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John Deere rhino pd54 User's Manual

1. 36268 39609 39610 39598 39611 39599 39612 39607 39637 38711 36311 39653 39584 47314 47315 39608 38662 38800 38602 38602 38559 38667 41007 42076 Part No Description Hour Meter Volt Meter Gauge Oil Pressure SendorOil Pressure Gauge Coolant Temperature SendorCoolant Temperature Push Button Key Switch Key Ignition Fuse Holder Fuse 20A Switch Rocker On Off Cable Throttle Cover Dust Gasket Cover Dust Relay Starter Clamp Cable Y Clamp Conduit Cable Forward Reverse Cable Forward Reverse Blade Unit Backup Alarm 112 dBA Hom 12V 125 dBA Clamp Cable LeverCable 2 e P FP N N N Controls PartNo A Q gt x lt x 80434 Description HHCS 1 4 20 X 3 4 GR ZN HHCS 1 4 20 X 3 4 GR ZN Blade Unit NUTFL 1 4 20 ZN NUTFL 1 4 20 ZN Blade Unit WSHR 1 4 WROTZN WSHR SPRING 1 4 ID Blade Unit PPHMS 1 4 20 X 3 4 BLK PINCT1 16 X 1 2 SHCS 10 32 X 1 2 BLK HHCS 5 16 18 X 1 GR5 ZN WSHRL 5 16 SPLITZN WSHR 5 16 WROTZN HHCS 3 8 16 3 4 688 ZN WSHR 10 SAEZN NUTNY 10 24 ZN HWHTB 5 16 18 X 1 ZN NUTNY 5 16 18 ZN NUTNY 3 8 16 ZN PPHMS 10 24 X 5 8 ZN HHCS 5 16 18 X 1 ZN HHCS 1 4 20 X 1 1 2 HHCS1 4 20X1 HHCS 1 4 20 X 2 GR8 ZN Blade Unit HWHST 1 4 20 X 3 4 ZN SHCS 10 24 X 5 8 BLK 2 Torque Qty Fr LBS Nm 6 6 REMARK Loctite Required
2. 3 E G Q N O O 5 8 Controls Contd Torque Description Qty FT LBS Nm HHCS 1 4 20 X 3 4 GR ZN 2 6 HHCS 1 4 20 X 3 4 ZN Blade Unit 6 NUTFL 1 4 20 ZN 1 4 20 ZN Blade Unit WSHR 1 4 WROTZN WSHR SPRING 1 4 ID Blade Unit PPHMS 1 4 20 X 3 4 BLK PINCT1 16 X 1 2 SHCS 10 32 X 1 2 BLK HHCS 5 16 18 X 1 GR5 ZN WSHRL 5 16 SPLITZN WSHR 5 16 WRO T ZN HHCS 3 8 16 X 3 4 GR8 ZN WSHR 10 SAE ZN NUTNY 10 24 ZN HWHTB 5 16 18 X 1 ZN NUTNY 5 16 18 ZN NUTNY 3 8 16 ZN PPHMS 10 24 X 5 8 ZN HHCS 5 16 18 X 1ZN HHCS 1 4 20 X 1 1 2 N HHCS1 4 20X1 HHCS 1 4 20 X 2 688 ZN Blade Unit HWHST 1 4 20 X 3 4 ZN SHCS 10 24 X 5 8 Part No Description 2 43759 2 Mount Cable Forward Reverse 38561 Clevis 48406 Wire Hamess 38618 Pivot Throttle 41006 Stop Throttle 38816 Clamp Assembly Blade Unit 39097 Lever Forward Reverse 43261 Lever Blade Blade Unit 43264 Yel Box Weld Forward Reverse 43265 Yel Weld Forward Reverse Blade Unit 39321 Switch Neutral Backup 39320 Knob Forward Reverse 42263 2 PanelWrap 43263 Yel Bracket Weld Pivot Blade Unit 43262 Yel Pivot Blade Unit 55343 Decal Control Blade Unit 48329 Cable Tie Holder 38817 Swivel Blade Unit 39319 Plate Forward Reverse Black 48399 Relay Timer 2 sec 48393 Light Red N HB PP N H Q
3. HYD 9 16 3 408 FTG HYD TEE 9 16 RUN FTG HYD 7 8 3 4NPT HOSE HYD 9 16 FJ 9 16 60 HOSE HYD 9 16 9 16 FJ 108 54 s HOSE 9 16 FJ X 9 16 FJ 103 43 s HOSE 7 8 FJ X 7 8 FJ 54 PUMP GEAR 1 54 CIR O RING 3 1 4ID 3 32 5 FIG HYF 7 8 1 1 160R FTG EL45 7 8 SW HOSE WRAP 2 5 ID POLY 54 s HOSE WRAP 2 5 ID POLY 4379 HHCS 1 2 13 X 1 3 4 685 WSHRL 1 2 SPUTAN HHSC 3 8 16 X 1 GR8 ZN WSHRL 3 8 SPLITZN HHCS 3 8 16 X 1 1 4 GR8 ZN 2 2 2 1 1 4 1 1 1 1 1 1 2 Loctite Required p S pb N 19 29 PORT T2 5 11 Blade Torque PartNo Description FT LBS Nm Part No Description 2 29830 2 Blade Weld 43 29820 2 Blade Weld 54 29819 2 Pivot Weld Blade 29856 2 Clevis Weld Blade LH 29857 2 ClevisWeld Blade RH 29846 2 Skid Weld Blade 29831 2 Lip WearBlade 43 42160 2 Blade Valve 46462 FTG EL90 7 8 SW 46124 FIG SIR 7 8 7 8 38526 Valve CONTROL 38828 Hose Wrap 1 5 ID POLY 38828 Hose Wrap 1 5 ID POLY 29817 2 29741 2 38561 Lip WearBlade 54 WSHR 2 3 4 ID X 17 32 X 1 4 TH Clevis 1 4 DIR X 1 4 28 NUTNY 1 2 13 ZN WSHR 1 2 SAE ZN HHSC 1 2 13X2 3 4 GR5 ZN HHCS 3 4 10 X GR8 ZN WSHRL 3 4 SPLIT ZN CRBLT 1 2 13 X 1 1 2 ZN WSHRL 1 2 SPLITZN HHCS 1 2 13 X 1 GR5 ZN HWHTB 5 16 18 X1 ZN WSHR 5 16 WROTZN PPHMS 10 24 X1 ZN NUTNY 5 16 18 ZN HHCS 5 16 18 X 2 1 2 685 ZN 38602 Cable F R
4. 12 5625 115 156 5 8 11 625 112 5 8 11 625 159 215 3 4 10 750 200 3 4 10 750 282 382 7 8 9 875 322 7 8 9 875 454 615 1 8 1 000 483 1 8 1 000 682 925 SAE GRADE 5 SAE GRADE 8 Fine Thread Zinc Plated Fine Thread Zinc Plated SIZE TORQUE SIZE TORQUE ft Ibs Nm ft Ibs Nm 1 4 28 250 7 10 1 4 28 250 10 14 5 16 24 3125 14 19 5 16 24 3125 20 27 3 8 24 375 26 35 3 8 24 375 37 50 7 16 20 4375 41 56 7 16 20 4375 58 79 1 2 20 500 64 87 1 2 20 500 90 122 9 16 18 5625 91 123 9 16 18 5625 129 175 5 8 18 625 128 173 5 8 18 625 180 244 3 4 16 750 223 302 3 4 16 750 315 427 7 8 14 875 355 481 7 8 9 875 501 679 1 12 1 000 529 717 1 12 1 000 746 1011 1 14 1 000 541 733 1 14 1 000 764 1036 5 2 Torque Charts and Guidelines Property Class 8 8 ZINC PLATED Coarse Thread Fine Thread Property Class 10 9 ZINC PLATED Coarse Thread Fine Thread Nm ft Ibs Nm ft lbs 6 50 pa 86 M16 285 M20 550 406 600 443 M24 1000 Property Class 12 9 ZINC PLATED Coarse Thread Fine Thread Nm ft Ibs Nm ft Ibs 660 487 Conversion Factor 1 ft 1 3558 Nm hA eng manuals rhinoY rhdrumas eps
5. 3 3 Drum Assembly 5 3 Drum Assembly tem Part No Description Description 9 lt 9 lt Ball Washer 1 8 3ID X3 1 2 OD FIG Hyd 3 4 NPTX 5 8 H BARB Block Yoke SET Hose Guard Weld LH Hose Guard Weld LH BLADE 423742 Drum Weld SD 43 42375 2 Drum Weld SD 54 42376 2 Drum Weld PD 43 42377 2 Drum Weld PD 54 22748 2 Frame Weld 43 22749 2 Frame Weld 54 22820 Kit Cap Bearing LH 22821 Kit Cap 6 Bearing RH 29514 Weight Eccentric 29513 Shaft Eccentric 43 29563 Shaft Eccentric 54 32234 Bearing Eccentric Hose Guard Weld RH Hose Guard Weld RH BLADE Hinge Weld ART OSC Plug Pipe 3 4 NPTSKT Hydraulic Bar Mount Hose Guard Hose Hydraulic Low Press 5 8 ID Elbow Pipe 3 4 NPT45 Street O Ring 10 ID X 1 8 CS 29601 Spline Extension 29980 2 CoverWeb Drum 38507 Seal Shaft 23015 Kit Wheelmotor amp Cap 32308 Seal Kit for Wheelmotor in 23015 42232 2 Bracket Weld S MOUNT RH 42233 2 Plate MOUNTWheelmotor 42234 2 Bracket Weld S Mount LH 42236 2 Plate Weld HOUSING 47281 Shock Mounts Per Side SpacerHouse Guard SD43 PD43 front 2 back 3 FIG 164 IB 5054 PD54 PDB43 front 3 back 3 Caplug Blue PDB54 front 3 back 4 Bearing Flange WSHR 2 15 16 X 2 1 4 ID Nilos Ring Strip ScraperSD 43 Strip ScraperSD 54 ScraperPD 43 ScraperPD 54 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 1 2 1 N N N N N NY FP N BPN N N N FP PP N 1 8 UJ 1 MotorGea
6. gt x lt x REMARK Loctite Required 8 Description PUMP VARIABLE MDT46 SIGHTGLASS DIVIDER FLOW 33 67 FILTER SUCTION ELEMENTHYDRAULIC 50AT 10C BREATHER FILTER MOTOR WHEEL 505 MOTOR WHEEL 505 W BRAKE STRAINER SL 25G PM FIG HYD EL 1 5 16 SW FIG STR 1 5 16 X 1 1 4 DIVIDER FLOW 50 50 O Ring Viton 29 5 VALVE SOL 3WAY 2 5 FIG SIR 9 16 X 3 4 EL901 5 16 1 1 16 1 1 16 FJ 1 1 16 FJ 24 HOSE 1 1 16 RJ 9 1 1 16 RJ 4 22 1 4 180 HOSE 1 1 16 FJ 1 1 16 RJ 4 29 1 2 FIG Outlet TEE 1 1 16 HOSE 1 1 16 FJ 1 1 16 FJ 91 SD PD43 HOSE 1 1 16 FJ 1 1 16 FJ 96 SD PD54 5 9 2 N N F P H WP P H N Q H H N H H H H Drive System Hydraulics Description FIG EL90 1 1 16 J SW FIG SIR916J 9 16 OR 1 1 16 FJ 1 1 16 FJ 52 HOSE1 1 16FJ 1 1 16F 52 SIR9 16J 1 4 BSPP FIG STR 9 16J 3 8 BSPP FIG SIR 1 1 16 3 4 BSPP HOSE HYD 9 16 FJ 9 16 FJ 12 FIG SIR1 5 16 1 5 16 FIG EL 45 9 16 HOSE 9 16 FJ X 9 16 FJ 23 1 2 TEE Run 9 16 FIG STR 7 8 IC X 3 4 FIG SIR1 1 16 1 5 160R FIG HYD EL 7 8 1 1 16 OR HOSE HYD 1 5 16 1 5 16 17 FTG EL901 1 4 STREET HOSE 1 1 16 FJ 1 1 16 RJ 9 44 5 HOSE 1 1 16 FJ 1 1 16 FJ 19 FIG HYD EL 3 40R 9 16 HOSE HYD 7 8 7 8 FJ 17 FIG HYD EL 7 8 1 1 160R HOSE HYD 9 16 FJ 9 16 RJ 4 55
7. 2 Q H H H N H H H H 5 9 Drive System Hydraulics Contd 5 9 Drive System Hydraulics Contd Description Qty Description HHCS 1 4 20 X 2 688 ZN HOSE HYD 9 16 9 16 FJ 108 WSHR 1 4 SPLIT ZN SD PD54 HHCS 3 8 16 X 2 1 2 GR5 ZN HOSE HYD 9 16 FJ X 9 16 FJ 103 WSHRL 3 8 SPLITZN SD PD43 WSHR 1 4 ZN HOSE HYD 9 16 FJ 9 16 FJ 30 HOSE HYD 1 5 16F 1 5 16 22 25 FIG ST7 8 1 1 160R FIG HYD EL45 1 1 16 HOSE WRAP 2 5 ID POLY REMARK NotShown Loctite Required zl E 7 El LA 5 10 Steering Eccentric System Hydraulics Description Qty Description CONTROL STEERING CYLINDER TIE ROD 2 5 X 10 PIN CLEVIS 1 RUE RING 1 PRIORITY VALVE MANIFOLD MODULAR HOSE HYD 7 8 FJ X 7 8 FJ 73 COOLERHYD OIL EL 7 8 1 1 160R SIR9 16J 1 4 HOSE 1 1 6 FJ X 1 1 16 FJ 96 54 s HOSE 1 1 16 F 1 1 16 FJ 91 43 5 HOSE HYD 7 8 FJ 7 8F 15 FTG HYD 1 16 7 8OR HYD EL 45 1 1 16 J SW HOSE 1 1 16 FJ 1 1 16 53 FIG EL1 1 16 J 7 808 FTG EL9 16 SW 9 16 FIG 9 16 9 16 OR HOSE 1 1 16 FJ 1 1 16 FJ 60 FIG EL1 1 16 SW SIR3 4J 9 16 OR MOTOR GEAR 1 48 CIR 5 9 16 3 4 RJ 88 N FPN P HB FF N N PF Q BPN N H HH N N P gt FTG HYD 7 8J X7 8 OR FTG SIR9 16J 3 8NPT HYD 1 1 16 1 1 16 OR
8. NUTNY 10 24 ZN HHC S 1 13 X Ya GR5 ZN WSHRL Y SPLIT ZN HHC S 3 8 16 X 2 685 ZN WSHR 3 8 SAE ZN NUTFL 3 8 16 REG ZN HHC S 5 16 18 X 1 1 2 685 ZN HHC S 17 13 X 1 1 2 GR5 ZN WSHR SAE ZN HHC S 5 8 11 X 1 1 2 G R5 ZN WSHR 5 8 SAE ZN WSHRL 5 8 SPLIT ZN WSHRL 3 8 SPLIT ZN HHC S 3 8 16 X 34 R8 ZN HHC S 3 8 16 X 1 1 4 G R8 ZN 5 3 8 16 X 5 GR5 ZN HWHTB Y 20 X 3 8 ZN NUTNY Y 20 ZN Torque Qty FT LBS Nm 13 18 hb P N N H BFF HB REMARK Loctite Required Description Filter Fuel Filter O il Belt Altemator Starter Injector Fuel Pump Water Pump Injection Pump Fuel Transfer Solenoid Fuel Thermostat Gasket Thermostat Intake Heater Sendor Pressure Sendor Temperature 5 6 Deere Engine Service Parts 2 lt 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 Description 5 7 AirCleaner n g j E 5 z Torque item Description item Description Qty FT LBS Nm AirCleaner Assembly Element Primary Outen CRBLT 3 8 16 x 1 ZN Element Safety Innen WSHR 3 8 SAE ZN Band NUTNY 3 8 16 ZN Cap HHCS 5 16 18 1 685 ZN Extension WSHR 5 16 Mount Air Cleaner NUTNY 5 16 18 ZN Pipe Intake Elbow 90 Clamp 3 1 4 Hose 180 Cover Tanks 2 3 4 5 6 7 8 9 Clamp 4 Clamp 3 3 4 Clamp 4 1 4 Plug 1 8 NPT REMARK Loctite Required
9. Slane OPERATOR SERVICE MANUAL MODELS SD 43 SD 54 PD 43 PD 54 PDB 43 PDB 54 RHINO MODEL SHOWN PD54 JOHN DEERE DIESEL A 100 employee owned American manufacturer 56322 REVISION B 6 01 TABLE OF CONTENTS OPERATOR SERVICE MANUAL RHINO 43 54 LIMITED WARRANTY SECTION 1 TECHNICAL DATA 1 1 Specifications 1 2 Engine RPM 1 3 Machine Data 1 4 Machine Sound Level Test SECTION 2 HEALTH amp SAFETY SECTION 3 OPERATION 3 1 Introduction and Operating Principle 3 2 Diesel Fuel 3 3 Engine Break in 3 4 Engine Oil and Filter 3 5 Warning Light 3 6 Hydraulic Oil Filter and Breather 3 7 Engine Coolant 3 8 Visual Inspection 3 9 Air Cleaner 3 10 Before Starting 3 11 3 12 3 13 Idling Engine 3 14 Warming Engine 3 15 Parking Brake 3 16 Brake Light 3 17 To Operate 3 18 Forward Reverse Neutral 3 19 Throttle 3 20 3 21 Panel Fuse 3 22 Cold Weather Starting Intake Heater Button 3 23 Blade Lever 3 24 Horn Back up Alarm 3 25 ROPS FOPS Seat Belt 3 26 Tires Lugnuts 3 27 Drum Scrapers 3 28 Cleaning 3 29 Eccentrics 3 30 Compaction Tips 3 31 Tie Downs 3 32 Towing Bypass 3 33 Storage SECTION 4 MAINTENANCE 4 1 Important 4 2 Maintenance Schedule 4 3 Important Maintenance Information 4 4 Engine Oil and Filter 4 5 Additional Service Information 4 6 Hydraulic Oil and Filter 4 7 Hydraulic Breather 4 8 Engine Cooling System 4 8 1 Replacing Engine Coolant 4 8 2 Adding Engi
10. sceny mcimail com 4 98 P N 51018 1 TECHNICAL DATA 1 TECHNICAL DATA one w nz 1 1 Spedfications Stone Rhino MODEL STONE SD 43 STONE SD 54 STONE PD 43 STONE PD 54 STONE PD 54 STONE PDB 54 Drum Type Smooth Smooth Padfoot Padfoot Padfoot Padfoot w blade Dimensions Operating Wt Kg 6100 2767 6540 2966 5 6409 2907 1 6880 3120 7 6880 3120 7 72754 3300 Drum Width cm 43 109 2 54 137 2 43 109 2 54 137 2 54 137 2 54 137 2 Hx Lx W cm 97 x 124 x 51 246 4 x 315 x 124 5 97 x 124 x 59 246 4 x 315 x 149 9 97 124 x 51 246 4 315 124 5 97 x 124 x 59 246 4 x 315 x 149 9 97 x 124 x 59 246 4 x 315 x 149 9 97 x 136 x 68 246 4 x 315 x 172 7 Tires cm 9 5 x 16 24 1 x 40 6 Diamond Tread 9 5 x 16 24 1 x 40 6 Diamond Tread 9 5 x 16 24 1 x 40 6 Cleated Tractor 9 5 x 16 24 1 x 40 6 Cleated Tractor 9 5 x 16 24 1 x 40 6 Cleated Tractor 9 5 x 16 24 1 x 40 6 Cleated Tractor Operating System Engine kW 58 hp John Deere 43 25 58 hp John Deere 43 25 58 hp John Deere 43 25 58 hp John Deere 43 25 58 hp John Deere 43 25 58 hp John Deere 43 25 RPM Hertz 2500 41 7 2500 41 7 2500 41 7 2500 41 7 2500 41 7 2500 41 7 F
11. 46489 Hose 7 8 X 7 8 14 46133 FIG EL90 7 8 7 8 42115 2 Mount Weld Blade Valve 46544 FIG EL45 9 16 46490 FIG SIR 9 16 X 3 4 OR 46528 Hose J SW X 9 16 SW 48 46388 FTG TEE 9 16 46547 Hose 9 16 FJ X 9 16 FJ 60 46551 Hose 9 16 J FJ 9 16 56 46546 Hose 9 16 FJ X 9 16 FJ 70 WSHR 3 8 SPLITZN 46552 Hose 9 16 FJ X 9 16 FJ 66 HHCS 3 8 16 X 1 1 4 GR8 N 46120 FTG EL90 9 16 X 3 8 NPT WSHR 10 SAE ZN 46369 EL 45 X 3 8 NPTX 9 16 NUTNY 10 24 ZN 46444 Cylinder Tie Rod 2 X 8 44203 Pin Clevis 1 44204 RUE RING 1 OO gm gt N N N H B PF H N N N N N N N REMARK Loctite Required r OPTIONAL BLADE PACKAGE 3 FLI W DIVIDER 7 STEERING CYLINDER 1 418 DIL COOLER TON S TROL STEERING SENSING 1 HYDROSTATIC TRANSMISS BREATHER FILLER 12 STRAINER RV3 SE 400 PSI S 800 PSI BLA 5 12 Hydraulic Schematic Description Descr
12. 9 16 1 3 4 X 1 4 HHCS 1 2 20 X 1685 N HHCS 1 2 20 X 1 685 ZN HHCS 1 2 20 X 3685 ZN HHCS 1 2 20 X 3685 N HHCS 1 2 20 X 3685 ZN REMARK 5043 PD43 SD54 PD54 PDB43 PDB54 Loctite Required E G 5 4 Main Frame 8 3 0 N O Part No 46059 43250 2 46127 46815 43738 2 43736 2 43240 2 46107 43845 2 38528 29539 2 29132 42062 2 42063 2 42065 2 43740 2 43808 39289 39290 38720 39195 39196 38722 42015 2 47295 2 38712 Description Cap Fuel Tank Fuel Fitting Retum Fuel 1 4H Fitting Supply Fuel 5 16H Panel Cover Tanks Panel Cover Filter Frame Main Plug 1 2 5 Hd Mount Manifold Wheelmotor Panel Seat Pin Hinge Pan Nose Pan Floor Plate Battery Cowl Set Sound Proof Tire Assembly RH Turf Tire Assembly LH Turf Tire Turf R 3 Tire Assembly RH Lug Tire Assembly LH Lug Tire Lug R 1 CoverLevel Hose Float Fuel 2 FPN HB PP P HH H Description Fitting Elbow Clamp Battery Box Hold Down Battery Liner Battery Box Battery 800 CCA Spacer Latch Keeper Seat Bumpers 2 e N N N e PP N N 5 4 Main Frame Contd Torque Torque Description Qty FT LBS Nm Item Description Qty FT LBS Nm Seat Belt 1 S 3 8 16 X1 1 2 N 23 1 WSHRL 3 8 SPLITZN 1 HHCS 3 4 1
13. distributor Drain Tighten Tighten See Engine Owner s Manual Add oil Drain fill crankcase with oil of proper viscosity and quality Drain fill to proper level See Engine Owner s Manual 4 MAINTENANCE 4 35 TROUBLESHOOTING cont d PROBLEM Engine emits white smoke Engine emits black or gray exhaust smoke Engine overheats CAUSE Improper type of fuel Low engine temperature Defective thermostat Defective injection nozzles Engine out of time Improper type of fuel Clogged or dirty air cleaner Injection nozzles dirty Engine out of time Engine overloaded Low coolant level Faulty radiator cap Loose or defective fan belts Low engine oil level Cooling system needs flushing Defective thermostat Defective temperature gauge or sender Incorrect grade of fuel REMEDY Use proper fuel Warm up engine to normal operating temperature Remove and check thermostat See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Use proper fuel Service air cleaner See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Reduce load check for mud build up clean if required Fill radiator to proper level check radiator and hoses for loose connections or leaks Have serviceman check Adjust belt tension
14. or warranty work 1 Machine Type Machine S N Engine Type Engine S N VIN Purchase Date Dealer Distributor Information Name Address Phone Fax Location of above information 1 Information on S N tag 2 Information on engine tag Information on S N tag if applicable Date you purchased machine Dealer machine was purchased from Stone Construction Equipment Inc P O Box 150 Honeoye New York 14471 Phone 800 888 9926 Fax 716 229 2363 4 us 427 z 1 XP e A f gt gt Y o n ext V a Lye a 5 r The Manufacturer warrants that products manufactured shall be free from defects in material and workmanship that develop under normal use for a period of 90 days for concrete vibrators and electric pumps one year for Rhino Bulldog Wolfpac Rollers trowels Stompers saws forward plates engine powered pumps and 6 months for all other products from the date of shipment The foregoing shall be the exclusive remedy of the buyer and the exclusive liability of the Manufacturer Our warranty excludes normal replaceable wear items i e gaskets wear plates seals O rings V belts drive chains clutches etc Any equipment part or product which is furnished by the Manufacturer but manufactured by another bears only the warranty given by such other manufacturer The Manufacturer extends the warranty p
15. 0 X 2 GR8 BLK 1 53 4 10 X2 1 2 2 HHCS1 8 X 3 GR8 BLK 1 WSHRL 1 SPLITZN Panel Front 1 NUTFX 3 4 10 BLK 1 1 1 1 1 1 Ta nk Hydra ulic ROPS ROPS Support Bracket Hose Bracket Hose Panel Rear WSHRL 3 4 SPLIT ZN WSHR 10 SAE ZN NUTNY 10 24 ZN FHSMS 10 24 X 1 ZN 5 10 24 5 8 ZN WSHR 5 16 WROTZN NUTNY 5 16 18 ZN NUTNY 1 2 13 ZN CRBLT 3 8 16 X 1 1 4 ZN WSHR 1 2 SAE ZN WSHR 3 8 WROT ZN CRBLT 3 8 16 X 1 ZN NUINY 3 8 16 ZN RHSMS 10 24 X 3 8 BLK Steering Wheel Column Hom Kit Nut Steering Grommet Rubber 2 ID HWHTB 3 8 16 X 1 1 4 N LUG NUTM14 x 60 HWHTB 5 16 18 X 1ZN NUINY 5 8 11 ZN WSHR 5 8 SAE ZN HHC 5 8 11 X 2 GR5 N HHCS 1 2 13 X1 3 4 GR5 ZN REMARK Loctite Required 5 5 Radiator and Engine Mount Description Qty tem Part No Description 80161 HHCS5 16 18X1GR5 ZN 80658 HHCS1 2 20X1GR5 N 80058 WSHRL 3 8 Split ZN 80041 CRBLT3 8 16 X 1 1 4 ZN 80043 WSHR 3 8 WROT ZN 80564 WSHR 3 8 ID X 1 4 OD ZN 80056 NUINY 3 8 16 ZN 80114 NUINY 5 16 18 ZN 80537 NUTFL 1 2 20 ZN 80343 WSHR 1 2 SAE ZN PL 80117 WSHRL 1 2 MED SPLIT ZN 80682 CRBLT 5 16 18 X2 1 2 ZN 80086 WSHRL 5 16 MED SPLIT ZN 80355 WSHR 5 8 SAE ZN 80082 NUTNY 5 8 11 ZN 80695 HHCS 5 8 11 X 2 GR5 N 80347 WSHR WRO T ZN 80116 WSHRL Ya SPLIT ZN 80174 HHC S 3 8 16 X 1 GR5 ZN 780561 HHCS1 2 13X1 3 4 GR5 ZN U 80051 NUTNY 1 2
16. 13 ZN V 80348 WSHR 5 16 WROT ZN 80434 5 1 4 20 x 3 4 GR5 ZN X 80474 HHC S 3 8 16 x 1 1 4 GR5 ZN Bracket Outer Bell Housing Shock Mounts Mount Weld LH Engine Mount Weld RH Engine Bracket S MTG Engine Guard Fan Radiator Cap Radiator Hose Radiator Upper N Hose RadiatorLower Clamp Hose 2 Clamp Hose 2 1 4 PetcockRadiator Mount Weld RadiatorRH Mount Weld Radiator LH Shroud Radiator Plate Mount Cooler Radiator Support Rubber Mount Cooler Bracket Cowl Stop Stop Cable BPN BPN NA 5 REMARK Loctite Required PartNo 30558 39577 39578 43799 48401 43782 39621 39620 43715 2 43714 2 43254 2 39636 39595 39596 39597 43749 2 43746 2 39585 O N not shown 46813 39593 46127 46814 46815 34089 Description Engine Deere 3029 Fan Nylon SpacerFan Mount Relay Relay 70A Muffler Gasket Half Clamp Mount Weld LH Engine Mount Weld RH Engine Bracket Inner Bell Housing Drive Plate and Cover Plate Throttle Bracket Throttle Spacer Throttle Support Exhaust Exha ust Pipe Clamp Muffler 2 1 4 Hose Return YID Fitting Retum Engine Fitting Retum Tank Hose Supply 5 16 ID Fitting Supply Tank Clamp Hose 5 8 o 2 N H PN H H HN PF Description 55 16 18 2 1 2 685 ZN WSHRL 5 16 SPLIT ZN PPHMS 10 24 X 5 8 ZN WSHR 10 SAE ZN
17. 6 44 0 2 mph 0 322 0 4 mph 0 6 44 0 2 mph 0 322 0 4 mph 0 6 44 Amplitude mm 071 1 80 062 1 57 059 1 50 053 1 35 059 1 50 053 1 35 Articulating Angle 35 35 35 35 35 35 Oscillating Angle 9 9 9 9 9 9 Gradeability 90 90 70 70 70 70 Inside Tuming Radius meten 94 25 2 39 88 75 2 25 94 25 2 39 88 75 2 25 94 25 2 39 88 75 2 25 Wall Clearance cm 2 1 2 6 35 2 1 2 6 35 2 1 2 6 35 2 1 2 6 35 7 17 78 7 17 78 Curb Clearance cm 14 35 56 14 35 56 14 35 56 14 35 56 14 35 56 14 35 56 Area Cap Sq R Hr 37 840 sq ft hr 3515 5 47 520 4414 8 37 840 sq ft hr 3515 5 47 520 sq ft hr 4414 8 37 840 sq ft hr 3515 5 47 520 sq ft hr 4414 8 Standard Features 2 drum scrappers ROPS FOPS gauges oil pressure volt meter coolant temp hour meter fuel sight hydraulic oil sight wa ming lights oil pressure and temperature hom back up alarm neutral safety start padded seat w flip up arm rests seat belt secondary parking brake 1 2 ENGINE RPM IDLE RPM 1 200 100 FULL RPM 2 500 100 ECCENTRIC FULL SPEED RPM 2 100 100 1 TECHNICAL DATA 1 3 MACHINE DATA Brakes
18. 93 dba With Vibe ll 2 HEALTH amp SAFETY 2 E A LT H amp SA F E T Y Safety Precautions SAFETY USE These machines are designed to carry out the function ofcompacting material ofthe non cohesive bituminous and granular varieties Ifused correctly they will provide an effective and safe means of compaction and meet the appropriate performance standards It is essential that the operator of the machine is adequately trained in its safe operation be authorized to operate it and have sufficient knowledge of the machine to ensure that it is in full working order before being put to use 14 2 LT H amp SA F Y Safety Precautions Before using this equipment study this entire manual When warning decals are destroyed or missing contact to become familiar with its operation Do not allow the Manufacturer immediately at 1 800 888 9926 for untrained or unauthorized personnel especially replacement For the safety of yourself and others it is children to operate this equipment Use only factory imperative that the following rules are observed authorized parts for service Failure to do so may result in serious injury or death FOLLOW SAFETY INSTRUCTIONS Carefully read all safety messages and decals in this manual and on your machine safety signs Keep decals in good condition Replace missing or damaged decals Be sure new
19. ER DO NOT ADD ATTACHMENTS TO THE MACHINE THAT INTRUDE INTO OPERATOR S PROTECTIVE AREA REDUCE VISIBILITY RESTRICT EMERGENCY EXITS OR ADD WEIGHT EXCEEDING CERTIFICATION WEIGHT OF ROPS DO NOT OPERATE MACHINE UNLESS SEAT BELT CONFORMING TO SAE AND OR ASAE STANDARDS IS FASTENED SEE OPERATOR S MANUAL OR CONTACT YOUR DEALER FOR COMPLETE INSPECTION REQUIREMENTS AND MAINTENANCE INSTRUCTIONS 3 26 TIRES LUG NUTS AWARNING DO NOT EXCEED RATED PRESSURE 35 PSI Clean and check daily 1 Tires are properly inflated 2 Lugnuts are in place and tight 190 ft Ibs 140 Nm 3 OPERATION 3 27 DRUM SCRAPPERS AW ARNING Clean and inspect daily to prevent excess mud and DO NOT ARTICULATE ON GRADES LARGER debris from building up Replace if missing or worn THAN 15 ROLLER MAY TIP OVER Pad drum scrappers are adjustable see Maintenance DO NOT OPERATE ACROSS THE SIDES OF section HILLS ROLLER MAY TIP OVER DO NOT OPERATE AT THE EDGE OF MATS OR 3 28 CLEANING ROADS ROLLER MAY TIP OVER DO NOT STAND ALWAYS WEAR SEAT BELT AWARNING 331 TIE DOWNS DIRT AND MUD BUILT UP WILL REDUCE 112 PERFORMANCE AND OR CAUSE AWA R N N G TIE DOWNS ARE NOT INTENDED FOR LIFTING Use pressurized water to remove dirt and mud Clean PURPOSES and inspect entire machine daily Use extra care when cleaning radiator and oil cooler Equipment is equipped with front and rear tie down rings for shipping purposes Use only these tie dow
20. EVER WORK ON THE ROLLER WITH ENGINE RUNNING SEVERE PERSONAL INJURY MAY OCCUR ALLOW ALL COMPONENTS IN THE ENGINE COMPARTMENT TO COOL BEFORE PERFORMING ANY SERVICE WORK IMPORTANT Read John Deere Emission Warranty Statement and Engine Manual before service or maintenance 4 4 ENGINE OILAND FILTER IMPORTANT Read Engine Manual and Engine Break in covered in Operating section of this manual Change oil and filter at 100 hours then every 250 hours Use SAE 15W 40 API CG 4 or API CF 4 Run engine approximately 5 minutes to warm up oil Shut engine off Remove oil pan drain plug drain into suitable container Drain crankcase oil from engine while warm Remove and discard oil filter using a filter wrench Clean filter mounting pad IMPORTANT Filtration of oils is critical to proper lubrication Always change filter regularly Use filter meeting John Deere performance specifications 6 Oil new filter seal and install new filter element tighten approximately 3 4 1 1 4 turn after packing contacts filter housing DO NOT overtighten filter element Install oil pan drain plug Fill engine crankcase with correct engine oil through timing gear cover opening of rocker arm cover opening IMPORTANT Immediately after completing any oil change crank engine for 30 seconds without permitting engine to start This will help insure adequate lubrication to engine components before engine starts 9 Start engine and run to ch
21. Engine not properly warmed up Idle before operating to achieve operating temperature Low hydraulic oil level Add Plugged hydraulic filter Replace Insufficient belt tension Check and adjust belts Engine RPM too low Check throttle linkage for proper actuation 3100 RPM Gas 2600 Diesel See Maintenance 4 MAINTENANCE PROBLEM High fuel consumption High oil consumption Low oil pressure Engine emits smoke CAUSE Improper type of fuel Clogged or dirty air cleaner Engine overloaded Improper valve clearance Injection nozzles dirty Engine out of time Low engine temperature Crankcase oil too light Oil leaks Restricted crankcase vent tube Defective turbocharger Too much oil in crankcase Loose oil filter or sending unit Loose bolts Engine in break in period Low oil level Improper type of oil Too much oil in crankcase Engine in break in period 4 35 TROUBLESHOOTING cont d REMEDY Use proper type of fuel Service air cleaner Excessive mud debris build up Clean pressure wash See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Check thermostat Use proper viscosity oil Check for leaks in lines gaskets and drain plug Clean vent tube See your authorized servicing dealer or engine
22. FORE DISCONNECTING FUEL OR OTHER LINES TIGHTEN ALL CONNECTIONS BEFORE APPLYING PRESSURE KEEP HANDS AND BODY AWAY FROM PINHOLES AND NOZZLES THAT EJECT FLUIDS UNDER HIGH PRESSURE USE A PIECE OF CARDBOARD OR PAPER TO SEARCH FOR LEAKS DO NOT USE YOUR HAND IF ANY FLUID IS INJECTED INTO THE SKIN A DOCTOR FAMILIAR WITH THIS TYPE INJURY MUST SURGICALLY REMOVE IT WITHIN A FEW HOURS OR GANGRENE MAY RESULT DOCTORS UNFAMILIAR WITH THIS TYPE OF INJURY MAY CALL THE DEERE amp COMPANY MEDICAL DEPARTMENT IN MOLINE ILLINOIS OR OTHER KNOWLEDGEABLE MEDICAL SOURCE Whenever the fuel system has been opened up for service lines disconnected or filters removed it will be necessary to bleed air from the system 1 Loosen the air bleed vent screw on fuel filter head two full turns by hand on fuel filter base 2 Operate supply pump primer lever until fuel flow is free from air bubbles Tighten bleed plug securely by hand or using a coin continue operating hand primer until pumping action is not felt Push hand primer inward toward engine as far as it will go 4 Start engine and check for leaks If engine will not start it may be necessary to bleed air from fuel system at fuel injection pump or injection nozzles as explained next 4 10 4 Bleeding at Fuel Injection Pump 1 Slightly loosen fuel supply line connector at injection pump 2 Operate fuel supply pump primer lever until fuel without air bubbles flows from fuel return li
23. HER ENGINE IS EQUIPPED WITH INTAKE HEATER AN EXPLOSION OR FIRE MAY RESULT REFER TO COLD WEATHER STARTING INSTRUCTIONS 3 12 TO STOP AWARNING ALWAYS OBEY THE FOLLOWING PROCEDURES BEFORE DISMOUNTING FROM THE ROLLER 1 Place the forward reverse lever in the NEUTRAL position 2 Throttle engine down to its slowest speed 3 Turn key switch to OFF position to stop the engine Remove ignition key NOTE Before stopping an engine that has been operating at working load idle engine at least 2 minutes 3 13 IDLING ENGINE IMPORTANT Avoid excessive engine idling Prolonged idling may cause the engine coolant temperature to fall below its normal range This in turn causes crankcase oil dilution due to incomplete fuel combustion and permits formation of gummy deposits on valve pistons and piston rings It also promotes rapid accumulation of engine sludge and unburned fuel in the exhaust system 3 14 WARMING ENGINE IMPORTANT To assure proper lubrication operate engine at idle with no load for 5 minutes Extend this period when operating at temperatures below freezing 1 Check oil pressure gauge as soon as engine starts If gauge needle does not rise above minimum oil pressure specification of 1 05 bar 15 0 psi within 5 seconds stop the engine and determine the cause Normal engine oil pressure is 3 45 bar 1 03 bar 50 15 psi at rated full load speed 1800 2500 rpm with oil at normal operating
24. 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 1 Drink large amounts of water or milk 2 Then drink milk of magnesia beaten eggs or vegetable oil 3 Get medical attention immediately In freezing weather run engine at lease 30 minutes to assure thorough mixing after adding water to battery If necessary to replace battery ies replacements must meet or exceed the following recommended capabilities at 18 C 0 F 12 Volt Heavy Duty Battery BCI Group 24 800 CCA 4 15 2 Battery Installation AWARNING ALWAYS CONNECT GROUNDED CABLE LAST CLEAN AND SECURELY CONNECT EACH CABLE END BATTERY TERMINAL OF POLARITY BATTERY SHOULD BE SECURELY FASTENED WITH PROPERLY INSTALLED HOLD DOWNS 4 15 3 Charging Jumping Battery A 12 volt booster battery can be connected in parallel with battery ies on the unit to aid in cold weather starting ALWAYS use heavy duty jumper cables AWARNING GAS GIVEN OFF BY BATTERY IS EXPLOSIVE KEEP SPARKS AND FLAMES AWAY FROM BATTERY BEFORE CONNECTING OR DISCONNECTINGA BATTERY CHARGER TURN CHARGER OFF MAKE LAST CONNECTION AND FIRST DISCONNECTION AT A POINT AWAY FROM BATTERY ALWAYS CONNECT NEGATIVE CABLE LAST AND DISCONNECT THIS CABLE FIRST IMPORTANT Be sure polarity is correct before mak
25. LEASE OF FLUIDS FROM HYDRAULIC SYSTEM CAN CAUSE SERIOUS BURNS SHUT OFF ENGINE ONLY REMOVE BREATHER CAP WHEN COOL ENOUGH TO TOUCH WITH BARE HANDS SLOWLY LOOSEN CAP TO FIRST STOP TO RELIEVE PRESSURE BEFORE REMOVING COMPLETELY Check the hydraulic oil level Use the sight gauge located on the hydraulic tank A 1 4 1 2 air bubble will be seen at the top of the gauge showing the fluid level 93s 3 OPERATION For satisfactory operation the following oil conditions apply 1 Accurate level readings can be checked only when the fluid is cold 2 Ifthe natural color of the fluid has become black or milky it is possible that an overheating or water contaminant problem exists Do not mix hydraulic fluids Mobil 424 is recommended for the hydraulic system CAUTION After a new unit has run 5 hours the oil filter should be changed This is to rid the system of any trapped contamination from the wear in ofthe parts Refer to Maintenance for hydraulic filter change 3 7 ENGINE COOLANT AWARNING CHECK COOLING SYSTEM CAREFULLY EXPLOSIVE RELEASE OF FLUIDS FROM PRESSURIZED COOLING SYSTEM CAN CAUSE SERIOUS BURNS To check coolant level 1 Shut off engine allow to cool 2 Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely Remove cap coolant level should just touch the bottom of radiator filler neck If co
26. NG NEVER OPERATE ON SLOPES GREATER THAN 15 DEGREES OR TIPPING MAY OCCUR 3 18 FORWARD REVERSE NEUTRAL The forward reverse lever should be aligned with NEUTRAL on the console when the roller is moving neither forward nor backward with the engine running The neutral interlock switch should not allow the engine to start unless the forward reverse lever is in neutral 3 19 THROTTLE Pull throttle out to increase engine speed Push throttle to reduce engine speed For best performance run engine at full throttle 3 20 GAUGES IMPORTANT Any time an electric gauge or meter does not register correctly replace it with a new one Do not attempt to repair it Oil Pressure Gauge Indicates engine oil pressure Coolant Temperature Gauge Indicates the engine coolant temperature Volt Meter Indicates charging current within electrical system Hour Meter Indicates the operating hours of the engine while key switch is in the ON position The hour meter should be used as a guide for scheduling AWARNING AVOID LEAVING THE KEY ON WHEN MACHINE IS NOT RUNNING THIS WILL HAVE AN EFFECT ON THE HOUR METER READINGS 26 3 OPERATION 3 21 PANEL FUSE 20 AMP Protects electrical system AWARNING NEVER USE FUSE WITH A DIFFERENT RATING FROM THAT SPECIFIED SERIOUS DAMAGE TO THE ELECTRICAL SYSTEM A FIRE MAY RESULT 3 22 COLD WEATHER STARTING INTAKE HEATER BUTTON AWARNING DO N
27. NG UNDER PRESSURE FROM A VERY SMALL HOLE CAN BE ALMOST INVISIBLE USE A PIECE OF 43 4 MAINTENANCE CARDBOARD OR WOOD TO SEARCH FOR POSSIBLE LEAKS NEVER USE YOUR HANDS TO DETECT PRESSURE LEAKS IF YOU ARE INJURED BY ESCAPING HYDRAULIC FLUIDS SEE A DOCTOR AT ONCE SERIOUS INFECTION OR REACTIONS CAN DEVELOP IF PROPER MEDICAL TREATMENT IS NOT ADMINISTERED IMMEDIATELY Before disconnecting any hydraulic lines be sure engine is shut off and relieve all pressure Before applying pressure to system be sure all connections are tight and lines fittings and hoses are not damaged Inspect for leaks daily Check connections for tightness every 100 hours Hydraulic system produces high pressures incorrect hose replacement can cause serious personal injury When performing service refer to hydraulic diagrams for hose identification and connections 4 23 FORWARD REVERSE NEUTRAL ADJUSTMENT The forward reverse lever should be aligned with NEUTRAL on the console when the roller is moving neither forward nor backward with the engine running If the lever is not aligned adjust it as described below 1 Shut off the engine with the forward reverse lever left in operating neutral position the position when the roller moves neither forward nor reverse Apply the parking brake Open the engine hood of the machine Disconnect the linkage from the hydrostatic transmission from the clevis Do this by removing th
28. NJURY OR DEATH COULD RESULT CONTROL CABLES WHICH HAVE MOISTURE INSIDE OF THEM AND OR HAVE FROZEN SHOULD BE REPLACED DO NOT APPLY HEAT TO THAW OR DRY CONTROL CABLES 44 4 MAINTENANCE 4 26 ECCENTRICS Test vibration with front drum on soft ground Run engine at full rpm to obtain vib spec 2100 100 rpm check per below To check vibration with a vibrotach place the vibrotach on the vibrating member surface record reading when the wire reaches maximum movement Vibrotach P N 37891 When checking vibration with strobe light place horizontal line on vibrating member surface Check with strobe light and record reading when the line reaches minimum movement 4 261 Housing Oil AWARNING ROLLER MUST BE PARKED ON LEVEL GROUND WITH PARKING BRAKE APPLIED AND ENGINE OFF REMOVE THE KEY AND OR DISCONNECT BATTERY TO AVOID ACCIDENTAL IGNITION OF ENGINE SEVERE PERSONAL INJURY MAY OCCUR NEVER WORK ON THE ROLLER WITH ENGINE RUNNING SEVERE PERSONAL INJURY MAY OCCUR Eccentric housing oil should be checked monthly and changed every 800 hours or yearly Refer to Maintenance Chart To check locate oil plug inside the right hand drum end and position drum so that oil plug is visible at 7 00 Loosen oil plug slowly until oil starts to drip out past the oil plug Oil must be present at the 7 00 position Add oil if required and reinstall oil plug use thread sealant Eccentric housin
29. OT USE STARTING FLUID ETHER ENGINE IS EQUIPPED WITH AIR INTAKE HEATER AN EXPLOSION OF FIRE MAY RESULT FOR COLD WEATHER STARTING SEE INSTRUCTIONS BELOW 1 Turn the key to the ON position do not crank engine 2 Press INTAKE HEATER BUTTON for approximately 30 seconds Start engine using starter switch As soon as the engine starts release button Never operate the starter for more than 20 seconds at a time If engine does not start release the starter switch and wait at least one minute before trying again Do not adjust the throttle setting Allow the engine to idle for 5 minutes to warm up At temperatures below freezing extend warm up time 3 23 BLADE LEVER OPTIONAL Controls the leveling blade height for pre leveling loose soil IMPORTANT Do not use the blade to dig or bulldoze or machine damage may occur 3 24 HORN AND BACK UP ALARM Check operation daily It is the driver s responsibility to operate equipment safely 3 25 ROPS FOPS SEAT BELT Inspect daily Certified factory installed for operator protection Do not remove or modify AWARNING DANGER AVOID CRUSHING DO NOT JUMP IF MACHINE TIPS ALWAYS WEAR SEAT BELT DO NOT OPERATE THIS MACHINE IF THE ROLLOVER PROTECTIVE STRUCTURE ROPS IS STRUCTURALLY DAMAGED SHOWS CRACKS IS NOT PROPERLY SECURED AS ORIGINALLY INSTALLED OR HAS BEEN ROLLED DO NOT REPAIR MODIFY OR ADD ATTACHMENTS TO ROPS UNLESS AUTHORIZED IN WRITING BY THE MANUFACTUR
30. R BUTTON lor approximately 30 seconds engine using starter switch as soon as the engine starts release bution 2 Never operale the starter for more than 29 seconds al time HOT SURFACES engine does nol start release Ihe starter switch and al least one minule belore irging again MUFFLER ENGINE AND ENGINE SHROUD 3 Do not adjust the throttle setting Allow fe engine to run for MAY BE HOT ALLOW ALL COMPONENTS IN 1152 minutes to warm up Al temperateres below freezing THE ENGINE COMPARTMENT TO COOL DOWN extend warm up time to 2 1n 4 minutes BEFORE PERFORMING SERVICE W RK 5 USERS MUST BE TRAINED OPERATE THIS ROLLER OR SERIOUS INJURY MAY OCCUR READ Operator s balore operating or sarvicisg LEARN lo agerale SAFELY ALWAYS CAUTION wear operate across the sides ol ze at edge of roads roller may eer DD park roller his DX pesh or pull fre roller with the engine nf Rater Owners Ma maing imapipas T Never push or pull the di gt roller with engine off refer to operators for towing instructions 3 55217 5 14 Decal Identification Contd zs Description Description DECAL SETWARNING S Includes 5 decals listed below Decal Cold Starting Instructions Decal Intake Heater Button Decal Waming Hot Surfaces DecalWaming No Ether Decal Waming Tipover Decal H
31. REATED DURING OPERATION WHICH COULD STOP FUEL FLOW DIESEL FUEL IS MANDATORY FOR USE IN THIS ENGINE ALWAYS USE CLEAN FUEL LOW QUALITY OR CONTAMINATED FUEL WILL DAMAGE FUEL INJECTION COMPONENTS DIESEL FUEL STORED IN GALVANIZED CONTAINERS REACTS CHEMICALLY WITH THE ZINC COATING ON THE CONTAINER THE CHEMICAL REACTION CREATES POWDERY FLAKES OF ZINC SULFIDE IF WATER IS PRESENT IN THE FUEL A ZINC HYDROXIDE GEL WILL FORM 3 3 ENGINE BREAK IN IMPORTANT Read Engine Manual for break in requirements 1 100 hours John Deere break in oil only TY 22041 Do not add oil until level is in the add area on the dipstick Do not fill above the crosshatched area on the dipstick 1 100 hours run engine at full throttle Operate engine at heavy loads do not idle longer than 5 minutes Check oil frequently do not exceed 100 hours with break in oil 3 4 ENGINE OILAND FILTER Change oil and filter at 100 hours then every 250 hours Use SAE 15W 40 API CG 4 or API CF 4 Refer to Engine Manual for additional oil types and recommendations Do not mix different brands or types of oil Mixing oils can degrade lubrication performance 3 5 WARNING LIGHT Unit is equipped with a warning light for low pressure and or hot engine temperature Specifications Oil pressure at full speed 40 50 psi 2 75 3 45 bar Coolant temperature range 180 202 F 82 94 C 3 6 HYDRAULIC OIL FILTER BREATHER AWARNING PRESSURIZED RE
32. RPM Replace or repair by authorized Service Center Check brake light operation Check for 12 volt A brake valve see Wiring Check wiring for loose or broken wiring Check pump for proper charge pressure 220 260psi Check replace if required 4 MAINTENANCE 4 36 ELECTRICAL TROUBLESHOOTING PROBLEM Undercharged system Battery used too much water Batteries will not charge Starter will not crank Starter cranks slowly Entire electrical system does not function CAUSE Excessive electrical load from added accessories Excessive engine idling Poor electrical connections on battery ground strap starter or alternator Defective battery Defective alternator Cracked battery case Defective battery Battery charging rate too high Loose or corroded connections Sulfated or worn out batteries Loose or defective alternator belt Loose or corroded connections Low battery output voltage Faulty start circuit relay Low battery output Crankcase oil too heavy Loose or corroded connections Faulty battery connection Sulfated or worn out batteries Blown fuse REMEDY Remove accessories Increase engine RPM when heavy electrical load is used Inspect and clean as necessary Test battery Test charging system Check for moisture and replace as necessary Test battery Test charging system Clean and tighten connections See your aut
33. Replace as required Check oil level Add oil as required Flush cooling system Remove and check thermostat Check water temperature with thermometer and replace if necessary Use correct grade of fuel 4 MAINTENANCE 4 35 TROUBLESHOOTING cont d CAUSE PROBLEM Roller won t move forward or reverse Unit lacks power moving forward but okay in reverse or vice versa Unit lacks power Objects in front of drums Unit in bypass loose or broken forward reverse linkage Low hydraulic oil Improperly adjusted forward reverse linkage Engine not properly warmed up Restricted fuel hose low hydraulic oil level Plugged hydraulic filter Leaking exhaust manifold gasket Engine RPM too low Defective Aneroid control line Dirty fuel filter Dirty fuel injectors Injection pump drawing in air Too much oil in crankcase Air filter dirty Injection pump out of time Faulty hydraulic pump or drive motor Remove Check bypass valve Readjust linkage or replace worn arm linkage make sure lever at pump is moving Check oil level gauge Add if required Adjust linkage so that lever travel is the same in either direction from neutral Idle before operating to achieve operating temperature Clean or replace fuel hose Add hydraulic oil Replace See your authorized servicing dealer or engine distributor Check throttle linkage for proper actuation Check full speed
34. See your authorized servicing dealer or engine distributor Replace Service or replace Check fuel lines or replace Drain and check Service or replace Clean and or replace See your authorized servicing dealer or engine distributor Test hydraulic pressure for 500psi at full load on drive motor with engine at full RPM Check charge pressure 220 260 psi with engine at full RPM 4 MAINTENANCE 4 35 TROUBLESHOOTING cont d CAUSE PROBLEM Unit lacks power cont d Unit won t steer Brakes don t hold properly Brake stays on Faulty hydraulic pump or drive motor cont d Improper type of fuel Excessive mud or debris build up Below normal engine temperature Improper valve clearance Cylinder leaking Piston rod bent Missing hydraulic cylinder pin Kinked or broken hoses Low hydraulic fluid Faulty hydraulic pump Brake valve faulty Loose wires No release pressure Faulty relay REMEDY Replace pump if pressure is not in specified range in hydraulic motor drive circuit Check drive motors case drain flow 5 max drum tires blocked engine running Use proper fuel Clean pressure wash Remove and check thermostat See your authorized servicing dealer or engine distributor Replace hydraulic cylinder Replace hydraulic cylinder Replace Replace Add fluid Check hydraulic steering circuit for maximum pressure of 2 300 psi at full
35. Service Parking Hydrostatic Automatic spring applied Recommended Fuel Diesel fuel blend meeting ASTM D975 or EN 590 Premium diesel fuel conditioner is also recommended Electric 12 Volt system battery BCI group 24 800 CCA 78 amp charge system Hydraulic Oil Mobilfluid 424 Capacity 20 gallons 76 liters Engine Oil 1st 100 hours John Deere break in oil TY22041 then SAE 15W 40 API CG 4 API 4 6 5 quarts 6 0 liters Engine Coolant 50 50 Mixture antifreeze distilled water meeting ASTM 4985 coolant additive is also recommended Eccentric Oil SAE 20W 50 API SJ or API SH SD PD 43 1 quart 95 liter SD PD 54 15 quarts 1 4 liters Engine HP John Deere 3029DF 58 HP 43 kW int 2 500 RPM Torque 153 ft lbs 208 Nm int 1 200 RPM Fuel Economy 377 lb hp hr 230 g kWh 1 600 RPM 1 4 MACHINE SOUND LEVEL TEST Machine Type PDB34 Rhino Sound Level Meter Calibration Date August 6 1997 Meter Type Simpson Model 886 2 Type 2 Test Date August 6 1997 Test Conditions Temperature 70 Fahrenheit 20 Celsius Ambient Sound 60 dba Slow Mode Soil Condition Silts and Clays Moisture Limit N A Engine Speed 2 500 RPM 41 Hz Frequency 2 100 VPM 34 Hz Test Site Honeoye New York USA Sound Level at Operator Position 93 dba Without Vibe
36. TER A 6 4 UR 100 HRS ILTER 625 ILTER 39624 NER VERY 60 50 50 MIX ADDITIVE DEERE 0 RS STONE 396 DEERE 23526 STONE 30626 RPM JO_HRS 24 MONTH VERY 600 HRS 12 MONTH ENGIN WAGE o 0o ooolooo o PLACE S NE 39629 IAL amp ENG INE OWNER 5 MANUA MOBI 00 HRS 424 HYDRAULIC ECCENTRI BLADE PIVOT 2 FRAME HING HROTTLE CHECK FO GHT REPLACE ON LUBE EVERY 250 HRS LIGHT JAMAGED STONE 38521 ER 4 TIRES LUC HORN amp BAC SPECT OPERATION DA BS INSPECT HARDWARE DRUM amp BATTERY CLEAN EXTERIOR amp IN AN amp CHECK RADIATOR EXTERIOR amp IN ROPS amp SEA XTERIOR amp IN FUEL REFER TO ENGINE CLEAN EXTERTOR 8 INSPECT TY STATEMENT STONE amp E SHOP MANUAL F R PROCEDURES NGINE OWNER 5 MANUA 55381 4 MAINTENANCE 4 3 IMPORTANT MAINTENANCE INFORMATION AWARNING REMOVE THE KEY AND OR DISCONNECT BATTERY TO AVOID ACCIDENTAL IGNITION OF ENGINE SEVERE PERSONAL INJURY MAY OCCUR ROLLER MUST BE PARKED ON LEVEL GROUND WITH PARKING BRAKE APPLIED ENGINE OFF AND DRUM BLOCKED N
37. Wear safety glasses and remove bystanders Remove air cleaner cover Remove primary outer element only Thoroughly clean all dirt from inside filter housing Air cleaner has rubber dust unloader valve on the air cleaner Squeeze valve tip to release any trapped dirt particles Inspect filter to determine if it is practical to clean or for damage after cleaning filter a Hold a bright light inside element and check carefully for holes Discard any element that shows the smallest hole or rupture Be sure outer screen is not dented Vibration would quickly wear a hole in filter Be sure filter gasket is in good condition If gasket is damaged or missing replace element 6 Gently pat sides of element with palm of hand to loosen dirt DO NOT tap element against a hard surface AWARNING ONLY A SPECIALAIR CLEANING GUN SHOULD BE USED CONCENTRATED AIR PRESSURE FROM AN ORDINARY AIR NOZZLE MAY SEVERELY DAMAGE FILTER ELEMENT DO NOT EXCEED 30 psi 2 1 bar WHEN CLEANING FILTER ELEMENT 7 Insert the cleaning gun into element hold air nozzle about 1 25 4 mm from perforated metal retainer Force air through filter from inside to outside and move air gun up and down pleats to remove as much dirt as possible Repeat steps 6 and 7 to remove additional dirt Inspect element for damage after cleaning Replace element if any damage is found Service air cleaner more frequently in dusty conditions 4 9 2 Air Cleaner Replacement Replace
38. acturers approval Modifications to basic design should be avoided as recertification is required 4 32 1 Maintenance of ROPS Seat Belts Inspection Scheduled frequent visual checks of mounting hardware by operator or service personnel are recommended Inspection with regular service intervals is suggested The inspection should check for Worn damaged or missing resilient mounts Excessive motion or rattling during operation are indications of a problem Loose missing or damaged mounting hardware bolts nuts washers etc Bolts should be checked for proper torque Cracks in ROPS FOPS structure and mounting system The machine should be cleaned as necessary to allow inspection for cracks in the structure and mounting system Rust lines should be taken as indications of cracks and verified by inspection Some cracks will badly affect the ROPS FOPS function If in doubt consult the manufacturer Water drainage paths Clear water drainage paths so that entrapped water will not freeze and crack or deform the structure Corrosion Extensive paint peeling and rust should be noted and corrective action taken Seat belt The presence and operability of a seat belt should be noted The belt should be clean free of dirt and grease and the latch should function smoothly The structure should be inspected following a rollover collision or fire Repair Replace missing or damaged hardware with the manufacturer s specified h
39. al for procedures 4 18 EMISSION REGULATION ENGINE RPM Do not adjust operating speed Full speed is factory set at 2500 rpm Do not adjust idle speed above 1400 rpm Proper idle rpm is 1200 100 Do not alter injection pumps TAMPERING with the following engine factory settings is ILLEGAL except to reset to published specifications and reseal by authorized engine dealer Engine Timing Fuel Delivery Aneroid Settings Rated Speed Deere will reissue emissions dataplates only to replace damaged plates Requests must be in writing and include name address engine model and serial number with reason for need Power rating changes WILL NOT be allowed on new engines 4 19 FUEL INJECTORS AWARNING ESCAPING FLUID UNDER PRESSURE CAN PENETRATE THE SKIN CAUSING SERIOUS INJURY RELIEVE PRESSURE BEFORE DISCONNECTING FUEL OR OTHER LINES TIGHTEN ALL CONNECTIONS BEFORE APPLYING PRESSURE KEEP HANDS AND BODY AWAY FROM PINHOLES AND NOZZLES THAT EJECT FLUIDS UNDER HIGH PRESSURE USE A PIECE OF CARDBOARD OR PAPER TO SEARCH FOR LEAKS DO NOT USE YOUR HAND IF ANY FLUID IS INJECTED INTO THE SKIN A DOCTOR FAMILIAR WITH THIS TYPE INJURY MUST SURGICALLY REMOVE IT WITHIN A FEW HOURS OR GANGRENE MAY RESULT DOCTORS UNFAMILIAR WITH THIS TYPE OF INJURY MAY CALL THE DEERE amp COMPANY MEDICAL DEPARTMENT IN MOLINE ILLINOIS OR OTHER KNOWLEDGEABLE MEDICAL SOURCE IMPORTANT Always use John Deere replacement parts meeting Joh
40. ardware Re torque all loose threaded fasteners to the manufacturer s specifications The manufacturer must be consulted to determine the repairability of cracks in ROPS FOPS structures 46 4 MAINTENANCE AWARNING THIS VEHICLE IS EQUIPPED WITH A BACK UP ALARM ALARM MUST SOUND WHEN BACKING UP IT IS THE DRIVER S RESPONSIBILITY TO OPERATE THIS VEHICLE SAFELY BE SURE BACK UP ALARM AND HORN ARE WORKING Inspect the sound decibel level of the horn and back up alarm daily and test weekly for proper dBA level 112 dBA Test results should be recorded in the vehicle s maintenance file If mud dirt or other debris is forced into alarm clean and test to ensure proper operation 4 33 1 Back Up Alarm Switch 1 Remove control panel wrap To check for proper switch operation connect ohmmeter leads to the wire connections The back up switch should be normally open in the neutral position and normally closed when shifted into reverse position With the ignition key in the on position shifting into reverse should actuate the back up alarm Check the assembly for proper switch actuation smooth lever operation and all hardware for tightness then assemble the panel wrap and hardware 4 34 SCRAPERS Prevent mud and debris from building up If urethane scrapers are worn or torn replace Steel scrapers are adjustable The scrapers should just clear the drum and pads If adjusting be sure to check that scraper
41. ation to prevent condensation in tank as moist air cools and freezing during cold weather Avoid storing fuel over long periods of time If fuel is stored for more than a month prior to use or there is a slow turnover in fuel tank or supply tank add a fuel conditioner such as John Deere PREMIUM DIESEL FUEL CONDITIONER or equivalent to stabilize the fuel and prevent water condensation John Deere PREMIUM DIESEL FUEL CONDITIONER is available in winter and summer formulas Fuel conditioner also reduces fuel gelling and controls wax separation during cold weather Proper fuel storage is critically important Use clean storage and transfer tanks Periodically drain water and sediment from bottom of tank Store fuel in a convenient place away from buildings IMPORTANT DO NOT store diesel fuel in galvanized containers Diesel fuel stored in galvanized containers reacts with zinc coating on container to form zinc flakes If fuel contains water a zinc gel will also form The gel and flakes will quickly plug fuel filters and damage injection nozzles and injection pump DO NOT use brass coated containers for fuel storage Brass is an alloy of copper and zinc 4 21 FUEL LINES Inspect fuel line condition and clamps Replace fuel lines every 2 years 4 22 HYDRAULIC HOSES CONNECTIONS AWARNING ESCAPING HYDRAULIC FLUID UNDER PRESSURE CAN HAVE SUFFICIENT FORCE TO PENETRATE THE SKIN CAUSING SERIOUS PERSONAL INJURY HYDRAULIC FLUID ESCAPI
42. belt an 89 N 20 Ib force applied halfway between pulleys should deflect belt by 19 mm 3 4 in If adjustment is necessary loosen alternator bracket cap screw and nut on mounting bolt Pull alternator frame outward until belts are correctly tensioned IMPORTANT Do not pry against the alternator rear frame Do not tighten or loosen belts while they are Tighten alternator bracket cap screw and nut firmly After a new or used belt has run for 10 minutes recheck belt tension STANDARD V BELTS Tension New Belt Tension Used Belt 578 623 N 378 423 N 130 140 Ib force 85 95 Ib force Single Belt 4 12 GREASE FITTINGS Use a grease gun to grease below fittings use lithium grease Remove the blue protection cap off fitting before greasing 4 13 FRAME HINGE Grease daily six fittings with lithium base grease using a grease gun There is one fitting on each of the top and bottom bearings for the vertical pin There are two fittings on the horizontal pin 4 14 BLADE PINS Grease the two fittings daily one on each of the blade pivot pins 4 15 BATTERY 4 15 1 Servicing Battery AWARNING BATTERY GAS CAN EXPLODE KEEP SPARKS AND FLAMES AWAY FROM BATTERIES USE A FLASHLIGHT TO CHECK BATTERY ELECTROLYTE LEVEL NEVER CHECK BATTERY CHARGE BY PLACING A METAL OBJECT ACROSS THE POSTS USE A VOLTMETER HYDROMETER ALWAYS REMOVE GROUNDED NEGATIVE BATTERY CLAMP FIRST AND REPLACE IT LAST 1 On regular batter
43. change the wiring harness 45 4 MAINTENANCE D Cold weather add ons should not be needed When cleaning machine caution should be used around regulator area Direct spraying of the regulator is not good Regulator should be covered or protected if direct spraying will happen Excessive water pressure may also loosen wire connections or cause terminal corrosion After cleaning all terminals should be dried if wet and connections checked for proper seating 4 30 ENGINE MOUNTING Check periodically tighten all mounting hardware for proper torque Refer to Torque Charts in Exploded Views with Parts Section 4 31 HARDWARE Inspect all hardware for tightness Refer to parts illustrations for proper torque and Torque Charts in Exploded Views with Parts Section 4 31 1 Loctite Loctite 262 threadlocker is required to prevent hard ware from loosening Refer to Exploded Diagram and Parts List for where loctite is required 432 ROLL OVER PROTECTIVE STRUCTURES ROPS Proper inspection and maintenance procedures can ensure that ROPS will perform the lifesaving function they are designed for and expected to do Make regular periodic inspections to ensure ROPS are damage free and thus capable of functioning in an upset Generally ROPS FOPS structures are not intended as external load carrying members and must not be used to mount attachments such as pull hooks winches side brooms etc without the manuf
44. d start the engine and purge the air from the system prior to checking the oil level To do this idle the engine for three minutes with control lever in NEUTRAL position Slowly engage forward to reverse This allows fluid to replace air introduced with filter change If this procedure is not followed partial or complete failure of the pump may result Change hydraulic oil filter at 5 hours then every 100 hours 1 Remove and discard hydraulic oil filter using a filter wrench 2 Oil new filter seal and install new filter element tighten approximately 3 4 1 1 4 turn after packing contacts filter housing DO NOT overtighten filter element IMPORTANT Immediately after completing filter change crank engine for 30 seconds without permitting engine to start This will help insure adequate lubrication to components before engine starts 3 Start engine and run to check for possible leaks 4 Stop engine and replenish hydraulic oil AWARNING NEVER OVERFILL THE HYDRAULIC TANK USE THE SIGHT GAUGE LOCATED ON THE HYDRAULIC TANK A 1 4 1 2 AIR BUBBLE WILL BE SEEN AT THE TOP OF THE GAUGE SHOWING THE FLUID LEVEL Change hydraulic oil every 800 hours Use Mobil 424 1 Run engine approximately 5 minutes to warm up oil Shut engine off 2 Remove breather cap and oil drain plug drain into suitable container Apply thread sealant to breather cap and drain plug install drain plug Fill hydraulic tank with correct hydra
45. e lock nut from the clevis pin and removing the pin Now screw clevis in or out to adjust Secure the clevis to the transmission lever with the clevis pin secure with the lock nut and tighten clevis nut Linkage play must be minimal at both connections Replace clevis and or link if required 4 24 NEUTRAL INTERLOCK The purpose of the neutral interlock switch is to prevent engine starting when the forward reverse lever is not in the neutral position To check 1 Disconnect battery cables from battery 2 a Disconnect 2 wires from neutral interlock switch and connect it to leads from an ohmmeter b When switch is actuated ohmmeter should read zero resistance Adjustments must be made at transmission Disconnect ohmmeter and reconnect interlock wires and battery cables 4 25 CONTROL CABLES FORWARD REVERSE THROTTLE BLADE Lubricate all cable ends with penetrating oil every 200 AWARNING DO NOT ADJUST THE CONTROL CABLE WITH THE POWER ON OR THE ENGINE RUNNING SERIOUS INJURY OR DEATH COULD RESULT A GRADUAL OR SUDDEN INCREASE IN THE NO LOAD FRICTION CABLE DISCONNECT AT BOTH ENDS OF A CONTROL CABLE IS AN INDICATION OF A PENDING OR PRESENT PERFORMANCE PROBLEM THE CONTROL CABLE SHOULD BE REPLACED OTHERWISE SERIOUS INJURY OR DEATH COULD RESULT A GRADUAL OR SUDDEN DECREASE IN THE USABLE STROKE IS AN INDICATION OF A PENDING OR PRESENT PERFORMANCE PROBLEM THE CONTROL CABLE SHOULD BE REPLACED OTHERWISE SERIOUS I
46. eck for possible leaks 10 Stop engine and check oil level after 10 minutes Oil level reading should be between arrows or within crosshatch of dipstick 4 5 ADDITIONAL SERVICE INFORMATION This is not a detailed service manual If you want more detailed service information see John Deere Manuals 55319 Manual Engine 55320 Manual Parts 55321 Manual Technical 4 6 HYDRAULIC OIL FILTER AWARNING PRESSURIZED RELEASE OF FLUIDS FROM HYDRAULIC SYSTEM CAN CAUSE SERIOUS BURNS SHUT OFF ENGINE ONLY REMOVE BREATHER CAP WHEN COOL ENOUGH TO TOUCH WITH BARE HANDS SLOWLY LOOSEN CAP TO FIRST STOP TO RELIEVE PRESSURE BEFORE REMOVING COMPLETELY ESCAPING HYDRAULIC FLUID UNDER PRESSURE CAN HAVE SUFFICIENT FORCE TO PENETRATE THE SKIN CAUSING SERIOUS PERSONAL INJURY HYDRAULIC FLUID ESCAPING UNDER PRESSURE FROM A VERY SMALL HOLE CAN BE ALMOST INVISIBLE USE A PIECE OF CARDBOARD OR WOOD TO SEARCH FOR POSSIBLE LEAKS NEVER USE YOUR HANDS TO DETECT PRESSURE LEAKS 34 4 MAINTENANCE HYDRAULIC TANK TEMPERATURE CAN REACH 180 DEGREES F MAXIMUM Refer to Operating section of this manual for hydraulic oil conditions and recommendations Before disconnecting any hydraulic components be sure engine is shut off and relieve all pressure Before applying pressure to system be sure all connections are tight and lines fittings and hoses are not damaged IMPORTANT When hoses oil filter and or hydraulic components are change
47. el starts to drain out tighten drain plug securely by hand or using a coin After draining water from the fuel filter the filter must be primed by bleeding all air from the fuel system 4 Operate primer lever of the fuel supply pump until fuel flow is free from air bubbles Tighten bleed plug securely by hand or using a coin continue operating hand primer until pumping action is not felt Push hand primer inward toward engine as far as it will go If the fuel system needs further bleeding of air see Bleeding Fuel System in Maintenance section of this manual 4 10 2 Fuel Filter Replacement AWARNING ESCAPING FLUID UNDER PRESSURE CAN PENETRATE THE SKIN CAUSING SERIOUS INJURY RELIEVE PRESSURE BEFORE DISCONNECTING FUEL OR OTHER LINES TIGHTEN ALL CONNECTIONS BEFORE APPLYING PRESSURE KEEP HANDS AND BODY AWAY FROM PINHOLES AND NOZZLES THAT EJECT FLUIDS UNDER HIGH PRESSURE USE A PIECE OF CARDBOARD OR PAPER TO SEARCH FOR LEAKS DO NOT USE YOUR HAND IF ANY FLUID IS INJECTED INTO THE SKIN A DOCTOR FAMILIAR WITH THIS TYPE INJURY MUST SURGICALLY REMOVE IT WITHIN A FEW HOURS OR GANGRENE MAY RESULT DOCTORS UNFAMILIAR WITH THIS TYPE OF INJURY MAY CALL THE DEERE amp COMPANY MEDICAL DEPARTMENT IN MOLINE ILLINOIS OR OTHER KNOWLEDGEABLE MEDICAL SOURCE Replace fuel filter every 600 hours or 12 months 1 Thoroughly clean fuel filter assembly and surrounding area 2 Loosen drain plug and drain fuel into a suitable contain
48. equipment components and repair parts include the current safety signs Replacement safety signs and decals are available through your dealer Learn how to operate the machine and how to use controls properly Do not let anyone operate without instruction 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 dealer UNDERSTAND SIGNAL WORDS A DANGER A WARNING A CAUTION A A signal word DANGER WARNING or CAUTION is used with the safety alert symbol DANGER identifies the most serious hazards 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 This notation appears before warnings in the text It means that the step which follows must be carried out to avoid the possibility of personal injury or death These warnings are intended to help the technician avoid any potential hazards encountered in the normal service procedures We strongly recommend that the reader takes advantage of the information provided to prevent personal injury or injury to others 15 2 HEALTH amp SAFETY Safety Precautions USE COMMON SENSE WHEN HANDLING FUELS HW Transport and handle fuel only when con
49. er 38 4 MAINTENANCE NOTE Lifting up on retaining ring as it is rotated helps to get it past raised locators 3 Firmly grasp the retaining ring and rotate it counterclockwise 1 4 turn Remove ring with filter element Inspect filter mounting base for cleanliness Clean as required NOTE Raised locators on fuel filter canister must be indexed properly with slots in mounting base for correct installation 5 Install new filter element onto mounting Be sure element is properly indexed and firmly seated on base It may be necessary to rotate filter for correct alignment Remove filter element from water separator bowl Drain and clean separator bowl Dry with compressed air Install water separator bowl onto new element Tighten securely Align keys on filter element with slots in filter base Install retaining ring onto mounting base making certain dust seal is in place on filter base Hand tighten ring about 1 3 turn until it snaps into the detent DO NOT overtighten retaining ring NOTE The proper installation is indicated when a click is heard and a release of the retaining ring is felt A plug is provided with the new element for plugging the used element 9 Bleed the fuel system See Bleeding Fuel System in Maintenance section of this manual 4 10 3 Bleeding Fuel System AWARNING ESCAPING FLUID UNDER PRESSURE CAN PENETRATE THE SKIN CAUSING SERIOUS INJURY RELIEVE PRESSURE BE
50. eriod to Lifetime for the drum bearings and seals for the mortar mixers and agrees to furnish free of charge the bearings and seals only upon receipt of the defective parts The warranty is two years for eccentric bearings on the forward plate compactors mortar and plaster mixer drums trowel gearboxes and five years on the Bulldog trench roller eccentric bearings A Warranty Evaluation Form must accompany all defective parts Warranty is voided by product abuse alterations and use of equipment in applications for which it was not intended use of non manufacturer parts or failure to follow documented service instructions The foregoing warranty is exclusive of all other warranties whether written or oral expressed or implied No warranty of merchantability or fitness for a particular purpose shall apply The agents dealer and employees of Manufacturer are not authorized to make modification to this warranty or additional warranties binding on Manufacturer Therefore additional statements whether oral or written do not constitute warranty and should not be relied upon The Manufacturer s sole responsibility for any breach of the foregoing provision of this contract with respect to any product or part not conforming to the Warranty or the description herein contained is at its option a to repair replace or refund such product or parts upon the prepaid return thereof to location designated specifically by the Manufacturer Product returns no
51. event rolling Keep engine cover closed during the operation Keep hands clothing and jewelry away from all moving parts Keep all guards in place 17 2 E A LT H amp SA F E T Y Safety Precautions Keep feet clear of all drums Keep work area free of bystanders For foot protection wear steel toe shoes or toe pads Caution Keep away from the machine s articulation area when the engine is running Only start engine from operator s seat Before starting machine make sure that there are no persons or obstacles near or under machine 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 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 Disconnect battery ground cable before making adjustments on electrical systems or welding on machine PREPARE FOR EMERGENCIES Be prepared fire starts Keep a first aid kit and fire extinguisher handy Keep emergency numbers for doctors ambulance
52. g oil SAE 20W 50 API SJ or API SH SD PD 43 1 qt 95 L SP PD 54 1 5 qt 1 4 L 4 27 CHARGE SYSTEM If gauge fails to function check charge system With the engine running at full speed voltage should be 13 14 volts across the battery check volt meter If unit is charging replace gauge If not see authorized engine dealer to check alternator 4 28 PANEL FUSE 20 AMP This fuse provides protection for the electrical system If the engine fails to turnover when starting check the AWARNING NEVER USE FUSE WITH A DIFFERENT RATING FROM THAT SPECIFIED SERIOUS DAMAGE TO THE ELECTRICAL SYSTEM OR A FIRE MAY RESULT TURN THE ENGINE SWITCH OFF AND REMOVE THE KEY BEFORE CHECKING OR REPLACING FUSES TO PREVENT ACCIDENTAL SHORT CIRCUITING When frequent fuse failure occurs it usually indicates a short circuit or an overload in the electrical system See your authorized engine dealer for repair 4 29 ENGINE INSTALLATION GUIDELINES When installing new or reworking used diesel engines this list of guidelines should be strictly adhered to Following these guidelines should prevent damage to the electrical system of diesel engines A Always disconnect the positive cable from the battery before performing any work on the machine that involves welding or working on the electrical system Avoid jump starting a diesel engine Either change the battery or remove the positive cable and charge the battery Do not alter or
53. g which connect the air cleaner and engine Squeeze dust unloader valve A on air cleaner assembly to remove dust deposits If clogged remove and clean the dust unloader valve Replace if damaged IMPORTANT Do not operate engine without the dust unloader valve 24 3 OPERATION AWARNING BEFORE STARTING ENGINE IN A CONFINED BUILDING INSTALL PROPER OUTLET EXHAUST VENTILATION EQUIPMENT ALWAYS USE SAFETY APPROVED FUEL STORAGE AND PIPING NEVER RUN THE ROLLER WITHOUT THE PANELS IN PLACE OR SEVERE PERSONAL INJURY MAY OCCUR 3 10 BEFORE STARTING Check for proper fluid levels engine oil coolant fuel and hydraulic oil Check the air cleaner Check throttle levers and controls for smooth operation Check seat belt horn and back up alarm operation 3 11 TO START Operator must always be seated and seat belt must be worn Forward reverse must be in NEUTRAL position and eccentric switch should be in OFF position Throttle should be set at idle Turn key clockwise until the engine cranks over Release the key when the engine starts DO NOT crank engine for more than 20 seconds at a time Check all gauges for normal engine operation If operation is not normal stop the engine and determine the cause NOTE If temperature is below 0 C 32 F it may be necessary to use cold weather starting aid See Cold Weather Starting later in this section AWARNING DO NOT USE STARTING FLUID ET
54. h Button Intake Heater Relay 70 Amp Switch Eccentric Light 12V Red Relay Timer 2 Sec Control Fwd Revs Coil Eccentric Valve Coil Brake Valve Alarm back up Battery 24F 800C CA Hourmeter Cable Battery Red 21 Cable Battery Blk HH pp 5 14 Decal Identification EAR PROTECTION REQUIRED a engine amp extinguish all flames amp smoking materials before refueling Use a satety can 5 14 Decal Identification d 8 3 Description Description 2 DECAL WARNING DIESEL DECALEAR PROTECTION DECALTANKLOGOS DECAL TIE DOWN ONLY DECALWARNING PINCH POINT INSTRUCTIO NS HYD FILTER DECAL STONE EAGLE 21 1 2 DECALMAINT C HART RHINO DECAL RHINO DASH DECAL BACK UP ALARM DECAL STRIPES DECAL G REASE WEEKLY DECALCONTROL DECAL THRO TILE DEC AL HYDRAULIC FLUID DECAL INSTRUM ENT P 1 2 3 4 5 REMARK Not Shown 5 14 Decal Identification Contd 2 i i 1 DO KOT USE STARTING FLUID ETHER ENGINE 15 EQUIPPED WITH HEATER AN EXPLOSION OR BO USE STARTING FLUID ETHER ENGINE 15 EDUIPPED FIRE MAY RESULT REFER TO OWNER S MANUAL WITH INTAKE HEATER AN EXPLOSION OR FIRE MAY RESULT FOR COLD STARTING INSTRUCTIONS FOR COLO WEATHER STARTING SEE INSTRUCTIONS BELOW 1 Press HEATE
55. horized servicing dealer or engine distributor Adjust belt tension or replace belts Clean and tighten loose connections See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor See your authorized servicing dealer or engine distributor Use proper viscosity oil Clean and tighten loose connections Clean and tighten connections See your authorized servicing dealer or engine distributor Replace fuse 4 MAINTENANCE 4 37 SERVICE RECORD Model No Roller 5 N Engine S N Record Hours and Date s of Maintenance Below Engine Oil and Filter Hydraulic Oil Filter and Breather Engine Coolant Air Cleaner Water Separator Fuel Filter Fan Altemator Belt Grease Fittings Battery Crankcase Vent Tube Valve Clearance Engine RPMS Fuel Injectors Fuel Tank Fuel Lines Hydraulic Hoses Connections Forward Reverse Neutral Interlock Control Cables Ecc entric s entric Housing Oil Change System Panel Fuse Hardware RO PS Seat Belts Scra pers 5 EXPLODED VIEWS WITH PARTS 5 9 L ST Exploded Views with Parts Hardware Key Torque Charts and Guidelines Drum Assembly Main Frame Radiator Engine Mount Air Cleaner Control
56. ies check electrolyte level Fill each cell to bottom of filler neck with distilled water Keep batteries clean by wiping them with a damp cloth Keep all connections clean and tight Remove any corrosion and wash terminals with a 40 4 MAINTENANCE solution of I part baking soda and 4 parts water Tighten all connections NOTE Coat battery terminals and connectors with a mixture of petroleum jelly and baking soda to retard corrosion 3 Keep battery fully charged especially during cold weather Ifa battery charger is used turn charger off before connecting charger to battery ies Attach POSITIVE battery charger lead to POSITIVE battery post Then attach NEGATIVE battery charger lead to a good ground Once a month check the battery for proper charge of 12 5 volts Check for proper fluid level Use distilled water when adding and run 30 minutes to mix Clean battery posts and terminals Disconnect battery cables before charging to avoid damage to the electrical system AWARNING 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 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
57. illed Loosen temperature sending unit fitting at rear of cylinder head to allow air to escape when filling system Retighten fitting when all the air has been expelled 3 Test the coolant solution at 600 hours or 12 month intervals and whenever excessive coolant is lost through leaks or overheating to ensure the necessary protection Coolant test strips are available from your John Deere dealer These test strips provide a simple effective method to check the freeze point and additive levels of your engine coolant After 600 hours or 12 months of engine operating time recharge your engine coolant with the recommended amount see label on container of 16004 TY 16005 Liquid Coolant Conditioner NOTE TY16004 TY 16005 Liquid Coolant Conditioner is a non chromate inhibitor and should be used only with low silicate ethylene glycol base antifreeze It does not protect the cooling system from freezing See Adding Coolant Usually recharging your engine coolant with the recommended amount of TY 16004 or TY 16005 Liquid Coolant Conditioner at 600 hours or 12 months of operation is adequate However with a CoolScan analysis report you will be given a more thorough evaluation of your engine coolant condition along with detailed service recommendations Refer to Engine Manual IMPORTANT Do not add supplemental coolant additives when the cooling system is drained and refilled with John Deere ANTIFREEZE SUMMER COOLANT or J
58. ing 5 14 Decal Identification CALIFORNIA PROPOSITION 65 WARNING FOREWORD These instructions include Safety regulations Operating instructions Maintenance instructions These instructions have been prepared for operation on the construction site and for the maintenance engineer These instructions are intended to simplify operation of the machine and to avoid malfunctions through improper operation Observing the maintenance instructions will increase the reliability and service life of the machine when used on the construction site and reduce repair costs and downtimes Always keep these instructions at the place of use of the machine Only operate the machine as instructed and follow these instructions Observe the safety regulations as well as the guidelines of the civil engineering trade association Observe safety rules for the operation of equipment and the pertinent regulations for the prevention of accidents Stone Construction Equipment Inc is not liable for the function of the machine when used in an improper manner and for other than the intended purpose Operating errors improper maintenance and the use of incorrect operating materials are not covered by the warranty The above information does not extend the warranty and liability conditions of business of Stone Construction Equipment Inc Warranty Information Please enter the following data This will help expedite any service
59. ing connections Reversed polarity will damage electrical system Always connect positive to 41 4 MAINTENANCE positive and negative to ground Always use 12 volt booster battery for 12 volt electrical systems 1 Connect booster battery or batteries to produce the required system voltage for your engine application NOTE To avoid sparks DO NOT allow the free ends of jumper cables to touch the engine Connect one end of jumper cable to the POSITIVE post of the booster battery Connect one end of jumper cable to the POSITIVE post of the battery connected to starter Connect one end of the other jumper cable to the NEGATIVE post of the booster battery ALWAYS complete the hook up by making the last connection of the NEGATIVE cable to a good ground on the engine frame and away from the battery ies Start the engine Disconnect jumper cables immediately after engine starts Disconnect NEGATIVE cable first 4 16 ENGINE CRANKCASE VENT TUBE Remove and clean every 600 hours or 12 months If you operate the engine in dusty conditions clean the tube at shorter intervals 1 Remove and clean crankcase vent tube 2 Install the vent tube Be sure the O ring fits correctly in the rocker arm cover for elbow adapter Tighten hose clamp securely 4 17 ENGINE VALVE CLEARANCE Check adjust at 900 hours then every 1200 hours or 24 months See authorized engine service dealer or refer to Engine Manu
60. iption Qty 2 Transmission Pump Pump Steering Eccentric Flow Divider Combiner 33 67 Filter Hydra ulic Element Filer Control Steering Breather Filler Cylinder Steering 2 5 10 Wheelmotor Rear Wheelmotor Front with Brake Valve Priority Steering Motor Eccentric Strainer 25G PM Manifold Eccentrics Valve Blade Cylinder Blade 2x8 Flow Divider Combiner 50 50 Valve Brake HN N H CoolerOil NING LIGHT OW DIL PRESSURE 1I COOLANT TEMP 2 WHT 12 INTAKE HEATER RED ORG GND 10 WHT TIMER RELAY GROUND F R BILT CHORN MTG BOLT 1 4 x PSI BRN W ED amp ORG WIRE ED k ORG WIRE GHT RE B ED amp ORG WIRE ACC SENDIR SENDIR SELAY BTM NDID FROW TERNINAL O WYN N N N N WN e O 0 O vu Description Volt Meter Gage Temp Gage Oil PSI Key Switch Hamess Wire Sendor Temp SendorOil PSI Relay Starter Holder Fuse Fuse 20A Pus
61. low air to escape when filling system 36 4 MAINTENANCE IMPORTANT When adding coolant to the system use the appropriate coolant solution Coolant 50 50 mixture of antifreeze distilled water meeting ASTM 4985 ASTM D5345 pre diluted coolant or John Deere COOL GARD 50 50 mixture provides protection to 34 F 37 C Do not overfill cooling system A pressurized system needs space for heat expansion without overflowing at top of radiator 2 Fill until coolant level touches bottom of radiator filler neck Tighten fitting when air has been expelled from system 4 8 3 Disposing of Coolant Improperly disposing of engine coolant can threaten the environment and ecology Use leakproof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center or from your dealer 4 9 AIRCLEANER 4 9 1 Air Cleaner Service IMPORTANT Do not operate engine without the dust unloader valve For daily inspection refer to the Operating section of this manual Clean the primary outer filter element every 100 hours IMPORTANT Always replace secondary safety inner filter elements DO NOT attempt to clean them Do not blow air from outside portion of filter with air nozzle
62. n Deere performance 42 4 MAINTENANCE specifications Only qualified technicians should attempt fuel injector diagnose Fuel injection nozzles are usually removed and tested or replaced when there is a noticeable loss of power or excessive smoking after break in period For detailed testing and diagnostic information on fuel system refer to John Deere Technical Manual P N 55321 4 191 Test Fuel Injection Nozzles engine running 1 Operate engine at intermediate speed and no load 2 Slowly loosen the fuel pressure line at one of the nozzles until fuel escapes at the connection fuel not opening nozzle valve NOTE The injection nozzle before and or after nozzle being checked could be the faulty nozzle Ifengine speed changes the injection nozzle is probably working satisfactory If engine speed does not change a nozzle is faulty and must be checked and repaired or replaced Repeat test for each remaining nozzle assembly Remove faulty injection nozzles and see authorized engine dealer or replace with new 4 20 FUEL TANK Drain and flush the fuel tank every year AWARNING HANDLE FUEL CAREFULLY DO NOT FILL THE FUEL TANK WHEN ENGINE IS RUNNING DO NOT SMOKE WHILE FILLING FUEL TANK OR SERVICING FUEL SYSTEM THE FUEL TANK IS VENTED THROUGH THE FILLER CAP IF A NEW FILLER CAP IS REQUIRED ALWAYS REPLACE IT WITH AN ORIGINAL VENTED CAP Fill fuel tank at the end of each day s oper
63. n to operate this roller safely Do not articulate on grades larger than 15 roller may tip over Do not operate across the sides of hills roller may tip over Do not operate at the edge of mats or roads roller may tip over Do not stand Be seated with seat belt on when roller is running Do not park the roller on hills Always turn off engine and apply brake before dismounting Caution Escaping hydraulic fluid under pressure can have sufficient force to penetrate the skin causing serious personal injury Hydraulic system produces high pressures incorrect hose replacement can cause serious personal injury When performing service refer to Operator s Manual for hose identification and connections Hydraulic fluid escaping under pressure from a very small hole can be almost invisible Use a piece of cardboard or wood to search for possible leaks Never use your hands to detect pressure leaks Hydraulic tank temperature can reach 180 F maximum SERVICE COOLING AND HYDRAULIC SYSTEMS SAFELY Pressurized release of fluids from hydraulic or coolant systems can cause serious burns 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 Never perform any work on the roller while it is running Before working on the roller stop the engine and disconnect the spark plug wire s to prevent accidental starting block drums to pr
64. ne connection Tighten return line connector to 16 Nm 12 Ib ft Leave hand primer in the inward position toward cylinder block 4 10 5 Bleeding at Fuel Injection Nozzles 1 Energize the electronic fuel shut off solenoid turn ignition key to ON position 39 4 MAINTENANCE Using two open end wrenches loosen fuel line connection at injection nozzle Crank engine over with starting motor but do not start engine until fuel free from air bubbles flows out of loosened connection Retighten connection to 27 Nm 20 Ib ft Repeat procedure for remaining injection nozzles if necessary until all air has been removed from fuel system If engine still will not start see your authorized servicing dealer or engine distributor 4 11 FAN ALTERNATOR BELT Low belt tension causes slippage resulting in excessive cover wear burn spots overheating or slip and grab causing belt breakage High belt tension causes belt heating and excessive stretch as well as damage to drive components such as pulleys and shafts V belts should ride on the sides of standard pulleys not on the bottom of the groove Standard V belt tension be checked with JDG529 Tension Gauge arrow or equivalent gauge 1 Inspect belts for cracks fraying or stretched out areas Replace if necessary 2 Using either JDG529 Tension Gauge or belt tension tester and straightedge check tension of warm belts For standard V
65. ne Coolant 4 8 3 Disposing of Coolant Air Cleaner 4 9 1 Air Cleaner Service 4 9 2 Air Cleaner Replacement 4 9 3 Element Storage Fuel Filter 4 10 1 Water Separator 4 10 2 Fuel Filter Replacement 4 10 3 Bleeding Fuel System 4 10 4 Bleeding at Fuel Injection Pump 4 10 5 Bleeding at Fuel Injection Nozzles Fan Alternator Belt Grease Fittings Frame Hinge Blade Pins 4 15 1 Servicing Battery 4 15 2 Battery Installation 4 15 3 Charging Jumping Battery Engine Crankcase Vent Tube Engine Valve Clearance Emission Regulation Engine RPM Fuel Injectors 4 19 1 Test Fuel Injection Nozzles Fuel Tank Fuel Lines Hydraulic Hoses Connections Forward Reverse Neutral Adjustment Neutral Interlock Control Cables Forward Reverse Throttle Blade Eccentrics 4 26 1 Eccentric Housing Oil Charge System Panel Fuse 20 AMP Engine Installation Guidelines Engine Mounting Hardware 4 31 1 Loctite Roll Over Protective Structures ROPS 4 32 1 Maintenance of ROPS Seat Belts Inspection amp Repair Horn Back up Alarm 4 33 1 Back up Alarm Switch Scrapers Troubleshooting Electrical Troubleshooting Service Record SECTION 5 EXPLODED DIAGRAMS amp PARTS LIST 5 1 Hardware Key 5 2 Torque Charts and Guidelines 53 Drum Assembly 5 4 Main Frame 5 5 Radiator Engine Mount 5 6 Engine 5 7 Air Cleaner 5 8 Controls 5 9 Drive System Hydraulics 5 10 Steering Eccentric System Hydraulics 5 11 Blade 5 12 Hydraulic Schematic 5 13 Wir
66. ns When cleaning machine caution should be used to secure unit around regulator area Direct spraying of the regulator is not good Regulator should be covered 3 32 TOWING BYPASS or protected if direct spraying will happen Excessive water pressure may also loosen wire connections or start terminals corroding After AWA R N N G cleaning all terminals should be dried if wet and NEVER PUSH OR PULLTHE ROLLER WITH THE connections checked for proper seating ENGINE OFF WHEN ENGINE ISNOT RUNNING THE BRAKE IS APPLIED WHEN THE ENGINE 3 29 ECCENTRICS IS RUNNING AND THE FORWARD REVERSE LEVER IS IN NEUTRAL THE BRAKE WILL When vibratory compaction is necessary engage APPLY WITHIN 2 SECONDS eccentrics by pushing the vibration switch to the ON position For best performance run engine at full In an emergency or during a breakdown it may be rpm The eccentrics should be turned off whenever necessary or desirable to tow the roller This may be the roller is stopped or stopped to change direction accomplished by mechanically releasing the brake and Do not run the eccentric on any non yielding surface bypassing the transmission pump Ifthese procedures such as concrete or aged asphalt are followed carefully the roller may be moved short distances at LOW speed without running the engine 3 30 COMPACTION TIPS The brake is located in the front wheel motor which Avoid sharp turns steer gradually If articulation is a drives the drum of the roller There i
67. ohn Deere COOL GARD ALWAYS maintain coolant at correct level and concentration DO NOT operate engine without coolant for even a few minutes If frequent coolant makeup is required the glycol concentration should be checked with JT05460 Refractometer to assure that the desired freeze point is maintained Follow manufacturer s instructions provided with Refractometer Water may be used as coolant in emergency situations only Foaming hot surface aluminum and iron corrosion scaling and cavitation will occur when water is used as the coolant even when coolant conditioners are added Drain cooling system and refill with recommended glycol base engine coolant as soon as possible 4 8 1 Replacing Engine Coolant Every 1200 hours or 24 months the coolant should be replaced The coolant system should also be flushed and pressure tested Refer to Engine Manual 4 8 2 Adding Coolant CAUTION Explosive release of fluids from pressurized cooling system can cause serious burns 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 IMPORTANT Never pour cold liquid into a hot engine as it may crack cylinder head or block DO NOT operate engine without coolant for even a few minutes Air must be expelled from cooling system when coolant is added 1 Loosen temperature sending unit fitting at rear of cylinder head to al
68. olant is required see Adding Coolant in the Maintenance section of this manual IMPORTANT Do not overfill radiator Refer to Coolant Maintenance if additional coolant is required Never pour cold liquid into a hot engine as it may crack cylinder head or block DO NOT operate engine without coolant for even a few minutes If coolant leaks or abnormal temperature is detected contact a service technician immediately NOTE It is normal for a small amount of leakage to occur as the engine cools down and parts contract Excessive coolant leakage may indicate the need to replace the water pump seal Contact your engine distributor or servicing dealer for repairs 3 8 VISUAL INSPECTION Make a thorough inspection of the engine compartment daily Look for oil or coolant leaks worn fan belt loose connections and trash build up Remove trash build up and have repairs made as needed if leaks are found NOTE Wipe all fittings caps and plugs before performing any maintenance to reduce the chance of system contamination Air intake system hoses and connections for cracks and loose clamps Fan belt for cracks breaks or other damage Water pump for coolant leaks 3 9 AIR CLEANER IMPORTANT The air intake system must not leak Any leak no matter how small may result in engine failure due to abrasive dirt and dust entering the intake system 1 Inspect all intake hoses piping for cracks 2 Check clamps on pipin
69. or bleed fuel system Consult authorized diesel repair station for repair or replacement Clean or replace Bleed fuel line Use cold weather starting aid Use oil of proper viscosity Consult fuel supplier use proper type fuel for operating conditions Drain flush fill and bleed system Replace filter element Turn key switch to OFF then to ON 4 MAINTENANCE 4 35 TROUBLESHOOTING cont d PROBLEM CAUSE REMEDY Engine starts but does not keep running Water dirt in fuel Drain fuel system Choke remains on Gas Only Adjust choke cable Clean choke linkage Carburetor improperly adjusted Gas Adjust as per Engine Manual Only Dirty fuel injectors Diesel Only Service or replace Injection pump drawing in air Diesel Check fuel lines or replace Only Roller won t move forward or reverse Objects in front of drums Remove Unit in bypass Check bypass valve Loose or broken forward reverse linkage Readjust linkage or replace worn arm linkage Loose or broken chain Make sure chain is on sprocket Adjust tension or replace if chain shows excessive war Loose or broken transmission belts Replace and or tighten Low hydraulic oil Check oil level gauge Add if required Unit lacks power moving forward but Improperly adjusted forward reverse Adjust linkage so that lever travel is the okay in reverse or vice versa linkage same in either direction from neutral Unit lacks power
70. primary outer element every 600 hours 1 Remove air cleaner cover 37 4 MAINTENANCE Remove primary outer element only Thoroughly clean all dirt from inside filter housing Air cleaner has a rubber dust unloader valve on the air cleaner Squeeze valve tip to release any trapped dirt particle IMPORTANT Remove secondary safety inner element ONLY for replacement DO NOT attempt to clean wash or reuse secondary element Replacement of secondary element is usually necessary ONLY when primary element has a hole in it To replace secondary element remove retaining nut and secondary element Immediately replace secondary element with new element to prevent dust from entering air intake system Install new primary element and tighten wing nut securely Install cover assembly and tighten retaining wing nut securely 4 9 3 Element Storage Seal element in a plastic bag and store in shipping container to protect against dust and damage NOTE cleaner element MUST BE DRY before storing in plastic bag 4 10 FUEL FILTER 4 10 1 Water Separator Fuel filter is equipped with a water drain plug check drain every 50 hours or 2 weeks NOTE Drain water into a suitable container and dispose of properly 1 Loosen drain plug at bottom of fuel filter two or three turns 2 Loosen air bleed plug two full turns on fuel filter base and drain water from bottom until fuel starts to drain out When fu
71. rEccentric REMARK Part Numbers 22820 22821 23015 include Item 7 Not required on blade unit Not Shown Lo lt u engn manuals rhinoY rhdrumas eps 5 3 Drum Assembly Contd Torque Torque Description Qty FT LBS Nm tem Part No Description Qty FT LBS Nm O Ring 1 4 ID X 1 16 CS Seal V RING 6 DIA 1 K 80474 53 8 16 1 1 4 5 ZN 31 1 80043 WSHR 3 8 WRO TZN Kit Brake Release 1 80056 NUINY 3 8 16 ZN Scraper POLY SD43 2 80058 WSHRL 3 8 MRD SPLIT ZN Scraper POLY SD54 2 80643 HHCS 3 8 16 X 7 GR5 ZN BarMount PIVOT 4 80405 HHCS 1 2 13 X2 3 4 GR5 ZN 80681 SHCS 5 8 11X1 1 2 BLK HHCS 1 2 13 X 1 3 4 GR5 ZN 80337 WSHRL 5 8 MED SPLIT ZN HHCS 1 2 13 X 1 3 4 GR5 ZN 80695 HHCS 5 8 11 X2 GR5 ZN HWHST 5 16 18 X 1 ZN 80355 WSHR 5 8 SAE ZN HWHST 5 16 18 X 1 ZN 80082 NUTNY 5 8 11 ZN WSHRL 1 2 MED SPLITZN 80051 NUTNY 1 2 13 ZN WSHRL 1 2 MED SPLITZN 80699 HHCS 5 8 11 X 3 1 4 GR5 ZN WSHRL 1 2 MED SPLITZN 80113 HHCS 1 2 13 X 3 4 ZN SHCS 1 2 13X2 1 2 4 80343 WSHR 1 2 SAE ZN WSHRL 5 16 MED SPLITZN 80343 WSHR 1 2 SAE ZN SHCS 5 16 18 X1 1 4 BLK 80343 WSHR 1 2 SAE ZN NUTFL 1 2 20 ZN 80694 HHCS 3 8 13X4 1 2 GR5 N NUTFL 1 2 20 ZN 80578 HHCS 1 2 13 X GR5 ZN NUTFL 1 2 20 ZN 80641 HHTB M12 X 100MM GR8 8 ZN WSHR 17 32 ID X 1 1 16 ZN 80700 NUTFX M12 ZN HHCS 1 2 20 X 1685 ZN 26326 WSHR
72. rigerants 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 19 3 OPERATION 3 OPERATION 3 1 INTRODUCTION AND OPERATING PRINCIPLE This roller is ergonomically engineered to optimize operator interface with the total machine it s really user friendly Besides good visibility to the roll edge as well as the work surface you ll find that the controls are exactly in the right places for maximum comfort And it is very convenient to monitor all the consumables fuel hydraulic oil etc Our common sense approach to servicing is a valuable benefit Thanks to our modular design everything that needs servicing is located behind one of the easy access service panels or is under the rear cowl For maneuverability and productivity nothing beats the proven performance of center point articulation Because the drum and tires track each other exactly tight turns are achieved smoothly The roller is equipped with full positive traction front to rear and side to side which keeps the roller moving through various conditions There s power steering a feature no operator wants to be without A variable hydrostatic drive system provides infinitely variable
73. s Drive System Hydraulics Steering Eccentric System Hydraulics Hydraulic Schematic Decal Identification 5 1 HARDWARE KEY HHCS HHCS GRS HHCS GR8 HWHST SHSHB im im SHCS FHSCS SHSS CUP PT THD ROD 5 hw Vm ETT WSHR WRUT WSHR BELLEVILLE WSHRL ei o 8 o 8 9 B NTFXJ ZN ZINC PLATED BLK BLACK OXIDE FINISH 59 que Charts and Guidelines Lm Do not use these values if a different torque value or tightening procedure is given for a specific application Torque values listed for general use Check tightness of fasteners periodically Shear bolts are designed to fail under predertermined loads Always replace shear bolts with identical grade Fasteners should be replaced with the same or higher grade If higher grade fasteners are used these should only be tightened to the strength of the original Make sure fasteners threads are clean and that you properly start thread engagement This will prevent them from failing when tightening SAE GRADE 5 SAE GRADE 8 Coarse Thread Zinc Plated Coarse Thread Zinc Plated SIZE TORQUE SIZE TORQUE ft lbs Nm ft lbs Nm 1 4 20 250 6 8 1 4 20 250 9 12 5 16 18 3125 13 18 5 16 18 3125 18 24 3 8 16 375 23 31 3 8 16 375 33 45 7 16 14 4375 37 50 7 16 14 4375 52 70 1 2 13 500 57 77 1 2 13 500 80 108 9 16 12 5625 82 9 16
74. s an access hole new concept we suggest the operator take 20 minutes the front frame to assist in releasing the brake Refer to or so to get used to the feel of the unit the Drum Assembly 39 22770 Kit Bypass to identify these parts The threaded hole in the center of the Recommended compaction speed should be at wheel motor requires a M12 bolt long enough to extend 3 m p h or less to achieve a uniform compaction beyond the frame when fully engaged A bolt washer and nut is included in a separate package for this 28 3 OPERATION purpose Fully install the nut and washer on the bolt Insert this assembly through the hole in the frame such that the washer is over the hole with the nut against the outside of this washer Thread the bolt finger tight into the wheel motor to the bottom of the hole Now tighten the nut against the washer until the brake is compressed and released This should require about 44 ft lbs torque Do not torque the bolt Be careful not to over torque beyond releasing the brake The bypass valve is located on the transmission pump The seat and battery plate should be removed for access to the transmission pump The bypass valve is controlled by a shaft with cross drilled holes and maybe a slot in the end This shaft may be turned manually to open the valve and allow the motor to turn The valve is fully open with two revolutions of the shaft DO NOT OPEN VALVE PAST TWO TURNS The valve mus
75. s clear drum and pads all the way around the drum To adjust loosen mounting bolts and slide scraper in or out check clearance and retighten 47 4 MAINTENANCE PROBLEM Engine Won t Start Engine won t start but cranks over Engine hard to start or will not start or Engine starts but does not keep running 4 35 TROUBLESHOOTING CAUSE Forward Reverse lever not in neutral position Panel fuse blown Loose battery or starter cables Faulty engine starting circuit Faulty or improperly adjusted neutral interlock switch Dirty fuel injectors Diesel Only Petcock plugged Low on fuel Fuel valve closed Fuel filter plugged Exhaust restricted Injection pump not getting fuel or air in fuel system Faulty injection pump or nozzles Fuel lines plugged Air in fuel line Cold weather Crankcase oil too heavy Improver type of fuel Water dirt or air in fuel system Clogged fuel filter Injection pump shut off not reset REMEDY Place lever in neutral position Replace 20A fuse required Check and tighten Check appropriate section in Engine Manual Make sure neutral switch is adjusted properly and wires are all secured Test with ohmmeter Readjust neutral switch Replace if defective Clean or replace Clean or replace Add fuel Open Check fuel filter replace if necessary Check and correct exhaust restriction Check fuel flow at supply pump
76. service hospital and fire department near your telephone 18 2 E A LT H amp SA E E T Y Safety Precautions Starting fluid ether is highly flammable Do not use or an explosion or fire may result WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises Operating equipment safely requires the full attention of the operator Do not wear radio or music headphones while operating machine PREVENT BYPASS STARTING Avoid possible injury or death from engine Do not start engine by shorting across starter terminal Engine will start with drive system engaged if normal circuitry is bypassed Start engine only from operator s seat with seat belt on and forward reverse in neutral DISPOSE OF WASTE PROPERLY Improperly disposing of waste can threaten the environment and ecology Potentially harmful waste used with John Deere equipment includes such items as oil fuel coolant brake fluid filters and batteries Use leakproof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source Air conditioning ref
77. speed control from 0 to 4 mph The eccentric delivers a centrifugal force sufficient to compact all types of soil Superior vibration isolation to the operator is achieved by mounting heavy duty shock mounts between the eccentric and support frames The following instructions were compiled to provide you information on how to obtain long and trouble free use of the roller Periodic maintenance of the roller is essential Read this manual in its entirety and follow the instructions carefully Failure to do so may cause injury to you or a bystander 22 3 OPERATION 3 2 DIESEL FUEL Do not mix oil with fuel The engine has a separate oil reservoir in the crankcase Diesel fuel blend meeting ASTM D915 or 590 and a premium diesel fuel conditioner is recommended AWARNING FUEL IS BOTH TOXIC AND FLAMMABLE DO NOT SMOKE WHILE WORKING WITH FUEL DO NOT USE NEAR OPEN FLAME ALWAYS STOP ENGINE BEFORE REFUELING CLEAN UP SPILLED FUEL BEFORE STARTING AVOID FIRES BY KEEPING ENGINE CLEAN OF ACCUMULATED GREASE AND DEBRIS START STORE AND REFUEL ON LEVEL GROUND TO PREVENT PERSONALINJURY DO NOT RUN UNIT IN AN ENCLOSED NON VENTILATED AREA AVOID PROLONGED BREATHING OF VAPORS AND SKIN CONTACT SERIOUS ILLNESS OR LOSS OF LIFE COULD RESULT KEEP THE VENT HOLE IN FUEL TANK CAP OPEN IF VENT HOLE IS PLUGGED PRESSURE MAY BUILD UP IN TANK CAUSING DANGEROUS SPRAYING OF FUEL WHEN TANK CAP IS REMOVED A VACUUM MAY ALSO BE C
78. t be fully closed for normal operation The torque required to close the valve is only 7 to 10 ft lbs DAMAGE MAY RESULT FROM OVER TORQUING 3 33 STORAGE IMPORTANT The front wheel motor has a rubber plug in the M12 hole to prevent contamination Reinstall the rubber plug after towing 1 Store the roller on level ground with drums blocked and parking brake on Remove the key Operations of roller by untrained persons could result in personal injury During extended storage drums can be coated with any type of oil or grease to prevent rusting Storage instructions for the engine are stated in the Engine Manual and should be carried out 29 4 MAINTENANCE CS 4 1 IMPORTANT The person attempting any of the following maintenance tasks must be authorized to do so and have read and understood all sections within this manual 4 MAINTENANCE 4 2 MAINTENANCE SCHEDULE CHART CHECK ADJUST CLEANREPLACE GINE OWNER S MANUAL BREAK IN 100 HRS RUN ENGINE AT FULL THROTTLE DPERATE ENGINE AT HEAVY LOADS UR BREAK IN PER ONLY J D AREA THE DIPSTICK TY22041 E ADD AREA ON DIPSTICK DO NOT IDLE LONGER THAN 5 MINUTES NGINE ENGINE OWNER MANUA EVE BE WITHIN ARROW D AN AND FIL
79. t shipped prepaid or on an economical transportation basis will be refused b as an alternative to the foregoing modes of settlement the Manufacturer s dealer to repair defective units with reimbursement for expenses except labor and be reviewed with the Manufacturer prior to repair A Warranty Evaluation Form must accompany all warranty claims Except as set forth hereinabove and without limitation of the above there are no warranties or other affirmations which extends beyond the description of the products and the fact hereof or as to operational efficiency product reliability or maintainability or compatibility with products furnished by others In no event whether as a result of breach of contract or warranty or alleged negligence shall the Manufacturer be liable for special or consequential damages including but not limited to Loss of profits or revenues loss of use of the product or any associated product cost of capital cost of substitute products facilities or services or claims of customers No claim will be allowed for products lost or damaged in transit Such claims should be filed with the carrier within fifteen days Effective April 1 1998 202 Stone Construction Equipment Inc Phone 1 800 888 9926 1 716 229 5141 Tough Technology Born To Work 32 East Main Street 150 Fax 1 716 229 2363 The Way It Ought To Be Honeoye NY 14471 0150 www stone equip com e mail
80. tained in approved safety container Do not smoke when refueling or during any other fuel handling operation Do not refuel while the engine is running or while it is still hot If fuel is spilled during refueling wipe it off from the engine immediately and discard the rag in a safe place Do not operate the equipment if fuel or oil leaks exist repair immediately Never operate this equipment in an explosive atmosphere Operator must always be seated with seat belt on when roller is running Never allow more than one person on roller Always turn engine off before dismounting from roller Always apply parking brake when not in use Never park roller on a hill Never operate roller on slope greater than 15 degrees Do not operate the roller in standing water Ear protection required when operating this equipment Exposure to loud noise can cause impairment or loss of hearing HOT SURFACES Muffler engine and engine shroud may be hot Allow all components in the engine compartment to cool before performing any service work Never operate unit in a poorly ventilated or enclosed area Avoid prolonged breathing of exhaust gases Engine exhaust fumes can cause sickness or death 16 2 HEALTH amp SAFETY Safety Precautions Qualified personnel only No untrained operators Serious injury may occur Users must be trained to operate this roller Read the Operator s Manual and Engine Owner s Manual Lear
81. temperature of 1059 221 F Watch coolant temperature gauge Do not place engine under full load until it is properly 25 3 OPERATION warmed up The normal engine coolant temperature range is 82 94 180 202 NOTE It is good practice to operate the engine under a lighter load and at lower speeds than normal for the first few minutes after start up 3 15 PARKING BRAKE AWARNING BLOCK THE DRUMS TO PREVENT ROLLING OF THE MACHINE OR SEVERE PERSONAL INJURY MAY OCCUR NEVER PARK ROLLER ON A HILL When engine is not running the brake is applied When the engine is running and the forward reverse lever is in NEUTRAL the brake will apply within 2 seconds 3 16 BRAKE LIGHT When the key is turned to ON the brake light should come on within 2 seconds Shifting into forward or reverse the light should go out 3 17 TO OPERATE IMPORTANT Follow Manufacturer s Before Starting and Break in procedures on engine Always allow engine to warm up five minutes before applying load Start and apply full throttle Move forward reverse lever slowly forward to gain speed desired The same procedure is for reverse To slow down move forward reverse lever toward NEUTRAL To gain power or speed by moving forward reverse lever slightly off of NEUTRAL will produce the greatest amount of torque Moving the lever all the way forward or reverse will give the greatest amount of speed AWARNI
82. uel Capacity liters 20 gal 757 20 gal 757 20 gal 757 20 gal 757 20 gal 757 20 gal 757 Steering Power Power Power Power Power Power Frame Articulating Oscillating Articulating Oscillating Articulating Oscillating Articulating Oscillating Articulating Oscillating Articulating Oscillating Drive System Positraction Positraction Positraction Positraction Positraction Positraction Eccentric Drive Hydrostatic Hydrostatic Hydrostatic Hydrostatic Hydrostatic Hydrostatic Cooling Water Water Water Water Water Water Parking Brake Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Security Braking Sys Hydrostatic Hydrostatic Hydrostatic Hydrostatic Hydrostatic Hydrostatic Performance Centrifugal Force Kn 12 000 53 38 12 0004 53 38 12 000 53 38 12 000 53 38 12 000 53 38 12 000 53 38 Frequency Hertz 2100 35 2100 35 2100 35 2100 35 2100 35 2100 35 Total Applied Force Kn 14 900 66 28 15 1004 67 17 15 209 67 65 15 4195 68 59 15 808 70 32 16 0755 71 51 Speed low Gear High Gear kilometers hour 0 2 mph 0 3 22 0 4 mph 0 6 44 0 2 mph 0 322 0 4 mph 0 6 44 0 2 mph 0 322 0 4 mph 0 6 44 0 2 mph 0 322 0 4 mph 0
83. ulic oil approximately 20 gallons Use the sight gauge to watch for proper oil level install breather cap IMPORTANT Immediately after completing oil change crank engine for 30 seconds without permitting engine to start This will help insure adequate lubrication to components before engine starts 5 Start engine and run to check for possible leaks 6 Stop engine and replenish hydraulic oil 4 7 HYDRAULIC BREATHER Replace every 800 hours or yearly P N 35483 AWARNING PRESSURIZED RELEASE OF FLUIDS FROM HYDRAULIC SYSTEM CAN CAUSE SERIOUS BURNS SHUT OFF ENGINE ONLY REMOVE BREATHER CAP WHEN COOL ENOUGH TO TOUCH WITH BARE HANDS SLOWLY LOOSEN CAP TO FIRST STOP TO RELIEVE PRESSURE BEFORE REMOVING COMPLETELY 4 8 ENGINE COOLING SYSTEM AWARNING EXPLOSIVE RELEASE OF FLUIDS FROM PRESSURIZED COOLING SYSTEM CAN CAUSE SERIOUS BURNS 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 35 LE 4 MAINTENANCE To check coolant level refer to Operating section of this manual and Engine Manual Inspect cooling system every 600 hours or 12 months 1 Check entire cooling system hoses Replace hoses when hard flimsy or cracked 2 Thoroughly inspect all cooling system hoses Replace hoses when hard flimsy or cracked IMPORTANT Air must be expelled from cooling system when system is ref
84. ydraulic Breather Removal Decal Rhino Towing Decal Maintenance Chart REMARK Not Shown

John Deere rhino pd54 User's Manual

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