624h loader and tc62h tc operation tm1640

624H Loader and TC62HTool Carrier Repair

TECHNICAL MANUAL624H Loader TC62H Tool Carrier

Repair

TM1640 15JAN04 (ENGLISH)

For complete service information also see:

624H Loader and TC62H Operation andTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM16394.5 L & 6.8 L 4045 and 6068 DieselEngines Repair . . . . . . . . . . . . . . . . . . . . . . . CTM104Alternators and Starting Motors . . . . . . . . . . CTM77TeamMate III Axles . . . . . . . . . . . . . . . . . . . CTM150

Worldwide ConstructionAnd Forestry Division

LITHO IN U.S.A.

Introduction

DX,TMIFC –19–29SEP98–1/1

Foreword

This manual is written for an experienced technician.Essential tools required in performing certain servicework are identified in this manual and arerecommended for use.

Live with safety: Read the safety messages in theintroduction of this manual and the cautions presentedthroughout the text of the manual.

This is the safety-alert symbol. When you see thissymbol on the machine or in this manual, be alert tothe potential for personal injury.

Technical manuals are divided in two parts: repair andoperation and tests. Repair sections tell how to repairthe components. Operation and tests sections help youidentify the majority of routine failures quickly.

Information is organized in groups for the variouscomponents requiring service instruction. At thebeginning of each group are summary listings of allapplicable essential tools, service equipment and tools,other materials needed to do the job, service parts kits,specifications, wear tolerances, and torque values.

Technical Manuals are concise guides for specificmachines. They are on-the-job guides containing onlythe vital information needed for diagnosis, analysis,testing, and repair.

Fundamental service information is available fromother sources covering basic theory of operation,fundamentals of troubleshooting, general maintenance,and basic type of failures and their causes.

TM1640 (15JAN04) 624H Loader and TC62H Tool Carrier011504

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Introduction

TX,TM,FAX –19–03JUL01–1/1

Technical Information Feedback Form

We need your help to continually improve our technicalpublications. Please copy this page and FAX or mail yourcomments, ideas and improvements.

SEND TO: John Deere Dubuque WorksP.O. Box 538Attn: Publications Supervisor, Dept. 303Dubuque, IA 52004-0538

FAX NUMBER: 563-589-5800

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OVERALL, how would you rate the quality of this publication? (Check one)

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THANK YOU!


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Introduction


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Contents00

SECTION 00—General Information SECTION 11—Park BrakeGroup 1111—Active ElementsGroup 0001—Safety Information

Group 0002—General Specifications Group 1160—Hydraulic SystemGroup 0003—Torque Values

SECTION 16—Electrical SystemGroup 0004—Fuels and Lubricants01Group 1671—Batteries, Support and Cables

Group 1672—Alternator, Regulator and ChargingSECTION 01—WheelsSystem WiringGroup 0110—Powered Wheels and Fasteners

Group 1673—Lighting SystemGroup 1674—Wiring Harness and Switches

SECTION 02—Axles and Suspension Systems Group 1675—System ControlsGroup 0200—Removal and Installation Group 1677—Motors and ActuatorsGroup 0225—Axle Shafts and U-JointsGroup 0250—Axle Shaft, Bearings, Reduction SECTION 17—Frame or Supporting Structure

Gears Group 1740—Frame InstallationGroup 0260—Hydraulic System Group 1746—Frame Bottom Guards

02

Group 1749—Chassis WeightsSECTION 03—Transmission

Group 0300—Removal and Installation SECTION 18—Operator’s StationGroup 1800—Removal and InstallationGroup 0350—Gears, Shafts, Bearings and PowerGroup 1810—Operator EnclosureShift ClutchGroup 1821—Seat and Seat BeltsGroup 0360—Hydraulic SystemGroup 1822—Steps and HandholdsGroup 0399—Dealer Fabricated ToolsGroup 1830—Heating and Air ConditioningGroup 1899—Dealer Fabricated ToolsSECTION 04—Engine

Group 0400—Removal and InstallationSECTION 19—Sheet Metal and Styling

03

Group 1910—Hood or Engine EnclosureSECTION 05—Engine Auxiliary Systems Group 1913—Miscellaneous Shields

Group 0505—Cold Weather Starting Aids Group 1921—Grille and Grille HousingGroup 0510—Cooling System Group 1927—Miscellaneous ShieldsGroup 0515—Speed ControlsGroup 0520—Intake System SECTION 20—Safety and ConvenienceGroup 0530—External Exhaust System Group 2002—MirrorGroup 0560—External Fuel Supply Systems Group 2003—Fire Extinguisher

Group 2004—Horn and Warning DevicesSECTION 07—Dampener Drive

SECTION 31—LoaderGroup 0752—Elements

04

Group 3102—BucketGroup 3140—FramesSECTION 09—Steering SystemGroup 3160—Hydraulic SystemGroup 0960—Hydraulic System

SECTION 10—Service BrakesGroup 1011—Active ElementsGroup 1060—Hydraulic System

All information, illustrations and specifications in this manual are based onthe latest information available at the time of publication. The right isreserved to make changes at any time without notice.

05

COPYRIGHT 2004DEERE & COMPANY

Moline, IllinoisAll rights reserved

A John Deere ILLUSTRUCTION ManualPrevious Editions

Copyright 1998, 1999, 2000, 2001, 2003

07

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TM1640 (15JAN04) i 624H Loader and TC62H Tool Carrier011504

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TM1640 (15JAN04) ii 624H Loader and TC62H Tool Carrier011504

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TM1640 (15JAN04) iii 624H Loader and TC62H Tool Carrier011504

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TM1640 (15JAN04) iv 624H Loader and TC62H Tool Carrier011504

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Section 00General Information

Contents

PagePage

Group 0001—Safety Information Service Recommendations For Flat FaceO-Ring Seal Fittings. . . . . . . . . . . . . . . . . .00-0003-9Handle Fluids Safely—Avoid Fires . . . . . . . .00-0001-1

Service Recommendations for MetricPrevent Battery Explosions . . . . . . . . . . . . . .00-0001-1Series Four Bolt Flange Fitting . . . . . . . .00-0003-10Prepare for Emergencies. . . . . . . . . . . . . . . .00-0001-1

Service Recommendations For InchPrevent Acid Burns . . . . . . . . . . . . . . . . . . . .00-0001-2Series Four Bolt Flange Fittings. . . . . . . .00-0003-11Handle Chemical Products Safely . . . . . . . . .00-0001-3

Avoid High-Pressure Fluids . . . . . . . . . . . . . .00-0001-3Group 0004—Fuels and LubricantsPark Machine Safely . . . . . . . . . . . . . . . . . . .00-0001-4Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-1Support Machine Properly . . . . . . . . . . . . . . .00-0001-4Lubricity of Diesel Fuel . . . . . . . . . . . . . . . . .00-0004-1Wear Protective Clothing. . . . . . . . . . . . . . . .00-0001-4Low Sulfur Diesel Fuel Conditioner . . . . . . . .00-0004-2Work in Clean Area. . . . . . . . . . . . . . . . . . . .00-0001-5Diesel Fuel Storage. . . . . . . . . . . . . . . . . . . .00-0004-2Service Machines Safely . . . . . . . . . . . . . . . .00-0001-5Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-3Work In Ventilated Area . . . . . . . . . . . . . . . .00-0001-5Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . .00-0004-3Illuminate Work Area Safely . . . . . . . . . . . . .00-0001-5Transmission, Hydraulic System, ParkReplace Safety Signs . . . . . . . . . . . . . . . . . .00-0001-6

Brake, and Differential Oil . . . . . . . . . . . . .00-0004-4Use Proper Lifting Equipment . . . . . . . . . . . .00-0001-6Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-5Remove Paint Before Welding or Heating . . .00-0001-7Alternative and Synthetic Lubricants . . . . . . .00-0004-6Avoid Heating Near Pressurized FluidLubricant Storage . . . . . . . . . . . . . . . . . . . . .00-0004-6Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-7Mixing of Lubricants . . . . . . . . . . . . . . . . . . .00-0004-7Keep ROPS Installed Properly . . . . . . . . . . .00-0001-8

Service Tires Safely . . . . . . . . . . . . . . . . . . .00-0001-8Avoid Harmful Asbestos Dust . . . . . . . . . . . .00-0001-9Practice Safe Maintenance . . . . . . . . . . . . .00-0001-10Use Proper Tools . . . . . . . . . . . . . . . . . . . .00-0001-10Dispose of Waste Properly . . . . . . . . . . . . .00-0001-11Live With Safety . . . . . . . . . . . . . . . . . . . . .00-0001-11

Group 0002—General Specifications624H Specifications. . . . . . . . . . . . . . . . . . . .00-0002-1Drain and Refill Capacities—624H/TC62H . .00-0002-4TC62H Specifications . . . . . . . . . . . . . . . . . .00-0002-5Drain and Refill Capacities—TC62H . . . . . . .00-0002-8

Group 0003—Torque ValuesHardware Torque Specifications . . . . . . . . . .00-0003-1ROPS Torque Specifications . . . . . . . . . . . . .00-0003-1Metric Bolt and Cap Screw Torque

Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2Additional Metric Cap Screw Torque

Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-3Unified Inch Bolt and Cap Screw Torque

Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-5Check Oil Lines And Fittings . . . . . . . . . . . . .00-0003-6Service Recommendations for O-Ring

Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0003-7

TM1640 (15JAN04) 00-1 624H Loader and TC62H Tool Carrier011504

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Contents

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Group 0001Safety Information

0000011

DX,FLAME –19–29SEP98–1/1

Handle Fluids Safely—Avoid Fires

TS

227

–UN

–23A

UG

88

When you work around fuel, do not smoke or work nearheaters or other fire hazards.

Store flammable fluids away from fire hazards. Do notincinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burnspontaneously.

DX,SPARKS –19–03MAR93–1/1

Prevent Battery Explosions

TS

204

–UN

–23A

UG

88

Keep sparks, lighted matches, and open flame away fromthe top of battery. Battery gas can explode.

Never check battery charge by placing a metal objectacross the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warmbattery to 16°C (60°F).

DX,FIRE2 –19–03MAR93–1/1

Prepare for Emergencies

TS

291

–UN

–23A

UG

88

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,hospital, and fire department near your telephone.

TM1640 (15JAN04) 00-0001-1 624H Loader and TC62H Tool Carrier011504

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Safety Information

000001

2

DX,POISON –19–21APR93–1/1

Prevent Acid Burns

TS

203

–UN

–23A

UG

88

Sulfuric acid in battery electrolyte is poisonous. It is strongenough to burn skin, eat holes in clothing, and causeblindness if splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.2. Wearing eye protection and rubber gloves.3. Avoiding breathing fumes when electrolyte is added.4. Avoiding spilling or dripping electrolyte.5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.2. Apply baking soda or lime to help neutralize the acid.3. Flush your eyes with water for 15—30 minutes. Get

medical attention immediately.

If acid is swallowed:

1. Do not induce vomiting.2. Drink large amounts of water or milk, but do not

exceed 2 L (2 quarts).3. Get medical attention immediately.


PN=10

Safety Information

0000013

DX,MSDS,NA –19–03MAR93–1/1

Handle Chemical Products Safely

TS

1132

–UN

–26N

OV

90

Direct exposure to hazardous chemicals can causeserious injury. Potentially hazardous chemicals used withJohn Deere equipment include such items as lubricants,coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specificdetails on chemical products: physical and health hazards,safety procedures, and emergency response techniques.

Check the MSDS before you start any job using ahazardous chemical. That way you will know exactly whatthe risks are and how to do the job safely. Then followprocedures and recommended equipment.

(See your John Deere dealer for MSDS’s on chemicalproducts used with John Deere equipment.)

DX,FLUID –19–03MAR93–1/1

Avoid High-Pressure Fluids

X98

11–U

N–2

3AU

G88

Escaping fluid under pressure can penetrate the skincausing serious injury.

Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tighten allconnections before applying pressure.

Search for leaks with a piece of cardboard. Protect handsand body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluidinjected into the skin must be surgically removed within afew hours or gangrene may result. Doctors unfamiliar withthis type of injury should reference a knowledgeablemedical source. Such information is available from Deere& Company Medical Department in Moline, Illinois, U.S.A.


PN=11

Safety Information

000001

4

DX,PARK –19–04JUN90–1/1

Park Machine Safely

TS

230

–UN

–24M

AY

89

Before working on the machine:

• Lower all equipment to the ground.• Stop the engine and remove the key.• Disconnect the battery ground strap.• Hang a "DO NOT OPERATE" tag in operator station.

DX,LOWER –19–24FEB00–1/1

Support Machine Properly

TS

229

–UN

–23A

UG

88

Always lower the attachment or implement to the groundbefore you work on the machine. If the work requires thatthe machine or attachment be lifted, provide securesupport for them. If left in a raised position, hydraulicallysupported devices can settle or leak down.

Do not support the machine on cinder blocks, hollow tiles,or props that may crumble under continuous load. Do notwork under a machine that is supported solely by a jack.Follow recommended procedures in this manual.

When implements or attachments are used with amachine, always follow safety precautions listed in theimplement or attachment operator’s manual.

DX,WEAR2 –19–03MAR93–1/1

Wear Protective Clothing

TS

206

–UN

–23A

UG

88Wear close fitting clothing and safety equipmentappropriate to the job.

Operating equipment safely requires the full attention ofthe operator. Do not wear radio or music headphoneswhile operating machine.


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Safety Information

0000015

DX,CLEAN –19–04JUN90–1/1

Work in Clean Area

T66

42E

J–U

N–1

8OC

T88

Before starting a job:

• Clean work area and machine.• Make sure you have all necessary tools to do your job.• Have the right parts on hand.• Read all instructions thoroughly; do not attempt

shortcuts.

DX,LOOSE –19–04JUN90–1/1

Service Machines Safely

TS

228

–UN

–23A

UG

88

Tie long hair behind your head. Do not wear a necktie,scarf, loose clothing, or necklace when you work nearmachine tools or moving parts. If these items were to getcaught, severe injury could result.

Remove rings and other jewelry to prevent electricalshorts and entanglement in moving parts.

DX,AIR –19–17FEB99–1/1

Work In Ventilated Area

TS

220

–UN

–23A

UG

88

Engine exhaust fumes can cause sickness or death. If it isnecessary to run an engine in an enclosed area, removethe exhaust fumes from the area with an exhaust pipeextension.

If you do not have an exhaust pipe extension, open thedoors and get outside air into the area

DX,LIGHT –19–04JUN90–1/1

Illuminate Work Area Safely

TS

223

–UN

–23A

UG

88

Illuminate your work area adequately but safely. Use aportable safety light for working inside or under themachine. Make sure the bulb is enclosed by a wire cage.The hot filament of an accidentally broken bulb can ignitespilled fuel or oil.


PN=13

Safety Information

000001

6

DX,SIGNS1 –19–04JUN90–1/1

Replace Safety Signs

TS

201

–UN

–23A

UG

88

Replace missing or damaged safety signs. See themachine operator’s manual for correct safety signplacement.

DX,LIFT –19–04JUN90–1/1

Use Proper Lifting Equipment

TS

226

–UN

–23A

UG

88

Lifting heavy components incorrectly can cause severeinjury or machine damage.

Follow recommended procedure for removal andinstallation of components in the manual.


PN=14

Safety Information

0000017

DX,PAINT –19–24JUL02–1/1

Remove Paint Before Welding or Heating

TS

220

–UN

–23A

UG

88

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heatedby welding, soldering, or using a torch.

Remove paint before heating:

• Remove paint a minimum of 100 mm (4 in.) from areato be affected by heating. If paint cannot be removed,wear an approved respirator before heating or welding.

• If you sand or grind paint, avoid breathing the dust.Wear an approved respirator.

• If you use solvent or paint stripper, remove stripper withsoap and water before welding. Remove solvent orpaint stripper containers and other flammable materialfrom area. Allow fumes to disperse at least 15 minutesbefore welding or heating.

Do not use a chlorinated solvent in areas where weldingwill take place.

Do all work in an area that is well ventilated to carry toxicfumes and dust away.

Dispose of paint and solvent properly.

DX,TORCH –19–03MAR93–1/1

Avoid Heating Near Pressurized Fluid Lines

TS

953

–UN

–15M

AY

90

Flammable spray can be generated by heating nearpressurized fluid lines, resulting in severe burns toyourself and bystanders. Do not heat by welding,soldering, or using a torch near pressurized fluid lines orother flammable materials. Pressurized lines can beaccidentally cut when heat goes beyond the immediateflame area.


PN=15

Safety Information

000001

8

DX,ROPS3 –19–03MAR93–1/1

Keep ROPS Installed Properly

TS

212

–UN

–23A

UG

88

Make certain all parts are reinstalled correctly if theroll-over protective structure (ROPS) is loosened orremoved for any reason. Tighten mounting bolts to propertorque.

The protection offered by ROPS will be impaired if ROPSis subjected to structural damage, is involved in anoverturn incident, or is in any way altered by welding,bending, drilling, or cutting. A damaged ROPS should bereplaced, not reused.

DX,RIM –19–24AUG90–1/1

Service Tires Safely

TS

211

–UN

–23A

UG

88

Explosive separation of a tire and rim parts can causeserious injury or death.

Do not attempt to mount a tire unless you have the properequipment and experience to perform the job.

Always maintain the correct tire pressure. Do not inflatethe tires above the recommended pressure. Never weld orheat a wheel and tire assembly. The heat can cause anincrease in air pressure resulting in a tire explosion.Welding can structurally weaken or deform the wheel.

When inflating tires, use a clip-on chuck and extensionhose long enough to allow you to stand to one side andNOT in front of or over the tire assembly. Use a safetycage if available.

Check wheels for low pressure, cuts, bubbles, damagedrims or missing lug bolts and nuts.


PN=16

Safety Information

0000019

DX,DUST –19–15MAR91–1/1

Avoid Harmful Asbestos Dust

TS

220

–UN

–23A

UG

88

Avoid breathing dust that may be generated whenhandling components containing asbestos fibers. Inhaledasbestos fibers may cause lung cancer.

Components in products that may contain asbestos fibersare brake pads, brake band and lining assemblies, clutchplates, and some gaskets. The asbestos used in thesecomponents is usually found in a resin or sealed in someway. Normal handling is not hazardous as long asairborne dust containing asbestos is not generated.

Avoid creating dust. Never use compressed air forcleaning. Avoid brushing or grinding material containingasbestos. When servicing, wear an approved respirator. Aspecial vacuum cleaner is recommended to cleanasbestos. If not available, apply a mist of oil or water onthe material containing asbestos.

Keep bystanders away from the area.


PN=17

Safety Information

000001

10

DX,SERV –19–17FEB99–1/1

Practice Safe Maintenance

TS

218

–UN

–23A

UG

88

Understand service procedure before doing work. Keeparea clean and dry.

Never lubricate, service, or adjust machine while it ismoving. Keep hands, feet , and clothing frompower-driven parts. Disengage all power and operatecontrols to relieve pressure. Lower equipment to theground. Stop the engine. Remove the key. Allow machineto cool.

Securely support any machine elements that must beraised for service work.

Keep all parts in good condition and properly installed. Fixdamage immediately. Replace worn or broken parts.Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery groundcable (-) before making adjustments on electrical systemsor welding on machine.

On towed implements, disconnect wiring harnesses fromtractor before servicing electrical system components orwelding on machine.

DX,REPAIR –19–17FEB99–1/1

Use Proper Tools

TS

779

–UN

–08N

OV

89Use tools appropriate to the work. Makeshift tools andprocedures can create safety hazards.

Use power tools only to loosen threaded parts andfasteners.

For loosening and tightening hardware, use the correctsize tools. DO NOT use U.S. measurement tools onmetric fasteners. Avoid bodily injury caused by slippingwrenches.

Use only service parts meeting John Deere specifications.


PN=18

Safety Information

00000111

DX,DRAIN –19–03MAR93–1/1

Dispose of Waste Properly

TS

1133

–UN

–26N

OV

90

Improperly disposing of waste can threaten theenvironment and ecology. Potentially harmful waste usedwith John Deere equipment include such items as oil, fuel,coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not usefood or beverage containers that may mislead someoneinto drinking from them.

Do not pour waste onto the ground, down a drain, or intoany water source.

Air conditioning refrigerants escaping into the air candamage the Earth’s atmosphere. Government regulationsmay require a certified air conditioning service center torecover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of wastefrom your local environmental or recycling center, or fromyour John Deere dealer.

DX,LIVE –19–25SEP92–1/1

Live With Safety

TS

231

–19–

07O

CT

88

Before returning machine to customer, make suremachine is functioning properly, especially the safetysystems. Install all guards and shields.


PN=19

Safety Information

000001

12


PN=20

Group 0002General Specifications

0000021

TX,9000,JC2184 –19–21APR99–1/3

624H Specifications

T10

7472

–UN

–19F

EB

97

Item Measurement Specification

A—Bucket Hinge Height Distance 3961 mm (13 ft 0 in.)

B—Dump Height Distance 2858 mm (9 ft 5 in.)

C—Dump Reach Distance 1038 mm (3 ft 5 in.)

D—Machine Overall Height 3300 mm (10 ft 10 in.)

E—Wheelbase Length 3030 mm (9 ft 11 in.)

F—Ground Clearance Distance 406 mm (16.0 in.)

G—Machine Overall Length 7610 m (25 ft 0 in.)


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General Specifications

000002

2

TX,9000,JC2184 –19–21APR99–2/3


Machine Standard Operating Weight 13 560 kg (29,894 lb)

Machine Optional Counterweight 474 kg (1,045 lb)

NOTE: Specifications and design subject to changewithout notice. Wherever applicable,specifications are in accordance with SAEstandards. Except where otherwise noted,specifications are based on a machineequipped with all standard equipment, with 474

kg (1,045 lb) optional counterweight, ROPScab, differential lock front axle with standardrear axle, 2 spool valve with two lever control,heater and defroster, 79 kg (175 lb) operatorand full fuel tank.


Engine:

John Deere PowerTech 6.8T with Power 160 SAE net hp (119 kW) @ 2200altitude compensating turbocharger rpm

172 SAE gross hp (128 kW) @ 2200rpm

Piston displacement Power 6.8 L (414 cu in.)

Air cleaner w/dual safety element Type Dual stage dry type with restrictionand restriction indicator indicator

Electrical system Voltage 24 volt 55-amp

Cold cranking capacity at -18°C (0°F) Current 2-12 volt with 625 amps

Reserve capacity Time 160 min.

Torque Converter Type Single phase, single stage

Transmission

Countershaft Type Computer controlled powershift

Forward Travel:

1 Speed 0—7.7 km/h (0—4.8 mph)

2 Speed 0—12.0 km/h (0—7.5 mph)

3 Speed 0—22.6 km/h (0—14.0 mph)

4 Speed 0—39.5 km/h (0—24.5 mph)

PowerTech is a trademark of Deere & Company.


PN=22



0000023

TX,9000,JC2184 –19–21APR99–3/3


Reverse Travel:

1 Speed 0—8.1 km/h (0—5.0 mph)

2 Speed 0—12.7 km/h (0—8.0 mph)

3 Speed 0—23.9 km/h (0—14.9 mph)

NOTE: All travel speeds are with 20.5 x 25 12PR (L2)tires.

Brakes, Service:• Hydraulically-actuated, 4 wheel, inboard-mounted,

wet disk• Foot-operated by either pedal• Left and right pedal also disconnects transmission (if

selected by operator)• External inspection• Low brake pressure warning light and buzzer in

monitor

Brakes, Park:

• Multi wet disk• Spring applied, hydraulically released parking brake

is bathed in cooling oil• Transmission disconnects with park brake applied• Warning light in monitor—dual-level

• Amber lights with transmission in neutral• Red STOP indicator lights and buzzer sounds with

transmission in gear

Steering:

• Fully hydraulic• Frame articulated 80° by two hydraulic cylinders• Turning radius (to centerline of outside tire): 5,187

mm (17 ft 0 in.)

Tires:

• 17.5x25 Bias (L2) and (L3)• 17.5R25 Radial XTLA (L2) XHAT (L3) and GP-2B

(L2)• 20.5x25 Bias (L2) and (L3)• 20.5R25 Radial XTLA (L2), XHAT (L3) and GP-2B

(L2)


PN=23


000002

4

CED,OUOE002,1792 –19–16SEP98–1/1

Drain and Refill Capacities—624H/TC62H


Cooling System Capacity 22 L (23 qt)

Fuel Tank Capacity 265 L (70 gal)

Engine Crankcase and Filter Capacity 20 L (21 qt) (S.N. —582360)21 L (22 qt) (S.N. 582361—)

Transmission Case and Filter Capacity 27 L (29 qt)

Front Differential Capacity 25 L (26 qt)

Rear Differential Capacity 20 L (21 qt)

Hydraulic Reservoir and Filters Capacity 117 L (31 gal)

Park Brake Capacity 0.300 L (10 oz)


PN=24


0000025

TX,9000,JC2185 –19–21APR99–1/3

TC62H Specifications

T10

7087

–UN

–20F

EB

97


A—Bucket Hinge Height Distance 4005 mm (13 ft 2 in.)

B—Dump Height Distance 2907 mm (9 ft 6 in.)

C—Dump Reach Distance 1278 mm (4 ft 2 in.)

D—Machine Overall Height 3300 mm (10 ft 10 in.)

E—Wheelbase Length 3030 mm (9 ft 11 in.)

F—Ground Clearance Distance 406 mm (16.0 in.)

G—Machine Overall Length 7671 m (25 ft 2 in.)


PN=25



000002

6

TX,9000,JC2185 –19–21APR99–2/3


Machine Standard Operating Weight 13 361 kg (29,456 lb)

Machine Optional Counterweight 474 kg (1,045 lb)

NOTE: Specifications and design subject to changewithout notice. Wherever applicable,specifications are in accordance with SAEstandards. Except where otherwise noted,specifications are based on a machineequipped with all standard equipment, with 474

kg (1,045 lb) optional counterweight, ROPScab, differential lock front axle with standardrear axle, 2 spool valve with two lever control,heater and defroster, 79 kg (175 lb) operatorand full fuel tank.


Engine:

John Deere PowerTech 6.8T with Power 160 SAE net hp (119 kW) @ 2200altitude compensating turbocharger rpm

172 SAE gross hp (128 kW) @ 2200rpm

Piston displacement Power 6.8 L (414 cu in.)

Air cleaner w/dual safety element Type Dual stage dry type with restrictionand restriction indicator indicator

Electrical system Voltage 24 volt 55-amp

Cold cranking capacity at -18°C (0°F) Current 2-12 volt with 625 amps

Reserve capacity Time 160 min.

Torque Converter Type Single phase, single stage

Transmission

Countershaft Type Computer controlled powershift

Forward Travel:

1 Speed 0—7.7 km/h (0—4.8 mph)

2 Speed 0—12.0 km/h (0—7.5 mph)

3 Speed 0—22.6 km/h (0—14.0 mph)

4 Speed 0—39.5 km/h (0—24.5 mph)



PN=26



0000027

TX,9000,JC2185 –19–21APR99–3/3


Reverse Travel:

1 Speed 0—8.1 km/h (0—5.0 mph)

2 Speed 0—12.7 km/h (0—8.0 mph)

3 Speed 0—23.9 km/h (0—14.9 mph)

NOTE: All travel speeds are with 20.5 x 25 12PR (L2)tires.

Brakes, Service:• Hydraulically-actuated, 4 wheel, inboard-mounted,

wet disk• Foot-operated by either pedal• Left and right pedal also disconnects transmission (if

selected by operator)• External inspection• Low brake pressure warning light and buzzer in

monitor

Brakes, Park:

• Multi wet disk• Spring applied, hydraulically released parking brake

is bathed in cooling oil• Transmission disconnects with park brake applied• Warning light in monitor—dual-level

• Amber lights with transmission in neutral• Red STOP indicator lights and buzzer sounds with

transmission in gear

Steering:

• Fully hydraulic• Frame articulated 80° by two hydraulic cylinders• Turning radius (to centerline of outside tire): 5,187

mm (17 ft 0 in.)

Tires:

• 17.5x25 Bias (L2) and (L3)• 17.5R25 Radial XTLA (L2) XHAT (L3) and GP-2B

(L2)• 20.5x25 Bias (L2) and (L3)• 20.5R25 Radial XTLA (L2), XHAT (L3) and GP-2B

(L2)


PN=27


000002

8

CED,OUOE002,1795 –19–16SEP98–1/1

Drain and Refill Capacities—TC62H


Cooling System Capacity 22 L (23 qt)

Fuel Tank Capacity 265 L (70 gal)

Engine Crankcase and Filter Capacity 20 L (21 qt) (S.N. —582360)21 L (22 qt) (S.N. 582361—)

Transmission Case and Filter Capacity 27 L (29 qt)

Front Differential Capacity 25 L (26 qt)

Rear Differential Capacity 20 L (21 qt)

Hydraulic Reservoir and Filters Capacity 117 L (31 gal)

Park Brake Capacity 0.300 L (10 oz)


PN=28

Group 0003Torque Values

0000031

T82,SKMA,AT –19–01AUG94–1/1

Hardware Torque Specifications

Check cap screws and nuts to be sure they are tight. Ifhardware is loose, tighten to torque shown on thefollowing charts unless a special torque is specified.

TX,9000,JC2196 –19–17SEP97–1/1

ROPS Torque Specifications

TS

176

–UN

–23A

UG

88

CAUTION: Make certain all parts are reinstalledcorrectly if the roll-over protective structure(ROPS) is loosened or removed for any reason.Tighten mounting bolts to proper torque.

The protection offered by ROPS will beimpaired if ROPS is subjected to structuraldamage, is involved in an overturn incident, oris in any way altered. A damaged ROPS shouldbe replaced, not reused.

When installation of equipment on a machine necessitatesloosening or removing ROPS, mounting bolts must betightened to 1150 N•m (850 lb-ft).


ROPS Mounting Bolts Torque 1150 N•m (850 lb-ft)


PN=29

Torque Values

000003

2

DX,TORQ2 –19–01OCT99–1/1

Metric Bolt and Cap Screw Torque Values

TO

RQ

2–U

N–0

7SE

P99

Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings

Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

Size Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb

N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft)

M6 4.7 (3.5) 6 (4.4) 9 (6.6) 11.5 (8.5) 13 (9.5) 16.5 (12.2) 15.5 (11.5) 19.5 (14.5)

M8 11.5 (8.5) 14.5 (10.7) 22 (16) 28 (20.5) 32 (23.5) 40 (29.5) 37 (27.5) 47 (35)

M10 23 (17) 29 (21) 43 (32) 55 (40) 63 (46) 80 (59) 75 (55) 95 (70)

M12 40 (29.5) 50 (37) 75 (55) 95 (70) 110 (80) 140 (105) 130 (95) 165 (120)

M14 63 (46) 80 (59) 120 (88) 150 (110) 175 (130) 220 (165) 205 (150) 260 (190)

M16 100 (74) 125 (92) 190 (140) 240 (175) 275 (200) 350 (255) 320 (235) 400 (300)

M18 135 (100) 170 (125) 265 (195) 330 (245) 375 (275) 475 (350) 440 (325) 560 (410)

M20 190 (140) 245 (180) 375 (275) 475 (350) 530 (390) 675 (500) 625 (460) 790 (580)

M22 265 (195) 330 (245) 510 (375) 650 (480) 725 (535) 920 (680) 850 (625) 1080 (800)

M24 330 (245) 425 (315) 650 (480) 820 (600) 920 (680) 1150 (850) 1080 (800) 1350 (1000)

M27 490 (360) 625 (460) 950 (700) 1200 (885) 1350 (1000) 1700 (1250) 1580 (1160) 2000 (1475)

M30 660 (490) 850 (625) 1290 (950) 1630 (1200) 1850 (1350) 2300 (1700) 2140 (1580) 2700 (2000)

M33 900 (665) 1150 (850) 1750 (1300) 2200 (1625) 2500 (1850) 3150 (2325) 2900 (2150) 3700 (2730)

M36 1150 (850) 1450 (1075) 2250 (1650) 2850 (2100) 3200 (2350) 4050 (3000) 3750 (2770) 4750 (3500)a "Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.b "Dry" means plain or zinc plated without any lubrication.

DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly startprocedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing whenfor general use only. Check tightness of fasteners periodically. tightening.

Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximatelyreplace shear bolts with identical property class. 50 percent of the dry torque shown in the chart, applied to the nut,

not to the bolt head. Tighten toothed or serrated-type lock nuts to thefull torque value.

Fasteners should be replaced with the same or higher property class.If higher property class fasteners are used, these should only betightened to the strength of the original.


PN=30

Torque Values

0000033

04T,90,M170 –19–29SEP99–1/2

Additional Metric Cap Screw Torque Values

T68

73A

A–U

N–1

8OC

T88

T68

73A

B–U

N–1

8OC

T88

T68

73A

C–U

N–1

8OC

T88

CAUTION: Use only metric tools on metrichardware. Other tools may not fit properly. Theymay slip and cause injury.

Check tightness of cap screws periodically. Torque valueslisted are for general use only. Do not use these values ifa different torque value or tightening procedure is listedfor a specific application.

Shear bolts are designed to fail under predeterminedloads. Always replace shear bolts with identical grade.

Fasteners should be replaced with the same or highergrade. If higher grade fasteners are used, these shouldonly be tightened to the strength of the original.

Make sure fastener threads are clean and you properlystart thread engagement. This will prevent them fromfailing when tightening.

Tighten cap screws having lock nuts to approximately 50percent of amount shown in chart.



PN=31

Torque Values

000003

4

04T,90,M170 –19–29SEP99–2/2

METRIC CAP SCREW TORQUE VALUESa

T-Bolt H-Bolt M-Bolt

NominalDia N•m lb-ft N•m lb-ft N•m lb-ft

8 29 21 20 15 10 7

10 63 46 45 33 20 15

12 108 80 88 65 34 25

14 176 130 137 101 54 40

16 265 195 206 152 78 58

18 392 289 294 217 118 87

20 539 398 392 289 167 125

22 735 542 539 398 216 159

24 931 687 686 506 274 202

27 1372 1012 1029 759 392 289

30 1911 1410 1421 1049 539 398

33 2548 1890 1911 1410 735 542

36 3136 2314 2401 1772 931 687aTorque tolerance is ±10%.


PN=32

Torque Values

0000035

DX,TORQ1 –19–01OCT99–1/1

Unified Inch Bolt and Cap Screw Torque Values

TO

RQ

1A–U

N–2

7SE

P99

Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings

Grade 1 (No Mark) Grade 2a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2

Size Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc

N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft)

1/4 3.8 (2.8) 4.7 (3.5) 6 (4.4) 7.5 (5.5) 9.5 (7) 12 (9) 13.5 (10) 17 (12.5)

5/16 7.7 (5.7) 9.8 (7.2) 12 (9) 15.5 (11.5) 19.5 (14.5) 25 (18.5) 28 (20.5) 35 (26)

3/8 13.5 (10) 17.5 (13) 22 (16) 27.5 (20) 35 (26) 44 (32.5) 49 (36) 63 (46)

7/16 22 (16) 28 (20.5) 35 (26) 44 (32.5) 56 (41) 70 (52) 80 (59) 100 (74)

1/2 34 (25) 42 (31) 53 (39) 67 (49) 85 (63) 110 (80) 120 (88) 155 (115)

9/16 48 (35.5) 60 (45) 76 (56) 95 (70) 125 (92) 155 (115) 175 (130) 220 (165)

5/8 67 (49) 85 (63) 105 (77) 135 (100) 170 (125) 215 (160) 240 (175) 305 (225)

3/4 120 (88) 150 (110) 190 (140) 240 (175) 300 (220) 380 (280) 425 (315) 540 (400)

7/8 190 (140) 240 (175) 190 (140) 240 (175) 490 (360) 615 (455) 690 (510) 870 (640)

1 285 (210) 360 (265) 285 (210) 360 (265) 730 (540) 920 (680) 1030 (760) 1300 (960)

1-1/8 400 (300) 510 (375) 400 (300) 510 (375) 910 (670) 1150 (850) 1450 (1075) 1850 (1350)

1-1/4 570 (420) 725 (535) 570 (420) 725 (535) 1280 (945) 1630 (1200) 2050 (1500) 2600 (1920)

1-3/8 750 (550) 950 (700) 750 (550) 950 (700) 1700 (1250) 2140 (1580) 2700 (2000) 3400 (2500)

1-1/2 990 (730) 1250 (930) 990 (730) 1250 (930) 2250 (1650) 2850 (2100) 3600 (2650) 4550 (3350)a Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,and for all other types of bolts and screws of any length.b "Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.c "Dry" means plain or zinc plated without any lubrication.

DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly startprocedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing whenfor general use only. Check tightness of fasteners periodically. tightening.

Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximatelyreplace shear bolts with identical grade. 50 percent of the dry torque shown in the chart, applied to the nut,

not to the bolt head. Tighten toothed or serrated-type lock nuts to thefull torque value.

Fasteners should be replaced with the same or higher grade. Ifhigher grade fasteners are used, these should only be tightened tothe strength of the original.


PN=33

Torque Values

000003

6

TX,90,DH1559 –19–01AUG94–1/1

Check Oil Lines And Fittings

X98

11–U

N–2

3AU

G88

CAUTION: Escaping fluid under pressure canpenetrate the skin causing serious injury. Avoidthe hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tightenall connections before applying pressure.Search for leaks with a piece of cardboard.Protect hands and body from high pressurefluids.

If an accident occurs, see a doctor immediately.Any fluid injected into the skin must besurgically removed within a few hours organgrene may result. Doctors unfamiliar withthis type of injury may call the Deere &Company Medical Department in Moline, Illinois,or other knowledgeable medical source.

Check all oil lines, hoses, and fittings regularly for leaks ordamage. Make sure all clamps are in position and tight.Make sure hoses are not twisted or touching movingmachine parts. If abrasion or wear occurs, replaceimmediately.

Tubing with dents may cause the oil to overheat. If youfind tubing with dents, install new tubing immediately.

IMPORTANT: Tighten fittings as specified in torquechart.

When you tighten connections, use two wrenches toprevent bending or breaking tubing and fittings.


PN=34

Torque Values

0000037

04T,90,K66 –19–29SEP99–1/2

Service Recommendations for O-Ring BossFittings

T62

43A

E–U

N–1

8OC

T88

Straight Fitting

1. Inspect O-ring boss seat for dirt or defects.

2. Lubricate O-ring with petroleum jelly. Place electricaltape over threads to protect O-ring. Slide O-ring overtape and into O-ring groove of fitting. Remove tape.

3. Tighten fitting to torque value shown on chart.



PN=35

Torque Values

000003

8

04T,90,K66 –19–29SEP99–2/2

T65

20A

B–U

N–1

8OC

T88

Angle Fitting

1. Back-off lock nut (A) and back-up washer (B)completely to head-end (C) of fitting.

2. Turn fitting into threaded boss until back-up washercontacts face of boss.

3. Turn fitting head-end counterclockwise to proper index(maximum of one turn).

NOTE: Do not allow hoses to twist when tighteningfittings.

4. Hold fitting head-end with a wrench and tighten locknutand back-up washer to proper torque value.

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size N•m lb-ft

3/8-24 UNF 8 6

7/16-20 UNF 12 9

1/2-20 UNF 16 12

9/16-18 UNF 24 18

3/4-16 UNF 46 34

7/8-14 UNF 62 46

1-1/16-12 UN 102 75

1-3/16-12 UN 122 90

1-5/16-12 UN 142 105

1-5/8-12 UN 190 140

1-7/8-12 UN 217 160

NOTE: Torque tolerance is ± 10%.


PN=36

Torque Values

0000039

04T,90,K67 –19–02MAR00–1/1

Service Recommendations For Flat Face O-Ring Seal Fittings

1. Inspect the fitting sealing surfaces and O-ring. Theymust be free of dirt or defects.

2. Lubricate O-rings and install into grove usingpetroleum jelly to hold in place.

3. Index angle fittings and tighten by hand pressingjoint together to insure O-ring remains in place.

4. Tighten fitting or nut to torque value shown on thechart. Do not allow hoses to twist when tightening

fittings, use backup wrench on straight hosecouplings.

IMPORTANT: Tighten fittings to 150% of listedtorque value if indexing is necessaryor if fitting is attached to anactuating devise.

Tighten fittings to 50% of listedtorque value if used in aluminumhousing.

FLAT FACE O-RING SEAL FITTING TORQUE*

Nominal Tube O.D. Thread Size Swivel Nut Bulkhead Nut

mm in. in. N•m lb-ft N•m lb-ft

6.35 0.250 9/16-18 16 12 12 9

9.52 0.375 11/16-16 24 18 24 18

12.70 0.500 13/16-16 50 37 46 34

15.88 0.625 1-14 69 51 62 46

19.05 0.750 1 3/16-12 102 75 102 75

22.22 0.875 1 3/16-12 102 75 102 75

25.40 1.000 1 7/16-12 142 105 142 105

31.75 1.250 1 11/16-12 190 140 190 140

38.10 1.500 2-12 217 160 217 160

*Torque tolerance is +15 -20% unless otherwise specified.

Stud End O-ring Seal Torque for Straight and Adjustable Fittings*

Thread Size Straight Hex Size Locknut Hex Size Straight Fitting or Locknut Toque

Inch Inch Inch N•m lb-ft

3/8-24 5/8 9/16 12 9

7/16-20 5/8 5/8 21 15

1/2-20 3/4 11/16 26 19

9/16-18 3/4 3/4 34 25

3/4-16 7/8 15/16 73 55

7/8-14 1 1/16 1 1/16 104 76

1 1/16-12 1 1/4 1 3/8 176 130

1 3/16-12 1 3/8 1 1/2 230 170

1 5/16-12 1 1/2 1 5/8 285 210

*Torque tolerance is +15 -20% unless otherwise specified.


PN=37

Torque Values

000003

10

04T,90,K175 –19–29SEP99–1/1

Service Recommendations for Metric Series Four Bolt Flange Fitting

T68

90B

B–U

N–0

1MA

R90

A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratchescause leaks. Roughness causes seal wear.Out-of-flat causes seal extrusion. If defects cannotbe polished out, replace component.

2. Install the correct O-ring (and backup washer ifrequired) into groove using petroleum jelly to hold itin place.

3. Split flange: Loosely assemble split flange (B)halves. Make sure split is centrally located andperpendicular to the port. Hand tighten cap screwsto hold parts in place. Do not pinch O-ring (C).

4. Single piece flange (D): Place hydraulic line incenter of flange and install four cap screws. Flangemust be centrally located on port. Hand tighten capscrews to hold flange in place. Do not pinch O-ring.

5. After components are properly positioned and capscrews are hand tightened, tighten one cap screw,

then tighten the diagonally opposite cap screw.Tighten two remaining cap screws. Tighten all capscrews as specified in the chart below.

DO NOT use air wrenches. DO NOT tighten onecap screw fully before tightening the others. DONOT over tighten.

TORQUE CHARTa

Threadb N•m lb-ft

M6 12 9

M8 30 22

M10 57 42

M12 95 70

M14 157 116

M16 217 160

M18 334 246

M20 421 318aTolerance ± 10%. The torques given are enough for the givensize connection with the recommended working pressure.Increasing cap screw torque beyond these amounts will result inflange and cap screw bending and connection failures.bMetric standard thread.


PN=38

Torque Values

00000311

04T,90,K174 –19–01AUG94–1/1

Service Recommendations For Inch Series Four Bolt Flange Fittings

T68

90B

B–U

N–0

1MA

R90

A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratchescause leaks. Roughness causes seal wear.Out-of-flat causes seal extrusion. If defects cannotbe polished out, replace component.

2. Install O-ring (and backup washer if required) intogroove using petroleum jelly to hold it in place.

3. Split flange: Loosely assemble split flange (B)halves. Make sure split is centrally located andperpendicular to port. Hand tighten cap screws tohold parts in place. Do not pinch O-ring (C).

4. Single piece flange (D): Place hydraulic line incenter of flange and install cap screws. Flangemust be centrally located on port. Hand tighten capscrews to hold flange in place. Do not pinch O-ring.

5. Tighten one cap screw, then tighten the diagonallyopposite cap screw. Tighten two remaining capscrews. Tighten all cap screws as specified in thechart below.

DO NOT use air wrenches. DO NOT tighten onecap screw fully before tightening the others. DONOT over tighten.

TORQUE CHART

N•m lb-ft

Nominal Cap ScrewFlange Size

Size Min Max Min Max

1/2 5/16-18 20 31 15 23UNC

3/4 3/8-16 UNC 28 54 21 40

1 3/8-16 UNC 37 54 27 40

1-1/4 7/16-14 47 85 35 63UNC

1-1/2 1/2-13 UNC 62 131 46 97

2 1/2-13 UNC 73 131 54 97

2-1/2 1/2-13 UNC 107 131 79 97

3 5/8-11 UNC 158 264 117 195

3-1/2 5/8-11 UNC 158 264 117 195

4 5/8-11 UNC 158 264 117 195

5 5/8-11 UNC 158 264 117 195


PN=39

Torque Values

000003

12


PN=40

Group 0004Fuels and Lubricants

0000041

TX,45,JC1132 –19–22MAY96–1/1

Diesel Fuel

Consult your local fuel distributor for properties of thediesel fuel available in your area.

In general, diesel fuels are blended to satisfy the lowtemperature requirements of the geographical area inwhich they are marketed.

Diesel fuels specified to EN 590 or ASTM D975 arerecommended.

In all cases, the fuel shall meet the followingproperties:

Cetane number of 40 minimum. Cetane numbergreater than 50 is preferred, especially fortemperatures below -20°C (-4°F) or elevations above1500 m (5,000 ft).

Cold Filter Plugging Point (CFPP) below theexpected low temperature OR Cloud Point at least5°C (9°F) below the expected low temperature.

Fuel lubricity should pass a minimum of 3100 gramload level as measured by the BOCLE scuffing test.

Sulfur content:

• Sulfur content should not exceed 0.5%. Sulfurcontent less than 0.05% is preferred.

• If diesel fuel with sulfur content greater than 0.5%sulfur content is used, reduce the service interval forengine oil and filter by 50%.

• DO NOT use diesel fuel with sulfur content greaterthan 1.0%.

Bio-diesel fuels may be used ONLY if the fuelproperties meet DIN 51606 or equivalent specification.

DO NOT mix used engine oil or any other type oflubricant with diesel fuel.

DX,FUEL5 –19–24JAN00–1/1

Lubricity of Diesel Fuel

Diesel fuel must have adequate lubricity to ensureproper operation and durability of fuel injection systemcomponents.

Diesel fuels for highway use in the United States andCanada require sulfur content less than 0.05%.

Diesel fuel in the European Union requires sulfurcontent less than 0.05%.

Experience shows that some low sulfur diesel fuelsmay have inadequate lubricity and their use mayreduce performance in fuel injection systems due toinadequate lubrication of injection pump components.The lower concentration of aromatic compounds inthese fuels also adversely affects injection pump sealsand may result in leaks.

Use of low lubricity diesel fuels may also causeaccelerated wear, injection nozzle erosion or corrosion,engine speed instability, hard starting, low power, andengine smoke.

Fuel lubricity should pass a minimum of 3100 gramload level as measured by the BOCLE scuffing test.

ASTM D975 and EN 590 specifications do not requirefuels to pass a fuel lubricity test.

If fuel of low or unknown lubricity is used, add JohnDeere PREMIUM DIESEL FUEL CONDITIONER (orequivalent) at the specified concentration.


PN=41

Fuels and Lubricants

000004

2

TX,45,JC2126 –19–15AUG97–1/1

Low Sulfur Diesel Fuel Conditioner

When possible, use existing fuel formulations for enginesused off-highway. This fuel will not require any additivesto provide good performance and engine reliability.However, many local fuel distributors will not carry bothlow and regular sulfur diesel fuels.

If the local fuel distributor will supply only low sulfur fuel,order and use John Deere PREMIUM DIESEL FUELCONDITIONER. It provides lubricating properties alongwith other useful benefits, such as cetane improver,anti-oxidant, fuel stabilizer, corrosion inhibitor and others.John Deere PREMIUM DIESEL FUEL CONDITIONER isspecifically for use with low sulfur fuels. Nearly all otherdiesel fuel conditioners only improve cold weather flowand stabilize long-term fuel storage. They do not containthe lubrication additives needed by rotary fuel injectionpumps.

TX,45,JC1772 –19–08JAN97–1/1

Diesel Fuel Storage

Proper fuel storage is critically important. Use cleanstorage and transfer tanks. Periodically drain waterand sediment from bottom of tank. Store fuel in aconvenient place away from buildings.

IMPORTANT: DO NOT store diesel fuel ingalvanized containers. Diesel fuelstored in galvanized containersreacts with zinc coating on containerto form zinc flakes. If fuel containswater, a zinc gel will also form. Thegel and flakes will quickly plug fuelfilters, damage injection nozzles andinjection pump.

DO NOT use brass-coated containersfor fuel storage. Brass is an alloy ofcopper and zinc.

Store diesel fuel in plastic, aluminum, and steelcontainers specially coated for diesel fuel storage.

Avoid storing fuel over long periods of time. If fuel isstored for more than a month prior to use, or there is aslow turnover in fuel tank or supply tank, add a fuelconditioner such as John Deere PREMIUM DIESELFUEL CONDITIONER or equivalent to stabilize the fueland prevent water condensation. John DeerePREMIUM DIESEL FUEL CONDITIONER is availablein winter and summer formulas. Fuel conditioner alsoreduces fuel gelling and controls wax separation duringcold weather.

Consult your John Deere engine distributor or servicingdealer for recommendations and local availability.Always follow manufacturer’s directions on label.


PN=42


0000043

CED,OUOE002,1783 –19–16SEP98–1/1

Fuel Tank

CAUTION: Handle fuel carefully. If the engineis hot or running, DO NOT fill the fuel tank.DO NOT smoke while you fill fuel tank orwork on fuel system.

To avoid condensation, fill the fuel tank at the end ofeach day’s operation. Shut off engine before filling.

SpecificationFuel Tank—Capacity 265 L (70 gal)....................................................

CED,OUO1021,176 –19–25MAR99–1/1

Diesel Engine Oil

T10

1239

–19–

22M

AY

96

Use oil viscosity based on the expected airtemperature range during the period between oilchanges.

The following oil is preferred:

• John Deere PLUS-50

If John Deere PLUS-50 engine oil and a John Deereoil filter are used, the service interval for oil and filterchanges may be extended by 50 hours.

The following oil is also recommended:

• John Deere TORQ-GARD SUPREME

Other oils may be used if they meet API ServiceClassification CG-4.

Multi-viscosity diesel engine oils are preferred.

If diesel fuel with sulfur content greater than 0.5% isused, reduce the service interval by 50%.

PLUS-50 is a trademark of Deere & CompanyTORQ-GARD SUPREME is a registered trademark of Deere &Company


PN=43


000004

4

TX,45,JC1864 –19–17FEB97–1/1

Transmission, Hydraulic System, Park Brake, and Differential Oil

T10

0663

–19–

10M

AY

96

Use oil viscosity based on the expected airtemperature range during the period between oilchanges.

The following oils are preferred:

• John Deere HY-GARD

• John Deere Low Viscosity HY-GARD

Other oils may be used if they meet one of thefollowing:

• John Deere Standard JDM J20C• John Deere Standard JDM J20D

Use the following oil when a biodegradable fluid isrequired:

• John Deere BIO-HY-GARD1

HY-GARD is a trademark of Deere & Company.BIO-HY-GARD is a trademark of Deere & Company.

1BIO-HY-GARD meets or exceeds the minimum biodegradability of80% within 21 days according to CEC-L-33-T-82 test method.BIO-HY-GARD should not be mixed with mineral oils because thisreduces the biodegradability and makes proper oil recyclingimpossible.


PN=44


0000045

TX,45,JC1134 –19–22MAY96–1/1

Grease

T83

58A

I–1

9–27

MA

R95

Use grease based on NLGI consistency numbers andthe expected air temperature range during the serviceinterval.

The following greases are preferred:

• John Deere MOLY HIGH TEMPERATURE EPGREASE

• John Deere HIGH TEMPERATURE EP GREASE• John Deere GREASE-GARD

Other greases may be used if they meet one of thefollowing:

• NLGI Performance Classification GC-LB


PN=45


000004

6

DX,ALTER –19–15JUN00–1/1

Alternative and Synthetic Lubricants

Conditions in certain geographical areas may requirelubricant recommendations different from those printed inthis manual.

Some John Deere brand coolants and lubricants may notbe available in your location.

Consult your John Deere dealer to obtain information andrecommendations.

Synthetic lubricants may be used if they meet theperformance requirements as shown in this manual.

The temperature limits and service intervals shown in thismanual apply to both conventional and synthetic oils.

Re-refined base stock products may be used if thefinished lubricant meets the performance requirements.

DX,LUBST –19–18MAR96–1/1

Lubricant Storage

Your equipment can operate at top efficiency onlywhen clean lubricants are used.

Use clean containers to handle all lubricants.

Whenever possible, store lubricants and containers inan area protected from dust, moisture, and othercontamination. Store containers on their side to avoidwater and dirt accumulation.

Make certain that all containers are properly marked toidentify their contents.

Properly dispose of all old containers and any residuallubricant they may contain.


PN=46


0000047

DX,LUBMIX –19–18MAR96–1/1

Mixing of Lubricants

In general, avoid mixing different brands or types of oil.Oil manufacturers blend additives in their oils to meetcertain specifications and performance requirements.

Mixing different oils can interfere with the properfunctioning of these additives and degrade lubricantperformance.

Consult your John Deere dealer to obtain specificinformation and recommendations.


PN=47


000004

8


PN=48

Section 01Wheels

Contents 01

Page

Group 0110—Powered Wheels and FastenersService Equipment and Tools . . . . . . . . . . . .01-0110-1Specifications . . . . . . . . . . . . . . . . . . . . . . . .01-0110-1Wheel

Remove and Install . . . . . . . . . . . . . . . . . .01-0110-1Tire

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-3Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-4


PN=1

Contents

01


PN=2

Group 0110Powered Wheels and Fasteners

0101101

CED,OUOE003,3284 –19–25MAR99–1/3

Service Equipment and Tools

NOTE: Order tools according to information given in theU.S. SERVICEGARD Catalog or from theEuropean Microfiche Tool Catalog (MTC). Sometools may be available from a local supplier.

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,3284 –19–25MAR99–2/3

10-Ton Shop Stand

To support machine while removing and installing wheels.

CED,OUOE003,3284 –19–25MAR99–3/3

Wheel and Axle Lift . . . . . . . . . . . . . . . . . . . . JT05726

To remove and install wheels.

CED,OUOE003,3285 –19–25MAR99–1/1

Specifications


Wheel Cap Screw Torque 675 N•m (500 lb-ft)

Valve Stem Retaining Nut Torque 6 N•m (50 lb-in.)

TX,01,111685 –19–01NOV02–1/2

Remove and Install Wheel

1. Raise machine and place 10-ton shop stand underaxle.

CAUTION: Use a lifting device for heavycomponents.

2. Place wheel and axle lift under wheel. Fasten safetychain around upper part of tire.


PN=51


Powered Wheels and Fasteners

010110

2

TX,01,111685 –19–01NOV02–2/2

T71

34F

A–U

N–2

4MA

Y90

A—Wheel Cap Screw (14 used)

3. Remove cap screws (A). Remove wheel.

4. Clean mounting surface on wheel and axle flange.

5. Install wheel. Tighten cap screws (A).

Remove and Install Wheel—SpecificationWheel Retainer Cap Screws—DryTorque 620 N•m (460 lb-ft).........................................................................


PN=52


0101103

TX,01,111686 –19–23OCT98–1/2

Remove Tire

TS

211

–UN

–23A

UG

88

CAUTION: Explosive separation of a tire andrim parts can cause serious injury or death.

Only attempt to mount a tire if you have theproper equipment and experience to performthe job. Have it done by your John Deere dealeror a qualified repair service.

Always maintain the correct tire pressure. Donot inflate the tires above the recommendedpressure.

When inflating tires, use a clip-on chuck andextension hose long enough to allow you tostand to one side and NOT in front of or overthe tire assembly. Use a safety cage if available.

Inspect tires and wheels daily. Do not operatewith low pressure, cuts, bubbles, damaged rimsor missing lug bolts and nuts.

Failure to follow proper procedures whendemounting a tire from a wheel or rim canproduce an explosion which may result inserious bodily injury. DO NOT attempt todemount a tire unless you have properequipment and experience to perform the jobsafely. Have it done by a qualified tire repairservice.

NOTE: See John Deere Off-The-Road Tire MaintenanceManual to remove tire from wheel.

Tire can be removed without removing wheel.



PN=53


010110

4

TX,01,111686 –19–23OCT98–2/2

T77

51G

U–U

N–2

2OC

T92

A—CapB—Valve CoreC—Valve Nut

Before attempting any demounting operation, alwayscompletely deflate tire. Remove cap (A) and valve core(B) from valve. Remove valve nut (C).

Inspect all parts for damage. Replace parts as necessary.

TX,01,111687 –19–23OCT98–1/1

Install Tire

T65

64B

R–U

N–2

2OC

T88

A—Front FlangeB—Bead Seat BandC—Lock RingD—O-RingE—Cap

CAUTION: Failure to follow proper procedureswhen mounting a tire from a wheel or rim canproduce an explosion which may result inserious bodily injury. DO NOT attempt to mounta tire unless you have proper equipment andexperience to perform the job safely. Have itdone by a qualified tire repair service.

NOTE: See John Deere Off-The-Road Tire MaintenanceManual to mount the tire on the wheel.

To prevent slipping of the wheel under load, the insideand outside wheel must be free of paint, rust, oil, grease,dirt or other foreign material before installation.

Install valve stem in rim base and tighten retaining nut.

SpecificationValve Stem Retaining Nut—Torque 6 N•m (50 lb-in.)..............................................................................

CAUTION: Serious bodily injury can occur fromexplosion when mounting and inflating tires ifsafe procedures are not followed.

Use only recommended air pressure. Pressure over thislimit can cause explosion.

Inflate tire.

Apply John Deere Non-Soap Lubricating Grease, or anequivalent, on threads of cap (E). Install cap on valvestem shield.


PN=54

Section 02Axles and Suspension Systems

Contents

Page

Group 0200—Removal and InstallationService Equipment and Tools . . . . . . . . . . . .02-0200-1 02Specifications . . . . . . . . . . . . . . . . . . . . . . . .02-0200-2Front Axle and Differential

Remove and Install . . . . . . . . . . . . . . . . . .02-0200-3Rear Axle And Differential

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-9Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-14

Axle Oscillating SupportsDisassemble and Assemble. . . . . . . . . . .02-0200-18

Group 0225—Axle Shafts and U-JointsSpecifications . . . . . . . . . . . . . . . . . . . . . . . .02-0225-1Universal Joint and Drive Shaft

Remove and Install . . . . . . . . . . . . . . . . . .02-0225-2Disassemble, Inspect and Assemble . . . . .02-0225-4

Group 0250—Axle Shaft, Bearings, ReductionGears

John Deere TeamMate III Axles—UseCTM150. . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-1

Essential Tools . . . . . . . . . . . . . . . . . . . . . . .02-0250-1Service Equipment and Tools . . . . . . . . . . . .02-0250-2Other Material . . . . . . . . . . . . . . . . . . . . . . . .02-0250-3Specifications . . . . . . . . . . . . . . . . . . . . . . . .02-0250-3Axle Disconnect Input Shaft

Cross-Section View . . . . . . . . . . . . . . . . . .02-0250-4Remove and Install . . . . . . . . . . . . . . . . . .02-0250-5Disassemble, Inspect and Assemble . . . . .02-0250-6

Group 0260—Hydraulic SystemSpecifications . . . . . . . . . . . . . . . . . . . . . . . .02-0260-1Differential Lock Solenoid Valve

Remove and Install . . . . . . . . . . . . . . . . . .02-0260-2Axle Recirculation System. . . . . . . . . . . . . . .02-0260-3Air Recirculation System

With Optional Oil Coolers. . . . . . . . . . . . . .02-0260-4Axle Oil Coolers

Exploded View. . . . . . . . . . . . . . . . . . . . . .02-0260-6Front Axle Oil Cooler

Remove and Install . . . . . . . . . . . . . . . . . .02-0260-7Disassemble and Assemble. . . . . . . . . . . .02-0260-9

Rear Axle Oil CoolerRemove and Install . . . . . . . . . . . . . . . . .02-0260-10


PN=1

Contents

02


PN=2

Group 0200Removal and Installation

0202001CED,OUOE003,3287 –19–25MAR99–1/4




CED,OUOE003,3287 –19–25MAR99–2/4

12-1/2 Ton Floor Stands

To support machine while removing axle and differential.

CED,OUOE003,3287 –19–25MAR99–3/4

Wheel and Axle Lift . . . . . . . . . . . . . . . . . . . . JT05726

To remove and install wheels.

CED,OUOE003,3287 –19–25MAR99–4/4

Low-Lift Jack . . . . . . . . . . . . . . . . . . . . . . . JT01642A

For removal and installation of axle and differential.


PN=57

Removal and Installation

020200

2

CED,OUOE003,3288 –19–25MAR99–1/2

Specifications


Front Axle and Differential

624H Loader Weight 13 560 kg (29,894 lb) approximate

TC62H Tool Carrier Weight 13 361 kg (29,456 lb) approximate

Front Frame Bottom Guard Weight 32 kg (72 lb) approximate

Axle and Differential Weight 580 kg (1280 lb) approximate

Cap Screw Nut Torque 675 N•m (500 lb-ft)

Drive Shaft Universal Joint Cap Torque 78 N•m (58 lb-ft)Screw


Rear Axle and Differential

Transmission Bottom Guard Weight 62 kg (137 lb) approximate

624H Loader Weight 13 560 kg (29,894 lb) approximate

TC62H Tool Carrier Weight 13 361 kg (29,456 lb) approximate

Axle and Differential with Weight 598 kg (1320 lb) approximateOscillating Supports

Thrust Plate-to- Rear Oscillating Torque 350 N•m (255 lb-ft)Support Cap Screw

Pivot Cover-to-Rear Oscillating Torque 140 N•m (105 lb-ft)Support Cap Screw

Axle Support-to-Rear Oscillating Torque 675 N•m (500 lb-ft)Support Cap Screw

Drive Shaft Universal Joint Cap Torque 78 N•m (58 lb-ft)Screw



PN=58



0202003

CED,OUOE003,3288 –19–25MAR99–2/2


Axle Oscillating Supports

Axle Oscillating Support End Play 0.762 mm (0.03 in.) maximum

Thrust Plate Between Thrust Wear 0.254 mm (0.01 in.) maximum onBearings front side

Thrust Plate-to-Rear Oscillating Torque 350 N•m (255 lb-ft)Support Cap Screw

Pilot Cover-to-Rear Oscillating Torque 140 N•m (105 lb-ft)Support Cap Screw

TX,02,111691 –19–25MAR99–1/6

Remove and Install Front Axle andDifferential

T10

1610

–UN

–03O

CT

96

A—Locking BarB—12-1/2 Ton Floor Stand

1. Apply park brake.

2. Install frame locking bar (A).

CAUTION: The approximate weight of machineis:

• 624H—13 560 kg (29,894 lb)• TC62H—13 361 kg (29,456 lb)

Front Axle and Differential—Specification624H Loader—Weight 13 560 kg (29,894 lb)

approximate.............................................

TC62H Tool Carrier—Weight 13 361 kg (29,456 lb)approximate

..................................

3. Raise front of machine. Install floor stands (B) underloader frame.

4. Install boom lock. Move bucket to dumped position andlower. This will provide clearance to remove capscrews.

5. Stop engine.


PN=59



020200

4

TX,02,111691 –19–25MAR99–2/6

CAUTION: Prevent possible injury fromunexpected boom or bucket movement whenequipped with ride control. Ride controlaccumulator energy must be discharged whenworking on hydraulic components. With boomraised slightly, turn ignition switch to ONposition. Cycle the ride control switch from OFFto ON (center position). Boom will jump upunexpectedly if ride control accumulator isenergized. Press boom enable switch and movethe control lever into the float position and holdfor 5 seconds.

6. If equipped with ride control. With boom raised slightly,turn ignition switch to ON position. Cycle the ridecontrol switch from OFF to ON (center position). Boomwill jump up unexpectedly if ride control accumulator isenergized. Press boom enable switch and move thecontrol lever into the float position and hold for 5seconds.

7. Drain differential. Approximate oil capacity is 25 L (26.0qt).

CAUTION: The approximate weight of bottomguard is 32 kg (72 lb).

Weight may increase significantly due tobuildup of mud or debris.

Front Axle and Differential—SpecificationFront Frame Bottom Guard—Weight 32 kg (72 lb) approximate................................................................

8. Remove bottom guard, if equipped.



PN=60


0202005

TX,02,111691 –19–25MAR99–3/6

T12

1376

–UN

–07M

AY

99

A—Brake PortB—Recirculation System Inlet PortC—Differential Lock PortD—Axle Disconnect Port (If Equipped)E—Recirculation System Outlet Port

NOTE: Label lines to aid in installation.

9. Disconnect lines from ports (A—E). Install caps andplugs in ports and hoses.

10. Remove cap screws to disconnect drive shaft.


11. Remove wheels using wheel and axle lift.



PN=61


020200

6

TX,02,111691 –19–25MAR99–4/6

T10

1609

–UN

–03O

CT

96

TeamMate II Axle Shown

A—NutsB—Low-Lift Jack

CAUTION: The approximate weight of axle anddifferential is 580 kg (1280 lb).

Front Axle and Differential—SpecificationAxle and Differential—Weight 580 kg (1280 lb) approximate.....................

12. Install low-lift jack (B) under axle and differential.

13. Remove nuts (A) to remove cap screws. Lower axleand differential.

14. Repair or replace axle or differential. (See procedurein this group.)

15. Clean mounting surface on axle housings and loaderframe.

16. Install axle and differential.

Install a washer under head of cap screws and awasher under the nuts. Hold the cap screws andtighten nuts.

Front Axle and Differential—SpecificationCap Screw Nut—Torque 675 N•m (500 lb-ft).............................................



PN=62


0202007

TX,02,111691 –19–25MAR99–5/6

T10

6373

B–U

N–2

9JA

N97

Left Front Differential Axle

A—Port

IMPORTANT: To properly check oil level, do notthread dipstick into port. Allow 10minutes for oil to stabilize in each sumpbefore checking.

NOTE: Each differential housing has three separatecomponents. To expedite filling differential,remove right axle plug.

17. Fill differential adding oil slowly through port (A) onthe left axle. Check oil level after waiting 10 minutes.Make sure machine is level. (See Differential Oil inGroup 0004 for recommended oil.)

IMPORTANT: DO NOT reuse drive shaft universaljoint cap screws. Replace cap screws toavoid machine damage.

18. Connect drive shaft. Install new drive shaft universaljoint cap screws. Tighten cap screws.

Front Axle and Differential—SpecificationDrive Shaft Universal Joint CapScrew—Torque 78 N•m (58 lb-ft)................................................................



PN=63


020200

8

TX,02,111691 –19–25MAR99–6/6

T12

1376

–UN

–07M

AY

99


19. Connect lines to ports (A—E).

20. Remove jack.

21. Install wheels. Tighten cap screws.

Front Axle and Differential—SpecificationWheel Cap Screw—Torque 675 N•m (500 lb-ft).........................................

NOTE: No bleeding of brakes is necessary. They areself-bleeding.

22. Install bottom guard, if equipped.


PN=64


0202009

TX,02,111692 –19–10FEB99–1/5

Remove Rear Axle and Differential

1. Apply park brake.

2. Install frame locking bar.

3. Raise boom and install boom lock. Move bucket todump position.

4. Stop engine. Release hydraulic pressure by operatingloader control while holding boom enable switch.



CAUTION: The approximate weight oftransmission bottom guard is 62 kg (137 lb).

Weight may increase significantly due tobuildup of mud or debris on guard.

Rear Axle and Differential—SpecificationTransmission Bottom Guard—Weight 62 kg (137 lb) approximate..............................................................

6. Remove transmission bottom guard if equipped.

7. Drain differential. Approximate oil capacity is 20 L (21qt).


PN=65



020200

10

TX,02,111692 –19–10FEB99–2/5

T71

34H

D–U

N–2

0FE

B90

T71

34H

E–U

N–0

6MA

R90

A—Floor Stand (4 used)

CAUTION: The approximate weight of machineis:

• 624H—13 560 kg (29,894 lb)• TC62H—13 361 kg (29,456 lb)

Rear Axle and Differential—Specification624H Loader—Weight 13 506 kg (29,894 lb)

approximate.............................................

TC62H Tool Carrier—Weight 13 361 kg (29,456 lb)approximate

..................................

8. Raise rear of machine using floor jack. Install floorstands (A) under frame on each side and under rearcorners of frame.


9. Remove wheels.

10. Remove caps screws to disconnect drive shaft.

CAUTION: The approximate weight of axle anddifferential with front and rear oscillatingsupports is 598 kg (1320 lb).

Rear Axle and Differential—SpecificationAxle and Differential withOscillating Supports—Weight 598 kg (1320 lb) approximate......................

11. Install low-lift jack under axle and differential.



PN=66


02020011

TX,02,111692 –19–10FEB99–3/5

T12

1376

–UN

–07M

AY

99


12. Disconnect lines (A and B) if equipped.



PN=67


020200

12

TX,02,111692 –19–10FEB99–4/5

TP

6039

8–U

N–2

2MA

Y98

Rear Differential Oscillating Supports and Lubrication Lines



PN=68


02020013

TX,02,111692 –19–10FEB99–5/5

1—Special Jam Nut (2 used) 9—Thrust Plate 16—Seal (3 used) 22—Washer (16 used)2—Fitting (2 used) 10—Washer (4 used) 17—Cap Screw (4 used) 23—Rear Axle Support3—Pipe Plug 11—Cap Screw (4 used) 18—Nut 24—Rear Axle Support4—Hydraulic Hose 12—O-Ring 19—Hydraulic Hose 25—Lubrication Fitting5—Elbow Fitting (3 used) 13—Cover 20—Elbow Fitting 26—Bushing (2 used S/N —6—Rear Oscillating Support 14—Cap Screw (6 used) 21—Lubrication Fitting XXXX) (4 used S/N7—Bushing (2 used) 15—Cap Screw (6 used) (2 used) XXXX— )8—Thrust Bearing (6 used)

NOTE: Bushings (26) are installed on center right andleft cap screws (Serial No. — XXXX) andinstalled two on the front and two on the rearcap screws (Serial No. XXXX — ).

13. Disconnect hydraulic hoses (4 and 19) from frontand rear oscillating supports.

14. Remove cap screws (17 and 15) from oscillatingsupports.

15. Lower supports, axle and differential assembly.

16. Remove rear axle support (23) from differentialassembly.

17. Remove cap screws from pivot cover (13) andthrust plate (9).

18. Remove rear oscillating support (6) fromdifferential assembly.

19. Repair or replace axle. See this group for repair.


PN=69


020200

14

TX,02,111693 –19–11FEB99–1/3

Install Rear Axle and Differential

TP

6039

8–U

N–2

2MA

Y98



PN=70



02020015

TX,02,111693 –19–11FEB99–2/3


1. Install front and rear oscillating supports.

2. Tighten thrust plate (9) cap screws (11) and pivotcover (13) cap screws (14).

Rear Axle and Differential—SpecificationThrust Plate-to- RearOscillating Support CapScrew—Torque 350 N•m (255 lb-ft).....................................................Pivot Cover-to-Rear OscillatingSupport Cap Screw—Torque 140 N•m (105 lb-ft)...............................

3. Install axle and differential.

4. Tighten cap screws (15 and 17).

Rear Axle and Differential—SpecificationAxle Support-to-RearOscillating Support CapScrew—Torque 675 N•m (500 lb-ft).....................................................

5. Connect lines to differential.

IMPORTANT: DO NOT reuse drive shaft universaljoint cap screws. Replace capscrews to avoid machine damage.

6. Connect drive shaft. Install new drive shaftuniversal joint cap screws. Tighten cap screws.

Rear Axle and Differential—SpecificationDrive Shaft Universal Joint CapScrew—Torque 78 N•m (58 lb-ft).........................................................

NOTE: No bleeding of brakes is necessary. They areself-bleeding.

7. Connect lubrication lines.

8. Install wheels. Tighten cap screws.

Rear Axle and Differential—SpecificationWheel Cap Screw—Torque 675 N•m (500 lb-ft)..................................

9. Remove floor stands.

10. Install bottom guard, if equipped.



PN=71


020200

16

TX,02,111693 –19–11FEB99–3/3

T10

6373

B–U

N–2

9JA

N97

Left Front Differential Axle

A—Port

IMPORTANT: To properly check oil level, do notthread dipstick into port. Allow 10minutes for oil to stabilize in each sumpbefore checking.

NOTE: Each differential housing has three separatecomponents. To expedite filling differential,remove right axle plug.

11. Fill differential adding oil slowly through port (A) onthe left axle. Check oil level after waiting 10 minutes.Make sure machine is level. (See Differential Oil inGroup 0004 for recommended oil.)


PN=72


02020017


PN=73


020200

18

TX,02,111694 –19–11FEB99–1/3

Disassemble and Assemble Axle Oscillating Supports

TP

6039

8–U

N–2

2MA

Y98



PN=74



02020019

TX,02,111694 –19–11FEB99–2/3


NOTE: Axle oscillation support assembly does notcontain any shims for setting end play. Ifexcessive end play is incurred due to wear,end play should be no greater than 0.762 mm(0.03 in). This can be checked with dialindicator measuring between front support andthe differential housing. If greater than 0.762mm (0.03 in.) thrust bearings should bereplaced. Also check thrust plate (betweenboth thrust bearings) for wear on front side.Disk should not have more than 0.254 mm(0.01 in.) wear step on face that contacts frontthrust bearings. If out of specification, replacethrust plate and thrust bearings.

1. Remove rear axle and differential assembly. (Seeprocedure in this group.)

2. Remove front oscillating support.

3. Remove cap screws (14) in pivot cover and capscrews (11) in thrust plate (9) in rear oscillatingsupport.

4. Remove rear oscillating support.

5. Repair and replace parts as necessary.

6. Inspect thrust bearings (8) and bushings (7) forwear.

Axle Oscillating Supports—SpecificationAxle Oscillating Support—EndPlay 0.762 mm (0.03 in.) maximum......................................................Thrust Plate Between ThrustBearings—Wear 0.254 mm (0.01 in.) maximum

on front side...................................

7. Lube thrust bearings and bushings with grease andpack cavity of cover (13).



PN=75


020200

20

TX,02,111694 –19–11FEB99–3/3

T10

8815

B–U

N–0

4AP

R97

A—SupportB—Grease FittingC—BushingD—Grease Slots

NOTE: If bushings were removed in front or rearoscillation supports note proper location ofbushing (C) grease slots (D) in relation to thegrease fitting (B). Slots should be facing uptoward the grease fitting to allow properlubrication of pivot area.

8. Press bushings into front and rear supports beingcareful not to damage.

9. Install rear and front oscillating supports to differential.

10. Tighten thrust plate cap screws (11) and pivot covercap screws (14).

Axle Oscillating Supports—SpecificationThrust Plate-to-Rear OscillatingSupport Cap Screw—Torque 350 N•m (255 lb-ft)......................................Pilot Cover-to-Rear OscillatingSupport Cap Screw—Torque 140 N•m (105 lb-ft)......................................

11. Install rear axle and differential assembly. (Seeprocedure in this group.)


PN=76

Group 0225Axle Shafts and U-Joints

0202251

CED,OUOE003,3291 –19–25MAR99–1/1

Specifications


Front and Rear Drive Shaft Universal Torque 78 N•m (58 lb-ft)Joint Cap Screw

Engine Drive Shaft Torque 78 N•m (58 lb-ft)Universal-to-Transmission CapScrew

Engine Drive Shaft-to-Damper Cap Torque 130 N•m (95 lb-ft)Screw


PN=77

Axle Shafts and U-Joints

020225

2

TX,02,111696 –19–25MAR99–1/1

Remove and Install Universal Joint and Drive Shaft

T10

8602

–19–

31M

AR

97

CAUTION: Prevent possible injury fromunexpected machine movement. Placeblocks front and rear of tires to preventmachine from rolling.


1. Remove drive shaft universal joint cap screws.

2. Inspect and replace parts as necessary.

3. Install new drive shaft universal joint cap screws.

SpecificationFront and Rear Drive ShaftUniversal Joint Cap Screw—Torque 78 N•m (58 lb-ft).......................................................................Engine Drive ShaftUniversal-to-Transmission CapScrew—Torque 78 N•m (58 lb-ft).........................................................Engine Drive Shaft-to-DamperCap Screw—Torque 130 N•m (95 lb-ft)...............................................


PN=78


0202253


PN=79


020225

4

TX,02,111697 –19–25MAR99–1/2

Disassemble, Inspect and Assemble Universal Joint and Drive Shaft

T11

2056

–19–

03N

OV

97

Transmission-to-Differential and Engine Shafts

1—Cap Screw (4 used) 3—Clamp (14 used) 5—Drive Shaft 7—Drive Shaft2—Cap Screw (28 used) 4—Drive Shaft 6—Cap Assembly (3 used) 8—Drive Shaft

CAUTION: Prevent possible injury fromunexpected machine movement. Placeblocks front and rear of tires to preventmachine from rolling.


1. Remove drive shaft universal joint cap screws.



PN=80



0202255TX,02,111697 –19–25MAR99–2/2

3. Install new drive shaft universal joint cap screws.

SpecificationFront and Rear Drive ShaftUniversal Joint Cap Screw—Torque 78 N•m (58 lb-ft).......................................................................

Engine Drive ShaftUniversal-to-Transmission CapScrew—Torque 78 N•m (58 lb-ft).........................................................Engine Drive Shaft-to-DamperCap Screw—Torque 130 N•m (95 lb-ft)...............................................


PN=81


020225

6


PN=82

Group 0250Axle Shaft, Bearings, Reduction Gears

0202501CED,OUOE006,18 –19–24SEP98–1/1

John Deere TeamMate III Axles—UseCTM150

TS

225

–UN

–17J

AN

89

For complete repair information, the Component TechnicalManual (CTM) is also required.

Use the CTM in conjunction with this repair manual.

TeamMate is a trademark of Deere & Company.

CED,OUOE003,3293 –19–25MAR99–1/8

Essential Tools

NOTE: Order tools according to information given in theU.S. SERVICEGARD Catalog or from theEuropean Microfiche Tool Catalog (MTC).


CED,OUOE003,3293 –19–25MAR99–2/8

RW25643 –UN–28FEB97

Lifting Screw . . . . . . . . . . . . . . . . . . . . . . . JDG1125

Used with JDG19 Special Mounting Bracket to removeand install axle disconnect input shaft.

CED,OUOE003,3293 –19–25MAR99–3/8

RW25781 –UN–19JUN97

Spanner Wrench . . . . . . . . . . . . . . . . . . . . . JDG1142

Used to remove and install auxiliary yoke retaining nut.

CED,OUOE003,3293 –19–25MAR99–4/8

RW25383 –UN–02APR96

Yoke Holding Tool . . . . . . . . . . . . . . . . . . . . JDG1090

Used to remove and install yoke retaining nut.

CED,OUOE003,3293 –19–25MAR99–5/8

RW25780 –UN–19JUN97

Bearing Installer Set . . . . . . . . . . . . . . . . . . JDG1141

Used to support disconnect input shaft and install outerbearing cone.


PN=83


Axle Shaft, Bearings, Reduction Gears

CED,OUOE003,3293 –19–25MAR99–6/8

RW25388 –UN–15JUN95

Seal Installer . . . . . . . . . . . . . . . . . . . . . . . JDG1092

Used with JDG926 Bearing Installer to install input shaftyoke seal on 1200 Series rear axle.

020250

2 CED,OUOE003,3293 –19–25MAR99–7/8

RW25388 –UN–15JUN95

Seal Installer . . . . . . . . . . . . . . . . . . . . . . . JDG1151

Used with JDG926 Bearing Installer to install input shaftyoke seal on 1400 Series front axle.

CED,OUOE003,3293 –19–25MAR99–8/8

RW25381 –UN–14JUN95

Bearing Installer . . . . . . . . . . . . . . . . . . . . . . JDG926

Used with seal installer to install input shaft seal.

CED,OUOE003,3294 –19–25MAR99–1/6




CED,OUOE003,3294 –19–25MAR99–2/6

Special Mounting Bracket . . . . . . . . . . . . . . . . . JDG19

Used with JDG1125 Lifting Screw to remove and installaxle disconnect input shaft.

CED,OUOE003,3294 –19–25MAR99–3/6

Driver Disk. . . . . . . . . . . . . . . . . . . . . . . . . 4-5/16 in.

To force piston downward for snap ring removal on a1200 Series rear axle.

CED,OUOE003,3294 –19–25MAR99–4/6

Driver Disk. . . . . . . . . . . . . . . . . . . . . . . . . . 5-1/2 in.

To force piston downward for snap ring removal on a1400 Series front axle.


PN=84



CED,OUOE003,3294 –19–25MAR99–5/6

Driver Disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 in.

To install bearing cups on a 1200 Series rear axle.

0202503CED,OUOE003,3294 –19–25MAR99–6/6

Driver Disk. . . . . . . . . . . . . . . . . . . . . . . . . 3-9/16 in.

To install bearing cups on a 1400 Series front axle.

CED,OUOE003,3295 –19–25MAR99–1/1

Other Material

Number Name Use

PT506 (U.S.) NEVER-SEEZ Lubricant Apply to shaft threads.

NEVER-SEEZ is a trademark of Emhart Chemical Group.

CED,OUOE003,3296 –19–25MAR99–1/1

Specifications


Axle Disconnect Input Shaft

Disconnect Assembly Weight 61 kg (135 lb) approximate

Retaining Cap Screw Torque 310 N•m (230 lb-ft)

Auxiliary Yoke-to-Differential Drive Torque 360 N•m (267 lb-ft)Shaft Nut

Collar Engagement Spring Free Length 73 mm (2.874 in.) approximateTest Length 44.45 mm at 352—431 N (1.750 in.

at 78—96 lb-force)

Yoke Retaining Nut Torque 360 N•m (267 lb-ft)


PN=85


020250

4

TX,02,111673 –19–21JUL97–1/1

Axle Disconnect Input Shaft, Cross-Sectional View

RW

3630

8–U

N–1

7MA

R97

A—Disconnect Input Shaft H—Collar Assembly N—Nut T—Needle Roller Bearing (2B—Nut Anti-Rotation Plug O—Spacer Washer used)C—Spacer Washer I—Collar Assembly Housing P—Piston Assembly Packing U—CollarD—Input Yoke J—Piston Housing Ring (2 used) V—Input Shaft Bearing SetE—Disconnect Housing K—Housing-to-Differential Q—Piston Packing Ring (4 W—Input Shaft SealF—Collar Engagement Spring Case Sealing Ring used) X—Dust Seal

(4 used) L—Disconnect Auxiliary Yoke R—Piston (4 used) Y—Oil RingG—Collar Assembly Spring M—Differential Drive Shaft S—Needle Bearing Thrust

Retainer Plate Washer


PN=86


0202505

TX,02,111675 –19–10MAY99–1/1

Remove and Install Axle Disconnect InputShaft

RW

3628

9–U

N–1

7MA

R97

A—Retaining Cap ScrewB—JDG1125 Lifting ScrewC—JDG19 Special Mounting Bracket

NOTE: Axle assembly is removed from vehicle.

CAUTION: The approximate weight ofdisconnect assembly is 61 kg (135 lb).

Axle Disconnect Input Shaft—SpecificationDisconnect Assembly—Weight 61 kg (135 lb) approximate.......................

Loosen retaining cap screw (A).

Install JDG1125 Lifting Screw (B) and JDG19 SpecialMounting Bracket (C) and attach to an overhead hoist.

Remove the disconnect assembly from the axle assembly.

Install axle disconnect assembly onto axle. Pushdisconnect assembly forward until snap ring stops againstaxle differential case oscillating input.

Slowly rotate disconnect until hydraulic fitting is at topcenter.

Install retaining cap screw (A), washers and nut ondisconnect housing compression joint.

Tighten retaining cap screw.

Axle Disconnect Input Shaft—SpecificationRetaining Cap Screw—Torque 310 N•m (230 lb-ft)...................................


PN=87


020250

6

TX,02,111677 –19–25MAR99–1/25

Disassemble, Inspect, and Assemble AxleDisconnect Input Shaft

RW

3629

0–U

N–1

7MA

R97

A—Auxiliary YokeB—Nut

Remove disconnect assembly from axle assembly. (SeeRemove and Install Axle Disconnect Input Shaft in thisgroup.)

Inspect disconnect auxiliary yoke (A) on differential driveshaft and remove and replace as necessary.

Install JDG1142 Spanner Wrench and remove nut (B).

Remove spacer washer and disconnect auxiliary yokefrom differential drive shaft.

Install in reverse order.

Tighten nut.

Axle Disconnect Input Shaft—SpecificationAuxiliary Yoke-to-DifferentialDrive Shaft Nut—Torque 360 N•m (267 lb-ft).............................................

TX,02,111677 –19–25MAR99–2/25

RW

3629

1–U

N–1

7MA

R97

A—Yoke Holding Tool

Install JDG1090 Yoke Holding Tool (A) to input shaftyoke.

Remove nut and spacer from shaft.

Remove yoke and oil ring from shaft.



PN=88


0202507

TX,02,111677 –19–25MAR99–3/25

RW

3629

2–U

N–1

7MA

R97

A—Input Shaft Seal

Remove input shaft seal (A).

TX,02,111677 –19–25MAR99–4/25R

W36

293

–UN

–17M

AR

97

A—Sealing Ring

Remove housing-to-differential case sealing ring (A).

TX,02,111677 –19–25MAR99–5/25

RW

3629

4–U

N–1

7MA

R97

A—Driver Disk and HandleB—Snap Ring

Install disconnect assembly in a press and place a 4-5/16in. (1200 Series Rear Axle) or a 5-1/2 in. (1400 SeriesFront Axle) driver disk and handle (A) on top of the pistonhousing.

Force the piston downward and remove snap ring (B).


PN=89



020250

8

TX,02,111677 –19–25MAR99–6/25

RW

3629

5–U

N–1

7MA

R97

A—Piston Housing Assembly

Remove piston housing assembly (A) using a 3-jaw pullerand a slide hammer.

TX,02,111677 –19–25MAR99–7/25

RW

3629

6–U

N–1

7MA

R97

A—HousingB—PistonC—Packing Rings

Remove pistons from housing by tapping the backside ofthe housing with a hammer.

Inspect housing (A), pistons (B), and packing rings (C).

Replace parts as necessary.

Install pistons with packing rings into the piston housing.



PN=90


0202509

TX,02,111677 –19–25MAR99–8/25

RW

3629

7–U

N–1

7MA

R97

A—Piston Packing Ring (2 used)B—Anti-Rotation PlugC—Collar Assembly

Remove piston packing rings (A).

Remove collar assembly anti-rotation plug (B).

Remove collar assembly (C) from disconnect assembly.

TX,02,111677 –19–25MAR99–9/25

RW

3629

8–U

N–1

7MA

R97

A—Spring Return Plate

Remove the collar assembly spring return plate (A) fromthe collar assembly housing.



PN=91


020250

10

TX,02,111677 –19–25MAR99–10/25

RW

3629

9–U

N–1

7MA

R97

A—Needle Roller BearingB—Shift CollarC—Needle Roller Bearing Thrust WasherD—Collar Assembly HousingE—Collar Assembly Spring Retainer Plate

Remove parts (A—C) from housing (D).

Inspect parts and replace as necessary.

Assemble in reverse order.

TX,02,111677 –19–25MAR99–11/25

RW

3630

0–U

N–1

7MA

R97

A—Collar Engagement Spring (4 used)

Remove collar engagement springs (A) from housing.

Inspect springs.

Axle Disconnect Input Shaft—SpecificationCollar Engagement Spring—FreeLength 73 mm (2.874 in.) approximate.....................................................Test Length 44.45 mm at 352—431 N

(1.750 in. at 78—96 lb-force)........................................................



PN=92


02025011

TX,02,111677 –19–25MAR99–12/25

RW

3630

1–U

N–1

7MA

R97

A—Input Shaft

Place the disconnect assembly in a press.

Remove the input shaft (A) from the housing and outerbearing cone while supporting the shaft inside the case toprevent shaft from falling.

TX,02,111677 –19–25MAR99–13/25R

W36

302

–UN

–17M

AR

97

A—Outer Bearing Cone

Remove outer bearing cone (A) from housing.



PN=93


020250

12

TX,02,111677 –19–25MAR99–14/25

RW

3630

3–U

N–1

7MA

R97

A—Bearing Cup (2 used)B—HousingC—Snap Ring

NOTE: The input shaft bearings are supplied as amatched set. When replacement is required,replace all parts.

Inspect and if necessary remove inner and outer bearingcups (A) from housing (B).

Inspect bearing cup spacer snap ring (C) and remove ifnecessary.

Install new bearing cup spacer snap ring in housing.

Install new bearing cups in housing using a 3 in. (1200Series Rear Axle) or a 3-9/16 in. (1400 Series Front Axle)driver disk and a press.

TX,02,111677 –19–25MAR99–15/25

RW

3630

4–U

N–1

7MA

R97

A—Input ShaftB—Inner Bearing ConeC—Bearing Spacer

Inspect disconnect input shaft (A), inner bearing cone (B),and bearing spacer (C) and replace as necessary.

If necessary, remove bearing spacer (C) from shaft andremove inner bearing (B) using a knife-edge puller and apress.

CAUTION: Heat parts in a bearing heater. Use athermometer and do not exceed 150°C (300°F).Plan a safe handling procedure to avoid burns.

Heat bearing cone to 150° C (300° F) and install on shaft.



PN=94


02025013

TX,02,111677 –19–25MAR99–16/25

RW

3631

0–U

N–1

1AP

R97

A—JDG1141-1 Centering ToolB—Input Shaft

NOTE: JDG1141-1 Centering Tool is part of the JDG1141Bearing Installer Set.

Install the disconnect housing in a press using JDG1141-1Centering Tool (A) to support the input shaft (B) that isinstalled through the housing.

TX,02,111677 –19–25MAR99–17/25

RW

3630

5–U

N–1

7MA

R97

A—Outer Bearing ConeB—JDG1141-2 Driver

NOTE: JDG1141-2 Driver is part of the JDG1141 BearingInstaller Set.

Install the outer bearing cone (A) onto the shaft usingJDG1141-2 Driver (B).


PN=95



020250

14

TX,02,111677 –19–25MAR99–18/25

RW

3630

0–U

N–1

7MA

R97

A—Collar Engagement Springs

Install collar engagement springs (A) into disconnecthousing.

TX,02,111677 –19–25MAR99–19/25

RW

3629

7–U

N–1

7MA

R97

A—Piston Packing Ring (2 used)B—Anti-Rotation PlugC—Collar Assembly

Install collar assembly (C) into housing aligning theanti-rotation slot in the collar assembly housing with theopening in disconnect housing for the anti-rotation plug.

Install anti-rotation plug (B).

Install piston packing rings (A).

Apply oil to the piston packing rings.



PN=96


02025015

TX,02,111677 –19–25MAR99–20/25

RW

3630

6–U

N–1

7MA

R97

A—Piston AssemblyB—Driver Disk and HandleC—Snap Ring

Install piston assembly (A) into the housing.

Place 4-5/16 in. (1200 Series Rear Axle) or a 5-1/2 in.(1400 Series Front Axle) driver disk and handle (B) on topof the piston housing.

Force the piston downward using a shop press and installsnap ring (C).

TX,02,111677 –19–25MAR99–21/25R

W36

293

–UN

–17M

AR

97

A—Sealing Ring

Install housing-to-differential case sealing ring (A).



PN=97


020250

16

TX,02,111677 –19–25MAR99–22/25

RW

3629

2–U

N–1

7MA

R97

A—Input Shaft Seal

Install input shaft seal (A) using JDG1092 (1200 SeriesRear Axle) or JDG1151 (1400 Series Front Axle) SealInstaller along with JDG926 Bearing Installer.

TX,02,111677 –19–25MAR99–23/25

RW

3619

1–U

N–0

9JA

N97

A—Dust Seal

IMPORTANT: DO NOT apply oil to the seal or theyoke recess.

Install the dust seal (A) into the yoke recess.

Install yoke onto the shaft.



PN=98


02025017

TX,02,111677 –19–25MAR99–24/25

RW

3630

7–U

N–1

7MA

R97

A—Oil Ring

NOTE: Be sure no part of the oil ring is out of thechamfer on the yoke.

Install oil ring (A) and spacer washer.

Apply PT506 NEVER-SEEZ Lubricant to the shaftthreads.

IMPORTANT: Install special locking nut by hand.

Install special locking nut by hand until the lockingmember engages at least one thread on shaft.


TX,02,111677 –19–25MAR99–25/25R

W36

291

–UN

–17M

AR

97

A—Yoke Holding Tool

Install JDG1090 Yoke Holding Tool (A).

Tighten yoke retaining nut.

Axle Disconnect Input Shaft—SpecificationYoke Retaining Nut—Torque 360 N•m (267 lb-ft)......................................

Remove tool.

Install disconnect assembly to axle assembly. (SeeRemove and Install Axle Disconnect Input Shaft in thisgroup.)


PN=99


020250

18


PN=100

Group 0260Hydraulic System

0202601CED,OUOE003,3297 –19–25MAR99–1/1

Specifications


Differential Lock Solenoid Valve Nut Torque 7 N•m (62 lb-in.)


PN=101

Hydraulic System

020260

2

TX,02,111682 –19–27OCT98–1/1

Remove and Install Differential LockSolenoid Valve

T10

8813

–UN

–04A

PR

97T

7751

LI–U

N–0

9NO

V92

A—Differential Lock SolenoidC—NutD—CapE—SolenoidF—SpoolG—O-RingH—Backup RingI—O-RingJ—O-RingK—Backup Ring

1. Operate controls to release hydraulic pressure.

2. Disconnect electrical connector.

3. Remove differential lock solenoid (A).

4. Remove parts (C—E).

5. Remove parts (F—K). Plug opening to prevent dirtfrom entering manifold.

6. Inspect for dirty, worn or damaged parts. Check thatspool inside solenoid valve moves freely. If spool doesnot move freely or if valve looks worn or damaged,replace complete solenoid assembly.

7. Install solenoid valve using new O-rings and backuprings.

8. Install parts (C—K). Tighten nut (C).

SpecificationDifferential Lock Solenoid ValveNut—Torque 7 N•m (62 lb-in.).....................................................................

9. Connect electrical connector.


PN=102

Hydraulic System

0202603

CED,OUOE003,2651 –19–13DEC98–1/1

Axle Recirculation System

T11

6474

–19–

26A

UG

98

A—O-Ring (2 used) F—O-Ring (3 used) L—Right Rear Recirculation O—Screen Filter (2 used)B—O-Ring Adapter G—ORFS Straight Thread Pump Port-to-Rear Axle P—Left Rear RecirculationC—O-Ring (2 used) Fitting Recirculation Outlet Port Pump Port-to-Front AxleD—Front Axle Recirculation H—O-Ring (3 used) Hydraulic Hose Recirculation Outlet Port

Inlet Port-to-Left Front I—Recirculation Pump Motor M—ORFS O-Ring Elbow Fitting Hydraulic HoseRecirculation Pump Port Outlet Port-to-Hydraulic (2 used) Q—Old Breather LocationHydraulic Hose Reservoir Hydraulic Hose N—O-Ring (2 used) R—New Breather Location

E—Recirculation Pump Motor J—ORFS ElbowInlet Port-to-Main Pump K—Right Front RecirculationPressure Port Hydraulic Pump Port-to-Rear AxleHose Inlet Port Hydraulic Hose


PN=103

Hydraulic System

020260

4

CED,OUOE003,2652 –19–13DEC98–1/2

Axle Recirculation System With Optional Oil Coolers

T11

8027

–19–

22O

CT

98



PN=104

Hydraulic System

0202605

CED,OUOE003,2652 –19–13DEC98–2/2

3—Front Axle Oil Cooler C—O-Ring (2 used) H—O-Ring (3 used) M—ORFS O-Ring Elbow Fitting21—Rear Axle Oil Cooler D—Front Axle Recirculation I—Recirculation Pump Motor (2 used)27a—Rear Axle Oil Cooler Top Inlet Port-to-Front Axle Oil Outlet Port-to-Hydraulic N—O-Ring (2 used)

Port-to-Rear Axle Cooler Upper Port Reservoir Hydraulic Hose O—Screen Filter (2 used)Recirculation Inlet Port Hydraulic Hose J—ORFS Elbow P—Left Rear RecirculationHydraulic Hose E—Recirculation Pump Motor K—Left Front Recirculation Pump Port-to-Front Axle

27b—Right Front Recirculation Inlet Port-to-Main Pump Pump Port-to-Front Axle Recirculation Outlet PortPump Port-to-Rear Axle Pressure Port Hydraulic Oil Cooler Lower Port Hydraulic HoseOil Cooler Bottom Port Hose Hydraulic HoseHydraulic Hose F—O-Ring (3 used) L—Right Rear Recirculation

A—O-Ring (2 used) G—ORFS Straight Thread Pump Port-to-Rear AxleB—O-Ring Adapter Fitting Recirculation Outlet Port

Hydraulic Hose


PN=105

Hydraulic System

020260

6

CED,OUOE003,2653 –19–13DEC98–1/2

Axle Oil Coolers—Exploded View

TP

6051

5–U

N–1

3OC

T98


PN=106


Hydraulic System

0202607CED,OUOE003,2653 –19–13DEC98–2/2

1—Nut (12 used) 10—O-Ring (2 used) 17—Elbow Fitting (2 used) 25—Washer (4 used)2—Washer (20 used) 11—Elbow Fitting (2 used) 18—Fitting Plug (2 used) 26—Cap Screw (4 used)3—Angle (2 used) 12—O-Ring (6 used) 19—O-Ring (4 used) 27—Hydraulic Hose, Fabricate4—Cap Screw (4 used) 13—Hyd. Quick-Connect 20—Adapter (2 used) (2 used)5—Cover Coupler (2 used) 21—Oil Cooler 28—Wiring Harness6—Washer (4 used) 14—Hyd. Quick-Connect 22—Strap (2 used) 29—Washer7—Rubber Mount (4 used) Coupler (2 used) 23—Nut (4 used) 30—Screw8—Cap Screw (4 used) 15—Adapter (2 used) 24—Screw (4 used) 31—Oil Cooler9—Oil Cooler 16—O-Ring (4 used)

CED,OUOE003,2654 –19–13DEC98–1/3

Remove and Install Front Axle Oil Cooler

T10

5496

B–U

N–1

2DE

C96

Frame Lock Bar

A—PinB—Retaining PinC—Frame Lock Bar

1. Position machine on a flat surface. Apply park brake.Stop engine.

CAUTION: Prevent possible injury fromunexpected boom or bucket movement whenequipped with ride control. Ride controlaccumulator energy must be discharged whenworking on hydraulic components.


3. Disconnect battery ground strap or turn batterydisconnect switch Off, if equipped.

4. Install frame locking bar (C) between machine framesto prevent unexpected movement.



PN=107

Hydraulic System

020260

8 CED,OUOE003,2654 –19–13DEC98–2/3

T11

7536

B–U

N–0

1OC

T98

3—Cover4—Washer5—Cap Screw

5. Remove cap screw (5) and washer (4) to open cover(3).

CED,OUOE003,2654 –19–13DEC98–3/3

T11

7526

B–U

N–0

1OC

T98

D—Front Axle Recirculation Inlet Port-to-Front AxleOil Cooler Upper Port Hydraulic Hose

K—Left Front Recirculation Pump Port-to-Front AxleCooler Lower Port Hydraulic Hose

3—Cover25—Oil Cooler with Fan Wiring Harness31—Oil Cooler with Fan

6. Disconnect hydraulic hoses (D and K) and wiringharness (25).

7. Remove cover (3) with attached oil cooler (31).

8. Repair or replace parts as necessary.

9. Install in reverse order.


PN=108

Hydraulic System

0202609

CED,OUOE003,2655 –19–13DEC98–1/1

Disassemble and Assemble Front Axle Oil Cooler

T11

7465

B–U

N–0

1OC

T98

2—Cap Screw (2 used) 19—M8 Nut (6 used) 27—ORFS Adapter (2 used) 30—Isolator Mount (2 used)3—Cover 20—Angle 28—ORFS Elbow Fitting (2 31—Oil Cooler with Fan6—Washer (2 used) 24—Female Coupler used) 32—Strap7—Cap Screw (2 used) 26—Male Coupler 29—Adapter (2 used)

NOTE: Lubricate O-rings with hydraulic oil.


PN=109

Hydraulic System

020260

10

CED,OUOE003,2656 –19–13DEC98–1/2

Remove and Install Rear Axle Oil Cooler

T10

5496

B–U

N–1

2DE

C96

Frame Lock Bar

A—PinB—Retaining PinC—Frame Lock Bar

1. Position machine on a flat surface. Apply park brake.Stop engine.

CAUTION: Prevent possible injury fromunexpected boom or bucket movement whenequipped with ride control. Ride controlaccumulator energy must be discharged whenworking on hydraulic components.


3. Disconnect battery ground strap or turn batterydisconnect switch Off, if equipped.

4. Install frame locking bar (C) between machine framesto prevent unexpected movement.



PN=110

Hydraulic System

02026011

CED,OUOE003,2656 –19–13DEC98–2/2

T11

8017

B–U

N–2

3OC

T98

1—Nut (12 used)2—Hardened Washer (20 used)20—ORFS Fitting (2 used)21—Oil Cooler22—Strap (2 used)27a—Hydraulic Hose (Rear Axle Cooler Lower

Port-to-Right Pump)27b—Hydraulic Hose (Rear Axle Cooler Upper

Port-to-Rear Axle Lower Port)32—Hydraulic Fan Motor34—Tie Band

5. Disconnect hydraulic hoses (27a and 27b).

6. Remove nuts (1), washers (2) and oil cooler (21).


8. Install in reverse order. Lubricate O-rings with hydraulicoil.


PN=111

Hydraulic System

020260

12


PN=112

Section 03Transmission

Contents

Page Page

Group 0300—Removal and Installation Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0360-15Essential Tools . . . . . . . . . . . . . . . . . . . . . . .03-0300-1 Converter Relief ValveSpecifications . . . . . . . . . . . . . . . . . . . . . . . .03-0300-2 Remove, Disassemble and Install . . . . . .03-0360-21Transmission Oil Pipes and Tubes

Remove and Install . . . . . . . . . . . . . . . . . .03-0300-3 Replace . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-23

Group 0399—Dealer Fabricated ToolsGroup 0350—Gears, Shafts, Bearings and Power 03Pre-Load Clutch Pack Compression RingShift Clutch

ToolEssential Tools . . . . . . . . . . . . . . . . . . . . . . .03-0350-1DFT1148 . . . . . . . . . . . . . . . . . . . . . . . . . .03-0399-1Service Equipment and Tools . . . . . . . . . . . .03-0350-2DFT1149 . . . . . . . . . . . . . . . . . . . . . . . . . .03-0399-2Other Material . . . . . . . . . . . . . . . . . . . . . . . .03-0350-3

Specifications . . . . . . . . . . . . . . . . . . . . . . . .03-0350-4Torque Converter and Housing

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-5Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-8

Clutches, Input and Output ShaftsRemove . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-11Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-17

Clutch Pack KV and KRDisassemble . . . . . . . . . . . . . . . . . . . . . .03-0350-26Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-28

Clutch Pack K1, K2, and K3Disassemble . . . . . . . . . . . . . . . . . . . . . .03-0350-35Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-37

Clutch Pack K4Disassemble . . . . . . . . . . . . . . . . . . . . . .03-0350-47Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-48

Input ShaftDissasemble . . . . . . . . . . . . . . . . . . . . . .03-0350-54Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-55

Group 0360—Hydraulic SystemSpecifications . . . . . . . . . . . . . . . . . . . . . . . .03-0360-1Transmission Pump

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-2Converter Minimum Pressure Regulator

ValveRemove and Install . . . . . . . . . . . . . . . . . .03-0360-4

Transmission PumpInstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-5

Hydraulic Control ValveRemove . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-7Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-8Cross Section View . . . . . . . . . . . . . . . . .03-0360-10

Transmission Control ValveDisassemble . . . . . . . . . . . . . . . . . . . . . .03-0360-12


PN=1

Contents

03


PN=2


CED,OUOE003,3298 –19–25MAR99–1/3

Essential Tools


0303001


CED,OUOE003,3298 –19–25MAR99–2/3

Engine Repair Stand . . . . . . . . . . . . . . . . .D052223ST

Used with JDG1129 Transmission Mounting Bracket tohold transmission.

CED,OUOE003,3298 –19–25MAR99–3/3

T10

9218

–UN

–29A

PR

97

Transmission Mounting Bracket . . . . . . . . . . . JDG1129

Used to mount transmission in repair stand.


PN=115


030300

2

CED,OUOE003,3301 –19–25MAR99–1/1

Specifications


Transmission

Transmission Weight 431 kg (950 lb) approximate

Isolator Cap Screw Torque 433 N•m (320 lb-ft)

Mounting Bracket-to-Transmission Torque 433 N•m (320 lb-ft)Cap Screw (Front)

Mounting Bracket-to-Transmission Torque 318 N•m (235 lb-ft)Cap Screw (Rear)

Drive Shaft Universal Joint Torque 78 N•m (58 lb-ft)(Output) Cap Screw

Drive Shaft Universal Joint (Input) Torque 78 N•m (58 lb-ft)Cap Screw

Engine-to-Transmission Shaft Torque 78 N•m (58 lb-ft)Universal Joint Cap Screw


PN=116


0303003

TX,03,RP3337 –19–12FEB99–1/5

Remove and Install Transmission

T10

7803

–UN

–10M

AR

97

A—Drive ShaftB—Drive ShaftC—Drive Shaft

1. Remove ROPS or cab. (See procedure in Group1800.)

2. Drain hydraulic reservoir. Collect oil in clean containerfor reuse. Approximate capacity is 117 L (31 gal).

3. Disconnect transmission drive shafts (A—C).

TX,03,RP3337 –19–12FEB99–2/5

T11

2003

–UN

–24N

OV

97

A—Converter in Hose from CoolerB—Converter out Hose to CoolerC—Dipstick TubeD—Return Hose from Park Brake to TransmissionE—Return from Filter to Transmission HoseF—Hose to Oil Filter from TransmissionG—Hose to Park Brake from Transmission

NOTE: Tag and cap all lines for identification and toprevent contamination.

4. Remove transmission filter hoses (F and E) fromtransmission.

5. Drain transmission. Collect oil in container and disposeof properly. Approximate capacity is 27 L (29 qt).

6. Remove dipstick tube (C).

7. Remove and cap park brake hoses (G and D).

8. Remove cooler hoses (A and B).


PN=117



030300

4

TX,03,RP3337 –19–12FEB99–3/5

T11

2004

–UN

–29O

CT

97

A—Load Sense HoseB—Suction HoseC—Pump InletD—Case DrainE—Pressure to Control ValveF—Pressure to Steering ValveG—Hose to Pressure Reducing Valve

9. Remove hose (E) going to the control valve and casedrain return hose (D) to manifold from the hydraulicpump.

10. Remove load sense hose (A) from hydraulic pump.

11. Remove suction hose at reservoir (B) and hydraulicpump at (C).

12. Remove pressure reducing valve hose (G), steeringhose (F) from hydraulic pump.



PN=118


0303005

TX,03,RP3337 –19–12FEB99–4/5

T11

1670

–UN

–03N

OV

97

A—Transmission Isolator Cap B—Transmission Mounting C—Transmission Mounting D—Transmission Isolator CapScrew (Rear) Bracket-to-Transmission Bracket-to-Transmission Screws (Front)

Cap Screws (Rear) Cap Screws (Front)

CAUTION: Use hoist to lift transmission.Approximate weight is 431 kg (950 lb) withhydraulic pump installed.

Transmission—SpecificationTransmission—Weight 431 kg (950 lb) approximate............................

13. Install hoist on transmission lifting brackets andsupport transmission.

14. Remove isolator cap screws (A and D).

15. Remove transmission front mount cap screws (C)and remove mounts from transmission.

NOTE: Rear transmission mount does not have to beremoved from transmission.

16. Carefully remove transmission and place in repairstand using JDG1129 Transmission MountingBracket.

17. Remove hydraulic pump from transmission.

18. After transmission repair, install hydraulic pump ontransmission before installing transmission inmachine. Inspect hydraulic pump to transmissionO-ring before installing pump.

19. Install transmission in machine.

Transmission—SpecificationIsolator Cap Screw—Torque 433 N•m (320 lb-ft)................................


PN=119



030300

6

TX,03,RP3337 –19–12FEB99–5/5

MountingBracket-to-Transmission CapScrew (Front)—Torque 433 N•m (320 lb-ft).........................................MountingBracket-to-Transmission CapScrew (Rear)—Torque 318 N•m (235 lb-ft)..........................................

20. Connect all hoses and lines to transmission andhydraulic pump.

21. Fill transmission and hydraulic reservoir tospecifications.

NOTE: Do NOT reuse drive shaft cap screws, replacewith new when removed.

22. Install transmission drive shafts using new capscrews.

Transmission—SpecificationDrive Shaft Universal Joint(Output) Cap Screw—Torque 78 N•m (58 lb-ft)...................................Drive Shaft Universal Joint(Input) Cap Screw—Torque 78 N•m (58 lb-ft)......................................Engine-to-Transmission ShaftUniversal Joint Cap Screw—Torque 78 N•m (58 lb-ft).......................................................................

23. Install ROPS or cab. (See procedure in Group1800.)


PN=120

Group 0350Gears, Shafts, Bearings and Power Shift Clutch

CED,OUOE003,3374 –19–21APR99–1/7

Essential Tools


0303501


CED,OUOE003,3374 –19–21APR99–2/7

T10

9218

–UN

–29A

PR

97

Transmission Mounting Brackets . . . . . . . . . . JDG1129

Used to mount transmission in repair stand.

CED,OUOE003,3374 –19–21APR99–3/7

T112434 –UN–10DEC97

Bearing Puller. . . . . . . . . . . . . . . . . . . . . . . JDG1134

Used with bearing puller mandrel to remove bearing fromclutch packs KV and K4.

CED,OUOE003,3374 –19–21APR99–4/7

T104040 –UN–27SEP96

Bearing Puller Mandrel . . . . . . . . . . . . . . . . . JDG1035

Used with bearing puller to remove bearing from clutchpacks.

CED,OUOE003,3374 –19–21APR99–5/7

T112434 –UN–10DEC97


Used with bearing puller mandrel to remove bearing fromclutch packs K1, K2, K3, K4, and KR.


PN=121


Gears, Shafts, Bearings and Power Shift Clutch

CED,OUOE003,3374 –19–21APR99–6/7

T112433 –UN–10DEC97

Bearing Puller Mandrel . . . . . . . . . . . . . . . . . JDG1034

Used with bearing puller to remove bearing from clutchpacks.

CED,OUOE003,3374 –19–21APR99–7/7

T112434 –UN–10DEC97


Used with bearing puller mandrel to remove bearing fromclutch packs K1 and K3.

030350

2

CED,OUOE003,3325 –19–26MAR99–1/5




CED,OUOE003,3325 –19–26MAR99–2/5

Repair Stand

Used to hold transmission for repair.

CED,OUOE003,3325 –19–26MAR99–3/5

Eye Bolt . . . . . . . . . . . . . . . . . . . . . . . M20 and M12

Used with hoist to remove transmission cover.

CED,OUOE003,3325 –19–26MAR99–4/5

Pre-Load Clutch Pack Compression RingTool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DFT11491

Used to compress the piston compression ring for removaland installation of snap ring.

1Fabricated tool, dealer made. (See Group 0399 for instructions to maketool.)


PN=122



CED,OUOE003,3325 –19–26MAR99–5/5

Pre-Load Clutch Pack Compression RingTool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DFT11481

Used to compress the piston compression ring for removaland installation of snap ring.

0303503


CED,OUOE003,3326 –19–26MAR99–1/1

Other Material

Number Name Use

T43513 (U.S.) Thread Lock and Sealer (High Apply to drive plate-to-torqueTY9474 (Canadian) Strength) converter cap screws.271 (LOCTITE)

T43512 (U.S.) Thread Lock and Sealer (Medium Apply to output shaft cover socketTY9473 (Canadian) Strength) head cap screws.242 (LOCTITE) Apply to threads of clutch pack shaft

studs.

TY16021 (U.S.) High Flex Form-In-Place Gasket Apply to transmission mounting faceTY9484 (Canadian) cover.17430 (LOCTITE) Apply to contact side of output flange

(yoke) retaining washer.

LOCTITE is a trademark of Loctite Corp.


PN=123


030350

4

CED,OUOE003,3327 –19–26MAR99–1/2

Specifications


Torque Converter

Transmission Weight 510 kg (1125 lb) approximate

Converter Housing M10/10.9 Cap Torque 68 N•m (50 lb-ft)Screw

Input Shaft-to-Drive Plate Torque 115 N•m (85 lb-ft)M12/10.9 Cap Screw

Drive Plate-to-Torque Converter Torque 115 N•m (85 lb-ft)M12/10.9 Cap Screw

Top Cover M10/8.8 Cap Screw Torque 46 N•m (34 lb-ft)

Input Flange-to-Torque Converter Torque 34 N•m (25 lb-ft)Shaft Cap Screw

Clutches, Input and Output Shafts

Output Shaft Cover Socket Head Torque 23 N•m (17 lb-ft)Screw

Housing Cover Hex Head Screw Torque 46 N•m (34 lb-ft)

Output Flange Temperature 90°C (194°F) maximum

Output Flange Cap Screw Torque 34 N•m (25 lb-ft)

Gasket-to-Cover Hex Head Screw Torque 23 N•m (17 lb-ft)

Oil Level Tube Screw Torque 25 N•m (18 lb-ft)

Speed Sensor Torque 30 N•m (22 lb-ft)

Drain Plug Torque 140 N•m (100 lb-ft)

Clutch Pack

KV and KR Clutch Pack Plate Clearance 2.7—2.9 mm (0.106—0.114 in.)

Shaft Stud Torque 17 N•m (150 lb-in.)

K1 Clutch Pack Plate Clearance 2.4—2.6 mm (0.094—0.102 in.)


PN=124



0303505

CED,OUOE003,3327 –19–26MAR99–2/2


K2 and K3 Clutch Pack Plate Clearance 1.8—2.0 mm (0.071—0.079 in.)

K4 Clutch Pack Shaft Temperature Cools at -80°C (-112°F)

K4 Clutch Pack Gear Temperature Heats at 120°C (248°F)

K4 Clutch Pack Plate Clearance 1.2—1.4 mm (0.047—0.055 in.)

Input Shaft

Input Shaft Temperature Cools at -80°C (-112°F)

Input Gear Temperature Heats at +120°C (250°F)

TX,0350,WW2497 –19–25MAR99–1/11

Remove Torque Converter and Housing

T10

9146

B–U

N–2

6JA

N98

A—Mounting Bracket (2 used)

CAUTION: The approximate weight oftransmission is 510 kg (1125 lb).

Torque Converter—SpecificationTransmission—Weight 510 kg (1125 lb) approximate.................................

1. Install transmission in repair stand using JDG1129mounting brackets (A).



PN=125


030350

6

TX,0350,WW2497 –19–25MAR99–2/11

T11

2589

–UN

–19D

EC

97

Bracket Sketch Showing Revised Mounting Hole (A)

A—Revised Mounting Hole

NOTE: Earlier JDG1129 Transmission Mounting Bracketsrequire the right side bracket revised. Notebracket sketch showing revised mounting hole (A).Revise hole by elongating the existing hole asrequired.

TX,0350,WW2497 –19–25MAR99–3/11

T10

8721

–UN

–17A

PR

97

2. Remove lock plate and hex head screws from inputflange washer.

3. Remove washer and pry input flange from the shaft.

TX,0350,WW2497 –19–25MAR99–4/11

T10

8722

–UN

–17A

PR

97

4. Remove torque converter housing cap screws. Place amark on the cover and housing for ease of assemblyand proper alignment later.



PN=126


TX,0350,WW2497 –19–25MAR99–5/11

T10

8723

–UN

–17A

PR

97

CAUTION: Component weighs more than 23 kg(50 lb). Use hoist to remove.

5. Separate torque converter with cover from gearbox,using a hoist and eye bolt.

0303507

TX,0350,WW2497 –19–25MAR99–6/11

T10

8724

–UN

–17A

PR

97

6. Press input shaft with converter out of the housing.

TX,0350,WW2497 –19–25MAR99–7/11T

1087

17–U

N–1

7AP

R97

7. Remove snap ring and remove bearing from housing.

TX,0350,WW2497 –19–25MAR99–8/11

T11

2416

–UN

–05D

EC

97

8. Remove hex head screws and separate drive platefrom converter.


PN=127



TX,0350,WW2497 –19–25MAR99–9/11

T11

2415

–UN

–05D

EC

97

9. Remove hex head screws and separate input shaftfrom drive plate.

030350

8

TX,0350,WW2497 –19–25MAR99–10/11

T10

8720

–UN

–17A

PR

97

10. Remove speed senor from converter housing.

TX,0350,WW2497 –19–25MAR99–11/11

T10

8729

–UN

–17A

PR

97

11. Remove hex head screws and remove converterlower housing.

TX,0350,RB228 –19–04DEC03–1/8

Install Torque Converter and Housing

T10

9095

–UN

–15A

PR

97

1. Fasten converter housing using hex head screws.

Tighten M10/10.9 cap screws.

Torque Converter—SpecificationConverter Housing M10/10.9 CapScrew—Torque 68 N•m (50 lb-ft)................................................................


PN=128



TX,0350,RB228 –19–04DEC03–2/8

T11

2415

–UN

–05D

EC

97

2. Fasten input shaft to plate with hex head screws.


Torque Converter—SpecificationInput Shaft-to-Drive PlateM12/10.9 Cap Screw—Torque 115 N•m (85 lb-ft)......................................

0303509

TX,0350,RB228 –19–04DEC03–3/8

T10

9121

–UN

–15A

PR

97

3. Install input shaft plate assembly to converter, usinghex head screws and flat washers.

Apply thread lock and sealer (high strength) to capscrews.


Torque Converter—SpecificationDrive Plate-to-Torque ConverterM12/10.9 Cap Screw—Torque 115 N•m (85 lb-ft).....................................

TX,0350,RB228 –19–04DEC03–4/8

T10

9097

–UN

–15A

PR

97T

1090

98–U

N–3

0AP

R97

4. Install converter in housing until contact is made.

NOTE: Speed pickup disk in the converter must becentered to the bore of the speed sensor. See artwith arrow showing. This insures that theconverter is seated properly.


PN=129



TX,0350,RB228 –19–04DEC03–5/8

T10

9099

–UN

–15A

PR

97

5. Insert ball bearing until contact is obtained in bore andinstall snap ring.

030350

10

TX,0350,RB228 –19–04DEC03–6/8

T10

9100

–UN

–15A

PR

97

6. Assemble housing.

Install input flange, washer and draw cover down withhex head screws evenly against shoulder.

NOTE: Line up alignment marks on housings that weremade while disassembling for proper assembly.

TX,0350,RB228 –19–04DEC03–7/8

T10

9101

–UN

–15A

PR

97

7. Install cover with hex head screws and nuts on theconverter housing. Tighten to specification.

Torque Converter—SpecificationTop Cover M10/8.8 Cap Screw—Torque 46 N•m (34 lb-ft).............................................................................



PN=130


03035011

TX,0350,RB228 –19–04DEC03–8/8

T10

9147

B–U

N–0

2MA

Y97

Output Flange Shown

A—Deep Well Socket

8. Fasten input flange with hex head screws and tighten.

Torque Converter—SpecificationInput Flange-to-Torque ConverterShaft Cap Screw—Torque 34 N•m (25 lb-ft)..............................................

Install locking plate using hammer and two deep wellsockets (A) taped together with a hex nut between themfor proper spread.

TX,0350,ME280 –19–25MAR99–1/19

Remove Clutches, Input and Output Shafts

T10

8778

–UN

–18A

PR

97

1. Remove lock plate, loosen hex head screws, and prythe rear output flange from the shaft.

2. Pry shaft seal out of the housing bore.

3. Turn gearbox 180° and remove front output flange insame manner.

TX,0350,ME280 –19–25MAR99–2/19

T10

8779

–UN

–29A

PR

97

4. Remove three sensors.



PN=131


TX,0350,ME280 –19–25MAR99–3/19

T10

8780

–UN

–29A

PR

97

5. Loosen hex nuts and remove the two small manifoldcovers (Arrows).

6. Remove cap screws from transmission cover.

030350

12

TX,0350,ME280 –19–25MAR99–4/19

T10

8781

–UN

–29A

PR

97

7. Drive both dowel pins (one on each end oftransmission cover) down far enough to clear cover forremoval of the cover.

TX,0350,ME280 –19–25MAR99–5/19

T10

8774

–UN

–18A

PR

97

8. Separate housing cover carefully from gearboxhousing, using lifting device.



PN=132


03035013

TX,0350,ME280 –19–25MAR99–6/19

T10

8775

–UN

–29A

PR

97

KV—Low Range Forward ClutchKR—Reverse ClutchK1—First Speed ClutchK2—Second Speed ClutchK3—Third Speed ClutchK4—High Range Forward ClutchAN—InputAB—Output

9. Figure shows the proper position of the single clutchesas well as of the input and output.

TX,0350,ME280 –19–25MAR99–7/19

T10

8776

–UN

–18A

PR

97

NOTE: For the removal of clutches, the output shaft mustbe removed first.

10. Loosen socket head screws from covers and removeoutput shaft with covers.



PN=133


030350

14

TX,0350,ME280 –19–25MAR99–8/19

T10

8777

–UN

–30A

PR

97

Special Handles Shown

T10

9149

B–U

N–0

9MA

Y97

24H1300 and M10 Hardware Shown

A—Flat Washer (6 used)

IMPORTANT: Remove sealing rings from clutch packshafts (cover side only) before installingcover. Sealing rings may be damagedwhile removing and installing clutchpacks later.

11. Place cover back on transmission until it contacts themounting surface so clutch packs can be removedfrom housing for repair or inspection.

NOTE: Six 24H1300 Flat Washers and M10 Hex Nuts aresubstituted for special handles shown in photo.

12. Install six (24H1300) flat washers (A) and six (M10)hex nuts on end of clutch packs. This will hold packsin place while mounting cover in rollover repair stand.

This method must be used to remove clutch packfrom transmission housing.

TX,0350,ME280 –19–25MAR99–9/19

T10

8786

–UN

–18A

PR

97

13. Separate housing cover along with all clutch packsfrom gearbox housing, using lifting device.

TX,0350,ME280 –19–25MAR99–10/19

T10

9149

C–U

N–0

9MA

Y97

NOTE: Transmission cover is used to properly removepacks from transmission housing.

14. Remove transmission housing from repair stand andinstall cover with clutch packs.


PN=134



TX,0350,ME280 –19–25MAR99–11/19

T10

9148

B–U

N–0

9MA

Y97

03035015

A—Mounting Bracket (2 used)B—Shop Hardware

15. Install cover with packs into stand using JDG1129Mounting Brackets (A). Using shop hardware (B) (capscrews, washers and nuts) fasten cover to mountingbrackets JDG1129 (A).

TX,0350,ME280 –19–25MAR99–12/19

T10

8788

–UN

–18A

PR

97

16. Turn cover in stand so clutch packs are facing up.This will allow them to be removed from cover.

17. Remove six M10 nuts and six washers from clutchpacks.

TX,0350,ME280 –19–25MAR99–13/19

T10

8789

–UN

–18A

PR

97

CAUTION: Use special care while removingclutch packs from cover due to closeness ofpacks and spline engagement to each other.

18. Remove clutch K2.

TX,0350,ME280 –19–25MAR99–14/19

T10

8782

–UN

–18A

PR

97

19. Remove clutch K1, at the same time lift clutch K4 tothe side to allow clearance.


PN=135



TX,0350,ME280 –19–25MAR99–15/19

T10

8783

–UN

–18A

PR

97

20. Remove clutch K3.

030350

16

TX,0350,ME280 –19–25MAR99–16/19

T10

8784

–UN

–18A

PR

97

21. Remove clutch K4, at the same time lift input slightly.

TX,0350,ME280 –19–25MAR99–17/19

T10

8785

–UN

–18A

PR

97

22. Separate clutches KV and KR together with inputfrom the housing cover.

TX,0350,ME280 –19–25MAR99–18/19

T10

8790

–UN

–18A

PR

97

23. Remove bearing outer race and pull output shaft outof the housing bore.


PN=136



TX,0350,ME280 –19–25MAR99–19/19

T10

8791

–UN

–29A

PR

97

24. Squeeze the square snap ring out and separate ballbearing from shaft.

03035017

TX,0350,JC2037 –19–25MAR99–1/32

Install Clutches, Input and Output Shafts

T10

9004

–UN

–30A

PR

97

KV—Low Range Forward ClutchKR—Reverse ClutchK1—First Speed ClutchK2—Second Speed ClutchK3—Third Speed ClutchK4—High Range Forward ClutchAN—InputAB—Output

IMPORTANT: High tolerance bearings are used in allclutch pack applications. Use only JohnDeere sourced bearings when replacing.

NOTE: If bearings are reused, they must be assembled insame bores.

1. Insert all bearing outer races into the housing coveruntil contact is obtained.

TX,0350,JC2037 –19–25MAR99–2/32

T10

9005

–UN

–29A

PR

97

KV—Low Range Forward ClutchKR—Reverse ClutchAN—Input

2. Insert clutch-KR, input shaft and clutch-KV into thehousing cover.


PN=137



TX,0350,JC2037 –19–25MAR99–3/32

T10

9006

–UN

–29A

PR

97

030350

18

K4—High Range Forward Clutch

3. Install clutch-K4.

TX,0350,JC2037 –19–25MAR99–4/32

T10

9007

–UN

–09M

AY

97

K3—Third Speed Clutch

4. Install clutch-K3.

TX,0350,JC2037 –19–25MAR99–5/32

T11

2554

B–U

N–1

7DE

C97

5. Position clutch-K2.

TX,0350,JC2037 –19–25MAR99–6/32

T11

2553

B–U

N–1

7DE

C97

6. Insert clutch-K1.


PN=138



TX,0350,JC2037 –19–25MAR99–7/32

T10

9010

–UN

–29A

PR

97

03035019

KV—Low Range Forward ClutchKR—Reverse ClutchK1—First Speed ClutchK2—Second Speed ClutchK3—Third Speed ClutchK4—High Range Forward Clutch

7. Figure on the right shows the installation position of thesingle clutches in the housing cover.

TX,0350,JC2037 –19–25MAR99–8/32

T10

9011

–UN

–09M

AY

97

8. Retain all clutches using six M10 hex nuts and six24H1300 flat washers.

TX,0350,JC2037 –19–25MAR99–9/32T

1090

12–U

N–2

9AP

R97

9. Install sealing rings (7 used) on clutch pack shafts.

10. Grease sealing rings and align.

TX,0350,JC2037 –19–25MAR99–10/32

T10

9013

–UN

–29A

PR

97

11. Turn housing cover 180°.

12. Mount eye bolts.

13. Remove transmission cover with clutch packs fromrepair stand.

14. Install transmission housing into repair stand.


PN=139



TX,0350,JC2037 –19–25MAR99–11/32

T10

9014

–UN

–09M

AY

97

15. Install alignment studs in housing.

NOTE: Pay attention to the engagement of the oil pipeswith the bores in the housing cover.

16. Install cover with clutch packs carefully onto housing.Make sure all components are properly seated.

030350

20

TX,0350,JC2037 –19–25MAR99–12/32

T10

9149

B–U

N–0

9MA

Y97

A—Flat Washer (6 used)

17. Remove M10 hex nuts and 24H1300 flat washers (A)from clutch packs.

TX,0350,JC2037 –19–25MAR99–13/32

T10

9016

–UN

–09M

AY

97

18. Remove housing cover from gearbox housing.

TX,0350,JC2037 –19–25MAR99–14/32

T10

9066

–UN

–15A

PR

97

19. Output Shaft

Assemble oil cover onto shaft and press both bearinginner races against shoulder until contact is obtained.


PN=140



TX,0350,JC2037 –19–25MAR99–15/32

T10

9068

–UN

–29A

PR

97

20. Insert bearing outer race into the housing bore untilcontact is obtained.

03035021

TX,0350,JC2037 –19–25MAR99–16/32

T10

9069

–UN

–15A

PR

97

21. Position inner oil cover.

TX,0350,JC2037 –19–25MAR99–17/32T

1090

70–U

N–1

5AP

R97

22. Install output shaft with cover in housing.

TX,0350,JC2037 –19–25MAR99–18/32

T10

9071

–UN

–15A

PR

97

NOTE: Insert socket head cap screws with thread lockand sealer (medium strength).

23. Fasten both covers by means of socket head screws.

Clutches, Input and Output Shafts—SpecificationOutput Shaft Cover Socket HeadScrew—Torque 23 N•m (17 lb-ft)................................................................


PN=141



TX,0350,JC2037 –19–25MAR99–19/32

T10

9072

–UN

–29A

PR

97

24. Install sealing rings (6 used) into the recesses of theclutch shafts and hook them in.

25. Grease sealing rings and align.

030350

22

TX,0350,JC2037 –19–25MAR99–20/32

T10

9075

–UN

–29A

PR

97

26. Lubricate and install both O-rings into the groove ofthe oil pipes.

TX,0350,JC2037 –19–25MAR99–21/32

T10

9076

–UN

–15A

PR

97

27. Apply High Flex Form-In-Place Gasket to mountingface of cover.

NOTE: Pay attention to the engagement of the oil pipewith the bores in the housing cover.

28. Install housing cover carefully against gearboxhousing until contact is obtained, using lifting device.

TX,0350,JC2037 –19–25MAR99–22/32

T10

9077

–UN

–29A

PR

97

29. Install dowel pins.


PN=142



TX,0350,JC2037 –19–25MAR99–23/32

T10

9078

–UN

–15A

PR

97

NOTE: Locate hanger in same position as it wasremoved.

30. Install housing cover using hex head screws.

Clutches, Input and Output Shafts—SpecificationHousing Cover Hex HeadScrew—Torque 46 N•m (34 lb-ft)................................................................

03035023

TX,0350,JC2037 –19–25MAR99–24/32

T10

9079

–UN

–15A

PR

97

NOTE: Grease sealing lip should face inward.

31. Install shaft seal with the seal lip facing inward, usingproper driver. Drive until seated. Do not over drive.

TX,0350,JC2037 –19–25MAR99–25/32

T10

9080

–UN

–15A

PR

97

32. Apply High Flex Form-In-Place Gasket to contact areaof washer.

33. Heat the output flange.

Clutches, Input and Output Shafts—SpecificationOutput Flange—Temperature 90°C (194°F) maximum...............................

34. Install flange and washer with cap screws. Tightencap screws.

Clutches, Input and Output Shafts—SpecificationOutput Flange Cap Screw—Torque 34 N•m (25 lb-ft).............................................................................



PN=143


TX,0350,JC2037 –19–25MAR99–26/32

T10

9147

B–U

N–0

2MA

Y97

030350

24

A—Deep Well Socket (2 used)

35. Install locking plate using two 5/8 in. deep wellsockets (A).

36. Install flange in same manner on opposite side.

TX,0350,JC2037 –19–25MAR99–27/32

T10

9094

–UN

–15A

PR

97

37. If removed, install flat gasket and cover. Fasten withhex head screws.

Clutches, Input and Output Shafts—SpecificationGasket-to-Cover Hex HeadScrew—Torque 23 N•m (17 lb-ft)................................................................

TX,0350,JC2037 –19–25MAR99–28/32

T10

9115

–UN

–15A

PR

97

38. Install O-ring into groove of two oil feed covers.

TX,0350,JC2037 –19–25MAR99–29/32

T10

9116

–UN

–15A

PR

97

39. Install cover onto transmission studs with hex nuts.Tighten hex nuts.

Clutches, Input and Output Shafts—SpecificationCover-To-Transmission HousingHex Nut—Torque 25 N•m (18 lb-ft.)............................................................


PN=144



TX,0350,JC2037 –19–25MAR99–30/32

T10

9117

–UN

–15A

PR

97

40. Install oil level tube and tighten screw.

Clutches, Input and Output Shafts—SpecificationOil Level Tube Screw—Torque 25 N•m (18 lb-ft).......................................

03035025

TX,0350,JC2037 –19–25MAR99–31/32

T10

9119

–UN

–29A

PR

97

21—Turbine Speed Sensor47—Middle Gear Speed Sensor48—Engine Speed Sensor

41. Install engine speed sensor (48), middle gear speedsensor (47) and turbine speed sensor (21).

Clutches, Input and Output Shafts—SpecificationSpeed Sensor—Torque 30 N•m (22 lb-ft)...................................................

42. Install breather (shown at arrow head).

TX,0350,JC2037 –19–25MAR99–32/32

T10

9120

–UN

–15A

PR

97

43. Install drain plug and tighten.

Clutches, Input and Output Shafts—SpecificationDrain Plug—Torque 140 N•m (100 lb-ft).....................................................


PN=145


TX,0350,ME284 –19–26MAR99–1/10

Disassemble Clutch Pack KV and KR

T10

8792

–UN

–29A

PR

97

1. Remove sealing ring.

030350

26

TX,0350,ME284 –19–26MAR99–2/10

T10

8793

–UN

–18A

PR

97

2. Pull tapered roller bearing from the shaft usingJDG1134 Bearing Puller and JDG1035 Bearing PullerMandrel. Remove opposite tapered roller bearing onclutch pack KV.

Remove opposite bearing on clutch pack KR withJDG1197 Bearing Puller and JDG1034 Bearing PullerMandrel.

TX,0350,ME284 –19–26MAR99–3/10

T10

8794

–UN

–18A

PR

97

3. Separate plate carrier from shaft.

TX,0350,ME284 –19–26MAR99–4/10

T10

8795

–UN

–18A

PR

97

4. Remove plates.


PN=146



TX,0350,ME284 –19–26MAR99–5/10

T10

8761

–UN

–17A

PR

97

5. Preload compression spring with DFT1149 Pre-LoadClutch Pack Compression Ring Tool in press andremove snap ring. (See Group 0399 for instructions tomake tool.)

6. Remove piston from carrier.

03035027

TX,0350,ME284 –19–26MAR99–6/10

T10

8758

–UN

–29A

PR

97

7. Remove O-rings from piston.

TX,0350,ME284 –19–26MAR99–7/10T

1087

59–U

N–1

7AP

R97

8. Remove inner circle snap ring.

TX,0350,ME284 –19–26MAR99–8/10

T10

8752

–UN

–17A

PR

97

9. Remove idler gear from shaft using a press.


PN=147



TX,0350,ME284 –19–26MAR99–9/10

T10

8753

–UN

–17A

PR

97

10. Remove released needle bearing.

030350

28

TX,0350,ME284 –19–26MAR99–10/10

T10

8754

–UN

–17A

PR

97

11. Remove circle snap ring and remove bearing.

TX,0350,ME288 –19–26MAR99–1/19

Assemble Clutch Pack KV and KR

T10

8981

–UN

–29A

PR

97

IMPORTANT: Check function of the drain valve.Check function of drain ball. Ball mustmove freely. If ball does not movefreely, check for contamination orreplace.

NOTE: Clutch KV and KR are assembled in the samemanner. Art shown in the following story is similarto both clutch packs.

1. Install both new O-rings (Arrows) into the ID and OD ofthe piston and oil them.



PN=148


TX,0350,ME288 –19–26MAR99–2/19

T10

8662

–UN

–10A

PR

97

2. Assemble piston until it bottoms out in plate carrier.

Pay attention to proper installation.

03035029

TX,0350,ME288 –19–26MAR99–3/19

T10

8663

–UN

–10A

PR

97

3. Install spring and two guides.

TX,0350,ME288 –19–26MAR99–4/19T

1086

64–U

N–1

0AP

R97

4. Press spring with DFT1149 Pre-Load Clutch PackCompression Ring Tool in press and install snap ringinto plate carrier groove. (See Group 0399 forinstructions to make tool.)



PN=149


030350

30

TX,0350,ME288 –19–26MAR99–5/19

T11

2158

–UN

–20N

OV

97

Clutch Packs KV and KR

1—Plate Carrier 3—Disk (Friction) (One Side 4—Plate (Separator) (10 used) 6—Snap Ring2—Piston Fiber Coated) 5—Disk (Friction) (10 used) 7—End Shim

IMPORTANT: Install one sided friction disk (3) withthe fiber side always facing towardplate. Smooth side should be againstpiston.

NOTE: Plate and disk position is the same for clutchKV and KR.

For proper adjustment of plate clearance installdisk and plates temporarily without being oiled.

5. Install one sided fiber disk into carrier with the fiberside facing out or away from piston.

TX,0350,ME288 –19–26MAR99–6/19

T10

8665

–UN

–10A

PR

97

6. Install plate and then disk alternately until eight platesand eight disks are installed in carrier.

7. Install two plates, then two disks.


PN=150



TX,0350,ME288 –19–26MAR99–7/19

T10

8666

–UN

–10A

PR

97

8. Install end shim and snap ring.

03035031

TX,0350,ME288 –19–26MAR99–8/19

T10

8667

–UN

–10A

PR

97

NOTE: For the adjustment of the plate clearance thereare snap rings of different thickness availablethrough parts system that can be used if properclearance is unable to be obtained. To ensureproper measuring result, install plates temporarilywithout oil.

9. Adjust plate clearance.

Clutch Pack—SpecificationKV and KR Clutch Pack Plate—Clearance 2.7—2.9 mm (0.106—0.114 in.)................................................

a. Press end shim and measure the dimension fromthe end face/plate carrier to the end shim with depthgage. Record dimension (No. 1).



PN=151


030350

32

TX,0350,ME288 –19–26MAR99–9/19

T10

8668

–UN

–10A

PR

97

b. Press end shim against snap ring (upward) untilcontact and measure with gage. Record dimension(No. 2).

Example for Clutch Pack Clearance Check

Dimension No. 1 7.25 mm (0.285 in.)


Difference = Plate Clearance 2.7 mm (0.106 in.)

Specification = Pack Clearance 2.7—2.9 mm (0.106—0.114 in.)

If a clutch pack clearance is not in specification, correct byusing the proper corresponding snap ring from serviceparts to increase or decrease clearance. Snap rings comein various sizes.

After proper clearance is obtained remove disks andplates from assembly.

10. Add oil to plates and disks.

11. Reassemble clutch pack assembly.

TX,0350,ME288 –19–26MAR99–10/19

T10

8669

–UN

–10A

PR

97

12. Install idler gear until all inner plates are engaged.This step makes later assembling of the idler geareasier.

13. Remove idler gear from clutch pack assembly.

TX,0350,ME288 –19–26MAR99–11/19

T10

8670

–UN

–10A

PR

97

14. Apply thread lock and sealer (medium strength) tostud.

15. Install stud on end of shaft if removed in assembly.

Tighten stud.

Clutch Pack—SpecificationShaft Stud—Torque 17 N•m (150 lb-in.)......................................................


PN=152



TX,0350,ME288 –19–26MAR99–12/19

T10

8671

–UN

–10A

PR

97

16. Insert ball bearing until seated and install snap ring.

03035033

TX,0350,ME288 –19–26MAR99–13/19

T10

8672

–UN

–10A

PR

97

17. Install needle bearing.

TX,0350,ME288 –19–26MAR99–14/19T

1086

73–U

N–1

0AP

R97

NOTE: Push against inner race of bearing.

18. Press idler gear against shoulder.

TX,0350,ME288 –19–26MAR99–15/19

T10

8674

–UN

–10A

PR

97

19. Retain idler gear by means of snap ring.


PN=153



TX,0350,ME288 –19–26MAR99–16/19

T10

8675

–UN

–10A

PR

97

NOTE: Clutch-KR, there is no recess in the shaft—assemble snap ring until contact on the bearinginner race is obtained.

20. Assemble pre-assembled plate carrier until all platesare engaged.

030350

34

TX,0350,ME288 –19–26MAR99–17/19

T10

8676

–UN

–10A

PR

97

21. Make sure carrier face is flush with shaft spline.

TX,0350,ME288 –19–26MAR99–18/19

T10

8677

–UN

–10A

PR

97

22. Press tapered roller bearing against shoulder.

Install opposite tapered roller bearing with press.

TX,0350,ME288 –19–26MAR99–19/19

T10

8678

–UN

–10A

PR

97

23. Check function of clutch by means of compressed air.

NOTE: When you have correctly installed components,the clutch packs will move freely as you will beable to hear them moving while inducingcompressed air.


PN=154


TX,0350,ME285 –19–26MAR99–1/9

Disassemble Clutch Pack K1, K2, and K3

T10

8755

–UN

–29A

PR

97

NOTE: The following art shows the disassembly of clutchK3. K1 and K2 are identical in disassemblymethods.

1. Remove rectangular sealing ring from shaft.

03035035

TX,0350,ME285 –19–26MAR99–2/9

T10

8764

–UN

–17A

PR

97

2. Pull tapered roller bearing from the shaft using mandreland puller as shown below.

Tool Usage Chart

Clutch Shaft Bearing Puller No. Bearing Puller MandrelNo.

K1 JDG1041 JDG1034

JDG1197 JDG1035

K2 JDG1197 JDG1035

K3 JDG1197 JDG1034

JDG1041 JDG1034

TX,0350,ME285 –19–26MAR99–3/9

T10

8765

–UN

–17A

PR

97

3. Remove disk, needle bearing and washer.



PN=155


TX,0350,ME285 –19–26MAR99–4/9

T10

8766

–UN

–17A

PR

97

4. Remove idler gear.

030350

36

TX,0350,ME285 –19–26MAR99–5/9

T10

8767

–UN

–17A

PR

97

5. Remove both needle bearings as well as axial bearing.

TX,0350,ME285 –19–26MAR99–6/9

T10

8760

–UN

–17A

PR

97

6. Remove snap ring and remove plates and disks.

TX,0350,ME285 –19–26MAR99–7/9

T10

8761

–UN

–17A

PR

97

7. Preload compression spring using DFT1148 (K2, K3)or DFT1149 (K1) Pre-Load Clutch Pack CompressionRing Tool in press.

8. Squeeze snap ring out and remove components.


PN=156



TX,0350,ME285 –19–26MAR99–8/9

T10

8762

–UN

–17A

PR

97

9. Press piston out of the plate carrier, using compressedair.

03035037

TX,0350,ME285 –19–26MAR99–9/9

T10

8763

–UN

–17A

PR

97

10. Pry plate carrier from the shaft.

TX,0350,ME289 –19–26MAR99–1/23

Assemble Clutch Pack K1, K2, and K3

T10

8679

–UN

–10A

PR

97

NOTE: Clutch K1, K2 and K3 are assembled in similarmanner. All the following assembly story art showclutch K3.


2. Install stud on end of shaft.

Tighten stud.




PN=157


TX,0350,ME289 –19–26MAR99–2/23

T10

8680

–UN

–10A

PR

97

3. Assemble plate carrier until bottomed.

030350

38

TX,0350,ME289 –19–26MAR99–3/23

T10

8981

–UN

–29A

PR

97



TX,0350,ME289 –19–26MAR99–4/23

T10

8734

–UN

–10A

PR

97

5. Install piston in carrier until seated.

Note proper position.



PN=158


03035039

TX,0350,ME289 –19–26MAR99–5/23

T10

8735

–UN

–10A

PR

97

Spring Type Shown May Vary

6. Install compression spring, two spring guides, into platecarrier.

TX,0350,ME289 –19–26MAR99–6/23

T10

8736

–UN

–10A

PR

97

7. Using DFT1149 Pre-Load Clutch Pack CompressionRing Tool and press, install snap ring into plate carriergroove for clutch K1.

Using DFT1148 Pre-Load Clutch Pack CompressionRing Tool and press, install snap ring into plate carriergroove for clutch K2 and K3.



PN=159


030350

40

TX,0350,ME289 –19–26MAR99–7/23

T11

2161

–UN

–20N

OV

97

Clutch Packs K1



NOTE: For proper adjustment of plate clearance,install disk and plates temporarily withoutbeing oiled.


TX,0350,ME289 –19–26MAR99–8/23

T10

8737

–UN

–10A

PR

97

9. Install plate and then disk alternately until seven platesand seven disks are installed in carrier.



PN=160



TX,0350,ME289 –19–26MAR99–9/23

T10

8738

–UN

–10A

PR

97


03035041

TX,0350,ME289 –19–26MAR99–10/23

T10

8739

–UN

–10A

PR

97


12. Adjust plate clearance to specification.

Clutch Pack—SpecificationK1 Clutch Pack Plate—Clearance 2.4—2.6 mm (0.094—0.102 in.)..........

a. Press end shim and measure the dimension fromthe end face/plate carrier to the end shim withdepth gage. Record dimension (No. 1).



PN=161


030350

42

TX,0350,ME289 –19–26MAR99–11/23

T10

8740

–UN

–09M

AY

97





Difference = Plate Clearance 2.50mm (0.079 in.)








PN=162


03035043

TX,0350,ME289 –19–26MAR99–12/23T

1121

60–U

N–2

0NO

V97

Clutch Packs K2 and K3



NOTE: Plate and disk position is the same for clutchK2 and K3.

For proper adjustment of plate clearance,install disk and plates temporarily withoutbeing oiled.

15. Install one sided fiber disk into carrier with thefiber side facing out or away from piston.

TX,0350,ME289 –19–26MAR99–13/23

T10

8737

–UN

–10A

PR

97

16. Install plate and then disk alternately until five platesand five disks are installed in carrier.



PN=163



TX,0350,ME289 –19–26MAR99–14/23

T10

8738

–UN

–10A

PR

97


030350

44

TX,0350,ME289 –19–26MAR99–15/23

T10

8739

–UN

–10A

PR

97



Clutch Pack—SpecificationK2 and K3 Clutch Pack Plate—Clearance 1.8—2.0 mm (0.071—0.079 in.)................................................




PN=164


03035045

TX,0350,ME289 –19–26MAR99–16/23

T10

8740

–UN

–09M

AY

97











TX,0350,ME289 –19–26MAR99–17/23T

1087

41–U

N–0

9MA

Y97

1—Thrust Disk2—Thrust Bearing3—Thrust Washer

22. Assemble thrust disk (1), thrust bearing (2), and thrustwasher (3).

TX,0350,ME289 –19–26MAR99–18/23

T10

8742

–UN

–09M

AY

97

23. Install both needle bearings.


PN=165



TX,0350,ME289 –19–26MAR99–19/23

T10

8743

–UN

–09M

AY

97

24. Install idler gear until all inner plates are engaged withsplines.

030350

46

TX,0350,ME289 –19–26MAR99–20/23

T10

8744

–UN

–09M

AY

97

1—Thrust Disk2—Thrust Bearing3—Thrust Washer

25. Install thrust washer (3), thrust bearing (2), and thrustdisk.

NOTE: Install disk (1) with chamfer facing the thrustbearing.

26. To assure proper assembly, top surface of thrust diskmust be flush with shaft step.

TX,0350,ME289 –19–26MAR99–21/23

T10

8745

–UN

–09M

AY

97




PN=166


TX,0350,ME289 –19–26MAR99–22/23

T10

8746

–UN

–09M

AY

97


03035047

TX,0350,ME289 –19–26MAR99–23/23

T10

8747

–UN

–09M

AY

97


NOTE: When you have correctly installed components,the clutch packs will move freely in carrier, as youwill be able to hear them moving while inducingcompressed air.

TX,0350,ME286 –19–26MAR99–1/4

Disassemble Clutch Pack K4

T10

8768

–UN

–17A

PR

97

1. Remove sealing ring.

2. Pull tapered roller bearing from the shaft with JDG1035Bearing Puller Mandrel and JDG1134 and JDG1197Bearing Pullers.

3. Remove opposite tapered roller bearing accordingly.

TX,0350,ME286 –19–26MAR99–2/4

T10

8769

–UN

–17A

PR

97

4. Remove snap ring and plate carrier from shaft.


PN=167



TX,0350,ME286 –19–26MAR99–3/4

T10

8770

–UN

–18A

PR

97

5. Remove snap ring and remove plates and disks.

030350

48

TX,0350,ME286 –19–26MAR99–4/4

T10

8983

–UN

–14A

PR

97

6. Preload compression spring using DFT1148 Pre-LoadClutch Pack Compression Ring Tool in press.

7. Remove snap ring and components. Remove piston.

TX,0350,ME291 –19–26MAR99–1/20

Assemble Clutch Pack K4

T10

8748

–UN

–14A

PR

97

NOTE: Gear is very tight press fit. Shaft or gear may bedamaged if pressed apart.

1. Cool shaft to specification. Heat gear to specificationand install it until bottomed.

Clutch Pack—SpecificationK4 Clutch Pack Shaft—Temperature Cools at -80°C (-112°F).........................................................K4 Clutch Pack Gear—Temperature Heats at 120°C (248°F).........................................................



PN=168


TX,0350,ME291 –19–26MAR99–2/20

T10

8749

–UN

–14A

PR

97

2. Install snap ring to retain gear.

03035049

TX,0350,ME291 –19–26MAR99–3/20

T10

8750

–UN

–29A

PR

97


4. Install stud on end of shaft.

Tighten stud.


TX,0350,ME291 –19–26MAR99–4/20T

1089

81–U

N–2

9AP

R97



TX,0350,ME291 –19–26MAR99–5/20

T10

8982

–UN

–14A

PR

97

6. Assemble piston until it bottoms out in disk carrier.

Pay attention to proper installation.


PN=169



TX,0350,ME291 –19–26MAR99–6/20

T10

8983

–UN

–14A

PR

97

7. Install compression spring, two spring guides, into diskcarrier.

8. Press spring with DFT1148 Pre-Load Clutch PackCompression Ring Tool in press and install snap ringinto disk carrier groove. (See Group 0399 forinstructions to make tool.)

030350

50

TX,0350,ME291 –19–26MAR99–7/20

T11

2159

–UN

–20N

OV

97

Clutch Packs K4



NOTE: For proper adjustment of plate clearance laterinstall disk and plates temporarily withoutbeing oiled.



PN=170



TX,0350,ME291 –19–26MAR99–8/20

T10

8984

–UN

–14A

PR

97

10. Install plate and then disk alternately until five platesand five disks are installed in carrier.

03035051

TX,0350,ME291 –19–26MAR99–9/20

T10

8985

–UN

–09M

AY

97


TX,0350,ME291 –19–26MAR99–10/20

T10

8986

–UN

–14A

PR

97



Clutch Pack—SpecificationK4 Clutch Pack Plate—Clearance 1.2—1.4 mm (0.047—0.055 in.)..........




PN=171


030350

52

TX,0350,ME291 –19–26MAR99–11/20

T10

8987

–UN

–14A

PR

97








After proper clearance is obtained remove disk and platesfrom assembly.



TX,0350,ME291 –19–26MAR99–12/20

T10

8988

–UN

–14A

PR

97

15. Install idler gear until inner plates are meshed withsplines.

NOTE: This will make it easier for installing idler gearlater.

16. Remove idler gear.

TX,0350,ME291 –19–26MAR99–13/20

T10

8989

–UN

–14A

PR

97

17. Install thrust washers and thrust bearing.


PN=172



TX,0350,ME291 –19–26MAR99–14/20

T10

8990

–UN

–14A

PR

97

18. Install two needle bearings.

03035053

TX,0350,ME291 –19–26MAR99–15/20

T10

8991

–UN

–14A

PR

97

19. Assemble idler gear.

TX,0350,ME291 –19–26MAR99–16/20T

1089

92–U

N–2

9AP

R97

1—Thrust Disc2—Thrust Bearing3—Thrust Washer

20. Install thrust washer (3), thrust bearing (2), and thrustdisk (1).

NOTE: Install thrust disk (1) with the chamfer facing thethrust washer.

TX,0350,ME291 –19–26MAR99–17/20

T10

8993

–UN

–14A

PR

97

21. Assemble K4 carrier assembly onto shaft until seatedand all plates are engaged.


PN=173



TX,0350,ME291 –19–26MAR99–18/20

T10

8994

–UN

–14A

PR

97

22. Install snap ring to retain plate.

030350

54

TX,0350,ME291 –19–26MAR99–19/20

T10

8995

–UN

–14A

PR

97


Install opposite tapered roller bearing.

TX,0350,ME291 –19–26MAR99–20/20

T10

8996

–UN

–14A

PR

97


NOTE: When you have correctly installed components,the clutch packs will move freely in carrier, as youwill be able to hear them moving while inducingcompressed air.

TX,0350,ME287 –19–05OCT98–1/2

Disassemble Input Shaft

T10

8772

–UN

–18A

PR

97

NOTE: The turbine shaft is axially fixed by means of asnap ring which will be destroyed when pressingout.

If necessary, press turbine shaft out of the input shaft.


PN=174



TX,0350,ME287 –19–05OCT98–2/2

T10

8773

–UN

–18A

PR

97

Remove rectangular ring out.

Pull off the tapered roller bearing using JDG1034 andJDG1035 Bearing Puller Mandrel.

Pull off the opposite tapered roller bearing.

NOTE: The separation of input shaft and gear is notpossible (press fit).

03035055

TX,0350,ME292 –19–12FEB99–1/8

Assemble Input Shaft

T10

8997

–UN

–14A

PR

97

Cool the input shaft to specification. Heat gear tospecification and assemble to shaft until seated.

Input Shaft—SpecificationInput Shaft—Temperature Cools at -80°C (-112°F)....................................Input Gear—Temperature Heats at +120°C (250°F)..................................

TX,0350,ME292 –19–12FEB99–2/8T

1089

98–U

N–1

4AP

R97

Install snap ring to retain gear.

TX,0350,ME292 –19–12FEB99–3/8

T10

8999

–UN

–14A

PR

97

Install snap ring into the recess of the turbine shaft.


PN=175



TX,0350,ME292 –19–12FEB99–4/8

T10

9000

–UN

–14A

PR

97

Install turbine shaft until the snap ring snaps into thegroove of the input shaft to retain turbine shaft.

030350

56

TX,0350,ME292 –19–12FEB99–5/8

T10

9001

–UN

–09M

AY

97

Press both bearing inner races against shoulder.

TX,0350,ME292 –19–12FEB99–6/8

T10

9002

–UN

–29A

PR

97

Install ball bearing

Install sealing ring.

TX,0350,ME292 –19–12FEB99–7/8

T10

9003

–UN

–09M

AY

97

Install output shaft into the housing bore until seated.


PN=176



TX,0350,ME292 –19–12FEB99–8/8

T10

8657

–UN

–10A

PR

97

NOTE: If bearings are reused, they must be assembled insame bores.

Insert all bearing outer races into transmission housingbores.

03035057


PN=177


030350

58


PN=178


0303601

TX04577,0000420 –19–23JAN01–1/1

Specifications


Transmission Pump

Socket Head Screw Torque 46 N•m (34 lb-ft)

Transmission Pump

Pump Cap Screw Torque 25 N•m (18 lb-ft)

Manifold Plate-to-Transmission Torque 25 N•m (18 lb-ft)Housing Socket Head Screw

Control Valve-to-Manifold Plate Torque 9.5 N•m (85 lb-in)Socket Head Screw

Housing-to-Control Valve (M5/10.9) Torque 5 N•m (44 lb-in.)Screw

Solenoid Valve (M5/8.8) Screw Torque 5 N•m (44 lb-in.)

Solenoid Cover-to-Housing (M5/10.9) Torque 5 N•m (44 lb-in.)Screw

Housing-to-Control Valve Block Torque 5 N•m (44 lb-in.)Screw (M5/10.9)

Solenoid Valve-to-Retaining Plate Torque 5 N•m (44 lb-in.)Screw

Alignment Stud-to-Cover Screw Torque 5 N•m (44 lb-in.)

Diagnostic Plug-to-Port (M10/1) Torque 6 N•m (55 lb-in.)Screw

Manifold Plate-to-Valve Body Torque 9.5 N•m (85 lb-in.)(M6/10.9) Screw

Converter Relief Valve

Manifold Socket Head Screw Torque 25 N•m (18 lb-ft)


PN=179

Hydraulic System

TX,0360,ME278 –19–20OCT98–1/5

Remove Transmission Pump

T10

8730

–UN

–17A

PR

97

1. Loosen socket head screws.

030360

2

TX,0360,ME278 –19–20OCT98–2/5

T10

8731

–UN

–17A

PR

97

2. Placing a puller on the splines runout of the statorshaft, pull pump assembly out of the housing bore.



PN=180

Hydraulic System

0303603

TX,0360,ME278 –19–20OCT98–3/5

TP

5549

0–U

N–1

5AP

R97

Oil Pump Assembly

1—O-Ring 4—Shim 6—Ring 8—O-Ring (10 used)2—Snap Ring 5—Needle Bearing 7—Pump Assembly 9—Cap Screw (10 used)3—Seal

TX,0360,ME278 –19–20OCT98–4/5

T10

8732

–UN

–17A

PR

97

3. Separate transmission pump from stator.

4. Separate cam plate from pump. Make note of drivegear spline location and two small dowel pins.

IMPORTANT: If traces of wear should be encounteredin the pump housing or the cam disk,the complete pump has to be replaced.

5. Inspect and replace parts as required

6. Install cam disk and retain it by means of grooved pins(2x).


PN=181


Hydraulic System

TX,0360,ME278 –19–20OCT98–5/5

T10

8725

–UN

–17A

PR

97

7. Loosen hex head screws and remove oil feed housing.

8. Remove flat gasket.

030360

4

TX,0350,ME279 –19–26MAR99–1/2

Remove and Install Converter MinimumPressure Regulator Valve

T11

2686

–UN

–05J

AN

98

1. Remove converter minimum pressure regulator valveout of the housing bore.

TX,0350,ME279 –19–26MAR99–2/2

T11

2685

–UN

–05J

AN

98

Minimum Pressure Regulator Valve

1—Piston2—Compression Spring3—Pressure Plate4—Lock Plate

2. Inspect and replace parts as required.

NOTE: Install pressure plate facing toward lock plate asshown in photo.

3. Install converter minimum pressure regulator valve intohousing bore.


PN=182

Hydraulic System

TX,07,ME297 –19–26MAR99–1/8

Install Transmission Pump

T11

2687

–UN

–05J

AN

98

1. Install alignment studs and install flat gasket.

0303605

TX,07,ME297 –19–26MAR99–2/8

T10

9086

–UN

–15A

PR

97

IMPORTANT: Screw hex head screws until contact isobtained. DO NOT TIGHTEN.

2. Install oil feed housing, washers and hex head screws.

Leave loose at this time. This allows for oil pumpalignment later in assembly.

TX,07,ME297 –19–26MAR99–3/8T

1090

87–U

N–1

5AP

R97

NOTE: Pay attention to the overlapping of the bores.

3. Install alignment studs and stator shaft until it isbottomed in housing.

TX,07,ME297 –19–26MAR99–4/8

T10

9088

–UN

–29A

PR

97

4. Lubricate and install O-ring.


PN=183


Hydraulic System

TX,07,ME297 –19–26MAR99–5/8

T10

9089

–UN

–15A

PR

97

5. Install transmission pump.

030360

6

TX,07,ME297 –19–26MAR99–6/8

T10

9090

–UN

–29A

PR

97

NOTE: Grease O-rings.

6. Install socket head screws with new O-rings.

TX,07,ME297 –19–26MAR99–7/8

T10

9091

–UN

–15A

PR

97

7. Install transmission pump and socket head screws.

Transmission Pump—SpecificationSocket Head Screw—Torque 46 N•m (34 lb-ft)..........................................

TX,07,ME297 –19–26MAR99–8/8

T10

9092

–UN

–15A

PR

97

NOTE: Note locations of hanger strap from originallocation.

8. Tighten cap screws.

Transmission Pump—SpecificationPump Cap Screw—Torque 25 N•m (18 lb-ft).............................................


PN=184

Hydraulic System

TX,0350,ME276 –19–15DEC98–1/3

Remove Transmission Hydraulic ControlValve

T10

8709

–UN

–17A

PR

97

1. Loosen socket head screws, install two alignmentstuds and separate control valve from manifold plate.

0303607

TX,0350,ME276 –19–15DEC98–2/3

T10

8710

–UN

–17A

PR

97

2. Remove both gaskets (9 ,11) and center plate (10).

TX,0350,ME276 –19–15DEC98–3/3T

1087

14–U

N–1

7AP

R97

3. Loosen socket head screws and hex nuts.

4. Separate manifold plate from transmission housing.

5. Remove gasket.


PN=185

Hydraulic System

030360

8

TX,0360,ME282 –19–15DEC98–1/4

Install Transmission Hydraulic Control Valve

TP

6030

4–U

N–0

8AP

R98

1—Stud (14 used) 5—Nut (16 used) 8—Cap Screw (39 used) 11—Gasket2—Gasket 6—O-Ring 9—Gasket 12—Cap Screw (23 used)3—Manifold Plate 7—Plug 10—Plate (Center) 13—Cap Screw (2 used)4—Washer (16 used)


PN=186


Hydraulic System

0303609

TX,0360,ME282 –19–15DEC98–2/4

T10

9106

–UN

–15A

PR

97T

1091

07–U

N–1

5AP

R97

1. Install gasket, manifold plate, and fasten it with sockethead screws hex nuts and washers. Tighten sockethead screws.

SpecificationManifold Plate-to-TransmissionHousing Socket Head Screw—Torque 25 N•m (18 lb-ft).............................................................................

TX,0360,ME282 –19–15DEC98–3/4T

1091

09–U

N–1

5AP

R97

2. Install two alignment studs. Install gasket (9), plate (10)and gasket (11).

TX,0360,ME282 –19–15DEC98–4/4

T10

9110

–UN

–15A

PR

97

3. Install complete control valve unit on the manifold platewith socket head screws.

IMPORTANT: Pay attention to the installation andposition of the different gaskets.

4. Tighten screw.

SpecificationControl Valve-to-Manifold PlateSocket Head Screw—Torque 9.5 N•m (85 lb-in).........................................


PN=187

Hydraulic System

030360

10

TX,0360,ME273 –19–11JAN01–1/1

Transmission Hydraulic Control Valve Cross Section View

T12

2180

–19–

07JU

L99

A—Pressure Regulating C—Connector—Wiring E—Valve Block—Control Valve H—Solenoid Valve—Valve—Piston Harness F—Housing (2 used) Proportional (6 used)

B—Pressure Reducing Valve— D—Cover (2 used) G—Modulation Circuit I—Transmission Control ValvePiston


PN=188

Hydraulic System

03036011


PN=189

Hydraulic System

030360

12

TX,0360,ME274 –19–26MAR99–1/7

Disassemble Transmission Control Valve

T13

7510

–UN

–20J

AN

01


PN=190


Hydraulic System

TX,0360,ME274 –19–26MAR99–2/7

1—Cap Screw (32 used) 11—Piston (Dampening Valve) 20—Gasket 30—Spring (6 used)2—Clamp (Clip) (6 used) 21—Housing 31—Orifice (6 used)3—Cover 12— Spring (6 used) 22—Plate (3 used) 32—Gasket4—Wiring Harness 13—Spring 23—Cap Screw (3 used) 33—Plate (Center)5—Gasket 14—Piston—System Pressure 24—Gasket 34—Gasket6—Solenoid Valve— Reducing Valve 25—Cover 35—Manifold Plate

Proportional (3 used) 15—Valve Block (Control) 26—Cap Screw (14 used) 36—Cap Screw (18 used)7—Cap Screw (3 used) 16—O-Ring (8 used) 27—Solenoid Valve— 37—Screen (Transmission S.N.8—Plate (3 used) 17—Drain Plug (8 used) Proportional (3 used) 000588— )(6 used)9—Housing 18— Spring 28—Cap Screw (18 used)10—Gasket 19— Piston (System Pressure 29—Piston (Pressure Control

Regulating Valve) valve) (6 used)

03036013

TX,0360,ME274 –19–26MAR99–3/7T

1086

86–U

N–1

6AP

R97

Hydraulic Control Valve

T10

8687

–UN

–16A

PR

97

1. Remove screws (26) and cover (25) and gasket (24).

2. Disconnect connectors to solenoid valves (27).

3. Remove screws (23) and retaining plates (22), andremove three solenoid valves (27).



PN=191

Hydraulic System

030360

14

TX,0360,ME274 –19–26MAR99–4/7

T13

5928

–UN

–12J

AN

01

Remove Housing And Valves

4. Loosen screw to housing (21), remove housing andgasket (20).

5. Remove three pressure control valve pistons (29) andcompression springs (30).

6. Remove three damping valves pistons (11) andcompression springs (12).

7. Remove system pressure valve piston (19)compression spring (18).

TX,0360,ME274 –19–26MAR99–5/7

T10

8689

–UN

–16A

PR

97

Clamp Removal from Harness Connector

8. Remove clamp (clip) (2) from wire harness connector.

TX,0360,ME274 –19–26MAR99–6/7

T10

8682

–UN

–16A

PR

97

9. Remove screws and cover (3) and gasket (5).

10. Disconnect connectors to solenoid valves (6).

11. Remove screws (7) and retaining plates (8). Pullsolenoid valves (6).


PN=192


Hydraulic System

03036015

TX,0360,ME274 –19–26MAR99–7/7

T10

8683

–UN

–16A

PR

97

12. Loosen screw to housing (9), remove housing andgasket (10).

13. Remove three pressure control valve pistons (29) andcompression springs (30).

14. Remove three damping valves pistons (11) andcompression springs (12).

15. Remove pressure reducing valve piston (14)compression spring (13).


TX,0360,ME275 –19–26MAR99–1/21

Assemble Transmission Control Valve

T10

8684

–UN

–09M

AY

97

1. Check all components for damage and replace ifnecessary.

2. Prior to the installation, check free travel of movingparts in the housing.

3. Oil components prior to the reassembly.

4. Insert orifices (31) (if removed) until contact is obtained(6 pieces, see arrows).

5. Install screens (37) if removed (Transmission S.N.000588— )

TX,0360,ME275 –19–26MAR99–2/21

T10

8683

–UN

–16A

PR

97

6. Install three pressure control valve pistons (29) andcompression springs (30).

7. Install three damping valve pistons (11) andcompression springs (12).

8. Install system Pressure reducing valve piston (14)compression spring (13).


PN=193


Hydraulic System

TX,0360,ME275 –19–26MAR99–3/21

T10

8694

–UN

–16A

PR

97

9. Screw two alignment studs in valve housing. Installgasket, assemble flat gasket (10).

NOTE: To aid assembly of solenoid housing, push spoolsinto bore and retain by using a 5mm pin or screw.

030360

16

TX,0360,ME275 –19–26MAR99–4/21

T10

8695

–UN

–16A

PR

97

10. Install housing (9) while routing wire harness (4) intoposition.

TX,0360,ME275 –19–26MAR99–5/21

T10

8696

–UN

–16A

PR

97

11. Fasten housing (9) with screws (1) and tightenevenly. Remove assembly aid pins or screws. Tighten(M5/10.9) screw.

SpecificationHousing-to-Control Valve(M5/10.9) Screw—Torque 5 N•m (44 lb-in.)................................................

TX,0360,ME275 –19–26MAR99–6/21

T10

8697

–UN

–16A

PR

97

12. Insert three solenoid valves (6) into housing (9),equipped with O-ring, and fasten by means ofretaining plate (8) and screws (7).

NOTE: Install retaining plate with the claw facing thehousing bottom.


PN=194


Hydraulic System

TX,0360,ME275 –19–26MAR99–7/21

T10

8698

–UN

–16A

PR

97

13. Install housing with solenoid valves onto control valve(15) and fasten with screws. Tighten (M5/8.8) screw.

SpecificationSolenoid Valve (M5/8.8) Screw—Torque 5 N•m (44 lb-in.)..............................................................................

03036017

TX,0360,ME275 –19–26MAR99–8/21

T10

8691

–UN

–16A

PR

97

14. Install wire harness connectors to solenoid valves.

TX,0360,ME275 –19–26MAR99–9/21T

1086

92–U

N–1

6AP

R97

15. Screw two alignment studs in, and assemble flatgasket (5) and cover (3).

16. Tighten screws (M5/10.9) 5 N•m (44 lb-in.)

SpecificationSolenoid Cover-to-Housing(M5/10.9) Screw—Torque 5 N•m (44 lb-in.)................................................

TX,0360,ME275 –19–26MAR99–10/21

T10

8693

–UN

–16A

PR

97

17. Install Wire harness connector (4) with clamp-clip (2)to cover (3).

NOTE: Make sure clamp snaps in.


PN=195


Hydraulic System

TX,0360,ME275 –19–26MAR99–11/21

T13

5928

–UN

–12J

AN

01

18. Install three pressure control valve pistons (29) andsprings 30).

19. Install three damping valve pistons(11) andcompression springs (12).

20. Install system pressure regulating valve (19), andspring (18).

030360

18

TX,0360,ME275 –19–26MAR99–12/21

T10

8703

–UN

–16A

PR

97

21. Push spools of the pressure control valves (29) intoposition. A straight pin (5 mm) may be used as anassembly aid.

TX,0360,ME275 –19–26MAR99–13/21

T10

8704

–UN

–16A

PR

97

22. Screw two alignment studs in, assemble gasket (20)and housing (21).



PN=196

Hydraulic System

03036019

TX,0360,ME275 –19–26MAR99–14/21

T10

8705

–UN

–16A

PR

97

23. Install housing and tighten evenly.

24. Tighten (M5/10.9) screw.

SpecificationHousing-to-Control Valve BlockScrew (M5/10.9)—Torque 5 N•m (44 lb-in.)................................................

TX,0360,ME275 –19–26MAR99–15/21T

1086

98–U

N–1

6AP

R97

25. Insert three solenoid valves (6), equipped with O-ring,and fasten by means of retaining plate (22) and screw(23).

NOTE: Install retaining plate with the claw facing thehousing bottom.


SpecificationSolenoid Valve-to-Retaining PlateScrew—Torque 5 N•m (44 lb-in.).................................................................

TX,0360,ME275 –19–26MAR99–16/21

T10

8699

–UN

–30A

PR

97

27. Fasten harness connectors to solenoid valves.

28. Screw two alignment studs in housing and assembleflat gasket (24) and cover (25). Tighten (M5/10.9)screw (26).

SpecificationAlignment Stud-to-Cover Screw—Torque 5 N•m (44 lb-in.)..............................................................................


PN=197


Hydraulic System

TX,0360,ME275 –19–26MAR99–17/21

T10

8700

–UN

–16A

PR

97

29. Install diagnostic plugs with O-rings, in ports, ifremoved during disassembly.

30. Tighten (M10/1) screw.

SpecificationDiagnostic Plug-to-Port (M10/1)Screw—Torque 6 N•m (55 lb-in.).................................................................

030360

20

TX,0360,ME275 –19–26MAR99–18/21

T10

8701

–UN

–16A

PR

97

31. Screw two (2) alignment studs in and assemble (first)flat gasket (32).

TX,0360,ME275 –19–26MAR99–19/21

T10

8706

–UN

–16A

PR

97

Intermediate Plate Assembly

32. Assemble intermediate plate (33).



PN=198

Hydraulic System

TX,0360,ME275 –19–26MAR99–20/21

T10

8707

–UN

–09M

AY

97

33. Assemble second gaske (34).

03036021

TX,0360,ME275 –19–26MAR99–21/21

T10

8708

–UN

–17A

PR

97

34. Assemble manifold plate (35) to valve body withscrews (36) and (remove alignment screws).

NOTE: Tightening order of the screw start with inboardscrews at first and continuing toward the outside.


SpecificationManifold Plate-to-Valve Body(M6/10.9) Screw—Torque 9.5 N•m (85 lb-in.).............................................

TX,0360,ME277 –19–26MAR99–1/4

Remove, Disassemble and Install ConverterRelief Valve

T10

8715

–UN

–17A

PR

97

1. Pull converter relief valve out of the housing bore.



PN=199

Hydraulic System

030360

22

TX,0360,ME277 –19–26MAR99–2/4

T10

9103

–UN

–30A

PR

97

Converter Relief Valve

1—Plate2—Ball3—Compression Spring4—Valve Insert5—Valve Sleeve6—Roll Pin

2. Remove preload compression spring carefully, removecylindrical pin as required to inspect and replace partsas needed.

TX,0360,ME277 –19–26MAR99–3/4

T10

9105

–UN

–15A

PR

97

3. Insert converter relief valve into the housing bore untilit bottoms.



PN=200

Hydraulic System

03036023

TX,0360,ME277 –19–26MAR99–4/4

T10

9106

–UN

–15A

PR

97T

1091

07–U

N–1

5AP

R97

4. Install gasket and manifold. Fasten it with socket headscrews hex nuts and washers. Tighten socket headscrews.

Converter Relief Valve—SpecificationManifold Socket Head Screw—Torque 25 N•m (18 lb-ft).............................................................................

TX,0360,ME293 –19–26MAR99–1/3

Replace Oil Pipes and Tubes

T10

8652

–UN

–09M

AY

971—Suction Tube2—Pressure Pipe (2 used)3—Pressure Lubrication Pipe (Transmission S.N. —

3320)

NOTE: The installation of all lubrication pipes, tubes andlines require special tools. Order tools accordingto information given in the U.S. SERVICEGARDCatalog or from the European Microfiche ToolCatalog (MTC). It is very important to have thesetools if repair or replacement is necessary. Ifrepair is needed contact DTAC (Dealer TechnicalAssistance Center) for assistance.



PN=201


Hydraulic System

030360

24

TX,0360,ME293 –19–26MAR99–2/3

T10

8658

–UN

–09M

AY

97

Cover Showing Two Oil Pipes



PN=202

Hydraulic System

03036025

TX,0360,ME293 –19–26MAR99–3/3T

P60

303

–UN

–08A

PR

98

1—Pipe (Transmission S.N. — 3—Cap Screw 6—Pipe (2 used) 9—Pipe3320) 4—Cap Screw 7—Pipe 10—Pipe

2—Tube 5—O-Ring (4 used) 8—Pipe 11—Cap Screw


PN=203

Hydraulic System

030360

26


PN=204

Group 0399Dealer Fabricated Tools

0303991

TX,0399,ME295 –19–08MAY97–1/1

DFT1148 Pre-Load Clutch Pack Compression Ring Tool

T10

9190

–UN

–08M

AY

97

The Clutch Pack Compression Ring Tool is used tocompress the piston compression ring so snap ringcan be removed.

Material is standard pipe (see dimensions above) withwindow cut out to allow for access when removingsnap ring.


PN=205

Dealer Fabricated Tools

030399

2

TX,0399,ME296 –19–08MAY97–1/1

DFT1149 Pre-Load Clutch Pack Compression Ring Tool

T10

9434

–UN

–07M

AY

97

The Clutch Pack Compression Ring Tool is used tocompress the piston compression ring so snap ringcan be removed.

Material is standard pipe (see dimensions above) withwindow cut out to allow for access when removingsnap ring.


PN=206

Section 04Engine

Contents

Page

Group 0400—Removal and InstallationPowerTech 4.5 L (4045) and 6.8 L (6068)

John Deere Engines—Use CTM104 . . . . .04-0400-1Service Equipment and Tools . . . . . . . . . . . .04-0400-1Specifications . . . . . . . . . . . . . . . . . . . . . . . .04-0400-2Engine

Remove and Install . . . . . . . . . . . . . . . . . .04-0400-3

04


PN=1

Contents

04


PN=2


TX,9010,SS3681 –19–05AUG96–1/1

PowerTech 4.5 L (4045) and 6.8 L (6068)John Deere Engines—Use CTM104

M44

215

–UN

–07S

EP

88

For additional engine information, the component technicalmanual (CTM) is also required.

Use the CTM in conjunction with this machine manual.


0404001

CED,OUOE003,3319 –19–26MAR99–1/3




CED,OUOE003,3319 –19–26MAR99–2/3

Lifting Sling . . . . . . . . . . . . . . . . . . . . . . . . . . JDG23

Used with load positioning sling to remove and installengine.

CED,OUOE003,3319 –19–26MAR99–3/3

Load Positioning Sling . . . . . . . . . . . . . . . . D01043AA

Used with lifting sling to remove and install engine.


PN=209


CED,OUOE003,3320 –19–26MAR99–1/1

Specifications


Engine Weight 567 kg (1250 lb) approximate

Engine Mounting Cap Screw Torque 434 ± 87 N•m (320 ± 64 lb-ft)fan end of engine

Torque 215 ± 43 N•m (160 ± 32 lb-ft)flywheel end of engine

Engine-to-Transmission Drive Shaft Torque 78 N•m (58 lb-ft)U-Joint Cap Screw

040400

2


PN=210


0404003

TX,04,JC2341 –19–16FEB99–1/7

Remove and Install Engine

TS

281

–UN

–23A

UG

88

1. Stop engine. Lower boom and bucket to ground.

2. Remove battery negative ground strap or turn batterydisconnect switch “Off” if equipped.

CAUTION: Explosive release of fluids frompressurized cooling system can cause seriousburns.

Shut off engine. Only remove filler cap whencool enough to touch with bare hands. Slowlyloosen cap to first stop to relieve pressurebefore removing completely.

3. Attach hose to radiator drain cock. Drain enginecoolant.

4. Remove hood with air cleaner and turbocharger inlethose. (See Group 1910 for hood removal.) (See Group0520 for air cleaner removal.)

5. Remove muffler with muffler mounting brackets. (SeeGroup 0530.)



PN=211


040400

4

TX,04,JC2341 –19–16FEB99–2/7

T11

2236

B–U

N–1

4NO

V97

A—Heater Hoses B—Fuel Suction Hose C—Radiator Hoses

6. Close shut-off valve at heater supply hose.

7. Disconnect heater hoses (A), fuel suction hose (B),and top and bottom radiator hoses (C). Disconnectfluid starting aid line, if equipped.



PN=212


0404005

TX,04,JC2341 –19–16FEB99–3/7

T11

2237

B–U

N–2

0NO

V97

D—Compressor Cap Screw (3 E—Ball Joint G—U-Bolt I—Air-to-Air Cooler Hosesused) F—Throttle Cable H—Starter J—Fuel Return Line

8. Disconnect throttle cable (F) from ball joint (E).Remove U-bolt (G) from throttle cable bracket.Remove bracket.

9. Disconnect fuel return line (J).

10. Disconnect air to air cooler hoses (I) fromturbocharger and intake manifold. Remove aircooler tube clamp from engine block.

11. Remove battery cables and E01 White wires fromstarter (H).

12. Remove air conditioning compressor cap screws(D) (if equipped). Move compressor out of theway.

13. Disconnect engine harness-to-load center harnessconnector from bottom right-hand side of cab orROPS.



PN=213


040400

6

TX,04,JC2341 –19–16FEB99–4/7

T10

8384

B–U

N–2

1MA

R97

A—U-Joint (4 used)

14. Remove four cap screws from theengine-to-transmission drive shaft U-joints (A) (at thetorque converter side).

15. Install JDG23 Lifting Sling and D01043AA LoadPositioning Sling to engine.

16. Remove the four front and rear engine mounting capscrews.

17. Remove the R.H. front and rear engine mounts fromengine.

CAUTION: Engine weighs approximately 567 kg(1250 lb).

SpecificationEngine—Weight 567 kg (1250 lb) approximate...........................................

18. Remove engine.



PN=214


0404007

TX,04,JC2341 –19–16FEB99–5/7

T10

8394

–UN

–11D

EC

98

A—Cap Screw (2 used) E—Washer (2 used) I—Support M—Isolator Assembly (2 used)B—Washer (2 used) F—Support J—Washer (4 used) N—Cap Screw (6 used)C—Support G—Cap Screw (4 used) K—Nut (4 used) O—SupportD—Cap Screw (2 used) H—Washer (4 used) L—Isolator Assembly (2 used)

19. Inspect engine mounting parts. Replace asneeded.


PN=215



TX,04,JC2341 –19–16FEB99–6/7

T10

9274

C–U

N–2

8AP

R97

040400

8

A—Mounting Cap Screw (4 used)

20. Install two front and two rear mounting cap screws.Tighten screws (A).

SpecificationEngine Mounting Cap Screw—Torque 434 ± 87 N•m (320 ± 64 lb-ft)

fan end of engine.........................................................

Torque 215 ± 43 N•m (160 ± 32 lb-ft)flywheel end of engine

.........................................................



PN=216


0404009

TX,04,JC2341 –19–16FEB99–7/7

T10

8384

B–U

N–2

1MA

R97

A—U-Joint Cap Screw (4 Used)

21. Install four NEW engine-to-transmission drive shaftU-joint cap screws (A) and two clamps. Tighten tospecification.

SpecificationEngine-to-Transmission DriveShaft U-Joint Cap Screw—Torque 78 N•m (58 lb-ft)..................................

22. Connect engine harness-to-load center harnessconnector.

23. Connect positive battery cables and E01 white wiresto starter. Connect ground wires to starter.

24. Connect fuel return line.

25. Connect air to air cooler hoses.

26. Install throttle cable bracket. Connect throttle cable.

27. Connect fluid start aid line (if equipped). Connect topand bottom radiator hoses. Connect fuel suction hoseand heater hoses.

28. Install muffler with muffler brackets. (See Group0530.)

29. Install hood with air cleaner and turbocharger inlethose. (See Group 1910 and Group 0520.)

30. Fill radiator with coolant.

31. Connect battery negative ground strap or turn batterydisconnect switch “On” if equipped.

32. Check engine rpm. Adjust cable if necessary. SeeSlow and Fast Idle Adjustment, Group 0515. Also seeSpeed Control Linkage Adjustment, Group 0515.


PN=217


040400

10


PN=218

Section 05Engine Auxiliary Systems

Contents

Page Page

Group 0505—Cold Weather Starting Aids Air Intake SystemOther Material . . . . . . . . . . . . . . . . . . . . . . . .05-0505-1 Leakage Test. . . . . . . . . . . . . . . . . . . . . . .05-0520-7Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0505-1Fluid Starting Aid Assembly Group 0530—External Exhaust System

Remove and Install . . . . . . . . . . . . . . . . . .05-0505-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0530-1Engine Coolant Heater Muffler

Remove and Install . . . . . . . . . . . . . . . . . .05-0505-4 Remove and Install . . . . . . . . . . . . . . . . . .05-0530-2

Group 0560—External Fuel Supply SystemsGroup 0510—Cooling SystemSpecifications . . . . . . . . . . . . . . . . . . . . . . . .05-0560-1Other Material . . . . . . . . . . . . . . . . . . . . . . . .05-0510-1Fuel TankSpecifications . . . . . . . . . . . . . . . . . . . . . . . .05-0510-2

Remove and Install . . . . . . . . . . . . . . . . . .05-0560-2Serpentine BeltPrimary Fuel Filter (Water Separator)Remove and Install . . . . . . . . . . . . . . . . . .05-0510-3

Drain and Clean. . . . . . . . . . . . . . . . . . . . .05-0560-5Fan and Fan DriveRemove and Install . . . . . . . . . . . . . . . . . .05-0560-6Remove and Install . . . . . . . . . . . . . . . . . .05-0510-5

Final Fuel FilterRadiator and Oil CoolerRemove and Install . . . . . . . . . . . . . . . . . .05-0560-9Remove and Install . . . . . . . . . . . . . . . . .05-0510-10

Fuel System 05Radiator, Oil Cooler and Air-to-Air AftercoolerBleed . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0560-10Disassemble and Assemble. . . . . . . . . . .05-0510-17

Group 0515—Speed ControlsSpecifications . . . . . . . . . . . . . . . . . . . . . . . .05-0515-1Speed Control Linkage

Remove and Install . . . . . . . . . . . . . . . . . .05-0515-1Fuel Shut-Off Solenoid

Remove and Install . . . . . . . . . . . . . . . . . .05-0515-2Fast and Slow Idle

Check and Adjust . . . . . . . . . . . . . . . . . . .05-0515-2Speed Control Linkage Adjustment . . . . . . . .05-0515-5Fuel Shut-Off Solenoid

Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0515-6

Group 0520—Intake SystemEssential Tools . . . . . . . . . . . . . . . . . . . . . . .05-0520-1Service Equipment and Tools . . . . . . . . . . . .05-0520-1Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0520-1Air Cleaner

Remove and Install . . . . . . . . . . . . . . . . . .05-0520-2Air Filter Elements

Remove and Install . . . . . . . . . . . . . . . . . .05-0520-3Primary Element

Clean Dusty. . . . . . . . . . . . . . . . . . . . . . . .05-0520-5Clean Oily or Sooty . . . . . . . . . . . . . . . . . .05-0520-5

ElementInspect. . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0520-6


PN=1

Contents

05


PN=2

Group 0505Cold Weather Starting Aids

CED,OUOE003,3322 –19–26MAR99–1/1

Other Material

Number Name Use

T43513 (U.S.) Thread Lock and Sealer (High Apply to threads of fluid starting aidTY9474 (Canadian) Strength) nozzle holder.271 (LOCTITE)

TY16004 (U.S.) John Deere Coolant Conditioner Add to cooling system.


05CED,OUOE024,404 –19–19FEB99–1/1

Specifications


Heating Element Nut Torque 34 N•m (25 lb-ft)

05051

TX,0505,111474 –19–20OCT98–1/4

Remove and Install Fluid Starting AidAssembly

T10

8966

–19–

17A

PR

97

1. Disconnect start aid solenoid connector that is locatedon sump tank harness.


PN=221


Cold Weather Starting Aids

TX,0505,111474 –19–20OCT98–2/4

T10

6395

D–U

N–1

6AP

R97

050505

2

A—Starting Aid CanisterB—ClampC—Starting Aid SolenoidD—LineE—Nozzle

2. Open left engine access door. Remove starting aidcomponents (A—E).

TX,0505,111474 –19–20OCT98–3/4

T10

4622

–UN

–08O

CT

97

A—Adapter ElbowB—Nozzle HolderC—Nozzle

3. Remove nozzle (C) from holder (B).

4. Clean or replace nozzle as required.

IMPORTANT: Nozzle must be secure in holder toprevent engine damage from dust. Donot overtighten or nozzle may break.

5. Carefully tighten nozzle in nozzle holder.

6. Apply thread lock and sealer (high strength) to threadsof nozzle holder.

7. Install nozzle holder so nozzle is toward center of airinlet so fluid is sprayed into incoming air flow. Arrow onhex flat indicates direction of nozzle.



PN=222


TX,0505,111474 –19–20OCT98–4/4

T10

6395

B–U

N–2

4JA

N97

0505053

B—ClampC—Start Aid CanisterD—Start Aid Plug

IMPORTANT: When operating machine withoutstarting aid container installed, protectcomponents from possible damage.Install starting aid plug (D) in startingaid base.

8. Install starting aid components. Remove safety capfrom new canister (C). Turn canister clockwise instarting aid base to install.

9. Tighten clamp (B).


PN=223


050505

4

TX,0505,111284 –19–26MAR99–1/2

Remove and Install Engine Coolant Heater

T66

42E

K–U

N–0

1NO

V88

T64

27A

O–U

N–2

1OC

T88

A—Power CordB—CapC—NutD—AdapterE—GasketF—O-RingG—Heating Element

CAUTION: Coolant may be hot. Wait untilradiator is cool to the touch before draining.

1. Drain cooling system

2. Remove power cord (A). Loosen nut (C) and pullheating element (G) from block.

CAUTION: DO NOT plug coolant heater intoelectrical power unless heating element isimmersed in coolant. Sheath could burst andresult in personal injury.

Use a heavy-duty grounded cord to connectcoolant heater to electrical power.

3. Disassemble parts (B—G).

4. Replace parts as necessary.

5. Assemble parts (B—G). Put heating element in cylinderblock so flats on threaded portion of element arevertical.

6. Turn element clockwise and then counterclockwiseuntil element contacts casting. Move element to thecenter position.

7. Hold element using a wrench. Tighten nut.

SpecificationHeating Element Nut—Torque 34 N•m (25 lb-ft)........................................

8. Install power cord (A).

Refill Cooling System

IMPORTANT: Use only permanent-type, low silicate,ethylene glycol base antifreeze incoolant solution. Other types ofantifreeze may damage cylinder seals.

FREEZING TEMPERATURES: Fill with permanent-type,low silicate, ethylene glycol antifreeze (without stop-leakadditive) and clean, soft water. Add TY16004 John DeereCoolant Conditioner or equivalent.


PN=224



0505055

TX,0505,111284 –19–26MAR99–2/2

NOTE: All machines are shipped from the factory with a50-50 mixture for protection to -34°C (-30°F).Adjust mixture accordingly to provide freezeprotection for your machine.

• Fill radiator to the bottom of the radiator fill neck.• Fill the recovery tank to the FULL mark.

Deaeration

The cooling system requires several warm-up and cooldown cycles to deaerate. It will NOT deaerate duringnormal operation. Only during warm-up and cool downcycles will the system deaerate.

• Start engine. Run engine until coolant reaches a warmtemperature.

• Stop engine. Allow coolant to cool.• Check coolant level at recovery tank.• Repeat Steps 1—3 until recovery tank coolant level is

repeatedly at the same level (stabilized).

NOTE: The level of the coolant in the cooling systemMUST BE repeatedly checked after all drain andrefill procedures to insure that all air is out of thesystem which allows the coolant level to stabilize.Check coolant level only when the engine is cold.


PN=225


050505

6


PN=226

Group 0510Cooling System

CED,OUOE003,3332 –19–27MAR99–1/1

Other Material

Number Name Use

PT569 (U.S.) John Deere NEVER-SEEZ Apply to fan shaft of drive motor.Lubricant


0505101


PN=227

Cooling System

050510

2

CED,OUOE003,3334 –19–27MAR99–1/1

Specifications


Fan Drive

Motor Housing Bolt Torque 55 N•m (40.5 lb-ft)

Motor Relief Valve Torque 32 N•m (23.5 lb-ft)

Pump Housing Bolt Torque 55 N•m (40.5 lb-ft)

Hub Hex Nut Torque 40 N•m (54 lb-ft)

Radiator and Oil Cooler

Hood, Air Cleaner and Exhaust Weight 45 kg (100 lb) approximatePipe

Grille Housing and Grille Weight 152 kg (335 lb) approximate

Radiator and Oil Cooler Assembly Weight 57 kg (125 lb) approximate

Side Plate-to-Frame Cap Screw Torque 128 N•m (95 lb-ft)

Fan Tip-to-Shroud Clearance 4.8—9.4 mm (0.189—0.370 in.)

Rod Hex Nut Torque 298 N•m (220 lb-ft)

Cooler-to-Rod Mount Bracket Cap Torque 46 N•m (34 lb-ft)Screw

Radiator/Oil Cooler Torque 129 N•m (95 lb-ft)Assembly-to-Frame Cap Screw

Fan-to-Shroud Clearance 4.8—9.4 mm (0.189—0.370 in.)

Grille Housing-to-Frame Cap Torque 129 N•m (95 lb-ft)Screw

Side Plate-to-Grille Housing Cap Torque 73 N•m (54 lb-ft)Screw


PN=228

Cooling System

05TX,05,RP3338 –19–27MAR99–1/2

Remove and Install Serpentine Belt

0510

T11

1242

B–U

N–2

7AU

G97

3

A—Belt

1. Check belt (A) regularly for wear, especially for cracksat the bottom of grooves and for frayed edges.



PN=229

Cooling System

050510

4

TX,05,RP3338 –19–27MAR99–2/2

T11

1698

–19–

09O

CT

97

Belt With Air Conditioning

T11

1700

–19–

09O

CT

97

Belt Without Air Conditioning

1—Crankshaft2—Air Conditioning Compressor3—Idler Pulley4—Alternator5—Water Pump6—Tensioner

IMPORTANT: If belt is stretched to the point that thebelt tensioner is against its stop, beltmust be replaced.

2. Replace belt if needed per diagram.

Replace belt if worn.

3. Hold tension adjuster assembly away from belt.Remove old belt; install new belt, release tensioner.


PN=230

Cooling System

0505105

TX,0510,111291 –19–27MAR99–1/5

Remove and Install Fan and Fan Drive

T11

1724

–19–

14O

CT

97

A—Cap Screw, Side Plate to B—Hex Nut, Rod D—Angle Bracket F—Bracket to FrameGrille Housing C—Cap Screw, Side Plate to E—T Bracket

Frame

1. Turn battery disconnect switch off (if equipped) ordisconnect battery ground strap.

2. Remove fan guard.

Remove fan and fan drive hub.

Remove hoses from fan drive motor, remove fandrive motor.



PN=231

Cooling System

050510

6

TX,0510,111291 –19–27MAR99–2/5

T11

1780

–UN

–17O

CT

97

A—Suction Hose C—Pump-to-Motor Hose E—Motor-to-Reservoir Return F—Motor-to-Hydraulic FilterB—Fan Drive Pump D—Fan Drive Motor Tube Hose Hose

3. Repair kits are available for the pump and motor.



PN=232

Cooling System

0505107

TX,0510,111291 –19–27MAR99–3/5

T11

1703

–UN

–23O

CT

97

A—Drive Hub B—Hex Nut C—Washer D—Label

4. Replace label if not readable.



PN=233

Cooling System

050510

8

TX,0510,111291 –19–27MAR99–4/5

T11

1705

–UN

–24N

OV

97

Fan Drive Motor

1—O-Ring (2 used) 6—Housing 10—Drive Gear 14—Bolt (4 used)2—Seal (2 used) 7—Valve Body 11—Idler Gear 15—Key3—Dust Seal 8—Relief Valve 12—Retaining Ring 16—19—Relief Valve Repair4—Shaft Seal 9—Flange 13—Dowel Pin (4 used) Kit5—Bushing Block (2 used)

5. Replace fan drive motor seals as necessary.

6. Repair or replace fan drive motor relief valve asneeded.

7. Install fan drive motor bolts (14) and tighten.

Fan Drive—SpecificationMotor Housing Bolt—Torque 55 N•m (40.5 lb-ft).................................

8. Install relief valve and tighten.

Fan Drive—SpecificationMotor Relief Valve—Torque 32 N•m (23.5 lb-ft)..................................



PN=234

Cooling System

0505109

TX,0510,111291 –19–27MAR99–5/5

T11

1779

–UN

–11N

OV

97

Fan Drive Pump

1—Retaining Ring 5—O-Ring (2 used) 8—Backup Ring (2 used) 11—Housing2—Shaft Seal (2 used) 6—Bearing (2 used) 9—End Cover 12—Gear (Number 2)3—Flange 7—“E” Seal (2 used) 10—Bolt (4 used) 13—Gear (Number 1)4—Dowel Pin

9. Repair or replace fan drive pump as needed.

10. Tighten fan drive pump housing bolts (10).

Fan Drive—SpecificationPump Housing Bolt—Torque 55 N•m (40.5 lb-ft).................................

11. Install pump, motor and hoses.

12. Apply John Deere NEVER-SEEZ Lubricant toshaft of drive motor. Install fan drive hub and fan.Tighten fan hub hex nut.

13. If label for fan drive hub hex nut torque is notreadable, replace it.

Fan Drive—SpecificationHub Hex Nut—Torque 40 N•m (54 lb-ft)..............................................

14. Install fan shroud, leave cap screws loose. Adjustclearance between shroud and fan blade tips tospecification. Move shroud for left-right adjustmentand use fan support for up-down adjustment.Tighten cap screws. Install fan guard.



PN=235

Cooling System

050510

10

TX,0510,JC2023 –19–27MAR99–1/9

Remove and Install Radiator and Oil Cooler

T11

1245

B–U

N–2

7AU

G97

B—Radiator Drain Cock

CAUTION: Do not remove radiator filler capunless engine is cool Then turn cap slowly tothe stop, then remove.

NOTE: Approximate capacity of cooling system is 22 L(23 qt).

1. Remove radiator cap. Attach hose to radiator draincock (B). Drain engine coolant into a container.Remove hose and tighten drain cock.

2. Remove coolant recovery tank from hood.

CAUTION: The approximate weight of hood, aircleaner and exhaust pipe is 45 kg (100 lb).

Radiator and Oil Cooler—SpecificationHood, Air Cleaner and ExhaustPipe—Weight 45 kg (100 lb) approximate...................................................

3. Remove hood with air cleaner and exhaust pipe.

4. Disconnect electrical harness connectors for coolantlevel sensor and lights in grille.

CAUTION: The approximate weight of grillehousing and grille is 152 kg (335 lb).

Radiator and Oil Cooler—SpecificationGrille Housing and Grille—Weight 152 kg (335 lb) approximate................

5. Remove grille and grille housing. (See Group 1921.)



PN=236

Cooling System

05051011

TX,0510,JC2023 –19–27MAR99–2/9

T11

1706

B–U

N–0

9OC

T97

T11

1707

B–U

N–0

9OC

T97

A—Upper Radiator HoseB—Lower Radiator Hose

6. Disconnect upper (A) and lower (B) radiator hoses andhose to coolant recovery reservoir.

7. Remove fan guard.

8. Remove fan shroud.

9. Remove fan and fan motor.


PN=237


Cooling System

05 TX,0510,JC2023 –19–27MAR99–3/9

T11

1713

B–U

N–0

9OC

T97

051012

C—HoseD—HoseE—HoseF—Hose

10. Disconnect transmission, hydraulic oil charge aircooler hoses (C—F).

TX,0510,JC2023 –19–27MAR99–4/9

T11

1714

B–U

N–0

9OC

T97

G—Clamp

11. Remove clamp (G) and tube from air cooler.


PN=238


Cooling System

05051013

TX,0510,JC2023 –19–27MAR99–5/9

T11

1724

–19–

14O

CT

97

A—Cap Screw, Side B—Hex Nut, Rod D—Angle Bracket F—Bracket-to-FramePlate-to-Grille Housing C—Cap Screw, Side E—T Bracket

Plate-to-Frame

12. Remove cap screws from air deflector brackets.Remove air deflector.



PN=239

Cooling System

05 TX,0510,JC2023 –19–27MAR99–6/9

T11

1807

B–U

N–2

3OC

T97

051014

A—Cap Screw (3 used)

13. Remove cap screws (A) from air conditionercondenser.

NOTE: Air conditioning system does NOT have to bedischarged to remove radiator and oil coolers.

TX,0510,JC2023 –19–27MAR99–7/9

T11

1806

B–U

N–2

3OC

T97

B—Cap Screw (3 used)

14. Remove cap screws (B). Do not disconnect airconditioning hoses from condenser. Lay airconditioning condenser forward and secure with rope.

CAUTION: The approximate weight of radiator,hydraulic oil cooler, transmission oil cooler andair cooler assembly is 57 kg (125 lb).

Radiator and Oil Cooler—SpecificationRadiator and Oil CoolerAssembly—Weight 57 kg (125 lb) approximate..........................................

15. Attach hoist to radiator and oil cooler assembly.Remove cap screws attaching assembly to frame.


PN=240


Cooling System

05051015

TX,0510,JC2023 –19–27MAR99–8/9

T10

9372

B–U

N–0

1MA

Y97

544H Shown

16. Carefully remove assembly.

17. Make necessary repairs.

18. Install radiator and oil cooler assembly.



PN=241

Cooling System

050510

16

TX,0510,JC2023 –19–27MAR99–9/9

T11

1724

–19–

14O

CT

97


Plate-to-Frame

19. Install side plate-to-frame cap screws (C) andwashers. Tighten cap screws.

Radiator and Oil Cooler—SpecificationSide Plate-to-Frame CapScrew—Torque 128 N•m (95 lb-ft).......................................................

20. Install fan and fan motor.

21. Replace foam strips on fan shroud. Install fanshroud leaving cap screws loose.

22. Adjust fan tip-to-shroud clearance evenly aroundfan to specification, tighten shroud cap screws.

Radiator and Oil Cooler—SpecificationFan Tip-to-Shroud—Clearance 4.8—9.4 mm (0.189—0.370 in.).........

23. Install fan guard.

24. Connect transmission cooler, hydraulic oil cooler,and charge air cooler hoses.

25. Connect radiators hoses and coolant recoveryreservoir hose.

26. Install grille and grille housing. (See Group 1921.)

27. Install hood.

28. Fill radiator with correct coolant mixture.

29. Cooling system must be deaerated to remove airfrom system and to properly fill it with coolant. SeeOperator’s Manual for deaeration of coolingsystem procedures.

30. Check transmission and hydraulic oil level andrefill as needed.


PN=242

Cooling System

05051017

TX,05,RP3341 –19–10MAY99–1/6

Disassemble and Assemble Radiator, Oil Cooler and Air-to-Air Aftercooler

T11

1724

–19–

14O

CT

97


Plate-to-Frame

1. Remove radiator/oil cooler/air-to-air aftercoolerassembly per procedures in this group.

2. Disassemble radiator/oil cooler/air-to-air aftercoolerassembly. Replace parts as necessary.



PN=243

Cooling System

05 TX,05,RP3341 –19–10MAY99–2/6

T11

1950

–UN

–19N

OV

97

051018

A—Foam Strip (4 used)

3. Apply foam strips (A) to both sides of radiator (4 piecesrequired).

TX,05,RP3341 –19–10MAY99–3/6

T10

9356

B–U

N–3

0AP

R97

B—Side PlateC—Oil Cooler

4. Assemble side plate (B) to oil cooler (C).



PN=244

Cooling System

TX,05,RP3341 –19–10MAY99–4/6

T10

9357

B–U

N–3

0AP

R97

05051019

D—Rod (4 used)E—Bracket (4 used)F—Isolator (3 used)G—Hex Nut (4 used)

5. Thread four rods (D) with fixed nuts into oil cooler sidemember. Tighten rods.

6. Assemble brackets (E) and straps (F) with isolatorsloosely to oil cooler and rods.

7. Thread jam nuts (G) on rods.

TX,05,RP3341 –19–10MAY99–5/6

T10

9358

B–U

N–3

0AP

R97

H—Side MemberI—RadiatorJ—Bracket (4 used, Front Shown)K—Cap Screw (3 used)L—Cooling Package Distance

8. Assemble side member (H) to radiator (I).

NOTE: For ease of assembly, cut a rod (L) 1092 ± 4 mm(43 ± 0.2 in.) to measure distance betweenradiator and oil cooler side plates.

9. Assemble cooling package. Adjust jam nuts onthreaded rods so cooling package is 1092 ± 4 mm (43± 0.2 in.) wide, measured inside the side plates andtighten rod hex nuts.

Radiator and Oil Cooler—SpecificationRod Hex Nut—Torque 298 N•m (220 lb-ft).................................................

10. Tighten cooler-to-rod mount bracket cap screws.

Radiator and Oil Cooler—SpecificationCooler-to-Rod Mount Bracket CapScrew—Torque 46 N•m (34 lb-ft)................................................................

11. Replace foam strips on top and bottom of fan shroud.

12. Install radiator/oil cooler assembly on machine.Tighten radiator/oil cooler assembly-to-frame capscrews.

Radiator and Oil Cooler—SpecificationRadiator/Oil CoolerAssembly-to-Frame Cap Screw—Torque 129 N•m (95 lb-ft)...........................................................................


PN=245


Cooling System

050510

20

TX,05,RP3341 –19–10MAY99–6/6

T11

1703

–UN

–23O

CT

97

A—Drive Hub B—Hex Nut C—Washer D—Label

13. Install fan motor and fan.

14. Install shroud on radiator, leaving cap screwsloose.

15. Adjust fan tip-to-shroud clearance evenly aroundfan. Move shroud for left-right adjustment and fansupport for up-down adjustment.

Radiator and Oil Cooler—SpecificationFan-to-Shroud—Clearance 4.8—9.4 mm (0.189—0.370 in.)...............

16. Tighten fan shroud cap screws.

17. Install grille housing. (See Group 1921). Installgrille housing-to-frame cap screws and tighten.

Radiator and Oil Cooler—SpecificationGrille Housing-to-Frame CapScrew—Torque 129 N•m (95 lb-ft).......................................................

18. Install side plate-to-grille housing cap screws andtighten.

Radiator and Oil Cooler—SpecificationSide Plate-to-Grille HousingCap Screw—Torque 73 N•m (54 lb-ft).................................................


PN=246

Group 0515Speed Controls

05CED,OUOE003,3377 –19–21APR99–1/1

Specifications


Fuel Shut-Off Solenoid

Injection Pump Lever Cap Screw Torque 15—20 N•m (11—15 lb-ft)

Fast and Slow Idle

Slow Idle Stop Screw RPM 900 ± 25 rpm

Fast Idle Stop Screw RPM 2350 ± 25 rpm

Speed Control Linkage

Accelerator Pedal Angle (with respect to pedal 9—11° @ low idle positionmounting plate)

30—35° @ fast idle position

Pedal Stop Screw Clearance (with injection pump lever 1—2 mm (0.0039—0.079 in.)on fast idle stop)

05151

TX,05,RP3343 –19–27MAR99–1/1

Remove and Install Speed Control Linkage

T11

1728

–UN

–28O

CT

97

A—Accelerator Pedal AssemblyB—IsolatorC—Accelerator CableD—BracketE—Ball Joint

1. Remove front and right cab shields.

2. Disassemble parts as shown.

3. Repair or replace as necessary.

4. Adjust linkage. (See Adjust Speed Control Linkage inthis group.)

5. Install shields.


PN=247

Speed Controls

05 TX,05,RP3344 –19–27MAR99–1/1

Remove and Install Fuel Shut-Off Solenoid

0515

T11

1753

–19–

19N

OV

97

2

1—Nut2—Cap Screw3—Bracket4—Cap Screw5—Washer6—Nut7—Fuel Shut-Off Solenoid8—Cap Screw9—Nut

1. Remove fuel shut-off solenoid. Disconnect solenoidconnector from machine harness.

2. Install cap screw (8) to injection pump lever andtighten.

Fuel Shut-Off Solenoid—SpecificationInjection Pump Lever CapScrew—Torque 15—20 N•m (11—15 lb-ft).................................................

3. Go to Adjust Fuel Shut-Off Solenoid in this group.

TX,9010,JC2149 –19–24JUN98–1/3

Check and Adjust Fast and Slow Idle

1. Connect a tachometer to check engine speeds.

2. Warm engine to normal operating temperature.

3. Stop the engine.

4. Disconnect speed control cable at injection pump lever.



PN=248

Speed Controls

0505153

TX,9010,JC2149 –19–24JUN98–2/3

T10

3678

–UN

–16S

EP

96

A—Nut C—Nut E—Nut F—Fast Idle Stop ScrewB—Slow Idle Stop Screw D—Supplementary Idle Screw

5.

Push injection pump lever against fast idle stopscrew (F). Record engine speed.

Push injection pump lever against slow idle stopscrew (B). Record engine speed.

Fast and Slow Idle—SpecificationSlow Idle Stop Screw—RPM 900 ± 25 rpm.........................................Fast Idle Stop Screw—RPM 2350 ± 25 rpm........................................

Adjust fast and slow idle stop screws on injectionpump as needed.

6. Loosen nut (C) on the supplementary idle screw(D).

Turn the screw out three turns.

7. Loosen nut (A) on the slow idle stop screw (B).

8. Hold injection pump lever against the screw.

Adjust the slow idle stop screw to obtain an enginespeed that is 30—40 rpm less than the slow idlespecification. Hold screw and tighten nut.

9. Turn the supplementary idle screw in to increaseengine speed to the slow idle specification. Holdscrew and tighten nut.

For example, to obtain the 900 rpm slow idlespeed, turn the slow idle stop screw (B) out to getapproximately 865 rpm. Hold screw and tighten thenut. Then turn the supplementary idle screw (D) into increase engine speed to 900 rpm. Hold screwand tighten nut

10. Pull injection pump lever rapidly to fast idle thendecelerate to slow idle. Slow idle must be tospecification.


PN=249


Speed Controls

TX,9010,JC2149 –19–24JUN98–3/3

NOTE: Increasing slow idle setting a small amount,but no more than the maximum specifications,may help to reduce surging or hunting. Ifsurging or hunting continues, repair injectionpump.

11. Loosen nut (E) on fast idle stop screw (F).

Pull lever against fast idle stop screw. Turn screwin to decrease engine speed; turn screw out to

increase engine speed. Adjust engine fast idlespeed to specification. Hold screw and tighten nut.

12. Stop the engine. Connect the cable to lever.

13. Adjust speed control linkage. (See procedure inthis group.)

050515

4


PN=250

Speed Controls

0505155

TX,9010,JC2148 –19–10MAY99–1/1

Speed Control Linkage Adjustment

T11

1247

B–U

N–1

0SE

P97

T11

1260

–UN

–29A

UG

97

A—Injection Pump LeverB—Fast Idle Stop ScrewC—Slow Idle Stop ScrewD—Speed Control CableE—Jam NutF—SwivelG—Pedal Stop Screw

SPECIFICATIONS

Accelerator Pedal Angle (with 9—11° @ low idle positionrespect to pedal mounting plate)

Accelerator Pedal (with respect to 30—35° @ fast idle positionpedal mounting plate)

Pedal Stop Screw Clearance 1—2 mm (0.039—0.079 in.)(with injection pump lever on fastidle stop)

1. Adjust pedal angle to 9—11° from the pedal mountingplate with the pedal released.

SpecificationAccelerator Pedal—Angle (withrespect to pedal mounting plate) 9—11° @ low idle position....................

30—35° @ fast idle position

2. Accelerator pedal at slow idle, disconnect swivel (F) onspeed control cable (D) from injection pump lever (A).With injection pump lever (A) held against the slow idlestop screw (C), adjust swivel (F) on cable (D) to alignwith injection pump lever (A). Install swivel and tightenjam nut (E).

3. Depress accelerator pedal until injection pump lever isagainst fast idle stop screw (B) and hold.

4. Adjust pedal stop screw (G) until it makes contact withthe pedal. Release pedal.

5. Shorten pedal stop screw until there is 1—2 mm(0.039—0.079 in.) clearance between the pedal andthe pedal stop screw (G).

SpecificationPedal Stop Screw—Clearance(with injection pump lever on fastidle stop) 1—2 mm (0.039—0.079 in.)........................................................


PN=251

Speed Controls

05 TX,9010,JC2145 –19–29AUG97–1/1

Adjust Fuel Shut-Off Solenoid

T11

1265

B–U

N–2

9AU

G97

A—StopB—Shut-Off LeverC—NutD—Rod

1. Turn key switch to START to "bump" starter. DO NOTstart engine. Leave key switch in ON position. This willenergize shut-off solenoid.

2. Loosen nut (C) and lengthen rod (D) until shut-off lever(B) moves away from stop (A).

3. Shorten rod (D) until shut-off lever (B) touches stop(A), then shorten rod two more turns to preload spring.

IMPORTANT: If rod (D) is adjusted too short, enginemay not shut off. If rod is adjusted toolong, engine may not start easily or maynot have full power. If adjustmentcannot be made, shut-off lever (B) maybe binding, solenoid mounting bracketmay be bent or injection pump may beworn or have internal failures.

4. Tighten nut (C) after adjustment is made.

05156


PN=252

Group 0520Intake System

CED,OUOE003,3338 –19–27MAR99–1/2

Essential Tools



CED,OUOE003,3338 –19–27MAR99–2/2

T7947AD –UN–05MAR93

Inlet Air Adapter . . . . . . . . . . . . . . . . . . . . . . . JDG51

To apply air pressure to intake system for leak checks.

0505201

CED,OUOE003,3339 –19–27MAR99–1/2




CED,OUOE003,3339 –19–27MAR99–2/2

Air Regulator with Gauge

To pressurize the air intake system for leakage tests.

CED,OUOE003,3340 –19–27MAR99–1/1

Specifications


Air Intake System Pressure 13.8—20.7 kPa (0.13—0.21 bar)(2—3 psi)


PN=253

Intake System

050520

2

TX,0520,111296 –19–27MAR99–1/3

Remove and Install Air Cleaner

TP

6058

5–U

N–2

1JA

N99


PN=254


Intake System

TX,0520,111296 –19–27MAR99–2/3

1—Air Cleaner 6—Valve 10—Band (2 used) 14—Clamp2—Air Filter Primary Element 7—Air Filter Secondary 11—Washer (4 used) 15—Clamp3—Cover Element 12—Screw (4 used) 16—Housing4—Hook (4 used) 8—Screen 13—Hose 17—Cover5—O-Ring 9—Sensor

1. Remove four screws (12) and bands (10).

2. Disconnect wiring harness connector from air filterrestriction switch.

3. Remove and install parts as needed.

4. Inspect elements for wear or damage and replaceas necessary.

5. Install parts.

6. Connect wiring harness connector to air filterrestriction switch.

0505203

TX,0520,111296 –19–27MAR99–3/3

T10

8196

–UN

–17M

AR

97

A—Hose ClampB—Hose Clamp

IMPORTANT: Tighten hose clamps until hoseprotrudes around clamp band.

7. Tighten hose clamps (A and B) until air intake hoseprotrudes around clamp band.

8. Test air intake system. (See Air Intake SystemLeakage Test in this group.)

TX,0520,111278 –19–16FEB99–1/3

Remove and Install Air Filter Elements

T10

6363

E–U

N–0

7MA

R97

A—Air Cleaner Cover

1. Open left service door.

2. Remove air cleaner cover (A).


PN=255


Intake System

TX,0520,111278 –19–16FEB99–2/3

T10

6369

B–U

N–2

4JA

N97

A—Primary Element

IMPORTANT: Install a new primary element:

1. If the element shows damage.2. If the element will not clean.3. After 1000 hours service or annually.

3. Remove primary element (A).

050520

4

TX,0520,111278 –19–16FEB99–3/3

T10

6370

B–U

N–2

8JA

N97

B—Secondary Element

IMPORTANT: Install a new secondary element:

1. If primary element is damaged andneeds to be replaced.

2. If element is visibly dirty.3. After 1000 hours service or annually.4. Always thoroughly clean air cleaner

canister before installing newelements.

Do not clean secondary element. Installa new element carefully centering it inthe canister.

4. Remove secondary element (B).


PN=256

Intake System

05TX,0520,111281 –19–14MAR97–1/1

Clean Dusty Primary Element

T47

764

–UN

–09N

OV

88

CAUTION: Prevent possible injury from flyingchips if compressed air is more than 210 kPa(2.1 bar) (30 psi). Reduce compressed air toless than 210 kPa (2.1 bar) (30 psi) when usingfor cleaning purposes. Clear area of bystanders,guard against flying chips, and wear personalprotection equipment including eye protection.

1. Tap element with the palm of your hand, NOT ON AHARD SURFACE.

2. If this does not remove dust, use compressed air under210 kPa (2.1 bar) (30 psi).

3. Direct air up and down the pleats from inside tooutside. Be careful not to make a break in the element.

05205

03T,55,C19 –19–24JUL91–1/1

Clean Oily or Sooty Primary Element

T90

673

–UN

–10N

OV

88

IMPORTANT: You can damage element. DO NOTwash element in fuel oil, oil, gasoline,or solvent. DO NOT use compressed airto remove water from an element.

1. Wash element in warm water and John Deere R36757Filter Element Cleaner or equivalent non-sudsingdetergent.

2. Flush with clean water. Use water pressure under 280kPa (2.8 bar) (40 psi).

3. Shake the element to remove water. Do not installelement unless it is dry.


PN=257

Intake System

050520

6

03T,55,C67 –19–24JUL91–1/1

Inspect Element

T90

684

–UN

–10N

OV

88

IMPORTANT: A damaged or dirty element may causeengine damage.

Install a new primary element:

1. If the element shows damage.2. If element will not clean.3. After 1000 hours service or annually.

Install a new secondary element:

1. If the primary element is damagedand needs to be replaced.

2. If the element is visibly dirty.3. After 1000 hours service or annually.

DO NOT clean a secondary element.Install a new element carefully centeringit in the canister.

1. Inspect element and gasket for damage.

2. Air restriction indicator will not signal correctly if anelement has a break or is not correctly sealed in aircleaner housing. Throw away element that has theslightest damage. If gasket is broken or missing, installa new element.

3. After installing elements, reinstall cover with the droptube as close to vertical as possible.


PN=258

Intake System

0505207

TX,9010,SS3694 –19–21APR99–1/1

Air Intake System Leakage Test

T59

06A

P–U

N–2

3FE

B89

T10

7289

C–U

N–1

2FE

B97

A—JDG51 Adapter

SPECIFICATIONS

Air Intake System Pressure 13.8—20.7 kPa (0.13—0.21 bar)(2—3 psi)

ESSENTIAL TOOLS

JDG51 Inlet Air Adapter

SERVICE EQUIPMENT AND TOOLS

Air Regulator with Gauge

IMPORTANT: Anytime the air intake system is openedit must be tested for leaks before themachine is returned to service.

1. Remove air cleaner cover and main filter element.

2. Put a plastic bag over safety element and install mainelement and cover.

3. Remove plug or ether start aid from air intake tube andinstall JDG51 Adapter (A).

4. Connect air pressure regulator to adapter using hoseand fitting.

CAUTION: Plastic bag can be sucked intoengine if engine is started when trying to closevalves.

5. Pressurize air intake system to specifications. If systemcannot be pressurized, turn engine slightly to closevalves. Check plastic bag.

SpecificationAir Intake System—Pressure 13.8—20.7 kPa (0.13—0.21 bar)

(2—3 psi).................

6. Spray soap solution over all connections from the aircleaner to the turbocharger or air inlet to check forleaks. Repair all leaks.


PN=259

Intake System

050520

8


PN=260

Group 0530External Exhaust System

CED,OUOE003,3337 –19–27MAR99–1/1

Specifications


Hood, Air Cleaner and Exhaust Pipe Weight 64 kg (140 lb) approximate

Bracket-to-Engine Cap Screw Torque 73 N•m (54 lb-ft)

0505301


PN=261

External Exhaust System

050530

2

TX,0530,111288 –19–27MAR99–1/2

Remove and Install Muffler

TP

6056

8–U

N–3

0NO

V98


PN=262



0505303

TX,0530,111288 –19–27MAR99–2/2

1—Screw, M10 x 30 (11 used) 5—Muffler 9—Clamp 12—Bracket2—Exhaust Pipe (Black) 6—Bracket 10—Bracket 13—Clamp3—Washer (8 used) 7—Screw M12 x 30 11—Screw, M10 x 25 14—Cap Screw4—Lock Nut (4 used) 8—Nut

CAUTION: Muffler may be hot. Allow mufflerto cool before removing.

The approximate weight of hood, air cleanerand exhaust pipe is 64 kg (140 lb).

SpecificationHood, Air Cleaner and ExhaustPipe—Weight 64 kg (140 lb) approximate............................................

1. Remove hood.

2. Remove clamp (9).

3. Remove cap screws (1), washers (3), and lock nuts(4).

4. Remove fuel filter from bracket (10).

5. Remove brackets (6 and 10).

6. Replace if necessary.

7. Install bracket-to-engine cap screws (7 and 8),screws (1) and washers (3). Do not tighten at thistime.

8. Reinstall fuel filter on bracket (10).

9. Install clamp (9) that connects muffler inlet toturbocharger. Tighten clamp until connection issnug, but inlet pipe can still rotate.

10. Adjust muffler position so that muffler body is leveland tighten mounting screws to keep it level.

11. Tighten cap screws.

SpecificationBracket-to-Engine Cap Screw—Torque 73 N•m (54 lb-ft).......................................................................

12. Tighten clamp (9).

13. Install hood.


PN=263


050530

4


PN=264

Group 0560External Fuel Supply Systems

CED,OUOE003,3343 –19–27MAR99–1/1

Specifications


Fuel Tank (Without Fuel) and Bottom Weight 123 kg (272 lb) approximateGuard

Fuel Tank Bottom Guard Cap Screw Torque 318 N•m (235 lb-ft)

0505601


PN=265

External Fuel Supply Systems

050560

2

TX,05,RP3346 –19–16FEB99–1/4

Remove and Install Fuel Tank

TP

6174

0–U

N–0

3SE

P98


PN=266



0505603

TX,05,RP3346 –19–16FEB99–2/4

1—Fuel Tank 9—Sender 16—O-Ring 23—Hose2—Drain Valve 10—Screw (5 used) 17—Bolt (4 used) 24—Elbow Fitting3—Elbow Fitting (2 used) 11—Clamp 18—Flange Nut (4 used) 25—Housing4—Clamp (2 used) 12—Hose 19—Screw (2 used) 26—Hose5—Clamp (8 used) 13—Filler Neck 20—Clamp (2 used) 27—Screw6—Elbow Fitting 14—Hose Fitting (10 used) 21—Hose 28—Clamp7—Elbow Fitting 15—Filler Cap 22—Clamp (2 used) 29—Filler Neck Assembly8—Gasket


2. Disconnect hose (23) from filler neck.

3. Disconnect hose (21) at tank.

CAUTION: Remove fuel to reduce weight ofthe fuel tank. Approximate capacity of fueltank is 265 L (70 gal).

4. Disconnect hose at primary fuel filter and drain fuelinto clean container or pump fuel out of the tank.

5. Disconnect hose (12) at leak-off line on enginehead.

6. Disconnect wiring leads from fuel gauge sendingunit (9).

CAUTION: The approximate weight of thefuel tank (without fuel) is 18 kg (40 lb).Approximate weight of fuel tank and fueltank bottom guard is 123 kg (272 lb).

SpecificationFuel Tank (Without Fuel) andBottom Guard—Weight 123 kg (272 lb) approximate...........................

7. Support fuel tank and bottom guard with a liftingtable or floor jack.



PN=267


05 TX,05,RP3346 –19–16FEB99–3/4

T10

8306

–UN

–19M

AR

97

A—Cap Screw (2 used)B—Strap (2 used)C—Washer (4 used)D—Cap Screw (4 used)E—Bottom GuardF—Washer

8. Remove cap screws (D) and washers (C) from bottomguard and lower tank to floor.

9. Remove straps (B) to remove fuel tank from guard.


11. Install straps, Tighten cap screws (D).

SpecificationFuel Tank Bottom Guard CapScrew—Torque 318 N•m (235 lb-ft)............................................................

12. Raise fuel tank into place with lifting device. Installcap screws (D) and washers (C).

13. Connect wiring leads to fuel level sending unit.

14. Connect hoses to fuel tank.

05604

TX,05,RP3346 –19–16FEB99–4/4

T11

1244

B–U

N–2

7AU

G97

A—Vent Hose

IMPORTANT: If fuel tank vent hose is plugged orpinched, the fuel tank could collapseand engine performance will beaffected.

15. Check fuel tank vent hose (A) for being plugged orpinched. Clean, reposition or replace hose.

16. Connect battery ground strap. Turn battery disconnectswitch on (if equipped).


PN=268


05TX,55,JC2157 –19–02SEP97–1/2

Drain and Clean Primary Fuel Filter (WaterSeparator)

T11

1238

D–U

N–2

7AU

G97

T83

87A

E–U

N–1

7DE

C94

05605

A—Hand PrimerB—Drain Valve (Primary Fuel Filter)C—Drain Valve (Final Fuel Filter)

1. Open left engine side shield to access primary fuelfilter (water separator).

2. Put container under drain valves (B and C).

3. Rotate retaining ring around filter elementcounterclockwise 1/4 turn. Lifting ring as it is rotatedhelps get it past retaining detent. Ring should dropdown and release filter from base.

4. Remove hand primer (A) from fuel filter base.Disassemble hand primer assembly and clean out anydebris.

TX,55,JC2157 –19–02SEP97–2/2

T83

87A

D–U

N–1

7DE

C94

A—Fuel Inlet LineB—Filter BaseC—Drain Plug

5. Remove fuel inlet line (A) and fuel drain plug (C).

6. Flush any debris from filter base (B).

7. Install fuel inlet drain plug and fuel inlet line.

8. Assemble primer assembly and install onto fuel filterbase.

9. Install filter element to fuel filter base.

10. Bleed fuel system.

11. Close side shield.

12. Dispose of waste properly.


PN=269


05 TX,05,RP3371 –19–21APR99–1/4

Remove and Install Primary Fuel Filter (WaterSeparator)

T11

1238

D–U

N–2

7AU

G97

T83

87A

E–U

N–1

7DE

C94

05606

A—Hand PrimerB—Drain Valve (Primary Fuel Filter)C—Drain Valve (Final Fuel Filter)

1. Open left engine side shield to access primary fuelfilter (water separator).

2. Put container under drain valves (B and C).

3. Rotate retaining ring around filter elementcounterclockwise 1/4 turn. Lifting ring as it is rotatedhelps get it past retaining detent. Ring should dropdown and release filter from base.

4. Remove hand primer (A) from fuel filter base.Disassemble hand primer assembly and clean out anydebris.

TX,05,RP3371 –19–21APR99–2/4

T83

87A

D–U

N–1

7DE

C94

A—Fuel Inlet LineB—Filter BaseC—Drain Plug

5. Remove fuel inlet line (A) and fuel drain plug (C).

6. Flush any debris from filter base (B).

7. Install fuel inlet drain plug and fuel inlet line.

8. Assemble primer assembly and install onto fuel filterbase.

9. Install filter element to fuel filter base.


11. Close side shield.




PN=270


0505607


PN=271


050560

8

TX,05,RP3371 –19–21APR99–3/4

TP

6175

2–U

N–0

1OC

T98


PN=272



TX,05,RP3371 –19–21APR99–4/4

1—Washer 8—Screw 14—O-Ring (4 used) 20—Filter Head2—Clamp (2 used) 9—Flange Nut 15—Kit 21—Fuel Line3—Washer 10—Bracket 16—Seal Kit 22—Bracket4—Screw 11—Filter Head 17—Fuel Filter 23—Cap Screw (4 used)5—Screw 12—Screw (4 used) 18—Drain Valve 24—Clamp (2 used)6—Bracket 13—Plug (2 used) 19—Fitting (2 used) 25—Ring7—Fuel Line

0505609

TX,05,RP3372 –19–16FEB99–1/1

Remove and Install Final Fuel Filter

T11

1238

B–U

N–2

7AU

G97

A—Filter Lock Ring

1. Turn filter lock ring (A) counterclockwise to removefilter. Drain sediment into a container and dispose ofproperly.

2. Clean filter base and install new filter.



PN=273


05 TX,0560,111294 –19–27MAR99–1/1

Bleeding Fuel System

T11

1238

E–U

N–2

7AU

G97

056010

A—Bleed Screw (Final Fuel Filter)B—Bleed Screw (Primary Fuel Filter)C—Hand PrimerD—Primary Fuel Filter (Water Separator)E—Drain Valve (Primary Fuel Filter)F—Drain Valve (Final Fuel Filter)G—Final Fuel Filter

1. Place container under filters (D and G).

2. Loosen bleed screw (A).

3. Pump hand primer (C) until bleed screw (A) has solidstream of fuel coming from it. Tighten bleed screw (A).

4. Open bleed screw (B). Pump hand primer until bleedscrew has solid stream of fuel coming from it. Tightenbleed screw (B).



PN=274

Section 07Dampener Drive

Contents

Page

Group 0752—ElementsDampener


07


PN=1

Contents

07


PN=2

Group 0752Elements

TX,07,JC2342 –19–21APR99–1/1

Remove and Install Dampener

T65

64A

S–U

N–2

7OC

T88

070752

A—CoverB—Dampener

1. Open engine side shields.

2. Remove drive shaft.

3. Remove covers (A) and dampener (B).

Dampener—SpecificationDampener-to-Flywheel CapScrew—Torque 68 N•m (50 lb-ft)................................................................

1


PN=277

Elements

070752

2


PN=278

Section 09Steering System

Contents

Page

Group 0960—Hydraulic SystemService Equipment and Tools . . . . . . . . . . . .09-0960-1Other Material . . . . . . . . . . . . . . . . . . . . . . . .09-0960-1Specifications . . . . . . . . . . . . . . . . . . . . . . . .09-0960-2Steering Valve

Remove and Install . . . . . . . . . . . . . . . . . .09-0960-3Steering Column

Remove and Install . . . . . . . . . . . . . . . . . .09-0960-8Steering Cylinder

Remove and Install . . . . . . . . . . . . . . . . . .09-0960-9Loader Start-Up Procedure . . . . . . . . . . .09-0960-11

Disassemble and Assemble SteeringCylinder . . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-12

Steering CylinderRemove and Install Bushings. . . . . . . . . .09-0960-12

09


PN=1

Contents

09


PN=2


CED,OUOE003,3347 –19–29MAR99–1/2




CED,OUOE003,3347 –19–29MAR99–2/2

Bushing, Bearing and Seal Driver Set

To remove and install steering cylinder bushings.

0909601

CED,OUOE003,3348 –19–29MAR99–1/1

Other Material

Number Name Use

PT569 (U.S.) NEVER-SEEZ Lubricant Apply to threads of steering wheelnut to prevent threads from seizing.Apply to steering column pivot bores.

TY16285 (U.S.) Cure Primer To clean surface prior to applicationTY9485 (Canadian) of adhesives or sealants.7649 (LOCTITE)

T43513 (U.S.) Thread Lock and Sealer (High Apply to threads of steering cylinderTY9474 (Canadian) Strength) rod guide and spanner nut for271 (LOCTITE) installation.

NEVER-SEEZ is a trademark of Emhart Chemical Group.LOCTITE is a trademark of Loctite Corp.


PN=281

Hydraulic System

CED,OUOE003,3349 –19–29MAR99–1/1

Specifications


Steering Valve

Isolator Cap Screw Torque 57 N•m (42 lb-ft)

Valve-to-Plate Cap Screw Torque 27 N•m (20 lb-ft)

Steering Column

Steering Wheel-to-Steering Torque 68 N•m (50 lb-ft)Column Nut

Steering Cylinder

Steering Cylinder Weight 65 kg (143 lb) approximate

Piston Nut Torque 136 N•m (100 lb-ft) plus (30°) 1/12turn

090960

2


PN=282

Hydraulic System

0909603

TX,0960,JC2036 –19–27MAR99–1/5

Remove and Install Steering Valve

T11

0749

–19–

23JU

L97

T11

0750

–19–

23JU

L97

T11

0754

–19–

23JU

L97

CAUTION: Prevent possible injury fromunexpected machine movement. Install framelocking bar before working in frame hinge area.


2. Stop engine.

CAUTION: Prevent possible injury fromunexpected boom or bucket movement. Ridecontrol accumulator MUST be discharged whenworking on hydraulic components.

Engine OFF.

With boom raised slightly, turn ignition switchto ON position.

Move ride control switch to ON (centerposition). Boom will jump up if ride controlaccumulator is pressurized.

Press Pilot Enable/Boom Down switch to BOOMDOWN and hold.

Move the control lever to lower bucket toground then hold in FLOAT position for 5seconds to completely discharge ride controlaccumulator(s).

3. Engine OFF.

With boom raised slightly, turn ignition switch to ONposition. Cycle the ride control switch from OFF to ON(center position). Boom will jump up unexpectedly ifride control accumulator is energized. Press boomenable switch and move the control lever into the floatposition and hold for 5 seconds.

If not equipped with ride control, press pilotenable/boom down switch to BOOM DOWN position,move the control lever into FLOAT position and holdfor 5 seconds to relieve any residual hydraulicpressure.


PN=283


Hydraulic System

TX,0960,JC2036 –19–27MAR99–2/5

4. Drain hydraulic reservoir or connect a vacuum pump tothe reservoir by removing the vent filter and attachingthe vacuum pump to its fitting in the reservoir.

5. Remove front cab shield.

090960

4

TX,0960,JC2036 –19–27MAR99–3/5

T11

0783

–UN

–23J

UL9

7

A—Return C—Right Turn D—Left Turn E—PressureB—Load Sense

6. Disconnect and label hoses. Plug or cap hoses andfittings.



PN=284

Hydraulic System

0909605


PN=285

Hydraulic System

090960

6

TX,0960,JC2036 –19–27MAR99–4/5

T10

9458

–UN

–08M

AY

97


PN=286


Hydraulic System

TX,0960,JC2036 –19–27MAR99–5/5

1—Isolator 4—Bracket 7—Lock Nut (3 used) 10—Cap Screw (3 used)2—Cap Screw (4 used) 5—Washer (4 used) 8—Washer (3 used) 11—Cap Screw (2 used)3—Washer (4 used) 6—Steering Column 9—Rubber Mount (3 used)

7. Remove cover from steering column.

8. Remove lock nuts (7), washers (8), rubber mounts(9), and cap screws (10).

9. Remove cap screw (11).

10. Remove steering valve.

11. Remove cap screws (2) and washers (3) toremove bracket (4) from steering column (6).


Steering Valve—SpecificationIsolator Cap Screw—Torque 57 N•m (42 lb-ft)....................................Valve-to-Plate Cap Screw—Torque 27 N•m (20 lb-ft).......................................................................

0909607


PN=287

Hydraulic System

090960

8

TX,0960,MA15 –19–29MAR99–1/1

Remove and Install Steering Column

T11

0814

–19–

25JU

L97

1—Cover 3—Nut 9—Screw (4 used) 15—Isolator2—Spring Assembly 4—Lock Washer (2 used) 10—Spring 16—Cover

5—Knob 11—Dowel Pin 17—Steering Column6—Steering Wheel 12—Screw (2 used) 18—Apply NEVER-SEEZ

7—Snap Ring 13—Bolt (2 used) 19—Apply NEVER-SEEZ

8—Seal 14—Brush Set

1. Remove steering column cover.

2. Remove shift selector and turn signal switch.

3. Disconnect spring (10).

4. Remove cap screws (9).

5. Remove parts (1—8) and (10—17).

6. Repair or replace parts as needed.

7. Apply NEVER-SEEZ Lubricant or equivalent tosteering column tilt pivots (18) and threads onsteering shaft (19).

8. Assemble parts (1—17).

Steering Column—SpecificationSteering Wheel-to-SteeringColumn Nut—Torque 68 N•m (50 lb-ft)................................................



PN=288

Hydraulic System

TX,0960,RB89 –19–29MAR99–1/3

Remove and Install Steering Cylinders

T10

1186

–UN

–21M

AY

96

CAUTION: Prevent possible injury fromunexpected machine frame movement. Installframe locking bar to both frames before youwork in the frame pivot area.

1. Install frame locking bar (C). Stop engine.


0909609


PN=289

Hydraulic System

090960

10

TX,0960,RB89 –19–29MAR99–2/3

X98

11–U

N–2

3AU

G88


If an accident occurs, see a doctor immediately.Any fluid injected into the skin must besurgically removed within a few hours organgrene may result. Doctors unfamiliar withthis type of injury should reference aknowledgeable medical source. Suchinformation is available from Deere & CompanyMedical Department in Moline, Illinois, U.S.A.

2. Turn steering wheel back and forth to release hydraulicpressure in the system.

3. Disconnect lines from cylinder. Close all openingsusing caps and plugs.

CAUTION: The approximate weight of thesteering cylinder is 65 kg (143 lb).

Steering Cylinder—SpecificationSteering Cylinder—Weight 65 kg (143 lb) approximate..............................

4. Remove pin from rod and head end of cylinder.

5. Remove cylinder from machine.

6. Install cylinder and connect lines.

7. Install washers between steering cylinder rod end andloader frame with maximum number of washers. Dividewashers above and below rod end so the cylinder doesnot bind.

8. Fill gap under rod end with spacers, then install oneadditional spacer. Fill gap over rod end with spacers.Install rod end pin.


PN=290


Hydraulic System

TX,0960,RB89 –19–29MAR99–3/3

IMPORTANT: When a machine is started for the firsttime after cylinder rebuild or oil isdrained from cylinder, the LoaderStart-Up Procedure must be performedto prevent oil from “dieseling” insidethe cylinder.

9. Perform Loader Start-Up Procedure (SteeringCylinder). (See procedure in this group.)

09096011

CED,OUOE024,236 –19–23SEP98–1/1

Loader Start-Up Procedure (SteeringCylinder)

IMPORTANT: System pressure must be reduced whenperforming this procedure. Adjust theLS valve to decrease system pressure.Turning the LS valve counterclockwisedecreases system pressure.

1. Remove loader frame access cover.

2. Loosen lock nut on LS valve. Turn LS valvecounterclockwise 2.5 complete turns. This willdecrease system pressure to approximately 8274—8963 kPa (82.74—89.63 bar) (1200—1300 psi).

IMPORTANT: Perform procedure with engine at lowidle (no acceleration.)

3. Slowly articulate the loader 3/4 turn to the right andthen 3/4 turn to the left. Do not make contact at loaderframe stops.

4. Repeat previous step four times.

5. Articulate the loader fully to the right and then fully tothe left. Repeat four times.

6. Reset system pressure by turning LS valve clockwise2.5 turns. Check pressures. See Group 9025-25.

7. Install loader frame access cover.


PN=291

Hydraulic System

OUT3019,000009A –19–19AUG03–1/1

Disassemble and Assemble SteeringCylinder

See Disassemble Cylinder in TMH120A. (Group 01.) SeeAssemble Cylinder in TMH120A. (Group 01.)

TX,0960,RB91 –19–23SEP98–1/1

Remove and Install Steering CylinderBushings

T90

813

–UN

–09N

OV

88

090960

12

A—Bushing

Remove and install bushing (A) using disks from driverset.


PN=292

Section 10Service Brakes

Contents

Page

Group 1011—Active ElementsService Equipment and Tools . . . . . . . . . . . .10-1011-1Specifications . . . . . . . . . . . . . . . . . . . . . . . .10-1011-1Inspect External Service Brakes . . . . . . . . . .10-1011-1Remove and Install Brake Assembly . . . . . . .10-1011-3

Group 1060—Hydraulic SystemBrake Valve

Remove and Install . . . . . . . . . . . . . . . . . .10-1060-1Brake Accumulator


10


PN=1

Contents

10


PN=2

Group 1011Active Elements

CED,OUOE003,3350 –19–29MAR99–1/2




CED,OUOE003,3350 –19–29MAR99–2/2

Feeler Gauge

Used to measure thickness of brake disks.

CED,OUOE003,3352 –19–29MAR99–1/1

Specifications


Brake Disk Thickness 2.92 mm (0.114 in.) newThickness 2.29 mm (0.090 in.) minimum used

Brake Separator Plate Thickness 3.05 mm (0.120 in.) new

1010111

TX,1011,JC2024 –19–23SEP98–1/3

Inspect External Service Brakes

Do first inspection at 5000 hours followed by 1000 hoursinspection intervals after the first 5000 hours inspection.

If the service brakes are subjected to severe duty, inspectmore frequently.

1. Remove plug from brake inspection port.

2. Start engine and run for one minute.

3. Stop and apply the brakes. Block pedal or havesomeone hold brakes on.


PN=295


Active Elements

TX,1011,JC2024 –19–23SEP98–2/3

T10

5193

B–U

N–0

2NO

V98

T10

5767

B–U

N–2

5FE

B97

101011

2

A—Feeler GaugeB—Disk Dimension

4. Using a feeler gauge (A), measure the thickness ofdisks at dimension (B). Check dimension of twodifferent disks.

SpecificationBrake Disk—Thickness 2.92 mm (0.114 in.) new.......................................Thickness 2.29 mm (0.090 in.)

minimum used....................................................................

TX,1011,JC2024 –19–23SEP98–3/3

T10

6873

–19–

12F

EB

97

5. If either of the disks thickness at dimension (B) is lessthan the minimum specification, the brake packs mustbe replaced.


PN=296

Active Elements

TX,1011,JC2282 –19–16FEB99–1/3

Remove and Install Brake Assembly

RW

3611

9–U

N–0

2JA

N97

A—Brake PistonB—Retaining Slot (6 used)

1. Remove differential and axle assembly. (See Group0225.)

2. Remove final drive assemblies and brake packs. (SeeGroup 0250.)

NOTE: A rolling head pry bar may be used to remove thepiston.

3. Remove brake piston (A) from case/cover usingcompressed air at the brake pressure inlet.

4. Inspect six separator plate retaining slots (B). Checkthe slots for galling or wear that might restrict themovement of the separator plates. Smooth the slotsusing a file or grinder. If there is too much wear,replace the differential case.

1010113

TX,1011,JC2282 –19–16FEB99–2/3

RW

3612

0–U

N–0

8JA

N97

A—Brake PistonB—OD Packing RingC—ID Packing RingD—Brake Separator Plates (6 used)E—Brake Disks (4 used)F—Planetary Carrier Brake Disk Splines

5. Inspect brake piston (A).

6. Remove and replace packing rings (B) and (C).

7. Replace piston as necessary.

8. Inspect parts (D) and (E). Check the tabs on theseparator plates for distortion or wear that mightrestrict there movement. Smooth the tabs using a fileor grinder or replace the plates.

SpecificationBrake Disk—Thickness 2.92 mm (0.114 in.) new.......................................Brake Separator Plate—Thickness 3.05 mm (0.120 in.) new.............................................................

9. Inspect the brake disk splines (F) on the planetarycarrier.



PN=297


Active Elements

TX,1011,JC2282 –19–16FEB99–3/3

RW

3615

0–U

N–0

8JA

N97

A—Brake Piston

11. Install brake piston (A) into differential case pistonbore.

12. Install final drive assemblies. (See Group 0250.)

13. Install differential and axle assembly. (See Group0225.)

101011

4


PN=298


TX,1060,JC2284 –19–16FEB99–1/3

Remove and Install Brake Valve

T10

3102

–UN

–14J

AN

97

1010601



PN=299

Hydraulic System

101060

2

TX,1060,JC2284 –19–16FEB99–2/3

X98

11–U

N–2

3AU

G88


If an accident occurs, see a doctor immediately.Any fluid injected into the skin must besurgically removed within a few hours organgrene may result. Doctors unfamiliar withthis type of injury may call the Deere &Company Medical Department in Moline, Illinois,or other knowledgeable medical source.

1. Stop engine.

2. Lower boom to ground, push pilot enable switch toboom down position and hold control lever in floatposition.



4. With machine OFF apply brakes approximately 30times to discharge both brake accumulators.


PN=300


Hydraulic System

TX,1060,JC2284 –19–16FEB99–3/3

T11

2343

B–U

N–2

1NO

V97

A—Return Hose

5. Remove shielding trim on front and right side of cab foraccess.

6. Remove clamp and return hose from brake valve.

7. Pinch off return hose (A) with vise grip to stop reservoirhydraulic oil from draining back.

8. Disconnect hoses and electric connectors.

9. Remove cap screws and brake valve.


11. Install brake valve.

12. Connect hoses and electric connectors.

13. Check for slight clearance between brake valveplunger and roller spinning freely on brake pedal.

1010603


PN=301

Hydraulic System

101060

4

TX,10,JC2344 –19–16FEB99–1/2

Remove and Install Brake Accumulator

CAUTION: Oil pressure must be released frombrake accumulator before disconnecting linesor removing fittings. Accumulator inlet checkvalve seat is the inlet fitting. Removingaccumulator inlet fitting will release oil pressurecausing possible injury.

1. Stop engine.

2. Lower bucket to ground. With bucket level, push pilotenable switch to boom down position and hold controllever in float position.



4. With machine OFF apply brakes approximately 30times to discharge both brake accumulators.



PN=302

Hydraulic System

TX,10,JC2344 –19–16FEB99–2/2

T15

8950

–UN

–28A

UG

02

A—Accumulator-to-Brake Valve LineB—Brake/PRV AccumulatorC—Cap Screw (2 used)D—Brake AccumulatorE—Brake/PRV Accumulator-to-Main Hydraulic

PumpF—Brake/PRV Accumulator-to-Pressure Reducing

ValveG—Brake/PRV Accumulator-to-Brake AccumulatorH—Check Valve



5. Slowly loosen connections and disconnect lines (A, E,F, and G).

6. Remove cap screws (C). Remove accumulators (B andD).


NOTE: Accumulator is not repairable. New accumulator isalready charged. Attach new decal.

NOTE: Check Valve (H) may be an adapter on olderunits. Sub check valve for adapter.

8. Install accumulators and connect lines.

1010605


PN=303

Hydraulic System

101060

6


PN=304

Section 11Park Brake

Contents

Page

Group 1111—Active ElementsOther Material . . . . . . . . . . . . . . . . . . . . . . . .11-1111-1Specifications . . . . . . . . . . . . . . . . . . . . . . . .11-1111-1Park Brake

Remove and Install . . . . . . . . . . . . . . . . . .11-1111-2Disassemble and Assemble. . . . . . . . . . . .11-1111-6

Group 1160—Hydraulic SystemSpecifications . . . . . . . . . . . . . . . . . . . . . . . .11-1160-1Park Brake

Remove and Install Release SolenoidValve . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1160-2

Remove and Install Pressure Switch . . . . .11-1160-4

11


PN=1

Contents

11


PN=2

Group 1111Active Elements

CED,OUOE003,3353 –19–29MAR99–1/1

Other Material

Number Name Use

PT569 (U.S.) NEVER-SEEZ Lubricant Apply to park brake shaft.


CED,OUOE003,3354 –19–29MAR99–1/1

Specifications


Park Brake Assembly Weight 43 kg (95 lb) approximate

Park Brake Mounting Cap Screw Torque 350 N•m (255 lb-ft)

Drive Shaft Cap Screw Torque 78 N•m (58 lb-ft)

Park Brake Housing Cap Screw Torque 122 N•m (90 lb-ft)

Park Brake Yoke Nut Torque 407 N•m (300 lb-ft)

1111111


PN=307

Active Elements

TX,11,JC2356 –19–16FEB99–1/3

Remove and Install Park Brake

CAUTION: Prevent possible injury fromunexpected machine movement. Never rely onloader bucket to keep machine from moving.Machine can unexpectedly roll, resulting indeath or serious injury. Always block wheels tohold machine when working on park brake.

1. Park machine on level surface.


3. Lower bucket to ground.

4. Stop engine. This will engage park brake.

5. Place blocks in front and behind tires.


111111

2


PN=308

Active Elements

TX,11,JC2356 –19–16FEB99–2/3

X98

11–U

N–2

3AU

G88

T10

4177

–UN

–01O

CT

96

A—Front Drive ShaftB—Park BrakeC—Park Brake Hydraulic LineD—Articulation Drive ShaftE—Cap Screw (4 used)

CAUTION: Escaping fluid under pressure canpenetrate the skin causing serious injury. Avoidthe hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tightenall connections before applying pressure.Search for leaks with a piece of cardboard.Protect hands and body form high pressurefluids.


6. Remove park brake hydraulic line (C).

7. Remove drive shafts (A and D).

8. Remove mounting cap screws (E).

CAUTION: The approximate weight of the parkbrake assembly is 43 kg (95 lb).

SpecificationPark Brake Assembly—Weight 43 kg (95 lb) approximate.........................

9. Remove park brake (B).

1111113



PN=309

Active Elements

TX,11,JC2356 –19–16FEB99–3/3

T11

2115

C–U

N–0

3NO

V97

A—Oil Check and Fill PortB—Park Brake Shaft

IMPORTANT: Do not overfill park brake. Fill only toport (A). Capacity of the park brake is300 mL (10 oz).

10. Check park brake oil level at port (A) and add oil asnecessary in port. Allow oil to drain to bottom of levelplug before installing plug to prevent overfilling.

11. Install new park brake. Tighten mounting cap screws.

SpecificationPark Brake Mounting CapScrew—Torque 350 N•m (255 lb-ft)............................................................

12. Place NEVER-SEEZ Lubricant on park brake shaft(B).

13. Install universal yoke on park brake shaft such thatholes between front and rear yokes are in alignment.Install drive shafts.

IMPORTANT: DO NOT reuse drive shaft universaljoint cap screws. Replace cap screws toavoid machine damage.

14. Install new drive shaft universal joint cap screws.Tighten cap screws.

SpecificationDrive Shaft Cap Screw—Torque 78 N•m (58 lb-ft).....................................

15. Install park brake hydraulic line.

111111

4



PN=310

Active Elements

1111115


PN=311

Active Elements

111111

6

TX,11,JC2357 –19–16FEB99–1/7

Disassemble and Assemble Park Brake

TP

5559

9–U

N–0

9SE

P97


PN=312


Active Elements

TX,11,JC2357 –19–16FEB99–2/7

1—Brake 10—Washer 19—O-Ring (2 used) 27—Screw (6 used)2—Plate 11—Yoke 20—Spring (18 used) 28—Brake Disk (7 used)3—Gasket 12—Washer 21—Compression Spring (18 29—Separator Plate (7 used)4—Housing 13—Nut used) 30—Washer (4 used)5—Bearing (2 used) 14—Retainer 22—Pin (2 used) 31—Cap Screw (4 used)6—Bearing Cup 15—Seal (2 used) 23—Brake Disk 32—Yoke7—Bearing Cone 16—Seal (2 used) 24—Piston 33—Elbow Fitting8—Universal Drive Shaft 17—Fitting (2 used) 25—O-Ring 34—O-Ring9—Snap Ring 18—Relief Valve 26—O-Ring 35—O-Ring

1. Remove nut (13), washer (12), and yoke (11).

CAUTION: Cover and cap screws are underpressure. Remove cap screws evenly toavoid possible injury.

2. Remove cap screws (27) evenly.

3. Remove cover plate (2) from housing (4).

4. Remove shaft with brake disks (28) and separatorplates (29).

5. Remove brake disk (23) from housing.

6. Remove springs (20), compression springs (21),and spring retainer (14).

7. Remove seals (15 and 16) from housing.

8. Remove bearing cup (6).

9. Remove piston (24) from cover plate.

10. Remove O-rings (25 and 26) from piston.

11. Remove seals (15 and 16) and bearing cup (6)from cover plate.

1111117

TX,11,JC2357 –19–16FEB99–3/7

T10

1612

–UN

–03O

CT

96

12. Remove bearing cone (7) using a bearing puller fromone end of shaft.

13. Remove bearing, disks, and plates from shaft.

14. Press other bearing off shaft.


16. Press bearing cup (6) against shoulder in cover plate.

17. Lubricate O-rings (25 and 26) and piston (24) withJ20C oil. Install inner and outer O-rings on piston.


PN=313


Active Elements

111111

8

TX,11,JC2357 –19–16FEB99–4/7

T10

1611

–UN

–03O

CT

96

A—Piston

18. Install piston (A) in cover so that dowel pins arecentered between slots.

19. Press bearing cup (6) against shoulder in housing.

20. Install spring retainer (14), springs (20), andcompression springs (21).

21. Remove dowel pins (22) from cover plate and installin housing.

22. Install brake disk (23).

23. Install bearing cone (7) on shaft end with long spline.

24. Dip brake disks and separator plates in J20C oil.Install brake disk (28) then alternate betweenseparator plate (29) and brake disk ending with aseparator plate on top.

25. Install bearing cone (7) against shoulder.

26. Insert shaft with brake disks and separator plates withlong spline end first into housing. Align separatorplates on dower pins.

27. Install two M12 aligning studs into housing.

28. Install gasket (3) on cover plate.

29. Install cover making sure dowel pins align in coveronto housing using cap screws.

30. Tighten cap screws (27) evenly.

SpecificationPark Brake Housing Cap Screw—Torque 122 N•m (90 lb-ft)...........................................................................

NOTE: Bearing and race are a select pair to create ashaft end play of 0.051—0.305 mm (0.002—0.012in.).

31. Install seals (15 and 16) against shoulder in housing.

32. Install seals (15 and 16) against shoulder in coverplate.


PN=314


Active Elements

TX,11,JC2357 –19–16FEB99–5/7

33. Install snap ring (9) and snap ring retainer (10) onuniversal drive shaft (8).

34. Place NEVER-SEEZ Lubricant on shaft splines.

35. Install yoke (11), washer (12), and nut (13). Tightennut.

SpecificationPark Brake Yoke Nut—Torque 407 N•m (300 lb-ft)...................................


1111119

TX,11,JC2357 –19–16FEB99–6/7

T11

2115

B–U

N–0

3NO

V97

A—Fill PlugB—Drain Plug

IMPORTANT: Do not overfill park brake. Fill only toport (A). Capacity of the bark brake is300 mL (10 oz).

36. Fill park brake at port (A) with 300 mL (10 oz) of oil.Allow oil to drain to bottom of level plug beforeinstalling plug to prevent overfilling.

37. Bench test the park brake.

38. Install a porta-power to the park brake.

39. Slowly increase pressure until the shaft rotates freely.Acceptable range is 896—1068 kPa (8.9—10.6 bar)(130—155 psi).

40. Increase the pressure to 3450 kPa (34.5 bar) 500 psi.

41. Slowly release brake pressure until free rotation of theshaft stops. Acceptable range is not more than 210kPa (2.1 bar) (30 psi) less than the release pressure.


PN=315


Active Elements

TX,11,JC2357 –19–16FEB99–7/7

T11

2153

–UN

–06N

OV

97

42. Align yokes of park brake.

NOTE: Replace all drive line hardware when ever driveline is disassembled.

111111

10


PN=316


CED,OUOE003,3355 –19–29MAR99–1/1

Specifications


Park Brake Release Solenoid Valve Torque 7 N•m (62 lb-in.)Nut

1111601


PN=317

Hydraulic System

TX,1160,RB184 –19–23SEP98–1/2

Remove and Install Park Brake ReleaseSolenoid Valve

X98

11–U

N–2

3AU

G88

T10

3614

C–U

N–0

6SE

P96

111160

2

A—Electrical ConnectorB—Solenoid




2. Disconnect electrical connector (A).



PN=318

Hydraulic System

TX,1160,RB184 –19–23SEP98–2/2

T77

51LI

–UN

–09N

OV

92

C—NutD—WasherE—CoverF—ValveG—O-RingH—Backup RingI—O-RingJ—O-RingK—Backup Ring






SpecificationPark Brake Release SolenoidValve Nut—Torque 7 N•m (62 lb-in.)...........................................................


1111603


PN=319

Hydraulic System

TX,1160,RB185 –19–12OCT98–1/1

Remove and Install Park Brake PressureSwitch

X98

11–U

N–2

3AU

G88

T10

3614

B–U

N–0

6SE

P96

111160

4

A—Electrical ConnectorB—Pressure Switch




2. Disconnect electrical connector (A).

3. Remove switch (B).


5. Install switch. Connect electrical connector.


PN=320

Section 1616Electrical System

Contents

Page Page

Group 1671—Batteries, Support and Cables Transmission Control Valve ConnectorService Equipment and Tools . . . . . . . . . . . .16-1671-1 ContactSpecifications . . . . . . . . . . . . . . . . . . . . . . . .16-1671-2 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-9Battery Amp Crimper Tool

Service Carefully . . . . . . . . . . . . . . . . . . . .16-1671-3 Operation. . . . . . . . . . . . . . . . . . . . . . . . .16-1674-11Check Electrolyte Level and Terminals . . .16-1671-5 Remove and Install Die Set . . . . . . . . . . .16-1674-12Charging Procedure. . . . . . . . . . . . . . . . . .16-1671-7 Contact Support Adjustment . . . . . . . . . .16-1674-14Using Booster—24 Volt System. . . . . . . . .16-1671-8 Crimping Procedure . . . . . . . . . . . . . . . . .16-1674-15Procedure for Testing . . . . . . . . . . . . . . . .16-1671-9 Crimp Height Inspection. . . . . . . . . . . . . .16-1674-17Remove and Install . . . . . . . . . . . . . . . . .16-1671-10 Crimp Height Adjustment . . . . . . . . . . . . .16-1674-18Remove and Install Disconnect Switch . .16-1671-11 Connector Terminals

Replace Transmission Controller Unit . . .16-1674-19Group 1672—Alternator, Regulator and Charging Chassis Computer Unit Connector Terminals

System Wiring Replace . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-20Bosch Alternator Install CINCH Contact . . . . . . . . . . . . . . .16-1674-23

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1672-1 Remove Connector Body from BladeAlternator Terminals. . . . . . . . . . . . . . . . . . . . . . . . .16-1674-24

Remove and Install . . . . . . . . . . . . . . . . . .16-1672-1 Blade TerminalsRegulator Remove From Fuse Block . . . . . . . . . . . .16-1674-24

Remove and Install . . . . . . . . . . . . . . . . . .16-1672-4 Boom Height Kickout Adjustment . . . . . . . .16-1674-25Return-to-Carry Kickout Adjustment . . . . . .16-1674-26Return-to-Dig Adjustment . . . . . . . . . . . . . .16-1674-27Group 1673—Lighting System

Halogen BulbsGroup 1675—System ControlsReplace . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1673-1Transmission Control Unit (TCU)Work Lights

Remove and Install . . . . . . . . . . . . . . . . . .16-1675-1Remove and Install . . . . . . . . . . . . . . . . . .16-1673-3Chassis Computer Unit (CCU)Front Turn Lights

Remove and Install . . . . . . . . . . . . . . . . . .16-1675-3Remove and Install . . . . . . . . . . . . . . . . . .16-1673-5Monitor Display UnitStop, Turn and Tail Light

Remove and Install . . . . . . . . . . . . . . . . . .16-1675-5Remove and Install . . . . . . . . . . . . . . . . . .16-1673-5Drive Lights and Guard

Group 1677—Motors and ActuatorsRemove and Install . . . . . . . . . . . . . . . . . .16-1673-6John Deere Starting Motor Repair . . . . . . . . .16-1677-1Dome Light and Door Light SwitchSpecifications . . . . . . . . . . . . . . . . . . . . . . . .16-1677-1Remove and Install . . . . . . . . . . . . . . . . . .16-1673-7Starting Motor

Remove and Install . . . . . . . . . . . . . . . . . .16-1677-1Group 1674—Wiring Harness and SwitchesEssential Tools . . . . . . . . . . . . . . . . . . . . . . .16-1674-1Other Material . . . . . . . . . . . . . . . . . . . . . . . .16-1674-3Specifications . . . . . . . . . . . . . . . . . . . . . . . .16-1674-3Replace METRI-PACK Connectors. . . . . . .16-1674-4Install DEUTSCH Contact. . . . . . . . . . . . . .16-1674-5Replace DEUTSCH Connectors . . . . . . . . .16-1674-6Replace WEATHER PACKConnector . . . . .16-1674-7Install WEATHER PACKContact. . . . . . . . .16-1674-8Transmission Control Valve Connector Body



PN=1

Contents

16


PN=2

Group 1671Batteries, Support and Cables

1616711

CED,OUOE003,3357 –19–29MAR99–1/5




CED,OUOE003,3357 –19–29MAR99–2/5

Battery Post/Clamp Cleaner . . . . . . . . . . . . . . JT05838

To clean corrosion off battery posts and clamps.

CED,OUOE003,3357 –19–29MAR99–3/5

Coolant and Battery Tester . . . . . . . . . . . . . . . JT05460

To check battery electrolyte specific gravity.

CED,OUOE003,3357 –19–29MAR99–4/5

Hydrometer

Used to measure specific gravity of battery electrolyte.

CED,OUOE003,3357 –19–29MAR99–5/5

Battery Load Tester . . . . . . . . . . . . . . . . . . . . JT05832

To check battery capacity.


PN=323

Batteries, Support and Cables

161671

2

TX,9015,MM3057 –19–04SEP96–1/1

Specifications

SpecificationStandard Battery—Voltage 12 Volts............................................................Cold Cranking Power 625 amps at -18°C (0°F).........................................Reserve Capacity 160 minutes at 25 amps................................................BCI Group Size 30H....................................................................................Electrolyte Specific Gravity 1.265—1.280 fully charged..............................Heavy Duty Battery—Voltage 12 Volts........................................................Cold Cranking Power 950 amps at -18°C (0°F).........................................Reserve Capacity 190 minutes at 25 amps................................................BCI Group Size 31......................................................................................Electrolyte Specific Gravity 1.265—1.280 fully charged..............................


PN=324


1616713

TX,1671,MM3121 –19–08OCT96–1/2

Service Batteries Carefully

TS

204

–UN

–23A

UG

88T

S20

3–U

N–2

3AU

G88



PN=325


161671

4

TX,1671,MM3121 –19–08OCT96–2/2

CAUTION: Battery gas can explode. Keepsparks and flames away from batteries. Use aflashlight to check battery electrolyte level.

Never check battery charge by placing a metalobject across the posts. Use a voltmeter orhydrometer.

Always remove grounded (-) battery clamp firstand replace it last.

Sulfuric acid in battery electrolyte is poisonous.It is strong enough to burn skin, eat holes inclothing, and cause blindness if splashed intoeyes.


1. Filling batteries in a well-ventilated area.2. Wearing eye protection and rubber gloves.3. Avoiding breathing fumes when electrolyte is

added.4. Avoiding spilling or dripping electrolyte.5. Use proper jump start procedure.


1. Flush your skin with water.2. Apply baking soda or lime to help neutralize

the acid.3. Flush your eyes with water for 10—15

minutes. Get medical attention immediately.


1. Drink large amounts of water or milk.2. Then drink milk of magnesia, beaten eggs, or

vegetable oil.3. Get medical attention immediately.

IMPORTANT: Electrolyte can damage paint and metalsurfaces of your machine. Do notoverfill the battery cells.

If electrolyte spills on the floor, use one of the followingmixtures to neutralize the acid: 0.5 kg (1 lb) baking sodain 4 L (1 gal) water, or 0.47 L (1 pt) household ammoniain 4 L (1 gal) water.


PN=326


1616715

TX,9015,MM3060 –19–04SEP96–1/2

Check Battery Electrolyte Level andTerminals

TS

203

–UN

–23A

UG

88

CAUTION: Battery gas can explode. Keepsparks and flames away from batteries. Use aflashlight to check battery electrolyte level.


Always remove grounded (-) battery clamp firstand replace it last.

Sulfuric acid in battery electrolyte is poisonous.It is strong enough to burn skin, eat holes inclothing, and cause blindness if splashed intoeyes.


1. Filling batteries in a well-ventilated area.2. Wearing eye protection and rubber gloves.3. Avoiding breathing fumes when electrolyte is

added.4. Avoiding spilling or dripping electrolyte.5. Use proper jump start procedure.


1. Flush your skin with water.2. Apply baking soda or lime to help neutralize

the acid.3. Flush your eyes with water for 10—15

minutes. Get medical attention immediately.


1. Drink large amounts of water or milk.2. Then drink milk of magnesia, beaten eggs, or

vegetable oil.3. Get medical attention immediately.

1. Remove hold-down clamps.

2. Remove battery covers.


PN=327



161671

6

TX,9015,MM3060 –19–04SEP96–2/2

T69

96D

B–U

N–0

9SE

P03

Single Level Fill Tube Application

T69

96D

A–U

N–0

9SE

P03

Dual Level Fill Tube Application

A—Battery PostB—Fill TubeC—Electrolyte Level Range

IMPORTANT: During freezing weather, batteries mustbe charged after water is added toprevent battery freezing. Charge batteryusing a battery charger or by runningthe engine.

3. Fill each cell to within specified range with distilledwater. DO NOT overfill.


PN=328


1616717

TX,1671,MM3122 –19–08OCT96–1/1

Battery Charging Procedure

TS

204

–UN

–23A

UG

88

CAUTION: Prevent possible personal injuryfrom exploding battery. A battery may explodeif charged when it is frozen. Warm battery to16°C (60°F) before charging.

Battery gas can explode. Keep sparks andflames away from batteries. Use a flashlight tocheck battery electrolyte level.


IMPORTANT: Do not use battery charger as a boosterif a battery has 1.150 gravity reading orlower. Turn off charger beforeconnecting or disconnecting it.

When charging a battery in unit, allcables must be disconnected to avoiddamaging electrical components ifbattery charger cables are inadvertentlyconnected to battery wrong.

NOTE: Batteries CANNOT be charged with battery cablesconnected. Each battery must chargedindividually. Voltage in both batteries must beequal. Alternator WILL NOT charge a single lowbattery.

1. Disconnect all battery cables starting at the negative (-)ground cable.

2. Turn charger off before connecting or disconnecting it.

3. Charge battery following manufacturer’s instructions forthe battery charger.

4. After battery is charged, connect the cables, thenegative (-) ground cable last.


PN=329


161671

8

TX,9015,MM3062 –19–01AUG96–1/2

Using Booster Batteries—24 Volt System

T67

13A

H1

–UN

–24O

CT

91A—Machine BatteriesB—Booster Batteries

Before boost starting, machine must be properly shutdown and secured to prevent unexpected machinemovement when engine starts.

CAUTION: An explosive gas is produced whilebatteries are in use or being charged. Keepflames or sparks away from the battery area.Make sure the batteries are in a well ventilatedarea.

IMPORTANT: The machine electrical system is a 24volt negative (-) ground. Connect two 12volt booster batteries together asshown for 24 volts.

Make last booster cable connection to frame.

TX,9015,MM3062 –19–01AUG96–2/2

TS

177

–UN

–11J

AN

89

CAUTION: Avoid possible injury or death frommachinery runaway.

Do not start engine by shorting across starterterminals. Machine will start in gear if normalcircuitry is bypassed.

NEVER start engine while standing on ground.Start engine only from operator’s seat, withtransmission in neutral or park.

Start engine while seated on operator’s seat.

After engine starts, disconnect clamp at machine framefirst and then disconnect remaining clamps.


PN=330


1616719

TX,9015,MM3061 –19–13OCT98–1/1

Procedure for Testing Batteries

IMPORTANT: If either battery is damaged or won’thold a charge, both batteries mustbe replaced.

Visual Check

1. Check for damage such as cracked or broken caseand electrolyte leakage.

If damage is seen, replace battery.

2. Check electrolyte level. (See procedure in thisgroup)

If low, add distilled water to specified level andcharge battery.

3. Check terminals for corrosion.

If corroded, clean using a wire brush or battery postcleaner such as JT05838 Battery Post/ClampCleaner.

4. Check posts for looseness.

If posts are loose in one battery, replace BOTHbatteries.

Hydrometer Test

1. Check specific gravity with a hydrometer or batterytester such as JT05460 Coolant/Battery Tester.

2. Record specific gravity reading for each cell.

If high and low readings vary LESS than 0.050 andaverage specific gravity is between 1.225 and1.280, battery is fully charged, go to LOAD TEST.

If high and low readings vary LESS than 0.050 andaverage specific gravity is LESS than 1.225, chargebattery and repeat test. If average specific gravity isstill LESS than 1.225, replace BOTH batteries.

If high and low readings vary MORE than 0.050,charge battery and repeat test. If high and lowreadings still vary MORE than 0.050, replace BOTHbatteries.

Load Test

1. Check battery capacity with a load tester such asJT05832 Battery Load Tester. Follow testermanufacturer’s instructions for proper load testprocedures.

2. If one battery fails load test, replace BOTHbatteries.


PN=331


161671

10

TX,1671,1111028 –19–29MAR99–1/1

Remove and Install Batteries

TP

5554

9–U

N–1

4JU

L97

1—Cable 6—Clamp (4 used) 10—Lock Nut (4 used) 14—Tie Band (As Required)2—Cable 7—Cover 11—Screw (2 used) 15—Tie Band3—Cable 8—Angle (2 used) 12—Washer (4 used) 16—Washer4—Cover (3 used) 9—Hook Bolt (4 used) 13—Ground Cable 17—Nut5—Battery (2 used)

• Disconnect negative (-) battery cables first, thenpositive cables.

• Check cables and clamps. Clean battery and batteryposts.

• Apply grease to bottom side of positive cableeyelets.

• Connect positive cables, then negative cables.


PN=332


16167111

TX,16,1111110 –19–29MAR99–1/1

Remove and Install Battery Disconnect Switch

TP

4865

3–U

N–0

3MA

R97

1—Handle 4—Switch 7—Cable 9—Cap Screw2—Nut 5—Bracket 8—Washer 10—Washer (2 used)3—Washer 6—Label


PN=333


161671

12


PN=334

Group 1672Alternator, Regulator and Charging System Wiring

1616721

TX,1672,MM3124 –19–09OCT96–1/1

Bosch Alternator Repair—Use CTM77

TS

225

–UN

–17J

AN

89

For complete repair information the component technicalmanual (CTM) is also required.

Use the CTM in conjunction with this machine manual.

TX,1672,RB100 –19–13OCT98–1/3

Remove and Install Alternator

TP

4860

0–U

N–1

3JA

N97

55 Amp Bosch Alternator

1—Capacitor 6—Alternator 10—Flange Nut 14—Belt2—Nut 7—Regulator 11—Cover 15—Bushing3—Washer 8—Flange Nut 12—Grommet 16—Screw4—Pulley 9—Lock Washer 13—Flange Nut 17—Idler5—Fan



PN=335

Alternator, Regulator and Charging System Wiring

161672

2

TX,1672,RB100 –19–13OCT98–2/3

TP

4860

1–U

N–1

3JA

N97

80 Amp Bosch Alternator Shown

1—Pulley 5—Nut 9—Grommet 13—Belt2—Alternator 6—Regulator 10—Flange Nut (4 used) 14—Screw3—Nut 7—Nut 11—Washer (2 used) 15—Idler4—Lock Washer 8—Screen 12—Fan

IMPORTANT: Disconnect battery ground cable toprevent accidental grounding ofalternator wiring leads.

1. Disconnect battery ground cable.

2. Disconnect wiring leads to alternator.

3. Remove mounting cap screws and belt.




PN=336


1616723

TX,1672,RB100 –19–13OCT98–3/3

T10

4350

–19–

22O

CT

96

5. Install alternator. Connect wiring leads.

Alternator belt tension is controlled by an automatictensioner.


PN=337


161672

4

CED,OUOE024,243 –19–29SEP98–1/2

Remove and Install Regulator

T10

9936

B–U

N–1

1JU

N97

T10

9938

B–U

N–1

1JU

N97

A—Wire LeadB—RegulatorC—Insulation

1. Remove old regulator (B) and cut wire lead (A) at base(at the soldered connection) and discard regulator andwire lead.

2. Scrape off insulation (C) from spring terminal.

CED,OUOE024,243 –19–29SEP98–2/2

T10

9939

B–U

N–1

1JU

N97

A—Regulator

3. Install new regulator (A) so regulator contact istouching spring terminal that was scraped of insulation.


PN=338

Group 1673Lighting System

1616731

T52,1673,C10 –19–17FEB99–1/2

Replace Halogen Bulbs

T58

94A

G1

–UN

–17A

PR

89

IMPORTANT: To get the correct lighting pattern, lensmust be installed so the word "TOP" ison top when lamp is installed onmachine. Bezel must be installed sowider section is on top when lamp isinstalled.

1. Before disassembling, take notice of how bezel andlens are installed with respect to mounting stud.

2. Remove four screws to remove bezel and lens.



PN=339

Lighting System

161673

2

T52,1673,C10 –19–17FEB99–2/2

T58

94A

I1–U

N–2

0OC

T88

T62

49A

U–U

N–1

9OC

T88

A—Flange NutB—Lock WasherC—HousingD—BulbE—GasketF—LensG—BezelH—Screw (4 used)

3. Disconnect wiring lead and release retainer clip toremove bulb (D).

To disconnect ground wiring lead, push tab up thenpull connector from terminal.

IMPORTANT: Do not touch the halogen bulb withbare hands. Oil and moisture maycause premature bulb failure. If bulbglass is touched, clean using a soft,oil-free cloth and alcohol.

4. Install new bulb so square notch is aligned with squaretab on reflector back.

5. Install retainer clip into locking tabs on reflector back.

6. Connect wiring leads. Check that wiring leads are freeof clip.

7. Install the gasket (E) into housing (C).

8. Install lens (F) into housing so the word "TOP" is ontop when lamp is installed on machine.

Check that wiring leads are not crimped.

9. Install bezel (G) so wider section is on top. Sealingflange must be inside housing on all four sides beforetightening screws.

10. Tighten screws (H) alternately. Do not overtighten asscrews may strip out plastic.


PN=340

Lighting System

1616733

TX,1673,MM3127 –19–17FEB99–1/2

Remove and Install Work Lights

TP

4831

1–U

N–0

8AU

G96

Front and Rear Work Lights

1—Screw 2—Washer 3—Light 4—Grommet



PN=341

Lighting System

161673

4

TX,1673,MM3127 –19–17FEB99–2/2

TP

4830

8–U

N–2

8MA

R96

Front Drive and Turn Light Guards

1—Bracket 3—Lock Nut 5—Rubber Mount 6—Screw2—Grommet 4—Washer (2 used)

IMPORTANT: Rubber isolators must be installedbetween light guard and loader

frame or failure of halogen lights canoccur.


PN=342

Lighting System

1616735

TX,1673,MM3128 –19–17FEB99–1/1

Remove and Install Front Turn Lights

TP

4830

9–U

N–0

1AP

R96

1—Lamp 2—Bulb, Turn 3—Bulb, Marker

TX,1673,RP3007 –19–17FEB99–1/1

Remove and Install Stop, Turn and Tail Light

TP

3538

5–U

N–1

9MA

R96

1—Stop Light 3—Bulb, Brake and Tail 5—Lens, Red 7—Flange Nut (2 used)2—Gasket 4—Bulb, Turn Signal 6—Lens, Amber


PN=343

Lighting System

161673

6

TX,1673,1111032 –19–17FEB99–1/1

Remove and Install Drive Lights and Guard

TP

5546

0–U

N–1

4AP

R97

1—Flange Nut (2 used) 3—Support (2 used) 6—Washer, 10.5 x 30 x 2.5 mm 7—Clip (4 used)2—Washer, 13 x 25 x 3 mm (2 4—Side Light (2 used) (6 used) 8—Lock Nut (6 used)

used) 5—Screw, M10 x 50 (6 used)


PN=344

Lighting System

1616737

TX,1673,1111033 –19–17FEB99–1/1

Remove and Install Dome Light and Door Light Switch

TP

4846

6–U

N–1

4SE

P96

1—Housing 3—Lens 5—Light 6—Screw (2 used)2—Bulb 4—Rocker Switch


PN=345

Lighting System

161673

8


PN=346

Group 1674Wiring Harness and Switches

1616741

CED,OUOE003,3358 –19–30MAR99–1/11

Essential Tools



CED,OUOE003,3358 –19–30MAR99–2/11

T85

16A

A–U

N–3

0JU

N95

Metri-Pack Extractor Tool . . . . . . . . . . . . . . . . JDG939

Used to remove contacts from Metri-Pack electricalconnectors.

CED,OUOE003,3358 –19–30MAR99–3/11

T6606AB –UN–23AUG88

DEUTSCH Electrical Repair Tool Kit . . . . . . . . JDG359

To repair DEUTSCH electrical connector bodies.

DEUTSCH is a trademark of the Deutsch Co.

CED,OUOE003,3358 –19–30MAR99–4/11

T6606AC –UN–23AUG88

WEATHER PACK Extraction Tool . . . . . . . . . JDG364

Used to replace terminal contact in WEATHER PACKconnector body.

WEATHER PACK is a trademark of Packard Electric.


PN=347


Wiring Harness and Switches

161674

2

CED,OUOE003,3358 –19–30MAR99–5/11

T104946 –UN–07NOV96

Electrical Repair Kit . . . . . . . . . . . . . . . . . . . JT07195A

Electrical repair kit includes the most commonly usedtools necessary to work on John Deere electrical wiringharness and connectors.

CED,OUOE003,3358 –19–30MAR99–6/11T

1004

73–U

N–0

5MA

R96

WEATHER PACK Crimping Tool . . . . . . . . . . JDG783

Use to crimp WEATHER PACK male and femaleconnectors. Tool crimps both connector and seal retainerat the same time.


CED,OUOE003,3358 –19–30MAR99–7/11

T104947 –UN–07NOV96

Metrimate Extractor Tool. . . . . . . . . . . . . . . . . JDG140

Used to remove pin and socket contacts from Metri-Pack,CPC and Kostal electrical connector housings.

CED,OUOE003,3358 –19–30MAR99–8/11

T105908 –UN–19DEC96

Packard Crimping Tool . . . . . . . . . . . . . . . . . . JDG707

Used to crimp open barrel contacts and seal retainers forKostal circular connectors.


PN=348



1616743

CED,OUOE003,3358 –19–30MAR99–9/11

T112340B –UN–24NOV97

Amp Extraction Tool . . . . . . . . . . . . . . . . . . JDG1177

Used to extract wires from the large terminals of the Amptransmission controller unit connector.

CED,OUOE003,3358 –19–30MAR99–10/11

T112340B –UN–24NOV97

Amp Extraction Tool . . . . . . . . . . . . . . . . . FKM10457

Used to extract wires from the small terminals of the Amptransmission controller unit connector.

CED,OUOE003,3358 –19–30MAR99–11/11

T112379 –UN–26NOV97

WEATHER PACK Narrow Extractor . . . . . . . . JDG777

Used to extract narrow pull-to-seat terminals from thechassis computer unit connectors.


CED,OUOE003,3360 –19–30MAR99–1/1

Other Material

Number Name Use

T43512 (U.S.) Thread Lock and Sealer (Medium Apply to threads of return-to-digTY9473 (Canadian) Strength) switch cap screws.242 (LOCTITE)


CED,OUOE003,3361 –19–30MAR99–1/1

Specifications


Boom Height Kickout Gap 5—8 mm (0.197— 0.315 in.)Switch-to-Adjustable Plate

Return-to-Dig Switch-to-Adjustable Gap 5—8 mm (0.197— 0.315 in.)Bar

Adjustable Bar Cap Screw Torque 121 N•m (89 lb-ft)


PN=349


161674

4

TX,1674,MM3188 –19–29SEP98–1/3

Replace METRI-PACK Connectors

T10

4764

B–U

N–0

1NO

V96

A—TabB—Screwdriver

1. A small locking tab is located inside of the Metri-Packconnector. Use a small screwdriver (B) to move tab (A)outward to the first detent position; the tab will “click.”

Metri-Pack is a trademark of Packard Electrical.

TX,1674,MM3188 –19–29SEP98–2/3

T10

4763

B–U

N–0

1NO

V96

A—WireB—Extractor Tool

2. Slide JDG939 Metri-Pack Extractor Tool (B) intoconnector body until it is positioned over terminalcontact.

3. Gently pull wire out of connector body.

IMPORTANT: Install contact in proper location usingcorrect size grommet.

4. Push contact straight into connector body until positivestop is felt.

5. Pull on wire slightly to be certain contact is locked inplace.

6. Transfer remaining wires to correct terminal in newconnector.

TX,1674,MM3188 –19–29SEP98–3/3

T10

4764

B–U

N–0

1NO

V96


7. Use a small screwdriver (B) to move tab (A) inward tothe first detent position; the tab will “click” and lock thewires in the connector body.


PN=350


1616745

DX,ECONN,W –19–04JUN90–1/4

Install DEUTSCH Contact

TS

117

–UN

–23A

UG

88

1. Strip 6 mm (1/4 in.) insulation from wire.

2. Adjust selector (A) on JDG360 Crimper for correct wiresize.

3. Loosen lock nut (B) and turn adjusting screw (C) inuntil it stops.



TS

0134

–UN

–23A

UG

88

IMPORTANT: Select proper size contact "sleeve" or"pin" to fit connector body.

4. Insert contact (A) and turn adjusting screw (D) untilcontact is flush with cover (B).

5. Tighten lock nut (C).

DX,ECONN,W –19–04JUN90–3/4T

S11

8–U

N–2

3AU

G88

IMPORTANT: Contact must remain centered betweenindentors while crimping.

6. Insert wire in contact and crimp until handle touchesstop.

7. Release handle and remove contact.


TS

0135

–UN

–23A

UG

88

IMPORTANT: If all wire strands are not crimped intocontact, cut off wire at contact andrepeat contact installation procedures.

NOTE: Readjust crimping tool for each crimpingprocedure.

8. Inspect contact to be certain all wires are in crimpedbarrel.


PN=351


161674

6

DX,ECONN,J –19–03NOV94–1/2

Replace DEUTSCH Connectors

TS

0124

–UN

–23A

UG

88T

S12

0–U

N–2

3AU

G88

1. Select correct size extractor tool for size of wire to beremoved:

• JDG361 Extractor Tool for 12 to 14 gauge wire.• JDG362 Extractor Tool for 16 to 18 gauge wire.• JDG363 Extractor Tool for 20 gauge wire.

2. Start correct size extractor tool over wire at handle (A).

3. Slide extractor tool rearward along wire until tool tipsnaps onto wire.

IMPORTANT: Do NOT twist tool when inserting inconnector.

4. Slide extractor tool along wire into connector body untilit is positioned over terminal contact.

5. Pull wire out of connector body, using extractor tool.


DX,ECONN,J –19–03NOV94–2/2

TS

122

–UN

–23A

UG

88






PN=352


1616747

DX,ECONN,O –19–03NOV94–1/2

Replace WEATHER PACKConnector

TS

0128

–UN

–23A

UG

88

IMPORTANT: Identify wire color locations withconnector terminal letters.

1. Open connector body.

2. Insert JDG364 Extraction Tool over terminal contact inconnector body.

3. Hold extractor tool fully seated and pull wire fromconnector body.

NOTE: If terminal cannot be removed, insert wire or nailthrough extractor tool handle and push terminalcontact from connector.


DX,ECONN,O –19–03NOV94–2/2

TS

0130

–UN

–23A

UG

88

IMPORTANT: Carefully spread contact lances toassure good seating on connectorbody.

NOTE: Connector bodies are "keyed" for proper contactmating. Be sure contacts are in proper alignment.

4. Push contact into new connector body until fullyseated.



7. Close connector body.


PN=353


161674

8

DX,ECONN,AA –19–04JUN90–1/2

Install WEATHER PACKContact

TS

0136

–UN

–23A

UG

88T

S16

23–U

N–0

2NO

V94

NOTE: Cable seals are color coded for three sizes ofwire:

• Green - 18 to 20 gauge wire• Gray - 14 to 16 gauge wire• Blue - 10 to 12 gauge wire

1. Slip correct size cable seal on wire.

2. Strip insulation from wire to expose 6 mm (1/4 in.) andalign cable seal with edge of insulation.

NOTE: Contacts have numbered identification for twosizes of wire: a) #15 for 14 to 16 gauge wire b)#19 for 18 to 20 gauge wire

3. Put proper size contact on wire and crimp in place witha "W" type crimp, using JDG783 Terminal Applicator.


DX,ECONN,AA –19–04JUN90–2/2

TS

0139

–UN

–02D

EC

88

IMPORTANT: Proper contact installation for "sleeve"(A) and "pin” (B) is shown.

4. Secure cable seal to contact as shown, using JDG783Terminal Applicator.

TX,16,RP3113 –19–13OCT98–1/3

Remove and Install Transmission ControlValve Connector Body

T10

4764

B–U

N–0

1NO

V96


1. A small locking tab is located inside of the connector.Use a small screwdriver (B) to move tab (A) outward tothe first detent position; the tab will “click.”


PN=354



1616749

TX,16,RP3113 –19–13OCT98–2/3

T10

4763

B–U

N–0

1NO

V96

A—WireB—JDG140 Metrimate Extractor Tool

2. Slide JDG140 Metrimate Extractor Tool (B) intoconnector body until it is positioned over terminalcontact.

3. Push on end of extractor tool (B) and gently pull wire(A) out of connector body.





TX,16,RP3113 –19–13OCT98–3/3

T10

4764

B–U

N–0

1NO

V96


7. Use a small screwdriver (B) to move tab (A) inward tothe first detent position; the tab will “click” and lock thewires in the connector body.

TX,16,RP3112 –19–29SEP98–1/2

Install Transmission Control Valve ConnectorContact

TS

0136

–UN

–23A

UG

88

1. Slip correct size cable seal on wire.

2. Strip insulation from wire to expose 6 mm (1/4 in.) andalign cable seal with edge of insulation.


PN=355



161674

10

TX,16,RP3112 –19–29SEP98–2/2

T10

5879

B–U

N–0

9JA

N97

A—Contact LocationB—Contact LocationC—Crimper LocationD—Crimper Location

3. Put contact on wire and insert into crimper at location(D) and crimp on contact at location (B) using JDG707crimping tool.

4. Secure cable seal to contact by crimping at location (A)on contact and crimp at location (C) on JDG707crimping tool.


PN=356


16167411

TX,16,1111102 –19–24NOV97–1/1

Amp Crimper Tool for Transmission Controller Unit Connector—Operation

T11

2326

–UN

–12J

UN

98

A—Stationary Jaw D—Frame G—Ratchet Adjustment Wheel J—Front of Tool (Locator Side)B—Back of Tool (Wire Side) E—Stationary Handle H—Moving Jaw K—Locator AssemblyC—Pivot Pin F—Moving Handle I—Die Assembly

The Amp Crimper Tool is used to crimp wires for thejunior timer contacts and the micro timer contacts ofthe transmission controller unit connector. The tool hasa frame with a stationary jaw and handle, a movingjaw, a moving handle and an adjustable ratchet thatensures full contact crimping. The tool frame holds adie assembly with two crimping sections.

The die assembly features a wire anvil, an insulationanvil, a wire crimper, and an insulation crimper.

Attached to the outside of the frame is a locatorassembly, which contains a locator, a spring retainer,and a contact support.

Die retaining pins and die retaining screws are used toposition and secure the dies in the tool frame. A nut isused on the upper die retaining screw to hold thelocator assembly in place.


PN=357


161674

12

TX,16,1111103 –19–24NOV97–1/2

Amp Crimper Tool for Transmission Controller Unit Connector—Remove and Install DieSet

T11

2329

–UN

–24N

OV

97

A—Nut E—Die Retaining Screws H—Wire Anvil K—ChamferB—Locator Assembly F—Chamfer I—Offset L—LocatorC—Tool Frame G—Insulation Anvil J—Wire Crimper M—Insulation CrimperD—Die Retaining Pins

1. Open the tool handles and remove the two dieretaining screws (E) from the tool jaws.

2. Place the wire anvil (H) and insulation anvil (G) sothat their chamfered sides and their markedsurfaces face outward, when mounted in themoving jaw of the tool frame.

3. Insert the two die retaining pins (D).

4. Insert the short die retaining screw through the jawand through both anvil dies, and tighten the screwjust enough to hold the dies in place. Do NOTtighten the screw completely at this time.

5. Place the wire crimper (J) and insulation crimper(M) so that their chamfered sides and their markedsurfaces face outward, when mounted in thestationary jaw of the tool frame.

6. Insert the two die retaining pins.

7. Insert the long die retaining screw through the jawand through both crimper dies. Tighten the screwjust enough to hold the dies in place. Do NOTtighten the screw completely at this time.


PN=358



16167413

TX,16,1111103 –19–24NOV97–2/2

8. Carefully close the tool handles, making sure thatthe anvils and crimpers align properly. Continueclosing the tool handles until the ratchet in the toolframe has engaged sufficiently to hold the anvilsand crimpers in place, then tighten both dieretaining screws.

9. Place the locator assembly over the end of the longscrew, and position the locator assembly againstthe side of the tool jaw.

10. Place the nut onto the end of the long screw andtighten the nut enough to hold the locator to slideup and down.

11. To disassemble, close the tool handles until theratchet releases. Remove the nut, the locatorassembly, the two die retaining screws, and thefour die retaining pins. Slide the anvils andcrimpers out of the tool jaws.


PN=359


161674

14

TX,16,1111104 –19–24NOV97–1/1

Amp Crimper Tool for TransmissionController Unit Connector—Contact SupportAdjustment

NOTE: The contact support is preset prior to shipment,but minor adjustment may be necessary.

1. Make a sample crimp and determine if the contact isstraight, bending upward, or bending downward.

2. If adjustment is required, loosen the screw that holdsthe contact support onto the locator assembly.

NOTE: The ratchet has detents that create audible clicksas the tool handles are closed.

3. Place a contact with wire into the proper nest andclose the tool handles until the ratchet reaches thesixth click, or until the contact support touches thecontact.

4. Slightly loosen the nut that holds the locator assemblyonto the tool frame.

5. Move the contact support as required to eliminate thebending of the contact.

6. Tighten the nut and close the handles until the ratchetreleases.

7. Remove and inspect the contact.

8. Make another sample crimp. If the contact is straight,tighten the contact support screw. If the contact is stillbeing bent during crimping, repeat the adjustmentprocedure.


PN=360


16167415

TX,16,1111105 –19–17FEB99–1/3

Amp Crimper Tool for TransmissionController Unit Connector—CrimpingProcedure

T11

2335

B–U

N–2

4NO

V97

Micro Timer Contact Slot

T11

2336

B–U

N–2

4NO

V97

Junior Timer Contact Slot

A—Slot

IMPORTANT: Verify crimp height before using thetool to crimp desired contacts and wiresizes. See Crimp Height Inspection andCrimp Height Adjustment, in this group.

1. Select wire of the specified size and insulationdiameter. Strip the wire to length indicated. Do not nickor cut wire strands.

CONTACT SIZE (AWG) WIRE INSUL STRIPDIAMETER LENGTH

Junior Timer 0.5—1.0 mm 2.0 mm (0.079 4.7 mm (0.185Contacts in.) Max. in.)

Micro Timer 0.5—1.0 mm 1.6 mm (0.063 4.3 mm (0.170Contacts in.) Max. in.)


PN=361



161674

16

TX,16,1111105 –19–17FEB99–2/3

T11

2229

–UN

–19N

OV

97

A—Adjustment Screw for C—Locator F—Junior Timer Slot H—Locator in Wire Stop SlotContact Support D—Wire G—Contact I—Wire Inserted to Stop

B—Contact Support E—Micro Timer Slot

2. Hold the tool so that the back (wire side) is facingyou. Squeeze tool handles together and allow themto open fully.

3. Holding the contact by the mating end, insert thecontact—insulation barrel first—through the front ofthe tool and into the appropriate crimp section.

IMPORTANT: Make sure that both sides of theinsulation barrel are started evenlyinto the crimping section. Do NOTattempt to crimp an improperlypositioned contact.

4. Position the contact so that the mating end of thecontact is on the locator side of the tool, so that theopen “U” of the wire and insulation barrels face the

top of the tool. Place the contact up into the nest sothat the movable locator drops into the slot in thecontact. Butt the front end of the wire barrel againstthe movable locator.

5. Hold the contact in position and squeeze the toolhandles together until ratchet engages sufficiently tohold the contact in position. Do NOT deforminsulation barrel or wise barrel.

6. Insert stripped wire into contact insulation and wirebarrels until it is butted against the wire stop.

7. Hold the wire in place: squeeze tool handlestogether until ratchet releases. Allow tool handles toopen and remove crimped contact.


PN=362



16167417

TX,16,1111105 –19–17FEB99–3/3

NOTE: The crimped contact may stick in the crimpingarea. It can be easily removed by pushingdownward on the top of the locator.

8. Check the contact crimp height. If necessary, adjustthe crimp height. See Crimp Height Inspection andCrimp Height Adjustment.

TX,16,1111106 –19–25NOV97–1/1

Amp Crimper Tool for TransmissionController Unit Connector—Crimp HeightInspection

T11

2327

–UN

–21N

OV

97

A—Position Point on Center of Wire BarrelOpposite Seam

B—Modified AnvilC—Dimension

1. Use a crimp height comparator to measure the wirebarrel crimp height as shown.

WIRE SIZE AWG CRIMP SECTION CRIMP HEIGHT(MAX) (WIRE SIZE DIM. (C) AND

MARKING) TOLERANCE (±)

1.0 mm Junior 1.27 ± 0.051 mm(0.0500 ± 0.0020 in.)

1.0 mm Micro 1.20 ± 0.051 mm(0.0472 ± 0.0020 in.)

2. If the crimp height conforms to specifications, the toolis considered dimensionally correct.

If not, the tool must be adjusted. See Crimp HeightAdjustment.


PN=363


161674

18

TX,16,1111107 –19–25NOV97–1/1

Amp Crimper Tool for TransmissionController Unit Connector—Crimp HeightAdjustment

T11

2328

–UN

–21N

OV

97

A—ScrewdriverB—Lock ScrewC—Ratchet Adjustment Wheel

1. Remove the lock screw (B) from the ratchet adjustmentwheel (C).

2. Adjust the ratchet wheel from the location side of thetool using a screwdriver (A).

3. If a tighter crimp is required, rotate the adjustmentwheel counterclockwise.

If a looser crimp is required, rotate the adjustmentwheel clockwise.

4. Install the lock screw.

5. Make a sample crimp and measure the crimp height. Ifthe dimension is correct, tighten the lock screw.

6. If the dimension is incorrect, readjust the ratchet.


PN=364


16167419

TX,16,1111113 –19–17FEB99–1/1

Replace Transmission Controller UnitConnector Terminals

T11

2380

B–U

N–0

1DE

C97

A—ExtractorB—WireC—Connector

The transmission controller unit connector has two sizeterminals:

• Junior Timer Contacts (Large)—Use JDG1177 Extractor• Micro Timer Contacts (Small)—Use FKM10457

Extractor

1. Insert extractor (A) into front (terminal side) ofconnector (C). Use extractor to press in the lockingtabs of terminal.

2. Remove extraction tool and pull wire with terminal (B)through rear of connector.

3. Install new terminal into rear of connector, pushing it inuntil it stops. Locking tabs must be properly lined upwith the socket.

4. Pull on wire slightly to be certain terminal is locked inplace.


PN=365


161674

20

TX,16,1111114 –19–17APR01–1/5

Replace Chassis Computer Unit ConnectorTerminals

T11

2370

B–U

N–2

6NO

V97

T10

9189

–UN

–16A

PR

97

A—WireB—Extraction ToolC—ConnectorD—Locking TabE—Tab

(S.N. —783564)

NOTE: The chassis computer unit connectors have“pull-to-seat” contacts.

1. Disconnect chassis computer unit connector (C).

2. Insert JDG777 Terminal Extraction Tool (B) into wireside of the connector. Push terminal locking tab (D)inward releasing tab (E).

3. Remove extraction tool and push wire with terminal (A)through socket.

TX,16,1111114 –19–17APR01–2/5

T11

2337

B–U

N–2

4NO

V97

JDG1179 Crimper For CCU Connector

4. Remove terminal, cut, strip and crimp wire throughconnector. Insert wire in the 18—16 slot of crimpingtool.

5. Make sure locking tab on new terminals is in outwardposition. Then pull back on wire until terminal locks inconnector body.



PN=366


16167421

TX,16,1111114 –19–17APR01–3/5

T13

2105

B–U

N–2

9JU

N00

1—Extraction Tool2—Secondary Lock Locking Tabs3—Secondary Lock

(S.N. 783565—)

1. Remove extraction tool (1) from the loading side ofconnector.

2. Insert blade of extraction tool into locking tabs (2) ofsecondary lock (3). Rotate tool away from theconnector to pry one side of the secondary lock out ofthe locked position. Repeat this step for the otherlocking tab.

NOTE: After unlocking one side of the secondary lock, ascrew driver or similar device may need to beused to hold it in the unlocked position whileunlocking the second locking tab.

TX,16,1111114 –19–17APR01–4/5T

1323

01B

–UN

–29J

UN

00

3—Secondary Lock

3. Remove secondary lock (3).



PN=367


161674

22

TX,16,1111114 –19–17APR01–5/5

T13

2107

B–U

N–2

9JU

N00

4. Insert pointed side of extraction tool into the contactcavity so that the flat side of tool faces secondary lockcavity (4). This will release the primary contact lockingtab.

5. Gently pull wire out of the connector.

6. Repair/Replace terminals as necessary usingprocedure in this group. (See Install CINCH Contact.)

7. Insert contact and wire into connector until it clicks.

8. Install secondary lock.


PN=368


16167423

CED,TX17994,330 –18–29JUN00–1/1

Install CINCH Contact

T13

8057

–UN

–14F

EB

01

A—Top of Tool D—Wire F—Junior Timer Slot I—Wire TabB—Contact Support E—Micro Timer Slot G—Contact J—Insulation TabC—Locator

1. Hold JDG708 crimping tool so that the tool is facingyou as shown (left side of graphic). Squeeze toolhandles together and allow them to open fully.

IMPORTANT: Make sure that both sides of theinsulation barrel are started evenlyinto the crimping section. Do NOTattempt to crimp an improperlypositioned contact.

2. Position the contact so that the mating end of thecontact (G) is on the locator side of the tool (C).Wire and insulation tabs (I and J) should point totop of tool (A). Butt wire tab (I) against the movablelocator (C).

3. Hold the contact in position and squeeze the toolhandles together until ratchet engages sufficiently tohold the contact in position. Do NOT deform wireand insulation tabs (I and J).

4. Insert stripped wire into contact insulation and wiretabs until it is butted against locator (C).

5. Hold the wire in place. Squeeze tool handlestogether until ratchet releases. Allow tool handles toopen and remove crimped contact.

6. Install contact into connector. See Install CINCHContact. (Go to procedure in this group.)

CINCH is a trademark of the Cinch Co.


PN=369


161674

24

DX,ECONN,V1 –19–02NOV94–1/1

Remove Connector Body from BladeTerminals

RW

4218

–UN

–23A

UG

88

1. Depress locking tang (A) on terminal, using a smallscrew driver. Slide connector body off.

2. Be sure to bend locking tang back to its originalposition (B) before installing connector body.

TX,1674,WW1218 –19–13OCT98–1/1

Remove Blade Terminals From Fuse Block

T76

70A

C–U

N–1

4DE

C91

A—Locking Tang (Depressed Position)B—Locking Tang (Original Position)

Use small screwdriver to depress each locking tang (A) onterminal. Pull terminal out of fuse block.

Be sure to bend locking tangs back to original position (B)before installing in fuse block.


PN=370


16167425

TX,20,SS3659 –19–22APR99–1/1

Boom Height Kickout Adjustment

T10

6999

B–U

N–0

6FE

B97

Loader

T10

7042

B–U

N–0

7FE

B97

Tool Carrier

A—Cap Screw (2 used)B—SwitchC—Adjustable Plate

SPECIFICATIONS

Boom Height Kickout 5—8 mm (0.197— 0.315 in.)Switch-to-Adjustable Plate Gap

1. Move loader control lever to boom raise detent positionand release.

2. After loader control lever returns to neutral, make amark on the adjustable plate and loader frame for thetool carrier. For the loader, make a mark on plate edgeand mounting block.

3. Position the boom in the desired boom height kickoutposition. Stop engine.

4. Loosen cap screws (A) and adjust plate to align markson plate and loader frame or mounting block.

5. Inspect air gap between switch (B) and adjustableplate (C).

SpecificationBoom Height KickoutSwitch-to-Adjustable Plate—Gap 5—8 mm (0.197— 0.315 in.).................

6. If air gap is out of specifications, loosen hex nuts andadjust switch (B) to get correct air gap.

7. Start engine and check boom height kickout for correctadjustment. Readjust as required.


PN=371


161674

26

TX,20,SS3660 –19–22APR99–1/1

Return-to-Carry Kickout Adjustment

T10

7043

B–U

N–0

7FE

B97

Loader

T10

7041

B–U

N–0

6FE

B97

Tool Carrier

A—Cap Screw (2 used)B—SwitchC—Adjustable Plate

SPECIFICATIONS

Boom Height Kickout 5—8 mm (0.197— 0.315 in.)Switch-to-Adjustable Plate Gap

1. Move Return-to-Carry switch on side dash to ONposition. Raise boom to maximum height.

2. Put boom lever in “Float” detent position and observeat what position boom stops lowering and control leverreleases from detent.

3. Stop engine. Make a mark on the adjustable plate andloader frame for the tool carrier. For the loader, make amark on plate edge and mounting block.

4. Start engine and position boom in desiredReturn-to-Carry position.

5. Stop engine. Loosen cap screws (A) and adjust plate(B) to align marks on plate and loader frame ormounting block.

6. Inspect air gap between switch (B) and adjustableplate (C).

SpecificationBoom Height KickoutSwitch-to-Adjustable Plate—Gap 5—8 mm (0.197— 0.315 in.).................

7. If air gap is out of specifications, loosen hex nuts onswitch and adjust switch (B) to get correct air gap.

8. Start engine and check boom Return-to-Carry kickoutfor correct adjustment. Readjust as required.

NOTE: The boom “Float” position detent will not operateat ground level with Return-to-Carry switch ON.Turn Return-to-Carry switch off to activate normal“Float” function of boom.


PN=372


16167427

TX,20,SS3661 –19–22APR99–1/1

Return-to-Dig Adjustment

T10

1721

–UN

–16A

UG

96

A—Air Gap Switch-to-BarB—Adjustable BarC—Cap Screw (2 used)D—Alignment MarksE—Adjusting Nut (2 used)F—Switch

SPECIFICATIONS

Return-to-Dig 5—8 mm (0.197— 0.315 in.)Switch-to-Adjustable Bar Gap

Adjustable Bar Cap Screw 121 N•m (89 lb-ft)Torque

OTHER MATERIAL

T43512 U.S. Thread Lock and Sealer (Medium Strength)

TY9473 Canadian Thread Lock and Sealer (Medium Strength)

242 LOCTITE Thread Lock and Sealer (Medium Strength)

1. Raise boom approximately 300 mm (12 in.) aboveground. Move bucket from full rollback to dump.

2. Move loader control lever to return-to-dig detentposition and release.

3. After control lever returns to neutral, make a mark (D)on switch bracket to align with end of adjustable bar.

4. Position the boom and bucket in the desiredreturn-to-dig position. Stop engine.

5. Loosen cap screws (C) and adjust bar to align marks(D) on switch bracket and end of bar.

6. Raise boom. Cycle bucket from full rollback to dump.Adjust as required to get desired position.

7. Remove cap screws (C), one at a time, apply threadlock and sealer (medium strength). Adjust air gap (A)between switch (F) and adjustable bar. Tighten capscrews.

SpecificationReturn-to-DigSwitch-to-Adjustable Bar—Gap 5—8 mm (0.197— 0.315 in.)....................Adjustable Bar Cap Screw—Torque 121 N•m (89 lb-ft)...........................................................................



PN=373


161674

28


PN=374

Group 1675System Controls

1616751

TX,1675,111939 –19–17FEB99–1/2

Remove and Install Transmission Control Unit (TCU)

T11

1632

–UN

–06O

CT

97

A—Transmission Control Unit B—Transmission Control UnitConnector

IMPORTANT: Whenever a transmission controlunit (TCU) is replaced, the monitordisplay unit must be “reconfigured.”This reconfiguration procedure isperformed in the Service Menu.

Transmission control unit (B) is located in the loadcenter compartment.

1. Turn battery disconnect switch to “Off.”



PN=375

System Controls

161675

2

TX,1675,111939 –19–17FEB99–2/2

T10

7726

B–U

N–2

7MA

R97

2. Lift tab on connector up, then pull connector out oftransmission control unit receiver.

3. Remove mounting screws to remove transmissioncontrol unit.

4. Install new control unit. Install and tighten mountingscrews.

5. Push transmission control unit connector into controlunit receiver, then push tab down to lock connector inplace.

6. Turn battery disconnect switch to “On.”

7. Reconfigure monitor display unit. See Monitor DisplayUnit Reconfiguration in Operation and Test Manual.


PN=376

System Controls

1616753

TX,1675,111943 –19–17FEB99–1/2

Remove and Install Chassis Computer Unit (CCU)

T11

1633

–UN

–06O

CT

97

A—Chassis Computer Unit B—Chassis Computer Unit C—Chassis Computer Unit D—Chassis Computer Unit60—Pin Connector (Part A) 60—Pin Connector (Part B) 30—Pin Connector

IMPORTANT: Whenever a chassis computer unit(CCU) is replaced, the monitordisplay unit must be “reconfigured.”This reconfiguration procedure isperformed in the Service Menu.

The chassis computer unit (C) is located in the loadcenter compartment.


2. Disconnect chassis computer unit connectors (A, B,and D).

3. Remove mounting cap screws to remove chassiscomputer unit.

4. Install new computer unit. Install and tightenmounting cap screws.

5. Connect chassis computer unit 30—pin connector(D) and 60—pin connector Part A (A) and Part B(B). Reference art on next page for chassiscomputer unit connector end views.


7. Reconfigure monitor display unit. See MonitorDisplay Unit Reconfiguration in Operation and TestManual.


PN=377


System Controls

161675

4

TX,1675,111943 –19–17FEB99–2/2

T11

6162

–19–

22JU

L98


PN=378

System Controls

1616755

TX,1675,MM3132 –19–17FEB99–1/2

Remove and Install Monitor Display Unit

T11

1634

–19–

06O

CT

97

IMPORTANT: Whenever a monitor display unit isreplaced, it must be “reconfigured.”This reconfiguration procedure isperformed in the Service Menu.


2. Disconnect all connectors from monitor display unit.

3. Remove mounting cap screws to remove monitordisplay unit.

4. Install new monitor display unit.

5. Connect all monitor display unit connectors in frontconsole harness. Reference art on next page forconnector end views.


7. Reconfigure monitor display unit. See MonitorDisplay Unit Reconfiguration in Operation and TestManual.



PN=379

System Controls

161675

6

TX,1675,MM3132 –19–17FEB99–2/2

T11

0548

–19–

05S

EP

97


PN=380

Group 1677Motors and Actuators

1616771

TX,1677,MM3151 –19–07SEP94–1/1

John Deere Starting Motor Repair—UseCTM77

TS

225

–UN

–17J

AN

89

For complete repair information on the John DeereStarting Motor, CTM77 is also required.

Use the component manual in conjunction with thismachine manual.

CED,OUOE003,3363 –19–30MAR99–1/1

Specifications


Starting Motor Weight 30 kg (66 lb) approximate

Starting Motor Mounting Cap Screw Torque 125 N•m (95 lb-ft)

TX,1677,MM3154 –19–30MAR99–1/3

Remove and Install Starting Motor

T11

1214

E–U

N–0

1DE

C97

A—Starter

IMPORTANT: Disconnect battery negative (-) cable orturn battery disconnect switch to OFF(if equipped) to prevent accidentalgrounding of starting motor wiringleads.

1. Disconnect battery negative (-) cable. Turn batterydisconnect switch Off (if equipped).

2. Disconnect positive (+) wiring leads and battery groundstrap from starter (A).

CAUTION: The approximate weight of thestarting motor is 30 kg (66 lb).

SpecificationStarting Motor—Weight 30 kg (66 lb) approximate.....................................

3. Remove mounting hardware to remove starting motor.



PN=381


Motors and Actuators

161677

2

TX,1677,MM3154 –19–30MAR99–2/3

T10

7768

–19–

04M

AR

97

5. Install starting motor.


PN=382



1616773

TX,1677,MM3154 –19–30MAR99–3/3

6. Tighten mounting cap screws.

SpecificationStarting Motor Mounting CapScrew—Torque 125 N•m (95 lb-ft).......................................................

7. Connect all wiring leads and ground strap. Turnbattery disconnect switch On.


PN=383


161677

4


PN=384

Section 17Frame or Supporting Structure

Contents

Page 17

Group 1740—Frame InstallationService Equipment and Tools . . . . . . . . . . . .17-1740-1Specifications . . . . . . . . . . . . . . . . . . . . . . . .17-1740-2Major Structure

Welding . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-3Engine and Loader Frame

Separate . . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-5Upper Pivot Bearing and Seals

Remove and Install . . . . . . . . . . . . . . . . .17-1740-10Lower Pivot Bearing and Seals

Remove and Install . . . . . . . . . . . . . . . . .17-1740-12

Group 1746—Frame Bottom GuardsSpecifications . . . . . . . . . . . . . . . . . . . . . . . .17-1746-1Fuel Tank Guard

Remove and Install . . . . . . . . . . . . . . . . . .17-1746-1Front Axle Guard

Remove and Install . . . . . . . . . . . . . . . . . .17-1746-1Transmission Bottom Guard

Remove and Install . . . . . . . . . . . . . . . . . .17-1746-2Transmission Side Guards


Group 1749—Chassis WeightsSpecifications . . . . . . . . . . . . . . . . . . . . . . . .17-1749-1Counterweights



PN=1

Contents

17


PN=2

Group 1740Frame Installation

1717401

CED,OUOE003,3365 –19–30MAR99–1/3




CED,OUOE003,3365 –19–30MAR99–2/3

17-1/2 Ton Puller Set

To remove and install bearing assembly and bushingsfrom pivot bores.

CED,OUOE003,3365 –19–30MAR99–3/3

Disk and Driver Set

To remove and install bearing assembly, bushings andseals.


PN=387

Frame Installation

171740

2

CED,OUOE003,3367 –19–30MAR99–1/1

Specifications


Weld Metal Tensile Strength 482.6 mPa (70 000 psi)Yield Strength 413.7 mPa (60 000 psi)Elongation 22%

Structural Assemblies Preheat Temperature 38°C (100°F)

Ground Engaging Tools Preheat Temperature 177°C (350°F)

Loader Frame

Universal Joint Cap Screw Torque 78 N•m (58 lb-ft)

Upper Pivot Bearing and Seals

Upper Pivot Bearing Preload 0.03—0.13 mm (0.001—0.005 in.)

Upper Pivot Bearing Cover Cap Torque 128 N•m (95 lb-ft)Screw

Lower Pivot Bearing and Seals

Lower Pivot Joint Bearing Preload 0.03—0.13 mm (0.001—0.005 in.)

Bearing Cover-to-Engine Frame Torque 128 N•m (95 lb-ft)Cap Screw

Plate-to-Loader Frame Cap Screw Torque 128 N•m (95 lb-ft)

Lower Pivot Retaining Pin Cap Torque 2129 N•m (1570 lb-ft)Screw


PN=388

Frame Installation

1717403

WELD,II –19–01OCT98–1/2

Welding Major Structure

TS

220

–UN

–23A

UG

88

CAUTION: Avoid potentially toxic fumes anddust. Hazardous fumes can be generated whenpaint is heated by welding, soldering, or using atorch. Do all work outside or in a well ventilatedarea. Dispose of paint and solvent properly.

If you sand or grind paint, avoid breathing thedust. Wear an approved respirator. If you usesolvent or paint stripper, remove stripper withsoap and water before welding. Remove solventor paint stripper containers and otherflammable material from area. Allow fumes todisperse at least 15 minutes before welding orheating.

Remove paint before welding.

IMPORTANT: Disconnect battery ground strap or turnbattery disconnect switch to OFF (ifapplicable).

Disconnect both negative and positivebattery cables and microprocessor unit(if applicable).

Have only a qualified welder do this job.Connect welder ground clamp close toeach weld area so electrical currentdoes not pass through any bearings.

Remove or protect all parts that can bedamaged by heat or weld splatter.

Use one of the following weld processes:

• AWS-E-7018 covered electrode with shielded metal arcwelding (SMAW) process.

• AWS-ER-70S-3f wire electrode with gas metal arcwelding (GMAW) process.

• AWS-E70T-1 or E71T-1 wire electrode with flux corearc welding (FCAW) process.


PN=389


Frame Installation

171740

4

WELD,II –19–01OCT98–2/2

SpecificationWeld Metal—Tensile Strength 482.6 mPa (70 000 psi)..............................Yield Strength 413.7 mPa (60 000 psi).......................................................Elongation 22%............................................................................................

Preheat area to be repaired to allow better weldpenetration.

To repair weld metal failure, remove failed weld metalusing arc or grinding equipment. Thoroughly clean area tobe welded. Preheat structural assemblies to a minimum of38°C (100°F). Preheat structural ground engaging tools(cutting edges, skid shoes, and teeth shanks) to 177°C(350°F).

SpecificationStructural Assemblies—PreheatTemperature 38°C (100°F)..........................................................................Ground Engaging Tools—PreheatTemperature 177°C (350°F)........................................................................

To repair base metal failure remove enough material toallow weld to penetrate to the bottom of crack. Preheatstructural ground engaging tools (cutting edges, skidshoes, and teeth shanks) to 177°C (350°F).


PN=390

Frame Installation

1717405

TX,17,RP3352 –19–17FEB99–1/7

Separate Engine and Loader Frame

1. Park machine on smooth level surface and alignframes.

2. Install chain around bucket and connect to boom.Place service jack under center of bucket. Service jackwheels must roll freely and straight ahead when loaderframe is moved forward.

3. Stop engine.

4. Connect hoist to loader frame using chains.

5. Install shop stands under front and rear of engineframe.

6. Hold down Boom Lower Switch and move pilot controllever to release hydraulic pressure. Depress brakepedal 40 times to discharge brake accumulator.

7. Remove cab. (See Procedure in Group 1800)

TX,17,RP3352 –19–17FEB99–2/7

T11

1829

–UN

–23O

CT

97

A—Loader Frame Harness Connector X8 to LoadCenter Harness

B—Loader Frame Harness Connector X7 to LoadCenter Harness

C—Loader Frame Harness Connector X9 to LoadCenter Harness

D—Loader Frame Harness Connector X25 to LoadCenter Harness

8. Disconnect electrical connectors.

9. Drain hydraulic reservoir. Approximate capacity ofreservoir is 117 L (31 gal).


PN=391


Frame Installation

171740

6

TX,17,RP3352 –19–17FEB99–3/7

T11

1830

–UN

–26N

OV

97

Loader

A—Boom Lower From Pilot C—To Steering Valve F—Boom Raise From Pilot H—Load Sense to PumpController D—Valve Inlet From Hydraulic Controller I—To Hydraulic Return Filter

B—Bucket Dump From Pilot Pump G—Pilot Pressure FromController E—Bucket Roll Back From Pressure Reducing Valve

Pilot Controller

10. Disconnect lines (A—I).



PN=392

Frame Installation

1717407

TX,17,RP3352 –19–17FEB99–4/7

T11

1833

–UN

–23O

CT

97

Tool Carrier

A—Boom Lower to Pilot D—Control Valve Return to G—To Pressure Reducing J—Boom Raise to PilotController Filter Valve Controller

B—Bucket Dump to Pilot to E—Load Sense to Steering H—Auxiliary to Pilot Controller K—Load Sense to HydraulicController Valve I—Bucket Roll Back to Pilot Pump

C—Auxiliary to Pilot Controller F—Loader Control Valve ControllerPressure From Pump

11. Disconnect lines (A—K).



PN=393

Frame Installation

171740

8

TX,17,RP3352 –19–17FEB99–5/7

T10

7858

–UN

–07M

AR

97

A—Brake PressureB—Differential LockC—Front Drive Shaft U-JointD—Center drive Shaft U-JointE—Park Brake ReturnF—Park Brake Pressure

12. Disconnect lines (A, B, E, F).

13. Disconnect drive shaft U-joints (C and D).

TX,17,RP3352 –19–17FEB99–6/7

T10

8046

–UN

–11M

AR

97

A—Upper Pivot PinB—Steering Cylinder PinsC—Lower Pivot PinD—SpacerE—Cap ScrewF—Plate

14. Remove steering cylinder pins (B).

15. Remove cap screw (E), plate (F) and spacer (D).Remove lower pivot pin (C).

16. Remove upper pivot pin (A).


PN=394


Frame Installation

1717409

TX,17,RP3352 –19–17FEB99–7/7T

7772

1–U

N–2

4OC

T88

17. Have a service technician at each front tire. Push ontires and slowly move overhead hoist forward. Makesure service jack rolls forward with bucket.


19. Attach loader frame to engine frame.

20. Connect lines and electrical connectors.

IMPORTANT: DO NOT reuse drive shaft universaljoint cap screws or bearing retainerstraps. Replace cap screws and bearingretainer straps to avoid machinedamage.

21. Connect drive shafts. Install new drive shaft universaljoint cap screws and bearing retainer straps. Tightencap screws.

Loader Frame—SpecificationUniversal Joint Cap Screw—Torque 78 N•m (58 lb-ft).............................................................................

22. Connect steering cylinders. Install maximum numberof washers between loader frame and steeringcylinder rod end. Install equal number above andbelow rod end.

23. Install cab. (See Group 1800.)

24. Add hydraulic oil. (See Hydraulic System Oil, Group0004.)

25. Start machine and check for leaks.


PN=395

Frame Installation

171740

10

TX,17,RP3353 –19–05OCT98–1/2

Remove and Install Upper Pivot Bearing and Seals

T10

7940

–UN

–13M

AR

97

A—Pin D—Cover G—Bearing (2 used) J—Engine FrameB—Engine Frame E—Shim (As Needed) H—Lower Seal Spacer K—Bearing SpacerC—Upper Seal F—Loader Frame I—Lower Seal L—Cap Screw (6 used)

1. Remove upper and lower pivot pins and separateframes. Remove cap screws (L) and cover (D) withupper seal (C). Remove parts (G, H, I, and K) fromloader frame bore using a puller disk against lowerseal spacer with seal (H).

NOTE: Lower seal cannot be pushed through spacer.Remove seal spacer to remove seal.

2. Remove seal (I) from seal spacer (H).


4. Apply a light coat of JDM J13E4 grease to rollers inbearings (G).


PN=396


Frame Installation

17174011

TX,17,RP3353 –19–05OCT98–2/2

5. Press lower seal (I) into seal spacer (H) with lipsfacing out. The seal must seat against seal spacershoulder.

6. Install seal spacer (H) in bottom of loader framebore.

7. Press first bearing cup into bore against sealspacer.

IMPORTANT: Do not apply load to bearing conewhen pressing in cup. Use oldbearing race to apply load on newbearing cup to prevent bearingdamage.

8. Install first bearing cone in cup.

IMPORTANT: Use the same spacer (K) which wasremoved from the bearing set.Spacer is not interchangeable withother bearings.

9. Install bearing spacer.

10. Press second bearing cup into bore againstspacer. Install second bearing cone.

11. Install upper seal (C) into cover with lip facing out.Press seal to cover shoulder.

12. Hold cover in place, measure gap between coverand frame, take readings in three places. Covermust contact top of bearing. Calculate the averageof these three reading to determine shim packrequired.

13. Install shims to obtain a preload of 0.03—0.13 mm(0.001—0.005 in.) on bearings.

Upper Pivot Bearing and Seals—SpecificationUpper Pivot Bearing—Preload 0.03—0.13 mm (0.001—0.005

in.)...........

14. Apply grease to the top of bearing, fill cavity abovebearing to machined surface, to prevent moisturefrom entering bearing through shims.

15. Tighten cap screws (L) to specification. Rotateinner race of bearing after tightening.

Upper Pivot Bearing and Seals—SpecificationUpper Pivot Bearing Cover CapScrew—Torque 128 N•m (95 lb-ft).......................................................


PN=397

Frame Installation

171740

12

TX,17,RP3354 –19–17FEB99–1/2

Remove and Install Lower Pivot Bearing and Seals

T10

7966

–UN

–11M

AR

97

A—Pin Retaining Cap Screw F—Spacer (Engine Frame) J—Shims (As Needed) N—Spacer SealB—Cap Screw (6 used) G—Cover Seal K—Loader Frame O—SpacerC—Plate H—Cap Screw (6 used) L—Bearing Spacer P—Loader FrameD—Engine Frame I—Cover M—Bearing (2 used) Q—Lower Pivot PinE—Spacer (Engine Frame)

1. Remove pin retaining cap screw (A), cap screws(B) and plate (C). Remove pivot pin (Q) andseparate machine frames.

2. Remove cap screws (H), cover (I) with seal (G) andspacers (J).


PN=398


Frame Installation

17174013

TX,17,RP3354 –19–17FEB99–2/2

NOTE: Spacer seal can not be pushed throughspacer. Remove seal and spacer to removeseal.

3. Remove bearing spacers, bearings, seals, andspacers (L, M, N, and O) from engine frame, usinga puller disk against seal spacer (O). Remove seal(N) from seal spacer (O).

4. Remove spacer (E) from engine frame bore.


6. Press spacer (E) into engine frame bore flush withbottom of frame.

7. Apply a light coat of JDM J13E4 grease to rollers inbearings (M).

8. Press seal into seal spacer, with lips facing out.Seal must seat against the seal spacer shoulder.

9. Install seal spacer to bottom of bore.

10. Press first bearing cup into engine frame boreagainst spacer.

IMPORTANT: Use the same bearing spacer (L)which was removed from the bearingset. Spacer is not interchangeablewith other bearings. Do not applyload to bearing cone when pressingin cup. Use old bearing race to applyload on new bearing cup to preventbearing damage.

11. Install first bearing cone.

12. Install bearing spacer.

13. Press second bearing cup in engine frame bore.Install second bearing cone. Then press secondbearing cup into bore against spacer.

14. Install seal into bearing cover (I) with lips facingout. Press seal to cover shoulder.

15. Hold bearing cover in place, measure gapbetween cover and frame, take readings in threeplaces. Bearing cover must contact top of bearing.Calculate the average of these three readings todetermine shim pack required.

16. Install shims (J) to obtain specified preload onbearings.

Lower Pivot Bearing and Seals—SpecificationLower Pivot Joint Bearing—Preload 0.03—0.13 mm

(0.001—0.005 in.)........................................................................

17. Apply grease to the top of bearing, fill cavity abovebearing to machined surface, to prevent moisturefrom entering bearing through shims.

18. Tighten cap screws (H). Rotate inner race ofbearing after tightening.

Lower Pivot Bearing and Seals—SpecificationBearing Cover-to-Engine FrameCap Screw—Torque 128 N•m (95 lb-ft)...............................................

19. Install spacer (F) into cover (I).

20. Move frames together and install pivot pin (Q) andplate (C). Install pin retaining cap screw (A) andcap screws (B) finger tight before torquing.

21. Tighten plate-to-loader frame cap screws (B).Tighten lower pivot pin retaining cap screw (A),steel dowels or cap screws may be inserted intoholes in top of pivot pin and a bar insertedbetween them to prevent pin from turning duringtightening of cap screw.

Lower Pivot Bearing and Seals—SpecificationPlate-to-Loader Frame CapScrew—Torque 128 N•m (95 lb-ft).......................................................Lower Pivot Retaining Pin CapScrew—Torque 2129 N•m (1570 lb-ft).................................................


PN=399

Frame Installation

171740

14


PN=400

Group 1746Frame Bottom Guards

1717461

CED,OUOE003,3368 –19–30MAR99–1/1

Specifications


Fuel Tank Guard Weight 166 kg (366 lb) approximate

Front Axle Guard Weight 32 kg (72 lb) approximate

Transmission Bottom Guard Weight 71.5 kg (158 lb) approximate

Transmission Side Guard Weight 14 kg (30 lb) approximate

TX,17,RP3356 –19–17FEB99–1/1

Remove and Install Fuel Tank Guard

T10

8116

–UN

–12M

AR

97

CAUTION: The approximate weight of the fueltank guard is 166 kg (366 lb).

Weight may increase due to build up of mudand debris.

Full tank full of fuel (267 L, 70 gal) will add 225kg (495 lb) to fuel tank and guard total weight.Drain fuel tank before removing guard.

SpecificationFuel Tank Guard—Weight 166 kg (366 lb) approximate.............................

Drain fuel into a clean container for reuse.

Remove fuel tank guard and fuel tank.

TX,17,RP3357 –19–17FEB99–1/1

Remove and Install Front Axle Guard

T10

8117

–UN

–12M

AR

97

CAUTION: The approximate weight of the frontaxle guard is 32 kg (72 lb).


SpecificationFront Axle Guard—Weight 32 kg (72 lb) approximate................................


PN=401

Frame Bottom Guards

171746

2

TX,17,RP3358 –19–30MAR99–1/1

Remove and Install Transmission BottomGuard

T10

8118

–UN

–12M

AR

97

CAUTION: The approximate weight of thetransmission bottom guard is 71.5 kg (158 lb).


SpecificationTransmission Bottom Guard—Weight 71.5 kg (158 lb) approximate...........................................................

TX,17,RP3359 –19–17FEB99–1/1

Remove and Install Transmission SideGuards

T10

8119

–UN

–12M

AR

97

CAUTION: The approximate weight of thetransmission side guard is 14 kg (30 lb).

SpecificationTransmission Side Guard—Weight 14 kg (30 lb) approximate................................................................

If a guard is bent, heat with a torch and straighten.

Weld any cracks using E7018 electrodes.


PN=402

Group 1749Chassis Weights

1717491

CED,OUOE003,3369 –19–30MAR99–1/1

Specifications


Secondary Counterweight Weight 468 kg (1030 lb) approximate

Main Counterweight Weight 873 kg (1925 lb) approximate

Counterweight Attaching Cap Screw Torque 1150 N•m (850 lb-ft)


PN=403

Chassis Weights

171749

2

TX,17,RP3361 –19–30MAR99–1/1

Remove and Install Counterweights

T10

8108

–UN

–12M

AR

97

A—Secondary Counterweight B—Main Counterweight C—Washer (6 used) D—Cap screw (6 used)

CAUTION: The approximate weight ofcounterweight components are:

• Secondary Counterweight (A)—468 kg(1030 lb)

• Main Counterweight (B)—873 kg (1925 lb).

SpecificationSecondary Counterweight—Weight 468 kg (1030 lb) approximate...................................................Main Counterweight—Weight 873 kg (1925 lb) approximate...............

Draw counterweight against engine frame with uppertwo screws first, then lower screws. Torque tospecifications in same pattern.

SpecificationCounterweight Attaching CapScrew—Torque 1150 N•m (850 lb-ft)...................................................


PN=404

Section 18Operator’s Station

Contents

Page Page

Group 1800—Removal and Installation R134a Component Oil Charge . . . . . . . . . .18-1830-12Essential Tools . . . . . . . . . . . . . . . . . . . . . . .18-1800-1 Leak Testing . . . . . . . . . . . . . . . . . . . . . . . .18-1830-13Specifications . . . . . . . . . . . . . . . . . . . . . . . .18-1800-1 Refrigerant Hoses and TubingCab or Canopy Inspection . . . . . . . . . . . . . . . . . . . . . . . .18-1830-13

18Remove and Install . . . . . . . . . . . . . . . . . .18-1800-2 R134a Refrigerant Recovery, Recycling andCharging

Group 1810—Operator Enclosure Station Installation Procedure . . . . . . . . .18-1830-14Other Material . . . . . . . . . . . . . . . . . . . . . . . .18-1810-1 Recover R134a System . . . . . . . . . . . . . . .18-1830-15Specifications . . . . . . . . . . . . . . . . . . . . . . . .18-1810-1 Evacuate R134a System. . . . . . . . . . . . . . .18-1830-16Windowpanes Charge R134a System . . . . . . . . . . . . . . . .18-1830-18

Remove and Install . . . . . . . . . . . . . . . . . .18-1810-2 Air Conditioner System CleaningWindshield Washer Procedures . . . . . . . . . . . . . . . . . . . . . . .18-1830-19

Remove and Install . . . . . . . . . . . . . . . . . .18-1810-4 Air Conditioner SystemFront and Rear Windshield Wiper Motor Purge. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-20

Remove and Install . . . . . . . . . . . . . . . . . .18-1810-6 Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-21Front Windshield Wiper Blower/Air Conditioner Harness (W20)

Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-8 Component Location . . . . . . . . . . . . . . . .18-1830-24Wrist Support Blower/Air Conditioner Harness (W20)

Remove and Install . . . . . . . . . . . . . . . . .18-1810-10 Connectors . . . . . . . . . . . . . . . . . . . . . . .18-1830-26Heater/Evaporator Coil

Group 1821—Seat and Seat Belts Air Conditioning Module. . . . . . . . . . . . . .18-1830-28Seat Belt Remove and Install . . . . . . . . . . . . . . . . .18-1830-30

Disassemble and Assemble. . . . . . . . . . . .18-1821-1 Expansion ValveSeat Remove and Install . . . . . . . . . . . . . . . . .18-1830-33

Disassemble and Assemble. . . . . . . . . . . .18-1821-2 Freeze Control SwitchRemove and Install . . . . . . . . . . . . . . . . .18-1830-34Bench Test . . . . . . . . . . . . . . . . . . . . . . .18-1830-35Group 1822—Steps and Handholds

Heater Control ValveAccess Platform and StepsRemove and Install . . . . . . . . . . . . . . . . .18-1830-36Remove and Install . . . . . . . . . . . . . . . . . .18-1822-2Leak Check . . . . . . . . . . . . . . . . . . . . . . .18-1830-37Engine Compartment Step

Main Blower AssemblyRemove and Install . . . . . . . . . . . . . . . . . .18-1822-4Remove and Install . . . . . . . . . . . . . . . . .18-1830-37Mounted Step

Remove and Install . . . . . . . . . . . . . . . . . .18-1822-5 Pressurizer Motor AssemblyRemove and Install . . . . . . . . . . . . . . . . .18-1830-40

Receiver-Dryer and CondenserGroup 1830—Heating and Air ConditioningRemove and Install . . . . . . . . . . . . . . . . .18-1830-41Essential Tools . . . . . . . . . . . . . . . . . . . . . . .18-1830-1

High and Low Pressure SwitchesService Equipment and Tools . . . . . . . . . . . .18-1830-3Remove and Install . . . . . . . . . . . . . . . . .18-1830-42Air Conditioning System Fittings

Fresh Air FilterReference Chart . . . . . . . . . . . . . . . . . . . .18-1830-4Remove and Install . . . . . . . . . . . . . . . . .18-1830-43Other Material . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6

Recirculating Air FilterSpecifications . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6Remove and Install . . . . . . . . . . . . . . . . .18-1830-46Refrigerant

CompressorTheory of Operation. . . . . . . . . . . . . . . . . .18-1830-7R134a Refrigerant Cautions . . . . . . . . . . . . .18-1830-9 Remove and Install . . . . . . . . . . . . . . . . .18-1830-48R134a Compressor Oil Charge Check . . . .18-1830-10R134a Compressor Oil Removal . . . . . . . . .18-1830-11 Continued on next page


PN=1

Contents

Page

Compressor ClutchDisassemble and Assemble. . . . . . . . . . .18-1830-50

CompressorCheck Clutch Hub Clearance. . . . . . . . . .18-1830-51

Compressor ManifoldInspect. . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-52

CompressorDisassemble, Inspect and Assemble . . . .18-1830-53

Group 1899—Dealer Fabricated ToolsDFRW20 Compressor Holding Fixture. . . . . .18-1899-118


PN=2


CED,OUOE003,2705 –19–30MAR99–1/2

Essential Tools


1818001


CED,OUOE003,2705 –19–30MAR99–2/2

T6585NN –UN–03NOV88

Lifting Brackets . . . . . . . . . . . . . . . . . . . . . . . JT01748

To be used with hoist to lift cab.

CED,OUOE003,2706 –19–30MAR99–1/1

Specifications


Cab Weight 771 kg (1700 lb) approximate

Cab Mounting Cap Screw Torque 1150 N•m (850 lb-ft)


PN=407


181800

2

TX,1800,111302 –19–28SEP98–1/8

Remove and Install Cab or Canopy

Cab or canopy can be removed for servicing oftransmission and hydraulic pumps.

1. Stop engine.

2. With boom raised slightly, turn ignition switch to ONposition. Cycle the ride control switch from OFF to ON(center position). Boom will jump up unexpectedly ifride control accumulator is energized. Press boomenable switch and move the control lever into the floatposition and hold for 5 seconds.

CAUTION: Prevent unexpected machinemovement and possible injury. Install framelocking bar before working in frame hinge area.


4. Turn battery disconnect switch OFF (if equipped) ordisconnect battery ground.

5. Remove steps and platforms from both sides ofmachine.

6. Remove front, left and right bottom cab shields.



PN=408


1818003

TX,1800,111302 –19–28SEP98–2/8

T10

4544

B–U

N–0

7MA

R97

A—Defroster Duct (2 used)

7. Remove two defroster ducts (A) located under front ofcab floor.

8. Remove throttle cable under cab front right side.

9. Remove windshield wiper/washer hoses.

10. Remove brake accumulator line-to-pressure reducingvalve.

TX,1800,111302 –19–28SEP98–3/8T

1012

06–U

N–2

1MA

Y96

A—Breather

11. Remove breather (A) from hydraulic reservoir plugbreather port and pull a vacuum on hydraulicreservoir.



PN=409


181800

4

TX,1800,111302 –19–28SEP98–4/8

X98

11–U

N–2

3AU

G88

T10

4543

C–U

N–0

7MA

R97

A—Steering Valve Hose (5 used)



12. Disconnect the five hoses (A) from steering valve.Plug and cap hoses.

TX,1800,111302 –19–28SEP98–5/8

T10

7920

B–U

N–2

4MA

R97

A—Brake Valve Return HoseB—Brake Valve Work Port Hose (2 used)

13. Disconnect brake valve return hose (A) and brakevalve work port hoses (B). Plug and cap hoses.


PN=410



TX,1800,111302 –19–28SEP98–6/8

T10

4524

B–U

N–1

2DE

C96

14. Disconnect hydraulic hoses from hydraulic pilotcontrollers.

1818005

TX,1800,111302 –19–28SEP98–7/8

T10

4541

D–U

N–0

7MA

R97

T10

4544

C–U

N–2

4OC

T96

A—Wiring Connector (3 used)B—Wiring Connector (4 used)

NOTE: Machines equipped with air conditioning willrequire that the A/C system be evacuated. SeeR134a Refrigerant Recovery/Recycling andCharging procedure in Group 1830. DisconnectA/C hoses under cab, not shown.

15. Shut off heater hose shut off valves on engine.Disconnect heater hoses under cab. Disconnect threewiring connectors (A) on right side of cab and wiringconnectors to loader frame (B) and disconnect thered, white and black wires from starter.

CAUTION: Cab weighs approximately 771 kg(1700 lb).

SpecificationCab—Weight 771 kg (1700 lb) approximate...............................................

16. Remove four cap screws from top of cab roof andinstall four JT01748 Lifting Brackets to the cab roof.Attach chains and hoist to lifting brackets.

17. Remove cab mounting cap screws.

18. Remove cab.

19. Do necessary repairs.

20. Inspect cab mounting parts. Replace as needed.



PN=411


181800

6

TX,1800,111302 –19–28SEP98–8/8

T10

8598

–19–

27M

AR

97

1—Nut (2 used)2—Washer (6 used)3—Washer (4 used)4—Rubber Mount (4 used)5—Cap Screw (M24 x 150) (2 used)6—Cap Screw (M24 x 120) (2 used)

21. Install cab. Install and tighten mounting cap screws.

SpecificationCab Mounting Cap Screw—Torque 1150 N•m (850 lb-ft).......................................................................

22. Remove lifting brackets from cab roof and install capscrews.

23. Connect wiring connectors and red, white and blackwires to starter.

24. Connect heater hoses and turn on heater shutoffvalves.

25. Connect hydraulic pilot controller hoses.

26. Connect brake valve return hose and brake valvework port hoses.

27. Connect steering valve hoses.

28. Remove plug from reservoir and install breather.

29. Install defroster ducts.

30. Install front, left and rear bottom cab shields.

31. Install steps and platforms.

32. Turn battery disconnect switch ON (if equipped) orconnect battery ground strap.

33. Bleed brakes. (See procedure in Group 1060.)


PN=412

Group 1810Operator Enclosure

CED,OUOE003,2707 –19–30MAR99–1/1

Other Material

Number Name Use

TY9375 (U.S.) Pipe Sealant To seal threads of washer tankTY9480 (Canadian) fittings.592 (LOCTITE)

1818101


CED,OUOE003,2708 –19–30MAR99–1/1

Specifications


Wiper Arm Mounting Nut Torque 8—9 N•m (72—86 lb-in.)


PN=413

Operator Enclosure

181810

2

T52,1810,C19 –19–05JUN98–1/1

Remove and Install Windowpanes

The adhesive used to hold the windowpanes in placeis a urethane adhesive that is used on mostautomobile windshields. Urethane adhesivemanufactured by Loctite Corporation or equivalent isrecommended. DO NOT use any other type ofadhesive. It is also recommended that an auto glassdealer install the windowpanes.

IMPORTANT: Windowpanes must have anultra-violet barrier around the edgeof the glass since ultra-violet rayswill deteriorate the adhesive.Windowpanes ordered through JohnDeere Parts have the ultra-violetbarrier. If the windowpane ispurchased through a glass dealer,the dealer must put an ultra-violetbarrier on the glass. DO NOT applypaint to the border of the glass.

If an auto glass dealer is not installing thewindowpanes, use the following procedure:

1. Purchase urethane adhesive from your local autoglass dealer.

2. If window frame is removable, remove frame fromcab.

3. Scrape broken glass off existing adhesive. DO NOTremove adhesive from window frame or cab.

IMPORTANT: Adhesive will not stick to bare metal.

4. If existing adhesive is removed from frame andpaint is scraped off window frame, paint windowframe. Paint must be fully cured before installingwindowpane.

5. Trim existing adhesive so it has a smooth surface.

6. Follow the manufacturer’s instructions for using theadhesive.

7. Apply a 6 mm (1/4 in.) bead of adhesive on top ofthe existing adhesive.

8. Put a new windowpane into position. Use handpressure to force windowpane down around theedges until even with metal frame.

9. If windowpane is installed directly on cab, use ducttape to hold it in place while adhesive cures.

10. Allow adhesive to cure for 24 hours beforeoperating machine.


PN=414

Operator Enclosure

1818103


PN=415

Operator Enclosure

181810

4

TX,18,1111061 –19–30MAR99–1/2

Remove and Install Windshield Washer

TP

6027

9–U

N–2

3MA

R98


PN=416


Operator Enclosure

TX,18,1111061 –19–30MAR99–2/2

1—Elbow Fitting (2 used) 4—Hose 7—Washer (As Required) 10—Grommet (2 used)2—Tie Band (As Required) 5—Pump (2 used) 8—Tank 11—Flange Nut (4 used)3—Hose 6—Hose (2 used) 9—Cap 12—Tank

Apply pipe sealant to threads of washer tank fittings. Cut washer hoses from bulk stock.

1818105


PN=417

Operator Enclosure

181810

6

TX,18,111317 –19–05JUN98–1/2

Remove and Install Front and Rear Windshield Wiper Motor

TP

5544

0–U

N–1

4MA

R97

1—24 Volt Motor (2 used) 12—Weld Nut (2 used) 19—Link 25—Screw with Washer2—Bracket (2 used) 13—Washer (2 used) 22—Nut (2 used) 28—Motor9—Washer (2 used) 14—Nut (2 used) 23—Crank 29—Screw (4 used)10—Nut (2 used) 15—Pivot 24—Washer (2 used)


PN=418


Operator Enclosure

1818107

TX,18,111317 –19–05JUN98–2/2T

1094

24–1

9–06

MA

Y97

1. Disconnect wiring harness connector from wipermotor.

2. Remove and disassemble parts as shown.

3. Install wiper motor.

NOTE: Also reference Cab Work Light HarnessComponent Location in Group 1674.

4. Connect cab work light harness connector to rearwiper motor.

NOTE: Also reference Front Console HarnessComponent Location in Group 1674.

5. Connect front console harness connector to frontwiper motor.


PN=419

Operator Enclosure

181810

8

TX,1810,RB128 –19–05JUN98–1/1

Adjust Front Windshield Wiper

CAUTION: Keep hands away from linkage whenthe motor is in operation. DO NOT adjust parkposition when the motor is in operation. Neverstart a windshield wiper when the blade isfrozen to the windshield or manually stop theblade when the wiper is operating.

1. If the blade does not park in the required position,adjust the wiper blade.

2. Loosen nut.

3. Reposition drive arm on shaft.

4. Tighten nut.

SpecificationWiper Arm Mounting Nut—Torque 8—9 N•m (72—86 lb-in.)....................

5. Start wiper motor, shut it off and note the new parkposition.

6. If blade does not park in the correct position, repeatsteps 2 through 6 until the correct park position isobtained.


PN=420

Operator Enclosure

1818109


PN=421

Operator Enclosure

181810

10

TX,18,111318 –19–05JUN98–1/2

Remove and Install Wrist Support

TP

3496

8–U

N–0

1JA

N94


PN=422


Operator Enclosure

TX,18,111318 –19–05JUN98–2/2

1—Plate 4—Groove Pin 7—Lock Washer 10—Washer2—Nut 5—Cotter Pin 8—Nut 11—Nut3—Rod 6—Bushing 9—Spring 12—Wrist Support Assembly

18181011


PN=423

Operator Enclosure

181810

12


PN=424

Group 1821Seat and Seat Belts

1818211

TX,1821,RB205 –19–31MAR99–1/1

Disassemble and Assemble Seat Belt

TP

5574

5–U

N–2

6NO

V97

1—Seat Belt 2—Hardware Kit 3—Cover 4—Screw (4 used)


PN=425

Seat and Seat Belts

181821

2

TX,18,1111073 –19–18FEB99–1/1

Disassemble and Assemble Seat

TP

5555

7–U

N–1

2JU

N97

1—Armrest 4—Extension 7—Seat Suspension 9—Seat and Suspension2—Support Bracket 5—Support Bracket 8—Cushion Assembly3—Seat Back 6—Armrest


PN=426

Group 1822Steps and Handholds

1818221


PN=427

Steps and Handholds

181822

2

TX,18,1111062 –19–18FEB99–1/2

Remove and Install Access Platform and Steps

TP

5577

9–U

N–0

8JA

N98


PN=428


Steps and Handholds

TX,18,1111062 –19–18FEB99–2/2

1—Platform 3—Strap (2 used) 5—Strap (4 used) 7—Lock Nut (8 used)2—Screw (4 used) 4—Step 6—Screw (8 used) 8—Washer (4 used)

1818223


PN=429

Steps and Handholds

181822

4

TX,18,1111063 –19–18FEB99–1/1

Remove and Install Engine Compartment Step

TP

6027

0–U

N–1

8MA

R98

1—Lock Nut (8 used) 3—Strap (4 used) 4—Screw (8 used) 5—Step2—Strap (2 used)


PN=430

Steps and Handholds

1818225

TX,18,1111074 –19–18FEB99–1/1

Remove and Install Mounted Step

TP

5569

3–U

N–1

4OC

T97

1—Step 3—Screw (4 used) 5—Strap (4 used) 7—Strap (2 used)2—Washer (4 used) 4—Screw (8 used) 6—Lock Nut (8 used) 8—Step


PN=431

Steps and Handholds

181822

6


PN=432

Group 1830Heating and Air Conditioning

CED,OUOE003,2710 –19–31MAR99–1/10

Essential Tools


1818301


CED,OUOE003,2710 –19–31MAR99–2/10

T7530AZ –UN–29MAY91

Vacuum Pump . . . . . . . . . . . . . . . . . . . . . D05267ST

To evacuate air conditioning system.

CED,OUOE003,2710 –19–31MAR99–3/10

RW

2161

3–U

N–1

7AU

G92

R134a Refrigerant Recovery/Recycling and ChargingStation . . . . . . . . . . . . . . . . . . . . . . . . . . . JT020451

Servicing air conditioning system using R134a refrigerant.

1JT02046 and JT02050 Recovery and Charging Stations can besubstituted for the JT02045 Station.

CED,OUOE003,2710 –19–31MAR99–4/10

T10

9996

–UN

–19J

UN

97

Air Conditioning Flusher . . . . . . . . . . . . . . . . . JT02075

To flush air conditioning system.



PN=433

Heating and Air Conditioning

CED,OUOE003,2710 –19–31MAR99–5/10

T10

9995

–UN

–19J

UN

97

Air Conditioning Flushing Fitting Kit. . . . . . . . . . JT02098

Used with JT02075 to flush air conditioning system.

181830

2

CED,OUOE003,2710 –19–31MAR99–6/10

RW19934 –UN–19MAY92

A/C Compressor Clutch Spanner . . . . . . . . . . . JDG747

Used to remove compressor clutch.

CED,OUOE003,2710 –19–31MAR99–7/10

Puller Adapter . . . . . . . . . . . . . . . . . . . . . . . JDG220

Used with JDG748 and JDG771 to remove compressorpulley.

CED,OUOE003,2710 –19–31MAR99–8/10

RW19935 –UN–19MAY92

Jaws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG748


CED,OUOE003,2710 –19–31MAR99–9/10

Hub Protector . . . . . . . . . . . . . . . . . . . . . . . . JDG771


CED,OUOE003,2710 –19–31MAR99–10/10

RW19943 –UN–19MAY92

Compressor Seal Protector . . . . . . . . . . . . . . . JDG746

Used to install seal on compressor.


PN=434


CED,OUOE003,2711 –19–31MAR99–1/4



1818303


CED,OUOE003,2711 –19–31MAR99–2/4

Manifold Pressure Gauge Assembly . . . . . . . . . JT02051

To purge air conditioner system.

CED,OUOE003,2711 –19–31MAR99–3/4

Compressor Holding Fixture . . . . . . . . . . . . . DFRW201

To hold air conditioning compressor during disassemblyand assembly.


CED,OUOE003,2711 –19–31MAR99–4/4

Bench Mounted Holding Fixture . . . . . . . . . . D01006AA

Used to hold compressor during repair.


PN=435


181830

4

TX,9031,MM2887 –19–12SEP96–1/2

Air Conditioning System Fittings Reference Chart

T10

3692

–UN

–16S

EP

96

A—Compressor C—Receiver-Dryer D—Expansion Valve E—EvaporatorB—Condenser

The JT02098 Flush Fitting Kit contains fittings forflushing or leak testing sections or individualcomponents to the air conditioning system. Followingchart lists service fittings used at each specificlocation.



PN=436


1818305

TX,9031,MM2887 –19–12SEP96–2/2

Location Size ServiceGard Number O-Ring Number

Compressor Manifold:

1. Suction Port (F) 7/8—18 JT02099 R113050

2. Discharge Port (F) 3/4—18 JT02100

Compressor Discharge Hose:

3. Inlet End (M) 3/4—18 JT02102 R113050

4. Outlet End (F) 3/4—18 JT02100 R113050

Condenser:

5. Inlet Port (M) 3/4—18 JT02102

6. Outlet Port (M) 5/8—18 JT03183

Condenser to Receiver-Dryer Hose:

7. Inlet End (F) 5/8—18 JT03188 R10093

8. Outlet End (M) 5/8—18 JT03197 R10093

Receiver-Dryer:

9. Inlet Port (F) 5/8—18 JT03196 or JT02110

10. Outlet Port (M) 5/8—18 JT03183

Receiver-Dryer to Evaporator Hose:

11. Inlet End (F) 5/8—18 JT03188 R10093

12. Outlet End (M) 5/8—18 JT03183

A/C Inlet Tube

13. Inlet End (F) 5/8—18 JT03188 R10093

14. Outlet End (M) 3/8 JT02106 and JT02104 R10093

Expansion Valve:

15. Liquid Inlet (F) 3/8 JT02103

16. Liquid Outlet (F) 1/2 JT02104

19. Gas Inlet (F) 5/8 JT02105

20. Gas Outlet (F) 3/4 JT02147

Evaporator Coil:

17. Inlet Tube (M) 1/2 JT02106 and JT02103 R113050

18. Outlet Tube (M) 5/8 JT02106 and JT02105 R33259

A/C Outlet Tube:

21. Inlet End (M) 3/4 TEV and JT02105 T143169

22. Outlet End (F) 1-1/16—14 Not Available T143169

Evaporator to Compressor Hose

23. Inlet End (M) 1-1/16—14 Not Available

24. Outlet End (M) 7/8—18 JT02101 R33259


PN=437


181830

6

CED,OUOE003,2712 –19–31MAR99–1/1

Other Material

Number Name Use

TY16134 (U.S.) R134a Flushing Solvent Flush R134a air conditioning system.

TY22025 (8.5 oz) (U.S.) R134a Compressor Oil Lubricate R134a air conditioningsystem.Lubricate compressor O-rings,gaskets, and lip seal duringassembly.

TY15949 (12 oz) (U.S.) R134a Refrigerant Charge R134a air conditioningsystem.

TY15950 (15 lb) (U.S.) R134a Refrigerant Charge R134a air conditioningsystem.

TY15951 (30 lb) (U.S.) R134a Refrigerant Charge R134a air conditioningsystem.

CED,OUOE003,2713 –19–31MAR99–1/1

Specifications


Freeze Control Switch Test

Switch Opens Temperature -0.56° ± 0.84°C (31° ± 1.5°F)

Switch Closes Temperature -2.22° ± 0.84°C (36° ± 1.5°F)

Compressor

Compressor Through Bolt Torque 26 N•m (19 lb-ft)

Compressor Suction Line Torque 31 N•m (23 lb-ft)

Compressor Discharge Line Torque 22 •m (16 lb-ft)

Clutch Shaft Bolt Torque 14 N•m (120 lb-in.)

Clutch Hub Clearance 0.35—0.65 mm (0.014—0.026 in)

Compressor Manifold Cap Screw Torque 26 N•m (19 lb-ft)


PN=438


1818307

TX,05,MM2873 –19–18FEB99–1/2

Refrigerant Theory of Operation

The compressor (G) draws low pressure gas (H) fromthe evaporator (I) and compresses it into high pressuregas (F). This causes the temperature of the refrigerantto rise higher than that of the outside air.

High pressure gas leaves the compressor and issensed by the high pressure switch (K). The switchmonitors refrigerant pressure. If the pressure becomestoo high, the switch will open and stop the compressor,interrupting the cycle.

As the high pressure gas flows through the condenser(E), heat is removed and transferred to the outside airbeing drawn through the condenser core by thecondenser fan (D). Cooling the refrigerant causes it tocondense and it leaves the condenser as a highpressure liquid (C). The high pressure liquid flows intothe receiver-dryer (B) where moisture andcontaminants (acid, solids, etc.) are removed. Thereceiver-dryer also acts as a reservoir for refrigerant.

The refrigerant flows from the receiver-dryer to theexpansion valve (J) and is sensed by the low pressureswitch (A). The switch monitors refrigerant pressure. Ifthe pressure becomes too low from refrigerant loss,the switch will open and stop the compressor,interrupting the cycle.

The actual cooling and drying of cab air takes place atthe evaporator. Flow of the high pressure liquidrefrigerant is controlled by the expansion valve. Theexpansion valve causes the temperature and pressureof the refrigerant to drop, where it becomes a lowpressure liquid (L). The expansion valve is a

diaphragm-type valve that uses a variable orifice tocontrol the flow of high pressure liquid refrigerant intothe evaporator to maintain a constant pressure andtemperature. (See Expansion Valve Operation in thisgroup for additional information on theory of operation.)

The blower motor (N) pulls a mixture of warm cab andoutside air through the evaporator where it is cooledby the refrigerant. The heat absorbed by theevaporator causes the refrigerant to vaporize into alow pressure gas.

A freeze control switch (M) senses temperature of theevaporator coil through a refrigerant filled capillarytube. The switch closes when the evaporator is abovethe switch setting and opens when the evaporator iscooled to the switch setting. The switch has a lowtemperature setting that prevents the evaporator frombecoming cold enough to freeze moisture thatcondenses on the coil.

Cab temperature is controlled by reheating theconditioned air by passing it through the heater coil.The heater coil temperature is controlled by regulatingthe amount of water flow through the heater coil withthe water valve.

The moisture, from the warm air, is condensed as itcontacts the cool evaporator coil during the coolingprocess and is drained away through drain tubesconnected to the drain pan under the evaporator. Withthe cab air cooled and dehumidified, the refrigerantcycle is complete.



PN=439


181830

8

TX,05,MM2873 –19–18FEB99–2/2

T10

3906

–19–

06N

OV

96

L—Low Pressure Switch


PN=440


1818309

TX,9031,SS3564 –19–11SEP96–1/1

R134a Refrigerant Cautions

CAUTION: DO NOT allow liquid refrigerant tocontact eyes or skin. Liquid refrigerant willfreeze eyes or skin on contact. Weargoggles, gloves and protective clothing.

If liquid refrigerant contacts eyes or skin, DONOT rub the area. Splash large amounts ofCOOL water on affected area. Go to aphysician or hospital immediately fortreatment.

DO NOT allow refrigerant to contact openflames or very hot surfaces such as electricwelding arc, electric heating element andlighted smoking materials.

DO NOT heat refrigerant over 52°C (125°F) ina closed container. Heated refrigerant will

develop high pressure which can burst thecontainer.

Keep refrigerant containers away from heatsources. Store refrigerant in a cool place.

DO NOT handle damp refrigerant containerwith your bare hands. Skin may freeze tocontainer. Wear gloves.

If skin freezes to container, pour COOLwater over container to free the skin. Go to aphysician or hospital immediately fortreatment.


PN=441


181830

10

TX,9031,SS4004 –19–22APR99–1/1

R134a Compressor Oil Charge Check

Remove compressor if refrigerant is leaking from itsseals, and repair is needed, or if compressor hasfailed. See Remove and Install Compressor in thisgroup.

Drain oil from the compressor and record the amount.See Compressor Oil Removal procedure in Group9031-20.

NOTE: Drain oil and save if this is a new compressor.

If the oil drained from a compressor removed fromoperation is very black or the amount of oil is less than6 mL (0.2 fl oz), perform the following:

1. Remove and discard the receiver-dryer. Go toRemove and Install Receiver-Dryer and Condenserin this group.

2. Remove, clean, but do not disassemble theexpansion valve. Go to Remove and InstallExpansion Valve in this group.

3. Flush the complete system with TY16134 airconditioning flushing solvent. Go to Air ConditioningSystem Cleaning Procedures in this group.

4. If the compressor is serviceable, pour flushingsolvent in the manifold ports and internally wash outthe old oil. Go to Air Conditioning System CleaningProcedures in this group.

5. Install a new receiver-dryer.

6. Install required amount of TY22025 refrigerant oil inthe compressor. (See R134a Component OilCharge in this group.)

7. Connect all components, evacuate and charge thesystem. Go to Evacuate R134a System and ChargeR134a System in this group.


PN=442


18183011

TX,9031,SS3593 –19–22APR99–1/1

R134a Compressor Oil Removal

1. Remove compressor from machine. See Remove andInstall Compressor in this group.

2. Remove inlet/outlet manifold from compressor, andclutch dust cover.

3. Drain oil into graduated container while rotatingcompressor shaft.

4. Record measured oil and discard oil properly.

5. Install new oil. See R134a Component Oil Charge inthis group.

6. Install compressor. See Remove and InstallCompressor in this group.


PN=443


181830

12

TX,1830,111266 –19–28SEP98–1/1

R134a Component Oil Charge

CAUTION: All new compressors are chargedwith a mixture of nitrogen, R134a refrigerantand TY22025 (R134a) refrigerant oil. Wearsafety goggles and discharge thecompressor slowly to avoid possible injury.

Compressors can be divided into three categorieswhen determining the correct oil charge for the system.

• New compressor from parts depot• Used compressor removed from operation• Compressor internally washed with flushing solvent

Use the following procedure to determine theamount of system oil charge prior to installation ofcompressor on a machine.

1. When the complete system, lines, and componentswere flushed add the correct amount of oil asdescribed.

• New compressor from parts depot contains theamount of new oil of 230 ± 20 mL (7.7 ± .7 fl oz).System requires an additional amount of new oilof 135 mL (4.58 fl oz) of new oil.

• Used compressor removed from operation, oildrained, and flushed requires 365 mL (12.35 floz) of new oil.

2. When the complete system was not flushed add thecorrect amount of oil for the compressor plus theamount of oil for each component that wasserviced.

• New compressor from parts depot, drain andreturn 45 mL (1.5 fl oz) of oil to the compressor.(See Compressor Oil Removal procedure in thisgroup.)

• Used compressor removed from operation and oildrained. (See Compressor Oil Removalprocedure in this group.) Add 45 mL (1.5 fl oz) ofnew oil.

• Used compressor removed from operation, oildrained, and flushed. Add 60 mL (2.0 fl oz) ofnew oil.

NOTE: Components listed below which have beenremoved, drained or flushed, require theremoval of the compressor to determine thecorrect oil charge. Use the following chart as aguide for adding oil to components:

Evaporator 158 mL (5.4 fl oz)

Condenser 70 mL (2.4 fl oz)

Receiver-Dryer 37 mL (1.25 fl oz)

Hoses 73 mL (2.5 fl oz)

NOTE: Hoses = 3 mL per 30 cm (0.1 fl oz per ft).Approximate total length equals 727 cm (24 ft)

If any section of hose is removed and flushed orreplaced, measure the length of hose and use theformula to determine the correct amount of oil to beadded.

CAUTION: DO NOT leave the system orR134a compressor oil containers open. Thisoil easily absorbs moisture. DO NOT spillR134a compressor oil on acrylic or ABSplastic. This oil will deteriorate thesematerials rapidly. Identify R134a oilcontainers and measures to eliminateaccidental mixing of different oils.


PN=444


TX,1830,MM3175 –19–19OCT96–1/1

Leak Testing

1. Inspect all lines, fittings and components for oily ordusty spots. When refrigerant leaks from thesystem, a small amount of oil is carried out with it.

2. A soap and water solution can be sprayed on thecomponents in the system to form bubbles at thesource of the leak.

3. If a leak detector is used, move the leak detectorprobe under the hoses and around the connectionsat a rate of 25 mm (1 in.) per second.

4. Some Freon manufacturers add dye to Freon to aidin leak detection.

18183013

TX,1830,MM3176 –19–19OCT96–1/1

Refrigerant Hoses and Tubing Inspection

IMPORTANT: Hose used for air conditioningsystems contains special barriers inits walls to prevent migration ofrefrigerant gas.

DO NOT use hydraulic hoses asreplacement hoses in the airconditioning system. Use ONLYcertified hose meeting SAE J51brequirements.

When a component is disconnected from the system,special care should be given to inspecting hoses andtubing for moisture, grease, dirt, rust, or other foreign

material. If such contamination is present in hoses,tubing, or fittings and cannot be removed by cleaning,then replace parts.

Fittings that have grease or dirt on them should bewiped clean with a cloth dampened with alcohol.Chlorinated solvents (such as trichloroethylene) arecontaminants, and must not be used for cleaning.

To assist in making leak-proof joints in R134asystems, use a small amount of cleanpolyakyleneglycol (PAG) refrigerant oil on all hosesand tube connections. Dip O-rings in PAG oil beforeassembly.


PN=445


181830

14

TX,9031,QQ3015 –19–07MAR95–1/1

R134a Refrigerant, Recovery, Recycling andCharging Station Installation Procedure

T84

22A

C–1

9–22

FE

B95

A—High Pressure Relief ValveB—High Pressure Test PortC—Red HoseD—Blue HoseE—High Pressure HoseF—Low Pressure HoseG—Low Pressure Test PortH—Refrigerant Recovery/Recycling and Charging

Station

ESSENTIAL TOOLS

JT02045a R134a Refrigerant Recovery/Recycling and ChargingStationaJT02046 and JT02050 Recovery and Charging Stations can besubstituted for the JT02045 Station.

CAUTION: Do not remove high pressure reliefvalve (A). Air conditioning system willdischarge rapidly causing possible injury.

IMPORTANT: Use correct refrigerant recovery,recycling and charging stations. DONOT mix refrigerant, hoses, fittings,components or refrigerant oils.

1. Close both high and low pressure valves on refrigerantrecovery, recycling and charging station (H).

2. Remove cap from low pressure test port (G).

3. Connect low pressure blue hose (D) from refrigerantrecovery, recycling and charging station (H) to lowpressure test port (G) on compressor.

4. Connect high pressure red hose (C) to high pressurequick disconnect (B).

5. Follow the manufactures instructions when using therefrigerant recovery, recycling and charging station.


PN=446


18183015

TX,9031,QQ3016 –19–07OCT98–1/1

Recover R134a System

T84

22A

C–1

9–22

FE

B95


Station

ESSENTIAL TOOLS

JT02045a R134a Refrigerant Recovery/Recycling and ChargingStationaJT02046 and JT02050 Recovery and Charging Stations can besubstituted for the JT02045 Station.



NOTE: Run the air conditioning system for three minutesto help in the recovery process. Turn airconditioning system off before proceeding withrecovery steps.

1. Connect refrigerant recovery, recycling and chargingstation. (See installation procedure in this group.)

2. Follow the manufacturer’s instructions when using therefrigerant recovery, recycling and charging station.


PN=447


181830

16

TX,9031,QQ3017 –19–07OCT98–1/2

Evacuate R134a System

T84

22A

C–1

9–22

FE

B95


Station

ESSENTIAL TOOLS

JT02045a R134a Refrigerant Recovery/Recycling and ChargingStation

D05267ST Vacuum PumpaJT02046 and JT02050 Recovery and Charging Stations can besubstituted for the JT02045 Station.



Do not run compressor whileevacuating.

1. Connect refrigerant recovery, recycling and chargingstation. (See installation procedure in this group.)

2. Open low and high pressure valves on refrigerantrecovery, recycling and charging station.

3. Follow the manufacturer’s instructions and evacuatethe system.

NOTE: The vacuum specifications listed are for sea levelconditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg)from 98 kPa (980 mbar) (29 in. Hg) for each 300m (1000 ft) elevation above sea level.

4. Evacuate system until low pressure gauge registers 98kPa (980 mbar) (29 in. Hg) vacuum.

If 98 kPa (980 mbar) (29 in. Hg) vacuum cannot beobtained in 15 minutes, test the system for leaks. (SeeLeak Testing, 9031-25). Correct any leaks.

5. When vacuum is 98 kPa (980 mbar) (29 in. Hg), closelow-side and high-side valves. Turn vacuum pump off.


PN=448



18183017

TX,9031,QQ3017 –19–07OCT98–2/2

6. If the vacuum decreases more than 3.4 kPa (34 mbar)(1 in. Hg) in 5 minutes, there is a leak in the system.

7. Repair leak.

8. Start to evacuate.

9. Open low-side and high-side valves.

10. Evacuate system for 30 minutes after 98 kPa (980mbar) (29 in. Hg) vacuum is reached.

11. Close low-side and high-side valves. Stop evacuation.

12. Charge the system. (See procedure in this group.)


PN=449


181830

18

TX,1830,111267 –19–28SEP98–1/1

Charge R134a System

T84

22A

C–1

9–22

FE

B95


Station



1. Connect JT02045 R134a refrigerant recovery, recyclingand charging station. (See installation procedure in thisgroup.)

2. Evacuate the system. (See Evacuate Air ConditioningSystem in this group.)

NOTE: Before beginning to charge air conditioningsystem, the following conditions must exist:Engine STOPPED, the pump must be capable ofpulling at least 28.6 in. Hg vacuum (sea level).Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa(980 mbar) (29 in. Hg) for each 300 m (1000 ft)elevation above sea level.

3. Follow the manufacturer’s instructions and charge thesystem.

4. Add refrigerant until system is charged with 2.381 kg(5.25 lb).

5. Do air conditioner checks and tests in Groups 9031-10and 9031-25.


PN=450


18183019

TX,1830,MM3158 –19–17OCT96–1/1

Air Conditioner System Cleaning Procedures

Flushing: Flushing the system or component is acleaning process using a liquid solvent to remove oiland debris. Purging is always necessary after flushingto remove solvent from the system or component.

Following is a list of situations that require a flushingprocedure be done:

• The compressor has an internal failure.• No oil remains in used compressor.• Oil drained from compressor appears or smells

overheated.• System was contaminated with a mixture of

refrigerant oils.• System was left open to the atmosphere long

enough for dirt, moisture, or debris to enter thetubing or components.

• System has an internal blockage.

The following solvent is recommended for flushing airconditioner systems. Use only solvents with anequivalent MSDS.

• TY16134 John Deere Air Conditioning SystemFlushing Solvent

Purging: Purging the system or a component is acleaning process using a gas to force liquid from thesystem. Purging alone will not remove refrigerant oilfrom the system.

Following is a list of situations that require a purgingprocedure be done:

• After flushing system with solvent, to prevent oildilution

• System was contaminated with nitrogen or tworefrigerants.

• System was left open to the atmosphere andflushing could not be performed.

• Installation of new lines, condenser, or evaporatorwas required.

Evacuating: Evacuating the system is a process toremove air and moisture from the system, creating avacuum.


PN=451


181830

20

TX,1830,MM3156 –19–14OCT98–1/1

Purge Air Conditioner System

IMPORTANT: Air compressors used for purgingsystems require a water separator.Purging without a separator addsmoisture, creating hydrofluoric acidwhen combined with refrigerant oil.Acid is corrosive to metal tubing.

1. Connect dry nitrogen hose to gauge manifold centerhose.

2. Connect gauge manifold suction hose to compressorsuction port, and open valves.

3. Connect gauge manifold discharge hose to compressordischarge post, and open valve. Disconnect dischargehose from gauge manifold to allow purging nitrogen toatmosphere.

4. Open nitrogen tank valve and adjust regulator to 275kPa (40 psi) (2.75 bar). Purge system for two minutes.Disconnect nitrogen supply.

5. Evacuate system. (See procedure in this group.)


PN=452


18183021

TX,1830,MM3159 –19–14OCT98–1/2

Flush Air Conditioner System

Add flushing solvent to system with JT02075 Flusherand JT02098 Fitting Kit.

NOTE: Flushing can be performed on vehicle.

1. Recover refrigerant. (See procedure in this group.)

2. Remove compressor and measure oil drained fromboth manifold ports.

3. Clean compressor as follows:

a. Pour 240 mL (8 fl oz) of flushing solvent intosuction port and 120 mL (4 fl oz) into dischargeport. Plug both ports in compressor manifoldusing JT02099 and JT02100 with JT03194Caps.

b. Turn compressor end for end and roll it side toside.

c. Remove both plugs from manifold ports anddrain solvent from compressor.

d. Connect battery power to compressor clutch coil.Rotate pulley at least five revolutions to movesolvent out of cylinders.

e. Invert compressor, roll end for end, and side toside. Drain thoroughly.

f. Let compressor sit inverted for three to fiveminutes.

g. Repeat previous two steps at least three times.

4. Remove and discard receiver-dryer.

5. Divide system into two circuits:

a. Condenser, including inlet and outlet hoses.(Steps 6—12)

b. Evaporator, including inlet and outlet hoses.(Steps 13—26)

IMPORTANT: DO NOT attempt to flush throughcompressor or receiver-dryer.Flushing through expansion valve isacceptable if refrigerant oil hasnormal odor and appearance.

6. To Flush/Purge Condenser:

Connect flusher outlet hose to inlet end ofcompressor discharge line using JT02102 Adapter.

7. Attach a return hose and aerator nozzle to outletend of receiver-dryer inlet hose using JT03197reducer. Put nozzle in container to collect flushingsolvent.

8. Fill flusher tank with 4 L (1 gal) of solvent andfasten all connections.

NOTE: Air pressure must be at least 620 kPa (6.2bar) (90 psi) for flushing and purging.

9. Connect a supply line of moisture-free compressedair or dry nitrogen to flusher air valve.

10. Open air valve to force flushing solvent intocondenser circuit. Flusher tank is empty whenhose pulsing stops. Additional flushing cycles arerequired if system is heavily contaminated withburned oil or metal particles.

NOTE: Purging the condenser circuit takes 10—12minutes to thoroughly remove solvent.

11. Disconnect hose from aeration nozzle to checkcircuit for solvent. Hold hose close to a piece ofcardboard; continue purging until cardboard is dry.

12. Go to step 13 to flush evaporator. Go to step 22 ifevaporator does not require flushing.

13. To Flush Evaporator:


PN=453



181830

22

TX,1830,MM3159 –19–14OCT98–2/2

If system is contaminated with burned refrigerantoil or debris, remove and bench flush evaporator.Go to step 18 to flush evaporator throughexpansion valve, if oil appears normal. Removeevaporator. (See procedure in this group.)

14. Force flushing solvent through evaporator inletwith compressed air.

15. Purge system until dry.

16. Reinstall evaporator.

17. Go to Step 22.

18. To Flush Evaporator Through ExpansionValve:

Connect flusher outlet hose to connection ofreceiver-dryer outlet hose using JT03188 Adapter.

19. Attach a hose and aerator nozzle to compressorinlet line using JT02101 Adapter. Put nozzle in acontainer to collect solvent.

20. Repeat Steps 8, 9 and 10 to flush evaporator.

NOTE: Purging the evaporator circuit takes 12—15minutes to thoroughly remove solvent.

21. Disconnect hose from aeration nozzle to checkcircuit for solvent. Hold hose close to a piece ofcardboard. Continue purging until cardboard is dry.

22. Install a new receiver-dryer compatible with R134arefrigerant. Fasten connections and mountingbracket.

23. Add required oil. (See procedure in this group.)

24. Install compressor, and connect refrigerant lines tomanifold.

25. Connect clutch coil wire. Install drive belt.

26. Purge system. (See procedure in this group.)


PN=454


18183023


PN=455


TX,1830,111268 –19–22OCT96–1/2

Blower/Air Conditioner Harness (W20) Component LocationT110709 –19–04SEP97


PN=456


TX,1830,111268 –19–22OCT96–2/2

A—Temperature Control F—Blower Motor 25A Fuse L—Expansion Valve S—Heating/Evaporator CoilSwitch (F19) M—Air Conditioning Low T—Freeze Control Switch

B—Blower Speed Switch (S21) G—Receiver/Dryer Pressure Switch (B36) (B35)C—Air Conditioning On/Off H—Air Conditioning Clutch 1 N—Heater Valve U—Air Ducts

Switch (S22) A Diode (V11) O—Pressurizer Motor (M7) V—Blower Speed Resistor (R3)D—Pressurizer Motor 7.5A I—Condenser P—Fresh Air Filter W—Main Blower Motor (M6)

Fuse (F20) J—Compressor Relief Valve Q—Recirculating Air Filter X—Service and Charge PortE—Blower/Pressurizer Motor K—Air Conditioning R—Air Conditioning High

Relay (K19) Compressor Clutch (Y16) Pressure Switch (B37)

18183025


PN=457


181830

26

TX,1830,MM3178 –19–22OCT96–1/1

Connectors for Blower/Air Conditioner Harness (W20)

T10

1385

–19–

31JU

L96


PN=458


18183027


PN=459


181830

28

CED,OUOE003,1031 –19–16DEC98–1/2

Air Conditioning Module With Heater/Evaporator Coil

TP

6042

3–U

N–1

8JU

N98


PN=460



18183029

CED,OUOE003,1031 –19–16DEC98–2/2

1—Nut (14 used) 19—Cover 36—Heater Hose 54—O-Ring (3 used)2—Seal (2 used) 20—Housing 37—Expansion Valve Plate 55—O-Ring (3 used)3—Impeller (2 used) 21—Screw (12 used) 38—Housing 56—A/C Lower Pressure4—Pressurizer Blower Motor 22—Isolator (3 used) 39—Heater Valve Switch5—Cap Screw (14 used) 23—Air Filter 40—Expansion Valve 57—Grommet6—Tube (2 used) 24—Nut 41—Valve Hose 58—Grommet7—Screw (2 used) 25—Housing 42—Tube 59—Clip8—Clamp (8 used) 26—Latch (2 used) 43—Clamp (4 used) 60—Cable9—Tube (2 used) 27—Rivet (4 used) 44—Heater Tube 61—Lock Washer10—Bracket 28—Filter Element 45—A/C Suction Tube 62—Nut11—Air Duct 29—AC/Heater Main Blower 46—A/C Inlet Tube 63—Knob12—Tie Band (4 used) Motor 47—A/C High Pressure Switch 64—Control13—Clip (2 used) 30—Seal 48—Cap Screw 65—Seal14—Thermostat 31—Heater/Evaporator Coil 49—Adapter Plate 66—Bushing15—Air Duct 32—Air Duct 50—Screw (4 used) 67—Gasket16—Air Plenum 33—Valve Hose 51—Plug (2 used) 68—Hose (As Required)17—Screw (2 used) 34—Knob 52—O-Ring 69—Clamp18—Resistor 35—Bolt (2 used) 53—Ring 70—Blower


PN=461


181830

30

TX,18,1111066 –19–18FEB99–1/4

Remove and Install Heater/Evaporator Coil

T11

2116

–UN

–04N

OV

97

A—Pressurizer Motor E—Resistor H—Cap Screws L—Heater ValveB—Inlet Plenum F—Main Blower Motor I—Lower Housing M—Air Conditioning LinesC—Expansion Valve G—Heater/Evaporator Coil Top J—Heater/Evaporator Coil N—HousingD—Freeze Control Switch Cover K—Heater Hoses (2 used) O—Knob

1. Recover refrigerant from the system. (See RecoverR134a System in this group.)

2. Open left-hand cab service door. Remove fresh airfilter. (See Remove Fresh Air Filter in this group.)

3. Remove knob (O) to remove housing (N).

4. Remove rear cover behind seat.

5. Remove seat cap screws and move seat forward toaccess air conditioning/heater components.

6. Remove cab recirculating filter. (See RemoveRecirculating Filter in this group.)

7. Remove upper two cap screws attaching inletplenum (B) to heater/evaporator coil top cover (G).

8. Remove cab left-hand shelf.

9. Remove cap screws from heater/evaporator coil topcover (G); remove cover.

10. Remove freeze control switch (D) probe from coil.

11. Remove upper two cap screws from main blowermotor (F).

12. Disconnect wire harness from freeze controlswitch (D) and resistor (E).

13. Shut off heater hose shut-off valves on engine.

14. Disconnect air conditioning lines (M) fromexpansion valve (C) and heater hoses (K) fromcoil.


PN=462



TX,18,1111066 –19–18FEB99–2/4

15. Remove expansion valve.

16. Remove heater/evaporator coil (J).

17. Install expansion valve on heater/evaporator coil.

18. Check lower housing (I) to make sure drain tube isnot plugged.

19. Install heater/evaporator coil.

20. Connect air conditioner lines and heater hoses.

21. Open heater hose shut-off valves on engine.

18183031



PN=463


181830

32

TX,18,1111066 –19–18FEB99–3/4

T11

0752

D–U

N–0

8AU

G97

A—SwitchB—Freeze Control Switch Line

22. Mount switch (A) to module.

23. Route freeze control switch line (B) as shown. Routeunder foam on module.

IMPORTANT: Freeze switch line is a capillary tubefilled with refrigerant. A generous bendradius is required to ensure properoperation. DO NOT kink freeze switchline when bending.

24. Carefully bend the end of the freeze control switchline at a 90 degree angle. Insert last 88.9 mm (3.5 in.)into evaporator core starting 190 mm (7.5 in.) fromthe left end and 114 mm (4.5 in.) from the bottom.Push freeze control switch line down into evaporatorcore at a 45 degree angle. Freeze switch line shouldslide smoothly between the tubes in the evaporatorcore.

25. Connect wire harness to freeze control switch andresistor.

26. Install main blower motor.

27. Install evaporator top cover and cab left-hand shelf.

28. Install inlet plenum to heater/evaporator coil topcover.

29. Install cab recirculating filter.

30. Install rear cover behind seat.

31. Move seat back and install and tighten cap screws.

32. Install housing and knob.

33. Install fresh air filter.

34. If the system is contaminated, each component in thesystem must be flushed and purged individually. (Seeprocedures in this group.)

35. Drain oil from compressor. (See procedure in thisgroup.)


PN=464



TX,18,1111066 –19–18FEB99–4/4

36. If system was not completely flushed, see flushingprocedure in this group.

37. Purge, evacuate, and charge the system. (Seeprocedures in this group.)

18183033

TX,18,1111067 –19–18FEB99–1/1

Remove and Install Expansion Valve

T11

2119

–UN

–04N

OV

97

A—Pressurizer MotorB—Expansion ValveC—Air Conditioning Lines

1. Recover refrigerant from the system. (See RecoverR134a System in this group.)

2. Open left-hand cab service door. Remove fresh airfilter. (See Remove Fresh Air Filter in this group.)

3. Remove pressurizer motor (A). (See Pressurizer Motor,Remove in this group.)

4. Disconnect air conditioning lines (C) from expansionvalve.

5. Remove expansion valve (B) and replace.

6. Apply refrigerant oil to new O-rings. Install expansionvalve and new O-rings.

7. Connect air conditioning lines to expansion valve.

8. Install pressurizer motor.

9. Install fresh air filter. (See Install Fresh Air Filter in thisgroup.)

10. Purge, evacuate, and charge the system. (Seeprocedures in this group.)


PN=465


181830

34

TX,1830,MM3162 –19–18FEB99–1/2

Remove and Install Freeze Control Switch

T10

3844

–UN

–23S

EP

96

A—Freeze Control SwitchB—Probe


2. Remove probe (B) of freeze control switch (A) fromheater/evaporator coil.

3. Disconnect wire leads from freeze control switch andremove switch from cover.

4. Test freeze control switch. (See Bench Test FreezeControl Switch in this group.)

TX,1830,MM3162 –19–18FEB99–2/2

T11

0752

D–U

N–0

8AU

G97

A—Freeze Control SwitchB—Freeze Control Switch Line

5. Attach freeze control switch (A) to heater/evaporatorcoil top cover.

6. Connect wiring leads to freeze control switch.

7. Route freeze control switch line (B) as shown. Routeunder foam on module.

IMPORTANT: Freeze switch line is a capillary tubefilled with refrigerant. A generous bendradius is required to ensure properoperation. DO NOT kink freeze switchline when bending.

8. Carefully bend the end of the freeze control switch lineat a 90 degree angle. Insert last 88.9 mm (3.5 in.) intoevaporator core starting 190 mm (7.5 in.) from the leftend and 114 mm (4.5 in.) from the bottom. Push freezecontrol switch line down into evaporator core at a 45degree angle. Freeze switch line should slide smoothlybetween the tubes in the evaporator core.



PN=466


18183035

TX,1830,MM3163 –19–14OCT98–1/1

Bench Test Freeze Control Switch

T83

921

–UN

–08N

OV

88

1. Connect ohmmeter to freeze control switch terminals.Put end of probe into an ice and salt water solution.

2. Switch must open at test specification.

Freeze Control Switch Test—SpecificationSwitch Opens—Temperature -0.56° ± 0.84°C (31° ± 1.5°F)......................

3. Warm the water.

4. Switch must close at test specification.

Freeze Control Switch Test—SpecificationSwitch Closes—Temperature -2.22° ± 0.84°C (36° ± 1.5°F)......................

If switch operates within specifications, reinstall switch andconnect leads.

If switch does not operate within specifications, replacewith new switch and connect leads.


PN=467


181830

36

TX,18,1111069 –19–04NOV97–1/1

Remove and Install Heater Control Valve

T11

2118

–UN

–04N

OV

97

A—HoseB—Heater Control Valve

1. Open left-hand side door. Remove cab fresh air filterhousing. (See Remove Fresh Air Filter in this group.)

2. Shut off the heater hose shut-off valves on the engineblock.


4. Disconnect temperature control switch cable fromheater control valve.

5. Disconnect hose (A).

6. Remove heater control valve (B) and test. (See HeaterControl Valve Leak Check in this group.)

7. Inspect heater hoses and replace as required.

IMPORTANT: Heater valve will leak if arrow on valveis not in the direction of coolant flow.

8. Install heater control valve with flow arrow (direction ofcoolant flow) on valve towards heater inlet (bottomport).

9. Connect the temperature control cable. Tighten allhose connections.


11. Turn on the heater hose shut-off valve.

12. Install cab fresh air filter housing.

13. Add coolant to the radiator. Start engine and run theheating system to check for leaks.

14. Add more coolant to account for coolant in the heatercircuit.


PN=468


TX,1830,MM3165 –19–09JUN98–1/1

Heater Control Valve Leak Check

1. Connect water pressure hose to control valve inlet andturn the valve arm to the closed position.

2. Check for leakage from the valve outlet.

NOTE: The heater control valve is not serviceable.

3. Replace heater control valve if required.

18183037

TX,18,1111130 –19–18FEB99–1/5

Remove and Install Main Blower Assembly

T11

2116

–UN

–04N

OV

97

A—Pressurizer Motor E—Resistor H—Cap Screws L—Heater ValveB—Inlet Air Plenum F—Main Blower Motor I—Lower Housing M—Air Conditioning LinesC—Expansion Valve G—Heater/Evaporator Upper J—Heater/Evaporator Coils N—HousingD—Freeze Control Switch Housing K—Heater Hoses O—Knob



PN=469


181830

38

TX,18,1111130 –19–18FEB99–2/5

T11

2347

B–U

N–2

5NO

V97

P—Cab Recirculation FilterQ—Foam CoverR—Left Hand Console ShelfS—Cab Access Door Release RodT—Cab Door Release

1. Park machine on a flat level surface, engine “OFF”.

2. Remove cab recirculation filter (P).

3. Remove seat. Disconnect wiring connector if machineis equipped with an air ride seat.

4. Remove seat base.

5. Remove foam cover (Q).

6. Open left rear cab service door.

7. Remove cab access door release rod (S).

8. Remove cab door release (T) from left hand consoleshelf (R).

9. Remove left hand side console shelf (R).

10. Remove fresh air filter housing with filter.

TX,18,1111130 –19–18FEB99–3/5

T11

2345

B–U

N–2

5NO

V97

B—Inlet Air PlenumU—Screw

11. Remove four screws attaching inlet plenum (B) toheater/evaporator coil housing.

12. Remove hidden screw (U) attaching inlet plenum (B)to cab floor.

13. Disconnect wiring harness from inlet air plenum.

14. Remove inlet air plenum (B).


PN=470



18183039

TX,18,1111130 –19–18FEB99–4/5

T11

2346

B–U

N–2

5NO

V97

D—Freeze Control SwitchE—ResistorF—Main Blower MotorG—Heater/Evaporator Upper HousingH—ScrewsI—Lower HousingJ—Main Blower Motor Cooling Tube

15. Disconnect main blower motor cooling tube (V) fromheater/evaporator upper housing (G).

16. Disconnect wire harness from freeze control switch(D) and resistor (E).

17. Remove freeze control switch (D) if equipped with airconditioning. Do not remove thermostat probe fromevaporator core.

18. Remove 13 screws from heater/evaporator upperhousing (G). Note position of hidden screws (H).

19. Remove four cap screws from main blower motor (F).

20. Remove upper housing (G) from heater/evaporatorcore.

21. Remove main blower motor (F).

22. Remove cage fan and clip from old blower motor.

23. Install cage fan and clip on new blower motorassembly.

24. Attach new main blower motor assembly to lowerhousing (I) using two screws.

25. Check lower housing (I) to make sure drain tube isplugged for the heater unit, or that drain tube is notplugged for the air conditioning unit.

26. Reinstall heater/evaporator core upper housing.

27. Attach two upper screws to main blower motor.

28. Connect main blower motor cooling tube (V) to upperheater/evaporator housing.

29. Reinstall freeze control switch (D) on upper housing(G).

30. Connect wiring harness to resistor (E) and freezecontrol switch (D).

31. Reinstall inlet air plenum (B) to heater/evaporatorhousing.


PN=471



181830

40

TX,18,1111130 –19–18FEB99–5/5

32. Reinstall screw (U) to cab floor and reinstall cabrecirculation filter.

33. Reinstall fresh air filter housing

34. Reinstall left hand side console shelf.

35. Reinstall cab access door release rod (S).

36. Reinstall cab door release (T) on left hand consoleshelf (R).

37. Reinstall foam cover (Q) behind seat.

38. Reinstall seat base and seat. Reconnect wiringconnector if machine is equipped with an air ride seat.

TX,18,1111071 –19–18FEB99–1/1

Remove and Install Pressurizer MotorAssembly

T11

2120

–UN

–04N

OV

97A—Pressurizer MotorB—Cooling Tube

1. Remove cab left-hand shelf.

2. Disconnect cooling tube (B).

3. Remove four screws from pressurizer motor (A).

4. Disconnect wiring harness from pressurizer motor.

5. Remove and inspect pressurizer motor.

6. Attach pressurizer motor assembly using screws.

7. Install cab left-hand shelf.


PN=472


18183041

TX,18,1111095 –19–18FEB99–1/2

Remove and Install Receiver-Dryer and Condenser

TP

6054

3–U

N–1

0NO

V98

1—O-Ring (4 used) 5—Ring 9—Vapor Condenser 13—Washer (3 used)2—Hose 6—Flange Nut (6 used) 10—Screw (6 used) 14—Washer3—Receiver-Dryer 7—Washer (21 used) 11—Bracket 15—Bracket4—Hose 8—Hinge 12—Screw (8 used) 16—Screw (2 used)


PN=473



181830

42

TX,18,1111095 –19–18FEB99–2/2

Receiver-Dryer


2. Discharge the system.

3. Disconnect lines (1 and 4) from receiver-dryer.

4. Remove receiver-dryer.

IMPORTANT: A new receiver-dryer must always beinstalled after purging the system.DO NOT use a flushed or usedreceiver/dryer. Contamination ofsystem can cause componentfailure.

5. Apply refrigerant oil to new O-rings. Remove plugsfrom receiver-dryer and immediately connect lines(1 and 14).

6. Add 15 mL (0.5 fl. oz.) refrigerant oil to system. Seeprocedure in this group.)

7. Evacuate and charge the system. (See procedurein this group.)

Condenser


2. Disconnect the condenser-to-compressor hose andcondenser-to-receiver-dryer hose.

3. Remove mounting cap screws. Remove condenser.


5. Install condenser and connect hoses

6. Evacuate and charge the air conditioning system.(See procedure in this group.)

TX,18,1111096 –19–18FEB99–1/1

Remove and Install High and Low PressureSwitches

T10

5454

B–U

N–1

2DE

C96

A—Low Pressure SwitchB—High Pressure Switch

1. Remove left-hand shelf.

2. Remove fresh air filter assembly. (See procedure inthis group.)

NOTE: The high pressure switch has a male connector;the low pressure switch has a female connector.

3. Disconnect wiring harness from the high pressureswitch (B) and the low pressure switch (A).

NOTE: A Schrader valve is located in the connection toprevent the air conditioning from discharging whenthe switches are removed.

4. Remove switches. Inspect and replace as required.


PN=474


TX,18,111479 –19–09JUN98–1/4

Remove and Install Fresh Air Filter

T10

5479

B–U

N–1

2DE

C96

18183043

A—Cab Door

1. Open cab fresh air filter door by pulling up on lever (A)to the left of the operator’s seat.

TX,18,111479 –19–09JUN98–2/4T

1031

87C

–UN

–12D

EC

96

A—Knob

2. Remove filter assembly by turning knob (A).



PN=475


181830

44

TX,18,111479 –19–09JUN98–3/4

T10

5493

B–U

N–1

2DE

C96

B—Clip (2 used)

NOTE: If operating in dusty conditions, cab fresh air filtershould be checked and cleaned as necessary.

3. Release clips (B).



PN=476


18183045

TX,18,111479 –19–09JUN98–4/4

T10

5494

B–U

N–1

2DE

C96

C—Filter

4. Remove filter (C). Replace if damaged.

5. Clean filter in one of these ways:

CAUTION: Prevent possible injury from flyingchips if compressed air is more than 210 kPa(2.1 bar) (30 psi). Reduce compressed air toless than 210 kPa (2.1 bar) (30 psi) when usingfor cleaning purposes. Clear area of bystanders,guard against flying chips, and wear personalprotection equipment including eye protection.

• Tap filter on a flat surface with the dirty side down.• Use compressed air opposite to the normal air flow.• Wash the filter in warm, soapy water. Flush the filter.

Let it dry before using the heater, defroster, or airconditioner.

6. Remove dust from filter housing.

IMPORTANT: Do not damage wire harness wheninstalling filter housing. Wiring can getpinched and damaged.

7. Install filter and filter duct work.

8. Install filter housing assembly. Close cab fresh air filterdoor.


PN=477


181830

46

TX,18,111480 –19–28SEP98–1/1

Remove and Install Recirculating Air Filter

T10

5499

B–U

N–1

2DE

C96

A—Air Filter Latch

NOTE: The cab recirculating air filter is located next tothe seat.

1. Turn latch (A) holding grille. Remove grille.

2. Remove filter.

CAUTION: Reduce compressed air to less than210 kPa (2 bar) (30 psi) when using for cleaningpurposes. Clear area of bystanders, guardagainst flying chips, and wear personalprotection equipment, including eye protection.

3. Clean filter in one of these ways:

• Tap it on a flat surface with the dirty side down.• Use compressed air opposite to the normal air flow.• Wash the filter in warm, soapy water. Flush the filter

and let it dry before using the air conditioner.

4. Install filter.

5. Install grille.


PN=478


18183047


PN=479


181830

48

TX,18,1111131 –19–31MAR99–1/2

Remove and Install Compressor

TP

6056

1–U

N–0

1DE

C98


PN=480



18183049

TX,18,1111131 –19–31MAR99–2/2

1—O-Ring 7—Clamp 12—Belt 17—Spacer (2 used)2—Hose 8—Screw (3 used) 13—Spring Pin (2 used) 18—Support3—Clamp 9—Ring 14—Screw 19—Tie Band (2 used)4—Screw 10—O-Ring 15—Screw 20—Cap5—Lock Nut 11—Compressor 16—Plate 21—Kit6—Refrigerant Hose

1. Recover refrigerant from the system. (Seeprocedure in this group.)

2. Loosen belt adjuster and remove drive belt (12).

3. Disconnect hoses (2 and 6). Remove compressorbelt cap screw.


5. Remove compressor.

6. Install compressor and tighten cap screws.

Compressor—SpecificationCompressor Through Bolt—Torque 26 N•m (19 lb-ft).......................................................................

7. Reconnect refrigerant lines. Tighten suction line (2)lb-ft) and discharge line (6) fitting.

Compressor—SpecificationCompressor Suction Line—Torque 31 N•m (23 lb-ft).......................................................................Compressor Discharge Line—Torque 22 •m (16 lb-ft)..........................................................................

8. Connect wiring lead.

9. If compressor was replaced due to an internalfailure, flush and purge each component in the airconditioning system individually. (See procedures inthis group.)

10. Add compressor oil. (See procedure in this group.)

IMPORTANT: Do not flush receiver/dryer or installa used one. Always install a newreceiver/dryer.

11. Remove existing receiver/dryer and install a newone. (See procedure in this group.)

12. Evacuate and charge the system. (See procedurein this group.)


PN=481


181830

50

TX,18,DY5297 –19–26OCT98–1/2

Disassemble and Assemble CompressorClutch—R134a

RW

2115

7–U

N–2

4JU

N92

T10

7716

–UN

–09M

AY

97

A—JDG747 Compressor C—Clutch Hub E—Pulley G—Clutch CoilClutch Spanner D—Pulley Snap Ring F—Clutch Coil Snap Ring H—Shim (As Required)

B—Clutch Shaft Bolt

1. Mount compressor on DFRW20 CompressorHolding Fixture using two 6 in. x 1/4 in. eye boltswith nuts as illustrated.

2. Remove dust cover.

3. Hold the clutch hub using JDG747 CompressorClutch Spanner (A) and remove the clutch shaft bolt(B).


PN=482



18183051

TX,18,DY5297 –19–26OCT98–2/2

4. Remove the clutch hub (C). Remove the shims (H)from the clutch hub and save for installation.

5. Remove and discard snap ring (D). Remove thepulley (E) using a plastic hammer or JDG220Puller, JDG748 Jaws, and JDG771 Hub Protector.

6. Disconnect the clutch coil lead wire. Remove anddiscard the snap ring (F) and remove the clutch coil(G).

NOTE: The bearing in the pulley is NOT serviceable.

7. Check pulley bearing operation. Replace pulley andbearing as required.

8. Install the clutch coil and new snap ring with flatside of the snap ring down. Connect the clutch coillead wire.

9. Install the pulley and new snap ring with flat side ofthe snap ring down. Apply grease to the shims (H)and install to the clutch hub.

10. Install clutch hub and shaft bolt and tighten. Installdust cover.

Compressor—SpecificationClutch Shaft Bolt—Torque 14 N•m (120 lb-in.).....................................

TX,1830,BA636 –19–14OCT98–1/1

Check Clutch Hub Clearance—R134a

RW

2115

9–U

N–2

4JU

N92

NOTE: The clutch coil is NOT polarity sensitive.

1. Check pulley-to-clutch hub clearance using a dialindicator. Mount the gauge to the pulley as illustratedand connect a set of jumper wires from the compressorto a 12V battery.

2. Rotate the pulley and check clearance in three equallyspaced locations around the clutch hub. Add or removeshims as required.

Compressor—SpecificationClutch Hub—Clearance 0.35—0.65 mm (0.014—0.026 in)........................

3. Tighten clutch shaft bolt after correct clearance isobtained.

Compressor—SpecificationClutch Shaft Bolt—Torque 14 N•m (120 lb-in.)............................................


PN=483


181830

52

TX,1830,BA637 –19–18FEB99–1/1

Inspect Compressor Manifold—R134a

RW

2116

0–U

N–2

4JU

N92A—Manifold Cap Screw

B—ManifoldC—Manifold Seal

1. Remove cap screws (A) and the manifold (B).

2. Remove and discard seal (C). Inspect porting surfaces.

3. Lubricate and install a new seal (C).

4. Install manifold and tighten cap screws.

Compressor—SpecificationCompressor Manifold CapScrew—Torque 26 N•m (19 lb-ft)................................................................


PN=484


18183053

TX,18,DY5026 –19–18FEB99–1/3

Disassemble, Inspect and Assemble Compressor—R134a

RW

2116

1–U

N–2

4JU

N92

A—Rear Pins G—Rear O-Ring L—Front Gasket Q—Felt HolderB—Rear Housing H—Front O-Ring M—Snap Ring R—FeltC—Rear Gasket I—Front Suction Reed Valve N—Lip Seal S—Front HousingD—Rear Discharge Reed Valve J—Front Valve Plate O—Washer T—Front PinsE—Rear Valve Plate K—Front Discharge Reed P—Through BoltF—Rear Suction Reed Valve Valve

1. Clean the compressor using solvent beforedisassembly. Mount compressor on holding fixtureand remove clutch. (See Disassemble andAssemble Compressor Clutch R134a in this group.)

IMPORTANT: When removing front and rearhousing, be careful NOT to damagethe sealing surfaces.

2. Disassemble the compressor as illustrated anddiscard the O-rings, gaskets, lip seal, snap ring,and through bolt washers. Replace parts fromservice kits.

NOTE: The valve plates, reed valves, cylinders, andcylinder housing are NOT serviceable. Somecylinder scuffing (light scratches) is normal.

3. Inspect the valves for an even wear pattern and thecylinders for scoring or excessive wear. Replacecompressor as required.

4. Remove the shaft seal snap ring (M). Turn thehousing over and remove the felt holder (Q) and felt(R) from the front housing (S).


PN=485



TX,18,DY5026 –19–18FEB99–2/3

5. Remove the shaft lip seal (N) from the front housing(S) using a small tool with 5/8 in. OD.

6. Wash all parts in clean solvent and dry beforeassembly.

IMPORTANT: Lubricate O-rings, gaskets, and lipseal using only TY22025 (R134a)

refrigerant oil during assembly.Other oils could damage thecompressor.

7. Apply R134a oil to the bore of the front housing andinstall new lip seal (N) to the bottom of the boreusing a socket. Install new snap ring (M) flat sidedown.

181830

54



PN=486


18183055

TX,18,DY5026 –19–18FEB99–3/3

RW

2116

2–U

N–2

4JU

N92

RW

2116

3–U

N–2

4JU

N92

C—Rear Gasket E—Rear Valve Plate F—Rear Suction Reed Valve U—Bushing SpacerD—Rear Discharge Reed Valve

IMPORTANT: Bushing spacer (U) must be inposition before assembling thecompressor.

8. Install pins (A) and new O-ring (G) in the rearcylinder.

NOTE: The rear valve plate is marked with an "R" andis installed face up.

9. Install parts (F—D) over the pins on the rearcylinder.

10. Install a new gasket (C) flat side down and therear housing (B) on the rear cylinder. Mount thecompressor onto the holding fixture.

11. Install pins (T) and new O-ring (H) in the frontcylinder.

NOTE: The front valve plate is marked with an "F" andis installed face up.

12. Install parts (I—K) over the pins on the frontcylinder.

13. Install a new gasket (L) flat side down. PutJDG746 Compressor Seal Protector on the shaftand lubricate with R134a oil.

14. Install the front housing (S) on the front cylinderand remove the lip seal protector. Install throughbolts (P) and new washers (O).

15. Partially tighten the through bolts and thentighten.

Compressor—SpecificationCompressor Through Bolt—Torque 26 N•m (19 lb-ft).......................................................................

16. Install the felt (R) and felt holder (Q) using theclutch hub.

17. Install the pulley-clutch hub and check clearance.(See Disassemble and Assemble CompressorClutch—R134a and Check Clutch HubClearance—R134a in this group.)


PN=487


181830

56


PN=488

Group 1899Dealer Fabricated Tools

1818991

TX,18,1111100 –19–22NOV97–1/1

DFRW20 Compressor Holding Fixture

RW

1361

9–U

N–2

0SE

P89

A—102 mm (4 in.) D—6.4 mm (0.25 in.) G—254 mm (10 in.) J—WeldB—76 mm (3 in.) E—19 mm (0.75 in.) H—114 mm (4.5 in.) K—Two HolesC—70 mm (2.75 in.) F—152 mm (6 in.) I—178 mm (7 in.)

This tool is used to hold the air conditioningcompressor during disassembly and assembly.

Materials required are:

• Two pieces of steel plate, approximately 70 x 120mm (2—3/4 in.) and 152 x 254 mm (6 x 10 in.)

• Two pieces of threaded rod, 13 mm (1/2 in.) threadsx 178 mm (7 in.) long and four lock washers andnuts.


PN=489

Dealer Fabricated Tools

181899

2


PN=490

Section 19Sheet Metal and Styling

Contents

Page

Group 1910—Hood or Engine EnclosureSpecifications . . . . . . . . . . . . . . . . . . . . . . . .19-1910-1Hood

Remove and Install . . . . . . . . . . . . . . . . . .19-1910-2Engine Side Shields


Group 1913—Miscellaneous ShieldsTransmission Shields

Remove and Install . . . . . . . . . . . . . . . . . .19-1913-1 19Battery Covers


Group 1921—Grille and Grille HousingService Equipment and Tools . . . . . . . . . . . .19-1921-1Specifications . . . . . . . . . . . . . . . . . . . . . . . .19-1921-1Grille and Grille Housing


Group 1927—Miscellaneous ShieldsFront Fenders

Remove and Install . . . . . . . . . . . . . . . . . .19-1927-1Fenders

Rear, Remove and Install . . . . . . . . . . . . .19-1927-2


PN=1

Contents

19


PN=2

Group 1910Hood or Engine Enclosure

CED,OUOE003,2714 –19–31MAR99–1/1

Specifications


Engine Side Shield Weight 23 kg (50 lb) approximate

1919101


PN=493

Hood or Engine Enclosure

191910

2

TX,19,1111039 –19–18FEB99–1/1

Remove and Install Hood

TP

5568

1–U

N–0

6OC

T97

1—Screw (4 used) 2—Washer (4 used) 3—Hood


PN=494


1919103

TX,19,1111040 –19–18FEB99–1/1

Remove and Install Engine Side Shields

TP

5568

0–U

N–0

7OC

T97

1—Hinge (2 used) 6—Washer (4 used) 9—Isolator (As Required) 13—Screw (6 used)2—Latch 7—Spring Locking Pin (4 10—Cap Screw (2 used) 14—Door3—Rivet (4 used) used) 11—Plate (2 used) 15—Shield4—Shield 8—Rod (2 used) 12—Washer (6 used) 16—Door5—Screw (6 used)

CAUTION: Each engine side shield weighsapproximately 23 kg (50 lb).

SpecificationEngine Side Shield—Weight 23 kg (50 lb) approximate......................


PN=495


191910

4


PN=496

Group 1913Miscellaneous Shields

1919131

TX,1910,111306 –19–18FEB99–1/1

Remove and Install Transmission Shields

TP

5581

0–U

N–1

2JA

N98

1—Screw (2 used) 2—Washer (2 used) 3—Cover 4—Cover


PN=497

Miscellaneous Shields

191913

2

TX,1910,111307 –19–18FEB99–1/1

Remove and Install Battery Covers

TP

5560

1–U

N–0

8JU

L97

1—Cover 2—Cover 3—Washer (8 used) 4—Cap Screw (8 used)


PN=498

Group 1921Grille and Grille Housing

CED,OUOE003,2715 –19–31MAR99–1/2



191921


1CED,OUOE003,2715 –19–31MAR99–2/2

Metric Lifting Eyebolt (2 used) . . . . . . . . . . . . . JT05550

Used in conjunction with a chain and hoist to remove andinstall grille and grille housing.

CED,OUOE003,2716 –19–31MAR99–1/1

Specifications


Grille Housing Weight 83 kg (183 lb) approximate

Grille Screen Weight 23 kg (50 lb) approximate


PN=499

Grille and Grille Housing

191921

2

TX,19,1111129 –19–18FEB99–1/3

Remove and Install Grille and Grille Housing

T11

2440

B–U

N–0

6JA

N98

A—Fan Guard C—Baffle Cap Screw (4 used) D—Rear Wiring Harness E—Fuel Tank Filler Neck withB—Grille Housing-to-Frame Connectors Hose

Cap Screw (2 used)

1. Disconnect battery ground strap or turn batterydisconnect switch “Off” if equipped.

2. Remove hood. (See Group 1910.)

3. Remove battery box covers.

4. Remove fan guard (A).

5. Disconnect rear wiring harness connectors (D) atgrille housing.

6. Remove fuel tank filler neck with hose (D).

7. Remove four cap screws (C) and remove radiatorbaffle plate.

CAUTION: Grille housing weighsapproximately 83 kg (183 lb).

Grille screen weighs approximately 23 kg (50lb).

SpecificationGrille Housing—Weight 83 kg (183 lb) approximate............................Grille Screen—Weight 23 kg (50 lb) approximate................................

8. Install two 12 mm JT05550 Eyebolts in tappedholes in top of grille housing.

9. Attach a chain and hoist to the eyebolts.


PN=500



TX,19,1111129 –19–18FEB99–2/3

10. Remove two grille housing-to-frame cap screws(B).

1919213

TX,19,1111129 –19–18FEB99–3/3

T11

2441

B–U

N–0

6JA

N98

A—Radiator and Oil Cooler OutsideFrame-to-Grille Housing Cap Screw (2 used)

B—Door Striker Plate (2 used)C—Bottom Grille Housing-to-Engine Frame Cap

Screw (2 used)

11. Remove two radiator and oil cooler outsideframe-to-grille housing cap screws (C).

12. Remove two door striker plates (B).

13. Carefully lift grille housing until it clears top of radiatorand oil cooler.

14. Install grille housing using eyebolts, in conjunctionwith a chain and a hoist.

15. Install and tighten two bottom grille housing-to-engineframe cap screws.

16. Install and tighten two radiator and oil cooler outsideframe-to-grille housing cap screws.

17. Install two door striker plates.

18. Install and tighten two grille housing-to-frame capscrews.

19. Connect rear wiring harness connector.

20. Install fuel tank filler neck with hose.

21. Install fan guard.

22. Install battery box covers.

23. Install hood. (See Group 1910.)

24. Connect battery ground strap or turn batterydisconnect switch On, if equipped.

25. Install engine side shields. (See Group 1910.)

26. Install hood. (See Group 1910.)

27. Connect battery ground strap or turn batterydisconnect switch “On” if equipped.


PN=501


191921

4


PN=502

Group 1927Miscellaneous Shields

1919271

TX,1927,111310 –19–29SEP98–1/1

Remove and Install Front Fenders

TP

4867

8–U

N–1

7MA

R97

1—Fender 4—Washer (8 used) 7—Lock Nut (8 used) 9—Washer (4 used)2—Fender 5—Support (4 used) 8—Washer (8 used) 10—Screw (4 used)3—Bolt (8 used) 6—Nut (8 used)


PN=503

Miscellaneous Shields

191927

2

TX,1927,111309 –19–18FEB99–1/1

Remove and Install Rear Fenders

TP

6043

8–U

N–2

0JU

L98

1—Kit 5—Screw (10 used) 9—Support (2 used) 12—Platform2—Screw (18 used) 6—Washer (10 used) 10—Platform 13—Fender3—Washer (36 used) 7—Lock Nut (18 used) 11—Strap (2 used) 14—Fender4—Support (2 used) 8—Platform


PN=504

Section 20Safety and ConvenienceContents

Page

Group 2002—MirrorRear View Mirror

Remove and Install . . . . . . . . . . . . . . . . . .20-2002-1Outside Mirror for Cab or Canopy


Group 2003—Fire ExtinguisherFire Extinguisher and Bracket


Group 2004—Horn and Warning DevicesHorn

Remove and Install . . . . . . . . . . . . . . . . . .20-2004-1Reverse Warning Alarm

Remove and Install . . . . . . . . . . . . . . . . . .20-2004-220Change Volume. . . . . . . . . . . . . . . . . . . . .20-2004-2


PN=1

Contents

20


PN=2

Group 2002Mirror

2020021

TX,2002,111312 –19–05JUN98–1/1

Remove and Install Rear View Mirror

TP

3376

9–U

N–0

1JA

N94

1—Rear View Mirror 2—Washer 3—Nut


PN=507

Mirror

202002

2

TX,2002,111313 –19–18FEB99–1/1

Remove and Install Outside Mirror for Cab or Canopy

TP

5550

1–U

N–0

1MA

Y97

1—Clamp 4—Cap Screw 7—Mirror Arm 10—Rear View Mirror2—Washer 5—Washer (2 used) 8—Cap Assembly3—Lock Nut 6—Washer 9—Rear View Mirror


PN=508

Group 2003Fire Extinguisher

2020031

TX,20,1111076 –19–18FEB99–1/1

Remove and Install Fire Extinguisher and Bracket

TP

5551

5–U

N–0

5MA

Y97

1—Fire Extinguisher Assembly 2—Bracket 3—Screw (2 used) 4—Nut (2 used)


PN=509

Fire Extinguisher

202003

2


PN=510

Group 2004Horn and Warning Devices

2020041

TX,2004,111465 –19–05JUN98–1/1

Remove and Install Horn

T10

9420

–UN

–06M

AY

97

Loader Frame Harness (Without Tool Carrier) Shown

A—High Note Horn (A03 Org/G05 Blk)B—Low Note Horn—If Equipped (A03 Org/G05 Blk)


PN=511

Horn and Warning Devices

202004

2

TX,2004,111466 –19–05JUN98–1/1

Remove and Install Reverse Warning Alarm

T10

9419

–UN

–06M

AY

97

Rear Frame Harness Shown

A—Reverse Warning Alarm

Disconnect M01 purple and G02 black wiring leads fromreverse warning alarm (A).

Remove and install reverse warning alarm mounted togrille housing.

TX,2004,111467 –19–05JUN98–1/1

Change Volume Reverse Warning Alarm

T78

53A

T–U

N–0

8OC

T92

A—Alarm Volume Switch

IMPORTANT: The reverse warning alarm is set onhigh volume at the factory. It may benecessary to adjust the volume to meetlocal regulations.

NOTE: Alarm removed from machine for clarity ofphotograph.

To change alarm volume, move switch (A) to desiredposition.


PN=512

Section 31Loader

Contents

PagePage

Group 3102—Bucket Hydraulic Pump Control ValveRemove and Install . . . . . . . . . . . . . . . . .31-3160-34Specifications . . . . . . . . . . . . . . . . . . . . . . . .31-3102-1Disassemble and Assemble. . . . . . . . . . .31-3160-36Ride Control Accumulator

Loader Control ValveSafety . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3102-2Remove and Install . . . . . . . . . . . . . . . . .31-3160-37Bucket Tooth Shanks and TipsDisassemble and Assemble. . . . . . . . . . .31-3160-40Remove and Install . . . . . . . . . . . . . . . . . .31-3102-3

Auxiliary Valve Section and Bucket SectionBucketDisassemble and Assemble. . . . . . . . . . .31-3160-41Remove and Install . . . . . . . . . . . . . . . . . .31-3102-5

Disassemble and Assemble Bucket ValveWelded Bucket Cutting EdgeSection—Tool Carrier . . . . . . . . . . . . . . .31-3160-42Remove and Install . . . . . . . . . . . . . . . . . .31-3102-6

Boom Valve SectionBolt-On Bucket Cutting Edges and WearDisassemble and Assemble. . . . . . . . . . .31-3160-43Plates

System Relief ValveRemove and Install . . . . . . . . . . . . . . . . . .31-3102-7Disassemble and Assemble. . . . . . . . . . .31-3160-44Cutting Edge

Bucket Circuit Relief ValveRepair Cracks . . . . . . . . . . . . . . . . . . . . . .31-3102-9Disassemble and Assemble. . . . . . . . . . .31-3160-44

Load Sense Relief ValveGroup 3140—FramesDisassemble and Assemble. . . . . . . . . . .31-3160-45Service Equipment and Tools . . . . . . . . . . . .31-3140-1

Boom Circuit Relief ValveOther Material . . . . . . . . . . . . . . . . . . . . . . . .31-3140-1Disassemble and Assemble. . . . . . . . . . .31-3160-45Specifications . . . . . . . . . . . . . . . . . . . . . . . .31-3140-2

Boom Cylinder 31Bucket Tilt LinkageRemove and Install . . . . . . . . . . . . . . . . .31-3160-46

Remove and Install . . . . . . . . . . . . . . . . . .31-3140-3Loader Start-Up Procedure . . . . . . . . . . .31-3160-48

Bucket Linkage Seals and BushingsBucket Cylinder

Remove and Install . . . . . . . . . . . . . . . . . .31-3140-4 Remove and Install . . . . . . . . . . . . . . . . .31-3160-49Tool Carrier Upper Tilt Linkage Loader Start-Up Procedure . . . . . . . . . . .31-3160-51

Disassemble and Assemble. . . . . . . . . . . .31-3140-5 Cross Section . . . . . . . . . . . . . . . . . . . . .31-3160-52Tool Carrier Lower Tilt Linkage Disassemble and Assemble. . . . . . . . . . .31-3160-53

Disassemble and Assemble. . . . . . . . . . . .31-3140-6 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-54Tool Carrier Boom Cylinder

Disassemble and assemble . . . . . . . . . . . .31-3140-8 Piston Wear Ring Configuration. . . . . . . .31-3160-56Loader Boom Bushings and Seals Cross Section . . . . . . . . . . . . . . . . . . . . .31-3160-58

Remove and Install . . . . . . . . . . . . . . . . . .31-3140-9 Disassemble and Assemble. . . . . . . . . . .31-3160-59Tool Carrier Boom Bushings and Seals Boom, Bucket or Tilt Cylinder

Remove and Install . . . . . . . . . . . . . . . . .31-3140-10 Remove and Install Bushings andSeals . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-67

Group 3160—Hydraulic System Hydraulic ReservoirEssential Tools . . . . . . . . . . . . . . . . . . . . . . .31-3160-1 Remove and Install . . . . . . . . . . . . . . . . .31-3160-68Service Equipment and Tools . . . . . . . . . . . .31-3160-2 Hydraulic Oil Clean-Up Procedure UsingOther Material . . . . . . . . . . . . . . . . . . . . . . . .31-3160-3 Portable Filter Caddy . . . . . . . . . . . . . . . .31-3160-69Specifications . . . . . . . . . . . . . . . . . . . . . . . .31-3160-4 Pilot Controller (Single Lever)Loader Hydraulic Pump Remove and Install . . . . . . . . . . . . . . . . .31-3160-70

Remove and Install . . . . . . . . . . . . . . . . . .31-3160-9 Cross Section . . . . . . . . . . . . . . . . . . . . .31-3160-71Hydraulic Pump Disassemble and Assemble. . . . . . . . . . .31-3160-71

Cross Section . . . . . . . . . . . . . . . . . . . . .31-3160-12Continued on next pageDisassemble, Inspect and Assemble . . . .31-3160-13


PN=1

Contents

Page

Pilot Controller Repair (Two Lever Controller)(S.N. —585560). . . . . . . . . . . . . . . . . . . .31-3160-87

Pilot Controller Repair (Two LeverController) (S.N. 585561—) . . . . . . . . . . .31-3160-91

Pressure Reducing Valve ManifoldRemove and Install . . . . . . . . . . . . . . . . .31-3160-94

Pressure Reducing ValveRemove and Install . . . . . . . . . . . . . . . . .31-3160-95Disassemble and Assemble. . . . . . . . . . .31-3160-96

Boom Down Solenoid ValveRemove and Install . . . . . . . . . . . . . . . . .31-3160-97

Differential Lock Solenoid ValveRemove and Install . . . . . . . . . . . . . . . . .31-3160-98

Pilot Enable Solenoid ValveRemove and Install . . . . . . . . . . . . . . . . .31-3160-99

Ride Control Repair (S.N. —582200) . . . .31-3160-100Ride Control Repair (S.N. 582201—) . . . .31-3160-104Ride Control Accumulator

Disassemble and Assemble. . . . . . . . . .31-3160-108Charge. . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-112

Pin Disconnect/Axle Disconnect ValveRemove and Install . . . . . . . . . . . . . . . .31-3160-114

Pin Disconnect ValveDisassemble and Assemble. . . . . . . . . .31-3160-115

Axle Disconnect ValveDisassemble and Assemble. . . . . . . . . .31-3160-116

31


PN=2

Group 3102Bucket

3131021

CED,OUOE003,3378 –19–22APR99–1/1

Specifications


Bucket

Cutting Edge-to-Center Tooth Torque 624 N•m (460 lb-ft)Shank Cap Screw

End Tooth Shank-to-Bucket Cap Torque 1171 N•m (790 lb-ft)Screw

Cutting Edge-to-Segment Cap Torque 624 N•m (460 lb-ft)Screw

2.3 M (3.0 yd) Bucket Weight 963 kg (2123 lb) approximate

2.7 M (3.5 yd) Bucket Weight 1034 kg (2280 lb) approximate

Boom End-to-Bucket Clearance 1 mm (0.04 in.) maximum

Bucket Link-to-Bucket Clearance 2 mm (0.08 in.) maximum

Cutting Edge Segment Weight 66 kg (145 lb) approximate

Cutting Edge-to-Bucket Cap Screw Torque 495 N•m (365 lb-ft)

Wear Plate-to-Bucket Cap Screw Torque 300 N•m (225 lb-ft)

Welding

Bucket Cutting Edge Preheat Temperature 204°C (400°F) minimum throughoutentire thickness of parts

Distance 51 mm (2 in.) minimumback from joint

Cracked Cutting Edge Preheat Temperature 149°—260°C (300°—500°F)Distance 13 mm (0.5 in.) beyond end of crack


PN=515

Bucket

313102

2

TX,31,RP3118 –19–30APR97–1/1

Ride Control Accumulator Safety

1. Stop engine.

CAUTION: Prevent possible injury fromunexpected boom or bucket movement whenequipped with ride control. Always be sure theride control accumulator energy is dischargedwhen working on hydraulic components. To dothis: With boom raised slightly, turn ignitionswitch to ON position. Cycle the ride controlswitch from OFF to ON (center position). Boomwill jump up unexpectedly if ride controlaccumulator is energized. Press boom enableswitch and move the control lever into the floatposition and hold for 5 seconds.



PN=516

Bucket

3131023

TX,31,RP3362 –19–17FEB99–1/2

Remove and Install Bucket Tooth Shanks and Tips

T11

1849

–UN

–22O

CT

97

1—Cutting Edge Segment (7 3—Cap Screw (2 used) 6—Tooth Tip (8 used) 9—Washer (24 used)used) 4—Washer (2 used) 7—Washer (8 used) 10—Nut (26 used)

2—Adapter (Shank) 5—Pin (8 used) 8—Cap Screw (12 used) 11—Bolt (14 used)

1. Remove cap screws to remove tooth shanks andcutting edge segments.

IMPORTANT: Shanks must be seated againstcutting edge as nuts are tightened.This places the load on the cuttingedge and not on the cap screws.

2. Install tooth shanks.

3. Install cutting edge segments between toothshanks.

4. Install cap screws in center tooth shanks andcutting edge segments with cap screw heads onbottom.

Bucket—SpecificationCutting Edge-to-Center ToothShank Cap Screw—Torque 624 N•m (460 lb-ft)..................................End Tooth Shank-to-BucketCap Screw—Torque 1171 N•m (790 lb-ft)...........................................

5. Install cap screws to corner tooth shanks with capscrew heads to outside.

Bucket—SpecificationCutting Edge-to-Segment CapScrew—Torque 624 N•m (460 lb-ft).....................................................

6. To remove tooth tip, drive pin (5) out from the leftside of machine.


PN=517


Bucket

TX,31,RP3362 –19–17FEB99–2/2

7. To install tooth tip, install retaining washer (4) inrecess on left side of tooth shank. Drive tip onshank until pin can be assembled or until center ofhole in shank aligns with center of slot in tooth tip.

8. Drive pin (5) through tip and shank from left side.Pin must not contact front edge of tooth tip slot.

NOTE: Pin may fail if in contact with front edge oftooth tip slot. Try a different tooth tip or grindslot in tooth tip longer.

313102

4


PN=518

Bucket

3131025

TX,31,ME119 –19–17FEB99–1/2

Remove and Install Bucket

T10

8202

–UN

–26N

OV

97

A—Shim, Bucket Link to C—Spacer (3 used) F—Grease Fitting (2 used) H—Shim, Bucket to Boom (asBucket (as needed) D—Washer (3 used) G—Pin, Bucket to Boom (2 needed)

B—Pin, Bucket Link to Bucket E—Cap Screw (3 used) used)

CAUTION: The approximate weight of the 2.3M (3.0 yd) bucket is 963 kg (2123 lb).

The approximate weight of the 2.7 M (3.5 yd)bucket is 1034 kg (2280 lb).

Bucket—Specification2.3 M (3.0 yd) Bucket—Weight 963 kg (2123 lb) approximate............2.7 M (3.5 yd) Bucket—Weight 1034 kg (2280 lb) approximate..........

1. Lower bucket to the ground.

2. Remove cap screws (E), washers (D), spacers (C),and pins (B and G).

3. Remove bucket.

4. Align boom ends with bucket. Install shims (H)between boom ends and bucket as needed to

obtain maximum clearance.

Bucket—SpecificationBoom End-to-Bucket—Clearance 1 mm (0.04 in.) maximum....................................................

Install an equal number of shims ± 1 on each side ofboom end.

Install pins (G), spacers (C), washers (D) and capscrews (E).

5. Align bucket link with bucket. Install shims (A)between bucket link and bucket to obtain maximumclearance.

Bucket—SpecificationBucket Link-to-Bucket—Clearance 2 mm (0.08 in.) maximum....................................................


PN=519


Bucket

TX,31,ME119 –19–17FEB99–2/2

Install an equal number of shims ± 1 on each side ofbucket link.

Install pin (B), spacers (C), washers (D), and capscrews (E).

313102

6

TX,31,ME120 –19–17FEB99–1/1

Remove and Install Welded Bucket Cutting Edges

1. Perform welding in an environment with a minimumambient temperature of 10°C (50°F).

2. Clean all joints to be welded of all foreign mattersuch as dirt, rust, mill scale, oil, etc. with grindersand/or solvents.

3. Use dry AWS-E7018 low hydrogen electrodes oreither of the following equivalent low hydrogen wirefeed electrodes: gas metal arc welding (CO2 orargon CO2) AWS-E70S6 or flux cored arc weldingAWS-E70T1.

4. Preheat parts to be welded (both tack and finalwelds) to minimum of 204°C (400°F). PREHEATTEMPERATURE MUST BE THROUGHOUT THEENTIRE THICKNESS OF THE PARTS JOINEDAND AT LEAST 51 mm (2 in.) BACK FROM THEJOINT. Maintain preheat throughout the entirewelding operation. Tempilstiks should be used ifpossible.

Welding—SpecificationBucket Cutting Edge—PreheatTemperature 204°C (400°F) minimum

throughout entirethickness of parts

.................................................

Distance 51 mm (2 in.) minimumback from joint

..........................................................

5. Tack weld preheated plates starting at center ofbucket and working toward the outside ends.

6. Final weld preheated plates starting at the center ofthe front edge of the bucket backing plate andworking toward the outside ends.

Repeat this operation at back edge of loader blade.

Tack welds may be incorporated into the final weld,providing they have been made with electrodes thatmeet the requirements of the final welds and nocracking has occurred in the weld metal. Tackwelds not meeting these requirements must becompletely removed by grinding or air arc gougingjust prior to making the final weld in that area.

7. Do not remove bucket from welding environmentuntil weld metal temperature has dropped to theambient temperature. Do not force cooling rate ofweld metal.


PN=520

Bucket

3131027

TX,31,RP3077 –19–17FEB99–1/2

Remove and Install Bolt-On Cutting Edges and Wear Plates

TP

4831

9–U

N–1

7AP

R96

1—Nut (12 used) 2—Cutting Edge (2 used) 3—Bolt (12 used) 4—Cutting Edge (2 used)



PN=521

Bucket

313102

8

TX,31,RP3077 –19–17FEB99–2/2

T10

9256

–UN

–29A

PR

97

1—Wear Plate 2—Bolt (8 used) 3—Washer (8 used) 4—Nut (8 used)

CAUTION: The approximate weight of thecutting edge segments is 66 kg (145 lb).

Bucket—SpecificationCutting Edge Segment—Weight 66 kg (145 lb) approximate...............

1. Remove hardware and cutting edge from bucket.

Remove hardware from wear plates and install newwear plates and hardware.

2. To install, hold cutting edge in position and installnew hardware.

Bucket—SpecificationCutting Edge-to-Bucket CapScrew—Torque 495 N•m (365 lb-ft).....................................................Wear Plate-to-Bucket CapScrew—Torque 300 N•m (225 lb-ft).....................................................


PN=522

Bucket

TX,31,ME122 –19–17FEB99–1/1

Repair Cracked Cutting Edge

1. If cutting edge has any cracks, clean the area to findend of crack.

2. Drill a small hole at end of crack to prevent spreading.

3. Grind V-grooves along crack on top and bottom ofcutting edge.

4. Preheat the cracked area.

Welding—SpecificationCracked Cutting Edge—PreheatTemperature 149°—260°C (300°—500°F)..................................................

5. Fill the V-grooves with weld. Use E7018 electrodes.Extend the weld beyond end of crack.

Welding—SpecificationCracked Cutting Edge—Distance 13 mm (0.5 in.) beyond end of

crack.............

3131029


PN=523

Bucket

313102

10


PN=524

Group 3140Frames

CED,OUOE003,3380 –19–22APR99–1/2




CED,OUOE003,3380 –19–22APR99–2/2

Bushing, Bearing and Seal Driver Set . . . . . . D01044AA

Used to remove and install bushings and seals.

3131401

CED,OUOE003,3382 –19–22APR99–1/1

Other Material

Number Name Use

PT569 (U.S.) John Deere NEVER-SEEZ Apply to bore of bellcrank pivot pin.Lubricant Apply to bushings and bushing

bores.



PN=525

Frames

313140

2

CED,OUOE003,3381 –19–22APR99–1/1

Specifications


Bellcrank Weight 318 kg (700 lb) approximate

Bellcrank Pivot Pin Weight 30 kg (65 lb) approximate

Bucket Link Weight 77 kg (170 lb) approximate

Bellcrank-to-Bucket Link Clearance 3 mm (0.12 in.) maximum

Bellcrank-to-Bucket Cylinder Clearance 3 mm (0.12 in.) maximum

Bellcrank-to-Loader Boom Clearance 3 mm (0.12 in.) maximum

Bucket Linkage Bushing Depth 6.4 mm (0.25 in.) minimum belowsurface or centered in bushing bore

Tool Carrier Tilt Linkage Bushing Depth 8 mm (0.31 in.) below surface of link

Tool Carrier Boom-to-Bellcrank Clearance 3 mm (0.12 in.) maximum

Tool Carrier Link Boom-to-Link Clearance 3 mm (0.12 in.) maximum

Tool Carrier Boom-to-Link Clearance 3 mm (0.12 in.) maximum

Tool Carrier Link-to-Tool Carrier Clearance 3 mm (0.12 in.) maximum

Tool Carrier Boom End-to-Tool Clearance 1 mm (0.04 in.) maximumCarrier

Tool Carrier Cylinder-to-Tool Carrier Clearance 1 mm (0.04 in.) maximum

Bucket Cylinder Weight 105 kg (232 lb) approximate

Loader Boom Weight 1089 kg (2400 lb) approximate

Loader Boom-to-Loader Frame Clearance 3 mm (0.12 in.) maximum

Tool Carrier Boom Weight 907 kg (2000 lb) approximate

Tilt Cylinder Weight 98 kg (216 lb) approximate


PN=526

Frames

3131403

TX,31,ME126 –19–17FEB99–1/1

Remove and Install Loader Bucket Tilt Linkage

T10

8207

–19–

03A

PR

97

A—Bucket Cylinder E—Grease Fitting (3 used) H—Pin K—Cap Screw (2 used)B—Shim (As Required) F—Seal (4 used) I—Spacer (2 used) L—PinC—Bellcrank G—Bucket Link J—Washer (2 used) M—Loader BoomD—Shim (As Required)

1. Lower bucket to the ground.

CAUTION: The approximate weight of thebellcrank is 318 kg (700 lb).

The approximate weight of the bellcrankpivot pin is 30 kg (65 lb).

The approximate weight of the bucket link is77 kg (170 lb).

SpecificationBellcrank—Weight 318 kg (700 lb) approximate..................................Bellcrank Pivot Pin—Weight 30 kg (65 lb) approximate.......................Bucket Link—Weight 77 kg (170 lb) approximate................................

2. Remove parts as necessary.

3. Install shims (B) on bellcrank-to-bucket link andbellcrank-to-bucket cylinder and shims (D) onbellcrank-to-loader boom to obtain maximumclearance.

SpecificationBellcrank-to-Bucket Link—Clearance 3 mm (0.12 in.) maximum....................................................Bellcrank-to-Bucket Cylinder—Clearance 3 mm (0.12 in.) maximum....................................................Bellcrank-to-Loader Boom—Clearance 3 mm (0.12 in.) maximum....................................................

4. Apply NEVER-SEEZ Lubricant or an equivalent tobore of bellcrank pivot pin.



PN=527

Frames

313140

4

TX,3140,RP3044 –19–17FEB99–1/1

Remove and Install Bucket Linkage Seals and Bushings

T10

8214

–19–

26N

OV

97

A—Bellcrank C—Bucket Link E—Bushing (2 used) G—BushingB—Seal (2 used) D—Seal (4 used) F—Shim (As Required)

1. Remove bushings and seals from bucket link andbellcrank using disks from Bushing, Bearing andSeal Driver Set.

2. Apply NEVER-SEEZ Lubricant or an equivalent tonew bushings and bushing bores.

3. Install bucket link and bellcrank bushings belowsurface, or centered in bushing bore.

SpecificationBucket Linkage Bushing—Depth 6.4 mm (0.25 in.) minimum

below surface or centered inbushing bore

........................................................

4. Install seals (D) into bores against bushings or flushwith surface of bucket link and bellcrank.



PN=528

Frames

3131405

TX,3140,DU755 –19–17FEB99–1/1

Disassemble and Assemble Tool Carrier Upper Tilt Linkage

T10

8217

–UN

–26N

OV

97

A—Bellcrank (2 used) E—Boom Upper Right End I—Grease Fitting (6 used) M—Washer (6 used)B—Pin Anchor (4 used) F—Seal (8 used) J—Pin (2 used) N—Cap Screw (6 used)C—Cap Screw (4 used) G—Bushing (8 used) K—Pin (4 used) O—Washer (As Required)D—Bushing (2 used) H—Link (2 used) L—Spacer (6 used) P—Bellcrank (2 used)

1. Lower attachment to the ground.


2. Disassemble upper tilt linkage.

3. Apply NEVER-SEEZ Lubricant or an equivalent tonew bushings and into bushing bores.

Install bushings (G) below surface of link (H) usingdisks from Bushing, Bearing and Seal Driver Set.

SpecificationTool Carrier Tilt LinkageBushing—Depth 8 mm (0.31 in.) below surface

of link...................................

4. Install seals (F) against bushing or flush withsurface with lips toward outside of bore.

5. Install pins (J and K) with flags outboard.

6. Install anchors (M) on pins.

7. Install washers (O) under flags to obtain amaximum clearance between the boom (E) andbellcranks (A and P) also between bellcranks (Aand P) and bucket cylinder ends.

SpecificationTool CarrierBoom-to-Bellcrank—Clearance 3 mm (0.12 in.) maximum..................Bellcrank-to-Bucket Cylinder—Clearance 3 mm (0.12 in.) maximum....................................................



PN=529

Frames

313140

6

TX,3140,RP3045 –19–17FEB99–1/2

Disassemble and Assemble Tool Carrier Lower Tilt Linkage

T10

8220

–19–

26N

OV

97

A—Link (2 used) E—Grease Fitting (4 used) I—Spacer (4 used) L—Link (4 used)B—Seal (4 used) F—Washer (As Required) J—Loader Boom, Left Lower M—Anchor (4 used)C—Seal (8 used) G—Cap Screw (4 used) End N—Cap Screw (4 used)D—Pin (4 used) H—Washer (4 used) K—Bushing (2 used) O—Bushing (4 used)

1. Lower attachment to the ground.


2. Disassemble lower tilt linkage.

3. Apply NEVER-SEEZ Lubricant or an equivalent tonew bushings and into bushing bores.

4. Install bushings (K and O) below surface of link (A)using disks from Bushing, Bearing and Seal Driver

Set.

SpecificationTool Carrier Tilt LinkageBushing—Depth 8 mm (0.31 in.) below surface

of link...................................

5. Install seals (B and C) against bushing or flush withsurface with lips toward outside of bore.

6. Install pins (D) with flags outboard.

7. Install anchors (M) on pins.



PN=530


Frames

TX,3140,RP3045 –19–17FEB99–2/2

8. Install washers (F) under flags to obtain a maximumclearance between the boom (J) and links (L),between boom links (L) and link (A) and betweenlink (A) and tool carrier.

SpecificationTool Carrier LinkBoom-to-Link—Clearance 3 mm (0.12 in.) maximum...........................

Tool Carrier Boom-to-Link—Clearance 3 mm (0.12 in.) maximum....................................................Tool Carrier Link-to-ToolCarrier—Clearance 3 mm (0.12 in.) maximum.....................................

3131407


PN=531

Frames

313140

8

TX,31,RP3363 –19–18FEB99–1/1

Disassemble and Assemble Tool Carrier

T11

1932

–UN

–11N

OV

97

A—Cap Screw (4 used) B—Pin (4 used) C—Spacer (As Needed) D—Spacer (As Needed)

1. Remove attachment from tool carrier.

2. Disconnect hoses to pin disconnect cylinder.

3. Remove cap screws (A) and pins (B). Remove capscrews and pin from bucket tilt linkage.

4. Install spacers (C) on each side of both boomends-to-tool carrier as needed to obtain maximumclearance.

SpecificationTool Carrier Boom End-to-ToolCarrier—Clearance 1 mm (0.04 in.) maximum.....................................

5. Install spacers (D) on each side of bothcylinders-to-tool carrier as needed to obtainmaximum clearance.

SpecificationTool Carrier Cylinder-to-ToolCarrier—Clearance 1 mm (0.04 in.) maximum.....................................


PN=532

Frames

3131409

TX,3140,RP3046 –19–18FEB99–1/1

Remove and Install Loader Boom Bushings and Seals

T10

8266

–UN

–26N

OV

97

A—Bushing (6 used) B—Seal (12 used) C—Loader Boom

1. Lower bucket to the ground and remove bucketfrom boom.

CAUTION: The approximate weight of thebucket cylinder is 105 kg (232 lb).

SpecificationBucket Cylinder—Weight 105 kg (232 lb) approximate........................

2. Remove bucket cylinder and linkage.

3. Disconnect boom cylinders from boom.

CAUTION: The approximate weight of theboom is 1089 kg (2400 lb).

SpecificationLoader Boom—Weight 1089 kg (2400 lb) approximate.......................

4. Remove boom pivot pins from machine frame andremove boom.

5. Remove bushings from boom using disks fromBushing, Bearing and Seal Driver Set.

6. Apply NEVER-SEEZ Lubricant or an equivalent onouter surface of new bushings and bores. Centernew bushings in boom bores and press sealsagainst bushings with lips outward.

7. Install boom and cylinders on machine. Installshims as needed in loader frame to boom joint.

SpecificationLoader Boom-to-LoaderFrame—Clearance 3 mm (0.12 in.) maximum......................................



PN=533

Frames

313140

10

TX,3140,RP3047 –19–18FEB99–1/1

Remove and Install Tool Carrier Boom Bushings and Seals

T10

8276

–UN

–26N

OV

97

Left Side of Boom Shown

A—Tool Carrier Boom C—Seal (8 used) E—Bushing (2 used) G—Bushing (4 used)B—Bushing (4 used) D—Seal (4 used) F—Seal (8 used)

1. Lower boom to ground and remove attachmentfrom tool carrier.

CAUTION: The approximate weight of theboom is 907 kg (2000 lb).

The approximate weight of the tilt cylinder is98 kg (216 lb).

SpecificationTool Carrier Boom—Weight 907 kg (2000 lb) approximate.................Tilt Cylinder—Weight 98 kg (216 lb) approximate................................

2. Remove bucket tilt linkage and cylinders.

3. Disconnect boom cylinder rod ends from boom.

4. Remove boom pivot pins and remove boom.

5. Remove bushings from boom using disks fromBushing, Bearing and Seal Driver Set.

6. Apply NEVER-SEEZ Lubricant or an equivalent onouter surface of new bushings and bores. Centernew bushings in boom bores and press sealsagainst bushings with lips outward.

7. Install boom on machine and replace cylinders,linkage and bucket. Install shims in originallocations. Measure clearances and adjust shims asrequired.



PN=534


CED,OUOE003,3383 –19–22APR99–1/5

Essential Tools



CED,OUOE003,3383 –19–22APR99–2/5

T11

1317

A–U

N–0

8SE

P97

Spanner Wrench . . . . . . . . . . . . . . . . . . . . . . JT07289

Used to tighten spanner nut on 125 series cylinders.

3131601

CED,OUOE003,3383 –19–22APR99–3/5

Torque Wrench. . . . . . . . . . . . . . . . . . . . . . . JT02004

Used with JT07289 Spanner Wrench to tighten spannernut on 125 series cylinders.

CED,OUOE003,3383 –19–22APR99–4/5

T10

6133

–UN

–08J

AN

97

WEATHER PACK Crimping Tool . . . . . . . . . . JDG783

Used to install terminals on Quickshift switch wire on pilotcontroller lever. Crimps WEATHER PACK male andfemale connectors. Tool crimps both the connector andseal retainer at the same time.


CED,OUOE003,3383 –19–22APR99–5/5

Gas Cock . . . . . . . . . . . . . . . . . . . . . . . . . . JT01735

To charge and reduce pressure to accumulator.


PN=535

Hydraulic System

CED,OUOE003,3384 –19–22APR99–1/9




CED,OUOE003,3384 –19–22APR99–2/9

Bench Mounted Holding Fixture . . . . . . . . . . D01006AA

Used to hold hydraulic pump.

CED,OUOE003,3384 –19–22APR99–3/9

Portable Filter Caddy

To filter contamination from hydraulic systems.

313160

2

CED,OUOE003,3384 –19–22APR99–4/9

3658 mm (12 ft) x 3/4 in. ID 100R1 Hose with 3/4 M NPTEnds (2 used)

To connect to the portable filter caddy.

CED,OUOE003,3384 –19–22APR99–5/9

Quick Disconnect Fittings

To test fittings.

CED,OUOE003,3384 –19–22APR99–6/9

Discharge Wand

To discharge hydraulic oil back into reservoir.

CED,OUOE003,3384 –19–22APR99–7/9

Connector (1-1/16 M ORB x 3/4 M NPT) . . . . . . JT03297

To connect reservoir to filter caddy.


PN=536


Hydraulic System

CED,OUOE003,3384 –19–22APR99–8/9

Torque Wrench

To tighten pilot controller hex nut.

CED,OUOE003,3384 –19–22APR99–9/9

Gauge . . . . . . (0—6895 kPa) (0—69 bar) (0—1000 psi)

To test pilot pressure coming from pilot controller.

3131603

CED,OUOE003,3385 –19–22APR99–1/1

Other Material

Number Name Use

T43513 (U.S.) Thread Lock and Sealer (High Apply to bucket and boom valveTY9474 (Canadian) Strength) sections hardware.271 (LOCTITE) Apply to threads of spool assembly

components. Apply to threads onpilot controller lever assembly.Apply to threads on pilot controllerlever assembly.Apply to universal joint threads.

PT569 (U.S.) John Deere NEVER-SEEZ Apply to bucket cylinder head andLubricant rod end pins.

Apply to bushing and seal.

TY24311 (U.S.) Thread Lock and Sealer (Low Apply to hydraulic cylinder rod guideCXTY24311 (Canadian) Strength) lock nut.222 (LOCTITE)

AT115876 (U.S.) KRYTOX GPL202 Fluorinated Apply to push bar and sleeveGrease adjusters inside pilot controller lever

housing.

LOCTITE is a trademark of Loctite Corp.NEVER-SEEZ is a trademark of Emhart Chemical Group.KRYTOX is a trademark of E.I. DuPont, DeNemours and Co. Inc.


PN=537

Hydraulic System

313160

4

CED,OUOE003,3387 –19–22APR99–1/5

Specifications


Hydraulic Pump

Hydraulic Pump Weight 49 kg (108 lb) approximate

Piston Shoe Wear 0.025 mm (0.001 in.) maximum atouter dimension

End Play 0.152 mm (0.006 in.) wornEnd Play 0.076 mm (0.003 in.) new

Saddle Bearing Thickness 0.152 mm (0.006 in.) maximumdifference between worn and unwornarea

Bearing Locate Pin Distance 1.3—1.6 mm (0.050—0.065 in.) intobearing locating hole

Guide Plate Cap Screw Torque 10 N•m (90.0 lb-in.)

Valve Plate-to-Pump Housing Hex Torque 95 N•m (70 lb-ft)Head Cap Screw

Socket Head Screw Torque 95 N•m (70 lb-ft)

Control Housing-to-Pump Cap Torque 60 N•m (44 lb-ft)Screw

Hydraulic Pump Control Valve

Control Housing-to-Pump Cap Torque 60 N•m (44 lb-ft)Screw

Control End Cap-to-Control Torque 40 N•m (30 lb-ft)Housing Screw

Load Sense Module (Valve)-to-End Torque 6 N•m (57 lb-in.)Cap Screw

Loader Control Valve

Loader Control Valve Weight 41 kg (90 lb) approximate

Loader Control Valve Tie Bolt Nut Torque 56 N•m (75 lb-ft)


PN=538


Hydraulic System

3131605

CED,OUOE003,3387 –19–22APR99–2/5


Bucket Valve

Circuit Relief Lock Torque 20 N•m (175 lb-in.)

Circuit Relief Housing Torque 102 N•m (75 lb-ft)

Compensator Cap Torque 102 N•m (75 lb-ft)

Cap Screw Torque 11 N•m (100 lb-in.)

Lift Check Hex Head Cap Torque 169 N•m (125lb-ft)

Port Plug Torque 20 N•m (175 lb-in.)


Nut Torque 20 N•m (175 lb-in.)

Boom Valve


Plug Torque 102 N•m (75 lb-ft)

Nut Torque 20 N•m (175 lb-in.)

Hex Head Cap Screw Torque 102 N•m (75 lb-ft)

Plug Torque 12 N•m (100 lb-in.)

Stripper Bolt Torque 20 N•m (175 lb-in.)

Check Hex Head Cap Torque 169 N•m (125lb-ft)

Socket Head Cap Screw Torque 20 N•m (175 lb-in.)

Boom Lower Pilot Plug Torque 12 N•m (100 lb-in.)

Anti Cavitation Plug Torque 102 N•m (75 lb-ft)

Boom Cylinder

Boom Cylinder Weight 105 kg (232 lb) approximate


PN=539


Hydraulic System

313160

6

CED,OUOE003,3387 –19–22APR99–3/5


Bucket Cylinder—185 Series

Bucket Cylinder Weight 105 kg (232 lb) approximate

Piston Retaining Nut Torque 3580 ± 180 N•m (2640 ± 133 lb-ft)

Set Screw Nut Torque 31.5 ± 5.9 N•m (23 ± 4 lb-ft)

Rod Guide Screw Torque 350 ± 70 N•m (258 ± 52 lb-ft)

Boom Cylinder—125 Series

624H Boom Cylinder Piston Torque 475 N•m (350 lb-ft)Retaining Nut plus 1/12 turn 30°

624H Bucket Cylinder Piston Torque 3580 ± 180 N•m (2641 ± 133 lb-ft)Retaining Nut

624H and TC62H Boom Cylinder Torque 1350 N•m (1000 lb-ft)Rod Guide Jam Nut

Tilt Cylinder—125 Series

TC62H Boom and Tilt Cylinder Torque 475 N•m (350 lb-ft)Piston Retaining Nut plus 1/12 turn 30°

TC62H Tilt Cylinder Rod Guide Torque 1350 N•m (1000 lb-ft)Jam Nut

Hydraulic Reservoir

Hydraulic Reservoir Weight 186 kg (410 lb) approximate

Hydraulic Reservoir-to-Frame Cap Torque 350 N•m (255 lb-ft)Screw

Pilot Controller (Two Lever)

Lever Housing-to-Housing Cap Torque 8.5 N•m (75 lb-in.)Screw

Multi-sectional Valve Tie Bolt Torque 11 N•m (100 lb-in.)


PN=540


Hydraulic System

3131607

CED,OUOE003,3387 –19–22APR99–4/5


Pilot Controller (Single Lever)

Lever Housing Allen Torque 8.5 N•m (75 lb-in.)Screw-to-Valve Housing

Universal Joint Hex Nut-to-Lever Torque 28 N•m (250 lb-in.)Bottom Housing

Grip/Switch Assembly Torque 28 N•m (250 lb-in.)

Lever Housing-to-Valve Housing Torque 8.5 N•m (75 lb-in.)Allen Screw

Lever Adjusting Screw Lock Hex Torque 11 N•m (100 lb-in.)Nut

Lever Housing-to-Valve Housing Torque 8.5 N•m (75 lb-in.)Allen Screw

Lever Adjusting Screw Lock Hex Torque 11 N•m (100 lb-in.)Nut

Oil Temperature 40 ± 6°C (100 ± 10°F)

Engine Speed Slow idle

Lever Travel to Begin Metering Distance 3/8—5/8 in. (measured at top end oflever)

Boom Float Detent Pressure 4137—4480 kPa (41—45 bar)(600—650 psi) in detent

Feel Position Pressure As the control lever is moved fromneutral, the pilot pressure willsuddenly jump up to approximately90 psi at 3/8—5/8 in. travel. Thepressure should then increasesmoothly to the specification at theFEEL position (or 75% lever travel),and then jump up to 600—650 psi asthe lever is moved into detent.

Boom Power Down Pressure 1860—2082 kPa (19—21 bar)(270—302 psi)


PN=541


Hydraulic System

313160

8

CED,OUOE003,3387 –19–22APR99–5/5


Boom Raise Pressure 1882—2227 kPa (19—22 bar)(273—323 psi)

Bucket Rollback Pressure 2110—2455 kPa (21—25 bar)(306—356 psi)

Bucket Dump and Auxiliary Valve Pressure Pressure must increase smoothly to2110—2455 kPa (21—25 bar)(306—356 psi) at 3/4 lever travel andthen increase to 4140—4480 kPa(41.4—44.8 bar) (600—650 psi) asthe lever is moved past 80—90%travel

Solenoid Valve

Retaining Nut Torque 7 N•m (62 lb-in.)

Ride Control

Accumulator Weight 40 kg (80 lb) approximate

Solenoid Nut Torque 8 N•m (72 lb-in.)

Accumulator Oil Temperature 40°C (104°F)

Accumulator Charge Pressure 2068 ± 138 kPa (20 ± 1 bar) (300 ±20 psi)


PN=542

Hydraulic System

3131609

TX,31,ME134 –19–18FEB99–1/3

Remove and Install Loader Hydraulic Pump

T11

2004

–UN

–29O

CT

97

A—Load Sense HoseB—Suction HoseC—Pump InletD—Case DrainE—Pressure-to-Control ValveF—Pressure-to-Steering ValveG—Hose to Pressure Reducing Valve

IMPORTANT: Do Hydraulic Pump Flow Test in Group9025-25 before removing hydraulicpump for repair. If pump does not meettest specification, replace it, do notrebuild pump.

1. Stop engine.

2. Lower all equipment to the ground.


CAUTION: Prevent unexpected machinemovement and possible injury. Install framelocking bar before working in frame hinge area.



6. Remove lower front, left and right side trim shieldsfrom cab.



PN=543

Hydraulic System

313160

10

TX,31,ME134 –19–18FEB99–2/3

X98

11–U

N–2

3AU

G88

CAUTION: Escaping fluid under pressure canpenetrate the skin causing serious injury.

Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tightenall connections before applying pressure.

Search for leaks with a piece of cardboard.Protect hands and body from high pressurefluids.


7. Drain hydraulic reservoir. Approximate capacity is 117L (31 gal).

8. Disconnect and cap lines (A—G).

9. Attach lifting device (such as DFT1132 HydrostaticMotor Removal Tool 850C/750C) to hydraulic pumphousing.

10. Remove hydraulic pump mounting cap screws.

CAUTION: The approximate weight of thehydraulic pump is 49 kg (108 lb).

Hydraulic Pump—SpecificationHydraulic Pump—Weight 49 kg (108 lb) approximate................................

11. Remove hydraulic pump.

12. Repair and replace parts as necessary.

13. Replace gasket on pump mounting surface.

14. Install pump with cap screws.

15. Fill pump body with hydraulic oil through case drain(D) line to assure lubrication for start up.


PN=544


Hydraulic System

TX,31,ME134 –19–18FEB99–3/3

16. Connect lines and fittings.

17. Fill hydraulic reservoir.

18. Switch battery disconnect on (if equipped) or installbattery ground cable.

19. Do Hydraulic Pump Margin and Low StandbyPressure Adjustment Test in Group 9025-25.

31316011


PN=545

Hydraulic System

313160

12

TX,3100,RP3048 –19–20MAR97–1/2

Hydraulic Pump (PVG 65) and (PVG 75) Cross Section

T10

4483

–UN

–18O

CT

96


PN=546


Hydraulic System

TX,3100,RP3048 –19–20MAR97–2/2

A—Roll Pin (2 used) H—Housing O—Spring U—Retainer SealB—Bearing I—Gasket P—Ball V—Retaining RingC—Roll Pin (4 used) J—Inlet Tube Q—Retainer Shoe W—Retaining RingD—Swash Plate K—Plate R—Bearing X—ShaftE—Screw L—Cylinder Barrel S—Bearing Y—BearingF—Retaining Ring M—Slipper (9 used) T—Roll Pin (2 used) Z—SealG—Piston (9 used) N—Plug

31316013

TX,31,JC2358 –19–18FEB99–1/45

Disassemble, Inspect and AssembleHydraulic Pump

T10

3480

–UN

–04N

OV

96

CAUTION: Reduce compressed air to less than210 kPa (2.1 bar) (30 psi) when using forcleaning purposes. Clear area of bystanders,guard against flying chips, and wear personalprotection equipment including eye protection.

CAUTION: The approximate weight of thehydraulic pump is 49 kg (108 lb).

Hydraulic Pump—SpecificationHydraulic Pump—Weight 49 kg (108 lb) approximate................................

IMPORTANT: Use only diesel fuel to clean pumpparts. Solvents can damage internalcomponents.

Perform Hydraulic Pump Case DrainTest in Group 9025-25, before removinghydraulic pump for repairs. If pumpdoes not pass the test, replace it, DONOT rebuild it.

1. Mount pump on D01006AA Bench Mounted HoldingFixture as shown.

2. As pump parts are removed wash in diesel fuel anddry using compressed air.


PN=547


Hydraulic System

TX,31,JC2358 –19–18FEB99–2/45

T10

3478

–UN

–04N

OV

96

3. Remove socket head cap screws and lift the controlgroup assembly straight up from the top of the pumpassembly. Remove control pin from swashblock.

313160

14

TX,31,JC2358 –19–18FEB99–3/45

T10

3480

–UN

–04N

OV

96

4. Remove valve plate by removing four cap screws andlifting it away from main pump assembly.

TX,31,JC2358 –19–18FEB99–4/45

T75

53B

G–U

N–2

4JU

N91

A—O-Ring

5. Remove O-ring (A).


PN=548


Hydraulic System

TX,31,JC2358 –19–18FEB99–5/45

T75

53B

A–U

N–2

4JU

N91

A—Gasket

6. Remove gasket (A).

TX,31,JC2358 –19–18FEB99–6/45

T10

3482

–UN

–04N

OV

96

7. Make sure pump is in a horizontal position.

Remove rotating group by turning input shaft slowlywhile pulling the cylinder barrel from the pump’shousing.

31316015

TX,31,JC2358 –19–18FEB99–7/45

T10

4036

–UN

–04N

OV

96

A—Cylinder BarrelB—Shoe AssemblyC—Shoe Retainer

8. Number each pump piston shoe assembly (B) and itsrespective bore in cylinder barrel (A) and shoe retainer(C) while disassembling. This will assure the sameparts are installed to the respective bore in the retainerand barrel.


PN=549


Hydraulic System

TX,31,JC2358 –19–18FEB99–8/45

T75

53B

B–U

N–2

4JU

N91

A—Piston (9 used)B—Shoe RetainerC—Shoe Retainer Spring

9. Remove shoe retainer (B) with pistons (A) and shoeretainer spring (C).

313160

16

TX,31,JC2358 –19–18FEB99–9/45

T10

4801

–UN

–04N

OV

96

A—Hydrodynamic Locking Screw

10. Remove hydrodynamic locking screw (A).



PN=550

Hydraulic System

31316017

TX,31,JC2358 –19–18FEB99–10/45

T10

4037

–UN

–04N

OV

96T

1040

41–U

N–0

4NO

V96

A—Retaining RingB—Flat Head Screwdriver

NOTE: Later pump models may not incorporate thisretaining ring.

11. Remove retaining ring (A) with flat head screwdriver(B).



PN=551

Hydraulic System

TX,31,JC2358 –19–18FEB99–11/45

T10

4028

–UN

–04N

OV

96

12. Remove hydrodynamic bearing by pulling it out of thepump’s housing evenly.

313160

18

TX,31,JC2358 –19–18FEB99–12/45

T10

3483

–UN

–04N

OV

96

13. Remove drive shaft bearing retainer ring with snapring pliers.


PN=552


Hydraulic System

TX,31,JC2358 –19–18FEB99–13/45

T10

4805

–UN

–12A

UG

97

A—Shaft Seal Retainer

14. Remove outboard end of drive shaft and pull out frompump housing. Remove shaft seal retainer (A).

TX,31,JC2358 –19–18FEB99–14/45

T75

53A

L–U

N–2

4JU

N91

31316019

A—Shaft Seal

15. Remove shaft seal (A) from housing only ifnecessary. This is not reusable.



PN=553

Hydraulic System

313160

20

TX,31,JC2358 –19–18FEB99–15/45

T10

4799

–UN

–04N

OV

96

T10

3484

–UN

–04N

OV

96

A—Guide Plate

16. Loader pump (130PVG) only: Remove flat headscrews with a 5/32 Allen wrench and remove guideplate (A).



PN=554

Hydraulic System

TX,31,JC2358 –19–18FEB99–16/45

T10

3485

–UN

–04N

OV

96

17. Remove the swashblock from pump housing.

31316021

TX,31,JC2358 –19–18FEB99–17/45T

8170

AE

–UN

–31J

AN

94

A—Saddle Bearing

18. Remove the saddle bearings (A) from pump housing.

19. Clean all parts thoroughly. Inspect all seals andO-rings for hardening, cracking or deterioration andreplace if necessary.



PN=555

Hydraulic System

TX,31,JC2358 –19–18FEB99–18/45

T75

53A

S–U

N–2

4JU

N91

20. Inspect valve plate group.

Inspect the valve plate surface that mates with thepump cylinder barrel for excessive wear or scoring.Remove minor defects by lightly stoning the surfacewith a hard stone that is flat to within 0.001". Be sureto stone lightly. Any excessive stoning will remove thehardened surface. If wear or damage is extensive,replace the valve plate.

Check drive shaft bushing for abnormal wear.

313160

22

TX,31,JC2358 –19–18FEB99–19/45

T10

3486

–UN

–04N

OV

96

21. Inspect suction inlet tube for cracks and damage fromhandling. If any cracks or damage, part must bereplaced.



PN=556

Hydraulic System

TX,31,JC2358 –19–18FEB99–20/45

T75

53A

T–U

N–2

4JU

N91

22. Rotating Group

Inspect cylinder barrel piston bores and the face thatmates with valve plate for wear and scoring. Removeminor defects on the face by lightly stoning thesurface. If defects can not be removed by thismethod, cylinder barrel is unusable.

23. Inspect all piston and shoe assemblies to be surethey ride properly on the swashblock.

TX,31,JC2358 –19–18FEB99–21/45

T75

53A

O–U

N–2

4JU

N91

24. Check each piston shoe for smooth pivot action onthe piston. Contaminates or burrs can cause them tostick.

31316023

TX,31,JC2358 –19–18FEB99–22/45

T10

4804

–19–

08N

OV

96

25. Check piston shoe wear. All shoes must be withinspecification at outer dimension.

Hydraulic Pump—SpecificationPiston Shoe—Wear 0.025 mm (0.001 in.) maximum at

outer dimension.............................

Check piston shoe end play. End play must not exceedspecification.

Hydraulic Pump—SpecificationPiston Shoe—End Play 0.152 mm (0.006 in.) worn...................................End Play 0.076 mm (0.003 in.) new............................................................



PN=557

Hydraulic System

TX,31,JC2358 –19–18FEB99–23/45

T10

4798

–UN

–04N

OV

96

26. Hydrodynamic Bearing

Inspect for contaminate damage or extreme wear.

313160

24

TX,31,JC2358 –19–18FEB99–24/45

T75

53A

Q–U

N–2

4JU

N91

27. Swashblock Group

Inspect the swashblock for wear and scoring. Ifdefects are minor, stone the swashblock lightly. Ifdamage is extensive, swashblock should be rejected.

Check that the very small holes in the face of theswashblock are open. These holes provide "porting"for the hydrostatic balance fluid (of the piston/shoeassembly) to be channeled through the swashblock tothe face of the saddle bearing (providing pressurelubrication).



PN=558

Hydraulic System

TX,31,JC2358 –19–18FEB99–25/45

T10

4033

–UN

–04N

OV

96

28. Check bearing mating surface of swashblock forcracks or excessive wear. Swashblock movement insaddle bearings must be smooth. Replace ifnecessary.

TX,31,JC2358 –19–18FEB99–26/45

T10

4803

–UN

–04N

OV

96

29. Compare saddle bearing thickness in worn area tothickness in an unworn area. Replace saddlebearings if difference is greater than specification.

Hydraulic Pump—SpecificationSaddle Bearing—Thickness 0.152 mm (0.006 in.) maximum

difference between worn andunworn area

.....................

31316025

TX,31,JC2358 –19–18FEB99–27/45

T10

4810

–UN

–08N

OV

96

A—Saddle Bearing (2 used)B—Locate Pin (2 used)

IMPORTANT: Bearing locate pins must not protrudethrough swash plate bearing. Seesketch below for proper installation ofpins.

30. Inspect bearing locate pins in housing. Pins (B) mustbe able to hold bearing in place without protrudingthrough bearing.



PN=559

Hydraulic System

TX,31,JC2358 –19–18FEB99–28/45

T10

3488

–UN

–04N

OV

96

A—Distance

Pins should extend specified distance (A).

Hydraulic Pump—SpecificationBearing Locate Pin—Distance 1.3—1.6 mm (0.050—0.065 in.)

into bearing locating hole................

TX,31,JC2358 –19–18FEB99–29/45

T10

4034

–UN

–04N

OV

96

31. Drive Shaft Group

Check shaft bearing for galling, pitting, binding,roughness.

Check seal of bearing for grease containment. If sealis worn or broken. Replace shaft and bearing.

Check shaft and it’s splines for wear. If worn, replaceshaft and bearing.

313160

26

TX,31,JC2358 –19–18FEB99–30/45

T75

53A

L–U

N–2

4JU

N91

A—Shaft Seal

32. Check shaft seal (A) for deterioration or cracks.Replace (press out) if necessary.

33. Pump assembly

Install new gaskets, seals and O-rings. Apply a thinfilm of CLEAN grease or hydraulic fluid to sealingcomponents to ease assembly. Apply fluid generouslyto all wear surfaces.



PN=560

Hydraulic System

TX,31,JC2358 –19–18FEB99–31/45

T75

53A

U–U

N–2

4JU

N91

34. Shaft Seal

If removed, press shaft seal into front of pumphousing with a 50 mm disk and seal driver.

31316027

TX,31,JC2358 –19–18FEB99–32/45

T10

4809

–UN

–04N

OV

96

A—Bearing (2 used)B—Control Pin SideC—Plastic Bearing

35. Swashblock Group

Position pump with drive shaft facing down. Greaseback side of saddle bearings and place on the locatorpins to locate the bearings (A) in pump case. Pinsmust not protrude through the bearing locator hole.Plastic bearing (C) position should be installed onopposite of control pin side (B) of swashblock.



PN=561

Hydraulic System

313160

28

TX,31,JC2358 –19–18FEB99–33/45

T10

4799

–UN

–04N

OV

96

T10

3484

–UN

–04N

OV

96

A—Flat Head Cap Screw

36. Loader Pump (130PVG) Only

Partially insert swashblock into rear of pump housingand insert guide plate into the pump’s housing, so flathead cap screws (A) can be used to fasten the guideplate to the housing. Place the swashblock on theguide plate making sure the guide plate is in thegroove of the swashblock. Install guide plate screwsand tighten. Make sure swashblock swivels in thesaddle bearings smoothly.

Hydraulic Pump—SpecificationGuide Plate Cap Screw—Torque 10 N•m (90.0 lb-in.)................................

37. Hydraulic Pump (75PVG) Only

Insert swashblock into rear of pump housing. Makesure swashblock swivels in the saddle bearingssmoothly.



PN=562

Hydraulic System

TX,31,JC2358 –19–18FEB99–34/45

T10

4798

–UN

–04N

OV

96

38. Hydrodynamic Bearing

Bearing should be positioned with "scarf" cutspositioned top and bottom. Bearing should fit intoplace with a little difficulty and be square to the axisof the pump. Tap bearing into place if necessaryusing extreme care not to damage the bearing.

31316029

TX,31,JC2358 –19–18FEB99–35/45

T10

4801

–UN

–04N

OV

96

A—Hydrodynamic Lock Screw

NOTE: Insert retaining ring to hold bearing in place onolder models.

39. Insert hydrodynamic lock screw (A) and hand tighten.


PN=563


Hydraulic System

TX,31,JC2358 –19–18FEB99–36/45

T10

4805

–UN

–12A

UG

97

A—Shaft Seal Retainer

40. Drive Shaft Group—Pump in Horizontal Position

Install shaft seal retainer (A).

313160

30

TX,31,JC2358 –19–18FEB99–37/45

T10

3483

–UN

–04N

OV

96

41. Insert drive shaft and bearing assembly into pumphousing and lock in place with drive shaft bearingretainer ring.



PN=564

Hydraulic System

TX,31,JC2358 –19–18FEB99–38/45

T10

4036

–UN

–04N

OV

96

31316031

A—Cylinder BarrelB—Piston (9 used)C—Shoe Retainer

42. Rotating Group

Place the cylinder barrel, wear surface down on aclean cloth. Place the shoe retainer spring in thecenter of the barrel with the fulcrum ball on top of it.Insert pistons into their corresponding (numbered)holes of the shoe retainer. As a unit, fit the pistonsinto their corresponding (numbered) bores in thecylinder barrel. DO NOT FORCE.

TX,31,JC2358 –19–18FEB99–39/45

T10

3482

–UN

–04N

OV

96

43. Support the weight of the cylinder barrel as cylinderspline is passed over the tail shaft, to avoidscratching or damage. Push cylinder forward until thecylinder spline reaches the drive shaft spline androtate the cylinder slightly to engage shaft splines.Continue to slide cylinder forward until it encountersthe cylinder bearing. Lifting the tail shaft slightly helpscylinder and cylinder bearing engagement. Continuepushing cylinder forward until the piston shoescontact the swashblock.

At this point, the back of the cylinder should belocated approximately 10.2 mm (0.4 in) outside theback of the pump housing.

NOTE: Make sure the rotate group has spring action.This assures correct assembly in relation to thespline.


PN=565


Hydraulic System

TX,31,JC2358 –19–18FEB99–40/45

T75

53B

G–U

N–2

4JU

N91

T11

2369

–UN

–26N

OV

97

313160

32

A—O-RingB—Gasket

44. Valve Plate Group

With the drive shaft facing down install O-ring (A) inpump housing.

With the drive shaft facing down install gasket (B) onpump housing.

TX,31,JC2358 –19–18FEB99–41/45

T10

4800

–UN

–04N

OV

96A—Cap ScrewB—Valve Plate

45. Position valve plate on housing pins, making sure tailend of shaft engages shaft bushing in valve plate (B).Finger tighten hex head cap screw closest to O-ringfirst. Alternately hand tighten the other cap screws(A).


PN=566


Hydraulic System

TX,31,JC2358 –19–18FEB99–42/45

T10

3487

–UN

–04N

OV

96

A—Control Pin

46. With control pin (A) in swashblock, move swashblockslowly to left side of pump housing until control pinstops at housing.

TX,31,JC2358 –19–18FEB99–43/45

T10

3480

–UN

–04N

OV

96

47. Tighten valve plate cap screws to specification.

Hydraulic Pump—SpecificationValve Plate-to-Pump HousingHex Head Cap Screw—Torque 95 N•m (70 lb-ft).......................................Socket Head Screw—Torque 95 N•m (70 lb-ft)..........................................

31316033

TX,31,JC2358 –19–18FEB99–44/45

T10

4806

–UN

–04N

OV

96

A—End Cap

48. Install new control gasket and O-ring. Place controlon pump housing making sure control pin fits intocontrol piston slot. Loosen end cap (A) to removespring pressure to aid in assembling of controlhousing.



PN=567

Hydraulic System

TX,31,JC2358 –19–18FEB99–45/45

T10

3478

–UN

–04N

OV

96

49. Install control valve cap screws and tighten.

Hydraulic Pump—SpecificationControl Housing-to-Pump CapScrew—Torque 60 N•m (44 lb-ft)................................................................

313160

34

TX,31,ME137 –19–18FEB99–1/3

Remove and Install Hydraulic Pump ControlValve

1. Mount pump on D01006AA Bench Mounted HoldingFixture.



PN=568

Hydraulic System

TX,31,ME137 –19–18FEB99–2/3

T10

3478

–UN

–04N

OV

96

2. Remove socket head cap screws and lift the controlgroup assembly straight up from the top of the pumpassembly. Remove control pin from swashblock.

3. Install new control gasket and O-ring. Place control onpump housing making sure control pin fits into controlpiston slot.

31316035

TX,31,ME137 –19–18FEB99–3/3

T10

4806

–UN

–04N

OV

96

A—End Cap

4.

Loosen end cap (A) to remove spring pressure to aidin assembling of control housing.

5. Install control valve cap screws and tighten tospecification.

Hydraulic Pump Control Valve—SpecificationControl Housing-to-Pump CapScrew—Torque 60 N•m (44 lb-ft)................................................................


PN=569

Hydraulic System

313160

36

TX,31,ME138 –19–18FEB99–1/2

Disassemble and Assemble Hydraulic Pump Control Valve

TP

5561

8–U

N–0

9SE

P97

1—Pump Control End Cap 2—Load Sense Module 3—Load Sense (Plus) Module 4—Pump ControlAssembly


PN=570


Hydraulic System

TX,31,ME138 –19–18FEB99–2/2

NOTE: Control valve is serviced as module (valve)(1—3) or complete control valve (4) as shown.

Disassemble, inspect, clean and replace parts asnecessary.

Hydraulic Pump Control Valve—SpecificationControl Housing-to-Pump CapScrew—Torque 60 N•m (44 lb-ft).........................................................

Control End Cap-to-ControlHousing Screw—Torque 40 N•m (30 lb-ft)...........................................Load Sense Module(Valve)-to-End Cap Screw—Torque 6 N•m (57 lb-in.)........................................................................

See Hydraulic Pump Stroke Limiter Adjustment, Group9025-20.

TX,31,ME139 –19–18FEB99–1/4

Remove and Install Loader Control Valve

1. Install boom locking bar.

2. Stop engine.

31316037



PN=571

Hydraulic System

313160

38

TX,31,ME139 –19–18FEB99–2/4

X98

11–U

N–2

3AU

G88

CAUTION: Escaping fluid under pressure canpenetrate the skin causing serious injury.

Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tightenall connections before applying pressure.

Search for leaks with a piece of cardboard.Protect hands and body from high pressurefluids.


3. Drain hydraulic reservoir. Approximate capacity ofhydraulic reservoir is 117 L (31 gal).

4. Remove control valve access panel.

5. Loosen hold-down clamps on bucket and boomcylinder lines.



PN=572

Hydraulic System

31316039

TX,31,ME139 –19–18FEB99–3/4

T10

6963

–19–

12F

EB

97


PN=573


Hydraulic System

TX,31,ME139 –19–18FEB99–4/4

NOTE: On later machines there is an orifice installedat the loader control valve return. The orifice isa double ORFS plate that is placed betweenreturn fitting (K) and hydraulic hose.

6. Disconnect all lines.

7. Remove cap screws.

CAUTION: The approximate weight of theloader control valve is 41 kg (90 lb).

Loader Control Valve—SpecificationLoader Control Valve—Weight 41 kg (90 lb) approximate...................

8. Slide control valve forward. Remove loader controlvalve.


10. Install loader control valve and connect all lines.

313160

40

TX,31,ME140 –19–18FEB99–1/1

Disassemble and Assemble Loader ControlValve

T10

8899

–19–

09A

PR

97

A—Inlet ManifoldB—Auxiliary Section ValveC—Bucket Section ValveD—Boom Section ValveE—Outlet ManifoldF—Seal (13 used)

1. Remove nuts and washers. Separate valve sections.


3. Install seals (F).

4. Assemble sections. Tighten nuts.

Loader Control Valve—SpecificationLoader Control Valve Tie BoltNut—Torque 102 N•m (75 lb-ft)..................................................................


PN=574

Hydraulic System

31316041

TX,31,RP3377 –19–19FEB99–1/1

Disassemble and Assemble Auxiliary Valve Section and Bucket Section

T11

2438

–19–

05D

EC

97

Bucket Section Shown

NOTE: Bucket valve section shown.

1. Disassemble valve.

IMPORTANT: Coat all internal surfaces with cleanhydraulic oil.

2. Replace all O-rings and backup rings.

3. Apply thread lock and sealer (high strength) to thefollowing components:

• Cap screws (L and V)

• Stripper bolt

4. Torque components.

Bucket Valve—SpecificationCircuit Relief Lock—Torque 20 N•m (175 lb-in.)...................................Circuit Relief Housing—Torque 102 N•m (75 lb-ft)..............................Compensator Cap—Torque 102 N•m (75 lb-ft)....................................Cap Screw—Torque 11 N•m (100 lb-in.)..............................................Lift Check Hex Head Cap—Torque 169 N•m (125.0 lb-ft)................................................................Port Plug—Torque 20 N•m (175 lb-in.).................................................


PN=575

Hydraulic System

313160

42

TX,31,RP3375 –19–19FEB99–1/1

Disassemble and Assemble Bucket Valve Section—Tool Carrier

T11

2400

–19–

09JA

N98





• Nut (I)• Hex Head Screws (J)• Stripper Bolt-to-Spool (L)• Tube Plug (R)

• Socket Head Screws (S)


Bucket Valve—SpecificationCompensator Cap—Torque 115 N•m (85 lb-ft)....................................Circuit Relief Cap—Torque 115 N•m (85 lb-ft).....................................Nut—Torque 20 N•m (175 lb-in.)..........................................................Hex Head Screw—Torque 11 N•m (100 lb-in.).....................................Lift Check Hex Head Cap—Torque 169 N•m (125.0 lb-ft)................................................................Socket Head Screw—Torque 11 N•m (100 lb-in.)................................Port Plug—Torque 20 N•m (175 lb-in.).................................................Circuit Relief Cap—Torque 115 N•m (85 lb-ft).....................................


PN=576

Hydraulic System

31316043

TX,31,RP3376 –19–19FEB99–1/1

Disassemble and Assemble Boom Valve Section

T11

2439

–19–

05D

EC

97





• Nut (I)• Hex Head Screws (J)• Stripper Bolt-to-Spool (M)• Socket Head Screws (U)


Boom Valve—SpecificationCompensator Cap—Torque 102 N•m (75 lb-ft)....................................Plug—Torque 102 N•m (75 lb-ft)..........................................................Nut—Torque 20 N•m (175 lb-in.)..........................................................Hex Head Cap Screw—Torque 102 N•m (75 lb-ft)..............................Plug—Torque 12 N•m (100 lb-in.).........................................................Stripper Bolt—Torque 20 N•m (175 lb-in.)............................................Check Hex Head Cap—Torque 169 N•m (125.0 lb-ft).........................Socket Head Cap Screw—Torque 20 N•m (175 lb-in.)....................................................................Boom Lower Pilot Plug—Torque 12 N•m (100 lb-in.)....................................................................Anti Cavitation Plug—Torque 102 N•m (75 lb-ft).................................


PN=577

Hydraulic System

TX,3100,RP3060 –19–19FEB99–1/1

Disassemble and Assemble Relief Valve

T10

4612

–UN

–22O

CT

96

313160

44

A—ReturnB—InletC—PoppetD—Floating SeatE—AdjusterF—Plunger

Remove the adjusting screw (E).

Inspect parts for wear or damage.

O-rings, backup ring and spring are the only repair partsavailable.

Assemble relief valve.

Check the pressure setting. (See Loader Relief and CircuitRelief Valve Pressure Test, Group 9025-25.)

TX,3100,RP3062 –19–19FEB99–1/1

Disassemble and Assemble Bucket CircuitRelief Valve

T10

8956

–19–

11A

PR

97

Remove adjusting screw from body.




PN=578

Hydraulic System

31316045

TX,3100,RP3061 –19–19FEB99–1/1

Disassemble and Assemble Load Sense Relief Valve

T10

6959

–19–

12F

EB

97

Remove adjusting screw from body.


O-rings, backup ring and spring are the only repairparts available.

TX,3100,RP3063 –19–19FEB99–1/1

Disassemble and Assemble Boom CircuitRelief Valve

T10

4611

–UN

–22O

CT

96

A—ReturnB—InletC—Poppet

Separate retainer from body.




PN=579

Hydraulic System

313160

46

TX,31,RP3058 –19–19FEB99–1/2

Remove and Install Boom Cylinder

NOTE: Boom cylinder may be disassembled on themachine for seal and packing replacement.


CAUTION: Before removing the boom cylinder,boom must be supported with a hoist orsupport stands.

2. Raise and support boom using a hoist or supportstands.

CAUTION: Prevent possible injury fromunexpected boom or bucket movement whenequipped with ride control. Always be sure theride control accumulator energy is dischargedwhen working on hydraulic components. To dothis: With boom raised slightly, turn ignitionswitch to ON position. Cycle the ride controlswitch from OFF to ON (center position). Boomwill jump up unexpectedly if ride controlaccumulator is energized. Press boom enableswitch and move the control lever into the floatposition and hold for 5 seconds.

3. Release hydraulic pressure.

CAUTION: The approximate weight of boomcylinder is 105 kg (232 lb).

Boom Cylinder—SpecificationBoom Cylinder—Weight 105 kg (232 lb) approximate................................

4. Connect hoist to cylinder using lifting straps.



PN=580

Hydraulic System

31316047

TX,31,RP3058 –19–19FEB99–2/2

X98

11–U

N–2

3AU

G88

T10

8857

B–U

N–0

9AP

R97

T10

8860

B–U

N–0

9AP

R97

A—Cylinder Head End LineB—Cylinder Rod End LineC—Rod End PinD—Head End Pin



5. Disconnect cylinder lines (A and B).

6. Support cylinder with hoist and remove rod and headend pins (C and D).

7. Remove cylinder.


9. Install cylinder. Connect lines.


10. Perform Loader Start-Up Procedure (Boom Cylinder).(See procedure in this group.)


PN=581

Hydraulic System

313160

48

CED,OUOE024,240 –19–25SEP98–1/1

Loader Start-Up Procedure (Boom Cylinder)




IMPORTANT: Perform procedure with engine at lowidle (no acceleration).

3. Raise boom until you are within 2—4 feet of full height.

4. Slowly lower the boom until bucket is 2—4 feet fromground and stop.

5. Repeat steps 3 and 4 five times.

6. Slowly raise the boom to full height.

7. Slowly lower the boom to ground.

8. Repeat steps 6 and 7 three times.




PN=582

Hydraulic System

31316049

TX,31,ME147 –19–19FEB99–1/2

Remove and Install 624H Bucket Cylinder—185 Series

T10

4844

–UN

–05N

OV

96

A—Bucket Level IndicatorB—Wiring Lead

NOTE: Bucket cylinder may be disassembled on themachine for seal and packing replacement.

1. Lower equipment to the ground.

2. Release hydraulic pressure by pushing pilotenable/boom down switch and moving control lever toall positions.


4. Remove bucket level indicator (A).

5. Remove clamps and disconnect wiring lead (B) toreturn-to-dig switch.

CAUTION: The approximate weight of bucketcylinder is 105 kg (232 lb).

Bucket Cylinder—185 Series —SpecificationBucket Cylinder—Weight 105 kg (232 lb) approximate...............................

6. Install lifting straps around cylinder and support with ahoist.



PN=583

Hydraulic System

TX,31,ME147 –19–19FEB99–2/2

T10

4843

–UN

–05N

OV

96

A—Head End PinB—Rod End Pin

7. Disconnect head and rod end cylinder lines.

8. Remove head and rod end pins (A and B).

9. Remove cylinder.


11. Install cylinder. Connect lines.


12. Perform Loader Start-Up Procedure (Bucket Cylinder).(See procedure in this group.)

313160

50


PN=584

Hydraulic System

31316051

CED,OUOE003,2588 –19–16NOV98–1/1

Loader Start-Up Procedure (Bucket Cylinder)




IMPORTANT: Perform procedure with engine at lowidle (no acceleration.)

3. Slowly raise boom half way up. Roll back bucket towithin a few feet of full rollback position.

4. Dump bucket to within a couple of feet of full dumpposition.

5. Repeat steps 3 and 4 five times.

6. Roll back bucket to full rollback position.

7. Dump bucket until it is in the full dump position.

8. Repeat steps 6 and 7 three times.




PN=585

Hydraulic System

313160

52

TX,31,RP3366 –19–25OCT97–1/1

624H Bucket Cylinder—185 Series, Cross Section

T10

9796

–UN

–18J

UL9

7

185 Cylinder Design

A—Wear Ring F—Barrel J—Wiper Seal N—O-RingB—Piston G—Buffer Seal K—Rod O—ShimC—Backup Ring H—Rod Bearing L—Rod Guide P—NutD—Cap Seal I—U-Cup Seal M—Backup Ring Q—Set ScrewE—Expander Seal


PN=586

Hydraulic System

31316053

TX,31,RP3367 –19–19FEB99–1/1

Disassemble 624H Bucket Cylinder—185Series

T61

90A

S–U

N–1

9OC

T88

IMPORTANT: Extend rod to remove oil or air betweenthe piston and rod guide. Excessiveamount of trapped oil or air will forceseals to expand making disassemblymore difficult.

NOTE: Repair procedures for cylinders are similar exceptas shown.

1. Extend rod so piston is approximately 25.4 mm (1 in.)from rod guide.

2. Make a mark on rod guide and cylinder barrel to aid inassembly.

3. Remove screws holding rod guide to barrel.

4. Remove rod guide, rod and piston.

5. To remove piston, remove set screw. Set screw isstaked in two places. Remove piston and rod guidefrom rod. (Refer to 624H Bucket Cylinder—185 Series,Cross Section in this group.)

6. Remove seals and backup ring from rod guide.

7. Inspect piston, rod guide and cylinder barrel for nicksor burrs that may damage seals or O-rings. Removenicks or burrs with fine crocus cloth.


PN=587

Hydraulic System

313160

54

TX,31,RP3368 –19–19FEB99–1/3

Assemble 624H Bucket Cylinder—185 Series

T80

05A

L–U

N–0

1JU

N93

A—Wiper SealB—U-Cup SealC—Wear RingD—Buffer SealE—Backup RingF—O-RingG—O-Ring

NOTE: Use a cylinder repair kit when assemblingcylinder. Put clean hydraulic oil on all internalparts before assembling.

1. Install buffer seal (D) and wear ring (C) in rod guide.Install U-cup seal (B) in rod guide with lip inward.Install wiper seal (A) in rod guide with seal lip outward.

2. Install O-ring (F) and backup ring (E) on rod guide.Install rod guide on rod.

3. Install expander seal, cap seals, and backup rings onpiston.

NOTE: Do not use thread lock and sealer on bucketcylinder rod threads.

4. Install nut on rod.

Bucket Cylinder—185 Series—SpecificationPiston Retaining Nut—Torque 3580 ± 180 N•m (2640 ± 133

lb-ft).....................

5. Install set screw in nut, torque to specification andstake in two places.

Bucket Cylinder—185 Series—SpecificationSet Screw Nut—Torque 31.5 ± 5.9 N•m (23 ± 4 lb-ft)................................

6. Install rod with rod guide and piston into barrel. Alignmarks on rod guide and barrel to orient port correctly.Install rod guide screws and torque to specification.

Bucket Cylinder—185 Series—SpecificationRod Guide Screw—Torque 350 ± 70 N•m (258 ± 52 lb-ft).........................

7. Inspect cylinder pivot bushings and seals. Replace ifneeded, see instructions in this group.



PN=588

Hydraulic System

TX,31,RP3368 –19–19FEB99–2/3

T10

4843

–UN

–05N

OV

96

31316055

A—Head End PinB—Rod End Pin

8. Install cylinder on machine. Apply NEVER-SEEZ

Lubricant or equivalent to pins (A) and (B) and install.Connect hydraulic hoses.

IMPORTANT: When machine is started for the firsttime after cylinder rebuild or oil isdrained from the cylinder, the followingsteps must be taken to prevent oil from“dieseling” inside the cylinder.

9. Perform Loader Start-Up Procedure (Bucket Cylinder).(See procedure in this group.)

NEVER-SEEZ is a trademark of the Emhart Chemical Group.

TX,31,RP3368 –19–19FEB99–3/3

T10

4844

–UN

–05N

OV

96

A—Bucket Level IndicatorB—Return-to-Dig Switch Wiring Clamp

10. Install bucket level indicator (A) and return-to-digswitch wiring clamps. Adjust return-to-dig componentsper instructions in Group 1674.


PN=589

Hydraulic System

313160

56

CED,OUOE003,2660 –19–16DEC98–1/1

Boom Cylinder Piston Wear Ring Configuration

T11

8506

–UN

–17F

EB

99A—Single Wear Ring Piston C—Wear Ring 8 mm (0.31 in.) E—Wear Ring 8 mm (0.31 in.) F—Rod Eye Pin Bore and

(Boom Cylinders SN — with Vertical Matting Gap with Slant Matting Gap CenterlineXXXXXX) D—Dual Wear Ring Piston

B—Wear Ring 15 mm (0.59 in.) (Boom Cylinders SNfor Single Wear Ring XXXXXX—)Pistons

IMPORTANT: On dual wear ring pistons (D), usepin bore centerline (F) for aligningwear rings (C and E) on piston. Gaps

on wear rings must be indexed 180°from each other.


PN=590

Hydraulic System

31316057


PN=591

Hydraulic System

313160

58

TX,31,RP3369 –19–19FEB99–1/2

Boom Cylinder 624H and TC62H and TC62H Tilt Cylinder—125 Series, Cross Section

T10

7291

–UN

–18F

EB

97


PN=592


Hydraulic System

TX,31,RP3369 –19–19FEB99–2/2

A—Nut F—Piston J—Wiper Seal N—O-RingB—Wear Ring G—Rod Seal K—Nut O—Backup RingC—Ring (2 used) H—Wear Ring L—Rod P—O-RingD—Cap Seal I—Rod Seal M—Rod Guide Q—BarrelE—Seal Expander

31316059

TX,31,RP3370 –19–19FEB99–1/13

Disassemble and Assemble 624H and TC62HBoom Cylinder and TC62H Tilt Cylinder—125Series

T10

7241

–UN

–15F

EB

97

JT07289 Spanner Wrench Used On 125-Series Cylinders

A—Rod Guide and Barrel Marks

1. Mark (A) rod guide and barrel to aid in assembly. TheJT07289 Spanner Wrench must be attached parallel tothe JT02004 torque wrench (or equivalent) to provide a2:1 multiplier. (Torque reading will be half of actualtorque.)

2. Loosen jam nut using appropriate adjustable spannerwrench.

3. Remove rod guide from barrel by rotatingcounterclockwise.



PN=593

Hydraulic System

TX,31,RP3370 –19–19FEB99–2/13

T61

72B

Q–U

N–1

9OC

T88

313160

60

A—NutB—PistonC—Wear RingD—Cap Seal

4. Remove nut to remove piston.

5. Remove piston wear ring (C) and seals (D).

6. Remove rod guide.

7. Remove O-ring, backup ring, rod seals, and rod wearring.

TX,31,RP3370 –19–19FEB99–3/13

T61

19A

O–U

N–1

9OC

T88

8. Inspect end of barrel. If necessary, remove nicks andburrs from the end of the barrel.

9. Thoroughly clean all components.

10. Install rod wear ring.

11. Install buffer seal with lip of seal toward inside (oilside) of cylinder.

12. Install buffer seal backup ring in notch provided in theoutboard side of the buffer seal.

13. Install rod seal with sealing lip toward inside (oil side)of cylinder.

14. Install wiper seal with extended lip toward outside (airside) of cylinder. Press metal ring flush with the outerend of guide (Use care not to damage the extendedsealing lip).

15. Install guide to barrel O-ring and backup ring with thebackup ring toward the outside (air side) of cylinder.



PN=594

Hydraulic System

TX,31,RP3370 –19–19FEB99–4/13

T61

22A

B–U

N–1

9OC

T88

IMPORTANT: To prevent damage of seal duringassembly, the lands on the piston mustbe clean and free of nicks and burrs.

16. Inspect the piston lands. If necessary, clean the landsof any nicks or burrs that can cut the piston seal.

NOTE: The cap seal can be made more pliable bywarming it with your hands or putting seal in hotwater for approximately 5 minutes.

Once started, install cap seal as quickly aspossible to keep the amount of time that the sealis stretched to a minimum.

17. Install seal expander.

18. Push seal on end of piston.

19. Install a plastic tie band around cap seal with thesmooth side against seal.

31316061

TX,31,RP3370 –19–19FEB99–5/13

T61

22A

C–U

N–0

6AU

G90

T61

22A

E–U

N–1

9OC

T88

IMPORTANT: For proper fit and operation, the backuprings must be installed with the radiustoward seal expander.

20. Pull cap seal across land into position over sealexpander using the plastic tie band.


PN=595


Hydraulic System

TX,31,RP3370 –19–19FEB99–6/13

T61

26A

O–U

N–1

9OC

T88

313160

62

A—Backup Ring (2 used)B—RadiusC—Cap SealD—Seal Expander

21. Install backup rings with radius toward seal expander.

22. Check the cap seal for looseness. Seal must fit tightagainst seal expander and not turn. If seal can beturned, it has been stretched too much and can bedamaged during assembly into barrel.

TX,31,RP3370 –19–19FEB99–7/13

T86

565

–UN

–09N

OV

88

A—Plastic Tie BandB—TaperC—Hose Clamp

NOTE: When using a ring compressor, put a piece ofshim stock between cap seal and compressor atthe joint so it does not damage seal.

When using a plastic tie band (A) and hoseclamp, grind a taper (B) on one end of the tieband. Install tie band with the taper against capseal. Before tightening the hose clamp (C), the tieband must be under hose clamp all around thepiston. Seal will also shrink to its original size ifleft for a minimum of 8 hours before installingassembly into barrel.

23. If necessary, shrink cap seal to its original size usinga ring compressor or plastic tie band and a hoseclamp.


PN=596


Hydraulic System

TX,31,RP3370 –19–19FEB99–8/13

T61

22A

F–U

N–1

9OC

T88

24. Install wear ring.


31316063


PN=597

Hydraulic System

313160

64

TX,31,RP3370 –19–19FEB99–9/13

T11

8506

–UN

–17F

EB

99

A—Single Wear Ring Piston B—Wear Ring 15 mm (0.59 in.) D—Dual Wear Ring Piston E—Wear Ring 8 mm (0.31 in.)(624H Boom Cylinders for Single Wear Ring (624H Boom Cylinders SN with Slant Matting GapSN —570631) (TC62H Pistons 570632—) (TC62H Boom F—Rod Eye Pin Bore andBoom Cylinders SN — C—Wear Ring 8 mm (0.31 in.) Cylinders SN 570463—) Centerline570463) with Vertical Matting Gap

IMPORTANT: On dual wear ring pistons (D), usepin bore centerline (F) for aligningwear rings (C and E) on piston. Gapson wear rings must be indexed 180°from each other.

25. Boom Cylinders—On early boom cylinders installsingle wear ring (B).

Later boom cylinders:

• 624H: (S.N. 570362—)• TC62H: (S.N. 570464—)

Install wear rings (C and E) on piston (D). Wheninstalling piston on rod, use pin bore centerline (F)for aligning wear rings. Gaps on wear rings mustbe indexed 180° from each other.

26. Install assembled rod guide and piston on rod.


PN=598


Hydraulic System

TX,31,RP3370 –19–19FEB99–10/13

NOTE: Do NOT apply thread lock and sealer tobucket cylinder piston retaining nut.

27. Apply thread lock and sealer (high strength) orequivalent to rod threads, under piston retainingnut on boom cylinder, but NOT bucket cylinder.Lubricate piston with hydraulic oil where retainingnut contacts it. Tighten piston retaining nut to thetorque specification.

Boom Cylinder—125 Series—Specification624H Boom Cylinder PistonRetaining Nut—Torque 475 N•m (350 lb-ft)

plus 1/12 turn 30°.........................................

624H Bucket Cylinder PistonRetaining Nut—Torque 3580 ± 180 N•m (2641 ± 133

lb-ft).........................

Tilt Cylinder—125 Series—SpecificationTC62H Boom and Tilt CylinderPiston Retaining Nut—Torque 475 N•m (350 lb-ft)

plus 1/12 turn 30°..............................

31316065

TX,31,RP3370 –19–19FEB99–11/13

T61

49A

G–U

N–1

9OC

T88

28. Put tape around a socket. Make marks on the tape todivide the socket into 1/12’s (30°).

TX,31,RP3370 –19–19FEB99–12/13

T61

72B

R–U

N–1

9OC

T88

29. Turn the nut to specified torque plus one mark (30°).

30. Apply thread lock and sealer (low strength) orequivalent to barrel threads that will be under jam nut.



PN=599

Hydraulic System

313160

66

TX,31,RP3370 –19–19FEB99–13/13

T10

7241

–UN

–15F

EB

97

A—Rod Guide and Barrel Marks

31. Thread jam nut onto the barrel.

IMPORTANT: To prevent seal damage, the barrel,piston and rod must be in alignmentduring installation.

32. Apply a light coat of clean hydraulic oil to piston sealsand barrel chamfer. Use care not to get oil on barrelthreads.

33. Carefully push piston into barrel.

34. Apply thread lock and sealer (low strength) orequivalent to barrel threads. Use care not to getsealant on end of barrel that engages internal O-ringand backup ring.

35. Carefully push and rotate rod guide to engagethreads.

36. Thread rod guide onto barrel until it bottoms internallyagainst the end of the barrel.

IMPORTANT: Do not turn the guide in place with aspanner wrench.

37. Loosen rod guide until the marks made beforedisassembly are aligned, or the rod guide port isproperly positioned.

38. Tighten the jam nut against the rod guide.

Boom Cylinder—125 Series—Specification624H and TC62H Boom CylinderRod Guide Jam Nut—Torque 1350 N•m (1000 lb-ft)..................................

Tilt Cylinder—125 Series—SpecificationTC62H Tilt Cylinder Rod GuideJam Nut—Torque 1350 N•m (1000 lb-ft)....................................................

IMPORTANT: When machine is started for the firsttime after cylinder rebuild or oil isdrained from the cylinder, the followingsteps must be taken to prevent oil from“dieseling” inside the cylinder.

39. Perform Loader Start-Up Procedure (Boom Cylinder).(See procedure in this group.)


PN=600

Hydraulic System

TX,31,ME150 –19–19FEB99–1/1

Remove and Install Boom, Bucket or TiltCylinder Bushings and Seals

T61

72B

E–U

N–2

7OC

T88

A—BushingB—Seals

1. Remove seals (B).

2. Remove bushings (A).

3. Install and center new bushings in bore.

4. Install new seals. Press seals into bore tight againstbushing with lip facing outward.

5. For initial lubrication, apply NEVER-SEEZ Lubricant oran equivalent to bushings and seals.

31316067



PN=601

Hydraulic System

313160

68

TX,31,ME151 –19–19FEB99–1/1

Remove and Install Hydraulic Reservoir

T10

9044

–UN

–14A

PR

97

A—Vent FilterB—Fill TubeC—To Loader Hydraulic PumpD—Reservoir Drain PlugE—To Return Filter

1. Remove hood and engine side shields.

2. Release hydraulic pressure by holding pilotenable/boom down switch and moving hydraulic controllever to boom float.

3. Drain reservoir. (See Operator’s Manual, Group 87,Change Hydraulic System Oil.) Approximate capacity is117 L (31 gal).

4. Disconnect lines (C and E).

CAUTION: The approximate weight of thereservoir is 186 kg (410 lb).

Hydraulic Reservoir—SpecificationHydraulic Reservoir—Weight 186 kg (410 lb) approximate........................

5. Install lifting strap around reservoir and attach hoist.

6. Remove cap screws to remove reservoir.


8. Install reservoir. Tighten reservoir-to-frame cap screws.Connect lines.

Hydraulic Reservoir—SpecificationHydraulic Reservoir-to-FrameCap Screw—Torque 350 N•m (255 lb-ft)....................................................

NOTE: If reservoir shows signs of contamination, performHydraulic Oil Clean-Up Procedure in this group.

9. Fill hydraulic reservoir with recommended oil. (SeeHydraulic System Oil, Group 0004.)


PN=602

Hydraulic System

31316069

TX,31,ME152 –19–05AUG96–1/1

Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy

SERVICE EQUIPMENT AND TOOLS

Portable Filter Caddy

3658 mm (12 ft) x 3/4 in. ID 100R1 Hose with 3/4 M NPT Ends (2used)

Quick Disconnect Fittings

Discharge Wand

JT03297 Connector (1-1/16 M ORB x 3/4 M NPT)

IMPORTANT: Brake system uses oil fromhydraulic reservoir. Flush all lines inthe brake, pilot, differential lock, andclutch cut-off system. Disassembleand clean pressure reducing valveand pilot controller. Remove andclean pilot caps from main controlvalve. Brake components may fail ifbrake system is not cleaned afterhydraulic reservoir contamination.

1. If hydraulic system is contaminated due to a majorcomponent failure, remove and disassemblesteering cylinders to clean debris from cylinders.

2. Install new return filter elements.

IMPORTANT: To prevent cavitation of filter caddypump, the minimum I.D. of connectoris 1/2 in.

NOTE: For a failure that creates a lot of debris,remove access cover from reservoir. Drainreservoir and connect filter caddy suction lineto drain port. Add a minimum of 19 L (5 gal) ofoil to reservoir. Operate filter caddy and washout the reservoir.

3. To minimize oil loss, pull a vacuum in reservoirusing a vacuum pump. Connect filter caddy suctionline to drain port at bottom of reservoir usingconnector and quick disconnect fitting. Check to besure debris has not closed drain port.

4. Put filter caddy discharge line into reservoir fillerhole so end is as far away from drain port aspossible to obtain a thorough cleaning of oil.

5. Start the filter caddy. Check to be sure oil is flowingthrough the filters.

Operate filter caddy approximately 15 minutes so oilin reservoir is circulated through filter a minimum offour times.

Leave filter caddy operating for the next steps.

NOTE: Filtering time for reservoir is 0.089 minute xnumber of liters (0.33 minute x number ofgallons). Reservoir capacity is 106 L (28 gal).

6. Start the engine and run it at fast idle.

IMPORTANT: For the most effective results,cleaning procedure must start withthe smallest capacity circuit thenproceed to the next largest capacitycircuit.

7. Operate all functions, one at a time, through acomplete cycle in the following order: clam,steering, bucket, and boom. Also include allauxiliary hydraulic functions.

Repeat procedure until the total system capacityhas circulated through filter caddy seven times,approximately 30 minutes. Each function must gothrough a minimum of three complete cycles for athorough cleaning of oil.

NOTE: Filtering time for complete hydraulic system is0.158 minute x number of liters (0.6 minute xnumber of gallons). Complete hydraulic systemcapacity is approximately 256 L (67 gal) .Filtering time for machines with auxiliaryhydraulic functions must be increased becausesystem capacity is larger.

8. Stop the engine. Remove the filter caddy.

9. Install new return filter elements.

10. Check oil level in reservoir; add oil if necessary.(See Fuels and Lubricants in Group 0004.)


PN=603

Hydraulic System

313160

70

TX,31,ME155 –19–19FEB99–1/1

Pilot Controller Valve Remove and Install(Single Lever Controller)

T10

4166

–UN

–01O

CT

96T

1041

68–U

N–0

1OC

T96

A—Auxiliary Pilot Controller-to-Auxiliary ValveB—Pilot Controller-to-Bucket Valve Bucket DumpC—Pilot Controller-to-Hydraulic ReservoirD—Pilot Controller-to-Boom Valve Boom LowerE—Pilot Controller-to-Bucket Valve Bucket RollbackF—Pilot Controller-to-Boom Valve Boom RaiseG—Pilot Controller-to-Pressure Reducing ManifoldH—Auxiliary Pilot Controller-to-Auxiliary Valve

1. Stop engine and relieve hydraulic pressure by usingboom lower switch and placing controller in boom floatposition.

2. Remove air vent filter from hydraulic oil reservoir andplug vent.

3. Place a vacuum on the hydraulic oil reservoir tank.

4. Open load center service door.


6. Disconnect lines (A—H).

7. Remove four cap screws. Remove pilot controller.


9. Install pilot controller. Connect lines and electricalconnectors.


PN=604

Hydraulic System

31316071

TX,31,ME156 –19–19FEB99–1/1

Cross Section Pilot Controller Valve (Single Lever Controller)

T10

9108

–UN

–01M

AY

97

Bucket Rollback

A—Control Lever E—“C” Port I—Spring Guide L—Pull PlateB—Plunger F—“P” Port J—Electric Coil M—Shim, Spool MeteringC—Metering Spring G—“A” Port K—Push Bar N—Shim, Spool PositionD—Spool Assembly H—Return Spring

TX,31,RP3064 –19–16OCT98–1/24

Pilot Controller Valve Disassemble andAssemble (Single Lever Controller)

Before Pilot Control Valve is disassembled the followingchecks should be done first to help isolate confirm theproblem is in the pilot controller. Perform Pilot ControlValve Pressure Test. (See Section 9025-25.) PerformPressure Reducing Valve Pressure Test. (See Section9025-25.)


PN=605


Hydraulic System

313160

72

TX,31,RP3064 –19–16OCT98–2/24

TP

5541

5–U

N–1

5MA

R97

Single Lever (Joystick) Assembly


PN=606


Hydraulic System

TX,31,RP3064 –19–16OCT98–3/24

1—Grip 19—Push Bar 35—Retainer (2 used) (Tool 46—Spring2—Sleeve 20—Grommet (4 used) Carrier 3 used) 47—Spring3—Nut 21—Strap (4 used) 36—Plunger (2 used) (Tool 48—Housing4—Retainer 22—Terminal Nipple (8 used) Carrier 1 used) 49—O-Ring5—Boot 23—Washer 37—Plunger (2 used) (Tool 50—Plug6—Nut (4 used) 24—Pin Contact (8 used) Carrier 3 used) 51—Plug (2 used)7—Lever 25—Nut 38—Shim (As required) (0.1 52—Valve8—Setscrew 26—Connector mm/.004 in) 53—Label9—Washer 27—O-Ring 39—Shim (As required) (0.2 54—O-Ring (6 used)10—Washer 28—Electrical Coil (3 used) mm/.007 in) 55—Adapter (5 used)11—Plug 29—Retainer (3 used) 40—Shim (As required) (0.4 56—O-Ring (6 used)12—Plate 30—Tube mm/.015 in) 57—Adapter13—Washer 31—Backup Ring 41—Spool (2 used) 58—Plate14—Nut 32—Seal 42—Spool 59—Screw (4 used)15—U-Joint (Center Post) 33—Ring (2 used) 43—Spool 60—Lock Nut (3 used)16—Ball Joint Socket (3 used) 34—Retainer (2 used) (Tool 44—Spring 61—Nut17—Cap Screw (4 used) Carrier 1 used) 45—Feel Position Kit 62—Spool18—Housing (top)

31316073

TX,31,RP3064 –19–16OCT98–4/24

T10

5756

B–U

N–1

9DE

C96

A—GripB—Boot and Retainer

Replacing Quickshift Switch In Controller Lever

1. Remove pilot controller from machine. (See Removeand Install Pilot Controller Valve in this group.)

2. Place controller in bench vice.

3. Slide boot and retainers (B) down with hands from grip(A).

TX,31,RP3064 –19–16OCT98–5/24

T10

5757

B–U

N–1

9DE

C96

A—Allen Screw (4 used)

4. Lift up bottom of boot and remove four allen screws (A)from lever housing.


PN=607


Hydraulic System

TX,31,RP3064 –19–16OCT98–6/24

T10

5758

B–U

N–1

9DE

C96

313160

74

A—Lever HousingB—Valve Housing

IMPORTANT: Scribe a mark along side of the leverhousing and valve housing of thecontroller before disassembling. Themark will be used when aligning thecontroller housings during theassembly procedure. If correctalignment is not done while assemblingincorrect operation and/or damage tocontroller may occur.

5. Remove lever housing (A) from valve housing (B).

6. Cut switch wire at bottom side of lever housing by tieband. Remove tie band and pull wire out of lever andhousing.

7. Remove grommet from lever housing.

TX,31,RP3064 –19–16OCT98–7/24

T10

5756

C–U

N–1

9DE

C96

A—Hex Jam NutB—Grip

NOTE: Note the position of the lever in relation to thewire opening in lever for proper assembly.

8. Loosen hex jam nut (A) and then turn complete grip(B) with switch assembly to remove.

9. Inspect parts and replace as necessary.

10. Apply thread lock and sealer (high strength) to leverthreads.

11. Place new boot retainers over lever for installing later.

12. Install new grip with switch assembly on lever notingthe proper index, then tighten hex jam nut.

13. Place shrink tube on wire and fish wire down throughlever handle and center of universal joint. Positionshrink tube so it is centered between the area it goesinto the lever and out the universal joint. Pull backwire and heat shrink tube on wire. Return wire to theproper position in lever assembly.


PN=608


Hydraulic System

31316075

TX,31,RP3064 –19–16OCT98–8/24

T10

5759

B–U

N–1

9DE

C96

A—Grommet LocationB—WireC—Terminal (2 used)D—ConnectorE—Shrink Tube

14. Feed wire through the housing passage and installgrommet at (A) noting the position of wire. Wire (B)should be positioned so it clears the coil bore. Wireshould have approximately a 51 mm (2.0 in.) loop.

15. Place clear wire protective sleeve over wire andinstall two terminals (C) with JDG783 WEATHERPACK Crimping Tool. Install wire with terminals inconnector (D).

16. Install lever assembly on valve housing with four allenscrews. Note scribe marks for proper index.

Pilot Controller (Single Lever)—SpecificationLever Housing AllenScrew-to-Valve Housing—Torque 8.5 N•m (75 lb-in.).................................

17. Pull up boot and position on grip assembly. Install twoshrink retainers by heating with heat blow gun.

18. Install lever assembly in tractor. (See Remove andInstall Pilot Control Valve in this group.)

WEATHER PACK is a trademark of Packard Electric. Continued on next page


PN=609

Hydraulic System

313160

76

TX,31,RP3064 –19–16OCT98–9/24

T10

5756

B–U

N–1

9DE

C96


Replace Pilot Control Lever Boot (Joystick)

1. Remove four cap screws from base of lever controllerassembly inside load center door on right side ofoperator station. (See Remove and Install PilotController Valve in this group.) This will allow boot tobe free at base of controller assembly.


3. Remove one Phillips screw from front of grip. Pull upon grip to remove.

4. Remove two shrink retainers.

5. Slide boot over switch assembly to remove.

6. Install new boot and retainers over switch assembly.

7. Install grip and fasten to lever with Phillips screw.

8. Pull up boot and position on grip with two shrinkretainers. Heat retainers with heat blow gun.

9. Install four cap screws in pilot controller in load centercompartment.



PN=610

Hydraulic System

TX,31,RP3064 –19–16OCT98–10/24

T10

5756

B–U

N–1

9DE

C96


Replace Pilot Control Lever Boot (Single Lever)

1. Cut the tie band off around base of lever housing.


3. Remove grip by sliding up and off of lever.

4. Remove boot.

5. Install new boot and retainers over lever.

6. Install grip on lever.

7. Pull up boot and position on grip with two shrinkretainers. Heat retainers with heat blow gun.

8. Install new tie band around base of boot and leverhousing.

31316077

TX,31,RP3064 –19–16OCT98–11/24

T10

5757

B–U

N–1

9DE

C96


Replace Universal Joint


2. Place controller in vice and pull boot up.

3. Remove four allen screws (A) in lever housing.



PN=611

Hydraulic System

313160

78

TX,31,RP3064 –19–16OCT98–12/24

T10

5758

B–U

N–1

9DE

C96


IMPORTANT: Scribe a mark along side of the leverhousing and valve housing of thecontroller before disassembling. Themark will be used when aligning thecontroller housings during theassembly procedure. If correctalignment is not done while assemblingincorrect operation and/or damage tocontroller may occur.


5. Cut quickshift wire off right behind connector and pullwire out of housing, up through universal joint andlever.

6. Remove lever from universal joint by using 1/2 wrenchon flats of lever.

NOTE: Make note of position of the ball socketsassembly in relationship to coil bores.

7. Remove ball socket assembly with plate and washers.

8. Remove hex nut from bottom side of universal jointand housing.


10. Apply thread lock and sealer (high strength) touniversal joint threads.

11. Install universal joint in bottom of housing with hexnut and washer. Index to the 12 o’clock position inrelation to coil bores. Tighten to specification.

Pilot Controller (Single Lever)—SpecificationUniversal Joint Hex Nut-to-LeverBottom Housing—Torque 28 N•m (250 lb-in.).............................................

12. Install washers, ball sockets with plate over universaljoint. Note proper index of ball sockets to relationshipof coil bores. On joystick controller the bore withoutcoil should be in the 3 o’clock position.


PN=612


Hydraulic System

TX,31,RP3064 –19–16OCT98–13/24

13. Install grip/switch assembly along with boot and newshrink retainers on universal joint. Note proper indexof grip handle (must be in 12 o’clock position). Alsonote the index of the passage way hole for thequickshift wire in the housing (should be in the 1o’clock position). Tighten assembly.

Pilot Controller (Single Lever)—SpecificationGrip/Switch Assembly—Torque 28 N•m (250 lb-in.)....................................

31316079

TX,31,RP3064 –19–16OCT98–14/24

T10

5759

B–U

N–1

9DE

C96

A—Tie Band AreaB—WireC—TerminalsD—ConnectorE—Shrink Tube

14. Feed quickshift wire from grip assembly down throughhandle, center of universal joint and housing. Makesure protective shrink tube (E) is properly positionedon wire, centered through lever and universal joint.Pull wire back out and heat the shrink tube onto wireand return wire to proper position.

15. Slide clear plastic sleeve on wire that sticks out ofhousing and install terminals (C) on wire with JDG783WEATHER PACK Crimping Tool. Install terminals inconnector (D).

16. Install grommet in housing and tie band at area (A)on wire. Position wire (B) so it clears coil bores asshown (approximately a 51 mm [02 in.] loop).

17. Install lever housing assembly onto valve housing.Note index marks scribed before disassembly forproper alignment to proper ports. Tighten four allenscrews.

Pilot Controller (Single Lever)—SpecificationLever Housing-to-Valve HousingAllen Screw—Torque 8.5 N•m (75 lb-in.).....................................................

WEATHER PACK is a trademark of Packard Electric. Continued on next page


PN=613

Hydraulic System

313160

80

TX,31,RP3064 –19–16OCT98–15/24

T10

5761

B–U

N–1

9DE

C96

T10

5760

B–U

N–1

2JU

N98

A—Ball SocketB—SetscrewC—Adjuster SleeveD—NutE—Special Tool

18. Adjust ball socket (A) to zero clearance. Lever mustbe perpendicular to mounting surface when finished.Use allen wrench to turn setscrew (B) while holdingadjuster sleeve (C). After adjusted, lock in place bytightening hex nut (D) to specification with torquewrench while holding adjuster sleeve with open endwrench. Note special tool (E) is used in manufacturingonly.

Pilot Controller (Single Lever)—SpecificationLever Adjusting Screw Lock HexNut—Torque 11 N•m (100 lb-in.).................................................................

19. Install lever housing assembly with four allen screwsonto valve housing. Note index scribe marks madebefore disassembly.

20. Install pilot controller in machine. (See Remove andInstall Pilot Controller Valve in this group.)

TX,31,RP3064 –19–16OCT98–16/24

T10

5757

B–U

N–1

9DE

C96


Replace Seals on Spool Retainers and Inspect SpoolAssembly


2. Place controller in bench vice.

3. Lift up bottom of boot and remove four allen screws (A)from lever housing.


PN=614


Hydraulic System

TX,31,RP3064 –19–16OCT98–17/24

T10

5758

B–U

N–1

9DE

C96

31316081


IMPORTANT: Scribe a mark along side of the leverhousing and valve housing of thecontroller before disassembling. Themark will be used when aligning thecontroller housings during theassembly procedure. If correctalignment is not done while assemblingincorrect operation and/or damage tocontroller may occur. Also note spoolplacement to bore for reassembly.When servicing it is important to keepthe representative retainer and spoolassembly in the same bore.


TX,31,RP3064 –19–16OCT98–18/24

T10

5762

B–U

N–1

9DE

C96

A—CoilB—Spool Retainer

5. Remove coil (A) and let hang on side of valve housing.Remove coil retainer. Remove spool retainer (B) withpliers from valve housing.



PN=615

Hydraulic System

TX,31,RP3064 –19–16OCT98–19/24

T10

5841

–UN

–06J

AN

97

313160

82

A—Backup RingB—O-RingC—RetainerD—Wiper SealE—Seal RetainerF—Stop Ring

6. Remove and replace seals.

7. Lubricate wiper seal (D) with petroleum jelly.

8. Install seal in bore along with seal retainer (E).

9. Slightly bend tangs on stop ring (F) to allow for ease ofinstallation to keep the ring centered in bore. Note,stop ring comes from factory with slightly concave orbent tangs. Make sure bending is done in the samedirection. Tangs must face out when installing. Installstop ring in retainer by using a 11 mm socket as driver.Be sure to have stop ring (F) centered in bore so itdoes not contact push bar or ball socket pins.



PN=616

Hydraulic System

31316083

TX,31,RP3064 –19–16OCT98–20/24

T10

5763

B–U

N–1

9DE

C96

Controller Spool Assembly with Retainer with Feel Position

A—Retainer (With Seals)B—Shims (Spool Positioning)C—Guide (Spring)D—SpoolE—Shims (Metering Adjustment)F—Spring (Spool)G—Retainer Plate (Spool Spring)H—Feel AssemblyI—Spring (Feel Position)J—Spring (Return)

IMPORTANT: When removing spool retainer do notlose shims located between retainerand spool spring guide.

10. Remove spool assembly and springs (B—G, I, and J).If equipped remove feel position assembly (H).

11. Inspect and replace parts as necessary

12. Apply KRYTOX GPL202 fluorinated grease tosliding surfaces of adjuster sleeves and push bar topwhere it contacts the adjusting screw.

13. Install spool assembly and retainer in same bores ifusing existing parts.

14. Install retainers and coils (if equipped).

15. Install lever housing assembly onto valve housing.Note index marks scribed before disassembly forproper alignment to proper ports. Tighten four allenscrews.

Pilot Controller (Single Lever)—SpecificationLever Housing-to-Valve HousingAllen Screw—Torque 8.5 N•m (75 lb-in.).....................................................

KRYTOX is a trademark of E.I. DuPont, DeNemours and Co. Inc. Continued on next page


PN=617

Hydraulic System

313160

84

TX,31,RP3064 –19–16OCT98–21/24

T10

5761

B–U

N–1

9DE

C96

Ball Socket Assembly

T10

5760

B–U

N–1

2JU

N98

A—Ball SocketB—SetscrewC—Adjuster SleeveD—Hex NutE—Special Tool

16. Adjust ball socket (A) to zero clearance. Lever mustbe perpendicular to mounting surface when finished.Use allen wrench to turn setscrew (B) while holdingadjuster sleeve (C). After adjusted, lock in place bytightening hex nut (D) to specification with torquewrench while holding adjuster sleeve with open endwrench. Note special tool (E) is used in manufacturingonly.

Pilot Controller (Single Lever)—SpecificationLever Adjusting Screw Lock HexNut—Torque 11 N•m (100 lb-in.).................................................................

17. Install lever housing assembly with four allen screwsonto valve housing. Note index scribe marks madebefore disassembly.

18. Do bench test on controller to check valve pressuresusing tractor as pressure source. (See Pilot ControlValve Pressure Test (Bench) in this group.)


TX,31,RP3064 –19–16OCT98–22/24

T10

5766

B–U

N–1

9DE

C96

Pilot Control Valve Pressure Test (Bench)

1. Place controller valve assembly in vice.

2. Plug all ports not being tested in controller and caplines from tractor (if pressure source is being usedfrom same machine controller is being repaired on).

3. Place quick coupler in drain port, inlet pressure portand outlet port to be tested in controller.

4. Connect test hose with quick couplers from drain portto reservoir or bucket.


PN=618


Hydraulic System

31316085

TX,31,RP3064 –19–16OCT98–23/24

T10

5765

B–U

N–1

9DE

C96

T10

5766

B–U

N–1

9DE

C96

A—Quick CouplerB—Test Hose

5. Connect test hose (B) to pressure reducing valve (rightside below operator station) quick coupler (A) to inletpressure port on controller.

6. Connect 6895 kPa (69 bar) (1000 psi) test gauge toport being tested quick coupler.

7. Run engine at idle, boom down with park brake ON.Check pilot controller pressures to specification.

Pilot Controller (Single Lever)—SpecificationOil—Temperature 40 ± 6°C (100 ± 10°F)...................................................Engine—Speed Slow idle............................................................................Lever Travel to Begin Metering—Distance 3/8—5/8 in. (measured at top end

of lever)................................................

Boom Float Detent—Pressure 4137—4480 kPa (41—45 bar)(600—650 psi) in detent

...................

Feel Position—Pressure As the control lever is movedfrom neutral, the pilot pressure

will suddenly jump up toapproximately 90 psi at 3/8—5/8

in. travel. The pressure shouldthen increase smoothly to the

specification at the FEEL position(or 75% lever travel), and then

jump up to 600—650 psi as thelever is moved into detent.

..............................

Boom Power Down—Pressure 1860—2082 kPa (19—21 bar)(270—302 psi)

...................

Boom Raise—Pressure 1882—2227 kPa (19—22 bar)(273—323 psi)

..............................

Bucket Rollback—Pressure 2110—2455 kPa (21—25 bar)(306—356 psi)

........................

Bucket Dump and AuxiliaryValve—Pressure Pressure must increase smoothly

to 2110—2455 kPa (21—25 bar)(306—356 psi) at 3/4 lever traveland then increase to 4140—4480

kPa (41.4—44.8 bar) (600—650psi) as the lever is moved past

80—90% travel

...................................



PN=619

Hydraulic System

313160

86

TX,31,RP3064 –19–16OCT98–24/24

T10

5535

–UN

–03D

EC

96

A—Spool Position Shims B—Spool Metering Shims C—Housing

8. If pressure reducing valve is to specification, add orremove shims to reach the correct pilot pressure asfollows:

To adjust lever travel specification to beginmetering, add or remove spool position shims (A).

To adjust pressure to specification for feel positionsand pressure at 3/4 level trade, add or removespool metering shims (B).

Shims are available in the following sizes: (0.004in., 0.007 in., and 0.015 in.).



PN=620

Hydraulic System

LS10960,0000029 –19–28OCT02–1/4

Pilot Controller Repair (Two Lever Controller)(S.N. —585560)

Remove And Install

1. Stop engine and relieve hydraulic pressure by usingboom lower switch and placing controller in boom floatposition.

2. Remove air vent filter from hydraulic oil reservoir andplug vent.

3. Place a vacuum on the hydraulic oil reservoir tank.

4. Open load center service door.


31316087



PN=621

Hydraulic System

313160

88

LS10960,0000029 –19–28OCT02–2/4

T10

4845

–UN

–05N

OV

96T

1041

67–U

N–0

1OC

T96

A—Auxiliary Pilot Controller-to-Auxiliary ValveB—Pilot Controller-to-Bucket Valve Bucket DumpC—Pilot Controller-to-Hydraulic ReservoirD—Pilot Controller-to-Boom Valve Boom LowerE—Pilot Controller-to-Bucket Valve Bucket RollbackF—Pilot Controller-to-Boom Valve Boom RaiseG—Pilot Controller-to-Pressure Reducing ManifoldH—Auxiliary Pilot Controller-to-Auxiliary Valve

6. Disconnect lines (A—H).

7. Remove four cap screws. Remove pilot controllers.


9. Install pilot controller. Connect lines and electricalconnectors.



PN=622

Hydraulic System

31316089


PN=623

Hydraulic System

313160

90

LS10960,0000029 –19–28OCT02–3/4

TP

5541

6–U

N–1

5MA

R97



PN=624

Hydraulic System

LS10960,0000029 –19–28OCT02–4/4

1—Grip 16—Plate 31—Seal 46—Feel Position Kit2—Grip (with quickshift) 17—Nut 32—Backup Ring 47—Spring3—Hex Nut 18—Bar 33—Retainer 48—Spring4—Retainer 19—Universal Joint 34—Retainer 49—Housing5—Tie Band 20—Ball Joint Socket 35—Fitting 50—Weatherpack Nipple6—Boot 21—Strap 36—Grommet 51—Terminal7—O-Ring 22—Grommet 37—Plunger 52—Connector8—Set Screw 23—Cap Screw 38—Plunger 53—Two Lever Controller9—Nut 24—Lever Housing 39—Shim (0.4mm /.015 in) Assembly10—Plug 25—Lever Housing 40—Shim (0.2mm /.007 in) 54—Nut11—Lever 26—Washer 41—Shim (0.1mm / .004 in) 55—Washer12—Nut 27—Tube 42—Spool 56—Sleeve13—Washer 28—Coil 43—Spool 57—Universal Joint14—Adjuster Sleeve 29—Retainer 44—Spool 58—Spool15—Lever 30—Stop Ring 45—Spring

Disassemble And Assemble

Perform Pilot Control Valve Pressure Test. (SeeSection 9025-25.)

Perform Pressure Reducing Valve Pressure Test. (SeeSection 9025-25.)

See Pilot Controller Valve (Single Lever Controller),Disassemble and Assemble in this group.

31316091

LS10960,0000024 –19–04SEP02–1/5

Pilot Controller Repair (Two Lever Controller)(S.N. 585561—)

Remove and Install

1. Stop engine.

2. Relieve hydraulic pressure by using boom lever switchand place controller in boom float position.



PN=625

Hydraulic System

313160

92

LS10960,0000024 –19–04SEP02–2/5

T15

8220

B–U

N–3

1JU

L02

1—Side Console Cover

3. Remove side console cover (1).

4. Disconnect, label and cap pilot lines for ease ofassembly.

5. Remove nuts and washers on top cover plate. (4 usedeach)

IMPORTANT: Do not twist control lever knobs,damage may occur to wires.

6. Remove pilot controller.


8. Install pilot controller.

9. Connect pilot lines and connect electrical connectors.See Hydraulic System Component Location. (Group9025-15.)

Disassemble and Assemble

1. Pull rubber boots over linkage.

2. Disconnect pilot controller connector.

NOTE: Label all wiring to aid in assembly.

3. Remove all pins from connector. See ReplaceDEUTSCH Connector. (Group 1674.)



PN=626

Hydraulic System

LS10960,0000024 –19–04SEP02–3/5

T15

8221

B–U

N–3

1JU

L02

31316093

1—Electromagnet Detents2—Dowel Pins3—Top Plate4—Wire Harnesses

4. Label electromagnet detents (1), with controller and pinlocation.

NOTE: Two dowel pins for electromagnetic detent (1).

5. Remove electromagnet detents (1).

6. Remove control lever knobs.

7. Remove rubber boots.

LS10960,0000024 –19–04SEP02–4/5

T15

8222

B–U

N–3

1JU

L02

1—Lock Nut2—Circlip (2 used)3—Pivot Pin

8. Loosen lock nut (1) and remove control lever.

9. Remove clip clamps (2) on pivot pin (3).

10. Drive out pivot pin (3).

LS10960,0000024 –19–04SEP02–5/5

T15

8223

B–U

N–3

1JU

L02

11. Disassemble parts as shown, replace if necessary.

IMPORTANT: Control valve is serviced as anassembly.

12. Assemble control valve.

13. See Pilot Controller Adjustment (Two Lever). (Group9025-20.)


PN=627

Hydraulic System

313160

94

TX,1060,JC2027 –19–19FEB99–1/1

Remove and Install Pressure Reducing ValveManifold

X98

11–U

N–2

3AU

G88

T10

9377

–UN

–02M

AY

97

A—Pressure Reducing Manifold-to-FrontDifferential Line

B—Pressure Reducing Manifold-to-Boom RaiseLine

C—Pressure Reducing Manifold-to-HydraulicReturn Tube Tee Line

D—Pressure Reducing Manifold-to-AccumulatorTee Line

E—Pressure Reducing Manifold-to-HydraulicPump Line

F—Pressure Reducing Manifold-to-Pilot ControllerLine

1. Engine OFF. Operate controls 20 times while holdingpilot enable/boom down switch ON to release hydraulicpressure from brake and brake/PRV accumulators.

2. Drain reservoir or pull a vacuum. Approximate capacityof reservoir is 117 L (31 gal).




4. Disconnect lines (A—F).

5. Remove cap screws. Remove manifold.


7. Install manifold

8. Connect all lines and electrical connectors.

9. Fill reservoir with oil to proper level. (See HydraulicSystem Oil, Group 0004.)


PN=628

Hydraulic System

31316095

TX,31,ME159 –19–28SEP98–1/1

Remove and Install Pressure Reducing Valve

X98

11–U

N–2

3AU

G88

T10

9123

–UN

–15A

PR

97

A—Boom Down SolenoidB—Differential Lock SolenoidC—Pilot Enable SolenoidD—Pressure Reducing Valve



1. Engine OFF. Operate controls 20 times while holdingpilot enable/boom down switch ON to release hydraulicpressure from brake and brake/PRV accumulators.

2. Discharge ride control accumulator to prevent escapingfluid under pressure. (See Ride Control AccumulatorSafety in Group 3102.)

3. Remove pressure reducing valve (D) from manifold.Plug opening to prevent dirt from entering manifold.


PN=629

Hydraulic System

313160

96

TX,31,RP3068 –19–19FEB99–1/1

Disassemble and Assemble PressureReducing Valve

T10

9134

–UN

–15A

PR

97

A—Orifice (Inside Pressure Reducing Valve Manifold)B—Backup Ring (2 used)C—O-RingD—Backup Ring (2 used)E—O-RingF—Backup Ring (2 used)G—O-RingH—O-RingI—Pressure Reducing Valve

NOTE: Pressure Reducing Valve cannot be taken apart.If O-rings are OK, and orifice is OK, but pilotpressure cannot be adjusted within specifications,replace Pressure Reducing Valve.

1. Inspect for dirty, worn or damaged parts.

2. Remove orifice from inside Pressure ReducingManifold and inspect for damage or clogging.

3. Replace orifice if damaged.

4. Install new O-rings and back up rings on pressurereducing valve and install parts in manifold.

5. Adjust pilot pressure. See Pressure Reducing PressureTest in Group 9025-25.


PN=630

Hydraulic System

31316097

TX,31,RP3067 –19–28SEP98–1/1

Remove and Install Boom Down SolenoidValve

X98

11–U

N–2

3AU

G88

T10

9124

–UN

–15A

PR

97T

7751

LI–U

N–0

9NO

V92

A—Boom Down SolenoidB—Pressure Reducing ManifoldC—NutD—ID PlateE—CoilF—Solenoid ValveG—O-RingH—Backup RingI—O-RingJ—O-RingK—Backup Ring



1. Discharge ride control accumulator to release hydraulicpressure from loader and pilot circuit. (See RideControl Accumulator Safety in Group 3102.)







Solenoid Valve—SpecificationRetaining Nut—Torque 7 N•m (62 lb-in.).....................................................



PN=631

Hydraulic System

313160

98

TX,31,RP3065 –19–28SEP98–1/1

Remove and Install Differential LockSolenoid Valve

X98

11–U

N–2

3AU

G88

T10

9125

–UN

–15A

PR

97T

7751

LI–U

N–0

9NO

V92

A—Differential Lock SolenoidB—Pressure Reducing ManifoldC—NutD—ID PlateE—CoilF—Solenoid ValveG—O-RingH—Backup RingI—O-RingJ—O-RingK—Backup Ring













PN=632

Hydraulic System

31316099

TX,31,RP3066 –19–14APR97–1/1

Remove and Install Pilot Enable SolenoidValve

X98

11–U

N–2

3AU

G88

T10

9139

–UN

–15A

PR

97T

7751

LI–U

N–0

9NO

V92

A—Pilot Enable SolenoidB—Pressure Reducing ManifoldC—NutD—ID PlateE—CoilF—Solenoid ValveG—O-RingH—Backup RingI—O-RingJ—O-RingK—Backup Ring













PN=633

Hydraulic System

313160,100

TE14778,0000017 –19–13OCT03–1/4

Ride Control Repair (S.N. —582200)

X98

11–U

N–2

3AU

G88

Remove and Install

CAUTION: Hydraulic oil may escape at pressurehigh enough to penetrate skin fromcomponents in the ride control solenoid circuitif components are removed without dischargingthe accumulator. Hydraulic oil in accumulatorcan be stored at pressures equal to or abovesystem relief pressures.

If ride control is NOT operational, the ridecontrol accumulator must be discharged byreleasing gas charge before starting repair ofcontrol valve or any of its components.

If ride control is operational: With boom raisedslightly, turn ignition switch to ON position.Cycle the ride control switch from OFF to ON(center position). Boom will jump upunexpectedly if ride control accumulator isenergized. Press boom enable switch and movethe control lever into the float position and holdfor 5 seconds.

1. Turn key to ON position.

CAUTION: Boom will jump upward when ridecontrol switch is turned ON. Make sure areaaround bucket is clear.




PN=634

Hydraulic System

313160,101

TE14778,0000017 –19–13OCT03–2/4T

1091

51–U

N–1

7AP

R97

A—Ride Control Harness D—Ride Control Pressure F—Ride Control Valve H—Ride Control ON/OFFB—Ride Control Accumulator Switch G—Ride Control Boom SolenoidC—Boom Cylinders E—Boom Cylinder Solenoid

CAUTION: Approximate weight of ridecontrol accumulator is approximately 40 kg(80 lb). Use hoist to remove.

Ride Control:—SpecificationAccumulator—Weight 40 kg (80 lb) approximate.................................

3. Replace ride control parts as required.



PN=635

Hydraulic System

313160,102

TE14778,0000017 –19–13OCT03–3/4

TP

5545

2–U

N–1

8AP

R97

1—Valve 8—O-Ring 15—Seal Kit 21—Seal Kit2—Coil 9—Housing 16—Housing 22—Spool3—Nut 10—O-Ring 17—Check Valve 23—Coil4—Boom Solenoid 11—Plug 18—Backup Ring (2 used) 24—Nut5—O-Ring 12—Backup Ring (2 used) 19—O-Ring 25—ON/OFF Solenoid6—Plug 13—O-Ring 20—O-Ring 26—Cap Screw7—O-Ring (4 used) 14—O-Ring



PN=636


Hydraulic System

313160,103

TE14778,0000017 –19–13OCT03–4/4

X98

11–U

N–2

3AU

G88

CAUTION: Hydraulic oil may escape at pressurehigh enough to penetrate skin fromcomponents in the Ride Control solenoid circuitif components are removed without dischargingthe accumulator. Hydraulic oil in accumulatorcan be stored at pressures equal to or abovesystem relief pressures.

If ride control is NOT operational, the ridecontrol accumulator must be discharged byreleasing gas charge before starting repair ofcontrol valve or any of its components.


NOTE: Valve components can be replaced while valve ison machine. Internal parts of solenoid and checkvalves are not serviceable.

1. Remove and inspect solenoids. Replace O-rings andbackup rings as required.

2. Boom solenoid valve cannot be repaired, replaceO-rings and valve as required.

3. Remove check valve and inspect. Replace O-rings andbackup rings as required.

4. Remove nut (3) and replace solenoid (1) as required.

5. Assemble solenoid and tighten nut to specification.

Ride Control:—SpecificationSolenoid Nut—Torque 8 N•m (72 lb-in.)......................................................


PN=637

Hydraulic System

313160,104

TE14778,0000019 –19–13OCT03–1/4

Ride Control Repair (S.N. 582201—)

X98

11–U

N–2

3AU

G88

Remove and Install

CAUTION: Hydraulic oil may escape at pressurehigh enough to penetrate skin fromcomponents in the Ride Control solenoid circuitif components are removed without dischargingthe accumulator. Hydraulic oil in accumulatorcan be stored at pressures equal to or abovesystem relief pressures.

If ride control is NOT operational, the ridecontrol accumulator must be discharged byreleasing gas charge before starting repair ofcontrol valve or any of it’s components


1. With boom raised slightly, turn ignition switch to ONposition.

CAUTION: Boom will jump upward when ridecontrol switch is turned ON. Make sure areaaround bucket is clear.

2. Cycle the ride control switch from OFF to ON (centerposition). Press boom enable switch and move thecontrol lever into the float position and hold for 5seconds.



PN=638

Hydraulic System

TE14778,0000019 –19–13OCT03–2/4

T11

7959

–UN

–05N

OV

98

313160,105

A—Ride Control Valve-to-Bucket Dump LineB—Ride Control Valve-to-Boom Raise LineC—Ride Control ValveD—Ride Control Valve-to-Control Valve Return LineE—Valve-to-Accumulator Line (2 used)F—Accumulator (2 used)G—Ride Control Valve-to-Boom Lower Line

CAUTION: Approximate weight of ride controlassembly is approximately 40 kg (80 lb). Usehoist to remove assembly.

Ride Control—SpecificationRide Control Assembly—Weight 40 kg (80 lb) approximate.......................

3. Replace ride control parts as required.

IMPORTANT: Make sure wire connections are tocorrect solenoids. Hydraulic functionswill not operate properly, especiallyBoom Down.



PN=639

Hydraulic System

313160,106

TE14778,0000019 –19–13OCT03–3/4

T11

7948

–UN

–05N

OV

98

1—Electrical Coil (3 used) 4—Boom Solenoid 6—Head End Solenoid 8—Check Valve2—Rod End Solenoid 5—Boom Solenoid 7—Housing 9—O-Ring3—Washer


1. Remove and inspect solenoids. Replace O-ringsand backup rings as required.

2. Remove and inspect orifice. Install orifice in boomhead end circuit with the cone end down.

3. Remove check valve and inspect. Repair O-ringsand backup rings as required.



PN=640

Hydraulic System

TE14778,0000019 –19–13OCT03–4/4

T77

51LI

–UN

–09N

OV

92

313160,107

C—Solenoid NutD—ID PlateE—Solenoid CoilF—Solenoid ValveG—O-RingH—Backup RingI—O-RingJ—O-RingK—Backup Ring

Disassemble and Assemble Ride Control SolenoidValves

1. Remove solenoid nut (C) and replace solenoid coil (E)as required.

2. Assemble solenoid coil and tighten solenoid nut.

Ride Control—SpecificationSolenoid Nut—Torque 8 N•m (72 lb-in.)......................................................


PN=641

Hydraulic System

313160,108

TX,31,ME164 –19–28SEP98–1/5

Disassemble and Assemble Ride ControlAccumulator

CAUTION: Ride control circuit may bepressurized if accumulator is on the machine.Lower boom to ground by pressing boom lowerswitch and put control lever in float detent.

If ride control is NOT operational, the ridecontrol accumulator must be discharged byreleasing gas charge before starting repair of itor any of its components.


1. Remove accumulator from machine. (See Ride ControlRepair (S.N. —582200) or Ride Control Repair (S.N.582201—) in this group.



PN=642

Hydraulic System

313160,109

TX,31,ME164 –19–28SEP98–2/5

T78

93A

J–U

N–2

0NO

V92

A—CapB—Accumulator BarrelC—PistonD—End CapE—Gas Valve

CAUTION: The gas end of accumulator is gascharged and will cause end cap to blow outwith deadly force if disassembly is attempted.Bleed off accumulator charge before attemptingto disassemble accumulator.

NOTE: Loosen only the top special nut. The bottom "nut"is actually the accumulator gas valve.

2. Loosen special nut (A) (counterclockwise) 2 and 1/2turns to open gas valve in accumulator and bleed offgas charge. (Resistance may be felt at approximately 1and 1/2 turns.)

3. Remove gas fitting (E).

NOTE: Both ends of accumulator are removed the sameway, piston can be removed from either end.

4. Remove end cap using spanner wrench and removepiston.



PN=643

Hydraulic System

TX,31,ME164 –19–28SEP98–3/5

T78

93A

L–U

N–2

0NO

V92

313160,110

A—Wear Ring (2 used)B—Split Backup Ring (2 used)C—Special O-Ring SealD—Inner O-Ring Seal (2 used)E—Piston

5. Remove old seals from piston (E).

6. Install center O-ring (C), then a split backup ring (B) oneach side of it.

7. Install O-ring (D) in outer groove, then install wear ring(A) on top of it.

8. Repeat previous step for other side.

TX,31,ME164 –19–28SEP98–4/5

T78

93A

K–U

N–2

0NO

V92

A—End CapB—Backup RingC—O-Ring

9. Remove O-ring and backup ring.

10. Install backup ring (B) with flat surface to inside ofgroove.

11. Install O-ring (C) next to curved surface of backupring.



PN=644

Hydraulic System

TX,31,ME164 –19–28SEP98–5/5

T78

93A

J–U

N–2

0NO

V92

313160,111

A—CapB—Accumulator BarrelC—PistonD—End CapE—Gas Valve

IMPORTANT: Put piston next to gas valve end toreduce amount of air in accumulatorbefore charging.

12. Install piston (C), with hollow end toward gas valve, inbarrel (B).

13. Install end cap (D) and gas valve (E). Install otherend cap if removed.

14. Charge accumulator, see Charge Ride ControlAccumulator in this group.

15. Install accumulator on machine. See Ride ControlRepair (S.N. —582200) or See Ride Control Repair(S.N. 582201—) in this group.


PN=645

Hydraulic System

313160,112

TX,31,ME165 –19–28SEP98–1/2

Charge Ride Control Accumulator

CAUTION: Hydraulic oil may escape atpressure high enough to penetrate skin fromcomponents in the Ride Control solenoidcircuit if components are removed withoutdischarging this accumulator. Hydraulic oilin accumulator can be stored at pressuresequal to or above system relief pressures.

IMPORTANT: Charge accumulator using only drynitrogen. Dry nitrogen does not mixwith oil and is non-combustible. Itwill not cause oxidation orcondensation inside accumulatorand is not harmful to piston seal. DONOT use air or any combustible gasas these can cause oxidation andcondensation. Oxidation andcondensation are harmful to pistonseal and accumulator.

NOTE: Ride control can not be discharged if switch isin (A) automatic position unless machine is

moving above 5 kmph (3 mph), use Onposition to discharge accumulator during thisprocedure.

1. If accumulator is to be charged on machine andhas some nitrogen pressure left. With boom raisedslightly, turn ignition switch to ON position. Cyclethe ride control switch from OFF to ON (centerposition). Boom will jump up unexpectedly if ridecontrol accumulator is energized. Press boomenable switch and move the control lever into thefloat position and hold for 5 seconds.

2. Remove hose.

3. Remove cover and cap from top of accumulator.

4. Turn handle on gas cock fully counterclockwise.Attach gas cock, hose, and regulator toaccumulator.



PN=646

Hydraulic System

313160,113

TX,31,ME165 –19–28SEP98–2/2

T75

94A

A–U

N–1

0SE

P91

T75

94A

B–U

N–1

0SE

P91

Cross Section of Gas Valve Fitting

A—Nut

CAUTION: Loosen only the top special nut. Thebottom "nut" is actually the accumulator gasvalve fitting. Do not loosen bottom fitting.Loose fitting under pressure can cause injury.

5. Loosen special nut (A) (counterclockwise) 2 1/2 turnsto open gas valve in accumulator. (Resistance may befelt at approximately 1 1/2 turns.)

6. Slowly open regulator valve to pressurize accumulatorto specification.

Ride Control—SpecificationAccumulator Oil—Temperature 40°C (104°F).............................................Accumulator Charge—Pressure 2068 ± 138 kPa (20 ± 1 bar) (300

± 20 psi)...........

7. If accumulator is to be charged on machine and hasNO nitrogen pressure left. With boom raised slightly,turn ignition switch to ON position. Cycle the ridecontrol switch from OFF to ON (center position). Boomwill jump up unexpectedly if ride control accumulator isenergized. Press boom enable switch and move thecontrol lever into the float position and hold for 5seconds.

8. Check that accumulator is pressurized tospecifications. Adjust regulator as required.

9. Tighten nut until snug to close gas valve.

10. Close the control on the nitrogen tank.

11. Slowly loosen the connector at pressure regulatorvalve to release pressure from hose.

12. Remove gas cock from accumulator. Install cap.


PN=647

Hydraulic System

313160,114

TX,31,RP3070 –19–28SEP98–1/2

Remove and Install Pin Disconnect/AxleDisconnect Valve

CAUTION: Hydraulic oil may escape at pressurehigh enough to penetrate skin fromcomponents in the Ride Control solenoid circuitif components are removed without dischargingthe accumulator. Hydraulic oil in accumulatorcan be stored at pressures equal to or abovesystem relief pressures. With boom raisedslightly, turn ignition switch to ON position.Cycle the ride control switch from OFF to ON(center position). Boom will jump upunexpectedly if ride control accumulator isenergized. Press boom enable switch and movethe control lever into the float position and holdfor 5 seconds.

Lower equipment to the ground.

CAUTION: If ride control switch is pushed,boom may unexpectedly move up.

Discharge ride control accumulator.

CAUTION: Brake accumulators supply pressureoil to pin disconnect valve when engine is OFF.Discharge brake accumulators before workingon Pin Disconnect/Axle Disconnect Valve.

Discharge brake accumulators by pushing brake pedal 40or more times. Brake accumulator pressure can be readusing the Monitor Basic Display. Go to menu d 052(Clutch Cutoff Pressure).



PN=648

Hydraulic System

TX,31,RP3070 –19–28SEP98–2/2

T10

9182

–UN

–18A

PR

97

313160,115

A—Lock Nut (2 used)B—Cap Screw (2 used)C—Solenoid Valve ManifoldD—Axle Disconnect SolenoidE—O-Ring (6 used)F—Pin Disconnect Solenoid

Mark hoses and harness connectors for reference duringassembly. Disconnect hoses and harness connectors.

Remove cap screws (B) and remove valve.

Replace O-rings, install valve and connect hoses andharness connectors.

TX,31,RP3069 –19–28SEP98–1/1

Disassemble and Assemble Pin DisconnectValve

T10

9214

B–U

N–2

8AP

R97

A—NutB—Identification PlateC—CoverD—CoilE—Bottom PlateF—SpoolG—O-RingH—Backup RingI—O-RingJ—O-RingK—Backup RingL—O-RingM—Backup Ring

1. Remove solenoid coil and spool. Inspect for damage orwear.

2. Replace parts as needed. Replace O-rings and backuprings.


PN=649

Hydraulic System

TX,31,RP3071 –19–28SEP98–1/1

Disassemble and Assemble Axle DisconnectValve

T77

51LI

–UN

–09N

OV

92

313160,116

C—NutD—Identification PlateE—CoilF—SpoolG—O-RingH—Backup RingI—O-RingJ—O-RingK—Backup Ring

1. Remove solenoid coil and spool. Inspect for damage orwear.

2. Replace parts as needed. Replace O-rings and backuprings.


PN=650

IndexPagePage

Air conditioning, R134a refrigerant, recovery,Arecycling and chargingStation installation. . . . . . . . . . . . . . . . .18-1830-14Access platform

Air conditioning, R134a systemRemove and install . . . . . . . . . . . . . . . . .18-1822-2Charge . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-18Access platform and steps

Air filter elementsRemove and install . . . . . . . . . . . . . . . . .18-1822-2Remove and install . . . . . . . . . . . . . . . . .05-0520-3Accumulator

Air systemBrake, remove and install . . . . . . . . . . . .10-1060-4Air intake leakage test. . . . . . . . . . . . . . .05-0520-7Accumulator, ride control

Air-to-air aftercoolerCharge . . . . . . . . . . . . . . . . . . . . . . . .31-3160-112Assemble . . . . . . . . . . . . . . . . . . . . . . .05-0510-17Disassemble and assemble . . . . . . . .31-3160-108Disassemble . . . . . . . . . . . . . . . . . . . . .05-0510-17Accumulator, ride control safety . . . . . . . . .31-3102-2

Alarm, reverse warningAdjust fuel shut-off solenoid . . . . . . . . . . . .05-0515-6Change volume. . . . . . . . . . . . . . . . . . . .20-2004-2Air conditioningRemove and install . . . . . . . . . . . . . . . . .20-2004-2Charge R134a system . . . . . . . . . . . . .18-1830-18

AlternatorCleaning procedures . . . . . . . . . . . . . . .18-1830-19Remove and install . . . . . . . . . . . . . . . . .16-1672-1Component location, harness . . . . . . . .18-1830-24

Amp crimper toolComponent oil charge. . . . . . . . . . . . . .18-1830-12Contact support adjustment . . . . . . . . .16-1674-14Compressor oil charge check . . . . . . . .18-1830-10Crimp height adjustment . . . . . . . . . . . .16-1674-18Compressor oil removal . . . . . . . . . . . .18-1830-11Crimp height inspection. . . . . . . . . . . . .16-1674-17

Compressor, remove and install . . . . . .18-1830-48Crimping procedure. . . . . . . . . . . . . . . .16-1674-15

Condenser . . . . . . . . . . . . . . . . . . . . . .18-1830-41Operation . . . . . . . . . . . . . . . . . . . . . . .16-1674-11

Connectors for harness. . . . . . . . . . . . .18-1830-26Remove and install die set . . . . . . . . . .16-1674-12

Evacuate R134a system . . . . . . . . . . . .18-1830-16 Auxiliary valve section and bucket sectionExpansion valve . . . . . . . . . . . . . . . . . .18-1830-33 Disassemble and assemble . . . . . . . . .31-3160-41Flush. . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-21 Axle and differentialFreeze control switch . . . . . . . . . . . . . .18-1830-34 Front, remove and install . . . . . . . . . . . .02-0200-3Freeze control switch bench test. . . . . .18-1830-35 Rear, install. . . . . . . . . . . . . . . . . . . . . .02-0200-14Heater control valve . . . . . . . . . . . . . . .18-1830-36 Rear, remove . . . . . . . . . . . . . . . . . . . . .02-0200-9Heater control valve leak check . . . . . .18-1830-37 Axle disconnect input shaftHeater/evaporator coil . . . . . . . . . . . . . .18-1830-30 Cross-sectional view . . . . . . . . . . . . . . . .02-0250-4High and low pressure switches . . . . . .18-1830-42 Disassemble, inspect and assemble . . . .02-0250-6Leak testing . . . . . . . . . . . . . . . . . . . . .18-1830-13 Remove and install disconnect . . . . . . . .02-0250-5

IndxMain blower assembly. . . . . . . . . . . . . .18-1830-37 Axle disconnect valve 1Module with heater/evaporator coil . . . .18-1830-28 Disassemble and assemble . . . . . . . .31-3160-116Pressurizer motor assembly . . . . . . . . .18-1830-40 Axle oil coolerPurge system . . . . . . . . . . . . . . . . . . . .18-1830-20 Front, disassemble and assemble. . . . . .02-0260-9Receiver-dryer . . . . . . . . . . . . . . . . . . .18-1830-41 Front, remove and install . . . . . . . . . . . .02-0260-7Recover R134a system. . . . . . . . . . . . .18-1830-15 Rear, remove and install . . . . . . . . . . . .02-0260-10Refrigerant hoses and tubing Axle oil coolers

inspection . . . . . . . . . . . . . . . . . . . . .18-1830-13 Exploded view. . . . . . . . . . . . . . . . . . . . .02-0260-6Refrigerant R134a caution . . . . . . . . . . .18-1830-9 Axle oscillation supportsSystem fittings reference chart . . . . . . . .18-1830-4 Disassemble and assemble . . . . . . . . .02-0200-18

Air conditioning R134a component oil Axle recirculating systemCharge . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12 With optional oil coolers . . . . . . . . . . . . .02-0260-4

Air conditioning R134a compressor oilRemoval . . . . . . . . . . . . . . . . . . . . . . . .18-1830-11

Air conditioning R134a refrigerantBCautions . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-9

Air conditioning R134a systemEvacuate. . . . . . . . . . . . . . . . . . . . . . . .18-1830-16 Batteries

Remove and install . . . . . . . . . . . . . . . .16-1671-10Recover . . . . . . . . . . . . . . . . . . . . . . . .18-1830-15

TM1640 (15JAN04) Index-1 624H Loader and TC62H Tool Carrier011504

PN=1

Index

Page Page

Battery BucketBooster . . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-8 Remove and install . . . . . . . . . . . . . . . . .31-3102-5Charging procedure . . . . . . . . . . . . . . . .16-1671-7 Bucket bolt-on cutting edgesDisconnect switch, remove and Remove and install . . . . . . . . . . . . . . . . .31-3102-7

install . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-11 Bucket circuit relief valveElectrolyte level. . . . . . . . . . . . . . . . . . . .16-1671-5 Disassemble and assemble . . . . . . . . .31-3160-44Specification . . . . . . . . . . . . . . . . . . . . . .16-1671-2 Bucket cylinderTesting . . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-9 Loader start-up procedure. . . . . . . . . . .31-3160-51

Battery covers Bucket cylinder 624HRemove and install . . . . . . . . . . . . . . . . .19-1913-2 Assemble . . . . . . . . . . . . . . . . . . . . . . .31-3160-54

Battery disconnect switch Cross section . . . . . . . . . . . . . . . . . . . .31-3160-52Remove and install . . . . . . . . . . . . . . . .16-1671-11 Disassemble and assemble . . . . . . . . .31-3160-53

Blade terminals Bucket linkage seals and bushingsRemove from fuse block . . . . . . . . . . . .16-1674-24 Remove and install . . . . . . . . . . . . . . . . .31-3140-4

Bleed Bucket tilt linkage, lowerFuel system . . . . . . . . . . . . . . . . . . . . .05-0560-10 Disassemble and assemble . . . . . . . . . .31-3140-6

Blower assembly Bucket tilt linkage, upperRemove and install . . . . . . . . . . . . . . . .18-1830-37 Disassemble and assemble . . . . . . . . . .31-3140-5

Blower/air conditioner harness (W20) Bucket tooth shanks and tipsComponent location . . . . . . . . . . . . . . .18-1830-24 Remove and install . . . . . . . . . . . . . . . . .31-3102-3Connectors . . . . . . . . . . . . . . . . . . . . . .18-1830-26 Bucket welded cutting edge

Boom Remove and install . . . . . . . . . . . . . . . . .31-3102-6Height kickout adjustment . . . . . . . . . . .16-1674-25 Bulbs

Boom circuit relief valve Replace halogen . . . . . . . . . . . . . . . . . . .16-1673-1Disassemble and assemble . . . . . . . . .31-3160-45 Bushings and seals, boom, bucket or tilt cylinder

Boom cylinder Remove and install . . . . . . . . . . . . . . . .31-3160-67Loader start-up procedure. . . . . . . . . . .31-3160-48 Bushings and seals, loader boomPiston wear ring configuration . . . . . . . .31-3160-56 Remove and install . . . . . . . . . . . . . . . . .31-3140-9Remove and install . . . . . . . . . . . . . . . .31-3160-46 Bushings, tool carrier boom

Boom cylinders 624H and TC62H Remove and install . . . . . . . . . . . . . . . .31-3140-10Cross section . . . . . . . . . . . . . . . . . . . .31-3160-58Disassemble and assemble . . . . . . . . .31-3160-59

Boom down solenoid valveRemove and install . . . . . . . . . . . . . . . .31-3160-97 C

Boom height kickoutAdjustment . . . . . . . . . . . . . . . . . . . . . .16-1674-25

Indx2

CabBoom valve sectionFresh air filter . . . . . . . . . . . . . . . . . . . .18-1830-43Disassemble and assemble . . . . . . . . .31-3160-43Recirculating air filter . . . . . . . . . . . . . .18-1830-46BrakeRemove and install . . . . . . . . . . . . . . . . .18-1800-2Park, Disassamble and assemble . . . . . .11-1111-6

Cab or CanopyPark, Remove and Install . . . . . . . . . . . .11-1111-2Remove and Install . . . . . . . . . . . . . . . . .18-1800-2Brake accumulator

CanopyInstall . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1060-4Remove and Install . . . . . . . . . . . . . . . . .18-1800-2Remove . . . . . . . . . . . . . . . . . . . . . . . . .10-1060-4

Capacities, drain and refillBrake valveTC62H . . . . . . . . . . . . . . . . . . . . . . . . . .00-0002-8Install . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1060-1624H. . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0002-4Remove . . . . . . . . . . . . . . . . . . . . . . . . .10-1060-1

Charging station, R134a refrigerantBrake, parkRecovery, recycling and charging . . . . .18-1830-14Remove and install . . . . . . . . . . . . . . . . .11-1111-2

Chassis computer unit (CCU)BrakesRemove and install . . . . . . . . . . . . . . . . .16-1675-3External inspection . . . . . . . . . . . . . . . . .10-1011-1

Cinch connectorInstall . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1011-3Remove . . . . . . . . . . . . . . . . . . . . . . . . .10-1011-3 Install contact . . . . . . . . . . . . . . . . . . . .16-1674-23


PN=2

Index

Page Page

Clean primary element Converter minimum pressure regulator valveOily or sooty . . . . . . . . . . . . . . . . . . . . . .05-0520-5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-4

Clutch Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-4Compressor . . . . . . . . . . . . . . . . . . . . .18-1830-50 Converter relief valveCompressor, check hub clearance . . . .18-1830-51 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-21

Clutch pack KV and KR Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-21Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0350-28 Remove . . . . . . . . . . . . . . . . . . . . . . . .03-0360-21Disassemble . . . . . . . . . . . . . . . . . . . . .03-0350-26 Converter, torque and housing

Clutch pack K1, K2, and K3 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-5Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0350-37 CounterweightsDisassemble . . . . . . . . . . . . . . . . . . . . .03-0350-35 Remove and install . . . . . . . . . . . . . . . . .17-1749-2

Clutch pack K4 Cover, batteryAssemble . . . . . . . . . . . . . . . . . . . . . . .03-0350-48

Remove and install . . . . . . . . . . . . . . . . .19-1913-2Disassemble . . . . . . . . . . . . . . . . . . . . .03-0350-47

Cutting edgeClutches, input and output shaftsCrack repair . . . . . . . . . . . . . . . . . . . . . .31-3102-9Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-17

Cutting edge, weldedComponent locationRemove and install . . . . . . . . . . . . . . . . .31-3102-6Blower/air conditioner harness

Cutting edges, bucket bolt-on(W20) . . . . . . . . . . . . . . . . . . . . . . . .18-1830-24Remove and install . . . . . . . . . . . . . . . . .31-3102-7Compressor

CylinderClutch hub clearance . . . . . . . . . . . . . .18-1830-51Steering, remove and install . . . . . . . . . .09-0960-9Clutch, disassemble and assemble . . . .18-1830-50Steering, remove and installDisassemble and assemble . . . . . . . . .18-1830-53

bushings . . . . . . . . . . . . . . . . . . . . . .09-0960-12Inspect . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-53Cylinder, boomManifold, inspect . . . . . . . . . . . . . . . . . .18-1830-52

Loader start-up procedure. . . . . . . . . . .31-3160-48Remove and install . . . . . . . . . . . . . . . .18-1830-48Compressor, air conditioning, R134a oil Remove and install . . . . . . . . . . . . . . . .31-3160-46

Removal . . . . . . . . . . . . . . . . . . . . . . . .18-1830-11 Cylinder, bucketCompressor, R134a, component oil Loader start-up procedure. . . . . . . . . . .31-3160-51

Charge . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12 Cylinder, steeringCondenser Assemble . . . . . . . . . . . . . . . . . . . . . . .09-0960-12

Remove and install . . . . . . . . . . . . . . . .18-1830-41 Disassemble . . . . . . . . . . . . . . . . . . . . .09-0960-12Connector Loader start-up procedure. . . . . . . . . . .09-0960-11

IndxMetri-Pack. . . . . . . . . . . . . . . . . . . . . . . .16-1674-4 Remove and install bushings . . . . . . . .09-0960-12 3Connector body, transmission control valve Cylinders bucket 624H

Remove and install . . . . . . . . . . . . . . . . .16-1674-8 Cross section . . . . . . . . . . . . . . . . . . . .31-3160-52Connector terminals Disassemble and assemble . . . . . . . . .31-3160-53

Replace transmission controller unit . . .16-1674-19Cylinders bushings and seals, boom, bucket or Tilt

Connector, transmission control valveRemove and install . . . . . . . . . . . . . . . .31-3160-67

Install contact . . . . . . . . . . . . . . . . . . . . .16-1674-9Cylinders, boom 624H and TC62HControl unit, transmission

Cross section . . . . . . . . . . . . . . . . . . . .31-3160-58Remove and install . . . . . . . . . . . . . . . . .16-1675-1Disassemble and assemble . . . . . . . . .31-3160-59Control valve

Cylinders, bucket 624HAssemble . . . . . . . . . . . . . . . . . . . . . . .03-0360-15Assemble . . . . . . . . . . . . . . . . . . . . . . .31-3160-54Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-12Remove and install . . . . . . . . . . . . . . . .31-3160-49Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-8

Cylinders, steeringControl valve, hydraulic pumpRemove and install . . . . . . . . . . . . . . . . .09-0960-9Disassemble and assemble . . . . . . . . .31-3160-36

Cylinders, Tilt TC62HController, chassisCross section . . . . . . . . . . . . . . . . . . . .31-3160-58Remove and install . . . . . . . . . . . . . . . . .16-1675-3

Cylinders, tilt TC62HConverterInstall . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-8 Disassemble and assemble . . . . . . . . .31-3160-59


PN=3

Index

Page Page

D Engine and loader frameSeparate . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-5

Engine compartment stepDampenerRemove and install . . . . . . . . . . . . . . . . .18-1822-4Install . . . . . . . . . . . . . . . . . . . . . . . . . . .07-0752-1

Engine coolant heaterRemove . . . . . . . . . . . . . . . . . . . . . . . . .07-0752-1Remove and install . . . . . . . . . . . . . . . . .05-0505-4Dealer fabricated tool

Engine oilDFRW20 compressor holding fixture. . . .18-1899-1Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-3DFT1148 pre-load clutch pack spring compression

Engine side shieldstool . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0399-1Remove and install . . . . . . . . . . . . . . . . .19-1910-3DFT1149 pre-load clutch pack compression ring

Engine speedtool . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0399-2Fast and slow idle, adjust . . . . . . . . . . . .05-0515-2DFRW20 Compressor Holding Fixture

Evaporator coilDealer fabricated tool . . . . . . . . . . . . . . .18-1899-1Remove and install . . . . . . . . . . . . . . . .18-1830-30Diesel engine oil . . . . . . . . . . . . . . . . . . . . .00-0004-3

Expansion valveDiesel fuel . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-1Remove and install . . . . . . . . . . . . . . . .18-1830-33Diesel fuel conditioner

Low sulfur . . . . . . . . . . . . . . . . . . . . . . . .00-0004-2Diesel fuel storage . . . . . . . . . . . . . . . . . . .00-0004-2Differential

Front remove and install . . . . . . . . . . . . .02-0200-3 FOil specification. . . . . . . . . . . . . . . . . . . .00-0004-4Rear axle, install . . . . . . . . . . . . . . . . . .02-0200-14 Fan

Differential lock solenoid valve Remove and install . . . . . . . . . . . . . . . . .05-0510-5Remove and install . . . . . . .02-0260-2, 31-3160-98 Fan belt

Differential, rear Remove and install . . . . . . . . . . . . . . . . .05-0510-3Install . . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-14 Fan driveRemove . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-9 Remove and install . . . . . . . . . . . . . . . . .05-0510-5

Display unit, monitor Fast idleRemove and install . . . . . . . . . . . . . . . . .16-1675-5 Adjust engine speed . . . . . . . . . . . . . . . .05-0515-2

Dome light Fenders, frontRemove and install . . . . . . . . . . . . . . . . .16-1673-7 Remove and install . . . . . . . . . . . . . . . . .19-1927-1

Door light switch Fenders, rearRemove and install . . . . . . . . . . . . . . . . .16-1673-7 Remove and install . . . . . . . . . . . . . . . . .19-1927-2

Drive lights and guard FilterRemove and install . . . . . . . . . . . . . . . . .16-1673-6 Cab air recirculating . . . . . . . . . . . . . . .18-1830-46

Drive shaft

Indx4

Cab fresh air . . . . . . . . . . . . . . . . . . . . .18-1830-43Disassemble, inspect and assemble . . . .02-0225-4 Filter caddyRemove and install . . . . . . . . . . . . . . . . .02-0225-2 Hydraulic oil clean-up procedure . . . . . .31-3160-69

Fire extinguisher and bracketRemove and install . . . . . . . . . . . . . . . . .20-2003-1

Fluid starting aidE Remove and install . . . . . . . . . . . . . . . . .05-0505-1

Frame pivot bearingLower, remove and install . . . . . . . . . . .17-1740-12ElectricalUpper, remove and install . . . . . . . . . . .17-1740-10Battery specification . . . . . . . . . . . . . . . .16-1671-2

Frame, engine and loaderElementSeparate . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-5Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .05-0520-6

Freeze control switchElements, air filterBench test. . . . . . . . . . . . . . . . . . . . . . .18-1830-35Remove and install . . . . . . . . . . . . . . . . .05-0520-3Remove and install . . . . . . . . . . . . . . . .18-1830-34Engine

Front axle and differentialBoost starting . . . . . . . . . . . . . . . . . . . . .16-1671-8Remove and install . . . . . . . . . . . . . . . . .04-0400-3 Remove and install . . . . . . . . . . . . . . . . .02-0200-3


PN=4

Index

Page Page

Front axle guard Heater control valveRemove and install . . . . . . . . . . . . . . . .18-1830-36Remove and install . . . . . . . . . . . . . . . . .17-1746-1

Front axle oil cooler Heater control valve leak check . . . . . . . .18-1830-37HoodDisassemble and assemble . . . . . . . . . .02-0260-9

Remove and install . . . . . . . . . . . . . . . . .02-0260-7 Remove and install . . . . . . . . . . . . . . . . .19-1910-2HornFront turn lights

Remove and install . . . . . . . . . . . . . . . . .16-1673-5 Remove and install . . . . . . . . . . . . . . . . .20-2004-1HydraulicFront windshield wiper

Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-8 Oil specification. . . . . . . . . . . . . . . . . . . .00-0004-4Hydraulic control valveFuel

Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-1 Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0360-15Cross section view . . . . . . . . . . . . . . . .03-0360-10Lubricity . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-1

System bleed . . . . . . . . . . . . . . . . . . . .05-0560-10 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-12Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-8Tank capacity . . . . . . . . . . . . . . . . . . . . .00-0004-3

Fuel filter, primary (water separator) Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-7Hydraulic oil clean-up procedureDrain and clean. . . . . . . . . . . . . . . . . . . .05-0560-5

Remove and install . . . . . . . . . . . . . . . . .05-0560-6 Using filter caddy . . . . . . . . . . . . . . . . .31-3160-69Hydraulic pumpFuel shut-off solenoid

Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0515-6 Disassemble, inspect and assemble . . .31-3160-13Hydraulic pump control valveFuel tank guard

Remove and install . . . . . . . . . . . . . . . . .17-1746-1 Disassemble and assemble . . . . . . . . .31-3160-36Hydraulic pump (PVG 65)Fuel, diesel

storage . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-2 Cross section drawing. . . . . . . . . . . . . .31-3160-12Hydraulic pump, loaderFuse block

Remove blade terminals . . . . . . . . . . . .16-1674-24 Remove and install . . . . . . . . . . . . . . . . .31-3160-9Hydraulic reservoir

Remove and install . . . . . . . . . . . . . . . .31-3160-68Hydrometer test . . . . . . . . . . . . . . . . . . . . .16-1671-9

G

Grease IExtreme pressure and multipurpose . . . .00-0004-5

Grille and grille housing Inch torque values . . . . . . . . . . . . . . . . . . .00-0003-5Remove and install . . . . . . . . . . . . . . . . .19-1921-2 Input and output clutches Indx

Guard, front axle 5Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-17Remove and install . . . . . . . . . . . . . . . . .17-1746-1 Input shaft

Guard, fuel tank Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0350-55Remove and install . . . . . . . . . . . . . . . . .17-1746-1 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0350-54

Guard, transmission bottom Remove . . . . . . . . . . . . . . . . . . . . . . . .03-0350-11Remove and install . . . . . . . . . . . . . . . . .17-1746-2 Inspection

Guard, transmission side External service brake. . . . . . . . . . . . . . .10-1011-1Remove and install . . . . . . . . . . . . . . . . .17-1746-2

JH

Jump starting . . . . . . . . . . . . . . . . . . . . . . .16-1671-8

Halogen bulbsReplace . . . . . . . . . . . . . . . . . . . . . . . . .16-1673-1

Hardware LTorque specifications . . . . . . . . . . . . . . .00-0003-1

Heater coil Light, domeRemove and install . . . . . . . . . . . . . . . . .16-1673-7Remove and install . . . . . . . . . . . . . . . .18-1830-30


PN=5

Index

Page Page

Light, door switch ORemove and install . . . . . . . . . . . . . . . . .16-1673-7

Lights, drive and guard O-ring boss fittings . . . . . . . . . . . . . . . . . . .00-0003-7Remove and install . . . . . . . . . . . . . . . . .16-1673-6 Oil

Lights, front turn Lines and fittings. . . . . . . . . . . . . . . . . . .00-0003-6Remove and install . . . . . . . . . . . . . . . . .16-1673-5 Specification differential . . . . . . . . . . . . .00-0004-4

Lights, stop, turn and tail Specification hydraulic system . . . . . . . .00-0004-4Remove and install . . . . . . . . . . . . . . . . .16-1673-5 Specification park brake . . . . . . . . . . . . .00-0004-4

Lights, work Specification transmission . . . . . . . . . . . .00-0004-4Remove and install . . . . . . . . . . . . . . . . .16-1673-3 Oil clean-up

Load sense relief valve Procedure . . . . . . . . . . . . . . . . . . . . . . .31-3160-69Disassemble and assemble . . . . . . . . .31-3160-45 Oil cooler

Load test, batteries. . . . . . . . . . . . . . . . . . .16-1671-9 Assemble . . . . . . . . . . . . . . . . . . . . . . .05-0510-17Loader boom bushings and seals Disassemble . . . . . . . . . . . . . . . . . . . . .05-0510-17

Remove and install . . . . . . . . . . . . . . . . .31-3140-9 Remove and install . . . . . . . . . . . . . . . .05-0510-10Loader bucket tilt linkage Oil lines and fittings . . . . . . . . . . . . . . . . . .00-0003-6

Remove and install . . . . . . . . . . . . . . . . .31-3140-3 Oil pipes and tubeLoader control valve Replace . . . . . . . . . . . . . . . . . . . . . . . .03-0360-23

Disassemble and assemble . . . . . . . . .31-3160-40 Oil, component, R134a air conditioningRemove and install . . . . . . . . . . . . . . . .31-3160-37 Charge . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12

Loader hydraulic pump Oscillation supportsRemove and install . . . . . . . . . . . . . . . . .31-3160-9 Disassemble and assemble . . . . . . . . .02-0200-18

Loader start-up procedure Output shaftBoom cylinder . . . . . . . . . . . . . . . . . . . .31-3160-48 Remove . . . . . . . . . . . . . . . . . . . . . . . .03-0350-11Bucket cylinder . . . . . . . . . . . . . . . . . . .31-3160-51 Outside mirror

Low sulfur diesel fuel conditioner . . . . . . . .00-0004-2 Remove and install . . . . . . . . . . . . . . . . .20-2002-2Lower pivot bearing and seals

Remove and install . . . . . . . . . . . . . . . .17-1740-12Lubricant

Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-7PStorage . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-6

Lubricity of diesel fuel. . . . . . . . . . . . . . . . .00-0004-1Park Brake

Assemble . . . . . . . . . . . . . . . . . . . . . . . .11-1111-6Disassemble . . . . . . . . . . . . . . . . . . . . . .11-1111-6

M Park brake

Indx6

Install . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1111-2Oil specification. . . . . . . . . . . . . . . . . . . .00-0004-4Manifold, compressorPressure switch, remove and install . . . .11-1160-4Inspect . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-52Release solenoid valve, remove andMetri-Pack connector

install . . . . . . . . . . . . . . . . . . . . . . . . . .11-1160-2Replace . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-4Remove . . . . . . . . . . . . . . . . . . . . . . . . .11-1111-2Metric torque values . . . . . . . . . . . . . . . . . .00-0003-2

Pilot controller valve (single lever)Mirror, outsideDisassemble and assemble . . . . . . . . .31-3160-71Remove and install . . . . . . . . . . . . . . . . .20-2002-2

Pilot controller valve, single leverMixing lubricants. . . . . . . . . . . . . . . . . . . . .00-0004-7Cross section . . . . . . . . . . . . . . . . . . . .31-3160-71Monitor display unitRemove and install . . . . . . . . . . . . . . . .31-3160-70Remove and install . . . . . . . . . . . . . . . . .16-1675-5

Pilot controller valve, two leverMotor, startingRemove and install . . . . . . . . . . . . . . . .31-3160-91Remove and install . . . . . . . . . . . . . . . . .16-1677-1

Pilot enable solenoid valveMounted stepRemove and install . . . . . . . . . . . . . . . .31-3160-99Remove and install . . . . . . . . . . . . . . . . .18-1822-5

Pin disconnect valveMufflerRemove and install . . . . . . . . . . . . . . . . .05-0530-2 Disassemble and assemble . . . . . . . .31-3160-115


PN=6

Index

Page Page

Pin disconnect/axle disconnect RegulatorInstall . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1672-4Remove and install . . . . . . . . . . . . . . .31-3160-114

Pivot bearing and seals Remove . . . . . . . . . . . . . . . . . . . . . . . . .16-1672-4Relief valveLower, remove and install . . . . . . . . . . .17-1740-12

Upper, remove and install . . . . . . . . . . .17-1740-10 Disassemble and assemble . . . . . . . . .31-3160-44Remove and installPre-load clutch pack compression ring tool

DFT1148. . . . . . . . . . . . . . . .03-0399-1, 03-0399-2 Loader bucket tilt linkage . . . . . . . . . . . .31-3140-3Reservoir, hydraulicPressure reducing valve

Disassemble and assemble . . . . . . . . .31-3160-96 Remove and install . . . . . . . . . . . . . . . .31-3160-68Return-to-carryRemove and install . . . . . . . . . . . . . . . .31-3160-95

Pressure reducing valve manifold Height kickout adjustment . . . . . . . . . . .16-1674-26Return-to-dig circuitInstall . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-94

Remove . . . . . . . . . . . . . . . . . . . . . . . .31-3160-94 Adjustment . . . . . . . . . . . . . . . . . . . . . .16-1674-27Reverse warning alarmPressurizer motor assembly

Remove and install . . . . . . . . . . . . . . . .18-1830-40 Change volume. . . . . . . . . . . . . . . . . . . .20-2004-2Remove and install . . . . . . . . . . . . . . . . .20-2004-2Primary element

Clean oily or sooty . . . . . . . . . . . . . . . . .05-0520-5 Ride controlRemove and install . . . . . . . . . . . . . . .31-3160-100Primary fuel filter (water separator)

Remove and install . . . . . . . . . . . . . . . . .05-0560-6 Ride control accumulatorDisassemble and assemble . . . . . . . .31-3160-108Primary fuel filter (water separatory)

Drain and clean. . . . . . . . . . . . . . . . . . . .05-0560-5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3102-2Ride control assumulatorPump, hydraulic

Disassemble, inspect and assemble . . .31-3160-13 Charge . . . . . . . . . . . . . . . . . . . . . . . .31-3160-112Ride control repair . . . . . . . . . . . . . . . . .31-3160-100Pump, hydraulic loader

Remove and install . . . . . . . . . . . . . . . . .31-3160-9 Remove and Install . . . . . . . . . . . . . . .31-3160-104Ride control solenoid valvesPump, transmission

Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-5 Disassemble and assemble . . . . . . . .31-3160-107Ride control valveRemove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-2

Disassemble and assemble . . . . . . . 31-3160-102,31-3160-106

Roll-over protective structureR Torque values . . . . . . . . . . . . . . . . . . . . .00-0003-1

Radiator IndxAssemble . . . . . . . . . . . . . . . . . . . . . . .05-0510-17 7

SDisassemble . . . . . . . . . . . . . . . . . . . . .05-0510-17Remove and install . . . . . . . . . . . . . . . .05-0510-10

Rear axle oil cooler Safe dischargeRide control accumulator . . . . . . . . . . . .31-3102-2Remove and install . . . . . . . . . . . . . . . .02-0260-10

Rear view mirror Seals and bushingsBucket linkage, remove and install . . . . .31-3140-4Remove and install . . . . . . . . . . . . . . . . .20-2002-1

Receiver-dryer Seals and bushings, loader boomRemove and install . . . . . . . . . . . . . . . . .31-3140-9Remove and install . . . . . . . . . . . . . . . .18-1830-41

Refrigerant Seals, tool carrier boomRemove and install . . . . . . . . . . . . . . . .31-3140-10R134a cautions. . . . . . . . . . . . . . . . . . . .18-1830-9

Theory of operation. . . . . . . . . . . . . . . . .18-1830-7 SeatDisassemble and assemble . . . . . . . . . .18-1821-2Refrigerant, air conditioning R134a system

Evacuate. . . . . . . . . . . . . . . . . . . . . . . .18-1830-16 Seat beltDisassemble and assemble . . . . . . . . . .18-1821-1Recover . . . . . . . . . . . . . . . . . . . . . . . .18-1830-15

Refrigerant, R134a Service brakesExternal inspection . . . . . . . . . . . . . . . . .10-1011-1Recovery, recycling and charging . . . . .18-1830-14

Refrigerant, R134a system Shield, transmissionRemove and install . . . . . . . . . . . . . . . . .19-1913-1Charge . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-18


PN=7

Index

Page Page

Shields, engine side TRemove and install . . . . . . . . . . . . . . . . .19-1910-3

Slow idle Tilt cylinder TC62HDisassemble and assemble . . . . . . . . .31-3160-59Adjust engine speed . . . . . . . . . . . . . . . .05-0515-2

Solenoid, ride control valves Tilt cylinders TC62HCross section . . . . . . . . . . . . . . . . . . . .31-3160-58Disassemble and assemble . . . . . . . .31-3160-107

Specification TipsBucket tooth, remove and install . . . . . . .31-3102-3Battery . . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-2

Differential oil . . . . . . . . . . . . . . . . . . . . .00-0004-4 TireInstall . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-4Hydraulic oil . . . . . . . . . . . . . . . . . . . . . .00-0004-4

Park brake . . . . . . . . . . . . . . . . . . . . . . .00-0004-4 Remove . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-3Tool carrierTransmission oil . . . . . . . . . . . . . . . . . . .00-0004-4

Specifications Disassemble and assemble . . . . . . . . . .31-3140-8Tool carrier boom bushings and sealsHardware torque . . . . . . . . . . . . . . . . . . .00-0003-1

TC62H . . . . . . . . . . . . . . . . . . . . . . . . . .00-0002-5 Remove and install . . . . . . . . . . . . . . . .31-3140-10Tool carrier lower tilt linkage624H. . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0002-1

Start-up procedure Disassemble and assemble . . . . . . . . . .31-3140-6Tool carrier upper tilt linkageSteering cylinder . . . . . . . . . . . . . . . . . .09-0960-11

Starting aid, fluid Disassemble and assemble . . . . . . . . . .31-3140-5Tooth shanksRemove and install . . . . . . . . . . . . . . . . .05-0505-1

Starting motor Bucket, remove and install . . . . . . . . . . .31-3102-3Torque converterRemove and install . . . . . . . . . . . . . . . . .16-1677-1

Steering Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-8Torque converter and housingCylinder bushings, remove and

install . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-12 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-5Torque converter relief valveSteering column

Remove and install . . . . . . . . . . . . . . . . .09-0960-8 Remove . . . . . . . . . . . . . . . . . . . . . . . .03-0360-21Torque specificationsSteering cylinder

Assemble . . . . . . . . . . . . . . . . . . . . . . .09-0960-12 Hardware . . . . . . . . . . . . . . . . . . . . . . . .00-0003-1Torque valueBushings, remove and install . . . . . . . .09-0960-12

Disassemble . . . . . . . . . . . . . . . . . . . . .09-0960-12 Flat face O-ring seal fitting . . . . . . . . . . .00-0003-9Inch SAE four bolt flange fitting. . . . . . .00-0003-11Loader start-up procedure. . . . . . . . . . .09-0960-11

Remove and install . . . . . . . . . . . . . . . . .09-0960-9 Metric cap screw. . . . . . . . . . . . . . . . . . .00-0003-3Metric four bolt flange fitting . . . . . . . . .00-0003-10Steering valve

Remove and install . . . . . . . . . . . . . . . . .09-0960-3 O-Ring boss fitting . . . . . . . . . . . . . . . . .00-0003-7Torque valuesStep

Indx8

Remove and install . . . . . . . . . . . . . . . . .18-1822-2 Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-5Metric . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2Step, engine compartment

Remove and install . . . . . . . . . . . . . . . . .18-1822-4 Roll-over protective structure. . . . . . . . . .00-0003-1TransmissionStep, mounted

Remove and install . . . . . . . . . . . . . . . . .18-1822-5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0300-3Oil specification. . . . . . . . . . . . . . . . . . . .00-0004-4Stop, turn and tail light

Remove and install . . . . . . . . . . . . . . . . .16-1673-5 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0300-3Transmission bottom guardStoring lubricants . . . . . . . . . . . . . . . . . . . .00-0004-6

Structure Remove and install . . . . . . . . . . . . . . . . .17-1746-2Transmission control unit (TCU)Welding. . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-3

Support, wrist Remove and install . . . . . . . . . . . . . . . . .16-1675-1Transmission control valveRemove and install . . . . . . . . . . . . . . . .18-1810-10

Switch, freeze control Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0360-15Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-12Bench test. . . . . . . . . . . . . . . . . . . . . . .18-1830-35

Remove and install . . . . . . . . . . . . . . . .18-1830-34 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-8Transmission control valve connector bodySwitch, park break pressure

Remove and install . . . . . . . . . . . . . . . . .11-1160-4 Remove and install . . . . . . . . . . . . . . . . .16-1674-8


PN=8

Index

Page Page

Transmission control valve connector contact Remove and install . . . . . . . . . . . . . . . .31-3160-37Install . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-9 Valve, pilot controller (single lever)

Transmission controller unit connector terminals Disassemble and assemble . . . . . . . . .31-3160-71Replace . . . . . . . . . . . . . . . . . . . . . . . .16-1674-19 Valve, pilot controller, single lever

Transmission pump Cross section . . . . . . . . . . . . . . . . . . . .31-3160-71Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-5 Remove and install . . . . . . . . . . . . . . . .31-3160-70Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-2 Valve, pilot controller, two lever

Transmission shields Remove and install . . . . . . . . . . . . . . . .31-3160-91Remove and install . . . . . . . . . . . . . . . . .19-1913-1 Valve, pilot enable solenoid

Transmission side guard Remove and install . . . . . . . . . . . . . . . .31-3160-99Remove and install . . . . . . . . . . . . . . . . .17-1746-2 Valve, pin disconnect

Disassemble and assemble . . . . . . . .31-3160-115Valve, pin disconnect/axle disconnect

Remove and install . . . . . . . . . . . . . . .31-3160-114UValve, pressure reducing

Disassemble and assemble . . . . . . . . .31-3160-96Universal jointRemove and install . . . . . . . . . . . . . . . .31-3160-95Disassemble, inspect and assemble . . . .02-0225-4

Valve, reliefRemove and Install . . . . . . . . . . . . . . . . .02-0225-2Disassemble and assemble . . . . . . . . .31-3160-44Upper pivot bearing and seals

Valve, ride controlRemove and install . . . . . . . . . . . . . . . .17-1740-10Disassemble and assemble . . . . . . . 31-3160-102,

31-3160-106Valve, solenoid

V Park brake release, remove andinstall . . . . . . . . . . . . . . . . . . . . . . . . . .11-1160-2

Valve Valve, steeringMinimum pressure regulator . . . . . . . . . .03-0360-4 Remove and install . . . . . . . . . . . . . . . . .09-0960-3Pressure reducing manifold, install . . . .31-3160-94 Valve, transmission controlPressure reducing manifold, remove . . .31-3160-94 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-7

Valve, auxiliary section and bucket section Valves solenoid, ride controlDisassemble and assemble . . . . . . . . .31-3160-41 Disassemble and assemble . . . . . . . .31-3160-107

Valve, axle disconnectDisassemble and assemble . . . . . . . .31-3160-116

Valve, boom circuit relief IndxDisassemble and assemble . . . . . . . . .31-3160-45 9W

Valve, boom down solenoidRemove and install . . . . . . . . . . . . . . . .31-3160-97

Wear platesValve, boom sectionRemove and install . . . . . . . . . . . . . . . . .31-3102-7Disassemble and assemble . . . . . . . . .31-3160-43

WeldingValve, brakeStructure . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-3Remove and install . . . . . . . . . . . . . . . . .10-1060-1

WheelValve, bucket circuit reliefRemove and Install . . . . . . . . . . . . . . . . .01-0110-1Disassemble and assemble . . . . . . . . .31-3160-44

WindowpanesValve, differential lock solenoidRemove and install . . . . . . . . . . . . . . . . .18-1810-2Remove and install . . . . . . . . . . . . . . . .31-3160-98

Windshield WasherValve, expansionRemove and install . . . . . . . . . . . . . . . . .18-1810-4Remove and install . . . . . . . . . . . . . . . .18-1830-33

Windshield wiperValve, heater controlAdjust front . . . . . . . . . . . . . . . . . . . . . . .18-1810-8Remove and install . . . . . . . . . . . . . . . .18-1830-36

Windshield wiper motorValve, load sense reliefRemove and install . . . . . . . . . . . . . . . . .18-1810-6Disassemble and assemble . . . . . . . . .31-3160-45

Windshield wiper, frontValve, loader controlDisassemble and assemble . . . . . . . . .31-3160-40 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-8


PN=9

Index

Page

Wiper motorRemove and install . . . . . . . . . . . . . . . . .18-1810-6

Work lightsRemove and install . . . . . . . . . . . . . . . . .16-1673-3

Wrist supportRemove and install . . . . . . . . . . . . . . . .18-1810-10

Indx10


PN=10

624h loader and tc62h tc operation tm1640

Documents

a03 orgg05

5r25 radial

tc62h tool

power shift

power shift

power shift

power shift

power shift