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TSE PTV100/72 Owner's Manual

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Table of Contents

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Owner's Manual
Model: PTV100/72
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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Summary of Contents for TSE PTV100/72

  • Page 1 Owner’s Manual Model: PTV100/72 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 • Hydraulic front and rear jacks. cable onto the storage reel. • Elastomer bullwheel segments. At TSE, engineering is a process of continuous product improvement; therefore, specifi cations are subject to change without notice. Toll Free: 800.825.2402 5301 Shreveport-Blanchard Hwy Telephone: 318.929.2368...
  • Page 3 30 days allowing for sufficient time for submission to TSE. Warranties claimed without a valid claim number may be denied. 2. Please retain any defective parts for a period of 60 days. TSE reserves the right to inspect and/or evaluate any parts submitted for warranty consideration.
  • Page 4 Recommendations for improving this publication are encouraged and should be forwarded to: TSE INTERNATIONAL 5301 Shreveport-Blanchard Hwy. Shreveport, Louisiana 71107 This is not a tension stringing operation procedures manual. No attempt is made or implied herein to instruct the user in methods peculiar to the individual application of the equipment described in this manual.
  • Page 5 PREMIUM CUSTOMER SERVICES TSE supports its innovative products with Premium Customer Service. Our comprehensive Service Department provides TSE customers with the service, parts, and technical assistance they need to maintain their equipment in top operating condition. For Customer Service on Your...
  • Page 6 On large components such as transmissions, engines, multiple pump drives, etc., the manufacturer’s serial number and spec. number is necessary to ensure receiving the proper replacement part. www.tse-international.com 5301 Shreveport Blanchard Hwy – Shreveport, Louisiana 71107 – USA P: 318-929-2368...
  • Page 7 Make certain all personnel are clear of this equipment before starting engine or operation. Before leaving the operators position, make sure that directional controls are in the neutral position and all brakes are set. www.tse-international.com 5301 Shreveport Blanchard Hwy – Shreveport, Louisiana 71107 – USA P: 318-929-2368 F: 318-929-4853...
  • Page 8 This Warranty to repair applies only to new and unused machinery, which, after shipment from the factory of TSE, has not been altered, changed, repaired or treated in any manner whatsoever unless such alteration, change, repair or treatment has been previously authorized in writing by TSE or has been performed by the authorized service representative of TSE.
  • Page 9 IEEE STD 524-2003” The above publication is available through the following organization: THE INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS, INC. 3 PARK AVENUE NEW YORK, NY 10016-5997 www.tse-international.com 5301 Shreveport Blanchard Hwy – Shreveport, Louisiana 71107 – USA P: 318-929-2368 F: 318-929-4853...
  • Page 10 If any of these decals are missing, please contact us for a replacement. Order the decal(s) by stating the decal description, number, and quantity. TSE INTERNATIONAL 5301 SHREVEPORT-BLANCHARD HWY. SHREVEPORT, LA 71107...
  • Page 13 CONTENTS MODEL: PTV 100-72 SECTION I GENERAL DESCRIPTION SECTION II OPERATING INSTRUCTIONS SECTION III MAINTENANCE SECTION IV PARTS LIST F602353 FINAL ASSEMBLY – PTV 100-72-JOHN DEERE 8602373 GENERAL ASSEMBLY – PTV 100-72 8601564-A V-GROOVE BULLWHEEL MODULE ASSEMBLY 8600890-A V-GROOVE BULLWHEEL ASSEMBLY 6800003-B DRIVE ASSEMBLY –...
  • Page 14 MODEL PTV100/72 V-GROOVE PULLER/TENSIONER General: The Model PTV100/72 V-GROOVE is a combination Cable Puller / Tensioner with a Self-Loading Storage Reel and a Single V-Groove Traction Drive Bullwheel powered by an Engine through Hydrostatic Drive systems. These Drives are remotely controlled from the Operator’s Control Panel to provide smooth continuous, Variable Speed and Direction Control.
  • Page 15 UNDERCARRIAGE Tires 12R22.5 – LR “H” Brakes Electric Brakes Hydraulic Leveling Jacks 1 Front, 2 Rear Axle 30,000 lb. Tandem 8 Studs on 275mm ENGINE Horsepower 173 HP Model John Deere FT4 Fuel Diesel Fuel Reservoir Capacity 40 Gallon PERFORMANCE Maximum Linepull 11,000 lbs Continuous Linepull...
  • Page 16 SECTION II OPERATIONS Controls: The controls that require explanation are described below. BEFORE OPERATING THIS EQUIPMENT FAMILIARIZE YOURSELF WITH ALL CONTROLS AND THEIR FUNCTION. FULLY TRAINED PERSONNEL SHOULD ONLY OPERATE EQUIPMENT. See descriptions below. Corresponding numbers below references each ballooned item number on FIGURE 1.
  • Page 17 BRAKE CONTROLS The Brake Control Valves allow the operator to apply or release the Bullwheel and Reel Drive Failsafe Brakes. CAUTION: NEVER OPERATE THIS FUNCTION WHEN A REEL IS INSTALLED AND MOVING. COMPONENT DAMAGE MAY OCCUR. BULLWHEEL LINEPULL GAUGE The Linepull Gauge shows the Hydraulic Working Pressure in the system. The Linepull Gauge may be used to approximate the Tension in the Conductor using the chart provided.
  • Page 18 FIGURE 2. FIGURE 3. REEL CRADLE, REAR STREETSIDE & CURBSIDE STABILIZERS These switches are located on the curbside of the unit in front of the fender (See figure 3). They are used to raise and lower the reel cradle, curbside and streetside rear stabilizers. REEL DRIVE ENGAGE/DISENGAGE (OPTIONAL) This switch is located on the rear of the curbside fender of the unit.
  • Page 19 Lower the reel cradle. See Figure 3. Remove the reel spindle from unit and install into reel to be used. Secure locking collar on shaft next to reel and install Spindle Bearings. Back unit into reel, or roll the reel to unit and install bearings into bearing supports. Flip the latches on the bearing supports down and install retainer pins.
  • Page 20 PROPER GROUNDING OF EQUIPMENT IS EXTREMELY IMPORTANT The machine is equipped with Grounding Bars. To protect against electrical hazards, the unit must be connected to a Ground Rod or the Electrical System NEUTRAL. Follow proper grounding procedures as required by I.E.C. and /or other applicable standards. Ground Mats and a Running Ground on the Conductor are recommended.
  • Page 21 MAXIMUM PULL WOULD BE THE PRESET PRESSURE. NORMALLY, THE PRESET PRESSURE ON THE REEL DRIVE IS THE SAME AS THE WORKING PRESSURE, BUT THE BULLWHEEL PRESET PRESSURE SHOULD BE ABOUT 200 PSI (13,8 BARS) ABOVE THE WORKING PRESSURE. PULLING When operated as a Puller, the function of the unit is to pull in the line against the resistance of the Tensioner, at the other end of the setup.
  • Page 22 Set the Reel Drive Brake. Return the Reel Drive Directional Control Lever to the ‘CENTER’ position. Reduce Engine Speed to idle for 3-5 minutes before stopping Engine. NOTE: IMMEDIATELY AFTER A PULL IS ONE OF THE BEST TIMES TO CHECK THE UNIT FOR WATER, OIL, OR HYDRAULIC FLUID LEAKS.
  • Page 23 E. TENSIONING DIRECTLY FROM THE REEL (Not threaded through Levelwind or Bullwheel) Perform pre-start checks and start the engine. Preset Pressure to 1500 PSI. Set Engine Speed at Maximum RPM. Release the Reel Drive Brake. Move the Direction Control Lever into the ‘TENSION’ direction. Instruct the Puller operator that you are ready for him to start the Pull.
  • Page 24 SECTION III MAINTENANCE This section contains schedules, recommendations, and procedures designed to ensure that the equipment is prepared for safe and efficient operation and to prolong the service life of the equipment. These maintenance instructions constitute basic requirements for an operational environment that is not extreme in temperature, humidity, airborne abrasives, or other conditions which would require preventative maintenance techniques to combat.
  • Page 25 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 26 LUBRICATION DATA LUBRICANT LUBRICANT INFORMATION GRADES APPLICATION PART # TSE STANDARD HYDRAULIC FLUID (REFER TO HYDRAULIC OIL HYDRAULIC AW46 DECAL LOCATED ON HYDRAULIC ISO 46 567851 SYSTEM FLUID RESERVOIR TO DETERMINE WHAT HYDRAULIC FLUID IS USED IN YOUR MACHINE) BEARINGS,...
  • Page 27 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. 1000 HOURS SERVICE DAILY...
  • Page 43 4.5 L OEM Diesel Engines (Final Tier 4/Stage IV Platform) OPERATOR'S MANUAL 4.5 L OEM Diesel Engines (Final Tier 4/Stage IV Platform) OMRG39498 ISSUE 19MAR15 (ENGLISH) CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
  • Page 45 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 46 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 47 Introduction Identification Views 4045HFC09 Left View 4045HFC09 Right View Continued on next page ZE59858,0000007 -19-11MAR14-1/2 032015 PN=5...
  • Page 48 Introduction 4045HFC04 Left View 4045HFC04 Right View ZE59858,0000007 -19-11MAR14-2/2 032015 PN=6...
  • Page 49 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 50 Introduction Vari-Cool™ Vari-Cool is a trademark of Deere & Company WEATHER PACK® WEATHER PACK is a trademark of Packard Electric WINDOWS® WINDOWS is a trademark of Microsoft Corporation ZE59858,0000006 -19-13FEB14-2/2 032015 PN=8...
  • Page 51 Contents Page Page Record Keeping Record Engine Serial Number......01-1 Fuels, Lubricants, and Coolants Engine Option Codes .........01-2 Diesel Exhaust Fluid (DEF) — Use in Record Aftertreatment Serial Numbers ....01-4 Selective Catalytic Reduction (SCR) Record High-Pressure Fuel Pump Equipped Engines ..........10-1 Model Number..........01-4 Storing Diesel Exhaust Fluid (DEF)....10-1 Record ECU Serial Number .......01-5...
  • Page 52 Contents Page Page Checking and Adjusting Engine Speeds ..40-10 Engine Operation Checking Engine Mounts........40-10 Checking Engine Ground Connection ....40-10 Break-In Service ..........20-1 Generator Set (Standby) Applications ....20-1 Starting the Engine ..........20-2 Lubrication & Maintenance — 1500 Hours Normal Engine Operation ........20-3 Changing Open Crankcase Ventilation Cold Weather Operation........20-4 (OCV) Filter ............45-1...
  • Page 53 Contents Page 4.5 L Wiring Diagram 2........70-25 4.5 L Wiring Diagram 3........70-27 4.5 L Wiring Diagram 4........70-28 4.5 L Wiring Diagram 5........70-30 4.5 L Wiring Diagram 6........70-32 4.5 L Wiring Diagram 7........70-34 4.5 L Wiring Diagram 8........70-36 4.5 L Wiring Diagram 9........70-38 4.5 L Wiring Diagram 10........70-40 4.5 L Wiring Diagram 11 ........70-42 4.5 L Wiring Diagram 12........70-44...
  • Page 54 Contents 032015 PN=4...
  • Page 55 Record Keeping Record Engine Serial Number JOHN DEERE Each engine has a 13-digit John Deere engine serial number. The first two digits identify the factory that Engine Serial Number produced the engine: PE4045U123456 • CD — Saran, France • PE — Torreon, Mexico 4045HFC09 1.
  • Page 56 Record Keeping Engine Option Codes JOHN DEERE PE4045U123456 Number 4045HFC09 4.5 L 2653PE 1111 1399 1425 1524 1606 1708 1928 2002 2699 2815 2909 3008 3512 3914 4026 4391 4607 4702 4803 4903 5002 5103 5215 5407 5511 5615 5709 5927 6543 6801...
  • Page 57 Record Keeping Option Codes Description Option Codes Description Open Crankcase Ventilation System Decomposition Tube Starter Motor SCR Converter Alternator Electronic Software Option DEF Line Air Conditioning (A/C) Compressor (Optional) DEF Tank Sender Switches and Sensors Fuel Filter Air Compressor Mounting Front Plate Engine Certification Thermostat Housing...
  • Page 58 Record Keeping Record Aftertreatment Serial Numbers Record the numbers from your aftertreatment device as shown on DPF (A and B), DOC (C and D), and SCR (E and F) serial number plates. Having these numbers recorded and kept in a safe location can aid in part ordering and assist in locating stolen items in case of theft.
  • Page 59 Record Keeping Record ECU Serial Number Record the part number and serial number information found on the serial number label on the Engine Control Unit (ECU). Part No. Serial No. A—Serial Number Label ZE59858,000000C -19-12AUG14-1/1 01-5 032015 PN=17...
  • Page 60 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 61 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 62 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 63 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 64 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 65 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 66 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 67 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 68 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 69 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 70 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 71 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 72 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 73 Safety Live With Safety Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields. DX,LIVE -19-25SEP92-1/1 05-14 032015 PN=31...
  • Page 74 Fuels, Lubricants, and Coolants Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines Diesel exhaust fluid (DEF) is a high purity liquid that is (API) Diesel Exhaust Fluid Certification Program or by injected into the exhaust system of engines equipped with the AdBlue™...
  • Page 75 Fuels, Lubricants, and Coolants Refilling Diesel Exhaust Fluid (DEF) Tank CAUTION: Avoid contact with eyes. In case of contact, immediately flush eyes with large amounts of water for a minimum of 15 minutes. Reference the Materials Safety Data Sheet (MSDS) for additional information. Do not ingest DEF.
  • Page 76 Fuels, Lubricants, and Coolants Testing Diesel Exhaust Fluid (DEF) IMPORTANT: Using DEF with the correct suspicion the engine or packaged DEF fluid has been concentration is critical to engine and contaminated with water. aftertreatment system performance. Extended Two approved tools are available through your John storage and other conditions can adversely Deere dealer: alter the DEF concentration.
  • Page 77 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 78 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 79 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 80 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 81 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 82 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 83 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 84 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 85 Fuels, Lubricants, and Coolants Alternative and Synthetic Lubricants Conditions in certain geographical areas may require The temperature limits and service intervals shown in lubricant recommendations different from those printed in this manual apply to both conventional and synthetic this manual. lubricants.
  • Page 86 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 87 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 88 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 89 Instrument Panels Instrument Panel John Deere PowerTech™ OEM engines have an electronic control system, which has controls and gauges as shown. The following information applies only to those controls and gauges supplied by John Deere. Refer to your engine application manual for specific guidelines if John Deere-sourced controls and instrumentation are not used.
  • Page 90 Instrument Panels Diagnostic Gauge — Using The diagnostic gauge (A) allows the operator to monitor engine functions, view diagnostic trouble codes (DTC’s), and perform preliminary diagnostics. The gauge is linked to the electronic control system and sensors. The arrow keys (B) allows the operator to scroll between menu items.
  • Page 91 Instrument Panels Diagnostic Gauge — Main Menu NOTE: The engine does not need to be running to navigate the diagnostic gauge screens. If engine start up is desired, see Starting the Engine in the Engine Operation Section. The main menu is the starting point in accessing engine information and configuring the diagnostic gauge.
  • Page 92 Engine Operation Break-In Service 500 hours (B). (Top-load oil filter illustrated.) (See Changing Engine Oil and Replacing Filter in the Extra care during the first 100 hours of operation results in Lubrication & Maintenance — 500 Hours/12 Months satisfactory long-term engine performance and life. DO Section.) Fill crankcase with seasonal viscosity grade NOT exceed 100 hours of operation with break-in oil.
  • Page 93 Engine Operation Starting the Engine NOTE: The controls and instruments for your engine may be different from those shown here; always follow manufacturer's instructions. The following instructions apply to the optional controls and instruments available through the John Deere Parts Distribution Network.
  • Page 94 Engine Operation Normal Engine Operation Observe engine coolant temperature and engine Stop engine immediately if there are any signs of part oil pressure. Temperatures and pressures will vary failure. Symptoms that may be early signs of engine between engines and with changing operating conditions, problems are: temperatures, and loads.
  • Page 95 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 96 Engine Operation Warming Engine within 5 seconds, stop the engine and determine the cause. Normal engine oil pressure is measured IMPORTANT: To assure proper lubrication, operate at rated full load speed (1800–2500 rpm) with oil at engine at or below 1200 rpm with no load for 1–2 normal operating temperature of 97 °C (207 °F).
  • Page 97 Engine Operation Stopping the Engine NOTE: Engines in generator set applications where the ECU is locked at a specified speed and no slow idle function is available, run engine for at least 2 minutes at fast idle and no load. If an Exhaust Filter Cleaning has just been performed, increase engine idle time to 4 minutes.
  • Page 98 Engine Operation Auxiliary Gear Drive Limitations IMPORTANT: When attaching an air compressor, hydraulic pump, or other accessory to be driven by the auxiliary gear drive (engine timing gear train at front of engine), power requirements of the accessory must be limited to values listed below: IMPORTANT: See OEM engine distributor for more information to prevent overloading the auxiliary...
  • Page 99 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 100 Aftertreatment System Diesel Particulate Filter Maintenance and removal service. Generally, the ash removal service interval will far exceed the EPA required minimums of Service 3,000 hours for engines below 175hp/130kW and 4,500 The Exhaust Filter includes the Diesel Oxidation Catalyst hours for engines at or above 175hp/130kW.
  • Page 101 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 102 Aftertreatment System Selective Catalytic Reduction (SCR) System Overview SCR System A—SCR Catalyst C—DEF Dosing Unit E—DEF Tank B—DEF Dosing Injector D—DEF Tank Header Assembly IMPORTANT: Do not remove battery leads for at least Water vapor is a normal by-product of combustion. During 4 minutes after engine stops.
  • Page 103 Aftertreatment System Diagnostic Gauge Keys and Indicators Overview Diagnostic Gauge Indicators and Keys A—Diesel Exhaust Fluid (DEF) C—Exhaust Filter Indicator F— Caution Indicator K—Stop Indicator Indicator D—Auto Cleaning Disable G—Arrow Keys B—Engine Emissions Indicator H—Menu Key Temperature Indicator E—Engine Emissions System I—...
  • Page 104 Aftertreatment System RG22487 —UN—21AUG13 RG22488 —UN—21AUG13 Aftertreatment Indicators Overview The Diesel Exhaust Fluid (DEF) indicator illuminates when the DEF is low. Fill DEF tank. When the DEF indicator is combined with the warning indicator or stop engine indicator engine performance is reduced by the Engine Control Unit (ECU) because the DEF is below a measurable level.
  • Page 105 Aftertreatment System Passive Regeneration/Natural Cleaning additional exhaust filter soot to accumulate. For the best possible engine operation which requires the least Periodically, the exhaust filter will experience higher heat amount of operator interaction, the engine should be levels simply through the engine operating at higher worked at higher load conditions whenever possible and loads.
  • Page 106 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 107 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 108 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 109 Lubrication and Maintenance Lubrication and Maintenance Service Interval Chart Lubrication and Maintenance Service Intervals 6000 3000 4500 Hours of Daily/Be- Hours of 1500 Hours of Hours of Operation fore Every Operation Hours of Operation Operation or Every Required Startup or Every Operation or Every or Every...
  • Page 110 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 111 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 112 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 113 Lubrication & Maintenance — 500 Hours/12 Months Changing Engine Oil and Replacing Filter IMPORTANT: Changing engine oil and filter every 500 hours or 12 months depends on the following requirements: • Engine equipped with an oil pan that allows capacity for this extended drain interval. •...
  • Page 114 Lubrication & Maintenance — 500 Hours/12 Months 5. Remove oil filter. Discard oil filter. 6. Apply clean engine oil to the new filter at the inner (B) and outer (C) seals and to filter threads. 7. Wipe both sealing surfaces of the header (D and E) with a clean rag.
  • Page 115 Lubrication & Maintenance — 500 Hours/12 Months Checking Open Crankcase Vent (OCV) Inspect OCV hoses (A, B, and C) for worn, cracked, leaking, or bulging. Check hose clamps (D, E, and F) for good clamp tension. Replace any worn or damaged parts. A—OCV Inlet Hose D—Clamp —...
  • Page 116 Lubrication & Maintenance — 500 Hours/12 Months Remove and Install Primary Fuel Filter Element NOTE: For applications other than OEM, refer to the application operator's manual for proper servicing, hourly replacement intervals, and filter locations. NOTE: Both the primary and the final fuel filter elements must be replaced at the same time.
  • Page 117 Lubrication & Maintenance — 500 Hours/12 Months Remove and Install Secondary Fuel Filter Element NOTE: For applications other than OEM, refer to the application operator's manual for proper servicing, hourly replacement intervals, and filter locations. 1. Thoroughly clean filter header (B) and surrounding area to prevent dirt and debris from entering fuel system.
  • Page 118 Lubrication & Maintenance — 500 Hours/12 Months Checking Tensioner Spring Tension A belt tension gauge will not give an accurate measure of the belt tension when automatic spring tensioner is used. Measure tensioner spring tension using a torque wrench and procedure outlined below: 1.
  • Page 119 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 120 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 121 Lubrication & Maintenance — 1500 Hours Changing Open Crankcase Ventilation (OCV) Filter Service checks of the OCV include checking and/or replacement of worn, cracked, leaking, or bulging hoses and for good clamp tension on all hose ends. Expectation for minimal service interval will be at least 1500 hours or when the service indicator light comes on or as indicated by the diagnostic gauge.
  • Page 122 Lubrication & Maintenance — 3000 Hours/36 Months • Checking Crankshaft Vibration Damper Visually inspect vibration damper for cracks or damage. • Visually inspect viscous damper for leaks. IMPORTANT: The vibration damper is not repairable, • Visually inspect viscous damper for dents or bends in and should only be replaced due to unexpected housing.
  • Page 123 Lubrication & Maintenance — 3000 Hours/36 Months Valve Clearance Adjustment — #1 TDC 5. With engine locked at “TDC” of No. 1 piston compression stroke, use a bent feeler gauge to check valve clearance on No. 1 and 3 exhaust and No. 1 and 2 intake valves.
  • Page 124 Lubrication & Maintenance — 3000 Hours/36 Months Valve Clearance Adjustment — #4 TDC 6. Rotate flywheel 360° until No. 4 piston is at “TDC” of 7. Check and adjust valve clearance to the same its compression stroke. Rocker arms for No. 4 piston specifications on for No.
  • Page 125 Lubrication & Maintenance — 3000 Hours/36 Months Testing Glow Plugs for Continuity CAUTION: To prevent accidental starting of engine while performing this test, always disconnect NEGATIVE (—) battery terminal. 1. Remove glow plug wiring harness connector (C). 2. Using a multimeter, check resistance from terminal (B) to the outer body of glow plug (A).
  • Page 126 Lubrication & Maintenance — 4500 Hours/36 Months Access DEF Dosing Unit See your application manual for information on accessing the DEF dosing unit. ZE59858,000008D -19-23AUG13-1/1 Changing Diesel Exhaust Fluid (DEF) Dosing Unit Filter CAUTION: Avoid contact with eyes. In case of contact, immediately flush eyes with large amounts of water for a minimum of 15 minutes.
  • Page 127 Lubrication & Maintenance — 6000 Hours/72 Months Flushing and Refilling Cooling System CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly remove the pressure cap and allow pressure to relive before completely removing cap.
  • Page 128 Lubrication & Maintenance — 6000 Hours/72 Months NOTE: Drain coolant from the lowest point in the cooling system. This location will vary by application. 3. Drain all coolant from engine block. 4. Open radiator drain valve. Drain all coolant from radiator.
  • Page 129 Lubrication & Maintenance — 6000 Hours/72 Months Testing Thermostat Opening Temperature Removing Thermostats CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. DO NOT drain coolant until it has cooled below operating temperature. Always loosen radiator pressure cap or drain valve slowly to relieve pressure.
  • Page 130 Lubrication & Maintenance — 6000 Hours/72 Months Testing Thermostats Opening Temperature NOTE: Perform the following test for both thermostats. 1. Visually inspect thermostats for corrosion or damage. Replace as a matched set, as necessary. CAUTION: DO NOT allow thermostat or thermometer to rest against the side or bottom of container when heating water.
  • Page 131 Lubrication & Maintenance — 6000 Hours/72 Months Installing Thermostats 1. Install new rubber seal for each thermostat (A). 2. Install thermostats into housing (D). 3. Install thermostat cover (B) and tighten thermostat cover cap screws (C) to specifications. Specification Thermostat Cover Cap Screw—Torque.............
  • Page 132 Service As Required Additional Service Information This is not a detailed service manual. If you want more detailed service information, contact your John Deere dealer or engine distributor. Component Technical Manuals RK80614,0000038 -19-16OCT12-1/1 Do Not Modify Fuel System IMPORTANT: Modification or alteration of the high-pressure fuel pump, the injection timing, or the fuel injectors in ways not recommended by the manufacturer will terminate the warranty...
  • Page 133 Service As Required Drain Water From Fuel Filters The primary fuel filter (A) is equipped with a sensor that detects the presence of water in the fuel filter element. This sensor will illuminate the “STOP ENGINE” warning light on the diagnostic gauge and also sound an audible alarm.
  • Page 134 Service As Required Cleaning Diesel Exhaust Fluid (DEF) Tank NOTE: Cleaning can take place with DEF tank installed or removed. CAUTION: Avoid contact with eyes. In case of contact, immediately flush eyes with large 2. Clean DEF tank with new DEF. amounts of water for a minimum of 15 minutes.
  • Page 135 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 136 Service As Required Replacing Air Filter Element IMPORTANT: ALWAYS REPLACE primary air cleaner element when air filter restriction indicator shows a vacuum of 625 mm (25 in.) H is torn, or visibly dirty. NOTE: This procedure applies to John Deere 2-stage radial seal air cleaner kits.
  • Page 137 Service As Required Inspecting Primary Air Filter Element 1. Hold a bright light (A) inside element and check carefully for holes. Discard any element which shows the smallest hole or rupture. 2. Be sure outer screen (B) is not dented. Vibration would quickly wear a hole in filter.
  • Page 138 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 139 Service As Required Replacing Fan Belt See Checking Tensioner Spring Tension in the Lubrication & Maintenance — 500 Hours/12 Months Section for additional information on the belt tensioner. 1. Inspect belt for cracks, fraying, or stretched out areas. Replace if necessary. 2.
  • Page 140 Service As Required • Checking Fuses JD Link fuse — 10 Amp • ECU fuse — 25 Amp (3 used) Check the following fuses located in the control panel • TVP fuse — 30 Amp wiring harness. Replace defective fuses. See 4.5 L Wiring Diagram 10 in the Troubleshooting •...
  • Page 141 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 142 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 143 Troubleshooting SPN Code SPN Name Injector #3 Injector #4 Injector #5 Injector #6 Unapproved Engine Speed Request External Shutdown Switch 1075 Low Pressure Fuel Pump Data 1136 ECU Temperature Signal 1172 Intake Air Temperature 1176 Intake Air Pressure 1180 Calculated VGT Turbine Inlet Temp 1209 Exhaust Manifold Pressure Signal 1347...
  • Page 144 Troubleshooting SPN Code SPN Name 4490 Intake Air Humidity 4765 DOC Inlet Temp 4766 DOC Outlet Temp 4795 DPF Missing 5018 DOC Fault Occurrences 5125 Sensor Supply #7 Voltage 5126 Sensor Supply #8 Voltage 5127 Sensor Supply #9 Voltage 5298 DOC Efficiency 5435 DEF Dosing Unit Pump...
  • Page 145 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 146 Troubleshooting Engine Troubleshooting display and perform the corrective actions. If any problems remain, use the following charts NOTE: Before troubleshooting the engine, first to solve engine problems. retrieve any fault codes on the diagnostic gauge Symptom Problem Solution Low battery output voltage or Engine Will Not Crank Charge or replace batteries.
  • Page 147 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 148 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 149 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 150 Troubleshooting Symptom Problem Solution Excessive valve clearance Check and adjust valve clearance. See Adjusting Valve Clearance in the Lubrication & Maintenance 3000 Hours/36 Months Section. Worn camshaft lobes Inspect camshaft. See your authorized John Deere engine distributor or servicing dealer. Worn rocker arm shaft(s) Inspect rocker arm shafts.
  • Page 151 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 152 Troubleshooting Symptom Problem Solution Fluid other than DEF has been added Drain, flush, and fill DEF tank with new to the DEF tank DEF. See Cleaning Diesel Exhaust Fluid (DEF) Tank in the Service As Required Section. Engine Emits White Smoke Engine compression too low Determine cause of low compression and repair as required.
  • Page 153 Troubleshooting Symptom Problem Solution Electronic Control System problem or See your authorized John Deere basic engine problem engine distributor or servicing dealer. Turbocharger not functioning properly See your authorized John Deere engine distributor or servicing dealer. Engine Overheats Air cleaner restricted or dirty Replace air cleaner element as required.
  • Page 154 Troubleshooting Symptom Problem Solution Coolant Temperature Below Normal Defective thermostat(s) Test thermostats, replace thermostats as required. Defective temperature gauge or Check gauge, sender, and temperature sender connections. Coolant in Crankcase Cylinder head gasket defective Replace cylinder head gasket. See your authorized John Deere engine distributor or servicing dealer.
  • Page 155 Troubleshooting Symptom Problem Solution Excessive oil temperature Remove and inspect oil cooler. See your authorized John Deere engine distributor or servicing dealer. Defective oil pump Remove and inspect oil pump. See your authorized John Deere engine distributor or servicing dealer. Incorrect oil Drain crankcase and refill with correct oil.
  • Page 156 Troubleshooting Symptom Problem Solution External oil leak(s) Determine source of oil leak(s) and repair as required. Excessive oil pressure See High Oil Pressure Oil control rings not seated See your authorized John Deere engine distributor or servicing dealer. Oil control rings worn or broken Replace piston rings.
  • Page 157 Troubleshooting Symptom Problem Solution Excessive engine idling Increase engine rpm when heavy electrical load is used. Poor electrical connections on battery, Inspect and clean as necessary. ground strap, starter, or alternator Defective battery Test batteries. Defective alternator Test charging system. Battery Used Too Much Water Cracked battery case Check for moisture and replace as...
  • Page 158 Troubleshooting Engine Wiring Harness Layout A—Intake Air Sensor C—Engine Coolant Temperature E—Engine Oil Pressure Sensor B—Exhaust Manifold Pressure Sensor Sensor D—Crankshaft Position Sensor Continued on next page ZE59858,0000027 -19-30JUL14-1/4 70-18 032015 PN=116...
  • Page 159 Troubleshooting A—Exhaust Throttle Actuator C—Fuel Rail Pressure Sensor E—Camshaft Position Sensor B—Fuel Rail Pressure Relief D—Suction Control Valve Valve Continued on next page ZE59858,0000027 -19-30JUL14-2/4 70-19 032015 PN=117...
  • Page 160 Troubleshooting A—EGR Valve C—Cold Start Aid Relay E—Crankcase Pressure Sensor B—Charge Air Cooler Outlet D—Water-In-Fuel (WIF) Sensor Temperature Sensor Continued on next page ZE59858,0000027 -19-30JUL14-3/4 70-20 032015 PN=118...
  • Page 161 Troubleshooting A—Manifold Air Pressure Sensor C—EGR Temperature Sensor F— Low-Pressure Fuel Pressure B—Fuel Injector Harness D—EGR Flow Sensor Sensor Connector E—Fuel Temperature Sensor G—Manifold Air Temperature Sensor ZE59858,0000027 -19-30JUL14-4/4 70-21 032015 PN=119...
  • Page 162 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 163 Troubleshooting 4.5 L Wiring Diagram 1 CYL 1 Y5021 Fuel Injector Harness Connector CYL 2 5495 5495 5495 5493 5493 5493 5498 5498 5498 5499 5499 5499 5496 5496 5496 5491 5491 5491 CYL 3 5410 Diagram 5 A5501 ECU Harness CYL 4 Connector 1 Y5004...
  • Page 164 Troubleshooting A— To 4.5 L Wiring Diagram 5 A5501-22— [5003 Orange] A5501-44— [5493 Orange] B5600— Water-In-Fuel Sensor A5501— ECU Harness Connector Low-Pressure Fuel Pump Injector #1 Pulse CYL 1— Cylinder 1 Power A5501-48— [5427 Violet] Fuel CYL 2— Cylinder 2 A5501-02—...
  • Page 165 Troubleshooting 4.5 L Wiring Diagram 2 B5101 Engine Oil Pressure Sensor 5631 5631 5633 5633 5467 5467 Y5402 Exhaust Throttle A5501 Actuator ECU Harness Connector 1 5631 5633 5509 5509 5018 5018 5016 5016 B5102 Exhaust Manifold Pressure Sensor 5626 5614 5465 5465...
  • Page 166 Troubleshooting A5501— ECU Harness Connector A5501-17— [5631 Brown] 5 A5501-41— [5633 Orange] 5 V K5803— Cold Start Aid Relay V Sensor Supply #3 Sensor Supply #3 Return R5604— Cold Start Aid A5501-07— [5423 Orange] EGR Positive A5501-52— [5425 Green] EGR Interconnect Valve Drive Negative A5501-21—...
  • Page 167 Troubleshooting 4.5 L Wiring Diagram 3 B5105 Crankcase Pressure Sensor 5621 5621 5623 5053 5053 B5205 Charge Air Cooler Outlet A5502 Temperature Sensor ECU Harness Connector 2 5455 5455 5623 5623 B5206 Manifold Air Temperature Sensor 5456 5456 5623 5628 Diagram 5 or 7 B5009...
  • Page 168 Troubleshooting 4.5 L Wiring Diagram 4 A5501 ECU Harness Connector 1 5818 5624 5015 5624 +5 V B5303 5023 5818 Fan Speed 5647 Return Sensor 5818 5015 5015 Signal 5023 Y5014 5647 Fan Solenoid Y5005 Variable Speed Fan 5624 5023 5023 5647 5647...
  • Page 169 Troubleshooting A5501— ECU Harness Connector A5502-24— [5625 Green] 5 V A5502-36— [5624 Yellow] 5 B5303— Fan Speed Sensor Sensor Supply #7 Return V Sensor Supply #7 E— To 4.5 L Wiring Diagram 9 A5501-47— [5818 Gray] Fan A5502-27— [5463 Orange] EGR Positive X5001—...
  • Page 170 Troubleshooting 4.5 L Wiring Diagram 5 B5500 Wiring Diagram For High Mount Dual Turbocharged Engines Intake Air Sensor Diagram 9 Or Single Turbocharged Engines A5501 5783 5628 ECU Harness 5804 Connector 1 5805 From Diagram 3 R5603 5805 5804 Engine CAN Terminator (120 Ohm) 5461...
  • Page 171 Troubleshooting A— [5410 Black] Wiring Shield A5501-29— [5443 Orange] A5501-45— [5804 Yellow] Engine F— [5783 Orange] 12 V Sensor From 4.5 L Wiring Diagram 1 Camshaft Position CAN High Supply To 4.5 L Wiring AA— Wiring Diagram For High Sensor Return A5501-46—...
  • Page 172 Troubleshooting 4.5 L Wiring Diagram 6 A5501 Wiring Diagram For Dual Turbocharged Engines ECU Harness With A Low Mount Fixed Turbocharger Connector 1 5030 5448 5447 5443 5445 5613 5611 5415 5756 5767 Diagram 9 B5301 Crankshaft X5040 Position Fuel System Sensor Interconnect (12 pin) (Used On Dual Turbocharged Engines With...
  • Page 173 Troubleshooting AA— Wiring Diagram For Dual A5501-29— [5443 Orange] A5501-38— [5447 Violet] X5040— Fuel System Turbocharged Engines Camshaft Position Crankshaft Position Interconnect (12 With A Low Mount Fixed Sensor Return Sensor Signal pin) (Used On Dual Turbocharger A5501-30— [5448 Gray] A5501-51—...
  • Page 174 Troubleshooting 4.5 L Wiring Diagram 7 A5501 Wiring Diagram For Dual Turbocharged Engines ECU Harness With A Low Mount Fixed Turbocharger Connector 1 B5500 Intake Air Sensor 5783 5628 5804 5805 5804 5805 5419 5424 5461 R5603 Engine CAN Terminator (120 Ohm) Y5002 Suction Control Valve...
  • Page 175 Troubleshooting 70-35 032015 PN=133...
  • Page 176 Troubleshooting 4.5 L Wiring Diagram 8 B5501 X5037 DEF Dosing Unit DEF Dosing Unit Interconnect 5141 5141 5309 5309 5146 5146 9 10 11 12 5303 5303 12 11 10 9 5301 5301 5305 5305 5304 5304 5306 5306 5308 5308 5307 5307...
  • Page 177 Troubleshooting A5502— ECU Harness Connector A5502-25— [5306 Blue] DEF A5502-46— [5309 White] DEF B5211— DEF Tank Fluid Dosing Unit Pump Dosing Unit Pressure Temperature Sensor A5502-07— [5141 Brown] 5 Position Signal Sensor Signal B5501— DEF Dosing Unit V Sensor Supply #8b A5502-31—...
  • Page 178 Troubleshooting 4.5 L Wiring Diagram 9 B5502 Aftertreatment Inlet NOx Sensor 5605 R5605 5602 5636 Aftertreatment 5636 CAN Terminator 5605 5604 (120 Ohm) 5604 B5503 Aftertreatment Outlet NOx Sensor A5502 ECU Harness Connector 2 5602 5636 5605 5604 5605 5604 B5109 5634 5785...
  • Page 179 Troubleshooting A5502— ECU Harness Connector A5502-35— [5604 Yellow] B5204— Aftertreatment G— [5030 Black] Wiring Shield Aftertreatment CAN High Temperature Module From 4.5 L Wiring Diagram 5 A5502-01— [5333 Orange] DEF A5502-38— [5786 Blue] B5502— Aftertreatment Inlet NOx or 4.5 L Wiring Diagram 6 Dosing Injector Drive Aftertreatment Sensor...
  • Page 180 Troubleshooting 4.5 L Wiring Diagram 10 A5502 ECU Harness Connector 2 5082 5426 G5000 5050 Battery 5422 5082 Diagram X5800 Starter Relay Coil (Power) Y5017 5422 Starter Solenoid G5001 Alternator K5801 Starter 5426 Relay 5082 From X5801 Diagram 2 Starter Relay Coil (Ground) V5700 5777 5050...
  • Page 181 Troubleshooting A5502— ECU Harness Connector A5503-27— [5050 Black] Battery F5010— Transient Voltage L— To 4.5 L Wiring Diagram 11 Negative Protection Fuse (30 A) M— [5092 Red] JD Link A5502-34— [5426 Blue] Alternator A5503-43— [5050 Black] Battery G5000— Battery Unswitched Power To 4.5 Excitation Negative G5001—...
  • Page 182 Troubleshooting 4.5 L Wiring Diagram 11 5911 5911 X5020 5012 5012 Auxiliary Connector 5714 5714 5971 5971 5954 5954 5913 5913 5027 5027 5039 5039 5939 5939 5941 5941 5917 5917 5773 5773 5648 5648 5937 5937 5816 5816 A5503 5981 5981 ECU Harness...
  • Page 183 Troubleshooting A5503— ECU Harness Connector A5503-21— [5020 Black] Primary A5503-41— [5956 Blue] Set I— [5002 Red] Control Panel CAN Shield Accelerator/Bump Up Unswitched Power From 4.5 A5503-01— [5905 Green] Primary A5503-22— [5017 Violet] AC High Switch L Wiring Diagram 10 CAN Low Pressure Switch A5503-45—...
  • Page 184 Troubleshooting 4.5 L Wiring Diagram 12 A5503 H5200 ECU Harness Exhaust Temperature High Lamp Connector 3 5025 5002 H5003 DPF Regeneration Required Lamp 5798 5002 5025 5798 5796 5029 5034 5038 5037 5047 5041 K5811 Y5025 Starter Relay Starter Solenoid (Application Specific) (Application Specific) 5034...
  • Page 185 Troubleshooting 4.5 L Wiring Diagram 13 5971 S5003 Cruise Cancel / 5050 Resume Switch 5954 S5004 5012 Cruise On Switch 5027 B5111 5050 Air Filter Switch 5039 P5301 5714 Vehicle Speed 5939 S5009 5050 External Derate Switch 5941 S5005 External Shutdown 5012 Switch X5020...
  • Page 186 Troubleshooting B5111— Air Filter Switch S5009— External Derate Switch X5020-G— [5027 Violet] Air Filter X5020-R— [5981 Brown] PWM H5000— Stop Engine Lamp S5100— AC High Pressure Switch Switch Throttle/Alternator O— Mating Connector Located U5000— PWM Throttle/Alternator X5020-H— [5039 White] Vehicle Feedback On 4.5 L Wiring Diagram 11 Feedback...
  • Page 187 Troubleshooting 70-47 032015 PN=145...
  • Page 188 Troubleshooting 4.5 L Wiring Diagram 14 X5021 S5000 Key Switch Control Panel Connector K5812 464 / 914 Control Panel 414 / 914 Start Relay Mating Connector Located On Diagram 11 S5013 Bump Enable Switch K5813 Control Panel Run Relay S5012 Speed Select Switch X5054 Remote Start...
  • Page 189 Troubleshooting A5504— Diagnostic Gauge A5504-25— [17 White] USB VBus X5021-D— [30 White] Start X5021-T— [936 White] Cruise A5504-1— [14 White] USB D K5812— Control Panel Start Relay X5021-E— [31 White] Battery Resume/Bump Down Negative K5813— Control Panel Run Relay Negative Switch A5504-3—...
  • Page 190 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 191 Storage Removing Engine from Long-Term Storage NOTE: The following storage removal procedure is used 7. Perform all appropriate prestarting checks. See Daily for long-term engine storage up to one year. After Prestarting Checks in the Lubrication & Maintenance that, the engine should be started, warmed up, and —...
  • Page 192 Specifications General OEM Engine Specifications 4045HFC09 4045HFC04 ITEM UNIT OF MEASURE 4045HFG09 4045HFG04 General Data Number of Cylinders Bore mm (in.) 106 (4.2) 106 (4.2) Stroke mm (in.) 127 (5.0) 127 (5.0) Displacement L (cu in.) 4.5 (275) 4.5 (275) 17.2:1 17.0:1 Compression Ratio...
  • Page 193 Specifications 4045HFC09 4045HFC04 ITEM UNIT OF MEASURE 4045HFG09 4045HFG04 Maximum Air Intake Restriction (Bar) (3.0) (3.0) (psi) (0.44) (0.44) Maximum Exhaust Back Pressure (Bar) (7.5) (7.5) (psi) (1.09) (1.09) ZE59858,0000028 -19-19AUG14-2/2 80-2 032015 PN=151...
  • Page 194 Specifications Engine Power and Speed Rating vary depending upon specific vehicle application requirements. Refer to your machine operator's Specifications manual for engine speeds that are different NOTE: Engine speeds listed are preset to factory from those preset at the factory. specification for application.
  • Page 195 Specifications Engine Crankcase Oil Fill Quantities Oil Pan Option Code(s) Crankcase Oil Capacity L (qt) To determine the option code for the oil fill quantity of your ........engine, refer to the engine option code label affixed to 1903 13 (13.7) ........
  • Page 196 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 197 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 198 Lubrication and Maintenance Records 1500 Hours of Operation Service Change open crankcase ventilation (OCV) filter. Hours Date Hours Date Hours Date Hours Date ZE59858,00000DD -19-02AUG13-1/1 3000 Hours of Operation or Every 36 Months Service Check crankshaft vibration damper. Testing glow plugs for continuity. Adjust valve clearance.
  • Page 199 Lubrication and Maintenance Records 6000 Hours of Operation or Every 72 Months Service Flush cooling system. Test Thermostats. Hours Date Hours Date Hours Date Hours Date ZE59858,00000E0 -19-02AUG13-1/1 Service as Required Replace fan-alternator belt. Drain water from fuel filters when alarm sounds. Check fuses.
  • Page 200 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 201 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 202 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 203 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 204 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 205 Warranty DX,EMISSIONS,EPA -19-12DEC12-2/2 90-6 032015 PN=163...
  • Page 206 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 207 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 208 Warranty Continued on next page DX,EMISSIONS,CARB -19-01AUG14-3/8 90-9 032015 PN=166...
  • Page 209 Warranty Continued on next page DX,EMISSIONS,CARB -19-01AUG14-4/8 90-10 032015 PN=167...
  • Page 210 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 211 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 212 Warranty Continued on next page DX,EMISSIONS,CARB -19-01AUG14-7/8 90-13 032015 PN=170...
  • Page 213 Warranty DX,EMISSIONS,CARB -19-01AUG14-8/8 90-14 032015 PN=171...
  • Page 214 Warranty 90-15 032015 PN=172...
  • Page 215 Index Page Page Crankshaft vibration damper Checking ..............50-1 A/C compressor............65-9 Additional service information........65-1 Aftertreatment indicators overview ......25-6 Aftertreatment Serial Number........01-4 Aftertreatment system Daily prestarting checks ..........35-1 Restored operation option........25-9 Air compressor Disposal ..............10-3 Checking ..............
  • Page 216 Index Page Page Starting..............20-2 Disposal............... 25-2 Stopping..............20-6 Indicators............. 25-5 Troubleshooting ............70-6 Manual/parked cleaning ........25-8 Warming..............20-5 Passive regeneration/natural cleaning ....25-7 Engine Control Unit (ECU) serial number....01-5 Service required ..........25-9 Engine coolant System overview ..........25-3 Disposing of ............
  • Page 217 Index Page Page Lubricant Storage Lubricity of diesel fuel ..........10-5 Storage, Lubricant..........10-12 Lubricants, Safety Safety, Lubricants ..........10-12 Lubrication and maintenance Maintenance interval chart ......... 30-2 1500 hours Manual/parked filter cleaning........25-8 Changing open crankcase vent (OCV) filter..45-1 Metric bolt and screw torque values ......
  • Page 218 Index Page Page Inspecting primary air filter element ....65-6 Pre-start cleaning guide ........65-4 Replacing air filter element........65-5 Safety, Avoid High-Pressure Fluids Replacing fan belt..........65-8 Avoid High-Pressure Fluids ........05-9 Daily Safety, Handle Fuel Safely, Avoid Fires Prestarting checks..........
  • Page 219 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 220 Engine Registration IBC-2 032015 PN=178...
  • Page 221 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 222 Engine Registration Mail-In Registration MAILING INFORMATION (Return Address) John Deere Power Systems P.O. Box 5100 Waterloo, IA 50704-5100 BL90236,0000029 -19-19NOV13-1/1 IBC-4 032015 PN=180...
  • Page 223 Engine Registration IBC-5 032015 PN=181...
  • Page 224 Engine Registration IBC-6 032015 PN=182...
  • Page 225 SERVICE MANUAL...
  • Page 226 TABLE OF CONTENTS WARNINGS AND CAUTIONS ..............1 MODEL IDENTIFICATION Nomenclature for Clutch Assemblies .
  • Page 227 CAUTION WARNING IMPORTANT INFORMATION Please Read Carefully Upon receipt of product, immediately inspect for any indication of rough handling or damage in transit. This includes but is not limited to: scuffed paint, broken or damaged containers, broken or cracked housings, bent shafts, metal deformation, or shift in alignment of components. Any evidence of damage or missing parts should be reported immediately to the carrier and a claim entered.
  • Page 228 MODEL IDENTIFICATION A Durst name plate is mounted on every pump drive that plate, as this is the only type of identification for warranty is assembled at the factory. This nameplate provides the repairs or replacement parts. part number, the ratio and basic description, unit serial number, date unit was assembled, and recommended oil If the Durst name plate has been destroyed the following type.
  • Page 229 NOMENCLATURE FOR DRIVE PLATE ASSEMBLIES 1PD06 2PD06, 2PD08, 2PD10 3PD06, 3PD08, 3PD10 2PD08 1.40D N23-CCH-DDH-RS 1PD06 1.32 D33-CCH-LS 3PD06 1.29 D22-CCH-CCH-CCH-NS 4PD08, 4PD09, 4PD11 ENGINE ADAPTER HOUSING WITH DRIVE PLATE 1 = SAE #1 1 = SAE 14 2 = SAE #2 2 = SAE 11.5 3 = SAE #3 3 = SAE 10...
  • Page 230 NOMENCLATURE FOR INDEPENDENT INPUT ASSEMBLIES 1PD06 2PD06, 2PD08, 2PD10 3PD06, 3PD08, 3PD10 2PD08 1.40D 001-CCH-DDH-RS 1PD06 1.32 003-CCH-LS 3PD06 1.29 002-CCH-CCH-CCH-NS 4PD08, 4PD09, 4PD11 INDEPENDENT INPUT 001 = 1810 Companion 002 = 1610 Companion 003 = 2.50 Dia. Keyed Shaft 004 = 2.25 Dia.
  • Page 231 ABOUT YOUR NEW DURST PUMP DRIVE The New Durst pump drives incorporate some of the INPUT SHAFT features from both the previous Terrell and Hub City The input shaft of the Durst pump drive is integral with the designs as well as many new and simplistic features. input gear through a 29T-12/24 spline.
  • Page 232 INSTALLATION INSTRUCTIONS INSTALLATION OF DURST PUMP DRIVES 3) Mount the clutch drive ring to the engine flywheel. There are 3 types of standard inputs that are available with Refer to the clutch service manual for the proper bolt the Durst pump drive models. torques.
  • Page 233 MOUNTING PROCEDURES FOR DURST PUMP DRIVES 2) Align the splines of the hydraulic pump to the The pump drive is to be supported on a rigid foundation spline adapter. DO NOT use the hydraulic pump using the mounting holes provided in the pump drive mounting bolts to seat the hydraulic pump onto the housing.
  • Page 234 REPAIR & REBUILDING INSTRUCTIONS DISASSEMBLY INSTRUCTIONS 6) Once the input drive shaft is removed, place the 1) Make certain that the power supply is disconnected pump drive on a flat surface with the pump pads before attempting to service or remove any facing up.
  • Page 235 7) Evenly lift the output housing half, being careful not 8) With all of the gears removed, drive the input to lift any of the gears. Inspect the gears and bearings seal out towards the engine adapter. It is required to for any defects, wear, or contamination before change the input seal any time the input gear has been removal.
  • Page 236 REASSEMBLY INSTRUCTIONS Then inspect both housings for any contaminates or Before reassembling the pump drive gear box, make sure visual defects. With a clean towel or rag wipe the that both housings have been cleaned and inspected. housings clean. Because of the modular design of the Durst pump drives, the adapter groups can be either installed after the gear 3) The gears have retaining ring grooves on the box has been assembled or left on during assembly.
  • Page 237 6) Press in the two (2) dowel pins to insure proper Do not use sharp objects for pressing in CAUTION alignment. Evenly install and tighten the cap seals. Press only on the outer edge of the seal to keep screws. Refer to Table 1 (see page 33) for proper from bending or damaging the seal casing.
  • Page 238 LUBRICATION AND OIL FILLING INSTRUCTIONS Oil flow and circulation in a gear box is one of the most OIL CAPACITY important features to give all internal parts the maximum The following charts indicate the quantity of oil that a NEW life.
  • Page 239 6 INCH GEAR CENTERS 1PD06 Normal Mounting 1PD06 Inverted Mounting Ratio Oil Capacity Ratio Oil Capacity 1.67 Inc. 2.88 Qts. / 2.75 Liters 1.67 Inc. 2.18 Qts. / 2.06 Liters 1.57 Inc. 1.57 Inc. 1.48 Inc. 3.00 Qts. / 2.84 Liters 1.48 Inc.
  • Page 240 8 INCH GEAR CENTERS 2PD08 Normal Mounting 2PD08 Vertical Mounting Ratio Oil Capacity Ratio Oil Capacity 1.40 Inc. 4.00 Qts. / 3.79 Liters 1.40 Inc. 1.34 Inc. 1.34 Inc. 1.23 Inc. 1.23 Inc. 4.00 Qts. / 3.79 Liters 1.23 Dec. 1.23 Dec.
  • Page 241 10.5 INCH GEAR CENTERS 2PD10 Normal Mounting 2PD10 Vertical Mounting Ratio Oil Capacity Ratio Oil Capacity 1.38 Inc. 4.50 Qts. / 4.25 Liters 1.38 Inc. 4.50 Qts. / 4.25 Liters 1.29 Inc. 1.29 Inc. 1.21 Inc. 5.25 Qts. / 4.97 Liters 1.21 Inc.
  • Page 242 PART NUMBER CHARTS FOR MODULAR GEAR BOXES & ADAPTERS Due to the modular design of the new pump drives, parts list for all the options and service parts for this the number of parts needed to build any model is pump drive line.
  • Page 243 2PD06 MODULE PUMP DRIVE SEE NOTE FOR DIPSTICK AND PLUG 4400-101 VENT 012166 FITTING D70 WASHER (10) J84 DOWEL PIN (2) D1353 CAP SCREW (10) A - INPUT GEAR 012059 PLUG 012042 SEAL 012015 BEARING (6) B - OUTPUT GEAR (2) 012136 INPUT HOUSING 012236 MAGNETIC DRAIN PLUG 012137 OUTPUT HOUSING...
  • Page 244 3PD06 MODULE PUMP DRIVE J84 DOWEL PIN (2) 4400-101 VENT 012166 FITTING SEE NOTE FOR DIPSTICK AND PLUG K38 INVERTED OIL LEVEL PLUG 012015 BEARING (8) A - INPUT GEAR 012042 SEAL B - OUTPUT GEAR (3) D70 WASHER (12) D1353 CAP SCREW (12) 012169 INPUT HOUSING 012236 MAGNETIC DRAIN PLUG...
  • Page 245 2PD08 MODULE PUMP DRIVE 4400-101 VENT 012166 FITTING SEE NOTE FOR DIPSTICK AND PLUG J84 DOWEL PIN (2) D1353 CAP SCREW (12) D70 WASHER (12) 012059 PLUG A - INPUT GEAR 012042 SEAL 012016 BEARING (6) B - OUTPUT GEAR (2) 012040 INPUT HOUSING 012236 MAGNETIC DRAIN PLUG 012041 OUTPUT HOUSING...
  • Page 246 3PD08 MODULE PUMP DRIVE D70 WASHER (16) 4400-101 VENT D1353 CAP SCREW (16) 012166 FITTING SEE NOTE FOR DIPSTICK AND PLUG 012016 BEARING (6) K38 INVERTED OIL LEVEL PLUG 012042 SEAL A - INPUT GEAR B - OUTPUT GEAR (3) J84 DOWEL PIN (2) 012114 INPUT HOUSING 012236 MAGNETIC DRAIN PLUG...
  • Page 247 4PD08 MODULE PUMP DRIVE SEE NOTE FOR DIPSTICK AND PLUG D1353 CAP SCREW (16) D70 WASHER (16) J84 DOWEL PIN (2) 4400-101 VENT 012166 FITTING 012016 BEARING (10) 012042 SEAL A - INPUT GEAR B - OUTPUT GEAR (4) 012236 MAGNETIC DRAIN PLUG 012118 INPUT HOUSING 012119 OUTPUT HOUSING The following chart lists all of the complete assembly part...
  • Page 248 4PD09 MODULE PUMP DRIVE SEE NOTE FOR DIPSTICK AND PLUG D1353 CAP SCREW (16) D70 WASHER (16) J84 DOWEL PIN (2) 4400-101 VENT 012166 FITTING 012016 BEARING (10) 012042 SEAL A - INPUT GEAR B - OUTPUT GEAR (4) 012236 MAGNETIC DRAIN PLUG 012468 INPUT HOUSING 012469 OUTPUT HOUSING The following chart lists all of the complete assembly part...
  • Page 249 2PD10 MODULE PUMP DRIVE 4400-101 VENT 012166 FITTING SEE NOTE FOR DIPSTICK AND PLUG D1353 CAP SCREW (16) D70 WASHER (16) 012059 PLUG 012042 SEAL A - INPUT GEAR 012016 BEARING (6) B - OUTPUT GEAR (2) 012236 MAGNETIC DRAIN PLUG 012193 INPUT HOUSING J84 DOWEL PIN (2) 012194 OUTPUT HOUSING...
  • Page 250 3PD10 MODULE PUMP DRIVE D70 WASHER (16) 4400-101 VENT D1353 CAP SCREW (16) 012166 FITTING SEE NOTE FOR DIPSTICK AND PLUG 012016 BEARING (8) 012042 SEAL K38 INVERTED OIL LEVEL PLUG A - INPUT GEAR B - OUTPUT GEAR (3) J84 DOWEL PIN (2) 012236 MAGNETIC DRAIN PLUG 012198 INPUT HOUSING...
  • Page 251 4PD11 MODULE PUMP DRIVE SEE NOTE FOR DIPSTICK AND PLUG D1353 CAP SCREW (18) D70 WASHER (18) J84 DOWEL PIN (2) 4400-101 VENT 012166 FITTING 012016 BEARING (10) 012042 SEAL A - INPUT GEAR B - OUTPUT GEAR (4) 012236 MAGNETIC DRAIN PLUG 012185 INPUT HOUSING 012186 OUTPUT HOUSING The following chart lists all of the complete assembly part...
  • Page 252 PUMP SPLINE ADAPTER The following chart lists all available spline adapters for the as either complete kits or individual components. Durst pump drives. The spline adapters can be purchased Complete Spline Pump Shaft Max. Torque Spline Retaining Adapter Kit P/N Size (in-lbs) Spline...
  • Page 253 PUMP PAD ADAPTER The following chart lists all available pump pad adapters be purchased as either complete kits or individual for the Durst pump drives. The pump pad adapters can components. NOTES: Complete Pump Pad SAE Pump Pump Pad Cap Screw O-Ring 1.
  • Page 254 INPUT SHAFT OPTIONS The following chart lists all available input shaft replaced without affecting the pump pads. However, in options for the Durst pump drives. The input shafts can some pump drive models, the pump pad(s) overlap the be purchased as either complete kits or individual expansion plug.
  • Page 255 CLUTCH HOUSINGS & ENGINE ADAPTERS 1723-115 INSPECTION COVER 4054-401 CAP SCREW (2) 4006-108 WASHER (2) ENGINE ADAPTER D70 WASHER (8) S2810-1 CAP SCREW (8) CLUTCH HOUSING D70 WASHER (8) S2812-1 CAP SCREW (8) The following chart lists all available clutch housings and housings and engine adapters can be purchased as either engine adapters for the Durst pump drives.
  • Page 256 DRIVE PLATE OPTIONS The following chart lists all available drive plate options for as complete kits only. the Durst pump drives. Drive plates are to be purchased Drive Plate SAE Drive Drive Plate Tapped Engine Assembly Plate Size Offset Flywheel Holes X12145 1.00 (8) 1/2-13...
  • Page 257 CLUTCH OPTIONS C - DRIVE RING K - HYDRAULIC HOSE ASSEMBLY E - SHIFTER HANDLE B - CLUTCH PLATE ASSEMBLY F - OPERATING SHAFT H - LOCKNUT J - DRIVE SHAFT KEY D - SHIFT YOKE A - BEARING G - LOCK WASHER The following chart lists all available clutch options for as complete kits or as individual components.
  • Page 258 CLUTCH INSTALLATION INSTRUCTIONS 7) With the clutch installed press in the drive shaft 1) Before assembling the clutch onto the Durst pump key. drive, position the pump drive with the input facing up. Note: The clutch housing and clutch shaft must be 8) Place the lock washer onto the clutch shaft so that in place and secured (see pages 28-29).
  • Page 259 GENERAL INFORMATION TOOLS NEEDED Increaser Ratio: When the output gears/shafts are turning  Sockets: 3/4", 5/8", 15/16", 1-1/8", 2-3/8" faster than the input shaft.  Allen Wrench: 3/8", 1/2"  Eye Bolts: 5/8", 3/4" Decreaser Ratio: When the output gears/shafts are  Gear Pullers (5.625"...
  • Page 260 DURST PUMP DRIVE WARRANTY WARRANTIES & LIMITATIONS OF LIABILITY. (a) Seller warrants to (f) THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF Buyer that the goods will conform to the following warranty. The goods ALL OTHER WARRANTIES OF MERCHANTABILITY, FITNESS FOR A will be commercially free from defects in materials and workmanship PARTICULAR PURPOSE AND/OR ANY OTHER TYPE, WHETHER under normal use for a period of 1 year from the date of shipment...
  • Page 261 A REGAL-BELOIT Company P.O. Box 298 • Beloit, WI 53512-0298 1-800-356-0775 • 608-365-2563 • Fax: 608-365-2182 www.durstusa.com REGAL-BELOIT CORPORATION is a worldwide manufacturer of mechanical and electrical motion control products. P/N 012530 (June, 2005) 4896D/500/06-05/BP/NP...

  • Page 262: Series 90

    CONTENTS saue Series 90 Axial Piston Pumps and Motors Service Manual...
  • Page 263 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 264 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 265 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 266 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 267 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 268 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 269 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 270 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 271 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 272 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 273 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 274 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 275 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 276 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 277 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 278 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 279 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 280 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 281 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 282 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 283 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 284 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 285 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 286 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 287 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 288 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 289 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 290 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 291 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 292 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 293 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 294 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 295 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 296 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 297 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 298 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 299 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 300 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 301 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 302 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 303 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 304 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 305 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 306 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 307 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 308 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 309 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 310 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 311 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 312: 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 313 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 314 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 315 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 316 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 317 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 318 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 319 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 320 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 321 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 322: 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 323: 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 324: 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 325 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 326 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 327 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 328 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 329 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 330 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 331 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 332 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 333 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 334 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 335 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 336 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 337 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 338 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 339 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 340 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 341 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 342 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 343 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 344 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 345 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 346 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 347 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 348 CONTENTS saue Series 90 Exploded View Parts Drawings Notes...
  • Page 349 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 398 OBILE QUIPMENT NERGY OLUTIONS NDUSTRY ROCESS UTOMATION OLUTIONS Installation, use and service manual A T E X INCLUDED...
  • Page 399 USE, INSTALLATION AND MAINTENANCE MANUAL 1.0 - GENERAL INFORMATION 1.1 - PURPOSE OF THE MANUAL ........................1.2 - PRODUCT IDENTIFICATION .

  • Page 400: 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 401: 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 402: 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 403: 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 404: 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 405: 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 406: 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 407 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 408 300 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 409 300 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 410 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 411 300 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 412: 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 413: 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 414 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 415 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 416: 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 417: 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 418 Shaft end: threads 300...315 HC-PC HC-PC DIN 332 HC-PC HC-PC HC-PC – – – – – – – – – – – – – – – – – – – – – – – – – – –...

  • Page 419: 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 420: 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 421: 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 422 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 423 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 424 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 425 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 426: 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 427: 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 428: 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 429: 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 430: 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 431: 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 432: 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 433: 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 434: 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 435 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 436 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 437 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 442 OPERATION MAINTENANCE SERVICE MANUAL 9,000 - 15,000 lb. Axles & Related Components www.dexteraxle.com...
  • Page 443 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 444 Introduction Maintenance Schedule ................. 4 Important Safety Notice ................5 Getting Started - Setup and Adjustment ............5 Answers to Commonly Asked Questions ............. 6 Braking Systems - Electric Electric Brakes ....................8 Features ...................... 10 Self Adjusting Feature ............... 11 Brake Controllers ................
  • Page 445 General Maintenance/Adjustment .............. 47 Brake Component Lubrication ............47 " Quick Change Brakes - PQ .............. 48 Recommended Disassembly ............48 Recommended Reassembly ............. 48 Air Brake Automatic Slack Adjustment ..........50 Air Brake Manual Slack Adjustment ..........51 Introduction to Troubleshooting ..............53 Troubleshooting Chart - Air ................

  • Page 446: Maintenance Schedule

    Maintenance Schedule l l o & n i l i t s & e l l l i a c t i & & s t l f i c . s ' c i f...

  • Page 447: Important Safety Notice

    Important Safety Notice Appropriate service methods and 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 448: Answers To Commonly Asked Questions

    Answers to Commonly Asked Questions Q: Why do my brakes and hubs get so hot? Braking systems use friction to slow the vehicle and the energy used to retard the trailer is converted to heat. Dexter brakes are designed to operate up to extremely high temperatures during hard braking application.
  • Page 449 A: The main reason is wheel capacity. Your entire car may weigh 3,000 lbs. which is spread over four wheels, while a 6,000 lb. trailer axle has 3,000 lbs. on a single tire and wheel. This places greater stress on the wheel/tire combination.

  • Page 450: 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 should operate as follows (see electric brake assembly illustration): When the electrical current is fed into the system by the...
  • Page 451 The resulting force causes the actuating cam block at the shoe end of the lever to push the primary shoe out against the inside surface of the brake drum. The force generated by the primary shoe acting through the adjuster link then moves the secondary shoe out into contact with the brake drum.

  • Page 452: 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 453: Self Adjusting Feature

    Self Adjusting Feature " brakes series only) Forward self adjust electric brakes were introduced in October of 1996. This feature adjusts the brakes on both forward and reverse stops. Brake adjustment occurs when lining wear results in enough gap between the shoes and the brake drum surface. This added clearance will allow the adjuster mechanism to rotate the screw assembly at the bottom of the brake.

  • Page 454: 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 455: 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 456: 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 457: 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 458: 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 459: 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 460: 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 " or less. Shoes contaminated with grease or oil, or abnormally scored or gouged should also be replaced.

  • Page 461: 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 462 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 463 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 464: 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 465: Magnet Amperes Chart

    Magnet Amperes Chart Brake Amps/ Four Size Magnet Brakes Brakes Brakes 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. Individual amperage draw can be measured by inserting the ammeter in the line at the...
  • Page 466 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. If the amperage reading remains high with all the brake magnets disconnected, the short is in the trailer wiring.

  • Page 467: Hydraulic Drum Brakes

    Hydraulic Drum Brakes The hydraulic brakes on your trailer are much like those on your automobile or light truck. The hydraulic fluid from a master cylinder is used to actuate the wheel cylinder which, in turn, applies force against the brake shoes and drum. The main difference between automotive hydraulic brakes and hydraulic trailer brakes is the trailers' actuation system.

  • Page 468: 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 an electric/ hydraulic, vacuum/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 469: Uni-Servo

    Uni-Servo This type of hydraulic brake utilizes a single acting cylinder. Upon actuation, the primary shoe is Anchor Post pressed against the brake Hydraulic Wheel Cylinder drum, which causes the shoe Retractor Spring to move in the direction of Actuating Pin rotation.
  • Page 470 The internal parking brake lever of Dexter 12 " brakes transfers the applied cable force through a cam mechanism. The cam mechanism generates a spreading force between the primary and secondary shoes. The shoes move toward the drum until contact is made.

  • Page 471: 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 472: Electric/Hydraulic Actuation Systems

    Electric/Hydraulic Actuation Systems To effectively operate your hydraulic trailer brakes, we recommend the Dexter E/H electro/hydraulic actuator, powered 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 473: Air/Hydraulic

    applied, the hydraulic pressure in the synchronizing valve forces a poppet to open which allows atmospheric air to enter the bottom chamber of the valve. Since this part of the valve is connected to the rear of the vacuum booster, the vacuum on this side of the booster chamber is lost.

  • Page 474: 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 475 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 476 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 477: Electric/Hydraulic Troubleshooting Guide

    Electric/Hydraulic Troubleshooting Guide YELLOW 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 478 Unit will not run when the ignition is on and the brake pedal is depressed 1. Verify that the trailer and tow vehicle are wired as detailed on the electrical schematic. 2. With the ignition switch on and the brakes not applied, you should have 12-13 volts between the black and white wires on the E/H unit.

  • Page 479: General Maintenance - Hydraulic Brakes

    General Maintenance - Hydraulic Brakes Drum 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 480: 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.

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