750c, 850c dozer repair tm1589

750C, 850CCrawler Dozer

Repair

TECHNICAL MANUAL750C, 850C, 750C Series II, 850C

Series II Crawler Dozers

TM1589 10AUG04 (ENGLISH)

For complete service information also see:

750C, 850C, Crawler Dozer Operation andTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM15886068 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . CTM86068 POWERTECH Engine. . . . . . . . . . . . . CTM1046076 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . CTM426081 POWERTECH Engine Repair . . . . . . . CTM86Undercarriage Appraisal Manual . . . . . . . . . SP326

Worldwide ConstructionAnd Forestry Division

LITHO IN U.S.A.

Introduction

TX,750C,SS2406 –19–13JUL95–1/1

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 problems 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 problems and their causes.

TM1589 (10AUG04) 750C, 850C, 750C II, 850C II Crawler081004

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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 16—Electrical SystemGroup 1671—Batteries, Support, and CablesGroup 01—Safety

Group 02—General Specifications Group 1672—Alternator, Regulator and ChargingSystem WiringGroup 03—Torque Values

Group 04—Fuels and Lubricants Group 1673—Lighting System01Group 1674—Wiring Harness and Switches

Group 1675—System ControlsSECTION 01—TracksGroup 1677—Motors and ActuatorsGroup 0130—Track System

Group 0199—Dealer Fabricated ToolsSECTION 17—Frames, Chassis, or Supporting

StructureSECTION 02—Axles and Suspension SystemsGroup 1740—Frame InstallationGroup 0201—Drive Axle Housing and SupportGroup 1746—Frame Bottom GuardsGroup 0250—Axle Shaft, Bearings and ReductionGroup 1749—Chassis WeightsGears

Group 0299—Dealer Fabricated ToolsSECTION 18—Operator’s Station

02

Group 1800—Removal and InstallationSECTION 03—Transmission Group 1810—Operator Enclosure

Group 0300—Remove and Install Group 1821—Seat and Seat BeltGroup 0315—Control Linkage Group 1830—Heating and Air ConditioningGroup 0360—Hydrostatic SystemGroup 0399—Dealer Fabricated Tools SECTION 19—Sheet Metal

Group 1910—Hood and Engine EnclosuresSECTION 04—Engine Group 1921—Grille and Grille Housing

Group 0400—Removal and InstallationSECTION 20—Safety, Convenience and

MiscellaneousSECTION 05—Engine Auxiliary Systems

03

Group 2004—Horn and Warning DevicesGroup 0505—Cold Weather Starting AidGroup 0510—Cooling System

SECTION 32—BulldozerGroup 0515—Speed ControlsGroup 3200—Removal and InstallationGroup 0520—Intake SystemGroup 3201—BladeGroup 0530—External Exhaust SystemsGroup 3215—Controls LinkageGroup 0560—External Fuel Supply SystemsGroup 3240—FramesGroup 0599—Dealer Fabricated ToolsGroup 3260—Hydraulic SystemGroup 3299—Dealer Fabricated ToolsSECTION 07—Dampener Drive

Group 0752—Elements

04

SECTION 11—Park BrakeGroup 1100—Park BrakeGroup 1115—Control LinkageGroup 1160—Hydraulic System

SECTION 15—Equipment AttachingGroup 1511—Drawbar

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 1995, 1997,1999, 2000, 2001

07

11

15

16

TM1589 (10AUG04) i 750C, 850C, 750C II, 850C II Crawler081004

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TM1589 (10AUG04) ii 750C, 850C, 750C II, 850C II Crawler081004

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INDX

TM1589 (10AUG04) iii 750C, 850C, 750C II, 850C II Crawler081004

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TM1589 (10AUG04) iv 750C, 850C, 750C II, 850C II Crawler081004

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00

Section 00General Information

Contents

Page Page

Group 01—Safety . . . . . . . . . . . . . . . . . . . . . .00-01-1 Track Rollers, Front Idler, Carrier Rollerand Track Frame Outer Pivot Oil . . . . . . . . . .00-04-7

Group 02—General Specifications Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-04-7750C Series II Specifications. . . . . . . . . . . . . . .00-02-1 Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . .00-04-8750C Series II Capacity Specifications . . . . . . .00-02-3 Alternative and Synthetic Lubricants . . . . . . . . .00-04-8750C Series II General Specifications . . . . . . . .00-02-4 Mixing of Lubricants . . . . . . . . . . . . . . . . . . . . .00-04-9750C LT Series II Dimensions. . . . . . . . . . . . . .00-02-6 Diesel Engine Coolant. . . . . . . . . . . . . . . . . . . .00-04-9750C WT Series II Dimensions . . . . . . . . . . . . .00-02-9750C LGP Series II Dimensions . . . . . . . . . . .00-02-11850C Series II Specifications. . . . . . . . . . . . . .00-02-13850C Series II Capacity Specifications . . . . . .00-02-16850C Series II General Specifications . . . . . . .00-02-17850C LT Series II Dimensions. . . . . . . . . . . . .00-02-19850C WT Series II Dimensions . . . . . . . . . . . .00-02-22850C LGP Series II Dimensions . . . . . . . . . . .00-02-24

Group 03—Torque ValuesHardware Torque Specifications . . . . . . . . . . . .00-03-1Keeping ROPS Installed Properly . . . . . . . . . . .00-03-1Checking Track Shoe Cap Screw Torque . . . . .00-03-2Checking Track Shoe Cap Screw Torque—

Master Link . . . . . . . . . . . . . . . . . . . . . . . . . .00-03-3Metric Bolt and Cap Screw Torque Values . . . .00-03-5Additional Metric Cap Screw Torque Values . . .00-03-6Service Recommendations for Metric

Series Four Bolt Flange Fitting . . . . . . . . . . .00-03-8Unified Inch Bolt and Cap Screw Torque

Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-03-9Check Oil Lines And Fittings . . . . . . . . . . . . . .00-03-10Service Recommendations for O-Ring

Boss Fittings . . . . . . . . . . . . . . . . . . . . . . . .00-03-11Service Recommendations for Flat Face

O-Ring Seal Fittings. . . . . . . . . . . . . . . . . . .00-03-13Service Recommendations for Inch Series

Four Bolt Flange Fittings . . . . . . . . . . . . . . .00-03-14

Group 04—Fuels and LubricantsDiesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-04-1Handling and Storing Diesel Fuel . . . . . . . . . . .00-04-1Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-04-2Low Sulfur Diesel Fuel Conditioner . . . . . . . . . .00-04-2Diesel Fuel Storage. . . . . . . . . . . . . . . . . . . . . .00-04-3Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . .00-04-4Transmission, Hydraulic, and Hand Pump

Reservoir Oil . . . . . . . . . . . . . . . . . . . . . . . . .00-04-5Inner and Outer Final Drive Oil . . . . . . . . . . . . .00-04-6

TM1589 (10AUG04) 00-1 750C, 850C, 750C II, 850C II Crawler081004

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Contents

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Group 01Safety

00011

DX,FLAME –19–04JUN90–1/1

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 specification.

SpecificationBattery—Warm 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.

TM1589 (10AUG04) 00-01-1 750C, 850C, 750C II, 850C II Crawler081004

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Safety

0001

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

00013

DX,MSDS –19–28SEP90–1/1

Handle Chemical Products Safely

TS

272

–UN

–23A

UG

88

Direct exposure to chemical products can cause severeskin irritation and injury. Hazardous fumes can begenerated when handling the chemicals.

Wear close fitting clothing and a face mask when handlingchemicals. Dispose of chemical waste and packagingmaterial properly.

A Material Safety Data Sheet provides specific details onchemical products and physical dangers, safetyprocedures, and emergency response techniques. Userawareness and training is required under U.S. workplaceand environmental laws. See your John Deere dealer forinformation on chemical products used with John Deereequipment.

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

0001

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 –19–04JUN90–1/1

Support Machine Properly

TS

229

–UN

–23A

UG

88

Always lower the attachment or implement to the groundbefore you work on the machine. If you must work on alifted machine or attachment, securely support themachine or attachment.

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.

DX,WEAR –19–10SEP90–1/1

Wear Protective Clothing

TS

206

–UN

–23A

UG

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

Prolonged exposure to loud noise can cause impairmentor loss of hearing.

Wear a suitable hearing protective device such asearmuffs or earplugs to protect against objectionable oruncomfortable loud noises.

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


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Safety

00015

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 –19–04JUN90–1/1

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.


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Safety

0001

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.

DX,PAINT –19–03MAR93–1/1

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.

Do all work outside or in a well ventilated area. Dispose ofpaint and solvent properly.

Remove paint before welding or heating:

• 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.


PN=14

Safety

00017

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.

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.


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Safety

0001

8

DX,SERV –19–03MAR93–1/1

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.

Disconnect battery ground cable (-) before makingadjustments on electrical systems or welding on machine.

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.


PN=16

Safety

00019

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=17

Safety

000110


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Group 02General Specifications

00021

TX,115,BG1050 –19–01OCT98–1/3

750C Series II Specifications

NOTE: Specifications and design subject to changewithout notice. Wherever applicable,specifications are in accordance with ICEDand SAE standards. Except where otherwisenoted, these specifications are based on a unitequipped with 560 mm (22 in.) grousers,roll-over protective canopy, full fuel tank, 79 kg(175 lb) operator, and standard equipment.

Net engine power is with standard equipment includingair cleaner, exhaust system, alternator, and coolingfan, at standard conditions per SAE J1349 and DIN6270B using No. 2-D fuel at 35 API gravity. Noderating is required up to 3050 m (10,000 ft) altitude.Gross power is without cooling fan.

Item Measurement Specification

John Deere 6—CylinderPOWERTECH TurbochargedDiesel Engine 6068T

Fuel Consumption, Typical Consumption 14.4—20.8 L/h (3.8—5.5 gal/hr)

Rated Power at 2100 rpm Power 104 kW (140 hp) SAE nethorsepower110 kW (148 hp) SAE grosshorsepower

Bore and Stroke Distance 106.4 x 127 mm (4.14 x 5 in.)

Piston Displacement 6.785 L (414 cu in.)

Electrical System Voltage 24-volt with 45-amp alternator

Maximum Net Torque at 1300 rpm Torque Rise 570 N•m (420 lb-ft)

Batteries Voltage Two 12-voltCold Cranking Amps 625 amps each at —18°C (0°F)Reserve Capacity 160 minutes each at —18°C (0°F)

Transmission Speed Infinite from 0—11 km/h (0—6.8mph) forward and reverse

Drawbar Pull at 1.9 km/h (1.2 mph) Force 141 kN (31,800 lb force)

Hydraulic System (Open Center) Pressure 13 790 kPa (2000 psi)Flow Rate 144 L/min (38 gpm) at 2100 rpm

POWERTECH is a trademark of Deere & Company


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Continued on next page

General Specifications

0002

2

TX,115,BG1050 –19–01OCT98–2/3


Undercarriage

750C Track Shoes (Each Side) Quantity 40

750C LGP Track Shoes (Each Quantity 42Side)

750C Track Rollers Quantity 7

750C Ground Contact Area (with Area 28 955 cm2 (4488 sq in.)22 in. Shoes)

750C WT Ground Contact Area Area 44 748 cm2 (6936 sq in.)(with 34 in. Shoes)

750C LGP Ground Contact Area Area 48 039 cm2 (7446 sq in.)(with 34 in. Shoes)

750C minimum with single-bar Clearance 371 mm (14.6 in.)grouser (excluding grouser height)

750C WT minimum with swamp Clearance 437 mm (17.2 in.)shoe (including grouser height)

750C LT/750C WT Track Pitch 190 mm (7.5 in.)Gauge 1880 mm (74 in.)

750 LGP Track Pitch 190 mm (7.5 in.)Gauge 2083 mm (82 in.)

750C LT/750C WT Track Length Distance 2591 mm (102 in.)on Ground

750 LPG Track Length on Ground Distance 2781 mm (109.5 in.)

Ground Pressure

750C LT Ground Pressure Semi-U Pressure 49.0 kPa (0.5 bar) (7.1 psi)Blade

750C LT Ground Pressure PAT Pressure 51.7 kPa (0.52 bar) (7.5 psi)Blade

750C WT Ground Pressure Pressure 33.6 kPa (0.3 bar) (4.9 psi)

750C LGP Ground Pressure Pressure 33.9 kPa (0.4 bar) (4.91 psi)


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00023

TX,115,BG1050 –19–01OCT98–3/3


SAE Operating Weight

750C with Semi-U Blade (High Weight 14 415 kg (31,712 lb)Production)

750C All-Hydraulic Dozer (PAT) Weight 15 335 kg (33,736 lb)

750C WT with Straight Blade Weight 15 147 kg (33,324 lb)

750C WT with Semi-U Blade (High Weight 15 383 kg (33,843 lb)Production)

750C LGP All-Hydraulic Dozer Weight 16 625 kg (36,576 lb)(PAT)

CED,OUO1065,110 –19–05JAN00–1/1

750C Series II Capacity Specifications


Drain and Refill Capacities

Cooling System (Including Capacity 26.5 L (7 gal)Recovery Tank)

Fuel Tank Capacity 280 L (74 gal)

Engine Oil (Including Filter) Capacity 19 L (5 gal)

750C LT/750C WT Inner Final Capacity 23.6 L (6.25 gal)Drive (Each Side)

750C LGP Inner Final Drive (Each Capacity 27.8 L (7.35 gal)Side)

Outer Final Drive (Each Side) Capacity 12.3 L (3.25 gal)

Hydraulic Reservoir Capacity 68 L (18 gal)

Hydrostatic Transmission Capacity 83.3 L (22 gal)


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0002

4

CED,OUO1032,751 –19–01OCT98–1/2

750C Series II General Specifications

Lubrication:

• Pressure system with full flow filters

Cooling:

• Pressured with thermostat and controlled bypass

Fan:

• Blower-type

Air Cleaner:

• Dual-stage aspirated with restriction indicator• Dry

Transmission:

• Automatic, dual-path hydrostatic drive.• Load sensing feature automatically adjusts speed and

power to match changing load conditions.• Dual path hydrostatic drive.• Live power turns: Both tracks remain fully powered

during turns. This affords greater maneuverability withlarger loads and less ground disturbance. This featurealso provides improved capability for working on softground, as well as the ability to counterbalance bladecorner loads when benching, ditching or backfilling.

• Counter-rotation: Separate control allows the twotransmissions to be driven in opposite directions,permitting spot turns with excellent maneuverability.Quick blade position changes can be made.

• Infinite speed selection: Infinitely variable groundspeeds, from 0—11 km/h (0—6.8 mph), allow precisespeed. Speed can be reduced without slowing enginerpm, so hydraulic power remains high and responsetime remains fast.

• Automatic load sensing: As a load increases andengine rpm lessens, the transmission automaticallyreduces ground speed to match load changes. Thisfeature works at all throttle settings, providing fulldrawbar pull even at reduced engine speed.


PN=22



00025

CED,OUO1032,751 –19–01OCT98–2/2

• Dynamic braking: Positive speed reduction is providedon slopes. When shifted to neutral, oil flow between thepump and motor is blocked. The crawler stops withoutuse of the service brakes.

Steering:

• Single lever steering and direction control withdecelerator or optional steering pedals and U-patternFNR lever without decelerator, full power turn,counter-rotation and infinitely variable track speedsprovide unlimited maneuverability and optimum control.

• Hydrostatic steering eliminates the need for steeringclutches and steering brakes as well as the need forcross-steering when working on steep slopes.

Brakes:

• Hydrostatic (dynamic) braking stops the machine whenthe direction/steering control lever is moved to neutral.

• Wet-disk brakes are automatically applied when engineis stopped or manually applied with center foot pedalduring normal operation.

Hydraulics:

• Open center system• 10 micron filter in return line with bypass• Gear-type pump

Forestry Application:

• The dozer can be equipped for forestry applications withthe addition of limb risers and screens for the roll-overprotective structure.


PN=23


0002

6

CED,OUO1065,117 –19–20JAN00–1/3

750C LT Series II Dimensions

T12

7264

–UN

–10J

AN

00


750C LT Series II with Semi-U(High-Production) Blade:

Blade Capacity 4.28 m3 (5.60 cu yd)

A—Blade Lift Height 1072 mm (42.2 in.)

B—Blade Height 1283 mm (50.5 in.)

C—Digging Depth 513 mm (20.2 in.)

D—Overall Machine (with standard Length 5011 mm (16 ft 5 in.)drawbar)


PN=24



00027

CED,OUO1065,117 –19–20JAN00–2/3


E—Tread Depth with Single-Bar Depth 56 mm (2.2 in.)Grouser (Moderate Duty)

E—Tread Depth with Single-Bar Depth 68 mm (2.7 in.)Grouser (Extreme Duty)

F—Overall Machine Height 3065 mm (10 ft 1 in.)

G—Blade Width 3216 mm (10 ft 6.6 in.)

H— Maximum Blade Tilt Height 700 mm (27.6 in.)

750C LT Series II All-HydraulicDozer (PAT)



B—Blade Height 1193 mm (47 in.)


D—Overall Machine (with standard Length 4955 mm (16 ft 3 in.)drawbar)





H— Maximum Blade Tilt Height 413 mm (16.2 in.)

I—Width Over Track Width 2438 mm (8 ft 0 in.)

J—Overall Blade Width (with Blade Width 3011 mm (9 ft 10.5 in.)Angled)

K—Maximum Blade Angle 24 degrees

L—Blade Cut Reach Distance 89 mm (3.5 in.)


PN=25



0002

8

CED,OUO1065,117 –19–20JAN00–3/3


M—Blade Cast Reach Distance 325 mm (12.8 in.)

N—Cutting Edge Angle 58 degrees


PN=26


00029

CED,OUO1065,118 –19–20JAN00–1/2

750C WT Series II Dimensions

T12

7264

–UN

–10J

AN

00


750C WT Series II with StraightBlade:





D—Overall Machine Length 4956 mm (16 ft 3 in.)


PN=27



000210

CED,OUO1065,118 –19–20JAN00–2/2



E—Tread Depth with Swamp Shoe Depth 80 mm (3.15 in.)


G—Blade Width 3363 mm (11 ft)

H—Maximum Blade Tilt Height 878 mm (34.6 in.)


750C WT Series II with Semi-U(High Profile) Blade:









G—Blade Width 3658 mm (12 ft)



PN=28


000211

CED,OUO1032,1008 –19–06JAN00–1/2

750C LGP Series II Dimensions

T12

7264

–UN

–10J

AN

00


750C LGP Series II All-HydraulicDozer (PAT)



B—Blade Height 1143 mm (45 in.)




PN=29



000212

CED,OUO1032,1008 –19–06JAN00–2/2




G—Blade Width 3861 mm (12 ft 8 in.)



J—Overall Blade Width (with Blade Width 3541 mm (11 ft 7 in.)Angled)






PN=30


000213

CED,OUO1032,754 –19–06JAN00–1/3

850C Series II Specifications

NOTE: Specifications and design subject to changewithout notice. Wherever applicable,specifications are in accordance with ICEDand SAE standards. Except where otherwisenoted, these specifications are based on a unitequipped with 610 mm (24 in.) grousers, rigiddrawbar, front hook, roll-over protectivecanopy, full fuel tank, 79 kg (175 lb) operator,and standard equipment.

Net engine power is with standard equipment includingair cleaner, exhaust system, alternator, and coolingfan, at standard conditions per SAE J1349 and DIN6270B using No. 2-D fuel at 35 API gravity. Noderating is required up to 3050 m (10,000 ft) altitude.Gross power is without cooling fan.


John Deere 6—CylinderPOWERTECH TurbochargedDiesel Engine 6081AT

Fuel Consumption, Typical Consumption 17.4—26.5 L/h (4.6—7.0 gal/hr)

Maximum Net Torque at 1300 rpm Torque Rise 815 N•m (601 lb-ft)

Rated Power at 2100 rpm Power 127 kW (170 hp) SAE nethorsepower135 kW (181 hp) SAE grosshorsepower

Bore and Stroke Distance 115.8 x 128.5 mm (4.56 x 5.06 in.)

Piston Displacement 8.1 L (496 cu in.)

Electrical System Voltage 24-volt with 45-amp alternator

Batteries Voltage Two 12-voltCold Cranking Amps 625 amps each at —18°C (0°F)Reserve Capacity 160 minutes each at —18°C (0°F)

Transmission Speed Infinite from 0—11 km/h (0—6.8mph) forward and reverse

Drawbar Pull at 1.9 km/h (1.2 mph) Force 156 kN (35,200 lb force)

Hydraulic System (Open Center) Pressure 15 514 kPa (2250 psi)Flow Rate 166 L/min (44 gpm) at 2100 rpm



PN=31



000214

CED,OUO1032,754 –19–06JAN00–2/3


Undercarriage:

850C LT/850C WT Track Shoes Quantity 40(Each Side)

850C LGP Track Shoes (Each Quantity 43Side)

850C Ground Contact Area (with Area 33 445 cm2 (5184 sq in.)24 in. Shoes)

850C WT Ground Contact Area Area 41 806 cm2 (6480 sq in.)(with 30 in. Shoes)

850C LGP Ground Contact Area Area 59 329 cm2 (9196 sq in.)(with 38 in. Shoes except PAT)

850C LGP Ground Contact Area Area 53 084 cm2 (8228 sq in.)(with 38 in. Shoes with PAT)

850C LT/850C WT (Excluding Clearance 406 mm (16 in.)Grouser Height) with Single-barGrouser

850C LGP (Including Grouser Clearance 483 mm (19.0 in.)Height) with Swamp Shoe

850C Track Pitch 203 mm (8 in.)

850C LT Semi-U Track Gauge 1880 m (74 in.)

850C LT PAT Track Gauge 2081 m (82 in.)

850C WT Semi-U Track Gauge 2032 m (80 in.)

850C WT PAT Track Gauge 2235 m (81 in.)

850C LGP Semi-U Track Gauge 2235 m (88 in.)

850C LGP PAT Track Gauge 2337 m (92 in.)

850C LT/850C WT Track on Length 2743 mm (108 in.)Ground Length

850C LGP Track on Ground Length 3073 mm (121 in.)Length


PN=32



000215

CED,OUO1032,754 –19–06JAN00–3/3


Ground Pressure:

850C Ground Pressure Pressure 53.8 kPa (0.5 bar) (7.8 psi) Semi-U57.3 kPa (0.6 bar) (8.3 psi) PAT

850C WT Ground Pressure Pressure 43.4 kPa (0.4 bar) (6.3 psi) Semi-U46.9 kPa (0.5 bar) (6.8 psi) PAT

850C LGP Ground Pressure Pressure 31.7 kPa (0.3 bar) (4.65 psi) Semi-U37.9 kPa (0.4 bar) (5.5 psi) PAT

850C Series II SAE OperatingWeight:

850C LT with Semi-U Blade (High Weight 18 402 kg (40,485 lb)Production)

850C WT with Semi-U Blade (High Weight 18 668 kg (41,070 lb)Production)

850C LGP with Semi-U Blade Weight 19 113 kg (42,048 lb)(High Production)

850C LT with All-Hydraulic (PAT) Weight 19 526 kg (42,957 lb)Dozer

850C WT with All-Hydraulic (PAT) Weight 19 969 kg (43,931 lb)Dozer

850C LGP with All-Hydraulic (PAT) Weight 20 577 kg (45,269 lb)Dozer


PN=33


000216

CED,OUO1065,110 –19–05JAN00–1/1

850C Series II Capacity Specifications


Drain and Refill Capacities:

Cooling System Capacity 34 L (9 gal)

Fuel Tank Capacity 348 L (92 gal)

Engine Oil (Including Filter) Capacity 32.2 L (8.5 gal)

850C LT Inner Final Drive (Each Capacity Semi-U 12.3 L (3.25 gal)Side) PAT 16.5 L (4.35 gal)

850C WT Inner Final Drive (Each Capacity Semi-U 16.5 L (4.35 gal)Side) PAT 37.9 L (10.0 gal)

850C LGP Inner Final Drive (Each Capacity 37.9 L (10 gal)Side)

Outer Final Drive (Each Side) Capacity 12.3 L (3.25 gal)

Hydraulic Reservoir Capacity 79 L (21 gal)

Hydrostatic Transmission Capacity 102.2 L (27 gal)


PN=34


000217

CED,OUO1032,755 –19–07OCT98–1/2

850C Series II General Specifications

Lubrication:

• Pressure system with full flow filters

Cooling:

• Pressured with thermostat and controlled bypass

Fan:

• Blower-type

Air Cleaner:

• Dual-stage aspirated with restriction indicator• Dry

Transmission:

• Automatic, dual-path hydrostatic drive.• Load sensing feature automatically adjusts speed and

power to match changing load conditions.• Dual path hydrostatic drive.• Live power turns: Both tracks remain fully powered

during turns. This affords greater maneuverability withlarger loads and less ground disturbance. This featurealso provides improved capability for working on softground, as well as the ability to counterbalance bladecorner loads when benching, ditching or backfilling.

• Counter-rotation: Separate control allows the twotransmissions to be driven in opposite directions,permitting spot turns with excellent maneuverability.Quick blade position changes can be made.

• Infinite speed selection: Infinitely variable groundspeeds, from 0—11 km/h (0—6.8 mph), allow precisespeed. Speed can be reduced without slowing enginerpm, so hydraulic power remains high and responsetime remains fast.

• Automatic load sensing: As a load increases andengine rpm lessens, the transmission automaticallyreduces ground speed to match load changes. Thisfeature works at all throttle settings, providing fulldrawbar pull even at reduced engine speed.


PN=35



000218

CED,OUO1032,755 –19–07OCT98–2/2

• Dynamic braking: Positive speed reduction is providedon slopes. When shifted to neutral, oil flow between thepump and motor is blocked. The crawler stops withoutuse of the service brakes.

Steering:

• Single lever steering and direction control withdecelerator or optional steering pedals and U-patternFNR lever without decelerator, full power turn,counter-rotation and infinitely variable track speedsprovide unlimited maneuverability and optimum control.

• Hydrostatic steering eliminates the need for steeringclutches and steering brakes as well as the need forcross-steering when working on steep slopes.

Brakes:

• Hydrostatic (dynamic) braking stops the machine whenthe direction/steering control lever is moved to neutral.

• Wet-disk brakes are automatically applied when engineis stopped or manually applied with center foot pedalduring normal operation.

Hydraulics:

• Open center system• 10 micron filter in return line with bypass• Gear-type pump

Forestry Application:

• The dozer can be equipped for forestry applications withthe addition of limb risers and screens for the roll-overprotective structure.


PN=36


000219

CED,OUO1032,756 –19–06JAN00–1/3

850C LT Series II Dimensions

T12

7264

–UN

–10J

AN

00


850C LT Series II with Semi-U(High-Production) Blade:







PN=37



000220

CED,OUO1032,756 –19–06JAN00–2/3







850C LT Series II with All-Hydraulic(PAT) Dozer:


A—Blade Lift Height 914 mm (36 in.)



D—Overall Machine Length 5144 mm (16 ft 10.5 in.)











PN=38



000221

CED,OUO1032,756 –19–06JAN00–3/3





PN=39


000222

CED,OUO1032,756 –19–06JAN00–1/2

850C WT Series II Dimensions

T12

7264

–UN

–10J

AN

00


850C WT Series II with Semi-U(High-Production) Blade:







PN=40



000223

CED,OUO1032,756 –19–06JAN00–2/2






850C WT Series II with All-Hydraulic(PAT) Dozer:

Blade Capacity 4.47 mm3 (5.85 cu yd)

A—Blade Lift Height 914 mm (36 in.)















PN=41


000224

CED,OUO1032,756 –19–06JAN00–1/2

850C LGP Series II Dimensions

T12

7264

–UN

–10J

AN

00


850C LGP Series II with Semi-U(High-Production) Blade:







PN=42



000225

CED,OUO1032,756 –19–06JAN00–2/2






H—Maximum Blade Tilt Height 940 mm (37 in.)

850C LGP Series II withAll-Hydraulic (PAT) Dozer:


















PN=43


000226


PN=44

Group 03Torque Values

00031

TX,9000,BD2408 –19–02DEC96–1/1

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,90,RR2484 –19–03AUG92–1/1

Keeping ROPS Installed Properly

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 Roll-Over Protective Structure,mounting bolts must be tightened to specification.

SpecificationROPS Mounting Bolts—Torque 410 ± 82 N•m (300 ± 60 lb-ft)................


PN=45

Torque Values

0003

2

TX,85,RR,A47 –19–11JAN00–1/2

Checking Track Shoe Cap Screw Torque

NOTE: Track shoe bolt torque specifications do not applyto split master link.

Cap screw threads and bearing surface under head mustbe lubricated with SAE 30 oil.

CAP SCREW TORQUE SPECIFICATION

Bolt Dia. Initial Torque Additional Turn

750C,750C II 5/8 in. 163 N•m ± 16 N•m (120 lb-ft ± 12 lb-ft) 1/3 turn (120°)

750C/750C II LGP 5/8 in. (w/swamp shoes) 163 N•m ± 16 N•m (120 lb-ft ± 12 lb-ft) 1/2 turn (180°)

850C, 850C II 3/4 in. 298 N•m ± 30 N•m (220 lb-ft ± 22 lb-ft) 1/3 turn (120°)

850C/850C IILGP 3/4 in. (w/swamp shoes) 298 N•m ± 30 N•m (220 lb-ft ± 22 lb-ft) 3/4 turn (270°)

Track shoe cap screw torque should be periodicallychecked. If cap screws do not meet minimum torquespecifications, remove shoes and clean mating surfaces ofshoes and links before tightening.

If machine is operated with loose track shoes, cap screwholes in the shoes and links will wear, making it difficult tokeep the shoes tight. Loose shoes can also causehardware failure and loss of shoes.

TX,85,RR,A47 –19–11JAN00–2/2

T67

94A

M–U

N–2

3FE

B89

A—Rounded EdgeB—Chamfered Edge

Install all nuts with rounded edges (A) against the link andchamfered edges (B) away. Be sure nut is properlypositioned in link so there is full contact between nut andlink.

If cap screws check less than above specification, removeshoes and clean paint or other foreign material from chainand shoe mating surfaces.

Lubricate cap screws and assemble shoes.


PN=46

Torque Values

00033

TX,85,RR,A48 –19–11JAN00–1/2

Checking Track Shoe Cap Screw Torque—Master Link

If cap screws check less than specification, remove shoeand clean paint or other foreign material from chain andshoe mating surfaces.

Lubricate cap screw threads and bearing surface of capscrew head using PT569 John Deere NEVER-SEEZ

Lubricant or equivalent.

IMPORTANT: DO NOT use impact wrench to startmaster shoe cap screws to avoidcross-threading.

Use only the torque turn methoddescribed below when assemblingmaster track shoe. This methodprovides the optimum tightness levelfor this critical area.

Install master shoe on master links and start cap screwsby hand to avoid cross-threading.

NEVER-SEEZ is a registered trademark of Emhart Chemical Group. Continued on next page


PN=47

Torque Values

0003

4

TX,85,RR,A48 –19–11JAN00–2/2

T96

302

–UN

–01N

OV

88

Tighten master cap screws in a crisscross sequence (A).Repeat sequence a second time. Use same tighteningsequence for additional turns.

SPLIT MASTER LINK CAP SCREW TORQUE SPECIFICATIONS

Bolt Dia. Initial Torque Additional Turn


750C, 750C II LGP 5/8 in. (w/swamp shoes) 163 N•m ± 16 N•m (120 lb-ft ± 12 lb-ft) 1/2 turn (180°)


850C, 850C II LGP 3/4 in. (w/swamp shoes) 298 N•m ± 30 N•m (220 lb-ft ± 22 lb-ft) 3/4 turn (270°)


PN=48

Torque Values

00035

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=49

Torque Values

0003

6

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=50

Torque Values

00037

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=51

Torque Values

0003

8

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=52

Torque Values

00039

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=53

Torque Values

000310

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=54

Torque Values

000311

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=55

Torque Values

000312

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=56

Torque Values

000313

04T,90,K67 –19–29SEP99–1/1

Service Recommendations for Flat FaceO-Ring Seal Fittings

T62

43A

D–U

N–1

8OC

T88

1. Inspect the fitting sealing surfaces. They must be freeof dirt or defects.

2. Inspect the O-ring. It must be free of damage ordefects.

3. Lubricate O-rings and install into groove usingpetroleum jelly to hold in place.

4. Push O-ring into the groove with plenty of petroleumjelly so O-ring is not displaced during assembly.

5. Index angle fittings and tighten by hand pressing jointtogether to insure O-ring remains in place.

6. Tighten fitting or nut to torque value shown on thechart per dash size stamped on the fitting. Do not allowhoses to twist when tightening fittings.

FLAT FACE O-RING SEAL FITTING TORQUE

Thread SizeNominal Tube O.D. Dash Size in. Swivel Nut Bulkhead Nut

mm in. N•m lb-ft N•m lb-ft

6.35 0.250 -4 9/16-18 16 12 5.0 3.5

9.52 0.375 -6 11/16-16 24 18 9.0 6.5

12.70 0.500 -8 13/16-16 50 37 17.0 12.5

15.88 0.625 -10 1-14 69 51 17.0 12.5

19.05 0.750 -12 1 3/16-12 102 75 17.0 12.5

22.22 0.875 -14 1 3/16-12 102 75 17.0 12.5

25.40 1.000 -16 1 7/16-12 142 105 17.0 12.5

31.75 1.250 -20 1 11/16-12 190 140 17.0 12.5

38.10 1.500 -24 2-12 217 160 17.0 12.5

NOTE: Torque tolerance is +15 -20%.


PN=57

Torque Values

000314

04T,90,K174 –19–01AUG94–1/2

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 overtighten.



PN=58

Torque Values

000315

04T,90,K174 –19–01AUG94–2/2

TORQUE CHART a

N•m lb-ft

Nominal Flange Size Cap Screw Size Min Max Min Max

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

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 UNC 47 85 35 63

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 195aTolerance ± 10%. The torques given are enough for the given size connection with the recommended working pressure. Torques can beincreased to the maximum shown for each cap screw size if desired. Increasing cap screw torque beyond this maximum will result in flangeand cap screw bending and connection failures.


PN=59

Torque Values

000316


PN=60

Group 04Fuels and Lubricants

00041

DX,FUEL1 –19–17FEB99–1/1

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,FUEL4 –19–18MAR96–1/1

Handling and Storing Diesel Fuel

CAUTION: Handle fuel carefully. Do not fillthe fuel tank when engine is running.

DO NOT smoke while you fill the fuel tank orservice the fuel system.

Fill the fuel tank at the end of each day’s operation toprevent condensation and freezing during coldweather.

IMPORTANT: The fuel tank is vented through thefiller cap. If a new filler cap isrequired, always replace it with anoriginal vented cap.

When fuel is stored for an extended period or if thereis a slow turnover of fuel, add a fuel conditioner tostabilize the fuel and prevent water condensation.Contact your fuel supplier for recommendations.


PN=61

Fuels and Lubricants

0004

2

CED,OUO1002,422 –19–20FEB98–1/1

Fuel Tank

CAUTION: Handle fuel carefully. If the engine ishot or running, DO NOT fill the fuel tank. DONOT smoke while you fill fuel tank or work onfuel system.

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

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.


PN=62


00043

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=63


0004

4

DX,ENOIL –19–10OCT97–1/1

Diesel Engine Oil

TS

1661

–UN

–10O

CT

97

Use oil viscosity based on the expected air temperaturerange during the period between oil changes.

The following oil is preferred:

• John Deere PLUS-50

The following oil is also recommended:

• John Deere TORQ-GARD SUPREME

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

• API Service Classification CG-4• API Service Classification CF-4• ACEA Specification E3• ACEA Specification E2

Multi-viscosity diesel engine oils are preferred.

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

Extended service intervals may apply when John Deerepreferred engine oils are used. Consult your John Deeredealer for more information.

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


PN=64


00045

TX,45,RR5077 –19–17SEP98–1/1

Transmission, Hydraulic, and Hand Pump Reservoir Oil

T85

94A

B–1

9–14

NO

V95

NOTE: For the 850C machines, use J20D (lowviscosity) oil in the transmission and hydraulicsystem if temperature is below —18°C (0°F).This oil will aid in starting the engine in coldweather.

Depending upon the expected air temperature rangebetween oil changes, use oil viscosity shown on thetemperature chart above.

The following oil is preferred:

John Deere HY-GARD Transmission andHydraulic Oil.

Engine oil (SAE 10W) meeting one or more of thefollowing:

API Service CD/SF, CD/SE, CD/SD, CD/SC(MIL-L-2104D, MIL-L-2104C).

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


PN=65


0004

6

TX,45,RR5121 –19–17SEP98–1/1

Inner and Outer Final Drive Oil

T84

48A

T–1

9–26

JUN

95

Depending on the expected air temperature rangebetween oil changes, use oil viscosity shown on thechart above.

John Deere HY-GARD is preferred.

Other oils may be used if they meet the following:

• John Deere API GL-5 Gear Oil (SAE 80W90)

Arctic oils (such as Military SpecificationsMIL-L-46167B) may be used at temperatures below —30°C (—22°F).

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


PN=66


00047

TX,45,RR5122 –19–12JUL95–1/1

Track Rollers, Front Idler, Carrier Roller andTrack Frame Outer Pivot Oil

Use oil viscosity based on the expected air temperaturerange during the period between oil changes.

The following oils are preferred:

• John Deere GEAR LUBRICANT (SAE 80W90)• John Deere EXTREME-GARD

The following oils are recommended:

• API Service Classification GL-5 gear oil (SAE 80W90)• Arctic oils such as (MIL-L-10324A) may be used at

temperatures below —30°C (—11°F).

DX,GREA1 –19–07JUL99–1/1

Grease

TS

1667

–UN

–30J

UN

99

Use grease based on NLGI consistency numbers and theexpected air temperature range during the service interval.

The following greases are preferred:

• John Deere SD POLYUREA GREASE

The following greases are also recommended:

• John Deere HD MOLY GREASE• John Deere HD LITHIUM COMPLEX GREASE• John Deere HD WATER RESISTANT GREASE• John Deere GREASE-GARD

Other greases may be used if they meet the following:

• NLGI Performance Classification GC-LB

IMPORTANT: Some types of grease thickener are notcompatible with others.


PN=67


0004

8

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.

DX,ALTER –19–18MAR96–1/1

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.


PN=68


00049

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.

DX,COOL3 –19–05FEB99–1/1

Diesel Engine Coolant

The engine cooling system is filled to provideyear-round protection against corrosion and cylinderliner pitting, and winter freeze protection to -37°C(-34°F).

The following engine coolant is preferred for service:

• John Deere COOL-GARD Prediluted Coolant

The following engine coolant is also recommended:

• John Deere COOL-GARD Coolant Concentrate in a40 to 60% mixture of concentrate with quality water.

Other low silicate ethylene glycol base coolants forheavy-duty engines may be used if they meet one ofthe following specifications:

• ASTM D5345 (prediluted coolant)• ASTM D4985 (coolant concentrate) in a 40 to 60%

mixture of concentrate with quality water

Coolants meeting these specifications require use ofsupplemental coolant additives, formulated forheavy-duty diesel engines, for protection againstcorrosion and cylinder liner erosion and pitting.

A 50% mixture of ethylene glycol engine coolant inwater provides freeze protection to -37°C (-34°F). If

protection at lower temperatures is required, consultyour John Deere dealer for recommendations.

Water quality is important to the performance of thecooling system. Distilled, deionized, or demineralizedwater is recommended for mixing with ethylene glycolbase engine coolant concentrate.

IMPORTANT: Do not use cooling system sealingadditives or antifreeze that containssealing additives.

Coolant Drain Intervals

Drain the factory fill engine coolant, flush the coolingsystem, and refill with new coolant after the first 3years or 3000 hours of operation. Subsequent drainintervals are determined by the coolant used forservice. At each interval, drain the coolant, flush thecooling system, and refill with new coolant.

When John Deere COOL-GARD is used, the draininterval may be extended to 5 years or 5000 hours ofoperation, provided that the coolant is tested annuallyAND additives are replenished, as needed, by addinga supplemental coolant additive.

If COOL-GARD is not used, the drain interval isreduced to 2 years or 2000 hours of operation.


PN=69


000410


PN=70

Section 01Tracks

Contents 01

PagePage

Disassemble Lubricated Track Chain toGroup 0130—Track SystemTurn Bushings and Lubricate Chain . . . . .01-0130-55Essential Tools . . . . . . . . . . . . . . . . . . . . . . .01-0130-1

Assemble Lubricated Track Chain to TurnService Equipment and Tools . . . . . . . . . . . .01-0130-2Bushings and Lubricate Chain . . . . . . . . .01-0130-58Other Material . . . . . . . . . . . . . . . . . . . . . . . .01-0130-4

Disassemble and Assemble Lubricated TrackSpecifications . . . . . . . . . . . . . . . . . . . . . . . .01-0130-5Chain to Turn Pins and Bushings and NotRemove and Install Rock Guards andLubricate . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-65Track Guides . . . . . . . . . . . . . . . . . . . . . .01-0130-11

Adjust Track Sag. . . . . . . . . . . . . . . . . . . . .01-0130-72Measure Carrier Roller Wear. . . . . . . . . . . .01-0130-12Track Adjuster Exploded View. . . . . . . . . . .01-0130-74Remove and Install Carrier Roller . . . . . . . .01-0130-13Remove Track Adjuster and RecoilDisassemble and Assemble Carrier

Spring . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-75Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-14Install Track Adjuster and Recoil Spring . . .01-0130-77Inspect Metal Face Seals . . . . . . . . . . . . . .01-0130-16Disassemble and Assemble RecoilTest Carrier Roller for Oil Leakage . . . . . . .01-0130-18

Spring . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-80Measure Track Roller Wear. . . . . . . . . . . . .01-0130-19Disassemble and Assemble TrackRemove and Install Track Roller . . . . . . . . .01-0130-20

Adjuster Cylinder . . . . . . . . . . . . . . . . . . .01-0130-83Disassemble Track Roller . . . . . . . . . . . . . .01-0130-22Remove Track Frame . . . . . . . . . . . . . . . . .01-0130-85Assemble Track Roller . . . . . . . . . . . . . . . .01-0130-25Welding Procedure . . . . . . . . . . . . . . . . . . .01-0130-87Test Track Roller for Leakage . . . . . . . . . . .01-0130-30Remove and Install A-Frame Bearing andMeasure Track Shoe Grouser Wear . . . . . .01-0130-31

A-Frame Bushings . . . . . . . . . . . . . . . . . .01-0130-88Remove and Install Track Shoe . . . . . . . . .01-0130-32

Install Track Frame . . . . . . . . . . . . . . . . . . .01-0130-90Exploded View of Front Crossbar and Remove and Install Wear Strip on Inner

Support—750C . . . . . . . . . . . . . . . . . . . .01-0130-34 Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-95Remove and Install Front Crossbar and Remove and Install Track Frame Upper Wear

Support—750C . . . . . . . . . . . . . . . . . . . .01-0130-35 Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-96Remove and Install Front Crossbar and Remove and Install Track Frame Lower Wear

Support—850C (S.N. —833331) . . . . . . .01-0130-37 Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-98Check and Adjust Front Crossbar-to-Crossbar Remove and Install Track Frame Wear

Support and Main Frame Clearances (S.N. — Strip Bar . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-99833331) . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-39 Measure Front Idler Wear . . . . . . . . . . . . .01-0130-100

Remove and Install Support Wear Plates Remove Front Idler . . . . . . . . . . . . . . . . . .01-0130-101(S.N. —833331). . . . . . . . . . . . . . . . . . . .01-0130-41 Disassemble Front Idler . . . . . . . . . . . . . .01-0130-102

Remove and Install Pinned Crossbar and Inspect Metal Face Seals . . . . . . . . . . . . .01-0130-104Support—850C (S.N. 833332— Exploded View of Front Idler . . . . . . . . . . .01-0130-105907600) . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-42 Assemble Front Idler . . . . . . . . . . . . . . . . .01-0130-106

Crossbar Lube Install Front Idler . . . . . . . . . . . . . . . . . . . .01-0130-113Remove and Install . . . . . . . . . . . . . . . . .01-0130-45 Adjust Front Idler Vertical Movement. . . . .01-0130-114

Crossbar Adjust Front Idler Horizontal Movement. . .01-0130-115Disassemble and Assemble. . . . . . . . . . .01-0130-46 Test Front Idler for Oil Leakage. . . . . . . . .01-0130-116

Measure Link Height . . . . . . . . . . . . . . . . . .01-0130-47 Remove and Install Sprocket Segment . . .01-0130-117Measure Bushing Outside Diameter for

Lubricated Track Chain . . . . . . . . . . . . . .01-0130-48 Group 0199—Dealer Fabricated ToolsMeasure Track Pitch for Lubricated Track DFT1087 Track Recoil Spring Compression

Chain. . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-50 Tool Guard . . . . . . . . . . . . . . . . . . . . . . . .01-0199-1Remove and Install Lubricated Track

Continued on next pageChain. . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-51


PN=1

Contents

Page

DFT1041 Track Nut Removal Tool . . . . . . . .01-0199-2ST4920 Track Recoil Spring Compression

Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0199-301


PN=2

Group 0130Track System

0101301

CED,OUO1020,3007 –19–13OCT98–1/8

Essential Tools

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

SERVICEGARD is a trademark of Deere & Company

CED,OUO1020,3007 –19–13OCT98–2/8

T8412AA –UN–25MAY95

Seal Installation Tool . . . . . . . . . . . . . . . . . . .JDG204

Used to install metal face seal in track rollers and frontidlers.

CED,OUO1020,3007 –19–13OCT98–3/8

T7348AB –UN–01AUG90

Front Idler Lube Nozzle Kit . . . . . . . . . . . . . . . JD313A

To inject oil into track roller and front idler.

CED,OUO1020,3007 –19–13OCT98–4/8

30 mm Offset Wrench . . . . . . . . . . . . . . . . . . JDG234

Used to torque carrier roller cap screws.

CED,OUO1020,3007 –19–13OCT98–5/8

T8410AC –UN–25MAY95

Plug Installer . . . . . . . . . . . . . . . . . . . . . . . .JDG190

Used to install rubber plug in lubricated track pins.

CED,OUO1020,3007 –19–13OCT98–6/8

750C—Twin Head Press . . . . . . . . . . . . . . A2656-145

Used to remove track shoes.

850C—Single Head Press. . . . . . . . . . . . . . A3005-221


850C—Twin Head Press . . . . . . . . . . . . . . A2656-221



PN=73


Track System

010130

CED,OUO1020,3007 –19–13OCT98–7/8

Track Shoe Gauge . . . . . . . . . . . . . . . . . . . . . 23058

Used to gauge track shoes to assure proper assembly.

2

CED,OUO1020,3007 –19–13OCT98–8/8

T8410AB –UN–20MAY95

Track Spring Compressor Kit . . . . . . . . . . . . . . JD314A

Used to remove and install track spring.

Track Spring Compressor Kit . . . . . . . . . . . . . . JD314B

Used to remove and install track spring.

CED,OUO1020,3008 –19–13OCT98–1/6

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.


CED,OUO1020,3008 –19–13OCT98–2/6

Undercarriage Inspection Service Tool Kit . . . . JT05518A

For inspection of undercarriage components.

CED,OUO1020,3008 –19–13OCT98–3/6

Track Nut Removal Tool . . . . . . . . . . . . . . . . DFT1041

To remove nuts and cap screws.

CED,OUO1020,3008 –19–13OCT98–4/6

Seal Tester and Lubricator for S.A.L.T. CrawlerEquipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 61119

Used to add oil to test and lubricate track pins.


PN=74


Track System

010130

CED,OUO1020,3008 –19–13OCT98–5/6

Recoil Spring Compression Tool. . . . . . . . . . . . ST4920

Used to compress track adjuster recoil spring.

3

CED,OUO1020,3008 –19–13OCT98–6/6

Recoil Spring Tool Guard . . . . . . . . . . . . . . . DFT1087

To disassemble and assemble recoil spring.


PN=75

Track System

010130

4

CED,TX14826,12118 –19–09NOV99–1/1

Other Material

Number Name Use

T43513 (U.S.) Thread Lock and Sealer (High Apply to rock guard and track guideTY9474 (Canadian) Strength) cap screws.271 (LOCTITE) Apply to track guide and rock guard

cap screws.Apply to pin crossbar support capscrews.

PT569 (U.S.) NEVER-SEEZ Lubricant Apply to threads and bearingsurfaces under head.Apply to cap screw threads andbearing surface under head.Apply to threads and under head oftrack spring compression kit capscrew.Apply to bore surfaces of adjustercylinder head.Apply to both ends of idler shaft fromO-ring outward.Apply to lock before installation.

TY16285 (U.S.) Cure Primer Apply to pin crossbar support capCXTY16285 (Canadian) screws.7649 (LOCTITE) Used to clean and prepare surfaces

for plastic gasket

T43512 (U.S.) Thread Lock and Sealer (Medium Apply to threads of crossbar supportTY9473 (Canadian) Strength) hold down pad cap screws.242 (LOCTITE) Apply to crossbar shim retainer cap

screws.

TY15934 (U.S.) John Deere Gasket Maker #3 Apply to track link bore.

T43514 (U.S.) Plastic Gasket Used throughout track frameTY9475 (Canadian) installation.277 (LOCTITE) Apply to pivot shaft cap-to-track

frame mating surface.Apply to threads of sprocket segmentcap screws before assembly.

LOCTITE is a trademark of Loctite Corp.NEVER-SEEZ is a registered trademark of Emhart Chemical GroupLOCTITE is a registered trademark of Loctite Corp.


PN=76

Track System

0101305

CED,OUO1020,3232 –19–08DEC98–1/6

Specifications


Outer Track Guide-to-Inner Track Torque 407 N•m (300 lb-ft)Guide Nut

Sprocket Shield-to-Track Guide Cap Torque 350 N•m (255 lb-ft)Screws

Sprocket Shield-to-Track Frame Cap Torque 675 N•m (500 lb-ft)Screws

750C New Carrier Roller OD 171.5 mm (6.75 in.)

750C 100 Percent Worn Carrier OD 158.5 mm (6.24 in.)Roller



Carrier Roller Retainer Plate Cap Torque 47 N•m (35 lb-ft)Screws

Carrier Roller—750C Oil Capacity 356 mL (12 oz)

Carrier Roller—850C Oil Capacity 410 mL (14 oz)

Carrier Roller Cover Cap Screws Torque 47 N•m (35 lb-ft)

Carrier Roller Leakage Test Air Pressure 117 ± 10 kPa (1 ± 0.2 bar) (17 ± 3psi)

Roller Tread Diameter

750C New OD 203.0 mm (7.99 in.)

750C 100 Percent Worn OD 184.2 mm (7.25 in.)

850C New OD 210 mm (8.27 in.)

850C 100 Percent Worn OD 188 mm (7.4 in.)

750C Track Roller-to-Track Frame Torque 320 N•m (235 lb-ft)Cap Screw


PN=77


Track System

010130

6

CED,OUO1020,3232 –19–08DEC98–2/6


850C Track Roller-to-Track Frame Torque 620 N•m. (460 lb-ft)Cap Screw

Track Roller Leakage Test Air Pressure 117 ± 10 kPa (1 ± 2 bar) (17 ± 3 psi)

Single Grouser (Moderate Duty)— Plate Thickness 13.5 mm (0.53 in.)750C and 850C

Single Grouser (Extreme Duty)— Plate Thickness 14.5 mm (0.57 in.)750C

Single Grouser (Extreme Duty)— Plate Thickness 14.7 mm (0.58 in.)850C

Track Shoe Cap Screw

750C (5/8 in.) Torque Turn 163 N•m (120 lb-ft) + 1/3 Turn (120°)

750C (5/8 in.) with Swamp Shoe Torque Turn 163 N•m (120 lb-ft) + 1/2 Turn (180°)



Split Master Link Shoe Cap Screw





Track Shoe Cap Screws 50—100Hour Check

750C Torque 380 N•m (280 lb-ft) Minimum

850C Torque 597 N•m (440 lb-ft) Minimum

Crossbar Support Cap Screws Torque 325 N•m (240 lb-ft)

Carrier Roller Cap Screws Torque 325 N•m (240 lb-ft)


PN=78


Track System

0101307

CED,OUO1020,3232 –19–08DEC98–3/6


Retainer Cap Screw Lock Nut Torque 407 N•m (300 lb-ft)

Crossbar Ends-To-Hold Down Pad

750C, 850C, 850C LGP and 850C Clearance 4.0 mm (0.16 in.) MinimumWT

750C, 850C, 850C LGP and 850C Clearance 5.0 mm (0.20 in.) MaximumWT

Crossbar Support Hold Down Pad Torque 325 N•m (240 lb-ft)Cap Screws

Crossbar Center-To-Shim Retainer



Crossbar Shim Retainer Cap Screws Torque 163 N•m (120 lb-ft)

Link Height

750C New Chain Link Height 110.0 mm (4.33 in.)


750C 100 Percent Worn Link Height 100.5 mm (3.96 in.)


750C New Bushing OD 64.3 mm (2.53 in.)


750C 100 Percent Worn Bushing OD 54.6 mm (2.23 in.)(High Shock Impact)



PN=79


Track System

010130

8

CED,OUO1020,3232 –19–08DEC98–4/6


750C 100 Percent Worn Bushing OD 54.1 mm (2.13 in.)(Normal Impact)


Track Pitch

750C Pitch Wear Limit (Single Length 205 mm (8.07 in.)Joint)


Track Press Relief Valve Settings

750C Force 378 080 N (85,000 lb force)Maximum

850C Force 444 800 N (100,000 lb force)Maximum

Lubricated Track Chain Seal Test Vacuum 68—102 kPa (2—30 in. Hg)

Lubricated Track Chain Oil Pressure 140—205 kPa (1.4—2.05 bar (20—30 psi)

Lubricated Track Pin End Chamfer 3 mm (0.12 in.) x 15°

Track Pin Bushing 750C Projection 0.9 ± 0.25 mm (0.035 ± 0.010 in.)

Track Pin Bushing 850C Projection 2.30 ± 0.25 mm (0.091 ± 0.010 in.)

Lubricated Track Chain Track Sag 51 ± 6 mm (2 ± 1/4 in.)

Adjuster Rod-to-Yoke Cap Screw Torque 575 N•m (425 lb-ft)

Insert Guide Cap Screws Torque 325 N•m (240 lb-ft)

Yoke-to-Guide Cap Screws Torque 576 N•m (425 lb-ft)

Track Adjuster Yoke-to-Idler Mount Torque 163 N•m (120 lb-ft)Cap Screw


PN=80


Track System

0101309

CED,OUO1020,3232 –19–08DEC98–5/6


Spring Cover-to-Track Frame Cap Torque 163 N•m (120 lb-ft)Screw

750C—Track Recoil Spring Free Length 592 mm (23.29 in.) Approximate

850C—Track Recoil Spring Free Length 616 mm (24.25 in.) Approximate

750C—Track Recoil Spring Installation Length 400 mm (15.75 in.)

850C—Track Recoil Spring Installation Length 470 mm (18.50 in.)

750C—Pivot Shaft-to-Final-Drive Torque Turn 270 N•m (200 lb-ft) + 1/4 Turn (90°)Housing Cap Screw

850C—Pivot Shaft-to-Final-Drive Torque Turn 295 ± 29 N•m (218 ± 22 lb-ft) + 1/3Housing Cap Screw Turn (120°)

750C—Pivot Shaft Inner Mounting Torque 732 N•m (540 lb-ft)Bracket-to-Main Frame Cap Screw

850C—Pivot Shaft Inner Mounting Torque Turn 207 ± 21 N•m (152 ± 15 lb-ft) + 1/3Bracket-to-Main Frame Cap Screw Turn (120°)

A-Frame Bearing-to-A-Frame Cap Torque 495 N•m (365 lb-ft)Screws

Pivot Shaft Cap-to-Track Frame Cap Torque 550 N•m (400 lb-ft)Screws

750C New Flange Height 19.0 mm (0.75 in.)

850C New Flange Height 22.5 mm (0.89 in.)

750C 100 Percent Worn Flange Height 25.5 mm (1.0 in.)

850C 100 Percent Worn Flange Height 28.8 mm (1.13 in.)

Bushing Case-to-Idler Cap Screw Torque 47 N•m (35 lb-ft)

Idler Lock Cap Screws Torque 54 N•m (40 lb-ft)

Track Adjuster Yoke-to-Guide Block Torque 576 N•m (425 lb-ft)Cap Screws

Deflector-to-Guide Block Cap Screws Torque 163 N•m (120 lb-ft)

Guide Block Asembly-to-Wear Strip Gap 3 mm (0.120 in.) Maximum


PN=81


Track System

010130

10

CED,OUO1020,3232 –19–08DEC98–6/6


Guide Block Asembly-to-Wear Strip Gap 0—1 mm (0—0.040 in.)

J-Bar and Lower Track Frame Wear Thickness 3 mm (0.120 in.) MinimumStrip

Inner Guide Cap Screws Torque 325 N•m (240 lb-ft)

Idler Guide Cap Screws Torque 325 N•m (240 lb-ft)

Front Idler Leakage Test Air Pressure 117 ± 10 kPa (1 ± 0.2 bar) (17 ± 3psi)

Idler Shaft Plug Torque 60 N•m (45 lb-ft)

Sprocket Segment Cap Screws, Torque 712 N•m (525 lb-ft)Normal Conditions

Sprocket Segment Cap Screws, Torque Turn 136 N•m (100 lb-ft) + 1/3 Turn (120°)Extreme Conditions or Rear MountedEquipment


PN=82

Track System

01013011

TX,0130,SS2454 –19–13JUN95–1/2

Remove and Install Rock Guards and Track Guides

T60

76A

D–U

N–2

6OC

T88

1—Cap Screw (4 used) 5—Track Guide 9—Cap Screw (12 used) 12—Rock Guard2—Washer (2 used) 6—Rock Guard 10—Lock Washer (6 used ) 13—Track Guide3—Cap Screw (6 used) 7—Washer (20 used) 11—Nut (6 used) 14—Spacer (3 used)4—Spacer (3 used) 8—Cap Screw (6 used)

NOTE: Removal and installation of rock guards andtrack guides are similar for both 750C and850C.

1. Remove parts (1—14).

IMPORTANT: Before welding on this machine: Toavoid control circuit damage, turnthe electrical disconnect switch off,disconnect wiring harness andbraided ground strap fromtransmission controller, anddisconnect the wiring harness fromthe display monitor panel in dash.Remove both components.

Good welds are important. Have onlya qualified welder repair thecomponents. Use E7018 electrodes.Before welding, clean all dirt andpaint from the weld areas and turnthe battery disconnect switch to"OFF". Connect the welder groundclamp close to each weld area soelectrical current does not passthrough any bearings.

2. Inspect rock guards (6 and 12) and track guides (5and 13) for wear and damage. Repair or replaceparts as necessary.

3. Apply high strength thread lock and sealer to capscrews (1, 3, 8 and 9).

4. Install inner rock guard, guide, washers and capscrews.

5. Put cap screws through inner guide or inner guard,spacer, outer guide or outer guard, washer (10) andnut. Tighten the nuts to specification.

SpecificationOuter Track Guide-to-InnerTrack Guide Nut—Torque 407 N•m (300 lb-ft)...................................

6. Install outer guard and guide cap screws.

7. Install bottom two sprocket shields-to-track guidecap screws and tighten to specification.

SpecificationSprocket Shield-to-Track GuideCap Screws—Torque 350 N•m (255 lb-ft)..........................................


PN=83


Track System

010130

12

TX,0130,SS2454 –19–13JUN95–2/2

8. Install sprocket shield to track frame cap screws.Tighten cap screws to specification.

SpecificationSprocket Shield-to-Track FrameCap Screws—Torque 675 N•m (500 lb-ft)..........................................

TX,9020,RR5396 –19–13JUN95–1/1

Measure Carrier Roller Wear

T58

19A

C–U

N–0

1NO

V88

NOTE: See Undercarriage Appraisal Manual SP326 foradditional information.






1. Position an outside calipers over the most worn area ofroller running surface, and close until caliper tips justtouch tread surface.

2. Measure caliper tip spread using the scale to thenearest 0.5 mm (0.002 in.).

3. Check for flat spots on carrier roller thread, whichindicate roller is not free to turn.


PN=84

Track System

01013013

TX,0130,SS2402 –19–13JUN95–1/1

Remove and Install Carrier Roller

T84

02A

A–U

N–2

0MA

Y95

CAUTION: Grease in track adjustment cylinderis under high pressure. Slowly loosen checkvalve fitting to release grease from tracktension adjuster.

1. Slowly turn check valve fitting counterclockwise oneturn to release track tension. (See Adjust Track Sag inthis group.)

2. Raise and support track chain using a chain and hoist.

CAUTION: The approximate weight of carrierroller is 27 kg (60 lb).

3. Loosen cap screws (A) to remove front or rear carrierrollers.

4. Install carrier roller and bottom into support. Tightencap screws.

5. Check for proper alignment of carrier rollers.

6. If out of alignment loosen cap screws (A) and adjustoutward.


PN=85

Track System

010130

14

TX,0130,SS2404 –19–13JUN95–1/3

Disassemble and Assemble Carrier Roller

T84

01A

B–U

N–2

0MA

Y95

A—Bearing Cup (2 used)B—Roller ShellC—Seal RetainerD—Snap RingE—Metal Face SealF—Bearing ConeG—Retainer PlateH—Cap Screw (3 used)I—CoverJ—Cap Screw (2 used)K—ShaftL—Bearing ConeM—O-RingN—SealO—JDG204 Seal Installation ToolP—Seal Retainer

1. Remove cap screws (H) and cover (I).

2. Drain oil from housing.

3. Remove cap screws (J) and retainer plate (G) fromshaft (K).

4. Press outer bearing cone (F) and shaft (K) out of rollershell (B) using a press.

5. Press inner bearing cone (L) from shaft. Bearing is apress fit.

IMPORTANT: Metal face seals can be reused if theyare not worn or damaged. A used sealmust be kept together as a set becauseof wear patterns on seal ring face.

6. Remove snap ring (D), seal retainer (C) and metal faceseals (E). Keep seal rings together as a matched setwith faces together to protect lapped surfaces. Inspectmetal face seal . (See procedure in this group.)

7. Remove bearing cups (A). Inspect roller shell forgrooved, burred or galled condition.

8. Replace parts as necessary.



PN=86

Track System

01013015

TX,0130,SS2404 –19–13JUN95–2/3

T84

01A

B–U

N–2

0MA

Y95

T84

01A

C–U

N–2

2MA

Y95

9. Install bearing cups (A) into roller shell, install tightagainst shoulders.

10. Install inner bearing cone (L) tight against shoulder onshaft. Bearing is a press fit.

11. Install shaft (K) in roller shell.

12. Press outer bearing cone (F) on shaft so bearing iseven with end of the shaft.

13. Install retainer plate (G) and cap screws (J). Tightencap screws to specification.

SpecificationCarrier Roller Retainer Plate CapScrews—Torque 47 N•m (35 lb-ft)..............................................................

IMPORTANT: O-ring and seat surfaces must be clean,dry and oil free so O-rings do not slipwhen roller is turning.

14. Thoroughly clean the O-rings and seat surfaces inroller, seal retainer and seal rings using a volatile,non-petroleum base solvent and lint-free tissues.

15. Install one half of metal face seal using JDG204 SealInstallation tool (O) into seal retainer (P). Install otherhalf of seal (N) into roller shell.

16. Apply equal pressure with the fingers at four equallyspaced points on seal ring face. O-ring and seal ringshould seat squarely in bore.

NOTE: A volatile, non-petroleum base solvent or talcumpowder may be used as a lubricant.

17. Wipe both metal seal ring faces dry with a lint-freetissue.

18. Apply a thin film of oil, as used in the roller, to theshiny sealing area on both metal seal rings.

19. Install seal retainer (C) and snap ring (D) on rollershaft.


PN=87


Track System

010130

16

TX,0130,SS2404 –19–13JUN95–3/3

20. Fill roller with 356 mL (12 oz) of clean oil in 750C and410 mL (14 oz) in 850C. (See Track Roller, FrontIdler, and Carrier Roller Oil, Group 0004.)

SpecificationCarrier Roller—750C Oil—Capacity 356 mL (12 oz).............................................................................Carrier Roller—850C Oil—Capacity 410 mL (14 oz).............................................................................

21. Install cover (I) and cap screws (H). Tighten capscrews to specification.

SpecificationCarrier Roller Cover CapScrews—Torque 47 N•m (35 lb-ft)..............................................................

T47,0130,5939HQ –19–25AUG93–1/3

Inspect Metal Face Seals

T85

079

–UN

–24A

UG

93

A—Seal RingB—Worn Area (shaded area)C—Seal Ring FaceD—Outer Half of Seal Ring FaceE—Sealing Area (dark line)

1. Inspect for the following conditions to determine ifseals can be reused:

• The narrow, highly polished sealing area (E) must bein the outer half of seal ring face (D).

• Sealing area must be uniform and concentric withthe ID and OD of seal ring (A).

• Sealing area must not be chipped, nicked, orscratched.



PN=88

Track System

01013017

T47,0130,5939HQ –19–25AUG93–2/3

T85

080

–UN

–05D

EC

96

A—Seal RingB—Worn Area (shaded area)C—Inner Half of Seal Ring FaceD—Sealing Area (dark line)

2. Illustration shows examples of worn seal rings (A).

I—Sealing area (D) is in inner half of seal ring face (C).

II—Sealing area (D) not concentric with ID and OD ofseal ring.

T47,0130,5939HQ –19–25AUG93–3/3

T82

840

–UN

–23F

EB

89

3. Clean reusable seals by removing all foreign materialfrom seal rings, except seal face (A), using a scraperor a stiff bristled fiber brush.

4. Wash seal rings and O-rings using a volatile,non-petroleum base solvent to remove all oil.Thoroughly dry parts using a lint-free tissue.

Apply a thin film of oil to seal ring face. Put face of sealrings together and hold using tape.


PN=89

Track System

010130

18

TX,0130,SS2405 –19–11MAR96–1/1

Test Carrier Roller for Oil Leakage

T84

02A

B–U

N–2

0MA

Y95

A—Pressure Gauge 0—689 kPa (0—6.89 bar) (0—100psi)

B—38H1338 Straight Male Connector (-6 M ORFS x-12 M ORB)

C—JT03456 O-Ring Face Seal (2 used) (17/16 -20 MJIC x 11/16-16 F ORFS)

D—Shut-Off ValveE—RegulatorF—38H1030 Tee (-6 F ORFS x -6 M ORFS x-6 M

ORFS) Parker No. (6R6LOS)

1. Turn roller several times to seat metal face seals.

2. Install parts (A—F).

3. Pressurize roller to specification using air pressure.

SpecificationCarrier Roller Leakage Test—AirPressure 117 ± 10 kPa (1 ± 0.2 bar) (17 ±

3 psi)................................................

4. Close valve and wait for two minutes. Make sure rollermaintains air pressure and oil does not leak pastO-ring or metal face seals.

5. If roller leaks oil or does not maintain pressure, checkO-ring or seals. Repair as necessary and recheck forleaks.

6. Install and tighten plug.


PN=90

Track System

01013019

TX,9020,YY994 –19–22MAR95–1/2

Measure Track Roller Wear


Roller Tread Diameter

750C New OD 203.0 mm (7.99 in.)

750C 100 Percent Worn OD 184.2 mm (7.25 in.)

850C New OD 210 mm (8.27 in.)

850C 100 Percent Worn OD 188 mm (7.4 in.)

NOTE: Minimum used is the maximum allowable wearfor rebuilding roller tread.

Under some conditions roller wear can be uneven.Ifwear is uneven, the single flange rollers may beinterchanged with other single flange rollers to evenout wear. Double flange rollers may be interchangedwith other double flange rollers.

1. Raise unit off the ground and support it using shopstands.

2. Release track tension by turning the check valveone turn counterclockwise to allow grease toescape.

TX,9020,YY994 –19–22MAR95–2/2

T68

13A

M–U

N–2

9JA

N98

3. Measure roller tread diameter using a caliper such asJT07193 Special Roller Caliper from JT05518AUndercarriage Inspection Kit.

NOTE: See Track Rollers , 750C, 750C-LGP and 750CSeries II Track Roller Tread Diameter , or 850C,850C Series II, and 850C-LGP Track Roller TreadDiameter in Undercarriage Appraisal ManualSP326 for additional information.


PN=91

Track System

010130

20

TX,0130,DU1324 –19–30SEP93–1/4

Remove and Install Track Roller

T60

33B

B1

–UN

–26O

CT

88

CAUTION: Grease in track adjuster cylinder isunder extreme pressure. DO NOT removegrease fittings to release track tension.

1. Turn check valve (1) one turn counterclockwise torelease grease from track adjuster.

2. Put a piece of pipe between the sprocket and the trackchain and rotate track to retract the adjusting cylinder ifrequired.

TX,0130,DU1324 –19–30SEP93–2/4

T80

581

–UN

–26O

CT

88

3. Remove inner and outer rock guards. (See Removeand Install Rock Guards and Track Guides in thisgroup.)

4. Raise crawler high enough to remove rollers. Put shopstands under machine.

CAUTION: The approximate weight of trackrollers is 59 kg (129 lb).

5. Remove cap screws (1) to remove roller (2).

TX,0130,DU1324 –19–30SEP93–3/4

T82634 –UN–26OCT88

6. All machines have seven track rollers. Single anddouble flange rollers are used alternately starting atidler with a single flange roller.


PN=92


Track System

01013021

TX,0130,DU1324 –19–30SEP93–4/4

T80

581

–UN

–26O

CT

88

7. Install track roller (2) with oil fill plug toward outside ofunit.

8. Carefully lower crawler until roller cap screws can beinstalled.

9. Tighten cap screws (1) to specification.

Specification750C Track Roller-to-TrackFrame Cap Screw—Torque 320 N•m (235 lb-ft)........................................

Specification850C Track Roller-to-TrackFrame Cap Screw—Torque 620 N•m. (460 lb-ft).......................................

10. Apply high strength thread lock and sealer to trackguide and rock guard cap screws before installingguides and guards. (See Remove and Install RockGuards and Track Guides in this group.)

11. Adjust track sag . (See Adjust Track Sag in thisgroup.)


PN=93

Track System

010130

22

TX,0130,DU1328 –19–11AUG93–1/5

Disassemble Track Roller

T60

18B

E–U

N–2

6OC

T88

1—Lock 6—O-Ring 11—O-Ring 16—Lock Washer2—Inner Collar 7—Dowel Pin 12—Roller 17—Cap Screw3—O-Ring 8—Bushing 13—Outer Collar 18—Cap Screw4—Metal Face Seal 9—Snap Ring 14—Plug 19—Lock Washer5—Bushing Case 10—Roller Shaft 15—O-Ring



PN=94

Track System

01013023

TX,0130,DU1328 –19–11AUG93–2/5

T80

426

–UN

–26O

CT

88

NOTE: Single and double flange rollers are of the samedesign. Disassembly procedures are the same forboth types of rollers.

1. Remove plug with O-ring to drain oil from roller.

2. Remove lock from inner collar before putting rollerassembly in press.

3. Use a 35 mm disk (1) and press to compress the metalface seals slightly. Remove the snap ring (2) from bothsides of roller shaft (3).

TX,0130,DU1328 –19–11AUG93–3/5T

8042

7–U

N–2

6OC

T88

4. Remove outer and inner covers (1).

NOTE: Metal face seals are a matched set. Seals are notinterchangeable with other seals.

5. Remove metal face seal from inner and outer covers.

TX,0130,DU1328 –19–11AUG93–4/5

T60

18B

C–U

N–2

6OC

T88

NOTE: Metal face seals are matched sets. Seals are notinterchangeable with other seals.

6. Remove and inspect metal face seals. (See InspectMetal Face Seals in this group.)

7. Remove O-rings (2) from both ends of shaft.

8. Remove cap screws (1) from bushing case at bothends of roller.


PN=95


Track System

010130

24

TX,0130,DU1328 –19–11AUG93–5/5

T80

432

–UN

–26O

CT

88

9. Remove roller shaft (1) and bushing case (2) using a55 mm disk (3) and press.

10. Remove roller shaft from bushing case.

11. Turn roller over. Use disk (3), shaft, and press toremove bushing case from roller housing.

12. Inspect bushing in bushing case for excessive wear,pitting or scoring. Replace, if necessary.


PN=96

Track System

01013025

TX,0130,DU1330 –19–25AUG93–1/11

Assemble Track Roller

T80

63A

G–U

N–0

8SE

P93

Double Flange Track Roller Shown

1—Inner Collar 6—O-Ring (2 used) 11—Snap Ring (2 used) 16—Bushing (2 used)2—Lock 7—Shaft 12—O-Ring (4 used) 17—Roller3—Cap Screw (12 used) 8—Outer Collar 13—Metal Face Seal (2 used) 18—Washer (4 used)4—Lock Washer (12 used) 9—Plug 14—Bushing Case (2 used) 19—Cap Screw (4 used)5—O-Ring (2 used) 10—O-Ring 15—Pin (2 used)



PN=97

Track System

010130

26

TX,0130,DU1330 –19–25AUG93–2/11

T84

04B

G–U

N–2

0MA

Y95

1—Bushing2—Dowel Pin3—Bushing Case4—Disk (107 mm)5—O-Ring Groove6—Alignment Mark

NOTE: Assembly of single and double flange roller is thesame. Single flange shown.

1. Using a straightedge mark the bushing (1) from thecenter line of the dowel pin holes (both sides) to thecenter line of the dowel pins (2). Align the marks onthe bushing with the dowel pins in the bushing case.

2. Press bushing into case.

TX,0130,DU1330 –19–25AUG93–3/11

T80

440

–UN

–26O

CT

88

1—Bushing Case2—Stud3—Roller4—Disk (80 mm)5—Pipe

3. Install bushing case (1) using studs (2), 80 mm disk(4), and a press.

4. Remove aligning studs. Install cap screws and lockwasher. Tighten cap screws.

5. Turn roller (3) over and carefully install roller shaft.

6. Install bushing case (1) using aligning studs (2), 80mm disk (4), and a press.

7. Remove studs. Install cap screws and lock washers.Tighten cap screws.


PN=98


Track System

01013027

TX,0130,DU1330 –19–25AUG93–4/11

T60

18B

A–U

N–2

6OC

T88

8. Install new O-ring on shaft groove (1).

9. Degrease seal bore in bushing case, inner collar, andouter collar using a volatile, non-petroleum base typesolvent. Make sure seal bores are clean and dry.

TX,0130,DU1330 –19–25AUG93–5/11

T80

574

–UN

–26O

CT

88

IMPORTANT: The metal face seal must be extremelyclean during assembly. Use a volatile,non-petroleum base type solvent toclean the metal seal ring (2) and rubberseal (1). DO NOT keep the rubber sealin a volatile, non-petroleum base typesolvent for more than one minute. Wipethe seals dry with lint-free tissue toremove finger prints and foreignmaterial.

10. Install rubber seal (1) on the metal seal ring (2). Makesure the rubber seal sits evenly on metal seal ring.

TX,0130,DU1330 –19–25AUG93–6/11

T60

77A

V–U

N–2

6OC

T88

1—Seal Ring Flange2—JDG204 Seal Installation Tool3—O-Ring

NOTE: A volatile, non-petroleum base solvent or talcumpowder may be used as a lubricant. SolventMUST NOT damage the O-rings or leave an oilresidue.

11. Install seal assembly in the JDG204 Seal InstallationTool (2) so tool lip is between seal ring flange (1) andO-ring (3).


PN=99


Track System

010130

28

TX,0130,DU1330 –19–25AUG93–7/11

T80

577

–UN

–26O

CT

88

12. Push seal ring and O-ring into bore using tool (1).After O-ring (2) is pushed past retainer lip, turn toolclockwise and counterclockwise to seat O-ringuniformly. Install seal rings and O-rings in the outerand inner collars using the same procedure.

13. Check to make sure seal ring is sitting squarely inbore. Make sure rubber seal is seated uniformly inseal bore below the retainer lip.

TX,0130,DU1330 –19–25AUG93–8/11

T80

578

–UN

–26O

CT

88

14. Wipe metal seal rings dry with a lint free tissue.

15. Apply a thin film of oil, as used in the roller, to theshiny sealing area on metal seal rings.

16. Be sure the rubber seals are free of oil.

TX,0130,DU1330 –19–25AUG93–9/11

T80

426

–UN

–26O

CT

881—35 mm Disk2—Snap Ring3—Shaft

17. Install outer collar.

18. Compress metal face seals slightly using a 35 mmdisk (1) and press.

19. Install snap ring (2) on shaft (3).

20. Remove roller from press. Install inner collar andsnap ring using same procedure.


PN=100


Track System

01013029

TX,0130,DU1330 –19–25AUG93–10/11

T60

90A

I–U

N–2

6OC

T88

1—JD313-1 Lube Nozzle2—JD313-2 Adapter3—Grease Gun

21. Thoroughly clean nozzle (1), from JD313A Front IdlerLube Nozzle Kit, and around the plug end of trackroller shaft.

22. Insert nozzle in roller shaft with flat side up, as far aspossible.

NOTE: Track roller shaft oil capacity is approximately378.5 mL (12.8 oz).

23. Slowly pump recommended oil into shaft usingadapter (2) and grease gun (3) until oil without airbubbles is seen leaking past the flat on nozzle. (SeeTrack Rollers, Front Idler, Carrier Roller and TrackFrame Outer Pivot, Group 0004.)

TX,0130,DU1330 –19–25AUG93–11/11

T80

580

–UN

–26O

CT

88

24. Test track roller for leakage . (See Test Track Rollerfor Leakage in this group.)

25. Install new O-ring and tighten plug.

26. Install lock.

27. Install track roller. (See Remove and Install TrackRoller in this group.)


PN=101

Track System

010130

30

TX,0130,SS2438 –19–13JUN95–1/1

Test Track Roller for Leakage

T80

613

–UN

–26O

CT

88

1—JTO5494 O-Ring Fitting (7/16 -20 M 37° x 3/4-16 M ORB)

2—JTO3001 Tee Fitting (7/16 -20 M 37° x 7/16 -20F 37° Sw x 7/16 -20 M 37°)

3—JTO3017 Pressure Hose4—Pressure Gauge 689 kPa (6.89 bar) (0—100

psi)5—JTO3087 Snubber Valve6—Regulator with Gauge

1. Remove plug from track roller.

2. Fill track roller with recommended oil. (See TrackRollers, Front Idler, Carrier Roller and Track FrameOuter Pivot , Group 0004.)

3. Turn roller several times to seal metal face seals.

4. Assemble parts (1—6) as shown.

5. Pressurize roller with compressed air to specificationand close valve (5).

SpecificationTrack Roller Leakage Test—AirPressure 117 ± 10 kPa (1 ± 2 bar) (17 ± 3

psi)................................................

6. Track roller must maintain air pressure for two minutes.Oil must not leak past metal seals or O-ring. If oil leakspast seals, repair as necessary.

7. Install O-ring and tighten plug.


PN=102

Track System

01013031

TX,9020,RR5397 –19–13JUN95–1/1

Measure Track Shoe Grouser Wear

T68

13A

N–U

N–2

9JA

N98

100 percent worn is the maximum allowable wear forrebuilding grouser bars with weld.

Measure grouser height of several track shoes to find anaverage using a depth gauge such as the JT05521 200mm Ruler, JT05534 Right Angle Attachment, andD-05231ST 300 mm Ruler from JT05518A UndercarriageInspection Kit.

NOTE: See Grouser Wear , Grouser Bar Height , 750C,750C-LGP and 750C Series II Single Bar GrouserHeight (Moderate Duty) or (Extreme Duty) , 850C,850C Series II, and 850C-LGP Single BarGrouser Height (Moderate Duty) or (ExtremeDuty) in Undercarriage Appraisal Manual SP326for additional information.

GROUSER HEIGHT SPECIFICATIONS

Model Moderate Duty Shoes Extreme Duty Shoes

750C (New) 55.5 mm (2.18 in.) 67.5 mm (2.66 in.)

850C (New) 65.0 mm (2.56 in.) 71.5 mm (2.81 in.)

750C (100 percent worn) 18.0 mm (0.71 in.) 21.5 mm (0.85 in.)

850C (100 percent worn) 25.4 mm (1.0 in.) 25.4 mm (1.0 in.)

Use plate thickness specifications below to help identify(Moderate Duty) and (Extreme Duty) grousers.

SpecificationSingle Grouser (ModerateDuty)—750C and 850C—PlateThickness 13.5 mm (0.53 in.)......................................................................Single Grouser (Extreme Duty)—750C—Plate Thickness 14.5 mm (0.57 in.)................................................Single Grouser (Extreme Duty)—850C—Plate Thickness 14.7 mm (0.58 in.)................................................


PN=103

Track System

010130

32

TX,0130,DU1343 –19–30SEP93–1/2

Remove and Install Track Shoe

NOTE: Cap screws hold the master shoe and split masterlink together. Link side of master shoe hasmachined surfaces.

CAUTION: The approximate weight of swampshoe is 25 kg (54 lb).

1. Remove nuts and cap screws using DFT1041 track nutremoval tool to remove shoes. (See Group 0199 forinstructions to make tool.)

2. Before installing shoes, clean paint, dirt, and debrisfrom mounting surfaces of shoes and links.

3. For all cap screws except those for split master linksand shoe, apply oil (SAE 30) to threads and bearingsurface under head.

For split master link and shoe cap screws, apply JohnDeere NEVER-SEEZ Lubricant or an equivalent tothreads and bearing surface under head.

NEVER-SEEZ is a registered trademark of Emhart Chemical Group Continued on next page


PN=104

Track System

01013033

TX,0130,DU1343 –19–30SEP93–2/2

T96

291

–UN

–23F

EB

89T

9629

2–U

N–2

3FE

B89

T63

52A

H–U

N–2

3FE

B89

IMPORTANT: Never use an impact wrench to startcap screws in split master link to avoidcross-threading.

4. Install new cap screws. Install new nuts usingDFT1041 tool with rounded edges (A) against link andchamfered edges (B) away from link.

5. Tighten cap screws to the initial torque using acrisscross sequence. Then repeat sequence for theadditional turn.

Track Shoe Cap Screw:

Track Shoe Cap Screw—Specification750C (5/8 in.)—Torque Turn 163 N•m (120 lb-ft) + 1/3 Turn

(120°).....................

750C (5/8 in.) with SwampShoe—Torque Turn 163 N•m (120 lb-ft) + 1/2 Turn

(180°)...................................

850C (3/4 in.)—Torque Turn 298 N•m (220 lb-ft) + 1/3 Turn(120°)

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


(270°)...................................

Split Master Link Shoe Cap Screw:

Split Master Link Shoe Cap Screw—Specification750C (5/8 in.)—Torque Turn 163 N•m (120 lb-ft) + 1/2 Turn

(180°).....................


(180°)...................................


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


(270°)...................................

6. Check torque after 50—100 hours of operation to makesure cap screws are tightened to minimum torque.

Track Shoe Cap Screws 50—100 Hour Check:

Track Shoe Cap Screws 50—100 Hour Check—Specification750C—Minimum Torque 380 N•m (280 lb-ft).............................................850C—Minimum Torque 597 N•m (440 lb-ft).............................................


PN=105

Track System

010130

34

TX,0130,SS2458 –19–13JUN95–1/1

Exploded View of Front Crossbar and Support—750C

T10

9343

–UN

–09J

UN

97

1—Cap Screw (8 used) 5—Front Crossbar 9—Hold Down Pad (2 used) 12—Cap Screw (2 used)2—Washer (8 used) 6—Cap Screw (4 used) 10—Shim (as required) 13—Washer (4 used)3—Wear Plate (2 used) 7—Washer (4 used) 11—Shim Retainer 14—Retainer Plate (4 used)4—Front Crossbar Support (2 8—Shim (as required)

used)


PN=106

Track System

01013035

TX,0130,SS2460 –19–13JUN95–1/2

Remove and Install Front Crossbar andSupport—750C

T10

9345

–UN

–13M

AY

97T

6056

AT

–UN

–26O

CT

881—Carrier Roller2—Hold Down Pad3—Support4—Crossbar5—Wear Plate6—3—4.6 mm (0.12—0.18 in.)7—Shim Retainer8—Cover

CAUTION: High pressure may be present in thetrack adjuster cylinder. Do not visually inspectthe grease escape passage.

1. Release track tension by turning check valve one turncounterclockwise to allow grease to escape.

2. Remove covers (8).

CAUTION: Put shop stands under main frame tohold crawler in raised position.

3. Raise crawler just enough to relieve weight on frontcrossbar (4) using a 9072 kg (10 ton) floor jack. Putshop stands under main frame.

4. Raise and support track high enough to remove carrierroller.

5. Remove cap screws to remove carrier roller (1).

6. Remove cap screws, hold down pad (2), and shims.

7. Remove cap screws to remove support (3).

8. Remove crossbar (4).

9. On 750C, inspect shim retainer (7), wear plate (5), andcrossbar for wear or damage. Repair or replace ifnecessary. If wear plate (5) on support (3) must bereplaced, see Remove and Install Support Wear Platesin this group.

10. Install crossbar (4).

11. Install support (3), cap screws and washers. Tightencap screws to specification.

SpecificationCrossbar Support Cap Screws—Torque 325 N•m (240 lb-ft).........................................................................

12. Lower machine to ground.


PN=107


Track System

010130

36

TX,0130,SS2460 –19–13JUN95–2/2

NOTE: It may be necessary to use JDG234 — 30 mmoffset wrench to torque carrier roller cap screws.

13. Install carrier roller, washers and cap screws. Makesure center line of roller is perpendicular to track andtighten cap screws to specification.

SpecificationCarrier Roller Cap Screws—Torque 325 N•m (240 lb-ft).........................................................................

14. Adjust clearance (6) between crossbar (4) to shimretainer (7) and clearance between crossbar to holddown pad (2). (See procedure in this group.)

15. Adjust track sag. (See procedure in this group.)


PN=108

Track System

01013037

TX,0130,SS2459 –19–24MAY02–1/2

Remove and Install Front Crossbar and Support—850C (S.N. —833331)

T10

0161

–19–

09F

EB

96

1—Cap Screw (8 used) 5—Front Crossbar 10—Shim (as required) 14—Retainer2—Washer (8 used) 6—Cap Screw (4 used) 11—Retainer 15—Cap Screw3—Wear Plate (2 used) 7—Washer (4 used) 12—Cap Screw (2 used) 16—Washer (2 used)4—Front Crossbar Support (2 8—Shim (as required) 13—Washer (2 used) 17—Lock Nut

used) 9—Hold Down Pad (2 used)

CAUTION: High pressure may be present inthe track adjuster cylinder. Do not visuallyinspect the grease escape passage.

1. Release track tension by turning check valve oneturn counterclockwise to allow grease to escape.

2. Remove spring cover.

CAUTION: Put shop stands under mainframe to hold crawler in raised position.

3. Raise crawler just enough to relieve weight on frontcrossbar (5) using a 9072 kg (10 ton) floor jack. Putshop stands under main frame.

4. Raise and support track high enough to removecarrier roller.

5. Remove cap screws to remove carrier roller.

6. Remove cap screws (6), hold down pad (9), andshims (8).

7. Remove cap screws to remove support (4).

8. Remove crossbar (5).

9. Inspect cap screw (15) and retainer (11). Front andcenter bottom guards will have to be removed toremove and install cap screw (15).


PN=109


Track System

010130

38

TX,0130,SS2459 –19–24MAY02–2/2

NOTE: Front crossbar (5) on 850C LGP is tapered atboth ends of crossbar.

10. Install cap screw (15), washers (16) and nut (17)finger tight. Install crossbar (5).

11. Install support (4), cap screws (1) and washers(2). Tighten cap screws to specification.

SpecificationCrossbar Support CapScrews—Torque 325 N•m (240 lb-ft)...................................................


13. Install crossbar retainer (11) directly under capscrew (15) and bottom plate. Install shims (10) asrequired. (See Check and Adjust FrontCrossbar-to-Crossbar Support and Main FrameClearances in this group.)

14. Tighten cap screw lock nut (17) to specification.

SpecificationRetainer Cap Screw LockNut—Torque 407 N•m (300 lb-ft).........................................................

NOTE: It may be necessary to use JDG234 — 30 mmoffset wrench to torque carrier roller capscrews.

15. Install carrier roller, washers and cap screws.Make sure center-line of roller is perpendicular totrack and tighten cap screws to specification.

SpecificationCarrier Roller Cap Screws—Torque 325 N•m (240 lb-ft)...................................................................

16. Adjust clearance between crossbar (5) andcrossbar hold down pad (9). (See Check andAdjust Front Crossbar-to-Crossbar Support andMain Frame Clearances in this group.)



PN=110

Track System

01013039

TX,0130,SS2461 –19–24MAY02–1/2

Check and Adjust FrontCrossbar-to-Crossbar Support and MainFrame Clearances (S.N. —833331)

T10

9346

–UN

–13M

AY

97

A—Cap Screw (2 used)B—Shim (as required)C—Hold Down PadD—Crossbar

1. Check clearance between front crossbar (D) and holddown pad (C).

Crossbar Ends-To-Hold Down Pad—Specification750C, 850C, 850C LGP and850C WT—Clearance 4.0 mm (0.16 in.) Minimum...................................750C, 850C, 850C LGP and850C WT—Clearance 5.0 mm (0.20 in.) Maximum....................................

2. If adjustment is needed, remove two cap screws (A).

3. Install shim(s) (B) under hold down pad (C) untilclearance is within specification. A minimum of threeshims must be used to keep cap screws fromprotruding through the hold down pad. Store anyexcess shims under the cap screw heads.

4. Apply thread lock and sealer (medium strength) to capscrews (A). Tighten to specification.

SpecificationCrossbar Support Hold Down PadCap Screws—Torque 325 N•m (240 lb-ft)..................................................



PN=111

Track System

010130

40

TX,0130,SS2461 –19–24MAY02–2/2

T60

56A

Q–U

N–0

1NO

V88

750C Shown

T10

0160

–19–

09F

EB

96

850C Shown

T10

0159

–19–

09F

EB

96850C LGP and 850C WT Shown

D—CrossbarE—ClearanceF—Shim RetainerG—Shim (As required)H—Cap Screw (2 used)I—Cap Screw

5. Check clearance (E) between crossbar (D) and shimretainer (F) at center of crossbar.

Crossbar Center-To-Shim Retainer—Specification750C, 850C, 850C LGP and850C WT—Clearance 2.0 mm (0.08 in.) Minimum.....................................750C, 850C, 850C LGP and850C WT—Clearance 3.0 mm (0.12 in.) Minimum.....................................

6. If clearance exceeds the maximum, remove capscrews (H) and washers to remove retainer and shimretainer (F).

7. Install shims under shim retainer to obtain theminimum clearance using as many of the thicker shimsas possible.

8. Install the shim retainer (F), cap screws (H) andwashers. Apply thread lock and sealer (mediumstrength) to cap screws and tighten to specification.Cap screws must not protrude through retainer morethan one thread.

SpecificationCrossbar Shim Retainer CapScrews—Torque 163 N•m (120 lb-ft)..........................................................


PN=112

Track System

01013041

TX,0130,SS2469 –19–24MAY02–1/2

Remove and Install Support Wear Plates(S.N. —833331)

T60

56A

R–U

N–2

6OC

T88

T60

56A

S–U

N–2

6OC

T88

A—Wear PadB—6.4 mm (0.25 in.) Fillet WeldC—Circle in Wear PadD—Surface Area of Wear PlateE—Gusset

1. Remove support. (See Remove and Install FrontCrossbar and Support in this group.)

2. Completely remove wear plate (A) from support usinga torch. DO NOT cut into support.

3. Grind weld area smooth.

4. Center wear plate on support as shown. Make surelarge surface area (D) of wear plate is away fromgusset (E).

5. Preheat wear plate (A) and support to 93°C (200°F)minimum before welding.

IMPORTANT: Before welding on this machine: Toavoid control circuit damage, turn theelectrical disconnect switch off,disconnect wiring harness and braidedground strap from transmissioncontroller, and disconnect the wiringharness from the display monitor panelin dash. Remove both components.

Good welds are important. Have only aqualified welder install this kit. Use therecommended electrodes. Beforewelding, clean all dirt and paint fromthe weld areas and turn batterydisconnect switch to "OFF". Connectthe welder ground clamp close to eachweld area so electrical current does notpass through any bearings.

6. Weld a bead around the inner edge of wear pad circle(C) using STELLITE 52 or MCKAY 58 Electrode. Fillcircle area with weld.

7. Grind weld area smooth.

8. Weld 6.4 mm (0.25 in.) fillet welds (B) on both ends ofwear pads using E-7018 Electrodes.

STELLITE 52 is a registered trademark of Cobot Corp.MCKAY 58 is a registered trademark of Teledyne McKay Corp.


PN=113


Track System

010130

42

TX,0130,SS2469 –19–24MAY02–2/2

9. Install support, roller, and adjust track tension.

10. Adjust crossbar. (See Adjust FrontCrossbar-to-Crossbar Support and Main FrameClearances in this group.)

CED,TX14826,12114 –19–04JUN02–1/3

Remove and Install Pinned Crossbar and Support—850C (S.N. 833332—907600)

T12

5573

–UN

–15D

EC

99

1—Washer (12 used) 5—Bushing (3 used) 9—Seal (2 used) 13—Support (2 used)2—Cap Screw (12 used) 6—Seal (4 used) 10—Bushing 14—Rear of Machine3—Cap Screw (3 used) 7—Snap Ring (4 used) 11—Pin 15—Front of Machine4—Pin (2 used) 8—Bushing (2 used) 12—Pin Crossbar

1. Remove spring cover, support cover, rear bottomguard and engine pan cover plate.


PN=114


Track System

01013043

CED,TX14826,12114 –19–04JUN02–2/3

CAUTION: Understand service procedurebefore doing work. Keep area clean and dry.

Never lubricate, service, or adjust machinewhile it is moving. Keep hands, feet, andclothing from power-driven parts. Disengageall power and operate controls to relievepressure. Lower equipment to the ground.Stop the engine. Remove the key. Allowmachine to cool.

Securely support any machine elements thatmust be raised for service work.

Keep all parts in good condition andproperly installed. Fix damage immediately.Replace worn or broken parts. Remove anybuildup of grease, oil, or debris.

On self-propelled equipment, disconnectbattery ground cable (-) before makingadjustments on electrical systems orwelding on machine.

On towed implements, disconnect wiringharnesses from tractor before servicingelectrical system components or welding onmachine.

CAUTION: High pressure may be present inthe track adjuster cylinder. Do not visuallyinspect the grease escape passage.

2. Release track tension by turning check valve oneturn counterclockwise to allow grease to escape.

3. Brake track chain at master split link and roll backchain allowing enough room for removal of pincrossbar. See remove and install track chain in thisgroup.

CAUTION: Put shop stands under mainframe to hold crawler in raised position.

4. Raise crawler just enough to relieve weight on pincrossbar (12) using a 9072 kg (10 ton) floor jack.Put shop stands under main frame.

5. Remove Cap Screws (3), pins (4) and bushings (5).Inspect pins (4) for wear or damage.

6. Remove cap screws and washers (1) and (2) fromsupport (13) and remove support with carrier rollerusing a over head hoist.

7. Remove pin (11), Cap Screw (3) and bushing (5)from center of cross bar. Inspect pin (11) for wearor damage.

8. Remove pin crossbar (12) and place on workbench.

9. Remove parts (6—8) from both sides of pincrossbar. Use a punch to remove bushing (8).

IMPORTANT: Do not push or bend swivel part ofbushing (8) when installing ordamage will occur.

10. Install new bushings (8) using DO1045AAbushing, bearing and seal driver set.

11. Install new seals (6) using DO1045AA bushing,bearing and seal driver set.

12. Remove parts (9) and (10). Use DO1045AAbushing, bearing and seal driver set. Use 50 tonpress when removing bushing (10).

13. Install new bushing (10) using DO1045AAbushing, bearing and seal driver set with 50 tonpress.

Press bushing (10) into bore to specification.

Pin Crossbar—SpecificationBushing—Depth 25.4 mm (1 in.)..........................................................


PN=115


Track System

010130

44

CED,TX14826,12114 –19–04JUN02–3/3

14. Install new seals (9) using DO1045AA bushing,bearing and seal driver set.

15. Install pin crossbar (12) using a over head hoist.

16. Install pin (11), Cap Screw (3) and bushing (5) intocross bar. Apply cure primer and thread lock andsealer (high strength) to cap screw (3).

NOTE: Support (13) cap screw holes are slottedallowing support to slide for alignment of pincrossbar pins (4).

17. Install carrier roller with support (13), cap screws(2) and washers (1).

18. Install Cap Screws (3), pins (4) and bushings (5).Apply cure primer and thread lock and sealer (highstrength) to cap screws (3).

19. Tighten cap screws (3).

20. Tighten cap screws (2).


22. Connect track chain to master split link. Seeremove and install track chain in this group.

Adjust track sag. See Adjust Track Sag procedurein this group.

Adjust track sag. (See procedure in this group.)

23. Install spring cover, support cover, rear bottomguard and engine pan cover plate.


PN=116

Track System

01013045

BT40170,0000019 –19–04JUN02–1/1

Remove and Install Crossbar and LubeLines—850C (S.N. 907601— )

T13

1910

B–U

N–2

0JU

N00

1—Cover2—Crossbar Side Pins (2 used) and Center Pin3—Cap Screw (5 used)

1. Remove necessary covers.

2. Remove track chain . (See Remove and InstallLubricated Track Chain in Group 0130.)

3. Raise crawler just enough to relieve weight on pincrossbar using a 9072 kg (10 ton) floor jack. Put shopstands under main frame.

4. Remove cover (1) to disconnect lube line on bothsides.

5. Remove pin (2) on both sides and center.

6. Remove cap screws (3) on one side and removecrossbar support.

CAUTION: The approximate weight of crossbaris 278 kg (613 lb).

Remove and Install Crossbar Lube Lines—SpecificationCrossbar—Weight 278 kg (613 lb.).............................................................

7. Attach a chain and hoist to crossbar and remove outthe side.

8. Install crossbar and pins.

9. Install crossbar support, connect lube line and installcover. Tighten cap screws.

10. Install track chain . (See Remove and InstallLubricated Track Chain in Group 0130.)


PN=117

Track System

010130

46

CED,TX03399,6113 –19–04JUN02–1/1

Disassemble and Assemble Crossbar—850C (907601— )

T13

1893

–UN

–05J

UL0

0

1—Cap Screw (3 used) 5—Snap Ring (4 used) 8—Hose (2 used) 12—Seal (2 used)2—Bushing (3 used) 6—Self-Aligning Bushing (2 9—Lubrication Fitting (2 used) 13—Bushing3—Pin (2 used) used) 10—Nut (2 used) 14—Pin4—Seal (4 used) 7—Crossbar 11—Elbow (2 used)

1. Inspect bushings (6) and (13). Replace if necessaryusing bushing, bearing and seal driver set.

2. Install new seals using a seal drive set.

3. Install seals with lip facing outward.

4. Inspect all parts for wear or damage, replace ifnecessary.


PN=118

Track System

01013047

TX,9020,YY1004 –19–13JUN95–1/1

Measure Link Height

T58

02A

D–U

N–0

2NO

V88


Link Height





Measure link height to the nearest 0.5 mm (0.020 in.)using depth gauge from JT05518A UndercarriageInspection Kit.Put the depth gauge on outside of track linkagainst pin boss as shown.Measure two links to thenearest 0.5 mm (0.020 in.).


PN=119

Track System

010130

48

TX,9020,YY1002 –19–13JUN95–1/2

Measure Bushing Outside Diameter forLubricated Track Chain

T58

02A

B–U

N–2

6OC

T88

NOTE: Lubricated track chain bushings are measured forvertical wear only using calipers. Bushing verticalwear can be measured using the depth gaugemethod only after bushing turn procedure is used(see Bushing Outer Diameter (Lubricated TrackChain) ,

750C, 750C-LGP and 750C Series II BushingOuter Diameter — Normal Impact LubricatedChain (Calipers) or High Impact Lubricated Chain(Calipers) ,

750C, 750C-LGP and 750C Series II BushingOuter Diameter — Normal Impact LubricatedChain (Depth Gauge) or High Impact LubricatedChain (Depth Gauge) ,

850C, 850C Series II, and 850C-LGP BushingOuter Diameter — Normal Impact LubricatedChain (Calipers) , Normal Impact LubricatedHeavy Duty Chain (Calipers) , High ImpactLubricated Chain (Calipers) , High ImpactLubricated Heavy Duty Chain (Calipers) ,

850C, 850C Series II, and 850C-LGP BushingOuter Diameter — Normal Impact LubricatedChain (Depth Gauge) , Normal Impact LubricatedHeavy Duty Chain (Depth Gauge) , High ImpactLubricated Chain (Depth Gauge) , or High ImpactLubricated Chain Heavy Duty (Depth Gauge) inUndercarriage Appraisal Manual, SP326).







PN=120


Track System

01013049

TX,9020,YY1002 –19–13JUN95–2/2




1. Clean surfaces to be measured of two adjacentbushings and underside of track shoe in the areabetween bushings.

2. For caliper method put caliper from undercarriageinspection service tool kit around bushing at area ofvertical wear as shown. Measure several differentbushings to nearest 0.5 mm (0.020 in.).


PN=121

Track System

010130

50

TX,9020,YY1001 –19–13JUN95–1/1

Measure Track Pitch for Lubricated TrackChain

T96

311

–UN

–02N

OV

88

NOTE: Track pitch does not extend unless there islubrication leakage, which causes a dry joint.Measure pitch only when there is a lubricationleakage or a visible extension of a joint.


Track Pitch



Track pin may be operated with a dry joint until it reacheswear limit specified. Then it must be repaired. A dry jointwill not hold lubrication until it is repaired. Track pin maybreak if joint is not repaired after it reaches wear limit.

1. Place a pin or block between sprocket and chain. Thenmove unit in reverse until chain is tight.

2. Measure from left side of pin in dry joint (A) to left sideof next pin.


PN=122

Track System

01013051

TX,0130,SS2395 –19–13JUN95–1/5

Remove and Install Lubricated Track Chain

T96

293

–UN

–27O

CT

88T

8400

AA

–UN

–20M

AY

95

CAUTION: Grease for track adjuster cylinder isunder high pressure. Never remove specialgrease fitting to release the grease. If greasedoes not escape immediately from vent holewith relief valve open, slowly drive unit inforward and reverse until grease escapes. DONOT disassemble parts unless you know thecorrect procedure and have correct tools. (Seeyour authorized dealer.)

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. Remove track tension by turning check valvecounterclockwise.

2. Drive unit forward until master split link is to the front ofthe idler.

3. Put wooden blocks under track shoe as shown.

4. Remove four bolts (A) to remove master track shoe (B)and disassemble master split link.

5. Slowly drive unit in reverse direction to move track offdrive sprocket.



PN=123

Track System

010130

52

TX,0130,SS2395 –19–13JUN95–2/5

T84

00A

B–U

N–2

0MA

Y95

IMPORTANT: Track chain MUST be installed undertrack frame with wide end of linkstoward rear of machine or acceleratedwear to track chain will occur.

6. Install track chain by putting chain under track framewith the wide end of links toward rear of machine.

7. Block track shoes so split link pin is approximatelylevel with track frame (B).

8. Attach chain and hoist (A) to track near the end ofchain to support track chain. Guide track over sprocketwhile operator drives machine slowly forward guidingtrack chain over carrier rollers and front idler.

9. Stop machine when end of split links meet.

TX,0130,SS2395 –19–13JUN95–3/5

T84

00A

C–U

N–2

2MA

Y95

A—Tip of Master Link RampB—HolesC—Ramp Surface

10. Remove any foreign material from master link toothracks and ramp surfaces (C). Clean surface with wirebrush if necessary.

11. Check for burrs, especially at tips (A) of master linkramps. Remove all burrs so ramp surfaces are flat.

12. Check the holes (B) in each master link. The holesmust be clean and free of foreign material.



PN=124

Track System

01013053

TX,0130,SS2395 –19–13JUN95–4/5

T84

00A

D–U

N–2

0MA

Y95

IMPORTANT: To prevent damage to threads, DO NOTuse a pry bar in holes to align splitmaster link.

13. Carefully assemble the master links (A) together andalign the holes.

14. Install master link cap screws by hand to checkalignment.



PN=125

Track System

010130

54

TX,0130,SS2395 –19–13JUN95–5/5

T84

00A

A–U

N–2

0MA

Y95

T96

302

–UN

–01N

OV

88

15. Apply John Deere NEVER-SEEZLubricant or anequivalent to cap screw threads and bearing surfaceunder head.

IMPORTANT: DO NOT use impact wrench to start themaster shoe cap screws to avoidcross-threading.

16. Remove any foreign material from master shoe andlink mounting surface. Install master shoe (B) onmaster links and start cap screws by hand to avoidcross-threading.

17. Initially tighten master cap screws (A) in a crosssequence as shown. Repeat the sequence perspecification.

Split Master Link Shoe Cap Screw:

Split Master Link Shoe Cap Screw—Specification750C (5/8 in.)—Torque Turn 163 N•m (120 lb-ft) + 1/2 Turn

(180°).....................


(180°)...................................


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


(270°)...................................

Check torque after 50—100 hours of operation to makesure cap screws are tightened to the minimum torquespecification. If not, repeat Step 17.

Lubricated Track Chain, Track Shoes 50—100 HourCheck:

Lubricated Track Chain, Track Shoes 50—100 Hour Check—Specification

750C—Torque 380 N•m (280 lb-ft) Minimum..............................................850C—Torque 597 N•m (440 lb-ft) Minimum..............................................


NEVER-SEEZ is a registered trademark of Emhart Chemical Group


PN=126

Track System

01013055

TX,0130,SS2441 –19–13JUN95–1/5

Disassemble Lubricated Track Chain to TurnBushings and Lubricate Chain

NOTE: The following procedure is for disassembly oftrack chain to inspect, clean, replace damaged orworn parts, turn bushings, and lubricate chain.

If track chain is disassembled only to turn pinsand bushings and no parts will be replaced, seeDisassemble and Assemble Lubricated TrackChain to Turn Pins and Bushings and NotLubricate, in this group.

1. Remove track shoes and track chain. (See Removeand Install Lubricated Track Chain and Remove andInstall Track Shoes in this group.)

NOTE: A clean track is necessary for proper disassembly.

2. Wash chain with high pressure water. It will not benecessary to wash links before reassembly if chain isthoroughly cleaned.

3. Use the following track press tool sets.

For 750C use Tooling Set—Twin Head Press(A2656-145).

For 850C use Tooling Set— Single Head Press(A3005-221) or Twin Head Press (A2656-221).



PN=127

Track System

010130

56

TX,0130,SS2441 –19–13JUN95–2/5

T96

266

–UN

–27O

CT

88

A—Left RamB—SaddleC—Right RamD—Right LinkE—BushingF—Left LinkG—Pin

IMPORTANT: Track press disassembly tools must bein proper alignment with links toprevent broaching of pin and bushing.Damaged link bores cannot be reused.

4. Start disassembly at pin-end half of split link. Check forproper alignment of tools with pin and bushing.

5. Make an index mark on bushings to aid in reassembly,when turning bushings 1/2 turn (180°) to expose a newwear surface.

CAUTION: Always wear safety glasses whenoperating the press. Parts may break or chip,which could create a risk of personal injury.

6. Extend right ram (C) to push pin (G) and bushing (E)from the right link (D). The right link is forced againstthe side of saddle (B) as pin and bushing are pushedout.

7. Retract right ram. The right link, with seals and thrustring, will stay on the ram tools.

TX,0130,SS2441 –19–13JUN95–3/5

T96

267

–UN

–27O

CT

88

A—Left RamB—SaddleC—PinD—Right RamE—Right LinkF—BushingG—Left Link

8. Extend left ram (A) to push the pin (C) and bushing (F)from left link (G). The left link is forced against the sideof saddle (B) as pin and bushing are pushed out.

9. Retract left ram. The left link, with seal and thrust ring,will remain on the ram tools.

10. Remove links, bushing, and thrust rings from press.


PN=128


Track System

01013057

TX,0130,SS2441 –19–13JUN95–4/5

T66

82A

J–U

N–0

1NO

V88

A—BushingB—Seal RingC—Load RingD—Thrust RingE—PinF—Rubber Plug

11. Inspect parts as they are disassembled to determinewhich ones can be reused.

If there is internal wear at any joint, replace seal ring,pin, bushing, thrust ring, and load ring. These partsmust be replaced to successfully lubricate chain.

12. If pin and bushing contains oil when disassembled,new pins, seals, bushings, or thrust rings are notnecessary. Do not remove usable seals from linkcounterbore. Do not remove any dirt from aroundseals.

13. Repeat steps 4—12 to disassemble rest of chain.

14. Remove rubber plug (F) from pins using a drill.

TX,0130,SS2441 –19–13JUN95–5/5

T96

269

–UN

–27O

CT

88

A—4 mm (0.16 in.)B—30°C—15°D—3 mm (0.12 in.)

15. Inspect pin ends. If the chamfer is missing due towear, grind a 3 mm (0.12 in.) x 15° chamfer on pin. Ifchamfer is missing in plug hole, add new 4 mm (0.16in.) x 30° chamfer.

16. Clean pins, bushings, and thrust rings in solvent.


PN=129

Track System

010130

58

TX,0130,SS2442 –19–13JUN95–1/14

Assemble Lubricated Track Chain to TurnBushings and Lubricate Chain

T96

272

–UN

–27O

CT

88

CAUTION: Make sure all control levers of pressare in the NEUTRAL position.

1. Assembly track using the following track press toolsets.


For 850C use Tooling Set—Single Head Press(A3005-221) or Twin Head Press (A2656-221).

2. Apply a mixture of 50% alcohol and 50% water torubber plug (A) and install using JDG190 Plug Installer(B).

TX,0130,SS2442 –19–13JUN95–2/14

T96

273

–UN

–27O

CT

88

NOTE: The pin end halves of master split link must betemporarily assembled to bushing end halves oflink for proper positioning on plungers. Pin endhalves will later have to be separated forinstallation at end of chain.

3. Assemble master split link halves using master shoebolts and washers (as required). Tighten bolts justenough to hold links together. Split links are a matchedset and must be assembled as a set.

4. Install assembled split links on ram plungers.

5. Install bushing (A) in front seat of saddle (B) so themark is 180° opposite original location to expose a newwear surface.



PN=130

Track System

01013059

TX,0130,SS2442 –19–13JUN95–3/14

T96

274

–UN

–27O

CT

88

6. Adjust track press pressure relief valve setting.

Track Press Relief Valve Settings:

Track Press Relief Valve Settings—Specification750C—Force 378 080 N (85,000 lb force)

Maximum.................................................

850C—Force 444 800 N (100,000 lb force)Maximum

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

7. Advance left ram until left split link contacts the saddle.Advance right ram until it stops to press split link andbushing assembly together.

TX,0130,SS2442 –19–13JUN95–4/14

T96

275

–UN

–27O

CT

88

8. Measure bushing projection from shoulder of link usinga depth micrometer. Bushing projection determinesclearance between overlapping links and properspacing of link bolt holes.

Specification750C Bushing Projection—Height 0.9 ± 0.25 mm (0.035 ± 0.010 in.)........850C Bushing Projection—Height 2.30 ± 0.25 mm (0.091 ± 0.010

in.)............

9. If bushing projection does not meet specification, checkpressure setting or adjust shim packs behind plungers.Only the first two joints must be checked for properbushing projection.



PN=131

Track System

010130

60

TX,0130,SS2442 –19–13JUN95–5/14

T96

276

–UN

–27O

CT

88

10. Apply track chain lubricant to bushing ends beforenext set of links are installed.

TX,0130,SS2442 –19–13JUN95–6/14

T96

277

–UN

–27O

CT

88

A—End HoleB—Cross-Drilled Hole

IMPORTANT: Pins must be installed so cross-drilledhole is toward link wear surface or theymay break when chain is used. To makeassembly easier, install all pins soholes in the end are toward the sameside of chain.

11. Install pin in bushing so cross-drilled hole (B) istoward link wear surface. Install all pins so end hole(A) is toward the same side of chain, either left orright.

TX,0130,SS2442 –19–13JUN95–7/14

T96

278

–UN

–27O

CT

88

12. Install a thrust ring on each end of pin.

13. Move completed split link assembly to rear seat ofsaddle.



PN=132

Track System

01013061

TX,0130,SS2442 –19–13JUN95–8/14

T96

279

–UN

–27O

CT

88

14. Apply TY15934 John Deere Gasket Maker #3 or anequivalent to the link bore. The sealant prevents lossof vacuum or lubricant leakage through the pin to linkjoint.

TX,0130,SS2442 –19–13JUN95–9/14T

9628

0–U

N–2

7OC

T88

B—LinkC—Load RingD—Seal RingF—Bushing

15. Install bushing (F) in front saddle seat. Install left link(B) and right link on ram plungers.

Assemble the load ring (C) and seal ring (D). Installthe assembly into link (B) counterbore so pointed lipof seal ring is toward bushing (F).



PN=133

Track System

010130

62

TX,0130,SS2442 –19–13JUN95–10/14

T96

282

–UN

–27O

CT

88T

9628

3–U

N–2

7OC

T88

A—Left RamB—SaddleC—PinD—PlungerE—Right RamF—Right LinkG—BushingH—ShimsI—Left Link

16. Advance left ram until left link contacts the saddle.Advance right ram until it stops (plungers in bothrams against shim pack).

TX,0130,SS2442 –19–13JUN95–11/14

T96

284

–UN

–27O

CT

88

A—Special Spacer

NOTE: To ensure zero end play in joint, special spacersmust be fabricated using a section of bushing. Adifferent size spacer is used for 750C and 850C.

17. Retract left ram. Install special spacer (A) betweenthe joint in rear seat of saddle and ram.

IMPORTANT: Too much pressure will crush the thrustrings

18. Advance left ram using only minimum force requiredto push joint tight. Pressure must be approximatelyone half the relief valve setting. Remove spacer.



PN=134

Track System

01013063

TX,0130,SS2442 –19–13JUN95–12/14

T96

285

–UN

–27O

CT

88

19. After one complete joint has been assembled, checkend play of track links to make sure bushing, thrustrings, and link counterbore faces are pressed solidagainst each other. Position base of dial indicator onone link assembly and pointer against the other linkassembly.

20. Pry link assemblies in one direction then in oppositedirection to measure the amount of end play. Endplay must be zero.

21. As track chain is being further assembled, end playmay be checked by manually prying upward on eachlink. If link rotates downward increase press force andre-press.



PN=135

Track System

010130

64

TX,0130,SS2442 –19–13JUN95–13/14

T96

286

–UN

–27O

CT

88T

9628

7–U

N–0

1NO

V88

T64

65A

Y–U

N–0

1NO

V88

T96

288

–UN

–27O

CT

88

A—First HoleB—Second HoleC—Nozzle

22. As chain is being assembled, check to make surethere is some clearance between the overlapping faceof links, using a feeler gauge. If links contact eachother, check bushing projection.

SpecificationBushing Projection 750C—Height 0.9 ± 0.25 mm (0.035 ± 0.010 in.)........Bushing Projection 850C—Height 2.30 ± 0.25 mm (0.091 ± 0.010

in.)............

23. Add oil (SAE 80W 90) using a Seal Tester andLubricator for S.A.L.T. Crawler Equipment. Pushnozzle through plug all the way into pin. Depresscontrol lever on the handle enough to draw specifiedvacuum as indicated on the gauge.

SpecificationLubricated Track Chain SealTest—Vacuum 68—102 kPa (2—30 in. Hg)...............................................

24. Release lever. If there is no decrease in vacuum for aminimum of five seconds, the joints are sealed. Ifthere is a vacuum decrease, seals are not sealingand the joint must be taken apart and repaired.

25. Add oil by depressing the second lever. Oil pressure(read on the same gauge) must be to specificationafter both levers are released.

SpecificationLubricated Track Chain Oil—Pressure 140—205 kPa (1.4—2.05 bar

(20—30 psi)......................................................

26. For pins using rubber plug and plastic plug,immediately install plug using JDG190 Plug Installerafter adding oil.

For pins using self-sealing plug, slowly pull nozzle (C)out to allow any compressed air to escape throughnozzle from first hole (A) to second hole (B).

Add oil to each joint after assembling so only onejoint would have to be disassembled if a vacuum leakoccurs.


PN=136


Track System

01013065

TX,0130,SS2442 –19–13JUN95–14/14

27. Repeat step 10—26 for all joints.

28. Install assembled split links on ram plungers, andadvance rams to press split links together.

29. Install lubricated track chain. (See procedure in thisgroup.)

30. Install track shoes (See procedure in this group.)

TX,0130,SS2440 –19–13JUN95–1/11

Disassemble and Assemble Lubricated TrackChain to Turn Pins and Bushings and NotLubricate

NOTE: The following procedure is for disassembly oftrack chain only to turn pins and bushings. (Chainis not lubricated after assembly.)

If this procedure does not apply to the repair job,see Disassemble Lubricated Track Chain to TurnBushings and Lubricate Chain in this group.

1. Remove track shoes. (See procedure in this group.)

2. Use the appropriate track press tool set.


For 850C use Tooling Set—Single Head Press(A3005-221) or Twin Head Press (A2656-221).



PN=137

Track System

010130

66

TX,0130,SS2440 –19–13JUN95–2/11

T96

266

–UN

–27O

CT

88

A—Left RamB—SaddleC—Right RamD—Right LinkE—BushingF—Left LinkG—Pin

IMPORTANT: Track press disassembly tools must bein proper alignment with links toprevent broaching of pin and bushing.Damaged links cannot be reused.

3. Check for proper alignment of tools with pin andbushing.

4. Make an index mark on bushings and pins to aid inreassembly, when turning bushings 1/2 turn (180°) toexpose a new wear surface.

CAUTION: Always wear safety glasses whenoperating the press. Parts may break or chip,which could create a risk of personal injury.

5. Extend right ram (C) to push pin (G) and bushing (E)from the right link (D). The right link is forced againstthe side of saddle (B) as the pin and bushing arepushed out.

6. Retract right ram. The right link, with seals and thrustring, will stay on the ram tools.



PN=138

Track System

01013067

TX,0130,SS2440 –19–13JUN95–3/11

T96

267

–UN

–27O

CT

88

A—Left RamB—SaddleC—PinD—Right RamE—Right LinkF—BushingG—Left Link

7. Extend left ram (A) to push the pin (C) and bushing (F)from the left link (G). The left link is forced against theside of saddle (B) as pin and bushing are pushed out.

8. Retract left ram. The left link, with seal and thrust ring,will remain on the ram tools.

9. Remove links and bushing from press.

10. Repeat steps 4—9 to disassemble rest of chain.

IMPORTANT: Pins must be installed so cross-drilledhole is toward link wear surface or theymay break when chain is used.

11. All pins, bushings, seals, and thrust rings are used forreassembly, because chain is not lubricated. Do notremove rubber plug and plastic plug from pins. Do notremove seals from track links.

Turn pin end-for-end to get a new wear surface, theninstall it into bushing so cross-drilled hole is towardlink wear surface. Install all pins so hole in end of pinis toward the same side of chain, either left or rightside.

TX,0130,SS2440 –19–13JUN95–4/11

T57

98A

J–U

N–2

6OC

T88

A—15°B—3 mm (0.12 in.)

12. Inspect pin ends for wear. If there is no chamfer (Aand B), grind a new chamfer to specification.

SpecificationLubricated Track Pin End—Chamfer 3 mm (0.12 in.) x 15°....................................................................



PN=139

Track System

010130

68

TX,0130,SS2440 –19–13JUN95–5/11

T96

289

–UN

–27O

CT

88

A—Track Link

13. Smooth area of track link wear (A) using a grinder, ifnecessary.

TX,0130,SS2440 –19–13JUN95–6/11

T96

273

–UN

–27O

CT

88

A—BushingB—Saddle

14. Assemble track links using the following track presstool sets.


For 850C use Tooling Set—Single Head Press(A3005-221), Twin Head Press (A2656-221).

NOTE: The pin end halves of master split link must betemporarily assembled to bushing end halves oflink for proper positioning of plungers. Pin endhalves will later have to be separated forinstallation at end of chain.

15. Assemble master split link halves using master shoebolts and washers (as required). Tighten bolts justenough to hold link together.

16. Install assembled split links on ram plungers.

17. Install bushing (A) in front seat of saddle (B) so themark is 180° opposite original location to expose anew wear surface.



PN=140

Track System

01013069

TX,0130,SS2440 –19–13JUN95–7/11

T96

274

–UN

–27O

CT

88

18. Adjust track press pressure relief valve setting.

Specification750C—Track Press ReliefValve—Force 378 080 N (85,000 lb force)

Maximum.................................................

850C—Track Press ReliefValve—Force 444 800 N (100,000 lb force)

Maximum...............................................

19. Advance rams to press split links together until thecorrect bolt spacing is obtained for the master shoe.

TX,0130,SS2440 –19–13JUN95–8/11

T96

277

–UN

–27O

CT

88

A—Pin End HoleB—Cross-Drilled Hole

IMPORTANT: Pins must be installed so cross-drilledhole is toward link wear surface or theymay break when chain is used.

20. Turn pin end-for-end to get a new wear surface, theninstall it into bushing so cross-drilled hole (B) istoward link wear surface. Install all pins so hole (A) inend of pin is toward the same side of chain, either leftor right side.



PN=141

Track System

010130

70

TX,0130,SS2440 –19–13JUN95–9/11

T96

278

–UN

–27O

CT

88

21. Install a thrust ring on each side of pin.

22. Move completed link assembly to rear seat of saddle.

TX,0130,SS2440 –19–13JUN95–10/11

T96

283

–UN

–27O

CT

88T

9629

0–U

N–2

7OC

T88

A—Left RamB—SaddleC—PinD—PlungerE—Right RamF—Right LinkG—BushingH—Plunger ShimsI—Left LinkJ—23058 Track Shoe Gauge

23. Install bushing (G) in front saddle seat. Install rightand left links (E and I) on ram plungers (D).

24. Advance left ram (A) until left link contacts the saddle(B). Advance right ram until link is pressed togetherand bolts can be installed through 23058 Track ShoeGauge (J).



PN=142

Track System

01013071

TX,0130,SS2440 –19–13JUN95–11/11

T96

286

–UN

–27O

CT

88

25. As chain is being assembled, check to make surethere is some clearance between the overlapping faceof links using a feeler gauge. If links contact eachother, check bushing projection.

SpecificationTrack Pin Bushing 750C—Projection 0.9 ± 0.25 mm (0.035 ± 0.010 in.)..............................................Track Pin Bushing 850C—Projection 2.30 ± 0.25 mm (0.091 ± 0.010

in.)..................................................

26. Repeat steps 14—25 to assemble rest of chain.

27. The last link assembled is the split link pin ends.Assemble a set of extra "slave" split link bushing endsto pin ends using bolts and washers used in step 15.Tighten bolts just enough to hold together link.

28. Install assembled split links on ram plungers andadvance rams to press split links together.

29. Install track shoes. (See procedure in this group.)

30. Install lubricated track chain. (See procedure in thisgroup.)


PN=143

Track System

010130

72

TX,9020,YY1008 –19–11MAR96–1/2

Adjust Track Sag

T60

44C

J–U

N–2

3FE

B89

T60

33B

B–U

N–0

2NO

V88

A—Grease FittingB—Check ValveC—Vent Hole

NOTE: Check sag after a short period of operation whenchanging from one ground condition to another orwhen operating in extreme soil packing conditions.

SpecificationLubricated Track Chain—TrackSag 51 ± 6 mm (2 ± 1/4 in.)........................................................................

1. Allow machine to slowly roll to a stop in the forwarddirection. For the most accurate measurement, a linkpin must be centered on carrier roller.

2. Measure track sag between carrier roller and front idlerat the lowest point. (See "Track Sag" decal onmachine. Decal located next to right enginecompartment access door.)

IMPORTANT: Grease fitting on track adjuster head isused for track sag adjustment only.Fitting on cylinder barrel adjusterhousing is used to fill cavity betweencylinder barrel and adjuster housing tokeep water out.

Piston must move using a 22 500 kPa(550 bar) (8000 psi) maximum capacitygrease gun or seals may be damaged. Ifpiston does not move, check for seizedtrack adjuster parts. (See Disassembleand Assemble Track Adjuster Cylinderin this group.)

3. To decrease sag, apply grease to fitting (A) using a 55200 kPa (550 bar) (8000 psi) maximum capacitygrease gun.

After adding grease, operate machine to allow trackadjuster cylinder to fully adjust and then check sagagain. Each time track is adjusted apply grease togrease fittings on cylinder barrel adjuster housing untilgrease escapes past wiper seal.


PN=144


Track System

01013073

TX,9020,YY1008 –19–11MAR96–2/2

CAUTION: Grease for track adjuster cylinder isunder high pressure. Never remove greasefitting to release the grease. If grease does notescape immediately from vent hole, slowly drivemachine in forward and reverse, then closecheck valve (B).

4. To increase sag, turn check valve (B) 1—3 turnscounterclockwise to release grease through vent hole(C). Turn check valve clockwise to close it. Afterreleasing grease, operate machine to allow trackadjuster cylinder to fully adjust and then check sagagain.


PN=145

Track System

010130

74

TX,0130,SS2439 –19–13JUN95–1/1

Track Adjuster Exploded View

T82

05A

B–U

N–0

4AP

R94

1—Wear Ring (2 used) 8—Check Valve 15—Yoke (2 used) 22—Adjuster Spring2—Seal 9—Rod 16—Washer 23—Washer (12 used)3—Hydraulic Cylinder Cap 10—Deflector (2 used) 17—Piston 24—Strap4—Relief Valve 11—Lock Washer (4 used) 18—O-Ring 25—Cap Screw (4 used)5—Strap 12—Cap Screw (4 used) 19—Seal 26—Spring6—Screw 13—Cap Screw (5 used) 20—Lubrication Fitting 27—Dowel Pin7—Lubrication Fitting 14—Washer (4 used) 21—Adjuster Housing 28—Set Screw


PN=146

Track System

01013075

TX,0130,SS2407 –19–13JUN95–1/3

Remove Track Adjuster and Recoil Spring

T84

03A

E–U

N–2

0MA

Y95

T84

03A

F–U

N–2

0MA

Y95

T84

03A

G–U

N–2

0MA

Y95

1—Special Screw2—Grease Fitting3—Bar Stock4—Adjuster Rod5—Round Stock6—Deflector Plates7—Cap Screw (4 used)8—Weld Block9—Angle Bar Stock10—Guide

NOTE: Track chain does not have to be removed toreplace track adjuster cylinder, recoil spring andadjuster rod.

1. Remove spring guard to remove special screw (1).Remove dowel and spring.

2. Pump grease into grease fitting (2) until idler movesforward and there is no track sag. Continue to pumpgrease into grease fitting until spring is compressed 38mm (1.5 in.).

3. If track adjuster cylinder will not compress recoil spring,install a piece of 2-1/2 x 12 in. round stock (5) betweensprocket and track. Back machine up.

4. Install 38 mm (1.5 in.) bar stock (3).

5. If round stock was used to compress spring, drive unitforward and remove round stock (5).

6. Measure distance from weld block (8) to guide (10)and install a 1/4 x 1-1/2 in. piece of angle bar stock (9)to keep idler from moving.

CAUTION: Grease for track adjuster cylinder isunder high pressure. Slowly loosen check valveto release grease.

7. Slowly loosen grease fitting check valve to releasecylinder pressure. Push cylinder towards spring.

8. Remove deflector plates (6).

9. Remove yoke cap screws (7) to move adjuster rod (4)aside.

10. Remove adjuster cylinder head.


PN=147


Track System

010130

76

TX,0130,SS2407 –19–13JUN95–2/3

T60

27A

E–U

N–2

6OC

T88

1—Plate (2 used)2—Bar Stock3—Cap Screw (4 used) and Washer (12 used)4—JD314-2B or 2C Screw

11. Thoroughly clean threads on JD314-2B or JD314-2Cscrew (4) and in spring adapter. Apply John DeereNEVER-SEEZ to threads and contact area betweencap screw head, washer and positioning guide.

12. Install JD314A or JD314B Track Spring CompressorKit (as shown in photo) through track adjuster housingand thread into spring adapter.

13. Tighten special screw until the bar stock (2) can beremoved.

CAUTION: Use care when handling spring asaccidental release of spring can cause seriouspersonal injury. Do not, under anycircumstances, attempt to remove springwithout special tools.

Release compression on track springimmediately after removal. (See Disassembleand Assemble Recoil Spring in this group.) Aspring stored in the compressed state cancause stress concentration resulting in a weakspot that may result in immediate or eventualfailure creating a risk of personal injury.

14. Remove cap screws (3) and hold down plates (1) toremove spring from track frame.



PN=148

Track System

01013077

TX,0130,SS2407 –19–13JUN95–3/3

T60

29A

A–U

N–2

6OC

T88

1—Cap Screw2—Yoke3—Idler

15. To remove track adjuster rod loosen cap screw (1)approximately 2—3 turns.

16. Loosely install four cap screws and washers in yoke(2) and guide.

17. Position a small square block (1-1/8 x 1-1/8 in.) or 3/4x 1-1/4 in. cap screw and nut between adjuster capscrew (1) head and idler (3).

18. Tighten yoke-to-guide cap screws evenly untiladjuster rod separates from yoke.

TX,0130,SS2411 –19–13JUN95–1/4

Install Track Adjuster and Recoil Spring

T60

29A

B–U

N–2

6OC

T88

1. Put track adjuster rod under support and position yokeon track frame.

2. Loosely assemble adjuster rod, yoke, special washer,and cap screw.

3. Make sure hole at cylinder end of adjuster rod ispointing directly upward.

4. Tighten cap screw to specification.

SpecificationAdjuster Rod-to-Yoke CapScrew—Torque 575 N•m (425 lb-ft)............................................................

Rap head of cap screw using a brass rod and a 2 kg (5lb) hammer. Retighten cap screw.

5. Slide yoke assembly forward.



PN=149

Track System

010130

78

TX,0130,SS2411 –19–13JUN95–2/4

T60

27A

E–U

N–2

6OC

T88

T84

04B

E–U

N–2

2MA

Y95

1—Plate (2 used)2—Bar Stock (2 used)3—Cap Screw (4 used)4—Track Spring Compressor Tool5—Washer (8 used)6—Grease Fitting

CAUTION: Do not release load on recoil springuntil it is installed in track frame and secured inposition with hold down plates. Accidentalrelease of recoil spring could create a risk ofpersonal injury.

6. Install preloaded recoil spring in track frame with trackadjuster housing toward idler and grease fitting (6) ontop as shown.

7. Assemble washers (5), hold down plate (1), and capscrews (3). Tighten cap screws to specification.

SpecificationInsert Guide Cap Screws—Torque 325 N•m (240 lb-ft).........................................................................

8. Install 38 mm (1.5 in.) bar stock (2).

9. Slowly remove track spring compressor tool (4).

10. Carefully install adjuster head in adjuster housing. Donot damage seal in adjuster housing.

TX,0130,SS2411 –19–13JUN95–3/4

T60

27A

D1

–UN

–26O

CT

88

1—Yoke-to-Guide Cap Screws2—Deflectors

11. Slide yoke forward to install washers and cap screws(1). Tighten cap screws to specification.

SpecificationYoke-to-Guide Cap Screws—Torque 576 N•m (425 lb-ft).........................................................................

12. Install deflectors (2), washers, and cap screws.Tighten cap screws to specification.

SpecificationTrack Adjuster Yoke-to-IdlerMount Cap Screw—Torque 163 N•m (120 lb-ft).........................................


PN=150


Track System

01013079

TX,0130,SS2411 –19–13JUN95–4/4T

8403

AE

–UN

–20M

AY

95T

8403

AF

–UN

–20M

AY

95

1—Special Screw Hole2—Check Valve3—Bar Stock4—Adjuster Rod5—Round Stock

13. Put adjuster rod (4) in adjuster head and installspring, dowel pin and set screw in hole (1).

14. Put grease in adjuster head to tighten track enough toremove angle bar stock between weld block and frontidler guide.

15. Continue to put grease into adjuster head tocompress the recoil spring. If track adjuster cylinderwill not compress the recoil spring, install a piece of2-1/2 x 12 in. round stock (5) between sprocket andtrack. Back machine up.

16. Remove bar stock (3).

17. Drive machine forward to remove round stock (5).

18. Slowly turn check valve (2) to release grease fromadjuster head until spring moves forward againststops.


20. Apply grease to grease fitting in adjuster housing untilgrease escapes past wiper seal to fill cavity betweenadjuster housing and adjuster head.

21. Install spring cover and tighten cap screws tospecification.

SpecificationSpring Cover-to-Track Frame CapScrew—Torque 163 N•m (120 lb-ft)............................................................


PN=151

Track System

010130

80

TX,0130,SS2413 –19–13JUN95–1/3

Disassemble and Assemble Recoil Spring

T65

57D

Y–U

N–2

5OC

T88

A—Recoil Spring Compression ToolB—Nut (4 used)C—Top Plate

CAUTION: Spring or rod may break if droppedwhile handling, transporting or disassembling.Nicks or weld craters in spring and rodassembly can cause stress concentrationresulting in a weak spot that may result inimmediate or eventual failure creating a risk ofpersonal injury. Put a heavy protective coveringaround spring assembly when handling,transporting or disassembling.

A compression tool must be used fordisassembly and assembly because of theextreme preload on spring.

1. Measure length of spring assembly before removingJD314A or JD314B Track Spring Compressor Kit, toaid in assembly.

2. Put a 20-ton jack on bottom of ST4920 Recoil SpringCompression Tool (A). (See Group 0199 forinstructions to make tool.)

3. Remove nuts (B) and top plate (C).

4. Put recoil spring in compression tool.

Specification750C—Track Recoil Spring—FreeLength 592 mm (23.29 in.) Approximate.....................................................850C—Track Recoil Spring—FreeLength 616 mm (24.25 in.) Approximate.....................................................



PN=152

Track System

01013081

TX,0130,SS2413 –19–13JUN95–2/3T

7126

AA

–UN

–15S

EP

89T

7247

BN

–UN

–09A

PR

90

A—PlateB—Nut (4 used)C—Cap Screw HeadD—Recoil SpringE—Hole in PlateF—DFT1087 Recoil Spring Compressor Tool Guard

5. Install DFT1087 Recoil Spring Compression ToolGuard (F). (See Group 0199 for instructions to maketool.)

6. Install plate (A) and nuts (B) from ST4920 RecoilSpring Compression Tool to secure spring.

IMPORTANT: Cap screw head and positioning guidemust be centered through hole in platefor proper operation of tool.

7. Be sure cap screw head (C) and positioning guide fromtrack spring compression kit fits through hole in plate.

8. Extend jack ram so there is enough travel to releasespring to the approximate free length. If jack ram travelis not enough that the spring compression can bereleased the procedure should be repeated until springis at free length.

9. Remove track spring compression kit cap screw (C).

10. Slowly release jack pressure.

11. Remove nuts and plate.

12. Remove spring. Replace parts if necessary.



PN=153

Track System

010130

82

TX,0130,SS2413 –19–13JUN95–3/3

T71

26A

A–U

N–1

5SE

P89

T72

47B

N–U

N–0

9AP

R90

A—PlateB—Nut (4 used)C—Track Spring Compression KitD—Recoil SpringE—Hole in PlateF—DFT1087 Recoil Spring Compressor Tool Guard

13. Install 20-ton jack on bottom of compression tool.

14. Apply John Deere NEVER-SEEZ lubricant to threadsand under head of track spring compression kit (C)cap screw.

15. Assemble spring adapter, recoil spring, track adjusterhousing, positioning guide, washer and screw.

16. Center recoil spring assembly (D) in compression toolso spring is centered.

17. Install DFT1087 Recoil Spring Compression ToolGuard (F). (See Group 0199 for instructions to maketool.)

18. Install plate (A) and nuts (B) to secure spring.

Maximum length of spring to install assembly intotrack frame is:

Specification750C—Track Recoil Spring—Installation Length 400 mm (15.75 in.).......................................................850C—Track Recoil Spring—Installation Length 470 mm (18.50 in.).......................................................

19. Operate jack to compress spring to specifications.Tighten track spring compression kit (C) cap screw.Repeat procedure as necessary.

20. Slowly release jack and remove nuts and plate.

21. Install spring assembly in track frame . (See InstallTrack Adjuster and Recoil Spring in this group.)



PN=154

Track System

01013083

TX,0130,DU1380 –19–07APR94–1/2

Disassemble and Assemble Track Adjuster Cylinder

T70

20A

B–U

N–1

4MA

R94

A—O-Ring E—Relief Valve I—Retainer M—Track Adjuster HeadB—Piston F—Set Screw J—Grease Fitting N—Wiper SealC—Piston Wear Rings (2 used) G—Dowel Pin K—Check Valve O—Track Adjuster HousingD—U-Cup Seal H—Spring L—Special Screw P—Lubrication Fitting

1. Disassemble parts (A—M).

2. Inspect for wear and damage. Replace asnecessary.

3. Inspect wiper seal (N) in track adjuster housing (O)for wear or damage. Replace if necessary with seallip towards front of machine.



PN=155

Track System

010130

84

TX,0130,DU1380 –19–07APR94–2/2

T60

33A

Q–U

N–2

6OC

T88

1—Piston Edge2—Seal

4. Put piston in a vise and lubricate edge (1).

5. Put seal in hot water to soften it.

6. Put seal (2) over edge of piston, with lips away frompiston.

7. Apply downward pressure and tap seal over edge ofpiston using a soft hammer.

8. Install new O-ring on piston.

9. Install wear rings on piston.

10. Apply NEVER-SEEZ lubricant to bore surfaces ofadjuster cylinder head.

11. Put piston assembly into adjuster head with U-cupseal end towards relief valve.

12. Install relief valve, check valve, retainer plate, andsocket head cap screw.

13. Carefully assemble adjuster, head, housing and recoilspring.

NEVER-SEEZ is a trademark of Emhart Chemical Group


PN=156

Track System

01013085

TX,0130,SS2419 –19–13JUN95–1/3

Remove Track Frame

T60

64A

H–U

N–2

6OC

T88

A—Pivot ShaftB—Inner Mounting BracketC—A-Frame BearingD—A-Frame

CAUTION: Do not work around raised machinewithout first supporting machine with shopstands. Doing so could cause serious personalinjury.

1. Remove pushbeam and blade assembly. (See RemovePushbeam in Group 3240.)

2. Raise crawler using a 9072 kg (10 ton) floor jack andsupport machine using shop stands. Machine must behigh enough so track guides and rock guards will clearchain when removed.

3. Disconnect track chain. (See procedure in this group.)

4. Remove A-frame bearing (C) to A-frame (D) capscrews.

IMPORTANT: Operating machine with loose A-framebearing-to-A-frame cap screws cancause mating surfaces of the A-framebearing and A-frame to be damaged. Ifwear is not extreme, a liquid steel fillercan be used to fill in gaps between thedowel pin and A-frame surfaces.

5. If A-frame bearing requires service, swing rear guardopen and remove bolting bar. Remove inner mountingbracket (B) and slide A-frame bearing (C) off pivotshaft (A).



PN=157

Track System

010130

86

TX,0130,SS2419 –19–13JUN95–2/3

T84

07A

D–U

N–2

0MA

Y95

A—Bracket CapB—Retainers

6. Remove two sprocket segments so inner guard willclear planetary housing.

CAUTION: The approximate weight of trackframe is 780 kg (1750 lb).

7. Connect a chain and hoist to track frame.

8. Remove bracket cap (A) and retainers (B). Slide trackframe off pivot shaft.

TX,0130,SS2419 –19–13JUN95–3/3

T58

17A

N–U

N–2

6OC

T88

A—Dowel PinB—Pivot ShaftC—ShimsD—A-Frame BearingE—Inner Mounting Bracket

IMPORTANT: Operating unit with loose pivot shaftbolts can cause pivot shaft bracket andfinal drive housing mating surfacesdamage.

9. Remove cap screws from pivot shaft (B) and innermounting bracket (E).

10. Remove pivot shaft (B) with dowel pin (A), A-framebearing (D), and shims (C).

11. Inspect dowel pin (A). If dowel pin needs to bereplaced, machine mating surfaces flat beforereplacing dowel pin.

12. Inspect pivot shaft for wear or damage. Replace ifnecessary.

13. Remove O-ring on shaft.


PN=158

Track System

01013087

TX,0130,DY180 –19–14MAR96–1/1

Welding Procedure

IMPORTANT: Before welding on this machine: Toavoid electronic component damage,turn the electrical (battery) disconnectswitch off.

• Turn (S2) electrical (battery) disconnect switch OFF.• Clamp the welding ground clamp as close to the point

of welding as possible.• Never attach welding ground clamp to a track pad.• Remove dirt, oil and paint from areas to be welded.• Use 5/32 inch diameter low hydrogen AWS-ASTM

E-7018 covered electrode.

NOTE: Flux covering on low hydrogen electrodes readilytakes on moisture which causes weldingproblems. Be sure electrodes are dry. Electrodesstored in open containers should be suspected ofcontaining excessive moisture and may requirebaking prior to use.

Use AC or DC reversed polarity welding currentELECTRODE POSITIVE (+). The suggested amperage is100—115 amps.


PN=159

Track System

010130

88

TX,0130,SS2422 –19–13JUN95–1/3

Remove and Install A-Frame Bearing andA-Frame Bushings

T60

70A

X–U

N–2

6OC

T88

A—A-Frame BearingB—Seal CupC—SealsD—Bearing

1. Remove seal cup (B) and oil seals (C).

2. Remove bearing (D) from A-Frame bearing (A) usingan 85 mm bearing driver disk for 750C or 87 mmbearing driver disk for 850C and a press.

TX,0130,SS2422 –19–13JUN95–2/3

T61

22A

L–U

N–2

6OC

T88

A—Outer BushingB—SealC—Inner Bushing

3. Remove seal.

4. Remove inner bushing (C) and outer bushing (A).

5. Install new bushings (A and C) into track frame evenwith bore edge.

6. Install new seal (B).



PN=160

Track System

01013089

TX,0130,SS2422 –19–13JUN95–3/3

T60

70A

X–U

N–2

6OC

T88

A—A-Frame BearingB—Seal CupC—Oil Seal (2 used)D—Bearing

7. Push bearing (D) into A-Frame bearing (A) even withbore edge using a 75 mm and 95 mm bearing driverdisk and a press.

8. Install oil seals (C) with lip toward outside.

9. Install cup (B) with flat side toward bottom of bore.


PN=161

Track System

010130

90

TX,0130,SS2424 –19–23JUL04–1/7

Install Track Frame

T84

77A

H–U

N–3

1MA

Y95

Pivot Shaft

1—Cap Screw (4 used) 7—Pin 13—Bearing 18—Shaft2—Washer (4 used) 8—Cap Screw (4 used) 14—Shim (as required) 19—Washer3—Cap 9—Cap 15—Bracket 20—Pipe Plug4—Retainer (2 used) 10—Bearing (A-frame) 16—Washer (8 used) 21—O-Ring5—Dowel Pin 11—Seal (2 used) 17—Cap Screw (4 used) 22—Fitting6—Adapter 12—Bushing



PN=162

Track System

01013091

TX,0130,SS2424 –19–23JUL04–2/7

T60

77A

X–U

N–2

6OC

T88

Pivot Shaft

A—Cap Screw (4 used)B—Shims (as required)C—SealsD—Cap Screw (4 used)

1. Position pivot shaft on dowel pin final drive housing.

2. Before installing, apply clean oil to cap screws (D).

3. Tighten cap screws, using a cross pattern beginningwith top outside cap screw.

Specification750C—Pivot Shaft-to-Final-DriveHousing Cap Screw—TorqueTurn 270 N•m (200 lb-ft) + 1/4 Turn

(90°)...........................................................

850C—Pivot Shaft-to-Final-DriveHousing Cap Screw—TorqueTurn 295 ± 29 N•m (218 ± 22 lb-ft) +

1/3 Turn (120°).........................................................

4. Apply multipurpose grease to A-frame bearing seals(C).

5. Carefully install A-frame bearing on pivot shaft.

6. Install inner mounting bracket on pivot shaft.

7. Use shims (B) to fill gap between inner mountingbracket and main frame.

8. Before installing, apply clean oil to cap screws (A).

9. Tighten cap screws (A) using a cross pattern so thebottom outside cap screw is tightened last.

Specification750C—Pivot Shaft InnerMounting Bracket-to-Main FrameCap Screw—Torque 732 N•m (540 lb-ft)....................................................850C—Pivot Shaft InnerMounting Bracket-to-Main FrameCap Screw—Torque Turn 207 ± 21 N•m (152 ± 15 lb-ft) +

1/3 Turn (120°).......................



PN=163

Track System

010130

92

TX,0130,SS2424 –19–23JUL04–3/7

T60

73A

M–U

N–2

6OC

T88

Special Washer

A—Special WasherB—O-RingC—Pivot Shaft

10. Install new O-ring (B) in special washer (A).

11. Make sure special washer (A) is free of grease or oil.Apply plastic gasket to O-ring side of special washer(A).

12. Apply petroleum jelly to pivot shaft (C) and slidespecial washer (A) with O-ring (B) on pivot shaft (C).

TX,0130,SS2424 –19–23JUL04–4/7

T20

1849

A–U

N–2

3JU

L04

Special Washer on Mounting Bracket

1—Pivot Shaft-to-Frame Final Drive Housing Bracket2—Washer with O-Ring

13. Slide special washer with O-ring (2) on to the pivotshaft to the mounting braket (1). Use clamps tosecure washer to bracket while the plastic gasket isallowed to cure. Make sure the washer is clampedtightly and evenly to the bracket.



PN=164

Track System

01013093

TX,0130,SS2424 –19–23JUL04–5/7

T60

74A

K–U

N–2

6OC

T88

Pivot Shaft Bushings

B—SealC—Bushing

14. Make sure pivot shaft bore and bushings (C) in trackframe are clean.

15. Clean A-frame bearing and A-frame mating surfaceswith clean and cure primer. Apply plastic gasket toA-frame surface only. Apply clean grease to seal (B)lip.

16. Carefully slide track frame on pivot shaft.

IMPORTANT: A-frame-to-A-frame bearing dowel pinmust fit tight or damage can occur tothe frame surfaces.

17. Assemble dowel pin, A-frame, A-frame bearing andinstall cap screws. Tighten cap screws tospecification.

SpecificationA-Frame Bearing-to-A-Frame CapScrews—Torque 495 N•m (365 lb-ft)..........................................................

TX,0130,SS2424 –19–23JUL04–6/7

T60

73A

Q–U

N–2

6OC

T88

Retainers

A—RetainersB—Cap

18. Install retainers (A).

19. Clean cap (B) and track frame mating surfaces.

20. Apply plastic gasket to cap. Install cap.

21. Install lock washers and cap screws. Tighten capscrews to specification.

SpecificationPivot Shaft Cap-to-Track FrameCap Screws—Torque 550 N•m (400 lb-ft)..................................................


PN=165


Track System

010130

94

TX,0130,SS2424 –19–23JUL04–7/7

T60

74A

I–U

N–2

6OC

T88

Fill and Check Plug

A—Oil Level Inspection PlugB—Fill Plug

22. Remove fill plug (B) and oil level inspection plug (A).

23. Add recommended oil until oil comes out of oil levelinspection plug hole. (See Track Rollers, Front Idler,Carrier Roller and Track Frame Outer Pivot, Group0004.)

24. Install plugs.

25. Install sprocket segments. (See Remove and InstallSprocket Segments in this group).

26. Connect track chain . (See procedure in this group.)

27. Lower machine to ground and adjust track sag. (SeeAdjust Track Sag in this group.)


PN=166

Track System

01013095

TX,0130,SS2462 –19–13JUN95–1/1

Remove and Install Wear Strip on InnerGuide

T60

49A

F–U

N–2

6OC

T88

A—Clamping LocationsB—Weld 6.4 mm (0.25 in.) Fillet WeldC—Weld 6.4 mm (0.25 in.) Fillet WeldD—Wear StripE—Weld 6.4 mm (0.25 in.) Fillet Weld

1. Separate track and remove idler. (See procedures inthis group.)

2. Remove wear strip. Grind inner guide surface smooth.

3. Center wear strip lengthwise from edges of inner guideto insure equal length overhang for welding welds (B).

4. Any bow in wear strip (D) should be oriented up beforeclamping. Clamp wear strip (D) at locations (A) flushwith and all along surface of inner guide.


Good welds are important. Have only aqualified welder install this kit. UseE7018 electrodes. Before welding, cleanall dirt and paint from the weld areas.Connect the welder ground clamp closeto each weld area so electrical currentdoes not pass through any bearings.

5. Weld (E) must be even with or below wear stripsurface (D). Weld sequence is critical to preventcracking after welding. Weld location (E) first, then (C)and (B) using 6.4 mm (0.25 in.) fillet weld.

6. Wear strip surface (D) must be free of weld and weldsplatter.

7. Install idler and reconnect track. (See procedure in thisgroup.)


PN=167

Track System

010130

96

TX,0130,SS2463 –19–13JUN95–1/4

Remove and Install Track Frame Upper WearStrips

T60

49A

G–U

N–2

6OC

T88

T84

09B

B–U

N–2

0MA

Y95

1—Wear Strip2—Track Frame (850C)3—Track Frame (750C)4—Inner Edge5—Machined Edge

1. Separate track and remove front idler. (See procedurein this group.)

2. Reverse wear strips (1).

3. Grind lower bar and track frame wear surfaces smooth.Area must be free of weld spatter.

4. Make sure the battery disconnect switch is turned tothe "OFF" position.

If machine is a 750C, go to step 5.

If machine is a 850C, go to step 9.

5. Position wear strip (1) even with inner edge (4) of trackframe and against machined surface edge (5).



PN=168

Track System

01013097

TX,0130,SS2463 –19–13JUN95–2/4

T84

09B

C–U

N–2

2MA

Y95

1—7.0 mm (0.28 in.) Groove Weld2—6.0 mm (0.24 in.) Fillet Weld3—96 mm (3.8 in.) Length of Welds4—136 mm (6.1 in.)


Good welds are important. Have only aqualified welder install this kit. UseE7018 electrodes. Before welding, cleanall dirt and paint from the weld areasand turn battery disconnect switch to"OFF". Connect the welder groundclamp close to each weld area soelectrical current does not pass throughany bearings.

6. Weld two 7.0 mm (0.28 in.) groove welds (1) on inneredge using E7018 Electrodes for dimension shown.

7. Grind surface area smooth and even with surface.

8. Weld a 6.0 mm (0.24 in.) fillet weld (2) across eachend of wear strip. Go to step 12.

TX,0130,SS2463 –19–13JUN95–3/4

T60

49A

J–U

N–2

6OC

T88

1—Machined Edge2—Wear Strip3—12 mm (0.47 in.)4—Track Frame Inner Edge

9. Position wear strip (2) against machined surface edge(1) and 12 mm (0.47 in.) from track frame inner edge(4).



PN=169

Track System

010130

98

TX,0130,SS2463 –19–13JUN95–4/4

T60

49A

L–U

N–2

6OC

T88

1—Fillet Welds (6 used)2—Welds Centered on Wear Strip

10. Use E-7018 Electrodes to weld strips to frame.

11. Weld six 4.5 mm (0.19 in.) fillet welds (1) 51 mm (2.0in.) in length in the locations shown. Welds (2) arecentered on wear strip.

12. Make sure there is no weld spatter on wear stripsurfaces.

13. Install front idler and reconnect track. (See procedurein this group.)

TX,0130,DU1393 –19–11AUG93–1/1

Remove and Install Track Frame Lower WearStrips

T60

49A

N–U

N–2

6OC

T88

T60

49A

M–U

N–2

6OC

T88

1—Lower Block2—Wear Strip3—Clamp Locations4—10 mm (0.39 in.)

1. Remove track and front idler. (See procedure in thisgroup.)

2. Remove wear strip (2) from lower block (1) using airarc.

3. Grind lower bar surface smooth.

4. Position wear strips (2) so edge is even with blockedge (1) using locating dimension (4).

5. Clamp wear strip in locations (3) shown.


PN=170

Track System

01013099

TX,0130,DU1394 –19–11AUG93–1/3

Remove and Install Track Frame Wear StripBar

T60

50A

C–U

N–2

6OC

T88

1—Block2—Welds

1. Remove track and front idler. (See procedure in thisgroup.)

2. Remove block (1) from track frame.

3. Grind welds (2) smooth.

TX,0130,DU1394 –19–11AUG93–2/3T

6050

AD

–UN

–26O

CT

88

1—Lower Bar2—750C—86 mm (3.39 in.), 850C—63 mm (2.5 in.)3—750C—87.5 mm (3.44 in.), 850C—92.5 mm (3.64 in.)4—Track Frame

4. Position lower bar (1) with beveled edges down usingdimensions shown. The larger beveled edge goesagainst track frame (4).

5. Clamp lower bar (1) to frame.



PN=171

Track System

010130,100

TX,0130,DU1394 –19–11AUG93–3/3

T60

50A

E–U

N–2

6OC

T88

1—6.0 mm (0.24 in.) Fillet Weld2—Lower Bar3—6 mm (0.24 in.) Groove Weld with 5 mm (0.20

in.) Penetration4—6.0 mm (0.24 in.) Fillet Weld Both Ends

IMPORTANT: Good welds are important. Have only aqualified welder install this kit. UseE7018 electrodes. Before welding, cleanall dirt and paint from the weld areasand turn battery disconnect switch to"OFF". Connect the welder groundclamp close to each weld area soelectrical current does not pass throughany bearings.

6. Weld lower bar to track frame using E7018 electrodeper weld symbols (1, 3 and 4).

7. Groove weld (3) must be even with lower bar surface(2).

8. Lower bar surface (2) must be free of spatter.

9. Install idler and track chain. (See procedure in thisgroup.)

TX,9020,YY996 –19–13JUN95–1/1

Measure Front Idler Wear

T96

419

–UN

–27O

CT

88

100 percent worn is the maximum allowable height offlange for rebuilding wear surface.

Measure height of flange using a depth gauge such as theJT05521 200 mm Ruler, JT05534 Right AngleAttachment, and D05231ST 300 mm Ruler fromJT05518A Undercarriage Inspection Kit.

Specification750C New Flange—Height 19.0 mm (0.75 in.)...........................................850C New Flange—Height 22.5 mm (0.89 in.)...........................................750C 100 Percent Worn Flange—Height 25.5 mm (1.0 in.).............................................................................850C 100 Percent Worn Flange—Height 28.8 mm (1.13 in.)...........................................................................

NOTE: See 750C and 750C-LGP Front Idler FlangeHeight , 750C Series II Front Idler Flange Height ,or 850C, 850C Series II, and 850C-LGP FrontIdler Flange Height in Undercarriage AppraisalManual SP326 for additional information.


PN=172

Track System

010130,101

TX,0130,SS2428 –19–13JUN95–1/1

Remove Front Idler

T60

44B

E–U

N–2

6OC

T88

1—Cap Screws2—Deflector3—Lifting Fork

NOTE: Removal procedures are similar for the 750C and850C.

1. Disconnect track chain. (See procedure in this group).

2. Attach lifting fork (3) to front idler and hoist.

3. Remove deflectors (2).

4. Remove yoke to guide block cap screws (1).

CAUTION: Approximate weight of front idler is175 kg (385 lb).

5. Remove idler.


PN=173

Track System

010130,102

TX,0130,SS2429 –19–13JUN95–1/3

Disassemble Front Idler

T60

44B

W–U

N–2

6OC

T88

1—Cap Screw (8 used)2—Special Washer (8 used)3—Outer Guide (2 used)4—Shim (as required)5—Shim (as required)6—Plug7—O-Ring8—Tapped Strip (4 used)9—Cap Screw (2 used)10—Special Washer (2 used)11—Lock (2 used)12—Right-Hand Block13—Shim (as required)14—Shim (as required)15—Inner Guide Wear Strip16—Inner Guide17—Cap Screw (8 used)

NOTE: Disassembly of 750C and 850C idler are similar.

1. Remove cap screws (1 and 17) and outer guide (3).

2. Loosen cap screw (9). Strike head of cap screw todislodge lock (11).

3. Remove cap screw (9) and push lock (11) down toremove lock and remaining parts as shown.

4. Turn idler over and repeat the above steps.

5. Inspect all parts for excessive wear or damage.Replace wear strips on inner guide if necessary. (Seeprocedure in this group.)



PN=174

Track System

010130,103

TX,0130,SS2429 –19–13JUN95–2/3

T60

44B

V–U

N–2

6OC

T88

1—O-Ring (2 used)2—Metal Faced Seal (2 used)3—Cap Screw (12 used)4—Washer (12 used)5—Bushing Assembly (2 used)6—Idler Shaft7—Front Idler Shell

NOTE: Tape metal face seals together to keep them inmatched sets.

6. Remove metal face seals (2) and tape together.

7. Remove O-ring (1) from shaft (6).

8. Remove cap screws (3) and washers (4).

9. Turn idler over and repeat above steps.

10. Using a press push shaft with bushing assembly (5)out of idler. Turn idler over and push the otherbushing assembly from idler using the sameprocedure. Bushing assemblies are a press fit.

11. Inspect parts for excessive wear or damage. Replaceparts as necessary.

TX,0130,SS2429 –19–13JUN95–3/3T

8137

9–U

N–2

6OC

T88

1—Bushing2—Disk

NOTE: DO NOT remove bushing from bushing caseunless replacement of parts is necessary.

12. Remove bushing (1) from bushing case using a disk(2) and press.


PN=175

Track System

010130,104

TX,0130,DU1400 –19–11AUG93–1/3


T85

079

–UN

–24A

UG

93






TX,0130,DU1400 –19–11AUG93–2/3

T85

080

–UN

–05D

EC

96

A—Seal RingB—Worn Area (shaded area)C—Inner Half of Seal Ring FaceD—Sealing Area (dark line)

2. Illustration shows examples of worn seal rings (A).

I—Sealing area (D) is in inner half of seal ring face (C).

II—Sealing area (D) not concentric with ID and OD ofseal ring.



PN=176

Track System

010130,105

TX,0130,DU1400 –19–11AUG93–3/3

T82

840

–UN

–23F

EB

89



Apply a thin film of oil to seal ring face. Put face of sealrings together and hold using tape.

TX,0130,DU1401 –19–11AUG93–1/1

Exploded View of Front Idler

T60

44B

X–U

N–2

4AU

G93

1—Cap Screw (8 used) 9—Cap Screw (2 used) 17—Cap Screw (4 used) 24—Bushing Case (2 used)2—Special Washer (8 used) 10—Special Washer (2 used) 18—Seal (2 used) 25—Bushing (2 used)3—Outer Guide (2 used) 11—Lock (2 used) 19—Idler Shaft 26—Pin (4 used)4—Shim (as required) 12—Right-Hand Block 20—Cap Screw (12 used) 27—Bushing Case with5—Shim (as required) 13—Shim (as required) 21—Lock Washer (12 used) Bushing (2 used)6—Plug (2 used) 14—Shim (as required) 22—O-Ring (4 used) 28—O-Ring (2 used)7—O-Ring (2 used) 15—Inner Guide Wear Strip 23—Metal Faced Seal (2 used) 29—Front Idler8—Tapped Strip (4 used) 16—Inner Guide

NOTE: Right and left side of idler are the same. Rightside shown.


PN=177

Track System

010130,106

TX,0130,SS2432 –19–13JUN95–1/13

Assemble Front Idler

T84

04B

G–U

N–2

0MA

Y95

Lower Track Roller Shown

1—Bushing2—Dowel Pin3—Bushing Case4—Disk (107 mm)5—O-Ring Groove6—Alignment Mark

NOTE: Track roller and front idler procedures are thesame. Track roller shown where noted.

1. Using a straightedge mark the bushing (1) from thecenter line of the dowel pin holes (both sides) to thecenterline of dowel pins (2). Align the marks (6) on thebushing with the dowel pins in the bushing case (3).

2. Press bushing into case.



PN=178

Track System

010130,107

TX,0130,SS2432 –19–13JUN95–2/13

T80

440

–UN

–26O

CT

88

Lower Track Roller Shown

1—Bushing Case2—Bushing Aligning Studs3—Idler4—Disk (107 mm)5—Pipe

3. Install bushing case (1) using studs, 107 mm disk (4),pipe (5) and a press.

4. Remove aligning studs. Install cap screws and lockwashers. Tighten cap screws to specification.

SpecificationBushing Case-to-Idler CapScrew—Torque 47 N•m (35 lb-ft)................................................................



PN=179

Track System

010130,108

TX,0130,SS2432 –19–13JUN95–3/13

T84

20A

B–U

N–1

6FE

B95

5. Turn idler over and carefully install idler shaft.

Install the idler shaft with the vent hole on top of theshaft and the retaining notches facing toward thefront of the machine. The vent hole will always bethe hole closest to the fill plug end of the shaft. Ifthe idler assembly has been installed on a machine,orientation of the vent hole can be verified byremoving the fill plug and using a bent wire toprobe for the vent hole. The vent hole is locatedclosest to the fill plug.

NOTE: After installing the shaft and if the idler is lyingon its side, oil can be added without theJD-313 Tool by pouring the oil through theplug end of the shaft. Add 532—621 ml (18—21 oz) of SAE 80W90 gear oil.

6. Repeat above procedure.

TX,0130,SS2432 –19–13JUN95–4/13

T60

45A

C–U

N–2

6OC

T88

1—O-Ring

7. Install inner guide.

8. Install O-ring (1).


PN=180


Track System

010130,109

TX,0130,SS2432 –19–13JUN95–5/13

T81

382

–UN

–26O

CT

88

9. Remove grease from seal bore in block and bushingcases using a volatile, non-petroleum base solvent. Besure seal bores are clean and dry.

TX,0130,SS2432 –19–13JUN95–6/13

T80

574

–UN

–26O

CT

88

1—Rubber Seal2—Metal Ring

IMPORTANT: The metal face seal must be extremelyclean during assembly. Use a volatile,non-petroleum base type solvent toclean the metal seal ring (2) and rubberseal (1). DO NOT keep the rubber sealin a volatile, non-petroleum base typesolvent for more than one minute. Wipethe seals dry with lint-free tissue toremove fingerprints and foreignmaterial.

10. Install the rubber seal (1) on the metal ring (2). Besure the rubber seal sits evenly on the metal sealring.

TX,0130,SS2432 –19–13JUN95–7/13

T60

77A

V–U

N–2

6OC

T88

1—Seal Ring Flange2—JDG204 Seal Installation Tool3—O-Ring

11. Position seal assembly in the JDG204 SealInstallation Tool (2) so tool lip is between seal ringflange (1) and O-ring (3).



PN=181

Track System

010130,110

TX,0130,SS2432 –19–13JUN95–8/13

T81

384

–UN

–26O

CT

88

1—JDG204 Seal Installation Tool2—Seal

NOTE: A volatile, non-petroleum base solvent or talcumpowder may be used as a lubricant. SolventMUST NOT damage the O-rings or leave an oilresidue.

12. Push down on JDG204 Seal Installation Tool (1) withuniform pressure until rubber seal (2) is belowretainer lip in bushing and block bores.

TX,0130,SS2432 –19–13JUN95–9/13

T60

46A

J–U

N–2

6OC

T88

3—Idler Shaft

13. Apply a thin film of 80W90 gear oil to shiny sealingarea on metal seal rings. Make sure the rubber sealsare free of oil.

14. Apply NEVER-SEEZ lubricant or equivalent on bothends of idler shaft (3) from O-ring outward. Make sureouter end of idler shaft is completely covered.



PN=182

Track System

010130,111

TX,0130,SS2432 –19–13JUN95–10/13

T60

46A

D–U

N–2

6OC

T88

1—Lock2—Block3—Cap Screw

15. Carefully install block (2). Do not damage O-ring ormetal face seals.

16. Put NEVER-SEEZ lubricant or equivalent on lock (1)before installation.

17. Push down on block to install lock. DO NOT use ahammer on the block to compress metal face seals.

18. Install and tighten lock cap screw (3) to specification.

SpecificationIdler Lock Cap Screws—Torque 54 N•m (40 lb-ft).....................................


TX,0130,SS2432 –19–13JUN95–11/13T

6046

AE

–UN

–26O

CT

88

19. Seat tapered lock using a hammer and punch. Hitlock at least three times. Tighten lock cap screw tospecification.

SpecificationIdler Lock Cap Screws—Torque 54 N•m (40 lb-ft).....................................

20. Repeat above step three more times. Be sure lock isfully seated.

21. Turn block and shaft several times to make sure themetal face seals are together.



PN=183

Track System

010130,112

TX,0130,SS2432 –19–13JUN95–12/13

T60

46A

C–U

N–2

6OC

T88

1—Tapped Straps2—Shims3—Outer Guide

22. Do front idler leakage test to check seals. (Seeprocedure in this group.)

23. Install tapped straps (1) between idler and innerguide.

24. Install shims (2) and outer guide (3).

25. Install cap screws and tighten finger tight.

TX,0130,SS2432 –19–13JUN95–13/13

T60

46A

H–U

N–2

6OC

T88

1—Shims

26. Install shims (1).

NOTE: If there are extra shims, then washers must beplaced between shims and top of inner guide andalso between cap screw head and shims.

27. Loosely install washers and cap screws.

28. Install front idler on unit. (See procedure in thisgroup.)

29. Install track on unit. (See procedure in this group.)


PN=184

Track System

010130,113

TX,0130,SS2435 –19–13JUN95–1/1

Install Front Idler

T60

44B

E–U

N–2

6OC

T88

T60

46A

I–U

N–2

6OC

T88

1—Cap Screw (4 used)2—Deflector (2 used)3—Fork4—JD313A Front Idler Lube Nozzle Kit

IMPORTANT: Do not use a welded shell idler with acast shell idler on the same machine.

1. Attach fork (3) to front idler and hoist.

2. Position idler on track frame. Check orientation of idlershaft oil vent and fill holes. (See Assemble Front Idlerin this group.)

3. Install yoke to guide block cap screws (1) andwashers. Tighten cap screws to specification.

SpecificationTrack Adjuster Yoke-to-GuideBlock Cap Screws—Torque 576 N•m (425 lb-ft)........................................

4. Install deflectors (2). Tighten cap screws tospecification.

SpecificationDeflector-to-Guide Block CapScrews—Torque 163 N•m (120 lb-ft)..........................................................

5. Use nozzle from JD313A Front Idler Lube Nozzle Kit tofill idler. Thoroughly clean nozzle (4) and around theplug end of idler shaft.

6. Insert nozzle (4) in idler shaft as far as it will go withthe flat up.

NOTE: Idler capacity is approximately 568 mL (19.2 oz).

7. Add oil to idler until oil without air bubbles leaks pastthe flat on nozzle. (See Group 0004, for recommendedoil.)

8. Install O-ring and plug.

9. Adjust idler on track frame. (See procedure in thisgroup.)

10. Install track. (See procedure in this group.)


PN=185

Track System

010130,114

TX,0130,SS2436 –19–13JUN95–1/1

Adjust Front Idler Vertical Movement

T60

36A

G–U

N–0

1NO

V88

T60

43B

F–U

N–0

1NO

V88

T60

50A

F–U

N–2

6OC

T88

A—Gap 3 mm (0.120 in.) MaximumB—BlockC—Wear StripD—Cap Screw (2 used)E—Shim (as required)F—Track FrameG—Wear StripH—Inner GuideI—3 mm (0.120 in.) Minimum

IMPORTANT: If front idler vertical gap is excessive,the ability to finish grade with thecrawler is affected. Also track adjusterdamage may result.

1. Drive crawler so front idler is on a block of wood or apile of dirt approximately 153 mm (6 in.) high.

2. Check the gap (A) between the guide block assembly(B) and the wear strip (C) on both sides of the idler.

SpecificationGuide Block Asembly-to-WearStrip—Gap 3 mm (0.120 in.) Maximum.......................................................

3. If gap exceeds specification remove two cap screws(D). Loosen outer guide cap screws.

4. Pry up between inner guide and guide block assembly.Insert shims (E), between top of block (B) and innerguide, as needed. Set gap to specification.

SpecificationGuide Block Asembly-to-WearStrip—Gap 0—1 mm (0—0.040 in.)............................................................

5. If more than 3 mm (0.120 in.) shim pack is required,the J-bar and lower track frame wear strips may needreplacing. Install new wear strips if either wear stripthickness is less than specification. (See procedure inthis group.)

SpecificationJ-Bar and Lower Track FrameWear Strip—Thickness 3 mm (0.120 in.) Minimum.....................................

6. Install washer, excess shims (E), washer and capscrews (D). Tighten all cap screws to specification.

SpecificationInner Guide Cap Screws—Torque 325 N•m (240 lb-ft)..............................


PN=186

Track System

010130,115

TX,9020,YY1009 –19–22MAR95–1/1

Adjust Front Idler Horizontal Movement

T61

21A

C–U

N–2

6OC

T88

A—GapB—Gap, innerC—Shims (As Required)D—Shims (As Required)E—Gap, innerF—Gap

NOTE: Idler horizontal adjustments for the 750C and850C are similar.

1. Center idler between track frame so dimensions (B andE) are equal.

2. Remove outer guides if required. Adjust right outerguide with shims (C) so the two dimensions (B and F)are equal.

3. Adjust left outer guide with shims (D) so the twodimensions (A and E) are equal.

4. Tighten idler guide cap screws to specification.

SpecificationIdler Guide Cap Screws—Torque 325 N•m (240 lb-ft)...............................


PN=187

Track System

010130,116

TX,0130,SS2437 –19–13JUN95–1/1

Test Front Idler for Oil Leakage

T80

612

–UN

–26O

CT

88

1—JT05494 O-Ring Fitting (7/16 -20 M 37° x 3/4-16 M ORB)

2—JT03001 Tee Fitting (7/16 -20 M 37° x 7/16 -20F 37° Sw x 7/16 -20 M 37°)

3—JT03017 Pressure Hose4—Pressure Gauge 0—689 kPa (0—6.89 bar) (0—

100 psi)5—JT03087 Snubber Valve6—Regulator with Gauge

1. Remove plug from idler shaft.

NOTE: Idler oil capacity is approximately 532—621 mL(18—21 oz).

2. Fill idler shaft with recommended oil. (See TrackRollers, Front Idler, Carrier Roller and Track FrameOuter Pivot, Group 0004.)

3. Turn idler several times to seat metal face seals.

4. Assemble fittings (1 and 2), hose (3), regulator withgauge (6) and valve (5).

5. Pressurize idler with air to specification.

SpecificationFront Idler Leakage Test—AirPressure 117 ± 10 kPa (1 ± 0.2 bar) (17 ±

3 psi)................................................

6. Close valve (5) and wait for two minutes. Make sureidler maintains air pressure and oil does not leak pastthe metal face seals or O-rings.

7. If idler leaks oil or does not maintain pressure, checkO-rings or seals. Repair as necessary and recheck forleaks.

8. Install plug in end of idler shaft and tighten tospecification.

SpecificationIdler Shaft Plug—Torque 60 N•m (45 lb-ft).................................................


PN=188

Track System

010130,117

TX,0130,SS2356 –19–13JUN95–1/1

Remove and Install Sprocket Segment

T83

90B

A–U

N–2

0MA

Y95

A—Sprocket SegmentB—Cap Screw

1. Move machine forward to locate sprocket segment tobe removed.

2. Lower equipment to the ground and stop engine.

3. Remove cap screws (B) and remove sprocket segment(A).

NOTE: If the machine is driven in one direction themajority of the time, most of the wear will occuron one side of the teeth. To extend life, thesprockets can be switched from one side of themachine to the other, which causes the chain towear on the opposite face of the tooth.

4. Remove all paint, oil, grease, or other foreign materialfrom the mounting surface of the sprocket andplanetary housing.

5. Install sprocket segment. Apply plastic gasket tothreads of cap screws. Tighten cap screw tospecification.

SpecificationSprocket Segment Cap Screws,Normal Conditions—Torque 712 N•m (525 lb-ft)........................................

For machines run in extreme conditions or with rearmounted equipment, apply plastic gasket to threads of capscrews and tighten to specification.

SpecificationSprocket Segment Cap Screws,Extreme Conditions or RearMounted Equipment—TorqueTurn 136 N•m (100 lb-ft) + 1/3 Turn

(120°)...........................................................

6. Continue this procedure until all sprocket segments areremoved and installed.


PN=189

Track System

010130,118


PN=190

Group 0199Dealer Fabricated Tools

0101991

CED,OUO1020,3001 –19–12OCT98–1/1

DFT1087 Track Recoil Spring Compression Tool Guard

T71

62A

F–U

N–1

7OC

T89

A—3/16 in. 1020 CR Steel Plate C—1/2 in. Nut (2 used) D—1/2 x 2 in. Cap Screw (2 E—1/2 x 3 in. Steel RoundB—9/16 in. Hole (2 places) used) Stock (2 used)

DFT1087 Track Recoil Spring Compression ToolGuard is used with ST4920 Track Recoil SpringCompression Tool.

Material required:

• 3/16 in. 1020 CR Steel Plate• 1/2 in. Nut (2 used)• 1/2 x 2 in. Cap Screw (2 used)• 1/2 x 3 in. Steel Round Stock (2 used)


PN=191

Dealer Fabricated Tools

010199

2

TX14826,0003243 –19–14DEC01–1/1

DFT1041 Track Nut Removal Tool

T66

90A

H–1

9–20

MA

R89

Track Nut Removal Tool is used to remove and installtrack shoe nuts.


PN=192


0101993

CED,OUO1020,3002 –19–12OCT98–1/4

ST4920 Track Recoil Spring CompressionTool

T65

85U

Y–U

N–2

4MA

R98

A—Nut (12 used)B—Stud (4 used)C—HolderD—Eyebolt (2 used)E—Supporting PlateF—Base PlateG—Base (4 used)H—Cap Screw (8 used)I—Lock Washer (8 used)

NOTE: It is recommended that DFT1087 Track RecoilSpring Compression Tool Guard be used withST4920 Track Recoil Spring Compression Tool.

ST4920 Track Recoil Spring Compression Tool is thesame as used on other machines except for the holder(C). For each JD314A or JD314B Track SpringCompressor Kit use the holder with the correct size holefor the track spring compressor kit nut.

Compression tool is used with a hydraulic jack tocompress recoil spring.

Material required:

• ST4047 Eyebolt (SAE Grade 5) (2 used)• ST4050 Nut (SAE Grade 5) (12 used)• ST4046 Cap Screw (SAE Grade 5) (8 used)• ST4045 Stud (SAE Grade 8) (4 used)• ST4049 Lock Washer• ST4041 Base (50.0 x 50.0 x 6.0 mm) 90° Angle Stock• 1020 HR Steel Plate for:• ST4035 Holder• ST4036 Holder• ST4037 Holder• ST4040 Supporting Plate• ST4042 Base Plate



PN=193


010199

4

CED,OUO1020,3002 –19–12OCT98–2/4

T70

29C

I–U

N–0

6JU

L89

ST4920 Track Recoil Spring Compression Tool

B—Stud (4 used) C—Holder



PN=194


0101995

CED,OUO1020,3002 –19–12OCT98–3/4

T70

29C

H–U

N–0

6JU

L89


PN=195



010199

6

CED,OUO1020,3002 –19–12OCT98–4/4

T70

29C

G–U

N–0

6JU

L89

ST4920 Track Recoil Spring Compression Tool

A—Nut (12 used) D—Eyebolt (2 used) H—Cap Screw (8 used) I—Lock Washer (8 used)


PN=196

Section 02Axles and Suspension Systems

Contents

Page

Group 0201—Drive Axle Housing and SupportService Equipment and Tools . . . . . . . . . . . .02-0201-1 02Other Material . . . . . . . . . . . . . . . . . . . . . . . .02-0201-1Specifications . . . . . . . . . . . . . . . . . . . . . . . .02-0201-2Remove and Install Final Drive Axle Housing

And Support . . . . . . . . . . . . . . . . . . . . . . .02-0201-3

Group 0250—Axle Shaft, Bearings and ReductionGears

Service Equipment and Tools . . . . . . . . . . . .02-0250-1Other Material . . . . . . . . . . . . . . . . . . . . . . . .02-0250-1Specifications . . . . . . . . . . . . . . . . . . . . . . . .02-0250-2Planet Carrier Housing Assembly Cross

Section . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-4Remove and Install Planet Housing. . . . . . . .02-0250-5Disassemble and Assemble Planet Carrier

Housing . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-8Remove Ring Gear, Hub and Sprocket

Frame . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-10Disassemble and Assemble Ring Gear

Hub and Sprocket Frame. . . . . . . . . . . . .02-0250-12Inspect Metal Face Seals . . . . . . . . . . . . . .02-0250-13Install Gear, Hub and Sprocket Frame . . . .02-0250-14Remove and Install Final Drive Housing

Assembly. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-17Disassemble and Assemble Final Drive

Housing Cover Assembly. . . . . . . . . . . . .02-0250-20

Group 0299—Dealer Fabricated ToolsDealer Fabricated Tools . . . . . . . . . . . . . . . .02-0299-1DFT1079 Final Drive Lifting Fixture

Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0299-2DFT1078 Final Drive Lifting Fixture . . . . . . . .02-0299-4


PN=1

Contents

02


PN=2

Group 0201Drive Axle Housing and Support

0202011CED,OUO1020,3012 –19–14OCT98–1/3




CED,OUO1020,3012 –19–14OCT98–2/3

Final Drive Lifting Fixture . . . . . . . . . . . . . . . DFT1078

Used to remove final drive assembly.

CED,OUO1020,3012 –19–14OCT98–3/3

Final Drive Lifting Fixture Adapter . . . . . . . . . . DFT1079

Used to remove final drive assembly with DFT1078 whenusing a hoist.

CED,OUO1020,3013 –19–14OCT98–1/1

Other Material

Number Name Use

T43514 (U.S.) Plastic Gasket Apply on mating surfaces of finalTY9475 (Canadian) drive and main frame.277 (LOCTITE) Apply to threads of hydrostatic motor

retaining cap screws.

T43512 (U.S.) Thread Lock and Sealer (Medium Apply to threads of sprocket segmentTY9473 (Canadian) Strength) cap screws.242 (LOCTITE)

LOCTITE is a registered trademark of Loctite Corp.


PN=199

Drive Axle Housing and Support

020201

2

CED,OUO1020,3014 –19–14OCT98–1/1

Specifications


750C Pivot Shaft-to-Final Drive Cap Torque Turn 270 N•m (200 lb-ft) + 1/4 Turn (90°)Screws

850C Pivot Shaft-to-Final Drive Cap Torque Turn 295 N•m (218 lb-ft) + 1/3 Turn (120°)Screws

3/4 in. Final Drive-to-Main Frame Torque 495 N•m (365 lb-ft)(Exterior) Cap Screws

M20 Transmission Motor-to-Park Torque 675 N•m (500 lb-ft)Brake Plate Cap Screws

7/8 in. Final Drive-to-Main Frame Torque 800 N•m (590 lb-ft)(Internal) Cap Screws

Sprocket Segment Cap Screws Torque 542 N•m (400 lb-ft)

Drain Plug Torque 74 N•m (54 lb-ft)

Fill Plug Torque 74 N•m (54 lb-ft)


PN=200


0202013

TX,0210,SS2357 –19–13JUN95–1/5

Remove and Install Final Drive Axle HousingAnd Support

T61

62A

O1

–UN

–18O

CT

88T

8394

AA

–UN

–20M

AY

95T

8394

AB

–UN

–20M

AY

95

A—Drain PlugB—Cap ScrewC—Sprocket SegmentsD—Cap Screws

NOTE: Remove the final drive as an assembly whenreplacing the final drive housing.

1. Disconnect track chain. (See Remove and Install TrackChain in Group 0130.)

NOTE: Final drive oil capacity is approximately:

750C (S.N.—831315 ) Inner Final Drive (eachside) — 24 L (6.25 gal)

750C (S.N. 831316— ) Inner Final Drive (eachside) — 20 L (5.25 gal)

750C LGP Inner Final Drive (each side) — 27.8 L(7.35 gal)

850C (S.N.—822867) Inner Final Drive (eachside) — 15 L (3.5 gal)

850C LGP Inner Final Drive (S.N.—822867) (eachside) — 25.6 L (6.75 gal)

850C (S.N. 822868—) Inner Final Drive (eachside) — 12.3 L (3.25 gal)

850C LGP Inner Final Drive (S.N. 822868—)(each side) — 38 L (10 gal)

Outer final drive (each side) — 12.3 L (3.25 gal)

2. Remove drain plug (A) to drain oil from final drivehousing.

3. Remove cap screws (B) and remove sprocket shield.

4. Remove two sprocket segments (C) from planetaryhub. Rotate final drive so that the removed sectionsare at the bottom.

5. Remove pivot shaft to final drive housing cap screws(D).


PN=201



020201

4

TX,0210,SS2357 –19–13JUN95–2/5

T83

94A

C–U

N–2

0MA

Y95

T83

94A

D–U

N–2

0MA

Y95

B—Cap Screw (5 used)C—Cap Screw (2 used)D—Cap Screw (4 used)E—Cap Screw (6 used)F—Final Drive Lifting ToolG—Attachment Final Drive Lifting ToolH—Park Brake Line and FittingI—Pivot Shaft Support

6. Remove rear transmission access cover and bottommain frame access covers.

NOTE: Final drive shown removed for clarity of location ofcap screws.

7. Remove exterior final drive to main frame cap screws(B) except for two (C).

CAUTION: The approximate weight of final driveaxle housing is 726 kg (1600 lb).

8. Attach DFT1078 Final Drive Lifting Tool (F) (seesection 0299 for instructions to make tool) to the toptwo 5/8 in. tapped holes in final drive housing.

9. Attach DFT1079 Final Drive Lifting Tool Adapter (G)(see section 0299 for instructions to make tool) toDFT1078 and a hoist.

10. Remove six internal cap screws (E) which attach finaldrive to main frame.

11. Remove four cap screws (D) from transmission motorto park brake plate.

12. Remove park brake line and fitting (H) from finaldrive.

13. Place blocking between bottom of main frame andhydrostatic transmission motor to support motor.

14. Pry motor inward away from park brake plate.

15. Remove two remaining exterior cap screws (C). Pryfinal drive housing out of the dowel on pivot shaftsupport (I). Remove final drive assembly.

16. Thoroughly clean final drive housing and main framesurfaces.

17. Inspect O-ring on hydrostatic transmission motorflange. Replace if necessary.


PN=202



0202015

TX,0210,SS2357 –19–13JUN95–3/5

T61

62A

R–U

N–1

8OC

T88

T83

94A

B–U

N–2

0MA

Y95

T83

94A

H–U

N–2

0MA

Y95

B—Track Frame PinC—Cap Screw LocationD—Cap ScrewE—Cap Screw LocationF—Cap Screw LocationG—Cap Screw Location

18. Apply plastic gasket on mating surfaces of final driveand main frame.

IMPORTANT: When installing the final driveassembly, all of the transmission tofinal drive cap screws must betightened evenly until flange gap isclosed. Then tighten cap screws tospecifications.

19. Install final drive housing, align track frame pin (B).Apply clean oil to cap screws (D) and install pivotshaft to final drive cap screws. Tighten only fingertight.

NOTE: Final drive removed for clarity of cap screwslocation.

20. Install six exterior cap screws (C).

21. Align hydrostatic motor output shaft with final drivesplines. Install motor.

22. Apply plastic gasket to threads of cap screws andinstall cap screws in location (F).

23. Install six interior main frame to final drive housingcap screws in location (G).

24. Remove final drive lifting brackets and install capscrews (E).

Tighten cap screws (D), using a cross patternbeginning with top outside cap screw.

Specification750C Pivot Shaft-to-Final DriveCap Screws—Torque Turn 270 N•m (200 lb-ft) + 1/4 Turn

(90°)........................

850C Pivot Shaft-to-Final DriveCap Screws—Torque Turn 295 N•m (218 lb-ft) + 1/3 Turn

(120°)........................


PN=203



020201

6

TX,0210,SS2357 –19–13JUN95–4/5

25. Tighten all cap screws evenly.

Specification3/4 in. Final Drive-to-Main Frame(Exterior) Cap Screws—Torque 495 N•m (365 lb-ft)..................................M20 Transmission Motor-to-ParkBrake Plate Cap Screws—Torque 675 N•m (500 lb-ft)..............................7/8 in. Final Drive-to-Main Frame(Internal) Cap Screws—Torque 800 N•m (590 lb-ft)...................................

26. Check inner mounting bracket on pivot shaft-to-mainframe shim pack. (See Install Track Frame in Group0130.)



PN=204


0202017

TX,0210,SS2357 –19–13JUN95–5/5T

8394

AA

–UN

–20M

AY

95T

6162

AO

–UN

–18O

CT

88

A—Fill plugB—Cap ScrewsC—Sprocket Segments

27. Connect park brake line and fitting from final drive.

28. Apply thread lock and sealer (medium strength) tothreads of cap screws. Install sprocket segments (C)and cap screws. Tighten cap screws to specification.

SpecificationSprocket Segment Cap Screws—Torque 542 N•m (400 lb-ft).........................................................................

29. Install sprocket shield and cap screws (B). Tightencap screws.

IMPORTANT: O-rings must be seated in groove of fillplug (A) to prevent leakage.

30. Remove fill plug (A).

31. Install and tighten drain plug with O-ring. Tighten plugto specification.

SpecificationDrain Plug—Torque 74 N•m (54 lb-ft).........................................................

32. Fill final drive housing with recommended oil tobottom edge of fill plug (A) hole. (See Fuels andLubricants, Group 0004.)

33. Install and tighten fill plug (A) with O-ring. Tightenplug to 74 N•m (54 lb-ft).

SpecificationFill Plug—Torque 74 N•m (54 lb-ft).............................................................

34. Connect chain. (See Remove and Install Track Chainin Group 0130.)


PN=205


020201

8


PN=206

Group 0250Axle Shaft, Bearings and Reduction Gears

0202501CED,OUO1020,3019 –19–15OCT98–1/2




CED,OUO1020,3019 –19–15OCT98–2/2

Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . . JT01748

Used to remove sprocket frame and final drive housingassemblies.

CED,OUO1020,3017 –19–15OCT98–1/1

Other Material

Number Name Use

T43514 (U.S.) Plastic Gasket Apply to machined surface ofTY9475 (Canadian) sprocket frame before assembly.277 (LOCTITE) Apply to pinion shaft and dowel

counterbores of planet carrierhousing.Apply to planet carrier cover capscrews before assembly.Apply to final drive housing andcover mating surfaces.

T43512 (U.S.) Thread Lock and Sealer (Medium Apply to threads of sprocket segmentTY9473 (Canadian) Strength) cap screws before installation.242 (LOCTITE) Apply to threads of final drive

housing pinion shaft quill cap screws.

TY16285 (U.S.) Cure Primer Used to clean planet carrier coverCXTY16285 (Canadian) cap screw threads.7649 (LOCTITE) Used to clean final drive housing and

cover mating surfaces.Used to clean final drive housingpinion shaft quill cap screws.

LOCTITE is a registered trademark of Loctite Corp.LOCTITE is a trademark of Loctite Corp.


PN=207

Axle Shaft, Bearings and Reduction Gears

020250

2

CED,OUO1020,3018 –19–15OCT98–1/1

Specifications


Planetary Housing-to-Sprocket Torque 130 N•m (95 lb-ft)Frame Cap Screws

Sprocket Segment Cap Screws Torque 542 N•m (400 lb-ft)

Planet Carrier Cover Cap Screws Torque 302 N•m (236 lb-ft)

Planet Pinion Assembly End Play 0—0.305 mm (0—0.012 in.)

Retainer Plate-to-Ring Gear Cap Torque 320 N•m (236 lb-ft)Screws

Final Drive Housing Cover Cap Torque 320 N•m (236 lb-ft)Screws

Final Drive Housing Drain Plug Torque 74 N•m (54 lb-ft)

Final Drive Housing Fill Plug Torque 74 N•m (54 lb-ft)

Final Drive Shaft Quill-to-Final Drive Torque 74 N•m (55 lb-ft)Housing Cover Cap Screws

Final Drive Shaft Assembly (To Bearing Setting 0.064 mm (0.0025 in.)Check Proper Assembly) preload-to-0.323 mm (0.0127 in.) end

play

Sun Pinion Shaft (To Check Proper End Play 0—0.28 mm (0.0—0.011 in.)Assembly)


PN=208


0202503


PN=209


020250

4

TX,0250,SS2364 –19–13JUN95–1/2

Planet Carrier Housing Assembly Cross Section

T83

95A

B–U

N–2

0MA

Y95

Planet Carrier Housing Assembly Cross Section—750C Shown



PN=210


0202505TX,0250,SS2364 –19–13JUN95–2/2

1—Snap Ring 750C, Snap Ring 11—Pinion Shaft Quill 21—Bearing Cup 30—Ring Gear Huband Cup Spacer 850C 12—Cap Screw (6 used) 22—Bearing Cup 31—Hollow Dowel (3 used)

2—Retaining Ring 13—Snap Ring 23—Cap Screw (15 used) 32—Planet Carrier3—O-Ring 14—Snap Ring 24—Sprocket Segment (5 33—Sun Pinion Shaft4—Cap Screw (5 used) 15—Sun Pinion Shaft used) 34—Bearing Cone5—Sprocket Frame 16—Seal 25—Cap Screw (25 used) 35—Retainer Plate6—Oil Seal 17—Final Drive Gear 26—Planet Carrier Cover 36—Bearing Cone7—Bearing Cup (10 used) 18—Final Drive Housing 27—Planetary Ring Gear 37—Planet Pinion Shaft (38—Bearing Cone (10 used) 19—Final Drive Housing Cover 28—Plug (4 used) used)9—Final Drive Pinion Shaft 20—Washer (22 used) 29—O-Ring (4 used) 38—Planet Pinion (3 used)10—Cap Screw (22 used)

TX,0250,SS2366 –19–13JUN95–1/5

Remove and Install Planet Housing

T83

96A

F–U

N–2

0MA

Y95

A—Cap Screws (25 used)B—Drain PlugC—Sprocket ShieldD—Fill Plug

NOTE: Planet housing with pinions and shaft can beremoved without removing final drive housingassembly. Removal and installation of 750C and850C planet housing are similar. 750C shown.

1. Position crawler with planet housing drain plug (B)toward ground.

2. Disconnect track chain. (See Remove Track Chain,Group 0130.)

NOTE: Planet housing oil capacity is approximately 13.75L (3.5 gal).

3. Remove plug (B) to drain oil from planet housing.

4. Remove outer sprocket shield (C).

5. Remove cap screws (A) and sprocket segments.



PN=211


020250

6

TX,0250,SS2366 –19–13JUN95–2/5

T61

63A

K–U

N–1

8OC

T88

T61

63A

L–U

N–1

8OC

T88

A—Planetary Housing-to-Sprocket Frame Cap Screw(5 used)

B—Planetary Housing Jack Screw (3 used)C—Planetary Housing AssemblyD—Sprocket FrameE—Lift Strap

CAUTION: The approximate weight of planetaryhousing assembly is 175 kg (285 lb).

6. Place lifting strap (E) around cover and attach strap tohoist.

7. Remove five cap screws (A).

8. Separate planetary housing assembly (C) fromsprocket frame (D) using three cap screws (B) as jackscrews.

9. Carefully remove housing assembly.

TX,0250,SS2366 –19–13JUN95–3/5

T61

63A

J–U

N–1

8OC

T88

A—O-RingB—Machined Surface

10. Clean sprocket frame and planetary housing covermating surfaces.

11. Install O-ring (A).

12. Apply plastic gasket to machined surface (B) ofsprocket frame.

TX,0250,SS2366 –19–13JUN95–4/5

T61

63A

K–U

N–1

8OC

T88

A—Planet Housing Assembly Cap Screw (5 used)

13. Align planetary gears with sun pinion shaft and ringgear and install planetary housing assembly.

14. Install and tighten cap screws (A) to specification.

SpecificationPlanetary Housing-to-SprocketFrame Cap Screws—Torque 130 N•m (95 lb-ft).........................................


PN=212



0202507

TX,0250,SS2366 –19–13JUN95–5/5T

8396

AF

–UN

–20M

AY

95

A—Cap Screws (25 used)B—Drain PlugC—Sprocket ShieldD—Fill Plug

15. Apply thread lock and sealer (medium strength) tothreads of cap screws (A). Install sprocket segmentsand cap screws. Tighten cap screws (A) tospecification.

SpecificationSprocket Segment Cap Screws—Torque 542 N•m (400 lb-ft).........................................................................

16. Install sprocket shield (C), washers, and cap screws.Tighten cap screws.

17. Remove fill plug (D).

IMPORTANT: O-rings must be seated in groove ofplugs (B and D) to prevent leakage.

18. Install and tighten drain plug (B) with O-ring. Tightenplug to specification.

SpecificationDrain Plug—Torque 74 N•m (54 lb-ft).........................................................

19. Fill planet housing with recommended oil to bottomedge of fill plug (D) hole. (See Fuels and Lubricants,Group 0004.)

20. Install and tighten fill plug (D) with O-ring. Tightenplug to specification.

SpecificationFill Plug—Torque 74 N•m (54 lb-ft).............................................................

21. Connect track chain. (See Install Track Chain, Group0130.)


PN=213


020250

8

CED,OUO1020,3144 –19–10NOV98–1/2

Disassemble and Assemble Planet Carrier Housing

T83

96A

N–U

N–2

0MA

Y95

Planet Carrier Housing Assembly—750C Shown

1—Plug (2 used) 5—Bearing Cone (6 used) 8—Snap Ring (3 used) 11—Planet Carrier Cover2—O-Ring (2 used) 6—Bearing Cup (6 used) 9—Planet Pinion Gear (3 used) 12—Hollow Dowel (3 used)3—Cap Screw (5 used) 7—Planet Pinion Shaft (3 10—Cap Screw (9 used) 13—Planet Carrier Housing4—O-Ring used)

1. Remove cap screws (10).

2. Install three cap screws in threaded holes of cover(11) and tighten evenly to separate cover fromplanetary housing (13).

3. Install an M20 x 120 cap screw into pinion shaft (7)and tighten to remove planet pinion assembly.

4. Bearing cones (5) are a press fit. Remove bearingcones from shaft (7) using a press.

5. Remove bearing cups (6), snap ring (8) and hollowdowels (12).

6. Inspect all parts. Replace if necessary.

7. Clean housing counterbores.

8. Apply plastic gasket to pinion shafts and hollowdowels counterbores.

9. Press pinion shafts and hollow dowels into housingto bottom of counterbore.


PN=214



0202509

CED,OUO1020,3144 –19–10NOV98–2/2

T61

67A

F–U

N–1

8OC

T88

Pinion Gear Assembly—850C Shown

T83

96A

T–U

N–2

0MA

Y95

A—Pinion GearB—Bearing CupC—SpacerD—Snap Ring

10. For 750C only, install snap ring (D) and bearing cups(B) tight against snap ring using a disk and press.

11. For 850C only, install snap ring (D), cup spacer (C)with slot toward snap ring and bearing cups (B) tightagainst spacer using a disk and press.

12. Heat bearing cones to 121°C (250°F) in a bearingoven.

13. Install lower bearing cone, gear assembly, and upperbearing cone on pinion shaft.

14. Clean threads of cap screws (10) and threaded holesin housing (13) with clean and cure primer.

15. Install cover (11). Apply plastic gasket to threads ofcap screws (10). Tighten cap screws to pull coveronto dowels evenly. Tighten cap screws tospecification.

SpecificationPlanet Carrier Cover CapScrews—Torque 302 N•m (236 lb-ft)..........................................................

16. Using a dial indicator and a pry bar check end playfor proper assembly of parts. End play must be tospecification.

SpecificationPlanet Pinion Assembly—EndPlay 0—0.305 mm (0—0.012 in.)................................................................


PN=215


020250

10

TX,0250,SS2365 –19–13JUN95–1/3

Remove Ring Gear, Hub and Sprocket Frame

T83

96A

O–U

N–2

0MA

Y95

1—Planetary Ring Gear 4—Retainer Ring 7—Sprocket Frame 10—Retainer Plate2—Cap Screw (6 used) 5—Bearing Cone 8—Bearing Cone 11—Metal Face Seal3—Ring Gear Hub 6—Bearing Cup 9—Bearing Cup

1. Disconnect track chain. (See procedure in Group0130.)

2. Remove planetary housing. (See procedure in thisgroup).

3. Remove retainer plate (10).


PN=216



02025011TX,0250,SS2365 –19–13JUN95–2/3

CAUTION: Approximate weight of planetaryring gear is 36 kg (80 lb). The approximateweight of ring gear hub is 30 kg (65 lb).

NOTE: Ring gear and hub can be removed togetheror in separate pieces by removing retainingring (4).

4. Remove ring gear (1) and hub (3).

TX,0250,SS2365 –19–13JUN95–3/3T

8398

AP

–UN

–20M

AY

95

A—Sprocket Frame AssemblyB—Metal Face Seals

CAUTION: Approximate weight of sprocketframe assembly is 86 kg (190 lb).

5. Attach lifting bracket and a hoist to sprocket frameassembly.

6. Remove sprocket frame assembly (A).

IMPORTANT: Metal face seals can be reused if theyare not worn or damaged. Used sealsmust be kept together as a set becauseof wear patterns on seal ring face.

7. Remove metal face seals (B). Keep seals together asa matched set.


PN=217


020250

12

TX,0250,SS2381 –19–30MAY01–1/1

Disassemble and Assemble Ring Gear Hub and Sprocket Frame

T83

97A

A–U

N–2

0MA

Y95

1—Ring Gear Hub 3—Bearing Cup 5—Bearing Cup 7—Final Drive Housing Cover2—Bearing Cone 4—Sprocket Frame 6—Bearing Cone

1. Remove bearing cups (3 and 5) from sprocketframe (4). Bearing cups are a press fit.

NOTE: If holes are not present in ring gear hub (1),drill and tap holes to accommodate the 17 1/2ton puller set from SERVICE-GARD.

2. Remove ring gear hub (1) using 17 1/2 ton pullerset from SERVICE-GARD (DO1173AA).

3. Remove bearing cone (2) from ring gear hub (1).Bearing cone is a press fit.

4. Remove bearing cone (6) from final drive housingcover (7). Bearing cone is a press fit.

5. Heat bearing cones (2 and 6) to 121°C (250°F) in abearing oven.

6. Install bearing cone (2) tight against shoulder ofring gear hub.

7. Install bearing cone (6) tight against final drivehousing cover shoulder.

8. Install bearing cups (3 and 5) tight against sprocketframe (4) shoulder using a press.


PN=218


02025013

TX,0130,SS2370 –19–13JUN95–1/2


T85

079

–UN

–24A

UG

93






TX,0130,SS2370 –19–13JUN95–2/2

T82

840

–UN

–23F

EB

89A—Seal Face



4. Apply a thin film of oil to seal ring face. Put face ofseal rings together and hold using tape.


PN=219


020250

14

TX,0250,SS2373 –19–30MAY01–1/3

Install Gear, Hub and Sprocket Frame

T61

72A

E–U

N–1

8OC

T88

A—Sprocket Frame CounterboreB—Retention BarbC—Seal Ring AssemblyD—Rubber Seal

1. Thoroughly clean final drive housing cover andsprocket frame counterbore (A).

2. Position seal ring assembly (C) squarely in front ofcounterbore.

3. Apply even pressure symmetrically on seal ringassembly and push into counterbore. Seal ringassembly must "POP" into counterbore, so rubber sealis tight against seal bore shoulder.

4. DO NOT tear retention barb. Carefully push onretention barb (B) with a blunt end instrument to makesure seal is to bottom of counterbore.

5. Wipe both sealing ring faces dry with lint free wipers.

6. Carefully apply final drive oil to shiny sealing area onmetal seal rings.



PN=220


02025015

TX,0250,SS2373 –19–30MAY01–2/3

T83

98A

P–U

N–2

0MA

Y95

A—Sprocket FrameB—Seal Ring Assembly

IMPORTANT: When sprocket frame is installed andmetal seal rings touch each other, theaxial pressure must be maintained,compressing seals until planetary ringgear is installed and cap screwstightened. If pressure is not maintained,seal ring may be tilted in rubber seal.Seal installation must be done again ifseal ring becomes tilted in rubber seal.

7. Make sure seal ring assemblies (B) are installedcorrectly.

8. Carefully install sprocket frame (A). Keep sprocketframe tight against final drive housing cover until ringgear hub is installed.



PN=221


020250

16

TX,0250,SS2373 –19–30MAY01–3/3

T83

98A

Q–U

N–2

0MA

Y95

A—Ring Gear HubB—Retainer PlateC—Snap RingD—Cap Screw (6 used)E—Ring Gear

9. Apply grease to splines and align ring gear hub (A)with final drive cover splines and install ring gear hub(A).

10. Using larger cap screws install retainer plate (B).

11. Apply plastic gasket to cap screw (D) threads.

12. Install and tighten cap screws (D) to 320 N•m (236lb-ft).

SpecificationRetainer Plate-to-Ring Gear CapScrews—Torque 320 N•m (236 lb-ft)..........................................................

13. Attach a strap and hoist and install ring gear (E).

14. Install snap ring (C) to hold ring gear in place.

15. Install planetary housing assembly. (See procedure inthis group.)

16. Connect track chain. (See Remove and Install TrackChain in Group 0130.)

17. Fill final drive housing with recommended oil to fillplug level. (See Fuels and Lubricants, Group 0004.)


PN=222


02025017

TX,0250,SS2382 –19–13JUN95–1/3

Remove and Install Final Drive HousingAssembly

T83

99A

P–U

N–2

0MA

Y95

T83

98A

O–U

N–2

0MA

Y95

A—M16 Guide Studs (2 used)B—Final Drive Cap Screw (22 used)C—Jack Screw (2 used)D—Drain PlugE—Fill Plug

1. Disconnect track chain. (See Remove and Install TrackChain in Group 0130.)

2. Remove planetary housing. (See procedure in thisgroup.)

3. Remove ring gear, hub and sprocket frame. (Seeprocedure in this group.)

NOTE: Final drive oil capacity is approximately:

750C (S.N.—831315 ) Inner Final Drive (eachside) — 24 L (6.25 gal)

750C (S.N. 831316— ) Inner Final Drive (eachside) — 20 L (5.25 gal)

750C LGP Inner Final Drive (each side) — 27.8 L(7.35 gal)

850C (S.N.—822867) Inner Final Drive (eachside) — 15 L (3.5 gal)

850C LGP Inner Final Drive (S.N.—822867) (eachside) — 25.6 L (6.75 gal)

850C (S.N. 822868—) Inner Final Drive (eachside) — 12.3 L (3.25 gal)

850C LGP Inner Final Drive (S.N. 822868—)(each side) — 38 L (10 gal)

Outer final drive (each side) — 12.3 L (3.25 gal)

4. Remove plug (D) to drain oil from final drive housing.

5. Remove two cap screws and install two M16 guidestuds (A).

6. Clean threaded holes on back side of final drivehousing and install two M16 x 50 jack screws (C) toremove final drive housing.


PN=223



020250

18

TX,0250,SS2382 –19–13JUN95–2/3

T83

98A

O–U

N–2

0MA

Y95

A—M16 Guide Studs (2 used)B—Final Drive Cap Screw (22 used)C—Jack Screw (2 used)D—Drain PlugE—Fill Plug

CAUTION: Approximate weight of final drivehousing assembly is 188 kg (415 lb).

7. Attach a JT01748 Lifting Bracket to threaded hole infinal drive cover and attach chain and hoist.

8. Remove final drive cap screws (B).

9. Slowly remove final drive housing by using the two jackscrews (C) to separate housing.

10. Clean final drive housing and cover mating surfaceswith cure primer.

11. Apply plastic gasket to final drive housing and covermating surfaces.

12. Install final drive housing cover assembly.

13. Install all cover cap screws (B), remove guide studsand install remaining cap screws and tighten capscrews to specification.

SpecificationFinal Drive Housing Cover CapScrews—Torque 320 N•m (236 lb-ft)..........................................................



PN=224


02025019

TX,0250,SS2382 –19–13JUN95–3/3

T83

99A

P–U

N–2

0MA

Y95

D—Drain PlugE—Fill Plug

14. Install ring gear, hub and sprocket frame andplanetary housing. (See procedures in this group.)

15. Install and tighten drain plug (D) with O-ring. Tightenplug to specification.

SpecificationFinal Drive Housing Drain Plug—Torque 74 N•m (54 lb-ft).............................................................................

16. Fill final drive housing with recommended oil tobottom edge of fill plug hole. (See Fuels andLubricants, Group 0004.)

17. Install and tighten fill plug (E) with O-ring. Tightenplug to specification.

SpecificationFinal Drive Housing Fill Plug—Torque 74 N•m (54 lb-ft).............................................................................

18. Connect track chain. (See Install Track Chain inGroup 0130.)


PN=225


020250

20

TX,0250,SS2383 –19–13JUN95–1/6

Disassemble and Assemble Final Drive Housing Cover Assembly

T83

96A

P–U

N–2

5MA

Y95

1—Final Drive Housing Cover 5—Retaining Ring 9—Washer (22 used) 12—Pinion Shaft Quill2—Sun Pinion Shaft 6—Final Drive Gear 10—Cap Screw (22 used) 13—Cap Screw (22 used)3—Oil Seal 7—Snap Ring 11—Final Drive Pinion Shaft 14—Final Drive Housing4—Bearing Cone (4 used) 8—Bearing Cup (4 used)



PN=226


02025021

TX,0250,SS2383 –19–13JUN95–2/6

T83

98A

A–U

N–2

0MA

Y95

4—Bearing Cones (2 used)11—Pinion Shaft

1. Remove the snap ring (7). Remove sun pinion shaft (2)using a press.

2. Remove final drive gear (6).

3. Remove cap screws (13), final drive shaft quill (12),and pinion shaft (11).

4. Remove bearing cup (8) from quill (12).

5. Remove retaining ring (5).

6. Remove bearing cones (4), cups (8), and oil seal (3)from final drive housing cover (1) using a driver.

7. Remove bearing cup (8) from final drive pinion shaft(11) hole in final drive housing cover (1).

8. Remove bearing cones (4) from final drive pinion shaft(11).

TX,0250,SS2383 –19–13JUN95–3/6

T83

98A

B–U

N–2

0MA

Y95

A—Final Drive Pinion Shaft Bearing CupB—Oil SealC—Bearing Cup (2 used)D—Bearing Cone (2 used)E—Snap Ring

9. Install bearing cup (A) tight against shoulder in finaldrive housing cover.

10. Install oil seal (B) 6 mm (0.24 in.) below bearing borewith lip (spring side) toward bearing.

11. Install cup (C), two bearing cones (D), and cup (C)using a press.

12. Install retaining ring (E).



PN=227


020250

22 TX,0250,SS2383 –19–13JUN95–4/6

T83

98A

A–U

N–2

0MA

Y95

4—Bearing Cone (2 used)11—Final Drive Pinion Shaft

13. Heat bearing cones (4) to 121°C (250°F) in bearingoven.

14. Install bearing cones tight against shoulders on finaldrive pinion shaft (11).

TX,0250,SS2383 –19–13JUN95–5/6

T83

98A

C–U

N–2

0MA

Y95

A—Final Drive Pinion ShaftB—QuillC—Cap Screw (6 used)

15. Install bearing cup into pinion shaft quill using adriver.

16. Install final drive pinion shaft (A),

17. Install quill (B).

18. Clean threads of cap screws (C) with cure primer.

19. Apply thread lock and sealer (medium strength) tothreads of cap screws. Install cap screws (C) andtighten to specification.

SpecificationFinal Drive Shaft Quill-to-FinalDrive Housing Cover CapScrews—Torque 74 N•m (55 lb-ft)..............................................................

NOTE: No shimming required, bearings are preset.

20. To assure proper assembly of the final drive pinionshaft, measure shaft end play with dial indicator. Endplay should be to specification.

SpecificationFinal Drive Shaft Assembly—Bearing Setting 0.064 mm (0.0025 in.)

preload-to-0.323 mm (0.0127 in.)end play

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



PN=228


02025023

TX,0250,SS2383 –19–13JUN95–6/6

T83

98A

D–U

N–2

0MA

Y95

T83

98A

N–U

N–2

0MA

Y95

A—Lip Side of GearB—Sun Pinion ShaftC—Snap Ring

21. Install final drive gear with lip side of gear (A) towardbearings.

NOTE: Support final drive gear hub while pressing pinionshaft into position.

22. Install sun pinion shaft (B) through bearing assemblyand into ring gear using a press.

23. Install snap ring (C).

24. To set bearings, tap on ring gear side of sun pinionshaft with a soft faced hammer.

25. To assure proper assembly of sun pinion shaft. Checkshaft end play with dial indicator. End play should beto specification.

SpecificationSun Pinion Shaft—End Play 0—0.28 mm (0.0—0.011 in.)........................


PN=229


020250

24


PN=230


TX,02,BA2028 –19–17JUN97–1/1


• DFT1079 Adapter• DFT1078 Final Drive Lifting Fixture

0202991


PN=231


020299

2

TX,9900,DU1506 –19–24AUG93–1/2

DFT1079 Final Drive Lifting Fixture Adapter

T80

66A

F–U

N–0

8SE

P93



PN=232


0202993TX,9900,DU1506 –19–24AUG93–2/2

1—3.18 mm (0.13 in.) Fillet 8—1/2-13 UNC x 1.250 Cap 16—86.4 mm (3.4 in.) 24—127 mm (5.0 in.)Weld (2 places) Screw (3 used) 17—203.8 mm (8.0 in.) 25—81.3 mm (3.2 in.)

2—6.35 mm (0.25 in.) Fillet 9—76.2 mm (3 in.) 18—38.1 mm (1.5 in.) 26—81.28 mm (2.9 in.)Weld (2 places) 10—31.8 mm (1.25 in.) 19—38.1 mm (1.5 in.) 27—27.9 mm (1.1 in.)

3—330.2 mm (13.0 in.) 11—6.4 mm (0.25 in.) 20—25.4 mm (1.0 in.) 28—112.5 mm (4.43 in.)4—1447.8 mm (57.0 in.) 12—76.2 mm (3.0 in.) Stock 21—127 mm (5.0 in.) 29—214.1 mm (8.43 in.)5—0.76 mm (0.03 in.) 13—38.1 mm (1.5 in.) Stock 22—9.5 mm (0.36 in.) 30—254 mm (10.0 in.)6—1.52 mm (0.06 in.) 14—4.76 mm (0.19 in.) 23—9.5 mm (0.36 in.) 31—45°7—1/2-13 UNC Nut (3 used) 15—90.8 mm (3.56 in.)


PN=233


020299

4

TX,9900,DU1505 –19–25MAR94–1/2

DFT1078 Final Drive Lifting Fixture

T80

66A

E–U

N–1

2AP

R94



PN=234


0202995TX,9900,DU1505 –19–25MAR94–2/2

1—6 mm (0.25 in.) Fillet Weld 10—38.1 mm (1.5 in.) 17—342 mm (13.46 in.) 25—9.5 mm (0.38 in.) Stock(8 places) 11—13.5 mm (0.531 in.) Drill 18—196.9 mm (7.75 in.) 26—51 mm (2.0 in.)

2—242 mm (9.52 in.) Three Holes 19—88.9 mm (3.5 in.) 27—50.8 mm (2.0 in.)3—4.7 mm (0.19 in.) Stock 12—127 mm (5.0 in.) Stock 20—127 mm (5.0 in.) Stock 28—50.8 mm (2.0 in.) Stock4—21.8 mm (0.86 in.) 13—63.5 mm (2.5 in.) 21—19 mm (0.75 in.) 29—609.6 mm (24 in.) Radius,5—12.7 mm (0.5 in.) 14—14 mm (0.55 in.) Radius (4 22—25.4 mm (1.0 in.) Back Side Only6—294.6 mm (11.6 in.) places) 23—17.5 mm (0.69 in.) Drill (4 30—12.7 mm (0.5 in.)7—81.3 mm (3.2 in.) 15—43.2 mm (1.7 in.) places) 31—45°8—21.6 mm (0.85 in.) 16—394.3 mm (15.53 in.) 24—19 mm (0.75 in.) 32—101.6 mm (4.0 in.)9—86.4 mm (3.4 in.)


PN=235


020299

6


PN=236

Section 03Transmission

Contents

Page Page

Group 0300—Remove and Install Group 0360—Hydrostatic SystemEssential Tools . . . . . . . . . . . . . . . . . . . . . . .03-0300-1 Essential Tools . . . . . . . . . . . . . . . . . . . . . . .03-0360-1Service Equipment and Tools . . . . . . . . . . . .03-0300-2 Service Equipment and Tools . . . . . . . . . . . .03-0360-1Other Material . . . . . . . . . . . . . . . . . . . . . . . .03-0300-2 Other Material . . . . . . . . . . . . . . . . . . . . . . . .03-0360-2Specifications . . . . . . . . . . . . . . . . . . . . . . . .03-0300-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . .03-0360-3Remove and Install Hydrostatic Pumps . . . . .03-0300-4 Disassemble Hydrostatic Pump. . . . . . . . . . .03-0360-6Remove and Install Hydrostatic Motors . . . .03-0300-11 Disassemble and Assemble Charge 03Hydrostatic Motor Speed Sensor Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-15

Adjustment. . . . . . . . . . . . . . . . . . . . . . . .03-0300-14 Disassemble and Assemble PumpHydrostatic Pump and Motor Initial Start-Up Displacement Control Valve (PDCV) . . . .03-0360-16

Procedure . . . . . . . . . . . . . . . . . . . . . . . .03-0300-15 Remove and Install Multi-Function Valve. . .03-0360-17Remove and Install Charge Pressure

Manifold. . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-18Group 0315—Control LinkageDisassemble and Assemble Multi-FunctionEssential Tools . . . . . . . . . . . . . . . . . . . . . . .03-0315-1

Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-19Service Equipment and Tools . . . . . . . . . . . .03-0315-1Assemble Hydrostatic Pump . . . . . . . . . . . .03-0360-20Other Material . . . . . . . . . . . . . . . . . . . . . . . .03-0315-2Disassemble and Assemble Oil CoolerSpecifications . . . . . . . . . . . . . . . . . . . . . . . .03-0315-3

Bypass Valve. . . . . . . . . . . . . . . . . . . . . .03-0360-30Remove and Install Steering Pedal . . . . . . . .03-0315-6Disassemble Hydrostatic Motor . . . . . . . . . .03-0360-30Disassemble and Assemble FNR ControlAssemble Hydrostatic Motor . . . . . . . . . . . .03-0360-41Assembly—Pedal Steer (S.N. —Remove and Install Hydrostatic Oil Filter. . .03-0360-50XXXXXX). . . . . . . . . . . . . . . . . . . . . . . . . .03-0315-8

FNR Control Assembly ComponentGroup 0399—Dealer Fabricated ToolsLocation—Pedal Steer (S.N. —DFT1063 Pump Lifting Bracket . . . . . . . . . . .03-0399-1XXXXXX). . . . . . . . . . . . . . . . . . . . . . . . .03-0315-10DFT1130 Adapter . . . . . . . . . . . . . . . . . . . . .03-0399-2FNR and Neutral Start SwitchDFT1132 Hydrostatic Motor Removal andAdjustment—Pedal Steer (S.N. —

Installation Tool . . . . . . . . . . . . . . . . . . . . .03-0399-3XXXXXX). . . . . . . . . . . . . . . . . . . . . . . . .03-0315-11DFT1137 Hydrostatic Motor Removal andDisassemble and Assemble FNR Control

Installation Tool . . . . . . . . . . . . . . . . . . . . .03-0399-4Assembly—Single Lever Steer (S.N. —DFT1164 Speed Sensor Adjusting Tool . . . .03-0399-5XXXXXX). . . . . . . . . . . . . . . . . . . . . . . . .03-0315-14

FNR Control Assembly ComponentLocation—Single Lever Steer (S.N. —XXXXXX). . . . . . . . . . . . . . . . . . . . . . . . .03-0315-16

FNR and Neutral Start SwitchAdjustment—Single Lever Steer (S.N. —XXXXXX). . . . . . . . . . . . . . . . . . . . . . . . .03-0315-17

Single Lever ControlExploded View. . . . . . . . . . . . . . . . . . . . .03-0315-22Remove and Install . . . . . . . . . . . . . . . . .03-0315-24

Disassemble and Assemble Single LeverControl Linkage (SLC) With Speed InGrip (S.N. XXXXXX— ) . . . . . . . . . . . . . .03-0315-25

Rotary Sensor Component Location With(SIG) Speed In Grip (S.N. XXXXXX—). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0315-42

Park Lock Linkage Adjustment . . . . . . . . . .03-0315-44


PN=1

Contents

03


PN=2

Group 0300Remove and Install

CED,OUO1020,3164 –19–01DEC98–1/4

Essential Tools


0303001


CED,OUO1020,3164 –19–01DEC98–2/4

Pump Lifting Bracket . . . . . . . . . . . . . . . . . . DFT1063

To remove hydrostatic pumps.

Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . DFT1130

Used with DFT1063 to remove hydrostatic pumps.

CED,OUO1020,3164 –19–01DEC98–3/4

Hydrostatic Motor Removal and InstallationTool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DFT1132

Used to remove and install hydrostatic motor.

Hydrostatic Motor Removal and InstallationTool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DFT1137

Used to remove and install hydrostatic motor.

CED,OUO1020,3164 –19–01DEC98–4/4

Speed Sensor Adjusting Tool. . . . . . . . . . . . . DFT1164

Used to adjust hydrostatic motor speed sensor.


PN=239

Remove and Install

CED,OUO1020,3024 –19–23OCT98–1/1



030300

2


CED,OUO1020,3025 –19–23OCT98–1/1

Other Material

Number Name Use

T43512 (U.S.) Thread Lock and Sealer (Medium Apply to threads of hydraulic pumpTY9473 (Canadian) Strength) cap screws.242 (LOCTITE) Apply to threads of hydraulic pump

set screws.

TY6305 (U.S.) Clean and Cure Primer Used to clean threads of hydrostaticTY9485 (Canadian) motor mounting cap screws.764 (LOCTITE)

T43514 (U.S.) Plastic Gasket Apply to threads of hydrostatic motorTY9475 (Canadian) mounting cap screws.277 (LOCTITE)



PN=240

Remove and Install

0303003

CED,OUO1020,3026 –19–23OCT98–1/1

Specifications


Front Pump-to-Rear Pump Cap Torque 102 N•m (75 lb-ft)Screw 750C

Front Pump-to-Rear Pump Cap Torque 339 N•m (250 lb-ft)Screw 850C

Hydraulic Pump Cap Screw Torque

Pump-to-Pump Cap Screws Torque 63 N•m (46 lb-ft)750C/850C

Support-to-Cover-to-Flywheel Torque 42 N•m (31 lb-ft)Housing 750C/850C

Cover-to-Flywheel 750C/850C Torque 42 N•m (31 lb-ft)

Pump-to-Cover 750C Torque 150 N•m (115 lb-ft)

Pump-to-Cover 850C Torque 495 ± 49 N•m (365 ± 36 lb-ft)

Pump Support-to-Cover Torque 620 ± 62 N•m (457 ± 46 lb-ft)750C/850C

Outer Face of Hub 750C Distance from Flywheel Cover 63 mm (2.48 in.)

Outer Face of Hub 850C Distance from Flywheel Cover 60 mm (2.36 in.)

Set Screws Torque 54 N•m (40 lb-ft) 750CTorque 122 N•m (90 lb-ft) 850C

Hydraulic Pump-to-Hydrostatic Pump Torque 140 N•m (103 lb-ft)Cap Screws

Sub-Frame Crossbar Cap Screws Torque 1070 N•m (790 lb-ft)

Hydrostatic Motor Mounting Cap Torque 675 N•m (500 lb-ft)Screws


PN=241

Remove and Install

030300

4

TX,0300,SS2308 –19–29AUG96–1/7

Remove and Install Hydrostatic Pumps

T83

59B

L–U

N–0

7JU

N95

A—Hydraulic Pump Cap Screw (4 used)B—Sub-Frame Crossbar (2 used)C—Pressure Control Pilot (PCP) (2 used)D—Fuel Supply LineE—Crossbar Cap Screws (4 used)

1. Lower all equipment to ground.

2. Stop engine. Operate all hydraulic controls to releasepressure in hydraulic system.

3. Turn battery disconnect switch to OFF.

4. Tilt cab or ROPS. (See procedure in Operation andTest Manual, Group 9026-25.)

5. Remove rear tank plate to drain transmission reservoirand to shut off fuel.

NOTE: Hydrostatic reservoir capacity is approximately 84L (22 gal) for 750C and 103 L (27 gal) for 850C.

6. Drain hydrostatic reservoir.

7. Close fuel shut-off valve.

8. Remove center bottom guard for ease of disassemblyand assembly.

9. Remove sub-frame crossbars (B).

10. Remove hydraulic pump cap screws (A).

11. Use a chain tightener to support and hold back thehydraulic pump from hydrostatic pump.

12. Disconnect parts (C and D).



PN=242

Remove and Install

0303005

TX,0300,SS2308 –19–29AUG96–2/7

T83

59B

D–U

N–1

2SE

P95

1—Rear Charge Pressure 4—Rear Charge Pressure 7—Front Hydrostatic 10—Rear Hydrostatic PumpManifold-to-Hydrostatic Manifold-to-Hydrostatic Pump-to-Right Hydrostatic Inlet-to-HydrostaticFilter (Return) Filter (Inlet) Motor Reservoir

2—Rear Charge Pressure 5—Front Charge Pressure 8—Hydrostatic 11—Multi-FunctionManifold-to-Final Drive Manifold-to-Park Brake Pump-to-Hydrostatic Filter Valve-to-Park Brake ValveBrake Inlet Valve Inlet (Bypass)

3—Hydrostatic Pump Case 6—Front Hydrostatic Pump 9—Rear HydrostaticDrain Port-to-Oil Cooler Inlet-to-Hydrostatic Pump-to-Left HydrostaticBypass Valve Reservoir Motor

CAUTION: To avoid injury from escapingfluid under pressure, stop engine and relievethe pressure in the system beforedisconnecting or connecting hydraulic orother lines. Tighten all connections beforeapplying pressure.

13. Disconnect lines (1—11). Cap and plug all lines toprevent contamination of system.

CAUTION: The approximate weight ofhydrostatic pumps, support and flywheel

cover is 250 kg (550 lb) for 750C and 299 kg(660 lb) for 850C.

14. Drill and tap 2 plugs (750C—1-1/16 in. or 850C—1-5/16 in.) to accommodate a 1/2 in. shoulderedlift eyebolt. Install plugs with eyebolts in eachpump case drain port. Trim end of eyebolt so it iseven with end of plug.


PN=243


Remove and Install

030300

6

TX,0300,SS2308 –19–29AUG96–3/7

T83

59B

E–U

N–0

7JU

N95

T85

45A

B–U

N–1

2SE

P95

A—Cap Screw (8 used)B—Washer (8 used)C—Flywheel AdaptorD—HubE—Set Screw (2 used)F—Distance 750C—63 mm (2.48 in.) 850C—60 mm

(2.36 in.)

NOTE: Use dealer fabricated lifting bracket and adapterto provide clearance around cab or ROPSsupports when removing pump assembly.

15. Connect hydrostatic pumps to a hoist using liftingstraps or chains and DFT1063 Pump Lifting Bracketand DFT1130 Adapter. (See Dealer Fabricated Toolsin Group 0399 for instructions to make tools.)

16. Remove set screws (E) and hub (D) from pump.


PN=244


Remove and Install

0303007

TX,0300,SS2308 –19–29AUG96–4/7T

8359

BG

–UN

–07J

UN

95

A—Cap Screw (4 used)B—Washer (4 used)C—Pump SupportD—Cap Screw (8 used)E—Washer (8 used)F—Cap Screw (4 used)G—Washer (4 used)H—Flywheel CoverI—Washer (4 used)J—Cap Screw (4 used)

17. Remove caps screws (A and D).

18. Carefully remove hydrostatic pumps.

19. Install hydrostatic pumps as an assembly. If front andrear hydrostatic pumps were separated, join the twopumps before installation. Align pump drive todamper.

SpecificationFront Pump-to-Rear Pump CapScrew 750C—Torque 102 N•m (75 lb-ft)....................................................Front Pump-to-Rear Pump CapScrew 850C—Torque 339 N•m (250 lb-ft)..................................................

20. Apply thread lock and sealer (medium strength) tothreads of cap screws (A and D). Install cap screwsand tighten to specifications.

Hydraulic Pump Cap Screw Torque—SpecificationSupport-to-Cover-to-FlywheelHousing 750C/850C—Torque 42 N•m (31 lb-ft).........................................Cover-to-Flywheel 750C/850C—Torque 42 N•m (31 lb-ft).............................................................................Pump-to-Cover 750C—Torque 150 N•m (115 lb-ft)....................................Pump-to-Cover 850C—Torque 495 ± 49 N•m (365 ± 36 lb-ft)..................Pump Support-to-Cover750C/850C—Torque 620 ± 62 N•m (457 ± 46 lb-ft)....................................



PN=245

Remove and Install

030300

8

TX,0300,SS2308 –19–29AUG96–5/7

T85

45A

B–U

N–1

2SE

P95

A—Cap Screw (8 used)B—Washer (8 used)C—Flywheel AdapterD—HubE—Set Screw (2 used)F—Distance 750C—63 mm (2.48 in.), 850C—60 mm

(2.36 in.)

21. Install hub (D) with tangs away from pump. Outerface of hub must be positioned at specified distance(F) from flywheel cover.

SpecificationOuter Face of Hub 750C—Distance from Flywheel Cover 63 mm (2.48 in.)........................................Outer Face of Hub 850C—Distance from Flywheel Cover 60 mm (2.36 in.)........................................

22. Apply thread lock and sealer (medium strength) tothreads of set screws (E). Install and tighten setscrews to specifications.

SpecificationSet Screws—Torque 54 N•m (40 lb-ft) 750C..............................................Torque 122 N•m (90 lb-ft) 850C..................................................................



PN=246

Remove and Install

0303009

TX,0300,SS2308 –19–29AUG96–6/7

T83

59B

D–U

N–1

2SE

P95

1—Rear Charge Pressure 4—Rear Charge Pressure 7—Front Hydrostatic 10—Rear Hydrostatic PumpManifold-to-Hydrostatic Manifold-to-Hydrostatic Pump-to-Right Hydrostatic Inlet-to-HydrostaticFilter (Return) Filter (Inlet) Motor Reservoir

2—Rear Charge Pressure 5—Front Charge Pressure 8—Hydrostatic 11—MultifunctionManifold-to-Final Drive Manifold-to-Park Brake Pump-to-Hydrostatic Filter Valve-to-Park Brake ValveBrake Inlet Valve Inlet (Bypass)

3—Hydrostatic Pump Case 6—Front Hydrostatic Pump 9—Rear HydrostaticDrain Port-to-Oil Cooler Inlet-to-Hydrostatic Pump-to-Left HydrostaticBypass Valve Reservoir Motor

23. Connect lines (1—11).

24. Remove lifting plugs from hydrostatic pumps. Fillhydrostatic pumps with oil. (See Fuels andLubricants in Group 0004.)



PN=247

Remove and Install

030300

10

TX,0300,SS2308 –19–29AUG96–7/7

T83

59B

L–U

N–0

7JU

N95

A—Hydraulic Pump Cap Screw (4 used)B—Sub-Frame Crossbar (2 used)C—Pump PCP Wiring Connector (2 used)D—Fuel Supply LineE—Crossbar Cap Screws (4 used)

25. Connect parts (C and D).

26. Install hydraulic pump. Tighten cap screws (A) tospecification.

SpecificationHydraulic Pump-to-HydrostaticPump Cap Screws—Torque 140 N•m (103 lb-ft).......................................

27. Install sub-frame crossbars (B), cap screws (E) andnuts. Tighten cap screws to specification.

SpecificationSub-Frame Crossbar CapScrews—Torque 1070 N•m (790 lb-ft)........................................................

28. Install center bottom guard, open fuel shut-off valveand install rear tank plate.

29. Fill hydrostatic reservoir. (See Fuels and Lubricants inGroup 0004.)

30. Lower cab or ROPS. (See Operation and TestManual, Group 9026-25 for procedure.)

31. Turn battery switch to ON.

32. Do hydrostatic pump start-up procedure. (Seeprocedure in this group.)

IMPORTANT: Calibrate transmission controllerwhenever a sensor or component isadjusted or replaced.

33. Calibrate transmission controller. (See Operation andTest Manual, Group 9015-20 for procedure.)


PN=248

Remove and Install

03030011

TX,0300,SS2324 –19–13JUL95–1/3

Remove and Install Hydrostatic Motors

T83

66A

A–U

N–3

0JU

N95

A—Hydrostatic Motor Case D—Right Hydrostatic F—Left Hydrostatic I—Charge PressureDrain Line Motor-to-Front Pump Line Motor-to-Rear Pump Line Line-to-Hydrostatic Motor

B—Hydrostatic Motor Case (Bottom Port) (Top Port) PCP’sDrain Line-to-Cooler E—Left Hydrostatic G—Pump Case Drain-to-Cooler J—Right and Left Brake LineBypass Valve Motor-to-Rear Pump Line Bypass Valve K—To Oil Cooler

C—Right Hydrostatic (Top Port) H—Park Brake Valve-to-BrakeMotor-to-Front Pump Line Piston(Top Port)

NOTE: Procedures are the same for left and rightmotors except right motor requires line (F) beremoved for clearance.

1. Disconnect battery.

NOTE: Reservoir capacity is approximately 84 L (22gal) for 750C or 103 L (27 gal) for 850C.

2. Drain reservoir or remove hydrostatic reservoircheck valve and attach vacuum pump to elbow.

3. Remove rear access cover and hydrostatic motorbottom guards.



PN=249

Remove and Install

030300

12

TX,0300,SS2324 –19–13JUL95–2/3

X98

11–U

N–2

3AU

G88

CAUTION: To avoid injury from escaping fluidunder pressure, stop engine and relieve thepressure in the system before disconnecting orconnecting hydraulic or other lines. Tighten allconnections before applying pressure.

NOTE: When removing left hand motor, brake line mustbe disconnected to provide clearance.

4. Disconnect charge pressure line at motor PCP andbrake piston. Disconnect case drain line to coolerbypass valve. Disconnect closed loop pressure lines.

5. Disconnect wire connector from PCP and motor speedsensor.

6. Remove motor speed sensor.

7. Remove four cap screws from motor-to-mountingflange. Rotate motor on its shaft so that case drain portis toward rear of machine.



PN=250

Remove and Install

03030013

TX,0300,SS2324 –19–13JUL95–3/3

T10

0194

–19–

09F

EB

96

A—DFT1137 Hydrostatic Motor Removal andInstallation Tool

B—DFT1132 Hydrostatic Motor Removal andInstallation Tool

C—DFT1137 Hydrostatic Motor Removal andInstallation Tool

CAUTION: The weight of 850C motor isapproximately 99.8 kg (220 lbs).

8.

Install DFT1132 and DFT1137 Hydrostatic MotorRemoval and Installation Tools. (See Dealer FabricatedTools in Group 0399.) Attach sling and hoist to tool.

9. Carefully pry motor away from mounting flange andremove through hole in rear of machine.

10. Clean threads of mounting cap screws and tappedholes in mounting flange with clean and cure primer.

11. Apply petroleum jelly to new O-ring and install ontransmission motor flange.

12. Install hydrostatic motor. Slide motor into spline as faras possible. Remove hydrostatic motor removal andinstallation tools. Rotate the motor toward front ofmachine to align cap screw holes.

13. Apply plastic gasket to threads of cap screws. Installand tighten cap screws to specification.

SpecificationHydrostatic Motor Mounting CapScrews—Torque 675 N•m (500 lb-ft)..........................................................

14. Connect hydrostatic lines and wiring connector.

15. Install motor speed sensor. (See Hydrostatic MotorSpeed Sensor Adjustment in this group.)

16. Fill reservoir if drained. (See Fuels and Lubricants inGroup 0004.)

17. Do hydrostatic motor start-up procedure in this group.

18. Calibrate transmission controller. (See procedure inOperation and Test Manual, Group 9015- 20.)


PN=251

Remove and Install

030300

14

TX,9026,YY1095 –19–22AUG96–1/2

Hydrostatic Motor Speed Sensor Adjustment

T10

9073

–UN

–15A

PR

97

NOTE: The speed sensors provide speed and directioninformation to the transmission controller. It isimportant that the air gap be adjusted asspecified. The speed sensor has two sensingcomponents. The relative position of these twocomponents in relation to the magnetic segmentson the speed ring is extremely important. Thetransmission controller must know machinedirection to function properly. It gets thisinformation from the relative phasing of the twooutputs from the sensor.

1. Remove sensor guard and disconnect sensor fromharness.

2. Loosen sensor lock nut and turn sensorcounterclockwise until O-ring is free from seat. Backlock nut out and move O-ring to upper position onsensor.

3. Turn sensor clockwise until contact is made with speedring. (Finger tighten only.)

NOTE: If adjusting tool rotates LESS than 1/4 turn (90°)or MORE than 1/2 turn (180°) to be perpendicularto motor shaft center line, turn adjusting tool overand repeat steps 3 and 4.

4. Install DFT1164 Speed Sensor Adjusting Tool onsensor and turn counterclockwise until back edge oftool is perpendicular to motor shaft centerline. (SeeDFT1164 Speed Sensor Adjusting Tool in Group0399.)

5. Hold sensor in this position with adjusting tool andtighten lock nut on sensor.



PN=252

Remove and Install

03030015

TX,9026,YY1095 –19–22AUG96–2/2

T10

9153

B–U

N–1

6AP

R97

6. Install sensor guard.

7. Connect sensor wire harness connector to guard with atie band as indicated (arrow).

TX,0300,SS2322 –19–06FEB96–1/4

Hydrostatic Pump and Motor Initial Start-UpProcedure

This procedure is used to bleed air from the hydrostaticcircuit after a major component repair.

IMPORTANT: Failure to follow this procedure when apump or motor case is drained of oilmay result in damage to the internalcomponents of pump and motor.

1. Remove front and rear pump case drain lines from theoutlet fitting on the top of each pump. Plug the linefittings.

2. Fill each pump case through the drain port with thespecified oil. Each pump should be completely filled.The motor cases are not filled with oil.

3. Connect lines.


PN=253


Remove and Install

TX,0300,SS2322 –19–06FEB96–2/4

T10

0066

–UN

–04J

AN

96

030300

16

3—Displacement Control Valve Test Port Plugs4—Servo Test Port Plugs

4. Remove servo test port plugs (4), then displacementcontrol valve test port plugs (3) until oil starts to flowfrom each port. Install plugs. Repeat procedure forboth pumps.



PN=254

Remove and Install

03030017

TX,0300,SS2322 –19–06FEB96–3/4

T86

00A

C–U

N–0

5DE

C95

1—Neutral Charge Relief Valve

5. Remove neutral charge relief valve (1) at hydrostaticfilter until oil starts to flow from port. Install valve.

6. Fill reservoir with specified oil. (See Fuels andLubricants in Group 0004.)

7. Disconnect the injection pump shut-off solenoidconnector.

850C (S.N. 822868— ) Remove engine controller fusein fuse panel.

IMPORTANT: Never operate starting motor more than30 seconds. Allow at least 2 minutes forcooling and battery recovery beforeoperating again. Overheating, causedby excessive operation, will seriouslydamage starting motor.

8. Crank engine in 30 second intervals until transmissionpressure gauge on the monitor panel shows 345 kPa(3.45 bar) (50 psi).

9. Connect injection pump wiring.

CAUTION: Leave park lock levers in UPposition. If park lock levers are lowered duringremainder of this procedure, machine will move.Operator must remain in seat while completingthis flushing procedure.

10. Start engine. Disconnect park brake switch connectorlocated next to battery disconnect switch. Leaveengine speed at low idle.

11. SINGLE LEVER STEER MACHINES Puttransmission speed control lever to mid-range. Cyclesingle lever to forward left counter-rotate through rightcounter-rotate position.

PEDAL STEER MACHINES Move FNR lever tomid-range forward position. Depress left and rightsteer pedals into counter-rotate position.


PN=255


Remove and Install

TX,0300,SS2322 –19–06FEB96–4/4

ALL MACHINES Continue cycling machine at low idlefor several minutes. Increase engine speed to 1500rpm and continue cycling control to actuatetransmission pumps for approximately 10 minutes.This will flush the displacement control valve areas.Stop engine and connect park brake switch.

12. With the transmission pressure reading normal, andengine at slow idle, operate the machine in forwardand reverse cycles for 4—5 minutes.

030300

18


PN=256

Group 0315Control Linkage

CED,OUO1020,3027 –19–23OCT98–1/4

Essential Tools


0303151


CED,OUO1020,3027 –19–23OCT98–2/4

3 Pin Test Harness . . . . . . . . . . . . . . . . . . JT07237-2

Used to Adjust Neutral Start Switch

CED,OUO1020,3027 –19–23OCT98–3/4

3 Pin Test Harness . . . . . . . . . . . . . . . . . . JT07237-5


CED,OUO1020,3027 –19–23OCT98–4/4

Single Pin Test Harness . . . . . . . . . . . . . . . JT07237-1


CED,OUO1020,3028 –19–23OCT98–1/2




CED,OUO1020,3028 –19–23OCT98–2/2

Digital Multimeter . . . . . . . . . . . . . . . . . . . . JT05791

Used to adjust neutral start and FNR switch.


PN=257

Control Linkage

CED,OUO1020,3029 –19–23OCT98–1/1

Other Material

Number Name Use

TY21517 (U.S.) Instant Gel Adhesive Apply to bottom of FNR controlNA (Canadian) assembly boot before installation.454 (LOCTITE)

030315

2



PN=258

Control Linkage

0303153

CED,OUO1020,3163 –19–01DEC98–1/2

Specifications


FNR Lever Pivot Screw Torque 47.46 N•m (35 lb-ft)

Neutral Start Switch ShimSpecification

No Shims Measured Distance 0.0 mm — 1.31 mm

1 Shim Measured Distance 1.32 mm — 1.56 mm

2 Shims Measured Distance 1.57 mm — 1.82 mm



Neutral Start Switch Torque 34 N•m (25 lb-ft)

Transmission Speed Sensor Contact Voltage 1.76—2.64 VPoint

Transmission Speed Sensor Voltage 2.44—3.66 VMaximum Speed

Transmission Speed Sensor Slow Voltage 1.51—2.27 VSpeed

FNR Sensor Forward Voltage 2.70—3.30 V

FNR Sensor Reverse Voltage 1.91—2.33 V

Lever Pivot Screw Torque 47.46 N•m (35 lb-ft)

Neutral Start Switch ShimSpecification

0 Shims Measured Distance 0.0 mm—0.45 mm

1 Shim Measured Distance 0.46 mm—0.71 mm





PN=259


Control Linkage

030315

4

CED,OUO1020,3163 –19–01DEC98–2/2


Switch Torque 34 N•m (25 lb-ft)

Key Switch ON, FNR Toward Voltage 2.16—2.98 VForward

FNR Lever Forward Detent Voltage 1.39—1.96 V

FNR Lever Reverse Detent Voltage 3.03—3.67 V

FNR Lever Right Steering Detent Voltage 2.80—4.20 V

FNR Lever Left Steering Detent Voltage 1.33—1.99 V

Transmission Speed Control Lever Voltage 2.53—3.79 VSlow Speed Position 1

Transmission Speed Control Lever Voltage 1.21—1.81 VMaximum Speed Position 3


PN=260

Control Linkage

0303155


PN=261

Control Linkage

030315

6

TX,0315,SS2355 –19–13JUL95–1/2

Remove and Install Steering Pedal

T83

88A

D–U

N–1

0JU

L95


PN=262


Control Linkage

0303157

TX,0315,SS2355 –19–13JUL95–2/2

1—Snap Ring Extension (2 7—45° Sensor 14—Pin 21—Nutused) 8—Bearing 15—Bellcrank 22—Pin

2—Washer (2 used) 9—Spring Pin 16—Cap Screw 23—Linkage Rod3—Spring 10—Spring 17—Washer (6 used) 24—Bellcrank4—Pin 11—Washer 18—Nut (3 used) 25—Cap Screw (3 used)5—Bearing 12—Cap Screw 19—Shaft 26—Cap Screw (4 used)6—Support 13—Steer Pedal 20—Washer 27—Roll Pin

1. Disconnect wiring connector.

2. Remove cap screws (12) and remove parts.

3. Install parts and tighten cap screws (12).


4. Calibrate transmission controller. (See procedure inOperation and Test Manual, Group 9015-20.)


PN=263

Control Linkage

030315

8

CED,OUO1020,3020 –19–23OCT98–1/2

Disassemble and Assemble FNR Control Assembly—Pedal Steer (S.N. —XXXXXX)

T10

0192

–19–

21A

UG

96


PN=264


Control Linkage

0303159

CED,OUO1020,3020 –19–23OCT98–2/2

1—Neutral Start Switch 3—B20 FNR 90° Rotary Sensor 4—B11 Transmission Speed 5—Seal2—Screw (2 used) 90° Rotary Sensor

NOTE: Pedal steer machines use two 45° sensors(Left and Right Steer Pedals) and three 90°sensors (Engine Speed Control Sensor, FNRSensor and Transmission Speed ControlSensor).

1. Remove and disassemble parts as shown.

IMPORTANT: Take note of how links are attachedto rotary sensors for reassembly.

2. Inspect for worn or damaged parts. Replace ifnecessary.

3. Tighten screw (2) to specification.

SpecificationFNR Lever Pivot Screw—Torque 47.46 N•m (35 lb-ft)..................................................................

4. Install seal (5) with lip towards plate.

5. Adjust FNR and neutral start switch. (See FNR andNeutral Start Switch Adjustment in this group.)

6. Assemble and install parts as shown.

7. Adjust park lock linkage. (See Park Lock LinkageAdjustment in this group.)

IMPORTANT: Calibrate transmission and enginecontrollers whenever a sensor,transmission component, or enginespeed control component is adjustedor replaced.

8. Calibrate transmission controller.

For 850C (S.N. 822868— ), also calibrate enginecontroller. (See procedures in Operation and TestManual, Group 9015-20.)


PN=265

Control Linkage

030315

10

CED,OUO1020,3021 –19–23OCT98–1/1

FNR Control Assembly Component Location—Pedal Steer (S.N. —XXXXXX)

T84

46A

C–1

9–07

JUN

95


PN=266

Control Linkage

03031511

TX,9026,YY1096 –19–01APR95–1/3

FNR and Neutral Start Switch Adjustment—Pedal Steer (S.N. —XXXXXX)

T84

43A

F–U

N–2

0MA

R95

T84

43A

G–U

N–2

0MA

R95

T84

43A

H–U

N–2

0MA

R95

1—Neutral Start Switch2—Rod3—Adjusting Screw4—Adjusting Cam Top Ramp5—Transmission Speed Sensor6—FNR Sensor

1.

IMPORTANT: Follow this procedure anytime theneutral start switch, sensors or linkageare changed or adjusted.

Remove FNR control assembly from machine. Positioncontrol assembly near left side of machine.

2. Put FNR lever in neutral and remove neutral startswitch (1).

3. Loosen lock nuts on rod (2). Turn adjusting screw (3)to lengthen rod until top ramp (4) of the adjusting camis beyond the center line of the neutral start switchhole.

NOTE: When the neutral start switch is installed, the ballon the switch must contact the top ramp surface.

4. Install washer and neutral start switch. Connect amultimeter to switch leads and turn switch in until overload disappears and a minimum resistance valueappears on multimeter. Using a feeler gauge, measurethe distance between the washer and the switch. Usethe specifications to determine how many shims arerequired. Tighten switch to specification.

Neutral Start Switch Shim Specification—SpecificationNo Shims—Measured Distance 0.0 mm — 1.31 mm.................................1 Shim—Measured Distance 1.32 mm — 1.56 mm....................................2 Shims—Measured Distance 1.57 mm — 1.82 mm..................................3 Shims—Measured Distance 1.83 mm — 2.08 mm..................................4 Shims—Measured Distance 2.09 mm — 2.33 mm..................................

SpecificationNeutral Start Switch—Torque 34 N•m (25 lb-ft)..........................................


PN=267


Control Linkage

030315

12

TX,9026,YY1096 –19–01APR95–2/3

5. Install JT07237-2 (3 pin test harness) to thetransmission speed control sensor (5) and toJT07237-5 (3 pin test harness). Connect remaining endof JT07237-5 harness to machine sensor connector.

6. Install JT07237-1 (single pin test harness) to terminalC (black wire) and terminal B (white wire) onJT07237-2 harness. Turn key switch to ON position.

NOTE: The following voltage ranges are necessary forproper operation of the transmission controller. Italso checks that linkage to the sensors areinstalled correctly.

7. Move the FNR lever from neutral to forward or reverseso that the lever is centered (from front to rear) on thefront edge of quadrant tongue. Hold lever in thisposition.

8. Install multimeter to neutral start switch and turnadjusting screw to shorten rod until multimeterindicates over load. Tighten lock nuts.

9. Disconnect multimeter from neutral start switch. Setmultimeter to DC volts. Be careful that lever did notmove from position set in step 7. Connect JT07237-1(single pin test harness) to multimeter. The voltagemust be within specification.

SpecificationTransmission Speed SensorContact Point—Voltage 1.76—2.64 V.........................................................

10. Move FNR lever to maximum speed forward orreverse. Voltage must be within specification.

SpecificationTransmission Speed SensorMaximum Speed—Voltage 2.44—3.66 V....................................................

11. Move the FNR lever to the front left or right corner ofthe quadrant. The voltage must be withinspecification.

SpecificationTransmission Speed Sensor SlowSpeed—Voltage 1.51—2.27 V.....................................................................


PN=268


Control Linkage

03031513

TX,9026,YY1096 –19–01APR95–3/3

12. Connect the JT07237-2 (3 pin test harness) to theFNR sensor (6). Move the FNR lever to the front rightcorner of the quadrant. The voltage must be withinspecification.

SpecificationFNR Sensor Forward—Voltage 2.70—3.30 V.............................................

13. Move FNR lever to the left front corner of thequadrant. The voltage must be within specification.

SpecificationFNR Sensor Reverse—Voltage 1.91—2.33 V............................................

14. Key switch off. Disconnect test equipment.

15. Install FNR control assembly.

IMPORTANT: Calibrate transmission and enginecontroller whenever a sensor,transmission component, or enginespeed control component is adjusted orreplaced.




PN=269

Control Linkage

030315

14

TX,0315,SS2481 –19–29AUG96–1/2

Disassemble and Assemble FNR Control Assembly—Single Lever Steer (S.N. —XXXXXX)

T10

9333

–UN

–05J

UN

97


PN=270


Control Linkage

03031515

TX,0315,SS2481 –19–29AUG96–2/2

1—Plate 13—Tooth Washer 26—Lock Nut 38—Counter Rotation Spring2—Boot 14—Spring Washer (3 used) 27—Seal Assembly3—B12 Transmission Speed 15—Nut 28—Lever, Pivot, FNR Control 39—Screw (2 used)

45° Rotary Sensor 16—Washer (2 used) 29—B11 FNR 90° Rotary 40—Bearing4—Seal 17—Shims (2 used) Sensor 41—Counter Rotation Spring5—Lock Nut 18—Neutral Start Switch 30—Sensor Pivot Assembly6—FNR Bracket 19—Washer (2 used) 31—Linkage Rod 42—Lever Body7—Transmission Speed Lever 20—Thrust Washer 32—Connecting Link 43—Spring8—Linkage Rod 21—Shaft 33—B20 Left/Right Steer 90° 44—Plate9—Transmission Speed 22—Lock Nut Rotary Sensor 45—Washer

Control Shaft 23—Shoulder Bolt 34—Bracket 46—Nut10—Thrust Pack Bearing 24—FNR Lever 35—Linkage Rod 47—Detent Assembly11—Bushing 25—Detent Spring Actuator 36—Body Lever Yoke 48—Detent Assembly12—Thrust Washer Assembly 37—Bearing (4 used)

NOTE: Single lever steer machines use two 45°sensors (decelerator sensor and transmissionspeed control sensor) and three 90° sensors(engine speed control sensor, FNR sensor andleft/right steer sensor).

1. Remove and disassemble parts as shown.

IMPORTANT: Take note of how links are attachedto rotary sensors for reassembly.

2. Inspect for worn or damaged parts. Replace ifnecessary.

3. Tighten screw (39) to specification.

SpecificationLever Pivot Screw—Torque 47.46 N•m (35 lb-ft).................................

4. Install seal (27) with lip toward plate.

5. Install detent assembly (47) and (48) into springand push together until detent latches into thesecond notch. Tighten lock nut.

6. Adjust FNR and neutral start switch. (See FNR andNeutral Start Switch Adjustment in this group.)

7. Apply a light coat of instant gel adhesive on bottomsealing surface of boot (2) before installation.

8. Assemble and install parts as shown.

9. Adjust park lock linkage. (See Park Lock LinkageAdjustment in this group.)

IMPORTANT: Calibrate transmission and enginecontroller whenever a sensor,transmission component, or enginespeed control component is adjustedor replaced.




PN=271

Control Linkage

030315

16

CED,OUO1020,3022 –19–23OCT98–1/1

FNR Control Assembly Component Location—Single Lever Steer (S.N. —XXXXXX)

T84

46A

B–1

9–07

JUN

95


PN=272

Control Linkage

03031517

TX,9026,YY1097 –19–01APR95–1/5

FNR and Neutral Start Switch Adjustment—Single Lever Steer (S.N. —XXXXXX)

NOTE: This adjustment and test must be performedanytime the neutral start switch, sensors orlinkage is changed. The following voltageranges are necessary for proper operation ofthe transmission controller. It also checks thatlinkage to the sensors are installed correctly.

IMPORTANT: Follow this procedure anytime theneutral start switch, sensors orlinkage are changed or adjusted.

1. Remove FNR and steering control assembly frommachine. Position control assembly near left side ofmachine.



PN=273

Control Linkage

030315

18

TX,9026,YY1097 –19–01APR95–2/5

T84

44A

C–U

N–2

0MA

R95

T84

44A

D–U

N–2

0MA

R95

T84

44A

E–U

N–2

0MA

R95

1—Neutral Start Switch2—Switch Cam3—Detent Block4—FNR Sensor5—Connecting Rod6—Left and Right Steer Sensor7—Transmission Speed Sensor

2. Remove neutral start switch (1).

3. Loosen cap screws holding the detent block (3) to theframe.

4. Rotate the switch cam (2) so that the top edge of thecam "V" is centered in the switch hole. Tighten capscrews on detent block (3).

5. Install two washers and neutral start switch. Connect amultimeter set to read continuity, to switch leads andturn switch in until over load disappears and aminimum resistance valve appears on multimeter.Using a feeler gauge, measure the distance betweenthe washer and the switch. Consult the specificationsto determine how many shims are required.

Neutral Start Switch Shim Specification—Specification0 Shims—Measured Distance 0.0 mm—0.45 mm......................................1 Shim—Measured Distance 0.46 mm—0.71 mm......................................2 Shims—Measured Distance 0.72 mm—0.96 mm....................................3 Shims—Measured Distance 0.97 mm—1.22 mm....................................4 Shims—Measured Distance 1.23 mm—1.47 mm....................................


PN=274


Control Linkage

03031519

TX,9026,YY1097 –19–01APR95–3/5

6. Tighten switch to specification.

SpecificationSwitch—Torque 34 N•m (25 lb-ft)...............................................................

7. Install JT07237-2 (3 pin test harness) to the FNRsensor (4) and to JT07237-5 (3 pin test harness).Connect remaining end of JT07237-5 harness tomachine sensor connector.

8. Install JT07237-1 (single pin test harness) to terminalC (black wire) and terminal B (white wire) onJT07237-2 harness.

NOTE: The following voltage ranges are necessary forproper operation of the transmission controller. Italso checks that linkage to the sensors areinstalled correctly.

9. Connect multimeter to neutral start switch. Turn keyswitch to ON position. Slowly move FNR out of neutraltoward forward. Initially the multimeter will readcontinuity. Stop FNR at the point multimeter readsoverload. Hold lever in this position.

10. Disconnect multimeter from neutral start switch. Setmultimeter to DC volts. Be careful that lever did notmove from position set in step 8. Connect JT07237-1(single pin test harness) to multimeter. The voltagemust be within specification.

SpecificationKey Switch ON, FNR TowardForward—Voltage 2.16—2.98 V..................................................................

11. Release FNR lever. It must return to the neutraldetent position. It may be necessary to tap lightly onframe to get lever to move. If however, the levermoves toward forward instead of neutral, adjustneutral switch.

12. Repeat steps 8—10 for reverse.



PN=275

Control Linkage

030315

20

TX,9026,YY1097 –19–01APR95–4/5

T84

44A

C–U

N–2

0MA

R95

T84

44A

D–U

N–2

0MA

R95

T84

44A

E–U

N–2

0MA

R95

1—Neutral Start Switch2—Switch Cam3—Detent Block4—FNR Sensor5—Connecting Rod6—Left and Right Steer Sensor

13. Move the FNR lever through the full travel rangeseveral times. Check the amount of clearancebetween the lever and the frame at the full forwardand full reverse positions. If not the same, adjustconnecting rod (5) to equal clearance.

14. Move FNR lever to forward detent. Voltage must bewithin specification.

SpecificationFNR Lever Forward Detent—Voltage 1.39—1.96 V...................................................................................

15. Move FNR lever to reverse detent. Voltage must bewithin specification.

SpecificationFNR Lever Reverse Detent—Voltage 3.03—3.67 V...................................................................................

16. Connect the JT07237-2 (3 pin test harness) tosteering sensor (6).


PN=276


Control Linkage

03031521

TX,9026,YY1097 –19–01APR95–5/5

17. Move FNR lever to the right steering detent. Holdlever and check sensor voltage. Voltage must bewithin specification.

SpecificationFNR Lever Right SteeringDetent—Voltage 2.80—4.20 V....................................................................

NOTE: DO NOT go beyond detent into the counter-rotateposition.

18. Move FNR lever to the left steering detent. Voltagemust be within specification.

SpecificationFNR Lever Left Steering Detent—Voltage 1.33—1.99 V...................................................................................

19. Connect the JT07237-2 (3 pin test harness) totransmission speed sensor (7).

20. Move transmission speed control lever to slow speedposition 1. Voltage must be within specification.

SpecificationTransmission Speed ControlLever Slow Speed Position 1—Voltage 2.53—3.79 V...................................................................................

21. Move transmission speed control lever to maximumspeed position 3. Voltage must be within specification.

SpecificationTransmission Speed ControlLever Maximum Speed Position3—Voltage 1.21—1.81 V.............................................................................

22. Key switch OFF, disconnect all test equipment. InstallFNR and steering control assembly.

IMPORTANT: Calibrate transmission controllerwhenever a sensor or transmissioncomponent, is adjusted or replaced.



PN=277

Control Linkage

030315

22

CED,TX14826,12097 –19–10SEP99–1/2

Single Lever Control (SLC) Exploded View With Speed In Grip (S.N. XXXXXX— )

T12

4796

–UN

–27S

EP

99


PN=278


Control Linkage

03031523

CED,TX14826,12097 –19–10SEP99–2/2

1—SLC With Speed In Grip 18—Spring 38—Cap Screw (2 used) 57—Lip Seal (2 used)Assembly 19—Spacer (2 used) 39—Detent Lever Assembly 58—Bracket Assembly

2—Speed In Grip Harness, 20—Spring 40—O-Ring (2 used) 59—Lip Seal (2 used)Switch and Cover 21—Stepped Washer (2 used) 41—Cap Screw (6 used) 60—Bearing Block

3—Boot Cover For Switch 22—Spring 42—Socket Head Cap Screw 61—Shaft4—Cap Screw (4 used) 23—Spring 43—Spacer 62—Needle Bearing5—Screw kit For Handle 24—Spring Pack Assembly 44—Spacer 63—Mounting Post (4 used)6—Reverse Speed Ratio 25—Linkage 45—Spring Longer Threaded Post

Switch 26—Ball Joint 46—Nut (2 used) Shown7—Spring Pin (3 used) 27—Nut (2 used) 47—Detent Shaft 64—Mounting Plate8—Cable Clamp 28—Ball Joint 48—Neutral Cam 65—Boot Assembly9—Tie Band 29—Rotary Sensor Kit 49—Cam Cover 66—Jam Nut10—Not Used 30—Rotary Sensor 50—SLC Body 67—Washer11—Not Used 31—Cap Screw (2 used) 51—O-Ring 68—Bearing12—Not Used 32—O-Ring 52—Neutral Start Switch 69—Decal13—Not Used 33—Bearing (3 used) 53—Spring Plate 70—Screw (4 used)14—Not Used 34—Washer (2 used) 54—Seal Plug (2 used) 71—Knob15—Ball Joint 35—Plate 55—Shaft 72—“SLC” Single Lever16—Nut 36—Washer 56—Needle Bearing (2 used) Assembly17—Nut (2 used) 37—Socket Head Screw


PN=279

Control Linkage

030315

24

CED,TX03543,2276 –19–09SEP99–1/1

Remove and Install Single Lever Control(SLC) With Speed In Grip (S.N. XXXXXX— )

T12

4637

B–U

N–1

7SE

P99

SLC With Speed In Grip Shown

T12

4610

B–U

N–1

7SE

P99

SLC with speed in grip shown

1—Reverse Ratio Switch2—Steer Sensor3—Neutral Start Switch4—F-N-R Sensor5—Harness to Transmission Speed Switch and Horn

1. Turn battery disconnect switch to the OFF position.

NOTE: Mark electrical connectors to aid in assembly.

2. Disconnect rotary sensors (2 and 4) and neutral startswitch (3).

3. Disconnect reverse ratio switch (1) connector.

4. Disconnect harness connectors (5) to transmissionspeed control switch and horn button.

5. Remove four cap screws and single lever controlassembly.

6. Install single lever control using four cap screws.

7. Connect reverse ratio switch connector.

8. Connect rotary sensors (2 and 4) and neutral startswitch (3).

9. Turn battery disconnect switch to the ON position.

10. Adjust single lever control. (See Single Lever ControlAdjustment in Operation and Test Manual, Group9026-20.)

11. Recalibrate transmission controller. (See CalibrateTransmission Controller in Operation and TestManual, Group 9015-20.)


PN=280

Control Linkage

03031525

CED,OUTX547,108 –19–29SEP99–1/28

Disassemble and Assemble Single LeverControl Linkage (SLC) With Speed In Grip(S.N. XXXXXX— )

T12

4637

B–U

N–1

7SE

P99


T12

4638

B–U

N–1

7SE

P99


1—Tie Bands2—Identification Marks3—Clamp

1. SLC (With Speed In Grip)

• Separate boot from plate using a screwdriver.• Remove tie bands (1).• Put identification marks (2) on both sides of wire

lead to aid in assembly.• Remove clamp (3) from wire lead.



PN=281

Control Linkage

030315

26

CED,OUTX547,108 –19–29SEP99–2/28

T12

4645

B–U

N–1

7SE

P99

SLC Assembly With Speed In Grip Shown

1—Screw (2 used)2—Screw3—Screw with nut (2 used)

• Remove screws (1, 2 and 3) and boot from SLC.

CED,OUTX547,108 –19–29SEP99–3/28

T12

4646

B–U

N–1

7SE

P99

Speed In Grip Switch

1—Grip2—Switch3—Boot

• Split grip halves (1) to remove switch (2). Boot (3) onswitch can be replaced, if necessary.


PN=282


Control Linkage

03031527

CED,OUTX547,108 –19–29SEP99–4/28

T12

4647

B–U

N–1

7SE

P99

Reverse Ratio Switch

• Remove reverse ratio switch (1) if replacement isnecessary.

CED,OUTX547,108 –19–29SEP99–5/28

T11

9639

B–U

N–1

9JA

N99

1—Lock Nut2—Steer Shaft3—Rod End4—Socket Head Cap Screw (2 used)

2. Loosen lock nut (1).

3. Remove steer shaft (2) from rod end (3).

4. Remove two socket head cap screws (4) and removesteer shaft assembly from body.



PN=283

Control Linkage

030315

28

CED,OUTX547,108 –19–29SEP99–6/28

T11

9641

B–U

N–1

9JA

N99

T11

9642

B–U

N–1

9JA

N99

1—Spring End Lock Nut (2 used)2—Spring Guide (2 used)3—Spacer (2 used)4—Springs (Chrome)5—Spring Seat (2 used)6—Steering Plate7—Springs (Gold)8—Rod End Lock Nut9—Steer Shaft

5. Remove rod end lock nut (8).

NOTE: Use two wrenches to loosen spring end lock nuts(1).

NOTE: Springs are color coded to aid in assembly.

6. Remove one spring end lock nut (1), spring guide (2),spacer (3), spring (4) or (7) and spring seat (5) fromone side of steering plate (6).

7. Place steer shaft (9) in soft jaw vise and remove springend lock nut (1), spring guide (2), spacer (3), spring (4)or (7) and spring seat (5) from other side of steeringplate.



PN=284

Control Linkage

03031529

CED,OUTX547,108 –19–29SEP99–7/28

T11

9643

B–U

N–1

9JA

N99

1—Socket Head Cap Screws (2 used)2—Retaining Plate3—Detent Spring4—Nut5—Spacer6—Tube7—Washer8—Socket Head Cap Screw9—Detent Lever

8. Remove two socket head cap screws (1), retainingplate (2) and detent spring (3).

9. Remove nut (4), socket head cap screw (8), spacer(5), washer (7) and detent lever (9).

10. Remove tube (6) from detent lever.

CED,OUTX547,108 –19–29SEP99–8/28

T11

9644

B–U

N–1

9JA

N99

T11

9645

B–U

N–1

9JA

N99

1—Steer Sensor2—Forward/Reverse Sensor3—Cover4—Neutral Start Switch

11. Remove socket head cap screws from steer sensor(1) and forward/reverse sensor (2).

Remove sensors and O-rings.

12. Remove cover (3) and neutral start switch (4).


PN=285


Control Linkage

CED,OUTX547,108 –19–29SEP99–9/28

T11

9646

B–U

N–1

9JA

N99

030315

30

1—Forward/Reverse Rod2—Steer Rod3—Bracket Assembly

13. Disconnect forward/reverse rod end (1) and removesteer rod end (2) from bracket assembly (3).

CED,OUTX547,108 –19–29SEP99–10/28

T11

9649

B–U

N–1

9JA

N99

1—Pivot Pin

NOTE: Care should be taken to avoid damaging bearingblock, bearings and seals.

14. Remove two seal plugs and using a 1/4 in. punchwith rounded edges, drive pivot pin (1) from bracketassembly. Remove bracket.

CED,OUTX547,108 –19–29SEP99–11/28

T11

9650

B–U

N–1

9JA

N99

1—Bearing Block2—Steer Sensor Shaft

15. Remove steer sensor shaft (2) and bearing block (1).



PN=286

Control Linkage

03031531

CED,OUTX547,108 –19–29SEP99–12/28

T11

9651

B–U

N–1

8JA

N99

1—Spring Pin2—Detent Plate3—Detent Shaft4—Spacers (2 used)5—Cam

NOTE: When driving pin out of detent plate, supportassembly to prevent damage to bearings andseals.

16. With the detent placed at the furthest reverseposition, drive spring pin (1) out until detent plate (2)can be rotated around detent shaft (3).

17. Remove detent shaft (3) by pulling on cam (5). Besure to catch detent plate (2) with rod end assemblyand two spacers (4) when removing detent shaft.

18. Remove rod end assembly from detent plate, ifreplacement is required.

19. Remove cam (5) from detent shaft (3) by driving outspring pin, if replacement is required.

20. Remove pin (1) from detent plate.



PN=287

Control Linkage

030315

32

CED,OUTX547,108 –19–29SEP99–13/28

T12

1377

B–U

N–1

1MA

Y99

T12

1378

B–U

N–1

1MA

Y99

T12

1379

B–U

N–1

1MA

Y99

1—Yoke Pivot Pin Seal (2 used)2—Yoke Pivot Pin Bearing (2 used)3—Steer Shaft Seal (2 used)4—Steer Shaft Bearing (2 used)5—Detent Shaft Bearing (2 used)

21. Remove yoke pivot pin seals (1) and steer shaft seals(3) using a pick.

22. Remove yoke pivot pin bearings (2) using a punch.

23. Remove steer shaft bearings (4) and detent shaftbearings (5) using JDG1303-1 Bearing Driver andJDG1303-2 or JDG1303-3 Sleeve from JDG1303Bearing Driver Kit.

24. Clean and inspect parts.



PN=288

Control Linkage

03031533

CED,OUTX547,108 –19–29SEP99–14/28

T12

1380

B–U

N–1

1MA

Y99

T12

1381

B–U

N–1

1MA

Y99

1—JDG1305-5 Driver Rod2—JDG1303-4 Driver Disk3—Yoke Pivot Pin Bearing (2 used)4—JDG1303-7 Driver Disk5—Yoke Pivot Pin (2 used)

IMPORTANT: Drive bearing from lettered side ofbearing only.

25. Install yoke pivot pin bearing (3) using JDG1303-4Driver Disk and JDG1303-5 Driver Rod. Drive bearinguntil driver disk is fully seated on yoke, this will setbearing to proper depth.

26. Repeat step 28 for installing other yoke pivot pinbearing.

IMPORTANT: Lip side of seal must face away frombearing.

27. Apply petroleum jelly to seal and install seal (5) onJDG1303-7 Driver Disk (4) with lip of seal facingtoward driver disk.

28. Place seal and driver disk square on yoke. InsertJDG1303-5 Driver Rod and drive seal until driver diskis fully seated on yoke.

29. Repeat steps 30 and 31 for installing other yoke pivotpin seals.



PN=289

Control Linkage

030315

34

CED,OUTX547,108 –19–29SEP99–15/28

T12

1382

B–U

N–1

1MA

Y99

T12

1383

B–U

N–1

1MA

Y99

T12

1384

B–U

N–1

1MA

Y99

1—JDG1303-1 Bearing Driver2—JDG1303-3 Sleeve3—Steer Shaft Cap Bearing4—Steer Shaft Bearing5—Steer Shaft Seal (2 used)


30. Install steer shaft cap bearing (3) using JDG1303-1Bearing Driver (1) and JDG1303-3 Sleeve (2). Drivebearing until driver is fully seated, this will set bearingto proper depth.

31. Install steer shaft bearing (4) using JDG1303-1Bearing Driver. Drive bearing until driver is fullyseated, this will set bearing to proper depth.

IMPORTANT: Lip side of seal must face away frombearing.

32. Apply petroleum jelly to seals install seal (5) onJDG1303-6 Driver Disk with lip of seal facing towarddriver disk.

33. Place seal and driver disk square in opening andfirmly press with finger pressure to install seal. Pressdisk driver until fully seated.

34. Repeat step 35 and 36 to install other steer shaftseals.



PN=290

Control Linkage

03031535

CED,OUTX547,108 –19–29SEP99–16/28

T12

1385

B–U

N–1

1MA

Y99

T12

1386

B–U

N–1

1MA

Y99

1—JDG1303-1 Bearing Driver2—JDG1303-2 Sleeve3—Detent Shaft Bearing4—Detent Shaft Bearing


35. Install detent shaft bearing (3) from the steppedrecess side (yellow) opening. Using JDG1303-1Bearing Driver (1) and JDG1303-2 Sleeve (2), drivebearing through until bearing driver is fully seated.This will set bearing to proper depth.

36. Install detent shaft bearing (4) using JDG1303-1Bearing Driver. Drive bearing until bearing driver isfully seated, this will set bearing to proper depth.



PN=291

Control Linkage

030315

36

CED,OUTX547,108 –19–29SEP99–17/28

T11

9651

B–U

N–1

8JA

N99

1—Spring Pin2—Detent Plate3—Detent Shaft4—Spacers (2 used)5—Cam

37.

Install rod on detent plate, if removed. Tighten nut tospecifications.

Single Lever Control—SpecificationDetent Plate Rod Ball Joint Nut—Torque 19 N•m (14 lb-ft) (168 lb-in.)...........................................................

38. Install cam (5) on detent shaft and install spring pin.

NOTE: When driving pin in detent plate, supportassembly to prevent damage to bearings andseals.

39. While holding detent plate (2) and spacers (4) inplace, install detent shaft (3) as shown with spring pinholes for plate and cam in line. Install spring pin (1) indetent plate.

CED,OUTX547,108 –19–29SEP99–18/28

T11

9650

B–U

N–1

9JA

N99

1—Bearing Block2—Steer Sensor Shaft

NOTE: Align pin bore in bearing block and sensor shaft.

40. Install bearing block (1) and steer sensor shaft (2).

CED,OUTX547,108 –19–29SEP99–19/28

T11

9649

B–U

N–1

9JA

N99

1—Pivot Pin

NOTE: Care should be taken to avoid damaging bearingblock, bearings and seals.

41. Install lever assembly, and using a 1/4 in. punch withrounded edges, drive pivot pin (1) into bracketassembly. Pin should protrude equally on both ends.

42. Install seal plugs.


PN=292


Control Linkage

03031537

CED,OUTX547,108 –19–29SEP99–20/28

T11

9646

B–U

N–1

9JA

N99

1—Forward/Reverse Rod2—Steer Rod3—Bracket Assembly

43. Apply cure primer and thread lock and sealer(medium strength) to threads of rod ends. Connectforward/reverse rod end (1) and install steer rod end(2) on bracket assembly (3). Tighten ball joint nuts tospecifications.

Single Lever Control—SpecificationForward/Reverse Rod Ball JointNut—Torque 14 N•m (10 lb-ft) (124 lb-in.)..................................................Steer Rod Ball Joint Nut—Torque 9 N•m (7 lb-ft) (84 lb-in.).......................

CED,OUTX547,108 –19–29SEP99–21/28

T11

9644

B–U

N–1

9JA

N99

T11

9645

B–U

N–1

9JA

N99

1—Steer Sensor2—Forward/Reverse Sensor3—Cover4—Neutral Start Switch

NOTE: Steer sensor and forward/reverse sensors areinterchangeable.

44.

Install sensors (1 and 2) and O-rings. Tighten capscrews to specifications.

Single Lever Control—SpecificationSteer Sensor Mounting CapScrews—Torque 5 N•m (4 lb-ft) (48 lb-in.)..................................................Forward/Reverse SensorMounting Cap Screws—Torque 5 N•m (4 lb-ft) (48 lb-in.)..........................

45. Install neutral start switch (4) and tighten tospecifications.

Single Lever Control—SpecificationNeutral Start Switch—Torque 14 N•m (10 lb-ft) (124 lb-in.)........................

46. Install cover (3) and tighten cap screws tospecifications.

Single Lever Control—SpecificationNeutral Start Switch Cover CapScrews—Torque 5 N•m (4 lb-ft) (48 lb-in.)..................................................


PN=293


Control Linkage

030315

38

CED,OUTX547,108 –19–29SEP99–22/28

T11

9643

B–U

N–1

9JA

N99

1—Socket Head Cap Screws (2 used)2—Retaining Plate3—Detent Spring4—Nut5—Spacer6—Tube7—Washer8—Socket Head Cap Screw9—Detent Lever

47.

Install tube (6), washer (7), spacer (5), socket headcap screw (8) and nut (4). Tighten cap screw first andthen nut, to specifications.

Single Lever Control—SpecificationDetent Lever Socket Head CapScrew and Nut—Torque 19 N•m (14 lb-ft) (168 lb-in.)................................

48. Install detent spring (3), retaining plate (2) and sockethead cap screws (1). Tighten cap screws tospecifications.

Single Lever Control—SpecificationDetent Spring Retaining PlateCap Screws—Torque 5 N•m (4 lb-ft) (48 lb-in.)..........................................



PN=294

Control Linkage

03031539

CED,OUTX547,108 –19–29SEP99–23/28

T11

9641

B–U

N–1

9JA

N99

T11

9642

B–U

N–1

9JA

N99

1—Spring End Lock Nut (2 used)2—Spring Guide (2 used)3—Spacer (2 used)4—Springs (Chrome)5—Spring Seat (2 used)6—Steering Plate7—Springs (Gold)8—Rod End Lock Nut9—Steer Shaft

NOTE: Steering plate (6) must be installed so that the flatside faces chrome spring (4).

49. Place steering shaft in soft jaw vise. Install steeringplate (6), spring seat (5), spring (4) or (7), spacer (3)spring guide (2) and spring end lock nut (1). Repeatsteps for opposite end, then tighten spring end locknuts (1) to specifications.

Single Lever Control—SpecificationSteer Shaft Spring End LockNuts—Torque 8 N•m (6 lb-ft) (72 lb-in.)......................................................

50. Install rod end lock nut (8).

CED,OUTX547,108 –19–29SEP99–24/28

T11

9639

B–U

N–1

9JA

N99

1—Lock Nut2—Steer Shaft3—Rod End4—Socket Head Cap Screw (2 used)

51.

Install steer shaft assembly and two socket head capscrews (4). Tighten cap screws to specifications.

Single Lever Control—SpecificationSteer Shaft Assembly MountingCap Screws—Torque 34 N•m (25 lb-ft)......................................................

52. Screw steer shaft into rod end (3) and tighten lock nut(1).



PN=295

Control Linkage

030315

40

CED,OUTX547,108 –19–29SEP99–25/28

T12

4646

B–U

N–1

7SE

P99

53. If removed, install boot (3) and switch (2) in grip (1).

CED,OUTX547,108 –19–29SEP99–26/28

T12

4645

B–U

N–1

7SE

P99

54. Install and tighten screws (1—3).


PN=296


Control Linkage

03031541

CED,OUTX547,108 –19–29SEP99–27/28

T12

4638

B–U

N–1

7SE

P99

IMPORTANT: Tie bands MUST be installed and wirelead MUST be positioned in clampbetween assembly marks to provide aloop in wiring harness for steering.

55. Install tie bands (1) on wire harness.

56. Install clamp (3).

CED,OUTX547,108 –19–29SEP99–28/28

T12

4637

C–U

N–2

7OC

T99

1—Handle2—Boot3—Socket Head Cap Screw (4 used)

57. Install four socket head cap screws (3) and tighten tospecifications.

Single Lever Control—SpecificationSingle Lever Control Top PlateCap Screws—Torque 19 N•m (14 lb-ft) (168 lb-in.)....................................

58. Install boot (2).

59. Install handle (1) and tighten lock nut tospecifications.

Single Lever Control—SpecificationSingle Lever Control Handle LockNut—Torque 34 N•m (25 lb-ft)....................................................................

60. Adjust single lever control. (See Single Lever Control"SLC" Adjustment in Operation and Test Manual,Group 9026-20.)

61. Recalibrate transmission controller. (See CalibrateTransmission Controller in Operation and TestManual, Group 9015-20.)


PN=297

Control Linkage

030315

42

CED,TX14826,12113 –19–27OCT99–1/2

Rotary Sensor Component Location With (SIG) Speed In Grip (S.N. XXXXXX— )

T12

4351

B–U

N–0

7SE

P99

A—B27 Reverse Speed Ratio C—S3 Neutral Start Switch. F—Reverse Speed Ratio H—B4 Transmission SpeedSwitch. T53 Blue, T52 Blue E09B White Wire, E03B Switch 3 pin connector. Control switch, and S6and Z37 Gray wires. White Wire. G—B2 FNR Sensor. (Marked Horn Switch.

B—B5 Left And Right Steer D—(SIG) Speed In Grip 3 pin YELLOW on housingSensor. (Marked BLUE on connector. below sensor. Wiringhousing below sensor. E—Horn Switch 2 pin harness end behindWiring harness end behind connector. connector is tapedconnector is taped BLUE ) YELLOW) T01 Blue, T02T10 Blue, T11 Blue, Z05 Blue, Z01 Gray wires.Gray wires.



PN=298

Control Linkage

03031543

CED,TX14826,12113 –19–27OCT99–2/2

T12

4532

B–U

N–1

3SE

P99

Transmission Speed Switch/Horn Switch

T12

2746

B–U

N–2

9JU

L99

Transmission Speed Switch/Horn Switch

A—Horn SwitchB—Transmission Speed Switch


PN=299

Control Linkage

030315

44

TX,9026,YY1024 –19–05FEB96–1/2

Park Lock Linkage Adjustment

T84

34A

K–U

N–0

7MA

R95

T84

34A

B–U

N–0

7MA

R95

1—Bracket2—Rod3—Jam Nut4—Link5—Park Lock Switch6—Ball Joint7—Ball Joint

This procedure is used to adjust the linkage from the parklock lever in the operators station to the park brake valve.

1. Turn battery disconnect switch OFF and removebatteries from machine.

2. Remove retaining cap screws from bracket (1).Position bracket to allow access to park brake valvelinkage.

3. Disconnect rod (2) from bellcrank.


5. Remove cover in front of cab or ROPS to gain accessto the park lock linkage.

6. Loosen jam nuts (3) on vertical rod.

7. Position park lock lever in UP position.

8. Hold park brake pedal fully DOWN. Adjust vertical rodagainst upper stop.

9. Tighten jam nuts (3).

10. Install front cover.

11. Lower cab or ROPS. (See procedure in Operationand Test Manual, Group 9026-25.)

12. Put park lock lever down.

13. Measure total travel of the park brake pedal.


PN=300


Control Linkage

03031545

TX,9026,YY1024 –19–05FEB96–2/2

T84

34A

C–U

N–0

7MA

R95

14. Disconnect park lock switch (5). Connect a multimeterto the switch leads.

15. Slowly depress park brake pedal and check forcontinuity. As pedal reaches 1/2 of its total travel,switch must show continuity.

16. If the switch does not meet specification, adjust balljoint (6) to obtain correct switch operation.

17. Put park lock lever UP. Push rod (2) toward center ofmachine and bottom brake valve spool in bore. Holdrod and adjust ball joint (7) to meet bellcrank.

18. Install cap screw.

19. Install bracket and batteries.


PN=301

Control Linkage

030315

46


PN=302

Group 0360Hydrostatic System

CED,OUO1020,3233 –19–09DEC98–1/4

Essential Tools


0303601


CED,OUO1020,3233 –19–09DEC98–2/4

Speed Ring Installer . . . . . . . . . . . . . . . . . . JDG1161

Used to install speed ring on hydrostatic pump cylinderblock.

CED,OUO1020,3233 –19–09DEC98–3/4

Swashplate Leveling Tool—750C . . . . . . . . . . JDG920-2

Used to Level Swashplate

Swashplate Leveling Tool—850C . . . . . . . . . . JDG920-1

Used to Level Swashplate

CED,OUO1020,3233 –19–09DEC98–4/4

Driver Set . . . . . . . . . . . . . . . . . . . . . . . . . . JT01800

Pull shaft assembly out of hydrostatic motor main housing

CED,OUO1020,3039 –19–26OCT98–1/2





PN=303


Hydrostatic System

CED,OUO1020,3039 –19–26OCT98–2/2

17-1/2 Ton Puller Set . . . . . . . . . . . . . . . . . D01173AA

Used to pull shaft assembly out of hydrostatic motor mainhousing.

030360

2

CED,OUO1020,3040 –19–26OCT98–1/1

Other Material

Number Name Use

T43512 (U.S.) Thread Lock and Sealer (Medium Apply to outside diameter ofTY9473 (Canadian) Strength) hydrostatic pump seal prior to242 (LOCTITE) installation.

Apply on slipper guide bearing plateretaining screw threads.Apply to threads of swashplate covercap screws.

TY6305 (U.S.) Clean and Cure Primer Used to clean feedback link capTY9485 (Canadian) screw threads.764 (LOCTITE)

T43513 (U.S.) Thread Lock and Sealer (High Apply to threads of feedback link capTY9474 (Canadian) Strength) screw.271 (LOCTITE)



PN=304

Hydrostatic System

0303603

CED,OUO1020,3157 –19–10JAN00–1/3

Specifications


Feedback Link Cap Screw Torque 32.5 N•m (24 lb-ft)—750CTorque 54.2 N•m (40 lb-ft)—850C

Charge Pump Cover-to-Housing Cap Torque 13.5 N•m (10 lb-ft)—750CScrew Torque 32 N•m (24 lb-ft)—850C

Charge Pump Mounting Pad Cap Torque 271 N•m (200 lb-ft)—750CScrew Torque 298 N•m (220 lb-ft)—850C

Multi-Function Valve Torque 78.6 N•m (58 lb-ft)—750CTorque 210 N•m (155 lb-ft)—850C

Charge Pressure Manifold Lock Nut Torque 122 N•m (90 lb-ft)

Hydrostatic Pump Cover-to-Housing Torque 13.5 N•m (10 lb-ft)—750CTorque 32.5 N•m (24 lb-ft)—850C

Servo Cylinder Cap Screw Torque 32 N•m (24 lb-ft)

Pump Guide Post Nut Torque 23 N•m (17 lb-ft)—750CTorque 54 N•m (32 lb-ft)—850C

Swashplate Depth 0.025 mm (0.001 in.)

Swashplate Cover Cap Screw Blind Torque 32 N•m (24 lb-ft)—750CHole Torque 64 N•m (47 lb-ft)—850C

Swashplate Cover Cap Screw Torque 25 N•m (18 lb-ft)—750CThrough Hole Torque 50 N•m (37 lb-ft)—850C

Shims are 0.5 mm (0.20 in.) each

750C—All Quantity One shim each pocket

850C—4.5 mm (0.177 in.) pocket Quantity One shim each pocketdepth

850C—6 mm (0.24 in.) pocket Quantity Add enough shims to get 3.5—4 mmdepth pocket depth.

850C—7 or 7.5 mm (0.28 or 0.29 Quantity One shim each pocketin.) pocket depth


PN=305


Hydrostatic System

030360

4

CED,OUO1020,3157 –19–10JAN00–2/3


Pump End Cap (Large Cap Screw) Torque 271 N•m (200 lb-ft)—750CTorque 298 N•m (220 lb-ft)—850C

Pump End Cap (Small Cap Screw) Torque 38 N•m (28 lb-ft)

Retaining Plate Screw Torque 16.3 N•m (12 lb-ft)—750CTorque 35.3 N•m (26 lb-ft)—850C

PDCV Screws Torque 16 N•m (12 lb-ft)

PCP Screw Torque 4 N•m (35 lb-in.)

Oil Cooler Bypass Valve

Spring (G) Free Length 87.9 mm (3.5 in.) ApproximateTest Length 52.3 mm (2.06 in.) at 74.5 ± 7.5 N

(17 ± 1.7 lb force)

Spring (C) Free Length 50.5 mm (1.99 in.) ApproximateTest Length 35 mm (1.38 in.) at 88.8 ± 8.8 N (20

± 2 lb force)

Hydrostatic Motor End Cap Cover Torque 110 N•m (81 lb-ft)Cap Screws

Flushing Valve Plug Torque 41 N•m (30 lb-ft)

Shaft Adjusting Nut Torque 20 N•m (15 lb-ft)

Servo Piston Cone Point Set Screw Torque 5 N•m (44 lb-in.)

Valve Segment Spindle Torque 36 N•m (27 lb-ft)

Valve Segment Spindle Dimension Length 39.4—39.6 mm (1.55—1.56 in.)—“A” 750C

Length 44.2—44.4 mm (1.74—1.75 in.)—850C

Cylinder Block Bearing Dimension Depth 14.5—15.0 mm (0.57—0.59 in.)—“B” 750C

Depth 18.5—19.0 mm (0.73—0.75 in.)—850C

Flange-to-Motor Housing Cap Torque 110 N•m (81 lb-ft)—750CScrew— Torque 174 N•m (128 lb-ft)—850C


PN=306


Hydrostatic System

0303605

CED,OUO1020,3157 –19–10JAN00–3/3


Motor End Cap-to-Housing Screw— Torque 135 N•m (100 lb-ft)—750CTorque 213 N•m (157 lb-ft)—850C

Shuttle Ball Seat Torque 11 N•m (8 lb-ft)

Shuttle Ball Plug Torque 37 N•m (27 lb-ft)

Adjusting Screw Distance 10 mm (0.399 in.)—750CDistance 12 mm (0.472 in.)—850CTorque 16 N•m (142 lb-in.)

Displacement Control Valve-to-End Torque 110 N•m (81 lb-ft)Cap


PN=307

Hydrostatic System

030360

6

TX,0300,YY1123 –19–09DEC98–1/20

Disassemble Hydrostatic Pump

T84

92A

C–U

N–0

2JU

N95

T10

0315

–UN

–13F

EB

96

1—Internal Hex Screw2—Retainer Plate Screw3—Internal Hex Screw4—O-Ring

NOTE: If only shaft and/or shaft seal are being replaced,major disassembly of pump or removal of speedsensor is not required. Pump MUST be positionedwith the shaft UP to prevent damage to sensor orspeed ring.

1. Remove pump speed sensor.

2. Remove four internal hex screws (3) and pressurecontrol pilot (PCP) from pump displacement controlvalve. PCP is serviced as an assembly. DO NOTdisassemble.

NOTE: Displacement control valve can be disassembledfor cleaning ONLY. (See procedure in this group.)

3. Remove six internal hex screws (1) and pumpdisplacement control valve from housing.

CAUTION: Protect machined surfaces fromdamage and foreign materials.

NOTE: After the seal carrier is removed, the shaft andbearing assembly are free in housing. DO NOTremove shaft unless it is positioned with the shaftUP. If pump is positioned horizontally when theshaft is removed, the cylinder block will move outof place, making shaft installation difficult.

4. Remove retainer plate screws (2).

5. Remove retainer plate. A spring inside the rotate groupwill try to overcome the friction from the O-ring on theseal carrier OD. If seal carrier does not move from itsbore, use a rubber hammer and tap on top of shaft.Spring inside rotor group will move seal carrier upwardfrom bore.

6. Remove O-ring (4) from carrier.

7. Inspect seal carrier and seal for any damage or nicks.


PN=308


Hydrostatic System

TX,0300,YY1123 –19–09DEC98–2/20

NOTE: Apply thread lock and sealer (medium strength) tooutside diameter of seal prior to installation.

8. Use a press to remove and install new seal whennecessary.

0303607

TX,0300,YY1123 –19–09DEC98–3/20

T84

64A

C–U

N–1

4JU

N95

T84

64A

D–U

N–1

4JU

N95

T10

0313

–UN

–13F

EB

96

A—Front Pump Shaft—750CB—Rear Pump Shaft—750C

9. Remove the shaft and bearing assembly from thehousing. The bearing outside diameter is a slip fit inthe housing bore.

NOTE: On the 750C the front pump shaft (A) is differentfrom the rear pump shaft (B). On the 850C thefront pump shaft and rear pump shaft are thesame.

10. Remove retaining ring and press shaft out of bearing.


PN=309


Hydrostatic System

030360

8

TX,0300,YY1123 –19–09DEC98–4/20

T84

93A

B–U

N–0

2JU

N95

1—Pump Housing Cap Screws2—Large Cap Screws

11. Place pump with auxiliary mounting flange UP.

12. Remove small end cap to pump housing cap screws(1).

13. Remove large cap screws (2) and mounting flange.

TX,0300,YY1123 –19–09DEC98–5/20

T84

64A

H–U

N–1

4JU

N95

T84

64A

I–U

N–1

4JU

N95

IMPORTANT: Note quantity of swashplate levelingspring shims removed from end capspring pockets. The same quantityMUST be used for assembly.

14. Remove end cap from housing. Remove end capgasket and swashplate leveling spring shims from thespring pockets in the end cap.

NOTE: The two long swashplate leveler springs arenested, with the smaller spring installed into thelarger spring.

15. Remove two long swashplate leveler springs and oneshort swashplate hold down spring.



PN=310

Hydrostatic System

0303609

TX,0300,YY1123 –19–09DEC98–6/20

T84

64A

J–U

N–1

4JU

N95

T84

64A

M–U

N–1

4JU

N95

T84

64A

L–U

N–1

4JU

N95

T84

64A

N–U

N–1

4JU

N95

16. Remove the alignment pins and valve plate. Note thedirection of the arrows on the valve plate forassembly.

17. Scribe a line on the side cover and the housing.

18. Remove side cover and swashplate leveler (T-bar)assembly from housing.

19. Remove spring seats from swashplate leveler.

TX,0300,YY1123 –19–09DEC98–7/20

T84

64A

O–U

N–1

4JU

N95

T84

64C

L–U

N–1

4JU

N95

T10

0196

–UN

–12F

EB

96

A—Side CoverB—Guide PostC—Swashplate Leveler (T-Bar)D—Wear StripsE—O-Ring

20. Remove two guide posts and sealing nuts holding theleveler to the side cover.

21. Remove swashplate leveler and O-ring from sidecover.


PN=311


Hydrostatic System

030360

10

TX,0300,YY1123 –19–09DEC98–8/20

T84

64A

S–U

N–1

4JU

N95

T84

64A

T–U

N–1

4JU

N95

22. Scribe a line on each servo cylinder and the housingto identify each servo cylinder with its respective sideof the housing.

23. Remove cap screws from each servo piston.

24. Carefully pry each cylinder from the housing using ascrewdriver in the groove of the cylinder. The servopiston will remain in the housing.

25. Remove the cylinder block through the housing endcap opening. The swashplate and piston assemblywill remain in the housing.

TX,0300,YY1123 –19–09DEC98–9/20

T84

64A

U–U

N–1

4JU

N95

T84

64A

V–U

N–1

4JU

N95

26. Remove the swashplate bearing cage link pin fromthe housing through the control opening.

27. Remove the bearing cage locator link from theswashplate through the control opening. Inspect linkfor wear or damage and replace as necessary.

TX,0300,YY1123 –19–09DEC98–10/20

T84

64A

W–U

N–1

4JU

N95

T84

64A

X–U

N–1

4JU

N95

28. Remove swashplate and pistons through the housingside cover. Disengage the servo arm from the sliderblock located in the servo piston as the assembly isremoved.

29. Remove the servo piston and slider block fromhousing.



PN=312

Hydrostatic System

TX,0300,YY1123 –19–09DEC98–11/20

T84

64A

Y–U

N–1

4JU

N95

03036011

T84

64A

Z–U

N–1

4JU

N95

30. Remove the swashplate cradle bearing cage.

31. Remove the bearing races. The bearing races are aloose fit on two locating pins in the housing.

TX,0300,YY1123 –19–09DEC98–12/20

T84

64B

B–U

N–1

4JU

N95

32. Remove four cap screws holding the slipper guidehold down mechanism to the swashplate.

TX,0300,YY1123 –19–09DEC98–13/20

T84

64B

E–U

N–1

4JU

N95

33. Remove the piston assemblies from the slipper guide.

34. After disassembly all parts should be thoroughlycleaned. Replace all O-rings, gaskets, and the shaftseal. Inspect all parts for damage, nicks, or unusualor excessive wear or discoloration.

If the end cap journal bearing needs replacement (asevidenced by large amounts of the metal back of thebearing being visible through the plastic bearingmaterial), replace end cap.



PN=313

Hydrostatic System

TX,0300,YY1123 –19–09DEC98–14/20

T84

64B

F–U

N–0

5JU

L95

35. Clean threaded holes in swashplate that attachslipper guide of all retaining compound prior toassembly.

030360

12

TX,0300,YY1123 –19–09DEC98–15/20

T85

00A

B–U

N–1

4JU

N95

1—Headed Roll Pin and Washer2—Swashplate Guide3—Feedback Link4—Servo Arm

NOTE: Servo arm and swashplate guide are bothretained with the same special locking screw.Servo arm alignment is critical to proper pumpoperation. For this reason, removal of the servoarm from the swashplate is not recommended.Swashplate is serviced as an assembly.

36. Inspect servo arm (4) and swashplate guide (2) forwear. Replace as necessary.

37. Inspect headed roll pin and washer (1) for the bearingcage locator link.

38. Remove cap screw securing feedback link (3) andinspect for wear or damage. Clean cap screw threadswith clean and cure primer. Apply thread lock andsealer (high strength) to threads. Install feedback link.Tighten cap screw to specification.

SpecificationFeedback Link Cap Screw—Torque 32.5 N•m (24 lb-ft)—750C..............................................................Torque 54.2 N•m (40 lb-ft)—850C..............................................................

TX,0300,YY1123 –19–09DEC98–16/20

T84

64B

I–U

N–1

4JU

N95

T84

64B

J–U

N–1

4JU

N95

39. Inspect servo piston and sealing rings for wear andreplace as necessary.

40. Install new expander O-rings and seal rings into thegrooves of the servo piston.

41. Lubricate seal rings and carefully slide the servopiston into the servo cylinders. Allow the assembly tosit 5—10 minutes to allow the seal rings to return totheir original size. Remove servo cylinders.


PN=314


Hydrostatic System

03036013

TX,0300,YY1123 –19–09DEC98–17/20

T11

0327

B–U

N–2

6JA

N98

IMPORTANT: Remove speed ring ONLY ifreplacement is necessary.

DO NOT damage sealing surface ofcylinder block.

42. Place cylinder block on a clean soft surface(cardboard or shop towel) to replace speed ring. Becareful NOT to damage sealing surface of cylinderblock.

43. Remove speed ring from cylinder block by gentlytapping on ring using a hammer and brass drift.

TX,0300,YY1123 –19–09DEC98–18/20

T11

0328

B–U

N–2

6JA

N98

44. Place new speed ring on chamfered edge of cylinderblock.

TX,0300,YY1123 –19–09DEC98–19/20

T11

0329

B–U

N–2

6JA

N98

IMPORTANT: To prevent damage to speed ring useinstallation tool. JDG1161 Speed RingInstaller is machined to fit the750C/850C hydrostatic pumps.

45. Carefully place JDG1161 Speed Ring Installer overspeed ring and cylinder block. Alternately tap edge ofinstaller using a rubber mallet to seat speed ring.Speed ring will be located correctly when installer isbottomed on cylinder block.



PN=315

Hydrostatic System

TX,0300,YY1123 –19–09DEC98–20/20

T84

92A

A–U

N–1

4JU

N95

46. Compress the cylinder block spring and remove thespiral retaining ring, retainer, spring and spring seat.Clean cylinder block components and reassemble.

030360

14


PN=316

Hydrostatic System

03036015

TX,0300,DY182 –19–12MAR96–1/1

Disassemble and Assemble Charge Pump

T10

0312

–UN

–13F

EB

96T

1003

30–U

N–1

3FE

B96

1—O-Ring2—Clockwise Rotation Hole3—Inner Port Plate4—Charge Pump Gerotor Assembly5—Recessed Edge6—Alignment Pin7—Cover8—Auxiliary Drive9—Key10—Charge Pump Shaft11—Alignment Pin Hole12—Mounting Pad

NOTE: The charge pump rotation is determined by theorientation of the gerotor assembly outer eccentricring and the location of the alignment pin in theend cap.

1. Disassemble charge pump as shown. Inspect all partsfor wear or damage and replace as necessary.

NOTE: Apply clean hydrostatic oil to all charge pumpparts prior to installation.

2. Install pin (6) into clockwise rotation hole (2) into pumphousing.

3. Install inner port plate (3).

4. Install gerotor assembly (4) with recessed edge (5)away from pump.

NOTE: Install charge pump shaft (10) with spline endtoward pump housing.

5. Install charge pump shaft (10), key (9), and auxiliarydrive (8).

6. Install cover (7). Align hole in cover with pin (6).

NOTE: It is normal that cover is not tight against end capwith cap screws at proper torque.

7. Install and tighten six cap screws in cover tospecification.

SpecificationCharge Pump Cover-to-HousingCap Screw—Torque 13.5 N•m (10 lb-ft)—750C.........................................Torque 32 N•m (24 lb-ft)—850C................................................................

8. Install O-ring (1) on pilot of end cap housing.

9. Install mounting pad (12) and four cap screws. Tightencap screws to specification.

SpecificationCharge Pump Mounting Pad CapScrew—Torque 271 N•m (200 lb-ft)—750C................................................Torque 298 N•m (220 lb-ft)—850C............................................................


PN=317

Hydrostatic System

030360

16

TX,0300,YY1162 –19–29AUG96–1/1

Disassemble and Assemble PumpDisplacement Control Valve (PDCV)

T10

2089

–UN

–23J

UL9

6

1—Outer Spring2—Inner Spring3—Spacer and O-Ring (850C only)4—Linkage Identification Stamp (750C—10),

(850C—13)5—Feedback Link6—Chamfered Side of Guide7—Guide8—Null Adjustment Screw9—PDCV Housing, Piston and Barrel Assembly

IMPORTANT: DO NOT disassemble the PDCVhousing, piston and barrel assembly (9).Correct backlash and neutraladjustment cannot be obtained ifdisassembled.

NOTE: The pump displacement control valve (PDCV) isserviced as an assembly and should only bedisassembled for cleaning.

1. Disassemble pump displacement control valve asshown. DO NOT disassemble the PDCV housing,piston and barrel assembly (9).

2. Clean and inspect all parts for wear or damage.

3. Assemble PDCV after cleaning.

4. Do Pump Displacement Control Valve NeutralAdjustment. (See procedure in Operation and TestManual, Group 9026-25.)

IMPORTANT: Calibrate transmission controllerwhenever a sensor or transmissioncomponent is adjusted or replaced.



PN=318

Hydrostatic System

03036017

TX,0300,YY1163 –19–10JAN00–1/1

Remove and Install Multi-Function Valve

T85

25A

B–U

N–1

3JU

L95

1—Charge Pressure Line

1. Disconnect charge pressure lines (1) frommulti-function valve.

2. Remove multi-function valve from hydrostatic pumphousing.

3. Inspect valve for wear or damage.

4. Install and tighten valve to specification.

SpecificationMulti-Function Valve—Torque 78.6 N•m (58 lb-ft)—750C..........................Torque 210 N•m (155 lb-ft)—850C.............................................................

5. If valve was disassembled for any reason or a newvalve is installed, do Multi-Function Relief Valve Test.(See procedure in Operation and Test Manual, Group9026-25.)


PN=319

Hydrostatic System

030360

18

TX,03,BA2012 –19–19MAY97–1/2

Remove and Install Charge Pressure Manifold

T85

70A

B–U

N–0

4OC

T95

1—From Hydrostatic Filter 4—To Park Brake Valve 6—To Rear Charge Pressure 7—To Rear Charge Pressure2—To Hydrostatic Motor PCPs 5—Charge Pressure Manifold Manifold Manifold3—To Hydrostatic Filter (2 used)

1. Install vacuum pump on hydrostatic reservoir.

2. Disconnect lines (1—3, 6 and 7) at charge pressuremanifold. Cap and plug all openings.

3. Scribe a line on pump and manifold to indexmanifold position.

4. Loosen lock nut and remove charge pressuremanifold, leaving tube in pump.

5. Move lock nut as far onto manifold as threadsallow. Install new O-ring (if required).

IMPORTANT: Tube MUST be installed in pumphousing; if installed in manifolddamage will occur.

6. If tube is replaced, install tube into pump housing.

NOTE: The O-ring may or may not contact the pumpas the tube is seated in manifold.

7. Install charge pressure manifold (by hand only) untilthe tube is fully seated in the manifold.

8. Rotate the manifold counterclockwise until it isoriented properly with scribe line from step 3.(Manifold should be turned less than one full turncounterclockwise.)

9. Tighten lock nut to specification.

SpecificationCharge Pressure Manifold LockNut—Torque 122 N•m (90 lb-ft)...........................................................

10. Repeat procedure on the other charge pressuremanifold.


PN=320


Hydrostatic System

TX,03,BA2012 –19–19MAY97–2/2

11. Connect lines to charge pressure manifold. 12. Remove vacuum pump.

03036019

TX,0300,YY1164 –19–13JUL95–1/1

Disassemble and Assemble Multi-FunctionValve

T84

97A

A–U

N–0

7JU

N95

1—High Pressure Relief Valve Poppet2—Check Valve Poppet3—Pressure Limiter Poppet4—Bypass Piston5—Bypass Sleeve6—O-Ring7—Lock Nut8—O-Ring9—Spring10—Spring Guide11—O-Ring12—Guide13—Shim14—Spring15—O-Ring

NOTE: Multi-function valve is serviced as an assembly.

1. Disassemble multi-function valve as shown. Clean andinspect all parts for wear or damage. Replace valve ifnecessary.

2. Install new O-rings and assemble valve.

3. After multi-function valve is installed on machine, doMulti-Function Relief Valve Test in Operation and TestManual, Group 9026-25.


PN=321

Hydrostatic System

030360

20

TX,0300,YY1139 –19–09DEC98–1/19

Assemble Hydrostatic Pump

T84

64B

K–U

N–3

1MA

Y95

T84

64B

L–U

N–1

4JU

N95

IMPORTANT: Be careful when handling parts withlapped surfaces.

NOTE: Apply clean hydrostatic oil to all internal partsbefore assembly.

Either side of slipper guide can be installedagainst slippers.

1. Install the piston assemblies into the slipper guide.(Pistons can be installed to either side of guide.)

2. Apply clean hydrostatic oil on slippers. Center thepistons and guide on the swashplate.

NOTE: The split between the slipper guide bearing platesmust be located in line with the swashplate arm.The bearing surface of the bearing plates must belocated next to the slipper guide.

TX,0300,YY1139 –19–09DEC98–2/19

T84

64B

O–U

N–1

4JU

N95

In this photo, bronze side of bearing plate will be facing UP (awayfrom slipper guide).

T84

64B

P–U

N–1

4JU

N95

IMPORTANT: Install bearing plates with bronze sideaway from slipper guide.

Always use new screws to retain slipperguide bearing plates.

NOTE: Inspect the flat washers for raised edges or burrs.The smooth side of the flat washers must beinstalled next to the bearing plates.

3. Apply thread lock and sealer (medium strength) onscrew threads. Install two new screws and flat washersthrough the slipper guide bearing and spacers. Fingertighten the screws into the swashplate.

4. Assemble other half of bearing plate.



PN=322

Hydrostatic System

03036021

TX,0300,YY1139 –19–09DEC98–3/19

T84

64B

Q–U

N–1

4JU

N95

T84

64B

R–U

N–1

4JU

N95

5. Torque screws into swashplate. The slipper guide andpiston slippers must slide freely on the swashplate.

SpecificationHydrostatic PumpCover-to-Housing—Torque 13.5 N•m (10 lb-ft)—750C...............................Torque 32.5 N•m (24 lb-ft)—850C.............................................................

6. Lubricate the pistons and cylinder block bores. Installthe assembled swashplate and pistons into the cylinderblock by inserting the pistons into the cylinder blockbores. The pistons and bores are not selectively fitted,therefore no specific piston and bore orientation isrequired.

TX,0300,YY1139 –19–09DEC98–4/19

T84

64B

S–U

N–1

4JU

N95

T84

64A

Z–U

N–1

4JU

N95

7. Check that the swashplate bearing race locating pinsare secure in the housing.

8. Install the swashplate bearing races into the housingon the locating pins. Retain the races in position usingpetroleum jelly. The locating pins are offset in thehousing to assure proper assembly.

TX,0300,YY1139 –19–09DEC98–5/19

T84

64B

U–U

N–1

4JU

N95

T84

64B

V–U

N–1

4JU

N95

9. Assemble and lubricate the bearing cage and install onthe bearing races.

10. Install the bronze slider block on the swashplateservo arm.



PN=323

Hydrostatic System

TX,0300,YY1139 –19–09DEC98–6/19

T84

64B

X–U

N–1

4JU

N95

11. Position the servo piston in the housing.

030360

22

TX,0300,YY1139 –19–09DEC98–7/19

T85

00A

C–U

N–1

4JU

N95

T84

80A

A–U

N–0

2JU

N95

T84

64B

Y–U

N–1

4JU

N95

12. Carefully lower the cylinder block and swashplateassembly into the housing through the end capopening.

NOTE: A cap screw (approximately 9 in. long), two flatwashers (2-1/2 OD) and nut can also be used toassist in lowering cylinder block into housing.


PN=324


Hydrostatic System

TX,0300,YY1139 –19–09DEC98–8/19

T84

64C

A–U

N–1

4JU

N95

03036023

T84

64C

B–U

N–1

4JU

N95

13. Hold the cylinder block and swashplate assemblyapproximately 13 mm (1/2 in.) above the cradlebearing. Properly position the feedback link in thecontrol opening.

14. Move the servo piston on the slider block, taking carenot to wedge the block. The parts must slide freely.

TX,0300,YY1139 –19–09DEC98–9/19

T84

64C

D–U

N–1

4JU

N95

15. Lower the cylinder block and swashplate assemblyuntil the swashplate is properly located on the cradlebearings.

NOTE: If an assembly tool was used to install cylinderblock, remove nut and washer and allow capscrew and washer to fall through the shaftopening of the housing.

16. Install new O-rings on servo cylinders. Hold the servopiston in position and install the servo cylinders.

NOTE: Be sure to assemble the correct servo cylinder oneach side of the housing.

17. Install and tighten servo cylinder cap screws tospecification.

SpecificationServo Cylinder Cap Screw—Torque 32 N•m (24 lb-ft).............................................................................

TX,0300,YY1139 –19–09DEC98–10/19

T84

64C

H–U

N–1

4JU

N95

T84

64C

J–U

N–1

4JU

N95

18. Align the slot in the swashplate bearing cage with theheaded spring pin in the swashplate and the pin holein the housing. Hook the cage locator link over thespring pin, between the washer and the swashplate.Rotate the link into the slot in the bearing cage.

19. Align the hole in the locator link with the hole in thehousing and install the link anchor pin though the linkand into the housing.


PN=325


Hydrostatic System

030360

24

TX,0300,YY1139 –19–09DEC98–11/19

T84

64C

K–U

N–1

4JU

N95

T84

64C

L–U

N–1

4JU

N95

T10

0196

–UN

–12F

EB

96

A—Side CoverB—Guide PostC—Swashplate Leveler (T-Bar)D—Wear StripE—O-Ring

20. Push the swashplate assembly toward the controlside of the housing until the swashplate guidecontacts the bearing race. Check for clearancebetween the servo arm and the slider block. If noclearance is present, recheck the assembly of thebearing cage and races.

21. Install wear strips and position the swashplate leveler(T-bar) on the side cover. Note the orientation of theleveler and the cover.

22. Install a new side cover O-ring.

TX,0300,YY1139 –19–09DEC98–12/19

T84

64C

M–U

N–1

4JU

N95

23. Apply thread lock and sealer (medium strength) toguide post threads. Install leveler, guide posts andsealing nuts. Tighten nuts to specification.

SpecificationPump Guide Post Nut—Torque 23 N•m (17 lb-ft)—750C..........................Torque 54 N•m (32 lb-ft)—850C.................................................................

TX,0300,YY1139 –19–09DEC98–13/19

T84

64C

N–U

N–1

4JU

N95

24. Install the leveler spring seats.

IMPORTANT: Tabs of T-bar MUST be positioned ontop of swashplate. Otherwise damage totabs will occur.

25. Install side cover and swashplate leveler (T-bar).Rotate the side cover to align the marks on the coverand housing that were made at disassembly.


PN=326


Hydrostatic System

TX,0300,YY1139 –19–09DEC98–14/19

T84

64C

O–U

N–1

4JU

N95

03036025

T84

64C

P–U

N–1

4JU

N95

26. Apply thread lock and sealer (medium strength) tocap screws. Install a cap screw finger tight to eachside of swashplate cover while checking the “zeroangle” position.



PN=327

Hydrostatic System

030360

26

TX,0300,YY1139 –19–09DEC98–15/19

T84

81B

L–U

N–0

2JU

N95

1—Swashplate Leveling Tool

27. Install nested swashplate leveling springs (one smallspring and one large spring on each side), servo armlink spring (single short spring) and JDG920-2 for750C or JDG920-1 for 850C, swashplate leveling tool(1).

NOTE: Depth gauge MUST be located on swashplateand NOT on piston retainer plate.

28. Make sure the swashplate is properly located on itsbearings. Using a depth micrometer, measure thedistance from the pump housing to the top ofswashplate. Take a second measurement on theopposite side of the swashplate. Thesemeasurements MUST not vary by more thanspecification. Rotate the side cover (which will alsorotate the leveler and swashplate) until the zero angleposition is established, as determined by the depthmeasurement.

When zero angle position has been established,tighten the two side cap screws.

SpecificationSwashplate—Depth 0.025 mm (0.001 in.)..................................................

NOTE: The two top cap screws have through holes.

29. Apply thread lock and sealer (medium strength) toscrews. Install and tighten remaining cap screws tospecification.

SpecificationSwashplate Cover Cap ScrewBlind Hole—Torque 32 N•m (24 lb-ft)—750C.............................................Torque 64 N•m (47 lb-ft)—850C.................................................................Swashplate Cover Cap ScrewThrough Hole—Torque 25 N•m (18 lb-ft)—750C........................................Torque 50 N•m (37 lb-ft)—850C.................................................................



PN=328

Hydrostatic System

TX,0300,YY1139 –19–09DEC98–16/19

T84

64A

J–U

N–1

4JU

N95

30. Install end cap alignment pins into housing.

31. Apply hydrostatic oil on running surface of cylinderblock and install valve plate on alignment pins.

NOTE: The arrow cutouts in the valve plate must point inthe direction of pump rotation when viewed fromthe shaft end.

03036027

TX,0300,YY1139 –19–09DEC98–17/19

T84

79A

J–U

N–1

4JU

N95

32. Install new end cap gasket on housing. Be carefulthat gasket does not get caught on dowel pins.

IMPORTANT: Use hardened swashplate leveler springshims ONLY. Using other shimmingmaterials could cause damage to pump.

33. Lubricate end cap journal bearings. Install swashplateleveler spring shims removed during disassembly, intoend cap pockets. Retain shims using petroleum jelly.

If quantity of shims removed is unknown, consultspecifications to determine number of shims needed.

Shims are 0.5 mm (0.20 in.) each—Specification750C—All—Quantity One shim each pocket...............................................850C—4.5 mm (0.177 in.) pocketdepth—Quantity One shim each pocket......................................................850C—6 mm (0.24 in.) pocketdepth—Quantity Add enough shims to get 3.5—4

mm (0.14—0.16 in.) pocketdepth.

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

850C—7 or 7.5 mm (0.28 or 0.29in.) pocket depth—Quantity One shim each pocket....................................



PN=329

Hydrostatic System

030360

28

TX,0300,YY1139 –19–09DEC98–18/19

T84

79A

G–U

N–1

4JU

N95

T84

79A

I–U

N–1

4JU

N95

T84

79A

K–U

N–1

4JU

N95

T84

64A

C–U

N–1

4JU

N95

34. Install end cap. Position springs into pockets in endcap.

35. Install four large cap screws. Tighten cap screwsevenly to specification.

SpecificationPump End Cap (Large CapScrew)—Torque 271 N•m (200 lb-ft)—750C...............................................Torque 298 N•m (220 lb-ft)—850C.............................................................

36. Install and tighten small screws to specification.

SpecificationPump End Cap (Small CapScrew)—Torque 38 N•m (28 lb-ft)...............................................................

37. Install shaft and bearing assembly.



PN=330

Hydrostatic System

03036029

TX,0300,YY1139 –19–09DEC98–19/19

T10

0315

–UN

–13F

EB

96T

8492

AC

–UN

–02J

UN

95

1—Cap Screw2—Retaining Plate Screw3—Cap Screw4—O-Ring

38. Install new O-ring (4) and carrier.

39. Install retaining plate. Tighten retaining plate screws(2) to specification.

SpecificationRetaining Plate Screw—Torque 16.3 N•m (12 lb-ft)—750C.......................Torque 35.3 N•m (26 lb-ft)—850C.............................................................

40. Install new gasket and displacement control valve onhousing. Engage the pin on the control linkage in themating hole in the link attached to the swashplate.Install and tighten pump displacement control valve(PDCV) screws (1) to specification.

SpecificationPDCV Screws—Torque 16 N•m (12 lb-ft)...................................................

41. Install four new O-rings and pressure control pilot(PCP). Install and tighten screws (3) to specification.

SpecificationPCP Screw—Torque 4 N•m (35 lb-in.)......................................................


PN=331

Hydrostatic System

030360

30

TX,0360,DU1211 –19–13JUL95–1/1

Disassemble and Assemble Oil Cooler Bypass Valve

T60

57A

B–U

N–0

4NO

V88

A—Plug (2 used) C—Spring E—Valve Spool G—SpringB—O-Ring (2 used) D—Thermostat F—Valve Body

1. Remove plugs (A) to disassemble valve.

2. Inspect springs (C and G).

Oil Cooler Bypass Valve —SpecificationSpring (G)—Free Length 87.9 mm (3.5 in.) Approximate....................Test Length 52.3 mm (2.06 in.) at 74.5 ± 7.5

N (17 ± 1.7 lb force).......................................

Spring (C)—Free Length 50.5 mm (1.99 in.) Approximate..................Test Length 35 mm (1.38 in.) at 88.8 ± 8.8

N (20 ± 2 lb force)..........................................

3. Inspect valve spool (E) for wear or damage.

4. Apply hydrostatic oil to all internal parts andassemble valve.

TX,0300,YY1171 –19–03MAR04–1/11

Disassemble Hydrostatic Motor

T85

12A

D–U

N–2

7JU

N95

1—Internal Hex Screw2—Internal Hex Screw

1. Thoroughly clean external surface of motor prior todisassembly.

2. Remove four internal hex screws (1) and pressurecontrol pilot (PCP) from displacement control valve.

IMPORTANT: PCP is serviced as an assembly. DONOT disassemble.

3. Remove four internal hex screws (2) and motordisplacement control valve from housing.

4. Remove motor speed sensor housing and sensor.


PN=332


Hydrostatic System

03036031

TX,0300,YY1171 –19–03MAR04–2/11

T85

12A

E–U

N–2

7JU

N95

T85

12A

G–U

N–2

7JU

N95

T85

12A

I–U

N–2

7JU

N95

1—Valve Block2—Spring Seat3—Spring4—Spool5—Spring Seat6—Spring7—Pin8—Gasket9—Cover10—Adjusting Screw11—Nut12—Plug13—Shuttle Ball Seat14—Ball

5. Disassemble displacement control valve as shown.

6. Remove plug (12), shuttle ball seat (13) and ball (14).

7. Remove four internal hex screws and parts (8—11).



PN=333

Hydrostatic System

030360

32

TX,0300,YY1171 –19–03MAR04–3/11

T85

17A

F–U

N–1

0JU

L95

1—O-Ring2—Spring3—Spring Seat4—Spool5—O-Ring6—O-Ring7—Cover8—Operating Charge Relief Valve9—Screw (4 used)10—O-Ring

8. Remove four internal hex screws (9) and cover (7)from end cap.

9. Remove flushing valve components (1—4).

NOTE: If plug on either end of flushing valve is replaced,use the same length as removed. Early machinesused a longer plug.

10. Remove operating charge relief valve (8).

11. Replace O-rings (1, 5, 6 and 10).

12. Install cover and screws. Tighten screws tospecification.

SpecificationHydrostatic Motor End Cap CoverCap Screws—Torque 110 N•m (81 lb-ft)....................................................

13. Install flushing valve components (1—4). Tightenplugs to specification.

SpecificationFlushing Valve Plug—Torque 41 N•m (30 lb-ft).........................................



PN=334

Hydrostatic System

03036033

TX,0300,YY1171 –19–03MAR04–4/11

T19

8215

–UN

–03M

AR

04

1—Spring Guide 4—Spring 7—Spring Guide 9—Valve Spool2—Spring 5—Spring Guide 8—Valve Body 10—O-Ring3—Spring Guide 6—Spring

14. Remove end cap components (1—10).



PN=335

Hydrostatic System

030360

34

TX,0300,YY1171 –19–03MAR04–5/11

T85

06A

C–U

N–1

0JU

L95

1—Cap Screw (4 used)2—Cap Screw (4 used)3—End Cap4—Gasket5—Alignment Pin (2 used)6—Segment7—Alignment Pins (2 used)8—Rollers9—Synchronizing Shaft10—Cylinder Block11—Bearing Plate

15. Scribe a line between end cap and housing to aid inassembly. Remove screws (1 and 2) retaining endcap assembly to motor housing. Remove end cap (3),gasket (4) and alignment pins (5).

IMPORTANT: Special attention should be given to theorientation of the segment (6) with endcap and housing, alignment pins (7),rollers (8) with synchronizing shaft(recess faces the center-line of theshaft) and synchronizing shaft (9) withcylinder block (10) and output shaft.

16. Remove hydrostatic motor parts (6—11) as shown.


PN=336


Hydrostatic System

03036035

TX,0300,YY1171 –19–03MAR04–6/11

T19

8216

–UN

–03M

AR

04

1—Lock Nut 4—O-Ring 7—Setting Lug 10—Spring Guide2—Nut 5—Glide Ring 8—Cone Point Set Screw 11—Spring Guide3—Shaft 6—Servo Piston 9—Lock Screw 12—O-Ring

17. Remove shaft (3) with lock nut (1) as anassembly. Replace O-ring (4).

18. Remove lock screw (9) and cone point set screw(8) from servo piston (6).

19. Remove setting lug (7) and servo piston from endcap. Inspect glide ring (5) for wear or damage andreplace if necessary.

20. Carefully install a new O-ring (12) and a new glidering (5) on the servo piston (6). Lubricate the glidering with clean hydrostatic oil and install the servopiston into the end cap.

21. Install the setting lug (7) into the servo piston frominside the end cap. The offset of the setting lugmust be located away from the control end of theend cap. Install spring guide (10) through settinglug.

22. Install the cone point set screw (8) so that thepoint enters the groove of the setting lug. DO NOTtighten set screw at this time.

NOTE: If shaft with adjusting nut was disassembled, itMUST be adjusted when end cap iscompletely assembled. Loosen lock nut (1)and adjust shaft (3) by turning internal hex onend of shaft clockwise until shaft bottoms. Turnshaft counterclockwise four turns and tightenlock nut.

23. Install shaft with adjusting nut through setting lugand spring guide. Tighten to specifications.

SpecificationShaft Adjusting Nut—Torque 20 N•m (15 lb-ft)....................................


PN=337


Hydrostatic System

030360

36

TX,0300,YY1171 –19–03MAR04–7/11

T85

06A

D–U

N–3

0JU

N95

1—Cap Screw (6 used)2—Flange3—O-Ring4—Shaft Seal5—Shaft Assembly6—Housing7—Flange Holes

24. Tighten cone point set screw to specification. Installand tighten lock screw to specification.

SpecificationServo Piston Cone Point SetScrew—Torque 5 N•m (44 lb-in.).................................................................Valve Segment Spindle—Torque 36 N•m (27 lb-ft)....................................

25. Scribe a line on housing and flange to aid inassembly. Remove six internal hex screws (1) fromflange. Install two M12 x 50 mm screws into flangeholes (7). Alternately tighten screws to remove flangefrom housing.

26. Remove old seal (4) from flange. Once removed, theseal is not reusable.

27. Inspect seal area for any damage or nicks.

28. Apply flexible sealant to outer diameter of new seal.Use a press to install new seal into flange until sealbottoms in flange. Be careful not to damage seal.

29. Install new O-ring (3) on flange.


PN=338


Hydrostatic System

03036037

TX,0300,YY1171 –19–03MAR04–8/11

T85

14A

B–U

N–3

0JU

N95

30. Pull shaft assembly out of main housing, taking careto not damage the shaft and speed sensor ring. DONOT damage piston sockets. Use attachments fromthe D01173AA 17-1/2 Ton Puller Set and JT01800Driver Set.



PN=339

Hydrostatic System

030360

38

TX,0300,YY1171 –19–03MAR04–9/11

T85

06A

E–1

9–10

JUL9

5

1—Piston Ring2—Identification Mark3—Spherical Surface4—Piston

31. Remove piston rings (1) from pistons (4) using asmall pair of retaining ring pliers and an O-ring pick.

IMPORTANT: When installing new spherical pistonrings, the spherical surface (3) MUSTconform to the shape of the piston.

A radial identification mark (2) isprovided on the outer edge of thepiston ring.

32. Install new piston rings on pistons. The ends of eachpiston ring MUST NOT overlap each other.

NOTE: Shaft assembly with exception to the piston ringsis serviced as an assembly.


PN=340


Hydrostatic System

03036039

TX,0300,YY1171 –19–03MAR04–10/11

T85

06A

F–U

N–1

2JU

L95

1—Bearing Plate2—Valve Segment3—Spindle4—Cylinder Block5—Cylinder Block Bearing

33. Inspect the bronze surface of the bearing plate (1) fordamage and excessive wear. The sealing surfacesmust be free from scratches and nicks. The locatingpin holes must not be worn. Replace the bearingplate if damaged or worn.

34. Inspect the valve segment (2) sealing surfaces andspindle (3) for damage or wear. Check that thespindle is located correctly in the valve segment bymeasuring dimension “A”. If this dimension is notwithin the specification, the spindle has moved in thevalve segment and the assembly must be replaced.

SpecificationValve Segment SpindleDimension “A”—Length 39.4—39.6 mm (1.55—1.56

in.)—750C.................................

Length 44.2—44.4 mm (1.74—1.75in.)—850C

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

35. Inspect cylinder block (4) for wear or damage. Thepiston bores must be smooth. The bearing platesurface must be free from scratches or nicks, and theholes for the bearing plate locating pins must not beworn. The races for the synchronizing shaft rollersmust not be worn.

IMPORTANT: Remove speed ring ONLY ifreplacement is necessary.

DO NOT damage sealing surface ofcylinder block.

36. Place cylinder block on a clean soft surface(cardboard or shop towel) to replace speed ring. Becareful NOT to damage sealing surface of cylinderblock.

37. Remove speed ring from cylinder block by gentlytapping on ring using a hammer and brass drift.

38. Place new speed ring on chamfered edge of cylinderblock.


PN=341


Hydrostatic System

030360

40

TX,0300,YY1171 –19–03MAR04–11/11

IMPORTANT: To prevent damage to speed ring useinstallation tool. JDG1332 Speed RingInstaller is machined to fit the750C/850C hydrostatic motors.

39. Carefully place JDG1332 Speed Ring Installer overspeed ring and cylinder block. Alternately tap edge ofinstaller using a rubber mallet to seat speed ring.Speed ring will be located correctly when installer isbottomed on cylinder block.

40. Inspect cylinder block bearing (5). If it requiresreplacement, remove bearing using a suitable puller.DO NOT damage the bearing plate surface of thecylinder block.

Press a new bearing (if removed) into the cylinderblock until it is located the proper distance (dimension“B”) below the bearing plate.

SpecificationCylinder Block Bearing Dimension“B”—Depth 14.5—15.0 mm (0.57—0.59

in.)—750C.....................................................

Depth 18.5—19.0 mm (0.73—0.75in.)—850C

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


PN=342

Hydrostatic System

03036041

TX,0360,YY1184 –19–03MAR04–1/9

Assemble Hydrostatic Motor

T10

0266

–UN

–07F

EB

96

1—Segment 8—Servo Piston 15—O-Ring 21—Roller (6 used)2—Bearing Plate 9—Setting Lug 16—Shaft Seal 22—Set Screw3—Bearing 10—Glide Ring 17—Flange 23—Cone Point Set Screw4—Cylinder Block 11—Synchronizing Shaft 18—O-Ring 24—Screw (8 used)5—End Cap 12—Housing 19—Alignment Pin (2 used) 25—O-Ring6—Dowel Pin (2 used) 13—Piston Ring (9 used) 20—Synchronizing Shaft7—Gasket 14—Shaft Assembly Support Pin (2 used)



PN=343

Hydrostatic System

030360

42

TX,0360,YY1184 –19–03MAR04–2/9

T85

06A

G–U

N–3

0JU

N95

1—Shaft Assembly2—Housing3—O-Ring4—Screw (8 used)5—Flange

NOTE: Apply clean hydrostatic oil to all internal partsprior to assembly.

1. Position shaft assembly (1) in housing (2). Align scribemark between housing and flange (5). Install flangeover shaft assembly as far as possible.

Install two screws (M12 x 65 mm—750C or M14 x 65mm—850C) 180° apart on flange. Alternately tightenscrews until bottomed to seat flange and shaftassembly. Remove two 65 mm screws and repeatprocedure using 50 mm screws. Remove screws.

Install eight screws (4). Alternately tighten screws toseat shaft assembly and flange against housing.Torque screws to specification.

SpecificationFlange-to-Motor Housing CapScrew——Torque 110 N•m (81 lb-ft)—750C..............................................Torque 174 N•m (128 lb-ft)—850C.............................................................


PN=344


Hydrostatic System

03036043

TX,0360,YY1184 –19–03MAR04–3/9

T85

06A

H–U

N–1

0JU

L95

1—Support Pin2—Rollers3—Recess4—Synchronizing Shaft5—Motor Shaft Assembly

2. Install synchronizing shaft support pin (1) into themotor shaft assembly (5) and retain with petroleumjelly.

IMPORTANT: The recess (3) on each roller MUST bepositioned to face the center-line of thesynchronizing shaft.

3. Install the synchronizing shaft rollers (2) on the journalsof the synchronizing shaft and retain with petroleumjelly. Position each roller with its outside edge evenwith the end of the synchronizing shaft journal.

4. Install the second synchronizing shaft support pin (1)into the recess of the synchronizing shaft and retainwith petroleum jelly.

5. Install the synchronizing shaft and rollers into the motorshaft (5). The cylinder block end of the shaft is largerthan the motor shaft end.

6. The rollers must enter the races in the motor shaftinsert, and the recess in the end of the synchronizingshaft must engage the support pin.

Tip and rotate the synchronizing shaft in all directionsto check for binding. The synchronizing shaft rollersmust move freely in the races in the motor shaft insert.


PN=345


Hydrostatic System

030360

44

TX,0360,YY1184 –19–03MAR04–4/9

T85

06A

I–U

N–1

0JU

L95

1—Motor Shaft 2—Synchronizing Shaft 3—Synchronizing ShaftSupport Pin Rollers

7. Position the motor shaft (1) in the housing asshown. Tip the three pistons closest to the highestside of housing.

8. With the synchronizing shaft supported in the motorshaft, install the cylinder block and its synchronizingshaft support pin (2) onto the pistons andsynchronizing shaft. The cylinder block must bepositioned so the synchronizing shaft rollers willenter their races in the block, while each pistonenters its corresponding bore in the block.

NOTE: A brass rod may be inserted through thecylinder block to guide the pistons intoposition.

9. Start with the six pistons closest to the lower part ofthe end cap mounting surface. After the six pistonsenter their bores, tilt the cylinder block so thesynchronizing shaft rollers (3) enter their races in

the cylinder block, and the support pin enters itsrecess in the synchronizing shaft.

NOTE: Apply clean hydrostatic oil to all cylinder blockbores.

10. Lift the cylinder block slightly and guide the threeremaining pistons into their bores.

After the last piston is in position, check theposition of the rollers at highest side of housing.Maintain an inward force on the cylinder block andcarefully push it toward the highest part of thehousing to check that all synchronizing shaftrollers are in position.

If cylinder block is properly assembled, there willbe very little (if any) rotational free-play betweenthe block and the motor shaft.


PN=346


Hydrostatic System

03036045

TX,0360,YY1184 –19–03MAR04–5/9

T11

8076

–UN

–28O

CT

98

1—Alignment Pin (2 used)2—Bearing Plate3—Alignment Pin (2 used)4—Gasket5—Valve Segment6—End Cap7—Hole

11. Install the bearing plate alignment pins (1) intocylinder block. The longer end of each shouldered pinis installed into block.

12. Install the bearing plate (2) on the cylinder block withthe steel side facing toward the block. Lubricate thebronze side of the plate with clean hydrostatic oil.

13. Install end cap alignment pins (3) and gasket (4).Carefully locate the cylinder block against highest partof housing.

IMPORTANT: DO NOT allow the pistons orsynchronizing shaft rollers to fall out ofposition.

14. Apply petroleum jelly to mating surfaces of valvesegment and end cap. Install the valve segment (5)with hole (7) on opposite side of speed sensor, intothe end cap (6) so the spindle engages the setting lugin the servo piston. Locate the valve segment andservo piston in the approximate center of its travel.


PN=347


Hydrostatic System

030360

46

TX,0360,YY1184 –19–03MAR04–6/9

T85

06A

P–U

N–1

0JU

L95

T85

06A

Q–U

N–1

0JU

L95

15. Apply clean hydrostatic oil to valve segment andbearing plate mating surfaces. Install end capassembly and valve segment. The spindle mustengage the bearing in the cylinder block.

IMPORTANT: DO NOT allow the pistons orsynchronizing shaft rollers to fall out ofposition.

16. Install correct length screws in correspondinglocations.

NOTE: The internal spring in the motor shaft should holdthe end cap away from the housing a shortdistance.

17. Tighten the screws by hand in the sequence shown(1—8) while rotating the motor shaft to ensure properpositioning of the synchronizing shaft rollers.

IMPORTANT: DO NOT force the end cap into positionon the housing.

18. Tighten screws using sequence shown toapproximately 1/2 final torque value. Repeatsequence and tighten to final torque.

SpecificationMotor End Cap-to-HousingScrew——Torque 135 N•m (100 lb-ft)—750C............................................Torque 213 N•m (157 lb-ft)—850C.............................................................

19. Rotate shaft 360° to check final assembly.



PN=348

Hydrostatic System

03036047

TX,0360,YY1184 –19–03MAR04–7/9

T19

8215

–UN

–03M

AR

04

1—Spring Guide 4—Spring 7—Spring Guide 9—Valve Spool2—Spring 5—Spring Guide 8—Valve Body 10—O-Ring3—Spring Guide 6—Spring

NOTE: Spring guide (1) was installed earlier inassembly.

20. Install parts (2—10).



PN=349

Hydrostatic System

030360

48

TX,0360,YY1184 –19–03MAR04–8/9

T85

12A

E–U

N–2

7JU

N95

T85

12A

G–U

N–2

7JU

N95

T85

12A

I–U

N–2

7JU

N95

1—Valve Block2—Spring Seat3—Spring4—Spool5—Spring Seat6—Spring7—Pin8—Gasket9—Cover10—Adjusting Screw11—Nut12—Plug13—Shuttle Ball Seat14—Ball

21. Install ball (14) and shuttle ball seat (13). Tighten seatto specification. Install and tighten plug (12) tospecification.

SpecificationShuttle Ball Seat—Torque 11 N•m (8 lb-ft).................................................Shuttle Ball Plug—Torque 37 N•m (27 lb-ft)...............................................

22. Install adjusting screw (10) into cover (9) until end ofscrew is specified distance from exterior surface ofcover. Install new nut (11) on adjusting screw andtighten. Install new gasket (8), cover and screws.Alternately tighten screws to specification.

SpecificationAdjusting Screw—Distance 10 mm (0.399 in.)—750C...............................Distance 12 mm (0.472 in.)—850C.............................................................Torque 16 N•m (142 lb-in.)..........................................................................

23. Assemble displacement control valve parts (1—7) asshown.



PN=350

Hydrostatic System

03036049

TX,0360,YY1184 –19–03MAR04–9/9

T85

16A

I–U

N–1

0JU

L95

24. On 750C (S.N. —907914) Install new O-rings (1—7)on end cap as shown.

On 750C (S.N. 907915— ) Install O-ring gasket onend cap.

25. Install displacement control valve and four screws.Tighten screws to specification.

SpecificationDisplacement ControlValve-to-End Cap—Torque 110 N•m (81 lb-ft)...........................................


PN=351

Hydrostatic System

030360

50

TX,0360,YY1207 –19–13JUL95–1/1

Remove and Install Hydrostatic Oil Filter

T85

18A

B–U

N–1

0JU

L95

1—Cap Screw (4 used) 3—Filter Base 4—Filter Element 5—Neutral Charge Relief Valve2—Cap Screw (3 used)

1. Loosen filler plug on reservoir to release pressure.

2. Tag and disconnect all lines from filter base (3).Cap or plug all openings.

3. Disconnect wire lead.

4. Remove cap screws (1) to remove filter assembly.

5. Remove neutral charge relief valve (5).

6. Install filter assembly and tighten cap screws.

7. Connect wire lead.

8. Connect all lines.


PN=352


0303991

TX,9900,YY1198 –19–13JUL95–1/1

DFT1063 Pump Lifting Bracket

T83

60A

M–1

9–10

JAN

95

Tool used to remove and install hydrostatic pumps.

Material required:

• 1-1/2 in. x 3 in. x 3/16 in. Square Tube

• 1/2 in. 1020 Steel• 5/8 in. x 5 in. Cap Screw• 3/8 in. x 1-1/2 in. Cap Screw with Nut (4 used)


PN=353


030399

2

TX,9900,YY1199 –19–13JUL95–1/1

DFT1130 Adapter

T83

19B

N–U

N–2

0SE

P94

A—Adapter Plate B—Tube C—Stop Plate

Adapter is used with DF1063 Lift Bracket to removeand install hydrostatic pumps.

Material required:

• 1/2 in. 1020 Steel Plate (A)• 1-1/2 in. x 1-1/2 in. x 3/16 in. Square Tube (B)• 1/4 in. 1020 Steel Plate (C)


PN=354


0303993

TX,9900,YY1166 –19–13JUL95–1/1

DFT1132 Hydrostatic Motor Removal and Installation Tool

T83

66A

C–U

N–1

0JU

L95

A—1 in. Nut C—Pipe 457 mm (18 in.) long E—Pipe G—PipeB—Pipe 2134 mm (7 ft.) long D—1 in. ID Heavy Wall Steel F—Weld

Pipe

This tool is used with DFT1137 to remove and installhydrostatic motors from rear of machine.

Material required:

• 1 in. piece heavy wall steel pipe 8 ft. x 6 in. long• Weld (E) to (G)


PN=355


030399

4

TX,9900,YY1200 –19–13JUL95–1/1

DFT1137 Hydrostatic Motor Removal and Installation Tool

T84

99B

B–1

9–10

JUL9

5

This tool is used with DFT1132 to remove and installhydrostatic motors from rear of machine.

Material required:

• 1-1/2 in. x 3/4 in. x 12 in. long steel bars (2 used)• M12 x 1.75 eyebolt

• 750C—1/2 in. x 9 in. cap screws (2 used)• 850C—1/2 in. x 10 in. cap screws (2 used)

Install and tighten eyebolt in bracket. Trim any excesseyebolt material so it is even with bottom surface ofbracket.


PN=356


0303995

CED,OUO1020,2433 –19–11SEP98–1/1

DFT1164 Speed Sensor Adjusting Tool

T11

7169

–UN

–21S

EP

98

A—50 mm (1.97 in.) C—06 mm (0.24 in.) E—50 mm (1.97 in.) G—48 mm (1.89 in.)B—12 mm (0.47 in.) D—101 mm (3.98 in.) F—39 mm (1.54 in.) H—13 mm (0.51 in) 1/2 in. Drill

DFT1164 Speed Sensor Adjusting Tool is used toadjust hydrostatic motor speed sensor.

Material required is:

• 1020 mild bar steel


PN=357


030399

6


PN=358

Section 04Engine

Contents

Page

Group 0400—Removal and Installation6068 John Deere Engine—Use CTM8 . . . . .04-0400-16068 John Deere POWERTECH Engine—

Use CTM104 . . . . . . . . . . . . . . . . . . . . . . .04-0400-16076 John Deere Engine—Use CTM42 . . . .04-0400-16081 John Deere POWERTECH Engine

Repair—Use CTM86 . . . . . . . . . . . . . . . . .04-0400-1Essential Tools . . . . . . . . . . . . . . . . . . . . . . .04-0400-2Other Material . . . . . . . . . . . . . . . . . . . . . . . .04-0400-4Specifications . . . . . . . . . . . . . . . . . . . . . . . .04-0400-5Remove and Install Engine . . . . . . . . . . . . . .04-0400-6Remove and Install Oil Pan. . . . . . . . . . . . .04-0400-15Remove and Install Fuel Filter Check 04

Valve—850C . . . . . . . . . . . . . . . . . . . . . .04-0400-16Remove DB4 Fuel Injection Pump—

750C . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-17Installing DB4 Fuel Injection Pump—

750C . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-19Remove In-Line Fuel Injection Pump—

850C . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-22Install In-Line Fuel Injection Pump—

850C . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-23JT07158 TIME TRAC Installation. . . . . . . .04-0400-28Injection Pump Dynamic Timing—750C . . .04-0400-29Fuel Shut-Off Solenoid Adjustment—850C

(S.N. —822867). . . . . . . . . . . . . . . . . . . .04-0400-31Disassemble and Assemble Final Fuel

Filter—750C . . . . . . . . . . . . . . . . . . . . . .04-0400-32Disassemble and Assemble Primary Fuel

Filter (Water Separator) . . . . . . . . . . . . . .04-0400-33Bleed the Fuel System—750C . . . . . . . . . .04-0400-34Bleed the Fuel System—850C . . . . . . . . . .04-0400-35Primary Fuel Filter, Drain Valve—750C. . . .04-0400-36Primary Fuel Filter, Drain Valve—850C. . . .04-0400-36Remove and Install Engine Mounts . . . . . . .04-0400-38


PN=1

Contents

04


PN=2

Group 0400Removal and Installation

CED,OUO1020,3224 –19–04DEC98–1/1

6068 John Deere Engine—Use CTM8

TS

225

–UN

–17J

AN

89

For additional engine information, the component technicalmanual (CTM) is also required.

Use the CTM in conjunction with this machine manual.

0404001

CED,OUO1020,3225 –19–04DEC98–1/1

6068 John Deere POWERTECH Engine—Use CTM104

TS

225

–UN

–17J

AN

89




CED,OUO1020,3226 –19–04DEC98–1/1


TS

225

–UN

–17J

AN

89



CED,OUO1020,3227 –19–04DEC98–1/1

6081 John Deere POWERTECH EngineRepair—Use CTM86

TS

225

–UN

–17J

AN

89

For additional engine repair information, the componenttechnical manual (CTM) is also required.




PN=361

Removal and Installation

CED,OUO1020,3173 –19–02DEC98–1/12

Essential Tools



040400

2

CED,OUO1020,3173 –19–02DEC98–2/12

RW18149 –UN–09APR90T8346AU –UN–07JUN95

Lift Sling . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG23

Remove and install engine.

Lifting Eyes . . . . . . . . . . . . . . . . . . . . . . . . JD244-2

Remove and install engine.

CED,OUO1020,3173 –19–02DEC98–3/12

RG

6032

–UN

–13J

AN

92

Drive Gear Puller . . . . . . . . . . . . . . . . . . . .JDG670A

Remove drive gear from tapered shaft on Stanadyne DB4fuel injection pumps with retained drive shafts.

CED,OUO1020,3173 –19–02DEC98–4/12

RG5068 –UN–05DEC97

Timing Pin . . . . . . . . . . . . . . . . . . . . . . . . . JDE81-4

Lock engine at TDC when timing valve train, adjustingvalve clearance, and installing fuel injection pump. Usewith JDG820 and JDE81-1 Flywheel Turning Tools.


PN=362



CED,OUO1020,3173 –19–02DEC98–5/12

RG5288 –UN–23AUG88

Crowfoot Wrench . . . . . . . . . . . . . . . . . . . . . .JDF22

Used to loosen and tighten fuel injection pump lines onStanadyne pumps.

CED,OUO1020,3173 –19–02DEC98–6/12

RG7212 –UN–23NOV97

Injection Pump Timing Pin. . . . . . . . . . . . . . . .JDG886

Used to set in-line fuel injection pump timing prior toremoval of pump.

0404003

CED,OUO1020,3173 –19–02DEC98–7/12

9/16-in. In-Line SOI Sensor (Optional) . . . . . . . . JT07155

To read rpm.

CED,OUO1020,3173 –19–02DEC98–8/12

SOI Clamp Assembly . . . . . . . . . . . . . . . . . . . JT07173

To read rpm.

CED,OUO1020,3173 –19–02DEC98–9/12

6 mm Clamp-On Transducer (green) . . . . . . . . . JT07177

To read rpm.

CED,OUO1020,3173 –19–02DEC98–10/12

Magnetic Pick-up Adapter . . . . . . . . . . . . . . . . JDG793

To read rpm.

CED,OUO1020,3173 –19–02DEC98–11/12

Magnetic Pick-up . . . . . . . . . . . . . . . . . . . . . JT07171

To read rpm.


PN=363



CED,OUO1020,3173 –19–02DEC98–12/12

TIME TRACKit . . . . . . . . . . . . . . . . . . . . . . JT07158

To time injection pump.

TIME TRAC is a registered trademark of the Stanadyne AutomotiveCorp.

040400

4

CED,OUO1020,3175 –19–02DEC98–1/1

Other Material

Number Name Use

AT66866 (U.S.) Solvent To clean tapered surfaces of shaftand gear for DB4 Fuel InjectionPumps.

T43512 (U.S.) Thread Lock and Sealer (Medium Secure Injection Pump timing holeTY9473 (Canadian) Strength)LOCTITE Products cover.242 (LOCTITE)



PN=364


0404005

CED,OUO1020,3176 –19–02DEC98–1/1

Specifications


Transmission Pump Mounting Torque 57 N•m (42 lb-ft)Plate-to-Flywheel Cap Screws

Engine Mounts-to-Main Frame Cap Torque 800 N•m (590 lb-ft)Screws

Engine Front Mounts-to-Engine Cap Torque 278 N•m (205 lb-ft)Screws

Engine Rear Support-to-Flywheel Torque 140 N•m (103 lb-ft)Housing Cap Screws

Fan-to-Engine Pulley Cap Screws Torque 63 N•m (46 lb-ft)

Oil Pan-to-Engine Block Cap Screws Torque 47 N•m (35 lb-ft)

Fuel Injection Pump Nut-to-Drive Torque 197 N•m (145 lb-ft)Shaft Nut

Injection Pump-to-Front Cover Hex Torque 25 N•m (18 lb-ft)Nuts

Fuel Injection Pressure Lines Torque 27 N•m (20 lb-ft)

850C Injection Pump Mounting Stud Torque 47 N•m (35 lb-ft)Nuts

850C Injection Pump Drive Torque 47 N•m (35 lb-ft)Gear-to-Pump Hub Cap Screws

850C Injection Pump Drive Gear Torque 27 N•m (20 lb-ft)Cover Cap Screws

850C Fuel Injection Pressure Lines Torque 27 N•m (20 lb-ft)

Engine Model 6068T

Net Power 104 kW (140 hp)

Engine Rated Speed 2100 rpm

Dynamic Timing (S.N. —831315) Angle 15° + 0 — 1° (BTDC)

Dynamic Timing (S.N. 831316— ) Angle 6.6° + 0 — 1° (BTDC)


PN=365


040400

6

TX,0400,SS2277 –19–29AUG96–1/13

Remove and Install Engine

TS

281

–UN

–23A

UG

88

750C (S.N. —831315) shown throughout, 750C (S.N.831316— ) and 850C procedures are the same exceptwhere noted.




CAUTION: Use suitable lifting device for heavycomponents.

4. Remove hood and grill housing top cover.

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.

NOTE: Approximate capacity of cooling system is 26.5 L(7 gal).

5. Remove lower radiator baffle to drain coolant fromradiator.



PN=366


0404007

TX,0400,SS2277 –19–29AUG96–2/13

T83

46A

D–U

N–0

7JU

N95

750C SN—831315 Shown

A—Radiator Hose-to-Thermostat HousingB—Air CleanerC—Muffler and BracketD—Rear Hood Support Cap Screws (2 used)E—Rear Hood SupportF—Side PanelG—Blade Lift HosesH—Fan GuardI—Fan ShroudJ—Side Panel for Lift Hoses

6. Remove parts (A—F).


7. Disconnect hoses (G) and remove panel (J). Layservice door with coolant recovery bottle, panel, andhoses to side.

8. Remove fan guards (H) and upper fan shroud (I).Remove fan.

9. Tilt cab or ROPS. (See Cab or ROPS Tilting Procedurein Operation and Test Manual, Group 9026-25.)



PN=367


040400

8

TX,0400,SS2277 –19–29AUG96–3/13

T84

95A

F–1

9–07

JUN

95

750C (S.N. —831315) Shown

10. Disconnect wiring leads, clamping, andconnectors.

11. Disconnect ground cable and strap at startingmotor.

12. Disconnect starter solenoid battery wiring lead.

TX,0400,SS2277 –19–29AUG96–4/13

T83

47B

D–U

N–0

7JU

N95

750C (S.N. —831315) Shown

A—Fuel Return LineB—Fuel Supply LineC—Start Aid Line

13. Open fuel shut-off door and close fuel shut-off valveat tank.

14. Disconnect fuel return line (A), supply line (B), andlower radiator hose.

15. Disconnect start aid line (C) if equipped.

16. For machines equipped with cab, disconnect heaterhoses. If equipped, remove air conditioningcompressor belt and compressor mounting capscrews. Lay compressor off to side.


PN=368



0404009

TX,0400,SS2277 –19–29AUG96–5/13

T83

47A

G–U

N–0

7JU

N95

A—JDG23 Lift SlingB—JD244-2 Lifting Eyes

CAUTION: Approximate weight of 750C, 850Cengine 1400 lb).

17. Install JDG23 Lift Sling (A) and JD244-2 Lifting Eyes(B) to engine.

18. Attach hoist to lift sling and raise hoist until engineweight is just supported by hoist. DO NOT lift engineany farther at this time.

TX,0400,SS2277 –19–29AUG96–6/13

T83

47B

F–U

N–0

7JU

N95

A—Hoist or WinchB—Cross Member

CAUTION: Approximate weight of hydrostaticpumps/hydraulic pump assembly is 814 kg (600lb).

19. Support hydrostatic pumps, and hydraulic pump as anassembly, using a suitable hoist-winch (A). Supportpumps from the cross member (B).

20. Remove transmission pump mounting plate toflywheel housing cap screws.


PN=369



040400

10

TX,0400,SS2277 –19–29AUG96–7/13

T12

5316

–UN

–22O

CT

99

T12

5317

–UN

–22O

CT

99T

1253

15–U

N–2

2OC

T99

A—Cap Screw (4 used)B—Washer (4 used)C—Flat Washer 750C (6 used), 850C (4 used)D—Rear Engine Support (2 used)E—Washer 750C (8 used), 850C (12 used)F—Cap Screw 750C (8 used), 850C (12 used)G—Rear Resilient Mount (2 used)H—Front Engine Support (2 used)I—Washer 750C (S.N. —831315) (4 used), 750C (S.N.

831316—) (6 used), 850C (6 used)J—Cap Screw 750C (S.N. —831315) (4 used), 750C

(S.N. 831316—) (6 used), 850C (6 used)K—Front Resilient Mount (2 used)

NOTE: Step 21 is for 750C (S.N.—831315) only.

21. To gain access to the right front engine mount capscrew remove the fan belt tightener and mountingbracket.


PN=370



TX,0400,SS2277 –19–29AUG96–8/13

CAUTION: Approximate weight of engine is 630kg (1400 lb).

22. Remove engine mount cap screws (A) and slowlyremove engine.


04040011

TX,0400,SS2277 –19–29AUG96–9/13T

8347

AG

–UN

–07J

UN

95

A—JDG23 Lift SlingB—JD244-2 Lifting Eyes

24. Install engine, aligning drive hub to damper.

25. Install transmission pump mounting plate to flywheelcap screws. Tighten cap screws to specification.

SpecificationTransmission Pump MountingPlate-to-Flywheel Cap Screws—Torque 57 N•m (42 lb-ft).............................................................................



PN=371


040400

12

TX,0400,SS2277 –19–29AUG96–10/13

T12

5316

–UN

–22O

CT

99

T12

5317

–UN

–22O

CT

99T

1253

15–U

N–2

2OC

T99




26. Install engine mounts and cap screws. Tighten capscrews to specifications.

SpecificationEngine Mounts-to-Main FrameCap Screws—Torque 800 N•m (590 lb-ft)..................................................Engine Front Mounts-to-EngineCap Screws—Torque 278 N•m (205 lb-ft)..................................................Engine Rear Support-to-FlywheelHousing Cap Screws—Torque 140 N•m (103 lb-ft)....................................


PN=372



TX,0400,SS2277 –19–29AUG96–11/13

T83

47B

D–U

N–0

7JU

N95

04040013

A—Fuel Return LineB—Fuel Supply LineC—Start Aid Line

27. Connect fuel return line (A) and fuel supply line (B). Ifequipped, connect start aid line (C).

28. Open fuel shut-off.

29. For machines equipped with cab, connect heaterhoses. If equipped, install air conditioningcompressor.

TX,0400,SS2277 –19–29AUG96–12/13

T84

95A

F–1

9–07

JUN

95

750C (S.N. —831315) Shown

30. Connect wiring leads and connectors.

31. Connect ground cable, strap at starting motor andstarter solenoid battery wiring lead.


PN=373



040400

14

TX,0400,SS2277 –19–29AUG96–13/13

T83

46A

D–U

N–0

7JU

N95

750C (S.N. —831315) Shown

A—Radiator Hose-to-Thermostat HousingB—Air CleanerC—Muffler and BracketD—Rear Hood Support Cap Screws (2 used)E—Rear Hood SupportF—Side PanelG—Blade Lift HosesH—Fan GuardI—Fan ShroudJ—Side Panel for Lift Hoses

32. Install fan, upper shroud (I) and fan guards (H).Tighten fan cap screws to specification.

SpecificationFan-to-Engine Pulley CapScrews—Torque 63 N•m (46 lb-ft)..............................................................

33. Connect hoses (G). Install service door and panel (J)with coolant bottle.

34. Install parts (A—F).

35. Fill radiator to proper level. (See Diesel EngineCoolant, Group 0004.)

36. Install grille housing top cover and hood.

37. Tilt cab down. (See Cab or ROPS Tilting Procedure inOperation and Test Manual, Group 9026-25.)

38. Turn battery disconnect switch to ON.

IMPORTANT: Calibrate transmission and enginecontrollers whenever a sensor,transmission component, or enginespeed control component is adjusted orreplaced.


For 850C (S.N. 822868— ), also calibrate enginecontroller. (See procedure in Operation and TestManual, Group 9015-20.)


PN=374


04040015

TX,0400,SS2286 –19–29AUG96–1/1

Remove and Install Oil Pan

T64

65A

P–U

N–1

8OC

T88

A—Oil Pan GasketB—Oil PanC—Cap Screws

NOTE: On the 850C the engine must be out of themachine to remove and install oil pan. The 750Cengine oil pan can be removed and installed withthe engine in the machine. (See procedurebelow.)

CAUTION: The approximate weight of bottomguard is 214 kg (472 lb).

1. Remove front bottom guard.

NOTE: Approximate capacity of engine oil is 19 L (20 qt).

2. Drain engine oil.

3. Remove dipstick and oil fill tube.

4. Remove cap screws (C) and washers to remove the oilpan (B).

5. Make engine repairs as necessary. (See procedure inengine component technical manual.)

6. Apply form-in-place gasket to joints between timinggear cover, front plate, cylinder block, and flywheelhousing to fill gap between end of gaskets and oil pangasket.

7. Install a new gasket (A).

8. Install oil pan. Tighten cap screws to specification.

SpecificationOil Pan-to-Engine Block CapScrews—Torque 47 N•m (35 lb-ft)..............................................................

9. Install new O-ring on dipstick tube. Install tube anddipstick.

10. Fill engine with appropriate oil. (See Fuels andLubricants in Group 0004.)


PN=375


040400

16

TX,0400,SS2289 –19–12JUL95–1/1

Remove and Install Fuel Filter Check Valve—850C

T77

51K

F–U

N–2

2OC

T92

T77

51K

G–U

N–2

2OC

T92

A—ConnectorB—O-RingC—O-RingD—SpringE—Check Valve

1. Disconnect fuel inlet line at secondary fuel filter andremove connector (A).

2. Remove parts (B—E). Inspect check valve for foreignmaterial or wear which could keep valve open andcause a fuel return leak.


4. Install parts (B—E).

5. Install connector and connect fuel inlet line.


PN=376


04040017

TX,0400,SS2294 –19–12JUL95–1/3

Remove DB4 Fuel Injection Pump—750C

TS

281

–UN

–23A

UG

88R

G56

59–U

N–3

1OC

T97

Four Cylinder Engine Shown

A—Fuel Return LineB—Fuel Delivery (Pressure) LinesC—Fuel Supply LineD—Mounting Stud Nuts



All Stanadyne DB4 injection pumps have retained driveshafts.

1. Remove lower baffle to drain coolant from radiator untilcoolant level is below upper radiator hose connection.

2. See Remove and Install Guards, Shroud and Fan inGroup 0510.

IMPORTANT: Never steam clean or pour cold wateron a fuel injection pump while the pumpis "running" or while it is "warm". Doingso may cause seizure of internalrotating pump parts.

3. Clean the fuel injection pump, lines and area aroundthe pump with cleaning solvent or a steam cleaner.

4. Disconnect speed control linkage. Disconnect electricalconnection to shut-off solenoid.

IMPORTANT: ALWAYS use a backup wrench whenloosening or tightening fuel lines atinjection pump so that dischargefittings are not altered to preventpossible internal pump damage.

5. Disconnect fuel return line (A) and fuel supply line (C).

6. Disconnect all fuel delivery (pressure) lines (B) frominjection pump using a suitable 17 mm deep-wellcrowfoot socket.


PN=377



040400

18

TX,0400,SS2294 –19–12JUL95–2/3

RG

6292

–UN

–22J

UL9

2

A—JDG670A Drive Gear PullerB—Center Forcing ScrewC—6 mm Grade 12.9 Screws

7. Remove injection pump drive gear cover. Removedrive gear retaining nut and washer from end of pumpshaft. Be careful not to let washer fall inside timinggear cover.

NOTE: The injection pump drive gear fits snugly onto atapered drive shaft and is indexed by a hollow pinor Woodruff Key installed in drive shaft.

8. Attach JDG670A Drive Gear Puller (A) to injectionpump drive gear as shown.

9. Evenly tighten the two 6 mm, Grade 12.9 screws (C,threaded in drive gear) and snugly tighten centerforcing screw (B) against end of pump shaft.

10. Tighten center forcing screw until pump drive gear isfree from tapered shaft. Remove JDG670A Puller andscrews from drive gear.

TX,0400,SS2294 –19–12JUL95–3/3

RG

6293

–UN

–03N

OV

97

A—Mark on Back Side of Front PlateB—Mark on Injection Pump Flange

11. Check to make sure that timing marks on back side offront plate (A) and injection pump flange (B) arepresent and properly aligned. This assures thatrepaired or replacement pump can be properly timedto engine when installed.

If timing mark is not clearly visible on front plate,scribe a visible reference mark as accurately aspossible in-line with mark on pump flange.

12. Remove three injection pump mounting stud nuts.Remove injection pump from mounting studs.


PN=378


TX,0400,SS2297 –19–12JUL95–1/4

Installing DB4 Fuel Injection Pump—750C

RG

6293

–UN

–03N

OV

97

04040019

A—Mark on Back Side of Front PlateB—Mark on Injection Pump Flange

1. Tapered surfaces of shaft and gear must be clean anddry for assembly. Clean tapered surfaces of shaft andgear using AT66866 solvent.

2. Install pump by aligning drive shaft key with gear keyslot. Align timing mark on pump flange (B) with timingmark on cylinder block front plate (A).

3. Install pump attaching nuts finger tight.

TX,0400,SS2297 –19–12JUL95–2/4

T70

42A

M–U

N–0

8JU

N89

4. Install washer (B) and nut (A) on drive shaft.

5. Tighten nut (A) to specification.

Specification750C Fuel Injection PumpNut-to-Drive Shaft Nut—Torque 197 N•m (145 lb-ft)..................................



PN=379


040400

20

TX,0400,SS2297 –19–12JUL95–3/4

T70

42A

T–U

N–0

8JU

N89

A—Speed Control RodB—Fuel Return LineC—Fuel Pressure LineD—Fuel Supply LineE—Timing Window Cover

6. Tighten pump attaching hex nuts to specification.

Specification750C Injection Pump-to-FrontCover Hex Nuts—Torque 25 N•m (18 lb-ft)................................................

IMPORTANT: When tightening fuel pressure lines atfuel injection pump, be sure not to turnfuel injection pump fittings. Turningthese fittings may cause internal pumpdamage.

7. Tighten fuel pressure lines (C) at pump using JDF22Wrench to specification.

Specification750C Fuel Injection PressureLines—Torque 27 N•m (20 lb-ft).................................................................

8. Install fuel shut-off connector, speed control rod (A),fuel supply line (D), and fuel return line (B).



PN=380


04040021

TX,0400,SS2297 –19–12JUL95–4/4

X98

11–U

N–2

3AU

G88

T66

83D

M–U

N–1

8OC

T88

T92

924

–UN

–01N

OV

88

A—Fuel Supply Line Connection

9. Bleed the fuel system. See procedure in this group.

10. Loosen fuel supply line (A) connection.

11. To purge air from filter to injection pump line, continueto operate primer lever several times or operateprimer lever until only fuel flows out of connection.Tighten connection.


12. To purge air from injection lines, loosenpump-to-nozzle connections at ALL nozzles using twowrenches. Cover connections with shop towels.

13. Crank engine until a small amount of fuel leaks frominjection lines.

14. Tighten injection line connections.

15. Adjust engine speed. (See procedures in Operationand Test Manual, Group 9010-20.)


16. Calibrate transmission controller. (See procedures inOperation and Test Manual, Group 9015-20.)


PN=381


040400

22

TX,9025,BS483 –19–12JUL95–1/2

Remove In-Line Fuel Injection Pump—850C

RG

5873

–UN

–19A

UG

91

A—Timing Hole PlugB—Injection Pump Drive HubC—Timing Pointer

IMPORTANT: Never steam clean or pour cold wateron an injection pump while pump isrunning, or while it is still warm. To doso may cause seizure of pump parts.

1. Disconnect battery, open right front access panel, andremove hood, alternator, alternator belt, and fan belttension adjuster.

2. Clean injection lines and area around the injectionpump with cleaning solvent or a steam cleaner.Remove timing hole plug (A), shown removed.

3. Rotate engine flywheel (in normal running direction)until No. 1 piston is at TDC of its compression stroke.At this point, JDE81-4 Timing Pin should enter hole inflywheel.

4. Timing marks on injection pump drive hub (B) andtiming pointer (C) should be in alignment.



PN=382


04040023

TX,9025,BS483 –19–12JUL95–2/2

RG

5874

–UN

–19A

UG

91R

G58

75–U

N–1

9AU

G91

A—Drive Gear Cap Screws (4 used)B—Injection Pump Lube LineC—Oil FilterD—Fuel Inlet LineE—Leak-Off LineF—Fuel Supply Pump Lines

5. Remove injection pump drive gear cover and gasket.

6. Remove injection pump drive gear cap screws (A).

7. Disconnect injection pump lube line (B) from cylinderblock fitting. Remove oil filter (C).

8. Remove fuel shut-off solenoid.

9. Remove fuel inlet line (D). Remove fuel leak-off line(E).

10. Disconnect fuel supply pump lines (F). Photo showsonly one line.

11. Remove fuel injection line nuts using JDF22 CrowfootWrench or a 3/4 in. line wrench.

12. Remove four mounting stud nuts which secureinjection pump to cylinder block.

13. Carefully remove injection pump and place on a cleanflat surface.

TX,9025,BS486 –19–12JUL95–1/6

Install In-Line Fuel Injection Pump—850C

RG

5791

–UN

–09A

UG

91

A—FlywheelB—JDE81-4 Timing Pin

1. If engine was rotated after injection pump wasremoved, rotate flywheel until JDE81-4 Timing Pinenters flywheel at No. 1 cylinder’s TDC compressionstroke.

NOTE: When No. 1 cylinder is at TDC compressionstroke, intake and exhaust valves for No. 1cylinder will be closed and both rocker arms willbe loose.

2. Install fuel shut-off solenoid.


PN=383



040400

24

TX,9025,BS486 –19–12JUL95–2/6

RG

7741

–UN

–28N

OV

97

A—PointerB—Drive HubC—O-RingD—Bearing PlateE—JDG886 Timing Pin

3. Rotate injection pump drive hub until marks on drivehub (B) and pointer (A) are aligned.

NOTE: It may be necessary to rotate pump hub slightly toallow JDG886 Timing Pin (E) to enter bearingplate.

4. Thread JDG886 Timing Pin into drive hub as shown,and tighten until it bottoms against bearing plate (D).

5. Install a new O-ring (C) on bearing plate (D). Lightlylubricate O-ring with petroleum jelly to aid in pumpinstallation and prevent O-ring damage.

6. Install injection pump using moderate forward pressureand slight rocking motion to work O-ring into mountingbore. Injection pump flange should seat solidly againstcylinder block.

7. Install mounting stud nuts and tighten to specification.

Specification850C Injection Pump MountingStud Nuts—Torque 47 N•m (35 lb-ft)..........................................................



PN=384


04040025

TX,9025,BS486 –19–12JUL95–3/6

RG

5881

–UN

–19A

UG

91

A—Drive GearB—Pump Drive HubC—Gear-to-Hub Cap Screws

8. Place injection pump drive gear in timing gear housing(if previously removed) with chamfered side of geartoward injection pump. Chamfer is at outer edge ofbore for easier installation of gear to pump drive hub.

9. Carefully install drive gear (A) on pump drive hub (B).Position gear so mounting cap screws areapproximately centered in mounting slots. This willallow for minor adjustment of pump timing, should theneed arise.

10. Install drive gear-to-pump hub cap screws (C) andtighten to specification.

Specification850C Injection Pump DriveGear-to-Pump Hub Cap Screws—Torque 47 N•m (35 lb-ft).............................................................................



PN=385


040400

26

TX,9025,BS486 –19–12JUL95–4/6

RG

7283

–UN

–07F

EB

95

A—JDG886 Timing Pin

11. Remove JDG886 Timing Pin (A) from injection pumphub. Install timing hole plug using LOCTITE 242(TY9473) Thread Lock and Sealant. Tighten plugsecurely.

12. Install injection pump drive gear cover using a newgasket. Tighten cap screws to specification.

Specification850C Injection Pump Drive GearCover Cap Screws—Torque 27 N•m (20 lb-ft)...........................................

IMPORTANT: DO NOT move delivery valve fittingswhile tightening line nuts. If deliveryvalve and barrel housing rotates whiletightening a fuel line nut, injectionpump fuel delivery will be altered. Theinjection pump will have to becalibrated on a test stand by anauthorized diesel repair station.

13. Connect fuel delivery lines using JDF22 CrowfootWrench. Tighten to specification.

Specification850C Fuel Injection PressureLines—Torque 27 N•m (20 lb-ft).................................................................

LOCTITE is a trademark of the Loctite Corp.

TX,9025,BS486 –19–12JUL95–5/6

RG

5875

–UN

–19A

UG

91

B—Injection Pump Oil LineC—Oil FilterD—Fuel Inlet LineE—Fuel Leak-Off LineF—Supply Pump Lines

14. Connect fuel supply pump lines (F).

15. Connect fuel inlet line (D) and leak-off line (E).

16. Install oil filter (C).

17. Connect injection pump oil line (B) to cylinder blockfitting.

18. Tighten all connections securely.


PN=386



04040027

TX,9025,BS486 –19–12JUL95–6/6

RG

2636

–UN

–20D

EC

88

19. Remove oil fill plug (arrow) and add enough cleanengine oil until oil comes out fill hole. Engine shouldbe level when checking oil level.

20. Bleed fuel system. (See Bleed Fuel System in thisgroup.)

21. Connect battery. Close right front access panel. Installhood, alternator, alternator belt, and fan belt tensionadjuster.

22. Adjust fuel shut-off solenoid. (See procedures inOperation and Test Manual, Group 9010-20.)

23. Adjust engine speed. (See procedures in Operationand Test Manual, Group 9010-20.)

IMPORTANT: Calibrate transmission and enginecontrollers whenever a sensor orcomponent is adjusted or replaced.




PN=387


040400

28

TX,TIMETRAC,300 –19–20JUN95–1/1

JT07158 TIME TRAC Installation

T80

10A

L–U

N–1

8MA

Y93

T80

10A

M–U

N–2

0MA

Y93

T80

10A

N–U

N–1

8MA

Y93

A—SOI SensorB—Transducer ClampC—GroundD—Meter ConnectionE—Clamp-On TransducerF—Injection LineG—GroundH—Meter ConnectionI—AdapterJ—Magnetic ProbeK—Meter Connection

IMPORTANT: Install clamp-on transducer as close aspossible to fuel injection nozzle.

Remove paint and clean injection line for installation ofclamp-on transducer (E).

TIME TRAC is a registered trademark of Stanadyne Automotive Corp,


PN=388


04040029

TX,9025,BS475 –19–29AUG96–1/2

Injection Pump Dynamic Timing—750C

RG

6293

–UN

–03N

OV

97

A—Front PlateB—Pump Flange

NOTE: Dynamic timing information is not available on the850C with the 6076T engine.

The JT07158 timing kit electronically indicates start ofinjection with respect to piston top dead center, andallows setting injection pump timing to provide optimumpower, smoke and exhaust emissions. Timing engineswith this tool improves consistency and helps controlcylinder pressures which can be a factor in head gasketfailures.

Specification750C Engine—Model 6068T.......................................................................750C Engine—Power 104 kW (140 hp) Net...............................................

1. Install JT07158 TIME TRAC. See procedure in thisgroup. (Also found on JT07175 Quick ReferenceSheet.)

2. Warm engine to operating temperature.

NOTE: If machine is not equipped with rear-mountedequipment, do steps 3—5.

3. Remove rear transmission motor access cover.

4. Disconnect brake line at left final drive housingtee-fitting.

5. Plug and cap line and fitting.

NOTE: If machine is equipped with rear-mountedequipment, do steps 6—9.

6. Tilt cab. (See procedure in Operation and Test Manual,Group 9026-25.)

7. Disconnect brake hose from brake valve port B. ("B"marking is cast in housing of brake valve.)

8. Plug and cap hose and fitting.

9. Return cab to operational position.

TIME TRAC is a registered trademark of the Stanadyne AutomotiveCorp.


PN=389



040400

30

TX,9025,BS475 –19–29AUG96–2/2

10. Test as indicated below.

LEVER STEER MACHINES: move the FNR lever toforward with speed selector lever in number 1position. Run engine at fast idle. Slowly move thespeed selector lever to the rear to obtain rated enginespeed. Lug machine for 15 seconds and recorddynamic timing. Repeat procedure to verify reading.

PEDAL STEER MACHINES: run engine at high idle.Slowly move FNR lever from neutral to forward toobtain rated engine speed. Lug machine for 15seconds and record dynamic timing. Repeatprocedure to verify reading.

Specification750C Engine—Speed 2100 rpm (Rated).....................................................

11. Record dynamic timing.

12. If timing is not to specification, follow procedure onJTO7175 Quick Reference Sheet, CTM8 and CTM42.

Specification750C Dynamic Timing (S.N. —831315 )—Angle 15° + 0 — 1° (BTDC)......................................................750C Dynamic Timing (S.N.831316— )—Angle 6.6° + 0 — 1° (BTDC).................................................


PN=390


04040031

TX,9010,DS6706 –19–29AUG96–1/1

Fuel Shut-Off Solenoid Adjustment—850C(S.N. —822867)

T84

13A

A–U

N–0

6FE

B95

T84

13A

F–1

9–06

FE

B95

A—SpringB—RodC—NutD—StopE—Shut-Off Lever

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 (B) until shut-off lever(E) moves away from stop (D). Solenoid bracket mayneed to be removed to rotate rod (B).

3. Shorten rod (B) until shut-off lever (E) touches stop(D), then shorten rod two more turns to preload spring(A).

NOTE: Orientate bend in rod so the lower end is closestto engine block. If rod is not orientated correctly,linkage will bind and not move freely.

4. Tighten nut (C) after final adjustment is made.

5. If rod (B) is adjusted too short, engine may not shutoff. If rod is adjusted too long, engine may not starteasily or may not have full power. If adjustment cannotbe made, shut-off lever (E) may be binding, solenoidmounting bracket may be bent or injection pump maybe worn or have internal problems.


PN=391


040400

32

TX,9025,BS499 –19–12JUL95–1/1

Disassemble and Assemble Final FuelFilter—750C

T83

60A

B–U

N–2

1DE

C94

A—RingB—Top CapC—SealD—DeflectorE—Filter HeadF—Vent PlugG—RingH—Seal KitI—PackingJ—Fuel Filter

1. Remove parts (A—J).

2. Inspect and replace parts as necessary.

3. Install parts (A—J) as shown.


PN=392


04040033

TX,9025,BS500 –19–12JUL95–1/1

Disassemble and Assemble Primary FuelFilter (Water Separator)

T77

51H

R–U

N–2

2OC

T92

T77

51H

S–U

N–2

2OC

T92

A—Drain PlugB—PackingC—Cap ScrewD—BowlE—Locking RingF—Filter ElementG—Water Separator CoverH—Vent PlugI—PackingJ—Plug (2 used)K—DiaphragmL—Spring SeatM—SpringN—Spring CoverO—Pump KnobP—Locking Ring

1. Remove parts (A—D).

2. Remove locking ring (E). Remove filter element (F).

3. Remove parts (G—P).

IMPORTANT: Clean debris from top of waterseparator cover (G) when disassembled.

4. Inspect and replace parts as necessary.

5. Install parts (G—P).

6. Install filter element and locking ring.

7. Install parts (A—D).


PN=393


040400

34

TX,9010,SS2287 –19–12JUL95–1/1

Bleed the Fuel System—750C

T78

33A

J–U

N–1

0SE

P92

(S.N. —831315)

T10

8337

–UN

–21A

PR

97

(S.N. 831316—)

A—Bleed Screw (Final Filter)B—PumpC—Primary Filter (Water Separator)D—Drain Valve (Primary Filter)E—Bleed Screw (Primary Filter)F—Drain Valve (Final Filter)G—Final FilterH—Pump

1. Place pan under filters (C and G).

2. For (S.N. —831315) open bleed screw (A) and pushpump (B) until fuel free of bubbles flows from aroundthe bleed screw.

For (S.N. 831316— ) open bleed screw (E) and pushpump (B) until bubble free fuel flows from bleed screw.Close bleed screw. Open bleed screw (A) and pushpump (H) until bubble free fuel flows from bleed screw.

3. Close bleed screw.

NOTE: If you run out of fuel and air is in the supply lineto the injection pump continue next step.

4. Loosen fuel line at injection pump and push pump (B)until fuel free of bubbles flows from around connection.

5. Tighten fuel line.


PN=394


04040035

TX,9025,BS470 –19–01APR95–1/1

Bleed the Fuel System—850C

T77

99C

J–U

N–1

0SE

P92

A—Final Fuel FilterB—PumpC—Fuel Supply LineD—Drain ValveE—Primary Filter (Water Separator)F—Bleed ScrewG—Bleed Screw

1. Place pan under primary filter (water separator) (E).

2. Open bleed screw (F) and push pump (B) until fuelfree of bubbles flows from around the bleed screw.

3. Close bleed screw (F) and loosen bleed screw (G)from final fuel filter (A).

4. Push pump until only fuel flows from fuel bleed screwopening.

NOTE: If you run out of fuel and air is in the supply lineto the injection pump continue next step.

5. Loosen fuel line (C) at injection pump and push pumpuntil fuel free of bubbles flows from connector.

6. Tighten fuel line.


PN=395


040400

36

TX,9025,BS477 –19–24JUL96–1/1

Primary Fuel Filter, Drain Valve—750C

T78

33A

J–U

N–1

0SE

P92

(S.N. —831315)

T10

8337

–UN

–21A

PR

97

(S.N. 831316—)

A—Bleed Screw (Final Filter)B—PumpC—Primary Filter (Water Separator)D—Drain Valve (Primary Filter)E—Bleed Screw (Primary Filter)F—Drain Valve (Final Filter)G—Final FilterH—Pump

1. Place pan under primary filter (water separator) (C).

2. Open drain valve (D) on the bottom of primary filterand press pump (B) to remove water from fuel system.

3. When water is removed close drain valve.

4. Open drain valve (F) on bottom of final filter (G) andpress pump (B) for (S.N. —831315) or pump (H) for(S.N. 831316— ) to remove water.


TX,9025,BS468 –19–24JUL96–1/1

Primary Fuel Filter, Drain Valve—850C

T77

99C

J–U

N–1

0SE

P92

A—Final Fuel FilterB—PumpC—Fuel Supply LineD—Drain ValveE—Primary Filter (Water Separator)F—Bleed ScrewG—Bleed Screw

1. Place pan under primary filter (water separator) (E).

2. Open drain valve (D) on the bottom of primary filterand press pump (B) to remove water from fuel system.



PN=396


04040037


PN=397


040400

38

TX,9025,BS482 –19–20OCT99–1/2

Remove and Install Engine Mounts

T12

5315

–UN

–22O

CT

99




Remove and install as shown. Tighten cap screws tospecification.

SpecificationEngine Mounts-to-Main FrameCap Screws—Torque 800 N•m (590 lb-ft)..................................................Engine Front Mounts-to-EngineCap Screws—Torque 278 N•m (205 lb-ft)..................................................Engine Rear Support to-FlywheelHousing Cap Screws—Torque 140 N•m (103 lb-ft)....................................



PN=398


04040039

TX,9025,BS482 –19–20OCT99–2/2

T12

5316

–UN

–22O

CT

99

T12

5317

–UN

–22O

CT

99


PN=399


040400

40


PN=400

Section 05Engine Auxiliary Systems

Contents

Page Page

Group 0505—Cold Weather Starting Aid Engine Speed Adjustment—850C . . . . . . . .05-0515-19Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0505-1 Engine Speed Control Cable Adjustment. . .05-0515-23Remove and Install Engine Coolant Engine Speed Control Sensor Adjustment

Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0505-2 (750C, 850C S.N.—875378) . . . . . . . . . .05-0515-25Decelerator Sensor Adjustment—Single

Lever Steer . . . . . . . . . . . . . . . . . . . . . . .05-0515-27Group 0510—Cooling SystemThrottle Sensor Adjustment—850C (S.N.6068 John Deere Engine—Use CTM8 . . . . .05-0510-1

822868— ). . . . . . . . . . . . . . . . . . . . . . . .05-0515-296068 John Deere POWERTECH Engine—Use CTM104 . . . . . . . . . . . . . . . . . . . . . . .05-0510-1

Group 0520—Intake System6076 John Deere Engine—Use CTM42 . . . .05-0510-1Remove and Install Air Cleaner. . . . . . . . . . .05-0520-16081 John Deere POWERTECH EngineTest Air Intake System for Leaks . . . . . . . . .05-0520-2Repair—Use CTM86 . . . . . . . . . . . . . . . . .05-0510-1

Essential Tools . . . . . . . . . . . . . . . . . . . . . . .05-0510-2Group 0530—External Exhaust SystemsService Equipment and Tools . . . . . . . . . . . .05-0510-2Remove and Install Muffler . . . . . . . . . . . . . .05-0530-1Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0510-3

Remove and Install Guards, Shroud andGroup 0560—External Fuel Supply SystemsFan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-4Other Material . . . . . . . . . . . . . . . . . . . . . . . .05-0560-1Remove and Install Fan Belt and 05Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0560-1Adjuster—750C (S.N.—831315) . . . . . . . .05-0510-5Remove and Install Fuel Tank. . . . . . . . . . . .05-0560-2Remove, Install, Inspect Serpentine FanRemove and Install Fuel Lines—750C . . . . .05-0560-4Belt—850C and 750C (S.N. 831316— ) . .05-0510-7Remove and Install Fuel Lines—850C . . . . .05-0560-5Remove and Install Radiator and Oil

Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-8Group 0599—Dealer Fabricated ToolsRemove and Install Hydraulic Oil Cooler . . .05-0510-12DFT1140 Serpentine Belt Removal and

Installation Tool (850C) . . . . . . . . . . . . . . .05-0599-1Group 0515—Speed ControlsEssential Tools . . . . . . . . . . . . . . . . . . . . . . .05-0515-1Service Equipment and Tools . . . . . . . . . . . .05-0515-1Other Material . . . . . . . . . . . . . . . . . . . . . . . .05-0515-2Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0515-3JT05801 Clamp-On Digital Tachometer

Installation . . . . . . . . . . . . . . . . . . . . . . . . .05-0515-5Remove and Install Engine Speed

Control. . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0515-6Remove and Install Engine Speed Control

Linkage and Shaft 750C and 850C (S.N. —822867) . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0515-8

Remove and Install Engine Speed ControlLinkage and Shaft 850C (S.N. 822868—). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0515-10

Engine Speed Control Linkage Rod—850C(S.N. —822867). . . . . . . . . . . . . . . . . . . .05-0515-12

Engine Speed Control Linkage Rod—750C . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0515-13

Remove and Install Decelerator . . . . . . . . .05-0515-14Engine Speed Adjustment—750C . . . . . . . .05-0515-16


PN=1

Contents

05


PN=2

Group 0505Cold Weather Starting Aid

CED,OUO1020,3172 –19–02DEC98–1/1

Specifications


Engine Coolant Heater Element Nut Torque 34 N•m (25 lb-ft)

0505051


PN=403

Cold Weather Starting Aid

050505

2

TX,0505,SS2486 –19–12JUL95–1/2

Remove and Install Engine Coolant Heater

TS

281

–UN

–23A

UG

88T

6427

AO

–UN

–21O

CT

88

A—Wiring LeadB—CapC—NutD—AdapterE—GasketF—O-RingG—Heater Element



NOTE: The approximate capacity of cooling system is26.5 L (7 gal) for 750C and 34L (9 gal) for 850C.

1. Drain cooling system.

2. Remove wiring lead (A).

3. Loosen nut (C) and pull heater element 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.


5. Install heater element (G) through adapter (D) andinstall nut (C), but do not tighten.

6. Install heater into cylinder block with element towardthe front.

7. Tighten adapter.

8. Turn element clockwise, then counterclockwise, untilelement contacts casting. Move element to the centerposition.

9. Hold element using wrench and tighten nut tospecification.


PN=404



TX,0505,SS2486 –19–12JUL95–2/2

SpecificationEngine Coolant Heater ElementNut—Torque 34 N•m (25 lb-ft)....................................................................

.

0505053


PN=405


050505

4


PN=406

Group 0510Cooling System

CED,OUO1020,3224 –19–04DEC98–1/1


TS

225

–UN

–17J

AN

89



05CED,OUO1020,3225 –19–04DEC98–1/1

6068 John Deere POWERTECH Engine—Use CTM104

05101

TS

225

–UN

–17J

AN

89




CED,OUO1020,3226 –19–04DEC98–1/1


TS

225

–UN

–17J

AN

89



CED,OUO1020,3227 –19–04DEC98–1/1

6081 John Deere POWERTECH EngineRepair—Use CTM86

TS

225

–UN

–17J

AN

89

For additional engine repair information, the componenttechnical manual (CTM) is also required.




PN=407

Cooling System

CED,OUO1020,3165 –19–02DEC98–1/2

Essential Tools



CED,OUO1020,3165 –19–02DEC98–2/2

Serpentine Belt Removal and InstallationTool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DFT1140

Remove and install serpentine fan belt.

050510

2

CED,OUO1020,3166 –19–02DEC98–1/2




CED,OUO1020,3166 –19–02DEC98–2/2

Lifting Brackets . . . . . . . . . . . . . . . . . . . . . . JTO1748

Remove and install radiator and oil cooler.


PN=408

Cooling System

CED,OUO1020,3168 –19–02DEC98–1/1

Specifications


Idler Pulley-to-Support Cap Screw Torque 75 N•m (55 lb-ft)

Fan Belt Strand Tension—750C Tension 400 N (90 lb force)(S.N.—831315)

Fan Belt—750C (S.N.—831315) Deflection 19 mm at 111 N (3/4 in. at 25 lbforce)

Radiator, Cooler Isolator Mounts— Torque 100 N•m (75 lb-ft)750C

Radiator, Cooler Isolator Mounts— Torque 230 N•m (170 lb-ft)850C

0505103


PN=409

Cooling System

050510

4

TX,0510,SS2290 –19–29AUG96–1/1

Remove and Install Guards, Shroud and Fan

TS

281

–UN

–23A

UG

88T

8355

AA

–UN

–09J

UN

95750C Shown

A—Upper Radiator HoseB—Recovery Tank HoseC—Upper Fan ShroudD—Upper Fan Guard



1. Turn battery disconnect switch to OFF position.

2. Remove lower baffle to drain coolant from radiator untilcoolant level is below upper radiator hose (A)connection.

3. Remove hood and grill housing cover.

4. Disconnect hose (A and B).

5. Remove upper fan guard (D) and upper fan shroud(C).

6. Remove fan.

7. Remove lower fan guards and shroud if needed.

8. Install lower fan guards, shroud and fan.

9. Install upper fan shroud and guard.

10. Install hoses (A and B).

11. Fill radiator with coolant.


PN=410

Cooling System

0505105

TX,0400,SS2291 –19–12JUL95–1/2

Remove and Install Fan Belt and Adjuster—750C (S.N.—831315)

T60

98A

B–U

N–2

5OC

T88

1—Spacer 8—Cap Screw 15—Cap Screw 22—Cap Screw (2 used)2—Spacer (2 used) 9—Oil Seal 16—Dust Cap 23—Washer (2 used)3—Bracket 10—Idler Pulley 17—Cap Screw 24—Shaft Key4—Lock Washer (4 used) 11—Hub 18—Washer 25—Crankshaft Pulley5—External Tooth Lock 12—Ball Bearing 19—Torsional Dampener 26—Cap Screw

Washer 13—Snap Ring 20—Cap Screw 27—Nut6—Cap Screw 14—Washer 21—Washer 28—Support7—Cap Screw

1. See Remove and Install Guard, Shroud and Fan inthis group.

2. Remove lower fan guard.

3. Loosen nut (27) and turn cap screw (26)counterclockwise to release belt tension. Removefan belts

4. Remove cap screws (22) lock washer (4) andwashers (23) to remove support (28) and idlerpulley assembly.

5. Remove dust cap (16) for access to cap screw (15)and washer (14) remove idler pulley (10).

6. Remove snap ring (13). Push on large end of hub(11) to remove ball bearing (12) and hub. Removehub from bearing.

7. Remove oil seal (9).


PN=411


Cooling System

050510

6

TX,0400,SS2291 –19–12JUL95–2/2

T60

98A

A–U

N–0

9DE

C88

1—Support2—Oil Seal3—Hub4—Ball Bearing5—Idler Pulley6—Snap Ring7—Cap Screw and Washer8—Dust Cap

8. Push ball bearing (4) to bottom of bore.

9. Install snap ring (6) making sure it fits into groove.

10. Install oil seal (2) with lip (spring side) toward ballbearing using 54 and 30 mm disks.

Install seal even with to 0.50 mm (0.020 in.) belowpulley (5) face.

11. Install small end of hub (3) through seal and intobearing. Use a small disk to support inner race of ballbearing while pushing hub into bearing.

12. Fasten idler pulley to support (1) using cap screw andwasher (7). Tighten cap screws to specification.

SpecificationIdler Pulley-to-Support CapScrew—Torque 75 N•m (55 lb-ft)................................................................

IMPORTANT: Dust cap may contact head of capscrew preventing pulley from turningfreely if cap is installed even with pulleyface.

13. Support rear face of pulley and then install dust cap(8) so flat side is 3 ± 0.38 mm (0.118 ± 0.915 in.)above pulley face using 54 mm disk.

14. Install the support and pulley assembly.

15. Install and tighten fan belts to specification.

SpecificationStrand Tension—750C (S.N.—831315)—Tension 400 N (90 lb force)........................................................Fan Belt—750C (S.N.—831315)—Deflection 19 mm at 111 N (3/4 in. at 25 lb

force)...............................


PN=412

Cooling System

0505107

TX,9025,BS495 –19–21AUG96–1/1

Remove, Install, Inspect Serpentine FanBelt—850C and 750C (S.N. 831316— )

T74

05B

G–U

N–1

5NO

V90


2. Check belt for wear, especially for cracks at the bottomof grooves and for frayed edges.

3. If necessary, replace belt.

4. Remove hood.

5. Remove upper fan guards.

6. Place DFT1140 Serpentine Belt Removal andInstallation Tool in square hole (A). Use tool to pulltension adjuster assembly (B) away from belt,releasing belt tension. (See Group 0599 for instructionsto make tool.)

7. Hold tension adjuster assembly away from belt whileremoving old belt and installing new belt.

8. Slowly release tension adjuster assembly against newbelt. Tension is automatically adjusted.

9. Replace tension adjuster assembly if required. (SeeCTM42 for spring tension check and remove, installprocedure.)

10. Install fan guard and hood.


PN=413

Cooling System

050510

8

TX,0510,SS2302 –19–12JUL95–1/5

Remove and Install Radiator and Oil Cooler

TS

281

–UN

–23A

UG

88

CAUTION: Use a suitable lifting device forheavy components.


2. Remove hood and grille housing top cover.

3. Open front grille screen.




4. Remove lower radiator baffle and drain coolant.



PN=414

Cooling System

0505109

TX,0510,SS2302 –19–12JUL95–2/5

T83

56A

S–U

N–0

9JU

N95

750C Shown


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.

5. Drain hydrostatic reservoir or connect a vacuum pumpto hold oil in reservoir.

6. Disconnect oil cooler line (A). Cap and plug all openlines. Remove upper isolator mount cap screws (B).

7. Remove front bottom guard.



PN=415

Cooling System

05 TX,0510,SS2302 –19–12JUL95–3/5

T83

56A

T–U

N–0

9JU

N95

750C Shown

T83

56A

U–U

N–0

9JU

N95

750C Shown

051010

A—Radiator Hose (Upper and Lower)B—Coolant Recovery LineC—Fan Shrouds (Upper and Lower)D—Fan Guards (Upper and Lower)

8. Remove parts (A—D).

9. Disconnect front work light wiring harness.

10. Remove fan belt, fan, and lower isolator mounts andcap screws.

11. Disconnect oil cooler bypass valve line.

12. Install JTO1748 Lifting Brackets and a hoist.

CAUTION: The approximate weight of radiatorand oil cooler is 130 kg (286 lb).

13. Carefully remove radiator and oil cooler.

TX,0510,SS2302 –19–12JUL95–4/5

T83

56A

U–U

N–0

9JU

N95

T60

74A

L–U

N–2

5OC

T88

850C Isolator Mount

A—Cap ScrewB—NutC—Washers (6 used)D—IsolatorE—Spacer (4 used)F—Radiator/CoolerG—Engine Frame

14. Install radiator and oil cooler.

NOTE: Shim isolators with washers to center fan shroudon fan. Indicated number of washers must beused or cap screw may contact bottom of radiatoror oil cooler.

15. Install radiator and cooler isolator mounts.

Specification750C Radiator, Cooler IsolatorMounts—Torque 100 N•m (75 lb-ft)............................................................850C Radiator, Cooler IsolatorMounts—Torque 230 N•m (170 lb-ft)..........................................................


PN=416


Cooling System

05051011

TX,0510,SS2302 –19–12JUL95–5/5

T80

59F

B–U

N–2

7AU

G93

750C Isolator Mount

A—Lower Radiator, Cooler SupportB—Washer (4 used)C—IsolatorD—Engine FrameE—IsolatorF—Washer (4 used)G—Cap Screw

16. Connect oil cooler line and cooler bypass valve line.

17. Install radiator hoses, radiator baffles, coolantrecovery line, fan, fan shrouds, fan belt, fan guards,hood, grille housing cover and front bottom guard.(See Remove and Install Guards, Shroud and Fan inthis group.)

18. Connect front work light wiring harness.

19. Disconnect vacuum pump from hydrostatic reservoir.


20. Fill radiator with coolant. (See Group 0004 for coolantspecifications.)


PN=417

Cooling System

050510

12

CED,TX14826,12122 –19–15DEC99–1/4

Remove and Install Hydraulic Oil Cooler

T12

6678

–UN

–21D

EC

99


PN=418


Cooling System

CED,TX14826,12122 –19–15DEC99–2/4

1—O-Ring 9—Hose Line (Hydraulic Oil 12—Tie Band (4 used) 18—Washer (2 used)2—Elbow Fitting Filter-To-Hydraulic Oil 13—Boss At Rear Engine 19—Bracket3—O-Ring Cooler) mount 20—Bracket4—Orifice Plate 10—Hose Line 14—Washer (2 used) 21—Mount Clamp (22) to Plate5—O-Ring (Reservoir-To-Hydraulic 15—Clamp on Front Engine Mount6—O-Ring Oil Cooler 16—Cap Screw (2 used) 22—Clamp7—Fitting 11—Tie Band (3 used) 17—Cap screw (2 used) 23—Hydraulic Oil Cooler8—Clamp

CAUTION: Use a suitable lifting device forheavy components.

1. Lower blade to ground.

2. Open front grille screen.

3. Remove baffle plate

05051013



PN=419

Cooling System

050510

14

CED,TX14826,12122 –19–15DEC99–3/4

X98

11–U

N–2

3AU

G88



4. Drain hydraulic reservoir or connect a vacuum pump tohold oil in reservoir.

5. Remove rear lower tank cover.

6. Open lower front engine oil pan cover.

7. Tilt cab. See Tilt Cab or Rops in TMS15889026

8. Disconnect hydraulic oil cooler hose lines (9) and (10)from oil cooler.

9. Remove hydraulic oil cooler (23).

10. Disconnect oil cooler hose lines (9) and (10) fromreservoir and hydraulic oil filter. Take note of thelocations of tie bands (11) and (12) and clamps (14)and (21).

11. Remove hose lines (9) and (10).

12. Install hydraulic oil cooler (23) and hose lines (9) and(10). Take note of the locations of tie bands (11) and(12) and clamps (14) and (21).

13. Move cab to up right position. See Tilt Cab or Rops inTMS15889026


PN=420


Cooling System

CED,TX14826,12122 –19–15DEC99–4/4

14. Install front belly pan, rear lower tank cover and baffleplate.

15. Close front grille screen.

16. Fill hydraulic reservoir.

05051015


PN=421

Cooling System

050510

16


PN=422

Group 0515Speed Controls

CED,OUO1020,3177 –19–02DEC98–1/3

Essential Tools



05CED,OUO1020,3177 –19–02DEC98–2/3

Single Pin Test Harness . . . . . . . . . . . . . . . JT07237-1

Used to test engine speed control sensor.

3-Pin Test Harness . . . . . . . . . . . . . . . . . . JT07237-2

Used to test engine speed control sensor.

05151

CED,OUO1020,3177 –19–02DEC98–3/3

4-Pin Test Harness . . . . . . . . . . . . . . . . . . JT07237-6

Used to test throttle sensor adjustment.

CED,OUO1020,3178 –19–02DEC98–1/3




CED,OUO1020,3178 –19–02DEC98–2/3

Digital Tachometer . . . . . . . . . . . . . . . . . . . . JT05801

Measure RPM


PN=423


Speed Controls

CED,OUO1020,3178 –19–02DEC98–3/3

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Used to measure voltage.

05 CED,OUO1020,3179 –19–02DEC98–1/1

Other Material

Number Name Use

TY9370 (U.S.) Thread Lock and Sealer (Medium Apply to threads of speed controlTY9477 (Canadian) Strength) LOCTITE Products hub cap screws.242 (LOCTITE)

TY6304 (U.S.) Flexible Sealant Apply to face of throttle sensorTY9484 (Canadian) mounting block.515 (LOCTITE)

05152



PN=424

Speed Controls

0505153

CED,OUO1020,3180 –19–02DEC98–1/2

Specifications


Speed Control Lever Force 31—33 N (7—9 lb)

Sensor-to-Mounting Block Cap Torque 6.1 ± 1.2 N•m (54 ± 11 lb-in.)Screws

Injection Pump Slow Idle Stop Screw Speed 900 + 25 — 0 rpmAdjustment—750C

Injection Pump Fast Idle Stop Screw Speed 2240 + 35 — 0 rpmAdjustment—750C

Pedal Steer Injection Pump Slow Speed 900 + 25 — 0 rpmIdle—750C

Single Lever Steer Injection Pump Speed 900 + 25 — 0 rpmSlow Idle (Decelerator Down)—750C

Single Lever Steer Injection Pump Speed 100—150 rpm above deceleratorSlow Idle (Decelerator Up)—750C down slow idle

Injection Pump Slow Idle Stop Screw Speed 875 rpmAdjustment—850C

Injection Pump Idle Spring Adjusting Speed 900 + 25 — 0 rpmScrew Adjustment—850C

Injection Pump Fast Idle Stop Screw Speed 2240 + 35 — 0 rpmAdjustment—850C

Pedal Steer Injection Pump Slow Speed 900 + 25 — 0 rpmIdle—850C

Single Lever Steer Injection Pump Speed 900 + 25 — 0 rpmSlow Idle (Decelerator Down)—850C

Single Lever Steer Injection Pump Speed 100—150 rpm above deceleratorSlow Idle (Decelerator Up)—850C down slow idle

Slow Idle—Single Lever Steer 750C Speed 100—150 rpm above deceleratorAll Machines, 850C (S.N.—822867) (down) slow idle

Slow Idle—Single Lever Steer 850C Speed 100—150 rpm above decelerator(S.N. 822868— ) (down) slow idle


PN=425


Speed Controls

050515

4

CED,OUO1020,3180 –19–02DEC98–2/2


Slow Idle—Pedal Steer 750C All Speed 1000 + 25 — 0 rpmMachines, 850C (S.N. —822867)

Slow Idle—Pedal Steer 850C (S.N. Speed 1000 + 25 — 0 rpm822868— )

Start of Engine Speed Control Lever Force 31—40 N (7—9 lb force)Movement

Slow Idle Stop Adjustment—All Voltage 1.57 V (nominal)Machines

Engine Speed Sensor (Fast Idle Voltage 2.88—4.32 VPosition)—All Machines

Slow Idle (Decelerator Down) Initial Voltage 0.96—1.44 VCheck—Single Lever Steer

Slow Idle Stop Adjustment—Single Voltage 1.20 V (nominal)Lever Steer

Decelerator Sensor (Fast Idle Voltage 2.61—3.91 VPosition)—Single Lever Steer

Throttle Sensor Output (Nominal)— Voltage 1.40 ± 0.1 V850C (S.N. 822868— )

Throttle Sensor Cap Screws—850C Torque 15.3 ± 1.5 N•m (132 ± 12 lb-in.)(S.N. —847803)

Throttle Sensor Cap Screw—850C Torque 11 N•m (97 lb-in.)(S.N. 847804— )


PN=426

Speed Controls

901025,AA57 –19–05OCT90–1/1

JT05801 Clamp-On Digital TachometerInstallation

T68

13A

G–U

N–2

8FE

B89

A—Clamp-On TransducerB—Black Clip (—)C—Red Clip (+)D—Tachometer Readout

SERVICE EQUIPMENT AND TOOLS

Tachometer

A—Clamp-on Transducer. Remove paint with emery cloth andconnect to a straight section of injection line within 100 mm (4 in.) ofpump. Finger tighten only. DO NOT overtighten.

B—Black Clip (—). Connect to main frame.

C—Red Clip (+). Connect to transducer.

D—Tachometer Readout. Install cable.

0505155


PN=427

Speed Controls

050515

6

TX,9025,BS507 –19–12JUL95–1/2

Remove and Install Engine Speed Control

T83

78B

N–1

9–28

JUN

95


PN=428


Speed Controls

0505157

TX,9025,BS507 –19–12JUL95–2/2

1—Knob 8—Thrust Washer 14—Linkage Rod 21—Cap Screw (4 used)2—Rod 9—Throttle Bracket 15—Washer (7 used) 22—Pivot Lever Hub3—Cap Screw 10—Bearing 16—Cap Screw (3 used) 23—90° Sensor4—Nut 11—Thrust pack Bearing 17—Spacer 24—Tie Band5—Nut 12—Rod (To engine speed 18—Washer 25—Washer (4 used)6—Spring Washer (4 used) control cable) 19—Sensor Pivot Bracket 26—Cap Screw (4 used)7—Tab Washer 13—Lock Nut (3 used) 20—Cap Screw (2 used)

IMPORTANT: Calibrate transmission and enginecontrollers whenever a sensor,transmission components, or enginespeed control components areadjusted or replaced.

1. Disconnect speed control cable from rod (12).

2. Remove clamp from bracket (9).

3. Disconnect wiring lead to speed sensor (23).

4. Remove knob (1) from rod (2). Remove rubber boot(not shown).

5. Remove cap screws (26) and washers (25).

6. Replace parts as needed.

7. Install bearing (10) into throttle bracket hub borefrom chamfered side. Press flush with bore face.

8. Install thrust pack bearing (11) on hub (22).

9. Install hub on bracket.

10. Install thrust washer (8) with steel side of washeragainst throttle bracket (9). Install tab washer (7)on hub shaft.

11. Install washers (6) in the following sequence.Stack first washer with the small end against thetab washer (7). Install second washer the same asthe first. Place the third washer large end againstthe large end of the second washer. The fourthwasher is installed the same as the third washer.The small end of the fourth washer should beagainst the lock nut (5).

NOTE: Adjust speed control lever when allcomponents are assembled on machine andwith speed control cable disconnected.Measure force using a spring scale.

12. Tighten lock nut (5) to obtain specified springscale force on lever to start movement. Measureat top of knob (1) on speed control rod.

SpecificationSpeed Control Lever—Force 31—33 N (7—9 lb).................................

13. Install cap screws (20) to fasten speed control rod(2) and engine speed control cable rod (12). Applythread lock and sealer (medium strength) to capscrews.

IMPORTANT: Note specific location of bracket,rod, and hardware (keys 12—19)when assembling sensor linkage. Ifnot assembled as shown sensorvoltage may not be withinspecification.

14. Assemble sensor linkage, sensor (23), andhardware.

15. Do Engine Speed Control Sensor Adjustment andEngine Speed Adjustment. (See adjustmentprocedures in this group.)




PN=429

Speed Controls

050515

8

TX,9025,BS509 –19–29AUG96–1/2

Remove and Install Engine Speed Control Linkage and Shaft 750C and 850C (S.N. —822867)

T85

06A

R–1

9–28

JUN

95


PN=430


Speed Controls

0505159

TX,9025,BS509 –19–29AUG96–2/2

1—Clamp (4 used) 8—Spring Pin (3 used) 14—Bracket—Right 19—Lever (to Speed Control2—Washer (9 used) 9—Lever (to 750C injection 15—Spacer (2 used) Cable)3—Cap Screw (2 used) pump rod) 16—Lever (to 850C injection 20—Jam Nut (2 used)4—Cap Screw 10—Cap Screw (4 used) pump rod) 21—Ball Joint (2 used)5—Speed Control Cable 11—Washer (2 used) 17—Spring 22—Cap Screw6—Bracket—Left 12—Cross Shaft 18—Spring Pin7—Bearing (3 used) 13—Lever (to decelerator

linkage-on lever steermachines)

IMPORTANT: Calibrate transmission controllerwhenever a sensor, pressure controlpilot valve (PCP), transmissioncomponent, or engine speed controlcomponent is adjusted or replaced.


2. Disconnect speed control cable (5).

3. Disconnect injection pump speed control rod fromlever (9) on 750C, or (16) on 850C.

4. Disconnect spring (17).

5. Disconnect decelerator shock absorber and pedallinkage (lever steer machines only).

6. Remove cap screws (10)


8. Assemble bearings (7) on mounting brackets (6)and (14) with the bearing flange ends facingoutward. On lever (19) the flange end points towardspacer. Grease bearings prior to assembly.

9. Install speed control cable (5) with the long leadend on the speed control cross shaft lever (19).Install the two threaded rod ends of the speedcontrol cable (5) at mid thread engagementposition.

10. Do Engine Speed Control Cable Adjustment. (Seeprocedure in this group.)

11. Calibrate transmission controller. (See procedurein Operation and Test Manual, Group 9015-20.)


PN=431

Speed Controls

050515

10

TX,0515,BA1911 –19–29AUG96–1/2

Remove and Install Engine Speed Control Linkage and Shaft 850C (S.N. 822868—)

T10

1809

–19–

21A

UG

96


PN=432


Speed Controls

05051511

TX,0515,BA1911 –19–29AUG96–2/2

1—Cap Screw (2 used) 9—Cap Screw (2 used) 16—Spacer (2 used) 22—Washer (4 used)2—Throttle Sensor 10—Washer (6 used) 17—Lever 23—Ball Joint (2 used)3—O-Ring 11—Cap Screw (4 used) 18—Spring 24—Jam Nut (2 used)4—Mounting Block 12—Washer (3 used) 19—Spring Pin 25—Cap Screw (2 used)5—Spring Pin 13—Cross Shaft 20—Lever (to speed control 26—Clamp (4 used)6—Bearing 14—Lever (to decelerator cable) 27—Speed Control Cable7—Bracket-Left pedal linkage) 21—Cap Screw 28—Cap Screw8—Washer (2 used) 15—Bracket-Right



2. Disconnect spring (18).

3. Disconnect speed control cable (27) from lever (20).

4. Disconnect decelerator pedal linkage from lever(14).

5. Disconnect throttle sensor (2) electrical connector.

6. Remove cap screws (11) and remove speed controllinkage and shaft as an assembly.


8. Assemble bearings (6) on mounting brackets (7)and (15) with the bearing flange ends facingoutboard. On lever (20) the flange end pointstoward spacer. Grease bearings prior to assembly.

IMPORTANT: DO NOT over tighten sensormounting cap screws. Overtightening cap screws could causedamage to sensor.

9. Install sensor (2) onto mounting block (4), makingsure O-ring (3) is in place. Install cap screws (1)and tighten to specification.

SpecificationSensor-to-Mounting Block CapScrews—Torque 6.1 ± 1.2 N•m (54 ± 11 lb-in.)...................................

10. Install bracket (7) on cross shaft (13) as shown,slide washers (12) on shaft and install spring pin(5) in hole.

11. Apply flexible sealant to face of mounting block(4). Install mounting block and sensor by firstengaging sensor key tab with shaft key slot andthen rotate sensor and block until electricalconnector is indexed UP toward floor andmounting cap screws can be installed. Install capscrews loosely at this time.

12. Install speed control and shaft assembly to caband tighten cap screws (11).

13. Connect electrical connector to sensor.

14. Connect decelerator pedal linkage to lever.

15. Install speed control cable with the long lead endon lever (20). Install the two threaded rod ends ofthe speed control cable at mid thread engagementposition.

16. Attach spring to lever using the front hole, asshown in exploded view.

17. Do Engine Speed Control Cable Adjustment. (Seeprocedure in this group.)

18. Do Throttle Sensor Adjustment. (See procedure inthis group.)

19. Calibrate transmission and engine controllers.(See procedures in Operation and Test Manual,Group 9015-20.)


PN=433

Speed Controls

050515

12

TX,9025,BS511 –19–29AUG96–1/1

Engine Speed Control Linkage Rod—850C (S.N. —822867)

T85

06A

S–1

9–28

JUN

95

Engine Speed Control Linkage Rod—850C

1—Linkage Rod (cross shaft 2—Jam Nut (2 used) 4—Nut 6—Washer (2 used)control lever to injection 3—Ball joint 5—Nut 7—Ball Jointpump)

IMPORTANT: Calibrate transmission controllerwhenever a sensor, pressure controlpilot valve (PCP), transmissioncomponent, or engine speed controlcomponent is adjusted or replaced.

1. Remove and install components as shown.

2. Adjust engine speed. (See Engine SpeedAdjustment. procedure in this group.)



PN=434

Speed Controls

05051513

TX,9025,BS512 –19–29AUG96–1/1


T85

06A

T–1

9–28

JUN

95


1—Cover 4—Linkage Rod (cross shaft 5—Cotter Pin 7—Pin2—Jam Nut (2 used) control lever to injection 6—Yoke3—Ball Joint pump)

IMPORTANT: Calibrate transmission controllerwhenever a sensor, pressure controlpilot valve (PCP), transmissioncomponent, or engine speed controlcomponent, is adjusted or replaced.

1. Remove and install components as shown.

2. Adjust engine speed. (See Engine SpeedAdjustment procedure in this group.)



PN=435

Speed Controls

050515

14

TX,9025,BS513 –19–15MAR96–1/2

Remove and Install Decelerator

T85

06A

U–1

9–01

MA

R96


PN=436


Speed Controls

05051515

TX,9025,BS513 –19–15MAR96–2/2

1—Speed Sensor 10—Cap Screw 19—Bellcrank 28—Cap Screw (2 used)2—Washer (8 used) 11—Washer (6 used) 20—Nut 29—Shock Absorber—750C3—Lock Nut (3 used) 12—Linkage Rod 21—Spring Pin and 850C (S.N. —824178);4—Cap Screw 13—Cap Screw 22—Screw (4 used) Shock Damper—750C5—Cap Screw (4 used) 14—Nut (2 used) 23—Cap Screw (3 used) (S.N. 824179—)6—Nut 15—Shaft 24—Rod 30—Washer (6 used)7—Washer (8 used) 16—Spring Pin 25—Bellcrank 31—Spacer (2 used)8—Bearing (2 used) 17—Washer (2 used) 26—Pedal 32—Lock Nut (2 used)9—Pedal Support 18—Cap Screw 27—Seal



2. Remove cab or ROPS front cover.

3. Disconnect decelerator linkage rod (12).

4. Disconnect wiring lead from sensor (1).


6. Remove pedal support (9) and deceleratorcomponents.

7. Replace parts as required.

8. Install bearings (8) in pedal support flush with roughside of support (9). Grease bearings prior toassembly.

9. Install seal (27) in sensor bore with sealing lip awayfrom sensor.

IMPORTANT: Note specific location of bellcranks,linkage components, rod, and

hardware (keys 16—27) whenassembling sensor linkage. If notassembled as shown sensor voltagemay not be within specification.

10. Assemble sensor linkage.

IMPORTANT: Note specific location of washers,spacers and lock nuts whenassembling decelerator shockabsorber/damper. If not assembledas shown sensor voltage may not bewithin specification.

11. Install shock absorber/damper (29) so that bothends rotate freely without binding. Thread capscrews through shock absorber/damper retainingeyes and into cab support bracket, and speedcontrol lever. Lock cap screws in place with locknut.

12. Do Decelerator Sensor Adjustment. (Seeprocedure in this group.)




PN=437

Speed Controls

050515

16

TX,9026,YY1106 –19–22NOV99–1/3

Engine Speed Adjustment—750C

T84

54A

A–U

N–3

1MA

R95

Engine Speed—750C

1—Yoke2—Slow Idle Stop3—Fast Idle Stop

SPECIFICATIONS

Injection Pump Slow Idle Stop 900 + 25 — 0 rpmScrew Adjustment Speed

Injection Pump Fast Idle Stop 2240 + 35 — 0 rpmScrew Adjustment Speed

PEDAL STEER:

Pedal Steer Injection Pump Slow 900 + 25 — 0 rpmIdle Speed

SINGLE LEVER STEER (S.N. —875378):

Single Lever Steer Injection 900 + 25 — 0 rpmPump Slow Idle (DeceleratorDown) Speed

Single Lever Steer Injection 100—150 rpm above deceleratorPump Slow Idle (Decelerator Up) down slow idleSpeed

SINGLE LEVER STEER (S.N. 875379— ) and SINGLE LEVERSTEER with SPEED IN GRIP



JT05801 Digital Tachometer

This procedure will set slow and fast idle at injection pumpand adjust connecting rod from quick disconnect in frontof cab or ROPS to injection pump.

1. Install digital tachometer. (See procedure in thisgroup.)

2. Warm engine to normal operating temperature.

3. Remove yoke (1) at fuel injection pump speed lever.

4. Move the fuel injection pump speed lever to slow idle(2) and fast idle (3) stops and check engine rpm’s.Adjust pump speed lever stop screws to get specifiedrpm’s.

SpecificationInjection Pump Slow Idle StopScrew Adjustment—Speed 900 + 25 — 0 rpm...........................................Injection Pump Fast Idle StopScrew Adjustment—Speed 2240 + 35 — 0 rpm.........................................


PN=438


Speed Controls

05051517

TX,9026,YY1106 –19–22NOV99–2/3

NOTE: Step 5 will adjust injection pump slow and fast idleONLY. See Engine Speed Control CableAdjustment, in this group, to adjust engine speedcontrol lever slow idle rpm.

5. PEDAL STEER: Hold the engine speed control leveragainst the slow idle stop and adjust yoke (1) onconnecting rod at injection pump speed lever for a slipfit at specified rpm. Move engine speed control lever tofast idle. There should be some over-travel of theinjection pump speed lever at fast idle.

Pedal Steer—SpecificationPedal Steer Injection Pump SlowIdle—Speed 900 + 25 — 0 rpm..................................................................

SINGLE LEVER STEER (S.N. —875378): Hold thedecelerator down against the stop screw and with the fuelinjection pump lever in the slow idle position, adjust yoke(1) on connecting rod at injection pump speed lever for aslip fit at specified rpm.

Single Lever Steer—SpecificationSingle Lever Steer InjectionPump Slow Idle (DeceleratorDown)—Speed 900 + 25 — 0 rpm.............................................................

With speed control lever against the slow idle stop,release decelerator pedal. Slow idle speed should be tospecification.

Single Lever Steer—SpecificationSingle Lever Steer InjectionPump Slow Idle (DeceleratorUp)—Speed 100—150 rpm above decelerator

down slow idle...........................................

SINGLE LEVER STEER (S.N. 875379—) and SINGLELEVER STEER with SPEED IN GRIP: Hold thedecelerator down against the stop screw and with the fuelinjection pump lever in the slow idle position, adjust yoke(1) on connecting rod at injection pump speed lever for aslip fit at specified rpm.



PN=439


Speed Controls

TX,9026,YY1106 –19–22NOV99–3/3

Move engine speed control lever to fast idle. There shouldbe some over-travel of the injection pump speed lever atfast idle.

6. Do Engine Speed Control Cable Adjustment, in thisgroup.

050515

18


PN=440

Speed Controls

05051519

TX,9026,YY1107 –19–02DEC99–1/5

Engine Speed Adjustment—850C

T10

0048

–UN

–21D

EC

95

Engine Speed—850C

1—Ball-Joint4—Fast Idle Stop Screw5—Slow Idle Stop Screw6—Idle Spring Adjusting Screw

SPECIFICATIONS

Injection Pump Slow Idle Stop 875 rpmScrew Adjustment Speed

Injection Pump Idle Spring 900 + 25 — 0 rpmAdjusting Screw AdjustmentSpeed

Injection Pump Fast Idle Stop 2240 + 35 — 0 rpmScrew Adjustment Speed

PEDAL STEER:

Pedal Steer Injection Pump Slow 900 + 25 — 0 rpmIdle Speed

SINGLE LEVER STEER (S.N. —875378):


Single Lever Steer Injection 100—150 rpm above deceleratorPump Slow Idle (Decelerator Up) down slow idleSpeed

SINGLE LEVER STEER (S.N.875379—) and SINGLE LEVER STEERwith SPEED IN GRIP




NOTE: 850C (S.N. 822868— ), uses electronic fuelinjection, so a mechanical speed adjustment is notnecessary. To set slow and fast idle, an enginecalibration is performed. See Calibrate EngineController 850C (S.N. 822868— ), Group 9015-20.

850C (S.N. —822867): This procedure will set slow andfast idle at injection pump and adjust connecting rod fromquick disconnect in front of cab or ROPS to injectionpump.


2. Warm engine to normal operating temperature.

3. Disconnect cap screw at ball-joint (1) on fuel injectionpump speed lever.


PN=441


Speed Controls

050515

20

TX,9026,YY1107 –19–02DEC99–2/5

4. Move injection pump speed lever to check slow idle (5)and fast idle (4) speeds. Adjust to specification.

5. Adjust slow idle as follows:

• Start engine.• Hold injection pump speed lever against slow idle

stop screw (5).• Loosen lock nut and turn supplementary idle spring

adjusting screw (6) OUT three turns.• Loosen lock nut and turn slow idle stop screw (5) to

adjust engine speed to specification. Tighten locknut. Turn supplementary idle spring adjusting screw(6) IN until speed increases to specified rpm. Tightenlock nut.

SpecificationInjection Pump Slow Idle StopScrew Adjustment—Speed 875 rpm............................................................Injection Pump Idle SpringAdjusting Screw Adjustment—Speed 900 + 25 — 0 rpm...........................................................................

6. Adjust fast idle as follows:

• Move injection pump speed lever against the fastidle stop screw (4).

• Adjust screw to specified rpm.

SpecificationInjection Pump Fast Idle StopScrew Adjustment—Speed 2240 + 35 — 0 rpm.........................................

NOTE: Steps 7 and 8 will adjust injection pump slow andfast idle ONLY. See Engine Speed Control CableAdjustment, in this group, to adjust engine speedcontrol lever slow idle rpm.

7. PEDAL STEER: Move engine speed control leveragainst the slow idle stop. Adjust ball-joint (1) onconnecting rod for a slip fit in the middle of the leverslot at specified rpm.


PN=442


Speed Controls

TX,9026,YY1107 –19–02DEC99–3/5

Pedal Steer—SpecificationPedal Steer Injection Pump SlowIdle—Speed 900 + 25 — 0 rpm..................................................................


05051521

TX,9026,YY1107 –19–02DEC99–4/5T

8434

AH

–UN

–06M

AR

95

Stop Screw

7—Decelerator Stop Screw

8. SINGLE LEVER STEER (S.N. —875378): Holddecelerator against stop screw (7). Adjust ball-joint onconnecting rod for a slip fit in the middle of the leverslot at specified rpm.


With speed control lever against the slow idle stop,release decelerator pedal. Slow idle speed should bewithin specification.

SpecificationSingle Lever Steer InjectionPump Slow Idle (DeceleratorUp)—Speed 100—150 rpm above decelerator

down slow idle...........................................



PN=443

Speed Controls

TX,9026,YY1107 –19–02DEC99–5/5

T84

34A

H–U

N–0

6MA

R95

Stop Screw

7—Decelerator Stop Screw

SINGLE LEVER STEER (S.N. 875379—) and SINGLELEVER STEER with SPEED IN GRIP: Hold deceleratoragainst stop screw (7). Adjust ball-joint on connecting rodfor a slip fit in the middle of the lever slot at specified rpm.



9. Do Engine Speed Control Cable Adjustment in thisgroup.

050515

22


PN=444

Speed Controls

05051523

TX,9026,YY1110 –19–07JAN00–1/3

Engine Speed Control Cable Adjustment

T84

34A

F–U

N–0

6MA

R95

3-Speed Control Sensor Shown (S.N.—875378)

T84

34A

G–U

N–0

6MA

R95

T84

34A

H–U

N–0

6MA

R95

Decelerator Stop Screw

2—Stop Screw3—Speed Control Sensor7—Decelerator Pedal Stop Screw8—Ball-Joint

SPECIFICATIONS

Slow Idle—750C/850C (S.N.— 100—150 rpm above decelerator875378) Single Lever Steer (down) slow idle

Slow Idle—750C/850C 900 + 25 — 0 rpm(S.N.875379—) Single LeverSteer

Slow Idle—Pedal Steer 1000 + 25 — 0 rpm

Start of Lever Movement Force 31—40 N (7—9 lb force)



This procedure will adjust the push/pull cable from theengine speed control lever to the cross shaft.


2. Disconnect cable ball-joint (8) from engine speed leverlinkage.

NOTE: Disconnect ball-joint and partially thread capscrew into speed control lever to assist indetermining slip fit between cable and lever.

3. SINGLE LEVER STEER (750C, 850C S.N. —875378)

Hold injection pump lever against slow idle stop. Putengine speed control lever against stop screw (2) anddecelerator pedal against stop screw (7).

Push cable IN and adjust ball-joint (8) for a slip fit tothe engine speed control lever. Finger tighten capscrew and nut.

Start engine and check slow idle. Slow idle must be tospecification. Turn ball-joint IN to adjust slow idle rpm.

SpecificationSlow Idle—Speed 100—150 rpm above decelerator

(down) slow idle..................................


PN=445


Speed Controls

050515

24

TX,9026,YY1110 –19–07JAN00–2/3

T84

34A

F–U

N–0

6MA

R95

Cable Ball Joint

T84

34A

G–U

N–0

6MA

R95

Stop Screw

T84

54A

C–U

N–3

1MA

R95Adjust Ball Joint for Slip Fit to Engine Speed Control Lever

2—Speed Control Lever Stop Screw3—Speed Sensor8—Ball-Joint9—Engine Speed Control Lever10—Lock Nut

Tighten cap screw and jam nut. Check engine slow andfast idle.

SINGLE LEVER STEER (750C/850C S.N. 875379— )

Put engine speed control lever against stop screw (2).Push cable IN and adjust ball-joint (8) for a slip fit toengine speed control lever (9). Turn ball-joint INapproximately 2—3 turns. Install and finger tighten capscrew and jam nut.

Start engine and check slow idle speed. Slow idle shouldbe to specification.

SpecificationSlow Idle—Speed 900 + 25 — 0 rpm.........................................................

Turn ball-joint to adjust slow idle rpm.

Tighten cap screw and jam nut. Check slow idle speed.

PEDAL STEER

Hold injection pump lever against slow idle stop. Putengine speed control lever against stop screw (2). Pushcable IN and adjust ball-joint (8) for a slip fit to enginespeed control lever (9). Turn ball-joint IN approximately2—3 turns. Install and finger tighten cap screw and jamnut.

Start engine and check slow idle speed. Slow idle shouldbe to specification.

SpecificationSlow Idle—Speed 1000 + 25 — 0 rpm.......................................................

Turn ball-joint to adjust slow idle rpm.

Tighten cap screw and jam nut. Check slow idle speed.

4. Do engine and transmission controller calibrationprocedures where applicable. (See Group 9015-20.)

5. ENGINE SPEED CONTROL LEVER TENSIONADJUSTMENT


PN=446


Speed Controls

TX,9026,YY1110 –19–07JAN00–3/3

With push/pull cable disconnected, loosen or tightenlock nut (10) until it takes specified force on enginespeed control lever to start movement. Use a springscale and measure from top of lever knob.

SpecificationStart of Lever Movement—Force 31—40 N (7—9 lb force).......................

05051525

TX,9026,YY1108 –19–02DEC99–1/2

Engine Speed Control Sensor Adjustment(750C, 850C S.N.—875378)

T84

34A

F–U

N–0

6MA

R95

Adjust Slow Idle Stop Screw

3—Speed Sensor8—Ball-Joint

SPECIFICATIONS

Slow Idle Stop Initial Check 1.26—1.88Voltage

Slow Idle Stop Adjustment 1.57 (nominal)Voltage

Sensor (Fast Idle Position) 2.88—4.32Voltage

ESSENTIAL TOOLS

JT07237-1 Single Pin Test Harness

JT07237-2 3-Pin Test Harness


JT05791 Digital Multimeter

This procedure will adjust the slow idle stop screw on theengine speed control lever.

NOTE: After S.N.—875378 the engine speed controlsensor is no longer used.

1. Install JT07237-1 and JT07237-2 test harnesses on theengine speed sensor (3). Connect digital multimeter topin B (white wire) and pin C (black wire) on the testharness.



PN=447

Speed Controls

050515

26

TX,9026,YY1108 –19–02DEC99–2/2

T84

34A

G–U

N–0

6MA

R95

Slow Idle Stop

2—Slow Idle Stop

NOTE: With engine speed slow idle stop set to nominalvalue, the high speed voltage must be withinspecified range. Fast idle position is notadjustable.

2. Turn key switch ON. With the engine speed controllever against the slow idle stop (2), check voltage. Ifvoltage is within specification, do not adjust stop.

SpecificationSlow Idle Stop Initial Check—Voltage 1.26—1.88.......................................................................................

When adjustment is required, loosen jam nut and turn capscrew (2). Set to specification and tighten jam nut.

SpecificationSlow Idle Stop Adjustment—Voltage 1.57 (nominal).................................................................................

NOTE: If voltage is not in specified range, check forproper assembly.

3. With the key switch ON, move the engine speed leverto the fast idle position. The sensor voltage should bewithin specification.

SpecificationSensor (Fast Idle Position)—Voltage 2.88—4.32.......................................................................................

4. For 850C (S.N. 822868— ) only: Do Throttle SensorAdjustment, in this group.

5. Do transmission controller calibration procedure. (SeeGroup 9015-20.)


PN=448

Speed Controls

05051527

TX,9026,YY1109 –19–22AUG96–1/2

Decelerator Sensor Adjustment—SingleLever Steer

T84

34A

H–U

N–0

6MA

R95

Stop Screw

7—Stop Screw

SPECIFICATIONS

Slow Idle (Decelerator Down) 0.96—1.44Initial Check Voltage

Slow Idle Stop Adjustment 1.20 (nominal)Voltage

Sensor (Fast Idle Position) 2.61—3.91Voltage

ESSENTIAL TOOLS





This procedure will adjust the decelerator slow idle stopscrew.

1. Connect JT07237-1 and JT07237-2 test harnesses andmultimeter to the decelerator sensor (located abovedecelerator pedal). Connect multimeter to pin B (whitewire) and C (black wire) on test harness.

2. Turn key switch ON. Depress decelerator pedal until itis against the stop screw (7) and check voltage. Ifvoltage is within specification, do not adjust stop.

SpecificationSlow Idle (Decelerator Down)Initial Check—Voltage 0.96—1.44...............................................................

When adjustment is required, loosen jam nut and turncap screw (7). Set to specification.

SpecificationSlow Idle Stop Adjustment—Voltage 1.20 (nominal).................................................................................

3. With the key switch ON, move the engine speed leverto the fast idle position. The sensor voltage should bewithin specified range.

SpecificationSensor (Fast Idle Position)—Voltage 2.61—3.91.......................................................................................


PN=449


Speed Controls

TX,9026,YY1109 –19–22AUG96–2/2

NOTE: If voltage is not in specified range, check forproper assembly.

4. Do transmission controller calibration procedure. (SeeGroup 9015-20.)

050515

28


PN=450

Speed Controls

05051529

TX,9010,BA1908 –19–02DEC99–1/2

Throttle Sensor Adjustment—850C (S.N.822868— )

T10

2141

–UN

–29J

UL9

6

Throttle Sensor Adjustment

T10

1746

–UN

–19J

UL9

6Cap Screws

1—X24 Diagnostic Connector2—JT07237-6 Test Harness3—Digital Multimeter4—JT07237-1 Test Harness5—Cap Screw, (S.N. —847803) (2 used), (S.N.

847804— ) (1 used)

SPECIFICATIONS

Sensor Output (Nominal) Voltage 1.40 ± 0.1

Sensor Cap Screws (S.N. — 15.3 ± 1.5 N•m (132 ± 12 lb-in.)847803) Torque

Sensor Cap Screw (S.N. 11 N•m (97 lb-in.)847804— ) Torque

ESSENTIAL TOOLS





This procedure will adjust the throttle sensor to meetengine speed specifications and calibrations.

1. Connect JT07237-6 test harnesses (2) to the X24 4-pinsquare diagnostic voltage connector (1), wires (E15white, E14 white, Z20 gray and M16 purple), locatedbelow engine controller connector, in left side consoleaccess door. Connect JT07237-1 test harness (4) toJT07237-6 harness, RED wire to pin A and BLACKwire to pin C. Connect other end of JT07237-1 harnessto digital multimeter (3), RED + and BLACK —.

2. Turn key switch ON, but DO NOT start engine.

SINGLE LEVER STEER: Depress decelerator pedaluntil it is against the stop screw and check nominalvoltage reading on multimeter. If nominal voltagereading is not within specification, do steps 3—5.

PEDAL STEER: Check nominal voltage with speedcontrol lever in slow idle position. If nominal voltagereading is not within specification, do steps 3—5.

SpecificationSensor Output (Nominal)—Voltage 1.40 ± 0.1........................................................................................

3. Tilt cab or ROPS. (See procedure in Group 9026-25.)


PN=451


Speed Controls

TX,9010,BA1908 –19–02DEC99–2/2

4. Loosen cap screw(s) (5) and slowly rotate sensor untilvoltage reading is within specification. Tighten capscrew(s) to specification. After cap screw(s) aretightened, check voltage reading to make sure it is stillwithin specification.

SpecificationSensor Cap Screws (S.N. —847803)—Torque 15.3 ± 1.5 N•m (132 ± 12 lb-in.).....................................Sensor Cap Screw (S.N.847804— )—Torque 11 N•m (97 lb-in.).......................................................

5. Calibrate engine controller, see Calibrate EngineController, in Group 9015-20.

050515

30


PN=452

Group 0520Intake System

0505201

TX,0520,SS2305 –19–29AUG96–1/1

Remove and Install Air Cleaner

T10

2789

–UN

–21A

UG

96750C and 850C Air Cleaners Shown

1—Cap 8—Cap Screw 15—Air Cleaner Support and 21—Spacer (2 used)2—Clamp (2 used) 9—Washer (2 used) Hardware 850C (S.N. 22—Cap Screw (2 used)3—Clamp 10—Spacer 822868— ) 23—Air Cleaner Support and4—Hose 11—Cap Screw 16—Cap Screw Hardware 750C5—Air Cleaner Housing 12—Washer (2 used) 17—Nut 24—Cap Screw (4 used)6—Air Cleaner Housing 850C 13—Cap Screw 18—Cap Screw (2 used) 25—Air Cleaner Support

(S.N. 822868— ) Only 14—Air Cleaner Support and 19—Nut (6 used) Clamps (2 used)7—Dust Unloader Valve Hardware 850C (S.N. — 20—Washer (9 used)

822867)

Remove and install component parts as shown.


PN=453

Intake System

050520

2

TX,0520,DV215 –19–12SEP91–1/1

Test Air Intake System for Leaks

T59

06A

P–U

N–2

3FE

B89

T65

66N

L–U

N–2

4OC

T88

1. Remove air cleaner cover and filter element.

2. Put large plastic bag into and over end of main filterelement. Install main filter element and cover.

3. Remove air cleaner restriction switch and install testfitting.

4. Connect air pressure regulator to manifold using hoseand fitting from air cleaner.

5. Pressurize air intake system to 14—21 kPa (0.14—0.21 bar) (2—3 psi). If intake system cannot bepressurized, turn engine slightly to close valves.

6. Spray soap solution over all connections from the aircleaner to turbocharger or air intake manifold andcheck for leaks. Correct all leaks.

IMPORTANT: When reinstalling starting aid nozzle,position arrow on nozzle pointingagainst intake air flow.


PN=454

Group 0530External Exhaust Systems

0505301

TX,0530,SS2361 –19–12JUL95–1/1

Remove and Install Muffler

T83

44B

S–U

N–1

2JU

N95

A—Muffler Extension C—Clamp E—Washer (5 used) G—ClampB—Muffler D—Nut F—Cap Screw (5 used)

1. Remove hood.

NOTE: On 750C also remove air cleaner.

2. Remove and install muffler components as shown.


PN=455

External Exhaust Systems

050530

2


PN=456

Group 0560External Fuel Supply Systems

CED,OUO1020,3181 –19–02DEC98–1/1

Other Material

Number Name Use

TY9375 (U.S.) Pipe SealantLOCTITE Products Apply to threads of fuel line shut-offTY9480 (Canadian) valve.592 (LOCTITE)


05CED,OUO1020,3061 –19–29OCT98–1/1

Specifications


Fuel Tank Mounting Cap Screws Torque 320 ± 64 N•M (235 ± 47 lb-ft)

05601


PN=457

External Fuel Supply Systems

050560

2

TX,9025,BS501 –19–12JUL95–1/2

Remove and Install Fuel Tank

T85

04A

C–U

N–2

8JU

N95

750C Shown

1—Fuel Cap (Includes Relief 5—Fuel Sender 10—Cap Screw 15—Grab BarValve and Breather) 6—Nut (2 used) 11—Washer (3 used) 16—Washer (2 used)

2—Washer (5 used) 7—Cap Screw (2 used) 12—Shims (as required) 17—Cap Screw (2 used)3—Cap Screw (2 used) 8—Washer (3 used) 13—Spacer (750C Only) 18—Fuel Tank4—Gasket 9—Drain Valve 14—Plate

NOTE: Approximate capacity of fuel tank is 280 L (74gal) for 750C and 348 L (92 gal) for 850C.

1. Drain fuel from tank.

2. Remove left hand service door.

3. Tilt ROPS or Cab. (See procedure in Operation andTest Manual, Group 9026-25.)

4. Remove lower tank cover and hydrostatic motorrear access cover.

5. Disconnect fuel supply and return lines from fueltank. (See procedure in this group.)

6. Disconnect wiring from fuel gauge sending unit.

7. Remove backup alarm from tank and set aside.

CAUTION: The approximate weight of thefuel tank is 170 kg (375 lb).

8. Attach a sling around center of fuel tank. Attachsling to hoist.

9. Remove cap screws (3), (7), (10) and slowlyremove fuel tank.


PN=458



TX,9025,BS501 –19–12JUL95–2/2

10. Install tank. Shim tank so that bottom of fuel andhydraulic tank are in alignment. Tighten capscrews (3), (7), (10) to specification.

SpecificationFuel Tank Mounting CapScrews—Torque 320 ± 64 N•M (235 ± 47 lb-ft)...................................

11. Connect electrical wiring to fuel gauge and installbackup alarm.

12. Connect fuel lines. (See procedure in this group.)

13. Install lower tank cover and hydrostatic motoraccess cover.

14. Lower cab.

15. Add fuel (see fuel specification in Group 0004).

0505603


PN=459


050560

4

TX,9025,BS502 –19–12JUL95–1/1

Remove and Install Fuel Lines—750C

T85

04A

B–1

9–03

JUN

97

1—Elbow 7—Fuel Line 12—Nut 17—Tie Band (as required)2—O-Ring 8—Cap Screw 13—Nut (2 used) 18—Hose3—Hose 9—Washer (2 used) 14—Clamp (4 used) 19—Shut-Off Valve4—Clamp 10—Bracket 15—Cap Screw (2 used) 20—O-Ring5—Adapter 11—Clamp 16—Tie Band (as required) 21—Roll Pin6—O-Ring (3 used)

1. Remove and install fuel lines as shown inillustration.

2. Install roll pin (21) approximately 1/8 in. into end ofshut-off valve (19) installed into fuel tank.

3. Apply pipe sealant to threads of shut-off valve priorto installing in tank.


PN=460


0505605

TX,9025,BS503 –19–12JUL95–1/1

Remove and Install Fuel Lines—850C

T85

04A

A–1

9–03

JUN

97

1—Elbow 5—O-Ring (3 used) 9—Clamp 12—Shut-Off Valve2—O-Ring 6—Adapter 10—Tie Band (as required) 13—O-Ring3—Hose 7—O-Ring 11—Drain Valve 14—Roll Pin4—Clamp 8—Hose

1. Remove and install fuel lines as shown inillustration.

2. Install roll pin (14) approximately 1/8 in. into end ofshut-off valve (12) installed into fuel tank.

3. Apply pipe sealant to threads of shut-off valve priorto installing in tank.


PN=461


050560

6


PN=462


0505991

DFT1140,YY1381 –19–29AUG96–1/1

DFT1140 Serpentine Belt Removal and Installation Tool (850C)

T10

1563

–19–

13JU

N96

1—1 in. 3—12-3/8 in. 5—1/2 in. x 1/2 in. x 5/8 in. 6—Weld2—11/16 in. hole 4—1/4 in. Square Stock (2 used) 7—5/8 in.

This tool is used to remove and install serpentine fanbelt.

Material required:

• 1/2 in. x 1/2 in. square stock 5/8 in. long

1. Drill 11/16 in. hole in each end of flat stock.

2. Install square stock through holes and even on oneside. Weld square stock to flat stock at location (6).Grind smooth.


PN=463


050599

2


PN=464

Section 07Dampener Drive

Contents

Page

Group 0752—ElementsOther Material . . . . . . . . . . . . . . . . . . . . . . . .07-0752-1Specifications . . . . . . . . . . . . . . . . . . . . . . . .07-0752-1Remove and Install Dampener Drive. . . . . . .07-0752-2

07


PN=1

Contents

07


PN=2

Group 0752Elements

CED,OUO1020,3062 –19–29OCT98–1/1

Other Material

Number Name Use

TY9370 (U.S.) Thread Lock and Sealer (Medium Apply to threads of dampener capTY9477 (Canadian) Strength) LOCTITE screws.242 (LOCTITE)


0707521

CED,OUO1020,3063 –19–29OCT98–1/1

Specifications


750C Outer Face of Hub to Flywheel Distance 63 mm (2.48 in.)Cover

850C Outer Face of Hub to Flywheel Distance 60 mm (2.36 in.)Cover

750C Dampener Drive Hub Set Torque 47—54 N•m (35—40 lb-ft)Screws

850C Dampener Drive Hub Set Torque 115—122 N•m (85—90 lb-ft)Screws

750C Dampener Cap Screws Torque 81 N•m (60 lb-ft)

850C Dampener Cap Screws Torque 130 N•m (95 lb-ft)


PN=467

Elements

070752

2

TX,0752,SS2306 –19–11MAR96–1/1

Remove and Install Dampener Drive

T85

45A

B–U

N–1

2SE

P95

A—Cap Screw (8 used)B—Washer (8 used)C—Dampener (Element)D—HubE—Set Screw (2 used)F—Dimension: 750C—63 mm (2.48 in.); 850C—60

mm (2.36 in.)

1. Remove hydrostatic pumps. (See Remove and InstallHydrostatic Pumps in Group 0300).

2. Remove set screws (E) from hub (D).

3. Remove hub (D).

4. Install new hub with tangs away from pump. Outer faceof hub must be positioned at specified distance (F)from fly wheel cover.

Specification750C Outer Face of Hub toFlywheel Cover—Distance 63 mm (2.48 in.)..............................................850C Outer Face of Hub toFlywheel Cover—Distance 60 mm (2.36 in.)..............................................

5. Apply thread lock and sealer (medium strength) tothreads of set screws (E). Install and tighten setscrews .

Specification750C Dampener Drive Hub SetScrews—Torque 47—54 N•m (35—40 lb-ft)...............................................850C Dampener Drive Hub SetScrews—Torque 115—122 N•m (85—90 lb-ft)...........................................

6. Remove cap screws (A) and dampener (C) fromflywheel.

7. Install new dampener with the largest offset side ofdampener away from flywheel. Apply thread lock andsealer (medium strength) to threads of cap screws (A).Install cap screws and washers (B). Tighten capscrews.

Specification750C Dampener Cap Screws—Torque 81 N•m (60 lb-ft).............................................................................850C Dampener Cap Screws—Torque 130 N•m (95 lb-ft)...........................................................................


PN=468

Section 11Park Brake

Contents

Page

Group 1100—Park BrakeSpecifications . . . . . . . . . . . . . . . . . . . . . . . .11-1100-1Park Brake Cross Section . . . . . . . . . . . . . . .11-1100-3Remove and Install Park Brakes . . . . . . . . . .11-1100-4

Group 1115—Control LinkageService Equipment and Tools . . . . . . . . . . . .11-1115-1Specifications . . . . . . . . . . . . . . . . . . . . . . . .11-1115-1Remove and Install Park Brake Pedal . . . . . .11-1115-2Remove and Install Park Brake Valve

Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1115-3Remove and Install Park Lock Lever and

Brake Cable and Linkage . . . . . . . . . . . . .11-1115-4Park Lock Linkage Adjustment . . . . . . . . . . .11-1115-6

Group 1160—Hydraulic SystemRemove and Install Park Brake Valve . . . . . .11-1160-1Disassemble and Assemble Park Brake

Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1160-2

11


PN=1

Contents

11


PN=2

Group 1100Park Brake

CED,OUO1020,3183 –19–03DEC98–1/1

Specifications


Dowel Pins (E), Amount Remaining Height 14 mm (0.55 in.)Outside of Brake Housing

Dowel Pins (M), Amount Remaining Height 10 mm (0.40 in.)Outside of Brake Housing

Hydrostatic Motor Mount Cap Screws Torque 100 N•m (75 lb-ft)

1111001


PN=471

Park Brake

111100

2


PN=472

Park Brake

1111003

CED,OUO1020,3065 –19–03NOV98–1/1

Park Brake Cross Section

T83

59A

M–U

N–1

2JU

L95

Park Brake (750C Shown)

A—Cap Screw (8 used) F—Disk 750C (4 used), 850C (6 J—Brake Piston N—O-RingB—Motor Mount used) K—Brake Hub O—O-RingC—Cap Screw (4 used) G—Brake Plate L—Snap Ring P—Spring (16 used)D—Gasket (2 used) H—Dowel Pins (4 used) M—Snap Ring Q—O-Ring (2 used)E—Separator Plates 750C (3 I—Brake Housing

used), 850C (5 used)


PN=473

Park Brake

111100

4

TX,0250,SS2325 –19–22JAN04–1/3

Remove and Install Park Brakes

T83

59A

K–U

N–0

1JU

L97

Park Brake, Exploded View (750C Shown)


PN=474


Park Brake

1111005

TX,0250,SS2325 –19–22JAN04–2/3

A—O-Ring G—Brake Housing L—Brake Hub Q—Lock Washer (4 used)B—Brake Piston H—O-Ring (2 used) M—Dowel Pin (2 used) (earlier R—Cap Screw (4 used)C—O-Ring I—Gasket units) S—Snap RingD—Spring (16 used) J—Snap Ring N—Motor Mount T—Disk 750C (4 used), 850C (6E—Dowel Pin (2 used) K—Separator Plates 750C (3 O—Lock Washer (8 used) used)F—Brake Plate used), 850C (5 used) P—Cap Screw (8 used) U—Gasket

1. Remove hydrostatic motor. (See Remove andInstall Hydrostatic Motor in Group 0300.)

2. Disassemble parts.

a. On brake plate (F) install two 3/8 in. x 1-3/4 in.cap screws. Tighten cap screws to compresssprings and remove snap ring (J).

b. Loosen cap screws evenly and remove brakeplate (F) and springs (D).

c. Install a puller and remove brake housing (G)with piston (B).

3. Install two dowel pins in final drive housing to aid inassembly.

4. Lubricate all O-rings and gasket (I).

5. Press dowel pins (E) into brake housing untilspecified amount of pins remain outside of brakehousing (G).

SpecificationDowel Pins (E), AmountRemaining Outside of BrakeHousing—Height 14 mm (0.55 in.).......................................................

NOTE: Earlier units use dowel pins (M) to align brakehousing (G) and motor mount (N). On laterunits motor mount (N) has a raised shoulderfor alignment with brake housing (G).

6. Press dowel pins (M) into brake housing (G) untilspecified amount of pins remain for motor mount toengage.

SpecificationDowel Pins (M), AmountRemaining Outside of BrakeHousing—Height 10 mm (0.40 in.).......................................................

7. Install brake housing on dowel pins, using two 1/2in. cap screws. Pull brake housing into final driveevenly until it bottoms. Remove cap screws.

8. Install springs and brake plate. Compress springsusing two 3/8 x 1-3/4 in. cap screws. Tighten untilsnap ring can be installed. Remove cap screws.

9. Disconnect cab tilt hose from quick disconnect onhand pump. Connect brake hose.

10. Connect brake line.

11. Put park lock lever in the down position.

12. Stroke hand pump and pressurize brake circuituntil dowels in the brake housing protrude slightlythrough holes in brake plate.

13. Install brake hub (L).

14. Starting with a disk, alternately install disks (T)and separator plates (K).

15. Install new gasket (U) on motor mount (N). Installmotor mount. Tighten cap screws (P) and (R) tospecifications.

SpecificationHydrostatic Motor Mount CapScrews—Torque 100 N•m (75 lb-ft).....................................................

16. Release brake.

17. Disconnect brake line.

18. Install hydrostatic motor. (See Remove and InstallHydrostatic Motor in Group 0300).

19. Recheck final drive oil level.


PN=475


Park Brake

TX,0250,SS2325 –19–22JAN04–3/3


20. Calibrate transmission controller. (See Operationand Test Manual, Group 9015-20.)

111100

6


PN=476

Group 1115Control Linkage

CED,OUO1020,3216 –19–03DEC98–1/2




CED,OUO1020,3216 –19–03DEC98–2/2

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Used to adjust park brake switch.

CED,OUO1020,3218 –19–03DEC98–1/1

Specifications


Park Brake Pedal Cap Screws Torque 80 N•m (59 lb-ft)

1111151


PN=477

Control Linkage

111115

2

TX,1115,SS2353 –19–29AUG96–1/1

Remove and Install Park Brake Pedal

T83

85A

A–U

N–1

1JU

L95

1—Spring Pin 6—Spring Pin 10—Pin 14—Pin2—Bearing (4 used) 7—Lever Pivot Shaft 11—Spring Pin (2 used) 15—Washer (4 used)3—Spring Pin 8—Lever 12—Spring 16—Cap Screw (4 used)4—Brake Pedal Support 9—Link 13—Pedal 17—Shaft5—Spring Pin (3 used)


2. Stop engine. Operate all hydraulic controls torelease pressure in hydraulic system.


4. Remove cab front access panel.

5. Disconnect park brake cable and rod from lever (8).

6. Remove park brake pedal assembly.


8. Install parts.

9. Install park brake pedal assembly

10. Install cap screws (16) and tighten to specification.

SpecificationPark Brake Pedal CapScrews—Torque 80 N•m (59 lb-ft).......................................................


PN=478

Control Linkage

1111153

TX,1115,QQ3171 –19–29AUG96–1/1

Remove and Install Park Brake Valve Linkage

T83

88A

A–U

N–1

1JU

L95

1—Cap Screw 8—Washer (2 used) 15—Washer 21—Link2—O-Ring (2 used) 9—Lock Nut (2 used) 16—Needle Bearing 22—Cap Screw (2 used)3—Elbow Fitting (2 used) 10—O-Ring 17—Shim 23—Cap Screw4—Cap Screw 11—Fitting 18—Park Lock Lever Switch 24—Washer5—O-Ring 12—Washer (3 used) (S4) 25—Bushing6—Adapter 13—Control Cable 19—Cotter Pin 26—Lever7—O-Ring 14—Cap Screw 20—Bracket


2. Stop engine. Operate all hydraulic controls torelease pressure in hydraulic system.


4. Remove parts as shown.

5. Install parts as shown.

6. Adjust park lock linkage. (See procedure in thisgroup.)


PN=479

Control Linkage

111115

4

TX,1115,QQ3172 –19–23APR96–1/2

Remove and Install Park Lock Lever and Brake Cable and Linkage

T83

86A

B–U

N–1

1JU

L95


PN=480


Control Linkage

TX,1115,QQ3172 –19–23APR96–2/2

1—Knob (2 used) 10—Lever End (2 used) 19—Washer (4 used) 28—Bellcrank2—Control Lever (2 used) 11—Pin (4 used) 20—Spring Guide Pin (2 used) 29—Washer3—Cap Screw (4 used) 12—Pin (2 used) 21—Spring (2 used) 30—Brake Link4—Retainer (4 used) 13—Washer (2 used) 22—Nut (3 used) 31—Cap Screw5—Ball Bearing (2 used) 14—Bushing 23—Washer (6 used) 32—Ball Joint6—Bearing Collar (2 used) 15—Cap Screw (2 used) 24—Headed Pin (2 used) 33—Nut7—Bearing Collar Assembly 16—Boss (2 used) 25—Cap Screw 34—Control Cable8—Nut (2 used) 17—Stop Plate 26—Bellcrank 35—Cap Screw9—Shaft 18—Cotter Pin 27—Rivet 36—Cotter Pin

1. Remove display monitor. (See procedure in Group1675.)

2. Disconnect wiring from key switch, light switch,alarm, and ether start aid switch.

3. Disconnect hose to transmission pressure gauge.

4. Remove dash.

5. Disconnect parts (1—36).

6. Install parts.

7. Install dash.

8. Connect hose and wiring.

9. Install display monitor.

10. Adjust park lock linkage. (See procedure in thisgroup.)

1111155


PN=481

Control Linkage

111115

6

TX,9026,YY1024 –19–05FEB96–1/2

Park Lock Linkage Adjustment

T84

34A

K–U

N–0

7MA

R95

T84

34A

B–U

N–0

7MA

R95

1—Bracket2—Bellcrank Link3—Jam Nuts4—Cap Screw5—Park Lock Lever Switch (S4)6—Control Cable7—Ball Joint

This procedure is used to adjust the linkage from the parklock lever in the operator’s station to the park brake valve.

1. Turn battery disconnect switch OFF and removebatteries from machine.

2. Remove retaining cap screws from bracket (1).Position bracket to allow access to park brake valvelinkage.

3. Disconnect bellcrank link (2) from bellcrank.


5. Remove cover in front of cab or ROPS to gain accessto the park lock linkage.

6. Loosen jam nuts (3) on vertical rod.

7. Position park lock lever in UP position.

8. Hold park brake pedal fully DOWN. Adjust vertical rodagainst upper stop.

9. Tighten jam nuts (3).



PN=482

Control Linkage

TX,9026,YY1024 –19–05FEB96–2/2

T84

34A

C–U

N–0

7MA

R95

10. Install front cover.

11. Lower cab or ROPS. (See procedure in Operationand Test Manual, Group 9026-25.)

12. Put park lock lever down.

13. Measure total travel of the park brake pedal.

14. Disconnect park brake position switch (S4) (5)connector. Connect a multimeter to the switch leads.

15. Slowly depress park brake pedal and check forcontinuity. As pedal reaches 1/2 of its total travel,switch must show continuity.

16. If the switch does not meet specification, adjust cable(6) to obtain correct switch operation.

17. Put park lock lever UP. Push bellcrank link (2) towardcenter of machine and bottom brake valve spool inbore. Hold rod and adjust ball joint (7) to meetbellcrank.

18. Install cap screw.

19. Install bracket and batteries.

1111157


PN=483

Control Linkage

111115

8


PN=484

Group 1160Hydraulic System

1111601

TX,1115,QQ3167 –19–23APR96–1/1

Remove and Install Park Brake Valve

X98

11–U

N–2

3AU

G88

T85

16A

F–U

N–1

1JU

L95

A—Cap ScrewB—Cap ScrewC—Brake ValveD—Charge Pressure Line from Charge Pressure

ManifoldE—Charge Pressure Line to Multi-Function ValvesF—Return Line to ReservoirG—Return Line to Hand PumpH—Charge Pressure Line to Brakes


1. Loosen reservoir cap.

2. Disconnect lines (D—H).

3. Remove cap screws (A and B).

4. Repair or replace valve as needed. (See disassemblyand assembly procedure in this group.)


PN=485

Hydraulic System

111160

2

TX,1115,QQ3168 –19–23APR96–1/1

Disassemble and Assemble Park Brake Valve

T85

01A

E–U

N–3

0JU

N95

1—To Multi-Function Valves 4—Brake Valve Spool 6—To Park Brakes 8—Orifice2—Charge Pressure Inlet 5—Tow Disconnect Relief 7—Shuttle Valve 9—From Hand Pump3—Safety Valve Valve

1. Remove end caps from shuttle valve, brake valve,safety valve and relief valve spools.

2. Remove and inspect for wear or damage onO-rings, seals and springs. Replace if necessary.

3. Install the same number of shims as removed frombottom of brake valve spool (4).


PN=486

Section 15Equipment Attaching

Contents

Page

Group 1511—DrawbarSpecifications . . . . . . . . . . . . . . . . . . . . . . . .15-1511-1Remove and Install Extended Rigid

Drawbar. . . . . . . . . . . . . . . . . . . . . . . . . . .15-1511-2Remove and Install Rigid Drawbar . . . . . . . .15-1511-4

15


PN=1

Contents

15


PN=2

Group 1511Drawbar

CED,OUO1020,3188 –19–03DEC98–1/1

Specifications


750C Extended Rigid Torque 1200 N•m (880 lb-ft)Drawbar-to-Main Frame Cap Screws(Four Outer and Two Top Inner)

750C Extended Rigid Torque 615 N•m (450 lb-ft)Drawbar-to-Main Frame Cap Screws(Two Bottom Inner)

850C Extended Rigid Torque 1200 N•m (880 lb-ft)Drawbar-to-Main Frame Cap Screws(Four Outer)

850C Extended Rigid Torque 615 N•m (450 lb-ft)Drawbar-to-Main Frame Cap Screws(Four Inner)

Rigid Drawbar-to-Main Frame Cap Torque 615 N•m (450 lb-ft)Screws

1515111


PN=489

Drawbar

151511

2

TX,1511,RR5385 –19–23APR96–1/2

Remove and Install Extended Rigid Drawbar

T84

77A

I–1

9–31

MA

Y95

Extended Rigid Drawbar

1—Retainer 3—Nut 5—Cap Screw (8 used) 7—Drawbar2—Cap Screw 4—Washer (4 used) 6—Quick Lock Pin

CAUTION: Drawbar is heavy. Preventpossible injury from falling parts. Use a hoistto remove drawbar.

750C Machine:

1. Tighten drawbar-to-main frame four outer and twoinner cap screws (5) to specification.

Specification750C Extended RigidDrawbar-to-Main Frame CapScrews (Four Outer and TwoTop Inner)—Torque 1200 N•m (880 lb-ft)............................................

2. Tighten drawbar-to-main frame two bottom innercap screws (5) to specifications.


PN=490


Drawbar

TX,1511,RR5385 –19–23APR96–2/2

Specification750C Extended RigidDrawbar-to-Main Frame CapScrews (Two Bottom Inner)—Torque 615 N•m (450 lb-ft)...................................................................

850C Machine:

1. Tighten drawbar-to-main frame four outer capscrews (5) to specification.

Specification850C Extended RigidDrawbar-to-Main Frame CapScrews (Four Outer)—Torque 1200 N•m (880 lb-ft)............................

2. Tighten drawbar-to-main frame four inner capscrews (5) to specification.

Specification850C Extended RigidDrawbar-to-Main Frame CapScrews (Four Inner)—Torque 615 N•m (450 lb-ft)...............................

1515113


PN=491

Drawbar

151511

4

TX,1551,RR5386 –19–23APR96–1/1

Remove and Install Rigid Drawbar

T10

9579

–UN

–05J

UN

97

Rigid Drawbar

1—Retainer 4—Washer (2 used) 6—Quick Lock Pin 7—Drawbar2—Cap Screw 5—Cap Screw, 750C (4 used),3—Nut 850C w/weights (4 used),

850C LGP (2 used)

CAUTION: Drawbar is heavy. Preventpossible injury from falling parts. Use a hoistto remove drawbar.

Tighten drawbar-to-main frame cap screws (5) tospecification.

SpecificationRigid Drawbar-to-Main FrameCap Screws—Torque 615 N•m (450 lb-ft)...........................................


PN=492

Section 16Electrical System

Contents

Page Page

Group 1671—Batteries, Support, and Cables Engine/Pump Harness ComponentService Equipment and Tools . . . . . . . . . . . .16-1671-1 Identification—850C (S.N. 822868—) . . .16-1674-28Specifications . . . . . . . . . . . . . . . . . . . . . . . .16-1671-1 Grille Housing Harness ComponentService Batteries Carefully . . . . . . . . . . . . . .16-1671-2 Identification—750C (S.N. —831315)Procedure for Testing Batteries . . . . . . . . . . .16-1671-4 and 850C (S.N. —822867) . . . . . . . . . . .16-1674-30Checking Electrolyte Specific Gravity . . . . . .16-1671-5 Grille Housing Harness ComponentCheck Battery Electrolyte Level and Identification—750C (S.N. 831316— )

Terminals. . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-7 and 850C (S.N. 822868— ) . . . . . . . . . . .16-1674-32Using Booster Batteries—24 Volt System . . .16-1671-9 Motor Harness Electrical Component

Identification . . . . . . . . . . . . . . . . . . . . . .16-1674-34Charge Battery . . . . . . . . . . . . . . . . . . . . . .16-1671-10Wiper Harness Electrical ComponentRemove and Install Batteries. . . . . . . . . . . .16-1671-11

Identification . . . . . . . . . . . . . . . . . . . . . .16-1674-36A/C Compressor Harness ComponentGroup 1672—Alternator, Regulator and Charging

Identification—750C (S.N. —831315)System Wiringand 850C (S.N. —822867) . . . . . . . . . . .16-1674-38Alternators and Starting Motors—Use

A/C Condenser Harness ElectricalCTM77. . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1672-1Component Identification . . . . . . . . . . . . .16-1674-40Essential Tools . . . . . . . . . . . . . . . . . . . . . . .16-1672-1

Replace DEUTSCH Connectors . . . . . . . .16-1674-41Specifications . . . . . . . . . . . . . . . . . . . . . . . .16-1672-1Install DEUTSCH Contact. . . . . . . . . . . . .16-1674-43Remove and Install Alternator . . . . . . . . . . . .16-1672-2Replace WEATHER PACK

Connectors . . . . . . . . . . . . . . . . . . . . . . .16-1674-44Group 1673—Lighting System Install WEATHER PACK Contact . . . . . . .16-1674-45Remove and Install Light Switch . . . . . . . . . .16-1673-1 Replace METRI-PACK Connector . . . . . .16-1674-47Remove and Install Halogen Bulb . . . . . . . . .16-1673-1 Remove Connector Body from BladeRemove and Install Dome Light and Terminals. . . . . . . . . . . . . . . . . . . . . . . . .16-1674-48

Swivel Light . . . . . . . . . . . . . . . . . . . . . . . .16-1673-2

Group 1675—System ControlsWelding Procedure . . . . . . . . . . . . . . . . . . . .16-1675-1Group 1674—Wiring Harness and SwitchesRemove and Install TransmissionEssential Tools . . . . . . . . . . . . . . . . . . . . . . .16-1674-1

Controller . . . . . . . . . . . . . . . . . . . . . . . . . .16-1675-2Cab/ROPS Harness ComponentRemove and Install Display Monitor . . . . . . .16-1675-3Identification—(750C S.N. —XXXXXX)Remove and Install Engine Controller—and (850C S.N. —822867) . . . . . . . . . . . .16-1674-4

850C (S.N. 822868— ) . . . . . . . . . . . . . . .16-1675-3Cab/ROPS Harness ComponentIdentification—850C (S.N. 822868—

Group 1677—Motors and ActuatorsXXXXXX). . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-8John Deere Starting Motor—Use CTM77 . . .16-1677-1Cab/ROPS Harness ComponentRemove and Install Starting Motor . . . . . . . .16-1677-1Identification—750C, 850C (S.N. XXXXXX—

). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-14Chassis Harness Component

Identification . . . . . . . . . . . . . . . . . . . . . .16-1674-20 16Engine/Pump Harness Component

Identification—750C (S.N. —831315) . . .16-1674-22Engine/Pump Harness Component

Identification—750C (S.N. 831316— ) . . .16-1674-24Engine/Pump Harness Component

Identification—850C (S.N. —822867) . . .16-1674-26


PN=1

Contents

16


PN=2

Group 1671Batteries, Support, and Cables

CED,OUO1020,3221 –19–03DEC98–1/4




CED,OUO1020,3221 –19–03DEC98–2/4

Battery Post/Clamp Cleaner . . . . . . . . . . . . . . JT05838

Clean battery post and clamp.

CED,OUO1020,3221 –19–03DEC98–3/4

Coolant/Battery Tester . . . . . . . . . . . . . . . . . . JT05460

Check specific gravity of electrolyte in batteries.

CED,OUO1020,3221 –19–03DEC98–4/4

Battery Load Tester . . . . . . . . . . . . . . . . . . . . JT05832

Check battery capacity.

16CED,OUO1020,3223 –19–03DEC98–1/1

Specifications


Battery Fully charged electrolyte specific 1.265—1.280gravity

Battery Cable Cap Screws Torque 9.2 N•m (82 lb-in.)

16711


PN=495

Batteries, Support, and Cables

04T,90,K153 –19–12MAY93–1/2

Service Batteries Carefully

TS

204

–UN

–23A

UG

88T

S20

3–U

N–2

3AU

G88

161671

2



PN=496


1616713

04T,90,K153 –19–12MAY93–2/2

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 clampfirst and 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 15—30

minutes. Get medical attention immediately.


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

not exceed 1.9 L (2 quarts).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=497


TX,901500,RP313 –19–01SEP95–1/1

Procedure for Testing Batteries

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 JT05838battery post/clamp cleaner.

4. Check posts for looseness.

If posts are loose, replace battery.

Hydrometer Test

1. Check specific gravity with a hydrometer orJT05460 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

Check battery capacity with a JT05832 load tester.Follow tester manufacturer’s instructions for properload test procedure.

If one battery fails load test, replace both batteries.

161671

4


PN=498


1616715

TX,1671,J7 –19–21SEP94–1/2

Checking Electrolyte Specific Gravity

TS

204

–UN

–23A

UG

88T

S20

3–U

N–2

3AU

G88

T85

402

–UN

–10N

OV

88







added.4. Avoiding spilling or dripping electrolyte.5. Use proper jump start procedure.






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

not exceed 1.9 L (2 quarts).3. Get medical attention immediately.

Check the specific gravity of electrolyte in each batterycell using a battery and coolant tester such as JT05460Battery/Coolant Tester. Follow directions included with thetester.


PN=499



TX,1671,J7 –19–21SEP94–2/2

A fully charged battery will have a corrected specificgravity reading of 1.260. If the reading is below 1.200,charge the battery.

SpecificationBattery—Fully charged electrolytespecific gravity 1.265—1.280.......................................................................

NOTE: In tropical areas, use 1.225 for the full chargereading. In cold areas, use 1.280 for thefull-charge reading.

161671

6


PN=500


1616717

TX,9015,QQ1696 –19–01SEP95–1/2

Check Battery Electrolyte Level andTerminals

TS

203

–UN

–23A

UG

88







added.4. Avoiding spilling or dripping electrolyte.5. Using proper jump start procedure.






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=501



TX,9015,QQ1696 –19–01SEP95–2/2

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

161671

8

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=502


TX,1671,DU2025 –19–21NOV94–1/2

Using Booster Batteries—24 Volt System

TS

204

–UN

–23A

UG

88T

6713

AH

1–U

N–2

4OC

T91

Two Battery Application

Before boost starting, machine must be properly shutdown and secured to prevent unexpected machinemovement when engine starts.




IMPORTANT: The machine electrical system is a24-volt negative (—) ground. Connecttwo 12-volt batteries together as shownfor 24 volts.

Connect booster batteries (B) to machine batteries (A)making the last connection at machine frame, away frombatteries.

Rock the clamps to make sure they make good contact.

When possible, use equipment with a switch in the cablethat connects booster batteries to machine batteries.

1616719



PN=503


TX,1671,DU2025 –19–21NOV94–2/2

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.

1671,BB16 –19–28FEB90–1/1

Charge Battery

TS

204

–UN

–23A

UG

88

CAUTION: An explosive gas is produced whilebatteries are in use or being charged. Keep allflames/sparks away from battery. Chargebattery in a well-ventilated area.

IMPORTANT: When charging a battery in the unit,disconnect the battery cables.

If unit has more than one battery,disconnect all cables and charge eachbattery separately.

161671

10


PN=504


TX,1671,QQ3121 –19–23APR96–1/1

Remove and Install Batteries

TS

281

–UN

–23A

UG

88T

8429

AW

–UN

–02M

AR

95

1. Turn battery disconnect switch to "OFF".

CAUTION: Prevent possible injury fromexploding battery. Always remove grounded (—)battery clamp first and replace it last.

2. Remove battery cover and disconnect negative (—)battery cables first, then positive (+) cables.

3. Remove nuts and hold-down frames. Lift batteries frommachine.

4. Check cables and clamps for damage and wear. Makecertain the batteries are fully charged.

5. Install batteries making sure they are level.

6. Install hold-down frames. Connect cables; positive thennegative. Tighten cable cap screws to specification.

SpecificationBattery Cable Cap Screws—Torque 9.2 N•m (82 lb-in.)...........................................................................

7. Turn battery disconnect switch to "ON".

16167111


PN=505


161671

12


PN=506

Group 1672Alternator, Regulator and Charging System Wiring

TX,1672,DV2829 –19–30JUN94–1/1

Alternators and Starting Motors—Use CTM77

TS

225

–UN

–17J

AN

89

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


CED,OUO1020,3193 –19–03DEC98–1/2

Essential Tools



CED,OUO1020,3193 –19–03DEC98–2/2

Belt Tension Gauge

Used to measure 750C (S.N. —831315) belt tension.

16CED,OUO1020,3194 –19–03DEC98–1/1

Specifications


Battery Terminal Wire Lead Nut Torque 3.73 ± 0.9 N•m (33 ± 8 lb-in.)

750C Alternator Belt (S.N. —831315) Strand Tension 267 N (60 lb force) Minimum

750C Alternator Belt (S.N. —831315) Deflection 15.9 mm at 111 N (5/8 in. at 25 lbforce)

16721


PN=507

Alternator, Regulator and Charging System Wiring

16TX,1672,QQ3125 –19–02JUN97–1/1

Remove and Install Alternator

T84

99B

E–U

N–1

5JU

N95

850C Shown

T10

9798

–19–

17JU

N97

A—Cap ScrewB—Cap ScrewC—Ground TerminalD—Terminal D+E—Terminal B+F—Terminal W

IMPORTANT: Turn battery disconnect switch to"OFF" to prevent accidental groundingof alternator wiring leads.

1. Turn battery disconnect switch to "OFF" position.

2. Remove hood. Release tension on fan belt and removefan belt from alternator pulley.

3. Disconnect wire leads (C, D, E and F) from alternator.Remove alternator.

4. Install alternator. Install lower cap screw so head is onthe side of bracket toward fan belts.

5. Connect wire leads (C, D, E and F). Tighten batteryterminal wire lead (E) nut to specification.

SpecificationBattery Terminal Wire Lead Nut—Torque 3.73 ± 0.9 N•m (33 ± 8 lb-in.).........................................................

6. Install fan belt on alternator.

7. For 750C (S.N. —831315) only, using a belt tensiongauge adjust belt strand tension to specification.

Specification750C Alternator Belt (S.N. —831315)—Strand Tension 267 N (60 lb force) Minimum............................

Specification750C Alternator Belt (S.N. —831315)—Deflection 15.9 mm at 111 N (5/8 in. at 25

lb force)................................

8. Tighten alternator mounting cap screws (A and B).

9. Install hood.

10. Turn battery disconnect switch to "ON" position.

16722


PN=508

Group 1673Lighting System

TX,1673,QQ3126 –19–23APR96–1/1

Remove and Install Light Switch

T85

01A

B–U

N–1

5JU

N95

A—Light Switch

1. Turn battery disconnect switch to "OFF".

2. Remove light switch (A) from front console.

3. Disconnect wire lead from switch (A) and removeswitch.

4. Connect wire lead to switch (A) and install into frontconsole.

1616731

TX,1673,QQ3127 –19–23APR96–1/1

Remove and Install Halogen Bulb

T85

01A

F–U

N–1

5JU

N95

A—Screw (4 used)B—Lamp CoverC—BulbD—LampE—Lamp Housing

1. Remove screws (A) to remove lamp cover (B), lamp(D), and lamp housing (E).

2. Disconnect wiring lead and release retainer clip toremove bulb (C).

CAUTION: Do not touch the halogen bulb withbare hands. Oil and moisture may causepremature bulb failure. Clean bulb glass iftouched, using an oil-free cloth with alcohol.

3. Install new bulb (C).

4. Install lamp (D) into lamp housing (E).

5. Install lamp cover (B) and screws (A).

6. Tighten screws (A) alternately. Do not overtighten asscrews may strip out plastic.


PN=509

Lighting System

TX,1673,QQ3128 –19–23APR96–1/1

Remove and Install Dome Light and SwivelLight

T85

01A

H–U

N–1

5JU

N95

T74

84A

T–U

N–1

2MA

R91

161673

2

A—Dome Light CoverB—Swivel Light CoverC—BulbD—BulbE—Dome LightF—Screw (2 used)

1. Remove dome light cover (A) and replace bulb (D).

2. Remove swivel light cover (B) and replace bulb (C).

3. When removing dome light (E), remove screws (F) anddisconnect wire leads.

4. Connect wire leads to dome light (E) and install parts(E, A, and B).


PN=510

Group 1674Wiring Harness and Switches

CED,OUO1020,3195 –19–03DEC98–1/8

Essential Tools



CED,OUO1020,3195 –19–03DEC98–2/8

Extractor Tool. . . . . . . . . . . . . . . . . . . . . . . . JDG361

To remove 12 to 14 gauge wire.

CED,OUO1020,3195 –19–03DEC98–3/8


To remove 16 to 18 gauge wire.

CED,OUO1020,3195 –19–03DEC98–4/8


To remove 20 gauge wire.

CED,OUO1020,3195 –19–03DEC98–5/8

Crimper. . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG360

To crimp wire while installing contacts.

16CED,OUO1020,3195 –19–03DEC98–6/8

T6606AC –UN–23AUG88

Extraction Tool . . . . . . . . . . . . . . . . . . . . . . .JDG364

To pull wire from connector body.

16741



PN=511

Wiring Harness and Switches

CED,OUO1020,3195 –19–03DEC98–7/8

T10

0473

–UN

–05M

AR

96

Terminal Applicator . . . . . . . . . . . . . . . . . . . .JDG783

To secure cable seal and contact to wire.

CED,OUO1020,3195 –19–03DEC98–8/8

Terminal Extraction Tool . . . . . . . . . . . . . . . . . JDG777

To remove terminal from socket.

161674

2


PN=512


1616743


PN=513


161674

4

TX,1674,QQ3132 –19–15OCT99–1/4

Cab/ROPS Harness Component Identification—(750C S.N. —XXXXXX) and (850C S.N. —822867)

T85

04A

D–1

9–26

JUN

95


PN=514



TX,1674,QQ3132 –19–15OCT99–2/4

B11—FNR or Trans. Speed E4—Work Lights (Optional) W3—Transmission Controller X6—Cab Harness ConnectorControl Sensor (TO1, (LO2 Brown, GO1 Black) Ground Strap To ROPS To Engine/Pump HarnessTO2 Blue, ZO1 Gray) K1—Start Relay (EO4, EO5, W5—ROPS Ground Strap to Connector

B12—Trans Speed Control EO7 White, BO1 Red) Frame Ground X7—Cab Harness ConnectorSensor (Single Lever R1—Start Circuit Resistor X1—Transmission Controller To Engine/Pump HarnessSteer) (TO3 Blue, TO4 (EO3 White, GO4 Black) Connector ConnectorBlue, ZO2 Gray) S3—Neutral Start Switch (EO9, X2—Transmission Controller X8—Cab Harness Connector

B13—Engine Speed Control EO3 White) Connector To Engine/Pump HarnessSensor (TO7, TO8 Blue, S7—Horn Switch (Single Lever X3—Machine Identity ConnectorZ11 Gray) Steer) (PO5 Red, AOO Connector X16—Cab Harness Connector

B20—Left/Right Steer or FNR Orange) X4—Cab Harness Connector To Motor HarnessSensor (T10, T11 Blue, S19—Horn Switch (Pedal To Chassis Harness ConnectorZO5 Gray) Switch) (PO5 Red, AOO Connector

B22—A/C Low Pressure Orange) X5—Cab Harness ConnectorSwitch (A28, A27 U1—24V to 12V Voltage To Motor HarnessOrange) Converter (P24, P25, P26, Connector

B23—A/C High Pressure P27 Red, GO7 BlK, EO3Switch (A26, A27 WHT)Orange)


1616745


PN=515


161674

6

TX,1674,QQ3132 –19–15OCT99–3/4

T85

04A

E–1

9–26

JUN

95

Cab/ROPS Harness Component Identification—750C and (850C S.N. —822867)


PN=516



TX,1674,QQ3132 –19–15OCT99–4/4

B9—Right Steer Sensor or E5—Transmission Gauge Light S5—Start Aid Switch (PO1 S17—A/C Shut-Off SwitchDecel Sensor (TO5, TO6 (P21 Red, GO1 Black) Red, E1O, E1O White) X17—Cab Harness ConnectorBlue, ZO3 Gray) H2—Audible Alarm (ZO6, ZO7 S6—Light Switch (PO5, P21, to Display Monitor

B10—Left Steer Sensor (Pedal Gray) P21 Red X19—Cab Harness ConnectorSteer) (TO3, TO4 Blue, S1—Key Switch (BO1, BO2, S9—Light Switch Optional To Heater/BlowerZO2 Gray) BO3 Red, EO1 White) (PO5, P21, P22 Red) Harness Connector

NOTE: In parentheses are the wire number and colorof wiring leads connected to the electricalcomponent.

1616747


PN=517


161674

8

TX,1674,BA1890 –19–15OCT99–1/6

Cab/ROPS Harness Component Identification—850C (S.N. 822868—XXXXXX)

T10

1621

–19–

11JU

L96


PN=518



TX,1674,BA1890 –19–15OCT99–2/6

B11—FNR or Trans. Speed R1—Start Circuit Resistor X2—Transmission Controller X16—Cab Harness ConnectorSensor (TO1, TO2 Blue, (EO3 White, GO4 Black) Connector To Motor HarnessZO1 Gray) S3—Neutral Start Switch (EO9, X3—Machine Identity Connector

B12—Trans Speed Control EO3 White) Connector X20—Engine ControllerSensor (Single Lever S4—Park Lock Lever Switch X4—Cab Harness Connector ConnectorSteer) (TO3 Blue, TO4 S7—Horn Switch (Single Lever To Chassis Harness X21—Diagnostic ReaderBlue, ZO2 Gray) Steer) (PO5 Red, AOO Connector Connector

B13—Engine Speed Control Orange) X5—Cab Harness Connector X22—Engine ControllerSensor (TO7, TO8 Blue, S19—Horn Switch (Pedal To Motor Harness ConnectorZ11 Gray) Steer) (PO5 Red, AOO Connector X23—Air Heater Option

B20—Left/Right Steer or FNR Orange) X6—Cab Harness Connector ConnectorSensor (T10, T11 Blue, S21—Engine Speed To Engine/Pump Harness X24—Diagnostic VoltageZO5 Gray) Calibration Switch Connector Connector

B22—A/C Low Pressure U1—24V to 12V Converter X7—Cab Harness Connector W3—Transmission ControllerSwitch (A28, A27 (P24, P25, P26, P27 Red, To Engine/Pump Harness Ground Strap To ROPSOrange) GO7 BlK, EO3 WHT) Connector W5—ROPS Ground Strap to

B23—A/C High Pressure V10—Neutral X8—Cab Harness Connector Frame GroundSwitch (A26, A27 Start/Transmission To Engine/Pump Harness W14—Engine ControllerOrange) Controller Diode Connector Ground Strap to ROPS

E4—Work Lights (Optional) X1—Transmission Controller X15—Cab Harness ConnectorK1—Start Relay Connector to Motor Harness

Connector


1616749


PN=519


161674

10

TX,1674,BA1890 –19–15OCT99–3/6

T10

1622

–19–

21A

UG

96

Cab/ROPS Harness Component Identification—850C (S.N. 822868—)


PN=520



TX,1674,BA1890 –19–15OCT99–4/6

B9—Right Steer Sensor or E5—Transmission Gauge Light S5—Start Aid Switch (PO1 X17—Cab Harness ConnectorDecel Sensor (TO5, TO6 (P21 Red, GO1 Black) Red, E1O, E1O White) to Display MonitorBlue, ZO3 Gray) H1—Display Monitor S6—Light Switch (PO5, P21, X19—Cab Harness Connector

B10—Left Steer Sensor (Pedal H2—Audible Alarm (ZO6, ZO7 P21 Red) To Heater/BlowerSteer) (TO3, TO4 Blue, Gray) S9—Light Switch Optional Harness ConnectorZO2 Gray) S1—Key Switch (BO1, BO2, (PO5, P21, P22 Red)

B34—Throttle Sensor (E14, BO3 Red, EO1 White) S17—A/C Shut-Off SwitchE15 White, Z20 Gray) (A25, A26 Orange)



16167411


PN=521


161674

12

TX,1674,BA1890 –19–15OCT99–5/6

T11

8266

–19–

10N

OV

98



PN=522



TX,1674,BA1890 –19–15OCT99–6/6

A2—Radio (P27, P26 Red, GO7 M2—Front Wiper Motor (AO8, S12—Left/Right Front Washer X10—Cab Harness To A/CBlack, A18, A19, A20, A21 AO9 Orange, PO8 Red, Motor Switch (PO8 Red, Condenser HarnessOrange) GO1 Black) AO6 Orange) Connector

B24—Left Speaker (A20, A21 S10—Left/Right Door Wiper S13—Front Wiper Switch (PO8, X14—Cab Harness ConnectorOrange) Switch (PO9 Red, A11, PO9 Red, AO8 Orange) To Right Wiper Harness

B25—Right Speaker (A18, A19 A12, A14, A15 Orange) X9—Cab Harness Connector ConnectorOrange) S11—Rear Wiper Switch To Left Wiper Harness X18—Rear Wiper Motor

E6—Dome Light (PO6, PO6 (Optional) (PO8 Red, Connector Connector (Optional)Red, GO1 Black) AO5 Orange)


16167413


PN=523


161674

14

CED,TX14826,12104 –19–15OCT99–1/6

Cab/ROPS Harness Component Identification—750C, 850C (S.N. XXXXXX— )

T12

5194

–19–

15O

CT

99


PN=524



CED,TX14826,12104 –19–15OCT99–2/6

B11—FNR Sensor (TO1, TO2 S22—Brake Pedal Switch (EO7 X5—Cab Harness Connector X22—Engine ControllerBlue, ZO1 Gray) White, GO4 Black) To Motor Harness Connector (850C)

B12—Trans Speed Control S4—Park Lock Lever Switch Connector X23—Air Heater OptionSwitch (Single Lever S7—Horn Switch (Single Lever X6—Cab Harness Connector Connector (850C)Steer With Speed In Steer With Speed In Grip) To Engine/Pump Harness X24—Diagnostic VoltageGrip) (TO3 Blue, TO4 (G01 Black, AO2 Orange) Connector Connector (850C)Blue, ZO2 Gray) S21—Engine Speed X7—Cab Harness Connector X35—ServiceEXPERT

B13—Reverse Speed Ratio Calibration Switch To Engine/Pump Harness Connector 850C (S.N.Switch (TO7, TO8 Blue, U1—24V to 12V Converter Connector XXXXXX— )Z11 Gray) (P24, P25, P26, P27 Red, X8—Cab Harness Connector X36—ServiceEXPERT

B20—Left/Right Steer (T10, GO7 BlK, EO3 WHT) To Engine/Pump Harness Connector 750C (S.N.T11 Blue, ZO5 Gray) V10—Neutral Connector XXXXXX— )

B22—A/C Low Pressure Start/Transmission X15—Cab Harness Connector W3—Transmission ControllerSwitch (A28, A27 Controller Diode to Motor Harness Ground Strap To ROPSOrange) X1—Transmission Controller Connector W5—ROPS Ground Strap to

B23—A/C High Pressure Connector X16—Cab Harness Connector Frame GroundSwitch (A26, A27 X2—Transmission Controller To Motor Harness W14—Engine ControllerOrange) Connector Connector Ground Strap to ROPS

E4—Work Lights (Optional) X3—Machine Identity X20—Engine ControllerK1—Start Relay Connector Connector (850C)R1—Start Circuit Resistor X4—Cab Harness Connector

(EO3 White, GO4 Black) To Chassis HarnessConnector


16167415


PN=525


161674

16

CED,TX14826,12104 –19–15OCT99–3/6

T12

5193

–19–

15O

CT

99


PN=526



CED,TX14826,12104 –19–15OCT99–4/6

B9—Right Steer Sensor or E5—Transmission Gauge Light S5—Start Aid Switch (PO1 X17—Cab Harness ConnectorDecel Sensor (TO5, TO6 (P21 Red, GO1 Black) Red, E1O, E1O White) to Display MonitorBlue, ZO3 Gray) H1—Display Monitor S6—Light Switch (PO5, P21, X19—Cab Harness Connector

B10—Left Steer Sensor (Pedal H2—Audible Alarm (ZO6, ZO7 P21 Red) To Heater/BlowerSteer) (TO3, TO4 Blue, Gray) S9—Light Switch Optional Harness ConnectorZO2 Gray) S1—Key Switch (BO1, BO2, (PO5, P21, P22 Red)

B34—Throttle Sensor (E14, BO3 Red, EO1 White) S17—A/C Shut-Off SwitchE15 White, Z20 Gray) (A25, A26 Orange)



16167417


PN=527


161674

18

CED,TX14826,12104 –19–15OCT99–5/6

T11

8266

–19–

10N

OV

98



PN=528



CED,TX14826,12104 –19–15OCT99–6/6

A2—Radio (P27, P26 Red, GO7 M2—Front Wiper Motor (AO8, S12—Left/Right Front Washer X10—Cab Harness To A/CBlack, A18, A19, A20, A21 AO9 Orange, PO8 Red, Motor Switch (PO8 Red, Condenser HarnessOrange) GO1 Black) AO6 Orange) Connector

B24—Left Speaker (A20, A21 S10—Left/Right Door Wiper S13—Front Wiper Switch (PO8, X14—Cab Harness ConnectorOrange) Switch (PO9 Red, A11, PO9 Red, AO8 Orange) To Right Wiper Harness

B25—Right Speaker (A18, A19 A12, A14, A15 Orange) X9—Cab Harness Connector ConnectorOrange) S11—Rear Wiper Switch To Left Wiper Harness X18—Rear Wiper Motor

E6—Dome Light (PO6, PO6 (Optional) (PO8 Red, Connector Connector (Optional)Red, GO1 Black) AO5 Orange)


16167419


PN=529


161674

20

TX,1674,QQ3138 –19–29AUG96–1/2

Chassis Harness Component Identification

T85

04A

G–1

9–26

JUN

95


PN=530



TX,1674,QQ3138 –19–29AUG96–2/2

B1—Hydraulic Oil Filter B6—Fuel Level Sender (RO1 M5—Doors/Front Washer X11—Chassis HarnessRestriction Switch (NO3 Black, YO1 Yellow) Motor (GO1 Black, AO6 Connector To WasherYellow) E3—Left Rear Light (LO1 Orange) Harness Connector

B2—Transmission Oil Filter Brown, GO1 Black) S14—Quick Drop Valve SwitchRestriction Switch (NO4 H3—Backup Alarm (AO1 (PO4 Red, HOO Green)Yellow) Orange, GO1 Black) X4—Cab Harness Connector

B4—Transmission Oil To Chassis HarnessTemperature Switch (XO5 ConnectorYellow)


16167421


PN=531


161674

22

CED,OUO1057,218 –19–08SEP98–1/2

Engine/Pump Harness Component Identification—750C (S.N. —831315)

T11

8284

–19–

12N

OV

98


PN=532



CED,OUO1057,218 –19–08SEP98–2/2

B3—Air Filter Restriction G1—Battery V9—Start Aid Diode (E1O X12—Engine/Pump HarnessSwitch (MO6 Purple, X1O G3—Alternator (BO1 Red, JO1 White, GO5 Black) To A/C CompressorYellow, GO5 Black) Tan, MO1 Purple, GO5 W1—Frame Ground Strap To Harness Connector

B7—Engine Coolant Black) ROPS Left Rear X13—Engine/Pump HarnessTemperature Sender (X1O M1—Starter Motor (GO5 Black, W2—Starter Ground Strap To To Grille HousingYellow, RO2 Black) EO2, EO5 White, BO1 Frame Ground Harness Connector.

B8—Engine Oil Pressure Red) X6—Cab Harness Connector X14—Engine/Pump HarnessSender (NO1 Yellow, RO3 S2—Battery Disconnect Switch To Engine/Pump Harness To Grille HousingBlack) S4—Park Lock Lever Switch Connector Harness Connector.

B14—Hydrostatic Pump Speed (EO7 White, GO4 Black) X7—Cab Harness Connector Y1—Fuel Shut-Off SolenoidSensor (Z10 Gray, T21, V5—Alternator Diode (EO8 To Engine/Pump Harness (EO8, EO2 White, GO5T22 Blue) White, JO1 Tan) Connector Black)

B17—Rear Pump Pressure V6—Starter Solenoid Diode X8—Cab Harness ConnectorControl Pilot (T38, T39, (EO5 White, GO5 Black) To Engine/Pump HarnessT40, T41 Blue) V7—Fuel Shutoff Diode (EO8 Connector

B18—Front Pump Pressure White, GO5 Black)Control Pilot (T42, T43,T44, T45 Blue)


16167423


PN=533


161674

24

TX,16,BD2866 –19–02JUN97–1/2

Engine/Pump Harness Component Identification—750C (S.N. 831316— )

T10

9769

–19–

19JU

N97


PN=534



TX,16,BD2866 –19–02JUN97–2/2

B3—Air Filter Restriction B18—Front Pump Pressure V5—Alternator Diode (EO8 X7—Cab Harness ConnectorSwitch (MO6 Purple, X1O Control Pilot (T42, T43, White, JO1 Tan) To Engine/Pump HarnessYellow, GO5 Black) T44, T45 Blue) V6—Starter Solenoid Diode Connector

B7—Engine Coolant G1—Battery (EO5 White, GO5 Black) X8—Cab Harness ConnectorTemperature Sender (X1O G3—Alternator (BO1 Red, JO1 V7—Fuel Shut-Off Diode (EO8 To Engine/Pump HarnessYellow, RO2 Black) Tan, MO1 Purple, GO5 White, GO5 Black) Connector

B8—Engine Oil Pressure Black) V9—Start Aid Diode (E1O X13—Engine/Pump HarnessSender (NO1 Yellow, RO3 M1—Starter Motor (GO5 Black, White, GO5 Black) To Grille HousingBlack) EO2, EO5 White, BO1 W1—Frame Ground Strap To Harness Connector

B14—Hydrostatic Pump Speed Red) ROPS (Left Rear) Y1—Fuel Shut-Off SolenoidSensor (Z10 Gray, T21, S2—Battery Disconnect Switch W2—Starter Ground Strap To Y4—A\C Compressor ClutchT22 Blue) S4—Park Lock Lever Switch Frame Ground Solenoid

B17—Rear Pump Pressure V3—A/C Compressor Clutch X6—Cab Harness Connector Y5—Quick Drop ValveControl Pilot (T38, T39, Diode To Engine/Pump Harness SolenoidT40, T41 Blue) V4—Quick Drop Valve Diode Connector


16167425


PN=535


161674

26

TX,1674,QQ3142 –19–29AUG96–1/2

Engine/Pump Harness Component Identification—850C (S.N. —822867)

T85

04A

I–1

9–26

JUN

95


PN=536



TX,1674,QQ3142 –19–29AUG96–2/2

B3—Air Filter Restriction B18—Front Pump Pressure V6—Starter Solenoid Diode X8—Cab Harness ConnectorSwitch (MO6 Purple, X1O Control Pilot (T42, T43, (EO5 White, GO5 Black) To Engine/Pump HarnessYellow, GO5 Black) T44, T45, Blue) V8—Fuel Shut-Off Diode (EO8 Connector

B7—Engine Coolant G1—Battery White, GO5 Black) X12—Engine/Pump HarnessTemperature Sender (X1O G3—Alternator (BO1 Red, JO1 V9—Start Aid Diode (E1O To A/C CompressorYellow, RO2 Black) Tan, MO1 Purple, GO5 White, GO5 Black) Harness Connector

B8—Engine Oil Pressure Black) W1—Frame Ground Strap To X13—Engine/Pump HarnessSender (NO1 Yellow, RO3 M1—Starter Motor (GO5 Black, ROPS (Left Rear) To Grille HousingBlack) EO2, EO5 White, BO1 W2—Starter Ground Strap To Harness Connector

B14—Hydrostatic Pump Speed Red) Frame Ground X14—Engine/Pump HarnessSensor (Z10 Gray, T21, S2—Battery Disconnect Switch X6—Cab Harness Connector To Grille HousingT22 Blue) S4—Park Lock Lever Switch To Engine/Pump Harness Harness Connector

B17—Rear Pump Pressure (EO7 White, GO4 Black) Connector Y2—Fuel Shut-Off SolenoidControl Pilot (T38, T39, V5—Alternator Diode (EO8 X7—Cab Harness ConnectorT40, T41, Blue) White, JO1 Tan) To Engine/Pump Harness

Connector


16167427


PN=537


161674

28

TX,1674,BA1977 –19–29AUG96–1/2

Engine/Pump Harness Component Identification—850C (S.N. 822868—)

T10

1623

–19–

31JU

L96


PN=538



TX,1674,BA1977 –19–29AUG96–2/2

B3—Air Filter Restriction B30—Primary Speed Sensor V5—Alternator Diode (EO8 X13—Engine/Pump HarnessSwitch (MO6 Purple, X1O (E22 White, Z20 Gray) White, JO1 Tan) To Grille HousingYellow, GO5 Black) B31—Fuel Temperature V6—Starter Solenoid Diode Harness Connector

B7—Engine Coolant Sensor (E18 White, Z20 (EO5 White, GO5 Black) X15—Cab Harness ConnectorTemperature Sender (X1O Gray) V9—Start Aid Diode (E1O To Engine/PumpYellow, RO2 Black) B33—Position Sensor (E16, White, GO5 Black) Harness Connector

B8—Engine Oil Pressure E17 White, Z21 Gray) W1—Frame Ground Strap To Y3—Start Aid Solenoid (E10Sender (NO1 Yellow, RO3 G1—Battery ROPS Left Rear White, G05 Black)Black) G3—Alternator (BO1 Red, JO1 W2—Starter Ground Strap To Y4—A/C Compressor Clutch

B14—Hydrostatic Pump Speed Tan, MO1 Purple, GO5 Frame Ground Solenoid (P18 Red, G05Sensor (Z10 Gray, T21, Black) X6—Cab Harness Connector Black)T22 Blue) M1—Starter Motor (GO5 Black, To Engine/Pump Harness Y5—Quick Drop Valve

B17—Rear Pump Pressure EO2, EO5 White, BO1 Connector Solenoid (H00 Green, G05Control Pilot (T38, T39, Red) X7—Cab Harness Connector Black)T40, T41, Blue) S2—Battery Disconnect Switch To Engine/Pump Harness Y6—Rack Actuator Solenoid

B18—Front Pump Pressure V3—A/C Compressor Clutch Connector (E08, E24 White)Control Pilot (T42, T43, Diode (P18 Red, G05 X8—Cab Harness Connector Y7—Secondary Fuel Shut-OffT44, T45, Blue) Black) To Engine/Pump Harness Solenoid (E23 White)

B29—Auxiliary Speed Sensor V4—Quick Drop Valve Diode Connector(E21 White, Z20 Gray) (H00 Green, G05 Black)


16167429


PN=539


161674

30

TX,1674,QQ3144 –19–02JUN97–1/2

Grille Housing Harness Component Identification—750C (S.N. —831315) and 850C(S.N. —822867)

T85

04A

J–1

9–26

JUN

95


PN=540



TX,1674,QQ3144 –19–02JUN97–2/2

B19—Horn (AOO Orange, GO5 V4—Quick Drop Valve Diode X14—Engine/Pump Harness to Y5—Quick Drop ValveBlack) (HOO Green, GO5 Black) Grille Housing Harness Solenoid HOO Green,

E1—Left Front Light (LO1 X13—Engine/Pump Harness to Connector GO5 Black)Brown, GO5 Black) Grille Housing Harness X15—Connector (Not Used)

E2—Right Front Light (LO1 Connector Y3—Start Aid Solenoid (E1OBrown, GO5 Black) White, GO5 Black)


16167431


PN=541


161674

32

TX,1674,BA1895 –19–02JUN97–1/2

Grille Housing Harness Component Identification—750C (S.N. 831316— ) and 850C (S.N.822868— )

T10

1624

–19–

26JU

N96


PN=542



TX,1674,BA1895 –19–02JUN97–2/2

B19—Horn (AOO Orange, GO5 E1—Left Front Light (LO1 E2—Right Front Light (LO1 X13—Engine/Pump Harness toBlack) Brown, GO5 Black) Brown, GO5 Black) Grille Housing Harness

Connector


16167433


PN=543


161674

34

TX,1674,QQ3146 –19–23APR96–1/2

Motor Harness Electrical Component Identification

T85

04A

K–1

9–26

JUN

95


PN=544



TX,1674,QQ3146 –19–23APR96–2/2

B16—Right Track Motor Speed B27—(L) Motor Pressure X5—Cab Harness Connector X16—Cab Harness ConnectorSensor (T19-T20-T36 Control Pilot (T39-T4O To Motor Harness To Motor HarnessBlue, ZO9 Gray) Blue, Z12-Z13 Gray) Connector Connector

B15—Left Track Motor Speed B28—(R) Motor PressureSensor (T17-T18-T35 Control Pilot (T43-T44Blue, ZO8 Gray) Blue, Z14-Z15 Gray)


16167435


PN=545


161674

36

TX,1674,QQ3148 –19–23APR96–1/2

Wiper Harness Electrical Component Identification

T85

04A

L–1

9–26

JUN

95


PN=546



TX,1674,QQ3148 –19–23APR96–2/2

M6—Left Door Wiper Motor M7—Right Door Wiper Motor X9—Cab Harness Connector(A11-A12 Orange, PO9 (A11-A12 Orange, PO9 To Wiper HarnessRed, GO1 Black) Red, GO1 Black) Connector


16167437


PN=547


161674

38

TX,1674,QQ3150 –19–02JUN97–1/2

A/C Compressor Harness Component Identification—750C (S.N. —831315) and 850C(S.N. —822867)

T85

04A

M–1

9–26

JUN

95


PN=548



TX,1674,QQ3150 –19–02JUN97–2/2

V3—A/C Compressor Clutch X12—Engine/Pump Harness Y4—A/C Compressor ClutchDiode (P18 Red, GO5 To A/C Compressor Solenoid (P18 Red, GO5Black) Harness Connector Black)


16167439


PN=549


161674

40

TX,1674,QQ3152 –19–23APR96–1/2

A/C Condenser Harness Electrical Component Identification

T85

04A

N–1

9–26

JUN

95


PN=550



TX,1674,QQ3152 –19–23APR96–2/2

M3—Condenser Fan Motor M10—Condenser Fan Motor X10—Cab Harness Connector(P17 Red, GO1 Black) (P16 Red, GO1 Black) To A/C Condenser

Harness Connector


TX,1674,QQ1180 –19–17APR93–1/5

Replace DEUTSCH Connectors

TS

0124

–UN

–23A

UG

88

A—Extractor Tool Handle

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).

DEUTSCH is a trademark of Deutsch Co.

16167441

TX,1674,QQ1180 –19–17APR93–2/5

TS

0125

–UN

–23A

UG

88

3. Slide extractor tool rearward along wire until tool tip (A)snaps onto wire.



PN=551


TX,1674,QQ1180 –19–17APR93–3/5

TS

120

–UN

–23A

UG

88

IMPORTANT: Do NOT twist tool when inserting inconnector.

4. Slide extractor tool along wire into connector body untilit is positioned over terminal contact.

TX,1674,QQ1180 –19–17APR93–4/5

TS

0126

–UN

–23A

UG

88

5. Pull wire, with extractor tool, out of connector body.

16TX,1674,QQ1180 –19–17APR93–5/5

TS

122

–UN

–23A

UG

88

IMPORTANT: Install contact in proper location usingcorrect size grommet.

6. Push contact straight into connector body until positivestop is felt.

7. Pull on wire slightly to be certain contact is locked inplace.

8. Transfer remaining wires to correct terminal in newconnector.

167442


PN=552


053,ECONN,W –19–16DEC82–1/4

Install DEUTSCH Contact

TS

117

–UN

–23A

UG

88

A—Wire Size SelectorB—Lock NutC—Adjusting Screw

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.

DEUTSCH is a trademark of Deutsch Co.

053,ECONN,W –19–16DEC82–2/4T

S01

34–U

N–2

3AU

G88

16167443

A—ContactB—CoverC—Lock NutD—Adjusting Screw

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).

053,ECONN,W –19–16DEC82–3/4

TS

118

–UN

–23A

UG

88

IMPORTANT: Contact must remain centered betweenindents while crimping.

6. Insert wire in contact and crimp until handle touchesstop.

7. Release handle and remove contact.


PN=553



053,ECONN,W –19–16DEC82–4/4

TS

0135

–UN

–23A

UG

88

IMPORTANT: If all wire strands are not crimped intocontact, cut off wire at contact andrepeat contact installation procedure.

NOTE: Readjust crimping tool for each crimpingprocedure.

8. Inspect contact to be certain all wires are in crimpedbarrel.

TX,1674,QQ1181 –19–27JUL94–1/4

Replace WEATHER PACK Connectors

TS

0127

–UN

–23A

UG

88

A—Handle

IMPORTANT: Identify wire color locations withconnector terminal letters.

1. Open connector body (A).

WEATHER PACK is a trademark of Packard Electric.

TX,1674,QQ1181 –19–27JUL94–2/4

TS

0128

–UN

–23A

UG

88

2. Insert JDG364 Extraction Tool over terminal contact inconnector body.

161674

44

TX,1674,QQ1181 –19–27JUL94–3/4

TS

0129

–UN

–23A

UG

88

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.


PN=554



TX,1674,QQ1181 –19–27JUL94–4/4

TS

0130

–UN

–23A

UG

88

IMPORTANT: Carefully spread contact lances toassure good seating in connector body.

NOTE: Connector bodies are "keyed" for proper contactmating. Be sure contacts are in proper alignment.

4. Push contact into new connector body until fullyseated.

5. Pull on wire slightly to be certain contact is locked inplace.

6. Transfer remaining wires to correct terminal in newconnector.

7. Close connector body.

053,ECONN,AA –19–16DEC82–1/3

Install WEATHER PACK Contact

TS

0136

–UN

–23A

UG

88

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.

16167445

WEATHER PACK is a trademark of Packard Electric. Continued on next page


PN=555


053,ECONN,AA –19–16DEC82–2/3

TS

1623

–UN

–02N

OV

94

NOTE: Contacts have numbered identification for twosizes of wire:

• #15 for 14 to 16 gauge wire• #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.

4. Secure cable seal to contact as shown, using JDG783Terminal Applicator.

053,ECONN,AA –19–16DEC82–3/3

TS

0139

–UN

–02D

EC

88

A—Sleeve (Female) ContactB—Pin (Male) Contact

IMPORTANT: Proper contact installation for "sleeve"(A) and "pin" (B) is shown.

161674

46


PN=556


TX,16,BD2867 –19–02JUN97–1/1

Replace METRI-PACK Connector

T10

9127

C–U

N–1

5AP

R97

T10

9189

–UN

–16A

PR

97

16167447

A—Metri-Pack ConnectorB—Connector BodyC—JDG777 Terminal Extraction ToolD—Locking TabE—Terminal

1. Disconnect the METRI-PACK connector (A).

2. Insert JDG777 Terminal Extraction Tool (C) intoconnector body close to the plastic socket edge. Pushterminal locking tab (D) inward, releasing tab.

3. Remove JDG777 Terminal Extraction Tool (C) andpush terminal (E) out of socket.

4. Remove terminal. Cut, strip and crimp wire throughconnector.

NOTE: Terminal will seat only one way. If terminal doesnot pull into the connector body socket, check tomake sure terminal is aligned correctly.

5. Check to make sure locking tab on new terminals is inoutward position. Then pull on wire until terminal locksin connector body socket.

METRI-PACK is a trademark of Packard Electric


PN=557


053,ECONN,V1 –19–18JAN83–1/1

Remove Connector Body from BladeTerminals

RW

4218

–UN

–23A

UG

88

A—Locking TangB—Locking Tang Original Position

1. Use a small screwdriver to depress locking tang (A) onterminal. Slide connector body off.

2. Be sure to bend locking tang back to its originalposition (B) before installing connector body.

161674

48


PN=558

Group 1675System Controls

TX,90,RR5081 –19–07FEB96–1/1

Welding Procedure

IMPORTANT: Before welding on this machine: Toavoid electronic component damage,turn the electrical (battery) disconnectswitch off.

Turn (S2) electrical (battery) disconnect switch OFF.

Clamp welding ground clamp as close to point of weldingas possible.

Never attach welding ground clamp to track pad.

1616751


PN=559

System Controls

TX,1675,QQ3130 –19–23APR96–1/1

Remove and Install Transmission Controller

T85

02A

G–U

N–1

5JU

N95

T85

03A

C–U

N–1

5JU

N95

161675

2

A—Welding DecalB—Transmission Controller CoverC—Ground StrapD—Cap Screw (4 used)E—Harness Connector (2 used)F—Transmission Controller

1. Turn battery ground disconnect switch to "OFF"position, or disconnect negative (—) ground batterycable.

2. Remove transmission controller cover (B).

3. Disconnect ground strap (C).

4. Remove four cap screws (D) and lift controller fromhousing.

5. Remove harness connectors (E) from transmissioncontroller (F) and remove controller.

6. Connect harness connectors (E) to controller, andinstall transmission controller (F).

7. Install cap screws (D), and connect ground strap (C).

8. Install cover (B).

9. Turn battery ground disconnect switch to "ON" position,or connect negative (—) ground battery cable.


PN=560

System Controls

TX,1675,QQ3131 –19–23APR96–1/1

Remove and Install Display Monitor

T84

34A

L–U

N–0

6MA

R95

A—Display MonitorB—Harness Connector

1. Remove four cap screws from display monitor (A) andpull display monitor from front console.

2. Disconnect harness connector (B) from display monitor(A) and remove.

3. Connect monitor to harness connector (B), and installdisplay monitor using four cap screws.

1616753

TX,1675,BA1979 –19–29AUG96–1/1

Remove and Install Engine Controller—850C(S.N. 822868— )

T10

1734

–UN

–02A

UG

96

A—Harness ConnectorsB—Ground StrapC—Cap Screw (4 used)D—Engine Controller

1. Turn battery ground disconnect switch to "OFF"position, or disconnect negative (—) ground batterycable.

2. Disconnect ground strap (B).

3. Remove four cap screws (C) and lift engine controller(D) from mounts.

4. Disconnect harness connectors (A) and removecontroller.

5. Connect harness connectors to controller, and installengine controller.

6. Install cap screws and connect ground strap.

7. Turn battery ground disconnect switch to "ON" position,or connect negative (—) ground battery cable.

8. Calibrate engine controller. (See procedures inOperation and Test Manual, Group 9015-20.)


PN=561

System Controls

161675

4


PN=562

Group 1677Motors and Actuators

055,1677,AA1 –19–02AUG94–1/1

John Deere Starting Motor—Use CTM77

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.

1616771

TX,3129,QQ2050 –19–23APR96–1/1

Remove and Install Starting Motor

T85

02A

A–U

N–1

5JU

N95

750C Crawler Dozer

T85

02A

B–U

N–1

5JU

N95

850C Crawler Dozer

1. Turn battery ground disconnect switch to OFF position,or disconnect negative (—) ground battery cable.

2. Disconnect all cables, wires and ground strap fromsolenoid and starting motor.

3. Remove starting motor and make necessary repairs.See Disassemble Delco-Remy Starting Motor orDisassemble John Deere/Nippondenso Starting Motorin CTM77.

4. Install starting motor.

5. Connect all cables, wires and ground strap to solenoidand starting motor.

6. Turn battery ground disconnect switch to ON position.


PN=563

Motors and Actuators

161677

2


PN=564

Section 1717Frames, Chassis, or Supporting Structure

Contents

Page

Group 1740—Frame InstallationSpecifications . . . . . . . . . . . . . . . . . . . . . . . .17-1740-1Welding Repair of Major Structures. . . . . . . .17-1740-1Remove and Install Sub-Frame Fasteners . .17-1740-2

Group 1746—Frame Bottom GuardsOther Material . . . . . . . . . . . . . . . . . . . . . . . .17-1746-1Remove and Install Bottom Guards—

750C . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1746-1Remove and Install Bottom Guards—

850C . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1746-2

Group 1749—Chassis WeightsSpecifications . . . . . . . . . . . . . . . . . . . . . . . .17-1749-1Remove and Install Counterweight—

850C . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1749-1


PN=1

Contents

17


PN=2

Group 1740Frame Installation

1717401

CED,OUO1020,3196 –19–03DEC98–1/1

Specifications


Weld Metal Tensile Strength 482.6 mPa (70,000 psi)Yield Strength 413.7 mPa (60,000 psi)Elongation 22%

Sub-Frame Cap Screws Torque 1071 N•m (790 lb-ft)

TX,1740,RR5420 –19–29AUG96–1/1

Welding Repair of Major Structures

IMPORTANT: Before welding on this machine: Toavoid electronic Component damage,turn the electrical disconnect switchto off.

SpecificationWeld Metal—Tensile Strength 482.6 mPa (70,000 psi).......................Yield Strength 413.7 mPa (60,000 psi)................................................Elongation 22%.....................................................................................

Use one of the following weld processes:

• AWS-E-7018 covered electrode with shielded metalarc welding (SMAW) process

• AWS-ER-70S-3 wire electrode with gas metal arcwelding (GMAW) process

• AWS-E70T-1 or E71T-1 wire electrode with flux corearc welding (FCAW) process.

Preheat area to be repaired to allow better weldpenetration.

To repair weld metal failure, remove failed weld metalusing arc or grinding equipment. Thoroughly cleanarea to be welded. Preheat structural assemblies to aminimum of 38°C (100°F). Preheat ground engagingtools (cutting edges, skid shoes, and teeth shanks) to177°C (350°F).

To repair base metal failure remove enough material toallow weld to penetrate to the bottom of crack. Preheatstructural assemblies to a minimum of 38°C (100°F).Preheat ground engaging tools (cutting edges, skidshoes, and teeth shanks) to 177°C (350°F).


PN=567

Frame Installation

171740

2

TX,1740,RR5429 –19–23APR96–1/1

Remove and Install Sub-Frame Fasteners

T85

13A

C–U

N–2

8JU

N95

1—Cap Screw (8 used) 3—Cap Screw (4 used) 5—Cap Screw (21 used) 6—Washer (21 used)2—Washer (16 used) 4—Nut (4 used)

CAUTION: Prevent possible injury fromfalling sub-frame. The sub-frame is veryheavy. Use a hoist to support the sub-frame.

Tighten all cap screws to specification.

SpecificationSub-Frame Cap Screws—Torque 1071 N•m (790 lb-ft).................................................................


PN=568

Group 1746Frame Bottom Guards

1717461

CED,OUO1020,3198 –19–03DEC98–1/1

Other Material

Number Name Use

TY9370 (U.S.) Thread Lock and Sealer (Medium Apply to threads of rear bottomTY9477 (Canadian) Strength)LOCTITE guard screws (850C only).242 (LOCTITE)


TX,1746,RR5426 –19–29AUG96–1/1

Remove and Install Bottom Guards—750C

T85

10A

D–U

N–2

7JU

N95

1—Rear Bottom Guard 4—Washer (3 used) 7—Washer (2 used) 10—Cap Screw (18 used)2—Front Bottom Guard 5—Cap Screw (3 used) 8—Washer (2 used) 11—Washer (18 used)3—Cover (Front bottom cover) 6—Cap Screw (4 used) 9—Strap

CAUTION: The approximate weight of 750Cbottom guards is 137 kg (303 lb).

Remove and install bottom guard as shown.

Tighten cap screws to specification. (See torquevalues in Group 0003.)


PN=569

Frame Bottom Guards

171746

2

TX,1746,RR5427 –19–23APR96–1/1

Remove and Install Bottom Guards—850C

T85

10A

C–U

N–2

7JU

N95

1—Cap Screw (6 used) 5—Guard, Rear 8—Cap Screw (2 used) 11—Cap Screw (10 used)2—Washer (6 used) 6—Strap 9—Guard, Front 12—Washer (10 used)3—Hinge (3 used) 7—Washer (18 used) 10—Cap Screw (16 used) 13—Cover, Front4—Cover, Rear

CAUTION: Prevent possible injury fromfalling bottom guards. The approximateweight of center bottom guard is 101 kg (223lb).

Apply thread lock and sealer (medium strength) tothreads of cap screws (1 and 11) before installation.

Tighten cap screws to specification. (See torquevalues in Group 0003.)


PN=570

Group 1749Chassis Weights

1717491

CED,OUO1020,3116 –19–06NOV98–1/1

Specifications


Counterweight Cap Screws Torque 215 ± 43 N•m (159 ± 32 lb-ft)

TX,1749,RR5425 –19–23APR96–1/1

Remove and Install Counterweight—850C

T84

99A

Z–U

N–2

7JU

N95

2—Washer (6 used)3—Cap Screw (6 used)4—Washer (7 used)5—Cap Screw (7 used)6—Left Cover7—Center Cover8—Right Cover

CAUTION: Prevent possible injury from fallingcounterweight. The weight of counterweight isvery heavy. Use a hoist or suitable lifting deviceto support weight.

1. Remove six cap screws and washers (2 and 3) toremove counterweight.

2. Install counterweight and tighten cap screws to 215 ±43 N•m (159 ± 32 lb-ft).

SpecificationCounterweight Cap Screws—Torque 215 ± 43 N•m (159 ± 32 lb-ft).........................................................


PN=571

Chassis Weights

171749

2


PN=572

Section 18Operator’s Station

Contents

Page Page 18

Group 1800—Removal and Installation Charge R134a System . . . . . . . . . . . . . . . .18-1830-15Service Equipment and Tools . . . . . . . . . . . .18-1800-1 Check and Adjust Compressor BeltSpecifications . . . . . . . . . . . . . . . . . . . . . . . .18-1800-1 Tension—750C (S.N. —831315) . . . . . . .18-1830-16Remove and Install Cab/ROPS . . . . . . . . . . .18-1800-2 Remove and Install Air Conditioning

Compressor—750C (S.N. —831315) . . . .18-1830-18Group 1810—Operator Enclosure Remove and Install Air ConditioningOther Material . . . . . . . . . . . . . . . . . . . . . . . .18-1810-1 Compressor—750C (S.N. 831316— ) . . .18-1830-20Specifications . . . . . . . . . . . . . . . . . . . . . . . .18-1810-1 Remove and Install Air ConditioningDisassemble and Assemble Cab/ROPS Tilt Compressor—850C . . . . . . . . . . . . . . . . .18-1830-21

Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-2 Disassemble and Inspect Compressor . . . .18-1830-22Remove and Install Cab/ROPS Tilt Assemble Compressor . . . . . . . . . . . . . . . .18-1830-29

Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-3 Inspect Compressor Manifolds . . . . . . . . . .18-1830-31Remove and Install Hand Pump Remove and Install Receiver/Dryer . . . . . . .18-1830-32

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-5 Remove and Install Evaporator . . . . . . . . . .18-1830-34Disassemble and Assemble Hand Pump. . . .18-1810-6 Remove and Install Condenser . . . . . . . . . .18-1830-36Remove and Install Cab/ROPS Mounts and Remove and Install Heater Pressurizer . . . .18-1830-38

Isolators. . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-7Remove and Install Window . . . . . . . . . . . . .18-1810-9Remove and Install Windowpanes . . . . . . .18-1810-10Remove and Install Cab Covers . . . . . . . . .18-1810-12Remove and Install Wiper Motor

Assemblies . . . . . . . . . . . . . . . . . . . . . . .18-1810-13Remove and Install Cab Doors and

Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-14Remove and Install Door Hold Open

Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-15Remove and Install Windshield Washer . . .18-1810-16

Group 1821—Seat and Seat BeltDisassemble and Assemble Seat . . . . . . . . .18-1821-1

Group 1830—Heating and Air ConditioningEssential Tools . . . . . . . . . . . . . . . . . . . . . . .18-1830-1Service Equipment and Tools . . . . . . . . . . . .18-1830-2Other Material . . . . . . . . . . . . . . . . . . . . . . . .18-1830-3Specifications . . . . . . . . . . . . . . . . . . . . . . . .18-1830-4R134a Refrigerant Theory of Operation. . . . .18-1830-6R134a Refrigerant Cautions . . . . . . . . . . . . .18-1830-7R134a Compressor Oil Charge Check . . . . .18-1830-8R134a Compressor Oil Removal . . . . . . . . . .18-1830-9R134a Component Oil Charge . . . . . . . . . .18-1830-10R134a Refrigerant Recovery, Recycling

and Charging Station InstallationProcedure . . . . . . . . . . . . . . . . . . . . . . . .18-1830-11

Recover R134a System . . . . . . . . . . . . . . .18-1830-12Evacuate R134a System. . . . . . . . . . . . . . .18-1830-13


PN=1

Contents

18


PN=2


1818001

CED,OUO1020,3199 –19–03DEC98–1/2




CED,OUO1020,3199 –19–03DEC98–2/2

Lifting Eyebolts . . . . . . . . . . . . . . . . . . . . . . . JT05552

To remove and install cab/ROPS.

CED,OUO1020,3201 –19–03DEC98–1/1

Specifications


ROPS Post Cap Screws Torque 543 N•m (400 lb-ft)

Radiator 750C Capacity 26.5 L (7 gal)

Radiator 850C Capacity 34 L (9 gal)


PN=575


181800

2

CED,OUO1057,219 –19–08SEP98–1/15

Remove and Install Cab/ROPS

T84

99A

L–U

N–1

2JU

N95

A—Battery Disconnect SwitchB—Battery Cover

Remove

1. Turn battery disconnect switch (A) to OFF and removebattery cover (B).

CED,OUO1057,219 –19–08SEP98–2/15

T84

99A

F–U

N–1

2JU

N95

T84

99A

M–U

N–1

7JU

N95

A—Door Latch BracketB—Battery CablesC—Wiring Harness

2. Disconnect battery cables (B) and remove batteriesfrom the machine.

3. Disconnect door latch bracket (A) and lay it down.

4. Disconnect wiring harness (C).



PN=576


1818003

CED,OUO1057,219 –19–08SEP98–3/15T

8499

AH

–UN

–12J

UN

95T

8499

AK

–UN

–17J

UN

95

A—Heater HosesB—Air Conditioner HoseC—Air Conditioner Hose

NOTE: The approximate capacity of the radiator is 26.5 L(7 gal) for a 750C and 34 L (9 gal) for a 850C.

5. Drain radiator if equipped with heater.

6. Disconnect heater hoses (A) if equipped.

7. Disconnect cab/ROPS tilt cylinder at rod end.

8. Recover air conditioner refrigerant, if equipped. (Seeprocedure in Operation and Test Manual, Group9031-20.)

9. Disconnect air conditioner hoses (B and C) if equipped.



PN=577


181800

4

CED,OUO1057,219 –19–08SEP98–4/15

T84

99A

J–U

N–1

7JU

N95

A—Cab Tilt Cylinder Rod End

10. Disconnect cab tilt cylinder at rod end (A).

CED,OUO1057,219 –19–08SEP98–5/15

T84

99A

G–U

N–2

6JU

N95

A—Neutral Park Lock CableB—Transmission Pressure Gauge HoseC—Cap Screws

11. Disconnect neutral park lock cable (A) andtransmission pressure gauge hose (B) at theT-connection.

12. Remove cap screws (C) from all ROPS posts.


PN=578



1818005

CED,OUO1057,219 –19–08SEP98–6/15

T84

99A

O–U

N–1

2JU

N95

A—Control Lever Linkage Lines

13. Disconnect control lever linkage lines (A).

CED,OUO1057,219 –19–08SEP98–7/15

T84

99A

P–U

N–1

2JU

N95

850C ShownT

8439

AR

–UN

–01J

UL9

6

750C Shown

A—Engine Speed Control Linkage

14. Disconnect engine speed control linage (A) at quickdisconnect.


PN=579



181800

6

CED,OUO1057,219 –19–08SEP98–8/15

T83

88A

H–U

N–1

2JU

N95

A—Lifting Eyebolts

CAUTION: Prevent possible injury from fallingheavy object. The approximate weight of ROPSis 703 kg (1550 lb) and cab is 953 kg (2100 lb).Use a hoist with lifting eyebolts to lift cab.

15. Install four JT05552 Lifting Eyebolts (A) in top of cab.Attach chain and slowly remove cab/ROPS.

Install

1. Lower cab/ROPS onto chassis.

CED,OUO1057,219 –19–08SEP98–9/15

T84

99A

P–U

N–1

2JU

N95

850C Shown

T84

39A

R–U

N–0

1JU

L96

750C Shown

A—Engine Speed Control Linkage

2. Connect engine speed control linkage (A) at quickdisconnect.


PN=580



1818007

CED,OUO1057,219 –19–08SEP98–10/15

T84

99A

O–U

N–1

2JU

N95

A—Control Lever Linkage Lines

3. Connect control lever linkage lines (A).

CED,OUO1057,219 –19–08SEP98–11/15

T84

99A

G–U

N–2

6JU

N95

A—Neutral Park Lock CableB—Transmission Pressure Gauge HoseC—Cap Screws

4. Install cap screws (C) in ROPS posts and tighten tospecification.

SpecificationROPS Post Cap Screws—Torque 543 N•m (400 lb-ft)..............................

5. Connect neutral park lock cable (A) and transmissionpressure gauge hose (B) at the T-connection.


PN=581



181800

8

CED,OUO1057,219 –19–08SEP98–12/15

T84

99A

J–U

N–1

7JU

N95

A—Cab Tilt Cylinder Rod End

6. Connect cab tilt cylinder at rod end (A)



PN=582


1818009

CED,OUO1057,219 –19–08SEP98–13/15T

8499

AH

–UN

–12J

UN

95T

8499

AK

–UN

–17J

UN

95

A—Heater HosesB—Air Conditioner HoseC—Air Conditioner Hose

7. Connect air conditioner hoses (B and C) (if equipped).

8. Charge air conditioning system with refrigerant (ifequipped). (See procedure in Operation and TestManual, Group 9031-20.)

9. Connect cab/ROPS tilt cylinder at rod end.

10. Connect heater hoses (A) (if equipped).

11. Fill radiator (if equipped with heater) to specification.

SpecificationRadiator 750C—Capacity 26.5 L (7 gal).....................................................Radiator 850C—Capacity 34 L (9 gal)........................................................



PN=583


181800

10

CED,OUO1057,219 –19–08SEP98–14/15

T84

99A

F–U

N–1

2JU

N95

T84

99A

M–U

N–1

7JU

N95

A—Door Latch BracketB—Battery CablesC—Wiring Harness

12. Connect wiring harnesses (C).

13. Connect door latch bracket (A).

14. Connect battery cables (B).

CED,OUO1057,219 –19–08SEP98–15/15

T84

99A

L–U

N–1

2JU

N95

A—Battery Disconnect SwitchB—Battery Cover

15. Install battery cover (B) and turn battery disconnectswitch (A) to ON.


PN=584

Group 1810Operator Enclosure

1818101

CED,OUO1020,3204 –19–03DEC98–1/1

Other Material

Number Name Use

T43512 (U.S.) Thread Lock and Sealer (Medium Apply to threads of cab/ROPSTY9473 (Canadian) Strength) isolator cap screws.242 (LOCTITE)


CED,OUO1020,3205 –19–03DEC98–1/1

Specifications


Cab/ROPS Tilt Cylinder Plug Torque 28.5—32.5 N•m (21—24 lb-ft)

Cab/ROPS Tilt Cylinder Piston Torque 44.7—51.5 N•m (33—38 lb-ft)

Hand Pump Cap Screws Torque 22—26 N•m (16—19 lb ft)

Reservoir-to-Valve Body Cap Screws Torque 6.6—11.6 N•m (48—84 lb-in.)

Cab/ROPS Support Cap Screws Torque 543 N•m (400 lb-ft)

Cab/ROPS Isolator Cap Screws Torque 543 N•m (400 lb-ft)


PN=585

Operator Enclosure

181810

2

TX,1800,SS2307 –19–23APR96–1/1

Disassemble and Assemble Cab/ROPS Tilt Cylinder

T83

57B

C–U

N–1

7JU

N95

A—Plunger F—Piston K—Rod Assembly O—Lock RingB—Seat (2 used) G—Wear Ring L—Rod Guide P—U-Cup SealC—Spring (2 used) H—Slipper Ring M—O-Ring Q—Retainer RingD—Poppet (2 used) I—O-Ring N—Backup Washer R—Wiper SealE—Plug (2 used) J—O-Ring

Disassemble and assemble cylinder as shown.

Tighten plug (E) and piston (F) to specifications.

SpecificationCab/ROPS Tilt Cylinder Plug—Torque 28.5—32.5 N•m (21—24 lb-ft)..................................................Cab/ROPS Tilt CylinderPiston—Torque 44.7—51.5 N•m (33—38 lb-ft)....................................


PN=586

Operator Enclosure

1818103

TX,1810,RR5424 –19–23APR96–1/3

Remove and Install Cab/ROPS Tilt Cylinder

T85

10A

E–U

N–3

0JU

N95

1—Nut 7—O-Ring 13—Hand Pump 18—O-Ring2—Washer 8—Hose 14—Washer 19—O-Ring3—Washer 9—Cylinder 15—Cap Screw 20—O-Ring4—Cable 10—Hose 16—Internal Half Coupler 21—Elbow Fitting5—O-Ring 11—Hose 17—Quick Connect Coupler 22—Cap Screw6—Adapter 12—Adapter


PN=587


Operator Enclosure

181810

4

TX,1810,RR5424 –19–23APR96–2/3

T85

13A

E–U

N–3

0JU

N95

A—Transmission Filter Base Cap ScrewB—Front Support Strap Cap Screw


IMPORTANT: For satisfactory operation of the cab tiltcylinder it is essential that all air bebled from the system. Therefore, anytime air is introduced into the system,the bleed procedure MUST beperformed.

1. Shut engine off and lower equipment to the ground.Operate all hydraulic functions to relieve pressure.


3. Operate cab/ROPS tilt hand pump in either directionuntil cylinder cap screws (22) are free to turn.

4. Remove four cap screws which attach transmissionfilter base (A) to mounting bracket. Remove upper capscrew (B) attaching front support strap to thetransmission mounting bracket and lay filter out of theway.

5. Disconnect hoses (10 and 11) from cylinder; plug andcap hoses and fittings.

6. Remove nuts (1) from cap screws (22). Removecylinder (9) and cable (4).

NOTE: Take note of the location of all washers (3) forassembly.

7. Replace or repair damaged parts.

8. Bleed cylinders if air entered the system. (Seeprocedure in Operation and Test Manual, Group9026-25.)

9. Install cylinder, cable, cap screws, washers and nuts.Turn nuts onto cap screws until the nuts stop turning(bottom out). Cap screws must be free enough not tobind on safety cable. If cable binds, remove smallwasher on nut side.


PN=588


Operator Enclosure

TX,1810,RR5424 –19–23APR96–3/3

10. Install transmission filter base and front support strap.

1818105

TX,1810,RR5434 –19–29AUG96–1/1

Remove and Install Hand Pump Assembly

T85

13A

G–U

N–0

5JU

L95

A—Cap ScrewsB—Quick Coupler HoseC—Top Hose



1. Shut engine off and lower equipment to the ground.Operate all hydraulic functions to relieve pressure.


3. Disconnect quick coupler hose (B) and top hose (C).Cap and plug hoses and fittings.

4. Remove cap screws (A) and remove pump.

5. Replace or repair damaged parts.

6. Bleed cylinders if air got into the system. (Seeprocedure in Operation and Test Manual, Group9026-25.)

7. Install pump and tighten cap screws to specification.

SpecificationHand Pump Cap Screws—Torque 22—26 N•m (16—19 lb ft)...................

8. Fill reservoir with oil if necessary. (See Fuels andLubricants in Group 0004.)


PN=589

Operator Enclosure

181810

6

TX,1810,RR5435 –19–23APR96–1/1

Disassemble and Assemble Hand Pump

T85

13A

F–U

N–0

5JU

L95

A—Plastic PlugB—Snap RingC—O-RingD—Suction ScreenE—Fill PlugF—Cylinder Insert AssemblyG—Link Assembly


1. Remove four cap screws from pump reservoir anddrain oil from reservoir. Check O-ring (C) for damage.

2. Remove plastic plug (A) from bottom of pump bodywith an O-ring pick.

3. Remove snap ring (B) from cylinder insert assembly(F) and tap assembly out of the valve body.

4. Inspect and replace damaged parts.

5. Apply clean oil to cylinder insert assembly and installinto valve body.

6. Install snap ring and plastic plug.

7. Assemble link assembly to cylinder insert assembly.

8. Remove and clean suction screen (D).

9. Install O-ring (C) into reservoir O-ring groove andinstall reservoir to the valve body. Tighten cap screwsto specification.

SpecificationReservoir-to-Valve Body CapScrews—Torque 6.6—11.6 N•m (48—84 lb-in.).........................................

10. Oil fill plug (E) is vented; check if plug is clean.

11. Fill reservoir with oil . (See Fuels and Lubricants inGroup 0004.)


PN=590

Operator Enclosure

1818107

TX,1810,RR5414 –19–11DEC98–1/2

Remove and Install Cab/ROPS Mounts and Isolators

T84

99A

U–U

N–2

6JU

N95

1—Cap Screw (4 used) 4—Shims Thick (12 used) 7—Shims Thin (8 used) 10—Washer (12 used)2—Cap Screw (4 used) 5—Shims Thin (6 used) 8—Shims Thick (8 used) 11—Cap Screw 12 used)3—Washer (4 used) 6—Isolator (8 used) 9—Support (4 used)

Remove

1. Remove cap screws (2) securing roof to roofsupports (9). Remove washers (3), shims (4, 5, 7and 8), and isolators (6).

2. Remove cap screws (11) securing supports (9) toROPS frame. Remove washers (10) and supports(9).

Install

NOTE: Cap screws (2) should remain loose untilsupports (9) are tightened securely to frame.

3. Install supports (9) with cap screws (11) andwashers (10). Tighten cap screws (11) tospecification.

SpecificationCab/ROPS Support CapScrews—Torque 543 N•m (400 lb-ft)...................................................


PN=591


Operator Enclosure

181810

8

TX,1810,RR5414 –19–11DEC98–2/2

4. Place two thick shims (8) between front ROPSisolator (6) and ROPS. Add as many thick shims (4)as possible to rear side of front isolator beforeadding thin shims. Add thin shims (5 and 7) asneeded.

5. When both front isolators are shimmed, use sameprocedures to shim rear isolators.

6. Apply thread lock and sealer (medium strength) tothreads of cap screws (2) and tighten cap screws tospecification.

SpecificationCab/ROPS Isolator CapScrews—Torque 543 N•m (400 lb-ft)...................................................


PN=592

Operator Enclosure

1818109

TX,1810,RR5410 –19–23APR96–1/1

Remove and Install Window

T84

99A

T–U

N–2

6JU

N95

1—Molding 3—Front Window Pane 4—Right Side Window 5—Rear Window2—Left Side Window

Remove and install windows as shown.


PN=593

Operator Enclosure

181810

10

CED,TX14826,12085 –19–17AUG99–1/2

Remove and Install Windowpanes

NOTE: Use this procedure to replace all doorwindowpanes and rear/front windowpanes.

Use a Urethane Auto Glass Adhesive Sealant to holdwindowpanes in place. Also use the primers, which arerecommended for the adhesive formulation which hasbeen selected. DO NOT use any other type of adhesiveother than a urethane. It is also recommended that anauto glass dealer install the windowpanes.

IMPORTANT: Windowpanes must have an ultravioletbarrier around the edge of the glasssince ultraviolet rays will deteriorate theadhesive. Windowpanes orderedthrough John Deere Parts have theultraviolet barrier. If the windowpane ispurchased through a glass dealer, thedealer must put an ultraviolet barrier onthe glass. DO NOT apply paint to theborder of the glass.

If an auto glass dealer is not installing the windowpanes,use the following procedure:

1. Purchase urethane adhesive and appropriate primersfrom your local auto glass dealer.

2. If window frame is removable, remove frame from cab.

3. Scrape broken glass off existing adhesive. DO NOTremove adhesive from window frame or cab.

4. Trim existing adhesive so it has a smooth surface.

5. Inspect and clean both replacement glass and windowframe. Use water with a mild detergent and allow todry.

6. Apply primers per adhesive manufacturer’srecommendations

7. Apply a 12.5 mm (1/2 in.) bead of adhesive on top ofthe existing adhesive. Bead must be high enough to fillgap between frame and installed window.


PN=594


Operator Enclosure

18181011

CED,TX14826,12085 –19–17AUG99–2/2

8. Put the new windowpane into position. Use light handpressure to force windowpane down around the edgesuntil even with metal frame. DO NOT over pressadhesive.

9. If windowpane is installed directly on cab, use tape tohold it in place while adhesive cures.

10. Allow adhesive to cure for 24 hours before operatingmachine.


PN=595

Operator Enclosure

181810

12

TX,1800,RR5413 –19–23APR96–1/1

Remove and Install Cab Covers

T84

99A

W–U

N–2

6JU

N95

1—Cap Screw (6 used) 3—Plate, Right Side 5—Washer (8 used) 6—Cap Screw2—Cover, Left Side 4—Plate, Front

Remove and install cab covers as shown.


PN=596

Operator Enclosure

18181013

TX,1810,RR5411 –19–23APR96–1/2

Remove and Install Wiper Motor Assemblies

T84

99A

S–U

N–2

8JU

N95

1—Motor 12—Washer 23—Cap Screw 30—Boot2—Bracket 13—Washer 24—Bushing (Used on front 31—Knurled Nut3—Washer 14—Pin window only) 32—Lock Washer4—Cap Screw 15—Shaft 25—Fiber Washer 33—Cap Nut5—Washer 16—Washer 26—Washer 34—Cap Screw6—Arm 17—Nut 27—Nut 35—Washer7—Lock Nut 18—Washer 28—Washer (Used on front 36—Arm8—Channel 19—Cap Screw window only) 37—Cap Screw9—Washer 20—Cap Screw 29—Snap Ring (Used on front 38—Wiper10—Cap Screw 21—Plate window only) 39—Nut11—Clip 22—Washer


PN=597


Operator Enclosure

TX,1810,RR5411 –19–23APR96–2/2

Remove and install as shown.

181810

14

TX,1810,RR5422 –19–23APR96–1/1

Remove and Install Cab Doors and Hinges

T83

91A

F–U

N–2

8JU

N95

1—Pin (4 used) 7—Washer (4 used) 12—Cover 18—Washer (10 used)2—Bushing (16 used) 8—Hinge (4 used) 13—Latch, Right Door 19—Grommet (2 used)3—Hinge (4 used) 9—Door, Right Cab 14—Knob (2 used) 20—Handle (2 used)4—Washer (16 used) 10—Self Locking Screw (4 15—Latch 21—Grommet (2 used)5—Cap Screw (16 used) used) 16—Cap Screw (8 used) 22—Grommet6—Snap Ring (4 used) 11—Grommet (2 used) 17—Cap Screw (4 used) 23—Cap Screw



PN=598

Operator Enclosure

18181015

TX,1810,RR5423 –19–23APR96–1/1

Remove and Install Door Hold Open Latch

T84

99A

R–U

N–2

9JU

N95

1—Nut 5—Washer 8—Grommet 11—Nut2—Washer 6—Bushing 9—Washer 12—Bumper3—Cap Screw 7—Lever Assembly 10—Spring 13—Latch4—Cap Screw



PN=599

Operator Enclosure

181810

16

TX,1810,RR5418 –19–23APR96–1/1

Remove and Install Windshield Washer

T84

99A

Y–U

N–2

6JU

N95

A—HarnessB—TankC—Cap Screws and Washers (4 used)D—LineE—Pump

1. Disconnect harness connector (A) and line (D).

2. Remove cap screws (C) and tank (B).

3. Install tank and connect line and harness connector.


PN=600

Group 1821Seat and Seat Belt

1818211

T52,1821,K120 –19–23AUG93–1/6

Disassemble and Assemble Seat

T83

88A

G–U

N–2

6JU

N95

1—Seat Support 4—Bracket (2 used) 7—Pad (2 used) 9—Washer (4 used)2—Seat Belt 5—Washer (12 used) 8—Plate (2 used) 10—Cap Screw (4 used)3—Armrest (2 used) 6—Cap Screw (12 used)

1. Remove only parts necessary to make repairs.

2. See following illustrations in this group todisassemble and assemble seat.



PN=601

Seat and Seat Belt

181821

2

T52,1821,K120 –19–23AUG93–2/6

T61

39A

U–U

N–1

9OC

T88

Seat Cushions With Tilt Latch

A—Washer (4 used)B—Armrest (2 used)C—BackrestD—Nut (2 used)E—Washer (2 used)F—Spacer (2 used)G—Screw (2 used)H—Washer (2 used)I—Cap Screw (2 used)J—Spring (2 used)K—Seat CushionL—CapM—Tilt LatchN—SpringO—Cap Screw (4 used)



PN=602

Seat and Seat Belt

1818213

T52,1821,K120 –19–23AUG93–3/6

T61

39A

T–U

N–1

9OC

T88

Scissors Suspension Arms With Shafts

A—BarB—Lock NutC—Cross Pivot Bearing (2 used)D—Outer ArmE—ShaftF—EndG—BarH—Bar



PN=603

Seat and Seat Belt

181821

4

T52,1821,K120 –19–23AUG93–4/6

T61

39A

S–U

N–1

9OC

T88

Suspension Housing With Spring and Shock

A—Height Adjustment Cap G—Bolt (4 used) M—Gear and Shaft Assembly S—Gear and ShaftB—Lever H—Upper Housing Plate N—Spring Pad T—Cap Screw (2 used)C—Pin (3 used) I—Springs (2 used) O—Conical Spring U—Outer ArmD—Latch Return Spring J—Bushing (2 used) P—Spring Washer V—Weight Adjusting KnobE—Latch K—Shock Absorber Q—Special Washer (2 used) W—Weight DecalF—Nut (2 used) L—Special Shoulder Bolt R—Isolator



PN=604

Seat and Seat Belt

1818215

T52,1821,K120 –19–23AUG93–5/6

T61

39A

W–U

N–1

9OC

T88

Seat Adjustment Link and Side Bracket

A—Right Side BracketB—BarC—Nut (2 used)D—Left Side BracketE—WasherF—WasherG—Cap Screw (2 used)H—Lock Nut (4 used)I—WasherJ—Link (2 used)K—Nut (4 used)L—Link (2 used)



PN=605

Seat and Seat Belt

181821

6

T52,1821,K120 –19–23AUG93–6/6

T61

39A

X–U

N–1

9OC

T88

Seat Adjuster Assembly

A—Lift-To-Side Cap G—Slide Stop Bolt M—Cable R—Roller (4 used)B—Washer H—Lower Housing N—Strap S—Washer (4 used)C—Latch Link I—Nut (2 used) O—Nut T—PlugD—Decal J—Right Side Latch P—Slide Track U—BootE—Spring Pin K—Tension Spring (2 used) Q—Cap Screw V—Latch RodF—Ride Height Indicator L—Left Side Latch


PN=606

Group 1830Heating and Air Conditioning

1818301

CED,OUO1020,3234 –19–10DEC98–1/9

Essential Tools



CED,OUO1020,3234 –19–10DEC98–2/9

RW

2161

3–U

N–1

7AU

G92

R134a Refrigerant Recovery/Recycling and ChargingStation . . . . . . . . . . . . . . . . . . . . . . . . . . . JT02045

Service air conditioning system using R134a refrigerant.

CED,OUO1020,3234 –19–10DEC98–3/9

T7530AZ –UN–29MAY91

Vacuum Pump . . . . . . . . . . . . . . . . . . . . . D05267ST

Used to evacuate air conditioning system.

CED,OUO1020,3234 –19–10DEC98–4/9

Belt Tension Gauge

To measure belt tension.

CED,OUO1020,3234 –19–10DEC98–5/9

Clutch Hub Holding Tool . . . . . . . . . . . . . . . . . JDG217

Used to hold clutch hub while removing retaining nut.

CED,OUO1020,3234 –19–10DEC98–6/9

Clutch Hub Puller . . . . . . . . . . . . . . . . . . . . . JDG216

Used to remove A/C compressor clutch hub.


PN=607


Heating and Air Conditioning

CED,OUO1020,3234 –19–10DEC98–7/9

Receiving Cup . . . . . . . . . . . . . . . . . . . . . . . JDG223

Used to remove A/C compressor pulley bearing.

181830

2

CED,OUO1020,3234 –19–10DEC98–8/9

Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG225

Used to install A/C compressor pulley bearing.

CED,OUO1020,3234 –19–10DEC98–9/9

Key Driver . . . . . . . . . . . . . . . . . . . . . . . . . . JDG219

Used to install A/C compressor shaft key.

CED,OUO1020,3235 –19–10DEC98–1/8




CED,OUO1020,3235 –19–10DEC98–2/8

Bench Mounted Holding Fixture . . . . . . . . . . D01006AA

Hold compressor during repair.

CED,OUO1020,3235 –19–10DEC98–3/8

Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG220

Used to remove A/C clutch pulley. Used to remove A/Ccompressor pulley bearing.

CED,OUO1020,3235 –19–10DEC98–4/8

Hex Head Adapter. . . . . . . . . . . . . . . . . . . . . JDG226

Used to remove A/C compressor head plate.


PN=608



CED,OUO1020,3235 –19–10DEC98–5/8

Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG227

Used to remove A/C compressor valve plate from head.

1818303

CED,OUO1020,3235 –19–10DEC98–6/8

Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG221

Used to remove A/C compressor pulley bearing.

CED,OUO1020,3235 –19–10DEC98–7/8

Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG228

Used to remove A/C compressor head seal seat.

CED,OUO1020,3235 –19–10DEC98–8/8

Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG229

Used to install A/C compressor head seal seat.

CED,OUO1020,3236 –19–10DEC98–1/1

Other Material

Number Name Use

TY16134 (U.S.) R134a Flushing Solvent Flush R134a air conditioning system.

TY22025 (U.S.) R134a Compressor Oil (8.5 oz) Lubricate R134a air conditioningsystem.


PN=609


181830

4

CED,OUO1020,3237 –19–10DEC98–1/2

Specifications


Compressor Oil Volume 6 mL (0.2 fl oz) minimum

Oil, New Compressor Installation, Volume 230 ± 20 mL (7.7 ± 0.7 fl oz)Complete System Flushed supplied by parts depot

100 mL (3.4 fl oz) additional required

Oil, Used Compressor Installation, Volume 330 ± 20 mL (11.1 ± .7 fl oz)Complete System Flushed

Oil, New Compressor Installation, Volume 45 mL (1.5 fl oz)Complete System Not Flushed, Drainand Return

Oil, Used Compressor Installation, Volume 45 mL (1.5 fl oz)Complete System Not Flushed, OilDrained, Add

Oil, Used Compressor Installation, Volume 60 mL (2.0 fl oz)Complete System Not Flushed, OilDrained, Flushed, Add

Evaporator Volume 130 mL (4.4 fl oz)

Condenser Volume 65 mL (2.2 fl oz)

Receiver/Dryer Volume 30 mL (1.0 fl oz)

Hoses Volume 3 mL per 30 cm (0.1 fl oz per ft)

R134a System, Evacuated Vacuum 98 kPa (980 mbar) (29 in. Hg) atSea Level

Vacuum Subtract 3.4 kPa (34 mbar) (1 in. Hg)for each 300 m (1000 ft) elevationAbove Sea Level

Refrigerant, R134a System Weight 2.3 Kg (5 lbs)

750C Compressor Belt Deflection Distance 13 mm (0.50 in.) at 90 N (20 lbforce)

Clutch Pulley Surfaces Wear from Tolerance 0.3 mm (0.012 in.) MaximumFlat

Compressor Head Bolts Torque 26 N•m (19 lb-ft)


PN=610



1818305

CED,OUO1020,3237 –19–10DEC98–2/2


Pulley-to-Hub Clearance 0.53—0.91 mm (0.021—0.036 in.)

Clutch Hub Nut Torque 16 N•m (12 lb-ft)


PN=611


181830

6

CED,OUO1020,3206 –19–03DEC98–1/2

R134a Refrigerant Theory of Operation

T11

8034

–19–

26O

CT

98

A—Compressor E—High Pressure Liquid I—Expansion Valve L—BlowersB—High Pressure Gas F—High Pressure Switch J—Low Pressure Liquid M—A/C Freeze SwitchC—Condenser Fans G—Low Pressure Switch K—Evaporator N—Low Pressure GasD—Condenser H—Receiver/Dryer

The compressor (A) draws low pressure gas (N) fromthe evaporator (K) and compresses it into highpressure gas (B). Increasing the pressure of theR134a refrigerant causes its boiling point to rise to atemperature higher than the outside air temperature.

High pressure gas (B) leaves the compressor (A) andpasses through the condenser (D). The condenserfans (C) draw air through the condenser core whichcools the R134a refrigerant. Cooling the refrigerantcauses it to condense and it leaves the condenser (D)as a high pressure liquid (E). The high pressure liquidpasses through two switches (F and G). Theseswitches monitor R134a refrigerant pressure. Shouldthe pressure become too great or too small, either the

high or low pressure switch will open and stop thecompressor, interrupting the cycle. From the switchesthe high pressure liquid flows into the receiver-dryer(H) where moisture and contaminants are removed.

The refrigerant flows from the receiver-dryer (H) to theexpansion valve (I). The expansion valve (I) is avariable orifice used to cause a pressure andtemperature drop in the refrigerant causing refrigerantto vaporize. The expansion valve (I) is one of thedividing lines between the high side and low side ofthe air conditioning system. At this point in the system,the high pressure/high temperature liquid R134a issprayed into the evaporator (K) where it changes andbecomes a gas.


PN=612



1818307

CED,OUO1020,3206 –19–03DEC98–2/2

The expansion valve diaphragm is activated bysensing temperature and pressure within the valvebody. The internal bulb senses the evaporator outlet ordischarge temperature and pressure of R134a as itpasses through the valve back to the low pressure orsuction side of the compressor.

If too much refrigerant is flowing into evaporator, theliquid refrigerant will still be evaporating as it leavesthe evaporator, causing a low temperature at theevaporator outlet. The low temperature causes the

expansion valve variable orifice to decrease in size,restricting refrigerant flow. If the evaporator outlettemperature is too warm, the orifice will increase insize, allowing more refrigerant into evaporator.

If evaporator (K) temperature becomes too low, theA/C freeze switch (M) will interrupt current flow to thecompressor clutch coil, stopping system operation untilthe temperature becomes normal, between 31°F and40°F.

TX,9031,HH1465 –19–19AUG94–1/1

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=613


181830

8

CED,OUO1020,3207 –19–03DEC98–1/1

R134a Compressor Oil Charge Check

Check

1. Remove compressor if R134a leakage wasdetected and repaired. (See Remove and InstallCompressor in this group.)

2. Drain oil from the compressor and record theamount. (See Compressor Oil Removal procedurein this group.)

NOTE: Drain oil and save if this is a new compressor.

3. If the oil drained from a compressor removed fromoperation is very black or the amount of oil is lessthan specification, flush the system.

SpecificationCompressor Oil—Volume 6 mL (0.2 fl oz) minimum............................

Flush

1. Remove and discard the receiver-dryer.

2. Remove, clean, but do not disassemble theexpansion valve.

3. Flush the complete system with TY16134 airconditioning flushing solvent.

4. If the compressor is serviceable, pour flushingsolvent in the manifold ports and internally wash outthe old oil.

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.


PN=614


1818309

CED,OUO1020,3208 –19–03DEC98–1/1

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=615


181830

10

CED,OUO1057,220 –19–08SEP98–1/2

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

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.

Use the following procedure to determine the amountof system oil charge prior to installation of compressoron a machine.

COMPLETE SYSTEM FLUSHED

When the complete system, lines, and componentswere flushed, add the specified amount of oil.

• New compressor from parts depot contains 230 ±20 mL (7.7 ± 0.7 fl oz) of new oil. System requires anadditional 100 mL (3.4 fl oz) of new oil.

SpecificationOil, New CompressorInstallation, Complete SystemFlushed—Volume 230 ± 20 mL (7.7 ± 0.7 fl oz)

supplied by parts depot..................................

100 mL (3.4 fl oz) additionalrequired

• Used compressor removed from operation, whenthe oil is drained and flushed requires 330 ± 20 mL(11.1 ± .7 fl oz) of new oil.

SpecificationOil, Used CompressorInstallation, Complete SystemFlushed—Volume 330 ± 20 mL (11.1 ± .7 fl oz)..................................

COMPLETE SYSTEM NOT FLUSHED

When the complete system was not flushed add thecorrect amount of oil for the compressor plus theamount of oil for each component that was serviced.

• New compressor from parts depot, drain andreturn 45 mL (1.5 fl oz) of oil to the compressor. (SeeCompressor Oil Removal procedure in this group)

SpecificationOil, New CompressorInstallation, Complete SystemNot Flushed, Drain andReturn—Volume 45 mL (1.5 fl oz).......................................................

• Used compressor removed from operation and oildrained, (See Compressor Oil Removal procedure inthis group), add 45 mL (1.5 fl oz) of new oil.

SpecificationOil, Used CompressorInstallation, Complete SystemNot Flushed, Oil Drained,Add—Volume 45 mL (1.5 fl oz)............................................................

• Used compressor removed from operation, oildrained and flushed, add 60 mL (2.0 fl oz) of new oil.

SpecificationOil, Used CompressorInstallation, Complete SystemNot Flushed, Oil Drained,Flushed, Add—Volume 60 mL (2.0 fl oz).............................................

HOSE AND COMPONENT OIL CAPACITY


PN=616



18183011

CED,OUO1057,220 –19–08SEP98–2/2

NOTE: If any section of hose is removed and flushedor replaced, measure the length of hose anduse the formula; 3 mL per 30 cm (0.1 fl oz perft) to determine the correct amount of oil to beadded. Approximate total length equals 600cm (20 ft).

Components listed which have been removed, drainedor flushed, require the removal of the compressor to

determine the correct oil charge. Use the followingspecifications as a guide for adding oil to components.

SpecificationEvaporator—Volume 130 mL (4.4 fl oz)...............................................Condenser—Volume 65 mL (2.2 fl oz).................................................Receiver/Dryer—Volume 30 mL (1.0 fl oz)..........................................Hoses—Volume 3 mL per 30 cm (0.1 fl oz per

ft)....................................

CED,OUO1057,221 –19–08SEP98–1/1

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

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.

NOTE: JT02046 and JT02050 recovery and chargingstations can be substituted for the JT02045station.

1. Close both high and low pressure valves on theJT02045 refrigerant recovery, recycling and chargingstation (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 pressuretest port (B).

5. Follow the manufacturer’s instructions when using therefrigerant recovery, recycling and charging station.


PN=617


181830

12

CED,OUO1057,222 –19–08SEP98–1/1

Recover R134a System

T84

22A

C–1

9–22

FE

B95


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 the JT02045 refrigerant recovery, recyclingand charging station. (See installation procedure in thisgroup.)

2. Follow the manufacturer’s instructions when using therefrigerant recovery, recycling and charging station.


PN=618


18183013

CED,OUO1057,223 –19–08SEP98–1/2

Evacuate R134a System

T84

22A

C–1

9–22

FE

B95


Station



Do not run compressor whileevacuating.


1. Connect the JT02045 refrigerant recovery, recyclingand charging station. (See installation procedure in thisgroup.)

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 gauge registers specifiedvacuum.

SpecificationR134a System, Evacuated—Vacuum 98 kPa (980 mbar) (29 in. Hg) at

Sea Level.................................................

Vacuum Subtract 3.4 kPa (34 mbar) (1 in.Hg) for each 300 m (1000 ft)

elevation Above Sea Level

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

If specified vacuum cannot be obtained in 15 minutes, testthe system for leaks. (See Leak Testing in Operation andTest Manual, Group 9031-25.)


PN=619



181830

14

CED,OUO1057,223 –19–08SEP98–2/2

NOTE: If vacuum decreases more than 3.4 kPa (34mbar) (1 in. Hg) in 5 minutes maximum, there is aleak in the system. Repair leak.

5. When vacuum is at specified level, close low-side andhigh-side valves. Turn vacuum pump off.

6. Open low-side and high-side valves and startevacuation.

7. Evacuate system for 30 minutes after 98 kPa (980mbar) (29 in. Hg) vacuum is reached.

8. Close low-side and high-side valves and stopevacuation.

9. Charge the system . (See procedure in this group.)


PN=620


18183015

CED,OUO1020,3209 –19–03DEC98–1/1

Charge R134a System

T84

22A

C–1

9–22

FE

B95


Station




1. Connect JT02045 R134a Refrigerant Recovery,Recycling and Charging Station. (See installationprocedure in this group.)

2. Evacuate the system. (See Evacuate R134a System inthis group.)

NOTE: Before beginning to charge air conditioningsystem, ensure that with the engine STOPPED,the pump is capable of pulling at least 96.8 kPa(969 mbar) (28.6 in. Hg) vacuum (at sea level).Subtract 3.4 kPa (34 mbar) (1 in. Hg) for each300 m (1000 ft) elevation above sea level.

3. Follow the manufacturer’s instructions and charge thesystem.

4. Add refrigerant until system is charged with thespecified weight of refrigerant.

SpecificationRefrigerant, R134a System—Weight 2.3 Kg (5 lbs)...................................................................................

5. Do air conditioning operational checks. (Seeprocedures in Operation and Test Manual, Group9031-10.)


PN=621


181830

16

CED,OUO1057,224 –19–08SEP98–1/1

Check and Adjust Compressor Belt Tension—750C (S.N. —831315)

NOTE: 750C (S.N. 831316— ) and 850C belt tensionis self-adjusting.

IMPORTANT: Never over tighten belt. Overtightening may cause belt corddamage and excessive load onbearings.

1. Run engine for five minutes. Stop the engine, andimmediately check tension using a belt tensiongauge. Measure strand tension or deflection at apoint halfway between pulleys.

2. Belt must deflect the specified amount. If not, allowbelt to cool for 8—10 minutes.

Specification750C Compressor BeltDeflection—Distance 13 mm (0.50 in.) at 90 N (20 lb

force).........................

IMPORTANT: Force to adjust belt must be appliedto front of compressor housing onlyto prevent damage to compressor.

3. Loosen compressor mounting cap screws. Applyforce to front of compressor housing to tighten belt.Tighten cap screws.

4. Repeat steps 1 and 2 to check belt tension.


PN=622


18183017


PN=623


181830

18

CED,OUO1057,225 –19–08SEP98–1/2

Remove and Install Air Conditioning Compressor—750C (S.N. —831315)

T10

9580

–UN

–19J

UN

97


PN=624



18183019

CED,OUO1057,225 –19–08SEP98–2/2

1—Cap Screw 9—Washer (5 used) 17—Cap Screw (2 used) 24—Bracket2—Compressor 10—Cap Screw 18—Cap Screw 25—Support Block3—Bracket 11—Cap Screw 19—Washer 26—Cap Screw4—Washer 12—Nut (2 used) 20—Cap Screw 27—Belt5—Nut 13—Washer (2 used) 21—Cap Screw (2 used) 28—Cap Screw6—Threaded Block 14—Bracket 22—Idler Assembly 29—Washer (2 used)7—Strap 15—Cap Screw 23—Support 30—Nut8—Nut 16—Washer

Remove

1. Recover refrigerant from the system. (Seeprocedure in this group.)

2. Disconnect wiring lead, suction, and dischargelines.

3. Loosen cap screw (20) and remove belt (27).

4. Remove mounting cap screws (1, 11 and 17), nuts(5 and 12) and washers (4 and 13).

5. Remove compressor (2) from bracket (14).

6. Repair or replace compressor as required. (Seeprocedure in this group.)

Install

1. Position compressor (2) on bracket (14) and installcap screws (17) washers (13) and nuts (12).

2. Position strap (7) and bracket (3) on compressorand install cap screws (1 and 11) washers (4) andnuts (5).

3. Tighten suction and discharge lines, and connectwiring lead.

IMPORTANT: Never overtighten belt.Overtightening may cause belt corddamage and excessive load onbearings.

4. Adjust belt tension . (See procedure in this group.)

5. Install a new receiver/dryer.

6. Evacuate and charge the system. (See proceduresin this group.)

7. Check and adjust belt tension before returning unitto service. (See procedure in this group.)


PN=625


181830

20

TX,18,BA2029 –19–17JUN97–1/1

Remove and Install Air Conditioning Compressor—750C (S.N. 831316— )

T11

0116

–UN

–19J

UN

97

1—Compressor 5—Heat Shield 8—Nut 11—Support2—Bushing (2 used) 6—Cap Screw 9—Washer (2 used) 12—Clamp3—Bracket 7—Cap Screw 10—Clamp 13—Cap Screw4—Bracket


2. Remove serpentine belt . (See procedure in Group0510.)


4. Remove compressor (1).

5. Repair or replace compressor. (See procedure inthis group.)

6. Install compressor (1).

7. Connect suction and discharge lines and wiringlead.

8. Install serpentine belt.


10. Evacuate and charge the system. (See procedurein this group.)


PN=626


18183021

CED,OUO1057,226 –19–08SEP98–1/2

Remove and Install Air Conditioning Compressor—850C

T10

1657

–19–

11JU

L96

1—Bracket 3—Cap Screw (3 used) 5—A/C Compressor 6—Belt2—Cap Screw (2 used) 4—Washer (3 used)


2. Remove serpentine belt (6). (See procedure inGroup 0510.)


4. Remove compressor (5).

5. Repair or replace compressor. (See procedure inthis group.)

6. Install compressor (5).

7. Connect suction and discharge lines and wiringlead.

8. Install serpentine belt (6).


PN=627



CED,OUO1057,226 –19–08SEP98–2/2


10. Evacuate and charge the system. (See procedurein this group.)

181830

22

T52,1830,K184 –19–10DEC98–1/26

Disassemble and Inspect Compressor

RW

3654

–UN

–23J

AN

89

NOTE: Mounting fixture can be made with two pieces offlat stock and two lengths of threaded rod.

Weld one piece of stack perpendicular to other,drill two holes and install threaded rod as shown.

Compressor can also be mounted in pivotingD01006AA Bench Mounted Holding Fixture orsimilar holding device.

1. Mount D01006AA Bench Mounted Holding Fixture in abench vise and mount compressor on holding fixture.

T52,1830,K184 –19–10DEC98–2/26

RW

3655

–UN

–23J

AN

89

2. Remove six dust cover cap screws (A) and removecover.



PN=628


18183023

T52,1830,K184 –19–10DEC98–3/26

RW

3656

–UN

–23J

AN

89

3. Hold clutch hub with JDG217 Clutch Hub Holding Tool(A), and remove clutch hub retaining nut from shaft.

NOTE: If clutch drive plate slips on hub, drill a 1/4 in. holethrough flanges of drive plate and hub. Insert apunch to hold clutch hub for removal of hubretaining nut.

T52,1830,K184 –19–10DEC98–4/26

RW

3657

–UN

–23J

AN

89

4. Screw lower portion (A) of JDG216 Clutch Hub Pullerinto hub.

5. Install forcing screw (B). Hold hub and tighten forcingscrew until hub can be removed.

T52,1830,K184 –19–10DEC98–5/26R

W36

58–U

N–2

3JA

N89

6. Remove shims (A) from shaft and note quantity. Saveshims for reinstallation.

7. Remove and discard snap ring (B) and shaft key (C).

T52,1830,K184 –19–10DEC98–6/26

RW

3659

–UN

–23J

AN

89

8. Install JDG220 Driver (A) and use a suitable three jawpuller as shown to remove clutch pulley.


PN=629



181830

24

T52,1830,K184 –19–10DEC98–7/26

RW

3660

–UN

–23J

AN

89

9. Remove snap ring (A) and disconnect clutch field coilwire from compressor body. Remove clutch field coil.

T52,1830,K184 –19–10DEC98–8/26

RW

3661

–UN

–23J

AN

89

10. Remove six through-bolts using JDG226 Hex HeadAdapter (A).

IMPORTANT: Do not remove through-bolts unlesssuction and discharge manifolds are inplace and tight.

11. Carefully pry head from body using a screw driver.Pry only slightly around the circumference of thehead. Repeat this procedure until head is removed.

T52,1830,K184 –19–10DEC98–9/26

RW

1090

8–U

N–0

7DE

C88

12. Remove and discard shaft seal (A).

13. Use two screw drivers to remove discharge valveplate (B).

T52,1830,K184 –19–10DEC98–10/26

RW

1090

9–U

N–0

7DE

C88

14. If shaft seal and valve plate remain with compressorhead, carefully separate inlet reed valve (A) fromvalve plate (C). Do not lose locating dowel pin (B).


PN=630



18183025

T52,1830,K184 –19–10DEC98–11/26

RW

3663

–UN

–23J

AN

89

15. Install JDG227 Puller (A) and carefully pull valve plate(B) from head (C).

T52,1830,K184 –19–10DEC98–12/26

RW

3665

–UN

–23J

AN

89

16. Inspect valve plate side of inlet reed valves for acomplete circular wear pattern (A).

17. If wear pattern has any voids in it, replace reed valve.

T52,1830,K184 –19–10DEC98–13/26R

W10

001

–UN

–07D

EC

88

18. Inspect discharge valve for general condition. Valves(A) should have slight pressure against valve plate.

19. Hold valve plate up to light and verify that valve isagainst its seat. If condition is doubtful, replace valveplate.

T52,1830,K184 –19–10DEC98–14/26

RW

3668

–UN

–23J

AN

89

20. Turn compressor over and remove rear head byprying on the small tabs cast into the head. Pry lightlyaround circumference of head.


PN=631



181830

26

T52,1830,K184 –19–10DEC98–15/26

RW

3663

–UN

–23J

AN

89

21. Remove inlet reed valve from valve plate.

22. Install JDG227 Puller (A) and carefully pull valve plate(B) from head (C).

T52,1830,K184 –19–10DEC98–16/26

RW

3665

–UN

–23J

AN

89

23. Inspect valve plate side of inlet reed valves for acomplete circular wear pattern (A).

24. If wear pattern has any voids in it, replace reed valve.

T52,1830,K184 –19–10DEC98–17/26

RW

1000

1–U

N–0

7DE

C88

25. Inspect discharge valve for general condition. Valves(A) should have slight pressure against valve plate.

26. Hold valve plate up to light and verify that valve isagainst its seat. If condition is doubtful, replace valveplate.

T52,1830,K184 –19–10DEC98–18/26

RW

3667

–UN

–23J

AN

89

27. Inspect cylinders for scoring or excessive wear. Ifcylinders are scored or damaged, replacecompressor.

NOTE: Some cylinder scuffing (light scratches) is normal.


PN=632



18183027

T52,1830,K184 –19–10DEC98–19/26

RW

3677

–UN

–23J

AN

89

28. Inspect surfaces of clutch pulley (A) and clutch hub(B). If pulley is more than 0.3 mm (0.012 in.) from flat,replace pulley and clutch hub.

SpecificationClutch Pulley Surfaces Wear fromFlat—Tolerance 0.3 mm (0.012 in.) Maximum............................................

29. Rotate bearing in pulley. If pulley is rough or hasevidence of loss of lube, replace bearing.

30. Clean as necessary.

T52,1830,K184 –19–10DEC98–20/26

RW

3670

–UN

–23J

AN

89

31. Remove retaining ring (A) from pulley bore.

T52,1830,K184 –19–10DEC98–21/26

RW

3671

–UN

–23J

AN

89

32. Put pulley on JDG223 Receiving Cup (A). Pressbearing from pulley using JDG221 Driver (B) andJDG220 Driver (C).



PN=633


181830

28

T52,1830,K184 –19–10DEC98–22/26

RW

3672

–UN

–23J

AN

89

33. Install dust shield, lip edge facing up, in pulley.

T52,1830,K184 –19–10DEC98–23/26

RW

3673

–UN

–23J

AN

89

34. Put pulley on JDG225 Support (A). Make sure dustshield seats in support before putting bearing onpulley.

35. Press bearing into pulley until bearing bottoms ondust shield using a JDG221 Driver (B) and JDG220Driver (C).

36. Install bearing retaining ring.

T52,1830,K184 –19–10DEC98–24/26

RW

3674

–UN

–23J

AN

89

37. Remove seal seat from head using a JDG228 Driver.

T52,1830,K184 –19–10DEC98–25/26

RW

3675

–UN

–23J

AN

89

38. Apply a small amount of clean refrigerant oil to O-ring(A).

39. Install seal seat (B) in bore with grooved surface ofseat facing up as shown.


PN=634



18183029

T52,1830,K184 –19–10DEC98–26/26

RW

3676

–UN

–23J

AN

89

40. Press seal seat in head until seat bottoms in boreusing JDG229 Driver.

T52,1830,J21 –19–10DEC98–1/6

Assemble Compressor

RW

1090

9–U

N–0

7DE

C88

A—Reed ValveB—Dowel PinC—Valve Plate

1. Remove gaskets from both front and rear heads. Besure all gasket material is removed. Wash all parts inclean solvent before assembly.

2. Place suction reed valve against compressor side ofrear head. Install locating dowel pin (B) to assure thatreed valve (A) and valve plate (C) are properlyindexed. Set in place in compressor.

3. Carefully install new head gasket. Be sure it is properlyin place.

T52,1830,J21 –19–10DEC98–2/6

RW

3662

–UN

–23J

AN

89

4. Carefully install rear head. Be sure locating dowel pinis correctly positioned in head. Lightly tap head intoplace.

5. Turn compressor over and install suction reed andvalve plate. Install new head gasket.

IMPORTANT: Draft seal is a two piece seal. Be surethey are properly installed or breakagewill occur during assembly of fronthead.

6. Install new shaft seal (A) as shown. Be sure slottedrear side of seal engages with flats on compressorshaft.


PN=635



181830

30

T52,1830,J21 –19–10DEC98–3/6

RW

3678

–UN

–23J

AN

89

7. Align head with dowel pin and install head. Use sixbolts to draw head down EVENLY, then tighten to 26N•m (19 lb-ft).

SpecificationCompressor Head Bolts—Torque 26 N•m (19 lb-ft)...................................

8. Install new shaft key in key way. Position JDG219 KeyDriver (A) with slotted area (B) over key.

9. Tap installer with a small hammer until key bottoms inkey way.

T52,1830,J21 –19–10DEC98–4/6

RW

3679

–UN

–23J

AN

89

10. Align clutch coil with roll pin (B) in head and installcoil. Install snap ring (A) with round edge facingupward.

11. Connect clutch coil wire to ground screw oncompressor.

T52,1830,J21 –19–10DEC98–5/6

RW

3684

–UN

–23J

AN

89

12. Install pulley. Slight tap may be needed to properlyposition pulley on shaft.

13. Install new snap ring (A) with rounded edge of snapring facing upward. Install removed shims (B) on fronthead.

14. Align clutch head key way with key and install hub.

15. Tighten nut until clutch hub is tight against shims oncompressor shaft shoulder.


PN=636



18183031

T52,1830,J21 –19–10DEC98–6/6

RW

3682

–UN

–23J

AN

89

16. Check pulley-to-hub for 0.53—0.91 mm (0.021—0.036in.) clearance in three equally spread locationsaround hub using a feeler gauge.

SpecificationPulley-to-Hub—Clearance 0.53—0.91 mm (0.021—0.036 in.)...................

17. Turn pulley one-half turn (180°) and check clearancein three equally spaced locations. Remove or installshims as necessary for proper clearance.

18. Tighten clutch hub nut to 16 N•m (12 lb-ft).

SpecificationClutch Hub Nut—Torque 16 N•m (12 lb-ft).................................................

TX,1830,DV2015 –19–23AUG93–1/1

Inspect Compressor Manifolds

RW

4983

–UN

–23J

AN

89R

W49

84–U

N–2

3JA

N89

A—Hex Drive

IMPORTANT: Do not remove manifolds unless frontand rear head cap screws are installedand tightened.

1. Remove cap screws using hex drive (A).

2. Inspect parting surfaces and O-rings.


4. Install manifolds.


PN=637


181830

32

TX,1830,QQ3157 –19–23APR96–1/1

Remove and Install Receiver/Dryer

T85

12A

C–U

N–3

0JU

N95

1—Receiver Dryer2—A/C Low Pressure Switch3—A/C High Pressure Switch4—Cap Screw (2 used)5—Washer (2 used)6—Spacer (2 used)7—Clamp (2 used)8—High Pressure Liquid To Condenser Line9—High Pressure Liquid To Evaporator Line

1. Do a recovery of the air conditioning system. (Seeprocedure in this group.)

2. Disconnect lines (8 and 9) from receiver/dryer.

3. Loosen clamps (7) and remove receiver/dryer (1).

4. Install new receiver/dryer (1) and tighten clamps (7).

5. Apply refrigerant oil to new O-rings and immediatelyconnect lines.

6. Add compressor oil . (See procedure in this group.)

7. Evacuate and charge the air conditioning system. (Seeprocedure in this group.)


PN=638


18183033


PN=639


181830

34

TX,1830,QQ3159 –19–23APR96–1/2

Remove and Install Evaporator

T85

12A

B–U

N–3

0JU

N95


PN=640



18183035

TX,1830,QQ3159 –19–23APR96–2/2

1—Case 4—Hose 6—Heater Core 8—Hose2—Resistor 5—Drain Tube (2 used) 7—Clamp 9—Evaporator3—Clamp

Remove and install evaporator as shown.


PN=641


181830

36

TX,1830,QQ3162 –19–23APR96–1/2

Remove and Install Condenser

T83

91A

G–U

N–3

0JU

N95


PN=642



18183037

TX,1830,QQ3162 –19–23APR96–2/2

1—Blower Motor 7—Cap Screw (12 used) 13—Tube 18—Strap (3 used)2—Cap Screw 8—Lock Nut (4 used) 14—Tube 19—Clamp (4 used)3—Washer (10 used) 9—Strap 15—Tube 20—Bracket4—Plate 10—Rubber Mount (8 used) 16—Condenser 21—Plate5—Seal 11—Bushing (4 used) 17—Cap Screw (2 used) 22—Plate6—Washer (12 used) 12—Cap Screw (4 used)

Remove and install condenser as shown.


PN=643


181830

38

TX,1830,QQ3164 –19–23APR96–1/2

Remove and Install Heater Pressurizer

T10

9581

–UN

–18J

UN

97


PN=644



18183039

TX,1830,QQ3164 –19–23APR96–2/2

1—Cover 6—Cover 11—Air Duct 15—Air Duct2—Filter 7—Housing 12—Air Duct 16—Adapter (2 used)3—Air Duct 8—Clamp (11 used) 13—Air Duct 17—Clamp (2 used)4—Retainer 9—Air Duct 14—Air Duct 18—Blower Motor (2 used)5—Filter 10—Air Duct

Remove and install pressurizer as shown.


PN=645


181830

40


PN=646

Section 19Sheet Metal

Contents

Page

Group 1910—Hood and Engine EnclosuresSpecifications . . . . . . . . . . . . . . . . . . . . . . . .19-1910-1Remove and Install Hood . . . . . . . . . . . . . . .19-1910-2Remove and Install Hood Support and

19Engine Side Shields. . . . . . . . . . . . . . . . . .19-1910-4

Group 1921—Grille and Grille HousingSpecifications . . . . . . . . . . . . . . . . . . . . . . . .19-1921-1Remove and Install Grille Housing . . . . . . . .19-1921-2


PN=1

Contents

19


PN=2

Group 1910Hood and Engine Enclosures

CED,OUO1020,3134 –19–06NOV98–1/1

Specifications


750C Hood Support-to-Main Frame Torque 68 N•m (50 lb-ft) InitialCap Screws 319 N•m (235 lb-ft) Final

1919101


PN=649

Hood and Engine Enclosures

191910

2

TX,1910,SS2510 –19–23APR96–1/2

Remove and Install Hood

TP

4733

1–U

N–0

9MA

R95

1—Cap Screw (6 used) 3—Cap Screw (8 used) 5—Hood 6—Hood (Perforated)2—Washer (6 used) 4—Washer (8 used)


PN=650



TX,1910,SS2510 –19–23APR96–2/2

Remove and install hood as shown.

1919103


PN=651


191910

4

TX,1910,SS2511 –19–03DEC98–1/2

Remove and Install Hood Support and Engine Side Shields

T85

13A

T–U

N–0

7JU

L95


PN=652



1919105

TX,1910,SS2511 –19–03DEC98–2/2

1—Hood Support 8—Cover 14—Side Shield 18—Cap Screw (4 used)2—Side Shield 9—Cap Screw (4 used) 15—Spherical Washer 19—Cap Screw (4 used)3—Latch Assembly (2 used) 10—Washer (4 used) Assembly (4 used) 20—Plate (2 used)4—Rivet (4 used) 11—Panel 16—Washer (4 used) 21—Rubber Stop (4 used)5—Washer (20 used) 12—Plate 17—Spacer (4 used, 750C 22—Nut (8 used)6—Cap Screw (20 used) 13—Cover only) 23—Panel7—Plate

1. Remove hood.

2. Remove cap screws (18), washers (16) andspacers (750C only) (17). Remove rear hoodsupport (1) and spherical washer assembly (15).

3. Remove parts (2—14 and 19—23). Inspect all partsand replace as necessary.

4. Install parts (2—14 and 19—23).

On rear hood support:

5. Install spherical washer assembly (15) betweenframe and hood support. Install:

• Thick washer with flat side toward main frame(concave up).

• Thin washer with flat side toward hood support(convex toward concave washer).

6. Install hood support (1), cap screws (18), washers(16) and spacers (750C only) (17). Tighten capscrews in sequence:

• Right Rear• Left Rear• Left Front• Right Front

For each cap screw:

a. Tighten cap screws to initial specification.

b. Strike each cap screw three times with a 1 to1.4 kg (2—3 lb) hammer and a large drift.

c. Tighten cap screws to final specification.

Specification750C Hood Support-to-MainFrame Cap Screws—Torque 68 N•m (50 lb-ft) Initial..........................

319 N•m (235 lb-ft) Final

7. Install hood.


PN=653


191910

6


PN=654

Group 1921Grille and Grille Housing

CED,OUO1020,3214 –19–03DEC98–1/1

Specifications


750C Radiator Volume 26.5 L (7 gal)

850C Radiator Volume 34 L (9 gal)

Grille Housing-to-Main Frame Cap Torque 800 N•m (590 lb-ft)Screws

1919211


PN=655

Grille and Grille Housing

191921

2

TX,1921,RR5412 –19–23APR96–1/2

Remove and Install Grille Housing

T84

99A

V–U

N–2

6JU

N95

850C Shown

1—Knob 7—Washer (4 used) 13—Cap Screw (18 used) 19—Washer (4 used) (850C)2—Spring Pin 8—Cap Screw (4 used) 14—Hinge 20—Strap (2 used) (850C)3—Spring 9—Cap Screw (2 used) 15—Door 21—Washer (8 used) (850C)4—Latch 10—Washer (2 used) 16—Shroud 22—Cap Screw (4 used) (850C)5—Nut (4 used) 11—Guard 17—Housing 23—Isolator (2 used) (850C)6—Grille 12—Washer (18 used) 18—Nut (18 used) 24—Cap Screw (2 used) (850C)



PN=656


1919213

TX,1921,RR5412 –19–23APR96–2/2

IMPORTANT: For 850C, remove radiator and oilcooler with the grille housing.

CAUTION: Escaping fluid under pressurecan penetrate the skin causing seriousinjury. Avoid the hazard by relievingpressure before disconnecting hydraulic orother lines. Tighten all connections beforeapplying pressure. Search for leaks with apiece of cardboard. Protect hands and bodyfrom high pressure fluids.

If an accident occurs, see a doctorimmediately. Any fluid injected into the skinmust be surgically removed within a fewhours or gangrene may result. Doctorsunfamiliar with this type of injury shouldreference a knowledgeable medical source.Such information is available from Deere &Company Medical Department in Moline,Illinois, U.S.A.

1. Lower blade to ground and operate hydrauliccontrols to release pressure. Disconnect lift cylinderhoses. Plug all openings.

CAUTION: The approximate weight of liftcylinder is 91 kg (200 lb).

2. Disconnect lift cylinders from grille housing and laythem on the tracks.

3. Remove tilt cylinder hose guard (11) anddisconnect hoses.

4. Remove hood, and shroud (16).

5. Disconnect light wire harness.

6. For 850C, open the grille screen and remove lowerbaffle to drain the radiator. Disconnect cooler hosesand upper and lower radiator hoses.

Specification750C Radiator—Volume 26.5 L (7 gal)................................................850C Radiator—Volume 34 L (9 gal)...................................................

For 750C, open grille screen and remove upperradiator to grille housing mounting hardware (19—24).

CAUTION: The approximate weight of grilleand grille housing is 290 kg (642 lb).

7. Attach hoist to grille housing (17). Remove capscrews and washers (12 and 13) to removehousing. Disassemble and repair grille housing asneeded.

8. Install grille housing. Tighten cap screws (13) tospecification.

SpecificationGrille Housing-to-Main FrameCap Screws—Torque 800 N•m (590 lb-ft)...........................................

9. Attach lift cylinders and hoses. For the 750C, installtop radiator to grille housing attaching hardware(19—24).

For the 850C, connect upper and lower radiator andcooler hoses and light wire harness.

10. Add coolant to radiator.

11. Install radiator shroud (16) and hood.


PN=657


191921

4


PN=658

Section 20Safety, Convenience and Miscellaneous

Contents

Page

Group 2004—Horn and Warning DevicesRemove and Install Reverse Alarm . . . . . . . .20-2004-1Adjust Reverse Warning Alarm Volume. . . . .20-2004-1

20


PN=1

Contents

20


PN=2

Group 2004Horn and Warning Devices

TX,9025,BS516 –19–23APR96–1/1

Remove and Install Reverse Alarm

T85

07A

I–U

N–1

9JU

N95

2020041

A—Rear Access PanelB—Alarm

1. Remove rear access panel (A).

2. Disconnect wiring leads to alarm.

3. Remove alarm (B).

TX,9025,BS515 –19–23APR96–1/1

Adjust Reverse Warning Alarm Volume

T84

29A

X–U

N–0

2MA

R95

A—Shorting BarB—TerminalC—Terminal

IMPORTANT: The reverse warning alarm is set on lowvolume at the factory. It may benecessary to adjust the volume to meetlocal regulations.

NOTE: Alarm removed from machine for clarity ofphotograph.

1. To change alarm to high volume, remove nuts fromterminals (B and C).

2. Attach shorting bar (A) to terminals (B and C).


PN=661

Horn and Warning Devices

202004

2


PN=662

Section 32Bulldozer

Contents

Page Page

Group 3200—Removal and Installation Other Material . . . . . . . . . . . . . . . . . . . . . . . .32-3260-2Specifications . . . . . . . . . . . . . . . . . . . . . . . .32-3200-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .32-3260-3Remove and Install Angledozer or Remove and Install Hydraulic Pump . . . . . . .32-3260-6

Bulldozer Blade and Frame (Outside Disassemble and Assemble HydraulicDozer) . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3200-2 Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-7

Remove and Install Trunnion (Outside Remove and Install Plug Or Winch PTODozer) . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3200-3 Shaft From Hydraulic Pump. . . . . . . . . . . .32-3260-9

Trunnion Shim Adjustment and 850C Pat Remove and Install Hydrostatic and HydraulicTrunnion (S.N. —898365) . . . . . . . . . . . . .32-3200-4 Reservoir . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-11

Trunnion Shim Adjustment 850C (PAT) (S.N. Hydraulic and Hydrostatic Reservoir898366— ). . . . . . . . . . . . . . . . . . . . . . . . .32-3200-4 Cleanout Cover Remove and Install (S.N. 925753—

Remove and Install (PAT) All Hydraulic ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-12Blade with C—Frame 850C . . . . . . . . . . . .32-3200-5

Disassemble and Assemble Reservoir . . . .32-3260-16Remove and Install Hydraulic Filter . . . . . . .32-3260-17

Group 3201—Blade Disassemble and Assemble Hydraulic 32Specifications . . . . . . . . . . . . . . . . . . . . . . . .32-3201-1Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-18

Remove and Install Bulldozer (OutsideRemove and Install Dozer Control Valve. . .32-3260-19

Dozer) . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3201-2Component Location—All HydraulicRemove and Install Cutting Edges and

Dozer. . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-20End Bits. . . . . . . . . . . . . . . . . . . . . . . . . . .32-3201-3Component Location—BulldozerRemove and Install (PAT) Six Way Blade

Hydraulics . . . . . . . . . . . . . . . . . . . . . . . .32-3260-21850C . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3201-4Component Location—Angle Dozer

Hydraulics . . . . . . . . . . . . . . . . . . . . . . . .32-3260-22Group 3215—Controls LinkageComponent Location—850C (PAT) BladeOther Material . . . . . . . . . . . . . . . . . . . . . . . .32-3215-1

(S.N. XXXXXX— ) . . . . . . . . . . . . . . . . . .32-3260-23Specifications . . . . . . . . . . . . . . . . . . . . . . . .32-3215-1Disassemble and Assemble Dozer ControlRemove and Install T-Bar Linkage . . . . . . . .32-3215-2

Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-24Remove and Install Two Function HydraulicInstalling Valve Seal Kit in Cap End . . . . . .32-3260-27Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3215-4Installing Valve Seal Kit in Tang End . . . . .32-3260-29Remove and Install Third Function HydraulicDisassemble and Assemble System ReliefLinkage . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3215-6

Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-31Disassemble and Assemble Circuit ReliefGroup 3240—Frames

Valve with Anti-Cavitation . . . . . . . . . . . .32-3260-32Specifications . . . . . . . . . . . . . . . . . . . . . . . .32-3240-1Remove and Install Quick Drop Valve . . . . .32-3260-33Remove and Install Bulldozer Pushbeam . . .32-3240-1Disassemble and Assemble Quick DropRemove and Install Pitch Jack . . . . . . . . . . .32-3240-3

Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-35Remove and Install Struts . . . . . . . . . . . . . . .32-3240-4Remove and Install Tilt Cylinder—OutsideDisassemble and Assemble Pushbeams,

Dozer. . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-36Struts and Pitch Jack. . . . . . . . . . . . . . . . .32-3240-6Cross Section of a 180 Series (Tilt)Blade Pitch Adjustment . . . . . . . . . . . . . . . . .32-3240-7

Cylinder—Outside Dozer . . . . . . . . . . . . .32-3260-37Disassemble and Assemble Lift CylinderPivot Sub-frame. . . . . . . . . . . . . . . . . . . . .32-3240-8 Disassemble Tilt Cylinder—Outside

Dozer. . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-37Assemble Tilt Cylinder—Outside Dozer. . . .32-3260-40Group 3260—Hydraulic System

Special or Essential Tools . . . . . . . . . . . . . . .32-3260-1Continued on next pageService Equipment and Tools . . . . . . . . . . . .32-3260-1


PN=1

Contents

Page

Remove and Install Blade Lift Cylinder—Outside Dozer . . . . . . . . . . . . . . . . . . . . .32-3260-45

Disassemble and Assemble Blade LiftCylinder (S.N.—831315 ). . . . . . . . . . . . .32-3260-47

Disassemble and Assemble Blade LiftCylinder—Outside Dozer (S.N. 831316—). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-50

Remove and Install Tilt Cylinder For (PAT)Six-Way Blade 850C (S.N. —XXXXXX). . . . . . . . . . . . . . . . . . . . . . . . .32-3260-52

Remove and Install Angle Cylinder For(PAT) Six-Way Blade 850C (S.N. —XXXXXX). . . . . . . . . . . . . . . . . . . . . . . . .32-3260-54

Disassemble 120 Series Blade Tilt (PAT)(S.N. XXXXXX— ) and Lift Cylinder(PAT) (S.N. XXXXXX— ) . . . . . . . . . . . . .32-3260-56

Cross Section of 120 Series Blade Lift (PAT)(S.N. XXXXXX—) and Tilt Cylinder(PAT) (S.N. XXXXXX— ) . . . . . . . . . . . . .32-3260-59

Assemble 120 Series Blade Tilt (PAT) (S.N.XXXXXX—) and Lift Cylinder (PAT) (S.N.XXXXXX— ) . . . . . . . . . . . . . . . . . . . . . .32-3260-60

Disassemble 125 Series Blade AngleCylinder (PAT) (S.N. XXXXXX— ) . . . . . .32-3260-65

Cross Section of 125 Series Blade Angle

32

Cylinder (PAT) (S.N. XXXXXX— ) . . . . . .32-3260-67Assemble 125 Series Blade Angle

Cylinder (PAT) (S.N. XXXXXX— ) . . . . . .32-3260-68

Group 3299—Dealer Fabricated ToolsDFT1180 Cylinder Nut Torque Tool. . . . . . . .32-3299-1


PN=2


CED,OUO1020,3145 –19–10NOV98–1/1

Specifications


Trunnion Cap, Cap Screws Torque 1000 N•m (750 lb-ft)

Lift Cylinder Cap Screws Torque 908 N•m (670 lb-ft)

Trunnion Mounting Cap Screws Torque 881 N•m (650 lb-ft)

3232001


PN=665


323200

2

TX,3200,SS2504 –19–11JUL95–1/2

Remove and Install Angledozer or BulldozerBlade and Frame (Outside Dozer)

X98

11–U

N–2

3AU

G88

T85

16A

C–U

N–0

5JU

L95

T85

14A

C–U

N–0

5JU

L95

A—Rod End LineB—Tilt Cylinder Head End LineC—CylinderD—PushbeamE—Trunnion Pivot Cap

1. Lower blade to the ground.



2. Disconnect blade lift cylinders (C) and retract rod.Attach cylinders to grille housing with brackets whichare supplied on machine. Operate all hydraulic controlvalves to release pressure in the hydraulic system.

3. Disconnect lines (A and B). Close all openings usingcaps and plugs.

4. Place blocks under pushbeam (D). Remove trunnionpivot cap (E).

5. Back machine away from frame. Repair as needed.

6. Drive machine between pushbeams.

7. Install trunnion caps. Tighten cap screws tospecification.

SpecificationTrunnion Cap, Cap Screws—Torque 1000 N•m (750 lb-ft).......................................................................


PN=666



TX,3200,SS2504 –19–11JUL95–2/2

8. If trunnion or cap has been repaired, check shimadjustment when installing. (See Trunnion ShimAdjustment in this group.)

9. Attach lines (A and B) and connect cylinders (C).Tighten cap screws to specification.

SpecificationLift Cylinder Cap Screws—Torque 908 N•m (670 lb-ft)..............................

3232003

TX,32,BA2022 –19–30MAY97–1/1

Remove and Install Trunnion (Outside Dozer)

T81

89A

J–U

N–1

1MA

Y94

A—TrunnionB—Cap Screw

NOTE: On 750C semi-U blades a spacer plate and longercap screws are used to allow clearance betweentracks and the inside of the pushbeam.

1. Support trunnion (A) and remove cap screws (B).

2. Install trunnion, washers and cap screws. Tighten capscrews to specification.

SpecificationTrunnion Mounting Cap Screws—Torque 881 N•m (650 lb-ft).........................................................................


PN=667


323200

4TX,3200,SS2514 –19–16OCT01–1/1

Trunnion Shim Adjustment and 850C PatTrunnion (S.N. —898365)

T81

89A

L–U

N–1

1MA

Y94

Connect Pushbeam to Trunnion—Outside Dozer Shown

T81

89A

I–U

N–1

1MA

Y94

Shim—Outside Dozer Shown

A—CapB—Pushbeam or frameC—Nut (2 used per side)D—Cap Screw (2 used per side)E—Shim (as required)

1. Connect pushbeam or frame to trunnion without shims(E). Tighten cap screws and measure gap. Installenough shims (E) equal to fill gap plus one extra thinshim. Install trunnion cap, cap screws and nuts.Tighten cap screws to specification.

SpecificationTrunnion Cap, Cap Screws—Torque 1000 N•m (750 lb-ft).......................................................................

2. Repeat on opposite side.

TX03399,0001916 –19–12OCT01–1/1

Trunnion Shim Adjustment 850C (PAT) (S.N.898366— )

T14

6632

B–U

N–1

6OC

T01

1—Cap Screw (4 used per side)2—Cap (1 per side)3—Shim (as required)4—C-Frame5—Nut (4 used per side)

Connect frame to trunnion without shims (E). Tighten capscrews and measure gap. Install enough shims (E) equalto fill gap plus one extra shim. Install trunnion cap, capscrews, washers and nuts. Tighten cap screws tospecification.

Trunnion Cap Screws—SpecificationCap Screw—Torque 1044 N•m (770 lb-ft)..................................................


PN=668


3232005

CED,TX14826,12130 –19–15OCT01–1/2

Remove and Install (PAT) All Hydraulic Blade with C—Frame 850C

T12

7476

–UN

–24J

AN

00

X98

11–U

N–2

3AU

G88

T12

7426

B–U

N–2

1JA

N00

1—Hydraulic Lines 2—Trunnion Cap Screws (2 3—Blade Lift Cylindersused per side) or (4 usedper side later machines)



PN=669



323200

6

CED,TX14826,12130 –19–15OCT01–2/2

CAUTION: Escaping fluid under pressurecan penetrate the skin causing seriousinjury. Avoid the hazard by relievingpressure before disconnecting hydraulic orother lines. Tighten all connections beforeapplying pressure. Search for leaks with apiece of cardboard. Protect hands and bodyfrom high pressure fluids.

If an accident occurs, see a doctorimmediately. Any fluid injected into the skinmust be surgically removed within a fewhours or gangrene may result. Doctorsunfamiliar with this type of injury shouldreference a knowledgeable medical source.Such information is available from Deere &Company Medical Department in Moline,Illinois, U.S.A.

2. Disconnect blade lift cylinders (3) and retract rod.Attach cylinders to grille housing.

3. Operate all hydraulic control valves to releasepressure in the hydraulic system. Disconnect

hydraulic lines (1). Close all openings using capsand plugs.

4. Place blocks under pushbeam or frame. Removetrunnion cap screws (2).

5. Back machine away from frame. Repair as needed.

6. Drive machine forward, and install frame. Checkshim adjustment at trunnion when installing.

When installing shims, connect pushbeam or frameto trunnion without shims. Tighten cap screws andmeasure gap. Install enough shims to fill gap plusone extra shim.

7. Install trunnion cap screws (2). Tighten cap screws.See Trunnion Shim Adjustment in this group.

8. Attach hydraulic lines (1) and lift cylinders (3).Tighten cap screws.


PN=670

Group 3201Blade

CED,OUO1020,3146 –19–10NOV98–1/1

Specifications


Tilt Cylinder and Pitch Jack Cap Torque 550 N•m (400 lb-ft)Screw—750C

Tilt Cylinder and Pitch Jack Cap Torque 871 N•m (650 lb-ft)Screw—850C

Lift Cylinder Cap Screws Torque 908 N•m (670 lb-ft)

Strut Cap Screws Torque 550 N•m (400 lb-ft)

3232011


PN=671

Blade

323201

2

TX,3201,SS2517 –19–15OCT01–1/2

Remove and Install Bulldozer (OutsideDozer)

T85

16A

D–U

N–0

5JU

L95

A—Clamp (2 used)B—Shim (as required)C—Tilt Cylinder and Cap ScrewsD—Pin (2 used)E—Strut (2 used)F—Pin Retainers (4 used)G—Pitch JackH—Lift Cylinder (2 used)I—Lift Cylinder Rod Mounting Ball (2 used)

1. Lower blade to ground.

2. Place blocks under pushbeams.

CAUTION: The approximate weight of tiltcylinder is 100 kg (220 lb).

3. Attach hoist to rod on tilt cylinder.

4. Remove hose clamps (A).

5. Disconnect cylinder (C) and pitch jack (G). Retainshims (B) for reassembly. Lay cylinder and pitch jackback on push beam.

CAUTION: The approximate weight of blade is1005 kg (2215 lb).

6. Attach hoist to blade.

7. Disconnect lift cylinder (H) and blade strut (E). Retainshims for reassembly.

8. Remove cap screws to remove blade pin retainers (F).Remove pin (D).

9. Remove and repair blade as needed. (See WeldingRepair of Major Structures in Group 1740.)

10. Position blade to push beams and install pins (D), pinretainers (F) and cap screws.

11. Attach tilt cylinder (C) and pitch jack (G) with shimsand cap screws. Tighten cap screws to specification.

SpecificationTilt Cylinder and Pitch Jack CapScrew—750C—Torque 550 N•m (400 lb-ft)................................................Tilt Cylinder and Pitch Jack CapScrew—850C—Torque 871 N•m (650 lb-ft)................................................

12. Attach lift cylinders (H). Tighten cap screws tospecifications.


PN=672


Blade

3232013

TX,3201,SS2517 –19–15OCT01–2/2

SpecificationLift Cylinder Cap Screws—Torque 908 N•m (670 lb-ft)..............................

13. Attach struts (E). Tighten cap screws tospecifications.

SpecificationStrut Cap Screws—Torque 550 N•m (400 lb-ft).........................................

14. Attach hoses with clamps (A).

15. If blade has been repaired in ball area (I) do thefollowing:

Tighten lift cylinder socket cap screws just enough sogap is equal on each side of ball and socket is tight.

Add enough shims to fill gap plus a thin shim to allowclearance on ball.

TX,3201,SS2516 –19–11JUL95–1/1

Remove and Install Cutting Edges and EndBits

T85

16A

E–U

N–0

5JU

L95

A—Cutting EdgeB—Cap Screw, Washer, Nut (as required)C—End Bit (2 used)

1. Block frame securely with cutting edge above groundlevel.

2. Remove parts (A—C).

3. Inspect parts and replace as necessary.

4. Install parts (A—C).


PN=673

Blade

323201

4

CED,TX14826,12131 –19–06MAY04–1/1

Remove and Install (PAT) Six Way Blade 850C

T12

7435

–UN

–21J

AN

00

1—Blade 4—Lock Pin (4 used) 8—Bolt (26 used) 12—Flat Washer (4 used)2—Ball Socket Retainer (2 5—Cutting Edge (3 used) 9—Nut (26 used) 13—Cap Screw (6 used)

used) 6—End Bit (2 used) 10—Flat Washer (32 used) 14—Rubber Bushing (8 used)3—Pin (4 used) 7—Shim (0.036”) 11—Cap Screw (4 used) 15—Grease Fitting

CAUTION: Prevent possible crushing injuryfrom falling blade. Use appropriate liftingand supporting devices.

1. Support blade on wood blocks to aid in installation.

Specification850C PAT Blade—Weight—Approximate 1380 kg............................................................................

3043 lb

2. Install shims:

• Install ball socket retainers (2) to ball and bladeusing cap screws (13) and washers (10).

• Tighten all cap screws equally so that gap isequal all the way around ball.

• Add enough shims (7) to fill the gap plus oneshim to allow clearance on ball.

3. Tighten cap screws evenly to specification.

SpecificationBall Socket-to-Blade CapScrews—Torque—Lubricated 691 N•m................................................

510 lb-ft

4. Lubricate ball and socket.


PN=674

Group 3215Controls Linkage

CED,OUO1020,3150 –19–10NOV98–1/1

Other Material

Number Name Use

TY9370 (U.S.) Thread Lock and Sealer (Medium Apply to lever pivot body internalTY9477 (Canadian) Strength)LOCTITE Products threads only.242 (LOCTITE)


3232151

CED,OUO1020,3151 –19–10NOV98–1/1

Specifications


Bottom of T-Bar Handle-to-Bottom of Measurement 310 mm (12 in.)Shaft

Handle-to-Shaft Nut Torque 47 N•m (35 lb-ft)

Special Screws-to-Lever Pivot Body Torque 47 N•m (35 lb-ft)

Lever Body Needle Bearings Distance 0.5—1.0 mm (0.020—0.040 in.)Deep


PN=675

Controls Linkage

323215

2

TX,3215,SS2501 –19–11JUL95–1/2

Remove and Install T-Bar Linkage

T85

13A

A–U

N–0

7JU

L95


PN=676


Controls Linkage

3232153

TX,3215,SS2501 –19–11JUL95–2/2

1—Handle 9—Lever Pivot Body 16—Washer (5 used) 23—Nut2—Nut 10—Special Screw 17—Rod End, Left with Stud 24—Connecting Link3—Rod 11—Lever Yoke Body 18—Nut 25—Set Screw4—Lever 12—Control Lever Support 19—Nut 26—Bellcrank Bracket5—Boot 13—Spring Pin (2 used) 20—Quick Disconnect 27—Nut6—Washer 14—Pin 21—Connecting Link 28—Bellcrank7—Needle Bearing (5 used) 15—Cap Screw (5 used) 22—Washer 29—Connecting Link8—Lock Nut (3 used)

1. Remove and install linkage as necessary.

2. Inspect all parts for wear or damage. Replace asnecessary.

3. Assemble nut (2) to rod (3). Position T-bar handleon shaft so that bottom of shaft-to-bottom of handlemeasures 310 mm (12 in.). Tighten nut (2) tospecification.

SpecificationBottom of T-BarHandle-to-Bottom of Shaft—Measurement 310 mm (12 in.).............................................................Handle-to-Shaft Nut—Torque 47 N•m (35 lb-ft)...................................

4. Needle bearings (7) are press fit.

5. Carefully apply thread lock and sealer (mediumstrength) to lever pivot body (9) internal threadsonly. Install special screws (10) and tighten tospecification.

SpecificationSpecial Screws-to-Lever PivotBody—Torque 47 N•m (35 lb-ft)...........................................................


PN=677

Controls Linkage

323215

4

TX,3215,SS2502 –19–11JUL95–1/2

Remove and Install Two Function Hydraulic Linkage

TP

4518

2–U

N–0

2MA

R95


PN=678


Controls Linkage

TX,3215,SS2502 –19–11JUL95–2/2

1—Lever 7—Spring Pin 12—Rod (2 used) 17—Connecting Link (2 used)2—Lever Pivot Body 8—Pin 13—Washer (3 used) 18—Lock Nut (2 used)3—Needle Bearing (4 used) 9—Control Lever Support 14—Cap Screw (3 used) 19—Nut4—Special Screw (2 used) 10—Quick Disconnect Coupler 15—Nut (2 used) 20—Washer5—Lever Yoke Body (2 used) 16—Rod End, Left with Stud (2 21—Grip6—Lock Nut (2 used) 11—Nut (2 used) used)


2. Inspect all parts for wear and damage. Replace ifnecessary.

3. Needle bearings (3) are press fit.

4. Carefully apply thread lock and sealer (mediumstrength) to lever pivot body (2) internal threads

only. Install special screws (4) and tighten tospecification.

SpecificationSpecial Screws-to-Lever PivotBody—Torque 47 N•m (35 lb-ft)...........................................................

3232155


PN=679

Controls Linkage

323215

6

TX,3215,SS2503 –19–11JUL95–1/2

Remove and Install Third Function Hydraulic Linkage

TP

4732

0–U

N–0

2MA

R95

1—Grip 6—Rod End, Left with Stud 10—Connecting Link 14—Spring Pin2—Washer 7—Nut 11—Lever Body 15—Control Lever Support3—Nut (2 used) 8—Nut 12—Lock Nut (2 used) 16—Washer (3 used)4—Rod 9—Quick Disconnect Coupler 13—Pin 17—Cap Screw (3 used)5—Needle Bearing (2 used)


PN=680


Controls Linkage

TX,3215,SS2503 –19–11JUL95–2/2


2. Inspect all parts for wear and damage. Replace ifnecessary.

3. Needle bearings (5) are press fit. Press into leverbody to specification. Press on outer case only,

letter side of bearing out.

SpecificationLever Body Needle Bearings—Distance 0.5—1.0 mm (0.020—0.040 in.)

Deep............................................

3232157


PN=681

Controls Linkage

323215

8


PN=682

Group 3240Frames

CED,OUO1020,3154 –19–10NOV98–1/1

Specifications


Trunnion Cap-to-Trunnion Cap Torque 950 N•m (700 lb-ft)Screw

Pitch Jack Cap Screw—750C Torque 550 N•m (400 lb-ft)

Pitch Jack Cap Screw—850C Torque 871 N•m (650 lb-ft)

Left Front of Measurement 15—30 mm (0.5—1.0 in.) more thanTrackframe-to-Pushbeam right

Strut-to-Blade Cap Screw Torque 542 N•m (400 lb-ft)

3232401

TX,3240,SS2521 –19–11JUL95–1/3

Remove and Install Bulldozer Pushbeam

T61

49A

F–U

N–2

0OC

T88

A—Blade-to-Pushbeam PinB—Cap Screw and Washer (4 used)C—Retainer Plate (2 used)D—Cap Screw and NutE—Pitch Jack-to-Pushbeam PinF—Pitch JackG—Strut-to-Pushbeam PinH—Cap Screws and NutI—Strut

Wide-track and narrow-gauge bulldozer frames aresimilar. 850C bulldozer shown.

CAUTION: The approximate weight ofpushbeam is 253 kg (580 lb).

1. Attach hoist to pushbeam. Remove parts (D, E, G, andH) to disconnect pitch jack (F) and remove strut (I).

2. Remove parts (A—C).

3. Disconnect pushbeam from trunnion and remove.Retain shims for assembly.

4. Disassemble and repair pushbeam as needed. (Seeprocedure in this group.)



PN=683

Frames

TX,3240,SS2521 –19–11JUL95–2/3

T61

49A

E–U

N–2

0OC

T88

1—Shim (as required)2—Shim (as required)3—End Cap4—Trunnion5—Cap Screw (2 used)

5. Install pushbeam to trunnion (4). If new trunnion pivothas been installed on pushbeam, shim using following:

Install beam and end cap (3) without shims (1 and 2)and tighten cap screws (5).

Measure gap. Add enough shims to fill gap plus onethin shim.

6. Tighten cap screws (5) to specification.

SpecificationTrunnion Cap-to-Trunnion CapScrew—Torque 950 N•m (700 lb-ft)............................................................

323240

2

TX,3240,SS2521 –19–11JUL95–3/3

T61

49A

F–U

N–2

0OC

T88

A—Blade-to-Pushbeam PinB—Cap Screw and Washer (4 used)C—Retainer Plate (2 used)D—Cap Screw and NutE—Pitch Jack-to-Pushbeam PinF—Pitch JackG—Strut-to-Pushbeam PinH—Cap Screws and NutI—Strut

7. Install beam to blade using parts (A—C). Install asmany shims as possible on inboard side betweenpushbeam and blade mounting pivot to movepushbeam outboard as far as possible. Putmulti-purpose grease on pins before installing.

8. Install parts (D—I) to pushbeam.


PN=684

Frames

3232403

TX,3240,SS2525 –19–11JUL95–1/1

Remove and Install Pitch Jack

T84

48A

X–U

N–0

1MA

Y95

A—GapB—Pitch Jack Socket SectionC—Cap Screws (4 used)D—Pitch JackE—Blade Socket Section

CAUTION: Use a lifting device for heavycomponents.

1. Remove yoke pin and socket end cap screws (C).

2. Remove pitch jack.

IMPORTANT: Clean paint from socket matingsurfaces before assembly.

3. Install pitch jack (D) to blade. Position the socket sothe grease fitting points away from machine. Tightensockets (B and E) without shims. Measure the gap (A)between the sockets. Install the number of shims equalto the gap plus one additional thin shim for themeasured clearance. Tighten cap screws (C) tospecifications.

SpecificationPitch Jack Cap Screw—750C—Torque 550 N•m (400 lb-ft).........................................................................Pitch Jack Cap Screw—850C—Torque 871 N•m (650 lb-ft).........................................................................


PN=685

Frames

323240

4

TX,3240,SS2526 –19–11JUL95–1/1

Remove and Install Struts

T85

16A

G–U

N–0

5JU

L95

A—Screw (8 used), Washer (8 used)B—Shim (as required)C—Socket (2 used)D—Grease Fitting (2 used)E—Pin (2 used)F—Strut (2 used)


1. Remove pin (E) and cap screws (A).

2. Remove strut (F).

NOTE: Struts MUST be adjusted so blade is slightly tothe right.

3. Position blade so measurement between left front oftrack frame and pushbeam is 15—30 mm (0.5—1.0 in.)more than right measurement.

SpecificationLeft Front ofTrackframe-to-Pushbeam—Measurement 15—30 mm (0.5—1.0 in.) more

than right............................................

4. Install pin (E) and socket (C) with grease fitting (D).Install as many solid shims (B) as possible betweenblade and socket. Install strut cap screws withoutshims and tighten evenly. Measure the shim gapbetween the strut socket section and the blade socketsection. Install the number of shims equal to the gapplus one additional thin shim for the measuredclearance. Tighten cap screws (A) to specification.

SpecificationStrut-to-Blade Cap Screw—Torque 542 N•m (400 lb-ft).........................................................................


PN=686

Frames

3232405


PN=687

Frames

323240

6

TX,3240,SS2505 –19–11JUL95–1/2

Disassemble and Assemble Pushbeams, Struts and Pitch Jack

T85

14A

D–U

N–0

7JU

L95


PN=688


Frames

TX,3240,SS2505 –19–11JUL95–2/2

1—Bushing (2 used) 12—Cap Screw 23—Socket 34—Washer (8 used)2—Pivot (2 used) 13—Pin 24—Shim (as required) 37—End (Rod)3—Bushing (2 used) 14—Lock Nut (4 used) 25—Shim (as required) 38—End (Strut)4—Trunnion (2 used) 15—Cap Screw (2 used) 26—Cap Screw (4 used) 39—Rod (2 used)5—Washer (16 used) 16—Pin (2 used) 27—End 40—Jack Assembly6—Step 17—Retainer (2 used) 28—Bushing (4 used) 41—Support (2 used)7—Strap (as required) 18—Cap Screw (8 used) 29—Pivot (2 used) 42—Yoke8—Strap (as required) 19—Socket (2 used) 30—Trunnion 43—Beam9—Cap (2 used) 20—Shim (as required) 31—Cap Screw (4 used) 44—Pin (2 used)10—Cap Screw (4 used) 21—Shim (as required) 32—Cap Screw (8 used) 45—Cap Screw (2 used)11—Lock Nut (4 used) 22—Lubrication Fitting (2 33—Strap (4 used)

used)

Disassemble and assemble parts as shown.

3232407

TX,3240,SS2527 –19–11JUL95–1/1

Blade Pitch Adjustment

T65

08A

W–U

N–1

9MA

Y89

A—Blade Left TiltB—Blade Right Tilt

1. With the machine on a level surface, start engine andraise blade high enough so that the tilt cylinder can bemoved to the end of its stroke in either direction.

2. To get equal tilt and proper blade pitch angle, do thefollowing:

a. With the blade tilted all the way in one direction (Aor B), lower the blade so the lower blade cornertouches the ground.

b. Now measure the distance from the ground to theother raised corner and record the measurement.Repeat this procedure for the other side by tiltingthe blade in the opposite direction.

c. Adjust the pitch jack so you have equal distancesmeasured from the ground.

3. Check hydraulic oil level and add oil as necessary.


PN=689

Frames

323240

8

TX,32,BA2023 –19–30MAY97–1/1

Disassemble and Assemble Lift Cylinder Pivot Sub-frame

T10

9684

–UN

–19J

UN

97

A—Handle (2 used) H—Lock Washer (4 used) O—Bushing (4 used) U—Cap Screw (2 used)B—Grease Fitting (4 used) I—Cap Screw (4 used) P—Cap Screw (2 used) V—Washer (2 used)C—Bushing (2 used) J—Grease Fitting (2 used) Q—Washer (2 used) W—Nut (2 used)D—Bushing (2 used) K—Seal (2 used) R—Bracket (2 used) X—Bracket (2 used)E—Retainer (2 used) L—Yoke (2 used) S—Bushing (2 used) Y—Cap Screw (4 used)F—Washer (2 used) M—Washer (4 used) T—Washer (2 used) Z—Washer (4 used)G—Plate (2 used) N—Cap Screw (4 used)

NOTE: Pivot sub-frame is part of the grille housing.

1. Remove retainers (E) and yokes (L).

2. Remove parts (C, D and K).

3. Install bushings (C and D) using a driver.

4. Install oil seal (K) with lip of seal toward seal driver.

5. Apply multi-purpose grease to yoke shaft. Installyokes (L) and retainers (E) into sub-frame.


PN=690

Group 3260Hydraulic System

DX,TOOLS –19–20JUL95–1/2

Special or Essential Tools

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


3232601

DX,TOOLS –19–20JUL95–2/2

T7976AM –UN–08APR93

Seal Installation Tool . . . . . . . . . . . . . . . . . . . JDG734

Install seals and wiper rings in spool valves.

CED,OUTX547,1198 –19–24JAN00–1/3




CED,OUTX547,1198 –19–24JAN00–2/3

Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . . JT01748

To remove and install reservoirs.

CED,OUTX547,1198 –19–24JAN00–3/3

Cylinder Nut Torque Tool . . . . . . . . . . . . . . . DFT1180

Used to keep cylinder from turning when loosening ortightening the piston nut.


PN=691

Hydraulic System

TX,3260,SS2535 –19–11JUL95–1/1

Other Material

Number Name Use

PT569 (U.S.) John Deere NEVERSEEZ Lubricant Apply to cylinder bushing head end.

TY6305 (U.S.) Clean And Cure PrimerLOCTITE Cleans and cures surfaces prior toTY9485 (Canadian) Products application of sealant.764 (LOCTITE)

TY9371 (U.S.) Thread Lock and Sealer (High Apply to threads of control valveTY9478 (Canadian) Strength)LOCTITE Products spool detent screw and lift cylinder271 (LOCTITE) retaining nut.

323260

2

NEVERSEEZ is a registered trademark of the Emhart Chemical GroupLOCTITE is a registered trademark of Loctite Corp.


PN=692

Hydraulic System

3232603

CED,OUTX547,1199 –19–24JAN00–1/3

Specifications


Hydraulic Pump-to-Hydrostatic Pump Torque 140 N•m (103 lb-ft)Cap Screw

Hydraulic Pump Housing Cap Torque 271 N•m (200 lb-ft)Screws

750C Hydraulic Reservoir Capacity 67 L (18 gal)

750C Hydrostatic Reservoir Capacity 84 L (22 gal)

850C Hydraulic Reservoir Capacity 81 L (21 gal)

850C Hydrostatic Reservoir Capacity 103 L (27 gal)

Reservoir Mounting Cap Screws Torque 320 N•m (236 lb-ft)

Reservoir Mounting Cap Screws Torque 320 N•m (236 lb-ft)

Reservoir Cover Plate Nuts Torque 30 N•m (22 lb-ft)

Dozer Control Valve

Control Valve-to-Tie Rod Nut (7/16 Torque 65 ± 7 N•m (48 ± 5 lb-ft)in.) (2 used)

Control Valve-to-Tie Rod Nut (1/2 Torque 100 ± 10 N•m (74 ± 8 lb-ft)in.)

Control Valve Spool Screws Torque 9 N•m (65 lb-in.)

Circuit Relief Valve Torque 54 N•m (40 lb-ft)

Quick Drop Switch Torque 14 N•m (97 lb-in.)

Cover Plate Cap Screw Torque 9 N•m (65 lb-in.)

Spool Cap Cap Screw Torque 9 N•m (65 lb-in.)

Spool End Screw Torque 9 N•m (65 lb-in.)

System Relief Valve Torque 61 N•m (45 lb-ft)

Circuit Relief Valve Torque 54 N•m (40 lb-ft)


PN=693


Hydraulic System

323260

4

CED,OUTX547,1199 –19–24JAN00–2/3


Quick Drop Valve-to-Grille Housing Torque 88 N•m (65 lb-ft)Cap Screws—Late Machines

Quick Drop Valve-to-Grille Housing Torque 68 N•m (50 lb-ft)Cap Screws—Early Machines

Quick Drop Valve TorqueSpecifications

Quick Drop Valve Plugs Torque 120 N•m (90 lb-ft)

Solenoid Valve-to-Quick Drop Torque 55 N•m (40 lb-ft)Valve

Solenoid Nut Torque 5 N•m (45 lb-in.)

750C Blade Tilt Cylinder-to-Blade Torque 500 N•m (400 lb-ft)Cap Screw

850C Blade Tilt Cylinder-to-Blade Torque 871 N•m (650 lb-ft)Cap Screw

Piston Nut Torque 3,580 N•m (2,640 lb-ft)

Set Screw Torque 57 N•m (42 lb-ft)

Rod Guide Cap Screw Torque 500 N•m (369 lb-ft)

Blade Lift Cylinder-to-Blade Cap Torque 908 N•m (670 lb-ft)Screws

Blade Lift Cylinder Lock Nut Torque 1000 ± 100 N•m (740 ± 74 lb-ft)

Blade Lift Cylinder Spanner Nut Torque 200 N•m (150 lb-ft)(S.N.—831315)

Blade Lift Cylinder Lock Nut Torque 1000 ± 100 N•m (740 ± 74 lb-ft)

Blade Lift Cylinder Spanner Nut Torque 720—840 N•m (530—620 lb-ft)(S.N. 831316—)

Blade Tilt Cylinder Piston Nut Torque 1,952 N•m (1440 lb-ft)

Blade Tilt Cylinder Piston Nut Torque 434 N•m (320 lb-ft)


PN=694


Hydraulic System

CED,OUTX547,1199 –19–24JAN00–3/3


Blade Tilt Cylinder Piston Nut Torque 1,952 N•m (1440 lb-ft)

Blade Tilt Cylinder Piston Nut Torque 434 N•m (320 lb-ft)

3232605


PN=695

Hydraulic System

323260

6

TX,3260,SS2326 –19–11JUL95–1/2

Remove and Install Hydraulic Pump

X98

11–U

N–2

3AU

G88

T85

01A

A–U

N–0

7JU

L95

750C Shown




4. Tilt Cab or ROPS . (See Tilt Cab or ROPS inOperation and Test Manual, Group 9026-25.)

NOTE: The approximate capacity of reservoir is 67 L (18gal) for 750C and 81 L (21 gal) for 850C.

5. Drain hydraulic reservoir.

6. Remove center bottom guard.


7. Disconnect lines (A and C).

CAUTION: The approximate weight of hydraulicpump is 41 kg (90 lb).

8. Attach lifting strap to hydraulic pump and a hoist.Remove cap screws (B) and remove pump withmounting flange O-ring.

9. Install pump, making sure mounting flange O-ring is inplace.

10. Install cap screws (B). Tighten to specification.

SpecificationHydraulic Pump-to-HydrostaticPump Cap Screw—Torque 140 N•m (103 lb-ft).........................................

11. Install lines (A and C).

12. Install center bottom guard.


PN=696


Hydraulic System

TX,3260,SS2326 –19–11JUL95–2/2

13. Fill reservoir. (See Fuels and Lubricants in Group0004.)

14. Lower cab or ROPS. (See Tilt Cab or ROPS inOperation and Test Manual, Group 9026-25.)

3232607

TX,3260,SS2327 –19–01MAR04–1/3

Disassemble and Assemble Hydraulic Pump

T19

8211

–UN

–04M

AR

04

Standard Drive Hydraulic Pump (S.N. —904934)



PN=697

Hydraulic System

323260

8

TX,3260,SS2327 –19–01MAR04–2/3

T19

8208

–UN

–08M

AR

04

Thru Drive Hydraulic Pump (S.N. 904935— )

1—Seal Retainer 5—Seal 9—Thrust Plate (2 used) 13—Dowel Pin (8 used)2—Snap Ring 6—Breather 10—Channel Seal (2 used) 14—Gear Housing3—O-Ring 7—Square Seal (2 used) 11—O-Ring 15—Front Housing4—Seal 8—Gear Shaft Set 12—Rear Housing 16—Stub Shaft Assembly

IMPORTANT: When replacing pump seal kits,machines (S.N —904934) will beconverted to seal arrangement asshown in machines (S.N. 904935— ).

NOTE: If removing and installing plug or winch PTOshaft on machines (S.N. —904934) seeRemove and Install Plug Or Winch PTO ShaftFrom Hydraulic Pump. (Group 3260.)

NOTE: Machines (S.N. 904935— ) entire pumpassembly must be replaced to switch from apump without winch PTO shaft to a pump withwinch PTO shaft.

NOTE: For repair of shaft seals (4 and 5) do steps1—6 only.

1. Remove snap ring (2) and seal retainer (1).

2. Remove seals (4 and 5).

3. Install seal (5) flush with face of recess in housingwith lip toward gear.

4. Install seal (4) flush with counterbore in retainerwith lip away from counterbore.

5. Install O-ring (3) on seal retainer (1). Applypetroleum jelly to lip of seals and O-ring.

IMPORTANT: For seal kit replacements, sealretainer must be installed withcounterbore facing away from pumphousing.

6. Install seal retainer and snap ring (2).


PN=698


Hydraulic System

3232609

TX,3260,SS2327 –19–01MAR04–3/3

7. Put a mark across housings (12, 14, and 15) to aidin assembly.

IMPORTANT: The assembly of gear shaft set,thrust plates, and channel seals iscritical. For correct assembly,identify location of parts.

8. Remove cap screws, nuts and washers andseparate housings. Remove gear shaft set (8) andthrust plates (9).

NOTE: Pump parts (8, 9 and 12—15) are notserviceable. If any of these parts are worn ordamaged, replace pump.

9. Inspect parts for wear or damage. Replace parts asnecessary.

10. Apply clean hydraulic oil on all internal parts.

11. Install thrust plates on the gear shaft set with thechannel seal (10) away from the gear and with theseal toward the pressure side of the pump.

12. Assemble gear housing (14) and front housing(15).

13. Tighten cap screws to specification.

SpecificationHydraulic Pump Housing CapScrews—Torque 271 N•m....................................................................

200 lb-ft

CED,TX14826,12135 –19–25JAN00–1/3

Remove and Install Plug Or Winch PTO ShaftFrom Hydraulic Pump

1. Drain hydraulic reservoir.

CED,TX14826,12135 –19–25JAN00–2/3

T12

5502

B–U

N–2

8OC

T99

Hydraulic Pump With Out Winch

1—Set Screws2—1/4 in. Cap Screws3—Plug

2. Loosen two set screws (1) using a 5/32 in. Allenwrench.

3. Install two 1/4 in. cap screws (2) into plug (3).

4. Turn plug (3) counterclockwise to remove.


PN=699


Hydraulic System

CED,TX14826,12135 –19–25JAN00–3/3

T12

5504

B–U

N–2

8OC

T99

Hydraulic Pump/PTO Shaft Assembly With Winch

4—PTO Shaft5—Retainer

5. Install PTO shaft (4) into pump.

IMPORTANT: When installing retainer over shaft,splines should be covered to protect lipseal on retainer.

6. Install retainer (5) onto shaft.

7. Install two 1/4 in. cap screws into retainer (5).

8. Turn retainer (5) clockwise to install.

9. Tighten set screws.

10. Refill hydraulic reservoir to correct level.

323260

10


PN=700

Hydraulic System

32326011

TX,3260,SS2328 –19–11JUL95–1/2

Remove and Install Hydrostatic and Hydraulic Reservoir

T83

69A

A–U

N–0

7JU

L95

1—Brake Valve-to-Hydrostatic 3—Hydraulic 5—Hydrostatic 6—HydraulicReservoir Reservoir-to-Hydraulic Reservoir-to-Rear Pump Filter-to-Hydraulic

2—Hydrostatic Pump ReservoirReservoir-to-Front Pump 4—Hydrostatic

Reservoir-to-Cooler BypassValve

NOTE: Machines (S.N. 925753— ) have circularcleanout covers.

1. Tilt Cab or ROPS . (See Tilt Cab or ROPS inOperation and Test Manual, Group 9026-25.)

2. Remove service door, reservoir rear access coverand transmission motor rear cover.

Loosen fill caps on reservoirs to release pressure.

3. Drain reservoirs. The approximate capacity ofreservoirs are:

Specification750C Hydraulic Reservoir—Capacity 67 L (18 gal)..........................................................................

750C Hydrostatic Reservoir—Capacity 84 L (22 gal)..........................................................................850C Hydraulic Reservoir—Capacity 81 L (21 gal)..........................................................................850C Hydrostatic Reservoir—Capacity 103 L (27 gal)........................................................................

4. Remove rear work light from reservoir, if equipped.

5. Disconnect lines (1-6)

6. Install JTO1748 Lifting Bracket and hoist.


PN=701


Hydraulic System

323260

12

TX,3260,SS2328 –19–11JUL95–2/2

T85

02A

H–U

N–0

7JU

L95

1—Nut2—Flat Washer3—Lock Washer4—Cap Screw5—Retainer Plate6—Shim7—Cap Screw8—Cap Screw

7. Remove cap screws (4, 7, and 8). Remove reservoir.

CAUTION: The approximate weight of reservoiris 131 kg (288 lb).

8. Set reservoir on sub-frame mounting pads and looselyinstall hardware at all four mounting surfaces. Lineright side of reservoir up with right side of sub-frame.Shim (6) reservoir until reservoir and fuel tank are inalignment. Tighten cap screws to specification.

SpecificationReservoir Mounting CapScrews—Torque 320 N•m (236 lb-ft)..........................................................

9. Install service door, rear work light, rear access paneland transmission rear motor cover.

10. Connect lines.

11. Lower cab or ROPS . (See Tilt Cab or ROPS inOperation and Test Manual, Group 9026-25.)

12. Fill reservoir. See Fuels and Lubricant in Group 0004.

BT40170,000000B –19–05MAR04–1/5

Hydraulic and Hydrostatic ReservoirCleanout Cover Remove and Install (S.N.925753— )

1. Drain reservoir. See 750C Series II CapacitySpecifications, or see 850C Series II CapacitySpecifications. (Operator’s Manual.)

2. Remove components as necessary to adequatelyaccess cleanout cover.


PN=702


Hydraulic System

32326013

BT40170,000000B –19–05MAR04–2/5T

1974

23A

–UN

–02F

EB

04

Hydraulic Reservoir Cleanout Cover

1—Hydraulic Reservoir2—Cap Screw3—Hydraulic Reservoir Cleanout Cover

IMPORTANT: Prevent fluid contamination. Removepaint and debris from sealing edge ofcleanout cover prior to removal.

3. Remove paint from sealing edge of hydraulic reservoircleanout cover (3).

NOTE: Do not fully remove cap screw (2) from innerplate.

4. Loosen cap screw (2) enough to remove cleanoutcover assembly.

IMPORTANT: Avoid fluid contamination. Paint may bechipped if cleanout cover drops intoreservoir. Clean all debris fromreservoir before installing cleanoutcover.

5. Inspect gasket and cover plates for any cuts or loosematerial that could lead to contamination. Repair orreplace parts as necessary.

IMPORTANT: Avoid fluid contamination. Do not allowpaint or debris to enter reservoir.Thoroughly clean if debris entersreservoir.

6. Inspect and remove paint build-up and debris fromreservoir exterior wall.

Inspect locator tabs in reservoir to verify that they areperpendicular to reservoir wall.



PN=703

Hydraulic System

323260

14BT40170,000000B –19–05MAR04–3/5

T19

8245

B–U

N–0

2MA

R04

4—Inner Plate Tabs

NOTE: Cap screw should turn into weld nut withoutresistance. If resistance is felt, inspect weld nutfor debris in threads and clean as necessary.

IMPORTANT: Avoid possible fluid leak. Verify O-ringis installed under head of cap screwbefore assembly.

7. Loosely assemble cleanout cover with gasket and innerplate.

NOTE: To ease installation, do not thread cap screw allthe way into weld nut. Orient as shown.

BT40170,000000B –19–05MAR04–4/5

T19

8238

B–U

N–0

2MA

R04

4—Inner Plate Tab (2 used)5—Upper Locator Tab (2 used)6—Lower Locator Tab (2 used)7—Inner Plate

IMPORTANT: Inner plate must seat flush againstreservoir wall. Damage will result tolocator tabs (5 and 6) if inner plate isinstalled incorrectly.

NOTE: Install inner plate with tabs (4) facing towards topof reservoir. Inner plate must be located betweenupper (5) and lower (6) locator tabs.

8. Install cleanout cover assembly starting with onecorner of inner plate upper tabs.

Rest one tab of inner plate on locator tab (5) androtate inner plate around until entirely inside reservoir.Pull back on cap screw to seat inner plate againstreservoir wall between locator tabs (5 and 6).



PN=704

Hydraulic System

32326015

BT40170,000000B –19–05MAR04–5/5

T19

8239

B–U

N–0

2MA

R04

2—Cap Screw5—Upper Locator Tab (2 used)6—Lower Locator Tab (2 used)

9. Hand tighten cap screw (2) while prying out on gasketand outer plate as shown to ensure that inner platestays seated between locator tabs (5 and 6).

IMPORTANT: Do not use impact gun to tighten capscrew. Damage will result to cleanoutcover assembly.

10. Tighten cap screw to specification.

SpecificationHydraulic Reservoir CleanoutCover Cap Screw—Torque 47 N•m............................................................

35 lb-ft

11. Paint affected areas using TY6522 spray paint.

12. Install components removed to access cleanoutcover.

13. Fill reservoir. See 750C Series II CapacitySpecifications, or see 850C Series II CapacitySpecifications. (Operator’s Manual.)


PN=705

Hydraulic System

323260

16

TX,3260,SS2329 –19–05MAR04–1/2

Disassemble and Assemble Reservoir

T83

67A

O–U

N–0

7JU

L95

1—Cap Screw (2 used) 8—Oil Filler Cap 14—Nut (2 used) 22—Shim (as required)2—Washer (38 used) (S.N. — 9—Gasket (2 used) (S.N. — 15—Washer (5 used) 23—Cap Screw

925752) 925752) 16—Washer (3 used) 24—O-Ring3—Handle 10—Cover Plate (2 used) 17—Cap Screw (2 used) 25—Elbow 90° (2 used) (Outlet4—Reservoir (S.N. —925752) (S.N. —925752) 18—Fitting (Brake Return Port) Ports)

Reservoir (S.N. 925753— ) 11—Nut (36 used) (S.N. — 19—O-Ring (3 used) 26—Plug (2 used)(not shown) 925752) 20—Fitting (Oil Cooler Bypass 27—O-Ring (2 used)

5—O-Ring 12—Elbow (2 used) (S.N. — Return Port) 28—Cap Screw (2 used)6—Plug 925752) 21—Retainer Plate7—Gasket 13—Tube (S.N. —925752)

Level Gauge (S.N.925753— )

NOTE: Cleanout cover (10) shown in illustrationapplies to reservoirs (S.N. —925752). Forcleanout cover repair procedure on machines(S.N. 925789— ) see Hydraulic andHydrostatic Reservoir Cleanout Cover Removeand Install (S.N. 925753— ). (Group 2160.)

1. Disassemble and assemble reservoir as shown.

2. Tighten cap screws (17, 23 and 28) to specification.

SpecificationReservoir Mounting CapScrews—Torque 320 N•m....................................................................

236 lb-ft


PN=706


Hydraulic System

TX,3260,SS2329 –19–05MAR04–2/2

3. Tighten nuts (11) to specification.

SpecificationReservoir Cleanout Cover PlateNuts (S.N. —925752)—Torque 30 N•m...............................................

22 lb-ft

Reservoir Cleanout Cover CapScrew (S.N. 925753— )—Torque 47 N•m......................................................................................

35 lb-ft

32326017

TX,3260,SS2497 –19–11JUL95–1/1

Remove and Install Hydraulic Filter

T85

10A

F–U

N–0

7JU

L95

A—Reservoir-to-Hydraulic Filter LineB—Hydraulic Filter-to-Control ValveC—Cap Screws (4 used)D—Wiring Lead

1. Loosen hydraulic reservoir cap to release pressure inreservoir.

2. Disconnect lines (A and B).

3. Disconnect wiring lead (D).

4. Remove four cap screws (C) and remove filterassembly.


PN=707

Hydraulic System

323260

18TX,3260,SS2498 –19–11JUL95–1/1

Disassemble and Assemble Hydraulic Filter

T73

00A

K–U

N–1

4AU

G90

A—HousingB—PistonC—SpringD—SpringE—Valve

1. Remove filter element.

2. Remove parts (A—E).

3. Clean and inspect parts. If any parts are damaged,replace filter base assembly.

4. Install parts (A—E).

5. Install new filter element.


PN=708

Hydraulic System

32326019

TX,3260,SS2338 –19–11JUL95–1/1

Remove and Install Dozer Control Valve

T83

76A

I–U

N–0

7JU

L95

A—Hand PumpB—Hydraulic Filter BracketC—Control Valve-to-Hydraulic Filter LineD—Control Valve LinkagesE—Valve BracketF—Hydraulic Pump-to-Control Valve LineG—Control Valve LinesH—Cotter PinI—Bracket

1. With engine OFF, operate all hydraulic control valvesto release pressure in the hydraulic system.

NOTE: The approximate capacity of hydraulic reservoir is67 L (18 gal) for 750C and 81 L (21 gal) for 850C.

2. Drain oil from hydraulic reservoir or connect a vacuumpump to reservoir.

3. Tilt cab or ROPS . (See Tilt Cab or ROPS in Operationand Test Manual, Group 9026-25.)

4. Remove cap screws from hand pump (A) and lay handpump to side.

5. Remove cotter pin (H).

6. Remove cap screws and remove bracket (I).

7. Disconnect line (C).

8. Remove cap screws from bracket (B). Lay bracket andfilter to side.

9. Disconnect valve linkages (D), control valve lines (G)and line (F).

CAUTION: The approximate weight of controlvalve is 38.6 kg (85 lbs).

10. Attach a strap and hoist around valve.

11. Remove cap screws from bracket (E) and removevalve.

12. Install valve. Use the following component locationdrawings to connect lines.

13. Install brackets and cap screws. Tighten cap screws.


PN=709

Hydraulic System

323260

20

TX,32,78126 –19–10OCT96–1/1

Component Location—All Hydraulic Dozer

T83

76A

J–U

N–0

7JU

L95

All Hydraulic Dozer

A—Control Valve-to-Hydraulic D—Hydraulic Pump-to-Control F—Valve Rear Port-to-Blade H—Valve Rear Port-to-RightFilter Valve Lift Cylinder Head End Port Angle Cylinder Head

B—Valve Front Port-to-Tilt E—Valve Front Port-to-Left G—Valve Rear Port-to-Tilt End/Left Cylinder Rod EndCylinder Rod End Port Angle Cylinder Head Cylinder Head End Port

C—Valve Front Port-to-Blade End/Right Cylinder RodLift Cylinder Rod End Port End


PN=710

Hydraulic System

32326021

TX,32,78127 –19–10OCT96–1/1

Component Location—Bulldozer Hydraulics

T83

76A

N–U

N–0

7JU

L95

Bulldozer

A—Valve Rear Port-to-Lift B—Valve Front Port-to-Lift C—Valve Front Port-to-Right D—Valve Rear Port-to-Left TiltCylinder Head End Cylinder Rod End Tilt Cylinder Rod End Cylinder Head End


PN=711

Hydraulic System

323260

22

TX,32,78128 –19–10OCT96–1/1

Component Location—Angle Dozer Hydraulics

T83

76A

O–U

N–0

7JU

L95

Angle Dozer

A—Valve Rear Port-to-Lift B—Valve Front Port-to-Lift C—Valve Front Port-to-Right D—Valve Rear Port-to-Left TiltCylinder Head End Cylinder Rod End Tilt Cylinder Head End Cylinder Head End


PN=712

Hydraulic System

32326023

TX03399,0001915 –19–10OCT01–1/1

Component Location—850C (PAT) Blade (S.N. XXXXXX— )

T14

6544

–UN

–12O

CT

01

1—Hose from R.H. Angle 3—Hose from Grille Bulkhead 5—Hose from L.H. Angle 7—Hose from Elbow at GrilleCylinder Head End through C-Frame Cylinder Head End Bulkhead through C-FramePort-to-Bulkhead Plate on Loop-to-Bulkhead Tees on Port-to-Bulkhead Plate on Loop to Tilt Cylinder RodC-Frame C-Frame (2 used) C-Frame End Port

2—Hose from R.H. Angle 4—Hose from Grille Bulkhead 6—Hose from L.H. AngleCylinder Rod End through C-Frame Cylinder Rod End Port-to-Port-to-Bulkhead Plate on Loop-to-Tilt Cylinder Head Bulkhead on C-FrameC-Frame End Port


PN=713

Hydraulic System

323260

24

TX,3260,SS2342 –19–11JUL95–1/4

Disassemble and Assemble Dozer Control Valve

T85

03A

H–U

N–0

7JU

L95



PN=714

Hydraulic System

TX,3260,SS2342 –19–11JUL95–2/4

1—Auxiliary Section 10—Plug 19—Filter 28—Spool Cap2—Blade Tilt Section 11—O-Ring 20—Spool Screw 29—Spring3—Blade Lift Section 12—Sleeve 21—Cover Plate 30—Spring Seat (2 used)4—Cap Screw (2 used) 13—Spool Seal 22—Cap Screw (2 used) 31—Cap Screw (2 used)5—Seal Plate 14—Ball (4 used) 23—Spring Seat 32—Wiper Seal6—Plug 15—Quick Drop Switch 24—Blade Lift Detent Housing 33—Spool Seal7—O-Ring (2 used) 16—Actuator Sleeve 25—Detent Cam 34—O-Ring8—Spring 17—Spring Seat 26—Spring 35—Nut (2 used)9—Unloading Section 18—Spring 27—Spool Screw 36—Nut


32326025


PN=715

Hydraulic System

323260

26

TX,3260,SS2342 –19–11JUL95–3/4

T10

9659

–UN

–19J

UN

97

Bottom View

37—Auxiliary Relief Valve w/Anti-Cavitation (2used)

38—Blade Raise Relief Valve w/Anti-Cavitation39—System Relief Valve40—Blade Lower Relief Valve w/Anti-Cavitation


2. Disassemble and assemble relief valves . (Seeprocedures in this group.)

3. Replace if necessary. When installing the unloadingvalve spool (9), install spool in direction as shown.

4. Apply clean hydraulic oil to all parts and assemblevalve. Tighten control valve nuts (35) and (36) tospecification. Tighten nuts in a even rotation.

Dozer Control Valve—SpecificationControl Valve-to-Tie Rod Nut(7/16 in.) (2 used)—Torque 65 ± 7 N•m (48 ± 5 lb-ft).................................Control Valve-to-Tie Rod Nut (1/2in.)—Torque 100 ± 10 N•m (74 ± 8 lb-ft).....................................................

5. On blade lift section to assemble spool, lubricate allparts with clean hydraulic oil and follow steps (5—10).

IMPORTANT: Cam detent must be installed with rampaway from spring.

6. Install spring (26) and cam detent (25).

7. Install balls (14) using petroleum jelly (one ball per holein spool).

8. Install actuator sleeve (16).

9. Compress cam detent and spring using a punch toseat balls. Release cam detent and spring to hold ballsin place with collar.

10. Install spring seat (17), spring (18) and spring seat(23).

11. Apply thread lock and sealer to threads of spoolscrews (20 and 27). Tighten spool screws tospecification.

SpecificationControl Valve Spool Screws—Torque 9 N•m (65 lb-in.)..............................................................................


PN=716


Hydraulic System

32326027

TX,3260,SS2342 –19–11JUL95–4/4

NOTE: Blade tilt, angle and auxiliary valve sections aresimilar. Circuit reliefs are used in blade lift, angleand auxiliary valve sections.

12. Install relief valves (37—40) and tighten tospecifications.

SpecificationCircuit Relief Valve—Torque 54 N•m (40 lb-ft)...........................................

13. Install quick drop switch (15) and tighten tospecification.

SpecificationQuick Drop Switch—Torque 14 N•m (97 lb-in.)...........................................

14. Install cover plate and spool caps. Tighten capscrews (22 and 31) to specification.

SpecificationCover Plate Cap Screw—Torque 9 N•m (65 lb-in.).....................................Spool Cap Cap Screw—Torque 9 N•m (65 lb-in.).......................................

TX,3260,SS2487 –19–09DEC98–1/2

Installing Valve Seal Kit in Cap End

T76

98A

D–U

N–2

7JA

N97

A—Cap ScrewB—Spool End Cap ScrewC—Spring Seat (2 used)D—SpringE—Seal PlateF—SpoolG—O-RingH—WiperI—SpringJ—End Cap

1. Remove cap end screws (A) with 3/16 in. socket. With1/4 in. Allen wrench, remove spool end screw (B).Remove spring (D) and seal plate (E).

2. With O-ring pick, remove and discard existing wiper (H)and O-ring (G).

3. Thoroughly clean cavity with clean solvent.


PN=717


Hydraulic System

323260

28

TX,3260,SS2487 –19–09DEC98–2/2

T76

77A

A–U

N–2

7JA

N97

A—Nylon SleeveB—SealC—WiperD—Guide

IMPORTANT: Do not damage OD or ID of new sealwhen installing. The JDG734 SealInstallation Tool MUST be used wheninstalling seal (B) and wiper (C).

4. The nylon sleeve (A) is cone shape. The flange of thesleeve must be toward the valve housing. Place thewiper (C) with the flange of wiper toward the valvehousing. Put the seal (B) on top of the wiper. The sealflange must be toward the valve housing. Slide thesleeve over the seal, wiper and guide. Do not force thesleeve on the guide.

5. Install new seal and wiper in valve section.

6. Install new O-ring.

7. Put thread lock and sealer (high strength) on spool endscrew and tighten to specification

SpecificationSpool End Screw—Torque 9 N•m (65 lb-in.)...............................................

8. Install cap end. Put thread lock and sealer (highstrength) on cap screws and tighten to specification.

9. Repeat steps 1 through 7 for each valve section.


PN=718

Hydraulic System

32326029

TX,3260,SS2489 –19–11JUL95–1/2

Installing Valve Seal Kit in Tang End

T76

98A

B–U

N–2

7JA

N97

A—WiperB—O-RingC—SpoolD—Seal PlateE—Machine Screw (2 used)

1. Remove machine screws (E) and seal plate (D).

2. Remove and discard wiper (A) and O-ring (B).



PN=719

Hydraulic System

323260

30

TX,3260,SS2489 –19–11JUL95–2/2

T76

77A

A–U

N–2

7JA

N97

A—Nylon SleeveB—SealC—WiperD—Guide

IMPORTANT: Do not damage OD or ID of new sealwhen installing. The JDG734 SealInstallation Tool MUST be used wheninstalling seal (B) and wiper (C).

3. The nylon sleeve (A) is cone shape. The flange of thesleeve must be toward the valve housing. Place thewiper (C) with the flange of wiper toward the valvehousing. Put the seal (B) on top of the wiper. The sealflange must be toward the valve housing. Slide thesleeve over the seal, wiper and guide. Do not force thesleeve on the guide.

4. Install new seal and wiper in valve section.

5. Install new O-ring.

6. Install seal plate and tighten screws.

IMPORTANT: Check that seal was correctly installedby pushing down on each spool. Springwill return spool to neutral position.

7. Repeat steps 1 through 5 for each valve section.

8. Install valve. (See Remove and Install Control Valve inthis group.)


PN=720

Hydraulic System

32326031

TX,3260,SS2344 –19–11JUL95–1/1

Disassemble and Assemble System ReliefValve

T66

83A

C–U

N–1

8OC

T88

A—Backup Ring (2 used)B—O-RingC—O-RingD—Pilot BodyE—Pilot PoppetF—SpringG—Shim (as required)H—SpoolI—Adjusting CapJ—O-RingK—SpringL—PoppetM—SpoolN—O-RingO—Backup RingP—Poppet SleeveQ—Backup RingR—O-RingS—Relief Valve BodyT—O-Ring

NOTE: Relief valve is not serviceable. If damaged,replace as an assembly.

1. Scribe a line on adjusting cap (I) and pilot body (D).Loosen lock nut and count the number of turns toremove adjusting cap (I).

2. Remove parts (A—T).

3. Inspect poppet (L) for plugged orifice. Inspect pilotpoppet (E) and pilot body (D) for contamination. Cleanfor reassembly. Check remaining parts for wear,plugged ports or damaged O-rings.

4. Assemble valve. Install spring (K) on poppet (L) withtab of spring away from poppet. Install adjusting cap (I)the same number of turns as removed. Tighten locknut to specification.

SpecificationSystem Relief Valve—Torque 61 N•m (45 lb-ft).........................................

5. Check valve pressure setting after installation. (Seeprocedure in Operation and Test Manual, Group9025-25.)


PN=721

Hydraulic System

323260

32TX,3260,SS2345 –19–11JUL95–1/2

Disassemble and Assemble Circuit ReliefValve with Anti-Cavitation

T66

84B

C–U

N–1

8OC

T88

A—CapB—O-RingC—SpringD—O-RingE—Backup RingF—Valve Body

NOTE: Only O-rings are serviceable. If other parts aredamaged, replace as an assembly.

1. Disassemble relief valve as shown.

2. Inspect parts for wear or damage and replace asnecessary.

TX,3260,SS2345 –19–11JUL95–2/2

T70

24A

A–U

N–2

1MA

R89

A—Valve BodyB—Cap

3. Valve body is not adjustable and must be replaced asan assembly.

4. Lubricate all parts with clean hydraulic oil.

IMPORTANT: Relief valve pressure setting is stampedon valve body (A) and on cap (B).Reinstall proper valve body in each cap.Install relief valve in correct valve portto prevent structural damage.

5. Assemble relief valve. Install in housing in proper portand tighten to specification.

SpecificationCircuit Relief Valve—Torque 54 N•m (40 lb-ft)...........................................


PN=722

Hydraulic System

32326033

TX,3260,SS2491 –19–11JUL95–1/2

Remove and Install Quick Drop Valve

T85

06A

O–U

N–0

7JU

L95

A—Valve Rear Port-to-Lift C—Quick Drop Valve Top E—Quick Drop Valve Top F—Quick Drop Valve BottomCylinder Head End Port-to-Left Cylinder Head Port-to-Right Cylinder Head Port-to-Right Cylinder Rod

B—Valve Front Port-to-Lift End End EndCylinder Rod End D—Quick Drop Valve Bottom

Port-to-Left Cylinder RodEnd


CAUTION: To avoid injury from escapingfluid under pressure, stop engine and relievethe pressure in the system beforedisconnecting or connecting hydraulic orother lines. Tighten all connections beforeapplying pressure.

2. With engine OFF, operate all hydraulic controlvalves to release pressure in the system.

3. Disconnect lines (A—F).

4. Remove cap screws, washers and valve.

5. Disassemble and assemble valve . (See proceduresin this group.)

6. Install valve and connect lines. Solenoid wiringmust be pointing down.

IMPORTANT: Hand tighten mounting cap screws.Using an air gun to tighten capscrews could cause valve spool tostick.

7. Install cap screws and washers. Tighten tospecification.


PN=723


Hydraulic System

TX,3260,SS2491 –19–11JUL95–2/2

SpecificationQuick Drop Valve-to-GrilleHousing Cap Screws—LateMachines—Torque 88 N•m (65 lb-ft)....................................................

For early machines a cap screw, washer and nut areused. Tighten nut to specification.

SpecificationQuick Drop Valve-to-GrilleHousing Cap Screws—EarlyMachines—Torque 68 N•m (50 lb-ft)....................................................

323260

34


PN=724

Hydraulic System

32326035

TX,3260,SS2492 –19–11JUL95–1/2

Disassemble and Assemble Quick Drop Valve

T85

10A

B–U

N–0

7JU

L95

A—Plug E—O-Ring I—O-Ring L—SolenoidB—O-Ring F—Plug J—Valve M—WasherC—Spool and Valve Body G—O-Ring K—Washer N—NutD—Spring H—Backup Rings

CAUTION: Disassemble quick drop valvefrom solenoid end only. There is a springunder compression. Avoid personal injury bygradually releasing spring force.

1. Disassemble parts (A—N).

2. Inspect quick drop valve for wear or signs ofdamage.

3. Apply hydraulic oil to all internal parts andassemble using new O-rings.

4. Install spool and spring (D) in valve body (C) on thesame end as the solenoid valve (J).

Quick Drop Valve Torque Specifications—SpecificationQuick Drop Valve Plugs—Torque 120 N•m (90 lb-ft).....................................................................


PN=725


Hydraulic System

TX,3260,SS2492 –19–11JUL95–2/2

Solenoid Valve-to-Quick DropValve—Torque 55 N•m (40 lb-ft)..........................................................Solenoid Nut—Torque 5 N•m (45 lb-in.)...............................................

323260

36

TX,3260,SS2528 –19–04OCT01–1/1

Remove and Install Tilt Cylinder—OutsideDozer

X98

11–U

N–2

3AU

G88

T84

48A

Y–U

N–0

1MA

Y95

A—Cap Screw (4 used)B—Shim Gap (As Required)C—Blade Socket SectionD—Cylinder Socket SectionE—Tube GuardF—Grease Fitting


1. Remove guard and disconnect lines.

CAUTION: Use a lifting device for heavycomponent.

2. Attach a hoist to cylinder.

3. Remove cap screws (A) and head end cylinder pin.Remove cylinder and retain shims for reassembly.

4. Install cylinder to pushbeam so tube guard is undercylinder.

5. Rotate socket section (C) so grease fitting (F) is facingout.

6. Install tilt cylinder to blade without shims and tightencap screws (A) evenly. Measure the shim gap (B)between the blade and cylinder socket sections (C andD). Install the number of shims equal to the gap plusone additional thin shim for the measured clearance.

7. Tighten cap screws (A) to specifications.

Specification750C Blade Tilt Cylinder-to-BladeCap Screw—Torque 500 N•m (400 lb-ft)....................................................850C Blade Tilt Cylinder-to-BladeCap Screw—Torque 871 N•m (650 lb-ft)....................................................

8. Connect lines and install guard.


PN=726

Hydraulic System

32326037

CED,OUTX547,1192 –19–04OCT01–1/1

Cross Section of a 180 Series (Tilt) Cylinder—Outside Dozer

T12

7587

–UN

–26J

AN

00

1—Piston Nut 5—Piston 9—Rod Wiper Seal 13—O-Ring2—Shim 6—Rod Guide 10—U-Cup Seal 14—Set Screw3—Wear Ring 7—Cap Screw (8 used) 11—Buffer Seal 15—Ball4—Seal 8—Rod Bearing 12—Backup Ring

CED,OUTX547,1193 –19–04OCT01–1/7

Disassemble Tilt Cylinder—Outside Dozer

T12

7589

B–U

N–1

9JA

N00

1—Cap Screw (8 used)

NOTE: Disassembly of cylinder is shown using theJT30043 Cylinder Service Stand.

1. Drain oil from cylinder.

2. Pin head end of cylinder to cylinder service stand.

3. Pull rod out so piston is against rod guide.

4. Support weight of rod using a lifting strap.


6. Pull rod assembly from barrel.


PN=727


Hydraulic System

CED,OUTX547,1193 –19–04OCT01–2/7

T12

7590

B–U

N–1

9JA

N00

323260

38

1—DFT1180 Cylinder Nut Torque Tool

7. Install rod end into tool (1). Slide tool and cylinder rodend into cylinder service stand.

CED,OUTX547,1193 –19–04OCT01–3/7

T12

7591

B–U

N–1

9JA

N00

1—Set Screw

8. Remove set screw (1) and steel ball from piston nut.

CED,OUTX547,1193 –19–04OCT01–4/7

T12

7593

B–U

N–1

9JA

N00

IMPORTANT: To avoid gouging side of nut or tappedhole for set screw, install piece of steelflat stock between nut and cap screw.The flat stock should measure 38 x 51 x6.4 mm (1.5 x 2.0 x 0.25 in.).

9. Tighten cap screw (1).

10. Loosen nut (2) by turning counterclockwise.


PN=728


Hydraulic System

CED,OUTX547,1193 –19–04OCT01–5/7

T12

7594

B–U

N–1

9JA

N00

32326039

1—Nut2—Piston

11. Remove nut (1), shim, and piston (2). The shim restsbetween piston and nut. If piston is tight on shank,use three-jaw puller.

CED,OUTX547,1193 –19–04OCT01–6/7

T12

7596

B–U

N–1

9JA

N00

1—Rod Guide

12. Protect rod shank and threads by wrapping withheavy tape.

13. Remove rod guide (1) using a twisting motion.Remember to support its weight upon removal andavoid contact with the rod shank.

14. Remove seals and bearings from rod guide andpiston.

15. Inspect piston and inside of rod guide for wear,scratches, and nicks that may cut or damage a sealor wear ring. If possible, remove scratches and nicksusing emery cloth. Replace parts as necessary.

CED,OUTX547,1193 –19–04OCT01–7/7

T12

7597

B–U

N–1

9JA

N00

1—Pin Bushings2—Dust Seals

16. Inspect pin bushings (1) and dust seals (2) for wearor damage. Replace as necessary.

17. Inspect rod surface and inside of barrel for scratchesor wear. If possible, remove scratches and nicksusing emery cloth. Replace parts as necessary.


PN=729

Hydraulic System

CED,OUTX547,1194 –19–04OCT01–1/9

Assemble Tilt Cylinder—Outside Dozer

T12

7597

B–U

N–1

9JA

N00

323260

40

1—Pin Bushings2—Dust Seals

IMPORTANT: All parts must be thoroughly cleanedand dried prior to reuse. Anycontamination can lead to leakageproblems and part damage.

NOTE: Assembly of cylinder is shown using the JT30043Cylinder Service Stand.

1. Install pin bushings (1) and dust seals (2) if they arebeing replaced. Center them in bores.



PN=730

Hydraulic System

32326041

CED,OUTX547,1194 –19–04OCT01–2/9

T12

7598

–UN

–19J

AN

00T

1275

99–U

N–1

9JA

N00

Bending Method

1—Rod Guide2—Wiper Seal3—U-Cup Seal4—Rod Bearing5—Backup Ring6—Backup Ring7—O-Ring8—Bending Method


NOTE: Use new parts from seal kit when assemblingcylinder.

2. Install backup ring (6) and O-ring (7).

3. Install buffer ring and buffer backup ring (5).

4. Install rod bearing (4) into its groove.

5. Install U-cup seal (3) with lip toward rod bearing (4)using the bending method.

6. Press wiper seal (2) in groove so lip is toward outsideof cylinder. Be sure that seal is bottomed on groove.

7. Wrap heavy tape around rod shank and threads toprotect seals during assembly. Coat seals andbearings with a light coat of clean hydraulic oil.

8. Install rod guide (1) on rod using a twisting motion.



PN=731

Hydraulic System

323260

42

CED,OUTX547,1194 –19–04OCT01–3/9

T12

7601

–UN

–19J

AN

00T

1276

02B

–UN

–19J

AN

00

1—Piston2—Cap Seal3—Wear Ring4—Seal Expander5—Backup Ring6—Plastic Tie Band


9. Install seal expander (4) into middle groove of piston.

NOTE: Cap seal can be made more pliable by warming itwith your hands or by putting seal in hot water forapproximately five minutes.

Once started, install cap seal as quickly aspossible to keep the amount of time seal isstretched to a minimum.

10. Push cap seal (2) on end of piston into wear ringgroove.

11. Install a plastic tie band (6) around cap seal (2) withthe smooth side against seal.

12. Pull cap seal across land into position over sealexpander (4) using plastic tie band.

13. Install a backup ring (5) on each side of cap seal.

14. Install wear ring (3). Some pistons may have wearrings on each side of middle groove.



PN=732

Hydraulic System

32326043

CED,OUTX547,1194 –19–04OCT01–4/9

T63

96A

C–U

N–2

7OC

T88

15. Check cap seal. Seal must fit tight against O-ring andnot turn.

16. Shrink cap seal to its original size using a ringcompressor or a plastic tie band and hose clamp.

When using a ring compressor, put a piece of shimstock between cap seal and compressor at the jointso it does not damage seal.

When using a plastic tie band and hose clamp, grinda taper on one end of tie band. Install tie band withthe taper against cap seal. Before tightening the hoseclamp, check to be sure tie band is under hose clampall around piston.

CED,OUTX547,1194 –19–04OCT01–5/9

T12

7605

–UN

–19J

AN

00

1—Piston2—Rod3—Shim4—Nut

17. Install piston (1) so flat side is toward rod (2).

18. Install shim (3) into counterbore of piston.

19. Install nut (4).



PN=733

Hydraulic System

CED,OUTX547,1194 –19–04OCT01–6/9

T12

7606

B–U

N–1

9JA

N00

323260

44

1—Cap Screw2—Nut

IMPORTANT: To avoid gouging side of nut or tappedhole for set screw, install piece of steelflat stock between nut and cap screw.The flat stock should measure 38 x 51 x6.4 mm (1.5 x 2.0 x 0.25 in.).

20. Tighten wrench cap screw (1).

21. Tighten nut (2) to 3,580 N•m (2,640 lb-ft).

SpecificationPiston Nut—Torque 3,580 N•m (2,640 lb-ft)...............................................

CED,OUTX547,1194 –19–04OCT01–7/9

T12

7591

B–U

N–1

9JA

N00

1—Set Screw

22. Install steel ball and set screw (1). Tighten set screwto 57 N•m (42 lb-ft).

SpecificationSet Screw—Torque 57 N•m (42 lb-ft).........................................................

23. Stake set screw in two places 90° from previousstake marks.



PN=734

Hydraulic System

CED,OUTX547,1194 –19–04OCT01–8/9

HC

D10

52–U

N–1

6SE

P98

24. Apply clean hydraulic oil to piston and seals. Attachhoist to rod using a lift strap.

IMPORTANT: To prevent contamination and leakage,make sure rod assembly is clean.

25. Carefully install rod assembly into barrel.

32326045

CED,OUTX547,1194 –19–04OCT01–9/9

T12

7589

B–U

N–1

9JA

N00

1—Cap Screw (8 used)

26. Put oil on threads and install eight cap screws (1).Snug cap screws to 20 N•m (15 lb-ft). Then tighten tospecification.

SpecificationRod Guide Cap Screw—Torque 500 N•m (369 lb-ft).................................

27. Remove and replace bushing in head end ifnecessary. Apply John Deere NEVERSEEZ

lubricant, or an equivalent, to bushing.

NEVERSEEZ is a registered trademark of Emhart Chemical Group.

TX,3260,SS2530 –19–08OCT01–1/3

Remove and Install Blade Lift Cylinder—Outside Dozer

T60

43B

V1

–UN

–20O

CT

88

A—CapB—Shims

NOTE: Cylinders on the 750C and 850C are similar. The850C lift cylinder is shown.

1. Remove cap screws and cap (A) to disconnect cylinderfrom blade. Keep shims (B) with cap for assembly.


PN=735


Hydraulic System

323260

46

TX,3260,SS2530 –19–08OCT01–2/3

X98

11–U

N–2

3AU

G88

T85

16A

H–U

N–0

7JU

L95

A—Line from Quick Drop Valve-to-Cylinder RodEnd Junction

B—Line from Quick Drop Valve-to-Cylinder RodEnd

C—Line from Rod End Junction-to-Cylinder HeadEnd


2. Operate all hydraulic control valves to release pressurein the hydraulic system.

3. Disconnect lines (A—C). Plug all openings.


4. Install a chain and hoist to cylinder. Remove capscrews.

IMPORTANT: Yoke caps are matched to yoke and arenumbered 1 and 2. Keep as a set.

5. Remove cylinder.

6. Install cylinder, yoke caps and cap screws. Tighten capscrews.

7. Connect lines (A—C). Extend rod to blade.

TX,3260,SS2530 –19–08OCT01–3/3

T60

43B

V1

–UN

–20O

CT

88

A—CapB—Shims

8. Connect cylinder to blade without shims. Tighten capscrews just tight enough so gap is equal and socket istight on ball.

9. Measure gap. Add enough shims to fill gap plus a thinshim to allow clearance for ball.

10. Install and tighten cap screws to specification.

SpecificationBlade Lift Cylinder-to-Blade CapScrews—Torque 908 N•m (670 lb-ft)..........................................................


PN=736

Hydraulic System

32326047

TX,32,78129 –19–10OCT96–1/2

Disassemble and Assemble Blade Lift Cylinder (S.N.—831315 )

T80

69A

B–U

N–0

8SE

P93

Blade Lift Cylinder

1—Barrel 8—Seal 15—Seal 23—Needle Roller2—Lock Nut 9—Rod 16—Wear Ring (2 used) 24—Piston3—Piston (2 used) 10—Wear Ring 18—Cap Screw (2 used) 25—O-Ring4—Rod Guide 11—Ring 19—O-Ring (2 used) 26—Seal5—Seal 12—Backup Ring 20—Ball (8 used) 27—Cap Screw (2 used)6—Backup Ring 13—O-Ring 21—Spring (4 used) 28—Lock Washer (2 used)7—Nut 14—Seal 22—Sleeve (4 used) 29—End


PN=737


Hydraulic System

TX,32,78129 –19–10OCT96–2/2

NOTE: Key (5) is not used in this application.

Disassemble and assemble cylinder as shown.

Lubricate lock nut (2) with clean hydraulic oil. Tightenlock nut to specification.

SpecificationBlade Lift Cylinder Lock Nut—Torque 1000 ± 100 N•m (740 ± 74 lb-ft)...............................................

Tighten nut (7) to specification.

SpecificationBlade Lift Cylinder Spanner Nut(S.N.—831315)—Torque 200 N•m (150 lb-ft)......................................

Install backup rings (6 and 12) with radius toward seal.

323260

48


PN=738

Hydraulic System

32326049


PN=739

Hydraulic System

323260

50

TX,32,BA2024 –19–30MAY97–1/2

Disassemble and Assemble Blade Lift Cylinder—Outside Dozer (S.N. 831316— )

T10

9672

–UN

–19J

UN

97


PN=740


Hydraulic System

TX,32,BA2024 –19–30MAY97–2/2

1—Barrel 8—Seal 15—Seal 21—Needle Roller2—Lock Nut 9—Rod 16—Wear Ring (2 used) 22—Piston3—Piston (2 used) 10—Wear Ring 17—O-Ring (2 used) 23—O-Ring4—Rod Guide 11—Retaining Ring 18—Ball (8 used) 24—Cap Screw (2 used)5—Seal 12—Backup Ring 19—Spring (4 used) 25—Lock Washer (2 used)6—Retaining Ring 13—O-Ring 20—Sleeve (4 used) 26—End Cap7—Nut 14—Seal

Disassemble and assemble lift cylinders as shown.

Lubricate lock nut (2) with clean hydraulic oil. Tightenlock nut to specification.

SpecificationBlade Lift Cylinder Lock Nut—Torque 1000 ± 100 N•m (740 ± 74 lb-ft)...............................................

Install backup rings (6 and 12) with radius toward seal.

Carefully apply thread lock and sealer (high strength)to threads of nut (7). Tighten nut to specification.

SpecificationBlade Lift Cylinder Spanner Nut(S.N. 831316—)—Torque 720—840 N•m (530—620 lb-ft)..................

32326051


PN=741

Hydraulic System

323260

52

CED,TX14826,12132 –19–08OCT01–1/2

Remove and Install Tilt Cylinder For (PAT) Six-Way Blade 850C (S.N. —XXXXXX)

T12

7437

–UN

–21J

AN

00

1—Cylinder Rod 7—Cylinder Head 13—Not Used 18—Packing2—Barrel 8—Piston Nut 14—Rod Wiper 19—O-Ring3—Ball Bushing (2 used) 9—Head Bolt (4 used) 15—O-Ring 20—Backup Ring (2 used)4—Internal Snap Ring (4 used) 10—Flat Washer (4 used) 16—Backup Ring 21—Piston Seal5—Grease Fitting (2 used) 11—Piston Washer 17—Rod Wear Ring 22—Piston Wear Ring6—Piston 12—Internal Snap Ring



PN=742

Hydraulic System

32326053

CED,TX14826,12132 –19–08OCT01–2/2

X98

11–U

N–2

3AU

G88





SpecificationBlade Tilt Cylinder Piston Nut—Torque 1,952 N•m (1440 lb-ft)....................................................................

Tighten cap screws (9) to specification.

SpecificationBlade Tilt Cylinder Piston Nut—Torque 434 N•m (320 lb-ft).........................................................................


PN=743

Hydraulic System

323260

54

CED,TX14826,12132 –19–13JAN00–1/2

Remove and Install Angle Cylinder For (PAT) Six-Way Blade 850C (S.N. —XXXXXX)

T12

7440

–UN

–21J

AN

00

1—Barrel 6—Piston Nut 11—Rod Wiper 16—O-Ring2—Rod End 7—Head Blot (4 used) 12—O-Ring 17—Backup Ring3—Head End 8—Washer (4 used) 13—Backup Ring 18—Piston Seal4—Piston 9—Head Plug (2 used) 14—Rod Wear Ring 19—Piston Wear Ring5—Piston Washer (2 used) 10—Internal Snap Ring 15—Packing 20—Welded Bracket



PN=744

Hydraulic System

32326055

CED,TX14826,12132 –19–13JAN00–2/2

X98

11–U

N–2

3AU

G88





SpecificationBlade Tilt Cylinder Piston Nut—Torque 1,952 N•m (1440 lb-ft)....................................................................

Tighten cap screws (9) to specification.

SpecificationBlade Tilt Cylinder Piston Nut—Torque 434 N•m (320 lb-ft).........................................................................


PN=745

Hydraulic System

TX03399,0001911 –19–08OCT01–1/7

Disassemble 120 Series Blade Tilt (PAT)(S.N. XXXXXX— ) and Lift Cylinder (PAT)(S.N. XXXXXX— )

T61

90A

S–U

N–1

9OC

T88

IMPORTANT: Extend rod to remove oil or air betweenthe rod piston and rod guide. Excessiveamount of trapped oil or air will forceseals to expand making disassemblymore difficult.

1. Extend rod so rod piston is approximately 25.4 mm (1in.) from rod guide.

323260

56

TX03399,0001911 –19–08OCT01–2/7

T61

19A

L–U

N–1

9OC

T88

2. Make a mark on rod guide and spanner nut (A) to aidin assembly.

NOTE: If nut and rod guide turn as an assembly, putcylinder in a vise. Vise jaws must contact cylinderbarrel behind nut and over rod guide area.Tighten vise just enough to hold rod guide.

3. Remove nut using adjustable spanner wrench or bluntchisel and a hammer.

TX03399,0001911 –19–08OCT01–3/7

T61

19A

M–U

N–1

2AP

R91

NOTE: Filler rings (used for disassembly only) areinstalled between spanner nut and rod guide toaid in disassembly. Filler rings are provided in thecylinder bore seal kit.

4. Move rod guide rearward, using a wooden dowel orbrass drift, just enough to remove retaining ring (A).Remove retaining ring. Do not damage rod guidethreads or seal.



PN=746

Hydraulic System

TX03399,0001911 –19–08OCT01–4/7

T61

19A

N–U

N–1

9OC

T88

NOTE: Rod piston assembly removed for illustrationpurposes only.

5. Install filler ring in snap ring groove.

6. Remove rod and piston assembly.

32326057

TX03399,0001911 –19–08OCT01–5/7

T61

72B

Q–U

N–1

9OC

T88

A—NutB—PistonC—Wear RingD—Cap Seal Assembly

7. Remove nut (A) to remove piston (B).

8. Remove wear ring (C) and cap seal assembly (D).

9. Remove O-ring from rod on lift cylinder only.

TX03399,0001911 –19–08OCT01–6/7

T61

19A

K–U

N–1

9OC

T88A—Rod Guide

B—Buffer SealC—O-RingD—Backup RingE—SealF—Wear RingG—Seal

10. Remove rod guide (A).

11. Remove O-ring (C), backup ring (D), seals (B, E andG) and wear ring (F).



PN=747

Hydraulic System

TX03399,0001911 –19–08OCT01–7/7

T61

19A

O–U

N–1

9OC

T88

12. Inspect retaining ring groove. If necessary, cleangroove of nicks or burrs.

323260

58


PN=748

Hydraulic System

32326059

TX03399,000190F –19–08OCT01–1/1

Cross Section of 120 Series Blade Lift (PAT) (S.N. XXXXXX—) and Tilt Cylinder (PAT)(S.N. XXXXXX— )

T14

6496

–UN

–16O

CT

01

1 —Nut 6—Nut 11—Backup Ring 15—Backup Ring (2 used)2—Wear Ring 7—Wiper Seal 12—O-Ring 16—Cap Seal3—Barrel 8—Rod 13—Rod Guide 17—O-Ring (Lift Cylinder Only)4—Buffer Seal 9—Wear Ring 14—Seal Expander 18—Piston5—Retaining Ring 10—Rod Seal


PN=749

Hydraulic System

TX03399,0001912 –19–08OCT01–1/12

Assemble 120 Series Blade Tilt (PAT) (S.N.XXXXXX—) and Lift Cylinder (PAT) (S.N.XXXXXX— )

T61

22A

A–U

N–1

9OC

T88

1. Install wiper seal. Push seal to bottom of bore.

323260

60

TX03399,0001912 –19–08OCT01–2/12

T13

3845

–UN

–27S

EP

00

1—Wiper Seal2—Wear Ring3—Seal4—Seal5—Backup Ring6—Rod Guide7—O-Ring8—Backup Ring

2. Install seals (3 and 4).

3. Install wear ring (2).

4. Install backup ring (8) and O-ring (7).

TX03399,0001912 –19–08OCT01–3/12

T61

22A

B–U

N–1

9OC

T88

IMPORTANT: To prevent damage of cap seal duringassembly, the lands on piston must beclean and free of nicks or burrs.

5. Inspect the piston lands. If necessary, clean lands ofany nicks or burrs that can cut cap seal.


PN=750


Hydraulic System

TX03399,0001912 –19–08OCT01–4/12

T61

22A

C–U

N–0

6AU

G90

6. Install seal expander by pushing seal expander ontoend of piston.

32326061

TX03399,0001912 –19–08OCT01–5/12

T61

22A

E–U

N–1

9OC

T88

NOTE: The cap seal can be made more pliable bywarming it with your hands or by putting seal inhot water for approximately 5 minutes.

Once started, install cap seal as quickly aspossible to keep the amount of time that seal isstretched to a minimum.

7. Install a plastic tie band around cap seal with thesmooth side against the cap seal.

8. Using the plastic tie band, pull cap seal across thepiston land and into position over seal expander.



PN=751

Hydraulic System

323260

62TX03399,0001912 –19–08OCT01–6/12

T61

26A

O–U

N–1

9OC

T88

A—Backup Ring (2 used)B—RadiusC—Cap SealD—Seal Expander

IMPORTANT: For proper fit, the backup rings must beinstalled with the radius toward sealexpander.

9. Install backup rings (A) with radius (B) toward sealexpander (D).

10. Check if cap seal is loose; seal must fit tight againstseal expander and not turn. If seal can be turned, ithas been stretched too much and can be damagedduring assembly into barrel.

TX03399,0001912 –19–08OCT01–7/12

T86

565

–UN

–09N

OV

88

11. If necessary, shrink cap seal to its original size usinga ring compressor or a plastic tie band (A) and hoseclamp (C).

When using a ring compressor, put a piece of shimstock between cap seal and compressor at the jointso it does not damage seal.

When using a plastic tie band and hose clamp, grinda taper (B) on one end of tie band. Install tie bandwith the taper against cap seal. Before tightening thehose clamp, tie band must be under hose clamp allaround piston.


PN=752


Hydraulic System

TX03399,0001912 –19–08OCT01–8/12

T61

22A

F–U

N–1

9OC

T88

12. Install wear ring.

13. Install O-ring on rod (lift cylinder only).

32326063

TX03399,0001912 –19–08OCT01–9/12

T61

72B

P–U

N–1

9OC

T88

14. Install spanner nut, retaining ring, rod guide, andpiston assembly on rod.

15. Apply cure primer, then thread lock and sealer (highstrength) to threads of rod.

16. Install and tighten piston nut:

Lift Cylinder (PAT)—SpecificationLift Cylinder Piston Nut—Torque 1000 N•m (738 lb-ft)..............................

Tilt Cylinder (PAT)—SpecificationTilt Cylinder Piston Nut—TorqueTurn 475 N•m (350 lb-ft) + 1/8 (45°)

turn...........................................................

TX03399,0001912 –19–08OCT01–10/12

T61

22A

H–U

N–1

9OC

T88

IMPORTANT: To prevent seal damage, the barrel,piston, and rod must be in alignmentduring installation.

17. Apply clean hydraulic oil to seals and chamfer ofbarrel.

18. Carefully push piston and rod guide into barrel. Keeppiston and rod guide together.



PN=753

Hydraulic System

TX03399,0001912 –19–08OCT01–11/12

T61

33A

E–U

N–2

7OC

T88

19. Push rod guide into barrel just enough to installretaining ring. Install retaining ring.

20. Pull rod guide against retaining ring.

21. Apply a light film of oil to ID of barrel at void betweenrod guide and spanner nut to help minimize rust.

323260

64

TX03399,0001912 –19–08OCT01–12/12

T61

19A

R–U

N–2

7OC

T88

22. Apply cure primer, then thread lock and sealer (highstrength) to spanner nut and rod guide threads.

IMPORTANT: The filler ring is used for disassemblypurposes only and must not beinstalled between rod guide andspanner nut during assembly.

23. Install spanner nut. Tighten nut until rod guide andnut marks (made before disassembly) align. Makesure spanner nut is tight.


PN=754

Hydraulic System

32326065

TX03399,0001913 –19–09OCT01–1/3

Disassemble 125 Series Blade AngleCylinder (PAT) (S.N. XXXXXX— )

T10

7241

–UN

–15F

EB

97

JT07289 Spanner Wrench

NOTE: The JT07289 Spanner Wrench must be attachedparallel to the JT02004 torque wrench (orequivalent) to provide a 2:1 multiplier. Torquereading will be half of actual torque.)

1. Put a mark (A) across rod guide and barrel to aid inassembly.

2. Loosen the jam nut using JT07289 spanner wrench.

3. Remove rod guide from barrel by rotatingcounterclockwise (viewed from rod end of cylinder).

TX03399,0001913 –19–09OCT01–2/3

T61

72B

Q–U

N–1

9OC

T88

A—NutB—PistonC—Wear RingD—Cap Seal

4. Remove nut (A) or cap screw with washer.

5. Remove piston (B), piston wear ring (C), and seals (D).

6. Remove spring and cushion valve on the boomcylinder.

7. Remove rod guide.

8. Remove O-ring, backup ring, rod seals, and rod wearring.


PN=755


Hydraulic System

TX03399,0001913 –19–09OCT01–3/3

T61

19A

O–U

N–1

9OC

T88

9. Inspect end of barrel. If necessary, remove nicks andburrs from the end of the barrel.

10. Thoroughly clean all components.

323260

66


PN=756

Hydraulic System

32326067

TX03399,000190E –19–08OCT01–1/1

Cross Section of 125 Series Blade Angle Cylinder (PAT) (S.N. XXXXXX— )

T14

6490

–UN

–12O

CT

01

1—Nut 6—Cap Seal 11—U-Cup Seal 16—Rod2—Ring (Not Serviced) 7—Piston Seal Expander 12—Rod Wiper Seal 17—Rod Guide3—Orifice (Not Serviced) 8—Piston 13—Nut 18—O-Ring4—Piston Wear Ring 9—Buffer Seal 14—Back-up Ring 19—Barrel5—Back-up Ring (2 used) 10—Wear Ring 15—O-Ring Seal


PN=757

Hydraulic System

323260

68

TX03399,0001914 –19–09OCT01–1/10

Assemble 125 Series Blade Angle Cylinder(PAT) (S.N. XXXXXX— )

T11

8575

–UN

–19N

OV

98

A—Inner Rod SealB—Wear RingC—Outer Rod SealD—Wiper SealE—RodF—Rod GuideG—O-RingH—Back-Up RingI—O-RingJ—BarrelK—Nut

1. Install seals and backup ring into rod guide (F):

a. Install rod wear ring (B).

b. Install inner rod seal (A) with lip of seal towardinside (oil side) of cylinder.

c. Install inner rod seal backup ring in notch provided.

d. Install outer rod seal (C) with sealing lip towardinside (oil side) of cylinder.

e. Install wiper seal (D) with extended lip towardoutside (air side) of cylinder. Install until metal ringis flush with the outer end of guide using care not todamage the extended sealing lip.

f. Install O-ring (G) and backup ring (H) in orientationshown.

TX03399,0001914 –19–09OCT01–2/10

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.

2. Inspect the piston lands. If necessary, clean the landsof any nicks or burrs that can cut the piston seal.


PN=758


Hydraulic System

TX03399,0001914 –19–09OCT01–3/10

T61

22A

C–U

N–0

6AU

G90

3. Install seal expander by pushing seal expander ontoend of piston.

32326069

TX03399,0001914 –19–09OCT01–4/10

T61

22A

E–U

N–1

9OC

T88

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.

4. Install a plastic tie band around cap seal with thesmooth side against the cap seal.

5. Using the plastic tie band, pull cap seal across pistonland and into position over seal expander.



PN=759

Hydraulic System

323260

70TX03399,0001914 –19–09OCT01–5/10

T61

26A

O–U

N–1

9OC

T88

A—Backup Ring (2 used)B—RadiusC—Cap SealD—Seal Expander

IMPORTANT: For proper fit and operation, the backuprings must be installed with the radiustoward seal expander.

6. Install backup rings with radius toward seal expander.

7. 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.

TX03399,0001914 –19–09OCT01–6/10

T86

565

–UN

–09N

OV

88

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 it original size if leftfor a minimum of 8 hours before installingassembly into barrel.

8. If necessary, shrink cap seal to its original size using aring compressor or plastic tie band and a hose clamp.


PN=760


Hydraulic System

TX03399,0001914 –19–09OCT01–7/10

T61

22A

F–U

N–1

9OC

T88

9. Install wear ring.

32326071

TX03399,0001914 –19–09OCT01–8/10

T61

49A

G–U

N–1

9OC

T88

10. Wrap light colored tape around socket being used totighten piston nut. Make several marks on socket tothe appropriate additional torque turn specification.



PN=761

Hydraulic System

323260

72

TX03399,0001914 –19–09OCT01–9/10

T61

72B

R–U

N–1

9OC

T88

11. Install assembled rod guide onto rod.

12. Apply cure primer, then thread lock and sealer (highstrength) to rod threads.

13. Install piston nut and tighten to specification using thefollowing directions.

14. Fasten a piece of wire to the piston rod using tape.Bend the wire over the piston so it points to one ofthe marks on the taped socket. (The wire is used as astationary pointer.)

Angle Cylinder—SpecificationAngle Cylinder Piston Nut—Torque Turn 475 N•m (350 lb-ft) + 1/8 (45°)...............................................

15. Apply cure primer, then thread lock and sealer (lowstrength) to barrel threads that will be under jam(spanner) nut.

16. Install jam (spanner) nut all the way onto barrel.

17. Install O-ring into gap in the barrel threads.



PN=762

Hydraulic System

32326073

TX03399,0001914 –19–09OCT01–10/10

T61

22A

H–U

N–1

9OC

T88

IMPORTANT: To prevent seal damage, the barrel,piston, and rod must be in alignmentduring installation.

18. Apply clean hydraulic oil to piston seals and barrelchamfer. Use care not to get oil on barrel threads.

19. Carefully push piston into barrel.

IMPORTANT: Use care not to get thread lock andsealer on the end of the barrel thatcontacts the inner O-ring and backupring.

20. Apply cure primer, then thread lock and sealer (lowstrength) to the remaining barrel threads.

21. Carefully push and rotate rod guide to engagethreads.

22. Turn guide onto barrel until it bottoms (internally)against the end of the barrel.

IMPORTANT: Do not turn the guide in place with aspanner wrench.

23. Rotate the guide counterclockwise (viewed from rodend of cylinder) until the marks made beforedisassembly are aligned, or the rod guide port isproperly positioned.

24. Tighten jam (spanner) nut against the rod guide tospecification.

SpecificationRod Guide Jam (Spanner) Nut—Torque 1350 N•m (1000 lb-ft).....................................................................


PN=763

Hydraulic System

323260

74


PN=764


3232991

CED,OUTX547,1195 –19–20JAN00–1/1

DFT1180 Cylinder Nut Torque Tool

T12

7586

–UN

–24J

AN

00

1—222 mm (8.74 in.) 4—38 mm (1.5 in.) 6—11/16 in. Hole (6 used) 8—14H1039 Nut (6 used)2—260 mm (10.24 in.) 5—73 mm (2.87 in.) 7—19H3168 .625 X 3.75 Cap3—38 mm (1.5 in.) Screw (6 used)

This tool is used to keep cylinder from turning whenloosening or tightening the piston nut.

Material required:

• 3 in. x 1 in. bar stock• 19H3168 5/8 in. x 3 3/4 in. Cap Screw (6 used)• 14H1039 5/8 in. Nut (6 used)

1. Cut bar stock to given dimensions.

2. Drill holes (6) in bar stock with 11/16 in. drill bit.

3. Assemble separate pieces of bar stock with capscrews and nuts.

4. Grind corners as needed so tool will fit into cylinderservice stand.


PN=765


323299

2


PN=766

IndexPage Page

A B

Backup alarm, adjust . . . . . . . . . . . . . . . . .20-2004-1A-Frame bearing and bushingsBatteryRemove and install . . . . . . . . . . . . . . . .01-0130-88

Charge . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-10A/C component, R134aElectrolyte level. . . . . . . . . . . . . . . . . . . .16-1671-7Oil charge . . . . . . . . . . . . . . . . . . . . . . .18-1830-10Electrolyte specific gravity . . . . . . . . . . . .16-1671-5A/C compressorRemove and install . . . . . . . . . . . . . . . .16-1671-11Assemble . . . . . . . . . . . . . . . . . . . . . . .18-1830-29Service . . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-2Disassemble and inspect . . . . . . . . . . .18-1830-22Testing . . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-4Inspect manifolds . . . . . . . . . . . . . . . . .18-1830-31

Battery explosion . . . . . . . . . . . . . . . . . . . .16-1671-9Remove and install -750C (S.N.Bearing and bushings, A-frame-831315) . . . . . . . . . . . . . . . . . . . . . .18-1830-18

Remove and install . . . . . . . . . . . . . . . .01-0130-88Remove and install -850C. . . . . . . . . . .18-1830-21Blade and frameRemove and install-750C (S.N. 831316-

Remove and install . . . . . . . . . . . . . . . . .32-3200-2). . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-20Blade and frame (PAT)A/C compressor, R134a

Remove and install . . . . . . . . . . . . . . . . .32-3200-5Oil charge check . . . . . . . . . . . . . . . . . . .18-1830-8Blade angle cylinder (PAT)Oil removal . . . . . . . . . . . . . . . . . . . . . . .18-1830-9

Cross section . . . . . . . . . . . . . . . . . . . .32-3260-67A/C condenserDisassemble . . . . . . . . . . . . . . . . . . . . .32-3260-65Remove and install . . . . . . . . . . . . . . . .18-1830-36

Blade edges and end bitsA/C evaporatorRemove and install . . . . . . . . . . . . . . . . .32-3201-3Remove and install . . . . . . . . . . . . . . . .18-1830-34

Blade lift cylinderA/C receiver dryerDisassemble and assembleRemove and install . . . . . . . . . . . . . . . .18-1830-32

(S.N. 831316— ) . . . . . . . . . . . . . . . .32-3260-50A/C, R134a system(S.N.—831315 ) . . . . . . . . . . . . . . . .32-3260-47Charge . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-15

Blade pitchEvacuate. . . . . . . . . . . . . . . . . . . . . . . .18-1830-13Adjustment . . . . . . . . . . . . . . . . . . . . . . .32-3240-7Recover . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12

Blade tilt and lift cylinder (PAT)Adjust front idler horizontal IndxAssemble . . . . . . . . . . . . . . . . . . . . . . .32-3260-60 1movement . . . . . . . . . . . . . . . . . . . . . .01-0130-115Disassemble . . . . . . . . . . . . . . . . . . . . .32-3260-56Adjust track sag . . . . . . . . . . . . . . . . . . . .01-0130-72

Blade tilt cylinder (PAT)Adjuster, trackCross section . . . . . . . . . . . . . . . . . . . .32-3260-59Exploded view. . . . . . . . . . . . . . . . . . . .01-0130-74

Blade, bulldozerInstall . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-77Remove and install . . . . . . . . . . . . . . . . .32-3201-2Remove . . . . . . . . . . . . . . . . . . . . . . . .01-0130-75

Bottom guard, frontAdjustmentRemove and install . . . . . . . .17-1746-1, 17-1746-2Decelerator sensor-single lever. . . . . . .05-0515-27

Brakes, parkEngine speed adjustment-750C . . . . . .05-0515-16Remove and install . . . . . . . . . . . . . . . . .11-1100-4Engine speed adjustment-850C . . . . . .05-0515-19

Bulb replacementEngine speed control cable. . . . . . . . . .05-0515-23Dome light and swivel light . . . . . . . . . . .16-1673-2Engine speed control sensor. . . . . . . . .05-0515-25Halogen bulb. . . . . . . . . . . . . . . . . . . . . .16-1673-1Fuel shut-off solenoid . . . . . . . . . . . . . .04-0400-31

BulldozerAir cleanerRemove and install . . . . . . . . . . . . . . . . .32-3201-2Remove and install . . . . . . . . . . . . . . . . .05-0520-1

Bulldozer pushbeamAir conditioningRemove and install . . . . . . . . . . . . . . . . .32-3240-1Refrigerant R134a caution . . . . . . . . . . .18-1830-7

Bypass valve, oil coolerR134a refrigerant operation . . . . . . . . . .18-1830-6Disassemble and assemble . . . . . . . . .03-0360-30Air intake

Test for leaks . . . . . . . . . . . . . . . . . . . . .05-0520-2Alternator C

Remove and install . . . . . . . . . . . . . . . . .16-1672-2Anti-cavitation relief valve Cab covers

Remove and install . . . . . . . . . . . . . . . .18-1810-12Disassemble and assemble . . . . . . . . .32-3260-32

TM1589 (10AUG04) Index-1 750C, 850C, 750C II, 850C II Crawler081004

PN=1

Index

Page Page

Cab doors and hinges Crossbar lubeRemove and install . . . . . . . . . . . . . . . .01-0130-45Remove and install . . . . . . . . . . . . . . . .18-1810-14

Cable, park lock and brake Crossbar, frontExploded view-750C . . . . . . . . . . . . . . .01-0130-34Remove and install . . . . . . . . . . . . . . . . .11-1115-4

Cab/ROPS mounts and isolators Crossbar-to-crossbar supportCheck and adjust . . . . . . . . . . . . . . . . .01-0130-39Remove and install . . . . . . . . . . . . . . . . .18-1810-7

Cab/ROPS, tilt cylinder Cutting edges and end bitsRemove and install . . . . . . . . . . . . . . . . .32-3201-3Disassemble and assemble . . . . . . . . . .18-1810-2

Remove and install . . . . . . . . . . . . . . . . .18-1810-3 Cylinder, liftRemove and install . . . . . . . . . . . . . . . .32-3260-45Capacity

750C machine. . . . . . . . . . . . . . .00-02-3, 00-02-16 Cylinder, tiltAssemble . . . . . . . . . . . . . . . . . . . . . . .32-3260-40Carrier roller

Remove and install . . . . . . . . . . . . . . . .01-0130-13 Cross section . . . . . . . . . . . . . . . . . . . .32-3260-37Disassemble . . . . . . . . . . . . . . . . . . . . .32-3260-37Test for oil leakage . . . . . . . . . . . . . . . .01-0130-18

Carrier roller wear measurement . . . . . . .01-0130-12 Remove and install . . . . . . . . . . . . . . . .32-3260-36Cylinder, track adjusterChain, lubricated track

Remove and install . . . . . . . . . . . . . . . .01-0130-51 Disassemble and assemble . . . . . . . . .01-0130-83Charge pressure manifold

Assemble and disassemble. . . . . . . . . .03-0360-18Charge pump

DDisassemble and assemble . . . . . . . . .03-0360-15Check valve

Fuel filter-850C, install . . . . . . . . . . . . .04-0400-16 Dampener driveRemove and install . . . . . . . . . . . . . . . . .07-0752-2Fuel filter-850C, remove . . . . . . . . . . . .04-0400-16

Cleanout cover Dealer fabricated toolDFT1063 pump lifting bracket . . . . . . . . .03-0399-1Remove and install . . . . . . . . . . . . . . . .32-3260-12

Clearances, main frame DFT1130 adapter . . . . . . . . . . . . . . . . . .03-0399-2DFT1132 hydrostatic motor removal . . . .03-0399-3Check and adjust . . . . . . . . . . . . . . . . .01-0130-39

Component location DFT1137 hydrostatic motor removal . . . .03-0399-4DFT1164 speed sensor adjusting tool . . .03-0399-5All hydraulic dozer hydraulics . . . . . . . .32-3260-20

Angle dozer hydraulics . . . . . . . . . . . . .32-3260-22 Dealer fabricated tools

Indx2

Bulldozer hydraulics . . . . . . . . . . . . . . .32-3260-21 DFT1140. . . . . . . . . . . . . . . . . . . . . . . . .05-0599-1DeceleratorCompressor

Assemble . . . . . . . . . . . . . . . . . . . . . . .18-1830-29 Remove and install . . . . . . . . . . . . . . . .05-0515-14DFT1041 Track Nut Removal Tool . . . . . . .01-0199-2Disassemble and inspect . . . . . . . . . . .18-1830-22

Inspect manifolds . . . . . . . . . . . . . . . . .18-1830-31 DFT1078Final drive lifting fixture . . . . . . . . . . . . . .02-0299-4Compressor belt tension

Check and adjust . . . . . . . . . . . . . . . . .18-1830-16 DFT1079, final drive lifting fixtureadapter . . . . . . . . . . . . . . . . . . . . . . . . . .02-0299-2Connectors

DEUTSCH . . . . . . . . . . . . . . . . . . . . . .16-1674-41 DFT1087 track recoil spring compression toolguard . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0199-1WEATHER PACK . . . . . . . . . . . . . . . . .16-1674-44

Control assembly, FNR (pedal steer) Diesel engine oil . . . . . . . . . . . . . . . . . . . . . . .00-04-4Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .00-04-1Component location . . . . . . . . . . . . . . .03-0315-10

Coolant Diesel fuel conditionerLow sulfur . . . . . . . . . . . . . . . . . . . . . . . . . .00-04-2Diesel engine . . . . . . . . . . . . . . . . . . . . . . .00-04-9

Coolant heater, engine Diesel fuel storage . . . . . . . . . . . . . . . . . . . . .00-04-3Display monitorRemove and install . . . . . . . . . . . . . . . . .05-0505-2

Counterweight Remove and install . . . . . . . . . . . . . . . . .16-1675-3Door hold open latchRemove and install . . . . . . . . . . . . . . . . .17-1749-1

Cover, cleanout Remove and install . . . . . . . . . . . . . . . .18-1810-15Dozer control valveHydraulic and hydrostatic reservoirs . . .32-3260-12

Crossbar Disassemble and assemble . . . . . . . . .32-3260-24Remove and install . . . . . . . . . . . . . . . .32-3260-19Disassemble and assemble . . . . . . . . .01-0130-46


PN=2

Index

Page Page

Drawbar, rigid Engine speed controlRemove and install . . . . . . . . . . . . . . . . .05-0515-6Remove and install . . . . . . . . . . . . . . . . .15-1511-4

Engine speed control linkage and shaftDrawbar, rigid, extended750C and 850C (SN -822867)Remove and install . . . . . . . . . . . . . . . . .15-1511-2

Remove and install . . . . . . . . . . . . . . .05-0515-8850C (SN 822868-)

Remove and install . . . . . . . . . . . . . .05-0515-10Engine speed control linkage rodE

750C. . . . . . . . . . . . . . . . . . . . . . . . . . .05-0515-13850C (SN -822867). . . . . . . . . . . . . . . .05-0515-12

Edges, cutting EvaporatorRemove and install . . . . . . . . . . . . . . . . .32-3201-3 Remove and install . . . . . . . . . . . . . . . .18-1830-34

ElectricalWelding procedure . . . . . . 01-0130-87, 16-1675-1,

17-1740-1Electrical component identification F

A/C compressor harness750C (S.N. -831315), 850C (S.N. Fan

-822867) . . . . . . . . . . . . . . . . . . . .16-1674-38 Remove and install . . . . . . . . . . . . . . . . .05-0510-4A/C condenser harness. . . . . . . . . . . . .16-1674-40 Fan belt-750C (SN-831315)Cab/Rops harness . . . . . . . . . . . . . . . . .16-1674-4 Remove and install . . . . . . . . . . . . . . . . .05-0510-5Chassis harness . . . . . . . . . . . . . . . . . .16-1674-20 Fan belt-850C and 750C (SN831316- )Engine/pump harness 750C (S.N. Remove and Install . . . . . . . . . . . . . . . . .05-0510-7

-831315) . . . . . . . . . . . . . . . . . . . . . .16-1674-22 Fan guardsEngine/pump harness 750C (S.N. 831316- Remove and install . . . . . . . . . . . . . . . . .05-0510-4

). . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-24 Fan shroudEngine/pump harness 850C (S.N. Remove and install . . . . . . . . . . . . . . . . .05-0510-4

-822867) . . . . . . . . . . . . . . . . . . . . . .16-1674-26 Filter, final fuel-750CEngine/pump harness 850C (S.N.822868- IndxDisassemble and assemble . . . . . . . . .04-0400-32

3). . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-28 Filter, hydraulicGrill housing housing Disassemble and assemble . . . . . . . . .32-3260-18

750C (S.N. -831315), 850C (S.N. Remove and install . . . . . . . . . . . . . . . .32-3260-17-822867) . . . . . . . . . . . . . . . . . . . .16-1674-30 Filter, primary fuel

750C (S.N.831315- ), 850C (S.N.822868- Disassemble and assemble . . . . . . . . .04-0400-33) . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-32 Final drive

Motor harness. . . . . . . . . . . . . . . . . . . .16-1674-34 Oil specification. . . . . . . . . . . . . . . . . . . . . .00-04-6Wiper harness. . . . . . . . . . . . . . . . . . . .16-1674-36 Remove and install . . . . . . . . . . . . . . . . .02-0201-3

Electrolyte specific gravity Final drive housing assemblyChecking. . . . . . . . . . . . . . . . . . . . . . . . .16-1671-5 Remove and install . . . . . . . . . . . . . . . .02-0250-17

End bits Final drive housing cover assy.Remove and install . . . . . . . . . . . . . . . . .32-3201-3 Disassemble and assemble . . . . . . . . .02-0250-20

Engine Final drive lifting fixtureRemove and Install . . . . . . . . . . . . . . . . .04-0400-6 DFT1078. . . . . . . . . . . . . . . . . . . . . . . . .02-0299-4

Engine controller Final drive lifting fixture adapter,Remove and install . . . . . . . . . . . . . . . . .16-1675-3 DFT1079. . . . . . . . . . . . . . . . . . . . . . . . .02-0299-2

Engine coolant heater Final fuel filter-750CRemove and install . . . . . . . . . . . . . . . . .05-0505-2 Disassemble and assemble . . . . . . . . .04-0400-32

Engine mounts FNR and neutral start switch (pedal steer)Remove and install . . . . . . . . . . . . . . . .04-0400-38 Adjustment . . . . . . . . . . . . . . . . . . . . . .03-0315-11

Engine oil FNR and neutral start switch (single lever steer)Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-04-4 Adjustment . . . . . . . . . . . . . . . . . . . . . .03-0315-17

Engine side shield FNR control assembly (pedal steer)Component location . . . . . . . . . . . . . . .03-0315-10Remove and install . . . . . . . . . . . . . . . . .19-1910-4


PN=3

Index

Page Page

Disassemble and assemble . . . . . . . . . .03-0315-8 GFNR control assembly (single lever steer)

Component location . . . . . . . . . . . . . . .03-0315-16 Gear, hub and sprocket frameDisassemble and assemble . . . . . . . . .03-0315-14 Install . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-14

Frame and blade GreaseRemove and install . . . . . . . . . . . . . . . . .32-3200-2 Extreme pressure and multipurpose . . . . . .00-04-7Remove and install (PAT) . . . . . . . . . . . .32-3200-5 Grille housing

Remove and install . . . . . . . . . . . . . . . . .19-1921-2Frame, trackGuard, bottom frontInstall . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-90

Remove and install . . . . . . . . . . . . . . . . .17-1746-1Remove . . . . . . . . . . . . . . . . . . . . . . . .01-0130-85Guard, rear centerFront bottom guard

Remove and install . . . . . . . . . . . . . . . . .17-1746-2Remove and install . . . . . . . . . . . . . . . . .17-1746-1Front crossbar and support

Exploded view-750C . . . . . . . . . . . . . . .01-0130-34Front crossbar and support-750C

HRemove and install . . . . . . . . . . . . . . . .01-0130-35Front crossbar and support-850C

Hand pumpRemove and install . . . . . . . . . . . . . . . .01-0130-37Disassemble and assemble . . . . . . . . . .18-1810-6Front crossbar-to-crossbar support

Hand pump assemblyCheck and adjust . . . . . . . . . . . . . . . . .01-0130-39Remove and install . . . . . . . . . . . . . . . . .18-1810-5Front idler

Heater pressurizerAdjust vertical movement . . . . . . . . . .01-0130-114Remove and install . . . . . . . . . . . . . . . .18-1830-38Assemble . . . . . . . . . . . . . . . . . . . . . .01-0130-106

Heater, engine coolantDisassemble . . . . . . . . . . . . . . . . . . . .01-0130-102Remove and install . . . . . . . . . . . . . . . . .05-0505-2Exploded view. . . . . . . . . . . . . . . . . . .01-0130-105

HoodInstall . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-113Remove and install . . . . . . . . . . . . . . . . .19-1910-2Oil specification. . . . . . . . . . . . . . . . . . . . . .00-04-7

Hood supportRemove . . . . . . . . . . . . . . . . . . . . . . .01-0130-101Remove and install . . . . . . . . . . . . . . . . .19-1910-4Test for oil leakage . . . . . . . . . . . . . . .01-0130-116

Housing, grilleFuel

Remove and install . . . . . . . . . . . . . . . . .19-1921-2

Indx4

Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-04-1Housing, planet

Handling and storing . . . . . . . . . . . . . . . . . .00-04-1Remove and install . . . . . . . . . . . . . . . . .02-0250-5

Tank capacity . . . . . . . . . . . . . . . . . . . . . . .00-04-2 Hydraulic Oil CoolerFuel filter check valve-850C Remove and install . . . . . . . . . . . . . . . .05-0510-12

Remove and install . . . . . . . . . . . . . . . .04-0400-16 Hydraulic pumpFuel filter (primary) Disassemble and assemble . . . . . . . . . .32-3260-7

Drain-750C . . . . . . . . . . . . . . . . . . . . . .04-0400-36 Remove and install . . . . . . . . . . . . . . . . .32-3260-6Drain-850C . . . . . . . . . . . . . . . . . . . . . .04-0400-36 Hydraulic reservoir cleanout cover

Fuel injection pump, in-line Remove and install . . . . . . . . . . . . . . . .32-3260-12Install . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-23 Hydrostatic motorRemove . . . . . . . . . . . . . . . . . . . . . . . .04-0400-22 Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0360-41

Fuel lines - 750C Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-30Remove and install . . . . . . . . . . . . . . . . .05-0560-4 Speed sensor adjustment . . . . . . . . . . .03-0300-14

Fuel Lines - 850C Hydrostatic motorsRemove and Install . . . . . . . . . . . . . . . . .05-0560-5 Remove and install . . . . . . . . . . . . . . . .03-0300-11

Fuel system Hydrostatic oil filterBleed-750C. . . . . . . . . . . . . . . . . . . . . .04-0400-34 Remove and install . . . . . . . . . . . . . . . .03-0360-50Bleed-850C. . . . . . . . . . . . . . . . . . . . . .04-0400-35 Hydrostatic pump

Fuel tank Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0360-20Remove and install . . . . . . . . . . . . . . . . .05-0560-2 Disassemble . . . . . . . . . . . . . . . . . . . . . .03-0360-6

Fuel, diesel Hydrostatic pumpsRemove and Install . . . . . . . . . . . . . . . . .03-0300-4storage . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-04-3


PN=4

Index

Page Page

Hydrostatic reservoir cleanout cover Linkage, single lever controlDisassemble and assemble . . . . . . . . .03-0315-25Remove and install . . . . . . . . . . . . . . . .32-3260-12

Linkage, T-barRemove and install . . . . . . . . . . . . . . . . .32-3215-2

Linkage, third function hydraulicI Remove and install . . . . . . . . . . . . . . . . .32-3215-6

Linkage, two function hydraulicIdler Remove and install . . . . . . . . . . . . . . . . .32-3215-4

Front, oil specification . . . . . . . . . . . . . . . . .00-04-7 Low sulfur diesel fuel conditioner . . . . . . . . . .00-04-2Idler, front Lubricant

Adjust vertical movement . . . . . . . . . .01-0130-114 Alternative. . . . . . . . . . . . . . . . . . . . . . . . . .00-04-8Assemble . . . . . . . . . . . . . . . . . . . . . .01-0130-106 Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-04-9Disassemble . . . . . . . . . . . . . . . . . . . .01-0130-102 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-04-8Exploded view. . . . . . . . . . . . . . . . . . .01-0130-105 Synthetic . . . . . . . . . . . . . . . . . . . . . . . . . . .00-04-8Install . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-113 Lubricated track chainMeasure wear . . . . . . . . . . . . . . . . . . .01-0130-100 Assemble and not relubricate . . . . . . . .01-0130-65Remove . . . . . . . . . . . . . . . . . . . . . . .01-0130-101 Assemble to lubricate . . . . . . . . . . . . . .01-0130-58Test for oil leakage . . . . . . . . . . . . . . .01-0130-116 Assemble to turn bushings . . . . . . . . . .01-0130-58

Inch torque values . . . . . . . . . . . . . . . . . . . . .00-03-9 Disassemble and assemble . . . . . . . . .01-0130-65Injection pump DB4 Disassemble and not relubricate . . . . . .01-0130-65

Install . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-19 Disassemble to lubricate . . . . . . . . . . . .01-0130-55Remove . . . . . . . . . . . . . . . . . . . . . . . .04-0400-17 Disassemble to turn bushing . . . . . . . . .01-0130-55

Injection pump, in-line Remove and install . . . . . . . . . . . . . . . .01-0130-51Install . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-23

Injection pump, in-line fuelRemove . . . . . . . . . . . . . . . . . . . . . . . .04-0400-22

MInner guide wear stripRemove and install . . . . . . . . . . . . . . . .01-0130-95

Main frame clearancesIntake IndxCheck and adjust . . . . . . . . . . . . . . . . .01-0130-39 5Air, test for leaks. . . . . . . . . . . . . . . . . . .05-0520-2

Measure bushing wear . . . . . . . . . . . . . . .01-0130-48Measure front idler wear. . . . . . . . . . . . .01-0130-100Measure link height . . . . . . . . . . . . . . . . .01-0130-47

J Measure track pitch . . . . . . . . . . . . . . . . .01-0130-50Measure track shoe wear . . . . . . . . . . . . .01-0130-31

JT05801 digital tachometer Metal face sealsInstallation. . . . . . . . . . . . . . . . . . . . . . . .05-0515-5 Inspect . . . . 01-0130-16, 01-0130-104, 02-0250-13

Metri-Pack connectorReplace . . . . . . . . . . . . . . . . . . . . . . . .16-1674-47

Metric torque values . . . . . . . . . . . . . . . . . . . .00-03-5LMixing lubricants. . . . . . . . . . . . . . . . . . . . . . .00-04-9Motors, hydrostatic

Lift cylinderRemove and install . . . . . . . . . . . . . . . .03-0300-11

Remove and install . . . . . . . . . . . . . . . .32-3260-45Muffler

Lift cylinder pivot subframeRemove and install . . . . . . . . . . . . . . . . .05-0530-1

Disassemble and assemble . . . . . . . . . .32-3240-8Multi-function valve

Lift cylinder, bladeAssemble and disassemble. . . . . . . . . .03-0360-19

Disassemble and assembleRemove and install . . . . . . . . . . . . . . . .03-0360-17

(S.N. 831316— ) . . . . . . . . . . . . . . . .32-3260-50(S.N.—831315 ) . . . . . . . . . . . . . . . .32-3260-47

Light switchRemove and install . . . . . . . . . . . . . . . . .16-1673-1 O

Linkage, park lock and brakeRemove and install . . . . . . . . . . . . . . . . .11-1115-4 O-ring boss fittings . . . . . . . . . . . . . . . . . . . .00-03-11


PN=5

Index

Page Page

Pump displacement control valve (PDCV)OilDisassemble and assemble . . . . . . . . .03-0360-16Lines and fittings. . . . . . . . . . . . . . . . . . . .00-03-10

Pump, hydraulicSpecification carrier roller . . . . . . . . . . . . . .00-04-7Remove and install . . . . . . . . . . . . . . . . .32-3260-6Specification final drive . . . . . . . . . . . . . . . .00-04-6

Pump, in-line fuel injectionSpecification front idler . . . . . . . . . . . . . . . .00-04-7Remove . . . . . . . . . . . . . . . . . . . . . . . .04-0400-22Specification track frame pivot . . . . . . . . . .00-04-7

Pumps, hydrostaticSpecification track roller . . . . . . . . . . . . . . .00-04-7Remove and Install . . . . . . . . . . . . . . . . .03-0300-4Specification transmission . . . . . . . . . . . . . .00-04-5

Pushbeam, bulldozerOil CoolerRemove and install . . . . . . . . . . . . . . . . .32-3240-1Remove and install . . . . . . . . . . . . . . . . .05-0510-8

Pushbeams, struts and pitch jackOil cooler bypass valveDisassemble and assemble . . . . . . . . . .32-3240-6Disassemble and assemble . . . . . . . . .03-0360-30

Oil lines and fittings . . . . . . . . . . . . . . . . . . .00-03-10Oil pan

Remove and install . . . . . . . . . . . . . . . .04-0400-15Q

Quick drop valveDisassemble and assemble . . . . . . . . .32-3260-35PRemove and install . . . . . . . . . . . . . . . .32-3260-33

Park brakeCross section . . . . . . . . . . . . . . . . . . . . .11-1100-3

Park brake pedal RRemove and install . . . . . . . . . . . . . . . . .11-1115-2

Park brake valve RadiatorDisassemble and assemble . . . . . . . . . .11-1160-2 Remove and install . . . . . . . . . . . . . . . . .05-0510-8Remove and install . . . . . . . . . . . . . . . . .11-1160-1 Rear bottom guard

Park brake valve linkage Remove and install . . . . . . . . . . . . . . . . .17-1746-2Remove and install . . . . . . . . . . . . . . . . .11-1115-3 Recoil spring

Park brakes Disassemble and assemble . . . . . . . . .01-0130-80

Indx6

Remove and install . . . . . . . . . . . . . . . . .11-1100-4 Recoil spring, track adjusterPark lock linkage Install . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-77

Adjustment . . . . . . . . . . . . . 03-0315-44, 11-1115-6 Remove . . . . . . . . . . . . . . . . . . . . . . . .01-0130-75PAT six way blade Recovery/recycling/charging station

Installation. . . . . . . . . . . . . . . . . . . . . . . .32-3201-4 Installation procedure . . . . . . . . . . . . . .18-1830-11Pedal, park brake Relief valve with anti-cavitation

Remove and install . . . . . . . . . . . . . . . . .11-1115-2 Disassemble and assemble . . . . . . . . .32-3260-32Pedal, steering Relief valve, system

Remove and install . . . . . . . . . . . . . . . . .03-0315-6 Disassemble and assemble . . . . . . . . .32-3260-31Pinned crossbar and support Reservoir cover

Exploded view-850C . . . . . . . . . . . . . . .01-0130-42 Remove and install . . . . . . . . . . . . . . . .32-3260-12Pitch jack Reservoir, hydraulic

Remove and install . . . . . . . . . . . . . . . . .32-3240-3 Disassemble and assemble . . . . . . . . .32-3260-16Planet carrier housing assembly Remove and install . . . . . . . . . . . . . . . .32-3260-11

Cross section . . . . . . . . . . . . . . . . . . . . .02-0250-4 Reservoir, hydrostaticPlanet housing Disassemble and assemble . . . . . . . . .32-3260-16

Disassemble and assemble . . . . . . . . . .02-0250-8 Remove and install . . . . . . . . . . . . . . . .32-3260-11Remove and install . . . . . . . . . . . . . . . . .02-0250-5 Reverse alarm,

Plates, wear Remove and install . . . . . . . . . . . . . . . . .20-2004-1Remove and install . . . . . . . . . . . . . . . .01-0130-41 Reverse warning alarm, adjust . . . . . . . . . .20-2004-1

Primary fuel filter Ring gear hub and sprocket frameDisassemble and assemble . . . . . . . . .02-0250-12Disassemble and assemble . . . . . . . . .04-0400-33


PN=6

Index

Page Page

Ring gear, hub and sprocket frame Steering pedalRemove and install . . . . . . . . . . . . . . . . .03-0315-6Remove . . . . . . . . . . . . . . . . . . . . . . . .02-0250-10

Storing fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .00-04-1Rock guards and track guidesStoring lubricants . . . . . . . . . . . . . . . . . . . . . .00-04-8Remove and install . . . . . . . . . . . . . . . .01-0130-11Strip, inner guide wearRoller, carrier

Remove and install . . . . . . . . . . . . . . . .01-0130-95Remove and install . . . . . . . . . . . . . . . .01-0130-13Strips, track lower frame wearTest for oil leakage . . . . . . . . . . . . . . . .01-0130-18

Remove and install . . . . . . . . . . . . . . . .01-0130-98Roller, trackStrips, track upper frame wearDisassemble . . . . . . . . . . . . . . . . . . . . .01-0130-22

Remove and install . . . . . . . . . . . . . . . .01-0130-96Remove and install . . . . . . . . . . . . . . . .01-0130-20StrutsTest for oil leakage . . . . . . . . . . . . . . . .01-0130-30

Remove and install . . . . . . . . . . . . . . . . .32-3240-4ROPSST4920 track recoil spring compressionTorque . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-03-1

tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0199-3ROPS or cabSub-frame fastenersRemove and install . . . . . . . . . . . . . . . . .18-1800-2

Remove and install . . . . . . . . . . . . . . . . .17-1740-2Support wear plates

Remove and install . . . . . . . . . . . . . . . .01-0130-41Synthetic lubricants . . . . . . . . . . . . . . . . . . . .00-04-8SSystem relief valve

Disassemble and assemble . . . . . . . . .32-3260-31Seals, metal face

Inspect . . . . 01-0130-16, 01-0130-104, 02-0250-13Seat

Disassemble and assemble . . . . . . . . . .18-1821-1 TShield, engine side

Remove and install . . . . . . . . . . . . . . . . .19-1910-4 T-bar linkageShoe, track Remove and install . . . . . . . . . . . . . . . . .32-3215-2

Remove and install . . . . . . . . . . . . . . . .01-0130-32 IndxThrottle sensor - 850C (SN 822868- )7Single lever control Adjustment . . . . . . . . . . . . . . . . . . . . . .05-0515-29

Remove and install . . . . . . . . . . . . . . . .03-0315-24 Tilt cylinderSingle lever control linkage Assemble . . . . . . . . . . . . . . . . . . . . . . .32-3260-40

Disassemble and assemble . . . . . . . . .03-0315-25 Cross section . . . . . . . . . . . . . . . . . . . .32-3260-37Six way blade 850C . . . . . . . 32-3201-4, 32-3260-52, Disassemble . . . . . . . . . . . . . . . . . . . . .32-3260-37

32-3260-54 Remove and install . . . . . . . . . . . . . . . .32-3260-36Specific gravity, electrolyte . . . . . . . . . . . . .16-1671-5 Tilt cylinder, cab/ROPSSpecification Disassemble and assemble . . . . . . . . . .18-1810-2

Carrier roller oil . . . . . . . . . . . . . . . . . . . . . .00-04-7 Remove and install . . . . . . . . . . . . . . . . .18-1810-3Final drive oil . . . . . . . . . . . . . . . . . . . . . . .00-04-6 Time TracFront idler oil. . . . . . . . . . . . . . . . . . . . . . . .00-04-7 Injection pump timing . . . . . . . . . . . . . .04-0400-29Track frame pivot oil . . . . . . . . . . . . . . . . . .00-04-7 Installation. . . . . . . . . . . . . . . . . . . . . . .04-0400-28Track roller oil . . . . . . . . . . . . . . . . . . . . . . .00-04-7 Tools, dealer fabricatedTransmission oil . . . . . . . . . . . . . . . . . . . . .00-04-5 DFT1063 pump lifting bracket . . . . . . . . .03-0399-1750C machine. . . . . . . . . . . . . . . . . . . . . . .00-02-1 DFT1130 adapter . . . . . . . . . . . . . . . . . .03-0399-2850C machine. . . . . . . . . . . . . . . . . . . . . .00-02-13 DFT1132 hydrostatic motor removal . . . .03-0399-3

Speed controls, engine DFT1137 hydrostatic motor removal . . . .03-0399-4Remove and install . . . . . . . . . . . . . . . . .05-0515-6 DFT1164 speed sensor adjusting tool . . .03-0399-5

Sprocket segment Torque valueRemove and install . . . . . . . . . . . . . . .01-0130-117 Flat face O-ring seal fitting . . . . . . . . . . . .00-03-13

Start-up procedure Inch SAE four bolt flange fitting. . . . . . . . .00-03-14Hydrostatic pump and motor . . . . . . . . .03-0300-15 Metric cap screw. . . . . . . . . . . . . . . . . . . . .00-03-6

Starting motor Metric four bolt flange fitting . . . . . . . . . . . .00-03-8O-Ring boss fitting . . . . . . . . . . . . . . . . . .00-03-11Remove and install . . . . . . . . . . . . . . . . .16-1677-1


PN=7

Index

Page Page

ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-03-1 Valve seal kit tang endInstall . . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-29Torque values

Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-03-9 Valve, control dozerdisassemble and assemble . . . . . . . . . .32-3260-24Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-03-5

Track Valve, dozer controlRemove and install . . . . . . . . . . . . . . . .32-3260-19Frame pivot oil specification . . . . . . . . . . . .00-04-7

Roller oil specification . . . . . . . . . . . . . . . . .00-04-7 Valve, oil cooler bypassDisassemble and assemble . . . . . . . . .03-0360-30Track adjuster

Exploded view. . . . . . . . . . . . . . . . . . . .01-0130-74 Valve, quick dropDisassemble and assemble . . . . . . . . .32-3260-35Track adjuster and recoil spring

Install . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-77 Remove and install . . . . . . . . . . . . . . . .32-3260-33Remove . . . . . . . . . . . . . . . . . . . . . . . .01-0130-75

Track adjuster cylinderDisassemble and assemble . . . . . . . . .01-0130-83 W

Track chain, lubricatedRemove and install . . . . . . . . . . . . . . . .01-0130-51

Water separatorTrack frame

Disassemble and assemble . . . . . . . . .04-0400-33Install . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-90

Wear platesRemove . . . . . . . . . . . . . . . . . . . . . . . .01-0130-85

Remove and install . . . . . . . . . . . . . . . .01-0130-41Track frame lower wear strips

Wear strip bar, track frameRemove and install . . . . . . . . . . . . . . . .01-0130-98

Remove and install . . . . . . . . . . . . . . . .01-0130-99Track frame upper wear strips

Wear strip, inner guideRemove and install . . . . . . . . . . . . . . . .01-0130-96

Remove and install . . . . . . . . . . . . . . . .01-0130-95Track frame wear strip bar

Wear strips, track lower frameRemove and install . . . . . . . . . . . . . . . .01-0130-99

Remove and install . . . . . . . . . . . . . . . .01-0130-98Track guides and rock guards

Wear strips, track upper frameRemove and install . . . . . . . . . . . . . . . .01-0130-11

Remove and install . . . . . . . . . . . . . . . .01-0130-96Track roller

Welding procedure . . . . . . . . 01-0130-87, 16-1675-1,Disassemble . . . . . . . . . . . . . . . . . . . . .01-0130-22

17-1740-1Remove and install . . . . . . . . . . . . . . . .01-0130-20

WindowTest for oil leakage . . . . . . . . . . . . . . . .01-0130-30

Indx8

Remove and install . . . . . . . . . . . . . . . . .18-1810-9Track sag

Windshield washerAdjust . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-72

Remove and install . . . . . . . . . . . . . . . .18-1810-16Track shoe

Wiper motor assembliesRemove and install . . . . . . . . . . . . . . . .01-0130-32

Remove and install . . . . . . . . . . . . . . . .18-1810-13Track shoe torque . . . . . . . . . . . . . . . . . . . . .00-03-2

850C PAT blade hydraulicsMaster link . . . . . . . . . . . . . . . . . . . . . . . . .00-03-3

Component location . . . . . . . . . . . . . . .32-3260-23Transmission

Oil specification. . . . . . . . . . . . . . . . . . . . . .00-04-5Transmission controller

Remove and install . . . . . . . . . . . . . . . . .16-1675-2Trunion, remove and install . . . . . . . . . . . .32-3200-3Trunnion Shim

Adjustment (S.N. 898366- ). . . . . . . . . . .32-3200-4Trunnion shim

Adjustment (S.N.-898365) . . . . . . . . . . . .32-3200-4

V

Valve seal kit end capInstall . . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-27


PN=8

750c, 850c dozer repair tm1589

Documents