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TSE DPT40-B Owner's Manual

Puller/tensioner
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Table of Contents

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Owner's Manual
Model: DPT40-B
Puller / Tensioner
Serial Number 1 -
-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: DPT40-B Puller / Tensioner Serial Number 1 - www.tse-international.com 5301 Shreveport Blanchard Hwy – Shreveport, Louisiana 71107 – USA P: 318-929-2368 F: 318-929-4853...
  • Page 2 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 3 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 4 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 5 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 6 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 7 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 8 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 9 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 12 7601116-C LIGHTING DIAGRAM 7601128 CONTROL PANEL ASSEMBLY 8600484-A OVERHEAD LEVELWIND ASSEMBLY 760188-N LEVELWIND ASSEMBLY 7600250-E LEVELWIND PLUMBING 8602493 LEVELWIND, OVER/UNDER – DPT40-B 860106-O OVERHEAD/UNDERGROUND BOOM-OPTIONAL 563016-C HIGH SPEED POLEMASTER–OPTIONAL 860952-G POLEMASTER LEVELWIND ASSEMBLY–OPTIONAL 880256-G BRAKE INSTALLATION SECTION V VENDOR INFORMATION...
  • Page 13 INTRODUCTION GENERAL DESCRIPTION The TSE Model DPT40-B is a trailer mounted single drum puller/tensioner powered by a three cylinder diesel engine and hydrostatic transmission. It incorporates the Timberland Quick-Change Reel Shaft System. The speed, torque, and direction of the transmission are regulated from the...
  • Page 14 SECTION II OPERATION CONTROLS The controls in Figure 1 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. Hydraulic Pressure Gauge - This gauge shows the hydraulic pressure in the system. Do not continuously exceed 3000 psi during the operation of the machine.
  • Page 15 Figure 2: Linepull Control Knob 3. Brake Control - The brake is spring applied and released by hydraulic pressure also shown in Figure 3. To hold the reel stationary, turn the Reel Brake Lever to the APPLY position. Turn to the RELEASE position before driving the reel.
  • Page 16 Figure 4 – Direction Control 5. Direction Lever Stop - A Stop positioned in front of the Direction Control Lever will not allow the Lever to be put in the ‘Pay Out’ direction without the operator lifting the Stop handle to allow the Direction Control Lever to pass.
  • Page 17 4. PROPER ANCHORING OF THE MACHINE IS VERY IMPORTANT! Anchor the unit using the anchoring lugs provided. Use an anchor that will hold three times the maximum pull of the unit. Figure 5: Anchoring Diagram 5. PROPER GROUNDING OF THE MACHINE IS VERY IMPORTANT! The machine is equipped with grounding bars.
  • Page 18 In extreme cold weather operations, special low temperature hydraulic oil is recommended. PULLING (BEGINNING WITH SLACK ROPE) The following procedure describes how to operate the DPT40-B when it is used as a puller and the rope is not under tension.
  • Page 19 TENSIONING (BEGINNING WITH SLACK ROPE) This procedure describes how to set the DPT40-B when it is used as a tensioner and the rope is not under tension. WARNING: DO NOT FOLLOW THIS PROCEDURE WHEN THERE IS TENSION ON THE CONDUCTOR.
  • Page 20 RESUMING TENSIONING AFTER A STOP This procedure describes how a pull is to be resumed after a short stop when the Linepull Control and Direction Control are still set from the previous pull. 1. Move the Brake Control to the RELEASE position 2.
  • Page 21 PULLING UNDERGOUND (OPTIONAL) This procedure describes how to use the DPT40-B as an underground puller with the optional underground pulling reel and heavy duty underground levelwind. 1. Load underground reel into machine (see Reel Loading procedure).
  • Page 22 REMOVING THE REEL 1. Turn the reel until the drive arm and lifting loop are in vertical (up) position, shown in Figure 7. Figure 7: Lifting Loop in Vertical Position 2. On the drive arm side, pull the ball lock pin straight up, and pull the reel shaft pin back enough to allow the reel shaft to be lifted up, shown in Figure 8.
  • Page 23 4. Attach lifting hooks to the drive arm and lifting loop. Ensure they are balanced so the reel remains level during lifting. 5. Lift the reel straight up. 6. Remove the bronze bearing from reel shaft. 7. Loosen the nuts on the lifting loop and remove it from reel shaft. 8.
  • Page 24 At the tensioner, the corresponding Polemaster drum is removed from its brake on the pole and installed on the DPT40-B High Speed PoleMaster drive as detailed below. 1. Disconnect the chain drive from the reel as described in Freewheeling Payout section. This allows the Polemaster drum to turn without also turning the reel shaft.
  • Page 25 5. Slide the Polemaster drum onto the Polemaster drive shaft making sure the rope exits from the top of the drum toward the rear of the DPT40-B. You may have to rotate the Drum slightly to line up the Drive Slots in the Drum with the Shaft Drive Pins.
  • Page 26 3. When the pulling rope for the first phase arrives at the Tensioner end, it is removed from the end of the pilot rope, and is attached to the end of the conductor. 4. In preparation for tensioning the conductor, remove the full Polemaster Drum from the DPT40-B. 5. Remove the Polemaster drive shaft and store.
  • Page 27 SECTION III MAINTENANCE SCOPE 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 28 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 29 LUBRICATION DATA LUBRICANT LUBRICANT INFORMATION GRADES APPLICATION PART # TSE STANDARD HYDRAULIC FLUID (REFER TO HYDRAULIC OIL DECAL HYDRAULIC SYSTEM AW46 LOCATED ON HYDRAULIC RESERVOIR ISO 46 567851 FLUID TO DETERMINE WHAT HYDRAULIC FLUID IS USED IN YOUR MACHINE) BEARINGS, SHAFTS,...
  • Page 30 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 48 2.9 L OEM Diesel Engines (Final Tier 4/Stage IV Platform) OPERATOR'S MANUAL 2.9 L OEM Diesel Engines (Final Tier 4/Stage IV Platform) OMRG39496 ISSUE 25MAR15 (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 3029HFC03 Left Rear View 3029HFC03 Right Front View ZE59858,0000048 -19-15SEP14-1/1 032715 PN=5...
  • Page 53 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 54 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 032715 PN=7...
  • Page 55 Introduction 032715 PN=8...
  • Page 56 Contents Page Page Record Keeping Supplemental Diesel Fuel Additives ....10-1 Record Engine Serial Number......01-1 Lubricity of Diesel Fuel ........10-2 Engine Option Codes .........01-2 Handling and Storing Diesel Fuel .......10-2 Record Aftertreatment Serial Numbers ....01-3 BioDiesel Fuel ............10-3 Record High-Pressure Fuel Pump Testing Diesel Fuel ..........10-4 Model Number..........01-3 Fuel Filters............10-4...
  • Page 57 Contents Page Page Pressure Testing Cooling System.....40-10 Engine Operation Checking and Adjusting Engine Speeds ..40-11 Break-In Service ..........20-1 Generator Set (Standby) Applications ....20-2 Lubrication & Maintenance — 1200 Hours Starting the Engine ..........20-2 Checking and Adjusting Valve Clearance...45-1 Normal Engine Operation ........20-3 Warming Engine ..........20-4 Lubrication &...
  • Page 58 Contents Page Storage Engine Storage Guidelines.........70-1 Preparing Engine for Long-Term Storage...70-1 Removing Engine from Long-Term Storage ..70-2 Specifications General OEM Engine Specifications ....75-1 Engine Power Ratings And Fuel System Specifications ........75-2 Engine Crankcase Oil Fill Quantities ....75-2 Unified Inch Bolt and Screw Torque Values..75-3 Metric Bolt and Screw Torque Values....75-4 Lubrication and Maintenance Records Using Lubrication and Maintenance Records..80-1...
  • Page 59 Contents 032715 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: CD3029U123456 • “CD” = Saran, France The engine serial number plate (C) is located on the 3029HFC03 right-hand side of cylinder block.
  • Page 61 Record Keeping Engine Option Codes JOHN DEERE PY3029R000093 Number 3029HFC09 2.9L 1553 C 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 Front Plate Switches and Sensors Fuel Transfer Pump Air Compressor Thermostat Housing Electronic Software (Vehicle Option) Oil Dipstick Electrical Wiring Harness Belt-Driven Front Auxiliary Drive Fan Pulley Starting Aid Belt Tensioner Timing Gear Cover Exhaust Gas Recirculating (EGR) System Balancer Shafts Software...
  • Page 63 Record Keeping Record Engine Control Unit (ECU) Serial Number Record the part number and serial number information found on the serial number label (A) on the Engine Control Unit (ECU) mounted on or near the engine. Part No. Serial No. A—Serial Number Label Record Engine Control Unit (ECU) Serial Number ZE59858,0000295 -19-04DEC13-1/1...
  • Page 64 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 65 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 66 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 67 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 68 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 69 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 70 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 71 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 72 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 73 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 74 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 75 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 76 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 77 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 032715 PN=30...
  • Page 78 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 79 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 80 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 81 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 82 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 83 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 84 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 85 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 86 Fuels, Lubricants, and Coolants Lubricant Storage Your equipment can operate at top efficiency only when Make certain that all containers are properly marked to clean lubricants are used. identify their contents. Use clean containers to handle all lubricants. Properly dispose of all old containers and any residual Store lubricants and containers in an area protected from lubricant they may contain.
  • Page 87 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 88 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 89 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 90 Instrument Panels Instrument Panels Final Tier 4/Stage IV John Deere PowerTech™ OEM Engines have an electronic control system, which has the following 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 91 Instrument Panels The throttle control (K) is used to control engine speed. H—Bump Speed Enable Rocker Switch This control is available only on engines with analog This is a three-position switch (H) with the center position throttle. as “OFF” (locked). With this switch in the “OFF” position, L—Engine Oil Pressure Gauge the speed select switch (I) is also locked, to prevent accidental changes in operating speed.
  • Page 92 Instrument Panels Using Diagnostic Gauge to Access Engine Information The diagnostic gauge (A) allows the operator to view many readouts of engine functions and trouble codes (DTCs). The gauge is linked to the electronic control system and its sensors. This allows the operator to monitor engine functions and to troubleshoot the engine systems when needed.
  • Page 93 Instrument Panels 2. The first seven items of the "Main Menu" will be displayed. Menu Display OURGP11,00000A9 -19-11OCT06-2/5 3. Pressing the "Arrow" keys will scroll through the menu selections. Main Menu Items OURGP11,00000A9 -19-11OCT06-3/5 4. Pressing the right arrow key will scroll down to reveal the last items of "Main Menu"...
  • Page 94 Instrument Panels 5. Use the arrow keys to scroll to the desired menu item or press the "Menu Button" to exit the main menu and return to the engine parameter display. Use Arrow Buttons To Scroll / Quadrant Display OURGP11,00000A9 -19-11OCT06-5/5 Engine Configuration Data NOTE: The engine configuration data is a read only function.
  • Page 95 Instrument Panels 3. Once "Engine Config" menu item has been highlighted, press the "Enter" key to view the engine configuration data. Enter Key OURGP11,00000AB -19-11OCT06-3/6 4. Use the "Arrow" keys to scroll through the engine configuration data. Use Arrow Keys To Scroll OURGP11,00000AB -19-11OCT06-4/6 5.
  • Page 96 Instrument Panels 6. Press the "Menu" key to exit the main menu and return to the engine parameter display. Exit Main Menu OURGP11,00000AB -19-11OCT06-6/6 Accessing Stored Trouble Codes 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.
  • Page 97 Instrument Panels 3. Once the "Stored Codes" menu item has been highlighted press the "Enter" key to view the stored codes. Enter Key OURGP11,00000AC -19-11OCT06-3/6 4. If the word "Next" appears above the "Arrow" keys, there are more stored codes that may be viewed. Use the "Arrow"...
  • Page 98 Instrument Panels 6. Press the "Menu" key to exit the main menu and return to the engine parameter display. Exit Main Menu OURGP11,00000AC -19-11OCT06-6/6 Accessing Active Trouble Codes 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.
  • Page 99 Instrument Panels IMPORTANT: Ignoring active trouble codes can result in severe engine damage. 4. To acknowledge and hide the code and return to the single or four parameter display, press the "Enter" Key. Hide Trouble Codes OURGP11,00000AD -19-11OCT06-4/7 5. The display will return to the single or four parameter display, but the display will contain the warning icon.
  • Page 100 Instrument Panels Engine Shutdown Codes 1. During normal operation the single or four parameter screen will be displayed. Normal Operation OURGP11,00000AE -19-11OCT06-1/6 2. When the diagnostic gauge receives a severe trouble code from an engine control unit, the single or four parameter screen will be replaced with the "Shutdown"...
  • Page 101 Instrument Panels 5. Pressing the "Enter" key once again will hide the trouble code and return the screen to the single or four parameter display. Redisplay Trouble Code OURGP11,00000AE -19-11OCT06-5/6 6. The single or four parameter screen will display the shutdown icon until the trouble code condition is corrected.
  • Page 102 Instrument Panels 3. Once the "Adjust Backlight" menu item has been highlighted, press the "Enter" key to activate the "Adjust Backlight" function. Press Enter Key OURGP11,0000237 -19-23AUG10-3/6 4. Use the "Arrow" keys to select the desired backlight intensity. Adjust Backlight Intensity OURGP11,0000237 -19-23AUG10-4/6 5.
  • Page 103 Instrument Panels 6. Press the "Menu" key to exit the main menu and return to the engine parameter display. Exit Main Menu OURGP11,0000237 -19-23AUG10-6/6 Adjusting Contrast 1. Turn the key switch to the ON position. Starting at the single or four engine parameter display press the "Menu"...
  • Page 104 Instrument Panels 4. Use the "Arrow" keys to select the desired contrast intensity. Adjust Contrast Intensity OURGP11,00000AF -19-11OCT06-4/6 5. Press the "Menu" key to return to the main menu. Return To Main Menu OURGP11,00000AF -19-11OCT06-5/6 6. Press the "Menu" key to exit the main menu and return to the engine parameter display.
  • Page 105 Instrument Panels 2. The main menu will be displayed. Use the "Arrow" keys to scroll through the menu until "Select Units" is highlighted. Select Units OURGP11,00000B0 -19-11OCT06-2/7 3. Once the "Select Units" menu item has been highlighted press the "Enter" key to access the "Select Units"...
  • Page 106 Instrument Panels 5. Press the "Enter" key to select the highlighted units. Press Enter Key to Select OURGP11,00000B0 -19-11OCT06-5/7 6. Press the "Menu" key to return to the main menu. Return To Main Menu OURGP11,00000B0 -19-11OCT06-6/7 7. Press the "Menu" key to return to the engine parameter display.
  • Page 107 Instrument Panels Use the "Arrow" keys to scroll through the menu until "Setup 1-Up Display" is highlighted. Setup 1-Up Display OURGP11,00000B1 -19-11OCT06-2/18 3. Once "Setup 1-Up Display" menu item has been highlighted press the "Enter" key to access the "Setup 1-Up Display"...
  • Page 108 Instrument Panels 5. Use Defaults - To select "Use Defaults" use the Arrow keys to scroll to and highlight "Use Defaults" in the menu display. Select Defaults OURGP11,00000B1 -19-11OCT06-5/18 6. Press the "Enter" key to activate the "Use Defaults" function. Defaults Selected OURGP11,00000B1 -19-11OCT06-6/18 The display parameters are reset to the factory...
  • Page 109 Instrument Panels 8. Custom Setup - To perform a custom setup of the 1-Up Display, use the arrow buttons to scroll to and highlight "Custom Setup" on the display. Select Custom Setup OURGP11,00000B1 -19-11OCT06-8/18 9. Press the "Enter" key to display a list of engine parameters.
  • Page 110 Instrument Panels 11. Press the "Enter" key to deselect the selected parameter, removing it from the list of parameters being displayed on the 1-Up Display. Deselect Parameters OURGP11,00000B1 -19-11OCT06-11/18 12. Use the "Arrow" keys to scroll and highlight the desired parameter that has not been selected for display (parameter without a number to right of it).
  • Page 111 Instrument Panels 15. Automatic Scan - Selecting the scan function will allow the 1- Up Display to scroll through the selected set of parameters one at a time. Use the "Arrow" keys to scroll to the "Automatic Scan" function. Automatic Scan Off OURGP11,00000B1 -19-11OCT06-14/18 16.
  • Page 112 Instrument Panels 18. Once the "Use Defaults", "Custom Setup" and "Automatic Scan" functions have been set, press the "Menu" key to return to the main menu. Menu Key OURGP11,00000B1 -19-11OCT06-17/18 19. Press the "Menu" key to exit the main menu and return to the engine parameter display.
  • Page 113 Instrument Panels 3. Once the "Setup 4-Up Display" menu item has been highlighted, press the "Enter" key to activate the "Setup 4-Up Display" menu. Press Enter Key OURGP11,00000B2 -19-11OCT06-3/14 4. Two options are available for the 4-Up Display. a. Use Defaults – This option contains the following engine parameters for display: Engine Speed, Battery Voltage, Coolant Temperature and Oil Pressure.
  • Page 114 Instrument Panels Custom Setup - To perform a custom setup of the 4-Up Display, use the arrow buttons to scroll to and highlight "Custom Setup" on the display. Custom Setup OURGP11,00000B2 -19-11OCT06-6/14 The quadrant with the highlighted parameter value is the current selected parameter. Use the "Arrow" keys to highlight the value in the quadrant you wish to change to a new parameter.
  • Page 115 Instrument Panels 9. The parameter that is highlighted is the selected parameter for the screen. Use the "arrow" keys to highlight the new parameter to be placed in the "4-Up Display". Select Desired Engine Parameter OURGP11,00000B2 -19-11OCT06-9/14 10. Press the "Enter" key to change the selected parameter in the quadrant to the new parameter.
  • Page 116 Instrument Panels 13. Repeat the parameter selection process until all spaces are as desired. 14. Press the "Menu" key to return to the main menu. Return To Main Menu OURGP11,00000B2 -19-11OCT06-13/14 15. Press the "Menu" key to exit the main menu and return to the engine parameter display.
  • Page 117 Engine Operation Break-In Service 1. This engine is factory-filled with John Deere Break-In Plus oil. Operate the engine at heavy loads with minimal idling during the break-in period. 2. If the engine has significant operating time at idle, constant speeds, and light load usage, or make-up oil is required in the first 100 hour period, a longer break-in period may be required.
  • Page 118 Engine Operation Generator Set (Standby) Applications use only petroleum based diesel fuel with John Deere approved fuel conditioners and additives. For fuel To assure that your engine will deliver efficient standby conditioners and additives, check with your local John generator operation when needed, start engine and run at Deere dealer.
  • Page 119 Engine Operation 5. Turn the key start switch (A) clockwise to the “ON” position. Wait until the Engine Preheater Indicator light turns off, then turn the key start switch clockwise “START” position to crank the engine. (In cold weather, preheater indicator light remains on longer while engine is warmed.
  • Page 120 Engine Operation Warming Engine IMPORTANT: To assure proper lubrication, operate engine at or below 1200 rpm with no load for 1–2 minutes. Extend this period 2–4 minutes when operating at temperatures below freezing. Engines used in generator set applications where the governor is locked at a specified speed may not have a slow idle function.
  • Page 121 Engine Operation Changing Engine Speed NOTE: On engines with 2-position throttles, speeds are not adjustable. These throttles allows operation only at the preset rated speed or at idle using the single switch (A). Changing from slow to fast speed using Standard High-Low Speed Select Rocker Switch (A) (If Equipped): •...
  • Page 122 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 123 Engine Operation Stopping the Engine 1. Pull PTO clutch lever rearward (away from engine) to disengage clutch, if equipped. IMPORTANT: Before stopping an engine that has been operating at working load, idle engine at least 2 minutes at 1000—1200 rpm to cool hot engine parts.
  • Page 124 Engine Operation Auxiliary Gear Drive Limitations IMPORTANT: See OEM engine distributor for more information to prevent overloading the auxiliary drive. Severe engine damage could result. 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: •...
  • Page 125 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 126 Aftertreatment System Diesel Particulate Filter Maintenance and engines below 175hp/130kW and 4,500 hours for engines at or above 175hp/130kW. The use of recommended Service John Deere fluids will extend the life of the aftertreatment The Exhaust Filter includes the Diesel Oxidation Catalyst system and extend the maintenance intervals of the DPF.
  • Page 127 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 128 Aftertreatment System Diagnostic Gauge Keys and Indicators Overview The image below shows all the keys and indicators you will see and use through the operator initiated or auto exhaust filter cleaning and disable processes. Diagnostic Gauge Indicators and Keys A—Exhaust Filter Cleaning C—Exhaust Filter Indicator E—Warning Indicator H—Menu Key...
  • Page 129 Aftertreatment System on the diagnostic gauge screen. The Menu key (H) is The instructions in this section refer to the keys on used to access the main menu of options from which the the diagnostic gauge. The Enter key (F) is used when operator can choose.
  • Page 130 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 131 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 132 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 133 Lubrication and Maintenance Lubrication and Maintenance Service Interval Chart Lubrication and Maintenance Service Intervals 1500 6000 Hours of Hours of Hours of Hours of Operation Operation 1200 Operation Operation or Every or Every Hours of or Every or Every 72 Service as Item Daily...
  • Page 134 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 135 Lubrication & Maintenance — 250 Hours/12 Months Removing and Installing Fuel Filter CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting fuel or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure.
  • Page 136 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 137 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 138 Lubrication & Maintenance — 500 Hours/12 Months Changing Engine Oil and Replacing Filter NOTE: During the initial operation of a new or rebuilt engine with Break-In Plus, change the oil and filter between a minimum of 100 hours and a maximum of up to 500 hours.
  • Page 139 Lubrication & Maintenance — 500 Hours/12 Months 5. Remove filter element (A) using a suitable filter wrench. Remove inner seal (B). Discard oil filter element and seal. NOTE: Depending on engine application, oil filter is mounted in the vertical or horizontal position. IMPORTANT: Filtration of oils is critical to proper lubrication.
  • Page 140 Lubrication & Maintenance — 500 Hours/12 Months Visually Inspecting Coolant Pump NOTE: Cooling pump drive pulley is transparent for clarity purposes. 1. Inspect coolant weep hole (B). Clean weep hole if blocked. 2. Coolant leakage indicates a damaged seal. 3. A slight weeping of coolant is normal. If enough coolant leaks from the weep hole that it drips from the engine, the coolant pump assembly should be replaced or repaired.
  • Page 141 Lubrication & Maintenance — 500 Hours/12 Months Checking Engine Mounts Engine mounting is the responsibility of the Original Equipment Manufacturer. Follow manufacturer's guidelines for mounting specifications. IMPORTANT: Use only Grade SAE 8 or higher grade of hardware for engine mounting. 1.
  • Page 142 Lubrication & Maintenance — 500 Hours/12 Months 3. If adjustment is necessary, loosen alternator bracket cap screw (C) and nut (D) on mounting bolt. Pull alternator frame outward until belts are correctly tensioned. 4. Tighten alternator bracket cap screw and nut to specification.
  • Page 143 Lubrication & Maintenance — 500 Hours/12 Months Checking Air Intake System IMPORTANT: The air intake system must not leak. Any leak, no matter how small, may result in internal engine damage due to abrasive dirt and dust entering the intake system. 1.
  • Page 144 Lubrication & Maintenance — 500 Hours/12 Months Checking Cooling System CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.
  • Page 145 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 146 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 147 Lubrication & Maintenance — 1200 Hours Checking and Adjusting Valve Clearance CAUTION: To prevent accidental starting of engine while performing valve adjustments, always disconnect NEGATIVE (—) battery terminal. IMPORTANT: Valve clearance MUST BE checked and adjusted with engine COLD. 1. Remove fuel injector heat shield, crankcase ventilator tube, and rocker arm cover.
  • Page 148 Lubrication & Maintenance — 1200 Hours Valve Clearance Adjustment — No. 1 TDC 4. With engine locked at TDC of No. 1 piston compression stroke, use a bent feeler gauge to check valve clearance on No. 1 and 2 exhaust and No. 1 and 3 intake valves.
  • Page 149 Lubrication & Maintenance — 1200 Hours Valve Clearance Adjustment — No. 1 TDC Exhaust 5. Using the flywheel turning tool, rotate engine in 7. Remove timing pin and flywheel turning tool. Replace operating direction 360°, until locking pin engages plug in flywheel housing. timing hole in flywheel.
  • Page 150 Lubrication & Maintenance — 1200 Hours 13. Engage the fuel injector heat shield (B) into the external groove (C) in the rocker arm cover. 14. Install cap screws (A) and tighten to specification. Specification Cap Screw —Torque............11 N·m (97 lb.-in.) 15.
  • Page 151 Lubrication & Maintenance — 1500 Hours/24 Months 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.
  • Page 152 Lubrication & Maintenance — 1500 Hours/24 Months Install OCV Filter Assembly 1. Install two cap screws (I) through the OCV filter assembly (J) into the threaded holes in the intake manifold. Tighten cap screws to specification. Specification OCV Filter Assembly Mounting Cap Screws —Torque...............
  • Page 153 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 loosen cap to first stop to relieve pressure before removing completely.
  • Page 154 Lubrication & Maintenance — 6000 Hours/72 Months 6. Remove the coolant pump bypass tube from the thermostat housing (H). Remove cap screws (G), thermostat housing (H) and thermostat (I). 7. Reinstall thermostat housing (H) and gasket (J) without the thermostat. Tighten cap screws (G) to specification.
  • Page 155 Lubrication & Maintenance — 6000 Hours/72 Months Testing Thermostat Opening Temperature Removing Thermostat 1. Visually inspect area around thermostat housing for leaks. CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. DO NOT drain coolant until it has cooled below operating temperature.
  • Page 156 Lubrication & Maintenance — 6000 Hours/72 Months Testing Thermostat Opening Temperature 1. Visually inspect thermostat for corrosion or damage. CAUTION: DO NOT allow thermostat or thermometer to rest against the side or bottom of container when heating water. Either may become damaged if overheated.
  • Page 157 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 OURGP11,0000048 -19-23AUG10-1/1 Do Not Modify Fuel System CAUTION: Do not open high-pressure fuel system. High-pressure fluid remaining in fuel lines can cause serious injury.
  • Page 158 Service As Required Drain Water From Fuel Filter 1. Loosen drain valve (A) to drain water and debris as needed. If necessary, open air bleed screw to allow water to drain from separator. 2. Retighten drain valve securely. 3. Bleed air from the fuel system as required. See Bleeding Fuel System in Service As Required section.
  • Page 159 Service As Required 1. Loosen the air bleed vent screw (B) two full turns. 2. On mechanical supply pumps, operate supply pump primer lever (A) until fuel flow is free from air bubbles. 3. On electric supply pumps, turn key switch to “ON” position until fuel flow is free from air bubbles.
  • Page 160 Service As Required Adding Coolant CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.
  • Page 161 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 162 Service As Required Replacing Single Stage Air Cleaner IMPORTANT: ALWAYS REPLACE air cleaner when air filter restriction indicator shows a vacuum of 625 mm (25 in.) H O, is torn, or visibly dirty. NOTE: This procedure applies to John Deere single stage air cleaner kits.
  • Page 163 Service As Required Replacing Axial Seal Air Cleaner Filter Element IMPORTANT: ALWAYS REPLACE primary air cleaner element when air restriction indicator (A) shows a vacuum of 625 mm (25 in.) H is torn, or visibly dirty. NOTE: This procedure applies to John Deere 2-stage axial seal air cleaner kits.
  • Page 164 Service As Required 1. Remove wing nut and remove canister cover shown in small illustration inset. 2. Remove wing nut (A) and remove primary element (B) from canister. 3. Thoroughly clean all dirt from inside canister. NOTE: Some engines may have a dust unloader valve (C) on the air cleaner.
  • Page 165 Service As Required Replacing Radial Seal Air Cleaner Filter Element IMPORTANT: ALWAYS REPLACE primary air cleaner element when air 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 166 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 167 Service As Required • Checking Fuses JDLink fuse — 10 Amp • ECU fuse — 20 Amp Check the following fuses located in the control panel • Transient Voltage Protection (TVP) fuse — 30 Amp wiring harness. Replace defective fuses. See 2.9 L Wiring Diagram 5 in the Troubleshooting Section.
  • Page 168 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 169 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 170 Troubleshooting 1136 ECU Temperature Signal 1180 Calculated Turbocharger Turbine Inlet Temperature 1209 Exhaust Manifold Pressure Signal 1347 Suction Control Valve Circuit 1569 Engine Power Derate 2002-2253 Source Address 2-253 2797 Injector High Voltage Supply #1 3246 DPF Outlet Temperature 3251 DPF Differential Pressure Signal 3465 Exhaust Throttle Actuator Drive Circuit...
  • Page 171 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 172 Troubleshooting Engine Troubleshooting and perform the corrective actions. (See earlier in this section.) If any problems remain, use the NOTE: Before troubleshooting the engine, first retrieve following charts to solve engine problems. any fault codes on the diagnostic gauge display Symptom Problem Solution...
  • Page 173 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 174 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 175 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 176 Troubleshooting Symptom Problem Solution Excessive valve clearance Check and adjust valve clearance. See Adjusting Valve Clearance in the Lubrication & Maintenance 2000 Hours/24 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 177 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 178 Troubleshooting Symptom Problem Solution Defective thermostat(s) (does not Test thermostats; replace thermostats as required. close) Coolant entering combustion chamber Repair or replace as required. See (failed cylinder head gasket or cracked your authorized John Deere engine cylinder head) distributor or servicing dealer. Electronic Control System problem or See your authorized John Deere basic engine problem...
  • Page 179 Troubleshooting Symptom Problem Solution Lack of coolant in cooling system Fill cooling system to proper level. Check radiator and hoses for loose connections or leaks. Low engine oil level Check oil level. Add oil as required. Radiator core dirty Clean cooling system as required. Cooling system needs flushing Flush coolant system.
  • Page 180 Troubleshooting Symptom Problem Solution Cylinder head or block cracked Locate crack, repair/replace components as required. See your authorized John Deere engine distributor or servicing dealer. Cylinder liner seals leaking Remove and inspect cylinder liners. See your authorized John Deere engine distributor or servicing dealer. Pitted cylinder liners Remove and inspect cylinder liners.
  • Page 181 Troubleshooting Symptom Problem Solution Crankcase oil level too high Check engine oil level and drain as necessary. High Oil Pressure Improper oil classification Drain crankcase and refill with correct oil. Faulty pressure sensor Replace sensor. See your authorized John Deere engine distributor or servicing dealer.
  • Page 182 Troubleshooting Symptom Problem Solution Worn valve guides or stems Inspect and measure valve stems and valve guides; repair as required. See your authorized John Deere engine distributor or servicing dealer. Piston ring grooves excessively worn Remove and inspect pistons. See your authorized John Deere engine distributor or servicing dealer.
  • Page 183 Troubleshooting Symptom Problem Solution Starter and Hourmeter Functions; Blown fuse Replace fuse. Rest of Electrical System Does Not Function Entire Electrical System Does Not Faulty battery connection Clean and tighten connections. Function Sulfated or worn-out batteries Replace batteries. Blown fuse Replace fuse.
  • Page 184 Troubleshooting Engine Wiring Harness Layout NOTE: Location of some sensors may change depending upon the application. A—Exhaust Throttle Actuator C—Manifold Air Pressure (MAP) D—Cold Start Aid Relay B—Manifold Air Temperature Sensor (MAT) Sensor Continued on next page ZE59858,000006A -19-17APR14-1/5 65-17 032715 PN=137...
  • Page 185 Troubleshooting A—Fuel Injector Harness B—Suction Control Valve Connector Continued on next page ZE59858,000006A -19-17APR14-2/5 65-18 032715 PN=138...
  • Page 186 Troubleshooting A—Engine Oil Pressure Sensor C—Fuel Rail Pressure Sensor B—Exhaust Manifold Pressure D—Fuel Temperature Sensor Sensor Continued on next page ZE59858,000006A -19-17APR14-3/5 65-19 032715 PN=139...
  • Page 187 Troubleshooting A—Intake Air Temperature B—Engine Coolant Temperature C—Camshaft Position Sensor Sensor Sensor D—Crankshaft Position Sensor Continued on next page ZE59858,000006A -19-17APR14-4/5 65-20 032715 PN=140...
  • Page 188 Troubleshooting A—Air Filter Restriction Indicator B—Exhaust Filter Temperature C—DPF Differential Pressure Connector Module Connector Sensor Connector ZE59858,000006A -19-17APR14-5/5 65-21 032715 PN=141...
  • Page 189 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 190 Troubleshooting 2.9 L Wiring Diagram 1 Injector 1 5493 5491 Injector 2 5493 5494 5495 5494 5491 5491 Y5021 Fuel Injector Harness Connector Injector 3 5493 5493 5495 5494 5494 A5501 5491 5495 5495 ECU Harness 5491 5491 Connector 1 5410 B5301A Crankshaft Position...
  • Page 191 Troubleshooting A5501— ECU Connector 1 A5501-23— [5495 Green] Injector A5501-51— [5447 Violet] C01— Fuel Injector #1 A5501-06— [5491 Brown] Injector #3 Pulse Crankshaft Position C02— Fuel Injector #2 #1, #2, and #3 Power A5501-30— [5448 Gray] Sensor Signal C03— Fuel Injector #3 A5501-09—...
  • Page 192 Troubleshooting 2.9 L Wiring Diagram 2 B5208 Engine Coolant Temperature Sensor 5461 5461 5643 5643 B5209 Fuel Temperature Sensor A5502 5427 5427 ECU Harness 5643 Connector 2 B5206 Manifold Air Temperature Sensor 5456 5456 5658 5658 B5214 Intake Air Temperature Sensor 5455 5455 5658...
  • Page 193 Troubleshooting 2.9 L Wiring Diagram 3 A5501 ECU Harness Connector 1 B5101 Engine Oil Pressure Sensor 5634 5634 5636 5636 5467 B5102 Exhaust Manifold Pressure Sensor 5634 5636 5465 A5502 ECU Harness Connector 2 B5100 Fuel Rail Pressure Sensor 5467 5465 5613 5613...
  • Page 194 Troubleshooting 2.9 L Wiring Diagram 4 A5501 ECU Harness Connector 1 Y5402 Exhaust Throttle Actuator 5631 5631 5633 5633 5509 5018 5018 5016 5016 5783 5786 B5204 Exhaust Filter Temperature Module 5786 5783 5474 5437 A5502 ECU Harness Connector 2 B5204A Exhaust Filter Temperature...
  • Page 195 Troubleshooting A5501— ECU Connector 1 A5501-19— [5633 Orange] 5 V A5502-12— [5509 White] Exhaust B5109A— DPF Differential A5501-02— [5018 Gray] Exhaust Sensor Supply #3 Return Throttle Actuator Pressure Sensor Throttle Actuator Drive A5501-20— [5783 Orange] 10 V Position Signal Interconnect Negative Sensor Supply A5502-31—...
  • Page 196 Troubleshooting 65-29 032715 PN=149...
  • Page 197 Troubleshooting 2.9 L Wiring Diagram 5 A5501 ECU Harness 5671 Connector 1 5637 R5607 K5803 Cold Start Aid Cold Start R5604 Aid Relay Cold Start Aid Relay Connector F5010 5671 5637 Cold Start Aid X5002 Fuse (50 A) Alternator Excitation Interconnect X5009 5671...
  • Page 198 Troubleshooting A— [5412 Red] Alternator A5503-43— [5050 Black] Battery F5004— JD Link Fuse (10 Amp) R5607— Cold Start Aid Excitation To 2.9 L Wiring Negative F5010— Cold Start Aid Fuse (50 V5700— Transient Voltage Diagram 6 A5503-44— [5050 Black] Battery Amp) Protection A5501—...
  • Page 199 Troubleshooting 2.9 L Wiring Diagram 6 5911 5911 X5020 5012 5012 Auxiliary Connector 5714 5714 5971 5971 5954 5954 5913 5913 5027 5027 5039 5039 5939 5939 A5503 5941 5941 ECU Harness 5917 5917 Connector 3 5948 5948 5436 5436 5943 5943 5937...
  • Page 200 Troubleshooting A— [5412 Red] Alternator A5503-18— [5019 White] Variable A5503-38— [5917 Violet] Cruise D— [5050 Black] Battery Negative Excitation From 2.9 L Wiring Speed Fan Signal Remote Switch To 2.9 L Wiring Diagram 7 Diagram 5 A5503-19— [5027 Violet] PTO A5503-39—...
  • Page 201 Troubleshooting 2.9 L Wiring Diagram 7 A5503 H5200 ECU Harness Exhaust Temperature High Lamp Connector 3 5025 5002 H5003 DPF Regeneration Required Lamp 5026 5002 5025 5026 5028 5029 5034 5038 5037 5047 5041 K5811 Y5025 Starter Relay Starter Solenoid (Application Specific) (Application Specific) 5034...
  • Page 202 Troubleshooting 2.9 L Wiring Diagram 8 5971 S5003 Cruise Cancel / 5050 Resume Switch 5954 S5004 5012 Cruise On Switch 5027 P5300 5050 PTO Speed 5039 P5301 5714 Vehicle Speed 5939 S5009 5050 External Derate Switch 5941 S5005 5911 External Shutdown 5012 X5020 5012...
  • Page 203 Troubleshooting H— From 2.9 L Wiring Diagram 6 S5009— External Derate Switch X5020-G— [5027 Violet] PTO X5020-Q— [5036 Blue] Optional For Mating Connector S5100— AC High Pressure Switch Speed Sensor H5000— Stop Engine Lamp U5000— PWM Throttle/Alternator X5020-H— [5039 White] Vehicle X5020-R—...
  • Page 204 Troubleshooting 2.9 L Wiring Diagram 9 X5021 Control Panel Connector S5000 Key Switch 464 / 914 414 / 914 R5608 Diagnostic Gauge From Diagram 6 CAN Terminator For Mating Connector (120 Ohm) S5013 Bump Enable Switch A5504 Diagnostic Gauge Data+ Data- S5012 Speed Select Switch...
  • Page 205 Troubleshooting A5504— Diagnostic Gauge S5000— Key Switch X5021-G— [012 White] Key Switch X5021-T— [936 White] Cruise A5504-01— [Red] Voltage Positive S5010— Shutdown Override X5021-J— [412 White] Alternator Resume/Bump Down A5504-03— [White] Data Positive Switch Excitation Switch A5504-04— [Orange] Data S5012— Speed Select Switch X5021-L—...
  • Page 206 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 207 Storage Removing Engine from Long-Term Storage NOTE: The following storage removal procedure is used 7. Crank engine for 20 seconds with starter. Do not allow for long-term engine storage up to one year. After the engine to start. Wait 2 minutes and crank engine that, the engine should be started, warmed up, and an additional 20 seconds to assure bearing surfaces retreated for an extended storage period.
  • Page 208 Specifications General OEM Engine Specifications 3029HFC03 ITEM UNIT OF MEASURE 3029HFG03 General Data Number of Cylinders Bore mm (in.) 106.5 (4.2) Stroke mm (in.) 110 (4.3) Displacement L (cu in.) 2.9 (177) 16.9:1 Compression Ratio Aspiration Turbocharged Engine Firing Order 1-2-3 1 Intake Valves Per Cylinder...
  • Page 209 Specifications Engine Power Ratings And Fuel System depending upon specific vehicle application requirements. Refer to your machine operator's Specifications manual for engine speeds that are different NOTE: Power ratings are for bare engines without from those preset at the factory. drag effect of cooling fan or accessories like air compressors.
  • Page 210 Specifications Unified Inch Bolt and Screw Torque Values TS1671 —UN—01MAY03 SAE Grade 1 SAE Grade 2 SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2 Bolt or Screw Size Lubricated Lubricated Lubricated Lubricated N·m lb.-in. N·m lb.-in. N·m lb.-in.
  • Page 211 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 212 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 213 Lubrication and Maintenance Records 500 Hours or 12 Months Service • • Service fire extinguisher. Check V-belt wear. • • Service battery. Check Air Intake System. • • Change engine oil and filter. Check engine electrical ground connection. • • Inspect coolant pump.
  • Page 214 Lubrication and Maintenance Records 1500 Hours or 24 Months Service • Changing Open Crankcase Ventilation (OCV) Filter. Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date Hours Date ZE59858,0000071 -19-19SEP14-1/1 6000 Hours or 72 Months Service •...
  • Page 215 Lubrication and Maintenance Records • Service As Required Clean exhaust filter. • Replace fan belt. • Drain water from fuel filter. • Check fuses. • Bleed fuel system. • Check electrical wiring and connections. • Add coolant. • Check air compressor (if equipped). •...
  • Page 216 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 217 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 218 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 219 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 220 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 221 Warranty DX,EMISSIONS,EPA -19-12DEC12-2/2 85-6 032715 PN=174...
  • Page 222 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 223 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 224 Warranty Continued on next page DX,EMISSIONS,CARB -19-01AUG14-3/8 85-9 032715 PN=177...
  • Page 225 Warranty Continued on next page DX,EMISSIONS,CARB -19-01AUG14-4/8 85-10 032715 PN=178...
  • Page 226 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 227 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 228 Warranty Continued on next page DX,EMISSIONS,CARB -19-01AUG14-7/8 85-13 032715 PN=181...
  • Page 229 Warranty DX,EMISSIONS,CARB -19-01AUG14-8/8 85-14 032715 PN=182...
  • Page 230 Index Page Page Flush ............... 55-1 Pressure test............40-10 Additional Service Information........60-1 Refill ................ 55-1 Aftertreatment Serial Number........01-3 Air cleaner Replace single stage element......... 60-6 Air compressor ............60-11 Air Filter Replacement ..........60-7 Daily prestarting checks ..........35-1 Air Filter, Radial, Replacement ........
  • Page 231 Index Page Page Engine oil Fire extinguisher, service..........40-1 Break-In Fuel Interim tier 4, final tier 4, stage IIIB, and BioDiesel..............10-3 stage IV ............. 10-6 Diesel ..............10-1 Change ..............40-3 Handling and storing ..........10-2 Diesel Lubricity..............10-2 Interim tier 4, final tier 4, stage IIIB, and Fuel filter stage IV .............
  • Page 232 Index Page Page Lubricant Idling ............... 20-4 Mixing..............10-8 Normal operation ............ 20-3 Lubricant Storage Warming engine............20-4 Storage, Lubricant........... 10-9 Option codes .............. 01-2 Lubricants, Safety Orientation View, Engine ..........-5 Safety, Lubricants ........... 10-8 Lubrication and maintenance 1500 hours Changing open crankcase vent (OCV) filter..
  • Page 233 Index Page Page Service Chart 500 hours or 12 months ......... 80-1, 80-2 As required.............. 80-4 Warranty Service Information, Additional........60-1 Non-road emissions control warranty Service intervals statement--compression ignition General information ..........30-1 CARB ..............85-7 Service Records EPA ..............85-5 1500 hours ..............
  • Page 234 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 235 Engine Registration IBC-2 032715 PN=188...
  • Page 236 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 237 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 032715 PN=190...
  • Page 238 Engine Registration IBC-5 032715 PN=191...
  • Page 239 Engine Registration IBC-6 032715 PN=192...

  • Page 240: Series 90

    CONTENTS saue Series 90 Axial Piston Pumps and Motors Service Manual...
  • Page 241 CONTENTS saue Series 90 Introduction 1. Introduction Use of This Manual This manual includes information for the normal be available, and the unit must be thoroughly cleaned operation, maintenance, and servicing of the Series before beginning maintenance, adjustment, or repair 90 family of hydrostatic pumps and motors.
  • Page 242 CONTENTS saue Series 90 Introduction (Continued Next Page) Contents 1. Introduction ..................................2 1.1 Use of This Manual ............................... 2 1.2 Safety Precautions ..............................2 2. Functional Description ..............................5 2.1 General Description and Cross Sectional Views ....................5 2.1.1 Variable Displacement Pumps ........................
  • Page 243 CONTENTS saue Series 90 Introduction (Continued Previous Page) 8. Inspections and Adjustments ............................. 31 8.1 Pump Adjustments .............................. 31 8.1.1 Charge Relief Valve Adjustment ......................31 8.1.2 Multi-Function Valve Pressure Adjustment ..................... 33 8.1.3 Engaging the Bypass Function ....................... 35 8.1.4 Pressure Override (POR) Valve Pressure Adjustment (Option for 180 Frame Size) ......
  • Page 244 CONTENTS saue Series 90 Functional Description 2. 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 2.1.1 Variable Displacement Pumps The Variable Displacement Pump (PV) is designed to convert an input torque into hydraulic power.
  • Page 245 CONTENTS saue Series 90 Functional Description Loop Flushing Valve In the Fixed Displacement Motor the "swashplate" is Piston Valve Plate fixed, so any variation in motor speed and torque Roller Bearing must be made by the input mechanism, i.e. the pump. Output Shaft Fixed Swashplate Cylinder Block...
  • Page 246 CONTENTS saue 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...
  • Page 247 CONTENTS saue Series 90 Functional Description Common Features of Pumps and Motors 2.3.1 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 248 CONTENTS saue Series 90 Functional Description Pump Features 2.4.1 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 transmission.
  • Page 249 CONTENTS saue Series 90 Functional Description 2.4.4 Multi-Function Valves All Series 90 pumps include two multi-function valves. The multi-function valve incorporates the system check valve, the pressure limiter valve, the high pressure relief valve, and the bypass valve in a replaceable cartridge.
  • Page 250 CONTENTS saue Series 90 Functional Description 2.4.7 Displacement Limiters Series 90 pumps sizes 042 - 250 are designed for optional mechanical displacement (stroke) limiters. The maximum displacement 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 Sec.
  • Page 251 CONTENTS saue Series 90 Functional Description 2.4.10 Pressure Override (POR) - 180 Frame Size Only The pressure override valve (POR) modulates the To Control control pressure to the displacement control to main- tain a pump displacement which will produce a sys- tem pressure level less than or equal to the POR Multi-Function Valve setting.
  • Page 252 CONTENTS saue Series 90 Functional Description Pump Control Options 2.5.1 Manual Displacement Control (MDC) The manual displacement control converts a mechani- cal 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.
  • Page 253 CONTENTS saue Series 90 Functional Description 2.5.3 Electric Displacement Control (EDC) The electric displacement control is similar to the hydraulic 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 254 CONTENTS saue Series 90 Functional Description Motor Features 2.6.1 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 installations which require additional fluid to be re- moved from the main hydraulic circuit because of transmission cooling requirements, or unusual cir- cuits requiring additional loop flushing to remove...
  • Page 255 CONTENTS saue Series 90 Functional Description Variable Motor Controls 2.7.1 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 normally held at its maximum displacement. Sup- plying pilot hydraulic pressure to the valve will cause the motor to go to its minimum displacement.
  • Page 256 CONTENTS saue Series 90 Technical Specifications 3. Technical Specifications General Specifications Port Connections (See Sec. 4.2 for exact specs.) Design Variable Pumps and Motors: Axial piston pump of Main pressure ports: SAE flange, Code 62 Remaining ports: SAE straight thread O-ring boss variable displacement, cradle swashplate design.
  • Page 257 CONTENTS saue Series 90 Technical Specifications Hydraulic Parameters System Pressure Range Temperature Range i n i ] i s 4 - °C ° ] F ] i s °C ° ] F °C ° ] F Charge Pump Inlet Vacuum (on pumps only) Fluid Viscosity Limits i n i i n i...
  • Page 258 CONTENTS saue Series 90 Technical Specifications Technical Data Table 1 - Variable Displacement Pumps i n i c i t • f ) t i Table 2 - Fixed and Variable Displacement Motors i n i — — — — —...
  • Page 259 CONTENTS saue Series 90 Pressure Measurement 4. Pressure Measurement Required Tools The service procedures described in this manual for Pressure gauges should be calibrated frequently to Series 90 pumps and motors can be performed using ensure accuracy. Snubbers are recommended to common mechanic's tools.
  • Page 260 CONTENTS saue Series 90 Pressure Measurement Servo / Displacement Charge Pressure Cylinder Pressure Gauge Port M3 Gauge Port M4 External Control Case Drain Pressure Supply Port L1 Port X3 System Pressure Port "B" Servo / Displacement Cylinder Pressure Gauge Port M5 90000814 Top View System Pressure...
  • Page 261 CONTENTS saue Series 90 Pressure Measurement Charge Pressure Gauge Port M6 (Before Filter) Port E (From Filter) Port D (To Filter) Charge Pressure Gauge Port M3 Charge Pressure (After Filter) Gauge Port M3 (After Filter) Rear View Rear View 90000817 90000818 PV with Side Port End Cap and Remote PV with Side Port End Cap and Integral...
  • Page 262 CONTENTS saue Series 90 Pressure Measurement 4.2.2 Fixed Motor t t i t t i — t t i t t i " t " A — — t t i " t " B — — t t i System Pressure Gauge Port M1 Charge Pressure...
  • Page 263 CONTENTS saue Series 90 Pressure Measurement 4.2.3 Variable Motor t t i t t i n i l — t t i — t t i " t " A n i l — t t i — t t i "...
  • Page 264 CONTENTS saue Series 90 Start-Up 5. Initial Start-Up Procedure The following start-up procedure should always be electrical connections for EDC) be disconnected at followed when starting-up a new Series 90 installa- the pump control until after initial start-up. This will tion or when restarting an installation in which either ensure that the pump remains in its neutral position.
  • Page 265 CONTENTS saue Series 90 Fluid and Filter Maintenance 6. Fluid and Filter Maintenance To ensure optimum service life of Series 90 products, Mano- Vacuummeter regular maintenance of the fluid and filter must be performed. Contaminated fluid is the main cause of unit failure.
  • Page 266 CONTENTS saue Series 90 Troubleshooting 7. 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 267 CONTENTS saue Series 90 Troubleshooting Transmission Operates Normally in One Direction Only Item Description Action 1. Check input to pump Input to control module is operating Check control input and repair or replace control. improperly. as necessary. 2. Check pump displace- Control linkages are not secure, con- Repair or replace control module as neces- ment control.
  • Page 268 CONTENTS saue Series 90 Troubleshooting 9. Check charge pump. A malfunctioning charge pump will Repair or replace the charge pump (9.2.4). provide insufficient charge flow. If OK go to last step. 10. Check pump displace- Control linkages are not secure, con- Repair or replace control module as neces- ment control.
  • Page 269 CONTENTS saue Series 90 Troubleshooting Excessive Noise and/or Vibration Item Description Action 1. Check 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 270 CONTENTS saue Series 90 Inspections and Adjustments 8. 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 Sec. 4 for location of gauge ports and suggested gauge size.
  • Page 271 CONTENTS saue Series 90 Inspections and Adjustments ± ± ) ] i ] i s ] i s ] i s NOTE: These pressures assume a pump speed of 1775 rpm. At higher pump input speeds (with higher charge flows) the charge pressure will rise over the rated setting.
  • Page 272 CONTENTS saue Series 90 Inspections and Adjustments 8.1.2 Multi-Function Valve Pressure Adjustment Adjustment of the pressure limiter setting and the high pressure relief valve setting is accomplished simultaneously. The latter is automatically set ap- proximately 35 bar (500 psi) above the former. For description of multi-function valve see Sec.
  • Page 273 CONTENTS saue Series 90 Inspections and Adjustments 6. Return the pump to its “neutral” (zero flow) posi- tion and adjust the pressure limiter setting by rotating the pressure adjusting screw with the internal hex wrench. Clockwise rotation of the pressure adjustment screw will increase the pressure setting, and counterclockwise rotation will decrease the pres- sure setting.
  • Page 274 CONTENTS saue Series 90 Inspections and Adjustments 8.1.3 Engaging the Bypass Function The bypass function (see Sec. 2.4.6 for description) 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 func- tion.
  • Page 275 CONTENTS saue Series 90 Inspections and Adjustments 8.1.4 Pressure Override (POR) Valve Pressure Adjustment (Option for 180 Frame Size) The Pressure Override Valve is explained in Sec. 2.4.10. Pressure Over-Ride Valve 1. Install two 1000 bar (or 10,000 psi) pressure Adjusting Screw gauges in the high pressure gauge ports (M1 and Lock Nut...
  • Page 276 CONTENTS saue Series 90 Inspections and Adjustments 8.1.5 Displacement Limiter Adjustment The maximum displacement can be limited in either direction (see Sec. 2.4.7). 1. Loosen the seal lock nut retaining the displace- ment limiter adjusting screw. 2. Rotate the adjusting screw. 90000267 Loosen Displacement Limiter Lock Nut Rotating the adjusting screw clockwise will de-...
  • Page 277 CONTENTS saue Series 90 Inspections and Adjustments Pump Control Adjustments 8.2.1 Standard Manual Displacement Control (MDC) Adjustment There are no adjustable elements in the manual displacement control. The control spool is held in its “neutral” position by centering springs and washers on each end of the spool.
  • Page 278 CONTENTS saue Series 90 Inspections and Adjustments 8.2.2 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 loose- ness (“free-play”) in the linkage.
  • Page 279 CONTENTS saue Series 90 Inspections and Adjustments 8.2.3 MDC Neutral Start Switch (NSS) Adjustments The neutral start switch (NSS) provides a means to prevent the system prime mover from starting while Washer the pump control handle and control input shaft are in O-Ring a position which would command the pump to go “in- O-Ring...
  • Page 280 CONTENTS saue Series 90 Inspections and Adjustments The NSS must be adjusted to meet the following three requirements: i. The distance the control handle can be turned Control Shaft without opening the NSS is called the “NSS "Free-Play" deadband.” The distance the control handle can NSS Deadband be moved without moving the control spool enough (Switch Closed, "ON")
  • Page 281 CONTENTS saue 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 282 CONTENTS saue Series 90 Inspections and Adjustments Neutral Start Switch Eccentric Plug Adjustment (Condition i) The NSS deadband and the control deadband must Washer be centered in relation to each other. O-Ring Since the position of the control deadband cannot be O-Ring Control Shaft adjusted, the position of the NSS deadband must be...
  • Page 283 CONTENTS saue Series 90 Inspections and Adjustments 3. Position the eccentric plug so the switch pin is offset toward the control mounting surface. This will provide the best contact between the pin and Switch Pin Eccentric Plug the cam on the control shaft. (Offset toward mounting surface) 4.
  • Page 284 CONTENTS saue 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 requires the vehicle/ machine to be disabled (wheels raised off the ground, work function disconnected, etc.) in the event the pump should go into stroke during this adjustment.
  • Page 285 CONTENTS saue Series 90 Inspections and Adjustments 8.2.4 Hydraulic Displacement Control (HDC) and Electric Displacement Control (EDC) Adjustment 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. For functional descriptions see Sec.
  • Page 286 CONTENTS saue 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 clockwise until the pressure increases in one of the pressure gauges.
  • Page 287 CONTENTS saue Series 90 Inspections and Adjustments Motor Adjustments 8.3.1 Charge Relief Valve Adjustment Motor charge relief is explained in Sec. 2.6.1. 1. To measure motor charge pressure, install a 50 bar (or 1000 psi) pressure gauge in the motor charge pressure gauge port (M3).
  • Page 288 CONTENTS saue Series 90 Inspections and Adjustments 8.3.2 Displacement Limiter Adjustment (MV) Tamper-Resistant Cap Seal Lock Nut Both the maximum and minimum displacement may Maximum Displacement be limited. For description see Sec. 2.6.2. Limiter Screw 1. Remove the tamper resistant cap from the dis- placement limiter screw.
  • Page 289 CONTENTS saue 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, see Sec.

  • Page 290: Minor Repair Instructions

    CONTENTS saue Series 90 Minor Repair Instructions 9. Minor Repair Instructions Minor repairs may be performed, following the proce- and related items must be kept free of foreign mate- dures in this section, without voiding the unit war- rials and chemicals. ranty.
  • Page 291 CONTENTS saue Series 90 Minor Repair Instructions Hydrostatic Unit Outlines for Minor Repair Reference Charge Pressure Relief Valve Filtration Options Control Control Orifices Charge Pump Shaft Seal Main Shaft Speed Sensor (Auxiliary Pad) Right Side View Left Side View 90000843 SAE Flange PV Charge Pressure Charge Pressure...
  • Page 292 CONTENTS saue Series 90 Minor Repair Instructions Pump and Motor Minor Repair 9.1.1 Plug / Fitting Torques If any plugs or fittings are removed from the pump or motor during servicing, they should be torqued as indicated in the accompanying table. —...
  • Page 293 CONTENTS saue Series 90 Minor Repair Instructions 9.1.2 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 re- placed without major disassembly of the unit. How- ever, replacement usually requires removal of the pump or motor from the machine.
  • Page 294 CONTENTS saue Series 90 Minor Repair Instructions Roller Bearing Retaining Assembly 8. Inspect the sealing area on the shaft for rust, Ring Tapered wear, or contamination. If the shaft is not being Shaft Roller Bearing Splined replaced proceed to step 12. Shaft 9.
  • Page 295 CONTENTS saue Series 90 Minor Repair Instructions Pump Minor Repairs 9.2.1 Multi-Function Valve Cartridges 1. The multi-function valve cartridge is removed with a 1-1/4 inch (030 through 100 pumps) or a 1- 5/8 inch (130 through 250 pumps) hex wrench on the largest hex on the cartridge.
  • Page 296 CONTENTS saue Series 90 Minor Repair Instructions 9.2.2 Pressure Override Valve (Option for 180 Frame Size) Screws 1. Remove the four screws attaching the pressure Pressure Override override valve to the pump end cap with a 5 mm Valve internal hex wrench. Remove the O-rings. O-rings 2.
  • Page 297 CONTENTS saue Series 90 Minor Repair Instructions 9.2.4 Charge Pump The following procedure shows how to remove and install a charge pump. 1. For pumps with an auxiliary mounting pad, re- move the four screws holding the pad to the end cap and remove the pad.
  • Page 298 CONTENTS saue Series 90 Minor Repair Instructions Standard End Cap Screw 4. Remove the charge pump shaft and charge pump drive key. Alignment Pin Charge Pump Assembly 5. Remove the spacer plate(s), if present (interme- Thin Port Plate diate production pumps only). Thick Port Plate Remove the charge pump outer port plate, if Shaft...
  • Page 299 CONTENTS saue Series 90 Minor Repair Instructions Installing the Charge Pump Discharge Gerotor Assembly Discharge Be sure to install the charge pump in the proper Alignment Pin orientation. If unsure of charge pump rotation, refer to the model code. Inlet Inlet NOTE: The charge pump rotation is determined Alignment Pin...

  • Page 300: Carefully Remove The Alignment Pin From The

    CONTENTS saue Series 90 Minor Repair Instructions 7. Install the charge pump drive key into the charge pump shaft and retain with petroleum jelly. NOTE: Intermediate production 75 cc and 100 cc 100 cc 75 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.

  • Page 301: E

    CONTENTS saue Series 90 Minor Repair Instructions 9.2.5 Auxiliary Pad Installation 1. Using a 10 mm (030 through 100 pumps) or a 13 mm (130 through 250 pumps) hex wrench, re- move the six screws holding the charge pump cover retainer. Remove the retainer. 2.

  • Page 302: Table Of Contents

    CONTENTS saue Series 90 Minor Repair Instructions 5. Install the auxiliary drive coupling onto the pump drive shaft spline (auxiliary drive spline must be toward the rear of the pump). 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 auxil- iary coupling) and retain with petroleum jelly.
  • Page 303 CONTENTS saue Series 90 Minor Repair 9.2.6 Filtration Options 9.2.6.1 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 304 CONTENTS saue Series 90 Minor Repair Pump Controls 9.3.1 Cover Plate 1. Thoroughly clean external surfaces prior to re- moval 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.
  • Page 305 CONTENTS saue Series 90 Minor Repair 9.3.2 Manual Displacement Control (MDC) 1. Thoroughly clean external surfaces prior to re- moval of control. 2. Using a 5 mm internal hex wrench, remove the eight control mounting screws. Remove the con- trol (with orifice check valve and spring) and control gasket from housing.
  • Page 306 CONTENTS saue Series 90 Minor Repair 9.3.3 Solenoid Override Valve for MDC 1. Thoroughly clean external surfaces prior to re- moval of valve. 2. Using a 5 mm internal hex wrench, remove the two screws and remove solenoid manifold from hous- ing.
  • Page 307 CONTENTS saue Series 90 Minor Repair 9.3.5 Hydraulic and Electric Displacement Controls 1. Thoroughly clean external surfaces prior to re- moval of control. 2. Using a 5 mm internal hex wrench, remove the eight control mounting screws. Remove the con- trol (with orifice check valve and spring) and control gasket from housing.
  • Page 308 CONTENTS saue Series 90 Minor Repair 9.3.7 3-Position (FNR) Electric Control 1. Thoroughly clean external surfaces prior to re- moval of control. 2. Using a 4 mm internal hex wrench, remove the four solenoid valve mounting screws. Remove the solenoid valve (with O-rings and orifice) from the adapter plate.
  • Page 309 CONTENTS saue Series 90 Minor Repair 9.3.8 Displacement Control Components 9.3.8.1 Displacement Control Adapter Plate (Early Production 130 Pumps Only) The screws fastening the control adapter plate to the housing have retaining compound on the threads. They are removed with a 6 mm internal hex wrench. When installing the adapter plate, ensure the O-rings are in the proper position and torque the screws to 32 Nm (24 ft•lbf).
  • Page 310 CONTENTS saue Series 90 Minor Repair Minor Repairs - Motor 9.4.1 Loop Flushing and Charge Relief Valves 9.4.1.1 Loop Flushing Valve 1. Using an 11/16 inch wrench, remove the hex plugs and O-rings from both sides of the valve. Remove the springs, shoulder washers, and flush- ing valve shuttle spool.
  • Page 311 CONTENTS saue Series 90 Minor Repair 9.4.1.3 Defeating the Loop Flushing Valve Lock Nut Plug 1. Remove loop flushing valve components (these Plug O-ring parts will not be used). O-ring Shims Spring Spring 2. Install defeating spool into spool bore in end cap. Poppet Poppet 3.
  • Page 312 CONTENTS saue Series 90 Minor Repair 9.4.2 Variable Motor Displacement Limiters 1. Remove the tamper-resistant cap from the dis- Tamper-Resistant Cap placement limiter. Using a 19 mm hex wrench, Seal Lock Nut loosen the seal lock nut and remove the nut. Maximum Displacement Remove the limiter screw from the motor housing Limiter Screw...
  • Page 313 CONTENTS saue Series 90 Minor Repair Variable Motor Controls 9.5.1 Electrohydraulic 2-Position Control (Types NA, NB, NC, and 1. Thoroughly clean external surfaces prior to re- moval of the control. 2. Disconnect the external electrical signal connec- tion. NOTE: Remove BEFORE removing control. Install AFTER installing control.
  • Page 314 CONTENTS saue Series 90 Minor Repair 9.5.4 Variable Motor Control Orifices 9.5.4.1 Control Supply Orifice Control Supply Orifice 1. Remove the control supply orifice from the motor Screen (Pressed In) housing with an 11/16 inch hex wrench. O-Ring 2. Remove the O-rings and the backup washers. Backup Washer Check that the filter screen is secure in the orifice O-Ring...
  • Page 315 CONTENTS saue Series 90 Minor Repair 9.5.4.3 Maximum Displacement Cylinder Orifice Check Valve 1. Remove the seal lock nut with a 3/4 inch hex wrench. Remove the maximum displacement cyl- Housing Plug inder orifice check valve from the motor housing Seal Lock Nut with a 1/4 inch end wrench.
  • Page 316 CONTENTS saue Series 90 Minor Repair Speed Sensor Housing Plug 1. Remove the speed sensor by disconnecting the 1/4 in. int. hex wrench Torque: 23 Nm (17 lbf•ft) electrical connector, loosening the lock nut, and unscrewing the speed sensor from the pump or Speed Sensor motor housing.
  • Page 317 CONTENTS saue Series 90 Exploded View Parts Drawings 10. Exploded View Parts Drawings 10.1 Variable Pumps 10.1.1 Name Plates saue saue Ames, Iowa, U.S.A. Neumünster, Germany Ames, Iowa, U.S.A. Neumünster, Germany Model Code Model Code 90L055 90L055 Model Model C6 C 03 C6 C 03 Code Code...
  • Page 318 CONTENTS saue Series 90 Exploded View Parts Drawings 10.1.3 Controls M0CA M0MA M0ME M0MB M0MF M90C MODC M0MC M0MG M1CA M87C M1DC MODD M90D M0MD M0M9 M11C M1DD M74M M9ME M76M M78M M92M M11D M0EA M0EF M91E M97M M77M M0EP M98M M75M M95M...
  • Page 319 CONTENTS saue Series 90 Exploded View Parts Drawings 10.1.4 Filtration Options, Charge Pump Options, Auxiliary Pad Options N40P N40L N00M N00S N35M N35S N10M N10S N30R N35M N25M N00R N20M N10R N15M N31R N20R N15R N35R N25R 90000862 H50L (H30) J80N H90L J40N...
  • Page 320 CONTENTS saue Series 90 Exploded View Parts Drawings 10.1.5 Pump Parts List Item Description Item Description Plug J50A-V O ring Plug J60A/T Flange adaptor Plug J60B/V Flange adaptor Plug J60C Flange adaptor Control Filter Screen J60D Flange adaptor J70A-V Washer Split Clamp J80A-V Screw...
  • Page 321 CONTENTS saue Series 90 Exploded View Parts Drawings Item Description Item Description M96E O ring M810 Adapter Plate - Control (130 cc) M97E O ring M820 O-ring (130 cc) M98E Screw M830 O-ring (130 cc) M840 O-ring (130 cc) M0HA HDC kit M850 Plug (130 cc)
  • Page 322 CONTENTS saue Series 90 Exploded View Parts Drawings 10.2 Fixed Motor 10.2.1 Name Plates saue saue Ames, Iowa, U.S.A. Neumünster, Germany Ames, Iowa, U.S.A. Neumünster, Germany Model Code Model Code 90M055 90M055 Model Model C6 W 00 C6 W 00 Code Code Mode...
  • Page 323 CONTENTS saue Series 90 Exploded View Parts Drawings 10.2.3 Fixed Motor Parts List Item Description Item Description Plug Seal carrier Plug Seal carrier Speed sensor Lip seal O ring Plug Retainer Plug Metric screw Split Clamp Screw - Shipping Cover Slotted nut H10N Loop flushing spool - defeat...
  • Page 324 CONTENTS saue Series 90 Exploded View Parts Drawings 10.3 Variable Motor 10.3.1 Name Plate saue Ames, Iowa, U.S.A. Neumünster, Germany Model Code 90S055 S1 W 01 Model Code Model No. Ident Nr Model Number 94 – 4002 A – 91 – 26 – 67890 Serial Number Serial No.
  • Page 325 CONTENTS saue Series 90 Exploded View Parts Drawings 10.3.3 Variable Motor Parts List Item Description Item Description Plug Seal carrier Plug Seal carrier Plug Lip seal Plug O-ring Speed sensor Retainer Screw Set screw Control valve - electric Nut - Seal Lock Control valve - hydraulic Plug P400...
  • Page 326 CONTENTS saue Series 90 Exploded View Parts Drawings Notes...
  • Page 327 CONTENTS saue Hydraulic Power Systems SAUER-SUNDSTRAND Hydraulic Power Systems - Market Leaders Worldwide SAUER-SUNDSTRAND is a world leader in the design and SAUER-SUNDSTRAND specializes in integrating a full manufacture of Hydraulic Power Systems. Research and range of system components to provide vehicle designers development resources in both North America and Europe with the most advanced total-design system.
  • Page 328 No. 06-161 ® Eaton May 1999 Medium Duty Piston Motors Parts Information Model 74624 and 74644, 82,6 cm /r [ 5.04 in /r] Displacement design code...
  • Page 329 Model 74624 and 74644...
  • Page 330 Model 74624 and 74644 Identification and Tools Required Identification Numbers Stamped on each unit. A - Product Number Descriptions 74624 = Fixed Motor 82,6 cm /r [5.04 in 74644 = Fixed Motor thru Shaft for Brake Mount 82,6 cm /r [5.04 in B - Rotation, D = Dual C - Sequential Letters...
  • Page 331 Model 74624 and 74644 Parts List Item Part No. Qty. Description Refer to List Drive Shaft Refer to List Backplate Assembly Refer to List Housing Assembly 74614-50 Rotating Kit Assembly - Refer to specific parts list 74614-52 Rotating Kit Assembly - Heat Treated - Refer to specific parts list +~ 5 16009-118 Retaining Ring...
  • Page 332 Model 74624 and 74644 Drive Shaft S/A - Item #1 Item # Part Number Description 74624-200 15 Tooth 16/32 Spline with Snap 74644-214 Front - 15 Tooth 16/32 Spline, Shaft Ring Groove with Snap Ring, .375- Ext 46 [ 1.81] 16 UNC-2B Thread, 18.3 [ .72] Min Rear - Straight Shaft Dia 22.22 Full Thread, Shaft Ext 39.6 [ 1.56]...
  • Page 333 Model 74624 Parts Drawing...
  • Page 334 Model 74624 Specific Parts List e t I # s ' # s ' # s ' # s ' r i a t i K...
  • Page 335 Model 74644 Parts Drawing - Through Shaft 35-1...
  • Page 336 Model 74644 Specific Parts List e t I # s ' # s ' # s ' # s ' r i a t i K...
  • Page 337 Model 74624 and 74644 Notes...
  • Page 338 Model 74624 and 74644 Notes...
  • Page 339 Eaton Corporation Eaton Ltd. Eaton B.V. Sumitomo Eaton Hydraulic Co. Hydraulics Division Hydraulics Division Boeing Avenue 11 8 Temasek Blvd. 15151 Hwy. 5 Glenrothes, Fife 1119 PC Schiphol-Rijk 42-01 Suntec Tower Three Eden Prairie, MN 55344 Scotland, KY7 4NW The Netherlands Singapore 03988 Telephone: 612/937-7254 Telephone: [+44] (0)1592-771-771...
  • Page 344 OBILE QUIPMENT NERGY OLUTIONS NDUSTRY ROCESS UTOMATION OLUTIONS Installation, use and service manual A T E X INCLUDED...
  • Page 346 USE, INSTALLATION AND MAINTENANCE MANUAL 1.0 - GENERAL INFORMATION 1.1 - PURPOSE OF THE MANUAL ........................1.2 - PRODUCT IDENTIFICATION .

  • Page 347: 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 348: 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 349: 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 350: 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 351: 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 352: 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 353: 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 354 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 355 300 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 356 300 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 357 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 358 300 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 359: 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 360: 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 361 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 362 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 363: 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 364: 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 365 Shaft end: threads 300...315 HC-PC HC-PC DIN 332 HC-PC HC-PC HC-PC – – – – – – – – – – – – – – – – – – – – – – – – – – –...

  • Page 366: 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 367: 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 368: 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 369 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 370 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 371 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 372 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 373: 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 374: 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 375: 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 376: 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 377: 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 378: 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 379: 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 380: 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 381: 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 382 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 383 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 385 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 386 OPERATION MAINTENANCE SERVICE MANUAL 600 - 8,000 lb. Axles & Related Components www.dexteraxle.com...
  • Page 387 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 388 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 389 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 390: 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 391: 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 392: 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 393: 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 394 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 395 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 396: 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 397: 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 398: 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 399: 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 400: 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 401: 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 402: 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 403: 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 404 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 405 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 406: 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 407: 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 408 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 409: 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 410: 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 411: 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 412 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 413: 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 414: 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 415: 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 416 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 417: 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 418: 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 419: 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 420: 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 421 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 422 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 423: 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 424 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 425: 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 426 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 427: 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 428 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 429 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 430: 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 431: 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 432: 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 433: 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 434: 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 435: 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 436: 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 437: 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 438: 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 439: 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 440: 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 441: 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 442 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 443: 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 444: 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 445: 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 446 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 447: 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 448: 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 449 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 450 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 451 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 452: 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 453: 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 454: 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 455: 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 456: 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 457: 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 458: 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 459: 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 460: Storage

    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 461: 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 462: 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 463: 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 464: 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 465 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 466 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 467 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 468 Service Record Date Service Performed Mileage...
  • Page 469 Service Record Date Service Performed Mileage...
  • Page 470 Service Record Date Service Performed Mileage...
  • Page 471 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 472 www.dexteraxle.com 2900 Industrial Parkway East • Elkhart, IN 46516 Fax: 574-295-8666 • Ph. 574-295-7888 2/07 © Dexter Axle 2007 LIT-001-00...

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