MODEL: 90 Skid-Steer Loader

Transcription

1 John Deere MODEL: 90 Skid-Steer Loader THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF JOHN DEERE OR IT'S SUCCESSORS. JOHN DEERE AND IT'S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL. TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS. JD-S-TM1205

2 90 SKID-STEER LOADER 1 TECHNICAL MANUAL TM-1205 (NOV-78) SECTION 10 - GENERAL Group 05 - Specifications Group 10 - Lubrication and Periodic Service SECTION 25 - GASOLINE ENGINE REPAIR Group 05 - Specifications and Tools Group 10 - Engine Separation Group 15 - Disassembly Group 20 - Assembly SECTION 30 - FUEL REPAIR Group 05 - Specifications Group 10 - Carburetor Group 15 - Governor SECTION 40 - ELECTRICAL REPAIR Group 05 - Specifications Group 10 - Starter SECTION 50 - POWER TRAIN REPAIR Group 05 - Specifications Group 10 - Hydrostatic Pump Group 15 - Hydrostatic Motor Group 20 - Final Drive SECTION 60 - STEERING AND BRAKE REPAIR Group 05 - Steering Group 10 - Brakes SECTION GASOLINE ENGINE, FUEL AND AIR OPERATION AND TESTS Group 05 - Specifications Group 10 - System Operation Group 15 - Engine Analysis Group 20 - Diagnosing Malfunctions SECTION ELECTRICAL OPERATION AND TESTS Group 05 - Specifications Group 10 - System Operation Group 15 - System Testing Group 20 - Diagnosing Malfunctions SECTION POWER TRAIN OPERATION AND TESTS Group 05 - Specifications Group 10 - System Operation Group 15 - System Testing Group 20 - Diagnosing Malfunctions SECTION HYDRAULIC OPERATION AND TESTS Group 05 - Specifications Group 10 - System Operation Group 15 - System Testing Group 20 - Diagnosing Malfunctions SECTION 70 - HYDRAULIC REPAIR Group 05 - Hydraulic Pump Group 10 - Hydraulic Cylinders (All information, illustrations, and specifications contained in this technical manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.) OOA TM-1205 (Nov-78) Litho in U.S.A. Skid-Steer Loader - 90

3 General Contents Section 10 GENERAL GROUP 05 - SPECIFICATIONS Engine Hydraulic System Drive System Travel Fluid Capacity Tires Attachments Operational Specifications Dimensions Bucket and Fork Specifications GROUP 10 - LUBRICATION AND PERIODIC SERVICE Lubricants Lubrication Periodic Service As Required Hours or Daily Hours or Weekly Hours Hours Hours Hours or Annually TM-1205 (Nov-78) Litho in U.S.A. Skid-Steer Loader - 90

4 Specifications General DRIVE SYSTEM Two hydrostatic pumps with variable angle swashplate and two hydrostatic motors with fixed angle swashplate. Forward, rearward and turning movements are controlled by a T-bar control lever. TRAVEL Speed mph (0-8 km/h) Turning in its own length FLUID CAPACITY Fuel Tank... 8 U.S. Gallons (30.4 L) Engine Lubricating Oil... 4 U.S. Quarts (3.8 L) Hydraulic/Hydrostatic Reservoir U.S. Gallons (41.8 L) Chain Case Reservoir /2 U.S. Gallons (5.7 L) TIRES Size Operating Pressure 27x psi (2 bar) (2 kg/ cm2) ATTACHMENTS Auxiliary hydraulic valve kit, cylinder rod stops, earth bucket, utility bucket, pallet fork, utility fork, grapple, and SMVemblem. OPERATIONAL SPECIFICATIONS Operating weight Ibs. ( kg) Tipping load (SAE with 47 in. [1 194 mm] bucket) Ibs. (635 kg) Load Rating (1/2 SAE tip-up) Ibs. (317.5 kg) Lift capacity to maximum height Ibs (590 kg) Raising time to full height (full)... 5 seconds Lowering time (empty)... 3 seconds Dumping time (full) seconds Rollback time (full rollback) seconds TM-1205 (Nov-78) Litho in U.S.A. Skid-Steer Loader - 90

5 Gasoline Engine Repair Contents Section 25 AS LINE EN INE REPAIR GROUP 05 - SPECIFICATIONS AND TOOLS Specifications Assembly Torques Tools GROUP 10 - ENGINE SEPARATION Removal Installation GROUP 15 - DISASSEMBLY Disassembly GROUP 20 - ASSEMBLY Oil Seals Camshaft Bearings Crankshaft Main Bearings Bearing Plate Crankshaft End Play Pistons Rings Piston Pins Cylinder Governor Cup Assembly Valves Cylinder Heads TM-1205 (Nov-78) Litho in U.S.A. Skid-Steer Loader - 90

6 Gasoline Engine Repair Disassembly DISASSEMBL Y A-Govenor Cover B-Oil Filter Adapter ic11870nx A-Drive Pulley Filter Lines C-Engine Mounting Fig. 1-Muffler Removal Drain oil. Remove muffler and drive pulley (A). Disconnect oil filter lines (8). Remove hydraulic belt guard and engine mount, all shrouding, and intake manifold and exhaust. Fig. 3-Removing Valves Remove valve with standard valve spring compressor. Remove starter, rectifier-regulator module bracket, govenor cover (A) with stator and oil filter adapter (8). A-Snap Ring B-Camshaft A-Valve Covers B-Breather Fig. 2-F/ywhee/ Removal Remove flywheel, heads, breaker point assembly, valve covers and breather. Fig. 4-Removing Camshaft Remove snap ring (A). Carefully remove camshaft (8). TM-1205 (Nov-78) Litho in U.S.A. Skid-Steer Loader - 90

7 Fuel Repair Contents FUE Section 30 REPAIR GROUP 05 - SPECIFICATIONS GROUP 15 - GOVERNOR Specifications... " 05-1 Adjustment GROUP 10 - CARBURETOR Removal Repair TM-1205 (Nov-78) Litho in U.S.A. Skid-Steer Loader - 90

8 Electrical Repair Contents Section 40 ELECTRICAL REPAIR GROUP 05 - SPECIFICATIONS Specifications GROUP 10 - STARTER Repair Disassembly Inspection Checking Armature Testing Field Coil..., 10-3 Testing Solenoid Assembly Testing Pinion Clearance TM-1205 (Nov-78) Litho in U.S.A. Skid-Steer Loader - 90

9 Power Train Contents R Section IN REPAIR GROUP 05 - SPECIFICATIONS GROUP 15 - HYDROSTATIC MOTOR Specifications Removal Disassembly GROUP 10 - HYDROSTATIC PUMP Repair Removal Assembly Disassembly Assembly GROUP 20 - FINAL DRIVE Installation Repair Removal Installation TM-1205 (Nov-78) Litho in U.SA Skid-Steer Loader - 90

10 Steering and Brake Repair STEERING Section 60 o BRAKE REP IR GROUP 05 - STEERING GROUP 10 - BRAKES Repair Repair Adjustment Adjustment TM-1205 (Nov-78) Litho in U.S.A Skid-Steer Loader - 90

11 Hydraulic Repair Contents 70~OO~ 1 ORA GROUP 05 - HYDRAULIC PUMP GROUP 10 - CYLINDERS Repair Repair TM-1205 (Nov-78) Litho in U.S.A. Skid-Steer Loader - 90

12 Gasoline Engine Operation and Test Contents Section 225 GASOLINE ENGINE OPERATION AND TEST GROUP 05 - SPECIFICATIONS GROUP 15 - ENGINE ANALYSIS Specifications Preliminary Engine Checks Preliminary Engine Test GROUP 10 - SYSTEM OPERATION Compression Test General Information Valves Cooling Piston and Piston Rings Fuel Pump GROUP 20 - DIAGNOSING MALFUNCTIONS Diagnosing Malfunctions TM-1205 (Nov-78) Litho in U.S.A. Skid-Steer Loader - 90

13 Gasoline Engine Operation and Tests Engine Analysis PISTON AND PISTON RINGS M1703CN Fig. 6-Top Ring and Groove Side Wear Fig. 4-Scored Piston and Rings Light scuffing or scoring of rings and piston occurs when high friction and combustion temperatures approach the melting point of the piston material. Check piston ring grooves carefully, especially the top groove. High temperature and pressure, plus airborne abrasives that enter the combustion chamber, cause wear on the top ring and groove.. If this condition is found, check for and correct the following causes: Dirty cooling shroud and cylinder head fins. Lack of cylinder lubrication. Improper combustion. Wrong bearing or piston clearance. Too much oil in crankcase. Fig. 7-Piston Rings Stuck and Broken Because of Lacquer, Varnish and Carbon Build-Up Fig. 5-Piston Rings with Improper End Gap. Wrong size rings or rings having improper end gap, will not conform to the cylinder. This results in high oil consumption and excessive blowby. High engine operating temperatures will cause varnish, lacquer or carbon deposits to form in the piston ring grooves causing the rings to stick. Sticking rings will cause high oil consumption and loss of compression. Engine heating and sticking rings are caused by: High oil consumption and blowby could also be caused by ring end gaps being in alignment. Ring end gaps should be staggered on the piston during installation. Overloading. Pre-Ignition. Dirty cooling fins. Incorrect oil. Low oil supply. Stale fuel. TM-1205 (Nov-78) Litho in U.S.A. Skid-Steer Loader - 90

14 Electrical Operation and Tests Section 240 ELE TRI AL PERATI N NO TESTS GROUP 05 - SPECIFICATIONS Specifications GROUP 10 - SYSTEM OPERATION Wiring Diagram General Information Battery..., GROUP 15 - SYSTEM TESTING Flywheel Alternator Inspection Stator Test Rectifier Test Regulator Test GROUP 20 - DIAGNOSING MALFUNCTIONS Diagnosing Malfunctions TM-1205 (Nov-78) Litho in U.S.A. Skid-Steer Loader - 90

15 Power Train Operation and Tests Contents p ER TRAIN PERATI N Secti GROUP 05 - SPECIFICATIONS Specifications GROUP 10 - SYSTEM OPERATION Hydrostatic Drive Final Drive GROUP 15 - SYSTEM TESTING Hydrostatic Drive GROUP 20 - DIAGNOSING MALFUNCTIONS Diagnosing Malfunctions TM-1205 (Nov-78) Litho in U.S.A. Skid-Steer Loader - 90

16 Hydraulic Operation and Tests Contents Section 270 HYDRAULIC OPERATION AND TESTS GROUP 05 - SPECIFICATIONS GROUP 15 - SYSTEM TESTING Specifications Relief Pressure GROUP 10 - SYSTEM OPERATION GROUP 20 - DIAGNOSING MALFUNCTION General Information Diagnosing Malfunctions Main Control Valve TM-1205 (Nov-78) Litho in U.S.A. Skid-Steer Loader - 90