John Deere pd54 Specifications

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OPERATOR/SERVICE MANUAL

MODELS: SD-43, SD-54, PD-43

PD-54, PDB-43, PDB-54

RHINO MODEL SHOWN: PD54

JOHN DEERE DIESEL

A 100% employee-owned American manufacturer

REVISION: B 6/01 P/N 56322

TABLE OF CONTENTS

OPERATOR/SERVICE MANUAL

RHINO 43/54

FOREWORD ................................................................................................... 6

LIMITED WARRANTY ....................................................................................... 7

SECTION 1 - TECHNICAL DATA ...................................................................... 9 - 11

1.1 Specifications .......................................................................................... 10

1.2 Engine RPM ............................................................................................ 10

1.3 Machine Data .......................................................................................... 11

1.4 Machine Sound Level Test ...................................................................... 11

SECTION 2 - HEALTH & SAFETY ................................................................... 13 - 19

SECTION 3 - OPERATION ................................................................................. 21 - 29

3.1 Introduction and Operating Principle ...................................................... 22

3.2 Diesel Fuel .............................................................................................. 23

3.3 Engine Break-in ...................................................................................... 23

3.4 Engine Oil and Filter ............................................................................... 23

3.5 Warning Light ......................................................................................... 23

3.6 Hydraulic Oil, Filter, and Breather ......................................................... 23 - 24

3.7 Engine Coolant........................................................................................ 24

3.8 Visual Inspection ..................................................................................... 24

3.9 Air Cleaner .............................................................................................. 24 - 25

3.10 Before Starting ........................................................................................ 25

3.11 To Start ................................................................................................... 25

3.12 To Stop ................................................................................................... 25

3.13 Idling Engine ........................................................................................... 25

3.14 Warming Engine...................................................................................... 25 - 26

3.15 Parking Brake .......................................................................................... 26

3.16 Brake Light ............................................................................................. 26

3.17 To Operate ............................................................................................... 26

3.18 Forward/Reverse/Neutral ........................................................................ 26

3.19 Throttle ................................................................................................... 26

3.20 Gauges ................................................................................................... 26

3.21 Panel Fuse ............................................................................................... 27

3.22 Cold Weather Starting / Intake Heater Button ........................................ 27

3.23 Blade Lever ............................................................................................. 27

3.24 Horn/Back-up Alarm ............................................................................... 27

3.25 ROPS/FOPS/Seat Belt ............................................................................ 27

3.26 Tires/Lugnuts .......................................................................................... 27

3.27 Drum/Scrapers ........................................................................................ 28

3.28 Cleaning .................................................................................................. 28

3.29 Eccentrics ................................................................................................ 28

3.30 Compaction Tips ..................................................................................... 28

3.31 Tie Downs ............................................................................................... 28

3.32 Towing (Bypass) ..................................................................................... 28 - 29

3.33 Storage ................................................................................................... 29

SECTION 4 - MAINTENANCE........................................................................... 31 - 55

4.1 Important ................................................................................................. 32

4.2 Maintenance Schedule ............................................................................ 32

4.3 Important Maintenance Information ....................................................... 34

4.4 Engine Oil and Filter ............................................................................... 34

4.5 Additional Service Information .............................................................. 34

4.6 Hydraulic Oil and Filter .......................................................................... 34 - 35

4.7 Hydraulic Breather .................................................................................. 35

4.8 Engine Cooling System........................................................................... 35 - 36

4.8.1 Replacing Engine Coolant......................................................... 36

4.8.2 Adding Engine Coolant ............................................................. 36 - 37

4.8.3 Disposing of Coolant................................................................. 37

4.9 Air Cleaner .............................................................................................. 37

4.9.1 Air Cleaner Service ................................................................... 37

4.9.2 Air Cleaner Replacement .......................................................... 37 - 38

4.9.3 Element Storage ........................................................................ 38

4.10 Fuel Filter ................................................................................................ 38

4.10.1 Water Separator ......................................................................... 38

4.10.2 Fuel Filter Replacement ............................................................ 38 - 39

4.10.3 Bleeding Fuel System ............................................................... 39

4.10.4 Bleeding at Fuel Injection Pump ............................................... 39

4.10.5 Bleeding at Fuel Injection Nozzles ........................................... 39 - 40

4.11 Fan/Alternator Belt ................................................................................. 40

4.12 Grease Fittings ........................................................................................ 40

4.13 Frame Hinge............................................................................................ 40

4.14 Blade Pins ............................................................................................... 40

4.15 Battery ................................................................................................... 40

4.15.1 Servicing Battery....................................................................... 40 - 41

4.15.2 Battery Installation .................................................................... 41

4.15.3 Charging/Jumping Battery ........................................................ 41 - 42

4.16 Engine Crankcase Vent Tube .................................................................. 42

4.17 Engine Valve Clearance .......................................................................... 42

4.18 Emission Regulation/Engine RPM ......................................................... 42

4.19 Fuel Injectors .......................................................................................... 42 - 43

4.19.1 Test Fuel Injection Nozzles ....................................................... 43

4.20 Fuel Tank................................................................................................. 43

4.21 Fuel Lines................................................................................................ 43

4.22 Hydraulic Hoses/Connections ................................................................. 43 - 44

4.23 Forward/Reverse/Neutral Adjustment .................................................... 44

4.24 Neutral Interlock ..................................................................................... 44

4.25 Control Cables: Forward/Reverse, Throttle, Blade................................. 44

4.26 Eccentrics ................................................................................................ 45

4.26.1 Eccentric Housing Oil ............................................................... 45

4.27 Charge System......................................................................................... 45

4.28 Panel Fuse: 20 AMP................................................................................ 45

4.29 Engine Installation Guidelines ................................................................ 45 - 46

4.30 Engine Mounting..................................................................................... 46

4.31 Hardware ................................................................................................. 46

4.31.1 Loctite ....................................................................................... 46

4.32 Roll Over Protective Structures (ROPS)................................................. 46

4.32.1 Maintenance of ROPS/Seat Belts (Inspection & Repair) ......... 46

4.33 Horn/Back-up Alarm ............................................................................... 47

4.33.1 Back-up Alarm Switch .............................................................. 47

4.34 Scrapers ................................................................................................... 47

4.35 Troubleshooting ...................................................................................... 48 - 53

4.36 Electrical Troubleshooting ...................................................................... 54

4.37 Service Record ........................................................................................ 55

SECTION 5 - EXPLODED DIAGRAMS & PARTS LIST................................ 57 - 97

5.1 Hardware Key ......................................................................................... 59

5.2 Torque Charts and Guidelines ................................................................. 60 - 61

5.3 Drum Assembly ....................................................................................... 62 - 65

5.4 Main Frame ............................................................................................. 66 - 69

5.5 Radiator/Engine Mount ........................................................................... 70 - 71

5.6 Engine ................................................................................................... 72 - 75

5.7 Air Cleaner .............................................................................................. 76 - 77

5.8 Controls ................................................................................................... 78 - 81

5.9 Drive System Hydraulics ........................................................................ 82 - 85

5.10 Steering/Eccentric System Hydraulics .................................................... 86 - 87

5.11 Blade ................................................................................................... 88 - 89

5.12 Hydraulic Schematic ............................................................................... 90 - 91

5.13 Wiring ................................................................................................... 92 - 93

5.14 Decal Identification ................................................................................. 94 - 97

CALIFORNIA PROPOSITION 65 WARNING .............................................................. 99

FOREWORD

These instructions include:

Safety regulations Operating instructions Maintenance instructions

These instructions have been prepared for operation on the construction site and for the maintenance engineer.

These instructions are intended to simplify operation of the machine and to avoid malfunctions through improper operation.

Observing the maintenance instructions will increase the reliability and service life of the machine when used on the construction site and reduce repair costs and downtimes.

Always keep these instructions at the place of use of the machine.

Only operate the machine as instructed and follow these instructions.

Warranty Information

Please enter the following data. This will help expedite any service or warranty work.

1. Machine Type: _______________________

Machine S/N: ________________________

2. Engine Type: _________________________

Engine S/N: __________________________

3. VIN: _______________________________

4. Purchase Date: _______________________

5. Dealer/Distributor Information:

Name: ______________________________

Address: ____________________________

____________________________________

Observe the safety regulations as well as the guidelines of the civil engineering trade association. Observe safety rules for the operation of equipment and the pertinent regulations for the prevention of accidents.

Stone Construction Equipment, Inc. is not liable for the function of the machine when used in an improper manner and for other than the intended purpose.

Operating errors, improper maintenance and the use of incorrect operating materials are not covered by the warranty.

The above information does not extend the warranty and liability conditions of business of Stone Construction Equipment, Inc.

Stone Construction Equipment, Inc.

P.O. Box 150, Honeoye, New York 14471

Phone: (800) 888-9926 Fax: (716) 229-2363

Phone #: ____________________________

Fax #: ______________________________

Location of above information:

1. Information on S/N tag.

2. Information on engine tag.

3. Information on S/N tag - if applicable.

4. Date you purchased machine.

5. Dealer machine was purchased from.

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L i m i t e d W a r r a n t y

The Manufacturer warrants that products manufactured shall be free from defects in material and workmanship that develop under normal use for a period of 90 days for concrete vibrators and electric pumps, one year for Rhino®, Bulldog®, Wolfpac Rollers, trowels, Stompers®, saws, forward plates, engine powered pumps, and 6 months for all other products from the date of shipment. The foregoing shall be the exclusive remedy of the buyer and the exclusive liability of the Manufacturer. Our warranty excludes normal replaceable wear items, i.e. gaskets, wear plates, seals, O-rings, V-belts, drive chains, clutches, etc. Any equipment, part or product which is furnished by the Manufacturer but manufactured by another, bears only the warranty given by such other manufacturer . (The Manufacturer extends the warranty period to “Lifetime” for the drum bearings and seals for the mortar mixers, and agrees to furnish, free of charge, the bearings and seals only upon receipt of the defective parts. The warranty is two years for eccentric bearings on the forward plate compactors, mortar and plaster mixer drums, trowel gearboxes and five years on the Bulldog trench roller eccentric bearings.) A Warranty Evaluation Form must accompany all defective parts. Warranty is voided by product abuse, alterations, and use of equipment in applications for which it was not intended, use of non-manufacturer parts, or failure to follow documented service instructions. The foregoing warranty is exclusive of all other warranties whether written or oral, expressed or implied. No warranty of merchantability or fitness for a particular purpose shall apply. The agents, dealer and employees of Manufacturer are not authorized to make modification to this warranty , or additional warranties binding on Manufacturer. Therefore, additional statements, whether oral or written, do not constitute warranty and should not be relied upon.

The Manufacturer’s sole responsibility for any breach of the foregoing provision of this contract, with respect to any product or part not conforming to the Warranty or the description herein contained, is at its option (a) to repair, replace or refund such product or parts upon the prepaid return thereof to location designated specifically by the Manufacturer. Product returns not shipped prepaid or on an economical transportation basis will be refused (b) as an alternative to the foregoing modes of settlement - the Manufacturer’s dealer to repair defective units with reimbursement for expenses, except labor, and be reviewed with the Manufacturer prior to repair. A Warranty Evaluation Form must accompany all warranty claims.

Except as set forth hereinabove and without limitation of the above, there are no warranties or other affirmations which extends beyond the description of the products and the fact hereof, or as to operational efficiency, product reliability or maintainability or compatibility with products furnished by others. In no event whether as a result of breach of contract or warranty or alleged negligence, shall the Manufacturer be liable for special or consequential damages including but not limited to: Loss of profits or revenues, loss of use of the product or any associated product, cost of capital, cost of substitute products, facilities or services or claims of customers.

No claim will be allowed for products lost or damaged in transit. Such claims should be filed with the carrier within fifteen days.

Effective April 1, 1998.

Bred Tough, Technology Born T o Work.

The Way It Ought T o Be.

Stone Construction Equipment, Inc.

32 East Main Street, P . O. Box 150 Honeoye, NY 14471-0150

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Phone: 1-800-888-9926 • 1-716-229-5141

Fax: 1-716-229-2363

www.stone-equip.com • e-mail: sceny@mcimail.com

4/98 P/N 51018

1. TECHNICAL DATA

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1. TECHNICAL DATA

MODEL

Drum Type

Dimensions

Operating Wt. (Kg)

Drum Width (cm)

H x L x W (cm)

Tires (cm)

Operating System

Engine (kW)

RPM (Hertz)

Fuel Capacity (liters)

Steering

Frame

Drive System

Eccentric Drive

Cooling

Parking Brake

Security Braking Sys.

Performance

Centrifugal Force (Kn)

Frequency (Hertz)

Total Applied Force (Kn) Speed

Low Gear High Gear

(kilometers/hour) Amplitude (mm) Articulating Angle Oscillating Angle Gradeability Inside Turning Radius

(meter) Wall Clearance (cm) Curb Clearance (cm) Area Cap.

(Sq.Ft./Hr.) (M2)

STONE

SD 43

Smooth

6100# (2767)

43" (109,2)

97" x 124" x 51"

(246,4 x 315 x 124,5)

9.5 x 16 (24,1 x 40,6) Diamond Tread

58 hp John Deere

(43.25)

2500 (41,7)

20 gal. (757)

Power

Articulating,

Oscillating Positraction Hydrostatic

Water

Mechanical

Hydrostatic

12,000# (53,38)

2100 (35)

14,900# (66,28)

0-2 mph (0-3,22) 0-4 mph (0-6,44)

.071" (1,80)

90%

94.25" (2,39) 2 1/2" (6,35)

14" (35,56)

37,840 sq.ft/hr.

(3515,5)

STONE

SD 54

Smooth

6540# (2966,5)

54" (137,2)

97" x 124" x 59"

(246,4 x 315 x 149,9)

9.5 x 16 (24,1 x 40,6) Diamond Tread

58 hp John Deere

(43.25)

2500 (41,7)

20 gal. (757)

Power

Articulating,

Oscillating Positraction Hydrostatic

Water

Mechanical

Hydrostatic

12,000# (53,38)

2100 (35)

15,100# (67,17)

0-2 mph (0-3,22) 0-4 mph (0-6,44)

.062" (1,57)

90%

88.75" (2,25) 2 1/2" (6,35)

14" (35,56)

47,520 sq.ft/hr.

(4414,8)

1.1 Specifications Stone Rhino

STONE

PD 43

Padfoot

6409# (2907,1)

43" (109,2)

97" x 124" x 51"

(246,4 x 315 x 124,5)

9.5 x 16 (24,1 x 40,6) Cleated Tractor

58 hp John Deere

(43.25)

2500 (41,7)

20 gal. (757)

Power

Articulating,

Oscillating Positraction Hydrostatic

Water

Mechanical

Hydrostatic

12,000# (53,38)

2100 (35)

15,209# (67,65)

0-2 mph (0-3,22) 0-4 mph (0-6,44)

.059" (1,50)

70%

94.25" (2,39) 2 1/2" (6,35)

14" (35,56)

37,840 sq.ft/hr.

(3515,5)

STONE

PD 54

Padfoot

6880# (3120,7)

54" (137,2)

97" x 124" x 59"

(246,4 x 315 x 149,9)

9.5 x 16 (24,1 x 40,6) Cleated Tractor

58 hp John Deere

(43.25)

2500 (41,7)

20 gal. (757)

Power

Articulating,

Oscillating Positraction Hydrostatic

Water

Mechanical

Hydrostatic

12,000# (53,38)

2100 (35)

15,419# (68,59)

0-2 mph (0-3,22) 0-4 mph (0-6,44)

.053" (1,35)

70%

88.75" (2,25) 2 1/2" (6,35)

14" (35,56)

47,520 sq.ft/hr.

(4414,8)

STONE

PD 54

Padfoot

6880# (3120.7)

54" (137.2)

97' x 124' x 59'

(246.4 x 315 x 149.9)

9.5 x 16 (24.1 x 40.6) Cleated Tractor

58 hp John Deere

(43.25)

2500 (41.7)

20 gal (757)

Power

Articulating

Oscillating Positraction Hydrostatic

Water Mechanical Hydrostatic

12,000# (53,38)

2100 (35)

15,808# (70,32)

0-2 mph (0-3,22) 0-4 mph (0-6,44)

.059" (1,50)

70%

94.25" (2,39)

7" (17,78)

14" (35,56)

37,840 sq.ft/hr.

(3515,5)

STONE PDB 54

Padfoot w/blade

7275# (3300)

54" (137,2)

97" x 136" x 68"

(246,4 x 315 x 172,7)

9.5 x 16 (24,1 x 40,6) Cleated Tractor

58 hp John Deere

(43.25)

2500 (41,7)

20 gal. (757)

Power

Articulating,

Oscillating Positraction Hydrostatic

Water Mechanical Hydrostatic

12,000# (53,38)

2100 (35)

16,075# (71,51)

0-2 mph (0-3,22) 0-4 mph (0-6,44)

.053" (1,35)

70%

88.75" (2,25) 7" (17,78)

14" (35,56)

47,520 sq.ft/hr.

(4414,8)

Standard Features: 2 drum scrappers; ROPS/FOPS; gauges – oil pressure, volt meter, coolant temp, hour meter, fuel sight, hydraulic oil sight; warning lights - oil pressure and temperature; horn; back-up alarm; neutral safety start; padded seat w/flip-up arm rests; seat belt; secondary parking brake

1.2 ENGINE RPM

IDLE RPM 1,200 + 100 18Hz

FULL RPM 2,500 + 100 41Hz

ECCENTRIC FULL SPEED RPM 2,100 + 100 34Hz

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1. TECHNICAL DATA

1.3 MACHINE DATA

Brakes

Service Parking

Recommended Fuel Diesel fuel blend meeting ASTM D975 or EN 590

Premium diesel fuel conditioner is also recommended

Electric 12 Volt system battery BCI group 24

Hydraulic Oil Mobilfluid 424

Engine Oil 1st 100 hours John Deere br eak-in oil (T Y22041) then

SAE 15W/40 API CG-4 or API CF-4 6.5 quarts (6.0 liters)

Engine Coolant 50/50 Mixture antifreeze / distilled water meeting ASTM 4985,

coolant additive is also recommended

Eccentric Oil SAE 20W/50 API SJ or API SH

Hydrostatic

Automatic spring applied

800 CCA 78 amp charge system

Capacity 20 gallons (76 liters)

SD / PD 43: 1 quart (.95 liter)

SD / PD 54: 15 quarts (1.4 liters)

Engine / HP John Deere 3029DF 58 HP (43 kW) int. @ 2,500 RPM

Torque 153 ft. lbs. (208 Nm) int. @ 1,200 RPM

Fuel Economy .377 lb./hp - hr. (230 g/kWh) @ 1,600 RPM

1.4 MACHINE SOUND LEVEL TEST

Machine Type: PDB54 Rhino Sound Level Meter Calibration Date: August 6, 1997 Meter Type: Simpson Model 886-2 Type 2 Test Date: August 6, 1997 Test Conditions:

Temperature 70° Fahrenheit / 20° Celsius Ambient Sound 60 dba Slow Mode Soil Condition Silts and Clays

Moisture Limit N/A Engine Speed: 2,500 RPM / 41 Hz Frequency: 2,100 VPM / 34 Hz Test Site: Honeoye, New York, USA Sound Level at Operator Position: 93 dba Without Vibe

93 dba With Vibe

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2. HEALTH & SAFETY

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2. HEALTH & SAFETY

SAFETY USE

These machines are designed to carry out the function of compacting material of the non-cohesive, bituminous and granular varieties.

Safety Precautions

If used correctly they will provide an effective and safe means of compaction and meet the appropriate performance standards.

It is essential that the operator of the machine is adequately trained in its safe operation, be authorized to operate it, and have sufficient knowledge of the machine to ensure that it is in full working order before being put to use.

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2. HEALTH & SAFETY

Safety Precautions

Before using this equipment, study this entire manual to become familiar with its operation. Do not allow untrained or unauthorized personnel, especially children, to operate this equipment. Use only factory authorized parts for service.

FOLLOW SAFETY INSTRUCTIONS

 Carefully read all safety messages and decals in this manual

and on your machine safety signs. Keep decals in good condition. Replace missing or damaged decals. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs and decals are available through your dealer.

 Learn how to operate the machine and how to use controls

properly. Do not let anyone operate without instruction.

 Keep your machine in proper working condition.

Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.

When warning decals are destroyed or missing, contact the Manufacturer immediately at 1-800-888-9926 for replacement. For the safety of yourself and others, it is imperative that the following rules are observed. Failure to do so may result in serious injury or death.

 If you do not understand any part of this manual and need

assistance, contact your dealer.

UNDERSTAND SIGNAL WORDS

 A signal word  DANGER, WARNING, or CAUTION  is

used with the safety-alert symbol. DANGER identifies the most serious hazards.

 DANGER or WARNING safety signs are located near

specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.

 This notation appears before warnings in the text. It means that

the step which follows must be carried out to avoid the possibility of personal injury or death. These warnings are intended to help the technician avoid any potential hazards encountered in the normal service procedures. We strongly recommend that the reader takes advantage of the information provided to prevent personal injury or injury to others.

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2. HEALTH & SAFETY

USE COMMON SENSE WHEN HANDLING FUELS

 Transport and handle fuel only when contained in approved safety

container.

 Do not smoke when refueling or during any other fuel handling

operation.  Do not refuel while the engine is running or while it is still hot.  If fuel is spilled during refueling, wipe it off from the engine

immediately and discard the rag in a safe place.  Do not operate the equipment if fuel or oil leaks exist - repair

immediately.  Never operate this equipment in an explosive atmosphere.

 Operator must always be seated with seat belt on when

roller is running.  Never allow more than one person on roller.  Always turn engine off before dismounting from roller.  Always apply parking brake when not in use.  Never park roller on a hill.  Never operate roller on slope greater than 15 degrees.  Do not operate the roller in standing water.

Safety Precautions

 Ear protection required when operating this equipment.  Exposure to loud noise can cause impairment or loss of

hearing.

HOT SURFACES

 Muffler, engine, and engine shroud may be hot.

 Allow all components in the engine compartment to cool before

performing any service work.

 Never operate unit in a poorly ventilated or enclosed area.  Avoid prolonged breathing of exhaust gases.  Engine exhaust fumes can cause sickness or death.

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2. HEALTH & SAFETY

 Qualified personnel only. No untrained operators. Serious injury may

occur.

 Users must be trained to operate this roller. Read the Operator's

Manual and Engine Owner's Manual. Learn to operate this roller

safely.  Do not articulate on grades larger than 15o, roller may tip over.  Do not operate across the sides of hills, roller may tip over.  Do not operate at the edge of mats or roads, roller may tip over.  Do not stand. Be seated, with seat belt on, when roller is running.  Do not park the roller on hills.  Always turn off engine and apply brake before dismounting.

 Caution: Escaping hydraulic fluid under pressure can have sufficient

force to penetrate the skin, causing serious personal injury.  Hydraulic system produces high pressures--incorrect hose replacement

can cause serious personal injury. When performing service, refer to

Operator's Manual for hose identification and connections.  Hydraulic fluid escaping under pressure from a very small hole can be

almost invisible. Use a piece of cardboard or wood to search for

possible leaks.  Never use your hands to detect pressure leaks.  Hydraulic tank temperature can reach 180

Safety Precautions

F maximum.

SERVICE COOLING AND HYDRAULIC SYSTEMS SAFELY

 Pressurized release of fluids from hydraulic or coolant systems can

cause serious burns.

 Shut off engine. Only remove filler cap when cool enough to touch

with bare hands. Slowly loosen cap to first stop to relieve pressure

before removing completely.

 Never perform any work on the roller while it is running. Before

working on the roller, stop the engine and disconnect the spark plug

wire(s) to prevent accidental starting, block drums to prevent rolling.  Keep engine cover closed during the operation.  Keep hands, clothing and jewelry away from all moving parts.  Keep all guards in place.

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2. HEALTH & SAFETY

 Keep feet clear of all drums.

 Keep work area free of bystanders.

 For foot protection wear steel toe shoes or toe pads.

 Caution: Keep away from the machines articulation area

when the engine is running.

 Only start engine from operators seat.

 Before starting machine, make sure that there are no persons

or obstacles near or under machine.

PRACTICE SAFE MAINTENANCE

 Understand service procedure before doing work. Keep area clean

and dry.

Safety Precautions

 Never lubricate, service, or adjust machine while it is moving. Keep

hands, feet, and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.

 Securely support any machine elements that must be raised for

service work.

 Keep all parts in good condition and properly installed. Fix damage

immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

 Disconnect battery ground cable (-) before making adjustments on

electrical systems or welding on machine.

PREPARE FOR EMERGENCIES

 Be prepared if a fire starts.

 Keep a first aid kit and fire extinguisher handy.

 Keep emergency numbers for doctors, ambulance service, hospital,

and fire department near your telephone.

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2. HEALTH & SAFETY

Starting fluid (ether) is highly flammable. Do not use or an explosion or fire may result.

WEAR PROTECTIVE CLOTHING

 Wear close fitting clothing and safety equipment appropriate to

the job.

 Prolonged exposure to loud noise can cause impairment or loss of

hearing.

 Wear a suitable hearing protective device such as earmuffs or

earplugs to protect against objectionable or uncomfortable loud noises.

 Operating equipment safely requires the full attention of the

operator. Do not wear radio or music headphones while operating machine.

Safety Precautions

PREVENT BYPASS STARTING

 Avoid possible injury or death from engine runaway.  Do not start engine by shorting across starter terminal. Engine will

start with drive system engaged if normal circuitry is bypassed.

 Start engine only from operators seat with seat belt on and

forward/reverse in neutral.

DISPOSE OF WASTE PROPERLY

 Improperly disposing of waste can threaten the environment and

ecology. Potentially harmful waste used with John Deere equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.

 Use leakproof containers when draining fluids. Do not use food or

beverage containers that may mislead someone into drinking from them.

 Do not pour waste onto the ground, down a drain, or into any water

source.

 Air conditioning refrigerants escaping into the air can damage the

Earths atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

 Inquire on the proper way to recycle or dispose of waste from your

local environmental or recycling center.

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3. OP ERATION

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3. OPERATION

3.1 INTRODUCTION AND OPERATING PRINCIPLE

This roller is ergonomically engineered to optimize operator interface with the total machine  its really user friendly. Besides good visibility to the roll-edge, as well as the work surface, youll find that the controls are exactly in the right places for maximum comfort. And it is very convenient to monitor all the consumables  fuel, hydraulic oil, etc.

Our common sense approach to servicing is a valuable benefit. Thanks to our modular design, everything that needs servicing is located behind one of the easy-access service panels or is under the rear cowl.

For maneuverability and productivity, nothing beats the proven performance of center-point articulation. Because the drum and tires track each other exactly, tight turns are achieved smoothly. The roller is equipped with full positive traction, front to rear and side to side, which keeps the roller moving through various conditions.

Theres power steering  a feature no operator wants to be without. A variable hydrostatic drive system provides infinitely variable speed control  from 0 to 4 mph. The eccentric delivers a centrifugal force sufficient to compact all types of soil. Superior vibration isolation to the operator is achieved by mounting heavy-duty shock mounts between the eccentric and support frames.

The following instructions were compiled to provide you information on how to obtain long and trouble-free use of the roller. Periodic maintenance of the roller is essential. Read this manual in its entirety and follow the instructions carefully. Failure to do so may cause injury to you or a bystander.

- 22 -

3. OPERATION

3.2 DIESEL FUEL

Do not mix oil with fuel. The engine has a separate oil reservoir in the crankcase. Diesel fuel blend meeting ASTM D915 or EN590 and a premium diesel fuel conditioner is recommended.

WARNING

FUEL IS BOTH TOXIC AND FLAMMABLE. DO NOT SMOKE WHILE WORKING WITH FUEL. DO NOT USE NEAR OPEN FLAME. ALWAYS STOP ENGINE BEFORE REFUELING. CLEAN UP SPILLED FUEL BEFORE STARTING. AVOID FIRES BY KEEPING ENGINE CLEAN OF ACCUMULATED GREASE AND DEBRIS.

START, STORE, AND REFUEL ON LEVEL GROUND TO PREVENT PERSONAL INJURY. DO NOT RUN UNIT IN AN ENCLOSED, NONVENTILATED AREA. AVOID PROLONGED BREATHING OF VAPORS AND SKIN CONTACT. SERIOUS ILLNESS OR LOSS OF LIFE COULD RESULT.

KEEP THE VENT HOLE IN FUEL TANK CAP OPEN. IF VENT HOLE IS PLUGGED, PRESSURE MAY BUILD UP IN TANK, CAUSING DANGEROUS SPRAYING OF FUEL WHEN TANK CAP IS REMOVED. A VACUUM MAY ALSO BE CREATED DURING OPERATION, WHICH COULD STOP FUEL FLOW. DIESEL FUEL IS MANDATORY FOR USE IN THIS ENGINE. ALWAYS USE CLEAN FUEL. LOW QUALITY OR CONTAMINATED FUEL WILL DAMAGE FUEL INJECTION COMPONENTS.

DIESEL FUEL STORED IN GALVANIZED CONTAINERS REACTS CHEMICALLY WITH THE ZINC COATING ON THE CONTAINER. THE CHEMICAL REACTION CREATES POWDERY FLAKES OF ZINC SULFIDE. IF WATER IS PRESENT IN THE FUEL, A ZINC HYDROXIDE GEL WILL FORM.

3.3 ENGINE BREAK-IN

IMPORTANT  Read Engine Manual for break-in requirements. 1st 100 hours John Deere break-in oil only (TY 22041). Do not add oil until level is in the add area on the dipstick. Do not fill above the crosshatched area on the dipstick. 1st 100 hours run engine at full throttle. Operate engine at heavy loads, do not idle longer than 5 minutes. Check oil frequently, do not exceed 100 hours with break-in oil.

3.4 ENGINE OIL AND FILTER

Change oil and filter at 100 hours, then every 250 hours. Use SAE 15W-40 API CG-4 or API CF-4. Refer to Engine Manual for additional oil types and recommendations. Do not mix different brands or types of oil. Mixing oils can degrade lubrication performance.

3.5 WARNING LIGHT

Unit is equipped with a warning light for low pressure and/or hot engine temperature. Specifications:

 Oil pressure at full speed: 40  50 psi

(2.75  3.45 bar)

 Coolant temperature range: 180° - 202°F

(82° - 94°C)

3.6 HYDRAULIC OIL, FILTER, BREATHER

WARNING

Check the hydraulic oil level. Use the sight gauge located on the hydraulic tank. A 1/4  1/2 air bubble will be seen at the top of the gauge showing the fluid level.

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3. OPERATION

For satisfactory operation, the following oil conditions apply:

1. Accurate level readings can be checked only when the fluid is cold.

2. If the natural color of the fluid has become black or milky, it is possible that an overheating or water contaminant problem exists.

3. Do not mix hydraulic fluids. Mobil 424 is recommended for the hydraulic system.

CAUTION: After a new unit has run 5 hours, the oil filter should be changed. This is to rid the system of any trapped contamination from the wearin of the parts. Refer to Maintenance for hydraulic filter change.

3.7 ENGINE COOLANT

WARNING

CHECK COOLING SYSTEM CAREFULLY. EXPLOSIVE RELEASE OF FLUIDS FROM PRESSURIZED COOLING SYSTEM CAN CAUSE SERIOUS BURNS.

To check coolant level:

1. Shut off engine, allow to cool.

2. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

3. Remove cap, coolant level should just touch the bottom of radiator filler neck. If coolant is required, see Adding Coolant in the Maintenance section of this manual.

IMPORTANT: Do not overfill radiator. Refer to Coolant Maintenance if additional coolant is required. Never pour cold liquid into a hot engine, as it may crack cylinder head or block. DO NOT operate engine without coolant for even a few minutes. If coolant leaks or abnormal temperature is detected, contact a service technician immediately.

replace the water pump seal. Contact your engine distributor or servicing dealer for repairs.

3.8 VISUAL INSPECTION

Make a thorough inspection of the engine compartment daily. Look for oil or coolant leaks, worn fan belt, loose connections and trash build-up. Remove trash build-up and have repairs made as needed if leaks are found.

NOTE:Wipe all fittings, caps, and plugs before performing any maintenance to reduce the chance of system contamination.

 Air intake system hoses and connections for

cracks and loose clamps.

 Fan belt for cracks, breaks, or other damage.  Water pump for coolant leaks.

3.9 AIR CLEANER

IMPORTANT: The air intake system must not leak. Any leak, no matter how small, may result in engine failure due to abrasive dirt and dust entering the intake system.

1. Inspect all intake hoses (piping) for cracks.

2. Check clamps on piping which connect the air cleaner and engine.

3. Squeeze dust unloader valve (A) on air cleaner assembly to remove dust deposits. If clogged, remove and clean the dust unloader valve. Replace if damaged.

IMPORTANT: Do not operate engine without the dust unloader valve.

NOTE:It is normal for a small amount of leakage to

occur as the engine cools down and parts contract. Excessive coolant leakage may indicate the need to

- 24 -

3. OPERATION

WARNING

BEFORE STARTING ENGINE IN A CONFINED BUILDING, INSTALL PROPER OUTLET EXHAUST VENTILATION EQUIPMENT. ALWAYS USE SAFETY APPROVED FUEL STORAGE AND PIPING. NEVER RUN THE ROLLER WITHOUT THE PANELS IN PLACE OR SEVERE PERSONAL INJURY MAY OCCUR.

3.10 BEFORE STARTING

1. Check for proper fluid levels, engine oil, coolant, fuel, and hydraulic oil.

2. Check the air cleaner.

3. Check throttle, levers, and controls for smooth operation.

4. Check seat belt, horn, and back-up alarm operation.

3.12 TO STOP

WARNING

ALWAYS OBEY THE FOLLOWING PROCEDURES BEFORE DISMOUNTING FROM THE ROLLER.

1. Place the forward/reverse lever in the NEUTRAL position.

2. Throttle engine down to its slowest speed.

3. Turn key switch to OFF position to stop the engine. Remove ignition key.

NOTE:Before stopping an engine that has been

operating at working load, idle engine at least 2 minutes.

3.13 IDLING ENGINE

3.11 TO START

1. Operator must always be seated and seat belt must be worn.

2. Forward/reverse must be in NEUTRAL position and eccentric switch should be in OFF position.

3. Throttle should be set at idle.

4. Turn key clockwise until the engine cranks over. Release the key when the engine starts. DO NOT crank engine for more than 20 seconds at a time.

5. Check all gauges for normal engine operation. If operation is not normal, stop the engine and determine the cause.

NOTE:If temperature is below 0° C (32° F), it may be necessary to use cold weather starting aid. See Cold Weather Starting later in this section.

WARNING

DO NOT USE STARTING FLUID (ETHER). ENGINE IS EQUIPPED WITH INTAKE HEATER. AN EXPLOSION OR FIRE MAY RESULT. REFER TO COLD WEATHER STARTING INSTRUCTIONS.

IMPORTANT: Avoid excessive engine idling. Prolonged idling may cause the engine coolant temperature to fall below its normal range. This, in turn, causes crankcase oil dilution, due to incomplete fuel combustion, and permits formation of gummy deposits on valve, pistons, and piston rings. It also promotes rapid accumulation of engine sludge and unburned fuel in the exhaust system.

3.14 WARMING ENGINE

IMPORTANT: To assure proper lubrication, operate engine at idle with no load for 5 minutes. Extend this period when operating at temperatures below freezing.

1. Check oil pressure gauge as soon as engine starts. If gauge needle does not rise above minimum oil pressure specification of (1.05 bar) (15.0 psi) within 5 seconds, stop the engine and determine the cause. Normal engine oil pressure is (3.45 bar + 1.03 bar) (50 + 15 psi) at rated full load speed (1800  2500 rpm) with oil at normal operating temperature of 105° C (221° F).

2. Watch coolant temperature gauge. Do not place engine under full load until it is properly

- 25 -

3. OPERATION

warmed up. The normal engine coolant temperature range is 82° - 94° C (180° - 202° F).

NOTE:It is good practice to operate the engine under a lighter load and at lower speeds than normal for the first few minutes after start-up.

WARNING

NEVER OPERATE ON SLOPES GREATER THAN 15 DEGREES OR TIPPING MAY OCCUR.

3.18 FORWARD/REVERSE/NEUTRAL

3.15 PARKING BRAKE

WARNING

BLOCK THE DRUMS TO PREVENT ROLLING OF THE MACHINE OR SEVERE PERSONAL INJURY MAY OCCUR. NEVER PARK ROLLER ON A HILL.

When engine is not running, the brake is applied. When the engine is running and the forward/reverse lever is in NEUTRAL, the brake will apply within 2 seconds.

3.16 BRAKE LIGHT

When the key is turned to ON, the brake light should come on within 2 seconds. Shifting into forward or reverse, the light should go out.

3.17 TO OPERATE

The forward/reverse lever should be aligned with NEUTRAL on the console when the roller is moving neither forward nor backward with the engine running.

The neutral interlock switch should not allow the engine to start unless the forward reverse lever is in neutral.

3.19 THROTTLE

Pull throttle out to increase engine speed. Push throttle to reduce engine speed. For best performance, run engine at full throttle.

3.20 GAUGES

IMPORTANT: Any time an electric gauge or meter does not register correctly, replace it with a new one. Do not attempt to repair it.

Oil Pressure Gauge Indicates engine oil pressure.

IMPORTANT: Follow Manufacturers "Before Starting" and "Break-in" procedures on engine. Always allow engine to warm up five minutes before applying load.

Start and apply full throttle. Move forward/reverse lever slowly forward to gain speed desired. The same procedure is for reverse. To slow down, move forward/reverse lever toward NEUTRAL.

To gain power or speed by moving forward/reverse lever slightly off of NEUTRAL will produce the greatest amount of torque. Moving the lever all the way forward or reverse will give the greatest amount of speed.

Coolant Temperature Gauge  Indicates the engine coolant temperature.

Volt Meter  Indicates charging current within electrical system.

Hour Meter  Indicates the operating hours of the engine while key switch is in the ON position. The hour meter should be used as a guide for scheduling maintenance.

WARNING

AVOID LEAVING THE KEY ON WHEN MACHINE IS NOT RUNNING. THIS WILL HAVE AN EFFECT ON THE HOUR METER READINGS.

- 26 -

3. OPERATION

3.21 PANEL FUSE 20 AMP

Protects electrical system.

WARNING

NEVER USE FUSE WITH A DIFFERENT RATING FROM THAT SPECIFIED. SERIOUS DAMAGE TO THE ELECTRICAL SYSTEM OR A FIRE MAY RESULT.

3.22 COLD WEATHER STARTING / INTAKE HEATER BUTTON

WARNING

DO NOT USE STARTING FLUID (ETHER). ENGINE IS EQUIPPED WITH AIR INTAKE HEATER. AN EXPLOSION OF FIRE MAY RESULT. FOR COLD WEATHER STARTING, SEE INSTRUCTIONS BELOW.

1. Turn the key to the ON position (do not crank engine).

2. Press INTAKE HEATER BUTTON for approximately 30 seconds. Start engine using starter switch. As soon as the engine starts, release button.

3. Never operate the starter for more than 20 seconds at a time. If engine does not start, release the starter switch and wait at least one minute before trying again.

4. Do not adjust the throttle setting. Allow the engine to idle for 5 minutes to warm up. At temperatures below freezing, extend warm up time.

3.23 BLADE LEVER (OPTIONAL)

3.24 HORN AND BACK-UP ALARM

Check operation daily. It is the drivers responsibility to operate equipment safely.

3.25 ROPS / FOPS / SEAT BELT

Inspect daily. Certified factory installed for operator protection. Do not remove or modify.

WARNING

DANGER: AVOID CRUSHING. DO NOT JUMP IF MACHINE TIPS. ALWAYS WEAR SEAT BELT.

DO NOT OPERATE THIS MACHINE IF THE ROLLOVER PROTECTIVE STRUCTURE (ROPS) IS STRUCTURALLY DAMAGED, SHOWS CRACKS, IS NOT PROPERLY SECURED AS ORIGINALLY INSTALLED, OR HAS BEEN ROLLED. DO NOT REPAIR, MODIFY, OR ADD ATTACHMENTS TO ROPS UNLESS AUTHORIZED IN WRITING BY THE MANUFACTURER.

DO NOT ADD ATTACHMENTS TO THE MACHINE THAT INTRUDE INTO OPERATORS PROTECTIVE AREA, REDUCE VISIBILITY, RESTRICT EMERGENCY EXITS, OR ADD WEIGHT EXCEEDING CERTIFICATION WEIGHT OF ROPS. DO NOT OPERATE MACHINE UNLESS SEAT BELT CONFORMING TO SAE AND/OR ASAE STANDARDS IS FASTENED. SEE OPERATORS MANUAL OR CONTACT YOUR DEALER FOR COMPLETE INSPECTION REQUIREMENTS AND MAINTENANCE INSTRUCTIONS.

Controls the leveling blade height for pre-leveling loose soil.

IMPORTANT: Do not use the blade to dig or bulldoze or machine damage may occur.

3.26 TIRES/LUG NUTS

WARNING

DO NOT EXCEED RATED PRESSURE 35 PSI.

Clean and check daily:

1. Tires are properly inflated.

2. Lug nuts are in place and tight 190 ft. lbs. (140 Nm).

- 27 -

3. OPERATION

3.27 DRUM/SCRAPPERS

Clean and inspect daily to prevent excess mud and debris from building up. Replace if missing or worn. Pad drum scrappers are adjustable, see Maintenance section.

3.28 CLEANING

WARNING

DIRT AND MUD BUILT UP WILL REDUCE MACHINE PERFORMANCE AND/OR CAUSE FAILURES.

Use pressurized water to remove dirt and mud. Clean and inspect entire machine daily. Use extra care when cleaning radiator and oil cooler.

When cleaning machine, caution should be used around regulator area. Direct spraying of the

regulator is not good. (Regulator should be covered or protected if direct spraying will happen). Excessive water pressure may also loosen wire connections or start terminals corroding. After cleaning, all terminals should be dried if wet and connections checked for proper seating.

3.29 ECCENTRICS

When vibratory compaction is necessary, engage eccentrics by pushing the vibration switch to the ON position. For best performance run engine at full rpm. The eccentrics should be turned off whenever the roller is stopped or stopped to change direction. Do not run the eccentric on any non-yielding surface such as concrete or aged asphalt.

3.30 COMPACTION TIPS

Avoid sharp turns, steer gradually. If articulation is a new concept, we suggest the operator take 20 minutes or so to get used to the feel of the unit.

Recommended compaction speed should be at 3 m.p.h. or less to achieve a uniform compaction.

WARNING

DO NOT ARTICULATE ON GRADES LARGER THAN 15, ROLLER MAY TIP OVER. DO NOT OPERATE ACROSS THE SIDES OF HILLS, ROLLER MAY TIP OVER. DO NOT OPERATE AT THE EDGE OF MATS OR ROADS, ROLLER MAY TIP OVER. DO NOT STAND, ALWAYS WEAR SEAT BELT.

3.31 TIE DOWNS

WARNING

TIE DOWNS ARE NOT INTENDED FOR LIFTING PURPOSES.

Equipment is equipped with front and rear tie down rings for shipping purposes. Use only these tie downs to secure unit.

3.32 TOWING (BYPASS)

WARNING

NEVER PUSH OR PULL THE ROLLER WITH THE ENGINE OFF. WHEN ENGINE IS NOT RUNNING, THE BRAKE IS APPLIED. WHEN THE ENGINE IS RUNNING AND THE FORWARD/REVERSE LEVER IS IN NEUTRAL, THE BRAKE WILL APPLY WITHIN 2 SECONDS.

In an emergency or during a breakdown, it may be necessary or desirable to tow the roller. This may be accomplished by mechanically releasing the brake and bypassing the transmission pump. If these procedures are followed carefully, the roller may be moved short distances at LOW speed without running the engine.

The brake is located in the front wheel motor, which drives the drum of the roller. There is an access hole in the front frame to assist in releasing the brake. Refer to the Drum Assembly #39 22770 Kit Bypass to identify these parts. The threaded hole in the center of the wheel motor requires a M12 bolt long enough to extend beyond the frame when fully engaged. A bolt, washer, and nut is included in a separate package for this

- 28 -

3. OPERATION

purpose. Fully install the nut and washer on the bolt. Insert this assembly through the hole in the frame such that the washer is over the hole with the nut against the outside of this washer. Thread the bolt, finger tight into the wheel motor to the bottom of the hole. Now tighten the nut against the washer until the brake is compressed and released. This should require about 44 ft. lbs. torque. Do not torque the bolt. Be careful not to over-torque beyond releasing the brake.

The bypass valve is located on the transmission pump. The seat and battery plate should be removed for access to the transmission pump. The bypass valve is controlled by a shaft with cross-drilled holes and maybe a slot in the end. This shaft may be turned manually to open the valve and allow the motor to turn. The valve is fully open with two revolutions of the shaft. DO NOT OPEN VALVE PAST TWO TURNS. The valve must be fully closed for normal operation. The torque required to close the valve is only 7 to 10 ft. lbs. DAMAGE MAY RESULT FROM OVERTORQUING.

3.33 STORAGE

IMPORTANT: The front wheel motor has a rubber plug in the M12 hole to prevent contamination. Reinstall the rubber plug after towing

1. Store the roller on level ground with drums blocked and parking brake on.

2. Remove the key. Operations of roller by untrained persons could result in personal injury.

3. During extended storage, drums can be coated with any type of oil or grease to prevent rusting.

4. Storage instructions for the engine are stated in the Engine Manual and should be carried out.

- 29 -

4. MAINTENANCE

- 31 -

4.1 IMPORTANT

The person attempting any of the following maintenance tasks must be authorized to do so and have read and understood all sections within this manual.

- 32 -

4. MAINTENANCE

4.2 MAINTENANCE SCHEDULE CHART

- 33 -

4. MAINTENANCE

4.3 IMPORTANT MAINTENANCE INFORMATION

WARNING

REMOVE THE KEY AND / OR DISCONNECT BATTERY TO AVOID ACCIDENTAL IGNITION OF ENGINE. SEVERE PERSONAL INJURY MAY OCCUR. ROLLER MUST BE PARKED ON LEVEL GROUND WITH PARKING BRAKE APPLIED, ENGINE OFF, AND DRUM BLOCKED. NEVER WORK ON THE ROLLER WITH ENGINE RUNNING. SEVERE PERSONAL INJURY MAY OCCUR. ALLOW ALL COMPONENTS IN THE ENGINE COMPARTMENT TO COOL BEFORE PERFORMING ANY SERVICE WORK.

IMPORTANT: Read John Deere Emission Warranty Statement and Engine Manual before service or maintenance.

4.4 ENGINE OIL AND FILTER

IMPORTANT: Read Engine Manual and Engine Break-in covered in Operating section of this manual.

packing contacts filter housing. DO NOT overtighten filter element.

7. Install oil pan drain plug.

8. Fill engine crankcase with correct engine oil through timing gear cover opening of rocker arm cover opening.

IMPORTANT: Immediately after completing any oil change, crank engine for 30 seconds without permitting engine to start. This will help insure adequate lubrication to engine components before engine starts.

9. Start engine and run to check for possible leaks.

10. Stop engine and check oil level after 10 minutes. Oil level reading should be between arrows or within crosshatch of dipstick.

4.5 ADDITIONAL SERVICE INFORMATION

This is not a detailed service manual. If you want more detailed service information see John Deere Manuals:

55319 Manual Engine 55320 Manual Parts 55321 Manual Technical

4.6 HYDRAULIC OIL/FILTER

Change oil and filter at 100 hours, then every 250 hours. Use SAE 15W-40 API CG-4 or API CF-4.

1. Run engine approximately 5 minutes to warm up oil. Shut engine off.

2. Remove oil pan drain plug, drain into suitable container.

3. Drain crankcase oil from engine while warm.

4. Remove and discard oil filter using a filter wrench.

5. Clean filter mounting pad.

IMPORTANT: Filtration of oils is critical to proper lubrication. Always change filter regularly. Use filter meeting John Deere performance specifications.

6. Oil new filter seal and install new filter element, tighten approximately 3/4  1 - 1/4 turn after

WARNING

PRESSURIZED RELEASE OF FLUIDS FROM HYDRAULIC SYSTEM CAN CAUSE SERIOUS BURNS. SHUT OFF ENGINE. ONLY REMOVE BREATHER CAP WHEN COOL ENOUGH TO TOUCH WITH BARE HANDS. SLOWLY LOOSEN CAP TO FIRST STOP TO RELIEVE PRESSURE BEFORE REMOVING COMPLETELY. ESCAPING HYDRAULIC FLUID UNDER PRESSURE CAN HAVE SUFFICIENT FORCE TO PENETRATE THE SKIN, CAUSING SERIOUS PERSONAL INJURY. HYDRAULIC FLUID ESCAPING UNDER PRESSURE FROM A VERY SMALL HOLE CAN BE ALMOST INVISIBLE. USE A PIECE OF CARDBOARD OR WOOD TO SEARCH FOR POSSIBLE LEAKS. NEVER USE YOUR HANDS TO DETECT PRESSURE LEAKS.

- 34 -

4. MAINTENANCE

HYDRAULIC TANK TEMPERATURE CAN REACH 180 DEGREES F MAXIMUM.

Refer to Operating section of this manual for hydraulic oil conditions and recommendations.

Before disconnecting any hydraulic components, be sure engine is shut off and relieve all pressure. Before applying pressure to system, be sure all connections are tight and lines, fittings, and hoses are not damaged.

IMPORTANT: When hoses, oil filter, and/or hydraulic components are changed, start the engine and purge the air from the system prior to checking the oil level. To do this, idle the engine for three minutes with control lever in NEUTRAL position. Slowly engage forward to reverse. This allows fluid to replace air introduced with filter change. If this procedure is not followed, partial or complete failure of the pump may result.

Change hydraulic oil filter at 5 hours then every 100 hours.

1. Remove and discard hydraulic oil filter using a filter wrench.

2. Oil new filter seal and install new filter element, tighten approximately 3/4  1 - 1/4 turn after packing contacts filter housing. DO NOT overtighten filter element.

IMPORTANT: Immediately after completing filter change, crank engine for 30 seconds without permitting engine to start. This will help insure adequate lubrication to components before engine starts.

3. Start engine and run to check for possible leaks.

4. Stop engine and replenish hydraulic oil.

WARNING

NEVER OVERFILL THE HYDRAULIC TANK. USE THE SIGHT GAUGE LOCATED ON THE HYDRAULIC TANK. A 1/4  1/2 AIR BUBBLE WILL BE SEEN AT THE TOP OF THE GAUGE SHOWING THE FLUID LEVEL.

Change hydraulic oil every 800 hours. Use Mobil 424.

1. Run engine approximately 5 minutes to warm up oil. Shut engine off.

2. Remove breather cap and oil drain plug, drain into suitable container.

3. Apply thread sealant to breather cap and drain plug, install drain plug.

4. Fill hydraulic tank with correct hydraulic oil (approximately 20 gallons). Use the sight gauge to watch for proper oil level, install breather cap.

IMPORTANT: Immediately after completing oil change, crank engine for 30 seconds without permitting engine to start. This will help insure adequate lubrication to components before engine starts.

5. Start engine and run to check for possible leaks.

6. Stop engine and replenish hydraulic oil.

4.7 HYDRAULIC BREATHER

Replace every 800 hours or yearly. P/N 35483.

WARNING

4.8 ENGINE COOLING SYSTEM

WARNING

EXPLOSIVE RELEASE OF FLUIDS FROM PRESSURIZED COOLING SYSTEM CAN CAUSE SERIOUS BURNS. SHUT OFF ENGINE. ONLY REMOVE FILLER CAP WHEN COOL ENOUGH TO TOUCH WITH BARE HANDS. SLOWLY LOOSEN CAP TO FIRST STOP TO RELIEVE PRESSURE BEFORE REMOVING COMPLETELY.

- 35 -

4. MAINTENANCE

WARNING

To check coolant level, refer to Operating section of this manual and Engine Manual.

Inspect cooling system every 600 hours or 12 months.

1. Check entire cooling system hoses. Replace hoses when hard, flimsy, or cracked.

2. Thoroughly inspect all cooling system hoses. Replace hoses when hard, flimsy, or cracked.

IMPORTANT: Air must be expelled from cooling system when system is refilled. Loosen temperature-sending unit fitting at rear of cylinder head to allow air to escape when filling system. Retighten fitting when all the air has been expelled.

3. Test the coolant solution at 600 hours or 12 month intervals and whenever excessive coolant is lost through leaks or overheating to ensure the necessary protection. Coolant test strips are available from your John Deere dealer. These test strips provide a simple, effective method to check the freeze point and additive levels of your engine coolant.

4. After 600 hours or 12 months of engine operating time, recharge your engine coolant with the recommended amount (see label on container) of TY16004 or TY16005 Liquid Coolant Conditioner.

ALWAYS maintain coolant at correct level and concentration. DO NOT operate engine without coolant for even a few minutes.

If frequent coolant makeup is required, the glycol concentration should be checked with JT05460 Refractometer to assure that the desired freeze point is maintained. Follow manufacturers instructions provided with Refractometer.

Water may be used as coolant in emergency situations

only.

Foaming, hot surface aluminum and iron corrosion, scaling, and cavitation will occur when water is used as the coolant, even when coolant conditioners are added.

Drain cooling system and refill with recommended glycol base engine coolant as soon as possible.

4.8.1 Replacing Engine Coolant

Every 1200 hours or 24 months, the coolant should be replaced. The coolant system should also be flushed and pressure tested. Refer to Engine Manual.

4.8.2 Adding Coolant

NOTE: TY16004 or TY16005 Liquid Coolant

Conditioner is a non-chromate inhibitor and should be used only with low silicate, ethylene-glycol base antifreeze. It does not protect the cooling system from freezing. See "Adding Coolant."

Usually recharging your engine coolant with the recommended amount of TY16004 or TY16005 Liquid Coolant Conditioner at 600 hours or 12 months of operation is adequate. However, with a CoolScan analysis report you will be given a more thorough evaluation of your engine coolant condition along with detailed service recommendations. Refer to Engine Manual.

IMPORTANT: Do not add supplemental coolant additives when the cooling system is drained and refilled with John Deere ANTIFREEZE/SUMMER COOLANT or John Deere COOL GARD.

CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

IMPORTANT: Never pour cold liquid into a hot engine, as it may crack cylinder head or block. DO NOT operate engine without coolant for even a few minutes.

Air must be expelled from cooling system when coolant is added.

1. Loosen temperature sending unit fitting at rear of cylinder head to allow air to escape when filling system.

- 36 -

4. MAINTENANCE

IMPORTANT: When adding coolant to the system, use the appropriate coolant solution. Coolant 50/50 mixture of antifreeze/distilled water meeting ASTM 4985, ASTM D5345 (pre-diluted coolant) or John Deere COOL-GARD. 50/50 mixture provides protection to -34° F (-37° C). Do not overfill cooling system. A pressurized system needs space for heat expansion without overflowing at top of radiator.

2. Fill until coolant level touches bottom of radiator filler neck.

3. Tighten fitting when air has been expelled from system.

4.8.3 Disposing of Coolant

Improperly disposing of engine coolant can threaten the environment and ecology.

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

1. Remove air cleaner cover.

2. Remove primary (outer) element only.

3. Thoroughly clean all dirt from inside filter housing.

4. Air cleaner has rubber dust unloader valve on the air cleaner. Squeeze valve tip to release any trapped dirt particles.

5. Inspect filter to determine if it is practical to clean or for damage after cleaning filter.

a. Hold a bright light inside element and

check carefully for holes. Discard any element that shows the smallest hole or rupture.

b. Be sure outer screen is not dented.

Vibration would quickly wear a hole in filter.

c. Be sure filter gasket is in good condition.

If gasket is damaged or missing, replace element.

6. Gently pat sides of element with palm of hand to loosen dirt. DO NOT tap element against a hard surface.

Do not pour waste onto the ground, down a drain, or into any water source.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center or from your dealer.

4.9 AIR CLEANER

4.9.1 Air Cleaner Service

IMPORTANT: Do not operate engine without the dust unloader valve.

For daily inspection refer to the Operating section of this manual.

Clean the primary (outer) filter element every 100 hours.

IMPORTANT: Always replace secondary safety (inner) filter elements. DO NOT attempt to clean them. Do not blow air from outside portion of filter with air nozzle. Wear safety glasses and remove bystanders.

WARNING

ONLY A SPECIAL AIR CLEANING GUN SHOULD BE USED. CONCENTRATED AIR PRESSURE FROM AN ORDINARY AIR NOZZLE MAY SEVERELY DAMAGE FILTER ELEMENT. DO NOT EXCEED 30 psi (2.1 bar) WHEN CLEANING FILTER ELEMENT.

7. Insert the cleaning gun into element, hold air nozzle about 1" (25.4) mm from perforated metal retainer. Force air through filter from inside to outside and move air gun up and down pleats to remove as much dirt as possible.

8. Repeat steps 6 and 7 to remove additional dirt.

9. Inspect element for damage after cleaning. Replace element if any damage is found.

Service air cleaner more frequently in dusty conditions.

4.9.2 Air Cleaner Replacement

Replace primary (outer) element every 600 hours.

1. Remove air cleaner cover.

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4. MAINTENANCE

2. Remove primary (outer) element only.

3. Thoroughly clean all dirt from inside filter housing.

4. Air cleaner has a rubber dust unloader valve on the air cleaner. Squeeze valve tip to release any trapped dirt particle.

IMPORTANT: Remove secondary safety (inner) element ONLY for replacement. DO NOT attempt to clean, wash, or reuse secondary element. Replacement of secondary element is usually necessary ONLY when primary element has a hole in it.

5. To replace secondary element, remove retaining nut and secondary element. Immediately replace secondary element with new element to prevent dust from entering air intake system.

6. Install new primary element and tighten wing nut securely. Install cover assembly and tighten retaining wing nut securely.

4.9.3 Element Storage

Seal element in a plastic bag and store in shipping container to protect against dust and damage.

NOTE: Air cleaner element MUST BE DRY before storing in plastic bag.

4.10 FUEL FILTER

4.10.1 Water Separator

Fuel filter is equipped with a water drain plug, check/ drain every 50 hours or 2 weeks.

NOTE: Drain water into a suitable container and dispose of properly.

1. Loosen drain plug at bottom of fuel filter two or three turns.

2. Loosen air bleed plug two full turns on fuel filter base and drain water from bottom until fuel starts to drain out.

3. When fuel starts to drain out, tighten drain plug securely by hand or using a coin.

After draining water from the fuel filter, the filter must be primed by bleeding all air from the fuel system.

4. Operate primer lever of the fuel supply pump until fuel flow is free from air bubbles.

5. Tighten bleed plug securely by hand or using a coin, continue operating hand primer until pumping action is not felt. Push hand primer inward (toward engine) as far as it will go.

If the fuel system needs further bleeding of air, see Bleeding Fuel System in Maintenance section of this manual.

4.10.2 Fuel Filter Replacement

WARNING

ESCAPING FLUID UNDER PRESSURE CAN PENETRATE THE SKIN CAUSING SERIOUS INJURY. RELIEVE PRESSURE BEFORE DISCONNECTING FUEL OR OTHER LINES. TIGHTEN ALL CONNECTIONS BEFORE APPLYING PRESSURE. KEEP HANDS AND BODY AWAY FROM PINHOLES AND NOZZLES THAT EJECT FLUIDS UNDER HIGH PRESSURE. USE A PIECE OF CARDBOARD OR PAPER TO SEARCH FOR LEAKS. DO NOT USE YOUR HAND.

IF ANY FLUID IS INJECTED INTO THE SKIN, A DOCTOR FAMILIAR WITH THIS TYPE INJURY MUST SURGICALLY REMOVE IT WITHIN A FEW HOURS OR GANGRENE MAY RESULT. DOCTORS UNFAMILIAR WITH THIS TYPE OF INJURY MAY CALL THE DEERE & COMPANY MEDICAL DEPARTMENT IN MOLINE, ILLINOIS, OR OTHER KNOWLEDGEABLE MEDICAL SOURCE.

Replace fuel filter every 600 hours or 12 months.

1. Thoroughly clean fuel filter assembly and surrounding area.

2. Loosen drain plug and drain fuel into a suitable container.

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4. MAINTENANCE

NOTE: Lifting up on retaining ring as it is rotated helps to get it past raised locators.

3. Firmly grasp the retaining ring and rotate it counterclockwise 1/4 turn. Remove ring with filter element.

4. Inspect filter mounting base for cleanliness. Clean as required.

NOTE: Raised locators on fuel filter canister must be indexed properly with slots in mounting base for correct installation.

5. Install new filter element onto mounting. Be sure element is properly indexed and firmly seated on base. It may be necessary to rotate filter for correct alignment.

6. Remove filter element from water separator bowl. Drain and clean separator bowl. Dry with compressed air. Install water separator bowl onto new element. Tighten securely.

7. Align keys on filter element with slots in filter base.

8. Install retaining ring onto mounting base making certain dust seal is in place on filter base. Hand tighten ring (about 1/3 turn) until it snaps into the detent. DO NOT overtighten retaining ring.

A PIECE OF CARDBOARD OR PAPER TO SEARCH FOR LEAKS. DO NOT USE YOUR HAND.

Whenever the fuel system has been opened up for service (lines disconnected or filters removed), it will be necessary to bleed air from the system.

1. Loosen the air bleed vent screw on fuel filter head two full turns by hand on fuel filter base.

2. Operate supply pump primer lever until fuel flow is free from air bubbles.

3. Tighten bleed plug securely by hand or using a coin, continue operating hand primer until pumping action is not felt. Push hand primer inward (toward engine) as far as it will go.

4. Start engine and check for leaks.

NOTE: The proper installation is indicated when a click is heard and a release of the retaining ring is felt. A plug is provided with the new element for plugging the used element.

9. Bleed the fuel system. See Bleeding Fuel System in Maintenance section of this manual.

4.10.3 Bleeding Fuel System

WARNING

If engine will not start, it may be necessary to bleed air from fuel system at fuel injection pump or injection nozzles as explained next.

4.10.4 Bleeding at Fuel Injection Pump

1. Slightly loosen fuel supply line connector at injection pump.

2. Operate fuel supply pump primer lever until fuel, without air bubbles, flows from fuel return line connection.

3. Tighten return line connector to 16 Nm (12 lb-ft.).

4. Leave hand primer in the inward position toward cylinder block.

4.10.5 Bleeding at Fuel Injection Nozzles

1. Energize the electronic fuel shut-off solenoid (turn ignition key to ON position).

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4. MAINTENANCE

2. Using two open-end wrenches, loosen fuel line connection at injection nozzle.

3. Crank engine over with starting motor, (but do not start engine), until fuel free from air bubbles flows out of loosened connection. Retighten connection to 27 Nm (20 lb-ft.).

4. Repeat procedure for remaining injection nozzles (if necessary) until all air has been removed from fuel system.

If engine still will not start, see your authorized servicing dealer or engine distributor.

4.11 FAN/ALTERNATOR BELT

Low belt tension causes slippage resulting in excessive cover wear, burn spots, overheating, or slip and grab causing belt breakage.

High belt tension causes belt heating and excessive stretch, as well as damage to drive components such as pulleys and shafts. V-belts should ride on the sides of standard pulleys not on the bottom of the groove.

Standard V-belt tension can be checked with JDG529 Tension Gauge (arrow) or equivalent gauge.

STANDARD V-BELTS

Tension New Belt Tension Used* Belt

Single Belt 578-623 N 378-423 N

(130-140 lb. force) (85-95 lb. force)

4.12 GREASE FITTINGS

Use a grease gun to grease below fittings, use lithium grease. Remove the blue protection cap off fitting before greasing.

4.13 FRAME HINGE

Grease daily six fittings with lithium base grease using a grease gun. There is one fitting on each of the top and bottom bearings for the vertical pin. There are two fittings on the horizontal pin.

4.14 BLADE PINS

Grease the two fittings daily; one on each of the blade pivot pins.

4.15 BATTERY

4.15.1 Servicing Battery

1. Inspect belts for cracks, fraying, or stretched out areas. Replace if necessary.

2. Using either JDG529 Tension Gauge or belt tension tester and straightedge, check tension of warm belts.

 For standard V-belt, an 89 N (20 lb. force)

applied halfway between pulleys should deflect belt by 19 mm (3/4 in.).

3. If adjustment is necessary, loosen alternator bracket cap screw and nut on mounting bolt. Pull alternator frame outward until belts are correctly tensioned.

IMPORTANT: Do not pry against the alternator rear frame. Do not tighten or loosen belts while they are hot.

4. Tighten alternator bracket cap screw and nut firmly.

5. After a new or used belt has run for 10 minutes recheck belt tension.

WARNING

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 NEGATIVE (-) BATTERY CLAMP FIRST AND REPLACE IT LAST.

1. On regular batteries, check electrolyte level. Fill each cell to bottom of filler neck with distilled water.

2. Keep batteries clean by wiping them with a damp cloth. Keep all connections clean and tight. Remove any corrosion, and wash terminals with a

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4. MAINTENANCE

solution of 1 part baking soda and 4 parts water. Tighten all connections securely.

NOTE: Coat battery terminals and connectors with a mixture of petroleum jelly and baking soda to retard corrosion.

3. Keep battery fully charged, especially during cold weather. If a battery charger is used, turn charger off before connecting charger to battery(ies). Attach POSITIVE (+) battery charger lead to POSITIVE (+) battery post. Then attach NEGATIVE (-) battery charger lead to a good ground.

Once a month, check the battery for proper charge of

12.5 volts. Check for proper fluid level. Use distilled

water when adding and run 30 minutes to mix. Clean battery, posts, and terminals. Disconnect battery cables before charging to avoid damage to the electrical system.

WARNING

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.

If acid is swallowed:

1. Drink large amounts of water or milk.

2. Then drink milk of magnesia, beaten eggs, or vegetable oil.

3. Get medical attention immediately.

In freezing weather, run engine at lease 30 minutes to assure thorough mixing after adding water to battery.

If necessary to replace battery(ies), replacements must meet or exceed the following recommended capabilities at -18° C (0° F):

12 Volt  Heavy Duty Battery BCI Group 24 800 CCA

4.15.2 Battery Installation

WARNING

ALWAYS CONNECT GROUNDED CABLE LAST. CLEAN AND SECURELY CONNECT EACH CABLE END TO BATTERY TERMINAL OF SAME POLARITY. BATTERY SHOULD BE SECURELY FASTENED WITH PROPERLY INSTALLED HOLD-DOWNS.

4.15.3 Charging / Jumping Battery

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling or dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 10  15 minutes. Get medical attention immediately.

A 12-volt booster battery can be connected in parallel with battery(ies) on the unit to aid in cold weather starting. ALWAYS use heavy-duty jumper cables.

WARNING

GAS GIVEN OFF BY BATTERY IS EXPLOSIVE. KEEP SPARKS AND FLAMES AWAY FROM BATTERY. BEFORE CONNECTING OR DISCONNECTING A BATTERY CHARGER TURN CHARGER OFF. MAKE LAST CONNECTION AND FIRST DISCONNECTION AT A POINT AWAY FROM BATTERY. ALWAYS CONNECT NEGATIVE (-) CABLE LAST AND DISCONNECT THIS CABLE FIRST.

IMPORTANT: Be sure polarity is correct before making connections. Reversed polarity will damage electrical system. Always connect positive to

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4. MAINTENANCE

positive and negative to ground. Always use 12-volt booster battery for 12-volt electrical systems.

1. Connect booster battery or batteries to produce the required system voltage for your engine application.

NOTE: To avoid sparks, DO NOT allow the free ends of jumper cables to touch the engine.

2. Connect one end of jumper cable to the POSITIVE (+) post of the booster battery.

3. Connect one end of jumper cable to the POSITIVE (+) post of the battery connected to starter.

4. Connect one end of the other jumper cable to the NEGATIVE (-) post of the booster battery.

5. ALWAYS complete the hook-up by making the last connection of the NEGATIVE (-) cable to a good ground on the engine frame and away from the battery(ies).

6. Start the engine. Disconnect jumper cables immediately after engine starts. Disconnect NEGATIVE (-) cable first.

4.16 ENGINE CRANKCASE VENT TUBE

Remove and clean every 600 hours or 12 months. If you operate the engine in dusty conditions, clean the tube at shorter intervals.

1. Remove and clean crankcase vent tube.

2. Install the vent tube. Be sure the O-ring fits correctly in the rocker arm cover for elbow adapter. Tighten hose clamp securely.

Do not alter injection pumps.

TAMPERING with the following engine factory settings is ILLEGAL except to reset to published specifications and reseal by authorized engine dealer:

- Engine Timing

- Fuel Delivery

- Aneroid Settings

- Rated Speed

Deere will reissue emissions dataplates only to replace damaged plates. Requests must be in writing and include name, address, engine model, and serial number with reason for need.

Power rating changes WILL NOT be allowed on new engines.

4.19 FUEL INJECTORS

WARNING

4.17 ENGINE VALVE CLEARANCE

Check/adjust at 900 hours then every 1200 hours or 24 months. See authorized engine service dealer or refer to Engine Manual for procedures.

4.18 EMISSION REGULATION/ENGINE RPM

Do not adjust operating speed. Full speed is factory set at 2500 rpm.

Do not adjust idle speed above 1400 rpm. Proper idle rpm is 1200 + 100.

IMPORTANT: Always use John Deere replacement parts meeting John Deere performance

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4. MAINTENANCE

specifications. Only qualified technicians should attempt fuel injector diagnose.

Fuel injection nozzles are usually removed and tested or replaced when there is a noticeable loss of power or excessive smoking after break-in period.

For detailed testing and diagnostic information on fuel system refer to John Deere Technical Manual (P/N

55321).

4.19.1 Test Fuel Injection Nozzles (engine running)

1. Operate engine at intermediate speed and no load.

2. Slowly loosen the fuel pressure line at one of the nozzles until fuel escapes at the connection (fuel not opening nozzle valve).

NOTE: The injection nozzle before and/or after

nozzle being checked could be the faulty nozzle.

 If engine speed changes, the injection

nozzle is probably working satisfactory.

 If engine speed does not change, a nozzle

is faulty and must be checked and repaired (or replaced).

3. Repeat test for each remaining nozzle assembly.

4. Remove faulty injection nozzles and see authorized engine dealer or replace with new.

Fill fuel tank at the end of each days operation to prevent condensation in tank as moist air cools and freezing during cold weather.

Avoid storing fuel over long periods of time. If fuel is stored for more than a month prior to use or there is a slow turnover in fuel tank or supply tank, add a fuel conditioner such as John Deere PREMIUM DIESEL FUEL CONDITIONER or equivalent to stabilize the fuel and prevent water condensation. John Deere PREMIUM DIESEL FUEL CONDITIONER is available in winter and summer formulas. Fuel conditioner also reduces fuel gelling and controls wax separation during cold weather.

Proper fuel storage is critically important. Use clean storage and transfer tanks. Periodically drain water and sediment from bottom of tank. Store fuel in a convenient place away from buildings.

IMPORTANT: DO NOT store diesel fuel in galvanized containers. Diesel fuel stored in galvanized containers reacts with zinc coating on container to form zinc flakes. If fuel contains water, a zinc gel will also form. The gel and flakes will quickly plug fuel filters and damage injection nozzles and injection pump.

DO NOT use brass-coated containers for fuel storage. Brass is an alloy of copper and zinc.

4.20 FUEL TANK

Drain and flush the fuel tank every year.

WARNING

HANDLE FUEL CAREFULLY. DO NOT FILL THE FUEL TANK WHEN ENGINE IS RUNNING.

DO NOT SMOKE WHILE FILLING FUEL TANK OR SERVICING FUEL SYSTEM.

THE FUEL TANK IS VENTED THROUGH THE FILLER CAP. IF A NEW FILLER CAP IS REQUIRED, ALWAYS REPLACE IT WITH AN ORIGINAL VENTED CAP.

4.21 FUEL LINES

Inspect fuel line condition and clamps. Replace fuel lines every 2 years.

4.22 HYDRAULIC HOSES/CONNECTIONS

WARNING

ESCAPING HYDRAULIC FLUID UNDER PRESSURE CAN HAVE SUFFICIENT FORCE TO PENETRATE THE SKIN, CAUSING SERIOUS PERSONAL INJURY. HYDRAULIC FLUID ESCAPING UNDER PRESSURE FROM A VERY SMALL HOLE CAN BE ALMOST INVISIBLE. USE A PIECE OF

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4. MAINTENANCE

WARNING

CARDBOARD OR WOOD TO SEARCH FOR POSSIBLE LEAKS. NEVER USE YOUR HANDS TO DETECT PRESSURE LEAKS. IF YOU ARE INJURED BY ESCAPING HYDRAULIC FLUIDS, SEE A DOCTOR AT ONCE. SERIOUS INFECTION OR REACTIONS CAN DEVELOP IF PROPER MEDICAL TREATMENT IS NOT ADMINISTERED IMMEDIATELY.

Before disconnecting any hydraulic lines, be sure engine is shut off and relieve all pressure. Before applying pressure to system, be sure all connections are tight and lines, fittings and hoses are not damaged.

Inspect for leaks daily. Check connections for tightness every 100 hours.

Hydraulic system produces high pressures  incorrect hose replacement can cause serious personal injury. When performing service, refer to hydraulic diagrams for hose identification and connections.

4.24 NEUTRAL INTERLOCK

The purpose of the neutral interlock switch is to prevent engine starting when the forward/reverse lever is not in the neutral position. To check:

1. Disconnect battery cables from battery.

2. a. Disconnect (2) wires from neutral interlock switch and connect it to leads from an ohmmeter.

b. When switch is actuated, ohmmeter should

read zero resistance.

3. Adjustments must be made at transmission.

4. Disconnect ohmmeter and reconnect interlock

wires and battery cables.

4.25 CONTROL CABLES: FORWARD/ REVERSE, THROTTLE, BLADE

Lubricate all cable ends with penetrating oil every 200 hours.

4.23 FORWARD/REVERSE/NEUTRAL ADJUSTMENT

The forward/reverse lever should be aligned with NEUTRAL on the console when the roller is moving neither forward nor backward with the engine running. If the lever is not aligned, adjust it as described below.

1. Shut off the engine with the forward/reverse lever left in operating neutral position, the position when the roller moves neither forward nor reverse. Apply the parking brake.

2. Open the engine hood of the machine.

3. Disconnect the linkage from the hydrostatic transmission from the clevis. Do this by removing the lock nut from the clevis pin and removing the pin.

4. Now screw clevis in or out to adjust.

5. Secure the clevis to the transmission lever with the clevis pin, secure with the lock nut and tighten clevis nut.

Linkage play must be minimal at both connections. Replace clevis and/or link if required.

DO NOT ADJUST THE CONTROL CABLE WITH THE POWER ON OR THE ENGINE RUNNING. SERIOUS INJURY OR DEATH COULD RESULT. A GRADUAL OR SUDDEN INCREASE IN THE NOLOAD FRICTION (CABLE DISCONNECT AT BOTH ENDS) OF A CONTROL CABLE IS AN INDICATION OF A PENDING OR PRESENT PERFORMANCE PROBLEM. THE CONTROL CABLE SHOULD BE REPLACED, OTHERWISE SERIOUS INJURY OR DEATH COULD RESULT. A GRADUAL OR SUDDEN DECREASE IN THE USABLE STROKE IS AN INDICATION OF A PENDING OR PRESENT PERFORMANCE PROBLEM. THE CONTROL CABLE SHOULD BE REPLACED, OTHERWISE SERIOUS INJURY OR DEATH COULD RESULT. CONTROL CABLES WHICH HAVE MOISTURE INSIDE OF THEM AND/OR HAVE FROZEN SHOULD BE REPLACED. DO NOT APPLY HEAT TO THAW OR DRY CONTROL CABLES.

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4. MAINTENANCE

4.26 ECCENTRICS

Test vibration with front drum on soft ground. Run engine at full rpm to obtain vib spec 2100 + 100 rpm  check per below.

To check vibration with a vibrotach, place the vibrotach on the vibrating member surface, record reading when the wire reaches maximum movement. (Vibrotach P/N 37891).

When checking vibration with strobe light, place horizontal line on vibrating member surface. Check with strobe light and record reading when the line reaches minimum movement.

4.26.1 Eccentric Housing Oil

WARNING

ROLLER MUST BE PARKED ON LEVEL GROUND WITH PARKING BRAKE APPLIED AND ENGINE OFF. REMOVE THE KEY AND / OR DISCONNECT BATTERY TO AVOID ACCIDENTAL IGNITION OF ENGINE. SEVERE PERSONAL INJURY MAY OCCUR.

NEVER WORK ON THE ROLLER WITH ENGINE RUNNING. SEVERE PERSONAL INJURY MAY OCCUR.

4.27 CHARGE SYSTEM

If gauge fails to function, check charge system. With the engine running at full speed, voltage should be 1314 volts across the battery (check volt meter). If unit is charging, replace gauge. If not, see authorized engine dealer to check alternator.

4.28 PANEL FUSE 20 AMP

This fuse provides protection for the electrical system. If the engine fails to turnover when starting, check the fuse.

WARNING

NEVER USE FUSE WITH A DIFFERENT RATING FROM THAT SPECIFIED. SERIOUS DAMAGE TO THE ELECTRICAL SYSTEM OR A FIRE MAY RESULT.

TURN THE ENGINE SWITCH OFF AND REMOVE THE KEY BEFORE CHECKING OR REPLACING FUSES TO PREVENT ACCIDENTAL SHORTCIRCUITING.

When frequent fuse failure occurs, it usually indicates a short circuit or an overload in the electrical system. See your authorized engine dealer for repair.

4.29 ENGINE INSTALLATION GUIDELINES

Eccentric housing oil should be checked monthly and changed every 800 hours or yearly. Refer to Maintenance Chart.

To check, locate oil plug inside the right hand drum end and position drum so that oil plug is visible at 7:00. Loosen oil plug slowly until oil starts to drip out past the oil plug. Oil must be present at the 7:00 position. Add oil if required and reinstall oil plug, use thread sealant.

Eccentric housing oil:

SAE 20W/50 API SJ or API SH SD/PD 43 1 qt. (.95 L.) SP/PD 54 1.5 qt. (1.4 L.)

When installing new or reworking used diesel engines, this list of guidelines should be strictly adhered to. Following these guidelines should prevent damage to the electrical system of diesel engines.

A. Always disconnect the positive cable from the

battery before performing any work on the machine that involves welding or working on the electrical system.

B. Avoid jump starting a diesel engine. Either change

the battery or remove the positive cable and charge the battery.

C. Do not alter or change the wiring harness.

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4. MAINTENANCE

D. Cold weather add-ons should not be needed.

When cleaning machine, caution should be used around regulator area. Direct spraying of the regulator is not good. (Regulator should be covered or protected if direct spraying will happen). Excessive water pressure may also loosen wire connections or cause terminal corrosion. After cleaning, all terminals should be dried if wet and connections checked for proper seating.

4.30 ENGINE MOUNTING

Check periodically, tighten all mounting hardware for proper torque. Refer to Torque Charts in Exploded Views with Parts Section.

4.31 HARDWARE

Inspect all hardware for tightness. Refer to parts illustrations for proper torque and Torque Charts in Exploded Views with Parts Section.

4.31.1 Loctite

Loctite 262 threadlocker is required to prevent hardware from loosening.

Refer to Exploded Diagram and Parts List for * where loctite is required.

4.32 ROLL OVER PROTECTIVE STRUCTURES (ROPS)

Proper inspection and maintenance procedures can ensure that ROPS will perform the lifesaving function they are designed for and expected to do. Make regular, periodic inspections to ensure ROPS are damage-free and thus capable of functioning in an upset.

Generally ROPS/FOPS structures are not intended as external load carrying members and must not be used to mount attachments such as pull hooks, winches, side brooms, etc. without the manufacturers approval.

4.32.1 Maintenance of ROPS/Seat Belts

Inspection

Scheduled, frequent visual checks of mounting hardware by operator or service personnel are recommended. Inspection with regular service intervals is suggested. The inspection should check for:

 Worn, damaged or missing resilient mounts.

Excessive motion or rattling during operation are indications of a problem.

 Loose, missing or damaged mounting

hardware (bolts, nuts, washers, etc.). Bolts should be checked for proper torque.

 Cracks in ROPS/FOPS structure and mounting

system. The machine should be cleaned, as necessary, to allow inspection for cracks in the structure and mounting system. Rust lines should be taken as indications of cracks and verified by inspection. Some cracks will badly affect the ROPS/FOPS function. If in doubt, consult the manufacturer.

 Water drainage paths. Clear water drainage

paths so that entrapped water will not freeze and crack or deform the structure.

 Corrosion. Extensive paint peeling and rust

should be noted and corrective action taken.

 Seat belt. The presence and operability of a

seat belt should be noted. The belt should be clean, free of dirt and grease and the latch should function smoothly.

 The structure should be inspected following a

rollover, collision or fire.

Repair

Replace missing or damaged hardware with the manufacturers specified hardware. Re-torque all loose threaded fasteners to the manufacturers specifications.

The manufacturer must be consulted to determine the repairability of cracks in ROPS/FOPS structures.

Modifications to basic design should be avoided, as recertification is required.

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4. MAINTENANCE

4.33 HORN/BACK-UP

WARNING

THIS VEHICLE IS EQUIPPED WITH A BACK-UP ALARM. ALARM MUST SOUND WHEN BACKING UP. IT IS THE DRIVERS RESPONSIBILITY TO OPERATE THIS VEHICLE SAFELY. BE SURE BACK-UP ALARM AND HORN ARE WORKING.

Inspect the sound decibel level of the horn and back-up alarm daily and test weekly for proper dBA level (112 dBA). Test results should be recorded in the vehicles maintenance file. If mud, dirt or other debris is forced into alarm, clean and test to ensure proper operation.

4.33.1 Back-Up Alarm Switch

1. Remove control panel wrap.

2. To check for proper switch operation, connect ohmmeter leads to the wire connections. The back-up switch should be normally open in the neutral position and normally closed when shifted into reverse position. With the ignition key in the on position, shifting into reverse should actuate the back-up alarm.

3. Check the assembly for proper switch actuation, smooth lever operation and all hardware for tightness, then assemble the panel wrap and hardware.

4.34 SCRAPERS

Prevent mud and debris from building up. If urethane scrapers are worn or torn, replace.

Steel scrapers are adjustable. The scrapers should just clear the drum and pads. If adjusting, be sure to check that scrapers clear drum and pads all the way around the drum. To adjust, loosen mounting bolts and slide scraper in or out, check clearance and retighten.

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4. MAINTENANCE

4.35 TROUBLESHOOTING

PROBLEM

Engine Won't Start.

Engine won't start but cranks over.

CAUSE REMEDY

Forward/Reverse lever not in neutral position.

Panel fuse blown.

Loose battery or starter cables.

Faulty engine starting circuit.

Faulty or improperly adjusted neutral interlock switch.

Dirty fuel injectors. (Diesel Only)

Petcock plugged.

Low on fuel.

Fuel valve closed.

Fuel filter plugged.

Place lever in neutral position.

Replace, 20A fuse required.

Check and tighten.

Check appropriate section in Engine Manual

Make sure neutral switch is adjusted properly and wires are all secured. Test with ohmmeter. Readjust neutral switch. Replace if defective.

Clean or replace.

Add fuel.

Open.

Check fuel filter, replace if necessary.

Engine hard to start or will not start (or) Engine starts but does not keep running.

Exhaust restricted.

Injection pump not getting fuel or air in fuel system.

Faulty injection pump or nozzles

Fuel lines plugged.

Air in fuel line.

Cold weather.

Crankcase oil too heavy.

Improver type of fuel.

Water, dirt, or air in fuel system.

Clogged fuel filter.

Injection pump shut-off not reset.

Check and correct exhaust restriction.

Check fuel flow at supply pump or bleed fuel system.

Consult authorized diesel repair station for repair or replacement.

Clean or replace.

Bleed fuel line.

Use cold weather starting aid.

Use oil of proper viscosity.

Consult fuel supplier; use proper type fuel for operating conditions.

Drain, flush, fill, and bleed system.

Replace filter element.

Turn key switch to "OFF" then to "ON".

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4. MAINTENANCE

4.35 TROUBLESHOOTING-cont'd.

PROBLEM

Engine starts but does not keep running.

Roller won't move forward or reverse.

CAUSE REMEDY

Water/dirt in fuel.

Choke remains on. (Gas Only)

Carburetor improperly adjusted. (Gas Only)

Dirty fuel injectors. (Diesel Only)

Injection pump drawing in air. (Diesel Only)

Objects in front of drums.

Unit in bypass.

Loose or broken forward/reverse linkage.

Loose or broken chain.

Loose or broken transmission belts.

Drain fuel system.

Adjust choke cable. Clean choke linkage.

Adjust as per Engine Manual.

Service or replace.

Check fuel lines or replace.

Remove.

Check bypass valve.

Readjust linkage or replace worn arm linkage.

Make sure chain is on sprocket. Adjust tension or replace if chain shows excessive war.

Replace and/or tighten.

Unit lacks power moving forward --but okay in reverse or vice versa.

Unit lacks power.

Low hydraulic oil.

Improperly adjusted forward/reverse linkage.

Engine not properly warmed up.

Low hydraulic oil level.

Plugged hydraulic filter.

Insufficient belt tension.

Engine RPM too low.

Check oil level gauge. Add if required.

Adjust linkage so that lever travel is the same in either direction from neutral.

Idle before operating to achieve operating temperature.

Add.

Replace.

Check and adjust belts.

Check throttle linkage for proper actuation (3100 RPM Gas/2600 Diesel). See Maintenance.

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4. MAINTENANCE

4.35 TROUBLESHOOTING-cont'd

PROBLEM

High fuel consumption.

High oil consumption.

CAUSE REMEDY

Improper type of fuel.

Clogged or dirty air cleaner.

Engine overloaded.

Improper valve clearance.

Injection nozzles dirty.

Engine out of time.

Low engine temperature.

Crankcase oil too light.

Oil leaks.

Use proper type of fuel.

Service air cleaner.

Excessive mud/debris build-up -- Clean/ pressure wash.

See your authorized servicing dealer or engine distributor.

Check thermostat.

Use proper viscosity oil.

Check for leaks in lines, gaskets, and drain plug.

Low oil pressure.

Engine emits smoke.

Restricted crankcase vent tube.

Defective turbocharger.

Too much oil in crankcase.

Loose oil filter or sending unit.

Loose bolts.

Engine in break-in period.

Low oil level.

Improper type of oil.

Too much oil in crankcase.

Engine in break-in period.

Clean vent tube.

See your authorized servicing dealer or engine distributor.

Drain.

Tighten.

See Engine Owner's Manual.

Add oil.

Drain, fill crankcase with oil of proper viscosity and quality.

Drain, fill to proper level.

See Engine Owner's Manual.

- 50 -

4. MAINTENANCE

4.35 TROUBLESHOOTING-cont'd

PROBLEM

Engine emits white smoke.

Engine emits black or gray exhaust smoke.

CAUSE REMEDY

Improper type of fuel.

Low engine temperature.

Defective thermostat.

Defective injection nozzles.

Engine out of time.

Improper type of fuel.

Clogged or dirty air cleaner.

Injection nozzles dirty.

Engine out of time

Use proper fuel.

Warm up engine to normal operating temperature.

Remove and check thermostat.

See your authorized servicing dealer or engine distributor.

Use proper fuel.

Service air cleaner.

See your authorized servicing dealer or engine distributor.

Engine overheats.

Engine overloaded.

Low coolant level.

Faulty radiator cap.

Loose or defective fan belts.

Low engine oil level.

Cooling system needs flushing.

Defective thermostat.

Defective temperature gauge or sender.

Incorrect grade of fuel.

Reduce load, check for mud build-up, clean if required.

Fill radiator to proper level, check radiator and hoses for loose connections or leaks.

Have serviceman check.

Adjust belt tension. Replace as required.

Check oil level. Add oil as required.

Flush cooling system.

Remove and check thermostat.

Check water temperature with thermometer and replace if necessary.

Use correct grade of fuel.

- 51 -

4. MAINTENANCE

4.35 TROUBLESHOOTING-cont'd

PROBLEM

Roller won't move forward or reverse.

Unit lacks power moving forward, but okay in reverse or vice versa.

Unit lacks power.

CAUSE REMEDY

Objects in front of drums.

Unit in bypass loose or broken forward/ reverse linkage.

Low hydraulic oil.

Improperly adjusted forward/reverse linkage.

Engine not properly warmed up.

Restricted fuel hose.

low hydraulic oil level.

Plugged hydraulic filter.

Leaking exhaust manifold gasket.

Remove.

Check bypass valve. Readjust linkage or replace worn arm linkage, make sure lever at pump is moving.

Check oil level gauge. Add if required.

Adjust linkage so that lever travel is the same in either direction from neutral.

Idle before operating to achieve operating temperature.

Clean or replace fuel hose

Add hydraulic oil.

Replace.

See your authorized servicing dealer or engine distributor.

Engine RPM too low.

Defective Aneroid control line.

Dirty fuel filter.

Dirty fuel injectors.

Injection pump drawing in air.

Too much oil in crankcase.

Air filter dirty.

Injection pump out of time.

Faulty hydraulic pump or drive motor.

Check throttle linkage for proper actuation. Check full speed.

See your authorized servicing dealer or engine distributor.

Replace.

Service or replace.

Check fuel lines or replace.

Drain and check. Service or replace.

Clean and/or replace.

See your authorized servicing dealer or engine distributor.

Test hydraulic pressure for 500psi at full load on drive motor with engine at full RPM.

Check charge pressure 220-260 psi with engine at full RPM.

- 52 -

4. MAINTENANCE

4.35 TROUBLESHOOTING-cont'd

PROBLEM

Unit lacks power - cont'd.

Unit won't steer.

CAUSE REMEDY

Faulty hydraulic pump or drive motor cont'd.

Improper type of fuel.

Excessive mud or debris build-up.

Below normal engine temperature.

Improper valve clearance.

Cylinder leaking.

Piston rod bent.

Missing hydraulic cylinder pin.

Kinked or broken hoses.

Replace pump if pressure is not in specified range in hydraulic motor drive circuit.

Check drive motors case, drain flow .5GPM max. drum, tires blocked, engine running.

Use proper fuel.

Clean/pressure wash.

Remove and check thermostat.

See your authorized servicing dealer or engine distributor.

Replace hydraulic cylinder.

Replace.

Brakes don't hold properly.

Brake stays on.

Low hydraulic fluid.

Faulty hydraulic pump.

Brake valve faulty.

Loose wires.

No release pressure.

Faulty relay.

Add fluid.

Check hydraulic steering circuit for maximum pressure of 2,300 psi at full RPM. Replace or repair by authorized Service Center.

Check brake light operation.

Check for 12 volt A brake valve, see Wiring.

Check wiring for loose or broken wiring.

Check pump for proper charge pressure 220-260psi.

Check, replace if required.

- 53 -

4. MAINTENANCE

4.36 ELECTRICAL TROUBLESHOOTING

PROBLEM

Undercharged system.

Battery used too much water.

Batteries will not charge.

CAUSE REMEDY

Excessive electrical load from added accessories.

Excessive engine idling.

Poor electrical connections on battery, ground strap, starter, or alternator.

Defective battery.

Defective alternator.

Cracked battery case.

Defective battery.

Battery charging rate too high.

Loose or corroded connections.

Sulfated or worn-out batteries.

Remove accessories.

Increase engine RPM when heavy electrical load is used.

Inspect and clean as necessary.

Test battery.

Test charging system.

Check for moisture and replace as necessary.

Test battery.

Test charging system.

Clean and tighten connections.

See your authorized servicing dealer or engine distributor.

Starter will not crank.

Starter cranks slowly.

Entire electrical system does not function.

Loose or defective alternator belt.

Loose or corroded connections.

Low battery output voltage.

Faulty start circuit relay.

Low battery output.

Crankcase oil too heavy.

Loose or corroded connections.

Faulty battery connection.

Sulfated or worn-out batteries.

Blown fuse.

Adjust belt tension or replace belts.

Clean and tighten loose connections.

See your authorized servicing dealer or engine distributor.

Use proper viscosity oil.

Clean and tighten loose connections.

Clean and tighten connections.

See your authorized servicing dealer or engine distributor.

Replace fuse.

- 54 -

4. MAINTENANCE

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- 55 -

5. EXPL ODED VIEWS

WITH PARTS

- 57 -

5. PARTS LIST