John deere 2305 compact utility tractor service repair manual (tm2289)

service repair manual

1. TM2289 FEBRUARY 2011
JOHN DEERE
WORLDWIDE COMMERCIAL & CONSUMER
EQUIPMENT DIVISION
*IFVYEV]
Compact Utility Tractor
2305
TECHNICAL MANUAL
North American Version
Litho In U.s.a.

2. -R XVSH YGX MSR
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WTI GM JMGEXMS RWM RX LMWQ ER YE PEV IF EWI H
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TY FP MGEXMS R 8 LI V M KL XMWV IWI V ZIH XS
QE OIGL ER KI WEX ER ]XMQ I[M XLS YX
RS XMGI
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(IIV I 'S
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% PPVMK LXW V IWI V ZIH
4 VIZMSY W) HMXMS RW
'34 = 6-+, 8
INTRODUCTION
Specifications and Information
Engine
Power Train
Brakes
Safety
Hydraulics
Electrical
Steering
Miscellaneous
Manual Description
8LMWXIGLRMGEPQERYEPMW[VMXXIRJSVERI\TIVMIRGIH
XIGLRMGMERERHGSRXEMRWWIGXMSRWXLEXEVIWTIGMJMGEPP]JSV
XLMWTVSHYGX-XMWETEVXSJEXSXEPTVSHYGXWYTTSVXTVSKVEQ
8LIQERYEPMWSVKERM^IHWSXLEXEPPXLIMRJSVQEXMSRSRE
TEVXMGYPEVW]WXIQMWOITXXSKIXLIV8LISVHIVSJKVSYTMRKMW
EWJSPPS[W
y 8EFPISJ'SRXIRXW
c 7TIGMJMGEXMSRWERH-RJSVQEXMSR
c -HIRXMJMGEXMSR2YQFIVW
c 8SSPWERH1EXIVMEPW
c 'SQTSRIRX0SGEXMSR
c 7GLIQEXMGWERH,EVRIWWIW
c 8LISV]SJ3TIVEXMSR
c 3TIVEXMSRERH(MEKRSWXMGW
c (MEKRSWXMGW
c 8IWXWERH%HNYWXQIRXW
c 6ITEMV
c 3XLIV
Note: Depending on the particular section or system
being covered, not all of the above groups may be
used.
8LIFPIIHXEFWJSVXLITEKIWSJIEGLWIGXMSR[MPPEPMKR[MXL
XLIWIGXMSRWPMWXIHSRXLMWTEKI4EKIRYQFIVMRKMW
GSRWIGYXMZIJVSQXLIFIKMRRMRKSJXLI7EJIX]WIGXMSR
XLVSYKLXLIPEWXWIGXMSR
;IETTVIGMEXI]SYVMRTYXSRXLMWQERYEP-J]SYJMRHER]
IVVSVWSV[ERXXSGSQQIRXSRXLIPE]SYXSJXLIQERYEP
TPIEWIGSRXEGXYW

3. 7E JI X]
SAFETY
7EJIX]
Recognize Safety Information
1-*
8LMWMWXLIWEJIX]EPIVXW]QFSP;LIR]SYWIIXLMWW]QFSP
SR]SYVQEGLMRISVMRXLMWQERYEPFIEPIVXXSXLITSXIRXMEP
JSVTIVWSREPMRNYV]
*SPPS[VIGSQQIRHIHTVIGEYXMSRWERHWEJIWIVZMGMRK
TVEGXMGIW
Understand Signal Words
%WMKREP[SVH(%2+)6;%62-2+SV'%98-32MW
YWIH[MXLXLIWEJIX]EPIVXW]QFSP(%2+)6MHIRXMJMIWXLI
QSWXWIVMSYWLE^EVHW
(%2+)6SV;%62-2+WEJIX]WMKRWEVIPSGEXIHRIEV
WTIGMJMGLE^EVHW+IRIVEPTVIGEYXMSRWEVIPMWXIHSR
'%98-32WEJIX]WMKRW'%98-32EPWSGEPPWEXXIRXMSRXS
WEJIX]QIWWEKIWMRXLMWQERYEP
Replace Safety Signs
1-*
6ITPEGIQMWWMRKSVHEQEKIHWEJIX]WMKRW7IIXLI
QEGLMRISTIVEXSVvWQERYEPJSVGSVVIGXWEJIX]WMKR
TPEGIQIRX
Handle Fluids Safely - Avoid Fires
Be Prepared For Emergencies
1-*
c ;LIR]SY[SVOEVSYRHJYIPHSRSXWQSOISV[SVORIEV
LIEXIVWSVSXLIVJMVILE^EVHW
c 7XSVIJPEQQEFPIJPYMHWE[E]JVSQJMVILE^EVHW(SRSX
MRGMRIVEXISVTYRGXYVITVIWWYVM^IHGSRXEMRIVW
c 1EOIWYVIQEGLMRIMWGPIERSJXVEWLKVIEWIERH
HIFVMW
c (SRSXWXSVISMP]VEKWXLI]GERMKRMXIERHFYVR
WTSRXERISYWP]
c &ITVITEVIHMJEJMVIWXEVXW
c /IITEJMVWXEMHOMXERHJMVII\XMRKYMWLIVLERH]
c /IITIQIVKIRG]RYQFIVWJSVHSGXSVWEQFYPERGI
WIVZMGILSWTMXEPERHJMVIHITEVXQIRXRIEV]SYVXIPITLSRI
Use Care In Handling and Servicing Batteries
1-*

4. 7E JI X]
SAFETY
Prevent Battery Explosions
c /IITWTEVOWPMKLXIHQEXGLIWERHSTIRJPEQIE[E]
JVSQXLIXSTSJFEXXIV]&EXXIV]KEWGERI\TPSHI
c 2IZIVGLIGOFEXXIV]GLEVKIF]TPEGMRKEQIXEPSFNIGX
EGVSWWXLITSWXW9WIEZSPXQIXIVSVL]HVSQIXIV
c (SRSXGLEVKIEJVS^IRFEXXIV]MXQE]I\TPSHI;EVQ
FEXXIV]XS”'”*
Prevent Acid Burns
c 7YPJYVMGEGMHMRFEXXIV]IPIGXVSP]XIMWTSMWSRSYW-XMW
WXVSRKIRSYKLXSFYVRWOMRIEXLSPIWMRGPSXLMRKERH
GEYWIFPMRHRIWWMJWTPEWLIHMRXSI]IW
Avoid acid burns by:
*MPPMRKFEXXIVMIWMRE[IPPZIRXMPEXIHEVIE
;IEVMRKI]ITVSXIGXMSRERHVYFFIVKPSZIW
%ZSMHMRKFVIEXLMRKJYQIW[LIRIPIGXVSP]XIMWEHHIH
%ZSMHMRKWTMPPMRKSVHVMTTMRKIPIGXVSP]XI
9WITVSTIVNYQTWXEVXTVSGIHYVI
If you spill acid on yourself:
*PYWL]SYVWOMR[MXL[EXIV
%TTP]FEOMRKWSHESVPMQIXSLIPTRIYXVEPM^IXLIEGMH
*PYWL]SYVI]IW[MXL[EXIVJSVQMRYXIW
+IXQIHMGEPEXXIRXMSRMQQIHMEXIP]
If acid is swallowed:
(VMROPEVKIEQSYRXWSJ[EXIVSVQMPO
8LIRHVMROQMPOSJQEKRIWMEFIEXIRIKKWSVZIKIXEFPI
SMP
+IXQIHMGEPEXXIRXMSRMQQIHMEXIP]
Wear Protective Clothing
1-*
;IEVGPSWIJMXXMRKGPSXLMRKERHWEJIX]IUYMTQIRX
ETTVSTVMEXIXSXLINSF
4VSPSRKIHI\TSWYVIXSPSYHRSMWIGERGEYWIMQTEMVQIRXSV
PSWWSJLIEVMRK;IEVEWYMXEFPILIEVMRKTVSXIGXMZIHIZMGI
WYGLEWIEVQYJJWSVIEVTPYKWXSTVSXIGXEKEMRWX
SFNIGXMSREFPISVYRGSQJSVXEFPIPSYHRSMWIW
3TIVEXMRKIUYMTQIRXWEJIP]VIUYMVIWXLIJYPPEXXIRXMSRSJXLI
STIVEXSV(SRSX[IEVVEHMSSVQYWMGLIEHTLSRIW[LMPI
STIVEXMRKQEGLMRI
Use Care Around High-pressure Fluid Lines
Avoid High-Pressure Fluids
1-*
)WGETMRKJPYMHYRHIVTVIWWYVIGERTIRIXVEXIXLIWOMR
GEYWMRKWIVMSYWMRNYV]
%ZSMHMRNYV]JVSQIWGETMRKJPYMHYRHIVTVIWWYVIF]WXSTTMRK
XLIIRKMRIERHVIPMIZMRKTVIWWYVIMRXLIW]WXIQFIJSVI
HMWGSRRIGXMRKSVGSRRIGXMRKL]HVEYPMGSVSXLIVPMRIW
8MKLXIREPPGSRRIGXMSRWFIJSVIETTP]MRKTVIWWYVI
7IEVGLJSVPIEOW[MXLETMIGISJGEVHFSEVH4VSXIGXLERHW
ERHFSH]JVSQLMKLTVIWWYVIJPYMHW
-JEREGGMHIRXSGGYVWWIIEHSGXSVMQQIHMEXIP]%R]JPYMH
MRNIGXIHMRXSXLIWOMRQYWXFIWYVKMGEPP]VIQSZIH[MXLMRE
JI[LSYVWSVKERKVIRIQE]VIWYPX(SGXSVWYRJEQMPMEV[MXL
XLMWX]TISJMRNYV]WLSYPHVIJIVIRGIEORS[PIHKIEFPI
QIHMGEPWSYVGI7YGLMRJSVQEXMSRMWEZEMPEFPIJVSQ(IIVI
'SQTER]1IHMGEP(ITEVXQIRXMR1SPMRI-PPMRSMW97%
Avoid Heating Near Pressurized Fluid Lines
1-*
*PEQQEFPIWTVE]GERFIKIRIVEXIHF]LIEXMRKRIEV
TVIWWYVM^IHJPYMHPMRIWVIWYPXMRKMRWIZIVIFYVRWXS]SYVWIPJ
ERHF]WXERHIVW(SRSXLIEXF][IPHMRKWSPHIVMRKSVYWMRK
EXSVGLRIEVTVIWWYVM^IHJPYMHPMRIWSVSXLIVJPEQQEFPI
QEXIVMEPW4VIWWYVM^IHPMRIWGERFIEGGMHIRXEPP]GYX[LIR
LIEXKSIWFI]SRHXLIMQQIHMEXIJPEQIEVIE

5. 7E JI X]
SAFETY
Service Machines Safely
1-*
8MIPSRKLEMVFILMRH]SYVLIEH(SRSX[IEVERIGOXMI
WGEVJPSSWIGPSXLMRKSVRIGOPEGI[LIR]SY[SVORIEV
QEGLMRIXSSPWSVQSZMRKTEVXW-JXLIWIMXIQW[IVIXSKIX
GEYKLXWIZIVIMRNYV]GSYPHVIWYPX
6IQSZIVMRKWERHSXLIVNI[IPV]XSTVIZIRXIPIGXVMGEPWLSVXW
ERHIRXERKPIQIRXMRQSZMRKTEVXW
Use Proper Tools
9WIXSSPWETTVSTVMEXIXSXLI[SVO1EOIWLMJXXSSPWERH
TVSGIHYVIWGERGVIEXIWEJIX]LE^EVHW9WITS[IVXSSPW
SRP]XSPSSWIRXLVIEHIHTEVXWERHJEWXIRIVW*SVPSSWIRMRK
ERHXMKLXIRMRKLEVH[EVIYWIXLIGSVVIGXWM^IXSSPWDO
NOTYWI97QIEWYVIQIRXXSSPWSRQIXVMGJEWXIRIVW
%ZSMHFSHMP]MRNYV]GEYWIHF]WPMTTMRK[VIRGLIW9WISRP]
WIVZMGITEVXWQIIXMRK.SLR(IIVIWTIGMJMGEXMSRW
Park Machine Safely
1-*
Before working on the machine:
7XSTQEGLMRISREPIZIPWYVJEGIRSXSREWPSTI
(MWIRKEKI483ERHWXSTEXXEGLQIRXW
0S[IVEXXEGLQIRXWXSXLIKVSYRH
0SGOTEVOFVEOI
7XSTIRKMRI
6IQSZIOI]
;EMXJSVIRKMRIERHEPPQSZMRKTEVXWXSWXSTFIJSVI]SY
PIEZIXLISTIVEXSVvWWXEXMSR
'PSWIJYIPWLYXSJJZEPZIMJ]SYVQEGLMRIMWIUYMTTIH
(MWGSRRIGXXLIRIKEXMZIFEXXIV]GEFPIFIJSVI
WIVZMGMRKXLIQEGLMRI
,ERKEw(323834)6%8)xXEKMRSTIVEXSVWXEXMSR
Support Machine Properly and Use Proper
Lifting Equipment
1-*
-J]SYQYWX[SVOSREPMJXIHQEGLMRISVEXXEGLQIRX
WIGYVIP]WYTTSVXXLIQEGLMRISVEXXEGLQIRX
(SRSXWYTTSVXXLIQEGLMRISRGMRHIVFPSGOWLSPPS[XMPIW
SVTVSTWXLEXQE]GVYQFPIYRHIVGSRXMRYSYWPSEH(SRSX
[SVOYRHIVEQEGLMRIXLEXMWWYTTSVXIHWSPIP]F]ENEGO
*SPPS[VIGSQQIRHIHTVSGIHYVIWMRXLMWQERYEP
0MJXMRKLIEZ]GSQTSRIRXWMRGSVVIGXP]GERGEYWIWIZIVI
MRNYV]SVQEGLMRIHEQEKI*SPPS[VIGSQQIRHIH
TVSGIHYVIJSVVIQSZEPERHMRWXEPPEXMSRSJGSQTSRIRXWMRXLI
QERYEP
Work In Clean Area
Before starting a job:
'PIER[SVOEVIEERHQEGLMRI
1EOIWYVI]SYLEZIEPPRIGIWWEV]XSSPWXSHS]SYVNSF
,EZIXLIVMKLXTEVXWSRLERH
6IEHEPPMRWXVYGXMSRWXLSVSYKLP]HSRSXEXXIQTX
WLSVXGYXW
Using High Pressure Washers
(MVIGXMRKTVIWWYVM^IH[EXIVEXIPIGXVSRMGIPIGXVMGEP
GSQTSRIRXWSVGSRRIGXSVWFIEVMRKWL]HVEYPMGWIEPWJYIP
MRNIGXMSRTYQTWSVSXLIVWIRWMXMZITEVXWERHGSQTSRIRXW
QE]GEYWITVSHYGXQEPJYRGXMSRW6IHYGITVIWWYVIERH
WTVE]EXEXSHIKVIIERKPI

6. 7T IGMJMG EXMS R W-R JS V Q EX MSR 8E FPISJ' SR XIRXW
SPECIFICATIONS & INFORMATION TABLE OF CONTENTS
7TIGMJMGEXMSRW-RJSVQEXMSR
Table of Contents
General Specifications...................................11
1IXVMG*EWXIRIV8SVUYI:EPYIW
1IXVMG*EWXIRIV8SVUYI:EPYIW{+VEHI
-RGL*EWXIRIV8SVUYI:EPYIW
Seal Service Recommendations ...................14
*EGI7IEP*MXXMRKW[MXL-RGL7XYH)RHW
8SVUYI
*EGI7IEP*MXXMRKW[MXL1IXVMG7XYH)RHW
8SVUYI
36MRK*EGI7IEP*MXXMRKW
36MRK&SWW*MXXMRKW
+EWOIX7IEPERX%TTPMGEXMSR
Fuels and Lubricants......................................17
(MIWIP*YIP7TIGMJMGEXMSRW
(MIWIP*YIP0YFVMGMX]
(MIWIP*YIP7XSVEKI
)RKMRI3MP
%PXIVREXMZI0YFVMGERXW
7]RXLIXMG0YFVMGERXW
0YFVMGERX7XSVEKI
1M\MRK3J0YFVMGERXW
'LEWWMW+VIEWI
8VERWE\PI3MP
*VSRX%\PI+IEV'EWI3MP
Coolant ............................................................20
6IGSQQIRHIH)RKMRI'SSPERX
Serial Number Locations ...............................20
1EGLMRI4VSHYGX-HIRXMJMGEXMSR2YQFIV
)RKMRI7IVMEP2YQFIV

7. 7T IGMJ MGEX MSR W -RJS V Q E XMSR + IR IVEP7 T IGMJ MGE XMSR W
SPECIFICATIONS & INFORMATION GENERAL SPECIFICATIONS
General Specifications Metric Fastener Torque Values
UT2274
c (3238YWIXLIWILERHXSVUYIZEPYIWMJEHMJJIVIRX
XSVUYIZEPYISVXMKLXIRMRKTVSGIHYVIMWKMZIRJSVEWTIGMJMG
ETTPMGEXMSR8SVUYIZEPYIWPMWXIHEVIJSVKIRIVEPYWISRP]
ERHMRGPYHIE• ZEVMERGIJEGXSV'LIGOXMKLXRIWWSJ
JEWXIRIVWTIVMSHMGEPP](3238YWIEMVTS[IVIH[VIRGLIW
c 7LIEVFSPXWEVIHIWMKRIHXSJEMPYRHIVTVIHIXIVQMRIH
PSEHW%P[E]WVITPEGIWLIEVFSPXW[MXLMHIRXMGEPKVEHI
c *EWXIRIVWWLSYPHFIVITPEGIH[MXLXLIWEQIGPEWW
1EOIWYVIJEWXIRIVXLVIEHWEVIGPIERERHXLEX]SYTVSTIVP]
WXEVXXLVIEHIRKEKIQIRX8LMW[MPPTVIZIRXXLIQJVSQJEMPMRK
[LIRXMKLXIRMRK
c ;LIRFSPXERHRYXGSQFMREXMSRJEWXIRIVWEVIYWIH
XSVUYIZEPYIWWLSYPHFIETTPMIHXSXLINUTMRWXIEHSJXLI
FSPXLIEH
c 8MKLXIRXSSXLIHSVWIVVEXIHX]TIPSGORYXWXSXLIJYPP
XSVUYIZEPYI
E
“Lubricated” means coated with a lubricant such as
engine oil, or fasteners with phosphate and oil
coatings. “Dry” means plain or zinc plated (yellow
dichromate—Specification JDS117) without any
lubrication.
6IJIVIRGI.(7
UT2274
4.8
8.8 9.8
10.9
12.9
5 10
Property
Class
and
Head
Markings
Property
Class
and
Nut
Markings
4.8
4.8
5
8.8
8.8
9.8
9.8
10.9
10.9 12.9
12.9
12.9
12
1210 10
10
10
10
'PEWW 'PEWWSV 'PEWW 'PEWW
Mvcsjdbufe
b
Esz
b
Mvcsjdbufe
b
Esz
b
Mvcsjdbufe
b
Esz
b
Mvcsjdbufe
b
Esz
b
7->)2cQPFJX 2cQ PFJX2cQPFJX 2cQ PFJX2cQPFJX 2cQ PFJX2cQPFJX 2cQ PFJX
N7 5/94/6 7 5/6 : 7/6 22 9/6 24 :/6 28 23 26 22/6 2: 25/6
N9 23 9/6 26 22 33 27 39 31 43 35 51 41 48 39 58 46
N21 34 28 3: 32 54 43 66 51 74 58 91 71 86 66 :6 81
N23 51 3: 61 48 86 66 :6 81 22191 251 216 241:6 276 231
N25 74 58 91 71 23199 261 221 286241 336 276 316261 371 2:1
N27 21184 236 :3 2:1251 351 286 386311 461 336 431351 511 411
N29 246211 286 236 3712:6 441 361 486386 586 461 551436 671 521
N31 2:1251 351 291 486386 586 461 641511 786 611 736571 911 691
N33 3712:1 441 361 621486 761 586 836651 :36 786 961736 2186 911
N35 441361 536 421 761586 936 711 :36786 2261 961 2186911 2461 2111
N38 5:1471 736 561 :61811 2311 986 24612111 2811 2361 27112261 3111 2611
N41 7865:1 961 736 2411:61 2761 2311 29612461 3411 2811 32612711 3811 3111
N44 :11786 2261 961 28612411 3311 2761 36112961 4261 3461 3:113261 4811 3861
N47 2261961 2561 2186 33612761 3961 3211 43113461 5161 4111 48613861 5861 4611

8. 7T IGMJ MGEX MSR W -RJS V Q E XMSR + IR IVEP7 T IGMJ MGE XMSR W
SPECIFICATIONS & INFORMATION GENERAL SPECIFICATIONS
Metric Fastener Torque Values—Grade 7
Size Steel or Gray
Iron Torque
Aluminum
Torque
2cQPFJX 2cQPFJX
1
1
1
1
1
1

9. 7T IGMJ MGEX MSR W -RJS V Q E XMSR + IR IVEP7 T IGMJ MGE XMSR W
SPECIFICATIONS & INFORMATION GENERAL SPECIFICATIONS
Inch Fastener Torque Values
UT2273
c (3238YWIXLIWILERHXSVUYIZEPYIWMJEHMJJIVIRX
XSVUYIZEPYISVXMKLXIRMRKTVSGIHYVIMWKMZIRJSVEWTIGMJMG
ETTPMGEXMSR8SVUYIZEPYIWPMWXIHEVIJSVKIRIVEPYWISRP]
ERHMRGPYHIE• ZEVMERGIJEGXSV'LIGOXMKLXRIWWSJ
JEWXIRIVWTIVMSHMGEPP](3238YWIEMVTS[IVIH[VIRGLIW
c 7LIEVFSPXWEVIHIWMKRIHXSJEMPYRHIVTVIHIXIVQMRIH
PSEHW%P[E]WVITPEGIWLIEVFSPXW[MXLMHIRXMGEPKVEHI
c *EWXIRIVWWLSYPHFIVITPEGIH[MXLXLIWEQIGPEWW
1EOIWYVIJEWXIRIVXLVIEHWEVIGPIERERHXLEX]SYTVSTIVP]
WXEVXXLVIEHIRKEKIQIRX8LMW[MPPTVIZIRXXLIQJVSQJEMPMRK
[LIRXMKLXIRMRK
c ;LIRFSPXERHRYXGSQFMREXMSRJEWXIRIVWEVIYWIH
XSVUYIZEPYIWWLSYPHFIETTPMIHXSXLINUTMRWXIEHSJXLI
FSPXLIEH
c 8MKLXIRXSSXLIHSVWIVVEXIHX]TIPSGORYXWXSXLIJYPP
XSVUYIZEPYI
E
“Lubricated” means coated with a lubricant such as
engine oil, or fasteners with phosphate and oil
coatings. “Dry” means plain or zinc plated (yellow
dichromate—Specification JDS117) without any
lubrication.
F
“Grade 2” applies for hex cap screws (not hex bolts)
up to 152 mm (6 in.) long “Grade 1” applies for hex cap
screws over 152 mm (6 in.) long, and for all other types
of bolts and screws of any length.
6IJIVIRGI.(7+
UT2273
1 or 2
b
2
5 5.1 5.2
5
8 8.2
8
No Marks
No Marks
SAE
Grade
and Nut
Markings
SAE
Grade
and Head
Markings
+VEHI +VEHI
c
+VEHISV +VEHISV
Mvcsjdbufe
b
Esz
b
Mvcsjdbufe
b
Esz
b
Mvcsjdbufe
b
Esz
b
Mvcsjdbufe
b
Esz
b
7->)2cQPFJX 2cQ PFJX2cQPFJX 2cQ PFJX2cQPFJX 2cQ PFJX2cQPFJX 2cQ PFJX
205 4/83/9 5/8 4/6 7 5/6 8/6 6/6 :/68 23 : 24/621 28 23/6
60278/86/6 21 8 23 : 26 22 31 26 36 29 39 32 46 37
409 25 21 28 24 33 27 38 31 46 37 55 44 61 47 74 57
802733 27 39 31 46 37 55 43 66 52 81 63 91 69 211 86
203 44 36 53 42 64 4: 78 61 96 74 221 91 231:1 261 226
:02759 47 71 56 86 67 :6 81 236:1 266 226 286241 336 271
609 78 61 96 73 21689 246 211 281236 326 271 326271 411 336
405 23198 261 221 2:1251 351 286 411336 486 391 536421 661 511
809 2:1251 351 286 2:1251 351 286 5:1471 736 561 811611 986 761
2 3:1321 471 381 3:1321 471 381 836651 :36 786 2161861 2411 :86
2.209581411 621 486 581411 621 486 :11786 2261 961 25612186 2961 2461
2.205681536 836 641 681536 836 641 2411:61 2761 2311 31612611 3711 2:61
2.409861661 :61 811 861661 :61 811 28112361 3261 2661 38113111 4511 3661
2.2032111836 2361 :36 ::1836 2361 :41 33612761 3961 3211 47113761 5661 4461

10. 7T IG MJMGE XMSR W -R JSV QEXM S R 7I EP7 IV ZMGI 6I GSQQ IR HE XMS RW
SPECIFICATIONS & INFORMATION SEAL SERVICE
Seal Service Recommendations Face Seal Fittings with Inch Stud Ends Torque
NJG
Note: Torque tolerance is +15%, -20%
Stud End Tube Nut
Swivel Nut
Lock Nut
Tube Nut
Stud End
7XVEMKLX7XYHERH8YFI2YX
&YPOLIEH9RMSRERH&YPOLIEH0SGO2YX
”7[MZIP)PFS[ERH8YFI2YX
”%HNYWXEFPI7XYH)PFS[
Nominal Tube OD/Hose ID Face Seal Tube/Hose End O-Ring Stud Ends
Metric
Tube
OD
Inch Tube OD Thread
Size
Tube Nut/
Swivel Nut
Torque
Bulkhead
Lock Nut
Torque
Thread
Size
Straight Fitting
or Lock Nut
Torque
mm Dash
Size
in. mm in. N•m lb-ft N•m lb-ft in. N•m lb-ft
.4 1/299 5/87 409.35 9 7
7 .5 1/361 7/46 :027.29 27 23 23 : 8027.31 23 :
9 .6 1/423 8/:5 203.31 27 23
21 .7 1/486 :/63 22027.27 35 29 35 29 :027.29 35 29
23 .9 1/611 23/81 24027.27 61 48 57 45 405.27 57 45
27 .21 1/736 26/99 2.25 7: 62 73 57 809.25 73 57
.23 1/861 2:/16 2.4027.23 213 86 213 86 2.2027.23 213 86
33 .25 1/986 33/33 2.4027.23 213 86 213 86 2.4027.23 233 :1
36 .27 2/111 36/51 2.8027.23 253 216 253 216 2.6027.23 253 216
43 .31 2/36 42/86 2.22027.23 2:1 251 2:1 251 2.609.23 2:1 251
49 .35 2/61 49/21 3.23 328 271 328 271 2.809.23 328 271

11. 7T IG MJMGE XMSR W -R JSV QEXM S R 7I EP7 IV ZMGI 6I GSQQ IR HE XMS RW
SPECIFICATIONS & INFORMATION SEAL SERVICE
Face Seal Fittings with Metric Stud Ends Torque
NJG
Note: Torque tolerance is +15%, -20%
Stud End Tube Nut
7XVEMKLX7XYHERH8YFI2YX
&YPOLIEH9RMSRERH&YPOLIEH0SGO2YX
Swivel Nut
Lock Nut
Tube Nut
Stud End
”7[MZIP)PFS[ERH8YFI2YX
”%HNYWXEFPI7XYH)PFS[
Groove for Metric
Identification
Groove for MetricIdentification
Nominal Tube OD/Hose ID Face Seal Tube/Hose End O-Ring Stud Ends, Straight Fitting or
Lock Nut
Metric
Tube
OD
Inch Tube OD Thread
Size
Hex
Size
Tube Nut/
Swivel
Nut
Torque
Bulkhead
Lock Nut
Torque
Thread
Size
Hex
Size
Steel or
Gray Iron
Torque
Aluminum
Torque
mm Dash
Size
in. mm in. mm N•m lb-ft N•m lb-ft mm mm N•m lb-ft N•m lb-ft
7 .5 1/361 7/46 :027.29 28 27 23 23 : N23Y2/6 28 32 26/6 : 7/7
9 .6 1/423 8/:5
N25Y2/6 2: 44 35 26 22
21 .7 1/486 :/63 22027.27 33 35 29 35 29 N27Y2/6 33 52 41 29 24
23 .9 1/611 23/81 24027.27 35 61 48 57 45 N29Y2/6 35 61 48 32 26
27 .21 1/736 26/99 2.25 41 7: 62 73 57 N33Y2/6 38 7: 62 39 32
.23 1/861 2:/16 2.4027.23 47 213 86 213 86 N38Y3 43 213 86 57 45
33 .25 1/986 33/33 2.4027.23 47 213 86 213 86 N41Y3 47
36 .27 2/111 36/51 2.8027.23 52 253 216 253 216 N44Y3 52 269 227 82 63
39 N49Y3 57 287 241 8: 69
43 .31 2/36 42/86 2.22027.23 61 2:1 251 2:1 251 N53Y3 61 2:1 251 96 74
49 .35 2/61 49/21 3.23 71 328 271 328 271 N59Y3 66 328 271 :9 83

12. 7T IG MJMGE XMSR W -R JSV QEXM S R 7I EP7 IV ZMGI 6I GSQQ IR HE XMS RW
SPECIFICATIONS & INFORMATION SEAL SERVICE
O-Ring Face Seal Fittings
NJG
-RWTIGXXLIJMXXMRKWIEPMRKWYVJEGIW%8LI]QYWXFI
JVIISJHMVXSVHIJIGXW
-RWTIGXXLI3VMRK&-XQYWXFIJVIISJHEQEKISV
efgfdut/
0YFVMGEXI3VMRKWERHMRWXEPPMRXSKVSSZIYWMRK
TIXVSPIYQNIPP]XSLSPHMRTPEGI
4YWL3VMRKMRXSXLIKVSSZI[MXLTPIRX]SJTIXVSPIYQ
NIPP]WS3VMRKMWRSXHMWTPEGIHHYVMRKEWWIQFP]
-RHI\ERKPIJMXXMRKWERHXMKLXIRF]LERHTVIWWMRKNSMRX
XSKIXLIVXSIRWYVI3VMRKVIQEMRWMRTPEGI
8MKLXIRJMXXMRKSVRYXXSXSVUYIZEPYIWLS[RSRXLIGLEVX
TIVHEWLWM^IWXEQTIHSRXLIJMXXMRK
O-Ring Boss Fittings
-RWTIGXFSWW3VMRKFSWWWIEX-XQYWXFIJVIISJHMVXERH
HIJIGXW-JVITIEXIHPIEOWSGGYVMRWTIGXJSVHIJIGXW[MXLE
QEKRMJ]MRKKPEWW7SQIVEMWIHHIJIGXWGERFIVIQSZIH
[MXLEWPMTWXSRI
NJG
4YXL]HVEYPMGSMPSVTIXVSPIYQNIPP]SRXLI3VMRK%
4PEGIIPIGXVMGEPXETISZIVXLIXLVIEHWXSTVSXIGX
3VMRKJVSQRMGOW7PMHI3VMRKSZIVXLIXETIERHMRXSXLI
KVSSZI&SJJMXXMRK6IQSZIXETI
NJG
*SVERKPIJMXXMRKWPSSWIRWTIGMEPRYX%ERHTYWL
WTIGMEP[EWLIV&EKEMRWXXLVIEHWWS3VMRKGERFI
MRWXEPPIHMRXSXLIKVSSZISJJMXXMRK
8YVRJMXXMRKMRXSXLIFSWWF]LERHYRXMPWTIGMEP[EWLIVSV
[EWLIVJEGIWXVEMKLXJMXXMRKGSRXEGXWFSWWJEGIERH3VMRK
MWWUYII^IHMRXSMXWWIEX
8STSWMXMSRERKPIJMXXMRKW'XYVRXLIJMXXMRKGSYRXIV
GPSGO[MWIEQE\MQYQSJSRIXYVR
8MKLXIRWXVEMKLXJMXXMRKWXSXSVUYIZEPYIWLS[RSRGLEVX
*SVERKPIJMXXMRKWXMKLXIRXLIWTIGMEPRYXXSZEPYIWLS[RMR
XLIGLEVX[LMPILSPHMRKFSH]SJJMXXMRK[MXLE[VIRGL
b
8SVUYIXSPIVERGIMW•TIVGIRX
c
8SFIYWIHMJEXSVUYI[VIRGLGERRSXFIYWIH%JXIV
XMKLXIRMRKJMXXMRKF]LERHTYXEQEVOSRRYXSVFSWWXLIR
XMKLXIRWTIGMEPRYXSVWXVEMKLXJMXXMRKXLIRYQFIVSJJPEXW
tipxo/
Important: Avoid Damage! DO NOT allow hoses
to twist when tightening fittings. Use two
wrenches to tighten hose connections; one to
hold the hose, and the other to tighten the swivel
fitting.
BAABA
Thread Size Torque
a
Number of
Flats
b
N•m lb-ft
409.35VOG 9 7 3
8027.31VOG 23 : 3
203.31VOG 27 23 3
:027.29VOG 35 29 3
405.27VOG 57 45 3
809.25VOG 73 57 2.203
2.2027.23VO 213 86 2
2.4027.23VO 233 :1 2
2.6027.23VO 253 216 405
2.609.23VO 2:1 251 405
2.809.23VO 328 271 203
ABC

13. 7TI GMJ MGEX MSR W -R JS V Q E XMS R *YI PWE RH 0YFV MGER XW
SPECIFICATIONS & INFORMATION FUELS AND LUBRICANTS
Gasket Sealant Application
Cleaning:
'PIERFSXLWYVJEGIWXLEX[MPPFINSMRIHYWMRK
MWSTVST]PEPGSLSP;MTII\GIWWSJJ[MXLEGPIERGPSXL
'PIERIVHIKVIEWIVGERFIWYFWXMXYXIHJSVMWSTVST]PEPGSLSP
How to Dispense/Apply/Assemble Gasket Sealants:
(MWTIRWIETTVS\MQEXIP]XSSYRGIWSJJPI\MFPIJSVQMR
TPEGIKEWOIXSREGPIERWLIIXSVXEFPIXST%ZSMHYWMRK
I\GIWWEQSYRXWXLEXQE]FII\TSWIHJSVPSRKTIVMSHWSJ
XMQI8LMW[MPPLIPTTVIZIRXGSRXEQMREXMSRJVSQWYVVSYRHMRK
EXQSWTLIVIWYGLEWHYWX[MXLQIXEPGSRXIRX
9WMRKERMROVSPPIVSVWMQMPEVHIZMWIETTP]XSSRIWYVJEGISJ
XLINSMRXF]PSEHMRKXLIVSPPIVJVSQETPEWXMGWLIIXERH
XVERWJIVVMRKXLIQEXIVMEPMREXLMRJMPQXSXLINSMRX8LI
ETTPMGEXMSRWLSYPHFIXLIXLMRRIWXJMPQTSWWMFPIFYX
TVSZMHMRKGSQTPIXIGSZIVEKI8LMWGERFINYHKIHF]XLI
ETTIEVERGISJXLINSMRXSRGIMXMWTYXXSKIXLIV)\GIWWMZI
EQSYRXWSJ[MPPGEYWIMRGSVVIGXFIEVMRKIRHTPE]I\XIRH
GYVIXMQIERH[MPPGEYWIVYRSJJSJXLIQEXIVMEP%WQEPP
FIEHSVFYMPHYTEXXLINSMRXMWTIVQMWWMFPIERHMRHMGEXIW
KSSHHMWTIVWMSRXLVSYKLXLINSMRX)\GIWWGERFI[MTIH
JVSQXLINSMRX.SMRMRKWLSYPHXEOITPEGI[MXLMRXLVII
QMRYXIWEJXIVWIEPERXETTPMGEXMSR
%TTP]TVSTIVGETWGVI[XSVUYIERHWIUYIRGIEW
ETTPMGEFPI%PPS[EQMRMQYQSJQMRYXIWFIJSVIEMVXIWXSV
EHHMRKSMPJSVXIWXWXERHYWEKI
Disassembly:
'YVIHQEXIVMEPGERFIVIQSZIH[MXLE[MVIFVYWLSV
WGVETIV'LIQMGEPGPIERIVWEVIEZEMPEFPIJSVGYWXSQIVYWI
WLSYPHXLI]FIHIIQIHRIGIWWEV]
Fuels and Lubricants
Diesel Fuel Specifications
-RKIRIVEPHMIWIPJYIPWEVIFPIRHIHXSWEXMWJ]XLIPS[EMV
XIQTIVEXYVIVIUYMVIQIRXWSJXLIKISKVETLMGEPEVIEMR
[LMGLXLI]EVIWSPH
-R2SVXL%QIVMGEHMIWIPJYIPMWYWYEPP]WTIGMJMIHXSASTM
D975ERHWSPHEWIMXLIVGrade 1JSVGSPHEMVXIQTIVEXYVIW
SVGrade 2JSV[EVQEMVXIQTIVEXYVIW
-JHMIWIPJYIPWFIMRKWYTTPMIHMR]SYVEVIE(3238QIIX
ER]SJXLIEFSZIWTIGMJMGEXMSRWYWIHMIWIPJYIPW[MXLXLI
JSPPS[MRKIUYMZEPIRXTVSTIVXMIW
cCetane Number 40 (minimum)
%GIXERIRYQFIVgreater than 50 is preferredIWTIGMEPP]
JSVEMVXIQTIVEXYVIWFIPS[z”'z”*SVIPIZEXMSRW
EFSZIQJX
cCold Filter Plugging Point (CFPP)
8LIEMVXIQTIVEXYVIEX[LMGLHMIWIPJYIPbegins to cloud
or jell{EXPIEWX”'”*FIPS[XLII\TIGXIHPS[EMV
XIQTIVEXYVIVERKI
cSulfur Content of 0.05% (maximum)
(MIWIPJYIPWJSVLMKL[E]YWIMRXLI9RMXIH7XEXIWRS[
VIUYMVIWYPJYVGSRXIRXXSFIless than 0.05%.
-JHMIWIPJYIPFIMRKYWIHLEWEWYPJYVGSRXIRXgreater than
0.05%, reduce the service interval for engine oil and
filter by 50%.
'SRWYPX]SYVPSGEPHMIWIPJYIPHMWXVMFYXSVJSVTVSTIVXMIWSJXLI
HMIWIPJYIPEZEMPEFPIMR]SYVEVIE
Diesel Fuel Lubricity
(MIWIPJYIPQYWXLEZIEHIUYEXIPYFVMGMX]XSIRWYVITVSTIV
STIVEXMSRERHHYVEFMPMX]SJJYIPMRNIGXMSRW]WXIQ
GSQTSRIRXW*YIPPYFVMGMX]WLSYPHTEWWEminimum of
3300 gram load levelEWQIEWYVIHF]XLIBOCLEWGYJJMRK
XIWX
G Caution: Avoid Injury! California
Proposition 65 Warning: Diesel engine
exhaust and some of its elements from this
product are known to the State of California
to cause cancer, birth defects, or other
reproductive harm.

14. 7TI GMJ MGEX MSR W -R JS V Q E XMS R *YI PWE RH 0YFV MGER XW
SPECIFICATIONS & INFORMATION FUELS AND LUBRICANTS
Diesel Fuel Storage
-XMWVIGSQQIRHIHXLEXHMIWIPJYIPFIWXSVIHONLYMRE
GPIERETTVSZIHPOLYETHYLENE PLASTIC GSRXEMRIV
WITHOUTER]QIXEPWGVIIRSVJMPXIV8LMW[MPPLIPTTVIZIRX
ER]EGGMHIRXEPWTEVOWJVSQSGGYVVMRK7XSVIJYIPMREREVIE
XLEXMW[IPPZIRXMPEXIHXSTVIZIRXTSWWMFPIMKRMXMRKSJJYQIW
F]ERSTIRJPEQISVWTEVOXLMWMRGPYHIWER]ETTPMERGI[MXL
ETMPSXPMKLX
/IITJYIPMREWEJITVSXIGXIHEVIEERHMREGPIERTVSTIVP]
QEVOIH(“DIESEL FUEL”)dpoubjofs/DO NOTYWIHIMGIVW
XSEXXIQTXXSVIQSZI[EXIVJVSQJYIPDO NOTHITIRHSR
JYIPJMPXIVWXSVIQSZI[EXIVJVSQJYIP-XMWVIGSQQIRHIH
XLEXE[EXIVWITEVEXSVFIMRWXEPPIHMRXLIWXSVEKIXERO
SYXPIXBE SUREXSTVSTIVP]HMWGEVHYRWXEFPISV
GSRXEQMREXIHHMIWIPJYIPERHSVXLIMVGSRXEMRIVW[LIR
ofdfttbsz/
Engine Oil
9WIXLIETTVSTVMEXISMPZMWGSWMX]FEWIHSRXLII\TIGXIHEMV
XIQTIVEXYVIVERKIHYVMRKXLITIVMSHFIX[IIR
VIGSQQIRHIHSMPGLERKIW3TIVEXMRKSYXWMHISJXLIWI
VIGSQQIRHIHSMPEMVXIQTIVEXYVIVERKIWQE]GEYWI
TVIQEXYVIIRKMRIJEMPYVI
8LIJSPPS[MRK.SLR(IIVISMPMW46)*)66)(
c .SLR(IIVI4097}
c 8365+%6(7946)1)}7%);
3XLIVSMPWQE]FIYWIHMJEFSZI.SLR(IIVISMPWEVIRSX
EZEMPEFPITVSZMHIHXLI]QIIXSRISJXLIJSPPS[MRK
WTIGMJMGEXMSRW
c 7%);%4-7IVZMGI'PEWWMJMGEXMSR'-SVLMKLIV
c %')%7TIGMJMGEXMSR))
c 7%);%4-7IVZMGI'PEWWMJMGEXMSR7,SVLMKLIV
Alternative Lubricants
'SRHMXMSRWMRGIVXEMRKISKVETLMGEPEVIEWSYXWMHIXLI9RMXIH
7XEXIWERH'EREHEQE]VIUYMVIHMJJIVIRXPYFVMGERX
VIGSQQIRHEXMSRWXLERXLISRIWTVMRXIHMRXLMWXIGLRMGEP
QERYEPSVXLISTIVEXSVWQERYEP'SRWYPX[MXL]SYV.SLR
(IIVI(IEPIVSV7EPIW&VERGLXSSFXEMRXLIEPXIVREXMZI
PYFVMGERXVIGSQQIRHEXMSRW
-JEPXIVREXMZIPYFVMGERXWEVIXSFIYWIHMXMWVIGSQQIRHIH
XLEXXLIJEGXSV]JMPPFIXLSVSYKLP]VIQSZIHFIJSVIW[MXGLMRK
XSER]EPXIVREXMZIPYFVMGERX
Synthetic Lubricants
7]RXLIXMGPYFVMGERXWQE]FIYWIHMR.SLR(IIVIIUYMTQIRX
MJXLI]QIIXXLIETTPMGEFPITIVJSVQERGIVIUYMVIQIRXW
MRHYWXV]GPEWWMJMGEXMSRERHSVQMPMXEV]WTIGMJMGEXMSREW
WLS[RMRXLMWQERYEP
8LIVIGSQQIRHIHEMVXIQTIVEXYVIPMQMXWERHWIVZMGISV
PYFVMGERXGLERKIMRXIVZEPWWLSYPHFIQEMRXEMRIHEWWLS[R
MRXLISTIVEXSVvWQERYEP
%ZSMHQM\MRKHMJJIVIRXFVERHWKVEHIWSVX]TIWSJSMP3MP
QERYJEGXYVIVWFPIRHEHHMXMZIWMRXLIMVSMPWXSQIIXGIVXEMR
WTIGMJMGEXMSRWERHTIVJSVQERGIVIUYMVIQIRXW1M\MRK
HMJJIVIRXSMPWGERMRXIVJIVI[MXLXLITVSTIVJYRGXMSRMRKSJ
XLIWIEHHMXMZIWERHHIKVEHIPYFVMGERXTIVJSVQERGI
Lubricant Storage
%PPQEGLMRIWSTIVEXIEXXSTIJJMGMIRG]SRP][LIRGPIER
PYFVMGERXWEVIYWIH9WIGPIERWXSVEKIGSRXEMRIVWXS
LERHPIEPPPYFVMGERXW7XSVIXLIQMREREVIETVSXIGXIHJVSQ
HYWXQSMWXYVIERHSXLIVGSRXEQMREXMSR7XSVIHVYQWSR
XLIMVWMHIW1EOIWYVIEPPGSRXEMRIVWEVITVSTIVP]QEVOIH
EWXSXLIMVGSRXIRXW(MWTSWISJEPPSPHYWIHGSRXEMRIVWERH
XLIMVGSRXIRXWTVSTIVP]
Important: Avoid Damage! DO NOT USE
GALVANIZED CONTAINERS—diesel fuel stored in
galvanized containers reacts with zinc coating in
the container to form zinc flakes. If fuel contains
water, a zinc gel will also form. The gel and flakes
will quickly plug fuel filters and damage fuel
injectors and fuel pumps.
Important: Avoid Damage! Keep all dirt, scale,
water or other foreign material out of fuel.
Important: Avoid Damage! Use of alternative
lubricants could cause reduced life of the
component.
43
1 213141 51.21.31.41
.33.5 25 61 79 97215
61
233
.51
.51
G
D
SAE 5W-30SAE 10W-30

15. 7TI GMJ MGEX MSR W -R JS V Q E XMS R *YI PWE RH 0YFV MGER XW
SPECIFICATIONS & INFORMATION FUELS AND LUBRICANTS
Mixing Of Lubricants
-RKIRIVEPEZSMHQM\MRKHMJJIVIRXFVERHWSVX]TIWSJ
PYFVMGERXW1ERYJEGXYVIVWFPIRHEHHMXMZIWMRXLIMVPYFVMGERXW
XSQIIXGIVXEMRWTIGMJMGEXMSRWERHTIVJSVQERGI
VIUYMVIQIRXW1M\MRKHMJJIVIRXPYFVMGERXWGERMRXIVJIVI[MXL
XLITVSTIVJYRGXMSRMRKSJXLIWIEHHMXMZIWERHPYFVMGERX
TVSTIVXMIW[LMGL[MPPHS[RKVEHIXLIMVMRXIRHIHWTIGMJMIH
qfsgpsnbodf/
Chassis Grease
9WIXLIJSPPS[MRKKVIEWIFEWIHSRXLIEMVXIQTIVEXYVI
VERKI3TIVEXMRKSYXWMHISJXLIVIGSQQIRHIHKVIEWIEMV
XIQTIVEXYVIVERKIQE]GEYWITVIQEXYVIJEMPYVIW
8LIJSPPS[MRK.SLR(IIVIKVIEWIMW46)*)66)(
cNON-CLAY HIGH-TEMPERATURE EP GREASE®—
JDM J13E4, NLGI Grade 2.
c 1YPXM4YVTSWI7(4SP]YVIE+VIEWI
c 1YPXM4YVTSWI,(0MXLMYQ'SQTPI\+VIEWI
3XLIVKVIEWIWQE]FIYWIHMJEFSZITVIJIVVIH.SLR(IIVI
KVIEWIMWRSXEZEMPEFPITVSZMHIHXLI]QIIXXLIJSPPS[MRK
WTIGMJMGEXMSR
c .SLR(IIVI7XERHEVH.(1.)20+-+VEHI
The following lubricant is preferred:
c 794)609&)}PYFVMGERX
2
Transaxle Oil
8LIWIQEGLMRIWEVIIUYMTTIH[MXLEMRXIVREP[IXHMWG
FVEOIXVERWQMWWMSR
(SRSXYWIX]TIw*xEYXSQEXMGXVERWQMWWMSRJPYMH
9WI,]+EVH}.'SV0S[:MWGSWMX],]+EVH.(
XVERWQMWWMSRSMP
.SLR(IIVI0S[:MWGSWMX],]+EVHXVERWQMWWMSRSMPMW
WTIGMEPP]JSVQYPEXIHJSVSTIVEXMSRFIPS[”'”*XS
TVSZMHIQE\MQYQTVSXIGXMSRJSVXLIL]HVEYPMGW]WXIQ
8LIJSPPS[MRK.SLR(IIVISMPMWPREFERRED:
cHy-Gard J20C Oil
8LIJSPPS[MRKSMPMWEPWSVIGSQQIRHIHMJEFSZITVIJIVVIHSMP
MWRSXEZEMPEFPISVJSVPS[XIQTIVEXYVISTIVEXMSR
cLow Viscosity Hy-Gard J20D Oil
9WIXLIETTVSTVMEXISMPZMWGSWMX]FEWIHSRXLIEMV
XIQTIVEXYVIVERKIW3TIVEXMRKSYXWMHISJXLIWI
VIGSQQIRHIHSMPEMVXIQTIVEXYVIVERKIWQE]GEYWI
TVIQEXYVIKIEVGEWIJEMPYVI
Front Axle Gear Case Oil
9WIXLIJSPPS[MRKSMPZMWGSWMX]FEWIHSRXLIEMVXIQTIVEXYVI
VERKI3TIVEXMRKSYXWMHISJXLIVIGSQQIRHIHSMPEMV
XIQTIVEXYVIVERKIQE]GEYWITVIQEXYVIKIEVGEWIJEMPYVI
8LIJSPPS[MRK.SLR(IIVIKIEVGEWISMPMWTVIJIVVIH
c +0+)%609&6-'%28’{7%);
3XLIVKIEVGEWISMPWQE]FIYWIHMJVIGSQQIRHIH.SLR
(IIVIKIEVGEWISMPMWRSXEZEMPEFPITVSZMHIHXLI]QIIXXLI
JSPPS[MRKWTIGMJMGEXMSR
c %4-7IVZMGI'PEWWMJMGEXMSR+0z
1. SUPER LUBE is a registered trademark of Synco Chemical Corp.
43
1 21 31 41 51.21.31.41
.33.5 25 61 79 97 215
61
233
.51
.51
G
D
J13E4 NLGI Grade 2
43
1 21 31 41 51.21.31.41
.33 .5 25 61 79 97 215
61
233
.51
.51
G
D
HY-GARD J20CLow Viscosity HY-GARD J20D
Important: Avoid Damage! Transaxle is filled with
John Deere HY-Gard™ (J20C) transmission oil at
the factory. DO NOT mix oils.
Important: Avoid Damage! If operating
temperatures are below -18°C (0°F), you must use
Low Viscosity HY-GARD™ or transmission
damage will occur.
Important: Avoid Damage! ONLY use a quality oil in
this gear case. DO NOT mix any other oils in this
gear case. DO NOT use BIO–HY–GARD® in this gear
case.
43
1 21314151.21.31.41
.33.525 61 79 97215
61
233
.51
.51
G
D
SAE 80W-90

16. 7TI GMJ MGE XMSR W -R JSV QEXM S R 'S SPE RX
SPECIFICATIONS & INFORMATION COOLANT
Coolant
Recommended Engine Coolant
8LIIRKMRIGSSPMRKW]WXIQMWJMPPIHXSTVSZMHI]IEVVSYRH
TVSXIGXMSREKEMRWXGSVVSWMSRERHG]PMRHIVPMRIVTMXXMRKERH
[MRXIVJVII^ITVSXIGXMSRXSHIKVIIW'HIKVIIW*-J
TVSXIGXMSREXPS[IVXIQTIVEXYVIWMWVIUYMVIHGSRWYPX]SYV
.SLR(IIVIHIEPIVJSVVIGSQQIRHEXMSRW
The following coolants are preferred:
c .SLR(IIVI'330+%6(--}4VIQM\
c .SLR(IIVI'330+%6(4VIQM\
c .SLR(IIVI'330+%6(4+4VIQM\
.SLR(IIVI'330+%6(--4VIQM\ERH.SLR(IIVI
'330+%6(4VIQM\EVIEZEMPEFPIMREGSRGIRXVEXMSRSJ
TVST]PIRIKP]GSP
.SLR(IIVI'330+%6(4+4VIQM\MWEZEMPEFPIMRE
GSRGIRXVEXMSRSJ TVST]PIRIKP]GSP
Additional recommended coolants:
c .SLR(IIVI'330+%6(--'SRGIRXVEXIMRE XS
QM\XYVISJGSRGIRXVEXI[MXL[EXIV
c .SLR(IIVI'330+%6('SRGIRXVEXIMRE XS
QM\XYVISJGSRGIRXVEXI[MXL[EXIV
If the recommended coolants are unavailable, use an
ethylene glycol or propylene glycol base coolant that
meets the following specification:
c %781(TVIHMPYXIH GSSPERX
c %781(GSSPERXGSRGIRXVEXIMRE XS
QM\XYVISJGSRGIRXVEXI[MXL[EXIV
'LIGOGSRXEMRIVPEFIPFIJSVIYWMRKXSFIWYVIMXLEWXLI
ETTVSTVMEXIWTIGMJMGEXMSRWJSV]SYVQEGLMRI9WIGSSPERX
[MXLGSRHMXMSRIVSVEHHGSRHMXMSRIVXSGSSPERXFIJSVIYWMRK
Water Quality
c ;EXIVUYEPMX]MWMQTSVXERXXSXLITIVJSVQERGISJXLI
GSSPMRKW]WXIQ(MWXMPPIHHIMSRM^IHSVHIQMRIVEPM^IH[EXIV
MWVIGSQQIRHIH[MXLIXL]PIRIKP]GSPFEWIIRKMRIGSSPERX
dpodfousbuf/
Serial Number Locations
Machine Product Identification Number
;LIRSVHIVMRKTEVXWSVWYFQMXXMRKE[EVVERX]GPEMQMXMW
-14368%28XLEXXLIQEGLMRITVSHYGXMHIRXMJMGEXMSR
RYQFIV4-2ERHGSQTSRIRXWIVMEPRYQFIVWEVIMRGPYHIH
8LIPSGEXMSRSJXLI4-2ERHGSQTSRIRXWIVMEPRYQFIVWEVI
tipxo/
NY46174
0SGEXIHSRVMKLXLERHWMHISJJVEQIFIRIEXLXLIJVSRXSJ
XLIIRKMRI
Engine Serial Number
NY46175
0SGEXIHSRXSTSJXLIIRKMRIVSGOIVGSZIV
Important: Avoid Damage! Using incorrect coolant
mixture can cause overheating and damage to the
radiator and engine:
• Do not operate engine with plain water.
• Do not exceed a 50% mixture of coolant and
water.
• Aluminum engine blocks and radiators require
approved ethylene-glycol based coolant.
A A

17. )R KMR I 82 : 8E FPI S J' SR XIRXW
ENGINE - 3TNV76 TABLE OF CONTENTS
)RKMRI82:
Table of Contents
Specifications .................................................23
+IRIVEP82:
3TIVEXMSREP8IWXW
8IWXWERH%HNYWXQIRX7TIGMJMGEXMSRW
6ITEMV7TIGMJMGEXMSRW
8MKLXIRMRK8SVUYIW
7TIGMEP8SSPW
3XLIV1EXIVMEPW
Component Location......................................30
)RKMRI
*YIP7]WXIQ
Theory of Operation .......................................33
'SSPMRK7]WXIQ3TIVEXMSR
0YFVMGEXMSR7]WXIQ3TIVEXMSR
*YIP7]WXIQ8LISV]SJ3TIVEXMSR
%MV7]WXIQ8LISV]SJ3TIVEXMSR
Diagnostics .....................................................37
7]WXIQ)RKMRI8VSYFPIWLSSXMRKERH
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7]QTXSQ'SSPERXMR3MPSV3MPMR'SSPERX
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Tests and Adjustments..................................45
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Repair.............................................................. 58
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18. )R KMR I 82 : 8E FPI S J' SR XIRXW
ENGINE - 3TNV76 TABLE OF CONTENTS
*YIP*MPXIV%WWIQFP]6IQSZEPERH
-RWXEPPEXMSR
*YIP*MPXIV6IQSZEPERH-RWXEPPEXMSR
Starting Motor ...............................................103
7XEVXMRK1SXSV6IQSZEPERH-RWXEPPEXMSR
7XEVXMRK1SXSV(MWEWWIQFP]ERH%WWIQFP]
7XEVXMRK1SXSV-RWTIGXMSRERH8IWX
7XEVXMRK1SXSV+IEV8VEMR
7XEVXMRK1SXSV7SPIRSMH
%QT%PXIVREXSV

19. )R KMRI 82: 7T IG MJMGE XMS RW
ENGINE - 3TNV76 SPECIFICATIONS
Specifications
General - 3TNV76
General Specifications:
Make. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yanmar
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNV76
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel
Injection Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indirect
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 mm (2.992 in.)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 mm (3.228 in.)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.115 L (68.04 cu in.)
Firing Order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3 - 2
Direction of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counterclockwise (viewed from flywheel)
Combustion System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indirect Injection Type
Compression Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.4: 1
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid
Cooling Capacity (includes coolant bottle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 L (3.4 qt)
Cooling System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.2 kPa (12.8 psi)
Oil Capacity (w/filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 L (3.4 qt)
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal
Rated Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm
Operating Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1170 - 3170 rpm
Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 ±50 rpm
High Idle (no-load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . 3170 ±25 rpm
Engine to Transmission Drive Shaft Lubrication Interval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 hours
Operational Tests
Compression:
Cylinder Compression Pressure (@ 250 rpm Cranking Speed). . . . . . . . . . . . . . . . . . . . . . . . . . . . 3432 kPa (498 psi)
(Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2746 kPa (398 psi)
Difference Between Cylinders (Maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 kPa (36 psi)
Cooling System:
Radiator Cap Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9 ± 0.15 kg/cm
2
, 88.3 ± 14.7 kPa, (12.8 ± 2.2 psi)
Cooling System Pressure Test . . . . . . . . . . .. . . . . . . . . . . . . . . . . 0.9 ± 0.15 kg/cm
2
, 88.3 ± 14.7 kPa, (12.8 ± 2.2 psi)
Thermostat Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.5 - 72.5 °C (157 - 163 °F)
Thermostat Minimum Lift Height above 85 °C (185 °F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 mm (0.315 in.)
Oil Pressure:
Rated Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 - 440 kPa (42 - 63 psi)
Slow Idle (Minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 kPa (9 psi)
Oil Pressure Switch Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4 kPa (6 - 9 psi)

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21. )R KMRI 82: 7T IG MJMGE XMS RW
ENGINE - 3TNV76 SPECIFICATIONS
Tests and Adjustment Specifications
Specifications:
Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 - 0.25 mm (0.006 - 0.010 in.)
Connecting Rod Side Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 - 0.4 mm (0.008 - 0.016 in.)
Connecting Rod Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 - 0.05 mm (0.001 in.)
Crankshaft End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.11 - 0.25 mm (0.004 - 0.001 in.)
Crankshaft Main Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 - 0.05 mm (0.001 - 0.001 in.)
Camshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.15 mm (0.002 - 0.006 in.)
Alternator Drive Belt Deflection (@98 N (22 lb) Applied Force) . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15 mm (0.4 - 0.6 in.)
Fuel Injection Nozzle:
Opening Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11800 - 12800 kPa (1711 - 1856 psi)
Leakage at 11032 kPa (1600 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .None for a minimum of 10 seconds
Chatter and Spray Pattern at 11800 - 12800 kPa (1711 - 1856 psi):
Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chatter Sound
Repair Specifications
Valve Train:
Rocker Arm Shaft OD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.97 - 11.98 mm (0.471 - 0.472 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.95 mm (0.470 in.)
Rocker Arm and Shaft Support Bushings ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.00 - 12.02 mm (0.472 - 0.473 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.07 mm (0.475 in.)
Oil Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 - 0.05 mm (0.001 - 0.002 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 mm (0.005 in.)
Push Rod Bend (maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0 - 0.03 mm (0.0 - 0.001 in.)
Cylinder Head:
Cylinder Head Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00 - 0.05 mm (0.000 - 0.002 in.)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Valves:
Valve Seat Angles:
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45°
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .30°
Lower Seat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70°
Upper Seat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15°
Intake Valve Head Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9 - 1.1 mm (0.035 - 0.043 in.)
Exhaust Valve Head Margin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 - 1.2 mm (0.039 - 0.047 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.02 in.)
Valve Recession:
Intake and Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 - 0.60 mm (0.016 - 0.024 in.)
Wear Limit Intake . . . . . . . . . . . . . . . . . . . . . . . . . 0.9 mm (0.035 in.)
Wear Limit Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 mm (0.031 in.)
Valve Stem Diameter:
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.96 - 5.98 mm (0.234 - 0.235 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.95 - 5.96 mm (0.234 - 0.235 in.)

22. )R KMRI 82: 7T IG MJMGE XMS RW
ENGINE - 3TNV76 SPECIFICATIONS
Wear Limit (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.90 mm (0.232 in.)
Valve Guides:
Valve Guide ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 - 6.01 mm (0.236 - 0.237 in.)
Valve Guide Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.08 mm (0.239 in.)
Valve Guide Installed Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 - 10 mm (0.386 - 0.394 in.)
Valve Stem-To-Guide Oil Clearance:
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.05 mm (0.001 - 0.002 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 - 0.07 mm (0.002 - 0.003 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.17 mm (0.007 in.)
Valve Springs:
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.8 mm (1.488 in.)
Maximum Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 mm (0.051 in.)
Connecting Rod:
Large End Bearing ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.98 - 42.00 mm (1.653 - 1.654 in.)
Large End Bearing Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 - 1.51 mm (0.059 - 0.059 in.)
Large End Bearing Oil Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 - 0.06 mm (0.001 - 0.002 in.)
Large End Bearing Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)
Connecting Rod Side Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.)
Twist and Parallelism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00 - 0.03 mm per 100 mm (0.00 - 0.001 in. per 6 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 mm per 100 mm (0.005 in. per 6 in.)
*SV'SRRIGXMRK6SH7QEPP)RH7TIGMJMGEXMSRW7IIw4MWXSR4MRx&IPS[
Top Piston Ring Specifications:
Ring Groove Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.55 - 1.57 mm (0.061 - 0.062 in.)
Ring Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.47 - 1.49 mm (0.058 - 0.059 in.)
Side Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 - 0.10 mm (0.002 - 0.004 in.)
Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 - 0.30 mm (0.006 - 0.012 in.)
Ring End Gap Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.39 mm (0.015 in.)
2nd Piston Ring Specifications:
Piston Groove Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.58 - 1.60 mm (0.062 - 0.063 in.)
Ring Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.43 - 1.45 mm (0.056 - 0.057 in.)
Side Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.01 - 0.17 mm (0.001 - 0.005 in.)
Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 - 0.33 mm (0.007 - 0.013 in.)
Ring End Gap Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.42 mm (0.017 in.)
Oil Control Ring Specifications:
Piston Groove Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.01 - 3.03 mm (0.118 - 0.119 in.)
Ring Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.97 - 2.99 mm (0.117 - 0.118 in.)
Minimum Side Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 - 0.06 mm (0.001 - 0.002 in.)
Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.35 mm (0.006 - 0.014 in.)
Ring End Gap Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.54 mm (0.021 in.)

23. )R KMRI 82: 7T IG MJMGE XMS RW
ENGINE - 3TNV76 SPECIFICATIONS
Piston:
Piston Pin OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.99 - 22.00 mm (0.866 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.97 mm (0.865 in.)
Piston Pin Bore (In Piston) ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.00 - 22.01 mm (0.866 - 0.867 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.04 mm (0.868 in.)
Connecting Rod Bushing ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.03 - 22.04 mm (0.867 - 0.868 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.07 mm (0.869 in.)
Piston Pin-To-Rod Bushing Oil Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.05 mm (0.001 - 0.002 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.11 mm (0.004 in.)
Piston Pin-To-Piston Oil Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00 - 0.01 mm (0 - 0.001 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 mm (0.003 in.)
Piston (Measured 24 mm (0.945 in.) up from bottom of piston skirt):
Standard Piston OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.96 - 75.99 mm (2.990 - 2.991 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.91 mm (2.988 in.)
Cylinder Bore:
Standard ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.01 - 76.03 mm (2.993 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.20 mm (2.999 in.)
Clearance (Piston-To-Cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 - 0.06 mm (0.001 - 0.002 in.)
Cylinder Roundness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00 - 0.01 mm (0.000 in.)
Cylinder Roundness Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.)
Cylinder Taper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00 - 0.01 mm (0.000 - 0.001 in.)
Cylinder Taper Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.)
Deglazing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° crosshatch pattern
Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° crosshatch pattern
Crankshaft:
Connecting Rod Crankpin Journal:
OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.95 - 41.96 mm (1.652 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.90 mm (1.650 in.)
Connecting Rod Bearing:
Inside Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.98 - 42.00 mm (1.653 - 1.654 in.)
Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 - 1.51 mm (0.059 in.)
Oil Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 - 0.05 mm (0.001 - 0.002 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.11 mm (0.004 in.)
Main Bearing Journal:
Outside Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.95 - 46.96 mm (1.848 - 1.849 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.90 mm (1.846 in.)
Main Bearing:
Insert Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.01 mm (0.079 in.)
Oil Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 - 0.05 mm (0.001 - 0.002 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)