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TSE DPT60 Owner's Manual

Puller/tensioner
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Table of Contents

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Owner's Manual
Model: DPT60
Puller/Tensioner
Serial Number 19-5230-01
www.tse-international.com
5301 Shreveport Blanchard Hwy – Shreveport, Louisiana 71107 – USA
P: 318-929-2368
F: 318-929-4853

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  • Page 1 Owner’s Manual Model: DPT60 Puller/Tensioner Serial Number 19-5230-01 www.tse-international.com 5301 Shreveport Blanchard Hwy – Shreveport, Louisiana 71107 – USA P: 318-929-2368 F: 318-929-4853...
  • Page 2 • Quick change reel shaft with straight vertical lift. *Maximum Linespeed ....... 0-4 mph • Engraved operator’s console. At TSE, engineering is a process of continuous product improvement; therefore, specifications are subject to change without notice. Toll Free: 800.825.2402 5301 Shreveport-Blanchard Hwy Telephone: 318.929.2368...
  • Page 3 30 days allowing for sufficient time for submission to TSE. Warranties claimed without a valid claim number may be denied. 2. Please retain any defective parts for a period of 60 days. TSE reserves the right to inspect and/or evaluate any parts submitted for warranty consideration.
  • Page 4 Recommendations for improving this publication are encouraged and should be forwarded to: TSE INTERNATIONAL 5301 Shreveport-Blanchard Hwy. Shreveport, Louisiana 71107 This is not a tension stringing operation procedures manual. No attempt is made or implied herein to instruct the user in methods peculiar to the individual application of the equipment described in this manual.
  • Page 5 PREMIUM CUSTOMER SERVICES TSE supports its innovative products with Premium Customer Service. Our comprehensive Service Department provides TSE customers with the service, parts, and technical assistance they need to maintain their equipment in top operating condition. For Customer Service on Your...
  • Page 6 On large components such as transmissions, engines, multiple pump drives, etc., the manufacturer’s serial number and spec. number is necessary to ensure receiving the proper replacement part. www.tse-international.com 5301 Shreveport Blanchard Hwy – Shreveport, Louisiana 71107 – USA P: 318-929-2368...
  • Page 7 Make certain all personnel are clear of this equipment before starting engine or operation. Before leaving the operators position, make sure that directional controls are in the neutral position and all brakes are set. www.tse-international.com 5301 Shreveport Blanchard Hwy – Shreveport, Louisiana 71107 – USA P: 318-929-2368 F: 318-929-4853...
  • Page 8 This Warranty to repair applies only to new and unused machinery, which, after shipment from the factory of TSE, has not been altered, changed, repaired or treated in any manner whatsoever unless such alteration, change, repair or treatment has been previously authorized in writing by TSE or has been performed by the authorized service representative of TSE.
  • Page 9 IEEE STD 524-2003” The above publication is available through the following organization: THE INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS, INC. 3 PARK AVENUE NEW YORK, NY 10016-5997 www.tse-international.com 5301 Shreveport Blanchard Hwy – Shreveport, Louisiana 71107 – USA P: 318-929-2368 F: 318-929-4853...
  • Page 10 If any of these decals are missing, please contact us for a replacement. Order the decal(s) by stating the decal description, number, and quantity. TSE INTERNATIONAL 5301 SHREVEPORT-BLANCHARD HWY. SHREVEPORT, LA 71107...
  • Page 13 DPT60 PULLER/TENSIONER SECTION I GENERAL DESCRIPTION SECTION II OPERATIONS SECTION III MAINTENANCE SECTION IV PARTS LIST F602501 FINAL ASSEMBLY – DPT60 8602488 GENERAL ASSEMBLY – DPT60 7601256-A POWER UNIT AND PUMP ASSEMBLY 7600517-B DRIVE ASSEMBLY 7600516 REEL SHAFT ASSEMBLY 8602229...
  • Page 14 GENERAL DESCRIPTION DPT60 PULLER / TENSIONER GENERAL The DPT60 is a Trailer mounted combination Puller/Tensioner used for both overhead and underground conductor installation. The unit has infinitely variable Linespeed and Linepull control from ZERO to the MAXIMUM performance of the machine.
  • Page 15 3. Reel Specifications Maximum Reel Diameter: 72 inch Maximum Width: 54 inch Maximum Weight: 6,000 lbs Reel Shaft Diameter: 3½ inch 4. Undercarriage Axle: 16K Tandem with Leaf Springs Tires: 9R17.5 HC Brakes: 12 1/4 x 3 3/8 ELECTRIC Leveling Jacks: 1- Front Manual Screw Type (Hydraulic Option) 2- Rear Manual or Hydraulic –...
  • Page 16 SECTION II OPERATIONS DPT60 PULLER / TENSIONER CONTROLS The controls that require explanation are described below. BEFORE OPERATING THIS EQUIPMENT FAMILIARIZE YOURSELF WITH ALL CONTROLS AND THEIR FUNCTION. ONLY FULLY TRAINED PERSONNEL SHOULD OPERATE THIS EQUIPMENT. Figure 1: Control Panel 1.
  • Page 17 pressure and therefore decreases the Linepull. Once the system pressure is set with the Linepull Control, the maximum Linepull will not exceed this setting. The Linepull can be set at any level from zero to the maximum Linepull rating. Figure 2 – Linepull Control Knob 3.
  • Page 18 4. Directional Control The reel turning speed (Linespeed) and direction is controlled by a single lever that regulates the degree of pump stroke in both directions from the NEUTRAL Position – See Figure 4. Movement of the Direction Control Lever in either direction – away from the operator for ‘Pay Out’, and toward the operator for ‘Pull In’...
  • Page 19 8. Charge Pressure Gauge This gauge displays the hydraulic system charge pressure. It should be approximately 300 psi. Engine: The manufacturer’s Engine Manual, which is included in the APPENDIX, contains detailed technical information regarding the engine. Make sure you read and understand the operating instructions contained therein.
  • Page 20 FIELD SET UP / ANCHORING Prepare the unit for operation as follows: 1. Locate the unit on level ground if possible, ensuring that the unit is aligned properly with the line to be pulled or tensioned. 2. Level the unit using the front and rear jacks. 3.
  • Page 21 6. Put a hazard barrier around the perimeter of the unit to keep unauthorized personnel away from the equipment. 7. Perform daily inspection and preventative maintenance as required. OPERATION Cold Weather Operation – Hydraulic Oil Warm-Up Start the engine. Leave the Direction Control Lever (4) in the NEUTRAL position. And allow the system to run at a medium idle for twenty (20) minutes or until the indicator gauge on the suction filter reads less than ten (10) inches vacuum.
  • Page 22 4. Turn Linepull Control (2) to give 800psi on the hydraulic Pressure Gauge (1). This presets the linepull, at which you will start pulling. 5. Move the Direction Control Lever (4) to the NEUTRAL position. 6. Make sure the Tensioner operator knows you are about to start pulling, and has his machine correctly set, then turn Brake Control (3) to the RELEASE position.
  • Page 23 Tensioning This procedure describes how to set the DPT-60 when it is used as a Tensioner, and you are starting with SLACK PULLING ROPE or CONDUCTOR. DO NOT FOLLOW THIS PROCEDURE WHEN THERE IS TENSION ON THE CONDUCTOR 1. Increase the engine speed to FULL throttle. An engine operated at idle speed does not sufficiently power the hydraulic system, and may let the brake drag causing overheating of the brake and erratic control.
  • Page 24 Paying Out FOLLOW THIS PROCEDURE TO PAY OUT A PULLING ROPE OR CONDUCTOR WHEN IT IS NOT UNDER TENSION 1. Increase the engine speed to FULL throttle. An engine operated at idle speed does not sufficiently power the hydraulic system, and may let the brake drag causing damage or overheating of the brake.
  • Page 25 5. Turn out the Linepull Control (2) slowly, and this will start to allow the reel to pay out the rope or conductor as it is pulled by the load on it. Continue to turn out the Linepull Control until it is fully out and no tension remains in the rope/conductor. Freewheeling Pay-out w/ Mechanical Brake The Freewheeling ‘PAY OUT’...
  • Page 26 This procedure describes how to use the DPT-60 as an Underground Puller with the OPTIONAL Underground Pulling Reel and Heavy Duty Underground Levelwind. Underground Puller 1. Load underground reel into machine – See the LOADING THE REEL SECTION. 2. Reeve pulling rope through the bottom guide rollers of levelwind with the rope exiting straight into the manhole.
  • Page 27 Figures 7, 8 – Removing Drive Pin, Locking Latch ! WARNING/CAUTION! NEVER ATTEMPT TO INSTALL OR REMOVE A REEL UNLESS THE DRIVE ARM LOOP IS IN THE UPRIGHT POSITION. IF THE REEL SHAFT PIN IS REMOVED WITH THE DRIVE ARM IN ANY OTHER POSITION, THE REEL MAY FALL OUT OF ITS SUPPORTED POSITION, AND MAY CAUSE PERSONAL INJURY OR EQUIPMENT DAMAGE.
  • Page 28 Figure 9- Drive Arm/Lifting Loop in Vertical Position ALWAYS MAKE SURE THAT THE REEL IS PUSHED TIGHT AGAINST THE DRIVE ARM AND HELD SECURELY BY LIFTING LOOP/LOCKING COLLAR 7. Install Bronze bearing on end of reel shaft. 8. Attach lifting hooks to Drive Arm and Lifting Loop, and ensure they are balanced so reel remains level during lift.
  • Page 29 Towing: Before towing always check the following: 1. Front and rear jacks are fully retracted. 2. Operator protective screens are folded down. 3. Wheel brakes are operational. 4. Tires are inflated to proper pressure. Check that wheel chocks are removed and stored away properly.
  • Page 30 SECTION III MAINTENANCE This section contains schedules, recommendations, and procedures designed to ensure that the equipment is prepared for safe and efficient operation and to prolong the service life of the equipment. These maintenance instructions constitute basic requirements for an operational environment that is not extreme in temperature, humidity, airborne abrasives, or other conditions which would require preventative maintenance techniques to combat.
  • Page 31 TSE International and our component suppliers. Prior to start-up of new TSE International products, all fluid levels are to be checked to ensure correct operating levels. All lubrication and maintenance points are to be inspected and lubricated as illustrated on the Lubrication and Maintenance Instructions sheet.
  • Page 32 LUBRICATION DATA GRAD LUBRICANT LUBRICANT INFORMATION PART APPLICATION TSE STANDARD HYDRAULIC FLUID (REFER TO HYDRAULIC OIL DECAL LOCATED ON 56785 HYDRAULIC AW46 ISO 46 HYDRAULIC RESERVOIR TO SYSTEM FLUID DETERMINE WHAT HYDRAULIC FLUID IS USED IN YOUR MACHINE) BEARINGS, UTILITY EP...
  • Page 33 SUGGESTED MAINTENANCE SCHEDULE The following schedule should be carried out by qualified personnel using proper lubricants to suit environmental and operating conditions. NOTE: THESE ARE SUGGESTED RECOMMENDATIONS ONLY. SPECIFIC SITUATIONS MAY REQUIRE A DIFFERENT LUBRICATION SCHEDULE. ALTER AS NECESSARY. HOURS 1000 SERVICE DAILY...
  • Page 34 Exhaust Regen Codes: Note: The Regen Interlock Switch must be turn on for manual/parked regen. WARNING! The Machine must not be operated while the engine is performing a manual/parked regen. See engine manual in vendor literature section of this manual for more detailed information on manual/parked regen.
  • Page 48 4.5 L OEM Diesel Engines (Final Tier 4/Stage IV Platform) OPERATOR'S MANUAL 4.5 L OEM Diesel Engines (Final Tier 4/Stage IV Platform) OMRG39498 ISSUE 19MAR15 (ENGLISH) CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
  • Page 50 Introduction OEM Engine and Drivetrain Warranty Registration RG24614 —UN—21OCT13 Why registering your OEM engine or drivetrain product is a really smart idea: Get faster service. Registering your engine or drivetrain product gives us the information we need to meet your service needs promptly and completely.
  • Page 51 Introduction Foreword READ THIS MANUAL carefully to learn how to operate needs these numbers when you order parts. File the and service your engine correctly. Failure to do so could identification numbers in a secure place off the engine. result in personal injury or equipment damage. SETTING FUEL DELIVERY beyond published factory THIS MANUAL SHOULD BE CONSIDERED a permanent specifications or otherwise overpowering will result in loss...
  • Page 52 Introduction Identification Views 4045HFC09 Left View 4045HFC09 Right View Continued on next page ZE59858,0000007 -19-11MAR14-1/2 032015 PN=5...
  • Page 53 Introduction 4045HFC04 Left View 4045HFC04 Right View ZE59858,0000007 -19-11MAR14-2/2 032015 PN=6...
  • Page 54 Introduction Trademarks Trademarks AdBlue is a trademark of VDA, the German Association of the AdBlue® Automotive Industry. AMP® AMP is a trademark of Tyco Electronics BIO-GREASE-GARD™ BIO-GREASE-GARD is a trademark of Deere & Company Bio Hy-Gard™ Bio Hy-Gard is a trademark of Deere & Company Bluetooth®...
  • Page 55 Introduction Vari-Cool™ Vari-Cool is a trademark of Deere & Company WEATHER PACK® WEATHER PACK is a trademark of Packard Electric WINDOWS® WINDOWS is a trademark of Microsoft Corporation ZE59858,0000006 -19-13FEB14-2/2 032015 PN=8...
  • Page 56 Contents Page Page Record Keeping Record Engine Serial Number......01-1 Fuels, Lubricants, and Coolants Engine Option Codes .........01-2 Diesel Exhaust Fluid (DEF) — Use in Record Aftertreatment Serial Numbers ....01-4 Selective Catalytic Reduction (SCR) Record High-Pressure Fuel Pump Equipped Engines ..........10-1 Model Number..........01-4 Storing Diesel Exhaust Fluid (DEF)....10-1 Record ECU Serial Number .......01-5...
  • Page 57 Contents Page Page Checking and Adjusting Engine Speeds ..40-10 Engine Operation Checking Engine Mounts........40-10 Checking Engine Ground Connection ....40-10 Break-In Service ..........20-1 Generator Set (Standby) Applications ....20-1 Starting the Engine ..........20-2 Lubrication & Maintenance — 1500 Hours Normal Engine Operation ........20-3 Changing Open Crankcase Ventilation Cold Weather Operation........20-4 (OCV) Filter ............45-1...
  • Page 58 Contents Page 4.5 L Wiring Diagram 2........70-25 4.5 L Wiring Diagram 3........70-27 4.5 L Wiring Diagram 4........70-28 4.5 L Wiring Diagram 5........70-30 4.5 L Wiring Diagram 6........70-32 4.5 L Wiring Diagram 7........70-34 4.5 L Wiring Diagram 8........70-36 4.5 L Wiring Diagram 9........70-38 4.5 L Wiring Diagram 10........70-40 4.5 L Wiring Diagram 11 ........70-42 4.5 L Wiring Diagram 12........70-44...
  • Page 59 Contents 032015 PN=4...
  • Page 60 Record Keeping Record Engine Serial Number JOHN DEERE Each engine has a 13-digit John Deere engine serial number. The first two digits identify the factory that Engine Serial Number produced the engine: PE4045U123456 • CD — Saran, France • PE — Torreon, Mexico 4045HFC09 1.
  • Page 61 Record Keeping Engine Option Codes JOHN DEERE PE4045U123456 Number 4045HFC09 4.5 L 2653PE 1111 1399 1425 1524 1606 1708 1928 2002 2699 2815 2909 3008 3512 3914 4026 4391 4607 4702 4803 4903 5002 5103 5215 5407 5511 5615 5709 5927 6543 6801...
  • Page 62 Record Keeping Option Codes Description Option Codes Description Open Crankcase Ventilation System Decomposition Tube Starter Motor SCR Converter Alternator Electronic Software Option DEF Line Air Conditioning (A/C) Compressor (Optional) DEF Tank Sender Switches and Sensors Fuel Filter Air Compressor Mounting Front Plate Engine Certification Thermostat Housing...
  • Page 63 Record Keeping Record Aftertreatment Serial Numbers Record the numbers from your aftertreatment device as shown on DPF (A and B), DOC (C and D), and SCR (E and F) serial number plates. Having these numbers recorded and kept in a safe location can aid in part ordering and assist in locating stolen items in case of theft.
  • Page 64 Record Keeping Record ECU Serial Number Record the part number and serial number information found on the serial number label on the Engine Control Unit (ECU). Part No. Serial No. A—Serial Number Label ZE59858,000000C -19-12AUG14-1/1 01-5 032015 PN=17...
  • Page 65 Safety 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.
  • Page 66 Safety Follow Safety Instructions Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer.
  • Page 67 Safety Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.
  • Page 68 Safety 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.
  • Page 69 Safety Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. DX,WEAR2 -19-03MAR93-1/1 Service Machines Safely Tie long hair behind your head.
  • Page 70 Safety Support Machine Properly Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices can settle or leak down.
  • Page 71 Safety Illuminate Work Area Safely Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.
  • Page 72 Safety Protect Against High Pressure Spray Spray from high pressure nozzles can penetrate the skin and cause serious injury. Keep spray from contacting hands or body. If an accident occurs, see a doctor immediately. Any high pressure spray injected into the skin must be surgically removed within a few hours or gangrene may result.
  • Page 73 Safety Do Not Open High-Pressure Fuel System High-pressure fluid remaining in fuel lines can cause serious injury. Do not disconnect or attempt repair of fuel lines, sensors, or any other components between the high-pressure fuel pump and nozzles on engines with High Pressure Common Rail (HPCR) fuel system.
  • Page 74 Safety Avoid Static Electricity Risk When Refueling The removal of sulfur and other compounds in Ultra-Low Sulfur Diesel (ULSD) fuel decreases its conductivity and increases its ability to store a static charge. Refineries may have treated the fuel with a static dissipating additive.
  • Page 75 Safety 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. DX,FIRE2 -19-03MAR93-1/1 Handle Starting Fluid Safely Starting fluid is highly flammable. Keep all sparks and flame away when using it.
  • Page 76 Safety Handling Batteries Safely Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Always remove grounded (-) battery clamp first and replace grounded clamp last.
  • Page 77 Safety Prevent Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2.
  • Page 78 Safety Live With Safety Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields. DX,LIVE -19-25SEP92-1/1 05-14 032015 PN=31...
  • Page 79 Fuels, Lubricants, and Coolants Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines Diesel exhaust fluid (DEF) is a high purity liquid that is (API) Diesel Exhaust Fluid Certification Program or by injected into the exhaust system of engines equipped with the AdBlue™...
  • Page 80 Fuels, Lubricants, and Coolants Refilling Diesel Exhaust Fluid (DEF) Tank CAUTION: Avoid contact with eyes. In case of contact, immediately flush eyes with large amounts of water for a minimum of 15 minutes. Reference the Materials Safety Data Sheet (MSDS) for additional information. Do not ingest DEF.
  • Page 81 Fuels, Lubricants, and Coolants Testing Diesel Exhaust Fluid (DEF) IMPORTANT: Using DEF with the correct suspicion the engine or packaged DEF fluid has been concentration is critical to engine and contaminated with water. aftertreatment system performance. Extended Two approved tools are available through your John storage and other conditions can adversely Deere dealer: alter the DEF concentration.
  • Page 82 Fuels, Lubricants, and Coolants Diesel Fuel Consult your local fuel distributor for properties of the Sulfur Content for Tier 3 and Stage III A Engines diesel fuel available in your area. • Use of diesel fuel with sulfur content less than 1000 In general, diesel fuels are blended to satisfy the low mg/kg (1000 ppm) is RECOMMENDED.
  • Page 83 Fuels, Lubricants, and Coolants Lubricity of Diesel Fuel Most diesel fuels manufactured in the United States, If fuel of low or unknown lubricity is used, add John Deere Canada, and the European Union have adequate lubricity Fuel-Protect Diesel Fuel Conditioner (or equivalent) at to ensure proper operation and durability of fuel injection the specified concentration.
  • Page 84 Fuels, Lubricants, and Coolants BioDiesel Fuel BioDiesel fuel is comprised of mono-alkyl esters of long BioDiesel Use Requirements and Recommendations chain fatty acids derived from vegetable oils or animal fats. BioDiesel blends are BioDiesel mixed with petroleum The petroleum diesel portion of all BioDiesel blends must diesel fuel on a volume basis.
  • Page 85 Fuels, Lubricants, and Coolants • Possible reduction in water separator efficiency ash loading and require more frequent cleaning of the • Possible damage to paint if exposed to BioDiesel Exhaust Filter (if present) • Possible corrosion of fuel injection equipment IMPORTANT: Raw pressed vegetable oils are •...
  • Page 86 Fuels, Lubricants, and Coolants Minimizing the Effect of Cold Weather on Diesel Engines John Deere diesel engines are designed to operate Diesel Fuel Flow Additive effectively in cold weather. Use John Deere Fuel-Protect Diesel Fuel Conditioner However, for effective starting and cold-weather (winter formula), which contains anti-gel chemistry, or operation, a little extra care is necessary.
  • Page 87 Fuels, Lubricants, and Coolants John Deere Break-In Plus™ Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV New engines are filled at the factory with John Deere • API Service Category CJ-4 Break-In Plus™ Engine Oil. During the break-in period, •...
  • Page 88 Fuels, Lubricants, and Coolants Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV — OEM Applications Recommended oil and filter service intervals are based Approved Oil Types on a combination of oil pan capacity, type of engine oil •...
  • Page 89 Fuels, Lubricants, and Coolants Diesel Engine Oil and Filter Service Intervals • The oil and filter service intervals in the following table Use only approved oil types. should be used as guidelines. Actual service intervals also depend on operation and maintenance practices. It Approved Oil Types is suggested to use oil analysis to determine the actual •...
  • Page 90 Fuels, Lubricants, and Coolants Alternative and Synthetic Lubricants Conditions in certain geographical areas may require The temperature limits and service intervals shown in lubricant recommendations different from those printed in this manual apply to both conventional and synthetic this manual. lubricants.
  • Page 91 Fuels, Lubricants, and Coolants Diesel Engine Coolant (engine with wet sleeve cylinder liners) • Preferred Coolants Coolant concentrate meeting ASTM D6210 requirements in a 40—60% mixture of concentrate with The following pre-mix engine coolants are preferred: quality water • John Deere COOL-GARD™II If coolant meeting one of these specifications is •...
  • Page 92 Fuels, Lubricants, and Coolants Water Quality for Mixing with Coolant Concentrate Engine coolants are a combination of three chemical Freeze Protection components: ethylene glycol (EG) or propylene glycol (PG) antifreeze, inhibiting coolant additives, and quality The relative concentrations of glycol and water in the water.
  • Page 93 Fuels, Lubricants, and Coolants Testing Coolant Freeze Point The use of a handheld coolant refractometer is the quickest, easiest, and most accurate method to determine coolant freeze point. This method is more accurate than a test strip or a float-type hydrometer which can produce poor results.
  • Page 94 Instrument Panels Instrument Panel John Deere PowerTech™ OEM engines have an electronic control system, which has controls and gauges as shown. The following information applies only to those controls and gauges supplied by John Deere. Refer to your engine application manual for specific guidelines if John Deere-sourced controls and instrumentation are not used.
  • Page 95 Instrument Panels Diagnostic Gauge — Using The diagnostic gauge (A) allows the operator to monitor engine functions, view diagnostic trouble codes (DTC’s), and perform preliminary diagnostics. The gauge is linked to the electronic control system and sensors. The arrow keys (B) allows the operator to scroll between menu items.
  • Page 96 Instrument Panels Diagnostic Gauge — Main Menu NOTE: The engine does not need to be running to navigate the diagnostic gauge screens. If engine start up is desired, see Starting the Engine in the Engine Operation Section. The main menu is the starting point in accessing engine information and configuring the diagnostic gauge.
  • Page 97 Engine Operation Break-In Service 500 hours (B). (Top-load oil filter illustrated.) (See Changing Engine Oil and Replacing Filter in the Extra care during the first 100 hours of operation results in Lubrication & Maintenance — 500 Hours/12 Months satisfactory long-term engine performance and life. DO Section.) Fill crankcase with seasonal viscosity grade NOT exceed 100 hours of operation with break-in oil.
  • Page 98 Engine Operation Starting the Engine NOTE: The controls and instruments for your engine may be different from those shown here; always follow manufacturer's instructions. The following instructions apply to the optional controls and instruments available through the John Deere Parts Distribution Network.
  • Page 99 Engine Operation Normal Engine Operation Observe engine coolant temperature and engine Stop engine immediately if there are any signs of part oil pressure. Temperatures and pressures will vary failure. Symptoms that may be early signs of engine between engines and with changing operating conditions, problems are: temperatures, and loads.
  • Page 100 Engine Operation Cold Weather Operation B C D E 41˚F (5˚C) 32˚F (0˚C) 14˚F (-10˚C) 0˚F (-18˚C) -4˚F (-20˚C) Starting Fluid is Flammable -13˚F (-25˚C) -22˚F (-30˚C) -31˚F (-35˚C) -40˚F (-40˚C) Cold Weather Starting Guidelines A— Minimum Cranking RPM C— Electric Air Heat E—...
  • Page 101 Engine Operation Warming Engine within 5 seconds, stop the engine and determine the cause. Normal engine oil pressure is measured IMPORTANT: To assure proper lubrication, operate at rated full load speed (1800–2500 rpm) with oil at engine at or below 1200 rpm with no load for 1–2 normal operating temperature of 97 °C (207 °F).
  • Page 102 Engine Operation Stopping the Engine NOTE: Engines in generator set applications where the ECU is locked at a specified speed and no slow idle function is available, run engine for at least 2 minutes at fast idle and no load. If an Exhaust Filter Cleaning has just been performed, increase engine idle time to 4 minutes.
  • Page 103 Engine Operation Auxiliary Gear Drive Limitations IMPORTANT: When attaching an air compressor, hydraulic pump, or other accessory to be driven by the auxiliary gear drive (engine timing gear train at front of engine), power requirements of the accessory must be limited to values listed below: IMPORTANT: See OEM engine distributor for more information to prevent overloading the auxiliary...
  • Page 104 Aftertreatment System Exhaust Filter Cleaning and Maintenance Exhaust Filter A—Exhaust Filter C—Diesel Oxidation Catalyst B—Diesel Particulate Filter (DPF) (DOC) The purpose of these instructions is to provide proper management of ash generated by the exhaust filter (or “filter”) along with its proper disposal. RK80614,0000013 -19-16OCT12-1/1 Exhaust Filter —...
  • Page 105 Aftertreatment System Diesel Particulate Filter Maintenance and removal service. Generally, the ash removal service interval will far exceed the EPA required minimums of Service 3,000 hours for engines below 175hp/130kW and 4,500 The Exhaust Filter includes the Diesel Oxidation Catalyst hours for engines at or above 175hp/130kW.
  • Page 106 Aftertreatment System Exhaust Filter System Overview a John Deere vehicle, please see the vehicle operator manual for all exhaust filter cleaning NOTE: Operator display icons and procedures can vary operation information and procedures. in other applications. The information contained in this section specifically applies to only OEM engines using the diagnostic gauge.
  • Page 107 Aftertreatment System Selective Catalytic Reduction (SCR) System Overview SCR System A—SCR Catalyst C—DEF Dosing Unit E—DEF Tank B—DEF Dosing Injector D—DEF Tank Header Assembly IMPORTANT: Do not remove battery leads for at least Water vapor is a normal by-product of combustion. During 4 minutes after engine stops.
  • Page 108 Aftertreatment System Diagnostic Gauge Keys and Indicators Overview Diagnostic Gauge Indicators and Keys A—Diesel Exhaust Fluid (DEF) C—Exhaust Filter Indicator F— Caution Indicator K—Stop Indicator Indicator D—Auto Cleaning Disable G—Arrow Keys B—Engine Emissions Indicator H—Menu Key Temperature Indicator E—Engine Emissions System I—...
  • Page 109 Aftertreatment System RG22487 —UN—21AUG13 RG22488 —UN—21AUG13 Aftertreatment Indicators Overview The Diesel Exhaust Fluid (DEF) indicator illuminates when the DEF is low. Fill DEF tank. When the DEF indicator is combined with the warning indicator or stop engine indicator engine performance is reduced by the Engine Control Unit (ECU) because the DEF is below a measurable level.
  • Page 110 Aftertreatment System Passive Regeneration/Natural Cleaning additional exhaust filter soot to accumulate. For the best possible engine operation which requires the least Periodically, the exhaust filter will experience higher heat amount of operator interaction, the engine should be levels simply through the engine operating at higher worked at higher load conditions whenever possible and loads.
  • Page 111 Aftertreatment System Manual/Parked Exhaust Filter Cleaning NOTE: Operator display icons and procedures can vary in other applications. The information contained in this section specifically applies to only OEM engines. If you are operating a John Deere vehicle, please see the vehicle operator manual for all exhaust filter cleaning and handling information and procedures.
  • Page 112 Aftertreatment System Disable Exhaust Filter Cleaning NOTE: When AUTO or PARKED/MANUAL cleaning is enabled, the exhaust temperature may be high NOTE: Operator display icons and procedures can vary in under no load or light load conditions at certain other applications. The information contained in this times during the exhaust filter cleaning cycle.
  • Page 113 Lubrication and Maintenance Observe Service Intervals A repair shop or person of the owner’s choosing may maintain, replace, or repair emission control devices and systems. However, warranty service must be performed by an authorized John Deere service facility except in the case of emergency.
  • Page 114 Lubrication and Maintenance Lubrication and Maintenance Service Interval Chart Lubrication and Maintenance Service Intervals 6000 3000 4500 Hours of Daily/Be- Hours of 1500 Hours of Hours of Operation fore Every Operation Hours of Operation Operation or Every Required Startup or Every Operation or Every or Every...
  • Page 115 Lubrication & Maintenance — Daily Daily Prestarting Checks may indicate the need to replace the coolant pump seal. Contact your engine distributor Check the following items BEFORE STARTING THE or servicing dealer for repairs. ENGINE for the first time each day: •...
  • Page 116 Lubrication & Maintenance — 500 Hours/12 Months Servicing Fire Extinguisher A fire extinguisher (A) is available from your authorized servicing dealer or engine distributor. Read and follow the instructions which are packaged with it. The extinguisher should be inspected at least every 500 hours of engine operation or every 12 months.
  • Page 117 Lubrication & Maintenance — 500 Hours/12 Months CAUTION: Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2.
  • Page 118 Lubrication & Maintenance — 500 Hours/12 Months Changing Engine Oil and Replacing Filter IMPORTANT: Changing engine oil and filter every 500 hours or 12 months depends on the following requirements: • Engine equipped with an oil pan that allows capacity for this extended drain interval. •...
  • Page 119 Lubrication & Maintenance — 500 Hours/12 Months 5. Remove oil filter. Discard oil filter. 6. Apply clean engine oil to the new filter at the inner (B) and outer (C) seals and to filter threads. 7. Wipe both sealing surfaces of the header (D and E) with a clean rag.
  • Page 120 Lubrication & Maintenance — 500 Hours/12 Months Checking Open Crankcase Vent (OCV) Inspect OCV hoses (A, B, and C) for worn, cracked, leaking, or bulging. Check hose clamps (D, E, and F) for good clamp tension. Replace any worn or damaged parts. A—OCV Inlet Hose D—Clamp —...
  • Page 121 Lubrication & Maintenance — 500 Hours/12 Months Remove and Install Primary Fuel Filter Element NOTE: For applications other than OEM, refer to the application operator's manual for proper servicing, hourly replacement intervals, and filter locations. NOTE: Both the primary and the final fuel filter elements must be replaced at the same time.
  • Page 122 Lubrication & Maintenance — 500 Hours/12 Months Remove and Install Secondary Fuel Filter Element NOTE: For applications other than OEM, refer to the application operator's manual for proper servicing, hourly replacement intervals, and filter locations. 1. Thoroughly clean filter header (B) and surrounding area to prevent dirt and debris from entering fuel system.
  • Page 123 Lubrication & Maintenance — 500 Hours/12 Months Checking Tensioner Spring Tension A belt tension gauge will not give an accurate measure of the belt tension when automatic spring tensioner is used. Measure tensioner spring tension using a torque wrench and procedure outlined below: 1.
  • Page 124 Lubrication & Maintenance — 500 Hours/12 Months Pressure Testing Cooling System Test Radiator Cap Test Cooling System 1. Allow engine to cool, then carefully remove radiator CAUTION: Explosive release of fluids from cap. pressurized cooling system can cause serious burns. 2.
  • Page 125 Lubrication & Maintenance — 500 Hours/12 Months Checking and Adjusting Engine Speeds Use tachometer on the diagnostic gauge (A) to verify engine speeds. (See Engine Power and Speed Rating Specifications in the Specifications Section for engine speed specifications.) If engine speed adjustment is required, see your authorized servicing dealer or engine distributor.
  • Page 126 Lubrication & Maintenance — 1500 Hours Changing Open Crankcase Ventilation (OCV) Filter Service checks of the OCV include checking and/or replacement of worn, cracked, leaking, or bulging hoses and for good clamp tension on all hose ends. Expectation for minimal service interval will be at least 1500 hours or when the service indicator light comes on or as indicated by the diagnostic gauge.
  • Page 127 Lubrication & Maintenance — 3000 Hours/36 Months • Checking Crankshaft Vibration Damper Visually inspect vibration damper for cracks or damage. • Visually inspect viscous damper for leaks. IMPORTANT: The vibration damper is not repairable, • Visually inspect viscous damper for dents or bends in and should only be replaced due to unexpected housing.
  • Page 128 Lubrication & Maintenance — 3000 Hours/36 Months Valve Clearance Adjustment — #1 TDC 5. With engine locked at “TDC” of No. 1 piston compression stroke, use a bent feeler gauge to check valve clearance on No. 1 and 3 exhaust and No. 1 and 2 intake valves.
  • Page 129 Lubrication & Maintenance — 3000 Hours/36 Months Valve Clearance Adjustment — #4 TDC 6. Rotate flywheel 360° until No. 4 piston is at “TDC” of 7. Check and adjust valve clearance to the same its compression stroke. Rocker arms for No. 4 piston specifications on for No.
  • Page 130 Lubrication & Maintenance — 3000 Hours/36 Months Testing Glow Plugs for Continuity CAUTION: To prevent accidental starting of engine while performing this test, always disconnect NEGATIVE (—) battery terminal. 1. Remove glow plug wiring harness connector (C). 2. Using a multimeter, check resistance from terminal (B) to the outer body of glow plug (A).
  • Page 131 Lubrication & Maintenance — 4500 Hours/36 Months Access DEF Dosing Unit See your application manual for information on accessing the DEF dosing unit. ZE59858,000008D -19-23AUG13-1/1 Changing Diesel Exhaust Fluid (DEF) Dosing Unit Filter CAUTION: Avoid contact with eyes. In case of contact, immediately flush eyes with large amounts of water for a minimum of 15 minutes.
  • Page 132 Lubrication & Maintenance — 6000 Hours/72 Months Flushing and Refilling Cooling System CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly remove the pressure cap and allow pressure to relive before completely removing cap.
  • Page 133 Lubrication & Maintenance — 6000 Hours/72 Months NOTE: Drain coolant from the lowest point in the cooling system. This location will vary by application. 3. Drain all coolant from engine block. 4. Open radiator drain valve. Drain all coolant from radiator.
  • Page 134 Lubrication & Maintenance — 6000 Hours/72 Months Testing Thermostat Opening Temperature Removing Thermostats CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. DO NOT drain coolant until it has cooled below operating temperature. Always loosen radiator pressure cap or drain valve slowly to relieve pressure.
  • Page 135 Lubrication & Maintenance — 6000 Hours/72 Months Testing Thermostats Opening Temperature NOTE: Perform the following test for both thermostats. 1. Visually inspect thermostats for corrosion or damage. Replace as a matched set, as necessary. CAUTION: DO NOT allow thermostat or thermometer to rest against the side or bottom of container when heating water.
  • Page 136 Lubrication & Maintenance — 6000 Hours/72 Months Installing Thermostats 1. Install new rubber seal for each thermostat (A). 2. Install thermostats into housing (D). 3. Install thermostat cover (B) and tighten thermostat cover cap screws (C) to specifications. Specification Thermostat Cover Cap Screw—Torque.............
  • Page 137 Service As Required Additional Service Information This is not a detailed service manual. If you want more detailed service information, contact your John Deere dealer or engine distributor. Component Technical Manuals RK80614,0000038 -19-16OCT12-1/1 Do Not Modify Fuel System IMPORTANT: Modification or alteration of the high-pressure fuel pump, the injection timing, or the fuel injectors in ways not recommended by the manufacturer will terminate the warranty...
  • Page 138 Service As Required Drain Water From Fuel Filters The primary fuel filter (A) is equipped with a sensor that detects the presence of water in the fuel filter element. This sensor will illuminate the “STOP ENGINE” warning light on the diagnostic gauge and also sound an audible alarm.
  • Page 139 Service As Required Cleaning Diesel Exhaust Fluid (DEF) Tank NOTE: Cleaning can take place with DEF tank installed or removed. CAUTION: Avoid contact with eyes. In case of contact, immediately flush eyes with large 2. Clean DEF tank with new DEF. amounts of water for a minimum of 15 minutes.
  • Page 140 Service As Required • Pre-Start Cleaning Guide Inspect difficult to observe areas daily as conditions may require additional cleaning care to remove debris. IMPORTANT: Before cleaning machine, allow ample • Check for oil and fuel leaks daily. Replace or repair any time for hot surfaces to cool.
  • Page 141 Service As Required Replacing Air Filter Element IMPORTANT: ALWAYS REPLACE primary air cleaner element when air filter restriction indicator shows a vacuum of 625 mm (25 in.) H is torn, or visibly dirty. NOTE: This procedure applies to John Deere 2-stage radial seal air cleaner kits.
  • Page 142 Service As Required Inspecting Primary Air Filter Element 1. Hold a bright light (A) inside element and check carefully for holes. Discard any element which shows the smallest hole or rupture. 2. Be sure outer screen (B) is not dented. Vibration would quickly wear a hole in filter.
  • Page 143 Service As Required Cleaning the Exhaust Filter The exhaust filter will require maintenance periodically. Some of the maintenance will be transparent to the operator. During continuous heavy loads and other conditions, the engine may create enough heat to naturally remove accumulated soot in the exhaust filter. When the exhaust filter has accumulated higher levels of soot, the display panel may request (depending on predefined user settings) an exhaust filter cleaning.
  • Page 144 Service As Required Replacing Fan Belt See Checking Tensioner Spring Tension in the Lubrication & Maintenance — 500 Hours/12 Months Section for additional information on the belt tensioner. 1. Inspect belt for cracks, fraying, or stretched out areas. Replace if necessary. 2.
  • Page 145 Service As Required • Checking Fuses JD Link fuse — 10 Amp • ECU fuse — 25 Amp (3 used) Check the following fuses located in the control panel • TVP fuse — 30 Amp wiring harness. Replace defective fuses. See 4.5 L Wiring Diagram 10 in the Troubleshooting •...
  • Page 146 Troubleshooting General Troubleshooting Information • Troubleshooting engine problems can be difficult. An Double-check before beginning the disassembly. • engine wiring diagram is provided in this section to help Determine cause and make a thorough repair. • isolate electrical problems on power units using John After making repairs, operate the engine under normal Deere wiring harness and instrument (gauge) panel.
  • Page 147 Troubleshooting FMI Code FMI Name Diagnostic Trouble Codes (DTCs) — Listing Extremely High NOTE: Not all of these codes are used in all Extremely Low engine applications. Invalid Out of Range High NOTE: Not all DTCs are listed below. See your application Out of Range Low technical manual for more information.
  • Page 148 Troubleshooting SPN Code SPN Name Injector #3 Injector #4 Injector #5 Injector #6 Unapproved Engine Speed Request External Shutdown Switch 1075 Low Pressure Fuel Pump Data 1136 ECU Temperature Signal 1172 Intake Air Temperature 1176 Intake Air Pressure 1180 Calculated VGT Turbine Inlet Temp 1209 Exhaust Manifold Pressure Signal 1347...
  • Page 149 Troubleshooting SPN Code SPN Name 4490 Intake Air Humidity 4765 DOC Inlet Temp 4766 DOC Outlet Temp 4795 DPF Missing 5018 DOC Fault Occurrences 5125 Sensor Supply #7 Voltage 5126 Sensor Supply #8 Voltage 5127 Sensor Supply #9 Voltage 5298 DOC Efficiency 5435 DEF Dosing Unit Pump...
  • Page 150 Troubleshooting Intermittent Fault Diagnostics Intermittent faults are problems that periodically “go • If diagnostic charts on preceding pages indicate that the away”. A problem such as a terminal that intermittently problem is intermittent, try to reproduce the operating doesn't make contact can cause an intermittent fault. conditions that were present when the diagnostic Other intermittent faults may be set only under certain trouble code (DTC) set.
  • Page 151 Troubleshooting Engine Troubleshooting display and perform the corrective actions. If any problems remain, use the following charts NOTE: Before troubleshooting the engine, first to solve engine problems. retrieve any fault codes on the diagnostic gauge Symptom Problem Solution Low battery output voltage or Engine Will Not Crank Charge or replace batteries.
  • Page 152 Troubleshooting Symptom Problem Solution Cold weather Use cold weather starting aids. See Cold Weather Operation in the Engine Operation Section. Too high viscosity crankcase oil Drain crankcase oil and replace with correct viscosity oil. Electronic Control System Problem or See your authorized John Deere Basic Engine Problem engine distributor or servicing dealer.
  • Page 153 Troubleshooting Symptom Problem Solution Turbocharger not functioning properly See your authorized John Deere engine distributor or servicing dealer. Air leak in engine intake or exhaust Check intake and exhaust manifold manifold gaskets and manifolds; repair as required. See your authorized John Deere engine distributor or servicing dealer.
  • Page 154 Troubleshooting Symptom Problem Solution Turbocharger not functioning properly Inspect turbocharger. See your authorized John Deere engine distributor or servicing dealer. Low engine temperature Remove and check thermostat. Fuel in Oil Restricted fuel return line Check and fix fuel return lines. Engine load too light Increase engine load Leaking fuel injectors...
  • Page 155 Troubleshooting Symptom Problem Solution Excessive valve clearance Check and adjust valve clearance. See Adjusting Valve Clearance in the Lubrication & Maintenance 3000 Hours/36 Months Section. Worn camshaft lobes Inspect camshaft. See your authorized John Deere engine distributor or servicing dealer. Worn rocker arm shaft(s) Inspect rocker arm shafts.
  • Page 156 Troubleshooting Symptom Problem Solution Excessive thrust bearing clearance Check and adjust thrust bearing clearance. See your authorized John Deere engine distributor or servicing dealer. High oil viscosity Drain engine oil and refill with correct viscosity engine oil Turbocharger “Screams” Leak in intake air system Check air system for loose clamps, damaged tubes, charged air cooler leaks, and intake manifold gasket...
  • Page 157 Troubleshooting Symptom Problem Solution Fluid other than DEF has been added Drain, flush, and fill DEF tank with new to the DEF tank DEF. See Cleaning Diesel Exhaust Fluid (DEF) Tank in the Service As Required Section. Engine Emits White Smoke Engine compression too low Determine cause of low compression and repair as required.
  • Page 158 Troubleshooting Symptom Problem Solution Electronic Control System problem or See your authorized John Deere basic engine problem engine distributor or servicing dealer. Turbocharger not functioning properly See your authorized John Deere engine distributor or servicing dealer. Engine Overheats Air cleaner restricted or dirty Replace air cleaner element as required.
  • Page 159 Troubleshooting Symptom Problem Solution Coolant Temperature Below Normal Defective thermostat(s) Test thermostats, replace thermostats as required. Defective temperature gauge or Check gauge, sender, and temperature sender connections. Coolant in Crankcase Cylinder head gasket defective Replace cylinder head gasket. See your authorized John Deere engine distributor or servicing dealer.
  • Page 160 Troubleshooting Symptom Problem Solution Excessive oil temperature Remove and inspect oil cooler. See your authorized John Deere engine distributor or servicing dealer. Defective oil pump Remove and inspect oil pump. See your authorized John Deere engine distributor or servicing dealer. Incorrect oil Drain crankcase and refill with correct oil.
  • Page 161 Troubleshooting Symptom Problem Solution External oil leak(s) Determine source of oil leak(s) and repair as required. Excessive oil pressure See High Oil Pressure Oil control rings not seated See your authorized John Deere engine distributor or servicing dealer. Oil control rings worn or broken Replace piston rings.
  • Page 162 Troubleshooting Symptom Problem Solution Excessive engine idling Increase engine rpm when heavy electrical load is used. Poor electrical connections on battery, Inspect and clean as necessary. ground strap, starter, or alternator Defective battery Test batteries. Defective alternator Test charging system. Battery Used Too Much Water Cracked battery case Check for moisture and replace as...
  • Page 163 Troubleshooting Engine Wiring Harness Layout A—Intake Air Sensor C—Engine Coolant Temperature E—Engine Oil Pressure Sensor B—Exhaust Manifold Pressure Sensor Sensor D—Crankshaft Position Sensor Continued on next page ZE59858,0000027 -19-30JUL14-1/4 70-18 032015 PN=116...
  • Page 164 Troubleshooting A—Exhaust Throttle Actuator C—Fuel Rail Pressure Sensor E—Camshaft Position Sensor B—Fuel Rail Pressure Relief D—Suction Control Valve Valve Continued on next page ZE59858,0000027 -19-30JUL14-2/4 70-19 032015 PN=117...
  • Page 165 Troubleshooting A—EGR Valve C—Cold Start Aid Relay E—Crankcase Pressure Sensor B—Charge Air Cooler Outlet D—Water-In-Fuel (WIF) Sensor Temperature Sensor Continued on next page ZE59858,0000027 -19-30JUL14-3/4 70-20 032015 PN=118...
  • Page 166 Troubleshooting A—Manifold Air Pressure Sensor C—EGR Temperature Sensor F— Low-Pressure Fuel Pressure B—Fuel Injector Harness D—EGR Flow Sensor Sensor Connector E—Fuel Temperature Sensor G—Manifold Air Temperature Sensor ZE59858,0000027 -19-30JUL14-4/4 70-21 032015 PN=119...
  • Page 167 Troubleshooting Precautions For Welding Remove paint before welding or heating (see Safety Section in this manual for more information on paint removal and high-pressure lines). CAUTION: Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.
  • Page 168 Troubleshooting 4.5 L Wiring Diagram 1 CYL 1 Y5021 Fuel Injector Harness Connector CYL 2 5495 5495 5495 5493 5493 5493 5498 5498 5498 5499 5499 5499 5496 5496 5496 5491 5491 5491 CYL 3 5410 Diagram 5 A5501 ECU Harness CYL 4 Connector 1 Y5004...
  • Page 169 Troubleshooting A— To 4.5 L Wiring Diagram 5 A5501-22— [5003 Orange] A5501-44— [5493 Orange] B5600— Water-In-Fuel Sensor A5501— ECU Harness Connector Low-Pressure Fuel Pump Injector #1 Pulse CYL 1— Cylinder 1 Power A5501-48— [5427 Violet] Fuel CYL 2— Cylinder 2 A5501-02—...
  • Page 170 Troubleshooting 4.5 L Wiring Diagram 2 B5101 Engine Oil Pressure Sensor 5631 5631 5633 5633 5467 5467 Y5402 Exhaust Throttle A5501 Actuator ECU Harness Connector 1 5631 5633 5509 5509 5018 5018 5016 5016 B5102 Exhaust Manifold Pressure Sensor 5626 5614 5465 5465...
  • Page 171 Troubleshooting A5501— ECU Harness Connector A5501-17— [5631 Brown] 5 A5501-41— [5633 Orange] 5 V K5803— Cold Start Aid Relay V Sensor Supply #3 Sensor Supply #3 Return R5604— Cold Start Aid A5501-07— [5423 Orange] EGR Positive A5501-52— [5425 Green] EGR Interconnect Valve Drive Negative A5501-21—...
  • Page 172 Troubleshooting 4.5 L Wiring Diagram 3 B5105 Crankcase Pressure Sensor 5621 5621 5623 5053 5053 B5205 Charge Air Cooler Outlet A5502 Temperature Sensor ECU Harness Connector 2 5455 5455 5623 5623 B5206 Manifold Air Temperature Sensor 5456 5456 5623 5628 Diagram 5 or 7 B5009...
  • Page 173 Troubleshooting 4.5 L Wiring Diagram 4 A5501 ECU Harness Connector 1 5818 5624 5015 5624 +5 V B5303 5023 5818 Fan Speed 5647 Return Sensor 5818 5015 5015 Signal 5023 Y5014 5647 Fan Solenoid Y5005 Variable Speed Fan 5624 5023 5023 5647 5647...
  • Page 174 Troubleshooting A5501— ECU Harness Connector A5502-24— [5625 Green] 5 V A5502-36— [5624 Yellow] 5 B5303— Fan Speed Sensor Sensor Supply #7 Return V Sensor Supply #7 E— To 4.5 L Wiring Diagram 9 A5501-47— [5818 Gray] Fan A5502-27— [5463 Orange] EGR Positive X5001—...
  • Page 175 Troubleshooting 4.5 L Wiring Diagram 5 B5500 Wiring Diagram For High Mount Dual Turbocharged Engines Intake Air Sensor Diagram 9 Or Single Turbocharged Engines A5501 5783 5628 ECU Harness 5804 Connector 1 5805 From Diagram 3 R5603 5805 5804 Engine CAN Terminator (120 Ohm) 5461...
  • Page 176 Troubleshooting A— [5410 Black] Wiring Shield A5501-29— [5443 Orange] A5501-45— [5804 Yellow] Engine F— [5783 Orange] 12 V Sensor From 4.5 L Wiring Diagram 1 Camshaft Position CAN High Supply To 4.5 L Wiring AA— Wiring Diagram For High Sensor Return A5501-46—...
  • Page 177 Troubleshooting 4.5 L Wiring Diagram 6 A5501 Wiring Diagram For Dual Turbocharged Engines ECU Harness With A Low Mount Fixed Turbocharger Connector 1 5030 5448 5447 5443 5445 5613 5611 5415 5756 5767 Diagram 9 B5301 Crankshaft X5040 Position Fuel System Sensor Interconnect (12 pin) (Used On Dual Turbocharged Engines With...
  • Page 178 Troubleshooting AA— Wiring Diagram For Dual A5501-29— [5443 Orange] A5501-38— [5447 Violet] X5040— Fuel System Turbocharged Engines Camshaft Position Crankshaft Position Interconnect (12 With A Low Mount Fixed Sensor Return Sensor Signal pin) (Used On Dual Turbocharger A5501-30— [5448 Gray] A5501-51—...
  • Page 179 Troubleshooting 4.5 L Wiring Diagram 7 A5501 Wiring Diagram For Dual Turbocharged Engines ECU Harness With A Low Mount Fixed Turbocharger Connector 1 B5500 Intake Air Sensor 5783 5628 5804 5805 5804 5805 5419 5424 5461 R5603 Engine CAN Terminator (120 Ohm) Y5002 Suction Control Valve...
  • Page 180 Troubleshooting 70-35 032015 PN=133...
  • Page 181 Troubleshooting 4.5 L Wiring Diagram 8 B5501 X5037 DEF Dosing Unit DEF Dosing Unit Interconnect 5141 5141 5309 5309 5146 5146 9 10 11 12 5303 5303 12 11 10 9 5301 5301 5305 5305 5304 5304 5306 5306 5308 5308 5307 5307...
  • Page 182 Troubleshooting A5502— ECU Harness Connector A5502-25— [5306 Blue] DEF A5502-46— [5309 White] DEF B5211— DEF Tank Fluid Dosing Unit Pump Dosing Unit Pressure Temperature Sensor A5502-07— [5141 Brown] 5 Position Signal Sensor Signal B5501— DEF Dosing Unit V Sensor Supply #8b A5502-31—...
  • Page 183 Troubleshooting 4.5 L Wiring Diagram 9 B5502 Aftertreatment Inlet NOx Sensor 5605 R5605 5602 5636 Aftertreatment 5636 CAN Terminator 5605 5604 (120 Ohm) 5604 B5503 Aftertreatment Outlet NOx Sensor A5502 ECU Harness Connector 2 5602 5636 5605 5604 5605 5604 B5109 5634 5785...
  • Page 184 Troubleshooting A5502— ECU Harness Connector A5502-35— [5604 Yellow] B5204— Aftertreatment G— [5030 Black] Wiring Shield Aftertreatment CAN High Temperature Module From 4.5 L Wiring Diagram 5 A5502-01— [5333 Orange] DEF A5502-38— [5786 Blue] B5502— Aftertreatment Inlet NOx or 4.5 L Wiring Diagram 6 Dosing Injector Drive Aftertreatment Sensor...
  • Page 185 Troubleshooting 4.5 L Wiring Diagram 10 A5502 ECU Harness Connector 2 5082 5426 G5000 5050 Battery 5422 5082 Diagram X5800 Starter Relay Coil (Power) Y5017 5422 Starter Solenoid G5001 Alternator K5801 Starter 5426 Relay 5082 From X5801 Diagram 2 Starter Relay Coil (Ground) V5700 5777 5050...
  • Page 186 Troubleshooting A5502— ECU Harness Connector A5503-27— [5050 Black] Battery F5010— Transient Voltage L— To 4.5 L Wiring Diagram 11 Negative Protection Fuse (30 A) M— [5092 Red] JD Link A5502-34— [5426 Blue] Alternator A5503-43— [5050 Black] Battery G5000— Battery Unswitched Power To 4.5 Excitation Negative G5001—...
  • Page 187 Troubleshooting 4.5 L Wiring Diagram 11 5911 5911 X5020 5012 5012 Auxiliary Connector 5714 5714 5971 5971 5954 5954 5913 5913 5027 5027 5039 5039 5939 5939 5941 5941 5917 5917 5773 5773 5648 5648 5937 5937 5816 5816 A5503 5981 5981 ECU Harness...
  • Page 188 Troubleshooting A5503— ECU Harness Connector A5503-21— [5020 Black] Primary A5503-41— [5956 Blue] Set I— [5002 Red] Control Panel CAN Shield Accelerator/Bump Up Unswitched Power From 4.5 A5503-01— [5905 Green] Primary A5503-22— [5017 Violet] AC High Switch L Wiring Diagram 10 CAN Low Pressure Switch A5503-45—...
  • Page 189 Troubleshooting 4.5 L Wiring Diagram 12 A5503 H5200 ECU Harness Exhaust Temperature High Lamp Connector 3 5025 5002 H5003 DPF Regeneration Required Lamp 5798 5002 5025 5798 5796 5029 5034 5038 5037 5047 5041 K5811 Y5025 Starter Relay Starter Solenoid (Application Specific) (Application Specific) 5034...
  • Page 190 Troubleshooting 4.5 L Wiring Diagram 13 5971 S5003 Cruise Cancel / 5050 Resume Switch 5954 S5004 5012 Cruise On Switch 5027 B5111 5050 Air Filter Switch 5039 P5301 5714 Vehicle Speed 5939 S5009 5050 External Derate Switch 5941 S5005 External Shutdown 5012 Switch X5020...
  • Page 191 Troubleshooting B5111— Air Filter Switch S5009— External Derate Switch X5020-G— [5027 Violet] Air Filter X5020-R— [5981 Brown] PWM H5000— Stop Engine Lamp S5100— AC High Pressure Switch Switch Throttle/Alternator O— Mating Connector Located U5000— PWM Throttle/Alternator X5020-H— [5039 White] Vehicle Feedback On 4.5 L Wiring Diagram 11 Feedback...
  • Page 192 Troubleshooting 70-47 032015 PN=145...
  • Page 193 Troubleshooting 4.5 L Wiring Diagram 14 X5021 S5000 Key Switch Control Panel Connector K5812 464 / 914 Control Panel 414 / 914 Start Relay Mating Connector Located On Diagram 11 S5013 Bump Enable Switch K5813 Control Panel Run Relay S5012 Speed Select Switch X5054 Remote Start...
  • Page 194 Troubleshooting A5504— Diagnostic Gauge A5504-25— [17 White] USB VBus X5021-D— [30 White] Start X5021-T— [936 White] Cruise A5504-1— [14 White] USB D K5812— Control Panel Start Relay X5021-E— [31 White] Battery Resume/Bump Down Negative K5813— Control Panel Run Relay Negative Switch A5504-3—...
  • Page 195 Storage Engine Storage Guidelines IMPORTANT: Special considerations should be 2. John Deere engines can be stored in a standard taken prior to storage when using BioDiesel. overseas shipping container for up to three months See BioDiesel Fuel in the Fuels, Lubricants, with no long-term preparation.
  • Page 196 Storage Removing Engine from Long-Term Storage NOTE: The following storage removal procedure is used 7. Perform all appropriate prestarting checks. See Daily for long-term engine storage up to one year. After Prestarting Checks in the Lubrication & Maintenance that, the engine should be started, warmed up, and —...
  • Page 197 Specifications General OEM Engine Specifications 4045HFC09 4045HFC04 ITEM UNIT OF MEASURE 4045HFG09 4045HFG04 General Data Number of Cylinders Bore mm (in.) 106 (4.2) 106 (4.2) Stroke mm (in.) 127 (5.0) 127 (5.0) Displacement L (cu in.) 4.5 (275) 4.5 (275) 17.2:1 17.0:1 Compression Ratio...
  • Page 198 Specifications 4045HFC09 4045HFC04 ITEM UNIT OF MEASURE 4045HFG09 4045HFG04 Maximum Air Intake Restriction (Bar) (3.0) (3.0) (psi) (0.44) (0.44) Maximum Exhaust Back Pressure (Bar) (7.5) (7.5) (psi) (1.09) (1.09) ZE59858,0000028 -19-19AUG14-2/2 80-2 032015 PN=151...
  • Page 199 Specifications Engine Power and Speed Rating vary depending upon specific vehicle application requirements. Refer to your machine operator's Specifications manual for engine speeds that are different NOTE: Engine speeds listed are preset to factory from those preset at the factory. specification for application.
  • Page 200 Specifications Engine Crankcase Oil Fill Quantities Oil Pan Option Code(s) Crankcase Oil Capacity L (qt) To determine the option code for the oil fill quantity of your ........engine, refer to the engine option code label affixed to 1903 13 (13.7) ........
  • Page 201 Specifications Metric Bolt and Screw Torque Values TS1670 —UN—01MAY03 12.9 10.9 12.9 12.9 12.9 10.9 Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9 Bolt or Screw Size Lubricated Lubricated Lubricated Lubricated N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in.
  • Page 202 Lubrication and Maintenance Records Using Lubrication and Maintenance Records Refer to specific Lubrication and Maintenance Section for the date in the spaces provided. For a complete listing detailed service procedures. of all items to be performed and the service intervals required, refer to the quick-reference chart near the 1.
  • Page 203 Lubrication and Maintenance Records 1500 Hours of Operation Service Change open crankcase ventilation (OCV) filter. Hours Date Hours Date Hours Date Hours Date ZE59858,00000DD -19-02AUG13-1/1 3000 Hours of Operation or Every 36 Months Service Check crankshaft vibration damper. Testing glow plugs for continuity. Adjust valve clearance.
  • Page 204 Lubrication and Maintenance Records 6000 Hours of Operation or Every 72 Months Service Flush cooling system. Test Thermostats. Hours Date Hours Date Hours Date Hours Date ZE59858,00000E0 -19-02AUG13-1/1 Service as Required Replace fan-alternator belt. Drain water from fuel filters when alarm sounds. Check fuses.
  • Page 205 Warranty John Deere Warranty in OEM Applications may ask our John Deere affiliates, dealers, or business partners to do work for us which involves your information. Overview For complete details on your privacy rights and to obtain a copy of the John Deere Privacy Statement, please visit This section focuses on John Deere engines marketed our website at https://www.johndeere.com/.
  • Page 206 Warranty At the time of requesting warranty service, the purchaser Service outlet costs incurred in solving or attempting to must be prepared to present evidence of the date of solve non-warrantable problems. delivery of the engine. Services performed by a party other than an authorized John Deere reimburses authorized service outlets for John Deere service dealer.
  • Page 207 Warranty Replacement Parts Warranty Local Warranty Requirements John Deere and John Deere Reman parts and Warranties required by local statutes will be furnished by components (excluding replacement engines) installed the seller. during engine warranty service are warranted for the Option Codes (Engine Manufacturing Configuration) remaining warranty period of the engine or the applicable warranty term for the installed service part, whichever is When in need of engine replacement parts, your...
  • Page 208 Warranty Emissions Control System Certification Label Engine Emissions Label The emissions label has applicable US EPA and/or CAUTION: Statutes providing severe penalties CARB regulatory year. The regulatory year determines for tampering with emissions controls may which warranty statement is applicable to engine. apply to the user or dealer.
  • Page 209 Warranty EPA Non-road Emissions Control Warranty Statement—Compression Ignition DXLOGOV1 —UN—28APR09 U.S. AND CANADA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS To determine if the John Deere engine qualifies for the additional warranties set forth below, look for the "Emissions Control Information" label located on the engine.
  • Page 210 Warranty DX,EMISSIONS,EPA -19-12DEC12-2/2 90-6 032015 PN=163...
  • Page 211 Warranty CARB Non-road Emissions Control Warranty Statement—Compression Ignition Emissions Control Warranty Statement 2013 through 2015 DXLOGOV1 —UN—28APR09 CALIFORNIA EMISSIONS CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS To determine if the John Deere engine qualifies for the additional warranties set forth below, look for the “Emission Control Information” label located on the engine.
  • Page 212 Warranty JOHN DEERE'S WARRANTY RESPONSIBILITY: Where a warrantable condition exists, John Deere will repair or replace, as it elects, your off-road diesel engine at no cost to you, including diagnosis, parts or labor. Warranty coverage is subject to the limitations and exclusions set forth herein. The off-road diesel engine is warranted for a period of five years from the date the engine is delivered to an ultimate purchaser or 3,000 hours of operation, whichever occurs first.
  • Page 213 Warranty Continued on next page DX,EMISSIONS,CARB -19-01AUG14-3/8 90-9 032015 PN=166...
  • Page 214 Warranty Continued on next page DX,EMISSIONS,CARB -19-01AUG14-4/8 90-10 032015 PN=167...
  • Page 215 Warranty Emissions Control Warranty Statement 2016 through 2018 DXLOGOV1 —UN—28APR09 CALIFORNIA EMISSIONS CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS To determine if the John Deere engine qualifies for the additional warranties set forth below, look for the “Emission Control Information” label located on the engine.
  • Page 216 Warranty JOHN DEERE'S WARRANTY RESPONSIBILITY: Where a warrantable condition exists, John Deere will repair or replace, as it elects, your off-road diesel engine at no cost to you, including diagnosis, parts or labor. Warranty coverage is subject to the limitations and exclusions set forth herein. The off-road diesel engine is warranted for a period of five years from the date the engine is delivered to an ultimate purchaser or 3,000 hours of operation, whichever occurs first.
  • Page 217 Warranty Continued on next page DX,EMISSIONS,CARB -19-01AUG14-7/8 90-13 032015 PN=170...
  • Page 218 Warranty DX,EMISSIONS,CARB -19-01AUG14-8/8 90-14 032015 PN=171...
  • Page 219 Warranty 90-15 032015 PN=172...
  • Page 220 Index Page Page Crankshaft vibration damper Checking ..............50-1 A/C compressor............65-9 Additional service information........65-1 Aftertreatment indicators overview ......25-6 Aftertreatment Serial Number........01-4 Aftertreatment system Daily prestarting checks ..........35-1 Restored operation option........25-9 Air compressor Disposal ..............10-3 Checking ..............
  • Page 221 Index Page Page Starting..............20-2 Disposal............... 25-2 Stopping..............20-6 Indicators............. 25-5 Troubleshooting ............70-6 Manual/parked cleaning ........25-8 Warming..............20-5 Passive regeneration/natural cleaning ....25-7 Engine Control Unit (ECU) serial number....01-5 Service required ..........25-9 Engine coolant System overview ..........25-3 Disposing of ............
  • Page 222 Index Page Page Lubricant Storage Lubricity of diesel fuel ..........10-5 Storage, Lubricant..........10-12 Lubricants, Safety Safety, Lubricants ..........10-12 Lubrication and maintenance Maintenance interval chart ......... 30-2 1500 hours Manual/parked filter cleaning........25-8 Changing open crankcase vent (OCV) filter..45-1 Metric bolt and screw torque values ......
  • Page 223 Index Page Page Inspecting primary air filter element ....65-6 Pre-start cleaning guide ........65-4 Replacing air filter element........65-5 Safety, Avoid High-Pressure Fluids Replacing fan belt..........65-8 Avoid High-Pressure Fluids ........05-9 Daily Safety, Handle Fuel Safely, Avoid Fires Prestarting checks..........
  • Page 224 Engine Registration OEM Engine and Drivetrain Warranty Registration RG24614 —UN—21OCT13 Why registering your OEM engine or drivetrain product is a really smart idea: Get faster service. Registering your engine or drivetrain product gives us the information we need to meet your service needs promptly and completely.
  • Page 225 Engine Registration IBC-2 032015 PN=178...
  • Page 226 Engine Registration Mail-In Registration OEM Engine and Drivetrain Warranty Registration Register your OEM engine or drivetrain product online at JohnDeere.com/warranty or fax this from to John Deere at 319-292-5844. PURCHASER INFORMATION*: Type or print in BLOCK letters PURCHASER TYPE: EQUIPMENT TYPE: Company Name: □...
  • Page 227 Engine Registration Mail-In Registration MAILING INFORMATION (Return Address) John Deere Power Systems P.O. Box 5100 Waterloo, IA 50704-5100 BL90236,0000029 -19-19NOV13-1/1 IBC-4 032015 PN=180...
  • Page 228 Engine Registration IBC-5 032015 PN=181...
  • Page 229 Engine Registration IBC-6 032015 PN=182...
  • Page 230 Series 90 Axial Piston Pumps and Motors Service Manual...
  • Page 231 Series 90 Introduction Introduction Use of this Manual This manual includes information for the normal opera- Since dirt and contamination are the greatest enemies of tion, maintenance, and servicing of the Series 90 family any type of hydraulic equipment, cleanliness require- of hydrostatic pumps and motors.
  • Page 232 Series 90 Contents Contents Introduction ..................................2 Use of this Manual ......................................2 Safety Precautions ......................................2 Functional Description ............................... 5 General Description and Cross Sectional Views ............................5 Variable Displacement Pumps ................................5 Fixed Displacement Motor ..................................5 Variable Displacement Motor .................................. 6 The System Circuit .......................................

  • Page 233: Table Of Contents

    Series 90 Contents Inspections and Adjustments ............................31 Pump Adjustments ...................................... 31 Charge Pressure Relief Valve Adjustment ............................31 Multi-Function Valve Pressure Adjustment ............................33 Engaging the Bypass Function ................................35 Pressure Override (POR) Valve Pressure Adjustment (Option for 180 Frame Size) ............... 36 Displacement Limiter Adjustment .................................
  • Page 234 Series 90 Functional Description Functional Description This section describes the operation of pumps, motors, and their various serviceable features. It is a useful reference for readers unfamiliar with the functioning of a specific system. General Description and Cross Sectional Views Variable Displacement Pumps The Variable Displacement Pump (PV) is designed to convert an input torque into hydraulic power.
  • Page 235 Series 90 Functional Description In the Fixed Displacement Motor the "swashplate" is fixed, so any variation in motor speed and torque must be Loop Flushing Valve made by the input mechanism, i.e. the pump. Piston Valve Plate Roller Bearing Output Shaft Fixed Swashplate End Cap Cylinder Block...
  • Page 236 Series 90 Functional Description The System Circuit System loop (low pressure) Control Handle Displacement Control Valve Case drain fluid Heat Exchanger System loop (high pressure) Bypass Valve Reservoir Orificed Control fluid Check Valve Vacuum Gauge Suction line Heat Exchanger Purge Relief Valve Charge Pressure Relief Valve Multi-Function...
  • Page 237 Series 90 Functional Description Common Features of Pumps and Motors End Caps and Shafts Series 90 pumps and motors can be supplied with a variety of end caps and shafts to allow for almost any configuration. For pumps, end caps are available with system ports on either side ("side ports") or both ports on one side ("twin ports").
  • Page 238 Series 90 Functional Description Pump Features Charge Pump The charge pump is necessary to supply cool fluid to the system, to maintain positive pressure in the main system loop, to provide pressure to operate the control system, and to make up for internal leakage. Charge pressure must be at its specified pressure under all conditions of driving and braking to prevent damage to the transmis- sion.
  • Page 239 Series 90 Functional Description Pressure Limiter and High Pressure Relief Valves Series 90 pumps are designed with a sequenced pres- Pressure Limiter Housing sure limiting system and high pressure relief valves. High Pressure Check Valve Relief / check When the preset pressure is reached, the pressure limiter Poppet Pressure Limiter Valve Poppet...
  • Page 240 Series 90 Functional Description Displacement Limiters All Series 90 pumps are designed for optional mechanical displacement (stroke) limiters. The maximum displace- ment of the pump can be limited in either direction. The setting can be set as low as 0° in either direction. For instructions on adjustment see corresponding Sec- tion.
  • Page 241 Series 90 Functional Description Pressure Override (POR) - 180 Frame Size Only To Control The pressure override valve (POR) modulates the control pressure to the displacement control to maintain a pump displacement which will produce a system pressure level Multi-Function Valve less than or equal to the POR setting.
  • Page 242 Series 90 Functional Description Pump Control Options Manual Displacement Control (MDC) The manual displacement control converts a mechanical input signal to a hydraulic signal using a spring- centered four- way servo valve. This valve ports hydraulic pressure to either side of a dual-acting servo piston. The servo piston rotates the cradle swashplate through an angular rotation of ±17°, thus varying the pump’s displacement from full displacement in one direction to full displacement in the opposite direction.
  • Page 243 Series 90 Functional Description Electric Displacement Control (EDC) The electric displacement control is similar to the hydrau- lic displacement control with the input signal pressure controlled by a pressure control pilot (PCP) valve. The PCP valve converts a DC electrical input signal to a hydraulic signal which operates a spring- centered four- way servo valve.
  • Page 244 Series 90 Functional Description Motor Features Motor Loop Flushing Valve and Charge Relief Valve All Series 90 motors are designed to accommodate a loop flushing valve. The loop flushing valve is used in instal- lations which require additional fluid to be removed from the main hydraulic circuit because of transmission cool- ing requirements, or unusual circuits requiring additional loop flushing to remove excessive contamination in the...
  • Page 245 Series 90 Functional Description Variable Motor Controls Hydraulic 2-Position Control This control utilizes a hydraulically operated three-way hydraulic valve to port system pressure to either of the motor displacement control pistons. The motor is nor- mally held at its maximum displacement. Supplying pilot hydraulic pressure to the valve will cause the motor to go to its minimum displacement.
  • Page 246 Series 90 Technical Specifications Technical Specifications General Specifications Design Port Connections (for details see chapter "Pressure Measurement") Variable Pumps and Motors: Axial piston pump of vari- able displacement, cradle swashplate design. Main pressure ports: SAE flange, Code 62, Remaining ports: SAE straight thread O-ring boss. Fixed Motors: Axial piston motor with fixed displacement, Direction of Rotation fixed swashplate design.
  • Page 247 Series 90 Technical Specifications Hydraulic Parameters ° ° [ n i t β β β β β β n i t β β ≥ ) β β β ≥ µ µm Hydraulic Fluid Cleanliness Refer to SAUER-SUNDSTRAND BLN 9887 or SDF (Id Refer to SAUER-SUNDSTRAND Publications BLN 9887 No.
  • Page 248 Series 90 Technical Specifications Size Specific Data Variable Displacement Pumps c i t • f ) t i Fixed and Variable Displacement Motors c i t • f o l f / l a r t r Refer to Series 90 technical information for definitions.
  • Page 249 Series 90 Pressure Measurement Pressure Measurement Required Tools The service procedures described in this manual for Pressure gauges should be calibrated frequently to en- Series 90 pumps and motors can be performed using sure accuracy. Snubbers are recommended to protect common mechanic's tools.
  • Page 250 Series 90 Pressure Measurement Servo / Displacement Cylinder Pressure Gauge Port M4 Case Drain Port L1 System Pressure Port B Servo / Displacement Cylinder Pressure Gauge Port M5 Top View 90000814E System Pressure External Control Pressure Port B System Pressure Supply Port X3 Gauge Port M2 Speed Sensor...
  • Page 251 Series 90 Pressure Measurement Servo / Displacement Cylinder Pressure Gauge Port M4 System Pressure Case Drain Gauge Port M2 Port L1 System Pressure Port B Charge Pump Inlet Port S System Pressure Port A System Pressure Servo / Displacement Gauge Port M1 Cylinder Pressure Case Drain Port L2 Gauge Port M5...
  • Page 252 Series 90 Pressure Measurement Fixed Motor t t i t t i " t " A " t " B System Pressure Gauge Port M1 Charge Pressure System Pressure Gauge Port M3 Case Drain Port L1 Gauge Port M2 System Pressure Port B Speed Sensor Case Drain Port L2 System Pressure Port A...
  • Page 253 Series 90 Pressure Measurement Variable Motor t t i t t i n i l " t " A " " t " t " B n i l " e " t Displacement Control Cylinder Pressure Gauge Port M4 System Pressure Min.
  • Page 254 Series 90 Initial Start-Up Procedure Initial Start-Up Procedure The following start-up procedure should always be fol- connections for EDC) be disconnected at the pump lowed when starting-up a new Series 90 installation or control until after initial start-up. This will ensure that the when restarting an installation in which either the pump or pump remains in its neutral position.
  • Page 255 Series 90 Fluid and Filter Maintenance Fluid and Filter Maintenance To ensure optimum service life of Series 90 products, regular maintenance of the fluid and filter must be per- formed. Contaminated fluid is the main cause of unit failure. Care should be taken to maintain fluid cleanliness Mano- Vacuummeter while performing any service procedure.
  • Page 256 Series 90 Toubleshooting Troubleshooting This section provides general steps to follow if certain undesirable system conditions are observed. Follow the steps in a section until the problem is solved. Some of the items will be system specific. For areas covered in this manual, a section is referenced.
  • Page 257 Series 90 Toubleshooting Transmission Operates Normally in One Direction Only Check Description Action Input to control module is operating Check control input and repair or re- 1. Input to pump control. improperly. place as necessary. Control linkages are not secure, control Repair or replace control module as 2.
  • Page 258 Series 90 Toubleshooting 10. Pump displacement control. Control linkages are not secure, control Repair or replace control module as orifices are blocked, etc. necessary. 11. System pressure. Low system pressure will not provide Measure system pressure. Continue power necessary to move load. with next step.
  • Page 259 Series 90 Toubleshooting Excessive Noise and/or Vibration Check Description Action 1. Oil in reservoir. Insufficient hydraulic fluid will lead to Fill reservoir to proper level. cavitation. 2. Air in system. Air bubbles will lead to cavitation. Look for foam in reservoir. Check for leaks on inlet side of system loop.

  • Page 260: Inspections And Adjustments

    Series 90 Inspections and Adjustments Inspections and Adjustments This section offers instruction on how to perform inspections and adjustments on pump and motor components. Read through the entire related section before beginning a service activity. Refer to the corresponding section for location of gauge ports and suggested gauge size.
  • Page 261 Series 90 Inspections and Adjustments 3. Earlier production Series 90 pumps are equipped with a shim adjustable charge pressure relief valve. Shim kits are available from SAUER-SUNDSTRAND. Adjustment of charge pressure is accomplished by removing the plug [1 inch Hex] and changing the shim thickness behind the spring.

  • Page 262: Multi-Function Valve Pressure Adjustment

    Series 90 Inspections and Adjustments Multi-Function Valve Pressure Adjustment Adjustment of the pressure limiter setting and the high pressure relief valve setting is accomplished simulta- neously. The latter is automatically set approximately 35 bar (500 psi) above the former. In order to adjust the pressure limiter setting, the motor output shaft must be locked so it does not rotate.
  • Page 263 Series 90 Inspections and Adjustments 5. The factory preset pressure limiter setting is shown 90L055 on the model code as at right. It is referenced to C6 C 03 charge pressure, so the pressure limiter setting is the difference between the high and low pressure sides of the system loop.

  • Page 264: Engaging The Bypass Function

    Series 90 Inspections and Adjustments Engaging the Bypass Function The bypass function is performed by the multi-function valve cartridges. The prime mover should be shut down when opening or closing the bypass valves. The bypass valves on both of the multi-function valves must be opened to engaged the bypass function.

  • Page 265: Pressure Override (Por) Valve Pressure Adjustment (Option For 180 Frame Size)

    Series 90 Inspections and Adjustments Pressure Override (POR) Valve Pressure Adjustment (Option for 180 Frame Size) The Pressure Override Valve is explained in the corre- sponding section. 1. Install two 1000 bar (or 10 000 psi) pressure gauges Pressure Override Valve in the high pressure gauge ports (M1 and M2).

  • Page 266: Displacement Limiter Adjustment

    Series 90 Inspections and Adjustments Displacement Limiter Adjustment The maximum displacement can be limited in either direction. 1. Loosen the seal lock nut retaining the displacement limiter adjusting screw. 2. Rotate the adjusting screw. 90000267 Loosen Displacement Limiter Lock Nut Rotating the adjusting screw clockwise will decrease the maximum displacement of the pump while rotat- ing the adjusting screw counterclockwise will in-...

  • Page 267: Pump Control Adjustments

    Series 90 Inspections and Adjustments Pump Control Adjustments Standard Manual Displacement Control (MDC) Adjustment There are no adjustable elements in the manual dis- placement control. The control spool is held in its “neutral” position by centering springs and washers on each end of the spool.

  • Page 268: Non-Linear Manual Displacement Control (Mdc)

    Series 90 Inspections and Adjustments Non-Linear Manual Displacement Control (MDC) A centering spring, located on the control input shaft, locates the control shaft in its “neutral” position. A bias spring on the control spool maintains a force on the spool and the control linkage to eliminate looseness (“free- play”) in the linkage.

  • Page 269: Mdc Neutral Start Switch (Nss) Adjustments

    Series 90 Inspections and Adjustments MDC Neutral Start Switch (NSS) Adjustments The neutral start switch (NSS) provides a means to prevent the system prime mover from starting while the pump control handle and control input shaft are in a Switch Cam position which would command the pump to go “in- Control Shaft stroke”...
  • Page 270 Series 90 Inspections and Adjustments The NSS must be adjusted to meet the following three requirements: Control Shaft NSS Deadband ("Free-Play") (Switch closed, "ON") The distance the control handle can be turned with- out opening the NSS is called the “NSS Deadband.” Control Deadband The distance the control handle can be moved with- ("Neutral")
  • Page 271 Series 90 Inspections and Adjustments NSS Deadband Adjustment (Conditions ii & iii) The NSS deadband must be wide enough so the NSS will not open within the control shaft “free-play” area, and it must be narrow enough so the NSS will open before the unit builds 7 bar (100 psi) differential system pressure in either direction.
  • Page 272 Series 90 Inspections and Adjustments Neutral Start Switch Eccentric Plug Adjustment (Con- 12.7 9.14 dition i) (0.36) (0.5) The NSS deadband and the control deadband must be centered in relation to each other. Since the position of the control deadband cannot be 3.175 1.52 adjusted, the position of the NSS deadband must be...
  • Page 273 Series 90 Inspections and Adjustments 3. Position the eccentric plug so the switch pin is offset toward the control mounting surface. This will provide Switch Pin Eccentric Plug the best contact between the pin and the cam on the control shaft. 4.
  • Page 274 Series 90 Inspections and Adjustments Checking Switch Continuity Recheck switch continuity to determine whether addi- tional adjustment of the eccentric plug is necessary. WARNING The following procedure may require the vehicle/ machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders.

  • Page 275: Hydraulic Displacement Control (Hdc) And Electric Displacement Control (Edc) Adjustment

    Series 90 Inspections and Adjustments Hydraulic Displacement Control (HDC) and Electric Displacement Control (EDC) Adjust- ment The “neutral” adjustment is the only adjustment that can be made on hydraulic and electric displacement controls. All other functions are preset at the factory. This adjustment must be made on a test stand or on the vehicle/machine with the prime mover operating.
  • Page 276 Series 90 Inspections and Adjustments 3. Using a 5 mm internal hex wrench for the neutral adjusting shaft or a 3 mm or 4 mm internal hex wrench for the neutral adjusting screw, rotate clock- wise until the pressure increases in one of the pressure gauges.

  • Page 277: Motor Adjustments

    Series 90 Inspections and Adjustments Motor Adjustments Charge Relief Valve Adjustment 1. To measure motor charge pressure, install a 50 bar (or 1000 psi) pressure gauge in the motor charge pressure gauge port (M3). Size 30 and 42 don’t have the M3 gauge port.

  • Page 278: Displacement Limiter Adjustment (Mv)

    Series 90 Inspections and Adjustments Displacement Limiter Adjustment (MV) Tamper-Resistant Cap Both the maximum and minimum displacement may be Seal Lock Nut limited. Maximum Displacement Limiter Screw 1. Remove the tamper resistant cap from the displace- ment limiter screw. Loosen the seal lock nut retaining the displacement limiter adjusting screw with a 19 mm wrench.

  • Page 279: Speed Sensor Adjustment

    Series 90 Inspections and Adjustments Speed Sensor Adjustment When installing or adjusting the speed sensor on a pump or motor, it must be set at a specific distance from the speed ring on the unit’s cylinder. To locate the position of the speed sensor on the unit or description see the corresponding section.

  • Page 280: Minor Repair Instructions

    Series 90 Minor Repair Instructions Minor Repair Instructions Minor repairs may be performed, following the proce- items must be kept free of foreign materials and chemi- dures in this section, without voiding the unit warranty. cals. Although specific models are shown, these procedures apply to all series and types of units in the Series 90 Protect all exposed sealing surfaces and open cavities Family.
  • Page 281 Series 90 Minor Repair Instructions Hydrostatic Unit Outlines for Minor Repair Reference Charge Pressure Relief Valve Filtration Options Control Control Orifice Charge Pump Shaft Seal Main Shaft Speed Sensor (Auxiliary Pad) Right Side View Left Side View 90000843E SAE-Flange PV Charge Pressure Charge Pressure Relief Valve...

  • Page 282: Pump And Motor Minor Repair

    Series 90 Minor Repair Instructions Pump and Motor Minor Repair Pump / Fitting Torques If any plugs or fittings are removed from the pump or motor during servicing, they should be torqued as indi- • f ) t f cated in the accompanying table. •...

  • Page 283: Shaft Seal And Shaft Replacement

    Series 90 Minor Repair Instructions Shaft Seal and Shaft Replacement Lip type shaft seals are used on Series 90 pumps and motors. These seals and/or the shafts can be replaced without major disassembly of the unit. However, replace- ment usually requires removal of the pump or motor from the machine.
  • Page 284 Series 90 Minor Repair Instructions Roller Bearing 8. Inspect the sealing area on the shaft for rust, wear, Assembly Retaining Ring or contamination. Tapered Shaft Splined If the shaft is not being replaced proceed to step Roller Bearing Shaft 9. Remove shaft and roller bearing assembly from pump or motor.

  • Page 285: Pump Minor Repairs

    Series 90 Minor Repair Instructions Pump Minor Repairs Multi-Function Valve Cartridges 1. The multi-function valve cartridge is removed with a hex wrench on the largest hex on the cartridge. 2. Inspect cartridge for damage to parts and O-rings. The multi-function valve cartridge may be disas- 90000276 90000277 Remove Multi-Function...

  • Page 286: Pressure Override Valve (Option For 180 Frame Size)

    Series 90 Minor Repair Instructions Screws Pressure Override Valve (Option for 180 Frame Size) Pressure Override Valve 1. Remove the four screws attaching the pressure override valve to the pump end cap with a 5 mm O-rings internal hex wrench. Remove the O-rings. 2.

  • Page 287: Charge Pump - Remove

    Series 90 Minor Repair Instructions Charge Pump - Remove The following procedure shows how to remove and install a charge pump. 1. For pumps with an auxiliary mounting pad, remove the four screws holding the pad to the end cap and remove the pad.
  • Page 288 Series 90 Minor Repair Instructions Note: If a different displacement charge pump is be- ing installed, the gerotor assembly, gerotor outer Standard End Cap Screws eccentric ring, and inner port plate (early and Alignment Pin late production pumps) or outer spacer plate(s) Charge Pump Assembly (intermediate production pumps) must be re- Thin Port Plate...

  • Page 289: Installing The Charge Pump

    Series 90 Minor Repair Instructions Installing the Charge Pump Discharge Discharge Gerotor Assembly Be sure to install the charge pump in the proper orienta- Alignment Pin tion. If unsure of charge pump rotation, refer to the model code. Inlet Inlet Note: The charge pump rotation is determined by the Alignment Pin...
  • Page 290 Series 90 Minor Repair Instructions Note: Intermediate production 75 cc and 100 cc pumps use the same charge pump drive shaft. Two keyways are provided in the drive shaft for the charge pumps used in these units. The rear 100 cc 75 cc keyway (with identifier groove) is used in 75 cc pumps.

  • Page 291: Auxiliary Pad Installation

    Series 90 Minor Repair Instructions Auxiliary Pad Installation 1. Remove the six screws holding the charge pump cover retainer. Remove the retainer. 2. Remove the charge pump cover and its O-ring. Note: The original charge pump cover will not be used when installing the auxiliary pad.

  • Page 292: Auxiliary Pad Conversion

    Series 90 Minor Repair Instructions 6. Carefully remove the alignment pin from the charge pump parts. Install the pin in its hole in the new charge pump cover (with hole for the auxiliary cou- pling) and retain with petroleum jelly. Install the new charge pump cover with alignment pin into the end cap and the aligned charge pump parts.

  • Page 293: Filtration Options

    Series 90 Minor Repair Filtration Options Suction Filtration Installation 1. Install the hydraulic fitting to connect the external suction filter to the charge pump inlet port. 2. The reducer fitting (placed on the charge pressure gauge port) is installed as follows. •...

  • Page 294: Pump Controls

    Series 90 Minor Repair Pump controls Cover Plate 1. Thoroughly clean external surfaces prior to removal of cover plate. 2. Using a 5 mm internal hex wrench, remove the eight cover plate mounting screws. Remove the cover plate and gasket from housing. Caution Protect exposed surfaces and cavities from damage and foreign material.

  • Page 295: Manual Displacement Control (Mdc)

    Series 90 Minor Repair Manual Displacement Control (MDC) 1. Thoroughly clean external surfaces prior to removal of control. 2. Using a 5 mm internal hex wrench, remove the eight control mounting screws. Remove the control (with orifice check valve and spring) and control gasket from housing.

  • Page 296: Solenoid Override Valve For Mdc

    Series 90 Minor Repair Solenoid Override Valve for MDC Thoroughly clean external surfaces prior to removal of valve. 2. Using a 5 mm internal hex wrench, remove the two screws and remove solenoid manifold from housing. Remove the old gasket. 3.

  • Page 297: Hydraulic And Electric Displacement Controls

    Series 90 Minor Repair Hydraulic and Electric Displacement Controls 1. Thoroughly clean external surfaces prior to removal of control. 2. Using a 5 mm internal hex wrench, remove the eight control mounting screws. Remove the control (with orifice check valve and spring) and control gasket from housing.

  • Page 298: 3-Position (Fnr) Electric Control

    Series 90 Minor Repair 3-Position (FNR) Electric Control 1. Thoroughly clean external surfaces prior to removal of control. 2. Using a 4 mm internal hex wrench, remove the four solenoid valve mounting screws. Remove the sole- noid valve (with O-rings and orifice) from the adapter plate.
  • Page 299 Series 90 Minor Repair Displacement Control Orifice Check Valve 1. Remove the control assembly as described in the instructions for the specific displacement control. 2. The orifice check valve is located in the control assembly, at the surface of the pump housing face. Remove the spring retainer and spring from the orifice check valve cavity and then remove the orifice check valve.

  • Page 300: Minor Repair - Motor

    Series 90 Minor Repair Minor Repair - Motor Loop Flushing and Charge Relief Valves Loop Flushing Valve 1. Using an 1-1/16 inch wrench, remove the hex plugs and O-rings from both sides of the valve. Remove the springs, shoulder washers, and flushing valve shuttle spool.
  • Page 301 Series 90 Minor Repair 4. Install the poppet and spring. For shim adjustable valves, install the plug and torque to 68 Nm (50 lbf•ft). For screw adjustable valves, install the plug with its lock nut, aligning the marks made at disassembly, and torque the lock nut to 52 Nm (38 lbf•ft).

  • Page 302: Variable Motor Displacement Limiters

    Series 90 Minor Repair Variable Motor Displacement Limiters 1. Remove the tamper-resistant cap from the displace- ment limiter. Measure and note the length of the adjustment screw up to the seal lock nut. Using a 19 mm hex wrench, loosen the seal lock nut and remove the nut.

  • Page 303: Variable Motor Controls

    Series 90 Minor Repair Variable Motor Controls Electrohydraulic 2-Position Control (Types NA, NB, NC, and ND) 1. Thoroughly clean external surfaces prior to removal of the control. 2. Disconnect the external electrical signal connection. Note: Remove BEFORE removing control. Install AFTER installing control. 3.

  • Page 304: Variable Motor Control Orifices

    Series 90 Minor Repair Variable Motor Control Orifices Control Suply Orifice Control Supply Orifice Screen (pressed in) 1. Remove the control supply orifice from the motor O-ring housing with an 1-1/16 inch hex wrench. Backup Washer 2. Remove the O-rings and the backup washers. Check O-ring that the filter screen is secure in the orifice body and Backup Washer...
  • Page 305 Series 90 Minor Repair Maximum Displacement Cylinder Orifice Check Valve 1. Remove the seal lock nut with a 3/4 inch hex wrench. Remove the maximum displacement cylinder orifice Housing Plug check valve from the motor housing with a 1/4 inch Seal Lock Nut end wrench.

  • Page 306: Speed Sensor

    Series 90 Minor Repair Speed Sensor 1. Remove the speed sensor by disconnecting the Housing Plug electrical connector, loosening the lock nut, and Speed Sensor 1/4 in. int. hex wrench unscrewing the speed sensor from the pump or Torque: 23 Nm (17 lbf•ft) motor housing.

  • Page 307: Exploded View Parts Drawings / Parts Lists

    Series 90 Exploded View Parts Drawings / Parts Lists Exploded View Parts Drawings / Parts Lists Variable Pumps Minor Repair Parts K018 (Early Production 075 Frame Size) (L70) G532 K042 G536 (L40) G542 (B80) G546 (B90) P2B_ (B70) P2A_ G512 G516 G502 G506...

  • Page 308: Parts List

    Series 90 Exploded View Parts Drawings / Parts Lists Parts List Item Description Item Description B70 ....Plug ............2 G532 .... Plug ............1 B71 ....Plug ............1 G536 .... O-ring ............1 B80 ....Plug ............1 G538 ....

  • Page 309: Variable Pump Controls

    Series 90 Exploded View Parts Drawings / Parts Lists Variable Pump Controls M0DC M1DC M0DD M90D M1DD M11D M0MA M0ME M0MB M0MF M0MC M0MG M0CA M0MD M0M9 M74M M90C M9ME M76M M1CA M78M M87C M11C M92M M97M M77M M98M M75M M95M M96M M72M...

  • Page 310: Control Parts List

    Series 90 Exploded View Parts Drawings / Parts Lists Control Parts List Item Description Item Description M0CA ... Cover plate kit ......... 1 M71M ... Washer ............ 1 M1CA ... Cover plate ..........1 M72M ... Nut ............1 M11C ... Control gasket ......... 1 M80 ....

  • Page 311: Filter And Options

    Series 90 Exploded View Parts Drawings / Parts Lists Filter and Options N40P N40L N00M N00S N35M N35S N10M N10S N30R N35M N25M N00R N20M N10R N15M N31R N20R N15R N35R N25R 90000862E H50L (H30) J80N H90L J40N J15N J15_ J10_ J70_ J80_...

  • Page 312: Parts List Filter And Options

    Series 90 Exploded View Parts Drawings / Parts Lists Parts List Filter and Options Item Description Item Description H05B-H ..Kit - Charge pump ........1 J80A-V ..Screw ............4 H50L .... Spacer (No charge pump) ...... 1 J80N ..... Screw ............4 H30 ....

  • Page 313: Fixed Motor

    Series 90 Exploded View Parts Drawings / Parts Lists Fixed Motor Minor Repair Parts H68W H60W (Early Production H62W (L70) 075 Frame Size) H64W (L40) H66W H60N (B80) (H50N) (G50) (H50W) (H30W) (H40W) (H20W) H10N (B80) H50N H20W (G63) H10W H40W H30W (CODE 61 OPTION)

  • Page 314: Parts List

    Series 90 Exploded View Parts Drawings / Parts Lists Parts List Item Description Item Description B80 ....Plug ............2 H50W ... Plug ............2 B83 ....Plug ............1 H60W ... Charge relief valve plug ......1 B83 ....Speed sensor .......... 1 H62W ...

  • Page 315: Variable Motor

    Series 90 Exploded View Parts Drawings / Parts Lists Variable Motor Minor Repair Parts Y100 Y102 Y101 (Early Production 075 Frame Size) (L70) (L40) (Y50) (B74) T100 H68W T101 H60W (B74) H62W (T50) H64W M1PT H66W H60N M1NA, M1NB P700 (G50) M1NC, M1ND P702...

  • Page 316: Parts List

    Series 90 Exploded View Parts Drawings / Parts Lists Parts List Item Description Item Description B74 ....Plug ............4 L30 ....Seal carrier ..........1 B76 ....Plug ............1 L35 ....Seal carrier ..........1 B80 ....Plug ............2 L40 ....
  • Page 317 Hydraulic Power Systems SAUER-DANFOSS Hydraulic Power Systems - Market Leaders Worldwide SAUER-DANFOSS is a world leader in the design SAUER-DANFOSS specializes in integrating a full and manufacture of Hydraulic Power Systems. Research range of system components to provide vehicle designers and development resources in both North America and with the most advanced total-design system.
  • Page 331 OBILE QUIPMENT NERGY OLUTIONS NDUSTRY ROCESS UTOMATION OLUTIONS Installation, use and service manual A T E X INCLUDED...
  • Page 333 USE, INSTALLATION AND MAINTENANCE MANUAL 1.0 - GENERAL INFORMATION 1.1 - PURPOSE OF THE MANUAL ........................1.2 - PRODUCT IDENTIFICATION .

  • Page 334: General Information

    1.0 - GENERAL INFORMATION 1.1 - PURPOSE OF THE MANUAL This Manufacturer’s manual provides information regarding the safe transport, handling, installation, mainte- nance, repair, disassembly and dismantling of the gear unit. All information for users and designers is given in the Sales Catalogue. As well as adhering to esta- blished engineering practices, the information given in this manual must be read carefully and rigo- rously applied.

  • Page 335: Product Identification

    1.2 - PRODUCT IDENTIFICATION The information identifying the product is shown on its nameplate. Gearmotors are equipped with two name- plates; one on the gear unit which bears the gear unit data, and one on the motor (electric or hydraulic), bea- ring the motor data.

  • Page 336: Glossary And Terminology

    INOLOGY 1.3 - GLOSSARY AND TERM Some of the frequently occurring terms used in this manual are described below to unequivocally define their meaning. Routine maintenance The set of operations required to preserve the functionality and efficiency of the gear unit. These operations are usually scheduled by the Manufacturer, who defines the qualifications and tasks involved.

  • Page 337: Technical Information

    2.0 - TECHNICAL INFORMATION 2.1 - DESCRIPTION OF THE GEAR UNIT The gear unit, driven by an electric or hydraulic motor, has been designed and constructed for integration into an assembly of interlocking parts or mechanisms as part of a specific application. Depending on the requirements of the application, the gear unit can be supplied in a variety of motor execu- tions and configurations.

  • Page 338: Safety Information

    Ambient conditions • Ambient temperature: min. - 20°C; max. + 40°C. • Do not use the gear unit, if not explicitly intended for the purpose, in a potentially explosive atmosphere or where the use of explosion-proof equipment is specified. The nameplate specifications regarding the maximum surface temperature, refer to readings ta- ken in normal ambient and installation conditions.

  • Page 339: Handling And Transport

    If the gear unit is to be serviced in a potentially explosive atmosphere, the operator must first switch off power to the gear unit and ensure that it is out of service, as well as taking all neces- sary precautions against it being accidentally switched on again or its parts moving without warning.

  • Page 340: Moving The Packages

    4.2.1 - Moving the packages • Prepare a suitable, delimited area with a level floor or surface for unloading the packages. • Prepare the equipment required to handle the package. The lifting and handling equipment (e.g. crane or lift truck) must be of adequate capacity for the weight and size of the load, taking into account its attac- hment points and centre of gravity.
  • Page 341 Identify the attachment points for lifting the gear unit. Refer to the diagrams given below. 300 L ... 316 L 317 L ... 321 L Screw clamp Maximum permissible tilt during 1 Ring harness (use with harness) handling: 15° Snap hook 2 Rope and hooks (use with rope) 3 Open harness...
  • Page 342 300 R ... 316 R 317 R ... 321 R Screw clamp 1 Ring harness Maximum permissible (use with harness) tilt during handling: 15° 2 Rope and hooks Snap hook (use with rope) 3 Open harness Eyebolt (already fitted on gear units 317-321) with eyelets...
  • Page 343 300 R ... 316 R 317 R ... 321 R Screw clamp 1 Ring harness (use with harness) 2 Rope and hooks Snap hook (use with rope) Maximum permissible 3 Open harness Eyebolt (already fitted tilt during handling: 15° on gear units 317-321) with eyelets...
  • Page 344 3V 00 ... 3V 16 3V 17 ... 3V 21 Screw clamp 1 Ring harness Maximum permissible tilt during (use with harness) handling: 15° 2 Rope and hooks Snap hook (use with rope) 3 Open harness Eyebolt (already fitted on gear units 317-321) with eyelets...
  • Page 345 300 L ... 321 L 300 R ... 321 R 3V 00 ... 3V 21 Screw clamp 1 Ring harness Maximum permissible tilt during (use with harness) handling: 15° Snap hook 2 Rope and hooks (use with rope) 3 Open harness Eyebolt (already fitted on gear units 317-321) with eyelets...

  • Page 346: Storage

    • Prepare the gear unit for lifting by attaching straps, hooks and screw clamps etc. to its attachment points. Alternatively, use a pallet to move the load. If using a crane, first lift the gear unit vertically out of its packa- ging.

  • Page 347: Installation

    5.0 - INSTALLATION 5.1 - INSTALLING THE GEAR UNIT The entire installation process must be planned as early as the general design phase of the ma- chine. The person authorised to do the work must, if necessary, set out a safety plan to protect the health and safety of all persons directly involved and apply all applicable legislation.
  • Page 348 For machining the spigot on the driven machine, refer to the diagrams below: 300...307 gear units - male output shaft motor execution 300...307 0.1 / 100 B 0.15 0.15 309...321 gear units - male output shaft motor execution These gear units are fitted with two spigots. When machining the coupling flanges, one spigot may be suffi- cient if the output shaft is not subject to overhung loads or loads are less than 60% of the permissible load.
  • Page 349 Mounting with hollow splined shaft Ensure that the gear unit and driven shaft are aligned and that the latter is not subject to flexing during ope- ration. See diagram below: 300...321 0.1 / 100 B B 0. 15 Flanged gear unit mounting bolts Bolt Quantity Class...

  • Page 350: Shaft Mounting

    5.1.3 - Shaft mounting Mount the torque arm with bolts of at least class 8.8 tightened to a torque of 70% of their failure stress. Clean and degrease both the internal coupling surface of the gear unit shaft and the external coupling surface of the machine’s driven shaft.

  • Page 351: Installing Accessories On Solid Input And Output Shafts

    Proceed with the installation as follows: 1. Place the gear unit in the vicinity of the installation area. 2. Mount the gear unit and secure it to the structure at the points provided. The gear unit should be secured to the structure at all the mounting points (bores) on the mount provided (feet or flange). 3.
  • Page 352 Shaft end: threads 300...315 HC-PC HC-PC DIN 332 HC-PC HC-PC HC-PC – – – – – – – – – – – – – – – – – – – – – – – – – – –...

  • Page 353: Installing The Electric Motor

    Installing accessories on splined shafts Do not use hammers or other tools that might damage the gear unit’s shafts or bearings when mounting external parts. Instead, proceed as illustrated in the diagram below: MZ-HZ Always use the stop end plate supplied with the gear unit. 5.2 - INSTALLING THE ELECTRIC MOTOR Further to all the precautions indicated above, when installing a standard IEC 72-1 electric motor, the follo- wing precautions must also be observed:...

  • Page 354: Installing The Hydraulic Motor

    5.3 - INSTALLING THE HYDRAULIC MOTOR Connecting the hydraulic motor Remove the protective plug. Hydraulic motor mountings are available in two versions: a) Version with O-ring oil gasket between motor flange and gear unit. In this case, mount the gasket to ensure an oil tight seal between the motor and gear unit, taking care to fit it correctly in its seat without damaging it.

  • Page 355: Connecting The Hydraulic Brake

    5.4 - CONNECTING THE HYDRAULIC BRAKE On gear units designed for coupling to hydraulic motors and fitted with a brake, connect the brake control fit- ting to the hydraulic circuit at the time of assembly. Start-up The minimum pressure to release the brake (see chart) must be less than 320 bar. Technical data 4...
  • Page 356 Installing the gearmotor If a gearmotor is supplied fully assembled, follow the precautions and instructions given above when moun- ting to the machine. For the electrical and hydraulic connection, refer instead to the two sample diagrams below. These are gene- ric only since each specific installation has its own special requirements, which must be evaluated on a per case basis by the Manufacturer.
  • Page 357 Drive with TRASMITAL MG orbital hydraulic motor In addition to the instructions governing installation of the gear unit, the following instructions should also be observed when installing a hydraulic motor. a) Connecting to the hydraulic circuit The motor can be installed on both a closed and open loop circuit. In the case of an open circuit installation, the solenoid valve or control valve may be of either the closed cen- tre or open type.
  • Page 358 b) Connecting drain hole T Standard motors are supplied without a drain hole. In this case the motor is equipped with internal drainage. This meets the requirements of the majority of applications with intermittent duty and an average drive pres- sure of less than 50% of the motor’s maximum rated pressure.
  • Page 359 e) Filtering To ensure the motor’s reliable operation and long service life, the hydraulic circuit must be equipped with a filter capable of guaranteeing the following purity levels: grade9 NAS 1638 grade6 SAE grade18/15 SO DIS 4406 Drive with hydraulic motor All motors must be charged with hydraulic fluid before being operated and during installation.

  • Page 360: Lubrication

    5.5 - LUBRICATION Before starting up the gear unit, it must be charged with lubricant to the level corresponding to its specified mounting position. The lubricant and its relative viscosity should be selected from the following chart, in accordance with the type of duty and ambient temperature.

  • Page 361: Testing The Gear Unit

    6.0 - TESTING THE GEAR UNIT The gear unit has been factory tested by the Manufacturer. Before start-up, make sure that: • the machine incorporating the gear unit complies with the provisions of the “Machinery Directive” 98/37/EC and any other applicable safety legislation •...

  • Page 362: Maintenance

    8.0 - MAINTEN ANCE Maintenance and replacement work must be carried out by expert maintenance technicians trained in the observance of applicable laws on health and safety at work and the special am- bient problems attendant on the installation. Before doing any work on the unit, the operator must first switch off power to the gear unit and ensure that it is out of service, as well as taking all necessary precautions against it being accidentally switched on again or its parts moving without warning (due to suspended loads or similar external factors).

  • Page 363: Routine Maintenance

    8.1 - ROUTINE MAINTENANCE Keep the gear unit at its maximum efficiency by following the routine maintenance schedule. Good maintenance ensures the unit’s maximum performance, extended service life and conti- nued compliance with safety regulations. (A3) Frequency Component Type of check Action Check that the external Stop the machine and contact...

  • Page 364: Oil Changes

    8.2 - OIL CHANGES 1. Place an adequate container under the drain plug. 2. Remove the filler and drain plugs and allow the oil to drain out. The oil will drain better if it is warm. 3. Wait for a few minutes until all the oil has drained out, then screw the drain plug back on after first chan- ging the plug seal.

  • Page 365: Replacing Parts

    9.0 - REPLACING PARTS • Immediately replace parts and components if they are not able to guarantee safe and reliable ope- ration. • Never improvise repairs. • The use of non-original spare parts not only renders the warranty null and void but can jeopardise the gear unit’s operation.

  • Page 366: Troubleshooting

    10.0 - TROUBLESHOOTING The following information is intended to serve as an aid in locating and eliminating defects and faults. In some cases, problems may be caused by the plant or machine to which the gear unit is assembled and hen- ce, the cause and remedy will be described in the Manufacturer’s technical documentation for the machi- ne/plant in question.

  • Page 367: Annex 1 - Checking The Oil Level On Atex-Specified Gear Units

    ANNEX 1 - CHECKING THE OIL LEVEL ON ATEX-SPECIFIED GEAR UNITS Gear units are normally fitted with oil level check plugs. To check the oil level, first identify the level plug. - Horizontal position: Remove the plug and insert a bar of the right size in the hole and of the shape shown in the fi- gure.

  • Page 368: Annex 2 - Lubricant Charge Quantity

    ANNEX 2 - LUBRICANT CHARGE QUANTITY Type Type Mounting position Mounting position 10.5 15.5 13.5 11.5 16.5 14.5 12.5 17.5 15.5 N.B. The quantities indicated are approximate only. Fill the unit according to the position of the level plug or level rod supplied with the gear unit.
  • Page 369 TA - TE - TF - TD OA - OE - OF- OD AA - EA - FD AF - EF - FE AE - EE - FF AD - ED - FA VA - VC - VF -IO QA - QE - QF- QD input input input...
  • Page 370 INDEX OF REVISIONS (R) Amended section 8.1 "Routine maintenance". We reserve the right to implement modifications without notice. This catalogue cannot be reproduced, even partially, without prior consent. COD. 7.998.3.3.01.7 R1...
  • Page 372 OBILE QUIPMENT NERGY OLUTIONS NDUSTRY ROCESS UTOMATION OLUTIONS w w w . b o n f i g l i o l i . c o m...
  • Page 373 OPERATION MAINTENANCE SERVICE MANUAL 600 - 8,000 lb. Axles & Related Components www.dexteraxle.com...
  • Page 374 Introduction This manual is designed to provide information for you to understand, use, maintain, and service your trailer running gear system. Your axles are manufactured by Dexter Axle. The Dexter product line, the most complete in the industry, is the result of over 30 years of experience in the design, testing and manufacturing of trailer axles.
  • Page 375 Introduction Important Safety Notice ................. 4 Getting Started - Setup and Adjustment ..........4 Braking Systems - Electric Electric Brakes ..................5 Features ....................6 Parking Brake Option ..............6 Self Adjusting Feature ..............6 Brake Controllers ................7 Typical Trailer Wiring ..............10 How To Use Your Electric Brakes Properly .......
  • Page 376 Hubs/Drums/Bearings Hubs/Drums/Bearings ..............44 Hub Removal - Standard Bearings ..........44 Brake Drum Inspection ............... 45 Bearing Inspection ..............46 Bearing Lubrication - Grease ............. 47 Bearing Lubrication - Oil ............. 48 Recommended Wheel Bearing Lubrication Specifications ..48 Seal Inspection and Replacement ..........49 Bearing Adjustment and Hub Replacement .......

  • Page 377: Important Safety Notice

    Important Safety Notice Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all running gear as well as the personal safety of the individual doing the work. This manual provides general directions for performing service and repair work with tested, effective techniques.

  • Page 378: Electric Brakes

    Electric Brakes The electric brakes on your trailer are similar to the drum brakes on your automobile. The basic difference is that your automotive brakes are actuated by hydraulic pressure while your electric trailer brakes are actuated by an electromagnet. With all of the brake components connected into the system, the brake will operate as follows: Retractor Spring...

  • Page 379: Features

    Features Electrically actuated brakes have several advantages over other brake actuation systems. 1. They can be manually adjusted at the controller to provide the correct braking capability for varying road and load conditions. 2. They can be modulated to provide more or less braking force, thus easing the brake load on the towing vehicle.

  • Page 380: Brake Controllers

    Brake Controllers Electric brake controllers provide power to the magnets to actuate the trailer brakes. Dexter Axle offers a state-of-the-art inertial controller called the Predator Series™ DX2. This controller features a patented pendulum design which senses the deceleration of the towing vehicle and sends a proportional voltage to the electric trailer brakes.
  • Page 381 Dexter Electric Brakes Wired in parallel. Breakaway Battery Provides power to actuate trailer brakes in the event of trailer breakaway. Breakaway Switch Switches battery power to brakes if breakaway occurs.
  • Page 382 Controller Electric brake controller provides power to the magnets to actuate the trailer brakes. Battery Connect controller directly. Connector Used to connect and disconnect trailer and tow vehicle. (Always ground trailer brakes through connector).

  • Page 383: Typical Trailer Wiring

    Typical Trailer Wiring Double Stop & Left Turn Signal Filament To Terminal #5 Bulb Yellow Auxiliary Circuit License Tail & White #1 Common Ground Terminal #7 Running Lights #3 To Tail Running & Green Grey Terminal #3 Auxiliary Circuit License Lights Terminal #8 #5 Stop &...

  • Page 384: How To Use Your Electric Brakes Properly

    How to Use Your Electric Brakes Properly Your trailer brakes are designed to work in synchronization with your tow vehicle brakes. Never use your tow vehicle or trailer brakes alone to stop the combined load. Your brake controller must be set up according to the manufacturer's recommendations to ensure proper synchronization between the tow vehicle and the trailer.

  • Page 385: Synchronizing Your Trailer Brakes

    Synchronizing Your Trailer Brakes To insure safe brake performance and synchronization, read the brake controller manufacturer's instructions completely before attempting any synchronization procedure. CAUTION Before road testing, make sure the area is clear of vehicular and pedestrian traffic. Failure to brake safely could result in an accident and personal injury to yourself and/or others.

  • Page 386: General Maintenance - Electric Brakes

    General Maintenance - Electric Brakes Brake Adjustment Most Dexter 12 " electric brakes have a self adjusting feature. If manual adjusting is required, use the following procedure: Brakes should be adjusted (1) after the first 200 miles of operation when the brake shoes and drums have “seated,” (2) at 3,000 mile intervals, (3) or as use and performance requires.

  • Page 387: Brake Cleaning And Inspection

    Brake Cleaning and Inspection Your trailer brakes must be inspected and serviced immediately if a loss of performance is indicated. With normal use, servicing at one year intervals is usually adequate. With increased usage, this work should be done more frequently as required. Magnets and shoes must be changed when they become excessively worn or scored, a condition which can reduce vehicle braking.

  • Page 388: Magnets

    Magnets Your electric brakes are equipped with high quality electromagnets that are designed to provide the proper input force and friction characteristics. Your magnets should be inspected and replaced if worn unevenly or abnormally. As indicated below, a straightedge should be used to check magnet condition.

  • Page 389: Shoes And Linings

    Shoes and Linings A simple visual inspection of your brake linings will tell if they are usable. Replacement is necessary if the lining is worn (to within " or less), contaminated with grease or oil, or abnormally scored or gouged. Hairline heat cracks are normal in bonded linings and should not be cause for concern.

  • Page 390: Introduction To Troubleshooting

    Introduction to Troubleshooting Proper brake function is critical to the safe operation of any vehicle. If problems are encountered with your trailer braking system, the following guide can be used to find the causes and remedies for some of the more common problems. If you are unsure or unable to resolve the problem, please contact your nearest repair facility for professional assistance.
  • Page 391 Troubleshooting SYMPTOM CAUSES REMEDIES Open Circuits Find & Correct Severe No Brakes Adjust Brakes Underadjustment Faulty Controller Test & Correct Short Circuits Find & Correct Grease or Oil on Clean or Replace Magnets or Linings Clean & Correct Corroded Connections Cause of Corrosion Worn Linings Replace...
  • Page 392 Troubleshooting SYMPTOM CAUSES REMEDIES Wrong Magnet Correct Lead Wire Color Adjust Incorrect Adjustment Grease or Oil on Clean or Replace Linings or Magnets Brakes Pull to One Side Broken Wires Find & Repair Find & Repair Bad Connections Adjust Underadjustment Improper Correct Synchronization...

  • Page 393: How To Measure Voltage

    How to Measure Voltage System voltage is measured at the magnets by connecting the voltmeter to the two magnet lead wires at any brake. This may be accomplished by using a pin probe inserted through the insulation of the wires. The engine of the towing vehicle should be running when checking the voltage so that a low battery will not affect the readings.

  • Page 394: Magnet Amperes Chart

    Magnet Amperes Chart Brake Amps/ Four Magnet Size Magnet Brakes Brakes Brakes Ohms 7 x 1 10.0 15.0 10 x 1 12.0 18.0 10 x 2 12.0 18.0 12 x 2 12.0 18.0 12.0 18.0 12.0 18.0 If a resistor is used in the brake system, it must be set at zero or bypassed completely to obtain the maximum amperage reading.
  • Page 395 Possible causes are: 1. Shorted magnet coils 2. Defective controllers 3. Bare wires contacting a grounded object Finding the cause of a short circuit in the system is done by isolating one section at a time. If the high amperage reading drops to zero by unplugging the trailer, then the short is in the trailer.

  • Page 396: Hydraulic Brakes

    Hydraulic Brakes Dexter offers several varieties of hydraulic trailer brakes. Your vehicle may be equipped with the traditional drum brakes or you may have disc brakes. The hydraulic brakes on your trailer are much like those on your automobile or light truck. The hydraulic fluid from a master cylinder or actuation system is used to actuate the wheel cylinder which, in turn, applies force against the brake shoes and drum.

  • Page 397: Hydraulic Brake Operation

    Hydraulic Brake Operation Duo-Servo The duo-servo brake uses a dual piston wheel cylinder to apply the brakes. This type of brake is typically used in a vacuum/ hydraulic, electric/hydraulic or air/hydraulic system. A description of operation of this brake is as follows: When the brakes are applied, the double-acting wheel cylinder moves the primary and secondary shoes towards the drum.

  • Page 398: Self-Adjusting Mechanism For

    backing with a surge brake hitch, normal brakes are applied through the surge mechanism and if there is more brake Anchor Post force on the trailer than Hydraulic Wheel Retractor Cylinder the tow vehicle can Springs override, no backing is possible.
  • Page 399 installed directly into the backing plate to provide a convenient means for the trailer manufacturer to attach an appropriate operating system. The internal parking brake lever of 10" and 12" Dexter brakes, which is mounted to the secondary shoe, transfers applied cable force through a parking strut which is attached to the primary shoe.

  • Page 400: Disc Brakes

    Disc Brakes Dexter Axle manufactures two types of disc brakes, the floating caliper and the fixed caliper brake. With both styles, the disc brake uses friction pads astride a ventilated rotor which is attached to the wheel hub. When the brake is actuated, the pads are pressed against the sides of the rotor causing drag to slow the rotating disc.

  • Page 401: Actuation Systems

    Actuation Systems To effectively operate your hydraulic trailer brakes we recommend the Dexter E/H electro/hydraulic actuator, controlled by the Predator series DX2™ electronic brake controller. These high performance hydraulic power modules will supply pressurized brake fluid to your trailer brakes in proportion to the amount of braking effort called for by the towing vehicles' deceleration rate.

  • Page 402: Electrical Schematic

    Troubleshooting Guide Brakes are slow to respond 1. Re-bleed the trailer brakes and actuator. 2. If the trailer is equipped with drum brakes, readjust the drum brakes to the brake manufacture's recommended running clearance. 3. Slow response can be caused by trailer wiring that is too small.
  • Page 403 actuator is functioning properly. The problem most likely is a defective electronic brake controller in the tow vehicle or defective wiring between the tow vehicle and the E/H unit. 3. If the unit runs but will not build pressure, the problem most likely is a defective solenoid valve in the E/H unit and the actuator should be returned for repair.

  • Page 404: General Maintenance - Hydraulic Brakes

    General Maintenance - Hydraulic Brakes Drum Brake Adjustment - Manual Most Dexter 12 " electric brakes have a self adjusting feature. If manual adjusting is required, use the following procedure: Brakes should be adjusted (1) after the first 200 miles of operation when the brake shoes and drums have “seated,”...

  • Page 405: Wheel Cylinders

    Most of the brake components are very similar to those used in electric brakes, and maintenance is comparable for the hub and drum, shoes and linings, and bearings. Specific maintenance activities are as follows: Wheel Cylinders Inspect for leaks and smooth operation. Clean with brake cleaner and flush with fresh brake fluid.

  • Page 406: Hardware

    After replacement of brake shoes and linings, the brakes must be re-burnished to seat in the new components. This should be done by applying the brakes 20 to 30 times from an initial speed of 40 m.p.h., slowing the vehicle to 20 m.p.h. Allow ample time for brakes to cool between applications.

  • Page 407: Instructions For Brake Rotor Kit - 3.5K Disc Brakes

    4. Remove the hose from the caliper. Then remove the two caliper mounting bolts. Do not allow the caliper to hang from the hose. Installing the new brake caliper 1. First inspect the brake assembly for grooves, flaking, cracks, heat checking, thickness variation, insufficient rotor thickness, and look to see that the mounting hardware is straight.
  • Page 408 CAUTION Do not lift or support the trailer on any part of the axle or suspension system. Never go under any trailer unless it is properly supported on jack stands which have been rated for the load. Improperly supported vehicles can fall unexpectedly and cause serious injury or death.
  • Page 409 Instructions for Brake Rotor Kit 6K or 8K Disc Hydraulic Brakes Notice to Buyer It is recommended that all brakes be replaced at the same time to insure balanced braking performance. Remove the old brake rotor 1. Jack up trailer and secure on adequate capacity jack stands.

  • Page 410: Instructions For Brake Pad Kit - 6K Or 8K Disc Brakes

    against the hub face when reassembling the calipers. After the calipers are assembled remove the lug nuts. 3. Remount the caliper assembly onto the caliper attaching bracket. It may be necessary to push the piston into the calipers to obtain enough clearance. Torque mounting bolts to 25-35 Ft.
  • Page 411 2. Remove the wheel from the hub, leaving the brake exposed. 3. Disconnect the brake actuation system. Check that the hydraulic system has zero pressure and that the hub and rotor rotates freely. 4. Remove the brake pad retaining bolt. 5.

  • Page 412: Instructions For Brake Caliper Kit - 6K Or 8K Disc Brakes

    4. Align the brake pad mounting holes with the holes in the caliper. Insert the brake pad retaining bolt and tighten nut until snug against shoulder of bolt. 5. Reconnect the brake actuation system. Refer to your Operation Maintenance Service Manual for proper operation.
  • Page 413 Installing the new brake caliper 1. First inspect the brake assembly for grooves, flaking, cracks, heat checking, thickness variation, insufficient rotor thickness, and look to see that the mounting hardware is straight. Replace any component as needed (or desired) per manufacturer recommendations. 2.

  • Page 414: Introduction To Troubleshooting

    Introduction to Troubleshooting Proper brake function is critical to the safe operation of any vehicle. A properly installed vacuum/hydraulic, electric/hydraulic or air/hydraulic system should not require any special attention with the exception of routine maintenance as defined by the manufacturer. If problems occur, the entire tow vehicle/trailer braking system should be analyzed by a qualified mechanic.
  • Page 415 Troubleshooting SYMPTOM CAUSES REMEDIES Adjust Underadjustment Lack of Lubrication Lubricate Noisy Brakes Broken Brake Replace Components Components Incorrect Brake Correct Components Loose, Bent or Broken Replace Components Brake Components Locking Brakes Underadjustment Adjust Out-of-Round Drums Machine or Replace Incorrect Tire Inflate Evenly on Both Pressure Sides to Req.
  • Page 416 Troubleshooting SYMPTOM CAUSES REMEDIES Broken or Kinked Repair or Replace Brake Line Severe No Brakes Adjust Brakes Underadjustment Malfunctioning Troubleshoot System Actuation System Manual-Adjust Brakes Brake Adjustment Automatic-Make Several Not Correct Reverse Stops Excessively Worn Replace Shoe Brake Linings and Lining Install Correct Incorrect Lining Shoe and Lining...

  • Page 417: Hubs/Drums/Bearings

    Hubs/Drums/Bearings Dexter Axle offers several types of bearing arrangements and lubrications methods. ” Dexter’s standard wheel bearing configuration consists of opposed tapered roller bearing cones and cups, fitted inside of a precision machined cast hub. This method of using tapered roller bearings requires that a minimal amount of axial end play be provided at assembly.

  • Page 418: Brake Drum Inspection

    CAUTION You must follow the maintenance procedures to prevent damage to important structural components. Damage to certain structural components such as wheel bearings can cause the wheel end to come off of the axle. Loss of a wheel end while the trailer is moving can cause you to lose control and lead to an accident, which can result in serious injury or death.

  • Page 419: Bearing Inspection

    .090" on the diameter, the drum must be replaced. When turning the drum surface, the maximum rebore diameter is as follows: 7" Brake Drum-7.090" diameter ” 10" Brake Drum-10.090" diameter ” 12" Brake Drum-12.090" diameter ” " Brake Drum-12.340" diameter ”...

  • Page 420: Bearing Lubrication - Grease

    IMPORTANT: Bearings must always be replaced in sets of a cone and a cup. CAUTION Be sure to wear safety glasses when removing or installing force fitted parts. Failure to comply may result in serious eye injury. When replacing the bearing cup proceed as follows: 1.

  • Page 421: Bearing Lubrication - Oil

    3. Repeat this while rotating the bearing from roller to roller. 4. Continue this process until you have the entire bearing completely filled with grease. 5. Before reinstalling, apply a light coat of grease on the bearing cup. Bearing Lubrication - Oil If your axles are equipped with oil lubricated hubs, periodically check and refill the hub as necessary with a high quality hypoid gear oil to the level indicated on the clear plastic oil cap.

  • Page 422: Seal Inspection And Replacement

    Note: The convenient lubrication provisions of the E-Z Lube® and the oil lubrication must not replace periodic inspection of the bearings. Seal Inspection and Replacement Whenever the hub is removed, inspect the seal to assure that it is not nicked or torn and is still capable of properly sealing the bearing cavity.

  • Page 423: Bearing Adjustment And Hub Replacement

    Bearing Adjustment and Hub Replacement If the hub has been removed or bearing adjustment is required, the following adjustment procedure must be followed: 1. After placing the hub, bearings, washers, and spindle nut back on the axle spindle in reverse order as detailed in the previous section on hub removal, rotate the hub assembly slowly while tightening the spindle nut to approximately 50 lbs.-ft.

  • Page 424: E-Z Lube® Lubrication

    E-Z Lube® Lubrication The procedure is as follows: 1. Remove the rubber plug from the end of the grease cap. 2. Place a standard grease gun onto the grease fitting located in the end of the spindle. Make sure the grease gun nozzle is fully engaged on the fitting.

  • Page 425: Nev-R-Lube™ Drums/Bearings

    Nev-R-Lube™ Drums/Bearings Dexter’s Nev-R-Lube™ bearings are comprised of opposed tapered roller bearing cones sealed inside of a precision ground, one piece double cup arrangement. These bearings are designed with a small amount of axial end play. This end play is essential to the longevity of the bearings service life.

  • Page 426: Bearing Inspection

    CAUTION Do not lift or support the trailer on any part of the axle or suspension system. Never go under any trailer unless it is properly supported on jack stands which have been rated for the load. Improperly supported vehicles can fall unexpectedly and cause serious injury or death.

  • Page 427: Nev-R-Lube™ Bearing End Play Inspection

    2. Check for excessive wheel end clearance by pulling the tire assembly towards you and by pushing the assembly away from you. Slight end play is acceptable. 3. Rotate tire slowly forwards and backwards. The wheel assembly should turn freely and smoothly. 4.

  • Page 428: Bearing Replacement And Drum Installation

    Bearing Replacement and Drum Installation 1. Once the drum and bearing assembly is removed from the axle, remove “internal” snap ring from the bearing bore that retains bearing. 2. Using an arbor press and mandrel, press the bearing out of the drum. Bearing will exit on the wheel side of the drum.
  • Page 429 Nut should be torqued to 145-155 lb.-ft. (this torque will set the internal bearing adjustment, no other adjustments are to be made). 10. Install “torque instruction” washer onto end of spindle. 11. Install “external” snap ring onto end of spindle to retain washer.

  • Page 430: Suspension Systems

    Suspension Systems The suspension systems incorporated into Dexter axles are designed to provide the trailer owner three basic functions: 1. Attach the axle to the trailer 2. Dampen the effects of road shock 3. Cushion the cargo or load All Dexter suspension systems are available in single and multiple axle configurations.

  • Page 431: Grease Lubricated Suspension Bushings

    Grease Lubricated Suspension Bushings Dexter Axle offers an optional heavy duty attaching parts kit for double eye leaf spring suspensions up to 7,000 lb. axle capacity. The kit contains extra heavy shackle links, bronze bushings for the spring eyes and suspension bolts and equalizers equipped with grease fittings to provide a convenient means to lubricate all the pivot points.

  • Page 432: Inspection And Replacement

    Inspection and Replacement All the components of your suspension system should be visually inspected at least every 6,000 miles for signs of excess wear, elongation of bolt holes, and loosening of fasteners. Whenever loose or replaced, the fasteners in your suspension system should be torqued as detailed in the charts below.
  • Page 433 CAUTION Do not lift or support the trailer on any part of the axle or suspension system. Never go under any trailer unless it is properly supported on jack stands which have been rated for the load. Improperly supported vehicles can fall unexpectedly and cause serious injury or death.

  • Page 434: Torflex® Suspension

    1. With both axles blocked up, remove the spring eye bolt, shackle bolt, and equalizer bolt from the equalizer to be repaired or replaced. 2. Take the equalizer to suitable work surface and remove the worn bushings using a suitable drift punch. 3.

  • Page 435: Airflex™ Suspension

    surrounded by four natural rubber cords encased in the main structural member of the axle beam. The wheel/hub spindle is attached to a lever, called the torsion arm, which is fastened to the rubber encased bar. As load is applied, the bar rotates causing a rolling/compressive resistance in the rubber cords.
  • Page 436 Axle Adjustment 1. Support the trailer frame on a level surface. If the wheels are already mounted, make sure they are clear of the ground. If the air actuation system has been installed, make sure the air pressure in the air bags is bled off before lifting the trailer.
  • Page 437 4. Re-measure A and B, as before, to assure that “A” and “B” dimensions are within " of each other. If dimensions are not to specification, then repeat adjustment procedure. Figure 1 -64-...
  • Page 438 Tandem Axle Adjustment 1. Adjust the second axle using it’s left hand spring seat adjusters to assure distances “C” and “D” are within tolerance. 2. Measure the distances “C” and “D” between the front and rear tandem axles. These distances must be within "...

  • Page 439: Wheels

    Wheels Wheel Selection Wheels are very important and critical components of your running gear system. When specifying or replacing your trailer wheels it is important that the wheels, tires, and axle are properly matched. The following characteristics are extremely important and should be thoroughly checked when replacement wheels are considered.

  • Page 440: Torque Requirements

    CAUTION Do not attempt to repair or modify a damaged wheel. Even minor modifications can cause a dangerous failure of the wheel and result in personal injury or death. Torque Requirements In June of 2004, Dexter Axle ceased production of trailer wheels. If your vehicle is equipped with Dexter steel wheels manufactured before that date, the following wheel torque information will be applicable.

  • Page 441: Wheel Torque Requirements

    Be sure to use only the fasteners matched to the cone angle of your wheel (usually 60 or 90 ). The proper procedure for attaching your wheels is as follows: 1. Start all bolts or nuts by hand to prevent cross threading. 2.

  • Page 442: Maximum Wheel Fastener Torque

    Maximum Wheel Fastener Torque The wheel mounting studs used on Dexter axles conform to the SAE standards for grade 8. The maximum torque level that can be safely applied to these studs is listed in the following chart: Stud Size Max.

  • Page 443: Tires

    Tires Before mounting tires onto the wheels, make certain that the rim size and contour is approved for the tire as shown in the Tire and Rim Association Yearbook or the tire manufacturers catalog. Also, make sure the tire will carry the rated load. If the load is not equal on all tires due to trailer weight distribution, use the tire rated for the heaviest wheel position.

  • Page 444: Tire Wear Diagnostic Chart

    Tire Wear Diagnostic Chart Cause Wear Pattern Action Adjust pressure to Center Wear Over Inflation particular load per tire catalog Adjust pressure to Edge Wear Under Inflation particular load per tire catalog Make sure load doesn't Side Wear Loss of camber exceed axle rating.

  • Page 445: Replacement Parts/Kits

    Replacement Parts/Kits Magnet Replacement Kits Brake Magnet Kit No. Wire Nut Torque Size (one magnet per kit) Color Brake Mounting 7 x 1 K71-057-00 White 45-70 10 x 2 K71-104-00 Green 45-70 12 x 2 K71-105-00 White 25-50 12 x 2 K71-125-00 (7K) Black 25-50...

  • Page 446: Bearing Replacement Chart

    Bearing Replacement Chart Brake Dexter Kit Industry Part # Axle Size Size Bearings Number Cup /Cone Capacity 7 x 1 4 or 5 Inner K71-306-00 L44610 / L44649 Bolt Outer K71-306-00 L44610 / L44649 10 x 1 4 or 5 Inner K71-307-00 LM67010 / LM67048...

  • Page 447: Storage Preparation

    Storage Storage Preparation If your trailer is to be stored for an extended period of time or over the winter, it is important that the trailer be prepared properly. 1. Remove the emergency breakaway battery and store inside, out of the weather. Charge the battery at least every 90 days.

  • Page 448: After Prolonged Storage - Inspection Procedures

    After Prolonged Storage - Inspection Procedures Before removing trailer from jack stands: 1. Remove all wheels and hubs or brake drums. Note which spindle and brake that the drum was removed from so that it can be reinstalled in the same location. 2.

  • Page 449: Trip Preparation Checklist

    Trip Preparation Checklist There are a number of simple rules to follow in caring for your trailer axle assembly that can add to its life and in the case of some of these rules, you may be protecting your own life as well. Using the following checklist before starting a trip with your trailer is highly recommended.

  • Page 450: Maintenance Schedule

    Maintenance Schedule 6 Months 3 Months or 12 Months Item Function Required Weekly or 6000 3000 Miles or 12000 Miles Miles Brakes Test that they are At Every operational. Brake Adjust to proper Adjustment operating clearance. Brake Inspect for wear and Magnets current draw.

  • Page 451: Dexter Axle Limited Warranty

    Dexter Axle Limited Warranty WHAT PRODUCTS ARE COVERED All Dexter trailer axles, suspensions, and brake control systems excluding Dexter 6000 series Manufactured Housing Axles. LIMITED 2 YEAR WARRANTY Dexter Axle warrants to the original purchaser that its axles, suspension systems, and E/H hydraulic brake actuators shall be free from defects in material and workmanship for a period of two (2) years from the date of first sale of the trailer incorporating such components.
  • Page 452 EXCLUSIONS These warranties do not extend to or do not cover defects caused by: The connecting of brake wiring to the trailer wiring or trailer wiring to the towing vehicle wiring. The attachment of the running gear to the frame. Hub imbalance, or any damage caused thereby.
  • Page 453 These warranties give you specific legal rights, and you may also have other rights which vary from state to state. THE DURATION OF ANY IMPLIED WARRANTIES, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO THE DURATION OF THE EXPRESS WARRANTIES HEREIN.
  • Page 454 Dexter Online Parts Store From magnet and seal kits to complete brake and hub kits, Dexter offers a complete line of genuine replacement parts for your trailer. Most products are available in-stock and ready to ship within 24 hours direct to you from the factory.
  • Page 455 Service Record Date Service Performed Mileage...
  • Page 456 Service Record Date Service Performed Mileage...
  • Page 457 Service Record Date Service Performed Mileage...
  • Page 458 Genuine Dexter axles and components are available nationwide from our plant locations listed below or through our network of distributors. Check our website for the distributor nearest you. Visit us online at: www.dexteraxle.com Dexter Axle Dexter Axle Road 75 East 11870 N.
  • Page 459 www.dexteraxle.com 2900 Industrial Parkway East • Elkhart, IN 46516 Fax: 574-295-8666 • Ph. 574-295-7888 2/07 © Dexter Axle 2007 LIT-001-00...

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