OPERATOR'S MANUAL HYDRAULIC PUMP - John...

OM 0399HP-A 05/11

OPERATOR'S MANUAL

HYDRAULIC PUMP

HP2025-HP2134

TABLE OF CONTENTS

OM 0399HP-A 1

SPECIFICATIONS ........................................................................................................................................... 3

INTRODUCTION – TO THE PURCHASER ................................................................................................... 4

SAFETY PRECAUTIONS ............................................................................................................................... 5

Before Operation ............................................................................................................................ 5

Notice ............................................................................................................................................. 6

The Hydraulic Pump ...................................................................................................................... 6 Before Operation ............................................................................................................. 6 Hydraulic Pump Operation .............................................................................................. 7

The Tractor .................................................................................................................................... 8 General Information ......................................................................................................... 8 Operating the Tractor ...................................................................................................... 8 During Operation ............................................................................................................. 8

Maintenance .................................................................................................................................. 9

Transport ........................................................................................................................................ 9

Storage ........................................................................................................................................ 9

SAFETY DECALS ................................................................................................................................... 10-11

ASSEMBLY ............................................................................................................................................... 12-19

Installation of the Hydraulic Pump ............................................................................................... 12 Hydraulic Oil Fill-Up ..................................................................................................... 12

Installation of the Driveline ........................................................................................... 12

Adjusting the Three Point Hitch ................................................................................... 12

Installation of the Quick Couplers ........................................................................... 13-14

Installation of the Hose Supports ............................................................................ 15-16

Installation of the Wiring Harness ........................................................................... 17-18

Installation of the Hoses .............................................................................................. 19

Installation of the Hydraulic Pump with a Quick Hitch Cat. 1 ....................................... 20

Installation of the Hydraulic Pump with a Quick Hitch Cat. 2 ....................................... 20

Installation of the Hydraulic Pump with a Three Point Hitch Cat. 1 .............................. 21

Installation of the Hydraulic Pump with a Three Point Hitch Cat. 2 .............................. 22

Determining Driveline Length ...................................................................................... 23

Connection the Driveline to the Tractor ....................................................................... 24

Connecting the Hoses and Wiring Harness ................................................................ 25

Installation of the Oil Cooler 5RDF0036 – Option .................................................. 26-27

TABLE OF CONTENTS

OM 0399HP-A 2

OPERATION ................................................................................................................................................ 28-31

Preparation ..................................................................................................................................... 28

Counterweights .............................................................................................................. 28

Operation ........................................................................................................................................ 29

Checking the Oil Temperature ........................................................................................ 29

Checking the Hydraulic Oil Level .................................................................................... 29

Checking Oil Level of the Multiplicator ........................................................................... 29

Removing the Hydraulic Pump ........................................................................................ 30

Reconnecting the Hydraulic pump .................................................................................. 31

MAINTENANCE ................................................................................................................................... 32-40

Lubrication & Periodic Maintenance ................................................................................................ 32

Oil Fill-Up ......................................................................................................................... 33 Oil Change ....................................................................................................................... 33 Replacing the Oil in the Multiplicator ................................................................................ 34 Recommended Hydraulic Oil ........................................................................................... 34 Cleaning the Oil Strainer – without an Oil Cooler ............................................................ 35 Cleaning the Oil Strainer – with an Oil Cooler ................................................................. 36 Instruction for Valve Adjustment ...................................................................................... 37

Troubleshooting .......................................................................................................................... 38-39

Electrical Diagram ............................................................................................................................ 40

PARTS ................................................................................................................................................ 41-53

Introduction .......................................................................................................................................... 41

Hydraulic Pump and Tank .............................................................................................................. 42-43

Miscellaneous ................................................................................................................................. 44-45

Hydraulic and Electrical System ...................................................................................................... 46-47

Hose Supports ................................................................................................................................ 48-49

Hydraulic Block ................................................................................................................................... 50

Hydraulic Pump .................................................................................................................................... 51

Multiplicator .......................................................................................................................................... 52

Oil Cooler 5RDF0036 - Option ............................................................................................................. 53

Driveline ............................................................................................................................................... 54

TORQUE SPECIFICATION TABLES .................................................................................................. 55-57

SPECIFICATIONS

OM 0399HP-A 3

Features and Specifications HP2025 HP2134 Width (with counterweights) 38" (60") 38" (60")

Transport Width 44" 44"

Height 47" (55" with oil cooler) 47" (55" with oil cooler)

Length 30" 30"

Hydraulic System 16 gpm at 2700 psi 20 gpm at 3000 psi

Hoses 3/4" 3/4"

Hydraulic Protection Relief valve at 2700 psi Relief valve at 3000 psi

Tank Mounted Strainer Standard Standard

Tank Mounted Return Filter Standard with breather Standard with breather

Hose Protection Standard Standard

Pump Manufacturer Salami Salami

Pump Description Gear pump

32 cc/rev. Model 2.5PB (Heavy Duty Series)Gear pump

40 cc/rev. Model 3PB (Heavy Duty Series)

Gearbox Manufacturer Breveni Breveni

Gearbox Description Model ML52 Model ML52

Tractor RPM 540 540

Pump RPM 1836 1836

PTO Manufacturer Comer Comer

PTO Description 40 40

Parking Stand Standard Standard

Hitch Category Cat. 1 & 2 Cat. 1 & 2

Quick Hitch Compatibility ASABE Compatible Cat. 1 & 2 ASABE Compatible Cat. 1 & 2

HP Requirements - min-max (hp) 25-35 35-56

Operating Weight (lbs) with hydraulic oil. 535 535

Shipping Weight (lbs) 535 535

Approx. Set-up Time 1.5 to 2 hrs 1.5 to 2 hrs

Counterweight Support Capacity of 700 lbs (5 x 70 lbs each side)

Accepts 42 & 70 lbs John Deere Quick Tatch Weights

Capacity of 700 lbs (5 x 70 lbs each side)Accepts 42 & 70 lbs John Deere Quick

Tatch Weights

Rear Attachment Bracket Standard (750 lbs) Standard (750 lbs)

Hose Support for JD3000 & JD4000 series loaders

Standard Standard

Quick Couplers – Front & Rear 1/2" Standard 3/4" Standard

Thermal Protection Standard Standard

Pre-drilled holes for oil cooler support Standard Standard

Oil Cooler Option Option

INTRODUCTION

OM 0399HP-A 4

TO THE PURCHASER All products are designed to give safe, dependable service if they are operated and maintained according to instructions. Read and understand this manual before operation. This manual has been prepared to assist the owner and operators in the safe operation and suitable maintenance of the implements. The information was applicable to products at the time of manufacture and does not include modifications made afterwards. Read and understand this operator's manual before attempting to put an implement into service. Familiarize yourself with the operating instructions and all the safety recommendations contained in this manual and those labeled on the implements and on the tractor. Follow the safety recommendations and make sure that those with whom you work follow them.

Illustrations

The illustrations may not necessarily reproduce the full detail and the exact shape of the parts or depict the actual models, but are intended for reference only

Direction Reference

Right Hand and Left Hand are determined by those seen by the operator standing behind the equipment.

The Dealer is responsible for warranty registration of the unit you have purchased. To assist your dealer in handling your needs, please record hereafter the model number and serial number of your implement and tractor. It is also advisable to supply them to your insurance company. It will be helpful in the event that an implement or tractor is lost or stolen. MODEL : SERIAL NUMBER : DATE OF PURCHASE :

SAFETY PRECAUTIONS

OM 0399HP-A 5

All products are designed to give safe, dependable service if they are operated and maintained according to instructions. Read and understand this manual before operation. It is the owner's responsibility to be certain anyone operating this product reads this manual, and all other applicable manuals, to become familiar with this equipment and all safety precautions. Failure to do so could result in serious personal injury or equipment damage. If you have any questions, consult your dealer.

BEFORE OPERATION Children and Bystanders

Tragic accidents can occur if the operator is not alert to the presence of children. Children are generally attracted to machines and the work being done. Never assume children will remain where you last saw them. 1. Keep children out of the operating area and

under the watchful eye of another responsible adult.

2. Be alert and turn machine off if children enter the work area.

3. Before and when backing, look behind and look for small children.

4. Never carry children while operating the machine. They may fall off and be seriously injured or interfere with safe operation of the machine.

5. Never allow children to play on the machine or attachment even when turned off.

6. Never allow children to operate the machine even under adult supervision.

7. Use extra care when approaching blind corners, shrubs, trees, or other obstructions that might hide children from sight.

SAFETY FIRST This symbol, the industry's "Safety Alert Symbol", is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully. It is essential that you read the instructions and safety regulations before you attempt to assemble or use this unit.

DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. IMPORTANT : Indicates that equipment or property damage could result if instructions are not followed. NOTE : Gives helpful information.

SAFETY PRECAUTIONS - continued

OM 0399HP-A 6

NOTICE A safe operator is the best insurance against accidents. All operators, no matter how experienced they may be, should read this Operator's Manual and all other related manuals before attempting to operate an implement. Please read the following section and pay particular attention to all safety recommen-dations contained in this manual and those labeled on the implements and on the tractor.

THE HYDRAULIC PUMP Before Operation

1. Read and understand this operator's manual and tractor operator's manual. Know how to operate all controls and how to stop the unit and disengage the controls quickly.

2. Never wear loose, torn, or bulky clothing around the tractor and implement. It may catch on moving parts or controls, leading to the risk of accident.

3. Before the snow season, thoroughly inspect the area where the equipment is to be used and remove all doormats, sleds, boards and other foreign objects.

4. Disengage clutch and shift into neutral before starting the engine.

5. Do not operate equipment in wintertime without wearing adequate winter garments.

6. Never attempt to make any adjustments while engine is running. Read this manual carefully to acquaint yourself with the equipment as well as the tractor operator's manual. Working with unfamiliar equipment can lead to accidents. Be thoroughly familiar with the controls and proper use of the equipment. Know how to stop the unit and disengage the controls quickly.

7. Keep all shields in place and properly tighten all mounting hardware.

8. Periodically, inspect all moving parts for wear and replace with authorized service parts if an excessive amount of wear is present.

9. Replace all missing, illegible, or damaged safety and warning decals. See list of decals in the operator's manual.

10. Do not modify or alter this equipment or any of its components or any equipment function without first consulting your dealer.

11. Keep safety decals clean of dirt and grime.


OM 0399HP-A 7

Hydraulic Pump Operation

1. Before leaving the tractor unattended, take all possible precautions. Disengage the PTO, stop the engine and remove the ignition key. Lower the implement to the ground.

2. Before starting the pump, make sure there's sufficient hydraulic oil and that hoses are properly connected.

3. Be sure the clutch switch/lever is in OFF position before starting engine.

4. Exercise extreme caution when operating on or crossing a gravel drive, walks, or roads. Stay alert for hidden hazards or traffic.

5. Do not carry passengers.

6. If the pump starts to vibrate abnormally, stop the engine immediately and check for cause. Excessive vibration is generally a sign of trouble.

7. Do not run the engine indoors except when starting engine and transporting attachment in or out of building. Carbon monoxide gas is colorless, odorless and deadly.

8. Exercise extreme caution when changing direction on slopes. Do not attempt to operate on steep slopes.

9. Never operate pump without guards, and other safety protective devices in place.

10. Never operate machine at high transport speeds on a slippery surface.

11. Use extra caution when backing up.

12. Disengage power to the PTO when transporting or when not in use.

13. 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 noises.

14. Always keep the "SMV" sign (Slow Moving Vehicle) visible and clean.

15. Make sure the protective nylon sheat is properly installed on the hoses since they contain fluid under pressure and at high heat that can cause injury.


OM 0399HP-A 8

THE TRACTOR General Information

1. Read the operator's manual carefully before using tractor. Lack of operating knowledge can lead to accidents.

2. Do not allow anyone but the operator to ride on the tractor. There is no safe place for extra riders

Operating the Tractor

1. Never run the tractor engine in a closed building without adequate ventilation, as the exhaust fumes are very dangerous.

2. Never allow an open flame near the fuel tank or battery.

3. Make sure the shield is installed when using PTO-driven equipment and always replace the shield if damaged.

4. Always bring the tractor to a complete stop, shut off the engine, lower the implement to the ground and remove the ignition key before leaving the tractor.

5. Never park the tractor on a steep slope.

6. Do not attempt to operate on steep slopes.

7. Use of tire chains for better traction and stability is recommended.

8. Always drive the tractor at speeds compatible with safety, especially when operating over rough ground, crossing ditches, or when turning.

9. Handle fuel with care, as it is highly flammable.

10. Use approved fuel container.

11. Never add fuel to a running engine or a hot engine.

12. Fill fuel tank outdoors with extreme care. Never fill fuel tank indoors. Replace fuel cap securely and wipe up spilled fuel.

13. Never allow anyone to operate the front mount implement until they are thoroughly familiar with basic tractor and implement operation.

14. A minimum 20% of tractor and equipment weight must be on the tractor front wheels when attachments are in transport position. Without this weight, tractor could tip over, causing personal injury or death. The weight may be attained with a loader, front wheel weights, ballast in tires, front tractor weights and/or on the power pack. Weigh the tractor and equipment. Do not estimate. Please refer to tractor manual for proper ballasting information.

15. Always make sure all hydraulic pump components are properly installed and securely fastened BEFORE operation.

During Operation

1. Do not allow anyone to ride on the tractor/implement at any time. There is no safe place for passengers on this equipment. The operator MUST sit in the tractor seat.

2. Eye and hearing protection is recommended when operating the hydraulic pump.

3. Operate only during daylight hours, or when the area is well lit with bright artificial light.

4. Disengage the PTO (turn to “OFF”), place the transmission in neutral, set the parking brake, shut off the engine and remove the key, and make sure rotating components have stopped BEFORE leaving the operator’s seat.

5. Inspect the hydraulic pump after striking any foreign object to assure that all implement parts are safe and secure and not damaged.


OM 0399HP-A 9

MAINTENANCE 1. Park the tractor/hydraulic pump on level

ground, set the parking brake, disengage the PTO, shut off the engine, remove the key, and lower the implement to the ground BEFORE making any hydraulic pump adjustments.

2. Keep the tractor/hydraulic pump clean. Snow and ice build-up can lead to malfunction or personal injury from thawing and refreezing in garage.

3. Always wear eye protection when cleaning or servicing the hydraulic pump.

4. Do not work under any part of the tractor or hydraulic pump, unless it is securely supported by safety stands.

5. Make sure all shields and guards are securely in place following all service, cleaning, or repair work.

6. Do not modify or alter this equipment or any of its components or operating functions. If you have questions concerning modifications, consult with your dealer.

7. Even when stopped, the hydraulic pump (hoses, oil tank, and pump) can contain fluids under pressure and at high heat. Be very careful when performing maintenance on this equipment.

TRANSPORTATION 1. If the tractor/hydraulic pump is to be driven

on public roads, it must be equipped with an SMV (Slow Moving Vehicle) sign. Check local traffic codes that may apply to unit usage on public roads and highways in your area.

2. Be alert for all other traffic when driving the tractor/ hydraulic pump on public roads or highways.

3. During transport, the hydraulic pump must be in the raised position.

STORAGE 1. Before storing the hydraulic pump, certain

precautions should be taken to protect it from deterioration.

2. Clean the hydraulic pump thoroughly.

3. Make all the necessary repairs.

4. Replace all Safety Signs that are damaged, lost, or otherwise become illegible. If a part to be replaced has a sign on it, obtain a new safety sign from your dealer and install it in the same place as on the removed part.

5. Repaint all parts from which paint has worn or peeled.

6. Lubricate the hydraulic pump as instructed under "Lubrication" section.

7. When the hydraulic pump is dry, oil all moving parts. Apply oil liberally to all surfaces to protect against rust.

8. Place the dust caps on the hoses. Store the hydraulic hoses in the hose support on top of the oil tank and secure in place with the connector support and the hairpins.

9. Attach the driveline to the pump with the chain provided with the pump.

10. Store in a dry place

.

DECALS

OM 0399HP-A 10

Replace immediately if damaged

5RD2500795 5RD2500794

5RD25007915RD2500796

5RD2500798

5RD25007925RD2500797 5RD2500793

5RD2500829

DECALS

OM 0399HP-A 11

Replace immediately if damaged

5RD655834 5RD655834

5RD2500822

5RD2500821

5RD2500616

5RD2500786

5RD2500785

ASSEMBLY

OM 0399HP-A 12

INSTALLATION OF THE THREE POINT HYDRAULIC PUMP The hydraulic pump is assembled at the factory; however it needs to be installed and connected. Use the present manual and lay out all parts. Separate bolts and nuts into various sizes. After installation, torque all the bolts and the hydraulic fittings according to the "Torque Specification Tables" at the end of the manual.

Hydraulic Oil Fill-Up The hydraulic pump is delivered without hydraulic oil. Fill up the oil tank according to the instructions in the "Maintenance" section.

Installation of the Driveline Figure 1: Remove the two M12 x 1.25 x 70 bolts (item 4) and the nylon insert locknuts (item 5). Connect the driveline (item 2) to the pump's driveshaft (item 1). Attach with the two M12 x 1.25 x 70 bolts (item 4) and the nylon insert locknuts (item 5). Maintain in place with the chain (item 3).

WARNING: To avoid serious personal injuries: If the collar is not locked to the shaft at tractor end and the bolts not well tighten to the pump shaft (a "click" must be heard), the driveline can fly loose with great force capable of causing serious injury or death.

NOTE: To better illustrate the installation of the pump on the tractor, figures 20 and up do not show the driveline.

Adjusting the 3 Point Hitch Figure 2: Adjust the three point hitch at maximum height by screwing the right arm adjustable link to its maximum using the handle (item 1). For the left arm, remove the linchpin (item 2) and remove the adjustable link (item 3) from the upper anchoring point (item 4). Screw the adjustable link (item 3) to the maximum and reinstall. Make sure the two lower arms are at the same height.

Figure 2

2

4

Figure 1

3 1

ASSEMBLY

OM 0399HP-A 13

Installation of the Quick Couplers

3X20 TRACTOR

Front support - fig.3

1. Install two 1 1/16"JIC x 3/4"NPT bulkhead adaptors (item 2) on the middle hose support (item 1) with 1 1/16" bulkhead nuts (item 3).

2. Install two 3/4"NPT x 1/2"NPT male adaptors (item 6) followed by a 1/2" male quick coupler, a 1/2" female quick coupler (item 4) with their respective dust plug and dust cap (item 5) in the order illustrated.

Rear support - fig.4 & 5

1. Install two 1 1/16"JIC x 3/4"NPT bulkhead adaptors (item 2) on the rear hose support (item 1) with 1 1/16" bulkhead nuts (item 3).

2. Install two 3/4"NPT x 1/2"NPT male adaptors (item 6) followed by a 1/2" male quick coupler, a 1/2" female quick coupler (item 4) with their respective dust plug and dust cap (item 5) in the order illustrated.

NOTE: Refer to figure 5 for the position of the quick couplers.

Tractor Legend: 3X20 = 3320, 3520, 3720 4X20 = 4120, 4320, 4520, 4720

Figure 3

Figure 4

Figure 5

ASSEMBLY

OM 0399HP-A 14

4X20 TRACTOR

Front support – figure 6

1. Install two 1 1/16"JIC x 3/4"NPT bulkhead adaptors (item 2) on the middle hose support (item 1) with 1 1/16" bulkhead nuts (item 3).

2. With thread sealant, install a 3/4" male quick coupler and a 3/4" female quick coupler (item 4) with their respective dust plug and dust cap (item 5).

Rear support – figures 7 & 8

1. Install two 1 1/16"JIC x 3/4"NPT bulkhead adaptors (item 2) on the rear hose support (item 1) with 1 1/16" bulkhead nuts (item 3).

2. With thread sealant, install a 3/4" male quick coupler, a 3/4" female quick coupler (item 4) with their respective dust plug and dust cap (item 5) in the order illustrated.

NOTE: Refer to figure 8 for the position of the quick couplers.

Figure 6

Figure 7

Figure 8

ASSEMBLY

OM 0399HP-A 15

Figure 9

Figure 9a

Figure 10a Figure 10

Installation of the Hose Supports NOTE: Refer to the parts section on page 50 to identify the hose supports and to figure 9a for their exact location on the loader arm.

1. Figure 9: Attach the rear hose support (item 1) and the fastening bracket (item 2) to the left front loader arm (item 3) with two 5/16" NC x 1 1/4" lg bolts, 5/16" flat washers and 5/16" NC nylon insert nuts (items 4-14-5).

2. Figure 9: Attach the middle hose support (item 7) and its fastening bracket (item 6) with two 5/16" NC x 1 1/4" lg. bolts and two 5/16" NC nylon insert nuts (items 8-9).

3. Figures 9: Attach the lower part of the front hose support (item 10) and its fastening plate (item 11) with one 5/16"NC x 3 1/2" lg bolts and one 5/16" NC nylon insert nuts (items 12-13) and the upper part with 1/4"NC x 6" flattened bolt, a bushing and a 1/4"NC nut (items 15-16-17).

CAUTION: Do not cover the loader arm decals particularly with the front support (items 10-11).

IMPORTANT - Detail A: Make sure the flattened portion of the 1/4"NC bolt faces the loader cylinder and is in a position that ensures the cylinder doesn't interfere with the bolt.

4. A- For 3X20 tractors - fig.10a:

Attach the hose support in the same location as the tractor hose support located under the left tractor step plate using the existing tractor bolt. Install the round wire lock pin in the support as shown.

On some tractor, it may be necessary to position the support with an angle as shown on fig.10a.

B- For 4X20 tractors - fig.10:

Attach the hose support (item 1) on the front loader support plate located under the step plate (item 2) with a 5/8" NC x 2" lg. bolt (item 3) and a 5/8" NC nylon insert nut (not illustrated). Install the round wire lock pin (item 4) in the holes of the support.

ASSEMBLY

OM 0399HP-A 16

5. Run the hydraulic hoses from the rear of the tractor to the front without inserting them in the hose supports. The straight hose fittings go on the front of the tractor.

6. Figures 11: Connect the hoses (item 2) to the rear bulkhead adaptors (item 1).

7. A- Without cab: Figure 12:

- Remove the bolt and the flat washer that holds the left fender to the tractor frame.

- Insert a M10 x 1.5 x 60mm bolt (not illustrated) in the hole of the bent section of the fastening bracket (item 1).

- Insert the fastening bracket, from the front to the rear, around the tractor post (item 2) and secure with a M10 x 1.5 x 60mm bolt for the 4X20 or a M10 x 1.5 x 40mm bolt for the 3X20 (item 3), and the tractor flat washer previously removed, located between the bracket and the tractor aisle. DO NOT use this flat washer for the 3X20 tractor.

- After installing the hoses on the bulk head adaptors, attach the rear hose support (item 4) around the tractor post inserting the front part first and secure in place with a 3/8" flat washer (not illustrated) and a 10mm nylon insert nut (not illustrated).

- Attach the rear section with a 10mm nylon insert nut (item 5).

B- With cab: Figure 12A:

Attach the rear hose support (item 1) and it's fastening bracket (item 2) to the tractor post (item 3) at about 9" from the axle's upper plate for the 3X20 series and at 6 3/4" for the 4X20 series with two M10 x 1.5 x 60mm bolt, 3/8" flat washers and two 10mm nylon insert nut (items 4-5-6).

3

4

1

6

5

2

3X20: 9"

4X20: 6 ¾"

Figure 12A

Figure 12

21

Figure 11

ASSEMBLY

OM 0399HP-A 17

Installation of the Wiring Harness 1. Figure 13: Connect the red wire

terminal (item 1) of the harness with the fuse holder, to the battery's positive terminal (item 2) and the black wire terminal (item 3) to the battery's negative terminal (item 4). Attach the harness to the tractor wiring close to the relay with a tie wrap (item 5).

2. Figures 14-15: Insert the wiring harness (item 1) in the rubber boot (item 2). On some tractor models it may be necessary to remove the hose clamp (item 3) to be able to insert the harness. Reinstall the clamp once the harness is installed.

3. Figure 15: Run the wiring harness (item 1) along the front of the tractor frame and attach to the tractor wiring or hoses (item 4) with tie wraps. Run the harness close to the hose support located under the step plate (not illustrated).

Figure 13

Figure 14

Figure 15

1

2 1

2

1

2 3

4 5

1

4

3

ASSEMBLY

OM 0399HP-A 18

4. Figure 16: Find the tractor's drive wheel activation switch on the transmission near the left rear axle (item 1), accessible from the bottom of the left footstep. Disconnect the 2 cavity connector. Connect the identical harness connector to the activation switch and the tractor's 2 cavity connector to the wiring harness.

5. Figure 17: Run the harness all the way to the back making sure not to interfere with the movement of the tractor levers and keeping as far away as possible from the wheel. Bring the harness to the rear hose support (item 1) and tie the harness close to it so the connector (item 2) is at the same level as the quick couplers previously installed. Tie the harness to all the critical areas on the tractor.

NOTE: Attach the surplus of the harness in a place far from the wheels and the tractor control levers in movement.

Figure 16

1

1

2

Figure 17

ASSEMBLY

OM 0399HP-A 19

12

Figure 19a

1

Figure 19b

2

Figure 18

1

2 3

Figure 19c

Installation of the Hydraulic Hoses

1. Figure 18: Connect the hoses to the front bulkhead adaptors (item 1). Hoses should not be inserted in the supports to make it easier to connect the hoses in the front. Tighten the lower hose first (item 2).

2. Figure 19a: Insert the hoses (item 1) in the rear hose support (item 2) of the left loader arm.

3. Figures 19b-19c: Run the hoses (item 1) under the tractor as shown on figure 19b then insert the hoses in the hose support located under the step plate (item 2) then lock in place with a round wire lock pin (item 3).

ASSEMBLY

OM 0399HP-A 20

Figure 21

Figure 22 Figure 23

Figure 20

Installation of the Hydraulic Pump with a Quick Hitch Cat. 1

Figure 20: Place the hydraulic pump (item 1) on flat hard ground. Unlock the lower locks of the quick hitch (item 2). Back up the tractor slowly aligning the three quick hitch hooks (item 4) with the three bushings (item 3) of the hydraulic pump and lock the quick hitch lower locks.

Installation of the Hydraulic Pump with a Quick Hitch Cat. 2

1. Figure 21: Remove the linchpins (item 1), lockwashers (item 3), nuts (item 2) and pins (item 4). Use a round stalk to block the cat.1 and 2 pin during the loosening and the tightening of the nut.

2. Figure 22: Install the pins (item 1) in the position illustrated and reinstall the lockwashers (item 3), nuts (item 2), and linchpins (item 4).

3. Figure 23: Place the hydraulic pump (item 1) on flat hard ground. Unlock the lower locks of the quick hitch (item 2). Back up the tractor slowly aligning the three quick hitch hooks (item 4) with the three bushings (item 3) of the hydraulic pump and lock the quick hitch lower locks.

ASSEMBLY

OM 0399HP-A 21

Figure 24

Figure 25

Figure 26

Installation of the Hydraulic Pump with a Three Point Hitch Cat. 1 1. Figure 24: Remove the linchpins (item 1),

nuts (item 2), lockwashers (item 3) and pins (item 4). Remove the hairpin (item 5), pin (item 6) and bushing (item 7). The lower quick hitch bushings (item 8) can remain in place.

2. Figure 25: Insert the pins (item 1) in the

position illustrated. Reinstall the lockwashers (item 3), the nuts (item 2) and the linchpins (item 4).

3. Figure 26 Insert the two pins (item 1) in the

lower links (item 2) and lock in place with linchpins (item 3). Attach the upper link (item 5) with the 4" lg. pin (item 4) and lock in place with the hairpin (item 6).

ASSEMBLY

OM 0399HP-A 22

Figure 27

Figure 28

Figure 29

Installation of the Hydraulic Pump with a Three Point Hitch Cat.2

1. Figure 27: Remove the linchpins (item 1), nuts (item 2), lockwashers (item 3) and pins (item 4). Remove the hairpin (item 5), pin (item 6) and bushing (item 7). Remove the spring pins (item 8) and the bushings (item 9).

2. Figure 28: Insert the pins (item 1) in the

position illustrated. Reinstall the nuts (item 2), lockwashers (item 3) and the linchpins (item 4).

3. Figure 29: Insert the two pins (item 1) in the

lower links (item 2) and lock in place with linchpins (item 3). Attach the upper link (item 7) by inserting a cat.1 & cat.2 bushing (item 5, sold separately #5RD4600056), the 4" pin (item 4) and a hairpin (item 6).

ASSEMBLY

OM 0399HP-A 23

Determining Driveline Length

IMPORTANT: To not damage the equipment, it is essential that the driveline is not too long. At working position, the two half drivelines must intersect each other sufficiently to insure maximum efficiency but there must not be any interference.

1. To determine the "L" length for your tractor model first find the "X" factor by measuring the distance between the end of the tractor's drive shaft and the end of the hydraulic pump's driven shaft when the hydraulic pump is in raised position as shown on Figure 30.

2. Deduct 4" from the "X" length measured from the tractor to obtain the "L" length from center to center of the journal crosses:

3. Hold the two half-shaft side by side and

locate the "L" length between the two center-to-center half-shaft universal joints. Mark off the zone to be cut on both halves opposite each half-shaft guard as shown on Figure 31.

4. Cut off inner and outer guard tubes as well as the inner and outer telescopic sections.

5. Cut the guard a second time leaving the same distance between the end of the guard and the end of the shaft as existed before. To obtain the proper distance "A" shown on Figure 32, cut the guard according to the following table:

DISTANCE A

Male Driveline Female Driveline

1 3/4" 1 1/4"

6. File down tubes and remove chips.

7. Apply grease to inside of outer telescopic section.

WARNING: To avoid serious personal injuries that may cause death, work with fully guarded shafts only.

Figure 31

Figure 32

A

Figure 30

L = X – 4"

ASSEMBLY

OM 0399HP-A 24

Figure 33a

Figure 33b

Connecting the Driveline to the Tractor

Figures 33a-33b: Release the springhook (item 1) to remove the chain (item 2) from around the driveline (item 3) and reattach the springhook in its original position (item 1). Connect the driveline (item 4) to the tractor driveshaft (item 5). Attach each driveline chains (item 6) to the tractor lower hitches (item 7) to prevent the guards from spinning.

ASSEMBLY

OM 0399HP-A 25

Figure 34

1

2

Figure 35

Connecting the Hydraulic Hoses and Wiring Harness

1. Figure 34: Remove the hoses (item 2) from the hose support (item 1) on the hydraulic pump.

2. Figure 35: Connect the hoses to the rear tractor ports (item 1).

3. Figure 35: Connect the wiring harness to the rear tractor connector (item 2).

ASSEMBLY

OM 0399HP-A 26

Figure 36

Figure 37 Figure 38

Figure 36a

Installation of the Oil Cooler 5RDF0036 - Option

1. Figure 36: Unscrew the 1 1/16" JIC elbow (item 1) from the in-tank filter. Remove the 3/4"NC x 2" lg bolt (item 2) and the stover nut (item 3). Remove the stover nut (item 4) from the 3/4"NC x 4 1/2" lg bolt but do not remove the bolt.

2. Figure 36a: Unscrew the straight 1-1/16"JIC adapter (item 1) and rotate the hose of 90° up to bring up the 90° 1-1/16"JIC elbow adapter (item 2). Tighten the straight 1-1/16"JIC adapter, to rotate the hose, at 65-75 ft-lb (93-101 N-M).

3. Figure 37: Install the oil cooler support (item 1) with a 3/4" NC x 2" lg bolt (item 2) and the 3/4" stover nut (item 3) removed previously. Reinstall the 3/4" NC stover nut (item 4) previously removed on the 3/4" NC x 4 1/2" bolt.

4. Figure 38: Install the support plates (item 1) with six 5/16" NC x 1" bolts (item 2), eight 5/16" flat washers (item 3) and six 5/16" NC nylon insert nuts (item 4) making sure to place a flat washer between the support plates and the "U" section of the frame.

ASSEMBLY

OM 0399HP-A 27

5. Figure 39: Install the rubber bushings (items 1-2) on the support then attach the oil cooler (item 3) with four 5/16" NC x 2 1/4" bolts (item 4), 5/16" flat washers (item 5), the flat washers supplied with the rubber bushings (item 6) and 5/16" NC nylon insert nuts (item 7). IMPORTANT: Position the oil cooler so the by-pass valve (item 8) faces the rear as illustrated.

6. Figure 40: Install the 1 5/8" ORB – 1 1/16" JIC elbows (item 1) on the oil cooler's inlet and outlet in the positions illustrated. Connect the straight end of the outlet hose (item 2) to the oil cooler elbow and the bent end to the filter. Connect the inlet hose (item 3) previously disconnected from the filter to the other elbow making sure it passes outside the support plate (item 4).

7. Figure 41: Connect the oil cooler fan harness (item 1) to the available connector on the hydraulic pump's wiring harness (item 2).

Figure 40

Figure 39

Figure 41

1

2

OPERATION

OM 0399HP-A 28

Figure 44

PREPARATION 1. Figure 42: Raise the three point hitch at

maximum making sure the adjustable arms are at maximum height. (see section "Adjusting the Three Point Hitch". When the pump is fully raised, the driveline must be at an angle nearest to 5º with the ground. If not, adjust the three point hitch until the driveline has the correct angle to prevent premature wear of the driveline. The angle of the pump's input shaft is also very important; it must be as parallel as possible with the output shaft of the tractor.

2. Raise the parking stands and lock in place with the wire lock pins.

IMPORTANT: If the three point hitch is not adjusted correctly and the parking stands are not raised, ground clearance and the pump's angle will be affected making it more difficult to travel on uneven terrain.

3. Before starting the tractor, make sure the oil level of the oil tank and multiplicator is correct (see sections "Checking the Hydraulic Oil Level" and "Checking Oil Level of the Multiplicator".

4. Attach a suitable implement to the tractor front loader making sure the implement is compatible with the hydraulic pump (see specifications for each).

5. For equipment other than the snowblower, working in warm region, use the 5RDF0036 oil cooler.

IMPORTANT: To not damage the oil cooler, it is essential to disconnect the fan of the oil cooler when the temperature is under 0°C.

6. Figure 43: The new HP2025 and HP2134 pumps are equipped with a safety system to prevent the hydraulic oil from overheating. When the hydraulic block is not power supplied, the oil is in recirculation mode meaning that the equipment will not function. To power the block, the ignition key must be in the "ON" (1) or "START" (2) position. If the system remains in the recirculation mode, refer to the "Troubleshooting" section at page 39.

7. Engage the tractor PTO. Run the equipment 2 to 3 minutes to make the hydraulic oil circulate throughout the system. Disengage the PTO and check the oil level in the oil tank once more. Add oil if needed.

Counterweights

IMPORTANT: Make sure the tractor has counterweights as recommended by the dealer. Weights provide the necessary balance to improve stability, traction and steering. The recommended Quick Tatch weights are available at your local John Deere dealer. Figure 44: Remove the counterweight rods (item 1) and the hairpins (item 2). Hang the counterweights (item 3) on each side of the hydraulic pump. Reinstall the rods (item 1) and the hairpins (item 2).

Figure 42

Without Cab | With Cab

Figure 43 1

2

OPERATION

OM 0399HP-A 29

Figure 45

Checking the Oil Temperature

Figure 45: Check the oil temperature indicated on the thermometer (item 1) of the hydraulic pump (item 2).

IMPORTANT: The oil temperature must never exceed 149ºF (65ºC). If the temperature is above that, disengage the hydraulic pump to allow the oil to return to a temperature below 149ºF (65ºC). A temperature higher than 149ºF (65ºC) could cause damage to the hydraulic components.

Checking the Hydraulic Oil Level

Figure 46: The oil level must be between the red line and blue line of the level indicator (item 1). If the level is close to the red line, add some oil to bring it back to the blue line. Make sure the oil level never goes below the red line on the indicator (item1).

IMPORTANT: Make sure the oil level never goes below the red line on the indicator while in operation or it could cause damage to the hydraulic pump.

Checking Oil Level of the Multiplicator

Figure 46: To check the oil level, simply look through the oil level plug (item 1) located on the right hand side of the multiplicator. If the gauge glass is yellowish, the oil level is good. If it's white, add someSAE80W90 oil.

Figure 46

OPERATION

OM 0399HP-A 30

Removing the Hydraulic Pump

1. Figure 47: Remove the wire lock pins (item 2), lower the parking stands (item 1) and lock in place with the wire lock pins (item 2). Lower the hydraulic pump to the ground.

IMPORTANT: The pump must be lowered on level ground since the hydraulic pump has a high center of gravity and could tip over if it's set on uneven ground.

2. Figure 48: Disconnect the hoses (item 1) and the harness (item 2) if they are connected to the tractor and install the appropriate dust caps/plugs on each hose connector and tractor outlets.

3. Figure 49: Place the hoses and wiring harness on top of the hydraulic pump. Insert the hoses (item 2) in the hose support (item 1).

4. Figure 47: Disconnect the driveline (item 3) from the tractor's driveshaft (item 4).

5. Figure 42: Attach the driveline (item 3) to the hydraulic pump with the chain (item 4).

Figure 49

1

2

Figure 48

Figure 47

OPERATION

OM 0399HP-A 31

6. A - For Quick Hitch Installation:

Figure 50: Unlock the lower locks of the quick hitch. Lower the three point hitch to release the hooks (item 1) from the pump's attaching points (item 2) and move the tractor forward slowly.

B - For Three Point Hitch Installation:

Figure 51: Remove the hairpin (item 6) and the pin (item 4) to release the upper link (item 5) and place it on its support (not illustrated). Remove the linchpins (item 3) to release the lower links (item 2) from the pins (item 1) and move the tractor forward slowly.

Reconnecting the Hydraulic Pump 1. Adjust the three point hitch according to the

instructions on page 12.

2. Install the hydraulic pump on the tractor according to the instructions starting on page 20:

- With quick hitch Cat. 1 – page 20 - With quick hitch Cat. 2 – page 20 - With 3 point hitch Cat. 1 – page 21 - With 3 point hitch Cat. 2 – page 22

3. Attach the driveline according to the instructions on page 24.

4. Install the hydraulic hoses according to the instructions on page 25.

5. Proceed with the operating procedures on page 28.

Figure 50

Figure 51

MAINTENANCE

OM 0399HP-A 32

LUBRICATION & PERIODIC MAINTENANCE Periodic maintenance is essential for top performance. Use the Table below as a guide for normal periodic maintenance. Keep a log of the maintenance performed and the hours run. Recording maintenance will help you keep it regular and provide a basis for supporting warranty claims.

BREAK IN – After first 24 hours

After first 100 hours

8 hours (DAILY)

400 hours or annually

PROCEDURE COMMENTS

X X Check all hardware for proper tightness Tighten appropriately

X Check for oil leaks Tighten the fittings that are leaking

X X Change hydraulic oil Change more often if the machine operated at hi temperatures.

X X Change hydraulic oil filter Change more often if machine operates in dusty and/or hot conditions

X Clean hydraulic oil tank strainer

Perform more often when operating in dusty and/or hot conditions

X Change the oil of the multiplicator Use SAE80W90 oil

X General inspection Check for oil leaks, loose parts, unusual noises or vibrations

X Check hydraulic oil level Add oil if needed

X Grease and oil driveline Grease each journal cross. Separate the sliding parts and cover each one of them with grease. Oil the connections.

Monthly: Check oil level of the multiplicator and add gear oil SAE80W90 if needed.

OIL CAPACITY

Type QTY (Liter/gallon)

Hydraulic oil (oil tank only)Hydraulic oil (complete hydraulic system without oil cooler Hydraulic oil (complete hydraulic system with oil cooler Gear oil (multiplicator)

57 / 1568 / 18 72 / 19

0.8 / 0.2

MAINTENANCE

OM 0399HP-A 33

NOTE: The hydraulic pump can remain attached to the tractor for oil fill ups and oil changes; just make sure the pump is level.

Oil Fill-Up - Figure 52

1. Remove the cap from the filter container (item 2), the spring (item 3) and the filter (item 4). Fill up the oil tank up to the blue line of the level indicator (item 5) through the filter container (item 6) (refer to the following page for the oil to use). Reinstall the filter, the spring and the cap (items 2-3-4).

2. Reinstall the hydraulic pump and run the equipment installed on the front loader 2 to 3 minutes. Readjust the oil level so it reaches the blue line of the level indicator if needed.

Oil Change - Figure 52

1. Remove the plug (item 1) under the oil tank and let it drain completely.

2. Reinstall the plug (item 1).

3. Remove the cap from the filter container (item 2), the spring (item 3) and the filter (item 4). Fill up the oil tank up to the blue line of the level indicator (item 5) through the filter container (item 6) (refer to the following page for the oil to use).

4. Install a new filter (item 4) (part number 5RD3900456). Reinstall the spring and the cap (items 3-2).

5. Reinstall the hydraulic pump and run the equipment installed on the front loader 2 to 3 minutes. Readjust the oil level so it reaches the blue line of the level indicator if needed.

.

WARNING: Escaping hydraulic/diesel fluid under pressure can penetrate the skin causing severe injuries.

• Do not use your hands to check for leaks. Use a piece of cardboard or paper to search for leaks.

1. Hydraulic line 2. Cardboard 3. Magnifying glass

• Shut engine off and relieve pressure before connecting or disconnecting lines.

• Tighten all connections before starting engine or pressurizing lines.

• If any fluid is injected into the skin, obtain medical attention immediately or gangrene may result.

6.

Figure 52

MAINTENANCE

OM 0399HP-A 34

-22F(-30C) -4F(-20C) 14F(-10C) 32F(0C) 50F(10C) 68F(20C) 86F(30C)

Oil Selection Chart

Temperature

Grade 10W40

Grade 22

Grade 32

Grade 68

Grade 46

Figure 53 Replacing the Oil in the Multiplicator (Figure 53)

1. Remove the oil plug (item 1) under the multiplicator and let it drain completely. Clean the plug if it's a magnetic plug.

2. Reinstall the plug (item 1).

3. Remove the breather (item 2) on top of the multiplicator. Add 0.85 quart (0.8 liter) of oil SAE 80W90. Check through the oil level plug (item 3) if there's enough oil. Add oil as needed until it reaches the proper level. Reinstall the breather (item 2).

Recommended Hydraulic Oil

1. Always use superior quality hydraulic oil.

The recommended brands are:

- Shell : Tellus 22-32-46-68, Tellus T 22-32-46-68 and Formula 10W40;

- Esso : Mobil DTE 10M series 12M-13M-15M-16M and Extra 10W40;

- Petro Canada : Hydrex AW 22-32-46-68, Hydrex MV 22-36-60 and Supreme 10W40;

- Chevron : ECO hydraulic ISO 32-46-68, AW hydraulic ISO 22-32-46-68 and Supreme 10W40;

- Irving : Hydraulic AW 22-32-46-68, Hydraulic LP 22-32-46-68 and Velco 10W40;

2. The viscosity of the oil to use is determined by the outdoor temperature when the machine is in use.

3. Never store oil with the intention of reusing it. Always use new oil when making an oil change.

4. When using hydraulic oil in the hydraulic system, always empty the oil tank completely to eliminate the water that can accumulate on the bottom.

5. When using 10W40 oil in the hydraulic system, always do an oil change in the spring and in the fall without taking into consideration the number of hours showing in order to eliminate water that might emulsify in the oil.

6. If the machine is not being operated or is in operation less than 200 hours a year, replace the hydraulic oil at least once a year except if using 10W40 oil when it must be changed in the spring and in the fall.

MAINTENANCE

OM 0399HP-A 35

Figure 55

Figure 56

Figure 54

Cleaning the Oil Strainer – without an oil cooler

1. Figure 54 Remove the pump from the tractor (see section "Removing the Hydraulic Pump" and place it on level ground. Remove the plug (item 1) under the oil tank and let it drain completely.

2. Figure 54: Unscrew the 1 1/16" JIC elbow (item 2) on the hydraulic bloc and the 1 1/16" JIC straight fitting (item 3) close to the pump.

WARNING: There should still be oil in the system and it will drain when the pump hose is removed. Once the oil is completely drained, remove the hose between the pump and the hydraulic block.

3. Figure 54: Unscrew the 1 1/16" JIC straight fitting (item 4) on the hydraulic block. This hose can remain in place when removing the tank.

4. Figure 55: Remove the flat bar (item 5) by taking off the four bolts and nuts (items 1-2-3-4) as well as the spacer rings and shim (items 6-7).

5. Figure 55: Remove the six bolts and nuts (items 8-9-10-11).

6. Figure 55: Loosen the upper collar (item 12) of the suction hose.

7. Figure 56: Lift the tank (item 1) and unscrew the strainer assembly (item 2). Inspect thoroughly for any damage and replace if necessary otherwise clean it. Put thread sealant and reinstall the strainer.

8. Reassemble the hydraulic pump by reversing the previous steps.

MAINTENANCE

OM 0399HP-A 36

Figure 57

Figure 58

Figure 59

Cleaning the Oil Strainer – with an oil cooler

1. Figure 54: Remove the pump from the tractor (see section "Removing the Hydraulic Pump" and place it on level ground. Remove the plug (item 1) under the oil tank and let it drain completely.

2. Figure 57: Remove the nut and bolt (items 1-2) then, without removing it, slightly loosen the nut of the support plate (item 3) to allow movement of the support.

3. Figure 58: Remove the nut (item 1) then partially remove the bolt (item 2) to free the oil cooler support. Without removing it, slightly loosen the nut of the support plate (item 3) to allow movement of the support. Unscrew the 1 1/16" JIC elbow (item 4) from the filter.

4. Figure 59: Flip the oil cooler (item 1) 90° towards the outside and unscrew the 1 1/16" JIC fitting (item 2). Continue with steps 2 to 7 of the section "without oil cooler".

5. Reassemble the hydraulic pump by reversing the previous steps.

MAINTENANCE

OM 0399HP-A 37

Pressure Valve Adjustment – with or without oil cooler

PRESSURE GAUGE INSTALLATION

1. Figure 60: Remove the 7/16"ORB plug (item 1) and insert a pressure gauge in that port. If the pressure gauge doesn't fit, install a 1/4" hose between the port and the gauge.

PRESSURE SETTING

2. Figure 60: Locate the relief valve (item 3) on the hydraulic pump located near the pump under the hydraulic tank. To have access to the adjustment screw, remove the plug (item 4). Engage the PTO and run the tractor engine at 1800 rpm. Check the pressure on gauge:

- 2700+/-100 psi for HP2025 - 3000+/-100 psi for HP2134.

If not, adjust pressure by turning the screw in the valve. (Screwing will increase pressure and unscrewing will decrease pressure). After the adjustment, reinstall the plug (item 4).

ATTENTION: The valve plug must be securely installed while the pump is in operation.

Figure 60

MAINTENANCE

OM 0399HP-A 38

TROUBLESHOOTING

WARNING: Several corrective measures present a certain risk, which may cause serious injuries or death.

Only a qualified person, familiar with the risks associated with hydraulics, electricity and machinery should perform the repairs. Review the safety precautions at the beginning of this manual.

The following chart serves as a guide in case of a malfunction. If the problem is not solved after taking the appropriate corrective measure, contact your dealer.

WARNING: Hot engine parts and hydraulic oil can cause serious burns. Always let the engine cool before proceeding with repairs or maintenance.

IMPORTANT: The oil temperature must never go above 65ºC (149ºF) to avoid damages to the hydraulic components.

PROBLEM CORRECTIVE MEASURE

1. The front mount equipment isn't working

• Check that the PTO is engaged. • Check that the hoses are connected correctly. • Check hydraulic pump oil level and add some if needed. • Check that the oil temperature is not too high. • Check that the hydraulic block is receiving electrical current. If not,

refer to item #5. • Check for oil leaks. • Check that solenoid valve is working properly and replace if needed.• Check that temperature gauge is working properly and replace if

needed. • Check that the pump is working properly and replace if necessary. • Check that the multiplicator is working properly and replace if

necessary

2. The front mount equipment is working at low speed (low hydraulic flow)

• Check engine RPM and increase as needed. • Check hydraulic pump oil level and add some if needed. • Check for oil leaks. • Check the viscosity of the hydraulic oil. • Check the front mount equipment. Refer to the Operator's manual of

the equipment.

MAINTENANCE

OM 0399HP-A 39

PROBLEM CORRECTIVE MEASURE

3. The front mount equipment is working but in reverse.

• Check that the pressure hose is connected to the letter "P" on the hydraulic blocks of the pump and the equipment.

• Check the connections of the equipment. Refer to the Operator's manual of the equipment.

4. The front mount equipment is working with low power (low hydraulic pressure)

• Check the oil level of the hydraulic pump. • Check the viscosity of the hydraulic oil. • Check if the tractor engine is at full RPM • Check for oil leaks. • Check the filter. Clean or replace if needed. • Check the strainer. Clean or replace if needed. • Check the adjustment of the pressure valve. Adjust if necessary.

(see page 38). • Check the front mount equipment. Refer to the Operator's manual of

the equipment. • Check that the pump is working properly and replace if necessary.

5. There is no electric signal on the hydraulic block.

• Check the connections between the hydraulic pump and the tractor. • Check the position of the ignition key (see page 28). • Check the fuse on the wiring harness. • Check the battery connections. • Check the connection on the tractor connector. • Check the relays. • Check the connections on the solenoid valve:

o solenoid valve: red on 1, purple on 2 o Temperature gauge: purple on 1, black on 2

MAINTENANCE

OM 0399HP-A 40

ELECTRICAL DIAGRAM

KEY

PARTS

OM 0399HP-A 41

INTRODUCTION

All parts are illustrated in "exploded views" which show the individual parts in their normal relationship to each other. Reference numbers are used in the illustrations. These numbers correspond to those in the "Reference Number" (REF) column, and are followed by the description and quantity required.

Right Hand and Left Hand are determined by those seen by the conductor standing behind the equipment.

The manufacturer reserves the rights to change, modify, or eliminate from time to time, for technical or other reasons, certain or all data, specifications, or the product or products themselves, without any liability or obligation.

The parts listed here are available through your local dealer.

MANUAL HOLDER REF. DESCRIPTION QTY PART #

1 Manual holder 1 5RD4200030 2 Bolt hex. 5/16" NC x 1" lg gr. 5, PTD 2 5RD0100019 3 Nut nylon insert 5/16" NC, PTD 2 5RD1000005

PARTS

OM 0399HP-A 42

HYDRAULIC PUMP & TANK

PARTS

OM 0399HP-A 43

HYDRAULIC PUMP & TANK REF. DESCRIPTION QTY PART #

Hardware bag (not illustrated) - for HP2025 1 5RD669531

- for HP2134 1 5RD669492

1 Hydraulic tank 1 5RD669167

2 Adaptor 2" NPT-hose 3 15/32" lg 1 5RD669207

3 Hose 2" x 3" lg 1 5RD669208

4 Hose 1" x 5" lg 1 5RD669212

5 Pump & multiplicator ass'y - for HP2025 1 5RD3910061

- for HP2134 5RD3910024

6 - Multiplicator 3.4:1 (incl. in 5RD3910024 or 5RD3910061) 1 5RD3910027

7 - Pump 32cc/rev 2.5PB (incl. in 5RD3910061) - for HP2025 1 5RD3910079

- Pump 40cc/rev 3PB (incl. in 5RD3910024) - for HP2134 1 5RD3910026

8 - Coupling for hydraulic pump 5RD3910026 (incl. in 5RD3910024) Or for hydraulic pump 5RD3910079 (incl. In 5RD3910061) 1

5RD3910029

9 Temperature and oil level gage 1 5RD3900464

- Seal kit for 5RD3900464 1 5RD3900465

- Repair kit for 5RD3900464 (including seal and screw) 1 5RD3900466

10 Strainer 50 GPM with 3 psi bypass 1 5RD3900449

11 In-tank filter 25 GPM with 22 psi bypass including element 1 5RD3900451

-Replacement element for 5RD3900451 1 5RD3900456

12 Air breather 1 5RD3900452

13 O-ring 0.118" x 1.475" 1 5RD3900454

14 Adaptor 1 5/8" ORB - 2 hoses 1 5RD2600198

15 Collar, stainless 3/4" to 1 3/4" for hose 1 5RD2600209

16 Collar, stainless 2.32" to 2.48" for hose 2 5RD4200035

17 Hex. bolt 3/8 NC x 1" gr.5, PTD 2 5RD0100038

18 Allen socket head cap screw 3/8" NC x 1 1/4", PTD 2 5RD0800048

19 Hex. bolt 3/8 NC x 3 1/2" gr.5, PTD 4 5RD0100047

20 Hex. bolt M12 x 1.75 x 25mm lg gr.8.8 PTD 4 5RD0200022

21 Hex. bolt M10 x 1.50 x 40mm lg, gr. 8.8 PTD 4 5RD0200071

22 Plug 3/8" NPT 1 5RD654068

23 Nylon insert locknut 3/8" NC PTD 6 5RD1000006

24 Lockwasher 3/8", PTD 2 5RD1200004

25 Lockwasher 10mm, PTD 4 5RD1200018

26 Lockwasher 12mm, PTD 4 5RD1200019

27 Seal kit for filter 5RD3900451 1 5RD3900468

PARTS

OM 0399HP-A 44

MISCELLANEOUS

PARTS

OM 0399HP-A 45

MISCELLANEOUS

REF. DESCRIPTION QTY PART # 1 Hyd. pump/tank support 1 5RD669485

2 Parking stand 2 5RD669168

3 Upper link 1 5RD669501

4 Counterweight rod 2 5RD669170

5 Shim 3/8", 2 holes PTD 1 5RD669172

6 Spacer ring .81int. dia x 1 15/32" lg x 1 1/4" ext. PTD 2 5RD669173

7 Chain 35" lg. with springhook 1 5RD669210

8 Bushing 1 1/4 " ext. x 2-13/32" lg x .770" int. PTD 1 5RD669211

9 Bushing 1.135" int. x 1 1/2" ext. x 2 15/16" lg 2 5RD668379

10 Driveline series 40 28" c/c closing 1 5RD4700159

11 SMV reflective sign 1 5RD4200029

12 Hex. bolt 1/4" NC x 1" gr.5, PTD 2 5RD0100004

13 Hex. bolt 3/4" NC x 2" gr.5, PTD 2 5RD0100117

14 Hex. bolt 3/4" NC x 4 1/2" gr.5, PTD 2 5RD0100125

15 Nylon insert locknut 1/4" NC, PTD 2 5RD1000003

16 Stover lock nut 3/4 NC, PTD 4 5RD1100008

17 Flat washer 1/4" (5/16 int), PTD 2 5RD1400002

18 Spring pin 3/8" x 1 1/2", black 2 5RD1600022

19 Hairpin 4mm x 80mm, PTD 2 5RD1800002

20 Hairpin 3mm x 65mm, PTD 1 5RD1800004

21 Linchpin 7/16", PTD 2 5RD1900003

22 Square wire lock pin 3/8" x 2 1/2" 2 5RD1900008

23 Hitch pin cat. 1 & 2, PTD 2 5RD654204

24 Pin 3/4" x 4", PTD 1 5RD665009

25 Protective rubber 1" lg. 2 5RD669348

PARTS

OM 0399HP-A 46

HYDRAULIC & ELECTRICAL SYSTEMS

PARTS

OM 0399HP-A 47

HYDRAULIC & ELECTRICAL SYSTEMS

REF. DESCRIPTION QTY PART #

5RDHP2025 PART #

5RDHP2134 1 Hydraulic hose ø3/4" x 38" 2 5RD3700184 5RD3700184

2 Hydraulic hose ø3/4" x 30 1/2" 1 5RD3700158 5RD3700158

3 Hydraulic hose ø3/4" x 53 1/2" 1 5RD3700180 5RD3700180

4 Hose guard 1 5RD669152 5RD669152

5 Hydraulic block 1 5RD3920033 5RD3920037

6 Hex. bolt ø1/4"NC x 2 3/4" gr.5 PTD 2 5RD0100013 5RD0100013

7 Nylon insert nut ø1/4"NC PTD 2 5RD1000003 5RD1000003

8 Fitting ø7/8"ORB x 1 1/16"JIC 4 5RD2600058 5RD2600058

9 Elbow 90° ø1 1/16"JIC M x 1 5/16"ORB M 2 5RD2600204 5RD2600204

10 Wiring harness 1 5RD4000085 5RD4000085

11 Dust plug 3 5RD2600133 5RD2600196

12 Female quick coupler ø1/2"NPT 3 5RD662702 ---

Female quick coupler ø3/4"NPT 3 --- 5RD661294

13 Dust cap 3 5RD664898 5RD2600197

14 Male quick coupler ø1/2"NPT 3 5RD2600092 ---

Male quick coupler ø3/4"NPT 3 --- 5RD661293

15 Adaptor 1/2"NPT male x 3/4"NPT fem 6 5RD2600217

16 Bulkhead adaptor ø1 1/16"JIC M x 3/4"NPT M 4 5RD2600221 5RD2600221

17 Bulkhead nut ø1 1/16"JIC 4 5RD2600165 5RD2600165

18 Hydraulic hose ø3/4" x 120" 2 5RD3700182 ---

Hydraulic hose ø3/4" x 134" 2 --- 5RD3700183

19 Protective nylon sheeting 1 5RD669536 5RD669534

20 Wiring harness for hydraulic pump 1 5RD4000084 5RD4000084

21 Fuse 40A ATO 1 5RD4000087 5RD4000087

22 Relay 12V 2 5RD4000028 5RD4000028

PARTS

OM 0399HP-A 48

HOSE SUPPORTS

PARTS

OM 0399HP-A 49

HOSE SUPPORTS REF. DESCRIPTION QTY PART #

1 Hose support/front loader 1 5RD669512

2 Fastening plate - front hose support 1 5RD669217

3 Middle hose support 1 5RD669511

4 Fastening bracket - middle hose support 1 5RD669219

5 Rear hose support 1 5RD669521

6 Fastening bracket - rear hose support 1 5RD669522

7 Hose support - tractor rear 1 5RD669532

8 Fastening bracket - tractor rear hose support 1 5RD669566

9 Hose support - tractor front 1 5RD669523

10 Hex. bolt 5/16" NC x 1 1/4" gr. 5, PTD 4 5RD0100020

11 Hex. bolt 5/16" NC x 3 1/2" gr. 5, PTD 1 5RD0100029

12 Hex. bolt 5/8" NC x 2" gr. 5, PTD 1 5RD0100095



15 Hairpin 2.5mm x 40mm 1 5RD1800001

16 Round wire lock pin 1/4" x 1 3/4" 1 5RD1900006

17 Spacer ring 2 3/8" lg, PTD 1 5RD669518

18 Chain 1/8" & pin, PTD 1 5RD669513

19 Chain 1/8" x 3 11/32", PTD 1 5RD669514

20 Cotter pin 5/32" x 3/4", PTD 2 5RD1500005

21 Bolt 1/4"NC x 6" flattened 1 5RD669516

22 Nylon insert nut 1/4", PTD 1 5RD1000003

23 Flat washer 5/16" (3/8" hole), PTD 2 5RD1400003

24 Bolt M10 x 1.5 x 60mm full thread 2 5RD0200134

25 Flat washer 1/4" (5/16" hole), PTD 1 5RD1400002

26 Nylon insert nut 10mm, PTD 2 5RD1000021

27 Bolt M10 x 1.5 x 40mm 1 5RD0200071

PARTS

OM 0399HP-A 50

HYDRAULIC BLOCK

REF. DESCRIPTION QTY 1 Cartridge 2 way, 2 positions 1 5RD3920039

- Seal kit for 5RD3920039 1 5RD3920041

2 Coil 12VDC DIN connector for 5RD3920039 1 5RD3920040

3 Relief valve preset at 3000 PSI for HP2134 1 5RD3920025

Relief valve preset at 2700 PSI for HP2025 1 5RD3920038

- Seal kit for 5RD39200025 and 5RD3920038 1 5RD3920032

4 Fitting 7/8"ORB M x 1 1/16"JIC M 4 5RD2600058

5 Temperature switch 210°F 1 5RD3920042

6 Hydraulic plug 7/16"ORB M Allen head 2 5RD2600213

7 DIN connector 2 5RD4000062

8 Hydraulic plug 9/16"ORB M 1 5RD2600212

PARTS

OM 0399HP-A 51

HYDRAULIC PUMP PART #

REF. DESCRIPTION QTY

HP2134 5RD3910026

HP2025 5RD3910079

Complete seal kit (incl. #1 to 5) 1 5RD3910050 5RD39100801 -Shaft seals incl.in 5RD3910050 incl.in 5RD3910080 2 -Washer incl.in 5RD3910050 incl.in 5RD39100803 -Retaining ring incl.in 5RD3910050 incl.in 5RD39100804 -Bushing seals and anti-extrusion incl.in 5RD3910050 incl.in 5RD39100805 -Housing seals incl.in 5RD3910050 incl.in 5RD39100806 Bolt kit (including #7) 1 5RD3910051 5RD39100817 -Reference pin incl.in 5RD3910051 incl.in 5RD39100818 Bushings (incl. #9 for HP2134) 1 5RD3910053 5RD39100839 -Plate incl.in 5RD3910053 N/A

10 Drive gear 1 5RD3910054 --- 11 Driven gear 1 5RD3910055 --- 12 Drive & driven gears 1 --- 5RD3910084 13 Flange 1 5RD3910052 5RD391008214 Housing 1 5RD3910056 5RD391008515 Cover 1 5RD3910057 5RD391008616 Key & nut 5RD3910087 5RD3910087

PARTS

OM 0399HP-A 52

MUTIPLICATOR

REF. DESCRIPTION QTY PART # 1 Body carter 1 5RD3910031 2 Filler breather plug 1 5RD3910032 3 Washer 2 5RD3910033 4 Level gauge 1 5RD3910034 5 3/8" BSP plug 2 5RD3910035 6 Gasket 1 5RD3910036 7 Shaft seal 50mm x 65mm x 8mm 1 5RD3910037 8 Bearing 50mm x 80mm x 16mm 1 5RD3910038 9 Seeger 1 5RD3910039

10 Key 1 5RD3910040 11 PTO shaft 1 5RD3910041 12 Crown 1 5RD3910042 13 Bearing 45mm x 75mm x 16mm 1 5RD3910043 14 Pinion 1 5RD3910044 15 Shaft seal 45mm x 60mm x 7mm 1 5RD3910045 16 Body cover 1 5RD3910046 17 Pin D=5 2 5RD3910047 18 Screw M8x28 8 5RD3910048

Magnetic plug 3/8" BSP (not shown) 1 5RD3910049

PARTS

OM 0399HP-A 53

OIL COOLER - 5RDF0036

REF. DESCRIPTION QTY PART # 1 Oil cooler with by-pass valve and fan 12V 1 5RD3900474 2 - Bolt and seal kit (incl.in 5RD3900474) 1 5RD3900475 3 - Hydraulic plug kit (incl.in 5RD3900474) 1 5RD3900476 4 - By-pass valve kit (incl.in 5RD3900474) 1 5RD3900477 5 - Fan 12V ass. (incl.in 5RD3900474) 1 5RD669620 6 Oil cooler support 1 5RD669510 7 Plate for oil cooler support 2 5RD669540 8 Hydraulic hose 3/4" x 30 1/2" lg 1 5RD3700158 9 Elbow 90° 1 5/8"ORB M x 1 1/16"JIC M 2 5RD2600218

10 Bushing for vibration damping 4 5RD4200043 11 Hex. bolt 3/4"NC x 2 1/4" gr5, PTD 1 5RD0100118 12 Hex. bolt 5/16"NC x 2 1/4" gr5, PTD 4 5RD0100025 13 Hex. bolt 5/16"NC x 1" gr5, PTD 6 5RD0100019 14 Flat washer 5/16" (3/8" hole), PTD 16 5RD1400003 15 Nylon insert nut 5/16"NC, PTD 10 5RD1000005

PARTS

OM 0399HP-A 54

DRIVELINE 5RD4700159

REF. DESCRIPTION QTY PART #

1 Yoke ass'y 1 5RD660764 2 Journal cross 2 5RD660765 3 Yoke for female tube 1 5RD663189 4 Female tube 1 5RD4700160 5 Male tube 1 5RD4700161 6 Yoke for male tube 1 5RD663193 7 Yoke ass'y 1 5RD4700058 8 Shear bolt M12 x 1.25 x 70 with nut 2 5RD662199 9 Grease fitting 1 5RD663129

10 Ball Ø1/4" 23 5RD663163 11 Shear bolt 8mm x 1.25 x 50 gr.5.8 and nut 1 5RD4700060 12 Protector and chain 1 5RD4700164 13 Pin for outer tube 1 5RD4700061 14 Pin for inner tube 1 5RD4700062

TORQUE SPECIFICATION TABLES

OM 0399HP-A 55

GENERAL SPECIFICATION TABLE Use the following torques when special torques are not given

NOTE: These values apply to fasteners as received from supplier, dry, or when lubricated with normal engine oil. They do not apply if special graphited or moly sidulphide greases or other extreme pressure lubricants are used. This applies to both UNF and UNC threads.

BOLT HEAD IDENTIFICATION MARKS AS PER GRADE

NOTE: MANUFACTURING MARKS WILL VARY.

Torque Torque Torque

BOLT SIZES Pounds-Foot Newtons-Meter Pounds-Foot Newtons-Meter Pounds-Foot Newtons-Meter Inches Millimeters MIN. MAX. MIN. MAX. MIN. MAX. MIN. MAX. MIN. MAX. MIN. MAX.

1/4 6.35 5 6 6.8 8.13 9 11.0 12.2 14.9 12 15 16.3 30.35/16 7.94 10 12 13.6 16.3 17 20.5 23.1 27.8 24 29 32.5 39.33/8 9.53 20 23 27.1 31.2 35 42.0 47.5 57.0 45 54 61.0 73.27/16 11.11 25 30 40.7 47.4 54 64.0 73.2 86.8 70 84 94.9 113.91/2 12.70 45 52 61.0 70.5 80 96.0 108.5 130.2 110 132 149.2 179.09/16 14.29 65 75 88.1 101.6 110 132.0 149.2 179.0 160 192 217.0 260.45/8 15.88 95 105 128.7 142.3 150 180 203.4 244.1 220 264 298.3 358.03/4 19.05 150 185 203.3 250.7 270 324 366.1 439.3 380 456 515.3 618.37/8 22.23 160 200 216.8 271.0 400 480 542.4 650.9 600 720 813.6 976.31 25.40 250 300 338.8 406.5 580 696 786.5 943.8 900 1080 1220.4 1464.5

1 1/8 25.58 - - - - 800 880 1084.8 1193.3 1280 1440 1735.7 1952.61 1/4 31.75 - - - - 1120 1240 1518.7 1681.4 1820 2000 2467.9 2712.01 3/8 34.93 - - - - 1460 1680 1979.8 2278.1 2380 2720 3227.3 3688.31 1/2 38.10 - - - - 1940 2200 2630.6 2983.2 3160 3560 4285.0 4827.4

METRIC BOLT TORQUE SPECIFICATIONS Coarse thread Fine Thread

Size of screw Grade No.

Pitch (mm)

Pounds-Foot Newtons-Meter Pitch (mm)

Pounds-Foot Newtons-Meter MIN. MAX. MIN. MAX. MIN. MAX. MIN. MAX.

M6 4T 7T 8T

1.0 3.6 5.8 7.2

5.89.4 10

4.97.9 9.8

7.912.7 13.6

- -- -

- - -

-- -

-- -

M8 4T 7T 8T

1.25 7.2 17 20

1422 26

9.823

27.1

19.029.8 35.2

1.0 1219 22

17 27 31

16.325.7 29.8

23.036.6 42

M10 4T 7T 8T

1.5 20 34 38

2540 46

27.146.1 51.5

33.954.2 62.3

1.25 2035 40

29 47 52

27.147.4 54.2

39.363.7 70.5

M12 4T 7T 8T

1.75 28 51 57

3459 66

37.969.1 77.2

46.179.9 89.4

1.25 3156 62

41 68 75

4275.9 84

55.692.1

101.6

M14 4T 7T 8T

2.0 49 81 96

5693 109

66.4109.8 130.1

75.9126

147.7 1.5

5290 107

64 106 124

70.5122 145

86.7143.6 168

M16 4T 7T 8T

2.0 67 116 129

77130 145

90.8157.2 174.8

104.3176.2 196.5

1.5 69120 140

83 138 158

93.5162.6 189.7

112.5187

214.1

M18 4T 7T 8T

2.0 88 150 175

100168 194

119.2203.3 237.1

136227.6 262.9

1.5 100177 202

117 199 231

136239.8 273.7

158.5269.6 313

M20 4T 7T 8T

2.5 108 186 213

130205 249

146.3252

288.6

176.2277.8 337.4

1.5 132206 246

150 242 289

178.9279.1 333.3

203.3327.9 391.6


OM 0399HP-A 56

TORQUE SPECIFICATION TABLE FOR HYDRAULIC FITTINGS Use the following torques when a specific torque is not given. Note: These values apply to

fittings when dry. These values do not apply if lubricants are used..

SIZE OF FITTINGS TORQUE

SIZE ( JIC ) - INCHES foot-pounds Newton-meters 03 - 3/8"- 24 8-9 12-13 04 - 7/16"- 20 13-15 18-20 05 - 1/2"- 20 14-15 19-21 06 - 9/16"- 18 23-24 32-33 08 - 3/4"- 16 40-43 55-57 10 - 7/8"- 14 43-48 59-64 12 - 1 1/16"- 12 68-75 93-101 14 - 1 3/16"- 12 83-90 113-122 16 - 1 5/16"- 12 112-123 152-166 20 - 1 5/8"- 12 146-161 198-218 24 - 1 7/8"- 12 154-170 209-230 32 - 2 1/2"- 12 218-240 296-325

SIZE ( ORB ) - INCHES foot-pounds Newton-meters 03 - 3/8"- 24 8-10 11-13 04 - 7/16"- 20 14-16 20-22 05 - 1/2"- 20 18-20 24-27 06 - 9/16"- 18 24-26 33-35 08 - 3/4"- 16 50-60 68-78 10 - 7/8"- 14 72-80 98-110 12 - 1 1/16"- 12 125-135 170-183 14 - 1 3/16"- 12 160-180 215-245 16 - 1 5/16"- 12 200-220 270-300 20 - 1 5/8"- 12 210-280 285-380 24 - 1 7/8"- 12 270-360 370-490


OM 0399HP-A 57

SIZE ( NPT ) - INCHES Torque FFT

1/8"- 27 2.0 - 3.0 1/4"- 18 2.0 - 3.0 3/8"- 18 2.0 - 3.0 1/2"- 14 2.0 - 3.0 3/4"- 16 2.0 - 3.0 1"- 11 1/2" 1.5 - 2.5 1 1/4"- 11 1/2" 1.5 - 2.5 1 1/2"- 11 1/2" 1.5 - 2.5

ASSEMBLY

The method used to assemble fittings with NPT threads is in two stages. First tighten firmly by hand then tighten one again according to the number of turns listed on the above table. The following method is recommended to minimize the risks of leaks and/or damages to the parts.

1. Inspect threads and tapping to make sure they are clean.

2. Apply a sealant/lubricant product to the NPT threads (teflon covered threads are preferable to other lubricating products). If PTFE tape (teflon) is used, make 1,5 or 2 turns clockwise.

Attention: More than 2 turns can cause distortion or cracks in the orifice.

3. Tighten the fitting by hand.

4. Screw the fitting the number of turns listed on the above table making sure that in the case of a shape fitting the end is aligned to the desired position. Never unscrew a fitting to obtain the proper alignment.

5. If the leak persists after having followed the preceding instructions, check that the threads are not damaged and the number of seated threads.

If the threads are very damaged, replace the fitting. If the tapping is damaged, retap if possible or replace the part.

Usually, the number of threads seated is between 3 and 6. If the range is different it would indicate that the fitting was tightened too much or not enough or that the tightening was not within thread tolerances. If the fitting is not tight enough, tighten but never more than one turn. If it's too tight, control the threading and tapping and replace the section that has threads that are not within tolerances.

OPERATOR'S MANUAL HYDRAULIC PUMP - John...

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