OPERATOR/SERVICE MANUAL
MODELS: SD-43, SD-54, PD-43
PD-54, PDB-43, PDB-54
RHINO MODEL SHOWN: PD54
JOHN DEERE DIESEL
A 100% employee-owned American manufacturer
REVISION: B 6/01
P/N 56322
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TABLE OF CONTENTS
OPERATOR/SERVICE MANUAL
RHINO 43/54
FOREWORD
................................................................................................... 6
LIMITED WARRANTY....................................................................................... 7
SECTION 1 - TECHNICAL DATA...................................................................... 9 - 11
1.1 Specifications .......................................................................................... 10
1.2 Engine RPM ............................................................................................ 10
1.3 Machine Data .......................................................................................... 11
1.4 Machine Sound Level Test...................................................................... 11
SECTION 2 - HEALTH & SAFETY ................................................................... 13 - 19
SECTION 3 - OPERATION ................................................................................. 21 - 29
3.1 Introduction and Operating Principle...................................................... 22
3.2 Diesel Fuel .............................................................................................. 23
3.3 Engine Break-in ...................................................................................... 23
3.4 Engine Oil and Filter ............................................................................... 23
3.5 Warning Light ......................................................................................... 23
3.6 Hydraulic Oil, Filter, and Breather ......................................................... 23 - 24
3.7 Engine Coolant........................................................................................ 24
3.8 Visual Inspection..................................................................................... 24
3.9 Air Cleaner .............................................................................................. 24 - 25
3.10 Before Starting ........................................................................................ 25
3.11 To Start ................................................................................................... 25
3.12 To Stop ................................................................................................... 25
3.13 Idling Engine ........................................................................................... 25
3.14 Warming Engine...................................................................................... 25 - 26
3.15 Parking Brake .......................................................................................... 26
3.16 Brake Light ............................................................................................. 26
3.17 To Operate ............................................................................................... 26
3.18 Forward/Reverse/Neutral ........................................................................ 26
3.19 Throttle ................................................................................................... 26
3.20 Gauges ................................................................................................... 26
3.21 Panel Fuse ............................................................................................... 27
3.22 Cold Weather Starting / Intake Heater Button ........................................ 27
3.23 Blade Lever ............................................................................................. 27
3.24 Horn/Back-up Alarm ............................................................................... 27
3.25 ROPS/FOPS/Seat Belt ............................................................................ 27
3.26 Tires/Lugnuts .......................................................................................... 27
3.27 Drum/Scrapers ........................................................................................ 28
3.28 Cleaning .................................................................................................. 28
3.29 Eccentrics ................................................................................................ 28
3.30 Compaction Tips ..................................................................................... 28
3.31 Tie Downs ............................................................................................... 28
3.32 Towing (Bypass) ..................................................................................... 28 - 29
3.33 Storage ................................................................................................... 29
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SECTION 4 - MAINTENANCE........................................................................... 31 - 55
4.1 Important ................................................................................................. 32
4.2 Maintenance Schedule ............................................................................ 32
4.3 Important Maintenance Information ....................................................... 34
4.4 Engine Oil and Filter ............................................................................... 34
4.5 Additional Service Information .............................................................. 34
4.6 Hydraulic Oil and Filter .......................................................................... 34 - 35
4.7 Hydraulic Breather .................................................................................. 35
4.8 Engine Cooling System ........................................................................... 35 - 36
4.8.1 Replacing Engine Coolant......................................................... 36
4.8.2 Adding Engine Coolant ............................................................. 36 - 37
4.8.3 Disposing of Coolant................................................................. 37
4.9 Air Cleaner .............................................................................................. 37
4.9.1 Air Cleaner Service ................................................................... 37
4.9.2 Air Cleaner Replacement .......................................................... 37 - 38
4.9.3 Element Storage ........................................................................ 38
4.10 Fuel Filter ................................................................................................ 38
4.10.1 Water Separator ......................................................................... 38
4.10.2 Fuel Filter Replacement ............................................................ 38 - 39
4.10.3 Bleeding Fuel System ............................................................... 39
4.10.4 Bleeding at Fuel Injection Pump ............................................... 39
4.10.5 Bleeding at Fuel Injection Nozzles ........................................... 39 - 40
4.11 Fan/Alternator Belt ................................................................................. 40
4.12 Grease Fittings ........................................................................................ 40
4.13 Frame Hinge ............................................................................................ 40
4.14 Blade Pins ............................................................................................... 40
4.15 Battery ................................................................................................... 40
4.15.1 Servicing Battery....................................................................... 40 - 41
4.15.2 Battery Installation .................................................................... 41
4.15.3 Charging/Jumping Battery ........................................................ 41 - 42
4.16 Engine Crankcase Vent Tube .................................................................. 42
4.17 Engine Valve Clearance .......................................................................... 42
4.18 Emission Regulation/Engine RPM ......................................................... 42
4.19 Fuel Injectors .......................................................................................... 42 - 43
4.19.1 Test Fuel Injection Nozzles ....................................................... 43
4.20 Fuel Tank................................................................................................. 43
4.21 Fuel Lines................................................................................................ 43
4.22 Hydraulic Hoses/Connections ................................................................. 43 - 44
4.23 Forward/Reverse/Neutral Adjustment .................................................... 44
4.24 Neutral Interlock ..................................................................................... 44
4.25 Control Cables: Forward/Reverse, Throttle, Blade................................. 44
4.26 Eccentrics ................................................................................................ 45
4.26.1 Eccentric Housing Oil ............................................................... 45
4.27 Charge System......................................................................................... 45
4.28 Panel Fuse: 20 AMP................................................................................ 45
4.29 Engine Installation Guidelines ................................................................ 45 - 46
4.30 Engine Mounting..................................................................................... 46
4.31 Hardware ................................................................................................. 46
4.31.1 Loctite ....................................................................................... 46
4.32 Roll Over Protective Structures (ROPS)................................................. 46
4.32.1 Maintenance of ROPS/Seat Belts (Inspection & Repair) ......... 46
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4.33 Horn/Back-up Alarm ............................................................................... 47
4.33.1 Back-up Alarm Switch .............................................................. 47
4.34 Scrapers ................................................................................................... 47
4.35 Troubleshooting ...................................................................................... 48 - 53
4.36 Electrical Troubleshooting ...................................................................... 54
4.37 Service Record ........................................................................................ 55
SECTION 5 - EXPLODED DIAGRAMS & PARTS LIST................................ 57 - 97
5.1 Hardware Key ......................................................................................... 59
5.2 Torque Charts and Guidelines................................................................. 60 - 61
5.3 Drum Assembly....................................................................................... 62 - 65
5.4 Main Frame ............................................................................................. 66 - 69
5.5 Radiator/Engine Mount........................................................................... 70 - 71
5.6 Engine ................................................................................................... 72 - 75
5.7 Air Cleaner .............................................................................................. 76 - 77
5.8 Controls ................................................................................................... 78 - 81
5.9 Drive System Hydraulics ........................................................................ 82 - 85
5.10 Steering/Eccentric System Hydraulics .................................................... 86 - 87
5.11 Blade ................................................................................................... 88 - 89
5.12 Hydraulic Schematic ............................................................................... 90 - 91
5.13 Wiring ................................................................................................... 92 - 93
5.14 Decal Identification ................................................................................. 94 - 97
CALIFORNIA PROPOSITION 65 WARNING .............................................................. 99
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FOREWORD
These instructions include:
Warranty Information
Safety regulations
Operating instructions
Maintenance instructions
Please enter the following data. This will help expedite
any service or warranty work.
1. Machine Type: _______________________
Machine S/N: ________________________
2. Engine Type: _________________________
Engine S/N: __________________________
3. VIN: _______________________________
4. Purchase Date: _______________________
5. Dealer/Distributor Information:
These instructions have been prepared for
operation on the construction site and for the
maintenance engineer.
These instructions are intended to simplify
operation of the machine and to avoid
malfunctions through improper operation.
Observing the maintenance instructions will
increase the reliability and service life of the
machine when used on the construction site and
reduce repair costs and downtimes.
Always keep these instructions at the place of
use of the machine.
Name: ______________________________
Address: ____________________________
____________________________________
Phone #: ____________________________
Fax #: ______________________________
Only operate the machine as instructed and
follow these instructions.
Observe the safety regulations as well as the
guidelines of the civil engineering trade
association. Observe safety rules for the
operation of equipment and the pertinent
regulations for the prevention of accidents.
Location of above information:
1. Information on S/N tag.
Stone Construction Equipment, Inc. is not liable
for the function of the machine when used in an
improper manner and for other than the intended
purpose.
2. Information on engine tag.
Operating errors, improper maintenance and the
use of incorrect operating materials are not
covered by the warranty.
3. Information on S/N tag - if applicable.
4. Date you purchased machine.
5. Dealer machine was purchased from.
The above information does not extend the
warranty and liability conditions of business of
Stone Construction Equipment, Inc.
Stone Construction Equipment, Inc.
P.O. Box 150, Honeoye, New York 14471
Phone: (800) 888-9926
Fax: (716) 229-2363
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L i m i t e d W a r r a n t y
The Manufacturer warrants that products manufactured shall be free from defects in material and
workmanship that develop under normal use for a period of 90 days for concrete vibrators and electric
pumps, one year for Rhino®, Bulldog®, Wolfpac Rollers™, trowels, Stompers®, saws, forward plates,
engine powered pumps, and 6 months for all other products from the date of shipment. The foregoing
shall be the exclusive remedy of the buyer and the exclusive liability of the Manufacturer. Our warranty
excludes normal replaceable wear items, i.e. gaskets, wear plates, seals, O-rings, V-belts, drive chains,
clutches, etc. Any equipment, part or product which is furnished by the Manufacturer but manufactured by
another, bears only the warranty given by such other manufacturer. (The Manufacturer extends the warranty
period to “Lifetime” for the drum bearings and seals for the mortar mixers, and agrees to furnish, free of
charge, the bearings and seals only upon receipt of the defective parts. The warranty is two years for
eccentric bearings on the forward plate compactors, mortar and plaster mixer drums, trowel gearboxes
and five years on the Bulldog trench roller eccentric bearings.) A Warranty Evaluation Form must accompany
all defective parts. Warranty is voided by product abuse, alterations, and use of equipment in applications
for which it was not intended, use of non-manufacturer parts, or failure to follow documented service
instructions. The foregoing warranty is exclusive of all other warranties whether written or oral, expressed
or implied. No warranty of merchantability or fitness for a particular purpose shall apply. The agents,
dealer and employees of Manufacturer are not authorized to make modification to this warranty, or additional
warranties binding on Manufacturer. Therefore, additional statements, whether oral or written, do not
constitute warranty and should not be relied upon.
The Manufacturer’s sole responsibility for any breach of the foregoing provision of this contract, with respect
to any product or part not conforming to the Warranty or the description herein contained, is at its option (a)
to repair, replace or refund such product or parts upon the prepaid return thereof to location designated
specifically by the Manufacturer. Product returns not shipped prepaid or on an economical transportation
basis will be refused (b) as an alternative to the foregoing modes of settlement - the Manufacturer’s dealer
to repair defective units with reimbursement for expenses, except labor, and be reviewed with the
Manufacturer prior to repair. A Warranty Evaluation Form must accompany all warranty claims.
Except as set forth hereinabove and without limitation of the above, there are no warranties or other
affirmations which extends beyond the description of the products and the fact hereof, or as to operational
efficiency, product reliability or maintainability or compatibility with products furnished by others. In no
event whether as a result of breach of contract or warranty or alleged negligence, shall the Manufacturer
be liable for special or consequential damages including but not limited to: Loss of profits or revenues, loss
of use of the product or any associated product, cost of capital, cost of substitute products, facilities or
services or claims of customers.
No claim will be allowed for products lost or damaged in transit. Such claims should be filed with the carrier
within fifteen days.
Effective April 1, 1998.
Stone Construc tion Equipm e nt, Inc .
32 Ea st Ma in Stre e t, P. O. Box 150
Phone : 1-800-888-9926 • 1-716-229-5141
Fa x: 1-716-229-2363
Bre d Toug h, Te c hnolog y Born To Work.
The Wa y It Oug ht To Be .
Hone oye , NY 14471-0150
•
e -ma il: sc e ny@mc ima il.c om
4/ 98 P/ N 51018
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1. TECHNICAL DATA
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1. TECHNICAL DATA
1.1 Specifications Stone Rhino®
STONE
SD 43
STONE
SD 54
STONE
PD 43
STONE
PD 54
STONE
PD 54
STONE
PDB 54
MODEL
Sm o o th
Sm o o th
Pa d fo o t
Pa d fo o t
Pa d fo o t
Pa d fo o t w/ b la d e
Drum Typ e
Dim e nsions
Op e ra ting Wt. (Kg )
6100# (2767)
43" (109,2)
6540# (2966,5)
54" (137,2)
6409# (2907,1)
43" (109,2)
6880# (3120,7)
54" (137,2)
6880# (3120.7)
54" (137.2)
7275# (3300)
54" (137,2)
Drum Wid th (c m )
H x L x W (c m )
97" x 124" x 51"
(246,4 x 315 x 124,5)
97" x 124" x 59"
(246,4 x 315 x 149,9)
97" x 124" x 51"
(246,4 x 315 x 124,5)
97" x 124" x 59"
(246,4 x 315 x 149,9)
97' x 124' x 59'
(246.4 x 315 x 149.9)
97" x 136" x 68"
(246,4 x 315 x 172,7)
9.5 x 16 (24,1 x 40,6)
Dia m o nd Tre a d
9.5 x 16 (24,1 x 40,6)
Dia m o nd Tre a d
9.5 x 16 (24,1 x 40,6)
C le a te d Tra c to r
9.5 x 16 (24,1 x 40,6)
C le a te d Tra c to r
9.5 x 16 (24.1 x 40.6)
C le a te d Tra c to r
9.5 x 16 (24,1 x 40,6)
C le a te d Tra c to r
Tire s (c m )
Op e ra ting Syste m
Eng ine (kW)
58 hp Jo hn De e re
(43.25)
58 hp Jo hn De e re
(43.25)
58 hp Jo hn De e re
(43.25)
58 hp Jo hn De e re
(43.25)
58 hp Jo hn De e re
(43.25)
58 hp Jo hn De e re
(43.25)
2500 (41,7)
20 g a l. (757)
Po we r
2500 (41,7)
20 g a l. (757)
Po we r
2500 (41,7)
20 g a l. (757)
Po we r
2500 (41,7)
20 g a l. (757)
Po we r
2500 (41.7)
20 g a l (757)
Po we r
2500 (41,7)
20 g a l. (757)
Po we r
RPM (He rtz)
Fue l Ca p a c ity (lite rs)
Ste e ring
Artic ula ting ,
O sc illa ting
Artic ula ting ,
O sc illa ting
Artic ula ting ,
O sc illa ting
Artic ula ting ,
O sc illa ting
Artic ula ting
O sc illa ting
Artic ula ting ,
O sc illa ting
Fra m e
Po sitra c tio n
Hyd ro sta tic
Wa te r
Po sitra c tio n
Hyd ro sta tic
Wa te r
Po sitra c tio n
Hyd ro sta tic
Wa te r
Po sitra c tio n
Hyd ro sta tic
Wa te r
Po sitra c tio n
Hyd ro sta tic
Wa te r
Po sitra c tio n
Hyd ro sta tic
Wa te r
Drive Syste m
Ec c e ntric Drive
Cooling
Me c ha nic a l
Hyd ro sta tic
Me c ha nic a l
Hyd ro sta tic
Me c ha nic a l
Hyd ro sta tic
Me c ha nic a l
Hyd ro sta tic
Me c ha nic a l
Hyd ro sta tic
Me c ha nic a l
Hyd ro sta tic
Pa rking Bra ke
Se c urity Bra king Sys.
Pe rform a nc e
Ce ntrifug a l Forc e (Kn)
12,000# (53,38)
2100 (35)
12,000# (53,38)
2100 (35)
12,000# (53,38)
2100 (35)
12,000# (53,38)
2100 (35)
12,000# (53,38)
2100 (35)
12,000# (53,38)
2100 (35)
Fre q ue nc y (He rtz)
14,900# (66,28)
15,100# (67,17)
15,209# (67,65)
15,419# (68,59)
15,808# (70,32)
16,075# (71,51)
Tota l Ap p lie d Forc e
(Kn)
Sp e e d
Low Ge a r
Hig h Ge a r
(kilom e te rs/ hour)
0-2 m p h (0-3,22)
0-4 m p h (0-6,44)
0-2 m p h (0-3,22)
0-4 m p h (0-6,44)
0-2 m p h (0-3,22)
0-4 m p h (0-6,44)
0-2 m p h (0-3,22)
0-4 m p h (0-6,44)
0-2 m p h (0-3,22)
0-4 m p h (0-6,44)
0-2 m p h (0-3,22)
0-4 m p h (0-6,44)
.062" (1,57)
.059" (1,50)
35o
.053" (1,35)
35o
.059" (1,50)
.053" (1,35)
.071" (1,80)
Am p litud e (m m )
Artic ula ting Ang le
Osc illa ting Ang le
Gra d e a b ility
35o
9o
35o
9o
35o
9o
35o
9o
9o
9o
90%
70%
90%
70%
70%
70%
Insid e Turning Ra d ius
(m e te r)
94.25" (2,39)
88.75" (2,25)
94.25" (2,39)
2 1/ 2" (6,35)
14" (35,56)
88.75" (2,25)
2 1/ 2" (6,35)
14" (35,56)
94.25" (2,39)
2 1/ 2" (6,35)
14" (35,56)
88.75" (2,25)
7" (17,78)
2 1/ 2" (6,35)
14" (35,56)
7" (17,78)
Wa ll Cle a ra nc e (c m )
Curb Cle a ra nc e (c m )
14" (35,56)
14" (35,56)
Are a Ca p .
37,840 sq .ft/ hr.
(3515,5)
37,840 sq .ft/ hr.
(3515,5)
47,520 sq .ft/ hr.
(4414,8)
47,520 sq .ft/ hr.
(4414,8)
47,520 sq .ft/ hr.
(4414,8)
(Sq .Ft./ Hr.) (M2)
37,840 sq .ft/ hr.
(3515,5)
Sta nd a rd Fe a ture s: 2 d rum sc ra p p e rs; RO PS/ FO PS; g a ug e s – o il p re ssure , vo lt m e te r, c o o la nt te m p , ho ur m e te r, fue l sig ht, hyd ra ulic o il sig ht; wa rning lig hts - o il p re ssure a nd
te m p e ra ture ; ho rn; b a c k-up a la rm ; ne utra l sa fe ty sta rt; p a d d e d se a t w/ flip -up a rm re sts; se a t b e lt; se c o nd a ry p a rking b ra ke
1.2 ENGINE RPM
IDLE RPM
FULL RPM
1,200 + 100 18Hz
2,500 + 100 41Hz
2,100 + 100 34Hz
ECCENTRIC FULL SPEED RPM
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1. TECHNICAL DATA
1.3 MACHINE DATA
Brakes
Service
Parking
Hydrostatic
Automatic spring applied
Recommended Fuel
Electric
Diesel fuel blend meeting ASTM D975 or EN 590
Premium diesel fuel conditioner is also recommended
12 Volt system battery BCI group 24
800 CCA 78 amp charge system
Hydraulic Oil
Engine Oil
Mobilfluid 424
Capacity 20 gallons (76 liters)
1st 100 hours John Deere break-in oil (TY22041) then
SAE 15W/40 API CG-4 or API CF-4 6.5 quarts (6.0 liters)
Engine Coolant
Eccentric Oil
50/50 Mixture antifreeze / distilled water meeting ASTM 4985,
coolant additive is also recommended
SAE 20W/50 API SJ or API SH
SD / PD 43: 1 quart (.95 liter)
SD / PD 54: 15 quarts (1.4 liters)
Engine / HP
Torque
John Deere 3029DF 58 HP (43 kW) int. @ 2,500 RPM
153 ft. lbs. (208 Nm) int. @ 1,200 RPM
Fuel Economy
.377 lb./hp - hr. (230 g/kWh) @ 1,600 RPM
1.4 MACHINE SOUND LEVEL TEST
Machine Type:
PDB54 Rhino
Sound Level Meter Calibration Date:
August 6, 1997
Meter Type:
Test Date:
Simpson Model 886-2 Type 2
August 6, 1997
Test Conditions:
Temperature
70° Fahrenheit / 20° Celsius
60 dba Slow Mode
Silts and Clays
Ambient Sound
Soil Condition
Moisture Limit
N/A
Engine Speed:
2,500 RPM / 41 Hz
2,100 VPM / 34 Hz
Honeoye, New York, USA
93 dba Without Vibe
93 dba With Vibe
Frequency:
Test Site:
Sound Level at Operator Position:
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2. HEALTH & SAFETY
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Safety Precautions
2. HEALTH & SAFETY
SAFETY USE
These machines are designed to carry out the function
of compacting material of the non-cohesive, bituminous
and granular varieties.
If used correctly they will provide an effective and safe
means of compaction and meet the appropriate
performance standards.
It is essential that the operator of the machine is
adequately trained in its safe operation, be authorized
to operate it, and have sufficient knowledge of the
machine to ensure that it is in full working order before
being put to use.
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Safety Precautions
2. HEALTH & SAFETY
Before using this equipment, study this entire manual
to become familiar with its operation. Do not allow
untrained or unauthorized personnel, especially
children, to operate this equipment. Use only factory
authorized parts for service.
When warning decals are destroyed or missing, contact
the Manufacturer immediately at 1-800-888-9926 for
replacement. For the safety of yourself and others, it is
imperative that the following rules are observed.
Failure to do so may result in serious injury or death.
FOLLOW SAFETY INSTRUCTIONS
•
Carefully read all safety messages and decals in this manual
and on your machine safety signs. Keep decals in good
condition. Replace missing or damaged decals. Be sure
new equipment components and repair parts include the
current safety signs. Replacement safety signs and decals
are available through your dealer.
•
•
Learn how to operate the machine and how to use controls
properly. Do not let anyone operate without instruction.
Keep your machine in proper working condition.
Unauthorized modifications to the machine may impair the
function and/or safety and affect machine life.
•
If you do not understand any part of this manual and need
assistance, contact your dealer.
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.
•
This notation appears before warnings in the text. It means that
the step which follows must be carried out to avoid the possibility
of personal injury or death. These warnings are intended to help
the technician avoid any potential hazards encountered in the
normal service procedures. We strongly recommend that the
reader takes advantage of the information provided to prevent
personal injury or injury to others.
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Safety Precautions
2. HEALTH & SAFETY
USE COMMON SENSE WHEN HANDLING FUELS
•
•
Transport and handle fuel only when contained in approved safety
container.
Do not smoke when refueling or during any other fuel handling
operation.
•
•
Do not refuel while the engine is running or while it is still hot.
If fuel is spilled during refueling, wipe it off from the engine
immediately and discard the rag in a safe place.
Do not operate the equipment if fuel or oil leaks exist - repair
immediately.
•
•
Never operate this equipment in an explosive atmosphere.
•
Operator must always be seated with seat belt on when
roller is running.
•
•
•
•
•
•
Never allow more than one person on roller.
Always turn engine off before dismounting from roller.
Always apply parking brake when not in use.
Never park roller on a hill.
Never operate roller on slope greater than 15 degrees.
Do not operate the roller in standing water.
•
•
Ear protection required when operating this equipment.
Exposure to loud noise can cause impairment or loss of
hearing.
HOT SURFACES
•
•
Muffler, engine, and engine shroud may be hot.
Allow all components in the engine compartment to cool before
performing any service work.
•
•
•
Never operate unit in a poorly ventilated or enclosed area.
Avoid prolonged breathing of exhaust gases.
Engine exhaust fumes can cause sickness or death.
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Safety Precautions
2. HEALTH & SAFETY
•
Qualified personnel only. No untrained operators. Serious injury may
occur.
•
Users must be trained to operate this roller. Read the Operator's
Manual and Engine Owner's Manual. Learn to operate this roller
safely.
•
•
•
•
•
•
Do not articulate on grades larger than 15o, roller may tip over.
Do not operate across the sides of hills, roller may tip over.
Do not operate at the edge of mats or roads, roller may tip over.
Do not stand. Be seated, with seat belt on, when roller is running.
Do not park the roller on hills.
Always turn off engine and apply brake before dismounting.
•
•
Caution: Escaping hydraulic fluid under pressure can have sufficient
force to penetrate the skin, causing serious personal injury.
Hydraulic system produces high pressures--incorrect hose replacement
can cause serious personal injury. When performing service, refer to
Operator's Manual for hose identification and connections.
Hydraulic fluid escaping under pressure from a very small hole can be
almost invisible. Use a piece of cardboard or wood to search for
possible leaks.
•
•
•
Never use your hands to detect pressure leaks.
Hydraulic tank temperature can reach 180o F maximum.
SERVICE COOLING AND HYDRAULIC SYSTEMS SAFELY
•
•
Pressurized release of fluids from hydraulic or coolant systems can
cause serious burns.
Shut off engine. Only remove filler cap when cool enough to touch
with bare hands. Slowly loosen cap to first stop to relieve pressure
before removing completely.
•
Never perform any work on the roller while it is running. Before
working on the roller, stop the engine and disconnect the spark plug
wire(s) to prevent accidental starting, block drums to prevent rolling.
Keep engine cover closed during the operation.
Keep hands, clothing and jewelry away from all moving parts.
Keep all guards in place.
•
•
•
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Safety Precautions
2. HEALTH & SAFETY
•
•
•
Keep feet clear of all drums.
Keep work area free of bystanders.
For foot protection wear steel toe shoes or toe pads.
•
Caution: Keep away from the machine’s articulation area
when the engine is running.
•
•
Only start engine from operator’s seat.
Before starting machine, make sure that there are no persons
or obstacles near or under machine.
PRACTICE SAFE MAINTENANCE
•
•
Understand service procedure before doing work. Keep area clean
and dry.
Never lubricate, service, or adjust machine while it is moving. Keep
hands, feet, and clothing from power-driven parts. Disengage all
power and operate controls to relieve pressure. Lower equipment
to the ground. Stop the engine. Remove the key. Allow machine
to cool.
•
•
Securely support any machine elements that must be raised for
service work.
Keep all parts in good condition and properly installed. Fix damage
immediately. Replace worn or broken parts. Remove any buildup
of grease, oil, or debris.
•
Disconnect battery ground cable (-) before making adjustments on
electrical systems or welding on machine.
PREPARE FOR EMERGENCIES
•
•
•
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.
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Safety Precautions
2. HEALTH & SAFETY
Starting fluid (ether) is highly flammable. Do not use or an explosion
or fire may result.
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.
PREVENT BYPASS STARTING
•
•
Avoid possible injury or death from engine runaway.
Do not start engine by shorting across starter terminal. Engine will
start with drive system engaged if normal circuitry is bypassed.
Start engine only from operator’s seat with seat belt on and
forward/reverse in neutral.
•
DISPOSE OF WASTE PROPERLY
•
Improperly disposing of waste can threaten the environment and
ecology. Potentially harmful waste used with John Deere equipment
includes such items as oil, fuel, coolant, brake fluid, filters, and
batteries.
•
Use leakproof containers when draining fluids. Do not use food or
beverage containers that may mislead someone into drinking from
them.
•
•
Do not pour waste onto the ground, down a drain, or into any water
source.
Air conditioning refrigerants escaping into the air can damage the
Earth’s atmosphere. Government regulations may require a certified
air conditioning service center to recover and recycle used air
conditioning refrigerants.
•
Inquire on the proper way to recycle or dispose of waste from your
local environmental or recycling center.
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3. OPERATION
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3. OPERATION
3.1 INTRODUCTION AND OPERATING PRINCIPLE
This roller is ergonomically engineered to optimize operator interface with the total machine – it’s really “user
friendly”. Besides good visibility to the roll-edge, as well as the work surface, you’ll find that the controls are
exactly in the right places for maximum comfort. And it is very convenient to monitor all the consumables – fuel,
hydraulic oil, etc.
Our common sense approach to servicing is a valuable benefit. Thanks to our modular design, everything that
needs servicing is located behind one of the easy-access service panels or is under the rear cowl.
For maneuverability and productivity, nothing beats the proven performance of center-point articulation. Because
the drum and tires track each other exactly, tight turns are achieved smoothly. The roller is equipped with full
positive traction, front to rear and side to side, which keeps the roller moving through various conditions.
There’s power steering – a feature no operator wants to be without. A variable hydrostatic drive system provides
infinitely variable speed control – from 0 to 4 mph. The eccentric delivers a centrifugal force sufficient to
compact all types of soil. Superior vibration isolation to the operator is achieved by mounting heavy-duty shock
mounts between the eccentric and support frames.
The following instructions were compiled to provide you information on how to obtain long and trouble-free use
of the roller. Periodic maintenance of the roller is essential. Read this manual in its entirety and follow the
instructions carefully. Failure to do so may cause injury to you or a bystander.
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3. OPERATION
3.2 DIESEL FUEL
3.3 ENGINE BREAK-IN
Do not mix oil with fuel. The engine has a separate oil
reservoir in the crankcase. Diesel fuel blend meeting
ASTM D915 or EN590 and a premium diesel fuel
conditioner is recommended.
IMPORTANT – Read Engine Manual for break-in
requirements. 1st 100 hours John Deere break-in oil
only (TY 22041). Do not add oil until level is in the
add area on the dipstick. Do not fill above the
crosshatched area on the dipstick. 1st 100 hours run
engine at full throttle. Operate engine at heavy
loads, do not idle longer than 5 minutes. Check oil
WARNING
FUEL IS BOTH TOXIC AND FLAMMABLE. DO frequently, do not exceed 100 hours with break-in
NOT SMOKE WHILE WORKING WITH FUEL. oil.
DO NOT USE NEAR OPEN FLAME. ALWAYS
STOPENGINE BEFORE REFUELING. CLEAN UP
SPILLED FUEL BEFORE STARTING. AVOID
3.4 ENGINE OILAND FILTER
FIRES BY KEEPING ENGINE CLEAN OF Change oil and filter at 100 hours, then every 250
ACCUMULATED GREASE AND DEBRIS.
hours. Use SAE 15W-40 API CG-4 or API CF-4. Refer
to Engine Manual for additional oil types and
START, STORE, AND REFUEL ON LEVEL recommendations. Do not mix different brands or
GROUND TO PREVENT PERSONALINJURY. DO types of oil. Mixing oils can degrade lubrication
NOT RUN UNIT IN AN ENCLOSED, NON- performance.
VENTILATED AREA. AVOID PROLONGED
BREATHING OF VAPORS AND SKIN CONTACT.
SERIOUS ILLNESS OR LOSS OF LIFE COULD
RESULT.
3.5 WARNING LIGHT
Unit is equipped with a warning light for low pressure
and/or hot engine temperature.
KEEP THE VENT HOLE IN FUEL TANK CAP Specifications:
OPEN. IFVENT HOLE IS PLUGGED, PRESSURE
MAY BUILD UP IN TANK, CAUSING
DANGEROUS SPRAYINGOF FUELWHEN TANK
CAP IS REMOVED. A VACUUM MAY ALSO BE
CREATED DURING OPERATION, WHICH
COULD STOP FUEL FLOW. DIESEL FUEL IS
MANDATORY FOR USE IN THIS ENGINE.
ALWAYS USE CLEAN FUEL. LOW QUALITY OR
CONTAMINATED FUEL WILL DAMAGE FUEL
INJECTION COMPONENTS.
•
Oil pressure at full speed: 40 – 50 psi
(2.75 – 3.45 bar)
Coolant temperature range: 180° - 202°F
(82° - 94°C)
•
3.6 HYDRAULIC OIL, FILTER, BREATHER
WARNING
PRESSURIZED RELEASE OF FLUIDS FROM
HYDRAULIC SYSTEM CAN CAUSE SERIOUS
BURNS. SHUT OFF ENGINE. ONLY REMOVE
BREATHER CAP WHEN COOL ENOUGH TO
TOUCH WITH BARE HANDS. SLOWLYLOOSEN
CAP TO FIRST STOP TO RELIEVE PRESSURE
BEFORE REMOVING COMPLETELY.
DIESEL FUEL STORED IN GALVANIZED
CONTAINERS REACTS CHEMICALLY WITH
THE ZINC COATINGON THE CONTAINER. THE
CHEMICAL REACTION CREATES POWDERY
FLAKES OF ZINC SULFIDE. IF WATER IS
PRESENT IN THE FUEL, A ZINC HYDROXIDE
GEL WILL FORM.
Check the hydraulic oil level. Use the sight gauge
located on the hydraulic tank. A 1/4 – 1/2” air bubble
will be seen at the top of the gauge showing the fluid
level.
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3. OPERATION
For satisfactory operation, the following oil
conditions apply:
replace the water pump seal. Contact your engine
distributor or servicing dealer for repairs.
1. Accurate level readings can be checked
only when the fluid is cold.
3.8 VISUAL INSPECTION
2. If the natural color of the fluid has become black
or milky, it is possible that an overheating or
water contaminant problem exists.
3. Do not mix hydraulic fluids. Mobil 424 is
recommended for the hydraulic system.
Make a thorough inspection of the engine compartment
daily. Look for oil or coolant leaks, worn fan belt,
loose connections and trash build-up. Remove trash
build-up and have repairs made as needed if leaks are
found.
CAUTION: After a new unit has run 5 hours, the
oil filter should be changed. This is to rid the
system of any trapped contamination from the wear-
in of the parts. Refer to Maintenance for hydraulic
filter change.
NOTE:Wipe all fittings, caps, and plugs before
performing any maintenance to reduce the chance of
system contamination.
•
Air intake system hoses and connections for
cracks and loose clamps.
3.7 ENGINE COOLANT
•
•
Fan belt for cracks, breaks, or other damage.
Water pump for coolant leaks.
WARNING
CHECK COOLING SYSTEM CAREFULLY.
EXPLOSIVE RELEASE OF FLUIDS FROM
PRESSURIZED COOLING SYSTEM CAN
CAUSE SERIOUS BURNS.
3.9 AIR CLEANER
IMPORTANT: The air intake system must not leak.
Any leak, no matter how small, may result in engine
failure due to abrasive dirt and dust entering the
intake system.
To check coolant level:
1. Shut off engine, allow to cool.
2. Only remove filler cap when cool enough to
touch with bare hands. Slowly loosen cap to
first stop to relieve pressure before removing
completely.
3. Remove cap, coolant level should just touch the
bottom of radiator filler neck. If coolant is
required, see “Adding Coolant” in the
Maintenance section of this manual.
1. Inspect all intake hoses (piping) for cracks.
2. Check clamps on piping which connect the air
cleaner and engine.
3. Squeeze dust unloader valve (A) on air cleaner
assembly to remove dust deposits. If clogged,
remove and clean the dust unloader valve. Replace
if damaged.
IMPORTANT: Do not operate engine without the
dust unloader valve.
IMPORTANT: Do not overfill radiator. Refer to
“Coolant Maintenance” if additional coolant is
required. Never pour cold liquid into a hot
engine, as it may crack cylinder head or block.
DO NOT operate engine without coolant for even
a few minutes. If coolant leaks or abnormal
temperature is detected, contact a service
technician immediately.
NOTE:It is normal for a small amount of leakage to
occur as the engine cools down and parts contract.
Excessive coolant leakage may indicate the need to
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3. OPERATION
3.12 TO STOP
WARNING
BEFORE STARTING ENGINE IN A CONFINED
BUILDING, INSTALL PROPER OUTLET
EXHAUST VENTILATION EQUIPMENT. ALWAYS
WARNING
FOLLOWING
OBEY
THE
ALWAYS USE SAFETY APPROVED FUEL PROCEDURES BEFORE DISMOUNTING FROM
STORAGE AND PIPING. NEVER RUN THE THE ROLLER.
ROLLER WITHOUT THE PANELS IN PLACE OR
SEVERE PERSONAL INJURY MAY OCCUR.
1. Place the forward/reverse lever in the NEUTRAL
position.
3.10 BEFORE STARTING
2. Throttle engine down to its slowest speed.
3. Turn key switch to OFF position to stop the
engine. Remove ignition key.
1. Check for proper fluid levels, engine oil,
coolant, fuel, and hydraulic oil.
2. Check the air cleaner.
3. Check throttle, levers, and controls for smooth
operation.
NOTE:Before stopping an engine that has been
operating at working load, idle engine at
least 2 minutes.
4. Check seat belt, horn, and back-up alarm
operation.
3.13 IDLING ENGINE
3.11 TO START
IMPORTANT: Avoid excessive engine idling.
Prolonged idling may cause the engine coolant
temperature to fall below its normal range. This, in
turn, causes crankcase oil dilution, due to
incomplete fuel combustion, and permits formation
of gummy deposits on valve, pistons, and piston
rings. It also promotes rapid accumulation of
engine sludge and unburned fuel in the exhaust
system.
1. Operator must always be seated and seat belt
must be worn.
2. Forward/reverse must be in NEUTRAL position
and eccentric switch should be in OFF position.
3. Throttle should be set at idle.
4. Turn key clockwise until the engine cranks over.
Release the key when the engine starts.
DO NOT crank engine for more than 20
seconds at a time.
3.14 WARMING ENGINE
5. Check all gauges for normal engine operation.
If operation is not normal, stop the engine and
determine the cause.
IMPORTANT: To assure proper lubrication,
operate engine at idle with no load for 5 minutes.
Extend this period when operating at temperatures
NOTE:If temperature is below 0° C (32° F), it may be below freezing.
necessary to use cold weather starting aid. See “Cold
Weather Starting” later in this section.
1. Check oil pressure gauge as soon as engine
starts. If gauge needle does not rise above
minimum oil pressure specification of
(1.05 bar) (15.0 psi) within 5 seconds, stop the
engine and determine the cause. Normal
engine oil pressure is (3.45 bar + 1.03 bar)
(50 + 15 psi) at rated full load speed
WARNING
DO NOT USE STARTING FLUID (ETHER).
ENGINE IS EQUIPPED WITH INTAKE HEATER.
AN EXPLOSION OR FIRE MAY RESULT. REFER
TO
COLD
WEATHER
STARTING
(1800 – 2500 rpm) with oil at normal operating
temperature of 105° C (221° F).
INSTRUCTIONS.
2. Watch coolant temperature gauge. Do not
place engine under full load until it is properly
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3. OPERATION
warmed up. The normal engine coolant
temperature range is 82° - 94° C (180° - 202° F).
WARNING
NEVER OPERATE ON SLOPES GREATER THAN
15 DEGREES OR TIPPING MAY OCCUR.
NOTE:It is good practice to operate the engine under
a lighter load and at lower speeds than normal for the
first few minutes after start-up.
3.18 FORWARD/REVERSE/NEUTRAL
3.15 PARKING BRAKE
The forward/reverse lever should be aligned with
“NEUTRAL” on the console when the roller is moving
neither forward nor backward with the engine running.
WARNING
BLOCK THE DRUMS TO PREVENT ROLLING
OF THE MACHINE OR SEVERE PERSONAL
INJURY MAY OCCUR. NEVER PARK ROLLER
ON A HILL.
The neutral interlock switch should not allow the
engine to start unless the forward reverse lever is in
neutral.
3.19 THROTTLE
When engine is not running, the brake is applied.
When the engine is running and the forward/reverse
lever is in NEUTRAL, the brake will apply within 2
seconds.
Pull throttle out to increase engine speed. Push throttle
to reduce engine speed. For best performance, run
engine at full throttle.
3.16 BRAKE LIGHT
3.20 GAUGES
When the key is turned to ON, the brake light should
come on within 2 seconds. Shifting into forward or
reverse, the light should go out.
IMPORTANT: Any time an electric gauge or meter
does not register correctly, replace it with a new
one. Do not attempt to repair it.
3.17 TO OPERATE
Oil Pressure Gauge –Indicates engine oil pressure.
IMPORTANT: Follow Manufacturer’s "Before
Starting" and "Break-in" procedures on engine.
Always allow engine to warm up five minutes
before applying load.
Coolant Temperature Gauge – Indicates the
engine coolant temperature.
Volt Meter – Indicates charging current within
electrical system.
Start and apply full throttle. Move forward/reverse
lever slowly forward to gain speed desired. The same
procedure is for reverse. To slow down, move
forward/reverse lever toward NEUTRAL.
Hour Meter – Indicates the operating hours of the
engine while key switch is in the ON position. The
hour meter should be used as a guide for scheduling
maintenance.
To gain power or speed by moving forward/reverse
lever slightly off of NEUTRAL will produce the
greatest amount of torque. Moving the lever all the
way forward or reverse will give the greatest amount
of speed.
WARNING
AVOID LEAVING THE KEY ON WHEN
MACHINE IS NOT RUNNING. THIS WILL
HAVE AN EFFECT ON THE HOUR METER
READINGS.
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3. OPERATION
3.21 PANEL FUSE 20 AMP
3.24 HORN AND BACK-UPALARM
Protects electrical system.
Check operation daily. It is the driver’s responsibility
to operate equipment safely.
WARNING
3.25 ROPS / FOPS / SEAT BELT
NEVER USE FUSE WITH A DIFFERENT RATING
FROM THAT SPECIFIED. SERIOUS DAMAGE Inspect daily. Certified factory installed for operator
TO THE ELECTRICALSYSTEM ORAFIRE MAY protection. Do not remove or modify.
RESULT.
WARNING
3.22 COLD WEATHER STARTING / INTAKE
HEATER BUTTON
DANGER: AVOID CRUSHING. DO NOT JUMP
IF MACHINE TIPS. ALWAYS WEAR SEAT
BELT.
WARNING
DO NOT USE STARTING FLUID (ETHER). DO NOT OPERATE THIS MACHINE IF THE
ENGINE IS EQUIPPED WITH AIR INTAKE ROLLOVER PROTECTIVE STRUCTURE
HEATER. AN EXPLOSION OF FIRE MAY (ROPS) IS STRUCTURALLY DAMAGED,
RESULT. FOR COLD WEATHER STARTING, SEE SHOWS CRACKS, IS NOT PROPERLY
INSTRUCTIONS BELOW.
SECURED AS ORIGINALLY INSTALLED, OR
HAS BEEN ROLLED. DO NOT REPAIR,
MODIFY, OR ADD ATTACHMENTS TO ROPS
UNLESS AUTHORIZED IN WRITING BY THE
MANUFACTURER.
1. Turn the key to the ON position (do not crank
engine).
2. Press INTAKE HEATER BUTTON for
approximately 30 seconds. Start engine using
starter switch. As soon as the engine starts, release DO NOT ADD ATTACHMENTS TO THE
button.
MACHINE THAT INTRUDE INTO OPERATOR’S
PROTECTIVE AREA, REDUCE VISIBILITY,
RESTRICT EMERGENCY EXITS, OR ADD
WEIGHT EXCEEDING CERTIFICATION
WEIGHT OF ROPS. DO NOT OPERATE
MACHINE UNLESS SEAT BELT CONFORMING
TO SAE AND/OR ASAE STANDARDS IS
FASTENED. SEE OPERATOR’S MANUAL OR
CONTACT YOUR DEALER FOR COMPLETE
INSPECTION REQUIREMENTS AND
3. Never operate the starter for more than 20
seconds at a time. If engine does not start,
release the starter switch and wait at least one
minute before trying again.
4. Do not adjust the throttle setting. Allow the
engine to idle for 5 minutes to warm up. At
temperatures below freezing, extend warm up
time.
3.23 BLADE LEVER (OPTIONAL)
MAINTENANCE INSTRUCTIONS.
Controls the leveling blade height for pre-leveling
loose soil.
3.26 TIRES/LUG NUTS
WARNING
IMPORTANT: Do not use the blade to dig or
bulldoze or machine damage may occur.
DO NOT EXCEED RATED PRESSURE 35 PSI.
Clean and check daily:
1. Tires are properly inflated.
2. Lug nuts are in place and tight
190 ft. lbs. (140 Nm).
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3. OPERATION
3.27 DRUM/SCRAPPERS
WARNING
Clean and inspect daily to prevent excess mud and
debris from building up. Replace if missing or worn.
Pad drum scrappers are adjustable, see Maintenance
section.
DO NOT ARTICULATE ON GRADES LARGER
THAN 15”, ROLLER MAY TIP OVER.
DO NOT OPERATE ACROSS THE SIDES OF
HILLS, ROLLER MAY TIP OVER.
DO NOT OPERATE AT THE EDGE OF MATS OR
ROADS, ROLLER MAY TIP OVER.
3.28 CLEANING
DO NOT STAND, ALWAYS WEAR SEAT BELT.
WARNING
3.31 TIE DOWNS
DIRT AND MUD BUILT UP WILL REDUCE
MACHINE PERFORMANCE AND/OR CAUSE
FAILURES.
WARNING
TIE DOWNSARE NOT INTENDED FOR LIFTING
PURPOSES.
Use pressurized water to remove dirt and mud. Clean
and inspect entire machine daily. Use extra care when
cleaning radiator and oil cooler.
Equipment is equipped with front and rear tie down
rings for shipping purposes. Use only these tie downs
to secure unit.
When cleaning machine, caution should be used
around regulator area. Direct spraying of the
regulator is not good. (Regulator should be covered
or protected if direct spraying will happen).
Excessive water pressure may also loosen wire
connections or start terminals corroding. After
cleaning, all terminals should be dried if wet and
connections checked for proper seating.
3.32 TOWING (BYPASS)
WARNING
NEVER PUSH OR PULLTHE ROLLER WITH THE
ENGINE OFF. WHEN ENGINE IS NOT RUNNING,
THE BRAKE IS APPLIED. WHEN THE ENGINE
IS RUNNING AND THE FORWARD/REVERSE
LEVER IS IN NEUTRAL, THE BRAKE WILL
APPLY WITHIN 2 SECONDS.
3.29 ECCENTRICS
When vibratory compaction is necessary, engage
eccentrics by pushing the vibration switch to the ON
position. For best performance run engine at full
rpm. The eccentrics should be turned off whenever
the roller is stopped or stopped to change direction.
Do not run the eccentric on any non-yielding surface
such as concrete or aged asphalt.
In an emergency or during a breakdown, it may be
necessary or desirable to tow the roller. This may be
accomplished by mechanically releasing the brake and
bypassing the transmission pump. If these procedures
are followed carefully, the roller may be moved short
distances at LOW speed without running the engine.
3.30 COMPACTION TIPS
The brake is located in the front wheel motor, which
drives the drum of the roller. There is an access hole in
the front frame to assist in releasing the brake. Refer to
the Drum Assembly #39 22770 Kit Bypass to identify
these parts. The threaded hole in the center of the
wheel motor requires a M12 bolt long enough to extend
beyond the frame when fully engaged. A bolt, washer,
and nut is included in a separate package for this
Avoid sharp turns, steer gradually. If articulation is a
new concept, we suggest the operator take 20 minutes
or so to get used to the feel of the unit.
Recommended compaction speed should be at
3 m.p.h. or less to achieve a uniform compaction.
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3. OPERATION
purpose. Fully install the nut and washer on the bolt.
Insert this assembly through the hole in the frame such
that the washer is over the hole with the nut against the
outside of this washer. Thread the bolt, finger tight
into the wheel motor to the bottom of the hole. Now
tighten the nut against the washer until the brake is
compressed and released. This should require about 44
ft. lbs. torque. Do not torque the bolt. Be careful not
to over-torque beyond releasing the brake.
The bypass valve is located on the transmission pump.
The seat and battery plate should be removed for
access to the transmission pump. The bypass valve is
controlled by a shaft with cross-drilled holes and
maybe a slot in the end. This shaft may be turned
manually to open the valve and allow the motor to turn.
The valve is fully open with two revolutions of the
shaft. DO NOT OPEN VALVE PAST TWO TURNS.
The valve must be fully closed for normal operation.
The torque required to close the valve is only 7 to 10 ft.
lbs.
DAMAGE MAY RESULT FROM OVER-
TORQUING.
3.33 STORAGE
IMPORTANT: The front wheel motor has a rubber
plug in the M12 hole to prevent contamination.
Reinstall the rubber plug after towing
1. Store the roller on level ground with drums
blocked and parking brake on.
2. Remove the key. Operations of roller by
untrained persons could result in personal injury.
3. During extended storage, drums can be coated with
any type of oil or grease to prevent rusting.
4. Storage instructions for the engine are stated in the
Engine Manual and should be carried out.
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4. MAINTENANCE
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4.1 IMPORTANT
F
The person attempting any of the
following maintenance tasks must be
authorized to do so and have read
and understood all sections within
this manual.
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4. MAINTENANCE
4.2 MAINTENANCE SCHEDULE CHART
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4. MAINTENANCE
4.3 IMPORTANT MAINTENANCE
INFORMATION
packing contacts filter housing. DO NOT
overtighten filter element.
7. Install oil pan drain plug.
8. Fill engine crankcase with correct engine oil
through timing gear cover opening of rocker arm
cover opening.
WARNING
REMOVE THE KEY AND / OR DISCONNECT
BATTERY TO AVOID ACCIDENTAL
IGNITION OF ENGINE. SEVERE PERSONAL
INJURY MAY OCCUR. ROLLER MUST BE
PARKED ON LEVEL GROUND WITH
PARKING BRAKE APPLIED, ENGINE OFF,
AND DRUM BLOCKED. NEVER WORK ON
THE ROLLER WITH ENGINE RUNNING.
SEVERE PERSONAL INJURY MAY OCCUR.
ALLOW ALL COMPONENTS IN THE
ENGINE COMPARTMENT TO COOL
BEFORE PERFORMING ANY SERVICE
WORK.
IMPORTANT: Immediately after completing any
oil change, crank engine for 30 seconds without
permitting engine to start. This will help insure
adequate lubrication to engine components
before engine starts.
9. Start engine and run to check for possible leaks.
10. Stop engine and check oil level after 10
minutes. Oil level reading should be between
arrows or within crosshatch of dipstick.
4.5 ADDITIONAL SERVICE INFORMATION
IMPORTANT: Read John Deere Emission
Warranty Statement and Engine Manual before
service or maintenance.
This is not a detailed service manual. If you want more
detailed service information see John Deere Manuals:
55319 Manual Engine
4.4 ENGINE OILAND FILTER
55320 Manual Parts
55321 Manual Technical
IMPORTANT: Read Engine Manual and Engine
Break-in covered in Operating section of this
manual.
4.6 HYDRAULIC OIL/FILTER
WARNING
Change oil and filter at 100 hours, then every 250
hours. Use SAE 15W-40 API CG-4 or API CF-4.
1. Run engine approximately 5 minutes to warm up
oil. Shut engine off.
PRESSURIZED RELEASE OF FLUIDS FROM
HYDRAULIC SYSTEM CAN CAUSE SERIOUS
BURNS.
2. Remove oil pan drain plug, drain into suitable
container.
3. Drain crankcase oil from engine while warm.
4. Remove and discard oil filter using a filter
wrench.
SHUT OFFENGINE. ONLYREMOVE BREATHER
CAP WHEN COOL ENOUGH TO TOUCH WITH
BARE HANDS. SLOWLYLOOSEN CAPTO FIRST
STOP TO RELIEVE PRESSURE BEFORE
REMOVING COMPLETELY.
5. Clean filter mounting pad.
ESCAPING HYDRAULIC FLUID UNDER
PRESSURE CAN HAVE SUFFICIENT FORCE TO
PENETRATE THE SKIN, CAUSING SERIOUS
PERSONAL INJURY. HYDRAULIC FLUID
ESCAPING UNDER PRESSURE FROM A VERY
SMALLHOLE CAN BEALMOST INVISIBLE. USE
A PIECE OF CARDBOARD OR WOOD TO
SEARCH FOR POSSIBLE LEAKS. NEVER USE
YOUR HANDS TO DETECT PRESSURE LEAKS.
IMPORTANT: Filtration of oils is critical to
proper lubrication. Always change filter
regularly. Use filter meeting John Deere
performance specifications.
6. Oil new filter seal and install new filter element,
tighten approximately 3/4 – 1 - 1/4 turn after
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4. MAINTENANCE
HYDRAULIC TANK TEMPERATURE CAN Change hydraulic oil every 800 hours. Use Mobil 424.
REACH 180 DEGREES F MAXIMUM.
1. Run engine approximately 5 minutes to warm up
Refer to Operating section of this manual for hydraulic
oil conditions and recommendations.
oil. Shut engine off.
2. Remove breather cap and oil drain plug, drain
into suitable container.
Before disconnecting any hydraulic components, be
sure engine is shut off and relieve all pressure. Before
3. Apply thread sealant to breather cap and drain
plug, install drain plug.
applying pressure to system, be sure all connections are 4. Fill hydraulic tank with correct hydraulic oil
tight and lines, fittings, and hoses are not damaged.
(approximately 20 gallons). Use the sight gauge to
watch for proper oil level, install breather cap.
IMPORTANT: When hoses, oil filter, and/or
hydraulic components are changed, start the engine IMPORTANT: Immediately after completing oil
and purge the air from the system prior to checking change, crank engine for 30 seconds without
the oil level. To do this, idle the engine for three
minutes with control lever in NEUTRAL position.
permitting engine to start. This will help insure
adequate lubrication to components before engine
Slowly engage forward to reverse. This allows fluid starts.
to replace air introduced with filter change. If this
procedure is not followed, partial or complete
failure of the pump may result.
5. Start engine and run to check for possible leaks.
6. Stop engine and replenish hydraulic oil.
4.7 HYDRAULIC BREATHER
Change hydraulic oil filter at 5 hours then every 100
hours.
1. Remove and discard hydraulic oil filter using a
filter wrench.
Replace every 800 hours or yearly. P/N 35483.
2. Oil new filter seal and install new filter element,
tighten approximately 3/4 – 1 - 1/4 turn after
packing contacts filter housing. DO NOT
overtighten filter element.
WARNING
PRESSURIZED RELEASE OF FLUIDS FROM
HYDRAULIC SYSTEM CAN CAUSE SERIOUS
BURNS. SHUT OFF ENGINE. ONLY REMOVE
IMPORTANT: Immediately after completing filter BREATHER CAP WHEN COOL ENOUGH TO
change, crank engine for 30 seconds without
permitting engine to start. This will help insure
adequate lubrication to components before engine
starts.
TOUCH WITH BARE HANDS. SLOWLYLOOSEN
CAP TO FIRST STOP TO RELIEVE PRESSURE
BEFORE REMOVING COMPLETELY.
4.8 ENGINE COOLING SYSTEM
3. Start engine and run to check for possible leaks.
4. Stop engine and replenish hydraulic oil.
WARNING
EXPLOSIVE RELEASE OF FLUIDS FROM
PRESSURIZED COOLING SYSTEM CAN
CAUSE SERIOUS BURNS. SHUT OFF ENGINE.
ONLY REMOVE FILLER CAP WHEN COOL
ENOUGH TO TOUCH WITH BARE HANDS.
SLOWLY LOOSEN CAP TO FIRST STOP TO
RELIEVE PRESSURE BEFORE REMOVING
COMPLETELY.
WARNING
NEVER OVERFILL THE HYDRAULIC TANK.
USE THE SIGHT GAUGE LOCATED ON THE
HYDRAULIC TANK. A 1/4 – 1/2” AIR BUBBLE
WILL BE SEEN AT THE TOP OF THE GAUGE
SHOWING THE FLUID LEVEL.
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WARNING
4. MAINTENANCE
To check coolant level, refer to Operating section of
this manual and Engine Manual.
ALWAYS maintain coolant at correct level and
concentration. DO NOT operate engine without
coolant for even a few minutes.
Inspect cooling system every 600 hours or 12 months.
1. Check entire cooling system hoses. Replace
hoses when hard, flimsy, or cracked.
2. Thoroughly inspect all cooling system hoses.
Replace hoses when hard, flimsy, or cracked.
If frequent coolant makeup is required, the glycol
concentration should be checked with JT05460
Refractometer to assure that the desired freeze point is
maintained. Follow manufacturer’s instructions
provided with Refractometer.
IMPORTANT: Air must be expelled from cooling
system when system is refilled. Loosen
Water may be used as coolant in emergency situations
temperature-sending unit fitting at rear of cylinder
head to allow air to escape when filling system.
Retighten fitting when all the air has been expelled.
only.
Foaming, hot surface aluminum and iron corrosion,
scaling, and cavitation will occur when water is used as
the coolant, even when coolant conditioners are added.
3. Test the coolant solution at 600 hours or 12 month
intervals and whenever excessive coolant is lost
through leaks or overheating to ensure the
necessary protection. Coolant test strips are
available from your John Deere dealer. These test
strips provide a simple, effective method to check
the freeze point and additive levels of your engine
coolant.
Drain cooling system and refill with recommended
glycol base engine coolant as soon as possible.
4.8.1 Replacing Engine Coolant
Every 1200 hours or 24 months, the coolant should be
replaced. The coolant system should also be flushed
and pressure tested. Refer to Engine Manual.
4. After 600 hours or 12 months of engine operating
time, recharge your engine coolant with the
recommended amount (see label on container) of
TY16004 or TY16005 Liquid Coolant Conditioner. 4.8.2 Adding Coolant
NOTE: TY16004 or TY16005 Liquid Coolant
Conditioner is a non-chromate inhibitor and should be
used only with low silicate, ethylene-glycol base
antifreeze. It does not protect the cooling system from
freezing. See "Adding Coolant."
CAUTION: Explosive release of fluids from
pressurized cooling system can cause serious burns.
Shut off engine. Only remove filler cap when cool
enough to touch with bare hands. Slowly loosen cap to
first stop to relieve pressure before removing
completely.
Usually recharging your engine coolant with the
recommended amount of TY16004 or TY16005 Liquid IMPORTANT: Never pour cold liquid into a hot
Coolant Conditioner at 600 hours or 12 months of
operation is adequate. However, with a CoolScan
analysis report you will be given a more thorough
evaluation of your engine coolant condition along with
detailed service recommendations. Refer to Engine
Manual.
engine, as it may crack cylinder head or block. DO
NOT operate engine without coolant for even a few
minutes.
Air must be expelled from cooling system when
coolant is added.
IMPORTANT: Do not add supplemental coolant
additives when the cooling system is drained and
refilled with John Deere ANTIFREEZE/SUMMER
COOLANT or John Deere COOL –GARD.
1. Loosen temperature sending unit fitting at rear
of cylinder head to allow air to escape when
filling system.
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4. MAINTENANCE
IMPORTANT: When adding coolant to the system,
use the appropriate coolant solution. Coolant 50/50 1. Remove air cleaner cover.
mixture of antifreeze/distilled water meeting ASTM 2. Remove primary (outer) element only.
4985, ASTM D5345 (pre-diluted coolant) or John
Deere COOL-GARD. 50/50 mixture provides
protection to -34° F (-37° C). Do not overfill cooling
system. A pressurized system needs space for heat
expansion without overflowing at top of radiator.
3. Thoroughly clean all dirt from inside filter housing.
4. Air cleaner has rubber dust unloader valve on the
air cleaner. Squeeze valve tip to release any
trapped dirt particles.
5. Inspect filter to determine if it is practical to clean
or for damage after cleaning filter.
a. Hold a bright light inside element and
check carefully for holes. Discard
any element that shows the smallest hole
or rupture.
2. Fill until coolant level touches bottom of
radiator filler neck.
3. Tighten fitting when air has been expelled from
system.
b. Be sure outer screen is not dented.
Vibration would quickly wear a hole in
filter.
4.8.3 Disposing of Coolant
Improperly disposing of engine coolant can threaten
the environment and ecology.
c. Be sure filter gasket is in good condition.
If gasket is damaged or missing, replace
element.
Use leakproof containers when draining fluids. Do not 6. Gently pat sides of element with palm of hand to
use food or beverage containers that may mislead
someone into drinking from them.
loosen dirt. DO NOT tap element against a
hard surface.
Do not pour waste onto the ground, down a drain, or
into any water source.
WARNING
ONLYASPECIALAIR CLEANINGGUN SHOULD
BE USED. CONCENTRATED AIR PRESSURE
FROM AN ORDINARY AIR NOZZLE MAY
SEVERELY DAMAGE FILTER ELEMENT. DO
NOT EXCEED 30 psi (2.1 bar) WHEN CLEANING
FILTER ELEMENT.
Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center or from your dealer.
4.9 AIR CLEANER
4.9.1 Air Cleaner Service
7. Insert the cleaning gun into element, hold air
nozzle about 1" (25.4) mm from perforated metal
retainer. Force air through filter from inside to
outside and move air gun up and down pleats to
remove as much dirt as possible.
IMPORTANT: Do not operate engine without the
dust unloader valve.
For daily inspection refer to the Operating section of
this manual.
8. Repeat steps 6 and 7 to remove additional dirt.
9. Inspect element for damage after cleaning.
Replace element if any damage is found.
Clean the primary (outer) filter element every 100
hours.
Service air cleaner more frequently in dusty conditions.
IMPORTANT: Always replace secondary safety
(inner) filter elements. DO NOT attempt to clean
4.9.2 Air Cleaner Replacement
them. Do not blow air from outside portion of filter Replace primary (outer) element every 600 hours.
with air nozzle. Wear safety glasses and remove
bystanders.
1. Remove air cleaner cover.
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4. MAINTENANCE
2. Remove primary (outer) element only.
After draining water from the fuel filter, the filter must
3. Thoroughly clean all dirt from inside filter housing. be primed by bleeding all air from the fuel system.
4. Air cleaner has a rubber dust unloader valve on the
air cleaner. Squeeze valve tip to release any
trapped dirt particle.
4. Operate primer lever of the fuel supply pump until
fuel flow is free from air bubbles.
5. Tighten bleed plug securely by hand or using a
coin, continue operating hand primer until pumping
action is not felt. Push hand primer inward (toward
engine) as far as it will go.
IMPORTANT: Remove secondary safety (inner)
element ONLY for replacement. DO NOT attempt
to clean, wash, or reuse secondary element.
Replacement of secondary element is usually
necessary ONLY when primary element has a hole
in it.
If the fuel system needs further bleeding of air, see
Bleeding Fuel System in Maintenance section of this
manual.
5. To replace secondary element, remove retaining
nut and secondary element. Immediately replace
secondary element with new element to prevent
dust from entering air intake system.
6. Install new primary element and tighten wing nut
securely. Install cover assembly and tighten
retaining wing nut securely.
4.10.2 Fuel Filter Replacement
WARNING
ESCAPING FLUID UNDER PRESSURE CAN
PENETRATE THE SKIN CAUSING SERIOUS
INJURY.
RELIEVE PRESSURE BEFORE
4.9.3 Element Storage
DISCONNECTING FUEL OR OTHER LINES.
TIGHTEN ALL CONNECTIONS BEFORE
APPLYINGPRESSURE. KEEPHANDSAND BODY
AWAY FROM PINHOLES AND NOZZLES THAT
EJECT FLUIDS UNDER HIGH PRESSURE. USE
A PIECE OF CARDBOARD OR PAPER TO
SEARCH FOR LEAKS. DO NOT USE YOUR
HAND.
Seal element in a plastic bag and store in shipping
container to protect against dust and damage.
NOTE: Air cleaner element MUST BE DRY before
storing in plastic bag.
4.10 FUEL FILTER
IF ANY FLUID IS INJECTED INTO THE SKIN, A
DOCTOR FAMILIAR WITH THIS TYPE INJURY
MUST SURGICALLY REMOVE IT WITHIN A
FEW HOURS OR GANGRENE MAY RESULT.
DOCTORS UNFAMILIAR WITH THIS TYPE OF
INJURY MAY CALL THE DEERE & COMPANY
MEDICALDEPARTMENT IN MOLINE, ILLINOIS,
OR OTHER KNOWLEDGEABLE MEDICAL
SOURCE.
4.10.1 Water Separator
Fuel filter is equipped with a water drain plug, check/
drain every 50 hours or 2 weeks.
NOTE: Drain water into a suitable container and
dispose of properly.
1. Loosen drain plug at bottom of fuel filter two or
three turns.
Replace fuel filter every 600 hours or 12 months.
2. Loosen air bleed plug two full turns on fuel filter
base and drain water from bottom until fuel starts
to drain out.
1. Thoroughly clean fuel filter assembly and
surrounding area.
3. When fuel starts to drain out, tighten drain plug
securely by hand or using a coin.
2. Loosen drain plug and drain fuel into a suitable
container.
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4. MAINTENANCE
NOTE: Lifting up on retaining ring as it is rotated
helps to get it past raised locators.
A PIECE OF CARDBOARD OR PAPER TO
SEARCH FOR LEAKS. DO NOT USE YOUR
HAND.
3. Firmly grasp the retaining ring and rotate it
counterclockwise 1/4 turn. Remove ring with
filter element.
IF ANY FLUID IS INJECTED INTO THE SKIN, A
DOCTOR FAMILIAR WITH THIS TYPE INJURY
4. Inspect filter mounting base for cleanliness. Clean MUST SURGICALLY REMOVE IT WITHIN A
as required.
FEW HOURS OR GANGRENE MAY RESULT.
DOCTORS UNFAMILIAR WITH THIS TYPE OF
INJURY MAY CALL THE DEERE & COMPANY
MEDICALDEPARTMENT IN MOLINE, ILLINOIS,
OR OTHER KNOWLEDGEABLE MEDICAL
SOURCE.
NOTE: Raised locators on fuel filter canister must be
indexed properly with slots in mounting base for
correct installation.
5. Install new filter element onto mounting. Be sure
element is properly indexed and firmly seated on
Whenever the fuel system has been opened up for
base. It may be necessary to rotate filter for correct service (lines disconnected or filters removed), it will
alignment.
be necessary to bleed air from the system.
6. Remove filter element from water separator bowl.
Drain and clean separator bowl. Dry with
compressed air. Install water separator bowl onto
new element. Tighten securely.
7. Align keys on filter element with slots in filter
base.
8. Install retaining ring onto mounting base making
certain dust seal is in place on filter base. Hand
tighten ring (about 1/3 turn) until it “snaps” into
the detent. DO NOT overtighten retaining ring.
1. Loosen the air bleed vent screw on fuel filter head
two full turns by hand on fuel filter base.
2. Operate supply pump primer lever until fuel flow
is free from air bubbles.
3. Tighten bleed plug securely by hand or using a
coin, continue operating hand primer until pumping
action is not felt. Push hand primer inward (toward
engine) as far as it will go.
4. Start engine and check for leaks.
NOTE: The proper installation is indicated when a
“click” is heard and a release of the retaining ring is
felt. A plug is provided with the new element for
plugging the used element.
If engine will not start, it may be necessary to bleed air
from fuel system at fuel injection pump or injection
nozzles as explained next.
4.10.4 Bleeding at Fuel Injection Pump
9. Bleed the fuel system. See Bleeding Fuel System
in Maintenance section of this manual.
1. Slightly loosen fuel supply line connector at
injection pump.
4.10.3 Bleeding Fuel System
2. Operate fuel supply pump primer lever until fuel,
without air bubbles, flows from fuel return line
connection.
WARNING
3. Tighten return line connector to 16 Nm (12 lb-ft.).
ESCAPING FLUID UNDER PRESSURE CAN 4. Leave hand primer in the inward position toward
PENETRATE THE SKIN CAUSING SERIOUS
INJURY. RELIEVE PRESSURE BEFORE
cylinder block.
DISCONNECTING FUEL OR OTHER LINES. 4.10.5 Bleeding at Fuel Injection Nozzles
TIGHTEN ALL CONNECTIONS BEFORE
APPLYINGPRESSURE. KEEPHANDSAND BODY 1. Energize the electronic fuel shut-off solenoid
AWAY FROM PINHOLES AND NOZZLES THAT
EJECT FLUIDS UNDER HIGH PRESSURE. USE
(turn ignition key to ON position).
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4. MAINTENANCE
2. Using two open-end wrenches, loosen fuel line
connection at injection nozzle.
3. Crank engine over with starting motor, (but do
not start engine), until fuel free from air bubbles
flows out of loosened connection. Retighten
connection to 27 Nm (20 lb-ft.).
STANDARD V-BELTS
Tension New Belt
Tension Used* Belt
Single Belt
578-623 N
378-423 N
(130-140 lb. force)
(85-95 lb. force)
4.12 GREASE FITTINGS
4. Repeat procedure for remaining injection nozzles
(if necessary) until all air has been removed from
fuel system.
Use a grease gun to grease below fittings, use lithium
grease. Remove the blue protection cap off fitting
before greasing.
If engine still will not start, see your authorized
servicing dealer or engine distributor.
4.13 FRAME HINGE
Grease daily six fittings with lithium base grease using
a grease gun. There is one fitting on each of the top
and bottom bearings for the vertical pin. There are two
fittings on the horizontal pin.
4.11 FAN/ALTERNATOR BELT
Low belt tension causes slippage resulting in excessive
cover wear, burn spots, overheating, or “slip and grab”
causing belt breakage.
4.14 BLADE PINS
High belt tension causes belt heating and excessive
stretch, as well as damage to drive components such as
pulleys and shafts. V-belts should ride on the sides of
standard pulleys not on the bottom of the groove.
Grease the two fittings daily; one on each of the blade
pivot pins.
4.15 BATTERY
Standard V-belt tension can be checked with JDG529
Tension Gauge (arrow) or equivalent gauge.
4.15.1 Servicing Battery
1. Inspect belts for cracks, fraying, or stretched out
areas. Replace if necessary.
2. Using either JDG529 Tension Gauge or belt
tension tester and straightedge, check tension of
warm belts.
WARNING
BATTERY GAS CAN EXPLODE. KEEP SPARKS
AND FLAMES AWAY FROM BATTERIES. USE A
FLASHLIGHT
TO
CHECK
BATTERY
ELECTROLYTE LEVEL.
–
For standard V-belt, an 89 N (20 lb. force)
applied halfway between pulleys should
deflect belt by 19 mm (3/4 in.).
NEVER CHECK BATTERY CHARGE BY
PLACING A METAL OBJECT ACROSS THE
POSTS. USEAVOLTMETER OR HYDROMETER.
3. If adjustment is necessary, loosen alternator bracket
cap screw and nut on mounting bolt. Pull
alternator frame outward until belts are correctly
tensioned.
ALWAYS REMOVE GROUNDED NEGATIVE (-)
BATTERY CLAMP FIRST AND REPLACE IT
LAST.
IMPORTANT: Do not pry against the alternator rear
frame. Do not tighten or loosen belts while they are
hot.
1. On regular batteries, check electrolyte level. Fill
each cell to bottom of filler neck with distilled
water.
2. Keep batteries clean by wiping them with a damp
cloth. Keep all connections clean and tight.
Remove any corrosion, and wash terminals with a
4. Tighten alternator bracket cap screw and nut
firmly.
5. After a new or used belt has run for 10 minutes
recheck belt tension.
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4. MAINTENANCE
solution of 1 part baking soda and 4 parts water.
Tighten all connections securely.
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
NOTE: Coat battery terminals and connectors with a
mixture of petroleum jelly and baking soda to retard
corrosion.
3. Get medical attention immediately.
3. Keep battery fully charged, especially during cold
weather. If a battery charger is used, turn charger
off before connecting charger to battery(ies).
Attach POSITIVE (+) battery charger lead to
POSITIVE (+) battery post. Then attach
NEGATIVE (-) battery charger lead to a good
ground.
In freezing weather, run engine at lease 30 minutes to
assure thorough mixing after adding water to battery.
If necessary to replace battery(ies), replacements must
meet or exceed the following recommended
capabilities at -18° C (0° F):
12 Volt – Heavy Duty Battery
BCI Group 24 800 CCA
Once a month, check the battery for proper charge of
12.5 volts. Check for proper fluid level. Use distilled
water when adding and run 30 minutes to mix. Clean
battery, posts, and terminals. Disconnect battery cables
before charging to avoid damage to the electrical
system.
4.15.2 Battery Installation
WARNING
ALWAYS CONNECT GROUNDED CABLE LAST.
CLEAN AND SECURELY CONNECT EACH
CABLE END TO BATTERYTERMINALOFSAME
POLARITY. BATTERY SHOULD BE SECURELY
WARNING
SULFURIC ACID IN BATTERY ELECTROLYTE FASTENED WITH PROPERLY INSTALLED
IS POISONOUS. IT IS STRONG ENOUGH TO HOLD-DOWNS.
BURN SKIN, EAT HOLES IN CLOTHING, AND
CAUSE BLINDNESS IF SPLASHED INTO EYES. 4.15.3 Charging / Jumping Battery
Avoid the hazard by:
A 12-volt booster battery can be connected in parallel
with battery(ies) on the unit to aid in cold weather
starting. ALWAYS use heavy-duty jumper cables.
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.
WARNING
GAS GIVEN OFF BY BATTERY IS EXPLOSIVE.
KEEP SPARKS AND FLAMES AWAY FROM
BATTERY.
BEFORE CONNECTING OR
If you spill acid on yourself:
DISCONNECTINGABATTERYCHARGER TURN
CHARGER OFF. MAKE LAST CONNECTION
AND FIRST DISCONNECTIONATAPOINTAWAY
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.
Get medical attention immediately.
FROM BATTERY.
NEGATIVE (-) CABLE LAST AND DISCONNECT
THIS CABLE FIRST.
ALWAYS CONNECT
IMPORTANT: Be sure polarity is correct before
making connections. Reversed polarity will damage
electrical system. Always connect positive to
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4. MAINTENANCE
positive and negative to ground. Always use 12-volt Do not alter injection pumps.
booster battery for 12-volt electrical systems.
TAMPERING with the following engine factory
1. Connect booster battery or batteries to
produce the required system voltage for your
engine application.
settings is ILLEGAL except to reset to published
specifications and reseal by authorized engine
dealer:
-
-
-
-
Engine Timing
Fuel Delivery
Aneroid Settings
Rated Speed
NOTE: To avoid sparks, DO NOT allow the free ends
of jumper cables to touch the engine.
2. Connect one end of jumper cable to the POSITIVE
(+) post of the booster battery.
Deere will reissue emissions dataplates only to replace
3. Connect one end of jumper cable to the POSITIVE damaged plates. Requests must be in writing and
(+) post of the battery connected to starter.
4. Connect one end of the other jumper cable to the
NEGATIVE (-) post of the booster battery.
include name, address, engine model, and serial
number with reason for need.
5. ALWAYS complete the hook-up by making the last Power rating changes WILL NOT be allowed on new
connection of the NEGATIVE (-) cable to a good
ground on the engine frame and away from the
battery(ies).
engines.
4.19 FUEL INJECTORS
6. Start the engine. Disconnect jumper cables
immediately after engine starts. Disconnect
NEGATIVE (-) cable first.
WARNING
ESCAPING FLUID UNDER PRESSURE CAN
PENETRATE THE SKIN CAUSING SERIOUS
INJURY. RELIEVE PRESSURE BEFORE
4.16 ENGINE CRANKCASE VENT TUBE
Remove and clean every 600 hours or 12 months. If
you operate the engine in dusty conditions, clean the
tube at shorter intervals.
DISCONNECTING FUEL OR OTHER LINES.
TIGHTEN ALL CONNECTIONS BEFORE
APPLYINGPRESSURE. KEEPHANDSAND BODY
AWAY FROM PINHOLES AND NOZZLES THAT
EJECT FLUIDS UNDER HIGH PRESSURE. USE
A PIECE OF CARDBOARD OR PAPER TO
1. Remove and clean crankcase vent tube.
2. Install the vent tube. Be sure the O-ring fits
correctly in the rocker arm cover for elbow adapter. SEARCH FOR LEAKS. DO NOT USE YOUR
Tighten hose clamp securely.
HAND.
4.17 ENGINE VALVE CLEARANCE
IF ANY FLUID IS INJECTED INTO THE SKIN, A
DOCTOR FAMILIAR WITH THIS TYPE INJURY
MUST SURGICALLY REMOVE IT WITHIN A
FEW HOURS OR GANGRENE MAY RESULT.
DOCTORS UNFAMILIAR WITH THIS TYPE OF
INJURY MAY CALL THE DEERE & COMPANY
MEDICALDEPARTMENT IN MOLINE, ILLINOIS,
OR OTHER KNOWLEDGEABLE MEDICAL
Check/adjust at 900 hours then every 1200 hours or 24
months. See authorized engine service dealer or refer
to Engine Manual for procedures.
4.18 EMISSION REGULATION/ENGINE RPM
Do not adjust operating speed. Full speed is factory set SOURCE.
at 2500 rpm.
IMPORTANT: Always use John Deere replacement
parts meeting John Deere performance
Do not adjust idle speed above 1400 rpm. Proper idle
rpm is 1200 + 100.
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4. MAINTENANCE
specifications. Only qualified technicians should
attempt fuel injector diagnose.
Fill fuel tank at the end of each day’s operation to
prevent condensation in tank as moist air cools and
freezing during cold weather.
Fuel injection nozzles are usually removed and tested
or replaced when there is a noticeable loss of power or
excessive smoking after break-in period.
Avoid storing fuel over long periods of time. If fuel is
stored for more than a month prior to use or there is a
slow turnover in fuel tank or supply tank, add a fuel
conditioner such as John Deere PREMIUM DIESEL
FUEL CONDITIONER or equivalent to stabilize the
fuel and prevent water condensation. John Deere
PREMIUM DIESEL FUEL CONDITIONER is
available in winter and summer formulas. Fuel
conditioner also reduces fuel gelling and controls wax
separation during cold weather.
For detailed testing and diagnostic information on fuel
system refer to John Deere Technical Manual (P/N
55321).
4.19.1 Test Fuel Injection Nozzles (engine running)
1. Operate engine at intermediate speed and no load.
2. Slowly loosen the fuel pressure line at one of the
nozzles until fuel escapes at the connection (fuel
not opening nozzle valve).
Proper fuel storage is critically important. Use clean
storage and transfer tanks. Periodically drain water and
sediment from bottom of tank. Store fuel in a
convenient place away from buildings.
NOTE: The injection nozzle before and/or after
nozzle being checked could be the faulty
nozzle.
IMPORTANT: DO NOT store diesel fuel in
galvanized containers. Diesel fuel stored in
galvanized containers reacts with zinc coating on
container to form zinc flakes. If fuel contains water,
–
If engine speed changes, the injection
nozzle is probably working satisfactory.
If engine speed does not change, a nozzle
–
is faulty and must be checked and repaired a zinc gel will also form. The gel and flakes will
(or replaced).
quickly plug fuel filters and damage injection
nozzles and injection pump.
3. Repeat test for each remaining nozzle assembly.
4. Remove faulty injection nozzles and see authorized DO NOT use brass-coated containers for fuel
engine dealer or replace with new.
storage. Brass is an alloy of copper and zinc.
4.20 FUEL TANK
4.21 FUEL LINES
Drain and flush the fuel tank every year.
Inspect fuel line condition and clamps. Replace fuel
lines every 2 years.
WARNING
4.22 HYDRAULIC HOSES/CONNECTIONS
HANDLE FUELCAREFULLY. DO NOT FILLTHE
FUEL TANK WHEN ENGINE IS RUNNING.
WARNING
DO NOT SMOKE WHILE FILLING FUEL TANK ESCAPING HYDRAULIC FLUID UNDER
OR SERVICING FUEL SYSTEM.
PRESSURE CAN HAVE SUFFICIENT FORCE TO
PENETRATE THE SKIN, CAUSING SERIOUS
THE FUEL TANK IS VENTED THROUGH THE PERSONAL INJURY.
FILLER CAP. IF A NEW FILLER CAP IS HYDRAULIC FLUID ESCAPING UNDER
REQUIRED, ALWAYS REPLACE IT WITH AN PRESSURE FROM A VERY SMALL HOLE CAN
ORIGINAL VENTED CAP.
BE ALMOST INVISIBLE. USE A PIECE OF
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4. MAINTENANCE
CARDBOARD OR WOOD TO SEARCH FOR
POSSIBLE LEAKS. NEVER USE YOUR HANDS
TO DETECT PRESSURE LEAKS.
4.24 NEUTRAL INTERLOCK
The purpose of the neutral interlock switch is to
IF YOU ARE INJURED BY ESCAPING prevent engine starting when the forward/reverse lever
HYDRAULIC FLUIDS, SEEADOCTORAT ONCE. is not in the neutral position. To check:
SERIOUS INFECTION OR REACTIONS CAN
DEVELOPIFPROPER MEDICALTREATMENT IS 1. Disconnect battery cables from battery.
NOT ADMINISTERED IMMEDIATELY.
2. a. Disconnect (2) wires from neutral interlock
switch and connect it to leads from an
ohmmeter.
b. When switch is actuated, ohmmeter should
read zero resistance.
3. Adjustments must be made at transmission.
4. Disconnect ohmmeter and reconnect interlock
wires and battery cables.
Before disconnecting any hydraulic lines, be sure
engine is shut off and relieve all pressure. Before
applying pressure to system, be sure all connections are
tight and lines, fittings and hoses are not damaged.
Inspect for leaks daily. Check connections for tightness
every 100 hours.
4.25 CONTROL CABLES: FORWARD/
REVERSE, THROTTLE, BLADE
Hydraulic system produces high pressures – incorrect
hose replacement can cause serious personal injury.
When performing service, refer to hydraulic diagrams
for hose identification and connections.
Lubricate all cable ends with penetrating oil every 200
hours.
4.23 FORWARD/REVERSE/NEUTRAL
ADJUSTMENT
DO NOT ADJUST THE CONTROL CABLE WITH
THE POWER ON OR THE ENGINE RUNNING.
The forward/reverse lever should be aligned with
“NEUTRAL” on the console when the roller is moving SERIOUS INJURY OR DEATH COULD RESULT.
neither forward nor backward with the engine running. AGRADUALOR SUDDEN INCREASE IN THE NO-
If the lever is not aligned, adjust it as described below.
LOAD FRICTION (CABLE DISCONNECT AT
BOTH ENDS) OF A CONTROL CABLE IS AN
INDICATION OF A PENDING OR PRESENT
1. Shut off the engine with the forward/reverse lever
left in operating neutral position, the position when PERFORMANCE PROBLEM. THE CONTROL
the roller moves neither forward nor reverse.
Apply the parking brake.
CABLE SHOULD BE REPLACED, OTHERWISE
SERIOUS INJURY OR DEATH COULD RESULT.
A GRADUAL OR SUDDEN DECREASE IN THE
USABLE STROKE IS AN INDICATION OF A
PENDING OR PRESENT PERFORMANCE
PROBLEM. THE CONTROLCABLE SHOULD BE
REPLACED, OTHERWISE SERIOUS INJURY OR
DEATH COULD RESULT. CONTROL CABLES
WHICH HAVE MOISTURE INSIDE OF THEM
AND/OR HAVE FROZEN SHOULD BE
REPLACED. DO NOT APPLY HEAT TO THAW
OR DRY CONTROL CABLES.
2. Open the engine hood of the machine.
3. Disconnect the linkage from the hydrostatic
transmission from the clevis. Do this by removing
the lock nut from the clevis pin and removing the
pin.
4. Now screw clevis in or out to adjust.
5. Secure the clevis to the transmission lever with
the clevis pin, secure with the lock nut and tighten
clevis nut.
Linkage play must be minimal at both connections.
Replace clevis and/or link if required.
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4. MAINTENANCE
4.26 ECCENTRICS
4.27 CHARGE SYSTEM
Test vibration with front drum on soft ground. Run
engine at full rpm to obtain vib spec 2100 + 100 rpm –
check per below.
If gauge fails to function, check charge system. With
the engine running at full speed, voltage should be 13-
14 volts across the battery (check volt meter). If unit is
charging, replace gauge. If not, see authorized engine
dealer to check alternator.
To check vibration with a vibrotach, place the
vibrotach on the vibrating member surface, record
reading when the wire reaches maximum movement.
(Vibrotach P/N 37891).
4.28 PANEL FUSE 20 AMP
This fuse provides protection for the electrical system.
If the engine fails to turnover when starting, check the
fuse.
When checking vibration with strobe light, place
horizontal line on vibrating member surface. Check
with strobe light and record reading when the line
reaches minimum movement.
WARNING
4.26.1 Eccentric Housing Oil
NEVER USE FUSE WITH A DIFFERENT RATING
FROM THAT SPECIFIED. SERIOUS DAMAGE
TO THE ELECTRICALSYSTEM ORAFIRE MAY
RESULT.
WARNING
ROLLER MUST BE PARKED ON LEVEL
GROUND WITH PARKINGBRAKEAPPLIEDAND TURN THE ENGINE SWITCH OFFAND REMOVE
ENGINE OFF. THE KEY BEFORE CHECKING OR REPLACING
REMOVE THE KEY AND / OR DISCONNECT FUSES TO PREVENT ACCIDENTAL SHORT-
BATTERY TO AVOID ACCIDENTAL IGNITION CIRCUITING.
OF ENGINE. SEVERE PERSONAL INJURY MAY
OCCUR.
When frequent fuse failure occurs, it usually indicates
a short circuit or an overload in the electrical system.
NEVER WORK ON THE ROLLER WITH ENGINE See your authorized engine dealer for repair.
RUNNING. SEVERE PERSONAL INJURY MAY
OCCUR.
4.29 ENGINE INSTALLATION GUIDELINES
Eccentric housing oil should be checked monthly and
changed every 800 hours or yearly. Refer to
Maintenance Chart.
When installing new or reworking used diesel engines,
this list of guidelines should be strictly adhered to.
Following these guidelines should prevent damage to
the electrical system of diesel engines.
To check, locate oil plug inside the right hand drum
end and position drum so that oil plug is visible at 7:00. A. Always disconnect the positive cable from the
Loosen oil plug slowly until oil starts to drip out past
the oil plug. Oil must be present at the 7:00 position.
Add oil if required and reinstall oil plug, use thread
sealant.
battery before performing any work on the
machine that involves welding or working on
the electrical system.
B. Avoid jump starting a diesel engine. Either change
the battery or remove the positive cable and charge
the battery.
Eccentric housing oil:
SAE 20W/50 API SJ or API SH
SD/PD 43 1 qt. (.95 L.)
C. Do not alter or change the wiring harness.
SP/PD 54 1.5 qt. (1.4 L.)
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4. MAINTENANCE
D. Cold weather add-ons should not be needed.
4.32.1 Maintenance of ROPS/Seat Belts
When cleaning machine, caution should be used around Inspection
regulator area. Direct spraying of the regulator is not
good. (Regulator should be covered or protected if
Scheduled, frequent visual checks of mounting
direct spraying will happen). Excessive water pressure hardware by operator or service personnel are
may also loosen wire connections or cause terminal
recommended. Inspection with regular service
corrosion. After cleaning, all terminals should be dried intervals is suggested. The inspection should check
if wet and connections checked for proper seating.
for:
• Worn, damaged or missing resilient mounts.
Excessive motion or rattling during operation
are indications of a problem.
• Loose, missing or damaged mounting
hardware (bolts, nuts, washers, etc.). Bolts
should be checked for proper torque.
4.30 ENGINE MOUNTING
Check periodically, tighten all mounting hardware for
proper torque. Refer to Torque Charts in Exploded
Views with Parts Section.
• Cracks in ROPS/FOPS structure and mounting
system. The machine should be cleaned, as
necessary, to allow inspection for cracks in
the structure and mounting system. Rust lines
should be taken as indications of cracks and
verified by inspection. Some cracks will badly
affect the ROPS/FOPS function. If in doubt,
consult the manufacturer.
4.31 HARDWARE
Inspect all hardware for tightness. Refer to parts
illustrations for proper torque and Torque Charts in
Exploded Views with Parts Section.
4.31.1 Loctite
• Water drainage paths. Clear water drainage
paths so that entrapped water will not freeze
and crack or deform the structure.
Loctite 262 threadlocker is required to prevent hard-
ware from loosening.
• Corrosion. Extensive paint peeling and rust
should be noted and corrective action taken.
• Seat belt. The presence and operability of a
seat belt should be noted. The belt should be
clean, free of dirt and grease and the latch
should function smoothly.
Refer to Exploded Diagram and Parts List for * where
loctite is required.
4.32 ROLL OVER PROTECTIVE
STRUCTURES (ROPS)
• The structure should be inspected following a
rollover, collision or fire.
Proper inspection and maintenance procedures can
ensure that ROPS will perform the lifesaving function
they are designed for and expected to do. Make
regular, periodic inspections to ensure ROPS are
damage-free and thus capable of functioning in an
upset.
Repair
Replace missing or damaged hardware with the
manufacturer’s specified hardware. Re-torque all loose
threaded fasteners to the manufacturer’s specifications.
Generally ROPS/FOPS structures are not intended as
external load carrying members and must not be used
to mount attachments such as pull hooks, winches, side
brooms, etc. without the manufacturers approval.
The manufacturer must be consulted to determine the
repairability of cracks in ROPS/FOPS structures.
Modifications to basic design should be avoided, as
recertification is required.
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4. MAINTENANCE
4.33 HORN/BACK-UP
WARNING
THIS VEHICLE IS EQUIPPED WITH A BACK-UP
ALARM. ALARM MUST SOUND WHEN
BACKING UP.
IT IS THE DRIVER’S
RESPONSIBILITYTO OPERATE THIS VEHICLE
SAFELY. BE SURE BACK-UPALARMAND HORN
ARE WORKING.
Inspect the sound decibel level of the horn and back-up
alarm daily and test weekly for proper dBA level (112
dBA). Test results should be recorded in the vehicle’s
maintenance file. If mud, dirt or other debris is forced
into alarm, clean and test to ensure proper operation.
4.33.1 Back-Up Alarm Switch
1. Remove control panel wrap.
2. To check for proper switch operation, connect
ohmmeter leads to the wire connections. The
back-up switch should be normally open in the
neutral position and normally closed when
shifted into reverse position. With the ignition
key in the on position, shifting into reverse
should actuate the back-up alarm.
3. Check the assembly for proper switch actuation,
smooth lever operation and all hardware for
tightness, then assemble the panel wrap and
hardware.
4.34 SCRAPERS
Prevent mud and debris from building up. If urethane
scrapers are worn or torn, replace.
Steel scrapers are adjustable. The scrapers should just
clear the drum and pads. If adjusting, be sure to check
that scrapers clear drum and pads all the way around
the drum. To adjust, loosen mounting bolts and slide
scraper in or out, check clearance and retighten.
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4. MAINTENANCE
4.35 TROUBLESHOOTING
PROBLEM
CAUSE
REMEDY
Engine Won't Start.
Place lever in neutral position.
Forward/Reverse lever not in neutral
position.
Replace, 20A fuse required.
Check and tighten.
Panel fuse blown.
Loose battery or starter cables.
Faulty engine starting circuit.
Check appropriate section in Engine
Manual
Make sure neutral switch is adjusted
properly and wires are all secured. Test
with ohmmeter. Readjust neutral switch.
Replace if defective.
Faulty or improperly adjusted neutral
interlock switch.
Clean or replace.
Clean or replace.
Dirty fuel injectors. (Diesel Only)
Petcock plugged.
Engine won't start but cranks over.
Add fuel.
Low on fuel.
Open.
Fuel valve closed.
Fuel filter plugged.
Exhaust restricted.
Check fuel filter, replace if necessary.
Check and correct exhaust restriction.
Check fuel flow at supply pump or bleed
fuel system.
Injection pump not getting fuel or air in
fuel
system.
Consult authorized diesel repair station
for repair or replacement.
Faulty injection pump or nozzles
Fuel lines plugged.
Clean or replace.
Engine hard to start or will not start (or)
Engine starts but does not keep running.
Bleed fuel line.
Air in fuel line.
Use cold weather starting aid.
Use oil of proper viscosity.
Cold weather.
Crankcase oil too heavy.
Improver type of fuel.
Consult fuel supplier; use proper type
fuel for operating conditions.
Drain, flush, fill, and bleed system.
Replace filter element.
Water, dirt, or air in fuel system.
Clogged fuel filter.
Turn key switch to "OFF" then to "ON".
Injection pump shut-off not reset.
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4. MAINTENANCE
4.35 TROUBLESHOOTING-cont'd.
PROBLEM
CAUSE
REMEDY
Engine starts but does not keep running.
Water/dirt in fuel.
Drain fuel system.
Choke remains on. (Gas Only)
Adjust choke cable.
Clean choke linkage.
Carburetor improperly adjusted. (Gas
Only)
Adjust as per Engine Manual.
Dirty fuel injectors. (Diesel Only)
Service or replace.
Injection pump drawing in air. (Diesel
Only)
Check fuel lines or replace.
Roller won't move forward or reverse.
Objects in front of drums.
Unit in bypass.
Remove.
Check bypass valve.
Loose or broken forward/reverse linkage.
Readjust linkage or replace worn arm
linkage.
Loose or broken chain.
Make sure chain is on sprocket. Adjust
tension or replace if chain shows
excessive war.
Loose or broken transmission belts.
Low hydraulic oil.
Replace and/or tighten.
Check oil level gauge. Add if required.
Unit lacks power moving forward --but
okay in reverse or vice versa.
Improperly adjusted forward/reverse
linkage.
Adjust linkage so that lever travel is the
same in either direction from neutral.
Unit lacks power.
Engine not properly warmed up.
Idle before operating to achieve operating
temperature.
Low hydraulic oil level.
Plugged hydraulic filter.
Insufficient belt tension.
Engine RPM too low.
Add.
Replace.
Check and adjust belts.
Check throttle linkage for proper
actuation (3100 RPM Gas/2600 Diesel).
See Maintenance.
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4. MAINTENANCE
4.35 TROUBLESHOOTING-cont'd
PROBLEM
CAUSE
REMEDY
High fuel consumption.
Improper type of fuel.
Use proper type of fuel.
Clogged or dirty air cleaner.
Engine overloaded.
Service air cleaner.
Excessive mud/debris build-up -- Clean/
pressure wash.
Improper valve clearance.
Injection nozzles dirty.
Engine out of time.
See your authorized servicing dealer or
engine distributor.
See your authorized servicing dealer or
engine distributor.
See your authorized servicing dealer or
engine distributor.
Low engine temperature.
Check thermostat.
High oil consumption.
Crankcase oil too light.
Oil leaks.
Use proper viscosity oil.
Check for leaks in lines, gaskets, and
drain plug.
Restricted crankcase vent tube.
Defective turbocharger.
Clean vent tube.
See your authorized servicing dealer or
engine distributor.
Too much oil in crankcase.
Loose oil filter or sending unit.
Loose bolts.
Drain.
Tighten.
Tighten.
Engine in break-in period.
See Engine Owner's Manual.
Low oil pressure.
Low oil level.
Add oil.
Improper type of oil.
Drain, fill crankcase with oil of proper
viscosity and quality.
Engine emits smoke.
Too much oil in crankcase.
Engine in break-in period.
Drain, fill to proper level.
See Engine Owner's Manual.
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4. MAINTENANCE
4.35 TROUBLESHOOTING-cont'd
PROBLEM
CAUSE
REMEDY
Engine emits white smoke.
Improper type of fuel.
Use proper fuel.
Low engine temperature.
Warm up engine to normal operating
temperature.
Defective thermostat.
Remove and check thermostat.
Defective injection nozzles.
See your authorized servicing dealer or
engine distributor.
Engine out of time.
See your authorized servicing dealer or
engine distributor.
Engine emits black or gray exhaust
smoke.
Improper type of fuel.
Use proper fuel.
Clogged or dirty air cleaner.
Injection nozzles dirty.
Service air cleaner.
See your authorized servicing dealer or
engine distributor.
Engine out of time
See your authorized servicing dealer or
engine distributor.
Engine overheats.
Engine overloaded.
Low coolant level.
Reduce load, check for mud build-up,
clean if required.
Fill radiator to proper level, check
radiator and hoses for loose connections
or leaks.
Faulty radiator cap.
Have serviceman check.
Loose or defective fan belts.
Low engine oil level.
Adjust belt tension. Replace as required.
Check oil level. Add oil as required.
Flush cooling system.
Cooling system needs flushing.
Defective thermostat.
Remove and check thermostat.
Defective temperature gauge or sender.
Check water temperature with
thermometer and replace if necessary.
Incorrect grade of fuel.
Use correct grade of fuel.
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4. MAINTENANCE
4.35 TROUBLESHOOTING-cont'd
PROBLEM
CAUSE
REMEDY
Roller won't move forward or reverse.
Objects in front of drums.
Remove.
Unit in bypass loose or broken forward/
reverse linkage.
Check bypass valve. Readjust linkage or
replace worn arm linkage, make sure
lever at pump is moving.
Low hydraulic oil.
Check oil level gauge. Add if required.
Unit lacks power moving forward, but
okay in reverse or vice versa.
Improperly adjusted forward/reverse
linkage.
Adjust linkage so that lever travel is the
same in either direction from neutral.
Unit lacks power.
Engine not properly warmed up.
Idle before operating to achieve operating
temperature.
Restricted fuel hose.
Clean or replace fuel hose
Add hydraulic oil.
Replace.
low hydraulic oil level.
Plugged hydraulic filter.
Leaking exhaust manifold gasket.
See your authorized servicing dealer or
engine distributor.
Engine RPM too low.
Check throttle linkage for proper
actuation. Check full speed.
Defective Aneroid control line.
See your authorized servicing dealer or
engine distributor.
Dirty fuel filter.
Replace.
Dirty fuel injectors.
Service or replace.
Injection pump drawing in air.
Too much oil in crankcase.
Air filter dirty.
Check fuel lines or replace.
Drain and check. Service or replace.
Clean and/or replace.
Injection pump out of time.
See your authorized servicing dealer or
engine distributor.
Faulty hydraulic pump or drive motor.
Test hydraulic pressure for 500psi at full
load on drive motor with engine at full
RPM.
Check charge pressure 220-260 psi with
engine at full RPM.
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4. MAINTENANCE
4.35 TROUBLESHOOTING-cont'd
PROBLEM
CAUSE
REMEDY
Unit lacks power - cont'd.
Faulty hydraulic pump or drive motor -
cont'd.
Replace pump if pressure is not in specified
range in hydraulic motor drive circuit.
Check drive motors case, drain flow
.5GPM max. drum, tires blocked, engine
running.
Improper type of fuel.
Use proper fuel.
Excessive mud or debris build-up.
Below normal engine temperature.
Improper valve clearance.
Clean/pressure wash.
Remove and check thermostat.
See your authorized servicing dealer or
engine distributor.
Unit won't steer.
Cylinder leaking.
Replace hydraulic cylinder.
Replace hydraulic cylinder.
Replace.
Piston rod bent.
Missing hydraulic cylinder pin.
Kinked or broken hoses.
Low hydraulic fluid.
Faulty hydraulic pump.
Replace.
Add fluid.
Check hydraulic steering circuit for
maximum pressure of 2,300 psi at full
RPM. Replace or repair by authorized
Service Center.
Brakes don't hold properly.
Brake valve faulty.
Loose wires.
Check brake light operation.
Check for 12 volt A brake valve, see
Wiring.
Check wiring for loose or broken wiring.
Brake stays on.
No release pressure.
Faulty relay.
Check pump for proper charge pressure
220-260psi.
Check, replace if required.
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4. MAINTENANCE
4.36 ELECTRICAL TROUBLESHOOTING
PROBLEM
CAUSE
REMEDY
Undercharged system.
Excessive electrical load from added
accessories.
Remove accessories.
Excessive engine idling.
Increase engine RPM when heavy
electrical load is used.
Poor electrical connections on battery,
ground strap, starter, or alternator.
Inspect and clean as necessary.
Defective battery.
Test battery.
Defective alternator.
Test charging system.
Battery used too much water.
Batteries will not charge.
Starter will not crank.
Cracked battery case.
Check for moisture and replace as
necessary.
Defective battery.
Test battery.
Battery charging rate too high.
Test charging system.
Loose or corroded connections.
Sulfated or worn-out batteries.
Clean and tighten connections.
See your authorized servicing dealer or
engine distributor.
Loose or defective alternator belt.
Adjust belt tension or replace belts.
Clean and tighten loose connections.
Loose or corroded connections.
Low battery output voltage.
See your authorized servicing dealer or
engine distributor.
Faulty start circuit relay.
Low battery output.
See your authorized servicing dealer or
engine distributor.
Starter cranks slowly.
See your authorized servicing dealer or
engine distributor.
Crankcase oil too heavy.
Use proper viscosity oil.
Loose or corroded connections.
Clean and tighten loose connections.
Entire electrical system does not
function.
Faulty battery connection.
Clean and tighten connections.
Sulfated or worn-out batteries.
See your authorized servicing dealer or
engine distributor.
Blown fuse.
Replace fuse.
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4. MAINTENANCE
4.37 SERVICE RECORD
Mod e l No.
Rolle r S/ N:
Eng ine S/ N:
Re c ord Hours a nd Da te s of Ma inte na nc e Be low
Eng ine Oil a nd
Filte r
Hyd ra ulic Oil, Filte r, a nd
Bre a the r
Eng ine Coola nt
Air Cle a ne r
Wa te r Se p a ra tor
Fue l Filte r
Fa n/ Alte rna tor Be lt
Gre a se Fitting s
Ba tte ry
Cra nkc a se Ve nt Tub e
Va lve Cle a ra nc e
Eng ine RPMS
Fue l Inje c tors
Fue l Ta nk
Fue l Line s
Hyd ra ulic
Hose s/ Conne c tions
Forwa rd / Re ve rse
Ne utra l Inte rloc k
Control Ca b le s
Ec c e ntric s/ Ec c e ntric
Housing Oil
Cha rg e Syste m
Pa ne l Fuse
Ha rd wa re
ROPS/ Se a t Be lts
Sc ra p e rs
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5. EXPLODED VIEWS
WITH PARTS
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Exploded Views with Parts
5. PARTS LIST
5.1 Hardware Key ......................................................................................... 59
5.2 Torque Charts and Guidelines................................................................. 60 - 61
5.3 Drum Assembly....................................................................................... 62 - 65
5.4 Main Frame ............................................................................................. 66 - 69
5.5 Radiator/Engine Mount........................................................................... 70 - 71
5.6 Engine ................................................................................................... 72 - 75
5.7 Air Cleaner .............................................................................................. 76 - 77
5.8 Controls ................................................................................................... 78 - 81
5.9 Drive System Hydraulics ........................................................................ 82 - 85
5.10 Steering/Eccentric System Hydraulics .................................................... 86 - 87
5.11 Blade ................................................................................................... 88 - 89
5.12 Hydraulic Schematic ............................................................................... 90 - 91
5.13 Wiring ................................................................................................... 92 - 93
5.14 Decal Identification ................................................................................. 94 - 97
5.1 HARDWARE KEY
ZN = ZINC PLATED
BLK = BLACK OXIDE FINISH
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5.2 Torq ue Cha rts a nd Guid e line s
Do not use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use. Check
tightness of fasteners periodically.
Shear bolts are designed to fail under predertermined loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original.
Make sure fasteners' threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.
SAE GRADE 5
SAE GRADE 8
Coarse Thread, Zinc-Plated
Coarse Thread, Zinc-Plated
SIZE
TORQUE
ft. lbs.
6
13
23
SIZE
TORQUE
ft. lbs.
9
18
33
Nm
8
18
31
50
Nm
12
24
45
70
108
156
215
382
615
925
1/4 - 20 (.250)
5/16 - 18 (.3125)
3/8 - 16 (.375)
7/16 - 14 (.4375)
1/2 - 13 (.500)
9/16 - 12 (.5625)
5/8 - 11 (.625)
3/4 - 10 (.750)
7/8 - 9 (.875)
1/4 - 20 (.250)
5/16 - 18 (.3125)
3/8 - 16 (.375)
7/16 - 14 (.4375)
1/2 - 13 (.500)
9/16 - 12 (.5625)
5/8 - 11 (.625)
3/4 - 10 (.750)
7/8 - 9 (.875)
37
57
52
80
77
82
111
152
271
436.5
655
115
159
282
454
682
112
200
322
483
1 - 8 (1.000)
1 - 8 (1.000)
SAE GRADE 5
SAE GRADE 8
Fine Thread, Zinc-Plated
Fine Thread, Zinc-Plated
SIZE
TORQUE
ft. lbs.
7
14
26
41
64
91
128
223
355
529
541
SIZE
TORQUE
ft. lbs.
10
20
37
58
Nm
10
19
35
56
Nm
14
27
50
79
1/4 - 28 (.250)
5/16 - 24 (.3125)
3/8 - 24 (.375)
7/16 - 20 (.4375)
1/2 - 20 (.500)
9/16 - 18 (.5625)
5/8 - 18 (.625)
3/4 - 16 (.750)
7/8 - 14 (.875)
1 - 12 (1.000)
1 -14 (1.000)
1/4 - 28 (.250)
5/16 - 24 (.3125)
3/8 - 24 (.375)
7/16 - 20 (.4375)
1/2 - 20 (.500)
9/16 - 18 (.5625)
5/8 - 18 (.625)
3/4 - 16 (.750)
7/8 - 9 (.875)
87
90
122
175
244
427
679
1011
1036
123
173
302
481
717
733
129
180
315
501
746
764
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5.2 Torq ue Cha rts a nd Guid e line s
Property Class 8.8
ZINC-PLATED
Coarse Thread
Fine Thread
SIZE
M6
M8
Nm
9.9
24
ft. lbs.
7
18
Nm
10
25
ft. lbs.
7
18
M10
M12
M14
M16
M20
M24
48
83
132
200
390
675
35
61
97
148
288
498
49
88
140
210
425
720
36
65
103
155
313
531
Property Class 10.9
ZINC-PLATED
Coarse Thread
Fine Thread
SIZE
M6
Nm
14
ft. lbs.
10
Nm
14
ft. lbs.
10
M8
34
25
35
26
M10
M12
M14
M16
M20
M24
67
49
86
136
210
406
701
68
50
92
142
218
443
738
117
185
285
550
950
125
192
295
600
1000
Property Class 12.9
ZINC-PLATED
Coarse Thread
Fine Thread
SIZE
M6
M8
Nm
16.5
40
ft. lbs.
12
30
Nm
16.5
42
ft. lbs.
12
31
M10
M12
M14
M16
M20
M24
81
60
82
60
140
220
340
660
1140
103
162
251
487
841
150
235
350
720
1200
111
173
258
531
885
- 61 -
Conversion Factor: 1 ft. lb. = 1.3558 Nm
REMARK:
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5.3 Drum Asse m b ly
h:\ e ng r\ m a nua ls\ rhino \ rhd rum a s.e p s
- 62 -
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5.3 Drum Asse m b ly
Ite m
Pa rt No.
De sc rip tion
Qty.
Ite m
Pa rt No.
De sc rip tion
Qty.
18
19
20
21
22
32243
Be a ring Ba ll
2
1
2
1
1
1
1
1
2
2
2
1
1
2
4
2
1
2
2
2
2
2
2
6
1
42374-2
42375-2
42376-2
42377-2
22748-2
22749-2
22820
Drum We ld SD 43
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
2
1
42210
Wa she r 1/ 8 - 3ID X 3 - 1/ 2 OD
FTG Hyd 3/ 4 NPT X 5/ 8 H - BARB
Blo c k Yo ke SET
Drum We ld SD 54
46403
Drum We ld PD 43
29524
Drum We ld PD 54
42490-2
42496-2
42491-2
42497-2
29505-2
46521
Ho se G ua rd We ld LH
Ho se G ua rd We ld LH BLADE
Ho se G ua rd We ld RH
Ho se G ua rd We ld RH BLADE
Hing e We ld ART / OSC
Plug Pip e 3/ 4 NPT SKT Hyd ra ulic
Ba r Mo unt Ho se G ua rd
Ho se Hyd ra ulic Lo w Pre ss 5/ 8 ID
Elb o w Pip e 3/ 4 NPT 45 Stre e t
O-Ring 10 ID X 1/ 8 CS
Be a ring Fla ng e
2
Fra m e We ld 43
Fra m e We ld 54
23
3
4
5
6
Kit Ca p & Be a ring LH
Kit Ca p & Be a ring RH
We ig ht Ec c e ntric
22821
24
25
26
27
28
29
30
31
32
33
29514
29513
Sha ft Ec c e ntric 43
42489-2
46131
29563
Sha ft Ec c e ntric 54
7
8
32234
Be a ring Ec c e ntric
46032
29601
Sp line Exte nsio n
47305
9
29980-2
38507
Co ve r We b Drum
32236
10
11
#
Se a l Sha ft
24017
WSHR 2 - 15/ 16 X 2 - 1/ 4 ID
Nilo s Ring
23015
Kit Whe e lm o to r & Ca p
Se a l Kit fo r Whe e lm o to r in 23015
Bra c ke t We ld S-MOUNT RH
Pla te MOUNT Whe e lm o to r
Bra c ke t We ld S-Mo unt LH
Pla te We ld HOUSING
Sho c k Mo unts (Pe r Sid e )
SD43, PD43 (fro nt 2, b a c k 3)
38760
32308
42243-2
42242-2
29547-2
29546-2
42494-2
46042
Strip Sc ra p e r SD 43
12
13
14
15
16
42232-2
42233-2
42234-2
42236-2
47281
Strip Sc ra p e r SD 54
Sc ra p e r PD 43
Sc ra p e r PD 54
34^
35
Sp a c e r Ho use G ua rd
FTG 164 IB
10
36
47001
Ca p lug Blue
SD54, PD54, PDB43 (fro nt 3, b a c k 3) 12
PDB54 (fro nt 3, b a c k 4)
Mo to r G e a r Ec c e ntric
14
1
- 63 -
17
38531
Pa rt Num b e rs 22820, 22821, 23015 inc lud e Ite m 7.
^ No t re q uire d o n b la d e unit
REMARK:
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#
No t Sho wn
5.3 Drum Asse m b ly Cont'd .
- 64 -
h:\ e ng r\ m a nua ls\ rhino \ rhd rum a s.e p s
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5.3 Drum Asse m b ly Cont'd .
Torq ue
Torq ue
Ite m
Pa rt No.
De sc rip tion
Qty.
FT. LBS. (Nm )
Ite m
Pa rt No.
De sc rip tion
Qty.
FT. LBS. (Nm )
37
38
39
40
47301
32251
22770
42345
42346
42493-2
O-Ring 3 - 1/ 4 ID X 1/ 16 CS
Se a l V-RING 6" DIA.
Kit Bra ke Re le a se
1
1
1
2
2
4
K*80474 HHCS 3/ 8 - 16 X 1 - 1/ 4 G R 5 ZN
2
23
-
(31)
-
M
80043
80056
80058
80643
80405
80681
80337
80695
80355
80082
80051
80699
80113
80343
80343
80343
80694
80578
80641
80700
26326
WSHR 3/ 8 WROTZN
14
7
N
NUTNY 3/ 8 - 16 ZN
23
-
(31)
Sc ra p e r POLY SD43
Sc ra p e r POLY SD54
Ba r Mo unt PIVOT
O
WSHRL 3/ 8 MRD SPLIT ZN
HHCS 3/ 8 - 16 X 7 G R5 ZN
HHCS 1/ 2 - 13 X 2 - 3/ 4 G R5 ZN
SHCS 5/ 8 - 11 X 1 - 1/ 2 BLK
WSHRL 5/ 8 MED SPLIT ZN
HHCS 5/ 8 - 11 X 2 G R5 ZN
WSHR 5/ 8 SAE ZN
2
P*
Q*
R*
S
1
23
57
190
-
(31)
41
12
8
(77)
(257)
A#*
##*
B#*
##*
C#
80561
80561
80085
80085
80117
80117
80117
80680
80086
80049
80537
80537
80537
80125
80658
80658
80658
80678
80678
80678
HHCS 1/ 2 - 13 X 1-3/ 4 G R5 ZN
HHCS 1/ 2 - 13 X 1-3/ 4 G R5 ZN
HWHST 5/ 16 - 18 X 1 ZN
HWHST 5/ 16 - 18 X 1 ZN
WSHRL 1/ 2 MED SPLIT ZN
WSHRL 1/ 2 MED SPLIT ZN
WSHRL 1/ 2 MED SPLIT ZN
SHCS 1/ 2 - 13 X 2 - 1/ 2 ZN
WSHRL 5/ 16 MED SPLIT ZN
SHCS 5/ 16 - 18 X 1 - 1/ 4 BLK
NUTFL 1/ 2 - 20 ZN
24
76
4
57
57
13
13
-
(77)
(77)
(18)
(18)
-
18
18
40
14
16
8
-
T*
112
-
(152)
V
-
13
43
44
47
5
W
NUTNY 5/ 8 - 11 ZN
112
57
112
57
-
(152)
X
NUTNY 1/ 2 - 13 ZN
(77)
##
-
-
Y*
Z*
HHCS 5/ 8 - 11 X 3 - 1/ 4 G R5 ZN
HHCS 1/ 2 - 13 X 3/ 4 ZN
WSHR 1/ 2 SAE ZN
(152)
###
D*
-
-
6
(77)
57
-
(77)
-
AA#
##
###
BB*
CC*
DD
EE
FF
64
68
72
4
-
E
3
WSHR 1/ 2 SAE ZN
-
-
F*
3
13
64
64
64
-
(18)
(87)
(87)
(87)
-
WSHR 1/ 2 SAE ZN
-
-
G #*
##
10
12
14
16
5
HHCS 3/ 8 - 13 X 4 - 1/ 2 GR5 ZN
HHCS 1/ 2 - 13 X 3 G R5 ZN
HHTB M12 X 100MM GR8.8 ZN
NUTFX M12 ZN
-
-
NUTFL 1/ 2 - 20 ZN
4
57
-
(77)
###
H
NUTFL 1/ 2 - 20 ZN
1
-
-
-
WSHR 17/ 32 ID X 1 - 1/ 16 ZN
HHCS 1/ 2 - 20 X 1 G R5 ZN
HHCS 1/ 2 - 20 X 1 G R5 ZN
HHCS 1/ 2 - 20 X 1 G R5 ZN
HHCS 1/ 2 - 20 X 3 G R5 ZN
HHCS 1/ 2 - 20 X 3 G R5 ZN
HHCS 1/ 2 - 20 X 3 G R5 ZN
1
-
I#*
64
64
64
64
64
64
(87)
(87)
(87)
(87)
(87)
(87)
WSHR 9/ 16 X 1 - 3/ 4 X 1/ 4
1
-
##*
###*
J#*
##*
###*
6
7
5
- 65 -
6
7
# SD43, PD43
## SD54, PD54, PDB43
### PDB54
*Lo c tite Re q uire d
REMARK:
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5.4 Ma in Fra m e
- 66 -
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5.4 Ma in Fra m e
Ite m
Pa rt No.
De sc rip tion
Qty.
Ite m
Pa rt No.
De sc rip tion
Qty.
1
46059
Ca p Fue l
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
21
22
23
24
25
26
27
28
29
30
31
34486
34089
43785-2
29560-2
29314
38519
42321-2
38610
38622
47268
47292
Fitting Elb o w
Cla m p
2
2
1
1
7
1
2
2
2
1
8
2
43250-2
46127
Ta nk Fue l
3
Fitting Re turn Fue l 1/ 4H
Fitting Sup p ly Fue l 5/ 16H
Pa ne l Co ve r Ta nks
Pa ne l Co ve r Filte r
Fra m e Ma in
Ba tte ry Bo x
Ho ld Do wn Ba tte ry
Line r Ba tte ry Bo x
Ba tte ry 800 CCA
Sp a c e r
4
46815
5
43738-2
43736-2
43240-2
46107
6
7
8
Plug 1/ 2 NPT Sq Hd
Mo unt Ma nifo ld
Whe e lm o to r
La tc h
9
43845-2
38528
Ke e p e r
10
11
12
13
14
15
16
Se a t
29539-2
29132
Pa ne l Se a t
Bum p e rs
Pin Hing e
42062-2
42063-2
42065-2
43740-2
43808
Pa n No se
Pa n Flo o r
Pla te Ba tte ry
Co wl
Se t So und Pro o f
Tire Asse m b ly RH Turf
Tire Asse m b ly LH Turf
Tire Turf (R-3)
Tire Asse m b ly RH Lug
Tire Asse m b ly LH Lug
Tire Lug (R-1)
17
18
39289
39290
38720
39195
39196
38722
19
20
42015-2
47295-2
38712
Co ve r Le ve l
Ho se
- 67 -
Flo a t Fue l
REMARK:
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5.4 Ma in Fra m e Cont'd .
- 68 -
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5.4 Ma in Fra m e Cont'd .
Torq ue
Torq ue
Ite m
Pa rt No.
De sc rip tion
Qty.
FT. LBS. (Nm )
Ite m
Pa rt No.
De sc rip tion
Qty.
FT. LBS. (Nm )
32
33
34
35
36
37
38
39
40
41
42
43
44
38600
Se a t Be lt
1
1
1
1
2
1
1
1
1
1
1
1
1
J*
K
80476
80058
80668
80669
80684
80685
80670
80671
80346
80693
80696
80527
80348
80114
80051
80343
80587
80257
41038
HHCS 3/ 8 - 16 X 1 - 1/ 2 ZN
WSHRL 3/ 8 SPLIT ZN
4
4
2
23
(31)
43251-2
29700-2
29702-2
42215-2
42216-2
42075-2
42222-2
46450
Ta nk Hyd ra ulic
ROPS
-
-
L*
M*
N*
O
HHCS 3/ 4 - 10 X 2 G R8 BLK
282
(382)
ROPS Sup p o rt
Bra c ke t Ho se
Bra c ke t Ho se
Pa ne l Fro nt
Pa ne l Re a r
Ste e ring Whe e l
Co lum n
HHCS 3/ 4 - 10 X 2 - 1/ 2 G R8 ZN
HHCS 1 - 8 X 3 G R8 BLK
WSHRL 1 SPLIT ZN
4
282
(382)
4
682
(925)
4
-
-
P
NUTFX 3/ 4 - 10 BLK
WSHRL 3/ 4 SPLIT ZN
WSHR #10 SAE ZN
4
-
-
Q
6
-
-
R
6
-
-
46452
S
NUTNY 10 - 24 ZN
4
-
-
46449
Ho rn Kit
T
FHSMS 10 - 24 X 1 ZN
PPHMS 10 - 24 X 5/ 8 ZN
WSHR 5/ 16 WROT ZN
NUTNY 5/ 16 - 18 ZN
NUTNY 1/ 2 - 13 ZN
2
-
-
47217
Nut Ste e ring
Gro m m e t Rub b e r 2" ID
V
4
-
-
47247
W
X
8
-
-
10
12
24
2
13
(18)
Y
-
-
A
B
C
D
E
80041
80043
80056
80610
80085
80082
80355
80695
80561
CRBLT 3/ 8 - 16 X 1 - 1/ 4 ZN
WSHR 3/ 8 WROT ZN
4
-
-
Z
WSHR 1/ 2 SAE ZN
-
-
6
-
-
AA
BB*
CC*
CRBLT 3/ 8 - 16 X 1 ZN
RHSMS 10 - 24 X 3/ 8 BLK
LUG NUT M14 x 60 °
-
-
NUTNY 3/ 8 - 16 ZN
6
23
23
13
112
-
(31)
(31)
(18)
(152)
-
2
-
-
HWHTB 3/ 8 - 16 X 1 - 1/ 4 ZN
HWHTB 5/ 16 - 18 X 1 ZN
NUTNY 5/ 8 - 11 ZN
8
10
184
(250)
22
12
24
12
F
G
H*
I*
WSHR 5/ 8 SAE ZN
HHCS 5/ 8 - 11 X 2 G R5 ZN
112
57
(152)
(77)
HHCS 1/ 2 - 13 X 1 - 3/ 4 G R5 ZN 12
- 69 -
REMARK:
* Lo c tite Re q uire d
Download from Www.Somanuals.com. All Manuals Search And Download.
5.5 Ra d ia tor a nd Eng ine Mount
- 70 -
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5.5 Ra d ia tor a nd Eng ine Mount
Torq ue
Ite m
Pa rt No.
De sc rip tion
Qty.
FT. LBS. (Nm )
Ite m
Pa rt No.
De sc rip tion
Qty.
A*
B*
C
80161
80658
80058
80041
80043
80564
80056
80114
80537
80343
80117
80682
80086
80355
80082
80695
80347
80116
80174
HHCS 5/ 16 - 18 X 1 G R 5 ZN
HHCS 1/ 2 - 20 X 1 G R5 ZN
WSHRL 3/ 8 Sp lit ZN
4
13
57
-
(18)
1
2
3
4
5
6
7
43255-2
47281
Bra c ke t Oute r Be ll Ho using
Sho c k Mo unts
1
6
1
1
2
1
1
1
1
1
2
2
1
1
1
1
2
1
4
1
1
6
(77)
6
-
43715-2
43714-2
42129-2
39576
Mo unt We ld LH Eng ine
Mo unt We ld RH Eng ine
Bra c ke t S-MTG Eng ine
G ua rd Fa n
D
E
CRBLT 3/ 8 - 16 X 1 - 1/ 4 ZN
WSHR 3/ 8 WROT ZN
3
-
-
15
4
-
-
F
WSHR 3/ 8 ID X 1/ 4 OD ZN
NUTNY 3/ 8 - 16 ZN
-
-
G
H
I
11
4
23
13
64
-
(31)
39574
Ra d ia to r
NUTNY 5/ 16 - 18 ZN
(18)
39606
Ca p Ra d ia to r
NUTFL 1/ 2 - 20 ZN
6
(87)
39602
Ho se Ra d ia to r Up p e r
Ho se Ra d ia to r Lo we r
Cla m p Ho se 2"
J
WSHR 1/ 2 SAE ZN PL
WSHRL 1/ 2 MED SPLIT ZN
CRBLT 5/ 16 - 18 X 2 - 1/ 2 ZN
WSHRL 5/ 16 MED SPLIT ZN
WSHR 5/ 8 SAE ZN
20
6
-
39603
K
L
-
-
39600
4
-
-
39601
Cla m p Ho se 2-1/ 4"
Pe tc o c k Ra d ia to r
Mo unt We ld Ra d ia to r RH
Mo unt We ld Ra d ia to r LH
Shro ud Ra d ia to r
M
N
O
P*
Q
R
4
-
-
39604
4
-
-
8
43245-2
43246-2
39575
NUTNY 5/ 8 - 11 ZN
2
112
112
-
(152)
(152)
-
9
HHCS 5/ 8 - 11 X 2 G R5 ZN
WSHR ¼ WROT ZN
2
10
11
12
13
14
15
4
43249-2
43805-2
38627
Pla te Mo unt Co o le r
Ra d ia to r Sup p o rt
Rub b e r Mo unt Co o le r
Bra c ke t Co wl Sto p
Sto p Ca b le
WSHRL ¼ SPLIT ZN
4
-
-
S*
HHCS 3/ 8 - 16 X 1 G R5 ZN
6
23
57
57
-
(31)
(77)
(77)
-
T*80561 HHCS 1/ 2 - 13 X 1 - 3/ 4 G R5 ZN
4
42460-2
38815
U
80051
80348
80434
80474
NUTNY 1/ 2 - 13 ZN
4
V
WSHR 5/ 16 WROT ZN
2
W*
X *
HHCS 1/ 4-20 x 3/ 4 G R5 ZN
HHCS 3/ 8-16 x 1-1/ 4 G R5 ZN
4
6
(8)
-
4
-
- 71 -
REMARK:
* Lo c tite Re q uire d
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5.6 Eng ine
- 72 -
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5.6 Eng ine
Torq ue
Ite m
Pa rt No.
De sc rip tion
Qty.
FT. LBS. (Nm )
Ite m
Pa rt No.
De sc rip tion
Qty.
A*
80170
80086
80527
80346
80693
80113
80117
80178
80342
80325
80163
80703
80343
80204
80355
80337
80058
80686
80716
80942
80567
80676
HHCS 5/ 16-18 X 2-1/ 2 G R5 ZN
WSHRL 5/ 16 SPLIT ZN
PPHMS 10-24 X 5/ 8 ZN
WSHR #10 SAE ZN
4
6
13
-
(18)
1
30558
39577
39578
43799
48401
43782
39621
39620
43715-2
43714-2
43254-2
39636
39595
39596
39597
43749-2
43746-2
39585
Eng ine De e re 3029
Fa n Nylo n
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
2
B
-
2
C
1
-
-
3
Sp a c e r Fa n
D
1
-
-
4
Mo unt Re la y
E
NUTNY 10-24 ZN
1
-
-
5
Re la y 70A
F*
G
HHCS ½-13 X ¾ G R5 ZN
WSHRL ½ SPLIT ZN
1
57
-
(77)
6
Muffle r
9
-
7
Ga ske t
H*
I
HHCS 3/ 8-16 X 2 G R5 ZN
WSHR 3/ 8 SAE ZN
1
23
-
31)
8
Ha lf Cla m p
2
-
9
Mo unt We ld LH Eng ine
Mo unt We ld RH Eng ine
Bra c ke t Inne r Be ll Ho using
Drive Pla te a nd Co ve r
Pla te Thro ttle
J
NUTFL 3/ 8-16 REG ZN
HHCS 5/ 16-18 X 1-1/ 2 G R5 ZN
HHCS ½-13 X 1-1/ 2 GR5 ZN
WSHR ½ SAE ZN
1
-
-
10
11
12
13
14
15
16
17
18
K*
L*
M
N*
O
2
-
-
8
-
-
8
-
-
HHCS 5/ 8-11 X 1-1/ 2 G R5 ZN
WSHR 5/ 8 SAE ZN
4
112
-
(152)
Bra c ke t Thro ttle
Sp a c e r Thro ttle
Sup p o rt Exha ust
Exha ust Pip e
4
-
P
WSHRL 5/ 8 SPLIT ZN
4
-
-
Q
WSHRL 3/ 8 SPLIT ZN
8
-
-
R*
S*
T*
U
HHCS 3/ 8-16 X ¾ G R8 ZN
HHCS 3/ 8-16 X 1-1/ 4 G R8 ZN
HHCS 3/ 8-16 X 5 G R5 ZN
HWHTB ¼-20 X 3/ 8 ZN
NUTNY ¼-20 ZN
20
12
2
23
23
23
6
(31)
(31)
(31)
(8)
-
Cla m p Muffle r 2-1/ 4
Fue l Line s (no t sho wn)
2
-
-
-
-
-
-
46813
39593
46127
46814
46815
34089
Ho se Re turn ¼ ID
Fitting Re turn Eng ine
Fitting Re turn Ta nk
Ho se Sup p ly 5/ 16 ID
Fitting Sup p ly Ta nk
Cla m p Ho se 5/ 8
25”
1
V
2
-
1
36”
1
- 73 -
4
* Lo c tite Re q uire d
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5.6 Eng ine Cont'd .
- 74 -
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5.6 De e re Eng ine Se rvic e Pa rts
Ite m
Pa rt No.
De sc rip tion
Qty.
Ite m
Pa rt No.
De sc rip tion
Qty.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
39624
39625
39626
39627
39628
39629
39630
39631
39632
39633
39634
39635
39592
39598
39599
Filte r Fue l
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
Filte r Oil
Be lt
Alte rna to r
Sta rte r
Inje c to r Fue l
Pum p Wa te r
Pum p Inje c tio n
Pum p Fue l Tra nsfe r
So le no id Fue l
The rm o sta t
Ga ske t The rm o sta t
Inta ke He a te r
Se nd o r Pre ssure
Se nd o r Te m p e ra ture
- 75 -
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5.7 Air Cle a ne r
- 76 -
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5.7 Air Cle a ne r
Torq ue
Ite m
Pa rt No.
De sc rip tion
Qty.
FT. LBS. (Nm )
Ite m
Pa rt No.
De sc rip tion
Qty.
1
39580
39622
39623
39581
39617
43804
43739-2
43747-2
39583
39618
39616
43738-2
39615
39619
39650
38147
Air Cle a ne r Asse m b ly
Ele m e nt Prim a ry (Oute r)
Ele m e nt Sa fe ty (Inne r)
Ba nd
1
1
1
1
1
1
1
1
1
3
1
1
1
2
1
1
A*
B
80587
80342
80056
80161
80348
80114
CRBLT 3/ 8-16 x 1 ZN
WSHR 3/ 8 SAE ZN
NUTNY 3/ 8-16 ZN
HHCS 5/ 16-18x1 G R5 ZN
WSHR 5/ 16
2
2
2
2
2
2
-
-
-
-
2
C
23
13
-
(31)
3
Ca p
D*
E
(18)
4
Exte nsio n
-
-
5
Mo unt Air Cle a ne r
Pip e Inta ke
F
NUTNY 5/ 16-18 ZN
-
6
7
Elb o w 90°
8
Cla m p 3-1/ 4”
Ho se 180°
9
10
11
12
13
14
Co ve r Ta nks
Cla m p 4”
Cla m p 3-3/ 4
Cla m p 4-1/ 4
Plug 1/ 8 NPT
- 77 -
* Lo c tite Re q uire d
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5.8 Controls
- 78 -
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5.8 Controls
Torq ue
Ite m
Pa rt No.
De sc rip tion
Qty.
FT. LBS. (Nm )
Ite m
Pa rt No.
De sc rip tion
Qty.
A*
80434 HHCS 1/ 4 - 20 X 3/ 4 GR ZN
2
6
6
-
(8)
1
2
3
36268
39609
39610
39598
39611
39599
39612
39607
39637
38711
36311
39653
39584
47314
47315
39608
38662
38800
38602
38602
38559
38667
41007
42076
Ho ur Me te r
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
2
2
1
HHCS 1/ 4 - 20 X 3/ 4 GR ZN (Bla d e Unit) 4
(8)
Vo lt Me te r
B
80518 NUTFL 1/ 4 - 20 ZN
NUTFL 1/ 4 - 20 ZN (Bla d e Unit)
80347 WSHR 1/ 4 WROT ZN
3
-
Ga ug e Oil Pre ssure
Se nd o r Oil Pre ssure
Ga ug e Co o la nt Te m p e ra ture
Se nd o r Co o la nt Te m p e ra ture
Push Butto n
6
-
-
C
16
6
-
-
4
D*
E*
F
80788 WSHR SPRING 1/ 4 ID (Bla d e Unit)
80791 PPHMS 1/ 4 - 20 X 3/ 4 BLK
80448 PINCT 1/ 16 X 1/ 2
-
-
4
-
-
5
6
1
-
-
Ke y Switc h
G
H*
I
80442 SHCS #10 - 32 X 1/ 2 BLK
80481 HHCS 5/ 16 - 18 X 1 G R5 ZN
80086 WSHRL 5/ 16 SPLIT ZN
80348 WSHR 5/ 16 WROT ZN
80686 HHCS 3/ 8 - 16 X 3/ 4 G R8 ZN
80346 WSHR #10 SAE ZN
1
-
-
(18)
-
Ke y Ig nitio n
2
13
-
7
Fuse Ho ld e r
4
8
Fuse 20A
J
8
-
-
9
Switc h Ro c ke r On/ Off
Ca b le Thro ttle
K
M
N
O
P
2
23
-
(31)
-
10
11
12
13
14
15
16
20
11
4
Co ve r Dust
80693 NUTNY 10 - 24 ZN
-
-
Ga ske t Co ve r Dust
Re la y Sta rte r
80085 HWHTB 5/ 16 - 18 X 1 ZN
80114 NUTNY 5/ 16 - 18 ZN
13
-
(18)
-
2
Cla m p Ca b le ½
Cla m p Co nd uit ½
Ca b le Fo rwa rd / Re ve rse
Q
R
80056 NUTNY 3/ 8 - 16 ZN
2
-
-
80527 PPHMS 10 - 24 X 5/ 8 ZN
80161 HHCS 5/ 16 - 18 X 1 ZN
80157 HHCS 1/ 4 - 20 X 1 - 1/ 2 ZN
80354 HHCS 1/ 4 - 20 X 1
6
-
-
S*
T*
V*
1
13
6
6
6
6
-
(18)
(8)
(8)
(8)
(8)
Ca b le Fo rwa rd / Re ve rse (Bla d e Unit)
Ba c kup Ala rm 112 d BA
Ho rn 12V 125 d BA
2
1
1
1
1
-
17
18
19
20
2
80709 HHCS 1/ 4 - 20 X 2 GR8 ZN (Bla d e Unit)
80153 HWHST 1/ 4 - 20 X 3/ 4 ZN
80449 SHCS 10 - 24 X 5/ 8 BLK
2
Cla m p Ca b le
X
Y
12
2
Le ve r Ca b le
- 79 --
* Lo c tite Re q uire d
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5.8 Controls Cont'd .
- 80 -
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5.8 Controls Cont'd .
Torq ue
Ite m
Pa rt No.
De sc rip tion
Qty.
FT. LBS. (Nm )
Ite m
Pa rt No.
De sc rip tion
Qty.
A*
80434 HHCS 1/ 4 - 20 X 3/ 4 GR ZN
2
6
6
-
(8)
21
22
23
24
43759-2
38561
48406
38618
41006
38816
39097
43261
Mo unt Ca b le Fo rwa rd / Re ve rse
Cle vis
1
1
1
1
1
1
1
1
1
HHCS 1/ 4 - 20 X 3/ 4 GR ZN (Bla d e Unit) 4
(8)
B
80518 NUTFL 1/ 4 - 20 ZN
NUTFL 1/ 4 - 20 ZN (Bla d e Unit)
80347 WSHR 1/ 4 WROT ZN
3
-
Wire Ha rne ss
6
-
-
Pivo t Thro ttle
C
16
6
-
-
Sto p Thro ttle
D*
E*
F
80788 WSHR SPRING 1/ 4 ID (Bla d e Unit)
80791 PPHMS 1/ 4 - 20 X 3/ 4 BLK
80448 PINCT 1/ 16 X 1/ 2
-
-
25
26
27
28
Cla m p Asse m b ly (Bla d e Unit)
Le ve r Fo rwa rd / Re ve rse
Le ve r Bla d e (Bla d e Unit)
4
-
-
1
-
-
-
G
H*
I
80442 SHCS #10 - 32 X 1/ 2 BLK
80481 HHCS 5/ 16 - 18 X 1 G R5 ZN
80086 WSHRL 5/ 16 SPLIT ZN
80348 WSHR 5/ 16 WROT ZN
80686 HHCS 3/ 8 - 16 X 3/ 4 G R8 ZN
80346 WSHR #10 SAE ZN
1
-
43264-Ye l Bo x We ld Fo rwa rd / Re ve rse
2
13
-
(18)
-
43265-Ye l Bo x We ld Fo rwa rd / Re ve rse (Bla d e Unit) 1
4
29
30
31
32
33
34
35
36
37
38
39
39321
Switc h Ne utra l / Ba c kup
Kno b Fo rwa rd / Re ve rse
Pa ne l Wra p
1
1
1
1
1
1
2
1
1
1
2
J
8
-
-
39320
K
M
N
O
P
2
23
-
31)
-
42263-2
20
11
4
43263-Ye l Bra c ke t We ld Pivo t (Bla d e Unit)
43262-Ye l Pivo t (Bla d e Unit)
80693 NUTNY 10 - 24 ZN
-
-
80085 HWHTB 5/ 16 - 18 X 1 ZN
80114 NUTNY 5/ 16 - 18 ZN
13
-
(18)
-
55343
48329
38817
39319
48399
48393
De c a l Co ntro l (Bla d e Unit)
Ca b le Tie Ho ld e r
2
Q
R
80056 NUTNY 3/ 8 - 16 ZN
2
-
-
Swive l (Bla d e Unit)
Pla te Fo rwa rd / Re ve rse Bla c k
Re la y/ Tim e r (2 se c )
Lig ht Re d
80527 PPHMS 10 - 24 X 5/ 8 ZN
80161 HHCS 5/ 16 - 18 X 1 ZN
80157 HHCS 1/ 4 - 20 X 1 - 1/ 2 ZN
80354 HHCS 1/ 4 - 20 X 1
6
-
-
S*
T*
V*
1
13
6
6
6
6
-
(18)
(8)
(8)
(8)
(8)
-
2
80709 HHCS 1/ 4 - 20 X 2 GR8 ZN (Bla d e Unit)
80153 HWHST 1/ 4 - 20 X 3/ 4 ZN
80449 SHCS 10 - 24 X 5/ 8 BLK
2
X
Y
12
2
- 81 --
* Lo c tite Re q uire d
REMARK:
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5.9 Drive Syste m Hyd ra ulic s
- 82 -
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5.9 Drive Syste m Hyd ra ulic s
Ite m
Pa rt No.
De sc rip tion
Qty.
Ite m
Pa rt No.
De sc rip tion
Qty.
1
2
3
4
38522
38534
38523
38520
38638
38521
38528
38527
35482
46534
46417
38663
47326
38689
46490
46390
46844
46843
46842
46394
46846
PUMP VARIABLE MDT 46
SIG HT G LASS
1
1
1
1
1
1
2
1
1
3
2
1
1
1
3
5
1
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
46396
46115
46757
46841
46400
46401
46402
46527
46509
46544
46387
46389
46345
46385
46404
46535
46447
46840
46845
46325
46531
46404
46808
FTG EL90 1 - 1/ 16 JSW
2
1
1
1
1
3
6
1
1
2
1
1
1
3
1
1
1
1
1
3
1
1
1
FTG STR 9/ 16 J 9/ 16 OR
DIVIDER FLOW 33/ 67
HOSE 1-1/ 16 FJ 1-1/ 16 FJ52
HOSE 1 - 1/ 16 FJ 1 - 1/ 16 FJ 52
FTG STR 9/ 16 J 1/ 4 BSPP
FILTER SUCTION
ELEMENT HYDRAULIC 50AT-10C
BREATHER / FILTER
5
FTG STR 9/ 16 J 3/ 8 BSPP
6
MOTOR WHEEL MS05
MOTOR WHEEL MS05 W/ BRAKE
STRAINER SL 25G PM
FTG STR 1 - 1/ 16 3/ 4 BSPP
HOSE HYD 9/ 16 FJ 9/ 16 FJ 12
FTG STR 1 - 5/ 16 J 1 - 5/ 16 OR
FTG EL 45 9/ 16
7
8
9
FTG HYD EL 1-5/ 16 JSW
FTG STR 1-5/ 16 J X 1 - 1/ 4 NPT
DIVIDER FLOW 50 / 50
O-Ring Vito n 29.5
10
11
HOSE 9/ 16 FJ X 9/ 16 FJ 23 - 1/ 2
FTG TEE Run 9/ 16 J
FTG STR 7/ 8 JIC X 3/ 4 NPT
FTG STR 1 - 1/ 16 J 1 - 5/ 16 OR
FTG HYD EL 7/ 8 J 1 - 1/ 16 OR
HOSE HYD 1 - 5/ 16 FJ 1 - 5/ 16 FJ 17
FTG EL90 1 - 1/ 4 STREET
12
13
14
15
16
17
18
19
VALVE SOL 3WAY 2POS
FTG STR 9/ 16 J X 3/ 4 OR
FTG EL90 1 - 5/ 16 OR X 1 - 1/ 16 J
HOSE 1-1/ 16 FJ 1-1/ 16 FJ 24
HOSE 1-1/ 16 RJ9 1-1/ 16 RJ4 22-1/ 4 180°
HOSE 1-1/ 16 FJ 1-1/ 16 RJ4 29-1/ 2
FTG Outle t TEE 1-1/ 16 J
HOSE 1-1/ 16 FJ 1-1/ 16 FJ 91
SD, PD43
1
1
2
2
HOSE 1-1/ 16 FJ 1-1/ 16 RJ9 44.5
HOSE 1 - 1/ 16 FJ 1 - 1/ 16 FJ 19"
FTG HYD EL 3/ 4 OR 9/ 16 J
HOSE HYD 7/ 8 FJ 7/ 8 FJ 17
FTG HYD EL 7/ 8 J 1 - 1/ 16 OR
HOSE HYD 9/ 16 FJ 9/ 16 RJ4 55"
46847
HOSE 1-1/ 16 FJ 1-1/ 16 FJ 96
SD, PD54
2
- 83 -
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5.9 Drive Syste m Hyd ra ulic s Cont'd .
- 84 -
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5.9 Drive Syste m Hyd ra ulic s Cont'd .
Torq ue
Ite m
Pa rt No.
De sc rip tion
Qty.
FT. LBS. (Nm )
Ite m
Pa rt No.
De sc rip tion
Qty.
A*
B
80709
80116
80181
80058
80347
HHCS 1/ 4 - 20 X 2 GR8 ZN
WSHR 1/ 4 SPLIT ZN
2
2
4
4
2
6
-
(8)
43
46529 HOSE HYD 9/ 16 FJ 9/ 16 FJ 108
SD, PD54
1
1
-
C*
D
HHCS 3/ 8 - 16 X 2 - 1/ 2 G R5 ZN
WSHRL 3/ 8 SPLIT ZN
23
-
(31)
46549 HOSE HYD 9/ 16 FJ X 9/ 16 FJ 103
SD, PD43
-
-
E
WSHR 1/ 4 ZN
-
44
45
46
47
#
46530 HOSE HYD 9/ 16 FJ 9/ 16 FJ 30
46812 HOSE HYD 1 - 5/ 16 FJ 1-5/ 16 FJ 22.25"
46411 FTG ST 7/ 8J 1-1/ 16 OR
46455 FTG HYD EL 45 1 - 1/ 16
38206 HOSE WRAP 2.5 ID POLY
1
1
2
3
7
- 85 -
# No t Sho wn
* Lo c tite Re q uire d
REMARK:
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5.10 Ste e ring / Ec c e ntric Syste m Hyd ra ulic s
- 86 -
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5.10 Ste e ring / Ec c e ntric Syste m Hyd ra ulic s
Torq ue
Ite m
Pa rt No.
De sc rip tion
Qty.
FT. LBS. (Nm )
Ite m
Pa rt No.
De sc rip tion
Qty.
23
46133
46181
46378
46490
46389
46345
46526
46529
46549
46532
38518
38776
46411
46558
38206
FTG HYD 7/ 8 J X 7/ 8 OR
FTG STR 9/ 16 J 3/ 8 NPT
FTG HYD 1-1/ 16J 1-1/ 16 OR
FTG HYD 9/ 16 J 3/ 4 OR
FTG HYD TEE 9/ 16 J RUN
FTG HYD 7/ 8 J 3/ 4 NPT
HOSE HYD 9/ 16 FJ 9/ 16 FJ 60
2
2
2
1
1
4
1
1
2
38524
46362
44203
44204
38529
38727
46533
38446
46404
46496
46416
46846
46536
46494
46455
46405
46511
46119
46121
46415
46396
46414
38531
46410
CONTROL STEERING
1
1
2
2
1
1
1
1
1
1
2
2
1
4
3
1
2
2
1
1
1
2
1
2
24
25
26
27
28
29
30
CYLINDER TIE ROD 2.5 X 10
PIN CLEVIS 1"
RUE RING 1"
3
4
5
6
7
8
9
PRIORITY VALVE
MANIFOLD MODULAR
HOSE HYD 7/ 8 FJ X 7/ 8 FJ 73
COOLER HYD OIL
HOSE HYD 9/ 16 FJ 9/ 16 FJ 108 (54’s)
HOSE 9/ 16 FJ X 9/ 16 FJ 103 (43’s)
HOSE 7/ 8 FJ X 7/ 8 FJ 54
1
1
FTG EL 7/ 8J 1-1/ 16OR
FTG STR 9/ 16 J 1/ 4 NPT
HOSE 1-1/ 6 FJ X 1-1/ 16 FJ 96 (54’s)
HOSE 1-1/ 16 FJ 1-1/ 16 FJ 91 (43’s)
HOSE HYD 7/ 8 FJ 7/ 8 FJ 15
FTG HYD 1-1/ 16 J 7/ 8 OR
FTG HYD EL 45 1-1/ 16 JSW
HOSE 1 - 1/ 16 FJ X 1 - 1/ 16 FJ 53
FTG EL 1-1/ 16 J 7/ 8 OR
FTG EL 9/ 16 JSW 9/ 16 J
FTG EL 9/ 16 J 9/ 16 OR
HOSE 1-1/ 16 FJ 1-1/ 16 FJ 60
FTG EL 1-1/ 16 JSW
31
32
33
34
35
1
PUMP G EAR 1.54 CIR
1
O-RING 3 - 1/ 4 ID X 3/ 32 CS
FTG HYF 7/ 8J 1-1/ 16OR
1
2
10
11
12
13
14
15
16
17
19
20
21
22
FTG EL45 7/ 8JSW
1
**
HOSE WRAP 2.5 ID POLY (54’s)
HOSE WRAP 2.5 ID POLY (43’s)
72”
60"
A*
B
80561
80117
80174
80058
80716
HHCS 1/ 2 - 13 X 1 - 3/ 4 G R5
WSHRL 1/ 2 SPLIT ZN
2
2
3
5
2
57
-
(77)
-
C*
D
HHSC 3/ 8 - 16 X 1 G R8 ZN
WSHRL 3/ 8 SPLIT ZN
23
-
(31)
-
E*
HHCS 3/ 8 - 16 X 1 - 1/ 4 G R8 ZN
23
(31)
FTG STR 3/ 4 J 9/ 16 OR
MOTOR G EAR 1.48 CIR
HOSE 9/ 16 FJ 3/ 4 RJ 88"
- 87 -
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5.11 Bla d e
- 88 -
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5.11 Bla d e
Torq ue
Ite m
Pa rt No.
De sc rip tion
Qty.
FT. LBS. (Nm )
Ite m
Pa rt No.
De sc rip tion
Qty.
1
29830-2
29820-2
29819-2
29856-2
29857-2
29846-2
29831-2
29817-2
29741-2
38561
Bla d e We ld 43
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
2
2
2
-
23
25
26
27
28
29
42160-2
46462
46124
38526
38828
38828
ADJ Bla d e Va lve
2
1
1
1
Bla d e We ld 54
FTG EL90 7/ 8 JSW
3
4
5
6
7
Pivo t We ld Bla d e
FTG STR 7/ 8 J X 7/ 8 OR
Va lve CONTROL
Cle vis We ld Bla d e LH
Cle vis We ld Bla d e RH
Skid We ld Bla d e
Ho se Wra p 1.5 ID POLY
Ho se Wra p 1.5 ID POLY
44"
44"
Lip We a r Bla d e 43
Lip We a r Bla d e 54
A
B
80051
80343
80405
80672
80671
80677
80117
80378
80085
80348
80070
80114
80170
80058
80088
80346
80693
NUTNY 1/ 2 - 13 ZN
22
30
8
57
-
(77)
8
9
WSHR 2 - 3/ 4 ID X 17/ 32 X 1/ 4 TH
Cle vis 1/ 4 DIR X 1/ 4 - 28
Ca b le F/ R
WSHR 1/ 2 SAE ZN
-
C
HHSC 1/ 2 - 13 X 2 - 3/ 4 G R5 ZN
HHCS 3/ 4 - 10 X 3 G R8 ZN
WSHRL 3/ 4 SPLIT ZN
57
282
-
(77)
10
11
12
13
14
15
16
17
18
38602
D
E
4
(382)
46489
Ho se 7/ 8 J X 7/ 8 J 14
FTG EL 90 7/ 8 J X 7/ 8 OR
Mo unt We ld Bla d e Va lve
FTG EL 45 9/ 16 J
4
-
46133
F
CRBLT 1/ 2 - 13 X 1 - 1/ 2 ZN
WSHRL 1/ 2 SPLIT ZN
14
2
-
-
42115-2
46544
G
H
I
-
-
HHCS 1/ 2 - 13 X 1 G R5 ZN
HWHTB 5/ 16 - 18 X 1 ZN
WSHR 5/ 16 WROT ZN
PPHMS 10 - 24 X 1 ZN
NUTNY 5/ 16 - 18 ZN
2
57
18
-
(77)
46490
FTG STR 9/ 16 J X 3/ 4 OR
Ho se JSW X 9/ 16 JSW 48"
FTG TEE TUBE 9/ 16J
2
(18)
46528
J
4
-
46388
K
L
1
-
-
46547
Ho se 9/ 16 FJ X 9/ 16 FJ 60"
Ho se 9/ 16 JFJ X 9/ 16 FJ 56"
Ho se 9/ 16 FJ X 9/ 16 FJ 70"
Ho se 9/ 16 FJ X 9/ 16 FJ 66"
FTG EL90 9/ 16 J X 3/ 8 NPT
FTG EL 45 X 3/ 8 NPT X 9/ 16 J
Cylind e r Tie Ro d 2 X 8
Pin Cle vis 1"
2
-
-
46551
M*
N
O*
P
HHCS 5/ 16 - 18 X 2 - 1/ 2 G R5 ZN
WSHR 3/ 8 SPLIT ZN
2
13
-
(18)
19
46546
2
-
2
-
46552
HHCS 3/ 8 - 16 X 1 - 1/ 4 G R8 ZN
WSHR #10 SAE ZN
2
23
-
(31)
20
21
22
46120
2
2
2
4
4
2
-
-
46369
Q
NUTNY #10 - 24 ZN
1
-
46444
- 89 -
44203
44204
RUE RING 1"
REMARK:
* Lo c tite Re q uire d
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5.12 Hyd ra ulic Sc he m a tic
- 90 -
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5.12 Hyd ra ulic Sc he m a tic
Ite m
Pa rt No.
De sc rip tion
Qty.
Ite m
Pa rt No.
De sc rip tion
Qty.
1
2
3
4
38522
38518
38523
38520
38638
38524
38521
46362
38528
38527
38529
38531
35482
38727
38526
46444
38663
38689
38446
Tra nsm issio n Pum p
Pum p Ste e ring Ec c e ntric
Flo w Divid e r Co m b ine r 33/ 67
Filte r Hyd ra ulic
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1
1
Ele m e nt File r
5
Co ntro l Ste e ring
6
Bre a the r Fille r
7
Cylind e r Ste e ring 2.5 x 10
Whe e lm o to r Re a r
Whe e lm o to r Fro nt with Bra ke
Va lve Prio rity Ste e ring
Mo to r Ec c e ntric
8
9
10
11
12
13
14
15
16
17
18
Stra ine r 25G PM
Ma nifo ld Ec c e ntric s
Va lve Bla d e
Cylind e r Bla d e 2 x 8
Flo w Divid e r Co m b ine r 50/ 50
Va lve Bra ke
Co o le r Oil
- 91 -
REMARK:
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5.13 Wiring
- 92 -
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5.13 Wiring
Ite m
Pa rt No.
De sc rip tion
Qty.
1
39609
39611
39610
39607
48406
39599
39598
39608
38711
36313
39612
39592
48401
39653
48393
48399
39097
39638
39639
38559
38519
36268
48404
48405
Vo lt Me te r
1
2
Ga g e Te m p
1
3
Ga g e Oil PSI
1
4
Ke y Switc h
1
5
Ha rne ss Wire
1
6
Se nd o r Te m p
1
7
Se nd o r Oil PSI
Re la y Sta rte r
1
8
1
9
Ho ld e r Fuse
1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Fuse 20A
1
Push Butto n
1
Inta ke He a te r
Re la y 70 Am p
Switc h Ec c e ntric
Lig ht 12V Re d
Re la y Tim e r 2 Se c
Co ntro l Fwd / Re vs
Co il Ec c e ntric Va lve
Co il Bra ke Va lve
Ala rm b a c k-up
Ba tte ry 24F 800CCA
Ho urm e te r
1
2
1
2
1
1
1
1
1
1
1
Ca b le Ba tte ry Re d 21”
Ca b le Ba tte ry Blk
1
23.4”
- 93 -
REMARK:
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5.14 De c a l Id e ntific a tion
2
3
1
4
- 94 -
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5.14 De c a l Id e ntific a tion
Ite m
Pa rt No.
De sc rip tion
Qty.
Ite m
Pa rt No.
De sc rip tion
Qty.
1
2
3
4
5
#
#
#
#
#
#
#
#
#
#
#
55148
55149
55204
55212
55215
55165
55201
55381
55213
55211
55374
55395
55206
55207
55422
55367
DECAL WARNING DIESEL
DECAL EAR PROTECTION
DECAL TANK LOG OS
1
1
2
4
2
1
2
1
1
1
1
1
1
1
1
1
DECAL TIE DOWN ONLY
DECAL WARNING PINCH POINT
INSTRUCTIONS HYD FILTER
DECAL STONE EAG LE 21-1/ 2
DECAL MAINT CHART RHINO
DECAL RHINO DASH
DECAL BACK-UP ALARM
DECAL COWL STRIPES
DECAL G REASE WEEKLY
DECAL CONTROL F/ R
DECAL THROTTLE
DECAL HYDRAULIC FLUID
DECAL INSTRUMENT
- 95 -
REMARK:
# No t Sho wn
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5.14 De c a l Id e ntific a tion Cont'd .
1
1
1
1
1
3
2
- 96 -
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5.14 De c a l Id e ntific a tion Cont'd .
Ite m
Pa rt No.
De sc rip tion
Qty.
Ite m
Pa rt No.
De sc rip tion
Qty.
1
55366
DECAL SET WARNINGS
1
(Inc lud e s 5 d e c a ls liste d b e lo w)
De c a l Co ld Sta rting Instruc tio ns
De c a l Inta ke He a te r Butto n
De c a l Wa rning Ho t Surfa c e s
De c a l Wa rning No Ethe r
55369
55370
55371
55372
55373
De c a l Wa rning Tip o ve r
2
3
#
55416
55217
55209
De c a l Hyd ra ulic Bre a the r Re m o va l
De c a l Rhino To wing
1
1
1
De c a l Ma inte na nc e Cha rt
- 97 -
# No t Sho wn
REMARK:
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