John Deere 425, 445 and 455 Lawn and Garden Tractors Technical Manual TM1517 28SEP99

Page
SPECIFICATIONS AND INFORMATION
GENERAL VEHICLE SPECIFICATIONS 10
TORQUE VALUES, NON-STANDARD FASTENERS 10
GASOLINE ENGINE 10
DIESEL ENGINE 11
POWER TRAIN, HYDROSTATIC12
STEERING 12
BRAKES 12
HYDRAULICS 12
METRIC FASTENER TORQUEVALUES 13
INCH FASTENER TORQUE VALUES 14
O-RING SEAL SERVICE RECOMMENDATIONS 15
FACE SEAL FITTINGS WITH INCH STUD ENDS TORQUE 15
FACE SEAL FITTINGS WITH METRIC STUD ENDS TORQUE16
O-RING FACE SEAL FITTINGS 17
O-RING BOSS FITTINGS 17
STRAIGHT FITTING OR SPECIAL NUT TORQUES 18
METRIC FASTENER TORQUE VALUE—GRADE 7 (SPECIAL) 18
GASOLINE 19
4–CYCLE ENGINES 19
GASOLINE STORAGE 19
DIESEL FUEL 20
DIESEL FUEL LUBRICITY 20
DIESEL FUEL STORAGE 20
ENGINE OIL SPECIFICATIONS 21
4–CYCLE DIESEL ENGINE OIL 21
4–CYCLE GASOLINE ENGINE OIL 22
BREAK-IN ENGINE OIL—DIESEL 23
BREAK-IN ENGINE OIL—4-CYCLE GASOLINE 24
HYDROSTATIC TRANSMISSION AND HYDRAULIC OIL 25
HYDROSTATIC TRANSMISSION AND HYDRAULIC OIL 25
GEAR CASE OIL SPECIFICATIONS 26
GEAR CASE OIL26
GEAR TRANSMISSION GREASE SPECIFICATIONS27
GEAR TRANSMISSION GREASE 27
ALTERNATIVE LUBRICANTS 28
SYNTHETIC LUBRICANTS28
LUBRICANT STORAGE 28
MIXING OF LUBRICANTS 28
OIL FILTERS 28
COOLANT SPECIFICATIONS 29
DIESEL AND GASOLINE ENGINE COOLANT29
DIESEL AND GASOLINE ENGINE COOLANT DRAIN INTERVAL 29
SERIAL NUMBER LOCATIONS30
PRODUCT SERIAL NUMBER 30
DIESEL ENGINE SERIAL NUMBER LOCATION30
GASOLINE ENGINE SERIAL NUMBER LOCATION 30
TRANSAXLE SERIAL NUMBER LOCATION30

ENGINE—FD620D, K SERIES
SPECIFICATIONS.3-3
TEST AND ADJUSTMENT SPECIFICATIONS 3-3
REPAIR SPECIFICATIONS 3-4
COMPONENT LOCATION .3-8
ENGINE—FD620D 3-8
THEORY OF OPERATION .3-9
COOLING SYSTEM OPERATION3-9
CARBURETED ENGINE FUEL AND AIR SYSTEM OPERATION—425 3-10
FUEL INJECTION AIR SYSTEM COMPONENTS AND OPERATION—445 3-13
FUEL INJECTOR OPERATION—445 3-14
FUEL PRESSURE REGULATOR OPERATION—4453-14
GOVERNOR OPERATION 3-15
LUBRICATION SYSTEM OPERATION 3-16
THROTTLE BODY OPERATION—445 3-17
TROUBLESHOOTING—425 CARBURETED ENGINES .3-18
TROUBLESHOOTING—425 CARBURETED ENGINES 3-22
TROUBLESHOOTING—445 FUEL INJECTED ENGINES .3-23
DIAGNOSIS—425 .3-28
ENGINE SYSTEM DIAGNOSIS—425 CARBURETED ENGINES 3-28
ENGINE SYSTEM TEST POINTS—425 CARBURETED ENGINES 3-29
DIAGNOSIS—425 .3-34
ENGINE SYSTEM DIAGNOSIS—445 FUEL INJECTED ENGINES3-34
ENGINE SYSTEM TEST POINTS—445 FUEL INJECTED ENGINES3-35
TESTS AND ADJUSTMENTS .3-40
THROTTLE LEVER ADJUSTMENT 3-40
THROTTLE CABLE ADJUSTMENT 3-40
CHOKE ADJUSTMENT3-40
GOVERNOR ADJUSTMENT3-41
SLOW IDLE ADJUSTMENT—425 NON-CARB/EPA ENGINES 3-41
FAST IDLE ADJUSTMENT 3-43
COMPRESSION TEST 3-44
VALVE CLEARANCE ADJUSTMENT 3-44
CRANKCASE VACUUM TEST 3-45
ENGINE OIL PRESSURE TEST (Engines With Oil Pressure Switch Ports) 3-45
ENGINE OIL PRESSURE TEST (Engines Without Oil Pressure Switch Ports) 3-46
FUEL PUMP FLOW TEST FOR CARBURETOR—425 3-47
FUEL PUMP PRESSURE TEST FOR CARBURETOR—4253-47
FUEL PUMP PRESSURE TEST FOR FUEL INJECTION—4453-48
FAN BELT TENSION ADJUSTMENT 3-48
RADIATOR BUBBLE TEST 3-49
RADIATOR CAP PRESSURE TEST 3-49
THERMOSTAT TEST3-49
COOLING SYSTEM TEST 3-49
ENGINE OIL DIPSTICK 3-50
REPAIR 3-51
ENGINE—REMOVAL/INSTALLATION—425 3-51
ENGINE—REMOVAL/INSTALLATION (445) 3-52
CARBURETOR—EXPLODED VIEW 3-53
CARBURETOR—CLEAN AND REBUILD 3-54
COOLANT PUMP—REMOVAL/INSTALLATION 3-55
COOLING FAN AND BRACKET3-56
FUEL INJECTOR—445 3-57
FUEL PRESSURE REGULATOR—445 3-57
FLYWHEEL—REMOVAL/INSTALLATION 3-57
GOVERNOR3-58
THROTTLE BODY REPAIR—445 3-59
CYLINDER HEAD—REMOVAL 3-60
CYLINDER HEAD AND VALVE COMPONENTS 3-60
VALVE, VALVE SEAT, AND GUIDE—INSPECTION3-61
PUSH ROD—INSPECTION 3-62
CYLINDER HEAD—INSTALLATION 3-63
CRANKCASE COVER—DISASSEMBLY 3-63
PISTONS—REMOVAL 3-63
PISTON RINGS—REMOVAL/INSTALLATION 3-64
PISTON RING END GAP 3-64
PISTON RING WEAR3-64
PISTON—INSPECTION3-65
CONNECTING ROD—INSPECTION3-67
CRANKSHAFT AND CONNECTING ROD WEAR3-67
CONNECTING ROD AND PISTON—ASSEMBLY 3-67
CAMSHAFT—REMOVAL/INSTALLATION 3-68
CAMSHAFT BEARINGS 3-69
TAPPETS—REMOVAL/INSTALLATION 3-69
CRANKSHAFT—REMOVAL3-69
CRANKSHAFT—INSPECTION 3-69
CRANKSHAFT AND CONNECTING ROD WEAR3-69
CRANKSHAFT—INSTALLATION3-70
CRANKSHAFT PLAIN BEARINGS 3-70
CRANKSHAFT JOURNAL BUSHING AND SEALS—REPLACEMENT 3-71
CYLINDERS—BLOCK INSPECTION 3-71
CYLINDER BORE—DEGLAZING 3-72
CYLINDER BLOCK—REBORING 3-72
OIL PUMP—REMOVAL/INSTALLATION 3-72
OIL PUMP—DISASSEMBLY, INSPECTION AND ASSEMBLY 3-73

Page
DIESEL ENGINE
SPECIFICATIONS—3TNA72 5
GENERAL SPECIFICATIONS5
TEST AND ADJUSTMENT SPECIFICATIONS 5
REPAIR SPECIFICATIONS 7
OTHER MATERIALS 15
SERVICE PARTS KITS 15
COMPONENT LOCATION 17
DIESEL ENGINE 17
THEORY OF OPERATION 18
DIESEL ENGINE FUEL AND AIR SYSTEM COMPONENTS AND OPERATION 18
COOLING SYSTEM OPERATION20
CRANKCASE BREATHER OPERATION 21
LUBRICATION SYSTEM OPERATION 22
OIL FILTER OPERATION 23
OIL PRESSURE REGULATING VALVE OPERATION 23
TROUBLESHOOTING 25
TROUBLESHOOTING CHART 25
DIAGNOSIS28
ENGINE SYSTEM DIAGNOSIS 28
ENGINE SYSTEM TEST POINTS29
TESTS AND ADJUSTMENTS 31
AIR INTAKE SYSTEM LEAKAGE TEST 31
AIR FILTER RESTRICTION INDICATOR TEST 31
THROTTLE LEVER FRICTION ADJUSTMENT 32
THROTTLE CABLE ADJUSTMENT 32
BLEED FUEL SYSTEM32
SLOW IDLE ADJUSTMENT 33
FAST IDLE ADJUSTMENT—NON-CARB/EPA ENGINES 33
FAST IDLE ADJUSTMENT—CARB/EPA ENGINES 34
FUEL CONTROL SCREW ADJUSTMENT—CARB/EPA ENGINES35
FUEL CONTROL SCREW ADJUSTMENT—NON-CARB/EPA ENGINES 38
FUEL TRANSFER PUMP FLOW TEST 40
FUEL TRANSFER PUMP PRESSURE TEST40
FUEL DRAIN-BACK TEST 41
FUEL INJECTION NOZZLE TEST (PINTLE-TYPE) 41
FUEL SHUTOFF SOLENOID ADJUSTMENT43
INJECTION PUMP TIMING ADJUSTMENT 43
RADIATOR BUBBLE TEST 44
RADIATOR CAP PRESSURE TEST 44
THERMOSTAT OPENING TEST45
COMPRESSION TEST 45
VALVE CLEARANCE CHECK AND ADJUSTMENT 46
VALVE LIFT CHECK 47
COOLANT TEMPERATURE SENSOR TEST 47
COOLING SYSTEM PRESSURE TEST 48
FAN/ALTERNATOR DRIVE BELT ADJUSTMENT 48
ENGINE OIL PRESSURE TEST 49
CAMSHAFT END PLAY CHECK 49
TIMING GEAR BACKLASH CHECK—LATE MODELS 50
CONNECTING ROD SIDE PLAY CHECK 51
CONNECTING ROD BEARING CLEARANCE CHECK51
CRANKSHAFT END PLAY CHECK 52
CRANKSHAFT MAIN BEARING CLEARANCE CHECK 53
REPAIR 54
DIESEL ENGINE—REMOVAL/INSTALLATION 54
COOLANT TEMPERATURE SENSOR 55
THERMOSTAT 55
FUEL INJECTION PUMP 56
FUEL CONTROL AND GOVERNOR LINKAGE 57
FUEL INJECTION NOZZLES61
FUEL INJECTOR CROSS SECTION63
EXHAUST MANIFOLD 64
INTAKE MANIFOLD 64
WATER PUMP 65
FLYWHEEL67
FLYWHEEL HOUSING68
FLYWHEEL PLATE68
ROCKER ARM COVER 69
ROCKER ARM ASSEMBLY 70
TIMING GEAR COVER 72
TIMING GEAR HOUSING 73
IDLER GEAR 74
CYLINDER HEAD AND VALVES 75
VALVE SEATS—GRINDING80
VALVES—LAPPING 80
CAMSHAFT REMOVAL 81
CAMSHAFT INSTALLATION 81
CAMSHAFT INSPECTION/REPLACEMENT 82
CAM FOLLOWERS 84
PISTON-TO-CYLINDER HEAD CLEARANCE—MEASURE 84
PISTON AND CONNECTING ROD 85
CRANKCASE EXTENSION HOUSING 91
CRANKSHAFT REAR OIL SEAL 91
CRANKSHAFT EXTENSION REAR OIL SEAL 92
CRANKSHAFT FRONT OIL SEAL92
CRANKSHAFT AND MAIN BEARINGS 93
CYLINDER BORE 97
OIL PAN AND STRAINER 98
FUEL INJECTION SENSOR AND DIAGNOSTIC LIGHT CIRCUIT SCHEMATIC—
445 (S.N—070000) 251
FUEL INJECTION SENSOR AND DIAGNOSTIC LIGHT CIRCUIT SCHEMATIC—
445 (S.N070001— ) 252
FUEL INJECTION SENSOR AND DIAGNOSTIC LIGHT CIRCUIT DIAGNOSIS—445
(S.N—070000) 254
FUEL INJECTION SENSOR AND DIAGNOSTIC LIGHT CIRCUIT TEST POINTS—
445 (S.N—070000) 255
FUEL INJECTION SENSOR AND DIAGNOSTIC LIGHT CIRCUIT DIAGNOSIS—
445 (S.N070001— ) 260
FUEL INJECTION SENSOR AND DIAGNOSTIC LIGHT CIRCUIT TEST POINTS—
445 S.N070001— )261
COMPONENT LOCATION—455 267
COMPONENT LOCATION—455 (S.N—070000)267
COMPONENT LOCATION—455 (S.N070001— ) 268
LEGENDS FOR ELECTRICAL COMPONENTS—455 269
LEGEND FOR ELECTRICAL COMPONENTS—455 (S.N—070000) 269
LEGEND FOR ELECTRICAL COMPONENTS—455 (S.N070001— )269
ELECTRICAL WIRING HARNESSES—455 270
MAIN WIRING HARNESS (W1)—455 EARLY MODELS 270
MAIN WIRING HARNESS (W1)—455 LATE MODELS (S.N—031477) 271
MAIN WIRING HARNESS (W1)—455 (S.N031478—070000) 272
MAIN WIRING HARNESS (W1)—455 (S.N070001— )273
REAR PTO WIRING HARNESS (W2)—455 EARLY MODELS 274
REAR PTO WIRING HARNESS (W2)—455 LATER MODELS 275
ELECTRICAL SCHEMATICS—455276
MAIN ELECTRICAL SCHEMATIC—455 (S.N—070000) 276
MAIN ELECTRICAL SCHEMATIC—455 (S.N070001— ) 277
TROUBLESHOOTING—455 278
ELECTRICAL SYSTEM QUICK TEST—455 278
ELECTRICAL SYSTEM TROUBLESHOOTING CHART 279
DIESEL MODULE—455281
CIRCUIT OPERATION AND DIAGNOSIS—455 282
POWER CIRCUIT OPERATION—455 (S.N—070000) 282
POWER CIRCUIT OPERATION—455 (S.N070001— ) 282
POWER CIRCUIT SCHEMATIC—455 (S.N—070000) 283
POWER CIRCUIT SCHEMATIC—455 (S.N070001— ) 284
POWER CIRCUIT DIAGNOSIS—455 (S.N—070000) 286
POWER CIRCUIT TEST POINTS—455 (S.N—070000) 287
POWER CIRCUIT DIAGNOSIS—455 (S.N070001— ) 288
POWER CIRCUIT TEST POINTS—455 (S.N070001— ) 289
CRANKING CIRCUIT OPERATION—455 (S.N—070000)290
CRANKING CIRCUIT OPERATION—455 (S.N070001— ) 290
CRANKING CIRCUIT SCHEMATIC—455 (S.N—070000)291
CRANKING CIRCUIT SCHEMATIC—455 (S.N070001— ) 292
CRANKING CIRCUIT DIAGNOSIS—455 (S.N—070000)294
CRANKING CIRCUIT TEST POINTS—455 (S.N—070000) 295
CRANKING CIRCUIT DIAGNOSIS—455 (S.N070001— ) 298
CRANKING CIRCUIT TEST POINTS—455 (S.N070001— ) 299
CHARGING CIRCUIT OPERATION—455 (S.N—070000) 302
CHARGING CIRCUIT OPERATION—455 (S.N070001— ) 302
CHARGING CIRCUIT SCHEMATIC—455 (S.N—070000) 303
CHARGING CIRCUIT SCHEMATIC—455 (S.N070001— ) 304
CHARGING CIRCUIT DIAGNOSIS—455 (S.N—070000) 305
CHARGING CIRCUIT TEST POINTS—455 (S.N—070000)306
CHARGING CIRCUIT DIAGNOSIS—455 (S.N070001— ) 307
CHARGING CIRCUIT TEST POINTS—455 (S.N070001— ) 308
PTO CIRCUIT OPERATION—455 (S.N—070000) 309
PTO CIRCUIT OPERATION—455 (S.N070001— )310
PTO CIRCUIT DIAGNOSIS—455 (S.N—070000) 314
PTO CIRCUIT TEST POINTS—455 (S.N—070000)315
PTO CIRCUIT DIAGNOSIS—455 (S.N070001— ) 320
PTO CIRCUIT TEST POINTS—455 (S.N070001— )321
INDICATOR LIGHTS, GAUGES, HOURMETER, AND LIGHTS CIRCUIT
OPERATION—455 (S.N—070000) 326
INDICATOR LIGHTS, GAUGES, HOURMETER, AND LIGHTS CIRCUIT
OPERATION—455 (S.N070001— ) 327
INDICATOR LIGHTS, GAUGES, HOURMETER, AND LIGHTS CIRCUIT
SCHEMATIC—455 (S.N070001— ) 330
OIL PRESSURE LIGHT AND HOURMETER CIRCUIT DIAGNOSIS—455 332
OIL PRESSURE LIGHT AND HOURMETER CIRCUIT TEST POINTS—455 333
COOLANT TEMPERATURE GAUGE CIRCUIT DIAGNOSIS—455 334
COOLANT TEMPERATURE GAUGE CIRCUIT TEST POINTS—455 335
FUEL GAUGE CIRCUIT DIAGNOSIS—455 336
FUEL GAUGE CIRCUIT TEST POINTS—455 337
LIGHTS CIRCUIT DIAGNOSIS—455 338
LIGHTS CIRCUIT TEST POINTS—455 339
FUEL PUMP CIRCUIT OPERATION—455 (S.N—070000) 340
FUEL PUMP CIRCUIT OPERATION—455 (S.N070001— ) 340
FUEL PUMP CIRCUIT SCHEMATIC—455 (S.N—070000) 341
FUEL PUMP CIRCUIT SCHEMATIC—455 (S.N070001— ) 342
FUEL PUMP CIRCUIT DIAGNOSIS—455 (S.N—070000) 344
FUEL PUMP CIRCUIT TEST POINTS—455 (S.N—070000) 345
FUEL PUMP CIRCUIT DIAGNOSIS—455 (S.N070001— ) 348
FUEL PUMP CIRCUIT TEST POINTS—455 (S.N070001— ) 349
FUEL SHUT-OFF SOLENOID CIRCUIT OPERATION—455 (S.N—070000) 353
FUEL SHUT-OFF SOLENOID CIRCUIT OPERATION—455 (S.N070001— ) 354
FUEL SHUT-OFF SOLENOID CIRCUIT SCHEMATIC—455 (S.N—070000) 355
FUEL SHUT-OFF SOLENOID CIRCUIT SCHEMATIC—455 (S.N070001— ) 356
FUEL SHUT-OFF SOLENOID CIRCUIT DIAGNOSIS—455 (S.N—070000) 358
FUEL SHUT-OFF SOLENOID CIRCUIT TEST POINTS—455 (S.N—070000) 359
FUEL SHUT-OFF SOLENOID CIRCUIT DIAGNOSIS—455 (S.N070001— ) 362
FUEL SHUT-OFF SOLENOID CIRCUIT TEST POINTS—455 (S.N070001— ) 363
GLOW PLUG AND LIGHT CIRCUIT OPERATION—455 (S.N—070000) 366
GLOW PLUG AND LIGHT CIRCUIT OPERATION—455 (S.N070001— )366
GLOW PLUG AND LIGHT CIRCUIT SCHEMATIC—455 (S.N—070000) 367
GLOW PLUG AND LIGHT CIRCUIT SCHEMATIC—455 (S.N070001— )368
GLOW PLUG AND LIGHT CIRCUIT DIAGNOSIS—455 (S.N—070000)370
GLOW PLUG AND LIGHT CIRCUIT TEST POINTS—455 (S.N—070000) 371
GLOW PLUG AND LIGHT CIRCUIT DIAGNOSIS—455 (S.N070001— ) 372
GLOW PLUG AND LIGHT CIRCUIT TEST POINTS—455 (S.N070001— ) 373
TESTS AND ADJUSTMENTS 375
COMMON CIRCUIT TESTS375
AIR PRESSURE SENSOR TEST—445376
AIR TEMPERATURE SENSOR TEST—445 377
BATTERY TEST 377
BATTERY CHARGING 378
BATTERY LOAD TEST379
BRAKE SWITCH TEST AND ADJUSTMENT 379
COOLANT TEMPERATURE SENSOR TEST—445380
CONTROL/FUSE MODULE TEST (S.N—070000) 381
CONTROL/FUSE MODULE TEST TABLE (S.N—070000) 382
CONTROL/FUSE MODULE TEST POINTS (S.N—070000) 383
CONTROL/FUSE MODULE TEST (S.N070001— ) 384
CONTROL/FUSE MODULE TEST TABLE (S.N070001— ) 384
CONTROL/FUSE MODULE TEST POINTS (S.N070001— )385
DIESEL CONTROL MODULE TEST—455 388
DIESEL CONTROL MODULE TEST POINTS 390
FUEL INJECTOR TEST—445 391
FUEL INJECTION MODULE TEST—445 391
FUEL SHUT-OFF SOLENOID AMPERAGE TEST—455 391
FUEL TANK SENSOR TEST 392
TESTS AND ADJUSTMENTS 393
GLOW PLUGS TEST—455 393
GROUND CIRCUIT TEST—425 and 445 393
GROUND CIRCUIT TEST—455 394
LIGHTS SWITCH TEST 395
IGNITION COIL TEST 395
OIL PRESSURE SENSOR SWITCH TEST 395
PTO SWITCH TEST (S.N—070000) 396
PTO SWITCH TEST (S.N070001— ) 397
PULSER COIL TEST 397
REGULATED AMPERAGE TEST—455 398
REGULATED VOLTAGE TEST—455 398
UNREGULATED AMPERAGE TEST—455 399
RELAY TEST 399
SEAT SWITCH TEST 400
STARTING MOTOR SYSTEM TEST401
STARTING MOTOR CONDITION 402
STARTER SOLENOID TEST402
STARTING MOTOR AMP DRAW TEST 403
STARTING MOTOR NO-LOAD AMPERAGE AND RPM TEST403
TEST FIELD WINDINGS404
TEST STARTER ARMATURE 404
SPARK PLUG CAP TEST405
SPARK PLUG GAP ADJUSTMENT 405
SPARK TEST406
REPLACE IGNITION COILS—425 and 445 406
REPLACE IGNITION MODULE—425 and 445 407
REPLACE PULSER COILS—425 and 445 407
REPLACE STATOR—425 and 445 407
REPAIR 408
STARTING MOTOR—425 and 445 408
STARTING MOTOR—455 409
STARTING MOTOR GEAR TRAIN AND OVERRUNNING CLUTCH—455411
STARTER SOLENOID—455 412
ALTERNATOR—455 (20-AMP) 413
VOLTAGE REGULATOR—455 (40 Amp)414
ALTERNATOR—455 (40-AMP) 415

Page
HYDROSTATIC POWER TRAIN
SPECIFICATIONS3
GENERAL SPECIFICATIONS3
TEST AND ADJUSTMENT SPECIFICATIONS 3
REPAIR SPECIFICATIONS 3
OTHER MATERIALS 4
SPECIAL OR ESSENTIAL TOOLS 4
SERVICE EQUIPMENT AND TOOLS 4
THEORY OF OPERATION 6
CENTER SECTION AND DIRECTIONAL CONTROL VALVES—REVERSE SYSTEM
OPERATION6
TRANSAXLE OIL FLOW SYSTEM OPERATION 9
EXTERNAL POWER TRAIN SYSTEM OPERATION 10
TRANSAXLE INTERNAL SYSTEM OPERATION13
REAR PTO COMPONENT LOCATION AND OPERATION—OPTIONAL14
TROUBLESHOOTING 16
HYDROSTATIC TRANSMISSION 16
MID-PTO SYSTEM 18
TRANSAXLE 19
DIAGNOSIS20
HYDROSTATIC TRANSMISSION 20
HYDROSTATIC TRANSMISSION TEST POINTS23
MID-PTO SYSTEM 24
TRANSAXLE 25
TRANSAXLE TEST POINTS26
TESTS AND ADJUSTMENTS 27
CHARGE PUMP FLOW AND PRESSURE TEST—AT CHARGE PUMP 27
CHARGE PRESSURE TEST—USING PRESSURE GAUGE (OPTIONAL) 28
HYDRAULIC OIL WARM-UP PROCEDURE29
MID-PTO ENGAGEMENT PRESSURE AND BRAKE TEST 29
TRANSMISSION NEUTRAL ADJUSTMENT 31
TRANSMISSION CONTROL LINKAGE ADJUSTMENT 32
TRANSMISSION LINKAGE FULL FORWARD ADJUSTMENT33
CRUISE CONTROL LINKAGE CHECK AND ADJUSTMENT33
CHARGE PUMP—REMOVAL/INSTALLATION 34
CHARGE PUMP—DISASSEMBLY/ASSEMBLY 34
CONTROL ARM DAMPER—REMOVAL/INSTALLATION 35
CONTROL ARM DAMPER—DISASSEMBLY/ASSEMBLY 36
DIFFERENTIAL (S.N—080000)—DISASSEMBLY/ASSEMBLY 37
DIFFERENTIAL (S.N080001— )—DISASSEMBLY/ASSEMBLY38
DIFFERENTIAL LOCK LINKAGE—INSPECTION 39
DIFFERENTIAL LOCK SHAFT DISASSEMBLY/ASSEMBLY 40
DIFFERENTIAL (FINAL PINION SHAFT)—INSPECTION 40
DIRECTIONAL CONTROL VALVES—REMOVAL/INSTALLATION 40
DIRECTIONAL CONTROL VALVES—
DISASSEMBLY/INSPECTION AND ASSEMBLY 40
HYDROSTATIC PRESSURE RELIEF VALVE (40 LOADER)—INSTALLATION 41
DRIVE SHAFT—REMOVAL/INSTALLATION 41
DRIVE SHAFT—DISASSEMBLY/INSPECTION AND ASSEMBLY 41
FOOT CONTROL LINKAGE—DISASSEMBLY/ASSEMBLY 42
PTO SOLENOID VALVE—REMOVAL/INSTALLATION 43
PTO SOLENOID VALVE—DISASSEMBLY/INSPECTION/ASSEMBLY 43
PTO RELIEF VALVE—REMOVAL/INSTALLATION 44
PTO RELIEF VALVE—DISASSEMBLY/INSPECTION AND ASSEMBLY44
PTO BRAKE—REMOVAL/ INSTALLATION 44
PTO BRAKE—DISASSEMBLY/INSPECTION AND ASSEMBLY 45
PTO DRIVE TRAIN (MID-PTO)—REMOVAL/INSTALLATION 46
PTO DRIVE TRAIN (MID- AND REAR PTO)—REMOVAL47
REAR PTO GEAR CASE—REMOVAL/INSTALLATION49
PTO DRIVE TRAIN (MID- AND REAR- MOUNT PTO)—INSTALLATION 51
PTO CLUTCH—DISASSEMBLY/INSPECTION/ASSEMBLY 52
HYDROSTATIC TRANSMISSION—REMOVAL 53
HYDROSTATIC TRANSMISSION MOTOR—REMOVAL 54
HYDROSTATIC MOTOR—DISASSEMBLY 55
MOTOR CASE ASSEMBLY—DISASSEMBLY/INSPECTION/ASSEMBLY 56
HYDROSTATIC TRANSMISSION MOTOR—ASSEMBLY 56
CENTER VALVE BLOCK—DISASSEMBLY/ASSEMBLY 57
HYDROSTATIC PUMP—INSPECTION 58
REAR AXLE ASSEMBLY—REMOVAL/INSTALLATION 59
REAR AXLE ASSEMBLY (TWO WHEEL STEER MODELS)—DISASSEMBLY/
ASSEMBLY 59
REAR AXLE ASSEMBLY (ALL WHEEL STEER)—DISASSEMBLY/ASSEMBLY60
KNUCKLE HOUSING—DISASSEMBLY/ASSEMBLY 62
TRANSAXLE—REMOVAL/INSTALLATION 63
TRANSAXLE—DISASSEMBLY 64
TRANSAXLE (RIGHT COVER)—DISASSEMBLY/ASSEMBLY 67
TRANSAXLE CASE—INSPECTION 67
TRANSAXLE—ASSEMBLY 68

STEERING
SPECIFICATIONS3
GENERAL SPECIFICATIONS3
TEST AND ADJUSTMENT SPECIFICATIONS 3
REPAIR SPECIFICATIONS 3
SERVICE TEST EQUIPMENT AND TOOLS3
OTHER MATERIAL 3
SERVICE PARTS KITS 3
THEORY OF OPERATION 4
STEERING SYSTEM OPERATION—ALL WHEEL STEER 4
STEERING VALVE OPERATION—NEUTRAL 7
STEERING VALVE OPERATION—TURNING9
STEERING VALVE OPERATION—MANUAL 10
TROUBLESHOOTING 12
STEERING SYSTEM TROUBLESHOOTING CHART 12
DIAGNOSIS14
STEERING SYSTEM 14
STEERING SYSTEM TEST POINTS 15
TESTS AND ADJUSTMENTS 18
HYDRAULIC OIL WARM-UP PROCEDURE18
STEERING VALVE AND CYLINDER LEAKAGE TEST18
TOE-IN ADJUSTMENT —TWO WHEEL STEER 19
TOE-IN ADJUSTMENT (FRONT AXLE)—ALL WHEEL STEER20
TOE-IN ADJUSTMENT (REAR AXLE)—ALL WHEEL STEER 21
REPAIR 22
STEERING COLUMN—REMOVAL/INSTALLATION 22
TILT STEERING ROD—REMOVAL/INSTALLATION23
STEERING VALVE—REMOVAL/INSTALLATION 23
STEERING VALVE—DISASSEMBLY/ASSEMBLY 24
STEERING CYLINDER—REMOVAL/INSTALLATION29
FRONT AXLE—REMOVAL/INSTALLATION 29
FRONT AXLE—DISASSEMBLY/ASSEMBLY 30
REAR STEERING LINKAGE—ALL WHEEL STEER 32
REAR STEERING LINKAGE—REMOVAL 33
REAR STEERING LINKAGE—DISASSEMBLY 33
REAR STEERING LINKAGE—ASSEMBLY 33
REAR STEERING LINKAGE—INSTALLATION 33
STEERING INTERMEDIATE LINKAGE (ALL WHEEL STEER)—REMOVAL/
INSTALLATION34
FRONT AND REAR PIVOTS—DISASSEMBLY/ASSEMBLY 35

Page
BRAKES
SPECIFICATIONS3
GENERAL SPECIFICATIONS3
TEST AND ADJUSTMENT SPECIFICATIONS 3
REPAIR SPECIFICATIONS 3
OTHER MATERIAL 3
SERVICE PARTS KITS 3
COMPONENT LOCATION 4
BRAKE SYSTEM COMPONENT LOCATION 4
THEORY OF OPERATION 5
BRAKE SYSTEM OPERATION5
TROUBLESHOOTING 6
TROUBLE SHOOTING CHART 6
DIAGNOSIS7
BRAKE SYSTEM 7
BRAKE SYSTEM TEST POINTS 8
TESTS AND ADJUSTMENTS 9
BRAKE/DIFFERENTIAL LINKAGE ADJUSTMENT 9
BRAKE/DIFFERENTIAL LINKAGE—DISASSEMBLY/ASSEMBLY 10
REPAIR 11
BRAKES—REMOVAL/INSTALLATION 11
BRAKE LINKAGE—ADJUSTMENT 12
BRAKE/DIFFERENTIAL LINKAGE—DISASSEMBLY/ASSEMBLY 13

Page
HYDRAULICS
SPECIFICATIONS3
GENERAL SPECIFICATIONS3
TEST AND ADJUSTMENT SPECIFICATIONS 3
REPAIR SPECIFICATIONS 3
SPECIAL OR ESSENTIAL TOOLS 4
OTHER MATERIALS 4
SERVICE PARTS KITS 4
THEORY OF OPERATION 6
HYDRAULIC SYSTEM 6
HYDRAULIC COMPONENTS AND OIL FLOW7
HYDRAULIC CONTROL VALVE OPERATION—NEUTRAL 8
HYDRAULIC CONTROL VALVE OPERATION—RAISE 10
HYDRAULIC CONTROL VALVE OPERATION—FLOAT 12
TROUBLESHOOTING 14
TROUBLE SHOOTING CHART 14
DIAGNOSIS16
PRELIMINARY HYDRAULIC SYSTEM INSPECTION 16
HYDRAULIC SYSTEM 17
HYDRAULIC SYSTEM TEST POINTS 18
TESTS AND ADJUSTMENTS 19
HYDRAULIC OIL WARM-UP PROCEDURE19
IMPLEMENT RELIEF VALVE PRESSURE QUICK TEST19
CHARGE PUMP FLOW AND PRESSURE QUICK TEST AT COUPLERS20
LIFT CYLINDER LEAKAGE TEST 21
CONTROL VALVE LEAKAGE TEST 22
CONTROL VALVE LINKAGE ADJUSTMENT 23
REPAIR 24
HYDRAULIC CONTROL VALVE—REMOVAL/INSTALLATION 24
HYDRAULIC CONTROL VALVE—
DISASSEMBLY/INSPECTION AND ASSEMBLY 24
LIFT CYLINDER—REMOVAL/INSTALLATION 26
HYDRAULIC CONTROL LEVERS AND LINKAGE—INSPECTION 27
HYDRAULIC SCHEMATIC—POWER TRAIN 28

Page
MISCELLANEOUS
SPECIFICATIONS3
REPAIR SPECIFICATIONS 3
OTHER MATERIALS 3
REPAIR 4
AIR CLEANER (FD620)—REMOVAL/INSPECTION/INSTALLATION 4
MUFFLER (FD620D)—REMOVAL/INSTALLATION 5
FAN BELT (FD620D)—REMOVAL/INSTALLATION 6
RADIATOR—REMOVAL/INSPECTION7
FUEL TANK—REMOVAL/INSTALLATION8
FUEL PUMP/FUEL GAUGE SENSOR—REMOVAL/INSTALLATION 9
AIR CLEANER (455)—DISASSEMBLY/INSPECTION/ASSEMBLY 10
MUFFLER (455)—REMOVAL/INSTALLATION 11
FAN/ALTERNATOR BELT (455)—REMOVAL/INSTALLATION 11
FUEL FILTER (455)—REMOVAL/INSTALLATION12
HEADLIGHTS—ADJUSTMENT 12
LIFT LINKAGE ADJUSTMENT 13