DOWNLOAD JOHN DEERE 3005 TRACTOR TECHNICAL REPAIR MANUAL TM102919 - PDF

tm102919 - 3005 Compact Utility Tractor Brake Pedals and Linkage

Brake Pedals and Linkage

LEGEND: Shaft Key Left-Hand Pedal Right-Hand Pedal Spring Lubrication Fitting E-Clip Pin Pin Yoke Nut T ur nbuck le Nut Yoke

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tm102919 - 3005 Compact Utility Tractor Brakes

Bra kes

LEGEND: Cam P ack ing Cap Screw Lock Washer C ov er Ga sk et Extension Spring Brake Shoe Brake Drum Cam

2002 1028 13512 56- 19-2 00702 2008 13

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tm102919 - 3005 Compact Utility Tractor Brake Pedal and Linkage Inspection and Repair

Brake Pedal and Linkage Inspection and Repair Removal and Inspection 1 .

2 .

3 .

4.

Park machine safely.

Block wheels to prevent movement and release brake.

Remove step plates.

MXML200803021913618-UN: With Mid PTO Disconnect clutch pedal spring (A) and link rod (B). An additional link rod will have to be disconnected at (C) if machine is equipped with mid PTO option.

5 .

6

Disconnect springs (D).

Remove pins (E) and (F) to disconnect brake linkage. Repeat on other side of machine.

Remove e-clip (G) and pedals (H) and (I).

Remove brake cross shaft from machine.

Inspect all parts for wear or damage. Replace as necessary.

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7 .

8 Assembly .

9 .1 .

2 .

3 .

4 .

5 .

Install all parts.

Connect linkages and springs.

Apply multipurpose grease to all lubrication fittings.

Check clutch pedal free-play. Adjust as necessary.

Check brake pedal free-play. Adjust as necessary. See Brake Pedal Freeplay Adjustment .

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tm102919 - 3005 Compact Utility Tractor Brakes Removal and Installation

Brakes Removal and Installation 1.

CAUTION: Avoid breathing dust that may be generated. Never use compressed air for cleaning. Keep bystanders away from the area.

2 .

3 .

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Park machine safely.

Support rear axle on stands.

Remove rear wheel.

Remove cap screws (A) and lock washers, then remove cover (B) and brake shoe assembly.

Remove snap ring (C) and drum (D).

Disassemble all other parts.

Inspect all parts for wear or damage. Replace as necessary.

Install new O-ring (E) and gasket (F).

Apply multipurpose grease to splined ID of brake drum.

Assemble all parts.

Install gasket, cover and brake shoe assembly.

Connect linkage.

Install rear wheel. Tighten wheel bolts to 190 N•m (140 lb-ft).

Adjust brakes. See Brake Pedal Freeplay Adjustment .

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tm102919 - 3005 Compact Utility Tractor Power Steering Hydraulic Lines Removal and Installation

Power Steering Hydraulic Lines Removal and Installation

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.

Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. 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 may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source.

1 .

2 .

3 .

Remove throttle control lever assembly.

Lower rockshaft arms.

Remove left lower dash cover.

4 .

5 .

6 .

Remove line clamps (A) and (B).

Disconnect flanges (C) and (D).

Disconnect hoses (E) and (F). Close all openings with caps and plugs.

7 .

8 .

9 .

10 .

11 .

12 .

13 .

Remove line clamp (G).

Disconnect power steering cylinder hydraulic lines (H). Close openings with caps and plugs.

NOTE: Banjo connector (I) also acts as a filter.

Remove three banjo connectors (J), banjo connector (I), and washers.

Remove lines.

IMPORTANT: There must be one copper washer on each side of banjo connector when installing connectors.

Install hydraulic lines, banjo connectors and washers.

Connect all hoses and flanges. Tighten capscrews to 6 N•m (53 lb-in.).

Install line clamps.

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tm102919 - 3005 Compact Utility Tractor Brake Pedal Freeplay Adjustment

Brake Pedal Freeplay Adjustment Purpose To ensure that neither set of brakes are dragging and that both brakes are similarly adjusted for best normal and park brake operation.

Check Adjustment Depress each pedal separately to check freeplay. The pedals should travel 25 - 35 mm (0.98 - 1.38 in.) before you feel resistance.

Adjustment Procedure

1.

2.

3.

Loosen locknuts (A) on brake rod.

Use the turnbuckle (B) to lengthen or shorten the brake rod until pedal travel (C) is correct.

Tighten locknuts (A).

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tm102919 - 3005 Compact Utility Tractor Drum Brake Operation

Drum Brake Operation

LEGEND: Brake Cover Brake Drum Differential Output Shaft Anchor Pin Brake Shoes Return Springs Brake Lever Operating Cam

The brakes on the 790 are mechanical internal expansion type. The brake drums (B) are splined to fit the differential output shafts (C) on each side.

When a brake pedal is applied, a brake rod rotates an operating cam (H). Rotation of the cam causes the brake shoes (E) to separate or expand against the drum. The result is that braking effect is applied to the differential output shaft.

When the brake is released, the return springs (F) pull the shoes back together.

The braking force is equal whether the brakes are applied for forward or reverse motion. The left and right side brakes operate independently since there is linkage on both sides.

The park brake mechanism is a locking device to hold the brake linkage in the applied position.

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tm102919 - 3005 Compact Utility Tractor Park Brake Lock Operation

Park Brake Lock Operation The park brake linkage locks against a catch on the left brake pedal.

NOTE: For park brake operation, the two brake pedals should be locked together so that both brakes are applied.

To engage the park brake, the brake pedals must first be depressed to apply the brakes. When the park brake lever is lifted, the park brake lock pivots down against the left brake pedal. A series of pawls on the park lock allow the park lock to catch on the pedal in several positions. This allows park brake operation within a wider range of pedal pressure and freeplay adjustment.

To disengage the park brake, the brake pedals must first be depressed to remove tension from the locking pawl. This allows the locking pawl to lift freely and release when the park brake lever is pushed down to the off position.

The spring for the park brake indicator switch is connected to the hole in the park lock. The indicator warns the operator that the brakes are locked. The switch is adjustable.

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tm102919 - 3005 Compact Utility Tractor Control Panel

Control Panel

LEGEND: Engine Tachometer P2 Fuel Gauge P1 Coolant Temperature Gauge H4 Engine Oil Pressure Light H1 Park Brake Light H2 Discharge Light Hour Meter S6 Light/Turn Signal Switch S7 Flasher Switch

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tm102919 - 3005 Compact Utility Tractor Control Pedestal

Control Pedestal

LEGEND: V3 Diode V2 Diode E8 Instrument Light E7 Instrument Light H2 Discharge Light H1 Park Brake Light H3 Engine Oil Pressure Light S7 Hazard Light Switch V1 Diode V5 Diode K3 Control Relay K1 Start Relay K4 Headlight Relay S1 Key Switch X3 Connector X4 Connector Fuse Block K2 Fuel Solenoid Relay K5 Flasher A1 Timer Module S6 Light/Turn Switch E9 Instrument Light

2002 0829 12421 -19 -200 70220 0812

tm102919 - 3005 Compact Utility Tractor Engine Compartment

Engine Compartment

LEGEND: G2 Alternator F2 Fuse (80 amp) F1 Fuse (80 amp) X2 Connector M1 Starting Motor, Y1 Starting Solenoid Starting Motor Tie Point Start Solenoid Terminal

LEGEND: R1 Glow Plugs B1 Engine Coolant Temperature Switch B3 Engine Oil Pressure Switch Y2 Fuel Shutoff Solenoid M2 Fuel Pump

2007 1206 12304 1-1 9-20 07022 0081 2

tm102919 - 3005 Compact Utility Tractor Rear of Machine

Rear of Machine

LEGEND: E1 & E2 Headlights B2 Fuel Gauge Sensor S5 park Brake Switch V4 Diode S2 Seat Switch Flood Lamp (Option) E4 Right Hazard/Turn Light E3 Right Tail/Turn Light S8 Mid PTO Switch (Option) S3 Rear PTO Switch E5 Left Tail/Turn Switch E6 Left Hazard/Turn Light S4 Transmission Neutral Switch G1 Battery

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tm102919 - 3005 Compact Utility Tractor Alternator Unregulated Amperage Test

Alternator Unregulated Amperage Test Reason: To determine charging output of the alternator stator.

Equipment: JTO5712 Current Gun

Conditions: 1 .

2 .

Put JTO5712 Current Gun over alternator Red wire.

Set current gun for DC current.

IMPORTANT: Proc edu re: Perform this test quickly to prevent damage to the battery. Do not apply full load to battery for more than 10 seconds.

1.Park machine safely. See “Park Machine Safely” in the Safety section.

2.Raise hood and remove left engine side cover.

3.Start and run engine at high idle.

4.

Insert a small Phillips screwdriver through the hole (A) in rear cover of alternator to ground the regulator to the rear cover. Read amperage on current gun.

Item

M eas ur emen t

Specification

S pe cif ica tio n : Minimum unregulated amperage

40 amps

Results: If reading does not meet specifications, verify voltage at the alternator regulated terminal and good alternator ground. If voltage and ground are ok, repair or replace the alternator.

20 071 019 101 10-1 9-2 007 080 211 0

tm102919 - 3005 Compact Utility Tractor Battery - Charge

Battery - Charge Reason: To increase battery charge after battery has been discharged.

Equipment: Battery charger (variable rate)

Proc edu re:

1 .

Connect variable rate charger to battery.

NOTE:

2

Maximum charge time at boost setting is 10 minutes. Allow an additional 5 minutes for each 10 degrees below 70 degrees F.

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3.

4.

Start charger at slow rate. Increase charge rate one setting at a time. Check charger ammeter after 1 minute at each setting. Maintain 10 amp charge rate. Use boost setting as necessary.

Check if battery is accepting a 10 amp charge after 10 minutes at boost setting.

Battery will not accept 10 amp charge after 10 minutes at boost setting: replace battery Battery is accepting 10 amp charge after 10 minutes at boost setting, and battery did not need water: go to steps 6 and 7 Battery is accepting 10 amp charge after 10 minutes at boost setting, but battery did need water or all cells were below 1.175: go to steps 4 and 5 IMPORTANT: Decrease charge rate if battery gases or bubbles excessively or becomes too warm to touch.

5.

Set charger at 15 -25 amps.

Check specific gravity after 30 minutes (60 minutes for maintenance-free battery).

NOTE: If battery was discharged at slow or unknown rate, charge at 10 -15 amps for 6 -12 hours (Maintenance-free battery: 12 -24 hours). If battery was discharged at fast rate, charge at 20 -25 amps for 2 -4 hours (Maintenance-free battery: 4 -8 hours).

6 .

7 .

More than 50 point variation between cells: replace battery Less than 50 point variation between cells: go to steps 6 and 7 Continue charging battery until specific gravity is 1.230 -1.265 points.

Load test battery. See “Battery Load Test” in this section.

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tm102919 -3005 Compact Utility Tractor Battery -Load Test

Battery -Load Test Reason: To check condition of battery under load.

NOTE: See “Battery Charge” before applying a load to battery.

Equipment:

JTO5685 Battery Testeror equivalent NOTE: Use the procedures given with the tester.

Procedure: 1 .

2

Turn load knob of tester clockwise until amperage reading is equal to: Cold cranking amperage rating (use blue scale) or Three times ampere hour rating (use black scale) Hold for 15 seconds and turn load knob of tester off.

Read battery voltage.

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Results: 3 .

If the battery does not indicate 9.6 volts or more, replace battery

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tm102919 - 3005 Compact Utility Tractor Battery Voltage and Specific Gravity Test

Battery Voltage and Specific Gravity Test Rea so n: To check voltage and determine condition of battery.

Equipment: Voltmeter or JTO5685 Battery Tester Hydrometer Procedure Clean battery terminals and top of battery

Procedure:

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

Avoid the hazard by: Filling batteries in a well-ventilated area.

Wearing eye protection and rubber gloves.

Avoiding breathing fumes when electrolyte is added.

Avoid spilling or dripping electrolyte.

Use proper jump-start procedure.

If you spill acid on yourself: Flush your skin with water, Apply baking soda or lime to help neutralize the acid.

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

If acid is swallowed: Drink large amounts of water or milk, then drink milk of magnesia, beaten eggs, or vegetable oil.

Get medical attention immediately.

1 .

2 .

3 .

4 .

5.

Park machine in safely with park brake locked. See Park Machine Safely in Safety section.

Inspect battery terminals and case for breakage or cracks.

Check electrolyte level in each battery cell. Add clean, soft water as needed. If water is added, charge battery for 20 minutes at 10 amps.

Remove surface charge by placing a small load on the battery for 15 seconds.

Check battery voltage with voltmeter or JTO5685 Battery Tester.

6.

Use a hydrometer to check for a minimum specific gravity of 1.265 with less than 50 point variation in each cell at full charge at 26.7˚C (80˚F).

Results: Battery voltage less than 12.4 VDC, charge battery Battery voltage more than 12.4 VDC, test specific gravity All cells less than 1.175, charge battery at 10 amp rate All cells less than 1.225 with less than 50 point variation, charge battery at 10 amp rate All cells more than 1.225 with less than 50 point variation, load test battery More than 50 point variation: replace battery Item

Measurement

Specification

S peci ficati ons: Minimum battery voltage

12.4 volts

Minimum specific gravity

1.225 with less than 50 point variation

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tm102919 - 3005 Compact Utility Tractor Charging Circuit Diagnosis

Charging Circuit Diagnosis Test Conditions: Machine parked safely with park brake locked.

Transmission in neutral.

Operator may be on or off seat.

Key switch in off position.

PTO(s) off.

Battery fully charged.

Power circuits functioning properly. See Power Circuit Operation .

Follow procedure in sequence.

Ensure all circuit grounds are in good condition and have continuity.

NOTE: The discharge light should illuminate anytime the key switch is in the run position with the engine not running.

NOTE: If the discharge light is illuminated and no fault can be found with the power circuit and charging circuit, test A2 display panel.

1 Charging Circuit: Action:

With the two pin connector to the G2 alternator disconnected, is there battery voltage (key switch on) at the connector, 500 Red/Blu wire (A)?

Result: YES: Go to next step.

NO: Check 500 Red/Blu wire and connections. Check power circuit as necessary.

Action: With key switch off, is battery voltage present at G2 alternator, 203 Wht/Red wire (B)?

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