Ctm67 Powertech Oem Engine Accesories

OEM EngineAccessories

TECHNICAL MANUALOEM Engine Accessories

CTM67 09DEC05 (ENGLISH)

John Deere Power SystemsLitho in U.S.A.

Introduction

RG,CTM67,IFC 1902FEB941/1

Foreword

This manual is written for an experienced technician.Essential tools required in performing certain servicework are identified in this manual and arerecommended for use.

Live with safety: Read the safety messages in theintroduction of this manual and the cautions presentedthroughout the text of the manual.

CAUTION: This is the safety-alert symbol.When you see this symbol on the machineor in this manual, be alert to the potential forpersonal injury.

This Component Technical Manual (CTM) contains thelatest available instructions necessary to repair OEMengine accessories. It includes theory of operation,and diagnostic and testing procedures to helptroubleshoot and understand potential failure modes.

The information is organized in groups for the variouscomponents requiring service instruction. At thebeginning of each repair group are summary listings ofall applicable essential tools, service equipment andtools, other materials needed to do the job, serviceparts kits, specifications, wear tolerances, and torquevalues.

Component Technical Manuals are concise serviceguides for specific components. Component technicalmanuals are written as stand-alone manuals coveringmultiple machine applications.

Fundamental service information is available fromother sources covering basic theory of operation,fundamentals of troubleshooting, general maintenance,and basic types of failures and their causes.

CTM67 (09DEC05) OEM Engine Accessories120905

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Introduction

OURGP12,0000180 1908DEC051/1

John Deere Dealers

The changes listed below make your CTM obsolete.Discard CTM 67 dated 24Sep02 and replace withthis new manual 09Dec05. Also, copy this page androute through your Service Department.

GROUP 20REVISED

Added Engine Wiring Diagrams for the PowerTech2.4 and 3.0 L engines and the PowerTech Plus 4.5,6.8, 9.0, and 13.5 L engines.

GROUP 21REVISED

Added Instrument Panelsfor the 2.4, 3.0, and 4.5 L(Later 270) engines without ECU and thePowerTech Plus 4.5, 6.8, 9.0, and 13.5 L engines.

GROUP 22REVISED

Added Cinch Connector Repair procedures. Added Replace Instrumentation procedures for 2.4,

3.0, and 4.5 L (Later 270) engines without ECU andengines with a John Deere ECU.

GROUP 25REVISED

Added Coolant Heater- Block Type (2.4 and 3.0 LEngines) remove and install information.

GROUP 40REVISED

Added Check Automatic Belt Tensionerinformation.

GROUP 46REVISED

Added Theory of Operation for John Deere rearPTO.

GROUP 54NEW

Added new Auxiliary Drive (9.0 L) group.

GROUP 55REVISED

Moved existing Auxiliary Drive (10.5 and 12.5 L)information from Group 54 to this new group, andadded information for the 13.5 L engine.

GROUP 70REVISED

Added newAir Conditioning Compressor hardwarefor 4045HF475 and 6068HF475 engines.

OTHER GROUPSMISCELLANEOUS REVISIONS


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Introduction


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ContentsSECTION OEM Engine Accessories

Group 05SafetyGroup 10General InformationGroup 20Electrical System Information and Wiring

DiagramsINDXGroup 21Electrical System Diagnostics, Tests and

OperationGroup 22Electrical System Repair and

AdjustmentsGroup 25Cold Weather Starting AidsGroup 30Fuel System AccessoriesGroup 31UTC Electric/Isochronous Governor

(8955 Engines)Group 32Electric Fuel Supply Pump8955

EnginesGroup 40Engine Cooling System AccessoriesGroup 45Rear PTO - Rockford/Twin DiscGroup 46Rear PTO - John DeereGroup 47Front PTOGroup 50Auxiliary Drive, 6076 (500000 )Group 51Auxiliary Drive (2.9 L)Group 52Auxiliary Drive (4.5 L and 6.8 L)Group 53Auxiliary Drive (8.1 L)Group 54Auxiliary Drive (9.0L)Group 55Auxiliary Drive (10.5L, 12.5L and 13.5L)Group 60Air CompressorsGroup 70Air Conditioning Compressors

All information, illustrations and specifications in this manual are based onthe latest information available at the time of publication. The right isreserved to make changes at any time without notice.

COPYRIGHT 2005DEERE & COMPANY

Moline, IllinoisAll rights reserved

A John Deere ILLUSTRUCTION ManualPrevious Editions

Copyright 1994, 1999, 2002

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INDX

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SectionOEM Engine Accessories

Contents

PagePage

Group 05Safety . . . . . . . . . . . . . . . . . . . . . . . . 05-1 Engine Wiring Diagram - PowerTech 8.1 L,10.5 L and 12.5 L Engines (With JohnDeere ECU) (Continued) . . . . . . . . . . . . . . . . . 20-29Group 10General Information

Engine Wiring DiagramPowerTech PlusAbout This Manual . . . . . . . . . . . . . . . . . . . . . . . . 10-14.5 L, 6.8 L, 9.0 L and 13.5 L Engines. . . . . . . 20-30Unified Inch Bolt and Screw Torque Values . . . . . 10-2

Engine Wiring DiagramPowerTech PlusMetric Bolt and Screw Torque Values . . . . . . . . . . 10-34.5 L, 6.8 L, 9.0 L and 13.5 L Engines(Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31

Group 20Electrical System Information and Engine Wiring DiagramSaran AEZWiring Diagrams Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . 20-33

Electrical Circuit Malfunctions . . . . . . . . . . . . . . . . 20-1 Engine Wiring Diagram LegendSaran VDOHigh Resistance Circuit . . . . . . . . . . . . . . . . . . . . . 20-2 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . 20-34Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3 Engine Wiring DiagramSaran VDOGrounded Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 20-5 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . 20-35Shorted Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-7 Engine Wiring DiagramPowerTech Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-8 2.4L and 3.0L Engines. . . . . . . . . . . . . . . . . . . 20-36Seven Step Electrical Test Procedure . . . . . . . . . . 20-9Wiring Diagram and Schematic Information. . . . . 20-11 Group 21Electrical System Diagnostics, TestsReading a System Functional Schematic . . . . . . 20-13 and OperationReading a Wiring Diagram . . . . . . . . . . . . . . . . . 20-14 Service Equipment and Tools . . . . . . . . . . . . . . . . 21-1Electrical Schematic Symbols . . . . . . . . . . . . . . . 20-15 Electrical System Specifications . . . . . . . . . . . . . . 21-1Component Identification Table . . . . . . . . . . . . . . 20-18 General Information. . . . . . . . . . . . . . . . . . . . . . . . 21-2Engine Wiring Diagram LegendNorth Component FunctionInstrument Panel

American Series 300, 400, 500 and 700 (Without ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . 21-3Engines and Early Model European Component FunctionInstrument Panel(Saran) Series 300 Engines. . . . . . . . . . . . . . . 20-20 (2.4L, 3.0L, and 4.5L (Later 270)-Without

Wiring DiagramNorth American Series ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-6300, 400 and 500 Engines. . . . . . . . . . . . . . . . 20-21 Component FunctionInstrument Panel

Wiring DiagramNorth American Series 700 (With Lucas ECU) . . . . . . . . . . . . . . . . . . . . . . . 21-8(8955) Engines . . . . . . . . . . . . . . . . . . . . . . . . 20-22 Component FunctionInstrument PanelWiring DiagramEuropean (Saran) Series (With Early Deere ECU). . . . . . . . . . . . . . . . . . 21-10

300 Engines (Early Model). . . . . . . . . . . . . . . . 20-23 Component FunctionInstrument PanelEngine Wiring Diagram Legend - PowerTech (PowerTech Plus 4.5 L, 6.8 L, 9.0

2.9 L, 4.5 L, 6.8 L and 8.1 L Engines (Without L,13.5 L and Later PowerTech 4.5L, 6.8L, 8.1L andECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24 12.5L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-14

Engine Wiring Diagram - PowerTech 2.9 Component FunctionSaran VDO InstrumentL, 4.5 L, 6.8 L and 8.1 L Engines (Without Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-18ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25 Component FunctionSaran AEZ

Engine Wiring Diagram Legend - Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . 21-20PowerTech 10.5 L and 12.5 L Engines Component FunctionCrankcase Oil Level(With Lucas ECU) . . . . . . . . . . . . . . . . . . . . . . 20-26 Switch/Gauge . . . . . . . . . . . . . . . . . . . . . . . . . 21-22

Engine Wiring Diagram - PowerTech 10.5 Before You Start Diagnostics . . . . . . . . . . . . . . . 21-23L and 12.5 L Engines (With Lucas ECU) . . . . . 20-27 Visually Inspect Electrical System . . . . . . . . . . . . 21-24

Engine Wiring Diagram - PowerTech 8.1 L, Diagnose Electrical System Malfunctions . . . . . . 21-2510.5 L and 12.5 L Engines (With John Deere

Continued on next pageECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28CTM67 (09DEC05) 1 OEM Engine Accessories

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Checking Fuses In Instrument Panels . . . . . . . . . 21-27 Group 25Cold Weather Starting AidsOther Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-1Test Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . 21-30

Test Magnetic Safety Switch . . . . . . . . . . . . . . . . 21-31 Cold Weather Starting Aids Specifications. . . . . . . 25-2Remove Coolant HeaterBlock TypeTest Starter Relay . . . . . . . . . . . . . . . . . . . . . . . . 21-31

(Except 2.4 L and 3.0 L Engines) . . . . . . . . . . . 25-3Install Coolant HeaterBlock TypeGroup 22Electrical System Repair and

Adjustments (Except 2.4 L and 3.0 L Engines) . . . . . . . . . . . 25-4Remove Coolant HeaterBlock Type (2.4Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1

Service Equipment and Tools . . . . . . . . . . . . . . . . 22-1 L and 3.0 L Engines) . . . . . . . . . . . . . . . . . . . . . 25-5Install Coolant HeaterBlock Type (2.4 LOther Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-2

Instrument Panel Specifications. . . . . . . . . . . . . . . 22-2 and 3.0 L Engines) . . . . . . . . . . . . . . . . . . . . . . 25-6Remove Coolant HeaterBlock Type (SaranRepair WEATHERPACK Connector . . . . . . . . . . 22-3

Remove Blade Terminals from Connector Body . . 22-6 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-7Install Coolant HeaterBlock Type (SaranRepair (Pull Type) METRI-PACK Connectors . . . 22-7

Repair (Push Type) METRI-PACK Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-8Remove Coolant HeaterTank Type . . . . . . . . . . 25-9Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-9

Repair DEUTSCH Connectors . . . . . . . . . . . . . 22-12 Install Coolant HeaterTank Type . . . . . . . . . . . . 25-9Remove and Install Fuel Heater . . . . . . . . . . . . . 25-10Repair AMP Connector . . . . . . . . . . . . . . . . . . . . 22-15

Repair SUMITOMO Connectors . . . . . . . . . . . . 22-17 Remove and Install Air Heater . . . . . . . . . . . . . . 25-11Remove and Install Glow Plugs (2.4 L andRepair YAZAKI Connectors . . . . . . . . . . . . . . . 22-19

Repair CINCH Flex Box Connector . . . . . . . . . 22-20 3.0 L Engines) . . . . . . . . . . . . . . . . . . . . . . . . . 25-12Remove and Install Glow Plugs (4.5L andReplace InstrumentationNorth American

Instrument Panel (Early Model Instrument 6.8L Engines) . . . . . . . . . . . . . . . . . . . . . . . . . 25-13Service Ether Starting Aid . . . . . . . . . . . . . . . . . . 25-14Panels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-28

Replace InstrumentationNorth AmericanInstrument Panel (Late Model Group 30Fuel System Accessories

Fuel System Accessories Specifications . . . . . . . . 30-1Instrument Panels W/O ECU) . . . . . . . . . . . . . 22-29Replace InstrumentationNorth American Check Injection Pump SolenoidD Engines. . . . 30-1

Check Rack PullerRP-20 (StationaryInstrument Panel (2.4L, 3.0L, and 4.5L(Later 270)W/O ECU) . . . . . . . . . . . . . . . . 22-30 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2

Check RP-75 Rack PullerStationary Engines. . . 30-3Replace InstrumentationInstrumentPanel with Lucas ECU. . . . . . . . . . . . . . . . . . . 22-31 Disassemble and Assemble RP-75 Rack Puller . . 30-4

Check Rotary Fuel Shut-Off Solenoid . . . . . . . . . . 30-5Replace InstrumentationEarlier ModelInstrument Panels with John Deere ECU. . . . . 22-32 Remove and Install Rotary Fuel Shut-Off

Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6Replace InstrumentationLater ModelInstrument Panels with John Deere ECU. . . . . 22-33 Adjust Rotary Fuel Shut-Off Solenoid . . . . . . . . . . 30-7

Replace InstrumentationEuropean(Saran) Instrument Panel (Early Model) . . . . . . 22-34 Group 31UTC Electric/Isochronous Governor

(8955 Engines)Replace InstrumentationSaran VDOInstrument Panel . . . . . . . . . . . . . . . . . . . . . . . 22-35 Service Equipment and Tools . . . . . . . . . . . . . . . . 31-1

Governor Specifications . . . . . . . . . . . . . . . . . . . . 31-1Replace InstrumentationSaran AEZInstrument Panel . . . . . . . . . . . . . . . . . . . . . . . 22-36 How the System Works. . . . . . . . . . . . . . . . . . . . . 31-2

Diagnosing Electric Governor Malfunctions . . . . . . 31-4Remove and Install Crankcase Oil LevelSwitch/Gauge . . . . . . . . . . . . . . . . . . . . . . . . . 22-37 Safety Guidelines when Testing Electronic

Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-8Calibrate Adjustable Electronic Tachometer . . . . 22-38Adjust Saran VDO Instrument Panel Electric Governor System Tests . . . . . . . . . . . . . . 31-9

Test Engine Speeds . . . . . . . . . . . . . . . . . . . . . . 31-10Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-40Adjust Saran AEZ Instrument Panel Adjust Engine Speeds . . . . . . . . . . . . . . . . . . . . . 31-11

Adjust Gain and Stability . . . . . . . . . . . . . . . . . . . 31-13Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-41Replace Electronic Foot Throttle (Later Engine Operation in Droop Mode . . . . . . . . . . . . 31-14

Electric Governor Installation Instruction . . . . . . . 31-15Engines with ECU) . . . . . . . . . . . . . . . . . . . . . 22-41Harness Repair (Splice Broken or Cut Wire) . . . . 22-43

Continued on next pageHarness Repair (Splice Connector) . . . . . . . . . . . 22-44CTM67 (09DEC05) 2 OEM Engine Accessories

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Connect Electric Governor Wiring Harness . . . . . 31-16 Service Equipment and Tools . . . . . . . . . . . . . . . . 45-1Rockford/Twin Disc Rear Power Take-OffRemove Electric Governor . . . . . . . . . . . . . . . . . 31-17

Service Magnetic Pickup . . . . . . . . . . . . . . . . . . . 31-17 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 45-3General Information. . . . . . . . . . . . . . . . . . . . . . . . 45-7Diagnosing Malfunctions . . . . . . . . . . . . . . . . . . . . 45-7Group 32Electric Fuel Supply Pump8955

Engines Remove Power Take-Off . . . . . . . . . . . . . . . . . . . . 45-8Power Take-Off Exploded View. . . . . . . . . . . . . . 45-10Service Equipment and Tools . . . . . . . . . . . . . . . . 32-1

Fuel Supply Pump Specifications . . . . . . . . . . . . . 32-2 Disassemble Power Take-Off . . . . . . . . . . . . . . . 45-12Inspect Power Take-Off Parts . . . . . . . . . . . . . . . 45-16Relieve System Pressure . . . . . . . . . . . . . . . . . . . 32-3

Test John Barnes Fuel Supply Pump Assemble Drive Shaft and BearingsSide-Load Application . . . . . . . . . . . . . . . . . . . 45-22Pressure8955T, A Engine Serial No. (

3076) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-3 Assemble Drive Shaft and BearingsIn-LineApplication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-23Adjust John Barnes Fuel Supply Pump

Relief Valve8955T, A Engines Serial No. ( Install Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-24Check and Adjust Drive Shaft End Play . . . . . . . 45-253076) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-5

Remove John Barnes Electric Fuel Supply Assemble Clutch Unit (Early Version) . . . . . . . . . 45-26Assemble Clutch Unit (Late Version) . . . . . . . . . . 45-29Pump8955 Engine Serial No. ( 3076) . . . 32-6

Remove Pressure Regulating Valve . . . . . . . . . . . 32-7 Install Clutch Unit . . . . . . . . . . . . . . . . . . . . . . . . 45-30Check Flywheel Housing Face Run-Out . . . . . . . 45-30Install Pressure Regulating Valve . . . . . . . . . . . . . 32-8

Repair Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . 32-8 Check Flywheel Face Flatness . . . . . . . . . . . . . . 45-31Check Pilot Bearing Bore . . . . . . . . . . . . . . . . . . 45-31Install John Barnes Fuel Supply Pump

8955 Engine Serial No. ( 3076) . . . . . . . . . 32-13 Inspect Drive Ring. . . . . . . . . . . . . . . . . . . . . . . . 45-32Install Power Take-Off. . . . . . . . . . . . . . . . . . . . . 45-32Test Bosch Fuel Supply Pump

Pressure8955T, A Engine Serial No. (3077 Check PTO Clutch AdjustmentEarly Version . . 45-33Check PTO Clutch AdjustmentLate Version. . . 45-34) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-13

Replace Bosch Fuel Supply Pump8955T, A Engines Serial No. (3077 ) . . . . . 32-15 Group 46Rear PTO - John Deere

Special Or Essential Tools . . . . . . . . . . . . . . . . . . 46-1Other Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-3Group 40Engine Cooling System Accessories

Service Equipment and Tools . . . . . . . . . . . . . . . . 40-1 Rear Power Take-Off Specifications For8.1L/9.0L and 12.5L/13.5L Engines WithOther Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1

Engine Cooling System Specifications. . . . . . . . . . 40-2 Primary and Auxiliary Pump Drives (DoublePump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-4Test Charge Air Cooler . . . . . . . . . . . . . . . . . . . . . 40-4

Remove and Install Charge Air Cooler . . . . . . . . . 40-5 Rear Power Take-Off Specifications For8.1L/9.0L and 12.5L/13.5L Engines WithRemove and Install Coolant Temperature

Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-6 Primary Pump Drive (Single Pump) . . . . . . . . . . 46-7General Information. . . . . . . . . . . . . . . . . . . . . . . . 46-9Pressure Test Cooling System and

Radiator Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-7 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . 46-10Lubrication Passages . . . . . . . . . . . . . . . . . . . . . 46-11Radiator and Hoses . . . . . . . . . . . . . . . . . . . . . . . 40-8

Install Radiator FanBlower and Suction Photo Disclosure . . . . . . . . . . . . . . . . . . . . . . . . . 46-12Remove Rear PTO . . . . . . . . . . . . . . . . . . . . . . . 46-12Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-8

Check Fan and Alternator Belts. . . . . . . . . . . . . . 40-10 Disassemble Auxiliary Pump Group . . . . . . . . . . 46-17Disassemble Primary Pump Group . . . . . . . . . . . 46-21Remove and Install Fan and Alternator Belts . . . 40-12

Manual Belt Tensioner Adjustment . . . . . . . . . . . 40-13 Disassemble Auxiliary Idler Shaft Group . . . . . . . 46-24Disassemble Primary Idler Shaft Group. . . . . . . . 46-29Manual Belt Tensioner Adjustment Using Belt

Tension Tool (Alternate Method For Inspect and Assemble Engine Rear PowerTake-Off Housing Group . . . . . . . . . . . . . . . . . 46-33Engines Without Auxiliary Drive) . . . . . . . . . . . 40-14

Check Automatic Belt Tensioner Spring Flywheel Access Cover Plate . . . . . . . . . . . . . . . 46-34Primary Idler Shaft Group . . . . . . . . . . . . . . . . . . 46-35Tension and Belt Wear . . . . . . . . . . . . . . . . . . 40-16

Adjust Fan and Alternator Belts. . . . . . . . . . . . . . 40-19 Assemble Primary Idler Shaft Group . . . . . . . . . . 46-35Auxiliary Idler Shaft Group . . . . . . . . . . . . . . . . . 46-41

Group 45Rear PTO - Rockford/Twin DiscEssential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-1 Continued on next page

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Assemble Auxiliary Idler Shaft Group . . . . . . . . . 46-42 Group 52Auxiliary Drive (4.5 L and 6.8 L)Auxiliary Drive (4.5 L and 6.8 L) Specifications . . . 52-1Auxiliary Pump Access Cover Plate (For

Single Pump Application Only). . . . . . . . . . . . . 46-48 Remove and Install Auxiliary Drive . . . . . . . . . . . . 52-1Remove and Install Offset Auxiliary Drive . . . . . . . 52-2Primary Pump Group . . . . . . . . . . . . . . . . . . . . . 46-50

Assemble Primary Pump Group . . . . . . . . . . . . . 46-51 Disassemble and Inspect Auxiliary DriveAdapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-3Auxiliary Pump Group . . . . . . . . . . . . . . . . . . . . . 46-54

Assemble Auxiliary Pump Group (Double Disassemble and Inspect Offset AuxiliaryDrive Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . 52-3Pump Rear Power Take-Off) . . . . . . . . . . . . . . 46-55

Input Gear Assembly and Seal RetainerGroup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-60 Group 53Auxiliary Drive (8.1 L)

Auxiliary Drive Specifications. . . . . . . . . . . . . . . . . 53-1Install Rear PTO . . . . . . . . . . . . . . . . . . . . . . . . . 46-61Remove Right-Hand Output Gear Assembly . . . . . 53-2Disassemble Right-Hand Output GearGroup 47Front PTO

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53-2Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 47-1Assemble Right-Hand Output Gear Assembly . . . . 53-3Front Power Take-Off Specifications . . . . . . . . . . . 47-2Install Right-Hand Output Gear Assembly . . . . . . . 53-5Checking Vibration Damper or PulleyRemove Left-Hand Output Gear Assembly . . . . . . 53-5(Engine With Front PTO) . . . . . . . . . . . . . . . . . . 47-4Disassemble Left-Hand Output Gear Assembly. . . 53-6Remove Vibration Damper or PulleyAssemble Left-Hand Output Gear Assembly . . . . . 53-7(Engine With Front PTO) . . . . . . . . . . . . . . . . . . 47-5Remove and Install Left-Hand Rear AdapterInstall Vibration Damper or Pulley (Engine

Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53-9With Front PTO) . . . . . . . . . . . . . . . . . . . . . . . . 47-6Remove Idler Housing and Idler Gear . . . . . . . . . . 53-9Installing PTO Drive Gear (CrankshaftReplace Idler Gear Bearing. . . . . . . . . . . . . . . . . 53-11Gear-Driven PTO) . . . . . . . . . . . . . . . . . . . . . . . 47-7Install Idler Housing and Idler Gear . . . . . . . . . . . 53-11Remove and Install Front PTO ClutchInstall Left-Hand Output Gear Assembly . . . . . . . 53-15Adapter (Electric) . . . . . . . . . . . . . . . . . . . . . . . . 47-8

Remove and Install Front PTO ClutchGroup 54Auxiliary Drive (9.0L)Adapter (Mechanical) . . . . . . . . . . . . . . . . . . . . 47-12Auxiliary Drive Specifications. . . . . . . . . . . . . . . . . 54-1Remove Left-Hand Output Gear Assembly . . . . . . 54-2Group 50Auxiliary Drive, 6076 (500000 ) Remove Left-Hand Rear Housing . . . . . . . . . . . . . 54-2Service Equipment and Tools . . . . . . . . . . . . . . . . 50-1 Remove Left-Hand Aux Drive Housing fromOther Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 54-3

Auxiliary Drive, 6076 (500000 ) Remove Left-Hand Aux Drive HousingSpecifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 50-2 from Timing Gear Cover . . . . . . . . . . . . . . . . . . 54-4Auxiliary Drive General Information . . . . . . . . . . . . 50-4 Remove and Install Idler Gear. . . . . . . . . . . . . . . . 54-5Remove Right-Hand Output Gear Assembly . . . . . 50-5 Install Left-Hand Aux Drive Housing to TimingDisassemble Right-Hand Output Gear Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54-6

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5 Install Left-Hand Aux Drive Housing toAssemble Right-Hand Output Gear Assembly . . . . 50-6 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 54-7Install Right-Hand Output Gear Assembly . . . . . . . 50-7 Torque Left-Hand Aux Drive Assembly . . . . . . . . . 54-8Remove Left-Hand Output Gear Assembly . . . . . . 50-8 Install Left-Hand Rear Housing . . . . . . . . . . . . . . . 54-9Disassemble Left-Hand Output Gear Assembly. . . 50-9 Install Left-Hand Output Gear Assembly . . . . . . . 54-10Assemble Left-Hand Output Gear Assembly . . . . 50-11Remove Left-Hand Rear Adapter Housing . . . . . 50-13 Group 55Auxiliary Drive (10.5L, 12.5L and 13.5L)Remove Idler Housing and Idler Gear . . . . . . . . . 50-13 Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-1Replace Idler Gear Bearing. . . . . . . . . . . . . . . . . 50-15 Auxiliary Drive (10.5 L, 12.5 L and 13.5 L)Install Idler Housing and Idler Gear . . . . . . . . . . . 50-16 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 55-1Install Left-Hand Output Gear Assembly . . . . . . . 50-19 Remove and Install Auxiliary Drive Idler GearInstall Left-Hand Rear Adapter Housing . . . . . . . 50-20 and Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-2

Remove and Install SAE A and B FrontGroup 51Auxiliary Drive (2.9 L) and SAE B Rear Auxiliary Drive Assembly . . . 55-3Auxiliary Drive (2.9 L) Specifications . . . . . . . . . . . 51-1

Continued on next pageRemove and Install Right-Hand Auxiliary Drive . . . 51-1


PN=4

Contents

Page

Group 60Air CompressorsEssential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1Service Equipment and Tools . . . . . . . . . . . . . . . . 60-1Air Compressor Specifications. . . . . . . . . . . . . . . . 60-3Air Compressor General Information . . . . . . . . . . . 60-4Compressor Troubleshooting Chart . . . . . . . . . . . . 60-5Compressor Troubleshooting Chart (Continued) . . 60-6Remove And Install Air Compressor (4.5 L

and 6.8 L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-7Remove And Install Air Compressor [6076

(S.N. 500000 ) and 8.1 L]. . . . . . . . . . . . . . . 60-10Remove and Install Air Compressor (10.5

L and 12.5 L) . . . . . . . . . . . . . . . . . . . . . . . . . . 60-14

Group 70Air Conditioning CompressorsEssential Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-1Air Conditioning Specifications . . . . . . . . . . . . . . . 70-3Air Conditioning General Information. . . . . . . . . . . 70-4Proper Refrigerant Handling . . . . . . . . . . . . . . . . . 70-5R-134a Refrigerant Cautions . . . . . . . . . . . . . . . . . 70-5Air Conditioning Retrofit . . . . . . . . . . . . . . . . . . . . 70-6System Information . . . . . . . . . . . . . . . . . . . . . . . . 70-6Discharge Air Conditioning System . . . . . . . . . . . . 70-7Flush/Clean Air Conditioning Compressor . . . . . . . 70-8Purge Air Conditioning System . . . . . . . . . . . . . . . 70-8Evacuate Air Conditioning System . . . . . . . . . . . . 70-9Check Refrigerant Oil Charge . . . . . . . . . . . . . . . 70-10Determine Correct Refrigerant Oil Charge. . . . . . 70-11Add Refrigerant Oil to Pressurized System . . . . . 70-12Charge Air Conditioning System . . . . . . . . . . . . . 70-14Diagnosing Air Conditioning Compressor

Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . 70-15Remove and Install Air Conditioning

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-18Test Volumetric Efficiency . . . . . . . . . . . . . . . . . . 70-20Compressor Leakage Test . . . . . . . . . . . . . . . . . 70-22Disassemble and Assemble Compressor

Clutch (Denso Compressor). . . . . . . . . . . . . . . 70-24Check Clutch Hub Clearance . . . . . . . . . . . . . . . 70-25Inspect Compressor Manifold (Denso

Compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . 70-26Disassemble, Inspect, and Assemble

Compressor (Denso Compressor) . . . . . . . . . . 70-27Remove and Install Compressor Relief Valve

(Denso Compressor) . . . . . . . . . . . . . . . . . . . . 70-29


PN=5

Contents


PN=6

Group 05Safety

051

DX,FIRE2 1903MAR931/1

Prepare for Emergencies

TS29

1

UN2

3AUG

88

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,hospital, and fire department near your telephone.

DX,SPARKS 1903MAR931/1

Prevent Battery Explosions

TS20

4UN

23A

UG88

Keep sparks, lighted matches, and open flame away fromthe top of battery. Battery gas can explode.

Never check battery charge by placing a metal objectacross the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warmbattery to 16 C (60 F).

CTM67 (09DEC05) 05-1 OEM Engine Accessories120905

PN=9

Safety

052

DPSG,OUO1004,2758 1911MAY001/1

Handling Batteries Safely

TS20

4UN

23A

UG88

Explosion

TS20

3UN

23A

UG88

Acid

CAUTION: Battery gas can explode. Keepsparks and flames away from batteries. Use aflashlight to check battery electrolyte level.

Never check battery charge by placing a metalobject across the posts. Use a voltmeter orhydrometer.

Always remove grounded () battery clampfirst and replace it last.

CAUTION: Sulfuric acid in battery electrolyte ispoisonous. It is strong enough to burn skin, eatholes in clothing, and cause blindness ifsplashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.2. Wearing eye protection and rubber gloves.3. Avoiding breathing fumes when electrolyte is

added.4. Avoiding spilling or dripping electrolyte.5. Using proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.2. Apply baking soda or lime to help neutralize

the acid.3. Flush your eyes with water for 1530

minutes. Get medical attention immediately.

If acid is swallowed:

1. Do not induce vomiting.2. Drink large amounts of water or milk, but do

not exceed 2 L (2 qt.).3. Get medical attention immediately.

WARNING: Battery posts, terminals, and relatedaccessories contain lead and lead compounds, chemicalsknown to the State of California to cause cancer andreproductive harm. Wash hands after handling.


PN=10

Safety

053

DX,MSDS,NA 1903MAR931/1

Handle Chemical Products Safely

TS11

32UN

26N

OV9

0

Direct exposure to hazardous chemicals can causeserious injury. Potentially hazardous chemicals used withJohn Deere equipment include such items as lubricants,coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specificdetails on chemical products: physical and health hazards,safety procedures, and emergency response techniques.

Check the MSDS before you start any job using ahazardous chemical. That way you will know exactly whatthe risks are and how to do the job safely. Then followprocedures and recommended equipment.

(See your John Deere dealer for MSDSs on chemicalproducts used with John Deere equipment.)

DX,FLUID 1903MAR931/1

Avoid High-Pressure Fluids

X981

1UN

23A

UG88

Escaping fluid under pressure can penetrate the skincausing serious injury.

Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tighten allconnections before applying pressure.

Search for leaks with a piece of cardboard. Protect handsand body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluidinjected into the skin must be surgically removed within afew hours or gangrene may result. Doctors unfamiliar withthis type of injury should reference a knowledgeablemedical source. Such information is available from Deere& Company Medical Department in Moline, Illinois, U.S.A.


PN=11

Safety

054

DX,LOWER 1924FEB001/1

Support Machine Properly

TS22

9UN

23A

UG88

Always lower the attachment or implement to the groundbefore you work on the machine. If the work requires thatthe machine or attachment be lifted, provide securesupport for them. If left in a raised position, hydraulicallysupported devices can settle or leak down.

Do not support the machine on cinder blocks, hollow tiles,or props that may crumble under continuous load. Do notwork under a machine that is supported solely by a jack.Follow recommended procedures in this manual.

When implements or attachments are used with amachine, always follow safety precautions listed in theimplement or attachment operators manual.

DX,BYPAS1 1929SEP981/1

Prevent Machine Runaway

TS17

7UN

11J

AN89

Avoid possible injury or death from machinery runaway.

Do not start engine by shorting across starter terminals.Machine will start in gear if normal circuitry is bypassed.

NEVER start engine while standing on ground. Startengine only from operators seat, with transmission inneutral or park.

OUO1004,0000BD8 1903NOV001/1

Stay Clear of Rotating Drivelines

TS16

44UN

22A

UG95

Rotating Drivelines

Entanglement in rotating driveline can cause serious injuryor death.

Keep master shield and driveline shields in place at alltimes. Make sure rotating shields turn freely.

Wear close-fitting clothing. Stop the engine and be surePTO driveline is stopped before making adjustments,connections, or performing any type of service on theengine or PTO-driven equipment.


PN=12

Safety

055

DX,FIRE3 1916APR921/1

Handle Starting Fluid Safely

TS13

56UN

18M

AR92

Starting fluid is highly flammable.

Keep all sparks and flame away when using it. Keepstarting fluid away from batteries and cables.

To prevent accidental discharge when storing thepressurized can, keep the cap on the container, and storein a cool, protected location.

Do not incinerate or puncture a starting fluid container.

DX,WEAR 1910SEP901/1

Wear Protective Clothing

TS20

6UN

23A

UG88

Wear close fitting clothing and safety equipmentappropriate to the job.

Prolonged exposure to loud noise can cause impairmentor loss of hearing.

Wear a suitable hearing protective device such asearmuffs or earplugs to protect against objectionable oruncomfortable loud noises.

Operating equipment safely requires the full attention ofthe operator. Do not wear radio or music headphoneswhile operating machine.

DX,CLEAN 1904JUN901/1

Work in Clean Area

T664

2EJ

UN

18O

CT88

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.


PN=13

Safety

056

DX,LOOSE 1904JUN901/1

Service Machines Safely

TS22

8UN

23A

UG88

Tie long hair behind your head. Do not wear a necktie,scarf, loose clothing, or necklace when you work nearmachine tools or moving parts. If these items were to getcaught, severe injury could result.

Remove rings and other jewelry to prevent electricalshorts and entanglement in moving parts.

DX,AIR 1917FEB991/1

Work In Ventilated Area

TS22

0UN

23A

UG88

Engine exhaust fumes can cause sickness or death. If it isnecessary to run an engine in an enclosed area, removethe exhaust fumes from the area with an exhaust pipeextension.

If you do not have an exhaust pipe extension, open thedoors and get outside air into the area

DX,LIGHT 1904JUN901/1

Illuminate Work Area Safely

TS22

3UN

23A

UG88

Illuminate your work area adequately but safely. Use aportable safety light for working inside or under themachine. Make sure the bulb is enclosed by a wire cage.The hot filament of an accidentally broken bulb can ignitespilled fuel or oil.

DX,SIGNS1 1904JUN901/1

Replace Safety Signs

TS20

1UN

23A

UG88

Replace missing or damaged safety signs. See themachine operators manual for correct safety signplacement.


PN=14

Safety

057

DX,LIFT 1904JUN901/1

Use Proper Lifting Equipment

TS22

6

UN2

3AUG

88

Lifting heavy components incorrectly can cause severeinjury or machine damage.

Follow recommended procedure for removal andinstallation of components in the manual.

DX,PAINT 1924JUL021/1

Remove Paint Before Welding or Heating

TS22

0UN

23A

UG88

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heatedby welding, soldering, or using a torch.

Remove paint before heating:

Remove paint a minimum of 101 mm (4 in.) from areato be affected by heating. If paint cannot be removed,wear an approved respirator before heating or welding.

If you sand or grind paint, avoid breathing the dust.Wear an approved respirator.

If you use solvent or paint stripper, remove stripper withsoap and water before welding. Remove solvent orpaint stripper containers and other flammable materialfrom area. Allow fumes to disperse at least 15 minutesbefore welding or heating.

Do not use a chlorinated solvent in areas where weldingwill take place.

Do all work in an area that is well ventilated to carry toxicfumes and dust away.

Dispose of paint and solvent properly.


PN=15

Safety

058

OUOD006,000009D 1904DEC021/1

Install Fan Guards

TS67

7UN

21S

EP89

Rotating Fan

Rotating cooling system fans can cause serious injury.

Keep fan guards in place at all times during engineoperation. Wear close fitting clothes. Stop the engine andbe sure fan is stopped before making adjustments orconnections, or cleaning near the front of the engine.

OURGP12,0000135 1919JUL051/1

Avoid Hot Parts

TS27

1UN

23A

UG88

Hot Surface

Avoid skin contact with exhaust manifolds, turbochargersand mufflers. Keep flammable materials clear of theturbocharger.

External dry exhaust parts become very hot duringoperation. Turbochargers and exhaust manifolds mayreach temperatures as high as 600 C (1112 F) under fullload. This may ignite paper, cloth or wooden materials.Parts on engines that have been at full load and reducedto no load idle will maintain approximately 150 C (302 F).

DX,TORCH 1910DEC041/1

Avoid Heating Near Pressurized Fluid Lines

TS95

3UN

15M

AY90

Flammable spray can be generated by heating nearpressurized fluid lines, resulting in severe burns toyourself and bystanders. Do not heat by welding,soldering, or using a torch near pressurized fluid lines orother flammable materials. Pressurized lines canaccidentally burst when heat goes beyond the immediateflame area.


PN=16

Safety

059

DX,DUST 1915MAR911/1

Avoid Harmful Asbestos Dust

TS22

0

UN2

3AUG

88

Avoid breathing dust that may be generated whenhandling components containing asbestos fibers. Inhaledasbestos fibers may cause lung cancer.

Components in products that may contain asbestos fibersare brake pads, brake band and lining assemblies, clutchplates, and some gaskets. The asbestos used in thesecomponents is usually found in a resin or sealed in someway. Normal handling is not hazardous as long asairborne dust containing asbestos is not generated.

Avoid creating dust. Never use compressed air forcleaning. Avoid brushing or grinding material containingasbestos. When servicing, wear an approved respirator. Aspecial vacuum cleaner is recommended to cleanasbestos. If not available, apply a mist of oil or water onthe material containing asbestos.

Keep bystanders away from the area.


PN=17

Safety

0510

DX,SERV 1917FEB991/1

Practice Safe Maintenance

TS21

8UN

23A

UG88

Understand service procedure before doing work. Keeparea clean and dry.

Never lubricate, service, or adjust machine while it ismoving. Keep hands, feet , and clothing frompower-driven parts. Disengage all power and operatecontrols to relieve pressure. Lower equipment to theground. Stop the engine. Remove the key. Allow machineto cool.

Securely support any machine elements that must beraised for service work.

Keep all parts in good condition and properly installed. Fixdamage immediately. Replace worn or broken parts.Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery groundcable (-) before making adjustments on electrical systemsor welding on machine.

On towed implements, disconnect wiring harnesses fromtractor before servicing electrical system components orwelding on machine.

DX,REPAIR 1917FEB991/1

Use Proper Tools

TS77

9UN

08N

OV8

9Use tools appropriate to the work. Makeshift tools andprocedures can create safety hazards.

Use power tools only to loosen threaded parts andfasteners.

For loosening and tightening hardware, use the correctsize tools. DO NOT use U.S. measurement tools onmetric fasteners. Avoid bodily injury caused by slippingwrenches.

Use only service parts meeting John Deere specifications.


PN=18

Safety

0511

DX,DRAIN 1903MAR931/1

Dispose of Waste Properly

TS11

33UN

26N

OV9

0

Improperly disposing of waste can threaten theenvironment and ecology. Potentially harmful waste usedwith John Deere equipment include such items as oil, fuel,coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not usefood or beverage containers that may mislead someoneinto drinking from them.

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

Air conditioning refrigerants escaping into the air candamage the Earths atmosphere. Government regulationsmay require a certified air conditioning service center torecover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of wastefrom your local environmental or recycling center, or fromyour John Deere dealer.

DX,LIVE 1925SEP921/1

Live With Safety

TS23

119

07O

CT88

Before returning machine to customer, make suremachine is functioning properly, especially the safetysystems. Install all guards and shields.


PN=19

Safety

0512


PN=20

Group 10General Information

101

OURGP12,0000144 1925AUG051/1

About This Manual

This component technical manual covers necessarydiagnostics and repair procedures for accessories usedon Series 300, 400, 500 and 700 OEM Engines andPowerTechTM1 and PowerTech PlusTM2 2.4 L, 2.9 L, 3.0 L,4.5 L, 6.8 L, 8.1 L, 9.0 L, 10.5 L, 12.5 L, and 13.5 L OEMEngines.

Measurements given in this manual are given in bothmetric and the U.S. unit equivalent. Use only correctreplacement parts and fasteners. Metric and inchfasteners may require a specific metric or inch wrench.

Right-hand and left-hand side of engine is determined bystanding at the flywheel end (rear of the engine), facingtowards front of engine.

Read each module completely, that pertains to theparticular job at hand, before performing any service.

1PowerTech is a trademark of Deere & Company

2PowerTech Plus is a trademark of Deere & Company


PN=21

General Information

102

TORQ1 1924APR031/1

Unified Inch Bolt and Screw Torque ValuesTS1671 UN01MAY03

Bolt or SAE Grade 1 SAE Grade 2a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2Screw Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc

Size Nm lb-in Nm lb-in Nm lb-in Nm lb-in Nm lb-in Nm lb-in Nm lb-in Nm lb-in1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150

Nm lb-ft Nm lb-ft5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26

Nm lb-ft Nm lb-ft3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46

Nm lb-ft Nm lb-ft Nm lb-ft7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74

Nm lb-ft1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115

9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 1655/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 2253/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 4007/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640

1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 9601-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 13501-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 19201-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 25001-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350

Torque values listed are for general use only, based on the strength of the Replace fasteners with the same or higher grade. If higherbolt or screw. DO NOT use these values if a different torque value or grade fasteners are used, tighten these to the strength of thetightening procedure is given for a specific application. For plastic insert or original. Make sure fastener threads are clean and that youcrimped steel type lock nuts, for stainless steel fasteners, or for nuts on properly start thread engagement. When possible, lubricateU-bolts, see the tightening instructions for the specific application. Shear plain or zinc plated fasteners other than lock nuts, wheel boltsbolts are designed to fail under predetermined loads. Always replace shear or wheel nuts, unless different instructions are given for thebolts with identical grade. specific application.aGrade 2 applies for hex cap screws (not hex bolts) up to 6. in (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,and for all other types of bolts and screws of any length.bLubricated means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with

JDM F13C zinc flake coating.cDry means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B zinc flake coating.


PN=22

General Information

103

DX,TORQ2 1924APR031/1

Metric Bolt and Screw Torque Values

4.84.8 8.8 9.8 10.9 12.9 12.9

12.912.910.99.88.84.8

TS16

70UN

01M

AY03

Bolt or Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9Screw Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb

Size Nm lb-in Nm lb-in Nm lb-in Nm lb-in Nm lb-in Nm lb-in Nm lb-in Nm lb-inM6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172

Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ftM8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35

Nm lb-ft Nm lb-ft Nm lb-ftM10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70

Nm lb-ftM12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500

Torque values listed are for general use only, based on the strength Shear bolts are designed to fail under predetermined loads. Alwaysof the bolt or screw. DO NOT use these values if a different torque replace shear bolts with identical property class. Replace fastenersvalue or tightening procedure is given for a specific application. For with the same or higher property class. If higher property classstainless steel fasteners or for nuts on U-bolts, see the tightening fasteners are used, tighten these to the strength of the original. Makeinstructions for the specific application. Tighten plastic insert or sure fastener threads are clean and that you properly start threadcrimped steel type lock nuts by turning the nut to the dry torque engagement. When possible, lubricate plain or zinc plated fastenersshown in the chart, unless different instructions are given for the other than lock nuts, wheel bolts or wheel nuts, unless differentspecific application. instructions are given for the specific application.aLubricated means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20 and larger fasteners with

JDM F13C zinc flake coating.bDry means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.


PN=23

General Information

104


PN=24

Group 20Electrical System Information and Wiring Diagrams

201

DPSG,OUO1004,785 1919APR991/1

Electrical Circuit Malfunctions

T771

3AD

19

27F

EB92

ABattery CSwitch DLight EGroundBFuse

1. There are four common circuit malfunctions.

High-Resistance Circuit Open Circuit Grounded Circuit Shorted Circuit

2. Three sections in a simple circuit where thesemalfunctions can occur:

Before the controlling switch (C). Between the controlling switch and before the

component, light (D).

After the component.

Component malfunctions can easily be confused withcircuit malfunctions. Therefore, care must be exercisedwhen isolating the cause of a problem.

Example: Light does not operate or is dim when switchis turned ON, until switch connector is disconnectedand reconnected.

Reason: High resistance caused by a dirty switchconnector, caused a voltage drop which prevented theproper amount of current from flowing to the light.


PN=25

Electrical System Information and Wiring Diagrams

202

DPSG,OUO1004,660 1915MAR991/1

High Resistance Circuit

T771

3AG

19

26F

EB92

ABattery DSwitch Terminal FHarness Connector HLightBFuse EHigh Resistance GLight Terminal IGroundCSwitch

A high resistance circuit can result in slow, dim or nocomponent operation.

Examples: Loose, corroded, dirty or oily terminals.Wire size too small. Strands broken inside the wire.Poor ground connection to frame.

To locate the cause of high resistance:

With switch (C) ON, check for battery voltage betweenswitch and ground (I) at an easily accessible location,like harness connector (F).

If less than battery voltage is indicated, check againcloser to switch.

If battery voltage is indicated, check closer to groundto locate point of voltage drop. The example showshigh resistance (E) between switch and harnessconnector.

Repair circuit as required. In the example, strandswere broken inside the wire. Replace that section ofwire.

Repeat check-out procedure after repair.


PN=26


203

DPSG,OUO1004,661 1915MAR991/2

Open Circuit

T771

3AF

19

27F

EB92

ABattery DSwitch Terminal FOpen Circuit HLightBFuse EHarness Connector GLight Terminal IGroundCSwitch

An open circuit will result in no components operating.Fuse may or may not be blown.

Example: Broken wire, disconnected componentterminal, pins inside a connector not making contact,blown fuse, open circuit breaker, failed switch orcomponent, or a disconnected ground wire.

To locate an open circuit:

Check fuse. If blown, replace and operate circuit. Iffuse blows a second time, continue check.

With switch (C) ON, check for battery voltage at switchterminal (D).

If no voltage is indicated, check switch, fuse and wiringto battery.

If battery voltage is indicated, check for voltage closerto ground at harness connector (E).

If no voltage is indicated, wire may be broken betweenswitch and connector.

If battery voltage is indicated, inspect connector pins. Ifpins are OK check for voltage at light terminal (G).

In the example, zero voltage will be indicated at lightterminal, indicating a broken wire between harnessconnector and light terminal.

If battery voltage had been indicated, the next checkfor voltage would be at ground connection (I).

Normal indicated voltage at a ground connectionshould be 0.0 to 0.5 volts.


PN=27

Continued on next page


204

DPSG,OUO1004,661 1915MAR992/2

If battery voltage is indicated, poor connection to frameor broken wire is indicated.

When problem is located, repair as needed, thenrepeat last check.


PN=28


205

DPSG,OUO1004,662 1915MAR991/2

Grounded Circuit

T771

3AE

19

27F

EB92

ABattery DSwitch GHarness Connector JLightBFuse ESwitch Terminal HGrounded Circuit KGroundCFuse Terminal FHarness Connector ILight (Component) Terminal

If no component operates, the fuse is blown andreplacement fuses blow immediately or the circuitbreaker is open and reopens when reset, a groundedcircuit exists. (Example: power wire contacting frameor other metal component). A wire may be pinched orinsulation may be worn from a wire.

To isolate the location of a grounded circuit:

If circuit is grounded between battery and fuse, wirewill be burned and circuit will be open. Fuse will not beblown.

If fuse is blown, remove fuse from circuit, disconnectcircuit near its center, such as harness connector (F).Turn switch (D) ON and check for continuity to groundat harness connector (F). This will check harness fromharness connector to fuse.

If continuity to ground is indicated, there is a pinchedor bare wire between fuse terminal (C) and harnessconnector (F).

If continuity to ground does not exist, disconnectground (K) from frame. Measure continuity to groundat harness connector (G). This checks harness fromharness connector to ground terminal. In the examplecontinuity to ground will exist because circuit isgrounded (wire is pinched) at (H).

If continuity exists, disconnect circuit at light terminal(I) and measure continuity to ground on light terminal.This checks harness from light to ground terminal. Inthe example, continuity will not exist, indicating agrounded circuit between the light and harnessconnector (G).


PN=29



206

DPSG,OUO1004,662 1915MAR992/2



PN=30


207

DPSG,OUO1004,664 1915MAR991/2

Shorted Circuit

T771

3AH

19

27F

EB92

ABattery ESwitch Terminal IHarness Connector LLightBFuse FSwitch JLight MGroundCFuse GHarness Connector KLight Terminal NGroundDSwitch HShorted Circuit

A shorted circuit causes components in separatecircuits to operate when a switch in either circuit isturned ON. (Example: two harnesses rubbing togetheruntil insulation is worn through allowing bare wires totouch). Components can also become shorted.However, shorted components will usually blow thefuse.

To locate a shorted circuit:

Turn switch (F) ON then OFF. Turn switch (D) ONthen OFF. Both lights (J and L) will be ON when eitherswitch (D or F) is ON.

Turn switch (F) ON. Both lights (J and L) will be ON;only light (L) should be ON.

Disconnect wire from switch of component that shouldnot be ON. In the example, disconnect wire fromterminal (E) at switch (D). Light (J) remains ON.

Disconnect circuit at convenient places like harnessconnectors (G) and (I) and light terminal (K) until light(J) goes OFF.

The short circuit will be between the last two placesthe circuit was disconnected. In the example, it isbetween harness connectors (G and I). Light (J) will goOFF when harness connector (I) is disconnected.Inspect harness between connectors (G and I).


PN=31



208

DPSG,OUO1004,664 1915MAR992/2

Repair or replace wires and harnesses as needed.Install tie bands and clamps on harnesses as requiredto prevent future problems.


DPSG,OUO1004,665 1915MAR991/1

Multimeter

T807

4AA

19

03S

EP93

ADisplayBVoltage AC (Alternating Current)CVoltage DC (Direct Current)DResistanceEDiode Test/ContinuityFCurrent AC (Alternating Current)GCurrent DC (Direct Current)HVoltage, Resistance, Diode/Continuity (Red Lead

Input)IGround (Black Lead Input)JCurrent/Amps (Red Lead Input)

The multimeter is an autoranging digital display thatallows very accurate readings to be taken.


PN=32


209

DPSG,OUO1004,666 1915MAR991/2

Seven Step Electrical Test Procedure

T771

9AA

19

05M

AR92

ABattery Ground DFuse or Circuit Breaker GBattery Side of Component IGround Side of ComponentBBattery EComponent Side of Fuse or Terminal TerminalCBattery Side of Fuse or Circuit Breaker HLight (Component) JComponent Ground

Circuit Breaker FSwitch

Step 1Switch ONCheck battery side of circuit breaker (C) for battery voltage. Battery voltage normal, go to Step 2.

Low voltage, repair high resistance. Open circuit from battery.Step 2Switch OFFCheck component side of circuit breaker (E) for battery voltage. Battery voltage normal, go to Step 4.

Low voltage, repair high resistance.No voltage, go to Step 3.



PN=33


2010

DPSG,OUO1004,666 1915MAR992/2

Step 3Switch OFFCheck component side of circuit breaker (E) for continuity to ground. Continuity to ground, repair grounded circuit at or before switch.

No continuity to ground, replace circuit breaker.Step 4Switch ONCheck component side of circuit breaker (E) for battery voltage. Battery voltage normal, go to Step 6.

Low voltage, repair high resistance.No voltage, go to Step 5.

Step 5a

Disconnect wire at battery side of component (G). Switch ON. Check Battery voltage, repair component.wire at (G) for battery voltage. No voltage, repair grounded or open circuit at or after switch.Step 6Switch ONCheck lead to component at (G) for battery voltage. Battery voltage normal, go to Step 7.

Low voltage, repair high resistance in circuit between fuse andcomponent.No voltage, repair high resistance or open circuit between fuse andcomponent.

Step 7Switch ONCheck ground wire of component at (I) for voltage. No voltage, good continuity to ground, repair component.

Voltage, poor continuity to ground, repair high resistance or openground circuit.

aA multimeter will not apply a load to the circuit at Step 5. The multimeter result is tested as a voltage condition in the result column.


PN=34


2011

DPSG,OUO1004,667 1915MAR991/2

Wiring Diagram and Schematic Information

T859

58UN

27F

EB90

System Functional Schematic Diagram

The System Functional Schematic is a schematic diagramof the complete machine. All harnesses are identified byletter/number designation and description (W1 EngineHarness, W2 Dash Harness, etc.). Each wire is identifiedby number and/or color (G01 BLK, R02 RED, RED/WHT,BLU/GRN, etc.). All components are identified byletter/number designation, description and are representedby a schematic symbol. Component letter/numberdesignation (K1 Start Relay, S1 Key Switch, B9 Horn,etc.) will indicate that component throughout the manual.The System Functional Schematic Diagram is divided intoSections. Each section contains one or more electricalcircuits. Each section is indicated by a number and circuit(SE1 CHARGING CIRCUIT, SE2 STARTING CIRCUIT,etc).

Wiring Diagram

The Wiring Diagram shows each wiring harness, wirecolor, wire destination, harness connectors and schematicsymbols for each electrical component connected to thatharness. Harnesses are identified by the sameletter/number designation and description used in theSystem Functional Schematic Diagram (W1 EngineHarness, W2 Dash Harness, etc.). Each componentschematic symbol will be identified by the sameletter/number designation used in the System FunctionalSchematic Diagram. Harness connectors will be identifiedby a letter/number designation and description (X1 CABHARNESS TO ENGINE HARNESS CONNECTOR, X3DASH HARNESS TO HEATER BLOWER HARNESSCONNECTOR, etc.).

Component Location Diagram

The Component Location Diagram is a pictorial view byharness showing location of all electrical components,connectors, harness main ground locations and harnessband and clamp location. Each component will beidentified by the same identification letter/number anddescription used in the System Functional SchematicDiagram.


PN=35



2012

DPSG,OUO1004,667 1915MAR992/2

NOTE: All System Functional Schematics, CircuitSchematics and Wiring Diagrams are shown withkey switch in the off position.


PN=36


2013

DPSG,OUO1004,668 1913SEP021/1

Reading a System Functional Schematic

T750

2CE

19

29M

AY91

APower Wires DComponent Identification EComponent Name GCircuit NameBContinuity Chart Code FGround Wires HSection NumberCComponent Schematic

Symbol

The System Functional Schematic is made up ofsections which contain one or more SubsystemFunctional Schematics laid out side by side in a logicalsequence of related functions. Each Subsystem is amajor group of components like starting components orcharging components (H). Sections are named toreflect that group of components (G). The SystemFunctional Schematic is formatted with power supplywires (A) shown across the top of the drawing andground wires (F) across the bottom. The diagramcontains no harness or connector information.

Each electrical component is shown by a schematicsymbol (C), the component name (E), and a

component identification code (D). A continuity chart(B) is included for each multi-terminal switch.

The same names and identification letter codes areused on all machine drawingsthe System FunctionalSchematic, System Wiring and Harness Diagram, andthe System Component Location Drawing.Components and connectors can easily becross-referenced from one drawing to another.

See the following pages for Electrical SchematicSymbols and the Component Identification Table.


PN=37


2014

DPSG,OUO1004,669 1915MAR991/1

Reading a Wiring Diagram

T853

4AC

19

10A

UG95

AHarness Connector DComponent Connector GHarness Identification JWire Number and/or ColorLetter/Number EWire Number and/or Color Letter/Number and KHarness Connector PinIdentification FComponent(s) Identification Description Number or Letter

BComponent Letter/Number Number/Letter Wire Is HWiring HarnessIdentification Routed To IComponent(s) Identification

CComponent Connector Pin Number/Letter Wire IsNumber or Letter Routed To

Each harness on the machine is drawn showingcomponents, connectors and wires. Harnesses (G) areidentified by a letter/number designation anddescription (W3 PARK BRAKE HARNESS, etc.).

Each component (B) is represented by a schematicsymbol and is identified by the same letter/numberdesignation and description used in the SystemFunctional Schematic. Components with integralconnectors (D) have pin number/letters indicated (C).Wires from harness to components are identified bynumber and/or color designation (E). Componentidentification letter/number (F) indicates componentwire is routed to.

Main harness connectors (A) are identified by aletter/number designation and description (X2 PARKBRAKE HARNESS TO DASH HARNESSCONNECTOR, etc.). Harness connector descriptionindicates which harnesses connect together.Connector pin numbers or letters (K) are indicated asthey are marked on the connector. Wires attached toeach connector pin are identified by number and/orcolor designation (J). Component identificationnumber/letter (I) indicates destination of each wire.

Harness, harness connector and componentidentification letter/numbers and description are thesame as used on the System Functional Schematic.


PN=38


2015

DPSG,OUO1004,670 1915MAR991/3

Electrical Schematic Symbols

T771

9BA

19

11O

CT93


PN=39



2016

DPSG,OUO1004,670 1915MAR992/3

T771

9BB

19

11O

CT93


PN=40



2017

DPSG,OUO1004,670 1915MAR993/3

T829

5BI

19

04D

EC94


PN=41


2018

DPSG,OUO1004,671 1913SEP021/2

Component Identification Table

Each component (electrical device) and main connectorwill have an identification letter assigned to it. A number isadded to the letter to separate and indicate the totalcomponents within that letter group.

Identification Letter Type ExamplesA System, subassembly, parts group Control units, trigger boxes, two-way radios, logic module, FNR

logic moduleB Transducer for conversion of Speed sensors, pressure sensors, pressure switches horns,

non-electrical variables to electrical and sensors, pickups, limit-value sensors, pulse generators,vice versa loudspeakers, inductive pickups, probes, air-flow sensors,

oil-pressure switches, temperature sensors, ignition-voltage pickupsC Condenser, capacitor Condensers and capacitors, generalD Binary device, memory Digital devices, integrated circuits, pulse counters, magnetic tape

recordersE Various devices and equipment Heating devices, air conditioners, light, headlights, spark plugs,

ignition distributorsF Protection device Release mechanisms, polarity protection devices, fuses, current

protection circuitsG Power supply, generator Batteries, generators, alternators, charging unitsH Monitor, alarm, signalling device Audible alarms, indicator lights, turn-signal lights, brake lights,

alarms, warning lights, buzzersK Relay Battery relays, turn-signal relays, solenoid switches, starting relays,

warning flashersL Inductor Choke coils, coils, windingsM Motor Blower motors, fan motors, starter motorsN Regulator, amplifier Regulators (electronic or electromechanical), voltage stabilizersP Measuring instrument Ammeter, diagnostic connectors, tachometers, fuel gauge, pressure

gauges, measuring points, test points, speedometersR Resistor Flame glow plugs, sheathed-element flame glow plugs, glow plugs,

heating resistors, NTC resistors, PTC resistors, potentiometers,regulating resistors



PN=42


2019

DPSG,OUO1004,671 1913SEP022/2

Identification Letter Type ExamplesS Switch Switches and push-button, general key switch, light switch, horn

switch, flasher switchT Transformer Ignition coil, ignition transformerU Modulator, converter DC transformersV Semiconductor, electron tubes Transistors, diodes, electron tubes, rectifiers, semiconductors,

thyristors, zener diodesW Transmission path, conductor, antenna Antennas, shielding components, shielded conductors, cable

harnesses, conductors, ground conductorsX Terminal, plug, plug and socket Terminal studs, electrical connections, connectors electrical line

connection couplers, line connectors, sockets, plugs, terminals, plug-and-socketconnections

Y Electrically actuated mechanical device Permanent magnets, (solenoid-operated) injection valves,electromagnetic clutches and brakes, air valves, fuel pumps,solenoids, switching valves, start valves, locking systems

Z Electrical filter Interference suppression filters


PN=43


2020

DPSG,OUO1004,672 1915MAR991/1

Engine Wiring Diagram LegendNorth American Series 300, 400, 500 and 700 Enginesand Early Model European (Saran) Series 300 EnginesA1 Speed Control UnitB1 Magnetic Speed SensorB2 Coolant Temperature SensorB3 Oil Pressure SensorF1 Starting Circuit Fuse (25 amp)F2 Safety Switch Fuse (14 amp)F3 Tachometer Fuse (3 amp)G1 BatteryG2 AlternatorH1 Coolant Temperature Indicator LampH2 Oil Pressure Indicator LampH3 Alternator Indicator LampK1 Starter RelayK2 Fuel Shut-off RelayM1 Starter MotorP1 Coolant Temperature Gauge

P2 Oil Pressure GaugeP3 Crankcase Oil Level Switch/GaugeP4 TachometerP5 Hourmeter1P6 AmmeterR1 Resistor (48 ohm)S1 Key SwitchS2 Magnetic Safety SwitchNorth AmericanAuto Override ModuleEuropean (Saran)X1 To Meter GroundX2 To Y2 Fuel Shut-Off SolenoidX3 X4 Power to MetersX5 To Ignition Switch (IGN)Y1 Starter SolenoidY2 Fuel Shut-off Solenoid

1 On North American Series 300 engines without electronictachometer: Early Units A purple wire (shown as a dashed line inwiring diagram) connects between hourmeter P5 and key switchS1. Later Units And All Other North American Series 400 And 500EnginesThe wire (shown as a solid line) connects between thehourmeter and magnetic safety switch S2 (C terminal).


PN=44


2021

RG,CTM67,G20,2 1919NOV931/1

Wiring DiagramNorth American Series 300, 400 and 500 Engines

RG

9538

UN

08A

PR99


PN=45


2022

RG,CTM67,G20,3 1919NOV931/1

Wiring DiagramNorth American Series 700 (8955) Engines

RG

9536

UN

08A

PR99


PN=46


2023

RG,CTM67,G20,4 1919NOV931/1

Wiring DiagramEuropean (Saran) Series 300 Engines (Early Model)

RG

9535

UN

08A

PR99


PN=47


2024

DPSG,OUO1004,626 1909MAR991/1

Engine Wiring Diagram Legend POWERTECH 2.9 L, 4.5 L, 6.8 L and 8.1 L Engines(Without ECU)A1 Speed Control UnitB1 Magnetic Speed SensorB2 Coolant Temperature SensorB3 Oil Pressure SensorF1 Starting Circuit Fuse (14 amp)F3 Fuse (Early Models)1G1 BatteryG2 AlternatorH1 Coolant Temperature Indicator LampH2 Oil Pressure Indicator LampH3 Alternator Indicator LampK1 Starter RelayK2 Fuel Shut-off RelayM1 Starter Motor

P1 Coolant Temperature GaugeP2 Oil Pressure GaugeP3 Crankcase Oil Level Switch/GaugeP4 Tachometer1P5 Hourmeter (Early Models)2P6 AmmeterR1 Resistor (48 ohm)3S1 Key SwitchS2 Magnetic Safety SwitchNorth AmericanAuto Override ModuleEuropean (Saran)W1 Ground on K1 Starter Relay Mounting StudY1 Starter SolenoidY2 Fuel Shut-off Solenoid4

POWERTECH is a registered trademark of Deere & Company

1 P4 tachometer has a built-in hourmeter. On some earlier engines,a separate hourmeter (P5) and fuse (F3) were used.2 P4 tachometer has a built-in hourmeter. On some engines, aseparate hourmeter (P5) and fuse (F3) are used.3 Later harnesses have two parallel 100 ohm resistors for thealternator.

4 Y2 Fuel Shut-Off Solenoid shown is for 3-wire in-line fuel injectionpump. Single connection rotary pumps will have one dark blue wirefor power and one black wire for ground.


PN=48


2025

DPSG,OUO1004,627 1909MAR991/1

Engine Wiring Diagram POWERTECH 2.9 L, 4.5 L, 6.8 L and 8.1 L Engines (Without ECU)

RG

9537

UN

08A

PR99



PN=49


2026

DPSG,OUO1004,731 1922MAR991/1

Engine Wiring Diagram Legend POWERTECH 10.5 L and 12.5 L Engines (With LucasECU)1

F1 Starting Circuit Fuse (30 amp)G1 AlternatorK1 Alternator Field RelayK2 Starter RelayK3 Analog Tachometer DisplayM1 Starter Motor

P1 Coolant Temperature GaugeP2 Engine Oil Pressure GaugeR1 Resistor 47 ohmS1 Key SwitchS2 Shut-Off SwitchS3 Tachometer Toggle Switch


1Wiring diagram shown does not show ECU (Engine Control Unit)components. See engine Operation and Diagnostics ManualCTM115 for ECU components and wiring diagrams.


PN=50


2027

DPSG,OUO1004,732 1922MAR991/1

Engine Wiring Diagram POWERTECH 10.5 L and 12.5 L Engines (With Lucas ECU)

RG

9502

UN

24M

AR99



PN=51


2028

DPSG,OUO1004,864 1905MAY991/1

Engine Wiring Diagram POWERTECH 8.1 L, 10.5 L and 12.5 L Engines (With John DeereECU)

RG

1003

919

18M

AY99

B1Analog Throttle or N2Voltage Regulator (for R1Resistor X1Vehicle HarnessEmulator 24V Operation) S1Ignition Key Switch Connector

E1Back Light Regulator P1Optional Gauge S2Speed Select Switch X2Alternator Harness(24V) or Plug (12V) P2Optional Gauge (Momentary) Connector

F1Fuse (30 Amp) P3Oil Pressure Gauge S3Bump Enable Switch X3Single Point GroundF2Fuse (5 amp) P4Coolant Temperature (Momentary) X4CAN TerminatorG1Alternator Gauge S4High-Low Speed Switch X5Analog ThrottleK1Starter Relay P5Tachometer Display S5Override Shutdown ConnectorM1Starter Motor P6Hourmeter/Diagnostic Switch (Momentary)N1Transient Voltage Meter S6Dimmer Control or

Protector Jumper Plug



PN=52


2029

DPSG,OUO1004,865 1905MAY991/1

Engine Wiring Diagram POWERTECH 8.1 L, 10.5 L and 12.5 L Engines (With John DeereECU) (Continued)

RG

1004

019

18M

AY99

B1Analog Throttle or N2Voltage Regulator (for R1Resistor X1Vehicle HarnessEmulator 24V Operation) S1Ignition Key Switch Connector

E1Back Light Regulator P1Optional Gauge S2Speed Select Switch X2Alternator Harness(24V) or Plug (12V) P2Optional Gauge (Momentary) Connector

F1Fuse (30 Amp) P3Oil Pressure Gauge S3Bump Enable Switch X3Single Point GroundF2Fuse (5 amp) P4Coolant Temperature (Momentary) X4CAN TerminatorG1Alternator Gauge S4High-Low Speed Switch X5Analog ThrottleK1Starter Relay P5Tachometer Display S5Override Shutdown ConnectorM1Starter Motor P6Hourmeter/Diagnostic Switch (Momentary)N1Transient Voltage Meter S6Dimmer Control or

Protector Jumper Plug



PN=53


2030

OURGP12,0000145 1925AUG051/1

Engine Wiring DiagramPowerTech Plus 4.5 L, 6.8 L, 9.0 L and 13.5 L Engines

RG

1387

4UN

08A

PR05

B1Analog Throttle F01Fuse (30 Amp)(System) P5Tachometer Display S5Override ShutdownC06Alternator Harness F02Fuse (20 Amp)(ECU) P6Hour Meter/Diagnostic Switch (Momentary)

Connector F03Fuse (15 Amp)(Fuel Gauge V1DiodeC12Transient Voltage Filter) S1Ignition Key Switch X1Vehicle Harness

Protector G1Alternator S2Speed Select Switch ConnectorC13Starter Relay M1Starter Motor (Momentary) X4CAN TerminatorC14Starter Relay P1Optional Gauge S3Bump Enable Switch X5Analog ThrottleC15Remote On/Off P2Optional Gauge (Momentary) ConnectorC16Battery P3Oil Pressure Gauge S4High-Low Speed SelectC17Single Point Ground P4Coolant Temperature Switch

Gauge


PN=54


2031

OURGP12,0000146 1925AUG051/1

Engine Wiring DiagramPowerTech Plus 4.5 L, 6.8 L, 9.0 L and 13.5 L Engines(Continued)

RG

1387

3UN

08A

PR05




Gauge


PN=55


2032

OURGP12,0000147 1925AUG051/1

Engine Wiring DiagramPowerTech Plus 4.5 L, 6.8 L, 9.0 L and 13.5 L Engines(Continued)

RG

1327

2UN

26J

AN04




Gauge


PN=56


2033

DPSG,OUO1004,779 1907APR991/1

Engine Wiring DiagramSaran AEZ Instrument Panel

RG

9539

UN

19A

PR99

ABlue GBlue MSky Blue SElectrical Shut-OffBRed HBrown NRed TAlternatorCGrey IGrey OFuse (16 amp) UOil Pressure SensorDBlack JPink PPreheater VCoolant TemperatureEOrange KYellow QBattery SensorFGreen LWhite RStarting Motor WFuel Tank Sending Unit


PN=57


2034

DPSG,OUO1004,628 1909MAR991/1

Engine Wiring Diagram LegendSaran VDO Instrument Panel

A 6 mm2, RedB 1.5 mm2, BlackC 6 mm2, BlueD 4 mm2, BlackE 0.75 mm2, OrangeF 0.75 mm2, WhiteG 0.75 mm2, BlueH 0.75 mm2, PurpleI 0.75 mm2, GreyJ 0.75 mm2, BrownK 0.75 mm2, Dark BlueL 0.75 mm2, Black

M 0.75 mm2, Green/YellowN 0.75 mm2, RedOR Not UsedS PreheaterT BatteryU Starting MotorV Electrical Shut-OffW AlternatorX Oil Pressure SensorY Coolant Temperature SensorZ Fuel Tank Gauge


PN=58


2035

DPSG,OUO1004,629 1909MAR991/1

Engine Wiring DiagramSaran VDO Instrument Panel

CD62

3P5

UN

13N

OV9

8


PN=59


2036

OURGP12,000016E 1914OCT051/1

Engine Wiring DiagramPowerTech 2.4L and 3.0L Engines

RG

1435

3UN

07D

EC05

ATo Preheater GTo Alternator LFuse (10 amp) QAlternatorBTo Battery/Starting Motor HTo Oil Pressure Switch MPreheater ROil Pressure SensorCTo Solenoid ITo Oil Pressure Sensor NBattery SCoolant TemperatureDTo Ground JTo Coolant Temperature OStarting Motor SensorETo Electrical Shut-Off Switch PElectrical Shut-OffFTo Alternator KTo Coolant Temperature

Sensor


PN=60

Group 21Electrical System Diagnostics, Tests and Operation

211

DPSG,OUO1004,644 1910MAR991/2

Service Equipment and Tools

NOTE: Order tools according to information given in theU.S. SERVICEGARD Catalog or from theEuropean Microfiche Tool Catalog (MTC). Sometools may be available from a local supplier.

SERVICEGARD is a trademark of Deere & Company

DPSG,OUO1004,644 1910MAR992/2

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Used to make the required measurements in thediagnostic procedures.

DPSG,OUO1004,646 1910MAR991/1

Electrical System Specifications

Item Measurement Specification

Oil Pressure Gauge Switch

Engines with Distributor Type Pressure Closes at 100 kPa (1 bar) (15 psi)Injection Pump

Series 400 and 500 Engines Pressure Closes at 69 kPa (0.69 bar) (10 psi)

Series 700 Engines Pressure Closes at 140 kPa (1.4 bar) (20 psi)

Coolant Temperature Gauge Switch Temperature Contacts close at 104 C (220 F)

Magnetic Safety Switch Coil Approximate Current Draw 0.7 amps at 12 volts1.4 amps at 24 volts


PN=61

Electrical System Diagnostics, Tests and Operation

212

DPSG,OUO1004,635 1910MAR991/1

General Information

NOTE: This group covers optional electrical controls andinstruments that are available on John DeereOEM Engines. They may be provided by theequipment manufacturer instead of the JohnDeere factory. The following information appliesonly to those controls and instruments provided bythe John Deere factory.

The electrical system has a negative ground and is eithera 12-volt or 24-volt system. Fuses are strategically placedin the system to protect related circuits and components.

NOTE: Location and sizes of system fuses vary byapplication.

System Fuses:

25-amp MDL Located between the ammeter and thekey switch.

14-amp SFE Located on the magnetic safety switch. 3-amp MDX Located between the tachometer and

safety switch. 3-amp Located between the fuel shut-off and safety

switch. 5, 14 or 30-amp Located in fuse holder on front of

instrument panel. 10-amp Located on control circuit card of Saran VDO

instrument panel. 16-amp In-line fuse located behind instrument panel

on Saran AEZ panel.


PN=62


213

OURGP12,0000169 1908SEP051/3

Component FunctionInstrument Panel(Without ECU)

RG

1152

7UN

01D

EC00

PowerTech 2.9 L- 8.1 L (W/O ECU) Panel Shown

AOil Pressure GaugeBCoolant Temperature GaugeCKey SwitchDTachometerEReset Safety SwitchFFuse Holder (14 Amp Fuse)GAmmeterHHour MeterIHand Throttle

IMPORTANT: Any time an electric gauge or meterdoes not register correctly, replace witha new one. Do not attempt to repair it.

The instrument panel may consist of the followingcomponents:

Hand throttle (if equipped) Hour meter Ammeter Oil pressure gauge Coolant temperature gauge Key switch Safety switch (reset button) Tachometer Fuse holder

Hand Throttle

NOTE: Engines equipped with electronic fuel injection oran electric governor do not use a hand throttle.

The hand throttle is used to manually control enginespeed. Turning the handle, either clockwise orcounterclockwise, will lock the throttle position. Turn thehandle half way between the two lock positions to unlockthe throttle.



PN=63


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Hour Meter

NOTE: On some instrument panels, the hour meter maybe an integral part of the tachometer. The electrichour meter shows the accumulated hours ofengine service. The hour meter operates whenthe engine is operating, or when the reset b

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Ctm67 Powertech Oem Engine Accesories