John Deere 2254 Cane Loader Repair Technical Manual - PDF DOWNLOAD

2254 Cane Loader Repair

TECHNICAL MANUAL 2254 Cane Loader Repair TMCM225401 04OCT06 (ENGLISH)

John Deere Thibodaux Litho in U.S.A.

Introduction Foreword This manual is written for an experienced technician.

Essential tools required in performing certain service work are identified in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specification, wear tolerances, and torque values.

Technical manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.

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

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Contents 10

SECTION 10—General Group 05—Safety Group 10—Machine Specifications Group 15—General References Group 25—Fluid Recommendations

20

SECTION 20—Engines Group 05—General Information SECTION 40—Electrical System Group 10—General Information

40

SECTION 50—Hydrostatic System Group 10—Pumps & Motors Group 20—Minor Pump Repairs Group 30—Displacement Control Components

50

SECTION 60—Steering System Group 10—Repair SECTION 70—Hydraulic System Group 10—Pumps & Valves Group 20—Hydraulic Checks Group 30—Hydraulic Cylinder

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SECTION 99—Service Tools Group 10—Service Supplies

70

99

INDX

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

COPYRIGHT  2006 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION Manual

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Section 10

General Contents Page

Page

Group 05—Safety . . . . . . . . . . . . . . . . . . . . . .10-05-1

Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . .10-25-2 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25-2 Tire Inflation Pressure1 . . . . . . . . . . . . . . . . . . .10-25-2 Pump Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25-3 Engine Coolant Requirements1 . . . . . . . . . . . . .10-25-3 Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25-4 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25-4 Inhibitors (Conditioners) . . . . . . . . . . . . . . . . . .10-25-5 Filling the System . . . . . . . . . . . . . . . . . . . . . . .10-25-5 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . .10-25-6 Sulphur Content . . . . . . . . . . . . . . . . . . . . . . . .10-25-6 Cetane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25-7 Cloud Point . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25-7 Storage and Handling . . . . . . . . . . . . . . . . . . . .10-25-7 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . .10-25-8 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25-9 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . .10-25-10 Gear Oil - Pump Drive. . . . . . . . . . . . . . . . . . .10-25-10 Gear Oil - Final Drive . . . . . . . . . . . . . . . . . . .10-25-10 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25-10

Group 10—Machine Specifications Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . .10-10-1 Visually Inspect Hydraulic Systems . . . . . . . . . .10-10-3 Hydraulic System Testing Precautions . . . . . . .10-10-5 Visually Inspect Electrical System . . . . . . . . . . .10-10-6 Electrical System Safety Precautions . . . . . . . .10-10-7 Machine Specifications . . . . . . . . . . . . . . . . . . .10-10-8 Loading System . . . . . . . . . . . . . . . . . . . . . . .10-10-14 Traction System . . . . . . . . . . . . . . . . . . . . . . .10-10-15 Front Axle Motor . . . . . . . . . . . . . . . . . . . . . . .10-10-15 Steering System . . . . . . . . . . . . . . . . . . . . . . .10-10-15 Piler Chain System (Optional Hydraulic Piler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-16 Grab and Lift Hydraulic Schematic . . . . . . . . .10-10-17 Steer, Swing Flex and Piler Lift Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-18 Joystick Control Valve Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-19 Optional Hydraulic Piler Schematic . . . . . . . . .10-10-20 Hydrostatic Transmission Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-21 Propulsion Schematic - High Traction Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-22 Conversions . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-23 Unified Inch Bolt and Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-25 Metric Bolt and Screw Torque Values . . . . . . .10-10-26 Group 15—General References Glossary of Terms. . . . . . . . . . . . . . . . . . . . . . .10-15-1 Visually Inspect Electrical System . . . . . . . . . . .10-15-5 Seven-Step Electrical Procedure . . . . . . . . . . . .10-15-7 Understanding Electrical vs. Electronic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-15-10 Intermittent Electronic Problems . . . . . . . . . . .10-15-12 Relay Circuit Types . . . . . . . . . . . . . . . . . . . . .10-15-16 Using a Digital Multimeter . . . . . . . . . . . . . . . .10-15-29 Troubleshooting Unresolved Problems . . . . . .10-15-30 Group 25—Fluid Recommendations Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25-1 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . .10-25-1 Rear Steering Axle . . . . . . . . . . . . . . . . . . . . . .10-25-1 Front Rigid Axle . . . . . . . . . . . . . . . . . . . . . . . .10-25-2 TMCM225401 (04OCT06)

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Group 05

Safety 10 05 1

Service Safety When a service person or mechanic is unfamiliar with all systems on this equipment, extra caution should be used when performing service work. A good working knowledge of the system and its components is important for removal or disassembly. The following is a list of basic precautions that should always be observed.

1. Make sure you read and understand all warning plates and decals before lubricating or performing other maintenance.

2. Always wear protective glasses and footwear when working. In particular, wear safety glasses when pounding on any part of the machine or attachments with a hammer. Use welding goggles or a face shield and use protective clothing when welding. Do not wear any loose fitting or torn clothing. Remove all rings from fingers before working on equipment.

3. Before starting work on the machine, turn disconnect master power switch to off position and hang a DO NOT OPERATE sign in the operator’s station. Also, remove key from inside cab when “Do not Start” tag is placed.

4. If at all possible, make all repairs with the machine parked on level ground. Block the machine so it cannot roll. DO NOT work on any machine that is supported only by lift jacks or a hoist.

5. Lower all implements to the ground before performing any work on the machine. If this cannot be done, make sure the implement is properly blocked to prevent it from dropping unexpectedly.

6. Relieve all pressure in air, oil, or water systems before any lines, fittings, or related parts are disconnected or removed. Always make sure that all raised components and implements are correctly blocked. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure.

7. To avoid back injuries, use a hoist when lifting components that weigh over 23 kg (50 lb). When using a hoist, make sure all hooks are correctly positioned.

8. To avoid burns, be alert for hot parts located on the machine after it has stopped. Be particularly careful of hot fluids in lines, tubes, and components.

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Safety 10 05 2

9. Be careful when removing cover plates. Gradually loosen the last two bolts or nuts located at the opposite ends of the cover or device. Carefully pry the cover loose to relieve any spring or other tension before removing it completely.

10. Be careful when removing filler caps, breathers, or plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by fluids under pressure.

11. Always use tools that are in good condition. Before performing any service, make sure you know how to use the proper tools. Use correct size tools to prevent damage to fasteners, etc.

12. Replace all fasteners with the same SAE or metric grade. Never substitute a softer part where a hardened part is used, conversely never substitute a harder part where a softer part is used.

13. Take precautions to prevent damage to wiring during removal. After re-installing the wiring, double check to make sure it is was not damaged during removal or installation. Ensure that the wiring does not touch any hot, sharp, or moving parts after it is installed.

Visually inspect wires and wire harnesses for damaged wire covering and exposed wires — repair or replace as required.

14. Ensure that all protective devices and guards are properly installed and are functioning correctly before starting any repairs. If a guard or shield must be removed to perform repair work, use extra caution while working.

15. Escaping fluid under pressure can have sufficient force to penetrate the skin. Therefore, before disconnecting any lines, be sure all pressure in the system is relieved. Before applying pressure, make sure all lines, fittings, and connections are tight and undamaged. Boom should be fully lowered, flex cylinder extended until grab tines are at rest on ground and piler should be lowered.

16. If you are injured by escaping fluid under pressure, see a doctor at once. A serious infection or reaction may result if proper medical attention is not received immediately.

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Safety 10 05 3

CAUTION: Liquid escaping from a very small hole can be almost invisible. Use wood or cardboard, instead of your hand, when searching for suspected leaks.

17. Avoid working on equipment with the engine running.

If it is absolutely necessary to make checks with the engine running, always use two men: one to operate the controls and the other to work where the operator can see him. The transmission must be in neutral, the braking system set, and all pertinent safety locks set.

18. Pick up tools and maintain area clear of other materials that can cause a trip hazard.

T803584,00001D4 –19–16OCT00–3/3

Recognize Safety Information

T81389

Follow recommended precautions and safe operating practices.

–UN–07DEC88

This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

DX,ALERT –19–29SEP98–1/1

Understand Signal Words

TS187

DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.

–19–30SEP88

A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards.

DX,SIGNAL –19–03MAR93–1/1

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Safety

Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer.

TS201

Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.

–UN–23AUG88

Follow Safety Instructions

Keep your machine in proper working condition.

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

If you do not understand any part of this manual and need assistance, contact your John Deere dealer.

DX,READ –19–03MAR93–1/1

Use Seat Belt Properly

–UN–05JAN89

Use a seat belt when you operate the loader to minimize the chance of injury from an accident.

RW16064

10 05 4

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Safety 10 05 5

Protect Bystanders

CM999999009

–UN–10NOV00

Be sure everyone is clear of the equipment before starting the engine or moving the steering wheel. Blow horn before starting engine to make sure everyone is clear.

T803584,00001DB –19–16OCT00–1/1

Use Handles and Steps

CM989999006

–UN–06JAN00

Clean off mud, grease, and any crop residue that may have accumulated on the steps and operator’s platform of your equipment. Remember that chains and tools carried on the platform may interfere with pedal operation or cause a fall from the equipment. Remove them.

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Safety 10 05 7

Handle Fluids Safely—Avoid Fires

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

TS227

Do not store oily rags; they can ignite and burn spontaneously.

–UN–23AUG88

When you work around fuel, do not smoke or work near heaters or other fire hazards.

DX,FLAME –19–29SEP98–1/1

Prevent Battery Explosions

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

TS204

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

–UN–23AUG88

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

DX,SPARKS –19–03MAR93–1/1

Prepare for Emergencies Be prepared if a fire starts.

TS291

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

–UN–23AUG88

Keep a first aid kit and fire extinguisher handy.

DX,FIRE2 –19–03MAR93–1/1

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Safety

Prevent Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by: 1.

2.

3.

4.

5.

Filling batteries in a well-ventilated area.

Wearing eye protection and rubber gloves.

Avoiding breathing fumes when electrolyte is added.

Avoiding spilling or dripping electrolyte.

Use proper jump start procedure.

If you spill acid on yourself:

–UN–23AUG88

1. Flush your skin with water.

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

3. Flush your eyes with water for 15—30 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 quarts).

3. Get medical attention immediately.

TS203

10 05 8

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Safety 10 05 9

Handle Chemical Products Safely

Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

TS1132

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

–UN–26NOV90

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.

(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)

DX,MSDS,NA –19–03MAR93–1/1

Avoid High-Pressure Fluids

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

X9811

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

–UN–23AUG88

Escaping fluid under pressure can penetrate the skin causing serious injury.

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

DX,FLUID –19–03MAR93–1/1

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Safety

Park Machine Safely

Lower all equipment to the ground.

Stop the engine and remove the key.

Disconnect the battery ground strap.

Hang a "DO NOT OPERATE" tag in operator station.

TS230

• • • •

–UN–24MAY89

Before working on the machine:

DX,PARK –19–04JUN90–1/1

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.

Follow recommended procedures in this manual.

TS229

Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices can settle or leak down.

–UN–23AUG88

Support Machine Properly

When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator’s manual.

DX,LOWER –19–24FEB00–1/1

Wear Protective Clothing

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

–UN–23AUG88

Wear close fitting clothing and safety equipment appropriate to the job.

TS206

10 05 10

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

DX,WEAR –19–10SEP90–1/1

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Safety 10 05 11

Work in Clean Area

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.

T6642EJ

• • • •

–UN–18OCT88

Before starting a job:

DX,CLEAN –19–04JUN90–1/1

Service Machines Safely

TS228

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

–UN–23AUG88

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

DX,LOOSE –19–04JUN90–1/1

Work In Ventilated Area

TS220

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

–UN–23AUG88

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

DX,AIR –19–17FEB99–1/1

TS223

Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage.

The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

–UN–23AUG88

Illuminate Work Area Safely

DX,LIGHT –19–04JUN90–1/1

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Safety

Replace Safety Signs

TS201

–UN–23AUG88

Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

DX,SIGNS1 –19–04JUN90–1/1

Use Proper Lifting Equipment Lifting heavy components incorrectly can cause severe injury or machine damage.

–UN–23AUG88

Follow recommended procedure for removal and installation of components in the manual.

TS226

10 05 12

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Safety 10 05 13

Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust.

• Remove paint a minimum of 100 mm (4 in.) from area to 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 with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

TS220

Remove paint before heating:

–UN–23AUG88

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

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

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

Dispose of paint and solvent properly.

DX,PAINT –19–24JUL02–1/1

TS953

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

–UN–15MAY90

Avoid Heating Near Pressurized Fluid Lines

DX,TORCH –19–10DEC04–1/1

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Safety

Use Caution on Hillsides Avoid holes, ditches, and obstructions that may cause the equipment to tip, especially on hillsides.

Never drive near the edge of a gully or steep embankment because it may cave in.

Before operating on extremely steep slopes, ensure oil is at or above upper sight glass.

CM999999011

Keep hydraulic oil level at upper level when operating on hillsides. Low oil level might result in loss of steering. If this should happen, hold equipment with brakes, shift to NEUTRAL, apply park brake, stop engine, and add hydraulic oil to proper level.

–UN–10NOV00

For hillside operation, always load uphill, not downhill.

Avoid sharp, uphill turns.

T803584,000025C –19–17OCT00–1/1

The loader should be operated with the boom flexed in (Flex Cylinder Extended) or as near as possible to the flexed-in position when picking up cane and with loaded grab for maximum stability.

As boom is flexed out or extended (Flex Cylinder Destroked) with a loaded grab, the extended boom and grab weight may exceed the loaders counterweight and begin to tip, especially when the boom is swung to the full right position.

–UN–24JAN06

Use Caution When Flexing (Extending) Boom

CM061850002

10 05 14

Extending a heavy load or swinging it to the side may cause machine to tip.

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Safety 10 05 15

Stopping and Parking Your ability to stop your equipment and park it safely is just as important as being able to get it underway safely.

Equipment, collisions, runaway tractors, and people being crushed under machines can happen when operators ignore safety.

Do Not Put Hand through Steering Wheel when Starting Unit.

Shut off engine. Remove radiator filler cap when cool enough to touch with bare hand. To relieve pressure, slowly loosen cap to first stop, and then remove completely.

To avoid these accidents, take some precautions: • Signal before stopping, turning, or slowing down on highways.

• Pull over to right-hand shoulder of highway • Slow down before braking.

• Shift to neutral/park and set parking brake.

• Lower all equipment when leaving unit.

• Turn off all electrical switches and remove key.

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Safety

Service Tires Safely Explosive separation of a tire and rim parts can cause serious injury or death.

Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.

Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion.

Welding can structurally weaken or deform the wheel.

Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

–UN–23AUG88

When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.

TS211

10 05 16

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Safety 10 05 17

Practice Safe Maintenance Understand service procedure before doing work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.

Securely support any machine elements that must be raised for service work.

On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.

TS218

On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.

–UN–23AUG88

Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts.

Remove any buildup of grease, oil, or debris.

DX,SERV –19–17FEB99–1/1

Use Proper Tools

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

TS779

Use power tools only to loosen threaded parts and fasteners.

–UN–08NOV89

Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

Use only service parts meeting John Deere specifications.

DX,REPAIR –19–17FEB99–1/1

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Safety

Dispose of Waste Properly

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

TS1133

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

–UN–26NOV90

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

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

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

DX,DRAIN –19–03MAR93–1/1

Prevent Machine Runaway Avoid possible injury or death from machinery runaway.

NEVER start engine while standing on ground. Start engine only from operator’s seat, with transmission in neutral or park.

–UN–11JAN89

Do not start engine by shorting across starter terminals.

Machine will start in gear if normal circuitry is bypassed.

TS177

10 05 18

DX,BYPAS1 –19–29SEP98–1/1

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10-05-18

2254 Cane Loader 100406

PN=24

Safety 10 05 19

Handle Starting Fluid Safely Starting fluid is highly flammable.

Do not incinerate or puncture a starting fluid container.

TS1356

To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected location.

–UN–18MAR92

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

DX,FIRE3 –19–16APR92–1/1

Service Cooling System Safely

TS281

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

–UN–23AUG88

Explosive release of fluids from pressurized cooling system can cause serious burns.

DX,RCAP –19–04JUN90–1/1

Protect Against High Pressure Spray

TS1343

If an accident occurs, see a doctor immediately. Any high pressure spray injected into the skin must be surgically removed within a few hours or gangrene may result.

Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

–UN–18MAR92

Spray from high pressure nozzles can penetrate the skin and cause serious injury. Keep spray from contacting hands or body.

DX,SPRAY –19–16APR92–1/1

TMCM225401 (04OCT06)

10-05-19

2254 Cane Loader 100406

PN=25

Safety

Construct Dealer-Made Tools Safely

–UN–01JUL97

Faulty or broken tools can result in serious injury. When constructing tools, use proper, quality materials, and good workmanship.

LX1016749

Do not weld tools unless you have the proper equipment and experience to perform the job.

DX,SAFE,TOOLS –19–10OCT97–1/1

Live With Safety

TS231

–19–07OCT88

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

DX,LIVE –19–25SEP92–1/1

–19–24JAN06

Safety Sign

CM061850004

10 05 20

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TMCM225401 (04OCT06)

10-05-20

2254 Cane Loader 100406

PN=26

Safety 10 05 21

Avoid Electrical Power Lines Lower boom and grab to transport position and lift piler before driving on public roads.

Avoid using equipment around high voltage power lines; this would result in the operator suffering a severe electrical shock.

CM999999008

–UN–10NOV00

Do not operate with any part of the loader, its boom or its grab closer than 3 meters (10 feet) from electrical lines.

T803584,00001EA –19–16OCT00–1/1

TMCM225401 (04OCT06)

10-05-21

2254 Cane Loader 100406

PN=27

Safety 10 05 22

TMCM225401 (04OCT06)

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Group 10

Machine Specifications 10 10 1

Troubleshooting To prevent unnecessary loss of time and money; the service technician should use the following seven steps for a quick and accurate diagnosis: CAUTION: Use caution when dealing with pressurized hydraulic fluid. Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin causing serious injury.

This fluid may also be hot enough to burn.

Serious infection or reactions can develop if proper medical treatment is not administered immediately.

1. Know the machine.

• Study this manual to understand how the individual components work and what functions each serves in the overall system.

• Keep up with the latest service information. Read upon receipt and then file it in this manual or another useful place. Information received today may have the cause or remedy of a problem being encountered.

2. Consult the operator. Ask the operator how the machine was performing when it started to fail.

• Find out what was unusual.

• Find out if any “do-it-yourself” service was performed. (You may find the problem somewhere else, but you should know if any corrective measures have already been taken.)

• Ask how the equipment is used and how often it is serviced. Many problems are caused by poor maintenance or abuse.

3. Operate the equipment. If the machine is operable, operate it yourself. Do not rely entirely on the operator’s story; check it out.

• Are gauges reading normally? If not, maybe the component being monitored is not functioning correctly or the gauge is faulty.

• How is the performance? Is the action perhaps too fast or too slow, erratic, or none at all?

• Do the controls feel solid or spongy? Do they seem to be sticking?

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Machine Specifications 10 10 2

• Do you smell smoke or see any signs of smoke?

• Do you hear any unusual sounds? Where?

4. Inspect the equipment. Make sure engine is shut off and all implements are on the ground. Get off the machine and make a visual check. Use your eyes, ears and nose to spot any signs of trouble.

• Look closely at the components. Inspect for cracked welds, loose hardware, damaged linkages, worn or broken lines, etc.

• During the inspection, make notes of all trouble signs.

5. Make a list of the problem’s possible cause(s) with the information obtained during steps 1 through 4..

• What were the signs you found while inspecting the equipment?

• What is the most likely cause?

6. Reach some conclusions. Look over the list of possible causes and decide which are the most likely and which are the easiest to verify.

7. Test your conclusions. Before repairing components in the system, test your conclusions to see which are correct.

• Some of the possible causes may be verified without further testing. Check these possibilities first.

• Testing will narrow down the remaining list of possible causes and soon the actual cause(s) of trouble will be pin pointed.

With the cause(s) accurately located, it is now a simple matter to remove and repair the component(s) at fault.

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Machine Specifications 10 10 3

Visually Inspect Hydraulic Systems Before performing any diagnosis on the machine, use the following steps for locating problems. Many failures can be located by making preliminary checks of operation.

No special tools are required for these preliminary checks, so repair obvious problems before performing further tests.

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury.

Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pin holes and nozzles, which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your hand.

1. Become acquainted with the hydraulic system and its components. Read all new Service Information Bulletins.

2. If possible, talk with the operator about how the machine performs.

3. With the engine stopped, check for evidence of external oil leakage around seals, gaskets, or hydraulic connections. Check for pinched or kinked lines that could restrict oil flow and cause overheating.

4. Check for broken drives, broken or binding linkages, or other mechanical failures.

5. Check hydraulic oil level. Only use oil specified by John Deere to fill tank.

6. Check hydraulic oil for a milky, dirty, or discolored appearance. Milky oil usually indicates there’s water in the oil. Smell the oil. A distinctive burned odor indicates excessive heat that can destroy the oil’s lubricating qualities. Determine the cause of the condition, correct it, and change oil.

7. Check for a plugged or damaged hydraulic oil filter. A failed filter will permit contaminants to circulate in the system, affecting system operation and tests. If the filter is plugged, an examination of the contaminant may indicate the cause of the failure.

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Machine Specifications 10 10 4

8. Check maintenance records to determine if the recommended service procedures have been done at correct intervals. Note any previous reports of unusual, frequent, or similar failures.

CAUTION: Keep hands away from moving parts.

Shut off engine before checking lines located near moving parts.

9. If possible, operate the machine. Use hydraulic functions and be alert for conditions that could isolate the problem. Also be alert for conditions that could cause further damage and be prepared to stop the engine immediately.

10. With someone in the driver’s seat and the engine running, check for external and internal leaks. With all hydraulic functions in neutral, check function component return lines and housings for heating.

Return lines will be hot if component control valves are leaking.

11. If these preliminary checks have failed to isolate the hydraulic problem, list the possible causes of failure and proceed to fault logic diagrams for the particular problem.

T803324,0000937 –19–14MAR06–2/2

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2254 Cane Loader 100406

PN=32

Machine Specifications 10 10 5

X9811

If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this injury type or gangrene may result. When disconnecting a line or hose from a hydraulic component, always mark it and the port from which it was removed. This will enable it to be reconnected to the proper port when reassembling.

If lines or hoses are not connected to the proper ports, serious damage can result to the component or to the entire hydraulic system.

–UN–23AUG88

Hydraulic System Testing Precautions

Avoid excessive twisting by using two wrenches when attaching a hose or line to a fitting. Check the entire length of lines and hoses to be certain they are not rubbing on moving parts or vibrating because of loose clamps.

CAUTION: Wear eye protection and remove rings, metal watchbands, and other metal jewelry when working on the electrical system.

T803324,0000938 –19–14MAR06–1/1

TMCM225401 (04OCT06)

10-10-5

2254 Cane Loader 100406

PN=33

Machine Specifications

Visually Inspect Electrical System

1. Look for bare wires that could ground a component or short across to another component.

2. Look for a missing or worn conduit. This could indicate a wire problem.

3. Look for loose or broken connectors and wires. Inspect batteries for: ! Corroded terminals. ! Loose terminals or battery posts. ! Dirty condition. ! Cracked case.

4. Proper electrolyte level.

5. Check alternator belt tension.

6. After machine has been shut down for five minutes inspect for overheated parts. They will often smell like burned insulation. Put your hand on the alternator.

Heat in these parts when the unit has not been operated for some time is a sure clue to charging circuit problems.

7. If your visual inspection does not indicate the possible malfunction, but your inspection does indicate that the machine can be run, turn the key switch to IGN. Try out the accessory circuits, indicators, lights and gauge lights, etc. How does each of these components work?

Look for sparks or smoke, which might indicate shorts.

8. Start machine. Check all gauges for good operation and check to see if system is charging or discharging.

9. In general, look for anything unusual. Many electrical failures cannot be detected even if the machine is running. Therefore, a systematic and complete inspection of the electrical system is necessary.

–UN–23AUG88

Make the following visual electrical inspection prior to starting the machine:

TS206

10 10 6

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TMCM225401 (04OCT06)

10-10-6

2254 Cane Loader 100406

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Machine Specifications 10 10 7

TS204

1. Keep all flames/sparks away from battery.

2. Charge battery in a well-ventilated area.

3. Always remove negative (-) battery cable first and replace it last.

4. Never lay a metal object on top of a battery: a short circuit can result, damaging the battery and metal object.

5. If acid spills on clothing, immediately remove clothing.

If acid contacts skin, rinse affected area with running water for 1 - 15 minutes.

–UN–23AUG88

Electrical System Safety Precautions

T803324,000093A –19–14MAR06–1/2

TS203

–UN–23AUG88

6. If acid splashes into eyes, hold eyelids open and flood eyes with running water for 10-15 minutes, then see a doctor at once.

7. DO NOT use any medication or eye drops unless prescribed by a doctor.

8. To neutralize acid spilled on the floor or machine, flood the spill with one of the following mixtures, then rinse thoroughly with clean water: • 0.5 kg (1 lb) of baking soda in 4 L (1 gal) of water !

• 0.4 (1 pt) of household ammonia in 4 L (1 gal) of water.

T803324,000093A –19–14MAR06–2/2

TMCM225401 (04OCT06)

10-10-7

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PN=35

Machine Specifications 10 10 8

Machine Specifications Engine: Engine Type ............................................................................................................................................................................... John Deere 6068T Cylinders ................................................................................................................................................................................................... 6 (in line) Displacement ............................................................................................................................................................................... 8.3 L (506 cu. in.)

Horsepower ............................................................................................................................................................. 200 hp (149 kw) at 2200 RPM Peak Torque ....................................................................................................................................................... 793 N•m (585 lb-ft) at 1500 RPM Oil Pressure .................................................................................................................................................................. 50 PSI (345 kPa) (Normal) Coolant Flow ........................................................................................................................................................ 67 GPM (253 L/m) at 2400 RPM High Idle ........................................................................................................................................ 2400 RPM (Full Load) / 2550 RPM (No Load)

T803324,00008DD –19–01FEB06–1/1

Machine Specifications Transmission: Type .............................................................................................................................................................................................. 3 Speed Manual Gearing • 1st ........................................................................................................................................................................................................... 11.25: 1 • 2nd ........................................................................................................................................................................................................... 5.874: 1 • 3rd ........................................................................................................................................................................................................... 2.869: 1 Final Drive (Front Axle) Type .................................................................................................................................................................................... 9.5 : 1 High Clearance Max Speed ................................................................................................................................................................................................ 940 RPM Max Torque ...................................................................................................................................................................... 34,000 lb-in. (3,842 N•m) Final Drive (Rear Axle) - Standard Power Assist Option Type ............................................................................................................................................................... Double Planetary Gear Torque Hub Reduction ................................................................................................................................................................................................... 26.28 : 1 Output Torque Rating Max Continuous ................................................................................................................................................................ 40,000 lb-in (4,519 N•m) Max Intermittent ................................................................................................................................................................ 80,000 lb-in (9,039 N•m) Max Peak ...................................................................................................................................................................... 100,000 lb-in (11,299 N•m) Max Input Speed (Continuous) .................................................................................................................................................... 3750 - 4500 RPM Final Drive (Rear Axle) - High Traction Option Type ............................................................................................................................................................................. Planetary Gear Torque Hub Reduction ...................................................................................................................................................................................................... 44.2: 1 Output Torque Rating Max Continuous ................................................................................................................................................................ 75,000 lb-in (8,468 N•m) Max Intermittent ............................................................................................................................................................. 150,000 lb-in (16,986 N•m) Max Peak ....................................................................................................................................................................... 200,000 lb-in (22,600 N•m) Max Input Speed (Continuous) .................................................................................................................................................... 2250 - 2700 RPM

T803324,00008DD –19–01FEB06–1/1

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2254 Cane Loader 100406

PN=36

Machine Specifications 10 10 9

Machine Specifications Pump Drive - Flywheel Mounted Type ............................................................................................................................................................................................................. Double Reduction ........................................................................................................................................................................................................... 1:1 Pump Rotation ........................................................................................................................................................................ Reverse Enginewise Final Drive (Rear Axle) - High Traction 4 Wheel Drive Option Type ............................................................................................................................................................................. Planetary Gear Torque Hub Reduction ..................................................................................................................................................................................................... 44.2: 1 Max Continuous ................................................................................................................................................................. 75,000 lb-in (8,475 N•m) Max Intermittent ............................................................................................................................................................ 150,000 lb-in (16,950 N•m) Max Peak ..................................................................................................................................................................... 200,000 lb-in (22,600 N•m) Max Input Speed .................................................................................................................................................................................... 3000 RPM Double Vane Pump Displacement: Shaft End Pump ........................................................................................................................................................ 4.12 cu. in./rev (67.5 cc/rev) Cover End Pump ....................................................................................................................................................... 1.67 cu. in./rev (27.4 cc/rev) Speed: Maximum ................................................................................................................................................................................................ 3000 RPM Pressure: Maximum at Max Speed ........................................................................................................................................................ 3000 PSI (206.8 bar) Rotation: Viewed from shaft end .............................................................................................................................................................................. Left Hand Typical Performance Shaft End Pump Input Horsepower @ 2250 PSI, 2400 RPM ..................................................................................................................................... 60 HP (45 kW) Delivery @2250 PSI, 2400 RPM ............................................................................................................................................ 37 GPM (140 L/Min) Cover End Pump Input Horsepower @ 2250 PSI, 2400 RPM ..................................................................................................................................... 22HP (16 kW) Delivery @ 2250 PSI, 2400 RPM ............................................................................................................................................ 15 GPM (57 L/Min) Weight: Normal ............................................................................................................................................................................................. 45 lb (20.4 kg)

T803324,00008F7 –19–02FEB06–1/1

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Machine Specifications 10 10 10

Machine Specifications Single Vane Pump - (Hydraulic Piler Option Only) Displacement: Maximum ................................................................................................................................................................... 2.76 cu. in./rev (45.2 cc/rev) Speed Maximum ................................................................................................................................................................................................ 2700 RPM Pressure: Maximum at Max. Speed ........................................................................................................................................................ 3000 PSI (207 bar) Rotation Viewed from Shaft End ........................................................................................................................................................................... Left Hand Typical Performance Input Horsepower at 2250 PSI, 2400 RPM ..................................................................................................................................... 42 HP (31 kW) Delivery at 2250 PSI, 2400 RPM ............................................................................................................................................ 27 GPM (102 L/Min) Weight: Normal ............................................................................................................................................................................................. 32 lb (14.5 Kg) Variable Displacement Pump - (Hydrostatic Transmission) Displacement: Maximum ...................................................................................................................................................................... 6.1 cu. in./rev (100 cc/rev) Input Rotation Viewed from Shaft End ........................................................................................................................................................................... Left Hand Input Speed Maximum ................................................................................................................................................................................................ 4300 RPM Continuous ............................................................................................................................................................................................. 3600 RPM Minimum .................................................................................................................................................................................................. 500 RPM Pressure: Maximum ................................................................................................................................................................................. 7000 PSI (480 bar) Continuous ............................................................................................................................................................................... 6000 PSI (420 bar) Case Pressure Continuous ....................................................................................................................................................................................... 40 PSI (3 bar) Maximum (Cold Start) ....................................................................................................................................................................... 75 PSI (5 bar) Charge Inlet Vacuum at Sea Level Normal ............................................................................................................................................................................ 10 In. Hg (0.7 Bar [ABS]) Cold Start ........................................................................................................................................................................ 25 In. Hg (0.2 bar [ABS]) Weight: Normal .............................................................................................................................................................................................. 150 lb (68 Kg)

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Machine Specifications Fixed Displacement Motor (Front Axle): Displacement Maximum .................................................................................................................................................................... 5.43 Cu. In./Rev (89 Cc/Rev) Speed: Maximum ......................................................................................................................................... 2900 RPM (Serial No. 100004988 and prior) Maximum ......................................................................................................................................... 3720 RPM (Serial No. 100004989 and after) Pressure Maximum at Max Speed, Max Displacement ..................................................................... 5000 PSI (345 Bar) (Serial No. 100004988 and prior) Maximum at Max Speed, Max Displacement ..................................................................... 6000 PSI (345 Bar) (Serial No. 100004989 and after) Case Pressure Maximum ........................................................................................................................................................................................... 40 PSI (3 bar) Charge Inlet Vacuum at Sea Level Normal ............................................................................................................................................................................ 10 In. Hg (0.7 Bar [ABS]) Weight Normal ........................................................................................................................................................................................... 108 Lb. (49 Kg)

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Machine Specifications Fixed Displacement Motor (Rear Axle) — Power Assist Option: Displacement .................................................................................................................................................... 2.78 Cu. In. / Rev. (45.5 cc/Rev) Output Speed Maximum ............................................................................................................................................................................................... 4250 RPM Pressure Maximum ................................................................................................................................................................................. 6500 PSI (450 Bar) ........................................................................................................................................................................................................... (0.26 N•m/Bar) At Max. Displacement ............................................................................................................................................................ 784 lb-in / 1000 PSI (1.28 N•m/Bar) Pressure Maximum ................................................................................................................................................................................... 6960 PSI (480 bar) Continuous ............................................................................................................................................................................... 5800 PSI (400 bar) Case Pressure Maximum ..................................................................................................................................................................................... 145 PSI (10 bar) Weight Normal ............................................................................................................................................................................................. 30 Lb. (14 Kg) Variable Displacement Motor (Rear Axle) - High Traction 4 Wheel Drive: Displacement Maximum .................................................................................................................................................................... 4.92 Cu. In./Rev (80 Cc/Rev) Minimum ................................................................................................................................................................... 1.23 Cu. In./Rev (20 Cc/Rev) Rated Speed At Min. Displacement ............................................................................................................................................................................ 5000 RPM At Max. Displacement ........................................................................................................................................................................... 3100 RPM Maximum Speed At Min. Displacement .............................................................................................................................................................................. 6250 RPM At Max Displacement .............................................................................................................................................................................. 4000 RPM Theoretical Torque At Min. Displacement ................................................................................................................................................................ 156 lb-in /1000 PSI ........................................................................................................................................................................................................... (0.26 N•m/Bar) At Max. Displacement ............................................................................................................................................................ 784 lb-in / 1000 PSI (1.28 N•m/Bar) Pressure Maximum ................................................................................................................................................................................... 6960 PSI (480 bar) Minimum ...................................................................................................................................................................................... 145 PSI (10 bar) Case Pressure (Maximum) Continuous ....................................................................................................................................................................................... 44 PSI (3 Bar) Maximum (Cold Start) ..................................................................................................................................................................... 73 PSI (5 bar) Weight Normal ............................................................................................................................................................................................. 72 Lb. (32 Kg)

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PN=40

Machine Specifications Steering Cylinder Oil Supply ....................................................................... Double Vane Pump ....................................................................... 15 GPM (57 L/M) ....................................................................................................................................................................................................... Cover End Pump Swing Cylinders Oil Supply ....................................................................... Double Vane Pump ....................................................................... 15 GPM (57 L/M) ....................................................................................................................................................................................................... Cover End Pump Valve .............................................................................................................................................................................. 3 Bank Directional Control ..................................................................................................................................................................................................... 3 Position / 4 Way ........................................................................................................................................................................................................... Pilot Operated ........................................................................................................................................................................................................... Cylinder Spool Relief Valve ......................................................................... Work Port Relief ......................................................................... 1350 PSI (93 Bar) Relief Valve ................................................................... Main D.C. Valve Relief ................................................................... 2250 PSI (155 Bar) Flex Cylinder Oil Supply ....................................................................... Double Vane Pump ....................................................................... 15 GPM (57 L/M) ....................................................................................................................................................................................................... Cover End Pump Valve ............................................................................................................................................................................. 3 Bank Directional Control ..................................................................................................................................................................................................... 3 Position / 4 Way ........................................................................................................................................................................................................... Pilot Operated ........................................................................................................................................................................................................... Cylinder Spool Relief Valve .................................................................. Work Port Relief .................................................................. 2000 PSI (138 Bar) Extd. .......................................................................................... .......................................................................................... 1000 PSI (69 Bar) Retract.

Relief Valve ................................................................. Main D.C. Valve Relief .................................................................. 2250 PSI (155 Bar) Piler Lift Cylinder Oil Supply ..................................................................... Double Vane Pump ..................................................................... 15 GPM (56.8 L/Min) ....................................................................................................................................................................................................... Cover End Pump Valve ............................................................................................................................................................................. 3 Bank Directional Control .................................................................................................................................................... 3 Position / 4 way Pilot Operated Cylinder Spool Relief Valve ................................................................... Work Port Reliefs ................................................................... 1000 PSI (69 Bar) Close ............................................................................................. ............................................................................................. 500 PSI (34 Bar) Open Relief Valve .................................................................... Main D.C. Valve Relief .................................................................... 2250 PSI (155 Bar) Grab Cylinders Oil Supply ...................................................................... Double Vane Pump ...................................................................... 37 GPM (140 L/Min) ..................................................................................................................................................................................................... Shaft End Section Valve ............................................................................................................................................................................. 2 Bank Directional Control .................................................................................................................................................... 3 Position / 4 way Pilot Operated Cylinder Spool Relief Valve .................................................................... Work Port Relief ................................................................... 1800 PSI (124 bar) Extd. ........................................................................................... ........................................................................................... 500 PSI (34 Bar) Retract.

Relief Valve .................................................................... Main D.C. Valve Relief .................................................................... 2250 PSI (155 bar) Lift Cylinder Oil Supply ...................................................................... Double Vane Pump ...................................................................... 36 GPM (138 L/Min) ........................................................................................................................................................................................................ Shaft End Pump Valve .............................................................................................................................................................................. 2 Bank Directional Control .................................................................................................................................................... 3 Position / 4 way Pilot Operated Cylinder Spool Relief Valve .................................................................... Work Port Relief ................................................................... 1800 PSI (124 bar) Extd. ............................................................ ............................................................ ........................................................... 500 PSI (34 Bar) Retract.

Relief Valve .................................................................... Main D.C. Valve Relief ................................................................... 2250 PSI (155 bar) Piler Motor Circuit (Hydraulic Piler Option Only) Oil Supply ............................................................................ Single Vane ............................................................................ 27 GPM (102 L/Min) .............................................................................................................................................................................................................. Single Pump Valve ............................................................................................................................................................................................ Directional Control

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Machine Specifications 10 10 14

.................................................................................................................................................... 3 Position / 4 way Pilot Operated Cylinder Spool Relief Valve ....................................................... Main D.C. Valve Cartridge Relief ....................................................... 2000 PSI (138 Bar) Extd.

Relief Valve ............................................................................. Main Relief ............................................................................. 1750 PSI (138 Bar)

T803324,00008DD –19–01FEB06–3/3

Loading System To check pressure, install gauges anywhere in the lines that go from the pump to the respective control valve. Run the engine at approximately 1000 RPM.1 Control Valve - Piler, Flex and Swing Main Relief ........................................................... 2250 PSI (155 Bar) Port Reliefs Boom Swing ........................................................... 1350 PSI (93 Boom Flex (Out) .................................................. 2000 PSI (138 Boom Flex (In) ....................................................... 1000 PSI (69 Piler Lift (Raise) ..................................................... 1000 PSI (69 Piler Lift (Lower) ....................................................... 500 PSI (34

Bar) Bar) Bar) Bar) Bar)

To check the pressure, actuate the piler or flex valve until the cylinder bottoms out. Hold in this position while observing pressure reading.

Control Valve - Boom Lift and Grab Main Relief ........................................................... 2250 PSI (155 Bar)

To check the main pressure, actuate the grab until the cylinder bottoms out. Hold in this position while observing pressure reading.

Port Reliefs Boom Lift (Raise) ................................................. 1800 PSI (124 Boom Lift (Lower) .................................................... 500 PSI (34 Grab (Close) ........................................................ 2000 PSI (138 Grab (Open) ........................................................... 1000 PSI (69

Bar) Bar) Bar) Bar)

To check the pressure, lower boom until pressure relief opens. Hold in this position while observing pressure reading.

Throttle Valve - Lift: The purpose of this valve is to slow the downward movement of the boom in order to reduce pressure peaks. It is fully open when the boom is lifting.

1

In order to properly check your hydraulic pressure settings, you must first warm the system oil to at least 120° F (49° C).

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Traction System Main System Pressure Main Relief ........................................................... 5500 PSI (380 Bar) Multipurpose valve for high pressure and relief and override.

Charge Pressure (Neutral) ....................................... 405 PSI (28 Bar) Charge Pressure (For/Rev) ....................................... 362 PSI (25 Bar) Crossover (Cushion) Relief - Power Assist Option Only Relief Cartridges (Rear Axle) ............................... 5000 PSI (345 Bar)

To check the pressure, engage fourth gear, lock the wheels and fully stroke the pump at maximum engine RPM. These readings are above the case drain pressure.

Vacuum Normal ...................................................... 0 - 10” Hg (0-0.7 Bar ABS) Cold Start .................................................. 25” Hg Max (0.2 Bar ABS) Case Drain Pressure Normal ................................................................. 0 - 40” Hg (0-3 Bar) Cold Start ..................................................................... 75 PSI (5 Bar)

T803324,00009A1 –19–24APR06–1/1

Front Axle Motor Flushing function only.

T803324,00009A2 –19–24APR06–1/1

Steering System Relief Valve: Priority Steering Circuit Relief Pressure .................................................... 2500 PSI (172 Bar) Priority Valve: Steering Supply Valve Pressure Setting .................................................. 1750 PSI (121 Bar) Steering Cylinder (Crossover) (Cushion) Relief - High Traction 4 Wheel Drive Option Only Reliefs .................................................................. 1500 PSI (104 Bar)

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Piler Chain System (Optional Hydraulic Piler) Relief Valve: Pump or Flow Control Pressure Setting .................................................. 1750 PSI (121 Bar) Directional Valve: For/Rev Rotation Pressure Setting .................................................. 2000 PSI (138 Bar)

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PN=44

Machine Specifications 10 10 17

CM40283576D4

–UN–24APR06

Grab and Lift Hydraulic Schematic

T803324,00009A3 –19–24APR06–1/1

TMCM225401 (04OCT06)

10-10-17

2254 Cane Loader 100406

PN=45

Machine Specifications

–UN–24APR06

Steer, Swing Flex and Piler Lift Hydraulic Schematic

CM40292299D2

10 10 18

T803324,00009A5 –19–24APR06–1/1

TMCM225401 (04OCT06)

10-10-18

2254 Cane Loader 100406

PN=46

Machine Specifications 10 10 19

CM40283579B3

–UN–24APR06

Joystick Control Valve Hydraulic Schematic

T803324,00009A4 –19–24APR06–1/1

TMCM225401 (04OCT06)

10-10-19

2254 Cane Loader 100406

PN=47

Machine Specifications

–UN–24APR06

Optional Hydraulic Piler Schematic

CM40292300C2

10 10 20

T803324,00009A6 –19–24APR06–1/1

TMCM225401 (04OCT06)

10-10-20

2254 Cane Loader 100406

PN=48

Machine Specifications 10 10 21

CM40297442D7

–UN–10MAR06

Hydrostatic Transmission Hydraulic Schematic

T803324,00009A7 –19–24APR06–1/1

TMCM225401 (04OCT06)

10-10-21

2254 Cane Loader 100406

PN=49

Machine Specifications

–UN–10MAR06

Propulsion Schematic - High Traction Option

CM43000396B2

10 10 22

T803324,00009A8 –19–24APR06–1/1

TMCM225401 (04OCT06)

10-10-22

2254 Cane Loader 100406

PN=50

Machine Specifications 10 10 23

Conversions The following information will be useful to you as you work with non-metric fasteners.

You may find frequent use for the fraction-decimal-millimeter conversion chart, especially when you have to cut or restore threads.

1 1 1 1

Gross or Long Ton Net or Short Ton Cubic Foot of Water Gallon of Water

1 Mile 1 Mile 1 Mile 1Mile 1 Mile 1 Furlong 1 Furlong 1 Station 1 Station 1 Station 1 Chain 1 Chain 1 Chain 1 Chain 1 Rod 1 Rod 1 Yard 1 Yard 1 Foot

= = = =

2,240 Lbs 2,000 Lbs. 62.5 Lbs. 8.33 Lbs.

= = = = = = = = = = = = = = = = = = =

8 Furlongs 80 Chains 320 Rods.

1,760 Yards.

5,280 Feet 10 Chains 220 Yards 6.06 Rods 33.3 Yards 100 Feet 4 Rods 22 Yards 66 Feet 100 Links 5.5 Yards 16.5 Feet 3 Feet 36 Inches 12 Inches

The following tables are provided to help you compare metric to English measurements, or to make conversions when you are required to do so.

1 1 1 1 1

Millimeter Centimeter Meter Meter Meter

1 Inch 1 Foot 1 Yard

Metric to English = 0.03937 inches = 0.3937 inches = 39.37 inches = 3.2808 feet = 1.0936 yards English to Metric = 25.4 millimeters = 2.54 centimeters = 304.8 millimeters = 30.48 centimeters = 91.4 centimeters = 0.9144 meter

Continued on next page

TMCM225401 (04OCT06)

10-10-23

T803324,0000934 –19–14MAR06–1/2

2254 Cane Loader 100406

PN=51

Machine Specifications 10 10 24

When you know Millimeters Centimeters Meters Newton-Meters Liters Liters Liters Inches Feet Yards Foot-pounds PSI a Approximate.

0° 30° 100°

Multiply bya 0.04 0.39 3.28 0.737 1.057 2.642 2.10 2.54 30.5 0.91 1.356 14.63

To Find inches inches feet foot-pounds quarts gallons pints centimeters centimeters meters Newton-meters Bar

Temperature Conversion Chart Celsius Fahrenheit 32° 86° 212°

To convert Celsius to Fahrenheit, multiply by 1.8 and add 32.

F = (C x 1.8) + 32

To convert Fahrenheit to Celsius, subtract 32 and divide by 1.8.

C = (F-32) ÷ 1.8

T803324,0000934 –19–14MAR06–2/2

TMCM225401 (04OCT06)

10-10-24

2254 Cane Loader 100406

PN=52

Machine Specifications 10 10 25

Unified Inch Bolt and Screw Torque Values TS1671 –UN–01MAY03

Bolt or

SAE Grade 2a

SAE Grade 1 b

Screw

Lubricated

Size 1/4

Dry

c

b

Lubricated

Dry

SAE Grade 5, 5.1 or 5.2 c

b

Lubricated

Dry

SAE Grade 8 or 8.2

c

Lubricatedb N•m

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

3.7

33

4.7

42

6

53

7.5

66

9.5

84

12

106

13.5 N•m

5/16

7.7

68

9.8

86

12

106

15.5

137

3/8

13.5

120

17.5

155

22

194

27

240

7/16

22

194

19.5 N•m

N•m

N•m 1/2

lb-ft

N•m

lb-ft

N•m

172 lb-ft

25 N•m

221

lb-in 120 lb-ft

Dryc N•m 17 N•m

lb-in 150 lb-ft

28

20.5

35

26

lb-ft

35

26

44

32.5

49

36

63

46

lb-ft

28

20.5

35

26

44

32.5

56

41

70

52

80

59

100

74

42

31

53

39

67

49

85

63

110

80

120

88

155

115

lb-ft

34

25

9/16

48

35.5

60

45

76

56

95

70

125

92

155

115

175

130

220

165

5/8

67

49

85

63

105

77

135

100

170

125

215

160

240

175

305

225

3/4

120

88

150

110

190

140

240

175

300

220

380

280

425

315

540

400

7/8

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

960

1-1/8

400

300

510

375

400

300

510

375

910

670

1150

850

1450

1075

1850

1350

1-1/4

570

420

725

535

570

420

725

535

1280

945

1630

1200

2050

1500

2600

1920

1-3/8

750

550

950

700

750

550

950

700

1700

1250

2140

1580

2700

2000

3400

2500

1-1/2

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 bolt or screw. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For plastic insert or crimped steel type lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the tightening instructions for the specific application. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

Replace fasteners with the same or higher grade. If higher grade fasteners are used, tighten these to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. When possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless different instructions are given for the specific application.

a

Grade 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. b

“Lubricated” 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. c

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

TORQ1 –19–24APR03–1/1

TMCM225401 (04OCT06)

10-10-25

2254 Cane Loader 100406

PN=53

Machine Specifications

4.8

8.8

9.8

10.9

12.9

12.9

4.8

8.8

9.8

10.9

12.9

12.9

–UN–01MAY03

Metric Bolt and Screw Torque Values

TS1670

10 10 26

Bolt or Screw

Class 4.8 Lubricateda

Class 8.8 or 9.8 Dryb

Lubricateda

Class 10.9

Dryb

Lubricateda

Size

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

M6

4.7

42

6

53

8.9

79

11.3

100

N•m 13 N•m

M8

11.5

102

14.5 N•m

M10

23 N•m

204

29

128 lb-ft 21

22 N•m

194 lb-ft

43

32

27.5 N•m 55

243

lb-in 115 lb-ft

Class 12.9 Dryb

N•m 16.5 N•m

Lubricateda

lb-in 146 lb-ft

N•m 15.5 N•m

lb-in 137 lb-ft

Dryb N•m

lb-in

19.5

172

N•m

lb-ft

32

23.5

40

29.5

37

27.5

47

35

40

63

46

80

59

75

55

95

70

lb-ft

lb-ft

M12

40

29.5

50

37

75

55

95

70

110

80

140

105

130

95

165

120

M14

63

46

80

59

120

88

150

110

175

130

220

165

205

150

260

190

M16

100

74

125

92

190

140

240

175

275

200

350

255

320

235

400

300

M18

135

100

170

125

265

195

330

245

375

275

475

350

440

325

560

410

M20

190

140

245

180

375

275

475

350

530

390

675

500

625

460

790

580

M22

265

195

330

245

510

375

650

480

725

535

920

680

850

625

1080

800

M24

330

245

425

315

650

480

820

600

920

680

1150

850

1080

800

1350

1000

M27

490

360

625

460

950

700

1200

885

1350

1000

1700

1250

1580

1160

2000

1475

M30

660

490

850

625

1290

950

1630

1200

1850

1350

2300

1700

2140

1580

2700

2000

M33

900

665

1150

850

1750

1300

2200

1625

2500

1850

3150

2325

2900

2150

3700

2730

M36

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 of the bolt or screw. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For stainless steel fasteners or for nuts on U-bolts, see the tightening instructions for the specific application. Tighten plastic insert or crimped steel type lock nuts by turning the nut to the dry torque shown in the chart, unless different instructions are given for the specific application.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class. Replace fasteners with the same or higher property class. If higher property class fasteners are used, tighten these to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. When possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless different instructions are given for the specific application.

a

“Lubricated” 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. b

“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.

DX,TORQ2 –19–24APR03–1/1

TMCM225401 (04OCT06)

10-10-26

2254 Cane Loader 100406

PN=54

Group 15

General References 10 15 1

Glossary of Terms ITEM

ABBREVIATION

DESCRIPTION

Accessory

ACC

Secondary electrical system

Air Conditioning

A/C

System used for cooling the air in the cab

Alternating Current

AC

Electrical current that reverses its direction at regularly recurring intervals

Battery

Bat

A device used to furnish electrical current

Brakes

BR

Abbreviation

Controller Area Network

CAN

A communication system linking on-board electronics

Central Control Unit

CCU

Computerized system for tractor monitoring

Circuit

CCT

A complete path of an electrical current

Clockwise

CW

Direction in which the hands of a clock rotate

Cold Cranking Amperes

CCA

Battery’s measured capability to perform during cold weather operation

Component Technical Manual

CTM

Technical manual developed for the servicing of major components

Counterclockwise

CCW

Direction opposite the rotation of the hands of a clock

Diagnostic Receptacle Digital Multimeter Direct Current

DR

A connection where hydraulic pressure can be measured

DMM

An electrical multi-functional measuring device

DC

Electrical current flowing in one direction only

Continued on next page

TMCM225401 (04OCT06)

10-15-1

OUO1089,000277F –19–13JAN05–1/4

2254 Cane Loader 100406

PN=55

General References 10 15 2

ITEM

ABBREVIATION

DESCRIPTION

Electro-Hydraulic

EH

Hydraulic valve function that is controlled electrically

Electronic Components Relay

ELX

Relay powering most of the electronic components

Excess Flow (SCV/Hitch Flow)

EF

Reference—SCV/Hitch flow

Excess Flow Load Sense (SCV/Hitch Flow)

EFL

Reference—SCV/Hitch load sense

Forward

FWD

Direction of movement

Gallons per Minute

gpm

Amount of fluid displaced over a period of one minute

Heating-Ventilating and Air Conditioning

HVAC

Abbreviation

High-Intensity Discharge Light

HID

Abbreviation

Hitch Control Unit

HCU

Computerized system used to control hitch functions

Housing

Hsg

Abbreviation

Ignition

IGN

Control for starting and stopping the tractor

Inside Diameter

ID

Abbreviation

International Standards Organization

ISO

Standards organization

Joint Industry Council Organization

JIC

Standards organization

Left-Hand Liquid Crystal Display

LH or L-H LCD

Abbreviation A technology used for displaying information

Continued on next page

TMCM225401 (04OCT06)

10-15-2

OUO1089,000277F –19–13JAN05–2/4

2254 Cane Loader 100406

PN=56

General References ITEM Manifold Air Pressure

ABBREVIATION MAP

Negative

Neg (—)

Number

No.

Air Pressure measured at engine air intake Electrical Ground Circuit Abbreviation

O-Ring Face Seal

ORFS ORS

Outside Diameter

OD

Abbreviation

Perf Mon (PrF)

Abbreviation

Performance Monitor Positive

Pos (+)

10 15 3

DESCRIPTION

A type of seal used in hydraulic connections

Charged part of an electrical circuit

Potentiometer

POT

A device used to vary electrical voltage

Power Take-Off

PTO

Abbreviation

Pressure Control Valve

PCV

Valve used to control pressure within a system

Pressure Regulating Valve

PRV

A device used to regulate pressure in a system

Product Identification Number

PIN

Serial number relating to tractor identification

Pulse-Width-Modulation

PWM

Method of controlling electrical signals

Pump Load Sense

PLD

Reference—Pump load sense

Reverse

Rev

Direction of movement

Revolutions per Minute

rpm

Abbreviation

RH or R-H

Abbreviation

RS

Abbreviation

Right-Hand Rockshaft

Continued on next page

TMCM225401 (04OCT06)

10-15-3

OUO1089,000277F –19–13JAN05–3/4

2254 Cane Loader 100406

PN=57

General References 10 15 4

ITEM

ABBREVIATION

DESCRIPTION

Selective Control Valve

SCV

Device used to control remote hydraulic functions

Slow Moving Vehicle

SMV

Warning sign on the rear of the tractor

Society of Automotive Engineers

SAE

Engineering Standards Organization

Specification

Spec

Abbreviation

Switch

SW

Abbreviation

Tachometer

Tach

Abbreviation

TL

Abbreviation

Temperature

Temp

Abbreviation

Transmission

Trans

Abbreviation

Tail Light

Transient Voltage Protection Voltage (Volts)

TVP

An electrical device used to protect a circuit from voltage surge

V

Abbreviation

V Det

Abbreviation

Warning Lamp

WL

Abbreviation

Without

W/O

Abbreviation

Wide-Open Throttle

WOT

Full throttle

Voltage Detector

OUO1089,000277F –19–13JAN05–4/4

TMCM225401 (04OCT06)

10-15-4

2254 Cane Loader 100406

PN=58

General References 10 15 5

Visually Inspect Electrical System Visually inspect the electrical system prior to starting the tractor, after receiving customer complaint: 1. Look for bare wires that could ground a component or short across to another component.

2. Look for missing or worn conduit. This could indicate a wire problem.

3. Look for loose or broken connectors and wires.

IMPORTANT: During any diagnostic operation involving harness connectors, always consider the possibility that a terminal may have pulled out from the connector body enough to lose connection. This can happen if the terminal did not seat properly when installed, and it is a condition that is generally not obvious simply by looking at the connectors when mated. Careful inspection may be required.

4. Inspect batteries for: • Corroded terminals • Loose terminals or battery posts • Dirty condition • Damp condition • Cracked case • Proper electrolyte level 5. Check alternator belt tension.

6. After machine has been shut down for five minutes, inspect for overheated parts. Parts will often smell like burned insulation. Place hand on the alternator. Heat in these parts when the unit has not been operated for some time is a sure clue to charging circuit problems.

7. If visual inspection does not indicate the possible malfunction, but inspection does indicate that the machine can be run, turn the key switch to the RUN position. Operate the accessory circuits, indicator lights, gauge lights, etc. How does each of these components work? Look for sparks or smoke which might indicate shorts.

8. Start machine. Check all gauges for good operation and check to see if system is charging or discharging.

Continued on next page

TMCM225401 (04OCT06)

10-15-5

OUO1089,0002784 –19–13JAN05–1/2

2254 Cane Loader 100406

PN=59

General References 10 15 6

9. In general, look for anything unusual.

Many electrical failures cannot be detected even if the machine is started. Therefore, a systematic and complete inspection of the electrical system is necessary.

OUO1089,0002784 –19–13JAN05–2/2

TMCM225401 (04OCT06)

10-15-6

2254 Cane Loader 100406

PN=60

General References 10 15 7

Seven-Step Electrical Procedure

J FUSE + F C

H

E

A

K

I

G

B D

L

LV12004

M

–UN–10JAN05

-

A—Battery Ground B—Battery C—Circuit Breaker Battery Side

D—DFRW26 Fuse Test Lead E—Circuit Breaker Load Side F—Switch G—Component Battery Lead

H—Load I—Component Ground Lead J—Component Battery Lead Disconnected Continued on next page

TMCM225401 (04OCT06)

10-15-7

K—Ground L—Voltage Check M—Ground Check

OUO1089,0002785 –19–13JAN05–1/3

2254 Cane Loader 100406

PN=61

General References 10 15 8

NOTE: A probe light or multimeter may be used when following this procedure.

Step

1-Switch Onb

Resultsa Probe—Multimeter Conditions

Sequence

Check circuit breaker battery side (C) for battery voltage.c

Bright Light—Battery voltage. Normal. GO TO 2.

Dim Light—Low voltage. Repair high resistance.

No Light—No voltage. Repair open circuit from battery.

2-Switch Off

Check circuit breaker load side (E) for battery voltage.

Bright light—Battery voltage. normal. GO TO 4.

Dim Light—Low voltage. Replace circuit breaker.

No light—No voltage. GO TO 3.

3-Switch Off

Check circuit breaker load side (E) for continuity to ground. (Clip of tester at battery voltage (+)).

Bright Light—Continuity to ground. Repair grounded circuit at or before switch.

No Light—no continuity to ground. Replace circuit breaker.

4-Switch On

Check circuit breaker load side (E) for battery voltage.

Bright Light—Battery voltage. Normal. GO TO 6.

Dim Light—Low voltage. Replace circuit breaker.

No Light—No voltage. GO TO 5.

5-Disconnect lead to component at (G)d. Switch on.

Check component battery lead disconnected (J) for battery voltage.

Bright Light—Battery voltage. Repair component.

No light—No voltage. Repair grounded circuit at or after switch.

a

Disregard probe light condition when using a multimeter.

Controlling switch or relay for component (load). c Use DFRW26—Test Lead when testing circuits with fuses. See Section 299, Dealer Fabricated Tools. d Multimeter will not apply a load to circuit at step 5. Use probe light. b

Continued on next page

TMCM225401 (04OCT06)

10-15-8

OUO1089,0002785 –19–13JAN05–2/3

2254 Cane Loader 100406

PN=62

General References Step

6-Switch On

10 15 9

Resultsa Probe—Multimeter Conditions

Sequence

Check component battery lead (G) for battery voltage.

Bright Light—Battery voltage normal. GO TO 7.

Dim Light—Low voltage - Repair high resistance in circuit between circuit breaker and component No Light—Repair high resistance in circuit between circuit breaker and component.

7-Switch On

Check component ground lead (I) for voltage.

Bright Light—High voltage - Open ground circuit. Repair open circuit.

Dim Light—Voltage - Poor continuity to ground. Repair high resistance circuit.

No Light—No voltage - Good continuity to ground. Repair component.

OUO1089,0002785 –19–13JAN05–3/3

TMCM225401 (04OCT06)

10-15-9

2254 Cane Loader 100406

PN=63

General References

–UN–13JAN05

Understanding Electrical vs. Electronic Circuits

LV12007

10 15 10

A—Fuse B—Circuit Resistance (5 Ohms) C—Test Point

D—Head Lamp E—Air Filter Restriction Switch F—Air Filter Restriction Indicator

IMPORTANT: Knowing the difference between electrical and electronic circuits is very important. The use of a probe (test) light in some electronic circuits will overload the circuit, creating damage to switches, transistors, resistors, capacitors and possibly microprocessors.

Test Light vs. Multimeter With probe light or multimeter.

Both multimeters and test lights may be used to check for voltage in a circuit. Both draw current from the circuit that is being tested to operate.

A typical multimeter (digital or analog) draws 0.05 milliamps to operate and a test light will draw 250— 300 milliamps during operation. This makes the current draw of the test light 5,000 times higher than the multimeter.

G—Circuit Resistance (20 Ohms) H—Test Point

Differences between the two test instruments are shown in Examples A and B. Example A — Electrical Circuit Refer to the above circuit.

The head lamp (D) will not operate with 5 ohms of resistance (B) in the circuit. If the head lamp is disconnected at point (C) and is checked for voltage at that point using a multimeter, the meter would indicate battery voltage.

NOTE: The meter does not draw enough current to create a voltage drop and place a load on the circuit. This gives a false indication of a good circuit to that point.

If the same check was made using a test light, the result would be either no light or a very dim light.

Continued on next page

TMCM225401 (04OCT06)

I—Electronic Control Module J—Key Switch K—Battery

10-15-10

OUO1089,000278A –19–13JAN05–1/2

2254 Cane Loader 100406

PN=64

General References NOTE: The test light draws enough current to place a load on the circuit. This gives a more realistic indication of the condition of the circuit.

Results were different for each test instrument for the following reasons: • The type of circuit being tested (ELECTRICAL) • The amount of current draw each test instrument requires to operate • The type of circuit malfunction (high resistance)

NOTE: The test light overloads the circuit because the control module cannot meet the high current demands of the test light. Thus it gives a false test result.

However, if a multimeter had been used to check point (H), it would have read correct voltage, indicating the air filter restriction indicator should be replaced.

NOTE: The multimeter does not overload the circuit because of its low current draw.

Example B — Electronic Circuit

Results were different for each test instrument for the following reasons:

Refer to the above circuit.

The air filter restriction indicator (F) will not operate with 20 ohms resistance (G) in the circuit when the air filter restriction switch (E) is closed (with 25 inches water vacuum at the switch).

If point (H) is checked for voltage (with air filter restriction switch (E) closed) using a test lamp, the result would be no light. The electronic control module (I) could be replaced in error.

• The type of circuit being tested (ELECTRONIC) • The amount of current draw each test instrument requires to operate • The type of circuit malfunction (high resistance) The next step would be to check for high resistance between the electronic control module (I) and the indicator lamp (F).

OUO1089,000278A –19–13JAN05–2/2

TMCM225401 (04OCT06)

10-15-11

2254 Cane Loader 100406

PN=65

10 15 11

General References

Intermittent Electronic Problems D

B C

E

M A

F G

H

L K

+

I

J

A—Component, First B—Wire Terminal to First Component (A) C—Isolated Wire

D—Wire Terminal to Second Component (E) E—Component, Second F—DFRW51 — Electronic Circuit Load Tester

G—Battery Positive Terminal H—Battery Negative Terminal I—Battery Ground to Frame J—Battery

Voltage Drop Method Checking a circuit for voltage drop is a method of identifying high resistance in the wire. Voltage drop checks on electrical circuits can be performed by using the electrical function as the load.

NOTE: Review Understanding Electrical vs. Electronic Circuits (Reference 210-15-014).

The following method is basically for checking wires in electronic circuits but can also be used in electrical circuits.

2.

3.

4.

5.

–UN–10JAN05

+

LV12008

10 15 12

K—Digital Multimeter L—Frame Ground M—Jumper Wire

possible, to isolate the circuit to a single wire (C), so that the wire is open at all ends.

Ground one end of wire (C) with a jumper wire (M) to the machine frame (L).

Connect DFRW51 Electronic Circuit Load Tester (F) at wire terminal (D) and battery positive (+) terminal (G). The current draw of the test lamp is 3.8 to 4.2 amps at 12.2 to 12.6 volts.

Connect a multimeter across battery terminals (G and H), red to positive (G) and black to negative (H). Record baseline voltage.

Move black multimeter lead to each point (I, L, B, and D) and record voltage.

1. Disconnect all components (A and E) from the circuit, including diodes and resistors when

Continued on next page

TMCM225401 (04OCT06)

10-15-12

OUO1089,000278B –19–13JAN05–1/4

2254 Cane Loader 100406

PN=66

General References

NOTE: Each connection should cause a 0.1 to 0.2 voltage drop. There are five connections in the example (H, I, L, B, and D) which will cause a total of 0.5 to 1.0 voltage difference between (H) and (D) as compared to the voltage across (G) and (H).

excessive resistance in the circuit (C) between those two points. Example: (G) to (H) = 12.4 volts, (G) to (I) = 12.2 volts, (G) to (L) = 12.1 volts, (G) to (B) = 12.0 volts and (G) to (D) = 10.8 volts would indicate high resistance between points (B) and (D).

The minimum expected voltage between (G) and (D) is 11.8 volts.

6. When the voltage drop between any two adjacent test points is greater than 0.4 volts, there is

Continued on next page

TMCM225401 (04OCT06)

10-15-13

OUO1089,000278B –19–13JAN05–2/4

2254 Cane Loader 100406

PN=67

10 15 13

General References 10 15 14

B

D

C

E

M A F

K

L

+

G

H

O

N

RW71273

I J A—Component, First B—Wire Terminal to First Component (A) C—Isolated Wire D—Wire Terminal to Second Component (E)

E—Component, Second F—DFRW51—Electronic Circuit Load Tester G—Battery Positive Terminal

Current Draw Method This current draw method can be used as an alternate method to check for excessive resistance in a circuit when the problem is intermittent and difficult to isolate.

The amount of current required for most electronic circuits to operate is commonly milliamps (1 mA is one thousandth of an amp). Sudden changes in circuit resistance can generate and send a false signal to the electronic control module causing intermittent operation. Digital multimeters also operate on very small amounts of current.

When the normal voltage and resistance (ohms) checks indicate the electronic circuit is normal, but the

H—Battery Negative Terminal I—Battery Ground to Frame J—Battery K—Digital Multimeter

L—Frame Ground M—Jumper Wire N—Meter Black (—) lead O—Meter Black (—) lead

system fails to provide continuous, uninterrupted operation, loading the circuit with 3—5 amps, as follows, may help to isolate unwanted resistance in the circuit.

1. Disconnect all components (A and E) from the circuit, including diodes and resistors when possible, to isolate the circuit to a single wire (C), open at all ends.

2. Ground one end of wire (C) with a jumper wire (M) to the machine frame (L).

3. Connect DFRW51 Electronic Circuit Load Tester (F) at battery positive (+) terminal (G). The current draw of the test lamp is 3.8 to 4.2 amps at 12.2 to 12.6 volts.

Continued on next page

TMCM225401 (04OCT06)

–UN–08JUN00

+

10-15-14

OUO1089,000278B –19–13JAN05–3/4

2254 Cane Loader 100406

PN=68

General References

Wire Gauge Current Draw—Specification 16 Gauge Wire—Amperage ..................... 75 mA Max per 4 m (16 ft) 14 Gauge Wire—Amperage ..................... 50 mA Max per 4 m (16 ft)

a. If the current draw is more than specification and the circuit does not have diodes or resistors, there is excessive resistance in the circuit.

Isolate the point of resistance and repair.

NOTE: The resistance can be a terminal that is dirty, loose, deformed, corroded, eroded or improperly crimped. The wire may be broken or contain several broken strands.

10 15 15

It is difficult to determine the conductivity of terminals when harness connectors are connected. Obtain the necessary connector terminals (pins and sockets) to be used as a troubleshooting tool to determine adequate frictional contact of mating terminals on the machine.

4. Set multimeter (K) dial and test leads for amperage test. Connect red meter lead to second lead of the test lamp (F). Connect black lead (N) to battery negative (-) terminal (H). Record the current (amps) after 30 seconds.

5. Move black multimeter lead (O) to terminal (D).

Record the current (amps) and compare the current recorded at step 4.

b. If the current draw is within specification, instruct another person to apply a moderate push-pull or twisting effort along the harness and at connectors as you observe the multimeter for a change in current draw. c. When this current draw method does not identify resistance in the circuit, the harness circuit should be considered normal and the electronic components should be thoroughly checked. Also check for intermittent operation by performing several operational checks of the electronic system.

OUO1089,000278B –19–13JAN05–4/4

TMCM225401 (04OCT06)

10-15-15

2254 Cane Loader 100406

PN=69

General References

Relay Circuit Types A relay is an electrical device used to allow a switch to control multiple loads and/or large current flows without damaging the switch. A small current from the switch energizes the relay and it connects a power supply to a load.

OUO1089,000278C –19–13JAN05–1/14

A

B

F 86

30 C

E 85

87

87A

–UN–10JAN05

D

LV12009

10 15 16

A—Switch B—Fuse

C—Internal Switch D—Load

E—Resistor

Common Relay Circuit • Terminal 30—supplied with battery power usually from a fuse (B) • Terminal 86—supplied with battery power from a switch (A) (key switch, light switch, fan switch, etc.)

• Terminal 85—ground circuit for switch (terminal 86) • Terminal 87A—OFF position for terminal 30 • Terminal 87—ON position for terminal 30 to complete circuit to load (D) (lights, blower motor, accessories, etc.)

Continued on next page

TMCM225401 (04OCT06)

F—Solenoid

10-15-16

OUO1089,000278C –19–13JAN05–2/14

2254 Cane Loader 100406

PN=70

General References 10 15 17

A

B

F 86

30 C

E 85

87

87A

LV12010

–UN–10JAN05

D

A—Switch B—Fuse

C—Internal Switch D—Load

E—Resistor

When the switch (A) is closed (turned ON), battery power is supplied to terminal 86. The current flows through the solenoid (F) inside the relay to terminal 85 and then to ground. As the current is flowing through

the solenoid, a magnetic field is created that pulls the relay internal switch (C) from terminal 87A to terminal 87. This allows battery power to flow from the fuse through terminal 30 to terminal 87 and to the load (D).

Continued on next page

TMCM225401 (04OCT06)

F—Solenoid

10-15-17

OUO1089,000278C –19–13JAN05–3/14

2254 Cane Loader 100406

PN=71

General References 10 15 18 A

B

F 86

30 C

E 85

87

87A

LV12009

–UN–10JAN05

D

A—Switch B—Fuse

C—Internal Switch D—Load

E—Resistor

When the switch (A) is opened (turned OFF), the battery power stops flowing through terminal 86 to terminal 85. The solenoid (F) inside the relay loses its magnetic field and the relay internal switch (C) returns to the OFF position at terminal 87A. The fixed resistor

(E), in parallel with the solenoid (F), helps to prevent or dampen a voltage spike from happening when the circuit is broken. If a voltage spike were to happen, control units and other electronic components could be damaged.

Continued on next page

TMCM225401 (04OCT06)

F—Solenoid

10-15-18

OUO1089,000278C –19–13JAN05–4/14

2254 Cane Loader 100406

PN=72

General References 10 15 19

A

B

G 86

30 C

F 85

E

87

87A

LV12012

–UN–07JAN05

D

A—Switch B—Fuse

C—Internal Switch D—Load

E—Indicator Light F—Resistor

Common Relay Circuit with Indicator Light • Terminal 30—supplied with battery power usually from a fuse (B) • Terminal 86—supplied with battery power from a switch (A) (key switch, light switch, fan switch, etc.)

• Terminal 85—indicator light, ground circuit for relay coil (terminal 86) • Terminal 87A—OFF position for terminal 30 • Terminal 87—ON position for terminal 30 to complete circuit to load (D) (lights, blower motor, accessories, etc.)

This circuit is identical to the common relay circuit, but it has an indicator light (E) added to the ground circuit (terminal 85). When the external switch (A) is closed, and current flows through relay terminals 86 and 85, the indicator light (E) will be lit to tell the operator the circuit is active. An indicator light may be added to any relay circuit.

Continued on next page

TMCM225401 (04OCT06)

G—Solenoid

10-15-19

OUO1089,000278C –19–13JAN05–5/14

2254 Cane Loader 100406

PN=73

General References 10 15 20 B

A

F 86

30 C

E 85

87

87A

LV12013

–UN–07JAN05

D

A—Fuse B—Switch

C—Internal Switch D—Load

E—Resistor

Relay Circuit with Power and Switch Terminals Reversed • Terminal 86—supplied with battery power from a switch (B) (key switch, light switch, fan switch, etc.)

• Terminal 30—supplied with battery power usually from a fuse (A) • Terminal 85—ground circuit for switch (terminal 86) • Terminal 87A—OFF position for terminal 30

• Terminal 87—ON position for terminal 30 to complete circuit to load (D) (lights, blower motor, accessories, etc.)

This relay circuit has battery power supplied to terminal 86 continuously, flowing through the solenoid (F) to terminal 85 and to ground. With the solenoid (F) energized, the relay internal switch (C) is connected to terminals 30 and 87.

Continued on next page

TMCM225401 (04OCT06)

F—Solenoid

10-15-20

OUO1089,000278C –19–13JAN05–6/14

2254 Cane Loader 100406

PN=74

General References 10 15 21

B A

F 86

30 C

E 87

87A

–UN–07JAN05

85

LV12014

D

A—Fuse B—Switch

C—Internal Switch D—Load

E—Resistor

F—Solenoid

Current flows to the load (D) when the external switch (B) is closed.

Continued on next page

TMCM225401 (04OCT06)

10-15-21

OUO1089,000278C –19–13JAN05–7/14

2254 Cane Loader 100406

PN=75

General References 10 15 22 A

B

G 86

30 C

F 85

87

87A

–UN–07JAN05

D

LV12015

E

A—Switch B—Fuse

C—Internal Switch D—Load 1

E—Load 2 F—Resistor

Common Relay Circuit with Two Loads • Terminal 30—supplied with battery power usually from a fuse (B) • Terminal 86—supplied with battery power from a switch (A) (key switch, light switch, fan switch, etc.)

• Terminal 85—ground circuit for switch (terminal 86)

• Terminal 87A—ON position for terminal 30 load 1 (D) • Terminal 87—ON position for terminal 30 load 2 (E) This relay circuit has the external switch (A) open.

Power flows through terminal 30 to terminal 87A and to load 1 (D).

Continued on next page

TMCM225401 (04OCT06)

G—Solenoid

10-15-22

OUO1089,000278C –19–13JAN05–8/14

2254 Cane Loader 100406

PN=76

General References 10 15 23

A

B

G 86

30 C

F 85

87

87A

–UN–07JAN05

D

LV12016

E

A—Switch B—Fuse

C—Internal Switch D—Load 1

E—Load 2 F—Resistor

G—Solenoid

When the external switch (A) is closed, the relay internal switch (C) connects terminals 30 and 87 to provide power to load 2 (E).

Continued on next page

TMCM225401 (04OCT06)

10-15-23

OUO1089,000278C –19–13JAN05–9/14

2254 Cane Loader 100406

PN=77

General References 10 15 24

A

B

G 86

30 C

F 85

87

87A –UN–07JAN05

E

LV12017

D

A—Switch B—Fuse

C—Internal Switch D—Load (Turn Signal Light)

Turn Signal Relay Circuits • Terminal 30—supplied with battery power usually from a fuse (B) and through a load (D) (turn signal light) • Terminal 86—supplied with battery power from a switch (A) (key switch, light switch, fan switch, etc.)

• Terminal 85—circuit grounded by flasher module

E—Flasher Module F—Resistor

• Terminal 87A—OFF position for terminal 30 • Terminal 87—ground circuit for load (D) When turn signal is activated, battery power is supplied to terminal 86 through solenoid (G) to terminal 85. Terminal 85 is connected to flasher module which grounds the circuit intermittently to flash the lights.

Continued on next page

TMCM225401 (04OCT06)

G—Solenoid

10-15-24

OUO1089,000278C –19–13JAN05–10/14

2254 Cane Loader 100406

PN=78

General References 10 15 25 A

B

I 86

30 C

H 85

87

87A

G 86

30

85

87

–UN–07JAN05

F

87A

LV12018

E D

A—Switch B—Fuse C—Internal Switch

D—Load 1 E—Low Beam Relay

F—Load 2 G—High Beam Relay

Low Beam Relay (E):

Multiple Relay Circuit: Keeping Two Loads from Being On at the Same Time.

The headlight circuit uses two relays wired together to control the headlights. This configuration prevents both high and low beams from being ON at the same time.

This same configuration can be used in other applications.

High Beam Relay (G): • Terminal 30—supplied with battery power from fuse (B) • Terminal 86—supplied with battery power from Hi/Lo beam switch (A) • Terminal 85—ground circuit for switch (terminal 86) • Terminal 87A—power to terminal 30 of low beam relay (E) • Terminal 87—ON position for terminal 30 to complete circuit to load 2 (high beam lights) (F)

• Terminal 30—supplied with battery power from terminal 87A of high beam relay (G) • Terminal 86—supplied with battery power from Hi/Lo beam switch (A) • Terminal 85—ground circuit for switch (terminal 86) • Terminal 87A— OFF position for terminal 30 • Terminal 87—ON position for terminal 30 to complete circuit to load 1 (D) When the Hi/Lo beam switch (A) is in the HIGH Beam position, battery power is supplied to terminal 86 of the high beam relay (G), through the solenoid (I) to terminal 85 and then to ground. Fused power (B) is supplied to terminal 30 of the high beam relay (G), through internal relay switch (C) to terminal 87 and then to load 2 (high beam lights) (F).

Continued on next page

TMCM225401 (04OCT06)

H—Resistor I—Solenoid

10-15-25

OUO1089,000278C –19–13JAN05–11/14

2254 Cane Loader 100406

PN=79

General References 10 15 26

A

B I 86

30 C

H 85

87

87A

G 86

30

F

87

87A

–UN–07JAN05

85 E

A—Switch B—Fuse C—Internal Switch

D—Load 1 E—Low Beam Relay

F—Load 2 G—High Beam Relay

When the Hi/Lo beam switch (A) is in the LOW beam position, battery power is supplied to terminal 86 of the low beam relay (E), through the solenoid to terminal 85 and then to ground. Fused power (B) is supplied to terminal 30 of the high beam relay (G), through

H—Resistor I—Solenoid

internal relay switch (C) to terminal 87A and then to terminal 30 of the low beam relay (E). Battery power flows from terminal 30 to terminal 87 and then to load 1 (low beam lights) (D).

Continued on next page

TMCM225401 (04OCT06)

LV12019

D

10-15-26

OUO1089,000278C –19–13JAN05–12/14

2254 Cane Loader 100406

PN=80

General References 10 15 27 A

B 86

30

I H

85 G

86

87

87A

30 C

D

87

E

87A

LV12020

85

–UN–07JAN05

F

A—Switch B—Fuse C—Load

D—Internal Switch E—Spotlight Grounding Relay

Multiple Relay Circuit: Allowing a Load to Be ON Only when Another Load Is ON. The light circuit has a spotlight that can only be ON when the light switch (A) is in the Field 1 or 2 position and the Hi/Lo beam switch (H) is in the HIGH beam position. This same configuration can be used in other applications.

SpotLight Relay (I): • Terminal 30—supplied with battery power from fuse (B) • Terminal 86—supplied with battery power from light switch (A), Field 1 or 2 position

F—Resistor G—Solenoid

• Terminal 85—ground circuit to terminal 30 of spotlight grounding relay (E) • Terminal 87A—OFF position for terminal 30 • Terminal 87—ON position for terminal 30 to complete circuit to load (spotlight) (C) Spotlight Grounding Relay (E): • Terminal 30—supplied with battery power from terminal 85 of spotlight relay (I) • Terminal 86—supplied with battery power from Hi/Lo beam switch (H), HIGH beam position • Terminal 85—ground circuit • Terminal 87A— OFF position for terminal 30 • Terminal 87— ground circuit

Continued on next page

TMCM225401 (04OCT06)

H—Hi/Lo Beam Switch I—Spotlight Relay

10-15-27

OUO1089,000278C –19–13JAN05–13/14

2254 Cane Loader 100406

PN=81

General References 10 15 28

A B 86

30

I

H 85 G

86

87

87A

30 C

D

87

87A

E

LV12021

85

–UN–07JAN05

F

A—Switch B—Fuse C—Load

D—Internal Switch E—Spotlight Grounding Relay

When the light switch (A) is in the Field 1 or 2 position and the Hi/Lo beam switch (H) is in the HIGH beam position, battery power is supplied to terminal 86 of the spotlight relay (I). Current flows through the relay solenoid to terminal 85 and on to terminal 30 of spotlight grounding relay (E). Current flows through the spotlight grounding relay internal switch (D) to terminal

F—Resistor G—Solenoid

H—Hi/Lo Beam Switch I—Spotlight Relay

87 and then to ground. Battery power flows through fuse (B) to terminal 30 of the spotlight relay (I) to terminal 87 and on to load (spotlight) (C). The Hi/Lo beam switch (H) provides battery power to spotlight grounding relay (E) terminal 86 through the solenoid (G) and on to terminal 85 and ground.

OUO1089,000278C –19–13JAN05–14/14

TMCM225401 (04OCT06)

10-15-28

2254 Cane Loader 100406

PN=82

General References 10 15 29

Using a Digital Multimeter It is recommended that a digital multimeter (JT05791 or equivalent with an analog display) be used to make the required electrical measurements in the diagnostics procedures. A knowledge of the operation of the particular meter used is assumed.

continuity test, autoranging, manual ranging, and touch hold.

Digital Multimeter Tests Current Measurements— For amperage readings, the red (+) contact must also be moved to the desired terminal on the meter.

NOTE: When using multimeters always refer to operation instructions supplied by the manufacturer. The descriptions below are specific to the JT05791.

The positive test lead from the volt-ohm input of the meter should be connected to point A and the negative test lead from the common input of the meter should be connected to point B. Unless otherwise stated, all voltage measurements are direct current (DC).

In making a resistance measurement, be careful to use the correct resistance range on the meter. Disconnect appropriate connectors or turn off key switch, as directed by diagnostic procedures later in this manual.

Digital Display— The digital display reads values of variables measured. It is updated 2-1/2 times a second. In normal operation the meter selects the range which will show the most accurate reading.

When the value being measured is too large for the meter to display, an OL (overload) will be shown.

Position of decimal point will change, depending upon range in use. The display also verifies the type and size of measurement being made.

Analog Display— This is a bar graph located below the digital display. The analog display is updated 25 times per second. It is more responsive to help see trends developing in variable readings. The polarity indicator is also part of this display. The full bar graph indicates the maximum reading for a scale. The arrowhead indicates OL. Selector— The selector is the command dial which allows the operator to select the type of variable to be measured, i.e., current measurements, diode test,

Diode Test— The “diode test” position can be used to test diodes. A single tone will sound in the forward bias direction along with a display of forward voltage drop.

Continuity Test— The meter also can be used to test continuity. If the circuit is open, there will be no tone. If the circuit made has continuity (less than 150 ohms), a continuous tone will sound.

Autoranging— The meter powers up in the autorange mode. Range is selected automatically. The digital display indicates the range.

Manual Ranging— When the button in the middle of the selector knob is pressed with the meter on, the range is selected manually. You can “dial” through ranges by repeatedly pressing the button. As in the autorange mode, range in use will be shown in the digital display. To return to autorange mode, press range button for 1 second. Meter will “chirp” once and return to autorange mode.

Touch Hold— If the button in the selector is pressed and held down while the meter is being turned on, and held until the display reaches full brightness, the meter is in the touch hold” mode. In touch hold, any reading which is constant for a minimum of 1/2 second and differs from the previous reading by at least one bar of the analog display will be “captured” by the meter. A tone (beep) will sound when the reading has been held. The operator can then remove the probes and the reading will be retained. Touch hold is always in autorange mode. Turn the selector switch to OFF to deactivate touch hold.

OUO1089,000278D –19–13JAN05–1/1

TMCM225401 (04OCT06)

10-15-29

2254 Cane Loader 100406

PN=83

General References 10 15 30

Troubleshooting Unresolved Problems NOTE: This reference is a guideline for troubleshooting problems that still exist after standard diagnostics have been performed. These problems are typically due to specific operating conditions, intermittent failures or, in rare cases, control unit failures. Depending on the situation, some or all of the following may be important.

Problems Due to Specific Operating Conditions Review all recorded codes and consult with operator to determine operating and vehicle conditions when the problem occurs. Record details. ❒ Does code/problem occur at the same time as other problems? ❒ Does code/problem occur when vehicle is warm or cold? ❒ Does code/problem occur during field or transport operation? ❒ Does code/problem occur while performing a specific action such as shifting, turning, braking, operating certain hydraulics? ❒ When did code/problem first appear? Was there any maintenance performed recently? (If yes, inspect areas of maintenance for inadvertent damage or improper installations.)

Attempt to recreate code/problem based on conditions. If possible, repeat operational, system, electrical, hydraulic or mechanical checks under these conditions.

Problems Due to Intermittent Electrical Failures

NOTE: Electrical intermittent failures are usually caused by harness, terminal or connector problems. ❒ Inspect all connectors and terminals of related circuits. ❒ Inspect mechanical linkages for interference with harnesses or connectors. ❒ Inspect harnesses for missing or improperly installed clamps or bands. Loose harnesses that are allowed to move too freely or harnesses that are banded too tightly may result in worn or damaged wires.

Continued on next page

TMCM225401 (04OCT06)

10-15-30

OUO1089,000278E –19–13JAN05–1/2

2254 Cane Loader 100406

PN=84

General References 10 15 31

❒ Inspect mechanical linkages for proper operating condition.

Problems Due to Control Unit Failures

NOTE: Before replacing control unit, review all tests.

Control units are the least likely cause of failure! ❒ If all checks have been made with no problems identified, check power and ground circuits. Power inputs must be within 1 V of battery voltage and ground circuits must be less than 1.0 ohm to the vehicle single point ground. ❒ Inspect all connectors and terminals of associated control units.

OUO1089,000278E –19–13JAN05–2/2

TMCM225401 (04OCT06)

10-15-31

2254 Cane Loader 100406

PN=85

General References 10 15 32

TMCM225401 (04OCT06)

10-15-32

2254 Cane Loader 100406

PN=86

Group 25

Fluid Recommendations 10 25 1

Radiator Antifreeze (Ethylene Glycol) 7.6 L (2 Gal) min.

Recommended 50 percent by volume Non-chromate inhibitor ..................................... 3-6 percent by volume Clean Water ......................................................................... Remainder

CAUTION: Cooling system is pressurized — radiator has a 10 PSI (0.7 Bar) pressure cap.

CAUTION: Do Not remove the radiator cap when it is hot!

Fill the radiator, operate the engine with the radiator cap off and when the engine reaches normal operating temperature, shut it off and check the coolant level. Top off the radiator with clean water, if necessary.

T803324,00008ED –19–02FEB06–1/1

Transmission SAE 85W140 (API-GL5) Oil ............................................................................................................................................................. 10.5 L (11 Qt.)

T803324,00008DD –19–01FEB06–1/1

Rear Steering Axle SAE 85W140 (API-GL5) Oil or Equivalenta Final Drives (2) - Power Assist Option ............................................................................................................................................. 1.3 L (1.4 Qt.) Final Drives (2) - High Traction Option .......................................................................................................................................... 2.6 L (2.75 Qt.) a Gear oil which meets AGMA (American Gear Manufacturers Association) Grade 5EP with a viscosity index of 95 min.

T803324,00008DD –19–01FEB06–1/1

TMCM225401 (04OCT06)

10-25-1

2254 Cane Loader 100406

PN=87

Fluid Recommendations 10 25 2

Front Rigid Axle SAE 85W140 (API-GL5) Oil or Equivalenta Large Final Drive(s) .............................................................................................................................................................................. 8 L (8.5 Qt) a Gear oil which meets AGMA (American Gear Manufacturers Association) Grade 5EP with a viscosity index of 95 min.

T803324,00008DD –19–01FEB06–1/1

Hydraulic Tank SAE 30W Motor Oil .......................................................................................................................................................................... 320 L (85 Gal)

Which complies with one or more of the API Classification CD/SF, CD/SD, CC/SF, CC/SD and MIL-I-2104D. Optional 15W30, CG-4 Motor Oil ..................................................................................................................................................... 320 L (85 Gal)

T803324,00008DD –19–01FEB06–1/1

Fuel Tank Clean Diesel Fuel ............................................................................................................................................................................. 303 L (80 Gal)

T803324,00008DD –19–01FEB06–1/1

Tire Inflation Pressure1 Front Tires 24.5 x 32 Bar (12 PR) ................................................................................................................................................................. 1.66 Bar 30.5 L x 32 (12PR) ........................................................................................................................................................................ 2.21 bar Rear Tires 18.4 x 26 (6PR) .......................................................................................................................................................................... 1.24 Bar 18.4 x 26 (8PR) .......................................................................................................................................................................... 1.38 Bar 18.4 x 30 (10PR) ......................................................................................................................................................................... 1.79 Bar 23.1 x 26 (10 PR) ........................................................................................................................................................................ 1.38 Bar

(24 PSI) (32 PSI) (18 (20 (26 (20

PSI) PSI) PSI) PSI)

1

Adjust to conditions.

T803324,00008DD –19–01FEB06–1/1

TMCM225401 (04OCT06)

10-25-2

2254 Cane Loader 100406

PN=88

Fluid Recommendations 10 25 3

Pump Drive If the double pump drive is used, lubricate the pump drive shafts and the splines with dry spline lubricant whenever installing a pump or pump drive.

85W140 (API GL5 ) Gear Oil ............................................................................................................................................................. 4.9L (1.3 Gal)

T803324,00008DD –19–01FEB06–1/1

Engine Coolant Requirements1 Proper cooling system maintenance helps control engine cylinder wall pitting caused by corrosion, cavitation and the accumulation of scale and rust in the cooling system.

Cylinder wall failure, or damage caused by overheated surfaces, can occur in a short time without the proper coolant.

Use a mixture of 50 percent clean water and 50 percent ethylene glycol (antifreeze). This will lower the freezing point of the mixture and raise the point at which boiling starts. This also lowers the concentration of impurities held in suspension by the water. Add to this mixture, a water conditioner (corrosion inhibitor) to give a 3 to 6 percent concentration.

The following prediluted engine coolant is preferred for service.

John Deere COOLGARD Prediluted Coolant

The following engine coolant is also recommended.

John Deere COOLGARD Coolant concentrate in a 40 to 60 percent mixture of concentrate with quality water. Other low silicate ethylene glycol base coolants for heavy duty diesel engines may be used if they meet one of the following specifications: ASTM D5345 (prediluted coolant) ASTM D4985 (coolant concentrate) in a 40 to 60 percent mixture of concentrate with quality water.

Coolants meeting these specifications require use of supplemental coolant additives, formulated for heavy duty diesel engines, for protection against corrosion and cylinder liner erosion and pitting.

1

For additional information, refer to Engine Manual.

T803324,00008EE –19–02FEB06–1/1

TMCM225401 (04OCT06)

10-25-3

2254 Cane Loader 100406

PN=89

Fluid Recommendations 10 25 4

Antifreeze Antifreeze must be ethylene glycol type, not more than 0.1 percent anhydrous metasilicate1. Some types of ethylene glycol antifreeze commonly available on the market are intended for automotive use. These products are often labeled for use in aluminum engines and usually have more than 0.1 percent anhydrous metasilicate. Use of this type antifreeze can cause a gel-like deposit to form that will reduce heat transfer and coolant flow. When wet, the gel is the same color as the coolant, but when dry, it forms a white, powdery deposit.

Antifreeze solutions should be used year round for freeze protection, boilover protection, and as a stable environment for seals and hoses.

1

Never use Methyl Alcohol based and Methoxy Propanol antifreezes.

T803324,00008EF –19–02FEB06–1/1

Water Water quality is important to the performance of the cooling system. Distilled, deionized or demineralized water is recommended for mixing with ethylene glycol base engine coolant concentrate.

Never use plain water as the engine coolant. This will shorten engine life and cause major damage. Plain water is corrosive, especially at high temperatures and under pressure. Use only clean drinking water in the solution.

DO NOT use water from field canals.

T803324,00008EF –19–02FEB06–1/1

TMCM225401 (04OCT06)

10-25-4

2254 Cane Loader 100406

PN=90

Fluid Recommendations 10 25 5

Inhibitors (Conditioners) Non-chromate inhibitors must be used. DO NOT use soluble oil. Always follow the supplier recommendations printed on the container. Overinhibiting antifreeze solutions can cause silicate dropout. When this happens, a gel-like deposit is created which retards heat transfer and coolant flow.

T803324,00008F0 –19–02FEB06–1/1

Filling the System 1. Mix antifreeze to provide protection to the lowest expected ambient temperature. Do not fill cooling system to the top, allow for addition of conditioner.

Most systems will require 2 L (2 Qts) of conditioner at initial fill and 0.50 L (1 pt) every 250 service meter hours thereafter.

2. To help avoid air pockets, add coolant slowly, fill at 19 L (5 US Gal) per minute or less.

3. Add cooling system conditioner.

4. Fill the coolant level to within 1 cm (1/2”) of the fill pipe’s bottom.

5. Start the engine with the radiator cap removed.

(Inspect cap after removing, replace seal, if it is damaged.) Add coolant, if necessary, when the level stabilizes.

6. Stop the engine and install the radiator cap. Be sure that the radiator cap has been properly reinstalled. The John Deere 6068D uses a 10 PSI cap.

7. Periodically blow or wash the oil cooler and radiator to remove accumulated dirt and trash.

T803324,00008F1 –19–02FEB06–1/1

TMCM225401 (04OCT06)

10-25-5

2254 Cane Loader 100406

PN=91

Fluid Recommendations

Fuel Specifications

–UN–02FEB06

Use either grade 1-D or grade 2-D fuel defined by the ASTM designation D975 or D396 for diesel fuels in John Deere engines1.

CM061850010

10 25 6

Ambient Temperature Chart

1 The grade you should use is determined by the ambient temperature in your area. Refer to the Ambient Temperature Chart to determine which fuel you should use. At altitudes above 1500 M (5000 ft), use only grade 1-D for all temperatures.

T803324,00008F2 –19–02FEB06–1/1

Sulphur Content Fuel sulphur content should be less than 0.5 percent when using the recommended crankcase oil drain intervals and API CF4 or CF4/ SG performance oils.

Diesel fuel, having a sulphur content greater than 1 percent, may cause increased wear on metal engine parts due to acids or ash produced during the combustion process.

T803324,00008F3 –19–02FEB06–1/1

TMCM225401 (04OCT06)

10-25-6

2254 Cane Loader 100406

PN=92

Fluid Recommendations 10 25 7

Cetane The cetane number should be no less than 40 to assure satisfactory starting and overall performance. A higher cetane number of 45 is necessary when operating in high altitudes or cold weather starting (temperatures below 0° C [32° F]).

T803324,00008F4 –19–02FEB06–1/1

Cloud Point Cloud point should be at least 10° C (6° F) below the lowest ambient temperature at time of starting. Wax can separate from the fuel when the temperature decreases to cloud point and may plug your filter.

T803324,00008F5 –19–02FEB06–1/1

Storage and Handling After buying good quality, clean fuel from a reputable supplier, proper storage is critically important.

1. Use clean storage and transfer tanks.

2. Periodically drain the water and sediments from the bottom of your storage tanks.

3. Avoid storing fuel over a long period of time, if you must; add a fuel conditioner to prevent water condensation.

T803324,00008F6 –19–02FEB06–1/1

TMCM225401 (04OCT06)

10-25-7

2254 Cane Loader 100406

PN=93

Fluid Recommendations 10 25 8

Hydraulic Fluid Engine oil may be used provided it meets one of the following: API Service CD/SF, CD/SD, CC/SF, CC/SD or MIL-L-2104C or John Deere TORQ-GARD SUPREME.

Recommended: SAE 30W Motor Oil Optional: SAE 15W30 CG-4 Motor Oil

TORQ-GARD SUPREME is a trademark of Deere & Company

TMCM225401 (04OCT06)

T803324,00008F8 –19–03FEB06–1/1

10-25-8

2254 Cane Loader 100406

PN=94

Fluid Recommendations 10 25 9

Engine Oil Due to significant variations in commercially available engine oils, we recommend John Deere PLUS-50.

If John Deere PLUS-50 engine oil and a John Deere oil filter are used, the service interval for oil and filter changes may be extended by 50 hours.

6068T John Deere (200 HP) ........................................... 20 L (21 Qt.) Break-in oil, 100 hrs, followed by above CG-4 15W40 Multi Grade.

Change filter and completely drain after 100 hours.

The following oil is also recommended: • John DeereTORQ-GARD SUPREME • 15W40+50 Multi-Grade Other oils may be used if they meet one or more of the following: • • • • • • •

John DeereUNI-GARD API Service Classification CG-4 API Service Classification CF-4 ACEA Specification E3 ACEA Specification E2 CCMC Specification D5 CCMC Specification D4

Multi-viscosity diesel engine oils are preferred.

IMPORTANT: If diesel fuel with sulfur content greater than 0.5 percent is used, reduce the service interval by 50 percent.

PLUS-50 is a trademark of Deere & Company TORQ-GARD SUPREME is a trademark of Deere & Company UNI-GARD is a trademark of Deere & Company

TMCM225401 (04OCT06)

T803324,00008F9 –19–03FEB06–1/1

10-25-9

2254 Cane Loader 100406

PN=95

Fluid Recommendations 10 25 10

Transmission Use an 85W140 multi-grade oil that meets extreme pressure (EP) gear lubricant specification MIL-L-210C or API classification.

T803324,00008FA –19–03FEB06–1/1

Gear Oil - Pump Drive Use an 85W140 multi-grade oil that meets extreme pressure (EP) gear lubricant specification MIL-L-210C or API classification GL-5.

T803324,00008FB –19–03FEB06–1/1

Gear Oil - Final Drive Use a gear oil which meets American Gear Manufacturers Association (AGMA) grade 5 EP with a viscosity index of 95.

T803324,00008FC –19–03FEB06–1/1

Grease Use an SAE multipurpose grease containing 3 to 5 percent molybdenum disulfide and having extreme pressure (EP) performance.

T803324,00008FD –19–03FEB06–1/1

TMCM225401 (04OCT06)

10-25-10

2254 Cane Loader 100406

PN=96

Section 20

Engines Contents

20

Page

Group 05—General Information John Deere Engine Repair—Use CTM104 . . . .20-05-1

TMCM225401 (04OCT06)

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PN=1

Contents

20

TMCM225401 (04OCT06)

20-2

2254 Cane Loader 100406

PN=2

Group 05

General Information John Deere Engine Repair—Use CTM104 For complete repair information the component technical manual (CTM) is also required. Use the component technical manual in conjunction with this machine manual.

TS225

–UN–17JAN89

• 6 cylinder 6.8 L engines—Use CTM104

OUO1089,000273E –19–07JAN05–1/1

TMCM225401 (04OCT06)

20-05-1

2254 Cane Loader 100406

PN=99

20 05 1

General Information

20 05 2

TMCM225401 (04OCT06)

20-05-2

2254 Cane Loader 100406

PN=100

Section 40

Electrical System Contents Page

Group 10—General Information Visually Inspect Electrical System . . . . . . . . . . .40-10-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . .40-10-2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .40-10-3 Alternator and Battery . . . . . . . . . . . . . . . . . . . .40-10-4 Cleaning Battery Posts . . . . . . . . . . . . . . . . . . .40-10-5 Jumping the Battery . . . . . . . . . . . . . . . . . . . . .40-10-6 Charging the Batteries. . . . . . . . . . . . . . . . . . . .40-10-6 Precautions for Alternators . . . . . . . . . . . . . . . .40-10-7 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-10-8 Common Circuit Tests. . . . . . . . . . . . . . . . . . . .40-10-9 Start Switch Check . . . . . . . . . . . . . . . . . . . . .40-10-10 Horn Switch Check . . . . . . . . . . . . . . . . . . . . .40-10-10 Horn Check . . . . . . . . . . . . . . . . . . . . . . . . . . .40-10-10 Electrical Checks continued... . . . . . . . . . . . . .40-10-12

TMCM225401 (04OCT06)

40-1

40

2254 Cane Loader 100406

PN=1

Contents

40

TMCM225401 (04OCT06)

40-2

2254 Cane Loader 100406

PN=2

Group 10

General Information Visually Inspect Electrical System Make the following visual electrical inspection prior to starting the equipment: CAUTION: Wear eye protection and remove rings, metal watch bands, and other metal jewelry when working on the electrical system.

1. Look for bare wires that could ground a component or short across to another component.

–UN–06JAN00

40 10 1

2. Look for a missing or worn conduit. This could indicate a wire problem.

CM989999014

3. Look for loose or broken connectors and wires.

4. Inspect battery for: • • • • •

Corroded Terminals Loose Terminals or Battery Posts Dirty Condition Cracked Case Proper Electrolyte Level

5. Check alternator belt tension.

6. After equipment has been shut down for five minutes inspect for overheated parts. They will often smell like burned insulation. Put your hand on the alternator.

Heat in these parts when the unit has not been operated for some time is a sure clue to charging circuit problems.

7. If your visual inspection does not indicate the possible malfunction, but your inspection does indicate that the machine can be run, turn the key switch to IGN. Try out the accessory circuits, indicators lights and gauge lights, etc. How does each of these components work?

Look for sparks or smoke, which might indicate shorts.

8. Start the machine. Check all gauges for good operation and check to see if system is charging or discharging.

Continued on next page

TMCM225401 (04OCT06)

40-10-1

T803324,000098E –19–17MAR06–1/2

2254 Cane Loader 100406

PN=103

General Information 9. In general, look for anything unusual. Many electrical failures cannot be detected even if the harvester is running. Therefore, a systematic and complete inspection of the electrical system is necessary.

T803324,000098E –19–17MAR06–2/2

Safety Precautions 40 10 2

CAUTION: Explosive gas is produced when battery is in use or being charged.

1. Keep all flames/sparks away from battery.

2. Charge battery in a well ventilated area.

3. Always remove negative (-) battery cable first and replace it last.

4. Never lay a metal object on top of a battery: a short circuit can result, damaging the battery and metal object.

5. If acid spills on clothing, immediately remove clothing.

6. If acid contacts skin, rinse affected area with running water for 15 minutes.

Continued on next page

TMCM225401 (04OCT06)

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T803324,000098F –19–17MAR06–1/2

2254 Cane Loader 100406

PN=104

General Information

8. To neutralize acid spilled on the floor of the machine, flood the spill with one of the following mixtures, then rinse thoroughly with clean water:

TS204

CAUTION: Sulfuric acid in battery electrolyte is poisonous. Electrolyte can cause severe burns if it contacts the eyes or skin. Always wear eye and face protection when working around batteries.

–UN–23AUG88

7. If acid splashes into eyes, hold eyelids open and flood eyes with running water for 10 to 15 minutes, then see a doctor at once. DO NOT use any medication or eye drops unless prescribed by a doctor.

• 0.5 kg (1 lb) of baking soda in 4 L (1 gal) of water • 0.4 L (1 pt) of household ammonia in 4 L (1 gal) of water

T803324,000098F –19–17MAR06–2/2

Specifications Your machine is equipped with a negative ground electrical system. It uses 12 volt batteries. Only use batteries that meet the following specifications: Part Number ......................................................................... AT144146 BCI Group Size ................................................................................ 31 Cold Cranking Amps at -18° C (0° F) ............................................ 925 Reserve capacity at 25 amps ........................................... 190 minutes

T803324,0000990 –19–17MAR06–1/1

TMCM225401 (04OCT06)

40-10-3

2254 Cane Loader 100406

PN=105

40 10 3

General Information

Alternator and Battery Theory of Operation A battery is a device for converting chemical energy to electrical energy. It is not a storage tank for electricity, but stores electrical energy in chemical form.

40 10 4

Because of the constant chemical to electrical change, the battery has a limited life. Proper care will extend the life of the battery.

In a fully charged battery, the electrolyte solution is approximately 1.27 times heavier than water. The amount that the solution is heavier than water is called specific gravity.

All batteries will self-discharge over a period of time.

Temperature and amount of time will both determine the rate of discharge. If a machine is not used for a period of time, the batteries must be stored in a cool place.

The batteries provide the energy to start the engine and power the electrical loads when they exceed the alternator’s capacity.

The alternator provides power for the electrical equipment when the machine is running. If the electrical load exceeds the alternator’s capacity for short periods, the batteries will supply the necessary power as long as possible.

The alternator is belt driven by the engine crankshaft and can provide power immediately after startup.

T803324,0000991 –19–17MAR06–1/1

TMCM225401 (04OCT06)

40-10-4

2254 Cane Loader 100406

PN=106

General Information

Cleaning Battery Posts NOTE: Before diagnosing an alternator or battery problem, be sure accessory electrical equipment has not been added that might exceed the alternator’s capacity. If excessive load has been added, the ability to recharge the batteries could be affected.

1. Disconnect battery clamps, grounded () clamp first, and wipe clean with a damp cloth.

40 10 5

2. If terminals are corroded, wash with a stiff brush and an ammonia solution.

3. After washing, flush battery and compartment with clear water. Keep caps in place while cleaning.

4. Apply lubricating grease around the battery terminal base only.

5. Install and retighten clamps; grounded clamp last ().

T803324,0000992 –19–17MAR06–1/1

TMCM225401 (04OCT06)

40-10-5

2254 Cane Loader 100406

PN=107

General Information

Jumping the Battery CAUTION: Loader electrical system is a 12V system. Do not use a 24V system to jumpstart.

CAUTION: Always remove the grounded (-) battery clamp first and replace it last.

40 10 6

1. When possible, use equipment with a switch in the line connecting the booster battery to the battery to be jumped.

2. Connect the booster cable to the batteries in parallel (positive to positive and negative to negative).

3. Rock the connector clips to ensure that they are fastened securely.

4. If only jumper cables are available, always make the last connection from the negative terminal of the booster battery to a ground point on the machine frame1, away from the batteries.

1

The machine electrical system has a negative (-) ground.

T803324,0000993 –19–17MAR06–1/1

Charging the Batteries 1. To start the engine using a battery charger; turn off the charger before connecting and disconnecting.

2. DO NOT use a battery charger as a booster if the battery has a 1.15 specific gravity reading or lower.

3. To charge a battery, disconnect positive and negative cables before charging.

4. If a unit has more than one battery, each battery must be charged separately.

5. DO NOT charge a battery if it is frozen— it may explode. Warm the battery to 10° C (50° F), before charging.

T803324,0000994 –19–17MAR06–1/1

TMCM225401 (04OCT06)

40-10-6

2254 Cane Loader 100406

PN=108

General Information

Precautions for Alternators CAUTION: Alternator is a 12V system. Do not use a 24V booster.

When batteries are connected, follow these rules: 1. Disconnect the negative (-) cable when you work on or near the alternator.

40 10 7

2. DO NOT try to polarize the alternator.

3. Be sure that alternator wires are connected correctly before connecting batteries.

4. DO NOT ground alternator output terminal.

5. DO NOT disconnect or connect any alternator wire while batteries are connected or while the alternator is working.

6. Connect batteries or booster battery in the correct polarity (positive [+] to positive [+] and negative [-] to negative [-]).

7. DO NOT disconnect the batteries when the engine is running and the alternator is charging.

8. Disconnect the battery cables before you connect a battery charger to the batteries.

T803324,0000995 –19–17MAR06–1/1

TMCM225401 (04OCT06)

40-10-7

2254 Cane Loader 100406

PN=109

General Information

Inspection Inspect the electrical system for clues to the malfunction.

Check to see if the unit can be operated without further damage to the system.

ALWAYS visually check the following before turning on switches or running the unit.

1. Look for bare wires that could cause grounds or shorts.

40 10 8

2. Look for loose or broken wires.

3. Inspect all connections, especially battery connecting points. The cleaning of harness connectors or ground connections can often correct what appears to be a malfunctioning component.

4. Check the engine fan belt tension.

5. Inspect for overheated parts after the unit has been stopped for a while. They will often smell like burned insulation. Put your hand on the alternator, heat in this area, after the unit has not been operated in some time, is a sure indication of charging circuit problems.

6. In general, look for anything unusual.

7. If your visual inspection does not turn up the possible malfunction, but the machine can be run, turn the ignition switch ON, look for sparks or smoke that may indicate a short.

T803324,0000996 –19–17MAR06–1/1

TMCM225401 (04OCT06)

40-10-8

2254 Cane Loader 100406

PN=110

General Information

Common Circuit Tests Symptom

Problem

Solution

Shorted Circuit

A shorted circuit may result in the wrong component operating (i.e. improper wire-to-wire) contact). To test for a shorted or improperly wired circuit.1

Turn component switch ON. Start at the controlling switch of the component that should not be operating. Follow the circuit and disconnect wires at connectors until the component stops operating.

Shorted or improper connections will be the last two wires disconnected.

High Resistance or Open Circuits

These usually result in slow, dim or no component operation (i.e. poor, corroded, or disconnected connections).

To test for high resistance and open circuits: Check all terminals and grounds in the circuit for corrosion. If terminals are not corroded or loose, the problem is in the component wiring.

Grounded Circuits

These usually result in no component operation or blown fuses.

Do operational tests.

Ignition Switch Test

Disconnect harness, turn switch off.

Test with ohmmeter. If ohmmeter reads continuity, the switch must be replaced.

Turn switch to ACC.

Connect ohmmeter. Ohmmeter must read continuity between B and ACC and B and ACC terminals. If not, replace switch.

Turn ignition switch off.

Measure battery voltage. Voltage must be 12-13 volts (only for 12 V DC systems).

Start engine and run at 1500 RPM.

Engine running voltage must be at 13 - 15 volts at alternator (for 12V DC system).

Alternator Output Check

1

All voltage readings are taken between the test point and the ground on the harvester unless otherwise specified.

Continued on next page

TMCM225401 (04OCT06)

40-10-9

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2254 Cane Loader 100406

PN=111

40 10 9

General Information Symptom

Problem

Solution

Starter Solenoid Check

Disconnect metal connector from starter motor large terminal. Connect battery voltage to solenoid small terminal. Ground metal strap from solenoid with heavy gauge wire.

Solenoid must click. If not, replace.

Starter Motor Check

Disconnect metal connector from starter motor large terminal. Connect a heavy gauge wire from battery positive cable to starter motor terminal.

Starter motor must turn, but should not crank engine. If so, it must be repaired or replaced.

40 10 10

T803324,0000997 –19–17MAR06–2/2

1 Start Switch Check

– – –1/1

1a Disconnect harness from switch. Connect ohmmeter to switch terminals. Push switch button.

Ohmmeter must read continuity.

OK: Done NOT OK: Replace switch

– – –1/1

1 Horn Switch Check

– – –1/1

1a Disconnect harness from switch. Connect ohmmeter to switch terminals. Push switch button.

Ohmmeter must read continuity.

OK: Done NOT OK: Replace switch

– – –1/1

1 Horn Check

– – –1/1

TMCM225401 (04OCT06)

40-10-10

2254 Cane Loader 100406

PN=112

General Information 1a Connect battery voltage to horn terminal and ground horn housing.

Horn must sound.

OK: Done NOT OK: Replace horn.

– – –1/1

40 10 11

TMCM225401 (04OCT06)

40-10-11

2254 Cane Loader 100406

PN=113

General Information

Electrical Checks continued...

Symptom

Problem

Solution

Nothing works.

Problem with power circuit components.

Check power circuit.

Battery undercharged or dead.

Charge or replace battery.

40 10 12

Some Electrical Components Work

Battery cables making poor connections.

Clean cable connections at battery, starter and frame ground.

Ignition switch failure.

Test switch and replace, if necessary.

Fuse blown.

Check fuses and replace, if necessary with same rate fuses.

Starter switch failure.

Check fuse and replace, if necessary.

Check switch and replace, if necessary.

Starter Will Not Crank Engine

Engine Cranks Slowly

Battery undercharged or dead.

Check and replace, if necessary.

Battery cables making poor connections.

Clean connections at battery, starter and frame ground.

Starter solenoid failure.

Test and replace, if necessary.

Starter motor failure.

Test and replace, if necessary.

Major engine failure.

See engine manual for repairs.

Batteries Undercharged.

Charge batteries.

Alternator belt loose or glazed.

Adjust or replace belt.

Starter armature bearings worn causing starter drag.

Repair or replace starter.

Alternator failure.

Inspect, repair or replace.

Battery cable connections loose or corroded.

Clean and tighten connections.

Continued on next page

TMCM225401 (04OCT06)

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2254 Cane Loader 100406

PN=114

General Information Symptom

Problem

Solution

Starter Turns, But Engine Will Not Crank

Wiring at starter solenoid making poor connections.

Clean and tighten connections.

Starter pinion not engaging flywheel ring gear.

Repair or replace starter.

Starter pinion or flywheel gear teeth broken.

Replace pinion or flywheel.

Starter Still Runs After Engine Starts

Starter solenoid stuck,

Lightly tap on case of solenoid.

Replace solenoid.

Starter not disengaging.

Lightly tap on starter case.

40 10 13

Replace or repair shift mechanism.

Low Battery Output

Starter Solenoid Chatters

Start relay stuck.

Lightly tap on relay.

Wiring harness shorted.

Check wiring harness.

Dirty or wet battery top, causing discharge.

Clean battery and wipe dry.

Corroded or loose battery cable ends.

Clean and tighten end clamps.

Recharge batteries separately.

Broken or loose battery posts.

If posts are loose or will turn, replace battery.

Loose fan/alternator belt or worn pulleys.

Inspect belt or pulley. Adjust or replace as necessary.

Poor connection at battery or starter.

Clean and tighten connections.

Low battery charge.

Charge or replace batteries.

Starter solenoid “hold-in” winding open.

Check solenoid, replace if necessary.

Continued on next page

TMCM225401 (04OCT06)

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T803324,0000999 –19–21MAR06–2/6

2254 Cane Loader 100406

PN=115

General Information

40 10 14

Symptom

Problem

Solution

Noisy Alternator

Worn drive belt.

Inspect and replace.

Pulley misaligned.

Adjust alternator mount.

Alternator bearing failure.

Loosen alternator belts, turn pulley by hand. If any roughness is felt, repair or replace.

Internal alternator failure.

Repair or replace alternator.

Fuse blown.

Replace fuse.

Gauge failure.

Test gauge and replace, if necessary.

Gauge sender failure.

Test and replace, if necessary.

Wiring harness problem.

Inspect and repair or replace.

Fuse Blown.

Replace fuse.

Horn Failure.

Test horn and replace, if necessary.

Horn switch failure.

Test and replace, if necessary.

Fuse Blown - Voltmeter should read zero. Also, the windshield wiper motor and the piler lift and lower commands should not work.

Replace fuse.

Reverse Alarm Failure

Replace Reverse Alarm.

Reverse Alarm Pressure Switch Failure

Replace Reverse Alarm Pressure Switch

Fuse Blown would also prevent engine start/run

Replace fuse.

Hour Meter Failure

Replace hour meter. Record time from old hour meter for the engine records.

Gauge Does Not Work (Applies To All Gauges)

Horn Does Not Work

Backup Alarm Does Not Work

Engine Hour Meter Not Working

Continued on next page

TMCM225401 (04OCT06)

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T803324,0000999 –19–21MAR06–3/6

2254 Cane Loader 100406

PN=116

General Information Symptom

Problem

Solution

Engine Oil Pressure Warning Alarm (Light or Audible Alarm) Does Not Work

Fuse Blown - Voltmeter should read zero. Also Windshield Wiper Motor, Piler Lift/Lower Commands, Reverse Alarm and Engine Water Temperature Alarm should not work.

Replace fuse.

Disconnected wire.

Verify wire is connected between alarm and the engine oil pressure gauge.

Engine Water Temperature Alarm (Light or Audible) Does Not Work

Oil Pressure Gauge failure. Gauge may still indicate oil pressure but pressure alarm switch inside gauge may have failed.

Replace Engine Oil Pressure Gauge

Alarm Failure - either light or audible

Replace alarm.

Fuse Blown - Voltmeter should read zero. Also windshield wiper motor, Piler Lift/Lower Commands, Reverse Alarm and Engine Oil Pressure Alarm Should Not Work

Replace fuse.

Disconnected wire.

Verify wire connected between alarm and the engine water temperature gauge.

Water Temperature Gauge Failure Gauge may still indicate engine water temperature, but the temperature alarm switch inside gauge may have failed.

Replace Engine Water Temperature Gauge

Alarm Failure - Either Light or Audible

Replace alarm.

Continued on next page

TMCM225401 (04OCT06)

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2254 Cane Loader 100406

PN=117

40 10 15

General Information Symptom

Problem

Solution

Neutral Start Does Not Work

Switch on Park Brake Level - Verify proper position (bracket not bent correctly) and switch being actuated.

Reset bracket and switch.

Switch on Park Brake Lever not working.

Replace switch.

Hydrostatic Destroke Solenoid Valve Failure

Replace solenoid valve.

Destroke Solenoid Relay Failure

Replace relay.

Blown Fuse - Horn should also not work.

Replace fuse.

Blown Fuse - Engine should not run.

Replace fuse.

Fuel Shutoff Solenoid Does Not Work

Replace Engine Fuel Solenoid

Blown Fuse - Windshield Wiper Motor, Reverse Alarm, Engine Oil Pressure Alarm, Engine Water Temperature Alarm should not work and Voltmeter should read zero.

Replace fuse.

Switch or wire failure in right hand joystick valve.

Repair or replace joystick valve.

Piler Lift/Lower Relay Failure

Replace relay.

Pilot Oil Pressure

Verify pilot oil supply and pressure.

Signals to solenoid valves.

Verify command signals to solenoid valves when commands given by switch on right hand joystick valve.

Solenoid Control, Pilot Operated Valve Section not working

Replace Solenoid Control Valve, Solenoid Control, Pilot Operated Valve Work Section or complete 3 Bank Directional Control Valve

40 10 16

Engine Fuel Shutoff Solenoid Does Not Work

Piler Lift/Lower Commands Do Not Work

Directional Valve Failure Solenoid controlled, pilot operated section of three bank directional control valve.

Continued on next page

TMCM225401 (04OCT06)

40-10-16

T803324,0000999 –19–21MAR06–5/6

2254 Cane Loader 100406

PN=118

General Information Symptom

Problem

Solution

Optional Engine Safety Shutoff Not Working - Activated by low engine oil pressure or high engine water temperature signals from the gauges on the dash.

Blown fuse.

Replace fuse.

Failure of switch in either Engine Oil Pressure Gauge or Engine Water Temperature Gauge

Replace gauge.

Engine Safety Shutoff Switch Failure

Replace the optional Engine Safety Shutoff Switch

T803324,0000999 –19–21MAR06–6/6

TMCM225401 (04OCT06)

40-10-17

2254 Cane Loader 100406

PN=119

40 10 17

General Information

40 10 18

TMCM225401 (04OCT06)

40-10-18

2254 Cane Loader 100406

PN=120

Section 50

Hydrostatic System Contents Page

Group 10—Pumps & Motors Rear Motor Displacement Control (High Traction Option) . . . . . . . . . . . . . . . . . . . . . . .50-10-1 Theory of Operation . . . . . . . . . . . . . . . . . . . . .50-10-2 Operating Principle . . . . . . . . . . . . . . . . . . . . . .50-10-3 Closed Loop Circuit (Hydrostatic Ground Drive Circuit) . . . . . . . . . . . . . . . . . . . . . . . . .50-10-4 Case Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-10-4 Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . .50-10-5 Charge Relief Valve . . . . . . . . . . . . . . . . . . . . .50-10-5 System Check Valves . . . . . . . . . . . . . . . . . . . .50-10-5 Multi-Function Valves . . . . . . . . . . . . . . . . . . . .50-10-6 Pressure Limiter and High Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-10-6 Bypass Valves . . . . . . . . . . . . . . . . . . . . . . . . .50-10-6 Auxiliary Mounting Pads . . . . . . . . . . . . . . . . . .50-10-7 Hydraulic Displacement Control. . . . . . . . . . . . .50-10-7 Initial Start-up Procedure. . . . . . . . . . . . . . . . . .50-10-8 Fluid and Filter Maintenance . . . . . . . . . . . . . .50-10-10 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . .50-10-10 Hydrostatic Pump . . . . . . . . . . . . . . . . . . . . . .50-10-14 Charge Relief Valve Adjustment . . . . . . . . . . .50-10-16 Multi-Function Valve Pressure Adjustment . . .50-10-17 Engaging the Bypass Function . . . . . . . . . . . .50-10-19 Hydraulic Displacement Control. . . . . . . . . . . .50-10-20 Shaft Seal and Shaft Replacement . . . . . . . . .50-10-22

50

Group 20—Minor Pump Repairs Multi-Function Valve Cartridges. . . . . . . . . . . . .50-20-1 Charge Relief Valve . . . . . . . . . . . . . . . . . . . . .50-20-2 Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . .50-20-3 Installing the Charge Pump . . . . . . . . . . . . . . . .50-20-5 Auxiliary Pad Installation . . . . . . . . . . . . . . . . . .50-20-7 Hydraulic Displacement Controls. . . . . . . . . . . .50-20-9 Group 30—Displacement Control Components Displacement Control Filter Screens . . . . . . . . .50-30-1 Displacement Control Orifice Check Valve . . . .50-30-1 Displacement Control Orifices . . . . . . . . . . . . . .50-30-2 Disassembly Procedures for Variable Displacement Pump. . . . . . . . . . . . . . . . . . . .50-30-3 Reconditioning and Replacement of Parts. . . . .50-30-6 Assembly Procedures for Variable Displacement Pump. . . . . . . . . . . . . . . . . . . .50-30-9

TMCM225401 (04OCT06)

50-1

2254 Cane Loader 100406

PN=1

Contents

50

TMCM225401 (04OCT06)

50-2

2254 Cane Loader 100406

PN=2

Group 10

Pumps & Motors Rear Motor Displacement Control (High Traction Option) 1—Bolt 2—Knob 3—Decal 4—Pin-Split 5—Collar 6—Bolt 7—Cartridge 8—Bolt 9—Body-Valve 10—Bolt 11—Washer 12—Nut 13—Valve Mount 14—Bolt

CM00312074A2

–UN–04OCT06

50 10 1

T803324,00009BF –19–04OCT06–1/1

TMCM225401 (04OCT06)

50-10-1

2254 Cane Loader 100406

PN=123

Pumps & Motors

Theory of Operation

50 10 2

CM062254015

A pressure reducing valve is for the purpose of establishing a lower pressure level in the branch circuit from that in the main pump line. The inlet is connected to a source of high pressure and the adjustment is set to deliver a constant maximum pressure at the outlet regardless of pressure fluctuations on the inlet, as long as the inlet pressure remains as high as or higher than the adjustment setting. Branch circuits operating from a reducing valve act the same way as any other hydraulic circuit. Pressure in the branch is directly proportional to the load resistance, and will be no higher than demanded by the load. But the maximum pressure available to the branch is limited by the adjustment setting. The load can move at full speed as long as it does not demand a pressure higher than the adjustment setting. But if the load should increase to the point that it demands more pressure than the adjustment setting, this in effect is an overload. The load will either stall or will be forced to move at a slower speed – one which does not require pressure higher than the adjustment setting.

–UN–04OCT06

The control valve, pressure reducing valve, simply varies the pressure signal that is sent to the rear wheel motor to adjust the displacement of the motors. A pressure reducing valve in hydraulics is equivalent of a pressure regulator in a compressed air system, and the operating principle of the two is basically the same although they are constructed quite differently.

Simplified Hydraulic Symbol

A reducing valve offers very little flow resistance and power loss until the branch circuit demands pressure higher than the adjustment setting. At this point, the valve spool moves to a throttling position and will limit the flow through the valve to a value where the pressure will stay within the limit of the adjustment setting.

T803324,00009C0 –19–04OCT06–1/1

TMCM225401 (04OCT06)

50-10-2

2254 Cane Loader 100406

PN=124

Pumps & Motors

Operating Principle 1—Inlet 2—External Drain 3—Outlet A—Main Spool B—Spring Chamber C—Adjustment Knob D—Pilot Spring and Poppet E—Internal Pilot Passage F—Orifice

CM062254016

–UN–04OCT06

50 10 3

T803324,00009C1 –19–04OCT06–1/2

CM062254017

–UN–04OCT06

The spool is held in a normally open position by a light, non-adjustable, spring. A small, direct acting, relief valve on the crosshead sets the maximum pressure level on the outlet port regardless of pressure fluctuations in pressure on the inlet. The spool remains in the wide open position for full free flow to the outlet until an excessive demand for pressure from the load connected to the outlet causes the spool to move into a throttling position. The higher the pressure demand on the outlet, the closer the spool will move toward its closed position. All pressure reducing valves must have an external drain line to tank. The drain port must NEVER be plugged.

Complete Hydraulic Symbol 1—Inlet 2—Drain 3—Outlet

T803324,00009C1 –19–04OCT06–2/2

TMCM225401 (04OCT06)

50-10-3

2254 Cane Loader 100406

PN=125

Pumps & Motors

Closed Loop Circuit (Hydrostatic Ground Drive Circuit) The main ports of the pump are connected by hydraulic lines to the main ports of the motor. Fluid flows, in either direction, from the pump to the motor then back to the pump in this closed circuit. Either of the hydraulic lines can be under high pressure. The position of the pump swashplate determines which line is high pressure as well as the direction of fluid flow in the hydrostatic circuit.

T803324,000093E –19–15MAR06–1/1

Case Drain 50 10 4

The pump and motor require case drain lines to remove hot fluid from the system. The motor should be drained from its top most drain port to ensure the case remains full of fluid. The motor case drain can then be connected to the lower drain port on the pump housing and out the top most port to the hydraulic tank.

NOTE: On the 2254 Hydrostatic Ground Drive System, there are three hydrostatic motors connected in parallel to the single variable hydrostatic pump.

The front axle has a fixed displacement motor connected to the input of the three speed transmission which is connected to the front wheel final drives.POWER ASSIST Option - All three motors are fixed displacement motors and there is a directional valve to allow or to block flow to the rear axle motors to adjust between field and transport speeds.HIGH TRACTION Option - The rear axle motors are variable displacement motors and these motors can be de-stroked to provide adjustment between field and transport speeds.

NOTE: On the 2254 Loader Hydrostatic Ground Drive System, the case drain from the top port of the front axle motor is routed to the bottom ports on the rear wheel drive motors and then from the rear wheel drive motor top ports to the hydraulic tank.

T803324,000093F –19–15MAR06–1/1

TMCM225401 (04OCT06)

50-10-4

2254 Cane Loader 100406

PN=126

Pumps & Motors

Charge Pump The charge pump is necessary to supply cool fluid to the system, to maintain positive pressure in the main system loop, to provide pressure to operate the control system, and to make up for internal leakage. Charge pressure must be at its specified pressure under all conditions of driving and braking to prevent damage to the transmission. The charge pump is a fixed displacement, gerotor type pump installed in the variable displacement pump and driven off the main pump shaft. Charge pressure is limited by a relief valve.

50 10 5 T803324,0000940 –19–15MAR06–1/1

Charge Relief Valve The charge relief valve on the pump serves to maintain charge pressure at a designated level. A direct acting poppet valve relieves charge pressure whenever it surpasses a certain level. This level is nominally set referencing case pressure at 1775 rpm. This nominal setting assumes the pump swashplate is in neutral (zero flow): in the forward or reverse flow modes; the charge pressure will be lower.

T803324,0000941 –19–15MAR06–1/1

System Check Valves The system check valves allow pressurized flow from the charge pump to enter the low pressure side of the loop whenever system pressure dips below a certain level. This is needed as the pump will generally lose system pressure due to leakage and other factors. Since the pump can operate in either direction, two system check valves are used to direct the charge supply into the low pressure lines. The system check valves are poppet valves located in the multifunction valve assembly.

T803324,0000942 –19–15MAR06–1/1

TMCM225401 (04OCT06)

50-10-5

2254 Cane Loader 100406

PN=127

Pumps & Motors

Multi-Function Valves The multifunction valve incorporates the system check valve, the pressure limiter valve, the high pressure relief valve, and the bypass valve in a replaceable cartridge.

These functions are described separately. There are two multifunction valve cartridges in each pump to handle functions in either direction.

T803324,0000943 –19–15MAR06–1/1

50 10 6

Pressure Limiter and High Pressure Relief Valves Pumps are designed with a sequenced pressure limiting system and high pressure relief valves. When the preset pressure is reached, the pressure limiter system acts to rapidly destroke the pump so as to limit the system pressure. For unusually rapid load application, the high pressure relief valve acts to immediately limit system pressure by crossporting system flow to the low pressure side of the loop. The pressure limiter valve acts as the pilot for the high pressure relief valve spool. The high pressure relief valve is sequenced to operate at approximately 35 bar (500 psi) above the level that initiates the pressure limiter valve. Both the pressure limiter sensing valves and relief valves are built into the multifunction valves

T803324,0000944 –19–15MAR06–1/1

Bypass Valves The bypass valves (“tow”) can be operated when it is desired to move the vehicle or mechanical function when the pump is not running. The valve is opened by manually resetting the valve position The bypass valves are built into the multifunction valves.

T803324,0000945 –19–15MAR06–1/1

TMCM225401 (04OCT06)

50-10-6

2254 Cane Loader 100406

PN=128

Pumps & Motors

Auxiliary Mounting Pads This pad is used for mounting auxiliary hydraulic pumps and for mounting additional pumps to make tandem pumps. The pads allow for full through-torque capability.

T803324,0000946 –19–15MAR06–1/1

Hydraulic Displacement Control 50 10 7

The hydraulic displacement control uses a hydraulic input signal to operate a spring-centered four-way servo valve.

This valve ports hydraulic pressure to either side of a dual-acting servo piston. The servo piston rotates the cradle swashplate through an angular rotation of ±17°, thus varying the pump’s displacement from full displacement in one direction to full displacement in the opposite direction. The HDC is designed so the angular position of the pump swashplate is proportional to input pressure.

T803324,0000947 –19–15MAR06–1/1

TMCM225401 (04OCT06)

50-10-7

2254 Cane Loader 100406

PN=129

Pumps & Motors

Initial Start-up Procedure The following start-up procedure should always be followed when starting-up a new installation or when restarting an installation in which either the pump or motor had been removed.

CAUTION: The following procedure may require the vehicle/machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders. Take necessary safety precautions before moving the vehicle/machine.

50 10 8

Prior to installing the pump and/or motor, inspect the units for damage incurred during shipping and handling. Make certain all system components (reservoir, hoses, valves, fittings, heat exchanger, etc.) are clean prior to filling with fluid.

Fill the reservoir with recommended hydraulic fluid. This fluid should be passed through a 10 micron (nominal, no bypass) filter prior to entering the reservoir. The use of contaminated fluid will cause damage to the components, which may result in unexpected vehicle / machine movement.

The inlet line leading from the reservoir to the pump must be filled prior to start-up. Check inlet line for properly tightened fittings and make sure it is free of restrictions and air leaks.

IMPORTANT: Be certain to fill the pump and/or motor housing with clean hydraulic fluid prior to start up.

Fill the housing by pouring filtered oil into the upper case drain port.

Install a 50 bar (or 1000 psi) pressure gauge in the charge pressure gauge port to monitor the charge pressure during start-up.

Continued on next page

TMCM225401 (04OCT06)

50-10-8

T803324,0000948 –19–15MAR06–1/2

2254 Cane Loader 100406

PN=130

Pumps & Motors It is recommended that the external control input signal (hydraulic lines for HDC) be disconnected at the pump control until after initial start-up. This will ensure that the pump remains in its neutral position.

CAUTION: Do not start prime mover unless pump is in neutral position (0 swashplate angle). Take precautions to prevent machine movement in case pump is actuated during initial start up.

Jog or slowly rotate prime mover until charge pressure starts to rise. Start the prime mover and run at the lowest possible RPM until charge pressure has been established.

Excess air may be bled from the high pressure lines through the high pressure system gauge port.

50 10 9

Once charge pressure has been established, increase speed to normal operating RPM. Charge pressure should be 31 bar (450 psi). If charge pressure is inadequate, shut down and determine cause for improper pressure. Refer to Troubleshooting Section.

CAUTION: Inadequate charge pressure will affect the operator’s ability to control the machine.

Shut down the prime mover and connect the external control input signal. Also reconnect the machine function if disconnected earlier. Start the prime mover, checking to be certain the pump remains in neutral.

With the prime mover at normal operating speed, slowly check for forward and reverse machine operation.

Charge pressure may slightly decrease during forward or reverse operation. Continue to cycle slowly between forward and reverse for at least five minutes.

Shut down prime mover, remove gauges, and plug ports.

Check reservoir level and add filtered fluid if needed. The transmission is now ready for operation.

T803324,0000948 –19–15MAR06–2/2

TMCM225401 (04OCT06)

50-10-9

2254 Cane Loader 100406

PN=131

Pumps & Motors

Fluid and Filter Maintenance To ensure optimum service life of hydrostatic products, regular maintenance of the fluid and filter must be performed. Contaminated fluid is the main cause of unit failure. Care should be taken to maintain fluid cleanliness while performing any service procedure.

Check the reservoir daily for proper fluid level, the presence of water (noted by a cloudy to milky appearance, or free water in bottom of reservoir), and rancid fluid odor (indicating excessive heat). If either of these conditions occur, change the fluid and filter immediately.

50 10 10

NOTE: It is recommended the fluid and filter be changed per the machine manufacturer’s recommendations.

It may be necessary to change the fluid more frequently than the above intervals if the fluid becomes contaminated with foreign matter (dirt, water, grease, etc.) or if the fluid has been subjected to temperature levels greater than the recommended maximum. Never reuse fluid.

The filter should be changed, and the strainer cleaned, whenever the fluid is changed.

T803324,0000949 –19–15MAR06–1/1

Troubleshooting Symptom

Problem

Solution

Continued on next page

TMCM225401 (04OCT06)

50-10-10

T803324,000094A –19–15MAR06–1/4

2254 Cane Loader 100406

PN=132

Pumps & Motors NOTE: Diagnose malfunction charts are arranged from most probable and simplest to verify.

“Neutral” Difficult or Impossible to Find

System Operation Hot

Check input to pump control.

If input to control module is operating properly, check control input and repair or replace as necessary•.

Check pump displacement control.

If control linkages are not secure, control orifices are blocked, etc., adjust, repair or replace control module as necessary.

Insufficient hydraulic fluid will not meet cooling demands of system.

Check oil level in reservoir and fill reservoir to proper level.

Heat Exchanger not sufficiently cooling the system.

Inspect heat exchanger. Check airflow and input air temperature for heat exchanger. Clean, repair or replace heat exchanger.

Low charge pressure will overwork system.

Check charge pressure. Inspect and adjust or replace charge relief valve or repair leaky charge pump.

High Inlet vacuum will overwork system. A dirty filter will increase the inlet vacuum. Inadequate line size will restrict flow.

Check charge pump inlet vacuum. If high, inspect inlet filter and replace as necessary. Check for adequate line size, length or other restrictions.

Leakage will reduce low side system pressure and overwork the system.

Check for internal leakage in motor.

Monitor motor case flow without loop flushing in the circuit. If flow is excessive, replace motor.

High system pressure will overheat system.

Check system pressure. If pressure is high, reduce loads.

Continued on next page

TMCM225401 (04OCT06)

50-10-11

T803324,000094A –19–15MAR06–2/4

2254 Cane Loader 100406

PN=133

50 10 11

Pumps & Motors Symptom

Problem

Solution

Transmission Operates Normally in One Direction Only

Input to control module is not operating properly.

Check control input and repair or replace as necessary.

Control linkages are not secure; control orifices are blocked, etc.

Repair or replace control module as necessary.

Valve functions.

Interchange multi-function valves. If the problem changes direction, repair or replace the valve on the side that does not operate.

If charge pressure decays in one direction, the loop flushing valve may be “sticking” in one direction.

Measure charge pressure in forward and reverse. If pressure decays in one direction, inspect and repair the motor loop flushing valve.

Low system pressure at the motor will reduce torque.

Check system pressure at motor. If pressure limiter setting is low, increase settings.

Minimum motor displacement yields low torque output.

Check control supply pressure or repair displacement control. Check motor control orifices.

Internal leakage will reduce system pressure.

Check for leakage in O-rings, gaskets, and other fittings. Repair unit as required or replace leaky unit.

Insufficient hydraulic fluid will reduce motor speed.

Check oil level reservoir. Fill oil to proper level.

Incorrect charge pressure can result in a low speed motor.

Check charge pressure. Adjust charge pressure if necessary.

Incorrect outflow will affect output speed. Incorrect output flow indicates the swashplate is out of position.

Measure pump output flow by teeing into outflow hose. Check for proper pump speed and see that the pump is in full stroke.

If variable motor displacement control is not functioning correctly, variable motor swashplate may be in wrong position.

See if variable motor displacement control is responding. If not, repair or replace control.

Continued on next page

T803324,000094A –19–15MAR06–3/4

50 10 12

Low Motor Output Torque

Improper Motor Output Speed

TMCM225401 (04OCT06)

50-10-12

2254 Cane Loader 100406

PN=134

Pumps & Motors Symptom

Problem

Solution

Excessive Noise and/or Vibration

Insufficient hydraulic fluid will lead to cavitation.

Check oil level reservoir. Fill oil to proper level.

Air bubbles will lead to cavitation.

Look for foam in reservoir. Check for leaks on inlet side of system loop.

Afterwards, let reservoir settle until bubbles are gone. Run system at low speed to move system fluid to reservoir. Repeat.

High inlet vacuum will create noise.

A dirty filter will increase the inlet vacuum.

Inspect and replace filter as necessary. Check for proper suction line size.

A loose shaft coupling will cause excessive noise.

Replace loose shaft coupling in charge pump or replace pump or motor.

Unaligned shafts will create excessive frictional noise.

Align shafts.

Insufficient hydraulic fluid will reduce output pressure.

Fill reservoir to proper level.

Incorrect pressure setting will affect system reaction time.

Adjust or replace multi-function valves.

High pump inlet vacuum will reduce system pressure.

Measure charge inlet vacuum. If high, replace inlet filter.

Low engine speed will reduce system performance.

Adjust engine speed.

Incorrect charge or control pressures will affect system performance.

Measure charge and control pressures and correct if necessary.

Internal leakage will reduce system pressure.

Check for leakage in O-rings, gaskets, and other fittings.

System Response Sluggish

50 10 13

T803324,000094A –19–15MAR06–4/4

TMCM225401 (04OCT06)

50-10-13

2254 Cane Loader 100406

PN=135

Pumps & Motors

Hydrostatic Pump

CM31351144B5

–UN–03OCT06

50 10 14

Continued on next page

TMCM225401 (04OCT06)

50-10-14

T803324,000094B –19–15MAR06–1/2

2254 Cane Loader 100406

PN=136

Pumps & Motors 1—Charge Relief Kit 2—Bearing 3—Pin 4—Plug 5—Plug 6—O-Ring 7—Screen Filter 8—Pump Valve Plate 9—Swashplate Assy 10—Cylinder Kit 11—Bolt 12—Washer 13—O-Ring 14—Coupling 15—Control Kit 16—Mounting Kit 17—Cage Locator Link

18—Pin 19—Spring 20—Pump Side Cover 21—Leveler 22—Seat 23—Shim 24—Control Gasket 25—Nut 26—O-Ring 27—Bolt 28—Relief Assy-HP 29—Spring 30—O-Ring 31—Sleeve Kit 32—O-Ring 33—O-Ring 34—Cover Plate

35—Servo Piston Kit 36—O-Ring 37—Piston Ring 38—Slider Block 39—Control Orifice Kit 40—Journal Bearing 41—Bushing 42—Gasket 43—Plug 44—Bolt 45—Spacer 46—Lifting Lug 47—Washer-FL 48—Bolt 50—Pin 51—Shaft 52—Key

53—Retaining Plate 54—Bolt 55—Charge Pump Cover 56—Screw 57—Manifold Fitting 58—O-Ring 59—Special Plug 60—Check Valve 61—O-Ring 62—Shaft 63—Roller Bearing 64—Retaining Ring 65—Seal Carrier 66—Lip Seal 67—O-Ring 68—Retainer Plate 69—Bolt

50 10 15 T803324,000094B –19–15MAR06–2/2

TMCM225401 (04OCT06)

50-10-15

2254 Cane Loader 100406

PN=137

Pumps & Motors

Charge Relief Valve Adjustment CAUTION: The following procedure may require the vehicle/machine to be disabled (wheels raised off the ground, work function disconnected, etc.) in order to prevent injury to the technician and bystanders.

1. To measure pump charge pressure, install a pressure gauge in the pump charge pressure gauge port (M3).

Also install a gauge to measure case pressure (tee into L1 or L2 or use servo gauge port). Operate the system with the pump in neutral (zero displacement) when measuring pump charge pressure.

50 10 16

2. The acceptable pump charge pressure for charge relief valve settings is 28 - 31 bar (400 - 450 PSI).

3. Pumps are equipped with an external screw adjustable charge relief valve. Adjustment of the charge pressure is accomplished by loosening the lock nut (with a 1-1/16 inch hex wrench), and turning the adjustment plug with a large screwdriver or a 1/2 inch hex wrench.

Clockwise rotation of the plug increases the setting, and counterclockwise rotation decreases the setting at a rate of approximately 3.4 bar (50 PSI) per turn. The lock nut for this type of charge relief valve should be torqued to 52 N•m (38 lb-ft).

4. Once the desired charge pressure setting is achieved, remove the gauges.

T803324,000094C –19–15MAR06–1/1

TMCM225401 (04OCT06)

50-10-16

2254 Cane Loader 100406

PN=138

Pumps & Motors

Multi-Function Valve Pressure Adjustment Adjustment of the pressure limiter setting and the high pressure relief valve setting is accomplished simultaneously. The latter is automatically set approximately 35 bar (500 psi) above the former.

In order to adjust the pressure limiter setting, the motor output shaft must be locked so it does not rotate. This may be accomplished by locking the vehicle’s brakes or rigidly fixing the work function so it cannot rotate.

CAUTION: Take necessary precautions to insure the motor shaft remains stationary during the adjustment procedure.

50 10 17

1. Install two 700 bar (10,000 psi) pressure gauges in the high pressure gauge ports (M1 and M2). Install a 200 bar (3000 psi) pressure gauge in the pump charge pressure gauge port (M3).

2. Start the prime mover and operate at normal speed.

3. Loosen locking nut (smallest hex on multi-function valve) with a 10 mm wrench.

4. Insert a 3 mm (early units), 5 mm (late units), internal hex wrench into the pressure adjusting screw.

NOTE: A plastic dust plug is installed in the adjusting screw.

5. The pressure limiter setting is the difference between the high and low pressure sides of the system loop.

Activate or move the control input so that pressure increases in the high pressure side of the closed circuit to the pressure limiter pressure setting. The pressure limiter setting is reached when the pressure stops increasing and remains steady at a given pressure level (as shown on the gauges).

6. Return the pump to its neutral (zero flow) position and adjust the pressure limiter setting by rotating the pressure adjusting screw with the internal hex wrench.

Continued on next page

TMCM225401 (04OCT06)

50-10-17

T803324,000094D –19–15MAR06–1/2

2254 Cane Loader 100406

PN=139

Pumps & Motors 7. Clockwise rotation of the pressure adjustment screw will increase the pressure setting, and counterclockwise rotation will decrease the pressure setting. Each complete rotation of the pressure adjusting screw changes the pressure setting by approximately 93 bar (1350 PSI).

8. To verify the actual pressure setting, actuate or move the control input so that the pump again develops pressure in the high pressure circuit to the newly adjusted pressure limiter pressure setting, and read the high pressure gauge. Then allow the pump to return to its neutral position. The pressure in the high pressure circuit should return to the charge pressure setting.

50 10 18

9. While holding the pressure adjusting screw stationary, tighten the pressure adjusting screw lock nut to 16 N•m (12 lb-ft). DO NOT overtorque.

10. Shut down the prime mover, remove the gauges and install the gauge port plugs. Replace the plastic dust plugs (if used).

The same procedure is used for setting the pressure limit of the other multi-function valve, but the control input signal must be activated or moved in the opposite direction so that high pressure develops in the opposite side of the closed circuit.

T803324,000094D –19–15MAR06–2/2

TMCM225401 (04OCT06)

50-10-18

2254 Cane Loader 100406

PN=140

Pumps & Motors

Engaging the Bypass Function The bypass function is performed by the multifunction valve cartridges. The prime mover should be shut down when opening or closing the bypass valves.

1. Using a 1-1/16 inch wrench on the middle sized hex of the multi-function valve cartridge, and a 1-1/4 inch wrench on the large hex to prevent rotation of the cartridge assembly, rotate the middle hex three revolutions counterclockwise to open the bypass valve.

Do not rotate more than 3-1/2 revolutions, as additional rotation will permit external leakage.

CAUTION: It is not recommended that this machine be towed. If towing is the only option, tow at extremely low speeds and for short distances only.

50 10 19

2. To close the bypass valve, rotate the middle hex clockwise until it is seated. Then torque the middle hex to 41 N•m (30 lb-ft).

T803324,000094E –19–15MAR06–1/1

TMCM225401 (04OCT06)

50-10-19

2254 Cane Loader 100406

PN=141

Pumps & Motors

Hydraulic Displacement Control The neutral adjustment is the only adjustment that can be made on hydraulic and electric displacement controls. All other functions are preset at the factory.

This adjustment must be made on a test stand or on the machine with the prime mover operating. The neutral adjustment is performed by adjusting a neutral adjusting screw.

50 10 20

CAUTION: The following procedure requires the vehicle/machine to be disabled (wheels raised off the ground, work function disconnected, etc.) in order to prevent injury to the technician and bystanders.

1. Install two 200 bar (3000 PSI) gauges in each of the two displacement control cylinder gauge ports (M4 and M5). Disconnect the external hydraulic control input from the control. Start the prime mover and operate at normal speed.

2. Loosen the lock nut with a 17 mm hex wrench for the neutral adjusting shaft or with a 10 mm or 13 mm hex wrench for the neutral adjusting screw.

3. Using a 5 mm internal hex wrench for the neutral adjusting shaft or a 3 mm or 4 mm internal hex wrench for the neutral adjusting screw, rotate clockwise until the pressure increases in one of the pressure gauges.

Note the angular position of the wrench. Then rotate the neutral adjusting shaft or screw counterclockwise until the pressure increases by an equal amount on the other gauge. Again note the angular position of the wrench.

4. Rotate the neutral shaft or adjusting screw clockwise half the distance between the locations noted above.

The gauges should read the same pressure (case pressure), indicating that the control is in its neutral position.

Continued on next page

TMCM225401 (04OCT06)

50-10-20

T803324,000094F –19–15MAR06–1/2

2254 Cane Loader 100406

PN=142

Pumps & Motors 5. Hold the neutral adjusting shaft or screw stationary.

Tighten the neutral adjusting screw lock nut to 7 N•m (62 lb-in) for the 6 mm screw or 13.6 Nm (120 lb-in) for the 8 mm screw. DO NOT over torque the nut.

6. Once the neutral position is set, stop the prime mover, remove the gauges, and install the gauge port plugs.

Reconnect the external control input.

T803324,000094F –19–15MAR06–2/2

50 10 21

TMCM225401 (04OCT06)

50-10-21

2254 Cane Loader 100406

PN=143

Pumps & Motors

Shaft Seal and Shaft Replacement Lip type shaft seals are used on pumps and motors.

These seals and/or the shafts can be replaced without major disassembly of the unit. However, replacement requires removal of the pump or motor from the machine.

NOTE: If the unit is positioned horizontally when the shaft is removed, the cylinder block could move out of place, making shaft installation difficult.

1. Position the pump with the shaft facing up.

50 10 22

2. Remove the three or four screws holding the retainer plate and seal carrier to the housing, using a 5 mm internal hex wrench. Remove the retainer plate.

3. After removing the screws, the spring force on the shaft may move the seal carrier out of its bore by approximately 5 mm (1/4 inch). If the seal carrier does not move from its bore after removing the screws, pry it from its bore as shown and/or lightly tap the end of the shaft with a soft mallet.

4. Remove the O-ring from the seal carrier.

5. Place seal carrier and seal in an arbor press and press out old seal.

6. Inspect the seal carrier, the new seal and the o-ring for any damage or nicks.

7. Using the arbor press, press the new seal into seal carrier. Be careful not to damage the seal.

The outside diameter of the seal may be lightly coated with a sealant (such as Loctite High Performance Sealant #59231, or Silicone Ultra Blue PN# 0841348827) prior to installation. This aids in preventing leaks caused by damage to the seal bore in the seal carrier.

8. Inspect the sealing area on the shaft for rust, wear, or contamination. If the shaft is not being replaced proceed to step 12.

Continued on next page

TMCM225401 (04OCT06)

50-10-22

T803324,0000950 –19–15MAR06–1/2

2254 Cane Loader 100406

PN=144

Pumps & Motors 9. Remove shaft and roller bearing assembly from pump or motor. The bearing assembly can be transferred to the new shaft.

10. Remove the retaining ring that secures roller bearing assembly with a snap ring pliers. Remove the roller bearing assembly.

11. Place roller bearing assembly on new shaft and secure with the retaining ring.

12. Wrap spline or key end of shaft with plastic film to prevent damage to the sealing lip on the seal during installation.

13. Prior to assembly, lubricate the O-ring on the O.D. of the seal carrier and the I.D. of the seal with clean petroleum jelly.

50 10 23

14. Assemble the seal carrier and seal over the shaft and into the housing bore. Install the retainer plate (if used).

15. Install the screws and torque to 16 N•m (12 lb-ft) pumps, 9.5 N•m (7 lb-ft) for motors.

NOTE: Torque the screws in a sequenced pattern then recheck.

T803324,0000950 –19–15MAR06–2/2

TMCM225401 (04OCT06)

50-10-23

2254 Cane Loader 100406

PN=145

Pumps & Motors

50 10 24

TMCM225401 (04OCT06)

50-10-24

2254 Cane Loader 100406

PN=146

Group 20

Minor Pump Repairs Multi-Function Valve Cartridges 1. The multi-function valve cartridge is removed with a 1-1/4 inch hex wrench on the largest hex on the cartridge.

2. Inspect cartridge for damage to parts and O-rings. The multi-function valve cartridge may be disassembled for cleaning. However, if the pressure limiter housing assembly is disassembled, the pressure settings must be readjusted. Usually, if there is contamination problem, it will be in the valve seat assembly. If it is not necessary to clean the interior of the cartridge, proceed to step 7.

NOTE: Multi-function valve components are not sold separately as service parts (except O-rings).

50 20 1

3. Release spring tension by turning the adjustment screw counterclockwise. The valve seat section is pressed over a lip. Place the cartridge in a vise and pry the lower section off with an appropriate tool.

Maintain sufficient control to prevent the contents from flying loose.

4. Remove pressure limiter lock nut and bypass actuator.

5. Unscrew the pressure limiter adjustment screw from the bypass actuator.

6. Clean and inspect all disassembled parts.

7. Reassemble with new, lightly lubricated O-rings by reversing the above procedure. For early versions assemble with the retaining ring. For late versions, place the cartridge in a vise and press on lower assembly.

CAUTION: The pressure settings must be readjusted after disassembling the pressure limiter housing of the multifunction valve cartridge.

8. Install cartridge in multi-function valve cavity and torque to 89 N•m (66 lb-ft). DO NOT over torque the multifunction valve cartridge.

T803324,0000951 –19–15MAR06–1/1

TMCM225401 (04OCT06)

50-20-1

2254 Cane Loader 100406

PN=147

Minor Pump Repairs

Charge Relief Valve The pump charge relief valve is screw adjustable.

1. Before removing the screw adjustable relief valve plug, mark the plug, lock nut, and housing so as to approximately maintain the original adjustment when assembling. Remove the screw adjustable charge relief valve plug by loosening the lock nut with a 1-1/16 inch wrench. Unscrew the plug with a large screwdriver. 2.

2. Remove the spring and relief valve poppet.

3. Inspect the poppet and mating seat in the end cap for damage or foreign material.

50 20 2

4. Install the poppet and spring. For screw adjustable valves, install the plug with its lock nut, aligning the marks made at disassembly, and torque the lock nut to 52 N•m (38 lb-ft).

5. Check the charge pressure and adjust, if necessary.

T803324,0000952 –19–15MAR06–1/1

TMCM225401 (04OCT06)

50-20-2

2254 Cane Loader 100406

PN=148

Minor Pump Repairs

Charge Pump 1. For pumps with an auxiliary mounting pad, remove the four screws holding the pad to the end cap and remove the pad. Refer to the Auxiliary Mounting Pad Installation instructions (next section) for details.

NOTE: NOTE: Late production pumps may not have the smaller screws installed to secure the end cap to the pump housing when the large screws are removed. On these pumps, secure the end cap to the pump housing with a clamp to avoid gasket damage.

CAUTION: Do not allow the force of the cylinder block spring and swashplate leveler springs to separate the end cap from the pump housing.

Gasket damage and external leakage may result.

50 20 3

2. Using a 10 mm hex wrench, remove the six screws holding the charge pump cover retainer.

3. Remove the retainer and the charge pump cover. For pumps with an auxiliary mounting pad, remove the auxiliary drive coupling. Note the orientation of the gerotor.

4. Remove the charge pump shaft and charge pump drive key.

5. Remove the spacer plate(s), if present (intermediate production pumps only). Remove the charge pump outer port plate, if present (early and intermediate production pumps). Remove the charge pump gerotor assembly.

6. Remove the outer eccentric ring and alignment pin.

7. Remove the inner port plate.

8. Inspect all parts for abnormal wear or damage.

Continued on next page

TMCM225401 (04OCT06)

50-20-3

T803324,0000953 –19–15MAR06–1/2

2254 Cane Loader 100406

PN=149

Minor Pump Repairs NOTE: If a different displacement charge pump is being installed, the gerotor assembly, gerotor outer eccentric ring, and inner port plate (early and late production pumps) or outer spacer plate(s) (intermediate production pumps) must be replaced together. If different thickness port plates are used in an early production charge pump assembly, the thicker plate is the inner port plate (installed next to the pump end cap).

T803324,0000953 –19–15MAR06–2/2

50 20 4

TMCM225401 (04OCT06)

50-20-4

2254 Cane Loader 100406

PN=150

Minor Pump Repairs

Installing the Charge Pump Be sure to install the charge pump in the proper orientation. If unsure of charge pump rotation, refer to parts catalog.

NOTE: The charge pump rotation is determined by the orientation of the gerotor assembly outer eccentric ring and the location of the alignment pin in the end cap.

NOTE: Do not mix charge pump piece parts from different production periods. Always install as a complete assembly.

1. Install the inner port plate and the gerotor assembly outer ring.

50 20 5

2. Install the alignment pin to properly orient the port plates and outer eccentric ring for corresponding pump rotation.

3. Prior to installation, apply a small quantity of petroleum jelly to the I.D., O.D., and side faces of the gerotor assembly to provide initial lubrication.

4. Install the gerotor assembly.

5. Install the outer port plate.

6. Install the spacer plate, if used.

7. Install the charge pump drive key into the charge pump shaft and retain with petroleum jelly.

NOTE: Intermediate production pumps use the same charge pump drive shaft. Two key-ways are provided in the drive shaft for the charge pumps used in these units. The rear key-way (with identifier groove)is used in 75 cc pumps. The front key-way (closest to the internally splined end of the shaft) is used in 100 cc pumps.

8. Install the charge pump shaft. The internally splined end of the shaft must engage the main pump shaft.

9. For pumps with an auxiliary mounting pad, install the auxiliary drive coupling.

Continued on next page

TMCM225401 (04OCT06)

50-20-5

T803324,0000954 –19–15MAR06–1/2

2254 Cane Loader 100406

PN=151

Minor Pump Repairs 10. Install a new O-ring onto the non-auxiliary pad charge pump cover. (If an auxiliary pad is installed, an O-ring is not used on the cover.)

11. Carefully remove the alignment pin from the charge pump parts. Install the pin in its hole in the charge pump cover (see previous page for correct orientation) and retain with petroleum jelly. Install the cover (with alignment pin) into the end cap and aligned charge pump parts. (Take care not to damage the cover O-ring, if used.)

12. Install the charge pump cover retainer and the six hex screws and torque the screws to 13.5 N•m (10 lb-ft).

50 20 6

13. For pumps with auxiliary mounting pads, install the o-ring and auxiliary mounting pad adapter onto the end cap.

T803324,0000954 –19–15MAR06–2/2

TMCM225401 (04OCT06)

50-20-6

2254 Cane Loader 100406

PN=152

Minor Pump Repairs

Auxiliary Pad Installation 1. Using a 10 mm hex wrench, remove the six screws holding the charge pump cover retainer. Remove the retainer.

2. Remove the charge pump cover and its O-ring.

NOTE: The original charge pump cover will not be used when installing the auxiliary pad.

3. Remove the four large screws which fasten the end cap to the pump housing using a 24 mm external hex wrench.

NOTE: Late production pumps may not have the smaller screws installed to secure the end cap to the pump housing when the large screws are removed. On these pumps, secure the end cap to the pump housing with a clamp to avoid gasket damage.

50 20 7

CAUTION: Do not allow the force of the cylinder block spring and swashplate leveler springs to separate the end cap from the pump housing.

Gasket damage and external damage may result.

4. Take care to assure the surfaces are clean and free of any foreign material or paint prior to installing the auxiliary pad.

5. Install the auxiliary drive coupling onto the pump drive shaft spline (auxiliary drive spline must be toward the rear of the pump).

6. Carefully remove the alignment pin from the charge pump parts. Install the pin in its hole in the new charge pump cover (with hole for the auxiliary coupling) and retain with petroleum jelly. Install the new charge pump cover with alignment pin into the end cap and the aligned charge pump parts.

Continued on next page

TMCM225401 (04OCT06)

50-20-7

T803324,0000955 –19–15MAR06–1/2

2254 Cane Loader 100406

PN=153

Minor Pump Repairs

CAUTION: In order to avoid loss of charge pressure, always install the charge pump cover with the pad drain hole located on the same side of the end cap as the charge inlet port.

7. Install the charge pump cover retainer and the six hex screws and torque the screws to 13.5 N•m (10 lb-ft).

8. Install O-ring on end cap pilot.

9. Install the auxiliary mounting pad adapter on external pilot on rear of end cap.

50 20 8

10. Install four new large screws and washers through the mounting pad and end cap into the housing. Torque per the accompanying table. 14 mm internal hex -256 N•m (189 lb-ft).

11. Install the O-ring and flange cover or auxiliary pump.

T803324,0000955 –19–15MAR06–2/2

TMCM225401 (04OCT06)

50-20-8

2254 Cane Loader 100406

PN=154

Minor Pump Repairs

Hydraulic Displacement Controls 1. Thoroughly clean external surfaces prior to removal of control.

2. Using a 5 mm internal hex wrench, remove the eight control mounting screws. Remove the control (with orifice check valve and spring) and control gasket from housing.

CAUTION: Protect exposed surfaces and cavities from damage and foreign material 3. In preparation for installing the control, place a new gasket on the housing. Inspect to ensure that the control orifice check valve and spring are in their proper position in the control.

50 20 9

4. While setting the control into position, engage the pin on the control linkage into the mating hole in the link attached to the swashplate.

5. With the control in position, move control assembly left and right to check engagement of pin in the link.

Proper engagement will be indicated by an increasing resistance as the control is moved away from center position. Non-engagement of pin will be indicated by lack of spring force. In case of non-engagement, remove control and repeat the above procedure.

6. Align the control gasket and install the screws. Torque the screws to 16 N•mNm (12 lb-ft).

NOTE: A sealing washer must be installed under the head of any mounting screws that are installed through holes in the housing.

T803324,0000956 –19–15MAR06–1/1

TMCM225401 (04OCT06)

50-20-9

2254 Cane Loader 100406

PN=155

Minor Pump Repairs

50 20 10

TMCM225401 (04OCT06)

50-20-10

2254 Cane Loader 100406

PN=156

Group 30

Displacement Control Components Displacement Control Filter Screens If the pump is equipped with control filter screens in the pump housing (late production), they should be pressed into position (with the rounded edge of the filter screens facing the control) until they are flush to 2.0 mm (0.08 inch) below the surface of the housing.

T803324,0000957 –19–15MAR06–1/1

Displacement Control Orifice Check Valve 50 30 1

1. Remove the control assembly as described in the instructions for the specific displacement control.

2. The orifice check valve is located in the control assembly, at the surface of the pump housing face.

Remove the spring retainer and spring from the orifice check valve cavity and then remove the orifice check valve.

3. Install the desired orifice check valve in the cavity and then install the spring and spring retainer to hold the orifice check valve in position.

4. Assemble the control onto the pump. Refer to the instructions for the specific control.

T803324,0000958 –19–15MAR06–1/1

TMCM225401 (04OCT06)

50-30-1

2254 Cane Loader 100406

PN=157

Displacement Control Components

Displacement Control Orifices 1. Remove the control assembly as described in the instructions for the specific displacement control.

2. Orifice plugs may be located in the control assembly, at the pump housing face surface. Remove the orifice plugs with a 4 mm internal hex wrench. Note the location of each plug, do not interchange plugs. Torque the orifice plugs to 3 N•m (32 lb-in).

3. Assemble the control onto the pump. Refer to the instructions for the specific control.

50 30 2 T803324,0000959 –19–15MAR06–1/1

TMCM225401 (04OCT06)

50-30-2

2254 Cane Loader 100406

PN=158

Displacement Control Components

Disassembly Procedures for Variable Displacement Pump Prior to performing major repairs on the variable displacement pump, remove the external components as described in the minor repair section of this service manual. These include the following: • • • •

Auxiliary Mounting Pad Charge Relief Valve Multi-Function Valves Shaft Seal

After removal of these components, place the pump on a work surface with the shaft up.

50 30 3

Remove the shaft and bearing assembly from the housing. The bearing outside diameter is a slip fit in the housing bore.

NOTE: If the shaft and bearing stick in the housing, lightly tap the end of the shaft with a soft mallet to free the bearing.

Remove the retaining ring and press the shaft out of the bearing. Place the pump on the work surface with the end cap up.

NOTE: If the pump was equipped with an auxiliary mounting pad, temporarily reinstall two (2) of the large screws which fasten the end cap to the housing. These screws will hold the end cap against internal spring pressure while the small screws are removed.

Using a 5 mm or 6 mm internal hex wrench or a 10 mm hex wrench, remove the two (2) or three (3) small screws which fasten the end cap to the pump housing. Using a 24 mm internal hex wrench, remove the large screws which fasten the end cap to pump housing. Remove end cap from housing. The alignment pins and valve plate will normally remain with the housing.

Remove the end cap gasket. Remove the swashplate leveler spring shims (if installed) from the spring pockets in the end cap.

Continued on next page

TMCM225401 (04OCT06)

50-30-3

T803324,000095A –19–15MAR06–1/3

2254 Cane Loader 100406

PN=159

Displacement Control Components Remove three (3) springs from pump: the two (2) long swashplate leveler (“T-Bar”) springs and the short swashplate hold down spring.

NOTE: Certain units are equipped with dual swash-plate leveler springs (an inner spring nested inside each of the standard springs).

Remove the alignment pins and valve plate, noting direction of arrows on valve plate.

Mark the orientation of the side cover to the housing.

Remove the six (6) side cover screws using a 13 mm hex wrench.

50 30 4

Remove side cover and swashplate leveler (“TBar”) assembly from housing.

NOTE: Certain units equipped with dual swashplate leveler springs have spacer washers on the leveler spring seats. They may be removed at this time.

Remove spring seats from swashplate leveler.

NOTE: Earlier production pumps do not have removable (hardened) spring seats.

For units with leveler guide posts and sealing nuts holding the leveler to the side cover, use a 3/4 in. open end wrench and a 13 mm hex wrench.

Remove swashplate leveler from side cover. Remove the side cover O-ring.

Mark the servo cylinders and housing to identify each servo cylinder with its respective side of the housing.

Remove the three (3) or four (4) screws retaining each servo cylinder to the housing, using a 10 mm or 13 mm hex wrench.

For earlier production units, carefully pry each cylinder from the housing by using a screwdriver in the notches in the cylinder. For later production units, install an 8 mm or 10 mm screw in the threaded hole in the center of each cylinder, and pull the cylinders from the housing. The servo piston will remain in the housing.

Continued on next page

TMCM225401 (04OCT06)

50-30-4

T803324,000095A –19–15MAR06–2/3

2254 Cane Loader 100406

PN=160

Displacement Control Components NOTE: For later production units with displacement limiters, remove the limiter screw from each servo cylinder and install an 8 mm or 10 mm screw in its place as a puller screw. Remove the cylinder block through the housing end cap opening. The swashplate and piston assembly will remain in the housing. Remove the swashplate bearing cage link pin from the housing through the control opening. Remove the bearing cage locater link from the swashplate through the control opening.

Remove the swashplate and pistons through the housing side cover opening. Disengage the servo arm from the slider block located in the servo piston as the assembly is removed.

50 30 5

Remove the servo piston and slider block from housing.

NOTE: Units equipped with an automotive control have a threaded hole in one end of the servo piston for the centering assist spring assembly. For these units, note the orientation of the servo piston in the housing.

Remove the swashplate cradle bearing cage.

Remove the bearing races. The bearing races are a loose fit on two (2) locating pins in the housing.

Remove the feedback link from the head of the special screw on the swashplate assembly.

Using a 10 mm or 13 mm hex wrench, remove the four (4) screws holding the slipper guide hold down mechanism to the swashplate.

Disassemble the hold down mechanism and remove the slipper guide and pistons from the swashplate.

NOTE: Pumps use a fixed-clearance hold down mechanism.

Remove the piston assemblies from the slipper guide.

T803324,000095A –19–15MAR06–3/3

TMCM225401 (04OCT06)

50-30-5

2254 Cane Loader 100406

PN=161

Displacement Control Components

Reconditioning and Replacement of Parts After disassembly, all parts should be thoroughly cleaned in a suitable solvent. Replace all o-rings, gaskets, and the shaft seal.

Inspect all parts for damage, nicks, or unusual wear patterns. Replace all parts having unusual or excessive wear or discoloration.

If the end cap journal bearing needs replacement (as evidenced by large amounts of the metal back of the bearing being visible through the plastic bearing material), remove the bearing with a suitable puller. Do not damage the valve plate surface of the end cap.

50 30 6

Lightly lubricate the steel backing of a new journal bearing. Press the journal bearing into the end cap using a suitable press pin.

When installed correctly, the bearing will be flush to 0.020 inches (0.50 mm) below the valve plate surface of the end cap.

If a new journal bearing is installed, the bearing must be sized with the appropriate arbor to assure the minimum bore diameter is met. Carefully press the sizing arbor into the bearing to size it.

CAUTION: The arbors are precision finished to size the journal bearings without damaging them. Damaged arbors must be replaced. Do not attempt to use the drive shaft in place of an arbor. Inadequate clearance between the shaft and bearing will result in inadequate lubrication and shortened bearing life.

NOTE: The charge pump shaft bushing in the end cap may be replaced in a similar manner to the drive shaft journal bearing.

Certain frame size pumps with twin port end caps may have the servo relief valves and rotation plugs located in a removable rotation block. Remove the rotation block screws with a 5 mm internal hex wrench and remove the block and gasket.

Continued on next page

TMCM225401 (04OCT06)

50-30-6

T803324,000095B –19–15MAR06–1/3

2254 Cane Loader 100406

PN=162

Displacement Control Components For pumps with pressure limiter function (except units with automotive control), remove the servo relief valves from the end cap or rotation block with a screw driver. For pumps with pressure limiter defeat and/or automotive control, remove the servo relief passage plug(s) from the end cap or rotation block with a 3/16 inch internal hex wrench.

Note the position of the rotation pipe plugs and remove them from the end cap or rotation block with a 1/ 8 inch internal hex wrench.

Install the servo relief valves or relief valve passage plugs into the end cap or rotation block as shown in the accompanying illustrations and chart.

50 30 7

NOTE: Pumps with pressure limiter function (except those units with automotive control) MUST have servo relief valves installed in the end cap or rotation block to limit servo pressures. Install the rotation pipe plugs into the end cap or rotation block as shown in the accompanying illustrations and chart.

The threaded holes in the swashplate (for the hold down screws) must be cleaned of old locking compound prior to reassembly. A 6 mm thread tap may be used for this purpose.

Inspect the swashplate guide for wear. The guide may be removed by removing the special locking screw with a 6 mm internal hex wrench.

Servo arm alignment is critical for proper pump operation.

For this reason, removal of the servo arm from the swashplate is not recommended.

If the servo arm must be removed from the swashplate, remove the locking screw with a 13 mm hex wrench.

Keystone design servo arms must be parallel (within 0.010 inches [0.25 mm] total) to the wide surface of the slot in the swashplate when installed. “Press fit” design servo arms must be carefully aligned with the slot and threaded holes in the swashplate while installing, and must be pressed completely into the swashplate slot.

Continued on next page

TMCM225401 (04OCT06)

50-30-7

T803324,000095B –19–15MAR06–2/3

2254 Cane Loader 100406

PN=163

Displacement Control Components NOTE: Keystone design servo arms and swashplates are no longer available for servicing pumps. A swashplate / servo arm kit is available to service these units.

Torque the servo arm to swashplate locking screw to 32 N•m (24 lb-ft.).

Assemble the swashplate guide to the swashplate with the special locking screw. Torque the screw to 32 N•m (24 lb-ft.).

50 30 8

If the headed roll pin and flat washer for the bearing cage locator link must be installed on the swashplate, the distance between the washer and the side of the swashplate must be as indicated below: Pump Distance = H ±0.240 in. (9.45) ±0.010 in. (±0.25 mm) Inspect the servo piston and seal rings for wear. If worn, remove the seal rings and expander O-rings from the piston. Install new expander O-rings into the seal grooves in the servo piston.

Carefully install the piston seal rings in the piston grooves, over the expander O-rings. DO NOT stretch the seal rings any more than necessary when installing.

Lubricate the seal rings and carefully slide the servo piston into the servo cylinders. Allow the assembly to set for at least 5 minutes to allow the seal rings to return to their original unstretched size. Then remove the servo cylinders.

Compress the cylinder block spring and remove the spiral retaining ring, retainer, spring, and spring seat.

Reassemble in the reverse order.

T803324,000095B –19–15MAR06–3/3

TMCM225401 (04OCT06)

50-30-8

2254 Cane Loader 100406

PN=164

Displacement Control Components

Assembly Procedures for Variable Displacement Pump Clean and lightly oil all parts prior to assembly of the pump. Be sure to torque all threaded parts to recommended torque levels.

CAUTION: Most parts have critical, high tolerance surfaces. Caution must be exercised to prevent damage to these surfaces during assembly. Protect exposed surfaces, openings, and ports from damage and foreign material.

Assemble the piston assemblies into the slipper guide.

50 30 9

Lubricate the slipper running surfaces. Center the pistons and guide on the swashplate.

NOTE: Pumps use a fixed clearance hold down mechanism.

Assemble one-half of the fixed-clearance hold down mechanism as follows: • Position two (2) spacers over the threaded holes in the swashplate as shown.

• Position the slipper guide bearing on top of the spacers and slipper guide.

CAUTION: The split between the slipper guide bearing plates must be located in line with the swashplate arm. The bearing surface of the bearing plates must be located next to the guide.

Install two (2) new screws (with locking compound) and flat washers through the slipper guide bearing, and spacers. Finger tighten the screws into the swashplate.

Continued on next page

TMCM225401 (04OCT06)

50-30-9

T803324,000095C –19–15MAR06–1/9

2254 Cane Loader 100406

PN=165

Displacement Control Components NOTE: Inspect the flat washers for raised edges or burrs.

The smooth side of the flat washers must be installed next to the slipper guide bearing.

CAUTION: Always use new screws with proper locking compound.

Assemble the other half of the fixed-clearance hold down mechanism in a similar manner.

Assemble one-half of the spring-loaded hold down mechanism as follows:

50 30 10

• Lubricate the slipper guide bearing and position it on top of the slipper guide.

• Position two (2) spacers in the holes of the guide bearing and over the threaded holes in the swashplate.

CAUTION: The split between the slipper guide bearing plates must be located in line with the swashplate arm. The bearing surface of the bearing plates must be located next to the slipper guide.

• Position two (2) flat washers on top of the spacers.

• Position two (2) leaf springs on top of the washers.

• Position two (2) spring aligners on top of the leaf springs.

• Install two (20 new screws (with locking compound) through the spring aligners, leaf springs, flat washers, and spacers. Finger tighten the screws into the swashplate.

Assemble the other half of the spring-loaded hold down mechanism in a similar manner.

CAUTION: Always use new screws with proper locking compound.

Torque the hold down screws to 10 lb-ft (13.5 N•m). The slipper guide and piston slippers must be able to slide freely on the swashplate.

Continued on next page

TMCM225401 (04OCT06)

50-30-10

T803324,000095C –19–15MAR06–2/9

2254 Cane Loader 100406

PN=166

Displacement Control Components Lubricate the pistons and cylinder block bores. Install the assembled swashplate and pistons into the cylinder block by inserting the pistons into the cylinder block bores. The pistons and bores are not selectively fitted, therefore no specific piston and bore orientation is required.

Check that the swashplate bearing race locating pins are secure in the housing.

Install the swashplate bearing races into the housing, positioning the races on the locating pins. Retain the races in position with petroleum jelly. The locating pins are offset in the housing to assure proper assembly.

Assemble and lubricate the bearing cage, and install it on the bearing races.

50 30 11

Install the bronze slider block on the swashplate servo arm.

Install the feedback link on the head of the special screw on the swashplate assembly. Position the servo piston in the housing.

NOTE: For units equipped with an automotive control, the machined end of the servo piston (with the threaded hole) must be located on the side of the housing where the centering assist spring sleeve will be installed.

CAUTION: To avoid the possibility of the pump sticking in stroke, the feedback link must NOT be installed in pumps equipped with nonfeedback controls (such as the cover plate, 3-position solenoid, and automotive control).

Carefully lower the cylinder block and swashplate assembly into the housing through the end cap opening.

Continued on next page

TMCM225401 (04OCT06)

50-30-11

T803324,000095C –19–15MAR06–3/9

2254 Cane Loader 100406

PN=167

Displacement Control Components NOTE: A tool to aid in holding and installing the assembled cylinder block and swashplate may be made from a positive lock, quick release pin and a large flat washer (1 inch inside diameter with clearance flats ground on the outside diameter).

Insert the pin thru the cylinder block and swashplate, and lock in place with the flat washer under the swash-plate.

Hold the cylinder block and swashplate assembly approximately 1/2 inch (12 mm) above the cradle bearings.

Properly position the feedback link in the control opening.

50 30 12

Position the servo piston on the slider block, taking care not to wedge the block. The parts should slide freely.

Lower the cylinder block and swashplate assembly until the swashplate is properly located on the cradle bearings.

NOTE: If an assembly tool was used to install the cylinder block and swashplate, release and remove the pin. The flat washer should fall through the shaft opening of the housing. Hold the servo piston in position and install the servo cylinders.

NOTE: Be sure to assemble the correct servo cylinder on each side of the housing. For units equipped with an automotive control, a special servo cylinder is installed on the centering assist spring side of the housing.

Install the rhree (3) or four (4) screws in each servo cylinder. Torque to 24 N•m (18 lb-ft).

NOTE: For units equipped with an automotive control, the servo cylinder screws on the centering assist spring side of the housing will be installed later.

Align the slot in the swashplate bearing cage with the headed spring pin in the swashplate and the pin hole in the housing. Hook the cage locator link over the spring pin, between the washer and the swashplate. Rotate the link into the slot in the bearing cage.

Continued on next page

TMCM225401 (04OCT06)

50-30-12

T803324,000095C –19–15MAR06–4/9

2254 Cane Loader 100406

PN=168

Displacement Control Components Align the hole in the locator link with the hole in the housing and install the link anchor pin through the link and into the housing.

Install a new screw (with locking compound) through the locator link and into the housing. Tighten the screw into the housing until the head of the screw is positioned at a height (distance “H”) of 0.178 to 0.188 inch (4.53 to 4.79 mm) from the machined surface of the pump housing.

CAUTION: Always use a new screw with proper locking compound. DO NOT torque this screw against the locator link. The link MUST rotate freely.

Push the swashplate assembly toward the control side of the housing until the swashplate guide contacts the bearing race. Check for clearance between the servo arm and the slider block. If no clearance is present, recheck the assembly of the bearing cage and races.

50 30 13

Position the swashplate leveler (“T-Bar”) on the side cover. Note the orientation of the leveler and the cover.

For units with leveler guide posts, install the two (2) guide posts and sealing nuts. Torque to 23 N•m (17 lb-ft).

NOTE: If the screw holes in the side cover are thru holes, the threads of the screws must be coated with sealing compound.

Install the leveler spring seats.

NOTE: Earlier production pumps do not have removable (hardened) swashplate leveler spring seats.

Install the inner spring spacer washers (if used). Install a new side cover O-ring.

Hold the swashplate leveler toward the end cap end of the housing so the leveler will clear the side of the swashplate during side cover installation. Install the side cover and swashplate leveler.

Install two (2) side cover screws (with flat washers) finger tight into the blind holes in the housing, to hold the cover while checking the zero angle position of the swashplate.

Continued on next page

TMCM225401 (04OCT06)

50-30-13

T803324,000095C –19–15MAR06–5/9

2254 Cane Loader 100406

PN=169

Displacement Control Components If all the parts which affect the zero angle setting are being reused, rotate the side cover to align the marks on the cover and housing that were made at disassembly.

Apply a force of 5 to 10 lbsf. (22 to 44 N) to the swashplate leveler to ensure both arms are in contact with the swashplate. Make sure the swashplate is properly located on its bearings. Use a depth micrometer to measure the distance from the end cap face of the housing to the outer edge of the swashplate surface. Take a second measurement at a point 180° from the first point of measurement (at the opposite edge of swashplate surface). These measurements must not vary by more than .001 inches (.025 mm).

50 30 14

Rotate the side cover (which will also rotate the leveler and swashplate) until the zero angle position is established, as determined by the depth measurement.

After the zero angle position has been established, tighten the two (2) screws to hold the side cover.

Install the remaining four (4) screws with flat washers.

NOTE: The threads of the two (2) side cover screws installed in thru holes in the housing must be coated with a sealing compound to prevent leaks.

New screws have sealant pre-applied.

First, torque the four (4) side cover screws installed in blind holes to 32.5 N•m (24 lb-ft).

Then, torque the two (2) side cover screws installed in thru holes to 25 N•m (18.5 lb-ft).

Install the end cap alignment pins into the housing.

Lubricate the running surface of the cylinder block and install the valve plate on the alignment pins.

Continued on next page

TMCM225401 (04OCT06)

50-30-14

T803324,000095C –19–15MAR06–6/9

2254 Cane Loader 100406

PN=170

Displacement Control Components NOTE: Note the direction of the arrow cut-outs in the valve plate. The arrows must point in the direction of pump rotation. For example, a right hand (clockwise) rotation pump must have the arrows pointing in the clockwise direction (when viewed from the shaft end).

Install the two (2) long springs (with inner springs, if used) on the swashplate leveler spring seats. Install the short spring on the servo arm link. Place new end cap gasket on the housing (located by the alignment pins). Take care not to bend or damage the end cap gasket during installation.

Lubricate the end cap journal bearing. Install the hardened shims in the end cap pockets for the swashplate leveler springs. Retain the shims with petroleum jelly.

50 30 15

Lower end cap onto housing while positioning the three (3) springs in their pockets in the end cap.

When properly installed, the end cap will engage the alignment pins, but the springs will hold the end cap 1/ 8 to 1/4 in. (3 to 8 mm) away from the housing.

Install the four (4) large end cap screws.

NOTE: If the pump will be equipped with an auxiliary mounting pad, temporarily install two (2) of the large screws which fasten the end cap to the housing. These screws will hold the end cap against internal spring pressure while the small screws are installed.

Tighten the large end cap screws evenly to the torque indicated in the accompanying table. Frame Torque 256 N•m (189 lb-ft).

Install the two (2) or three (3) smaller screws holding the end cap to the housing. Torque the 6 mm screws to 13.5 N•m (10 lb-ft), and the 8 mm screws to 38 N•m (28 ft-lb).

NOTE: A lifting bracket is installed on one (1) of the smaller end cap screws.

Position the pump on its end cap.

Continued on next page

TMCM225401 (04OCT06)

50-30-15

T803324,000095C –19–15MAR06–7/9

2254 Cane Loader 100406

PN=171

Displacement Control Components Using caution to prevent damage to the sealing surface, press the roller bearing onto the drive shaft.

(For units with a 3-piece bearing, press the inner race onto the shaft, then install the outer race/cage assembly and the special washer.) Install the bearing retaining ring onto the shaft.

Install the shaft and bearing assembly through front of housing, aligning the shaft spline with the cylinder block spline. Continue to lower the shaft into the unit and carefully align the end of the shaft with the end cap journal bearing. Then lower the shaft and bearing assembly into position.

50 30 16

Rotate the shaft by hand. The rotating assembly should turn freely. If it does not rotate freely, the pump must be disassembled and the problem corrected.

Rotate the pump shaft with a torque wrench to assure correct assembly. When properly assembled, the torque required to turn the shaft (after “break-away”) should be within the ranges shown in the accompanying table.

Torque to Turn Shaft (Variable Pump at 0°) Specification Pump Shaft—Minimum Torque ................................................... 6.71 N•m 5 lb-ft Maximum Torque......................................................................... 13.6 N•m 10 lb-ft

CAUTION: Always test the pump prior to putting it into service to verify correct pressure limiter and control function. Improper function of these systems can result in uncontrollable movement of the vehicle / machine.

Assemble and adjust the following components as described in the Minor Repair section.

• • • • • •

Charge Pump Auxiliary Mounting Pad (If Applicable) Shaft Seal Control Filter Option Charge Relief Valve

Continued on next page

TMCM225401 (04OCT06)

50-30-16

T803324,000095C –19–15MAR06–8/9

2254 Cane Loader 100406

PN=172

Displacement Control Components • Multi-Function Valves • Displacement Limiter(s)

T803324,000095C –19–15MAR06–9/9

50 30 17

TMCM225401 (04OCT06)

50-30-17

2254 Cane Loader 100406

PN=173

Displacement Control Components

50 30 18

TMCM225401 (04OCT06)

50-30-18

2254 Cane Loader 100406

PN=174

Section 60

Steering System Contents Page

Group 10—Repair Steering Valve. . . . . . . . . . . . . . . . . . . . . . . . . .60-10-2 Repair Instructions . . . . . . . . . . . . . . . . . . . . . .60-10-3 Necessary Tools . . . . . . . . . . . . . . . . . . . . . . . .60-10-3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-4 Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . .60-10-6 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-7 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . .60-10-11 Steering Troubleshooting. . . . . . . . . . . . . . . . .60-10-12

60

TMCM225401 (04OCT06)

60-1

2254 Cane Loader 100406

PN=1

Contents

60

TMCM225401 (04OCT06)

60-2

2254 Cane Loader 100406

PN=2

Group 10

Repair

60 10 1

TMCM225401 (04OCT06)

60-10-1

2254 Cane Loader 100406

PN=177

Repair

Steering Valve

CM20045077A0

–UN–17MAR06

60 10 2

Continued on next page

TMCM225401 (04OCT06)

60-10-2

T803324,0000985 –19–17MAR06–1/2

2254 Cane Loader 100406

PN=178

Repair 1—Seal 2—Snap Ring 3—Retainer Ring 4—Seal 5—Ring 6—Needle Bearing Kit 7—Racer

8—Bearing 9—Special Bolt 10—Seal 11—Check Ball Seat 12—O-ring 13—Check Ball 14—Check Ball Retainer

15—Control Assy 16—Housing 17—Control Sleeve 18—Spool 19—Centering Spring 20—Pin 21—O-Ring

22—Spacer 23—Drive 24—Geroter Set 25—Spacer Assy 26—End Cover 27—Special Bolt

T803324,0000985 –19–17MAR06–2/2

Repair Instructions Cleanliness is extremely important when repairing this steering control valve. Always work in a clean area.

Before disconnecting the hydraulic lines, clean the port area of the valve thoroughly. Use a wire brush to remove dirt and debris from around the exterior joints of the valve.

60 10 3

All troubleshooting information defines the terms and problems, possible causes for problems, and recommended procedures for correcting them.

It is recommended that you keep the valve in a vise during disassembly, follow the clamping instructions as explained in this section.

T803324,0000986 –19–17MAR06–1/1

Necessary Tools • • • • • • • • •

Screwdriver, 4-6” long; 1/8” blade 5/16”, 12 Point Socket Breaker Bar Wrench Torque Wrench, 31 N•m (275 lb-in) Plastic or Rubber Hammer 1/4” Allen Wrench 1/8” - 24 x 1-1/2” long machine screw Needle Nose Pliers Spring Installation Tool - 0841320104

T803324,0000987 –19–17MAR06–1/1

TMCM225401 (04OCT06)

60-10-3

2254 Cane Loader 100406

PN=179

Repair

Disassembly 1. 1. Clamp the valve in a vise gerotor end up. Clamp lightly on the edges of the mounting area. Use protective material on the vise jaws and Do Not over-tighten.

2. Remove seven bolts (27).

3. Remove end cover (26).

4. Remove seal (21) from end cover.

5. Remove gerotor (24), take care not to drop star shaped spacer (part of 25).

6. Remove seal (21) from gerotor.

7. Remove drive spacer assembly (25).

8. Remove drive (23).

60 10 4

9. Remove spacer (22).

10. Remove seal (21) from housing (16).

11. Remove the valve from the vise and place the housing on a clean soft cloth to protect the surface finish. Use the thin-bladed screwdriver to pry snap ring (2) from the housing.

12. Rotate spool (18) and control sleeve (17) until pin (20) is horizontal. Push the spool and sleeve assembly forward with your thumbs just far enough to free retainer ring (3) from the housing and remove it.

13. Remove seal (4) from retainer ring (3).

14. Use the thin-bladed screwdriver to pry seal (1) from retaining ring (3). Take care not to damage retainer.

15. Remove the two bearing races (7) and needle thrust bearing (8) from the spool and sleeve assy.

16. Remove the spool and sleeve assembly from the gerotor end of housing. Do Not bind the spool and sleeve assembly in housing. Rotate the unit slowly when removing.

Continued on next page

TMCM225401 (04OCT06)

60-10-4

T803324,0000988 –19–17MAR06–1/2

2254 Cane Loader 100406

PN=180

Repair 17. Push pin (20) from the spool and sleeve assy.

18. Push the spool partially from the control end of the sleeve, and carefully remove six centering springs (19) from the spool by hand.

19. Push the spool back through and out of the sleeve.

Rotate the spool slowly when removing from the sleeve.

20. Remove seal (4) from housing.

21. Remove setscrew (9) from the housing.

22. Screw a 1/8" - 24 machine screw into the end of check ball seat (11). Pull on the screw with a pair of needle nose pliers and lift the assembly out of the housing.

23. Remove the two seals (10 & 12) from the check valve seat.

60 10 5

24. Tip the housing to remove check ball (13) and retainer (14).

T803324,0000988 –19–17MAR06–2/2

TMCM225401 (04OCT06)

60-10-5

2254 Cane Loader 100406

PN=181

Repair

Clean and Inspect 1. Check all mating surfaces and replace any parts that have scratches or burrs that could cause leakage. DO NOT try to file or grind parts.

2. Clean all metals parts in clean nonflammable solvent and blow dry with air. DO NOT wipe parts dry with a cloth or paper towel. Lint or other foreign material could get into the hydraulic system and cause damage.

3. Discard all seals and o-rings and replace with new ones.

4. Lubricate all seals, except ring (5), with O-Ring Lube (0841304202) or equivalent. DO NOT use excessive lubricant on the seals for the gerotor section.

60 10 6

T803324,0000989 –19–17MAR06–1/1

TMCM225401 (04OCT06)

60-10-6

2254 Cane Loader 100406

PN=182

Repair

Reassembly 1. Use the needle nose pliers to lower check ball retainer (14) into the check ball holes of the housing. Make sure that the retainer is straight in the housing and not tilted on edge.

2. Install check ball (13) in housing.

3. Lubricate seals (10 & 12) and install on check ball seat (11).

4. Lubricate check ball seat and seals thoroughly before installing the seat into the housing. When installing do not twist or damage the seals. To install, insert the open end first and push until it bottoms in the hole.

5. Install setscrew (9) using the 5/16" Allen wrench and torque to 11.3 N•m (100 lb-in). To prevent interference, make sure that the top of setscrew (9) is slightly below the mounting surface of the housing.

60 10 7

6. Assemble spool (18) and sleeve (17) carefully so that the spring slots align at the same end. Rotate the spool while sliding the parts together. Some spool and sleeve sets have identification marks, align these marks. Test the assembly for free rotation, the spool should rotate smoothly within the sleeve when force is applied to the splines with the finger tips.

7. Bring spring slots of both parts in line and stand parts on the end of bench. Insert the spring installation tool through the slots on both parts. Position three pairs of centering springs (or two sets of three) on the bench so that the extended edge is down and the arched center section is together. In this position, insert one end of entire set into the spring installation tool.

8. Compress the extended end of the centering spring set and push into the spool sleeve assembly while withdrawing the installation tool.

9. Center the spring set in the parts so that they push down evenly and flush with the upper surface of the spool and sleeve.

Continued on next page

TMCM225401 (04OCT06)

60-10-7

T803324,000098A –19–17MAR06–1/5

2254 Cane Loader 100406

PN=183

Repair 10. Install pin (20) through spool and sleeve until is becomes flush with both sides of the sleeve.

11. Position the spool and sleeve assembly so that the splined end of the spool enters the gerotor end of the housing first. Be extremely careful that the parts do not tilt out of position while inserting. Push parts gently into place with a slight rotating action, but keep pin nearly horizontal.

12. Bring the spool assembly entirely within the housing bore until the parts are flush at the gerotor end of housing. Do Not pull the spool assembly beyond this point to prevent the cross pin from dropping into the discharge groove of the housing. With the spool assembled in this flush position, check for free rotation within the housing by lightly applying finger tip force to the splined end of spool.

13. Place the housing on clean, lint-free cloth. Install seal (21) in housing.

60 10 8

14. Install two bearing races (7) and needle thrust bearing (8) in the order shown in figure 1.

15. Install seal (1) in retaining ring (3), the flat or smooth side of the seal must face downward towards the bushing.

16. Install ring (5), dry, (that is without lubricant) into retaining ring (5). Smooth the ring in place with your finger. Do Not use any ring that falls freely into the recessed area of the retainer.

17. Install the retaining ring assembly over the spool, with a twisting motion. Tap the retainer in place with a rubber hammer. Make sure that it is flush against the bearing race.

18. Install snap ring (2) into housing. After installing, tap on ring end or pry with a screwdriver around the entire circumference of the ring to properly seat it in the housing groove.

Continued on next page

TMCM225401 (04OCT06)

60-10-8

T803324,000098A –19–17MAR06–2/5

2254 Cane Loader 100406

PN=184

Repair 19. Clamp the housing in a vise with the gerotor end up.

Clamp lightly on the edges of the mounting area. Use protective material on the vise jaws and DO NOT over-tighten. Check to insure that the spool and sleeve are flush or slightly below the surface with the fourteen holes.

IMPORTANT: DO NOT use cloth or paper to clean surfaces.

20. Clean the upper surface of the housing by wiping with the palm of a clean hand. Clean each of the flat surfaces of the gerotor section in a similar manner when ready for reassembly.

21. Install seal (21) in housing.

22. Install spacer (22), align bolt holes in spacer with the tapped holes in housing (16).

23. Rotate spool and sleeve assembly until the pin is parallel with the port face. Install drive (23) making sure that drive is engaged with pin. To assure proper alignment, mark the drive, as shown in Figure 2. Note the relationship between the slotted end of drive to the splined end of drive when marking.

60 10 9

24. Install seal (21) in gerotor.

Continued on next page

TMCM225401 (04OCT06)

60-10-9

T803324,000098A –19–17MAR06–3/5

2254 Cane Loader 100406

PN=185

Repair 25. With the seal side of the gerotor (24) faced toward spacer (22), align star valleys (A) on drive (B). Note the parallel relationship of reference lines A, B, C and D. Align the bolt holes without disengaging the gerotor from the drive.

26. Install drive spacer assembly (25) in the gerotor.

27. Install seal (21) in end cover (26).

28. Install end cover (26) on gerotor and align bolt holes.

–UN–17MAR06

1—Gerotor Star Valley 2—Drive (Mark on Top) 3—Pin 4—Port Face

CM061850028

60 10 10

T803324,000098A –19–17MAR06–4/5

CM061850029

–UN–17MAR06

29. Install seven special bolts (27) without lubricant.

Pre-tighten bolts to 17 N•m (150 lb-in), and then torque to 31N•m (275 lb-in) in the sequence shown.

T803324,000098A –19–17MAR06–5/5

TMCM225401 (04OCT06)

60-10-10

2254 Cane Loader 100406

PN=186

Repair

Troubleshooting Most steering problems can be corrected if the problem is properly defined. The entire steering system should be evaluated before removing any components. The steering valve is generally not the cause of most steering problems. The following is a list of steering problems along with the possible causes and suggested corrections.

T803324,000098B –19–17MAR06–1/1

60 10 11

TMCM225401 (04OCT06)

60-10-11

2254 Cane Loader 100406

PN=187

Repair

Steering Troubleshooting Symptom

Problem

Solution

Slow Steering, Hard Steering or Loss of Power Assist

Worn or malfunctioning pump

Repair or replace pump.

Malfunctioning relief valve allows the system pressure to fall lower than specifications.

Repair or replace the relief valve.

Overloaded steering axle

Reduce load.

Symptom

Problem

Solution

Wander: Loader Will Not Stay In A Straight Line

Air in system due to low oil level, cavitating pump, leaky fitting, pinched hoses, etc.

Find problem and correct.

Worn steering linkage.

Repair or replace.

Bent linkage or cylinder rod.

Repair or replace.

Loose cylinder piston.

Repair or replace.

Leaky crossover relief valve.

Repair or replace the crossover relief valve.

Severe wear in steering valve.

Replace the steering valve.

The cylinder slowly extends without turning the steering wheel.

A small amount of extension is normal.

Worn or damaged steering linkage.

Replace linkage and align front end.

Leakage of cylinder piston seals.

Replace the seals.

Worn steering valve gerotor.

Repair or replace the steering valve.

60 10 12

Drift: Loader Veers Slowly In One Direction

Slip: A Slow Movement of Steering Wheel Fails To Cause Any Movement Of The Steered Wheels

Continued on next page

TMCM225401 (04OCT06)

60-10-12

T803324,000098C –19–17MAR06–1/4

2254 Cane Loader 100406

PN=188

Repair Symptom

Problem

Solution

Hang-Up: Temporarily Hard Steering

Thermal Shock1

Check loader for proper operation and cause of thermal shock.

Soft Steering

Air in hydraulic system; most likely air is trapped in the cylinders or lines.

Bleed air from system.

Low system fluid.

Add system oil and check for leaks.

Air in system due to low oil level, cavitating pump, leaky fitting, pinched hoses, etc.

Find problem and correct.

Loose cylinder piston.

Replace cylinder.

Thermal shock damage.

Replace steering valve.

Sticking flow control spool.

Repair or replace flow control valve.

Steering column upper shaft is loose or damaged.

Check for damage and replace if necessary or tighten steering wheel nut.

Lower splines of column may be disengaged or broken.

Check for engagement and replace if splines are damaged.

Steering valve is low on oil. This can happen on start-up, after repair or after long periods of non-use.

Starting engine and circulating system will usually correct the problem.

There is no flow to steering valve caused by a ruptured hose.

Replace hose.

There is no flow to steering valve caused by thermal shock.

Replace steering valve.

Erratic Steering

Free Wheeling: Steering Wheel Turns Freely With No Feeling of Pressure and No Action on Steered Wheels

1 Thermal shock is a condition caused when the hydraulic system is operated for some time without turning the steering wheel, so that fluid in the tank and system is hot and the steering valve is relatively cool (more than 50° temperature differential). When the steering wheel is turned quickly, the result is temporary seizure and possible damage to internal parts of the steering valve. The temporary seizure may be followed by total free-wheeling.

Continued on next page

TMCM225401 (04OCT06)

60-10-13

T803324,000098C –19–17MAR06–2/4

2254 Cane Loader 100406

PN=189

60 10 13

Repair Symptom

Problem

Solution

Free Wheeling: Steering Wheel Turns Freely With Slight Resistance But Results In Little or No Steered Wheel Action

Leaking crossover relief in steering circuit.

Repair or replace the crossover relief valve.

Cylinder piston seal blown.

Determine the cause, correct and replace seal.

Loose steering wheel nut.

Tighten steering wheel nut.

Steering column shaft worn or damaged. (There should be very little free play in valve itself.)

Replace steering column.

Broken or worn linkage between cylinder or steered wheels.

Check for loose or damaged mechanical parts in the steering linkage system.

Leaking cylinder seals.

Replace cylinder seals.

Binding or misalignment in the steering column or the splined input connection.

Align column pilot and spline to steering valve.

High back-pressure in tank line can cause a slow return to center. This pressure should not exceed 20.7 bar (300 PSI).

Find problem with line and correct.

Large particles of contamination in system oil can cause binding between the spool and sleeve in steering valve.

Clean the steering valve and check the oil filters; replace the filters if necessary. If another component has failed causing contaminants, flush the system and replace system filters.

Large contamination particles in gerotor section of steering valve.

Clean the steering valve and check for the source of contamination.

Broken cross pin in spool and sleeve assembly.

Repair or replace steering valve.

Severely worn steering valve.

Replace the steering valve.

Thermal shock.

Replace the steering valve.

Excessive Free Play at Steering Wheel

Excessive Free Play at Steered Wheels

60 10 14

Binding or Centering of Steering Wheel

Steering Valve Locks Up

Continued on next page

TMCM225401 (04OCT06)

60-10-14

T803324,000098C –19–17MAR06–3/4

2254 Cane Loader 100406

PN=190

Repair Symptom

Problem

Solution

Steering Wheel Oscillates or Turns By Itself

Parts assembled wrong during repair.

Reassemble correctly.

Steering unit improperly timed.

Correct the timing.

Hydraulic lines connected to wrong ports.

Reconnect the lines to proper ports.

Hydraulic lines connected to wrong ports.

Reconnect the lines to wrong ports.

Steered Wheels Turn In Wrong Direction When Operator Activates Steering Wheel

T803324,000098C –19–17MAR06–4/4

60 10 15

TMCM225401 (04OCT06)

60-10-15

2254 Cane Loader 100406

PN=191

Repair

60 10 16

TMCM225401 (04OCT06)

60-10-16

2254 Cane Loader 100406

PN=192

Section 70

Hydraulic System Contents Page

Group 10—Pumps & Valves Double Gear Pump . . . . . . . . . . . . . . . . . . . . . .70-10-2 Pump - Priority End Cover Assembly . . . . . . . .70-10-4 Multiple Gear Pump Repair . . . . . . . . . . . . . . . .70-10-5 Suggested Tools . . . . . . . . . . . . . . . . . . . . . . . .70-10-6 Repair Precautions . . . . . . . . . . . . . . . . . . . . . .70-10-7 Bushing Removal Tool . . . . . . . . . . . . . . . . . . .70-10-7 Seal Removal Tool . . . . . . . . . . . . . . . . . . . . . .70-10-7 Bushing Installation Tool . . . . . . . . . . . . . . . . . .70-10-8 Special Steel Sleeve . . . . . . . . . . . . . . . . . . . . .70-10-8 Directional Control Valve - Boom Swing, Boom Flex and Piler Lift . . . . . . . . . . . . . . .70-10-10 Seal Installation Tool . . . . . . . . . . . . . . . . . . . .70-10-11 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-12 Clean and Inspect . . . . . . . . . . . . . . . . . . . . . .70-10-14 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-16 Start-Up Procedure . . . . . . . . . . . . . . . . . . . . .70-10-19 Recommended Test Procedure . . . . . . . . . . . .70-10-20

70

Group 20—Hydraulic Checks Hydraulic Troubleshooting . . . . . . . . . . . . . . . . .70-20-1 Suggested Tools . . . . . . . . . . . . . . . . . . . . . . .70-20-11 External Relief Settings . . . . . . . . . . . . . . . . . .70-20-12 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-12 Valve Bank Disassembly . . . . . . . . . . . . . . . . .70-20-13 Cleaning, Inspection and Repair . . . . . . . . . . .70-20-15 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-15 Spool Assembly — Spring Centered . . . . . . . .70-20-16 Detented . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-16 Valve Section Assembly . . . . . . . . . . . . . . . . .70-20-17 Valve Bank Assembly . . . . . . . . . . . . . . . . . . .70-20-17 Section Disassembly . . . . . . . . . . . . . . . . . . . .70-20-18 Preparation of Parts . . . . . . . . . . . . . . . . . . . .70-20-18 Section Assembly . . . . . . . . . . . . . . . . . . . . . .70-20-19 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . .70-20-20 Directional Control Valve — Boom Lift and Grab Open/Close. . . . . . . . . . . . . . . . . . . . .70-20-22 Group 30—Hydraulic Cylinder Hydraulic Cylinder Diagnostics . . . . . . . . . . . . .70-30-1 Hydraulic Cylinder Drift Diagnostics. . . . . . . . . .70-30-1 Cylinder Tube Assembly . . . . . . . . . . . . . . . . . .70-30-4 Grab Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . .70-30-5 Disassemble and Assemble Cylinder . . . . . . . .70-30-5

TMCM225401 (04OCT06)

70-1

2254 Cane Loader 100406

PN=1

Contents

70

TMCM225401 (04OCT06)

70-2

2254 Cane Loader 100406

PN=2

Group 10

Pumps & Valves

70 10 1

TMCM225401 (04OCT06)

70-10-1

2254 Cane Loader 100406

PN=195

Pumps & Valves

Double Gear Pump

CM11451507E1

–UN–26MAY06

70 10 2

Continued on next page

TMCM225401 (04OCT06)

70-10-2

T803324,000095E –19–15MAR06–1/2

2254 Cane Loader 100406

PN=196

Pumps & Valves 1—Lip Seal 2—Shaft End Cover 3—Gear Housing 4—Plug 5—Backup Seal

6—Channel Seal 7—Thrust Plate 8—Gear Shaft 9—Square Seal 10—Dowel Pin

11—Gear Housing 12—Bearing Carrier Housing 13—Connecting Shaft 14—Gear Set 15—Gear Housing

16—Pump - Priority End Cover Assembly 17—Stud 18—Washer 19—Nut T803324,000095E –19–15MAR06–2/2

70 10 3

TMCM225401 (04OCT06)

70-10-3

2254 Cane Loader 100406

PN=197

Pumps & Valves

Pump - Priority End Cover Assembly

CM11454381B1

–UN–26MAY06

70 10 4

Continued on next page

TMCM225401 (04OCT06)

70-10-4

T803324,000095F –19–15MAR06–1/2

2254 Cane Loader 100406

PN=198

Pumps & Valves 1—Housing 2—Bushing 3—Priority Valve Spool 4—Priority Valve Outer Spring

5—Priority Valve Cap End 6—O-ring 7—Plug 8—Adjusting Screw

9—Set Locking Nut 10—O-ring 11—O-ring 12—Backup Ring

13—Relief Valve Poppet 14—Relief Valve Spring 15—Hex Lug 17‘—Inner Spring

T803324,000095F –19–15MAR06–2/2

Multiple Gear Pump Repair These service instructions will familiarize you with multiple pumps, their component parts, the relative position of each part, proper methods for assembly or disassembly of the units, and care and use of these pumps. This will give you the best performance and a longer working life.

To facilitate the repair of these pumps, and before any work is done, we suggest you first read all of the repair steps.

The first requirement for good maintenance of hydraulic equipment is cleanliness. Make sure you perform all repair work in a clean area.

The repair graphics show a double pump, but is also applicable to the triple pump.

It is important to air blast all parts and wipe them with a clean, lintless cloth before assembly.

70 10 5

CAUTION: Use caution in gripping all parts in the vise to avoid damaging machined surfaces.

A pump must be driven in the direction of rotation for which it is was built, otherwise the pressure will blow the shaft seal.

Check all replacement parts before installation to be certain they were not damaged in shipment.

T803324,0000960 –19–15MAR06–1/1

TMCM225401 (04OCT06)

70-10-5

2254 Cane Loader 100406

PN=199

Pumps & Valves

Suggested Tools • • • • • • • • • • • • • • • • • • • • • •

Arbor Press 1-1/2 in. diameter steel ball Bearing Puller Bushing Removal Tool - 0841329345 Clean lintless cloths Deburring Tool (an old file with cutting teeth ground off) Machinist’s Hammer Soft Hammer Permatex form-a-gasket number C2 non-hardening sealant or equivalent Medium Grit Carborundum Stone Seal Removal Tool System Oil and Grease Snap Ring Pliers Prick Punch Bushing Installation Tool Scale (1/32 In. or 1/64 In. graduations) Small screwdriver Torque Wrench Vise with 6 in. minimum open spread Seal Installation Tool - 0840249684 Special Steel Sleev - 0290244683 Awl

70 10 6

T803324,0000961 –19–15MAR06–1/1

TMCM225401 (04OCT06)

70-10-6

2254 Cane Loader 100406

PN=200

Pumps & Valves

Repair Precautions 1. If it is necessary to pry off sections, take extreme care not to mar or damage machined surfaces. Excessive force while prying can result in misalignment and may seriously damage parts.

2. If parts are difficult to install during assembly, tap gently with a soft hammer. Never use a metal hammer.

3. All gears are closely matched; therefore; they must be kept as sets when removed from the pump. Handle with care to avoid damage to the journals or teeth.

Avoid touching gear journals.

4. Never hammer bushings into bores, use an arbor press.

T803324,0000962 –19–15MAR06–1/1

Bushing Removal Tool The bushing in the double and triple pumps should be removed from their bores by using bushing removal tool, 0841329345.

T803324,0000963 –19–15MAR06–1/1

Seal Removal Tool The seal removal tool can be easily made from an old screwdriver. Heat the tip and bend to 90°. Grind the tip to fit the notch behind the shaft seal.

T803324,0000964 –19–15MAR06–1/1

TMCM225401 (04OCT06)

70-10-7

2254 Cane Loader 100406

PN=201

70 10 7

Pumps & Valves

Bushing Installation Tool To install the bushings, use bushing installation tool, 0290244461.

T803324,0000965 –19–15MAR06–1/1

Special Steel Sleeve Special Steel Sleeve, 0290244683, is used to install the drive shaft through the lip seal without damage.

T803324,0000966 –19–15MAR06–1/1

70 10 8

TMCM225401 (04OCT06)

70-10-8

2254 Cane Loader 100406

PN=202

Pumps & Valves

70 10 9

TMCM225401 (04OCT06)

70-10-9

2254 Cane Loader 100406

PN=203

Pumps & Valves

Directional Control Valve - Boom Swing, Boom Flex and Piler Lift

CM11451509E1

–UN–29SEP06

70 10 10

Continued on next page

TMCM225401 (04OCT06)

70-10-10

T803324,0000967 –19–15MAR06–1/2

2254 Cane Loader 100406

PN=204

Pumps & Valves 1—Section Valve 2—Power Beyond Plug 3—Washer 4—Square Seal

5—Square Seal 6—Section Valve 7—Section Valve Inlet

8—O-ring 9—Washer 10—Main Relief Valve

11—Stud 12—Washer 13—Nut

T803324,0000967 –19–15MAR06–2/2

Seal Installation Tool Seal installation tool, 0290244684, is used to install the lip seal into the housing.

T803324,0000968 –19–15MAR06–1/1

70 10 11

TMCM225401 (04OCT06)

70-10-11

2254 Cane Loader 100406

PN=205

Pumps & Valves

Disassembly 1. Place the pump in a vise1 with the drive shaft pointing downward. Matchmark all sections and be sure to align these marks when assembling.

2. Use a socket wrench to remove four hex nuts (19), studs (17) and washers (18).

3. Lift off port end cover (16). If prying is necessary, be careful not to damage the machined surfaces. Dowel pins (10) will remain in either port end cover, gear housing, or against other hard surfaces. Keep these gears together, they are a matched set. Remove thrust plate (7) from bearing carrier (12).

4. Lift gear housing (15) from bearing carrier (12). If prying is necessary, take care not to damage machined surfaces.

5. Carefully lift or pry off bearing carrier (12) to prevent damage to contact face and edges. Dowel pins (10) will remain in either bearing carrier (12) or gear housings (11 & 15). Do Not remove them.

70 10 12

6. Remove connecting shaft (13). Remove thrust plate (7). Remove front drive shaft assembly (8). Keep these together, they are a matched set. Be careful not to damage the machined surfaces of the gears.

7. Lift or pry off first section gear housing (11). Be careful not to damage surfaces.

8. Use a bushing puller to remove bushings and inspect all bushings for scoring or discoloration. Replace, if necessary.

9. Place front cover (2) in a vise with the mounting face pointing downward. Remove lip seal (1) by inserting seal removal tool into the notch between the double lip seal and the front cover. Tap the seal out and discard.

10. Examine check assy, replace only if damaged.

Remove with a screwdriver.

1

Do not grip on or near any machined surfaces during assembly or disassembly.

Continued on next page

TMCM225401 (04OCT06)

70-10-12

T803324,0000969 –19–15MAR06–1/2

2254 Cane Loader 100406

PN=206

Pumps & Valves 11. Remove and discard all rubber and polymer O-rings and seals.

T803324,0000969 –19–15MAR06–2/2

70 10 13

TMCM225401 (04OCT06)

70-10-13

2254 Cane Loader 100406

PN=207

Pumps & Valves

Clean and Inspect Clean and inspect all parts for wear or damage, replace if necessary. See parts catalog for the correct part numbers to order. Notice that all gear assemblies are a matched set and cannot be ordered separately.

Replace gear housings if either has wear in excess of 0.13 mm (0.005 in) cutout.

Use the following method to determine cutout: Place a straightedge across the bore. If you can slip a 0.13 mm (0.005 in) feeler gauge under the straightedge in the cutout area, replace the gear housing.

1. Pressure pushes the gears against the housing on the low pressure side. As the hubs and bushings wear, the cutout becomes more pronounced. Excessive cutout in a short period of time indicates excessive pressure or oil contamination. If the relief valve settings are within prescribed limits, check for shock pressures or tampering. Check an oil sample and the tank itself for contamination.

70 10 14

2. Where cutout is moderate, 0.13 mm (0.005 in) or less, the gear housing is in good condition and may be reused.

3. Gears (14) which exhibit any scoring on the gear hub, should be replaced. Any scoring, grooving, or burring of the outer tooth diameter will require replacement.

Nicking, grooving, or fretting of teeth surfaces will also necessitate replacement.

4. Drive shaft (8) should be replaced if any wear is detectable, by touch, in the seal area or at the drive coupling. The maximum allowable wear is 0.05 mm (0.002 in). Wear in the shaft seal area indicates oil contamination. Wear or damage to splines will necessitate replacement.

5. Thrust plates (7) seal the gear sections at the sides of the gears. Wear here will allow internal slippage and oil bypass within the pump. A maximum of 0.05 mm (0.002 in) wear is allowable. Replace thrust plates if they are scored, eroded or pitted.

Continued on next page

TMCM225401 (04OCT06)

70-10-14

T803324,000096A –19–15MAR06–1/2

2254 Cane Loader 100406

PN=208

Pumps & Valves 6. Check the center of the thrust plates where the gears mesh, erosion here indicates oil contamination. Pitted thrust plates indicate cavitation or oil aeration.

Discolored thrust plates indicate overheating, probably due to insufficient oil.

7. Dowel pins (10) must be replaced if either the dowel or dowel hole is damaged. If there is damage, the dowel or machined housing or both must be replaced. If more than reasonable force is required to seat dowel pins the cause may be poorly deburred or dirty parts, cocking of the dowel pin in the hole, or improper pin-to-hole fit.

8. Bushings (3) must be replaced if gears are replaced.

Bushings should fit into the bore with a heavy press fit.

9. All sealing parts: lip seal (1), channel seal (5), backup seal (6), and square seal (9) must be replaced. See parts catalog for complete seal kit part numbers.

10. Examine check assembly located in front cover (2).

Ensure that it is in the proper position and tightly seated.

70 10 15

T803324,000096A –19–15MAR06–2/2

TMCM225401 (04OCT06)

70-10-15

2254 Cane Loader 100406

PN=209

Pumps & Valves

Assembly 1. Rub a medium grit carborundum stone over the machined surfaces. If bushings were removed or a new section is used, debur the bores with a fine emery cloth. Wash in a solvent, blow dry with air and wipe with a clean lintless cloth before assembly.

2. Place front cover (2), mounting face downward, in a vise. If check assembly is to be replaced, apply Loctite to threads. Stake the check assembly with a prick punch at both ends of the screwdriver slot and around the edges. Peen the edge of the hole, in front cover (2), with a 11/ 2 in diameter ball from 0.79 to 1.58 mm (1/32 to 1/ 16 in) deep, before installing the check assembly. The check assembly should be screwed in tightly.

3. Any bushings (3), removed from front cover (2), end cover (16) or bearing carrier (12) should be assembled in the drive bores with its groove facing toward the top of the pump (12 o’clock). Assemble the bushings in the driven bores with the groove facing toward the bottom of the pump (6 o’clock).

70 10 16

4. Bushings should be pressed into the bores, one at a time, using installation tool (0290244461) and an arbor press. Be sure the grooves are positioned, as specified, in step 3. Bushings must be pressed into the bores flush with the housing face. Be sure to support the housings so they are square and level.

5. Repeat Step 1.

6. After installing the bushings in all housings, ensure that the dowel pins are in place in any new housings.

Examine all dowel pins, and before inserting, make certain the hole is clean and free from burrs. Gently start pin (10) straight into the hole and tap lightly with a soft hammer.

Continued on next page

TMCM225401 (04OCT06)

70-10-16

T803324,000096B –19–15MAR06–1/3

2254 Cane Loader 100406

PN=210

Pumps & Valves 7. Before inserting a new lip seal (1) into the front cover, coat the outer edge and its recess with non-hardening gasket sealant. With the metal side of the lip seal facing upward and the spring facing toward the gear, press it into the mounting flange side of the front cover with an arbor press and seal installer (0290244684).

Be careful not to damage the lip of the seal. Press inward until flush with the recess and wipe off any excess sealant.

8. Lubricate O-rings (9) with O-ring lube (0841304202) and install into the grooves, located on both sides, of all gear housings.

9. Position gear housing (11) over the front cover and dowel pins. Tap it with a soft hammer until it rests tightly against the cover. Be careful not to pinch the gasket seal. Be sure that the large rounded area is located on the inlet side.

10. Install channel seals (5) and backup seals (4) into the grooves located in thrust plates (7). The flat side of the seal must face away from the thrust plate.

11. Gently, slip the thrust plate through the gear housing and into place onto the shaft end cover. The channel seal from Step 10 should face the shaft end cover.

The relief groove, located in the thrust plate, should face the outlet side of the pump.

70 10 17

12. Slide the driven gear, from set (8), through the housing and into the bushing located in the front cover. Coat steel sleeve tool (0290244683) with grease. Lightly grease drive shaft, from set (8), and place inside the sleeve. Slide both through the shaft end cover with a twisting motion until the integral gear rests against the thrust plate. Avoid damaging the lip seal. Remove the steel sleeve. Squirt clean system oil over the gears.

13. Slip thrust plate with seal over gear journals and into housing bore. The flat side of the seal should face upward with the relief groove facing the outlet side.

Continued on next page

TMCM225401 (04OCT06)

70-10-17

T803324,000096B –19–15MAR06–2/3

2254 Cane Loader 100406

PN=211

Pumps & Valves 14. Position bearing carrier (12) over the gear housing so the bushings receive the journals of the drive and driven gears. Be sure to line up the dowel holes over the dowel pins. When the parts are parallel, squeeze them together or alternately tap over each dowel until the parts are together.

15. Insert connecting shaft (13) into the spline of the drive gear, from set (8). Position and place gear housing (15) over the front cover and dowel pins. Tap it with a soft hammer until it rests tightly against the cover. Be careful not to pinch the gasket seal. Be sure the large rounded area is located on the inlet side.

16. Place thrust plate (7) in gear housing (15) as instructed in Step 11. Insert gear assembly (14) into bearings located in carrier (12). Make certain gears are in contact with the face of the thrust plate.

17. Place end cover (16) on the housing as instructed in Step 11.

70 10 18

18. Place end cover (16) over the gear journals. Align the dowel pins with the holes in the mating housing. Be careful not to pinch the gasket seal, tap the end cover lightly in the center between bearing bores to engage the dowel pins and to move the parts together in a final seating.

19. Thread the four studs, washers and nuts into the front cover and cross-tighten. Rotate the drive shaft with a wrench to make certain there is no binding in the pump.

20. After the fasteners are tight and there is no internal binding, cross-torque nuts to 272 N•m (200 lb-ft).

T803324,000096B –19–15MAR06–3/3

TMCM225401 (04OCT06)

70-10-18

2254 Cane Loader 100406

PN=212

Pumps & Valves

Start-Up Procedure 1. Before installing a new or rebuilt pump, back off the main relief valve until the spring tension on the adjusting screw is relieved. This will avoid the possibility of immediate damage to the replacement pump, in the event the relief valve setting has been increased beyond the recommended operating pressure, prior to removing the old unit.

2. Before connecting any lines to the pump, fill all ports with clean system oil to provide initial lubrication.

3. After connecting the lines and mounting the replacement pump, operate the pump at least two minutes at no load and at low RPM (400 minimum).

During this break-in period, the unit should run free and not develop an excessive amount of heat. If the pump operates properly, speed and pressure can then be increased to normal operating settings.

4. Set the main relief valve to its proper setting while the pump is running at maximum operating speed for the engine.1

70 10 19

1 Always use an accurate gauge when adjusting the relief valve pressure setting.

T803324,000096C –19–15MAR06–1/1

TMCM225401 (04OCT06)

70-10-19

2254 Cane Loader 100406

PN=213

Pumps & Valves

Recommended Test Procedure 1. Be sure there is an adequate supply of system oil for the pump, at least one liter (one gallon) of oil for each L/min (GPM) of pump capacity.

2. If only one section of the tandem pump is being tested, make sure that all other sections, not being tested, are adequately supplied with oil. If any of the other sections run dry, or if plugs are left in ports, serious and permanent damage will result.

3. The oil should be a good quality hydraulic oil rated at 150 SSU at 38° C (100° F) with the oil temperature held at 46° to 52° C (115° to 125° F).

4. The suction line must be of adequate size with no more than 17 kPa (5 in) of mercury vacuum adjacent to the pump inlet. As a rule, the feed line must provide a feed flow velocity not in excess of 2.4 meters per second (8 feet per second).

5. Feeding hot oil into a cold pump may cause the pump to seize. Jog the pump by momentarily starting the driving engine to gradually equalize pump and oil temperatures.

70 10 20

6. Run the pump at least two minutes at no load and moderate speed (not over 1500 RPM). If the pump becomes excessively hot, shut down immediately and locate the problem.

7. Gradually increase pressure on pump in 34 bar (500 PSI) increments until the desired test pressure has been reached. This should take about five minutes.

8. Delivery should run close to rated performance figures which are averaged from testing several pumps. A 5% lower reading may be used as a rated minimum if new, or relatively new, parts have been used. When rebuilding the pump with parts from the original pump (which, while worn, appear satisfactory for reuse) a 10% or 15% lower reading should be used, depending upon the performance expected from the equipment.

One’s own experience will prove the best guide here.

Continued on next page

TMCM225401 (04OCT06)

70-10-20

T803324,000096D –19–15MAR06–1/2

2254 Cane Loader 100406

PN=214

Pumps & Valves 9. Many service representatives measure the output at normal operating speed and at zero pressure, then again at 69 bar (1000 PSI ) (or the operating pressure of the equipment) and allow a volume decrease approximating the listing below. It is a suggested reference only which makes allowance for reused parts. At test speeds other than 1800 RPM, L/Min (GPM) delivery will vary almost proportionately, but the same (dropoff) figures should be used.

After completing testing procedures, the pump is ready for installation and immediate operation on the combine.

Again, it must be remembered that to prevent seizure, hot oil must not be fed into a cold pump.

GPM Drop Off — GPM Delivery at 1800 RPM 100 PSI

1000 PSI

2000 PSI

3000 PSI

10 — 30

1-1/2 — 3

2 — 3 -1/2

2-1/2 — 4

30 — 50

2—3

2-1/2 — 4

3 — 4-1/2

50 — 70

2-1/2 — 3-1/2

3—5

3-1/2 — 5-1/2

L/Min Drop Off — L/Min Delivery at 1800 RPM 6.9 Bar

69 Bar

138 Bar

207 Bar

38 — 113.6 L

5.7 — 11.4 L

7.6 — 13 L

9.5 — 15 L

113.6 — 189 L

7.6 — 11.4 L

9.5 — 15.1 L

11.4 — 17 L

189 — 265 L

9.5 — 13.2

11.4 — 18.9

13.2 — 20.8

70 10 21

T803324,000096D –19–15MAR06–2/2

TMCM225401 (04OCT06)

70-10-21

2254 Cane Loader 100406

PN=215

Pumps & Valves

70 10 22

TMCM225401 (04OCT06)

70-10-22

2254 Cane Loader 100406

PN=216

Group 20

Hydraulic Checks Hydraulic Troubleshooting Symptom

Problem

Solution

All Hydraulic Functions Slow

Low oil level

Check tank level.

Oil viscosity too heavy or too light.

Use recommended oil

Slow engine speed.

Check engine fast idle adjustment.

Restricted pump section screen.

Check pump section screen.

Worn pump.

Test pump using cycle times.

Cold hydraulic oil.

Warm up hydraulic system.

Symptom

Problem

Solution

Hydraulic Functions Slow

Plugged oil cooler.

Clean oil cooler.

Restricted oil cooler hoses.

Check hose routing and condition.

System relief valve.

Test system relief valve.

Circuit relief valve.

Test circuit relief valve.

Control valve spool stuck.

Check hydraulic system open center pressure with all valves in neutral.

Cylinder or hydraulic motor has an internal leak.

Test components for leakage and repair or replace.

Symptom

Problem

Solution

No Hydraulic Functions

No oil

Check oil level in tank.

Pump drive failure.

Remove pump. Check pump drive coupling and drive shaft.

Relief valve stuck open.

Remove relief valve and clean, repair or replace.

Spools not shifting due to low pilot pressure.

Check pilot pressure from hydrostatic pump to charge pressure.

Continued on next page

TMCM225401 (04OCT06)

70-20-1

T803324,000096E –19–15MAR06–1/11

2254 Cane Loader 100406

PN=217

70 20 1

Hydraulic Checks Symptom

Problem

Solution

Pump Not Delivering Oil

Driven in the wrong direction of rotation.

The drive direction must be changed IMMEDIATELY to prevent seizure.

Check pump repair section for the correct ring position for each direction of rotation.

Coupling or shaft sheared or disengaged.

Disassemble the pump and check the shaft for damage. Replace the necessary parts.

Fluid intake pipe in tank restricted.

Check all strainers and filters for dirt and sludge. Clean if necessary.

Air leaks at the intake pump not priming.

Check the inlet connections to determine where air is being drawn in.

Tighten any loose connections.

Ensure oil in the tank is above intake opening.

70 20 2

Check the minimum drive speed which may be too slow to prime the pump.

Symptom

Problem

Solution

Insufficient Pressure Buildup in Pump

System relief valve setting too low.

Use a pressure gauge to correctly adjust the relief valve.

Loss of flow from pump.

Worn pump parts.

Damaged inlet or pressure lines.

Symptom

Problem

Solution

Pump Making Noise

Pump intake partially blocked.

Service the intake strainers.

Check the oil condition and if necessary, drain and flush the system. Refill with clean oil.

Air leaks at the intake or shaft seal.

(Oil in tank will appear to be foamy.)

Continued on next page

TMCM225401 (04OCT06)

70-20-2

Check the intake connections and seal to determine where air is being drawn in.

T803324,000096E –19–15MAR06–2/11

2254 Cane Loader 100406

PN=218

Hydraulic Checks Symptom

Problem

Solution

Tighten any loose connections and replace worn seals, if necessary.

Ensure oil in the tank is above intake opening.

Pump drive speed too slow or too fast.

Operate pump at the recommended speed.

Coupling misalignment.

Check if the shaft seal bearing or any other parts have been damaged.

Replace any damaged parts and realign the coupled shafts.

Symptom

Problem

Solution

Slow Steering — Both Directions

Manifold or spacer plate installed upside down.

Check steering valve.

Worn parts or improperly torqued assembly.

Rebuild.

Steering cylinders leaking.

Test cylinder for leaks.

Steering valve orifices plugged.

Check load sense line orifices at the steering valve.

Symptom

Problem

Solution

High Steering Effort

Check steering valve.

Inspect valve for incorrectly installed torsion pin or misaligned upper cover. Rebuild valve.

Directional Control Valve Can’t Get Pressure

Relief valve poppet stuck open or dirt under seat of same.

Check for foreign matter between poppets and their mating members.

Members must slide freely.

Directional Control Valve Delivers Erratic Pressure

Pilot poppet seat damaged.

Check and replace damaged parts.

Piston poppet sticking in relief valve poppet.

Clean dirt and remove surface marks for free movement.

Pressure setting incorrect due to dirt.

Clean and reset.

Pressure setting incorrect due to loose adjustment screw and locknut.

Tighten and reset.

Continued on next page

TMCM225401 (04OCT06)

70-20-3

T803324,000096E –19–15MAR06–3/11

2254 Cane Loader 100406

PN=219

70 20 3

Hydraulic Checks Symptom

No Response When Steering Wheel Is Slowly Turned

Wrong Response to Steering Wheel

70 20 4

Continuous Steering Wheel Rotation

No Response to Steering Wheel

Drive Elements (Coupling, Gears and Shafts)

Problem

Solution

Leaking due to damaged seats.

Check for scratches, nicks or other marks. Replace all worn or damaged parts.

Leaking due to worn O-rings.

Inspect and replace all O-rings and seals.

Leakage from parts sticking due to dirt.

Clean and inspect. Check for free movement of parts.

Oil Reservoir is too low.

Check and fill to proper level.

Dirty filters and screens.

Inspect and clean or replace filters and screens.

Dirt in Hydraulic System.

Drain, flush and refill with clean oil.

Hydraulic lines hooked to wrong ports on steering valve.

Reconnect lines to proper ports.

Steering valve orbit gear misaligned.

Realign gear.

Dirt in Hydraulic System.

Drain, flush and refill with clean oil.

Broken centering springs in steering valve.

Replace broken part.

Input linkage in steering valve is binding.

Realign linkage.

Burr or sleeve or spool of steering valve.

Repair or replace part.

Malfunction in pump or lines from pump.

Inspect and repair or replace.

Sleeve and spool locked-up in steering valve.

Disassemble and repair or replace.

Excessive Noise

Faulty mechanical drive components (fit of coupling, misalignment, etc.)

No or insufficient system pressure.

Defective transmission of torque.

Unstable pressure or flow.

Defective drive components.

Continued on next page

TMCM225401 (04OCT06)

70-20-4

T803324,000096E –19–15MAR06–4/11

2254 Cane Loader 100406

PN=220

Hydraulic Checks Symptom

Problem

Solution

Hydraulic Cylinder or Motor

Excessive Noise

Faulty sealing.

No or insufficient flow.

Internal losses.

Defective seals.

Wear due to dirt.

No or insufficient system pressure.

Internal or external leakage.

Wear due to dirt.

Unstable pressure or flow.

System insufficiently bled.

Defective seals.

Stick-slip effect, alternating direction of load.

Directional Valves

Excessive Noise

Faulty directional control.

Local throttle effect.

No or insufficient flow.

Spool position incorrect.

70 20 5

Negative overlap.

No or insufficient system pressure.

Wrong position.

Mechanically jammed.

Return spring broken.

Leakage.

Unstable pressure or flow.

Dynamic flow forces influence actuating force and opening of directional valve..

Positioning error.

Position of spool unstable.

System fluid temperature too high.

Wrong position.

Wear

Flow Control Valves

Excessive Noise

Enclosed air.

Continued on next page

TMCM225401 (04OCT06)

70-20-5

T803324,000096E –19–15MAR06–5/11

2254 Cane Loader 100406

PN=221

Hydraulic Checks Symptom

Problem

Solution

Pressure difference too low.

Vibrations.

No or insufficient flow.

Control orifice blocked.

Unstable pressure or flow.

Enclosed air.

Pressure difference too low.

Dirt in flow control valve.

Fluid temperature too high.

Wear Lap losses.

Pressure Relief Valves

Excessive Noise

Vibrations, rumbling noises indicate enclosed air or lack of damping.

Incorrect pressure setting.

No or insufficient flow.

Setting too low.

Valve seat damaged.

70 20 6

Jammed by dirt.

No or insufficient system pressure.

Setting too low.

Damaged valve seat.

Broken spring.

Vibration.

Foreign matter in valve seat.

Unstable pressure or flow.

Vibration noise.

Changes in back pressure.

Irregular operating of pressure relief valve.

Oscillation.

Fluid Pressure too high.

Continued on next page

TMCM225401 (04OCT06)

70-20-6

Setting too high.

T803324,000096E –19–15MAR06–6/11

2254 Cane Loader 100406

PN=222

Hydraulic Checks Symptom

Problem

Solution

Excessive gap losses in all components.

Excessive leakage.

Load cycle too high.

Return Lines

Excessive Noise

Turbulence towards suction area.

Not securely mounted.

Mechanical vibration.

Filters

Excessive Noise

Incorrectly mounted.

Mechanical vibration.

Coolers

Fluid temperature too high.

Relief valve pressure set too high.

Excessive Noise

Noise of fan.

Fluid temperature too high.

Ambient temperature too high.

Interrupted fanning/flow of water.

Pressure Gauge

No or insufficient system pressure.

Defective gauge.

Unstable pressure or flow.

Incorrect reading.

70 20 7

Defective gauge.

Pressure Line

Fluid temperature too high.

Faulty pressure gauge selector switch.

Excessive Noise

Incorrect mounting.

Transmission of noise.

No or insufficient flow.

Fittings leaking.

Local throttle points.

Pressure increase.

Pressure relief valve open.

No or insufficient system pressure.

Continued on next page

TMCM225401 (04OCT06)

70-20-7

Broken pipe

T803324,000096E –19–15MAR06–7/11

2254 Cane Loader 100406

PN=223

Hydraulic Checks Symptom

Problem

Solution

Fittings leaking.

Diesel Engine

Unstable pressure or flow.

System not bled correctly.

Excessive Noise

Speed too high.

Bearing damage.

Bearing play.

No or insufficient flow.

Speed too low.

No or insufficient system pressure.

Insufficient input horsepower.

Unstable pressure or flow.

Excessive fluctuation of engine speed.

Idling speed too low.

Oil Line Leakage

Fluid temperature too high.

Engine speed too high.

Excessive Noise

Excessive leakage.

Oil foaming effect on suction.

70 20 8

Damaged rotary group in pump.

No or insufficient flow.

Excessive leakage due to oil of too low viscosity Too high temperature.

Wear of pump.

No or insufficient system pressure.

Bends in line.

Suction line not airtight, enclosed air.

Unstable pressure or flow.

Leakage line clogged.

Bent lines.

Leakage due to back pressure on the pump driveshaft.

Suction Line Characteristics

Excessive Noise

Reduced section in suction pipe.

Suction pipe not airtight, air bubbles.

Continued on next page

TMCM225401 (04OCT06)

70-20-8

T803324,000096E –19–15MAR06–8/11

2254 Cane Loader 100406

PN=224

Hydraulic Checks Symptom

Problem

Solution

No or insufficient flow.

Defective suction characteristics, bends and reduced section.

Suction line not airtight, enclosed air.

No or insufficient system pressure.

Faulty suction characteristics, bends, reduced section.

Line not airtight, enclosed air.

Unstable pressure or flow.

Bends, reducing pipe area.

Suction line not airtight, enclosed air.

Oil Tank - Hydraulic Fluid

Fluid temperature too high.

Engine speed too high.

Excessive Machine Noise

Oil level low.

Oil foaming.

Air bubbles.

Water in oil (cloudy) Cold system fluid.

70 20 9

Viscosity too high.

Tank not bled.

No or insufficient flow.

Oil level too low.

Bleeding not effective.

No or insufficient system pressure.

Oil level too low.

Oil viscosity too low.

High leakage, gap losses.

Unstable pressure or flow.

Air bubbles.

Turbulence from return port to suction port of tank.

Fluid temperature too high.

Oil tank not filled properly.

Wrong viscosity.

Continued on next page

TMCM225401 (04OCT06)

70-20-9

T803324,000096E –19–15MAR06–9/11

2254 Cane Loader 100406

PN=225

Hydraulic Checks Symptom

Problem

Solution

Local overheating causing excessive clearances.

Overheating.

Pump not delivering fluid.

70 20 10

Driven in the wrong direction of rotation.

The drive direction must be changed immediately to prevent seizure.

Coupling or shaft sheared or disengaged.

Disassemble the pump and check the shaft and cartridge for damage.

Replace all damaged parts.

Fluid intake line in tank is restricted.

Check all strainers and filters for dirt and sludge. Clean if necessary.

Fluid viscosity too heavy to pick up prime.

Completely drain the system and add fluid of the proper viscosity.

Air leaks at intake, pump not priming.

Check the inlet connections to determine whether air is being drawn in. Tighten any loose connections.

Make sure that fluid in the tank is above the intake pipe opening. If not, add fluid.

Insufficient Pressure Build-up

System relief valve set too low.

Using a pressure gauge, adjust the relief valve to its proper setting.

Loss of flow from pump.

Worn pump parts. Repair or replace pump.

Broken inlet or pressure line.

Replace line.

Pump Making Noise

Pump intake partially blocked

Clean the intake air filter elements.

Check the fluid condition and, if necessary, drain and flush the system. Refill with clean fluid.

Air leaks at the intake or shaft 5 seal.

Continued on next page

TMCM225401 (04OCT06)

70-20-10

Check the inlet connection and seal to determine where air is being drawn in. Tighten any loose connections and replace the seal if necessary.

T803324,000096E –19–15MAR06–10/11

2254 Cane Loader 100406

PN=226

Hydraulic Checks Symptom

Problem

Solution

Make sure that the fluid is above the intake opening in the tank. Fill, if necessary.

Pump drive speed too fast or too slow.

Operate the pump at the recommended speed.

Coupling misaligned.

Check the shaft seal bearing and other parts for misalignment.

Replace any damaged parts.

T803324,000096E –19–15MAR06–11/11

Suggested Tools 1. 1/2” Wrench 2. 9/16” Wrench 70 20 11

3. Torque Wrench 4. 1/8” Allen Wrench 5. Flat Blade Screwdriver 6. LOCTITE 271 - 0841303179 7. O-ring Lube - 0841304202

LOCTITE is a trademark of Loctite Corp.

TMCM225401 (04OCT06)

T803324,000096F –19–16MAR06–1/1

70-20-11

2254 Cane Loader 100406

PN=227

Hydraulic Checks

External Relief Settings 1. The inlet section of the valve has an adjustable relief which is set at 179 bar (2500 ± 100 PSI).

2. The main relief and port reliefs are adjusted by loosening the locking jamnut with a 9/16” wrench.

Using a 1/8” allen wrench, screw inward to increase pressure and outward to decrease. After adjusting, tighten the locking jamnut.

3. The third bank has two port reliefs for the conveyor swing circuit.

T803324,0000970 –19–16MAR06–1/1

Overhaul

70 20 12

Valves are often used in hazardous environments, therefore care should be taken to frequently inspect the product for damage due to improper use, corrosion, or normal wear. Repairs should be made immediately, if needed.

Always refer to the machine’s owners manual for the proper procedure to remove the valve from the machine.

Remove the valve bank from the equipment and disconnect all hoses, fittings, control handles, and linkage connectors that might be attached to the valve. Plug all ports and thoroughly clean the valve bank’s exterior, then remove the port plugs.

NOTE: All work must be performed in a clean area.

T803324,0000971 –19–16MAR06–1/1

TMCM225401 (04OCT06)

70-20-12

2254 Cane Loader 100406

PN=228

Hydraulic Checks

Valve Bank Disassembly 1. Mark the valve bank.

This step is the most critical step in the disassembly procedure. It should be followed very closely to ensure that the valve bank is properly reassembled after repairs have been made.

1. Take a waterproof, quick-drying marker and mark each casting with a sequential number. Start by marking the inlet casting as #1 and finish by marking the outlet with the highest number.

2. Then mark the port boss closest to the back cap on each work section with a “B” (for black cap end).

3. Next mark the port boss closest to the spool clevis on each work section with a “C” (for clevis end).

4. Lastly if relief valves must be removed from the valve bank, they should be marked with the number of the casting and port to which they belong. Inlet and mid-inlet relief valves are marked with their casting number only!

2. Tie Bolts Remove the four (4) tie bolts which hold the bank together and separate the sections.

70 20 13

3. Section Seals The inlet, mid-inlet and each parallel work section have four (4) section seals on the downstream mating face.

A series work section has three (3) section seals on its downstream mating face. These section seals should be removed and discarded.

4. Control Spool and Seals Grasp the spring end of the spool with a clean rag and pull the spool with a twisting motion. Generally the rear retainer plate backup ring and spool seal will come out with the spool.

Continued on next page

TMCM225401 (04OCT06)

70-20-13

T803324,0000972 –19–16MAR06–1/3

2254 Cane Loader 100406

PN=229

Hydraulic Checks

CAUTION: For detented spool models, be careful not to remove the detent poppet sleeve unless it is to be serviced.

Next remove the two retainer screws from the spool clevis end of the work section. Then remove the two retainer plates, the backup ring , and the spool seal .

The spool should now be tagged or marked with its work section’s identification number (from Step 1).

Spool seals and backup rings should be discarded.

5. Transition Check The transition check is located in the bottom of the work section housing. Remove the check valve cap and its O-ring seal, then remove the check spring and the check valve poppet.

NOTE: Only cylinder (ports blocked in neutral) work sections have a transition check.

6. Spool Disassembly — Spring Centered Spool

70 20 14

These parts should not be removed from the spool unless they need to be replaced. Once the spool is free of the work section housing, it must be handled carefully to avoid damage. Place the spool in a soft jawed vise and remove the stripper bolt with a wrench.

Since an anaerobic thread adhesive is used in its assembly, cautious application of heat may be required to free the stripper bolt.

As the stripper bolt threads, disengage the spring and spring guides will pop free of the spool.

7. Detented Spool

Continued on next page

TMCM225401 (04OCT06)

70-20-14

T803324,0000972 –19–16MAR06–2/3

2254 Cane Loader 100406

PN=230

Hydraulic Checks Again these parts should not be removed from the spool unless they need to be replaced. Wrap the detent sleeve with a clean rag. Grip the rag covered sleeve; pull firmly. As the sleeve moves backwards, the detent balls and the detent spring will pop free. The rag should capture these parts and prevent their loss.

Next clamp the spool in a soft jawed vise and remove the detent poppet retainer. Use an undersized bar through the detent ball bore as a wrench. Again, because an anaerobic adhesive is used in the retainer’s assembly, cautious application of heat may be required.

CAUTION: Too much heat may distort the spool.

T803324,0000972 –19–16MAR06–3/3

Cleaning, Inspection and Repair 1. Inspect the spool bores. Check seats and spools for deep scratches, gouges, or excessive wear. If any of these conditions exist, replace section. Minor surface damage on the control spool and check poppet may be carefully polished away with very fine crocus cloth.

70 20 15

2. Examine the machined surfaces of the valve housing for nicks and burrs that could cause leakage between sections. Lightly stone these surfaces to remove any rough spots.

3. Wash all parts thoroughly in a clean solvent and blow dry before beginning reassembly. Pay special attention to the number and letters marked on the parts in Step 1. If any marks are removed during cleaning remark immediately.

CAUTION: Too much heat may distort the spool.

T803324,0000973 –19–16MAR06–1/1

Assembly Reverse the procedures outlined in Steps 1 through 8.

Also, follow the additional instructions below.

T803324,0000974 –19–16MAR06–1/1

TMCM225401 (04OCT06)

70-20-15

2254 Cane Loader 100406

PN=231

Hydraulic Checks

Spool Assembly — Spring Centered CAUTION: A shallow milled relief area extends across the O-ring face of the valve housing. It should not be stoned or ground off.

Clamp the control spool in a soft jawed vise. Apply a small amount of LOCTITE 262 or equivalent anaerobic adhesive to the stripper bolt before assembly.

Assemble the spring, spring guides, and stripper bolt onto the spool (Reverse of Step 7). Lightly coat the spring assembly with high temperature grease to prevent rusting.

CAUTION: Follow the adhesive manufacturer’s instructions for proper cleaning and curing.

Failure to clean and prepare parts properly may result in assembly failure.

70 20 16

LOCTITE is a trademark of Loctite Corp.

T803324,0000975 –19–16MAR06–1/1

Detented Clamp the control spool in a soft jawed vise. Apply a small amount of LOCTITE 262 or equivalent anaerobic adhesive to the detent popper retainer and thread it into the control spool.

CAUTION: Follow the adhesive manufacturer’s instructions for proper cleaning and curing.

Failure to clean and prepare parts properly may result in assembly failure.

Then, lightly coat the detent balls, detent spring and detent sleeve with high temperature grease. Next, place the detent balls and spring into the detent poppet retainer as described in Step 8 and partially compress them with a small clamp. Now, slide the detent sleeve into position, pushing the clamp out of the way at the same time.

LOCTITE is a trademark of Loctite Corp.

TMCM225401 (04OCT06)

T803324,0000976 –19–16MAR06–1/1

70-20-16

2254 Cane Loader 100406

PN=232

Hydraulic Checks

Valve Section Assembly Apply a light coating of clean hydraulic oil to the valve spool. Place the retaining plates, new backup rings and new spool seals in position as shown in Figure 4.

Carefully insert the spool into the housing. Make sure that the spool and housing are in the proper orientation (See Step 1). Place LOCTITE 262 or its equivalent on the backcap screws and front retainer screws threading them into the valve housing. When installing the transition check refer to Step 6. Torque cap screws to 122 N•m (8990 lb-ft).

LOCTITE is a trademark of Loctite Corp.

T803324,0000977 –19–16MAR06–1/1

Valve Bank Assembly Return all relief valves to their proper positions (See Step 1). Coat the section seals with grease and place them in their grooves. Place the valve sections on the tie bolts in their proper sequence (See Step 1). Torque the tie bolts in a cross pattern to 60 N•m ( 42 lb-ft) for the chopper valve or 101 N•m ( 75 lb-ft) for the five bank, topper/sideknives, or crop divider valves.

70 20 17

T803324,0000978 –19–16MAR06–1/1

TMCM225401 (04OCT06)

70-20-17

2254 Cane Loader 100406

PN=233

Hydraulic Checks

Section Disassembly Read these instructions carefully. Failure to follow these procedures can result in poop performance and/or product failure.

1. Remove cap screws from both ends of the valve section.

2. Remove end caps, seal and end cap tube from each end of casing.

3. Remove seal retainer and seals from the clevis end of the spool assembly.

4. Remove spool and spring package assembly from valve section. Remove seal retainer and seals to replace seals.

5. If stripper bolt must be removed from the spool for replacement of parts, it may be necessary to apply heat to the hex nut and stripper bolt to loosen adhesive that was applied to the threads.

NOTE: Use heat carefully to keep spool from warping.

70 20 18

CAUTION: Failure to follow these recommended assembly instructions can result in poor performance and/or failure of the product.

Product should be thoroughly tested to ensure proper operation before the valve is put into service.

T803324,0000979 –19–16MAR06–1/1

Preparation of Parts 1. Clean adhesive from threads of spool, stripper bolt, housing, cap screw holes and hex nut with LOCTITE chisel gasket remover.

2. Wash all parts in solvent to remove grease and oil.

Blow dry.

LOCTITE is a trademark of Loctite Corp.

TMCM225401 (04OCT06)

T803324,000097A –19–16MAR06–1/1

70-20-18

2254 Cane Loader 100406

PN=234

Hydraulic Checks

Section Assembly NOTE: If stripper bolt was not removed from spool, proceed to Step 6.

1. Place spool in a soft-jawed vise, threaded end up.

2. Spray the threads of the new stripper bolt and hex nut with Locquic Primer Grade NF and let dry. Apply LOCTITE 262 Red to threads.

3. Slide one of the spring retainers on to the end of the stripper bolt with the longest threads. Screw the stripper bolt into the valve spool as far as it will go. Be sure the spring guide slides freely.

4. Slide the springs over the stripper bolt.

CAUTION: Seals are similar in size. Be sure to insert seals in their proper position. They are not interchangeable.

Install the other spring retainer and compress the springs so the hex nut can be screwed onto the stripper bolt.

NOTE: Be sure the spring retainer slides freely.

70 20 19

5. Torque the hex nut to 19 N•m ± 2 N•m (175 ± 25lb-in) and set the spool assembly aside to cure for a minimum of 8 hours. After curing, test the hex nut to be sure it withstands 14 N•m (125 lb-in) of breakaway torque.

6. Apply light grease to seals. Assemble O-ring on OD of seal retainer and O-ring in the end of the seal retainer.

7. Install one seal retainer with O-rings on spool. Then slide the spool into the housing.

8. Lightly grease O-ring and install it on the valve cap 9. Install end cap tube on seal retainer. Then slip end cap on the end cap tube.

LOCTITE is a trademark of Loctite Corp.

TMCM225401 (04OCT06)

Continued on next page

70-20-19

T803324,000097B –19–16MAR06–1/2

2254 Cane Loader 100406

PN=235

Hydraulic Checks 10. Spray threads of the cap screws and the cap screw holes in the housing with LOCQUIC Primer Grade NFTM and let dry.

11. Apply LOCTITE 262 Red to threads of the two cap screws. Insert them through valve cap and screw them into the valve housing. Tighten cap screws evenly and torque to 14.6 N•m ± 2 N•m (175 ± 17 lb-in).

12. Install seal retainer with seals on clevis end of spool.

Install end cap tube and valve cap.

13. Install two cap screws, tighten evenly and torque to 14.6 N•m ± 2 N•m (175 ± 17 lb-in) to complete assembly.

70 20 20

LOCTITE is a trademark of Loctite Corp.

T803324,000097B –19–16MAR06–2/2

Troubleshooting Periodic inspection of spool operation, oil condition and pressure connections save time-consuming breakdowns and unnecessary parts replacement. All hydraulic connections must be tight. Loose connections, not only allow leakage, but also permit air to be drawn into the system, resulting in noisy and erratic operation.

T803324,000097C –19–16MAR06–1/1

TMCM225401 (04OCT06)

70-20-20

2254 Cane Loader 100406

PN=236

Hydraulic Checks

Troubleshooting Symptom

Problem

Solution

Oil Leaks at End of Spool

Defective O-rings in valve body.

Replace O-rings.

Spool Does Not Return to Neutral

Broken spring.

Replace spring.

Bent spool.

Replace complete section assembly.

Foreign particles jamming spool passage.

Clean system and valve.

Misalignment of operating linkage.

Check linkage for binding conditions.

Valve banks improperly torqued.

Torque nuts to 57 N•m (42 lb-ft) on 2 bank valve and 102 N•m (75 lb-ft) on 3 bank valve.

Relief valve not properly set, or stuck in base and/or worn.

Repair, clean and readjust.

Dirt or foreign particles lodged between relief valve control poppet and seat.

Disassemble, clean and reassemble.

Valve body cracked inside.

Replace complete section assembly.

Spool not moved to full stroke.

Check travel.

Debris plugging orifice in relief valve assembly.

Remove relief valve, check orifice hole and clean hole if blocked.

Relief valve assembly installed backwards.

Install properly.

Oil bypassing between spool and body.

Replace complete valve section.

Oil bypassing piston in cylinder.

Repair or replace cylinder.

Spool not centered.

Refer to above spool remedies.

Debris lodged between check valve ball and seat.

Disassemble, clean and reassemble.

Scored or sticking check valve.

Replace poppet.

No Motion, Slow or Jerky Action of Hydraulic System

No Relief Valve Action (High Pressure)

Load Will Not Hold

Load Drops When Spool Is Moved From Neutral To A Power Position

T803324,000097D –19–16MAR06–1/1

TMCM225401 (04OCT06)

70-20-21

2254 Cane Loader 100406

PN=237

70 20 21

Hydraulic Checks

Directional Control Valve — Boom Lift and Grab Open/Close

CM11451518B2

–UN–26MAY06

70 20 22

Continued on next page

TMCM225401 (04OCT06)

70-20-22

T803324,000097E –19–16MAR06–1/2

2254 Cane Loader 100406

PN=238

Hydraulic Checks 1—Section Valve 2—Square Seal 3—Square Seal

4—Section Valve 5—Section Valve Inlet 6—O-ring

7—Washer 8—Main Relief Valve 9—Stud

10—Washer 11—Nut

T803324,000097E –19–16MAR06–2/2

70 20 23

TMCM225401 (04OCT06)

70-20-23

2254 Cane Loader 100406

PN=239

Hydraulic Checks

70 20 24

TMCM225401 (04OCT06)

70-20-24

2254 Cane Loader 100406

PN=240

Group 30

Hydraulic Cylinder Hydraulic Cylinder Diagnostics

AG,HX00517,18 –19–17MAY04–1/1

Hydraulic Cylinder Drift Diagnostics

– – –1/1

1 Cylinder Identification

Is the cylinder you are working with a rephasing cylinder?

YES: GO TO 4 NO: GO TO 2

– – –1/1

2

Preparing Cylinder for Testing

Relieve all pressure from the cylinder by either putting the valve, that controls the cylinder, into the float position or by turning off the machine’s engine and moving the valve controlling the cylinder(s) from extend to retract positions.

YES: GO TO 3

NOTE: If machine has pilot operated or electro-hydraulic valves see machine manual for instructions on how to relieve all pressure from the cylinder.

70 30 1

Disconnect the cylinder from the machine by removing the pin at the ROD END. RETRACT the cylinder fully and shut off the machine.

NOTE: To check individual cylinders, disconnect the hoses or lines from the cylinder not being tested and cap off the fittings on the lines for those cylinders to allow you to isolate the cylinder you are testing.

– – –1/1

TMCM225401 (04OCT06)

70-30-1

2254 Cane Loader 100406

PN=241

Hydraulic Cylinder 3 Testing Cylinder for Leaks

Disconnect the PISTON END line from the machine, and remove coupler if necessary, and place the line in a pail or pan.

Cap line remaining on machine.

Start the machine and move the valve slowly in the direction to retract the cylinder.

Does oil continue to escape out of the return line as you hold the valve in the retract position?

Note: A small amount of oil may escape from the fitting or line do to oil being trapped in the line when it was disconnected.

YES: Cylinder is leaking around the piston seal or the cylinder bore is scored.

Repair or Replace Cylinder.

GO TO 1 NO: Cylinder is good.

Test the other cylinders in this system with this same procedure.

GO TO 1 OR refer to machine manual to test the valve.

HCD1095 –UN–28NOV01

A—Pressure B—Pail C—Cap

70 30 2

– – –1/1

4 Rephasing Cylinder Identification

Does this rephasing cylinder rephase in the RETRACT position?

YES: GO TO 5 NO: GO TO 2

– – –1/1

TMCM225401 (04OCT06)

70-30-2

2254 Cane Loader 100406

PN=242

Hydraulic Cylinder 5 Preparing Cylinder for Testing

Relieve all pressure off of the cylinder by either putting the valve, that controls the cylinder, into the float position or by turning off the machine’s engine and moving the valve controlling the cylinder(s) from extend to retract positions.

YES: GO TO 6

Disconnect the cylinder from the machine by removing the pin at the ROD END.

CAUTION: Make sure you have room on the machine to fully extend the cylinder with out the rod contacting anything. If there is insufficient room remove the cylinder completely from the machine.

EXTEND the cylinder fully and shut off the machine.

CAUTION: If the piston nut is missing off of the rod, the rod could be propelled out of the cylinder.

NOTE: To check individual cylinders, disconnect the hoses or lines from the cylinder not being tested and cap off the fittings on the lines for those cylinders to allow you to isolate the cylinder you are testing.

– – –1/1

6 Testing Cylinder for Leaks

Disconnect the ROD END line from the machine, and remove coupler if necessary, and place the line in a pail or pan.

Cap line remaining on machine.

Start the machine and slowly move the valve in the direction to extend the cylinder.

CAUTION: If the piston nut is missing off of the rod, the rod could be propelled out of the cylinder.

YES: Cylinder is leaking around the piston seal or the cylinder bore is scored.

Repair or Replace Cylinder.

70 30 3

GO TO 1 NO: Cylinder is good.

Does oil continue to escape out of the ROD END as you hold the valve in the extend position?

NOTE: A small amount of oil may escape from the fitting or line do to oil being trapped in the line when it was disconnected.

Test the other cylinders in this system with this same procedure or refer to machine manual to test the valve.

GO TO 1

HCD1094 –UN–28NOV01

A—Pressure B—Pail C—Cap

– – –1/1

TMCM225401 (04OCT06)

70-30-3

2254 Cane Loader 100406

PN=243

Hydraulic Cylinder

Cylinder Tube Assembly

CM212071E1

–UN–26MAY06

70 30 4

Continued on next page

TMCM225401 (04OCT06)

70-30-4

T803324,0000982 –19–17MAR06–1/2

2254 Cane Loader 100406

PN=244

Hydraulic Cylinder 1—Cylinder Tube Assembly 2—O-ring 3—Pipe Plug 4—Hex Nut 6—O-ring 7—Wear Ring

8—Seal 9—Seal 10—Seal 11—Seal 13—O-ring 14—Ring

15—Snap Ring 16—O-ring 17—Seal 18—Snap Ring 19—Seal

20—O-ring 21—Rod 22—Rod End 23—Piston 24—Guide

T803324,0000982 –19–17MAR06–2/2

Grab Cylinder Number

Name

Use

T43512 (U.S.) (U.S.) TY9473 (Canadian) (U.S.) 242 (U.S.)

Thread Lock and Sealer (Medium Strength)

Used to lock threads during assembly.

LOCTITE is a trademark of Loctite Corp.

T803324,0000983 –19–17MAR06–1/1

Disassemble and Assemble Cylinder

–UN–28NOV01

IMPORTANT: Clamping cylinder in a vise at the middle or rod end of barrel may damage the barrel. Clamp only at the cylinder base end.

HCD1072

Extend rod to remove oil or air between rod piston and rod guide. Excessive amounts of trapped oil or air will expand seals and make disassembly more difficult.

A—Snap Ring B—Rod Guide

1. Open both ports and drain all oil from the cylinder.

2. Extend rod fully.

3. Clean outside surface of cylinder with suitable solvent and dry to prevent dirt and debris from entering cylinder barrel.

4. Remove snap ring (A) from rod guide (B).

Continued on next page

TMCM225401 (04OCT06)

70-30-5

OUO6046,00016AF –19–17MAY04–1/10

2254 Cane Loader 100406

PN=245

70 30 5

Hydraulic Cylinder 5. Using a wooden dowel or brass drift, drive rod guide (A) into cylinder past barrel snap ring groove.

6. Remove any debris in barrel snap ring groove.

–UN–13NOV01

IMPORTANT: If filler ring (B) is installed backwards, snap ring may not disengage and filler ring could be damaged.

HCD1073

7. Install filler ring (B), supplied with cylinder seal kit, into barrel snap ring groove in the direction shown to prevent snap ring from engaging in barrel snap ring groove during removal.

HCD1075

–UN–29NOV01

A—Rod Guide B—Filler Ring

HCD1097

–UN–28NOV01

70 30 6

Continued on next page

TMCM225401 (04OCT06)

70-30-6

OUO6046,00016AF –19–17MAY04–2/10

2254 Cane Loader 100406

PN=246

Hydraulic Cylinder 8. Pull rod assembly (A) from cylinder barrel (B).

NOTE: Install rod end in soft-jawed vise in order to remove nut.

–UN–08NOV01

9. Remove nut (C), piston (D) and rod guide (E).

HCD1076

10. Remove groove filler ring from snap ring groove. Do not use for reassembly.

NOTE: When removing seals from piston and rod guide, do not damage, mark or score any surfaces that contact the seals.

11. Remove all seals and rings on piston and rod guide.

–UN–08NOV01

12. Inspect piston, barrel and rod guide for nicks or burrs.

Repair or replace as necessary.

HCD1077

A—Rod Assembly B—Cylinder Barrel C—Nut D—Piston E—Rod Guide

70 30 7

OUO6046,00016AF –19–17MAY04–3/10

13. Inspect groove in cylinder barrel. If necessary, clean groove and remove nicks, burrs, or rust from inside of barrel using emery cloth.

HCD1061

–UN–19NOV01

14. Clean inside of barrel using a safe solvent and blow dry using compressed air.

Continued on next page

TMCM225401 (04OCT06)

70-30-7

OUO6046,00016AF –19–17MAY04–4/10

2254 Cane Loader 100406

PN=247

Hydraulic Cylinder NOTE: All parts must be cleaned and dry before assembly.

15. Install O-ring (B) and seal (D).

–UN–28NOV01

NOTE: Cap seal (E) can be made more pliable by putting the seal in hot water for approximately 5 minutes.

HCD1062

Install cap seal as quickly as possible once it has been removed from the water and dried to keep the amount of time that seal is stretched to a minimum.

16. Push cap seal (E) on end of piston.

17. Install a plastic tie band around cap seal with the smooth side against seal.

–UN–13NOV01

18. Pull cap seal across land into position over seal (D) using the plastic tie band.

HCD1088

IMPORTANT: For proper fit, the back-up rings (C) must be installed with the radius (F) toward cap seal (E).

19. Install ring (A) and back-up rings (C).

–UN–28NOV01

HCD1100

–UN–26NOV01

A—Ring B—O-Ring C—Back-up Ring (2 used) D—Seal E—Cap Seal F—Radius

HCD1087

70 30 8

Continued on next page

TMCM225401 (04OCT06)

70-30-8

OUO6046,00016AF –19–17MAY04–5/10

2254 Cane Loader 100406

PN=248

Hydraulic Cylinder 20. Check if cap seal is loose; seal must fit tight against seal expander and not turn. If seal can be turned, it has been stretched too much and can be damaged during assembly into barrel.

21. If necessary, shrink cap seal to its original size using a ring compressor or hose clamp (B).

Protect by placing shim stock or protective material between seal and clamp when compressing.

HCD1098

–UN–30NOV01

Seal will also shrink to its original size if left for a minimum of 8 hours before installing assembly into barrel.

A—Shim Stock B—Hose Clamp

Continued on next page

TMCM225401 (04OCT06)

70-30-9

OUO6046,00016AF –19–17MAY04–6/10

2254 Cane Loader 100406

PN=249

70 30 9

Hydraulic Cylinder NOTE: Seal (D) must be installed with lip facing inside of cylinder as shown.

22. Install seals (E) and (D), snap ring (F), O-ring (C), back-up ring (B) and O-ring (A).

HCD1064

–UN–27NOV01

A—O-Ring B—Back-up Ring C—O-Ring D—Seal E—Seal F—Snap Ring

HCD1091

–UN–13NOV01

HCD1085

–UN–13NOV01

70 30 10

Continued on next page

TMCM225401 (04OCT06)

70-30-10

OUO6046,00016AF –19–17MAY04–7/10

2254 Cane Loader 100406

PN=250

Hydraulic Cylinder NOTE: Install rod end in soft-jawed vise in order to torque nut.

–UN–28NOV01

23. Install external snap ring (A), rod guide (B), piston (C) and nut (D) on rod.

HCD1107

24. Apply light coat of LOCTITE 242 and tighten to torque specified in table: NUT TORQUE SPECIFICATIONS Thread Size

Torque

3/4-16 UNF-2A

210 N•m (155 lb-ft)

7/8-14 UNF-2A

320 N•m (236 lb-ft)

1-12 UNF-2A

463 N•m (341 lb-ft)

1 1/8-12 UNF-2A

492 N•m (363 lb-ft)

1 1/4-12 UNF-2A

965 N•m (712 lb-ft)

A—External Snap Ring B—Rod Guide C—Piston D—Nut

OUO6046,00016AF –19–17MAY04–8/10

25. Apply light film of clean hydraulic oil on seals and chamfer (A) of barrel.

–UN–19NOV01

26. Compress the internal snap ring using a hose clamp (B) until snap ring is seated in groove on rod guide and then loosen a little.

HCD1071

NOTE: Remove hose clamp once internal snap ring has entered cylinder bore to prevent damage to external O-ring.

27. Drive rod guide (C) into barrel until snap ring seats in the barrel groove.

A—Chamfer B—Hose clamp C—Rod Guide

28. Pull forward on rod to ensure that it has locked.

Continued on next page

TMCM225401 (04OCT06)

70-30-11

OUO6046,00016AF –19–17MAY04–9/10

2254 Cane Loader 100406

PN=251

70 30 11

Hydraulic Cylinder 29. Install snap ring (A) in rod guide (B).

HCD1072

–UN–28NOV01

A—Snap Ring B—Rod Guide

OUO6046,00016AF –19–17MAY04–10/10

70 30 12

TMCM225401 (04OCT06)

70-30-12

2254 Cane Loader 100406

PN=252

Section 99

Service Tools Contents Page

Group 10—Service Supplies Service Supplies . . . . . . . . . . . . . . . . . . . . . . . .99-10-1 Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . .99-10-6 Flow Meter Test Kit . . . . . . . . . . . . . . . . . . . . . .99-10-8 Mechanic’s Tool Set . . . . . . . . . . . . . . . . . . . .99-10-10 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99-10-12

99

TMCM225401 (04OCT06)

99-1

2254 Cane Loader 100406

PN=1

Contents

99

TMCM225401 (04OCT06)

99-2

2254 Cane Loader 100406

PN=2

Group 10

Service Supplies Service Supplies Number

Name

Use

0841303194 (U.S.)

LOCTITE Primer

Recommended as a surface preparative, use before any type of Loctite application. This part number is for a 6 oz. spray can.

0840008762 (U.S.)

LOCTITE PST

Recommended for use on all types of threads to prevent leakage at the joint. This is for use on hydraulic, air or water lines. This part number is for a 50 ml bottle.

0841304201 (U.S.)

LOCTITE 242

Recommended for use on parts that will be removed again. This is for the prevention of parts loosening during normal operation. The part can still be removed by a mechanic without too much difficulty. This part number is for a 50 ml bottle.

0841322669 (U.S.)

LOCTITE 620

Recommended for use when repairing a cylinder. This is specifically used for the internal bolt that holds the head in place. This part number is for a 50 ml bottle.

0841332513 (U.S.)

LOCTITE 640

Recommended for use when installing a press fit. This part number is for a 50 ml bottle.

0841304200 (U.S.)

Silicone Sealant (RTV)

Recommended for use on parts that will be never be removed again. This can only be removed by burning.

This part number is for a 50 ml bottle.

0430024221 (U.S.)

LOCTITE242

Recommended as a general sealant.

This can, in many instances, replace older gasket materials. This part number is for a 4.7 oz. tube.

LOCTITE is a trademark of Loctite Corp.

TMCM225401 (04OCT06)

Continued on next page

99-10-1

OUO1089,00027F8 –19–16FEB05–1/4

2254 Cane Loader 100406

PN=255

99 10 1

Service Supplies

99 10 2

Number

Name

Use

PM38656 (U.S.)

Plastic Gasket

Recommended as a general sealant.

It hardens in the assembled joint to form a tough, thin gasket that resists lubricants and chemicals.

Metal-to-metal contact of flanges provides an excellent bond. Joint is locked against vibration loosening.

Operating limit is 300° F (150° C).

This part number is for a 50 ml bottle.

0841305658 (U.S.)

Anti-seize Compound

Recommended for use on all types of threads to prevent galling. This part number is for a 16 oz. can with a brush top.

0840021386 (U.S.)

Teflon Thread Tape

Recommended for use on all types of threads to prevent leakage at the joint. This is for use on hydraulic, air or water lines. This part number is for a 1/2” x 50 ft. roll.

0840008762 (U.S.)

Teflon Thread Paste

Recommended for use on all types of threads to prevent leakage at the joint. It has the same uses as Teflon thread tape. The use of either of the two forms is strictly a matter of personal preference. This part number is for a 1.69 oz. tube.

0841304202 (U.S.)

O-Ring Lube

Recommended for the ease of installing rings, seals and gaskets.

This holds them in place and also protects them from damage during installation. This part number is for a 2 oz. tube.

0910041171 (U.S.)

Dry Spline Lube

Recommended for the lubrication of the splines in pumps and motors.

This will prolong the service life of parts that are subjected to high torques. This part number is for a 2.8 oz. tube.

Continued on next page

TMCM225401 (04OCT06)

99-10-2

OUO1089,00027F8 –19–16FEB05–2/4

2254 Cane Loader 100406

PN=256

Service Supplies

Number

Name

Use

0491310039 (U.S.)

O-ring Kit

This is an assortment of all the O-rings used on the boss O-ring hydraulic fittings. These fittings are used on your equipment where it is necessary to seal a joint. A supply of these O-rings is recommended to be on hand. The kit contains 5 of size 24; 10 of size 4, 6, 10 and 20; and 20 of size 8 and 16.

0561310037 (U.S.)

Cap and Plug Kit

This is an assortment of plastic caps and plugs used to cap-off or plug hoses and components during service or repairs. The kit contains 40 of size 04, 06, and 12 in both caps and plugs; 50 of size 16 in both caps and plugs and 60 of size 08 in both caps and plugs.

0841346779 (U.S.)

Wrench Set Angled

This is a heavy-duty, open-ended, offset wrench set. It is recommended for removing hydraulic hoses and fittings located in tight places. The set has 2”, 1-7/8”, 1-3/4”, 1-5/8”, 1-1/2” and a 1-3/8” wrench.

0601305130 (U.S.)

Flow Tester 75 GPM Kit

This is a 75 GPM in-line hydraulic flow tester.

0840317083 (U.S.)

Hose Kit

This is for the flow meter, 0601305130.

99 10 3

0840322463 (U.S.)

Flow Meter

This is a 125 GPM flow meter kit with adapter fittings.

0841340040 (U.S.)

Araldite Adhesive Kit

Recommended as a locking element for mating parts with the tendency to loosen during operation. It is also used for special isolation purposes during construction and repair. This part number includes Reusable Gun P/N 0841306707, Cartridge P/N 0841306708 and Nozzle-Mix P/N 0841306709

Continued on next page

TMCM225401 (04OCT06)

99-10-3

OUO1089,00027F8 –19–16FEB05–3/4

2254 Cane Loader 100406

PN=257

Service Supplies

Number

Name

Use

0841306707 (U.S.)

Araldite Applicator Gun

This is included in the above Araldite Adhesive Kit and is necessary for the Araldite Cartridge, 0841307790.

0841346780 (U.S.)

Wrench Set Angled

This set is comprised of fourteen of the most popular sizes from 3/8” to 1-1/8” in increments of 1/16” and a 1-1/4” wrench.

OUO1089,00027F8 –19–16FEB05–4/4

99 10 4

TMCM225401 (04OCT06)

99-10-4

2254 Cane Loader 100406

PN=258

Service Supplies

99 10 5

TMCM225401 (04OCT06)

99-10-5

2254 Cane Loader 100406

PN=259

Service Supplies

Service Tools

CM00044329A0

–UN–14MAR06

99 10 6

Complete Kit, 0600044329

Continued on next page

TMCM225401 (04OCT06)

99-10-6

T803324,000093B –19–14MAR06–1/2

2254 Cane Loader 100406

PN=260

Service Supplies 1—Test Gauge (10,000 PSI), 2 ea., 0600041562 2—Test Gauge (600 PSI), 2 ea., 0600041563 3—Test Gauge (3,000 PSI), 2 ea., 0600041560 4—Test Gauge (30” hg - 160 PSI), 1 ea, 0600041561 5—Fitting, 8 ea., 0070031967 6—Fitting, 2 ea., 0070009570 7—Fitting, 6 ea., 0070030583 8—Female Coupling, 4 ea., 0070030582

9—Hose, 3 ea., 0880208565 10—Manifold - Test Kit, 1 ea., 0290207833 11—Chain, 3 ft., 0600048641 12—“S” Hook, 2 ea., 0600048642 13—Eyebolt, 2 ea., 0600048644 14—Fitting, 2 ea., 0070042880 15—Fitting, 1 ea., 0070044383 16—Fitting, 2 ea., 0070019443 17—Fitting, 2 ea., 0070018871 18—Fitting, 2 ea., 0070019334

19—Fitting, 2 ea., 0070019355 20—Fitting, 4 ea., 0071392920 21—Fitting, 4 ea., R31147 22—Jam Nut, 2 ea., 0050009936 23—Fitting, 8 ea., 0071307471 24—Toolbox, 1 ea., CB01434314 25—Combination Wrench, 1 ea., 0840044385 26—Allen Wrench (3 mm), 1 ea., 0840046360

27—Allen Wrench (1/8”), 1 ea., 0840044386 28—Allen Wrench (3/16”), 1 ea., 0841371362 29—Fitting, 1 ea., 0070038010 30—Fitting, 1 ea., 0070005274 31—Fitting, 1 ea., 0070019355 32—Tee Assy-Test (12), 1 ea., 0600053177 33—Tee Assy-Test (16), 1 ea., 0600053176

T803324,000093B –19–14MAR06–2/2

99 10 7

TMCM225401 (04OCT06)

99-10-7

2254 Cane Loader 100406

PN=261

Service Supplies

Flow Meter Test Kit

CM01305130A0

–UN–15MAR06

99 10 8

Flow Meter Test Kit, 0601305130

Continued on next page

TMCM225401 (04OCT06)

99-10-8

T803324,000093C –19–15MAR06–1/2

2254 Cane Loader 100406

PN=262

Service Supplies 1—Fitting, 2 ea., 0070033020 (Included in 7) 2—Fitting, 2 ea., 0070033019 (Included in 7)

3—Fitting, 2 ea., 0070034210 (Included in 7) 4—Fitting, 2 ea., 0071341751 (Included in 7)

For optional tester hose kit, order 0840317083.

1. 06 Hoses, 2 ea.

2. 08 Hoses, 2 ea.

5—Fitting, 2 ea., 0070021925 (Included in 7) 6—O-Ring, 2 ea., U12547 (Included in 1, 7)

7—Flowmeter Fitting Kit, 1 ea., 0840282569 8—Flowmeter, 1 ea., Not Available Separately

3. 12 Hoses, 2 ea.

4. 16 Hoses, 2 ea.

5. Male Adapters, 8 ea.

T803324,000093C –19–15MAR06–2/2

99 10 9

TMCM225401 (04OCT06)

99-10-9

2254 Cane Loader 100406

PN=263

Service Supplies

Mechanic’s Tool Set

99 10 10

ITEM

QTY

PART NUMBER

DESCRIPTION

1

1

0840021427

Tool Box

2

1

0840021426

Padlock

3

1

TY15643

Socket Set - 1/4” Square Drive

4

1

0840021413

Socket Set - 3/8” Square Drive

5

1

0840021420

Socket Set - 1/2” Square Drive

6

1

0840021408

Screw Extractor Set

7

1

0840021395

Flat Chisel Set (1/4” - 1/2”)

8

1

0840021394

Punch Set - 1/8” - 1/2”

9

1

0840052512

Wrench Set

10

1

0840021409

Allen Wrench Set (14 pieces)

11

1

0840030555

Spanner Wrench (Cylinder)

12

1

0840030554

Spanner Wrench (Adjustable Cylinder)

13

1

0840021389

Flat Screwdriver - 6”

14

1

0840021390

Flat Screwdriver - 4”

15

1

0840021402

Needle Nose Pliers (1/2”)

16

2

0840021403

Channelock Pliers (1/2”)

17

1

0840021405

Combination Pliers (8”)

18

1

0840022006

Truarc Pliers #6700

19

1

0840021388

Visegrop Pliers (10”)

20

1

0840021422

Rethreading Tap (1/2” - 13 NC)

21

1

0840021423

Rethreading Tap (3/8” - 16 NC)

22

1

0840021393

Tapered Punch

23

1

0840021424

Engineers Hammer (48 oz.)

24

1

0840021425

Ball Peen Hammer (16 oz.)

25

1

0840021428

Slotted Yoke Puller

26

1

0840021429

Bearing Separator

27

1

0840024824

Drag Link Socket (1/2”)

28

1

0840021406

Blade Scraper (1-1/2”)

29

1

0840021404

Diagonal Cutter (7 - 1/2”)

30

1

0840021401

Western Hacksaw

31

10

0840021400

Hacksaw Blade

32

1

0840021392

Pinch Bar - 18

33

1

0840021391

Wrecking Pry Bar (24”)

34

1

0840021385

Round File (1/2” diameter)

35

1

0840021407

Mill File (10”)

36

1

0840021386

Teflon Tape

37

1

0840021387

Electrical Tape (3/4” x 66’ roll)

Continued on next page

TMCM225401 (04OCT06)

99-10-10

T803324,000093D –19–15MAR06–1/2

2254 Cane Loader 100406

PN=264

Service Supplies 38

1

0840021421

Steel Wire Brush (12”)

39

1

0840021430

Emery Cloth Roll

T803324,000093D –19–15MAR06–2/2

99 10 11

TMCM225401 (04OCT06)

99-10-11

2254 Cane Loader 100406

PN=265

Service Supplies

Symbols

CM053510055

–19–17MAR05

99 10 12

Continued on next page

TMCM225401 (04OCT06)

99-10-12

T803324,0000656 –19–13APR05–1/4

2254 Cane Loader 100406

PN=266

Service Supplies

CM053510056

–19–17MAR05

99 10 13

Continued on next page

TMCM225401 (04OCT06)

99-10-13

T803324,0000656 –19–13APR05–2/4

2254 Cane Loader 100406

PN=267

Service Supplies

CM053510057

–19–17MAR05

99 10 14

Continued on next page

TMCM225401 (04OCT06)

99-10-14

T803324,0000656 –19–13APR05–3/4

2254 Cane Loader 100406

PN=268

Service Supplies

CM053510058

–19–17MAR05

99 10 15

T803324,0000656 –19–13APR05–4/4

TMCM225401 (04OCT06)

99-10-15

2254 Cane Loader 100406

PN=269

Service Supplies

99 10 16

TMCM225401 (04OCT06)

99-10-16

2254 Cane Loader 100406

PN=270