Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
John Deere 240 & 250 Skid Steer Technical Manual TM1747 – PDF DOWNLOAD
$29.95
John Deere 240 & 250 Skid Steer Technical Manual TM1747 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
John Deere 240 & 250 Skid Steer Technical Manual TM1747 – PDF DOWNLOAD
FILE DETAILS:
John Deere 240 & 250 Skid Steer Technical Manual TM1747 – PDF DOWNLOAD
Language : English
Pages : 490
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 240 & 250 Skid Steer Technical Manual TM1747 – PDF DOWNLOAD
This technical manual is written for an experienced technician and contains sections that are specifically for this product. It is a part of a total product support program.
The manual is organized so that all the information on a particular system is kept together: The order of grouping is as follows:
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
TABLE OF CONTENTS:
John Deere 240 & 250 Skid Steer Technical Manual TM1747 – PDF DOWNLOAD
tm1747.pdf.................................................................................. 0 240 and 250 Skid Steer.................................................................. 1 SPECIFICATIONS AND INFORMATION...................................................... 11 SPECIFICATIONS.................................................................. 12 ENGINE...................................................................... 12 FUEL SYSTEM................................................................. 12 ELECTRICAL SYSTEM........................................................... 12 CAPACITIES.................................................................. 12 HYDRAULICS AND HYDROSTATICS................................................. 13 DIMENSIONS—240.............................................................. 13 DIMENSIONS—250.............................................................. 14 TIRES....................................................................... 14 RECOMENDED LUBRICANTS....................................................... 14 METRIC FASTENER TORQUE VALUES................................................... 15 METRIC FASTENER TORQUE VALUES—GRADE 7........................................... 16 INCH FASTENER TORQUE VALUES..................................................... 17 O-RING SEAL SERVICE RECOMMENDATIONS............................................. 18 FACE SEAL FITTINGS WITH INCH STUD ENDS TORQUE............................... 18 FACE SEAL FITTINGS WITH METRIC STUD ENDS TORQUE............................. 19 O-RING FACE SEAL FITTINGS................................................... 20 O-RING BOSS FITTINGS........................................................ 20 DIESEL FUEL SPECIFICATIONS...................................................... 21 LUBRICITY................................................................... 21 STORAGE..................................................................... 21 ENGINE OIL SPECIFICATIONS....................................................... 22 4-CYCLE DIESEL ENGINE OIL— NORTH AMERICA.................................... 22 BREAK-IN DIESEL ENGINE OIL— NORTH AMERICA................................... 23 HYDROSTATIC TRANSMISSION AND HYDRAULIC OIL—NORTH AMERICA.................... 23 CHAIN CASE OIL SPECIFICATIONS................................................... 24 CHAIN CASE OIL—NORTH AMERICA................................................ 24 GENERAL APPLICATION GREASE SPECIFICATIONS....................................... 25 GREASE—NORTH AMERICA........................................................ 25 COOLANT SPECIFICATIONS.......................................................... 25 DIESEL AND GASOLINE ENGINE COOLANT—NORTH AMERICA............................ 25 SUPPLEMENTAL COOLANT ADDITIVES.............................................. 26 DIESEL AND GASOLINE ENGINE COOLANT DRAIN INTERVAL— NORTH AMERICA............ 26 SERIAL NUMBER LOCATION.......................................................... 27 SKID STEER PRODUCT IDENTIFICATION NUMBER.................................... 27 ENGINE SERIAL NUMBER........................................................ 27 DIESEL ENGINE....................................................................... 29 SPECIAL OR ESSENTIAL TOOLS...................................................... 44 SEALANT APPLICATION GUIDELINES.................................................. 46 TROUBLESHOOTING................................................................. 47 DIAGNOSIS....................................................................... 49 TESTS AND ADJUSTMENTS........................................................... 51 PRELIMINARY ENGINE TESTING.................................................. 51 GENERAL TUNE-UP RECOMMENDATIONS............................................. 51 TEST THERMOSTAT OPENING TEMPERATURE......................................... 51 CHECK ENGINE OIL PRESSURE................................................... 52 MEASURE ENGINE BLOW-BY...................................................... 52 CYLINDER COMPRESSION PRESSURE TEST.......................................... 53 FUEL SUPPLY PUMP PRESSURE................................................... 54 FAST AND SLOW IDLE ADJUSTMENT............................................... 54 FUEL INJECTION PUMP TIMING ADJUSTMENT....................................... 55 CHECK AND ADJUST VALVE CLEARANCE............................................ 59 REPAIR.......................................................................... 60 ENGINE REPAIR STAND......................................................... 60 MOUNT ENGINE ON REPAIR STAND................................................ 61 ENGINE REMOVAL/INSTALLATION................................................. 61 RADIATOR REMOVAL, INSPECTION, and INSTALLATION.............................. 69 CLEAN ENGINE................................................................ 72 ENGINE DISASSEMBLY SEQUENCE................................................. 73 ENGINE ASSEMBLY SEQUENCE.................................................... 73 CYLINDER HEAD–EXPLODED VIEW................................................. 74 CHECK VALVE LIFT............................................................ 75 REMOVE CYLINDER HEAD........................................................ 75 CLEAN INJECTION NOZZLE BORES................................................ 76 VALVE ACTUATING PARTS....................................................... 77 REMOVE VALVES AND VALVE SPRINGS............................................. 77 CHECKING CYLINDER HEAD FLATNESS............................................. 77 CLEAN VALVE GUIDES.......................................................... 78 MEASURE VALVE GUIDES........................................................ 78 CLEAN AND INSPECT VALVE SEATS............................................... 78 LAPPING VALVE SEATS......................................................... 79 CHECK VALVE RECESS.......................................................... 79 REMOVE VALVE SEAT INSERTS................................................... 79 VALVE SEAT INSERT INSTALLATION.............................................. 80 INSPECT AND MEASURE VALVES.................................................. 80 GRIND VALVES................................................................ 81 INSPECT AND MEASURE VALVE SPRINGS........................................... 81 INSPECT VALVE ROTATORS...................................................... 81 INSTALL VALVES.............................................................. 82 INSTALL CYLINDER HEAD....................................................... 82 TORQUE TURN TIGHTENING METHOD............................................... 83 CHECKING ROCKER ARM SHAFT................................................... 84 INSTALL ROCKER ARM ASSEMBLY................................................. 84 INSTALL ROCKER ARM COVER.................................................... 85 FINAL WORK.................................................................. 85 CYLINDER BLOCK EXPLODED VIEW................................................ 86 REMOVE PISTONS AND CONNECTING RODS.......................................... 87 MEASURE CYLINDER LINER BORE................................................. 88 REMOVE CYLINDER LINERS...................................................... 88 CYLINDER LINER DEGLAZING.................................................... 89 CYLINDER BLOCK CLEANING..................................................... 89 CHECK PISTON COOLING JETS................................................... 89 CAM FOLLOWER BORE MEASURE................................................... 89 MEASURE CAMSHAFT BORE....................................................... 90 REMOVE CAMSHAFT BUSHING..................................................... 90 INSTALL CAMSHAFT BUSHING.................................................... 90 MEASURE CRANKSHAFT BORE..................................................... 91 REPLACE CRANKSHAFT BEARING CAPS............................................. 91 CYLINDER BLOCK TOP DECK FLATNESS............................................ 91 MEASURE CYLINDER LINER PROTRUSION........................................... 92 LINER PACKING INSTALLATION.................................................. 93 LINER O-RING INSTALLATION................................................... 93 INSTALL CYLINDER LINERS..................................................... 93 MEASURE CONNECTING ROD BEARING.............................................. 93 ROD BEARING CLEARANCE....................................................... 94 CONNECTING ROD BUSHING...................................................... 94 REPLACE CONNECTING ROD BUSHING.............................................. 95 MEASURE PISTON PIN.......................................................... 96 CLEAN AND INSPECT PISTONS................................................... 96 MEASURE PISTON PIN BORE..................................................... 96 PISTON TOP RING GROOVE...................................................... 96 PISTON SECOND AND THIRD RING GROOVES........................................ 97 PISTON HEAD AND SKIRT CHECKING.............................................. 97 INSTALL PISTON RINGS........................................................ 97 PISTON RINGS STAGGERING..................................................... 98 PISTON/LINER SET INFORMATION................................................ 98 ASSEMBLE PISTON AND CONNECTING ROD.......................................... 99 INSTALL PISTON AND CONNECTING ROD........................................... 99 MEASURE PISTON PROTRUSION...................................................101 COMPLETE FINAL ASSEMBLY.....................................................102 REMOVE CRANKSHAFT PULLEY....................................................103 INSTALL CRANKSHAFT PULLEY...................................................103 FLYWHEEL REMOVAL............................................................103 FLYWHEEL RING GEAR REPLACEMENT..............................................104 INSTALL BALL BEARING........................................................104 INSTALL FLYWHEEL............................................................104 CRANKSHAFT REAR OIL SEAL....................................................105 FLYWHEEL HOUSING REPLACEMENT................................................107 MEASURING CRANKSHAFT END PLAY...............................................107 REMOVE CRANKSHAFT...........................................................108 CRANKSHAFT INSPECTION.......................................................108 MEASURE CRANKSHAFT JOURNAL DIAMETER.........................................108 DETERMINE CRANKSHAFT MAIN BEARING CLEARANCE.................................109 REGRINDING CRANKSHAFT.......................................................109 CRANKSHAFT REGRINDING GUIDELINES............................................109 MICRO-FINISHING SPECIFICATIONS..............................................110 REPLACE CRANKSHAFT GEAR.....................................................110 INSTALL MAIN BEARING INSERTS................................................111 INSTALL 2-PIECE THRUST BEARING..............................................111 INSTALL 6-PIECE THRUST BEARING..............................................111 CRANKSHAFT INSTALLATION.....................................................111 MEASURE TIMING GEAR BACKLASH................................................112 REMOVE CAMSHAFT.............................................................112 MEASURE CAMSHAFT JOURNAL....................................................113 MEASURE HEIGHT OF CAM LOBE..................................................113 REPLACE CAMSHAFT GEAR.......................................................113 TACHOMETER PICK-UP PIN REMOVAL..............................................114 INSTALL CAMSHAFT............................................................114 MEASURE CAM FOLLOWER........................................................114 MEASURE IDLER GEAR END PLAY.................................................114 REMOVE FRONT PLATE..........................................................114 IDLER GEAR BUSHING AND SHAFT MEASURE........................................115 IDLER GEAR BUSHING REPLACEMENT..............................................116 REMOVE IDLER SHAFT..........................................................116 INSTALL IDLER SHAFT SPRING PIN..............................................116 INSTALL IDLER SHAFTS........................................................117 INSTALL FRONT PLATE.........................................................117 INSTALL UPPER TIMING GEAR...................................................118 INSTALL LOWER TIMING GEAR...................................................119 INSTALL OIL DEFLECTOR.......................................................119 INSTALL TIMING GEAR COVER...................................................119 INSTALL CRANKSHAFT FRONT OIL SEAL...........................................120 INSTALL WEAR RING...........................................................120 REMOVE OIL COOLER...........................................................120 REPLACE OIL COOLER NIPPLE...................................................121 INSTALL OIL COOLER..........................................................121 REMOVE OIL PRESSURE REGULATING VALVE........................................121 REPLACE OIL PRESSURE REGULATING VALVE SEAT..................................121 INSTALL OIL PRESSURE REGULATING VALVE.......................................122 REPLACE OIL DIPSTICK GUIDE ADAPTER..........................................122 REPLACE OIL BYPASS VALVE....................................................122 REPLACE OIL PUMP STRAINER...................................................122 REMOVE OIL PUMP.............................................................123 GEAR AXIAL CLEARANCE........................................................123 GEAR RADIAL CLEARANCE.......................................................123 OIL PUMP SPECIFICATIONS.....................................................123 OIL PUMP INSTALLATION.......................................................124 INSTALL OIL PAN.............................................................125 WATER PUMP—EXPLODED VIEW....................................................126 REMOVE WATER PUMP...........................................................126 DISASSEMBLE WATER PUMP......................................................127 ASSEMBLE WATER PUMP.........................................................128 INSTALL WATER PUMP..........................................................129 REMOVE/INSTALL THERMOSTAT...................................................129 COLD START ADVANCE WIRE HARNESS (IF EQUIPPED)...............................129 COOLING SYSTEM DEAERATION...................................................130 CHECK FAN/ALTERNATOR BELT TENSION...........................................130 INSTALL FAN.................................................................131 BLOCK HEATER (OPTIONAL).....................................................131 CHECK AIR INLET PIPE........................................................132 EXHAUST MANIFOLD INSPECTION.................................................133 REMOVE TURBOCHARGER.........................................................133 CHECK RADIAL BEARING CLEARANCE..............................................133 CHECK AXIAL BEARING END PLAY................................................134 REPAIR TURBOCHARGER.........................................................134 PRELUBE TURBOCHARGER........................................................134 INSTALL TURBOCHARGER........................................................134 TURBOCHARGER BREAK-IN.......................................................135 TURBOCHARGER RECOMMENDATIONS................................................135 REPLACE FUEL/WATER SEPARATOR FILTER.........................................135 REPLACE FUEL PUMP...........................................................136 REMOVE STANADYNE DB4 FUEL INJECTION PUMP....................................136 REPAIR OF INJECTION PUMP....................................................137 INSTALL STANADYNE DB4 FUEL INJECTION PUMP...................................138 REMOVE FUEL INJECTION NOZZLE................................................139 CLEAN FUEL INJECTION NOZZLE.................................................139 FUEL INJECTION NOZZLE TEST..................................................140 FUEL INJECTION NOZZLE DISASSEMBLY...........................................141 ADJUST FUEL INJECTION NOZZLE................................................141 INSTALL FUEL INJECTION NOZZLE...............................................142 BLEED FUEL SYSTEM...........................................................142 ENGINE BREAK-IN INSTRUCTIONS................................................143 ENGINE BREAK-IN OIL.........................................................143 USING STANADYNE "TIME-TRAC" AS TACHOMETER...................................144 TURBOCHARGER OPERATION......................................................144 CHECK TURBOCHARGER BOOST PRESSURE...........................................145 DIAGNOSING TURBOCHARGER MALFUNCTIONS........................................145 FUEL INJECTION PUMP.........................................................145 COLD START ADVANCE SYSTEM OPERATION (IF EQUIPPED)...........................146 FUEL INJECTION NOZZLES— GENERAL INFORMATION.................................147 DIAGNOSING FUEL SYSTEM MALFUNCTIONS.........................................147 TESTING FUEL INJECTION NOZZLES ON A RUNNING ENGINE..........................148 STARTING MOTOR..................................................................149 THEORY OF OPERATION.........................................................149 EXPLODED VIEW OF STARTING MOTOR.............................................151 STARTING MOTOR SPECIFICATIONS...............................................152 STARTING MOTOR TORQUE SPECIFICATIONS........................................152 DISASSEMBLY OF STARTING MOTOR...............................................152 TESTING SOLENOID SWITCH.....................................................154 TESTING BRUSHES.............................................................154 POSITIVE BRUSH REPLACEMENT..................................................154 TESTING ARMATURE............................................................154 TESTING FIELD WINDING.......................................................155 CHECKING OVERRUNNING CLUTCH PINION..........................................155 ASSEMBLY OF STARTING MOTOR..................................................156 TORQUE SPECIFICATIONS:......................................................156 ALTERNATOR......................................................................157 THEORY OF OPERATION.........................................................157 ALTERNATOR SPECIFICATIONS:..................................................158 ALTERNATOR—EXPLODED VIEW....................................................159 TROUBLESHOOTING.............................................................160 ALTERNATOR—IDENTIFICATION...................................................161 DISASSEMBLE—ALTERNATOR......................................................161 TESTING ALTERNATOR BRUSH/ REGULATOR ASSEMBLY................................162 TESTING ALTERNATOR ROTOR....................................................163 TESTING ALTERNATOR STATOR/ RECTIFIER BRIDGE ASSEMBLY........................163 REPLACE RECTIFIER BRIDGE....................................................164 ASSEMBLE ALTERNATOR.........................................................164 SPECIFICATIONS.................................................................. 35 CYLINDER HEAD AND VALVES SPECIFICATIONS..................................... 35 CYLINDER BLOCK, LINERS, PISTONS, AND RODS SPECIFICATIONS.................... 37 CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONS...................... 39 CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS............................... 40 LUBRICATION SYSTEM SPECIFICATIONS........................................... 41 COOLING SYSTEM SPECIFICATIONS............................................... 41 FUEL SYSTEM SPECIFICATIONS.................................................. 42 ENGINE SYSTEM—DIAGNOSIS AND TESTS SPECIFICATIONS............................ 43 FUEL SYSTEM—OPERATION AND TESTS SPECIFICATIONS.............................. 43 CAPACITIES.................................................................. 43 ELECTRICAL..........................................................................165 SPECIFICATIONS..................................................................170 ELECTRICAL DIAGNOSTIC INFORMATION...............................................171 READING ELECTRICAL SCHEMATICS...............................................171 THEORY OF OPERATION INFORMATION.............................................172 COMMON CIRCUIT TESTS........................................................172 WIRE COLOR ABBREVIATION CHART...............................................172 LEGEND FOR ELECTRICAL COMPONENTS................................................173 COMPONENT LOCATION..............................................................175 ELECTRICAL SCHEMATICS...........................................................177 MAIN SCHEMATIC..............................................................177 ELECTRICAL WIRE HARNESSES.......................................................183 ENGINE WIRE HARNESS (W1)....................................................183 ROPS WIRE HARNESS (W2)......................................................185 DUAL FLASHER WIRE HARNESS (W3)..............................................187 COLD START WIRE HARNESS (W4)................................................188 CAB HEATER/DEFROSTER WIRE HARNESS (W5, W6, W7)..............................189 BACKUP ALARM WIRE HARNESS (W8)..............................................190 WIPER/WASHER WIRE HARNESS (W9)..............................................191 TROUBLESHOOTING CHART...........................................................192 THEORY OF OPERATION AND DIAGNOSIS...............................................193 POWER AND CRANKING CIRCUIT OPERATION........................................193 POWER AND CRANKING CIRCUIT SCHEMATIC........................................195 POWER AND CRANKING CIRCUIT DIAGNOSIS........................................196 POWER AND CRANKING CIRCUIT TEST POINTS......................................199 FUEL AND PREHEAT CIRCUIT OPERATION..........................................200 FUEL AND PREHEAT CIRCUIT SCHEMATIC..........................................201 FUEL CIRCUIT DIAGNOSIS......................................................202 FUEL CIRCUIT TEST POINTS....................................................204 PREHEAT CIRCUIT DIAGNOSIS...................................................205 PREHEAT CIRCUIT TEST POINTS.................................................207 CHARGING CIRCUIT OPERATION..................................................208 CHARGING CIRCUIT SCHEMATIC..................................................209 CHARGING CIRCUIT DIAGNOSIS..................................................210 CHARGING CIRCUIT TEST POINTS................................................212 BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT OPERATION....................213 BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT SCHEMATIC....................214 BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT DIAGNOSIS....................215 BOOM AND BUCKET LOCKOUT AND PARK BRAKE CIRCUIT TEST POINTS..................219 GAUGES AND WARNING LIGHTS CIRCUIT OPERATION.................................220 GAUGES AND WARNING LIGHTS CIRCUIT SCHEMATIC.................................223 SEAT BELT WARNING LIGHT CIRCUIT DIAGNOSIS...................................224 SEAT BELT WARNING LIGHT CIRCUIT TEST POINTS.................................226 PARK BRAKE SWITCH AND WARNING LIGHT CIRCUIT DIAGNOSIS.......................227 PARK BRAKE SWITCH AND WARNING LIGHT CIRCUIT TEST POINTS.....................229 AIR FILTER RESTRICTION WARNING LIGHT CIRCUIT DIAGNOSIS......................230 AIR FILTER RESTRICTION WARNING LIGHT CIRCUIT TEST POINTS....................231 HYDRAULIC OIL OVERTEMPERATURE WARNING LIGHT CIRCUIT DIAGNOSIS...............232 HYDRAULIC OIL OVERTEMPERATURE WARNING LIGHT CIRCUIT TEST POINTS.............233 HYDRAULIC FILTER RESTRICTION WARNING LIGHT CIRCUIT DIAGNOSIS................234 HYDRAULIC FILTER RESTRICTION WARNING LIGHT CIRCUIT TEST POINTS..............235 FUEL GAUGE CIRCUIT DIAGNOSIS................................................236 FUEL GAUGE CIRCUIT TEST POINTS..............................................238 ENGINE OVERTEMPERATURE WARNING LIGHT CIRCUIT DIAGNOSIS......................239 ENGINE OVERTEMPERATURE WARNING LIGHT CIRCUIT TEST POINTS....................240 COOLANT TEMPERATURE GAUGE CIRCUIT DIAGNOSIS.................................241 COOLANT TEMPERATURE GAUGE CIRCUIT TEST POINTS...............................243 ENGINE OIL PRESSURE WARNING LIGHT CIRCUIT DIAGNOSIS.........................244 ENGINE OIL PRESSURE WARNING LIGHT CIRCUIT TEST POINTS.......................245 ENGINE OIL PRESSURE GAUGE CIRCUIT DIAGNOSIS.................................246 ENGINE OIL PRESSURE GAUGE CIRCUIT TEST POINTS...............................248 HIGH-FLOW CIRCUIT (OPTIONAL) OPERATION......................................249 HIGH-FLOW CIRCUIT SCHEMATIC.................................................250 HIGH-FLOW CIRCUIT DIAGNOSIS.................................................251 HIGH FLOW CIRCUIT TEST POINTS...............................................254 LIGHTS CIRCUIT OPERATION....................................................255 LIGHTS CIRCUIT SCHEMATIC....................................................256 LIGHTS CIRCUIT DIAGNOSIS....................................................257 LIGHT CIRCUIT TEST POINTS...................................................261 DUAL FLASHER CIRCUIT (OPTIONAL) OPERATION...................................262 DUAL FLASHER CIRCUIT SCHEMATIC..............................................263 DUAL FLASHER CIRCUIT DIAGNOSIS..............................................264 DUAL FLASHER CIRCUIT TEST POINTS............................................267 CAB HEATER/DEFROSTER CIRCUIT (OPTIONAL) OPERATION...........................268 CAB HEATER/DEFROSTER CIRCUIT SCHEMATIC......................................269 CAB HEATER/DEFROSTER CIRCUIT DIAGNOSIS......................................270 CAB HEATER/DEFROSTER CIRCUIT TEST POINTS....................................274 BACKUP ALARM CIRCUIT (OPTIONAL) OPERATION...................................275 BACKUP ALARM CIRCUIT SCHEMATIC..............................................276 BACKUP ALARM CIRCUIT DIAGNOSIS..............................................277 BACKUP ALARM CIRCUIT TEST POINTS............................................278 WIPER/WASHER CIRCUIT (OPTIONAL) OPERATION...................................279 WIPER/WASHER CIRCUIT SCHEMATIC..............................................280 WIPER/WASHER CIRCUIT DIAGNOSIS..............................................281 WIPER/WASHER CIRCUIT TEST POINTS............................................283 TESTS AND ADJUSTMENTS...........................................................284 BATTERY TEST................................................................284 CHARGE BATTERY..............................................................285 BATTERY LOAD TEST...........................................................286 REGULATED AMPERAGE AND VOLTAGE TEST.........................................287 STARTING MOTOR LOADED AMPERAGE DRAW TEST....................................288 STARTING MOTOR NO-LOAD AMPERAGE AND RPM TESTS...............................289 STARTING MOTOR SOLENOID TEST................................................290 AIR FILTER RESTRICTION SWITCH TEST..........................................291 ENGINE COOLANT TEMPERATURE SENDER/SWITCH TEST...............................291 COLD WEATHER START SWITCH TEST (MODEL 250 ONLY).............................292 ENGINE OIL PRESSURE SWITCH/ SENDER TEST.....................................293 MANIFOLD PREHEATER TEST.....................................................293 MANIFOLD PREHEATER RELAY TEST...............................................294 KEY SWITCH TEST.............................................................295 PARK BRAKE SWITCH TEST......................................................295 PRE-HEATER SWITCH TEST......................................................296 LIGHT SWITCH TEST...........................................................296 CAB DOOR SWITCH TEST........................................................297 DUAL FLASHER SWITCH TEST....................................................297 HIGH-FLOW SWITCH TEST.......................................................298 BLOWER SWITCH TEST..........................................................298 WIPER/WASHER SWITCH TEST....................................................299 FUEL LEVEL SENDER TEST......................................................299 SEAT SAFETY SWITCH TEST.....................................................300 SEAT BELT SWITCH TEST.......................................................301 HYDRAULIC OIL OVERTEMPERATURE SWITCH TEST...................................301 PARK BRAKE SOLENOID TEST....................................................302 BOOM LOCKOUT SOLENOID TEST..................................................302 BUCKET LOCKOUT SOLENOID TEST................................................303 HYDRAULIC OIL FILTER RESTRICTION SWITCH TEST................................303 COMPONENT REPLACEMENT...........................................................304 AIR FILTER RESTRICTION SWITCH...............................................304 COOLANT TEMPERATURE SENDER/SWITCH...........................................304 COLD WEATHER START SWITCH (MODEL 250 ONLY)..................................304 ENGINE OIL PRESSURE SWITCH/ SENDER..........................................305 MANIFOLD PREHEATER..........................................................305 MANIFOLD PREHEAT RELAY......................................................306 INSTRUMENT PANEL COMPONENT LOCATION.........................................307 KEY SWITCH..................................................................307 INSTRUMENT PANEL SWITCHES...................................................308 CAB HEATER THERMOSTAT (IF EQUIPPED).........................................308 INSTRUMENT CLUSTER..........................................................309 FUEL LEVEL SENDER...........................................................309 SEAT SAFETY SWITCH..........................................................310 SEAT BELT SWITCH............................................................311 STARTER.....................................................................311 ALTERNATOR..................................................................312 HYDRAULIC OIL OVERTEMPERATURE SWITCH........................................312 PARK BRAKE SOLENOID.........................................................313 HYDRAULIC OIL FILTER RESTRICTION SWITCH.....................................313 BACKUP ALARM (OPTIONAL).....................................................314 ALARM.......................................................................314 SWITCH......................................................................314 POWER TRAIN (CHAINCASE AND AXLES)...................................................317 SPECIFICATIONS..................................................................318 OTHER MATERIALS.............................................................318 SPECIAL TOOLS...............................................................318 TROUBLESHOOTING.................................................................321 DIAGNOSIS.......................................................................322 REPAIR..........................................................................324 CHAIN CASE OIL LEVEL CHECK..................................................324 CHAIN CASE ACCESS PLATE.....................................................324 DRIVE CHAIN TENSION ADJUSTMENT..............................................325 AXLE HOUSING REMOVAL/ INSTALLATION..........................................325 AXLE HOUSING DISASSEMBLY/ ASSEMBLY..........................................326 DRIVE CHAIN AND SPROCKET REMOVAL/INSTALLATION...............................328 POWER TRAIN COMPONENT LOCATION..................................................319 OPERATION.......................................................................320 POWER TRAIN COMPONENT LOCATION.................................................. 0 OPERATION....................................................................... 0 HYDROSTATIC POWER TRAIN.............................................................329 SPECIFICATIONS..................................................................331 TESTS AND ADJUSTMENTS SPECIFICATIONS........................................331 SERVICE PARTS KITS..........................................................331 TORQUE SPECIFICATIONS.......................................................331 REPAIR SPECIFICATIONS.......................................................331 SPECIAL OR ESSENTIAL TOOLS..................................................332 OTHER MATERIALS.............................................................332 HYDROSTATIC SYSTEM OPERATION....................................................333 HYDROSTATIC COMPONENT LOCATION..................................................334 HYDROSTATIC SYSTEM SCHEMATIC....................................................335 TROUBLESHOOTING.................................................................336 DIAGNOSIS.......................................................................337 TESTS AND ADJUSTMENTS...........................................................338 HYDRAULIC/CHARGE PUMP PRESSURE TEST.........................................338 HYDRAULIC/CHARGE PUMP FLOW TEST.............................................339 HYDROSTATIC PUMP HIGH PRESSURE RELIEF TEST..................................340 WHEEL SPEED TEST............................................................341 HYDROSTATIC PUMP FLOW TEST..................................................342 HYDROSTATIC PUMP CASE DRAIN TEST............................................345 HYDROSTATIC CASE DRAIN PRESSURE TEST........................................347 REPAIR..........................................................................348 START-UP PROCEDURE AFTER COMPONENT REPLACEMENT..............................348 HYDROSTATIC PUMP REMOVAL....................................................349 FRONT HYDROSTATIC PUMP EXPLODED VIEW........................................351 CENTER MANIFOLD EXPLODED VIEW (EARLY MODELS)................................352 CENTER MANIFOLD EXPLODED VIEW (LATE and CONVERTED MODELS)...................353 REAR HYDROSTATIC PUMP EXPLODED VIEW.........................................354 HYDROSTATIC PUMP DISASSEMBLY................................................355 HYDROSTATIC PUMP INSPECTION.................................................358 HYDROSTATIC PUMP ASSEMBLY...................................................359 HYDROSTATIC PUMP INSTALLATION...............................................363 HYDROSTATIC MOTOR REMOVAL/ INSTALLATION.....................................365 HYDROSTATIC MOTOR EXPLODED VIEW.............................................366 HYDROSTATIC MOTOR DISASSEMBLY...............................................367 HYDROSTATIC MOTOR INSPECTION................................................367 HYDROSTATIC MOTOR ASSEMBLY..................................................368 STEERING............................................................................371 THEORY OF OPERATION.............................................................374 TROUBLESHOOTING.................................................................377 TESTS AND ADJUSTMENTS...........................................................379 CENTERING PLATE ADJUSTMENT—SINGLE PLATE MODELS..............................379 CENTERING PLATE ADJUSTMENT—DUAL PLATE MODELS................................382 STEERING CONTROL LEVER ADJUSTMENT—CENTERING.................................384 STEERING DETENT ADJUSTMENT - DUAL PLATE MODELS..............................385 STEERING CONTROL LEVER STOPS ADJUSTMENT—TRACKING............................386 AUXILIARY HYDRAULIC CONTROL HANDLE ADJUSTMENT...............................387 HYDRAULIC CONTROL HANDLE ADJUSTMENT – HANDS ONLY MACHINES...................387 REPAIR..........................................................................388 CENTERING PLATE REMOVAL— SINGLE PLATE MODELS................................388 CENTERING PLATE REMOVAL— DUAL PLATE MODELS..................................389 CENTERING PLATE INSPECTION..................................................390 CENTERING PLATE INSTALLATION—SINGLE PLATE MODELS............................391 CENTERING PLATE INSTALLATION—DUAL PLATE MODELS..............................391 STEERING DAMPENER REMOVAL/ INSPECTION/INSTALLATION..........................392 STEERING CONTROL LEVER REMOVAL/INSPECTION/ INSTALLATION.....................393 STEERING CROSS SHAFT ASSEMBLY REMOVAL/INSTALLATION — SINGLE PLATE MODELS....394 STEERING CROSS SHAFT ASSEMBLY REMOVAL/INSTALLATION — DUAL PLATE MODELS......394 STEERING CROSS SHAFT ASSEMBLY REPAIR—DUAL PLATE MODELS......................395 STEERING CONTROL LEVER HANDLE DISASSEMBLY/ASSEMBLY..........................396 STEERING COMPONENT LOCATION—SINGLE PLATE MODELS.................................375 STEERING COMPONENT LOCATION—DUAL PLATE MODELS...................................376 DIAGNOSTICS.....................................................................378 SPECIFICATIONS..................................................................373 TESTS AND ADJUSTMENTS SPECIFICATIONS........................................373 TORQUE SPECIFICATIONS.......................................................373 SPECIAL OR ESSENTIAL TOOLS..................................................373 BRAKES..............................................................................397 SPECIFICATIONS..................................................................399 OTHER MATERIALS.................................................................399 THEORY OF OPERATION.............................................................400 BRAKE EXPLODED VIEW.............................................................401 DIAGNOSIS AND TROUBLESHOOTING...................................................402 DIAGNOSIS...................................................................402 TROUBLESHOOTING.............................................................402 REPAIR..........................................................................403 BRAKE REMOVAL...............................................................403 BRAKE DISASSEMBLY...........................................................404 BRAKE INSPECTION............................................................406 BRAKE ASSEMBLY..............................................................406 BRAKE INSTALLATION..........................................................407 BURNISH BRAKES..............................................................408 BRAKE ACTUATOR CYLINDER REMOVAL/INSTALLATION................................408 HYDRAULICS..........................................................................411 TESTS AND ADJUSTMENTS...........................................................425 BOOM AND BUCKET LOCKOUT SOLENOIDS CHECK.....................................425 SYSTEM RELIEF VALVE PRESSURE TEST...........................................425 HYDRAULIC/CHARGE PUMP PRESSURE TEST.........................................426 HYDRAULIC/CHARGE PUMP FLOW TEST.............................................428 CIRCUIT RELIEF VALVE TEST...................................................429 BOOM DRIFT DOWN CHECK.......................................................429 BOOM LIFT CHECK TEST........................................................430 BOOM DRIFT UP CHECK.........................................................430 BUCKET DRIFT DUMP POSITION CHECK............................................430 BUCKET DRIFT ROLLBACK POSITION CHECK........................................430 BUCKET LIFT CHECK TEST......................................................431 BUCKET SELF-LEVELING ADJUSTMENT.............................................431 REPAIR..........................................................................432 HYDRAULIC/CHARGE PUMP REMOVAL...............................................432 HYDRAULIC/CHARGE PUMP DISASSEMBLY...........................................432 HYDRAULIC/CHARGE PUMP COMPONENT INSPECTION..................................433 HYDRAULIC/CHARGE PUMP ASSEMBLY..............................................434 HYDRAULIC/CHARGE PUMP INSTALLATION..........................................435 HIGH-FLOW PUMP..............................................................436 HIGH-FLOW VALVE.............................................................437 CONTROL VALVE REMOVAL.......................................................437 CONTROL VALVE DISASSEMBLY...................................................439 CONTROL VALVE INSPECTION....................................................444 CONTROL VALVE CROSS SECTION.................................................446 CONTROL VALVE ASSEMBLY......................................................448 CONTROL VALVE INSTALLATION..................................................451 SELF-LEVELING VALVE.........................................................453 BOOM CYLINDER REMOVAL.......................................................453 BOOM CYLINDER INSTALLATION..................................................454 BUCKET CYLINDER REMOVAL.....................................................454 BUCKET CYLINDER INSTALLATION................................................455 BOOM AND BUCKET CYLINDER REPAIR.............................................456 SYSTEM COMPONENTS AND OPERATION.................................................415 SYSTEM SCHEMATIC................................................................417 SPECIFICATIONS..................................................................413 TORQUE SPECIFICATIONS.......................................................414 OTHER MATERIALS.............................................................414 SERVICE PARTS KITS..........................................................414 BUCKET CYLINDER COMPONENT LOCATION..........................................422 BOOM CYLINDER COMPONENT LOCATION............................................422 TROUBLESHOOTING.................................................................423 DIAGNOSIS.......................................................................424 SYSTEM COMPONENT LOCATION.......................................................418 CONTROL VALVE COMPONENT LOCATION............................................420 HYDRAULIC/CHARGE PUMP COMPONENT LOCATION....................................421 SYSTEM SCHEMATIC................................................................ 0 SYSTEM COMPONENT LOCATION....................................................... 0 MISCELLANEOUS.......................................................................459 SPECIFICATIONS..................................................................461 TORQUE SPECIFICATIONS.......................................................461 OTHER MATERIALS.............................................................461 SPECIAL OR ESSENTIAL TOOLS..................................................461 REPAIR..........................................................................462 RAISING ROPS (ROLLOVER PROTECTION STRUCTURE)................................462 BOOM LOCK REMOVAL/INSTALLATION..............................................463 RAISING AND BLOCKING SKID STEER.............................................464 COVER PLATE REMOVAL/ INSTALLATION...........................................464 USING REMOTE START BOX......................................................465 ROPS REMOVAL/INSTALLATION...................................................466 BOOM........................................................................468 LOWER BOOM LINK REMOVAL/ INSTALLATION.......................................468 UPPER BOOM LINK REMOVAL/ INSTALLATION.......................................470 QUIK-TATCH® HITCH COUPLING REMOVAL/INSTALLATION.............................471 QUIK-TATCH® REPAIR..........................................................473 BOOM REMOVAL/INSTALLATION...................................................474 CAB HEATER/DEFROSTER (OPTIONAL).............................................475 FILTER REPLACEMENT..........................................................475 HEATER CORE REMOVAL/ INSTALLATION...........................................475 BLOWER REMOVAL/INSTALLATION.................................................477 CONTROL VALVE REMOVAL/ INSTALLATION.........................................478 CAB HEATER DEAERATION.......................................................479 CAB DOOR (IF EQUIPPED)......................................................480 WINDSHIELD WIPER/WASHER (OPTIONAL)..........................................481 WIPER MOTOR.................................................................481 WASHER PUMP.................................................................482 INDEX...............................................................................483
S.S 24/02/2025
