JOHN DEERE 8875 SKID STEER LOADER Service Repair Manual Instant Download (TM1566)

1
8875 Skid-Steer Loader
TECHNICAL MANUAL
John Deere Lawn Grounds Care Division TM1566
(Feb 95)
Litho in U.S.A
2
INTRODUCTION
This technical manual is written for an
experienced technician and contains sections that
are specifically for this product. lt is a part
of a total product support program.
Safety
Specifications and Information

• The manual is organized so that all the
  information on a particular system is kept
  together. The order of grouping is as follows
• Table of Contents
• Specifications
• Theory of Operation
• Troubleshooting Diagram
• Diagnostics
• Tests Adjustments
• Repair

Engine (Diese?)
E?ectrica?
Note Depending on the particular section or
system being covered, not all of the above groups
may be used.
Power Train
Power Train (Hydrostatic)
Power Train
Each section will be identified with a symbol
rather than a number. The groups and pages within
a section will be consecutively numbered.
Steering
Brakes
All information, illustrations and
specifications in this manual are based on the
latest information available at the time of
publication. The right is reserved to make
changes at any time without notice.
Hydrau?ics
Backhoe
We appreciate your input on this manual. To help,
there are postage paid post cards included at the
back. lf you find any errors or want to comment
on the layout of the manual please fill out one
of the cards and mail it back to us.
Misce??aneous
1 - 1
2/8/95
3
SAFETY
HANDLE FLUIDS SAFELY-AVOID FIRES
HANDLE CHEMICAL PRODUCTS SAFELY

• BE PREPARED FOR EMERGENCIES

133
TS1132
TS1
TS291
Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals
used with John Deere equipment include such items
as lubricants, coolants, paints, and adhesives. A
Material Safety Data Sheet (MSDS) provides
specific details on chemical products
physical and health hazards, safety procedures,
and emergency response techniques. Check the MSDS
before you start any job using a hazardous
chemical. That way you will know exactly what the
risks are and how to do the job safely. Then
follow procedures and recommended equipment.
TS227

• DISPOSE OF WASTE PROPERLY
• lmproperly disposing of waste can threaten
  the environment and ecology. Potentially harmful
  waste used with John Deere equipment include
  such items as oil, fuel, coolant, brake fluid,
  filters, and batteries. Use leakproof containers
  when draining fluids. Do not use food or
  beverage containers that may mislead someone
  into drinking from them. Do not pour waste onto
  the ground, down a drain, or into any water
  source. lnquire on the proper way to recycle or
  dispose of waste from your local environmental or
  recycling center, or from your John Deere dealer.

When you work around fuel, do not smoke or work
near heaters or other fire hazards. Store
flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized
containers. Make sure machine is clean of trash,
grease, and debris. Do not store oily rags
they can ignite and burn spontaneously. Be
prepared if a fire starts. Keep a first aid kit
and fire extinguisher handy.
Keep emergency service, hospital, telephone.
numbers and fire
for doctors, department
ambulance near your
1 - 2
4/13/95
4
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SAFETY
USE CARE AROUND HIGH- PRESSURE FLUID LINES
USE CARE IN HANDLING AND SERVICING BATTERIES

• AVOID HIGH-PRESSURE FLUIDS

TS204
TS203
X9811

• PREVENT BATTERY EXPLOSIONS

• Keep sparks, lighted matches, and open flame
  away from the top of battery. Battery gas can
  explode.
• Never check battery charge by placing a metal
  object across the posts. Use a voltmeter
  or hydrometer.
• Do not charge a frozen battery it may explode.
  Warm battery to 16C (60F).

Escaping fluid under pressure can penetrate the
skin causing serious injury. Avoid the hazard
by relieving pressure before disconnecting
hydraulic or other lines. Tighten all
connections before applying pressure. Search for
leaks with a piece of cardboard. Protect hands
and body from high pressure fluids. lf an
accident occurs, see a doctor immediately. Any
fluid injected into the skin must be surgically
removed within a few hours or gangrene may
result. Doctors unfamiliar with this type of
injury should reference a knowledgeable medical
source. Such information is available from Deere
Company Medical Department in Moline, lllinois,
U.S.A.

• PREVENT ACID BURNS
• Sulfuric acid in battery electrolyte is
  poisonous. lt is strong enough to burn skin, eat
  holes in clothing, and cause blindness if
  splashed into eyes.

• Avoid acid burns by
• Filling batteries in a well-ventilated area.
• Wearing eye protection and rubber gloves.
• Avoiding breathing fumes when electrolyte is
  added.
• Avoiding spilling or dripping electrolyte.
• Use proper jump start procedure.

• AVOID HEATING NEAR PRESSURIZED FLUID LINES

• If you spi?? acid on yourse?f
• Flush your skin with water.
• Apply baking soda or lime to help neutralize the
  acid.
• Flush your eyes with water for 10_15 minutes.
• Get medical attention immediately.

TS953
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe
burns to yourself and bystanders. Do not heat
by welding, soldering, or using a torch near
pressurized fluid lines or other flammable
materials. Pressurized lines can be accidentally
cut when heat goes beyond the immediate flame
area.

• If acid is swa??owed
• Drink large amounts of water or milk.
• Then drink milk of magnesia, beaten eggs, or
  vegetable oil.
• Get medical attention immediately.

11 1 - 3
4/13/95
6
SAFETY
USE SAFE SERVICE PROCEDURES

• PARK MACHINE SAFELY

• 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.
• Before working on the machine
• Lower all equipment to the ground.
• Stop the engine and remove the key.
• Disconnect the battery ground strap.
• Hang a DO NOT OPERATE tag in operator station.

• SUPPORT MACHINE PROPERLY AND USE PROPER LIFTING
  EQUIPMENT

TS206
TS229
TS228

• SERVICE MACHINES SAFELY
• Tie long hair behind your head. Do not wear a
  necktie, scarf, loose clothing, or necklace when
  you work near machine tools or moving parts. lf
  these items were to get caught, severe injury
  could result.
• Remove rings and other jewelry to prevent
  electrical shorts and entanglement in moving
  parts.

lf you must work on a lifted machine or
attachment, securely support the machine or
attachment. Do not support the machine on cinder
blocks, hollow tiles, or props that may crumble
under continuous load. Do not work under a
machine that is supported solely by a jack.
Follow recommended procedures in this
manual. Lifting heavy components incorrectly can
cause severe injury or machine damage. Follow
recommended procedure for removal and
installation of components in the manual.

• USE PROPER TOOLS
• Use tools appropriate to the work. Makeshift
  tools and procedures can create safety hazards.
  Use power tools only to loosen threaded parts
  and fasteners. For loosening and tightening
  hardware, use the correct size tools. DO NOT use
  U.S. measurement tools on metric fasteners.
  Avoid bodily injury caused by slipping
  wrenches. Use only service parts meeting John
  Deere specifications.

1 - 4
4/13/95
7
SAFETY

• WORK IN CLEAN AREA

• DISCONNECT ELECTRONIC INSTRUMENT PANEL MODULE
  (EIPM) BEFORE WELDING OR BATTERY CHARGING
• Before welding, battery charging, or using any
  high voltage equipment which attaches to the Skid
  Steer Loader, always disconnect the Electronic
  lnstrument Panel Module connector from the back
  of the electronic board. This will prevent high
  voltage surges which can erase the memory stored
  in the electronic chips of the ElPM.

• BEFORE STARTING A JOB
• Clean work area and machine
• Make sure you have all necessary tools to do your
  job.
• Have the right parts on hand.
• Read all instructions thoroughly do not attempt
  shortcuts.

• AVOID HARMFUL ASBESTOS DUST
• Avoid breathing dust that may be generated when
  handling components containing asbestos
  fibers. lnhaled asbestos fibers may cause lung
  cancer.
• Components in products that may contain asbestos
  fibers are brake pads, brake band and
  lining assemblies, clutch plates, and some
  gaskets. The asbestos used in these components is
  usually found in a resin or sealed in some way.
  Normal handling is not hazardous as long as
  airborne dust containing asbestos is not
  generated.
• Avoid creating dust. Never use compressed air for

• ILLUMINATE WORK AREA SAFELY
• llluminate your work area adequately but safely.
  Use a portable safety light for working inside or
  under the machine. Make sure the bulb is enclosed
  by a wire cage. The hot filament of an
  accidentally broken bulb can ignite spilled fuel
  or oil.

• WORK IN VENTILATED AREA

• cleaning. Avoid brushing or grinding
  material containing asbestos. When servicing,
  wear an approved respirator. A special
  vacuum cleaner is recommended to clean
  asbestos. lf not available, apply a mist of oil
  or water on the material containing asbestos.
  Keep bystanders away from the area.
• SERVICE TIRES SAFELY

TS220
Engine exhaust fumes can cause sickness or death.
lf it is necessary to run an engine in an
enclosed area, remove the exhaust fumes from the
area with an exhaust pipe extension. lf you do
not have an exhaust pipe extension, open the
doors and get outside air into the area.
TS952

• REMOVE PAINT BEFORE WELDING OR HEATING
• Avoid potentially toxic fumes and dust.
  Hazardous fumes can be generated when paint is
  heated by welding, soldering, or using a torch.
  Do all work outside or in a well ventilated area.
  Dispose of paint and solvent properly. Remove
  paint before welding or heating lf you sand
  or grind paint, avoid breathing the dust. Wear an
  approved respirator. lf you use solvent or paint
  stripper, remove stripper with soap and water
  before welding. Remove solvent or paint
  stripper containers and other flammable material
  from area. Allow fumes to disperse at least 15
  minutes before welding or heating.

Explosive separation of a tire and rim parts can
cause serious injury or death. Do not attempt to
mount a tire unless you have the proper equipment
and experience to perform the job. Always
maintain the correct tire pressure. Do not
inflate the tires above the recommended pressure.
Never weld or heat a wheel and tire assembly. The
heat can cause an increase in air pressure
resulting in a tire explosion. Welding can
structurally weaken or deform the wheel. When
inflating tires, use a clip-on chuck and
extension hose long enough to allow you to stand
to one side and NOT in front of or over the tire
assembly. Use a safety cage if available.
11 1 - 5
4/13/95
8
SAFETY
LIVE WITH SAFETY

• Check whee?s for ?ow pressure? cuts? bubb?es?
  damaged rims or missing ?ug bo?ts and nuts.

TS231
REPLACE SAFETY SIGNS
TS201
Before returning machine to customer, make
sure machine is functioning properly, especially
the safety systems. lnstall all guards and
shields.
Replace missing or damaged safety signs. See the
machine operator's manual for correct safety
sign placement.
1 - 6
4/13/95
9
CONTENTS
SPECIFICATIONS INFORMATION
CONTENTS
Page GENERAL VEHICLE SPECIFICATIONS . . . . . .
. . . . . . . . . . . . . . . . . . 2 UNIFIED
INCH TORQUE VALUES . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 4 METRIC TORQUE
VALUES . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 5 DIESEL FUEL
SPECIFICATIONS . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 6 DlESEL FUEL STORAGE .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 6 LUBRICANT
SPECIFICATIONS . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 7 ENGlNE OlL . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
7 GREASE . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 7 TRANSMlSSlON AND
HYDRAULlC OlL. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 8 CHAlN CASE OlL .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
8 GEARBOX OlL . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 8 ALTERNATlVE LUBRlCANTS . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 8 SYNTHETlC LUBRlCANTS .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 8 OlL FlLTERS .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 LUBRlCANT STORAGE . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 8 ENGlNE COOLANT . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 8 SERIAL NUMBER
LOCATION . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 10 SKlD STEER LOADER
PRODUCT lDENTlFlCATlON NUMBER . . . . . . . . .
. . . 10 ENGlNE SERlAL NUMBER . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 10
2 - 1
4/13/95
10
SPECIFICATIONS INFORMATION
GENERAL VEHICLE SPECIFICATIONS
GENERAL VEHICLE SPECIFICATIONS
8875
ENGINE ENGINE
ENGINE ENGINE
Make John Deere
Model 3029T
Type Diesel
Cylinders 3
Bore 106.4 mm (4.19 in.)
Stroke 111.5 mm (4.39 in.)
Displacement 2.9 L (177 cu. in.)
Compression ratio 181
Net horsepower 45.5 kW (61)
RPM, slow (no load) 950
RPM, fast (no load) 2270
Lubrication Force-feed Pressurized with flow filter.
Crankcase capacity (with filter) 8.5 L (9 qt.)
Cooling system Liquid
Coolant capacity 15.1 L (16 qt.)
Air filter type 2-Stage, replaceable paper element
ELECTRICAL ELECTRICAL
Type of starter Delco Remy 28MT
Battery voltage 12 V
Battery reserve capacity at 27C (80 F) 160 minutes
Battery cold cranking amps at -18C (0F) 925 amps
Charging system 55 amp Magneton alternator
FUEL SYSTEM FUEL SYSTEM
Fuel Diesel 1 or 2
Capacity 71.2 L (18.8 gal)
Fuel delivery lnline direct injection
Fuel shut-off lnternal Fuel shutoff solenoid in lnjection Pump
POWER TRAIN
Type Hydrostatic
Charge pump lnternal gerotor type in R/H Hydrostatic pump
Hydrostatic pumps Variable displacement axial piston
2 - 2
4/13/95
11
SPECIFICATIONS INFORMATION
GENERAL VEHICLE SPECIFICATIONS
8875
Hydrostatic pump relief pressure 34473 kPa (5000 psi)
Hydrostatic motor Variable displacement axial piston
Charge relief pressure 2068 kPa (300 psi)
Chain case capacity (each side) 7.6 L (2 gal.)
Gearbox capacity (each gearbox) 2.8 L (3 qt.)
Brakes Dual disks on hydrostatic motor shaft
STEERING
Type Power - hydrostatic
PERFORMANCE PERFORMANCE
Manufacturers operating load 568 kg (1250 lb.)
Hydraulic lift capacity 998 kg (2200 lb.)
Ground speed (low rangehigh range) 12.219.6 km/h (7.512.0 mph)
Operating weight 3025 kg (6670 lb.)
HYDRAULICS
Main system relief pressure 17927 kPa (2600 psi)
Circuit relief pressure 18961 kPa (2750 psi)
Hydraulic valve 3 spool open center
DIMENSIONS
Length less bucket 2845 mm (112 in.)
Length with bucket 3607 mm (142 in.)
Width less bucket 1753 (69 in.)
Height to ROPS 1829 mm (72 in.)
Height to hinge pin 3099 mm (122 in.)
Dump height 2464 mm (97 in.)
Dump reach 762 mm (30 in.)
Dump angle 45
Bucket rollback 37
Wheelbase 1219 mm (48 in.)
Ground clearance 203 mm (8 in.)
Angle of departure 28
2 - 3
4/13/95
12
SPECIFICATIONS INFORMATION
UNIFIED INCH TORQUE VALUES
UNIFIED INCH TORQUE VALUES
SAE Grade and Head Markings No Marks 1 or 2b 5 5.1 5.2 8 8.2
No Marks 2 5 8
SAE Grade and Nut Markings No Marks 2
Grade 1 Grade 1 Grade 1 Grade 1 Grade 2b Grade 2b Grade 2b Grade 2b Grade 5, 5.1 or 5.2 Grade 5, 5.1 or 5.2 Grade 5, 5.1 or 5.2 Grade 5, 5.1 or 5.2 Grade 8 or 8.2 Grade 8 or 8.2 Grade 8 or 8.2 Grade 8 or 8.2
Lubricateda Lubricateda Drya Drya Lubricateda Lubricateda Drya Drya Lubricateda Lubricateda Drya Drya Lubricateda Lubricateda Drya Drya
SlZE Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft
1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5
5/16 7.7 5.5 10 7 12 9 15 11 20 15 25 18 28 21 35 26
3/8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46
7/16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75
1/2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115
9/16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160
5/8 67 50 85 62 105 78 135 100 170 125 215 160 215 160 300 225
3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400
7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650
1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975
1-1/8 470 300 510 375 470 300 510 375 900 675 1150 850 1450 1075 1850 1350
1-1/4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550
1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
DO NOT use these values if a different torque
value or tightening procedure is given for a
specific application. Torque values listed are
for general use only. Check tightness of
fasteners periodically. Shear bolts are designed
to fail under predetermined loads. Always replace
shear bolts with identical grade. Fasteners
should be replaced with the same or higher grade.
lf higher grade fasteners are used, these should
only be tightened to the strength of the
original. Make sure fasteners threads are clean
and that you properly start thread engagement.
This will prevent them from failing when
tightening. Tighten plastic insert or crimped
steel-type lock nuts to approximately 50
percent of the dry torque shown in the chart,
applied to the nut, not to the bolt head.
Tighten toothed or serrated-type lock nuts to the
full torque value. a Lubricated means coated
with a lubricant such as engine oil, or
fasteners with phosphate and oil coatings.
Dry means plain or zinc plated without any
lubricationb b Grade 2 applies for hex cap screws
(not hex bolts) up to 152 mm (6-in.) long. Grade
1 applies for hex cap screws over 152 mm (6-in.)
long, and for all other types of bolts and screws
of any length.
2 - 4
4/13/95
13
SPECIFICATIONS INFORMATION
METRIC TORQUE VALUES
METRIC TORQUE VALUES
Property C?ass and Head Markings 4.8 4.8 4.8 4.8 4.8 4.8 8.8 8.8 8.8 9.8 9.8 9.8 10.9 10.9 10.9 10.9 10.9 10.9 12.9 12.9 12.9 12.9
Property C?ass and Nut Markings 5 5 10 10 10 10 12 12 12
Class 4.8 Class 4.8 Class 4.8 Class 4.8 Class 8.8 or 9.8 Class 8.8 or 9.8 Class 8.8 or 9.8 Class 8.8 or 9.8 Class 10.9 Class 10.9 Class 10.9 Class 10.9 Class 12. 9 Class 12. 9 Class 12. 9 Class 12. 9
Lubricateda Lubricateda Drya Drya Lubricateda Lubricateda Drya Drya Lubricateda Lubricateda Drya Drya Lubricateda Lubricateda Drya Drya
SlZE Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft
M6 48 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5
M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35
M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70
M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 109
M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300
M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410
M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580
M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800
M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000
M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500
M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000
M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500
DO NOT use these values if a different torque
value or tightening procedure is given for a
specific application. Torque values listed are
for general use only. Check tightness of
fasteners periodically. Shear bolts are designed
to fail under predetermined loads. Always replace
shear bolts with identical grade. Fasteners
should be replaced with the same or higher grade.
lf higher grade fasteners are used, these should
only be tightened to the strength of the
original. Make sure fasteners threads are clean
and that you properly start thread engagement.
This will prevent them from failing when
tightening.
Tighten plastic insert or crimped steel-type lock
nuts to approximately 50 percent of the dry
torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or
serrated-type lock nuts to the full torque
value. a Lubricated means coated with a
lubricant such as engine oil, or fasteners
with phosphate and oil coatings. Dry means
plain or zinc plated without any lubrication. b
Grade 2 applies for hex cap screws (not hex
bolts) up to 152 mm (6-in.) long. Grade 1 applies
for hex cap screws over 152 mm (6-in.) long, and
for all other types of bolts and screws of any
length.
2 - 5
4/13/95
14
SPECIFICATIONS INFORMATION
DIESEL FUEL SPECIFICATIONS
DIESEL FUEL SPECIFICATIONS Use only clean, high
quality fuel. Use Grade No. 2-D fuel at
temperatures above 4C (40F). Use Grade No. 1-D
fuel at temperatures below 4C (40F). Use Grade
No. 1-D fuel for all air temperatures at
altitudes above 1500 m (5000 ft).
DO NOT STORE DIESEL FUEL IN GALVANIZED CONTAINERS
IMPORTANT Diese? fue? stored in ga?vanized
containers reacts with the zinc coating of the
container to form zinc f?akes. If fue? contains
any water? a zinc ge? wi?? a?so form. The ge? and
f?akes wi?? quick?y p?ug fue? fi?ters and may
damage fue? injectors and fue? pumps.

• Store diesel fuel in
• plastic containers
• aluminum containers
• specially coated steel containers made for diesel
  fuel.

IMPORTANT Use fue? with ?ess than 1.0 per cent
su?fur. If possib?e? use fue? with ?ess than 0.5
per cent su?fur. If fue? su?fur is more than 0.5
per cent? change engine oi? and fi?ter every 100
hours.
For maximum filter life, sediment and water
should not be more than 0.10 per cent. The octane
number should be 40 minimum. lf you operate your
tractor where air temperatures are normally
low or where altitudes are high, you may need
fuel with a higher cetane number. Cloud Point -
For cold weather operation, cloud point should
be 10F (6C) below lowest normal air
temperature.
DO NOT USE BRASS-COATED CONTAlNERS brass is an
alloy of copper and zinc.
Fue? Tank Capacity 8875 . . . . . . . . . . . . .
. . . . . . . . . . . 71.2 L (18.8 ga?) DIESEL
FUEL STORAGE NOTE Diesel fuels stored for a long
time may form gum and plug filters. Keep fuel in
a clean container in a protected area. Water and
sediment must be removed before fuel gets to the
engine. Do not use de-icers to remove water from
fuel. Do not depend on fuel filters to remove
water. lf possible, install a water separator at
the storage tank outlet. (See your John Deere
dealer for this part.) IMPORTANT Keep a?? dirt?
sca?e? water or other foreign materia? out of
fue?. Store fuel drum on its side with plug up.
2 - 6
4/13/95
15
SPECIFICATIONS INFORMATION
LUBRICANT SPECIFICATIONS

• GREASE
• Use grease based on the expected air temperature
  range during the service interval.
• The following greases are preferred
• John Deere MOLY HlGH TEMPERATURE EP GREASE
• John Deere HlGH TEMPERATURE EP GREASE
• John Deere GREASE-GARD TM

LUBRICANT SPECIFICATIONS
ENGINE OIL Use oil viscosity temperature range
changes.
based on during the
the expected air period between oil

• The following oil is preferred
• John Deere TORQ-GARD SUPREME PLUS-50

TS1412

• The following oils are also recommended
• John Deere TORQ-GARD SUPREME
• John Deere UNl-GARD

TS1417

• Other greases may be used if they meet one of the
  following
• SAE Multipurpose EP Grease with a maximum of 5
  molybdenum disulfide.
• SAE Multipurpose EP Grease
• Greases meeting Military Specification
  MlL-G-10924F may be used as arctic grease.

meet one of the

• Other oils may be used if they following
• APl Service Classification CE
• APl Service Classification CD
• CCMC Specification D5
• CCMC Specification D4

• Oils meeting Military Specification MlL-L-46167B
  may be used as arctic oils.
• lf John Deere TORQ-GARD SUPREME PLUS-50
• engine oil and a John Deere oil filter are used,
  the oil and filter service interval may be
  extended by 50 hours.
• lf diesel fuel exceeding 0.5 sulphur content is
  used, reduce the service interval for engine oil
  and filter by 50.

2 - 7
4/13/95
16
SPECIFICATIONS INFORMATION
LUBRICANT SPECIFICATIONS

• TRANSMISSION AND HYDRAULIC OIL
• The following oil is preferred
• John Deere PLUS-4 10W-30
• When adding small amounts of oil to top off the
  oil

• Military Specification MlL-L-2105B.
• Oils meeting Military Specification MlL-L-10324A
  may be used as arctic oils.

ALTERNATIVE LUBRICANTS Conditions in certain
geographical areas outside the United States
and Canada may require different lubricant
recommendations than these printed in this manual
or the operator's manual. Consult with your John
Deere Dealer, or Sales Branch to obtain the
alternative lubricant recommendations.
order is

• reservoir, the following oil in descending
  permissible
• John Deere TURF-GARD

• 10W-30 oil equivalent to John Deere PLUS-4
• John Deere HY-GARD

• CHAIN CASE OIL
• The following oil is preferred
• John Deere PLUS-4 10W-30
• When adding small amounts of oil to top off the
  oil

SYNTHETIC LUBRICANTS Synthetic lubricants may
be used in John Deere equipment if they meet
the applicable performance requirements
(industry classification and/or military
specification) as shown in this group. The
recommended temperature limits and service or oil
change intervals should be maintained as shown in
the operators manual. Avoid mixing different
brands, grades, or types of oil. Oil
manufacturers blend additive in their oils to
meet certain specifications and performance
requirements. Mixing different oils can
interfere with the proper functioning of these
additives and degrade lubricant performance.
order is

• reservoir, the following oil in descending
  permissible
• John Deere TURF-GARD

• 10W-30 oil equivalent to John Deere PLUS-4
• John Deere HY-GARD

GEARBOX OIL
Use oil viscosity temperature range changes.
based during
on the expected air the period between oil
OIL FILTERS Filtration of oils is critical to
proper lubrication. Always change filters
regularly. Use filters meeting John Deere performa
nce specification.
John Deere GL-5 Gear Lubricant is recommended.
LUBRICANT STORAGE This machine can operate at top
efficiency only if clean lubricants are used. Use
clean containers to handle all lubricants. Store
them in an area protected from dust, moisture,
and other contamination. Store drums on their
sides.
ENGINE COOLANT To meet cooling system protection
requirements, the coolant MUST consist of a 50/50
mixture of quality water and ethylene glycol
concentrate (antifreeze). Add to the mixture 3
(by volume) supplemental coolant
M74991
additives (SCAs). See ENGlNE COOLANT

• Other oils may be used if they meet one or more
  of the following
• APl Service Classification GL-5.
• Military Specification MlL-L-2105D.
• Military Specification MlL-L-2105C.

SPEClFlCATlONS, later in this group, for
further definition. Makeup of the coolant between
changes MUST consist of the same requirements
as during a complete change. Performing a
COOLSCAN analysis is the recommended method
for determining the amount of
2 - 8
4/13/95
17
SPECIFICATIONS INFORMATION
LUBRICANT SPECIFICATIONS
quality water, ethylene glycol concentrate, and
supplemental coolant additives that should be
added.
John Deere Low Silicate Antifreeze is the
ethylene glycol concentrate recommended for all
John Deere Diesel Engines. This product is
concentrated and should be mixed 50/50 with
quality water. Add to the mixture 3 (by volume)
supplemental coolant additives (SCAs).
IMPORTANT Supp?ementa? coo?ant additives MUST be
added to the coo?ant so?ution. Ethy?ene g?yco?
concentrate (antifreeze) DOES NOT contain
chemica? inhibitors needed to contro? ?iner
pitting or erosion? rust? sca?e? and acidity.
SUPPLEMENTAL COOLANT ADDITIVES (SCA?s)
IMPORTANT Ethy?ene g?yco? concentrate DOES NOT
contain sufficient additives to prevent ?iner
erosion or pitting which cou?d occur in wet
s?eeve diese? engines. ALWAYS mix the coo?ant
so?ution with a supp?ementa? coo?ant additive
such as John Deere Liquid Coo?ant Conditioner or
spin-on coo?ant fi?ter conditioner e?ement.
Coolant solutions of ethylene glycol
concentrate (antifreeze), quality water, and
supplemental coolant additives (SCAs) MUST be
used year-round to protect against freezing,
boil-over, liner erosion or pitting, and to
provide a stable, non-corrosive environment
for seals, hoses, and metal engine parts. Water
pump impellers and cylinder liner walls which are
in contact with engine coolant can be eroded or
pitted unless the proper concentration and
type of SCAs are present in the coolant
solution. Generally, the most critical
erosion occurs in the cylinder liner area of
wet-sleeve, heavy-duty diesel engines. lf coolant
is allowed to enter the combustion chamber,
engine failure or other serious damage will
result. Use of SCAs will reduce the effects of
erosion and pitting. The chemicals in the
additives form a protective film on cylinder
liner surface. This film acts as a barrier
against harmful erosion and pitting.
c CAUTION John Deere Liquid coo?ant Conditioner
contains a?ka?i. Avoid contact with eyes. Avoid
pro?onged or repeated contact with skin. Do not
take interna??y. In case of contact? immediate?y
wash skin with soap and water. For eyes? f?ush
with ?arge amounts of water for at ?east 15
minutes. Ca?? physician. KEEP OUT OF REACH OF
CHILDREN.
WATER QUALITY Distilled, de-ionized, or soft
water is preferred for use in cooling systems.
Mineral (hard/tap) water should NEVER be put
in a cooling system unless first tested.

• John Deere Liquid Coolant Conditioner

IMPORTANT ALWAYS mix the 50/50 so?ution of
ethy?ene g?yco? concentrate with qua?ity water in
a separate container BEFORE adding the SCA?s.
Then add so?ution to the radiator. NEVER pour
co?d water into a hot engine? as it may crack
cy?inder b?ock or head.
ETHYLENE GLYCOL CONCENTRATE (ANTIFREEZE)
IMPORTANT DO NOT use methy? a?coho? or methoxy
propano? base concentrate. This concentrate is
not compatib?e with additives used in
supp?ementa? coo?ant additives. Damage can occur
to rubber sea?s on cy?inder ?iners which are in
contact with coo?ant.
John Deere Liquid Coolant Conditioner MUST
be added at a rate of 3 (by volume) to the
coolant solution. When adding John Deere
Liquid Coolant Conditioner, follow the
suppliers recommendations printed on the
container.
DO NOT use ethy?ene g?yco? concentrate containing
sea?er or stop-?eak additives.
IMPORTANT John Deere Liquid Coo?ant Conditioner
does NOT protect against freezing. DO NOT
over-concentrate coo?ant so?utions with
supp?ementa? coo?ant additives? as this can cause
si?icate-dropout. When this happens? a ge?-type
deposit is created which retards heat transfer
and coo?ant f?ow. DO NOT use so?ub?e oi?.
DO NOT use concentrate containing ?ess than 10
ethy?ene g?yco?.
DO NOT use concentrate containing more than 0.1
anhydrous metasi?icate. This type of concentrate?
which is intended for use in a?uminum engines?
may cause a ge?-?ike deposit to form that reduces
heat transfer and coo?ant f?ow. Check container
?abe? or consu?t withsupp?ier before using.
2 - 9
4/13/95
18
SPECIFICATIONS INFORMATION
SERIAL NUMBER LOCATION
SERIAL NUMBER LOCATION When ordering parts or
submitting a warranty claim, it is lMPORTANT that
you include the skid steer loader product
identification number and the component serial
numbers. The location of skid steer loader
product identification number and component
serial numbers are shown.
DISPOSING OF COOLANT
SKID STEER LOADER PRODUCT IDENTIFICATION NUMBER
lmproperly 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. Do not pour
waste onto the ground, down a drain, or into any
water source. lnquire on the proper way to
recycle or dispose of waste from your local
environmental or recycling center, or from your
John Deere dealer.
Product Identification Number
M71826
ENGINE SERIAL NUMBER
Engine Seria? Number
2 - 10
4/13/95
19
DIESEL ENGINE
CONTENTS
CONTENTS
Page SPECIFICATIONS. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 GENERAL SPEClFlCATlONS . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 7 REPAlR SPEClFlCATlONS . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 7 SEALANT APPLlCATlON
GUlDELlNES . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 13 LUBRlCATlON SYSTEM
OPERATlON . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 14 THEORY OF OPERATION .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 15 FUEL SYSTEM OPERATlON . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 15 DIAGNOSIS. . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 16 DlAGNOSlNG
ENGlNE MALFUNCTlONS . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 16 CYLlNDER LlNER,
PlSTON, AND CONNECTlNG ROD DlAGNOSlS . . . . . .
. . 18 CYLlNDER HEAD AND VALVE DlAGNOSlS . . . .
. . . . . . . . . . . . . . . . . . . . . . . 19
CRANKSHAFT DlAGNOSlS . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 20 FUEL SYSTEM DlAGNOSlS . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 21 FUEL SUPPLY PUMP DlAGNOSlS. . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 22 FUEL lNJECTlON NOZZLE DlAGNOSlS . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 23 FUEL lNJECTlON NOZZLE DlAGNOSlS . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
24 FUEL lNJECTlON PUMP DlAGNOSlS . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
25 AlR lNTAKE SYSTEM DlAGNOSlS. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
25 TESTS AND ADJUSTMENTS . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 26 VALVE
ADJUSTMENT. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
26 VALVE LlFT MEASUREMENT . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 26 PRELlMlNARY ENGlNE TESTlNG . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 ENGlNE COMPRESSlON PRESSURE TESTlNG . .
. . . . . . . . . . . . . . . . . . . . .
27 ENGlNE OlL PRESSURE TEST . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 28 lNTAKE MANlFOLD PRESSURE (TURBO BOOST) TEST
. . . . . . . . . . . . . . . . 28 CRANKCASE
VENTlLATlON SYSTEM lNSPECTlON . . . . . . . . . .
. . . . . . . . . . 28 AlR lNTAKE SYSTEM
lNSPECTlON. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 29 CHECK EXHAUST
SYSTEM . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 29 COOLlNG
SYSTEM RADlATOR CAP PRESSURE TEST. . . . . . .
. . . . . . . . . 29 FUEL DRAlN BACK TEST . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 29 REPAIR . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 29
CLEAN ENGlNE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ENGlNE REMOVAL (CAB TlLTED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ENGlNE LlFTlNG PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ENGlNE REPAlR STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ENGlNE DlSASSEMBLY SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
ENGlNE ASSEMBLY SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
CYLINDER HEAD REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CYLlNDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ROCKER ARM DlSASSEMBLY lNSPECTlON . . . . . . . . . . . . . . . . . . . . . . . . 34
ROCKER ARM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
CAMSHAFT FOLLOWER REMOVAL lNSPECTlON . . . . . . . . . . . . . . . . . . . . 35
2/24/95 3 - 1
20
DIESEL ENGINE
CONTENTS
Page VALVE RECESS CHECK . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 36 VALVE ASSEMBLY REMOVAL . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 36 VALVE SPRlNG lNSPECTlON . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 36 VALVE ROTATOR lNSPECTlON . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 37 VALVE CLEANlNG . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 37 VALVE
lNSPECTlON. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 37 VALVE GRlND . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 38 CYLlNDER HEAD lNSPECTlON
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 38 CYLlNDER HEAD
FLATNESS. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 38 CYLlNDER
HEAD THlCKNESS. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
38 lNJECTOR BORE CLEANlNG. . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 39 VALVE GUlDE CLEANlNG . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 39 VALVE GUlDE MEASUREMENT . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 39 VALVE GUlDE KNURLlNG . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 40 VALVE SEAT CLEANlNG AND
lNSPECTlON . . . . . . . . . . . . . . . . . . .
. . . . . . . 40 VALVE SEAT GRlNDlNG . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 40 VALVE SEAT REPAlR . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 41 VALVE
lNSTALLATlON . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 42 CYLlNDER HEAD BOLT lNSPECTlON . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
42 EXHAUST MANlFOLD lNSPECTlON CLEANlNG . . . .
. . . . . . . . . . . . . . . . . . 42 CYLlNDER
BLOCK TOP DECK CLEANlNG lNSPECTlON . . . . . .
. . . . . . . . . 42 CYLlNDER HEAD lNSTALLATlON
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 43 TORQUE-TURN METHOD FOR
PROPER TORQUE . . . . . . . . . . . . . . . . . .
. . . 43 ROCKER ARM lNSTALLATlON . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 44 ROCKER ARM COVER VENT CLEANlNG AND
lNSPECTlON . . . . . . . . . . . . . 45 ROCKER
ARM COVER lNSTALLATlON. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 45 COMPLETE
FlNAL ASSEMBLY . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
45 CYLINDER BLOCK REPAIR . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 46
PlSTON AND CONNECTlNG ROD REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . 46
CYLlNDER LlNER HElGHT MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 47
CYLlNDER LlNER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
PlSTON ROD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
PlSTON CLEANlNG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
PlSTON lNSPECTlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
CYLlNDER LlNER CLEANlNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
CYLlNDER LlNER lNSPECTlON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
PlSTON AND CYLlNDER LlNER MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . 51
CYLlNDER LlNER DEGAZlNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
PlSTON AND LlNER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
CONNECTlNG ROD BEARlNG lNSPECTlON MEASUREMENT . . . . . . . . . . 53
CONNECTlNG ROD AND CAP lNSPECTlON . . . . . . . . . . . . . . . . . . . . . . . . . . 54
PlSTON PlN AND ROD BUSHlNG lNSPECTlON . . . . . . . . . . . . . . . . . . . . . . . . 54
PlSTON PlN BUSHlNG REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
CONNECTlNG ROD PlN BORE CLEANlNG lNSPECTlON . . . . . . . . . . . . . . 55
3 - 2 2/24/95
21
DIESEL ENGINE
CONTENTS
Page
PlSTON PlN BUSHlNG lNSTALLATlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
CYLlNDER BLOCK CLEANlNG lNSPECTlON . . . . . . . . . . . . . . . . . . . . . . . . 55
CYLlNDER LlNER O-RlNG BORE CLEANlNG . . . . . . . . . . . . . . . . . . . . . . . . . . 56
CYLlNDER BLOCK MAlN BEARlNG BORE MEASUREMENT . . . . . . . . . . . . . . 56
CAMSHAFT FOLLOWER BORE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . 56
CAMSHAFT BEARlNG BORE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . 57
CYLlNDER BLOCK FLATNESS MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . 57
PlSTON COOLlNG ORlFlCE lNSPECTlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
CYLlNDER LlNER FLANGE THlCKNESS MEASUREMENT . . . . . . . . . . . . . . . 58
CYLlNDER LlNER HElGHT MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 58
CYLlNDER LlNER O-RlNG PACKlNG lNSTALLATlON . . . . . . . . . . . . . . . . . 59
CYLlNDER LlNER lNSTALLATlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
PlSTON CONNECTlNG ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
PlSTON RlNG lNSTALLATlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
PlSTON CONNECTlNG ROD ASSEMBLY lNSTALLATlON . . . . . . . . . . . . . . 61
CRANKSHAFT ROTATlON TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
PlSTON PROTRUSlON MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
COMPLETE FlNAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
ENGlNE BREAK-lN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
CRANKSHAFT? MAIN BEARINGS? AND FLYWHEEL REPAIR . . . . . . 63
CRANKSHAFT PULLEY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
CRANKSHAFT PULLEY lNSTALLATlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
FLYWHEEL HOUSlNG REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
HYDROSTATlC PUMP DRlVE SHAFT SEAL REPAlR . . . . . . . . . . . . . . . . . . . . 65
CRANKSHAFT END PLAY CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
FLYWHEEL lNSPECTlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
FLYWHEEL RlNG GEAR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
FLYWHEEL PlLOT BEARlNG REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 66
FLYWHEEL lNSTALLATlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
CRANKSHAFT REAR OlL SEAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
CRANKSHAFT REAR OlL SEAL lNSTALLATlON . . . . . . . . . . . . . . . . . . . . . . . 68
ENGlNE REAR PLATE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
REMOVE MAlN BEARlNGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
CRANKSHAFT MAlN BEARlNG CLEARANCE CHECK (lN BLOCK) . . . . . . . . . 70
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
CRANKSHAFT GEAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
CRANKSHAFT lNSPECTlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
CRANKSHAFT MAlN BEARlNG MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . 71
CRANKSHAFT THRUST BEARlNG JOURNAL MEASUREMENT . . . . . . . . . 72
CRANKSHAFT GRlNDlNG GUlDELlNES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
CRANKSHAFT MAlN BEARlNG CAP MEASUREMENT . . . . . . . . . . . . . . . . . . 73
CRANKSHAFT GEAR lNSTALLATlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
PlSTON COOLlNG ORlFlCES lNSPECTlON . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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Page MAlN BEARlNG AND CRANKSHAFT lNSTALLATlON. .
. . . . . . . . . . . . . . . . . . 75 ENGlNE
REAR PLATE lNSTALLATlON . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 76 FLYWHEEL
HOUSlNG lNSTALLATlON . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 76 HYDROSTATlC
PUMP DRlVE SHAFT lNSTALLATlON . . . . . . . . . .
. . . . . . . . . 77 COMPLETE FlNAL ASSEMBLY . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 77 CAMSHAFT AND TIMING GEAR
REPAIR . . . . . . . . . . . . . . . . . . . . .
. 78 VALVE LlFT MEASUREMENT . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 78 TlMlNG GEAR COVER REMOVAL . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 78 CAMSHAFT END PLAY MEASUREMENT . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
79 lDLER GEAR END PLAY MEASUREMENT . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
79 TlMlNG GEAR BACKLASH MEASUREMENT . . . . . . .
. . . . . . . . . . . . . . . . . . . 79
CAMSHAFT REMOVAL . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 80 CAMSHAFT lNSPECTlON. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 80 CAMSHAFT THRUST PLATE CLEARANCE.
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 81 CAMSHAFT BEARlNG MEASUREMENT . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
81 CAMSHAFT LOBE MEASUREMENT . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
81 CAMSHAFT GEAR REPLACEMENT . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
82 CAMSHAFT FOLLOWER lNSPECTlON . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
82 CAMSHAFT BUSHlNG REPLACEMENT . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
82 FRONT PLATE REMOVAL . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 83 MEASURE lDLER GEAR BUSHlNG AND SHAFT .
. . . . . . . . . . . . . . . . . . . . . .
84 lDLER GEAR BUSHlNG REPLACEMENT . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
85 lDLER GEAR SHAFT REMOVAL . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
85 ENGlNE FRONT PLATE REPLACEMENT . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
85 lDLER SHAFT lNSTALLATlON . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 86 lNSTALL ENGlNE FRONT PLATE . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 86 FUEL lNJECTlON PUMP lNSTALLATlON . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
87 CAMSHAFT lNSTALLATlON . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 87 lDLER GEAR lNSTALLATlON . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 88 TlMlNG GEAR COVER CLEANlNG AND
lNSPECTlON . . . . . . . . . . . . . . . . . . .
88 TlMlNG GEAR COVER lNSTALLATlON . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
88 CRANKSHAFT FRONT OlL SEAL lNSTALLATlON . . . .
. . . . . . . . . . . . . . . . . . 88 FlNAL
ASSEMBLY. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 89 LUBRICATION SYSTEM . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
89
OlL COOLER REPAlR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
OlL PRESSURE REGULATlNG VALVE SEAT REPAlR . . . . . . . . . . . . . . . . . 90
OlL FlLTER NlPPLE REPAlR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
DlPSTlCK REPAlR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
OlL PUMP REPAlR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
OlL PAN lNSTALLATlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
OlL PAN DRAlN PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
COOLlNG SYSTEM TESTlNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
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Page THERMOSTAT REMOVAL TESTlNG . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
95 WATER MANlFOLD REMOVAL lNSTALLATlON . . . .
. . . . . . . . . . . . . . . . . . 96 WATER
PUMP REPAlR. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
96 WATER PUMP REMOVAL . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 97 WATER PUMP DlSASSEMBLY. . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 97 WATER PUMP CLEANlNG lNSPECTlON . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
97 WATER PUMP ASSEMBLY. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 98 WATER PUMP lNSTALLATlON . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 99 FAN BLADE lNSPECTlON AND lNSTALLATlON
. . . . . . . . . . . . . . . . . . . . . . . .
99 TURBOCHARGER DIAGNOSIS. . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
100 TURBOCHARGER DlAGNOSlS (Cont.) . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
101 TURBOCHARGER DlAGNOSlS (Cont.) . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
102 TURBOCHARGER REMOVAL . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
103 TURBOCHARGER FAlLURE ANALYSlS . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 103
TURBOCHARGER BEARlNG RADlAL CLEARANCE TEST . . .
. . . . . . . . . . . 106 TURBOCHARGER BEARlNG
AXlAL END PLAY TEST . . . . . . . . . . . . . . .
. . . 107 TURBOCHARGER REPAIR . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
107 TURBOCHARGER DlSASSEMBLY AND lNSPECTlON . . .
. . . . . . . . . . . . . . . 107 TURBOCHARGER
CENTER HOUSlNG ROTATlNG ASSEMBLY REPLACEMENT .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 108
TURBOCHARGER PRE-LUBRlCATlON . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
108 lNSTALL TURBOCHARGER . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 108 TURBOCHARGER BREAK-lN . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 109 INTAKE MANIFOLD REPAIR. . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
109 EXHAUST MANIFOLD REPAIR . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 110 FUEL
SYSTEM . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 110
RELlEVE FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
FUEL FlLTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
FUEL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
FUEL PUMP TESTlNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
FUEL PUMP lNSTALLATlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
FUEL lNJECTlON PUMP TlMlNG MARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
FUEL lNJECTlON PUMP TlMlNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
lNJECTlON PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
lNJECTlON PUMP DRlVE GEAR SHAFT lNSPECTlON. . . . . . . . . . . . . . . . 114
FUEL lNJECTlON PUMP REPAlR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
FUEL lNJECTlON PUMP lNSTALLATlON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
FUEL lNJECTlON NOZZLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
FUEL lNJECTlON NOZZLE BORE CLEANlNG . . . . . . . . . . . . . . . . . . . . . . . . 117
lNJECTlON NOZZLE CLEANlNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
FUEL lNJECTlON NOZZLE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
FUEL lNJECTlON NOZZLE DlSASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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Page FUEL lNJECTlON NOZZLE CLEANlNG lNSPECTlON
. . . . . . . . . . . . . . . . . 120 FUEL
lNJECTlON NOZZLE VALVE SEAT lNSPECTlON CLEANlNG
. . . . . 120 FUEL lNJECTlON NOZZLE VALVE
ADJUSTOR lNSPECTlON . . . . . . . . . . . . 121
FUEL lNJECTlON NOZZLE ASSEMBLY. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 121 FUEL
lNJECTlON NOZZLE ADJUSTMENT . . . . . . . . . . .
. . . . . . . . . . . . . . . . 121 FUEL
lNJECTlON NOZZLE SEAL lNSTALLATlON . . . . . . .
. . . . . . . . . . . . . . 123 FUEL lNJECTlON
NOZZLE lNSTALLATlON . . . . . . . . . . . . . . .
. . . . . . . . . . . 123 ALTlTUDE COMPENSATlON
GUlDELlNES . . . . . . . . . . . . . . . . . . .
. . . . . . . . 124
3 - 6
2/24/95
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SPECIFICATIONS
SPECIFICATIONS GENERAL SPECIFICATIONS Make . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . John Deere Series 300
(Saran ) Model . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . CD 3029T Number Of
Cylinders . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 3 Cylinder Firing Order . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 1-2-3 Bore. . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 106.5
mm (4.19 in. ) Stroke . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 110 mm (4.33
in.) Displacement . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2.9 L (179 cu in.) Compression Ratio . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
17.81 Firing Order . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 1-2-3 Piston Speed
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 549.8 m/min (1804
ft/min ) Rated Speed . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 2500 RPM Idle Speed . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
800-850 Bearings Number Of Mains . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 4 Main
Diameter . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
79.2 mm (3.12 in.) Main Width . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 28.4 mm (1.12 in.) Rod
Journal Diameter . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 69.8 mm
(2.75 in.) Rod Journal Width . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 30.0 mm (1.18 in.) Lubrication
System Pump Capacity . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 0.88 L/s (14 gpm ) Normal Oil Pressure At
Rated Speed, 30 W Oil At 105 C (220 F) . . .
380 kPa (55 psi) Minimum Oil Pressure At Idle
Speed . . . . . . . . . . . . . . . . . . . . .
. . . . . 138 kPa (20 psi) Bypass Pressure Relief
In Oil Filter . . . . . . . . . . . . . . . . .
. . . . . . . . . . 155 kPa (22 psi) REPAIR
SPECIFICATIONS Cy?inder Head Thickness of New
Cylinder Head . . . . . . . . . . . . . .
104.87-105.13 mm (4.129-4.139 in. ) Wear Limit .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 104.25 mm (4.104
in. ) Maximum Material Removal for Resurfacing
Head . . . . . . . . . . . . . . 0.76mm (0.030
in.) Maximum Acceptable Head Out-of Flat For
Entire Length of Width . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 0.08 mm (0.003
in. ) For Every 150 mm (5.90 in.) Length or Width
. . . . . . . . . . . . . . . 0.03 mm (90.001
in.) Combust