc. The main bearing cap at gear train end
does not have a number. Also install bearing
caps with the “arrow” toward the flywheel end.
4. Install crankshaft.
5. Install smooth bearing inserts in main bearing caps,
aligning tangs with slots in caps.
6. Install cap thrust bearings, with oil grooves facing
away from cap, in the number “1” main bearing cap.
7. Install main bearing caps in their original locations
with arrows pointing toward flywheel side of engine.
Installation:
1. Apply clean engine oil on all parts during installation.
2. Install bearing inserts drilled with oil passage in
cylinder block bearing bores, aligning tangs with
slots in bores.
IMPORTANT: DO NOT use high speed power tools
or air wrenches to tighten main bearing cap
screws.
8. Dip entire main bearing cap screws in clean engine
oil. Install cap screws and tighten. DO NOT tighten
to specifications.
9. Using a soft-faced hammer, tap the front end of the
crankshaft then the rear end of the crankshaft to
align the thrust bearings.
10. Tighten main bearing cap screws to specifications.
When tightening, start at center main bearing cap
3 - 62
2/9/00
DIESEL ENGINE
and work your way out, alternating to the ends. Turn
crankshaft by hand. If it does not turn easily,
disassemble the parts and find the cause.
Torque Specification:
Main Bearing Cap Screws . . . . . . . . 88 N•m (65 lb-ft)
CRANKSHAFT AND MAIN BEARINGS
be installed. Bearing inserts are available in 0.25 mm
(0.010 in.) undersize.
4. Install bearing inserts and main bearing cap on main
bearing. Tighten main bearing cap screws to a
minimum of 54 N•m (40 lb-ft) to compress main
bearing for measurement.
5. Measure main bearing diameter.
Inspection/Replacement:
1. Inspect crankshaft gear for chipped or broken teeth.
Replace if necessary.
To replace gear:
• Remove gear from crankshaft using a knife-edge
puller and a press.
c CAUTION
DO NOT heat oil over 182° C (360° F). Oil fumes
or oil can ignite above 193° C (380° F). Use a
thermometer. Do not allow a flame or heating
element to come in direct contact with the oil.
Heat the oil in a well-ventilated area. Plan a safe
handling procedure to avoid burns.
• Heat gear to approximately 150°C (300°F). Install
gear with timing mark “A” toward press table. Align
slot in gear with key in shaft. Press crankshaft into
gear until gear is tight against crankshaft shoulder.
2. Inspect crankshaft for bend using v-blocks and a dial
indicator. Turn crankshaft slowly and read variation
on indicator. If variation is greater than 0.02 mm
(0.0008 in.), replace crankshaft.
3. Measure crankshaft connecting rod journal and main
bearing journal diameters. Measure several places
around each journal.
NOTE: If engine has had a previous major overhaul,
journals may have been ground and undersized bearing inserts installed.
M82063
Main Bearing ID Specifications:
Standard . . . . 40.000 - 40.042 mm (1.575 - 1.577 in.)
Wear Limit . . . . . . . . . . . . . . . . . 40.07 mm (1.578 in.)
Clearance . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
• If bearing diameter exceeds wear limit, replace
bearing inserts.
• If bearing clearance (bearing ID minus crankshaft
main bearing journal OD) exceeds specification,
replace bearing inserts and crankshaft or have
crankshaft journals ground undersize by a qualified
machine shop and install undersized bearing
inserts.
Bearing inserts are available in 0.25 mm (0.010 in.)
undersize.
6. Clean and inspect oil passages in main bearing
journals, connecting rod journals and main bearing
bores in cylinder block.
7. Inspect crankshaft for cracks or damage. Replace if
necessary.
Connecting Rod Journal OD Specifications:
Standard . . . . 35.97 - 35.98 mm (1.4161 - 1.4165 in.)
Wear Limit. . . . . . . . . . . . . . . . . 35.92 mm (1.414 in.)
Main Bearing Journal OD Specifications:
Standard . . . . 39.97 - 39.98 mm (1.5736 - 1.5740 in.)
Wear Limit. . . . . . . . . . . . . . . . . 39.92 mm (1.572 in.)
• If journal diameter is less than wear limit, replace
crankshaft or have journals ground undersize by a
qualified machine shop.
If journals are ground, undersize bearing inserts must
2/9/00
3 - 63
FLYWHEEL
DIESEL ENGINE
FLYWHEEL
FLYWHEEL PLATE
Removal:
Removal:
1. Remove engine drive clutch. See GEAR POWER
TRAIN SECTION.
1. Remove clutch from crankshaft.
2. Remove flywheel guard.
3. Remove flywheel. See “FLYWHEEL” on page 64.
4. Remove starting motor.
Mounting Cap Screw (7)
M10 x 20
B
A
Flywheel Plate
M76891
M82290A
1. Remove flywheel guard.
2. Remove four cap screws (A) securing engine drive
clutch stub shaft (B) to flywheel hub.
3. Remove five flywheel mounting cap screws from
flywheel to crankshaft.
4. Pull flywheel from crankshaft alignment pin.
IMPORTANT: Never reuse flywheel mounting cap
screws. Always install new.
5. Remove seven mounting cap screws and flywheel
plate.
Installation:
Installation is done in reverse order of removal.
• Tighten mounting cap screws to 49 N•m (36 lb-ft).
5. Inspect flywheel ring gear teeth for wear or chips.
Replace flywheel if worn.
Installation:
1. Align flywheel on spring pin and install five new
flywheel mounting cap screws (see note above).
Tighten cap screws to 83 N•m (61 lb-ft).
2. Install stub shaft to flywheel hub and tighten four
mounting cap screws to 59 N•m (44 lb-ft).
3. Install flywheel guard.
3 - 64
2/9/00
TIMING GEAR HOUSING
DIESEL ENGINE
TIMING GEAR HOUSING
OIL PUMP
Removal:
Removal/Installation
1. Remove engine. See “ENGINE REMOVAL AND
INSTALLATION” on page 34.
2. Remove timing gear cover. See “TIMING GEAR
COVER” on page 46.
3. Remove fuel injector lines from engine. See “FUEL
INJECTION NOZZLE” on page 71.
4. Remove engine camshaft. See “CAMSHAFT” on
page 49.
5. Remove water pump. See “WATER PUMP” on
page 68.
6. Remove oil dipstick tube.
7. Remove oil pan. See “OIL PAN AND STRAINER” on
page 52.
8. Remove timing gear housing mounting cap screws
and remove housing from cylinder block.
9. Replace O-rings.
1. Remove timing gear cover. See “TIMING GEAR
COVER” on page 46.
2. Check oil pump gear backlash. Replace entire oil
pump assembly if backlash is more than 0.25 mm
(0.010 in.).
3. Remove three mounting cap screws, oil pump and
gasket.
4. Inspect all parts for wear or damage. See
Disassembly/Assembly procedures.
Installation:
• Tighten mounting cap screw to 25 N•m (18 lb-ft).
Installation:
Installation is done in the reverse order of removal.
• Apply low strength thread lock to studs before
installing into timing gear housing.
• Replace O-rings.
• Tighten timing gear housing mounting cap screws
to 11 N•m (96 lb-in.).
Oil Pump
Oil Pump Gasket
Mounting Cap Screw
M6 x 20
M82309A
John Deere Form-in-Place Gasket
(RTV rubber silicone sealant)
Stud (4)
Spring Pin (2)
Timing Gear Housing
Stud (4)
Mounting Cap Screw (4)
M6 x 16
Alignment Dowel
O-Rings
2/9/00
M82299A
3 - 65
OIL PRESSURE REGULATING VALVE
DIESEL ENGINE
Disassembly/Assembly:
1. Remove gear using a knife edge puller and a press.
Gear is press fit on rotor shaft.
2. Inspect parts for wear or damage. (See Inspection
procedures.)
3. Coat all parts with clean engine oil.
4. Install outer rotor with identification mark facing
toward rotor shaft assembly.
Outer Rotor
Body
Feeler Gauge
Backing Plate
Pin (2)
Pump Body
M37776
Gear
3. Check outer rotor-to-pump body clearance. If
clearance is more than wear limit, replace entire
assembly.
Rotor Shaft
Inner Rotor
Outer rotor
Identification
Mark
Outer Rotor-to-Pump Body Clearance:
M82301A
Standard . . . . . . 0.03 - 0.09 mm (0.0011 - 0.0035 in.)
Wear Limit . . . . . . . . . . . . . . . . . 0.13 mm (0.0051 in.)
Inspection:
1. Check rotor shaft outer diameter and the shaft hole
diameter in backing plate. If clearance is more than
wear limit, replace entire assembly.
Inner Rotor
Outer Rotor
Rotor Shaft and Plate Clearance:
Standard . . . . . . 0.015 - 0.048 mm (0.001 - 0.004 in.)
Wear Limit. . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Straight Edge
Feeler Gauge
M37777
Feeler Gauge
4. Check inner-to-outer rotor clearance. If clearance is
more than 0.15 mm (0.0059 in.), replace rotor
assembly.
Outer Rotor
Housing
OIL PRESSURE REGULATING
VALVE
M37775
Removal:
2. Check rotor recess. If rotors are below face of pump
housing more than 0.25 mm (0.01 in.), replace
rotor assembly.
1. Remove oil filter and O-ring.
2. Remove retaining nut and valve assembly.
3. If adjusting pressure only, remove cap and add
shims. Each 1 mm (0.039 in.) of shim thickness
increases oil pressure 13.8 kPa (2.0 psi).
NOTE: Valve components are not serviced individually.
Replace complete regulating valve if any components are defective.
3 - 66
2/9/00
COOLANT TEMPERATURE SWITCH
DIESEL ENGINE
4. Inspect all parts for wear or damage. Replace
complete valve if necessary.
5. Check spring free and compressed length.
THERMOSTAT
Removal:
Spring Specifications:
Free
Length . . . . .21.90 mm - 24.50 mm (0.860 - 0.960 in.)
Compressed
Length . . . . . 14.70 mm (.580 in.)@12 N (2.7 lb-force)
Installation:
1. Open engine drain valve to drain coolant level to
below thermostat level.
2. Disconnect upper radiator hose from thermostat
housing.
3. Remove two cap screws holding thermostat cover to
water pump.
4. Test thermostat. See “THERMOSTAT TEST” on
page 29.
Installation is done in the reverse order of removal.
Cap Screw (2)
M8 x 20
• Tighten retaining nut to 30 N•m (22 lb-ft).
Retaining Nut
Shims
Cover
O-Ring
Valve
Spring
Cap
Stake to
valve body.
Thermostat
Valve Body
Oil Filter
M82311B
COOLANT TEMPERATURE SWITCH
Replacement:
M82314A
1. Open engine drain valve to drain coolant level to
below coolant sensor level.
2. Disconnect wiring lead.
3. Remove sensor and washer.
4. Test sensor. (See ELECTRICAL SECTION.)
5. Installation is done in reverse order of removal.
• Replace copper washer.
Installation:
• Replace O-ring when installing thermostat.
• Tighten cap screws securing cover to 26 N•m (230
lb-in.).
Water Pump
Housing
Coolant Temperature
Switch
Copper
Washer
M82313A
2/9/00
3 - 67
WATER PUMP
DIESEL ENGINE
WATER PUMP
COOLANT FILLING
Removal:
NOTE: Capacity of cooling system is approximately
4.5 L (4.8 qt).
1. Remove engine belt guard.
2. Open engine drain valve to drain coolant from
cylinder block.
3. Disconnect coolant temperature switch lead.
4. Disconnect upper and lower radiator hoses.
5. Remove water pump/alternator drive belt.
Fill Procedure with Coolant in Engine Block
1. Ensure engine is cool.
2. Remove upper radiator bleed screw.
A
Gasket
Pulley
M76754
O-Ring
3. Fill system with coolant through remote fill until
coolant comes out bleed screw hole (A).
4. Install bleed screw.
Water Pump
Mounting Cap Screw (3)
M8 x 45
.
M82316B
6. Remove four pulley cap screws and pulley.
7. Remove three pump mounting cap screws, pump
and gasket.
8. Inspect all parts for wear or damage.
9. Clean cylinder block mating surfaces of all old
gasket material.
B
M76771
Installation:
Installation is done in the reverse order of removal.
1. Install new gasket and O-ring.
2. Tighten mounting cap screws to 26 N•m (226 lb-in.).
3. Install coolant temperature switch. See “COOLANT
TEMPERATURE SWITCH” on page 67.
4. Install thermostat. See “THERMOSTAT” on page 67.
5. Adjust water pump/alternator drive belt tension. See
“WATER PUMP/ALTERNATOR DRIVE BELT
ADJUSTMENT” on page 28.
6. Install engine belt cover.
3 - 68
5. Continue filling through remote fill (B) until full.
Fill Procedure without Coolant in Engine Block
1. Remove thermostat housing (A) and thermostat.
2/9/00
FUEL TRANSFER PUMP
DIESEL ENGINE
FUEL TRANSFER PUMP
c
CAUTION
Fuel tank shutoff valve must be closed before
disconnecting fuel lines.
A
M76753
2. Fill engine block until full.
3. Install thermostat and thermostat housing.
4. Tighten thermostat housing cap screws to 9 N•m (78
lb-in).
5. Remove upper radiator bleed screw.
6. Fill system with coolant through remote fill (B) until
coolant comes out bleed screw hole.
A
M76722
.
1. Close fuel shutoff valve (A) at tank and at filter.
B
B
M76771
7. Install bleed screw.
8. Continue filling through remote fill (B) until full.
M76729
2. Remove inlet and outlet hose clamps at fuel transfer
pump (B) and disconnect hoses.
3. Disconnect two cap screws securing fuel pump
assembly to frame.
4. Remove all old gasket material from mating surfaces
before installation.
5. Installation is done in the reverse order of removal.
2/9/00
3 - 69
FUEL FILTER
DIESEL ENGINE
FUEL FILTER
FUEL TANK COMPONENTS
On/Off Valve (Fuel Supply)
Vent
Fuel Return Gauge
C
B
A
M76723
M76800
1. Remove two fuel lines (A) from fuel filter assembly.
2. Remove two fuel return lines (B) from fuel filter
assembly.
3. Remove nut (C) securing filter assembly to mounting
stud.
4. Slide fuel filter off of mounting stud.
.
Filter
Water Indicator
Ring
M76799
Installation:
Installation is done in the reverse order of removal.
3 - 70
2/9/00
FUEL INJECTION NOZZLE
DIESEL ENGINE
FUEL INJECTION NOZZLE
1. Clean the injection pump lines and area around the
pump using a parts cleaning solvent or steam
cleaner.
Removal:
c
CAUTION
Escaping fluid under pressure can penetrate the
skin causing serious injury. Avoid the hazard by
relieving
pressure
before
disconnecting
hydraulic or other lines. Tighten all connections
before applying pressure. Search for leaks with a
piece of cardboard. Protect hands and body from
high pressure fluids.
NOTE: Nozzles are matched to the cylinders. If removing more than one nozzle, tag nozzles, according to the cylinder from which it was removed.
IMPORTANT: When removing injection lines, DO
NOT turn pump delivery valve fittings. Turning
fittings may damage pump internally. Always
use a backup wrench when removing lines.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury should reference a
knowledgable source. Such information is
available from the Deere & Company Medical
Department in Moline, Illinois, U.S.A.
M76730
IMPORTANT: Never steam clean or pour cold water
on injection pump while the pump is running or
warm. Doing so can damage the pump.
2. Loosen fuel line connectors at injection pump to
release pressure in the fuel system. When
loosening connectors, use a backup wrench to
Nut
40 N•m (30 lb-ft)
Bronze Washer
Replace.
O-Ring
Replace.
Leak-Off Hose
Assembly
Leak-Off Hose (Long)
Hose Clamp
Injection Nozzle
50 N•m (37 lb-ft)
Bronze Washers
Replace.
Heat Protector
Replace.
M82323A
2/9/00
3 - 71
FUEL INJECTION NOZZLE
DIESEL ENGINE
prevent delivery valves from turning.
3. Loosen fuel line clamp, and remove fuel lines.
4. Disconnect long leak-off hose.
5. Remove nuts and leak-off hose assembly.
6. Remove bronze washers and O-rings.
7. Remove injection nozzle, washers and heat
protector.
8. Test injection nozzles. See Tests and Adjustment
section.
INJECTION NOZZLE CROSS SECTION
Injector
Body
Installation:
Installation is done in reverse order of removal.
• Tighten injection nozzle to 50 N•m (37 lb-ft).
• Tighten leak-off hose nuts to 40 N•m (30 lb-ft).
Shim
(as required)
Repair:
Spring
NOTE: If servicing more than one nozzle, keep parts
for each nozzle separate from one another.
Nozzle
Fitting
IMPORTANT: If injection nozzles are disassembled
to be cleaned, the same number and thickness
of shims must be installed.
Spring
Seat
Separator
Plate
• Clean and inspect nozzle assembly. See “Cleaning
and Inspection:” on page 72.
• After assembly is complete, test injection nozzle.
See Test and Adjustment section.
Injector Body
Separator
Plate
Nozzle
Valve
Nozzle
Body
M82325A
Nozzle
Valve
Shims
(as required)
Cleaning and Inspection:
Nozzle
Body
Nozzle
Fitting
40 N•m
(30 lb-ft)
NOTE:
Spring
Spring Seat
M82324A
To clean nozzles properly, JDF13 Nozzle
Cleaning Kit is recommended. The Cleaning
Kit is available through the John Deere SERVICEGARD™ Catalog.
1. Remove anticorrosive grease from new or
reconditioned nozzles by washing them thoroughly
in diesel fuel.
IMPORTANT: Never use a steel brush to clean
nozzles as this will distort the spray hole.
2. Remove carbon from used nozzles, and clean by
washing in diesel fuel. If parts are coated with
3 - 72
2/9/00
FUEL INJECTION PUMP
DIESEL ENGINE
hardened carbon or lacquer, it may be necessary to
use a brass wire brush (supplied in Nozzle
Cleaning Kit).
3. After removing carbon or lacquer from the exterior of
nozzle, inspect sealing surfaces between separator
plate and nozzle body for nicks or scratches.
4. Inspect condition of separator plate and nozzle body.
Contact area of separator plate (both parts) must
not be scored or pitted. Use an inspection magnifier
(No. 16487 or equivalent) to aid in making the
inspection.
5. Check nozzle contact surface on separator plate for
wear. If contact surface is more than 0.10 mm
(0.0039 in.), replace nozzle assembly.
Nozzle Contact
Surface
Separator Plate
Sealing Surfaces
FUEL INJECTION PUMP
Removal:
c
CAUTION
Escaping fluid under pressure can penetrate the
skin causing serious injury. Avoid the hazard by
relieving
pressure
before
disconnecting
hydraulic or other lines. Tighten all connections
before applying pressure. Search for leaks with
a piece of cardboard. Protect hands and body
from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury should reference a
knowledgable source. Such information is
available from the Deere & Company Medical
Department in Moline, Illinois, U.S.A.
Nozzle Body
ATTENTION!
M82326A
6. Inspect the piston (large) part of nozzle valve to see
that it is not scratched or scored and that lower (tip)
end of valve is not broken. If any of these conditions
are present, replace the nozzle assembly.
7. Further inspect the nozzle assembly by performing a
slide test. Use the following procedure:
• Dip the nozzle valve in clean diesel fuel. Insert
valve in nozzle body.
• Hold nozzle vertical, and pull valve out about
1/3 of its engaged length.
• Release valve. Valve should slide down to its seat
by its own weight.
Piston Part of
Nozzle Valve
DO NOT attempt to remove the CARB/EPA Certified
Emissions fuel injection pump unless you are a
factory trained technician with authorization to
service CARB/EPA Certified Emissions engines.
IMPORTANT: Never steam clean or pour cold water
on injection pump while the pump is running or
warm. Doing so can damage the pump.
1. Clean the injection pump lines and area around the
pump using a parts cleaning solvent or steam
cleaner.
IMPORTANT: When removing injection lines, DO
NOT turn pump delivery valve fittings. Turning
fittings may damage pump internally. Always
use a backup wrench when removing lines.
Nozzle Body
M35919
• Replace nozzle assembly if the valve does not slide
freely to its seat.
2/9/00
3 - 73
FUEL INJECTION PUMP
DIESEL ENGINE
IMPORTANT: If injection pump is being removed to
be serviced or replaced, the same thickness of
new shims must be installed when pump is
assembled. New shims must be used with
protective seal coating.
F
M76730
2. Disconnect injector/bypass fuel line.
3. Remove hose from air cleaner to intake manifold.
4. Loosen fuel line connectors at fuel injection pump to
release pressure in the fuel system. When
loosening connectors, use a backup wrench to
keep delivery valves from loosening.
5. Loosen line clamp and remove fuel injection lines.
6. Disconnect hoses from fuel injection pump.
7. Disconnect leak-off hoses from injectors.
Shims
E
M76732
10. Remove four nuts (E) to remove fuel injection pump
(F) and shims.
Installation:
Installation is done in the reverse order of removal.
Gasket
Replace.
A
M76731
8. Remove four nuts, governor linkage cover (A) and
gasket.
ATTENTION!
DO NOT attempt to adjust the CARB/EPA Certified
Emissions fuel injection pump unless you are a
factory trained technician with authorization to
service CARB/EPA Certified Emissions engines.
NOTE: Governor linkage has two holes. Connect governor linkage to injection pump rack using hole
closest to injection pump gear.
NOTE: Do not drop pin or washer during installation.
C
IMPORTANT: If a serviced or replacement fuel
injection pump is installed, measure old shim
thickness and install new shims of the same
thickness.
B
D
M82685
NOTE: Washer may be fixed to linkage. Do not drop
pin during removal.
9. Remove pin (B) and washer (C) if equipped.
Disconnect governor linkage (D).
3 - 74
2/9/00
FUEL INJECTION PUMP CAMSHAFT
DIESEL ENGINE
G
E
F
M82685
• When connecting governor linkage to injection
pump rack (G), attach link to rack at hole closest to
injection pump gear.
• Bleed the fuel system.
• If new injection pump is being installed, check and
adjust injection pump timing. See Injection Pump
Timing.
• Tighten injection body nuts to 20 N•m (180 lb-in.).
• Tighten injection nozzle to 50 N•m (37 lb-ft).
• Tighten leak-off hose nuts to 40 N•m (30 lb-ft).
D
M37755
8. Remove sleeve (D), nut (E) and governor weights (F)
from end of injection pump camshaft.
G
FUEL INJECTION PUMP CAMSHAFT
Removal:
1. Remove timing gear cover. See “TIMING GEAR
COVER” on page 46.
2. Remove fuel injection pump. See “FUEL INJECTION
PUMP” on page 73.
3. Remove fuel pump.
M37804
9. Remove bearing retaining screw (G).
IMPORTANT: DO NOT allow fuel injection pump
camshaft lobes to hit bearing surfaces while
removing camshaft. Machined surfaces may be
damaged.
C
B
10. Carefully tap the rear of camshaft (H) with plastic
hammer to remove from housing.
H
A
M76734
4. Remove throttle return spring and oil dipstick tube
(A).
5. Disconnect and remove fuel shutoff solenoid (B).
6. Remove five cap screws attaching governor
assembly (C) to timing gear housing.
7. Remove governor assembly.
2/9/00
M37796
11. Disassemble and inspect all parts for wear or
damage. (See Fuel Injection Pump Camshaft
Inspection.)
3 - 75
FUEL INJECTION PUMP CAMSHAFT
Installation:
DIESEL ENGINE
Assembly:
Installation is done in reverse order of removal.
• After installing camshaft assembly into housing, tap
on end of camshaft gear with a plastic hammer to
seat bearings in bores.
• Tighten bearing retainer screw (G) to 20 N•m (180
lb-in.).
• Align timing marks on injection pump gear and idler
gear when installing camshaft.
NOTE: Install large bearing on gear end.
IMPORTANT:
When pressing bearings apply
pressure on the inner bearing race only.
1. Install bearings on ends of camshaft using a 3/4 inch
deep well socket and a press. Press until bearing
races bottom on camshaft shoulders.
2. Install key.
3. Put camshaft gear on a flat surface and press
camshaft assembly into gear. Press until gear
shoulder butts up against inner bearing race.
Inspection:
Timing
Marks
M37832
Disassembly:
M35905
NOTE: Gear and bearings are press fit on shaft.
IMPORTANT: Hold camshaft while removing gear
and bearings. Shaft can be damaged if dropped.
1. Measure height of each camshaft lobe. Replace
camshaft if lobe height is less than 30.90 mm
(1.217 in.).
Front Bearing
Support
M37803
M37797
1. Remove gear using knife edge puller and a press.
2. Remove key.
3. Remove bearings using a knife edge puller and a
press.
4. Inspect all parts for wear or damage. (See Fuel
Injection Pump Camshaft Inspection.)
3 - 76
2. Inspect camshaft bearing supports in timing gear
housing. Check for cracks, damage or indications
that bearings have spun in support.
• If rear bearing bore is damaged, replace timing
gear housing.
• If front bearing bore is damaged, remove three cap
screws and replace support.
3. Inspect all parts for wear or damage. Replace as
necessary.
2/9/00
FUEL CONTROL AND GOVERNOR LINKAGE
DIESEL ENGINE
FUEL CONTROL AND GOVERNOR
LINKAGE
Gasket
Replace.
Removal:
F
Gasket
Replace
A
D
E
M76734
M76731
1. Disconnect and remove fuel shutoff solenoid.
2. Remove four nuts, governor linkage cover (A) and
gasket. Discard old gasket.
6. Remove throttle return spring (D) and dipstick tube
(E).
7. Remove five cap screws attaching fuel linkage
housing (F).
8. Remove linkage housing and gasket.
B
I
H
C
G
M82685
3. Remove muffler.
4. Remove valve cover breather hose.
NOTE: Washer may be fixed to linkage. Do not drop
pin during removal.
5. Remove pin (B) and washer to disconnect governor
linkage (C).
M37755
9. Remove sleeve (G).
10. Remove nut (H) and governor weights (I).
11. Disassemble and inspect all parts for wear or
damage. See Fuel Control and Governor Linkage
Inspection.
Installation:
Installation is done in the reverse order of removal.
• Governor linkage has two holes. Connect governor
linkage to injection pump rack using hole closest to
injection pump gear.
• Check and adjust slow idle settings. See “SLOW
IDLE ADJUSTMENT” on page 22.
2/9/00
3 - 77
FUEL CONTROL AND GOVERNOR LINKAGE
DIESEL ENGINE
Disassembly:
J
L
K
A
M
M82690
Replace
M76735
1. Remove spring (A).
E
6. Rotate throttle shaft assembly as shown.
7. Remove tapered pin (J) from tapered hole using a
punch.
8. Remove throttle shaft (K), shaft lever (L) and O-ring
(M).
C
D
Throttle
Shaft
N
O
B
P
Q
M82676B
M76736
2. Remove nut (B) and throttle lever plate (C).
3. Remove cap screw and throttle shaft retaining plate.
4. Remove cap screw (D) and governor shaft retaining
plate (E).
N. Cap Screw (3 used)
P. Slow Idle Stop
O. Gasket (replace)
Q. Spring Pin (2 used)
G
I
Replace
H
F
M82689
5. Remove governor shaft (F), governor linkage
assembly (G), shims (H) and O-ring (I).
3 - 78
2/9/00
FUEL CONTROL AND GOVERNOR LINKAGE
DIESEL ENGINE
Inspection:
3
4
5
2
1
6
7
8
9
14
M37763
10
13
12
11
6
MX0762
1. Throttle Shaft
8. Shim
2. O-ring
9. Bushing
3. Adjuster Stud
10. Spring
4. Shim(s) (as required)
11. Pin
5. Spring
12. Governor Lever
6. Spring Pin
13. Bracket
7. Spring
14. Governor Link
1. Measure governor shaft diameter. If OD is less than
specification, replace governor shaft.
2. Measure governor shaft bore diameter in governor
linkage.
Governor Shaft Specifications:
Shaft OD (Wear Limit) . . . . . . . . 8.01 mm (0.315 in.)
Bore ID (Wear Limit). . . . . . . . . . 8.50 mm (0.335 in.)
Clearance . . . . . . . . . . . . . . . . . . 0.09 mm (0.004 in.)
• If shaft bore exceeds wear limit, replace governor
linkage.
• If bore clearance (bore ID minus shaft OD) exceeds
specification, replace governor shaft, governor
linkage or both.
15. Disassemble governor linkage assembly.
16. Inspect all parts for wear or damage. Replace as
necessary.
Assembly:
Assembly is done in the reverse order of disassembly.
• Apply clean engine oil on all internal parts.
• When installing throttle shaft:
Install new O-ring, throttle shaft and shaft lever.
Install tapered pin in tapered hole.
• Slow idle adjustments are made after engine has
been installed in the machine. (Refer to Slow Idle
Adjustment.)
M37756
3. Measure inside diameter of sleeve. If ID is more than
specification, replace sleeve.
Specification:
Sleeve ID (Maximum) . . . . . . . . . 9.00 mm (0.354 in.)
2/9/00
3 - 79
STARTING MOTOR
DIESEL ENGINE
Installation:
1. Install starting motor on studs as removed and
tighten mounting bolts to 28 N•m (20 lb-ft).
2. Install all wires as removed, note that white wire is
connected to lower starting motor stud.
3. Reconnect negative battery lead to battery.
STARTING MOTOR REPAIR
Disassembly and Inspection:
M37757
A
4. Measure injection pump camshaft diameter.
C
Injection Pump Camshaft OD:
Wear Limit. . . . . . . . . . . . . . . . . . 7.90 mm (0.311 in.)
Clearance . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
• If camshaft diameter is less than wear limit, replace
injection pump camshaft.
• If clearance (sleeve ID minus camshaft OD)
exceeds specification, replace sleeve, injection
pump camshaft or both.
STARTING MOTOR
Removal:
1. Park vehicle on level surface, engine OFF, park
brake ON, cargo box UP.
2. Disconnect negative battery cable.
B
M76738
E
D
1. Disconnect field lead (A).
2. Remove two cap screws and two screws from rear
cover (B).
3. Pry off cap (C).
4. Remove E-clip (D), shims (E) and rear cover .
5. Inspect rear cover bushing for wear or damage.
• To replace rear cover bushing:
Remove bushing using a blind-hole puller set.
Install new bushing until it bottoms in cover bore
using a driver set.
F
M37874
A
M76900
6. Ream bushing (F) to 12.50 - 12.53 mm (0.492 0.493 in.)
3. Mark and remove all wires to starting motor. Note
that white wire (A) is connected to lower starting
motor stud.
4. Remove two mounting nuts holding starting motor to
frame, and pull starting motor off of studs and out of
engine compartment.
3 - 80
2/9/00
STARTING MOTOR REPAIR
DIESEL ENGINE
14. Inspect end frame bushing for wear or damage.
Replace if necessary.
G
H
P
O
M37879
Q
M37875
7. Remove field coil brushes (G) from brush holder.
8. Pry brush springs (H) away and pull negative
brushes up enough to allow spring to hold brush in
place.
9. Remove brush holder.
15. Slide pinion stopper (O) away from retaining wire
(P) using a piece of pipe or deep socket. Remove
retaining wire, pinion stopper, and clutch assembly
(Q) from armature shaft.
16. Inspect clutch assembly for wear or damage. Gear
should rotate in one direction only. Replace if
necessary.
S
I
M37876
10. Remove field coil housing (I) from armature/
solenoid assembly.
N
J
M
R
T
V
M76739
U
17. Remove clutch fork pivot (R), plunger (S), spring (T)
and shim(s) (U) from solenoid (V).
18. Inspect all parts for wear or damage. Replace as
necessary.
19. Inspect and test brushes, holder, field coil and
armature. See Starting Motor Component Testing
procedures.
Assembly:
Assembly is done in the reverse order of disassembly.
K
M37877
P
L
O
11. Remove two cap screws (J).
12. Remove dust cover (K).
13. Remove solenoid (L) and armature assembly (M)
from end frame (N).
2/9/00
M37831
3 - 81
STARTING MOTOR REPAIR
DIESEL ENGINE
• After installing clutch assembly, pinion stopper (O)
and retaining wire (P) on armature shaft, use two
pliers to press pinion stopper over retaining wire.
(A) and other probe to field brush holder (B). If
there is continuity, replace the brush holder.
3. Inspect springs (C) for wear or damage. Replace if
necessary.
NOTE: Test field coil using an ohmmeter or test light.
Notch
M37881
D
• When installing solenoid and armature assemblies
into end frame, make sure fork pivot seats in notch
on clutch fork.
E
IMPORTANT: When installing rear cover, be sure
field coil brush wires do not touch cover. Turn
brush holder slightly to take up slack in brush
wires. Press wires inward to clear rear cover.
Starting Motor Component Testing:
1. Measure holder and field coil brush lengths.
Minimum brush length is 7.70 mm (0.303 in.).
Replace brush holder or field coil if brush length is
below minimum.
NOTE: Test brush holder using an ohmmeter or test
light.
C
M82235
4. Test for grounded field winding:
Touch one probe of tester to field coil brush (D) and
other probe to field coil housing (E). Be sure the
brush lead is not touching the frame. If there is
continuity, the coil is grounded and the field coil
housing assembly must be replaced.
5. Test for open field coil:
Touch one probe of tester to each field coil brush. If
there is no continuity, the field coil is open and the
field coil housing assembly must be replaced.
IMPORTANT: Do not clean armature with solvent.
Solvent can damage insulation on windings.
Use only mineral spirits and a brush.
A
C
C
M82246
F
B
C
M82234
2. Test brush holder:
Touch one probe of tester to negative brush holder
3 - 82
6. Inspect armature. Look for signs of dragging against
pole shoes.
7. Inspect commutator (F). Look for roughness, burned
bars, or any material which might cause short
2/9/00
ALTERNATOR
DIESEL ENGINE
circuits between bars. If necessary, clean and touch
up with 400 sandpaper. NEVER use emery cloth.
Clean all dust from armature when finished.
front of cover.
C
A
NOTE: Test armature windings using an ohmmeter or
test light.
B
8. Test for grounded windings:
Touch probes on one commutator bar and armature
shaft. Armature windings are connected in series,
so only one commutator bar needs to be checked.
If test shows continuity, a winding is grounded and the
armature must be replaced.
9. Test for open circuited windings:
Touch probes on two different commutator bars.
If test shows no continuity, there is an open circuit and
the armature must be replaced.
Hacksaw Blade
Armature
M76901
4. Lift red plastic protective cover from positive (red)
lead (A) from battery. Remove nut and washer and
remove lead from alternator stud.
5. Remove indicator lamp connector (B) and ground
wire (C) from alternator and move wiring harness to
the side
6. Loosen alternator mounting bolts and remove belt
from drive pulley.
7. Remove mounting bolts. Pull alternator from frame.
Installation:
Installation in reverse of removal.
Growler
M82125A
10. Test for short circuited windings using a growler.
Put armature in a growler and hold a hacksaw
blade above each slot while slowly rotating
armature.
If coil is shorted, the blade will vibrate on the slot.
NOTE: A short circuit most often occurs because of
copper dust or filings between two commutator
segments.
• Tension drive belt. See “WATER PUMP/
ALTERNATOR DRIVE BELT ADJUSTMENT” on
page 28.
Repair:
Equipment:
• Volt-Ohm-Amp Meter
• 13 Ton Bearing Puller Set
Disassembly:
11. If test indicates short circuited windings, clean the
commutator of dust and filings. Check the armature
again. If the test still indicates a short circuit,
replace the armature.
A
ALTERNATOR
Removal:
1. Park vehicle on level surface, park brake ON, engine
OFF, cargo box RAISED.
2. Disconnect negative (–) battery cable from battery.
3. Remove alternator/water pump belt cover from front
of engine by removing three nuts and washers from
2/9/00
B
M52469
1. Clamp sheave in a soft jaw vise and remove sheave
3 - 83
ALTERNATOR
DIESEL ENGINE
nut (A).
2. Use puller to remove sheave (B).
D
I
J
M52473
C
9. Remove rear case assembly (I).
10. Press rotor shaft (J) from rear case.
M52470
3. Remove insulator (C).
4. Remove cover (D).
L
F
K
E
M52475
M52472
5. Remove brush holder and cover (E).
11. Remove retainer plate (K).
12. Press bearing (L) from case.
NOTE: Remember location of short screw on regulator
tab.
Inspection:
6. Remove regulator (F).
G
H
M
O
M52471
7. Remove screw and straighten wire leads (G).
8. Remove rectifier (H).
3 - 84
N
M52474
1. Inspect bearing (M) for smooth rotation. Replace if
necessary.
2. Inspect slip rings (N) for dirt or rough spots. If
necessary, use No. 00 sandpaper or 400-grit silicon
carbide paper to polish rings.
3. Measure outer diameter of slip rings (N). Replace
2/9/00
ALTERNATOR
DIESEL ENGINE
rotor if less than specification.
Brush Length Specifications:
Specification:
Slip Ring Diameter (Minimum) . . 14.0 mm (0.55 in.)
4. Check continuity between slip rings (N) using
ohmmeter or continuity tester. Replace rotor
assembly if there is no continuity.
5. Check continuity between slip rings and rotor core
(O). Replace rotor assembly if there is continuity.
Exposed Brush Length:
Minimum . . . . . . . . . . . . . . . . . . . 4.5 mm (0.17 in.)
Maximum. . . . . . . . . . . . . . . . . . 10.5 mm (0.41 in.)
S
T
M52479
NOTE: Use an ohmmeter that is sensitive to 0 - 1 ohm.
6. Inspect stator for defective insulation, discoloration,
or burned odor.
7. Check for continuity between each stator lead and
body. Replace stator if there is continuity.
10. Check continuity between brush and terminal (S).
Check continuity between brush and terminal (T).
There should be continuity only at these points.
Assembly:
1. Press new bearing (L) into case.
2. Install retainer plate (K).
Q
NOTE: Check that rotor fan does not contact case and
that rotor assembly turns smoothly in bearing.
P
3. Press rotor shaft (J) into rear case.
4. Install rear case assembly (I).
5. Install rectifier (H).
6. Install screws through loop formed in wire leads (G).
M52477
IMPORTANT: Check that short screw is installed in
regulator tab. Longer screw will contact frame
and will cause damage to the charging system.
NOTE: Set ohmmeter to the K ohm range.
8. Check continuity between lead (P) and each diode
lead (Q). Reverse ohmmeter leads and recheck.
There should be continuity in one direction, but not
the other. Replace diodes or rectifier plate if bad.
R
7. Install regulator (F).
8. Install brush holder (E).
9. Install regulator cover (D).
10. Install insulator (C) and nut.
11. Install sheave (B).
12. Clamp sheave in soft jaw vise. Install sheave nut
(A) and tighten to 69 N•m (51 lb-ft).
M52478
9. Measure length of brush protruding from holder.
Dimension (R) should be within specification.
Replace brushes if worn below minimum.
2/9/00
3 - 85
ALTERNATOR
3 - 86
DIESEL ENGINE
2/9/00
CONTENTS
ELECTRICAL
CONTENTS
THEORY OF OPERATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSTIC INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WIRE COLOR ABBREVIATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
READING ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMMON CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CONDUCTORS FOR 12 VOLT CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CARGO BOX LIFT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TROUBLESHOOTING – CARGO BOX LIFT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 11
ELECTRICAL SCHEMATIC AND WIRING HARNESS LEGEND . . . . . . . . . . . . . . . 12
ELECTRICAL SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
W1 MAIN WIRING HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
W1 WIRE COLOR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
W2 ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
W3 ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
W4 ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
W5 ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
W6 ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
W7 ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
W8 ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
W9 HEADLIGHT WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
W10 CARGO BOX LIFT WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
W10 WIRE COLOR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
W11 BLACKOUT LIGHT KIT WIRING HARNESS (opt.). . . . . . . . . . . . . . . . . . . . . . 19
THEORY AND DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
POWER CIRCUIT OPERATION AND SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . 20
POWER CIRCUIT DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
POWER CIRCUIT DIAGNOSIS (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CRANKING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CRANKING CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CRANKING CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
GLOW PLUG/FUEL SUPPLY CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 30
GLOW PLUG/FUEL SUPPLY CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . 31
GLOW PLUG/FUEL SUPPLY CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 32
CHARGING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
CHARGING CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
CHARGING CIRCUIT DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INDICATOR LIGHTS CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INDICATOR LIGHTS CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INDICATOR LIGHTS CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
RADIATOR FAN MOTOR CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
RADIATOR FAN MOTOR CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2/9/00
4-1
CONTENTS
RADIATOR FAN MOTOR CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHTS AND BLACKOUT LIGHTS KIT CIRCUIT OPERATION . . . . . . . . . .
HEADLIGHTS AND BLACKOUT LIGHTS KIT CIRCUIT SCHEMATIC . . . . . . . . . .
HEADLIGHTS AND BLACKOUT LIGHTS KIT CIRCUIT DIAGNOSIS . . . . . . . . . . .
HOUR METER CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUR METER CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOUR METER CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARGO BOX LIFT SYSTEM CIRCUIT OPERATION. . . . . . . . . . . . . . . . . . . . . . . .
CARGO BOX LIFT SYSTEM CIRCUIT SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . .
CARGO BOX LIFT SYSTEM CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . .
CARGO BOX LIFT SYSTEM CIRCUIT DIAGNOSIS (Continued) . . . . . . . . . . . . . .
ELECTRICAL
44
46
47
48
50
51
52
54
55
56
58
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERY LOAD TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM AMPERAGE DRAW TESTS . . . . . . . . . . . . . . . . . . . . . . .
UNREGULATED AMPERAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REGULATED AMPERAGE AND VOLTAGE TESTS . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING MOTOR LOADED AMPERAGE DRAW TEST . . . . . . . . . . . . . . . . . . . .
STARTING MOTOR NO-LOAD AMPERAGE AND RPM TESTS . . . . . . . . . . . . . . .
STARTING MOTOR SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NEUTRAL START SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARK BRAKE SWITCH TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL PRESSURE SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHT SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIFFERENTIAL LOCK SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
START SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARGO BOX LIFT SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SHUTOFF SOLENOID TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RADIATOR CORE TEMPERATURE SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE COOLANT TEMPERATURE SWITCH TEST . . . . . . . . . . . . . . . . . . . . . .
GROUND CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARGO BOX MOTOR AMPERAGE DRAW TEST. . . . . . . . . . . . . . . . . . . . . . . . . .
60
60
61
62
62
63
64
65
66
66
67
67
68
68
69
69
70
70
71
72
72
73
CARGO BOX LIFT REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
REPLACE ACTUATOR CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
REPLACE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
COVER TUBE SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4-2
2/9/00
ELECTRICAL
THEORY OF OPERATION INFORMATION
THEORY OF OPERATION
INFORMATION
WIRE COLOR ABBREVIATION
CHART
The theory of operation stories divide the electrical
system into individual circuits by function. Each circuit
is isolated from the main wiring schematic and only
shows the components that are used in it. The story
contains information on function, operating conditions,
and theory of operation. The circuit schematics are
drawn with the components in the operating position,
with the power, or battery positive, into them across the
top and the ground, or battery negative, across the
bottom.
Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black
Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue
Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown
Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green
Gry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gray
Org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange
Pnk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pink
Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple
DIAGNOSTIC INFORMATION
The diagnostic procedures is used to test the complete
circuit regardless of the problem or complaint. Select a
symptom or system from the quick check or
troubleshooting chart and follow the test procedures
under that heading.
The diagnostic procedure lists:
• Test conditions
• Test sequence
• Test location
• Normal reading
• Check or test to perform if reading is not normal
When performing the test or check, be sure to set your
machine up to the test conditions listed and follow the
sequence carefully. The middle “NORMAL” column
gives the reading or condition that should be obtained
when performing the test or check. If the results of the
test or check are not normal, perform the test, check, or
adjustment listed in the third “IF NOT NORMAL”
column to repair the malfunction. The detailed tests or
adjustments referred to in the “IF NOT NORMAL”
column are located at the end of that group. The
system diagram that accompanies each test procedure
is drawn to resemble machine components. The key
number on the art matches the number in the “TEST
LOCATION” column and the leader line points to the
exact point the test is to be made.
Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tan
Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .White
Yel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow
Blk/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . Black/White
Blu/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . Blue/White
Brn/Wht . . . . . . . . . . . . . . . . . . . . . . . . Brown/White
Brn/Yel . . . . . . . . . . . . . . . . . . . . . . . . .Brown/Yellow
Dk Blu. . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Blue
Dk Brn/Lt Grn . . . . . . . . . . Dark Brown/Light Green
Dk Brn/Red . . . . . . . . . . . . . . . . . Dark Brown/Red
Dk Brn/Yel . . . . . . . . . . . . . . . . . Dark Brown/Yellow
Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . . Dark Green
Lt Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue
Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . . Light Green
Org/Wht . . . . . . . . . . . . . . . . . . . . . . . Orange/White
Pnk/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . Pink/Black
Pur/Wht . . . . . . . . . . . . . . . . . . . . . . . . Purple/White
Red/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black
Red/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . Red/White
Wht/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . White/Black
Wht/Red . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red
Yel/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Black
Yel/Red . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Red
Yel/Wht . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/White
2/9/00
4-3
READING ELECTRICAL SCHEMATICS
ELECTRICAL
READING ELECTRICAL
SCHEMATICS
The identifying letter is always the same for a specific
component, but the identifying numbers are numbered
consecutively from upper left to lower right. The
terminal designation (J) is placed directly outside the
symbol next to the connecting wire path. Switch
positions (K) are also placed directly outside the
symbol. The solid line (L) shows the position the switch
is currently in and dash lines (M) represent other switch
positions.
The schematic is made up of individual circuits laid out
in a sequence of related functions. It is formatted with
all power wires (A) across the top and all ground wires
(B) across the bottom. Current flow is generally from
top to bottom through each circuit and component. All
components are shown in the OFF position. The
diagram does not list connector (C) information unless
needed to avoid confusion. If the connector is shown,
the number next to it is the terminal pin location (D) in
the connector.
Each circuit is identified at the bottom of the drawing by
a section number (N) and section name (O).
The circuit number (P) and wire color (Q) of the wires
are shown directly next to the wire path.
Each component is shown by a symbol (E), its name
(F), and an identification code (G). The identification
code contains a device identifying letter (H) and
number (I).
The same component name and identification code are
used consistently on all diagrams in this section.
Components can be easily cross-referenced.
S1 Start
Switch
B
F2
15 Amp
Fuse
Wht
Wht
Red
Red
X1
S1
X2
X3
M
S2
Seat
Switch
D
D
6
K2
Ignition
Relay
Run
Off
L
K
30
87
86
85
J
F3
15 Amp
Fuse
K1
Start
Relay
F1
Fusible
Link
X3
215
Org
X2
721
Pur/
Wht
Red
S
G
E
I
X3
G1
Battery
M1
Starting
Motor
M
H
W2
Engine
X4
Wiring
Yel/
Harness
T1
Wht
Ignition
X5
Yel/Wht
Yel/Wht
Coil
E
X3
T2
Ignition
Coil
P
E1
Spark
Plug
B
F
SE1-Power and Starting Circuit
4-4
F
805 Pnk/Blk
B
W1
Shielded
Ground
710
Pur
H
1
Blk
A
800
Pink
X3
C
Start
210
Red
Off
Seat
On
Seat
414
Yel/
Blk
O
E2
Spark
Plug
Yel/
Wht
Wht
C
SE2-Ignition and Interlock Circuit
Blk/Yel
N
Q
105 Blk
SE3-PTO and Interlock
2/9/00
COMMON CIRCUIT TESTS
ELECTRICAL
COMMON CIRCUIT TESTS
1. Check all terminals and grounds of the circuit for
corrosion.
2. If terminals are not corroded or loose, the problem
is in the component or wiring.
Shorted Circuit:
A shorted circuit may result in the wrong component
operating (i.e. improper wire-to-wire contact). To test for
a shorted or improperly wired circuit:
1. Turn component switch ON.
2. Start at the controlling switch of the component that
should not be operating.
3. Follow the circuit and disconnect wires at
connectors until component stops operating.
4. Shorted or improper connections will be the last two
wires disconnected.
M85601 mif
Grounded Circuit:
Grounded circuits usually result in no component
operation, a blown fuse, or a blown fusible link.
M85600 mif
High Resistance or Open Circuit:
M85602 mif
High resistance or open circuits usually result in slow,
dim or no component operation (i.e. poor, corroded, or
disconnected connections). Voltage at the component
will be low when the component is in operation. To test
for high resistance and open circuits:
CONDUCTORS FOR 12 VOLT CIRCUITS
STRANDED CONDUCTORS FOR 12 VOLT CIRCUITS
SAE WIRE SIZE (GAUGE)
20
18
16
14
12
10
METRIC WIRE SIZE (MM)
0.5
0.8
1.0
2.0
3.0
5.0
TYPICAL STRANDING
7 X 28
16 X 30
19 X 29
19 X 27
19 X 25
19 X 23
MINIMUM CONDUCTOR AREA
IN CIRCULAR MILS
1072
1537
2336
3702
5833
9343
2/9/00
4-5
SPECIFICATIONS
ELECTRICAL
SPECIFICATIONS
Battery:
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BCI group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .U-1
CCA rating (Amps at 0o) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Reserve capacity (minutes). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Specific gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.225 or above
Electrolyte required fill (Approx.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt)
Load test (minimum.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 amp for 15 seconds
Starting Motor:
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Shift
Amp draw (on vehicle). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 amps (max.)
No-load amp draw (free running) . . . . . . . . . . . . . . . . . . . . 50 amps (max.) at 6000 rpm
Alternator:
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 amps
Regulated amperage:
1000 RPM (engine cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 amps
1000 RPM (engine hot) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 amps
3300 RPM (engine cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 amps
3300 RPM (engine hot) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 amps
Unregulated amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 amps (min.)
Regulated voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.2 - 14.8 VDC
Fuel Shutoff Solenoid:
Pull-in voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8 VDC
Hold voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 VDC
Glow Plug:
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 - 0.5 ohms
Engine Coolant Temperature Switch (Control Panel Light):
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . From off to on at 109° ± 1° C (228° ± 2°F)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ON: Continuity
Radiator Core Temperature Switch (Fan Control):
Closes (Continuity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 - 75° C (153 - 167° F)
Opens (Infinity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 - 63° C (135 - 145° F)
Lighting:
Headlights (halogen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.5 Watts
Neutral Start Switch:
Neutral (depressed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuity
In gear (released) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No Continuity
4-6
2/9/00
ELECTRICAL
CARGO BOX LIFT SPECIFICATIONS
CARGO BOX LIFT SPECIFICATIONS
Electrical Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VDC
Lift Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 Kg (880 lbs) min.
Lift Rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 in/sec
Stroke Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 mm (5.12 in.)
Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 amps @ 12 VDC - Full Load
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25% on time at rated load per cycle
Motor Protection . . . . . . . . . . . . . . . . . . . . Automatic reset thermal overload in windings
Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ball Detent Overload Clutch
Temperature Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . -40 ° to 66° C (-40° F to 150° F)
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ball Bearing Screw
Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Packard Series 56
Lead Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 gauge
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clevis mounting only
Restraining Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (150 lb-in.)
End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 mm (0.045 in.) max.
Static Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1818 Kg (4000 lbs)
Duty cycle means that for an actuator operating continuously for 10 seconds, it must cool for 30 seconds.
2/9/00
4-7
COMPONENT LOCATION
ELECTRICAL
COMPONENT LOCATION
Instrumentation Lights
(Left To Right)
H1 Discharge Light
H5 Oil Pressure Light
H4 Engine Coolant Temperature Light
H2 Park Brake Light
H3 Differential Lock Light
B2 Radiator Core
Temperature Switch
M2 Radiator Fan Motor
S5 Light Switch
P1 Hour Meter
W9 Headlight
Wiring Harness
S2 Start Switch
S6 Cargo Box
Lift Switch
E2 RH Headlight
W1 Main Wiring Harness
E1 LH Headlight
M76676L
4-8
2/9/00
COMPONENT LOCATION
ELECTRICAL
K1 Start Relay
A1 Glow Plug Module
B3 Engine Coolant
Temperature Switch
Y2 Fuel Shutoff
Solenoid
G1 Battery
K2 Pull-in Coil
Cut Out Relay
R1, R2 & R3
Glow Plugs
K3 & K4 Cargo Box
Lift Directional Relays
G3 Alternator
W10 Cargo Box Lift
Wiring Harness
G2 Battery
W1 Shielded
Ground
B1 Engine Oil
Pressure Switch
S1 Neutral
Start Switch
Y1 Starting
Motor Solenoid
M1 Starting
Motor
S4 Differential Lock Switch
M76676R
S3 Park Brake Switch
2/9/00
4-9
TROUBLESHOOTING
ELECTRICAL
●
Test battery and battery
connections
●
See glow plug/fuel supply
diagnosis
●
●
●
●
Headlight problem
Engine oil light problem
Improper component operating with
switch
●
Instrument lights problems
Check ground circuit
Cooling fan problems
●
Engine coolant temperature light
problem
See cranking circuit
diagnosis
Discharge light problem
●
Battery goes dead, discharges or
overcharges
See power circuit
diagnosis
Engine will not shut off
Check or
Solution
Starter cranking problems
Problem or
Symptom
Engine cranks but will not start
TROUBLESHOOTING
●
●
●
See charging circuit
diagnosis
See instrumentation
circuits
●
See lighting and horn
circuit diagnosis
Check for shorted circuit
See headlight circuit
4 - 10
●
●
●
2/9/00
TROUBLESHOOTING – CARGO BOX LIFT SYSTEM
ELECTRICAL
Thermal overload cut-out; let cool.
●
Stripped nut or gears; check for excessive shock
loads.
●
Excessive loaded; reduce load.
●
●
Brake worn seized or broken; replace brake.
●
Fusible link burnt; replace.
●
●
Actuator binding; check distribution of load, cargo
box and lift pivot points for binding and wear.
Cylinder at end of stroke or clutch slipping.
Wire location switched at lift control switch outlet
terminals or in lift motor connector.
2/9/00
●
●
●
●
Low voltage.
Faulty Switch. See switch test.
●
●
●
Clutch Worn; replace clutch.
●
Switch operates in wrong direction
●
Fast thumping noise
●
Lift is slow
Lift will not retract to lower cargo box
●
Lift will not hold position
Lift will not extend or raise cargo box
Lift not receiving power; check connection and
fusible links at starter. See Lift circuit diagnosis.
Problem or
Symptom
Lift stops in mid-stroke
Check or
Solution
Lift does not operate
TROUBLESHOOTING – CARGO BOX LIFT SYSTEM
●
●
●
●
●
●
●
4 - 11
ELECTRICAL SCHEMATIC AND WIRING HARNESS LEGEND
ELECTRICAL SCHEMATIC AND
WIRING HARNESS LEGEND
V1—Diode (SE4, W1)
A1—Glow Plug Module (SE4, W1)
Y1—Starting Motor Solenoid (SE1, W1)
B1—Engine Oil Pressure Switch (SE5, W1)
Y2—Fuel Shutoff Solenoid (SE4, W1)
ELECTRICAL
W1—Shielded Ground (SE1, W1)
B2—Radiator Core Temperature Switch (SE5, W1)
B3—Engine Coolant Temperature Switch (SE6, W1)
CONNECTORS:
E1—LH Headlight (SE7, W9)
X1—W1 Main Wiring Harness to W8 Engine Wiring
Harness (SE4, W1)
E2—RH Headlight (SE7, W9)
E3—LH Rear Marker Light (SE8, W11) (opt.)
E4—LH Front Marker Light (SE8, W11) (opt.)
E5—RH Rear Marker Light (SE8, W11) (opt.)
E6—RH Front Marker Light (SE8, W11) (opt.)
F1—Fusible Link (SE1, W1)
F2—Fusible Link (SE1, W1)
F3—Fusible Link (SE1, W1)
F4—Fusible Link (SE1, W1)
F5—Fusible Link (SE1, W1)
G1—Battery (SE1, W1)
G2—Battery (SE1, W1)
G3—Alternator (SE2, W1)
H1—Discharge Light (SE5, W1)
H2—Park Brake Light (SE6, W1)
H3—Differential Lock Light (SE6, W1)
H4—Engine Coolant Temperature Light (SE6, W1)
H5—Engine Oil Pressure Light (SE6, W1)
K1—Start Relay (SE2, W1)
K2—Pull-in Coil Cut Out Relay (SE4, W1)
K3—Cargo Box Raise Relay (SE8, W10)
K4—Cargo Box Lower Relay (SE8, W10)
M1—Starting Motor (SE1, W1)
M2—Radiator Fan Motor (SE5, W1)
M3—Cargo Box Lift Motor (SE7, W10)
P1—Hour Meter (SE6, W1)
R1—Glow Plug (SE3, W7)
R2—Glow Plug (SE3, W7)
R3—Glow Plug (SE3, W7)
X2—W1 Main Wiring Harness to B2 Radiator Core
Temperature Switch (SE5, W1)
X3—M2 Radiator Fan Motor to W1 Main Wiring
Harness (SE5, W1)
X4—M2 Radiator Fan Motor to B2 Radiator Core
Temperature Switch (SE5, W1)
X5—W1 Main Wiring Harness to W9 Headlight Wiring
Harness (SE6, W1)
X5A—W9 Headlight Wiring Harness to W11 Blackout
Light Kit Wiring Harness (SE6, W1) (opt.)
X6—W1 Main Wiring Harness to W9 Headlight Wiring
Harness (SE6, W1)
X6A—W9 Headlight Wiring Harness to W11 Blackout
Light Kit Wiring Harness (SE6, W1) (opt.)
X7—W10 Cargo Box Lift Wiring Harness to M3 Cargo
Box Lift Motor (SE7, W10)
X8—W1 Main Wiring Harness to W10 Cargo Box Lift
Wiring Harness (SE8, W1)
WIRING HARNESSES:
W1—Main Wiring Harness
W2—Engine Wiring Harness (Battery Jumper)
W3—Engine Wiring Harness (Battery Jumper)
W4—Engine Wiring Harness (Ground)
W5—Engine Wiring Harness (Ground)
W6—Engine Wiring Harness (Alternator)
W7—Engine Wiring Harness (Glow Plugs)
W8—Engine Wiring Harness (Fuel Shut Off)
W9—Headlight Wiring Harness
W10—Cargo Box Lift Wiring Harness
W11—Blackout Light Kit Wiring Harness (opt.)
S1—Neutral Start Switch (SE2, W1)
S2—Start Switch (SE3, W1)
S3—Park Brake Switch (SE6, W1)
S4—Differential Lock Switch (SE6, W1)
S5—Light Switch (SE6, W1)
S6—Cargo Box Lift Switch (SE7, W1)
S7—Blackout Light Switch (SE7, W1) (opt.)
4 - 12
2/9/00
ELECTRICAL SCHEMATIC
ELECTRICAL
ELECTRICAL SCHEMATIC
REPLACE WITH FOLD-OUT
FILE 4-13_2PG.FM
2/9/00
4 - 13
W1 MAIN WIRING HARNESS
ELECTRICAL
W1 MAIN WIRING HARNESS
REPLACE WITH FOLD-OUT
FILE 4-13_2PG.FM
4 - 14
2/9/00
W1 WIRE COLOR CODES
ELECTRICAL
W1 WIRE COLOR CODES
Circuit Wire
Number Size
Color
Termination Points
100
105
110
120
125
130
135
145
150
170
200
201
205
210
211
215
216
220
221
230
240
300
301
400
402
403
404
410
415
420
423
425
430
435
439
440
441
450
600
620
621
625
1.0
1.0
0.5
0.5
0.5
3.0
3.0
1.0
3.0
0.8
2.0
0.8
5.0
3.0
1.0
2.0
0.8
3.0
1.0
2.0
5.0
0.8
0.5
2.0
0.8
0.8
0.5
1.0
1.0
0.8
0.8
1.0
0.8
0.8
1.0
3.0
3.0
0.8
0.5
0.5
0.8
0.5
Blk
Blk
Blk
Blk
Blk
Blk
Blk
Blk
Blk
Blk
Red
Fuselink, F1
Red
Red/Blk
Fuselink, F4
Red
Fuselink, F2
Red
Fuselink, F5
Red
Red
Org/Wht
Org/Wht
Yel/Red
Yel
Yel
Yel
Yel/Red
Yel/Red
Yel
Yel
Yel
Yel
Yel
Fuselink, F3
Wht
Wht
Yel
Brn
Tan
Tan
Diode
630
640
670
0.8
0.5
1.0
Gry/Blk
Grn
Yel/Wht
Splice #2, A1
X6, K1
H3, X6
H2, H3
W1, Splice #2
G3, Splice #2
Splice #2, X2
K1, A1
Splice #2, X1
H2, P1
F1, S2
Splice #1, 200 Red
Y1, G3
F4, X4
Splice #1, 210 Red/Blk
F2, K1
Splice #1, 215 Red
F5, A1
Splice #1, 220 Red
S2, S2
Y1, Splice #1
H4, B3
H4, A1
S2, Splice #3
X5, H4
H4, H5
H5, H1
X5, Splice #3
Splice #3, S6
Splice #3, S4
S4, S3
Splice #3, G3
A1, S3
A1, X1
Splice #1, 440 Wht
F3, K2
X1, K2
Splice #3, P1
G3, H1
H5, V1
V1, B1
K2, 620 Tan and 621
Tan
S3, H2
S4, H3
X8, S6
2/9/00
Circuit Wire
Number Size
Color
Termination Points
675
700
706
710
711
920
Yel/Blk
Pur
Pur
Pur/Blk
Pur
Red/Wht
X8, S6
K1, Y1
S1, K1
S2, S1
S1, K2
A1; R1, R2 & R3
1.0
2.0
0.8
0.8
0.8
3.0
4 - 15
W2 ENGINE WIRING HARNESS
ELECTRICAL
W2 ENGINE WIRING HARNESS
Red
To G2 Battery Pos. (+) Terminal
To G1 Battery Pos. (+) Terminal
W3 ENGINE WIRING HARNESS
Blk
To G1 Battery (-) Terminal
To G2 Battery (-) Terminal
W4 ENGINE WIRING HARNESS
Blk
To G2 Battery (-) Terminal
To Engine Block
W5 ENGINE WIRING HARNESS
Silver
To Engine Block
To Chassis
W6 ENGINE WIRING HARNESS
Red
To G2 Battery Pos (+) Terminal
4 - 16
To Y1 Starting Motor Solenoid Terminal
2/9/00
W7 ENGINE WIRING HARNESS
ELECTRICAL
W7 ENGINE WIRING HARNESS
Blk
Blk
To R1 Glow Plug
To R3 Glow Plug
To R2 Glow Plug
W8 ENGINE WIRING HARNESS
Y2 Fuel Shutoff Solenoid
Blk
Red
Wht
X1 To W1 Main Wiring Harness
W9 HEADLIGHT WIRING HARNESS
455
Yel
100 Blk
110 Blk
E2 RH
Headlight
S6
Headlight Switch
E1 LH
Headlight
400 Yel
456 Yel
455 Yel
456 Yel
X6 to W1 Main
Wiring Harness
X5 to W1 Main
Wiring Harness
400 Yel
2/9/00
100 Blk
110 Blk
4 - 17
W10 CARGO BOX LIFT WIRING HARNESS
ELECTRICAL
W10 CARGO BOX LIFT WIRING HARNESS
K4 Lower Relay
K3 Raise Relay
103
104
103 Blk
104 Blk
402 Red
401 Blk
800 Org
850 Blk
101 Blk
103 Blk
102 Blk
104 Blk
675 Yel/Blk
670 Yel/Wht
W10 WIRE COLOR CODES
101
102
402
401
Circuit
Number
Wire
Size
Color
Termination Points
100
3.0
Blk
101
2.0
Blk
101 Blk and 102 Blk
solder connection,
G2 (–)
K3, 102 Blk and 100
Blk solder
connection
102
2.0
Blk
K4, 101 Blk and 100
Blk solder
connection
103
0.8
Blk
K3, K3
104
0.8
Blk
K4, K4
400
3.0
Red
G2 (+), 401 Red and
402 Red solder
connection
401
2.0
Blk
402
2.0
Red
400 Red and 402
Red solder
connection, K3
400 Red and 401
Red solder
connection, K4
670
0.8
Yel/Wht
X8, K3
675
800
0.8
2.0
Yel/Blk
Org
X8, K4
K3, X7
850
2.0
Blk
K4, X7
850
800
100
400
675
850 Blk
W10 To G2 (–)
800 Org
X7 To M3 Cargo Box Motor
670 Yel/Wht
X8 To W1 Main Wiring Harness
W10 To G2 (+)
M56348
4 - 18
2/9/00
W11 BLACKOUT LIGHT KIT WIRING HARNESS (opt.)
ELECTRICAL
W11 BLACKOUT LIGHT KIT WIRING HARNESS (opt.)
206 Yel
205 Yel
S7 Blackout Light
Switch
Splice #4
Splice #3
101
100 102
200
Yel
100
Blk
201
200 202
205
204
202 203
105
104
102 103
203
Yel
E5 Right Front
Marker Light
E6 Right Rear
Marker Light
105 Blk
106 Blk
X6A to W9 Headlight
Wiring Harness
106 Blk
201
Yel
101
Blk
Splice #5 Splice #6
X6 to W1 Main
Wiring Harness
X5A to W9 Headlight
Wiring Harness
E3 Left Rear
Marker Light
206 Yel
207 Yel
X5 to W1
Main
Wiring
Harness
103
Blk
204
Yel
E4 Left Front
HeadLight
104
Blk
207 Yel
B2 RADIATOR CORE TEMPERATURE SWITCH WIRING
B2 Radiator Core
Temperature Switch
X2 to W1 Main
Wiring Harness
Blk
Blk
X3 to M2
Radiator Fan Motor
M2 RADIATOR FAN MOTOR WIRING
M2 Radiator
Fan Motor
X4 to W1 Main
Wiring Harness
Red
Blk
X3 to B2
Radiator Core
Temperature Switch
2/9/00
4 - 19
THEORY AND DIAGNOSIS
ELECTRICAL
THEORY AND DIAGNOSIS
• “B” & "S2" Terminal of S2 Start Switch
• K1 Start Relay
• K2 Pull-in Coil Cut Out Relay
• A1 Glow Plug Module
• M2 Radiator Fan Motor
The positive battery cable connects the battery to the
starting motor. The starting motor bolt is used as a tie
point for the rest of the electrical system.
POWER CIRCUIT OPERATION AND
SCHEMATIC
Function:
Provides unswitched power to the primary components
whenever the battery is connected.
The battery cables and the starting motor tie point
connections must be good for the vehicle electrical
system to work properly.
Operating Conditions, Unswitched Circuits:
The ground cable connections is equally important as
the positive cable. Proper starter operation depends on
these cables and connections to carry the high current
for its operation.
Voltage must be present at the following components
with the start switch “OFF”:
• G1 & G2 Battery Positive Terminals
• “B” Terminal of Starting Motor Solenoid
• G3 Alternator Positive Terminal
• K3 Cargo Box Raise Relay
• K4 Cargo Box Lower Relay
The connections between the starting motor solenoid
and start switch, start relay, cut out relay, glow plug
module and radiator fan motor are each fused by a
fusible link. This is a short piece of wire that is
designed to fail if current load is too high or a short
occurs. It protects the wiring harness from damage.
400 Red
S1 Neutral
Start Switch
Non-Switched Power
Switched Power
706 Pur
711 Pur
710 Pur/Blk
710
Pur/Blk
230 Red
(Neutral)
(In Gear)
215
Red
706
Pur
S2
ST
400 Yel/Red
A
200 B
Red M
G
Start
Run
200
Red
F1
Fusible
Links
400
Red
201
K1
Start
Relay
215
Red
F2
F3
440 Wht
F4
216 439
Off
S2 Start
Switch
210
Red/Blk
435 Yel
X1
220
F5 Red
Red
211
221
Red
240
Red
Red
G2
Battery
B
Y2 Fuel
Shutoff
Solenoid
205 Red
S
Blk
G1
Battery
430
Yel
920
Red
/Wht
Blk
3
4
M
301
Org/Wht
435
Yel
5
TIMER
M1
Starting
Motor
W1 Shielded
Ground
4 - 20
Y1
Starting
Motor
Solenoid
425
Yel
A
205
Red
+ B
1
220
Red
G
3
G3
Alternator
2
A1 Glow
Plug
Module
U
R1 R2 R3
Glow Plugs
2/9/00
POWER CIRCUIT OPERATION AND SCHEMATIC
ELECTRICAL
The charge wire running between the alternator and
starting motor is unprotected.
Switched Power:
• A1 Glow Plug Module
• Y2 Fuel Shutoff Solenoid
These circuits are controlled by the start switch and are
protected by the fusible link.
Voltage must be present at the following components
with the start switch in the “ON or RUN” position:
• “A “ and “S1” Terminals of S2 Start Switch
• S1 Neutral Start Switch
• K1 Start Relay
• K2 Pull-in Coil Cut out relay
• P1 Hour Meter
• S6 Cargo Box Lift Switch
• G3 Alternator
• S5 Headlight Switch
• H4 Engine Coolant Temperature Light
• H5 Engine Oil Pressure Light
• H1 Discharge Light
• S4 Differential Lock Switch
• S3 Park Brake Switch
400 Red
Non-Switched Power
Switched Power
P1
Hour Meter
450
Yel
400 Yel/Red
K2 Pull-in
Coil Cut
Out Relay
415 Yel/Red
Off
S5 Headlight
Switch
On
S3 Park
Brake Switch
630
Gry/Blk
640
Grn
S4
Differential
Lock Switch
+
301
Org
/Wht
210
Red/Blk
300
Org
/Wht
Red
X4
Blk
t0
2/9/00
Blk
M
M2
Radiator
Fan Motor
B2 Radiator
Core
Temperature
Switch
87
400
Red
401 Blk
K4
402
Yel
X3
30
K3
Raise
Relay
87a
_
H1
Discharge
Light
86
402
Yel
404
Yel
440
Wht
85
Off
X5
711
Pur
(Off)
(Lower)
415 Yel/Red
420
Yel
On Off
423 Yel
On
(Raise)
410 Yel/Red
425 Yel
430
Yel
S6 Cargo Box
Lift Switch
403 Yel
H4 Engine
Coolant
Temperature
Light
404
Yel
85
86 Lower
30
87
Relay
402 Red
87a
H5 Engine Oil
Pressure Light
t0
B3 Engine Coolant
Temperature
Switch
4 - 21
POWER CIRCUIT DIAGNOSIS
ELECTRICAL
POWER CIRCUIT DIAGNOSIS
Test Conditions:
• Start switch in OFF position
Test/Check Point
Normal
If Not Normal
1. Starting motor solenoid battery
(B) terminal
Battery voltage
Check battery cables and test battery. See Battery
Tests.
2. Alternator
Battery voltage
Check 205 Red wire and connections.
3. Raise and Lower relays
Battery voltage
Check 400 Red wire and connections.
4. Start switch
Battery voltage
Check 200 Red wire and connections. Replace F1
fusible link.
5. Start relay
Battery voltage
Check 215 Red wire. Replace F2 fusible link.
6. Pull-in Coil Cut Out Relay
Battery voltage
Check 440 Wht wire. Replace F3 fusible link.
7. Glow plug module
Battery voltage
Check 220 Red wire. Replace F5 fusible link.
8. Radiator fan motor
Battery voltage
Check 210 Red wire. Replace F4 fusible link.
Battery voltage
Replace start switch.
10. Neutral Start Switch
Battery voltage
Check 710 Pur/Blk wire and connections.
11. Start Relay
Battery voltage
Check 706 Pur wire and connections. If OK, replace
neutral start switch.
12. Pull-in Coil Cut out relay
Battery voltage
Check 711 Pur wire and connections.
Test Conditions:
• Start switch in RUN position
9. Start switch
4 - 22
2/9/00
POWER CIRCUIT DIAGNOSIS
ELECTRICAL
G3
Alternator
F1 Fuse-Link
1
F2 Fuse-Link
2
F3 Fuse-Link
205 Red
F4 Fuse-Link
F5 Fuse-Link
M1 Starting Motor
K4 Lower Relay
K3 Raise Relay
3
G1 & G2
Batteries
401 Red
3
M2 Radiator Fan Motor
402 Red
S1 Neutral Start Switch
S2 Start Switch
9
400
Yel/Red
10
710 Pur/Blk
711 Pur
8
4
210 Red/Blk
9
710
Pur/Blk
K1 Start Relay
K2 Pull-in Coil
Cut Out Relay
A1 Glow Plug Module
200 Red
230 Red
6
5
7
440 Wht
220 Red
11
215 Red
11
706 Pur
706 Pur
2/9/00
4 - 23
POWER CIRCUIT DIAGNOSIS (Continued)
ELECTRICAL
POWER CIRCUIT DIAGNOSIS (Continued)
Test Conditions:
• Start switch in RUN position.
Test/Check Point
Normal
If Not Normal
13. Hour Meter
Battery voltage
Check 400 Yel/Red and 450 Yel wire and connections.
14. Cargo Box Lift Switch
Battery voltage
Check 415 Yel/Red wire and connections.
15. Alternator
Battery voltage
Check 425 Yel wire and connections.
16. Headlight Switch
Battery voltage
Check 410 Yel/Red wire and connections.
17. Engine Coolant Temperature
Light
Battery voltage
Check 402 Yel wire and connections.
18. Engine Oil Pressure Light
Battery voltage
Check 403 Yel wire and connections.
19. Discharge Light
Battery voltage
Check 404 Yel wire and connections.
20. Differential Lock Switch
Battery voltage
Check 420 Yel wire and connections.
21. Park Brake Switch
Battery voltage
Check 423 Yel wire and connections.
22. Glow Plug Module
Battery voltage
Check 430 Yel wire and connections.
23. Fuel Shutoff Solenoid
Battery voltage
Check 435 Yel wire and connections.
4 - 24
2/9/00
POWER CIRCUIT DIAGNOSIS (Continued)
ELECTRICAL
S6 Cargo Box
Lift Switch
P1 Hour Meter
14
415 Yel/Red
13
G3
Alternator
450 Yel
15
425 Yel
Y2 Fuel Shutoff Solenoid
435 Yel
23
A1 Glow Plug Module
S5 Headlight Switch
16
400
Yel/Red
22
430 Yel
435 Yel
H4 Engine Coolant Temperature Light
S3 Park Brake Switch
17
402 Yel
403 Yel
423 Yel
430 Yel
21
H1 Discharge Light
H5 Engine Oil Pressure Light
S4 Differential Lock Switch
18
20
19
420 Yel
423 Yel
2/9/00
404 Yel
403 Yel
404 Yel
4 - 25
CRANKING CIRCUIT OPERATION
ELECTRICAL
CRANKING CIRCUIT OPERATION
Function:
To energize the starting motor solenoid and engage the
starting motor to crank the engine.
Operating Conditions:
• Start switch in START position
• Transmission in neutral
Theory of Operation:
Current from the power circuit (200 Red) flows through
the F1 fusible link to the start switch, and is connected
from the B terminal of the start switch to the S2
terminal of the start switch through circuit 230 Red.
When in the start position the start switch allows
current to flow to the neutral start switch (710 Pur/Blk).
With the transmission in neutral, current flows to the K1
start relay coil allowing the start relay to activate.
When activated, the start relay contacts pass current
from the battery, and the F2 fusible link to energize the
Y1 starting motor solenoid (215 Red, 700 Pur).
With the starting motor solenoid activated, high current
from the battery passes through the battery cable and
solenoid contacts, and energizes the starting motor.
4 - 26
2/9/00
CRANKING CIRCUIT SCHEMATIC
ELECTRICAL
CRANKING CIRCUIT SCHEMATIC
S1 Neutral
Start Switch
706 Pur
710 Pur/Blk
710
Pur/Blk
230 Red
(Neutral)
(In Gear)
200
Red
F1
215
Red
215
Red
Red
200 B
Red M
ST
A
G
Start
Run
Off
F2
K1
Start
Relay
Fusible
Links
201
706
Pur
S2
700
Pur
216
145
Blk
S2 Start
Switch
Red
240
Red
G2
Battery
B
700
Pur
S
Blk
G1
Battery
M
M1
Starting
Motor
Blk
145
Blk
Y1
Starting
Motor
Solenoid
100
Blk
125 Blk
W1 Shielded
Ground
2/9/00
4 - 27
CRANKING CIRCUIT DIAGNOSIS
ELECTRICAL
CRANKING CIRCUIT DIAGNOSIS
Test Conditions:
• Transmission in neutral and brake set
• Start switch in OFF position
Test/Check Point
Normal
If Not Normal
1. Start switch
Battery voltage
Check 200 and 230 Red wires and F1 fusible link. See
“POWER CIRCUIT DIAGNOSIS” on page 22.
2. Start relay
Battery voltage
Check 215 Red wire and F2 fusible link. See “POWER
CIRCUIT DIAGNOSIS” on page 22.
Test Conditions:
• Transmission in neutral and brake set
• Start switch in START position while performing each test.
NOTE: Engine will turn over during this test. Allow time for starter to cool between each test.
3. Start switch
Battery voltage
Replace start switch.
4. Neutral start switch connector
Battery voltage
Check 710 Pur/Blk wire and connections.
5. Start relay
Battery voltage
Check 706 Pur wire and connections. If OK, replace
the neutral start switch.
6. Start relay
Continuity to
ground
Check 145, 100 and 125 Blk wires and connections. If
OK, test relay. See “RELAY TEST” on page 66.
7. Starting motor solenoid
Battery voltage
Check 700 Pur wire and connections. If OK, test relay.
See “RELAY TEST” on page 66.
If relay tests OK, test starting motor solenoid. See
“STARTING MOTOR SOLENOID TEST” on page 66.
4 - 28
2/9/00
CRANKING CIRCUIT DIAGNOSIS
ELECTRICAL
S2 Start Switch
K1 Start Relay
6
105/145 Blk
1
230 Red
1
710 Pur/Blk
5
2
200 Red
230 Red
3
215 Red
706 Pur
S1 Neutral Start Switch
710 Pur/Blk
711 Pur
4
700 Pur
7
200 Red
F1 Fuse-Link
215 Red
F2 Fuse-Link
125 Blk
M1 Starting Motor
W1 Shielded Ground
G1 & G2
Batteries
2/9/00
4 - 29
GLOW PLUG/FUEL SUPPLY CIRCUIT OPERATION
GLOW PLUG/FUEL SUPPLY
CIRCUIT OPERATION
Function:
To control the injection of diesel fuel and provide and
an added source of heat for combustion.
Operating Conditions:
• Start switch must be in the START or RUN position.
Theory of Operation:
The ignition system is designed to inject diesel fuel into
the precombustion chamber and piston cylinder where
heat from compression ignites the fuel and air mixture.
When starting a cold engine, compression pressure
may not provide enough heat to ignite the fuel when
injected into a cold precombustion chamber. An
electronically operated glow plug is installed into the
precombustion chamber to provide added heat to ignite
the fuel as it is injected. The glow plugs are energized
during starting, and also may be preheated by turning
the start switch to the RUN position for up to 30
seconds before turning the start switch to the start
position.
ELECTRICAL
Diesel fuel is provided to the engine when the fuel
shutoff solenoid is energized. The fuel shutoff solenoid
is initially pulled in when current from the starting motor
energizes it. After oil pressure opens the oil pressure
switch and de-energizes the pull-in coil, the fuel shutoff
solenoid is held in the energized state by current
provided through the start switch in the RUN position.
The glow plugs heat when current is provided through
the glow plug module. The glow plug module provides
current to the glow plugs through relay contacts
controlled by a timer.
The timer is started by turning the start switch to either
the RUN or START position. The length of time the
timer stays on is a function of ambient air temperature
and ranges from approximately 10 to 30 seconds. The
colder the temperature, the longer the timer stays on.
Stopping the electronic timer de-energizes the glow
plugs.
In the START position current flows from the start
switch to the start relay which in turn energizes the
starting motor. The differential lock, park brake, pull-in
coil cut out relay, fuel shutoff solenoid and glow plug
module are all provided current by the start switch in
both the RUN and START position.
When the start switch is turned to the START position
the starting motor turns the engine over. Before oil
pressure opens the engine oil pressure switch
(normally closed), the closed engine oil pressure switch
provides a ground path for the pull-in coil cut out relay.
While this ground is provided, the pull-in coil energizes,
closing cut out relay contacts which allow current flow
from the starting motor to energize the fuel shutoff
solenoid.
4 - 30
2/9/00
GLOW PLUG/FUEL SUPPLY CIRCUIT SCHEMATIC
ELECTRICAL
GLOW PLUG/FUEL SUPPLY CIRCUIT SCHEMATIC
S1 Neutral
Start Switch
710 Pur/Blk
706 Pur
ST
S2
(In Gear)
420
Yel
710
Pur/Blk
230 Red
(Neutral)
200 B
Red M
430
Yel
400 Yel/Red
A
G
Start
Run
On
706
Pur
K1
Start
Relay
200
Red
700
Pur
215
Red
F2
F1
440
Wht
F3
K2 Pull-in
Coil Cut
Out Relay
441 Wht
105
Blk
X1
X1
Red
Wht
Y2 Fuel
Shutoff
Solenoid
221
423 Yel
On Off
Off
120
Blk
S3 Park
Brake Switch
640
Grn
630
Gry/Blk
H3
Differential
Lock Light
H2 Park
Brake
Light
120
Blk
110
Blk
V1
Diode
Blk
X1
620
Tan
150
Blk
621
Tan
240
Red
G1
Battery
Red
S4
Differential
Lock Switch
440
Wht 625
F5
Fusible
Links
711
Pur
435 Yel
220
Red
216 439
201
145
Blk
402
Yel
S2 Start
Switch
Off
215
Red
410 Yel/Red
400 Yel/Red
711 Pur
Red
700
Pur
B
S
430
Yel
920
Red
/Wht
435
Yel
402
Yel
5
3
4
301
Org/Wht
403 Yel
Blk
TIMER
G2
Battery
M
M1
Starting Y1
Motor Starting
Motor
Solenoid
2
R1 R2 R3
Glow Plugs
1
220
Red
145
Blk 100
Blk
A1 Glow
Plug
Module
301
Org
/Wht
300
Org
/Wht
H4 Engine
H5 Engine Oil
Coolant
Pressure Light
Temperature 620
Light
Tan
621
Tan
Blk
t0
t0
125 Blk
B3 Engine Coolant
Temperature
Switch
B1 Engine Oil
Pressure
Switch (NC)
W1 Shielded
Ground
2/9/00
4 - 31
GLOW PLUG/FUEL SUPPLY CIRCUIT DIAGNOSIS
ELECTRICAL
GLOW PLUG/FUEL SUPPLY CIRCUIT DIAGNOSIS
Test Conditions:
• Start switch in OFF position
Test/Check Point
Normal
If Not Normal
1. Start Switch
Battery voltage
Check 200 Red wire and F1 fusible link.
2. Pull-in Coil Cut out relay
Battery voltage
Check 440 Wht wire and F3 fusible link.
3. Glow Plug Module
Battery voltage
Check 220 Red wire and F5 fusible link.
4. Park Brake light
Continuity to ground
Check 120, 110, 105, 145, 100, and 125 Blk wires
and connections.
5. Fuel shutoff solenoid
Continuity to ground
Check 150 and 125 Blk wires and connections.
6. Engine Oil Pressure Light
Continuity to ground
Check 620 and 621 Tan wires and connections.
7. Diode
Continuity in one
direction only
Replace diode.
8. Start switch
Battery voltage
Replace start switch.
9. Fuel shutoff solenoid
Battery voltage
Check 435, 430, 423, 420 Yel and 400 Yel/Red
wires and connections.
Battery voltage
Check 402 Yel and 410 and 400 Yel/Red wires and
connections.
Test Conditions:
• Start switch in RUN position
10. Engine Coolant Temperature
Light
Test Conditions:
• Start switch in RUN position. (Turn start switch to the OFF position while setting up for each test listed below.
Then turn the start switch to the RUN position and perform each test within 10 - 30 seconds.
11. Engine Coolant Temperature
Switch
Low voltage raising to
battery voltage after a
few seconds.
Check 300 and 301 Org/Wht wire and connections
and the engine coolant temperature light. If OK,
replace glow plug module.
12. Glow plugs
Battery voltage for up
to 30 seconds
Check 920 Red/Wht wire and connections. If OK,
replace glow plug module.
Test Conditions:
• K1 Start Relay unplugged from W1 Main wiring harness to prevent engine from turning over and starting.
• Start switch in START position during each test.
13. Pull-in Coil Cut Out Relay
Battery voltage
Check 711 Pur and 710 Pur/Blk wires and
connections. If OK, replace start switch.
14. Fuel shutoff solenoid
Battery voltage
Check 441 Wht wire and connections. If OK,
replace pull-in coil cut out relay
15. Fuel shutoff solenoid
Audible click
Replace fuel shutoff solenoid
4 - 32
2/9/00
GLOW PLUG/FUEL SUPPLY CIRCUIT DIAGNOSIS
ELECTRICAL
S2 Start Switch
K2 Pull-in Coil Cut Out Relay
1
230 Red
13
2
1
8
711 Pur
200 Red
230 Red
400 Yel/Red
440 Wht
710 Pur/Blk
A1 Glow Plug Module
100 Blk
145 Blk
W7 Engine Wiring Harness
to W1 Main Wiring Harness
3
220 Red
12
920 Red/Wht
430 Yel
435 Yel
H4 Engine Coolant Temperature Light
B3 Engine Coolant
Temperature Switch
920 Red/Wht
H2 Park Brake Light
300 Org/Wht
11
10
402 Yel
403 Yel
170 Blk
120 Blk
301 Org/Wht
300 Org/Wht
H5 Engine Oil Pressure Light
4
Y2 Fuel Shutoff Solenoid
V1 Diode
441 Wht
14
Pin
to connect
test lead too
5
Diode
7
2/9/00
620 Tan
6
435 Yel
9
150 Blk
4 - 33
CHARGING CIRCUIT OPERATION
ELECTRICAL
CHARGING CIRCUIT OPERATION
FUNCTION:
To maintain battery voltage between 12.4 and 13.2
volts.
OPERATING CONDITIONS:
The start switch must be in the RUN position with the
engine running for the charging system to operate.
SYSTEM OPERATION:
The charging system is a permanent magnet and
stator design alternator (G3). Charging output is
controlled by a regulator/rectifier built into the
alternator. The status of the charge rate is indicated by
the H1 discharge light.
With the start switch in the RUN position, battery
sensing circuit current flows from battery positive
terminal to starter terminal, fusible link F1 (200 Red),
start switch, and to regulator/rectifier (425 Yel). The
battery sensing circuit allows the voltage regulator/
rectifier to monitor battery voltage.
A rotating permanent magnet in the alternator induces
AC current in the alternator stator coils. The AC current
flows to the voltage regulator/rectifier. The voltage
regulator/rectifier converts AC current to DC current
needed to charge the battery.
If battery voltage is low, the regulator/rectifier allows
DC current to flow to the battery to charge it through
the battery charging circuit (205 Red). When the
battery is fully charged, the voltage regulator/rectifier
stops current flow to the battery.
If the stator output current falls below the system usage
or is insufficient to maintain a preset voltage, the
voltage regulator/rectifier provides a current path (600
Brn) to turn on the discharge light.
The ground circuit (130 and 125 Blk) provides a path to
ground for the voltage regulator/rectifier.
4 - 34
2/9/00
CHARGING CIRCUIT SCHEMATIC
ELECTRICAL
CHARGING CIRCUIT SCHEMATIC
230 Red
ST
S2
400 Yel/Red
400 Yel/Red
A
200 B
Red M
425 Yel
410 Yel/Red
G
Start
X5
Run
Off
402
Yel
S2 Start
Switch
200
Red
F1
Fusible
Links
404
Yel
201
+
600
Brn
_
H1
Discharge
Light
240
Red
Red
Red
205 Red
G2
Battery
B
402
Yel
S
403 Yel
Blk
G1
Battery
404
Yel
M
M1
Starting
Motor
Blk
Y1
Starting
Motor
Solenoid
425
Yel
A
205
Red
+ B
600
Brn
H4 Engine
Coolant
Temperature
Light
H5 Engine Oil
Pressure Light
G
3
G3
Alternator
U
130
Blk
125 Blk
W1 Shielded
Ground
2/9/00
4 - 35
CHARGING CIRCUIT DIAGNOSIS
ELECTRICAL
CHARGING CIRCUIT DIAGNOSIS
Test Conditions:
• Park brake set
• Transmission in neutral
• Engine and start switch in OFF position
Test/Check Point
Normal
If Not Normal
1. Battery positive terminal
Battery voltage (11.8 13.2 volts)
Test battery. See “BATTERY TEST” on
page 60.
2. Starting motor solenoid battery
(B) terminal
Battery voltage
Test battery and starter cable connections.
3. Alternator (+) terminal)
Battery voltage
Check 205 Red wire and connections. See
Power Circuit Diagnosis.
4. Alternator (A terminal)
Battery voltage
Check 425 Yel wire and connections. See
Power Circuit Diagnosis. Check F1 fusible link
and start switch.
5. Alternator (B terminal)
Greater than 0 volts - less
than 0.2 volts
Greater the 0.2 volts: Test voltage regulator/
rectifier ground circuit.
6. Discharge light (404 Yel wire)
Battery voltage
Check 402, 403 and 404 Yel wires and
connections
7. Discharge light (600 Brn wire)
Greater than 0 volts - less
than 0.2 volts
0 volts: Replace bulb
Greater than 0.2 volts: Check all connection
and ground wires for open or poor connection.
8. Alternator
Minimum 40 Amps at
12.2 to 13.8 volts
See Amperage Output Test. Replace voltage
regulator/rectifier.
9. Battery
Voltage above normal
battery voltage.
Check for excessive load on electrical system.
Test Conditions:
• Engine OFF
• Start Switch in RUN position
Test Conditions:
• Engine running
4 - 36
2/9/00
CHARGING CIRCUIT DIAGNOSIS
ELECTRICAL
2
240 Red
205 Red
200 Red
F1 Fuse-Link
125 Blk
M1 Starting Motor
W1 Shielded Ground
G1 & G2
Batteries
1
G3
Alternator
3 8
205 Red
425 Yel
4
600 Brn
5
H1 Discharge Light
6
404 Yel
600 Brn
7
2/9/00
4 - 37
INDICATOR LIGHTS CIRCUIT OPERATION
INDICATOR LIGHTS CIRCUIT
OPERATION
Function:
ENGINE DISCHARGE LIGHT
Inform the operator of a low charge rate by illuminating
a warning light.
ENGINE OIL PRESSURE LIGHT
To alert operator of low engine oil pressure by
illuminating a warning light.
ENGINE COOLANT TEMPERATURE LIGHT
Dual function to inform operator of critical engine and
coolant operating temperature by illuminating a
warning light, and inform operator of glow plug
operation.
PARK BRAKE LIGHT
Inform the operator that the parking brake is ON by
illuminating a warning light.
ELECTRICAL
ENGINE COOLANT TEMPERATURE LIGHT
When the start switch is in the start position, the
ground circuit is allowed to pass through the glow plug
module ground. This will turn on the light for a few
seconds depending on air temperature. When the glow
plug control times out, the light will go out. If the engine
temperature reaches 109°C ±1°C (228°F ±2°F) the
switch contacts will close, providing a path to ground
through the engine block which turns on the engine
coolant temperature light.
PARK BRAKE LIGHT
When the park brake is set the switch is released
(closes), allowing current to flow to the warning light.
When the park brake is released the park brake switch
is opened and the light goes out.
DIFFERENTIAL LOCK LIGHT
When the differential lock lever is moved to engage the
differential lock, the differential lock switch is depressed
(closed), allowing current flow to the differential lock
light. When the differential is released, the switch is
released (open), and the light goes out.
DIFFERENTIAL LOCK LIGHT
Inform the operator that the differential Lock is ON by
illuminating a warning light.
Operating Condition:
The start switch must be in RUN position.
Theory of Operation:
ENGINE DISCHARGE LIGHT
With the engine off and start switch in RUN position,
the voltage regulator built into the alternator provides a
voltage difference across the discharge light allowing
the light to go on.
When the engine is started and running the light should
go out when the voltage across the regulator equalizes
and allows too low of a current flow to illuminate the
light.
OIL PRESSURE LIGHT
With the engine off and start switch in RUN position, oil
pressure will be below 28 kPa (4 psi). The oil pressure
switch will be closed, completing the circuit path to
ground and illuminating the light. This will inform the
operator that the light is functioning.
When the engine is started and running the light should
go out when the oil pressure is adequate to open the
B1 engine oil pressure switch.
4 - 38
2/9/00
INDICATOR LIGHTS CIRCUIT SCHEMATIC
ELECTRICAL
INDICATOR LIGHTS CIRCUIT SCHEMATIC
230 Red
ST
S2
A
200 B
Red M
X5
410 Yel/Red
400 Yel/Red
425 Yel
G
Start
420
Yel
423 Yel
Run
On
S4
Differential
Lock Switch
402
Yel
On Off
Off
Off
S3 Park
Brake Switch
S2 Start
Switch
640
Grn
630
Gry/Blk
200
Red
F1
120
Blk
Fusible
Links
H2 Park
Brake
Light
120
Blk
110
Blk
H3
Differential
Lock Light
H5 Engine Oil
Pressure Light
201
402
Yel
+
Red
Red
600
Brn
205 Red
G2
Battery
B
404
Yel
110
Blk X6
404
Yel
240
Red
403 Yel
_
301
Org
/Wht
105
Blk
H1
Discharge
Light
300
Org
/Wht
H4 Engine
Coolant
Temperature
Light
620
Tan
S
Blk
G1
Battery
301
Org/Wht
M
Blk
Y1
Starting
Motor
Solenoid
425
Yel
A
205
Red
+ B
G
3
G3
Alternator
U
130
Blk
5
3
4
M1
Starting
Motor
600
Brn
TIMER
2
t0
B3 Engine Coolant
Temperature
Switch
1
145
Blk 100
Blk
A1 Glow
Plug
Module
625
V1
Diode
621
Tan
620
Tan
130 Blk
125 Blk
125 Blk
t0
B1 Engine Oil
Pressure
Switch (NC)
W1 Shielded
Ground
2/9/00
4 - 39
INDICATOR LIGHTS CIRCUIT DIAGNOSIS
ELECTRICAL
INDICATOR LIGHTS CIRCUIT DIAGNOSIS
Test Conditions:
• Start switch in OFF position
• Differential lock engaged
• Park brake set
Test/Check Point
Normal
If Not Normal
1. Park Brake light
Continuity to ground
Check 120, 110, 105, 145, 100, and 125 Blk
wires and connections.
2. Engine oil pressure light
Continuity to ground
Check 620 and 621 Tan wires and
connections. Check engine ground. If engine
ground OK, replace oil pressure switch.
Test Conditions:
• Start switch in RUN position, engine OFF
• Differential lock engaged
• Park brake set
3. Discharge light
Battery voltage (light
should be ON)
Check 404, 403 and 402 Yel wires and
connections. See Power Circuit Diagnosis. If
OK, replace light bulb.
4. Engine oil pressure light
Battery voltage (light
should be ON)
Check 402 and 403 Yel wires and
connections. See Power Circuit Diagnosis.
5. Engine oil pressure light
Continuity to ground (light
should be ON)
Check 620 and 621 Tan wires and
connections. If OK, replace light bulb.
6. Engine coolant temperature
light
Battery voltage (light
should be on for 3 to 30
seconds after turning
start switch to RUN
position)
Check 402 Yel wire. See Power Circuit
Diagnosis. Replace engine coolant
temperature light.
7. Engine coolant temperature
switch
Battery voltage after 10
seconds. Sensor open
lower than 109°C ±1°C
(228°F ±2°F)
Check 300 Org/Wht wire and connections.
See Power Circuit Diagnosis. Replace engine
coolant temperature switch.
8. Engine coolant temperature
switch
Battery voltage after 10
seconds. Switch open
lower than 109°C ±1°C
(228°F ±2°F)
Disconnect 300 Org/Wht wire at engine
coolant temperature switch. Check 301 Org/
Wht wire and connections. Replace glow plug
module.
9. Park brake light
Battery voltage (light
should be ON)
Check 630 Gry/Blk wire and connections. See
Power Circuit Diagnosis. Adjust or replace
park brake switch.
10. Park brake switch
Battery voltage
Check 420 and 423 Yel wires. Adjust or
replace park brake switch.
11. Differential lock light
Battery voltage
Check 640 Grn wire and connections. Check
differential lock switch. See Power Circuit
Diagnosis.
12. Differential lock switch
Battery voltage
Check 420 Yel wires. Adjust or replace
differential lock switch.
4 - 40
2/9/00
INDICATOR LIGHTS CIRCUIT DIAGNOSIS
ELECTRICAL
H2 Park Brake Light
H1 Discharge Light
H5 Engine Oil Pressure Light
1
120 Blk
3
170 Blk
4
620 Tan
9
2
5
630 Gry/Blk
404 Yel
600 Brn
403 Yel
404 Yel
0
H4 Engine Coolant Temperature Light
S4 Differential Lock Switch
6
402 Yel
12
403 Yel
8
301 Org/Wht
420 Yel
7
300 Org/Wht
423 Yel
B3 Engine Coolant
Temperature Switch
H3 Differential Lock Light
8 7
300 Org/Wht
11
S3 Park Brake Switch
640 Grn
10
423 Yel
430 Yel
2/9/00
4 - 41
RADIATOR FAN MOTOR CIRCUIT OPERATION
ELECTRICAL
RADIATOR FAN MOTOR CIRCUIT
OPERATION
Function:
To provide a means of moving air across the radiator
core to dissipating the heat from the engine coolant.
Operating Conditions:
With the batteries connected, the radiator fan motor
operates when the radiator core temperature switch
closes. The radiator core temperature switch closes
when the coolant heats to 86°-93°C (186°-200°F)
raising the outer radiator core temperature to
68°-74°C (153°-167°F).
NOTE: The outer radiator core temperature is
approximately 20°C (36°F) lower than engine
coolant temperature.
The fan motor will stop when the coolant temperature
drops to 77°-84°C (170°-184°F), the outer radiator core
temperature cools to 57°-63°C (135°-145°F), and the
radiator core temperature switch opens. The radiator
fan motor circuit is connected directly to the battery and
does not depend upon the start switch position.
Theory of Operation:
Operates when the radiator core temperature switch
closes when coolant heats the outer radiator core to
68°-74°C (153°-167°F). The radiator core temperature
switch monitors outer radiator core temperature, not
engine coolant temperature.
Fan motor may run after engine is shutoff. Fan motor
will stop when outer radiator core temperature cools to
57°-63°C (135°-145°F) and radiator core temperature
switch opens.
The radiator fan motor is connected to the battery
terminal of the starting motor solenoid and is protected
by the F4 fusible link. The 210 Red/Blk wire connects to
the radiator fan motor at the X3 connector.
The X4 connector links the fan motor to the radiator
core temperature switch. The radiator core temperature
switch is a normally open switch that closes when the
temperature around the switch reaches 68°-74°C
(153°-167°F).
With the core temperature switch closed a ground path
is provided through the switch, the X2 connector and
the 135 and 125 Blk wires.
4 - 42
2/9/00
RADIATOR FAN MOTOR CIRCUIT SCHEMATIC
ELECTRICAL
RADIATOR FAN MOTOR CIRCUIT SCHEMATIC
Fusible
Links
F4
210
Red/Blk
211
240
Red
Red
Red
210
Red/Blk
G2
Battery
B
S
X4
Blk
Red
G1
Battery
X3
M
Blk
M1
Starting
Motor
Blk
Y1
Starting
Motor
Solenoid
Blk
M
M2
Radiator
Fan Motor
B2 Radiator
Core
Temperature
Switch
t0
Blk
X2
125 Blk
135 Blk
W1 Shielded
Ground
2/9/00
4 - 43
RADIATOR FAN MOTOR CIRCUIT DIAGNOSIS
ELECTRICAL
RADIATOR FAN MOTOR CIRCUIT DIAGNOSIS
Test Conditions:
• Start switch in OFF position, engine cool.
Test/Check Point
Normal
If Not Normal
1. Radiator fan motor
Battery voltage
See Power Circuit Diagnosis. Check 210 Red/
Blk wire, F4 fuse link and connections.
2. Radiator core temperature
switch
Battery voltage
Check fan motor and core temperature switch
Blk wires and connections.
3. Radiator core temperature
switch
Continuity to ground
Check X2 connector, 135 and 125 Blk wires
and connections.
4 - 44
2/9/00
RADIATOR FAN MOTOR CIRCUIT DIAGNOSIS
ELECTRICAL
B2 Radiator Core
Temperature Switch
2
Blk
3
135 Blk
M2 Radiator Fan Motor
1
2/9/00
210 Blk
4 - 45
HEADLIGHTS AND BLACKOUT LIGHTS KIT CIRCUIT OPERATION
ELECTRICAL
HEADLIGHTS AND BLACKOUT
LIGHTS KIT CIRCUIT OPERATION
Function:
HEADLIGHTS
Provide power to illuminate the headlights.
BLACKOUT LIGHTS
Provide power to illuminate the front and rear marker
lights.
Operating Conditions:
HEADLIGHTS
The start switch in the RUN position and the headlight
switch ON.
BLACKOUT LIGHTS
The start switch in the RUN position and the blackout
light switch ON.
Theory of Operation:
HEADLIGHTS
With the start switch in the RUN position, power is
supplied to the headlight switch S5 via the 400 and 410
Yel/Red wires to the X5 connector to the 400 Yel/Red
wire and the S5 headlight switch. With the headlight
switch in the ON position, power is supplied to the 455
Yel/Wht wire and the LH headlight and the 456 Yel/Wht
wire and the RH headlight. The 100 and 110 Blk wires
provide the ground from the headlights to the X6
connector. From the X6 connector the ground path is
provided by the 105, 145, 100 and 125 Blk wires.
BLACKOUT LIGHTS
With the start switch in the RUN position, power is supplied to the blackout light switch S7 via the 400 and 410
Yel/Red wires to the X5 connector to the 207 and 206
Yel wires and the S7 blackout light switch. With the
blackout light switch in the ON position, power is supplied to the 205, 204, 203, 202, 201 and 200 Yel wires.
The 204 Yel wire supplies voltage to the right front
marker light.
The 203 Yel wire supplies voltage to the left front headlight.
The 201 Yel wire supplies voltage to the left rear marker
light.
The 200 Yel wire supplies voltage to the right rear marker light.
The 100, 101, 102, 103, 104, 105 and 106 Blk wires of
the W11 wiring harness provide the ground from the
marker lights to the X6 connector. From the X6 connector the ground path is provided by the 105, 145, 100 and
125 Blk wires of the W1 wiring harness.
4 - 46
2/9/00
HEADLIGHTS AND BLACKOUT LIGHTS KIT CIRCUIT SCHEMATIC
ELECTRICAL
HEADLIGHTS AND BLACKOUT LIGHTS KIT CIRCUIT SCHEMATIC
S7 Blackout
Light Switch
X5 to W1
207 Yel
On
Off
205 Yel
206 Yel
204 Yel
203
Yel
X5A to W9
202
Yel
S5 Headlight
Switch
On
230 Red
200 Red
ST
S2
B
A
M
G
Start
400
Yel/Red
410
Yel/Red
X5
400
Yel/Red
Off
E4 LH
Front
Head
Light
W9 Headlight
Wiring
Harness
Run
203
Yel
204
Yel
Off
S2 Start
Switch
200
Red
E1 LH
Headlight
455
Yel/Wht
F1
E2 RH
Headlight
Fusible
Links
110
Blk
201
100
Blk
X6
G1
G2
Battery Battery
Red
Red
B
E3 LH
Rear
Marker
Light
S
Blk
E6 RH
Front
Marker
Light
W11 Blackout
Light Kit Wiring
Harness
Blk
102
Blk
200
Yel
100
Blk
101
Blk
E5 RH
Rear
Marker
Light
M
M1
Starting
Motor
104
Blk
202
Yel
201
Yel
105
Blk
240
Red
103
Blk
456
Yel/Wht
100
Blk
Y1
Starting
Motor
Solenoid
102
Blk
101 Blk
106 Blk
105
Blk
X6 to W1
X6A to W9
105
Blk
125 Blk
100 Blk
145 Blk
145 Blk
W1 Shielded
Ground
2/9/00
4 - 47
HEADLIGHTS AND BLACKOUT LIGHTS KIT CIRCUIT DIAGNOSIS
ELECTRICAL
HEADLIGHTS AND BLACKOUT LIGHTS KIT CIRCUIT DIAGNOSIS
Test Conditions:
• Start switch must be in the RUN position
• Headlight switch ON
• Blackout light switch OFF
Test/Check Point
Normal
If Not Normal
1. Headlight switch
Battery voltage
See Power Circuit Diagnosis. Check
connection at X5 headlight wiring harness
power connector.
2. Headlight switch
Battery voltage
Replace headlight switch.
3. LH headlight
Battery voltage
Check 455 Yel/Wht wire and connections.
4. LH headlight
Greater than 0 volts - less
than 0.2 volts
0 volts: Replace headlight.
Greater than 0.2 volts: Check ground circuit
connection at (X6), 105/145/100/125 Blk wires
and connections to W1 shielded ground.
5. RH headlight
Battery voltage
Check 456 Yel/Wht wire and connections.
6. RH headlight
Greater than 0 volts - less
than 0.2 volts
0 volts: Replace headlight.
Greater than 0.2 volts: Check ground circuit
connection at (X6), 105/145/100/125 Blk wires
and connections to W1 shielded ground.
Test Conditions:
• Start switch must be in the RUN position
• Headlight switch OFF
• Blackout light switch ON
7. Blackout light switch
Battery voltage
Check connection at X5 connector.
8. Blackout light switch
Battery voltage
Replace blackout light switch.
9. LH rear marker light
Battery voltage
Check 201 Yel wire and connections.
10. RH rear marker light
Battery voltage
Check 200 Yel wire and connections.
11. LH front headlight
Battery voltage
Check 203 Yel wire and connections.
12. RH front marker light
Battery voltage
Check 204 Yel wire and connections.
13. Marker light
Greater than 0 volts - less
than 0.2 volts
0 volts: Replace marker light.
Greater than 0.2 volts: Check ground circuit
connection at X6 connector, 105/145/100/125
Blk wires and connections to W1 shielded
ground.
4 - 48
2/9/00
ELECTRICAL
HEADLIGHTS AND BLACKOUT LIGHTS KIT CIRCUIT DIAGNOSIS
S5 Light Switch
1
400 Yel/Red
456 Yel/Wht
RH
455 Yel/Wht
LH
2
E1 LH Headlight
E2 RH Headlight
455 Yel/Wht
456 Yel/Wht
3
5
6
100 Blk
4
110 Blk
S7 Blackout Light Switch
7
206 Yel
8
205 Yel
E5 Right Rear Marker Light
E3 Left Rear Marker Light
200 Yel
201 Yel
10
9
13
13
101 Blk
100 Blk
E4 Left Front Headlight
203 Yel
11
13
103 Blk
2/9/00
E6 Right Front Marker Light
204 Yel
13
13
104 Blk
4 - 49
HOUR METER CIRCUIT OPERATION
ELECTRICAL
HOUR METER CIRCUIT OPERATION
Function:
To record the number of hours the start switch is in the
RUN position.
Operating Conditions:
• Start switch in RUN position.
Theory of Operation:
The power circuit provides current to the start switch
(S1) and protects the hour meter circuit with a fusible
link (F1). Current flows from the battery (G1) positive
(+) terminal to the fusible link and start switch. With the
start switch in the RUN position, current flows to the
400 Yel/Red and 450 Yel wires to the (P1) hour meter.
The ground circuit 170, 120, 110, 105, 145, 100 and
125 Blk wires provides a path to frame ground for the
hour meter.
4 - 50
2/9/00
HOUR METER CIRCUIT SCHEMATIC
ELECTRICAL
HOUR METER CIRCUIT SCHEMATIC
170
Blk
230 Red
200
Red
ST
S2
400 Yel/Red
400 Yel/Red
B
A
M
G
Start
Run
Off
P1
Hour Meter
450
Yel
170
Blk
S2 Start
Switch
200
Red
F1
120
Blk
Fusible
Links
201
X6
110
Blk
240
Red
Red
105
Blk
Red
G2
Battery
B
S
Blk
G1
Battery
M
145
Blk
M1
Starting
Motor
Blk
Y1
Starting
Motor
Solenoid
100 Blk
125 Blk
125 Blk
W1 Shielded
Ground
2/9/00
4 - 51
HOUR METER CIRCUIT DIAGNOSIS
ELECTRICAL
HOUR METER CIRCUIT DIAGNOSIS
Test Conditions:
• Start switch in OFF position.
• Park brake set.
Test/Check Point
Normal
If Not Normal
1. Battery positive post
Battery voltage (11.8 13.3 volts)
Check and clean battery cable connections.
Test battery.
2. Start switch “B” terminal
Battery voltage
Check 240 Red wire, F1 fusible link and 200
Red and connections.
3. Start switch “A” terminal
Battery voltage
Replace start switch.
4. Hour meter (positive terminal)
Battery voltage
Check 400 Yel/Red and 450 Yel wire and
connections.
5. Hour meter (negative terminal)
Disconnect hour meter
connector. Measure
resistance of ground
circuit for less than 0.3
ohm resistance.
Check 170, 120, 110, 105, 145, 100 and 125
Blk wires and connections. If OK, replace hour
meter.
Test Conditions:
• Turn start switch in RUN position
4 - 52
2/9/00
HOUR METER CIRCUIT DIAGNOSIS
ELECTRICAL
F1 Fusible Link
200 Red
M1 Starting Motor
2
1
200 Red
3
G1 & G2 Batteries
S2 Start Switch
400 Yel/Red
4
450 Yel
5
170 Blk
P1 Hour Meter
2/9/00
4 - 53
CARGO BOX LIFT SYSTEM CIRCUIT OPERATION
ELECTRICAL
CARGO BOX LIFT SYSTEM CIRCUIT
OPERATION
Function:
Controls the direction of current through the actuator
motor, raising and lowering the cargo box.
Theory of Operation:
The primary controlling circuit passes through the start
switch and cargo box lift switch. The cargo box lift
switch is a three position self-centering switch. The
start switch must be in the RUN position for the system
to operate. When the cargo box lift switch is held to the
raised or lower position, it energizes the appropriate
directional relay.
The control circuit is protected by the F1 fusible link.
When the control circuit energizes a directional relay,
the relay allows high current from the battery to flow to
the motor.
The motor is a linear actuator. It is a screw type
actuator. It consist of a electric motor, gear train, drive
screw and ram. The motor turns the drive screw that
extends and retracts the ram from the ram tube. The
direction in which the motor turns is determined by
which way current flows through it. The motor circuit is
connected directly to the battery positive terminal.
Current flow is controlled by the cargo box lift switch
and directional control relays.
The motor ground circuit grounds through the other
non-operating relay to the battery negative bolt.
4 - 54
2/9/00
CARGO BOX LIFT SYSTEM CIRCUIT SCHEMATIC
ELECTRICAL
CARGO BOX LIFT SYSTEM CIRCUIT SCHEMATIC
400 Red
400 Red
S6 Cargo Box
Lift Switch
(Raise)
(Off)
(Lower)
230 Red
S2
ST
400 Yel/Red
670 Yel/Wht
675 Yel/Blk
415 Yel/Red
A
200 B
Red M
G
Start
Run
Off
S2 Start
Switch
200
Red
F1
675
Yel/Blk
Fusible
Links
400
Red
201
X8
X8
675
Yel/Blk
670
Yel/Wht
240
Red
Red
W10 Cargo
Box Lift
Wiring
Harness
670
Yel/Wht
K3
Raise
Relay
103
86 Blk
85
Red
800 Org 30
87
400
Red
401 Blk
X7
G2
Battery
B
87a 101
Blk
S
M
Blk
100
Blk
G1
Battery
M3 Cargo
Box Lift
Motor
M
M1
Starting
Motor
Blk
Y1
Starting
Motor
Solenoid
675
Yel/Blk
104
85
850 Blk 30
X7
K4
Lower
Relay
86 Blk
87
402 Red
87a 102
Blk
W10 Cargo
Box Lift
Wiring Harness
100 Blk
100 Blk
W1 Shielded
Ground
2/9/00
4 - 55
CARGO BOX LIFT SYSTEM CIRCUIT DIAGNOSIS
ELECTRICAL
CARGO BOX LIFT SYSTEM CIRCUIT DIAGNOSIS
Test Conditions:
• Start switch in OFF position
Test/Check Point
Normal
If Not Normal
1. Battery positive post
Battery voltage (11.8 13.3 volts)
Check and clean battery cable connections.
Test battery.
2. Terminal 87 of both control
relays
Battery voltage
Check 400 Red wire and connections. Also
check for short to ground.
Perform Raise Motor Amperage Draw Test.
3. Start switch “B” terminal
Battery voltage
Check 240 Red, F1 fusible link and 200 Red
wires and connections.
4. Start switch “A” terminal
Battery voltage
Replace start switch.
5. Cargo box lift switch
Battery voltage
Check 400 and 415 Yel/Red wires and
connections.
Test Conditions:
• Turn start switch in RUN position
Test Conditions:
• Depress cargo box motor control switch to raise position. Hold in position for the following test.
6. Cargo box lift switch Yel/Wht
wire
Battery voltage
Replace cargo box control switch
NOTE: If no voltage, test with switch in lower position. Position of raise wire and lower wire may be switched.
Switch position of Yel/Blk wire and Yel/Wht wire if switch direction does not match box direction.
7. Raise relay terminal 85
Battery voltage
Check 670 Yel/Wht wire and connections.
8. Raise relay terminal 30
Battery voltage
Replace relay.
9. Motor connector
Battery voltage
Check connections and continuity of 800 Org
wire between connector and relay.
Greater than 0 volts - less
than 0.2 volts
Check connections at lower relay and
continuity through 30 and 87a. Replace relay.
Check ground wires 100, 101, 102, 103 and
104 Blk connections and continuity. Check
battery ground cable connections.
10. Motor connector (ground side)
OR:
Disconnect motor
connector and measure
resistance of ground
circuit for less than 1 ohm
resistance
4 - 56
2/9/00
CARGO BOX LIFT SYSTEM CIRCUIT DIAGNOSIS
ELECTRICAL
1
K3 Raise Relay
F1 Fusible Link
200 Red
7
670 Yel/Wht
8
400 Red
M1 Starting Motor
800 Org
2
101 Blk
103 Blk
401 Red
10
K4 Lower Relay
G1 & G2 Batteries
M3 Cargo Box Lift Motor
102 Blk
9
2
104 Blk
10
850 Blk
402 Red
800 Org
S2 Start Switch
3
200 Red
S5 Cargo Box
Lift Switch
400 Yel/Red
4
675 Yel/Blk
5
415 Yel/Red
670 Yel/Wht
6
2/9/00
4 - 57
CARGO BOX LIFT SYSTEM CIRCUIT DIAGNOSIS (Continued)
ELECTRICAL
CARGO BOX LIFT SYSTEM CIRCUIT DIAGNOSIS (Continued)
Test Conditions:
• Depress cargo box motor control switch to raise position. Hold in position for the following test.
Test/Check Point
11. Actuator motor
Normal
Operates and raises
maximum load and holds
set position
If Not Normal
Motor operates slow. Perform Motor
Amperage Draw Test.
Will not hold position. See Actuator Clutch
Repair.
Repair or replace motor.
Test Conditions:
• Depress and hold cargo box control switch to lower position.
12. Cargo box lift switch Yel/Blk
wire
Battery voltage
Replace cargo box control switch.
NOTE: If no voltage, test with switch in raised position. Position of raise wire and lower wire may be switched.
Switch position of Yel/Blk wire and Yel/Wht wire if switch direction does not match box direction.
13. Lower relay terminal 85
Battery voltage
Check 675 Yel/Blk wire and connections.
14. Lower relay terminal 30
Battery voltage
Replace relay.
15. Cargo box motor connector
Battery voltage
Check connections and continuity of 850 Blk
wire between motor and relay.
16. Cargo box motor connector
(ground side).
Greater than 0 volts - less
than 0.2 volts
Check connections at raise relay and
continuity through 30 and 87a. Replace relay.
Check 100, 101, 102, 103 and 104 Blk ground
wire connections and continuity.
4 - 58
2/9/00
CARGO BOX LIFT SYSTEM CIRCUIT DIAGNOSIS (Continued)
ELECTRICAL
M3 Cargo Box Motor
850 Blk
800 Org
15
11
S5 Cargo Box
Lift Switch
12
675 Yel/Blk
415 Yel/Red
670 Yel/Wht
F1 Fusible Link
200 Red
K4 Lower Relay
13
675 Yel/Blk
14
850 Blk
M1 Starting Motor
400 Red
16
102 Blk
104 Blk
402 Red
100/101/102/103/104 Blk
G1 & G2 Batteries
2/9/00
4 - 59
TESTS AND ADJUSTMENTS
ELECTRICAL
TESTS AND ADJUSTMENTS
BATTERY TEST
Reason:
To check condition of battery and determine battery
voltage.
Equipment:
• If all cells less than 1.225 with less than 50 point
variation, charge battery at 10 amp rate, See
“CHARGE BATTERY” on page 60.
• If all cells more than 1.225 with less than 50 point
variation, load test battery, See “BATTERY LOAD
TEST” on page 61.
• If more than 50 point variation, replace battery.
10. Use a voltmeter or JTO5685 Battery Tester to
check for a minimum battery voltage of 12.4
volts.
Results:
• Hydrometer
• Voltmeter or JTO5685 Battery Tester
Procedure:
1. Park machine on level surface and turn start switch
OFF.
2. Shift lever in NEUTRAL and park brake LOCKED.
3. Cargo box RAISED and LOCKED.
4. Clean cable ends, battery terminals and top of
battery.
5. Remove battery to workbench.
6. Inspect battery terminals and case for breakage or
cracks.
7. Check electrolyte level in each battery cell. Add
clean, soft water as needed. If water was added,
charge battery for 20 minutes at 10 amps.
8. Remove surface charge by placing a small load on
the battery for 15 seconds.
• If battery voltage less than 12.4 VDC, charge
battery See “CHARGE BATTERY” on page 60.
• If battery voltage more than 12.4 VDC, test specific
gravity.
11. Install battery.
CHARGE BATTERY
Reason:
To increase battery charge after battery has been
discharged.
Equipment:
• Battery charger (variable rate))
Procedure:
NOTE: See BATTERY TEST in this group before
charging battery.
1. Park machine on level surface and turn start switch
OFF.
2. Shift lever in NEUTRAL and park brake LOCKED.
3. Cargo box RAISED and LOCKED.
4. Clean cable ends, battery terminals and top of
battery.
5. Remove battery to workbench.
M49596
9. Use an hydrometer to check for a minimum
specific gravity of 1.225 with less than 50 point
variation in each cell.
Results:
• if all cells less than 1.175, charge battery at 10 amp
rate, See “CHARGE BATTERY” on page 60.
4 - 60
M49598
2/9/00
BATTERY LOAD TEST
ELECTRICAL
6. Connect variable rate charger to battery.
NOTE: Maximum charge time at boost setting is 10
minutes. Allow additional 5 minutes for each 10
degrees below 70 degrees F.
7. Start charger at SLOW rate. Increase charge rate
ONE setting at a time. Check charger ammeter
after 1 minute at each setting. Maintain 10 amp
charge rate. Use boost setting as necessary.
8. Check if battery is accepting a 10 amp charge after
10 minutes at boost setting.
Results:
• If battery WILL NOT accept 10 amp charge after
10 minutes at boost setting, replace battery.
• If battery is accepting 10 amp charge after 10
minutes at boost setting, and battery did NOT need
water, go to Steps 10 and 11.
• If battery is accepting 10 amp charge after 10
minutes at boost setting, but battery DID need
water or all cells were BELOW 1.175, go to Steps
9 and 10.
9. Set charger at 15-25 amps.
BATTERY LOAD TEST
Reason:
To check condition of battery under load.
Equipment:
• JTO5685 Battery Tester
Procedure:
1. Park machine on level surface and turn start switch
OFF.
2. Shift lever in NEUTRAL and park brake LOCKED.
3. Cargo box RAISED and LOCKED.
4. Clean cable ends, battery terminals and top of
battery.
5. Remove battery to workbench.
D
C
E
B
IMPORTANT: Decrease charge rate if battery gases
or bubbles excessively or becomes too warm to
touch.
A
10. Check specific gravity after 30 minutes (60 minutes
for maintenance-free battery).
Results:
• If MORE THAN 50 point variation between cells,
replace battery.
• If LESS THAN 50 point variation between cells, go
to Steps 11 and 12.
NOTE: If battery was discharged at slow or unknown
rate, charge at 10-15 amps for 6-12 hours.
(Maintenance-free battery: 12-24 hours.) If
battery was discharged at fast rate, charge at
20-25 amps for 2-4 hours. (Maintenance-free
battery: 4-8 hours.)
11. Continue to charge battery until specific gravity is
1.230-1.265 points.
12. Load test battery. See “BATTERY LOAD TEST” on
page 61.
13. Install battery.
2/9/00
M49597
6. Turn load knob (A) counterclockwise to OFF
position.
7. Connect tester positive cable (red) to battery
positive (+) terminal (B).
8. Connect tester negative cable (black) to battery
negative (-) terminal (C).
9. Turn load knob (A) of tester clockwise (in) until
amperage reading (D) is equal to:
• cold cranking amperage rating of battery (use blue
scale).
—or—
• three times ampere hour rating (use black scale).
10. Hold for 15 seconds and turn load knob (A) of tester
counterclockwise (out) into OFF position.
11. Repeat Steps 9 and 10 above and read condition of
battery at DC Volts scale (E).
Results:
• If battery DOES NOT pass test and has NOT been
charged, charge battery and retest. See “CHARGE
BATTERY” on page 60.
• If battery DOES NOT pass the test and HAS BEEN
charged, replace the battery.
4 - 61
ELECTRICAL SYSTEM AMPERAGE DRAW TESTS
ELECTRICAL SYSTEM AMPERAGE
DRAW TESTS
ELECTRICAL
Alternator Output
RPM
With cold engine
With hot engine
Reason:
1000
23
16
To measure amperage draw of electrical components
when battery has a discharge problem.
3300
51
42
NOTE: The battery will discharge if operating several
electrical components at the same time with
the engine at low idle.
Component Amperage Draw:
Item
Amp Draw
Radiator fan motor
10
Differential lock light*
1.4
Headlights*
6.9
Lift motor (Maximum load)*
28
Lift motor (No load)*
7.9
Hour meter*
1.1
Equipment:
• Ammeter
• JTO5792 Ammeter Shunt Assembly
Procedure:
1. Turn start switch to off position.
C
* Tests conducted with start switch ON.
A
Results:
• If component amperage draw exceeds alternator
output at that engine speed, the battery will
discharge. Either reduce amperage draw or do not
let engine idle for extended period of time.
B
UNREGULATED AMPERAGE TEST
MX0604
Reason:
2. Disconnect battery positive cables (A). Connect
ammeter shunt red lead (B) to battery positive
cables and the black lead (C) to battery positive
terminal.
3. Set the Multi-Meter to the 300 mV scale for these
tests.
4. Turn start switch to on position.
5. Turn one component ON at a time and measure
amperage draw. Several components can be ON
to measure total amperage draw to match a
specific operating condition that a battery
discharge occurs.
The following tables show approximate charging output
and component amperage draw.
4 - 62
To determine charging output of the alternator stator.
Equipment:
• JTO5712 Current Gun
Connections:
1. Put JTO5712 Current Gun over alternator red wire
(A). Set Current Gun for DC current.
2/9/00
REGULATED AMPERAGE AND VOLTAGE TESTS
ELECTRICAL
REGULATED AMPERAGE AND
VOLTAGE TESTS
B
Reason:
To determine regulated voltage (charging) output of
voltage regulator/rectifier.
Equipment:
• JTO5712 Current Gun
• JTO5685 Battery Tester
A
M46290
Procedure:
Procedure:
IMPORTANT: Perform this test quickly to prevent
damage to battery. DO NOT apply full load to
battery for more than 10 seconds.
1. Start and run engine at 3300 RPM.
2. Insert a Phillips screwdriver through hole (B) in rear
cover of alternator to ground the regulator to the
rear cover. Read amperage on current gun.
1. Park machine on level surface and turn start switch
OFF.
2. Shift lever in NEUTRAL and park brake LOCKED.
3. Cargo box RAISED and LOCKED.
NOTE: Battery must be in good state of charge. See
“BATTERY TEST” on page 60.
Specifications:
D
Minimum unregulated amperage . . . . . . . . 40 amps
Results:
• If reading does not meet specifications, verify
voltage at the alternator regulated terminal and
good alternator ground. If voltage and ground are
OK, replace the alternator.
• If reading meets the specification, replace the
regulator. See ALTERNATOR REPAIR in DIESEL
ENGINE SECTION.
B
A
C
M56407
4. Put JTO5712 Current Gun (A) around positive (red)
battery cable (B) going to starting motor so
current-flow arrow points towards battery. Set
current gun for DC current.
IMPORTANT:
Turn
load
knob
(C)
fully
counterclockwise (out) into OFF position
BEFORE making any test connections.
5. Connect battery tester to battery.
2/9/00
4 - 63
STARTING MOTOR LOADED AMPERAGE DRAW TEST
ELECTRICAL
IMPORTANT: Perform this test quickly to prevent
damage to battery tester. DO NOT apply full load
to battery for more than 5—10 seconds.
6. Turn load knob (C) clockwise (in) until voltage on
tester voltage scale (D) reads 11 volts for 5
seconds only to partially drain battery.
7. Quickly turn load knob (C) completely
counterclockwise (out) into OFF position.
8. Start and run engine at FAST idle. Battery voltage
should read between 12.2—14.7 volts DC.
9. Turn load knob (C) clockwise (in) until voltage on
tester voltage scale (D) reads 11 volts and look at
current gun (A) for a “minimum” amperage reading
of 40 amps.
10. Quickly turn load knob (C) completely
counterclockwise (out) into OFF position.
11. After load test, voltmeter should return to a
maximum of 14.7 volts DC.
12. If current gun amp reading is BELOW specification,
test for unregulated output. See “UNREGULATED
AMPERAGE TEST” on page 62.
13. If unregulated voltage output test meets
specifications and you have verified voltage and
ground to voltage regulator/rectifier, replace
voltage regulator/rectifier.
14. If at anytime voltage increase exceeds 14.7 volts
DC, replace voltage regulator/rectifier.
STARTING MOTOR LOADED
AMPERAGE DRAW TEST
Reason:
To determine the amperage required to crank the
engine and check starting motor operation under load.
Equipment:
• JTO5685 Battery Tester
Procedure:
1. Park machine on flat surface and turn start switch
OFF.
2. Shift lever in NEUTRAL and park brake LOCKED.
3. Cargo box RAISED and LOCKED.
4. Test system ground connections and battery. See
“GROUND CIRCUIT TESTS” on page 72, and
“BATTERY LOAD TEST” on page 61.
5. Disconnect fuel shutoff solenoid connector.
4 - 64
B
C
A
MX0611
IMPORTANT:
Turn
load
knob
(A)
fully
counterclockwise (out) into OFF position before
making any test connections.
6. Connect JTO5685 Battery Tester to battery.
7. Crank engine—read and record voltage on DC
voltage scale (B) of battery tester.
8. Turn start switch to OFF position.
IMPORTANT: Perform following procedure within
15 seconds to prevent damage to tester and/or
machine components.
9. Turn load knob (A) clockwise (in) until DC voltage
(B) reads the same as when cranking.
10. Read and record DC amperage (C).
11. Turn load knob (A) completely counterclockwise
(out) into OFF position.
Results:
• Maximum starting motor draw on should be 60
amps.
• If amperage is above specification, perform Starting
Motor No-Load Amperage and RPM Test to
determine if starting motor is binding or damaged.
• If starting motor is good, check internal engine
components for binding, ware, or damage.
2/9/00
ELECTRICAL
STARTING MOTOR NO-LOAD AMPERAGE AND RPM TESTS
STARTING MOTOR NO-LOAD
AMPERAGE AND RPM TESTS
9. Use jumper wire to briefly connect terminal (A) and
solenoid engagement terminal (B).
10. Measure and record starting motor amperage and
rpm’s.
Reason:
To determine if starting motor is binding or has
excessive amperage draw under no-load.
Equipment:
• JTO5712 Current Gun
• JDM71 Vibration Tachometer or JT07270 Digital
Pulse Tachometer
Results:
• a good starting motor should have a maximum
amperage reading of 50 amps and a minimum
rotational reading 6000 rpm.
• If amperage reading is above 50 amps or starting
motor rpm is less than 6000, check for binding or
seized bearings, sticky brushes, and dirty or worn
commutator.
11. Repair or replace starting motor.
Procedure:
NOTE: Check that battery is fully charged and of
proper size to ensure accuracy of test.
1. Park machine on flat surface and turn start switch
OFF.
2. Shift lever in NEUTRAL and park brake LOCKED.
3. Cargo box RAISED and LOCKED.
4. Remove starting motor assembly to workbench.
5. Connect jumper cables to battery.
M56406
6. Connect negative jumper cable to starting motor
body and positive cable (red) to solenoid battery
terminal (A).
7. Use reflective tape on starting motor worm gear
and JTO5719 Photo Tachometer to measure
starting motor rpm’s.
8. Put JTO5712 current gun around positive jumper
cable (red).
IMPORTANT: Complete this test in 20 seconds or
less to prevent starting motor damage.
2/9/00
4 - 65
STARTING MOTOR SOLENOID TEST
ELECTRICAL
STARTING MOTOR SOLENOID TEST
RELAY TEST
Reason:
Reason:
To determine if starting motor solenoid or starting
motor is defective.
To check relay terminal continuity in the energized and
de-energized condition.
Equipment:
Equipment:
• Jumper wire.
• Ohmmeter
Procedure:
Procedure:
1. Park machine on level surface and turn start switch
OFF.
2. Shift lever in NEUTRAL and park brake LOCKED.
3. Disconnect the X1 connector to the fuel shutoff
solenoid.
4. Cargo box RAISED and LOCKED.
1. Park machine on level surface and turn start switch
OFF.
2. Shift lever in NEUTRAL and park brake LOCKED.
3. Cargo box RAISED and LOCKED.
4. Disconnect relay connector from harness.
D
B
B
C
E
C
D
A
MX0607
A
MX0609
5. Check continuity.
5. Disconnect wire (A) from starting motor solenoid
terminal (B).
6. Connect jumper wire to positive battery terminal (+)
and briefly jump to starting motor solenoid terminal
(B).
Results:
• Starting motor runs—solenoid is good, check circuit
wiring.
• Starting motor DOES NOT run—go to Step 7.
7. Remove rubber boot(s) from terminals (C and D).
8. Connect jumper wire between starting motor
solenoid large terminals (C and D).
Results:
• there should be continuity between terminals (A)
and (B), and between terminals (C) and (D);
• there should NOT be continuity between terminals
(E) and (B).
6. Connect a jumper wire from battery positive (+)
terminal to relay terminal (C). Connect a jumper
wire from relay terminal (D) to ground (-).
Results:
• there should be continuity between terminals (E)
and (B).
• If continuity is NOT correct, replace relay.
Results
• Starting motor runs—replace solenoid.
• Starting motor DOES NOT run—check battery
cables, then replace starting motor.
4 - 66
2/9/00
NEUTRAL START SWITCH TEST
ELECTRICAL
NEUTRAL START SWITCH TEST
Reason:
To make sure the neutral start switch terminals have
continuity when the gear shift is in neutral position.
in FORWARD and REVERSE.
• If the neutral start switch DOES have continuity with
the plunger RELEASED (while the gear shift is in
either FORWARD or REVERSE position), replace
the switch.
PARK BRAKE SWITCH TESTS
Equipment:
• Ohmmeter
Reason:
To make sure the park brake switch has continuity
when plunger is RELEASED.
Procedure:
1. Park machine on level surface and turn start switch
OFF.
2. Shift lever in NEUTRAL and park brake LOCKED.
3. Cargo box RAISED and LOCKED.
Equipment:
• Ohmmeter
Procedure:
1. Park machine on level surface and turn start switch
OFF.
2. Shift lever in NEUTRAL and park brake LOCKED.
3. Remove seats, and operator’s station black plastic
shroud.
4. Disconnect harness connector from park brake
switch.
A
A
B
MX0608
NOTE: When transaxle shift lever is in NEUTRAL the
neutral start switch plunger is DEPRESSED.
4. Disconnect neutral start switch from harness and
check continuity across neutral start switch
terminals (A).
Results:
• There should BE continuity when shift lever is in
NEUTRAL position.
• If the neutral start switch DOES NOT have
continuity with the plunger DEPRESSED (while the
gear shift is in NEUTRAL position), replace the
switch.
5. Move transaxle shift lever into FORWARD and then
REVERSE (this should RELEASE switch plunger)
and check continuity across neutral start switch
terminals (A).
Results:
M56409
NOTE: Two of the four terminals ARE NOT used in
each of these applications.
5. Check continuity.
Results:
• there should BE continuity between terminals (A
and B) when plunger is RELEASED,
• there should NOT BE continuity between terminals
(A and B) when plunger is DEPRESSED.
• If continuity is NOT correct, replace switch.
• there should NOT BE continuity when shift lever is
2/9/00
4 - 67
ENGINE OIL PRESSURE SWITCH TEST
ENGINE OIL PRESSURE SWITCH
TEST
Reason:
To determine if the oil pressure switch is functioning
properly.
Equipment:
ELECTRICAL
Results:
• it should NOT have continuity to ground.
• If the switch DOES have continuity to ground with
the engine running, check engine oil pressure. See
OIL PRESSURE TEST in ENGINE TESTS AND
ADJUSTMENTS SECTION.
• If the oil pressure is to specification, replace the
switch. BE SURE to apply John Deere Pipe
Thread Sealant with TEFLON®, or an equivalent
to threads of switch anytime it is installed.
• Ohmmeter
LIGHT SWITCH TEST
Procedure:
1. Park machine on level surface and turn start switch
OFF.
2. Shift lever in NEUTRAL and park brake LOCKED.
3. Cargo box RAISED and LOCKED.
Reason:
To make sure the light switch terminals have continuity
when the light switch is ON.
Equipment:
• Ohmmeter or Continuity Tester
B
Procedure:
C
1. Park machine on level surface and turn start switch
OFF.
2. Shift lever in NEUTRAL and park brake LOCKED.
NOTE: You may want to remove front hood for easy
access to dash panel electrical components.
A
MX0605
3. Disconnect light switch connector.
IMPORTANT: Do not allow wire connector to
contact engine or frame because there will be
voltage at that point during the test.
A
B
4. Disconnect wiring lead (A) from switch.
5. Connect black lead of meter to engine block (B) and
red lead of meter to terminal (C) of switch.
6. Set ohmmeter for 1X ohms scale.
7. Read meter.
M56813
Results:
• there should be continuity to ground.
• If the switch does NOT have continuity to ground,
replace the switch.
NOTE: BE SURE to apply John Deere Pipe Thread
Sealant with TEFLON®, or an equivalent to
threads of switch anytime it is installed.
8. Start and run engine.
9. Read meter.
4 - 68
4. Move light switch to the ON and then the OFF
position. Check continuity between terminals (A
and B).
Results:
• Terminals should have continuity with switch ON.
• Terminals should NOT have continuity with switch
OFF.
• If continuity is NOT correct, replace light switch.
2/9/00
DIFFERENTIAL LOCK SWITCH TEST
ELECTRICAL
DIFFERENTIAL LOCK SWITCH TEST
START SWITCH TEST
Reason:
Reason:
To make sure differential lock switch terminals have
continuity when the plunger is DEPRESSED.
To verify start switch functions are operating properly.
Equipment:
Equipment:
• Ohmmeter or Continuity Tester
• Ohmmeter
Procedure:
Procedure:
1. Park machine on level surface and turn start switch
OFF.
2. Shift lever in NEUTRAL and park brake LOCKED.
3. Remove seats and operator’s station black plastic
shroud.
4. Disconnect differential lock switch connector.
1. Park machine on level surface and turn start switch
OFF.
2. Shift lever in NEUTRAL and park brake LOCKED.
NOTE: You may want to remove front hood for easy
access to dash panel electrical components.
3. Disconnect start switch connector.
A
B
A
B
C
F
M56409
D
E
NOTE: Two of these terminals ARE NOT used in this
application.
5. Check continuity.
Results:
• there should NOT BE continuity between terminals
(A and B) when plunger is RELEASED,
• there should BE continuity between terminals (A
and B) when plunger is DEPRESSED.
• If continuity is NOT correct, replace switch.
M56827
4. Use an ohmmeter to test switch continuity in OFF,
RUN, and START positions.
NOTE: DO NOT refer to markings stamped on
terminals. Identify terminals by art keys ONLY.
Terminal combinations other than those listed
in chart should NOT have continuity.
Start Switch Continuity:
Switch Position. . . . . . . . . . . . . . Terminal Continuity
OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A and B
RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C and D
START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C and D
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E and F
Results:
• If any continuity is NOT correct, replace switch.
2/9/00
4 - 69
CARGO BOX LIFT SWITCH TEST
ELECTRICAL
CARGO BOX LIFT SWITCH TEST
FUEL SHUTOFF SOLENOID TEST
Reason:
Reason:
To make sure the cargo box lift switch terminals have
continuity in the proper positions.
To verify fuel shutoff solenoid is functioning properly.
Equipment:
Equipment:
• Ohmmeter
• Ohmmeter or Continuity Tester
Procedure:
Procedure:
1. Park machine on level surface with the start switch
OFF.
2. Shift lever in NEUTRAL and park brake LOCKED.
3. Remove front hood for access to dash panel
electrical components.
4. Disconnect cargo box lift switch connector.
1. Park machine on level surface and turn start switch
OFF.
2. Shift lever in NEUTRAL and park brake LOCKED.
3. Cargo box RAISED and LOCKED.
4. Disconnect fuel shutoff solenoid connector.
B
A
C
A
C
B
MX0612
MX0603
5. Check continuity between terminals (A, B and C)
with the switch in its normal (static) position.
Results:
• Terminals should NOT have continuity.
• If continuity is NOT correct, replace switch.
6. Press the switch to the RAISE position and check
continuity between terminals (A, B and C).
5. Measure and record the resistance across each
combination of terminals as listed below.
The red lead position of the VOM is listed across the top
and the black lead position of the VOM is listed down
the side.
Results:
Results:
• Terminals (B and C) should have continuity.
• Terminals (A and B) and (A and C) should NOT
have continuity.
• If continuity is NOT correct, replace switch.
7. Press the switch to the LOWER position and check
continuity between terminals (A, B and C).
Results:
• Terminals (A and B) should have continuity.
• Terminals (A and C) and (B and C) should NOT
have continuity.
• If continuity is NOT correct, replace switch.
4 - 70
Blk Wire
(A)
Blk Wire
(A)
Red Wire
(B)
12
Wht Wire
(C)
0.4
Red Wire
(B)
Wht Wire
(C)
12
0.4
12.4
12.4
• If continuity is NOT correct, replace fuel shutoff
solenoid.
2/9/00
RADIATOR CORE TEMPERATURE SWITCH TEST
ELECTRICAL
RADIATOR CORE TEMPERATURE
SWITCH TEST
Reason:
To verify radiator core temperature/fan motor switch is
functioning properly at specified temperatures to turn
cooling fan ON and OFF to protect engine from
overheating.
M76887
Equipment:
• Thermometer
• Glass Container
• Heating Unit
• Ohmmeter
9. Pull radiator core temperature/fan motor switch
from left side of radiator.
c
Procedure:
1. Park machine on level surface and turn start switch
OFF.
2. Shift lever in NEUTRAL and park brake LOCKED.
3. Disconnect negative battery cable from battery.
c
CAUTION
Radiator fan can start at any time, even with start
switch in the OFF position. Always disconnect
the negative battery cable before doing any
electrical repair.
4. Remove seats and operator’s station black plastic
shroud.
5. Disconnect electrical leads to radiator core
temperature/fan motor switch sending unit on top
rear inside edge of radiator.
6. Remove screen bolted to frame under passenger’s
right side grab handle.
7. Remove slide-in screen on right side of radiator.
CAUTION
DO NOT allow switch or thermometer to rest
against the side or bottom of glass container
when heating water. Either may rupture if
overheated.
1. Connect lead wires from ohmmeter probes (A), to
switch terminals.
2. Suspend switch (B) and a thermometer (C) in a
container of water.
3. Heat and stir the water. Observe water temperature
when continuity occurs. Water temperature should
be 67–75°C (153–145°F)
A
C
B
M82123A
Results:
A
• If continuity does not occur within temperature
listed, replace switch.
B
M76888
8. Reaching up into frame where screens were
removed, bend tabs of push-on nut (A) and
remove nut and protective pad (B) from end of
radiator core temperature/fan motor switch.
2/9/00
Specifications:
• Fan should turn on (switch closes) when
temperature reaches 67–75°C (153–167°F).
• Fan should turn off (switch opens) when
temperature reaches 57–63°C (135–145°F).
• If switch fails to meet either of these specifications,
replace it.
4 - 71
ENGINE COOLANT TEMPERATURE SWITCH TEST
ENGINE COOLANT TEMPERATURE
SWITCH TEST
ELECTRICAL
GROUND CIRCUIT TESTS
Reason:
Reason:
To verify coolant temperature switch is functioning
properly to warn operator of an overheating engine.
To check for opens, loose terminal wire crimps, poor
connections, or corrosion in the ground circuit.
Equipment:
Procedure:
1. Park machine on level surface and turn start switch
OFF.
2. Shift lever in NEUTRAL and park brake LOCKED.
3. Cargo box RAISED and LOCKED.
• Ohmmeter or Voltmeter.
The voltmeter method checks ground connections
under load.
A
A
MX0605
MX0606
Procedure:
4. There is no means to test the coolant temperature
switch (A) out of the engine. Check all related
components of the cooling system to determine if
the switch is functioning properly:
• check that air intake screen is clean
• check that radiator trash screen is clean
• check that radiator core fins are clean
• check that coolant is properly mixed
• perform cooling system fill/bleed procedure
• perform thermostat test
• check that coolant is flowing adequately
through entire system
• perform all radiator and radiator cap tests
• check that there are no leaks in cooling system
• perform radiator core coolant
temperature/fan motor switch test.
5. If all above checks and tests prove OK, replace
engine coolant temperature switch.
4 - 72
OHMMETER METHOD:
1. Park machine on level surface and turn start switch
OFF.
2. Shift lever in NEUTRAL and park brake LOCKED.
3. Cargo box RAISED and LOCKED.
4. Connect ohmmeter negative (black) lead to
negative terminal of battery. Put meter positive
(red) lead on negative terminal of battery and
record reading.
5. Put meter red lead on ground terminal of circuit or
component (A, B, and/or C) to be tested that is
closest to the battery negative terminal.
Resistance reading must be very close to or
the same as the battery negative terminal
reading. Work backwards from the battery on
the ground side of the problem circuit until the
resistance reading increases above 0.1 ohms.
The problem is between the last two test points. If
a problem is indicated, disconnect the wiring
harness connector to isolate the wire or
component and check resistance again. Maximum
allowable resistance in the circuit is 0.1 ohms.
Check both sides of connectors closely as
disconnecting and connecting may temporarily
solve problem.
2/9/00
CARGO BOX MOTOR AMPERAGE DRAW TEST
ELECTRICAL
VOLTMETER METHOD:
1. Park machine on level surface and turn start switch
ON.
2. Shift lever in NEUTRAL and park brake LOCKED.
3. Cargo box RAISED and LOCKED.
4. Connect voltmeter negative (black) lead to negative
terminal of battery.
5. Put meter positive (red) lead on ground terminal of
circuit or component (A, B, and/or C) to be tested.
Be sure the component circuit is activated (key on,
switches closed) so voltage will be present at the
component. Record voltage. Voltage must be
greater than 0 but less than 1 volt. Some
components will have a very small voltage reading
on the ground side and still be operating correctly.
2. Connect shunt in series between battery
connection and cargo box motor. (Some jumper
wire required).
3. Connect shunt leads to voltmeter.
4. Set meter to the milli-amp scale.
5. Raise box and observe amperage reading
6. Lower box and observe amperage reading.
Maximum Amperage Draw Specifications:
No Load Up . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6 Amps
No Load Down . . . . . . . . . . . . . . . . . . . . . 3 - 4 Amps
With Clutch Operating . . . . . . . . . . . . . . 4 - 28 Amps
880 lb Load . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Amps
Results:
Results:
• If voltage is 0, the component is open.
• If voltage is greater than 1 volt, the ground circuit is
bad. Check for open wiring, loose terminal wire
crimps, poor connections, or corrosion in the
ground circuit.
CARGO BOX MOTOR AMPERAGE
DRAW TEST
Reason:
• If amperage is below specification, cargo box motor
is OK, or if unit does not raise, check for stripped
gears or worn clutch.
• If amperage is zero, check control circuit or fusible
link.
• If control circuit and fusible link are OK, and motor
will not run, thermal protector or motor maybe
defective. Replace motor.
• If amperage is above specification, check cargo box
for binding or gears, worm gear or bearings
causing an excessive load.
• Repair or replace cargo box actuator.
To determine the condition of cargo box motor and
actuator assembly.
Equipment:
• JTO5791 Multimeter (A)
• JTO5792 Shunt (B)
B
A
MX0610
Procedure:
1. Battery fully charged and start switch in RUN
position.
2/9/00
4 - 73
CARGO BOX LIFT REPAIR
ELECTRICAL
CARGO BOX LIFT REPAIR
2. Remove nuts from motor.
3. Replace motor and seal.
4. Tighten nuts evenly.
REPLACE ACTUATOR CLUTCH
Specifications:
Gear Case
Housing Cap Screws
Motor Mounting Nuts . . . . . . . . . . . . 8 N•m (70 lb-in.)
Clutch
Key
Intermediate
Gear
COVER TUBE SEAL
Lip Seal
O-Ring
Gasket
Tube Gasket
Gear Case
Housing
Cap Screws
Thrust Washers
Gear Case
Housing
Cap Screws
Retaining Plate
Gear Case
Housing Screw
M566967
Gear Case
Housing
Cap Screws
1. Remove gear case housing, intermediate gear,
clutch and thrust washers.
2. Install new clutch.
3. Install new gear case housing gasket.
4. Tighten hardware evenly.
Tabbed Thrust
Washer
Thrust
Washers
M56349
Specifications:
Gear Case Housing Cap Screws. . . 8 N•m (70 lb-in.)
Gear Case Housing Screw . . . . . 2.3 N•m (20 lb-in.)
REPLACE MOTOR
IMPORTANT: When replacing motor, note direction
that motor gear is installed. Intermediate gear
teeth should ride close to the center of motor
gear.
If tube is removed or leaking, replace the upper O-ring
and lip seal. Drive seal and O-ring from end of tube
with a disk and driver.
1. Install new lip seal and O-ring flush with end of
tube.
2. Install new tube retaining gasket.
3. Install tabbed thrust washer and thicker thrust
washer.
4. Tighten hardware evenly.
Specifications:
Gear Case Housing Cap Screws. . . 8 N•m (70 lb-in.)
Gear Case Housing Screw . . . . . 2.3 N•m (20 lb-in.)
Motor
Mounting
Nuts
M56702
1. Remove gear case housing.
4 - 74
2/9/00
CONTENTS
POWER TRAIN
CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TRANSAXLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TRANSAXLE COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS/TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DRIVE BELT CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TRANSAXLE SHIFT LINKAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DRIVE TRAIN PERFORMANCE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECONDARY CLUTCH SPRING TORSION CHECK . . . . . . . . . . . . . . . . . . . . . . . . 13
DIFFERENTIAL LOCK LINKAGE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DRIVE CHAIN ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PRIMARY CLUTCH FLYWEIGHT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . 18
PRIMARY CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECONDARY CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DRIVE AXLES - COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DRIVE AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2/9/00
5-1
NOTES
5-2
POWER TRAIN
2/9/00
POWER TRAIN
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 - 38 mm (0.5 - 1.5 in.)
Chain Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Number 50
Chain Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Links
Clutch Engagement Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1350 - 1600 rpm
Clutch Disengage Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm
Drive Belt Width
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approximately 30.2 mm (1.19 in.)
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 mm (1.06 in.)
Secondary Clutch Spring Torsion - Standard Wrap . . . . . . . . . . . . . . 22 - 40 N (5 - 9 lb)
Transaxle Oil Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 L (4.75 qt)
REPAIR SPECIFICATIONS
Transaxle:
Input Shaft
Washer Thickness (Reverse Drive Gear End)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.45 - 1.55 mm (0.057 - 0.061 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 mm (0.047 in.)
Washer Thickness (Forward Drive Sprocket End)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.52 - 1.68 mm (0.060 - 0.066 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30 mm (0.051 in.)
Shift Collar
Shift Groove Width . . . . . . . . . . . . . . . . . . . . . . . .6.10 - 16.30 mm (0.634 - 0.642 in.)
Shift Groove-to-Block Clearance (Max). . . . . . . . . . . . . . . . . . . . . . . 2 mm (0.080 in.)
Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.50 mm (1.161 in.)
Shifter Arm
Shifter Block Width . . . . . . . . . . . . . . . . . . . . . . . . . . .15.7 - 15.9 mm (0.618 - 0.626 in.)
Shifter Block-to-Collar Groove Clearance (Max) . . . . . . . . . . . . . . . . . . 2 mm (0.080 in.)
Transaxle Case Thrust Washer Thickness . . . . . . . . .1.12 - 1.28 mm (0.044 - 0.050 in.)
Differential:
Bevel Gear Washer Thickness
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.50 - 1.70 mm (0.059 - 0.067 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30 mm (0.051 in.)
Pinion Gear Washer Thickness
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.96 - 1.04 mm (0.038 - 0.041 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.70 mm (0.028 in.)
Differential Lock Collar
Groove Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.10 - 7.30 mm (0.280 - 0.287 in.)
Collar Groove-to-Lock Fork Finger Clearance (Max). . . . . . . . . . . . . 2 mm (0.080 in.)
Differential Lock:
Differential Lock Fork
Finger Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . .6.70 - 6.90 mm (0.264 - 0.272 in.)
Finger-to-Collar Groove Clearance (Max) . . . . . . . . . . . . . . . . . . . . . 2 mm (0.080 in.)
Spring
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.2 mm (3.67 in.)
Working Load . . . . . . . . . . . . . . . . . . . . . 74 mm at 150 N (2.913 in. at 33.72 lb force)
2/9/00
5-3
TORQUE SPECIFICATIONS
POWER TRAIN
TORQUE SPECIFICATIONS
Differential Housing Half Cap Screw and Nut . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)
Differential Lock Lever Bracket Cap Screw . . . . . . . . . . . . . . . . . . . . 26 N•m (230 lb-in.)
Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft)
Drive Axle Mounting Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 N•m (67 lb-ft)
Engine-to-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 - 42 N•m (20 - 30 lb-ft)
Neutral Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft)
Primary Clutch Mounting Cap Screw . . . . . . . . . . . . . . . . . . . 40 - 60 N•m (30 - 44 lb-ft)
Primary Clutch Spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 N•m (100 lb-ft)
Rear Axle Housing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 - 108 N•m (66 - 80 lb-ft)
Rear Wheel Mounting Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 N•m (75 lb-ft)
Secondary Clutch Mounting Cap Screw . . . . . . . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft)
Shifter Arm Retaining Plate Cap Screw . . . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.)
Transaxle-to-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 - 195 N•m (114 - 143 lb-ft)
Transaxle Case Half Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 N•m (26 lb-ft)
SPECIAL OR ESSENTIAL TOOLS
Number
(U.S./Canadian)
(Loctite)
Name
Use
JDG1175
Clutch Center Distance Gauge
Used to space clutches and engine isolator.
JDG813-1
Clutch Removal Tool
Used to remove the clutch from the engine
stub shaft.
JDG813-2
Spanner Wrench
Used to remove spider.
JDG813-3
Tapered Holding Tool
Used to remove clutch cover bolts.
JDG1175-2
Center Distance Gauge
Measure and adjust rubber mounts
OTHER MATERIALS
5-4
Number
(U.S./Canadian)
(Loctite)
Name
Use
TY6305
John Deere Clean and Cure Primer
Cleans parts and speeds cure of sealant.
TY15139/
TY15443
John Deere Sealant
Seals transaxle case halves.
TY6333
Moly High Temperature EP Grease
Apply to splines of transaxle input shaft.
TY22034
John Deere SuperLube®
Apply to rollers and cam weigh pivots of
primary clutch.
TY9370/TY9477
#242
Thread Lock and Sealer
(Medium Strength)
Apply to threads of secondary clutch set
screw and ramp tabs. Threads of retaining
screw.
2/9/00
OTHER MATERIALS
POWER TRAIN
COMPONENT LOCATION
D
E
C
F
B
A
G
H
L
K
J
I
A. Transaxle
B. Shift Linkage
C. Secondary Clutch
D. Engine
E. Primary Clutch
F. Rear Sprocket and Axle
G. Drive Chain
H. Drive Belt
I. . Axle Housing
J. Front Axle and Sprocket
K. Coupler
L. Internal Wet Brake
2/9/00
5-5
CLUTCH OPERATION
POWER TRAIN
THEORY OF OPERATION
minimal load.
CLUTCH OPERATION
High Engine RPM, Light Load, High Output Speed:
Theory of Operation:
The variable clutch system is speed and load sensitive.
The primary and secondary clutches work together,
automatically up-shifting and down-shifting. This
shifting changes the ratio between the clutches,
allowing the engine to operate at optimum efficiently, at
the peak of its power curve.
The primary clutch (A) is engine speed sensitive, and is
mounted on the engine crankshaft. It operates on the
principle of centrifugal force. The secondary clutch (B),
mounted on the transaxle input shaft, is load sensitive
to the rear drive wheels.
Idle Speed:
Primary clutch is spinning with engine crankshaft, but
engine speed is not enough to overcome primary
spring tension. The primary clutch sheave remains
opened wide and does not engage drive belt.
Engagement RPM, Minimum Load, Low Output
Speed:
Primary clutch sheaves are moving closer together, just
starting to move drive belt. Drive belt is running at the
top of secondary clutch. A high ratio between the
clutches exist, similar to a low gear, as long as there is
UP-SHIFTING
MINIMUM
LOAD
As engine speed increases, centrifugal forces of the
flyweights (F) force the primary clutch to up-shift,
moving the drive belt to outer pulley diameter,
overcoming secondary clutch spring (C). Drive belt
then is pulled deep in secondary clutch giving a low
ratio, similar to a high gear.
High Engine RPM, Increasing Load, Lower Output
Speed
down-shifting occurs as a load is encountered, such as
a hill or soft terrain. The stationary side of the
secondary clutch resists forward movement of the
wheels, at the same time, torque from the drive belt
moves the moveable sheave up the ramp (D). The
ramp and spring forces the belt to the outside diameter
of the secondary clutch, and overcomes centrifugal
forces of the primary clutch causing the down-shifting.
TRANSAXLE OPERATION
Function:
The transaxle provides:
• shifting into forward, neutral and reverse.
• differential action between axles for turning
• differential lock, locking axles together for better
traction.
DOWN-SHIFTING
INCREASING LOAD
C
B
D
ENGAGEMENT RPM
LOW OUTPUT SPEED
HIGH RPM
E
F
A
M56089
5-6
2/9/00
TRANSAXLE OPERATION
POWER TRAIN
Neutral:
In neutral the shift arm (B) centers the shift collar (P)
between the forward drive gear (Q), and reverse drive
sprocket (E), so they are not engaged. The input shaft
(R) rotates freely, not transferring power to the gear on
the reduction shaft (O). The shift fork (C) also
depresses the neutral start switch (A) only allowing the
engine to be started when the transaxle is in neutral.
differential gear (L) in the reverse direction. Power is
then transferred through the pinion (K) and side gears
(M) to the output shafts (H and N).
Differential Lock:
When the differential lock (G) is engaged, the
differential lock collar (I) and pins (J) are pushed in,
locking the side gears (M) to the differential housing.
Power then flows equally out of both output shafts (H
and N).
Forward Power Flow:
When shifted into the forward position, the shift collar
(P) engages the forward drive gear (Q). Power is
transmitted through the reduction shaft (O) that is in
constant mesh with the differential gear (L). The
differential gear (L) and assembly rotate, transferring
power through the pinion (K) and side gears (M) to the
output shafts (H and N).
Reverse Power Flow:
When shifted into reverse, the shift collar (P) engages
the reverse drive sprocket (E), that transmits power
through the reverse drive chain (D) to the reduction
shaft (O). The chain drives the reduction shaft in the
opposite direction of the forward gear (Q), rotating the
A
B
C
R
D
E
Q
P
F
O
G
N
M
H
L
K
J
I
M56345A
2/9/00
5-7
TRANSAXLE COMPONENT LOCATION
POWER TRAIN-GEAR
TRANSAXLE COMPONENT LOCATION
B
C
A
D
A
E
U
F
G
H
T
I
S
R
J
Q
K
P
O
N
M
L
M56084
M. Forward Drive Gear
N. Neutral Switch
O. Shift Fork
P. Reverse Drive Sprocket
Q. Reverse Drive Chain
R. Reverse Driven Sprocket
S. Reduction Drive Shaft
T. Brake Actuator Plate
U. Ball and Ramp
V. Right Output Shaft
W. Brake Shaft
X. Differential Lock Pin
Y. Differential Lock Collar
Z. Differential Gear
AA. Differential Pinion Gears
AB. Brake Lever
AC. Left Output Shaft
AD. Brake Discs and Plates
AE. Reduction Gear Shaft
AF. Forward Driven Gear
AG. Input Shaft
5-8
2/9/00
DIAGNOSIS/TEST POINTS
POWER TRAIN
DIAGNOSIS/TEST POINTS
Test Conditions:
• Engine off. Rear wheels jacked up
• Air pressure equal in all driving tires. All driving tires all close to same radius.
Test/Check Point
Normal
If Not Normal
Drive belt
Drive belt must be in good condition;
minimum width 27 mm (1-1/16 in.)
Replace drive belt.
Shift linkage
Transaxle shifts into forward, neutral and
reverse
Adjust shift linkage.
Transaxle stays in gear during operation
Adjust shift linkage.
Transaxle is driving axles and wheels
Check transaxle internal
components.
Axles rotate smoothly and quietly; no free
play in axles, bearings, or housings
Check axles and housings.
Check axle couplers.
Brakes not dragging
Adjust brakes.
Engages when in a turn or when wheels
slip on one side; disengages when lever is
released and torque is equalized on axles
Adjust differential lock.
No ratcheting sound in transaxle
Check internal components.
Slack between 12 mm (0.5 in.) and 38 mm
(1.5 in.) during rotation
Adjust drive chain tension.
Axles and brakes
Differential lock
Drive chain
Test Conditions:
• Engine running at operating temperature and brakes set.
• Transmission in neutral position.
• Ensure engine is at correct slow idle speed. See appropriate engine specifications.
34. Engine primary clutch
Primary clutch disengaged (drive belt not
moving)
Repair or replace primary clutch.
Test Conditions:
• Engine running at operating temperature and brakes set.
• Transmission in neutral position.
• Accelerate engine to 1600 rpm.
35. Engine primary clutch
Primary clutch must engage drive belt at
1350 - 1600 rpm
Replace drive belt. Repair or
replace primary clutch.
Test Conditions:
• Engine running at operating temperature and brakes set.
• Transmission in neutral position.
• Ensure engine is at correct fast idle speed. See appropriate engine specifications.
36. Engine primary clutch
Primary clutch sheave (movable clutch
sheave) moves toward stationary sheave
Repair or replace primary clutch.
37. Secondary clutch
Secondary clutch sheaves separate
Repair or replace secondary
clutch.
2/9/00
5-9
DIAGNOSIS/TEST POINTS
Test/Check Point
Vehicle performance
POWER TRAIN-GEAR
Normal
If Not Normal
Secondary clutch fully up-shifted. Primary
clutch sheaves completely closed.(Drive
belt will not ride at top of primary clutch).
Repair or replace drive and/or
secondary clutches.
Top speed 4.5 sec. minimum per 100 ft.
Acceleration to 70 ft. in maximum of 5.5
sec.
Check drive train components
and engine performance.
Check
for
correct
mounting location.
6
9
7
engine
8
2
4
5
1
3
5 - 10
2/9/00
DRIVE BELT CHECK
POWER TRAIN
TESTS AND ADJUSTMENTS
DRIVE BELT CHECK
A
A
Reason:
To check drive belt wear and condition of drive belt.
M56086
M56085
B
Procedure:
1. Measure drive belt width. Drive belt must not be
less than 27 mm (1-1/16 in.)
2. Check drive belt condition. Drive belt must not be
cracked. Some amount of glazing is normal.
Results:
• If drive belt less than specification, replace.
• If drive belt is within specification, and there is
performance complaint, check primary clutch and
secondary clutch, and run Power Train
Performance Test.
TRANSAXLE SHIFT LINKAGE
ADJUSTMENT
Reason:
• To insure gear shift lever is centered in neutral
when transaxle is in neutral
• To insure both forward and reverse gears will be
completely engaged
• To help prevent shifter from disengaging from gear
during operation
Procedure:
1. Park on level surface and LOCK park brake. Engine
OFF, cargo box RAISED. Plastic shroud under
operator’s seats must be bolted into place.
2. Move shift lever until detent inside transaxle clicks
firmly into the center neutral position.
2/9/00
M55796
3. With transaxle in neutral detent, adjust shift rod nuts
(A) so shift lever (B) is contacting the shift
quadrant in neutral slot (C).
NOTE: There should be approximately 15 - 20 threads.
4. Shift into forward and reverse. Shift lever should not
contact shift quadrant in the forward or reverse
positions. This ensures the shift lever is not
preventing the transaxle from fully engaging.
NOTE:
Note location of spring. If assembled
incorrectly,
rod
will
contact
other
components.
5. Shift into neutral and check neutral start.
6. Drive machine over rough ground to check
adjustments.
5 - 11
DRIVE TRAIN PERFORMANCE TESTS
DRIVE TRAIN PERFORMANCE
TESTS
Result:
ENGAGEMENT AND FULL UP–SHIFT CHECK
c
POWER TRAIN
CAUTION
When operating vehicle to observe drive train
performance, always operate in an area flat and
free of obstacles. Use a passenger to observe
power train so you can concentrate on driving
safely. Never back vehicle with cargo box raised.
Reason:
To determine if the engine and drive train are operating
at peak performance.
• Clutch should slowly start to engage and move
drive belt between 1350 - 1600 rpm. Drive belt
should be riding high in primary clutch and low in
secondary clutch (C).
• If clutch has harsh engagement, erratic transition,
hesitation, or clutch noise (chirping); perform
primary clutch lubrication. Check primary clutch for
flyweights binding, pivot pins worn, flat spots on
rollers or rollers sticking, and no groove in sheave.
Repair or replace primary clutch.
• If engine is surging; check engine and governor
performance.
• Smooth engagement and transition (up-shift),
primary clutch is good. Go to Drive Train
Performance Tests; secondary clutch downshifting check.
SECONDARY CLUTCH DOWN-SHIFTING CHECK
Reason:
To determine condition of secondary clutch (C) and
down-shifting performance.
A
B
MX0763
Conditions:
• Engine slow and fast idle speed set correctly
• Drive belt width at or above minimum specification
• Engine warmed up
C
MX0764
Conditions:
Procedure:
1. Transaxle in neutral and park brake set. Start
engine.
2. Slowly increase engine rpm. Observe engine rpm
when clutch starts to engage and move drive belt.
3. Accelerate from idle to wide-open-throttle and back
to idle several times. Watch drive belt for a smooth
transition from bottom to top of primary clutch (A).
Watch closely for any hesitation or engine surging.
Observe gap between primary clutch movable
sheave and stationary sheave. Gap should
completely close (B).
4. When approaching idle, watch for a positive
disengagement from drive belt.
NOTE: On clutches with some hours of use, system
may not disengage as smoothly due to
primary clutch spring taking a set and other
wear in the drive components.
• Cargo box raised
• Indoor testing - all rear wheels off ground and
vehicle supported safely on jack-stands.
• Front wheels chocked
• Differential lock engaged
• Tachometer displaying engine speed
Procedure:
c
CAUTION
Rear wheels will rotate during test. Keep clear!
1. Start engine.
2. Put transaxle in gear.
3. Operate engine at wide open throttle.
Results:
5. Shut off engine.
5 - 12
• Engine and wheel speed should remain at constant
2/9/00
POWER TRAIN
SECONDARY CLUTCH SPRING TORSION CHECK
speed. Drive belt should be riding high in primary
clutch and low in secondary clutch.
Procedure:
4. Momentarily load power train by slowly applying
brake or park brake until down-shift is made.
5. Quickly observe engine speed, then release brake.
SECONDARY CLUTCH SPRING
TORSION CHECK
Reason:
Verify condition and spring adjustment of secondary
clutch.
Results:
• Clutches should down-shift as load is increased.
• Drive belt should not squeal or slip.
• If engine speed drops below 2400 rpm or clutches
are not down-shifting, see Secondary Clutch
Spring Torsion Check.
• Check secondary clutch for complete up-shift.
Check for load on drive train, such as an engaged
brake or failed axle bearings. (See brake
adjustment procedure.)
B
A
C
MX0828
Conditions:
DRIVING CHECK
Conditions:
• Cargo box empty, no passengers.
• Test on hard surface.
• Engine OFF and key removed
• Transmission in gear
• Park brake set
• Drive belt removed from secondary clutch
Procedure:
Procedure:
1. From a standing start, accelerate through 21.3
meters (70 ft). This should take approximately 4.55.5 seconds.
2. Once up to speed, travel time to cover 30.5 meters
(100 ft.) should be approximately 4.5 seconds.
Results:
• If performance is not to specifications, check
engine performance; engine rpm, governor,
compression and valve clearance.
• Check secondary clutch opens freely, has correct
spring tension, and all three ramp shoes are in
place and against ramps. Repair secondary clutch.
IMPORTANT:
Do not damage sheave when
clamping vise-grip. Use protective strips of
brass or aluminum.
1. Clamp vise grip to movable sheave (A).
2. Using spring scale hooked into jaw of vise-grips,
measure the force required to rotate the movable
sheave, to where the sheave is almost contacting
ramp (B).
Torque Specification for Movement:
With Standard Wrap. . . . . . . . . . . . . . . 75.6 N (17 lb)
NOTE: Standard torsion spring installation sets spring
tab in hole “2” in moveable sheave half
(Standard Wrap). Due to variations in the
spring rate of the torsion spring, the spring tab
may be factory set in holes “1” or “3”.
Results:
• Spring force within specification, secondary clutch
is OK.
Check engine rpm and performance.
• Spring force less than specification, up-shift will be
faster and engine load greater, reducing engine
rpm and response time. Check spring position, set
2/9/00
5 - 13
SECONDARY CLUTCH SPRING TORSION CHECK
spring tab in next higher number hole. (i.e. move
from hole “2” to ”3”) See “SECONDARY CLUTCH”
on page 19. Re-check spring force. Replace spring
if still not within specifications.
• Spring force higher than specification, up-shift or
acceleration will be slower, reducing engine load,
increasing engine rpm and response time. Check
spring position, set spring tab in next lower number
hole. (i.e. move from hole “2” to ”1”) Recheck
spring force. Replace spring (C) if still not within
specifications.
POWER TRAIN
E
C
D
CLUTCH CENTER DISTANCE CHECK
3. Insert snubber step gauge (C) into opening
between front surface of engine isolator bracket
(D) and the rear surface of the frame bracket (E).
• Identify which step on gauge is inserted into
opening to determine the number of spacer
washers to install.
4. Remove gauges from machine.
A
B
1. Remove fifth isolator.
2. Place the closed end (A) of clutch center distance
gauge over the end of the secondary clutch.
Position the open end (B) over the center shaft of
the primary clutch.
G
F
M76748
5. Install fifth isolator parts in shown order.
• Assemble bushings and rubber mounts onto frame
bracket. The spacer(s) (H), metal cup (F) and one
rubber mounting are installed between the frame
bracket (E) and the engine isolator bracket (D).
Install correct number of spacer(s) as determined
using snubber gauge.
• Loosely install fifth isolation mounting cap screw
and nut.
B
A
MX0768
• Make sure closed end is seated completely over
bushing end at secondary clutch.
G
F
NOTE: It may be necessary to push the engine toward
the driven clutch to allow the gauge to drop
onto the drive clutch shaft.
D
E
H
M76770
6. Tighten fifth isolation mounting cap screw (G) to
37 ±7 N•m (27 ±5 lb-ft).
5 - 14
2/16/00
POWER TRAIN
DIFFERENTIAL LOCK LINKAGE ADJUSTMENT
DIFFERENTIAL LOCK LINKAGE
ADJUSTMENT
Reason:
2. Move differential lock arm (B) at transaxle forward
by hand and check for free play. Arm should be
depressing differential lock shaft completely.
To insure complete disengagement and engagement of
differential lock, and that indicator lamp switch is
adjusted properly.
NOTE: If internal differential lock collar pins do not
align, differential may not be engaged.
Engagement spring should be compressed.
Rotate tires until engagement spring pulls
differential lock into position.
DISENGAGEMENT CHECK:
Results:
Conditions:
• Engine OFF
• Park brake OFF
• Cargo box raised
• Differential lock lever in disengaged (UP) position
• Right side wheels jacked up and free to rotate
• Left side of vehicle wheels on ground and chocked
Procedure:
• Differential lock should engage, or engage as tires
are rotated. When locked, tires should not rotate. If
differential will not lock, adjust cable.
• Differential lock shaft (C) should be bottomed out
within transaxle after rotating tires. If not, adjust
cable.
• If lock lever will not move to full engaged (DOWN)
position, check lock switch actuating rod is not
contacting switch before lock lever is going over
center, or that secondary brake linkage (Road
Homolagated only) is not binding.
1. By hand, rotate right side drive wheels.
A
Results:
• Wheels should rotate freely with no clicking sound
in transaxle.
• Differential should be disengaged and cable loose.
• Differential lock arm on transaxle should be just
touching differential lock shaft.
• If there is noise or wheel will not rotate, loosen
differential lock cable at rear adjusting nuts (A),
and slacken cable:
– If differential releases, check cable adjustment.
– If differential will not release, move differential
lock arm on transaxle by hand while trying to rotate
tires and check if differential lock shaft is moving
freely into and out of transaxle case. If not, repair
transaxle.
• If cable is adjusted correctly and lock lever
movement will still not disengage transaxle, check
that differential lock switch rod linkage is not
preventing the cable from going slack when lock
lever is raised to disengaged (UP) position.
C
B
M56342
ENGAGEMENT CHECK:
Conditions:
• Engine OFF
• Park brake OFF
• Cargo box raised
• Differential lock lever in engaged (DOWN) position
Procedure:
1. Engage differential lock lever at operator’s station.
2/9/00
5 - 15
DIFFERENTIAL LOCK LINKAGE ADJUSTMENT
Cable Adjustmtent:
POWER TRAIN
Differential
Adjustment:
Conditions:
Lock
Switch
Actuating
Rod
Conditions:
• Park brake must be OFF
• Differential lock lever must be disengaged (UP)
• Transaxle in NEUTRAL
• Engine OFF
• Park brake OFF
• Key switch in ON position
Procedure:
1. Engage differential lock lever (DOWN position). The
tab on the end of the differential lock switch
actuating rod (A) should move forward, depressing
the switch (B) , and lighting indicator lamp on the
dashboard.
B
A
NOTE:
If park brake is ON, differential lock is
automatically ENGAGED, and both park brake
and differential lock indicator lamps will be
ON.
M56343
A
B
1. Adjust differential lock cable front (A) and rear
adjusting nuts (C) so that all cable slack is
removed, and there is no gap between bracket and
nut at location shown (B).
C
E
2. Disengage differential lock. Indicator light should go
out.
D
M56342
C
D
2. Check that all cable slack is removed and that
differential lock arm (D) is just touching differential
lock shaft (E).
IMPORTANT: Do not over tighten cable so that
differential will not disengage.
3. To adjust switch rod (D), engage differential lock
(DOWN position). Loosen rod nut (C). Position
switch rod so it is centered on switch plunger and
plunger is depressed, but not bottomed out.
4. Tighten rod nut.
5 - 16
2/9/00
DRIVE CHAIN ADJUSTMENT
POWER TRAIN
DRIVE CHAIN ADJUSTMENT
A
B
Minimum: 13 mm (0.5 in.)
Maximum: 38 mm (1.5 in.)
M56087
Reason:
Proper chain slack prevents excessive wear and
backlash problems that could cause chain damage.
Conditions:
• Engine off
• Park brake set
• Box raised
• Jack-up side of vehicle to be adjusted so wheels
are off ground and properly supported with jack
stands.
Adjust Chain Slack:
IMPORTANT: Do NOT use adjusting bolt to move
axle housing. Damage to axle housing could
result.
1. Loosen rear axle housing bolts (B).
2. Move axle housings to obtain chain slack. Slack
should be 13 - 38 mm (0.5 - 1.5 in.).
3. Use adjusting bolt (A) to hold axle in place while
tightening axle-to-frame bolts.
4. Torque rear axle bolts and recheck chain slack.
Readjust if necessary.
Check Chain Slack:
1. Jack up one side so tires are free to rotate. Properly
support vehicle with jack stands.
2. With brakes set, attempt to rotate rear wheel
forward against resistance of transaxle.
3. Measure chain slack on top run of chain at center
point between axles.
2/9/00
NOTE:
If chain is too long, remove one link and
replace with half-link.
5 - 17
PRIMARY CLUTCH FLYWEIGHT IDENTIFICATION
REPAIR
POWER TRAIN
Installation:
Installation is done in the reverse order of removal.
• Torque clutch bolt to 40 - 60 N•m (30 - 44 lb-ft).
PRIMARY CLUTCH FLYWEIGHT
IDENTIFICATION
Repair:
1. Remove clutch cover bolts. Remove cover. (Cover
should pop off; do not pry on cover).
2. Install JDG813-3 Tapered Holding Tool and retain it
with a M10 X 1.5 X 150 mm hex-head bolt.
IMPORTANT: Always use spider wrench to remove
spider. Unequal pressure on clutch towers
could cause stress fractures or break them off.
A medium strength thread lock is used on
spider threads.
J-11
.
The primary clutches can be identified by a model
number, stamped on the face of the flyweights.
JDG813-2
PRIMARY CLUTCH
IMPORTANT: Lightly grease end of puller to help
prevent puller wear. To prevent clutch thread
damage, DO NOT thread bolt in any farther than
necessary to remove clutch.
Removal:
1. Remove left rear wheel.
2. Remove black plug between tires on left side of
frame.
3. Remove drive belt guard and drive belt.
Grease
M56708
JDG813-1
JDG813-3
M56706
M56704
3. Use JDG813-2 Spanner Wrench to remove spider.
4. Remove plastic plug from left side of clutch cover.
5. Remove clutch mounting bolt and washers.
6. Use JDG813-1 Clutch Removal Tool. Thread puller
into clutch and against crankshaft. Tighten until
clutch pops free from crankshaft taper.
NOTE: Check threads in primary clutch. Damage to
threads may occur during removal.
5 - 18
NOTE: Washers and rollers are one piece.
4. Lubricate using TY22034 SuperLube® Spray or
equivalent. Lubricate cam weight pivot area. Slide
bolts side to side for lubricant to penetrate pivot
area. Bolt may need to be removed to lubricate
properly. Replace bolt if worn through plating.
Check flyweight for binding.
5. Lubricate spider rollers. Check for flat spots or
binding.
2/9/00
SECONDARY CLUTCH
POWER TRAIN
SECONDARY CLUTCH
C
E
Removal:
1. Remove drive belt and muffler.
2. Hold clutch with a strap wrench and remove cap
screw (A) and bushing (C).
3. Tap on inside of clutch with a rubber mallet.
4. Remove secondary clutch (B).
B
D
A
A
D
M82418
B
NOTE: Cam is press fit on shaft. Use a three-jaw puller
and an impact wrench, at low speed, to
remove cam from shaft.
C
M82417
c
CAUTION
Hold cam securely to prevent sudden spring
release.
Installation:
Installation is done in the reverse order of removal.
• Apply Moly High Temperature EP Grease, or
equivalent, to splines of transaxle input shaft.
• Install new cap screw (A) or apply Thread Lock and
Sealer to original cap screw. New cap screw will
have thread lock applied. Tighten to 38 N•m (28 lbft).
4. Remove cam using a three-jaw puller and impact
wrench.
NOTE: Before removing spring, mark the hole (E) on
the sheave that the spring tab is installed in.
5. Remove spring, movable sheave and spacer from
shaft.
Disassembly:
1. Release tension on spring (A) by prying spring out
of hole in cam (B).
2. Remove set screw (C).
3. Place alignment marks (D) on cam and movable
sheave to aid in assembly.
NOTE:
Ramp shoes are mounted with tabs on
backside. Tabs are interference fit into holes
on face of ramps. Remove shoes only if
replacement is necessary.
Inspection:
1. Inspect ramp shoes for wear or cracks.
To replace shoes:
• Apply heat to movable sheave ramp (F) until shoe
mounting tabs release from holes in ramp. Pull off
shoes (G).
• If shoe mounting tabs break off inside holes in
ramp, remove tabs using a drill bit.
• Install ramp shoe tabs into ramp holes. If shoes are
too difficult to install, sand tab as necessary. If tabs
are loose, apply thread lock and sealer (medium
strength) on tabs.
2/9/00
5 - 19
SECONDARY CLUTCH
POWER TRAIN
2. Inspect bushing (H) for wear or damage. Replace
movable sheave if necessary.
H
G
ramps. Install small block of wood (B) between
other ramps and shoes to hold sheave half in
position.
c
CAUTION
Prevent burns. Hold allen wrench with locking
pliers.
A
F
M82422
C
Assembly:
1. Install spacer and movable sheave on fixed sheave.
2. Install spring. Insert spring tab into previously
marked hole in movable sheave. Place cam on
spring.
3. Align set screw bores and alignment marks (D).
Press cam on shaft until it stops.
4. Apply thread lock and sealer (medium strength) to
threads of set screw (C) and install.
5. Pry spring away from cam and loop a piece of string
(I) around top spring tab. Pull on string until tab
seats in hole in cam.
C
E
I
D
Replace Ramp
Machine):
Shoes
(Clutch
B
M82423
4. Clamp long end of 2 mm (0.078 in.) allen wrench
(C) into locking pliers. Heat short end of allen
wrench until red. Insert wrench into center of ramp
shoe as plastic melts.
5. Hold wrench in place until plastic hardens.
6. Twist and pull on allen wrench to remove ramp
shoe.
7. Install new ramp shoes. Push ramp shoe straight in
with a screwdriver by prying against cam.
• If shoe is difficult to install, sand mounting tab as
necessary.
• If shoe is loose, apply thread lock and sealer
(medium strength) on mounting tabs.
M82421
Mounted
On
1. Remove drive belt.
2. Install locking pliers (A) on outer edge of fixed
sheave half. Rotate sheave until pliers contact
frame and prevent sheave from turning.
3. Turn moveable sheave until shoes are away from
5 - 20
2/9/00
TRANSAXLE
POWER TRAIN
TRANSAXLE
• Adjust brake linkage.
• Adjust shift rod and differential lock cable.
• Fill transaxle with John Deere J20C Hy-Gard.
Removal:
1. Remove cargo box, drive belt and drive axles.
2. Drain transaxle. Capacity is 4.5 L (4.75 qt).
A
Disassembly And Inspection:
E
C
D
B
E
A
F
C
B
D
G
M82428
M82426
3. Disconnect neutral start switch (A), differential lock
cable (B), shift rod (C), and brake return springs
(D).
F
1. Remove secondary clutch (A), thrust washer (if
used), neutral start switch (F), O-ring, shift lever
(D), spacer (E), and differential lock bracket (G).
2. Remove dipstick (C) and O-ring.
3. Remove 16 cap screws. Tap seam of case with a
plastic hammer or pry apart at pry points and
separate case halves.
G
I
H
K
J
J
I
H
M82427
L
4. Remove lock nut (K) and adjustment nut (J) from
brake rods (H) on each side of transaxle. Remove
brake rods and cross pins (I) from cam levers (G).
5. Remove support bracket (E), mounting cap screws
(F) and washers. Remove transaxle.
Installation:
Installation is in the reverse order of removal.
2/9/00
M82429
K
5 - 21
TRANSAXLE
POWER TRAIN
4. Lift input shaft (J) and secondary shaft H) just
enough to unseat from bearing bores.
c
NOTE: Do not to lose shift block (I) when removing
input and secondary shaft assembly.
Balls (S) and spring (T) will shoot from hole in
shaft when shift collar is removed.
5. Remove differential unit (K) and differential lock
shaft (L) together as an assembly.
9. Remove shift collar (N), balls (S) and spring (T),
reverse drive gear (O), needle bearing (P), washer
(Q), and ball bearing (R) from input shaft (H).
10. Measure thickness of washers (Q and Y), and width
of shift groove in shift collar (N).
M
H
CAUTION
Input Shaft Specifications:
J
Washer (Q) Thickness
Standard . . . . . . 1.45 - 1.55 mm (0.057 - 0.061 in.)
Wear Limit . . . . . . . . . . . . . . . . 1.20 mm (0.047 in.)
Washer (Y) Thickness
Standard . . . . . . 1.52 - 1.68 mm (0.060 - 0.066 in.)
Wear Limit . . . . . . . . . . . . . . . . 1.30 mm (0.051 in.)
M82430
6. Remove input shaft (J) and secondary shaft (H)
together as an assembly.
7. Remove reverse drive chain (M) from input (H) and
secondary shaft assembly (H).
8. Remove sleeve (U), bearing (V), washer (W),
needle bearing (X), and forward drive sprocket (Y)
from the input shaft (H).
Shift Collar (N):
Shift Groove
Width . . . . . . . . . 6.10 - 16.30 mm (0.24 - 0.642 in.)
Shift Groove-to-Block Clearance
(Max) . . . . . . . . . . . . . . . . . . . . . . .2 mm (0.080 in.)
Spring Free Length . . . . . . . 29.50 mm (1.161 in.)
R
Q
P
O
N
H
T
S
Y
X
W
V
U
5 - 22
M82431B
2/9/00
TRANSAXLE
POWER TRAIN
.
AB
Pinion Gear Washer (AG) Thickness:
Standard . . . . . . 0.96 - 1.04 mm (0.038 - 0.041 in.)
Wear Limit . . . . . . . . . . . . . . . . 0.70 mm (0.028 in.)
AA
AD
AC
AA
Differential Lock Collar (AK):
Groove Width . . 7.10 - 7.30 mm (0.280 - 0.287 in.)
Collar Groove-to-Lock Fork
Finger Clearance (Max) . . . . . . . . 2 mm (0.080 in.)
Z
M82432A
16. Disassemble differential lock shaft. Remove
washer.
AT
11. Remove the ball bearing (Z), forward driven gear
(AA), snap ring (AB), and ball bearing (AD), from
secondary shaft (AC). Inspect all parts for wear
and damage.
AU
NOTE: Bearings (Z and AD) on the secondary shaft
are press fit.
AV
AW
AX
AF
AJ
AI
AH
AK
AL
AG
AE
M82434
AN
AS
AM
AR
AQ
AP
AO
M82433b
12. Disassemble differential. Remove bevel gear
washers (AE), bevel side gear (AF), bevel pinion
washers (AG), bevel pinion gears (AH), bevel
pinion shaft (AI), and notched bevel gear (AM).
13. Remove bearing (AL) and differential lock collar
(AK).
14. Remove nuts (AP), and lock washers (AQ) from 10
cap screws (AJ), and separate the differential
housing halves (AN, AR) from final drive gear
(AS).
15. Measure thickness of washers and groove width of
differential lock collar.
17. Put end of differential lock shaft (AT) in a soft jawed
vise as shown. Push down on lock shaft until
washer (AW) is away from short spring pin (AX).
Tighten vise around shaft.
18. Drive out short spring pin.
19. Hold differential lock fork (AU) and slowly loosen
vise. Remove washer and spring.
20. Drive out long spring pin (AV). Remove differential
lock fork.
21. Inspect all parts. Measure thickness of lock fork
fingers and spring free length and working load.
AV
AU
AX
AY
Differential Specifications:
Bevel Side Washer (AE) Thickness:
Standard . . . . . . 1.50 - 1.70 mm (0.059 - 0.067 in.)
Wear Limit . . . . . . . . . . . . . . . . 1.30 mm (0.051 in.)
2/9/00
AW
AT
M82435A
5 - 23
TRANSAXLE
POWER TRAIN
not within 1.12 - 1.28 mm (0.044 - 0.050 in.),
replace washer.
Differential Lock Shaft Specifications:
Differential Lock Fork (AU) Finger
Thickness . . . . . 6.70 - 6.90 mm (0.264 - 0.272 in.)
Finger-to-Collar Groove
Clearance (Max) . . . . . . . . . . . . . . 2 mm (0.080 in.)
Spring (AY)
Free Length. . . . . . . . . . . . . . . 93.2 mm (3.669 in.)
Working
Load. 74 mm @ 150 N (2.913 in. @ 33.72 lb force)
AZ
BA
BB
BC
BD
Assembly:
NOTE: Lubricate all internal parts with clean oil during
assembly.
1. Apply multipurpose grease to new o-ring and inside
lips of seals.
2. Install input shaft seal into case bore until it stops
with seal lips facing away from case half.
3. Install differential lock shaft seal until flush with case
bore and with seal lips facing toward case half.
4. Apply multipurpose grease on thrust washer to hold
in place.
5. Apply multipurpose grease to shifter arm shaft, new
o-ring and shifter block to hold in place.
AT
BE
AU
AV
AW
M82436A
22. Remove cap screw (AZ), snap ring (BA) and
retaining plate (BB).
23. Remove the shifter arm (BD) and block (BE).
24. Inspect all parts of shifter arm for wear or damage.
Replace as necessary.
25. Measure width of shifter block. Replace block if not
within specifications.
Shifter Arm (BD) Specifications:
Shifter Block (BE)
Width . . . . . . . . . . . . 15.7 - 15.9 mm (0.618 - 0.626)
Block-to-Collar Groove
Clearance (Max) . . . . . . . . . . . . . . 2 mm (0.080 in.)
AX
M82434
6. Install differential lock fork (AU) on shaft (AT).
7. Drive in long spring pin (AV) with split facing toward
long end of shaft.
8. Install spring (AW) and washer.
9. Put end of differential lock shaft in a soft jawed vise
as shown. Push down on lock shaft until washer is
away from hole in shaft. Tighten vise around shaft.
10. Drive in short spring pin (AX) with split facing
washer.
11. Install snap ring and washer.
IMPORTANT:
Replace all seals and o-rings.
Damaged or worn parts will leak.
26. Inspect case halves for cracks or damage.
27. Measure thickness of thrust washer. If thickness is
5 - 24
2/9/00
TRANSAXLE
POWER TRAIN
AF
AJ
AI
AH
AK
15. Install washer (AE) and bevel side gear (AF) into
other housing half (AR).
AL
AG
AE
AG
AI
AH
AN
AE
AM
AS
AR
AQ
AP
AO
M82433b
M82441
AS
16. Place final drive gear (AS) on differential housing
half (AN).
17. Install bevel pinion shaft (AI) with pinion gears (AH)
and washers (AG).
AK
AS
AR
AN
AJ
AP
AQ
M82438
12. Install differential lock collar (AK).
13. Press bearings tight against housing half shoulders
(AN, AR).
AN
AR
M82442
AM
18. Place other differential housing half (AR) on final
drive gear (AS).
M82439
AE
14. Install washer (AE) and notched bevel side gear
(AM) into housing half with lock collar (AN).
IMPORTANT: Use new cap screws (AJ), lock
washers (AQ), and nuts (AP) to secure
differential halves. Locking strength of existing
hardware is lost when removed. Reuse of
existing hardware will result in damage to
differential assembly.
19. Install ten new cap screws, washers and nuts.
Tighten nuts to 27 N•m (20 lb-ft).
AR
AE
AF
M82440
2/9/00
5 - 25
TRANSAXLE
AB
POWER TRAIN
AC
AA
AD
N
AA
O
Q
P
R
Z
M82432A
AB
AA
AC
AD
Z
M82445
25. Install reverse drive gear (O) onto short end of input
shaft with shift splines facing shift collar (N).
26. Install needle bearing (P) inside gear.
27. Install washer (Q) tight against shoulder of shaft.
28. Press bearing (R) tight against washer.
N
M82443
20. Install snap ring (AB) and forward secondary gear
(AA) with shoulder facing snap ring.
21. Press bearings (Z, AD) tight against shoulders of
secondary shaft (AC).
X
W
V
BF
U
H
N
Y
T
S
M82444
22. Apply multipurpose grease to balls (S) and spring
(T).
23. Insert spring and balls into hole in input shaft (H).
24. Install shift collar (N) with shoulder toward short
end of input shaft (H). Move shift collar to “neutral”
position.
5 - 26
M82446
29. Install forward drive sprocket (Y) onto long end of
input shaft with shift splines facing shift collar (N).
30. Install needle bearing (X) inside gear.
31. Install ID washer (W) tight against shoulder of shaft.
32. Press bearing (V) tight against washer using a
piece of pipe and a press.
33. Install OD washer (BF) tight against bearing.
34. Apply multipurpose grease to inside diameter of
sleeve and on input shaft.
35. Press sleeve (U) tight against bearing using a piece
of pipe and a press.
2/9/00
TRANSAXLE
POWER TRAIN
I
AK
H
J
AU
L
M82447
36. Assemble differential lock shaft fork (AU) into
differential lock collar (AK).
M
H
J
M82430
37. Assemble input shaft (J) and secondary shaft (H)
with reverse drive chain (M).
NOTE:
Apply multipurpose grease to input and
differential lock shafts to avoid damaging seal
lips.
38. Apply multipurpose grease to splined end of input
shaft.
39. Align shifter block with groove in shift collar and
install input shaft and secondary shaft together as
an assembly.
2/9/00
M82429
K
40. Lift input shaft (H) and secondary shaft (J) to seat
into bearing bores, and then install differential (K)
and differential lock shaft (L) together as an
assembly.
41. Tap on end of shafts and differential with a rubber
mallet to seat bearings.
42. Clean mating surfaces of transaxle case halves
using Clean and Cure Primer. Apply a coat of John
Deere Plastic Gasket, or an equivalent, to case
halves.
43. Apply multipurpose grease to end of differential
lock shaft.
44. Assemble case halves. Install 16 cap screws and
tighten to 35 N•m (26 lb-ft).
IMPORTANT: Allow sealant to cure at least 30
minutes before filling transaxle with oil.
45. Install:
• Dipstick and O-ring (C)
• Spacer (E) and gear shift lever (D). Tighten nut.
• Neutral start switch (F) and new o-ring. Tighten to
39 N•m (29 lb-ft).
• Differential lock lever bracket (G) and cap screws.
46. Apply Moly High Temperature EP Grease, or an
equivalent, to splines of transaxle input shaft,
before installing secondary clutch.
5 - 27
TRANSAXLE
POWER TRAIN
C
D
B
E
A
F
G
M82428
47. Install secondary clutch (A) .
NOTE: Secondary clutch mounting cap screw (B) has
left-hand threads. Install new bolt or apply
medium strength Thread Lock and Sealer.
48. Install bushing and cap screw (B). Hold clutch with
a strap wrench and tighten cap screw to 38 N•m
(28 lb-ft).
5 - 28
2/9/00
DRIVE AXLES - COMPONENT LOCATION
POWER TRAIN
DRIVE AXLES - COMPONENT LOCATION
D
C
B
A
E
F
G
H
I
L
K
J
M76919
A. Grease Fitting
B. Snap Ring (2 used)
C. Splined Coupler
D. Chain Sprocket
E. Carriage Bolt
F. Axle Housing
G. Flanged Lock Nut (M12)
H. Axle Shaft
I. Cap
J. Wheel Bolt
K. Outer (Large) Bearing
L. Inner (Small) Bearing
2/9/00
5 - 29
DRIVE AXLES
DRIVE AXLES
POWER TRAIN
Assembly:
Assembly is done in reverse order of disassembly.
Removal:
1. Lift cargo box and remove master link from drive
chain on the axle being serviced. Remove drive
chain from chain sprockets (D).
2. Jack frame and remove tire and wheel from axle
being serviced.
3. Remove four carriage head bolts (E) and flange
nuts (G) holding axle housing (F) to frame.
Remove axle and sprocket assembly from vehicle.
• The small bearing may unseat from housing bore
during axle installation. Install small bearing into
housing bore using a piece of pipe and a hammer.
Apply force on inner race of bearing only.
• Apply Moly High Temperature EP Grease, or an
equivalent, to splines of axle shaft before installing
secondary coupler.
Installation:
1. Apply Moly High Temperature EP Grease, or an
equivalent, to splines of transaxle output shaft.
2. Align splines of coupler on front axle with splines of
transaxle output shaft.
3. Torque axle housing mounting nuts (G) to 90 N•m
(67 lb-ft.).
4. Install drive chain around axle sprockets and install
master link.
5. Install wheels and tires. Torque wheel mounting cap
screws to 100 N•m (75 lb-ft).
6. Adjust drive chain tension.
Disassembly :
1. Remove splined coupler (C) from end of axle shaft
(H) if coupler remained with shaft when removed.
2. Remove snap ring, washer or spacer, from end of
axle shaft.
NOTE: Bearings are press fit on shaft and in housing.
Remove bearings only if replacement is
necessary. Do not reuse bearings.
3. Remove axle from axle housing (H) using a softfaced mallet.
4. Inspect bearings (L, K) for wear or damage.
Replace if necessary.
To replace large outside bearing (K):
• Remove bearing from axle shaft using a knife-edge
puller and a press.
• Install bearing in axle housing using a driver set,
only pressing on inside race of bearing.
To replace small bearing (L):
• Replace bearing using a driver set.
5 - 30
2/9/00
CONTENTS
STEERING
CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS/TEST/CHECK POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TOE-IN ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STEERING WHEEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TIE ROD END REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STEERING WHEEL AND SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
RACK AND PINION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPINDLE SHAFT AND BUSHING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2/9/00
6-1
NOTES
6-2
STEERING
2/9/00
STEERING
SPECIFICATIONS
SPECIFICATIONS
REPAIR SPECIFICATIONS
Lubrication Interval:
Spindle grease fitting and kingpin
Severe Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every 25 hours
Normal Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every 50 hours
Toe-In Adjustment:
Front-to-rear difference . . . . front dimension is 1 - 7 mm (0.04 ± 0.28 in.) less than rear
TORQUE SPECIFICATIONS
Shock absorber lock nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 N•m (60 lb-ft)
Spindle assembly lock nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 N•m (44 lb-ft)
A-Arm assembly lock nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 N•m (67 lb-ft)
Rack and pinion assembly lock nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 N•m (52 lb-ft)
Rubber boot assembly tie straps
. . . . . . . . . . . . Snug Only — boot must not turn with tie rod when tie rod is adjusted
Front wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 - 98 N•m (58 - 72 lb-ft)
Tie rod
Lock nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 N•m (37 lb-ft)
Jam nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 N•m (52 lb-ft)
Steering shaft U-joint assembly cap screw . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Steering wheel nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Snug Only
2/9/00
6-3
COMPONENT LOCATION
STEERING
COMPONENT LOCATION
B
C
D
A
E
B
F
I
H
G
J
A
MX0597
A. Tie Rod
B. Shock Absorber
C. Upper Steering Shaft
D. Steering Shaft U-Joint
E. Lower Steering Shaft
F. Tie Rod End
G. Spindle Assembly
H. A-Arm
I. Rack and Pinion
J. Rubber Boot
6-4
2/9/00
TROUBLESHOOTING
STEERING
●
●
Rack and pinion assembly worn or broken
●
●
●
●
●
Tie rods bent, loose, or toe-in incorrect
●
●
●
●
●
●
Steering shaft u-joint worn or cap screw loose
●
●
●
Tire size incorrect, out-of-round, or air pressure
incorrect
●
●
●
●
●
Steering wheel and/or shaft splines worn or
stripped
●
Steering wheel nut loose, stripped, or fallen off
●
●
●
●
●
Rubber boots cracked or torn
●
●
●
●
●
●
●
●
●
Shock absorbers leaking or springs broken
Steering shaft-to-rack and pinion assembly snap
ring dislodged or broken
●
●
Wheel bearings worn or lost lubricating properties
Front steering suspension weak or unstable
Steering locks in hard left or right turns
●
Noise during turns or over rough terrain
Steers hard left or right or both
●
Steering wheel spins freely
Steering shimmies or vibrates
●
Check or
Solution
Steering wheel pulls upward
Steering wonders
Spindles, king pins, or king pins A-frame bearings
worn or not lubricated sufficiently
Problem or
Symptom
Wheel bearing noise
Steering pulls in one direction
TROUBLESHOOTING
●
●
●
●
●
●
●
●
●
●
●
A-arm bent, pivot bushings worn or lost
lubricating properties
●
●
●
●
●
Shock absorbers mounts bent or hardware worn,
loose, or broken
●
●
●
●
●
●
●
Shock absorbers installed upside down
2/9/00
6-5
DIAGNOSIS/TEST/CHECK POINTS
STEERING
DIAGNOSIS/TEST/CHECK POINTS
Test/Check Point
1. Rims
Normal
If Not Normal
Runout less than 3 mm (0.12 in.)
Replace rims.
Wheel bolts tight
Tighten to specification.
Runout less than 10 mm (0.4 in.)
Remount or replace tires.
Tires properly inflated
Inflate tires to proper pressure.
3. Wheel bearings and bushings
Wheels rotate freely without rough
spots
Replace rims.
4. Spindle and kingpin
assemblies
Assemblies tight and turn smoothly
Tighten assemblies.
Replace assemblies.
King pins properly greased
Grease.
Fastened securely
Tighten lock nuts to specification.
Assemblies not bent
Replace A-arm assemblies.
Pivot bushing not worn or binding
Replace bushings.
Installed and tightened properly
Tighten lock nuts to specification.
Operate smoothly and not leaking
Replace shock absorbers.
Jam nuts tight, tie rod ends tight, and
toe-in adjusted properly
Adjust toe-in and tighten jam nuts
and lock nuts.
Tie rods straight, not worn
Replace components as necessary.
Assembly fastened securely
Tighten assembly.
Operates from stop-to-stop smoothly
with little effort
Replace assembly.
Fastened securely to rack and pinion
assembly
Fasten securely.
Straight
Replace shaft.
U-joint fastened securely
Tighten U-joint cap screw to
specification.
Operates smoothly. Shaft splines
good
Replace upper steering shaft and
U-joint.
Installed properly, nut snug
Install and tighten properly.
No cracks or breaks, splines good
Replace components as necessary.
2. Tires
5. A-arm assemblies
6. Shock absorbers
7. Tie rods and tie rod ends
8. Rack and pinion assembly
9. Lower steering shaft
10. Upper steering shaft and
U-joint
11. Steering wheel and leaping
deer emblem
6-6
2/9/00
DIAGNOSIS/TEST/CHECK POINTS
STEERING
4
6
5
7
8
6
9
11
7
1
2
3
11
M55738
2/9/00
6-7
TOE-IN ADJUSTMENT
STEERING
TOE-IN ADJUSTMENT
rod if boot clamp (D) is too tight. DO NOT allow
this to happen. Loosen clamp enough to allow
the rubber boot to remain stationary.
Reason:
To prevent tire wear and steering wander.
STEERING WHEEL ADJUSTMENT
Procedure:
Reason:
1. Park machine on level surface, turn key switch OFF,
shift transmission to NEUTRAL, and LOCK park
brake.
To position steering wheel properly.
Procedure:
NOTE: Toe-in cannot be correctly adjusted with:
- wheels off surface
- an uneven surface
- any weight or load on machine.
2. Turn steering wheel until front drivers-side tire aligns
with drivers-side rear tire(s). Use straight 2 x 4 or
piece of angle iron for guide.
1. Park machine on level surface, turn key switch OFF,
shift transmission to NEUTRAL, and LOCK park
brake.
2. Turn steering wheel to right or left steering stop.
3. Turn wheel to other stop while counting number of
turns.
4. Turn wheel back 1/2 of total turns counted.
A
A
B
Front
B
C
Front Toe-In Adjustment
(B) = (A) - 1 - 7 mm (0.04 - 0.28in.)
M55739
MX0602
3. At hub height and center of tire tread, measure rear
distance (A) and front distance (B).
4. At right side tie rod, loosen jam nut (C) and turn tie
rod until front distance (B) is 1 - 7 mm (0.04 - 0.28
in.) less than rear distance (A).
5. Tighten jam nut.
NOTE: Proper position of steering wheel is as shown
with spokes at approximately 2, 6, and 10
o’clock.
5. If wheel is not correct, remove leaping deer emblem,
nut (A), and washer.
6. Without moving steering shaft, remove steering
wheel and align on splines (B) so bottom spoke (C)
points to 6 o’clock.
7. Install washer and nut, tighten until snug only
8. Install leaping deer emblem.
D
C
M97093
IMPORTANT: The rubber boot may turn with the tie
6-8
2/9/00
REPAIR
STEERING
REPAIR
STEERING WHEEL AND SHAFT
TIE ROD END REPLACEMENT
Removal:
Removal:
1. Remove front wheel.
NOTE: Tie rod end is a tapered bore fit. Use a ball joint
fork or puller to ease removal.
1. Remove cap (A), lock nut (B).and steering wheel (C).
2. Remove U-joint cap screw (D) and nut (E).
3. Pull up on steering shaft (F). Remove snap ring (G).
4. Remove shaft (F) and bushing (H).
5. Inspect all parts for wear or damage. Replace as
necessary.
Installation:
2. Remove tie rod end lock nuts and disconnect tie rod
ends from spindles.
3. Remove tie rod end (A).
Installation is done in the reverse order of removal.
• Tighten U-joint cap screw to 40 N•m (30 lb-ft).
A
Installation:
1. Install new tie rod end. Position spindle shaft 90° to
machine and turn wheel on other side to straight
position.
2. Turn tie rod end until tapered end fits into arm of
spindle. Tighten lock nut (B) to 50 N•m (37 lb-ft)
3. Adjust toe-in.
4. Tighten jam nut (C) to 70 N•m (52 lb-ft).
B
C
H
G
C
F
A
E
B
M82450A
D
M82448A
2/9/00
6-9
RACK AND PINION ASSEMBLY
STEERING
RACK AND PINION ASSEMBLY
Installation:
Installation is done in the reverse order of removal.
Removal:
1. Remove front wheels.
2. Remove U-joint cap screw (A) and nut (B).
3. Pull up on steering wheel to disconnect U-joint from
lower steering shaft (J).
4. Remove tie rod end lock nuts (C) and disconnect tie
rod ends from spindles.
5. Remove mounting cap screws (D) and lock nuts (E).
Loosen the mounting bracket (G) and isolator (H).
6. Remove nine mounting screws and washers from
left-hand fender.
7. Remove steering assembly (F) from left-hand side of
machine.
8. Inspect all parts for wear or damage. Replace as
necessary.
• Adjust toe-in.
Torque Specifications:
Tie rod end lock nut (C) . . . . . . . . . . 50 N•m (37 lb-ft)
U-joint cap screw (A) . . . . . . . . . . . . 40 N•m (30 lb-ft)
Mounting lock nuts (E) . . . . . . . . . . 70 N•m (52 lb-ft)
RACK AND PINION COMPONENT LOCATION
B
A
G
H
F
J
D
E
C
M82449A
6 - 10
2/9/00
SPINDLE SHAFT AND BUSHING
STEERING
SPINDLE SHAFT AND BUSHING
Installation:
Installation is done in the reverse order of removal.
• Apply multipurpose grease to lubrication fitting (D).
• Tighten lock nut (C) to 60 N•m (46 lb-ft).
Removal:
1. Remove tire.
2. Disconnect tie rod end from spindle shaft (A).
3. Remove lock nut (B) and cap screw (C).
4. Remove spindle shaft.
5. Replace bushings (E).
NOTE: Bushings are press fit into the a-arm. Use an
inside puller set to remove bushings, and a
driver set to install bushings
SPINDLE COMPONENT LOCATION
B
E
D
A
C
M82451A
2/9/00
6 - 11
SPINDLE SHAFT AND BUSHING
6 - 12
STEERING
2/9/00
CONTENTS
BRAKES
CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OTHER MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPONENT LOCATION - BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPONENT LOCATION - BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS/TEST/CHECK POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BRAKE ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2/9/00
7-1
NOTES
7-2
BRAKES
2/9/00
SPECIFICATIONS
BRAKES
SPECIFICATIONS
Brake Plate Thickness. . . . . . . . . . . . . . . . . . . . . . . . .1.44 - 1.60 mm (0.057 - 0.063 in.)
Friction Disk Thickness . . . . . . . . . . . . . . . . . . . . . . . .4.60 - 4.80 mm (0.181 - 0.189 in.)
Thrust Washer Thickness . . . . . . . . . . . . . . . . . . . . . . .0.92 - 1.08 mm (0.036 - 0.43 in.)
Brake Pedal Freeplay Adjustment (Maximum) . . . . . . . . . . . . . . . . . . . . 4 mm (0.16 in.)
TORQUE SPECIFICATIONS
Driven Clutch Mounting Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft)
Brake Cover-to-Transaxle Case Cap Screw . . . . . . . . . . . . . . . . . . . 26 N•m (230 lb-in.)
OTHER MATERIALS
2/9/00
Number
Name
Use
TY6305
John Deere Clean and
Cure Primer
Cleans parts and speeds
cure of sealant.
TY15130 or TY15443
John Deere Sealant
Seals brake cover to
transaxle case.
TY6333
Moly High Temperature EP
Grease
Apply to splines of
transaxle input shaft.
7-3
COMPONENT LOCATION - BRAKE ASSEMBLY
BRAKES
COMPONENT LOCATION - BRAKE ASSEMBLY
C
B
A
F
E
D
J
K
I
H
O
N
M82425
M
L
G
A. Actuator Ring
B. Brake Plates (3 used)
C. Transaxle Housing (left side)
D. Ball (6 used)
E. Output Shaft (left side)
F. Brake Discs (2 used)
G. Cap Screw (10 used)
H. Brake Arm
I. O-Ring
J. Snap Ring
K. Seal
L. Transaxle Housing Cover
M. Alignment Pin (2 used)
N. Thrust Washer
O. Ball Bearing
7-4
2/9/00
COMPONENT LOCATION - BRAKE SYSTEM
BRAKES
COMPONENT LOCATION - BRAKE SYSTEM
F
E
D
C
A
B
I
G
H
J
K
L
M
N
O
A. Brake Pedal Switch
B. Brake Pedal Assembly
C. Park Brake Release Button
D. Park Brake Lever
E. Park Brake Switch
F. Park Brake Release Pawl
G. Park Brake Locking Pawl
H. Park Brake Rod
I. Brake Rods
J. Transaxle Assembly
K. Brake Arm Return Spring
L. Load Spring (1 per side)
M. Brake Pedal Bracket
N. Brake Cable
O. Brake Pedal Return Spring
2/9/00
7-5
TROUBLESHOOTING
BRAKES
●
●
●
●
Brake pedal stop plate worn or mis-adjusted.
●
●
●
●
Brake cable mis-adjusted, stretched, worn, or
binding.
●
●
●
●
Brake linkage freeplay adjustment incorrect.
●
●
●
●
●
Mid-frame brake springs mis-adjusted,
collapsed or broken.
●
●
●
●
●
Mid-frame brake arm linkage loose, misadjusted, binding, worn, or broken.
●
●
●
●
Park brake lever, locking pawl, slotted rod, or
park brake arm bent, binding, worn, or broken.
Mid-frame -to-transaxle brake rods misadjusted, loose, or bent.
●
●
Transaxle brake arm return springs stretched or
broken.
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
Transaxle brake arm and shaft bent, binding, or
worn.
●
●
Internal brake plates and discs warped, grooved,
or worn.
●
●
●
●
●
●
●
●
●
Internal actuator ring warped, grooved, missing
balls, or worn.
●
●
●
●
●
●
●
●
●
Change Transaxle oil - use ONLY HY–GARD®
J20C
7-6
Brakes noisy or chattering
●
Brake pedal travel excessive
●
Park brake will not hold
●
Park brake will not release
Excessive brake wear
Brake pedal return spring stretched or broken.
●
Park brake will not engage
●
Brakes will not release
●
Brakes noisy or chattering
Brake pedal bent, binding, or worn.
Brake engagement too aggressive
Check or
Solution
Brakes binding or brake effort excessive
Problem or
Symptom
Brakes will not engage or show poor response
TROUBLESHOOTING
●
2/9/00
BRAKES
THEORY OF OPERATION
THEORY OF OPERATION
Function:
To provide a means of stopping the unit and also
prevent movement when not in use.
Theory Of Operation:
When the brake pedal (A) is depressed, the brake
cable (B) pulls U-bracket (C) and mid-frame brake arms
(D) forward. Mid-frame brake arms pull left and right
side brake rods (E) which pull transaxle brake arms (F)
forward. When transaxle brake arms are pulled forward
the flat edge at the internal end of the brake arm shaft
(G) pushes against the actuator ring tab (H). This
rotates the right-side actuator ring clockwise and the
left-side actuator ring counter-clockwise causing the six
angled ramps (I) to move against the six captured balls
(J). This action forces the actuator ring against the
outer brake plate (K), outer brake disc (L), middle brake
plate (M), inner brake disc (N), and finally the inner
brake plate (O).
The friction between the brake plates and brake discs
slows or stops output shaft (S) rotation, which slows or
stops the drive wheels. The brake plates are held
stationary by four tabs (P) on each of three brake
plates which are seated in four transaxle housing
grooves (Q). The brake discs are spline engaged to the
output shaft’s center splines (R).
When the park brake lever (T) is raised into its locked
position, the slotted rod (U) pulls the park brake arm
(V) up and the mid-frame brake arms (D) forward. From
hereon, everything works the same. To release the
park brake lever, first raise the lever slightly, then
depress the release button (W) and lower lever all-theway.
2/9/00
7-7
SYSTEM OPERATION
BRAKES
SYSTEM OPERATION
1 Test One - Vehicle Operating
W
A
2
T
V
F
5
U
B
G
C
3
D
J
I
H
E
R
S
4
K
P
L
Q
M
N
O
M55755
7-8
2/9/00
DIAGNOSIS/TEST/CHECK POINTS
BRAKES
DIAGNOSIS/TEST/CHECK POINTS
Test Conditions:
• Engine running at operating temperature - Test 1
only.
• Shift lever in forward or reverse - Test 1 only.
• Minimum of 50 feet of open and flat pavement
away from any people - Test 1 only.
• Key switch OFF and shift lever in NEUTRAL - all
except Test 1.
• Operator in seat.
Test/Check Point
1. Vehicle operating
2. Brake pedal
3. Mid-frame
4. Transaxle
5. Park brake
2/9/00
Normal
If Not Normal
When brakes applied, machine stops
aggressively with rear wheels locking.
Check linkage and brake
components for adjustment, binding,
wear or damage
Brake pedal should depress smoothly
and with little effort.
Check linkage and brake
components for binding, wear or
damage.
Components not worn or damaged.
Repair or replace as necessary.
Hardware not worn or loose.
Repair or replace as necessary.
Springs not broken or stretched.
Replace as necessary.
Cable not binding, mount and jam nut
good.
Repair or replace as necessary.
Rubber boot and clamps good.
Repair or replace as necessary.
Load springs not broken or
compressed.
Repair or replace as necessary.
Linkage adjusted properly and not
damaged or worn.
Adjust
Repair or replace as necessary.
Internal components not worn or
damaged.
Repair or replace as necessary
Properly adjusted.
Adjust.
Linkage not worn or damaged
Repair or replace as necessary.
7-9
BRAKE ADJUSTMENTS
BRAKES
BRAKE ADJUSTMENTS
Reason:
C
To ensure service brake linkage and park brake linkage
are adjusted properly.
F
G
D
Procedure:
B
E
NOTE: If this is a NEW transaxle or you have replaced
the brake pack assembly, ONLY perform steps
1-7, 9 and 10. DO NOT perform step 8
because NEW brake parts require a tighter
linkage adjustment to account for initial breakin wear.
1. Park machine on level surface and turn key switch
OFF.
2. Shift lever in NEUTRAL and park brake lever in
released position, and front wheels BLOCKED.
3. Use jack stands or hoist to raise rear wheels at
least 25 mm (1.0 in.) off ground.
NOTE:
If brake cable is being replaced, DO NOT
attach cable to brake pedal at this time. Attach
cable only at mid-frame mounting and brake
arm assembly.
4. Disconnect brake arm return spring (A).
H
M76917
5. Loosen jam nut (B) and coupler nut (C).
6. Hold brake rod (D) to rear and brake arm (E)
forward to remove all play.
7. Turn coupler nut (C) forward until it pushes spacer
(F) and washer (G) forward until washer just
contacts coupler pin (H).
8. Turn coupler nut (C) 3 turns (eighteen flats of nut)
away from pin (H).
9. Tighten jam nut (B).
10. Install brake arm return spring (A).
11. Turn rear wheel, it should rotate with a slight drag
(considerably higher drag for NEW parts) and
provide even braking on both sides. See alternate
procedure, step 12 (Except: DO NOT use for NEW
parts).
12. Alternate procedure to Step 11. (DO NOT use this
step for NEW parts):
• Turn any lug of rear wheel. Wheel should rotate at
less than 20 N•m (15 lb-ft), ideally 14 N•m (10 lbft).
Axle Center Line
A
Torque Wrench Center Line
M55781
M56087A
Wheel Lugs
NOTE: When using torque wrench, the torque wrench
centerline should intersect the axle flange
centerline!
13. After repeating procedure for both sides, check
both sides for EVEN braking. If UNEVEN, repeat
entire procedure.
7 - 10
2/9/00
BRAKE
BRAKES
NOTE: This completes the routine portion of brake
adjustment procedure. If brake cable has been
replaced or foot pedal linkage needs
adjustment, complete Steps 14 - 20.
NOTE: Brake pedal freeplay is necessary to prevent
any preload of brake linkage. If stop plate (N) is
adjusted too high, brakes will be preloaded. If
stop plate (N) is adjusted too low, return spring
(J) pressure, will kink brake cable.
18. Loosen cap screw (M) of stop plate (N). Adjust stop
plate up to reduce amount of freeplay in brake
pedal. Apply only enough up force to stop plate to
take up freeplay. Do not start actuating brake.
Maximum freeplay pedal travel is 4 mm (0.16 in.).
19. Hold stop plate (N) while you tighten cap screw (M).
• If light and horn kit is installed, stop plate (N) will
have a switch fastened to it. Stop plate must be
positioned so switch is aligned with bottom of
brake pedal rod (O). Be sure brake pedal rod
contacts switch plunger (plunger depressed) but
does not contact the switch body.
20. Install brake pedal return spring (J) in hole (P).
J
BRAKE
L
M56376
K
Removal:
1. Remove transaxle assembly (C).
14. Pull park brake lever into LOCKED position.
15. Unhook brake pedal return spring (J).
IMPORTANT: DO NOT allow brake cable to slip out
of slot or cable may become kinked. Hold cable
in slot by holding cable below lower nut (K)
when loosening top nut (L).
NOTE: Driven clutch must be removed to service left
hand brake assembly (D). Mounting cap screw
(E) has left-hand threads.
2. Remove driven clutch (A). Hold clutch with a strap
wrench and remove left hand thread cap screw (E)
and bushing (F).
3. Tap on inside of clutch with a rubber mallet.
16. Adjust brake cable nuts (K) and (L) to provide a
20 mm (0.79 in.) gap between the bottom of the
brake pedal and the floor.
17. Tighten nuts (K) and (L).
A
F
B
E
J
M
D
O
C
M82424
P
N
M56376
NOTE: Balls may fall out when cover is removed.
Bearing is slip fit on output shaft and in cover.
2/9/00
7 - 11
BRAKE
BRAKES
4. Remove brake cover and brake parts.
IMPORTANT: Replace all seals and O-rings.
5. Pry out seal using a screwdriver.
6. Inspect all parts for wear or damage. Installation is
done in the reverse order of removal.
• Apply multipurpose grease to lips of new seal.
Install seal flush to inside of cover using a driver
set.
• Apply petroleum jelly on thrust washer and balls to
hold in place during installation.
• Clean mating surfaces of transaxle case and brake
cover using Clean and Cure Primer. Apply a coat
of John Deere Sealant, or an equivalent, to mating
surfaces.
• Apply Moly High Temperature EP Grease, or an
equivalent, to splines of transaxle input shaft
before installing driven clutch.
Inspection:
Inspect all parts for wear or damage. Measure
thickness of brake plates, friction discs and thrust
washer. If not within specifications, replace.
Thickness Specifications:
Brake Plates . . . . . 1.44 - 1.60 mm (0.057 - 0.063 in.)
Friction Discs . . . . 4.60 - 4.80 mm (0.181 - 0.189 in.)
Thrust Washer . . . 0.92 - 1.08 mm (0.036 - 0.043 in.)
Installation:
Installation is done in the reverse order of removal.
7 - 12
2/9/00
CONTENTS
MISCELLANEOUS
CONTENTS
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HOOD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SHOCK RIDE HEIGHT AND SPRING PRELOAD ADJUST . . . . . . . . . . . . . . . . . . . . 4
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SHOCK ABSORBER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FRONT WHEEL REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
WHEEL BEARING REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
A-ARM REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2/9/00
8-1
NOTES
8-2
MISCELLANEOUS
2/9/00
MISCELLANEOUS
TORQUE SPECIFICATIONS
Shock Absorber:
Mounting Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 N•m (52 lb-ft)
A-Arm:
Shock Absorber to A-Arm lock nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 N•m (52 lb-ft)
A-Arm to Frame Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 N•m (67 lb-ft)
Wheels:
Front Wheel Mounting Hub Cap Screw . . . . . . . . . . . . . . . . . . 78 - 98 N•m (58 - 72 lb-ft)
Rear Wheel Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 78 - 98 N•m (58 - 72 lb-ft)
Rear Wheel Mounting Bolts (EMT tires) . . . . . . . . . . . . . . . . . 78 - 98 N•m (58 - 72 lb-ft)
Cargo Box:
Hinge Bolts (side and tail gate) . . . . . . . . . . . . . . . . . . . . . . . . 41 - 60 N•m (30 - 44 lb-ft)
2/9/00
8-3
HOOD ADJUSTMENT
MISCELLANEOUS
HOOD ADJUSTMENT
SHOCK RIDE HEIGHT AND SPRING
PRELOAD ADJUST
1. Ensure all tires are inflated to 41 kPa (6 psi).
Reason:
To position hood so openings for the headlights are
centered around headlights.
Procedure:
1. Park machine on level surface, turn key switch OFF,
place shift lever in NEUTRAL, and lock park brake.
B
A
A
M97093
B
MX0601
2. Loosen cap screws (A) and (B).
IMPORTANT: Hood MUST NOT touch headlights or
vibration may cause headlights to fail.
3. Adjust hood so openings around headlights are
equal.
4. Tighten bottom cap screws (B), then tighten top cap
screws (A)
5. Make sure hood has not shifted during tightening.
Adjust again, if necessary.
2. Measure center of bolt head to center of bolt head
(B) on each shock and average the two
dimensions.
IMPORTANT: The cam position (A) on each shock
needs to be the same to maintain a stable ride.
3. If average dimension is less than 305 mm
(12 in.), adjust the cam to provide more spring
preload. DO NOT exceed 315 mm
(12-3/8 in.).
C
M97096
4. Use the adjusting wrench (C) to adjust the shock up
to 5 levels of adjustment. Each level of the
adjustment is approximately 3 mm (1/8 in.) more
spring preload.
5. Drive to allow settling and setting in of the shocks,
then check measurements. Adjust if necessary.
8-4
2/9/00
SHOCK ABSORBER REPLACEMENT
MISCELLANEOUS
REPAIR
2. Remove hub cap (A).
3. Remove mounting cap screw (B).
4. Tap on backside of wheel rim with a soft-faced
mallet to remove wheel.
5. Inspect and replace bearings, if necessary.
SHOCK ABSORBER
REPLACEMENT
Installation:
Removal:
Installation is done in the reverse order of removal.
1. Remove front wheel.
• Apply multipurpose grease to spindle shaft before
installing wheel.
• Install front wheels with stems toward outside of
machine. Tighten cap screw to 78 - 98 N•m (58 72 lb-ft)
A
WHEEL BEARING REPLACEMENT
Removal:
M97093
B
2. Remove top and bottom mounting lock nuts and
cap screws (A or B).
3. Remove shock absorber(s).
1. Remove front wheel.
2. Remove snap ring (A).
3. Remove bearing (B) on one side using an inside
puller and slide hammer.
NOTE: Bearings are press fit in wheel rim.
4. Remove snap ring and bearing on opposite end
using a driver set.
Installation:
1. Install new shocks, leaving in lowest spring preload
setting, with rod end up.
2. Tighten mounting lock nuts to 70 N•m (52 lb-ft).
FRONT WHEEL REMOVAL AND
INSTALLATION
A
B
A
B
Removal:
M82455A
1. Raise and support machine.
Installation:
B
Installation is done in the reverse order of removal.
• Pack inside of rim with multipurpose grease before
installing spacer and bearings.
A
M82454
2/9/00
8-5
A-ARM REMOVAL AND INSTALLATION
A-ARM REMOVAL AND
INSTALLATION
MISCELLANEOUS
3. Remove mounting cap screws, lock nuts and AArm.
Installation:
Removal:
Installation is done in the reverse order of removal.
NOTE: If replacing A-Arm, remove spindle shaft and
bushings. (See STEERING section.)
Shock absorber should be in place to provide proper
orientation of A-Arm when tightening mounting
hardware.
1. Remove front wheel.
2. Remove shock absorber mounting cap screw and
lock nut.
D
C
B
E
A
F
G
H
Right Hand Side A-Arm Shown
M82453A
A. Bushing (2 used)
D.Shock Absorber
G. Lock Nut (2 used)
B. King Pin
E. Cap Screw M10 X 40, Head Marked 10.9 (2 used)
H. A-Arm
C. Lock Nut (2 used)
F. Cap Screw M12 X 90 (2 used)
8-6
2/9/00
INDEX
A
Air Intake System
Indicator Tests . . . . . . . . . . . . . . . . . . . . . . .
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Repair . . . . . . . . . . . . . . . . . . . . . . . .
3-32
3-32
3-13
3-83
B
Battery
Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
Blackout Lights Wiring Harness W11 . . . . . . . . 4-19
Brakes
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Other Materials . . . . . . . . . . . . . . . . . . . . . . . 7-3
Removal and Installation . . . . . . . . . . . . . . . 7-11
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Theory of Operation . . . . . . . . . . . . . . . . . . . . 7-7
Torque Specifications . . . . . . . . . . . . . . . . . . 7-3
Transaxle Components . . . . . . . . . . . . . . . . . 7-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 7-6
Break-In Engine Oil . . . . . . . . . . . . . . . . . . . . . . . 2-8
C
Cam Followers . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Camshaft
End Play Check . . . . . . . . . . . . . . . . . . . . . . 3-46
End Play Check - 3TN66C-JUV . . . . . . . . . . 3-46
Removal/Installation . . . . . . . . . . . . . . . . . . 3-49
Cargo Box Lift System
Actuator
Clutch Replacement . . . . . . . . . . . . . . . 4-74
Circuit Diagnosis . . . . . . . . . . . . . . . . . . . . . 4-56
Cover Tube Seal Replacement . . . . . . . . . . 4-74
Motor
Amperage Draw Test . . . . . . . . . . . . . . 4-73
Replacement . . . . . . . . . . . . . . . . . . . . 4-74
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-11
Wire Color Codes . . . . . . . . . . . . . . . . . . . . 4-18
Wiring Harness W10 . . . . . . . . . . . . . . . . . . 4-18
Charging Circuit
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Electrical Schematic . . . . . . . . . . . . . . . . . . 4-35
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Component Location
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Drive Axles . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
2/9/00
Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Connecting Rod
Bearing Clearance Check . . . . . . . . . . . . . . 3-53
Side Play Check . . . . . . . . . . . . . . . . . . . . . 3-52
Side Play Check - 3TN66C-JUV . . . . . . . . . 3-52
Cooling System
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . 3-30
Cranking Circuit
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Crankshaft
End Play Check . . . . . . . . . . . . . . . . . . . . . . 3-53
Front Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Main Bearing Clearance Check . . . . . . . . . . 3-54
Main Bearings . . . . . . . . . . . . . . . . . . . . . . . 3-62
Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Cylinder Compression Test . . . . . . . . . . . . . . . . 3-21
Cylinder Head
Recondition . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Removal/Installation . . . . . . . . . . . . . . . . . . 3-38
D
Diesel Fuel
Lubricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Driven Clutch
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Back-Shift Check . . . . . . . . . . . . . . . . . . . . . 5-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Driving Check . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
E
Electrical
Amperage Draw Tests . . . . . . . . . . . . . . . . . 4-62
Blackout lights
Wiring Harness W11 . . . . . . . . . . . . . . 4-19
Brake Pedal Switch Tests . . . . . . . . . . . . . . 4-67
Cargo Box Lift
Schematic . . . . . . . . . . . . . . . . . . . . . . 4-55
Switch Test . . . . . . . . . . . . . . . . . . . . . 4-70
Wiring Harness W10 . . . . . . . . . . . . . . 4-18
Charging Circuit Diagnosis . . . . . . . . . . . . . 4-36
Charging Circuit Electrical Schematic . . . . . 4-35
Charging Circuit Operation . . . . . . . . . . . . . 4-34
Common Circuit Tests . . . . . . . . . . . . . . . . . . 4-5
Component Location . . . . . . . . . . . . . . . . . . . 4-8
Cranking Circuit Diagnosis . . . . . . . . . . . . . 4-28
Cranking Circuit Operation . . . . . . . . . . . . . 4-26
Diagnostic Information . . . . . . . . . . . . . . . . . . 4-3
Differential Lock Switch Test . . . . . . . . . . . . 4-69
INDEX - 1
INDEX
Engine Coolant Temperature Switch Test . . 4-72
Fuel Shutoff Solenoid
Wiring Harness W8 . . . . . . . . . . . . . . . 4-17
Fuel Shutoff Solenoid Test . . . . . . . . . . . . . 4-70
Glow Plug/Fuel Supply
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 4-32
Operation . . . . . . . . . . . . . . . . . . . . . . . 4-30
Ground Circuit Tests . . . . . . . . . . . . . . . . . . 4-72
Headlight
Wiring Harness W9 . . . . . . . . . . . . . . . 4-17
Headlights & Blackout Lights
Circuit Diagnosis . . . . . . . . . . . . . . . . . 4-48
Circuit Operation . . . . . . . . . . . . . . . . . 4-46
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 4-48
Operation . . . . . . . . . . . . . . . . . . . . . . . 4-46
Indicator Lights
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 4-40
Operation . . . . . . . . . . . . . . . . . . . . . . . 4-38
Key Switch Test . . . . . . . . . . . . . . . . . . . . . . 4-69
Light Switch Test . . . . . . . . . . . . . . . . . . . . . 4-68
Main Electrical Schematic . . . . . . . . . . . . . . 4-13
Neutral Start Switch Test . . . . . . . . . . . . . . . 4-67
Park Brake Switch Tests . . . . . . . . . . . . . . . 4-67
Power Circuit Diagnosis . . . . . . . . . . . . . . . . 4-22
Power Circuit Operation . . . . . . . . . . . . . . . . 4-20
Radiator Fan Motor
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 4-44
Operation . . . . . . . . . . . . . . . . . . . . . . . 4-42
Reading Electrical Schematics . . . . . . . . . . . 4-4
Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
Schematics and Wiring Harness Legend . . . 4-12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Starting Motor . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Amperage & RPM Test . . . . . . . . . . . . 4-65
Amperage Draw Test . . . . . . . . . . . . . . 4-64
Solenoid Test . . . . . . . . . . . . . . . . . . . . 4-66
Tests & Adjustments . . . . . . . . . . . . . . . . . . 4-60
Theory and Diagnosis . . . . . . . . . . . . . . . . . 4-20
Theory of Operation Information . . . . . . . . . . 4-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-10
Unregulated Amperage Test . . . . . . . . . . . . 4-62
Voltage Test
Regulated Amperage & Voltage Tests . 4-63
Wire Color Abbreviation Chart . . . . . . . . . . . . 4-3
Electrical Wiring Harness
Blackout Lights W11 . . . . . . . . . . . . . . . . . . 4-19
Cargo Box Lift W10 . . . . . . . . . . . . . . . . . . . 4-18
Engine W2 . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Engine W3 . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Engine W4 . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Engine W5 . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Engine W6 . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Engine W7 . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Engine W8 . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
INDEX - 2
Headlight W9 . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Main W1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Engine
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Flywheel Plate . . . . . . . . . . . . . . . . . . . . . . . 3-64
Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . 3-31
Removal/Installation . . . . . . . . . . . . . . . . . . 3-34
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Fuel Control and Governor Linkage
Assembly . . . . . . . . . . . . . . . . . . . . 3-79
Disassembly . . . . . . . . . . . . . . . . . 3-78
Inspection . . . . . . . . . . . . . . . . . . . 3-79
Installation . . . . . . . . . . . . . . . . . . . 3-77
Removal . . . . . . . . . . . . . . . . . . . . 3-77
Fuel Injection Pump
Installation . . . . . . . . . . . . . . . . . . . 3-74
Removal . . . . . . . . . . . . . . . . . . . . 3-73
Fuel Injection Pump Camshaft
Assembly . . . . . . . . . . . . . . . . . . . . 3-76
Disassembly . . . . . . . . . . . . . . . . . 3-76
Inspection . . . . . . . . . . . . . . . . . . . 3-76
Installation . . . . . . . . . . . . . . . . . . . 3-76
Removal . . . . . . . . . . . . . . . . . . . . 3-75
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Tests & Adjustments . . . . . . . . . . . . . . . . . . 3-21
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 3-17
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Drain Interval . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Temperature Switch . . . . . . . . . . . . . . . . . . . 3-67
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Exhaust Manifold Removal/Installation . . . . . . . 3-40
F
Flywheel Removal/Installation . . . . . . . . . . . . .
Fuel Control and Governor Linkage
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Drain Back Test . . . . . . . . . . . . . . . . . . . .
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injection Nozzle
Cross Section . . . . . . . . . . . . . . . . . . . . . . .
Removal/Installation . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injection Pump
Camshaft Assembly . . . . . . . . . . . . . . . . . . .
Camshaft Disassembly . . . . . . . . . . . . . . . .
Camshaft Inspection . . . . . . . . . . . . . . . . . .
Camshaft Installation . . . . . . . . . . . . . . . . . .
Camshaft Removal . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Static Timing Adjustment . . . . . . . . . . . . . . .
3-64
3-79
3-78
3-79
3-77
3-77
3-32
3-70
3-72
3-71
3-72
3-25
3-76
3-76
3-76
3-76
3-75
3-73
3-26
2/9/00
INDEX
Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Pressure Test . . . . . . . . . . . . . . . . .
Fuel Shutoff Solenoid
Wiring Harness W8 . . . . . . . . . . . . . . . . . . .
Fuel System
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . .
3-69
3-31
4-17
3-32
3-14
3-70
H
Headlight Wiring Harness W9 . . . . . . . . . . . . . . 4-17
Headlights & Blackout Lights
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Hydrostatic Transmission & Hydraulic Oil . . . . . . 2-9
I
Idle
Fast Speed Adjustment . . . . . . . . . . . . . . . .
Slow Speed Adjustment . . . . . . . . . . . . . . .
Idler Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indicator Lights
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold
Removal/Installation . . . . . . . . . . . . . . . . . .
3-22
3-22
3-47
4-40
4-38
3-39
L
Lighting Specifications . . . . . . . . . . . . . . . . . . . . 4-6
Lubricants
Alternative Lubricants . . . . . . . . . . . . . . . . . 2-10
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Mixing of Lubricants . . . . . . . . . . . . . . . . . . . 2-10
Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Synthetic Lubricants . . . . . . . . . . . . . . . . . . 2-10
M
Muffler Removal/Installation . . . . . . . . . . . . . . . 3-36
N
Neutral Start Switch Specifications . . . . . . . . . . . 4-6
O
Oil Pan and Strainer . . . . . . . . . . . . . . . . . . . . .
Oil Pressure
Regulating Valve . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump
Removal/Installation . . . . . . . . . . . . . . . . . .
3-52
3-66
3-31
3-65
P
Piston and Connecting Rod Repair . . . . . . . . . 3-55
Piston to Cylinder Head Clearance . . . . . . . . . . 3-55
Power Circuit Diagnosis . . . . . . . . . . . . . . . . . . 4-22
2/9/00
Power Circuit Operation . . . . . . . . . . . . . . . . . . 4-20
Power Train
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
R
Radiator
Bubble Test . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Cap Pressure Test . . . . . . . . . . . . . . . . . . . . 3-30
Radiator Fan
Switch Specifications . . . . . . . . . . . . . . . . . . . 4-6
Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
Radiator Fan Motor
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Repair
Drive Axles . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Primary Clutch . . . . . . . . . . . . . . . . . . . . . . . 5-18
Rack and Pinion . . . . . . . . . . . . . . . . . . . . . . 6-10
Replace Ramp Shoes . . . . . . . . . . . . . . . . . 5-20
Shock Absorber Replacement . . . . . . . . . . . . 8-5
Spindle Shaft . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Steering Wheel and Shaft . . . . . . . . . . . . . . . 6-9
Tie Rod End . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Rocker Arm
Cover Removal/Installation . . . . . . . . . . . . . 3-36
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Removal/Installation . . . . . . . . . . . . . . . . . . 3-37
S
Specifications
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Break-In Engine Oil . . . . . . . . . . . . . . . . . . . . 2-8
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Diesel Fuel Lubricity . . . . . . . . . . . . . . . . . . . 2-7
Diesel Fuel Storage . . . . . . . . . . . . . . . . . . . . 2-7
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . 2-11
Drain Interval . . . . . . . . . . . . . . . . . . . . 2-12
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Engine Repair . . . . . . . . . . . . . . . . . . . . . . . . 3-3
General Vehicle . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubricants
Alternative Lubricants . . . . . . . . . . . . . 2-10
Chassis Grease . . . . . . . . . . . . . . . . . . 2-10
Hydrostatic Transmission & Hydraulic Oil 2-9
Mixing of Lubricants . . . . . . . . . . . . . . . 2-10
Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Storage . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Synthetic Lubricants . . . . . . . . . . . . . . . 2-10
Powertrain
General . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Torques . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
INDEX - 3
INDEX
Product Identification Locations . . . . . . . . . . 2-12
Torque Values, Inch Fastener . . . . . . . . . . . . 2-5
Torque Values, Metric Fastener . . . . . . . . . . 2-6
Starting Motor
Disassembly/Repair . . . . . . . . . . . . . . . . . . . 3-80
Loaded Amperage Draw Test . . . . . . . . . . . 4-64
No-Load Amperage & RPM Tests . . . . . . . . 4-65
Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . 4-66
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Steering
Component Location . . . . . . . . . . . . . . . . . . . 6-4
Diagnosis/Test/Check Points . . . . . . . . . . . . . 6-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 6-5
T
Tests & Adjustments
Battery Load Test . . . . . . . . . . . . . . . . . . . . 4-61
Battery Test . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
Brake Pedal & Park Brake Switch Tests . . . 4-67
Cargo Box Lift Switch Test . . . . . . . . . . . . . 4-70
Charge Battery . . . . . . . . . . . . . . . . . . . . . . 4-60
Differential Lock Linkage . . . . . . . . . . . . . . . 5-15
Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Drive Train Performance . . . . . . . . . . . . . . . 5-12
Electrical System Amperage Draw Tests . . 4-62
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Engine Coolant Temperature Switch Test . . 4-72
Engine Oil Pressure Switch Test . . . . . . . . . 4-68
Fuel Shutoff Solenoid Test . . . . . . . . . . . . . 4-70
Ground Circuit Tests . . . . . . . . . . . . . . . . . . 4-72
Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Key Switch Test . . . . . . . . . . . . . . . . . . . . . . 4-69
Light Switch Test . . . . . . . . . . . . . . . . . . . . . 4-68
Neutral Start Switch Test . . . . . . . . . . . . . . . 4-67
Radiator Fan Switch Test . . . . . . . . . . . . . . 4-71
Regulated Amperage & Voltage Tests . . . . 4-63
Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
Secondary Clutch Spring . . . . . . . . . . . . . . . 5-13
Starting Motor
Loaded Amperage Draw Test . . . . . . . 4-64
No-Load Amperage and RPM Tests . . 4-65
Solenoid Test . . . . . . . . . . . . . . . . . . . . 4-66
Steering Wheel Adjustment . . . . . . . . . . . . . . 6-8
Throttle Cable Adjustment . . . . . . . . . . . . . . 3-21
Toe-In Adjustment . . . . . . . . . . . . . . . . . . . . . 6-8
Transaxle Shift Linkage . . . . . . . . . . . . . . . . 5-11
Unregulated Amperage Test . . . . . . . . . . . . 4-62
Theory of Operation
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Thermostat
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Throttle Cable Adjustment . . . . . . . . . . . . . . . . 3-21
INDEX - 4
Timing Gear
Backlash Check . . . . . . . . . . . . . . . . . . . . . . 3-47
Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Torque Values
Inch Fastener . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Metric Fastener . . . . . . . . . . . . . . . . . . . . . . . 2-6
Transaxle
Brake Components . . . . . . . . . . . . . . . . . . . . 7-4
Disassembly/Inspection . . . . . . . . . . . . . . . . 5-21
Troubleshooting
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
V
Valve Clearance Adjustment . . . . . . . . . . . . . . . 3-23
Valve Lapping . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Valve Lift Check . . . . . . . . . . . . . . . . . . . . . . . . 3-24
W
Water Pump Removal/Installation . . . . . . . . . . . 3-68
Water Pump/Alternator Drive Belt
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
2/9/00
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