624H Loader and TC62H TC Operation TM1640

Return to INDEX

624H Loader and TC62H Tool Carrier Repair

TECHNICAL MANUAL 624H Loader TC62H Tool Carrier Repair TM1640 15JAN04 (ENGLISH)

For complete service information also see: 624H Loader and TC62H Operation and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 L & 6.8 L 4045 and 6068 Diesel Engines Repair . . . . . . . . . . . . . . . . . . . . . . . Alternators and Starting Motors . . . . . . . . . . TeamMate III Axles . . . . . . . . . . . . . . . . . . .

TM1639 CTM104 CTM77 CTM150

Worldwide Construction And Forestry Division LITHO IN U.S.A.

Introduction Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable 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 specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

DX,TMIFC –19–29SEP98–1/1

TM1640 (15JAN04)

624H Loader and TC62H Tool Carrier 011504

PN=2

Introduction

Technical Information Feedback Form We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments, ideas and improvements. SEND TO:

John Deere Dubuque Works P.O. Box 538 Attn: Publications Supervisor, Dept. 303 Dubuque, IA 52004-0538

FAX NUMBER:

563-589-5800

Ideas, Comments (Please State Page Number):

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Company Name: Technician Name: Address: Phone: Fax No.: Dealer Acct. No.: THANK YOU!

TX,TM,FAX –19–03JUL01–1/1

TM1640 (15JAN04)


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Introduction

TM1640 (15JAN04)


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Contents 00

SECTION 00—General Information Group 0001—Safety Information Group 0002—General Specifications Group 0003—Torque Values Group 0004—Fuels and Lubricants

SECTION 11—Park Brake Group 1111—Active Elements Group 1160—Hydraulic System SECTION 16—Electrical System Group 1671—Batteries, Support and Cables Group 1672—Alternator, Regulator and Charging System Wiring Group 1673—Lighting System Group 1674—Wiring Harness and Switches Group 1675—System Controls Group 1677—Motors and Actuators

SECTION 01—Wheels Group 0110—Powered Wheels and Fasteners SECTION 02—Axles and Suspension Systems Group 0200—Removal and Installation Group 0225—Axle Shafts and U-Joints Group 0250—Axle Shaft, Bearings, Reduction Gears Group 0260—Hydraulic System

01

02

SECTION 17—Frame or Supporting Structure Group 1740—Frame Installation Group 1746—Frame Bottom Guards Group 1749—Chassis Weights

SECTION 03—Transmission Group 0300—Removal and Installation Group 0350—Gears, Shafts, Bearings and Power Shift Clutch Group 0360—Hydraulic System Group 0399—Dealer Fabricated Tools

03

SECTION 18—Operator’s Station Group 1800—Removal and Installation Group 1810—Operator Enclosure Group 1821—Seat and Seat Belts Group 1822—Steps and Handholds Group 1830—Heating and Air Conditioning Group 1899—Dealer Fabricated Tools

SECTION 04—Engine Group 0400—Removal and Installation

04

SECTION 19—Sheet Metal and Styling Group 1910—Hood or Engine Enclosure Group 1913—Miscellaneous Shields Group 1921—Grille and Grille Housing Group 1927—Miscellaneous Shields

SECTION 05—Engine Auxiliary Systems Group 0505—Cold Weather Starting Aids Group 0510—Cooling System Group 0515—Speed Controls Group 0520—Intake System Group 0530—External Exhaust System Group 0560—External Fuel Supply Systems

05

SECTION 20—Safety and Convenience Group 2002—Mirror Group 2003—Fire Extinguisher Group 2004—Horn and Warning Devices

SECTION 07—Dampener Drive Group 0752—Elements

07

SECTION 31—Loader Group 3102—Bucket Group 3140—Frames Group 3160—Hydraulic System

SECTION 09—Steering System Group 0960—Hydraulic System

09

SECTION 10—Service Brakes Group 1011—Active Elements Group 1060—Hydraulic System

10

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

11

COPYRIGHT  2004 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION Manual Previous Editions Copyright  1998, 1999, 2000, 2001, 2003

TM1640 (15JAN04)

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00

Section 00

General Information Contents Page

Page

Group 0001—Safety Information Handle Fluids Safely—Avoid Fires . . . . . . . .00-0001-1 Prevent Battery Explosions . . . . . . . . . . . . . .00-0001-1 Prepare for Emergencies. . . . . . . . . . . . . . . .00-0001-1 Prevent Acid Burns . . . . . . . . . . . . . . . . . . . .00-0001-2 Handle Chemical Products Safely . . . . . . . . .00-0001-3 Avoid High-Pressure Fluids . . . . . . . . . . . . . .00-0001-3 Park Machine Safely . . . . . . . . . . . . . . . . . . .00-0001-4 Support Machine Properly . . . . . . . . . . . . . . .00-0001-4 Wear Protective Clothing. . . . . . . . . . . . . . . .00-0001-4 Work in Clean Area. . . . . . . . . . . . . . . . . . . .00-0001-5 Service Machines Safely . . . . . . . . . . . . . . . .00-0001-5 Work In Ventilated Area . . . . . . . . . . . . . . . .00-0001-5 Illuminate Work Area Safely . . . . . . . . . . . . .00-0001-5 Replace Safety Signs . . . . . . . . . . . . . . . . . .00-0001-6 Use Proper Lifting Equipment . . . . . . . . . . . .00-0001-6 Remove Paint Before Welding or Heating . . .00-0001-7 Avoid Heating Near Pressurized Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-7 Keep ROPS Installed Properly . . . . . . . . . . .00-0001-8 Service Tires Safely . . . . . . . . . . . . . . . . . . .00-0001-8 Avoid Harmful Asbestos Dust . . . . . . . . . . . .00-0001-9 Practice Safe Maintenance . . . . . . . . . . . . .00-0001-10 Use Proper Tools . . . . . . . . . . . . . . . . . . . .00-0001-10 Dispose of Waste Properly . . . . . . . . . . . . .00-0001-11 Live With Safety . . . . . . . . . . . . . . . . . . . . .00-0001-11

Service Recommendations For Flat Face O-Ring Seal Fittings. . . . . . . . . . . . . . . . . .00-0003-9 Service Recommendations for Metric Series Four Bolt Flange Fitting . . . . . . . .00-0003-10 Service Recommendations For Inch Series Four Bolt Flange Fittings. . . . . . . .00-0003-11 Group 0004—Fuels and Lubricants Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-1 Lubricity of Diesel Fuel . . . . . . . . . . . . . . . . .00-0004-1 Low Sulfur Diesel Fuel Conditioner . . . . . . . .00-0004-2 Diesel Fuel Storage. . . . . . . . . . . . . . . . . . . .00-0004-2 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-3 Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . .00-0004-3 Transmission, Hydraulic System, Park Brake, and Differential Oil . . . . . . . . . . . . .00-0004-4 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-5 Alternative and Synthetic Lubricants . . . . . . .00-0004-6 Lubricant Storage . . . . . . . . . . . . . . . . . . . . .00-0004-6 Mixing of Lubricants . . . . . . . . . . . . . . . . . . .00-0004-7

Group 0002—General Specifications 624H Specifications. . . . . . . . . . . . . . . . . . . .00-0002-1 Drain and Refill Capacities—624H/TC62H . .00-0002-4 TC62H Specifications . . . . . . . . . . . . . . . . . .00-0002-5 Drain and Refill Capacities—TC62H . . . . . . .00-0002-8 Group 0003—Torque Values Hardware Torque Specifications . . . . . . . . . .00-0003-1 ROPS Torque Specifications . . . . . . . . . . . . .00-0003-1 Metric Bolt and Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2 Additional Metric Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-3 Unified Inch Bolt and Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-5 Check Oil Lines And Fittings . . . . . . . . . . . . .00-0003-6 Service Recommendations for O-Ring Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0003-7 TM1640 (15JAN04)

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TM1640 (15JAN04)

00-2


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Group 0001

Safety Information 00 0001 1

Handle Fluids Safely—Avoid Fires

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris.

TS227

Do not store oily rags; they can ignite and burn spontaneously.

–UN–23AUG88

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

DX,FLAME –19–29SEP98–1/1

Prevent Battery Explosions

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

TS204

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

–UN–23AUG88

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

DX,SPARKS –19–03MAR93–1/1

Prepare for Emergencies Be prepared if a fire starts.

TS291

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

–UN–23AUG88

Keep a first aid kit and fire extinguisher handy.

DX,FIRE2 –19–03MAR93–1/1

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PN=9

Safety Information

Prevent Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. 2. 3. 4. 5.

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

If you spill acid on yourself:

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.

–UN–23AUG88

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.

TS203

00 0001 2

DX,POISON –19–21APR93–1/1

TM1640 (15JAN04)

00-0001-2


PN=10


Handle Chemical Products Safely

Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

TS1132

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

–UN–26NOV90

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.

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

DX,MSDS,NA –19–03MAR93–1/1

Avoid High-Pressure Fluids

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

X9811

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

–UN–23AUG88

Escaping fluid under pressure can penetrate the skin causing serious injury.

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

DX,FLUID –19–03MAR93–1/1

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00-0001-3


PN=11

Safety Information

Park Machine Safely

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.

TS230

• • • •

–UN–24MAY89

Before working on the machine:

DX,PARK –19–04JUN90–1/1

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

TS229

Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices can settle or leak down.

–UN–23AUG88

Support Machine Properly

When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator’s manual.

DX,LOWER –19–24FEB00–1/1

Wear Protective Clothing

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

–UN–23AUG88

Wear close fitting clothing and safety equipment appropriate to the job.

TS206

00 0001 4

DX,WEAR2 –19–03MAR93–1/1

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PN=12


Work in Clean Area

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.

T6642EJ

• • • •

–UN–18OCT88

Before starting a job:

DX,CLEAN –19–04JUN90–1/1

Service Machines Safely

TS228

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

–UN–23AUG88

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

DX,LOOSE –19–04JUN90–1/1

Work In Ventilated Area

TS220

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

–UN–23AUG88

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

DX,AIR –19–17FEB99–1/1

TS223

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

–UN–23AUG88

Illuminate Work Area Safely

DX,LIGHT –19–04JUN90–1/1

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PN=13

Safety Information

Replace Safety Signs

TS201

–UN–23AUG88

Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

DX,SIGNS1 –19–04JUN90–1/1

Use Proper Lifting Equipment Lifting heavy components incorrectly can cause severe injury or machine damage.

–UN–23AUG88

Follow recommended procedure for removal and installation of components in the manual.

TS226

00 0001 6

DX,LIFT –19–04JUN90–1/1

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PN=14


Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust.

• Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding. • If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. • If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

TS220

Remove paint before heating:

–UN–23AUG88

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

Do not use a chlorinated solvent in areas where welding will take place. Do all work in an area that is well ventilated to carry toxic fumes and dust away. Dispose of paint and solvent properly.

DX,PAINT –19–24JUL02–1/1

TS953

Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.

–UN–15MAY90

Avoid Heating Near Pressurized Fluid Lines

DX,TORCH –19–03MAR93–1/1

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PN=15

Safety Information

Keep ROPS Installed Properly

TS212

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

–UN–23AUG88

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

DX,ROPS3 –19–03MAR93–1/1

Service Tires Safely Explosive separation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel.

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

–UN–23AUG88

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

TS211

00 0001 8

DX,RIM –19–24AUG90–1/1

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PN=16


Avoid Harmful Asbestos Dust

TS220

Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated.

–UN–23AUG88

Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.

Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos. Keep bystanders away from the area.

DX,DUST –19–15MAR91–1/1

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PN=17

Safety Information

Practice Safe Maintenance Understand service procedure before doing work. Keep area clean and dry. Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool. Securely support any machine elements that must be raised for service work.

On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.

TS218

On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.

–UN–23AUG88

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

DX,SERV –19–17FEB99–1/1

Use Proper Tools

Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

–UN–08NOV89

Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

TS779

00 0001 10

Use only service parts meeting John Deere specifications.

DX,REPAIR –19–17FEB99–1/1

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PN=18


Dispose of Waste Properly

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

TS1133

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

–UN–26NOV90

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

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.

DX,DRAIN –19–03MAR93–1/1

Live With Safety

TS231

–19–07OCT88

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

DX,LIVE –19–25SEP92–1/1

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Group 0002

General Specifications 00 0002 1

T107472

–UN–19FEB97

624H Specifications

Item

Measurement

Specification

A—Bucket Hinge Height

Distance

3961 mm (13 ft 0 in.)

B—Dump Height

Distance

2858 mm (9 ft 5 in.)

C—Dump Reach

Distance

1038 mm (3 ft 5 in.)

D—Machine

Overall Height

3300 mm (10 ft 10 in.)

E—Wheelbase

Length

3030 mm (9 ft 11 in.)

F—Ground Clearance

Distance

406 mm (16.0 in.)

G—Machine

Overall Length

7610 m (25 ft 0 in.)

Continued on next page

TM1640 (15JAN04)

00-0002-1

TX,9000,JC2184 –19–21APR99–1/3


PN=21


Item

Measurement

Specification

Machine

Standard Operating Weight

13 560 kg (29,894 lb)

Machine

Optional Counterweight

474 kg (1,045 lb)

NOTE: Specifications and design subject to change without notice. Wherever applicable, specifications are in accordance with SAE standards. Except where otherwise noted, specifications are based on a machine equipped with all standard equipment, with 474 Item

kg (1,045 lb) optional counterweight, ROPS cab, differential lock front axle with standard rear axle, 2 spool valve with two lever control, heater and defroster, 79 kg (175 lb) operator and full fuel tank.

Measurement

Specification

John Deere PowerTech 6.8T with altitude compensating turbocharger

Power

160 SAE net hp (119 kW) @ 2200 rpm 172 SAE gross hp (128 kW) @ 2200 rpm

Piston displacement

Power

6.8 L (414 cu in.)

Air cleaner w/dual safety element and restriction indicator

Type

Dual stage dry type with restriction indicator

Electrical system

Voltage

24 volt 55-amp

Engine:

Cold cranking capacity at -18°C (0°F) Current

2-12 volt with 625 amps

Reserve capacity

Time

160 min.

Torque Converter

Type

Single phase, single stage

Type

Computer controlled powershift

1

Speed

0—7.7 km/h (0—4.8 mph)

2

Speed

0—12.0 km/h (0—7.5 mph)

3

Speed

0—22.6 km/h (0—14.0 mph)

4

Speed

0—39.5 km/h (0—24.5 mph)

Transmission Countershaft Forward Travel:

PowerTech is a trademark of Deere & Company.

TM1640 (15JAN04)


00-0002-2

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PN=22

General Specifications

Item

00 0002 3

Measurement

Specification

1

Speed

0—8.1 km/h (0—5.0 mph)

2

Speed

0—12.7 km/h (0—8.0 mph)

3

Speed

0—23.9 km/h (0—14.9 mph)

Reverse Travel:

NOTE: All travel speeds are with 20.5 x 25 12PR (L2) tires. Brakes, Service: • Hydraulically-actuated, 4 wheel, inboard-mounted, wet disk • Foot-operated by either pedal • Left and right pedal also disconnects transmission (if selected by operator) • External inspection • Low brake pressure warning light and buzzer in monitor Brakes, Park: • Multi wet disk • Spring applied, hydraulically released parking brake is bathed in cooling oil • Transmission disconnects with park brake applied • Warning light in monitor—dual-level

• Amber lights with transmission in neutral • Red STOP indicator lights and buzzer sounds with transmission in gear Steering: • Fully hydraulic • Frame articulated 80° by two hydraulic cylinders • Turning radius (to centerline of outside tire): 5,187 mm (17 ft 0 in.) Tires: • 17.5x25 Bias (L2) and (L3) • 17.5R25 Radial XTLA (L2) XHAT (L3) and GP-2B (L2) • 20.5x25 Bias (L2) and (L3) • 20.5R25 Radial XTLA (L2), XHAT (L3) and GP-2B (L2)

TX,9000,JC2184 –19–21APR99–3/3

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PN=23


Drain and Refill Capacities—624H/TC62H Item

Measurement

Specification

Cooling System

Capacity

22 L (23 qt)

Fuel Tank

Capacity

265 L (70 gal)

Engine Crankcase and Filter

Capacity

20 L (21 qt) (S.N. —582360) 21 L (22 qt) (S.N. 582361—)

Transmission Case and Filter

Capacity

27 L (29 qt)

Front Differential

Capacity

25 L (26 qt)

Rear Differential

Capacity

20 L (21 qt)

Hydraulic Reservoir and Filters

Capacity

117 L (31 gal)

Park Brake

Capacity

0.300 L (10 oz)

CED,OUOE002,1792 –19–16SEP98–1/1

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PN=24


T107087

–UN–20FEB97

TC62H Specifications

Item

Measurement

Specification

A—Bucket Hinge Height

Distance

4005 mm (13 ft 2 in.)

B—Dump Height

Distance

2907 mm (9 ft 6 in.)

C—Dump Reach

Distance

1278 mm (4 ft 2 in.)

D—Machine

Overall Height

3300 mm (10 ft 10 in.)

E—Wheelbase

Length

3030 mm (9 ft 11 in.)

F—Ground Clearance

Distance

406 mm (16.0 in.)

G—Machine

Overall Length

7671 m (25 ft 2 in.)


TM1640 (15JAN04)

00-0002-5

TX,9000,JC2185 –19–21APR99–1/3


PN=25


Item

Measurement

Specification

Machine

Standard Operating Weight

13 361 kg (29,456 lb)

Machine

Optional Counterweight

474 kg (1,045 lb)

NOTE: Specifications and design subject to change without notice. Wherever applicable, specifications are in accordance with SAE standards. Except where otherwise noted, specifications are based on a machine equipped with all standard equipment, with 474 Item

kg (1,045 lb) optional counterweight, ROPS cab, differential lock front axle with standard rear axle, 2 spool valve with two lever control, heater and defroster, 79 kg (175 lb) operator and full fuel tank.

Measurement

Specification

John Deere PowerTech 6.8T with altitude compensating turbocharger

Power

160 SAE net hp (119 kW) @ 2200 rpm 172 SAE gross hp (128 kW) @ 2200 rpm

Piston displacement

Power

6.8 L (414 cu in.)

Air cleaner w/dual safety element and restriction indicator

Type

Dual stage dry type with restriction indicator

Electrical system

Voltage

24 volt 55-amp

Engine:

Cold cranking capacity at -18°C (0°F) Current

2-12 volt with 625 amps

Reserve capacity

Time

160 min.

Torque Converter

Type

Single phase, single stage

Type

Computer controlled powershift

1

Speed

0—7.7 km/h (0—4.8 mph)

2

Speed

0—12.0 km/h (0—7.5 mph)

3

Speed

0—22.6 km/h (0—14.0 mph)

4

Speed

0—39.5 km/h (0—24.5 mph)

Transmission Countershaft Forward Travel:


TM1640 (15JAN04)


00-0002-6

TX,9000,JC2185 –19–21APR99–2/3


PN=26

General Specifications

Item

00 0002 7

Measurement

Specification

1

Speed

0—8.1 km/h (0—5.0 mph)

2

Speed

0—12.7 km/h (0—8.0 mph)

3

Speed

0—23.9 km/h (0—14.9 mph)

Reverse Travel:

NOTE: All travel speeds are with 20.5 x 25 12PR (L2) tires. Brakes, Service: • Hydraulically-actuated, 4 wheel, inboard-mounted, wet disk • Foot-operated by either pedal • Left and right pedal also disconnects transmission (if selected by operator) • External inspection • Low brake pressure warning light and buzzer in monitor Brakes, Park: • Multi wet disk • Spring applied, hydraulically released parking brake is bathed in cooling oil • Transmission disconnects with park brake applied • Warning light in monitor—dual-level

• Amber lights with transmission in neutral • Red STOP indicator lights and buzzer sounds with transmission in gear Steering: • Fully hydraulic • Frame articulated 80° by two hydraulic cylinders • Turning radius (to centerline of outside tire): 5,187 mm (17 ft 0 in.) Tires: • 17.5x25 Bias (L2) and (L3) • 17.5R25 Radial XTLA (L2) XHAT (L3) and GP-2B (L2) • 20.5x25 Bias (L2) and (L3) • 20.5R25 Radial XTLA (L2), XHAT (L3) and GP-2B (L2)

TX,9000,JC2185 –19–21APR99–3/3

TM1640 (15JAN04)

00-0002-7


PN=27


Drain and Refill Capacities—TC62H Item

Measurement

Specification

Cooling System

Capacity

22 L (23 qt)

Fuel Tank

Capacity

265 L (70 gal)

Engine Crankcase and Filter

Capacity

20 L (21 qt) (S.N. —582360) 21 L (22 qt) (S.N. 582361—)

Transmission Case and Filter

Capacity

27 L (29 qt)

Front Differential

Capacity

25 L (26 qt)

Rear Differential

Capacity

20 L (21 qt)

Hydraulic Reservoir and Filters

Capacity

117 L (31 gal)

Park Brake

Capacity

0.300 L (10 oz)

CED,OUOE002,1795 –19–16SEP98–1/1

TM1640 (15JAN04)

00-0002-8


PN=28

Group 0003

Torque Values 00 0003 1

Hardware Torque Specifications Check cap screws and nuts to be sure they are tight. If hardware is loose, tighten to torque shown on the following charts unless a special torque is specified.

T82,SKMA,AT –19–01AUG94–1/1

ROPS Torque Specifications

–UN–23AUG88

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

TS176

The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered. A damaged ROPS should be replaced, not reused. When installation of equipment on a machine necessitates loosening or removing ROPS, mounting bolts must be tightened to 1150 N•m (850 lb-ft). Item

Measurement

Specification

ROPS Mounting Bolts

Torque

1150 N•m (850 lb-ft)

TX,9000,JC2196 –19–17SEP97–1/1

TM1640 (15JAN04)

00-0003-1


PN=29

Torque Values

–UN–07SEP99

Metric Bolt and Cap Screw Torque Values

TORQ2

00 0003 2

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

Lubricateda N•m(lb-ft)

Dryb N•m(lb-ft)


Dryb N•m(lb-ft)


Dryb N•m(lb-ft)


Dryb 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)

Size

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 procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically.

Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class.

Tighten plastic insert or crimped steel-type lock nuts to approximately 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 the full torque value.

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

DX,TORQ2 –19–01OCT99–1/1

TM1640 (15JAN04)

00-0003-2


PN=30

Torque Values 00 0003 3 –UN–18OCT88

Additional Metric Cap Screw Torque Values

T6873AA

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

–UN–18OCT88

Check tightness of cap screws periodically. Torque values listed are for general use only. Do not use these values if a different torque value or tightening procedure is listed for a specific application. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

T6873AB

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

–UN–18OCT88

Make sure fastener threads are clean and you properly start thread engagement. This will prevent them from failing when tightening.

T6873AC

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


TM1640 (15JAN04)

00-0003-3

04T,90,M170 –19–29SEP99–1/2


PN=31


METRIC CAP SCREW TORQUE VALUESa T-Bolt Nominal Dia 8

H-Bolt

N•m

lb-ft

29

21

N•m

lb-ft

M-Bolt N•m

lb-ft

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

687

Torque tolerance is ±10%.

a

04T,90,M170 –19–29SEP99–2/2

TM1640 (15JAN04)

00-0003-4


PN=32


TORQ1A

–UN–27SEP99

Unified Inch Bolt and Cap Screw Torque Values

Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings Grade 1 (No Mark) Size 1/4

Grade 2a (No Mark)

Grade 5, 5.1 or 5.2

Grade 8 or 8.2

Lubricatedb N•m(lb-ft)

Dryc N•m(lb-ft)


Dryc N•m(lb-ft)


Dryc N•m(lb-ft)


Dryc N•m(lb-ft)

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 procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically.

Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.

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

Tighten plastic insert or crimped steel-type lock nuts to approximately 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 the full torque value.

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

DX,TORQ1 –19–01OCT99–1/1

TM1640 (15JAN04)

00-0003-5


PN=33

Torque Values

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

–UN–23AUG88

Check Oil Lines And Fittings

X9811

00 0003 6

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this 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 or damage. Make sure all clamps are in position and tight. Make sure hoses are not twisted or touching moving machine parts. If abrasion or wear occurs, replace immediately. Tubing with dents may cause the oil to overheat. If you find tubing with dents, install new tubing immediately. IMPORTANT: Tighten fittings as specified in torque chart. When you tighten connections, use two wrenches to prevent bending or breaking tubing and fittings.

TX,90,DH1559 –19–01AUG94–1/1

TM1640 (15JAN04)

00-0003-6


PN=34


Service Recommendations for O-Ring Boss Fittings Straight Fitting –UN–18OCT88

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

T6243AE

2. Lubricate O-ring with petroleum jelly. Place electrical tape over threads to protect O-ring. Slide O-ring over tape and into O-ring groove of fitting. Remove tape. 3. Tighten fitting to torque value shown on chart.


TM1640 (15JAN04)

00-0003-7

04T,90,K66 –19–29SEP99–1/2


PN=35

Torque Values Angle Fitting

2. Turn fitting into threaded boss until back-up washer contacts face of boss. 3. Turn fitting head-end counterclockwise to proper index (maximum of one turn).

NOTE: Do not allow hoses to twist when tightening fittings.

–UN–18OCT88

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

T6520AB

00 0003 8

4. Hold fitting head-end with a wrench and tighten locknut and 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%.

04T,90,K66 –19–29SEP99–2/2

TM1640 (15JAN04)

00-0003-8


PN=36


Service Recommendations For Flat Face O-Ring Seal Fittings 1. Inspect the fitting sealing surfaces and O-ring. They must be free of dirt or defects.

fittings, use backup wrench on straight hose couplings.

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

IMPORTANT: Tighten fittings to 150% of listed torque value if indexing is necessary or if fitting is attached to an actuating devise.

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

Tighten fittings to 50% of listed torque value if used in aluminum housing.

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

FLAT FACE O-RING SEAL FITTING TORQUE* Nominal Tube O.D.

Thread Size

Swivel Nut

Bulkhead Nut

mm

in.

in.

N•m

lb-ft

N•m

lb-ft

6.35

0.250

9/16-18

16

12

12

9

9.52

0.375

11/16-16

24

18

24

18

12.70

0.500

13/16-16

50

37

46

34

15.88

0.625

1-14

69

51

62

46

19.05

0.750

1 3/16-12

102

75

102

75

22.22

0.875

1 3/16-12

102

75

102

75

25.40

1.000

1 7/16-12

142

105

142

105

31.75

1.250

1 11/16-12

190

140

190

140

38.10

1.500

2-12

217

160

217

160

*Torque tolerance is +15 -20% unless otherwise specified. Stud End O-ring Seal Torque for Straight and Adjustable Fittings* Thread Size

Straight Hex Size

Locknut Hex Size

Inch

Inch

Inch

Straight Fitting or Locknut Toque N•m

lb-ft

3/8-24

5/8

9/16

12

9

7/16-20

5/8

5/8

21

15

1/2-20

3/4

11/16

26

19

9/16-18

3/4

3/4

34

25

3/4-16

7/8

15/16

73

55

7/8-14

1 1/16

1 1/16

104

76

1 1/16-12

1 1/4

1 3/8

176

130

1 3/16-12

1 3/8

1 1/2

230

170

1 5/16-12

1 1/2

1 5/8

285

210

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

04T,90,K67 –19–02MAR00–1/1

TM1640 (15JAN04)

00-0003-9


PN=37

Torque Values

–UN–01MAR90

Service Recommendations for Metric Series Four Bolt Flange Fitting

T6890BB

00 0003 10

A—Sealing Surface

B—Split Flange

C—Pinched O-Ring

D—Single Piece Flange

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

1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component.

DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten.

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

TORQUE CHARTa

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

Thread

N•m

lb-ft

M6

12

9

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

M12

95

70

M14

157

116

M16

217

160

M18

334

246

M20

421

318

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

b

M8

30

22

M10

57

42

Tolerance ± 10%. The torques given are enough for the given size connection with the recommended working pressure. Increasing cap screw torque beyond these amounts will result in flange and cap screw bending and connection failures. a

b

Metric standard thread.

04T,90,K175 –19–29SEP99–1/1

TM1640 (15JAN04)

00-0003-10


PN=38


T6890BB

–UN–01MAR90

Service Recommendations For Inch Series Four Bolt Flange Fittings

A—Sealing Surface

B—Split Flange

C—Pinched O-Ring

1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component. 2. Install O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C). 4. Single piece flange (D): Place hydraulic line in center of flange and install cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5. Tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below.

D—Single Piece Flange TORQUE CHART N•m

Nominal Flange Size 1/2

lb-ft

Cap Screw Size 5/16-18 UNC

Min

Max

Min

Max

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

195

DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten.

04T,90,K174 –19–01AUG94–1/1

TM1640 (15JAN04)

00-0003-11


PN=39


TM1640 (15JAN04)

00-0003-12


PN=40

Group 0004

Fuels and Lubricants 00 0004 1

Diesel Fuel Consult your local fuel distributor for properties of the diesel fuel available in your area.

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

In general, diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed.

Sulfur content:

Diesel fuels specified to EN 590 or ASTM D975 are recommended. In all cases, the fuel shall meet the following properties: Cetane number of 40 minimum. Cetane number greater than 50 is preferred, especially for temperatures below -20°C (-4°F) or elevations above 1500 m (5,000 ft).

• Sulfur content should not exceed 0.5%. Sulfur content less than 0.05% is preferred. • If diesel fuel with sulfur content greater than 0.5% sulfur content is used, reduce the service interval for engine oil and filter by 50%. • DO NOT use diesel fuel with sulfur content greater than 1.0%. Bio-diesel fuels may be used ONLY if the fuel properties meet DIN 51606 or equivalent specification. DO NOT mix used engine oil or any other type of lubricant with diesel fuel.

Cold Filter Plugging Point (CFPP) below the expected low temperature OR Cloud Point at least 5°C (9°F) below the expected low temperature.

TX,45,JC1132 –19–22MAY96–1/1

Lubricity of Diesel Fuel Diesel fuel must have adequate lubricity to ensure proper operation and durability of fuel injection system components. Diesel fuels for highway use in the United States and Canada require sulfur content less than 0.05%. Diesel fuel in the European Union requires sulfur content less than 0.05%.

Use of low lubricity diesel fuels may also cause accelerated wear, injection nozzle erosion or corrosion, engine speed instability, hard starting, low power, and engine smoke. Fuel lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE scuffing test. ASTM D975 and EN 590 specifications do not require fuels to pass a fuel lubricity test.

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

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

DX,FUEL5 –19–24JAN00–1/1

TM1640 (15JAN04)

00-0004-1


PN=41


Low Sulfur Diesel Fuel Conditioner When possible, use existing fuel formulations for engines used off-highway. This fuel will not require any additives to provide good performance and engine reliability. However, many local fuel distributors will not carry both low and regular sulfur diesel fuels. If the local fuel distributor will supply only low sulfur fuel, order and use John Deere PREMIUM DIESEL FUEL CONDITIONER. It provides lubricating properties along with other useful benefits, such as cetane improver, anti-oxidant, fuel stabilizer, corrosion inhibitor and others. John Deere PREMIUM DIESEL FUEL CONDITIONER is specifically for use with low sulfur fuels. Nearly all other diesel fuel conditioners only improve cold weather flow and stabilize long-term fuel storage. They do not contain the lubrication additives needed by rotary fuel injection pumps.

TX,45,JC2126 –19–15AUG97–1/1

Diesel Fuel Storage Proper fuel storage is critically important. Use clean storage and transfer tanks. Periodically drain water and sediment from bottom of tank. Store fuel in a convenient place away from buildings. IMPORTANT: DO NOT store diesel fuel in galvanized containers. Diesel fuel stored in galvanized containers reacts with zinc coating on container to form zinc flakes. If fuel contains water, a zinc gel will also form. The gel and flakes will quickly plug fuel filters, damage injection nozzles and injection pump. DO NOT use brass-coated containers for fuel storage. Brass is an alloy of copper and zinc.

Store diesel fuel in plastic, aluminum, and steel containers specially coated for diesel fuel storage. Avoid storing fuel over long periods of time. If fuel is stored for more than a month prior to use, or there is a slow turnover in fuel tank or supply tank, add a fuel conditioner such as John Deere PREMIUM DIESEL FUEL CONDITIONER or equivalent to stabilize the fuel and prevent water condensation. John Deere PREMIUM DIESEL FUEL CONDITIONER is available in winter and summer formulas. Fuel conditioner also reduces fuel gelling and controls wax separation during cold weather. Consult your John Deere engine distributor or servicing dealer for recommendations and local availability. Always follow manufacturer’s directions on label.

TX,45,JC1772 –19–08JAN97–1/1

TM1640 (15JAN04)

00-0004-2


PN=42


Fuel Tank CAUTION: Handle fuel carefully. If the engine is hot or running, DO NOT fill the fuel tank. DO NOT smoke while you fill fuel tank or work on fuel system.

Specification Fuel Tank—Capacity .................................................... 265 L (70 gal)

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

CED,OUOE002,1783 –19–16SEP98–1/1

T101239

–19–22MAY96

Diesel Engine Oil

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

The following oil is also recommended:

The following oil is preferred:

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

• John Deere TORQ-GARD SUPREME

• John Deere PLUS-50

Multi-viscosity diesel engine oils are preferred. If John Deere PLUS-50 engine oil and a John Deere oil filter are used, the service interval for oil and filter changes may be extended by 50 hours.

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

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

TM1640 (15JAN04)

CED,OUO1021,176 –19–25MAR99–1/1

00-0004-3


PN=43

Fuels and Lubricants

–19–10MAY96

Transmission, Hydraulic System, Park Brake, and Differential Oil

T100663

00 0004 4

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

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

Use the following oil when a biodegradable fluid is required:

The following oils are preferred: • John Deere HY-GARD • John Deere Low Viscosity HY-GARD

• John Deere BIO-HY-GARD1

Other oils may be used if they meet one of the following:

HY-GARD is a trademark of Deere & Company. BIO-HY-GARD is a trademark of Deere & Company. 1

BIO-HY-GARD meets or exceeds the minimum biodegradability of 80% within 21 days according to CEC-L-33-T-82 test method. BIO-HY-GARD should not be mixed with mineral oils because this reduces the biodegradability and makes proper oil recycling impossible. TX,45,JC1864 –19–17FEB97–1/1

TM1640 (15JAN04)

00-0004-4


PN=44


T8358AI

–19–27MAR95

Grease

Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval. The following greases are preferred: • John Deere MOLY HIGH TEMPERATURE EP GREASE

• John Deere HIGH TEMPERATURE EP GREASE • John Deere GREASE-GARD Other greases may be used if they meet one of the following: • NLGI Performance Classification GC-LB

TX,45,JC1134 –19–22MAY96–1/1

TM1640 (15JAN04)

00-0004-5


PN=45


Alternative and Synthetic Lubricants Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual. Some John Deere brand coolants and lubricants may not be available in your location. Consult your John Deere dealer to obtain information and recommendations. Synthetic lubricants may be used if they meet the performance requirements as shown in this manual. The temperature limits and service intervals shown in this manual apply to both conventional and synthetic oils. Re-refined base stock products may be used if the finished lubricant meets the performance requirements.

DX,ALTER –19–15JUN00–1/1

Lubricant Storage Your equipment can operate at top efficiency only when clean lubricants are used.

Make certain that all containers are properly marked to identify their contents.

Use clean containers to handle all lubricants.

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

Whenever possible, store lubricants and containers in an area protected from dust, moisture, and other contamination. Store containers on their side to avoid water and dirt accumulation.

DX,LUBST –19–18MAR96–1/1

TM1640 (15JAN04)

00-0004-6


PN=46


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

Consult your John Deere dealer to obtain specific information and recommendations.

Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance.

DX,LUBMIX –19–18MAR96–1/1

TM1640 (15JAN04)

00-0004-7


PN=47


TM1640 (15JAN04)

00-0004-8


PN=48

Section 01

Wheels Contents

01

Page

Group 0110—Powered Wheels and Fasteners Service Equipment and Tools . . . . . . . . . . . .01-0110-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .01-0110-1 Wheel Remove and Install . . . . . . . . . . . . . . . . . .01-0110-1 Tire Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-3 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-4

TM1640 (15JAN04)

01-1


PN=1

Contents

01

TM1640 (15JAN04)

01-2


PN=2

Group 0110

Powered Wheels and Fasteners Service Equipment and Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.

01 0110 1

SERVICEGARD is a trademark of Deere & Company.

CED,OUOE003,3284 –19–25MAR99–1/3

10-Ton Shop Stand To support machine while removing and installing wheels.

CED,OUOE003,3284 –19–25MAR99–2/3

Wheel and Axle Lift . . . . . . . . . . . . . . . . . . . . JT05726 To remove and install wheels.

CED,OUOE003,3284 –19–25MAR99–3/3

Specifications Item

Measurement

Specification

Wheel Cap Screw

Torque

675 N•m (500 lb-ft)

Valve Stem Retaining Nut

Torque

6 N•m (50 lb-in.)

CED,OUOE003,3285 –19–25MAR99–1/1

Remove and Install Wheel 1. Raise machine and place 10-ton shop stand under axle. CAUTION: Use a lifting device for heavy components. 2. Place wheel and axle lift under wheel. Fasten safety chain around upper part of tire. Continued on next page

TM1640 (15JAN04)

01-0110-1

TX,01,111685 –19–01NOV02–1/2


PN=51

Powered Wheels and Fasteners 3. Remove cap screws (A). Remove wheel. 4. Clean mounting surface on wheel and axle flange. 5. Install wheel. Tighten cap screws (A). Remove and Install Wheel—Specification Wheel Retainer Cap Screws—Dry Torque ......................................................................... 620 N•m (460 lb-ft)

–UN–24MAY90

A—Wheel Cap Screw (14 used)

T7134FA

01 0110 2

TX,01,111685 –19–01NOV02–2/2

TM1640 (15JAN04)

01-0110-2


PN=52

Powered Wheels and Fasteners

Remove Tire CAUTION: Explosive separation of a tire and rim parts can cause serious injury or death. 01 0110 3

Only attempt to mount a tire if you have the proper equipment and experience to perform the job. Have it done by your John Deere dealer or a qualified repair service. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.

–UN–23AUG88

Inspect tires and wheels daily. Do not operate with low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

TS211

Failure to follow proper procedures when demounting a tire from a wheel or rim can produce an explosion which may result in serious bodily injury. DO NOT attempt to demount a tire unless you have proper equipment and experience to perform the job safely. Have it done by a qualified tire repair service.

NOTE: See John Deere Off-The-Road Tire Maintenance Manual to remove tire from wheel. Tire can be removed without removing wheel.


TM1640 (15JAN04)

01-0110-3

TX,01,111686 –19–23OCT98–1/2


PN=53

Powered Wheels and Fasteners Before attempting any demounting operation, always completely deflate tire. Remove cap (A) and valve core (B) from valve. Remove valve nut (C).

–UN–22OCT92

Inspect all parts for damage. Replace parts as necessary.

T7751GU

A—Cap B—Valve Core C—Valve Nut

TX,01,111686 –19–23OCT98–2/2

Install Tire

–UN–22OCT88

CAUTION: Failure to follow proper procedures when mounting a tire from a wheel or rim can produce an explosion which may result in serious bodily injury. DO NOT attempt to mount a tire unless you have proper equipment and experience to perform the job safely. Have it done by a qualified tire repair service.

T6564BR

01 0110 4

NOTE: See John Deere Off-The-Road Tire Maintenance Manual to mount the tire on the wheel. To prevent slipping of the wheel under load, the inside and outside wheel must be free of paint, rust, oil, grease, dirt or other foreign material before installation.

A—Front Flange B—Bead Seat Band C—Lock Ring D—O-Ring E—Cap

Install valve stem in rim base and tighten retaining nut. Specification Valve Stem Retaining Nut— Torque .............................................................................. 6 N•m (50 lb-in.)

CAUTION: Serious bodily injury can occur from explosion when mounting and inflating tires if safe procedures are not followed. Use only recommended air pressure. Pressure over this limit can cause explosion. Inflate tire. Apply John Deere Non-Soap Lubricating Grease, or an equivalent, on threads of cap (E). Install cap on valve stem shield.

TX,01,111687 –19–23OCT98–1/1

TM1640 (15JAN04)

01-0110-4


PN=54

Section 02

Axles and Suspension Systems Contents Page

Group 0200—Removal and Installation Service Equipment and Tools . . . . . . . . . . . .02-0200-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .02-0200-2 Front Axle and Differential Remove and Install . . . . . . . . . . . . . . . . . .02-0200-3 Rear Axle And Differential Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-9 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-14 Axle Oscillating Supports Disassemble and Assemble. . . . . . . . . . .02-0200-18

02

Group 0225—Axle Shafts and U-Joints Specifications . . . . . . . . . . . . . . . . . . . . . . . .02-0225-1 Universal Joint and Drive Shaft Remove and Install . . . . . . . . . . . . . . . . . .02-0225-2 Disassemble, Inspect and Assemble . . . . .02-0225-4 Group 0250—Axle Shaft, Bearings, Reduction Gears John Deere TeamMate III Axles—Use CTM150. . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-1 Essential Tools . . . . . . . . . . . . . . . . . . . . . . .02-0250-1 Service Equipment and Tools . . . . . . . . . . . .02-0250-2 Other Material . . . . . . . . . . . . . . . . . . . . . . . .02-0250-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . .02-0250-3 Axle Disconnect Input Shaft Cross-Section View . . . . . . . . . . . . . . . . . .02-0250-4 Remove and Install . . . . . . . . . . . . . . . . . .02-0250-5 Disassemble, Inspect and Assemble . . . . .02-0250-6 Group 0260—Hydraulic System Specifications . . . . . . . . . . . . . . . . . . . . . . . .02-0260-1 Differential Lock Solenoid Valve Remove and Install . . . . . . . . . . . . . . . . . .02-0260-2 Axle Recirculation System. . . . . . . . . . . . . . .02-0260-3 Air Recirculation System With Optional Oil Coolers. . . . . . . . . . . . . .02-0260-4 Axle Oil Coolers Exploded View. . . . . . . . . . . . . . . . . . . . . .02-0260-6 Front Axle Oil Cooler Remove and Install . . . . . . . . . . . . . . . . . .02-0260-7 Disassemble and Assemble. . . . . . . . . . . .02-0260-9 Rear Axle Oil Cooler Remove and Install . . . . . . . . . . . . . . . . .02-0260-10

TM1640 (15JAN04)

02-1


PN=1

Contents

02

TM1640 (15JAN04)

02-2


PN=2

Group 0200

Removal and Installation Service Equipment and Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.


CED,OUOE003,3287 –19–25MAR99–1/4

12-1/2 Ton Floor Stands To support machine while removing axle and differential.

CED,OUOE003,3287 –19–25MAR99–2/4

Wheel and Axle Lift . . . . . . . . . . . . . . . . . . . . JT05726 To remove and install wheels.

CED,OUOE003,3287 –19–25MAR99–3/4

Low-Lift Jack . . . . . . . . . . . . . . . . . . . . . . . JT01642A For removal and installation of axle and differential.

CED,OUOE003,3287 –19–25MAR99–4/4

TM1640 (15JAN04)

02-0200-1


PN=57

02 0200 1

Removal and Installation

Specifications Item

Measurement

Specification

624H Loader

Weight

13 560 kg (29,894 lb) approximate

TC62H Tool Carrier

Weight


Front Frame Bottom Guard

Weight

32 kg (72 lb) approximate

Axle and Differential

Weight


Cap Screw Nut

Torque

675 N•m (500 lb-ft)

Drive Shaft Universal Joint Cap Screw

Torque

78 N•m (58 lb-ft)

Wheel Cap Screw

Torque

675 N•m (500 lb-ft)

Transmission Bottom Guard

Weight


624H Loader

Weight


TC62H Tool Carrier

Weight


Axle and Differential with Oscillating Supports

Weight


Thrust Plate-to- Rear Oscillating Support Cap Screw

Torque

350 N•m (255 lb-ft)

Pivot Cover-to-Rear Oscillating Support Cap Screw

Torque

140 N•m (105 lb-ft)

Axle Support-to-Rear Oscillating Support Cap Screw

Torque

675 N•m (500 lb-ft)

Drive Shaft Universal Joint Cap Screw

Torque

78 N•m (58 lb-ft)

Wheel Cap Screw

Torque

675 N•m (500 lb-ft)

Front Axle and Differential

02 0200 2

Rear Axle and Differential


TM1640 (15JAN04)

02-0200-2

CED,OUOE003,3288 –19–25MAR99–1/2


PN=58


Item

Measurement

Specification

Axle Oscillating Support

End Play

0.762 mm (0.03 in.) maximum

Thrust Plate Between Thrust Bearings

Wear

0.254 mm (0.01 in.) maximum on front side

Thrust Plate-to-Rear Oscillating Support Cap Screw

Torque

350 N•m (255 lb-ft)

Pilot Cover-to-Rear Oscillating Support Cap Screw

Torque

Axle Oscillating Supports

02 0200 3

140 N•m (105 lb-ft)

CED,OUOE003,3288 –19–25MAR99–2/2

Remove and Install Front Axle and Differential 1. Apply park brake. –UN–03OCT96

2. Install frame locking bar (A).

T101610

CAUTION: The approximate weight of machine is: • 624H—13 560 kg (29,894 lb) • TC62H—13 361 kg (29,456 lb) A—Locking Bar B—12-1/2 Ton Floor Stand

Front Axle and Differential—Specification 624H Loader—Weight ............................................. 13 560 kg (29,894 lb) approximate TC62H Tool Carrier—Weight .................................. 13 361 kg (29,456 lb) approximate

3. Raise front of machine. Install floor stands (B) under loader frame. 4. Install boom lock. Move bucket to dumped position and lower. This will provide clearance to remove cap screws. 5. Stop engine.


TM1640 (15JAN04)

02-0200-3

TX,02,111691 –19–25MAR99–1/6


PN=59


02 0200 4

CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with ride control. Ride control accumulator energy must be discharged when working on hydraulic components. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 6. If equipped with ride control. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 7. Drain differential. Approximate oil capacity is 25 L (26.0 qt). CAUTION: The approximate weight of bottom guard is 32 kg (72 lb). Weight may increase significantly due to buildup of mud or debris. Front Axle and Differential—Specification Front Frame Bottom Guard— Weight................................................................ 32 kg (72 lb) approximate

8. Remove bottom guard, if equipped.


TM1640 (15JAN04)

02-0200-4

TX,02,111691 –19–25MAR99–2/6


PN=60

Removal and Installation NOTE: Label lines to aid in installation. 9. Disconnect lines from ports (A—E). Install caps and plugs in ports and hoses. 10. Remove cap screws to disconnect drive shaft. CAUTION: Use a lifting device for heavy components. 02 0200 5

11. Remove wheels using wheel and axle lift.

T121376

–UN–07MAY99

A—Brake Port B—Recirculation System Inlet Port C—Differential Lock Port D—Axle Disconnect Port (If Equipped) E—Recirculation System Outlet Port


TM1640 (15JAN04)

02-0200-5

TX,02,111691 –19–25MAR99–3/6


PN=61


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

–UN–03OCT96

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

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

02 0200 6

T101609

13. Remove nuts (A) to remove cap screws. Lower axle and differential. 14. Repair or replace axle or differential. (See procedure in this group.)

TeamMate II Axle Shown A—Nuts B—Low-Lift Jack

15. Clean mounting surface on axle housings and loader frame. 16. Install axle and differential. Install a washer under head of cap screws and a washer under the nuts. Hold the cap screws and tighten nuts. Front Axle and Differential—Specification Cap Screw Nut—Torque ............................................. 675 N•m (500 lb-ft)


TM1640 (15JAN04)

02-0200-6

TX,02,111691 –19–25MAR99–4/6


PN=62

Removal and Installation IMPORTANT: To properly check oil level, do not thread dipstick into port. Allow 10 minutes for oil to stabilize in each sump before checking. –UN–29JAN97

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

T106373B

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

Left Front Differential Axle A—Port

IMPORTANT: DO NOT reuse drive shaft universal joint cap screws. Replace cap screws to avoid machine damage. 18. Connect drive shaft. Install new drive shaft universal joint cap screws. Tighten cap screws. Front Axle and Differential—Specification Drive Shaft Universal Joint Cap Screw—Torque ................................................................ 78 N•m (58 lb-ft)


TM1640 (15JAN04)

02-0200-7

TX,02,111691 –19–25MAR99–5/6


PN=63

02 0200 7

Removal and Installation 19. Connect lines to ports (A—E). 20. Remove jack. 21. Install wheels. Tighten cap screws. Front Axle and Differential—Specification Wheel Cap Screw—Torque......................................... 675 N•m (500 lb-ft)

NOTE: No bleeding of brakes is necessary. They are self-bleeding.

–UN–07MAY99

22. Install bottom guard, if equipped. A—Brake Port B—Recirculation System Inlet Port C—Differential Lock Port D—Axle Disconnect Port (If Equipped) E—Recirculation System Outlet Port

T121376

02 0200 8

TX,02,111691 –19–25MAR99–6/6

TM1640 (15JAN04)

02-0200-8


PN=64


Remove Rear Axle and Differential 1. Apply park brake. 2. Install frame locking bar. 3. Raise boom and install boom lock. Move bucket to dump position. 4. Stop engine. Release hydraulic pressure by operating loader control while holding boom enable switch.

02 0200 9

CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with ride control. Ride control accumulator energy must be discharged when working on hydraulic components. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 5. If equipped with ride control. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. CAUTION: The approximate weight of transmission bottom guard is 62 kg (137 lb). Weight may increase significantly due to buildup of mud or debris on guard. Rear Axle and Differential—Specification Transmission Bottom Guard— Weight.............................................................. 62 kg (137 lb) approximate

6. Remove transmission bottom guard if equipped. 7. Drain differential. Approximate oil capacity is 20 L (21 qt).


TM1640 (15JAN04)

02-0200-9

TX,02,111692 –19–10FEB99–1/5


PN=65


CAUTION: The approximate weight of machine is:

T7134HD

Rear Axle and Differential—Specification 624H Loader—Weight ............................................. 13 506 kg (29,894 lb) approximate TC62H Tool Carrier—Weight .................................. 13 361 kg (29,456 lb) approximate

8. Raise rear of machine using floor jack. Install floor stands (A) under frame on each side and under rear corners of frame. CAUTION: Use a lifting device for heavy components. 9. Remove wheels. 10. Remove caps screws to disconnect drive shaft. CAUTION: The approximate weight of axle and differential with front and rear oscillating supports is 598 kg (1320 lb). Rear Axle and Differential—Specification Axle and Differential with Oscillating Supports—Weight ...................... 598 kg (1320 lb) approximate

–UN–06MAR90

11. Install low-lift jack under axle and differential. A—Floor Stand (4 used)

T7134HE

02 0200 10

–UN–20FEB90

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


TM1640 (15JAN04)

02-0200-10

TX,02,111692 –19–10FEB99–2/5


PN=66

Removal and Installation 12. Disconnect lines (A and B) if equipped. A—Brake Port B—Recirculation System Inlet Port C—Differential Lock Port D—Axle Disconnect Port (If Equipped) E—Recirculation System Outlet Port

T121376

–UN–07MAY99

02 0200 11


TM1640 (15JAN04)

02-0200-11

TX,02,111692 –19–10FEB99–3/5


PN=67


TP60398

–UN–22MAY98

02 0200 12

Rear Differential Oscillating Supports and Lubrication Lines Continued on next page

TM1640 (15JAN04)

02-0200-12

TX,02,111692 –19–10FEB99–4/5


PN=68

Removal and Installation 1—Special Jam Nut (2 used) 2—Fitting (2 used) 3—Pipe Plug 4—Hydraulic Hose 5—Elbow Fitting (3 used) 6—Rear Oscillating Support 7—Bushing (2 used) 8—Thrust Bearing (6 used)

9—Thrust Plate 10—Washer (4 used) 11—Cap Screw (4 used) 12—O-Ring 13—Cover 14—Cap Screw (6 used) 15—Cap Screw (6 used)

16—Seal (3 used) 17—Cap Screw (4 used) 18—Nut 19—Hydraulic Hose 20—Elbow Fitting 21—Lubrication Fitting (2 used)

NOTE: Bushings (26) are installed on center right and left cap screws (Serial No. — XXXX) and installed two on the front and two on the rear cap screws (Serial No. XXXX — ). 13. Disconnect hydraulic hoses (4 and 19) from front and rear oscillating supports. 14. Remove cap screws (17 and 15) from oscillating supports.

22—Washer (16 used) 23—Rear Axle Support 24—Rear Axle Support 25—Lubrication Fitting 26—Bushing (2 used S/N — XXXX) (4 used S/N XXXX— )

16. Remove rear axle support (23) from differential assembly. 02 0200 13

17. Remove cap screws from pivot cover (13) and thrust plate (9). 18. Remove rear oscillating support (6) from differential assembly. 19. Repair or replace axle. See this group for repair.

15. Lower supports, axle and differential assembly.

TX,02,111692 –19–10FEB99–5/5

TM1640 (15JAN04)

02-0200-13


PN=69


Install Rear Axle and Differential

TP60398

–UN–22MAY98

02 0200 14

Rear Differential Oscillating Supports and Lubrication Lines


TM1640 (15JAN04)

02-0200-14

TX,02,111693 –19–11FEB99–1/3


PN=70





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

1. Install front and rear oscillating supports. 2. Tighten thrust plate (9) cap screws (11) and pivot cover (13) cap screws (14). Rear Axle and Differential—Specification Thrust Plate-to- Rear Oscillating Support Cap Screw—Torque ..................................................... 350 N•m (255 lb-ft) Pivot Cover-to-Rear Oscillating Support Cap Screw—Torque ............................... 140 N•m (105 lb-ft)

3. Install axle and differential.

Rear Axle and Differential—Specification Drive Shaft Universal Joint Cap Screw—Torque ......................................................... 78 N•m (58 lb-ft)

NOTE: No bleeding of brakes is necessary. They are self-bleeding. 7. Connect lubrication lines. 8. Install wheels. Tighten cap screws.

4. Tighten cap screws (15 and 17).

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

Rear Axle and Differential—Specification Axle Support-to-Rear Oscillating Support Cap Screw—Torque ..................................................... 675 N•m (500 lb-ft)

9. Remove floor stands. 10. Install bottom guard, if equipped.

5. Connect lines to differential. IMPORTANT: DO NOT reuse drive shaft universal joint cap screws. Replace cap screws to avoid machine damage.


TM1640 (15JAN04)

02-0200-15

TX,02,111693 –19–11FEB99–2/3


PN=71

02 0200 15

Removal and Installation IMPORTANT: To properly check oil level, do not thread dipstick into port. Allow 10 minutes for oil to stabilize in each sump before checking.

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

T106373B

02 0200 16

–UN–29JAN97

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

Left Front Differential Axle A—Port

TX,02,111693 –19–11FEB99–3/3

TM1640 (15JAN04)

02-0200-16


PN=72


02 0200 17

TM1640 (15JAN04)

02-0200-17


PN=73


Disassemble and Assemble Axle Oscillating Supports

TP60398

–UN–22MAY98

02 0200 18

Rear Differential Oscillating Supports and Lubrication Lines


TM1640 (15JAN04)

02-0200-18

TX,02,111694 –19–11FEB99–1/3


PN=74




NOTE: Axle oscillation support assembly does not contain any shims for setting end play. If excessive end play is incurred due to wear, end play should be no greater than 0.762 mm (0.03 in). This can be checked with dial indicator measuring between front support and the differential housing. If greater than 0.762 mm (0.03 in.) thrust bearings should be replaced. Also check thrust plate (between both thrust bearings) for wear on front side. Disk should not have more than 0.254 mm (0.01 in.) wear step on face that contacts front thrust bearings. If out of specification, replace thrust plate and thrust bearings. 1. Remove rear axle and differential assembly. (See procedure in this group.) 2. Remove front oscillating support.

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

02 0200 19

4. Remove rear oscillating support. 5. Repair and replace parts as necessary. 6. Inspect thrust bearings (8) and bushings (7) for wear. Axle Oscillating Supports—Specification Axle Oscillating Support—End Play ...................................................... 0.762 mm (0.03 in.) maximum Thrust Plate Between Thrust Bearings—Wear................................... 0.254 mm (0.01 in.) maximum on front side

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


TM1640 (15JAN04)


02-0200-19

TX,02,111694 –19–11FEB99–2/3


PN=75


–UN–04APR97

NOTE: If bushings were removed in front or rear oscillation supports note proper location of bushing (C) grease slots (D) in relation to the grease fitting (B). Slots should be facing up toward the grease fitting to allow proper lubrication of pivot area.

02 0200 20

T108815B

8. Press bushings into front and rear supports being careful not to damage. 9. Install rear and front oscillating supports to differential. 10. Tighten thrust plate cap screws (11) and pivot cover cap screws (14). Axle Oscillating Supports—Specification Thrust Plate-to-Rear Oscillating Support Cap Screw—Torque ...................................... 350 N•m (255 lb-ft) Pilot Cover-to-Rear Oscillating Support Cap Screw—Torque ...................................... 140 N•m (105 lb-ft)

A—Support B—Grease Fitting C—Bushing D—Grease Slots

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

TX,02,111694 –19–11FEB99–3/3

TM1640 (15JAN04)

02-0200-20


PN=76

Group 0225

Axle Shafts and U-Joints Specifications Item

Measurement

Specification

Front and Rear Drive Shaft Universal Torque Joint Cap Screw

78 N•m (58 lb-ft)

Engine Drive Shaft Universal-to-Transmission Cap Screw

78 N•m (58 lb-ft)

Engine Drive Shaft-to-Damper Cap Screw

Torque

Torque

02 0225 1

130 N•m (95 lb-ft)

CED,OUOE003,3291 –19–25MAR99–1/1

TM1640 (15JAN04)

02-0225-1


PN=77

Axle Shafts and U-Joints

Remove and Install Universal Joint and Drive Shaft

T108602

–19–31MAR97

02 0225 2

3. Install new drive shaft universal joint cap screws.

CAUTION: Prevent possible injury from unexpected machine movement. Place blocks front and rear of tires to prevent machine from rolling. IMPORTANT: DO NOT reuse drive shaft universal joint cap screws. Replace cap screws to avoid machine damage.

Specification Front and Rear Drive Shaft Universal Joint Cap Screw— Torque....................................................................... 78 N•m (58 lb-ft) Engine Drive Shaft Universal-to-Transmission Cap Screw—Torque ......................................................... 78 N•m (58 lb-ft) Engine Drive Shaft-to-Damper Cap Screw—Torque ............................................... 130 N•m (95 lb-ft)

1. Remove drive shaft universal joint cap screws. 2. Inspect and replace parts as necessary.

TX,02,111696 –19–25MAR99–1/1

TM1640 (15JAN04)

02-0225-2


PN=78


02 0225 3

TM1640 (15JAN04)

02-0225-3


PN=79


Disassemble, Inspect and Assemble Universal Joint and Drive Shaft

T112056

–19–03NOV97

02 0225 4

Transmission-to-Differential and Engine Shafts 1—Cap Screw (4 used) 2—Cap Screw (28 used)

3—Clamp (14 used) 4—Drive Shaft

5—Drive Shaft 6—Cap Assembly (3 used)

7—Drive Shaft 8—Drive Shaft

1. Remove drive shaft universal joint cap screws.

CAUTION: Prevent possible injury from unexpected machine movement. Place blocks front and rear of tires to prevent machine from rolling.

2. Inspect and replace parts as necessary.

IMPORTANT: DO NOT reuse drive shaft universal joint cap screws. Replace cap screws to avoid machine damage.


TM1640 (15JAN04)

02-0225-4

TX,02,111697 –19–25MAR99–1/2


PN=80

Axle Shafts and U-Joints 3. Install new drive shaft universal joint cap screws. Specification Front and Rear Drive Shaft Universal Joint Cap Screw— Torque....................................................................... 78 N•m (58 lb-ft)

Engine Drive Shaft Universal-to-Transmission Cap Screw—Torque ......................................................... 78 N•m (58 lb-ft) Engine Drive Shaft-to-Damper Cap Screw—Torque ............................................... 130 N•m (95 lb-ft)

TX,02,111697 –19–25MAR99–2/2

TM1640 (15JAN04)

02-0225-5


PN=81

02 0225 5


02 0225 6

TM1640 (15JAN04)

02-0225-6


PN=82

Group 0250

Axle Shaft, Bearings, Reduction Gears John Deere TeamMate III Axles—Use CTM150 For complete repair information, the Component Technical Manual (CTM) is also required.

TS225

–UN–17JAN89

Use the CTM in conjunction with this repair manual.

TeamMate is a trademark of Deere & Company.

CED,OUOE006,18 –19–24SEP98–1/1

Essential Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC).


CED,OUOE003,3293 –19–25MAR99–1/8 RW25643 –UN–28FEB97

Lifting Screw . . . . . . . . . . . . . . . . . . . . . . . JDG1125 Used with JDG19 Special Mounting Bracket to remove and install axle disconnect input shaft. CED,OUOE003,3293 –19–25MAR99–2/8 RW25781 –UN–19JUN97

Spanner Wrench . . . . . . . . . . . . . . . . . . . . . JDG1142 Used to remove and install auxiliary yoke retaining nut.

CED,OUOE003,3293 –19–25MAR99–3/8 RW25383 –UN–02APR96

Yoke Holding Tool . . . . . . . . . . . . . . . . . . . . JDG1090 Used to remove and install yoke retaining nut.

CED,OUOE003,3293 –19–25MAR99–4/8 RW25780 –UN–19JUN97

Bearing Installer Set . . . . . . . . . . . . . . . . . . JDG1141 Used to support disconnect input shaft and install outer bearing cone. Continued on next page

TM1640 (15JAN04)

02-0250-1

CED,OUOE003,3293 –19–25MAR99–5/8


PN=83

02 0250 1

Axle Shaft, Bearings, Reduction Gears RW25388 –UN–15JUN95

Seal Installer . . . . . . . . . . . . . . . . . . . . . . . JDG1092 Used with JDG926 Bearing Installer to install input shaft yoke seal on 1200 Series rear axle. CED,OUOE003,3293 –19–25MAR99–6/8 RW25388 –UN–15JUN95

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

02 0250 2

Used with JDG926 Bearing Installer to install input shaft yoke seal on 1400 Series front axle. CED,OUOE003,3293 –19–25MAR99–7/8 RW25381 –UN–14JUN95

Bearing Installer . . . . . . . . . . . . . . . . . . . . . . JDG926 Used with seal installer to install input shaft seal.

CED,OUOE003,3293 –19–25MAR99–8/8

Service Equipment and Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.


CED,OUOE003,3294 –19–25MAR99–1/6

Special Mounting Bracket . . . . . . . . . . . . . . . . . JDG19 Used with JDG1125 Lifting Screw to remove and install axle disconnect input shaft. CED,OUOE003,3294 –19–25MAR99–2/6

Driver Disk. . . . . . . . . . . . . . . . . . . . . . . . . 4-5/16 in. To force piston downward for snap ring removal on a 1200 Series rear axle. CED,OUOE003,3294 –19–25MAR99–3/6

Driver Disk. . . . . . . . . . . . . . . . . . . . . . . . . . 5-1/2 in. To force piston downward for snap ring removal on a 1400 Series front axle. Continued on next page

TM1640 (15JAN04)

02-0250-2

CED,OUOE003,3294 –19–25MAR99–4/6


PN=84

Axle Shaft, Bearings, Reduction Gears Driver Disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 in. To install bearing cups on a 1200 Series rear axle.

CED,OUOE003,3294 –19–25MAR99–5/6

Driver Disk. . . . . . . . . . . . . . . . . . . . . . . . . 3-9/16 in. To install bearing cups on a 1400 Series front axle.

CED,OUOE003,3294 –19–25MAR99–6/6

Other Material Number

Name

Use

PT506 (U.S.)

NEVER-SEEZ Lubricant

Apply to shaft threads.

NEVER-SEEZ is a trademark of Emhart Chemical Group.

CED,OUOE003,3295 –19–25MAR99–1/1

Specifications Item

Measurement

Specification

Disconnect Assembly

Weight


Retaining Cap Screw

Torque

310 N•m (230 lb-ft)

Auxiliary Yoke-to-Differential Drive Shaft Nut

Torque

360 N•m (267 lb-ft)

Collar Engagement Spring

Free Length Test Length

73 mm (2.874 in.) approximate 44.45 mm at 352—431 N (1.750 in. at 78—96 lb-force)

Yoke Retaining Nut

Torque

360 N•m (267 lb-ft)

Axle Disconnect Input Shaft

CED,OUOE003,3296 –19–25MAR99–1/1

TM1640 (15JAN04)

02-0250-3


PN=85

02 0250 3

Axle Shaft, Bearings, Reduction Gears

Axle Disconnect Input Shaft, Cross-Sectional View

RW36308

–UN–17MAR97

02 0250 4

A—Disconnect Input Shaft B—Nut C—Spacer Washer D—Input Yoke E—Disconnect Housing F—Collar Engagement Spring (4 used) G—Collar Assembly Spring Retainer Plate

H—Collar Assembly Anti-Rotation Plug I—Collar Assembly Housing J—Piston Housing K—Housing-to-Differential Case Sealing Ring L—Disconnect Auxiliary Yoke M—Differential Drive Shaft

N—Nut O—Spacer Washer P—Piston Assembly Packing Ring (2 used) Q—Piston Packing Ring (4 used) R—Piston (4 used) S—Needle Bearing Thrust Washer

T—Needle Roller Bearing (2 used) U—Collar V—Input Shaft Bearing Set W—Input Shaft Seal X—Dust Seal Y—Oil Ring

TX,02,111673 –19–21JUL97–1/1

TM1640 (15JAN04)

02-0250-4


PN=86


Remove and Install Axle Disconnect Input Shaft NOTE: Axle assembly is removed from vehicle. CAUTION: The approximate weight of disconnect assembly is 61 kg (135 lb). Axle Disconnect Input Shaft—Specification Disconnect Assembly—Weight ....................... 61 kg (135 lb) approximate 02 0250 5

Loosen retaining cap screw (A). –UN–17MAR97

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

Install axle disconnect assembly onto axle. Push disconnect assembly forward until snap ring stops against axle differential case oscillating input. Slowly rotate disconnect until hydraulic fitting is at top center.

RW36289

Remove the disconnect assembly from the axle assembly.

A—Retaining Cap Screw B—JDG1125 Lifting Screw C—JDG19 Special Mounting Bracket

Install retaining cap screw (A), washers and nut on disconnect housing compression joint. Tighten retaining cap screw. Axle Disconnect Input Shaft—Specification Retaining Cap Screw—Torque ................................... 310 N•m (230 lb-ft)

TX,02,111675 –19–10MAY99–1/1

TM1640 (15JAN04)

02-0250-5


PN=87


Disassemble, Inspect, and Assemble Axle Disconnect Input Shaft

–UN–17MAR97

Remove disconnect assembly from axle assembly. (See Remove and Install Axle Disconnect Input Shaft in this group.)

Install JDG1142 Spanner Wrench and remove nut (B). Remove spacer washer and disconnect auxiliary yoke from differential drive shaft.

A—Auxiliary Yoke B—Nut

Install in reverse order. Tighten nut. Axle Disconnect Input Shaft—Specification Auxiliary Yoke-to-Differential Drive Shaft Nut—Torque ............................................. 360 N•m (267 lb-ft)

TX,02,111677 –19–25MAR99–1/25

Install JDG1090 Yoke Holding Tool (A) to input shaft yoke. Remove nut and spacer from shaft. –UN–17MAR97

Remove yoke and oil ring from shaft. A—Yoke Holding Tool

RW36291

02 0250 6

RW36290

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


TM1640 (15JAN04)

02-0250-6

TX,02,111677 –19–25MAR99–2/25


PN=88

Axle Shaft, Bearings, Reduction Gears Remove input shaft seal (A).

RW36292

–UN–17MAR97

A—Input Shaft Seal

TX,02,111677 –19–25MAR99–3/25

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

RW36293

–UN–17MAR97

A—Sealing Ring

TX,02,111677 –19–25MAR99–4/25

Install disconnect assembly in a press and place a 4-5/16 in. (1200 Series Rear Axle) or a 5-1/2 in. (1400 Series Front Axle) driver disk and handle (A) on top of the piston housing. –UN–17MAR97

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

RW36294

A—Driver Disk and Handle B—Snap Ring


TM1640 (15JAN04)

02-0250-7

TX,02,111677 –19–25MAR99–5/25


PN=89

02 0250 7

Axle Shaft, Bearings, Reduction Gears Remove piston housing assembly (A) using a 3-jaw puller and a slide hammer.

–UN–17MAR97

A—Piston Housing Assembly

RW36295

02 0250 8

TX,02,111677 –19–25MAR99–6/25

Remove pistons from housing by tapping the backside of the housing with a hammer. Inspect housing (A), pistons (B), and packing rings (C). Replace parts as necessary.

–UN–17MAR97

Install pistons with packing rings into the piston housing.

RW36296

A—Housing B—Piston C—Packing Rings


TM1640 (15JAN04)

02-0250-8

TX,02,111677 –19–25MAR99–7/25


PN=90

Axle Shaft, Bearings, Reduction Gears Remove piston packing rings (A). Remove collar assembly anti-rotation plug (B). Remove collar assembly (C) from disconnect assembly. A—Piston Packing Ring (2 used) B—Anti-Rotation Plug C—Collar Assembly

RW36297

–UN–17MAR97

02 0250 9

TX,02,111677 –19–25MAR99–8/25

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

RW36298

–UN–17MAR97

A—Spring Return Plate


TM1640 (15JAN04)

02-0250-9

TX,02,111677 –19–25MAR99–9/25


PN=91

Axle Shaft, Bearings, Reduction Gears Remove parts (A—C) from housing (D). Inspect parts and replace as necessary.

RW36299

A—Needle Roller Bearing B—Shift Collar C—Needle Roller Bearing Thrust Washer D—Collar Assembly Housing E—Collar Assembly Spring Retainer Plate

TX,02,111677 –19–25MAR99–10/25

Remove collar engagement springs (A) from housing. Inspect springs. Axle Disconnect Input Shaft—Specification Collar Engagement Spring—Free Length ..................................................... 73 mm (2.874 in.) approximate Test Length........................................................ 44.45 mm at 352—431 N (1.750 in. at 78—96 lb-force)

–UN–17MAR97

A—Collar Engagement Spring (4 used)

RW36300

02 0250 10

–UN–17MAR97

Assemble in reverse order.


TM1640 (15JAN04)

02-0250-10

TX,02,111677 –19–25MAR99–11/25


PN=92

Axle Shaft, Bearings, Reduction Gears Place the disconnect assembly in a press. Remove the input shaft (A) from the housing and outer bearing cone while supporting the shaft inside the case to prevent shaft from falling.

RW36301

–UN–17MAR97

A—Input Shaft

TX,02,111677 –19–25MAR99–12/25

Remove outer bearing cone (A) from housing.

RW36302

–UN–17MAR97

A—Outer Bearing Cone


TM1640 (15JAN04)

02-0250-11

TX,02,111677 –19–25MAR99–13/25


PN=93

02 0250 11

Axle Shaft, Bearings, Reduction Gears NOTE: The input shaft bearings are supplied as a matched set. When replacement is required, replace all parts. Inspect and if necessary remove inner and outer bearing cups (A) from housing (B). Inspect bearing cup spacer snap ring (C) and remove if necessary.

–UN–17MAR97

Install new bearing cup spacer snap ring in housing.

RW36303

Install new bearing cups in housing using a 3 in. (1200 Series Rear Axle) or a 3-9/16 in. (1400 Series Front Axle) driver disk and a press. A—Bearing Cup (2 used) B—Housing C—Snap Ring

TX,02,111677 –19–25MAR99–14/25

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

–UN–17MAR97

If necessary, remove bearing spacer (C) from shaft and remove inner bearing (B) using a knife-edge puller and a press. CAUTION: Heat parts in a bearing heater. Use a thermometer and do not exceed 150°C (300°F). Plan a safe handling procedure to avoid burns.

RW36304

02 0250 12

Heat bearing cone to 150° C (300° F) and install on shaft. A—Input Shaft B—Inner Bearing Cone C—Bearing Spacer


TM1640 (15JAN04)

02-0250-12

TX,02,111677 –19–25MAR99–15/25


PN=94

Axle Shaft, Bearings, Reduction Gears NOTE: JDG1141-1 Centering Tool is part of the JDG1141 Bearing Installer Set. Install the disconnect housing in a press using JDG1141-1 Centering Tool (A) to support the input shaft (B) that is installed through the housing. A—JDG1141-1 Centering Tool B—Input Shaft

RW36310

–UN–11APR97

02 0250 13

TX,02,111677 –19–25MAR99–16/25

NOTE: JDG1141-2 Driver is part of the JDG1141 Bearing Installer Set. Install the outer bearing cone (A) onto the shaft using JDG1141-2 Driver (B).

RW36305

–UN–17MAR97

A—Outer Bearing Cone B—JDG1141-2 Driver


TM1640 (15JAN04)

02-0250-13

TX,02,111677 –19–25MAR99–17/25


PN=95

Axle Shaft, Bearings, Reduction Gears Install collar engagement springs (A) into disconnect housing. A—Collar Engagement Springs

RW36300

–UN–17MAR97

02 0250 14

TX,02,111677 –19–25MAR99–18/25

Install collar assembly (C) into housing aligning the anti-rotation slot in the collar assembly housing with the opening in disconnect housing for the anti-rotation plug. Install anti-rotation plug (B). Install piston packing rings (A). Apply oil to the piston packing rings.

RW36297

–UN–17MAR97

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


TM1640 (15JAN04)

02-0250-14

TX,02,111677 –19–25MAR99–19/25


PN=96

Axle Shaft, Bearings, Reduction Gears Install piston assembly (A) into the housing.

–UN–17MAR97

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

RW36306

Force the piston downward using a shop press and install snap ring (C). A—Piston Assembly B—Driver Disk and Handle C—Snap Ring

TX,02,111677 –19–25MAR99–20/25

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

RW36293

–UN–17MAR97

A—Sealing Ring


TM1640 (15JAN04)

02-0250-15

TX,02,111677 –19–25MAR99–21/25


PN=97

02 0250 15

Axle Shaft, Bearings, Reduction Gears Install input shaft seal (A) using JDG1092 (1200 Series Rear Axle) or JDG1151 (1400 Series Front Axle) Seal Installer along with JDG926 Bearing Installer.

–UN–17MAR97

A—Input Shaft Seal

RW36292

02 0250 16

TX,02,111677 –19–25MAR99–22/25

IMPORTANT: DO NOT apply oil to the seal or the yoke recess. Install the dust seal (A) into the yoke recess. Install yoke onto the shaft.

RW36191

–UN–09JAN97

A—Dust Seal


TM1640 (15JAN04)

02-0250-16

TX,02,111677 –19–25MAR99–23/25


PN=98

Axle Shaft, Bearings, Reduction Gears NOTE: Be sure no part of the oil ring is out of the chamfer on the yoke. Install oil ring (A) and spacer washer.

IMPORTANT: Install special locking nut by hand.

–UN–17MAR97

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

RW36307

Apply PT506 NEVER-SEEZ Lubricant to the shaft threads.

A—Oil Ring


TX,02,111677 –19–25MAR99–24/25

Install JDG1090 Yoke Holding Tool (A).

Remove tool. Install disconnect assembly to axle assembly. (See Remove and Install Axle Disconnect Input Shaft in this group.)

RW36291

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

–UN–17MAR97

Tighten yoke retaining nut.

A—Yoke Holding Tool

TX,02,111677 –19–25MAR99–25/25

TM1640 (15JAN04)

02-0250-17


PN=99

02 0250 17


02 0250 18

TM1640 (15JAN04)

02-0250-18


PN=100

Group 0260

Hydraulic System Specifications Item

Measurement

Specification

Differential Lock Solenoid Valve Nut

Torque

7 N•m (62 lb-in.)

CED,OUOE003,3297 –19–25MAR99–1/1

TM1640 (15JAN04)

02-0260-1


PN=101

02 0260 1

Hydraulic System

Remove and Install Differential Lock Solenoid Valve 1. Operate controls to release hydraulic pressure. –UN–04APR97

2. Disconnect electrical connector. 3. Remove differential lock solenoid (A).

T108813

4. Remove parts (C—E). 5. Remove parts (F—K). Plug opening to prevent dirt from entering manifold.

–UN–09NOV92

6. Inspect for dirty, worn or damaged parts. Check that spool inside solenoid valve moves freely. If spool does not move freely or if valve looks worn or damaged, replace complete solenoid assembly. 7. Install solenoid valve using new O-rings and backup rings. 8. Install parts (C—K). Tighten nut (C). Specification Differential Lock Solenoid Valve Nut—Torque ..................................................................... 7 N•m (62 lb-in.)

9. Connect electrical connector.

T7751LI

02 0260 2

A—Differential Lock Solenoid C—Nut D—Cap E—Solenoid F—Spool G—O-Ring H—Backup Ring I—O-Ring J—O-Ring K—Backup Ring

TX,02,111682 –19–27OCT98–1/1

TM1640 (15JAN04)

02-0260-2


PN=102

Hydraulic System

Axle Recirculation System

T116474

–19–26AUG98

02 0260 3

A—O-Ring (2 used) B—O-Ring Adapter C—O-Ring (2 used) D—Front Axle Recirculation Inlet Port-to-Left Front Recirculation Pump Port Hydraulic Hose E—Recirculation Pump Motor Inlet Port-to-Main Pump Pressure Port Hydraulic Hose

F—O-Ring (3 used) G—ORFS Straight Thread Fitting H—O-Ring (3 used) I—Recirculation Pump Motor Outlet Port-to-Hydraulic Reservoir Hydraulic Hose J—ORFS Elbow K—Right Front Recirculation Pump Port-to-Rear Axle Inlet Port Hydraulic Hose

L—Right Rear Recirculation Pump Port-to-Rear Axle Recirculation Outlet Port Hydraulic Hose M—ORFS O-Ring Elbow Fitting (2 used) N—O-Ring (2 used)

O—Screen Filter (2 used) P—Left Rear Recirculation Pump Port-to-Front Axle Recirculation Outlet Port Hydraulic Hose Q—Old Breather Location R—New Breather Location

CED,OUOE003,2651 –19–13DEC98–1/1

TM1640 (15JAN04)

02-0260-3


PN=103

Hydraulic System

Axle Recirculation System With Optional Oil Coolers

T118027

–19–22OCT98

02 0260 4


TM1640 (15JAN04)

02-0260-4

CED,OUOE003,2652 –19–13DEC98–1/2


PN=104

Hydraulic System 3—Front Axle Oil Cooler 21—Rear Axle Oil Cooler 27a—Rear Axle Oil Cooler Top Port-to-Rear Axle Recirculation Inlet Port Hydraulic Hose 27b—Right Front Recirculation Pump Port-to-Rear Axle Oil Cooler Bottom Port Hydraulic Hose A—O-Ring (2 used) B—O-Ring Adapter

C—O-Ring (2 used) D—Front Axle Recirculation Inlet Port-to-Front Axle Oil Cooler Upper Port Hydraulic Hose E—Recirculation Pump Motor Inlet Port-to-Main Pump Pressure Port Hydraulic Hose F—O-Ring (3 used) G—ORFS Straight Thread Fitting

H—O-Ring (3 used) I—Recirculation Pump Motor Outlet Port-to-Hydraulic Reservoir Hydraulic Hose J—ORFS Elbow K—Left Front Recirculation Pump Port-to-Front Axle Oil Cooler Lower Port Hydraulic Hose L—Right Rear Recirculation Pump Port-to-Rear Axle Recirculation Outlet Port Hydraulic Hose

M—ORFS O-Ring Elbow Fitting (2 used) N—O-Ring (2 used) O—Screen Filter (2 used) P—Left Rear Recirculation Pump Port-to-Front Axle Recirculation Outlet Port Hydraulic Hose

02 0260 5

CED,OUOE003,2652 –19–13DEC98–2/2

TM1640 (15JAN04)

02-0260-5


PN=105

Hydraulic System

Axle Oil Coolers—Exploded View

TP60515

–UN–13OCT98

02 0260 6


TM1640 (15JAN04)

02-0260-6

CED,OUOE003,2653 –19–13DEC98–1/2


PN=106

Hydraulic System 1—Nut (12 used) 2—Washer (20 used) 3—Angle (2 used) 4—Cap Screw (4 used) 5—Cover 6—Washer (4 used) 7—Rubber Mount (4 used) 8—Cap Screw (4 used) 9—Oil Cooler

10—O-Ring (2 used) 11—Elbow Fitting (2 used) 12—O-Ring (6 used) 13—Hyd. Quick-Connect Coupler (2 used) 14—Hyd. Quick-Connect Coupler (2 used) 15—Adapter (2 used) 16—O-Ring (4 used)

17—Elbow Fitting (2 used) 18—Fitting Plug (2 used) 19—O-Ring (4 used) 20—Adapter (2 used) 21—Oil Cooler 22—Strap (2 used) 23—Nut (4 used) 24—Screw (4 used)

25—Washer (4 used) 26—Cap Screw (4 used) 27—Hydraulic Hose, Fabricate (2 used) 28—Wiring Harness 29—Washer 30—Screw 31—Oil Cooler

CED,OUOE003,2653 –19–13DEC98–2/2

Remove and Install Front Axle Oil Cooler

–UN–12DEC96

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

T105496B

CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with ride control. Ride control accumulator energy must be discharged when working on hydraulic components. 2. If equipped with ride control. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds.

Frame Lock Bar A—Pin B—Retaining Pin C—Frame Lock Bar

3. Disconnect battery ground strap or turn battery disconnect switch Off, if equipped. 4. Install frame locking bar (C) between machine frames to prevent unexpected movement.


TM1640 (15JAN04)

02-0260-7

CED,OUOE003,2654 –19–13DEC98–1/3


PN=107

02 0260 7

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

T117536B

–UN–01OCT98

3—Cover 4—Washer 5—Cap Screw

02 0260 8

CED,OUOE003,2654 –19–13DEC98–2/3

6. Disconnect hydraulic hoses (D and K) and wiring harness (25). 7. Remove cover (3) with attached oil cooler (31). 8. Repair or replace parts as necessary. 9. Install in reverse order.

T117526B

–UN–01OCT98

D—Front Axle Recirculation Inlet Port-to-Front Axle Oil Cooler Upper Port Hydraulic Hose K—Left Front Recirculation Pump Port-to-Front Axle Cooler Lower Port Hydraulic Hose 3—Cover 25—Oil Cooler with Fan Wiring Harness 31—Oil Cooler with Fan

CED,OUOE003,2654 –19–13DEC98–3/3

TM1640 (15JAN04)

02-0260-8


PN=108

Hydraulic System

Disassemble and Assemble Front Axle Oil Cooler

T117465B

–UN–01OCT98

02 0260 9

2—Cap Screw (2 used) 3—Cover 6—Washer (2 used) 7—Cap Screw (2 used)

19—M8 Nut (6 used) 20—Angle 24—Female Coupler 26—Male Coupler

27—ORFS Adapter (2 used) 28—ORFS Elbow Fitting (2 used) 29—Adapter (2 used)

30—Isolator Mount (2 used) 31—Oil Cooler with Fan 32—Strap

NOTE: Lubricate O-rings with hydraulic oil.

CED,OUOE003,2655 –19–13DEC98–1/1

TM1640 (15JAN04)

02-0260-9


PN=109

Hydraulic System

Remove and Install Rear Axle Oil Cooler

CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with ride control. Ride control accumulator energy must be discharged when working on hydraulic components.

T105496B

02 0260 10

–UN–12DEC96

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

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

Frame Lock Bar A—Pin B—Retaining Pin C—Frame Lock Bar

3. Disconnect battery ground strap or turn battery disconnect switch Off, if equipped. 4. Install frame locking bar (C) between machine frames to prevent unexpected movement.


TM1640 (15JAN04)

02-0260-10

CED,OUOE003,2656 –19–13DEC98–1/2


PN=110

Hydraulic System 5. Disconnect hydraulic hoses (27a and 27b). 6. Remove nuts (1), washers (2) and oil cooler (21). 7. Repair or replace parts as necessary. 8. Install in reverse order. Lubricate O-rings with hydraulic oil. 1—Nut (12 used) 2—Hardened Washer (20 used) 20—ORFS Fitting (2 used) 21—Oil Cooler 22—Strap (2 used) 27a—Hydraulic Hose (Rear Axle Cooler Lower Port-to-Right Pump) 27b—Hydraulic Hose (Rear Axle Cooler Upper Port-to-Rear Axle Lower Port) 32—Hydraulic Fan Motor 34—Tie Band

T118017B

–UN–23OCT98

02 0260 11

CED,OUOE003,2656 –19–13DEC98–2/2

TM1640 (15JAN04)

02-0260-11


PN=111

Hydraulic System

02 0260 12

TM1640 (15JAN04)

02-0260-12


PN=112

Section 03

Transmission Contents Page

Page

Group 0300—Removal and Installation Essential Tools . . . . . . . . . . . . . . . . . . . . . . .03-0300-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .03-0300-2 Transmission Remove and Install . . . . . . . . . . . . . . . . . .03-0300-3

Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0360-15 Converter Relief Valve Remove, Disassemble and Install . . . . . .03-0360-21 Oil Pipes and Tubes Replace . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-23

Group 0350—Gears, Shafts, Bearings and Power Shift Clutch Essential Tools . . . . . . . . . . . . . . . . . . . . . . .03-0350-1 Service Equipment and Tools . . . . . . . . . . . .03-0350-2 Other Material . . . . . . . . . . . . . . . . . . . . . . . .03-0350-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . .03-0350-4 Torque Converter and Housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-5 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-8 Clutches, Input and Output Shafts Remove . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-11 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-17 Clutch Pack KV and KR Disassemble . . . . . . . . . . . . . . . . . . . . . .03-0350-26 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-28 Clutch Pack K1, K2, and K3 Disassemble . . . . . . . . . . . . . . . . . . . . . .03-0350-35 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-37 Clutch Pack K4 Disassemble . . . . . . . . . . . . . . . . . . . . . .03-0350-47 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-48 Input Shaft Dissasemble . . . . . . . . . . . . . . . . . . . . . .03-0350-54 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-55

Group 0399—Dealer Fabricated Tools Pre-Load Clutch Pack Compression Ring Tool DFT1148 . . . . . . . . . . . . . . . . . . . . . . . . . .03-0399-1 DFT1149 . . . . . . . . . . . . . . . . . . . . . . . . . .03-0399-2

Group 0360—Hydraulic System Specifications . . . . . . . . . . . . . . . . . . . . . . . .03-0360-1 Transmission Pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-2 Converter Minimum Pressure Regulator Valve Remove and Install . . . . . . . . . . . . . . . . . .03-0360-4 Transmission Pump Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-5 Hydraulic Control Valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-7 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-8 Cross Section View . . . . . . . . . . . . . . . . .03-0360-10 Transmission Control Valve Disassemble . . . . . . . . . . . . . . . . . . . . . .03-0360-12 TM1640 (15JAN04)

03-1


PN=1

03

Contents

03

TM1640 (15JAN04)

03-2


PN=2

Group 0300

Removal and Installation Essential Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC).


CED,OUOE003,3298 –19–25MAR99–1/3

Engine Repair Stand . . . . . . . . . . . . . . . . .D052223ST 03 0300 1

Used with JDG1129 Transmission Mounting Bracket to hold transmission. CED,OUOE003,3298 –19–25MAR99–2/3

–UN–29APR97

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

T109218

Used to mount transmission in repair stand.

CED,OUOE003,3298 –19–25MAR99–3/3

TM1640 (15JAN04)

03-0300-1


PN=115


Specifications Item

Measurement

Specification

Transmission

Weight


Isolator Cap Screw

Torque

433 N•m (320 lb-ft)

Mounting Bracket-to-Transmission Cap Screw (Front)

Torque

433 N•m (320 lb-ft)

Mounting Bracket-to-Transmission Cap Screw (Rear)

Torque

318 N•m (235 lb-ft)

Drive Shaft Universal Joint (Output) Cap Screw

Torque

78 N•m (58 lb-ft)

Drive Shaft Universal Joint (Input) Cap Screw

Torque

78 N•m (58 lb-ft)

Engine-to-Transmission Shaft Universal Joint Cap Screw

Torque

78 N•m (58 lb-ft)

Transmission

03 0300 2

CED,OUOE003,3301 –19–25MAR99–1/1

TM1640 (15JAN04)

03-0300-2


PN=116


Remove and Install Transmission 1. Remove ROPS or cab. (See procedure in Group 1800.) 2. Drain hydraulic reservoir. Collect oil in clean container for reuse. Approximate capacity is 117 L (31 gal). 3. Disconnect transmission drive shafts (A—C). A—Drive Shaft B—Drive Shaft C—Drive Shaft

T107803

–UN–10MAR97

03 0300 3

TX,03,RP3337 –19–12FEB99–1/5

NOTE: Tag and cap all lines for identification and to prevent contamination. 4. Remove transmission filter hoses (F and E) from transmission. 5. Drain transmission. Collect oil in container and dispose of properly. Approximate capacity is 27 L (29 qt). 6. Remove dipstick tube (C). 7. Remove and cap park brake hoses (G and D). 8. Remove cooler hoses (A and B).

T112003

–UN–24NOV97

A—Converter in Hose from Cooler B—Converter out Hose to Cooler C—Dipstick Tube D—Return Hose from Park Brake to Transmission E—Return from Filter to Transmission Hose F—Hose to Oil Filter from Transmission G—Hose to Park Brake from Transmission


TM1640 (15JAN04)

03-0300-3

TX,03,RP3337 –19–12FEB99–2/5


PN=117

Removal and Installation 9. Remove hose (E) going to the control valve and case drain return hose (D) to manifold from the hydraulic pump. 10. Remove load sense hose (A) from hydraulic pump. 11. Remove suction hose at reservoir (B) and hydraulic pump at (C). 12. Remove pressure reducing valve hose (G), steering hose (F) from hydraulic pump.

–UN–29OCT97 T112004

03 0300 4

A—Load Sense Hose B—Suction Hose C—Pump Inlet D—Case Drain E—Pressure to Control Valve F—Pressure to Steering Valve G—Hose to Pressure Reducing Valve


TM1640 (15JAN04)

03-0300-4

TX,03,RP3337 –19–12FEB99–3/5


PN=118


T111670

–UN–03NOV97

03 0300 5

A—Transmission Isolator Cap Screw (Rear)

B—Transmission Mounting Bracket-to-Transmission Cap Screws (Rear)

CAUTION: Use hoist to lift transmission. Approximate weight is 431 kg (950 lb) with hydraulic pump installed. Transmission—Specification Transmission—Weight ............................ 431 kg (950 lb) approximate

13. Install hoist on transmission lifting brackets and support transmission.

C—Transmission Mounting Bracket-to-Transmission Cap Screws (Front)

D—Transmission Isolator Cap Screws (Front)

16. Carefully remove transmission and place in repair stand using JDG1129 Transmission Mounting Bracket. 17. Remove hydraulic pump from transmission. 18. After transmission repair, install hydraulic pump on transmission before installing transmission in machine. Inspect hydraulic pump to transmission O-ring before installing pump.

14. Remove isolator cap screws (A and D). 19. Install transmission in machine. 15. Remove transmission front mount cap screws (C) and remove mounts from transmission.

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

NOTE: Rear transmission mount does not have to be removed from transmission.


TM1640 (15JAN04)

03-0300-5

TX,03,RP3337 –19–12FEB99–4/5


PN=119

Removal and Installation Mounting Bracket-to-Transmission Cap Screw (Front)—Torque ......................................... 433 N•m (320 lb-ft) Mounting Bracket-to-Transmission Cap Screw (Rear)—Torque.......................................... 318 N•m (235 lb-ft)

20. Connect all hoses and lines to transmission and hydraulic pump. 21. Fill transmission and hydraulic reservoir to specifications.

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

22. Install transmission drive shafts using new cap screws. Transmission—Specification Drive Shaft Universal Joint (Output) Cap Screw—Torque ................................... 78 N•m (58 lb-ft) Drive Shaft Universal Joint (Input) Cap Screw—Torque...................................... 78 N•m (58 lb-ft) Engine-to-Transmission Shaft Universal Joint Cap Screw— Torque....................................................................... 78 N•m (58 lb-ft)

23. Install ROPS or cab. (See procedure in Group 1800.)

03 0300 6 TX,03,RP3337 –19–12FEB99–5/5

TM1640 (15JAN04)

03-0300-6


PN=120

Group 0350

Gears, Shafts, Bearings and Power Shift Clutch Essential Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC).


CED,OUOE003,3374 –19–21APR99–1/7

–UN–29APR97

Transmission Mounting Brackets . . . . . . . . . . JDG1129 03 0350 1

T109218

Used to mount transmission in repair stand.

CED,OUOE003,3374 –19–21APR99–2/7 T112434 –UN–10DEC97

Bearing Puller. . . . . . . . . . . . . . . . . . . . . . . JDG1134 Used with bearing puller mandrel to remove bearing from clutch packs KV and K4. CED,OUOE003,3374 –19–21APR99–3/7 T104040 –UN–27SEP96

Bearing Puller Mandrel . . . . . . . . . . . . . . . . . JDG1035 Used with bearing puller to remove bearing from clutch packs.

CED,OUOE003,3374 –19–21APR99–4/7 T112434 –UN–10DEC97

Bearing Puller. . . . . . . . . . . . . . . . . . . . . . . JDG1197 Used with bearing puller mandrel to remove bearing from clutch packs K1, K2, K3, K4, and KR. Continued on next page

TM1640 (15JAN04)

03-0350-1

CED,OUOE003,3374 –19–21APR99–5/7


PN=121

Gears, Shafts, Bearings and Power Shift Clutch T112433 –UN–10DEC97

Bearing Puller Mandrel . . . . . . . . . . . . . . . . . JDG1034 Used with bearing puller to remove bearing from clutch packs. CED,OUOE003,3374 –19–21APR99–6/7 T112434 –UN–10DEC97

Bearing Puller. . . . . . . . . . . . . . . . . . . . . . . JDG1041 Used with bearing puller mandrel to remove bearing from clutch packs K1 and K3. CED,OUOE003,3374 –19–21APR99–7/7

Service Equipment and Tools 03 0350 2

NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.


CED,OUOE003,3325 –19–26MAR99–1/5

Repair Stand Used to hold transmission for repair.

CED,OUOE003,3325 –19–26MAR99–2/5

Eye Bolt . . . . . . . . . . . . . . . . . . . . . . . M20 and M12 Used with hoist to remove transmission cover.

CED,OUOE003,3325 –19–26MAR99–3/5

Pre-Load Clutch Pack Compression Ring Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DFT11491 Used to compress the piston compression ring for removal and installation of snap ring.

1

Fabricated tool, dealer made. (See Group 0399 for instructions to make tool.) Continued on next page

TM1640 (15JAN04)

03-0350-2

CED,OUOE003,3325 –19–26MAR99–4/5


PN=122

Gears, Shafts, Bearings and Power Shift Clutch Pre-Load Clutch Pack Compression Ring Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DFT11481 Used to compress the piston compression ring for removal and installation of snap ring.

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

CED,OUOE003,3325 –19–26MAR99–5/5

Other Material 03 0350 3

Number

Name

Use

T43513 (U.S.) TY9474 (Canadian) 271 (LOCTITE)

Thread Lock and Sealer (High Strength)

Apply to drive plate-to-torque converter cap screws.


Thread Lock and Sealer (Medium Strength)

Apply to output shaft cover socket head cap screws. Apply to threads of clutch pack shaft studs.

TY16021 (U.S.) TY9484 (Canadian) 17430 (LOCTITE)

High Flex Form-In-Place Gasket

Apply to transmission mounting face cover. Apply to contact side of output flange (yoke) retaining washer.

LOCTITE is a trademark of Loctite Corp.

TM1640 (15JAN04)

CED,OUOE003,3326 –19–26MAR99–1/1

03-0350-3


PN=123

Gears, Shafts, Bearings and Power Shift Clutch

Specifications Item

Measurement

Specification

Transmission

Weight


Converter Housing M10/10.9 Cap Screw

Torque

68 N•m (50 lb-ft)

Input Shaft-to-Drive Plate M12/10.9 Cap Screw

Torque

115 N•m (85 lb-ft)

Drive Plate-to-Torque Converter M12/10.9 Cap Screw

Torque

115 N•m (85 lb-ft)

Top Cover M10/8.8 Cap Screw

Torque

46 N•m (34 lb-ft)

Input Flange-to-Torque Converter Shaft Cap Screw

Torque

34 N•m (25 lb-ft)

Output Shaft Cover Socket Head Screw

Torque

23 N•m (17 lb-ft)

Housing Cover Hex Head Screw

Torque

46 N•m (34 lb-ft)

Output Flange

Temperature

90°C (194°F) maximum

Output Flange Cap Screw

Torque

34 N•m (25 lb-ft)

Gasket-to-Cover Hex Head Screw

Torque

23 N•m (17 lb-ft)

Oil Level Tube Screw

Torque

25 N•m (18 lb-ft)

Speed Sensor

Torque

30 N•m (22 lb-ft)

Drain Plug

Torque

140 N•m (100 lb-ft)

KV and KR Clutch Pack Plate

Clearance

2.7—2.9 mm (0.106—0.114 in.)

Shaft Stud

Torque

17 N•m (150 lb-in.)

K1 Clutch Pack Plate

Clearance

2.4—2.6 mm (0.094—0.102 in.)

Torque Converter

03 0350 4

Clutches, Input and Output Shafts

Clutch Pack


TM1640 (15JAN04)

03-0350-4

CED,OUOE003,3327 –19–26MAR99–1/2


PN=124


Item

Measurement

Specification

K2 and K3 Clutch Pack Plate

Clearance

1.8—2.0 mm (0.071—0.079 in.)

K4 Clutch Pack Shaft

Temperature

Cools at -80°C (-112°F)

K4 Clutch Pack Gear

Temperature

Heats at 120°C (248°F)

K4 Clutch Pack Plate

Clearance

1.2—1.4 mm (0.047—0.055 in.)

Input Shaft

Temperature

Cools at -80°C (-112°F)

Input Gear

Temperature

Heats at +120°C (250°F)

Input Shaft

03 0350 5

CED,OUOE003,3327 –19–26MAR99–2/2

Remove Torque Converter and Housing

–UN–26JAN98

CAUTION: The approximate weight of transmission is 510 kg (1125 lb). Torque Converter—Specification Transmission—Weight................................. 510 kg (1125 lb) approximate

T109146B

1. Install transmission in repair stand using JDG1129 mounting brackets (A). A—Mounting Bracket (2 used)


TM1640 (15JAN04)

03-0350-5

TX,0350,WW2497 –19–25MAR99–1/11


PN=125


–UN–19DEC97

NOTE: Earlier JDG1129 Transmission Mounting Brackets require the right side bracket revised. Note bracket sketch showing revised mounting hole (A). Revise hole by elongating the existing hole as required.

T112589

A—Revised Mounting Hole

Bracket Sketch Showing Revised Mounting Hole (A)

03 0350 6 TX,0350,WW2497 –19–25MAR99–2/11

2. Remove lock plate and hex head screws from input flange washer.

T108721

–UN–17APR97

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

TX,0350,WW2497 –19–25MAR99–3/11

T108722

–UN–17APR97

4. Remove torque converter housing cap screws. Place a mark on the cover and housing for ease of assembly and proper alignment later.


TM1640 (15JAN04)

03-0350-6

TX,0350,WW2497 –19–25MAR99–4/11


PN=126


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

T108723

–UN–17APR97

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

TX,0350,WW2497 –19–25MAR99–5/11

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

T108724

–UN–17APR97

03 0350 7

TX,0350,WW2497 –19–25MAR99–6/11

T108717

–UN–17APR97

7. Remove snap ring and remove bearing from housing.

TX,0350,WW2497 –19–25MAR99–7/11

T112416

–UN–05DEC97

8. Remove hex head screws and separate drive plate from converter.


TM1640 (15JAN04)

03-0350-7

TX,0350,WW2497 –19–25MAR99–8/11


PN=127


T112415

–UN–05DEC97

9. Remove hex head screws and separate input shaft from drive plate.

TX,0350,WW2497 –19–25MAR99–9/11

10. Remove speed senor from converter housing.

T108720

–UN–17APR97

03 0350 8

TX,0350,WW2497 –19–25MAR99–10/11

T108729

–UN–17APR97

11. Remove hex head screws and remove converter lower housing.

TX,0350,WW2497 –19–25MAR99–11/11

Install Torque Converter and Housing 1. Fasten converter housing using hex head screws.

–UN–15APR97

Tighten M10/10.9 cap screws.

T109095

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


TM1640 (15JAN04)

03-0350-8

TX,0350,RB228 –19–04DEC03–1/8


PN=128

Gears, Shafts, Bearings and Power Shift Clutch 2. Fasten input shaft to plate with hex head screws. Tighten M12/10.9 cap screws.

T112415

–UN–05DEC97

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

TX,0350,RB228 –19–04DEC03–2/8

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

03 0350 9

–UN–15APR97

Apply thread lock and sealer (high strength) to cap screws. Tighten M12/10.9 cap screws.

T109121

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

TX,0350,RB228 –19–04DEC03–3/8

4. Install converter in housing until contact is made.

T109098

–UN–30APR97

T109097

–UN–15APR97

NOTE: Speed pickup disk in the converter must be centered to the bore of the speed sensor. See art with arrow showing. This insures that the converter is seated properly.


TM1640 (15JAN04)

03-0350-9

TX,0350,RB228 –19–04DEC03–4/8


PN=129


T109099

–UN–15APR97

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

TX,0350,RB228 –19–04DEC03–5/8

6. Assemble housing. Install input flange, washer and draw cover down with hex head screws evenly against shoulder.

T109100

–UN–15APR97

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

TX,0350,RB228 –19–04DEC03–6/8

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

–UN–15APR97

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

T109101

03 0350 10


TM1640 (15JAN04)

03-0350-10

TX,0350,RB228 –19–04DEC03–7/8


PN=130

Gears, Shafts, Bearings and Power Shift Clutch 8. Fasten input flange with hex head screws and tighten.

–UN–02MAY97

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

T109147B

Install locking plate using hammer and two deep well sockets (A) taped together with a hex nut between them for proper spread. A—Deep Well Socket

Output Flange Shown

03 0350 11 TX,0350,RB228 –19–04DEC03–8/8

Remove Clutches, Input and Output Shafts 1. Remove lock plate, loosen hex head screws, and pry the rear output flange from the shaft. –UN–18APR97

2. Pry shaft seal out of the housing bore.

T108778

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

TX,0350,ME280 –19–25MAR99–1/19

T108779

–UN–29APR97

4. Remove three sensors.


TM1640 (15JAN04)

03-0350-11

TX,0350,ME280 –19–25MAR99–2/19


PN=131

Gears, Shafts, Bearings and Power Shift Clutch 5. Loosen hex nuts and remove the two small manifold covers (Arrows).

T108780

–UN–29APR97

6. Remove cap screws from transmission cover.

TX,0350,ME280 –19–25MAR99–3/19

–UN–29APR97 T108781

TX,0350,ME280 –19–25MAR99–4/19

–UN–18APR97

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

T108774

03 0350 12

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


TM1640 (15JAN04)

03-0350-12

TX,0350,ME280 –19–25MAR99–5/19


PN=132

Gears, Shafts, Bearings and Power Shift Clutch 9. Figure shows the proper position of the single clutches as well as of the input and output.

T108775

–UN–29APR97

KV—Low Range Forward Clutch KR—Reverse Clutch K1—First Speed Clutch K2—Second Speed Clutch K3—Third Speed Clutch K4—High Range Forward Clutch AN—Input AB—Output

03 0350 13 TX,0350,ME280 –19–25MAR99–6/19

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

T108776

–UN–18APR97

10. Loosen socket head screws from covers and remove output shaft with covers.


TM1640 (15JAN04)

03-0350-13

TX,0350,ME280 –19–25MAR99–7/19


PN=133


–UN–30APR97

IMPORTANT: Remove sealing rings from clutch pack shafts (cover side only) before installing cover. Sealing rings may be damaged while removing and installing clutch packs later.

T108777

11. Place cover back on transmission until it contacts the mounting surface so clutch packs can be removed from housing for repair or inspection.

NOTE: Six 24H1300 Flat Washers and M10 Hex Nuts are substituted for special handles shown in photo. Special Handles Shown

–UN–09MAY97

This method must be used to remove clutch pack from transmission housing.

T109149B

A—Flat Washer (6 used)

24H1300 and M10 Hardware Shown TX,0350,ME280 –19–25MAR99–8/19

T108786

–UN–18APR97

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

TX,0350,ME280 –19–25MAR99–9/19

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

–UN–09MAY97

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

T109149C

03 0350 14

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


TM1640 (15JAN04)

03-0350-14

TX,0350,ME280 –19–25MAR99–10/19


PN=134


–UN–09MAY97

15. Install cover with packs into stand using JDG1129 Mounting Brackets (A). Using shop hardware (B) (cap screws, washers and nuts) fasten cover to mounting brackets JDG1129 (A).

T109148B

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

TX,0350,ME280 –19–25MAR99–11/19

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

03 0350 15

T108788

–UN–18APR97

17. Remove six M10 nuts and six washers from clutch packs.

TX,0350,ME280 –19–25MAR99–12/19

CAUTION: Use special care while removing clutch packs from cover due to closeness of packs and spline engagement to each other.

T108789

–UN–18APR97

18. Remove clutch K2.

TX,0350,ME280 –19–25MAR99–13/19

T108782

–UN–18APR97

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


TM1640 (15JAN04)

03-0350-15

TX,0350,ME280 –19–25MAR99–14/19


PN=135


T108783

–UN–18APR97

20. Remove clutch K3.

TX,0350,ME280 –19–25MAR99–15/19

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

T108784

–UN–18APR97

03 0350 16

TX,0350,ME280 –19–25MAR99–16/19

T108785

–UN–18APR97

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

TX,0350,ME280 –19–25MAR99–17/19

T108790

–UN–18APR97

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


TM1640 (15JAN04)

03-0350-16

TX,0350,ME280 –19–25MAR99–18/19


PN=136


T108791

–UN–29APR97

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

TX,0350,ME280 –19–25MAR99–19/19

Install Clutches, Input and Output Shafts 03 0350 17

IMPORTANT: High tolerance bearings are used in all clutch pack applications. Use only John Deere sourced bearings when replacing.

–UN–30APR97

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

T109004

1. Insert all bearing outer races into the housing cover until contact is obtained. KV—Low Range Forward Clutch KR—Reverse Clutch K1—First Speed Clutch K2—Second Speed Clutch K3—Third Speed Clutch K4—High Range Forward Clutch AN—Input AB—Output

TX,0350,JC2037 –19–25MAR99–1/32

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

T109005

–UN–29APR97

KV—Low Range Forward Clutch KR—Reverse Clutch AN—Input


TM1640 (15JAN04)

03-0350-17

TX,0350,JC2037 –19–25MAR99–2/32


PN=137

Gears, Shafts, Bearings and Power Shift Clutch 3. Install clutch-K4.

T109006

–UN–29APR97

K4—High Range Forward Clutch

TX,0350,JC2037 –19–25MAR99–3/32

4. Install clutch-K3.

T109007

–UN–09MAY97

K3—Third Speed Clutch

TX,0350,JC2037 –19–25MAR99–4/32

T112554B

–UN–17DEC97

5. Position clutch-K2.

TX,0350,JC2037 –19–25MAR99–5/32

–UN–17DEC97

6. Insert clutch-K1.

T112553B

03 0350 18


TM1640 (15JAN04)

03-0350-18

TX,0350,JC2037 –19–25MAR99–6/32


PN=138

Gears, Shafts, Bearings and Power Shift Clutch 7. Figure on the right shows the installation position of the single clutches in the housing cover.

T109010

–UN–29APR97

KV—Low Range Forward Clutch KR—Reverse Clutch K1—First Speed Clutch K2—Second Speed Clutch K3—Third Speed Clutch K4—High Range Forward Clutch

TX,0350,JC2037 –19–25MAR99–7/32

8. Retain all clutches using six M10 hex nuts and six 24H1300 flat washers.

T109011

–UN–09MAY97

03 0350 19

TX,0350,JC2037 –19–25MAR99–8/32

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

T109012

–UN–29APR97

10. Grease sealing rings and align.

TX,0350,JC2037 –19–25MAR99–9/32

11. Turn housing cover 180°. 12. Mount eye bolts.

–UN–29APR97

13. Remove transmission cover with clutch packs from repair stand.

T109013

14. Install transmission housing into repair stand.


TM1640 (15JAN04)

03-0350-19

TX,0350,JC2037 –19–25MAR99–10/32


PN=139

Gears, Shafts, Bearings and Power Shift Clutch 15. Install alignment studs in housing.

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

T109014

–UN–09MAY97

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

TX,0350,JC2037 –19–25MAR99–11/32

–UN–09MAY97

A—Flat Washer (6 used)

T109149B

TX,0350,JC2037 –19–25MAR99–12/32

T109016

–UN–09MAY97

18. Remove housing cover from gearbox housing.

TX,0350,JC2037 –19–25MAR99–13/32

19. Output Shaft

–UN–15APR97

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

T109066

03 0350 20

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


TM1640 (15JAN04)

03-0350-20

TX,0350,JC2037 –19–25MAR99–14/32


PN=140


T109068

–UN–29APR97

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

TX,0350,JC2037 –19–25MAR99–15/32

21. Position inner oil cover.

T109069

–UN–15APR97

03 0350 21

TX,0350,JC2037 –19–25MAR99–16/32

T109070

–UN–15APR97

22. Install output shaft with cover in housing.

TX,0350,JC2037 –19–25MAR99–17/32

NOTE: Insert socket head cap screws with thread lock and sealer (medium strength). 23. Fasten both covers by means of socket head screws.

T109071

–UN–15APR97

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


TM1640 (15JAN04)

03-0350-21

TX,0350,JC2037 –19–25MAR99–18/32


PN=141

Gears, Shafts, Bearings and Power Shift Clutch 24. Install sealing rings (6 used) into the recesses of the clutch shafts and hook them in.

T109072

–UN–29APR97

25. Grease sealing rings and align.

TX,0350,JC2037 –19–25MAR99–19/32

–UN–29APR97 T109075

TX,0350,JC2037 –19–25MAR99–20/32

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

–UN–15APR97

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

T109076

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

TX,0350,JC2037 –19–25MAR99–21/32

–UN–29APR97

29. Install dowel pins.

T109077

03 0350 22

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


TM1640 (15JAN04)

03-0350-22

TX,0350,JC2037 –19–25MAR99–22/32


PN=142

Gears, Shafts, Bearings and Power Shift Clutch NOTE: Locate hanger in same position as it was removed. 30. Install housing cover using hex head screws.

T109078

–UN–15APR97

Clutches, Input and Output Shafts—Specification Housing Cover Hex Head Screw—Torque ................................................................ 46 N•m (34 lb-ft)

TX,0350,JC2037 –19–25MAR99–23/32

NOTE: Grease sealing lip should face inward. 03 0350 23

T109079

–UN–15APR97

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

TX,0350,JC2037 –19–25MAR99–24/32

32. Apply High Flex Form-In-Place Gasket to contact area of washer. 33. Heat the output flange. –UN–15APR97

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

T109080

34. Install flange and washer with cap screws. Tighten cap screws. Clutches, Input and Output Shafts—Specification Output Flange Cap Screw— Torque ............................................................................. 34 N•m (25 lb-ft)


TM1640 (15JAN04)

03-0350-23

TX,0350,JC2037 –19–25MAR99–25/32


PN=143

Gears, Shafts, Bearings and Power Shift Clutch 35. Install locking plate using two 5/8 in. deep well sockets (A).

–UN–02MAY97

36. Install flange in same manner on opposite side.

T109147B

A—Deep Well Socket (2 used)

TX,0350,JC2037 –19–25MAR99–26/32

T109094

–UN–15APR97

Clutches, Input and Output Shafts—Specification Gasket-to-Cover Hex Head Screw—Torque ................................................................ 23 N•m (17 lb-ft)

TX,0350,JC2037 –19–25MAR99–27/32

T109115

–UN–15APR97

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

TX,0350,JC2037 –19–25MAR99–28/32

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

–UN–15APR97

Clutches, Input and Output Shafts—Specification Cover-To-Transmission Housing Hex Nut—Torque............................................................ 25 N•m (18 lb-ft.)

T109116

03 0350 24

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


TM1640 (15JAN04)

03-0350-24

TX,0350,JC2037 –19–25MAR99–29/32


PN=144

Gears, Shafts, Bearings and Power Shift Clutch 40. Install oil level tube and tighten screw.

T109117

–UN–15APR97

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

TX,0350,JC2037 –19–25MAR99–30/32

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

03 0350 25

–UN–29APR97

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

42. Install breather (shown at arrow head).

T109119

21—Turbine Speed Sensor 47—Middle Gear Speed Sensor 48—Engine Speed Sensor

TX,0350,JC2037 –19–25MAR99–31/32

43. Install drain plug and tighten.

T109120

–UN–15APR97

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

TX,0350,JC2037 –19–25MAR99–32/32

TM1640 (15JAN04)

03-0350-25


PN=145


Disassemble Clutch Pack KV and KR

T108792

–UN–29APR97

1. Remove sealing ring.

TX,0350,ME284 –19–26MAR99–1/10

T108793

–UN–18APR97

Remove opposite bearing on clutch pack KR with JDG1197 Bearing Puller and JDG1034 Bearing Puller Mandrel.

TX,0350,ME284 –19–26MAR99–2/10

T108794

–UN–18APR97

3. Separate plate carrier from shaft.

TX,0350,ME284 –19–26MAR99–3/10

–UN–18APR97

4. Remove plates.

T108795

03 0350 26

2. Pull tapered roller bearing from the shaft using JDG1134 Bearing Puller and JDG1035 Bearing Puller Mandrel. Remove opposite tapered roller bearing on clutch pack KV.


TM1640 (15JAN04)

03-0350-26

TX,0350,ME284 –19–26MAR99–4/10


PN=146

Gears, Shafts, Bearings and Power Shift Clutch 5. Preload compression spring with DFT1149 Pre-Load Clutch Pack Compression Ring Tool in press and remove snap ring. (See Group 0399 for instructions to make tool.)

T108761

–UN–17APR97

6. Remove piston from carrier.

TX,0350,ME284 –19–26MAR99–5/10

7. Remove O-rings from piston.

T108758

–UN–29APR97

03 0350 27

TX,0350,ME284 –19–26MAR99–6/10

T108759

–UN–17APR97

8. Remove inner circle snap ring.

TX,0350,ME284 –19–26MAR99–7/10

T108752

–UN–17APR97

9. Remove idler gear from shaft using a press.


TM1640 (15JAN04)

03-0350-27

TX,0350,ME284 –19–26MAR99–8/10


PN=147


T108753

–UN–17APR97

10. Remove released needle bearing.

TX,0350,ME284 –19–26MAR99–9/10

11. Remove circle snap ring and remove bearing.

T108754

–UN–17APR97

03 0350 28

TX,0350,ME284 –19–26MAR99–10/10

Assemble Clutch Pack KV and KR

–UN–29APR97

IMPORTANT: Check function of the drain valve. Check function of drain ball. Ball must move freely. If ball does not move freely, check for contamination or replace.

T108981

NOTE: Clutch KV and KR are assembled in the same manner. Art shown in the following story is similar to both clutch packs. 1. Install both new O-rings (Arrows) into the ID and OD of the piston and oil them.


TM1640 (15JAN04)

03-0350-28

TX,0350,ME288 –19–26MAR99–1/19


PN=148

Gears, Shafts, Bearings and Power Shift Clutch 2. Assemble piston until it bottoms out in plate carrier.

T108662

–UN–10APR97

Pay attention to proper installation.

TX,0350,ME288 –19–26MAR99–2/19

3. Install spring and two guides.

T108663

–UN–10APR97

03 0350 29

TX,0350,ME288 –19–26MAR99–3/19

T108664

–UN–10APR97

4. Press spring with DFT1149 Pre-Load Clutch Pack Compression Ring Tool in press and install snap ring into plate carrier groove. (See Group 0399 for instructions to make tool.)


TM1640 (15JAN04)

03-0350-29

TX,0350,ME288 –19–26MAR99–4/19


PN=149


T112158

–UN–20NOV97

03 0350 30

Clutch Packs KV and KR 1—Plate Carrier 2—Piston

3—Disk (Friction) (One Side Fiber Coated)

IMPORTANT: Install one sided friction disk (3) with the fiber side always facing toward plate. Smooth side should be against piston.

4—Plate (Separator) (10 used) 5—Disk (Friction) (10 used)

6—Snap Ring 7—End Shim

For proper adjustment of plate clearance install disk and plates temporarily without being oiled. 5. Install one sided fiber disk into carrier with the fiber side facing out or away from piston.

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

TX,0350,ME288 –19–26MAR99–5/19

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

T108665

–UN–10APR97

7. Install two plates, then two disks.


TM1640 (15JAN04)

03-0350-30

TX,0350,ME288 –19–26MAR99–6/19


PN=150


T108666

–UN–10APR97

8. Install end shim and snap ring.

TX,0350,ME288 –19–26MAR99–7/19

NOTE: For the adjustment of the plate clearance there are snap rings of different thickness available through parts system that can be used if proper clearance is unable to be obtained. To ensure proper measuring result, install plates temporarily without oil.

–UN–10APR97

03 0350 31

9. Adjust plate clearance.

T108667

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

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


TM1640 (15JAN04)

03-0350-31

TX,0350,ME288 –19–26MAR99–8/19


PN=151

Gears, Shafts, Bearings and Power Shift Clutch b. Press end shim against snap ring (upward) until contact and measure with gage. Record dimension (No. 2).

7.25 mm (0.285 in.)

Dimension No. 2

4.55 mm (0.179 in.)

Difference = Plate Clearance

2.7 mm (0.106 in.)

Specification = Pack Clearance

2.7—2.9 mm (0.106—0.114 in.)

T108668

Dimension No. 1

–UN–10APR97

Example for Clutch Pack Clearance Check

If a clutch pack clearance is not in specification, correct by using the proper corresponding snap ring from service parts to increase or decrease clearance. Snap rings come in various sizes. After proper clearance is obtained remove disks and plates from assembly. 10. Add oil to plates and disks. 11. Reassemble clutch pack assembly.

TX,0350,ME288 –19–26MAR99–9/19

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

T108669

–UN–10APR97

13. Remove idler gear from clutch pack assembly.

TX,0350,ME288 –19–26MAR99–10/19

14. Apply thread lock and sealer (medium strength) to stud. 15. Install stud on end of shaft if removed in assembly. –UN–10APR97

Tighten stud. Clutch Pack—Specification Shaft Stud—Torque ...................................................... 17 N•m (150 lb-in.)

T108670

03 0350 32


TM1640 (15JAN04)

03-0350-32

TX,0350,ME288 –19–26MAR99–11/19


PN=152


T108671

–UN–10APR97

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

TX,0350,ME288 –19–26MAR99–12/19

17. Install needle bearing.

T108672

–UN–10APR97

03 0350 33

TX,0350,ME288 –19–26MAR99–13/19

NOTE: Push against inner race of bearing.

T108673

–UN–10APR97

18. Press idler gear against shoulder.

TX,0350,ME288 –19–26MAR99–14/19

T108674

–UN–10APR97

19. Retain idler gear by means of snap ring.


TM1640 (15JAN04)

03-0350-33

TX,0350,ME288 –19–26MAR99–15/19


PN=153


T108675

20. Assemble pre-assembled plate carrier until all plates are engaged.

–UN–10APR97

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

TX,0350,ME288 –19–26MAR99–16/19

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

T108676

–UN–10APR97

03 0350 34

TX,0350,ME288 –19–26MAR99–17/19

22. Press tapered roller bearing against shoulder.

T108677

–UN–10APR97

Install opposite tapered roller bearing with press.

TX,0350,ME288 –19–26MAR99–18/19

T108678

NOTE: When you have correctly installed components, the clutch packs will move freely as you will be able to hear them moving while inducing compressed air.

–UN–10APR97

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

TX,0350,ME288 –19–26MAR99–19/19

TM1640 (15JAN04)

03-0350-34


PN=154


Disassemble Clutch Pack K1, K2, and K3

–UN–29APR97

NOTE: The following art shows the disassembly of clutch K3. K1 and K2 are identical in disassembly methods.

T108755

1. Remove rectangular sealing ring from shaft.

TX,0350,ME285 –19–26MAR99–1/9

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

03 0350 35

Bearing Puller Mandrel No.

K1

JDG1041

JDG1034

JDG1197

JDG1035

K2

JDG1197

JDG1035

K3

JDG1197

JDG1034

JDG1041

JDG1034

T108764

Bearing Puller No.

–UN–17APR97

Tool Usage Chart Clutch Shaft

TX,0350,ME285 –19–26MAR99–2/9

T108765

–UN–17APR97

3. Remove disk, needle bearing and washer.


TM1640 (15JAN04)

03-0350-35

TX,0350,ME285 –19–26MAR99–3/9


PN=155


T108766

–UN–17APR97

4. Remove idler gear.

TX,0350,ME285 –19–26MAR99–4/9

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

T108767

–UN–17APR97

03 0350 36

TX,0350,ME285 –19–26MAR99–5/9

T108760

–UN–17APR97

6. Remove snap ring and remove plates and disks.

TX,0350,ME285 –19–26MAR99–6/9

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

T108761

–UN–17APR97

8. Squeeze snap ring out and remove components.


TM1640 (15JAN04)

03-0350-36

TX,0350,ME285 –19–26MAR99–7/9


PN=156


T108762

–UN–17APR97

9. Press piston out of the plate carrier, using compressed air.

TX,0350,ME285 –19–26MAR99–8/9

10. Pry plate carrier from the shaft.

T108763

–UN–17APR97

03 0350 37

TX,0350,ME285 –19–26MAR99–9/9

Assemble Clutch Pack K1, K2, and K3

–UN–10APR97

NOTE: Clutch K1, K2 and K3 are assembled in similar manner. All the following assembly story art show clutch K3. 1. Apply thread lock and sealer (medium strength) to stud.

T108679

2. Install stud on end of shaft. Tighten stud. Clutch Pack—Specification Shaft Stud—Torque ...................................................... 17 N•m (150 lb-in.)


TM1640 (15JAN04)

03-0350-37

TX,0350,ME289 –19–26MAR99–1/23


PN=157


T108680

–UN–10APR97

3. Assemble plate carrier until bottomed.

TX,0350,ME289 –19–26MAR99–2/23

–UN–29APR97 T108981

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

TX,0350,ME289 –19–26MAR99–3/23

5. Install piston in carrier until seated.

–UN–10APR97

Note proper position.

T108734

03 0350 38



TM1640 (15JAN04)

03-0350-38

TX,0350,ME289 –19–26MAR99–4/23


PN=158


T108735

–UN–10APR97

6. Install compression spring, two spring guides, into plate carrier.

Spring Type Shown May Vary

03 0350 39 TX,0350,ME289 –19–26MAR99–5/23

7. Using DFT1149 Pre-Load Clutch Pack Compression Ring Tool and press, install snap ring into plate carrier groove for clutch K1.

T108736

–UN–10APR97

Using DFT1148 Pre-Load Clutch Pack Compression Ring Tool and press, install snap ring into plate carrier groove for clutch K2 and K3.


TM1640 (15JAN04)

03-0350-39

TX,0350,ME289 –19–26MAR99–6/23


PN=159


T112161

–UN–20NOV97

03 0350 40

Clutch Packs K1 1—Plate Carrier 2—Piston





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

NOTE: For proper adjustment of plate clearance, install disk and plates temporarily without being oiled.

TX,0350,ME289 –19–26MAR99–7/23

9. Install plate and then disk alternately until seven plates and seven disks are installed in carrier.

T108737

–UN–10APR97



TM1640 (15JAN04)

03-0350-40

TX,0350,ME289 –19–26MAR99–8/23


PN=160


T108738

–UN–10APR97


TX,0350,ME289 –19–26MAR99–9/23


–UN–10APR97

03 0350 41

12. Adjust plate clearance to specification.

T108739

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



TM1640 (15JAN04)

03-0350-41

TX,0350,ME289 –19–26MAR99–10/23


PN=161


8.50 mm (0.335 in.)

Dimension No. 2

6.00 mm (0.236 in.)


2.50mm (0.079 in.)


2.4—2.6 mm (0.094—0.102 in.)

T108740

Dimension No. 1

–UN–09MAY97


If a clutch pack clearance is not in specification, correct by using the proper corresponding snap ring from service parts to increase or decrease clearance. Snap rings come in various sizes. 03 0350 42

After proper clearance is obtained remove disks and plates from assembly. 13. Add oil to plates and disks. 14. Reassemble clutch pack assembly.


TM1640 (15JAN04)

03-0350-42

TX,0350,ME289 –19–26MAR99–11/23


PN=162


T112160

–UN–20NOV97

03 0350 43

Clutch Packs K2 and K3 1—Plate Carrier 2—Piston



For proper adjustment of plate clearance, install disk and plates temporarily without being oiled.


NOTE: Plate and disk position is the same for clutch K2 and K3.



TX,0350,ME289 –19–26MAR99–12/23

16. Install plate and then disk alternately until five plates and five disks are installed in carrier.

T108737

–UN–10APR97



TM1640 (15JAN04)

03-0350-43

TX,0350,ME289 –19–26MAR99–13/23


PN=163


T108738

–UN–10APR97


TX,0350,ME289 –19–26MAR99–14/23

–UN–10APR97

19. Adjust plate clearance to specification. Clutch Pack—Specification K2 and K3 Clutch Pack Plate— Clearance ................................................ 1.8—2.0 mm (0.071—0.079 in.)

T108739

03 0350 44




TM1640 (15JAN04)

03-0350-44

TX,0350,ME289 –19–26MAR99–15/23


PN=164


8.00 mm (0.315 in.)

Dimension No. 2

6.00 mm (0.236 in.)


2.0 mm (0.079 in.)


1.8—2.0 mm (0.071—0.079 in.)

T108740

Dimension No. 1

–UN–09MAY97


If a clutch pack clearance is not in specification, correct by using the proper corresponding snap ring from service parts to increase or decrease clearance. Snap rings come in various sizes.

03 0350 45

After proper clearance is obtained remove disks and plates from assembly. 20. Add oil to plates and disks. 21. Reassemble clutch pack assembly.

TX,0350,ME289 –19–26MAR99–16/23

22. Assemble thrust disk (1), thrust bearing (2), and thrust washer (3).

T108741

–UN–09MAY97

1—Thrust Disk 2—Thrust Bearing 3—Thrust Washer

TX,0350,ME289 –19–26MAR99–17/23

T108742

–UN–09MAY97

23. Install both needle bearings.


TM1640 (15JAN04)

03-0350-45

TX,0350,ME289 –19–26MAR99–18/23


PN=165


T108743

–UN–09MAY97

24. Install idler gear until all inner plates are engaged with splines.

TX,0350,ME289 –19–26MAR99–19/23

–UN–09MAY97

NOTE: Install disk (1) with chamfer facing the thrust bearing. 26. To assure proper assembly, top surface of thrust disk must be flush with shaft step.

T108744

1—Thrust Disk 2—Thrust Bearing 3—Thrust Washer

TX,0350,ME289 –19–26MAR99–20/23

–UN–09MAY97


T108745

03 0350 46

25. Install thrust washer (3), thrust bearing (2), and thrust disk.


TM1640 (15JAN04)

03-0350-46

TX,0350,ME289 –19–26MAR99–21/23


PN=166


T108746

–UN–09MAY97


TX,0350,ME289 –19–26MAR99–22/23

29. Check function of clutch by means of compressed air. 03 0350 47

T108747

–UN–09MAY97

NOTE: When you have correctly installed components, the clutch packs will move freely in carrier, as you will be able to hear them moving while inducing compressed air.

TX,0350,ME289 –19–26MAR99–23/23

Disassemble Clutch Pack K4 1. Remove sealing ring.

–UN–17APR97

2. Pull tapered roller bearing from the shaft with JDG1035 Bearing Puller Mandrel and JDG1134 and JDG1197 Bearing Pullers.

T108768

3. Remove opposite tapered roller bearing accordingly.

TX,0350,ME286 –19–26MAR99–1/4

T108769

–UN–17APR97

4. Remove snap ring and plate carrier from shaft.


TM1640 (15JAN04)

03-0350-47

TX,0350,ME286 –19–26MAR99–2/4


PN=167


T108770

–UN–18APR97

5. Remove snap ring and remove plates and disks.

TX,0350,ME286 –19–26MAR99–3/4

T108983

–UN–14APR97

7. Remove snap ring and components. Remove piston.

TX,0350,ME286 –19–26MAR99–4/4

Assemble Clutch Pack K4 NOTE: Gear is very tight press fit. Shaft or gear may be damaged if pressed apart. –UN–14APR97

1. Cool shaft to specification. Heat gear to specification and install it until bottomed. Clutch Pack—Specification K4 Clutch Pack Shaft— Temperature ......................................................... Cools at -80°C (-112°F) K4 Clutch Pack Gear— Temperature ......................................................... Heats at 120°C (248°F)

T108748

03 0350 48

6. Preload compression spring using DFT1148 Pre-Load Clutch Pack Compression Ring Tool in press.


TM1640 (15JAN04)

03-0350-48

TX,0350,ME291 –19–26MAR99–1/20


PN=168


T108749

–UN–14APR97

2. Install snap ring to retain gear.

TX,0350,ME291 –19–26MAR99–2/20

3. Apply thread lock and sealer (medium strength) to stud.

03 0350 49

4. Install stud on end of shaft. –UN–29APR97

Tighten stud.

T108750

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

TX,0350,ME291 –19–26MAR99–3/20

–UN–29APR97


T108981

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

TX,0350,ME291 –19–26MAR99–4/20

6. Assemble piston until it bottoms out in disk carrier.

T108982

–UN–14APR97

Pay attention to proper installation.


TM1640 (15JAN04)

03-0350-49

TX,0350,ME291 –19–26MAR99–5/20


PN=169

Gears, Shafts, Bearings and Power Shift Clutch 7. Install compression spring, two spring guides, into disk carrier.

T108983

–UN–14APR97

8. Press spring with DFT1148 Pre-Load Clutch Pack Compression Ring Tool in press and install snap ring into disk carrier groove. (See Group 0399 for instructions to make tool.)

TX,0350,ME291 –19–26MAR99–6/20

T112159

–UN–20NOV97

03 0350 50

Clutch Packs K4 1—Plate Carrier 2—Piston






NOTE: For proper adjustment of plate clearance later install disk and plates temporarily without being oiled.


TM1640 (15JAN04)

03-0350-50

TX,0350,ME291 –19–26MAR99–7/20


PN=170


T108984

–UN–14APR97

10. Install plate and then disk alternately until five plates and five disks are installed in carrier.

TX,0350,ME291 –19–26MAR99–8/20


T108985

–UN–09MAY97

03 0350 51

TX,0350,ME291 –19–26MAR99–9/20

–UN–14APR97

NOTE: For the adjustment of the plate clearance there are snap rings of different thickness available through parts system that can be used if proper clearance is unable to be obtained. To ensure proper measuring result, install plates temporarily without oil. 12. Adjust plate clearance to specification.

T108986

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



TM1640 (15JAN04)

03-0350-51

TX,0350,ME291 –19–26MAR99–10/20


PN=171


7.20 mm (0.283 in.)

Dimension No. 2

6.00 mm (0.236 in.)


1.2 mm (0.047 in.)


1.2—1.4 mm (0.047—0.055 in.)

T108987

Dimension No. 1

–UN–14APR97


If a clutch pack clearance is not in specification, correct by using the proper corresponding snap ring from service parts to increase or decrease clearance. Snap rings come in various sizes. After proper clearance is obtained remove disk and plates from assembly. 13. Add oil to plates and disks. 14. Reassemble clutch pack assembly.

TX,0350,ME291 –19–26MAR99–11/20

15. Install idler gear until inner plates are meshed with splines.

–UN–14APR97

NOTE: This will make it easier for installing idler gear later.

T108988

16. Remove idler gear.

TX,0350,ME291 –19–26MAR99–12/20

–UN–14APR97

17. Install thrust washers and thrust bearing.

T108989

03 0350 52


TM1640 (15JAN04)

03-0350-52

TX,0350,ME291 –19–26MAR99–13/20


PN=172


T108990

–UN–14APR97

18. Install two needle bearings.

TX,0350,ME291 –19–26MAR99–14/20

19. Assemble idler gear.

T108991

–UN–14APR97

03 0350 53

TX,0350,ME291 –19–26MAR99–15/20

20. Install thrust washer (3), thrust bearing (2), and thrust disk (1).

–UN–29APR97

NOTE: Install thrust disk (1) with the chamfer facing the thrust washer.

T108992

1—Thrust Disc 2—Thrust Bearing 3—Thrust Washer

TX,0350,ME291 –19–26MAR99–16/20

T108993

–UN–14APR97

21. Assemble K4 carrier assembly onto shaft until seated and all plates are engaged.


TM1640 (15JAN04)

03-0350-53

TX,0350,ME291 –19–26MAR99–17/20


PN=173


T108994

–UN–14APR97

22. Install snap ring to retain plate.

TX,0350,ME291 –19–26MAR99–18/20


T108995

–UN–14APR97

Install opposite tapered roller bearing.

TX,0350,ME291 –19–26MAR99–19/20

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

T108996

–UN–14APR97

NOTE: When you have correctly installed components, the clutch packs will move freely in carrier, as you will be able to hear them moving while inducing compressed air.

TX,0350,ME291 –19–26MAR99–20/20

Disassemble Input Shaft

–UN–18APR97

NOTE: The turbine shaft is axially fixed by means of a snap ring which will be destroyed when pressing out. If necessary, press turbine shaft out of the input shaft.

T108772

03 0350 54


TM1640 (15JAN04)

03-0350-54

TX,0350,ME287 –19–05OCT98–1/2


PN=174

Gears, Shafts, Bearings and Power Shift Clutch Remove rectangular ring out. Pull off the tapered roller bearing using JDG1034 and JDG1035 Bearing Puller Mandrel. –UN–18APR97

Pull off the opposite tapered roller bearing.

T108773

NOTE: The separation of input shaft and gear is not possible (press fit).

TX,0350,ME287 –19–05OCT98–2/2

Assemble Input Shaft 03 0350 55

Cool the input shaft to specification. Heat gear to specification and assemble to shaft until seated.

T108997

–UN–14APR97

Input Shaft—Specification Input Shaft—Temperature .................................... Cools at -80°C (-112°F) Input Gear—Temperature .................................. Heats at +120°C (250°F)

TX,0350,ME292 –19–12FEB99–1/8

T108998

–UN–14APR97

Install snap ring to retain gear.

TX,0350,ME292 –19–12FEB99–2/8

T108999

–UN–14APR97

Install snap ring into the recess of the turbine shaft.


TM1640 (15JAN04)

03-0350-55

TX,0350,ME292 –19–12FEB99–3/8


PN=175


T109000

–UN–14APR97

Install turbine shaft until the snap ring snaps into the groove of the input shaft to retain turbine shaft.

TX,0350,ME292 –19–12FEB99–4/8

Press both bearing inner races against shoulder.

T109001

–UN–09MAY97

03 0350 56

TX,0350,ME292 –19–12FEB99–5/8

Install ball bearing

T109002

–UN–29APR97

Install sealing ring.

TX,0350,ME292 –19–12FEB99–6/8

T109003

–UN–09MAY97

Install output shaft into the housing bore until seated.


TM1640 (15JAN04)

03-0350-56

TX,0350,ME292 –19–12FEB99–7/8


PN=176

Gears, Shafts, Bearings and Power Shift Clutch NOTE: If bearings are reused, they must be assembled in same bores.

T108657

–UN–10APR97

Insert all bearing outer races into transmission housing bores.

TX,0350,ME292 –19–12FEB99–8/8

03 0350 57

TM1640 (15JAN04)

03-0350-57


PN=177


03 0350 58

TM1640 (15JAN04)

03-0350-58


PN=178

Group 0360


Measurement

Specification

Torque

46 N•m (34 lb-ft)

Torque

25 N•m (18 lb-ft)

Manifold Plate-to-Transmission Housing Socket Head Screw

Torque

25 N•m (18 lb-ft)

Control Valve-to-Manifold Plate Socket Head Screw

Torque

9.5 N•m (85 lb-in)

Housing-to-Control Valve (M5/10.9) Screw

Torque

5 N•m (44 lb-in.)

Solenoid Valve (M5/8.8) Screw

Torque

5 N•m (44 lb-in.)

Solenoid Cover-to-Housing (M5/10.9) Torque Screw

5 N•m (44 lb-in.)

Housing-to-Control Valve Block Screw (M5/10.9)

Torque

5 N•m (44 lb-in.)

Solenoid Valve-to-Retaining Plate Screw

Torque

5 N•m (44 lb-in.)

Alignment Stud-to-Cover Screw

Torque

5 N•m (44 lb-in.)

Diagnostic Plug-to-Port (M10/1) Screw

Torque

6 N•m (55 lb-in.)

Manifold Plate-to-Valve Body (M6/10.9) Screw

Torque

9.5 N•m (85 lb-in.)

Torque

25 N•m (18 lb-ft)

Transmission Pump Socket Head Screw

Transmission Pump Pump Cap Screw

03 0360 1

Converter Relief Valve Manifold Socket Head Screw

TX04577,0000420 –19–23JAN01–1/1

TM1640 (15JAN04)

03-0360-1


PN=179

Hydraulic System

Remove Transmission Pump

T108730

–UN–17APR97

1. Loosen socket head screws.

TX,0360,ME278 –19–20OCT98–1/5

–UN–17APR97 T108731

03 0360 2

2. Placing a puller on the splines runout of the stator shaft, pull pump assembly out of the housing bore.


TM1640 (15JAN04)

03-0360-2

TX,0360,ME278 –19–20OCT98–2/5


PN=180

Hydraulic System

TP55490

–UN–15APR97

03 0360 3

Oil Pump Assembly 1—O-Ring 2—Snap Ring 3—Seal

4—Shim 5—Needle Bearing

6—Ring 7—Pump Assembly

8—O-Ring (10 used) 9—Cap Screw (10 used)

TX,0360,ME278 –19–20OCT98–3/5

3. Separate transmission pump from stator. 4. Separate cam plate from pump. Make note of drive gear spline location and two small dowel pins. –UN–17APR97

IMPORTANT: If traces of wear should be encountered in the pump housing or the cam disk, the complete pump has to be replaced.

T108732

5. Inspect and replace parts as required 6. Install cam disk and retain it by means of grooved pins (2x).


TM1640 (15JAN04)

03-0360-3

TX,0360,ME278 –19–20OCT98–4/5


PN=181

Hydraulic System 7. Loosen hex head screws and remove oil feed housing.

T108725

–UN–17APR97

8. Remove flat gasket.

TX,0360,ME278 –19–20OCT98–5/5

T112686

–UN–05JAN98

1. Remove converter minimum pressure regulator valve out of the housing bore.

TX,0350,ME279 –19–26MAR99–1/2

2. Inspect and replace parts as required.

NOTE: Install pressure plate facing toward lock plate as shown in photo. –UN–05JAN98

3. Install converter minimum pressure regulator valve into housing bore. 1—Piston 2—Compression Spring 3—Pressure Plate 4—Lock Plate

T112685

03 0360 4

Remove and Install Converter Minimum Pressure Regulator Valve

Minimum Pressure Regulator Valve

TX,0350,ME279 –19–26MAR99–2/2

TM1640 (15JAN04)

03-0360-4


PN=182

Hydraulic System

Install Transmission Pump

T112687

–UN–05JAN98

1. Install alignment studs and install flat gasket.

TX,07,ME297 –19–26MAR99–1/8

IMPORTANT: Screw hex head screws until contact is obtained. DO NOT TIGHTEN.

03 0360 5

2. Install oil feed housing, washers and hex head screws.

T109086

–UN–15APR97

Leave loose at this time. This allows for oil pump alignment later in assembly.

TX,07,ME297 –19–26MAR99–2/8

NOTE: Pay attention to the overlapping of the bores.

T109087

–UN–15APR97

3. Install alignment studs and stator shaft until it is bottomed in housing.

TX,07,ME297 –19–26MAR99–3/8

T109088

–UN–29APR97

4. Lubricate and install O-ring.


TM1640 (15JAN04)

03-0360-5

TX,07,ME297 –19–26MAR99–4/8


PN=183

Hydraulic System

T109089

–UN–15APR97

5. Install transmission pump.

TX,07,ME297 –19–26MAR99–5/8

NOTE: Grease O-rings.

T109090

–UN–29APR97

6. Install socket head screws with new O-rings.

TX,07,ME297 –19–26MAR99–6/8

7. Install transmission pump and socket head screws.

T109091

–UN–15APR97

Transmission Pump—Specification Socket Head Screw—Torque .......................................... 46 N•m (34 lb-ft)

TX,07,ME297 –19–26MAR99–7/8

NOTE: Note locations of hanger strap from original location.

Transmission Pump—Specification Pump Cap Screw—Torque ............................................. 25 N•m (18 lb-ft)

–UN–15APR97

8. Tighten cap screws.

T109092

03 0360 6

TX,07,ME297 –19–26MAR99–8/8

TM1640 (15JAN04)

03-0360-6


PN=184

Hydraulic System

Remove Transmission Hydraulic Control Valve

T108709

–UN–17APR97

1. Loosen socket head screws, install two alignment studs and separate control valve from manifold plate.

TX,0350,ME276 –19–15DEC98–1/3

2. Remove both gaskets (9 ,11) and center plate (10).

T108710

–UN–17APR97

03 0360 7

TX,0350,ME276 –19–15DEC98–2/3

3. Loosen socket head screws and hex nuts. 4. Separate manifold plate from transmission housing.

T108714

–UN–17APR97

5. Remove gasket.

TX,0350,ME276 –19–15DEC98–3/3

TM1640 (15JAN04)

03-0360-7


PN=185

Hydraulic System

Install Transmission Hydraulic Control Valve

TP60304

–UN–08APR98

03 0360 8

1—Stud (14 used) 2—Gasket 3—Manifold Plate 4—Washer (16 used)

5—Nut (16 used) 6—O-Ring 7—Plug

8—Cap Screw (39 used) 9—Gasket 10—Plate (Center)


TM1640 (15JAN04)

03-0360-8

11—Gasket 12—Cap Screw (23 used) 13—Cap Screw (2 used)

TX,0360,ME282 –19–15DEC98–1/4


PN=186

Hydraulic System

T109106

Specification Manifold Plate-to-Transmission Housing Socket Head Screw— Torque ............................................................................. 25 N•m (18 lb-ft)

–UN–15APR97

1. Install gasket, manifold plate, and fasten it with socket head screws hex nuts and washers. Tighten socket head screws.

T109107

–UN–15APR97

03 0360 9

TX,0360,ME282 –19–15DEC98–2/4

T109109

–UN–15APR97

2. Install two alignment studs. Install gasket (9), plate (10) and gasket (11).

TX,0360,ME282 –19–15DEC98–3/4

3. Install complete control valve unit on the manifold plate with socket head screws.

Specification Control Valve-to-Manifold Plate Socket Head Screw—Torque ......................................... 9.5 N•m (85 lb-in)

T109110

4. Tighten screw.

–UN–15APR97

IMPORTANT: Pay attention to the installation and position of the different gaskets.

TX,0360,ME282 –19–15DEC98–4/4

TM1640 (15JAN04)

03-0360-9


PN=187

Hydraulic System

Transmission Hydraulic Control Valve Cross Section View

T122180

–19–07JUL99

03 0360 10

A—Pressure Regulating Valve—Piston B—Pressure Reducing Valve— Piston

C—Connector—Wiring Harness D—Cover (2 used)

E—Valve Block—Control Valve F—Housing (2 used) G—Modulation Circuit

H—Solenoid Valve— Proportional (6 used) I—Transmission Control Valve

TX,0360,ME273 –19–11JAN01–1/1

TM1640 (15JAN04)

03-0360-10


PN=188

Hydraulic System

03 0360 11

TM1640 (15JAN04)

03-0360-11


PN=189

Hydraulic System

Disassemble Transmission Control Valve

T137510

–UN–20JAN01

03 0360 12


TM1640 (15JAN04)

03-0360-12

TX,0360,ME274 –19–26MAR99–1/7


PN=190

Hydraulic System 1—Cap Screw (32 used) 2—Clamp (Clip) 3—Cover 4—Wiring Harness 5—Gasket 6—Solenoid Valve— Proportional (3 used) 7—Cap Screw (3 used) 8—Plate (3 used) 9—Housing 10—Gasket

11—Piston (Dampening Valve) (6 used) 12— Spring (6 used) 13—Spring 14—Piston—System Pressure Reducing Valve 15—Valve Block (Control) 16—O-Ring (8 used) 17—Drain Plug (8 used) 18— Spring 19— Piston (System Pressure Regulating Valve)

20—Gasket 21—Housing 22—Plate (3 used) 23—Cap Screw (3 used) 24—Gasket 25—Cover 26—Cap Screw (14 used) 27—Solenoid Valve— Proportional (3 used) 28—Cap Screw (18 used) 29—Piston (Pressure Control valve) (6 used)

30—Spring (6 used) 31—Orifice (6 used) 32—Gasket 33—Plate (Center) 34—Gasket 35—Manifold Plate 36—Cap Screw (18 used) 37—Screen (Transmission S.N. 000588— )(6 used)

TX,0360,ME274 –19–26MAR99–2/7

1. Remove screws (26) and cover (25) and gasket (24). 03 0360 13

2. Disconnect connectors to solenoid valves (27).

T108686

–UN–16APR97

3. Remove screws (23) and retaining plates (22), and remove three solenoid valves (27).

T108687

–UN–16APR97

Hydraulic Control Valve


TM1640 (15JAN04)

03-0360-13

TX,0360,ME274 –19–26MAR99–3/7


PN=191

Hydraulic System 4. Loosen screw to housing (21), remove housing and gasket (20).

–UN–12JAN01

5. Remove three pressure control valve pistons (29) and compression springs (30). 6. Remove three damping valves pistons (11) and compression springs (12).

T135928

7. Remove system pressure valve piston (19) compression spring (18). Remove Housing And Valves

03 0360 14 TX,0360,ME274 –19–26MAR99–4/7

T108689

–UN–16APR97

8. Remove clamp (clip) (2) from wire harness connector.

Clamp Removal from Harness Connector

TX,0360,ME274 –19–26MAR99–5/7

9. Remove screws and cover (3) and gasket (5). 10. Disconnect connectors to solenoid valves (6).

T108682

–UN–16APR97

11. Remove screws (7) and retaining plates (8). Pull solenoid valves (6).


TM1640 (15JAN04)

03-0360-14

TX,0360,ME274 –19–26MAR99–6/7


PN=192

Hydraulic System 12. Loosen screw to housing (9), remove housing and gasket (10).

–UN–16APR97

13. Remove three pressure control valve pistons (29) and compression springs (30). 14. Remove three damping valves pistons (11) and compression springs (12).

T108683

15. Remove pressure reducing valve piston (14) compression spring (13). 16. Inspect and replace parts as necessary.

03 0360 15 TX,0360,ME274 –19–26MAR99–7/7

Assemble Transmission Control Valve 1. Check all components for damage and replace if necessary. –UN–09MAY97

2. Prior to the installation, check free travel of moving parts in the housing.

T108684

3. Oil components prior to the reassembly. 4. Insert orifices (31) (if removed) until contact is obtained (6 pieces, see arrows). 5. Install screens (37) if removed (Transmission S.N. 000588— )

TX,0360,ME275 –19–26MAR99–1/21

6. Install three pressure control valve pistons (29) and compression springs (30).

–UN–16APR97

7. Install three damping valve pistons (11) and compression springs (12).

T108683

8. Install system Pressure reducing valve piston (14) compression spring (13).


TM1640 (15JAN04)

03-0360-15

TX,0360,ME275 –19–26MAR99–2/21


PN=193

Hydraulic System 9. Screw two alignment studs in valve housing. Install gasket, assemble flat gasket (10).

T108694

–UN–16APR97

NOTE: To aid assembly of solenoid housing, push spools into bore and retain by using a 5mm pin or screw.

TX,0360,ME275 –19–26MAR99–3/21

–UN–16APR97 T108695

TX,0360,ME275 –19–26MAR99–4/21

11. Fasten housing (9) with screws (1) and tighten evenly. Remove assembly aid pins or screws. Tighten (M5/10.9) screw.

T108696

–UN–16APR97

Specification Housing-to-Control Valve (M5/10.9) Screw—Torque ................................................ 5 N•m (44 lb-in.)

TX,0360,ME275 –19–26MAR99–5/21

12. Insert three solenoid valves (6) into housing (9), equipped with O-ring, and fasten by means of retaining plate (8) and screws (7).

–UN–16APR97

NOTE: Install retaining plate with the claw facing the housing bottom.

T108697

03 0360 16

10. Install housing (9) while routing wire harness (4) into position.


TM1640 (15JAN04)

03-0360-16

TX,0360,ME275 –19–26MAR99–6/21


PN=194

Hydraulic System 13. Install housing with solenoid valves onto control valve (15) and fasten with screws. Tighten (M5/8.8) screw.

T108698

–UN–16APR97

Specification Solenoid Valve (M5/8.8) Screw— Torque .............................................................................. 5 N•m (44 lb-in.)

TX,0360,ME275 –19–26MAR99–7/21

14. Install wire harness connectors to solenoid valves.

T108691

–UN–16APR97

03 0360 17

TX,0360,ME275 –19–26MAR99–8/21

15. Screw two alignment studs in, and assemble flat gasket (5) and cover (3). 16. Tighten screws (M5/10.9) 5 N•m (44 lb-in.)

T108692

–UN–16APR97

Specification Solenoid Cover-to-Housing (M5/10.9) Screw—Torque ................................................ 5 N•m (44 lb-in.)

TX,0360,ME275 –19–26MAR99–9/21

17. Install Wire harness connector (4) with clamp-clip (2) to cover (3).

T108693

–UN–16APR97

NOTE: Make sure clamp snaps in.


TM1640 (15JAN04)

03-0360-17

TX,0360,ME275 –19–26MAR99–10/21


PN=195

Hydraulic System 18. Install three pressure control valve pistons (29) and springs 30).

–UN–12JAN01

19. Install three damping valve pistons(11) and compression springs (12).

T135928

20. Install system pressure regulating valve (19), and spring (18).

TX,0360,ME275 –19–26MAR99–11/21

–UN–16APR97 T108703

TX,0360,ME275 –19–26MAR99–12/21

–UN–16APR97

22. Screw two alignment studs in, assemble gasket (20) and housing (21).

T108704

03 0360 18

21. Push spools of the pressure control valves (29) into position. A straight pin (5 mm) may be used as an assembly aid.


TM1640 (15JAN04)

03-0360-18

TX,0360,ME275 –19–26MAR99–13/21


PN=196

Hydraulic System 23. Install housing and tighten evenly. 24. Tighten (M5/10.9) screw.

T108705

–UN–16APR97

Specification Housing-to-Control Valve Block Screw (M5/10.9)—Torque ................................................ 5 N•m (44 lb-in.)

03 0360 19 TX,0360,ME275 –19–26MAR99–14/21

25. Insert three solenoid valves (6), equipped with O-ring, and fasten by means of retaining plate (22) and screw (23).

–UN–16APR97

NOTE: Install retaining plate with the claw facing the housing bottom. 26. Tighten (M5/8.8) screw.

T108698

Specification Solenoid Valve-to-Retaining Plate Screw—Torque ................................................................. 5 N•m (44 lb-in.)

TX,0360,ME275 –19–26MAR99–15/21

27. Fasten harness connectors to solenoid valves.

–UN–30APR97

28. Screw two alignment studs in housing and assemble flat gasket (24) and cover (25). Tighten (M5/10.9) screw (26).

T108699

Specification Alignment Stud-to-Cover Screw— Torque .............................................................................. 5 N•m (44 lb-in.)


TM1640 (15JAN04)

03-0360-19

TX,0360,ME275 –19–26MAR99–16/21


PN=197

Hydraulic System 29. Install diagnostic plugs with O-rings, in ports, if removed during disassembly. 30. Tighten (M10/1) screw.

T108700

–UN–16APR97

Specification Diagnostic Plug-to-Port (M10/1) Screw—Torque ................................................................. 6 N•m (55 lb-in.)

TX,0360,ME275 –19–26MAR99–17/21

–UN–16APR97 T108701

TX,0360,ME275 –19–26MAR99–18/21

–UN–16APR97

32. Assemble intermediate plate (33).

T108706

03 0360 20

31. Screw two (2) alignment studs in and assemble (first) flat gasket (32).

Intermediate Plate Assembly


TM1640 (15JAN04)

03-0360-20

TX,0360,ME275 –19–26MAR99–19/21


PN=198

Hydraulic System

T108707

–UN–09MAY97

33. Assemble second gaske (34).

TX,0360,ME275 –19–26MAR99–20/21

34. Assemble manifold plate (35) to valve body with screws (36) and (remove alignment screws).

03 0360 21

–UN–17APR97

NOTE: Tightening order of the screw start with inboard screws at first and continuing toward the outside. 35. Tighten (M6/10.9) screw.

T108708

Specification Manifold Plate-to-Valve Body (M6/10.9) Screw—Torque ............................................. 9.5 N•m (85 lb-in.)

TX,0360,ME275 –19–26MAR99–21/21

Remove, Disassemble and Install Converter Relief Valve

T108715

–UN–17APR97

1. Pull converter relief valve out of the housing bore.


TM1640 (15JAN04)

03-0360-21

TX,0360,ME277 –19–26MAR99–1/4


PN=199

Hydraulic System 2. Remove preload compression spring carefully, remove cylindrical pin as required to inspect and replace parts as needed.

T109103

–UN–30APR97

1—Plate 2—Ball 3—Compression Spring 4—Valve Insert 5—Valve Sleeve 6—Roll Pin

Converter Relief Valve

03 0360 22 TX,0360,ME277 –19–26MAR99–2/4

T109105

–UN–15APR97

3. Insert converter relief valve into the housing bore until it bottoms.


TM1640 (15JAN04)

03-0360-22

TX,0360,ME277 –19–26MAR99–3/4


PN=200

Hydraulic System 4. Install gasket and manifold. Fasten it with socket head screws hex nuts and washers. Tighten socket head screws.

T109106

–UN–15APR97

Converter Relief Valve—Specification Manifold Socket Head Screw— Torque ............................................................................. 25 N•m (18 lb-ft)

T109107

–UN–15APR97

03 0360 23

TX,0360,ME277 –19–26MAR99–4/4

Replace Oil Pipes and Tubes NOTE: The installation of all lubrication pipes, tubes and lines require special tools. Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). It is very important to have these tools if repair or replacement is necessary. If repair is needed contact DTAC (Dealer Technical Assistance Center) for assistance.

T108652

–UN–09MAY97

1—Suction Tube 2—Pressure Pipe (2 used) 3—Pressure Lubrication Pipe (Transmission S.N. — 3320)


TM1640 (15JAN04)


03-0360-23

TX,0360,ME293 –19–26MAR99–1/3


PN=201

T108658

–UN–09MAY97

Hydraulic System

Cover Showing Two Oil Pipes

03 0360 24 Continued on next page

TM1640 (15JAN04)

03-0360-24

TX,0360,ME293 –19–26MAR99–2/3


PN=202

Hydraulic System

TP60303

–UN–08APR98

03 0360 25

1—Pipe (Transmission S.N. — 3320) 2—Tube

3—Cap Screw 4—Cap Screw 5—O-Ring (4 used)

6—Pipe (2 used) 7—Pipe 8—Pipe

9—Pipe 10—Pipe 11—Cap Screw

TX,0360,ME293 –19–26MAR99–3/3

TM1640 (15JAN04)

03-0360-25


PN=203

Hydraulic System

03 0360 26

TM1640 (15JAN04)

03-0360-26


PN=204

Group 0399

Dealer Fabricated Tools DFT1148 Pre-Load Clutch Pack Compression Ring Tool

T109190

–UN–08MAY97

03 0399 1

The Clutch Pack Compression Ring Tool is used to compress the piston compression ring so snap ring can be removed.

Material is standard pipe (see dimensions above) with window cut out to allow for access when removing snap ring. TX,0399,ME295 –19–08MAY97–1/1

TM1640 (15JAN04)

03-0399-1


PN=205

Dealer Fabricated Tools

DFT1149 Pre-Load Clutch Pack Compression Ring Tool

T109434

–UN–07MAY97

03 0399 2

The Clutch Pack Compression Ring Tool is used to compress the piston compression ring so snap ring can be removed.

Material is standard pipe (see dimensions above) with window cut out to allow for access when removing snap ring. TX,0399,ME296 –19–08MAY97–1/1

TM1640 (15JAN04)

03-0399-2


PN=206

Section 04

Engine Contents Page

Group 0400—Removal and Installation PowerTech 4.5 L (4045) and 6.8 L (6068) John Deere Engines—Use CTM104 . . . . .04-0400-1 Service Equipment and Tools . . . . . . . . . . . .04-0400-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .04-0400-2 Engine Remove and Install . . . . . . . . . . . . . . . . . .04-0400-3

04

TM1640 (15JAN04)

04-1


PN=1

Contents

04

TM1640 (15JAN04)

04-2


PN=2

Group 0400

Removal and Installation PowerTech 4.5 L (4045) and 6.8 L (6068) John Deere Engines—Use CTM104

M44215

Use the CTM in conjunction with this machine manual.

–UN–07SEP88

For additional engine information, the component technical manual (CTM) is also required.


TX,9010,SS3681 –19–05AUG96–1/1

Service Equipment and Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier. 04 0400 1


CED,OUOE003,3319 –19–26MAR99–1/3

Lifting Sling . . . . . . . . . . . . . . . . . . . . . . . . . . JDG23 Used with load positioning sling to remove and install engine. CED,OUOE003,3319 –19–26MAR99–2/3

Load Positioning Sling . . . . . . . . . . . . . . . . D01043AA Used with lifting sling to remove and install engine.

CED,OUOE003,3319 –19–26MAR99–3/3

TM1640 (15JAN04)

04-0400-1


PN=209


Specifications Item

Measurement

Specification

Engine

Weight


Engine Mounting Cap Screw

Torque

434 ± 87 N•m (320 ± 64 lb-ft) fan end of engine 215 ± 43 N•m (160 ± 32 lb-ft) flywheel end of engine

Torque

Engine-to-Transmission Drive Shaft U-Joint Cap Screw

Torque

78 N•m (58 lb-ft)

CED,OUOE003,3320 –19–26MAR99–1/1

04 0400 2

TM1640 (15JAN04)

04-0400-2


PN=210


Remove and Install Engine 1. Stop engine. Lower boom and bucket to ground.

–UN–23AUG88

2. Remove battery negative ground strap or turn battery disconnect switch “Off” if equipped.

TS281

CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. 3. Attach hose to radiator drain cock. Drain engine coolant. 4. Remove hood with air cleaner and turbocharger inlet hose. (See Group 1910 for hood removal.) (See Group 0520 for air cleaner removal.)

04 0400 3

5. Remove muffler with muffler mounting brackets. (See Group 0530.)


TM1640 (15JAN04)

04-0400-3

TX,04,JC2341 –19–16FEB99–1/7


PN=211

–UN–14NOV97


T112236B

04 0400 4

A—Heater Hoses

B—Fuel Suction Hose

C—Radiator Hoses

6. Close shut-off valve at heater supply hose. 7. Disconnect heater hoses (A), fuel suction hose (B), and top and bottom radiator hoses (C). Disconnect fluid starting aid line, if equipped.


TM1640 (15JAN04)

04-0400-4

TX,04,JC2341 –19–16FEB99–2/7


PN=212

–UN–20NOV97


T112237B

04 0400 5

D—Compressor Cap Screw (3 used)

E—Ball Joint F—Throttle Cable

G—U-Bolt H—Starter

I—Air-to-Air Cooler Hoses J—Fuel Return Line

8. Disconnect throttle cable (F) from ball joint (E). Remove U-bolt (G) from throttle cable bracket. Remove bracket.

12. Remove air conditioning compressor cap screws (D) (if equipped). Move compressor out of the way.

9. Disconnect fuel return line (J).

13. Disconnect engine harness-to-load center harness connector from bottom right-hand side of cab or ROPS.

10. Disconnect air to air cooler hoses (I) from turbocharger and intake manifold. Remove air cooler tube clamp from engine block. 11. Remove battery cables and E01 White wires from starter (H).


TM1640 (15JAN04)

04-0400-5

TX,04,JC2341 –19–16FEB99–3/7


PN=213

Removal and Installation 14. Remove four cap screws from the engine-to-transmission drive shaft U-joints (A) (at the torque converter side).

–UN–21MAR97

15. Install JDG23 Lifting Sling and D01043AA Load Positioning Sling to engine.

T108384B

16. Remove the four front and rear engine mounting cap screws. 17. Remove the R.H. front and rear engine mounts from engine. A—U-Joint (4 used)

CAUTION: Engine weighs approximately 567 kg (1250 lb). Specification Engine—Weight ........................................... 567 kg (1250 lb) approximate

18. Remove engine. 04 0400 6


TM1640 (15JAN04)

04-0400-6

TX,04,JC2341 –19–16FEB99–4/7


PN=214


T108394

–UN–11DEC98

04 0400 7

A—Cap Screw (2 used) B—Washer (2 used) C—Support D—Cap Screw (2 used)

E—Washer (2 used) F—Support G—Cap Screw (4 used) H—Washer (4 used)

I—Support J—Washer (4 used) K—Nut (4 used) L—Isolator Assembly (2 used)

M—Isolator Assembly (2 used) N—Cap Screw (6 used) O—Support

19. Inspect engine mounting parts. Replace as needed.


TM1640 (15JAN04)

04-0400-7

TX,04,JC2341 –19–16FEB99–5/7


PN=215

Removal and Installation 20. Install two front and two rear mounting cap screws. Tighten screws (A).

T109274C

–UN–28APR97

Specification Engine Mounting Cap Screw— Torque ......................................................... 434 ± 87 N•m (320 ± 64 lb-ft) fan end of engine Torque ......................................................... 215 ± 43 N•m (160 ± 32 lb-ft) flywheel end of engine

A—Mounting Cap Screw (4 used)


TX,04,JC2341 –19–16FEB99–6/7

04 0400 8

TM1640 (15JAN04)

04-0400-8


PN=216

Removal and Installation 21. Install four NEW engine-to-transmission drive shaft U-joint cap screws (A) and two clamps. Tighten to specification.

–UN–21MAR97

Specification Engine-to-Transmission Drive Shaft U-Joint Cap Screw—Torque .................................. 78 N•m (58 lb-ft)

T108384B

22. Connect engine harness-to-load center harness connector. 23. Connect positive battery cables and E01 white wires to starter. Connect ground wires to starter. A—U-Joint Cap Screw (4 Used)

24. Connect fuel return line. 25. Connect air to air cooler hoses. 26. Install throttle cable bracket. Connect throttle cable. 27. Connect fluid start aid line (if equipped). Connect top and bottom radiator hoses. Connect fuel suction hose and heater hoses.

04 0400 9

28. Install muffler with muffler brackets. (See Group 0530.) 29. Install hood with air cleaner and turbocharger inlet hose. (See Group 1910 and Group 0520.) 30. Fill radiator with coolant. 31. Connect battery negative ground strap or turn battery disconnect switch “On” if equipped. 32. Check engine rpm. Adjust cable if necessary. See Slow and Fast Idle Adjustment, Group 0515. Also see Speed Control Linkage Adjustment, Group 0515.

TX,04,JC2341 –19–16FEB99–7/7

TM1640 (15JAN04)

04-0400-9


PN=217


04 0400 10

TM1640 (15JAN04)

04-0400-10


PN=218

Section 05

Engine Auxiliary Systems Contents Page

Page

Group 0505—Cold Weather Starting Aids Other Material . . . . . . . . . . . . . . . . . . . . . . . .05-0505-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0505-1 Fluid Starting Aid Assembly Remove and Install . . . . . . . . . . . . . . . . . .05-0505-1 Engine Coolant Heater Remove and Install . . . . . . . . . . . . . . . . . .05-0505-4

Air Intake System Leakage Test. . . . . . . . . . . . . . . . . . . . . . .05-0520-7

Group 0510—Cooling System Other Material . . . . . . . . . . . . . . . . . . . . . . . .05-0510-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0510-2 Serpentine Belt Remove and Install . . . . . . . . . . . . . . . . . .05-0510-3 Fan and Fan Drive Remove and Install . . . . . . . . . . . . . . . . . .05-0510-5 Radiator and Oil Cooler Remove and Install . . . . . . . . . . . . . . . . .05-0510-10 Radiator, Oil Cooler and Air-to-Air Aftercooler Disassemble and Assemble. . . . . . . . . . .05-0510-17

Group 0560—External Fuel Supply Systems Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0560-1 Fuel Tank Remove and Install . . . . . . . . . . . . . . . . . .05-0560-2 Primary Fuel Filter (Water Separator) Drain and Clean. . . . . . . . . . . . . . . . . . . . .05-0560-5 Remove and Install . . . . . . . . . . . . . . . . . .05-0560-6 Final Fuel Filter Remove and Install . . . . . . . . . . . . . . . . . .05-0560-9 Fuel System Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0560-10

Group 0530—External Exhaust System Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0530-1 Muffler Remove and Install . . . . . . . . . . . . . . . . . .05-0530-2

Group 0515—Speed Controls Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0515-1 Speed Control Linkage Remove and Install . . . . . . . . . . . . . . . . . .05-0515-1 Fuel Shut-Off Solenoid Remove and Install . . . . . . . . . . . . . . . . . .05-0515-2 Fast and Slow Idle Check and Adjust . . . . . . . . . . . . . . . . . . .05-0515-2 Speed Control Linkage Adjustment . . . . . . . .05-0515-5 Fuel Shut-Off Solenoid Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0515-6 Group 0520—Intake System Essential Tools . . . . . . . . . . . . . . . . . . . . . . .05-0520-1 Service Equipment and Tools . . . . . . . . . . . .05-0520-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0520-1 Air Cleaner Remove and Install . . . . . . . . . . . . . . . . . .05-0520-2 Air Filter Elements Remove and Install . . . . . . . . . . . . . . . . . .05-0520-3 Primary Element Clean Dusty . . . . . . . . . . . . . . . . . . . . . . . .05-0520-5 Clean Oily or Sooty . . . . . . . . . . . . . . . . . .05-0520-5 Element Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0520-6 TM1640 (15JAN04)

05-1


PN=1

05

Contents

05

TM1640 (15JAN04)

05-2


PN=2

Group 0505

Cold Weather Starting Aids Other Material Number

Name

Use



Apply to threads of fluid starting aid nozzle holder.

TY16004 (U.S.)

John Deere Coolant Conditioner

Add to cooling system.


CED,OUOE003,3322 –19–26MAR99–1/1

Specifications Item

Measurement

Specification

Heating Element Nut

Torque

34 N•m (25 lb-ft)

CED,OUOE024,404 –19–19FEB99–1/1

Remove and Install Fluid Starting Aid Assembly

T108966

–19–17APR97

1. Disconnect start aid solenoid connector that is located on sump tank harness.


TM1640 (15JAN04)

05-0505-1

TX,0505,111474 –19–20OCT98–1/4


PN=221

05 0505 1

Cold Weather Starting Aids 2. Open left engine access door. Remove starting aid components (A—E).

T106395D

–UN–16APR97

A—Starting Aid Canister B—Clamp C—Starting Aid Solenoid D—Line E—Nozzle

TX,0505,111474 –19–20OCT98–2/4

3. Remove nozzle (C) from holder (B). 4. Clean or replace nozzle as required.

–UN–08OCT97

IMPORTANT: Nozzle must be secure in holder to prevent engine damage from dust. Do not overtighten or nozzle may break. 5. Carefully tighten nozzle in nozzle holder.

T104622

05 0505 2

6. Apply thread lock and sealer (high strength) to threads of nozzle holder. A—Adapter Elbow B—Nozzle Holder C—Nozzle

7. Install nozzle holder so nozzle is toward center of air inlet so fluid is sprayed into incoming air flow. Arrow on hex flat indicates direction of nozzle.


TM1640 (15JAN04)

05-0505-2

TX,0505,111474 –19–20OCT98–3/4


PN=222

Cold Weather Starting Aids

T106395B

8. Install starting aid components. Remove safety cap from new canister (C). Turn canister clockwise in starting aid base to install.

–UN–24JAN97

IMPORTANT: When operating machine without starting aid container installed, protect components from possible damage. Install starting aid plug (D) in starting aid base.

9. Tighten clamp (B). B—Clamp C—Start Aid Canister D—Start Aid Plug

TX,0505,111474 –19–20OCT98–4/4

05 0505 3

TM1640 (15JAN04)

05-0505-3


PN=223


Remove and Install Engine Coolant Heater CAUTION: Coolant may be hot. Wait until radiator is cool to the touch before draining. –UN–01NOV88

1. Drain cooling system

T6642EK

2. Remove power cord (A). Loosen nut (C) and pull heating element (G) from block. CAUTION: DO NOT plug coolant heater into electrical power unless heating element is immersed in coolant. Sheath could burst and result in personal injury.

–UN–21OCT88

Use a heavy-duty grounded cord to connect coolant heater to electrical power. 3. Disassemble parts (B—G).

T6427AO

4. Replace parts as necessary. 5. Assemble parts (B—G). Put heating element in cylinder block so flats on threaded portion of element are vertical. 05 0505 4

A—Power Cord B—Cap C—Nut D—Adapter E—Gasket F—O-Ring G—Heating Element

6. Turn element clockwise and then counterclockwise until element contacts casting. Move element to the center position. 7. Hold element using a wrench. Tighten nut. Specification Heating Element Nut—Torque ........................................ 34 N•m (25 lb-ft)

8. Install power cord (A). Refill Cooling System IMPORTANT: Use only permanent-type, low silicate, ethylene glycol base antifreeze in coolant solution. Other types of antifreeze may damage cylinder seals. FREEZING TEMPERATURES: Fill with permanent-type, low silicate, ethylene glycol antifreeze (without stop-leak additive) and clean, soft water. Add TY16004 John Deere Coolant Conditioner or equivalent.


TM1640 (15JAN04)

05-0505-4

TX,0505,111284 –19–26MAR99–1/2


PN=224

Cold Weather Starting Aids NOTE: All machines are shipped from the factory with a 50-50 mixture for protection to -34°C (-30°F). Adjust mixture accordingly to provide freeze protection for your machine. • Fill radiator to the bottom of the radiator fill neck. • Fill the recovery tank to the FULL mark. Deaeration The cooling system requires several warm-up and cool down cycles to deaerate. It will NOT deaerate during normal operation. Only during warm-up and cool down cycles will the system deaerate. • Start engine. Run engine until coolant reaches a warm temperature. • Stop engine. Allow coolant to cool. • Check coolant level at recovery tank. • Repeat Steps 1—3 until recovery tank coolant level is repeatedly at the same level (stabilized).

NOTE: The level of the coolant in the cooling system MUST BE repeatedly checked after all drain and refill procedures to insure that all air is out of the system which allows the coolant level to stabilize. Check coolant level only when the engine is cold.

05 0505 5

TX,0505,111284 –19–26MAR99–2/2

TM1640 (15JAN04)

05-0505-5


PN=225


05 0505 6

TM1640 (15JAN04)

05-0505-6


PN=226

Group 0510

Cooling System Other Material Number

Name

Use

PT569 (U.S.)

John Deere NEVER-SEEZ Lubricant

Apply to fan shaft of drive motor.


CED,OUOE003,3332 –19–27MAR99–1/1

05 0510 1

TM1640 (15JAN04)

05-0510-1


PN=227

Cooling System

Specifications Item

Measurement

Specification

Motor Housing Bolt

Torque

55 N•m (40.5 lb-ft)

Motor Relief Valve

Torque

32 N•m (23.5 lb-ft)

Pump Housing Bolt

Torque

55 N•m (40.5 lb-ft)

Hub Hex Nut

Torque

40 N•m (54 lb-ft)

Hood, Air Cleaner and Exhaust Pipe

Weight


Grille Housing and Grille

Weight


Radiator and Oil Cooler Assembly

Weight


Side Plate-to-Frame Cap Screw

Torque

128 N•m (95 lb-ft)

Fan Tip-to-Shroud

Clearance

4.8—9.4 mm (0.189—0.370 in.)

Rod Hex Nut

Torque

298 N•m (220 lb-ft)

Cooler-to-Rod Mount Bracket Cap Screw

Torque

46 N•m (34 lb-ft)

Radiator/Oil Cooler Assembly-to-Frame Cap Screw

Torque

129 N•m (95 lb-ft)

Fan-to-Shroud

Clearance

4.8—9.4 mm (0.189—0.370 in.)

Grille Housing-to-Frame Cap Screw

Torque

129 N•m (95 lb-ft)

Side Plate-to-Grille Housing Cap Screw

Torque

73 N•m (54 lb-ft)

Fan Drive

Radiator and Oil Cooler

05 0510 2

CED,OUOE003,3334 –19–27MAR99–1/1

TM1640 (15JAN04)

05-0510-2


PN=228

Cooling System

Remove and Install Serpentine Belt 1. Check belt (A) regularly for wear, especially for cracks at the bottom of grooves and for frayed edges.

T111242B

–UN–27AUG97

A—Belt


TM1640 (15JAN04)

05-0510-3

TX,05,RP3338 –19–27MAR99–1/2


PN=229

05 0510 3

Cooling System IMPORTANT: If belt is stretched to the point that the belt tensioner is against its stop, belt must be replaced. 2. Replace belt if needed per diagram. Replace belt if worn. 3. Hold tension adjuster assembly away from belt. Remove old belt; install new belt, release tensioner.

T111698

–19–09OCT97

1—Crankshaft 2—Air Conditioning Compressor 3—Idler Pulley 4—Alternator 5—Water Pump 6—Tensioner

Belt With Air Conditioning

T111700

–19–09OCT97

05 0510 4

Belt Without Air Conditioning TX,05,RP3338 –19–27MAR99–2/2

TM1640 (15JAN04)

05-0510-4


PN=230

Cooling System

T111724

–19–14OCT97

Remove and Install Fan and Fan Drive

A—Cap Screw, Side Plate to Grille Housing

B—Hex Nut, Rod C—Cap Screw, Side Plate to Frame

1. Turn battery disconnect switch off (if equipped) or disconnect battery ground strap. 2. Remove fan guard.

D—Angle Bracket E—T Bracket

Remove fan and fan drive hub. Remove hoses from fan drive motor, remove fan drive motor.


TM1640 (15JAN04)

F—Bracket to Frame

05-0510-5

TX,0510,111291 –19–27MAR99–1/5


PN=231

05 0510 5

T111780

–UN–17OCT97

Cooling System

05 0510 6

A—Suction Hose B—Fan Drive Pump

C—Pump-to-Motor Hose D—Fan Drive Motor

E—Motor-to-Reservoir Return Tube Hose

F—Motor-to-Hydraulic Filter Hose

3. Repair kits are available for the pump and motor.


TM1640 (15JAN04)

05-0510-6

TX,0510,111291 –19–27MAR99–2/5


PN=232

T111703

–UN–23OCT97

Cooling System

A—Drive Hub

B—Hex Nut

C—Washer

05 0510 7

D—Label

4. Replace label if not readable.


TM1640 (15JAN04)

05-0510-7

TX,0510,111291 –19–27MAR99–3/5


PN=233

T111705

–UN–24NOV97

Cooling System

05 0510 8

Fan Drive Motor 1—O-Ring (2 used) 2—Seal (2 used) 3—Dust Seal 4—Shaft Seal 5—Bushing Block (2 used)

6—Housing 7—Valve Body 8—Relief Valve 9—Flange

10—Drive Gear 11—Idler Gear 12—Retaining Ring 13—Dowel Pin (4 used)

14—Bolt (4 used) 15—Key 16—19—Relief Valve Repair Kit

5. Replace fan drive motor seals as necessary.

8. Install relief valve and tighten.

6. Repair or replace fan drive motor relief valve as needed.

Fan Drive—Specification Motor Relief Valve—Torque .................................. 32 N•m (23.5 lb-ft)

7. Install fan drive motor bolts (14) and tighten. Fan Drive—Specification Motor Housing Bolt—Torque ................................. 55 N•m (40.5 lb-ft)


TM1640 (15JAN04)

05-0510-8

TX,0510,111291 –19–27MAR99–4/5


PN=234

T111779

–UN–11NOV97

Cooling System

Fan Drive Pump 1—Retaining Ring 2—Shaft Seal (2 used) 3—Flange 4—Dowel Pin

5—O-Ring (2 used) 6—Bearing (2 used) 7—“E” Seal (2 used)

8—Backup Ring (2 used) 9—End Cover 10—Bolt (4 used)

9. Repair or replace fan drive pump as needed.

05 0510 9

11—Housing 12—Gear (Number 2) 13—Gear (Number 1)

13. If label for fan drive hub hex nut torque is not readable, replace it.

10. Tighten fan drive pump housing bolts (10). Fan Drive—Specification Pump Housing Bolt—Torque ................................. 55 N•m (40.5 lb-ft)

11. Install pump, motor and hoses. 12. Apply John Deere NEVER-SEEZ Lubricant to shaft of drive motor. Install fan drive hub and fan. Tighten fan hub hex nut.

Fan Drive—Specification Hub Hex Nut—Torque .............................................. 40 N•m (54 lb-ft)

14. Install fan shroud, leave cap screws loose. Adjust clearance between shroud and fan blade tips to specification. Move shroud for left-right adjustment and use fan support for up-down adjustment. Tighten cap screws. Install fan guard.


TM1640 (15JAN04)

TX,0510,111291 –19–27MAR99–5/5

05-0510-9


PN=235

Cooling System

Remove and Install Radiator and Oil Cooler

–UN–27AUG97

CAUTION: Do not remove radiator filler cap unless engine is cool Then turn cap slowly to the stop, then remove.

T111245B

NOTE: Approximate capacity of cooling system is 22 L (23 qt). 1. Remove radiator cap. Attach hose to radiator drain cock (B). Drain engine coolant into a container. Remove hose and tighten drain cock. B—Radiator Drain Cock

2. Remove coolant recovery tank from hood. CAUTION: The approximate weight of hood, air cleaner and exhaust pipe is 45 kg (100 lb). Radiator and Oil Cooler—Specification Hood, Air Cleaner and Exhaust Pipe—Weight ................................................... 45 kg (100 lb) approximate

3. Remove hood with air cleaner and exhaust pipe. 4. Disconnect electrical harness connectors for coolant level sensor and lights in grille. 05 0510 10

CAUTION: The approximate weight of grille housing and grille is 152 kg (335 lb). Radiator and Oil Cooler—Specification Grille Housing and Grille—Weight ................ 152 kg (335 lb) approximate

5. Remove grille and grille housing. (See Group 1921.)


TM1640 (15JAN04)

05-0510-10

TX,0510,JC2023 –19–27MAR99–1/9


PN=236

Cooling System 6. Disconnect upper (A) and lower (B) radiator hoses and hose to coolant recovery reservoir. 7. Remove fan guard. 8. Remove fan shroud. 9. Remove fan and fan motor.

T111706B

–UN–09OCT97

A—Upper Radiator Hose B—Lower Radiator Hose

T111707B

–UN–09OCT97

05 0510 11


TM1640 (15JAN04)

05-0510-11

TX,0510,JC2023 –19–27MAR99–2/9


PN=237

Cooling System 10. Disconnect transmission, hydraulic oil charge air cooler hoses (C—F).

T111713B

–UN–09OCT97

C—Hose D—Hose E—Hose F—Hose

TX,0510,JC2023 –19–27MAR99–3/9

11. Remove clamp (G) and tube from air cooler.

–UN–09OCT97

G—Clamp

T111714B

05 0510 12


TM1640 (15JAN04)

05-0510-12

TX,0510,JC2023 –19–27MAR99–4/9


PN=238

T111724

–19–14OCT97

Cooling System

A—Cap Screw, Side Plate-to-Grille Housing

B—Hex Nut, Rod C—Cap Screw, Side Plate-to-Frame


05 0510 13

F—Bracket-to-Frame

12. Remove cap screws from air deflector brackets. Remove air deflector. Continued on next page

TM1640 (15JAN04)

05-0510-13

TX,0510,JC2023 –19–27MAR99–5/9


PN=239

Cooling System 13. Remove cap screws (A) from air conditioner condenser.

NOTE: Air conditioning system does NOT have to be discharged to remove radiator and oil coolers.

T111807B

–UN–23OCT97

A—Cap Screw (3 used)

TX,0510,JC2023 –19–27MAR99–6/9

14. Remove cap screws (B). Do not disconnect air conditioning hoses from condenser. Lay air conditioning condenser forward and secure with rope. CAUTION: The approximate weight of radiator, hydraulic oil cooler, transmission oil cooler and air cooler assembly is 57 kg (125 lb). Radiator and Oil Cooler—Specification Radiator and Oil Cooler Assembly—Weight .......................................... 57 kg (125 lb) approximate

15. Attach hoist to radiator and oil cooler assembly. Remove cap screws attaching assembly to frame.

–UN–23OCT97

B—Cap Screw (3 used)

T111806B

05 0510 14


TM1640 (15JAN04)

05-0510-14

TX,0510,JC2023 –19–27MAR99–7/9


PN=240

Cooling System 16. Carefully remove assembly. 17. Make necessary repairs.

T109372B

–UN–01MAY97

18. Install radiator and oil cooler assembly.

544H Shown


TM1640 (15JAN04)

05-0510-15

05 0510 15

TX,0510,JC2023 –19–27MAR99–8/9


PN=241

T111724

–19–14OCT97

Cooling System

05 0510 16





19. Install side plate-to-frame cap screws (C) and washers. Tighten cap screws.

25. Connect radiators hoses and coolant recovery reservoir hose.

Radiator and Oil Cooler—Specification Side Plate-to-Frame Cap Screw—Torque ....................................................... 128 N•m (95 lb-ft)

26. Install grille and grille housing. (See Group 1921.)

20. Install fan and fan motor.

27. Install hood. 28. Fill radiator with correct coolant mixture.

21. Replace foam strips on fan shroud. Install fan shroud leaving cap screws loose. 22. Adjust fan tip-to-shroud clearance evenly around fan to specification, tighten shroud cap screws. Radiator and Oil Cooler—Specification Fan Tip-to-Shroud—Clearance ......... 4.8—9.4 mm (0.189—0.370 in.)

29. Cooling system must be deaerated to remove air from system and to properly fill it with coolant. See Operator’s Manual for deaeration of cooling system procedures. 30. Check transmission and hydraulic oil level and refill as needed.

23. Install fan guard. 24. Connect transmission cooler, hydraulic oil cooler, and charge air cooler hoses.

TX,0510,JC2023 –19–27MAR99–9/9

TM1640 (15JAN04)

05-0510-16


PN=242

Cooling System

T111724

–19–14OCT97

Disassemble and Assemble Radiator, Oil Cooler and Air-to-Air Aftercooler



1. Remove radiator/oil cooler/air-to-air aftercooler assembly per procedures in this group.


2. Disassemble radiator/oil cooler/air-to-air aftercooler assembly. Replace parts as necessary.


TM1640 (15JAN04)


05-0510-17

TX,05,RP3341 –19–10MAY99–1/6


PN=243

05 0510 17

Cooling System 3. Apply foam strips (A) to both sides of radiator (4 pieces required).

T111950

–UN–19NOV97

A—Foam Strip (4 used)

TX,05,RP3341 –19–10MAY99–2/6

4. Assemble side plate (B) to oil cooler (C).

–UN–30APR97

B—Side Plate C—Oil Cooler

T109356B

05 0510 18


TM1640 (15JAN04)

05-0510-18

TX,05,RP3341 –19–10MAY99–3/6


PN=244

Cooling System 5. Thread four rods (D) with fixed nuts into oil cooler side member. Tighten rods.

–UN–30APR97

6. Assemble brackets (E) and straps (F) with isolators loosely to oil cooler and rods. 7. Thread jam nuts (G) on rods.

T109357B

D—Rod (4 used) E—Bracket (4 used) F—Isolator (3 used) G—Hex Nut (4 used)

TX,05,RP3341 –19–10MAY99–4/6

8. Assemble side member (H) to radiator (I).

NOTE: For ease of assembly, cut a rod (L) 1092 ± 4 mm (43 ± 0.2 in.) to measure distance between radiator and oil cooler side plates. 05 0510 19

–UN–30APR97

9. Assemble cooling package. Adjust jam nuts on threaded rods so cooling package is 1092 ± 4 mm (43 ± 0.2 in.) wide, measured inside the side plates and tighten rod hex nuts. Radiator and Oil Cooler—Specification Rod Hex Nut—Torque ................................................. 298 N•m (220 lb-ft)

T109358B

10. Tighten cooler-to-rod mount bracket cap screws. Radiator and Oil Cooler—Specification Cooler-to-Rod Mount Bracket Cap Screw—Torque ................................................................ 46 N•m (34 lb-ft)

H—Side Member I—Radiator J—Bracket (4 used, Front Shown) K—Cap Screw (3 used) L—Cooling Package Distance

11. Replace foam strips on top and bottom of fan shroud. 12. Install radiator/oil cooler assembly on machine. Tighten radiator/oil cooler assembly-to-frame cap screws. Radiator and Oil Cooler—Specification Radiator/Oil Cooler Assembly-to-Frame Cap Screw— Torque ........................................................................... 129 N•m (95 lb-ft)


TM1640 (15JAN04)

05-0510-19

TX,05,RP3341 –19–10MAY99–5/6


PN=245

T111703

–UN–23OCT97

Cooling System

05 0510 20

A—Drive Hub

B—Hex Nut

C—Washer

13. Install fan motor and fan.

17. Install grille housing. (See Group 1921). Install grille housing-to-frame cap screws and tighten.

14. Install shroud on radiator, leaving cap screws loose. 15. Adjust fan tip-to-shroud clearance evenly around fan. Move shroud for left-right adjustment and fan support for up-down adjustment. Radiator and Oil Cooler—Specification Fan-to-Shroud—Clearance ............... 4.8—9.4 mm (0.189—0.370 in.)

16. Tighten fan shroud cap screws.

D—Label

Radiator and Oil Cooler—Specification Grille Housing-to-Frame Cap Screw—Torque ....................................................... 129 N•m (95 lb-ft)

18. Install side plate-to-grille housing cap screws and tighten. Radiator and Oil Cooler—Specification Side Plate-to-Grille Housing Cap Screw—Torque ................................................. 73 N•m (54 lb-ft)

TX,05,RP3341 –19–10MAY99–6/6

TM1640 (15JAN04)

05-0510-20


PN=246

Group 0515

Speed Controls Specifications Item

Measurement

Specification

Torque

15—20 N•m (11—15 lb-ft)

Slow Idle Stop Screw

RPM

900 ± 25 rpm

Fast Idle Stop Screw

RPM

2350 ± 25 rpm

Angle (with respect to pedal mounting plate)

9—11° @ low idle position

Fuel Shut-Off Solenoid Injection Pump Lever Cap Screw

Fast and Slow Idle

Speed Control Linkage Accelerator Pedal

30—35° @ fast idle position Pedal Stop Screw

Clearance (with injection pump lever on fast idle stop)

1—2 mm (0.0039—0.079 in.)

CED,OUOE003,3377 –19–21APR99–1/1

Remove and Install Speed Control Linkage 1. Remove front and right cab shields. 2. Disassemble parts as shown. 3. Repair or replace as necessary. 4. Adjust linkage. (See Adjust Speed Control Linkage in this group.) 5. Install shields.

T111728

–UN–28OCT97

A—Accelerator Pedal Assembly B—Isolator C—Accelerator Cable D—Bracket E—Ball Joint

TX,05,RP3343 –19–27MAR99–1/1

TM1640 (15JAN04)

05-0515-1


PN=247

05 0515 1

Speed Controls

Remove and Install Fuel Shut-Off Solenoid 1. Remove fuel shut-off solenoid. Disconnect solenoid connector from machine harness. 2. Install cap screw (8) to injection pump lever and tighten. Fuel Shut-Off Solenoid—Specification Injection Pump Lever Cap Screw—Torque ................................................. 15—20 N•m (11—15 lb-ft)

3. Go to Adjust Fuel Shut-Off Solenoid in this group.

T111753

–19–19NOV97

1—Nut 2—Cap Screw 3—Bracket 4—Cap Screw 5—Washer 6—Nut 7—Fuel Shut-Off Solenoid 8—Cap Screw 9—Nut

05 0515 2

TX,05,RP3344 –19–27MAR99–1/1

Check and Adjust Fast and Slow Idle 1. Connect a tachometer to check engine speeds. 2. Warm engine to normal operating temperature. 3. Stop the engine. 4. Disconnect speed control cable at injection pump lever.


TM1640 (15JAN04)

05-0515-2

TX,9010,JC2149 –19–24JUN98–1/3


PN=248

T103678

–UN–16SEP96

Speed Controls

A—Nut B—Slow Idle Stop Screw

C—Nut D—Supplementary Idle Screw

5.

E—Nut

05 0515 3

F—Fast Idle Stop Screw

8. Hold injection pump lever against the screw. Push injection pump lever against fast idle stop screw (F). Record engine speed.

Adjust the slow idle stop screw to obtain an engine speed that is 30—40 rpm less than the slow idle specification. Hold screw and tighten nut.

Push injection pump lever against slow idle stop screw (B). Record engine speed. Fast and Slow Idle—Specification Slow Idle Stop Screw—RPM ......................................... 900 ± 25 rpm Fast Idle Stop Screw—RPM........................................ 2350 ± 25 rpm

Adjust fast and slow idle stop screws on injection pump as needed. 6. Loosen nut (C) on the supplementary idle screw (D). Turn the screw out three turns. 7. Loosen nut (A) on the slow idle stop screw (B).

9. Turn the supplementary idle screw in to increase engine speed to the slow idle specification. Hold screw and tighten nut. For example, to obtain the 900 rpm slow idle speed, turn the slow idle stop screw (B) out to get approximately 865 rpm. Hold screw and tighten the nut. Then turn the supplementary idle screw (D) in to increase engine speed to 900 rpm. Hold screw and tighten nut 10. Pull injection pump lever rapidly to fast idle then decelerate to slow idle. Slow idle must be to specification.


TM1640 (15JAN04)

05-0515-3

TX,9010,JC2149 –19–24JUN98–2/3


PN=249

Speed Controls NOTE: Increasing slow idle setting a small amount, but no more than the maximum specifications, may help to reduce surging or hunting. If surging or hunting continues, repair injection pump.

increase engine speed. Adjust engine fast idle speed to specification. Hold screw and tighten nut. 12. Stop the engine. Connect the cable to lever. 13. Adjust speed control linkage. (See procedure in this group.)

11. Loosen nut (E) on fast idle stop screw (F). Pull lever against fast idle stop screw. Turn screw in to decrease engine speed; turn screw out to

TX,9010,JC2149 –19–24JUN98–3/3

05 0515 4

TM1640 (15JAN04)

05-0515-4


PN=250

Speed Controls

Speed Control Linkage Adjustment SPECIFICATIONS Accelerator Pedal Angle (with respect to pedal mounting plate)

9—11° @ low idle position

Accelerator Pedal (with respect to pedal mounting plate)

30—35° @ fast idle position

Pedal Stop Screw Clearance (with injection pump lever on fast idle stop)

1—2 mm (0.039—0.079 in.)

–UN–10SEP97

1. Adjust pedal angle to 9—11° from the pedal mounting plate with the pedal released.

T111247B

Specification Accelerator Pedal—Angle (with respect to pedal mounting plate) .................... 9—11° @ low idle position 30—35° @ fast idle position

2. Accelerator pedal at slow idle, disconnect swivel (F) on speed control cable (D) from injection pump lever (A). With injection pump lever (A) held against the slow idle stop screw (C), adjust swivel (F) on cable (D) to align with injection pump lever (A). Install swivel and tighten jam nut (E).

–UN–29AUG97

3. Depress accelerator pedal until injection pump lever is against fast idle stop screw (B) and hold.

T111260

4. Adjust pedal stop screw (G) until it makes contact with the pedal. Release pedal. 5. Shorten pedal stop screw until there is 1—2 mm (0.039—0.079 in.) clearance between the pedal and the pedal stop screw (G). Specification Pedal Stop Screw—Clearance (with injection pump lever on fast idle stop) ........................................................ 1—2 mm (0.039—0.079 in.)

A—Injection Pump Lever B—Fast Idle Stop Screw C—Slow Idle Stop Screw D—Speed Control Cable E—Jam Nut F—Swivel G—Pedal Stop Screw

TX,9010,JC2148 –19–10MAY99–1/1

TM1640 (15JAN04)

05-0515-5


PN=251

05 0515 5

Speed Controls

Adjust Fuel Shut-Off Solenoid 1. Turn key switch to START to "bump" starter. DO NOT start engine. Leave key switch in ON position. This will energize shut-off solenoid. 2. Loosen nut (C) and lengthen rod (D) until shut-off lever (B) moves away from stop (A).

T111265B

IMPORTANT: If rod (D) is adjusted too short, engine may not shut off. If rod is adjusted too long, engine may not start easily or may not have full power. If adjustment cannot be made, shut-off lever (B) may be binding, solenoid mounting bracket may be bent or injection pump may be worn or have internal failures.

–UN–29AUG97

3. Shorten rod (D) until shut-off lever (B) touches stop (A), then shorten rod two more turns to preload spring.

A—Stop B—Shut-Off Lever C—Nut D—Rod

4. Tighten nut (C) after adjustment is made.

TX,9010,JC2145 –19–29AUG97–1/1

05 0515 6

TM1640 (15JAN04)

05-0515-6


PN=252

Group 0520

Intake System Essential Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC).


CED,OUOE003,3338 –19–27MAR99–1/2 T7947AD –UN–05MAR93

Inlet Air Adapter . . . . . . . . . . . . . . . . . . . . . . . JDG51 To apply air pressure to intake system for leak checks.

CED,OUOE003,3338 –19–27MAR99–2/2


05 0520 1


CED,OUOE003,3339 –19–27MAR99–1/2

Air Regulator with Gauge To pressurize the air intake system for leakage tests.

CED,OUOE003,3339 –19–27MAR99–2/2

Specifications Item

Measurement

Specification

Air Intake System

Pressure

13.8—20.7 kPa (0.13—0.21 bar) (2—3 psi)

CED,OUOE003,3340 –19–27MAR99–1/1

TM1640 (15JAN04)

05-0520-1


PN=253

Intake System

Remove and Install Air Cleaner

TP60585

–UN–21JAN99

05 0520 2


TM1640 (15JAN04)

05-0520-2

TX,0520,111296 –19–27MAR99–1/3


PN=254

Intake System 1—Air Cleaner 2—Air Filter Primary Element 3—Cover 4—Hook (4 used) 5—O-Ring

6—Valve 7—Air Filter Secondary Element 8—Screen 9—Sensor

10—Band (2 used) 11—Washer (4 used) 12—Screw (4 used) 13—Hose

14—Clamp 15—Clamp 16—Housing 17—Cover

1. Remove four screws (12) and bands (10).

5. Install parts.

2. Disconnect wiring harness connector from air filter restriction switch.

6. Connect wiring harness connector to air filter restriction switch.

3. Remove and install parts as needed. 4. Inspect elements for wear or damage and replace as necessary.

TX,0520,111296 –19–27MAR99–2/3

IMPORTANT: Tighten hose clamps until hose protrudes around clamp band. 7. Tighten hose clamps (A and B) until air intake hose protrudes around clamp band. 05 0520 3

–UN–17MAR97

8. Test air intake system. (See Air Intake System Leakage Test in this group.)

T108196

A—Hose Clamp B—Hose Clamp

TX,0520,111296 –19–27MAR99–3/3

Remove and Install Air Filter Elements 1. Open left service door.

–UN–07MAR97

2. Remove air cleaner cover (A).

T106363E

A—Air Cleaner Cover


TM1640 (15JAN04)

05-0520-3

TX,0520,111278 –19–16FEB99–1/3


PN=255

Intake System IMPORTANT: Install a new primary element:

–UN–24JAN97

1. If the element shows damage. 2. If the element will not clean. 3. After 1000 hours service or annually. 3. Remove primary element (A).

T106369B

A—Primary Element

TX,0520,111278 –19–16FEB99–2/3

IMPORTANT: Install a new secondary element:

05 0520 4

T106370B

–UN–28JAN97

1. If primary element is damaged and needs to be replaced. 2. If element is visibly dirty. 3. After 1000 hours service or annually. 4. Always thoroughly clean air cleaner canister before installing new elements. Do not clean secondary element. Install a new element carefully centering it in the canister. B—Secondary Element

4. Remove secondary element (B).

TX,0520,111278 –19–16FEB99–3/3

TM1640 (15JAN04)

05-0520-4


PN=256

Intake System

T47764

CAUTION: Prevent possible injury from flying chips if compressed air is more than 210 kPa (2.1 bar) (30 psi). Reduce compressed air to less than 210 kPa (2.1 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection.

–UN–09NOV88

Clean Dusty Primary Element

1. Tap element with the palm of your hand, NOT ON A HARD SURFACE. 2. If this does not remove dust, use compressed air under 210 kPa (2.1 bar) (30 psi). 3. Direct air up and down the pleats from inside to outside. Be careful not to make a break in the element.

TX,0520,111281 –19–14MAR97–1/1

Clean Oily or Sooty Primary Element

2. Flush with clean water. Use water pressure under 280 kPa (2.8 bar) (40 psi).

T90673

1. Wash element in warm water and John Deere R36757 Filter Element Cleaner or equivalent non-sudsing detergent.

–UN–10NOV88

IMPORTANT: You can damage element. DO NOT wash element in fuel oil, oil, gasoline, or solvent. DO NOT use compressed air to remove water from an element.

3. Shake the element to remove water. Do not install element unless it is dry.

03T,55,C19 –19–24JUL91–1/1

TM1640 (15JAN04)

05-0520-5


PN=257

05 0520 5

Intake System

Inspect Element IMPORTANT: A damaged or dirty element may cause engine damage.

T90684

1. If the element shows damage. 2. If element will not clean. 3. After 1000 hours service or annually.

–UN–10NOV88

Install a new primary element:

Install a new secondary element: 1. If the primary element is damaged and needs to be replaced. 2. If the element is visibly dirty. 3. After 1000 hours service or annually. DO NOT clean a secondary element. Install a new element carefully centering it in the canister. 1. Inspect element and gasket for damage.

05 0520 6

2. Air restriction indicator will not signal correctly if an element has a break or is not correctly sealed in air cleaner housing. Throw away element that has the slightest damage. If gasket is broken or missing, install a new element. 3. After installing elements, reinstall cover with the drop tube as close to vertical as possible.

03T,55,C67 –19–24JUL91–1/1

TM1640 (15JAN04)

05-0520-6


PN=258

Intake System

Air Intake System Leakage Test SPECIFICATIONS 13.8—20.7 kPa (0.13—0.21 bar) (2—3 psi) –UN–23FEB89

Air Intake System Pressure

ESSENTIAL TOOLS JDG51 Inlet Air Adapter

T5906AP

SERVICE EQUIPMENT AND TOOLS Air Regulator with Gauge

IMPORTANT: Anytime the air intake system is opened it must be tested for leaks before the machine is returned to service.

–UN–12FEB97

1. Remove air cleaner cover and main filter element. 2. Put a plastic bag over safety element and install main element and cover.

4. Connect air pressure regulator to adapter using hose and fitting.

T107289C

3. Remove plug or ether start aid from air intake tube and install JDG51 Adapter (A).

A—JDG51 Adapter 05 0520 7

CAUTION: Plastic bag can be sucked into engine if engine is started when trying to close valves. 5. Pressurize air intake system to specifications. If system cannot be pressurized, turn engine slightly to close valves. Check plastic bag. Specification Air Intake System—Pressure ................. 13.8—20.7 kPa (0.13—0.21 bar) (2—3 psi)

6. Spray soap solution over all connections from the air cleaner to the turbocharger or air inlet to check for leaks. Repair all leaks.

TX,9010,SS3694 –19–21APR99–1/1

TM1640 (15JAN04)

05-0520-7


PN=259

Intake System

05 0520 8

TM1640 (15JAN04)

05-0520-8


PN=260

Group 0530

External Exhaust System Specifications Item

Measurement

Specification

Hood, Air Cleaner and Exhaust Pipe

Weight


Bracket-to-Engine Cap Screw

Torque

73 N•m (54 lb-ft)

CED,OUOE003,3337 –19–27MAR99–1/1

05 0530 1

TM1640 (15JAN04)

05-0530-1


PN=261

External Exhaust System

Remove and Install Muffler

TP60568

–UN–30NOV98

05 0530 2


TM1640 (15JAN04)

05-0530-2

TX,0530,111288 –19–27MAR99–1/2


PN=262

External Exhaust System 1—Screw, M10 x 30 (11 used) 2—Exhaust Pipe (Black) 3—Washer (8 used) 4—Lock Nut (4 used)

5—Muffler 6—Bracket 7—Screw M12 x 30 8—Nut

9—Clamp 10—Bracket 11—Screw, M10 x 25

12—Bracket 13—Clamp 14—Cap Screw

CAUTION: Muffler may be hot. Allow muffler to cool before removing.

7. Install bracket-to-engine cap screws (7 and 8), screws (1) and washers (3). Do not tighten at this time.

The approximate weight of hood, air cleaner and exhaust pipe is 64 kg (140 lb).

8. Reinstall fuel filter on bracket (10).

Specification Hood, Air Cleaner and Exhaust Pipe—Weight ............................................ 64 kg (140 lb) approximate

1. Remove hood.

9. Install clamp (9) that connects muffler inlet to turbocharger. Tighten clamp until connection is snug, but inlet pipe can still rotate. 10. Adjust muffler position so that muffler body is level and tighten mounting screws to keep it level.

2. Remove clamp (9). 11. Tighten cap screws. 3. Remove cap screws (1), washers (3), and lock nuts (4). 4. Remove fuel filter from bracket (10). 5. Remove brackets (6 and 10). 6. Replace if necessary.

Specification Bracket-to-Engine Cap Screw— Torque....................................................................... 73 N•m (54 lb-ft)

12. Tighten clamp (9). 13. Install hood. 05 0530 3

TX,0530,111288 –19–27MAR99–2/2

TM1640 (15JAN04)

05-0530-3


PN=263

External Exhaust System

05 0530 4

TM1640 (15JAN04)

05-0530-4


PN=264

Group 0560

External Fuel Supply Systems Specifications Item

Measurement

Specification

Fuel Tank (Without Fuel) and Bottom Weight Guard


Fuel Tank Bottom Guard Cap Screw

318 N•m (235 lb-ft)

Torque

CED,OUOE003,3343 –19–27MAR99–1/1

05 0560 1

TM1640 (15JAN04)

05-0560-1


PN=265

External Fuel Supply Systems

Remove and Install Fuel Tank

TP61740

–UN–03SEP98

05 0560 2


TM1640 (15JAN04)

05-0560-2

TX,05,RP3346 –19–16FEB99–1/4


PN=266

External Fuel Supply Systems 1—Fuel Tank 2—Drain Valve 3—Elbow Fitting (2 used) 4—Clamp (2 used) 5—Clamp (8 used) 6—Elbow Fitting 7—Elbow Fitting 8—Gasket

9—Sender 10—Screw (5 used) 11—Clamp 12—Hose 13—Filler Neck 14—Hose Fitting (10 used) 15—Filler Cap

1. Turn battery disconnect switch off (if equipped) or disconnect battery ground strap.

16—O-Ring 17—Bolt (4 used) 18—Flange Nut (4 used) 19—Screw (2 used) 20—Clamp (2 used) 21—Hose 22—Clamp (2 used)

23—Hose 24—Elbow Fitting 25—Housing 26—Hose 27—Screw 28—Clamp 29—Filler Neck Assembly

6. Disconnect wiring leads from fuel gauge sending unit (9).

2. Disconnect hose (23) from filler neck.

CAUTION: The approximate weight of the fuel tank (without fuel) is 18 kg (40 lb). Approximate weight of fuel tank and fuel tank bottom guard is 123 kg (272 lb).

3. Disconnect hose (21) at tank. CAUTION: Remove fuel to reduce weight of the fuel tank. Approximate capacity of fuel tank is 265 L (70 gal). 4. Disconnect hose at primary fuel filter and drain fuel into clean container or pump fuel out of the tank.

Specification Fuel Tank (Without Fuel) and Bottom Guard—Weight........................... 123 kg (272 lb) approximate

7. Support fuel tank and bottom guard with a lifting table or floor jack.

5. Disconnect hose (12) at leak-off line on engine head.

05 0560 3


TM1640 (15JAN04)

05-0560-3

TX,05,RP3346 –19–16FEB99–2/4


PN=267

External Fuel Supply Systems 8. Remove cap screws (D) and washers (C) from bottom guard and lower tank to floor. 9. Remove straps (B) to remove fuel tank from guard. –UN–19MAR97

10. Replace parts as necessary. 11. Install straps, Tighten cap screws (D).

12. Raise fuel tank into place with lifting device. Install cap screws (D) and washers (C). 13. Connect wiring leads to fuel level sending unit. 14. Connect hoses to fuel tank.

A—Cap Screw (2 used) B—Strap (2 used) C—Washer (4 used) D—Cap Screw (4 used) E—Bottom Guard F—Washer

TX,05,RP3346 –19–16FEB99–3/4

IMPORTANT: If fuel tank vent hose is plugged or pinched, the fuel tank could collapse and engine performance will be affected. 15. Check fuel tank vent hose (A) for being plugged or pinched. Clean, reposition or replace hose. 16. Connect battery ground strap. Turn battery disconnect switch on (if equipped).

–UN–27AUG97

A—Vent Hose

T111244B

05 0560 4

T108306

Specification Fuel Tank Bottom Guard Cap Screw—Torque ............................................................ 318 N•m (235 lb-ft)

TX,05,RP3346 –19–16FEB99–4/4

TM1640 (15JAN04)

05-0560-4


PN=268


Drain and Clean Primary Fuel Filter (Water Separator)

–UN–27AUG97

1. Open left engine side shield to access primary fuel filter (water separator). 2. Put container under drain valves (B and C).

T111238D

3. Rotate retaining ring around filter element counterclockwise 1/4 turn. Lifting ring as it is rotated helps get it past retaining detent. Ring should drop down and release filter from base. 4. Remove hand primer (A) from fuel filter base. Disassemble hand primer assembly and clean out any debris.

T8387AE

–UN–17DEC94

A—Hand Primer B—Drain Valve (Primary Fuel Filter) C—Drain Valve (Final Fuel Filter)

TX,55,JC2157 –19–02SEP97–1/2

5. Remove fuel inlet line (A) and fuel drain plug (C). 6. Flush any debris from filter base (B).

–UN–17DEC94

7. Install fuel inlet drain plug and fuel inlet line. 8. Assemble primer assembly and install onto fuel filter base.

T8387AD

9. Install filter element to fuel filter base. 10. Bleed fuel system. A—Fuel Inlet Line B—Filter Base C—Drain Plug

11. Close side shield. 12. Dispose of waste properly.

TX,55,JC2157 –19–02SEP97–2/2

TM1640 (15JAN04)

05-0560-5


PN=269

05 0560 5


Remove and Install Primary Fuel Filter (Water Separator)

–UN–27AUG97

1. Open left engine side shield to access primary fuel filter (water separator). 2. Put container under drain valves (B and C).

T111238D

3. Rotate retaining ring around filter element counterclockwise 1/4 turn. Lifting ring as it is rotated helps get it past retaining detent. Ring should drop down and release filter from base. 4. Remove hand primer (A) from fuel filter base. Disassemble hand primer assembly and clean out any debris.

T8387AE

–UN–17DEC94

A—Hand Primer B—Drain Valve (Primary Fuel Filter) C—Drain Valve (Final Fuel Filter)

TX,05,RP3371 –19–21APR99–1/4

5. Remove fuel inlet line (A) and fuel drain plug (C). 6. Flush any debris from filter base (B).

–UN–17DEC94

7. Install fuel inlet drain plug and fuel inlet line. 8. Assemble primer assembly and install onto fuel filter base. 9. Install filter element to fuel filter base.

T8387AD

05 0560 6

10. Bleed fuel system. A—Fuel Inlet Line B—Filter Base C—Drain Plug

11. Close side shield. 12. Dispose of waste properly.


TM1640 (15JAN04)

05-0560-6

TX,05,RP3371 –19–21APR99–2/4


PN=270


05 0560 7

TM1640 (15JAN04)

05-0560-7


PN=271


TP61752

–UN–01OCT98

05 0560 8


TM1640 (15JAN04)

05-0560-8

TX,05,RP3371 –19–21APR99–3/4


PN=272

External Fuel Supply Systems 1—Washer 2—Clamp (2 used) 3—Washer 4—Screw 5—Screw 6—Bracket 7—Fuel Line

8—Screw 9—Flange Nut 10—Bracket 11—Filter Head 12—Screw (4 used) 13—Plug (2 used)

14—O-Ring (4 used) 15—Kit 16—Seal Kit 17—Fuel Filter 18—Drain Valve 19—Fitting (2 used)

20—Filter Head 21—Fuel Line 22—Bracket 23—Cap Screw (4 used) 24—Clamp (2 used) 25—Ring

TX,05,RP3371 –19–21APR99–4/4

Remove and Install Final Fuel Filter

–UN–27AUG97

1. Turn filter lock ring (A) counterclockwise to remove filter. Drain sediment into a container and dispose of properly. 2. Clean filter base and install new filter.

T111238B

3. Bleed fuel system. A—Filter Lock Ring

05 0560 9

TX,05,RP3372 –19–16FEB99–1/1

TM1640 (15JAN04)

05-0560-9


PN=273


Bleeding Fuel System 1. Place container under filters (D and G).

4. Open bleed screw (B). Pump hand primer until bleed screw has solid stream of fuel coming from it. Tighten bleed screw (B).

T111238E

3. Pump hand primer (C) until bleed screw (A) has solid stream of fuel coming from it. Tighten bleed screw (A).

–UN–27AUG97

2. Loosen bleed screw (A).

5. Dispose of waste properly. A—Bleed Screw (Final Fuel Filter) B—Bleed Screw (Primary Fuel Filter) C—Hand Primer D—Primary Fuel Filter (Water Separator) E—Drain Valve (Primary Fuel Filter) F—Drain Valve (Final Fuel Filter) G—Final Fuel Filter

TX,0560,111294 –19–27MAR99–1/1

05 0560 10

TM1640 (15JAN04)

05-0560-10


PN=274

Section 07

Dampener Drive Contents Page

Group 0752—Elements Dampener Remove and Install . . . . . . . . . . . . . . . . . .07-0752-1

07

TM1640 (15JAN04)

07-1


PN=1

Contents

07

TM1640 (15JAN04)

07-2


PN=2

Group 0752

Elements Remove and Install Dampener 1. Open engine side shields.

Dampener—Specification Dampener-to-Flywheel Cap Screw—Torque ................................................................ 68 N•m (50 lb-ft)

T6564AS

3. Remove covers (A) and dampener (B).

–UN–27OCT88

2. Remove drive shaft.

A—Cover B—Dampener

TX,07,JC2342 –19–21APR99–1/1

07 0752 1

TM1640 (15JAN04)

07-0752-1


PN=277

Elements

07 0752 2

TM1640 (15JAN04)

07-0752-2


PN=278

Section 09

Steering System Contents Page

Group 0960—Hydraulic System Service Equipment and Tools . . . . . . . . . . . .09-0960-1 Other Material . . . . . . . . . . . . . . . . . . . . . . . .09-0960-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .09-0960-2 Steering Valve Remove and Install . . . . . . . . . . . . . . . . . .09-0960-3 Steering Column Remove and Install . . . . . . . . . . . . . . . . . .09-0960-8 Steering Cylinder Remove and Install . . . . . . . . . . . . . . . . . .09-0960-9 Loader Start-Up Procedure . . . . . . . . . . .09-0960-11 Disassemble and Assemble Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-12 Steering Cylinder Remove and Install Bushings. . . . . . . . . .09-0960-12

09

TM1640 (15JAN04)

09-1


PN=1

Contents

09

TM1640 (15JAN04)

09-2


PN=2

Group 0960

Hydraulic System Service Equipment and Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.


CED,OUOE003,3347 –19–29MAR99–1/2

Bushing, Bearing and Seal Driver Set To remove and install steering cylinder bushings.

CED,OUOE003,3347 –19–29MAR99–2/2


Name

Use

PT569 (U.S.)


Apply to threads of steering wheel nut to prevent threads from seizing. Apply to steering column pivot bores.


Cure Primer

To clean surface prior to application of adhesives or sealants.



Apply to threads of steering cylinder rod guide and spanner nut for installation. 09 0960 1

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

TM1640 (15JAN04)

CED,OUOE003,3348 –19–29MAR99–1/1

09-0960-1


PN=281

Hydraulic System

Specifications Item

Measurement

Specification

Isolator Cap Screw

Torque

57 N•m (42 lb-ft)

Valve-to-Plate Cap Screw

Torque

27 N•m (20 lb-ft)

Torque

68 N•m (50 lb-ft)

Steering Cylinder

Weight


Piston Nut

Torque

136 N•m (100 lb-ft) plus (30°) 1/12 turn

Steering Valve

Steering Column Steering Wheel-to-Steering Column Nut

Steering Cylinder

CED,OUOE003,3349 –19–29MAR99–1/1

09 0960 2

TM1640 (15JAN04)

09-0960-2


PN=282

Hydraulic System

–19–23JUL97 T110750

1. Install frame locking bar.

–19–23JUL97

CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before working in frame hinge area.

T110749

Remove and Install Steering Valve

–19–23JUL97

2. Stop engine.

T110754

CAUTION: Prevent possible injury from unexpected boom or bucket movement. Ride control accumulator MUST be discharged when working on hydraulic components. Engine OFF. With boom raised slightly, turn ignition switch to ON position. Move ride control switch to ON (center position). Boom will jump up if ride control accumulator is pressurized. Press Pilot Enable/Boom Down switch to BOOM DOWN and hold. Move the control lever to lower bucket to ground then hold in FLOAT position for 5 seconds to completely discharge ride control accumulator(s). 3. Engine OFF. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds.

09 0960 3

If not equipped with ride control, press pilot enable/boom down switch to BOOM DOWN position, move the control lever into FLOAT position and hold for 5 seconds to relieve any residual hydraulic pressure.


TM1640 (15JAN04)

09-0960-3

TX,0960,JC2036 –19–27MAR99–1/5


PN=283

Hydraulic System 4. Drain hydraulic reservoir or connect a vacuum pump to the reservoir by removing the vent filter and attaching the vacuum pump to its fitting in the reservoir. 5. Remove front cab shield.

T110783

–UN–23JUL97

TX,0960,JC2036 –19–27MAR99–2/5

A—Return B—Load Sense 09 0960 4

C—Right Turn

D—Left Turn

E—Pressure

6. Disconnect and label hoses. Plug or cap hoses and fittings. Continued on next page

TM1640 (15JAN04)

09-0960-4

TX,0960,JC2036 –19–27MAR99–3/5


PN=284

Hydraulic System

09 0960 5

TM1640 (15JAN04)

09-0960-5


PN=285

Hydraulic System

T109458

–UN–08MAY97

09 0960 6


TM1640 (15JAN04)

09-0960-6

TX,0960,JC2036 –19–27MAR99–4/5


PN=286

Hydraulic System 1—Isolator 2—Cap Screw (4 used) 3—Washer (4 used)

4—Bracket 5—Washer (4 used) 6—Steering Column

7—Lock Nut (3 used) 8—Washer (3 used) 9—Rubber Mount (3 used)

10—Cap Screw (3 used) 11—Cap Screw (2 used)

7. Remove cover from steering column.

12. Repair or replace parts as necessary.

8. Remove lock nuts (7), washers (8), rubber mounts (9), and cap screws (10).

Steering Valve—Specification Isolator Cap Screw—Torque .................................... 57 N•m (42 lb-ft) Valve-to-Plate Cap Screw— Torque....................................................................... 27 N•m (20 lb-ft)

9. Remove cap screw (11). 10. Remove steering valve. 11. Remove cap screws (2) and washers (3) to remove bracket (4) from steering column (6).

TX,0960,JC2036 –19–27MAR99–5/5

09 0960 7

TM1640 (15JAN04)

09-0960-7


PN=287

Hydraulic System

T110814

–19–25JUL97

Remove and Install Steering Column

1—Cover 2—Spring Assembly

3—Nut 4—Lock Washer (2 used) 5—Knob 6—Steering Wheel 7—Snap Ring 8—Seal

15—Isolator 16—Cover 17—Steering Column 18—Apply NEVER-SEEZ 19—Apply NEVER-SEEZ

2. Remove shift selector and turn signal switch.

7. Apply NEVER-SEEZ Lubricant or equivalent to steering column tilt pivots (18) and threads on steering shaft (19).

3. Disconnect spring (10).

8. Assemble parts (1—17).

4. Remove cap screws (9).

Steering Column—Specification Steering Wheel-to-Steering Column Nut—Torque ................................................ 68 N•m (50 lb-ft)

1. Remove steering column cover. 09 0960 8

9—Screw (4 used) 10—Spring 11—Dowel Pin 12—Screw (2 used) 13—Bolt (2 used) 14—Brush Set

5. Remove parts (1—8) and (10—17). 6. Repair or replace parts as needed.


TM1640 (15JAN04)

TX,0960,MA15 –19–29MAR99–1/1

09-0960-8


PN=288

Hydraulic System

Remove and Install Steering Cylinders

–UN–21MAY96

CAUTION: Prevent possible injury from unexpected machine frame movement. Install frame locking bar to both frames before you work in the frame pivot area.

T101186

1. Install frame locking bar (C). Stop engine.


TX,0960,RB89 –19–29MAR99–1/3

09 0960 9

TM1640 (15JAN04)

09-0960-9


PN=289

Hydraulic System

–UN–23AUG88


X9811

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 2. Turn steering wheel back and forth to release hydraulic pressure in the system. 3. Disconnect lines from cylinder. Close all openings using caps and plugs. CAUTION: The approximate weight of the steering cylinder is 65 kg (143 lb). Steering Cylinder—Specification Steering Cylinder—Weight .............................. 65 kg (143 lb) approximate

4. Remove pin from rod and head end of cylinder. 5. Remove cylinder from machine. 6. Install cylinder and connect lines.

09 0960 10

7. Install washers between steering cylinder rod end and loader frame with maximum number of washers. Divide washers above and below rod end so the cylinder does not bind. 8. Fill gap under rod end with spacers, then install one additional spacer. Fill gap over rod end with spacers. Install rod end pin.


TM1640 (15JAN04)

09-0960-10

TX,0960,RB89 –19–29MAR99–2/3


PN=290

Hydraulic System IMPORTANT: When a machine is started for the first time after cylinder rebuild or oil is drained from cylinder, the Loader Start-Up Procedure must be performed to prevent oil from “dieseling” inside the cylinder. 9. Perform Loader Start-Up Procedure (Steering Cylinder). (See procedure in this group.)

TX,0960,RB89 –19–29MAR99–3/3

Loader Start-Up Procedure (Steering Cylinder) IMPORTANT: System pressure must be reduced when performing this procedure. Adjust the LS valve to decrease system pressure. Turning the LS valve counterclockwise decreases system pressure. 1. Remove loader frame access cover. 2. Loosen lock nut on LS valve. Turn LS valve counterclockwise 2.5 complete turns. This will decrease system pressure to approximately 8274— 8963 kPa (82.74—89.63 bar) (1200—1300 psi). IMPORTANT: Perform procedure with engine at low idle (no acceleration.) 3. Slowly articulate the loader 3/4 turn to the right and then 3/4 turn to the left. Do not make contact at loader frame stops. 4. Repeat previous step four times.

09 0960 11

5. Articulate the loader fully to the right and then fully to the left. Repeat four times. 6. Reset system pressure by turning LS valve clockwise 2.5 turns. Check pressures. See Group 9025-25. 7. Install loader frame access cover.

CED,OUOE024,236 –19–23SEP98–1/1

TM1640 (15JAN04)

09-0960-11


PN=291

Hydraulic System

Disassemble and Assemble Steering Cylinder See Disassemble Cylinder in TMH120A. (Group 01.) See Assemble Cylinder in TMH120A. (Group 01.)

OUT3019,000009A –19–19AUG03–1/1

Remove and Install Steering Cylinder Bushings

–UN–09NOV88

Remove and install bushing (A) using disks from driver set.

T90813

A—Bushing

TX,0960,RB91 –19–23SEP98–1/1

09 0960 12

TM1640 (15JAN04)

09-0960-12


PN=292

Section 10

Service Brakes Contents Page

Group 1011—Active Elements Service Equipment and Tools . . . . . . . . . . . .10-1011-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .10-1011-1 Inspect External Service Brakes . . . . . . . . . .10-1011-1 Remove and Install Brake Assembly . . . . . . .10-1011-3 Group 1060—Hydraulic System Brake Valve Remove and Install . . . . . . . . . . . . . . . . . .10-1060-1 Brake Accumulator Remove and Install . . . . . . . . . . . . . . . . . .10-1060-4

10

TM1640 (15JAN04)

10-1


PN=1

Contents

10

TM1640 (15JAN04)

10-2


PN=2

Group 1011

Active Elements Service Equipment and Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.


CED,OUOE003,3350 –19–29MAR99–1/2

Feeler Gauge Used to measure thickness of brake disks.

CED,OUOE003,3350 –19–29MAR99–2/2

Specifications Item

Measurement

Specification

Brake Disk

Thickness Thickness

2.92 mm (0.114 in.) new 2.29 mm (0.090 in.) minimum used

Brake Separator Plate

Thickness

3.05 mm (0.120 in.) new

CED,OUOE003,3352 –19–29MAR99–1/1

Inspect External Service Brakes Do first inspection at 5000 hours followed by 1000 hours inspection intervals after the first 5000 hours inspection. If the service brakes are subjected to severe duty, inspect more frequently. 10 1011 1

1. Remove plug from brake inspection port. 2. Start engine and run for one minute. 3. Stop and apply the brakes. Block pedal or have someone hold brakes on.


TM1640 (15JAN04)

10-1011-1

TX,1011,JC2024 –19–23SEP98–1/3


PN=295

Active Elements

Specification Brake Disk—Thickness ....................................... 2.92 mm (0.114 in.) new Thickness.................................................................... 2.29 mm (0.090 in.) minimum used

T105767B

–UN–25FEB97

T105193B

A—Feeler Gauge B—Disk Dimension

–UN–02NOV98

4. Using a feeler gauge (A), measure the thickness of disks at dimension (B). Check dimension of two different disks.

TX,1011,JC2024 –19–23SEP98–2/3

5. If either of the disks thickness at dimension (B) is less than the minimum specification, the brake packs must be replaced.

T106873

–19–12FEB97

10 1011 2

TX,1011,JC2024 –19–23SEP98–3/3

TM1640 (15JAN04)

10-1011-2


PN=296

Active Elements

Remove and Install Brake Assembly 1. Remove differential and axle assembly. (See Group 0225.) 2. Remove final drive assemblies and brake packs. (See Group 0250.)

–UN–02JAN97

NOTE: A rolling head pry bar may be used to remove the piston. 3. Remove brake piston (A) from case/cover using compressed air at the brake pressure inlet.

RW36119

4. Inspect six separator plate retaining slots (B). Check the slots for galling or wear that might restrict the movement of the separator plates. Smooth the slots using a file or grinder. If there is too much wear, replace the differential case.

A—Brake Piston B—Retaining Slot (6 used)

TX,1011,JC2282 –19–16FEB99–1/3

5. Inspect brake piston (A). 6. Remove and replace packing rings (B) and (C). 7. Replace piston as necessary.

–UN–08JAN97

8. Inspect parts (D) and (E). Check the tabs on the separator plates for distortion or wear that might restrict there movement. Smooth the tabs using a file or grinder or replace the plates.

RW36120

Specification Brake Disk—Thickness ....................................... 2.92 mm (0.114 in.) new Brake Separator Plate— Thickness............................................................. 3.05 mm (0.120 in.) new

9. Inspect the brake disk splines (F) on the planetary carrier. A—Brake Piston B—OD Packing Ring C—ID Packing Ring D—Brake Separator Plates (6 used) E—Brake Disks (4 used) F—Planetary Carrier Brake Disk Splines

10. Replace parts as necessary.


TM1640 (15JAN04)

10-1011-3

TX,1011,JC2282 –19–16FEB99–2/3


PN=297

10 1011 3

Active Elements 11. Install brake piston (A) into differential case piston bore. 12. Install final drive assemblies. (See Group 0250.) 13. Install differential and axle assembly. (See Group 0225.)

RW36150

–UN–08JAN97

A—Brake Piston

TX,1011,JC2282 –19–16FEB99–3/3

10 1011 4

TM1640 (15JAN04)

10-1011-4


PN=298

Group 1060

Hydraulic System

T103102

–UN–14JAN97

Remove and Install Brake Valve


TX,1060,JC2284 –19–16FEB99–1/3

10 1060 1

TM1640 (15JAN04)

10-1060-1


PN=299

Hydraulic System

–UN–23AUG88


X9811

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. 1. Stop engine. 2. Lower boom to ground, push pilot enable switch to boom down position and hold control lever in float position. CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with ride control. Ride control accumulator energy must be discharged when working on hydraulic components. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds.

10 1060 2

3. If equipped with ride control. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 4. With machine OFF apply brakes approximately 30 times to discharge both brake accumulators.


TM1640 (15JAN04)

10-1060-2

TX,1060,JC2284 –19–16FEB99–2/3


PN=300

Hydraulic System 5. Remove shielding trim on front and right side of cab for access. 6. Remove clamp and return hose from brake valve. 7. Pinch off return hose (A) with vise grip to stop reservoir hydraulic oil from draining back.

–UN–21NOV97

8. Disconnect hoses and electric connectors. 9. Remove cap screws and brake valve.

T112343B

10. Replace parts as necessary. 11. Install brake valve. 12. Connect hoses and electric connectors. 13. Check for slight clearance between brake valve plunger and roller spinning freely on brake pedal.

A—Return Hose

TX,1060,JC2284 –19–16FEB99–3/3

10 1060 3

TM1640 (15JAN04)

10-1060-3


PN=301

Hydraulic System

Remove and Install Brake Accumulator CAUTION: Oil pressure must be released from brake accumulator before disconnecting lines or removing fittings. Accumulator inlet check valve seat is the inlet fitting. Removing accumulator inlet fitting will release oil pressure causing possible injury. 1. Stop engine. 2. Lower bucket to ground. With bucket level, push pilot enable switch to boom down position and hold control lever in float position. CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with ride control. Ride control accumulator energy must be discharged when working on hydraulic components. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 3. If equipped with ride control. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 4. With machine OFF apply brakes approximately 30 times to discharge both brake accumulators.

10 1060 4


TM1640 (15JAN04)

10-1060-4

TX,10,JC2344 –19–16FEB99–1/2


PN=302

Hydraulic System

5. Slowly loosen connections and disconnect lines (A, E, F, and G).

T158950


–UN–28AUG02


A—Accumulator-to-Brake Valve Line B—Brake/PRV Accumulator C—Cap Screw (2 used) D—Brake Accumulator E—Brake/PRV Accumulator-to-Main Hydraulic Pump F—Brake/PRV Accumulator-to-Pressure Reducing Valve G—Brake/PRV Accumulator-to-Brake Accumulator H—Check Valve

6. Remove cap screws (C). Remove accumulators (B and D). 7. Replace parts as necessary.

NOTE: Accumulator is not repairable. New accumulator is already charged. Attach new decal. NOTE: Check Valve (H) may be an adapter on older units. Sub check valve for adapter. 8. Install accumulators and connect lines.

TX,10,JC2344 –19–16FEB99–2/2

10 1060 5

TM1640 (15JAN04)

10-1060-5


PN=303

Hydraulic System

10 1060 6

TM1640 (15JAN04)

10-1060-6


PN=304

Section 11

Park Brake Contents Page

Group 1111—Active Elements Other Material . . . . . . . . . . . . . . . . . . . . . . . .11-1111-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .11-1111-1 Park Brake Remove and Install . . . . . . . . . . . . . . . . . .11-1111-2 Disassemble and Assemble. . . . . . . . . . . .11-1111-6 Group 1160—Hydraulic System Specifications . . . . . . . . . . . . . . . . . . . . . . . .11-1160-1 Park Brake Remove and Install Release Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1160-2 Remove and Install Pressure Switch . . . . .11-1160-4

11

TM1640 (15JAN04)

11-1


PN=1

Contents

11

TM1640 (15JAN04)

11-2


PN=2

Group 1111

Active Elements Other Material Number

Name

Use

PT569 (U.S.)


Apply to park brake shaft.


CED,OUOE003,3353 –19–29MAR99–1/1

Specifications Item

Measurement

Specification

Park Brake Assembly

Weight


Park Brake Mounting Cap Screw

Torque

350 N•m (255 lb-ft)

Drive Shaft Cap Screw

Torque

78 N•m (58 lb-ft)

Park Brake Housing Cap Screw

Torque

122 N•m (90 lb-ft)

Park Brake Yoke Nut

Torque

407 N•m (300 lb-ft)

CED,OUOE003,3354 –19–29MAR99–1/1

11 1111 1

TM1640 (15JAN04)

11-1111-1


PN=307

Active Elements

Remove and Install Park Brake CAUTION: Prevent possible injury from unexpected machine movement. Never rely on loader bucket to keep machine from moving. Machine can unexpectedly roll, resulting in death or serious injury. Always block wheels to hold machine when working on park brake. 1. Park machine on level surface. 2. Install frame locking bar. 3. Lower bucket to ground. 4. Stop engine. This will engage park brake. 5. Place blocks in front and behind tires.


TX,11,JC2356 –19–16FEB99–1/3

11 1111 2

TM1640 (15JAN04)

11-1111-2


PN=308

Active Elements

–UN–23AUG88

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body form high pressure fluids.

–UN–01OCT96

X9811

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 6. Remove park brake hydraulic line (C).

T104177

7. Remove drive shafts (A and D). 8. Remove mounting cap screws (E). CAUTION: The approximate weight of the park brake assembly is 43 kg (95 lb).

A—Front Drive Shaft B—Park Brake C—Park Brake Hydraulic Line D—Articulation Drive Shaft E—Cap Screw (4 used)

Specification Park Brake Assembly—Weight ......................... 43 kg (95 lb) approximate

9. Remove park brake (B).


TX,11,JC2356 –19–16FEB99–2/3

11 1111 3

TM1640 (15JAN04)

11-1111-3


PN=309

Active Elements IMPORTANT: Do not overfill park brake. Fill only to port (A). Capacity of the park brake is 300 mL (10 oz). 10. Check park brake oil level at port (A) and add oil as necessary in port. Allow oil to drain to bottom of level plug before installing plug to prevent overfilling. 11. Install new park brake. Tighten mounting cap screws. Specification Park Brake Mounting Cap Screw—Torque ............................................................ 350 N•m (255 lb-ft)

12. Place NEVER-SEEZ Lubricant on park brake shaft (B).

–UN–03NOV97

13. Install universal yoke on park brake shaft such that holes between front and rear yokes are in alignment. Install drive shafts.

T112115C

IMPORTANT: DO NOT reuse drive shaft universal joint cap screws. Replace cap screws to avoid machine damage. 14. Install new drive shaft universal joint cap screws. Tighten cap screws. Specification Drive Shaft Cap Screw—Torque ..................................... 78 N•m (58 lb-ft)

A—Oil Check and Fill Port B—Park Brake Shaft

15. Install park brake hydraulic line.


TX,11,JC2356 –19–16FEB99–3/3

11 1111 4

TM1640 (15JAN04)

11-1111-4


PN=310

Active Elements

11 1111 5

TM1640 (15JAN04)

11-1111-5


PN=311

Active Elements

Disassemble and Assemble Park Brake

TP55599

–UN–09SEP97

11 1111 6


TM1640 (15JAN04)

11-1111-6

TX,11,JC2357 –19–16FEB99–1/7


PN=312

Active Elements 1—Brake 2—Plate 3—Gasket 4—Housing 5—Bearing (2 used) 6—Bearing Cup 7—Bearing Cone 8—Universal Drive Shaft 9—Snap Ring

10—Washer 11—Yoke 12—Washer 13—Nut 14—Retainer 15—Seal (2 used) 16—Seal (2 used) 17—Fitting (2 used) 18—Relief Valve

19—O-Ring (2 used) 20—Spring (18 used) 21—Compression Spring (18 used) 22—Pin (2 used) 23—Brake Disk 24—Piston 25—O-Ring 26—O-Ring

1. Remove nut (13), washer (12), and yoke (11).

27—Screw (6 used) 28—Brake Disk (7 used) 29—Separator Plate (7 used) 30—Washer (4 used) 31—Cap Screw (4 used) 32—Yoke 33—Elbow Fitting 34—O-Ring 35—O-Ring

6. Remove springs (20), compression springs (21), and spring retainer (14).

CAUTION: Cover and cap screws are under pressure. Remove cap screws evenly to avoid possible injury. 2. Remove cap screws (27) evenly.

7. Remove seals (15 and 16) from housing. 8. Remove bearing cup (6). 9. Remove piston (24) from cover plate.

3. Remove cover plate (2) from housing (4).

10. Remove O-rings (25 and 26) from piston.

4. Remove shaft with brake disks (28) and separator plates (29).

11. Remove seals (15 and 16) and bearing cup (6) from cover plate.

5. Remove brake disk (23) from housing.

TX,11,JC2357 –19–16FEB99–2/7

12. Remove bearing cone (7) using a bearing puller from one end of shaft. 13. Remove bearing, disks, and plates from shaft. 14. Press other bearing off shaft. 15. Replace parts as necessary. 16. Press bearing cup (6) against shoulder in cover plate.

T101612

–UN–03OCT96

17. Lubricate O-rings (25 and 26) and piston (24) with J20C oil. Install inner and outer O-rings on piston.


TM1640 (15JAN04)

11-1111-7

TX,11,JC2357 –19–16FEB99–3/7


PN=313

11 1111 7

Active Elements 18. Install piston (A) in cover so that dowel pins are centered between slots. 19. Press bearing cup (6) against shoulder in housing. 20. Install spring retainer (14), springs (20), and compression springs (21). 21. Remove dowel pins (22) from cover plate and install in housing. 22. Install brake disk (23). 23. Install bearing cone (7) on shaft end with long spline.

–UN–03OCT96

24. Dip brake disks and separator plates in J20C oil. Install brake disk (28) then alternate between separator plate (29) and brake disk ending with a separator plate on top. 25. Install bearing cone (7) against shoulder.

T101611

26. Insert shaft with brake disks and separator plates with long spline end first into housing. Align separator plates on dower pins. 27. Install two M12 aligning studs into housing. A—Piston

28. Install gasket (3) on cover plate. 29. Install cover making sure dowel pins align in cover onto housing using cap screws. 30. Tighten cap screws (27) evenly. Specification Park Brake Housing Cap Screw— Torque ........................................................................... 122 N•m (90 lb-ft)

NOTE: Bearing and race are a select pair to create a shaft end play of 0.051—0.305 mm (0.002—0.012 in.). 31. Install seals (15 and 16) against shoulder in housing. 32. Install seals (15 and 16) against shoulder in cover plate.

11 1111 8


TM1640 (15JAN04)

11-1111-8

TX,11,JC2357 –19–16FEB99–4/7


PN=314

Active Elements 33. Install snap ring (9) and snap ring retainer (10) on universal drive shaft (8). 34. Place NEVER-SEEZ Lubricant on shaft splines. 35. Install yoke (11), washer (12), and nut (13). Tighten nut. Specification Park Brake Yoke Nut—Torque ................................... 407 N•m (300 lb-ft)


TX,11,JC2357 –19–16FEB99–5/7

IMPORTANT: Do not overfill park brake. Fill only to port (A). Capacity of the bark brake is 300 mL (10 oz). 36. Fill park brake at port (A) with 300 mL (10 oz) of oil. Allow oil to drain to bottom of level plug before installing plug to prevent overfilling. 37. Bench test the park brake. 38. Install a porta-power to the park brake. 39. Slowly increase pressure until the shaft rotates freely. Acceptable range is 896—1068 kPa (8.9—10.6 bar) (130—155 psi). 40. Increase the pressure to 3450 kPa (34.5 bar) 500 psi.

–UN–03NOV97

41. Slowly release brake pressure until free rotation of the shaft stops. Acceptable range is not more than 210 kPa (2.1 bar) (30 psi) less than the release pressure.

T112115B

A—Fill Plug B—Drain Plug

11 1111 9


TM1640 (15JAN04)

11-1111-9

TX,11,JC2357 –19–16FEB99–6/7


PN=315

Active Elements 42. Align yokes of park brake.

T112153

–UN–06NOV97

NOTE: Replace all drive line hardware when ever drive line is disassembled.

TX,11,JC2357 –19–16FEB99–7/7

11 1111 10

TM1640 (15JAN04)

11-1111-10


PN=316

Group 1160


Measurement

Specification

Park Brake Release Solenoid Valve Nut

Torque

7 N•m (62 lb-in.)

CED,OUOE003,3355 –19–29MAR99–1/1

11 1160 1

TM1640 (15JAN04)

11-1160-1


PN=317

Hydraulic System

Remove and Install Park Brake Release Solenoid Valve

X9811

–UN–23AUG88

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 1. Operate controls to release hydraulic pressure. 2. Disconnect electrical connector (A).

T103614C

–UN–06SEP96

A—Electrical Connector B—Solenoid


TX,1160,RB184 –19–23SEP98–1/2

11 1160 2

TM1640 (15JAN04)

11-1160-2


PN=318

Hydraulic System 3. Remove parts (C—E). 4. Remove parts (F—K). Plug opening to prevent dirt from entering manifold.

T7751LI

–UN–09NOV92

5. Inspect for dirty, worn or damaged parts. Check that spool inside solenoid valve moves freely. If spool does not move freely or if valve looks worn or damaged, replace complete solenoid assembly. 6. Install solenoid valve using new O-rings and backup rings. 7. Install parts (C—K). Tighten nut (C). Specification Park Brake Release Solenoid Valve Nut—Torque ........................................................... 7 N•m (62 lb-in.)


C—Nut D—Washer E—Cover F—Valve G—O-Ring H—Backup Ring I—O-Ring J—O-Ring K—Backup Ring

TX,1160,RB184 –19–23SEP98–2/2

11 1160 3

TM1640 (15JAN04)

11-1160-3


PN=319

Hydraulic System

X9811


–UN–23AUG88

Remove and Install Park Brake Pressure Switch

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 1. Operate controls to release hydraulic pressure. 2. Disconnect electrical connector (A). 3. Remove switch (B). 4. Replace parts as necessary.

–UN–06SEP96

5. Install switch. Connect electrical connector.

T103614B

A—Electrical Connector B—Pressure Switch

TX,1160,RB185 –19–12OCT98–1/1

11 1160 4

TM1640 (15JAN04)

11-1160-4


PN=320

Section 16

Electrical System Contents Page

Page

Group 1671—Batteries, Support and Cables Service Equipment and Tools . . . . . . . . . . . .16-1671-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .16-1671-2 Battery Service Carefully . . . . . . . . . . . . . . . . . . . .16-1671-3 Check Electrolyte Level and Terminals . . .16-1671-5 Charging Procedure. . . . . . . . . . . . . . . . . .16-1671-7 Using Booster—24 Volt System . . . . . . . . .16-1671-8 Procedure for Testing . . . . . . . . . . . . . . . .16-1671-9 Remove and Install . . . . . . . . . . . . . . . . .16-1671-10 Remove and Install Disconnect Switch . .16-1671-11

Transmission Control Valve Connector Contact Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-9 Amp Crimper Tool Operation. . . . . . . . . . . . . . . . . . . . . . . . .16-1674-11 Remove and Install Die Set . . . . . . . . . . .16-1674-12 Contact Support Adjustment . . . . . . . . . .16-1674-14 Crimping Procedure . . . . . . . . . . . . . . . . .16-1674-15 Crimp Height Inspection. . . . . . . . . . . . . .16-1674-17 Crimp Height Adjustment . . . . . . . . . . . . .16-1674-18 Connector Terminals Replace Transmission Controller Unit . . .16-1674-19 Chassis Computer Unit Connector Terminals Replace . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-20 Install CINCH Contact . . . . . . . . . . . . . . .16-1674-23 Remove Connector Body from Blade Terminals. . . . . . . . . . . . . . . . . . . . . . . . .16-1674-24 Blade Terminals Remove From Fuse Block . . . . . . . . . . . .16-1674-24 Boom Height Kickout Adjustment . . . . . . . .16-1674-25 Return-to-Carry Kickout Adjustment . . . . . .16-1674-26 Return-to-Dig Adjustment . . . . . . . . . . . . . .16-1674-27

Group 1672—Alternator, Regulator and Charging System Wiring Bosch Alternator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1672-1 Alternator Remove and Install . . . . . . . . . . . . . . . . . .16-1672-1 Regulator Remove and Install . . . . . . . . . . . . . . . . . .16-1672-4 Group 1673—Lighting System Halogen Bulbs Replace . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1673-1 Work Lights Remove and Install . . . . . . . . . . . . . . . . . .16-1673-3 Front Turn Lights Remove and Install . . . . . . . . . . . . . . . . . .16-1673-5 Stop, Turn and Tail Light Remove and Install . . . . . . . . . . . . . . . . . .16-1673-5 Drive Lights and Guard Remove and Install . . . . . . . . . . . . . . . . . .16-1673-6 Dome Light and Door Light Switch Remove and Install . . . . . . . . . . . . . . . . . .16-1673-7 Group 1674—Wiring Harness and Switches Essential Tools . . . . . . . . . . . . . . . . . . . . . . .16-1674-1 Other Material . . . . . . . . . . . . . . . . . . . . . . . .16-1674-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . .16-1674-3 Replace METRI-PACK Connectors. . . . . . .16-1674-4 Install DEUTSCH Contact. . . . . . . . . . . . . .16-1674-5 Replace DEUTSCH Connectors . . . . . . . . .16-1674-6 Replace WEATHER PACKConnector . . . . .16-1674-7 Install WEATHER PACKContact. . . . . . . . .16-1674-8 Transmission Control Valve Connector Body Remove and Install . . . . . . . . . . . . . . . . . .16-1674-8 TM1640 (15JAN04)

Group 1675—System Controls Transmission Control Unit (TCU) Remove and Install . . . . . . . . . . . . . . . . . .16-1675-1 Chassis Computer Unit (CCU) Remove and Install . . . . . . . . . . . . . . . . . .16-1675-3 Monitor Display Unit Remove and Install . . . . . . . . . . . . . . . . . .16-1675-5 Group 1677—Motors and Actuators John Deere Starting Motor Repair . . . . . . . . .16-1677-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .16-1677-1 Starting Motor Remove and Install . . . . . . . . . . . . . . . . . .16-1677-1

16-1


PN=1

16

Contents

16

TM1640 (15JAN04)

16-2


PN=2

Group 1671

Batteries, Support and Cables Service Equipment and Tools 16 1671 1

NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.


CED,OUOE003,3357 –19–29MAR99–1/5

Battery Post/Clamp Cleaner . . . . . . . . . . . . . . JT05838 To clean corrosion off battery posts and clamps.

CED,OUOE003,3357 –19–29MAR99–2/5

Coolant and Battery Tester . . . . . . . . . . . . . . . JT05460 To check battery electrolyte specific gravity.

CED,OUOE003,3357 –19–29MAR99–3/5

Hydrometer Used to measure specific gravity of battery electrolyte.

CED,OUOE003,3357 –19–29MAR99–4/5

Battery Load Tester . . . . . . . . . . . . . . . . . . . . JT05832 To check battery capacity.

CED,OUOE003,3357 –19–29MAR99–5/5

TM1640 (15JAN04)

16-1671-1


PN=323

Batteries, Support and Cables

Specifications 16 1671 2

Specification Standard Battery—Voltage ............................................................ 12 Volts Cold Cranking Power ......................................... 625 amps at -18°C (0°F) Reserve Capacity ................................................ 160 minutes at 25 amps BCI Group Size .................................................................................... 30H Electrolyte Specific Gravity.............................. 1.265—1.280 fully charged Heavy Duty Battery—Voltage........................................................ 12 Volts Cold Cranking Power ......................................... 950 amps at -18°C (0°F) Reserve Capacity ................................................ 190 minutes at 25 amps BCI Group Size ...................................................................................... 31 Electrolyte Specific Gravity.............................. 1.265—1.280 fully charged

TX,9015,MM3057 –19–04SEP96–1/1

TM1640 (15JAN04)

16-1671-2


PN=324


Service Batteries Carefully

TS203

–UN–23AUG88

TS204

–UN–23AUG88

16 1671 3


TM1640 (15JAN04)

16-1671-3

TX,1671,MM3121 –19–08OCT96–1/2


PN=325


16 1671 4

CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Always remove grounded (-) battery clamp first and replace it last. Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness 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 10—15 minutes. Get medical attention immediately. If acid is swallowed: 1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or vegetable oil. 3. Get medical attention immediately. IMPORTANT: Electrolyte can damage paint and metal surfaces of your machine. Do not overfill the battery cells. If electrolyte spills on the floor, use one of the following mixtures to neutralize the acid: 0.5 kg (1 lb) baking soda in 4 L (1 gal) water, or 0.47 L (1 pt) household ammonia in 4 L (1 gal) water.

TX,1671,MM3121 –19–08OCT96–2/2

TM1640 (15JAN04)

16-1671-4


PN=326


Check Battery Electrolyte Level and Terminals 16 1671 5

CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Always remove grounded (-) battery clamp first and replace it last. Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. –UN–23AUG88

Avoid the hazard by:

TS203

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 10—15 minutes. Get medical attention immediately. If acid is swallowed: 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.


TM1640 (15JAN04)

16-1671-5

TX,9015,MM3060 –19–04SEP96–1/2


PN=327


–UN–09SEP03 T6996DB

3. Fill each cell to within specified range with distilled water. DO NOT overfill. A—Battery Post B—Fill Tube C—Electrolyte Level Range

–UN–09SEP03

Single Level Fill Tube Application

T6996DA

16 1671 6

IMPORTANT: During freezing weather, batteries must be charged after water is added to prevent battery freezing. Charge battery using a battery charger or by running the engine.

Dual Level Fill Tube Application TX,9015,MM3060 –19–04SEP96–2/2

TM1640 (15JAN04)

16-1671-6


PN=328


Battery Charging Procedure

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

–UN–23AUG88

Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.

16 1671 7

TS204

CAUTION: Prevent possible personal injury from exploding battery. A battery may explode if charged when it is frozen. Warm battery to 16°C (60°F) before charging.

IMPORTANT: Do not use battery charger as a booster if a battery has 1.150 gravity reading or lower. Turn off charger before connecting or disconnecting it. When charging a battery in unit, all cables must be disconnected to avoid damaging electrical components if battery charger cables are inadvertently connected to battery wrong.

NOTE: Batteries CANNOT be charged with battery cables connected. Each battery must charged individually. Voltage in both batteries must be equal. Alternator WILL NOT charge a single low battery. 1. Disconnect all battery cables starting at the negative (-) ground cable. 2. Turn charger off before connecting or disconnecting it. 3. Charge battery following manufacturer’s instructions for the battery charger. 4. After battery is charged, connect the cables, the negative (-) ground cable last.

TX,1671,MM3122 –19–08OCT96–1/1

TM1640 (15JAN04)

16-1671-7


PN=329


Using Booster Batteries—24 Volt System Before boost starting, machine must be properly shut down and secured to prevent unexpected machine movement when engine starts. CAUTION: An explosive gas is produced while batteries are in use or being charged. Keep flames or sparks away from the battery area. Make sure the batteries are in a well ventilated area. IMPORTANT: The machine electrical system is a 24 volt negative (-) ground. Connect two 12 volt booster batteries together as shown for 24 volts.

–UN–24OCT91

Make last booster cable connection to frame.

T6713AH1

A—Machine Batteries B—Booster Batteries

TX,9015,MM3062 –19–01AUG96–1/2

CAUTION: Avoid possible injury or death from machinery runaway.

NEVER start engine while standing on ground. Start engine only from operator’s seat, with transmission in neutral or park. Start engine while seated on operator’s seat.

–UN–11JAN89

Do not start engine by shorting across starter terminals. Machine will start in gear if normal circuitry is bypassed.

TS177

16 1671 8

After engine starts, disconnect clamp at machine frame first and then disconnect remaining clamps.

TX,9015,MM3062 –19–01AUG96–2/2

TM1640 (15JAN04)

16-1671-8


PN=330


Procedure for Testing Batteries IMPORTANT: If either battery is damaged or won’t hold a charge, both batteries must be replaced. Visual Check 1. Check for damage such as cracked or broken case and electrolyte leakage. If damage is seen, replace battery.

2. Record specific gravity reading for each cell. If high and low readings vary LESS than 0.050 and average specific gravity is between 1.225 and 1.280, battery is fully charged, go to LOAD TEST. If high and low readings vary LESS than 0.050 and average specific gravity is LESS than 1.225, charge battery and repeat test. If average specific gravity is still 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 low readings still vary MORE than 0.050, replace BOTH batteries.

2. Check electrolyte level. (See procedure in this group) If low, add distilled water to specified level and charge battery.

Load Test 3. Check terminals for corrosion. If corroded, clean using a wire brush or battery post cleaner such as JT05838 Battery Post/Clamp Cleaner.

1. Check battery capacity with a load tester such as JT05832 Battery Load Tester. Follow tester manufacturer’s instructions for proper load test procedures. 2. If one battery fails load test, replace BOTH batteries.

4. Check posts for looseness. If posts are loose in one battery, replace BOTH batteries. Hydrometer Test 1. Check specific gravity with a hydrometer or battery tester such as JT05460 Coolant/Battery Tester.

TX,9015,MM3061 –19–13OCT98–1/1

TM1640 (15JAN04)

16-1671-9


PN=331

16 1671 9


Remove and Install Batteries

TP55549

–UN–14JUL97

16 1671 10

1—Cable 2—Cable 3—Cable 4—Cover (3 used) 5—Battery (2 used)

6—Clamp (4 used) 7—Cover 8—Angle (2 used) 9—Hook Bolt (4 used)

10—Lock Nut (4 used) 11—Screw (2 used) 12—Washer (4 used) 13—Ground Cable

• Disconnect negative (-) battery cables first, then positive cables. • Check cables and clamps. Clean battery and battery posts.

14—Tie Band (As Required) 15—Tie Band 16—Washer 17—Nut

• Apply grease to bottom side of positive cable eyelets. • Connect positive cables, then negative cables.

TX,1671,1111028 –19–29MAR99–1/1

TM1640 (15JAN04)

16-1671-10


PN=332


Remove and Install Battery Disconnect Switch

TP48653

–UN–03MAR97

16 1671 11

1—Handle 2—Nut 3—Washer

4—Switch 5—Bracket 6—Label

7—Cable 8—Washer

9—Cap Screw 10—Washer (2 used)

TX,16,1111110 –19–29MAR99–1/1

TM1640 (15JAN04)

16-1671-11


PN=333


16 1671 12

TM1640 (15JAN04)

16-1671-12


PN=334

Group 1672

Alternator, Regulator and Charging System Wiring Bosch Alternator Repair—Use CTM77 16 1672 1

For complete repair information the component technical manual (CTM) is also required.

TS225

–UN–17JAN89

Use the CTM in conjunction with this machine manual.

TX,1672,MM3124 –19–09OCT96–1/1

TP48600

–UN–13JAN97

Remove and Install Alternator

55 Amp Bosch Alternator 1—Capacitor 2—Nut 3—Washer 4—Pulley 5—Fan

6—Alternator 7—Regulator 8—Flange Nut 9—Lock Washer

10—Flange Nut 11—Cover 12—Grommet 13—Flange Nut


TM1640 (15JAN04)

16-1672-1

14—Belt 15—Bushing 16—Screw 17—Idler

TX,1672,RB100 –19–13OCT98–1/3


PN=335

Alternator, Regulator and Charging System Wiring

TP48601

–UN–13JAN97

16 1672 2

80 Amp Bosch Alternator Shown 1—Pulley 2—Alternator 3—Nut 4—Lock Washer

5—Nut 6—Regulator 7—Nut 8—Screen

9—Grommet 10—Flange Nut (4 used) 11—Washer (2 used) 12—Fan

13—Belt 14—Screw 15—Idler

IMPORTANT: Disconnect battery ground cable to prevent accidental grounding of alternator wiring leads.

2. Disconnect wiring leads to alternator.

1. Disconnect battery ground cable.


3. Remove mounting cap screws and belt.


TM1640 (15JAN04)

16-1672-2

TX,1672,RB100 –19–13OCT98–2/3


PN=336

Alternator, Regulator and Charging System Wiring 5. Install alternator. Connect wiring leads. 16 1672 3

T104350

–19–22OCT96

Alternator belt tension is controlled by an automatic tensioner.

TX,1672,RB100 –19–13OCT98–3/3

TM1640 (15JAN04)

16-1672-3


PN=337

Alternator, Regulator and Charging System Wiring

Remove and Install Regulator 1. Remove old regulator (B) and cut wire lead (A) at base (at the soldered connection) and discard regulator and wire lead. 2. Scrape off insulation (C) from spring terminal.

T109938B

–UN–11JUN97

T109936B

–UN–11JUN97

A—Wire Lead B—Regulator C—Insulation

CED,OUOE024,243 –19–29SEP98–1/2

3. Install new regulator (A) so regulator contact is touching spring terminal that was scraped of insulation.

–UN–11JUN97

A—Regulator

T109939B

16 1672 4

CED,OUOE024,243 –19–29SEP98–2/2

TM1640 (15JAN04)

16-1672-4


PN=338

Group 1673

Lighting System Replace Halogen Bulbs 16 1673 1 –UN–17APR89

IMPORTANT: To get the correct lighting pattern, lens must be installed so the word "TOP" is on top when lamp is installed on machine. Bezel must be installed so wider section is on top when lamp is installed.

T5894AG1

1. Before disassembling, take notice of how bezel and lens are installed with respect to mounting stud. 2. Remove four screws to remove bezel and lens.


TM1640 (15JAN04)

16-1673-1

T52,1673,C10 –19–17FEB99–1/2


PN=339

Lighting System 3. Disconnect wiring lead and release retainer clip to remove bulb (D).

–UN–20OCT88

To disconnect ground wiring lead, push tab up then pull connector from terminal.

T5894AI1

IMPORTANT: Do not touch the halogen bulb with bare hands. Oil and moisture may cause premature bulb failure. If bulb glass is touched, clean using a soft, oil-free cloth and alcohol. 4. Install new bulb so square notch is aligned with square tab on reflector back. 5. Install retainer clip into locking tabs on reflector back.

–UN–19OCT88

6. Connect wiring leads. Check that wiring leads are free of clip. 7. Install the gasket (E) into housing (C). 8. Install lens (F) into housing so the word "TOP" is on top when lamp is installed on machine.

T6249AU

16 1673 2

Check that wiring leads are not crimped. 9. Install bezel (G) so wider section is on top. Sealing flange must be inside housing on all four sides before tightening screws. 10. Tighten screws (H) alternately. Do not overtighten as screws may strip out plastic.

A—Flange Nut B—Lock Washer C—Housing D—Bulb E—Gasket F—Lens G—Bezel H—Screw (4 used)

T52,1673,C10 –19–17FEB99–2/2

TM1640 (15JAN04)

16-1673-2


PN=340

Lighting System

Remove and Install Work Lights

TP48311

–UN–08AUG96

16 1673 3

Front and Rear Work Lights 1—Screw

2—Washer

3—Light


TM1640 (15JAN04)

16-1673-3

4—Grommet

TX,1673,MM3127 –19–17FEB99–1/2


PN=341

Lighting System

TP48308

–UN–28MAR96

16 1673 4

Front Drive and Turn Light Guards 1—Bracket 2—Grommet

3—Lock Nut 4—Washer (2 used)

5—Rubber Mount

IMPORTANT: Rubber isolators must be installed between light guard and loader

6—Screw

frame or failure of halogen lights can occur.

TX,1673,MM3127 –19–17FEB99–2/2

TM1640 (15JAN04)

16-1673-4


PN=342

Lighting System

Remove and Install Front Turn Lights

TP48309

–UN–01APR96

16 1673 5

1—Lamp

2—Bulb, Turn

3—Bulb, Marker TX,1673,MM3128 –19–17FEB99–1/1

TP35385

–UN–19MAR96

Remove and Install Stop, Turn and Tail Light

1—Stop Light 2—Gasket

3—Bulb, Brake and Tail 4—Bulb, Turn Signal

5—Lens, Red 6—Lens, Amber

7—Flange Nut (2 used)

TX,1673,RP3007 –19–17FEB99–1/1

TM1640 (15JAN04)

16-1673-5


PN=343

Lighting System

Remove and Install Drive Lights and Guard

TP55460

–UN–14APR97

16 1673 6

1—Flange Nut (2 used) 2—Washer, 13 x 25 x 3 mm (2 used)

3—Support (2 used) 4—Side Light (2 used) 5—Screw, M10 x 50 (6 used)

6—Washer, 10.5 x 30 x 2.5 mm (6 used)

7—Clip (4 used) 8—Lock Nut (6 used)

TX,1673,1111032 –19–17FEB99–1/1

TM1640 (15JAN04)

16-1673-6


PN=344

Lighting System

Remove and Install Dome Light and Door Light Switch

TP48466

–UN–14SEP96

16 1673 7

1—Housing 2—Bulb

3—Lens 4—Rocker Switch

5—Light

6—Screw (2 used)

TX,1673,1111033 –19–17FEB99–1/1

TM1640 (15JAN04)

16-1673-7


PN=345

Lighting System

16 1673 8

TM1640 (15JAN04)

16-1673-8


PN=346

Group 1674

Wiring Harness and Switches Essential Tools 16 1674 1

NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC).


CED,OUOE003,3358 –19–30MAR99–1/11

–UN–30JUN95

Metri-Pack Extractor Tool . . . . . . . . . . . . . . . . JDG939

T8516AA

Used to remove contacts from Metri-Pack electrical connectors.

CED,OUOE003,3358 –19–30MAR99–2/11 T6606AB –UN–23AUG88

DEUTSCH Electrical Repair Tool Kit . . . . . . . . JDG359 To repair DEUTSCH electrical connector bodies.

DEUTSCH is a trademark of the Deutsch Co.

CED,OUOE003,3358 –19–30MAR99–3/11 T6606AC –UN–23AUG88

WEATHER PACK Extraction Tool . . . . . . . . . JDG364 Used to replace terminal contact in WEATHER PACK connector body.

WEATHER PACK is a trademark of Packard Electric.

TM1640 (15JAN04)


16-1674-1

CED,OUOE003,3358 –19–30MAR99–4/11


PN=347

Wiring Harness and Switches T104946 –UN–07NOV96

Electrical Repair Kit . . . . . . . . . . . . . . . . . . . JT07195A Electrical repair kit includes the most commonly used tools necessary to work on John Deere electrical wiring harness and connectors.

CED,OUOE003,3358 –19–30MAR99–5/11

–UN–05MAR96

WEATHER PACK Crimping Tool . . . . . . . . . . JDG783 Use to crimp WEATHER PACK male and female connectors. Tool crimps both connector and seal retainer at the same time.

T100473

16 1674 2


CED,OUOE003,3358 –19–30MAR99–6/11 T104947 –UN–07NOV96

Metrimate Extractor Tool. . . . . . . . . . . . . . . . . JDG140 Used to remove pin and socket contacts from Metri-Pack, CPC and Kostal electrical connector housings.

CED,OUOE003,3358 –19–30MAR99–7/11 T105908 –UN–19DEC96

Packard Crimping Tool . . . . . . . . . . . . . . . . . . JDG707 Used to crimp open barrel contacts and seal retainers for Kostal circular connectors.


TM1640 (15JAN04)

16-1674-2

CED,OUOE003,3358 –19–30MAR99–8/11


PN=348

Wiring Harness and Switches T112340B –UN–24NOV97

Amp Extraction Tool . . . . . . . . . . . . . . . . . . JDG1177 16 1674 3

Used to extract wires from the large terminals of the Amp transmission controller unit connector. CED,OUOE003,3358 –19–30MAR99–9/11 T112340B –UN–24NOV97

Amp Extraction Tool . . . . . . . . . . . . . . . . . FKM10457 Used to extract wires from the small terminals of the Amp transmission controller unit connector. CED,OUOE003,3358 –19–30MAR99–10/11 T112379 –UN–26NOV97

WEATHER PACK Narrow Extractor . . . . . . . . JDG777 Used to extract narrow pull-to-seat terminals from the chassis computer unit connectors.


CED,OUOE003,3358 –19–30MAR99–11/11


Name

Use


Thread Lock and Sealer (Medium Strength)

Apply to threads of return-to-dig switch cap screws.


CED,OUOE003,3360 –19–30MAR99–1/1

Specifications Item

Measurement

Specification

Boom Height Kickout Switch-to-Adjustable Plate

Gap

5—8 mm (0.197— 0.315 in.)

Return-to-Dig Switch-to-Adjustable Bar

Gap

5—8 mm (0.197— 0.315 in.)

Adjustable Bar Cap Screw

Torque

121 N•m (89 lb-ft) CED,OUOE003,3361 –19–30MAR99–1/1

TM1640 (15JAN04)

16-1674-3


PN=349

Wiring Harness and Switches

Replace METRI-PACK Connectors

–UN–01NOV96

1. A small locking tab is located inside of the Metri-Pack connector. Use a small screwdriver (B) to move tab (A) outward to the first detent position; the tab will “click.”

T104764B

A—Tab B—Screwdriver

Metri-Pack is a trademark of Packard Electrical.

TX,1674,MM3188 –19–29SEP98–1/3

2. Slide JDG939 Metri-Pack Extractor Tool (B) into connector body until it is positioned over terminal contact.

–UN–01NOV96

3. Gently pull wire out of connector body.

T104763B

IMPORTANT: Install contact in proper location using correct size grommet. 4. Push contact straight into connector body until positive stop is felt. 5. Pull on wire slightly to be certain contact is locked in place.

A—Wire B—Extractor Tool

6. Transfer remaining wires to correct terminal in new connector.

TX,1674,MM3188 –19–29SEP98–2/3

7. Use a small screwdriver (B) to move tab (A) inward to the first detent position; the tab will “click” and lock the wires in the connector body.

–UN–01NOV96


T104764B

16 1674 4

TX,1674,MM3188 –19–29SEP98–3/3

TM1640 (15JAN04)

16-1674-4


PN=350


Install DEUTSCH Contact 16 1674 5

1. Strip 6 mm (1/4 in.) insulation from wire.

TS117

3. Loosen lock nut (B) and turn adjusting screw (C) in until it stops.

–UN–23AUG88

2. Adjust selector (A) on JDG360 Crimper for correct wire size.


DX,ECONN,W –19–04JUN90–1/4

IMPORTANT: Select proper size contact "sleeve" or "pin" to fit connector body.

–UN–23AUG88

4. Insert contact (A) and turn adjusting screw (D) until contact is flush with cover (B).

TS0134

5. Tighten lock nut (C).


IMPORTANT: Contact must remain centered between indentors while crimping.

–UN–23AUG88

6. Insert wire in contact and crimp until handle touches stop.

TS118

7. Release handle and remove contact.


NOTE: Readjust crimping tool for each crimping procedure.

TS0135

8. Inspect contact to be certain all wires are in crimped barrel.

–UN–23AUG88

IMPORTANT: If all wire strands are not crimped into contact, cut off wire at contact and repeat contact installation procedures.


TM1640 (15JAN04)

16-1674-5


PN=351


Replace DEUTSCH Connectors

2. Start correct size extractor tool over wire at handle (A). 3. Slide extractor tool rearward along wire until tool tip snaps onto wire.

TS0124

• 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.

–UN–23AUG88

1. Select correct size extractor tool for size of wire to be removed:

4. Slide extractor tool along wire into connector body until it is positioned over terminal contact.

TS120

5. Pull wire out of connector body, using extractor tool.

–UN–23AUG88

IMPORTANT: Do NOT twist tool when inserting in connector.


DX,ECONN,J –19–03NOV94–1/2

IMPORTANT: Install contact in proper location using correct size grommet.

7. Pull on wire slightly to be certain contact is locked in place. 8. Transfer remaining wires to correct terminal in new connector.

–UN–23AUG88

6. Push contact straight into connector body until positive stop is felt.

TS122

16 1674 6

DX,ECONN,J –19–03NOV94–2/2

TM1640 (15JAN04)

16-1674-6


PN=352


Replace WEATHER PACKConnector 16 1674 7

2. Insert JDG364 Extraction Tool over terminal contact in connector body. 3. Hold extractor tool fully seated and pull wire from connector body.

TS0128

1. Open connector body.

–UN–23AUG88

IMPORTANT: Identify wire color locations with connector terminal letters.

NOTE: If terminal cannot be removed, insert wire or nail through extractor tool handle and push terminal contact from connector.


DX,ECONN,O –19–03NOV94–1/2

IMPORTANT: Carefully spread contact lances to assure good seating on connector body.

5. Pull on wire slightly to be certain contact is locked in place.

TS0130

4. Push contact into new connector body until fully seated.

–UN–23AUG88

NOTE: Connector bodies are "keyed" for proper contact mating. Be sure contacts are in proper alignment.

6. Transfer remaining wires to correct terminal in new connector. 7. Close connector body.

DX,ECONN,O –19–03NOV94–2/2

TM1640 (15JAN04)

16-1674-7


PN=353


Install WEATHER PACKContact NOTE: Cable seals are color coded for three sizes of wire: –UN–23AUG88

• Green - 18 to 20 gauge wire • Gray - 14 to 16 gauge wire • Blue - 10 to 12 gauge wire

TS0136

1. Slip correct size cable seal on wire. 2. Strip insulation from wire to expose 6 mm (1/4 in.) and align cable seal with edge of insulation.

NOTE: Contacts have numbered identification for two sizes of wire: a) #15 for 14 to 16 gauge wire b) #19 for 18 to 20 gauge wire

TS1623

–UN–02NOV94

3. Put proper size contact on wire and crimp in place with a "W" type crimp, using JDG783 Terminal Applicator.


DX,ECONN,AA –19–04JUN90–1/2

IMPORTANT: Proper contact installation for "sleeve" (A) and "pin” (B) is shown.

TS0139

–UN–02DEC88

4. Secure cable seal to contact as shown, using JDG783 Terminal Applicator.

DX,ECONN,AA –19–04JUN90–2/2

Remove and Install Transmission Control Valve Connector Body

–UN–01NOV96

1. A small locking tab is located inside of the connector. Use a small screwdriver (B) to move tab (A) outward to the first detent position; the tab will “click.” A—Tab B—Screwdriver

T104764B

16 1674 8


TM1640 (15JAN04)

16-1674-8

TX,16,RP3113 –19–13OCT98–1/3


PN=354

Wiring Harness and Switches 2. Slide JDG140 Metrimate Extractor Tool (B) into connector body until it is positioned over terminal contact.

16 1674 9 –UN–01NOV96

3. Push on end of extractor tool (B) and gently pull wire (A) out of connector body.

T104763B

IMPORTANT: Install contact in proper location using correct size grommet. 4. Push contact straight into connector body until positive stop is felt. A—Wire B—JDG140 Metrimate Extractor Tool

5. Pull on wire slightly to be certain contact is locked in place. 6. Transfer remaining wires to correct terminal in new connector.

TX,16,RP3113 –19–13OCT98–2/3

7. Use a small screwdriver (B) to move tab (A) inward to the first detent position; the tab will “click” and lock the wires in the connector body.

T104764B

–UN–01NOV96


TX,16,RP3113 –19–13OCT98–3/3

Install Transmission Control Valve Connector Contact

–UN–23AUG88

1. Slip correct size cable seal on wire.

TS0136

2. Strip insulation from wire to expose 6 mm (1/4 in.) and align cable seal with edge of insulation.


TM1640 (15JAN04)

16-1674-9

TX,16,RP3112 –19–29SEP98–1/2


PN=355


A—Contact Location B—Contact Location C—Crimper Location D—Crimper Location

–UN–09JAN97

4. Secure cable seal to contact by crimping at location (A) on contact and crimp at location (C) on JDG707 crimping tool.

T105879B

16 1674 10

3. Put contact on wire and insert into crimper at location (D) and crimp on contact at location (B) using JDG707 crimping tool.

TX,16,RP3112 –19–29SEP98–2/2

TM1640 (15JAN04)

16-1674-10


PN=356


Amp Crimper Tool for Transmission Controller Unit Connector—Operation

T112326

–UN–12JUN98

16 1674 11

A—Stationary Jaw B—Back of Tool (Wire Side) C—Pivot Pin

D—Frame E—Stationary Handle F—Moving Handle

G—Ratchet Adjustment Wheel H—Moving Jaw I—Die Assembly

The Amp Crimper Tool is used to crimp wires for the junior timer contacts and the micro timer contacts of the transmission controller unit connector. The tool has a frame with a stationary jaw and handle, a moving jaw, a moving handle and an adjustable ratchet that ensures full contact crimping. The tool frame holds a die assembly with two crimping sections.

J—Front of Tool (Locator Side) K—Locator Assembly

Attached to the outside of the frame is a locator assembly, which contains a locator, a spring retainer, and a contact support. Die retaining pins and die retaining screws are used to position and secure the dies in the tool frame. A nut is used on the upper die retaining screw to hold the locator assembly in place.

The die assembly features a wire anvil, an insulation anvil, a wire crimper, and an insulation crimper.

TX,16,1111102 –19–24NOV97–1/1

TM1640 (15JAN04)

16-1674-11


PN=357


Amp Crimper Tool for Transmission Controller Unit Connector—Remove and Install Die Set

T112329

–UN–24NOV97

16 1674 12

A—Nut B—Locator Assembly C—Tool Frame D—Die Retaining Pins

E—Die Retaining Screws F—Chamfer G—Insulation Anvil

H—Wire Anvil I—Offset J—Wire Crimper

1. Open the tool handles and remove the two die retaining screws (E) from the tool jaws. 2. Place the wire anvil (H) and insulation anvil (G) so that their chamfered sides and their marked surfaces face outward, when mounted in the moving jaw of the tool frame. 3. Insert the two die retaining pins (D). 4. Insert the short die retaining screw through the jaw and through both anvil dies, and tighten the screw just enough to hold the dies in place. Do NOT tighten the screw completely at this time.

5. Place the wire crimper (J) and insulation crimper (M) so that their chamfered sides and their marked surfaces face outward, when mounted in the stationary jaw of the tool frame. 6. Insert the two die retaining pins. 7. Insert the long die retaining screw through the jaw and through both crimper dies. Tighten the screw just enough to hold the dies in place. Do NOT tighten the screw completely at this time.


TM1640 (15JAN04)

K—Chamfer L—Locator M—Insulation Crimper

16-1674-12

TX,16,1111103 –19–24NOV97–1/2


PN=358

Wiring Harness and Switches 8. Carefully close the tool handles, making sure that the anvils and crimpers align properly. Continue closing the tool handles until the ratchet in the tool frame has engaged sufficiently to hold the anvils and crimpers in place, then tighten both die retaining screws. 9. Place the locator assembly over the end of the long screw, and position the locator assembly against the side of the tool jaw.

10. Place the nut onto the end of the long screw and tighten the nut enough to hold the locator to slide up and down. 11. To disassemble, close the tool handles until the ratchet releases. Remove the nut, the locator assembly, the two die retaining screws, and the four die retaining pins. Slide the anvils and crimpers out of the tool jaws.

TX,16,1111103 –19–24NOV97–2/2

TM1640 (15JAN04)

16-1674-13


PN=359

16 1674 13


16 1674 14

Amp Crimper Tool for Transmission Controller Unit Connector—Contact Support Adjustment NOTE: The contact support is preset prior to shipment, but minor adjustment may be necessary. 1. Make a sample crimp and determine if the contact is straight, bending upward, or bending downward. 2. If adjustment is required, loosen the screw that holds the contact support onto the locator assembly.

NOTE: The ratchet has detents that create audible clicks as the tool handles are closed. 3. Place a contact with wire into the proper nest and close the tool handles until the ratchet reaches the sixth click, or until the contact support touches the contact. 4. Slightly loosen the nut that holds the locator assembly onto the tool frame. 5. Move the contact support as required to eliminate the bending of the contact. 6. Tighten the nut and close the handles until the ratchet releases. 7. Remove and inspect the contact. 8. Make another sample crimp. If the contact is straight, tighten the contact support screw. If the contact is still being bent during crimping, repeat the adjustment procedure.

TX,16,1111104 –19–24NOV97–1/1

TM1640 (15JAN04)

16-1674-14


PN=360


Amp Crimper Tool for Transmission Controller Unit Connector—Crimping Procedure

16 1674 15

IMPORTANT: Verify crimp height before using the tool to crimp desired contacts and wire sizes. See Crimp Height Inspection and Crimp Height Adjustment, in this group. 1. Select wire of the specified size and insulation diameter. Strip the wire to length indicated. Do not nick or cut wire strands. SIZE (AWG)

WIRE INSUL DIAMETER

STRIP LENGTH

Junior Timer Contacts

0.5—1.0 mm

2.0 mm (0.079 in.) Max.

4.7 mm (0.185 in.)

Micro Timer Contacts

0.5—1.0 mm

1.6 mm (0.063 in.) Max.

4.3 mm (0.170 in.) –UN–24NOV97

CONTACT

T112335B

A—Slot

T112336B

–UN–24NOV97

Micro Timer Contact Slot

Junior Timer Contact Slot Continued on next page

TM1640 (15JAN04)

16-1674-15

TX,16,1111105 –19–17FEB99–1/3


PN=361


T112229

–UN–19NOV97

16 1674 16

A—Adjustment Screw for Contact Support B—Contact Support

C—Locator D—Wire E—Micro Timer Slot

F—Junior Timer Slot G—Contact

2. Hold the tool so that the back (wire side) is facing you. Squeeze tool handles together and allow them to open fully. 3. Holding the contact by the mating end, insert the contact—insulation barrel first—through the front of the tool and into the appropriate crimp section. IMPORTANT: Make sure that both sides of the insulation barrel are started evenly into the crimping section. Do NOT attempt to crimp an improperly positioned contact. 4. Position the contact so that the mating end of the contact is on the locator side of the tool, so that the open “U” of the wire and insulation barrels face the

top of the tool. Place the contact up into the nest so that the movable locator drops into the slot in the contact. Butt the front end of the wire barrel against the movable locator. 5. Hold the contact in position and squeeze the tool handles together until ratchet engages sufficiently to hold the contact in position. Do NOT deform insulation barrel or wise barrel. 6. Insert stripped wire into contact insulation and wire barrels until it is butted against the wire stop. 7. Hold the wire in place: squeeze tool handles together until ratchet releases. Allow tool handles to open and remove crimped contact.


TM1640 (15JAN04)

H—Locator in Wire Stop Slot I—Wire Inserted to Stop

16-1674-16

TX,16,1111105 –19–17FEB99–2/3


PN=362

Wiring Harness and Switches NOTE: The crimped contact may stick in the crimping area. It can be easily removed by pushing downward on the top of the locator.

8. Check the contact crimp height. If necessary, adjust the crimp height. See Crimp Height Inspection and Crimp Height Adjustment.

TX,16,1111105 –19–17FEB99–3/3

Amp Crimper Tool for Transmission Controller Unit Connector—Crimp Height Inspection

CRIMP SECTION (WIRE SIZE MARKING)

CRIMP HEIGHT DIM. (C) AND TOLERANCE (±)

1.0 mm

Junior

1.27 ± 0.051 mm (0.0500 ± 0.0020 in.)

1.0 mm

Micro

1.20 ± 0.051 mm (0.0472 ± 0.0020 in.)

2. If the crimp height conforms to specifications, the tool is considered dimensionally correct.

T112327

WIRE SIZE AWG (MAX)

–UN–21NOV97

1. Use a crimp height comparator to measure the wire barrel crimp height as shown.

A—Position Point on Center of Wire Barrel Opposite Seam B—Modified Anvil C—Dimension

If not, the tool must be adjusted. See Crimp Height Adjustment.

TX,16,1111106 –19–25NOV97–1/1

TM1640 (15JAN04)

16-1674-17


PN=363

16 1674 17


1. Remove the lock screw (B) from the ratchet adjustment wheel (C). 2. Adjust the ratchet wheel from the location side of the tool using a screwdriver (A). 3. If a tighter crimp is required, rotate the adjustment wheel counterclockwise. If a looser crimp is required, rotate the adjustment wheel clockwise.

5. Make a sample crimp and measure the crimp height. If the dimension is correct, tighten the lock screw. 6. If the dimension is incorrect, readjust the ratchet. A—Screwdriver B—Lock Screw C—Ratchet Adjustment Wheel

–UN–21NOV97

4. Install the lock screw.

T112328

16 1674 18

Amp Crimper Tool for Transmission Controller Unit Connector—Crimp Height Adjustment

TX,16,1111107 –19–25NOV97–1/1

TM1640 (15JAN04)

16-1674-18


PN=364


Replace Transmission Controller Unit Connector Terminals 16 1674 19

The transmission controller unit connector has two size terminals: • Junior Timer Contacts (Large)—Use JDG1177 Extractor • Micro Timer Contacts (Small)—Use FKM10457 Extractor 1. Insert extractor (A) into front (terminal side) of connector (C). Use extractor to press in the locking tabs of terminal.

3. Install new terminal into rear of connector, pushing it in until it stops. Locking tabs must be properly lined up with the socket.

T112380B

4. Pull on wire slightly to be certain terminal is locked in place.

–UN–01DEC97

2. Remove extraction tool and pull wire with terminal (B) through rear of connector.

A—Extractor B—Wire C—Connector

TX,16,1111113 –19–17FEB99–1/1

TM1640 (15JAN04)

16-1674-19


PN=365


Replace Chassis Computer Unit Connector Terminals (S.N. —783564) –UN–26NOV97

NOTE: The chassis computer unit connectors have “pull-to-seat” contacts.

T112370B

1. Disconnect chassis computer unit connector (C). 2. Insert JDG777 Terminal Extraction Tool (B) into wire side of the connector. Push terminal locking tab (D) inward releasing tab (E). 3. Remove extraction tool and push wire with terminal (A) through socket.

T109189

–UN–16APR97

A—Wire B—Extraction Tool C—Connector D—Locking Tab E—Tab

TX,16,1111114 –19–17APR01–1/5

4. Remove terminal, cut, strip and crimp wire through connector. Insert wire in the 18—16 slot of crimping tool.

–UN–24NOV97

5. Make sure locking tab on new terminals is in outward position. Then pull back on wire until terminal locks in connector body.

T112337B

16 1674 20

JDG1179 Crimper For CCU Connector


TM1640 (15JAN04)

16-1674-20

TX,16,1111114 –19–17APR01–2/5


PN=366

Wiring Harness and Switches (S.N. 783565—) 16 1674 21

1. Remove extraction tool (1) from the loading side of connector. 2. Insert blade of extraction tool into locking tabs (2) of secondary lock (3). Rotate tool away from the connector to pry one side of the secondary lock out of the locked position. Repeat this step for the other locking tab.

–UN–29JUN00

NOTE: After unlocking one side of the secondary lock, a screw driver or similar device may need to be used to hold it in the unlocked position while unlocking the second locking tab.

T132105B

1—Extraction Tool 2—Secondary Lock Locking Tabs 3—Secondary Lock

TX,16,1111114 –19–17APR01–3/5

3. Remove secondary lock (3).

T132301B

–UN–29JUN00

3—Secondary Lock


TM1640 (15JAN04)

16-1674-21

TX,16,1111114 –19–17APR01–4/5


PN=367


6. Repair/Replace terminals as necessary using procedure in this group. (See Install CINCH Contact.) 7. Insert contact and wire into connector until it clicks.

–UN–29JUN00

5. Gently pull wire out of the connector.

T132107B

16 1674 22

4. Insert pointed side of extraction tool into the contact cavity so that the flat side of tool faces secondary lock cavity (4). This will release the primary contact locking tab.

8. Install secondary lock.

TX,16,1111114 –19–17APR01–5/5

TM1640 (15JAN04)

16-1674-22


PN=368


Install CINCH Contact

T138057

–UN–14FEB01

16 1674 23

A—Top of Tool B—Contact Support C—Locator

D—Wire E—Micro Timer Slot

F—Junior Timer Slot G—Contact

1. Hold JDG708 crimping tool so that the tool is facing you as shown (left side of graphic). Squeeze tool handles together and allow them to open fully. IMPORTANT: Make sure that both sides of the insulation barrel are started evenly into the crimping section. Do NOT attempt to crimp an improperly positioned contact. 2. Position the contact so that the mating end of the contact (G) is on the locator side of the tool (C). Wire and insulation tabs (I and J) should point to top of tool (A). Butt wire tab (I) against the movable locator (C).

3. Hold the contact in position and squeeze the tool handles together until ratchet engages sufficiently to hold the contact in position. Do NOT deform wire and insulation tabs (I and J). 4. Insert stripped wire into contact insulation and wire tabs until it is butted against locator (C). 5. Hold the wire in place. Squeeze tool handles together until ratchet releases. Allow tool handles to open and remove crimped contact. 6. Install contact into connector. See Install CINCH Contact. (Go to procedure in this group.)

CINCH is a trademark of the Cinch Co.

TM1640 (15JAN04)

I—Wire Tab J—Insulation Tab

CED,TX17994,330 –18–29JUN00–1/1

16-1674-23


PN=369


Remove Connector Body from Blade Terminals

RW4218

2. Be sure to bend locking tang back to its original position (B) before installing connector body.

–UN–23AUG88

1. Depress locking tang (A) on terminal, using a small screw driver. Slide connector body off.

DX,ECONN,V1 –19–02NOV94–1/1

Remove Blade Terminals From Fuse Block Use small screwdriver to depress each locking tang (A) on terminal. Pull terminal out of fuse block. Be sure to bend locking tangs back to original position (B) before installing in fuse block.

–UN–14DEC91

A—Locking Tang (Depressed Position) B—Locking Tang (Original Position)

T7670AC

16 1674 24

TX,1674,WW1218 –19–13OCT98–1/1

TM1640 (15JAN04)

16-1674-24


PN=370


Boom Height Kickout Adjustment 16 1674 25

SPECIFICATIONS 5—8 mm (0.197— 0.315 in.) –UN–06FEB97

Boom Height Kickout Switch-to-Adjustable Plate Gap

2. After loader control lever returns to neutral, make a mark on the adjustable plate and loader frame for the tool carrier. For the loader, make a mark on plate edge and mounting block.

T106999B

1. Move loader control lever to boom raise detent position and release.

Loader

3. Position the boom in the desired boom height kickout position. Stop engine.

–UN–07FEB97

4. Loosen cap screws (A) and adjust plate to align marks on plate and loader frame or mounting block.

T107042B

5. Inspect air gap between switch (B) and adjustable plate (C). Specification Boom Height Kickout Switch-to-Adjustable Plate—Gap ................. 5—8 mm (0.197— 0.315 in.)

Tool Carrier

6. If air gap is out of specifications, loosen hex nuts and adjust switch (B) to get correct air gap.

A—Cap Screw (2 used) B—Switch C—Adjustable Plate

7. Start engine and check boom height kickout for correct adjustment. Readjust as required.

TX,20,SS3659 –19–22APR99–1/1

TM1640 (15JAN04)

16-1674-25


PN=371


Return-to-Carry Kickout Adjustment SPECIFICATIONS 5—8 mm (0.197— 0.315 in.) –UN–07FEB97

Boom Height Kickout Switch-to-Adjustable Plate Gap

2. Put boom lever in “Float” detent position and observe at what position boom stops lowering and control lever releases from detent.

T107043B

1. Move Return-to-Carry switch on side dash to ON position. Raise boom to maximum height.

Loader

3. Stop engine. Make a mark on the adjustable plate and loader frame for the tool carrier. For the loader, make a mark on plate edge and mounting block.

–UN–06FEB97

4. Start engine and position boom in desired Return-to-Carry position. 5. Stop engine. Loosen cap screws (A) and adjust plate (B) to align marks on plate and loader frame or mounting block. 6. Inspect air gap between switch (B) and adjustable plate (C). Specification Boom Height Kickout Switch-to-Adjustable Plate—Gap ................. 5—8 mm (0.197— 0.315 in.)

T107041B

16 1674 26

Tool Carrier A—Cap Screw (2 used) B—Switch C—Adjustable Plate

7. If air gap is out of specifications, loosen hex nuts on switch and adjust switch (B) to get correct air gap. 8. Start engine and check boom Return-to-Carry kickout for correct adjustment. Readjust as required.

NOTE: The boom “Float” position detent will not operate at ground level with Return-to-Carry switch ON. Turn Return-to-Carry switch off to activate normal “Float” function of boom.

TX,20,SS3660 –19–22APR99–1/1

TM1640 (15JAN04)

16-1674-26


PN=372


Return-to-Dig Adjustment 16 1674 27

SPECIFICATIONS 5—8 mm (0.197— 0.315 in.)

Adjustable Bar Cap Screw Torque

121 N•m (89 lb-ft)

–UN–16AUG96

Return-to-Dig Switch-to-Adjustable Bar Gap

OTHER MATERIAL

T101721

T43512 U.S. Thread Lock and Sealer (Medium Strength) TY9473 Canadian Thread Lock and Sealer (Medium Strength) 242 LOCTITE Thread Lock and Sealer (Medium Strength)

1. Raise boom approximately 300 mm (12 in.) above ground. Move bucket from full rollback to dump. 2. Move loader control lever to return-to-dig detent position and release.

A—Air Gap Switch-to-Bar B—Adjustable Bar C—Cap Screw (2 used) D—Alignment Marks E—Adjusting Nut (2 used) F—Switch

3. After control lever returns to neutral, make a mark (D) on switch bracket to align with end of adjustable bar. 4. Position the boom and bucket in the desired return-to-dig position. Stop engine. 5. Loosen cap screws (C) and adjust bar to align marks (D) on switch bracket and end of bar. 6. Raise boom. Cycle bucket from full rollback to dump. Adjust as required to get desired position. 7. Remove cap screws (C), one at a time, apply thread lock and sealer (medium strength). Adjust air gap (A) between switch (F) and adjustable bar. Tighten cap screws. Specification Return-to-Dig Switch-to-Adjustable Bar—Gap .................... 5—8 mm (0.197— 0.315 in.) Adjustable Bar Cap Screw— Torque ........................................................................... 121 N•m (89 lb-ft)


TM1640 (15JAN04)

TX,20,SS3661 –19–22APR99–1/1

16-1674-27


PN=373


16 1674 28

TM1640 (15JAN04)

16-1674-28


PN=374

Group 1675

System Controls Remove and Install Transmission Control Unit (TCU)

T111632

–UN–06OCT97

16 1675 1

A—Transmission Control Unit Connector

IMPORTANT: Whenever a transmission control unit (TCU) is replaced, the monitor display unit must be “reconfigured.” This reconfiguration procedure is performed in the Service Menu.

B—Transmission Control Unit

Transmission control unit (B) is located in the load center compartment. 1. Turn battery disconnect switch to “Off.”


TM1640 (15JAN04)

16-1675-1

TX,1675,111939 –19–17FEB99–1/2


PN=375

System Controls 2. Lift tab on connector up, then pull connector out of transmission control unit receiver. 3. Remove mounting screws to remove transmission control unit. 4. Install new control unit. Install and tighten mounting screws. 5. Push transmission control unit connector into control unit receiver, then push tab down to lock connector in place. 6. Turn battery disconnect switch to “On.”

–UN–27MAR97

7. Reconfigure monitor display unit. See Monitor Display Unit Reconfiguration in Operation and Test Manual.

T107726B

16 1675 2

TX,1675,111939 –19–17FEB99–2/2

TM1640 (15JAN04)

16-1675-2


PN=376

System Controls

Remove and Install Chassis Computer Unit (CCU)

T111633

–UN–06OCT97

16 1675 3

A—Chassis Computer Unit 60—Pin Connector (Part A)

B—Chassis Computer Unit 60—Pin Connector (Part B)

IMPORTANT: Whenever a chassis computer unit (CCU) is replaced, the monitor display unit must be “reconfigured.” This reconfiguration procedure is performed in the Service Menu. The chassis computer unit (C) is located in the load center compartment.

C—Chassis Computer Unit

D—Chassis Computer Unit 30—Pin Connector

4. Install new computer unit. Install and tighten mounting cap screws. 5. Connect chassis computer unit 30—pin connector (D) and 60—pin connector Part A (A) and Part B (B). Reference art on next page for chassis computer unit connector end views. 6. Turn battery disconnect switch to “On.”

1. Turn battery disconnect switch to “Off.” 2. Disconnect chassis computer unit connectors (A, B, and D).


3. Remove mounting cap screws to remove chassis computer unit.


TM1640 (15JAN04)

16-1675-3

TX,1675,111943 –19–17FEB99–1/2


PN=377

System Controls

T116162

–19–22JUL98

16 1675 4

TX,1675,111943 –19–17FEB99–2/2

TM1640 (15JAN04)

16-1675-4


PN=378

System Controls

Remove and Install Monitor Display Unit

T111634

–19–06OCT97

16 1675 5

IMPORTANT: Whenever a monitor display unit is replaced, it must be “reconfigured.” This reconfiguration procedure is performed in the Service Menu.

4. Install new monitor display unit. 5. Connect all monitor display unit connectors in front console harness. Reference art on next page for connector end views.

1. Turn battery disconnect switch to “Off.” 6. Turn battery disconnect switch to “On.” 2. Disconnect all connectors from monitor display unit. 3. Remove mounting cap screws to remove monitor display unit.



TM1640 (15JAN04)

16-1675-5

TX,1675,MM3132 –19–17FEB99–1/2


PN=379

System Controls

T110548

–19–05SEP97

16 1675 6

TX,1675,MM3132 –19–17FEB99–2/2

TM1640 (15JAN04)

16-1675-6


PN=380

Group 1677

Motors and Actuators John Deere Starting Motor Repair—Use CTM77 16 1677 1

For complete repair information on the John Deere Starting Motor, CTM77 is also required.

TS225

–UN–17JAN89

Use the component manual in conjunction with this machine manual.

TX,1677,MM3151 –19–07SEP94–1/1

Specifications Item

Measurement

Specification

Starting Motor

Weight


Starting Motor Mounting Cap Screw

Torque

125 N•m (95 lb-ft)

CED,OUOE003,3363 –19–30MAR99–1/1

Remove and Install Starting Motor

–UN–01DEC97

IMPORTANT: Disconnect battery negative (-) cable or turn battery disconnect switch to OFF (if equipped) to prevent accidental grounding of starting motor wiring leads.

T111214E

1. Disconnect battery negative (-) cable. Turn battery disconnect switch Off (if equipped). 2. Disconnect positive (+) wiring leads and battery ground strap from starter (A). A—Starter

CAUTION: The approximate weight of the starting motor is 30 kg (66 lb). Specification Starting Motor—Weight ..................................... 30 kg (66 lb) approximate

3. Remove mounting hardware to remove starting motor. 4. Replace parts as necessary.


TM1640 (15JAN04)

16-1677-1

TX,1677,MM3154 –19–30MAR99–1/3


PN=381

Motors and Actuators

T107768

–19–04MAR97

16 1677 2

5. Install starting motor. Continued on next page

TM1640 (15JAN04)

16-1677-2

TX,1677,MM3154 –19–30MAR99–2/3


PN=382

Motors and Actuators 6. Tighten mounting cap screws.

7. Connect all wiring leads and ground strap. Turn battery disconnect switch On. 16 1677 3

Specification Starting Motor Mounting Cap Screw—Torque ....................................................... 125 N•m (95 lb-ft)

TX,1677,MM3154 –19–30MAR99–3/3

TM1640 (15JAN04)

16-1677-3


PN=383

Motors and Actuators

16 1677 4

TM1640 (15JAN04)

16-1677-4


PN=384

Section 17

Frame or Supporting Structure Contents Page

17

Group 1740—Frame Installation Service Equipment and Tools . . . . . . . . . . . .17-1740-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .17-1740-2 Major Structure Welding . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-3 Engine and Loader Frame Separate . . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-5 Upper Pivot Bearing and Seals Remove and Install . . . . . . . . . . . . . . . . .17-1740-10 Lower Pivot Bearing and Seals Remove and Install . . . . . . . . . . . . . . . . .17-1740-12 Group 1746—Frame Bottom Guards Specifications . . . . . . . . . . . . . . . . . . . . . . . .17-1746-1 Fuel Tank Guard Remove and Install . . . . . . . . . . . . . . . . . .17-1746-1 Front Axle Guard Remove and Install . . . . . . . . . . . . . . . . . .17-1746-1 Transmission Bottom Guard Remove and Install . . . . . . . . . . . . . . . . . .17-1746-2 Transmission Side Guards Remove and Install . . . . . . . . . . . . . . . . . .17-1746-2 Group 1749—Chassis Weights Specifications . . . . . . . . . . . . . . . . . . . . . . . .17-1749-1 Counterweights Remove and Install . . . . . . . . . . . . . . . . . .17-1749-2

TM1640 (15JAN04)

17-1


PN=1

Contents

17

TM1640 (15JAN04)

17-2


PN=2

Group 1740

Frame Installation Service Equipment and Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier. 17 1740 1


CED,OUOE003,3365 –19–30MAR99–1/3

17-1/2 Ton Puller Set To remove and install bearing assembly and bushings from pivot bores. CED,OUOE003,3365 –19–30MAR99–2/3

Disk and Driver Set To remove and install bearing assembly, bushings and seals. CED,OUOE003,3365 –19–30MAR99–3/3

TM1640 (15JAN04)

17-1740-1


PN=387

Frame Installation

Specifications

17 1740 2

Item

Measurement

Specification

Weld Metal

Tensile Strength Yield Strength Elongation

482.6 mPa (70 000 psi) 413.7 mPa (60 000 psi) 22%

Structural Assemblies

Preheat Temperature

38°C (100°F)

Ground Engaging Tools

Preheat Temperature

177°C (350°F)

Torque

78 N•m (58 lb-ft)

Upper Pivot Bearing

Preload

0.03—0.13 mm (0.001—0.005 in.)

Upper Pivot Bearing Cover Cap Screw

Torque

128 N•m (95 lb-ft)

Lower Pivot Joint Bearing

Preload

0.03—0.13 mm (0.001—0.005 in.)

Bearing Cover-to-Engine Frame Cap Screw

Torque

128 N•m (95 lb-ft)

Plate-to-Loader Frame Cap Screw

Torque

128 N•m (95 lb-ft)

Lower Pivot Retaining Pin Cap Screw

Torque

2129 N•m (1570 lb-ft)

Loader Frame Universal Joint Cap Screw

Upper Pivot Bearing and Seals

Lower Pivot Bearing and Seals

CED,OUOE003,3367 –19–30MAR99–1/1

TM1640 (15JAN04)

17-1740-2


PN=388

Frame Installation

Welding Major Structure

–UN–23AUG88

CAUTION: Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly.

TS220

If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. Remove paint before welding. IMPORTANT: Disconnect battery ground strap or turn battery disconnect switch to OFF (if applicable). Disconnect both negative and positive battery cables and microprocessor unit (if applicable). Have only a qualified welder do this job. Connect welder ground clamp close to each weld area so electrical current does not pass through any bearings. Remove or protect all parts that can be damaged by heat or weld splatter. Use one of the following weld processes: • AWS-E-7018 covered electrode with shielded metal arc welding (SMAW) process. • AWS-ER-70S-3f wire electrode with gas metal arc welding (GMAW) process. • AWS-E70T-1 or E71T-1 wire electrode with flux core arc welding (FCAW) process.


TM1640 (15JAN04)

17-1740-3

WELD,II –19–01OCT98–1/2


PN=389

17 1740 3

Frame Installation Specification Weld Metal—Tensile Strength.............................. 482.6 mPa (70 000 psi) Yield Strength ....................................................... 413.7 mPa (60 000 psi) Elongation ............................................................................................ 22%

Preheat area to be repaired to allow better weld penetration. 17 1740 4

To repair weld metal failure, remove failed weld metal using arc or grinding equipment. Thoroughly clean area to be welded. Preheat structural assemblies to a minimum of 38°C (100°F). Preheat structural ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177°C (350°F). Specification Structural Assemblies—Preheat Temperature .......................................................................... 38°C (100°F) Ground Engaging Tools—Preheat Temperature ........................................................................ 177°C (350°F)

To repair base metal failure remove enough material to allow weld to penetrate to the bottom of crack. Preheat structural ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177°C (350°F).

WELD,II –19–01OCT98–2/2

TM1640 (15JAN04)

17-1740-4


PN=390

Frame Installation

Separate Engine and Loader Frame 1. Park machine on smooth level surface and align frames. 2. Install chain around bucket and connect to boom. Place service jack under center of bucket. Service jack wheels must roll freely and straight ahead when loader frame is moved forward.

17 1740 5

3. Stop engine. 4. Connect hoist to loader frame using chains. 5. Install shop stands under front and rear of engine frame. 6. Hold down Boom Lower Switch and move pilot control lever to release hydraulic pressure. Depress brake pedal 40 times to discharge brake accumulator. 7. Remove cab. (See Procedure in Group 1800)

TX,17,RP3352 –19–17FEB99–1/7

8. Disconnect electrical connectors. 9. Drain hydraulic reservoir. Approximate capacity of reservoir is 117 L (31 gal). Connector X8 to Load Connector X7 to Load Connector X9 to Load Connector X25 to Load

T111829

–UN–23OCT97

A—Loader Frame Harness Center Harness B—Loader Frame Harness Center Harness C—Loader Frame Harness Center Harness D—Loader Frame Harness Center Harness


TM1640 (15JAN04)

17-1740-5

TX,17,RP3352 –19–17FEB99–2/7


PN=391

Frame Installation

T111830

–UN–26NOV97

17 1740 6

Loader A—Boom Lower From Pilot Controller B—Bucket Dump From Pilot Controller

C—To Steering Valve D—Valve Inlet From Hydraulic Pump E—Bucket Roll Back From Pilot Controller

F—Boom Raise From Pilot Controller G—Pilot Pressure From Pressure Reducing Valve

H—Load Sense to Pump I—To Hydraulic Return Filter

10. Disconnect lines (A—I).


TM1640 (15JAN04)

17-1740-6

TX,17,RP3352 –19–17FEB99–3/7


PN=392

Frame Installation

T111833

–UN–23OCT97

17 1740 7

Tool Carrier A—Boom Lower to Pilot Controller B—Bucket Dump to Pilot to Controller C—Auxiliary to Pilot Controller

D—Control Valve Return to Filter E—Load Sense to Steering Valve F—Loader Control Valve Pressure From Pump

G—To Pressure Reducing Valve H—Auxiliary to Pilot Controller I—Bucket Roll Back to Pilot Controller

J—Boom Raise to Pilot Controller K—Load Sense to Hydraulic Pump

11. Disconnect lines (A—K).


TM1640 (15JAN04)

17-1740-7

TX,17,RP3352 –19–17FEB99–4/7


PN=393

Frame Installation 12. Disconnect lines (A, B, E, F). 13. Disconnect drive shaft U-joints (C and D).

–UN–07MAR97 T107858

TX,17,RP3352 –19–17FEB99–5/7

14. Remove steering cylinder pins (B). 15. Remove cap screw (E), plate (F) and spacer (D). Remove lower pivot pin (C). 16. Remove upper pivot pin (A).

–UN–11MAR97

A—Upper Pivot Pin B—Steering Cylinder Pins C—Lower Pivot Pin D—Spacer E—Cap Screw F—Plate

T108046

17 1740 8

A—Brake Pressure B—Differential Lock C—Front Drive Shaft U-Joint D—Center drive Shaft U-Joint E—Park Brake Return F—Park Brake Pressure


TM1640 (15JAN04)

17-1740-8

TX,17,RP3352 –19–17FEB99–6/7


PN=394

Frame Installation 17. Have a service technician at each front tire. Push on tires and slowly move overhead hoist forward. Make sure service jack rolls forward with bucket. 18. Replace parts as necessary. 19. Attach loader frame to engine frame. 17 1740 9

20. Connect lines and electrical connectors. IMPORTANT: DO NOT reuse drive shaft universal joint cap screws or bearing retainer straps. Replace cap screws and bearing retainer straps to avoid machine damage.

22. Connect steering cylinders. Install maximum number of washers between loader frame and steering cylinder rod end. Install equal number above and below rod end.

T77721

Loader Frame—Specification Universal Joint Cap Screw— Torque ............................................................................. 78 N•m (58 lb-ft)

–UN–24OCT88

21. Connect drive shafts. Install new drive shaft universal joint cap screws and bearing retainer straps. Tighten cap screws.

23. Install cab. (See Group 1800.) 24. Add hydraulic oil. (See Hydraulic System Oil, Group 0004.) 25. Start machine and check for leaks.

TX,17,RP3352 –19–17FEB99–7/7

TM1640 (15JAN04)

17-1740-9


PN=395

Frame Installation

Remove and Install Upper Pivot Bearing and Seals

T107940

–UN–13MAR97

17 1740 10

A—Pin B—Engine Frame C—Upper Seal

D—Cover E—Shim (As Needed) F—Loader Frame

G—Bearing (2 used) H—Lower Seal Spacer I—Lower Seal

1. Remove upper and lower pivot pins and separate frames. Remove cap screws (L) and cover (D) with upper seal (C). Remove parts (G, H, I, and K) from loader frame bore using a puller disk against lower seal spacer with seal (H).

J—Engine Frame K—Bearing Spacer L—Cap Screw (6 used)

2. Remove seal (I) from seal spacer (H). 3. Replace parts as necessary. 4. Apply a light coat of JDM J13E4 grease to rollers in bearings (G).

NOTE: Lower seal cannot be pushed through spacer. Remove seal spacer to remove seal.


TM1640 (15JAN04)

17-1740-10

TX,17,RP3353 –19–05OCT98–1/2


PN=396

Frame Installation 5. Press lower seal (I) into seal spacer (H) with lips facing out. The seal must seat against seal spacer shoulder. 6. Install seal spacer (H) in bottom of loader frame bore. 7. Press first bearing cup into bore against seal spacer. IMPORTANT: Do not apply load to bearing cone when pressing in cup. Use old bearing race to apply load on new bearing cup to prevent bearing damage. 8. Install first bearing cone in cup. IMPORTANT: Use the same spacer (K) which was removed from the bearing set. Spacer is not interchangeable with other bearings. 9. Install bearing spacer.

11. Install upper seal (C) into cover with lip facing out. Press seal to cover shoulder. 12. Hold cover in place, measure gap between cover and frame, take readings in three places. Cover must contact top of bearing. Calculate the average of these three reading to determine shim pack required. 13. Install shims to obtain a preload of 0.03—0.13 mm (0.001—0.005 in.) on bearings. Upper Pivot Bearing and Seals—Specification Upper Pivot Bearing—Preload ........... 0.03—0.13 mm (0.001—0.005 in.)

14. Apply grease to the top of bearing, fill cavity above bearing to machined surface, to prevent moisture from entering bearing through shims. 15. Tighten cap screws (L) to specification. Rotate inner race of bearing after tightening. Upper Pivot Bearing and Seals—Specification Upper Pivot Bearing Cover Cap Screw—Torque ....................................................... 128 N•m (95 lb-ft)

10. Press second bearing cup into bore against spacer. Install second bearing cone.

TX,17,RP3353 –19–05OCT98–2/2

TM1640 (15JAN04)

17-1740-11


PN=397

17 1740 11

Frame Installation

Remove and Install Lower Pivot Bearing and Seals

T107966

–UN–11MAR97

17 1740 12

A—Pin Retaining Cap Screw B—Cap Screw (6 used) C—Plate D—Engine Frame E—Spacer (Engine Frame)

F—Spacer (Engine Frame) G—Cover Seal H—Cap Screw (6 used) I—Cover

1. Remove pin retaining cap screw (A), cap screws (B) and plate (C). Remove pivot pin (Q) and separate machine frames.

J—Shims (As Needed) K—Loader Frame L—Bearing Spacer M—Bearing (2 used)

2. Remove cap screws (H), cover (I) with seal (G) and spacers (J).


TM1640 (15JAN04)

N—Spacer Seal O—Spacer P—Loader Frame Q—Lower Pivot Pin

17-1740-12

TX,17,RP3354 –19–17FEB99–1/2


PN=398

Frame Installation NOTE: Spacer seal can not be pushed through spacer. Remove seal and spacer to remove seal. 3. Remove bearing spacers, bearings, seals, and spacers (L, M, N, and O) from engine frame, using a puller disk against seal spacer (O). Remove seal (N) from seal spacer (O).

15. Hold bearing cover in place, measure gap between cover and frame, take readings in three places. Bearing cover must contact top of bearing. Calculate the average of these three readings to determine shim pack required. 16. Install shims (J) to obtain specified preload on bearings. Lower Pivot Bearing and Seals—Specification Lower Pivot Joint Bearing— Preload........................................................................ 0.03—0.13 mm (0.001—0.005 in.)

4. Remove spacer (E) from engine frame bore. 5. Replace parts as necessary. 6. Press spacer (E) into engine frame bore flush with bottom of frame. 7. Apply a light coat of JDM J13E4 grease to rollers in bearings (M). 8. Press seal into seal spacer, with lips facing out. Seal must seat against the seal spacer shoulder. 9. Install seal spacer to bottom of bore. 10. Press first bearing cup into engine frame bore against spacer. IMPORTANT: Use the same bearing spacer (L) which was removed from the bearing set. Spacer is not interchangeable with other bearings. Do not apply load to bearing cone when pressing in cup. Use old bearing race to apply load on new bearing cup to prevent bearing damage.

17. Apply grease to the top of bearing, fill cavity above bearing to machined surface, to prevent moisture from entering bearing through shims. 18. Tighten cap screws (H). Rotate inner race of bearing after tightening. Lower Pivot Bearing and Seals—Specification Bearing Cover-to-Engine Frame Cap Screw—Torque ............................................... 128 N•m (95 lb-ft)

19. Install spacer (F) into cover (I). 20. Move frames together and install pivot pin (Q) and plate (C). Install pin retaining cap screw (A) and cap screws (B) finger tight before torquing. 21. Tighten plate-to-loader frame cap screws (B). Tighten lower pivot pin retaining cap screw (A), steel dowels or cap screws may be inserted into holes in top of pivot pin and a bar inserted between them to prevent pin from turning during tightening of cap screw.

11. Install first bearing cone. 12. Install bearing spacer. 13. Press second bearing cup in engine frame bore. Install second bearing cone. Then press second bearing cup into bore against spacer.

Lower Pivot Bearing and Seals—Specification Plate-to-Loader Frame Cap Screw—Torque ....................................................... 128 N•m (95 lb-ft) Lower Pivot Retaining Pin Cap Screw—Torque ................................................. 2129 N•m (1570 lb-ft)

14. Install seal into bearing cover (I) with lips facing out. Press seal to cover shoulder.

TX,17,RP3354 –19–17FEB99–2/2

TM1640 (15JAN04)

17-1740-13


PN=399

17 1740 13

Frame Installation

17 1740 14

TM1640 (15JAN04)

17-1740-14


PN=400

Group 1746

Frame Bottom Guards Specifications Item

Measurement

Specification

Fuel Tank Guard

Weight


Front Axle Guard

Weight


Transmission Bottom Guard

Weight

71.5 kg (158 lb) approximate

Transmission Side Guard

Weight


17 1746 1

CED,OUOE003,3368 –19–30MAR99–1/1

Remove and Install Fuel Tank Guard

Full tank full of fuel (267 L, 70 gal) will add 225 kg (495 lb) to fuel tank and guard total weight. Drain fuel tank before removing guard.

T108116

Weight may increase due to build up of mud and debris.

–UN–12MAR97

CAUTION: The approximate weight of the fuel tank guard is 166 kg (366 lb).

Specification Fuel Tank Guard—Weight............................. 166 kg (366 lb) approximate

Drain fuel into a clean container for reuse. Remove fuel tank guard and fuel tank.

TX,17,RP3356 –19–17FEB99–1/1

Remove and Install Front Axle Guard

Specification Front Axle Guard—Weight ................................ 32 kg (72 lb) approximate

T108117


–UN–12MAR97

CAUTION: The approximate weight of the front axle guard is 32 kg (72 lb).

TX,17,RP3357 –19–17FEB99–1/1

TM1640 (15JAN04)

17-1746-1


PN=401

Frame Bottom Guards

Remove and Install Transmission Bottom Guard

Specification Transmission Bottom Guard— Weight........................................................... 71.5 kg (158 lb) approximate

T108118


TX,17,RP3358 –19–30MAR99–1/1

Remove and Install Transmission Side Guards

Specification Transmission Side Guard— Weight................................................................ 14 kg (30 lb) approximate

–UN–12MAR97

CAUTION: The approximate weight of the transmission side guard is 14 kg (30 lb).

T108119

17 1746 2

–UN–12MAR97

CAUTION: The approximate weight of the transmission bottom guard is 71.5 kg (158 lb).

If a guard is bent, heat with a torch and straighten. Weld any cracks using E7018 electrodes.

TX,17,RP3359 –19–17FEB99–1/1

TM1640 (15JAN04)

17-1746-2


PN=402

Group 1749

Chassis Weights Specifications Item

Measurement

Specification

Secondary Counterweight

Weight


Main Counterweight

Weight


Counterweight Attaching Cap Screw

Torque

1150 N•m (850 lb-ft)

17 1749 1

CED,OUOE003,3369 –19–30MAR99–1/1

TM1640 (15JAN04)

17-1749-1


PN=403

Chassis Weights

Remove and Install Counterweights

T108108

–UN–12MAR97

17 1749 2

A—Secondary Counterweight

B—Main Counterweight

C—Washer (6 used)

D—Cap screw (6 used)

CAUTION: The approximate weight of counterweight components are:

Draw counterweight against engine frame with upper two screws first, then lower screws. Torque to specifications in same pattern.

• Secondary Counterweight (A)—468 kg (1030 lb) • Main Counterweight (B)—873 kg (1925 lb).

Specification Counterweight Attaching Cap Screw—Torque ................................................... 1150 N•m (850 lb-ft)

Specification Secondary Counterweight— Weight ................................................... 468 kg (1030 lb) approximate Main Counterweight—Weight ............... 873 kg (1925 lb) approximate

TX,17,RP3361 –19–30MAR99–1/1

TM1640 (15JAN04)

17-1749-2


PN=404

Section 18

Operator’s Station Contents Page

Page

Group 1800—Removal and Installation Essential Tools . . . . . . . . . . . . . . . . . . . . . . .18-1800-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .18-1800-1 Cab or Canopy Remove and Install . . . . . . . . . . . . . . . . . .18-1800-2

R134a Component Oil Charge . . . . . . . . . .18-1830-12 Leak Testing . . . . . . . . . . . . . . . . . . . . . . . .18-1830-13 Refrigerant Hoses and Tubing Inspection . . . . . . . . . . . . . . . . . . . . . . . .18-1830-13 R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure . . . . . . . . .18-1830-14 Recover R134a System . . . . . . . . . . . . . . .18-1830-15 Evacuate R134a System . . . . . . . . . . . . . . .18-1830-16 Charge R134a System . . . . . . . . . . . . . . . .18-1830-18 Air Conditioner System Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . .18-1830-19 Air Conditioner System Purge. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-20 Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-21 Blower/Air Conditioner Harness (W20) Component Location . . . . . . . . . . . . . . . .18-1830-24 Blower/Air Conditioner Harness (W20) Connectors . . . . . . . . . . . . . . . . . . . . . . .18-1830-26 Heater/Evaporator Coil Air Conditioning Module. . . . . . . . . . . . . .18-1830-28 Remove and Install . . . . . . . . . . . . . . . . .18-1830-30 Expansion Valve Remove and Install . . . . . . . . . . . . . . . . .18-1830-33 Freeze Control Switch Remove and Install . . . . . . . . . . . . . . . . .18-1830-34 Bench Test . . . . . . . . . . . . . . . . . . . . . . .18-1830-35 Heater Control Valve Remove and Install . . . . . . . . . . . . . . . . .18-1830-36 Leak Check . . . . . . . . . . . . . . . . . . . . . . .18-1830-37 Main Blower Assembly Remove and Install . . . . . . . . . . . . . . . . .18-1830-37 Pressurizer Motor Assembly Remove and Install . . . . . . . . . . . . . . . . .18-1830-40 Receiver-Dryer and Condenser Remove and Install . . . . . . . . . . . . . . . . .18-1830-41 High and Low Pressure Switches Remove and Install . . . . . . . . . . . . . . . . .18-1830-42 Fresh Air Filter Remove and Install . . . . . . . . . . . . . . . . .18-1830-43 Recirculating Air Filter Remove and Install . . . . . . . . . . . . . . . . .18-1830-46 Compressor Remove and Install . . . . . . . . . . . . . . . . .18-1830-48

Group 1810—Operator Enclosure Other Material . . . . . . . . . . . . . . . . . . . . . . . .18-1810-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .18-1810-1 Windowpanes Remove and Install . . . . . . . . . . . . . . . . . .18-1810-2 Windshield Washer Remove and Install . . . . . . . . . . . . . . . . . .18-1810-4 Front and Rear Windshield Wiper Motor Remove and Install . . . . . . . . . . . . . . . . . .18-1810-6 Front Windshield Wiper Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-8 Wrist Support Remove and Install . . . . . . . . . . . . . . . . .18-1810-10 Group 1821—Seat and Seat Belts Seat Belt Disassemble and Assemble. . . . . . . . . . . .18-1821-1 Seat Disassemble and Assemble. . . . . . . . . . . .18-1821-2 Group 1822—Steps and Handholds Access Platform and Steps Remove and Install . . . . . . . . . . . . . . . . . .18-1822-2 Engine Compartment Step Remove and Install . . . . . . . . . . . . . . . . . .18-1822-4 Mounted Step Remove and Install . . . . . . . . . . . . . . . . . .18-1822-5 Group 1830—Heating and Air Conditioning Essential Tools . . . . . . . . . . . . . . . . . . . . . . .18-1830-1 Service Equipment and Tools . . . . . . . . . . . .18-1830-3 Air Conditioning System Fittings Reference Chart . . . . . . . . . . . . . . . . . . . .18-1830-4 Other Material . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6 Specifications . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6 Refrigerant Theory of Operation. . . . . . . . . . . . . . . . . .18-1830-7 R134a Refrigerant Cautions . . . . . . . . . . . . .18-1830-9 R134a Compressor Oil Charge Check . . . .18-1830-10 R134a Compressor Oil Removal . . . . . . . . .18-1830-11 TM1640 (15JAN04)

18-1



PN=1

18

Contents

Page

Compressor Clutch Disassemble and Assemble. . . . . . . . . . .18-1830-50 Compressor Check Clutch Hub Clearance. . . . . . . . . .18-1830-51 Compressor Manifold Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-52 Compressor Disassemble, Inspect and Assemble . . . .18-1830-53

18

Group 1899—Dealer Fabricated Tools DFRW20 Compressor Holding Fixture. . . . . .18-1899-1

TM1640 (15JAN04)

18-2


PN=2

Group 1800

Removal and Installation Essential Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC).


CED,OUOE003,2705 –19–30MAR99–1/2

18 1800 1

T6585NN –UN–03NOV88

Lifting Brackets . . . . . . . . . . . . . . . . . . . . . . . JT01748 To be used with hoist to lift cab.

CED,OUOE003,2705 –19–30MAR99–2/2

Specifications Item

Measurement

Specification

Cab

Weight


Cab Mounting Cap Screw

Torque

1150 N•m (850 lb-ft)

CED,OUOE003,2706 –19–30MAR99–1/1

TM1640 (15JAN04)

18-1800-1


PN=407


Remove and Install Cab or Canopy Cab or canopy can be removed for servicing of transmission and hydraulic pumps. 1. Stop engine. 2. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 18 1800 2

CAUTION: Prevent unexpected machine movement and possible injury. Install frame locking bar before working in frame hinge area. 3. Install frame locking bar. 4. Turn battery disconnect switch OFF (if equipped) or disconnect battery ground. 5. Remove steps and platforms from both sides of machine. 6. Remove front, left and right bottom cab shields.


TM1640 (15JAN04)

18-1800-2

TX,1800,111302 –19–28SEP98–1/8


PN=408

Removal and Installation 7. Remove two defroster ducts (A) located under front of cab floor. 8. Remove throttle cable under cab front right side. 9. Remove windshield wiper/washer hoses. 10. Remove brake accumulator line-to-pressure reducing valve. A—Defroster Duct (2 used)

T104544B

–UN–07MAR97

18 1800 3

TX,1800,111302 –19–28SEP98–2/8

11. Remove breather (A) from hydraulic reservoir plug breather port and pull a vacuum on hydraulic reservoir.

T101206

–UN–21MAY96

A—Breather


TM1640 (15JAN04)

18-1800-3

TX,1800,111302 –19–28SEP98–3/8


PN=409


X9811

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 12. Disconnect the five hoses (A) from steering valve. Plug and cap hoses.

T104543C

–UN–07MAR97

A—Steering Valve Hose (5 used)

TX,1800,111302 –19–28SEP98–4/8

13. Disconnect brake valve return hose (A) and brake valve work port hoses (B). Plug and cap hoses.

–UN–24MAR97

A—Brake Valve Return Hose B—Brake Valve Work Port Hose (2 used)

T107920B

18 1800 4

–UN–23AUG88



TM1640 (15JAN04)

18-1800-4

TX,1800,111302 –19–28SEP98–5/8


PN=410


T104524B

–UN–12DEC96

14. Disconnect hydraulic hoses from hydraulic pilot controllers.

TX,1800,111302 –19–28SEP98–6/8

18 1800 5

–UN–07MAR97

NOTE: Machines equipped with air conditioning will require that the A/C system be evacuated. See R134a Refrigerant Recovery/Recycling and Charging procedure in Group 1830. Disconnect A/C hoses under cab, not shown.

T104541D

15. Shut off heater hose shut off valves on engine. Disconnect heater hoses under cab. Disconnect three wiring connectors (A) on right side of cab and wiring connectors to loader frame (B) and disconnect the red, white and black wires from starter. CAUTION: Cab weighs approximately 771 kg (1700 lb).

–UN–24OCT96

Specification Cab—Weight ............................................... 771 kg (1700 lb) approximate

T104544C

16. Remove four cap screws from top of cab roof and install four JT01748 Lifting Brackets to the cab roof. Attach chains and hoist to lifting brackets. 17. Remove cab mounting cap screws. 18. Remove cab. A—Wiring Connector (3 used) B—Wiring Connector (4 used)

19. Do necessary repairs. 20. Inspect cab mounting parts. Replace as needed.


TM1640 (15JAN04)

18-1800-5

TX,1800,111302 –19–28SEP98–7/8


PN=411

Removal and Installation 21. Install cab. Install and tighten mounting cap screws. Specification Cab Mounting Cap Screw— Torque ....................................................................... 1150 N•m (850 lb-ft)

22. Remove lifting brackets from cab roof and install cap screws. 23. Connect wiring connectors and red, white and black wires to starter.

25. Connect hydraulic pilot controller hoses. 26. Connect brake valve return hose and brake valve work port hoses. –19–27MAR97

27. Connect steering valve hoses. 28. Remove plug from reservoir and install breather. 29. Install defroster ducts.

T108598

18 1800 6

24. Connect heater hoses and turn on heater shutoff valves.

30. Install front, left and rear bottom cab shields. 31. Install steps and platforms. 32. Turn battery disconnect switch ON (if equipped) or connect battery ground strap.

1—Nut (2 used) 2—Washer (6 used) 3—Washer (4 used) 4—Rubber Mount (4 used) 5—Cap Screw (M24 x 150) (2 used) 6—Cap Screw (M24 x 120) (2 used)

33. Bleed brakes. (See procedure in Group 1060.)

TX,1800,111302 –19–28SEP98–8/8

TM1640 (15JAN04)

18-1800-6


PN=412

Group 1810

Operator Enclosure Other Material Number

Name

Use


Pipe Sealant

To seal threads of washer tank fittings.


CED,OUOE003,2707 –19–30MAR99–1/1

18 1810 1

Specifications Item

Measurement

Wiper Arm Mounting Nut

Torque

Specification

8—9 N•m (72—86 lb-in.)

CED,OUOE003,2708 –19–30MAR99–1/1

TM1640 (15JAN04)

18-1810-1


PN=413

Operator Enclosure

Remove and Install Windowpanes The adhesive used to hold the windowpanes in place is a urethane adhesive that is used on most automobile windshields. Urethane adhesive manufactured by Loctite Corporation or equivalent is recommended. DO NOT use any other type of adhesive. It is also recommended that an auto glass dealer install the windowpanes.

18 1810 2

IMPORTANT: Windowpanes must have an ultra-violet barrier around the edge of the glass since ultra-violet rays will deteriorate the adhesive. Windowpanes ordered through John Deere Parts have the ultra-violet barrier. If the windowpane is purchased through a glass dealer, the dealer must put an ultra-violet barrier on the glass. DO NOT apply paint to the border of the glass. If an auto glass dealer is not installing the windowpanes, use the following procedure: 1. Purchase urethane adhesive from your local auto glass dealer. 2. If window frame is removable, remove frame from cab.

3. Scrape broken glass off existing adhesive. DO NOT remove adhesive from window frame or cab. IMPORTANT: Adhesive will not stick to bare metal. 4. If existing adhesive is removed from frame and paint is scraped off window frame, paint window frame. Paint must be fully cured before installing windowpane. 5. Trim existing adhesive so it has a smooth surface. 6. Follow the manufacturer’s instructions for using the adhesive. 7. Apply a 6 mm (1/4 in.) bead of adhesive on top of the existing adhesive. 8. Put a new windowpane into position. Use hand pressure to force windowpane down around the edges until even with metal frame. 9. If windowpane is installed directly on cab, use duct tape to hold it in place while adhesive cures. 10. Allow adhesive to cure for 24 hours before operating machine.

T52,1810,C19 –19–05JUN98–1/1

TM1640 (15JAN04)

18-1810-2


PN=414

Operator Enclosure

18 1810 3

TM1640 (15JAN04)

18-1810-3


PN=415

Operator Enclosure

Remove and Install Windshield Washer

TP60279

–UN–23MAR98

18 1810 4


TM1640 (15JAN04)

18-1810-4

TX,18,1111061 –19–30MAR99–1/2


PN=416

Operator Enclosure 1—Elbow Fitting (2 used) 2—Tie Band (As Required) 3—Hose

4—Hose 5—Pump (2 used) 6—Hose (2 used)

7—Washer (As Required) 8—Tank 9—Cap

Apply pipe sealant to threads of washer tank fittings.

10—Grommet (2 used) 11—Flange Nut (4 used) 12—Tank

Cut washer hoses from bulk stock.

TX,18,1111061 –19–30MAR99–2/2

18 1810 5

TM1640 (15JAN04)

18-1810-5


PN=417

Operator Enclosure

Remove and Install Front and Rear Windshield Wiper Motor

TP55440

–UN–14MAR97

18 1810 6

1—24 Volt Motor (2 used) 2—Bracket (2 used) 9—Washer (2 used) 10—Nut (2 used)

12—Weld Nut (2 used) 13—Washer (2 used) 14—Nut (2 used) 15—Pivot

19—Link 22—Nut (2 used) 23—Crank 24—Washer (2 used)


TM1640 (15JAN04)

18-1810-6

25—Screw with Washer 28—Motor 29—Screw (4 used)

TX,18,111317 –19–05JUN98–1/2


PN=418

Operator Enclosure

T109424

–19–06MAY97

18 1810 7

1. Disconnect wiring harness connector from wiper motor.

4. Connect cab work light harness connector to rear wiper motor.

2. Remove and disassemble parts as shown.

NOTE: Also reference Front Console Harness Component Location in Group 1674.

3. Install wiper motor.

NOTE: Also reference Cab Work Light Harness Component Location in Group 1674.

5. Connect front console harness connector to front wiper motor.

TX,18,111317 –19–05JUN98–2/2

TM1640 (15JAN04)

18-1810-7


PN=419

Operator Enclosure

Adjust Front Windshield Wiper CAUTION: Keep hands away from linkage when the motor is in operation. DO NOT adjust park position when the motor is in operation. Never start a windshield wiper when the blade is frozen to the windshield or manually stop the blade when the wiper is operating. 1. If the blade does not park in the required position, adjust the wiper blade. 18 1810 8

2. Loosen nut. 3. Reposition drive arm on shaft. 4. Tighten nut. Specification Wiper Arm Mounting Nut—Torque .................... 8—9 N•m (72—86 lb-in.)

5. Start wiper motor, shut it off and note the new park position. 6. If blade does not park in the correct position, repeat steps 2 through 6 until the correct park position is obtained.

TX,1810,RB128 –19–05JUN98–1/1

TM1640 (15JAN04)

18-1810-8


PN=420

Operator Enclosure

18 1810 9

TM1640 (15JAN04)

18-1810-9


PN=421

Operator Enclosure

Remove and Install Wrist Support

TP34968

–UN–01JAN94

18 1810 10


TM1640 (15JAN04)

18-1810-10

TX,18,111318 –19–05JUN98–1/2


PN=422

Operator Enclosure 1—Plate 2—Nut 3—Rod

4—Groove Pin 5—Cotter Pin 6—Bushing

7—Lock Washer 8—Nut 9—Spring

10—Washer 11—Nut 12—Wrist Support Assembly

TX,18,111318 –19–05JUN98–2/2

18 1810 11

TM1640 (15JAN04)

18-1810-11


PN=423

Operator Enclosure

18 1810 12

TM1640 (15JAN04)

18-1810-12


PN=424

Group 1821

Seat and Seat Belts Disassemble and Assemble Seat Belt

TP55745

–UN–26NOV97

18 1821 1

1—Seat Belt

2—Hardware Kit

3—Cover

4—Screw (4 used)

TX,1821,RB205 –19–31MAR99–1/1

TM1640 (15JAN04)

18-1821-1


PN=425

Seat and Seat Belts

Disassemble and Assemble Seat

TP55557

–UN–12JUN97

18 1821 2

1—Armrest 2—Support Bracket 3—Seat Back

4—Extension 5—Support Bracket 6—Armrest

7—Seat Suspension 8—Cushion

9—Seat and Suspension Assembly

TX,18,1111073 –19–18FEB99–1/1

TM1640 (15JAN04)

18-1821-2


PN=426

Group 1822

Steps and Handholds

18 1822 1

TM1640 (15JAN04)

18-1822-1


PN=427

Steps and Handholds

Remove and Install Access Platform and Steps

TP55779

–UN–08JAN98

18 1822 2


TM1640 (15JAN04)

18-1822-2

TX,18,1111062 –19–18FEB99–1/2


PN=428

Steps and Handholds 1—Platform 2—Screw (4 used)

3—Strap (2 used) 4—Step

5—Strap (4 used) 6—Screw (8 used)

7—Lock Nut (8 used) 8—Washer (4 used)

TX,18,1111062 –19–18FEB99–2/2

18 1822 3

TM1640 (15JAN04)

18-1822-3


PN=429

Steps and Handholds

Remove and Install Engine Compartment Step

TP60270

–UN–18MAR98

18 1822 4

1—Lock Nut (8 used) 2—Strap (2 used)

3—Strap (4 used)

4—Screw (8 used)

5—Step TX,18,1111063 –19–18FEB99–1/1

TM1640 (15JAN04)

18-1822-4


PN=430

Steps and Handholds

Remove and Install Mounted Step

TP55693

–UN–14OCT97

18 1822 5

1—Step 2—Washer (4 used)

3—Screw (4 used) 4—Screw (8 used)

5—Strap (4 used) 6—Lock Nut (8 used)

7—Strap (2 used) 8—Step TX,18,1111074 –19–18FEB99–1/1

TM1640 (15JAN04)

18-1822-5


PN=431

Steps and Handholds

18 1822 6

TM1640 (15JAN04)

18-1822-6


PN=432

Group 1830

Heating and Air Conditioning Essential Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC).


CED,OUOE003,2710 –19–31MAR99–1/10

18 1830 1

T7530AZ –UN–29MAY91

Vacuum Pump . . . . . . . . . . . . . . . . . . . . . D05267ST To evacuate air conditioning system.

CED,OUOE003,2710 –19–31MAR99–2/10

R134a Refrigerant Recovery/Recycling and Charging Station . . . . . . . . . . . . . . . . . . . . . . . . . . . JT020451

RW21613

–UN–17AUG92

Servicing air conditioning system using R134a refrigerant.

1 JT02046 and JT02050 Recovery and Charging Stations can be substituted for the JT02045 Station.

CED,OUOE003,2710 –19–31MAR99–3/10

Air Conditioning Flusher . . . . . . . . . . . . . . . . . JT02075

T109996

–UN–19JUN97

To flush air conditioning system.


TM1640 (15JAN04)

18-1830-1

CED,OUOE003,2710 –19–31MAR99–4/10


PN=433

Heating and Air Conditioning Air Conditioning Flushing Fitting Kit. . . . . . . . . . JT02098

T109995

–UN–19JUN97

Used with JT02075 to flush air conditioning system.

CED,OUOE003,2710 –19–31MAR99–5/10

18 1830 2

RW19934 –UN–19MAY92

A/C Compressor Clutch Spanner . . . . . . . . . . . JDG747 Used to remove compressor clutch.

CED,OUOE003,2710 –19–31MAR99–6/10

Puller Adapter . . . . . . . . . . . . . . . . . . . . . . . JDG220 Used with JDG748 and JDG771 to remove compressor pulley. CED,OUOE003,2710 –19–31MAR99–7/10 RW19935 –UN–19MAY92

Jaws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG748 Used with JDG220 and JDG771 to remove compressor pulley. CED,OUOE003,2710 –19–31MAR99–8/10

Hub Protector . . . . . . . . . . . . . . . . . . . . . . . . JDG771 Used with JDG220 and JDG748 to remove compressor pulley. CED,OUOE003,2710 –19–31MAR99–9/10 RW19943 –UN–19MAY92

Compressor Seal Protector . . . . . . . . . . . . . . . JDG746 Used to install seal on compressor.

CED,OUOE003,2710 –19–31MAR99–10/10

TM1640 (15JAN04)

18-1830-2


PN=434

Heating and Air Conditioning



CED,OUOE003,2711 –19–31MAR99–1/4

18 1830 3

Manifold Pressure Gauge Assembly . . . . . . . . . JT02051 To purge air conditioner system.

CED,OUOE003,2711 –19–31MAR99–2/4

Compressor Holding Fixture . . . . . . . . . . . . . DFRW201 To hold air conditioning compressor during disassembly and assembly.

1 Fabricated tool, dealer made. (See Group 1899 for instructions to make tool.)

CED,OUOE003,2711 –19–31MAR99–3/4

Bench Mounted Holding Fixture . . . . . . . . . . D01006AA Used to hold compressor during repair.

CED,OUOE003,2711 –19–31MAR99–4/4

TM1640 (15JAN04)

18-1830-3


PN=435


Air Conditioning System Fittings Reference Chart

T103692

–UN–16SEP96

18 1830 4

A—Compressor B—Condenser

C—Receiver-Dryer

D—Expansion Valve

E—Evaporator

The JT02098 Flush Fitting Kit contains fittings for flushing or leak testing sections or individual components to the air conditioning system. Following chart lists service fittings used at each specific location.


TM1640 (15JAN04)

18-1830-4

TX,9031,MM2887 –19–12SEP96–1/2


PN=436

Heating and Air Conditioning Location

Size

ServiceGard Number

O-Ring Number

1. Suction Port (F)

7/8—18

JT02099

R113050

2. Discharge Port (F)

3/4—18

JT02100

3. Inlet End (M)

3/4—18

JT02102

R113050

4. Outlet End (F)

3/4—18

JT02100

R113050

5. Inlet Port (M)

3/4—18

JT02102

6. Outlet Port (M)

5/8—18

JT03183

7. Inlet End (F)

5/8—18

JT03188

R10093

8. Outlet End (M)

5/8—18

JT03197

R10093

9. Inlet Port (F)

5/8—18

JT03196 or JT02110

10. Outlet Port (M)

5/8—18

JT03183

11. Inlet End (F)

5/8—18

JT03188

12. Outlet End (M)

5/8—18

JT03183

Compressor Manifold:

Compressor Discharge Hose:

Condenser:

Condenser to Receiver-Dryer Hose: 18 1830 5

Receiver-Dryer:

Receiver-Dryer to Evaporator Hose: R10093

A/C Inlet Tube 13. Inlet End (F)

5/8—18

JT03188

R10093

14. Outlet End (M)

3/8

JT02106 and JT02104

R10093

3/8

JT02103

Expansion Valve: 15. Liquid Inlet (F) 16. Liquid Outlet (F)

1/2

JT02104

19. Gas Inlet (F)

5/8

JT02105

20. Gas Outlet (F)

3/4

JT02147

Evaporator Coil: 17. Inlet Tube (M)

1/2

JT02106 and JT02103

R113050

18. Outlet Tube (M)

5/8

JT02106 and JT02105

R33259

21. Inlet End (M)

3/4

TEV and JT02105

T143169

22. Outlet End (F)

1-1/16—14

Not Available

T143169

A/C Outlet Tube:

Evaporator to Compressor Hose 23. Inlet End (M)

1-1/16—14

Not Available

24. Outlet End (M)

7/8—18

JT02101

R33259

TX,9031,MM2887 –19–12SEP96–2/2

TM1640 (15JAN04)

18-1830-5


PN=437


Other Material

18 1830 6

Number

Name

Use

TY16134 (U.S.)

R134a Flushing Solvent

Flush R134a air conditioning system.

TY22025 (8.5 oz) (U.S.)

R134a Compressor Oil

Lubricate R134a air conditioning system. Lubricate compressor O-rings, gaskets, and lip seal during assembly.

TY15949 (12 oz) (U.S.)

R134a Refrigerant

Charge R134a air conditioning system.

TY15950 (15 lb) (U.S.)

R134a Refrigerant


TY15951 (30 lb) (U.S.)

R134a Refrigerant


CED,OUOE003,2712 –19–31MAR99–1/1

Specifications Item

Measurement

Specification

Switch Opens

Temperature

-0.56° ± 0.84°C (31° ± 1.5°F)

Switch Closes

Temperature

-2.22° ± 0.84°C (36° ± 1.5°F)

Compressor Through Bolt

Torque

26 N•m (19 lb-ft)

Compressor Suction Line

Torque

31 N•m (23 lb-ft)

Compressor Discharge Line

Torque

22 •m (16 lb-ft)

Clutch Shaft Bolt

Torque

14 N•m (120 lb-in.)

Clutch Hub

Clearance

0.35—0.65 mm (0.014—0.026 in)

Compressor Manifold Cap Screw

Torque

26 N•m (19 lb-ft)

Freeze Control Switch Test

Compressor

CED,OUOE003,2713 –19–31MAR99–1/1

TM1640 (15JAN04)

18-1830-6


PN=438


Refrigerant Theory of Operation The compressor (G) draws low pressure gas (H) from the evaporator (I) and compresses it into high pressure gas (F). This causes the temperature of the refrigerant to rise higher than that of the outside air. High pressure gas leaves the compressor and is sensed by the high pressure switch (K). The switch monitors refrigerant pressure. If the pressure becomes too high, the switch will open and stop the compressor, interrupting the cycle. As the high pressure gas flows through the condenser (E), heat is removed and transferred to the outside air being drawn through the condenser core by the condenser fan (D). Cooling the refrigerant causes it to condense and it leaves the condenser as a high pressure liquid (C). The high pressure liquid flows into the receiver-dryer (B) where moisture and contaminants (acid, solids, etc.) are removed. The receiver-dryer also acts as a reservoir for refrigerant. The refrigerant flows from the receiver-dryer to the expansion valve (J) and is sensed by the low pressure switch (A). The switch monitors refrigerant pressure. If the pressure becomes too low from refrigerant loss, the switch will open and stop the compressor, interrupting the cycle. The actual cooling and drying of cab air takes place at the evaporator. Flow of the high pressure liquid refrigerant is controlled by the expansion valve. The expansion valve causes the temperature and pressure of the refrigerant to drop, where it becomes a low pressure liquid (L). The expansion valve is a

diaphragm-type valve that uses a variable orifice to control the flow of high pressure liquid refrigerant into the evaporator to maintain a constant pressure and temperature. (See Expansion Valve Operation in this group for additional information on theory of operation.) The blower motor (N) pulls a mixture of warm cab and outside air through the evaporator where it is cooled by the refrigerant. The heat absorbed by the evaporator causes the refrigerant to vaporize into a low pressure gas. A freeze control switch (M) senses temperature of the evaporator coil through a refrigerant filled capillary tube. The switch closes when the evaporator is above the switch setting and opens when the evaporator is cooled to the switch setting. The switch has a low temperature setting that prevents the evaporator from becoming cold enough to freeze moisture that condenses on the coil. Cab temperature is controlled by reheating the conditioned air by passing it through the heater coil. The heater coil temperature is controlled by regulating the amount of water flow through the heater coil with the water valve. The moisture, from the warm air, is condensed as it contacts the cool evaporator coil during the cooling process and is drained away through drain tubes connected to the drain pan under the evaporator. With the cab air cooled and dehumidified, the refrigerant cycle is complete.


TM1640 (15JAN04)

18-1830-7

TX,05,MM2873 –19–18FEB99–1/2


PN=439

18 1830 7


T103906

–19–06NOV96

18 1830 8

L—Low Pressure Switch

TX,05,MM2873 –19–18FEB99–2/2

TM1640 (15JAN04)

18-1830-8


PN=440


R134a Refrigerant Cautions CAUTION: DO NOT allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. If liquid refrigerant contacts eyes or skin, DO NOT rub the area. Splash large amounts of COOL water on affected area. Go to a physician or hospital immediately for treatment. DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element and lighted smoking materials.

develop high pressure which can burst the container. Keep refrigerant containers away from heat sources. Store refrigerant in a cool place. DO NOT handle damp refrigerant container with your bare hands. Skin may freeze to container. Wear gloves. If skin freezes to container, pour COOL water over container to free the skin. Go to a physician or hospital immediately for treatment.

DO NOT heat refrigerant over 52°C (125°F) in a closed container. Heated refrigerant will

TX,9031,SS3564 –19–11SEP96–1/1

TM1640 (15JAN04)

18-1830-9


PN=441

18 1830 9


R134a Compressor Oil Charge Check Remove compressor if refrigerant is leaking from its seals, and repair is needed, or if compressor has failed. See Remove and Install Compressor in this group.

18 1830 10

3. Flush the complete system with TY16134 air conditioning flushing solvent. Go to Air Conditioning System Cleaning Procedures in this group.

Drain oil from the compressor and record the amount. See Compressor Oil Removal procedure in Group 9031-20.

4. If the compressor is serviceable, pour flushing solvent in the manifold ports and internally wash out the old oil. Go to Air Conditioning System Cleaning Procedures in this group.

NOTE: Drain oil and save if this is a new compressor.

5. Install a new receiver-dryer.

If the oil drained from a compressor removed from operation is very black or the amount of oil is less than 6 mL (0.2 fl oz), perform the following:

6. Install required amount of TY22025 refrigerant oil in the compressor. (See R134a Component Oil Charge in this group.)

1. Remove and discard the receiver-dryer. Go to Remove and Install Receiver-Dryer and Condenser in this group.

7. Connect all components, evacuate and charge the system. Go to Evacuate R134a System and Charge R134a System in this group.

2. Remove, clean, but do not disassemble the expansion valve. Go to Remove and Install Expansion Valve in this group.

TX,9031,SS4004 –19–22APR99–1/1

TM1640 (15JAN04)

18-1830-10


PN=442


R134a Compressor Oil Removal 1. Remove compressor from machine. See Remove and Install Compressor in this group. 2. Remove inlet/outlet manifold from compressor, and clutch dust cover. 3. Drain oil into graduated container while rotating compressor shaft. 4. Record measured oil and discard oil properly. 18 1830 11

5. Install new oil. See R134a Component Oil Charge in this group. 6. Install compressor. See Remove and Install Compressor in this group.

TX,9031,SS3593 –19–22APR99–1/1

TM1640 (15JAN04)

18-1830-11


PN=443


R134a Component Oil Charge CAUTION: All new compressors are charged with a mixture of nitrogen, R134a refrigerant and TY22025 (R134a) refrigerant oil. Wear safety goggles and discharge the compressor slowly to avoid possible injury. Compressors can be divided into three categories when determining the correct oil charge for the system.

18 1830 12

• New compressor from parts depot • Used compressor removed from operation • Compressor internally washed with flushing solvent Use the following procedure to determine the amount of system oil charge prior to installation of compressor on a machine. 1. When the complete system, lines, and components were flushed add the correct amount of oil as described. • New compressor from parts depot contains the amount of new oil of 230 ± 20 mL (7.7 ± .7 fl oz). System requires an additional amount of new oil of 135 mL (4.58 fl oz) of new oil. • Used compressor removed from operation, oil drained, and flushed requires 365 mL (12.35 fl oz) of new oil.

• Used compressor removed from operation and oil drained. (See Compressor Oil Removal procedure in this group.) Add 45 mL (1.5 fl oz) of new oil. • Used compressor removed from operation, oil drained, and flushed. Add 60 mL (2.0 fl oz) of new oil.

NOTE: Components listed below which have been removed, drained or flushed, require the removal of the compressor to determine the correct oil charge. Use the following chart as a guide for adding oil to components: Evaporator

158 mL (5.4 fl oz)

Condenser

70 mL (2.4 fl oz)

Receiver-Dryer

37 mL (1.25 fl oz)

Hoses

73 mL (2.5 fl oz)

NOTE: Hoses = 3 mL per 30 cm (0.1 fl oz per ft). Approximate total length equals 727 cm (24 ft) If any section of hose is removed and flushed or replaced, measure the length of hose and use the formula to determine the correct amount of oil to be added.

2. When the complete system was not flushed add the correct amount of oil for the compressor plus the amount of oil for each component that was serviced. • New compressor from parts depot, drain and return 45 mL (1.5 fl oz) of oil to the compressor. (See Compressor Oil Removal procedure in this group.)

CAUTION: DO NOT leave the system or R134a compressor oil containers open. This oil easily absorbs moisture. DO NOT spill R134a compressor oil on acrylic or ABS plastic. This oil will deteriorate these materials rapidly. Identify R134a oil containers and measures to eliminate accidental mixing of different oils.

TX,1830,111266 –19–28SEP98–1/1

TM1640 (15JAN04)

18-1830-12


PN=444


Leak Testing 1. Inspect all lines, fittings and components for oily or dusty spots. When refrigerant leaks from the system, a small amount of oil is carried out with it.

3. If a leak detector is used, move the leak detector probe under the hoses and around the connections at a rate of 25 mm (1 in.) per second.

2. A soap and water solution can be sprayed on the components in the system to form bubbles at the source of the leak.

4. Some Freon manufacturers add dye to Freon to aid in leak detection.

TX,1830,MM3175 –19–19OCT96–1/1

18 1830 13

Refrigerant Hoses and Tubing Inspection IMPORTANT: Hose used for air conditioning systems contains special barriers in its walls to prevent migration of refrigerant gas. DO NOT use hydraulic hoses as replacement hoses in the air conditioning system. Use ONLY certified hose meeting SAE J51b requirements. When a component is disconnected from the system, special care should be given to inspecting hoses and tubing for moisture, grease, dirt, rust, or other foreign

material. If such contamination is present in hoses, tubing, or fittings and cannot be removed by cleaning, then replace parts. Fittings that have grease or dirt on them should be wiped clean with a cloth dampened with alcohol. Chlorinated solvents (such as trichloroethylene) are contaminants, and must not be used for cleaning. To assist in making leak-proof joints in R134a systems, use a small amount of clean polyakyleneglycol (PAG) refrigerant oil on all hoses and tube connections. Dip O-rings in PAG oil before assembly.

TX,1830,MM3176 –19–19OCT96–1/1

TM1640 (15JAN04)

18-1830-13


PN=445


R134a Refrigerant, Recovery, Recycling and Charging Station Installation Procedure ESSENTIAL TOOLS JT02045a R134a Refrigerant Recovery/Recycling and Charging Station a

JT02046 and JT02050 Recovery and Charging Stations can be substituted for the JT02045 Station.

CAUTION: Do not remove high pressure relief valve (A). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils.

–19–22FEB95

1. Close both high and low pressure valves on refrigerant recovery, recycling and charging station (H). 2. Remove cap from low pressure test port (G). 3. Connect low pressure blue hose (D) from refrigerant recovery, recycling and charging station (H) to low pressure test port (G) on compressor. 4. Connect high pressure red hose (C) to high pressure quick disconnect (B). 5. Follow the manufactures instructions when using the refrigerant recovery, recycling and charging station.

T8422AC

18 1830 14

A—High Pressure Relief Valve B—High Pressure Test Port C—Red Hose D—Blue Hose E—High Pressure Hose F—Low Pressure Hose G—Low Pressure Test Port H—Refrigerant Recovery/Recycling and Charging Station

TX,9031,QQ3015 –19–07MAR95–1/1

TM1640 (15JAN04)

18-1830-14


PN=446


Recover R134a System ESSENTIAL TOOLS a

JT02045 R134a Refrigerant Recovery/Recycling and Charging Station a



18 1830 15

–19–22FEB95

NOTE: Run the air conditioning system for three minutes to help in the recovery process. Turn air conditioning system off before proceeding with recovery steps.

T8422AC

1. Connect refrigerant recovery, recycling and charging station. (See installation procedure in this group.) 2. Follow the manufacturer’s instructions when using the refrigerant recovery, recycling and charging station. A—High Pressure Relief Valve B—High Pressure Test Port C—Red Hose D—Blue Hose E—High Pressure Hose F—Low Pressure Hose G—Low Pressure Test Port H—Refrigerant Recovery/Recycling and Charging Station

TX,9031,QQ3016 –19–07OCT98–1/1

TM1640 (15JAN04)

18-1830-15


PN=447


Evacuate R134a System ESSENTIAL TOOLS a

JT02045 R134a Refrigerant Recovery/Recycling and Charging Station D05267ST Vacuum Pump a



–19–22FEB95

Do not run compressor while evacuating. 1. Connect refrigerant recovery, recycling and charging station. (See installation procedure in this group.)

T8422AC

18 1830 16

2. Open low and high pressure valves on refrigerant recovery, recycling and charging station. A—High Pressure Relief Valve B—High Pressure Test Port C—Red Hose D—Blue Hose E—High Pressure Hose F—Low Pressure Hose G—Low Pressure Test Port H—Refrigerant Recovery/Recycling and Charging Station

3. Follow the manufacturer’s instructions and evacuate the system.

NOTE: The vacuum specifications listed are for sea level conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level. 4. Evacuate system until low pressure gauge registers 98 kPa (980 mbar) (29 in. Hg) vacuum. If 98 kPa (980 mbar) (29 in. Hg) vacuum cannot be obtained in 15 minutes, test the system for leaks. (See Leak Testing, 9031-25). Correct any leaks. 5. When vacuum is 98 kPa (980 mbar) (29 in. Hg), close low-side and high-side valves. Turn vacuum pump off.


TM1640 (15JAN04)

18-1830-16

TX,9031,QQ3017 –19–07OCT98–1/2


PN=448

Heating and Air Conditioning 6. If the vacuum decreases more than 3.4 kPa (34 mbar) (1 in. Hg) in 5 minutes, there is a leak in the system. 7. Repair leak. 8. Start to evacuate. 9. Open low-side and high-side valves. 10. Evacuate system for 30 minutes after 98 kPa (980 mbar) (29 in. Hg) vacuum is reached. 11. Close low-side and high-side valves. Stop evacuation. 18 1830 17

12. Charge the system. (See procedure in this group.)

TX,9031,QQ3017 –19–07OCT98–2/2

TM1640 (15JAN04)

18-1830-17


PN=449


Charge R134a System CAUTION: Do not remove high pressure relief valve (A). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils.

2. Evacuate the system. (See Evacuate Air Conditioning System in this group.)

3. Follow the manufacturer’s instructions and charge the system. 4. Add refrigerant until system is charged with 2.381 kg (5.25 lb). 5. Do air conditioner checks and tests in Groups 9031-10 and 9031-25.

–19–22FEB95

NOTE: Before beginning to charge air conditioning system, the following conditions must exist: Engine STOPPED, the pump must be capable of pulling at least 28.6 in. Hg vacuum (sea level). Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.

T8422AC

18 1830 18

1. Connect JT02045 R134a refrigerant recovery, recycling and charging station. (See installation procedure in this group.)

A—High Pressure Relief Valve B—High Pressure Test Port C—Red Hose D—Blue Hose E—High Pressure Hose F—Low Pressure Hose G—Low Pressure Test Port H—Refrigerant Recovery/Recycling and Charging Station

TX,1830,111267 –19–28SEP98–1/1

TM1640 (15JAN04)

18-1830-18


PN=450


Air Conditioner System Cleaning Procedures Flushing: Flushing the system or component is a cleaning process using a liquid solvent to remove oil and debris. Purging is always necessary after flushing to remove solvent from the system or component.

Purging: Purging the system or a component is a cleaning process using a gas to force liquid from the system. Purging alone will not remove refrigerant oil from the system.

Following is a list of situations that require a flushing procedure be done:

Following is a list of situations that require a purging procedure be done:

• The compressor has an internal failure. • No oil remains in used compressor. • Oil drained from compressor appears or smells overheated. • System was contaminated with a mixture of refrigerant oils. • System was left open to the atmosphere long enough for dirt, moisture, or debris to enter the tubing or components. • System has an internal blockage.

• After flushing system with solvent, to prevent oil dilution • System was contaminated with nitrogen or two refrigerants. • System was left open to the atmosphere and flushing could not be performed. • Installation of new lines, condenser, or evaporator was required.

The following solvent is recommended for flushing air conditioner systems. Use only solvents with an equivalent MSDS.

18 1830 19

Evacuating: Evacuating the system is a process to remove air and moisture from the system, creating a vacuum.

• TY16134 John Deere Air Conditioning System Flushing Solvent

TX,1830,MM3158 –19–17OCT96–1/1

TM1640 (15JAN04)

18-1830-19


PN=451


Purge Air Conditioner System IMPORTANT: Air compressors used for purging systems require a water separator. Purging without a separator adds moisture, creating hydrofluoric acid when combined with refrigerant oil. Acid is corrosive to metal tubing. 1. Connect dry nitrogen hose to gauge manifold center hose. 18 1830 20

2. Connect gauge manifold suction hose to compressor suction port, and open valves. 3. Connect gauge manifold discharge hose to compressor discharge post, and open valve. Disconnect discharge hose from gauge manifold to allow purging nitrogen to atmosphere. 4. Open nitrogen tank valve and adjust regulator to 275 kPa (40 psi) (2.75 bar). Purge system for two minutes. Disconnect nitrogen supply. 5. Evacuate system. (See procedure in this group.)

TX,1830,MM3156 –19–14OCT98–1/1

TM1640 (15JAN04)

18-1830-20


PN=452


Flush Air Conditioner System Add flushing solvent to system with JT02075 Flusher and JT02098 Fitting Kit.

NOTE: Flushing can be performed on vehicle.

IMPORTANT: DO NOT attempt to flush through compressor or receiver-dryer. Flushing through expansion valve is acceptable if refrigerant oil has normal odor and appearance.

1. Recover refrigerant. (See procedure in this group.) 6. To Flush/Purge Condenser: 2. Remove compressor and measure oil drained from both manifold ports.

Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter.

3. Clean compressor as follows: a. Pour 240 mL (8 fl oz) of flushing solvent into suction port and 120 mL (4 fl oz) into discharge port. Plug both ports in compressor manifold using JT02099 and JT02100 with JT03194 Caps. b. Turn compressor end for end and roll it side to side. c. Remove both plugs from manifold ports and drain solvent from compressor. d. Connect battery power to compressor clutch coil. Rotate pulley at least five revolutions to move solvent out of cylinders.

18 1830 21

7. Attach a return hose and aerator nozzle to outlet end of receiver-dryer inlet hose using JT03197 reducer. Put nozzle in container to collect flushing solvent. 8. Fill flusher tank with 4 L (1 gal) of solvent and fasten all connections.

NOTE: Air pressure must be at least 620 kPa (6.2 bar) (90 psi) for flushing and purging. 9. Connect a supply line of moisture-free compressed air or dry nitrogen to flusher air valve.

e. Invert compressor, roll end for end, and side to side. Drain thoroughly.

10. Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing stops. Additional flushing cycles are required if system is heavily contaminated with burned oil or metal particles.

f. Let compressor sit inverted for three to five minutes.

NOTE: Purging the condenser circuit takes 10—12 minutes to thoroughly remove solvent.

g. Repeat previous two steps at least three times.

11. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard; continue purging until cardboard is dry.

4. Remove and discard receiver-dryer. 5. Divide system into two circuits:

12. Go to step 13 to flush evaporator. Go to step 22 if evaporator does not require flushing.

a. Condenser, including inlet and outlet hoses. (Steps 6—12)

13. To Flush Evaporator:

b. Evaporator, including inlet and outlet hoses. (Steps 13—26)


TM1640 (15JAN04)

18-1830-21

TX,1830,MM3159 –19–14OCT98–1/2


PN=453

Heating and Air Conditioning If system is contaminated with burned refrigerant oil or debris, remove and bench flush evaporator. Go to step 18 to flush evaporator through expansion valve, if oil appears normal. Remove evaporator. (See procedure in this group.) 14. Force flushing solvent through evaporator inlet with compressed air. 15. Purge system until dry.

18 1830 22

20. Repeat Steps 8, 9 and 10 to flush evaporator.

NOTE: Purging the evaporator circuit takes 12—15 minutes to thoroughly remove solvent. 21. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard. Continue purging until cardboard is dry.

16. Reinstall evaporator.

22. Install a new receiver-dryer compatible with R134a refrigerant. Fasten connections and mounting bracket.

17. Go to Step 22.

23. Add required oil. (See procedure in this group.)

18. To Flush Evaporator Through Expansion Valve:

24. Install compressor, and connect refrigerant lines to manifold.

Connect flusher outlet hose to connection of receiver-dryer outlet hose using JT03188 Adapter.

25. Connect clutch coil wire. Install drive belt. 26. Purge system. (See procedure in this group.)

19. Attach a hose and aerator nozzle to compressor inlet line using JT02101 Adapter. Put nozzle in a container to collect solvent.

TX,1830,MM3159 –19–14OCT98–2/2

TM1640 (15JAN04)

18-1830-22


PN=454


18 1830 23

TM1640 (15JAN04)

18-1830-23


PN=455


Blower/Air Conditioner Harness (W20) Component Location T110709 –19–04SEP97

TX,1830,111268 –19–22OCT96–1/2

TM1640 (15JAN04)

18-1830-24


PN=456

Heating and Air Conditioning A—Temperature Control Switch B—Blower Speed Switch (S21) C—Air Conditioning On/Off Switch (S22) D—Pressurizer Motor 7.5A Fuse (F20) E—Blower/Pressurizer Motor Relay (K19)

F—Blower Motor 25A Fuse (F19) G—Receiver/Dryer H—Air Conditioning Clutch 1 A Diode (V11) I—Condenser J—Compressor Relief Valve K—Air Conditioning Compressor Clutch (Y16)

L—Expansion Valve M—Air Conditioning Low Pressure Switch (B36) N—Heater Valve O—Pressurizer Motor (M7) P—Fresh Air Filter Q—Recirculating Air Filter R—Air Conditioning High Pressure Switch (B37)

S—Heating/Evaporator Coil T—Freeze Control Switch (B35) U—Air Ducts V—Blower Speed Resistor (R3) W—Main Blower Motor (M6) X—Service and Charge Port

TX,1830,111268 –19–22OCT96–2/2

18 1830 25

TM1640 (15JAN04)

18-1830-25


PN=457


Connectors for Blower/Air Conditioner Harness (W20)

T101385

–19–31JUL96

18 1830 26

TX,1830,MM3178 –19–22OCT96–1/1

TM1640 (15JAN04)

18-1830-26


PN=458


18 1830 27

TM1640 (15JAN04)

18-1830-27


PN=459


Air Conditioning Module With Heater/Evaporator Coil

TP60423

–UN–18JUN98

18 1830 28


TM1640 (15JAN04)

18-1830-28

CED,OUOE003,1031 –19–16DEC98–1/2


PN=460

Heating and Air Conditioning 1—Nut (14 used) 2—Seal (2 used) 3—Impeller (2 used) 4—Pressurizer Blower Motor 5—Cap Screw (14 used) 6—Tube (2 used) 7—Screw (2 used) 8—Clamp (8 used) 9—Tube (2 used) 10—Bracket 11—Air Duct 12—Tie Band (4 used) 13—Clip (2 used) 14—Thermostat 15—Air Duct 16—Air Plenum 17—Screw (2 used) 18—Resistor

19—Cover 20—Housing 21—Screw (12 used) 22—Isolator (3 used) 23—Air Filter 24—Nut 25—Housing 26—Latch (2 used) 27—Rivet (4 used) 28—Filter Element 29—AC/Heater Main Blower Motor 30—Seal 31—Heater/Evaporator Coil 32—Air Duct 33—Valve Hose 34—Knob 35—Bolt (2 used)

36—Heater Hose 37—Expansion Valve Plate 38—Housing 39—Heater Valve 40—Expansion Valve 41—Valve Hose 42—Tube 43—Clamp (4 used) 44—Heater Tube 45—A/C Suction Tube 46—A/C Inlet Tube 47—A/C High Pressure Switch 48—Cap Screw 49—Adapter Plate 50—Screw (4 used) 51—Plug (2 used) 52—O-Ring 53—Ring

54—O-Ring (3 used) 55—O-Ring (3 used) 56—A/C Lower Pressure Switch 57—Grommet 58—Grommet 59—Clip 60—Cable 61—Lock Washer 62—Nut 63—Knob 64—Control 65—Seal 66—Bushing 67—Gasket 68—Hose (As Required) 69—Clamp 70—Blower

18 1830 29

CED,OUOE003,1031 –19–16DEC98–2/2

TM1640 (15JAN04)

18-1830-29


PN=461


Remove and Install Heater/Evaporator Coil

T112116

–UN–04NOV97

18 1830 30

A—Pressurizer Motor B—Inlet Plenum C—Expansion Valve D—Freeze Control Switch

E—Resistor F—Main Blower Motor G—Heater/Evaporator Coil Top Cover

1. Recover refrigerant from the system. (See Recover R134a System in this group.) 2. Open left-hand cab service door. Remove fresh air filter. (See Remove Fresh Air Filter in this group.)

H—Cap Screws I—Lower Housing J—Heater/Evaporator Coil K—Heater Hoses (2 used)

L—Heater Valve M—Air Conditioning Lines N—Housing O—Knob

8. Remove cab left-hand shelf. 9. Remove cap screws from heater/evaporator coil top cover (G); remove cover. 10. Remove freeze control switch (D) probe from coil.

3. Remove knob (O) to remove housing (N). 4. Remove rear cover behind seat.

11. Remove upper two cap screws from main blower motor (F).

5. Remove seat cap screws and move seat forward to access air conditioning/heater components.

12. Disconnect wire harness from freeze control switch (D) and resistor (E).

6. Remove cab recirculating filter. (See Remove Recirculating Filter in this group.)

13. Shut off heater hose shut-off valves on engine.

7. Remove upper two cap screws attaching inlet plenum (B) to heater/evaporator coil top cover (G).

14. Disconnect air conditioning lines (M) from expansion valve (C) and heater hoses (K) from coil.


TM1640 (15JAN04)

18-1830-30

TX,18,1111066 –19–18FEB99–1/4


PN=462

Heating and Air Conditioning 15. Remove expansion valve.

19. Install heater/evaporator coil.

16. Remove heater/evaporator coil (J).

20. Connect air conditioner lines and heater hoses.

17. Install expansion valve on heater/evaporator coil.

21. Open heater hose shut-off valves on engine.

18. Check lower housing (I) to make sure drain tube is not plugged.


TX,18,1111066 –19–18FEB99–2/4

18 1830 31

TM1640 (15JAN04)

18-1830-31


PN=463

Heating and Air Conditioning 22. Mount switch (A) to module. 23. Route freeze control switch line (B) as shown. Route under foam on module.

18 1830 32

T110752D

–UN–08AUG97

IMPORTANT: Freeze switch line is a capillary tube filled with refrigerant. A generous bend radius is required to ensure proper operation. DO NOT kink freeze switch line when bending. 24. Carefully bend the end of the freeze control switch line at a 90 degree angle. Insert last 88.9 mm (3.5 in.) into evaporator core starting 190 mm (7.5 in.) from the left end and 114 mm (4.5 in.) from the bottom. Push freeze control switch line down into evaporator core at a 45 degree angle. Freeze switch line should slide smoothly between the tubes in the evaporator core.

A—Switch B—Freeze Control Switch Line

25. Connect wire harness to freeze control switch and resistor. 26. Install main blower motor. 27. Install evaporator top cover and cab left-hand shelf. 28. Install inlet plenum to heater/evaporator coil top cover. 29. Install cab recirculating filter. 30. Install rear cover behind seat. 31. Move seat back and install and tighten cap screws. 32. Install housing and knob. 33. Install fresh air filter. 34. If the system is contaminated, each component in the system must be flushed and purged individually. (See procedures in this group.) 35. Drain oil from compressor. (See procedure in this group.)


TM1640 (15JAN04)

18-1830-32

TX,18,1111066 –19–18FEB99–3/4


PN=464

Heating and Air Conditioning 36. If system was not completely flushed, see flushing procedure in this group. 37. Purge, evacuate, and charge the system. (See procedures in this group.)

TX,18,1111066 –19–18FEB99–4/4

18 1830 33

Remove and Install Expansion Valve 1. Recover refrigerant from the system. (See Recover R134a System in this group.) 2. Open left-hand cab service door. Remove fresh air filter. (See Remove Fresh Air Filter in this group.) 3. Remove pressurizer motor (A). (See Pressurizer Motor, Remove in this group.) 4. Disconnect air conditioning lines (C) from expansion valve. 5. Remove expansion valve (B) and replace. 6. Apply refrigerant oil to new O-rings. Install expansion valve and new O-rings.

–UN–04NOV97

7. Connect air conditioning lines to expansion valve. 8. Install pressurizer motor.

10. Purge, evacuate, and charge the system. (See procedures in this group.)

T112119

9. Install fresh air filter. (See Install Fresh Air Filter in this group.)

A—Pressurizer Motor B—Expansion Valve C—Air Conditioning Lines

TX,18,1111067 –19–18FEB99–1/1

TM1640 (15JAN04)

18-1830-33


PN=465


Remove and Install Freeze Control Switch 1. Remove rear cover behind seat.

–UN–23SEP96

2. Remove probe (B) of freeze control switch (A) from heater/evaporator coil.

T103844

3. Disconnect wire leads from freeze control switch and remove switch from cover. 4. Test freeze control switch. (See Bench Test Freeze Control Switch in this group.) A—Freeze Control Switch B—Probe

TX,1830,MM3162 –19–18FEB99–1/2

5. Attach freeze control switch (A) to heater/evaporator coil top cover. 6. Connect wiring leads to freeze control switch. –UN–08AUG97

7. Route freeze control switch line (B) as shown. Route under foam on module. IMPORTANT: Freeze switch line is a capillary tube filled with refrigerant. A generous bend radius is required to ensure proper operation. DO NOT kink freeze switch line when bending. 8. Carefully bend the end of the freeze control switch line at a 90 degree angle. Insert last 88.9 mm (3.5 in.) into evaporator core starting 190 mm (7.5 in.) from the left end and 114 mm (4.5 in.) from the bottom. Push freeze control switch line down into evaporator core at a 45 degree angle. Freeze switch line should slide smoothly between the tubes in the evaporator core.

T110752D

18 1830 34

A—Freeze Control Switch B—Freeze Control Switch Line

9. Install rear cover behind seat.

TX,1830,MM3162 –19–18FEB99–2/2

TM1640 (15JAN04)

18-1830-34


PN=466


Bench Test Freeze Control Switch

2. Switch must open at test specification. Freeze Control Switch Test—Specification Switch Opens—Temperature ...................... -0.56° ± 0.84°C (31° ± 1.5°F)

T83921

3. Warm the water.

–UN–08NOV88

1. Connect ohmmeter to freeze control switch terminals. Put end of probe into an ice and salt water solution.

4. Switch must close at test specification. 18 1830 35

Freeze Control Switch Test—Specification Switch Closes—Temperature ...................... -2.22° ± 0.84°C (36° ± 1.5°F)

If switch operates within specifications, reinstall switch and connect leads. If switch does not operate within specifications, replace with new switch and connect leads.

TX,1830,MM3163 –19–14OCT98–1/1

TM1640 (15JAN04)

18-1830-35


PN=467


Remove and Install Heater Control Valve 1. Open left-hand side door. Remove cab fresh air filter housing. (See Remove Fresh Air Filter in this group.) 2. Shut off the heater hose shut-off valves on the engine block. 3. Remove rear cover behind seat. 4. Disconnect temperature control switch cable from heater control valve. 5. Disconnect hose (A). 6. Remove heater control valve (B) and test. (See Heater Control Valve Leak Check in this group.)

–UN–04NOV97

7. Inspect heater hoses and replace as required. IMPORTANT: Heater valve will leak if arrow on valve is not in the direction of coolant flow. 8. Install heater control valve with flow arrow (direction of coolant flow) on valve towards heater inlet (bottom port). 9. Connect the temperature control cable. Tighten all hose connections.

T112118

18 1830 36

A—Hose B—Heater Control Valve

10. Install rear cover behind seat. 11. Turn on the heater hose shut-off valve. 12. Install cab fresh air filter housing. 13. Add coolant to the radiator. Start engine and run the heating system to check for leaks. 14. Add more coolant to account for coolant in the heater circuit.

TX,18,1111069 –19–04NOV97–1/1

TM1640 (15JAN04)

18-1830-36


PN=468


Heater Control Valve Leak Check 1. Connect water pressure hose to control valve inlet and turn the valve arm to the closed position. 2. Check for leakage from the valve outlet.

NOTE: The heater control valve is not serviceable. 3. Replace heater control valve if required.

TX,1830,MM3165 –19–09JUN98–1/1

18 1830 37

T112116

–UN–04NOV97

Remove and Install Main Blower Assembly

A—Pressurizer Motor B—Inlet Air Plenum C—Expansion Valve D—Freeze Control Switch

E—Resistor F—Main Blower Motor G—Heater/Evaporator Upper Housing

H—Cap Screws I—Lower Housing J—Heater/Evaporator Coils K—Heater Hoses Continued on next page

TM1640 (15JAN04)

18-1830-37

L—Heater Valve M—Air Conditioning Lines N—Housing O—Knob TX,18,1111130 –19–18FEB99–1/5


PN=469

Heating and Air Conditioning 1. Park machine on a flat level surface, engine “OFF”. 2. Remove cab recirculation filter (P). 3. Remove seat. Disconnect wiring connector if machine is equipped with an air ride seat. 4. Remove seat base. 5. Remove foam cover (Q). 6. Open left rear cab service door. 7. Remove cab access door release rod (S). 8. Remove cab door release (T) from left hand console shelf (R).

–UN–25NOV97

9. Remove left hand side console shelf (R). 10. Remove fresh air filter housing with filter.

T112347B

P—Cab Recirculation Filter Q—Foam Cover R—Left Hand Console Shelf S—Cab Access Door Release Rod T—Cab Door Release

TX,18,1111130 –19–18FEB99–2/5

11. Remove four screws attaching inlet plenum (B) to heater/evaporator coil housing.

–UN–25NOV97

12. Remove hidden screw (U) attaching inlet plenum (B) to cab floor. 13. Disconnect wiring harness from inlet air plenum. 14. Remove inlet air plenum (B).

T112345B

18 1830 38

B—Inlet Air Plenum U—Screw


TM1640 (15JAN04)

18-1830-38

TX,18,1111130 –19–18FEB99–3/5


PN=470

Heating and Air Conditioning 15. Disconnect main blower motor cooling tube (V) from heater/evaporator upper housing (G).

–UN–25NOV97

16. Disconnect wire harness from freeze control switch (D) and resistor (E).

T112346B

17. Remove freeze control switch (D) if equipped with air conditioning. Do not remove thermostat probe from evaporator core. 18. Remove 13 screws from heater/evaporator upper housing (G). Note position of hidden screws (H).

18 1830 39

D—Freeze Control Switch E—Resistor F—Main Blower Motor G—Heater/Evaporator Upper Housing H—Screws I—Lower Housing J—Main Blower Motor Cooling Tube

19. Remove four cap screws from main blower motor (F). 20. Remove upper housing (G) from heater/evaporator core. 21. Remove main blower motor (F). 22. Remove cage fan and clip from old blower motor. 23. Install cage fan and clip on new blower motor assembly. 24. Attach new main blower motor assembly to lower housing (I) using two screws. 25. Check lower housing (I) to make sure drain tube is plugged for the heater unit, or that drain tube is not plugged for the air conditioning unit. 26. Reinstall heater/evaporator core upper housing. 27. Attach two upper screws to main blower motor. 28. Connect main blower motor cooling tube (V) to upper heater/evaporator housing. 29. Reinstall freeze control switch (D) on upper housing (G). 30. Connect wiring harness to resistor (E) and freeze control switch (D). 31. Reinstall inlet air plenum (B) to heater/evaporator housing.


TM1640 (15JAN04)

18-1830-39

TX,18,1111130 –19–18FEB99–4/5


PN=471

Heating and Air Conditioning 32. Reinstall screw (U) to cab floor and reinstall cab recirculation filter. 33. Reinstall fresh air filter housing 34. Reinstall left hand side console shelf. 35. Reinstall cab access door release rod (S). 36. Reinstall cab door release (T) on left hand console shelf (R). 37. Reinstall foam cover (Q) behind seat. 38. Reinstall seat base and seat. Reconnect wiring connector if machine is equipped with an air ride seat.

TX,18,1111130 –19–18FEB99–5/5

Remove and Install Pressurizer Motor Assembly 1. Remove cab left-hand shelf. 2. Disconnect cooling tube (B). 3. Remove four screws from pressurizer motor (A). 4. Disconnect wiring harness from pressurizer motor. 5. Remove and inspect pressurizer motor. 6. Attach pressurizer motor assembly using screws. 7. Install cab left-hand shelf.

–UN–04NOV97

A—Pressurizer Motor B—Cooling Tube

T112120

18 1830 40

TX,18,1111071 –19–18FEB99–1/1

TM1640 (15JAN04)

18-1830-40


PN=472


Remove and Install Receiver-Dryer and Condenser

TP60543

–UN–10NOV98

18 1830 41

1—O-Ring (4 used) 2—Hose 3—Receiver-Dryer 4—Hose

5—Ring 6—Flange Nut (6 used) 7—Washer (21 used) 8—Hinge

9—Vapor Condenser 10—Screw (6 used) 11—Bracket 12—Screw (8 used)


TM1640 (15JAN04)

18-1830-41

13—Washer (3 used) 14—Washer 15—Bracket 16—Screw (2 used)

TX,18,1111095 –19–18FEB99–1/2


PN=473

Heating and Air Conditioning 7. Evacuate and charge the system. (See procedure in this group.)

Receiver-Dryer 1. Recover refrigerant. (See procedure in this group.)

Condenser 2. Discharge the system. 1. Recover refrigerant. (See procedure in this group.) 3. Disconnect lines (1 and 4) from receiver-dryer. 2. Disconnect the condenser-to-compressor hose and condenser-to-receiver-dryer hose.

4. Remove receiver-dryer.

5. Apply refrigerant oil to new O-rings. Remove plugs from receiver-dryer and immediately connect lines (1 and 14).

3. Remove mounting cap screws. Remove condenser. 4. Replace parts as necessary. 5. Install condenser and connect hoses 6. Evacuate and charge the air conditioning system. (See procedure in this group.)

6. Add 15 mL (0.5 fl. oz.) refrigerant oil to system. See procedure in this group.)

TX,18,1111095 –19–18FEB99–2/2

Remove and Install High and Low Pressure Switches 1. Remove left-hand shelf. 2. Remove fresh air filter assembly. (See procedure in this group.)

NOTE: The high pressure switch has a male connector; the low pressure switch has a female connector. 3. Disconnect wiring harness from the high pressure switch (B) and the low pressure switch (A).

NOTE: A Schrader valve is located in the connection to prevent the air conditioning from discharging when the switches are removed.

–UN–12DEC96

4. Remove switches. Inspect and replace as required. A—Low Pressure Switch B—High Pressure Switch

T105454B

18 1830 42

IMPORTANT: A new receiver-dryer must always be installed after purging the system. DO NOT use a flushed or used receiver/dryer. Contamination of system can cause component failure.

TX,18,1111096 –19–18FEB99–1/1

TM1640 (15JAN04)

18-1830-42


PN=474


Remove and Install Fresh Air Filter

–UN–12DEC96

1. Open cab fresh air filter door by pulling up on lever (A) to the left of the operator’s seat.

T105479B

A—Cab Door

TX,18,111479 –19–09JUN98–1/4

18 1830 43

2. Remove filter assembly by turning knob (A).

T103187C

–UN–12DEC96

A—Knob


TM1640 (15JAN04)

18-1830-43

TX,18,111479 –19–09JUN98–2/4


PN=475

Heating and Air Conditioning NOTE: If operating in dusty conditions, cab fresh air filter should be checked and cleaned as necessary. 3. Release clips (B). B—Clip (2 used)

T105493B

–UN–12DEC96

18 1830 44


TM1640 (15JAN04)

18-1830-44

TX,18,111479 –19–09JUN98–3/4


PN=476

Heating and Air Conditioning 4. Remove filter (C). Replace if damaged.

–UN–12DEC96

5. Clean filter in one of these ways:

• Tap filter on a flat surface with the dirty side down. • Use compressed air opposite to the normal air flow. • Wash the filter in warm, soapy water. Flush the filter. Let it dry before using the heater, defroster, or air conditioner.

T105494B

CAUTION: Prevent possible injury from flying chips if compressed air is more than 210 kPa (2.1 bar) (30 psi). Reduce compressed air to less than 210 kPa (2.1 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection. C—Filter

18 1830 45

6. Remove dust from filter housing. IMPORTANT: Do not damage wire harness when installing filter housing. Wiring can get pinched and damaged. 7. Install filter and filter duct work. 8. Install filter housing assembly. Close cab fresh air filter door.

TX,18,111479 –19–09JUN98–4/4

TM1640 (15JAN04)

18-1830-45


PN=477


Remove and Install Recirculating Air Filter NOTE: The cab recirculating air filter is located next to the seat.

–UN–12DEC96

1. Turn latch (A) holding grille. Remove grille. 2. Remove filter.

T105499B

18 1830 46

CAUTION: Reduce compressed air to less than 210 kPa (2 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment, including eye protection. A—Air Filter Latch

3. Clean filter in one of these ways: • Tap it on a flat surface with the dirty side down. • Use compressed air opposite to the normal air flow. • Wash the filter in warm, soapy water. Flush the filter and let it dry before using the air conditioner. 4. Install filter. 5. Install grille.

TX,18,111480 –19–28SEP98–1/1

TM1640 (15JAN04)

18-1830-46


PN=478


18 1830 47

TM1640 (15JAN04)

18-1830-47


PN=479


Remove and Install Compressor

TP60561

–UN–01DEC98

18 1830 48


TM1640 (15JAN04)

18-1830-48

TX,18,1111131 –19–31MAR99–1/2


PN=480

Heating and Air Conditioning 1—O-Ring 2—Hose 3—Clamp 4—Screw 5—Lock Nut 6—Refrigerant Hose

7—Clamp 8—Screw (3 used) 9—Ring 10—O-Ring 11—Compressor

12—Belt 13—Spring Pin (2 used) 14—Screw 15—Screw 16—Plate

1. Recover refrigerant from the system. (See procedure in this group.)

17—Spacer (2 used) 18—Support 19—Tie Band (2 used) 20—Cap 21—Kit

8. Connect wiring lead.

2. Loosen belt adjuster and remove drive belt (12). 3. Disconnect hoses (2 and 6). Remove compressor belt cap screw.

9. If compressor was replaced due to an internal failure, flush and purge each component in the air conditioning system individually. (See procedures in this group.) 10. Add compressor oil. (See procedure in this group.)

4. Disconnect electrical connector. IMPORTANT: Do not flush receiver/dryer or install a used one. Always install a new receiver/dryer.

5. Remove compressor. 6. Install compressor and tighten cap screws. Compressor—Specification Compressor Through Bolt— Torque....................................................................... 26 N•m (19 lb-ft)

7. Reconnect refrigerant lines. Tighten suction line (2) lb-ft) and discharge line (6) fitting.

11. Remove existing receiver/dryer and install a new one. (See procedure in this group.) 12. Evacuate and charge the system. (See procedure in this group.)

Compressor—Specification Compressor Suction Line— Torque....................................................................... 31 N•m (23 lb-ft) Compressor Discharge Line— Torque.......................................................................... 22 •m (16 lb-ft)

TX,18,1111131 –19–31MAR99–2/2

TM1640 (15JAN04)

18-1830-49


PN=481

18 1830 49


Disassemble and Assemble Compressor Clutch—R134a

T107716

–UN–09MAY97

RW21157

–UN–24JUN92

18 1830 50

A—JDG747 Compressor Clutch Spanner B—Clutch Shaft Bolt

C—Clutch Hub D—Pulley Snap Ring

E—Pulley F—Clutch Coil Snap Ring

1. Mount compressor on DFRW20 Compressor Holding Fixture using two 6 in. x 1/4 in. eye bolts with nuts as illustrated.

G—Clutch Coil H—Shim (As Required)

3. Hold the clutch hub using JDG747 Compressor Clutch Spanner (A) and remove the clutch shaft bolt (B).

2. Remove dust cover.


TM1640 (15JAN04)

18-1830-50

TX,18,DY5297 –19–26OCT98–1/2


PN=482

Heating and Air Conditioning 4. Remove the clutch hub (C). Remove the shims (H) from the clutch hub and save for installation. 5. Remove and discard snap ring (D). Remove the pulley (E) using a plastic hammer or JDG220 Puller, JDG748 Jaws, and JDG771 Hub Protector. 6. Disconnect the clutch coil lead wire. Remove and discard the snap ring (F) and remove the clutch coil (G).

NOTE: The bearing in the pulley is NOT serviceable.

8. Install the clutch coil and new snap ring with flat side of the snap ring down. Connect the clutch coil lead wire. 9. Install the pulley and new snap ring with flat side of the snap ring down. Apply grease to the shims (H) and install to the clutch hub. 10. Install clutch hub and shaft bolt and tighten. Install dust cover. Compressor—Specification Clutch Shaft Bolt—Torque ..................................... 14 N•m (120 lb-in.) 18 1830 51

7. Check pulley bearing operation. Replace pulley and bearing as required.

TX,18,DY5297 –19–26OCT98–2/2

Check Clutch Hub Clearance—R134a NOTE: The clutch coil is NOT polarity sensitive. 1. Check pulley-to-clutch hub clearance using a dial indicator. Mount the gauge to the pulley as illustrated and connect a set of jumper wires from the compressor to a 12V battery. 2. Rotate the pulley and check clearance in three equally spaced locations around the clutch hub. Add or remove shims as required. Compressor—Specification Clutch Hub—Clearance ........................ 0.35—0.65 mm (0.014—0.026 in)

RW21159

Compressor—Specification Clutch Shaft Bolt—Torque............................................ 14 N•m (120 lb-in.)

–UN–24JUN92

3. Tighten clutch shaft bolt after correct clearance is obtained.

TX,1830,BA636 –19–14OCT98–1/1

TM1640 (15JAN04)

18-1830-51


PN=483


Inspect Compressor Manifold—R134a 1. Remove cap screws (A) and the manifold (B). 2. Remove and discard seal (C). Inspect porting surfaces. 3. Lubricate and install a new seal (C). 4. Install manifold and tighten cap screws.

A—Manifold Cap Screw B—Manifold C—Manifold Seal

RW21160

18 1830 52

–UN–24JUN92

Compressor—Specification Compressor Manifold Cap Screw—Torque ................................................................ 26 N•m (19 lb-ft)

TX,1830,BA637 –19–18FEB99–1/1

TM1640 (15JAN04)

18-1830-52


PN=484


Disassemble, Inspect and Assemble Compressor—R134a

RW21161

–UN–24JUN92

18 1830 53

A—Rear Pins B—Rear Housing C—Rear Gasket D—Rear Discharge Reed Valve E—Rear Valve Plate F—Rear Suction Reed Valve

G—Rear O-Ring H—Front O-Ring I—Front Suction Reed Valve J—Front Valve Plate K—Front Discharge Reed Valve

1. Clean the compressor using solvent before disassembly. Mount compressor on holding fixture and remove clutch. (See Disassemble and Assemble Compressor Clutch R134a in this group.) IMPORTANT: When removing front and rear housing, be careful NOT to damage the sealing surfaces. 2. Disassemble the compressor as illustrated and discard the O-rings, gaskets, lip seal, snap ring, and through bolt washers. Replace parts from service kits.

L—Front Gasket M—Snap Ring N—Lip Seal O—Washer P—Through Bolt

NOTE: The valve plates, reed valves, cylinders, and cylinder housing are NOT serviceable. Some cylinder scuffing (light scratches) is normal. 3. Inspect the valves for an even wear pattern and the cylinders for scoring or excessive wear. Replace compressor as required. 4. Remove the shaft seal snap ring (M). Turn the housing over and remove the felt holder (Q) and felt (R) from the front housing (S).


TM1640 (15JAN04)

Q—Felt Holder R—Felt S—Front Housing T—Front Pins

18-1830-53

TX,18,DY5026 –19–18FEB99–1/3


PN=485

Heating and Air Conditioning 5. Remove the shaft lip seal (N) from the front housing (S) using a small tool with 5/8 in. OD. 6. Wash all parts in clean solvent and dry before assembly. IMPORTANT: Lubricate O-rings, gaskets, and lip seal using only TY22025 (R134a)

refrigerant oil during assembly. Other oils could damage the compressor. 7. Apply R134a oil to the bore of the front housing and install new lip seal (N) to the bottom of the bore using a socket. Install new snap ring (M) flat side down.


TX,18,DY5026 –19–18FEB99–2/3

18 1830 54

TM1640 (15JAN04)

18-1830-54


PN=486

C—Rear Gasket D—Rear Discharge Reed Valve

E—Rear Valve Plate

–UN–24JUN92 RW21163

RW21162

–UN–24JUN92


F—Rear Suction Reed Valve

U—Bushing Spacer

IMPORTANT: Bushing spacer (U) must be in position before assembling the compressor.

13. Install a new gasket (L) flat side down. Put JDG746 Compressor Seal Protector on the shaft and lubricate with R134a oil.

8. Install pins (A) and new O-ring (G) in the rear cylinder.

14. Install the front housing (S) on the front cylinder and remove the lip seal protector. Install through bolts (P) and new washers (O).

NOTE: The rear valve plate is marked with an "R" and is installed face up. 9. Install parts (F—D) over the pins on the rear cylinder. 10. Install a new gasket (C) flat side down and the rear housing (B) on the rear cylinder. Mount the compressor onto the holding fixture. 11. Install pins (T) and new O-ring (H) in the front cylinder.

NOTE: The front valve plate is marked with an "F" and is installed face up.

15. Partially tighten the through bolts and then tighten. Compressor—Specification Compressor Through Bolt— Torque....................................................................... 26 N•m (19 lb-ft)

16. Install the felt (R) and felt holder (Q) using the clutch hub. 17. Install the pulley-clutch hub and check clearance. (See Disassemble and Assemble Compressor Clutch—R134a and Check Clutch Hub Clearance—R134a in this group.)

12. Install parts (I—K) over the pins on the front cylinder.

TX,18,DY5026 –19–18FEB99–3/3

TM1640 (15JAN04)

18-1830-55


PN=487

18 1830 55


18 1830 56

TM1640 (15JAN04)

18-1830-56


PN=488

Group 1899

Dealer Fabricated Tools DFRW20 Compressor Holding Fixture

RW13619

–UN–20SEP89

18 1899 1

A—102 mm (4 in.) B—76 mm (3 in.) C—70 mm (2.75 in.)

D—6.4 mm (0.25 in.) E—19 mm (0.75 in.) F—152 mm (6 in.)

G—254 mm (10 in.) H—114 mm (4.5 in.) I—178 mm (7 in.)

J—Weld K—Two Holes

• Two pieces of threaded rod, 13 mm (1/2 in.) threads x 178 mm (7 in.) long and four lock washers and nuts.

This tool is used to hold the air conditioning compressor during disassembly and assembly. Materials required are: • Two pieces of steel plate, approximately 70 x 120 mm (2—3/4 in.) and 152 x 254 mm (6 x 10 in.)

TX,18,1111100 –19–22NOV97–1/1

TM1640 (15JAN04)

18-1899-1


PN=489

Dealer Fabricated Tools

18 1899 2

TM1640 (15JAN04)

18-1899-2


PN=490

Section 19

Sheet Metal and Styling Contents Page

Group 1910—Hood or Engine Enclosure Specifications . . . . . . . . . . . . . . . . . . . . . . . .19-1910-1 Hood Remove and Install . . . . . . . . . . . . . . . . . .19-1910-2 Engine Side Shields Remove and Install . . . . . . . . . . . . . . . . . .19-1910-3 Group 1913—Miscellaneous Shields Transmission Shields Remove and Install . . . . . . . . . . . . . . . . . .19-1913-1 Battery Covers Remove and Install . . . . . . . . . . . . . . . . . .19-1913-2

19

Group 1921—Grille and Grille Housing Service Equipment and Tools . . . . . . . . . . . .19-1921-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .19-1921-1 Grille and Grille Housing Remove and Install . . . . . . . . . . . . . . . . . .19-1921-2 Group 1927—Miscellaneous Shields Front Fenders Remove and Install . . . . . . . . . . . . . . . . . .19-1927-1 Fenders Rear, Remove and Install . . . . . . . . . . . . .19-1927-2

TM1640 (15JAN04)

19-1


PN=1

Contents

19

TM1640 (15JAN04)

19-2


PN=2

Group 1910

Hood or Engine Enclosure Specifications Item

Measurement

Specification

Engine Side Shield

Weight


CED,OUOE003,2714 –19–31MAR99–1/1

19 1910 1

TM1640 (15JAN04)

19-1910-1


PN=493

Hood or Engine Enclosure

–UN–06OCT97

Remove and Install Hood

TP55681

19 1910 2

1—Screw (4 used)

2—Washer (4 used)

3—Hood TX,19,1111039 –19–18FEB99–1/1

TM1640 (15JAN04)

19-1910-2


PN=494


Remove and Install Engine Side Shields

TP55680

–UN–07OCT97

19 1910 3

1—Hinge (2 used) 2—Latch 3—Rivet (4 used) 4—Shield 5—Screw (6 used)

6—Washer (4 used) 7—Spring Locking Pin (4 used) 8—Rod (2 used)

9—Isolator (As Required) 10—Cap Screw (2 used) 11—Plate (2 used) 12—Washer (6 used)

CAUTION: Each engine side shield weighs approximately 23 kg (50 lb).

13—Screw (6 used) 14—Door 15—Shield 16—Door

Specification Engine Side Shield—Weight ...................... 23 kg (50 lb) approximate

TX,19,1111040 –19–18FEB99–1/1

TM1640 (15JAN04)

19-1910-3


PN=495


19 1910 4

TM1640 (15JAN04)

19-1910-4


PN=496

Group 1913

Miscellaneous Shields

TP55810

–UN–12JAN98

Remove and Install Transmission Shields

1—Screw (2 used)

2—Washer (2 used)

3—Cover

19 1913 1

4—Cover

TX,1910,111306 –19–18FEB99–1/1

TM1640 (15JAN04)

19-1913-1


PN=497


Remove and Install Battery Covers

TP55601

–UN–08JUL97

19 1913 2

1—Cover

2—Cover

3—Washer (8 used)

4—Cap Screw (8 used)

TX,1910,111307 –19–18FEB99–1/1

TM1640 (15JAN04)

19-1913-2


PN=498

Group 1921

Grille and Grille Housing Service Equipment and Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.


CED,OUOE003,2715 –19–31MAR99–1/2

Metric Lifting Eyebolt (2 used) . . . . . . . . . . . . . JT05550 Used in conjunction with a chain and hoist to remove and install grille and grille housing. CED,OUOE003,2715 –19–31MAR99–2/2

Specifications Item

Measurement

Specification

Grille Housing

Weight


Grille Screen

Weight


CED,OUOE003,2716 –19–31MAR99–1/1

TM1640 (15JAN04)

19-1921-1


PN=499

19 1921 1

Grille and Grille Housing

Remove and Install Grille and Grille Housing

T112440B

–UN–06JAN98

19 1921 2

A—Fan Guard B—Grille Housing-to-Frame Cap Screw (2 used)

C—Baffle Cap Screw (4 used)

D—Rear Wiring Harness Connectors

1. Disconnect battery ground strap or turn battery disconnect switch “Off” if equipped.

E—Fuel Tank Filler Neck with Hose

CAUTION: Grille housing weighs approximately 83 kg (183 lb).

2. Remove hood. (See Group 1910.)

Grille screen weighs approximately 23 kg (50 lb).

3. Remove battery box covers.

Specification Grille Housing—Weight ............................ 83 kg (183 lb) approximate Grille Screen—Weight ................................ 23 kg (50 lb) approximate

4. Remove fan guard (A). 5. Disconnect rear wiring harness connectors (D) at grille housing.

8. Install two 12 mm JT05550 Eyebolts in tapped holes in top of grille housing.

6. Remove fuel tank filler neck with hose (D). 9. Attach a chain and hoist to the eyebolts. 7. Remove four cap screws (C) and remove radiator baffle plate.


TM1640 (15JAN04)

19-1921-2

TX,19,1111129 –19–18FEB99–1/3


PN=500

Grille and Grille Housing 10. Remove two grille housing-to-frame cap screws (B).

TX,19,1111129 –19–18FEB99–2/3

11. Remove two radiator and oil cooler outside frame-to-grille housing cap screws (C). 12. Remove two door striker plates (B). 13. Carefully lift grille housing until it clears top of radiator and oil cooler. 14. Install grille housing using eyebolts, in conjunction with a chain and a hoist. 15. Install and tighten two bottom grille housing-to-engine frame cap screws.

19 1921 3

16. Install and tighten two radiator and oil cooler outside frame-to-grille housing cap screws. 17. Install two door striker plates. –UN–06JAN98

18. Install and tighten two grille housing-to-frame cap screws.

T112441B

19. Connect rear wiring harness connector. 20. Install fuel tank filler neck with hose. 21. Install fan guard. A—Radiator and Oil Cooler Outside Frame-to-Grille Housing Cap Screw (2 used) B—Door Striker Plate (2 used) C—Bottom Grille Housing-to-Engine Frame Cap Screw (2 used)

22. Install battery box covers. 23. Install hood. (See Group 1910.) 24. Connect battery ground strap or turn battery disconnect switch On, if equipped. 25. Install engine side shields. (See Group 1910.) 26. Install hood. (See Group 1910.) 27. Connect battery ground strap or turn battery disconnect switch “On” if equipped.

TX,19,1111129 –19–18FEB99–3/3

TM1640 (15JAN04)

19-1921-3


PN=501

Grille and Grille Housing

19 1921 4

TM1640 (15JAN04)

19-1921-4


PN=502

Group 1927

Miscellaneous Shields Remove and Install Front Fenders

TP48678

–UN–17MAR97

19 1927 1

1—Fender 2—Fender 3—Bolt (8 used)

4—Washer (8 used) 5—Support (4 used) 6—Nut (8 used)

7—Lock Nut (8 used) 8—Washer (8 used)

9—Washer (4 used) 10—Screw (4 used)

TX,1927,111310 –19–29SEP98–1/1

TM1640 (15JAN04)

19-1927-1


PN=503


Remove and Install Rear Fenders

TP60438

–UN–20JUL98

19 1927 2

1—Kit 2—Screw (18 used) 3—Washer (36 used) 4—Support (2 used)

5—Screw (10 used) 6—Washer (10 used) 7—Lock Nut (18 used) 8—Platform

9—Support (2 used) 10—Platform 11—Strap (2 used)

12—Platform 13—Fender 14—Fender

TX,1927,111309 –19–18FEB99–1/1

TM1640 (15JAN04)

19-1927-2


PN=504

Section 20

Safety and Convenience Contents Page

Group 2002—Mirror Rear View Mirror Remove and Install . . . . . . . . . . . . . . . . . .20-2002-1 Outside Mirror for Cab or Canopy Remove and Install . . . . . . . . . . . . . . . . . .20-2002-2 Group 2003—Fire Extinguisher Fire Extinguisher and Bracket Remove and Install . . . . . . . . . . . . . . . . . .20-2003-1 Group 2004—Horn and Warning Devices Horn Remove and Install . . . . . . . . . . . . . . . . . .20-2004-1 Reverse Warning Alarm Remove and Install . . . . . . . . . . . . . . . . . .20-2004-2 Change Volume . . . . . . . . . . . . . . . . . . . . .20-2004-2

TM1640 (15JAN04)

20-1

20


PN=1

Contents

20

TM1640 (15JAN04)

20-2


PN=2

Group 2002

Mirror

TP33769

–UN–01JAN94

Remove and Install Rear View Mirror

1—Rear View Mirror

2—Washer

3—Nut 20 2002 1 TX,2002,111312 –19–05JUN98–1/1

TM1640 (15JAN04)

20-2002-1


PN=507

Mirror

TP55501

–UN–01MAY97

Remove and Install Outside Mirror for Cab or Canopy

20 2002 2

1—Clamp 2—Washer 3—Lock Nut

4—Cap Screw 5—Washer (2 used) 6—Washer

7—Mirror Arm 8—Cap 9—Rear View Mirror

10—Rear View Mirror Assembly

TX,2002,111313 –19–18FEB99–1/1

TM1640 (15JAN04)

20-2002-2


PN=508

Group 2003

Fire Extinguisher Remove and Install Fire Extinguisher and Bracket

TP55515

–UN–05MAY97

20 2003 1

1—Fire Extinguisher Assembly

2—Bracket

3—Screw (2 used)

4—Nut (2 used)

TX,20,1111076 –19–18FEB99–1/1

TM1640 (15JAN04)

20-2003-1


PN=509

Fire Extinguisher

20 2003 2

TM1640 (15JAN04)

20-2003-2


PN=510

Group 2004

Horn and Warning Devices Remove and Install Horn

T109420

–UN–06MAY97

A—High Note Horn (A03 Org/G05 Blk) B—Low Note Horn—If Equipped (A03 Org/G05 Blk)

Loader Frame Harness (Without Tool Carrier) Shown

TX,2004,111465 –19–05JUN98–1/1

TM1640 (15JAN04)

20-2004-1


PN=511

20 2004 1

Horn and Warning Devices

Remove and Install Reverse Warning Alarm Disconnect M01 purple and G02 black wiring leads from reverse warning alarm (A). Remove and install reverse warning alarm mounted to grille housing.

–UN–06MAY97

A—Reverse Warning Alarm

T109419

20 2004 2

Rear Frame Harness Shown

TX,2004,111466 –19–05JUN98–1/1

NOTE: Alarm removed from machine for clarity of photograph. To change alarm volume, move switch (A) to desired position.

T7853AT

IMPORTANT: The reverse warning alarm is set on high volume at the factory. It may be necessary to adjust the volume to meet local regulations.

–UN–08OCT92

Change Volume Reverse Warning Alarm

A—Alarm Volume Switch

TX,2004,111467 –19–05JUN98–1/1

TM1640 (15JAN04)

20-2004-2


PN=512

Section 31

Loader Contents Page

Page

Group 3102—Bucket Specifications . . . . . . . . . . . . . . . . . . . . . . . .31-3102-1 Ride Control Accumulator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3102-2 Bucket Tooth Shanks and Tips Remove and Install . . . . . . . . . . . . . . . . . .31-3102-3 Bucket Remove and Install . . . . . . . . . . . . . . . . . .31-3102-5 Welded Bucket Cutting Edge Remove and Install . . . . . . . . . . . . . . . . . .31-3102-6 Bolt-On Bucket Cutting Edges and Wear Plates Remove and Install . . . . . . . . . . . . . . . . . .31-3102-7 Cutting Edge Repair Cracks . . . . . . . . . . . . . . . . . . . . . .31-3102-9

Hydraulic Pump Control Valve Remove and Install . . . . . . . . . . . . . . . . .31-3160-34 Disassemble and Assemble. . . . . . . . . . .31-3160-36 Loader Control Valve Remove and Install . . . . . . . . . . . . . . . . .31-3160-37 Disassemble and Assemble. . . . . . . . . . .31-3160-40 Auxiliary Valve Section and Bucket Section Disassemble and Assemble. . . . . . . . . . .31-3160-41 Disassemble and Assemble Bucket Valve Section—Tool Carrier . . . . . . . . . . . . . . .31-3160-42 Boom Valve Section Disassemble and Assemble. . . . . . . . . . .31-3160-43 System Relief Valve Disassemble and Assemble. . . . . . . . . . .31-3160-44 Bucket Circuit Relief Valve Disassemble and Assemble. . . . . . . . . . .31-3160-44 Load Sense Relief Valve Disassemble and Assemble. . . . . . . . . . .31-3160-45 Boom Circuit Relief Valve Disassemble and Assemble. . . . . . . . . . .31-3160-45 Boom Cylinder Remove and Install . . . . . . . . . . . . . . . . .31-3160-46 Loader Start-Up Procedure . . . . . . . . . . .31-3160-48 Bucket Cylinder Remove and Install . . . . . . . . . . . . . . . . .31-3160-49 Loader Start-Up Procedure . . . . . . . . . . .31-3160-51 Cross Section . . . . . . . . . . . . . . . . . . . . .31-3160-52 Disassemble and Assemble. . . . . . . . . . .31-3160-53 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-54 Boom Cylinder Piston Wear Ring Configuration . . . . . . . .31-3160-56 Cross Section . . . . . . . . . . . . . . . . . . . . .31-3160-58 Disassemble and Assemble. . . . . . . . . . .31-3160-59 Boom, Bucket or Tilt Cylinder Remove and Install Bushings and Seals . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-67 Hydraulic Reservoir Remove and Install . . . . . . . . . . . . . . . . .31-3160-68 Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy . . . . . . . . . . . . . . . .31-3160-69 Pilot Controller (Single Lever) Remove and Install . . . . . . . . . . . . . . . . .31-3160-70 Cross Section . . . . . . . . . . . . . . . . . . . . .31-3160-71 Disassemble and Assemble. . . . . . . . . . .31-3160-71

Group 3140—Frames Service Equipment and Tools . . . . . . . . . . . .31-3140-1 Other Material . . . . . . . . . . . . . . . . . . . . . . . .31-3140-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .31-3140-2 Bucket Tilt Linkage Remove and Install . . . . . . . . . . . . . . . . . .31-3140-3 Bucket Linkage Seals and Bushings Remove and Install . . . . . . . . . . . . . . . . . .31-3140-4 Tool Carrier Upper Tilt Linkage Disassemble and Assemble. . . . . . . . . . . .31-3140-5 Tool Carrier Lower Tilt Linkage Disassemble and Assemble. . . . . . . . . . . .31-3140-6 Tool Carrier Disassemble and assemble . . . . . . . . . . . .31-3140-8 Loader Boom Bushings and Seals Remove and Install . . . . . . . . . . . . . . . . . .31-3140-9 Tool Carrier Boom Bushings and Seals Remove and Install . . . . . . . . . . . . . . . . .31-3140-10 Group 3160—Hydraulic System Essential Tools . . . . . . . . . . . . . . . . . . . . . . .31-3160-1 Service Equipment and Tools . . . . . . . . . . . .31-3160-2 Other Material . . . . . . . . . . . . . . . . . . . . . . . .31-3160-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . .31-3160-4 Loader Hydraulic Pump Remove and Install . . . . . . . . . . . . . . . . . .31-3160-9 Hydraulic Pump Cross Section . . . . . . . . . . . . . . . . . . . . .31-3160-12 Disassemble, Inspect and Assemble . . . .31-3160-13 TM1640 (15JAN04)

31-1



PN=1

31

Contents

Page

Pilot Controller Repair (Two Lever Controller) (S.N. —585560). . . . . . . . . . . . . . . . . . . .31-3160-87 Pilot Controller Repair (Two Lever Controller) (S.N. 585561—) . . . . . . . . . . .31-3160-91 Pressure Reducing Valve Manifold Remove and Install . . . . . . . . . . . . . . . . .31-3160-94 Pressure Reducing Valve Remove and Install . . . . . . . . . . . . . . . . .31-3160-95 Disassemble and Assemble. . . . . . . . . . .31-3160-96 Boom Down Solenoid Valve Remove and Install . . . . . . . . . . . . . . . . .31-3160-97 Differential Lock Solenoid Valve Remove and Install . . . . . . . . . . . . . . . . .31-3160-98 Pilot Enable Solenoid Valve Remove and Install . . . . . . . . . . . . . . . . .31-3160-99 Ride Control Repair (S.N. —582200) . . . . 31-3160-100 Ride Control Repair (S.N. 582201—) . . . . 31-3160-104 Ride Control Accumulator Disassemble and Assemble. . . . . . . . . . 31-3160-108 Charge. . . . . . . . . . . . . . . . . . . . . . . . . . 31-3160-112 Pin Disconnect/Axle Disconnect Valve Remove and Install . . . . . . . . . . . . . . . . 31-3160-114 Pin Disconnect Valve Disassemble and Assemble. . . . . . . . . . 31-3160-115 Axle Disconnect Valve Disassemble and Assemble. . . . . . . . . . 31-3160-116 31

TM1640 (15JAN04)

31-2


PN=2

Group 3102

Bucket Specifications Item

Measurement

Specification

Cutting Edge-to-Center Tooth Shank Cap Screw

Torque

624 N•m (460 lb-ft)

End Tooth Shank-to-Bucket Cap Screw

Torque

1171 N•m (790 lb-ft)

Cutting Edge-to-Segment Cap Screw

Torque

624 N•m (460 lb-ft)

2.3 M (3.0 yd) Bucket

Weight


2.7 M (3.5 yd) Bucket

Weight


Boom End-to-Bucket

Clearance

1 mm (0.04 in.) maximum

Bucket Link-to-Bucket

Clearance


Cutting Edge Segment

Weight


Bucket

Cutting Edge-to-Bucket Cap Screw Torque

495 N•m (365 lb-ft)

Wear Plate-to-Bucket Cap Screw

300 N•m (225 lb-ft)

Torque

31 3102 1

Welding Bucket Cutting Edge

Preheat Temperature Distance

Cracked Cutting Edge

Preheat Temperature Distance

204°C (400°F) minimum throughout entire thickness of parts 51 mm (2 in.) minimum back from joint 149°—260°C (300°—500°F) 13 mm (0.5 in.) beyond end of crack

CED,OUOE003,3378 –19–22APR99–1/1

TM1640 (15JAN04)

31-3102-1


PN=515

Bucket

Ride Control Accumulator Safety 1. Stop engine. CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with ride control. Always be sure the ride control accumulator energy is discharged when working on hydraulic components. To do this: With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 2. If equipped with ride control. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds.

31 3102 2

TX,31,RP3118 –19–30APR97–1/1

TM1640 (15JAN04)

31-3102-2


PN=516

Bucket

T111849

–UN–22OCT97

Remove and Install Bucket Tooth Shanks and Tips

1—Cutting Edge Segment (7 used) 2—Adapter (Shank)

3—Cap Screw (2 used) 4—Washer (2 used) 5—Pin (8 used)

6—Tooth Tip (8 used) 7—Washer (8 used) 8—Cap Screw (12 used)

1. Remove cap screws to remove tooth shanks and cutting edge segments. IMPORTANT: Shanks must be seated against cutting edge as nuts are tightened. This places the load on the cutting edge and not on the cap screws. 2. Install tooth shanks.

31 3102 3

Bucket—Specification Cutting Edge-to-Center Tooth Shank Cap Screw—Torque .................................. 624 N•m (460 lb-ft) End Tooth Shank-to-Bucket Cap Screw—Torque ........................................... 1171 N•m (790 lb-ft)

5. Install cap screws to corner tooth shanks with cap screw heads to outside. Bucket—Specification Cutting Edge-to-Segment Cap Screw—Torque ..................................................... 624 N•m (460 lb-ft)

3. Install cutting edge segments between tooth shanks. 4. Install cap screws in center tooth shanks and cutting edge segments with cap screw heads on bottom.

6. To remove tooth tip, drive pin (5) out from the left side of machine.


TM1640 (15JAN04)

9—Washer (24 used) 10—Nut (26 used) 11—Bolt (14 used)

31-3102-3

TX,31,RP3362 –19–17FEB99–1/2


PN=517

Bucket 7. To install tooth tip, install retaining washer (4) in recess on left side of tooth shank. Drive tip on shank until pin can be assembled or until center of hole in shank aligns with center of slot in tooth tip.

NOTE: Pin may fail if in contact with front edge of tooth tip slot. Try a different tooth tip or grind slot in tooth tip longer.

8. Drive pin (5) through tip and shank from left side. Pin must not contact front edge of tooth tip slot.

TX,31,RP3362 –19–17FEB99–2/2

31 3102 4

TM1640 (15JAN04)

31-3102-4


PN=518

Bucket

T108202

–UN–26NOV97

Remove and Install Bucket

A—Shim, Bucket Link to Bucket (as needed) B—Pin, Bucket Link to Bucket

C—Spacer (3 used) D—Washer (3 used) E—Cap Screw (3 used)

F—Grease Fitting (2 used) G—Pin, Bucket to Boom (2 used)

CAUTION: The approximate weight of the 2.3 M (3.0 yd) bucket is 963 kg (2123 lb). The approximate weight of the 2.7 M (3.5 yd) bucket is 1034 kg (2280 lb). Bucket—Specification 2.3 M (3.0 yd) Bucket—Weight ............ 963 kg (2123 lb) approximate 2.7 M (3.5 yd) Bucket—Weight .......... 1034 kg (2280 lb) approximate

1. Lower bucket to the ground. 2. Remove cap screws (E), washers (D), spacers (C), and pins (B and G). 3. Remove bucket. 4. Align boom ends with bucket. Install shims (H) between boom ends and bucket as needed to

31 3102 5

obtain maximum clearance. Bucket—Specification Boom End-to-Bucket— Clearance.................................................... 1 mm (0.04 in.) maximum

Install an equal number of shims ± 1 on each side of boom end. Install pins (G), spacers (C), washers (D) and cap screws (E). 5. Align bucket link with bucket. Install shims (A) between bucket link and bucket to obtain maximum clearance. Bucket—Specification Bucket Link-to-Bucket— Clearance.................................................... 2 mm (0.08 in.) maximum


TM1640 (15JAN04)

H—Shim, Bucket to Boom (as needed)

31-3102-5

TX,31,ME119 –19–17FEB99–1/2


PN=519

Bucket Install an equal number of shims ± 1 on each side of bucket link.

Install pin (B), spacers (C), washers (D), and cap screws (E).

TX,31,ME119 –19–17FEB99–2/2

Remove and Install Welded Bucket Cutting Edges 1. Perform welding in an environment with a minimum ambient temperature of 10°C (50°F).

5. Tack weld preheated plates starting at center of bucket and working toward the outside ends.

2. Clean all joints to be welded of all foreign matter such as dirt, rust, mill scale, oil, etc. with grinders and/or solvents.

6. Final weld preheated plates starting at the center of the front edge of the bucket backing plate and working toward the outside ends.

3. Use dry AWS-E7018 low hydrogen electrodes or either of the following equivalent low hydrogen wire feed electrodes: gas metal arc welding (CO2 or argon CO2) AWS-E70S6 or flux cored arc welding AWS-E70T1.

31 3102 6

4. Preheat parts to be welded (both tack and final welds) to minimum of 204°C (400°F). PREHEAT TEMPERATURE MUST BE THROUGHOUT THE ENTIRE THICKNESS OF THE PARTS JOINED AND AT LEAST 51 mm (2 in.) BACK FROM THE JOINT. Maintain preheat throughout the entire welding operation. Tempilstiks should be used if possible.

Repeat this operation at back edge of loader blade. Tack welds may be incorporated into the final weld, providing they have been made with electrodes that meet the requirements of the final welds and no cracking has occurred in the weld metal. Tack welds not meeting these requirements must be completely removed by grinding or air arc gouging just prior to making the final weld in that area. 7. Do not remove bucket from welding environment until weld metal temperature has dropped to the ambient temperature. Do not force cooling rate of weld metal.

Welding—Specification Bucket Cutting Edge—Preheat Temperature ................................................. 204°C (400°F) minimum throughout entire thickness of parts Distance .......................................................... 51 mm (2 in.) minimum back from joint

TX,31,ME120 –19–17FEB99–1/1

TM1640 (15JAN04)

31-3102-6


PN=520

Bucket

TP48319

–UN–17APR96

Remove and Install Bolt-On Cutting Edges and Wear Plates

1—Nut (12 used)

2—Cutting Edge (2 used)

3—Bolt (12 used)

4—Cutting Edge (2 used)

31 3102 7


TM1640 (15JAN04)

31-3102-7

TX,31,RP3077 –19–17FEB99–1/2


PN=521

T109256

–UN–29APR97

Bucket

1—Wear Plate 31 3102 8

2—Bolt (8 used)

3—Washer (8 used)

CAUTION: The approximate weight of the cutting edge segments is 66 kg (145 lb). Bucket—Specification Cutting Edge Segment—Weight............... 66 kg (145 lb) approximate

1. Remove hardware and cutting edge from bucket.

4—Nut (8 used)

2. To install, hold cutting edge in position and install new hardware. Bucket—Specification Cutting Edge-to-Bucket Cap Screw—Torque ..................................................... 495 N•m (365 lb-ft) Wear Plate-to-Bucket Cap Screw—Torque ..................................................... 300 N•m (225 lb-ft)

Remove hardware from wear plates and install new wear plates and hardware. TX,31,RP3077 –19–17FEB99–2/2

TM1640 (15JAN04)

31-3102-8


PN=522

Bucket

Repair Cracked Cutting Edge 1. If cutting edge has any cracks, clean the area to find end of crack. 2. Drill a small hole at end of crack to prevent spreading. 3. Grind V-grooves along crack on top and bottom of cutting edge. 4. Preheat the cracked area. Welding—Specification Cracked Cutting Edge—Preheat Temperature .................................................. 149°—260°C (300°—500°F)

5. Fill the V-grooves with weld. Use E7018 electrodes. Extend the weld beyond end of crack. Welding—Specification Cracked Cutting Edge—Distance ............. 13 mm (0.5 in.) beyond end of crack

TX,31,ME122 –19–17FEB99–1/1

31 3102 9

TM1640 (15JAN04)

31-3102-9


PN=523

Bucket

31 3102 10

TM1640 (15JAN04)

31-3102-10


PN=524

Group 3140

Frames Service Equipment and Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.


CED,OUOE003,3380 –19–22APR99–1/2

Bushing, Bearing and Seal Driver Set . . . . . . D01044AA Used to remove and install bushings and seals.

CED,OUOE003,3380 –19–22APR99–2/2


Name

Use

PT569 (U.S.)


Apply to bore of bellcrank pivot pin. Apply to bushings and bushing bores. 31 3140 1


TM1640 (15JAN04)

CED,OUOE003,3382 –19–22APR99–1/1

31-3140-1


PN=525

Frames

Specifications

31 3140 2

Item

Measurement

Specification

Bellcrank

Weight


Bellcrank Pivot Pin

Weight


Bucket Link

Weight


Bellcrank-to-Bucket Link

Clearance


Bellcrank-to-Bucket Cylinder

Clearance


Bellcrank-to-Loader Boom

Clearance


Bucket Linkage Bushing

Depth

6.4 mm (0.25 in.) minimum below surface or centered in bushing bore

Tool Carrier Tilt Linkage Bushing

Depth

8 mm (0.31 in.) below surface of link

Tool Carrier Boom-to-Bellcrank

Clearance


Tool Carrier Link Boom-to-Link

Clearance


Tool Carrier Boom-to-Link

Clearance


Tool Carrier Link-to-Tool Carrier

Clearance


Tool Carrier Boom End-to-Tool Carrier

Clearance


Tool Carrier Cylinder-to-Tool Carrier

Clearance


Bucket Cylinder

Weight


Loader Boom

Weight


Loader Boom-to-Loader Frame

Clearance


Tool Carrier Boom

Weight


Tilt Cylinder

Weight


CED,OUOE003,3381 –19–22APR99–1/1

TM1640 (15JAN04)

31-3140-2


PN=526

Frames

T108207

–19–03APR97

Remove and Install Loader Bucket Tilt Linkage

A—Bucket Cylinder B—Shim (As Required) C—Bellcrank D—Shim (As Required)

E—Grease Fitting (3 used) F—Seal (4 used) G—Bucket Link

1. Lower bucket to the ground. CAUTION: The approximate weight of the bellcrank is 318 kg (700 lb). The approximate weight of the bellcrank pivot pin is 30 kg (65 lb). The approximate weight of the bucket link is 77 kg (170 lb). Specification Bellcrank—Weight .................................. 318 kg (700 lb) approximate Bellcrank Pivot Pin—Weight ....................... 30 kg (65 lb) approximate Bucket Link—Weight ................................ 77 kg (170 lb) approximate

H—Pin I—Spacer (2 used) J—Washer (2 used)

K—Cap Screw (2 used) L—Pin M—Loader Boom

31 3140 3

3. Install shims (B) on bellcrank-to-bucket link and bellcrank-to-bucket cylinder and shims (D) on bellcrank-to-loader boom to obtain maximum clearance. Specification Bellcrank-to-Bucket Link— Clearance.................................................... 3 mm (0.12 in.) maximum Bellcrank-to-Bucket Cylinder— Clearance.................................................... 3 mm (0.12 in.) maximum Bellcrank-to-Loader Boom— Clearance.................................................... 3 mm (0.12 in.) maximum

4. Apply NEVER-SEEZ Lubricant or an equivalent to bore of bellcrank pivot pin.

2. Remove parts as necessary.


TM1640 (15JAN04)

TX,31,ME126 –19–17FEB99–1/1

31-3140-3


PN=527

Frames

T108214

–19–26NOV97

Remove and Install Bucket Linkage Seals and Bushings

31 3140 4

A—Bellcrank B—Seal (2 used)

C—Bucket Link D—Seal (4 used)

E—Bushing (2 used) F—Shim (As Required)

1. Remove bushings and seals from bucket link and bellcrank using disks from Bushing, Bearing and Seal Driver Set. 2. Apply NEVER-SEEZ Lubricant or an equivalent to new bushings and bushing bores.

G—Bushing

Specification Bucket Linkage Bushing— Depth ........................................................ 6.4 mm (0.25 in.) minimum below surface or centered in bushing bore

4. Install seals (D) into bores against bushings or flush with surface of bucket link and bellcrank.

3. Install bucket link and bellcrank bushings below surface, or centered in bushing bore.


TM1640 (15JAN04)

TX,3140,RP3044 –19–17FEB99–1/1

31-3140-4


PN=528

Frames

T108217

–UN–26NOV97

Disassemble and Assemble Tool Carrier Upper Tilt Linkage

A—Bellcrank (2 used) B—Pin Anchor (4 used) C—Cap Screw (4 used) D—Bushing (2 used)

E—Boom Upper Right End F—Seal (8 used) G—Bushing (8 used) H—Link (2 used)

1. Lower attachment to the ground.

I—Grease Fitting (6 used) J—Pin (2 used) K—Pin (4 used) L—Spacer (6 used)

31 3140 5

4. Install seals (F) against bushing or flush with surface with lips toward outside of bore.

CAUTION: Use a lifting device for heavy components.

5. Install pins (J and K) with flags outboard. 6. Install anchors (M) on pins.

2. Disassemble upper tilt linkage. 3. Apply NEVER-SEEZ Lubricant or an equivalent to new bushings and into bushing bores. Install bushings (G) below surface of link (H) using disks from Bushing, Bearing and Seal Driver Set. Specification Tool Carrier Tilt Linkage Bushing—Depth ................................... 8 mm (0.31 in.) below surface of link

7. Install washers (O) under flags to obtain a maximum clearance between the boom (E) and bellcranks (A and P) also between bellcranks (A and P) and bucket cylinder ends. Specification Tool Carrier Boom-to-Bellcrank—Clearance .................. 3 mm (0.12 in.) maximum Bellcrank-to-Bucket Cylinder— Clearance.................................................... 3 mm (0.12 in.) maximum


TM1640 (15JAN04)

M—Washer (6 used) N—Cap Screw (6 used) O—Washer (As Required) P—Bellcrank (2 used)

TX,3140,DU755 –19–17FEB99–1/1

31-3140-5


PN=529

Frames

T108220

–19–26NOV97

Disassemble and Assemble Tool Carrier Lower Tilt Linkage

31 3140 6

A—Link (2 used) B—Seal (4 used) C—Seal (8 used) D—Pin (4 used)

E—Grease Fitting (4 used) F—Washer (As Required) G—Cap Screw (4 used) H—Washer (4 used)

1. Lower attachment to the ground.

I—Spacer (4 used) J—Loader Boom, Left Lower End K—Bushing (2 used)

L—Link (4 used) M—Anchor (4 used) N—Cap Screw (4 used) O—Bushing (4 used)

Set. Specification Tool Carrier Tilt Linkage Bushing—Depth ................................... 8 mm (0.31 in.) below surface of link

CAUTION: Use a lifting device for heavy components. 2. Disassemble lower tilt linkage. 

3. Apply NEVER-SEEZ Lubricant or an equivalent to new bushings and into bushing bores.

5. Install seals (B and C) against bushing or flush with surface with lips toward outside of bore. 6. Install pins (D) with flags outboard.

4. Install bushings (K and O) below surface of link (A) using disks from Bushing, Bearing and Seal Driver

7. Install anchors (M) on pins.



TM1640 (15JAN04)

31-3140-6

TX,3140,RP3045 –19–17FEB99–1/2


PN=530

Frames 8. Install washers (F) under flags to obtain a maximum clearance between the boom (J) and links (L), between boom links (L) and link (A) and between link (A) and tool carrier.

Tool Carrier Boom-to-Link— Clearance.................................................... 3 mm (0.12 in.) maximum Tool Carrier Link-to-Tool Carrier—Clearance ..................................... 3 mm (0.12 in.) maximum

Specification Tool Carrier Link Boom-to-Link—Clearance ........................... 3 mm (0.12 in.) maximum

TX,3140,RP3045 –19–17FEB99–2/2

31 3140 7

TM1640 (15JAN04)

31-3140-7


PN=531

Frames

T111932

–UN–11NOV97

Disassemble and Assemble Tool Carrier

31 3140 8

A—Cap Screw (4 used)

B—Pin (4 used)

C—Spacer (As Needed)

D—Spacer (As Needed)

Specification Tool Carrier Boom End-to-Tool Carrier—Clearance ..................................... 1 mm (0.04 in.) maximum

1. Remove attachment from tool carrier. 2. Disconnect hoses to pin disconnect cylinder. 3. Remove cap screws (A) and pins (B). Remove cap screws and pin from bucket tilt linkage.

5. Install spacers (D) on each side of both cylinders-to-tool carrier as needed to obtain maximum clearance.

4. Install spacers (C) on each side of both boom ends-to-tool carrier as needed to obtain maximum clearance.

Specification Tool Carrier Cylinder-to-Tool Carrier—Clearance ..................................... 1 mm (0.04 in.) maximum

TX,31,RP3363 –19–18FEB99–1/1

TM1640 (15JAN04)

31-3140-8


PN=532

Frames

T108266

–UN–26NOV97

Remove and Install Loader Boom Bushings and Seals

A—Bushing (6 used)

B—Seal (12 used)

1. Lower bucket to the ground and remove bucket from boom.

C—Loader Boom

4. Remove boom pivot pins from machine frame and remove boom.

CAUTION: The approximate weight of the bucket cylinder is 105 kg (232 lb). Specification Bucket Cylinder—Weight ........................ 105 kg (232 lb) approximate

2. Remove bucket cylinder and linkage.

5. Remove bushings from boom using disks from Bushing, Bearing and Seal Driver Set. 6. Apply NEVER-SEEZ Lubricant or an equivalent on outer surface of new bushings and bores. Center new bushings in boom bores and press seals against bushings with lips outward. 7. Install boom and cylinders on machine. Install shims as needed in loader frame to boom joint.

3. Disconnect boom cylinders from boom. CAUTION: The approximate weight of the boom is 1089 kg (2400 lb).

Specification Loader Boom-to-Loader Frame—Clearance...................................... 3 mm (0.12 in.) maximum

Specification Loader Boom—Weight ....................... 1089 kg (2400 lb) approximate


TM1640 (15JAN04)

TX,3140,RP3046 –19–18FEB99–1/1

31-3140-9


PN=533

31 3140 9

Frames

T108276

–UN–26NOV97

Remove and Install Tool Carrier Boom Bushings and Seals

Left Side of Boom Shown 31 3140 10

A—Tool Carrier Boom B—Bushing (4 used)

C—Seal (8 used) D—Seal (4 used)

E—Bushing (2 used) F—Seal (8 used)

1. Lower boom to ground and remove attachment from tool carrier. CAUTION: The approximate weight of the boom is 907 kg (2000 lb). The approximate weight of the tilt cylinder is 98 kg (216 lb). Specification Tool Carrier Boom—Weight ................. 907 kg (2000 lb) approximate Tilt Cylinder—Weight ................................ 98 kg (216 lb) approximate

2. Remove bucket tilt linkage and cylinders.

G—Bushing (4 used)

4. Remove boom pivot pins and remove boom. 5. Remove bushings from boom using disks from Bushing, Bearing and Seal Driver Set. 6. Apply NEVER-SEEZ Lubricant or an equivalent on outer surface of new bushings and bores. Center new bushings in boom bores and press seals against bushings with lips outward. 7. Install boom on machine and replace cylinders, linkage and bucket. Install shims in original locations. Measure clearances and adjust shims as required.

3. Disconnect boom cylinder rod ends from boom.


TM1640 (15JAN04)

TX,3140,RP3047 –19–18FEB99–1/1

31-3140-10


PN=534

Group 3160

Hydraulic System Essential Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC).


CED,OUOE003,3383 –19–22APR99–1/5

–UN–08SEP97

Spanner Wrench . . . . . . . . . . . . . . . . . . . . . . JT07289

T111317A

Used to tighten spanner nut on 125 series cylinders.

CED,OUOE003,3383 –19–22APR99–2/5

Torque Wrench. . . . . . . . . . . . . . . . . . . . . . . JT02004

31 3160 1

Used with JT07289 Spanner Wrench to tighten spanner nut on 125 series cylinders. CED,OUOE003,3383 –19–22APR99–3/5

T106133

Used to install terminals on Quickshift switch wire on pilot controller lever. Crimps WEATHER PACK male and female connectors. Tool crimps both the connector and seal retainer at the same time.

–UN–08JAN97

WEATHER PACK Crimping Tool . . . . . . . . . . JDG783


CED,OUOE003,3383 –19–22APR99–4/5

Gas Cock . . . . . . . . . . . . . . . . . . . . . . . . . . JT01735 To charge and reduce pressure to accumulator.

CED,OUOE003,3383 –19–22APR99–5/5

TM1640 (15JAN04)

31-3160-1


PN=535

Hydraulic System



CED,OUOE003,3384 –19–22APR99–1/9

Bench Mounted Holding Fixture . . . . . . . . . . D01006AA Used to hold hydraulic pump.

CED,OUOE003,3384 –19–22APR99–2/9

Portable Filter Caddy To filter contamination from hydraulic systems.

CED,OUOE003,3384 –19–22APR99–3/9

31 3160 2

3658 mm (12 ft) x 3/4 in. ID 100R1 Hose with 3/4 M NPT Ends (2 used) To connect to the portable filter caddy. CED,OUOE003,3384 –19–22APR99–4/9

Quick Disconnect Fittings To test fittings.

CED,OUOE003,3384 –19–22APR99–5/9

Discharge Wand To discharge hydraulic oil back into reservoir.

CED,OUOE003,3384 –19–22APR99–6/9

Connector (1-1/16 M ORB x 3/4 M NPT) . . . . . . JT03297 To connect reservoir to filter caddy.


TM1640 (15JAN04)

31-3160-2

CED,OUOE003,3384 –19–22APR99–7/9


PN=536

Hydraulic System Torque Wrench To tighten pilot controller hex nut.

CED,OUOE003,3384 –19–22APR99–8/9

Gauge . . . . . . (0—6895 kPa) (0—69 bar) (0—1000 psi) To test pilot pressure coming from pilot controller.

CED,OUOE003,3384 –19–22APR99–9/9


Name

Use



Apply to bucket and boom valve sections hardware. Apply to threads of spool assembly components. Apply to threads on pilot controller lever assembly. Apply to threads on pilot controller lever assembly. Apply to universal joint threads.

PT569 (U.S.)


Apply to bucket cylinder head and rod end pins. Apply to bushing and seal.

TY24311 (U.S.) CXTY24311 (Canadian) 222 (LOCTITE)

Thread Lock and Sealer (Low Strength)

Apply to hydraulic cylinder rod guide lock nut.

AT115876 (U.S.)

KRYTOX GPL202 Fluorinated Grease

Apply to push bar and sleeve adjusters inside pilot controller lever housing.

LOCTITE is a trademark of Loctite Corp. NEVER-SEEZ is a trademark of Emhart Chemical Group. KRYTOX is a trademark of E.I. DuPont, DeNemours and Co. Inc.

TM1640 (15JAN04)

31-3160-3

CED,OUOE003,3385 –19–22APR99–1/1


PN=537

31 3160 3

Hydraulic System

Specifications Item

Measurement

Specification

Hydraulic Pump

Weight


Piston Shoe

Wear

0.025 mm (0.001 in.) maximum at outer dimension 0.152 mm (0.006 in.) worn 0.076 mm (0.003 in.) new

Hydraulic Pump

End Play End Play

31 3160 4

Saddle Bearing

Thickness

0.152 mm (0.006 in.) maximum difference between worn and unworn area

Bearing Locate Pin

Distance

1.3—1.6 mm (0.050—0.065 in.) into bearing locating hole

Guide Plate Cap Screw

Torque

10 N•m (90.0 lb-in.)

Valve Plate-to-Pump Housing Hex Head Cap Screw

Torque

95 N•m (70 lb-ft)

Socket Head Screw

Torque

95 N•m (70 lb-ft)

Control Housing-to-Pump Cap Screw

Torque

60 N•m (44 lb-ft)

Control Housing-to-Pump Cap Screw

Torque

60 N•m (44 lb-ft)

Control End Cap-to-Control Housing Screw

Torque

40 N•m (30 lb-ft)

Load Sense Module (Valve)-to-End Torque Cap Screw

6 N•m (57 lb-in.)

Hydraulic Pump Control Valve

Loader Control Valve Loader Control Valve

Weight


Loader Control Valve Tie Bolt Nut

Torque

56 N•m (75 lb-ft)


TM1640 (15JAN04)

31-3160-4

CED,OUOE003,3387 –19–22APR99–1/5


PN=538

Hydraulic System

Item

Measurement

Specification

Circuit Relief Lock

Torque

20 N•m (175 lb-in.)

Circuit Relief Housing

Torque

102 N•m (75 lb-ft)

Compensator Cap

Torque

102 N•m (75 lb-ft)

Cap Screw

Torque

11 N•m (100 lb-in.)

Lift Check Hex Head Cap

Torque

169 N•m (125lb-ft)

Port Plug

Torque

20 N•m (175 lb-in.)

Compensator Cap

Torque

115 N•m (85 lb-ft)

Nut

Torque

20 N•m (175 lb-in.)

Compensator Cap

Torque

102 N•m (75 lb-ft)

Plug

Torque

102 N•m (75 lb-ft)

Nut

Torque

20 N•m (175 lb-in.)

Hex Head Cap Screw

Torque

102 N•m (75 lb-ft)

Plug

Torque

12 N•m (100 lb-in.)

Stripper Bolt

Torque

20 N•m (175 lb-in.)

Check Hex Head Cap

Torque

169 N•m (125lb-ft)

Socket Head Cap Screw

Torque

20 N•m (175 lb-in.)

Boom Lower Pilot Plug

Torque

12 N•m (100 lb-in.)

Anti Cavitation Plug

Torque

102 N•m (75 lb-ft)

Weight


Bucket Valve

Boom Valve

31 3160 5

Boom Cylinder Boom Cylinder


TM1640 (15JAN04)

31-3160-5

CED,OUOE003,3387 –19–22APR99–2/5


PN=539

Hydraulic System

Item

Measurement

Specification

Bucket Cylinder

Weight


Piston Retaining Nut

Torque

3580 ± 180 N•m (2640 ± 133 lb-ft)

Set Screw Nut

Torque

31.5 ± 5.9 N•m (23 ± 4 lb-ft)

Rod Guide Screw

Torque

350 ± 70 N•m (258 ± 52 lb-ft)

624H Boom Cylinder Piston Retaining Nut

Torque

475 N•m (350 lb-ft) plus 1/12 turn 30°

624H Bucket Cylinder Piston Retaining Nut

Torque

3580 ± 180 N•m (2641 ± 133 lb-ft)

624H and TC62H Boom Cylinder Rod Guide Jam Nut

Torque

1350 N•m (1000 lb-ft)

TC62H Boom and Tilt Cylinder Piston Retaining Nut

Torque

475 N•m (350 lb-ft) plus 1/12 turn 30°

TC62H Tilt Cylinder Rod Guide Jam Nut

Torque

1350 N•m (1000 lb-ft)

Hydraulic Reservoir

Weight


Hydraulic Reservoir-to-Frame Cap Screw

Torque

350 N•m (255 lb-ft)

Lever Housing-to-Housing Cap Screw

Torque

8.5 N•m (75 lb-in.)

Multi-sectional Valve Tie Bolt

Torque

11 N•m (100 lb-in.)

Bucket Cylinder—185 Series

Boom Cylinder—125 Series

Tilt Cylinder—125 Series

31 3160 6

Hydraulic Reservoir

Pilot Controller (Two Lever)


TM1640 (15JAN04)

31-3160-6

CED,OUOE003,3387 –19–22APR99–3/5


PN=540

Hydraulic System

Item

Measurement

Specification

Lever Housing Allen Screw-to-Valve Housing

Torque

8.5 N•m (75 lb-in.)

Universal Joint Hex Nut-to-Lever Bottom Housing

Torque

28 N•m (250 lb-in.)

Grip/Switch Assembly

Torque

28 N•m (250 lb-in.)

Lever Housing-to-Valve Housing Allen Screw

Torque

8.5 N•m (75 lb-in.)

Lever Adjusting Screw Lock Hex Nut

Torque

11 N•m (100 lb-in.)

Lever Housing-to-Valve Housing Allen Screw

Torque

8.5 N•m (75 lb-in.)

Lever Adjusting Screw Lock Hex Nut

Torque

11 N•m (100 lb-in.)

Oil

Temperature

40 ± 6°C (100 ± 10°F)

Engine

Speed

Slow idle

Lever Travel to Begin Metering

Distance

3/8—5/8 in. (measured at top end of lever)

Pilot Controller (Single Lever)

Boom Float Detent

Pressure

4137—4480 kPa (41—45 bar) (600—650 psi) in detent

Feel Position

Pressure

As the control lever is moved from neutral, the pilot pressure will suddenly jump up to approximately 90 psi at 3/8—5/8 in. travel. The pressure should then increase smoothly to the specification at the FEEL position (or 75% lever travel), and then jump up to 600—650 psi as the lever is moved into detent.

Boom Power Down

Pressure

1860—2082 kPa (19—21 bar) (270—302 psi)


TM1640 (15JAN04)

31-3160-7

CED,OUOE003,3387 –19–22APR99–4/5


PN=541

31 3160 7

Hydraulic System

Item

Measurement

Specification

Boom Raise

Pressure

1882—2227 kPa (19—22 bar) (273—323 psi)

Bucket Rollback

Pressure

2110—2455 kPa (21—25 bar) (306—356 psi)

Bucket Dump and Auxiliary Valve

Pressure

Pressure must increase smoothly to 2110—2455 kPa (21—25 bar) (306—356 psi) at 3/4 lever travel and then increase to 4140—4480 kPa (41.4—44.8 bar) (600—650 psi) as the lever is moved past 80—90% travel

Torque

7 N•m (62 lb-in.)

Accumulator

Weight


Solenoid Nut

Torque

8 N•m (72 lb-in.)

Accumulator Oil

Temperature

40°C (104°F)

Accumulator Charge

Pressure

2068 ± 138 kPa (20 ± 1 bar) (300 ± 20 psi)

Solenoid Valve Retaining Nut

Ride Control

31 3160 8

CED,OUOE003,3387 –19–22APR99–5/5

TM1640 (15JAN04)

31-3160-8


PN=542

Hydraulic System

Remove and Install Loader Hydraulic Pump IMPORTANT: Do Hydraulic Pump Flow Test in Group 9025-25 before removing hydraulic pump for repair. If pump does not meet test specification, replace it, do not rebuild pump. 1. Stop engine. 2. Lower all equipment to the ground. 3. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds.

–UN–29OCT97

CAUTION: Prevent unexpected machine movement and possible injury. Install frame locking bar before working in frame hinge area.

T112004

4. Install frame locking bar. 5. Turn battery disconnect switch off (if equipped) or disconnect battery ground strap.

A—Load Sense Hose B—Suction Hose C—Pump Inlet D—Case Drain E—Pressure-to-Control Valve F—Pressure-to-Steering Valve G—Hose to Pressure Reducing Valve

6. Remove lower front, left and right side trim shields from cab.


TM1640 (15JAN04)

31-3160-9

31 3160 9

TX,31,ME134 –19–18FEB99–1/3


PN=543

Hydraulic System

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury.

–UN–23AUG88


X9811

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 7. Drain hydraulic reservoir. Approximate capacity is 117 L (31 gal). 8. Disconnect and cap lines (A—G). 9. Attach lifting device (such as DFT1132 Hydrostatic Motor Removal Tool 850C/750C) to hydraulic pump housing. 31 3160 10

10. Remove hydraulic pump mounting cap screws. CAUTION: The approximate weight of the hydraulic pump is 49 kg (108 lb). Hydraulic Pump—Specification Hydraulic Pump—Weight ................................ 49 kg (108 lb) approximate

11. Remove hydraulic pump. 12. Repair and replace parts as necessary. 13. Replace gasket on pump mounting surface. 14. Install pump with cap screws. 15. Fill pump body with hydraulic oil through case drain (D) line to assure lubrication for start up.


TM1640 (15JAN04)

31-3160-10

TX,31,ME134 –19–18FEB99–2/3


PN=544

Hydraulic System 16. Connect lines and fittings. 17. Fill hydraulic reservoir. 18. Switch battery disconnect on (if equipped) or install battery ground cable. 19. Do Hydraulic Pump Margin and Low Standby Pressure Adjustment Test in Group 9025-25.

TX,31,ME134 –19–18FEB99–3/3

31 3160 11

TM1640 (15JAN04)

31-3160-11


PN=545

Hydraulic System

Hydraulic Pump (PVG 65) and (PVG 75) Cross Section

T104483

–UN–18OCT96

31 3160 12


TM1640 (15JAN04)

31-3160-12

TX,3100,RP3048 –19–20MAR97–1/2


PN=546

Hydraulic System A—Roll Pin (2 used) B—Bearing C—Roll Pin (4 used) D—Swash Plate E—Screw F—Retaining Ring G—Piston (9 used)

H—Housing I—Gasket J—Inlet Tube K—Plate L—Cylinder Barrel M—Slipper (9 used) N—Plug

O—Spring P—Ball Q—Retainer Shoe R—Bearing S—Bearing T—Roll Pin (2 used)

U—Retainer Seal V—Retaining Ring W—Retaining Ring X—Shaft Y—Bearing Z—Seal

TX,3100,RP3048 –19–20MAR97–2/2

Disassemble, Inspect and Assemble Hydraulic Pump

T103480

–UN–04NOV96

CAUTION: Reduce compressed air to less than 210 kPa (2.1 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection. CAUTION: The approximate weight of the hydraulic pump is 49 kg (108 lb). Hydraulic Pump—Specification Hydraulic Pump—Weight ................................ 49 kg (108 lb) approximate

31 3160 13

IMPORTANT: Use only diesel fuel to clean pump parts. Solvents can damage internal components. Perform Hydraulic Pump Case Drain Test in Group 9025-25, before removing hydraulic pump for repairs. If pump does not pass the test, replace it, DO NOT rebuild it. 1. Mount pump on D01006AA Bench Mounted Holding Fixture as shown. 2. As pump parts are removed wash in diesel fuel and dry using compressed air.


TM1640 (15JAN04)

31-3160-13

TX,31,JC2358 –19–18FEB99–1/45


PN=547

Hydraulic System

T103478

–UN–04NOV96

3. Remove socket head cap screws and lift the control group assembly straight up from the top of the pump assembly. Remove control pin from swashblock.

TX,31,JC2358 –19–18FEB99–2/45

T103480

–UN–04NOV96

4. Remove valve plate by removing four cap screws and lifting it away from main pump assembly.

TX,31,JC2358 –19–18FEB99–3/45

5. Remove O-ring (A).

–UN–24JUN91

A—O-Ring

T7553BG

31 3160 14


TM1640 (15JAN04)

31-3160-14

TX,31,JC2358 –19–18FEB99–4/45


PN=548

Hydraulic System 6. Remove gasket (A).

T7553BA

–UN–24JUN91

A—Gasket

TX,31,JC2358 –19–18FEB99–5/45

7. Make sure pump is in a horizontal position.

T103482

–UN–04NOV96

Remove rotating group by turning input shaft slowly while pulling the cylinder barrel from the pump’s housing.

TX,31,JC2358 –19–18FEB99–6/45

8. Number each pump piston shoe assembly (B) and its respective bore in cylinder barrel (A) and shoe retainer (C) while disassembling. This will assure the same parts are installed to the respective bore in the retainer and barrel.

31 3160 15

T104036

–UN–04NOV96

A—Cylinder Barrel B—Shoe Assembly C—Shoe Retainer


TM1640 (15JAN04)

31-3160-15

TX,31,JC2358 –19–18FEB99–7/45


PN=549

Hydraulic System 9. Remove shoe retainer (B) with pistons (A) and shoe retainer spring (C).

T7553BB

–UN–24JUN91

A—Piston (9 used) B—Shoe Retainer C—Shoe Retainer Spring

TX,31,JC2358 –19–18FEB99–8/45

10. Remove hydrodynamic locking screw (A). A—Hydrodynamic Locking Screw

T104801

–UN–04NOV96

31 3160 16


TM1640 (15JAN04)

31-3160-16

TX,31,JC2358 –19–18FEB99–9/45


PN=550

Hydraulic System NOTE: Later pump models may not incorporate this retaining ring. 11. Remove retaining ring (A) with flat head screwdriver (B).

T104037

–UN–04NOV96

A—Retaining Ring B—Flat Head Screwdriver

T104041

–UN–04NOV96

31 3160 17


TM1640 (15JAN04)

31-3160-17

TX,31,JC2358 –19–18FEB99–10/45


PN=551

Hydraulic System

T104028

–UN–04NOV96

12. Remove hydrodynamic bearing by pulling it out of the pump’s housing evenly.

TX,31,JC2358 –19–18FEB99–11/45

–UN–04NOV96

13. Remove drive shaft bearing retainer ring with snap ring pliers.

T103483

31 3160 18


TM1640 (15JAN04)

31-3160-18

TX,31,JC2358 –19–18FEB99–12/45


PN=552

Hydraulic System 14. Remove outboard end of drive shaft and pull out from pump housing. Remove shaft seal retainer (A).

T104805

–UN–12AUG97

A—Shaft Seal Retainer

TX,31,JC2358 –19–18FEB99–13/45

15. Remove shaft seal (A) from housing only if necessary. This is not reusable.

T7553AL

–UN–24JUN91

A—Shaft Seal


TX,31,JC2358 –19–18FEB99–14/45

31 3160 19

TM1640 (15JAN04)

31-3160-19


PN=553

Hydraulic System 16. Loader pump (130PVG) only: Remove flat head screws with a 5/32 Allen wrench and remove guide plate (A).

T103484

–UN–04NOV96

T104799

–UN–04NOV96

A—Guide Plate

31 3160 20


TM1640 (15JAN04)

31-3160-20

TX,31,JC2358 –19–18FEB99–15/45


PN=554

Hydraulic System

T103485

–UN–04NOV96

17. Remove the swashblock from pump housing.

TX,31,JC2358 –19–18FEB99–16/45

18. Remove the saddle bearings (A) from pump housing.

31 3160 21

–UN–31JAN94

19. Clean all parts thoroughly. Inspect all seals and O-rings for hardening, cracking or deterioration and replace if necessary.

T8170AE

A—Saddle Bearing


TM1640 (15JAN04)

31-3160-21

TX,31,JC2358 –19–18FEB99–17/45


PN=555

Hydraulic System 20. Inspect valve plate group.

T7553AS

–UN–24JUN91

Inspect the valve plate surface that mates with the pump cylinder barrel for excessive wear or scoring. Remove minor defects by lightly stoning the surface with a hard stone that is flat to within 0.001". Be sure to stone lightly. Any excessive stoning will remove the hardened surface. If wear or damage is extensive, replace the valve plate. Check drive shaft bushing for abnormal wear.

TX,31,JC2358 –19–18FEB99–18/45

21. Inspect suction inlet tube for cracks and damage from handling. If any cracks or damage, part must be replaced.

T103486

–UN–04NOV96

31 3160 22


TM1640 (15JAN04)

31-3160-22

TX,31,JC2358 –19–18FEB99–19/45


PN=556

Hydraulic System 22. Rotating Group

–UN–24JUN91

Inspect cylinder barrel piston bores and the face that mates with valve plate for wear and scoring. Remove minor defects on the face by lightly stoning the surface. If defects can not be removed by this method, cylinder barrel is unusable.

T7553AT

23. Inspect all piston and shoe assemblies to be sure they ride properly on the swashblock.

TX,31,JC2358 –19–18FEB99–20/45

T7553AO

–UN–24JUN91

24. Check each piston shoe for smooth pivot action on the piston. Contaminates or burrs can cause them to stick.

TX,31,JC2358 –19–18FEB99–21/45

25. Check piston shoe wear. All shoes must be within specification at outer dimension.

31 3160 23

–19–08NOV96

Hydraulic Pump—Specification Piston Shoe—Wear ............................. 0.025 mm (0.001 in.) maximum at outer dimension

T104804

Check piston shoe end play. End play must not exceed specification. Hydraulic Pump—Specification Piston Shoe—End Play ................................... 0.152 mm (0.006 in.) worn End Play ............................................................ 0.076 mm (0.003 in.) new


TM1640 (15JAN04)

31-3160-23

TX,31,JC2358 –19–18FEB99–22/45


PN=557

Hydraulic System 26. Hydrodynamic Bearing

T104798

–UN–04NOV96

Inspect for contaminate damage or extreme wear.

TX,31,JC2358 –19–18FEB99–23/45

27. Swashblock Group

–UN–24JUN91

Inspect the swashblock for wear and scoring. If defects are minor, stone the swashblock lightly. If damage is extensive, swashblock should be rejected. Check that the very small holes in the face of the swashblock are open. These holes provide "porting" for the hydrostatic balance fluid (of the piston/shoe assembly) to be channeled through the swashblock to the face of the saddle bearing (providing pressure lubrication).

T7553AQ

31 3160 24


TM1640 (15JAN04)

31-3160-24

TX,31,JC2358 –19–18FEB99–24/45


PN=558

Hydraulic System

T104033

–UN–04NOV96

28. Check bearing mating surface of swashblock for cracks or excessive wear. Swashblock movement in saddle bearings must be smooth. Replace if necessary.

TX,31,JC2358 –19–18FEB99–25/45

29. Compare saddle bearing thickness in worn area to thickness in an unworn area. Replace saddle bearings if difference is greater than specification.

T104803

–UN–04NOV96

Hydraulic Pump—Specification Saddle Bearing—Thickness ..................... 0.152 mm (0.006 in.) maximum difference between worn and unworn area

TX,31,JC2358 –19–18FEB99–26/45

IMPORTANT: Bearing locate pins must not protrude through swash plate bearing. See sketch below for proper installation of pins.

31 3160 25

–UN–08NOV96

30. Inspect bearing locate pins in housing. Pins (B) must be able to hold bearing in place without protruding through bearing.

T104810

A—Saddle Bearing (2 used) B—Locate Pin (2 used)


TM1640 (15JAN04)

31-3160-25

TX,31,JC2358 –19–18FEB99–27/45


PN=559

Hydraulic System Pins should extend specified distance (A).

–UN–04NOV96

Hydraulic Pump—Specification Bearing Locate Pin—Distance ................ 1.3—1.6 mm (0.050—0.065 in.) into bearing locating hole

T103488

A—Distance

TX,31,JC2358 –19–18FEB99–28/45

31. Drive Shaft Group Check shaft bearing for galling, pitting, binding, roughness. –UN–04NOV96

Check seal of bearing for grease containment. If seal is worn or broken. Replace shaft and bearing.

T104034

Check shaft and it’s splines for wear. If worn, replace shaft and bearing.

TX,31,JC2358 –19–18FEB99–29/45

32. Check shaft seal (A) for deterioration or cracks. Replace (press out) if necessary. 33. Pump assembly –UN–24JUN91

Install new gaskets, seals and O-rings. Apply a thin film of CLEAN grease or hydraulic fluid to sealing components to ease assembly. Apply fluid generously to all wear surfaces.

T7553AL

31 3160 26

A—Shaft Seal


TM1640 (15JAN04)

31-3160-26

TX,31,JC2358 –19–18FEB99–30/45


PN=560

Hydraulic System 34. Shaft Seal

T7553AU

–UN–24JUN91

If removed, press shaft seal into front of pump housing with a 50 mm disk and seal driver.

TX,31,JC2358 –19–18FEB99–31/45

35. Swashblock Group

T104809

–UN–04NOV96

Position pump with drive shaft facing down. Grease back side of saddle bearings and place on the locator pins to locate the bearings (A) in pump case. Pins must not protrude through the bearing locator hole. Plastic bearing (C) position should be installed on opposite of control pin side (B) of swashblock. A—Bearing (2 used) B—Control Pin Side C—Plastic Bearing

31 3160 27


TM1640 (15JAN04)

31-3160-27

TX,31,JC2358 –19–18FEB99–32/45


PN=561

Hydraulic System 36. Loader Pump (130PVG) Only Partially insert swashblock into rear of pump housing and insert guide plate into the pump’s housing, so flat head cap screws (A) can be used to fasten the guide plate to the housing. Place the swashblock on the guide plate making sure the guide plate is in the groove of the swashblock. Install guide plate screws and tighten. Make sure swashblock swivels in the saddle bearings smoothly. Hydraulic Pump—Specification Guide Plate Cap Screw—Torque ................................ 10 N•m (90.0 lb-in.)

–UN–04NOV96

37. Hydraulic Pump (75PVG) Only

T104799

Insert swashblock into rear of pump housing. Make sure swashblock swivels in the saddle bearings smoothly.

T103484

–UN–04NOV96

A—Flat Head Cap Screw

31 3160 28


TM1640 (15JAN04)

31-3160-28

TX,31,JC2358 –19–18FEB99–33/45


PN=562

Hydraulic System 38. Hydrodynamic Bearing

T104798

–UN–04NOV96

Bearing should be positioned with "scarf" cuts positioned top and bottom. Bearing should fit into place with a little difficulty and be square to the axis of the pump. Tap bearing into place if necessary using extreme care not to damage the bearing.

TX,31,JC2358 –19–18FEB99–34/45

NOTE: Insert retaining ring to hold bearing in place on older models.

31 3160 29

39. Insert hydrodynamic lock screw (A) and hand tighten.

T104801

–UN–04NOV96

A—Hydrodynamic Lock Screw


TM1640 (15JAN04)

31-3160-29

TX,31,JC2358 –19–18FEB99–35/45


PN=563

Hydraulic System 40. Drive Shaft Group—Pump in Horizontal Position Install shaft seal retainer (A).

T104805

–UN–12AUG97

A—Shaft Seal Retainer

TX,31,JC2358 –19–18FEB99–36/45

–UN–04NOV96

41. Insert drive shaft and bearing assembly into pump housing and lock in place with drive shaft bearing retainer ring.

T103483

31 3160 30


TM1640 (15JAN04)

31-3160-30

TX,31,JC2358 –19–18FEB99–37/45


PN=564

Hydraulic System 42. Rotating Group Place the cylinder barrel, wear surface down on a clean cloth. Place the shoe retainer spring in the center of the barrel with the fulcrum ball on top of it. Insert pistons into their corresponding (numbered) holes of the shoe retainer. As a unit, fit the pistons into their corresponding (numbered) bores in the cylinder barrel. DO NOT FORCE.

T104036

–UN–04NOV96

A—Cylinder Barrel B—Piston (9 used) C—Shoe Retainer

TX,31,JC2358 –19–18FEB99–38/45

43. Support the weight of the cylinder barrel as cylinder spline is passed over the tail shaft, to avoid scratching or damage. Push cylinder forward until the cylinder spline reaches the drive shaft spline and rotate the cylinder slightly to engage shaft splines. Continue to slide cylinder forward until it encounters the cylinder bearing. Lifting the tail shaft slightly helps cylinder and cylinder bearing engagement. Continue pushing cylinder forward until the piston shoes contact the swashblock.

T103482

–UN–04NOV96

31 3160 31

At this point, the back of the cylinder should be located approximately 10.2 mm (0.4 in) outside the back of the pump housing.

NOTE: Make sure the rotate group has spring action. This assures correct assembly in relation to the spline.


TM1640 (15JAN04)

31-3160-31

TX,31,JC2358 –19–18FEB99–39/45


PN=565

Hydraulic System 44. Valve Plate Group With the drive shaft facing down install O-ring (A) in pump housing. –UN–24JUN91

With the drive shaft facing down install gasket (B) on pump housing.

T112369

–UN–26NOV97

T7553BG

A—O-Ring B—Gasket

TX,31,JC2358 –19–18FEB99–40/45

45. Position valve plate on housing pins, making sure tail end of shaft engages shaft bushing in valve plate (B). Finger tighten hex head cap screw closest to O-ring first. Alternately hand tighten the other cap screws (A).

–UN–04NOV96

A—Cap Screw B—Valve Plate

T104800

31 3160 32


TM1640 (15JAN04)

31-3160-32

TX,31,JC2358 –19–18FEB99–41/45


PN=566

Hydraulic System 46. With control pin (A) in swashblock, move swashblock slowly to left side of pump housing until control pin stops at housing.

T103487

–UN–04NOV96

A—Control Pin

TX,31,JC2358 –19–18FEB99–42/45

47. Tighten valve plate cap screws to specification.

T103480

–UN–04NOV96

Hydraulic Pump—Specification Valve Plate-to-Pump Housing Hex Head Cap Screw—Torque....................................... 95 N•m (70 lb-ft) Socket Head Screw—Torque .......................................... 95 N•m (70 lb-ft)

TX,31,JC2358 –19–18FEB99–43/45

48. Install new control gasket and O-ring. Place control on pump housing making sure control pin fits into control piston slot. Loosen end cap (A) to remove spring pressure to aid in assembling of control housing.

31 3160 33

T104806

–UN–04NOV96

A—End Cap


TM1640 (15JAN04)

31-3160-33

TX,31,JC2358 –19–18FEB99–44/45


PN=567

Hydraulic System 49. Install control valve cap screws and tighten.

T103478

–UN–04NOV96

Hydraulic Pump—Specification Control Housing-to-Pump Cap Screw—Torque ................................................................ 60 N•m (44 lb-ft)

TX,31,JC2358 –19–18FEB99–45/45

31 3160 34

Remove and Install Hydraulic Pump Control Valve 1. Mount pump on D01006AA Bench Mounted Holding Fixture.


TM1640 (15JAN04)

31-3160-34

TX,31,ME137 –19–18FEB99–1/3


PN=568

Hydraulic System 2. Remove socket head cap screws and lift the control group assembly straight up from the top of the pump assembly. Remove control pin from swashblock.

T103478

–UN–04NOV96

3. Install new control gasket and O-ring. Place control on pump housing making sure control pin fits into control piston slot.

TX,31,ME137 –19–18FEB99–2/3

4.

31 3160 35

Loosen end cap (A) to remove spring pressure to aid in assembling of control housing.

Hydraulic Pump Control Valve—Specification Control Housing-to-Pump Cap Screw—Torque ................................................................ 60 N•m (44 lb-ft)

T104806

A—End Cap

–UN–04NOV96

5. Install control valve cap screws and tighten to specification.

TX,31,ME137 –19–18FEB99–3/3

TM1640 (15JAN04)

31-3160-35


PN=569

Hydraulic System

Disassemble and Assemble Hydraulic Pump Control Valve

TP55618

–UN–09SEP97

31 3160 36

1—Pump Control End Cap Assembly

2—Load Sense Module

3—Load Sense (Plus) Module


TM1640 (15JAN04)

31-3160-36

4—Pump Control

TX,31,ME138 –19–18FEB99–1/2


PN=570

Hydraulic System NOTE: Control valve is serviced as module (valve) (1—3) or complete control valve (4) as shown. Disassemble, inspect, clean and replace parts as necessary. Hydraulic Pump Control Valve—Specification Control Housing-to-Pump Cap Screw—Torque ......................................................... 60 N•m (44 lb-ft)

Control End Cap-to-Control Housing Screw—Torque........................................... 40 N•m (30 lb-ft) Load Sense Module (Valve)-to-End Cap Screw— Torque........................................................................ 6 N•m (57 lb-in.)

See Hydraulic Pump Stroke Limiter Adjustment, Group 9025-20.

TX,31,ME138 –19–18FEB99–2/2

Remove and Install Loader Control Valve 1. Install boom locking bar. 2. Stop engine.


TX,31,ME139 –19–18FEB99–1/4

31 3160 37

TM1640 (15JAN04)

31-3160-37


PN=571

Hydraulic System

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury.

–UN–23AUG88


X9811

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 3. Drain hydraulic reservoir. Approximate capacity of hydraulic reservoir is 117 L (31 gal). 4. Remove control valve access panel. 5. Loosen hold-down clamps on bucket and boom cylinder lines. 31 3160 38


TM1640 (15JAN04)

31-3160-38

TX,31,ME139 –19–18FEB99–2/4


PN=572

Hydraulic System

T106963

–19–12FEB97

31 3160 39


TM1640 (15JAN04)

31-3160-39

TX,31,ME139 –19–18FEB99–3/4


PN=573

Hydraulic System NOTE: On later machines there is an orifice installed at the loader control valve return. The orifice is a double ORFS plate that is placed between return fitting (K) and hydraulic hose. 6. Disconnect all lines.

Loader Control Valve—Specification Loader Control Valve—Weight ................... 41 kg (90 lb) approximate

8. Slide control valve forward. Remove loader control valve. 9. Replace parts as necessary.

7. Remove cap screws.

10. Install loader control valve and connect all lines.

CAUTION: The approximate weight of the loader control valve is 41 kg (90 lb).

TX,31,ME139 –19–18FEB99–4/4

Disassemble and Assemble Loader Control Valve 1. Remove nuts and washers. Separate valve sections. 2. Replace parts as necessary. 3. Install seals (F). 4. Assemble sections. Tighten nuts. Loader Control Valve—Specification Loader Control Valve Tie Bolt Nut—Torque .................................................................. 102 N•m (75 lb-ft)

–19–09APR97

A—Inlet Manifold B—Auxiliary Section Valve C—Bucket Section Valve D—Boom Section Valve E—Outlet Manifold F—Seal (13 used)

T108899

31 3160 40

TX,31,ME140 –19–18FEB99–1/1

TM1640 (15JAN04)

31-3160-40


PN=574

Hydraulic System

T112438

–19–05DEC97

Disassemble and Assemble Auxiliary Valve Section and Bucket Section

Bucket Section Shown 31 3160 41

• Stripper bolt

NOTE: Bucket valve section shown. 1. Disassemble valve.

4. Torque components.

IMPORTANT: Coat all internal surfaces with clean hydraulic oil.

Bucket Valve—Specification Circuit Relief Lock—Torque................................... 20 N•m (175 lb-in.) Circuit Relief Housing—Torque .............................. 102 N•m (75 lb-ft) Compensator Cap—Torque.................................... 102 N•m (75 lb-ft) Cap Screw—Torque .............................................. 11 N•m (100 lb-in.) Lift Check Hex Head Cap— Torque................................................................ 169 N•m (125.0 lb-ft) Port Plug—Torque ................................................. 20 N•m (175 lb-in.)

2. Replace all O-rings and backup rings. 3. Apply thread lock and sealer (high strength) to the following components: • Cap screws (L and V)

TX,31,RP3377 –19–19FEB99–1/1

TM1640 (15JAN04)

31-3160-41


PN=575

Hydraulic System

T112400

–19–09JAN98

Disassemble and Assemble Bucket Valve Section—Tool Carrier

31 3160 42

• Socket Head Screws (S)

1. Disassemble valve. IMPORTANT: Coat all internal surfaces with clean hydraulic oil. 2. Replace all O-rings and backup rings. 3. Apply thread lock and sealer (high strength) to the following components: • • • •

Nut (I) Hex Head Screws (J) Stripper Bolt-to-Spool (L) Tube Plug (R)

4. Torque components. Bucket Valve—Specification Compensator Cap—Torque.................................... 115 N•m (85 lb-ft) Circuit Relief Cap—Torque..................................... 115 N•m (85 lb-ft) Nut—Torque .......................................................... 20 N•m (175 lb-in.) Hex Head Screw—Torque..................................... 11 N•m (100 lb-in.) Lift Check Hex Head Cap— Torque................................................................ 169 N•m (125.0 lb-ft) Socket Head Screw—Torque ................................ 11 N•m (100 lb-in.) Port Plug—Torque ................................................. 20 N•m (175 lb-in.) Circuit Relief Cap—Torque..................................... 115 N•m (85 lb-ft)

TX,31,RP3375 –19–19FEB99–1/1

TM1640 (15JAN04)

31-3160-42


PN=576

Hydraulic System

T112439

–19–05DEC97

Disassemble and Assemble Boom Valve Section

1. Disassemble valve.

4. Torque components.

IMPORTANT: Coat all internal surfaces with clean hydraulic oil.

Boom Valve—Specification Compensator Cap—Torque.................................... 102 N•m (75 lb-ft) Plug—Torque .......................................................... 102 N•m (75 lb-ft) Nut—Torque .......................................................... 20 N•m (175 lb-in.) Hex Head Cap Screw—Torque .............................. 102 N•m (75 lb-ft) Plug—Torque ......................................................... 12 N•m (100 lb-in.) Stripper Bolt—Torque ............................................ 20 N•m (175 lb-in.) Check Hex Head Cap—Torque......................... 169 N•m (125.0 lb-ft) Socket Head Cap Screw— Torque.................................................................... 20 N•m (175 lb-in.) Boom Lower Pilot Plug— Torque.................................................................... 12 N•m (100 lb-in.) Anti Cavitation Plug—Torque ................................. 102 N•m (75 lb-ft)

2. Replace all O-rings and backup rings. 3. Apply thread lock and sealer (high strength) to the following components: • • • •

Nut (I) Hex Head Screws (J) Stripper Bolt-to-Spool (M) Socket Head Screws (U)

TX,31,RP3376 –19–19FEB99–1/1

TM1640 (15JAN04)

31-3160-43


PN=577

31 3160 43

Hydraulic System

Disassemble and Assemble Relief Valve Remove the adjusting screw (E).

Assemble relief valve. Check the pressure setting. (See Loader Relief and Circuit Relief Valve Pressure Test, Group 9025-25.)

T104612

O-rings, backup ring and spring are the only repair parts available.

–UN–22OCT96

Inspect parts for wear or damage.

A—Return B—Inlet C—Poppet D—Floating Seat E—Adjuster F—Plunger

TX,3100,RP3060 –19–19FEB99–1/1

Disassemble and Assemble Bucket Circuit Relief Valve

Inspect parts for wear or damage. O-rings, backup ring and spring are the only repair parts available.

–19–11APR97

Remove adjusting screw from body.

T108956

31 3160 44

TX,3100,RP3062 –19–19FEB99–1/1

TM1640 (15JAN04)

31-3160-44


PN=578

Hydraulic System

T106959

–19–12FEB97

Disassemble and Assemble Load Sense Relief Valve

Remove adjusting screw from body.


31 3160 45

Inspect parts for wear or damage. TX,3100,RP3061 –19–19FEB99–1/1

Disassemble and Assemble Boom Circuit Relief Valve

Inspect parts for wear or damage.

T104611


–UN–22OCT96

Separate retainer from body.

A—Return B—Inlet C—Poppet

TX,3100,RP3063 –19–19FEB99–1/1

TM1640 (15JAN04)

31-3160-45


PN=579

Hydraulic System

Remove and Install Boom Cylinder NOTE: Boom cylinder may be disassembled on the machine for seal and packing replacement. 1. Install frame locking bar. CAUTION: Before removing the boom cylinder, boom must be supported with a hoist or support stands. 2. Raise and support boom using a hoist or support stands. CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with ride control. Always be sure the ride control accumulator energy is discharged when working on hydraulic components. To do this: With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 3. Release hydraulic pressure. 31 3160 46

CAUTION: The approximate weight of boom cylinder is 105 kg (232 lb). Boom Cylinder—Specification Boom Cylinder—Weight ................................ 105 kg (232 lb) approximate

4. Connect hoist to cylinder using lifting straps.


TM1640 (15JAN04)

31-3160-46

TX,31,RP3058 –19–19FEB99–1/2


PN=580


X9811


–UN–23AUG88

Hydraulic System

5. Disconnect cylinder lines (A and B). 6. Support cylinder with hoist and remove rod and head end pins (C and D). 7. Remove cylinder. 8. Repair or replace as necessary.

10. Perform Loader Start-Up Procedure (Boom Cylinder). (See procedure in this group.)

T108857B

IMPORTANT: When a machine is started for the first time after cylinder rebuild or oil is drained from cylinder, the Loader Start-Up Procedure must be performed to prevent oil from “dieseling” inside the cylinder.

–UN–09APR97

9. Install cylinder. Connect lines.

T108860B

–UN–09APR97

A—Cylinder Head End Line B—Cylinder Rod End Line C—Rod End Pin D—Head End Pin

TX,31,RP3058 –19–19FEB99–2/2

TM1640 (15JAN04)

31-3160-47


PN=581

31 3160 47

Hydraulic System

Loader Start-Up Procedure (Boom Cylinder) IMPORTANT: System pressure must be reduced when performing this procedure. Adjust the LS valve to decrease system pressure. Turning the LS valve counterclockwise decreases system pressure. 1. Remove loader frame access cover. 2. Loosen lock nut on LS valve. Turn LS valve counterclockwise 2.5 complete turns. This will decrease system pressure to approximately 8274— 8963 kPa (82.74—89.63 bar) (1200—1300 psi). IMPORTANT: Perform procedure with engine at low idle (no acceleration). 3. Raise boom until you are within 2—4 feet of full height. 4. Slowly lower the boom until bucket is 2—4 feet from ground and stop. 5. Repeat steps 3 and 4 five times. 6. Slowly raise the boom to full height. 7. Slowly lower the boom to ground. 31 3160 48

8. Repeat steps 6 and 7 three times. 9. Reset system pressure by turning LS valve clockwise 2.5 turns. Check pressures. See Group 9025-25. 10. Install loader frame access cover.

CED,OUOE024,240 –19–25SEP98–1/1

TM1640 (15JAN04)

31-3160-48


PN=582

Hydraulic System

Remove and Install 624H Bucket Cylinder— 185 Series

–UN–05NOV96

NOTE: Bucket cylinder may be disassembled on the machine for seal and packing replacement. 1. Lower equipment to the ground.

T104844

2. Release hydraulic pressure by pushing pilot enable/boom down switch and moving control lever to all positions. 3. Install frame locking bar.

A—Bucket Level Indicator B—Wiring Lead

4. Remove bucket level indicator (A). 5. Remove clamps and disconnect wiring lead (B) to return-to-dig switch. CAUTION: The approximate weight of bucket cylinder is 105 kg (232 lb). Bucket Cylinder—185 Series —Specification Bucket Cylinder—Weight............................... 105 kg (232 lb) approximate

6. Install lifting straps around cylinder and support with a hoist.

31 3160 49


TM1640 (15JAN04)

31-3160-49

TX,31,ME147 –19–19FEB99–1/2


PN=583

Hydraulic System 7. Disconnect head and rod end cylinder lines. 8. Remove head and rod end pins (A and B).

–UN–05NOV96

9. Remove cylinder. 10. Repair or replace as necessary.

IMPORTANT: When a machine is started for the first time after cylinder rebuild or oil is drained from cylinder, the Loader Start-Up Procedure must be performed to prevent oil from “dieseling” inside the cylinder.

T104843

11. Install cylinder. Connect lines.

A—Head End Pin B—Rod End Pin

12. Perform Loader Start-Up Procedure (Bucket Cylinder). (See procedure in this group.)

TX,31,ME147 –19–19FEB99–2/2

31 3160 50

TM1640 (15JAN04)

31-3160-50


PN=584

Hydraulic System

Loader Start-Up Procedure (Bucket Cylinder) IMPORTANT: System pressure must be reduced when performing this procedure. Adjust the LS valve to decrease system pressure. Turning the LS valve counterclockwise decreases system pressure. 1. Remove loader frame access cover. 2. Loosen lock nut on LS valve. Turn LS valve counterclockwise 2.5 complete turns. This will decrease system pressure to approximately 8274— 8963 kPa (82.74—89.63 bar) (1200—1300 psi). IMPORTANT: Perform procedure with engine at low idle (no acceleration.) 3. Slowly raise boom half way up. Roll back bucket to within a few feet of full rollback position. 4. Dump bucket to within a couple of feet of full dump position. 5. Repeat steps 3 and 4 five times. 6. Roll back bucket to full rollback position. 7. Dump bucket until it is in the full dump position. 31 3160 51

8. Repeat steps 6 and 7 three times. 9. Reset system pressure by turning LS valve clockwise 2.5 turns. Check pressures. See Group 9025-25. 10. Install loader frame access cover.

CED,OUOE003,2588 –19–16NOV98–1/1

TM1640 (15JAN04)

31-3160-51


PN=585

Hydraulic System

–UN–18JUL97

624H Bucket Cylinder—185 Series, Cross Section

T109796

31 3160 52

185 Cylinder Design A—Wear Ring B—Piston C—Backup Ring D—Cap Seal E—Expander Seal

F—Barrel G—Buffer Seal H—Rod Bearing I—U-Cup Seal

J—Wiper Seal K—Rod L—Rod Guide M—Backup Ring

N—O-Ring O—Shim P—Nut Q—Set Screw

TX,31,RP3366 –19–25OCT97–1/1

TM1640 (15JAN04)

31-3160-52


PN=586

Hydraulic System

NOTE: Repair procedures for cylinders are similar except as shown.

T6190AS

IMPORTANT: Extend rod to remove oil or air between the piston and rod guide. Excessive amount of trapped oil or air will force seals to expand making disassembly more difficult.

–UN–19OCT88

Disassemble 624H Bucket Cylinder—185 Series

1. Extend rod so piston is approximately 25.4 mm (1 in.) from rod guide. 2. Make a mark on rod guide and cylinder barrel to aid in assembly. 3. Remove screws holding rod guide to barrel. 4. Remove rod guide, rod and piston. 5. To remove piston, remove set screw. Set screw is staked in two places. Remove piston and rod guide from rod. (Refer to 624H Bucket Cylinder—185 Series, Cross Section in this group.) 6. Remove seals and backup ring from rod guide. 7. Inspect piston, rod guide and cylinder barrel for nicks or burrs that may damage seals or O-rings. Remove nicks or burrs with fine crocus cloth.

31 3160 53

TX,31,RP3367 –19–19FEB99–1/1

TM1640 (15JAN04)

31-3160-53


PN=587

Hydraulic System

Assemble 624H Bucket Cylinder—185 Series NOTE: Use a cylinder repair kit when assembling cylinder. Put clean hydraulic oil on all internal parts before assembling. 1. Install buffer seal (D) and wear ring (C) in rod guide. Install U-cup seal (B) in rod guide with lip inward. Install wiper seal (A) in rod guide with seal lip outward. –UN–01JUN93

2. Install O-ring (F) and backup ring (E) on rod guide. Install rod guide on rod.

T8005AL

3. Install expander seal, cap seals, and backup rings on piston.

NOTE: Do not use thread lock and sealer on bucket cylinder rod threads.

A—Wiper Seal B—U-Cup Seal C—Wear Ring D—Buffer Seal E—Backup Ring F—O-Ring G—O-Ring

4. Install nut on rod. Bucket Cylinder—185 Series—Specification Piston Retaining Nut—Torque..................... 3580 ± 180 N•m (2640 ± 133 lb-ft)

5. Install set screw in nut, torque to specification and stake in two places. Bucket Cylinder—185 Series—Specification Set Screw Nut—Torque ................................ 31.5 ± 5.9 N•m (23 ± 4 lb-ft) 31 3160 54

6. Install rod with rod guide and piston into barrel. Align marks on rod guide and barrel to orient port correctly. Install rod guide screws and torque to specification. Bucket Cylinder—185 Series—Specification Rod Guide Screw—Torque ......................... 350 ± 70 N•m (258 ± 52 lb-ft)

7. Inspect cylinder pivot bushings and seals. Replace if needed, see instructions in this group.


TM1640 (15JAN04)

31-3160-54

TX,31,RP3368 –19–19FEB99–1/3


PN=588

Hydraulic System

9. Perform Loader Start-Up Procedure (Bucket Cylinder). (See procedure in this group.)

T104843

IMPORTANT: When machine is started for the first time after cylinder rebuild or oil is drained from the cylinder, the following steps must be taken to prevent oil from “dieseling” inside the cylinder.

–UN–05NOV96

8. Install cylinder on machine. Apply NEVER-SEEZ Lubricant or equivalent to pins (A) and (B) and install. Connect hydraulic hoses.

A—Head End Pin B—Rod End Pin

NEVER-SEEZ is a trademark of the Emhart Chemical Group.

TX,31,RP3368 –19–19FEB99–2/3

10. Install bucket level indicator (A) and return-to-dig switch wiring clamps. Adjust return-to-dig components per instructions in Group 1674.

T104844

–UN–05NOV96

A—Bucket Level Indicator B—Return-to-Dig Switch Wiring Clamp

31 3160 55

TX,31,RP3368 –19–19FEB99–3/3

TM1640 (15JAN04)

31-3160-55


PN=589

Hydraulic System

Boom Cylinder Piston Wear Ring Configuration

T118506

–UN–17FEB99

31 3160 56

A—Single Wear Ring Piston (Boom Cylinders SN — XXXXXX) B—Wear Ring 15 mm (0.59 in.) for Single Wear Ring Pistons

C—Wear Ring 8 mm (0.31 in.) with Vertical Matting Gap D—Dual Wear Ring Piston (Boom Cylinders SN XXXXXX—)

E—Wear Ring 8 mm (0.31 in.) with Slant Matting Gap

IMPORTANT: On dual wear ring pistons (D), use pin bore centerline (F) for aligning wear rings (C and E) on piston. Gaps

F—Rod Eye Pin Bore and Centerline

on wear rings must be indexed 180° from each other.

CED,OUOE003,2660 –19–16DEC98–1/1

TM1640 (15JAN04)

31-3160-56


PN=590

Hydraulic System

31 3160 57

TM1640 (15JAN04)

31-3160-57


PN=591

Hydraulic System

Boom Cylinder 624H and TC62H and TC62H Tilt Cylinder—125 Series, Cross Section

T107291

–UN–18FEB97

31 3160 58


TM1640 (15JAN04)

31-3160-58

TX,31,RP3369 –19–19FEB99–1/2


PN=592

Hydraulic System A—Nut B—Wear Ring C—Ring (2 used) D—Cap Seal E—Seal Expander

F—Piston G—Rod Seal H—Wear Ring I—Rod Seal

J—Wiper Seal K—Nut L—Rod M—Rod Guide

N—O-Ring O—Backup Ring P—O-Ring Q—Barrel

TX,31,RP3369 –19–19FEB99–2/2

Disassemble and Assemble 624H and TC62H Boom Cylinder and TC62H Tilt Cylinder—125 Series 1. Mark (A) rod guide and barrel to aid in assembly. The JT07289 Spanner Wrench must be attached parallel to the JT02004 torque wrench (or equivalent) to provide a 2:1 multiplier. (Torque reading will be half of actual torque.) 2. Loosen jam nut using appropriate adjustable spanner wrench. 3. Remove rod guide from barrel by rotating counterclockwise.

T107241

–UN–15FEB97

A—Rod Guide and Barrel Marks

JT07289 Spanner Wrench Used On 125-Series Cylinders


TM1640 (15JAN04)

31-3160-59

TX,31,RP3370 –19–19FEB99–1/13


PN=593

31 3160 59

Hydraulic System 4. Remove nut to remove piston. 5. Remove piston wear ring (C) and seals (D).

–UN–19OCT88

6. Remove rod guide.

T6172BQ

7. Remove O-ring, backup ring, rod seals, and rod wear ring. A—Nut B—Piston C—Wear Ring D—Cap Seal

TX,31,RP3370 –19–19FEB99–2/13

8. Inspect end of barrel. If necessary, remove nicks and burrs from the end of the barrel. 9. Thoroughly clean all components.

11. Install buffer seal with lip of seal toward inside (oil side) of cylinder.

T6119AO

31 3160 60

–UN–19OCT88

10. Install rod wear ring.

12. Install buffer seal backup ring in notch provided in the outboard side of the buffer seal. 13. Install rod seal with sealing lip toward inside (oil side) of cylinder. 14. Install wiper seal with extended lip toward outside (air side) of cylinder. Press metal ring flush with the outer end of guide (Use care not to damage the extended sealing lip). 15. Install guide to barrel O-ring and backup ring with the backup ring toward the outside (air side) of cylinder.


TM1640 (15JAN04)

31-3160-60

TX,31,RP3370 –19–19FEB99–3/13


PN=594

Hydraulic System IMPORTANT: To prevent damage of seal during assembly, the lands on the piston must be clean and free of nicks and burrs.

–UN–19OCT88

16. Inspect the piston lands. If necessary, clean the lands of any nicks or burrs that can cut the piston seal.

T6122AB

NOTE: The cap seal can be made more pliable by warming it with your hands or putting seal in hot water for approximately 5 minutes. Once started, install cap seal as quickly as possible to keep the amount of time that the seal is stretched to a minimum. 17. Install seal expander. 18. Push seal on end of piston. 19. Install a plastic tie band around cap seal with the smooth side against seal.

TX,31,RP3370 –19–19FEB99–4/13

IMPORTANT: For proper fit and operation, the backup rings must be installed with the radius toward seal expander.

31 3160 61

T6122AE

–UN–19OCT88

T6122AC

–UN–06AUG90

20. Pull cap seal across land into position over seal expander using the plastic tie band.


TM1640 (15JAN04)

31-3160-61

TX,31,RP3370 –19–19FEB99–5/13


PN=595

Hydraulic System 21. Install backup rings with radius toward seal expander. 22. Check the cap seal for looseness. Seal must fit tight against seal expander and not turn. If seal can be turned, it has been stretched too much and can be damaged during assembly into barrel.

T6126AO

–UN–19OCT88

A—Backup Ring (2 used) B—Radius C—Cap Seal D—Seal Expander

TX,31,RP3370 –19–19FEB99–6/13

NOTE: When using a ring compressor, put a piece of shim stock between cap seal and compressor at the joint so it does not damage seal. When using a plastic tie band (A) and hose clamp, grind a taper (B) on one end of the tie band. Install tie band with the taper against cap seal. Before tightening the hose clamp (C), the tie band must be under hose clamp all around the piston. Seal will also shrink to its original size if left for a minimum of 8 hours before installing assembly into barrel. 23. If necessary, shrink cap seal to its original size using a ring compressor or plastic tie band and a hose clamp.

–UN–09NOV88

A—Plastic Tie Band B—Taper C—Hose Clamp

T86565

31 3160 62


TM1640 (15JAN04)

31-3160-62

TX,31,RP3370 –19–19FEB99–7/13


PN=596

Hydraulic System

T6122AF

–UN–19OCT88

24. Install wear ring.


TX,31,RP3370 –19–19FEB99–8/13

31 3160 63

TM1640 (15JAN04)

31-3160-63


PN=597

Hydraulic System

T118506

–UN–17FEB99

31 3160 64

A—Single Wear Ring Piston (624H Boom Cylinders SN —570631) (TC62H Boom Cylinders SN — 570463)

B—Wear Ring 15 mm (0.59 in.) for Single Wear Ring Pistons C—Wear Ring 8 mm (0.31 in.) with Vertical Matting Gap

IMPORTANT: On dual wear ring pistons (D), use pin bore centerline (F) for aligning wear rings (C and E) on piston. Gaps on wear rings must be indexed 180° from each other. 25. Boom Cylinders—On early boom cylinders install single wear ring (B).

D—Dual Wear Ring Piston (624H Boom Cylinders SN 570632—) (TC62H Boom Cylinders SN 570463—)

E—Wear Ring 8 mm (0.31 in.) with Slant Matting Gap F—Rod Eye Pin Bore and Centerline

• 624H: (S.N. 570362—) • TC62H: (S.N. 570464—) Install wear rings (C and E) on piston (D). When installing piston on rod, use pin bore centerline (F) for aligning wear rings. Gaps on wear rings must be indexed 180° from each other. 26. Install assembled rod guide and piston on rod.

Later boom cylinders:


TM1640 (15JAN04)

31-3160-64

TX,31,RP3370 –19–19FEB99–9/13


PN=598

Hydraulic System 624H Bucket Cylinder Piston Retaining Nut—Torque ......................... 3580 ± 180 N•m (2641 ± 133 lb-ft)

NOTE: Do NOT apply thread lock and sealer to bucket cylinder piston retaining nut. 27. Apply thread lock and sealer (high strength) or equivalent to rod threads, under piston retaining nut on boom cylinder, but NOT bucket cylinder. Lubricate piston with hydraulic oil where retaining nut contacts it. Tighten piston retaining nut to the torque specification.

Tilt Cylinder—125 Series—Specification TC62H Boom and Tilt Cylinder Piston Retaining Nut—Torque .............................. 475 N•m (350 lb-ft) plus 1/12 turn 30°

Boom Cylinder—125 Series—Specification 624H Boom Cylinder Piston Retaining Nut—Torque ......................................... 475 N•m (350 lb-ft) plus 1/12 turn 30°

TX,31,RP3370 –19–19FEB99–10/13

T6149AG

–UN–19OCT88

28. Put tape around a socket. Make marks on the tape to divide the socket into 1/12’s (30°).

TX,31,RP3370 –19–19FEB99–11/13

29. Turn the nut to specified torque plus one mark (30°).

T6172BR

–UN–19OCT88

30. Apply thread lock and sealer (low strength) or equivalent to barrel threads that will be under jam nut.


TM1640 (15JAN04)

31-3160-65

TX,31,RP3370 –19–19FEB99–12/13


PN=599

31 3160 65

Hydraulic System 31. Thread jam nut onto the barrel. IMPORTANT: To prevent seal damage, the barrel, piston and rod must be in alignment during installation. 32. Apply a light coat of clean hydraulic oil to piston seals and barrel chamfer. Use care not to get oil on barrel threads. 33. Carefully push piston into barrel. 34. Apply thread lock and sealer (low strength) or equivalent to barrel threads. Use care not to get sealant on end of barrel that engages internal O-ring and backup ring. 35. Carefully push and rotate rod guide to engage threads. –UN–15FEB97

36. Thread rod guide onto barrel until it bottoms internally against the end of the barrel.

37. Loosen rod guide until the marks made before disassembly are aligned, or the rod guide port is properly positioned. 31 3160 66

T107241

IMPORTANT: Do not turn the guide in place with a spanner wrench.

A—Rod Guide and Barrel Marks

38. Tighten the jam nut against the rod guide. Boom Cylinder—125 Series—Specification 624H and TC62H Boom Cylinder Rod Guide Jam Nut—Torque.................................. 1350 N•m (1000 lb-ft) Tilt Cylinder—125 Series—Specification TC62H Tilt Cylinder Rod Guide Jam Nut—Torque .................................................... 1350 N•m (1000 lb-ft)

IMPORTANT: When machine is started for the first time after cylinder rebuild or oil is drained from the cylinder, the following steps must be taken to prevent oil from “dieseling” inside the cylinder. 39. Perform Loader Start-Up Procedure (Boom Cylinder). (See procedure in this group.)

TX,31,RP3370 –19–19FEB99–13/13

TM1640 (15JAN04)

31-3160-66


PN=600

Hydraulic System

Remove and Install Boom, Bucket or Tilt Cylinder Bushings and Seals 1. Remove seals (B). –UN–27OCT88

2. Remove bushings (A). 3. Install and center new bushings in bore.

5. For initial lubrication, apply NEVER-SEEZ Lubricant or an equivalent to bushings and seals.


T6172BE

4. Install new seals. Press seals into bore tight against bushing with lip facing outward. A—Bushing B—Seals

TX,31,ME150 –19–19FEB99–1/1

31 3160 67

TM1640 (15JAN04)

31-3160-67


PN=601

Hydraulic System

Remove and Install Hydraulic Reservoir 1. Remove hood and engine side shields. 2. Release hydraulic pressure by holding pilot enable/boom down switch and moving hydraulic control lever to boom float. 3. Drain reservoir. (See Operator’s Manual, Group 87, Change Hydraulic System Oil.) Approximate capacity is 117 L (31 gal). 4. Disconnect lines (C and E). CAUTION: The approximate weight of the reservoir is 186 kg (410 lb).

–UN–14APR97

Hydraulic Reservoir—Specification Hydraulic Reservoir—Weight ........................ 186 kg (410 lb) approximate

5. Install lifting strap around reservoir and attach hoist.

T109044

6. Remove cap screws to remove reservoir. 7. Replace parts as necessary. 8. Install reservoir. Tighten reservoir-to-frame cap screws. Connect lines. 31 3160 68

Hydraulic Reservoir—Specification Hydraulic Reservoir-to-Frame Cap Screw—Torque .................................................... 350 N•m (255 lb-ft)

A—Vent Filter B—Fill Tube C—To Loader Hydraulic Pump D—Reservoir Drain Plug E—To Return Filter

NOTE: If reservoir shows signs of contamination, perform Hydraulic Oil Clean-Up Procedure in this group. 9. Fill hydraulic reservoir with recommended oil. (See Hydraulic System Oil, Group 0004.)

TX,31,ME151 –19–19FEB99–1/1

TM1640 (15JAN04)

31-3160-68


PN=602

Hydraulic System

Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy SERVICE EQUIPMENT AND TOOLS

5. Start the filter caddy. Check to be sure oil is flowing through the filters.

Portable Filter Caddy 3658 mm (12 ft) x 3/4 in. ID 100R1 Hose with 3/4 M NPT Ends (2 used) Quick Disconnect Fittings Discharge Wand JT03297 Connector (1-1/16 M ORB x 3/4 M NPT)

Operate filter caddy approximately 15 minutes so oil in reservoir is circulated through filter a minimum of four times. Leave filter caddy operating for the next steps.

IMPORTANT: Brake system uses oil from hydraulic reservoir. Flush all lines in the brake, pilot, differential lock, and clutch cut-off system. Disassemble and clean pressure reducing valve and pilot controller. Remove and clean pilot caps from main control valve. Brake components may fail if brake system is not cleaned after hydraulic reservoir contamination. 1. If hydraulic system is contaminated due to a major component failure, remove and disassemble steering cylinders to clean debris from cylinders. 2. Install new return filter elements. IMPORTANT: To prevent cavitation of filter caddy pump, the minimum I.D. of connector is 1/2 in.

NOTE: For a failure that creates a lot of debris, remove access cover from reservoir. Drain reservoir and connect filter caddy suction line to drain port. Add a minimum of 19 L (5 gal) of oil to reservoir. Operate filter caddy and wash out the reservoir. 3. To minimize oil loss, pull a vacuum in reservoir using a vacuum pump. Connect filter caddy suction line to drain port at bottom of reservoir using connector and quick disconnect fitting. Check to be sure debris has not closed drain port. 4. Put filter caddy discharge line into reservoir filler hole so end is as far away from drain port as possible to obtain a thorough cleaning of oil.

NOTE: Filtering time for reservoir is 0.089 minute x number of liters (0.33 minute x number of gallons). Reservoir capacity is 106 L (28 gal). 6. Start the engine and run it at fast idle. IMPORTANT: For the most effective results, cleaning procedure must start with the smallest capacity circuit then proceed to the next largest capacity circuit. 7. Operate all functions, one at a time, through a complete cycle in the following order: clam, steering, bucket, and boom. Also include all auxiliary hydraulic functions. Repeat procedure until the total system capacity has circulated through filter caddy seven times, approximately 30 minutes. Each function must go through a minimum of three complete cycles for a thorough cleaning of oil.

31 3160 69

NOTE: Filtering time for complete hydraulic system is 0.158 minute x number of liters (0.6 minute x number of gallons). Complete hydraulic system capacity is approximately 256 L (67 gal) . Filtering time for machines with auxiliary hydraulic functions must be increased because system capacity is larger. 8. Stop the engine. Remove the filter caddy. 9. Install new return filter elements. 10. Check oil level in reservoir; add oil if necessary. (See Fuels and Lubricants in Group 0004.)

TX,31,ME152 –19–05AUG96–1/1

TM1640 (15JAN04)

31-3160-69


PN=603

Hydraulic System

Pilot Controller Valve Remove and Install (Single Lever Controller) 1. Stop engine and relieve hydraulic pressure by using boom lower switch and placing controller in boom float position. 2. Remove air vent filter from hydraulic oil reservoir and plug vent. 3. Place a vacuum on the hydraulic oil reservoir tank. 4. Open load center service door. 5. Disconnect electrical connectors. 6. Disconnect lines (A—H).

9. Install pilot controller. Connect lines and electrical connectors.

–UN–01OCT96 T104168

31 3160 70

A—Auxiliary Pilot Controller-to-Auxiliary Valve B—Pilot Controller-to-Bucket Valve Bucket Dump C—Pilot Controller-to-Hydraulic Reservoir D—Pilot Controller-to-Boom Valve Boom Lower E—Pilot Controller-to-Bucket Valve Bucket Rollback F—Pilot Controller-to-Boom Valve Boom Raise G—Pilot Controller-to-Pressure Reducing Manifold H—Auxiliary Pilot Controller-to-Auxiliary Valve

T104166


–UN–01OCT96

7. Remove four cap screws. Remove pilot controller.

TX,31,ME155 –19–19FEB99–1/1

TM1640 (15JAN04)

31-3160-70


PN=604

Hydraulic System

T109108

–UN–01MAY97

Cross Section Pilot Controller Valve (Single Lever Controller)

Bucket Rollback A—Control Lever B—Plunger C—Metering Spring D—Spool Assembly

E—“C” Port F—“P” Port G—“A” Port H—Return Spring

I—Spring Guide J—Electric Coil K—Push Bar

31 3160 71

L—Pull Plate M—Shim, Spool Metering N—Shim, Spool Position

TX,31,ME156 –19–19FEB99–1/1

Pilot Controller Valve Disassemble and Assemble (Single Lever Controller) Before Pilot Control Valve is disassembled the following checks should be done first to help isolate confirm the problem is in the pilot controller. Perform Pilot Control Valve Pressure Test. (See Section 9025-25.) Perform Pressure Reducing Valve Pressure Test. (See Section 9025-25.)


TM1640 (15JAN04)

31-3160-71

TX,31,RP3064 –19–16OCT98–1/24


PN=605

Hydraulic System

TP55415

–UN–15MAR97

31 3160 72

Single Lever (Joystick) Assembly


TM1640 (15JAN04)

31-3160-72

TX,31,RP3064 –19–16OCT98–2/24


PN=606

Hydraulic System 1—Grip 2—Sleeve 3—Nut 4—Retainer 5—Boot 6—Nut (4 used) 7—Lever 8—Setscrew 9—Washer 10—Washer 11—Plug 12—Plate 13—Washer 14—Nut 15—U-Joint (Center Post) 16—Ball Joint Socket (3 used) 17—Cap Screw (4 used) 18—Housing (top)

19—Push Bar 20—Grommet (4 used) 21—Strap (4 used) 22—Terminal Nipple (8 used) 23—Washer 24—Pin Contact (8 used) 25—Nut 26—Connector 27—O-Ring 28—Electrical Coil (3 used) 29—Retainer (3 used) 30—Tube 31—Backup Ring 32—Seal 33—Ring (2 used) 34—Retainer (2 used) (Tool Carrier 1 used)

35—Retainer (2 used) (Tool Carrier 3 used) 36—Plunger (2 used) (Tool Carrier 1 used) 37—Plunger (2 used) (Tool Carrier 3 used) 38—Shim (As required) (0.1 mm/.004 in) 39—Shim (As required) (0.2 mm/.007 in) 40—Shim (As required) (0.4 mm/.015 in) 41—Spool (2 used) 42—Spool 43—Spool 44—Spring 45—Feel Position Kit

46—Spring 47—Spring 48—Housing 49—O-Ring 50—Plug 51—Plug (2 used) 52—Valve 53—Label 54—O-Ring (6 used) 55—Adapter (5 used) 56—O-Ring (6 used) 57—Adapter 58—Plate 59—Screw (4 used) 60—Lock Nut (3 used) 61—Nut 62—Spool

TX,31,RP3064 –19–16OCT98–3/24

Replacing Quickshift Switch In Controller Lever 1. Remove pilot controller from machine. (See Remove and Install Pilot Controller Valve in this group.) –UN–19DEC96

2. Place controller in bench vice.

T105756B

3. Slide boot and retainers (B) down with hands from grip (A). A—Grip B—Boot and Retainer

TX,31,RP3064 –19–16OCT98–4/24

4. Lift up bottom of boot and remove four allen screws (A) from lever housing.

T105757B

–UN–19DEC96

A—Allen Screw (4 used)


TM1640 (15JAN04)

31-3160-73

TX,31,RP3064 –19–16OCT98–5/24


PN=607

31 3160 73

Hydraulic System IMPORTANT: Scribe a mark along side of the lever housing and valve housing of the controller before disassembling. The mark will be used when aligning the controller housings during the assembly procedure. If correct alignment is not done while assembling incorrect operation and/or damage to controller may occur. 5. Remove lever housing (A) from valve housing (B). 6. Cut switch wire at bottom side of lever housing by tie band. Remove tie band and pull wire out of lever and housing. 7. Remove grommet from lever housing.

T105758B

–UN–19DEC96

A—Lever Housing B—Valve Housing

TX,31,RP3064 –19–16OCT98–6/24

NOTE: Note the position of the lever in relation to the wire opening in lever for proper assembly.

–UN–19DEC96

8. Loosen hex jam nut (A) and then turn complete grip (B) with switch assembly to remove. 9. Inspect parts and replace as necessary. 10. Apply thread lock and sealer (high strength) to lever threads.

T105756C

31 3160 74

11. Place new boot retainers over lever for installing later. A—Hex Jam Nut B—Grip

12. Install new grip with switch assembly on lever noting the proper index, then tighten hex jam nut. 13. Place shrink tube on wire and fish wire down through lever handle and center of universal joint. Position shrink tube so it is centered between the area it goes into the lever and out the universal joint. Pull back wire and heat shrink tube on wire. Return wire to the proper position in lever assembly.


TM1640 (15JAN04)

31-3160-74

TX,31,RP3064 –19–16OCT98–7/24


PN=608

Hydraulic System 14. Feed wire through the housing passage and install grommet at (A) noting the position of wire. Wire (B) should be positioned so it clears the coil bore. Wire should have approximately a 51 mm (2.0 in.) loop. 15. Place clear wire protective sleeve over wire and install two terminals (C) with JDG783 WEATHER PACK Crimping Tool. Install wire with terminals in connector (D). 16. Install lever assembly on valve housing with four allen screws. Note scribe marks for proper index. Pilot Controller (Single Lever)—Specification Lever Housing Allen Screw-to-Valve Housing—Torque ................................. 8.5 N•m (75 lb-in.)

17. Pull up boot and position on grip assembly. Install two shrink retainers by heating with heat blow gun. –UN–19DEC96

18. Install lever assembly in tractor. (See Remove and Install Pilot Control Valve in this group.)

T105759B

A—Grommet Location B—Wire C—Terminal (2 used) D—Connector E—Shrink Tube

31 3160 75


TM1640 (15JAN04)


31-3160-75

TX,31,RP3064 –19–16OCT98–8/24


PN=609

Hydraulic System Replace Pilot Control Lever Boot (Joystick)

–UN–19DEC96

1. Remove four cap screws from base of lever controller assembly inside load center door on right side of operator station. (See Remove and Install Pilot Controller Valve in this group.) This will allow boot to be free at base of controller assembly.

T105756B

2. Slide boot and retainers (B) down with hands from grip (A). 3. Remove one Phillips screw from front of grip. Pull up on grip to remove. A—Grip B—Boot and Retainer

4. Remove two shrink retainers. 5. Slide boot over switch assembly to remove. 6. Install new boot and retainers over switch assembly. 7. Install grip and fasten to lever with Phillips screw. 8. Pull up boot and position on grip with two shrink retainers. Heat retainers with heat blow gun. 9. Install four cap screws in pilot controller in load center compartment.

31 3160 76


TM1640 (15JAN04)

31-3160-76

TX,31,RP3064 –19–16OCT98–9/24


PN=610

Hydraulic System Replace Pilot Control Lever Boot (Single Lever) 1. Cut the tie band off around base of lever housing.

–UN–19DEC96

2. Slide boot and retainers (B) down with hands from grip (A). 3. Remove grip by sliding up and off of lever.

T105756B

4. Remove boot. 5. Install new boot and retainers over lever. A—Grip B—Boot and Retainer

6. Install grip on lever. 7. Pull up boot and position on grip with two shrink retainers. Heat retainers with heat blow gun. 8. Install new tie band around base of boot and lever housing.

TX,31,RP3064 –19–16OCT98–10/24

Replace Universal Joint

31 3160 77

1. Remove pilot controller from machine. (See Remove and Install Pilot Controller Valve in this group.) –UN–19DEC96

2. Place controller in vice and pull boot up.

T105757B

3. Remove four allen screws (A) in lever housing. A—Allen Screw (4 used)


TM1640 (15JAN04)

31-3160-77

TX,31,RP3064 –19–16OCT98–11/24


PN=611

Hydraulic System IMPORTANT: Scribe a mark along side of the lever housing and valve housing of the controller before disassembling. The mark will be used when aligning the controller housings during the assembly procedure. If correct alignment is not done while assembling incorrect operation and/or damage to controller may occur. 4. Remove lever housing (A) from valve housing (B). 5. Cut quickshift wire off right behind connector and pull wire out of housing, up through universal joint and lever. 6. Remove lever from universal joint by using 1/2 wrench on flats of lever. –UN–19DEC96

NOTE: Make note of position of the ball sockets assembly in relationship to coil bores.

T105758B

7. Remove ball socket assembly with plate and washers. 8. Remove hex nut from bottom side of universal joint and housing. 9. Replace parts as necessary. 31 3160 78


10. Apply thread lock and sealer (high strength) to universal joint threads. 11. Install universal joint in bottom of housing with hex nut and washer. Index to the 12 o’clock position in relation to coil bores. Tighten to specification. Pilot Controller (Single Lever)—Specification Universal Joint Hex Nut-to-Lever Bottom Housing—Torque ............................................. 28 N•m (250 lb-in.)

12. Install washers, ball sockets with plate over universal joint. Note proper index of ball sockets to relationship of coil bores. On joystick controller the bore without coil should be in the 3 o’clock position.


TM1640 (15JAN04)

31-3160-78

TX,31,RP3064 –19–16OCT98–12/24


PN=612

Hydraulic System 13. Install grip/switch assembly along with boot and new shrink retainers on universal joint. Note proper index of grip handle (must be in 12 o’clock position). Also note the index of the passage way hole for the quickshift wire in the housing (should be in the 1 o’clock position). Tighten assembly. Pilot Controller (Single Lever)—Specification Grip/Switch Assembly—Torque.................................... 28 N•m (250 lb-in.)

TX,31,RP3064 –19–16OCT98–13/24

14. Feed quickshift wire from grip assembly down through handle, center of universal joint and housing. Make sure protective shrink tube (E) is properly positioned on wire, centered through lever and universal joint. Pull wire back out and heat the shrink tube onto wire and return wire to proper position. 15. Slide clear plastic sleeve on wire that sticks out of housing and install terminals (C) on wire with JDG783 WEATHER PACK Crimping Tool. Install terminals in connector (D). 16. Install grommet in housing and tie band at area (A) on wire. Position wire (B) so it clears coil bores as shown (approximately a 51 mm [02 in.] loop). 31 3160 79

–UN–19DEC96

17. Install lever housing assembly onto valve housing. Note index marks scribed before disassembly for proper alignment to proper ports. Tighten four allen screws.

T105759B

Pilot Controller (Single Lever)—Specification Lever Housing-to-Valve Housing Allen Screw—Torque..................................................... 8.5 N•m (75 lb-in.)

A—Tie Band Area B—Wire C—Terminals D—Connector E—Shrink Tube


TM1640 (15JAN04)


31-3160-79

TX,31,RP3064 –19–16OCT98–14/24


PN=613

Hydraulic System

T105761B

–UN–19DEC96

18. Adjust ball socket (A) to zero clearance. Lever must be perpendicular to mounting surface when finished. Use allen wrench to turn setscrew (B) while holding adjuster sleeve (C). After adjusted, lock in place by tightening hex nut (D) to specification with torque wrench while holding adjuster sleeve with open end wrench. Note special tool (E) is used in manufacturing only. Pilot Controller (Single Lever)—Specification Lever Adjusting Screw Lock Hex Nut—Torque ................................................................. 11 N•m (100 lb-in.)

19. Install lever housing assembly with four allen screws onto valve housing. Note index scribe marks made before disassembly.

–UN–12JUN98

20. Install pilot controller in machine. (See Remove and Install Pilot Controller Valve in this group.)

T105760B

A—Ball Socket B—Setscrew C—Adjuster Sleeve D—Nut E—Special Tool

31 3160 80

TX,31,RP3064 –19–16OCT98–15/24

Replace Seals on Spool Retainers and Inspect Spool Assembly

–UN–19DEC96

1. Remove pilot controller from machine. (See Remove and Install Pilot Controller Valve in this group.) 2. Place controller in bench vice.

T105757B

3. Lift up bottom of boot and remove four allen screws (A) from lever housing. A—Allen Screw (4 used)


TM1640 (15JAN04)

31-3160-80

TX,31,RP3064 –19–16OCT98–16/24


PN=614

Hydraulic System IMPORTANT: Scribe a mark along side of the lever housing and valve housing of the controller before disassembling. The mark will be used when aligning the controller housings during the assembly procedure. If correct alignment is not done while assembling incorrect operation and/or damage to controller may occur. Also note spool placement to bore for reassembly. When servicing it is important to keep the representative retainer and spool assembly in the same bore. 4. Remove lever housing (A) from valve housing (B).

T105758B

–UN–19DEC96


TX,31,RP3064 –19–16OCT98–17/24

5. Remove coil (A) and let hang on side of valve housing. Remove coil retainer. Remove spool retainer (B) with pliers from valve housing.

31 3160 81

T105762B

–UN–19DEC96

A—Coil B—Spool Retainer


TM1640 (15JAN04)

31-3160-81

TX,31,RP3064 –19–16OCT98–18/24


PN=615

Hydraulic System 6. Remove and replace seals. 7. Lubricate wiper seal (D) with petroleum jelly.

–UN–06JAN97

8. Install seal in bore along with seal retainer (E).

T105841

9. Slightly bend tangs on stop ring (F) to allow for ease of installation to keep the ring centered in bore. Note, stop ring comes from factory with slightly concave or bent tangs. Make sure bending is done in the same direction. Tangs must face out when installing. Install stop ring in retainer by using a 11 mm socket as driver. Be sure to have stop ring (F) centered in bore so it does not contact push bar or ball socket pins. A—Backup Ring B—O-Ring C—Retainer D—Wiper Seal E—Seal Retainer F—Stop Ring


TX,31,RP3064 –19–16OCT98–19/24

31 3160 82

TM1640 (15JAN04)

31-3160-82


PN=616

Hydraulic System IMPORTANT: When removing spool retainer do not lose shims located between retainer and spool spring guide.

–UN–19DEC96

10. Remove spool assembly and springs (B—G, I, and J). If equipped remove feel position assembly (H). 11. Inspect and replace parts as necessary

T105763B

12. Apply KRYTOX GPL202 fluorinated grease to sliding surfaces of adjuster sleeves and push bar top where it contacts the adjusting screw. Controller Spool Assembly with Retainer with Feel Position

13. Install spool assembly and retainer in same bores if using existing parts.

A—Retainer (With Seals) B—Shims (Spool Positioning) C—Guide (Spring) D—Spool E—Shims (Metering Adjustment) F—Spring (Spool) G—Retainer Plate (Spool Spring) H—Feel Assembly I—Spring (Feel Position) J—Spring (Return)

14. Install retainers and coils (if equipped). 15. Install lever housing assembly onto valve housing. Note index marks scribed before disassembly for proper alignment to proper ports. Tighten four allen screws. Pilot Controller (Single Lever)—Specification Lever Housing-to-Valve Housing Allen Screw—Torque..................................................... 8.5 N•m (75 lb-in.)

31 3160 83

KRYTOX is a trademark of E.I. DuPont, DeNemours and Co. Inc.

TM1640 (15JAN04)


31-3160-83

TX,31,RP3064 –19–16OCT98–20/24


PN=617

Hydraulic System

T105761B

–UN–19DEC96

16. Adjust ball socket (A) to zero clearance. Lever must be perpendicular to mounting surface when finished. Use allen wrench to turn setscrew (B) while holding adjuster sleeve (C). After adjusted, lock in place by tightening hex nut (D) to specification with torque wrench while holding adjuster sleeve with open end wrench. Note special tool (E) is used in manufacturing only. Pilot Controller (Single Lever)—Specification Lever Adjusting Screw Lock Hex Nut—Torque ................................................................. 11 N•m (100 lb-in.)

Ball Socket Assembly

17. Install lever housing assembly with four allen screws onto valve housing. Note index scribe marks made before disassembly.

–UN–12JUN98

18. Do bench test on controller to check valve pressures using tractor as pressure source. (See Pilot Control Valve Pressure Test (Bench) in this group.)

T105760B

19. Install pilot controller in machine. (See Remove and Install Pilot Controller Valve in this group.)

A—Ball Socket B—Setscrew C—Adjuster Sleeve D—Hex Nut E—Special Tool

31 3160 84

TX,31,RP3064 –19–16OCT98–21/24

Pilot Control Valve Pressure Test (Bench) 1. Place controller valve assembly in vice.

–UN–19DEC96

2. Plug all ports not being tested in controller and cap lines from tractor (if pressure source is being used from same machine controller is being repaired on).

T105766B

3. Place quick coupler in drain port, inlet pressure port and outlet port to be tested in controller. 4. Connect test hose with quick couplers from drain port to reservoir or bucket.


TM1640 (15JAN04)

31-3160-84

TX,31,RP3064 –19–16OCT98–22/24


PN=618

Hydraulic System 5. Connect test hose (B) to pressure reducing valve (right side below operator station) quick coupler (A) to inlet pressure port on controller.

–UN–19DEC96

6. Connect 6895 kPa (69 bar) (1000 psi) test gauge to port being tested quick coupler.

T105765B

7. Run engine at idle, boom down with park brake ON. Check pilot controller pressures to specification.

T105766B

–UN–19DEC96

Pilot Controller (Single Lever)—Specification Oil—Temperature ................................................... 40 ± 6°C (100 ± 10°F) Engine—Speed ............................................................................ Slow idle Lever Travel to Begin Metering— Distance ................................................ 3/8—5/8 in. (measured at top end of lever) Boom Float Detent—Pressure ................... 4137—4480 kPa (41—45 bar) (600—650 psi) in detent Feel Position—Pressure .............................. As the control lever is moved from neutral, the pilot pressure will suddenly jump up to approximately 90 psi at 3/8—5/8 in. travel. The pressure should then increase smoothly to the specification at the FEEL position (or 75% lever travel), and then jump up to 600—650 psi as the lever is moved into detent. Boom Power Down—Pressure................... 1860—2082 kPa (19—21 bar) (270—302 psi) Boom Raise—Pressure .............................. 1882—2227 kPa (19—22 bar) (273—323 psi) Bucket Rollback—Pressure ........................ 2110—2455 kPa (21—25 bar) (306—356 psi) Bucket Dump and Auxiliary Valve—Pressure ................................... Pressure must increase smoothly to 2110—2455 kPa (21—25 bar) (306—356 psi) at 3/4 lever travel and then increase to 4140—4480 kPa (41.4—44.8 bar) (600—650 psi) as the lever is moved past 80—90% travel

A—Quick Coupler B—Test Hose

31 3160 85


TM1640 (15JAN04)

31-3160-85

TX,31,RP3064 –19–16OCT98–23/24


PN=619

T105535

–UN–03DEC96

Hydraulic System

A—Spool Position Shims 31 3160 86

B—Spool Metering Shims

8. If pressure reducing valve is to specification, add or remove shims to reach the correct pilot pressure as follows: To adjust lever travel specification to begin metering, add or remove spool position shims (A).

C—Housing

Shims are available in the following sizes: (0.004 in., 0.007 in., and 0.015 in.). 9. Install pilot controller in machine. (See Remove and Install Pilot Controller Valve in this group.)

To adjust pressure to specification for feel positions and pressure at 3/4 level trade, add or remove spool metering shims (B).

TX,31,RP3064 –19–16OCT98–24/24

TM1640 (15JAN04)

31-3160-86


PN=620

Hydraulic System

Pilot Controller Repair (Two Lever Controller) (S.N. —585560) Remove And Install 1. Stop engine and relieve hydraulic pressure by using boom lower switch and placing controller in boom float position. 2. Remove air vent filter from hydraulic oil reservoir and plug vent. 3. Place a vacuum on the hydraulic oil reservoir tank. 4. Open load center service door. 5. Disconnect electrical connectors.


LS10960,0000029 –19–28OCT02–1/4

31 3160 87

TM1640 (15JAN04)

31-3160-87


PN=621

Hydraulic System 6. Disconnect lines (A—H). 7. Remove four cap screws. Remove pilot controllers. 8. Replace parts as necessary. 9. Install pilot controller. Connect lines and electrical connectors.

T104845

–UN–05NOV96

A—Auxiliary Pilot Controller-to-Auxiliary Valve B—Pilot Controller-to-Bucket Valve Bucket Dump C—Pilot Controller-to-Hydraulic Reservoir D—Pilot Controller-to-Boom Valve Boom Lower E—Pilot Controller-to-Bucket Valve Bucket Rollback F—Pilot Controller-to-Boom Valve Boom Raise G—Pilot Controller-to-Pressure Reducing Manifold H—Auxiliary Pilot Controller-to-Auxiliary Valve

T104167

–UN–01OCT96

31 3160 88


TM1640 (15JAN04)

31-3160-88

LS10960,0000029 –19–28OCT02–2/4


PN=622

Hydraulic System

31 3160 89

TM1640 (15JAN04)

31-3160-89


PN=623

Hydraulic System

TP55416

–UN–15MAR97

31 3160 90


TM1640 (15JAN04)

31-3160-90

LS10960,0000029 –19–28OCT02–3/4


PN=624

Hydraulic System 1—Grip 2—Grip (with quickshift) 3—Hex Nut 4—Retainer 5—Tie Band 6—Boot 7—O-Ring 8—Set Screw 9—Nut 10—Plug 11—Lever 12—Nut 13—Washer 14—Adjuster Sleeve 15—Lever

16—Plate 17—Nut 18—Bar 19—Universal Joint 20—Ball Joint Socket 21—Strap 22—Grommet 23—Cap Screw 24—Lever Housing 25—Lever Housing 26—Washer 27—Tube 28—Coil 29—Retainer 30—Stop Ring

31—Seal 32—Backup Ring 33—Retainer 34—Retainer 35—Fitting 36—Grommet 37—Plunger 38—Plunger 39—Shim (0.4mm /.015 in) 40—Shim (0.2mm /.007 in) 41—Shim (0.1mm / .004 in) 42—Spool 43—Spool 44—Spool 45—Spring

Disassemble And Assemble

46—Feel Position Kit 47—Spring 48—Spring 49—Housing 50—Weatherpack Nipple 51—Terminal 52—Connector 53—Two Lever Controller Assembly 54—Nut 55—Washer 56—Sleeve 57—Universal Joint 58—Spool

See Pilot Controller Valve (Single Lever Controller), Disassemble and Assemble in this group.

Perform Pilot Control Valve Pressure Test. (See Section 9025-25.) Perform Pressure Reducing Valve Pressure Test. (See Section 9025-25.)

LS10960,0000029 –19–28OCT02–4/4

Pilot Controller Repair (Two Lever Controller) (S.N. 585561—)

31 3160 91

Remove and Install 1. Stop engine. 2. Relieve hydraulic pressure by using boom lever switch and place controller in boom float position.


TM1640 (15JAN04)

31-3160-91

LS10960,0000024 –19–04SEP02–1/5


PN=625

Hydraulic System 3. Remove side console cover (1). 4. Disconnect, label and cap pilot lines for ease of assembly. 5. Remove nuts and washers on top cover plate. (4 used each)

–UN–31JUL02

IMPORTANT: Do not twist control lever knobs, damage may occur to wires. 6. Remove pilot controller.

T158220B

7. Replace parts as necessary. 8. Install pilot controller. 9. Connect pilot lines and connect electrical connectors. See Hydraulic System Component Location. (Group 9025-15.)

1—Side Console Cover

Disassemble and Assemble 1. Pull rubber boots over linkage. 2. Disconnect pilot controller connector.

NOTE: Label all wiring to aid in assembly. 31 3160 92

3. Remove all pins from connector. See Replace DEUTSCH Connector. (Group 1674.)


TM1640 (15JAN04)

31-3160-92

LS10960,0000024 –19–04SEP02–2/5


PN=626

Hydraulic System 4. Label electromagnet detents (1), with controller and pin location.

NOTE: Two dowel pins for electromagnetic detent (1). 5. Remove electromagnet detents (1).

–UN–31JUL02

6. Remove control lever knobs. 7. Remove rubber boots.

T158221B

1—Electromagnet Detents 2—Dowel Pins 3—Top Plate 4—Wire Harnesses

LS10960,0000024 –19–04SEP02–3/5

8. Loosen lock nut (1) and remove control lever. 9. Remove clip clamps (2) on pivot pin (3).

–UN–31JUL02

10. Drive out pivot pin (3).

T158222B

1—Lock Nut 2—Circlip (2 used) 3—Pivot Pin

LS10960,0000024 –19–04SEP02–4/5

11. Disassemble parts as shown, replace if necessary. IMPORTANT: Control valve is serviced as an assembly.

T158223B

13. See Pilot Controller Adjustment (Two Lever). (Group 9025-20.)

–UN–31JUL02

12. Assemble control valve.

LS10960,0000024 –19–04SEP02–5/5

TM1640 (15JAN04)

31-3160-93


PN=627

31 3160 93

Hydraulic System

Remove and Install Pressure Reducing Valve Manifold

–UN–23AUG88

1. Engine OFF. Operate controls 20 times while holding pilot enable/boom down switch ON to release hydraulic pressure from brake and brake/PRV accumulators.

X9811

2. Drain reservoir or pull a vacuum. Approximate capacity of reservoir is 117 L (31 gal). 3. Disconnect electrical connectors.

31 3160 94

4. Disconnect lines (A—F). 5. Remove cap screws. Remove manifold. 6. Replace parts as necessary.

T109377


–UN–02MAY97


A—Pressure Reducing Manifold-to-Front Differential Line B—Pressure Reducing Manifold-to-Boom Raise Line C—Pressure Reducing Manifold-to-Hydraulic Return Tube Tee Line D—Pressure Reducing Manifold-to-Accumulator Tee Line E—Pressure Reducing Manifold-to-Hydraulic Pump Line F—Pressure Reducing Manifold-to-Pilot Controller Line

7. Install manifold 8. Connect all lines and electrical connectors. 9. Fill reservoir with oil to proper level. (See Hydraulic System Oil, Group 0004.)

TX,1060,JC2027 –19–19FEB99–1/1

TM1640 (15JAN04)

31-3160-94


PN=628

Hydraulic System

Remove and Install Pressure Reducing Valve

X9811

–UN–23AUG88


–UN–15APR97


2. Discharge ride control accumulator to prevent escaping fluid under pressure. (See Ride Control Accumulator Safety in Group 3102.) 3. Remove pressure reducing valve (D) from manifold. Plug opening to prevent dirt from entering manifold.

T109123

1. Engine OFF. Operate controls 20 times while holding pilot enable/boom down switch ON to release hydraulic pressure from brake and brake/PRV accumulators.

A—Boom Down Solenoid B—Differential Lock Solenoid C—Pilot Enable Solenoid D—Pressure Reducing Valve 31 3160 95

TX,31,ME159 –19–28SEP98–1/1

TM1640 (15JAN04)

31-3160-95


PN=629

Hydraulic System

Disassemble and Assemble Pressure Reducing Valve NOTE: Pressure Reducing Valve cannot be taken apart. If O-rings are OK, and orifice is OK, but pilot pressure cannot be adjusted within specifications, replace Pressure Reducing Valve. 1. Inspect for dirty, worn or damaged parts. 2. Remove orifice from inside Pressure Reducing Manifold and inspect for damage or clogging. 3. Replace orifice if damaged. 4. Install new O-rings and back up rings on pressure reducing valve and install parts in manifold.

T109134

A—Orifice (Inside Pressure Reducing Valve Manifold) B—Backup Ring (2 used) C—O-Ring D—Backup Ring (2 used) E—O-Ring F—Backup Ring (2 used) G—O-Ring H—O-Ring I—Pressure Reducing Valve

–UN–15APR97

5. Adjust pilot pressure. See Pressure Reducing Pressure Test in Group 9025-25.

31 3160 96

TX,31,RP3068 –19–19FEB99–1/1

TM1640 (15JAN04)

31-3160-96


PN=630

Hydraulic System

Remove and Install Boom Down Solenoid Valve

X9811

–UN–23AUG88


–UN–15APR97


T109124

1. Discharge ride control accumulator to release hydraulic pressure from loader and pilot circuit. (See Ride Control Accumulator Safety in Group 3102.) 2. Disconnect electrical connector. 3. Remove parts (C—E).

–UN–09NOV92

4. Remove parts (F—K). Plug opening to prevent dirt from entering manifold.

6. Install solenoid valve using new O-rings and backup rings. 7. Install parts (C—K). Tighten nut (C). Solenoid Valve—Specification Retaining Nut—Torque ..................................................... 7 N•m (62 lb-in.)


T7751LI

5. Inspect for dirty, worn or damaged parts. Check that spool inside solenoid valve moves freely. If spool does not move freely or if valve looks worn or damaged, replace complete solenoid assembly. A—Boom Down Solenoid B—Pressure Reducing Manifold C—Nut D—ID Plate E—Coil F—Solenoid Valve G—O-Ring H—Backup Ring I—O-Ring J—O-Ring K—Backup Ring

TX,31,RP3067 –19–28SEP98–1/1

TM1640 (15JAN04)

31-3160-97


PN=631

31 3160 97

Hydraulic System

Remove and Install Differential Lock Solenoid Valve

X9811

–UN–23AUG88


–UN–15APR97


T109125


–UN–09NOV92

4. Remove parts (F—K). Plug opening to prevent dirt from entering manifold. 5. Inspect for dirty, worn or damaged parts. Check that spool inside solenoid valve moves freely. If spool does not move freely or if valve looks worn or damaged, replace complete solenoid assembly. 6. Install solenoid valve using new O-rings and backup rings. 7. Install parts (C—K). Tighten nut (C). Solenoid Valve—Specification Retaining Nut—Torque ..................................................... 7 N•m (62 lb-in.)


T7751LI

31 3160 98

A—Differential Lock Solenoid B—Pressure Reducing Manifold C—Nut D—ID Plate E—Coil F—Solenoid Valve G—O-Ring H—Backup Ring I—O-Ring J—O-Ring K—Backup Ring

TX,31,RP3065 –19–28SEP98–1/1

TM1640 (15JAN04)

31-3160-98


PN=632

Hydraulic System

Remove and Install Pilot Enable Solenoid Valve

X9811

–UN–23AUG88


–UN–15APR97


T109139


–UN–09NOV92

4. Remove parts (F—K). Plug opening to prevent dirt from entering manifold.

6. Install solenoid valve using new O-rings and backup rings. 7. Install parts (C—K). Tighten nut (C). Solenoid Valve—Specification Retaining Nut—Torque ..................................................... 7 N•m (62 lb-in.)


T7751LI

5. Inspect for dirty, worn or damaged parts. Check that spool inside solenoid valve moves freely. If spool does not move freely or if valve looks worn or damaged, replace complete solenoid assembly. A—Pilot Enable Solenoid B—Pressure Reducing Manifold C—Nut D—ID Plate E—Coil F—Solenoid Valve G—O-Ring H—Backup Ring I—O-Ring J—O-Ring K—Backup Ring

TX,31,RP3066 –19–14APR97–1/1

TM1640 (15JAN04)

31-3160-99


PN=633

31 3160 99

Hydraulic System

Ride Control Repair (S.N. —582200) Remove and Install

X9811

–UN–23AUG88

CAUTION: Hydraulic oil may escape at pressure high enough to penetrate skin from components in the ride control solenoid circuit if components are removed without discharging the accumulator. Hydraulic oil in accumulator can be stored at pressures equal to or above system relief pressures. If ride control is NOT operational, the ride control accumulator must be discharged by releasing gas charge before starting repair of control valve or any of its components. If ride control is operational: With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 1. Turn key to ON position. 31 3160 ,100

CAUTION: Boom will jump upward when ride control switch is turned ON. Make sure area around bucket is clear. 2. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds.


TM1640 (15JAN04)

31-3160-100

TE14778,0000017 –19–13OCT03–1/4


PN=634

T109151

–UN–17APR97

Hydraulic System

A—Ride Control Harness B—Ride Control Accumulator C—Boom Cylinders

D—Ride Control Pressure Switch E—Boom Cylinder

F—Ride Control Valve G—Ride Control Boom Solenoid

H—Ride Control ON/OFF Solenoid 31 3160 ,101

CAUTION: Approximate weight of ride control accumulator is approximately 40 kg (80 lb). Use hoist to remove. Ride Control:—Specification Accumulator—Weight ................................. 40 kg (80 lb) approximate

3. Replace ride control parts as required. Continued on next page

TM1640 (15JAN04)

31-3160-101

TE14778,0000017 –19–13OCT03–2/4


PN=635

Hydraulic System

TP55452

–UN–18APR97

31 3160 ,102

1—Valve 2—Coil 3—Nut 4—Boom Solenoid 5—O-Ring 6—Plug 7—O-Ring (4 used)

8—O-Ring 9—Housing 10—O-Ring 11—Plug 12—Backup Ring (2 used) 13—O-Ring 14—O-Ring

15—Seal Kit 16—Housing 17—Check Valve 18—Backup Ring (2 used) 19—O-Ring 20—O-Ring

21—Seal Kit 22—Spool 23—Coil 24—Nut 25—ON/OFF Solenoid 26—Cap Screw

Disassemble and Assemble


TM1640 (15JAN04)

31-3160-102

TE14778,0000017 –19–13OCT03–3/4


PN=636

If ride control is NOT operational, the ride control accumulator must be discharged by releasing gas charge before starting repair of control valve or any of its components.

X9811

CAUTION: Hydraulic oil may escape at pressure high enough to penetrate skin from components in the Ride Control solenoid circuit if components are removed without discharging the accumulator. Hydraulic oil in accumulator can be stored at pressures equal to or above system relief pressures.

–UN–23AUG88

Hydraulic System

If ride control is operational: With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds.

NOTE: Valve components can be replaced while valve is on machine. Internal parts of solenoid and check valves are not serviceable. 1. Remove and inspect solenoids. Replace O-rings and backup rings as required. 31 3160 ,103

2. Boom solenoid valve cannot be repaired, replace O-rings and valve as required. 3. Remove check valve and inspect. Replace O-rings and backup rings as required. 4. Remove nut (3) and replace solenoid (1) as required. 5. Assemble solenoid and tighten nut to specification. Ride Control:—Specification Solenoid Nut—Torque ...................................................... 8 N•m (72 lb-in.)

TE14778,0000017 –19–13OCT03–4/4

TM1640 (15JAN04)

31-3160-103


PN=637

Hydraulic System

Ride Control Repair (S.N. 582201—) Remove and Install

X9811

–UN–23AUG88

CAUTION: Hydraulic oil may escape at pressure high enough to penetrate skin from components in the Ride Control solenoid circuit if components are removed without discharging the accumulator. Hydraulic oil in accumulator can be stored at pressures equal to or above system relief pressures. If ride control is NOT operational, the ride control accumulator must be discharged by releasing gas charge before starting repair of control valve or any of it’s components If ride control is operational: With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 1. With boom raised slightly, turn ignition switch to ON position. 31 3160 ,104

CAUTION: Boom will jump upward when ride control switch is turned ON. Make sure area around bucket is clear. 2. Cycle the ride control switch from OFF to ON (center position). Press boom enable switch and move the control lever into the float position and hold for 5 seconds.


TM1640 (15JAN04)

31-3160-104

TE14778,0000019 –19–13OCT03–1/4


PN=638

Hydraulic System

CAUTION: Approximate weight of ride control assembly is approximately 40 kg (80 lb). Use hoist to remove assembly. Ride Control—Specification Ride Control Assembly—Weight ....................... 40 kg (80 lb) approximate

3. Replace ride control parts as required.

–UN–05NOV98

IMPORTANT: Make sure wire connections are to correct solenoids. Hydraulic functions will not operate properly, especially Boom Down.

T117959

A—Ride Control Valve-to-Bucket Dump Line B—Ride Control Valve-to-Boom Raise Line C—Ride Control Valve D—Ride Control Valve-to-Control Valve Return Line E—Valve-to-Accumulator Line (2 used) F—Accumulator (2 used) G—Ride Control Valve-to-Boom Lower Line


TE14778,0000019 –19–13OCT03–2/4

31 3160 ,105

TM1640 (15JAN04)

31-3160-105


PN=639

T117948

–UN–05NOV98

Hydraulic System

1—Electrical Coil (3 used) 2—Rod End Solenoid 3—Washer 31 3160 ,106

4—Boom Solenoid 5—Boom Solenoid

6—Head End Solenoid 7—Housing

Disassemble and Assemble

8—Check Valve 9—O-Ring

3. Remove check valve and inspect. Repair O-rings and backup rings as required.

1. Remove and inspect solenoids. Replace O-rings and backup rings as required. 2. Remove and inspect orifice. Install orifice in boom head end circuit with the cone end down.


TM1640 (15JAN04)

31-3160-106

TE14778,0000019 –19–13OCT03–3/4


PN=640

Hydraulic System Disassemble and Assemble Ride Control Solenoid Valves

2. Assemble solenoid coil and tighten solenoid nut.

T7751LI

Ride Control—Specification Solenoid Nut—Torque ...................................................... 8 N•m (72 lb-in.)

–UN–09NOV92

1. Remove solenoid nut (C) and replace solenoid coil (E) as required.

C—Solenoid Nut D—ID Plate E—Solenoid Coil F—Solenoid Valve G—O-Ring H—Backup Ring I—O-Ring J—O-Ring K—Backup Ring

TE14778,0000019 –19–13OCT03–4/4

31 3160 ,107

TM1640 (15JAN04)

31-3160-107


PN=641

Hydraulic System

Disassemble and Assemble Ride Control Accumulator CAUTION: Ride control circuit may be pressurized if accumulator is on the machine. Lower boom to ground by pressing boom lower switch and put control lever in float detent. If ride control is NOT operational, the ride control accumulator must be discharged by releasing gas charge before starting repair of it or any of its components. If ride control is operational: With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 1. Remove accumulator from machine. (See Ride Control Repair (S.N. —582200) or Ride Control Repair (S.N. 582201—) in this group.

31 3160 ,108


TM1640 (15JAN04)

31-3160-108

TX,31,ME164 –19–28SEP98–1/5


PN=642

Hydraulic System

CAUTION: The gas end of accumulator is gas charged and will cause end cap to blow out with deadly force if disassembly is attempted. Bleed off accumulator charge before attempting to disassemble accumulator.

NOTE: Loosen only the top special nut. The bottom "nut" is actually the accumulator gas valve. 2. Loosen special nut (A) (counterclockwise) 2 and 1/2 turns to open gas valve in accumulator and bleed off gas charge. (Resistance may be felt at approximately 1 and 1/2 turns.) 3. Remove gas fitting (E).

NOTE: Both ends of accumulator are removed the same way, piston can be removed from either end. –UN–20NOV92

4. Remove end cap using spanner wrench and remove piston.

T7893AJ

A—Cap B—Accumulator Barrel C—Piston D—End Cap E—Gas Valve

31 3160 ,109


TM1640 (15JAN04)

31-3160-109

TX,31,ME164 –19–28SEP98–2/5


PN=643

Hydraulic System 5. Remove old seals from piston (E). 6. Install center O-ring (C), then a split backup ring (B) on each side of it. 7. Install O-ring (D) in outer groove, then install wear ring (A) on top of it. 8. Repeat previous step for other side.

T7893AL

–UN–20NOV92

A—Wear Ring (2 used) B—Split Backup Ring (2 used) C—Special O-Ring Seal D—Inner O-Ring Seal (2 used) E—Piston

TX,31,ME164 –19–28SEP98–3/5

9. Remove O-ring and backup ring. 10. Install backup ring (B) with flat surface to inside of groove. –UN–20NOV92

11. Install O-ring (C) next to curved surface of backup ring. A—End Cap B—Backup Ring C—O-Ring

T7893AK

31 3160 ,110


TM1640 (15JAN04)

31-3160-110

TX,31,ME164 –19–28SEP98–4/5


PN=644

Hydraulic System IMPORTANT: Put piston next to gas valve end to reduce amount of air in accumulator before charging. 12. Install piston (C), with hollow end toward gas valve, in barrel (B). 13. Install end cap (D) and gas valve (E). Install other end cap if removed. 14. Charge accumulator, see Charge Ride Control Accumulator in this group. 15. Install accumulator on machine. See Ride Control Repair (S.N. —582200) or See Ride Control Repair (S.N. 582201—) in this group.

T7893AJ

–UN–20NOV92

A—Cap B—Accumulator Barrel C—Piston D—End Cap E—Gas Valve

TX,31,ME164 –19–28SEP98–5/5

31 3160 ,111

TM1640 (15JAN04)

31-3160-111


PN=645

Hydraulic System

Charge Ride Control Accumulator CAUTION: Hydraulic oil may escape at pressure high enough to penetrate skin from components in the Ride Control solenoid circuit if components are removed without discharging this accumulator. Hydraulic oil in accumulator can be stored at pressures equal to or above system relief pressures. IMPORTANT: Charge accumulator using only dry nitrogen. Dry nitrogen does not mix with oil and is non-combustible. It will not cause oxidation or condensation inside accumulator and is not harmful to piston seal. DO NOT use air or any combustible gas as these can cause oxidation and condensation. Oxidation and condensation are harmful to piston seal and accumulator.

moving above 5 kmph (3 mph), use On position to discharge accumulator during this procedure. 1. If accumulator is to be charged on machine and has some nitrogen pressure left. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 2. Remove hose. 3. Remove cover and cap from top of accumulator. 4. Turn handle on gas cock fully counterclockwise. Attach gas cock, hose, and regulator to accumulator.

NOTE: Ride control can not be discharged if switch is in (A) automatic position unless machine is

31 3160 ,112


TM1640 (15JAN04)

31-3160-112

TX,31,ME165 –19–28SEP98–1/2


PN=646

Hydraulic System

CAUTION: Loosen only the top special nut. The bottom "nut" is actually the accumulator gas valve fitting. Do not loosen bottom fitting. Loose fitting under pressure can cause injury. 5. Loosen special nut (A) (counterclockwise) 2 1/2 turns to open gas valve in accumulator. (Resistance may be felt at approximately 1 1/2 turns.) 6. Slowly open regulator valve to pressurize accumulator to specification. Ride Control—Specification Accumulator Oil—Temperature ............................................. 40°C (104°F) Accumulator Charge—Pressure ........... 2068 ± 138 kPa (20 ± 1 bar) (300 ± 20 psi)

T7594AA

–UN–10SEP91

7. If accumulator is to be charged on machine and has NO nitrogen pressure left. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 8. Check that accumulator is pressurized to specifications. Adjust regulator as required. 9. Tighten nut until snug to close gas valve.

31 3160 ,113

10. Close the control on the nitrogen tank. –UN–10SEP91

11. Slowly loosen the connector at pressure regulator valve to release pressure from hose.

T7594AB

12. Remove gas cock from accumulator. Install cap. A—Nut

Cross Section of Gas Valve Fitting

TX,31,ME165 –19–28SEP98–2/2

TM1640 (15JAN04)

31-3160-113


PN=647

Hydraulic System

Remove and Install Pin Disconnect/Axle Disconnect Valve CAUTION: Hydraulic oil may escape at pressure high enough to penetrate skin from components in the Ride Control solenoid circuit if components are removed without discharging the accumulator. Hydraulic oil in accumulator can be stored at pressures equal to or above system relief pressures. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. Lower equipment to the ground. CAUTION: If ride control switch is pushed, boom may unexpectedly move up. Discharge ride control accumulator.

31 3160 ,114

CAUTION: Brake accumulators supply pressure oil to pin disconnect valve when engine is OFF. Discharge brake accumulators before working on Pin Disconnect/Axle Disconnect Valve. Discharge brake accumulators by pushing brake pedal 40 or more times. Brake accumulator pressure can be read using the Monitor Basic Display. Go to menu d 052 (Clutch Cutoff Pressure).


TM1640 (15JAN04)

31-3160-114

TX,31,RP3070 –19–28SEP98–1/2


PN=648

Hydraulic System Mark hoses and harness connectors for reference during assembly. Disconnect hoses and harness connectors. Remove cap screws (B) and remove valve. Replace O-rings, install valve and connect hoses and harness connectors.

T109182

–UN–18APR97

A—Lock Nut (2 used) B—Cap Screw (2 used) C—Solenoid Valve Manifold D—Axle Disconnect Solenoid E—O-Ring (6 used) F—Pin Disconnect Solenoid

TX,31,RP3070 –19–28SEP98–2/2

Disassemble and Assemble Pin Disconnect Valve

31 3160 ,115

T109214B

2. Replace parts as needed. Replace O-rings and backup rings.

–UN–28APR97

1. Remove solenoid coil and spool. Inspect for damage or wear.

A—Nut B—Identification Plate C—Cover D—Coil E—Bottom Plate F—Spool G—O-Ring H—Backup Ring I—O-Ring J—O-Ring K—Backup Ring L—O-Ring M—Backup Ring

TX,31,RP3069 –19–28SEP98–1/1

TM1640 (15JAN04)

31-3160-115


PN=649

Hydraulic System

Disassemble and Assemble Axle Disconnect Valve

2. Replace parts as needed. Replace O-rings and backup rings.

T7751LI

C—Nut D—Identification Plate E—Coil F—Spool G—O-Ring H—Backup Ring I—O-Ring J—O-Ring K—Backup Ring

–UN–09NOV92

1. Remove solenoid coil and spool. Inspect for damage or wear.

TX,31,RP3071 –19–28SEP98–1/1

31 3160 ,116

TM1640 (15JAN04)

31-3160-116


PN=650

Index Page

Page

A Access platform Remove and install . . . . . . . . . . . . . . . . .18-1822-2 Access platform and steps Remove and install . . . . . . . . . . . . . . . . .18-1822-2 Accumulator Brake, remove and install . . . . . . . . . . . .10-1060-4 Accumulator, ride control Charge . . . . . . . . . . . . . . . . . . . . . . . . 31-3160-112 Disassemble and assemble . . . . . . . . 31-3160-108 Accumulator, ride control safety . . . . . . . . .31-3102-2 Adjust fuel shut-off solenoid . . . . . . . . . . . .05-0515-6 Air conditioning Charge R134a system . . . . . . . . . . . . .18-1830-18 Cleaning procedures . . . . . . . . . . . . . . .18-1830-19 Component location, harness . . . . . . . .18-1830-24 Component oil charge . . . . . . . . . . . . . .18-1830-12 Compressor oil charge check . . . . . . . .18-1830-10 Compressor oil removal . . . . . . . . . . . .18-1830-11 Compressor, remove and install . . . . . .18-1830-48 Condenser . . . . . . . . . . . . . . . . . . . . . .18-1830-41 Connectors for harness. . . . . . . . . . . . .18-1830-26 Evacuate R134a system . . . . . . . . . . . .18-1830-16 Expansion valve . . . . . . . . . . . . . . . . . .18-1830-33 Flush. . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-21 Freeze control switch . . . . . . . . . . . . . .18-1830-34 Freeze control switch bench test. . . . . .18-1830-35 Heater control valve . . . . . . . . . . . . . . .18-1830-36 Heater control valve leak check . . . . . .18-1830-37 Heater/evaporator coil . . . . . . . . . . . . . .18-1830-30 High and low pressure switches . . . . . .18-1830-42 Leak testing . . . . . . . . . . . . . . . . . . . . .18-1830-13 Main blower assembly. . . . . . . . . . . . . .18-1830-37 Module with heater/evaporator coil . . . .18-1830-28 Pressurizer motor assembly . . . . . . . . .18-1830-40 Purge system . . . . . . . . . . . . . . . . . . . .18-1830-20 Receiver-dryer . . . . . . . . . . . . . . . . . . .18-1830-41 Recover R134a system. . . . . . . . . . . . .18-1830-15 Refrigerant hoses and tubing inspection . . . . . . . . . . . . . . . . . . . . .18-1830-13 Refrigerant R134a caution . . . . . . . . . . .18-1830-9 System fittings reference chart . . . . . . . .18-1830-4 Air conditioning R134a component oil Charge . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12 Air conditioning R134a compressor oil Removal . . . . . . . . . . . . . . . . . . . . . . . .18-1830-11 Air conditioning R134a refrigerant Cautions . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-9 Air conditioning R134a system Evacuate. . . . . . . . . . . . . . . . . . . . . . . .18-1830-16 Recover . . . . . . . . . . . . . . . . . . . . . . . .18-1830-15 TM1640 (15JAN04)

Air conditioning, R134a refrigerant, recovery, recycling and charging Station installation . . . . . . . . . . . . . . . . .18-1830-14 Air conditioning, R134a system Charge . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-18 Air filter elements Remove and install . . . . . . . . . . . . . . . . .05-0520-3 Air system Air intake leakage test. . . . . . . . . . . . . . .05-0520-7 Air-to-air aftercooler Assemble . . . . . . . . . . . . . . . . . . . . . . .05-0510-17 Disassemble . . . . . . . . . . . . . . . . . . . . .05-0510-17 Alarm, reverse warning Change volume. . . . . . . . . . . . . . . . . . . .20-2004-2 Remove and install . . . . . . . . . . . . . . . . .20-2004-2 Alternator Remove and install . . . . . . . . . . . . . . . . .16-1672-1 Amp crimper tool Contact support adjustment . . . . . . . . .16-1674-14 Crimp height adjustment . . . . . . . . . . . .16-1674-18 Crimp height inspection. . . . . . . . . . . . .16-1674-17 Crimping procedure. . . . . . . . . . . . . . . .16-1674-15 Operation . . . . . . . . . . . . . . . . . . . . . . .16-1674-11 Remove and install die set . . . . . . . . . .16-1674-12 Auxiliary valve section and bucket section Disassemble and assemble . . . . . . . . .31-3160-41 Axle and differential Front, remove and install . . . . . . . . . . . .02-0200-3 Rear, install. . . . . . . . . . . . . . . . . . . . . .02-0200-14 Rear, remove . . . . . . . . . . . . . . . . . . . . .02-0200-9 Axle disconnect input shaft Cross-sectional view . . . . . . . . . . . . . . . .02-0250-4 Disassemble, inspect and assemble . . . .02-0250-6 Remove and install disconnect . . . . . . . .02-0250-5 Axle disconnect valve Disassemble and assemble . . . . . . . . 31-3160-116 Axle oil cooler Front, disassemble and assemble. . . . . .02-0260-9 Front, remove and install . . . . . . . . . . . .02-0260-7 Rear, remove and install . . . . . . . . . . . .02-0260-10 Axle oil coolers Exploded view. . . . . . . . . . . . . . . . . . . . .02-0260-6 Axle oscillation supports Disassemble and assemble . . . . . . . . .02-0200-18 Axle recirculating system With optional oil coolers . . . . . . . . . . . . .02-0260-4

B Batteries Remove and install . . . . . . . . . . . . . . . .16-1671-10

Index-1


PN=1

Indx 1

Index

Indx 2

Page

Page

Battery Booster . . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-8 Charging procedure . . . . . . . . . . . . . . . .16-1671-7 Disconnect switch, remove and install. . . . . . . . . . . . . . . . . . . . . . . . .16-1671-11 Electrolyte level. . . . . . . . . . . . . . . . . . . .16-1671-5 Specification . . . . . . . . . . . . . . . . . . . . . .16-1671-2 Testing . . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-9 Battery covers Remove and install . . . . . . . . . . . . . . . . .19-1913-2 Battery disconnect switch Remove and install . . . . . . . . . . . . . . . .16-1671-11 Blade terminals Remove from fuse block . . . . . . . . . . . .16-1674-24 Bleed Fuel system . . . . . . . . . . . . . . . . . . . . .05-0560-10 Blower assembly Remove and install . . . . . . . . . . . . . . . .18-1830-37 Blower/air conditioner harness (W20) Component location . . . . . . . . . . . . . . .18-1830-24 Connectors . . . . . . . . . . . . . . . . . . . . . .18-1830-26 Boom Height kickout adjustment . . . . . . . . . . .16-1674-25 Boom circuit relief valve Disassemble and assemble . . . . . . . . .31-3160-45 Boom cylinder Loader start-up procedure. . . . . . . . . . .31-3160-48 Piston wear ring configuration . . . . . . . .31-3160-56 Remove and install . . . . . . . . . . . . . . . .31-3160-46 Boom cylinders 624H and TC62H Cross section . . . . . . . . . . . . . . . . . . . .31-3160-58 Disassemble and assemble . . . . . . . . .31-3160-59 Boom down solenoid valve Remove and install . . . . . . . . . . . . . . . .31-3160-97 Boom height kickout Adjustment . . . . . . . . . . . . . . . . . . . . . .16-1674-25 Boom valve section Disassemble and assemble . . . . . . . . .31-3160-43 Brake Park, Disassamble and assemble . . . . . .11-1111-6 Park, Remove and Install . . . . . . . . . . . .11-1111-2 Brake accumulator Install . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1060-4 Remove . . . . . . . . . . . . . . . . . . . . . . . . .10-1060-4 Brake valve Install . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1060-1 Remove . . . . . . . . . . . . . . . . . . . . . . . . .10-1060-1 Brake, park Remove and install . . . . . . . . . . . . . . . . .11-1111-2 Brakes External inspection . . . . . . . . . . . . . . . . .10-1011-1 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1011-3 Remove . . . . . . . . . . . . . . . . . . . . . . . . .10-1011-3

Bucket Remove and install . . . . . . . . . . . . . . . . .31-3102-5 Bucket bolt-on cutting edges Remove and install . . . . . . . . . . . . . . . . .31-3102-7 Bucket circuit relief valve Disassemble and assemble . . . . . . . . .31-3160-44 Bucket cylinder Loader start-up procedure. . . . . . . . . . .31-3160-51 Bucket cylinder 624H Assemble . . . . . . . . . . . . . . . . . . . . . . .31-3160-54 Cross section . . . . . . . . . . . . . . . . . . . .31-3160-52 Disassemble and assemble . . . . . . . . .31-3160-53 Bucket linkage seals and bushings Remove and install . . . . . . . . . . . . . . . . .31-3140-4 Bucket tilt linkage, lower Disassemble and assemble . . . . . . . . . .31-3140-6 Bucket tilt linkage, upper Disassemble and assemble . . . . . . . . . .31-3140-5 Bucket tooth shanks and tips Remove and install . . . . . . . . . . . . . . . . .31-3102-3 Bucket welded cutting edge Remove and install . . . . . . . . . . . . . . . . .31-3102-6 Bulbs Replace halogen . . . . . . . . . . . . . . . . . . .16-1673-1 Bushings and seals, boom, bucket or tilt cylinder Remove and install . . . . . . . . . . . . . . . .31-3160-67 Bushings and seals, loader boom Remove and install . . . . . . . . . . . . . . . . .31-3140-9 Bushings, tool carrier boom Remove and install . . . . . . . . . . . . . . . .31-3140-10

TM1640 (15JAN04)

C Cab Fresh air filter . . . . . . . . . . . . . . . . . . . .18-1830-43 Recirculating air filter . . . . . . . . . . . . . .18-1830-46 Remove and install . . . . . . . . . . . . . . . . .18-1800-2 Cab or Canopy Remove and Install . . . . . . . . . . . . . . . . .18-1800-2 Canopy Remove and Install . . . . . . . . . . . . . . . . .18-1800-2 Capacities, drain and refill TC62H . . . . . . . . . . . . . . . . . . . . . . . . . .00-0002-8 624H. . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0002-4 Charging station, R134a refrigerant Recovery, recycling and charging . . . . .18-1830-14 Chassis computer unit (CCU) Remove and install . . . . . . . . . . . . . . . . .16-1675-3 Cinch connector Install contact . . . . . . . . . . . . . . . . . . . .16-1674-23

Index-2


PN=2

Index

Page

Page

Clean primary element Oily or sooty . . . . . . . . . . . . . . . . . . . . . .05-0520-5 Clutch Compressor . . . . . . . . . . . . . . . . . . . . .18-1830-50 Compressor, check hub clearance . . . .18-1830-51 Clutch pack KV and KR Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0350-28 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0350-26 Clutch pack K1, K2, and K3 Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0350-37 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0350-35 Clutch pack K4 Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0350-48 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0350-47 Clutches, input and output shafts Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-17 Component location Blower/air conditioner harness (W20) . . . . . . . . . . . . . . . . . . . . . . . .18-1830-24 Compressor Clutch hub clearance . . . . . . . . . . . . . .18-1830-51 Clutch, disassemble and assemble . . . .18-1830-50 Disassemble and assemble . . . . . . . . .18-1830-53 Inspect . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-53 Manifold, inspect . . . . . . . . . . . . . . . . . .18-1830-52 Remove and install . . . . . . . . . . . . . . . .18-1830-48 Compressor, air conditioning, R134a oil Removal . . . . . . . . . . . . . . . . . . . . . . . .18-1830-11 Compressor, R134a, component oil Charge . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12 Condenser Remove and install . . . . . . . . . . . . . . . .18-1830-41 Connector Metri-Pack. . . . . . . . . . . . . . . . . . . . . . . .16-1674-4 Connector body, transmission control valve Remove and install . . . . . . . . . . . . . . . . .16-1674-8 Connector terminals Replace transmission controller unit . . .16-1674-19 Connector, transmission control valve Install contact . . . . . . . . . . . . . . . . . . . . .16-1674-9 Control unit, transmission Remove and install . . . . . . . . . . . . . . . . .16-1675-1 Control valve Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0360-15 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-8 Control valve, hydraulic pump Disassemble and assemble . . . . . . . . .31-3160-36 Controller, chassis Remove and install . . . . . . . . . . . . . . . . .16-1675-3 Converter Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-8

Converter minimum pressure regulator valve Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-4 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-4 Converter relief valve Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-21 Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-21 Remove . . . . . . . . . . . . . . . . . . . . . . . .03-0360-21 Converter, torque and housing Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-5 Counterweights Remove and install . . . . . . . . . . . . . . . . .17-1749-2 Cover, battery Remove and install . . . . . . . . . . . . . . . . .19-1913-2 Cutting edge Crack repair . . . . . . . . . . . . . . . . . . . . . .31-3102-9 Cutting edge, welded Remove and install . . . . . . . . . . . . . . . . .31-3102-6 Cutting edges, bucket bolt-on Remove and install . . . . . . . . . . . . . . . . .31-3102-7 Cylinder Steering, remove and install . . . . . . . . . .09-0960-9 Steering, remove and install bushings . . . . . . . . . . . . . . . . . . . . . .09-0960-12 Cylinder, boom Loader start-up procedure. . . . . . . . . . .31-3160-48 Remove and install . . . . . . . . . . . . . . . .31-3160-46 Cylinder, bucket Loader start-up procedure. . . . . . . . . . .31-3160-51 Cylinder, steering Assemble . . . . . . . . . . . . . . . . . . . . . . .09-0960-12 Disassemble . . . . . . . . . . . . . . . . . . . . .09-0960-12 Loader start-up procedure. . . . . . . . . . .09-0960-11 Remove and install bushings . . . . . . . .09-0960-12 Cylinders bucket 624H Cross section . . . . . . . . . . . . . . . . . . . .31-3160-52 Disassemble and assemble . . . . . . . . .31-3160-53 Cylinders bushings and seals, boom, bucket or Tilt Remove and install . . . . . . . . . . . . . . . .31-3160-67 Cylinders, boom 624H and TC62H Cross section . . . . . . . . . . . . . . . . . . . .31-3160-58 Disassemble and assemble . . . . . . . . .31-3160-59 Cylinders, bucket 624H Assemble . . . . . . . . . . . . . . . . . . . . . . .31-3160-54 Remove and install . . . . . . . . . . . . . . . .31-3160-49 Cylinders, steering Remove and install . . . . . . . . . . . . . . . . .09-0960-9 Cylinders, Tilt TC62H Cross section . . . . . . . . . . . . . . . . . . . .31-3160-58 Cylinders, tilt TC62H Disassemble and assemble . . . . . . . . .31-3160-59

TM1640 (15JAN04)

Index-3


PN=3

Indx 3

Index

Page

D

Indx 4

Dampener Install . . . . . . . . . . . . . . . . . . . . . . . . . . .07-0752-1 Remove . . . . . . . . . . . . . . . . . . . . . . . . .07-0752-1 Dealer fabricated tool DFRW20 compressor holding fixture. . . .18-1899-1 DFT1148 pre-load clutch pack spring compression tool . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0399-1 DFT1149 pre-load clutch pack compression ring tool . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0399-2 DFRW20 Compressor Holding Fixture Dealer fabricated tool . . . . . . . . . . . . . . .18-1899-1 Diesel engine oil. . . . . . . . . . . . . . . . . . . . .00-0004-3 Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-1 Diesel fuel conditioner Low sulfur . . . . . . . . . . . . . . . . . . . . . . . .00-0004-2 Diesel fuel storage . . . . . . . . . . . . . . . . . . .00-0004-2 Differential Front remove and install . . . . . . . . . . . . .02-0200-3 Oil specification. . . . . . . . . . . . . . . . . . . .00-0004-4 Rear axle, install . . . . . . . . . . . . . . . . . .02-0200-14 Differential lock solenoid valve Remove and install . . . . . . . 02-0260-2, 31-3160-98 Differential, rear Install . . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-14 Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-9 Display unit, monitor Remove and install . . . . . . . . . . . . . . . . .16-1675-5 Dome light Remove and install . . . . . . . . . . . . . . . . .16-1673-7 Door light switch Remove and install . . . . . . . . . . . . . . . . .16-1673-7 Drive lights and guard Remove and install . . . . . . . . . . . . . . . . .16-1673-6 Drive shaft Disassemble, inspect and assemble . . . .02-0225-4 Remove and install . . . . . . . . . . . . . . . . .02-0225-2

E Electrical Battery specification . . . . . . . . . . . . . . . .16-1671-2 Element Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .05-0520-6 Elements, air filter Remove and install . . . . . . . . . . . . . . . . .05-0520-3 Engine Boost starting . . . . . . . . . . . . . . . . . . . . .16-1671-8 Remove and install . . . . . . . . . . . . . . . . .04-0400-3 TM1640 (15JAN04)

Page

Engine and loader frame Separate . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-5 Engine compartment step Remove and install . . . . . . . . . . . . . . . . .18-1822-4 Engine coolant heater Remove and install . . . . . . . . . . . . . . . . .05-0505-4 Engine oil Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-3 Engine side shields Remove and install . . . . . . . . . . . . . . . . .19-1910-3 Engine speed Fast and slow idle, adjust . . . . . . . . . . . .05-0515-2 Evaporator coil Remove and install . . . . . . . . . . . . . . . .18-1830-30 Expansion valve Remove and install . . . . . . . . . . . . . . . .18-1830-33

F Fan Remove and install . . . . . . . . . . . . . . . . .05-0510-5 Fan belt Remove and install . . . . . . . . . . . . . . . . .05-0510-3 Fan drive Remove and install . . . . . . . . . . . . . . . . .05-0510-5 Fast idle Adjust engine speed . . . . . . . . . . . . . . . .05-0515-2 Fenders, front Remove and install . . . . . . . . . . . . . . . . .19-1927-1 Fenders, rear Remove and install . . . . . . . . . . . . . . . . .19-1927-2 Filter Cab air recirculating . . . . . . . . . . . . . . .18-1830-46 Cab fresh air . . . . . . . . . . . . . . . . . . . . .18-1830-43 Filter caddy Hydraulic oil clean-up procedure . . . . . .31-3160-69 Fire extinguisher and bracket Remove and install . . . . . . . . . . . . . . . . .20-2003-1 Fluid starting aid Remove and install . . . . . . . . . . . . . . . . .05-0505-1 Frame pivot bearing Lower, remove and install . . . . . . . . . . .17-1740-12 Upper, remove and install . . . . . . . . . . .17-1740-10 Frame, engine and loader Separate . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-5 Freeze control switch Bench test. . . . . . . . . . . . . . . . . . . . . . .18-1830-35 Remove and install . . . . . . . . . . . . . . . .18-1830-34 Front axle and differential Remove and install . . . . . . . . . . . . . . . . .02-0200-3

Index-4


PN=4

Index

Page

Page

Front axle guard Remove and install . . . . . . . . . . . . . . . . .17-1746-1 Front axle oil cooler Disassemble and assemble . . . . . . . . . .02-0260-9 Remove and install . . . . . . . . . . . . . . . . .02-0260-7 Front turn lights Remove and install . . . . . . . . . . . . . . . . .16-1673-5 Front windshield wiper Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-8 Fuel Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-1 Lubricity . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-1 System bleed . . . . . . . . . . . . . . . . . . . .05-0560-10 Tank capacity . . . . . . . . . . . . . . . . . . . . .00-0004-3 Fuel filter, primary (water separator) Drain and clean. . . . . . . . . . . . . . . . . . . .05-0560-5 Remove and install . . . . . . . . . . . . . . . . .05-0560-6 Fuel shut-off solenoid Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0515-6 Fuel tank guard Remove and install . . . . . . . . . . . . . . . . .17-1746-1 Fuel, diesel storage . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-2 Fuse block Remove blade terminals . . . . . . . . . . . .16-1674-24

Heater control valve Remove and install . . . . . . . . . . . . . . . .18-1830-36 Heater control valve leak check . . . . . . . .18-1830-37 Hood Remove and install . . . . . . . . . . . . . . . . .19-1910-2 Horn Remove and install . . . . . . . . . . . . . . . . .20-2004-1 Hydraulic Oil specification. . . . . . . . . . . . . . . . . . . .00-0004-4 Hydraulic control valve Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0360-15 Cross section view . . . . . . . . . . . . . . . .03-0360-10 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-8 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-7 Hydraulic oil clean-up procedure Using filter caddy . . . . . . . . . . . . . . . . .31-3160-69 Hydraulic pump Disassemble, inspect and assemble . . .31-3160-13 Hydraulic pump control valve Disassemble and assemble . . . . . . . . .31-3160-36 Hydraulic pump (PVG 65) Cross section drawing. . . . . . . . . . . . . .31-3160-12 Hydraulic pump, loader Remove and install . . . . . . . . . . . . . . . . .31-3160-9 Hydraulic reservoir Remove and install . . . . . . . . . . . . . . . .31-3160-68 Hydrometer test . . . . . . . . . . . . . . . . . . . . .16-1671-9

G Grease Extreme pressure and multipurpose . . . .00-0004-5 Grille and grille housing Remove and install . . . . . . . . . . . . . . . . .19-1921-2 Guard, front axle Remove and install . . . . . . . . . . . . . . . . .17-1746-1 Guard, fuel tank Remove and install . . . . . . . . . . . . . . . . .17-1746-1 Guard, transmission bottom Remove and install . . . . . . . . . . . . . . . . .17-1746-2 Guard, transmission side Remove and install . . . . . . . . . . . . . . . . .17-1746-2

I Inch torque values . . . . . . . . . . . . . . . . . . .00-0003-5 Input and output clutches Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-17 Input shaft Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0350-55 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0350-54 Remove . . . . . . . . . . . . . . . . . . . . . . . .03-0350-11 Inspection External service brake. . . . . . . . . . . . . . .10-1011-1

J H Jump starting . . . . . . . . . . . . . . . . . . . . . . .16-1671-8 Halogen bulbs Replace . . . . . . . . . . . . . . . . . . . . . . . . .16-1673-1 Hardware Torque specifications . . . . . . . . . . . . . . .00-0003-1 Heater coil Remove and install . . . . . . . . . . . . . . . .18-1830-30 TM1640 (15JAN04)

L Light, dome Remove and install . . . . . . . . . . . . . . . . .16-1673-7

Index-5


PN=5

Indx 5

Index

Page

Light, door switch Remove and install . . . . . . . . . . . . . . . . .16-1673-7 Lights, drive and guard Remove and install . . . . . . . . . . . . . . . . .16-1673-6 Lights, front turn Remove and install . . . . . . . . . . . . . . . . .16-1673-5 Lights, stop, turn and tail Remove and install . . . . . . . . . . . . . . . . .16-1673-5 Lights, work Remove and install . . . . . . . . . . . . . . . . .16-1673-3 Load sense relief valve Disassemble and assemble . . . . . . . . .31-3160-45 Load test, batteries. . . . . . . . . . . . . . . . . . .16-1671-9 Loader boom bushings and seals Remove and install . . . . . . . . . . . . . . . . .31-3140-9 Loader bucket tilt linkage Remove and install . . . . . . . . . . . . . . . . .31-3140-3 Loader control valve Disassemble and assemble . . . . . . . . .31-3160-40 Remove and install . . . . . . . . . . . . . . . .31-3160-37 Loader hydraulic pump Remove and install . . . . . . . . . . . . . . . . .31-3160-9 Loader start-up procedure Boom cylinder . . . . . . . . . . . . . . . . . . . .31-3160-48 Bucket cylinder . . . . . . . . . . . . . . . . . . .31-3160-51 Low sulfur diesel fuel conditioner . . . . . . . .00-0004-2 Lower pivot bearing and seals Remove and install . . . . . . . . . . . . . . . .17-1740-12 Lubricant Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-7 Storage . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-6 Lubricity of diesel fuel. . . . . . . . . . . . . . . . .00-0004-1 Indx 6

M Manifold, compressor Inspect . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-52 Metri-Pack connector Replace . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-4 Metric torque values . . . . . . . . . . . . . . . . . .00-0003-2 Mirror, outside Remove and install . . . . . . . . . . . . . . . . .20-2002-2 Mixing lubricants. . . . . . . . . . . . . . . . . . . . .00-0004-7 Monitor display unit Remove and install . . . . . . . . . . . . . . . . .16-1675-5 Motor, starting Remove and install . . . . . . . . . . . . . . . . .16-1677-1 Mounted step Remove and install . . . . . . . . . . . . . . . . .18-1822-5 Muffler Remove and install . . . . . . . . . . . . . . . . .05-0530-2 TM1640 (15JAN04)

Page

O O-ring boss fittings . . . . . . . . . . . . . . . . . . .00-0003-7 Oil Lines and fittings. . . . . . . . . . . . . . . . . . .00-0003-6 Specification differential . . . . . . . . . . . . .00-0004-4 Specification hydraulic system . . . . . . . .00-0004-4 Specification park brake . . . . . . . . . . . . .00-0004-4 Specification transmission . . . . . . . . . . . .00-0004-4 Oil clean-up Procedure . . . . . . . . . . . . . . . . . . . . . . .31-3160-69 Oil cooler Assemble . . . . . . . . . . . . . . . . . . . . . . .05-0510-17 Disassemble . . . . . . . . . . . . . . . . . . . . .05-0510-17 Remove and install . . . . . . . . . . . . . . . .05-0510-10 Oil lines and fittings . . . . . . . . . . . . . . . . . .00-0003-6 Oil pipes and tube Replace . . . . . . . . . . . . . . . . . . . . . . . .03-0360-23 Oil, component, R134a air conditioning Charge . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12 Oscillation supports Disassemble and assemble . . . . . . . . .02-0200-18 Output shaft Remove . . . . . . . . . . . . . . . . . . . . . . . .03-0350-11 Outside mirror Remove and install . . . . . . . . . . . . . . . . .20-2002-2

P Park Brake Assemble . . . . . . . . . . . . . . . . . . . . . . . .11-1111-6 Disassemble . . . . . . . . . . . . . . . . . . . . . .11-1111-6 Park brake Install . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1111-2 Oil specification. . . . . . . . . . . . . . . . . . . .00-0004-4 Pressure switch, remove and install . . . .11-1160-4 Release solenoid valve, remove and install. . . . . . . . . . . . . . . . . . . . . . . . . .11-1160-2 Remove . . . . . . . . . . . . . . . . . . . . . . . . .11-1111-2 Pilot controller valve (single lever) Disassemble and assemble . . . . . . . . .31-3160-71 Pilot controller valve, single lever Cross section . . . . . . . . . . . . . . . . . . . .31-3160-71 Remove and install . . . . . . . . . . . . . . . .31-3160-70 Pilot controller valve, two lever Remove and install . . . . . . . . . . . . . . . .31-3160-91 Pilot enable solenoid valve Remove and install . . . . . . . . . . . . . . . .31-3160-99 Pin disconnect valve Disassemble and assemble . . . . . . . . 31-3160-115

Index-6


PN=6

Index

Page

Page

Pin disconnect/axle disconnect Remove and install . . . . . . . . . . . . . . . 31-3160-114 Pivot bearing and seals Lower, remove and install . . . . . . . . . . .17-1740-12 Upper, remove and install . . . . . . . . . . .17-1740-10 Pre-load clutch pack compression ring tool DFT1148. . . . . . . . . . . . . . . . 03-0399-1, 03-0399-2 Pressure reducing valve Disassemble and assemble . . . . . . . . .31-3160-96 Remove and install . . . . . . . . . . . . . . . .31-3160-95 Pressure reducing valve manifold Install . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-94 Remove . . . . . . . . . . . . . . . . . . . . . . . .31-3160-94 Pressurizer motor assembly Remove and install . . . . . . . . . . . . . . . .18-1830-40 Primary element Clean oily or sooty . . . . . . . . . . . . . . . . .05-0520-5 Primary fuel filter (water separator) Remove and install . . . . . . . . . . . . . . . . .05-0560-6 Primary fuel filter (water separatory) Drain and clean. . . . . . . . . . . . . . . . . . . .05-0560-5 Pump, hydraulic Disassemble, inspect and assemble . . .31-3160-13 Pump, hydraulic loader Remove and install . . . . . . . . . . . . . . . . .31-3160-9 Pump, transmission Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-5 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-2

Regulator Install . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1672-4 Remove . . . . . . . . . . . . . . . . . . . . . . . . .16-1672-4 Relief valve Disassemble and assemble . . . . . . . . .31-3160-44 Remove and install Loader bucket tilt linkage . . . . . . . . . . . .31-3140-3 Reservoir, hydraulic Remove and install . . . . . . . . . . . . . . . .31-3160-68 Return-to-carry Height kickout adjustment . . . . . . . . . . .16-1674-26 Return-to-dig circuit Adjustment . . . . . . . . . . . . . . . . . . . . . .16-1674-27 Reverse warning alarm Change volume. . . . . . . . . . . . . . . . . . . .20-2004-2 Remove and install . . . . . . . . . . . . . . . . .20-2004-2 Ride control Remove and install . . . . . . . . . . . . . . . 31-3160-100 Ride control accumulator Disassemble and assemble . . . . . . . . 31-3160-108 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3102-2 Ride control assumulator Charge . . . . . . . . . . . . . . . . . . . . . . . . 31-3160-112 Ride control repair . . . . . . . . . . . . . . . . . 31-3160-100 Remove and Install . . . . . . . . . . . . . . . 31-3160-104 Ride control solenoid valves Disassemble and assemble . . . . . . . . 31-3160-107 Ride control valve Disassemble and assemble . . . . . . . 31-3160-102, 31-3160-106 Roll-over protective structure Torque values . . . . . . . . . . . . . . . . . . . . .00-0003-1

R Radiator Assemble . . . . . . . . . . . . . . . . . . . . . . .05-0510-17 Disassemble . . . . . . . . . . . . . . . . . . . . .05-0510-17 Remove and install . . . . . . . . . . . . . . . .05-0510-10 Rear axle oil cooler Remove and install . . . . . . . . . . . . . . . .02-0260-10 Rear view mirror Remove and install . . . . . . . . . . . . . . . . .20-2002-1 Receiver-dryer Remove and install . . . . . . . . . . . . . . . .18-1830-41 Refrigerant R134a cautions . . . . . . . . . . . . . . . . . . . .18-1830-9 Theory of operation. . . . . . . . . . . . . . . . .18-1830-7 Refrigerant, air conditioning R134a system Evacuate. . . . . . . . . . . . . . . . . . . . . . . .18-1830-16 Recover . . . . . . . . . . . . . . . . . . . . . . . .18-1830-15 Refrigerant, R134a Recovery, recycling and charging . . . . .18-1830-14 Refrigerant, R134a system Charge . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-18 TM1640 (15JAN04)

Indx 7

S Safe discharge Ride control accumulator . . . . . . . . . . . .31-3102-2 Seals and bushings Bucket linkage, remove and install . . . . .31-3140-4 Seals and bushings, loader boom Remove and install . . . . . . . . . . . . . . . . .31-3140-9 Seals, tool carrier boom Remove and install . . . . . . . . . . . . . . . .31-3140-10 Seat Disassemble and assemble . . . . . . . . . .18-1821-2 Seat belt Disassemble and assemble . . . . . . . . . .18-1821-1 Service brakes External inspection . . . . . . . . . . . . . . . . .10-1011-1 Shield, transmission Remove and install . . . . . . . . . . . . . . . . .19-1913-1

Index-7


PN=7

Index

Page

Indx 8

Shields, engine side Remove and install . . . . . . . . . . . . . . . . .19-1910-3 Slow idle Adjust engine speed . . . . . . . . . . . . . . . .05-0515-2 Solenoid, ride control valves Disassemble and assemble . . . . . . . . 31-3160-107 Specification Battery . . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-2 Differential oil . . . . . . . . . . . . . . . . . . . . .00-0004-4 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . .00-0004-4 Park brake . . . . . . . . . . . . . . . . . . . . . . .00-0004-4 Transmission oil . . . . . . . . . . . . . . . . . . .00-0004-4 Specifications Hardware torque . . . . . . . . . . . . . . . . . . .00-0003-1 TC62H . . . . . . . . . . . . . . . . . . . . . . . . . .00-0002-5 624H. . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0002-1 Start-up procedure Steering cylinder . . . . . . . . . . . . . . . . . .09-0960-11 Starting aid, fluid Remove and install . . . . . . . . . . . . . . . . .05-0505-1 Starting motor Remove and install . . . . . . . . . . . . . . . . .16-1677-1 Steering Cylinder bushings, remove and install. . . . . . . . . . . . . . . . . . . . . . . . .09-0960-12 Steering column Remove and install . . . . . . . . . . . . . . . . .09-0960-8 Steering cylinder Assemble . . . . . . . . . . . . . . . . . . . . . . .09-0960-12 Bushings, remove and install . . . . . . . .09-0960-12 Disassemble . . . . . . . . . . . . . . . . . . . . .09-0960-12 Loader start-up procedure. . . . . . . . . . .09-0960-11 Remove and install . . . . . . . . . . . . . . . . .09-0960-9 Steering valve Remove and install . . . . . . . . . . . . . . . . .09-0960-3 Step Remove and install . . . . . . . . . . . . . . . . .18-1822-2 Step, engine compartment Remove and install . . . . . . . . . . . . . . . . .18-1822-4 Step, mounted Remove and install . . . . . . . . . . . . . . . . .18-1822-5 Stop, turn and tail light Remove and install . . . . . . . . . . . . . . . . .16-1673-5 Storing lubricants . . . . . . . . . . . . . . . . . . . .00-0004-6 Structure Welding. . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-3 Support, wrist Remove and install . . . . . . . . . . . . . . . .18-1810-10 Switch, freeze control Bench test. . . . . . . . . . . . . . . . . . . . . . .18-1830-35 Remove and install . . . . . . . . . . . . . . . .18-1830-34 Switch, park break pressure Remove and install . . . . . . . . . . . . . . . . .11-1160-4 TM1640 (15JAN04)

Page

T Tilt cylinder TC62H Disassemble and assemble . . . . . . . . .31-3160-59 Tilt cylinders TC62H Cross section . . . . . . . . . . . . . . . . . . . .31-3160-58 Tips Bucket tooth, remove and install . . . . . . .31-3102-3 Tire Install . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-4 Remove . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-3 Tool carrier Disassemble and assemble . . . . . . . . . .31-3140-8 Tool carrier boom bushings and seals Remove and install . . . . . . . . . . . . . . . .31-3140-10 Tool carrier lower tilt linkage Disassemble and assemble . . . . . . . . . .31-3140-6 Tool carrier upper tilt linkage Disassemble and assemble . . . . . . . . . .31-3140-5 Tooth shanks Bucket, remove and install . . . . . . . . . . .31-3102-3 Torque converter Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-8 Torque converter and housing Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-5 Torque converter relief valve Remove . . . . . . . . . . . . . . . . . . . . . . . .03-0360-21 Torque specifications Hardware . . . . . . . . . . . . . . . . . . . . . . . .00-0003-1 Torque value Flat face O-ring seal fitting . . . . . . . . . . .00-0003-9 Inch SAE four bolt flange fitting. . . . . . .00-0003-11 Metric cap screw. . . . . . . . . . . . . . . . . . .00-0003-3 Metric four bolt flange fitting . . . . . . . . .00-0003-10 O-Ring boss fitting . . . . . . . . . . . . . . . . .00-0003-7 Torque values Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-5 Metric . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2 Roll-over protective structure. . . . . . . . . .00-0003-1 Transmission Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0300-3 Oil specification. . . . . . . . . . . . . . . . . . . .00-0004-4 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0300-3 Transmission bottom guard Remove and install . . . . . . . . . . . . . . . . .17-1746-2 Transmission control unit (TCU) Remove and install . . . . . . . . . . . . . . . . .16-1675-1 Transmission control valve Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0360-15 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-8 Transmission control valve connector body Remove and install . . . . . . . . . . . . . . . . .16-1674-8

Index-8


PN=8

Index

Page

Page

Transmission control valve connector contact Install . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-9 Transmission controller unit connector terminals Replace . . . . . . . . . . . . . . . . . . . . . . . .16-1674-19 Transmission pump Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-5 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-2 Transmission shields Remove and install . . . . . . . . . . . . . . . . .19-1913-1 Transmission side guard Remove and install . . . . . . . . . . . . . . . . .17-1746-2

Remove and install . . . . . . . . . . . . . . . .31-3160-37 Valve, pilot controller (single lever) Disassemble and assemble . . . . . . . . .31-3160-71 Valve, pilot controller, single lever Cross section . . . . . . . . . . . . . . . . . . . .31-3160-71 Remove and install . . . . . . . . . . . . . . . .31-3160-70 Valve, pilot controller, two lever Remove and install . . . . . . . . . . . . . . . .31-3160-91 Valve, pilot enable solenoid Remove and install . . . . . . . . . . . . . . . .31-3160-99 Valve, pin disconnect Disassemble and assemble . . . . . . . . 31-3160-115 Valve, pin disconnect/axle disconnect Remove and install . . . . . . . . . . . . . . . 31-3160-114 Valve, pressure reducing Disassemble and assemble . . . . . . . . .31-3160-96 Remove and install . . . . . . . . . . . . . . . .31-3160-95 Valve, relief Disassemble and assemble . . . . . . . . .31-3160-44 Valve, ride control Disassemble and assemble . . . . . . . 31-3160-102, 31-3160-106 Valve, solenoid Park brake release, remove and install. . . . . . . . . . . . . . . . . . . . . . . . . .11-1160-2 Valve, steering Remove and install . . . . . . . . . . . . . . . . .09-0960-3 Valve, transmission control Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-7 Valves solenoid, ride control Disassemble and assemble . . . . . . . . 31-3160-107

U Universal joint Disassemble, inspect and assemble . . . .02-0225-4 Remove and Install . . . . . . . . . . . . . . . . .02-0225-2 Upper pivot bearing and seals Remove and install . . . . . . . . . . . . . . . .17-1740-10

V Valve Minimum pressure regulator . . . . . . . . . .03-0360-4 Pressure reducing manifold, install . . . .31-3160-94 Pressure reducing manifold, remove . . .31-3160-94 Valve, auxiliary section and bucket section Disassemble and assemble . . . . . . . . .31-3160-41 Valve, axle disconnect Disassemble and assemble . . . . . . . . 31-3160-116 Valve, boom circuit relief Disassemble and assemble . . . . . . . . .31-3160-45 Valve, boom down solenoid Remove and install . . . . . . . . . . . . . . . .31-3160-97 Valve, boom section Disassemble and assemble . . . . . . . . .31-3160-43 Valve, brake Remove and install . . . . . . . . . . . . . . . . .10-1060-1 Valve, bucket circuit relief Disassemble and assemble . . . . . . . . .31-3160-44 Valve, differential lock solenoid Remove and install . . . . . . . . . . . . . . . .31-3160-98 Valve, expansion Remove and install . . . . . . . . . . . . . . . .18-1830-33 Valve, heater control Remove and install . . . . . . . . . . . . . . . .18-1830-36 Valve, load sense relief Disassemble and assemble . . . . . . . . .31-3160-45 Valve, loader control Disassemble and assemble . . . . . . . . .31-3160-40 TM1640 (15JAN04)

Indx 9

W Wear plates Remove and install . . . . . . . . . . . . . . . . .31-3102-7 Welding Structure . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-3 Wheel Remove and Install . . . . . . . . . . . . . . . . .01-0110-1 Windowpanes Remove and install . . . . . . . . . . . . . . . . .18-1810-2 Windshield Washer Remove and install . . . . . . . . . . . . . . . . .18-1810-4 Windshield wiper Adjust front . . . . . . . . . . . . . . . . . . . . . . .18-1810-8 Windshield wiper motor Remove and install . . . . . . . . . . . . . . . . .18-1810-6 Windshield wiper, front Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-8

Index-9


PN=9

Index

Page

Wiper motor Remove and install . . . . . . . . . . . . . . . . .18-1810-6 Work lights Remove and install . . . . . . . . . . . . . . . . .16-1673-3 Wrist support Remove and install . . . . . . . . . . . . . . . .18-1810-10

Indx 10

TM1640 (15JAN04)

Index-10


PN=10

624H Loader and TC62H TC Operation TM1640

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