748H Novo Monitor Repair BookTM11813 PDF

748H Skidder
Repair
(Serial No. 630436
TECHNICAL MANUAL
748H Skidder
Repair
(S.N. 630436 )
TM11813 13OCT10
For complete service information also see:

748H Skidder Operation and Test (S.N.
630436 ).............................................................
HSeries Skidder Operators Manual
(S.N. 630436 )....................................................
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Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
(ENGLISH)
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 safetyalert 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 onthejob 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.
,0004E4A 1908SEP081/1
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Introduction
Technical Information Feedback Form

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USA
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TX,TM,FAX 1903JUL011/1
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Introduction
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Contents
Section 00General Information
Group 1746Frame Bottom Guards
Group 0001Safety
Group 0003Torque Values
Section 18Operators Station

Group 1800Removal and Installation
Group 1810Operator Enclosure
Group 1821Seat and Seat Belt
Group 1830Heating and Air Conditioning
Section 01Wheels
Group 0110Powered Wheels and Fasteners
Section 02Axles
Section 19Sheet Metal and Styling
Group 0200Remove and Install

Group 0225Input Drive Shaft and UJoints
Group 0260Hydraulic System
Group 1910Hood or Engine Enclosure
Section 20Safety, Convenience, and

Miscellaneous
Section 03Transmission
Group 0315Controls
Group 0325Input Drive Shafts and UJoints
Group 0350Gears, Shafts, and Power Shift Clutches
Section 04Engine
Group 2003Pressurized Water System

Group 2004Horn and Warning Devises
Section 21Main Hydraulic System

Section 30Winch

Group 3015Control Linkage
Group 3050Drive and Clutch
Section 05Engine Auxiliary Systems

Group 0505Cold Weather Starting Aids
Group 0510Cooling System
Group 0520Intake System
Group 0530Exhaust System
Group 0560External Fuel Supply System
Section 32Stacking Blades

Group 3201Blades
Group 3215Controls Linkage
Section 07Dampener Drive

Group 0752Elements
Section 38Grapple
Group 3803Grapple Mechanism
Group 3840Frames
Section 09Steering System

Group 0930Secondary Steering
Group 0962Dual Mode Steering
Section 99Dealer Fabricated Tools

Group 9900Dealer Fabricated Tools
Section 10Service Brakes

Section 11Park Brake

Group 1111Active Elements
Section 17Frame, Chassis, or Supporting

Structures
Group 1740Frame Installation
Original Instructions. 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.
COPYRIGHT 2010
DEERE & COMPANY
Moline, Illinois
All rights reserved.
A John Deere ILLUSTRUCTION Manual
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Contents
Section 00
General Information
Page
Group 0001Safety ................................0000011

Group 0003Torque Values
Hardware Torque Specifications................ 0000031
Keeping ROPS Installed Properly.............. 0000031
Torque Value
Metric Bolt and Cap Screw....................0000032
Additional Metric Cap Screw
Torque Values ........................................ 0000033
Unified Inch Bolt and Cap Screw ..........0000034
Check Oil Lines And Fittings ..................... 0000035
Service Recommendations for
37 Flare and 30 Cone Seat
Connectors ............................................ 0000035
ORing Boss Fittings.............................. 0000036
Service Recommendations For
Flat Face ORing Seal Fittings .............. 0000037
Metric Series Four Bolt Flange
Fitting..................................................... 0000038
Service Recommendations For
Inch Series Four Bolt Flange
Fittings ................................................... 0000039
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Group 0001
Safety
Recognize Safety Information
T133555 UN28AUG00
This is the safety alert symbol. When you see this

symbol on your machine or in this manual, be alert
for the potential of personal injury.
Follow the precautions and safe operating practices
highlighted by this symbol.
A signal word DANGER, WARNING, or CAUTION
is used with the safety alert symbol. DANGER identifies
the most serious hazards.
T133588 1928AUG00
On your machine, DANGER signs are red in color,

WARNING signs are orange, and CAUTION signs are
yellow. DANGER and WARNING signs are located near
specific hazards. General precautions are on CAUTION
labels.
TX03679,00016CC 1903NOV081/1
Follow Safety Instructions
TS201 UN23AUG88
Carefully read all safety messages in this manual and on

your machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
available from your John Deere dealer.
There can be additional safety information contained on
parts and components sourced from suppliers that is not
reproduced in this operators manual.
Learn how to operate the machine and how to use controls
properly. Do not let anyone operate without instruction.
Keep your machine in proper working condition.
Unauthorized modifications to the machine may impair the
function and/or safety and affect machine life.
If you do not understand any part of this manual and need

assistance, contact your John Deere dealer.
DX,READ 1916JUN091/1
Operate Only If Qualified

Do not operate this machine unless you have read the
operators manual carefully and you have been qualified
by supervised training and instruction.
Know and observe all safety rules that may apply to your
work situation and your work site.
Familiarize yourself with the job site and your surroundings

before operating. Try all controls and machine functions
with the machine in an open area before starting to work.
TX03679,00016FA 1903NOV081/1
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Safety
Wear Protective Equipment

Guard against injury from flying pieces or metal or debris
wear goggles or safety glasses.
TS206 UN23AUG88
Wear close fitting clothing and safety equipment

appropriate to the job.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
Prolonged exposure to loud noise can cause impairment
or loss of hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises. Radio or music headphones
are not suitable to use for hearing protection.
OUT4001,0000570 1912FEB101/1
Avoid Unauthorized Machine Modifications

John Deere recommends using only genuine John Deere
replacement parts to ensure machine performance.
Never substitute genuine John Deere parts with alternate
parts not intended for the application as these can
create hazardous situations or hazardous performance.
NonJohn Deere parts, or any damage or failures resulting
from their use are not covered by any John Deere
warranty.
Modifications of this machine, or addition of unapproved
products or attachments, may affect machine stability or
reliability, and may create a hazard for the operator or

others near the machine. The installer of any modification
which may affect the electronic controls of this machine is
responsible for establishing that the modification does not
adversely affect the machine or its performance.
Always contact an authorized dealer before making
machine modifications that change the intended use,
weight or balance of the machine, or that alter machine
controls, performance or reliability.
AM40430,00000A9 1920AUG091/1
Inspect Machine
Keep all guards and shields in good condition and properly

installed. Fix damage and replace worn or broken parts
immediately. Pay special attention to hydraulic hoses and
electrical wiring.
T6607AQ UN18OCT88
Inspect machine carefully each day by walking around it

before starting.
TX03679,0001734 1903NOV081/1
Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting or maintaining
any part of machine with moving parts.
Keep guards and shields in place. Replace any guard
or shield that has been removed for access as soon as
service or repair is complete.
T133592 UN12SEP01
Stay Clear of Moving Parts
TX03679,00016D2 1903NOV081/1
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Safety
Avoid HighPressure Fluids

Escaping fluid under pressure can penetrate the skin
causing serious injury.
X9811 UN23AUG88
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 highpressure 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 in
English from Deere & Company Medical Department in
Moline, Illinois, U.S.A., by calling 18008228262 or +1

3097485636.
DX,FLUID 1920AUG091/1
Avoid HighPressure Oils
Never search for leaks with your hands. Protect hands.

Use a piece of cardboard to find location of escaping oil.
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.
T133840 UN20SEP00
If hydraulic oil penetrates your skin, see a doctor

immediately. Injected oil must be removed surgically
within hours or gangrene may result. Contact a
knowledgeable medical source or the Deere & Company
Medical Department in Moline, Illinois, U.S.A.
T133509 UN17MAR06
This machine uses a highpressure hydraulic system.

Escaping oil under pressure can penetrate the skin
causing serious injury.
TX03679,00016D3 1903NOV081/1
Do Not Use Starting Fluid
This machine is equipped with a Tier III engine. Fire,

explosion or engine damage will result from using starting
fluids of any type on this machine.
T145705 UN18SEP01
IMPORTANT: Avoid an explosion or fire. Machine

is equipped with electrical cold start assist
system. Do not use starting fluid of any
type on the machine.
OUO1065,00001B7 1909JUN081/1
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Safety
Work In Ventilated Area
TS220 UN23AUG88
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.
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.
DX,AIR 1917FEB991/1
T133552 UN14SEP00
Prevent Fires
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines, exhaust components, and
electrical wiring. Never store oily rags or flammable
materials inside a machine compartment.
T133553 UN07SEP00
Maintain Hoses and Wiring: Replace hydraulic hoses

immediately if they begin to leak, and clean up any oil
spills. Examine electrical wiring and connectors frequently
for damage.
Keep A Fire Extinguisher Available: Always keep a
multipurpose fire extinguisher on or near the machine.
Know how to use extinguisher properly.
T133554 UN07SEP00
TX03679,00016F5 1903NOV081/1
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Safety
Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from
the top of battery. Battery gas can explode.
Do not charge a frozen battery it may explode. Warm

battery to 16C (60F).
TS204 UN23AUG88
Never check battery charge by placing a metal object

across the posts. Use a voltmeter or hydrometer.
DX,SPARKS 1903MAR931/1
Handle Chemical Products Safely
A Material Safety Data Sheet (MSDS) provides specific

details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
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 UN26NOV90
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 MSDSs on chemical

products used with John Deere equipment.)
DX,MSDS,NA 1903MAR931/1
Dispose of Waste Properly
Use leakproof containers when draining fluids. Do not use

food or beverage containers that may mislead someone
into drinking from them.
Do not pour waste onto the ground, down a drain, or into
any water source.
TS1133 UN26NOV90
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 Earths 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 1903MAR931/1
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Safety
Prepare for Emergencies

Be prepared if a fire starts.
Keep emergency numbers for doctors, ambulance

service, hospital, and fire department near your telephone.
TS291 UN23AUG88
Keep a first aid kit and fire extinguisher handy.
DX,FIRE2 1903MAR931/1
Clean Debris from Machine
Clean any oil spills or fuel spills on machine surfaces.

Temperature in engine compartment may go up
immediately after engine is stopped. BE ON GUARD
FOR FIRES DURING THIS PERIOD.
Open access door(s) to cool the engine faster, and clean
engine compartment.
T6669AG UN18OCT88
Keep engine compartment, radiator, batteries, hydraulic

lines, exhaust components, fuel tank, and operators
station clean and free of debris.
OUT4001,00000E3 1920AUG091/1
Prevent falls by facing the machine when you get on and

off. Maintain 3point contact with steps and handrails.
Never use machine controls as handholds.
Use extra care when mud, snow, or moisture present
slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.
T133468 UN30AUG00
Use Steps and Handholds Correctly
TX03679,00016F2 1903OCT071/1
Avoid unexpected machine movement. Start engine only

while sitting in operators seat. Ensure all controls and
working tools are in proper position for a parked machine.
Never attempt to start engine from the ground. Do not
attempt to start engine by shorting across the starter
solenoid terminals.
T133715 UN07SEP00
Start Only From Operators Seat
TX03679,0001799 1903OCT071/1
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Safety
Use and Maintain Seat Belt

T133716 1914SEP00
Use seat belt when operating machine. Remember to

fasten seat belt when loading and unloading from trucks
and during other uses.
Examine seat belt frequently. Be sure webbing is not
cut or torn. Replace seat belt immediately if any part is
damaged or does not function properly.
The complete seat belt assembly should be replaced
every three years, regardless of appearance.
TX03679,00016DD 1903OCT071/1
Prevent Unintended Machine Movement

Be careful not to accidentally actuate controls. Move
transmission out of gear and lower all equipment to the
ground during work interruptions. Follow these steps
before allowing coworkers to approach the machine,
before standing up, leaving the operators seat, or exiting
the machine:
2
1
TX1076184 UN16APR10
Lower equipment to the ground

Move transmission gear selector to neutral position
Engage park brake by pressing park brake switch.
Verify park brake indicator light on the standard display

monitor comes on.
Stop the engine
1 Gear Selector
2 Gear Enable/Differential
Lock Switch
3 Park Brake Switch
TX1076187A UN16APR10
Gear Enable/Differential Lock Switch
Park Brake Switch

OU90V02,000042C 1925MAY101/1
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Safety
Avoid Work Site Hazards
T146611 UN22OCT01
Plan your operation before starting work. Check skidding

trails and landings for stumps, large rocks, dropoffs,
muddy areas and standing water. Carefully examine
overhead for trees and branches that might fall or strike
the operators station. Take precautions to avoid these
hazards.
Be sure coworkers and bystanders are clear of
machine before operating. Keep bystanders away
from attachments and unsupported loads over or near
personnel. Keep coworkers a safe distance away when
skidding, because logs may kickout unexpectedly.
Use extra care if you must drive over logs or saplings
that may be dislodged or springup against the machine
or bystanders.
Keep bystanders clear at all times. Keep bystanders
away from raised booms, attachments, and unsupported
loads. Avoid swinging or raising booms, attachments, or
loads over or near personnel. Use barricades or a signal
person to keep vehicles and pedestrians away. Use a
signal person if moving machine in congested areas or
where visibility is restricted. Always keep signal person in
view. Coordinate hand signals before starting machine.
Do not operate under lowhanging electrical wires.

Contact may cause serious injury or death by
electrocution.
Reduce machine speed when operating equipment with
tool on or near ground when obstacles may be hidden
(e.g., during snow removal or clearing mud, dirt, etc). At
high speeds, hitting obstacles (rocks, uneven concrete or
manholes) can cause a sudden stop. Always wear your
seat belt. On units equipped with shoulder belts, always
wear both the seat and shoulder belts and do not lean
forward while operating.
OU90V02,000042D 1912APR101/1
Operate Machine Safely
T146610 UN22OCT01
Wear the seat belt when operating this machine. Do

not operate the machine if all elements of the operator
protective structure (OPS) are not in place and in good
repair.
Use extra care around landings where bystanders are
more likely to be present. Do not skid logs past people
that are not a safe distance away from logs that may
swing or kickout.
Use extra care when backingup with logs attached. Make
sure the delimbing grate is in good repair and bystanders
are a safe distance away.
Be careful when operating in muddy or frozen conditions
because the machine may slide or tip more easily. Avoid
side slopes when possible. Drive straight up or down

slopes to reduce the possibility of tipping.
TX03679,000180A 1903OCT071/1
Keep Riders Off Machine

Riders are subject to injury. They may fall from machine,
be caught between machine parts, or be struck by foreign
objects.
Riders may obstruct operators view or impair his ability
to operate machine safely.
T145263 UN06SEP01
Only allow operator on machine.
TX03679,0001800 1903OCT071/1
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Safety
Before moving machine, be sure all persons are clear

of machine path. Turn around and look directly for best
visibility. Use mirror to assist in checking around machine.
Keep windows and mirror clean, adjusted, and in good
repair.
Be certain reverse warning alarm is working properly.
Use a signal person when backing if view is
obstructed or when in close quarters. Keep signal
person in view at all times. Use prearranged hand signals
to communicate.
T145264 UN06SEP01
Avoid Backover Accidents
TX03679,0001801 1903OCT071/1
Use seat belt at all times.

Do not jump if the machine tips. You will be unlikely to
jump clear and the machine may crush you.
Load and unload from trucks or trailers carefully. Be
sure truck is wide enough and on a firm level surface. Use
loading ramps and attach them properly to truck bed.
T133716 1914SEP00
Avoid Machine Tip Over
Do not overload. Know the capacity of the machine.

Be careful with heavy loads which may affect machine
stability.
T146612 UN06NOV01
Ensure solid footing. Use extra care in soft ground

conditions that may not uniformly support the wheels. Do
not operate close to banks that may cave in and cause
machine to tip or fall.
T145266 UN06SEP01
Be careful on slopes. Avoid sharp turns. Avoid stumps,

rocks and dropoffs when possible. Use extra care on
soft, uneven or frozen ground.
TX03679,0001802 1903OCT071/1
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Safety
Operating on Slopes
T145730 UN20SEP01
Avoid side slope travel whenever possible. When working

on steep slopes, travel as straight up and down as
possible to prevent machine tip over.
Select low gear before starting down slope. The slope on
which you can operate safely will be limited by ground
condition and the load being handled. Use service brakes
to control speed.
TX03679,0001803 1903OCT071/1
Operating or Traveling On Public Roads

T141891 UN22MAY01
Machines that work near vehicle traffic or travel slower

than normal highway speeds must have proper lighting
and markings to assure they are visible to other drivers.
Install additional lights, beacons, slow moving vehicle
(SMV) emblems, or other devices and use as required
to make the machine visible and identify it as a work
machine. Check state and local regulations to assure
compliance. Keep these devices clean and in working
condition.
TX03679,00017C8 1903OCT071/1
Inspect and Maintain ROPS

A damaged rollover protective structure (ROPS) should
be replaced, not reused.
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.
If ROPS was loosened or removed for any reason, inspect
it carefully before operating the machine again.
To maintain the ROPS:
Replace missing hardware using correct grade

hardware.
Check hardware torque.

Check isolation mounts for damage, looseness or wear
replace them if necessary.
Check ROPS for cracks or physical damage.

TX03679,000179F 1903OCT071/1
Keep the Operator Protective Structure (OPS) in Place

It is important to keep the operator protective structure
(OPS) in place (doors, screens, windows, windshield,
etc.) to minimize hazards from whipping or intruding
objects. To maintain OPS protection, replace damaged
parts immediately.
The protection offered by OPS will be impaired if OPS is

subjected to structural damage, is involved in an overturn
incident, or is altered by welding, bending, drilling, or
cutting. Damaged OPS components should be replaced,
not reused.
The polycarbonate windows are part of the operator

protection system. Replace if damaged, cloudy, or has
visible microcracking or crazing.
Keep all bolts and attaching hardware tight.
OU90V02,0000477 1920MAY101/1
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Safety
Add and Operate Attachments Safely

Always verify compatibility of attachments by contacting
your authorized dealer. Adding unapproved attachments
may affect machine stability or reliability, and may create
a hazard for others near the machine.
Ensure that a qualified person is involved in attachment
installation. Add guards to machine if operator protection
is required or recommended. Verify that all connections

are secure and attachment responds properly to controls.
Carefully read attachment manual and follow all
instructions and warnings. In an area free of bystanders
and obstructions, carefully operate attachment to learn its
characteristics and range of motion.
TX03679,00016F0 1903OCT071/1
Park and Prepare for Service Safely

Warn others of service work. Always park and prepare
your machine for service or repair properly.
to the ground.
Engage park brake.

Stop engine and remove key.
Install articulation locking bar.
Attach a Do Not Operate tag in an obvious place in
the operators station.
IMPORTANT: Engine side panels may be warm

immediately after machine shut down and
gloves may need to be worn.
T133332 1914DEC01
Park machine on a level surface and lower equipment
Support machine or attachment before working under it.
Do not support machine with any hydraulically actuated

pieces that may crumble or crush.
Do not support machine with a single jack or other

devices that may slip out of place.
Understand service procedures before beginning repairs.

Keep service area clean and dry. Use two people
whenever the engine must be running for service work.
TS229 UN23AUG88
tools or attachments.
Do not support machine with cinder blocks or wooden
OUTJ003,00007AB 1917AUG061/1
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Safety
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.
When inflating tires, use a clipon 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 UN23AUG88
Check wheels for low pressure, cuts, bubbles, damaged

rims or missing lug bolts and nuts.
DX,RIM 1924AUG901/1
Service Cooling System Safely
Do not service radiator through the radiator cap. Only fill

through the surge tank filler cap. Shut off engine. Only
remove surge tank filler cap when cool enough to touch
with bare hands. Slowly loosen cap to relieve pressure
before removing completely.
TS281 UN23AUG88
Explosive release of fluids from pressurized cooling

system can cause serious burns.
VD76477,0001157 1920DEC061/1
TM11813 (13OCT10)
00000112
748H Repair (S.N. 630436

)
101310
PN=20
Safety
Service Accumulator Systems Safely
TS281 UN23AUG88
Escaping fluid or gas from pressurized hydraulic

accumulator systems can cause serious injury. Extreme
heat can cause the accumulator to burst, and pressurized
lines can be accidentally cut. Do not weld or use a torch
near a pressurized accumulator or pressurized line.
Relieve pressure from the hydraulic system before
removing accumulator. Never attempt to relieve hydraulic
system or accumulator pressure by loosening a fitting.
Accumulators cannot be repaired.
DX,WW,ACCLA 1915APR031/1
Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch.
TS220 UN23AUG88
Remove paint before heating:
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.
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 1924JUL021/1
Make Welding Repairs Safely
Avoid welding or heating near pressurized fluid lines.

Flammable spray may result and cause severe burns if
pressurized lines fail as a result of heating. Do not let heat
go beyond work area to nearby pressurized lines.
Remove paint properly. Do not inhale paint dust or fumes.
Use a qualified welding technician for structural repairs.
T133547 UN31AUG00
IMPORTANT: Disable electrical power before

welding. Turn off main battery switch
or disconnect positive battery cable.
Separate harness connectors to engine
and vehicle microprocessors.
Make sure there is good ventilation. Wear eye protection

and protective equipment when welding.
TX03679,00016D5 1904JUN071/1
TM11813 (13OCT10)
00000113
748H Repair (S.N. 630436

)
101310
PN=21
Safety
Always wear protective goggles or safety glasses and

other protective equipment before striking hardened
parts. Hammering hardened metal parts such as pins and
bucket teeth may dislodge chips at high velocity.
Use a soft hammer or a brass bar between hammer and
object to prevent chipping.
T133738 UN14SEP00
Drive Metal Pins Safely
TX03679,0001745 1907SEP061/1
TM11813 (13OCT10)
00000114
748H Repair (S.N. 630436

)
101310
PN=22
Group 0003
Torque Values
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.
04T,90,K271 1908AUG911/1
CAUTION: Make certain all parts are reinstalled

correctly if the rollover protective structure
(ROPS) is loosened or removed for any reason.
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.
IMPORTANT: Do not overtighten cap screws
as clevis will be deformed.
T129546C UN31MAR00
Keeping ROPS Installed Properly
Tighten pin locking cap screws (D) to specification.

Keeping ROPS Installed ProperlySpecification
Pin Locking Cap
ScrewTorque.............................................................. 130 Nm (95 lbft)
ALock Nut (2 used)
BCap Screw (2 used)
CWasher (As required)

DPin Locking Cap Screw (2
used)
T129547D UN03APR00
Install lock nuts (A) onto cap screws (B) until full thread
engagement is achieved so nut, washers (C), and head of
cap screw are flush against each clevis.
CED,OUO1079,98 1926MAY001/1
TM11813 (13OCT10)
0000031
748H Repair (S.N. 630436

)
101310
PN=23
Torque Values
Metric Bolt and Cap Screw Torque Values
TORQ2 UN07SEP99
METRIC BOLT AND CAP SCREW TORQUE VALUESTolerance is 10% unless otherwise specified
TopProperty Class and Head Markings BottomProperty Class and Nut Markings
Class 4.8
Thread
Size
Lubricateda
Nm (lbft)
Class 8.8 or 9.8
Dryb
Nm (lbft)
Class 10.9
Lubricateda
Nm (lbft)
Dryb
Nm (lbft)
Class 12.9
Lubricateda
Nm (lbft)
Dryb
Nm (lbft)
Lubricateda
Nm (lbft)
Dryb
Nm (lbft)
M6
4.7 (3.5)
6 (4.4)
9 (6.6)
11.5 (8.5)
13 (9.5)
16.5 (12.2)
15.5 (11.5)
19.5 (14.5)
M8
11.5 (8.5)
14.5 (10.7)
22 (16)
28 (20.5)
32 (23.5)
40 (29.5)
37 (27.5)
47 (35)
M10
23 (17)
29 (21)
43 (32)
55 (40)
63 (46)
80 (59)
75 (55)
95 (70)
M12
40 (29.5)
50 (37)
75 (55)
95 (70)
110 (80)
140 (105)
130 (95)
165 (120)
M14
63 (46)
80 (59)
120 (88)
150 (110)
175 (130)
220 (165)
205 (150)
260 (190)
M16
100 (74)
125 (92)
190 (140)
240 (175)
275 (200)
350 (255)
320 (235)
400 (300)
M18
135 (100)
170 (125)
265 (195)
330 (245)
375 (275)
475 (350)
440 (325)
560 (410)
M20
190 (140)
245 (180)
375 (275)
475 (350)
530 (390)
675 (500)
625 (460)
790 (580)
M22
265 (195)
330 (245)
510 (375)
650 (480)
725 (535)
920 (680)
850 (625)
1080 (800)
M24
330 (245)
425 (315)
650 (480)
820 (600)
920 (680)
1150 (850)
1080 (800)
1350 (1000)
M27
490 (360)
625 (460)
950 (700)
1200 (885)
1350 (1000)
1700 (1250)
1580 (1160)
2000 (1475)
M30
660 (490)
850 (625)
1290 (950)
1630 (1200)
1850 (1350)
2300 (1700)
2140 (1580)
2700 (2000)
M33
900 (665)
1150 (850)
1750 (1300)
2200 (1625)
2500 (1850)
3150 (2325)
2900 (2150)
3700 (2730)
M36
1150 (850)
1450 (1075)
2250 (1650)
2850 (2100)
3200 (2350)
4050 (3000)
3750 (2770)
4750 (3500)
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
"Dry" means plain or zinc plated without any lubrication.
CAUTION: Use only metric tools on metric hardware. Other

tools may not fit properly. Tool may slip and cause injury.
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.
Make sure fastener threads are clean and that you properly start thread
engagement. This will prevent them from failing when tightening.
DO NOT use these values if a different torque value or tightening
procedure is given for a specific application. Torque values listed are for
Tighten plastic insert or crimped steeltype lock nuts to approximately
general use only. Check tightness of fasteners periodically.
50 percent of the dry torque shown in the chart, applied to the nut, not
to the bolt head. Tighten toothed or serratedtype lock nuts to the full
Shear bolts are designed to fail under predetermined loads. Always
torque value.
replace shear bolts with identical property class.
OUT3035,TORQUE2 1922MAR061/1
TM11813 (13OCT10)
0000032
748H Repair (S.N. 630436

)
101310
PN=24
Torque Values
Shear bolts are designed to fail under predetermined

loads. Always replace shear bolts with identical grade.
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.
Make sure fastener threads are clean and you properly
start thread engagement. This will prevent them from
failing when tightening.
Tighten cap screws having lock nuts to approximately 50
percent of amount shown in chart.
METRIC CAP SCREW TORQUE VALUES
TBolt
Nomi
nal Dia
8
HBolt
Nm
lbft
29
21
Nm
20
lbft
15
MBolt
Nm
10
lbft
T6873AB UN18OCT88
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.
T6873AC UN18OCT88
CAUTION: Use only metric tools on metric

hardware. Other tools may not fit properly.
They may slip and cause injury.
T6873AA UN18OCT88
Additional Metric Cap Screw Torque Values
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%.

04T,90,M170 1929SEP991/1
TM11813 (13OCT10)
0000033
748H Repair (S.N. 630436

)
101310
PN=25
Torque Values
Unified Inch Bolt and Cap Screw Torque

Values
TORQ1A UN27SEP99
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUESTolerance is 10% unless otherwise specified
TopSAE Grade and Head Markings BottomSAE Grade and Nut Markings
Grade 2a (No Mark)
Grade 1 (No Mark)

Thread
Size
Lubricated
Nm (lbft)
Dry
Nm (lbft)
Lubricatedb
Nm (lbft)
Dryc
Nm (lbft)
Grade 5, 5.1 or 5.2

Lubricatedb
Nm (lbft)
Dryc
Nm (lbft)
Grade 8 or 8.2
Lubricatedb
Nm (lbft)
Dryc
Nm (lbft)
1/4
3.8 (2.8)
4.7 (3.5)
6 (4.4)
7.5 (5.5)
9.5 (7)
12 (9)
13.5 (10)
17 (12.5)
5/16
7.7 (5.7)
9.8 (7.2)
12 (9)
15.5 (11.5)
19.5 (14.5)
25 (18.5)
28 (20.5)
35 (26)
3/8
13.5 (10)
17.5 (13)
22 (16)
27.5 (20)
35 (26)
44 (32.5)
49 (36)
63 (46)
7/16
22 (16)
28 (20.5)
35 (26)
44 (32.5)
56 (41)
70 (52)
80 (59)
100 (74)
1/2
34 (25)
42 (31)
53 (39)
67 (49)
85 (63)
110 (80)
120 (88)
155 (115)
9/16
48 (35.5)
60 (45)
76 (56)
95 (70)
125 (92)
155 (115)
175 (130)
220 (165)
5/8
67 (49)
85 (63)
105 (77)
135 (100)
170 (125)
215 (160)
240 (175)
305 (225)
3/4
120 (88)
150 (110)
190 (140)
240 (175)
300 (220)
380 (280)
425 (315)
540 (400)
7/8
190 (140)
240 (175)
190 (140)
240 (175)
490 (360)
615 (455)
690 (510)
870 (640)
285 (210)
360 (265)
285 (210)
360 (265)
730 (540)
920 (680)
1030 (760)
1300 (960)
11/8
400 (300)
510 (375)
400 (300)
510 (375)
910 (670)
1150 (850)
1450 (1075)
1850 (1350)
11/4
570 (420)
725 (535)
570 (420)
725 (535)
1280 (945)
1630 (1200)
2050 (1500)
2600 (1920)
13/8
750 (550)
950 (700)
750 (550)
950 (700)
1700 (1250)
2140 (1580)
2700 (2000)
3400 (2500)
11/2
990 (730)
1250 (930)
990 (730)
1250 (930)
2250 (1650)
2850 (2100)
3600 (2650)
4550 (3350)
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.
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or tightening

Make sure fastener threads are clean and that you properly start thread
procedure is given for a specific application. Torque values listed are for engagement. This will prevent them from failing when tightening.
general use only. Check tightness of fasteners periodically.
Tighten plastic insert or crimped steeltype lock nuts to approximately
Shear bolts are designed to fail under predetermined loads. Always
50 percent of the dry torque shown in the chart, applied to the nut, not
replace shear bolts with identical grade.
to the bolt head. Tighten toothed or serratedtype 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.
OUT3035,TORQUE1 1914JAN041/1
TM11813 (13OCT10)
0000034
748H Repair (S.N. 630436

)
101310
PN=26
Torque Values
Check Oil Lines And Fittings
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.
X9811 UN23AUG88
CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
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.
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 1901AUG941/1
Service Recommendations for 37 Flare and

30 Cone Seat Connectors
1. Inspect flare and flare seat. They must be free of dirt
or obvious defects.
T6234AC UN18OCT88
2. Defects in tube flare cannot be repaired.

Overtightening a defective flared fitting will not stop
leaks.
3. Align tube with fitting before attempting to start nut.
4. Lubricate male threads with hydraulic fluid or
petroleum jelly.
5. Index angle fittings and tighten by hand.
6. Tighten fitting or nut to torque value shown on torque
chart. Do not allow hoses to twist when tightening
fittings.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size
Nm
lbft
3/8 24 UNF
7/16 20 UNF
12
1/2 20 UNF
16
12
9/16 18 UNF
24
18
3/4 16 UNF
46
34
7/8 14 UNF
62
46
11/16 12 UN
102
75
13/16 12 UN
122
90
15/16 12 UN
142
105
15/8 12
190
140
17/8 12 UN
217
160
NOTE: Torque tolerance is 10%.

T82,BHMA,EL 1929SEP991/1
TM11813 (13OCT10)
0000035
748H Repair (S.N. 630436

)
101310
PN=27
Torque Values
Service Recommendations for ORing Boss

Fittings
Straight Fitting
2. Lubricate Oring with petroleum jelly. Place electrical

tape over threads to protect Oring. Slide Oring over
tape and into Oring groove of fitting. Remove tape.
3. Tighten fitting to torque value shown on chart.
T6243AE UN18OCT88
1. Inspect Oring boss seat for dirt or defects.
04T,90,K66 1929SEP991/2
Angle Fitting
2. Turn fitting into threaded boss until backup washer

contacts face of boss.
3. Turn fitting headend counterclockwise to proper index
(maximum of one turn).
NOTE: Do not allow hoses to twist when tightening fittings.
4. Hold fitting headend with a wrench and tighten locknut
and backup washer to proper torque value.
T6520AB UN18OCT88
1. Backoff lock nut (A) and backup washer (B)

completely to headend (C) of fitting.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size
Nm
lbft
3/824 UNF
7/1620 UNF
12
1/220 UNF
16
12
9/1618 UNF
24
18
3/416 UNF
46
34
7/814 UNF
62
46
11/1612 UN
102
75
13/1612 UN
122
90
15/1612 UN
142
105
15/812 UN
190
140
17/812 UN
217
160
NOTE: Torque tolerance is 10%.

04T,90,K66 1929SEP992/2
TM11813 (13OCT10)
0000036
748H Repair (S.N. 630436

)
101310
PN=28
Torque Values
Service Recommendations For Flat Face ORing Seal Fittings

1. Inspect the fitting sealing surfaces and Oring. They
must be free of dirt or defects.
IMPORTANT: Tighten fittings to 150% of listed torque

value if indexing is necessary or if fitting is
attached to an actuating devise.
2. Lubricate Orings and install into grove using

petroleum jelly to hold in place.
Tighten fittings to 50% of listed torque value

if used in aluminum housing.
3. Index angle fittings and tighten by hand pressing joint

together to insure Oring remains in place.
4. Tighten fitting or nut to torque value shown on the
chart. Do not allow hoses to twist when tightening
fittings, use backup wrench on straight hose couplings.
FLAT FACE ORING SEAL FITTING TORQUE*

Nomial Tube O.D.
mm
in.
Thread Size
Bulkhead Nut
Swivel Nut
in.
Nm
lbft
Nm
lbft
6.35
0.250
9/1618
16
12
12
9.52
0.375
11/1616
24
18
24
18
12.70
0.500
13/1616
50
37
46
34
15.88
0.625
114
69
51
62
46
19.05
0.750
1 3/1612
102
75
102
75
22.22
0.875
1 3/1612
102
75
102
75
25.40
1.000
1 7/1612
142
105
142
105
31.75
1.250
1 11/1612
190
140
190
140
38.10
1.500
212
217
160
217
160
*Torque tolerance is +15 20% unless otherwise specified.

Stud End Oring Seal Torque for Straight and Adjustable Fittings*
Thread Size
Straight Hex Size
Locknut Hex Size
Inch
Inch
Inch
Straight Fitting or Locknut Toque

Nm
3/824
5/8
9/16
12
7/1620
5/8
5/8
21
15
1/220
3/4
11/16
26
19
9/1618
3/4
3/4
34
25
55
lbft
3/416
7/8
15/16
73
7/814
1 1/16
1 1/16
104
76
1 1/1612
1 1/4
1 3/8
176
130
1 3/1612
1 3/8
1 1/2
230
170
1 5/1612
1 1/2
1 5/8
285
210
*Torque tolerance is +15 20% unless otherwise specified.

04T,90,K67 1902MAR001/1
TM11813 (13OCT10)
0000037
748H Repair (S.N. 630436

)
101310
PN=29
Torque Values
T6890BB UN01MAR90
Service Recommendations for Metric Series Four Bolt Flange Fitting
ASealing Surface
BSplit Flange
CPinched ORing
1. Clean sealing surfaces (A). Inspect. Scratches cause

leaks. Roughness causes seal wear. Outofflat
causes seal extrusion. If defects cannot be polished
out, replace component.
DSingle Piece Flange
DO NOT use air wrenches. DO NOT tighten one cap

screw fully before tightening the others. DO NOT over
tighten.
TORQUE CHART
2. Install the correct Oring (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 the port. Hand tighten cap screws to hold parts in
place. Do not pinch Oring (C).
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 Oring.
5. After components are properly positioned and cap
screws are hand tightened, 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.
Thread
Nm
M6
12
M8
30
22
M10
57
42
M12
95
70
M14
157
116
M16
217
160
M18
334
246
M20
421
318
lbft
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.
b
Metric standard thread.
04T,90,K175 1929SEP991/1
TM11813 (13OCT10)
0000038
748H Repair (S.N. 630436

)
101310
PN=30
Torque Values
T6890BB UN01MAR90
Service Recommendations For Inch Series Four Bolt Flange Fittings
ASealing Surface
BSplit Flange
CPinched ORing
1. Clean sealing surfaces (A). Inspect. Scratches cause

leaks. Roughness causes seal wear. Outofflat
causes seal extrusion. If defects cannot be polished
out, replace component.
DSingle Piece Flange

TORQUE CHART
Nm
Nominal
Flange
Size
lbft
Cap Screw
Size
Min
Max
Min
Max
1/2
5/1618 UNC
20
31
15
23
3/4
3/816 UNC
28
54
21
40
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 Oring (C).
3/816 UNC
37
54
27
40
11/4
7/1614 UNC
47
85
35
63
11/2
1/213 UNC
62
131
46
97
1/213 UNC
73
131
54
97
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 Oring.
21/2
1/213 UNC
107
131
79
97
5/811 UNC
158
264
117
195
31/2
5/811 UNC
158
264
117
195
5/811 UNC
158
264
117
195
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.
5/811 UNC
158
264
117
195
2. Install Oring (and backup washer if required) into

groove using petroleum jelly to hold it in place.
DO NOT use air wrenches. DO NOT tighten one cap

screw fully before tightening the others. DO NOT over
tighten.
04T,90,K174 1901AUG941/1
TM11813 (13OCT10)
0000039
748H Repair (S.N. 630436

)
101310
PN=31
Torque Values
TM11813 (13OCT10)
00000310
748H Repair (S.N. 630436

)
101310
PN=32
Contents
Section 01
Wheels
Page
Group 0110Powered Wheels and Fasteners

Wheel Remove and Install......................... 0101101
Tire Remove and Install............................. 0101102
Dual Wheel Installation.............................. 0101103
TM11813 (13OCT10)
011
748H Repair (S.N. 630436

)
101310
PN=1
Contents
TM11813 (13OCT10)
012
748H Repair (S.N. 630436

)
101310
PN=2
Group 0110
Powered Wheels and Fasteners
Wheel Remove and Install
1. Prepare machine for service. See Park and Prepare
for Service Safely. (Group 0001.)
T7382AN UN27SEP90
2. Turn battery disconnect switch to the OFF position.

See Battery Disconnect. (Operators Manual.)
CAUTION: Avoid possible injury from unexpected
machine movement. Install wheel chocks under
one or more wheels not being removed.
3. Install wheel chocks under one or more wheels not
being removed.
Wheel
CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.
4. Raise machine. Place an 18t (20ton) floor stand
under axle.
Specification
MachineWeight
(approximate)........................................................................... 17 030 kg
37 540 lb.
surfaces. Paint, rust, and dirt prevent good

contact between the surfaces and can result
in the wheels coming loose.
8. Clean the threads of cap screws and axle flange and
the mating surfaces on washers, rim, and axle flange.
Apply a drop of oil to cap screw threads after cleaning
with solvent.
9. Install three studs, equally spaced, into the axle flange.


5. Place wheel lift under wheel. Fasten safety chain

around upper part of tire.
10. Install wheel.
Specification
WheelWeight
(approximate)................................................................................ 545 kg
1200 lb.
Specification
WheelWeight
(approximate)................................................................................ 545 kg
1200 lb.
IMPORTANT: The rim dropping onto the cap screws

when loosened can damage the threads.
Install studs before loosening all the cap
screws to keep wheel centered on axle flange
to prevent thread damage.
11. Install cap screws and washers.
6. Remove three cap screws equally spaced around bolt

circle. Install T45672 Studs.
7. Remove cap screws and washers to remove wheel.
IMPORTANT: Paint, rust, and dirt must be removed
from the cap screws and axle flange threads,
washers, and mating surfaces of axle flange
and rim to ensure good contact between all
Tighten the cap screws just enough to hold wheel

in position. Remove the studs. Install the three
remaining cap screws.
Tighten cap screws to specification in a circular pattern
continuing past the starting point by four cap screws.
Specification
RimtoAxle Flange Cap
ScrewTorque............................................................................868 Nm
640 lbft
For machines with dual wheels, see Dual Wheel

Installation. (Group 0110.)
SW03989,0000B30 1917SEP101/1
TM11813 (13OCT10)
0101101
748H Repair (S.N. 630436

)
101310
PN=35
Tire Remove and Install
Always maintain the correct tire pressure. Do not inflate

the tires above the recommended pressure. Never weld or
heat a wheel and tire assembly, as heating can increase
air pressure and result in tire explosion. Welding can also
structurally weaken or deform the wheel.
TS952 UN12APR90
CAUTION: Tire repair should only be performed

by a qualified tire repair service. Do not attempt
to mount or demount a tire unless you have the
proper equipment and experience to perform the
job safely. Failure to follow proper procedures
when mounting or demounting a tire from a wheel
or rim can result in explosive separation of a tire
and rim parts, causing serious injury or death
Explosive Single Piece Rim and Tire
For initial inflation, always use a clipon chuck and

extension hose long enough to allow you to stand to one
side and NOT in front of, or over, the tire assembly. Inflate
in a safety cage if available. Use safety chains, cables, or
equivalent restraining devices during inflation.
CAUTION: Stand clear when using a cable or
chain sling. These devices can snap and lash
out, causing serious injury or death.
Check tire and wheel assemblies for low pressure, cuts,
bubbles, damaged rim components, or missing lug bolts
and nuts.
Check that the tire size exactly matches the rim size.
Improperlysized tires may not perform as intended.
TS211 UN23AUG88
Wheels may contain multipiece rim components. Inspect

all rim components and replace those that are cracked,
worn, damaged, or severely rusted. Use only rim
components designed to work with one another. Do not
combine rim components from different rim types or rim
manufacturers. Incorrectly assembled or mismatched rim
components can fly apart with explosive force.
NOTE: See supplied OffTheRoad Tire Maintenance
Manual to remove tire from wheel.
Explosive MultiPiece Rim and Tire
VD76477,000049C 1912NOV081/1
TM11813 (13OCT10)
0101102
748H Repair (S.N. 630436

)
101310
PN=36
Dual Wheel Installation

1. Position outer dual wheel flangetoflange with inner
wheel.
Specification
Dual WheelWeight
(approximate)................................................................................ 545 kg
1200 lb
2. Align cap screw holes in flanges using punches if

necessary.
3. Lubricate cap screw threads with grease.
4. Insert each cap screw outward through inner washer,

inner flange and outer washer. Install nut.
5. Seat wheels to rim by tightening nuts in a crisscross
pattern to specification.
Specification
Dual Wheel NutsInitial
Torque.........................................................................................407 Nm
300 lbft
6. Tighten nuts to final specification.

Specification
Dual Wheel NutsFinal
Torque.........................................................................................712 Nm
525 lbft
AC12469,0000462 1906AUG071/1
TM11813 (13OCT10)
0101103
748H Repair (S.N. 630436

)
101310
PN=37
TM11813 (13OCT10)
0101104
748H Repair (S.N. 630436

)
101310
PN=38
Contents
Section 02
Axles
Page

TeamMate IV Axles ................................ 0202001
Front Axle, Differential, and
Oscillation Supports Remove
and Install .............................................. 0202001
Rear Axle and Differential Remove
and Install .............................................. 0202005
Front Axle Guards Remove and
Install ..................................................... 0202008
Oscillation Supports Repair ....................... 0202008
Group 0225Input Drive Shaft and UJoints
Front Axle Drive Shaft Remove and
Install ..................................................... 0202251
Rear Axle and Transmission Drive
Shaft Remove and Install ...................... 0202252
Differential Lock Solenoid Valve
Repair .................................................... 0202601
TM11813 (13OCT10)
021
748H Repair (S.N. 630436

)
101310
PN=1
Contents
TM11813 (13OCT10)
022
748H Repair (S.N. 630436

)
101310
PN=2
Group 0200
Remove and Install
TeamMate IV Axles
For additional information on TeamMate IV axles and
components, see TeamMate IV 1200 1400 Series
Inboard Planetary Axles. (CTM442.)
TeamMate is a trademark of Deere & Company
AC12469,0000382 1901JUN071/1
Front Axle, Differential, and Oscillation

Supports Remove and Install
1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)
CAUTION: To avoid injury from escaping fluid
under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
TX1024537A UN06JUN07
2. Operate all hydraulic functions, including brake, to

release pressure in the hydraulic system. Depress
brake pedal at 1second intervals 20 times to remove
pressure from service brake accumulator.
4. Identify axle fitted to machine. See Axle Identification.
(CTM442.)
Front AxletoDrive Shaft Disconnect
5. Remove engine frame rear bottom guard.

1 Rear Oscillation Support

Lubrication Hose
2 Cap Screw (4 used)
3 Drive Shaft
4 Front Axle Yoke
6. Raise front of machine and support with stands.

Specification
MachineWeight
(approximate)........................................................................... 17 030 kg
37 540 lb.
7. Remove front wheels. See Wheel Remove and Install.

(Group 0110.)
8. Drain differential oil into an appropriate container for
storage or disposal. See Change Front Axle Oil.
(Operators Manual.)
9. Remove engine frame side guards.
10. Remove cap screws (2). Disconnect universal joint
from front axle.
11. Disconnect rear oscillation support lubrication hose
(1). Close all openings using caps and plugs.
Continued on next page
TM11813 (13OCT10)
0202001
MH66088,0000D71 1910SEP101/5
748H Repair (S.N. 630436

)
101310
PN=41
Remove and Install
12. Disconnect service brake hose (5) and differential lock

hose (6) from axle. Close all openings using caps and
plugs.
6 Differential Lock Hose
5 Service Brake Hose
Service Brake and Differential Lock Hoses

MH66088,0000D71 1910SEP102/5
13. Disconnect front axle vent hose (7). Close all openings
using caps and plugs.
14. Remove front engine frame bottom guard.
TX1081761A UN10SEP10
7 Front Axle Vent Hose
Front Axle Vent Hose

TM11813 (13OCT10)
0202002
MH66088,0000D71 1910SEP103/5
748H Repair (S.N. 630436

)
101310
PN=42
Remove and Install
15. Disconnect lubrication hose (8) from front axle

oscillation support (9). Close all openings using caps
and plugs.
16. Remove cap screws from front and rear oscillation
supports. Lower axle and remove from under machine.
Specification
1400 Series
AxleWeight
(approximate)................................................................................ 862 kg
1900 lb.
1400 Series Super
Wide Extreme Duty
Axle (SWEDA)Weight
(approximate).............................................................................. 1450 kg
3200 lb.
17. Repair or replace axle. See TeamMate IV Axles.

(Group 0200.)
Front Oscillation Support Lubrication Hose
18. For oscillation supports repair procedure, see

Oscillation Supports Repair. (Group 0200.)
8 Lubrication Hose
19. Clean mounting surfaces on oscillation supports,

dowels, and engine frame. Mounting surfaces should
be free from dirt, paint, and corrosion.
20. Install dowels in oscillation supports if they were
removed during removal or repair.
21. Support and raise axle into position.
Specification
1400 Series
AxleWeight
(approximate)................................................................................ 862 kg
1900 lb.
1400 Series Super
Wide Extreme Duty
Axle (SWEDA)Weight
(approximate).............................................................................. 1450 kg
3200 lb.
TM11813 (13OCT10)
9 Front Axle Oscillation

Support
0202003
MH66088,0000D71 1910SEP104/5
748H Repair (S.N. 630436

)
101310
PN=43
Remove and Install
22. Position oscillation supports. Install front and rear

oscillation supporttoengine frame cap screws (10
and 11 and tighten to specification..
Specification
Oscillation Support
toEngine Frame Cap
ScrewTorque.................................................................. 488596 Nm
360440 lbft
NOTE: It may be necessary to loosen the front

covertooscillation support cap screws (12) in
order to align support cap screws with holes
in engine frame. Hold thrust washer (13) in
place using a hex key wrench.
23. Adjust axle end play to specification. See Adjust Axle
Assembly End Play In Vehicle. (CTM442.)
24. Connect front oscillation support lubrication line.
25. Install front engine frame bottom guard and tighten

cap screws to specification.
Specification
Bottom GuardtoEngine
Frame Cap
ScrewTorque............................................................................620 Nm
457 lbft
26. Connect axle vent tube.

Oscillation Support Cap Screws
27. Connect service brake and differential lock hoses.

28. Connect rear oscillation support lubrication hose.
10 Front Oscillation
SupporttoEngine Frame
Cap Screw (6 used)
29. Install front differential drive shaft and tighten cap

screws to specification.
11 Rear Oscillation
SupporttoEngine Frame
Cap Screw (6 used)
Specification
3/8 in. Cross and Bearing
AssemblytoYoke Cap
ScrewTorque...................................................................... 5157 Nm
3842 lbft
AssemblytoYoke Cap
ScrewTorque.................................................................. 127142 Nm
94105 lbft
30. Install engine frame side guards.

31. Fill axle with oil. See Change Front Axle Oil.
(Operators Manual.)
Front Oscillation Support Cap Screws
32. Install front wheels. See Wheel Remove and Install.

(Group 0110.)
12 Front CovertoOscillation
Support Cap Screw (6
used)
33. Lower front of machine to the ground.
13 Thrust Washer
34. Install rear engine frame bottom guard.

Specification
Bottom GuardtoEngine
Frame Cap
ScrewTorque............................................................................620 Nm
457 lbft
35. Bleed service brakes. See Service Brake Bleeding

Procedure. (Group 902520.)
36. Turn battery disconnect switch to the ON position.
MH66088,0000D71 1910SEP105/5
TM11813 (13OCT10)
0202004
748H Repair (S.N. 630436

)
101310
PN=44
Remove and Install
Rear Axle and Differential Remove and Install


4. Identify axle fitted to machine. See TeamMate
IV 1200 1400 Series Inboard Planetary Axles.
(CTM442.)
Rear Drive Shaft

5. Raise rear of machine and support with stands.
1 TransmissiontoRear Axle
Drive Shaft
Specification
MachineWeight
(approximate)........................................................................... 17 030 kg
37 540 lb
6. Remove rear wheels. See Wheel Remove and Install.

(Group 0110.)
7. Drain differential oil into an appropriate container for
storage or disposal. See Change Front Axle Oil.
(Operators Manual.)
Bottom guard weight increases due to trash
buildup in equipment frame.
8. Remove equipment frame rear bottom guard.
Specification
Equipment Frame Rear
Bottom GuardWeight
(approximate).................................................................................. 34 kg
75 lb.
9. Disconnect transmissiontorear axle drive shaft (1) by

removing cap screws (2).
TM11813 (13OCT10)
0202005
MH66088,0000D72 1910SEP101/4
748H Repair (S.N. 630436

)
101310
PN=45
Remove and Install
10. Disconnect service brake hose (3) and differential lock

hose (4) from axle. Close all openings using caps and
plugs.
4 Differential Lock Hose
3 Service Brake Hose
Service Brake and Differential Lock Hoses

TM11813 (13OCT10)
0202006
MH66088,0000D72 1910SEP102/4
748H Repair (S.N. 630436

)
101310
PN=46
Remove and Install

11. Support rear axle. Remove nuts, washers, and
cap screws. Lower axle and differential slightly and
disconnect breather hose.
Specification
1400 Series
AxleWeight
(approximate)................................................................................ 862 kg
1900 lb.
1400 Series Super
Wide Extreme Duty
Axle (SWEDA)Weight
(approximate).............................................................................. 1450 kg
3200 lb.
12. Lower axle and differential and remove from under

machine.
13. Repair or replace axle. See TeamMate IV Axles.

(Group 0200.)
14. Clean mounting surface on axle housing and
equipment frame. Mounting surface should be free
of dirt and corrosion.
Rear Axle Cap Screws
15. Position axle underneath equipment frame.

Specification
1400 Series
AxleWeight
(approximate)................................................................................ 862 kg
1900 lb.
1400 Series Super
Wide Extreme Duty
Axle (SWEDA)Weight
(approximate).............................................................................. 1450 kg
3200 lb.
16. Connect breather hose.

IMPORTANT: The tightening sequence for cap screws
and nuts must be followed to prevent binding
which would result in inadequate clamping
force applied to the axle and frame joint.
NOTE: Apply oil to threads of rear axle and
differentialtoequipment frame cap screws
before installation.
17. Apply oil to threads of cap screws. Hold the cap
screws and tighten the nuts from the inside to the
outside, alternating sides. Tighten nuts until they are
snug.
5 Rear Axle Cap Screws
Specification
Rear Axle and
DifferentialtoEquipment
Frame Cap
ScrewsTorque..........................................................................660 Nm
487 lbft
19. Install rear differential drive shaft and tighten cap

Specification
AssemblytoYoke Cap
ScrewTorque...................................................................... 5157 Nm
3842 lbft
AssemblytoYoke Cap
ScrewTorque.................................................................. 127142 Nm
94105 lbft
20. Connect service brake and differential lock hoses.

18. Tighten cap screws to specification, from inside to

outside, alternating sides.
TM11813 (13OCT10)
0202007
MH66088,0000D72 1910SEP103/4
748H Repair (S.N. 630436

)
101310
PN=47
Remove and Install
22. Install rear equipment frame bottom guard. Tighten

23. Fill axle with oil. See Change Rear Axle Oil.
(Operators Manual.)
Specification
Bottom Guardto
Equipment Frame Cap
ScrewTorque............................................................................620 Nm
460 lbft
24. Install rear wheels. See Wheel Remove and Install.

(Group 0110.)
25. Lower rear of machine to ground.
26. Turn battery disconnect switch to the ON position. See
Battery Disconnect. (Operators Manual.)
MH66088,0000D72 1910SEP104/4
Front Axle Guards Remove and Install

1
TX1024347 UN06JUN07
TX1024347
1 Cap Screw (2 used per guard) 2 Washer (8 used per guard)
3 Guard (2 used per axle)
Remove and install parts as shown.

Item
Measurement
Specification
Axle GuardtoTransmission
Case Cap Screw
Torque
346 Nm
255 lbft
AC12469,000033E 1929MAY071/1
Oscillation Supports Repair

See TeamMate IV 12001400 Axles (CTM442)
for disassembly, assembly, adjustment, and repair
information for front and rear oscillation supports.
To repair oscillation supports, front axle must be removed

from machine. See Front Axle, Differential, and Oscillation
Supports Remove and Install. (Group 0200.)
To adjust oscillation supports, front axle must be installed

in machine. See Front Axle, Differential, and Oscillation
Supports Remove and Install. (Group 0200.)
PM10405,0000576 1907OCT101/1
TM11813 (13OCT10)
0202008
748H Repair (S.N. 630436

)
101310
PN=48
Group 0225
Input Drive Shaft and UJoints
Front Axle Drive Shaft Remove and Install
2
3
2
3
2
TX1024375 UN07JUN07
4
TX1024375
1 Front Differential Yoke
3 Cross and Bearing Assembly 5 Double Universal Joint

6 Transmission Yoke
(2 used)

2. Remove bottom guards on engine frame to gain
access to drive shaft. See Engine Frame Bottom
Guard Remove and Install. (Group 1746.)
3. Remove cap screws (2 and 4) to remove double
universal joint (5).
IMPORTANT: Yoke faces, pilots, keyways, bearing
cup mounting face, and key must be free of
foreign material, burrs, and nicks which will
prevent the cross and bearing assembly and
yoke from becoming properly seated.
4. Inspect parts for wear or damage. Repair or replace
as necessary.
IMPORTANT: Universal joints are precision
components. The fit is intended to be tight and
some compression of seals and thrust washers
is required to seat the bearing cups in the yoke.
Hand pressure, a tap with a softfaced hammer
or a C clamp can be used to seat a bearing
cup in the yoke. DO NOT use the cap screws
to pull bearing cups into the yokes.
5. Assemble universal joint so lubrication fittings are

aligned. Bearing cup keys must engage the keyway
and bearing cups the yoke pilot.
Tighten cap screws in even steps to specification.
Specification
AssemblytoYoke Cap
ScrewTorque...................................................................... 5157 Nm
3842 lbft
AssemblytoYoke Cap
ScrewTorque.................................................................. 127142 Nm
94105 lbft
6. Install lubrication fittings and tighten to specification.

Specification
Lubrication
FittingTorque........................................................................ 516 Nm
48144 lbin.
7. Lubricate universal joints. See Grease Front Axle

Drive Shaft UJoints and Transmission Output Shaft
Seal. (Operators Manual.)
SW03989,0000B3A 1924SEP101/1
TM11813 (13OCT10)
0202251
748H Repair (S.N. 630436

)
101310
PN=49
TX1024417 UN07JUN07
Rear Axle and Transmission Drive Shaft

Remove and Install
TM11813 (13OCT10)
0202252
SW03989,0000B3B 1924SEP101/3
748H Repair (S.N. 630436

)
101310
PN=50

1 Transmission Yoke
2 Snap Ring
3 Slotted Nut
4 Cotter Pin
5 Cap Screw (8 per universal
joint)
6 Universal Joint
7 Lubrication Fitting
8 Telescoping Drive Shaft
9 Lock Nut
10 Washer
11 Drive Shaft Yoke

12 Snap Ring
13 Nut
14 Washer
15 Nut

machine movement. Install articulation locking
bar before working in frame hinge area.
2. Remove shields at the articulation joint as needed for
access. Remove the equipment frame bottom guard
for access at rear axle and differential. See Equipment
Frame Bottom Guard Remove and Install. (Group
1746.)
16 Set Screw
17 Support Bearing
18 Drive Shaft
20 Alignment Marks
9. Install universal joint so drive shaft yoke is to the rear

of machine.
10. Apply PM37566 AntiSeize Lubricant to support
bearingtocoupling shaft contact surface of support
bearing (17).
11. Install support bearing on drive shaft so set screw is
towards the threaded end of shaft.
12. Install set screw to contact bottom of slot in shaft and
then loosen one turn. Install nut over set screw and
tighten.
IMPORTANT: Yoke faces, pilots, keyways, bearing

cup mounting face, and key must be free of
foreign material, burrs, and nicks which will
prevent the cross and bearing assembly and
yoke from becoming properly seated.
Specification
Support Bearingto
Coupling Shaft Slot Set
ScrewClearance....................................................... One turn out from
bottom of slot in coupling shaft.
3. Disassemble parts as shown. Inspect parts for wear

or damage and replace as necessary.
13. Install snap ring (12) into groove of drive shaft.

Position snap ring opening opposite the slot in the
drive shaft.
4. Loosen the nut (15) and then the set screw (16) to
remove support bearing (17) from drive shaft (18).
14. Install yoke (11) on drive shaft so alignment marks

(20) are aligned.
5. Install snap ring (2) into groove of transmission yoke

(1).
15. Install washer (10) and lock nut (9). Tighten lock nut
to specification.
6. Install transmission yoke on transmission output shaft.

Install slotted nut (3) and tighten to specification.
Specification
YoketoTransmission
Output Shaft Slotted
NutTorque...................................................................... 271339 Nm
200250 lbft
NOTE: Slotted nut can be tightened up to an additional

1/24 turn to align slot with hole.
7. Install cotter pin (4). Bend legs of cotter pin against
sides of nut.
IMPORTANT: Both universal joints (6) on telescoping
drive shaft must be assembled with alignment
mark and yokes aligned. Yokes not aligned
will cause excessive vibration during turns
resulting in failure of bearings.
Specification
Lock Nut (Machines
with 1200 Series
Axle)Torque.................................................................... 542610 Nm
400450 lbft
Lock Nut (Machines
with 1400 Series
Axle)Torque.................................................................... 720800 Nm
531590 lbft
16. Install drive shaft so support bearing is on the front

side of mounting plate.
17. Install washers (14) under the head of the cap screws
(19) and nuts (13). Tighten nuts to specification.
Specification
NutTorque................................................................................325 Nm
240 lbft
8. Assemble telescoping drive shaft (8) so alignment

mark (20) on drive shaft yoke (11) and transmission
yoke are aligned.
TM11813 (13OCT10)
0202253
SW03989,0000B3B 1924SEP102/3
748H Repair (S.N. 630436

)
101310
PN=51

Hand pressure, a tap with a softfaced hammer,
18. Assemble universal joint so lubrication fittings are
aligned. Bearing cup keys (21) must engage the
keyways and bearing cups engage the yoke pilot (22).
19. Install and tighten cap screws to specification.

Specification
AssemblytoYoke Cap
ScrewTorque...................................................................... 5157 Nm
3842 lbft
AssemblytoYoke Cap
ScrewTorque.................................................................. 127142 Nm
94105 lbft
20. Install and tighten lubrication fittings (7) to specification.

Specification
Lubrication
48144 lbin.
Air Relief ValveTorque.......................................................... 516 Nm
48144 lbin.
21 Bearing Cup Key
22 Yoke Pilot
22. Install shields at the articulation joint and install the

equipment frame bottom guard. See Equipment
Frame Bottom Guard Remove and Install. (Group
1746.)
21. Grease drive shaft. See Grease Rear Axle Drive Shaft
UJoints, Telescoping Splines, Support Bearing, and
Transmission Output Shaft Seal. (Operators Manual.)
SW03989,0000B3B 1924SEP103/3
TM11813 (13OCT10)
0202254
748H Repair (S.N. 630436

)
101310
PN=52
Group 0260
Hydraulic System
Differential Lock Solenoid Valve Repair
For Service Safely. (Group 0001.)

3. Operate all hydraulic control valves to release pressure
in hydraulic system. Depress brake pedal at 1 second
intervals 20 times to drain oil from accumulator.
4. Remove cap screws (1 and 2) to remove access panel
(3).
Left Access Panel

1 Cap Screw
2 Cap Screw
3 Access Panel
NM00125,0000583 1904OCT101/2
5. Disconnect wire connector from differential lock

solenoid valve (5).
6. Remove cap screws (4) and remove solenoid from
valve body (6). Close all openings using caps and
plugs.
7. Repair or replace parts as necessary.
8. Install new Orings and backup rings on solenoid valve
using petroleum jelly for installation.
9. Connect electrical connector to solenoid valve.

12. Before returning machine to service, check operation
of differential lock solenoid valve. See Differential
Lock Switch. (Operators Manual.)
5 Differential Lock Solenoid
Valve
6 Valve Body
TX1024458 UN06JUN07
10. Install access panel.
NM00125,0000583 1904OCT102/2
TM11813 (13OCT10)
0202601
748H Repair (S.N. 630436

)
101310
PN=53
Hydraulic System
TM11813 (13OCT10)
0202602
748H Repair (S.N. 630436

)
101310
PN=54
Contents
Section 03
Transmission
Page

Transmission Remove and Install.............. 0303001
Transmission Mount Remove and
Install ..................................................... 0303006
Group 0315Controls
Transmission Bump Shifter
Remove and Install................................ 0303151
EnginetoTransmission Drive
Shaft Remove and Install ...................... 0303251
Group 0350Gears, Shafts, and Power Shift Clutches
Transmission Repair Procedures .............. 0303501
Winch Drive Repair.................................... 0303502
Input Yoke Remove and Install.................. 0303507
Transmission Charge Pump
Transmission Charge Pump Drive
Repair .................................................... 0303604
Transmission Suction Tube
Repair .................................................... 0303608
Transmission Control Valve
Repair .................................................... 0303609
TM11813 (13OCT10)
031
748H Repair (S.N. 630436

)
101310
PN=1
Contents
TM11813 (13OCT10)
032
748H Repair (S.N. 630436

)
101310
PN=2
Group 0300
Remove and Install
Transmission Remove and Install
TX1080860A UN16AUG10

2. Operate all hydraulic controls to relieve pressure
in the hydraulic system. Depress brake pedal at
1second intervals 20 times to discharge pressure
from accumulator.
Transmission
3. Turn the battery disconnect switch to the OFF position.

4. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operators

Manual.)
5. Remove engine frame side access covers. See
Opening Engine Side Shields. (Operators Manual.)
6. Apply vacuum or drain hydraulic reservoir. If draining
hydraulic reservoir, see Change Hydraulic Oil.
(Operators Manual.)
Spline Coupler
7. Remove priority valve. See Priority Valve Remove and

Install. (Group 2160.)
8. Remove hydraulic attenuator, (if equipped). See

Hydraulic Attenuator Remove and Install. (Group
2160.)
9. Remove hydraulic pump (1). See Hydraulic Pump
Remove and Install. (Group 2160.)
10. Remove hydraulic fan and cooling loop pump (3) from
transmission case. See Hydraulic Fan and Cooling
Loop Pump Remove and Install. (Group 2160.)
11. Remove spline coupler (6).
12. Drain transmission oil. See Change Transmission Oil,
Replace Filter, and Clean Suction Screen. (Operators
Manual.)
13. Remove enginetotransmission drive shaft. See
EnginetoTransmission Drive Shaft Remove and
14. Disconnect transmission charge pumptofilter hose
Transmission Harness
1 Main Hydraulic Pump
2 Transmission Charge
PumptoFilter Hose
3 Hydraulic Fan and Cooling
Loop Pump
4 Transmission Harness
toFuel Sender Harness
Connector
5 Transmission Charge Pump
6 Spline Coupler
7 Clamp and Cap Screw
8 Transmission Wiring
Harness
9 Transmission Wiring
Harness Plug
15. Disconnect transmission wiring harness plug (9) from

cab.
16. Disconnect transmission harnesstofuel sender
harness connector (4), park brake solenoid connector,
differential lock solenoid connector, and park brake

pressure switch connector.
TM11813 (13OCT10)
0303001
SW03989,0000B37 1907OCT101/7
748H Repair (S.N. 630436

)
101310
PN=57
Remove and Install
17. Remove dipstick (10) from transmission.
18. Disconnect transmission fill hose (11) and transmission

vent hose (12). Close all openings using caps and
plugs.
19. Disconnect winch drive shaft (if equipped) from winch
output yoke. See Winch Drive Shaft Remove and
20. Disconnect rear axle drive shaft from transmission.
See Rear Axle and Transmission Drive Shaft Remove
and Install. (Group 0225.)
12 Transmission Vent Hose
Transmission Dipstick
10 Dipstick
11 Transmission Fill Hose
Transmission Vent Hose and Fill Hose

SW03989,0000B37 1907OCT102/7
21. Identify and disconnect park brake and differential lock

valve return hose (13), winch return hose (17), and
park brake valve hose (18). Close all openings using
caps and plugs.
14
22. Remove cap screw (15), washer (16), and winch

output yoke (14).
16 Washer
17 Winch Return Hose
18 Park Brake Valve Hose
15
16
17
TX1081025 UN24AUG10
13 Park Brake and

Differential Lock Return
Hose
14 Winch Output Yoke
15 Cap Screw
13
18
TX1081025
Winch Drive
TM11813 (13OCT10)
0303002
SW03989,0000B37 1907OCT103/7
748H Repair (S.N. 630436

)
101310
PN=58
Remove and Install
23. Identify and disconnect hoses (1923) at transmission

control valve. Close all openings using caps and
plugs.
24. Remove front axle drive shaft. See Front Axle Drive
Shaft Remove and Install. (Group 0225.)
22 Oil Cooler Return Hose
23 Winch Control Valve
Pressure Hose
19 TransmissiontoOil
Cooler Hose
20 Charge Pump Pressure
Hose
21 Park Brake and
Differential Valve Supply
Hose

TM11813 (13OCT10)
0303003
SW03989,0000B37 1907OCT104/7
748H Repair (S.N. 630436

)
101310
PN=59
Remove and Install
25. Remove cap screws (24) and washers (25) securing

lower transmission mount to machine frame.
26. Remove upper transmission mounting cap screws
(26), washers (27 and 28), nut (31) and upper isolators
(29).
28 Washer (4 used)
29 Upper Isolator (2 used)
30 Lower Isolator (2 used)
31 Nut (2 used)

25 Washer (2 used)
27 Washer (4 used)
Lower Transmission Mount
26
27
28
29
28
27
31
TX1081024
TX1081024 UN01SEP10
30
Upper Right Transmission Mount

TM11813 (13OCT10)
0303004
SW03989,0000B37 1907OCT105/7
748H Repair (S.N. 630436

)
101310
PN=60
Remove and Install
27. Remove cap screw (32) from upper left transmission

mount. Install JT01748 Lifting Bracket (33) using a
cap screw 12.7 mm (1/2 in.) longer than cap screw
removed.
28. Attach D01043AA Load Positioning Sling (34) to
appropriate lifting device.
29. Attach one hook from load positioning sling to lifting
bracket (33).
Lifting Bracket
30. Attach remaining hook to lifting location at rear slot in

upper right transmission mount.
31. Adjust load positioning sling to raise right side of
transmission first. Carefully remove transmission from
machine and support on an appropriate stand.
Specification
TransmissionWeight
(approximate)................................................................................ 590 kg
1300 lb.

33. Inspect and replace transmission mounts as needed.
See Transmission Mount Remove and Install. (Group
0300.)
NOTE: Make sure lower isolators are installed

in transmission upper mount before setting
transmission into place.
34. Install transmission into engine frame.
Specification
TransmissionWeight
(approximate)................................................................................ 590 kg
1300 lb.
35. Install cap screws and washers. Tighten to

specification.
Load Positioning Sling
Specification
Lower Transmission
Mount PlatetoFrame
Cap ScrewTorque.......................................................... 230312 Nm
170230 lbft
36. Install upper transmission mounting hardware and

tighten to specification.
32 Cap Screw
33 Lifting Bracket
34 Load Positioning Sling
38. Connect hoses to transmission control valve.
Specification
Upper Transmission
Mount Cap Screw and
NutTorque...................................................................... 607743 Nm
450550 lbft
39. Install enginetotransmission drive shaft. See

40. Connect park brake and differential lock valve return
hose, winch return hose, and park brake valve hose.
37. Install front axle drive shaft. See Front Axle Drive
TM11813 (13OCT10)
0303005
SW03989,0000B37 1907OCT106/7
748H Repair (S.N. 630436

)
101310
PN=61
Remove and Install
41. Install winch output yoke on shaft. Apply Thread Lock

and Sealer (medium strength) to cap screw and install
with washer. Tighten cap screw to specification.
Specification
Winch Output Shaft Yoke
Cap ScrewTorque....................................................................215 Nm
159 lbft
42. Install remaining drive shafts. See Winch Drive Shaft

Remove and Install (Group 3025.) and see Rear Axle
and Transmission Drive Shaft Remove and Install.
(Group 0225.)
49. Connect transmission charge pumptofilter hose.

50. Install hydraulic attenuator, if equipped. See Hydraulic
Attenuator Remove and Install. (Group 2160.)
51. Install priority valve. See Priority Valve Remove and
52. Remove vacuum if hydraulic reservoir was not drained
or fill hydraulic reservoir. See Change Hydraulic Oil.
(Operators Manual.)
53. Install engine frame side access covers. See Opening
Engine Side Shields. (Operators Manual.)
43. Install transmission vent hose and transmission fill

hose.
54. Lower cab. See Hydraulic Cab Tilt Procedure.

(Operators Manual.)
44. Connect transmission wiring harness to cab.
55. Fill transmission with proper oil. See Change

Transmission Oil, Replace Filter, and Clean Suction
Screen. (Operators Manual.)
45. Connect transmission harnesstofuel sender harness

connector, park brake solenoid connector, differential
lock solenoid connector, and park brake pressure
switch connector. Install all harness clamps in original
locations.
56. Check hydraulic fluid level. See Check Hydraulic

System Oil Level. (Operators Manual.)
46. Install spline coupler.

47. Install hydraulic fan and cooling loop pump. See

Hydraulic Fan and Cooling Loop Pump Remove and
58. Calibrate transmission. See Transmission Control Unit

(TCU) Calibration. (Group 901520.)
48. Install hydraulic pump. See Hydraulic Pump Remove

SW03989,0000B37 1907OCT107/7
Transmission Mount Remove and Install

2. Turn the battery disconnect switch to the OFF position.
Manual.)
4. Install JT05552 20mm Ringbolt (1) to rear half of

transmission case and support with appropriate
device.
Specification
TransmissionWeight
(approximate)................................................................................ 590 kg
1300 lb.
5. Remove dipstick support (2) from upper right

transmission mount.
Transmission Support
6. Remove harness clamp (3) from upper left

transmission mount.
1 JT05552 20mm Ringbolt

2 Dipstick Support
TM11813 (13OCT10)
0303006
3 Harness Clamp
NM00125,000057C 1930SEP101/3
748H Repair (S.N. 630436

)
101310
PN=62
Remove and Install
CAUTION: Prevent possible crushing injury

or death, and damage to machine from
transmission shifting. Service only one
transmission mount at a time
7. Remove cap screw (5), washers (6 and 7), nut (12),

and upper isolator (8).
NOTE: For upper right transmission mount, it may be

necessary to disconnect transmission harness at
cab for removal of mount bracket cap screws.
8. Remove cap screws (10) and transmission mount

bracket (9).
9. Separate lower isolator (11) from mount bracket

10. Inspect and replace parts as necessary.
10
11. Install lower isolator to mount bracket before

installation.
11
Specification
Upper Transmission
Mount Bracketto
Transmission Housing
235 lbft
12
Upper Right Transmission Mount
13. Install upper isolator with washers. Tighten cap screw

and nut to specification.
Specification
Upper Transmission
Mount Cap Screw and
NutTorque...................................................................... 607743 Nm
450550 lbft
TX1081404 UN03SEP10
12. Position mount bracket and install cap screws. Tighten

to specification.

6 Washer (4 used)
7 Washer (4 used)
8 Upper Isolator (2 used)
9 Mount Bracket (2 used)

11 Lower Isolator (2 used)
12 Nut (2 used)
15. Connect transmission harness to cab.
14. Install harness clamp and dipstick support.

TM11813 (13OCT10)
0303007
NM00125,000057C 1930SEP102/3
748H Repair (S.N. 630436

)
101310
PN=63
Remove and Install
16. Remove lower transmission mount cap screws (19)

and remove mount block (17).
17. Remove cap screw (13) and lower mount hardware
(1416 and 18).
17
19. Install lower transmission mount hardware. Tighten

15
16
15
19
20. Remove JT05552 20mm Ringbolt.

(Operators Manual.)
18
TX1081405 UN03SEP10
Specification
Lower Transmission
Mount BlocktoFrame
170230 lbft
Lower Transmission
Mount Cap
ScrewTorque.................................................................. 607743 Nm
450550 lbft
13
14
Lower Transmission Mount
13 Cap Screw
14 Washer
15 Washer (2 used)
16 Front Isolator
17 Mount Block
18 Rear Isolator
19 Cap Screw With Washer
(2 used)
NM00125,000057C 1930SEP103/3
TM11813 (13OCT10)
0303008
748H Repair (S.N. 630436

)
101310
PN=64
Group 0315
Controls
T210585 UN23MAR06
Transmission Bump Shifter Remove and Install
Transmission Bump Shifter

ATransmission Bump Shifter
BScrews (4 used)
CWiring Harness Connector
1. Remove four screws (B) securing bump shifter (A).
5. Connect wiring harness connector (C) to bump shifter.
2. Lift out bump shifter.
6. Position bump shifter.
3. Disconnect wiring harness connector (C) from bump

shifter.
7. Install four screws (B) securing bump shifter (A).

OUO1065,0000312 1910MAR091/1
TM11813 (13OCT10)
0303151
748H Repair (S.N. 630436

)
101310
PN=65
Controls
TM11813 (13OCT10)
0303152
748H Repair (S.N. 630436

)
101310
PN=66
Group 0325
Input Drive Shafts and UJoints
EnginetoTransmission Drive Shaft Remove
and Install
Machines Without Cold Weather Disconnect
2. Remove engine side shields. See Opening Engine

Side Shields. (Operators Manual.)


Manual.)
6
5
4
3
TX1024482 UN06JUN07
2
1
TX1024482
7
Drive ShaftWithout Cold Weather Disconnect
1 Cap Screw (8 used per joint)

2 Universal Joint
3 Cap
4 Drive Shaft

6 Washer (12 used)
5. Remove and inspect drive shaft. Repair or replace

parts as necessary.
Specification
Lubrication
48144 lbin.

7. Align lubrication fittings and fasten universal joint (2) to
drive shaft (4.) Tighten cap screws (1) to specification.
Specification
Cross and Bearing
AssemblytoYoke Cap
ScrewTorque...................................................................... 5157 Nm
3842 lbft
8. Install drive shaft and tighten cap screws to

specification.
Specification
Cross and Bearing
Assemblyto
Transmission Input Yoke
Cap ScrewTorque.............................................................. 5157 Nm
3842 lbft
Drive ShafttoDamper
Cap ScrewsTorque..................................................................150 Nm
110 lbft

(Operators Manual.)
TM11813 (13OCT10)
0303251
SW03989,0000B3D 1906OCT101/3
748H Repair (S.N. 630436

)
101310
PN=67
11. Install engine side shields. See Opening Engine Side

Shields. (Operators Manual.)

Machines With Cold Weather Disconnect

Manual.)

5. Remove bottom guard on cold weather disconnect.

See Transmission Cold Weather Disconnect
RepairIf Equipped. (Group 0752.)
TM11813 (13OCT10)
0303252
SW03989,0000B3D 1906OCT102/3
748H Repair (S.N. 630436

)
101310
PN=68
7
6
5
4
TX1024664 UN06JUN07
2
TX1024664
1
Drive ShaftWith Cold Weather Disconnect
1 Cap Screw (8 used per

universal joint)
2 Universal Joint
4 Drive Shaft

6 Washer (12 used)
NOTE: Engine must be rotated to remove all cap

screws on cold weather disconnect.
6. Remove and inspect drive shaft. Repair or replace
parts as necessary.
For cold weather disconnect repair, see Transmission
Cold Weather Disconnect RepairIf Equipped.
(Group 0752).
Specification
Lubrication
48144 lbin.

8. Align lubrication fittings and fasten universal joint (2) to
drive shaft (4.) Tighten cap screws (1) to specification.
7 Cold Weather Disconnect
Specification
Cross and Bearing
AssemblytoYoke Cap
ScrewTorque...................................................................... 5157 Nm
3842 lbft
9. Install drive shaft and tighten cap screws to

specification.
Specification
Cross and Bearing
Assemblyto
Cap ScrewTorque.............................................................. 5157 Nm
3842 lbft
Drive ShafttoDamper
Cap ScrewsTorque..................................................................150 Nm
110 lbft

(Operators Manual.)
11. Install cold weather disconnect bottom guard.
SW03989,0000B3D 1906OCT103/3
TM11813 (13OCT10)
0303253
748H Repair (S.N. 630436

)
101310
PN=69
TM11813 (13OCT10)
0303254
748H Repair (S.N. 630436

)
101310
PN=70
Group 0350
Gears, Shafts, and Power Shift Clutches
Inspect bushings, remove burrs and sharp edges.
Transmission Repair Procedures

For repair procedures not covered in this book such
as clutch replacement and gear replacement, see
DF180 Series Powershift Transmission Repair Manual.
(CTM308.)
Before beginning repair:
Drain transmission oil.

Thoroughly clean the outside of the transmission before
disassembly to reduce the possibility of contamination.
Disassembly:
Replace bushings if outofround, scored or excessively

worn.
Inspect control valve bores for contamination.
Inspect clutch and brake plates for facing material
condition wear to teeth and flatness of the plate.
Inspect clutch and brake separator plates for
discoloration, teeth wear, scoring and flatness.
Inspect all thrust surfaces for scoring.
Inspect all gear and spline teeth.
Inspect all gasket and sealing surfaces for damage.
IMPORTANT: If the transmission has had a major
failure, replace all bearings, springs, oil seals,
Orings, ring seals, and gaskets.
Clean all parts and flush any debris from oil passages.
Use moisturefree air to dry parts (except bearings) and
to clean out oil passages.
Assembly:
IMPORTANT: DO NOT use solvent to clean the

clutch and brake disks use a lintfree cloth.
Lightly oil all bearings.

Use new Orings, seal rings, oil seals and gaskets.
Lubricate oil seals and Orings.
Wet clutch and brake plates with clean hydraulic oil
Lightly oil all bearings after cleaning.

IMPORTANT: Spinning a bearing without lubrication
can damage the bearing.
before assembly.
Clean and prepare all gasket and sealing surfaces.
Inspect bearings for discoloration, roughness of

rotation, and excessive wear of rollers or balls.
PM10405,0000575 1907OCT101/1
TM11813 (13OCT10)
0303501
748H Repair (S.N. 630436

)
101310
PN=71
TX1081448 UN01SEP10
Winch Drive Repair
Winch Drive and Cap Screw Tightening Sequence

1 Winch Drive Cover
3 Oil Seal
4 VRing Seal
5 Cap Screw
6 Yoke Washer
7 Yoke
8 Dowel Pin
9 Dowel Pin
10 Bearing
11 Output Shaft
12 Bearing
13 Bearing (2 used)
14 Idler Gear
15 Drive Gear


TM11813 (13OCT10)
16 Snap Ring
17 Cover Assembly (if winch
option not present)
18 ORing
19 Cover
0303502
NM00125,000057F 1927SEP101/6
748H Repair (S.N. 630436

)
101310
PN=72
3. Remove cap screw (5), yoke washer (6), and yoke (7).
4. Remove Vring seal (4) and oil seal (3).

3 Oil Seal
4 VRing Seal
5. Remove cap screws (2) securing winch cover to

transmission housing.
5 Cap Screw
6 Yoke Washer
7 Yoke
Winch Output Yoke
Output Shaft Seals
Winch Cover Cap Screw Removal

TM11813 (13OCT10)
0303503
NM00125,000057F 1927SEP102/6
748H Repair (S.N. 630436

)
101310
PN=73
6. Remove winch cover (1) and output shaft (11).

7. Remove idler gear (14).
8. Remove snap ring (16) and drive gear (15).
1 Winch Cover
11 Output Shaft
14 Idler Gear

15 Drive Gear
16 Snap Ring
Winch Cover Removal
Idler Gear
Snap Ring Removal

NM00125,000057F 1927SEP103/6
10. Install winch output shaft.

11. Install idler gear.
11 Output Shaft
14 Idler Gear
12. Install drive gear and snap ring.

15 Drive Gear
16 Snap Ring
Winch Drive Gears

TM11813 (13OCT10)
0303504
NM00125,000057F 1927SEP104/6
748H Repair (S.N. 630436

)
101310
PN=74
13. Clean mating surfaces of housings with isopropyl

alcohol or equivalent.
IMPORTANT: Excessive amounts of gasket adhesive

may cause incorrect bearing end play, extend
cure time, and cause runoff of material.
Using a small roller will help to apply a
thin, even layer of adhesive.
14. Apply PM38655 Flexible FormInPlace Gasket to rear
housing mating surface, using care to apply a thin
layer over the entire surface.Excess gasket material
should be wiped from joint. Installation should occur
within three minutes of application. Allow a minimum
of 30 minutes of cure time before adding oil.
Winch Cover Installation
15. Ensure dowel pins (8 and 9) are installed in rear

housing.
16. Install winch drive cover.
YZ4114 UN20MAR01
17. Install and tighten cap screws to specification in

sequence shown. Repeat sequence again to check
cap screw torques.
Specification
Winch CovertoRear
Housing Cap
ScrewTorque...................................................................... 2030 Nm
1422 lbft
18. Apply PM37418 Thread Lock and Sealer (medium

strength) to outside diameter of oil seal. Apply
petroleum jelly to inside diameter of oil seal between
seal lips.
Winch Drive Cover Torque Sequence

1 Winch Drive Cover
TM11813 (13OCT10)
0303505

NM00125,000057F 1927SEP105/6
748H Repair (S.N. 630436

)
101310
PN=75
19. Install new oil seal using JDG1110 Input Shaft Seal
Installation Tool (20) and JDG1108 Clutch Bearing
Driver (21).
20. Lubricate and install Vring seal.
NOTE: OPTIMOLY PASTE WHITE T reduces

spline wear.
21. Apply OPTIMOLY PASTE WHITE T on output shaft
spline before installing yoke.
22. Install yoke.
23. Apply PM37421 Thread Lock and Sealer (high
strength) to cap screw.
24. Install yoke washer and cap screw. Tighten cap screw
to specification.
Installing New Output Oil Seal
Specification
159 lbft
3 Oil Seal
4 VRing Seal

20 JDG1110 Input Shaft Seal
Installation Tool
21 JDG1108 Clutch Bearing
Driver
Output Shaft Seals

OPTIMOLY PASTE WHITE T is a trademark of Optimal Lubricants, Inc.
NM00125,000057F 1927SEP106/6
TM11813 (13OCT10)
0303506
748H Repair (S.N. 630436

)
101310
PN=76
Input Yoke Remove and Install


3. Remove cap screw (1).
4. Remove washer (2).
5. Remove Oring (3).
6. Remove yoke (4).
7. Remove oil seal (5).
8. Apply PM37418 Thread Lock and Sealer (medium

strength) to outside diameter of oil seal. Apply
petroleum jelly to inside diameter of new oil seal .
Install using a disk driver.
NOTE: OPTIMOLY PASTE WHITE T reduces

spline wear.
9. Apply OPTIMOLY PASTE WHITE T on input shaft
spline before installing yoke.
IMPORTANT: The yoke may need to be moved up
and down until the seal lip is over the full
circumference of yoke. Seal lip of oil seal must
not be rolled when yoke is installed.
Transmission Input Yoke Removal
10. Install yoke.

11. Install Oring.
12. Install washer.

13. Apply PM37421 Thread Lock and Sealer (high
strength) to cap screw.
14. Install and tighten cap screw to specification.
Specification
Input Yoke Cap
ScrewTorque............................................................................215 Nm
159 lbft
15. Turn battery disconnect to the ON position.
Torque Wrench
1 Cap Screw
2 Washer
3 ORing
4 Yoke
5 Oil Seal
6 Torque Wrench

NM00125,0000580 1927SEP101/1
TM11813 (13OCT10)
0303507
748H Repair (S.N. 630436

)
101310
PN=77
TM11813 (13OCT10)
0303508
748H Repair (S.N. 630436

)
101310
PN=78
Group 0360
Hydraulic System
Transmission Charge Pump Remove and
Install

Manual.)
Cooling Loop Pump

Manual.)
IMPORTANT: Cooling loop pump must be removed

prior to charge pump removal. This eliminates
the potential of dropping cooling loop
drive coupler into transmission during
charge pump removal.
6. Remove cap screws (1) and lay cooling loop pump
(2) aside.
7. Remove drive coupler (3).
8. Remove hydraulic pump. See Hydraulic Pump
Drive Coupler
2 Cooling Loop Pump
TM11813 (13OCT10)
0303601
3 Drive Coupler
NM00125,0000591 1930SEP101/4
748H Repair (S.N. 630436

)
101310
PN=79
Hydraulic System
9. Remove transmission charge pump suction tube (6).

See Transmission Suction Tube Repair. (Group 0360.)
10. Remove charge pumptotransmission filter hose (4).
11. Remove cap screws (5) and remove transmission
charge pump.
Suction Tube
4 Charge Pumpto
Transmission Filter Hose
Transmission Charge Pump

NM00125,0000591 1930SEP102/4
12. Inspect spline coupler and drive gear assembly (8).

Repair or replace parts as necessary.
IMPORTANT: Always replace charge pump flange

Oring. Old or damaged Orings may leak.
13. Apply petroleum jelly to new Oring (7) and install on
charge pump flange.
14. Apply OPTIMOLY PASTE WHITE T to pump splines.
IMPORTANT: Install gear assembly with seal side of
bearing facing transmission charge pump.
15. Install drive gear assembly to charge pump splines.
8 Drive Gear Assembly
7 ORing
Charge Pump Flange
Transmission Charge Pump Drive Coupler

TM11813 (13OCT10)
0303602
NM00125,0000591 1930SEP103/4
748H Repair (S.N. 630436

)
101310
PN=80
Hydraulic System
16. Position charge pump to transmission housing. Install

and tighten cap screws in the sequence shown to
specification.
T114002 UN16MAR98
Specification
Cap ScrewTorque......................................................................73 Nm
55 lbft
17. Install transmission charge pump suction tube. See

Transmission Suction Tube Repair. (Group 0360.)
IMPORTANT: Transmission charge pump must
be filled with oil prior to startup to
prevent pump damage.
18. Remove 90degree fitting from top of transmission
charge pump and fill pump with proper oil. See
Transmission, Park Brake, Differential, Cab Tilt
Hydraulic Pump and Winch Oil. (Operators Manual.)
19. Install 90degree fitting and transmission charge
pumptotransmission filter hose.
20. Install hydraulic pump. See Hydraulic Pump Remove
21. Install spline coupler.
Cap Screw Torque Sequence
24. Fill transmission with proper oil. See Change

Transmission Oil, Replace Filter, and Clean Suction
Screen. (Operators Manual.)
26. Calibrate transmission control unit. See Transmission
Control Unit (TCU) Calibration. (Group 9025.)
22. Install cooling loop pump.

(Operators Manual.)
NM00125,0000591 1930SEP104/4
TM11813 (13OCT10)
0303603
748H Repair (S.N. 630436

)
101310
PN=81
Hydraulic System
Transmission Charge Pump Drive Repair

Manual.)
5. Remove transmission charge pump. See Transmission

Charge Pump Remove and Install. (Group 0360.)
6. Remove drive gear (1).
7. Remove cap screw (2).
1 Drive Gear
2 Cap Screw
Drive Gear
Cap Screw
TM11813 (13OCT10)
0303604
NM00125,0000592 1906OCT101/5
748H Repair (S.N. 630436

)
101310
PN=82
Hydraulic System
8. Install M8 x 35 mm cap screw (3) in tapped hole.

9. Use cap screw to remove idler shaft (4).
IMPORTANT: There are 2 Orings (5), one at each end

of shaft. The Oring located on the bottom of the
idler shaft may slip off at removal of shaft.
10. Remove and discard Orings (5).
11. Remove idler gear (6).
12. Replace bearings in idler gear if worn or damaged.
5 ORing (2 used)
6 Idler Gear
M8 x 35 mm Cap Screw
3 M8 x 35 mm Cap Screw
4 Idler Shaft
Idler Shaft, ORings, and Idler Gear

TM11813 (13OCT10)
0303605
NM00125,0000592 1906OCT102/5
748H Repair (S.N. 630436

)
101310
PN=83
Hydraulic System
13. Install idler gear (6) into front housing.

NOTE: Lubricate Orings to avoid damage
during assembly.
14. Install new Orings (5) on idler shaft.

15. Install M8 x 35 mm cap screw (3) in tapped hole.
16. Install idler shaft through idler shaft port and idler gear
assembly.
NOTE: Using cap screw (3) turn idler shaft to align
holes in shaft and housing.
17. Use cap screw, align idler shaft with rear housing hole.
Idler Gear and ORings
18. Remove M8 x 35 mm cap screw.

6 Idler Gear
5 ORing (2 used)
M8 x 35 mm Cap Screw
TM11813 (13OCT10)
0303606
NM00125,0000592 1906OCT103/5
748H Repair (S.N. 630436

)
101310
PN=84
Hydraulic System
19. Install and tighten cap screw in idler shaft to

specification.
Specification
Idler Gear ShafttoFront
Housing Cap
ScrewTorque..............................................................................87 Nm
64 lbft
2 Cap Screw
YZ1148 UN23DEC97
Cap Screw
Tighten Idler Shaft Cap Screw

NM00125,0000592 1906OCT104/5
IMPORTANT: Seal on bearing must face

transmission charge pump.
20. Install bearing (7), drive gear (8), and bearing (9).
21. Install charge pump. See Transmission Charge Pump

7 Bearing
8 Drive Gear
9 Bearing
Drive Gear and Bearings

NM00125,0000592 1906OCT105/5
TM11813 (13OCT10)
0303607
748H Repair (S.N. 630436

)
101310
PN=85
Hydraulic System
Transmission Suction Tube Repair

1
1. Remove cap screws (3).

2. Disconnect suction tube (2) from charge pump (1).
3. Remove suction screen (5).
4. Remove and discard Oring (5).
5. Inspect suction screen for signs of collapse or
plugging. Clean or replace suction screen as
necessary.
7. Install suction screen (5) and new Oring (4).

8. Install suction tube (2).
9. Install cap screws and tighten to specification.
Specification
Suction TubetoFront
Housing Cap
ScrewsTorque............................................................................25 Nm
18 lbft
4 ORing
5 Suction Screen

2 Transmission Suction Tube
TX1024819 UN13JUN07
6. Inspect and replace suction tube as necessary.
AC12469,0000388 1909JUL071/1
TM11813 (13OCT10)
0303608
748H Repair (S.N. 630436

)
101310
PN=86
Hydraulic System
YZ104543A UN11SEP03
Transmission Control Valve Repair

AValve Housing
BProportional Solenoid ( 8
used)
CCooler Pressure Relief Valve

DMain Pressure Valve
EPlug (12 used)

F Plug (2 used)
GORing
HTemperature Sensor
AC12469,0000389 1913JUL071/22
1. Remove cap screws from control valve.

Specification
Control ValveWeight
(approximate)............................................................................... 27.5 kg
61 lb
AControl Valve
TM11813 (13OCT10)
0303609
YZ1077 UN17DEC97
2. Remove valve (A).
AC12469,0000389 1913JUL072/22
748H Repair (S.N. 630436

)
101310
PN=87
Hydraulic System
3. Remove gasket (A), plate (B) and gasket (C) from

front housing and discard gaskets.
CGasket
YZ1078 UN17DEC97
AGasket
BPlate
AC12469,0000389 1913JUL073/22
4. Remove nut (A), washer (B) and coil (C) from

proportional solenoid valve. Flange nut also used in
place of nut and washer.
CCoil
YZ1079 UN17DEC97
ANut or Flanged Nut

BWasher (Not used with
Flanged Nut)
AC12469,0000389 1913JUL074/22
IMPORTANT: When any proportional solenoid valves

are removed or replaced, Transmission Control
Unit (TCU) must be calibrated.
5. Remove proportional valve (D).
YZ1080 UN17DEC97
6. Inspect for contamination.

DProportional Valve
TM11813 (13OCT10)
03036010
AC12469,0000389 1913JUL075/22
748H Repair (S.N. 630436

)
101310
PN=88
Hydraulic System
7. Remove relief valve (A).

8. Inspect for wear or contamination.
NOTE: Check backup rings for damage.
YZ1081 UN17DEC97
ACooler Pressure Relief

Valve
AC12469,0000389 1913JUL076/22
9. Remove main pressure regulator (A).

10. Inspect for wear or contamination.
YZ1082 UN17DEC97
AMain Pressure Regulator
AC12469,0000389 1913JUL077/22
11. Remove temperature sensor (A).

12. Remove Oring (B).
13. Inspect for contamination.
BORing
YZ1083 UN17DEC97
ATemperature Sensor
Temperature Sensor and ORing

TM11813 (13OCT10)
03036011
AC12469,0000389 1913JUL078/22
748H Repair (S.N. 630436

)
101310
PN=89
Hydraulic System
14. Remove twelve plugs (A).

15. Inspect for contamination in control valve passages.
YZ1084 UN17DEC97
NOTE: Apply lubricant to all Orings prior to

installing into valve housing.
16. Install new Oring.
17. Install plugs (A) and fitting into valve housing.
18. Tighten plugs (A) to specification.
Specification
PlugtoValve
HousingTorque...........................................................................12 Nm
106 lbin.
APlugs (12 used)
AC12469,0000389 1913JUL079/22
19. Install new Oring (B).

20. Install temperature sensor (A).
Specification
Temperature
SensortoValve
142 lbin.
ATemperature Sensor
BORing
YZ1083 UN17DEC97
21. Tighten temperature sensor to specification.
AC12469,0000389 1913JUL0710/22
22. Install new Orings on main pressure regulator.
Specification
Main Regulator
AssemblytoValve
HousingTorque................................................................... 3447 Nm
2535 lbft
AMain Pressure Regulator
TM11813 (13OCT10)
03036012
YZ1082 UN17DEC97
23. Install and tighten main pressure regulator (A) to

specification.
AC12469,0000389 1913JUL0711/22
748H Repair (S.N. 630436

)
101310
PN=90
Hydraulic System
24. Install new Orings (A) on relief valve.

NOTE: Install new backup rings as needed.
Specification
Cooler Relief
ValvetoValve
2535 lbft
AORings
YZ1081 UN17DEC97
25. Install and tighten relief valve to specifcation.
AC12469,0000389 1913JUL0712/22
IMPORTANT: When any proportional solenoid valves

are removed or replaced, Transmission Control
Unit (TCU) must be calibrated.
AORing
BORing
YZ327 UN24SEP96
26. Lubricate and install new Orings (AC) on

proportional valve.
CORing
AC12469,0000389 1913JUL0713/22
27. Install proportional valve (D) into valve housing.
Specification
Proportional Valveto
Valve HousingTorque......................................................... 1620 Nm
142177 lbft
DProportional Valve
TM11813 (13OCT10)
03036013
YZ1080 UN17DEC97
28. Tighten proportional valve.
AC12469,0000389 1913JUL0714/22
748H Repair (S.N. 630436

)
101310
PN=91
Hydraulic System
29. Install coil (E) and washer (F) on proportional valve.

NOTE: Make sure nut threads and valve are
free of oil before applying sealer to ensure
sealer will set up properly.
YZ1079D UN12JAN98
30. Clean threads on proportional valve and nut. Apply

cure primer.
31. Apply high strength thread lock and sealer to nut (G)
and install on proportional valve.
ECoil
F Washer (Not used with
Flange Nut)
GNut or Flange Nut
AC12469,0000389 1913JUL0715/22
Specification
Proportional Valve
NuttoProportional
SolenoidTorque................................................................ 4.56.8 Nm
4060 lbin.
33. Repeat steps to install remaining proportional solenoid

and valve assemblies.
YZ4136 UN22MAR01
32. Tighten solenoid coil nut.
AC12469,0000389 1913JUL0716/22
34. Install two guide pins (A) in the front housing.

NOTE: The guide pins help align the gaskets by holding
them in place and ease valve assembly installation.
YZ1088 UN23DEC97
AGuide Pins
TM11813 (13OCT10)
03036014
AC12469,0000389 1913JUL0717/22
748H Repair (S.N. 630436

)
101310
PN=92
Hydraulic System
35. Gasket, Plate and Gasket Alignment

IMPORTANT: Gaskets and plate must be in correct
order and correct side up. Printed side of gasket
must be towards the control valve.
DGasket
YZ5087 UN18SEP03
BGasket
CPlate
AC12469,0000389 1913JUL0718/22
36. Put gasket (B), plate (C) and gasket (D) on front
housing using guide bolts as alignment guide.
DGasket
YZ1078A UN23DEC97
BGasket
CPlate
TM11813 (13OCT10)
03036015
AC12469,0000389 1913JUL0719/22
748H Repair (S.N. 630436

)
101310
PN=93
Hydraulic System
37. Install control valve (A) on front housing.

38. Remove guide pins.
39. Install and tighten cap screws (B) per numerical
sequence drawing.
BCap Screws
YZ1087 UN23DEC97
AControl Valve
TM11813 (13OCT10)
03036016
AC12469,0000389 1913JUL0720/22
748H Repair (S.N. 630436

)
101310
PN=94
T163650 UN14JAN03
Hydraulic System
Cap Screw Tightening Sequence

ACap Screw, 45 mm long and
Flat Washer (5 used)
BCap Screw, 90 mm long and

CCap Screw, 75 mm long and

TM11813 (13OCT10)
03036017
AC12469,0000389 1913JUL0721/22
748H Repair (S.N. 630436

)
101310
PN=95
Hydraulic System
40. Tighten cap screws (AC) again in sequence shown.
Specification
Control ValvetoFront
Housing Cap
ScrewsTorque............................................................................39 Nm
29 lbft
AC12469,0000389 1913JUL0722/22
TM11813 (13OCT10)
03036018
748H Repair (S.N. 630436

)
101310
PN=96
Section 04
Engine
Contents
Page

PowerTech Plus 6.8L (6068)
John Deere Engine6.8L Tier
3/Stage IIIA............................................ 0404001
PowerTech Plus 6.8L (6068)
John Deere Engine6.8L Stage
II............................................................. 0404001
Engine Remove and Install........................ 0404002
TM11813 (13OCT10)
041
748H Repair (S.N. 630436

)
101310
PN=1
Contents
TM11813 (13OCT10)
042
748H Repair (S.N. 630436

)
101310
PN=2
Group 0400
Removal and Installation
For additional information on John Deere PowerTech

and PowerTech Plus engines and components, see
the following component technical manuals:
PowerTech 4.5 L and 6.8 L Diesel EnginesBase
Engine. (CTM104.)
PowerTech Plus 4.5 L and 6.8 L Diesel Engines
Level 14 Electronic Fuel System with Denso HPCR.
(CTM320.)
M44215 UN07SEP88
PowerTech Plus 6.8L (6068) John Deere

Engine6.8L Tier 3/Stage IIIA
PowerTech is a trademark of Deere & Company

PowerTech Plus is a trademark of Deere & Company
PM10405,0000573 1907OCT101/1
For additional information on John Deere PowerTech

and PowerTech Plus engines and components, see
the following component technical manuals:
PowerTech 4.5 L and 6.8 L Diesel EnginesBase
Engine. (CTM104.)
PowerTech Plus 4.5 L and 6.8 L Diesel Engines
Level 14 Electronic Fuel System with Denso HPCR.
(CTM320.)
M44215 UN07SEP88
PowerTech Plus 6.8L (6068) John Deere

Engine6.8L Stage II
PowerTech is a trademark of Deere & Company

PowerTech Plus is a trademark of Deere & Company
PM10405,0000574 1907OCT101/1
TM11813 (13OCT10)
0404001
748H Repair (S.N. 630436

)
101310
PN=99
Engine Remove and Install

brake pedal at 1second intervals 20 times to
discharge pressure from brake accumulator.
Hydraulic Oil Return Filter Assembly

1 Hydraulic Oil Return Hose

2 Hydraulic Reservoir

3 Hydraulic Return Filter

Assembly

5. Drain cooling system. See Draining the Cooling
System. (Operators Manual.)
6. Remove hood. See Hood Remove and Install. (Group
1910.)
7. Remove hydraulic fan motor. See Hydraulic Fan Motor
8. Remove fan shroud. See Fan Shroud Remove and
9. Disconnect hydraulic oil return hose (1) at hydraulic
reservoir (2). Close all openings using caps and plugs.
Secure hydraulic filter assembly (3) to the side.
10. Remove air cleaner assembly. See Air Cleaner
TM11813 (13OCT10)
0404002
MH66088,0000DAC 1907OCT101/9
748H Repair (S.N. 630436

)
101310
PN=100
11. Remove engine deaeration hose (4) from thermostat

housing. Disconnect coolant fill hose (5) at engine
block and remove surge tank. Close all openings
12. Disconnect heater hoses from engine. Remove any

hose clamps or wire ties. Close all openings using
caps and plugs.
4 Engine Deaeration Hose
5 Coolant Fill Hose
TX1080867 UN13AUG10
Surge Tank Removal

MH66088,0000DAC 1907OCT102/9
13. Disconnect fuel supply hose (6) at final fuel filter (7) on
right side of engine. Disconnect fuel return hose (8)
on left side of engine at high pressure fuel pump (9).
Close all openings using caps and plugs.
6 Fuel Supply Hose

7 Final Fuel Filter
14. Remove serpentine belt. See Serpentine Belt Remove

8 Fuel Return Hose
9 High Pressure Fuel Pump
Fuel Supply Hose
Fuel Return Hose

TM11813 (13OCT10)
0404003
MH66088,0000DAC 1907OCT103/9
748H Repair (S.N. 630436

)
101310
PN=101
NOTE: It is not necessary to disconnect air conditioner

lines when removing the compressor for engine
removal and installation.
10 Wire Harness Connector

11 Ground Wire
15. Disconnect wire harness connector (10) and ground

wire (11) at air conditioner compressor (13). Remove
cap screws (12) and secure compressor to the side.
12 Cap Screw
13 Air Conditioner
Compressor
Air Conditioner Compressor

MH66088,0000DAC 1907OCT104/9
16. Remove cap screw (14) and clamp (15). Tag and
disconnect wiring harness connectors (16) from
engine control unit (19).
17. Remove cap screws (17) and remove ECU (19) and
ECU mouting bracket (18).
18. Remove wiring harness clamps along right side frame.
19. Tag and disconnect all electrical connections at starter.
20. Tag and disconnect all electrical connections at
alternator.
21. Remove ground wire from battery disconnect switch.

22. Remove batteries from machine. See Remove and
Install Batteries. (Operators Manual.)
23. Remove two engine wiring harness clamps on back
side of engine and on left rear engine mount.
Manual.)
25. Remove ground strap from engine, located near right
rear engine mount.
Engine Control Unit (ECU)
26. Disconnect cold weather disconnect linkage,

if equipped. See Transmission Cold Weather
Disconnect Linkage Remove and InstallIf Equipped.
(Group 0752.)
14 Cap Screw
15 Clamp
16 Wiring Harness Connector
(3 used)

18 Engine Control Unit (ECU)
Mounting Bracket
19 Engine Control Unit (ECU)
27. Remove enginetotransmission drive shaft. See

TM11813 (13OCT10)
0404004
MH66088,0000DAC 1907OCT105/9
748H Repair (S.N. 630436

)
101310
PN=102

TX1081034 UN23AUG10
NOTE: If engine does not have lifting lugs, they can

be procured through service parts.
Use of an engine lifting sling (as shown) is the
ONLY APPROVED method for lifting engine.
28. Install engine lifting lugs (20) to engine. Attach JDG23
Engine Lifting Sling (21) and appropriate lifting device
to engine lifting lugs. Support engine.
Specification
EngineWeight
(approximate)................................................................................ 771 kg
1700 lb.
Engine Removal
20 Engine Lifting Lug (2
used)
21 JDG23 Engine Lifting

Sling
MH66088,0000DAC 1907OCT106/9
29. Remove cap screws (22), nuts (28), and washers (23,
24, and 27) securing engine mounts to frame.
30. Remove engine from machine.
Specification
EngineWeight
(approximate)................................................................................ 771 kg
1700 lb.
TX1081035 UN23AUG10
31. Repair or replace engine as necessary.

32. Inspect engine mount rubber isolators (25 and 26) for
damage or excessive wear. Replace as necessary.
33. Install engine mount brackets to engine block, if
removed, and tighten to specification.
Specification
Engine Mount Bracket
236 lbft
Engine Mounts
34. Install engine isolators to engine mounts.

23 Washer (4 used)
24 Washer (4 used)
25 Upper Isolator
35. Install engine to machine.

Specification
EngineWeight
(approximate)................................................................................ 771 kg
1700 lb.
36. Tighten engine mounttoframe cap screws to

specification.
Specification
Front Engine
MounttoFrame Cap
ScrewTorque............................................................................620 Nm
457 lbft
Rear Engine
MounttoFrame Cap
ScrewTorque............................................................................712 Nm
525 lbft
37. Install enginetotransmission drive shaft. See

TM11813 (13OCT10)
26 Lower Isolator
27 Washer (4 used)
28 Nut (4 used)
0404005
MH66088,0000DAC 1907OCT107/9
748H Repair (S.N. 630436

)
101310
PN=103
TX1081054 UN23AUG10
EnginetoTransmission Drive Shaft Alignment

29 Torsional Dampener
30 Top Measurement
31 Bottom Measurement
38. Using a 6inch steel scale (32) or depth gauge,

measure distance at top and bottom (30 and 31) of
torsional dampener (29). Measurements should be
less than a 2 mm (0.08 in.) difference. Loosen engine
mounttoengine cap screws and raise or lower rear
of engine to change measurement.
39. Once correct measurement is achieved, tighten engine
mounttoengine cap screws to specified torque.
32 6inch Steel Scale
46. Connect electrical connections at starter.

47. Install ECU mounting bracket and ECU. Connect
electrical connectors to ECU.
48. Install air conditioner compressor and connect wiring
harness connector and ground wire.
49. Connect fuel supply and fuel return hoses.
Specification
Engine MounttoEngine
236 lbft
50. Connect heater hoses.
40. Remove lifting sling and lifting lugs from engine.
52. Install air cleaner assembly. See Air Cleaner Remove

41. Connect cold weather disconnect linkage, if equipped.

See Transmission Cold Weather Disconnect Linkage
Remove and InstallIf Equipped. (Group 0752.)
53. Connect hydraulic return line at hydraulic reservoir.
51. Connect coolant fill hose at engine block. Connect

deaeration hose to thermostat housing.
42. Install ground strap to engine.
54. Install fan shroud. See Fan Shroud Remove and

43. Install batteries. See Remove and Install Batteries.

(Operators Manual.)
55. Install hydraulic fan motor. See Hydraulic Fan Motor

44. Install ground wire to battery disconnect switch.
56. Install hood. See Hood Remove and Install. (Group

1910.)
45. Connect electrical connections at alternator.

TM11813 (13OCT10)
0404006
MH66088,0000DAC 1907OCT108/9
748H Repair (S.N. 630436

)
101310
PN=104
57. Fill cooling system. See Filling the Cooling System.

(Operators Manual.)
61. Bleed fuel system. See Bleed Fuel System.

(Operators Manual.)

62. Check Engine Oil Level. See Check Engine Oil Level.
(Operators Manual.)

60. Check hydraulic oil level. Add hydraulic oil, if
necessary. See Check Hydraulic System Oil Level.
(Operators Manual.)
MH66088,0000DAC 1907OCT109/9
TM11813 (13OCT10)
0404007
748H Repair (S.N. 630436

)
101310
PN=105
TM11813 (13OCT10)
0404008
748H Repair (S.N. 630436

)
101310
PN=106
Section 05
Engine Auxiliary Systems
Contents
Page
Group 0505Cold Weather Starting Aids

Do Not Use Ether Start Aid........................ 0505051
Group 0510Cooling System
Air Baffle Enclosure Remove and
Install ..................................................... 0505101
Serpentine Belt Remove and
Install ..................................................... 0505102
Serpentine Belt TensionerSpring
Tension Check ....................................... 0505103
Serpentine Belt Tensioner Remove
and Install .............................................. 0505104
Aftercooler Remove and Install ................. 0505105
Radiator Remove and Install ..................... 0505108
Transmission Oil Cooler Remove
and Install ............................................ 05051010
Hydraulic Oil Cooler Remove and
Install ................................................... 05051013
Fan Blade Remove and Install ................ 05051016
Fan Shroud Remove and Install .............. 05051016
Group 0520Intake System
Air Cleaner Remove and Install................. 0505201
Group 0530Exhaust System
Muffler Remove and Install........................ 0505301
Group 0560External Fuel Supply System
Fuel Tank Remove and Install ................... 0505601
TM11813 (13OCT10)
051
748H Repair (S.N. 630436

)
101310
PN=1
Contents
TM11813 (13OCT10)
052
748H Repair (S.N. 630436

)
101310
PN=2
Group 0505
Cold Weather Starting Aids
Do Not Use Ether Start Aid
This machine is equipped with a Tier III engine. Fire,

explosion or engine damage will result from using starting
fluids of any type on this machine.
T145705 UN18SEP01
IMPORTANT: Avoid an explosion or fire. Machine

is equipped with electrical cold start assist
system. Do not use ether start aid or any type
of starting fluids on this machine.
SW03989,0000B39 1924SEP101/1
TM11813 (13OCT10)
0505051
748H Repair (S.N. 630436

)
101310
PN=109
Cold Weather Starting Aids
TM11813 (13OCT10)
0505052
748H Repair (S.N. 630436

)
101310
PN=110
Group 0510
Cooling System
Air Baffle Enclosure Remove and Install
1 Grille Housing Side Panel

(2 used)
TX1080338A UN29JUL10
4. Remove grille housing side panels (1) and grille

housing top left panel (2).
2 Grille Housing Top Left
Panel
Grille Housing Access Panels

MH66088,0000D7D 1910SEP101/3
NOTE: Access to hose bracket cap screws (3) and

hose bracket (4) is obtained after grille housing
top left panel (2) is removed.
5. Remove caps screws (3) and hose bracket (4) from

grille housing.
6. Remove left side engine side shields. See Opening
7. Remove upper charge air tube. Close all openings

TX1080210 UN29JUL10
8. Disconnect upper radiator hose from radiator and

remove hose from air baffle. Close all openings using
caps and plugs.
4 Hose Bracket
Access for Hose Bracket Removal

TM11813 (13OCT10)
0505101
MH66088,0000D7D 1910SEP102/3
748H Repair (S.N. 630436

)
101310
PN=111
Cooling System
9. Remove caps screws (5), washers (6), nuts (7), and

washers (8) securing air baffle panels (912) to grille
housing.
10. Remove upper right air baffle panel (9).

11. Remove lower left air baffle panel (10).
12. Remove upper left air baffle panel (11).
11
13. Remove lower right air baffle panel (12).

NOTE: Air baffle panels must be installed in
reverse order of removal.
12
15. Install air baffle panels in reverse order of removal.

Install cap screws, nuts, and washers securing air
baffle panels to grille housing.
17. Install upper charge air tube.

18. Install left side engine side shields. See Opening
10
7
19. Install hose bracket to grille housing.
20. Install grille housing top left panel.

21. Install grille housing side panels.
TX1080209 UN18AUG10
16. Install upper radiator hose.
Air Baffle Panel Removal (view from front of machine)
22. Fill cooling system. See Filling the Cooling System.

(Operators Manual.)

6 Washer (20 used)
7 Nut (2 used)
8 Washer (2 used)
9 Upper Right Air Baffle

Panel
10 Lower Left Air Baffle Panel
11 Upper Left Air Baffle Panel
12 Lower Right Air Baffle
Panel
MH66088,0000D7D 1910SEP103/3
Serpentine Belt Remove and Install

3. Remove right side grille housing vent panel (1).

4. Remove top right air baffle panel. See Air Baffle
Enclosure Remove and Install. (Group 0510.)
1 Right Side Grille Housing
Vent Panel
Right Side Grille Housing Vent Panel

TM11813 (13OCT10)
0505102
MH66088,0000D7E 1910SEP101/2
748H Repair (S.N. 630436

)
101310
PN=112
Cooling System
5. Install a 1/2in. drive wrench into belt tensioner (4)

arm and pull wrench and arm downward to loosen
serpentine belt.
5
6
6. Remove serpentine belt.
8. Install serpentine belt as shown.
TX1080369 UN30JUL10
7. Check serpentine belt for wear or damage. Replace if

necessary. See Inspect Serpentine Belt. (Operators
Manual.)
9. Install air baffle panel. See Air Baffle Enclosure

Remove and Install. (Group 0510).
10. Install right side grille housing vent panel.

2 Crankshaft Pully
3 Water Pump Pully
4 Tensioner
Serpentine Belt Routing
5 Alternator Pully
6 Idler Pully
7 Air Conditioner
Compressor Pully
MH66088,0000D7E 1910SEP102/2
Serpentine Belt TensionerSpring Tension

Check

Enclosure Remove and Install. (Group 0510).
Vent Panel

TM11813 (13OCT10)
0505103
MH66088,0000D7F 1918AUG101/2
748H Repair (S.N. 630436

)
101310
PN=113
Cooling System
6. Put an alignment mark (2) on swing arm of tensioner

as shown.
7. Measure 21 mm (0.83 in.) down from swing arm mark
and put a mark (3) on tensioner mounting base.
Specification
Belt Tensioner
SpringDistance.......................................................................... 21 mm
0.83 in.
8. Rotate the swing arm tensioner using a torque wrench

until marks (2 and 3) are aligned.
9. Record torque wrench measurement and compare
with specification. Replace tensioner as required.
Specification
Spring TensionTorque........................................................ 1822 Nm
159195 lbin.
Alignment Marks
10. Install serpentine belt. See Serpentine Belt Remove

11. Install top right air baffle panel. See Air Baffle
2 Swing Arm Mark
3 Tensioner Mark

MH66088,0000D7F 1918AUG102/2
Serpentine Belt Tensioner Remove and

Install

5. Remove serpentine belt from tensioner pulley. See
Serpentine Belt Remove and Install. (Group 0510.)
Vent Panel

TM11813 (13OCT10)
0505104
MH66088,0000D80 1910SEP101/2
748H Repair (S.N. 630436

)
101310
PN=114
Cooling System
6. Remove cap screw (2) and belt tensioner (3).

7. Inspect and replace tensioner as needed.
8. Install belt tensioner (3). Install and tighten cap screw

(2) to specification.
Specification
Belt Tensioner Cap
ScrewTorque..............................................................................50 Nm
37 lbft
9. Install serpentine belt, making sure that belt is correctly

seated in all pulley grooves. See Serpentine Belt
10. Install top right air baffle panel. See Air Baffle
Serpentine Belt Tensioner

3 Belt Tensioner
2 Cap Screw

MH66088,0000D80 1910SEP102/2
Aftercooler Remove and Install


3. Open grille. See Opening the Grille. (Operators
Manual.)
NOTE: Air conditioner condenser is hinged on the
left side of the grill housing.
4. Remove cap screws (1) and swing air conditioner
condenser (2) open.
Air Conditioner Condenser

TM11813 (13OCT10)
0505105
2 Air Conditioner Condenser

MH66088,0000D9A 1923SEP101/6
748H Repair (S.N. 630436

)
101310
PN=115
Cooling System
5. Support air conditioner condenser. Remove cap

screws (3) and move assembly to the side.
Air Conditioner Condenser Hinge Mounting Cap Screws

MH66088,0000D9A 1923SEP102/6
6. Remove cap screws (4) and washers (5). Remove

lower air baffle insert (6).
6 Lower Air Baffle Insert

5 Washer (3 used)
Lower Air Bafe Insert

MH66088,0000D9A 1923SEP103/6
7. Remove cap screws (7), washers (8), and lower cooler

support (9).

8 Washer (3 used)
9 Lower Cooler Support
8. Remove cap screws (10) and aftercoolertoradiator

bracket (11).
11 AftercoolertoRadiator
Bracket
Lower Cooler Support

TM11813 (13OCT10)
0505106
MH66088,0000D9A 1923SEP104/6
748H Repair (S.N. 630436

)
101310
PN=116
Cooling System
9. Remove grille housing access panels (12 and 13).
12
12 Top Panel (2 used)
13 Side Panel (2 used)
TX1080450
13
TX1080450 UN03AUG10
10. Disconnect upper and lower aftercooler air piping from

aftercooler. Close all openings using caps and plugs.

MH66088,0000D9A 1923SEP105/6
11. Remove cap screws (14) securing upper support (16)

to top of coolers.
16
17
14
12. Remove nuts (15) and remove upper support and

foam insert (17).
13. Remove aftercooler.
Specification
AftercoolerWeight
(approximate).................................................................................. 29 kg
64 lb.
TX1080515 UN04AUG10
15
14. Inspect and replace as necessary.

TX1080515
15. Install aftercooler.
Upper Support
Specification
AftercoolerWeight
(approximate).................................................................................. 29 kg
64 lb.

15 Nut (4 used)
16 Upper Support
17 Foam Insert
16. Install upper support.

17. Connect upper and lower aftercooler air piping to
aftercooler.
18. Install grille housing access panels
19. Install aftercoolertoradiator bracket.
20. Install lower support.
21. Install lower air baffle insert.

22. Install air conditioner condenser.
23. Close grille.
MH66088,0000D9A 1923SEP106/6
TM11813 (13OCT10)
0505107
748H Repair (S.N. 630436

)
101310
PN=117
Cooling System
Radiator Remove and Install


Manual.)
condenser (2) open.


MH66088,0000D9C 1915SEP101/6

6. Perform Draining the Cooling System. (Operators
Manual.)

MH66088,0000D9C 1915SEP102/6


5 Washer (3 used)

TM11813 (13OCT10)
0505108
MH66088,0000D9C 1915SEP103/6
748H Repair (S.N. 630436

)
101310
PN=118
Cooling System

support (9).

8 Washer (3 used)
9. Remove cap screws (10), aftercoolertoradiator

bracket (11), and transmissiontoradiator bracket (12).
11 AftercoolertoRadiator
Bracket
12 TransmissiontoRadiator
Bracket

MH66088,0000D9C 1915SEP104/6
14
12. Disconnect lower radiator hose from radiator. Close

all openings using caps and plugs.
13 Grille Housing Side
Access Panel (2 used)
14 Grille Housing Top Access

Panel (2 used)
TX1080595
13
TX1080595 UN05AUG10
11. Disconnect upper radiator hose and deaeration hose

from radiator. Close all openings using caps and
plugs.

TM11813 (13OCT10)
0505109
MH66088,0000D9C 1915SEP105/6
748H Repair (S.N. 630436

)
101310
PN=119
Cooling System
13. Remove cap screws (14) securing upper cooler

support (16) to top of coolers.
16
17
14

foam insert (17).
15. Remove radiator.
Specification
RadiatorWeight
(approximate).................................................................................. 50 kg
110 lb.
TX1080515 UN04AUG10
15

TX1080515
17. Install radiator.
Upper Cooler Support
Specification
RadiatorWeight
(approximate).................................................................................. 50 kg
110 lb.

15 Nut (4 used)
16 Upper Cooler Support

17 Foam Insert
18. Install upper cooler support.

19. Install upper radiator hose and deaeration hose to
radiator.
20. Install lower radiator hose to radiator.
21. Install top and side grille housing access panels.

25. Install air conditioner condenser assembly.
26. Perform Filling the Cooling System. (Operators
Manual.)
27. Close grille.
22. Install aftercoolertoradiator bracket and

transmissiontoradiator bracket.
23. Install lower cooler support.

MH66088,0000D9C 1915SEP106/6
Transmission Oil Cooler Remove and Install


Manual.)
left side of the grille housing.
condenser (2) open.

TM11813 (13OCT10)
05051010

MH66088,0000DA8 1930AUG101/6
748H Repair (S.N. 630436

)
101310
PN=120
Cooling System


MH66088,0000DA8 1930AUG102/6


5 Washer (3 used)

MH66088,0000DA8 1930AUG103/6

support (9).

8 Washer (3 used)
8. Remove cap screws (10) and hydraulic oil

coolertotransmission oil cooler bracket (11).
11 Hydraulic Oil
CoolertoTransmission
Oil Cooler Bracket

TM11813 (13OCT10)
05051011
MH66088,0000DA8 1930AUG104/6
748H Repair (S.N. 630436

)
101310
PN=121
Cooling System
12
TX1080450 UN03AUG10
NOTE: Some loss of transmission fluid will occur during

removal of transmission oil cooler lines from cooler.
Use an appropriate container to capture fluid.
10. Disconnect transmission oil cooler lines at cooler.
12 Grille Housing Upper

TX1080450
13
MH66088,0000DA8 1930AUG105/6

17
16
14
12. Remove nuts (15) and remove upper cooler support

and foam insert (17).
13. Remove transmission oil cooler.
Specification
Transmission Oil
CoolerWeight
(approximate).................................................................................. 28 kg
62 lb.
TX1080515 UN04AUG10
15

TX1080515
15. Install transmission oil cooler.
Specification
Transmission Oil
CoolerWeight
(approximate).................................................................................. 28 kg
62 lb.

15 Nut (4 used)

17 Foam Insert
17. Connect transmission oil cooler lines at cooler.
22. Close grille.
18. Install hydraulic oil coolertotransmission oil cooler

bracket.

24. Check transmission oil level. See Check Transmission

Oil Level. (Operators Manual.)

MH66088,0000DA8 1930AUG106/6
TM11813 (13OCT10)
05051012
748H Repair (S.N. 630436

)
101310
PN=122
Cooling System
Hydraulic Oil Cooler Remove and Install

brake pedal at 1second intervals 20 times to relieve


Manual.)
condenser (2) open.
MH66088,0000DA2 1923SEP101/6


TM11813 (13OCT10)
05051013
MH66088,0000DA2 1923SEP102/6
748H Repair (S.N. 630436

)
101310
PN=123
Cooling System
7. Remove cap screws (4), washers (5), and lower air

baffle insert (6).

5 Washer (3 used)

MH66088,0000DA2 1923SEP103/6

support (9).

8 Washer (3 used)
9. Remove cap screws (10) and remove hydraulic oil

coolertotransmission oil cooler and hydraulic oil
coolertoradiator brackets (11 and 12).
11 Hydraulic Oil
CoolertoTransmission
Oil Cooler Bracket
12 Hydraulic Oil
CoolertoRadiator
Bracket
13 Hydraulic Oil Cooler
MH66088,0000DA2 1923SEP104/6
10. Remove upper and side grille housing access panels

(14 and 15).
15
14 Grille Housing Upper

14

TM11813 (13OCT10)
05051014
MH66088,0000DA2 1923SEP105/6
748H Repair (S.N. 630436

)
101310
PN=124
Cooling System

19
18
16

foam insert (19).
13. Apply vacuum to hydraulic oil reservoir to minimize
oil loss.
14. Disconnect hydraulic oil hoses at hydraulic oil cooler.
15. Remove hydraulic oil cooler.
17
TX1081462 UN30AUG10

17. Install hydraulic oil cooler.
18. Connect hoses to hydraulic oil cooler.
19. Remove vacuum from hydraulic oil reservoir.
20. Install hydraulic oil coolertoradiator bracket and
hydraulic oil coolertotransmission oil cooler bracket.
TX1080836

17 Nut (4 used)

19 Foam Insert

25. Remove vacuum pump.
28. Check hydraulic oil level. See Check Hydraulic

26. Close grille.

27. Turn battery disconnect switch to ON position.
MH66088,0000DA2 1923SEP106/6
TM11813 (13OCT10)
05051015
748H Repair (S.N. 630436

)
101310
PN=125
Cooling System
Fan Blade Remove and Install

4. Remove radiator. See Radiator Remove and Install.
(Group 0510.)
5. Remove fan blade retaining lock nut (1). Remove fan
blade.
6. Inspect and replace fan blade as necessary.

7. Install fan blade. Install fan blade retaining lock nut
and tighten to specification.
TX1080211 UN03AUG10
Specification
Fan Blade Retaining Lock
NutTorque..........................................................................81 16 Nm
60 12 lbft
8. Install radiator. See Radiator Remove and Install.

(Group 0510.)
Fan Blade Retaining Lock Nut

1 Fan Blade Retaining Lock
Nut
SW03989,0000B3E 1927SEP101/1
Fan Shroud Remove and Install

1. Remove grille housing. See Grille Housing Remove

2. Remove fan shroud.
Specification
Fan ShroudWeight
(approximate).................................................................................. 25 kg
55 lb.
4. Install fan shroud.

Specification
Fan ShroudWeight
(approximate).................................................................................. 25 kg
55 lb.
5. Install grille housing. See Grille Housing Remove and


MH66088,0000D84 1930AUG101/1
TM11813 (13OCT10)
05051016
748H Repair (S.N. 630436

)
101310
PN=126
Group 0520
Intake System
Air Cleaner Remove and Install
Prepare for Service Safely. (Operators Manual.)
TX1024247A UN29MAY07

See Battery disconnect. (Operators Manual.)
3. Remove air cleaner cap (1).
4. Remove left and right engine side shields. See
1 Air Cleaner Cap
2 Air Cleaner
Air Cleaner Cap
MH66088,0000DA5 1930AUG101/3
5. Loosen clamp (4) and disconnect turbocharger inlet

pipe (5). Close all openings using caps and plugs.
6. Disconnect electrical connector.
5 Turbocharger Inlet Pipe
2 Air Cleaner
4 Clamp
Turbocharger Inlet Pipe

MH66088,0000DA5 1930AUG102/3
7. Remove cap screws (3) and air cleaner (2).

9. Install air cleaner.
10. Connect electrical connector.

11. Connect turbocharger inlet pipe.
12. Install left and right engine side shields.
13. Install air cleaner cap.
2 Air Cleaner
Air Cleaner
MH66088,0000DA5 1930AUG103/3
TM11813 (13OCT10)
0505201
748H Repair (S.N. 630436

)
101310
PN=127
Intake System
TM11813 (13OCT10)
0505202
748H Repair (S.N. 630436

)
101310
PN=128
Group 0530
Exhaust System
Muffler Remove and Install

CAUTION: Prevent possible burn injury. Hot
equipment can cause burns to unprotected
skin. Allow equipment to cool before servicing.
Wear gloves and protective clothing when
working with hot equipment.
Mufer
3. Loosen upper muffler clamp (3).

4. Remove cap screws (2) and muffler outlet tube (1).
1 Muffler Outlet Tube

3 Upper Muffler Clamp
5. Loosen lower muffler clamp (5).
4 Muffler
5 Lower Muffler Clamp
6 Muffler Inlet Tube
6. Remove upper muffler clamp and muffler (4).

Specification
MufflerWeight
(approximate).................................................................................... 7 kg
17 lb.
9. Install muffler outlet tube. Tighten upper muffler clamp.


8. Install muffler and tighten lower muffler clamp. Leave
upper muffler clamp loose.
MH66088,0000DA6 1930AUG101/1
TM11813 (13OCT10)
0505301
748H Repair (S.N. 630436

)
101310
PN=129
Exhaust System
TM11813 (13OCT10)
0505302
748H Repair (S.N. 630436

)
101310
PN=130
Group 0560
External Fuel Supply System
Fuel Tank Remove and Install
TX1081659 UN07SEP10
NOTE: Model 648H with 4000 Series winch is shown.

Other configurations are similar.
Standard Fuel Tank

1 Fuel Tank
2 Lift Mounting Hole (2 used)
3 Wire Guard

5 Washer (6 used)
6 Drain Plug

8 Washer (2 used)
9 Bushing (2 used)


TM11813 (13OCT10)
10 Nut (2 used)
11 Fuel Level Sending Unit
0505601
SW03989,0000AF1 1904OCT101/6
748H Repair (S.N. 630436

)
101310
PN=131
3. Drain fuel tank (1). For fuel tank capacity, See Fuel
Tank. (Operators Manual.)
4. Remove arch. See Dual Function Grapple Arch

SW03989,0000AF1 1904OCT102/6
5. Remove two cap screws (13) and guard (12).
6. Remove winch, if equipped. See Winch 4000 Series

Remove and Install or see Winch 6000 Series Remove
7. Remove reverse warning alarm. See Reverse
Warning Alarm Remove and Install. (Group 2004.)
8. Disconnect fuel suction hose (14) and fuel return hose
12 Guard
14 Fuel Suction Hose

15 Fuel Return Hose
Fuel Hose Guard
Fuel Hose Connections

TM11813 (13OCT10)
0505602
SW03989,0000AF1 1904OCT103/6
748H Repair (S.N. 630436

)
101310
PN=132
9. Remove cover (17).

10. Disconnect wire leads from wire lead connections
(18). Pull wire leads free from wire guard (3).
17 Cover
18 Wire Lead Connection (2
used)
1 Fuel Tank
3 Wire Guard
Fuel Level Sending UnitCover
Fuel Level Sending Unit

TM11813 (13OCT10)
0505603
SW03989,0000AF1 1904OCT104/6
748H Repair (S.N. 630436

)
101310
PN=133

11. Attach JT01748 Lifting Brackets (19) to fuel tank.
Specification
Fuel TankStan
dardWeight (approxi
mate)............................................................................................. 165 kg
364 lb.
Fuel TankDual
FunctionWeight
(approximate)................................................................................ 205 kg
452 lb.
Fuel TankDual
Function Without
WinchWeight.............................................................................. 325 kg
718 lb.
12. Remove cap screws (4 and 7), washers (5 and 8),

bushings (9), and nuts (10).
13. Remove fuel tank.
Specification
Fuel TankStan
dardWeight (approxi
mate)............................................................................................. 165 kg
364 lb.
Fuel TankDual
FunctionWeight
(approximate)................................................................................ 205 kg
452 lb.
Fuel TankDual
Function Without
WinchWeight.............................................................................. 325 kg
718 lb.
JT01748 Lifting Brackets (shown on grapple machine)

19 JT01748 Lifting Bracket (2
used)
Fuel TankDual
Function Without
WinchWeight.............................................................................. 325 kg
718 lb.
16. Install cap screws, washers, bushings, and nuts.

17. Pull unit wire leads through wire guard.
14. Inspect fuel tank and components. Repair or replace

parts as necessary.
18. Connect wire leads to wire lead connections. Install

cover.

19. Connect fuel tank return line and fuel tank suction line.
20. Install guard.
15. Install fuel tank.

Specification
Fuel TankStan
dardWeight (approxi
mate)............................................................................................. 165 kg
364 lb.
Fuel TankDual
FunctionWeight
(approximate)................................................................................ 205 kg
452 lb.
21. Install reverse warning alarm. See Reverse Warning

Alarm Remove and Install. (Group 2004.)
22. Install winch, if equipped. See Winch 4000 Series
Remove and Install or see Winch 6000 Series Remove
23. Install arch. See Dual Function Grapple Arch Remove
24. Fill tank with fuel. See Diesel Fuel. (Operators
Manual.)
TM11813 (13OCT10)
0505604
SW03989,0000AF1 1904OCT105/6
748H Repair (S.N. 630436

)
101310
PN=134

26. Remove articulation locking bar.

SW03989,0000AF1 1904OCT106/6
TM11813 (13OCT10)
0505605
748H Repair (S.N. 630436

)
101310
PN=135
TM11813 (13OCT10)
0505606
748H Repair (S.N. 630436

)
101310
PN=136
Contents
Section 07
Dampener Drive
Page
Group 0752Elements
Dampener Remove and Install .................. 0707521
Transmission Cold Weather
Disconnect Linkage Remove
and InstallIf Equipped ........................ 0707522
Transmission Cold Weather
Disconnect RepairIf
Equipped ............................................... 0707524
TM11813 (13OCT10)
071
748H Repair (S.N. 630436

)
101310
PN=1
Contents
TM11813 (13OCT10)
072
748H Repair (S.N. 630436

)
101310
PN=2
Group 0752
Elements
Dampener Remove and Install
1. Set battery disconnect switch to OFF position.
2. Remove engine side shields.
3. Remove drive shaft. See EnginetoTransmission
Drive Shaft Remove and Install. (Group 0325.)
4. Remove cap screws (A) to remove cover (B).
For machines equipped with transmission disconnect,
see Transmission Cold Weather Disconnect Linkage
ACap Screw (6 used)

BCover
CCap Screw (6 used)
T114951B UN23APR98
5. Remove cap screws (C) and remove damper (D).

DTorsional Damper
EDowel Pin (2 used)
PM10405,0000572 1907OCT101/2
6. Position damper (D) on dowel pins (E).

7. Install and tighten cap screws (C) to specification.
Specification
FlywheeltoFlywheel
Housing Cap
ScrewTorque..............................................................................68 Nm
50 lbft
8. Install cover (B). Tighten cap screws (A).
9. Install drive shaft. See EnginetoTransmission Drive

10. Turn battery disconnect switch to ON.
11. Install engine side shields.
ACap Screw (6 used)
BCover
CCap Screw (6 used)
DTorsional Damper
EDowel Pin (2 used)
T114951B UN23APR98
On machines equipped with transmission disconnect,

see Transmission Cold Weather Disconnect Linkage
PM10405,0000572 1907OCT102/2
TM11813 (13OCT10)
0707521
748H Repair (S.N. 630436

)
101310
PN=139
Elements
Transmission Cold Weather Disconnect Linkage Remove and InstallIf Equipped

NOTE: Before repairing cold weather disconnect, ensure it
is properly adjusted. See Cold Weather Disconnect
Linkage AdjustmentIf Equipped. (Group 902020.)


For Service Safely. (Group 0001.)
4. Remove transmission drive shaft. See


4
6
7
3
5
9
11
10
2
14
13
12
TX1081470 UN30AUG10
15
15
15
TX1081470
16
Transmission Cold Weather Disconnect

2 Washer (6 used)
3 Lever
4 Cotter Pin
5 Pin
6 Yoke
7 Nut
8 Bracket

10 Flange Nut (2 used)
11 Actuator Rod
12 Housing
5. Remove cap screws (15) securing cover (16).
Weather Disconnect RepairIf Equipped. (Group

0752.)
6. Remove cotter pin (4) and pin (5).

7. Remove cap screws (9) and flange nuts (10).

8. Remove actuator rod and bracket.
12. Install housing. Tighten cap screws to specification.
9. Remove cap screws (13) and cover (14).

10. Remove cap screws (1) and washers (2) and remove
housing (12).
11. Inspect housing for cracks or damage. Inspect linkage
for damage or excessive wear. See Transmission Cold
Specification
Transmission Disconnect
HousingtoFlywheel
Housing Cap
ScrewTorque............................................................................217 Nm
160 lbft
13. Install cover (14).
TM11813 (13OCT10)

14 Cover
16 Cover
0707522
NM00125,0000581 1929SEP101/2
748H Repair (S.N. 630436

)
101310
PN=140
Elements
14. Install actuator rod and bracket.

15. Install cover (16).
19. Turn battery disconnect switch ON position. See

16. Install transmission drive shaft. See

17. Adjust cold weather disconnect. See Cold Weather
Disconnect Linkage AdjustmentIf Equipped. (Group
902020.)
NM00125,0000581 1929SEP102/2
TM11813 (13OCT10)
0707523
748H Repair (S.N. 630436

)
101310
PN=141
Elements
T8483AD UN15MAY95
Transmission Cold Weather Disconnect

RepairIf Equipped
TM11813 (13OCT10)
0707524
NM00125,0000582 1927SEP101/5
748H Repair (S.N. 630436

)
101310
PN=142
Elements
2 Universal Joint Cross
3 Stub Shaft
4 Seal
6 Collar
7 ORing
8 Snap Ring
9 Inner Collar
10 Bushing
11 Oil Seal
12 Needle Bearing
14 Washer (12 used)
15 Cover
16 Pipe Plug (2 used)
17 Thrust Bearing Race (2

used)
18 Needle Thrust Bearing
19 Compression Spring
20 Sliding Shaft
21 Bearing
22 ORing
23 Splined Hub
25 Snap Ring
26 Cap
27 Bearing Kit
28 Disconnect Spline Kit
29 Washer (6 used)
30 Transmission Disconnect
31 Transmission Disconnect
Kit
1. Remove cap screws (1) from stub shaft (3).
4. Remove cap (26).
2. Remove cap screws (13) and washers (14) to remove

disconnect cover (15) from damper.
5. Remove snap ring (25) to pull out stub shaft.
3. Remove cap screws (5) and washers (29) to remove

collar (6).
6. Remove seal (4) and collar from stub shaft.

NM00125,0000582 1927SEP102/5
CAUTION: Splined hub is spring loaded. Follow

proper procedure to remove splined hub and
collar to prevent personal injury. If splined
hub is removed improperly the spring will
pull hub up against collar.
7. Press inner collar (9) down to release pressure on
snap ring (8).
8. Remove snap ring.
8 Snap Ring
9 Inner Collar
23 Splined Hub
Splined Hub With Collar
Snap Ring Removal

TM11813 (13OCT10)
0707525
NM00125,0000582 1927SEP103/5
748H Repair (S.N. 630436

)
101310
PN=143
Elements
NOTE: Hydraulic press is shown for removal. If

press is not available, a lead hammer and
appropriate drivers can be used.
T7502HP UN11JUL91
9. Remove collar from sliding shaft using a 35mm disk.

Collar is a light press fit.
10. Remove sliding shaft from splined hub.
TM11813 (13OCT10)
0707526
NM00125,0000582 1927SEP104/5
748H Repair (S.N. 630436

)
101310
PN=144
Elements
CAUTION: Splined hub is spring loaded.

Follow proper removal procedure to
avoid personal injury.
11. Loosen cap screws (24) until heads are exposed.

12. Install cap screws (32) in lifting holes of splined hub.
Tighten puller cap screws until hub releases.
13. Disassemble parts from cover.
14. Press seal into collar counterbore. Install on stub shaft
with lip on ground diameter of shaft.
15. Install Oring (7) on stub shaft.
Cap Screws
16. Install all bushings and bearings that were removed.

17. Install sliding shaft bushing (10) to specified depth in

sliding shaft (20).
Specification
Sliding Shaft
BushingDepth...............................................................1.972.23 mm
0.0750.085 in.
Specification
CollartoCollar Cap
ScrewTorque..............................................................................14 Nm
124 lbin.
18. Install needle bearing (12) flush with bottom of 81mm

(3.2in.) diameter cavity in cover.
28. Apply plastic gasket into bore of cap and drive into
splined hub.
19. Install cover bearing to specified depth below end

surface of cover.
29. Install and tighten cap screws (13) to specification.
Specification
Cover BearingDepth........................................................1717.5 mm
0.670.69 in.
20. Install parts (1721) in cover as shown.
Specification
Cap ScrewTorque.................................................................... 113 Nm
83 lbft
30. Remove pipe plug (16) and add specified amount of

hydraulic fluid.
22. Install Oring (22) into groove of splined hub (23).
Specification
Cold Weather
DisconnectCapacity.................................................................. 118 mL
4 oz
23. Press collar onto sliding shaft past snap ring groove.
Install snap ring (8). Pull collar back against snap ring.
31. Install universal joint cross and tighten cap screws to

specification.
24. Install splined hub on cover. Tighten cap screws (24)

to specification.
Specification
45 lbft
21. Apply grease between lips of seal. Install oil seal (11)
into cover after installing sliding shaft.
Specification
124 lbin.
25. Apply grease to splines of stub shaft. Install cover with

splined hub assembly onto stub shaft.
26. Install snap ring (25) in stub shaft groove.
27. Install washers (29) into collar counterbores. Apply
Thread Lock and Sealer (medium strength) on cap
screws. Install and tighten to specification. Recheck
torque after all cap screws are tightened.
32. Install transmission cold weather disconnect. See

Transmission Cold Weather Disconnect Linkage
of transmission cold weather disconnect. See
Transmission Cold Weather Disconnect Clutch Check.
(Group 900510.)
NM00125,0000582 1927SEP105/5
TM11813 (13OCT10)
0707527
748H Repair (S.N. 630436

)
101310
PN=145
Elements
TM11813 (13OCT10)
0707528
748H Repair (S.N. 630436

)
101310
PN=146
Section 09
Steering System
Contents
Page
Group 0930Secondary Steering

Secondary Steering Pump Remove
and Install .............................................. 0909301
Steering Valve Remove and
Install ..................................................... 0909601
Steering Valve Disassemble and
Assemble............................................... 0909605
Steering Cylinder Remove and
Install ..................................................... 0909609
Group 0962Dual Mode Steering
Dual Mode Steering Solenoid Valve
TM11813 (13OCT10)
091
748H Repair (S.N. 630436

)
101310
PN=1
Contents
TM11813 (13OCT10)
092
748H Repair (S.N. 630436

)
101310
PN=2
Group 0930
Secondary Steering
TX1080206 UN18AUG10
Secondary Steering Pump Remove and

Install
TX1080206
Secondary Steering Pump Location

4. Turn battery disconnect to the OFF position.

NOTE: Secondary steering pump is located inside right
engine frame, forward of front axle.
5. Disconnect all electrical connections at secondary
steering pump and pump relay. See Secondary
Steering Harness (W19) Wiring DiagramIf Equipped.
(Group 901510.)
2. Operate all hydraulic controls to release pressure in

the hydraulic system.
3. Remove right side engine shields. See Opening
TM11813 (13OCT10)
0909301
NM00125,0000598 1907OCT101/2
748H Repair (S.N. 630436

)
101310
PN=149
Secondary Steering
4
2
1
TX1080205 UN27JUL10
8
7
TX1080205
Secondary Steering Pump Exploded View
1 Secondary Steering Pump
2 Bracket
3 Supply HosetoSecondary
5 Secondary Steering Relay
Steering Valve
4 Pressure HosetoSecondary
Steering Valve
7 Washer (3 used)
8 Rubber Bushing (3 used)
6. Disconnect supply hosetosecondary steering valve

(3) and pressure hosetosecondary steering valve (4)
at secondary steering pump. Close all openings using
caps and plugs.
12. Connect all electrical connections at secondary

steering pump and pump relay. See Secondary
Steering Harness (W19) Wiring DiagramIf Equipped.
(Group 901510.)
7. Support pump (1). Remove cap screws (6) and

washers (7) securing bracket (2) to frame.
13. Install right side engine shields.
8. Remove secondary steering pump and bracket from

frame.
9. Repair or replace components as required.
10. Install secondary steering pump and bracket assembly
to frame using washers and cap screws.
11. Connect pressure hose and supply hose to secondary
steering valve.

15. Check hydraulic oil level in the hydraulic reservoir
before starting engine. See Check Hydraulic System
of secondary steering system. See Secondary
Steering System Check. (Group 900510.)
NM00125,0000598 1907OCT102/2
TM11813 (13OCT10)
0909302
748H Repair (S.N. 630436

)
101310
PN=150
Group 0960
Hydraulic System
Steering Valve Remove and Install
T131633B UN15JUN00

1. Install articulation locking bar.
2. Operate hydraulic control valves to relive pressure in
3. Remove cap screws (1) to remove lower console
(2). As necessary, remove the fire extinguisher and
windshield washer tank.
4. Remove the cap screw from lower end of universal
joint (4).

2 Lower Console
T131635B UN15JUN00

Manual.)
3 Lower Steering Column
4 Universal Joint
TM11813 (13OCT10)
0909601
AC12469,0000396 1923JUL071/4
748H Repair (S.N. 630436

)
101310
PN=151
Hydraulic System

X9811 UN23AUG88

all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure fluids.
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.
NOTE: Attach labels to all lines before disconnection.
6. Disconnect lines 814. Close all openings using
caps and plugs.
11 Port RtoSteering
Cylinders Line
12 Priority Valve Port
CFtoPort P Line
13 Port LtoSteering
Cylinders Line
14 Port TtoReturn Oil Filter
Line

6 Nut and Washer (3 used)
8 Dual Mode Steering
Solenoid ValvetoSteering
Valve Pressure Hose
Solenoid Valveto
Steering Valve Return
Hose
Steering ValveDual Mode Steering

TM11813 (13OCT10)
0909602
AC12469,0000396 1923JUL072/4
748H Repair (S.N. 630436

)
101310
PN=152
Hydraulic System
NOTE: Make note of rubber isolator position between

mounting support and cab for installation.
7. Remove nuts and washers (6) and remove steering

valve (17) lower steering column, mounting plate (15),
and adapter plate (16) (Dual Mode Steering machines
only). Seal may come with the valve or remain stuck
to the platform.
8. For machines equipped with standard steering,
remove cap screws (5) and separate steering valve
from mounting plate (18) and lower steering column.
For machine equipped with dual mode steering,
remove cap screws (7) and separate adapter plate
(16) from mounting plate (15). Remove cap screws (5)
and separate adapter plate (16) and lower steering
column from steering valve.
Steering Valve MountingStandard Steering
9. For machines equipped with standard steering, inspect

and repair parts as necessary. See Steering Valve
Disassemble and Assemble. (Group 0960.)
For machines equipped with dual mode steering,
inspect and replace parts as necessary.
16 Adapter Plate
17 Steering Valve
18 Mounting Plate (Standard
Steering)
20 Rubber Isolators (3 Used)
6 Nut and Washer (3 used)

Solenoid ValvetoSteering
Valve Pressure Hose
9 Port LStoPriority Valve
Port LS Line
15 Mounting Plate (Dual
Mode Steering)
Steering Valve MountingDual Mode Steering

TM11813 (13OCT10)
0909603
AC12469,0000396 1923JUL073/4
748H Repair (S.N. 630436

)
101310
PN=153
Hydraulic System
10. Install lower steering column (19).
11. For machines with standard steering, install mounting

plate (18) so the side with the single rubber isolator is
toward the Port T and Port P corner of the steering
valve.
For machines with dual mode steering, install the
adapter plate so the side with two holes faces the inlet
and outlet ports.
12. Install cap screws (5) and tighten to specification.
Specification
Mounting Plate and
Lower Steering
ColumntoSteering Valve
234 lbin.
Lower Steering Column Installation (standard steering shown)

17 Steering Valve
18 Mounting Plate (Standard
Steering)
13. For dual mode steering machines, attach adapter

plate to mounting plate.
14. Install seal between mounting plate and cab.

20 Rubber Isolators (3 Used)
19. Connect hydraulic lines.
15. Install one washer on each stud.

CAUTION: Cab door is heavy. Use caution when
opening cab door while cab is tilted.
16. With the help of an assistant working through the right
cab door, install steering valve (17) so the splines of
the lower steering column engage splines in the lower
universal joint.
17. Install nuts and washers.
18. Install cap screw in lower universal joint. Check that
splines are engaged to specification.
IMPORTANT: Check for pinched lines when cab is

lowered. Adjust line position if necessary.
20. Lower the cab. See Hydraulic Cab Tilt Procedure.
(Operators Manual.)
21. Install lower console cover.
22. Turn battery disconnect to ON position.
24. Remove articulation lock bar.
Specification
Lower Steering
ColumntoLower
Universal Joint Spline
EngagementDistance................................................................ 19 mm
0.75 in.
AC12469,0000396 1923JUL074/4
TM11813 (13OCT10)
0909604
748H Repair (S.N. 630436

)
101310
PN=154
Hydraulic System
T162227B UN04DEC02
Steering Valve Disassemble and Assemble
Steering Valve Components
IMPORTANT: Perform all service on steering valve in

a clean isolated work area. Use proper tools,
cleaning material, and lubricants.
T162221 UN12DEC02
Use wooden blocks or similar material to protect

steering valve. Tighten vise just enough to hold
valve. Overtightening can damage the valve.
1. Put steering valve in a vise with the gerotor end up.
Tighten just enough to hold valve.
2. Remove the two cap screws (1) to remove pins (2)
and anticavitation steel balls (3).
3. Remove the remaining cap screws to remove end

cap (4), gerotor star (8), gerotor housing (9) and plate
spacer (10).
4. Hold spool (7) and reposition valve with lower steering
column (11) end up.
5. Remove mounting plate (12) and lower steering
column.
Cap Screws
2 Pins (2 used)
3 AntiCavitation Steel Balls
(2 used)
4 End Cap
7 Spool
8 Gerotor Star
TM11813 (13OCT10)
0909605
9 Gerotor Housing
10 Plate Spacer
12 Mounting Plate
13 Housing
AC12469,000039A 1913JUN071/5
748H Repair (S.N. 630436

)
101310
PN=155
Hydraulic System
6. Assemble tool using a M10 x 120 mm cap screw (22)

and two nuts (28).
7. Install cap screw into housing so head engages into
input spline.
8. Hold drive spline head (20) with 20 mm socket (21).
IMPORTANT: Spring tension must be compressed
before spool is removed.
T162215B UN04DEC02
9. Rotate cap screw using a wrench to compress spring

tension.
10. Push spool (7) down out of housing (13) while spring
tension is compressed.
Be careful not to remove pin (14) from spool (7) and
drive spline (19).
11. Inspect all parts for contamination, nicks and burrs.
Spring Compression Tools
Spool is not serviceable. Do not disassemble spool.

12. Replace Orings (18), dust seal (24), backup washer
(25) and seals (26, 27).
21 20 mm Socket
28 Nuts
T162222B UN04DEC02
7 Spool
13 Housing
20 Spline Head
Spool Removed From Housing

TM11813 (13OCT10)
0909606
AC12469,000039A 1913JUN072/5
748H Repair (S.N. 630436

)
101310
PN=156
Hydraulic System
18
26
25
24
T162216
T162216 UN20DEC02
27
Seal Placement
18 ORing (3 used)
24 Dust Seal
25 Backup Washer
26 Seal
27 ORing
13. Lubricate Orings (18 and 27) and seals (24 and 26)
with TY24416 MultiPurpose HD Lithium Complex
Grease. If petroleum jelly is used for Oring lubrication,
use small enough amount to avoid spreading on
surfaces of other parts.
15. Install spool (7) by compressing spring tension.

16. Hold drive spline head (20) with 20 mm socket (21).
17. Rotate cap screw (22) using wrench on nuts (28) to
compress spring tension.
14. Lubricate spool with clean hydraulic oil to ease

assembly.
IMPORTANT: Make sure drive pin does not slip
out of spool and drive spline.
TM11813 (13OCT10)
0909607
AC12469,000039A 1913JUN073/5
748H Repair (S.N. 630436

)
101310
PN=157
Hydraulic System
IMPORTANT: Timing of drive with respect to

gerotor star is critical.
18. Drive pin (14) must be aligned with valley (minor

diameter) of gerotor star.
19. Align pin (14), drive spline (19) and gerotor star (8)
as shown.
9
17
18
20. Install plate spacer (10).

21. Install gerotor star (8) and gerotor housing (9).
10
22. Install end cap (4).
18
23. Apply pipe sealant to bottom side of cap screw (1)

heads.
19
24. Install the cap screws except in the holes (1) for
anticavitation steel balls (3) and pins (2).
25. Install anticavitation steel balls and pins.
8 Gerotor Star
9 Gerotor Housing
10 Plate Spacer
14 Drive Pin
15 Alignment Line
T160389 UN02DEC02
16
26. Install remainder cap screws.
14
16 Alignment Line
17 Alignment Line
18 ORing (3 used)
19 Drive Spline
15
Component Alignment
AC12469,000039A 1913JUN074/5
IMPORTANT: Any cap screw can be tightened first,

but the sequence shown must be followed.
Specification
End CapToHousing Cap
ScrewTorque (Initial)..................................................................17 Nm
150 lbin.
End CapToHousing Cap
ScrewTorque (Final)...................................................................34 Nm
300 lbin.
T160436 UN17OCT02
27. Tighten cap screws to the initial specification in the

tightening sequence (17). Then tighten in sequence
to final specification.
Tightening Sequence
17 Tightening Sequence
AC12469,000039A 1913JUN075/5
TM11813 (13OCT10)
0909608
748H Repair (S.N. 630436

)
101310
PN=158
Hydraulic System
Steering Cylinder Remove and Install

1. Engage park brake.
X9811 UN23AUG88



3. Operate all controls to release hydraulic pressure.

4. Remove engine frame shields.
AC12469,0000397 1925JUL071/2
5. Disconnect lines (6 and 7) at rod and head end of

steering cylinder (5). Close openings with caps and
plugs.
1
3
5
3

7. Remove the cylinder.

2 Lock Nut (2 used)
3 Pin (2 used)
4 Thrust Washer (as required)
8. Repair or replace cylinder.

9. Install cylinder so work ports are on the bottom, and
cap screw hole in rod end clevis is on top.
10. Install thrust washers (4) to center cylinder clevises on
the mounting plates.
12. Install cap screws and lock nuts. Tighten to

specifications.
T162743
Steering Cylin
derWeight (approxi
mate)............................................................................................... 45 kg
100 lb
11. Install the pins (3).
Specification
T162743 UN18DEC02
6. Remove lock nuts (2) and cap screws (1) to remove

pins (3) and thrust washer (4).
5 Steering Cylinder
6 Rod EndtoSteering Valve
Line
7 Head EndtoSteering Valve
Line
Specification
CylindertoPin Cap
Screw and Lock
NutTorque..................................................................................27 Nm
20 lbft
13. Connect hydraulic lines and check for leaks.

AC12469,0000397 1925JUL072/2
TM11813 (13OCT10)
0909609
748H Repair (S.N. 630436

)
101310
PN=159
Hydraulic System
TM11813 (13OCT10)
09096010
748H Repair (S.N. 630436

)
101310
PN=160
Group 0962
Dual Mode Steering
Dual Mode Steering Solenoid Valve Remove
and Install
1. Turn battery disconnect switch to OFF.
X9811 UN23AUG88


3. Operate hydraulic control valves to relive pressure in
Manual.)
AC12469,0000398 1910MAR091/2
NOTE: Attach labels to hoses before disconnection.

If hoses are reversed, dual mode steering
switch operation will be reversed.
5. Disconnect wire connectors from solenoid (6).
6. Disconnect all hydraulic lines. Close all openings
7. Remove cap screws (2) and remove valve.
8. Inspect valve and repair or replace parts as necessary.
9. Install valve on underside of cab.
10. Connect hydraulic hoses.

11. Connect wiring to solenoid.
(Operators Manual.)
Dual Mode Steering Solenoid Valve

15. Turn battery disconnect switch to ON.
1 Return Hose
3 System Pressure Hose
4 Steering ValvetoSolenoid
Valve Return Hose
5 Solenoid ValvetoSteering
Valve Pressure Hose
6 Solenoid
AC12469,0000398 1910MAR092/2
TM11813 (13OCT10)
0909621
748H Repair (S.N. 630436

)
101310
PN=161
Dual Mode Steering
TM11813 (13OCT10)
0909622
748H Repair (S.N. 630436

)
101310
PN=162
Contents
Section 10
Service Brakes
Page

Service Brake Pedal Remove and
Install ..................................................... 1010151
Service Brake Valve Remove and
Install ..................................................... 1010601
Service Brake Valve Disassemble
and Assemble........................................ 1010603
Service Brake Accumulator
TM11813 (13OCT10)
101
748H Repair (S.N. 630436

)
101310
PN=1
Contents
TM11813 (13OCT10)
102
748H Repair (S.N. 630436

)
101310
PN=2
Group 1015
Controls Linkage
TX1056808 UN06MAR09
Service Brake Pedal Remove and Install
TX1056808
Service Brake Pedal
1 Pedal
2 Shaft
3 Spring
7 Flange Nut
8 Cap Screw
4 Bushing (2 used)
5 Bracket
6 Spring Pin
1. Remove spring pin (6).

2. Slide out shaft (2).
3. Inspect parts for wear or damage. Replace parts as
necessary.
4. Assemble parts as shown. Adjust brake pedal to

specifications. See Service Brake Pedal Adjustment.
(Group 902520.)
AC12469,000039C 1906MAR091/1
TM11813 (13OCT10)
1010151
748H Repair (S.N. 630436

)
101310
PN=165
Controls Linkage
TM11813 (13OCT10)
1010152
748H Repair (S.N. 630436

)
101310
PN=166
Group 1060
Hydraulic System
Service Brake Valve Remove and Install
X9811 UN23AUG88

Actuate the brake pedal 20 times at onesecond

intervals to relieve oil pressure from brake accumulator.
2. Tilt cab for access to service brake valve. See
Hydraulic Cab Tilt Procedure. (Operators Manual.)
1. Operate all hydraulic functions, including service

brakes, to relieve pressure in the hydraulic system.
AC12469,000039D 1913JUN071/3
NOTE: Observe position of lines before disconnection

to aid in assembly.
3. Disconnect hoses (25). Close openings using caps
and plugs.
4. Disconnect wiring connectors for the service brake
pressure switch (7).
4 Brake AccumulatortoPort
P Hose
5 Port TtoHydraulic
Reservoir Hose
7 Service Brake Pressure
Switch
1 Service Brake Valve

2 Port BStoFront Axle
Service Brake Pistons Hose
3 Port BRtoRear Axle
Service Brake Pistons Hose
TM11813 (13OCT10)
1010601
AC12469,000039D 1913JUN072/3
748H Repair (S.N. 630436

)
101310
PN=167
Hydraulic System
CAUTION: Cab door is heavy. Use caution when

opening cab door while cab is tilted.
5. While holding valve in place, have an assistant,
working through right cab door, remove cap screws
(F) to remove valve.
6. Repair or replace service brake valve as necessary.
See Service Brake Valve Disassemble and Assemble.
(Group 1060.)
7. Install fittings and pressure switch.
T114341B UN10APR98
Specification
Fitting to
2029 lbft
Service Brake
Pressure Switch to
106 lbin.
8. Install valve. Install and tighten cap screws.

Specification
Cab PlatformtoValve
Cap ScrewTorque........................................................... 2332.5 Nm
1724 lbft
F Cap Screw (2 used)
9. Connect hoses and wiring connectors.

10. Lower the cab. Check that hoses do not become
pinched as cab is lowered. Adjust angle of elbows
and hoses as necessary.
11. To adjust clearance between pedal and brake valve
plunger, see Service Brake Pedal Adjustment. (Group
902520.)
CAUTION: Before operating machine, the brake

bleed procedure must be done to remove air
from service brake hydraulic system.
AC12469,000039D 1913JUN073/3
TM11813 (13OCT10)
1010602
748H Repair (S.N. 630436

)
101310
PN=168
Hydraulic System
IMPORTANT: Perform all service on brake valve in

a clean isolated work area. Use proper tools,
cleaning material and lubricants.
Disassemble valve for cleaning and inspection only. Only
a seal repair kit is available for service.
If any parts, except seals, are damaged, replace the valve
as a complete assembly.
I Spring
J Spring Retainer
KSpring
L Plunger
MORing
NPlug
OPlug
PORing
T7516AP UN23APR91
ABoot
BPlug
CORing
DSpring
ESpool
F Valve Housing
GSeal
HSpring Retainer
T7516AO UN23APR91
Service Brake Valve Disassemble and

Assemble
AC12469,000039F 1913JUN071/1
TM11813 (13OCT10)
1010603
748H Repair (S.N. 630436

)
101310
PN=169
Hydraulic System
Service Brake Accumulator Remove and

Install
X9811 UN23AUG88
IMPORTANT: Clean all dirt and debris from service

brake accumulator before disconnecting hoses.
Contamination introduced into the hydraulic
system can lead to premature equipment failure.
1. Operate all hydraulic functions including brakes to

relieve pressure in the hydraulic system. Depress
brake pedal at onesecond intervals approximately 20
times to relieve pressure from brake accumulator.
2. Remove right rear engine side shield for access to
brake accumulator.
3.
Tag and disconnect hoses at accumulator. Close all

openings using caps and plugs.
AC12469,000039E 1923JUL071/3
4. Remove two cap screws, spacers, bands and nuts

securing service brake accumulator to reservoir leg.
5. Remove fittings from accumulator. Save fittings for
use on new accumulator.
NOTE: The inlet check valve fitting is serviced
with the brake accumulator.
6. Install accumulator so the inlet check valve fitting is
towards the center of machine.
7. Install two cap screws, spacers, bands and nuts
securing service brake accumulator to reservoir leg.
Note that upper cap screw and spacer are shorter
than lower cap screw and spacer.
DBand (2 used)
ESpacer (2 used)
WC1005587 UN12APR06
AService Brake Accumulator

BCap Screw (2 used)
CNut (2 used)
Service Brake Accumulator Mounting

TM11813 (13OCT10)
1010604
AC12469,000039E 1923JUL072/3
748H Repair (S.N. 630436

)
101310
PN=170
Hydraulic System
IMPORTANT: Always use new Orings and seals.

Damaged or used Orings and seals will leak.
8. Install fittings on new accumulator.
9. Connect hoses at accumulator as tagged.
10. Install new decal on accumulator.
11. Install right rear engine side shield.
CAUTION: Before operating machine, the brake
bleed procedure must be done to remove
air from hydraulic system.
12. Before operating machine, see Service Brake Bleeding
F Hose to Brake Pedal Valve
port P
GHose from Priority
Valve/Hydraulic Pump
HHose to Main Control Valve
I Hose to Grapple Rotate
Solenoid Valve port P
WC1006701 UN19APR06
AService Brake Accumulator

BCheck Valve
CSwivel Tee Fitting
DSwivel Tee Fitting
EAdapter
Service Brake Accumulator Hoses and Fittings

AC12469,000039E 1923JUL073/3
TM11813 (13OCT10)
1010605
748H Repair (S.N. 630436

)
101310
PN=171
Hydraulic System
TM11813 (13OCT10)
1010606
748H Repair (S.N. 630436

)
101310
PN=172
Contents
Section 11
Park Brake
Page
Group 1111Active Elements

Park Brake Remove and Install .................. 1111111
Park Brake Solenoid Valve Repair...............1111601
TM11813 (13OCT10)
111
748H Repair (S.N. 630436

)
101310
PN=1
Contents
TM11813 (13OCT10)
112
748H Repair (S.N. 630436

)
101310
PN=2
Group 1111
Active Elements
Park Brake Remove and Install
4
3
7
8
20
10
19
T162978 UN02JAN03
11
1
12
13
T162978
18 17 16
15
14
Park Brake Cross Section

1 Transmission Housing
2 Transmission Output Shaft
3 Disk (8 used)
4 ORing
5 Piston
6 Disk Spring
7 Oil Seal
8 Grease Seal (2 used)
9 Transmission Yoke, Nut, and
Cotter Pin

11 Separator Plate (9 used)

(10 used)
13 M12 x 110 mm Cap Screw (4
used) (recessed in cover)
14 Cover
15 Outer Seal Ring
16 Inner Seal Ring

17 Housing
18 Gasket
19 Hub
20 Snap Ring

Manual.)
3. Install wheel chocks under one or more wheels before

disconnecting drive shaft.
5. Remove engine frame shields as needed to access

park brake assembly.
TM11813 (13OCT10)
1111111
NM00125,0000585 1906OCT101/2
748H Repair (S.N. 630436

)
101310
PN=175
Active Elements

6. Disconnect park brake release hose (22). Close all
7. Disconnect rear axle drive shaft and remove
transmission output yoke. See Rear Axle and
Transmission Drive Shaft Remove and Install. (Group
0225.)
Park Brake Hose
CAUTION: Park brake contains a disk spring (6)

under load. Four M12 x 110 mm cap screws
(13) are shorter and recessed into park brake
cover. These four recessed cap screws hold
cover (14) and housing (17) together.
Prevent possible crushing injury from heavy
component. Use appropriate lifting device.
8. Remove 2 of 10 M12 x 140 mm cap screws (12) from

opposite sides of cover. Install guide pins.
9. Only remove remaining 10 M12 x 140 mm cap screws
(12), leaving M12 x 110 mm cap screws (13) installed
securing park brake housing (17) and cover (14)
together. Remove park brake as an assembly.
Specification
Park Brake
AssemblyWeight
(approximate).................................................................................. 43 kg
95 lb.
Park Brake Housing

9 Transmission Yoke, Nut,
and Cotter Pin
(10 used)
(4 used) (recessed in
cover)
14 Cover
10. Repair or replace parts as necessary. See Remove

Park Brake and see Install Park Brake. (CTM308.)
11. Install drive shaft and yoke. See Rear Axle and
Transmission Drive Shaft Remove and Install. (Group
0225.)
17 Housing
21 Double Universal Joint
(Telescoping Drive Shaft)
22 Park Brake Release Hose
12. Connect park brake release hose.

13. Install shields at articulation point.
16. Before returning machine to service, check park

brake operation. See Operational Checkout. (Group
900510.)
15. Fill transmission with oil and check transmission oil

level. See Change Transmission Oil, Replace Filter,
and Clean Suction Screen. (Operators Manual.)
NM00125,0000585 1906OCT102/2
TM11813 (13OCT10)
1111112
748H Repair (S.N. 630436

)
101310
PN=176
Group 1160
Hydraulic System
Park Brake Solenoid Valve Repair
2. Remove cap screws (1 and 2) and remove access
panel (3).
3 Access Panel
1 Cap Screw
2 Cap Screw
Left Access Panel

NM00125,0000584 1906OCT101/2
3. Disconnect wire connector from park brake solenoid

valve (5).
4. Remove cap screws (4) and pull park brake solenoid
from valve body (6). Close all openings using caps
and plugs.
6. Install new ORings and backup rings on solenoid

valve using petroleum jelly for installation.
TX1024459 UN06JUN07
7. Connect electrical connector to solenoid valve.
8. Install access panel and cap screws.
9. Before returning machine to service check park

brake operation. See Operational Checkout. (Group
900510.)
5 Park Brake Solenoid Valve
6 Valve Body
NM00125,0000584 1906OCT102/2
TM11813 (13OCT10)
1111601
748H Repair (S.N. 630436

)
101310
PN=177
Hydraulic System
TM11813 (13OCT10)
1111602
748H Repair (S.N. 630436

)
101310
PN=178
Section 17
Frame, Chassis, or Supporting Structures
Contents
Page
Group 1740Frame Installation

Welding Repair of Major Structure.............. 1717401
Engine and Equipment
FramesSeparate ................................ 1717402
Lower Pivot Pin Repair .............................. 1717406
Upper Pivot Pin Repair ............................ 17174012
Group 1746Frame Bottom Guards
Bottom Guard
Engine Frame........................................1717461
Equipment Frame..................................1717462
TM11813 (13OCT10)
171
748H Repair (S.N. 630436

)
101310
PN=1
Contents
TM11813 (13OCT10)
172
748H Repair (S.N. 630436

)
101310
PN=2
Group 1740
Frame Installation
AWSE70T1 or E71T1 wire electrode with flux core
Welding Repair of Major Structure
arc welding (FCAW) process.
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.
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.
1. Remove paint before welding or heating.
IMPORTANT: Electrical current traveling from the
welder through the machine electrical system
may damage the machine electrical system,
including battery, machine information center,
and pump and valve controller. Disconnect
battery ground cable, machine information
center, and pump and valve controller electrical
connectors before welding on the machine.
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.
2. Use one of the following weld processes:
AWSE7018 covered electrode with shielded metal
Welding Repair of Major StructureSpecification

Weld MetalTensile
Strength...................................................................................482.6 mPa
70 000 psi
Yield Strength .........................................................................413.7 mPa
60 000 psi
Elongation......................................................................................... 22%
IMPORTANT: Area to be repaired must be preheated

to allow better weld penetration.
3. 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 38C (100F). Preheat ground engaging
tools (cutting edges, skid shoes, and teeth shanks) to
177C (350F).
To repair base metal failure remove enough material to
allow weld to penetrate to the bottom of crack. Preheat
structural assemblies to a minimum of 38C (100F).
Preheat ground engaging tools (cutting edges, skid
shoes, and teeth shanks) to 177C (350F).
Welding Repair of Major StructureSpecification
Structural
AssembliesPreheat
Temperature..................................................................................... 38C
100F
Ground Engaging
ToolsPreheat
Temperature................................................................................... 177C
350F
arc welding (SMAW) process.
AWSER70S3 wire electrode with gas metal arc

welding (GMAW) process.
JW40272,0000028 1918APR081/1
TM11813 (13OCT10)
1717401
748H Repair (S.N. 630436

)
101310
PN=181
Frame Installation
Engine and Equipment FramesSeparate

1. Park machine on smooth, level surface and align
frames straight ahead.
T8465AE UN09MAY95
2. With engine running, lower blade. Close grapple tong

and lower boom to rest grapple tong on lift table (if
grapple equipped).
Grapple Tong on Lift Table

heavy component. Use proper lifting device.
4. Operate all hydraulic functions including brake to

brake pedal at 1second intervals 20 times to
discharge oil from accumulator.
6. Install floor stands under grille housing.
5. Turn battery disconnect switch to OFF position. See

SW03989,0000A9F 1907OCT101/5
7. Support grapple arch as shown.

Manual.)
IMPORTANT: Clean all dirt and debris from
hydraulic reservoir before removing fill cap
or disconnecting hoses. Contamination
introduced into the hydraulic system can lead
to premature equipment failure.
T114406B UN29APR98
9. Drain hydraulic reservoir. See Change Hydraulic Oil.

(Operators Manual.)
Grapple Arch Support

TM11813 (13OCT10)
1717402
SW03989,0000A9F 1907OCT102/5
748H Repair (S.N. 630436

)
101310
PN=182
Frame Installation
10. Remove right equipment frame shield (1) and bottom

engine frame shield (2).
11. Remove hose brackets (3).
12. Remove left frame shields (46).
1 Right Equipment Frame

Shield
2 Bottom Engine Frame
Shield
3 Hose Bracket (2 used)
13. Remove drive shafts. See Rear Axle and Transmission

Drive Shaft Remove and Install. (Group 0225.) Also
see Winch Drive Shaft Remove and Install. (Group
3025.)
4 Top Engine Frame Shield
5 Left Equipment Frame
Shield
6 Left Engine Frame Shield
Right Frame Shields
Hose Brackets
Left Frame Shields

TM11813 (13OCT10)
1717403
SW03989,0000A9F 1907OCT103/5
748H Repair (S.N. 630436

)
101310
PN=183
Frame Installation
14. Disconnect winch control cable (8). See Winch Control

Cable Remove and Install. (Group 3015.)
16. Disconnect rear axle differential lock hose (11). Close

17. Disconnect reverse alarm and fuel sender electrical

connector (10).
18. Identify and disconnect hydraulic and fuel hoses at

hose junction bracket (12). Close all openings using
caps and plugs.
10 Reverse Alarm and
Fuel Sender Electrical
Connector
11 Rear Axle Differential
Lock Hose
12 Hose Junction Bracket
Winch
7 Winch Supply Hose

8 Winch Control Cable
9 Winch Return Hose
TX1080654 UN06AUG10
15. Identify and disconnect winch supply hose (7) and

winch return hose (9). Close all openings using caps
and plugs.
Differential Lock Valve
Hose Junction Bracket

TM11813 (13OCT10)
1717404
SW03989,0000A9F 1907OCT104/5
748H Repair (S.N. 630436

)
101310
PN=184
Frame Installation
IMPORTANT: Identify hoses and fittings at bulkhead

before removal. Hoses can be interchanged,
causing machine damage.
19. Identify and disconnect hydraulic hoses (1318).

Close all openings using caps and plugs (grapple
machines only).
20. Disconnect steering cylinder from equipment frame.
See Steering Cylinder Remove and Install. (Group
0960.)
Bulkhead
21. Remove pivot pins. See Upper Pivot Pin Repair and
see Lower Pivot Pin Repair. (Group 1740.)
13 Arch Retract Hose

14 Arch Extend Hose
15 Grapple Rotate Hose
22. With the aid of an assistant, slowly roll equipment

frame and service jack away from front engine frame.
24. With the aid of an assistant, slowly roll equipment
frame and service jack to engine frame and align
upper and lower pivot pin sleeves.
16 Boom Retract Hose

17 Boom Extend Hose
18 Grapple Rotate Hose
34. Install left engine frame shield and left equipment

frame shield and hose brackets.
35. Install right equipment frame shield and bottom engine
frame shield.
25. Install pivot pins. See Lower Pivot Pin Repair and see
Upper Pivot Pin Repair. (Group 1740.)

(Operators Manual.)
26. Connect steering cylinder to equipment frame. See

Steering Cylinder Remove and Install. (Group 0960.)
37. Fill hydraulic reservoir. See Change Hydraulic Oil.

(Operators Manual.)
27. Connect all hydraulic hoses to bulkhead (if grapple

equipped).
38. Remove floor stands under grille housing.
28. Install drive shafts. See Rear Axle and Transmission

Drive Shaft Remove and Install. (Group 0225.) Also
see Winch Drive Shaft Remove and Install. (Group
3025.)
29. Connect reverse alarm and fuel sender electrical
connector.
39. Turn battery disconnect switch to ON position. See

40. Start engine and follow hydraulic oil warmup
procedure. Operate all hydraulic functions to remove
any air trapped in system. See Hydraulic Oil Warmup
31. Connect hydraulic hoses to junction bracket.
41. Stop engine. Check for leaks and check hydraulic

reservoir oil level. See Check Hydraulic System Oil
Level. (Operators Manual.)
32. Connect winch cable. See Winch Control Cable


33. Connect winch hoses.
30. Connect rear axle differential lock hose.
SW03989,0000A9F 1907OCT105/5
TM11813 (13OCT10)
1717405
748H Repair (S.N. 630436

)
101310
PN=185
Frame Installation
TX1056815 UN06MAR09
Lower Pivot Pin Repair
TX1056815
Lower Pivot Pin
TM11813 (13OCT10)
1717406
SW03989,0000B40 1927SEP101/9
748H Repair (S.N. 630436

)
101310
PN=186
Frame Installation
8 Seal (2 used)
9 Pin Retainer Guard

11 Snap Ring (2 used)
12 Lubrication Fitting (2 used)
13 ORing (2 used)
14 Ring (2 used)
20 Seal (2 used)
21 Lower Pivot Pin
22 Pin Sleeve
23 Bushing (2 used)
24 Upper Quill
25 Special Washer
31 Spherical Bushing
2. Lower blade and grapple equipment to ground.
CAUTION: Avoid possible injury from

unexpected machine movement. Install
articulation locking bar.
Operate all hydraulic functions including brake, to

brake pedal at one second intervals 20 times to
discharge oil from accumulator.
1. Park machine on a level surface with frames aligned.

Install articulation locking bar.
SW03989,0000B40 1927SEP102/9
3. Remove shields and retainers (3238).

4. Remove drive shafts.
See Winch Drive Shaft Remove and Install. (Group

3025.)
32 Left Engine Frame Shield
33 Left Equipment Frame
Shield
34 Hose Retainer
35 Hose Retainer
36 Top Engine Frame Shield

37 Bottom Engine Frame
Shield
38 Right Equipment Frame
Shield
Left Shields
Right Shields
TM11813 (13OCT10)
1717407
SW03989,0000B40 1927SEP103/9
748H Repair (S.N. 630436

)
101310
PN=187
Frame Installation
5. Remove bottom cover (9).

9 Bottom Cover
Bottom Cover
SW03989,0000B40 1927SEP104/9
6. Remove upper quill (24).

7. Place 10ton service jacks under engine and
equipment frames at hinge area for support.
24 Upper Quill
Upper Quill
SW03989,0000B40 1927SEP105/9
8. Remove cap screws (4) to remove special washer

(25).
25 Special Washer

22 Pin Sleeve
Special Washer
TM11813 (13OCT10)
1717408
SW03989,0000B40 1927SEP106/9
748H Repair (S.N. 630436

)
101310
PN=188
Frame Installation
21
23
31
20
TX1026427 UN16JUL07
23
22
TX1026427
Lower Pivot Pin
3 Engine Frame
7 Equipment Frame
20 Seal (2 used)
21 Lower Pivot Pin
22 Pin Sleeve
23 Bushing (2 used)
NOTE: Lower pivot pin is a press fit in the pin sleeve.

9. Press lower pivot pin (21) out of pin sleeve (22).
10. Remove pin sleeve (22).
11. Remove seals from lower pivot pin (21) and from pin
sleeve.
14. Apply several shots of grease to three articulation

joint grease fittings to purge the old grease and to
ensure that the grease is getting through upper and
lower bushings in engine frame and through spherical
bushings in equipment frame.
15. Clean all articulation joint components.
12. Clean and inspect seals.

13. Remove seals (20) from lower articulation joint
bushings (23). Discard seals.
TM11813 (13OCT10)
1717409
SW03989,0000B40 1927SEP107/9
748H Repair (S.N. 630436

)
101310
PN=189
Frame Installation
11
20
TX1026459 UN13JUL07
20
11
TX1026459
Bushing
3 Engine Frame
7 Equipment Frame
11 Snap Ring (2 used)
16. Remove snap rings (11).
20 Seal (2 used)
The lip on the lower seal should point up.
17. Remove bushings (23) using a driver. For bushings

with a groove machined into the end surface, apply
force to that end of bushing to remove.
18. Remove spherical bushing (31) from equipment frame
(7) using a driver that applies force to the outer race.
23. Install new seals into bushings. Install seals with the
slotted side of the seal towards the short side of the
bushing.
24. Install new seal into pin sleeve. Install pin sleeve into
bushing.
25. Support pin sleeve in bushing.
IMPORTANT: Force must only be applied to

the outer race of spherical bushing to
avoid damaging bushing.
26. Install new seal in lower pivot pin.

27. Apply grease to lower pivot pin and bushings.
20. Install spherical bushing into equipment frame using

a driver that applies force to the outer race. Install
bushing so it is centered in equipment frame.
NOTE: Lower pivot pin is a press fit in the pin sleeve.
IMPORTANT: Bushings with a groove machined

into the end surface must be installed
applying force to that end of the bushing.
The bushing shoulders only have a leadin
machined on one side.
29. Install special washer and cap screws. Evenly tighten

cap screws to draw pivot pin into pin sleeve.
28. Install pivot pin in pin sleeve.
30. Tighten cap screws to specification.
21. Install bushings into engine frame. For bushings with

the groove machined into the end surface, apply force
to that end of bushing to install.
22. Install snap rings.
Specification
Lower Pivot Pin Cap
ScrewTorque............................................................................319 Nm
235 lbft
31. Grease pivot pins.
NOTE: The lip on the upper seal should point down.

TM11813 (13OCT10)
17174010
SW03989,0000B40 1927SEP108/9
748H Repair (S.N. 630436

)
101310
PN=190
Frame Installation
32. Clean upper quill, clean and inspect Oring and

packing.
36. Install drive shafts.
33. Install upper quill with cap screws.
See Winch Drive Shaft Remove and Install. (Group

3025.)
34. Clean bottom cover, clean and inspect Oring and

packing.
35. Install bottom cover with cap screws and tighten to
specification.

37. Install shields.
Specification
Bottom CovertoEngine
Frame Cap
ScrewTorque............................................................................624 Nm
460 lbft
SW03989,0000B40 1927SEP109/9
TM11813 (13OCT10)
17174011
748H Repair (S.N. 630436

)
101310
PN=191
Frame Installation
TX1056816 UN06MAR09
Upper Pivot Pin Repair
TX1056816
Upper Pivot Pin
TM11813 (13OCT10)
17174012
GD61784,0000067 1906MAR091/9
748H Repair (S.N. 630436

)
101310
PN=192
Frame Installation
15 Upper Pivot Pin
16 Quill
17 Lock Collar
18 Special Washer
26 Seal
27 Shim
28 Shim
29 Shim
release pressure in hydraulic system. Depress brake

pedal at one second intervals 20 times to discharge
oil from accumulator.
CAUTION: Avoid possible injury from

unexpected machine movement. Install
articulation locking bar.
1. Park machine on a level surface and install articulation
locking bar.
3. Install floor stands under grille housing and ahead of

lower pivot pin of engine frame. Support equipment
frame behind lower pin with 10ton jack.
2. Lower blade and grapple equipment to ground and

operate all hydraulic functions, including brake, to
GD61784,0000067 1906MAR092/9
4. Remove cap screws (6) and special washer (18).

18 Special Washer
Special Washer
GD61784,0000067 1906MAR093/9
5.
Use the 171/2 ton hydraulic pushpuller from

D01047AA 171/2 and 30Ton Puller Set, to press on
bottom of upper pivot pin (1).
6. Push pin through spherical bushing (2) in engine

frame (3) and out the top of equipment frame (4).
3 Engine Frame
7 Equipment Frame
10
15 Upper Pivot Pin
TX1024982 UN22JUN07
15
Upper Pivot Pin

TM11813 (13OCT10)
17174013
GD61784,0000067 1906MAR094/9
748H Repair (S.N. 630436

)
101310
PN=193
Frame Installation
7. Remove cap screws (1) and quill (16).

8. Using a bushing driver, drive out bushing (10) from
the bottom of engine frame through the top of engine
frame.
9. Install new spherical bushing until it bottom in bore
of engine frame.

10. Install quill without shims. Contact with spherical

bushing must be made.
16 Quill
Cap Screw and Quill

GD61784,0000067 1906MAR095/9
Specification
Shim Pack Less Than
GapPreload...................................................................0.030.13 mm
0.0010.005 in.
T128532 UN17FEB00
11. Measure gap from quill to frame with a feeler gauge.

Add shims to attain 0.030.13 mm (0.0010.005 in.)
preload on spherical bushing.
GD61784,0000067 1906MAR096/9
T128533 UN17FEB00
12. Install seal in quill with sealing lip toward the quill.
TM11813 (13OCT10)
17174014
GD61784,0000067 1906MAR097/9
748H Repair (S.N. 630436

)
101310
PN=194
Frame Installation
13. Install required shims, quill (16) and cap screws (1).
Tighten cap screws to specification. Bushing (10)
must oscillate.

Specification
Quill Cap
ScrewTorque............................................................................140 Nm
103 lbft
16 Quill
Install Shims
TM11813 (13OCT10)
17174015
GD61784,0000067 1906MAR098/9
748H Repair (S.N. 630436

)
101310
PN=195
Frame Installation
15
26
16
10
26
TX1024991 UN22JUN07
17
30
18
TX1024991
6
Lower Seal

3 Engine Frame
7 Equipment Frame
15 Upper Pivot Pin
14. Install lower seal (26) into engine frame (3) with
sealing lip facing away from spherical bushing (10).
15. Install lock collar (17) into seal.
16. Apply grease to pivot pin and install into bushing (10).
17. Install special washer (18) and cap screws (6).
18. Evenly tighten cap screws to draw pin through
bushing. Tighten cap screws to specification.
Specification
Retaining Cap
ScrewsInitialTorque...........................................................230.5 Nm
170 lbft
Retaining Cap
ScrewsFinalTorque
Turn.....................................................................................................90
16 Quill
17 Lock Collar
18 Special Washer
26 Seal
30 Gap
19. Grease pivot pin.

IMPORTANT: There must be a 1.0 mm (0.039 in.)
gap between special washer (7) and upper
pivot pin (1) after cap screws have been
tightened to specification.
20. Measure gap between special washer and upper pivot
pin. Gap must be to specification.
Specification
Special Washer and
Upper Pivot PinGap.................................................................. 1.0 mm
0.039 in.
GD61784,0000067 1906MAR099/9
TM11813 (13OCT10)
17174016
748H Repair (S.N. 630436

)
101310
PN=196
Group 1746
Frame Bottom Guards
T114595 UN29APR98
Engine Frame Bottom Guard Remove and

Install
ARear Bottom Guard

BWasher (2 used)
CCap Screw (4 used)
DCap Screw (2 used)

EFront Bottom Guard
F Cotter Pin (2 used)
GWasher (2 used)
HWasher (4 used)
I Cap Screw (2 used)
1. Use a service jack to hold the bottom guards (A and

E) in place while removing the cap screws (C and I).
CAUTION: Heavy component use a hoist.

Weights may increase due to the buildup
of mud and debris.
The front bottom guard is hinged and will swing down

to the front of machine.
Specification
Front Bottom
GuardWeight
(approximate).................................................................................. 36 kg
80 lb
Rear Bottom
GuardWeight
(approximate).................................................................................. 25 kg
55 lb
2. Tighten cap screws (C, D, and I) to specifications.

Specification
Front and Rear Bottom
GuardtoEngine Frame
460 lbft
GD61784,0000068 1902JUL071/1
TM11813 (13OCT10)
1717461
748H Repair (S.N. 630436

)
101310
PN=197
Frame Bottom Guards
T114596 UN29APR98
Equipment Frame Bottom Guard Remove

and Install
AWasher (8 used)
BCap Screw (4 used)
CCover
DPlate (2 used)
EBottom Door
F Cap Screw (2 used)
GCap Screw (4 used)

HWasher (4 used)
I Rear Bottom Guard
J Cap Screw (4 used)
CAUTION: Heavy component use a hoist.
2. Tighten cap screws to specifications.
Weights may increase due to the buildup

of mud and debris.
Specification
Bottom Guardto
Equipment Frame Cap
ScrewTorque............................................................................620 Nm
460 lbft
Bottom Doorto
Equipment Frame Cap
ScrewsTorque..........................................................................130 Nm
95 lbft
Specification
Bottom GuardWeight
(approximate).................................................................................. 27 kg
60 lb
1. Use a service jack to hold the bottom guard (I) in place

while removing the cap screws (G).
GD61784,0000069 1915JUN071/1
TM11813 (13OCT10)
1717462
748H Repair (S.N. 630436

)
101310
PN=198
Contents
Section 18
Operators Station
Page
Page

Cab Remove and Install ............................ 1818001
Cab Isolators Remove and Install.............. 1818008
Steering Column and Steering
Wheel Remove and Install..................... 1818009
Steering Column and Steering
Wheel Disassemble and
Assemble............................................. 18180011
Cab Tilt Hand Pump Remove and
Install ................................................... 18180013
Cab Tilt Hand Pump Disassemble
and Assemble...................................... 18180014
Cab Tilt Hand Pump Bleeding
Procedure ............................................ 18180015
Cab Tilt Cylinder Remove and
Install ................................................... 18180017

Manifold Remove and Install ............... 18183011
Air Conditioner Condenser Remove
and Install ............................................ 18183011
Blower Motor Remove and Install............ 18183013
Precleaner Blower Assembly
Remove and Install.............................. 18183014
Refrigerant High/Low Pressure
Switch Remove and Install .................. 18183015
Coolant Valve Remove and Install............ 18183016
Freeze Control Switch Remove
and Install ............................................ 18183017
Expansion Valve Remove and
Install ................................................... 18183018
Heater Core Remove and Install ............. 18183019
Evaporator Remove and Install ............... 18183020
ReceiverDryer Remove and
Install ................................................... 18183021
Group 1810Operator Enclosure

Window Remove and Install ...................... 1818101
Window Cleaning Procedure ..................... 1818104
Cab Door Remove and Install ................... 1818104
Cab Door and Door Latch
Disassemble and Assemble .................. 1818105
Front Windshield Wiper Remove
and Install .............................................. 1818106
Rear Windshield Wiper Remove
and Install .............................................. 1818107
Windshield Wiper Adjustment.................... 1818109
Group 1821Seat and Seat Belt
Seat Remove and Install ........................... 1818211
Seat Disassemble and Assemble.............. 1818212
Seat Belt Remove and Install .................... 1818217
Group 1830Heating and Air Conditioning
R134a Refrigerant Cautions and
Proper Handling..................................... 1818301
Air Conditioning System Flush and
Purge ..................................................... 1818302
R134a Refrigerant Oil Information.............. 1818304
R134a Refrigerant
Recovery/Recycling and
Charging Station Installation
Procedure .............................................. 1818305
R134a Refrigerant Recovery ..................... 1818306
R134a System Evacuate ........................... 1818306
R134a System Charge .............................. 1818307
Compressor Relief Valve Remove
and Install .............................................. 1818307
Air Conditioner Compressor Clutch
TM11813 (13OCT10)
181
748H Repair (S.N. 630436

)
101310
PN=1
Contents
TM11813 (13OCT10)
182
748H Repair (S.N. 630436

)
101310
PN=2
Group 1800
Cab Remove and Install
2. Operate all hydraulic controls to relieve pressure
in the hydraulic system. Depress brake pedal at
1second intervals 20 times to discharge pressure
from accumulator.
TX1082472 UN05OCT10

5. Remove right limb riser (1).
Specification
Right Limb
RiserWeight
(approximate).................................................................................. 39 kg
85 lb.
Limb Riser Remove and Install

1 Right Limb Riser
CAUTION: Muffler and left limb riser may be hot

from exhaust. Allow riser to cool before removal.
6. Disconnect muffler flex pipe from turbocharger outlet
elbow. Close opening using cap or plug.
CAUTION: Coolant may be hot. Wait until radiator

is cool to the touch before draining radiator.

9. Remove lower cab shields.

10. Disconnect steering column from steering valve. See
Steering Valve Remove and Install. (Group 0960.)
7. Remove left limb riser with muffler (2).

Specification
Left Limb Riser
with MufflerWeight
(approximate).................................................................................. 50 kg
110 lb.

Manual.)
12. Recover air conditioning refrigerant. See R134a
Refrigerant Recovery. (Group 1830.)
TM11813 (13OCT10)
2 Left Limb Riser with Muffler
1818001
SW03989,0000B47 1905OCT101/13
748H Repair (S.N. 630436

)
101310
PN=201
13. Disconnect air conditioner suction hose (3) at air

conditioner compressor.
14. Remove clamp (4) and slide protective sleeve (5)
up on hose. Disconnect pressure hose at fitting (6).
TX1082473A UN05OCT10
15. Remove hoses from hangers routed to cab. Attach

hose temporarily to bottom of cab. Hoses will be
removed with cab.
(Operators Manual.)
5 Protective Sleeve
6 Air Conditioner Pressure
Hose Fitting
Air Conditioner Suction Hose
3 Air Conditioner Suction

Hose
4 Clamp
Air Conditioner Pressure Hose

SW03989,0000B47 1905OCT102/13

17. Identify and disconnect hydraulic lines from service
brake valve (7). Close all openings using caps and
plugs.
18. Remove hydraulic hoses through hanger and set
aside.
19. Disconnect service brake pressure switch connector
(8) and engine speed control harness connector (9).
Service Brake Valve and Engine Speed Control
20. Disconnect dual mode steering solenoid valve. See

Dual Mode Steering Solenoid Valve Remove and
7 Service Brake Valve

8 Service Brake Pressure
Switch Connector
TM11813 (13OCT10)
1818002
9 Engine Speed Control

Harness Connector
SW03989,0000B47 1905OCT103/13
748H Repair (S.N. 630436

)
101310
PN=202
21. Disconnect heater hoses (9). Close all openings using

caps and plugs.
NOTE: Do not disconnect hoses from steering valve.
22. Remove steering valve from bottom of cab. See
Steering Valve Remove and Install. (Group 0960.)
10 Heater Hose (2 used)
Heater Hoses
SW03989,0000B47 1905OCT104/13
11 Wire Harness Connection

12 Wire Harness Connection
23. Disconnect wire harness connections (11 and 12)

and transmission wire harness connection (13) from
bottom of cab. Remove cap screws and clamps
securing wire harnesses to cab.
13 Transmission Wire
Harness Connection
Wire Harness Connections
Transmission Wire Harness Connection

TM11813 (13OCT10)
1818003
SW03989,0000B47 1905OCT105/13
748H Repair (S.N. 630436

)
101310
PN=203
24. Disconnect ground strap (14) from cab mount.

15 Cap Screw
14 Ground Strap
Cab Ground Strap

SW03989,0000B47 1905OCT106/13
NOTE: Leave nut (19) finger tight, so it can be removed

later without the use of a wrench.
16 Cap Screw
17 Shim (as needed)
25. Loosen nut (19) but DO NOT remove from cap screw
(16).
18 Washer (2 used)
19 Nut
Cab Tilt Cylinder Cap Screw and Nut

SW03989,0000B47 1905OCT107/13
IMPORTANT: All components, hydraulic lines, and

electrical harnesses disconnected from machine
and cab must be placed in areas that will be
clear when lowering cab. Lowering cab on
top of such items will cause damage.
(Operators Manual.)
Remove cap screw (20) to disconnect tether cable
(21) from cab.
20 Cap Screw
21 Tether Cable
Cab Tether Cable
TM11813 (13OCT10)
1818004
SW03989,0000B47 1905OCT108/13
748H Repair (S.N. 630436

)
101310
PN=204
NOTE: Mark quantity and location of shims to

aid in assembly.
16 Cap Screw
17 Shim (as needed)
18 Washer (2 used)
27. Remove nut (19), shims (17), washer (18), and cap
screw (16). Move cab tilt cylinder (22) away from
clevis.
19 Nut
22 Cab Tilt Cylinder
Cab Tilt Cylinder

SW03989,0000B47 1905OCT109/13
28. Disconnect winch control cable (23), if equipped.

29. Disconnect transmission vent hose (25).
30. Tag and disconnect hydraulic hoses (24, 2731).
31. Remove all clamps and ties securing hydraulic hoses
to cab.
28 Boom Hose (if equipped,
2 used)
29 Blade Hose (2 used)
30 Valve Return Hose
31 Valve Supply Hose
23 Winch Control Cable (if

equipped)
24 Pilot Pressure Hose
25 Transmission Vent Hose
26 Grapple Tong Hose (2
used)
27 Arch Hoses (2 used)
Dual Function Pilot Control Valve Shown

TM11813 (13OCT10)
1818005
SW03989,0000B47 1905OCT1010/13
748H Repair (S.N. 630436

)
101310
PN=205
32. Attach lifting chains to rear lift points (32) on right and
left sides of cab.
32 Rear Lift Point
33. Install JDG909 Lifting Brackets (33) in both limb

riser eyelets. Attach lifting chains to JDG909 Lifting
Brackets.
33 JDG909 Lifting Bracket (2
used)
Cab Rear Lift Point
JDG909 Lifting Brackets

TM11813 (13OCT10)
1818006
SW03989,0000B47 1905OCT1011/13
748H Repair (S.N. 630436

)
101310
PN=206

NOTE: Mark quantity and location of washers and

shims to aid in assembly.
34. Remove nuts (34). Raise cab slightly to remove cap
screws (37), washers (35), and shims (36) from both
cab pivots.
Cab Pivots
IMPORTANT: Carefully remove cab, making sure

all hydraulic lines, harnesses, and valves
are clear as cab is lifted.
34 Nut (2 used)
35 Washer (4 used)
36 Shim (as needed)

35. Remove cab.

Specification
CabWeight
(approximate).............................................................................. 1281 kg
2825 lb.
36. Inspect, repair, or replace cab components as

necessary.
45. Position tilt cylinder into cab clevis and install cap
screw, washers, shims, and nut as were marked
during removal. Do not tighten nut at this time.
46. Install tether cable and cap screw.
Manual.)
37. Inspect and replace cab isolators if necessary. See

Cab Isolators Remove and Install. (Group 1800.)
IMPORTANT: DO NOT overtighten tilt cylinder

nut. Overtightening of nut can cause
cab clevis to deform.
48. Tighten tilt cylinder nut until washers are snug.
IMPORTANT: Hydraulic lines, hoses, and electric

harnesses must be clear of cab while
lowering, or damage may occur.
49. Install cab ground strap.
38. Install cab onto frame mounts, guiding hydraulic lines,

valves, and electrical harnesses into position for
hookup.
51. Attach steering valve to bottom of cab. See Steering

Valve Remove and Install. (Group 0960.)
50. Connect all electrical harnesses to cab and install all

clamps in original positions.
Specification
CabWeight
(approximate).............................................................................. 1281 kg
2825 lb.
39. Install shims, washers, cap screw, and nut at cab pivot
mounts as marked during removal.
IMPORTANT: Overtightening of cap screws and nuts
can cause cab clevis to deform.
40. Tighten nuts until washers are snug.
41. Remove lifting chains and lifting brackets from cab.
52. Install dual mode steering solenoid valve. See Dual

Mode Steering Solenoid Valve Remove and Install.
(Group 0962.)
53. Connect hoses to service brake valve.
(Operators Manual.)
55. Connect service brake pressure switch connector and
engine speed control connector.
56. Route heater hoses through hangers and connect.
42. Connect all hydraulic hoses to pilot control valve.
57. Route air conditioner suction hose and pressure hose

through hangers and connect.
43. Connect winch control cable (if equipped) and

transmission vent hose.
58. Install protective sleeve over pressure hose and install

clamp in original position.
44. Install all clamps and tie bands in original locations.

Replace any cut tie bands.

(Operators Manual.)
TM11813 (13OCT10)
1818007
SW03989,0000B47 1905OCT1012/13
748H Repair (S.N. 630436

)
101310
PN=207
60. Install rear lower cab shields.


61. Install limb risers.
Specification
Right Limb
RiserWeight
(approximate).................................................................................. 39 kg
85 lb.
Left Limb Riser
with MufflerWeight
(approximate).................................................................................. 50 kg
110 lb.
65. Check hydraulic oil level and add oil if necessary.

See Check Hydraulic System Oil Level. (Operators
Manual.)
66. Adjust winch control cable. See Winch Control Cable
Adjustment Check. (Group 903020.)
67. Charge air conditioning system. See R134a System
Charge. (Group 1830.)
69. Remove articulation lock bar.
62. Connect muffler flex pipe to turbocharger outlet elbow.

63. Check and fill cooling system. See Filling the Cooling
SW03989,0000B47 1905OCT1013/13
Cab Isolators Remove and Install

NOTE: If cab isolators become worn or damaged,
replace isolators.
T114570B UN29APR98
Left Cab Mount Isolators

1. Raise cab. See Hydraulic Cab Tilt Procedure.
(Operators Manual.)
2. Remove isolators from mounts.
3. Apply soap on isolators to aid in installation. Install
isolators.
4. Lower cab, install shims.
5. Install one shim at front of rear cab mount support and
three at rear of support. Align shims and mounting
holes. Install cap screw.
CAUTION: Prevent unexpected machine

movement and possible injury. Install articulation
locking bar before you work in frame pivot area.
6. Install one shim at front of front cab mount support and

IMPORTANT: Overtightening of nuts can cause

2. Park machine on level ground, turn battery disconnect

switch OFF, and set park brake switch to PARK
position.
7. Tighten nuts until washers are snug and full thread

engagement is attained.
3. Remove left engine side shields.

4. Disconnect both limb risers from top of cab.
Right Cab Mount Isolators

TM11813 (13OCT10)
1818008
AC12469,00003A1 1910MAR091/3
748H Repair (S.N. 630436

)
101310
PN=208
CAUTION: Left cab mounting pins MUST be

installed before tilting right side of cab. Tilting
cab without opposite side mounting pins installed
could cause serious personal injury.
T114970 UN29APR98
5. Open and remove lower cab shield (B).

6. Remove nuts (A).
7. Using hydraulic cab tilting jack, lift cab until weight of
cab is removed from cap screws. Remove cap screws,
washers, and shims. Note location and quantity of
washers and shims to aid in assembling.
ANut (2 used)
BLower Cab Shield

AC12469,00003A1 1910MAR092/3
8.
Raise cab until mounts clear cab clevises. Support

cab using a wooden block (C) as shown.
9. Remove isolators from mounts.

T131398B UN21JUN00
10. Apply soap on new isolators to aid in installation.

Install isolators.
11. Remove wooden block and lower cab.
12. Install one shim at front of rear cab mount support and
13. Install one shim at front of front cab mount support and
CWooden Block
IMPORTANT: Overtightening of nuts can cause

14. Tighten nuts until washers are snug and full thread
engagement is attained.
15. Install lower cab shields.

18. Install engine side shields.
16. Connect limb risers to cab.

AC12469,00003A1 1910MAR093/3
Steering Column and Steering Wheel

Remove and Install

2 Bracket
T131257B UN31MAY00
1. Remove fire extinguisher from bracket. Remove cap

screws (1 and 3) and bracket (2).
3 Cap Screw
TM11813 (13OCT10)
1818009
AC12469,00003A2 1914JUN071/4
748H Repair (S.N. 630436

)
101310
PN=209
2. Disconnect electrical connectors (3) from windshield

washer pumps and disconnect hoses (4). Close all
openings with caps and plugs.
3. Remove cap screws (1) and remove windshield
washer tank (2).
3 Electrical Connector (2
used)
4 Windshield Washer Hose (2
used)
T131258B UN31MAY00
1 Cap Screws (2 used)

2 Windshield Washer Tank
AC12469,00003A2 1914JUN072/4
4. Remove screws (1) and lower dash panel (2).

2 Lower Dash Panel
T131259B UN31MAY00
1 Screws (4 used)
TM11813 (13OCT10)
18180010
AC12469,00003A2 1914JUN073/4
748H Repair (S.N. 630436

)
101310
PN=210
5. Disconnect horn wire connector (2).

6. Remove cap screws (1 and 4) and slide steering
column with universal joint (3) up and off of steering
valve.
7. Inspect and repair parts as necessary. See Steering
Column and Steering Wheel Disassemble and
Assemble. (Group 1800.)
8.
Install cap screws (14).
9. Connect horn wire connector (2).
11. Install windshield washer tank and cap screws.

12. Connect windshield washer pump hoses and electrical
connectors.
13. Install fire extinguisher bracket and cap screws. Install
fire extinguisher.
2 Horn Wire Connector
T131260B UN31MAY00
10. Install lower dash panel and cap screws.
3 Universal Joint
4 Cap Screw
AC12469,00003A2 1914JUN074/4
Steering Column and Steering Wheel

Disassemble and Assemble
T131263B UN31MAY00
1. Remove cap in center of steering wheel. Remove nut

(1).
CAUTION: Spring behind steering wheel is under
tension. Remove steering wheel with caution.
2. Install puller to steering wheel and slowly remove
wheel from steering column while holding downward
pressure on wheel to restrain spring tension.
1 Steering Wheel Nut
AC12469,00003A3 1919JUL071/3
3. Remove covers (2, 4, and 5), horn wiring lead (1) and
knob (3).
4 Cover
5 Cover
T131265B UN31MAY00
1 Horn Wiring Lead

2 Cover
3 Knob
TM11813 (13OCT10)
18180011
AC12469,00003A3 1919JUL072/3
748H Repair (S.N. 630436

)
101310
PN=211
4. Replace parts as necessary.

5. Connect horn wiring connector to cap (7).
1 Steering Column
2 Disk
3 Spring
4 Cover
T131266B UN31MAY00
6. Install cap.
5 Steering Wheel
6 Nut
7 Cap
AC12469,00003A3 1919JUL073/3
TM11813 (13OCT10)
18180012
748H Repair (S.N. 630436

)
101310
PN=212
Cab Tilt Hand Pump Remove and Install
X9811 UN23AUG88
IMPORTANT: For satisfactory operation of the

cab tilt cylinder, it is essential that all air be
bled from the system. Therefore, any time
air is induced into the system, the bleed
procedure MUST be performed.
T131385B UN02JUN00
1. Shut engine off and lower equipment to the ground.

Operate all hydraulic functions to relieve pressure.
2. Turn battery disconnect switch to OFF position.
3. Disconnect hose (2) and top hose (1). Close all
4. Remove cap screws (3) and remove pump.
5. Replace or repair damaged parts. See Cab Tilt Hand
Pump Disassemble and Assemble. (Group 1800.)
6. Install pump and cap screws. Tighten cap screws to
specification.
1 Head End Lift Hose

2 Head End Retract Hose
Specification
Hand Pump Mounting
Cap ScrewsTorque............................................................ 2226 Nm
195230 lbin.
9. Bleed cab tilt hand pump circuit to remove air from

system. See Cab Tilt Hand Pump Bleeding Procedure.
(Group 1800.)
7. Connect hoses (1 and 2).
10. Check oil reservoir level.
8. Fill hand pump oil reservoir. See Transmission, Park

Brake, Differential, Cab Tilt Hydraulic Pump and Winch
Oil. (Operators Manual.)
Specification
Cab Tilt Hand Pump
ReservoirCapacity.................................................................... 574 mL
20 oz
AC12469,00003A4 1910MAR091/1
TM11813 (13OCT10)
18180013
748H Repair (S.N. 630436

)
101310
PN=213
Cab Tilt Hand Pump Disassemble and

Assemble
IMPORTANT: For satisfactory operation of the
cab tilt cylinder, it is essential that all
air be bled from the system. Any time a
system component is changed the bleed
1. Remove cab tilt hand pump. See Cab Tilt Hand Pump
2. Remove four cap screws from pump reservoir and
drain oil from reservoir. Check Oring (C) and replace
if damaged.
3. Remove plastic plug (A) from bottom of pump body
with an Oring pick.
4. Remove pump handle link (G).
T8513AF UN05JUL95
5. Remove snap ring (B) from pump valve (F) and tap
assembly out of the valve body.
6. Inspect and replace damaged parts.
7. Apply clean hydraulic oil to pump valve (F) and install
into valve body.
8. Install snap ring (B) and plastic plug (A).
9. Install pump handle link (G) to pump valve (F).
10. Remove and clean suction screen (D).
11. Install Oring (C) into reservoir Oring groove and
install reservoir to the valve body. Tighten cap screws.
Specification
ReservoirtoValve Body
Cap ScrewsTorque........................................................ 6.611.6 Nm
4884 lbin.
12. Fill hand pump oil reservoir. See Transmission, Park

Brake, Differential, Cab Tilt Hydraulic Pump and Winch
Oil. (Operators Manual.)
APlastic Plug
BSnap Ring
CORing
DSuction Screen
EFill Plug
F Pump Valve
GPump Handle Link
13. Oil fill plug (E) is vented check to see if plug is clean.
Install fill plug (E).
14. Install cab tilt hand pump. See Cab Tilt Hand Pump
Specification
Cab Tilt Hand Pump
20 oz
AC12469,00003A5 1914JUN071/1
TM11813 (13OCT10)
18180014
748H Repair (S.N. 630436

)
101310
PN=214
Cab Tilt Hand Pump Bleeding Procedure

CAUTION: For satisfactory operation of the cab
tilt cylinder, it is essential that all air be bled from
the system. Any time a system component is
changed the bleed procedure MUST be performed.
1. Attach hoist and chains to cab and raise cab.
T115133B UN29APR98
2. Support cab and remove cab lift cylinder pin and cap
screw.
3. Position cylinder so that there is enough clearance to
extend and retract cylinder.
4. Completely retract cylinder using pump.
CLever
T115132B UN29APR98
AHead End Hose

BRod End Hose
TM11813 (13OCT10)
18180015
AC12469,00003A6 1914JUN071/2
748H Repair (S.N. 630436

)
101310
PN=215

X9811 UN23AUG88

5. Disconnect the rod end hose (B) and install plug in
hose.
6. Disconnect head end hose (A) at the base of the
hydraulic cylinder.
IMPORTANT: Keep hand pump reservoir full during
bleeding procedure to avoid air entering circuit.
7. Fill cab tilt hand pump reservoir and maintain hydraulic
oil level. See Transmission, Park Brake, Differential,
Cab Tilt Hydraulic Pump and Winch Oil. (Operators
Manual.)
Specification
Cab Tilt Hand Pump
20 oz
Cab Tilt Hand Pump
CircuitCapacity
(approximate)...................................................................................... 2 L
2 qt
9. Place a container under head end hose (A) and

operate pump until all air is bled from hose. Connect
hose (A) to cylinder.
10. Place a container under cylinder rod end port.
11. Operate hand pump until cylinder is completely
extended.
12. Remove plug from rod end hose (B). Place a container
under hose end.
13. Position lever (C) on pump to retract cylinder. Operate
hand pump until all air is bled from line.
14. Connect hose (B) to cylinder and retract cylinder.
IMPORTANT: Overtightening of cap screw and nut
15. Install cab tilt cylinder with pin and cap screw.
16. Make sure nut is fully threaded on cap screw. Do not
overtighten cap screw.
17. Remove cab support and lower cab.
8. Position lever (C) on pump to extend cylinder.

AC12469,00003A6 1914JUN072/2
TM11813 (13OCT10)
18180016
748H Repair (S.N. 630436

)
101310
PN=216
Cab Tilt Cylinder Remove and Install

X9811 UN23AUG88

T131387B UN02JUN00

IMPORTANT: For satisfactory operation of cab
tilt cylinder, it is essential that all air be
bled from the system. Therefore, any time
air is induced into the system, the bleed
(Operators Manual.)
T131386B UN02JUN00

2. Attach hoist and chains to cab for support and aid of
removal and installation of cylinder pin and cap screw.
3. Remove cap screw and nut (1) from cab. Retract
cylinder.
4. Remove cylinder pin (4) from engine frame.
5. Disconnect hydraulic lines (2 and 3). Close all
openings with caps and plugs.
1 Cap Screw and Nut
2 Head End Retract Hydraulic
Line
6. Remove cylinder.
7. Install new cylinder.
3 Head End Lift Hydraulic

Line
4 Pin
8. Connect hydraulic lines (2 and 3).

9. Install cylinder.
IMPORTANT: Overtightening of cap screw and nut
10. Bleed cab tilt hand pump circuit. See Cab Tilt Hand
Pump Bleeding Procedure. (Group 1800.)
11. Extend cylinder to line up cylinder rod end with cab

clevis. Install rubber bushings, washers, cap screw
and nut (1). Make sure nut is fully threaded onto cap
screw. Do not overtighten cap screw.
12. Remove cab support and lower cab.
AC12469,00003A7 1914JUN071/1
TM11813 (13OCT10)
18180017
748H Repair (S.N. 630436

)
101310
PN=217
TM11813 (13OCT10)
18180018
748H Repair (S.N. 630436

)
101310
PN=218
Group 1810
Operator Enclosure
Window Remove and Install
TX1056818 UN06MAR09
Front, Rear, and Side Windows
TX1056818
Front, Rear, and Side Windows
2 Spacer (57 used)
5 Rear Windowpane
6 Front Windowpane (2 used)
3 Side Windowpane (2 used)

4 Spacer (22 used)
1. Remove cap screws securing window to cab.

2. Clean cabtowindowpane contact area of dirt and old
weatherstripping.
CAUTION: DO NOT replace polycarbonate
windows with glass or plastic. Polycarbonate
material impact resistance is recommended
for forestry use.
7 Front Windowpane
3. Install new weatherstripping, windowpane, spacers,

and cap screws. Tighten cap screws to specification.
Specification
Windowpane Cap
ScrewTorque..............................................................................20 Nm
180 lbin.
Door Windows
IMPORTANT: Spacers must be installed before cap

screws are tightened. Tightening cap screws
without spacers could damage windowpane.
TM11813 (13OCT10)
1818101
PM10405,0000571 1906OCT101/3
748H Repair (S.N. 630436

)
101310
PN=219
TX1056817 UN06MAR09
Operator Enclosure
TX1056817
Sliding Windows in Doors
8 Window (2 used)
9 Nut (4 used per side)
10 Plate (2 used per side)
11 Latch
14 Isolator
12 Cap Screw (4 used per side) 15 Washer (2 used per side)
13 Screen
16 Cap Screw (2 used per side)
1. Remove cap screws (15) and swing screen (13) open.
2. Remove screen by lifting straight up.
TM11813 (13OCT10)
1818102
PM10405,0000571 1906OCT102/3
748H Repair (S.N. 630436

)
101310
PN=220
Operator Enclosure
3. Open locking tab (D) using JDG1281 Tool Assembly

(A) from JDG128 Glass Service Set.
4. Loosen molding (F) around window frame (B) using
JDG1282 Insert Tool (E).
T6148AE UN19OCT88
5. Carefully remove window frame.

6. Remove molding and inspect for damage. Replace if
necessary.
7. If molding must be replaced, start molding so the joint
is on the side of window. If joint is on top or bottom of
window, water might enter into the cab.
CAUTION: DO NOT replace polycarbonate
windows with glass or plastic. Polycarbonate
material impact resistance is recommended
for forestry use.
T6148AF UN19OCT88
8. Install window frame using insert tool.

9. Push locking tab into groove using tool assembly.
10. Install screen and tighten cap screws.
DMolding Locking Tab
EJDG1282 Insert Tool
F Molding
Locking TabClosed Position
T6148AH UN19OCT88
T6148AG UN19OCT88
AJDG1281 Tool Assembly

BWindow Frame
CCab Frame
Locking TabOpen Position

PM10405,0000571 1906OCT103/3
TM11813 (13OCT10)
1818103
748H Repair (S.N. 630436

)
101310
PN=221
Operator Enclosure
Window Cleaning Procedure

IMPORTANT: NEVER use abrasive or highly alkaline
cleaners on polycarbonate windows.
NEVER use aromatic or halogenated solvents
like toluene, benzene, gasoline, acetone, or
carbon tetrachloride on polycarbonate windows.
Contact with harsh solvents can result in
surface degradation and possible crazing.
regularly. If surface crazing or cracks are observed,

replace window using only John Deere replacement parts
to ensure the original operator protection level. Inspect
the windows after any significant impact to the windows
or frame.
The windows are made of a polycarbonate material, which
is softer but stronger than glass. It will scratch.
For window cleaning information, see Inspect and Clean
Windows. (Operators Manual.)
IMPORTANT: If cracks or surface crazing are

observed, replace windshield.
Windows are important for the protection of the operator
and the safe operation of the machine. Inspect windows
SW03989,0000AC8 1905OCT101/1
Cab Door Remove and Install

1. Remove door limiting strap from mount on door by
sliding strap up and pulling it out of notch.
1 Door Strap Mount
AC12469,00003B5 1923JUL071/3
2. Remove nuts retaining gas charged strut and remove

strut from door.

3. Support weight of door.
2 Nut (2 used)
3 Gas Charged Strut
TM11813 (13OCT10)
1818104
AC12469,00003B5 1923JUL072/3
748H Repair (S.N. 630436

)
101310
PN=222
Operator Enclosure
4. Mark position of hinges on cab for ease of installation.

5. Remove hinges and remove door from cab.
7. Install door and door hinges. Check alignment to

ensure door is even all the way around opening.
Specification
Cab Hinge Mounting Cap
ScrewTorque..............................................................................73 Nm
54 lbft
9. Install gas charged strut.

door)
10. Install door travel limiting strap.
AC12469,00003B5 1923JUL073/3
Cab Door and Door Latch Disassemble and

Assemble
NOTE: Lower latch mechanism does not need to be
removed to remove upper latch mechanism.
1. Remove inner door panel.
3. Remove clip (4) and disconnect linkage rod from door
lock.
1 Door Lock
2 Bracket (2 used)
4. Remove door lock.

4 Clip
Door Latch (lower)

TM11813 (13OCT10)
1818105
AC12469,00003AA 1923JUL071/2
748H Repair (S.N. 630436

)
101310
PN=223
Operator Enclosure
5. Remove knob and cover from upper door latch.

6. Disconnect spring (8) from bracket (9). Remove upper
two cap screws and remove bracket.
7. Disconnect yoke (11) from latch (7). Remove
remaining cap screws and remove latch.
9. Install door lock.
10. Connect rod to lower door latch.
11. Install upper latch (7) and plate (5) using lower two
cap screws.
12. Connect rod to upper latch. Check for correct
adjustment of yoke.
13. Adjust yoke to allow for full travel of upper latch
mechanism without contacting rod at bottom of travel.
14. Install bracket (9) using remaining two cap screws.
Install spring.
Door Latch (upper)
15. Test operation of latch mechanism and readjust if

necessary.
5 Plate
7 Latch
8 Spring
16. Install knob and cover on upper latch.

17. Install door panel.
9 Bracket
10 Clip
11 Yoke
12 Rod
AC12469,00003AA 1923JUL072/2
Front Windshield Wiper Remove and Install

2. Remove trim caps on screws on left and right side of
front trim panel (1).
3. Remove screws (2) securing trim panel to cab and
remove trim panel.
4. Note position of wiper arm and routing of washer fluid
hose. Remove wiper arm and disconnect washer fluid
hose.
1 Trim Panel
2 Screw (2 used)
TM11813 (13OCT10)
1. Remove sun visor.
1818106
AC12469,00003AB 1910MAR091/3
748H Repair (S.N. 630436

)
101310
PN=224
Operator Enclosure
5. Have an assistant support wiper motor from inside

cab.
3 Wiper Shaft
4 Nut
Remove cap screw (5) and washer securing wiper

motor frame to cab. Remove nut (4) and washer on
wiper shaft (3).
5 Cap Screw
AC12469,00003AB 1910MAR092/3
6. Disconnect electrical connection (6).

7.
Remove wiper motor (8) and wiper motor frame (7).

9. Have an assistant position wiper motor inside cab.

Install cap screw (5) and washer and nut (4) and
washer securing wiper motor to cab.
10. Connect electrical connection.
11. Install wiper arm and connect washer fluid hose.
Tighten nut to specification.
Specification
Wiper Retaining
NuttoPivotTorque............................................................. 1421 Nm
124186 lbin.
6 Electrical Connection
7 Wiper Motor Frame
8 Wiper Motor
12. Install trim cover and sun visor.

13. Install trim caps over screws supporting trim cover.
14. Check windshield wiper position. See Windshield
Wiper Adjustment. (Group 1810.)
AC12469,00003AB 1910MAR093/3
Rear Windshield Wiper Remove and Install
2. Remove trim caps (1) on screws securing trim panel

(2) to cab.
3. Remove screws (3) and remove trim panel.
4. Note position of wiper arm and routing of washer fluid
hose. Remove wiper arm and disconnect washer fluid
hose.
1 Trim Cap
2 Trim Panel
3 Screw (4 used)
4 Plastic Washer
TM11813 (13OCT10)
1. Remove switch panel in right rear of cab. Label

electrical connections for assembly.
1818107
AC12469,00003AC 1930JUL071/3
748H Repair (S.N. 630436

)
101310
PN=225
Operator Enclosure
5. Have an assistant support wiper motor from inside

cab.
5 Cap Screw
6 Wiper Shaft
Remove cap screw (5) and washer securing wiper

motor frame to cab. Remove nut (7) and washer on
wiper shaft (6).
7 Nut
AC12469,00003AC 1930JUL072/3
6. Disconnect electrical connection (9)

7. Remove wiper motor (10) and wiper motor frame (8).
9. Have an assistant position wiper motor inside cab.
Install cap screw (5) and washer and nut (7) and
washer securing wiper motor to cab.
10. Connect electrical connection.
11. Install wiper arm and connect washer fluid hose.
Tighten nut to specification.
Specification
Wiper Retaining
124186 lbin.
12. Install trim panel.

13. Install switch panel and connect electrical connections.
14. Install trim caps over screws securing trim panel to
cab.
15. Check windshield wiper position. See Windshield
Wiper Adjustment. (Group 1810.)
8 Wiper Motor Frame

9 Electrical Connection
10 Wiper Motor
AC12469,00003AC 1930JUL073/3
TM11813 (13OCT10)
1818108
748H Repair (S.N. 630436

)
101310
PN=226
Operator Enclosure
Windshield Wiper Adjustment
T131540B UN27MAR01
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 with the tip 63.5 mm (2.50
in.) (1) from the top edge of windshield, adjust the
wiper blade.
Headlight Shown Removed for Illustration Purposes
Specification
BladetoTop Edge of
WindshieldDistance................................................................ 63.5 mm
2.5 in.
1 63.5 mm (2.50 in.)

Measurement
AC12469,00003AD 1910JUL071/2
2.
Lift wiper arm (3) away from windshield to full

extended position.
3. Lift pivot cover (1) and return wiper arm to windshield.

T131542B UN09JUN00
4. Remove retaining nut (2).

5. Pull wiper arm from pivot shaft. Position to
specification and tighten retaining nut just until snug
against wiper arm.
6. Start wiper motor, shut off and note the new park
position.
7. If blade tip still does not park the specified distance
from top edge of windshield, check for bent wiper arm.
Headlight Shown Removed for Illustration Purposes
If wiper arm is not bent, repeat adjustment procedure.
1 Pivot Cover
2 Retaining Nut
8. Tighten retaining nut (2) to specification.

Specification
Wiper Retaining
124186 lbin.
3 Wiper Arm
9. Close pivot cover (1).

AC12469,00003AD 1910JUL072/2
TM11813 (13OCT10)
1818109
748H Repair (S.N. 630436

)
101310
PN=227
Operator Enclosure
TM11813 (13OCT10)
18181010
748H Repair (S.N. 630436

)
101310
PN=228
Group 1821
Seat and Seat Belt
Seat Remove and Install
1. Disconnect electrical connection for air suspension.
2. Remove cap screws (1) securing vent (2) under seat.

2 Vent
AC12469,00003B2 1911JUL071/2
3. Lift floor mat (6) out of the way and remove vent from
under seat.
4. Remove cap screws (5) securing seat bracket (4) to

cab floor.
5. Remove seat from cab.
Specification
SeatWeight
(approximate).................................................................................. 71 kg
156 lb
6. Inspect and repair parts as necessary. See Seat

7. Install seat in cab.
3 Vent Inlet
4 Seat Bracket

6 Floor Mat
9. Install vent under seat. Align vent with vent inlet (3)
before installing cap screws.
NOTE: Do not install mat on top of transmission
calibration connections or air seat wiring.
Specification
SeatWeight
(approximate).................................................................................. 71 kg
156 lb
10. Install floor mat.

11. Connect air seat wiring.
8. Install cap screws securing seat bracket to cab floor.

AC12469,00003B2 1911JUL072/2
TM11813 (13OCT10)
1818211
748H Repair (S.N. 630436

)
101310
PN=229
Seat and Seat Belt
Seat Disassemble and Assemble

1. Remove seat from machine. See Seat Remove and
2. Determine which part of seat needs service. Seat can

be broken down into individual sections and serviced
independently.
4
3
5
2
5
3
6
3
6
8
9
6
10
11
12
13
TX1025108 UN18JUL07
TX1025108
TM11813 (13OCT10)
1818212
AC12469,00003B3 1919JUN071/6
748H Repair (S.N. 630436

)
101310
PN=230
Seat and Seat Belt

1 Plate
2 Wiring Harness
3 Pivot Shaft
4 Compressor
5 Limiting Strap
6 Bearing
7 Dampener
8 Air Seat Frame
9 Air Spring
10 Air Hose
11 Boot Hardware
12 Boot
13 Plate
3. Disassemble and assemble air suspension. If air lines

are disconnected, check all connections for leaks with
soapy water.
TM11813 (13OCT10)
1818213
AC12469,00003B3 1919JUN072/6
748H Repair (S.N. 630436

)
101310
PN=231
Seat and Seat Belt
14
15
28
17
18
19
20
TX1025111 UN18JUL07
21
22
23
TX1025111
14 Plate
15 Swivel Plate
16 Slider
17 Ball (24 used)

18 Spacer
19 Swivel Plate
20 Nut (5 used)
21 Plate
22 Washer (5 used)
TM11813 (13OCT10)
1818214
AC12469,00003B3 1919JUN073/6
748H Repair (S.N. 630436

)
101310
PN=232
Seat and Seat Belt

4. Disassemble and assemble swivel mechanism.
Lubricate rotating parts with light grease.
TM11813 (13OCT10)
1818215
AC12469,00003B3 1919JUN074/6
748H Repair (S.N. 630436

)
101310
PN=233
Seat and Seat Belt
25
25
24
25
25
26
27
28
29
30
31
31
34
31
32
31
33
TX1025110 UN18JUL07
33
32
32
33
TX1025110
24 Cushion
25 Clip (4 used)
26 Pan
27 Seat Frame
28 Arm Rest
29 Air Suspension
30 Cushion
32 Washer (4 used)
TM11813 (13OCT10)
1818216

34 Riser
AC12469,00003B3 1919JUN075/6
748H Repair (S.N. 630436

)
101310
PN=234
Seat and Seat Belt

5. Disassemble and assemble seat pads.
AC12469,00003B3 1919JUN076/6
T114924 UN29APR98
Seat Belt Remove and Install
ACap Screw (2 used)
BWasher (4 used)
CSeat Belt Assembly
1. Remove covers to gain access to cap screws.

Remove cap screws.
3. Install cap screw (A) with washers (B) through seat
belt and another washer (B) on right and left sides.
Specification
Seat Belt Cap
ScrewTorque.......................................... Until retractor is slightly snug,
retractor can rotate 10 either direction
4. Tighten bolt until retractor is slightly snug, but retractor

can still be rotated about ten degrees in either
direction.
AC12469,00003B4 1918JUN071/1
TM11813 (13OCT10)
1818217
748H Repair (S.N. 630436

)
101310
PN=235
Seat and Seat Belt
TM11813 (13OCT10)
1818218
748H Repair (S.N. 630436

)
101310
PN=236
Group 1830
Heating and Air Conditioning
R134a Refrigerant Cautions and Proper Handling
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.
DO NOT heat refrigerant over 52C (125F) in a
closed container. Heated refrigerant will 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.
IMPORTANT: To meet government standards relating

to the use of refrigerants, R134a is used in
the air conditioning system. Because it does
not contain chlorine, R134a is not detrimental
to the ozone in the atmosphere. However,
it is illegal to discharge any refrigerant into
the atmosphere. It must be recovered using
the appropriate recovery stations.
Use correct refrigerant recovery/recycling and
charging stations. Never mix refrigerants,
hoses, fittings, components, or refrigerant oils.
IMPORTANT: Use only John Deere approved R134a
refrigerant products. Mixing of products not
compatible will cause system damage and
contaminate recovery/recycling and charging
station equipment. Care must be taken to
identify and use equipment, refrigerant oil, and
refrigerant designed only for R134a refrigerant
systems. Refrigerant should be tested for
type and purity before recovery, recycling, or
charging of system. JT02167A refrigerant test
instrument should be used before any testing
or repair to system is performed.
SW03989,0000A7F 1921SEP101/2
Prism Pro Refrigerant Identification Instrument.. JT02167A
To safely identify type and check purity of refrigerant prior

to recovery, recycling and recharging of A/C systems.
SW03989,0000A7F 1921SEP102/2
TM11813 (13OCT10)
1818301
748H Repair (S.N. 630436

)
101310
PN=237
Air Conditioning System Flush and Purge

CAUTION: Liquid refrigerant will freeze eyes or
skin on contact. Wear goggles, gloves, and
protective clothing. See R134a Refrigerant
Cautions and Proper Handling. (Group 1830.)
Specification
Flushing Solvent in
Suction PortVolume.................................................................. 240 mL
8 fl oz.
Flushing Solvent
in Discharge
PortVolume............................................................................... 120 mL
4 fl oz.
NOTE: Flushing can be performed on machine.

1. Follow refrigerant cautions and proper handling
procedures. See R134a Refrigerant Cautions and
Proper Handling. (Group 1830.)
d. Turn compressor end for end and roll it side to side.

e. Remove both plugs from manifold ports and drain
solvent from compressor.
2. Recover refrigerant. See R134a Refrigerant Recovery.

(Group 1830.)
f. Connect battery power to compressor clutch coil.

Rotate pulley at least 5 revolutions to move solvent
out of cylinders.
3. Add TY25601 ACCFlushII to system with JT02075 Air

Conditioning Flusher and JT02098 Air Conditioning
Fitting Kit.
g. Invert compressor. Roll end for end and side to

side. Drain thoroughly.
4. Remove and discard receiverdryer. See

ReceiverDryer Remove and Install. (Group 1830.)
5. Connect flusher outlet hose to inlet end of compressor
discharge line using JT02102 Adapter.
h. Repeat previous two steps at least three times.

10. Divide system into two circuits:
Condenser circuit, including inlet and outlet hoses.

Evaporator circuit, including inlet and outlet hoses.
6. Fill flusher tank with 4 L (1 gal) of solvent and fasten

all connections.
Specification
A/C Flusher
TankCapacity................................................................................... 4 L
1 gal
IMPORTANT: DO NOT attempt to flush through

compressor or receiverdryer. Flushing through
expansion valve is acceptable if refrigerant oil
has a normal odor and appearance.
NOTE: Air pressure must be at least 620 kPa (6.2

bar) (90 psi) for flushing and purging.
11. Flush and purge condenser:
Specification
A/C Flusher Tank
Minimum Air Pressure
for Flushing and
PurgingPressure...................................................................... 620 kPa
6.2 bar
90 psi
7. Connect a supply line of moisturefree compressed air

or dry nitrogen to flusher air valve.
8. 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.
9. Clean compressor as follows:
a. Remove compressor and measure oil drained from
both manifold ports.
b. Connect flusher outlet hose to inlet end of
compressor discharge line using JT02102 Adapter.
a. Remove and discard receiverdryer.

b. Connect flusher outlet hose to inlet end of
compressor discharge line using JT02102 Adapter.
c. Fill flusher tank with 4 L (1 gal) of solvent and fasten
all connections.
Specification
A/C Flusher
TankCapacity................................................................................... 4 L
1 gal

Specification
A/C Flusher Tank
Minimum Pressure
Air Pressure When
FlushingPressure..................................................................... 620 kPa
6.2 bar
90 psi
c. 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 Adapter and JT03194 Caps.
d. Connect a supply line of moisturefree compressed

air or dry nitrogen to flusher air valve.
TM11813 (13OCT10)
1818302
SW03989,0000A80 1905OCT101/2
748H Repair (S.N. 630436

)
101310
PN=238
e. 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. Attach a return hose and aerator nozzle to end of
receiver dryer inlet hose using JT03197 Adapter.
Put nozzle in container to collect flushing solvent.
NOTE: Purging the condenser circuit takes 1012
minutes to thoroughly remove solvent.

Specification
A/C Flusher Tank
Minimum Pressure
Air Pressure When
FlushingPressure..................................................................... 620 kPa
6.2 bar
90 psi
c. Connect a supply line of moisturefree compressed

air or dry nitrogen to flusher air valve.
g. Disconnect hose from aeration nozzle to check

circuit for solvent. Hold hose close to a piece of
cardboard continue purging until cardboard is dry.
d. Attach a hose and aerator nozzle to compressor

inlet line using JT02101 Adapter. Put nozzle in a
container to collect solvent.
12. See flush evaporator if evaporator requires flushing.

If system is contaminated with burned refrigerant oil
or debris, remove and bench flush evaporator. See
following steps to flush evaporator through expansion
valve, if oil appears normal.
13. Flush evaporator:
NOTE: Purging evaporator circuit takes 1215 minutes

to thoroughly remove solvent.
15. Disconnect hose from aeration nozzle to check circuit
for solvent. Hold hose close to a piece of cardboard
and continue purging until cardboard is dry.
a. Remove evaporator. See Evaporator Remove and

16. Install new receiverdryer. See ReceiverDryer

b. Force flushing solvent through evaporator inlet with

compressed air.
17. Add required oil. See R134a Refrigerant Oil

Information in this group.
c. Purge system until dry.
18. Install compressor and connect refrigerant lines

to compressor manifold. See Air Conditioner
Compressor Remove and Install. (Group 1830.)
d. Install evaporator and then go to step 14.

14. Flush evaporator through expansion valve:
a. Connect flusher outlet hose to connection of
receiverdryer outlet hose using JT03188 Adapter.
b. Fill flusher tank with 4 L (1 gal) of solvent and fasten
all connections.
19. Evacuate air conditioning system. See R134a System

Evacuate. (Group 1830.)
Specification
A/C Flusher
TankCapacity................................................................................... 4 L
1 gal
SW03989,0000A80 1905OCT102/2
TM11813 (13OCT10)
1818303
748H Repair (S.N. 630436

)
101310
PN=239
R134a Refrigerant Oil Information

CAUTION: All new compressors are charged
with a mixture of nitrogen, R134a refrigerant,
and TY22101 (R134a) refrigerant oil. Wear
safety goggles and discharge the compressor
slowly to avoid possible injury.
2. When complete system was not flushed add correct

amount of oil for compressor plus amount of oil for
each component that was serviced.
New compressor or remanufactured
CAUTION: DO NOT leave system or R134a

compressor oil containers open. Refrigerant 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.
Specification
New Compressor
Operating Oil
LevelVolume (drain
and return)...................................................................................... 45 mL
1.5 fl oz.
Used compressor removed from operation and oil

drained.
Specification
Used Compressor
Drained OilVolume...................................................................... 45 mL
1.5 fl oz.
IMPORTANT: Do not add any more oil than required

or maximum cooling will be reduced.
A new compressor from parts depot contains 220240
mL (7.08.4 fl. oz.) of new oil. Oil level visible through
suction port normally is below drive shaft.
Used compressor removed from operation
Normal operating oil level of a compressor removed from

operation is 3045 mL (1.01.5 fl oz.). This level cannot
be seen through suction port of compressor.
Specification
Used Compressor
Flushed OilVolume...................................................................... 60 mL
2.0 fl oz.
Components listed below which have been removed,
Compressors can be divided into three categories when

determining correct oil charge for system.
drained, and flushed, require removal of compressor

to determine correct oil charge. Use following chart
as a guide for adding oil to components:
New compressor from parts depot

Used compressor removed from operation
Compressor internally washed with flushing solvent
Determining the amount of system oil charge prior to
installation of compressor on a machine.
1. When complete system, lines, and components are
flushed, add correct amount of oil as described.
New or remanufactured compressor (system

requires an additional amount of new oil)
Specification
New CompressorVol
ume.....................................................................................210250 mL
7.08.4 fl oz.
Air Conditioning System
Additional Oil Volume................................................................ 182 mL
4.0 fl oz.
Compressor Operating
Oil LevelVolume...................................................................3045 mL
1.01.5 fl oz.
Specification
Evaporator OilVolume............................................................... 130 mL
4.4 fl oz.
Condenser OilVolume................................................................. 65 mL
2.2 fl oz.
Receiver Dryer
OilVolume................................................................................... 30 mL
1.0 fl oz.
Flushed Compressor
OilVolume................................................................................... 60 mL
2.0 fl oz.
Hose OilVolume
(approximate total
length)............................................................................. 3 mL per 30 cm
0.1 fl oz. per ft
NOTE: Hoses = 3 mL per 30 cm (0.1 fl oz. per ft)

Approximate total length equals 600 cm (20 ft).
If any section of hose is removed and flushed or
Used compressor removed from operation, oil

drained, and system flushed
Specification
Used Compressor
and System Flushed
OilVolume........................................................................391479 mL
13.216.2 fl oz.
replaced, measure length of hose and use formula 3

mL per 30 cm (0.1 fl oz. per ft) to determine correct
amount of oil to be added.
Drain compressor oil into graduated container while
rotating compressor shaft and record amount.
3. If oil drained from a compressor removed from

operation is very black or amount of oil is less than
6 mL (0.2 fl oz.), perform the following and discard
oil properly:
TM11813 (13OCT10)
1818304
SW03989,0000A81 1910SEP101/2
748H Repair (S.N. 630436

)
101310
PN=240
Determine if R134a leakage was detected, remove
component, and repair or replace component.

Remove and discard receiverdryer.
Flush complete system with TY25601 Air
Conditioning Flushing Solvent.
4. If component is serviceable, pour flushing solvent in

ports and internally wash out old oil and discard oil
properly.
6. Install required amount of TY22101 Refrigerant Oil

in compressor.
7. Connect all components.
8. Evacuate and charge system. See R134a System
Evacuate and R134a System Charge. (Group 1830.)
5. Install a new receiverdryer. See ReceiverDryer

SW03989,0000A81 1910SEP102/2
R134a Refrigerant Recovery/Recycling and

Charging Station Installation Procedure
CAUTION: Liquid refrigerant will freeze eyes
or skin on contact. Wear goggles, gloves and
protective clothing. See R134a Refrigerant
Cautions and Proper Handling. (Group 1830.)
TX1080093 UN22JUL10
IMPORTANT: Use only John Deere approved R134a

refrigerant products. Mixing of products not
compatible will cause system damage and
contaminate recovery/recycling and charging
station equipment. Care must be taken to
identify and use equipment, refrigerant oil, and
refrigerant designed only for R134a refrigerant
systems. Refrigerant should be tested for type
and purity before recovery/recycling or charging
of system. JT02167A Prism Pro Refrigerant
Identification Instrument should be used before
any testing or repair to system is performed.
IMPORTANT: Use only John Deere approved
refrigerant recovery/recycling and charging
stations. DO NOT mix refrigerant, hoses,
fittings, components, or refrigerant oils.
Refrigerant Recovery/Recycling and Charging Station Installation
CAUTION: Do not remove high pressure relief

valve (4). Air conditioning station will discharge
rapidly causing possible injury.
1 Cap
2 Red Hose
3 Blue Hose

2. Close both highside and lowside valves on refrigerant
recovery/recycling and charging station (5).
3. Remove cap from low pressure charge port
and connect blue hose (3) from refrigerant
recovery/recycling and charging station.
4 High Pressure Relief Valve

5 Refrigerant Recovery/Recy
cling and Charging Station
4. Remove cap (1) from high pressure charge port and

connect red hose (2).
5. Follow the manufacturers instructions when using the
refrigerant recovery/recycling and charging station.
SW03989,0000A82 1904OCT101/1
TM11813 (13OCT10)
1818305
748H Repair (S.N. 630436

)
101310
PN=241
R134a Refrigerant Recovery

or skin on contact. Wear goggles, gloves,
and protective clothing.
Do not remove high pressure relief valve. Air
conditioning system will discharge rapidly
causing possible injury.
IMPORTANT: Use correct refrigerant recovery/re
cycling and charging stations. Do not mix
refrigerant, hoses, ttings, components, or
refrigerant oils. Damage to air conditioning
system components may occur.

2. Run air conditioning system for 3 minutes to help in
recovery process. Turn air conditioning system off
before proceeding with recovery steps.
3. With engine OFF, identify refrigerant type using
JT02167A Refrigerant Identification Instrument.
4. Connect refrigerant recovery system. See R134a
Refrigerant Recovery/Recycling and Charging Station
Installation Procedure. (Group 1830.)
5. Follow manufacturers instructions when using the
refrigerant recovery/recycling and charging station.
SW03989,0000A83 1910SEP101/1
R134a System Evacuate

Do not remove high pressure relief valve. Air
conditioning system will discharge rapidly
causing possible injury.
2. Connect refrigerant recovery system. See R134a
Refrigerant Recovery/Recycling and Charging Station
Installation Procedure. (Group 1830.)
3. Open lowside and highside valves on refrigerant
recovery/recycling and charging station.
4. Follow charging station manufacturers instructions
to evacuate system.
NOTE: 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.
5. Evacuate system until lowside gauge vacuum reading
is to specification.
Value to Subtract for

Elevation Above Sea
LevelVacuum.....................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
If the specified vacuum reading cannot be obtained

in 15 minutes, check the system for leaks. See
Refrigerant Leak Test. (Group 903125.)
6. When vacuum reaches above specification, close
lowside and highside valves. Turn vacuum pump off.
7. If vacuum decreases more than specification in 5
minutes, there is a leak in system.
Specification
Evacuate
SystemVacuum......................................................................... 3.4 kPa
34 mbar
1 in. Hg
8. Repair the leak.

9. Evacuate system for 30 minutes after 98 kPa (980
mbar) (29 in. Hg) vacuum is reached.
Specification
Evacuation
ProcedureTime....................................................................30 minutes
10. Close lowside and highside valves. Stop evacuation.
Specification
Evacuate
SystemVacuum.......................................................................... 98 kPa
980 mbar
29 in. Hg

SW03989,0000A84 1910SEP101/1
TM11813 (13OCT10)
1818306
748H Repair (S.N. 630436

)
101310
PN=242
R134a System Charge

IMPORTANT: Use only John Deere approved
refrigerant recovery/recycling and charging
stations. DO NOT mix refrigerant, hoses,
fittings, components, or refrigerant oils.
Damage to seals may occur resulting in air
conditioning system leaks.
2. Identify refrigerant type using JT02167A Prism Pro
Refrigerant Identification Instrument.
3. Connect R134a Refrigerant Recovery/Recycling
and Charging Station. See R134a Refrigerant
Recovery/Recycling and Charging Station Installation
4. Evacuate system. See R134a System Evacuate.
(Group 1830.)
NOTE: Before beginning to charge air conditioning

system, the following conditions must exist: Engine
STOPPED, 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.
Specification
Evacuate
SystemVacuum..................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
5. Follow manufacturers instructions and charge system.

6. Add refrigerant to system.
Specification
Air Conditioning System
RefrigerantRefrigerant
Quantity........................................................................................ 3.17 kg
7.00 lb
7. Check air conditioning for proper function. See

Complete Machine Operational Checkout. (Group
900510.)
SW03989,0000A85 1904OCT101/1
Compressor Relief Valve Remove and Install
CAUTION: DO NOT allow liquid refrigerant to

contact eyes or skin. DO NOT spill R134a
compressor oil on acrylic or ABS plastic. High
pressure may exist at the discharge fitting. If this
pressure is released too rapidly, there may be
considerable discharge of refrigerant and oil.
1. Remove front left engine shield.
(Group 1830.)
Relief Valve
3. Slowly remove relief valve (1) from air conditioner

compressor manifold (2).
1 Relief Valve
NOTE: The relief valve is not serviceable. Replace

valve as required.
2 Air Conditioner
Compressor Manifold

5. Install relief valve and tighten to specification.

Specification
Relief ValveTorque............................................................. 1216 Nm
103142 lbin.
7. Install engine side shield.
SW03989,0000A86 1921SEP101/1
TM11813 (13OCT10)
1818307
748H Repair (S.N. 630436

)
101310
PN=243
Air Conditioner Compressor Remove and

Install

2. Locate air conditioner compressor at front left side
of engine. Remove leftside engine shields. See
3. Remove left fan guard. See Fan Shroud Remove and
4. Recover air conditioner refrigerant. See R134a


4 Air Conditioner
Compressor
5 Air Conditioner Refrigerant
Suction Hose
6. Disconnect air conditioner refrigerant hoses (5 and

6) at compressor. Close all openings using caps and
plugs.
7. Disconnect electrical connector and ground wire (7
and 8).
8. Remove cap screws (3) and air conditioner
compressor (4).

Pressure Hose to
Condenser
7 Electrical Connector
8 Ground Wire
Pressure Hoseto
CondenserTorque.............................................................. 2027 Nm
177239 lbin.
15. Install new receiverdryer. See ReceiverDryer

10. Install air conditioner compressor.

11. Add compressor oil. See R134a Refrigerant Oil
Information. (Group 1830.)
12. Install serpentine belt. See Serpentine Belt Remove
13. Connect electrical connector and ground wire.
16. Evacuate and charge the air conditioning system.

See R134a System Evacuate and see R134a System
17. Install left fan guard. See Fan Shroud Remove and
18. Install leftside engine shields. See Opening Engine
of air conditioning system. See Complete Machine
Operational Checkout. (Group 9005.)
14. Connect air conditioner refrigerant hoses at

compressor. Tighten hoses to specification.
Specification
Suction Hoseto
CompressorTorque............................................................ 2428 Nm
212248 lbin.
SW03989,0000A88 1905OCT101/1
TM11813 (13OCT10)
1818308
748H Repair (S.N. 630436

)
101310
PN=244
Air Conditioner Compressor Clutch Remove

and Install
1. Remove compressor (3) from machine. See Air
Conditioner Compressor Remove and Install. (Group
1830.)
2. Install compressor on DFRW20 Compressor Holding
Fixture using two 6 in. x 1/4 in. eyebolts and nuts as
illustrated. See DFRW20 Compressor Holding Fixture.
(Group 9900.)
TX1008957 UN17JUL06
4. Remove dust cover (11).

5. Hold clutch hub (9) using JDG747 Compressor Clutch
Spanner (A) to remove clutch hubtoshaft cap screw
(10).
6. Remove clutch hub. Remove washers (4, 13, and 14)
from clutch hub and save for installation.
7. Remove and discard ring (8).
Compressor Clutch Components
8. Remove pulley (7) using a 3jaw puller or a Vbelt

pulley pulling attachment.
9. Remove the screw for the ground wire (1) and clamp
for clutch coil wire (2).
10. Remove and discard snap ring (6).
11. Remove clutch coil (5).
13. Install clutch coil.
14. Install new snap ring, flat side toward coil.
TX1056811A UN06MAR09
15. Connect clutch coil wire.

16. Connect ground wire.
17. Install pulley.
18. Install new ring, flat side toward pulley.
19. Apply grease to washers. Install in clutch hub.
20. Install clutch hub.
JDG747 Compressor Clutch Spanner
21. Install clutch hubtoshaft cap screw. Tighten to

specification.
Specification
Clutch HubtoShaft
BoltTorque..................................................................................14 Nm
120 lbin.
1 Ground Wire
2 Clutch Coil Wire
3 Compressor
4 Washer
5 Clutch Coil
6 Snap Ring
7 Pulley
8 Ring
TM11813 (13OCT10)
1818309
9 Clutch Hub
10 Clutch HubtoShaft Cap
Screw
11 Dust Cover
13 Washer
14 Washer
AJDG747 Compressor
Clutch Spanner
SW03989,0000A89 1910SEP101/2
748H Repair (S.N. 630436

)
101310
PN=245
NOTE: The clutch coil is NOT polarity sensitive.

22. Check pulleytoclutch hub clearance using a dial
indicator as illustrated. Connect a set of jumper wires
from the compressor to a 12V supply to engage clutch.
Check clearance at three equally spaced locations
around the clutch hub. Add or remove washers as
required.
Specification
PulleytoClutch
HubClearance...............................................................0.350.65 mm
0.0140.026 in.
23. Install dust cover.

24. Install compressor. See Air Conditioner Compressor
25. Evacuate and charge air conditioning system. Perform

R134a System Evacuate and perform R134a System
PulleytoClutch Hub Clearance

SW03989,0000A89 1910SEP102/2
TM11813 (13OCT10)
18183010
748H Repair (S.N. 630436

)
101310
PN=246
Air Conditioner Compressor Manifold

Remove and Install
1. Remove leftside engine shields. Locate air
conditioner compressor at front left side of engine.
2. Recover air conditioning refrigerant. See R134a
3. Remove cap screws (2) and the manifold (1).
4. Remove and discard manifold seal (3).
5. Inspect surfaces.
6. Lubricate and install a new seal.

7. Install manifold and tighten cap screws to specification.
Specification
230 lbin.

9. Install left fan guard. See Fan Shroud Remove and
Compressor Manifold
1 Cap Screw
2 Manifold
3 Manifold Seal
10. Install leftside engine shields.

of air conditioning system. See Complete Machine
Operational Checkout. (Group 9005.)
SW03989,0000A8A 1905OCT101/1
Air Conditioner Condenser Remove and

Install

Manual.)
3. Recover air conditioner refrigerant. See R134a
4. Remove nuts (1) and swing open air conditioner
condenser.
1 Nut (2 used)

TM11813 (13OCT10)
18183011
SW03989,0000A8B 1910SEP101/2
748H Repair (S.N. 630436

)
101310
PN=247
5. Disconnect air conditioner refrigerant hose fittings (3).

6. Remove nuts (4) and air conditioner condenser (2).

8. Install air conditioner condenser and tighten nuts to
specification.
Specification
Air Conditioner
Condenser
NutsTorque................................................................................73 Nm
54 lbft

9. Connect air conditioner refrigerant hoses. Tighten
hose fittings to specification.
Specification
Air Conditioner
Condenser Inlet Hose
Fitting (upper)Torque.................................................................24 Nm
212 lbin.
Air Conditioner
Condenser Outlet Hose
Fitting (lower)Torque..................................................................17 Nm
150 lbin.

Hose Fitting (2 used)
4 Nut (4 used)
10. Swing close air conditioner condenser and secure

with nuts.
SW03989,0000A8B 1910SEP102/2
TM11813 (13OCT10)
18183012
748H Repair (S.N. 630436

)
101310
PN=248
Blower Motor Remove and Install

1. Remove cap screws (3) and HVAC compartment
cover (1).
2. Disconnect wiring harness from blower motor

connector (6) and blower resistor (7).
3. Remove cap screws (5) from HVAC fuse and relay
panel (4).
4. Disconnect cooling hose (9) from blower motor (10).
5. Remove cap screws (8) and blower motor.
6. Inspect and repair as necessary.
HVAC and Precleaner Compartment Covers
7. Install blower motor and cap screws.

8. Connect cooling hose to blower motor.
9. Connect wiring harness to blower resistor and blower
motor connector.
10. Install HVAC fuse and relay panel.

11. Close and secure HVAC compartment cover.
1 HVAC Compartment Cover
2 Precleaner Compartment
Cover
4 HVAC Fuse and Relay Panel
6 Blower Motor Connector

7 Blower Resistor
9 Cooling Hose
10 Blower Motor
Heating and Air Conditioning Blower Motor
SW03989,0000A8E 1910SEP101/1
TM11813 (13OCT10)
18183013
748H Repair (S.N. 630436

)
101310
PN=249
Precleaner Blower Assembly Remove and

Install
1. Remove cap screws (3) and open precleaner
compartment cover (2).
2. Release holddowns (4) and remove precleaner cover

(5).
3. Disconnect wiring harness from precleaner blower
motor connector (6).
4. Remove cap screws (8) and precleaner blower motor
(7).
6. Install precleaner blower motor.

7. Connect wiring harness to precleaner blower motor
connector.
8. Install precleaner cover and secure with holddowns.

9. Close and secure precleaner compartment cover.
Cover
4 HoldDown (2 used)
5 Precleaner Cover
6 Precleaner Blower Motor
Connector
7 Precleaner Blower Motor
Precleaner Blower Assembly
SW03989,0000A94 1910SEP101/1
TM11813 (13OCT10)
18183014
748H Repair (S.N. 630436

)
101310
PN=250
Refrigerant High/Low Pressure Switch Remove and Install

cover (1).
NOTE: It is not necessary to recover refrigerant

from the system. A valve prevents the
system from discharging when high/low
pressure switch is removed.
2. Disconnect wiring harness from wire connector (5).
IMPORTANT: Remove pressure switch using a wrench
on hex nut fitting. Damage to switch will occur
if removed by plastic switch housing.
3. Remove high/low pressure switch (4) using a wrench
on hex nut fitting.
4. Test switch and replace if necessary. See Air

Conditioning High/Low Pressure Switch Test. (Group
903125.)
5. Install high/low pressure switch.

6. Connect wiring harness to wire connector.
7. Close and secure HVAC compartment cover.
Cover
4 High/Low Pressure Switch

5 Wire Connector
High/Low Pressure Switch

SW03989,0000A87 1910SEP101/1
TM11813 (13OCT10)
18183015
748H Repair (S.N. 630436

)
101310
PN=251
Coolant Valve Remove and Install
CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious
burns. Coolant may be hot. Wait until radiator is
cool to the touch before draining radiator.
1. Drain the coolant system. Perform Draining the
Cooling System. (Operators Manual.)
cover (1).
3. Disconnect wire harness connector (5).
4. Move clamps (6) and disconnect coolant hoses.
5. Remove cap screws (7) and coolant valve (4).

NOTE: The coolant valve is serviced as an assembly.
7. Install coolant valve with cap screws.
8. Connect coolant hoses and secure with clamps.
9. Connect wire harness connector.

10. Close HVAC compartment cover.
11. Fill coolant system. Perform Filling the Cooling
Cover
4 Coolant Valve
5 Wire Harness Connector

6 Clamp (2 used)
Coolant Valve
SW03989,0000A90 1910SEP101/1
TM11813 (13OCT10)
18183016
748H Repair (S.N. 630436

)
101310
PN=252
Freeze Control Switch Remove and Install

1. Remove cap screws (3) to remove HVAC compartment
cover (1) and open precleaner compartment cover (2).
2. Release holddowns and remove precleaner cover

and air filter. See Precleaner Blower Assembly
3. Remove freeze control switch thermocouple (5) from
evaporator (4).
4. Disconnect electrical connectors (6) from freeze
control switch (7).
5. Remove freeze control switch by guiding freeze control
switch thermocouple (5) back through bulkhead
grommet (9).
7. Insert freeze control switch thermocouple through

bulkhead grommet.
8. Install freeze control switch.
9. Connect electrical connectors.
10. Install freeze control switch thermocouple to
evaporator.
11. Install air filter and precleaner cover using holddowns.
12. Close HVAC compartment and precleaner
compartment covers.
6 Electrical Connector (2
used)
7 Freeze Control Switch
8 Pan Head Screw (2 used)
9 Bulkhead Grommet

Cover
4 Evaporator
5 Freeze Control Switch
Thermocouple
Freeze Control Switch Thermocoupler
Freeze Control Switch

SW03989,0000A93 1910SEP101/1
TM11813 (13OCT10)
18183017
748H Repair (S.N. 630436

)
101310
PN=253
Expansion Valve Remove and Install

1. Recover refrigerant from the air conditioning system.
See R134a Refrigerant Recovery. (Group 1830.)
2. Remove HVAC compartment cover (1).
3. Disconnect refrigerant line fittings (4).

4. Remove cap screw (5) and flange (6) to disconnect
refrigerant lines (7) from expansion valve.
5. Remove cap screws (8) to flange of evaporator.
Remove expansion valve (9).
7. Replace Orings. Install expansion valve to evaporator

using flange and cap screws.
8. Install refrigerant lines and flange to expansion valve.
9. Close HVAC compartment cover.
6 Flange
7 Refrigerant Line (2 used)
9 Expansion Valve
Refrigerant Lines and Flange

Cover
4 Line Fitting (2 used)
5 Cap Screw

Expansion Valve
SW03989,0000A8D 1910SEP101/1
TM11813 (13OCT10)
18183018
748H Repair (S.N. 630436

)
101310
PN=254
Heater Core Remove and Install
T131235B UN25MAY00
CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious
burns. Wait until radiator is cool to the
touch before draining radiator.
1. Drain the coolant system. Perform Draining the
Cooling System. (Operators Manual.)
2. Remove blower motor. See Blower Motor Remove
3. Remove cap screws (1) and blower housing (3).
Blower Housing
4. Disconnect coolant hoses (2) from heater core (8).

5. Remove cap screws (4) and blower mounting plate (5).
6. Remove cap screws (6) and isolator (7).

7. Remove heater core (8).
9. Install heater core.
10. Install isolator.
11. Install blower mounting plate and cap screws.
Blower Mounting Plate
12. Connect coolant hoses to heater core.

13. Install blower housing.
14. Install blower motor. See Blower Motor Remove and

2 Coolant Hose (2 used)
3 Blower Housing
15. Fill the coolaning system. Perform Filling the Cooling

5 Blower Mounting Plate
7 Isolator
8 Heater Core
Heater Core
SW03989,0000A8F 1910SEP101/1
TM11813 (13OCT10)
18183019
748H Repair (S.N. 630436

)
101310
PN=255
Evaporator Remove and Install

1. Recover refrigerant from air conditioning system. See
R134a Refrigerant Recovery. (Group 1830.)
2. Remove blower motor. See Blower Motor Remove

3. Remove precleaner cover and filter. See Precleaner
Blower Assembly Remove and Install. (Group 1830.)
4. Remove coolant valve. See Coolant Valve Remove
5. Remove heater core. See Heater Core Remove and
6. Remove freeze control switch. See Freeze Control
Switch Remove and Install. (Group 1830.)
Evaporator
2 Evaporator

14. Install precleaner cover and filter. See Precleaner
8. Remove evaporator (2).

15. Install blower motor. See Blower Motor Remove and

10. Install evaporator.

11. Install freeze control switch. See Freeze Control
Switch Remove and Install. (Group 1830.)
12. Install heater core. See Heater Core Remove and

13. Install coolant valve. See Coolant Valve Remove and

SW03989,0000A8C 1910SEP101/1
TM11813 (13OCT10)
18183020
748H Repair (S.N. 630436

)
101310
PN=256
ReceiverDryer Remove and Install


(Group 1830.)
4. Open precleaner compartment. See Precleaner
ReceiverDryer
5. Disconnect refrigerant lines (1 and 2). Close all

6. Loosen clamp cap screws (4) and remove
receiverdryer (3).
IMPORTANT: A new receiverdryer must always be
installed after purging system. DO NOT use a
flushed or used receiverdryer. Contamination
of system can cause component failure.
7. Before installing new receiverdryer, add refrigerant oil.
See R134a Refrigerant Oil Information. (Group 1830.)
Specification
Refrigerant
OilQuantity.................................................................................. 15 mL
0.5 fl oz
8. Install new receiverdryer and tighten clamp cap

screws.
1 Refrigerant Line From

Condenser
2 Refrigerant Line to
Expansion Valve
3 ReceiverDryer
4 Clamp Cap Screw (2 used)

9. Lubricate new Orings with refrigerant oil. Remove
plugs from receiverdryer and immediately connect
refrigerant lines.
10. Evacuate and charge the system. See R134a System
Evacuate and see R134a System Charge. (Group
1830.)
SW03989,0000A91 1901OCT101/1
TM11813 (13OCT10)
18183021
748H Repair (S.N. 630436

)
101310
PN=257
TM11813 (13OCT10)
18183022
748H Repair (S.N. 630436

)
101310
PN=258
Section 19
Sheet Metal and Styling
Contents
Page
Group 1910Hood or Engine Enclosure

Hood Remove and Install .......................... 1919101
Grille Guard Remove and Install ............... 1919103
Grille Housing Remove and
Install ..................................................... 1919105
TM11813 (13OCT10)
191
748H Repair (S.N. 630436

)
101310
PN=1
Contents
TM11813 (13OCT10)
192
748H Repair (S.N. 630436

)
101310
PN=2
Group 1910
Hood or Engine Enclosure
Hood Remove and Install

3. Remove engine compartment side shields. See
4. Remove mufflertoturbocharger flex pipe clamp (1).
MufflertoTurbocharger Flex Pipe Clamp
5. Remove left limb riser with muffler attached. Close

turbocharger opening using an appropriate cap or
plug.
1 MufflertoTurbocharger
Flex Pipe Clamp
Specification
Left Limb Riser
with MufflerWeight
(approximate).................................................................................. 50 kg
110 lb
6. Remove right side hood panel.
MH66088,0000D7C 1919AUG101/4
7. Remove cap screws (2) securing hydraulic oil return

filter housing (3) to hood (4) and secure to the side.
Hoses remain connected to filter.

3 Hydraulic Oil Return Filter
Housing
8. Remove hydraulic oil return filter electrical harness

clamps from underside of hood.
4 Hood
Hydraulic Oil Return Filter

MH66088,0000D7C 1919AUG102/4
9. Remove cap screws (5) securing hydraulic fan return

filter housing to hood and secure to the side. Hoses
remain connected to filter.
10. Disconnect air cleaner assembly from hood. See Air

Cleaner Remove and Install. (Group 0520.)
NOTE: Draining coolant from surge tank is not necessary
for hood removal and installation.
11. Disconnect surge tank from hood, leaving all hoses
attached. Secure to the side.
Hydraulic Fan Return Filter Cap Screws

TM11813 (13OCT10)
1919101
MH66088,0000D7C 1919AUG103/4
748H Repair (S.N. 630436

)
101310
PN=261
12. Install JT01748 Lifting Brackets (6) and lifting device

as shown.
13. Loosen Jbolts (7) and remove hood retaining cap

screws (8).
NOTE: Make sure hydraulic reservoir filler cap is
installed after removal or installation of hood to
prevent contamination of hydraulic oil.
14. Remove hydraulic tank filler cap.
JT01748 Lifting Brackets
15. Attach appropriate lifting device to lifting brackets.

Remove hood.
Specification
HoodWeight
(approximate).................................................................................. 57 kg
125 lb
6 JT01748 Lifting Bracket

7 Jbolt (2 used)
8 Hood Retaining Cap Screw

(4 used)
24. Install hydraulic fan return filter housing.

25. Install hydraulic oil return filter.

26. Install hydraulic oil return filter electrical harness

clamps to underside of hood.
27. Install right hood panel.
17. Set hood in place.

Specification
HoodWeight
(approximate).................................................................................. 57 kg
125 lb
28. Install left limb riser with muffler.
20. Remove lifting device and JT01748 Lifting Brackets.
Specification
Left Limb Riser
with MufflerWeight
(approximate).................................................................................. 50 kg
110 lb
21. Install and tighten Jbolts.
29. Install mufflertoturbocharger flex pipe clamp.
22. Install surge tank.
30. Turn battery disconnect to the ON position.
23. Install air filter assembly. See Air Cleaner Remove

31. Install engine compartment side shields. See Opening

18. Align hood and install hood retaining cap screws.

19. Install hydraulic tank filler cap.
MH66088,0000D7C 1919AUG104/4
TM11813 (13OCT10)
1919102
748H Repair (S.N. 630436

)
101310
PN=262
Grille Guard Remove and Install

NOTE: The following procedure is for both standard
grille guard and high debris grille guard
removal and installation.
3. Remove cap screws (1) and washers (2). Open grille

guard.
2 Washer (2 used)
Standard Grille Guard Shown

MH66088,0000D90 1914SEP101/3

4. Support grille guard using lifting straps (3) as shown.
Specification
Standard Grille
GuardWeight
(approximate).................................................................................. 68 kg
150 lb.
High Debris Grille
GuardWeight
(approximate).................................................................................. 84 kg
200 lb.
Remove parts (48) and remove grille guard.

3 Lifting Strap (2 used)
5 Nut (2 used)
6 Washer (2 used)
7 Wave Washer (2 used)
8 Washer (2 used)
Lifting Straps
TM11813 (13OCT10)
1919103
MH66088,0000D90 1914SEP102/3
748H Repair (S.N. 630436

)
101310
PN=263

6. Raise grille guard to machine and install parts (48)
as shown. Do not tighten cap screws at this time.
7. Remove lifting device and lifting straps from grille

guard.
8. Close grille guard and adjust for proper alignment.
Tighten cap screws (4) and nuts (5). Open and close
grille guard several times to ensure proper alignment.
9. Close grille guard and install cap screws (1) and
washers (2).
5 Nut (2 used)
6 Washer (2 used)
Grille Guard Mounting Hardware
7 Wave Washer (2 used)

8 Washer (2 used)
MH66088,0000D90 1914SEP103/3
TM11813 (13OCT10)
1919104
748H Repair (S.N. 630436

)
101310
PN=264
Grille Housing Remove and Install


1910.)

Specification
Right Limb
RiserWeight
(approximate).................................................................................. 39 kg
85 lb.
5. Remove grille guard. See Grille Guard Remove and

1 Fan Motor
2 Fan Support
3 Hydraulic Hoses (3 used)
4 Fan Blade
NOTE: Air conditioner condenser and hydraulic oil

cooler share the same mounting bracket on
torque converter drive machines and can be
removed as an assembly.
7. Remove air conditioner condenser. See Air
Conditioner Condenser Remove and Install. (Group
1830.)
9. Remove transmission oil cooler. See Transmission Oil

Cooler Remove and Install. (Group 0510.)
10. Remove radiator. See Radiator Remove and Install.
(Group 0510.)
11. Remove aftercooler. See Aftercooler Remove and
16. Support grille housing (9) using an appropriate lifting

device. Remove cap screws (8) and remove grille
housing.
Specification
Grille HousingWeight
(approximate)................................................................................ 181 kg
400 lb.

12. Remove air baffle enclosure. See Air Baffle Enclosure

NOTE: It is not necessary to disconnect fan motor (1)

from fan support (2) during fan shroud removal
and installation. Fan hydraulic hoses (3) and
fan blade (4) do not need to be removed when
disconnecting fan support from fan shroud (6).
14. While supporting the fan assembly, remove cap
screws (5) and allow assembly to tilt back and rest
against the engine.
6 Fan Shroud
9 Grille Housing

8. Remove hydraulic oil cooler. See Hydraulic Oil Cooler

13. Disconnect all hydraulic hose clamps and electrical

harness clamps from grille housing.
Fan Assembly
6. Discharge air conditioning system. See R134a

18. Install grille housing.

Specification
Grille HousingWeight
(approximate)................................................................................ 181 kg
400 lb.
19. Attach fan assembly to fan guard.

20. Route all hydraulic hoses and electrical harnesses.
Install all hydraulic hose clamps and electrical harness
clamps to grille housing.
21. Install air baffle enclosure. See Air Baffle Enclosure
TM11813 (13OCT10)
TX1081428 UN01SEP10
4. Remove right limb riser.
1919105
MH66088,0000DB1 1907OCT101/2
748H Repair (S.N. 630436

)
101310
PN=265
22. Install aftercooler. See Aftercooler Remove and

23. Install radiator. See Radiator Remove and Install.
(Group 0510.)
24. Install transmission oil cooler. See Transmission Oil
Cooler Remove and Install. (Group 0510.)
25. Install hydraulic oil cooler. See Hydraulic Oil Cooler
NOTE: Air conditioner condenser and hydraulic
oil cooler share the same mounting bracket
on torque converter drive machines and are
installed as an assembly.
26. Install air conditioner condenser. See Air Conditioner
Condenser Remove and Install. (Group 1830.)
27. Install grille guard. See Grille Guard Remove and

28. Install right limb riser.
Specification
Right Limb
RiserWeight
(approximate).................................................................................. 39 kg
85 lb.

1910.)
31. Evacuate air conditioning system. See R134a System
Evacuate. (Group 1830.)
MH66088,0000DB1 1907OCT102/2
TM11813 (13OCT10)
1919106
748H Repair (S.N. 630436

)
101310
PN=266
Section 20
Safety, Convenience, and Miscellaneous
Contents
Page
Group 2003Pressurized Water System

Pressurized Water SystemIf
Equipped ............................................... 2020031
Group 2004Horn and Warning Devises
Horn Remove and Install ........................... 2020041
Reverse Warning Alarm Remove
and Install .............................................. 2020041
TM11813 (13OCT10)
201
748H Repair (S.N. 630436

)
101310
PN=1
Contents
TM11813 (13OCT10)
202
748H Repair (S.N. 630436

)
101310
PN=2
Group 2003
Pressurized Water System
Pressurized Water SystemIf Equipped
4
4
2
5
7
8
9
10
10
13
6
12
9
11
17
16
19
14
23
15
18
25
23
24
22
24
21
26
27
TX1081958
TX1081958 UN20SEP10
20

1 Tank
2 Filler Plug
3 ORing
5 Washer (8 used)
6 Reducer
7 Seal
8 ORing (2 used)
9 Adapter (2 used)
10 Hose
11 Bracket
12 Washer
13 Latch
14 Label

16 Fitting
17 Pressure Gauge
18 Relief Valve
19 Manifold
20 Nozzle
21 Adapter
TM11813 (13OCT10)
2020031
22 Hose
24 Adapter (2 used)
25 Valve
26 Cover
27 Label
SW03989,0000B2F 1924SEP101/2
748H Repair (S.N. 630436

)
101310
PN=269
CAUTION: Release pressure by discharging fluid

at hose and before removing fill plug. Injury
may result from plug or cap under force.
2. Move valve (25) handle to ON position.
CAUTION: Pressurized water system. Release
pressure by discharging fluid at hose end
before removing fill plug. Injury may result
from plug removed under pressure.
Cover and Latch
3. Squeeze nozzle (20) to release water.

4. Slowly remove filler plug (2).
5. For tank removal, remove trim caps on screws

securing trim panel to cab and remove head liner.
6. Disconnect hose (10) from adapter (9). Close all
tank using lifting loops.
Valve, Hose, and Nozzle
Specification
TankWeight................................................................................ 373 kg
822 lb.
8. Replace or repair as necessary.

9. Install tank and connect hose. Install head liner and
trim panel.
10. Fill tank with water. See Fill and Charge Pressurized
Water SystemIf Equipped. (Operators Manual.)
CAUTION: Plug has a vent cross hole for release
of air pressure. Do not use a substitute plug.
11. Install filler plug.
12. To pressurize system, apply air to fitting (16), add air,
watching pressure gauge (17) to correct air pressure
specification.
Specification
Water TankPressure................................................................ 410 kPa
3.8 bar
55 psi
Plug Location
2 Filler Plug
5 Washer (8 used)
13 Latch
16 Fitting
17 Pressure Gauge
20 Nozzle
25 Valve
26 Cover
SW03989,0000B2F 1924SEP102/2
TM11813 (13OCT10)
2020032
748H Repair (S.N. 630436

)
101310
PN=270
Group 2004
Horn and Warning Devises
Horn Remove and Install
1. Open front grille (3).
2. Disconnect electrical connectors (1).

3. Remove horn (2).
5. Install horn.
7. Close front grille.
2 Horn
Horn
3 Nut
4 Grille
GD61784,000002B 1929MAY071/1
Reverse Warning Alarm Remove and Install

1. Remove cover (1).
1 Reverse Warning Alarm

Cover
Reverse Warning Alarm Cover

GD61784,000002C 1929MAY071/2
2. Disconnect electrical connectors (3).

3. Remove reverse warning alarm (5).
5. Install reverse warning alarm.

7. Install cover.
4 Nut (2 used)
5 Reverse Warning Alarm
Reverse Warning Alarm

GD61784,000002C 1929MAY072/2
TM11813 (13OCT10)
2020041
748H Repair (S.N. 630436

)
101310
PN=271
Horn and Warning Devises
TM11813 (13OCT10)
2020042
748H Repair (S.N. 630436

)
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Section 21
Main Hydraulic System
Contents
Page

General Oil Cleanup Procedure ................ 2121601
Hydraulic Component Failure
Cleanup Procedure................................ 2121603
Hydraulic Pump Remove and
Install ..................................................... 2121605
Priority Valve Remove and Install.............. 2121607
Priority Valve Disassemble and
Assemble............................................... 2121608
Hydraulic Attenuator Remove and
Install ..................................................... 2121609
Fan Variable Speed and Reversing
Manifold Remove and Install ............... 21216010
Fan Variable Speed and Reversing
Manifold Disassemble and
Assemble............................................. 21216011
Hydraulic Fan Motor Remove and
Install ................................................... 21216012
Hydraulic Reservoir Remove and
Install ................................................... 21216014
Hydraulic Fan and Cooling Loop
Pump Remove and Install ................... 21216018
TM11813 (13OCT10)
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Contents
TM11813 (13OCT10)
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Group 2160
Hydraulic System
General Oil Cleanup Procedure
This procedure is to be used on machines that have had

hydraulic system repair without a catastrophic component
failure. Filter caddy procedure must be done prior to
starting machine after a component has been repaired
or replaced.
IMPORTANT: Intermixing of oils can cause premature

hydraulic component damage and oil
contamination. Oil types and filters must not
be intermixed. Use filter element in same
type oil to avoid intermixing of oils.
Oil contamination could result if filter caddy is
used in dusty or wet conditions. Clean work
practices and cleanliness of filter caddy and
attachments are critical when filtering oil.
TX1080703 UN09AUG10
NOTE: Filter oil should be at 27C (80F) or above for

best Super Caddy performance. Reduce flow
rate to filter oil below 27C (80F).
Super Caddy requires a 20amp electric circuit. Use
of electrical extension cord is not recommended.
1. Park machine on a flat, level surface with attachments
lowered to the ground and turn engine off.
2. Remove hydraulic tank cap and filler screen.
Super Caddy Wand Placement
NOTE: When installing suction and discharge wands into

the hydraulic oil reservoir, locate the submerged
ends of the wands as far away from each other
as possible to ensure maximum oil movement
during cleanup procedure.
1 Suction Wand
9. Fill hydraulic oil reservoir to operating level. See

Check Hydraulic System Oil Level. (Operators
Manual.)
3. Install JDG10712 Super Caddy suction wand (1) and

discharge wand (2) into the reservoir as shown.
4. Secure wands to prevent them from coming out of
reservoir during cleaning process.
5. Cover the wands and reservoir openings with a plastic
tarp to prevent contamination.
10. Run machine at slow idle. Operate each circuit

a minimum of 2 minutes in each direction to flush
any remaining contaminants back through hydraulic
system filters.
11. Stop engine. Install Super Caddy to machine as
before.
CAUTION: Prevent possible personal injury

from unexpected machine movement. Clear all
persons from area before operating machine.
12. Repeat Super Caddy operation procedure until

contaminant value is at specifications per Super
Caddy operators manual or see Super Caddy in
Service ADVISOR for operating procedure.
Avoid entanglement and possible electrocution

from filter caddy power cord. Do not
operate machine while filter caddy is
connected to machine.
13. When oil reaches an acceptable level of cleanliness,

disconnect Super Caddy from machine.
6. Use JDG10712 Super Caddy to remove oil

contaminants. Refer to the Super Caddy operators
manual or see Super Caddy in Service ADVISOR
for operating procedure.
14. Install new hydraulic system filters.

15. Clean and Install reservoir breather.
7. When cleaning process is done, disconnect Super

Caddy from machine.
8. Make sure machine is parked in an area that will allow
all hydraulic functions to be operated.
NOTE: Instrument cleanliness and clean work practices

are critical when taking oil samples. Dust, wind,
and moisture, as well as contaminated sample
pumps, bottles, and tubing, can affect results.
TM11813 (13OCT10)
2 Discharge Wand
2121601
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Hydraulic System
16. Obtain oil sample for fluid analysis. Oil sample must be
taken from system before oil passes through the filter
when oil is warm. See Fluid Analysis Program Test
Kits and 3Way Coolant Test Kit. (Operators Manual.)
18. Return machine to service.
17. Fill hydraulic oil reservoir to proper operating level.

See Check Hydraulic System Oil Level and see
Hydraulic System Oil. (Operators Manual.)
Service ADVISOR is a trademark of Deere & Company
BR98087,00000B3 1918AUG102/2
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Hydraulic System
Hydraulic Component Failure Cleanup

Procedure
Fan Variable Speed and Reversing ManifoldSee
This procedure is to be used on machines that have

had a system catastrophic component failure. Cleanup
procedure must be done prior to starting machine after a
component has been repaired or replaced. The use of
attachments increases the need to monitor and filter oil to
a safe contamination value.
IMPORTANT: Intermixing of oils can cause

premature hydraulic component damage
and oil contamination. Oil types and Super
Caddy filters must not be intermixed. Use
super caddy filter element in same type oil
to avoid intermixing of oils.
Oil contamination could result if Super Caddy

is used in dusty or wet conditions. Clean work
practices and cleanliness of filter caddy and
attachments are critical when filtering oil.
NOTE: Filter oil should be at 27C (80F) or above for

best Super Caddy performance. Reduce flow
rate to filter oil below 27C (80F).
Super Caddy requires a 20amp electric circuit. Use

of electrical extension cord is not recommended.


2. Remove hydraulic reservoir. See Hydraulic Reservoir

IMPORTANT: To prevent hydraulic system

contamination, after cleaning, disassembling,
and assembling each hydraulic component,
store component in a dry, dustfree area
until installation.
3. Clean hydraulic reservoir completely.
4. Remove each hydraulic component from the machine.

Disassemble, clean, inspect, and assemble each
component, working one circuit at a time. Repair or
replace damaged components.
Main Hydraulic PumpSee Hydraulic Pump

Priority ValveSee Priority Valve Remove and
Priority ValveSee Priority Valve Disassemble and
Hydraulic AttenuatorSee Hydraulic Attenuator
Fan Variable Speed and Reversing ManifoldSee
Fan Variable Speed and Reversing Manifold

Hydraulic Fan MotorSee Hydraulic Fan Motor
Hydraulic ReservoirSee Hydraulic Reservoir
Hydraulic Fan and Cooling Loop PumpSee
Hydraulic Fan and Cooling Loop Pump Remove and
Blade Lift CylinderSee Blade Lift Cylinder Remove
Boom or Arch CylinderDual Function
GrappleSee Boom or Arch Cylinder Remove and
InstallDual Function Grapple. (Group 3860.)
Grapple Tong CylinderSee Grapple Tong Cylinder
Grapple Rotate MotorSee Grapple Rotate Motor
Disassemble. (Group 3860.)
Pilot Operated Control ValveSee Pilot Operated
Control Valve Remove and Install. (Group 3860.)
Dual Function Pilot Operated Control ValveSee
Dual Function Pilot Operated Control Valve
Control Valve Relief ValvesSee Control Valve
Relief Valves Remove and Install. (Group 3860.)
Lift Check ValveSee Lift Check Valve Disassemble
and Assemble. (Group 3860.)
Nonadjustable Circuit Relief ValveSee
Nonadjustable Circuit Relief Valve Disassemble and
Adjustable Circuit Relief ValveSee Adjustable
Circuit Relief Valve Disassemble and Assemble.
(Group 3860.)
Spool ValveSee Spool Valve Disassemble and
DetentSee Detent Disassemble and Assemble.
(Group 3860.)
Pilot Operated ValveSee Pilot Operated Valve
Solenoid Operated ValveSee Solenoid Operated
Grapple RotateSee Grapple Rotate Solenoid
Grapple RotateSee Grapple Rotate Solenoid
Valve Disassemble and Assemble. (Group 3860.)
Flow DividerSee Flow Divider Repair. (Group
3860.)
Rotary ManifoldSee Rotary Manifold Remove and
Rotary ManifoldSee Rotary Manifold Disassemble
Park Brake Solenoid ValveSee Park Brake
Solenoid Valve Repair. (Group 1160.)
Service Brake ValveSee Service Brake Valve
Service Brake ValveSee Service Brake Valve
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Service Brake AccumulatorSee Service Brake
Accumulator Remove and Install. (Group 1060.)

Steering ValveSee Steering Valve Remove and
Steering ValveSee Steering Valve Disassemble
Steering CylinderSee Steering Cylinder Remove
Transmission Charge PumpSee Transmission
Charge Pump Remove and Install. (Group 0360.)
Transmission Charge PumpSee Transmission
Charge Pump Drive Repair. (Group 0360.)
Transmission Control ValveSee Transmission
Control Valve Repair. (Group 0360.)
Differential Lock Solenoid ValveSee Differential
Lock Solenoid Valve Repair. (Group 0260.)
IMPORTANT: Disconnect hydraulic hoses and lines

from all tee fittings before cleaning. Cleaning
sponge will become trapped in hose and lines
as it passes through a tee fitting.
5. Disconnect and label all hydraulic hoses and lines.
Close open fittings using caps and plugs. See
Hydraulic System Component Location. (Group
902515.)
IMPORTANT: Airborne debris can cause premature
hydraulic component failure. After hoses and
lines are cleaned, close all openings with caps

and plugs to minimize additional contamination.
6. Clean all hydraulic hoses and lines using JDG1770
Ultra Clean Hose Kit.
NOTE: During installation, fill hydraulic components,
hoses, and lines with clean hydraulic oil where
possible to prevent a dry startup.
7. Install all cleaned hydraulic components, hoses, and
lines.
8. Install new hydraulic oil filters. See Replace Hydraulic
Oil Filter. (Operators Manual.)
9. Install new hydraulic oil breather filter. See Replace
Hydraulic Reservoir Breather Filter. (Operators
Manual.)
10. With all components installed, fill reservoir to proper
level. See Check Hydraulic Oil Level. (Operators
Manual.)
11. Remove air from hydraulic system.
12. Remove residual oil contaminants using JDG10712
Super Caddy. Perform General Oil Cleanup
SW03989,0000B25 1907OCT102/2
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Hydraulic System
Hydraulic Pump Remove and Install

IMPORTANT: Test main pump for leakage before
starting repair. If pump does not pass the
test, replace it. DO NOT rebuild it.

2. Operate all hydraulic control valves to release
pressure in hydraulic system. Depress brake pedal at
1second intervals 20 times to drain oil from service
brake accumulator.
Hydraulic Pump Hose and Lines

Manual.)

(Operators Manual.)
7. Disconnect hydraulic hose and lines (13). Close all
8. Disconnect wire harness at electrical connector (4).
Hydraulic Pump Remove or Install
9. Support pump with lifting strap. Remove cap screws

(5) to remove pump.
Specification
Hydraulic PumpWeight
(approximate).................................................................................. 40 kg
90 lb
1 Case DraintoReservoir
Hose
2 Supply Line
3 PumptoPrioity Valve Line
10. Inspect and replace pump as necessary.

TM11813 (13OCT10)
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IMPORTANT: Always replace Orings and seals.

Damaged or used Orings will leak.
11. Replace Oring (6) on pump flange.
NOTE: Hydraulic pump has a spline coupler that couples
the pump to transmission charge pump.
12. Inspect spline coupler (7). Install on torque converter
spline shaft.
13. Install hydraulic pump to torque converter.
IMPORTANT: The hydraulic pump must be filled with

oil to prevent pump damage at startup.
14. Connect pumptoprioity valve line using a new Oring
at face seal. Tighten to specification.
Specification
Line Mounting Cap
ScrewTorque............................................................................120 Nm
89 lbft
Hydraulic Pump Flange ORing
15. Fill supply and case drain ports with hydraulic oil. See
Hydraulic System Oil. (Operators Manual.)
16. Connect case drain hose.
17. Connect supply line using a new Oring at face seal.
Tighten to specification.
Specification
Line Mounting Cap
ScrewTorque............................................................................120 Nm
89 lbft

(Operators Manual.)
(Operators Manual.)

procedure. See Hydraulic Oil Warmup Procedure.
(Group 9025.)
22. Stop engine and check for leaks.
23. Check hydraulic reservoir oil level. See Check
Hydraulic System Oil Level. (Operators Manual.)
Coupler
6 ORing
7 Coupler

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Hydraulic System
Priority Valve Remove and Install


brake accumulator.
Priority Valve

(Operators Manual.)
1 Hydraulic Line to Main

Control Valve
2 Hydraulic Line to Steering
Valve
3 Hydraulic Line From
Hydraulic Pump

(Operators Manual.)
6. Tag and remove hydraulic lines (15). Close all
7. Remove vacuum if used.
8. Remove cap screws (6) to remove priority valve.
9. Inspect and repair or replace parts as necessary. See
Priority Valve Disassemble and Assemble. (Group
2160.)
4 Hydraulic Line to Hydraulic

Reservoir
5 Hydraulic Line to
Secondary Steering Valve

(Operators Manual.)
10. Secure priority valve with cap screws. Tighten

securely.
17. Start engine and allow to run at slow idle for several
minutes.
11. Apply vacuum if hydraulic reservoir was not drained.
12. Install hydraulic lines.


(Operators Manual.)

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Hydraulic System
Priority Valve Disassemble and Assemble

1. Remove priority valve from machine. See Priority
2. Disassemble parts (210) from housing (1).

3. Clean and inspect parts. Replace as necessary.
4. Check length of spring (4). Replace if not to
specification.
Specification
SpringLength
(approximate)................................................................................ 62 mm
2.4 in.
Priority Valve Disassembled
IMPORTANT: Always replace Orings. Damaged

or used Orings will leak.
1 Housing
2 Spool
3 Orifice (2 used)
4 Spring
5 Plug
5. Install new Orings.

6. Lubricate all parts with clean hydraulic oil and
assemble.
7. Tighten orifices (3) to specification.
Specification
OrificesTorque.................................................................. 7.39.7 Nm
6585 lbin.
6 ORing
7 Relief Valve Cartridge
8 ORing
9 Plug
10 ORing
Specification
Relief Valve
CartridgeTorque................................................................. 3454 Nm
2540 lbft
8. Tighten plugs (5 and 9) to specification.

Specification
PlugTorque......................................................................... 5481 Nm
4060 lbft
10. Install priority valve. See Priority Valve Remove and

9. Tighten relief valve cartridge (7) to specification.

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Hydraulic System
Hydraulic Attenuator Remove and Install


brake accumulator.
(Operators Manual.)
(Operators Manual.)
Hydraulic Attenuator Remove and Install
6. Remove hydraulic line (1) and hydraulic hose (3) from

hydraulic attenuator (5). Close all openings using
caps and plugs.
1 Hydraulic Line
3 Hydraulic Hose
4 Retaining Clamp (2 used)

5 Hydraulic Attenuator
7. Remove cap screws (2) from retaining clamps (4).

Remove hydraulic attenuator.
8. Install hydraulic attenuator, retaining clamps, and cap
screws.
9. Install hydraulic line and hose.
(Operators Manual.)

15. Start machine and allow hydraulic oil to reach
operating temperature. See Hydraulic Oil Warmup
16. Stop machine and check hydraulic oil level. See Check

(Operators Manual.)
SW03989,0000B20 1905OCT101/1
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Hydraulic System

Remove and Install

onesecond intervals 20 times to drain oil from service
brake accumulator.

3. Turn battery disconnect switch to OFF position.


1910.)
2
3
1
2
TX1080592 UN05AUG10
TX1080592
Fan Manifold Remove and Install
1 Solenoid Electrical Connector 2 Hydraulic Hose (4 used)
(2 used)
6. Disconnect wiring harness from solenoid electrical

connectors (1).
14. Connect wiring harness to solenoid electrical

connectors.
7. Apply vacuum to hydraulic reservoir.

1910.)
8. Tag and disconnect hydraulic hoses (2). Close all

10. Inspect and replace components, as necessary.
See Fan Variable Speed and Reversing Manifold
11. Install fan manifold with cap screws. Tighten securely.
13. Remove vacuum from hydraulic reservoir.
16. Turn battery disconnect to ON position.

19. Check reversing fan operation before returning
machine to service. See Complete Machine
Operational Checkout. (Operators Manual.)
SW03989,0000A98 1906OCT101/1
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1. Remove fan manifold. See Fan Variable Speed and
Reversing Manifold Remove and Install. (Group 2160.)
2
4
4
5
TX1081043 UN18AUG10
4
8
4
4
6
TX1081043

1 Solenoid Valve (2 used)
2 Check Valve (4 used)
3 Orifice
4 Plug (5 used)
2. Disassemble and assemble.
5 Pressure Relief Valve

6 Solenoid Valve Coil (2 used)
7 Nut (2 used)
8 Valve Manifold
3. Install fan manifold. See Fan Variable Speed and

Reversing Manifold Remove and Install. (Group 2160.)
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Hydraulic System
Hydraulic Fan Motor Remove and Install


4. Remove fan blade. See Fan Blade Remove and
5. Remove both side grille housing access panels.
6. Remove upper air baffle enclosure. See Air Baffle


brake accumulator.
Fan Motor Mounting

1 Fan Reversing Manifold
toFan Motor Hose (2 used)
2 Fan Motor Case Drain Hose
7. Disconnect and identify fan reversing manifoldtofan

motor hoses (1). Close all openings using caps and
plugs.
8. Disconnect fan motor case drain hose (2). Close all
9. Remove cap screws (3) securing hydraulic fan motor
to mounting bracket.
10. Remove hydraulic fan motor from machine.
IMPORTANT: Installing hydraulic fan motor hoses

backwards will cause engine overheating.
13. Connect fan reversing manifoldtofan motor hoses.
14. Connect fan motor case drain hose.
15. Install fan blade. See Fan Blade Remove and Install.
(Group 0510.)
16. Install both upper air baffle panels. See Air Baffle

12. Install hydraulic fan motor to mounting bracket using
cap screws.
17. Install both side grille housing access panels.

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20. Check operation of hydraulic fan motor. See Complete

Machine Operational Checkout. (Operators Manual.)
MH66088,0000D93 1906OCT102/2
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Hydraulic System
Hydraulic Reservoir Remove and Install

Manual.)




1910.)

brake accumulator.
IMPORTANT: Clean all dirt and debris from

hydraulic reservoir before removing fill cap
or disconnecting hoses. Contamination
introduced into the hydraulic system can lead
to premature equipment failure.
(Operators Manual.)
TX1080622 UN06AUG10
TX1080622
Hydraulic Reservoir Bottom View
1 Hydraulic Oil Temperature
Sensor Connector
2 Wire Harness
8. Disconnect wire harness (2) from hydraulic oil

temperature sensor connector (1).
NOTE: Hoses may vary depending on machine options.
9. Tag and disconnect hydraulic hoses from bottom of

hydraulic reservoir. Close all openings using caps and
plugs.
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NOTE: Do not disconnect hoses or wire connectors.

10. Remove transmission filter (3), breather (5), and
grapple valve bracket (6).
6 Grapple Valve Bracket
3 Transmission Filter
5 Breather
Breather, Transmission Filter, and Grapple Valve Mounting

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11. Loosen band clamps (10). Disconnect cooling loop

filter hose (8) and hydraulic return filter hose (9) from
reservoir.
12. Disconnect chain slings (11) and set hoses aside.
13. Remove service accumulator. See Service Brake
Accumulator Remove and Install. (Group 1060.)
11 Chain Sling (2 used)
13 Nut (2 used)
TX1080623 UN06AUG10
8 Cooling Loop Filter Hose

9 Hydraulic Return Filter
Hose
10 Band Clamp (2 used)
TX1080624 UN06AUG10
Cooling Loop and Hydraulic Return Filter Hoses
Hose Chain Slings

TM11813 (13OCT10)
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Hydraulic System

14. Attach hoist and chains to reservoir using JT01748
lifting bracket (14) and M12 lifting eyebolt (15).
Specification
Hydraulic
ReservoirWeight
(approximate).................................................................................. 60 kg
132 lb.
15. Remove hydraulic reservoir support (16) from machine

frame (17).
16. Lift hydraulic reservoir from machine.
Hoist, Chain, Lifting Brackets
18. Install fittings on hydraulic reservoir, if removed.

19. Attach hoist and chains to reservoir using JT01748
Lifting Brackets.
Specification
Hydraulic
ReservoirWeight
(approximate).................................................................................. 60 kg
132 lb.
TX1080626 UN06AUG10
20. Install hydraulic reservoir on frame.

21. Install chain slings and service brake accumulator.
See Service Brake Accumulator Remove and Install.
(Group 1060.).
22. Install transmission filter, grapple valve bracket, and
breather.
23. Install cooling loop and hydraulic return filter hoses.
Hydraulic Reservoir Support Mounting
24. Replace hydraulic oil return filters. See Replace

Hydraulic Oil Filter and see Replace Hydraulic Cooler
Filter. (Operators Manual.)
14 JT01748 Lifting Bracket (2

used)
15 M12 Lifting Eyebolt
16 Hydraulic Reservoir
Support
17 Machine Frame
19 Nut (6 used)
25. Install hoses to hydraulic reservoir.

26. Connect wire harness to hydraulic oil temperature
sensor connector.

(Group 9025.)

(Operators Manual.)
32. Stop engine. Check for leaks.

1910.)
(Operators Manual.)

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Hydraulic System
SW03989,0000A9A 1905OCT105/5
Hydraulic Fan and Cooling Loop Pump

Remove and Install
Manual.)
3. Install a vacuum pump on hydraulic reservoir to
minimize leakage.

4. Disconnect hoses from pump. Close all openings with
caps and plugs.
5. Remove cap screws (1) and washers and remove
pump.
2 Pump Outlet
3 Cooling Loop Pump

4 Pump Inlet
SW03989,0000B2E 1906OCT101/2

7. Install drive coupler and Oring on cooling loop pump.

8. Install cooling loop pump.
9. Connect hose to pump inlet.
IMPORTANT: Pump must be filled with oil prior to
startup to prevent pump damage.
10. Fill pump with oil through pump outlet. See
Transmission, Park Brake, Differential, Cab Tilt
Hydraulic Pump and Winch Oil. (Operators Manual.)
11. Connect hose to pump outlet.
3 Cooling Loop Pump

5 ORing
6 Drive Coupler
12. Remove vacuum pump from hydraulic tank.

16. Check for leaks.


(Operators Manual.)
15. Check operation of reversing fan. See Operational
Checkout. (Group 900510.)
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Contents
Section 30
Winch
Page

Winch 4000 Series Remove and
Install ..................................................... 3030001
Fastening Cable to Winch
Drum4000 Series ............................... 3030005
Winch Free Spool Drag
Adjustment............................................. 3030007
Winch 6000 Series Remove and
Install ..................................................... 3030008
Fastening Cable to Winch
Drum6000 Series ............................. 30300010
Group 3015Control Linkage
Winch Control Valve Linkage
Winch Control Cable Remove and
Install ..................................................... 3030152
Winch Drive Shaft Remove and
Install ..................................................... 3030251
Winch Drive Shaft Disassemble
and Assemble........................................ 3030251
Group 3050Drive and Clutch
Winch 4000 Series Drive and
Clutch Repair......................................... 3030501
Winch 6000 Series Drive and
Clutch Repair......................................... 3030501
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Group 3000
Winch 4000 Series Remove and Install
NOTE: Cable must be removed from winch
before servicing.

4
in hydraulic system. Depress brake pedal at 1second
TX1080905 UN16AUG10

Winch Yoke Control Cable and Drive Yoke

1 Pressure Inlet Line
2 Drive Yoke

Manual.)
5. Remove winch drive shaft. See Winch Drive Shaft
3 Yoke Control Cable

4 Return Oil Line
8. Disconnect and remove control cable.
6. Disconnect winch yoke control cable (3).

TM11813 (13OCT10)
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9. Remove guards.
10. Label and disconnect hydraulic lines (712).
11. Remove fittings (13).
12. Disconnect grapple lowering valve (14).

13. Remove fuel tank mounting cap screws and slide
fuel tank rearward as far as possible. See Fuel Tank
14. Remove winch mounting cap screws.
10 Boom Retract Line
11 Boom Extend Line
12 Grapple Rotate Line
13 Fitting (6 used)
14 Grapple Lowering Valve
Winch Guard

6 Guard (2 used)
7 Arch Retract Line
8 Arch Extend Line
9 Grapple Rotate Line
Hydraulic Connections
Grapple Lowering Valve

TM11813 (13OCT10)
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15. Attach lifting chains to winch as shown.

T7516AV UN05JUN91
16. Remove winch.

Specification
WinchWeight
(approximate)................................................................................ 630 kg
1390 lb.
Shown with Cable Removed

SW03989,0000A9D 1905OCT103/5
NOTE: If winch is to be stored or reinstalled without

disassembly, do not drain oil.
If winch is to be disassembled, drain oil using
drain plug on left side of cover.
17. Remove plug (16) to drain oil. See Change Winch
OilIf Equipped. (Operators Manual.)
18. Inspect and repair winch as necessary. See 40 and
4000 Winches. (CTM25.)
17 Return Line Cap
15 Fill Plug
16 Drain Plug
Winch 4000 Oil Plugs

TM11813 (13OCT10)
3030003
SW03989,0000A9D 1905OCT104/5
748H Repair (S.N. 630436

)
101310
PN=297
19. Clean grease, dirt, oil, and paint from mounting holes.
T7516AV UN05JUN91
20. Install winch.

Specification
WinchWeight
(approximate)................................................................................ 630 kg
1390 lb.
21. Tighten mounting cap screws to specification.

Specification
Equipment Frame
toWinch Cap
ScrewTorque............................................................................620 Nm
455 lbft
22. Position fuel tank and install mounting cap screws.

See Fuel Tank Remove and Install. (Group 0560.)
23. Install fittings to mounting bracket.
Shown with Cable Removed

IMPORTANT: Oil capacity for winch is greater than
transmission oil capacity. Check transmission
oil level frequently while filling to avoid
transmission pump cavitation.
NOTE: Power In position will deliver 7.89.5 L (221/2
gal) per minute to fill winch. Free Spool position
will take approximately 1/2 hour to fill winch.

25. Install guards.
(Operators Manual.)
27. Connect and adjust control cable yoke. See Winch
Control Valve Linkage Remove and Install or see
Winch Control Cable Remove and Install. (Group
3015.)
28. Install winch drive shaft. See Winch Drive Shaft
31. Operate winch in either Power In or Free Spool

position to finish filling winch. Check transmission oil
level frequently and add oil through the transmission
dipstick. See Check Transmission Oil Level.
(Operators Manual.)
32. Install cable. See Fastening Cable to Winch
Drum4000 Series. (Group 3000.)
29. Fill winch with recommended oil. See Change Winch

SW03989,0000A9D 1905OCT105/5
TM11813 (13OCT10)
3030004
748H Repair (S.N. 630436

)
101310
PN=298
CAUTION: Prevent possible injury from cable

wire. Wear gloves when handling cable to
protect hands from cable wire cuts. DO NOT
guide cable on winch with your hands.
IMPORTANT: If a ferruled cable is used, the drum
plug (3) must be installed to prevent cable
from bending cable slot.
1. Attach cable to winch drum using one of the following
methods:
Fastening Cable to Winch Drum4000 Series
Method 1: Attach a ferrule or cable clamp (1) to end

of cable.
2. Wrap cable around the drum. Slide the ferrule or
cable clamp under the cable and into slot in drum, and
secure with tab (2).
3. Adjust free spool drag to operators preference.
NOTE: Factory free spool drag setting was done
without cable adjust free spool drag to operators
preference when cable is added.
NOTE: Ten inch drum only has pocket method of
locating ferrule cable to drum.
3 Drum Plug
1 Cable Clamp
2 Tab
TM11813 (13OCT10)
3030005
GD61784,00000B1 1902JUL071/3
748H Repair (S.N. 630436

)
101310
PN=299
IMPORTANT: If cable is unwound below one turn

on drum, cable will come off drum.
1. Method 2: Remove drum plug (2).
2. Thread cable up through small hole and insert cable
back down through lower hole. Pull loop into drum.
2 Drum Plug
TM11813 (13OCT10)
3030006
GD61784,00000B1 1902JUL072/3
748H Repair (S.N. 630436

)
101310
PN=300
1. Method 3: Remove drum plug.

2. Thread cable up through small hole and wrap cable
around wedge (1). Insert cable back down through
lower hole and pull wedge into drum slot (2).
2 Drum Slot
1 Wedge
GD61784,00000B1 1902JUL073/3
Winch Free Spool Drag Adjustment
NOTE: The winch drum drag can be adjusted to

operators preference.
1. Start engine.
2. Lower equipment to ground.
4. Block wheels.
5. Move winch control handle to FREE SPOOL position.
6. Loosen nut (1).
4000 Winch
7. Adjust slotted shaft (2) to desired winch drum drag.

8. Tighten nut.
2 Slotted Shaft
1 Nut
6000 Winch
GD61784,00000B2 1902JUL071/1
TM11813 (13OCT10)
3030007
748H Repair (S.N. 630436

)
101310
PN=301
Winch 6000 Series Remove and Install

NOTE: Cable must be removed from winch
before servicing.
TX1080950 UN17AUG10
4. Remove cotter pin and pin (2) to disconnect yoke.

5. Remove cap screws (3) and washers to remove
mounting bracket and winch control cable.
6. Remove cap screws to disconnect winch driveline (5).
Pin, Cap Screws, and Winch Input Yoke
8. Drain winch oil. See Change Winch OilIf Equipped.

(Operators Manual.)
1 Pressure Inlet Line

2 Pin
TM11813 (13OCT10)
3030008
4 Return Oil Line

5 Driveline
SW03989,0000A9E 1905OCT101/2
748H Repair (S.N. 630436

)
101310
PN=302
9. Fasten lifting chain around winch as shown and

connect chain to a hoist.
10. Remove front and rear winch mounting cap screws.
11. Lift winch off equipment frame.
Specification
WinchWeight
(approximate)................................................................................ 780 kg
1720 lb
12. Inspect and repair winch as necessary. See 60 and

6000 Winches. (CTM41.)
T7533AX UN09JUL91
13. Install winch.

Specification
WinchWeight
(approximate)................................................................................ 780 kg
1720 lb
14. Install front and rear mounting cap screws and tighten
to specification.
Specification
Winch Mounting Cap
ScrewTorque............................................................................620 Nm
455 lbft

16. Connect winch driveline. Install and tighten cap
Specification
Winch CrosstoYoke
43 lbft
17. Install control cable mounting bracket and washers,

and tighten cap screws.
18. Install and adjust control cable. See Winch Control
Valve Linkage Remove and Install or see Winch
Control Cable Remove and Install. (Group 3015.)
19. Connect yoke to valve. Install pin and cotter pin.
Chain Around Winch

IMPORTANT: Oil capacity for winch is greater than
transmission oil capacity. Check transmission
oil level frequently while filling to avoid
transmission pump cavitation.
NOTE: Power In position will deliver 7.89.5 L (221/2
gal) per minute to fill winch. Free Spool position
will take approximately 1/2 hour to fill winch.
22. Operate the winch in either Power In or Free Spool
position to fill winch. Check transmission oil levels
frequently when filling winch. See Check Transmission
23. Install cable. See Fastening Cable to Winch
Drum6000 Series. (Group 3000.)
20. Fill winch with recommended oil. See Change Winch

SW03989,0000A9E 1905OCT102/2
TM11813 (13OCT10)
3030009
748H Repair (S.N. 630436

)
101310
PN=303
CAUTION: Prevent possible personal injury from

cutting wire. Wear gloves when handling cable
to protect hands from cable wire cuts. DO NOT
1. Insert cable end through small hole (3) of nibble (1).
2. Separate cable end so wedges (2) are positioned tight
against cable wires (4). Pull cable tight against nibble.
3 Small Hole in Nibble
4 Cable Wires
1 Nibble
2 Wedge (2 used)
Fastening Cable to Winch Drum6000 Series
GD61784,00000B4 1902JUL071/2
3. Lay cable in winch drum slot and install tab (5) tight
against drum.
5 Tab
GD61784,00000B4 1902JUL072/2
TM11813 (13OCT10)
30300010
748H Repair (S.N. 630436

)
101310
PN=304
TM11813 (13OCT10)
30300011
748H Repair (S.N. 630436

)
101310
PN=305
Group 3015
Control Linkage
T131308 UN01JUN00
Winch Control Valve Linkage Remove and Install
TM11813 (13OCT10)
3030151
GD61784,00000B5 1902JUL071/2
748H Repair (S.N. 630436

)
101310
PN=306
Control Linkage
1 Pin (4000 Winch3 used)
2 Yoke
3 Pin (4000 Winch3 used)
4 Nut
5 Bracket
6 Bracket
7 Washer (3 used)
8 Nut (3 used)
9 Spacer (2 used)
11 Control Cable
23 Boot
24 Clip (6 used)
25 Ring
27 Washer (2 used)
28 Plate
29 Bracket
30 Strap (2 used)
31 UBolt
32 Cap Screw
33 Lock Nut (2 used)

13 Clamp (2 used)
14 Spring
15 Strap
16 Strap (2 used)
17 Bellcrank
18 Bushing
19 Bolt
21 Bushing
22 Knob
1. Remove worn or damaged parts and replace as

necessary.
34 Ball Joint
35 Washer (3 used)
36 Nut
37 Lock Nut
38 Wedge
39 Lever
40 Ball Joint
41 Nut
43 Washer (2 used)
44 Label
2. Apply one drop of medium strength thread lock and

sealer to threads of ball joint (40).
GD61784,00000B5 1902JUL072/2
Winch Control Cable Remove and Install

1. Remove old cable.
3. Install ball joint (34) six turns.

4. Secure the lever to the right rear of the BRAKE OFF
slot.
5. Push cable winch end IN to remove slack. Measure
from end of cable to center of mounting groove
and adjust ball joint (34) until distance (A) is to
specification.
Specification
End of CabletoCenter
of Mounting
GrooveDistance....................................................................... 159 mm
6.250 in.
6. Install cable through frame and attach bracket (6),

strap (15), clamp (13), bushing (21) and cap screws
(20) on winch.
7. Install spring (14), washer (7), nut (4) and yoke (2) on
winch end of cable.
T129676B UN04APR00
T7711AG UN13MAR92
2. Install new cable into cab. Install straps (30), Ubolt

(31), and lock nuts (33).
AEnd of CabletoCenter of
Mounting Groove Distance
TM11813 (13OCT10)
3030152
GD61784,00000B6 1902JUL071/5
748H Repair (S.N. 630436

)
101310
PN=307
Control Linkage
IMPORTANT: Winch valve must be in FREE SPOOL

position to correctly adjust linkage.
8. Push winch valve spool IN, as far as possible, into
FREE SPOOL position.
T7402AE UN06NOV90
9. With the 4000 winch bellcrank or 6000 winch valve

spool in free spool position, pull cable with 44.5 N (10
lbforce).
Specification
Cable Pull (Free Spool
Position)Force.............................................................................44.5 N
10 lbforce
On 4000 Series winch only, apply 22.2 N (5 lbforce)

to bellcrank toward cable end.
Specification
4000 Series Winch (Only)
BellcrankForce............................................................................22.2 N
5 lbforce
10. Adjust the 4000 winch yoke to align with hole in

bellcrank. Adjust the 6000 winch yoke to align with
valve spool.
11. Connect the yoke to the 4000 winch bellcrank (or 6000
winch valve spool) and install pin.
GD61784,00000B6 1902JUL072/5
12. Move control lever to BRAKE ON (hold) position.

13. Slide bracket (A) so that lip contacts spring.
14. Tighten bracket and control cable cap screws.
T113917 UN13APR98
ABracket
T7402AI UN26NOV90
4000 Series Winch
6000 Series Winch

TM11813 (13OCT10)
3030153
GD61784,00000B6 1902JUL073/5
748H Repair (S.N. 630436

)
101310
PN=308
Control Linkage
T7374AY 1930OCT90
15. Run engine at slow idle.
T7374AZ 1930OCT90
16. Move control lever to FREE SPOOL position and

release lever. There must be 35 mm (0.1200.160
in.) distance between lever and stop screw.
Specification
Control LevertoStop
Screw (Free Spool
Position)Distance....................................................................35 mm
0.1200.160 in.
NOTE: It is normal for engine to pull down when

POWER IN is first engaged. This valve
sequencing is to prevent winch brake from
dropping load before clutch engages.
17. Slowly move control lever to POWER IN position until
drum turns. There must be 68 mm (0.2400.320
in.) distance between lever and stop screw. Adjust
as required.
18. While POWER IN is engaged, release lever. Lever

must return to BRAKE ON (hold) when released from
any POWER IN position. If lever does not return,
increase return spring tension as described earlier in
this procedure.
Specification
Control LevertoStop
Screw (Power In
Position)Distance....................................................................68 mm
0.2400.320 in.
GD61784,00000B6 1902JUL074/5
19. Move winch control lever to free spool position.
T7374AY 1930OCT90
T7397AZ 1930OCT90
20. Pull lever rearward with specified force, then move

lever to left side.
Specification
Winch Control Lever
(Rearward Pull)Force..................................................................22.2 N
5 lbforce
Lever must move freely through the gate and not rub
against rear of right slot or front of left slot. If lever
rubs slot gate, readjust winch cable yoke as described
earlier in this procedure.
GD61784,00000B6 1902JUL075/5
TM11813 (13OCT10)
3030154
748H Repair (S.N. 630436

)
101310
PN=309
Control Linkage
TM11813 (13OCT10)
3030155
748H Repair (S.N. 630436

)
101310
PN=310
Group 3025
Winch Drive Shaft Remove and Install

3. Remove guards in frame pivot area as necessary to
gain access to winch drive shaft.
4. Remove cap screws (1) on each end of drive shaft.
5. Remove drive shaft. Inspect and replace parts as
necessary.
6. Install drive shaft with male yoke end (2) toward

transmission and female yoke end (3) toward winch.
Specification
AssemblytoYoke Cap
ScrewTorque...................................................................... 5157 Nm
3842 lbft
AssemblytoYoke Cap
ScrewTorque.................................................................. 127142 Nm
94105 lbft
8. Remove articulation locking bar

joint)
2 Male Yoke End
3 Female Yoke End
AC12469,0000420 1930JUL071/1
Winch Drive Shaft Disassemble and Assemble

1. Disassemble parts (15).
3. Assemble parts.
1
2
4. Tighten cap screws (5).
4
3
Specification
Winch Drive Shaft

Cross and Bearing
AssemblytoYoke 3/8 in.
43 lbft
1
1
TX1024077 UN04JUN07
2. Inspect for excessively worn or damaged parts.

Replace parts as necessary.
Drive Shaft
5. Lubricate shaft after installation on machine.

2 Drive Shaft
3 Cross and Bearing
Assembly (2 used)
SW03989,0000A9C 1906AUG101/1
TM11813 (13OCT10)
3030251
748H Repair (S.N. 630436

)
101310
PN=311
TM11813 (13OCT10)
3030252
748H Repair (S.N. 630436

)
101310
PN=312
Group 3050
Drive and Clutch
Winch 4000 Series Drive and Clutch Repair
For winch repair, go to the appropriate repair story using
the table of contents in component technical manual.
(CTM25.)
GD61784,00000BF 1903JUL071/1
Winch 6000 Series Drive and Clutch Repair

For winch repair, go to the appropriate repair story using
the table of contents in component technical manual.
(CTM41.)
GD61784,00000C0 1903JUL071/1
TM11813 (13OCT10)
3030501
748H Repair (S.N. 630436

)
101310
PN=313
Drive and Clutch
TM11813 (13OCT10)
3030502
748H Repair (S.N. 630436

)
101310
PN=314
Section 32
Stacking Blades
Contents
Page
Group 3201Blades
Stacking Blade Remove and
Install ..................................................... 3232011
Spherical Bushing Remove and
Install ..................................................... 3232015
Blade Control Linkage Remove
and Install .............................................. 3232151
Blade Control Valve Remove and
Install ..................................................... 3232152
Blade Lift Cylinder Remove and
Install ..................................................... 3232601
TM11813 (13OCT10)
321
748H Repair (S.N. 630436

)
101310
PN=1
Contents
TM11813 (13OCT10)
322
748H Repair (S.N. 630436

)
101310
PN=2
Group 3201
Blades
Stacking Blade Remove and Install
1. Lower all equipment to the ground. Operate all control
levers to relieve pressure in the hydraulic system.
T195555B UN21OCT03
NOTE: One front wheel must be removed before

stacking blade pin can be removed.
2. Remove one front wheel. See Wheel Remove and
Right Stacking Blade Cylinder
3. Support blade cylinder using lifting straps.

Specification
Blade CylinderWeight
(approximate).................................................................................. 35 kg
77 lb
1 Cylinder Pin
2 Retainer
3 Cap Screw
4. Remove cap screws and retainers (2 and 3) and

cylinder pins (1) to disconnect right and left blade
cylinders.
TM11813 (13OCT10)
3232011
GD61784,0000031 1910MAR091/5
748H Repair (S.N. 630436

)
101310
PN=317
TX1056819 UN06MAR09
Blades
TX1056819
Exploded View of Stacking Blade
4 Stacking Blade
5 Bushing
7 Cap Screw
8 Bushing
9 Washer
10 Seal
11 Washer
12 Cap Screw
13 Pin
14 Lock Nut
8. Remove lock nut (14) and cap screw (12).

9. Remove pin (13) and stacking blade (4).
5. Support stacking blade (4).
10. Inspect stacking blade for cracks or damage.
Specification
Stacking BladeWeight
(approximate).............................................................................. 1360 kg
3000 lb
11. Inspect spherical bushings in cylinder bores and blade

pivot bores for wear or damage. If a bushing must be
replaced, see Spherical Bushing Remove and Install.
(Group 3201.)
6. Lower bottom guard.

TM11813 (13OCT10)
3232012
GD61784,0000031 1910MAR092/5
748H Repair (S.N. 630436

)
101310
PN=318
T8509AC UN19JUN95
Blades
Blade Lower Pin
TM11813 (13OCT10)
3232013
GD61784,0000031 1910MAR093/5
748H Repair (S.N. 630436

)
101310
PN=319
Blades
AWasher (as required)
BShim (as required)
CEngine Frame
DSeal Washer
EHardened Washer
F Cap Screw
GBlade Pin Cap

Washer
H36 mm (0.1200.240 in.)
Clearance Dimension
12. Install stacking blade with washers properly positioned

as shown.
13. Replace lubrication fittings if necessary.
14. Apply medium strength thread lock and sealer to cap
screw (F).
15. Install one washer (A) on pin, then put new cap or
washer (G) on pin, and hold in place.
IMPORTANT: A minimum of 3 mm (0.120 in.) gap (H)
must be left on each side of pin to prevent a side
impact from breaking off pin cap screws.
16. Measure gap (H) between cap and washer. Install or
remove shims (B) until specified gap is obtained.
IMPORTANT: If blade is sprung so that specified

gap cannot be obtained, the blade must be
removed and pushbeams bent back until gap
specification can be obtained.
17. Install seal washer (D) on pin. Install cap or washer
(G) and washer (E).
18. Apply medium strength thread lock and sealer to cap
screw (F) and tighten to specification.
Specification
Blade Pin Cap Assembly
Cap ScrewTorque.....................................................................495 Nm
365 lbft
Specification
CaptoWasherGap.................................................................36 mm
0.1200.240 in.
GD61784,0000031 1910MAR094/5

T195568A UN21OCT03
19. Lift blade using a hoist. Install washer shims (5)

equally to each side of rod end as required so that
cylinders do not bind. Install pin (3) through cylinder,
shims and spherical bushing (4).
Specification
Stacking BladeWeight
(approximate).............................................................................. 1360 kg
3000 lb
(approximate).................................................................................. 35 kg
77 lb
20. Install cap screw (1) and retainer (2) and tighten.
21. Install front wheel. See Wheel Remove and Install.
(Group 0110.)
Cap Screw and Cylinder Pin

1 Cap Screw
2 Retainer
3 Pin
4 Spherical Bushing
5 Washer Shim (as required)
GD61784,0000031 1910MAR095/5
TM11813 (13OCT10)
3232014
748H Repair (S.N. 630436

)
101310
PN=320
Blades
Spherical Bushing Remove and Install

1. If bushing (A) in blade pivot bore must be replaced,
remove washer (B) using a grinder to remove weld.
BWasher
T7502HJ UN02JUL91
ABushing
GD61784,0000032 1930MAY071/3
2.
Remove bushing (B). See DFT1099 Bushing Drivers.

(Group 9900.)
DWasher
ENut
T7569AM UN09JUL91
APipe Assembly
BSpherical Bushing
CPipe Assembly
TM11813 (13OCT10)
3232015
GD61784,0000032 1930MAY072/3
748H Repair (S.N. 630436

)
101310
PN=321
Blades
3. Install bushing. See DFT1099 Bushing Drivers.

(Group 9900.)
4. Turn nut (F) until center line (B) of bushing aligns with
center line (C) of frame.
5. Weld new washers in place at the same location

where old ones were removed.
See Make Welding Repairs Safely. (Group 900001.)
T7569AL UN09JUL91
CAUTION: Have only a qualified welder do the

welding. Be sure the area near the machine is
free of debris and flammable material. Before
welding, clean all dirt and paint from weld
area. Disconnect the battery negative cable.
Connect the welder ground clamp as close
as possible to each weld area.
APipe Assembly
BBushing Center Line
CFrame Center Line
DBar Stock
EWasher
F Nut
See Remove Paint Before Welding or Heating. (Group

900001.)
GD61784,0000032 1930MAY073/3
TM11813 (13OCT10)
3232016
748H Repair (S.N. 630436

)
101310
PN=322
Group 3215
Controls Linkage
TX1056821 UN06MAR09
Blade Control Linkage Remove and Install
TX1056821
Blade Control Linkage
1 Shim
2 Bushing (2 used)
3 Knob
4 Control Lever
5 Boot
6 Nut
7 Washer
8 Bushing
9 Lock Nut
10 Pin
11 Spring Locking Pin

12 Rod
13 Jam Nut
14 Ball Joint
15 Boot
1. Lower blade and relieve all hydraulic pressure.

16 Boot Retainer
17 Nut
4. Clean threads of pivot ball joint (14) and apply medium

strength thread lock and sealer.
5. Adjust length of rod (12) so horizontal leg of control
lever (4) is level.
6. Clean threads of lever (4) and apply medium strength
thread lock and sealer then install knob (3).

3. Inspect and replace blade control linkage parts as
necessary.
GD61784,0000039 1906MAR091/1
TM11813 (13OCT10)
3232151
748H Repair (S.N. 630436

)
101310
PN=323
Controls Linkage
TX1056822 UN06MAR09
Blade Control Valve Remove and Install
TX1056822
Blade Control Valve
2 Rubber Mount (3 used)
3 Blade Valve Support

4 Washer (5 used)
1. Lower blade and relieve all hydraulic pressure.


6 Rod
7 Spring Lock Pin

8 Pin
3. Remove blade control valve.

5. Inspect blade control valve support and replace parts
as necessary.
6. Install blade control valve.
GD61784,000003A 1906MAR091/1
TM11813 (13OCT10)
3232152
748H Repair (S.N. 630436

)
101310
PN=324
Group 3260
Hydraulic System
Blade Lift Cylinder Remove and Install
X9811 UN23AUG88

pressure in hydraulic system.
2. Disconnect lines (5).
3. Attach hoist to blade lift cylinder using a lifting strap.
T195555A UN21OCT03
Specification
(approximate).................................................................................. 35 kg
77 lb
4. Remove cap screws and retainers (1).

5. Remove pins (2) to remove blade lift cylinder.
6. Repair or replace blade lift cylinder as required.
Wheel Removed for Illustration Purposes Only
7. Install blade lift cylinder.

1 Cap Screw and Retainer
2 Pin
3 Cap Screw
4 Hydraulic Line Guard

5 Hydraulic Lines
GD61784,0000033 1925JUL071/1
TM11813 (13OCT10)
3232601
748H Repair (S.N. 630436

)
101310
PN=325
Hydraulic System
TM11813 (13OCT10)
3232602
748H Repair (S.N. 630436

)
101310
PN=326
Contents
Section 38
Grapple
Page
Page
Group 3803Grapple Mechanism

Grapple Remove and Install ...................... 3838031
Grapple Disassemble and
Assemble............................................... 3838032
Grapple Dampener Disassemble
and Assemble........................................ 3838034
Grapple Dampener Adjustment ................. 3838036
Dampener, Yoke, and Crosshead
Pins Lubricate........................................ 3838037
Grapple Rotate Yoke Disassemble
and Assemble........................................ 3838038
Solenoid Operated Valve Remove

and Install ............................................ 38386035
Grapple Rotate Solenoid Valve
Grapple Rotate Solenoid Valve
Disassemble and Assemble ................ 38386037
Flow Divider Repair ................................. 38386038
Rotary Manifold Remove and
Install ................................................... 38386040
Rotary Manifold Disassemble and
Assemble............................................. 38386041
Group 3840Frames
Dual Function Grapple Cable
Rollers Remove and Install.................... 3838401
Dual Function Grapple Boom
Dual Function Grapple Arch
Boom or Arch Cylinder Remove
and InstallDual Function
Grapple.................................................. 3838601
Grapple Tong Cylinder Remove
and Install .............................................. 3838603
Grapple Rotate Motor Remove and
Install ..................................................... 3838605
Grapple Rotate Motor
Disassemble .......................................... 3838607
Grapple Rotate Motor Assemble ............. 38386012
Rotate Motor Drive Gear Remove
and Install ............................................ 38386020
Control Valve Options.............................. 38386020
Pilot Operated Control Valve
Dual Function Pilot Operated
Control Valve Disassemble and
Assemble............................................. 38386025
Control Valve Relief Valves
Lift Check Valve Disassemble and
Assemble............................................. 38386028
Nonadjustable Circuit Relief Valve
Adjustable Circuit Relief Valve
Spool Valve Disassemble and
Assemble............................................. 38386032
Detent Disassemble and
Assemble............................................. 38386033
Pilot Operated Valve Remove and
Install ................................................... 38386034
TM11813 (13OCT10)
381
748H Repair (S.N. 630436

)
101310
PN=1
Contents
TM11813 (13OCT10)
382
748H Repair (S.N. 630436

)
101310
PN=2
Group 3803
Grapple Mechanism
Grapple Remove and Install
2. Operate hydraulic control valves to release pressure
3. Disconnect rotary manifoldtocylinder rod end hose
(3) and rotary manifoldtoflow divider hose (4). Close
4. Disconnect shock absorber (2) from rotary yoke.

5. Remove grapple by removing pins (1).
Specification
Grapple Head and
TongsWeight
(approximate)...............................................................................1134 kg
2500 lb
Grapple Remove and Install
6. Inspect and repair as necessary. See Grapple

1 Pin (2 used)
2 Shock Absorber

7. Install grapple using pins.
Specification
Grapple Head and
TongsWeight
(approximate)...............................................................................1134 kg
2500 lb
3 Rotary ManifoldtoCylinder
Rod End Hose
4 Rotary ManifoldtoFlow
Divider Hose
8. Connect shock absorber to rotary yoke. Tighten nut

snug, then back off 1/2 turn.
9. Connect rotary manifold hoses to cylinder rod end and
flow divider.
SW03989,0000AA4 1902SEP101/1
TM11813 (13OCT10)
3838031
748H Repair (S.N. 630436

)
101310
PN=329
Grapple Mechanism
TX1081371 UN03SEP10
Grapple Disassemble and Assemble
Grapple Components
TM11813 (13OCT10)
3838032
SW03989,0000AA5 1903SEP101/2
748H Repair (S.N. 630436

)
101310
PN=330
Grapple Mechanism
1 Top Cover (2 used)
3 Grapple Frame
4 Shim (2 used)
5 Shim (4 used)
6 Bushing (2 used)
7 Washer (2 used)
9 Grapple Pin (2 used)
10 Tong Pin (2 used)
11 Washer (2 used)
12 Washer (2 used)

IMPORTANT: The pins that attach the head end of
the cylinder also attach the opposite tong to
the frame. Tong cylinders should be removed
one at a time to prevent both grapple tongs
from falling out of the frame.
1. Disassemble parts as shown. See Grapple Tong
Cylinder Remove and Install for removal procedure.
(Group 3860.)

14 Bushing (4 used)
15 Cylinder Rod Pin (2 used)
16 Bushing (2 used)
17 Washer (2 used)
19 Nut (2 used)
21 Tong (2 used)
22 Tooth (2 used)
Grapple Head
FrameWeight
(approximate).................................................................................115 kg
254 lb
Grapple TongWeight
(approximate).......................................................................104194 kg
230428 lb
2. Inspect for worn or damaged parts. Replace parts as

necessary.
3. Assemble parts. Install all washers in the same
locations and quantities as removed.
Specification
Grapple Head and
TongsWeight
(approximate)...............................................................................1134 kg
2500 lb
SW03989,0000AA5 1903SEP102/2
TM11813 (13OCT10)
3838033
748H Repair (S.N. 630436

)
101310
PN=331
Grapple Mechanism
T131307 UN01JUN00
Grapple Dampener Disassemble and Assemble
Grapple Dampener
TM11813 (13OCT10)
3838034
SW03989,0000AA6 1902SEP101/2
748H Repair (S.N. 630436

)
101310
PN=332
Grapple Mechanism
1 Plug (6 used)
2 Spring (6 used)
3 Washer (18 used)
4 Snap Ring
5 ORing
6 ORing
7 Housing
8 Bushing
9 ORing
10 Plug
11 Shaft
12 ORing
13 Snap Ring
14 Bushing
16 Plate (6 used)
17 Disk (5 used)
18 Cotter Pin
19 Pin
20 Pin
21 Washer
22 Cap Screw
23 Lock Nut
24 Shock Absorber Cylinder
assembled, this plate must be installed next to

the springs. Installing this galled plate next to a
friction element will damage the friction element.

1. Remove grapple using a suitable lifting device. See
Grapple Remove and Install. (Group 3803.)
25 Washer
27 Bushing (2 used)
28 Grapple Dampener Housing
29 Pin
30 Spacer
31 Washer
32 Cap Screw
NOTE: If any friction material remains on disks (17),

they are considered usable.
6. Grease plates and disks with a clean coat of grease
containing 35% moly. Wipe off excess grease.
2. Remove grapple dampener using a suitable lifting

device.
7. Install Orings (9 and 12), shaft, and snap ring (13)

into housing.
Specification
Grapple Damp
enerWeight (approxi
mate)............................................................................................. 105 kg
231 lb
8. Alternately install plates and disks, ensuring that the

galled steel plate is toward springs.
NOTE: Install snap ring (4) with gap located at
12 oclock position. Snap ring helps retain
grease inside the housing.
3. Remove plugs (1), washers (3), and springs (2).

4. Push housing (7) inward to remove snap ring (4).
5. Remove plates (16), disks (17), shaft (11), and snap
ring (13) from grapple dampener housing (28). Inspect
for wear or damage.
9. Install Orings (5 and 6) into housing. Push housing

into grapple dampener housing to install snap ring (4)
with snap ring gap at 12 oclock position.
10. Adjust dampener. See Grapple Dampener Adjustment.
(Group 3803.)
IMPORTANT: The plate located next to springs (2) will

show normal wear or galling. When dampener is
SW03989,0000AA6 1902SEP102/2
TM11813 (13OCT10)
3838035
748H Repair (S.N. 630436

)
101310
PN=333
Grapple Mechanism
Grapple Dampener Adjustment

The grapple dampener limits the motion of the grapple
head when traveling empty and prevents damage to the
structural components, especially the yoke, crosshead,
and pins.
Adjust the dampener if the head swings to extreme
heights or hits the stops. Adjust the dampener by
adding or subtracting the number of shim washers in the
dampener assembly.
1. Slightly loosen adjusting plugs (1) (every other plug or
all six plugs) evenly to remove spring tension and to
keep housing from rotating.
2. Remove three plugs.
3. Remove one shim washer (2) from each of the three

plugs to tighten grapple dampener, or add one shim
washer to each plug to loosen.
4. Apply 35% moly grease to adjusting plug thread and
the inside of plugs. Tighten plugs evenly until plugs
contact shim washers.
5. Repeat for other three plugs. Be sure that all plugs
have an equal number of shims.
TEST CONDITIONS:
NOTE: The grapple head should be 1015 from vertical
under the following test conditions.
Adjusting Plugs and Shim Washer
a. Close tongs and raise the grapple arch or boom to

full height.
b. Lower the arch or boom slowly and bring to a
smooth stop when the tongs are approximately 300
mm (12 in.) above the ground.
c. When properly adjusted, the grapple head will be
1015 from vertical. Measure with a magnetic
base inclinometer (3).
IMPORTANT: The snap ring gap is positioned at
vertical top to maintain the grease level in the
dampener housing. Retain this position while
tightening plugs by holding the dampener
housing with a pry bar.
Do not add any washers to the inside of the

adjusting plugs in an attempt to tighten the
dampener assembly. This will cause the
springs to become a solid member. Damage
to the outer dampener housing will result.
If additional dampening is required after all
shim washers are removed, it is necessary
to replace the disks inside the dampener
assembly. See your authorized dealer.
Magnetic Base Inclinometer
6. If additional tightness is required, remove shim

washers from plugs with the greatest number of shim
1 Plug (6 used)
washers. If additional looseness is required, add
2 Shim Washer (up to 24
shim washers to plugs with the least number of shim
used)
washers. Repeat steps 14 until desired tightness
is achieved.
TM11813 (13OCT10)
3838036
3 Magnetic Base Inclinometer
SW03989,0000AA7 1902SEP101/2
748H Repair (S.N. 630436

)
101310
PN=334
Grapple Mechanism
7. To hold dampener housing in place, use a pry bar

between plugs. Tighten plugs to specification.
Specification
Grapple Dampener
Adjusting PlugTorque...............................................................184 Nm
250 lbft
SW03989,0000AA7 1902SEP102/2
Dampener, Yoke, and Crosshead Pins

Lubricate
IMPORTANT: If dampener spline grease fitting (4)

is not greased at proper intervals, premature
spline failure could occur.
If grease fitting does not accept grease, make
sure the grapple head is on the ground before
attempting to lubricate again.
NOTE: Lubricate the four fittings until grease
escapes at joints.
Lubricate fittings until clean grease escapes at joints. For
grease specification, see Grease. (Operators Manual.)
4 Dampener Spline Grease
Fitting
5 Brake Plate Grease Fitting
6 Dampener Brake Assembly
TX1019054 UN12MAR07
1 Top Locating Point

2 Bushing Next to Dampener
Assembly Grease Fitting
3 Dampener Head Outer
Bushing Grease Fitting
Dampener, Yoke and Crosshead Pins
T102161 UN22JUL96
Cross Section of Upper Dampener Pin
Lower Pin
SW03989,0000AA8 1902SEP101/1
TM11813 (13OCT10)
3838037
748H Repair (S.N. 630436

)
101310
PN=335
Grapple Mechanism
Grapple Rotate Yoke Disassemble and Assemble
10
12
11
TX1051670
TX1051670 UN20FEB09
Grapple Rotate Yoke

1 Grapple Yoke
2 Bushing
3 Spacer
7 Upper Bearing Race

8 Upper Bearing Cone
9 Shim (as required)
4 Seal
5 Lower Bearing Cone
6 Lower Bearing Race
1. Remove grapple. See Grapple Remove and Install.

(Group 3803.)
8. Clean all mating surfaces.

9. Install spacer (3) tight against shoulder of grapple
yoke.
2. Remove grapple crosshead. See Grapple Dampener

10. Install seal (4) in spacer groove.
3. Remove rotary manifold. See Rotary Manifold

CAUTION: Prevent possible burn injury.

Hot equipment and fluids can cause burns
to unprotected skin. Wear gloves and
protective clothing when working with hot
equipment and fluids.

4. Support the grapple yoke (1) using appropriate lifting
device.
IMPORTANT: Damage to the bearing may occur

use proper heating device.
Specification
Grapple YokeWeight
(approximate).................................................................................. 54 kg
119 lb
IMPORTANT: Use new cap screws to install grapple

yoke to prevent cap screw failure.
5. Remove and discard cap screws (12).
6. Remove parts (111).
10 Shim (as required)

11 Rotate Motor Driven Gear
12 Cap Screw (12 or 14 used)
11. Heat lower bearing cone (5) to specification.

Specification
Lower Bearing
ConeTemperature......................................................................... 78C
175F
12. Install bearing cone with large end toward spacer.

Bearing cone must be tight against spacer.

TM11813 (13OCT10)
3838038
SW03989,0000AA9 1915SEP101/9
748H Repair (S.N. 630436

)
101310
PN=336
Grapple Mechanism
13. Install upper and lower bearing races (6 and 7).

Bearing races must be tight against housing.
TX1056637 UN05MAR09

14. Install and support grapple yoke into arch or boom
(13).
Specification
Grapple YokeWeight
(approximate).................................................................................. 54 kg
119 lb
Bearing Races
CAUTION: Prevent possible burn injury.

Hot equipment and fluids can cause burns
to unprotected skin. Wear gloves and
protective clothing when working with hot
equipment and fluids.
IMPORTANT: Damage to the bearing may occur
use proper heating device.
15. Heat upper bearing cone (8) to specification.

Specification
Upper Bearing
ConeTemperature......................................................................... 78C
175F
14
TX1081181 UN25AUG10
13
Grapple Yoke
16. Install upper bearing cone.

1 Grapple Yoke
6 Lower Bearing Race
7 Upper Bearing Race
17. Turn grapple yoke so the pivot pin bore (14) is 90 to

arch or boom (13) as shown.
TM11813 (13OCT10)
3838039
13 Arch or Boom
14 Pivot Pin Bore
SW03989,0000AA9 1915SEP102/9
748H Repair (S.N. 630436

)
101310
PN=337
Grapple Mechanism
18. Install rotate motor driven gear (11) so cutout (17) is

aligned with rotate motor drive gear (15). Align two 4
mm holes (16) as shown.
15
11
19. Install four cap screws (12) 90 apart as shown from

top.
15 Rotate Motor Drive Gear
16
12
16 Hole (4 mm) (2 used)

17 Cutout
12
TX1081182 UN25AUG10
17
12
16
12
Cap Screw Location (12 cap screw yoke)
15
11
16
12
12
12
16
12
TX1081183 UN25AUG10
17
Cap Screw Location (14 cap screw yoke)

TM11813 (13OCT10)
38380310
SW03989,0000AA9 1915SEP103/9
748H Repair (S.N. 630436

)
101310
PN=338
Grapple Mechanism
IMPORTANT: Bearing cones and bearing races

must be properly seated to maintain proper
bearing preload. Bearing failure may result
from improper bearing preload.
20. Grapple Yoke Bearing Preload Measurement:
a. Tighten cap screws in order shown to specification.
Specification
GeartoYoke Cap
ScrewTorque..............................................................................41 Nm
30 lbft
1
4
b. Tighten cap screws again in order shown to

specification.
TX1056258 UN23FEB09
3
2
Specification
GeartoYoke Cap
ScrewTorque..............................................................................81 Nm
60 lbft
c. Tighten cap screws again in order shown to

specification.
Cap Screw Tighten Order (12 cap screw yoke)
Specification
GeartoYoke Cap
ScrewTorque............................................................................122 Nm
90 lbft
d. Rotate grapple yoke ten revolutions. Tighten cap

screws in order shown to specification.
Specification
GeartoYoke Cap
ScrewTorque............................................................................170 Nm
125 lbft
1
4
TX1056256 UN23FEB09
e. Rotate grapple yoke a second time ten revolutions.

Tighten cap screws again in order shown to
specification.
Specification
GeartoYoke Cap
ScrewTorque............................................................................170 Nm
125 lbft
f. Rotate grapple yoke a third time ten revolutions.

specification.
Specification
GeartoYoke Cap
ScrewTorque............................................................................170 Nm
125 lbft
g. Rotate grapple yoke a fourth time ten revolutions.

specification.
Specification
GeartoYoke Cap
ScrewTorque............................................................................170 Nm
125 lbft
TM11813 (13OCT10)
38380311
SW03989,0000AA9 1915SEP104/9
748H Repair (S.N. 630436

)
101310
PN=339
Grapple Mechanism
21. Measure distance from top surface of rotate motor

driven gear to grapple yoke through both 4 mm holes
using a depth micrometer.
18
19
20
Record the average distance measurement from both

holes.
11

22. Support yoke.

Specification
Grapple YokeWeight
(approximate).................................................................................. 54 kg
119 lb
23. Remove rotate motor driven gear.
TX1081184 UN25AUG10
24. Measure rotate motor driven gear thickness (20) at

both locations as shown.
Record the average thickness measurement from
both locations.
NOTE: The formula for this procedure is: A B +
0.33 mm (0.013 in.) = C.
25. Subtract the average thickness of the rotate motor
driven gear (B) from the average distance from the top
surface of the gear to the yoke (A). This is the shim
pack thickness (C).
Shim Pack Measurement
Add 0.33 mm (0.013 in.) to gap difference to obtain

shim pack dimension for bearing preload.
11
26. Arrange shims in shim pack so thickest shims are on

outside of shim pack.
18 Shim Pack Thickness
Thickness
20 Top of Gear to Yoke
16
19
19
16
19
19
TX1081185 UN25AUG10
1 Grapple Yoke
Rotate Motor Driven Gear Measurement

TM11813 (13OCT10)
38380312
SW03989,0000AA9 1915SEP105/9
748H Repair (S.N. 630436

)
101310
PN=340
Grapple Mechanism
27. Verify grapple yoke is positioned so pivot pin bore is

90 to arch or boom as shown.
28. Install shim pack.
14 Pivot Pin Bore
14
TX1081181 UN25AUG10
1 Grapple Yoke
13 Arch or Boom
13
Grapple Yoke
TM11813 (13OCT10)
38380313
SW03989,0000AA9 1915SEP106/9
748H Repair (S.N. 630436

)
101310
PN=341
Grapple Mechanism
29. Install rotate motor driven gear so the long

measurement of cutout is aligned with rotate motor
drive gear. Align two 4 mm holes as shown.
15 Rotate Motor Drive Gear
15
11

17 Cutout
16
12
TX1081187 UN25AUG10
17
16
Rotate Driven Gear Cap Screw Location (12 cap screw yoke)
15
11
13
16
12
TX1081188 UN25AUG10
17
16
Rotate Driven Gear Cap Screw Location (14 cap screw yoke)
TM11813 (13OCT10)
38380314
SW03989,0000AA9 1915SEP107/9
748H Repair (S.N. 630436

)
101310
PN=342
Grapple Mechanism
IMPORTANT: Use new cap screws to install grapple

yoke to prevent cap screw failure.
30. Rotate Motor Driven Gear Torque Procedure:
a. Tighten cap screws in order shown to specification.
Specification
GeartoYoke Cap
ScrewTorque..............................................................................41 Nm
30 lbft
11
Specification
12
GeartoYoke Cap
ScrewTorque..............................................................................81 Nm
60 lbft
6
10
TX1056259 UN24FEB09
b. Tighten cap screws again in order shown to

specification.
c. Tighten cap screws again in order shown to

specification.
Specification
GeartoYoke Cap
ScrewTorque............................................................................122 Nm
90 lbft
d. Rotate grapple yoke ten revolutions. Tighten cap

screws in order shown to specification.
13
e. Rotate grapple yoke a second time ten revolutions.

specification.
11
12
8
5
14
f. Rotate grapple yoke a third time ten revolutions.

specification.
Specification
GeartoYoke Cap
ScrewTorque............................................................................170 Nm
125 lbft
10
Specification
GeartoYoke Cap
ScrewTorque Turn....................................60 (1 flat on hex cap screw)
TM11813 (13OCT10)
Specification
GeartoYoke Cap
ScrewTorque............................................................................170 Nm
125 lbft
g. Mark each cap screw. Tighten cap screws in order

shown to specification.
TX1056262 UN23FEB09
Specification
GeartoYoke Cap
ScrewTorque............................................................................170 Nm
125 lbft
38380315
SW03989,0000AA9 1915SEP108/9
748H Repair (S.N. 630436

)
101310
PN=343
Grapple Mechanism
31. Pump grease into arch tube grease fitting (21) while
rotating the grapple yoke until grease comes out from
under driven gear teeth all around gear.
32. Install rotary manifold. See Rotary Manifold Remove
33. Install grapple crosshead. See Grapple Dampener
13
21
IMPORTANT: Grapple dampener must be adjusted

properly. Improper grapple dampener
adjustment may cause bearing damage.
1
35. Perform grapple dampener adjustment. See Grapple
Dampener Adjustment. (Group 3303.)
1 Grapple Yoke
13 Arch
21 Grease Fitting
TX1081189 UN25AUG10
34. Install grapple. See Grapple Remove and Install.

(Group 3803.)
Yoke Grease Fitting Location

SW03989,0000AA9 1915SEP109/9
TM11813 (13OCT10)
38380316
748H Repair (S.N. 630436

)
101310
PN=344
Group 3840
Frames
Dual Function Grapple Cable Rollers Remove and Install
17 13
12
14
13
8
3
5
2
15
11
17
1
7
10
10
7
4
T195678 UN24OCT03
16
T195678
Dual Function Grapple Cable Rollers
1 Nut (4 used)
Lubrication Fitting (4 used)
5 Washer (2 used)
6 Washer (2 used)
7 Washer (4 used)
8 Horizontal Roller
9 Vertical Roller (2 used)
11 Roller Frame
13 Bushing (2 used)
14 Shaft
15 Strap
16 Shaft (2 used)
17 Washer (2 used)
1. Remove rollers (8 and 9).
3. Install bushings even with end surface of rollers.
2. Inspect bushings (13) and shafts (14 and 16) for wear
or damage.
4. Install rollers.
GD61784,00000C5 1905JUL071/1
TM11813 (13OCT10)
3838401
748H Repair (S.N. 630436

)
101310
PN=345
Frames
Dual Function Grapple Boom Remove and

Install

2. Inspect boom for cracks.
IMPORTANT: Have only a qualified welder do the
area. Disconnect the battery ground () cable.
3. Weld any cracks using E7018 electrodes or equivalent.
900010.)
Boom
1 Boom
2 Boom Cylinder Pin (2 used)
3 Boom Pin (2 used)

4. Remove Grapple. See Grapple Remove and Install.

(Group 3803.)
13. Install boom.

14. Install boom pins.

15. Install boom cylinder pins.
5. Support boom (1).
16. Install hydraulic hoses in boom.
6. Remove grapple motor. See Grapple Rotate Motor

7. Remove rotary manifold. See Rotary Manifold
8. Remove hydraulic hoses from boom.
17. Install rotary manifold. See Rotary Manifold Remove

18. Install grapple motor. See Grapple Rotate Motor
9. Remove boom cylinder pins (2).
19. Install grapple. See Grapple Remove and Install.

(Group 3803.)
10. Remove boom pins (3).
11. Remove boom.

GD61784,00000C6 1925JUL071/1
TM11813 (13OCT10)
3838402
748H Repair (S.N. 630436

)
101310
PN=346
Frames
Dual Function Grapple Arch Remove and

Install

2. Inspect arch for cracks.
IMPORTANT: Have only a qualified welder do the
area. Disconnect the battery ground () cable.
3. Weld any cracks using E7018 electrodes or equivalent.
900010.)
4. Remove boom. See Dual Function Grapple Boom
5. Support arch.
Arch
1 Arch
2 Arch Cylinder Pin (2 used)
3 Arch Pin (2 used)

10. Install arch.
11. Install arch pins.
12. Install arch cylinder pins.
6. Remove arch cylinder pins (2).
13. Install boom. See Dual Function Grapple Boom

7. Remove arch pins (3).
8. Remove arch (1).

GD61784,00000C7 1925JUL071/1
TM11813 (13OCT10)
3838403
748H Repair (S.N. 630436

)
101310
PN=347
Frames
TM11813 (13OCT10)
3838404
748H Repair (S.N. 630436

)
101310
PN=348
Group 3860
Hydraulic System
Boom or Arch Cylinder Remove and
InstallDual Function Grapple
1. Lower grapple to the ground.

Arch Cylinder Remove and Install

1 second intervals 20 times to drain oil from service
brake accumulator.
5. Disconnect arch cylinder hydraulic hoses (2) or boom
cylinder hydraulic hoses (5). Close all openings using
caps and plugs.
6. Connect lifting strap to arch cylinder (3) or boom
cylinder (6).
Specification
Boom CylinderWeight
(approximate).................................................................................. 66 kg
145 lb
Arch CylinderWeight
(approximate).................................................................................. 62 kg
137 lb
7. Remove pins (1) to remove arch cylinder.

8. Remove pins (4) to remove boom cylinder.
9. Inspect bushings for looseness, wear, or damage.
Remove bushings only if replacement is necessary.
See Spherical Bushing Remove and Install. (Group
3201.)
Boom Cylinder Remove and Install

1 Pin (4 used)
2 Arch Cylinder Hydraulic
Hose (4 used)
3 Arch Cylinder (2 used)
10. Repair hydraulic cylinder as necessary. For additional

information, see 120 Series Hydraulic Cylinders.
(CTM114319.)
11. Install arch cylinder or boom cylinder and pins.
Specification
Boom CylinderWeight
(approximate).................................................................................. 66 kg
145 lb
Arch CylinderWeight
(approximate).................................................................................. 62 kg
137 lb
NOTE: Fill hydraulic cylinder with hydraulic oil

before connecting hoses to prevent damage
to Orings and seals.
12. Connect arch cylinder hydraulic hoses or boom
cylinder hydraulic hoses.
TM11813 (13OCT10)
4 Pin
5 Boom Cylinder Hydraulic
Hose (4 used)
6 Boom Cylinder (2 used)
3838601
SW03989,0000AB0 1905OCT101/2
748H Repair (S.N. 630436

)
101310
PN=349
Hydraulic System

(Group 9025.)


SW03989,0000AB0 1905OCT102/2
TM11813 (13OCT10)
3838602
748H Repair (S.N. 630436

)
101310
PN=350
Hydraulic System
Grapple Tong Cylinder Remove and Install
10
4
3
11
TX1081258 UN01SEP10
TX1081258
Grapple Tong Cylinder Removal and Installation
1 Frame
3 Top Cover (2 used)
4 Tong Pin (2 used)

5 Washer (2 used)

8 Spacer (2 used)
9 Washer (2 used)
1. Close grapple and lower to the ground.
onesecond intervals 20 times to drain oil from service

brake accumulator.


5. Remove top cover (3). Disconnect hose at tong
cylinder (11) head end. Close all openings using caps
and plugs.

6. Disconnect hose at tong cylinder rod end. Close all



TM11813 (13OCT10)
10 Cylinder Rod Pin (2 used)

11 Tong Cylinder (2 used)
3838603
SW03989,0000AB1 1904OCT101/2
748H Repair (S.N. 630436

)
101310
PN=351
Hydraulic System
7. Connect lifting strap to tong cylinder.
Specification
Tong CylinderWeight
(approximate).................................................................................. 66 kg
146 lb
8. Remove cap screw (7), washer (9), and spacer (8)

from cylinder rod pin (10). Remove cylinder rod pin.
CAUTION: The pin that attaches the cylinder head
end also attaches the opposite tong. Cylinders
should be removed one at a time to prevent both
grapple tongs from falling out of the frame.
9. Remove cap screw (6) and washer (5). Use either
another pin or round bar stock that is slightly smaller in
diameter and approximately equal to the width of the
grapple frame in length to drive out the tong pin and
still hold the tong in place.
For some grapple head and tong configurations, it
is only necessary to push out the pin far enough to
disconnect the head end of the cylinder from the
grapple frame.
10. Remove tong cylinder.
12. Install tong cylinder into frame (1).

Specification
Tong CylinderWeight
(approximate).................................................................................. 66 kg
146 lb
13. Install tong pin and cylinder rod pin. Install spacer,
washers, and cap screws.
15. Install top cover.
(Group 9025.)
11. Inspect and repair tong hydraulic cylinder as

necessary. For additional information, see 120 Series
Hydraulic Cylinders. (CTM114319.)
SW03989,0000AB1 1904OCT102/2
TM11813 (13OCT10)
3838604
748H Repair (S.N. 630436

)
101310
PN=352
Hydraulic System
TX1081257 UN01SEP10
Grapple Rotate Motor Remove and Install
Grapple Rotate Motor Removal and Installation

1 Grapple Rotate Motor
2 Rotate Hose from Grapple
Rotate Solenoid Valve
3 Case Drain Hose to Tank

4 Rotate Hose from Grapple
Rotate Solenoid Valve
1. Lower grapple to the ground.

5 Case Drain Hose from Rotate 7 Washer (2 used)

Manifold

1 second intervals 20 times to drain oil from service
brake accumulator.
5. Remove rotate motor cover from top of boom.
6. Tag and disconnect hoses. Close all openings using
caps and plugs.
TM11813 (13OCT10)
3838605
SW03989,0000AB2 1903SEP101/2
748H Repair (S.N. 630436

)
101310
PN=353
Hydraulic System

rotate motor.
Specification
Grapple Rotate
MotorWeight
(approximate).................................................................................. 25 kg
55 lb
10. Install cap screws and washers. Tighten cap screws

to specification.
Specification
86105 lbft
11. Connect hoses.

(Group 9025.)


9. Install rotate motor.

Specification
Grapple Rotate
MotorWeight
(approximate).................................................................................. 25 kg
55 lb
17. Install rotate motor cover.
SW03989,0000AB2 1903SEP102/2
TM11813 (13OCT10)
3838606
748H Repair (S.N. 630436

)
101310
PN=354
Hydraulic System
Grapple Rotate Motor Disassemble

Check the shaft and key slot, and remove all
nicks, burrs, or sharp edges that might damage
the bearing housing seals when installing the
shaft and bearing assembly.
Before starting the disassembly procedures,
drain the oil from inside the motor.
T214865 UN21SEP05
NOTE: Cleanliness is extremely important when repairing

a hydraulic motor. Work in a clean area. Before
disconnecting the lines, clean the port area
of the motor thoroughly. Use a wire brush to
remove foreign material and debris from around
the exterior joints of the motor.
TM11813 (13OCT10)
3838607
SW03989,0000AB3 1901OCT101/12
748H Repair (S.N. 630436

)
101310
PN=355
Hydraulic System
Grapple Rotate Motor Components

1 Shaft Exclusion Seal
2 Bearing Housing
3 Backup Ring
4 Shaft Seal
5 Bearing and Shaft
SubAssembly
6 Seal
7 Shaft Face Seal
8 Splined Drive
9 Wear Plate
10 Seal
11 Geroler SubAssembly
12 Seal
13 Valve Plate
14 Valve Drive
15 Valve
16 Balance Ring
17 Outer Face Seal

18 Pin (2 used)
19 Spring (2 used)
20 Inner Face Seal
21 Seal
22 Plug with ORing
23 Valve Housing
24 Name Plate
25 Washer (4 used)
26 Tie Bolt (4 used)
27 ORing (2 used)
28 Relief Valve (2 used)
29 ORing (2 used)
30 Cap (2 used)
SW03989,0000AB3 1901OCT102/12
1. Place motor upright in vise with output shaft down.

Clamp across mounting flange of bearing housing (2).
Excessive clamping pressure will cause distortion.
When clamping, use some protective device on vise,
such as special soft jaws, pieces of hard rubber or
board.
T214867 UN21SEP05
NOTE: Although not all drawings show motor in vise,

we recommend that you keep motor upright in
vise during disassembly and reassembly.
Motor in Vise
SW03989,0000AB3 1901OCT103/12
2. Remove four tie bolts (26) and washers (25) from

motor.
TX1081255 UN01SEP10
25 Washer (4 used)
Remove Tie Bolts and Washers

TM11813 (13OCT10)
3838608
SW03989,0000AB3 1901OCT104/12
748H Repair (S.N. 630436

)
101310
PN=356
Hydraulic System
3. Lift valve housing (23) straight up. If done carefully,

the pins (18), springs (19), balance ring assembly
(16), and valve (15) will remain on the valve plate (13).
4. Carefully remove seal (21) from valve housing.
23 Valve Housing
TX1081254 UN01SEP10
21 Seal
Remove Valve Housing and Seal

SW03989,0000AB3 1901OCT105/12
5. Remove case drain plug with Oring (22) from valve

housing.
6. Remove relief valves (26) and Orings (27 and 29)
from valve housing. Inspect and clean relief valves.
Replace Orings and install relief valves.
29 ORing (2 used)
30 Cap (2 used)
TX1081253 UN01SEP10
22 Case Drain Plug with

Oring
27 ORing (2 used)
Remove Plug and Relief Valves

TM11813 (13OCT10)
3838609
SW03989,0000AB3 1901OCT106/12
748H Repair (S.N. 630436

)
101310
PN=357
Hydraulic System
7. Remove two pins (18) and springs (19) from balance

ring assembly (16).
8. Remove balance ring assembly.
TX1081252 UN01SEP10
9. Remove inner and outer face seals (17 and 20) from
balance ring.
10. Remove valve (15).
15 Valve
16 Balance Ring
17 Outer Face Seal
18 Pin (2 used)
19 Spring (2 used)
20 Inner Face Seal
Remove Balance Ring, Face Seals, and Valve
SW03989,0000AB3 1901OCT107/12
11. Remove valve plate (13).

12. Remove seal (12) from valve plate.
12 Seal
13 Valve Plate
TX1081251 UN01SEP10
13. Remove valve drive (14).

14 Valve Drive
Remove Valve Plate, Seal, and Valve Drive

SW03989,0000AB3 1901OCT108/12
14. Remove geroler subassembly (11).

15. Remove splined drive (8).
TX1081250 UN01SEP10
8 Splined Drive
Remove Geroler SubAssembly and Splined Drive

TM11813 (13OCT10)
38386010
SW03989,0000AB3 1901OCT109/12
748H Repair (S.N. 630436

)
101310
PN=358
Hydraulic System
16. Remove seal (10) from wear plate (9).

17. Remove wear plate.
18. Remove shaft face seal (7) from wear plate.
2 Bearing Housing
6 Seal
7 Shaft Face Seal
TX1081249 UN01SEP10
19. Remove seal (6) from bearing housing.

9 Wear Plate
10 Seal
Remove Wear Plate and Seals

SW03989,0000AB3 1901OCT1010/12
20. Remove bearing and shaft subassembly (5) from

bearing housing. Use press, if necessary.
5 Bearing and Shaft

SubAssembly
TX1081248 UN01SEP10
NOTE: Individual parts of shaft and bearing subassembly

are not sold separately. Replace as a unit.
2 Bearing Housing
Remove Bearing and Shaft SubAssembly

SW03989,0000AB3 1901OCT1011/12
21. Use a small screwdriver to remove shaft seal (4),

backup ring (3), and shaft exclusion seal (1) from
bearing housing.
3 Backup Ring
4 Shaft Seal
TX1081247 UN01SEP10

2 Bearing Housing
Remove Exclusion Seal and Shaft Seal

SW03989,0000AB3 1901OCT1012/12
TM11813 (13OCT10)
38386011
748H Repair (S.N. 630436

)
101310
PN=359
Hydraulic System
T214865 UN21SEP05
Grapple Rotate Motor Assemble
Grapple Rotate Motor Components
TM11813 (13OCT10)
38386012
SW03989,0000AB4 1901OCT101/13
748H Repair (S.N. 630436

)
101310
PN=360
Hydraulic System
2 Bearing Housing
3 Backup Ring
4 Shaft Seal
5 Bearing and Shaft
SubAssembly
6 Seal
7 Shaft Face Seal
8 Splined Drive
9 Wear Plate
10 Seal
12 Seal
13 Valve Plate
14 Valve Drive
15 Valve
16 Balance Ring
17 Outer Face Seal

18 Pin (2 used)
19 Spring (2 used)
20 Inner Face Seal
21 Seal
22 Plug with ORing
23 Valve Housing
24 Name Plate
NOTE: Check all mating surfaces. Replace any parts that

have scratches or burrs that could cause leakage.
Clean all metal parts in clean solvent. Blow dry
with air. Do not wipe dry with cloth or paper
towel because lint or other matter can get in the
hydraulic system and cause damage.
Do not use a coarse grit or try to file or
grind these parts.
Check around chamfered area of the shaft for burrs,

nicks or sharp edges that can damage the seals
when reassembling the bearing housing.
NOTE: Lubricate all seals, prior to installation,
with petroleum jelly . Use new seals when
reassembling this motor.
TM11813 (13OCT10)
25 Washer (4 used)
27 ORing (2 used)
29 ORing (2 used)
30 Cap (2 used)
38386013
SW03989,0000AB4 1901OCT102/13
748H Repair (S.N. 630436

)
101310
PN=361
TX1081246 UN01SEP10
Hydraulic System
Shaft Seals
1. Use a press to install shaft exclusion seal (1) in outer

bore of bearing housing (2).
TX1081247 UN01SEP10
NOTE: Lip of seal must face outward. If a press is not

available, use a plastic or rubber hammer, being
careful not to damage or cock the seal in the bore.
2. Place backup ring (3) into seal bore. Place shaft seal
(4) onto Eaton 600496 Seal Installation Tool and press
seal into seal bore of bearing housing.
3. Clamp bearing housing upright in vise.
NOTE: Although not all drawings show motor in vise,
we recommend that you keep motor upright in
vise during disassembly and reassembly.
Install Exclusion Seal and Shaft Seal

2 Bearing Housing
3 Backup Ring
4 Shaft Seal
TM11813 (13OCT10)
38386014
5 Bearing and Shaft

SubAssembly
6 Seal
7 Shaft Face Seal
9 Wear Plate
SW03989,0000AB4 1901OCT103/13
748H Repair (S.N. 630436

)
101310
PN=362
Hydraulic System
TX1081245 UN30AUG10
4. Place Eaton 600465 Protective Bullet over shaft spline

of bearing and shaft subassembly. Apply petroleum
jelly to inside diameter of exclusion seal and shaft seal.
Use press to install bearing and shaft subassembly
in bearing housing.
NOTE: Do not distort shaft seal. Damage to this
seal will cause leakage.
5. Apply small amount of petroleum jelly to seal (6) and
install into bearing housing.
2 Bearing Housing
5 Bearing and Shaft
SubAssembly
6 Seal
31 Eaton 600465 Protective
Bullet
Install Bearing and Shaft SubAssembly
SW03989,0000AB4 1901OCT104/13
6. Alignment studs (32) can be very helpful in reassembly

of the motor. If studs are used, install two studs
diagonally opposed in the bearing housing.
TX1081243 UN30AUG10
32 Alignment Stud (2 used)
Install Alignment Studs

SW03989,0000AB4 1901OCT105/13
7. Install shaft face seal (7) in wear plate (9).
16
15
8. Install wear plate onto bearing housing.

9. Apply a light film of petroleum jelly to seal (10) and
install in groove of wear plate.
16
10 Seal
14
5
6
TX1081342 UN25AUG10
7 Shaft Face Seal

9 Wear Plate
Install Wear Plate and Seals

TM11813 (13OCT10)
38386015
SW03989,0000AB4 1901OCT106/13
748H Repair (S.N. 630436

)
101310
PN=363
Hydraulic System
10. Install splined drive (8) into bearing and shaft

subassembly.
TX1081241 UN30AUG10
8 Splined Drive
Install Splined Drive

TM11813 (13OCT10)
38386016
SW03989,0000AB4 1901OCT107/13
748H Repair (S.N. 630436

)
101310
PN=364
TX1081240 UN30AUG10
Hydraulic System
Install Geroler SubAssembly and ValveSet Timing

9 Wear Plate
14 Valve Drive
15 Valve
12 Seal
13 Valve Plate
11. Align notch on outside of geroler subassembly (11)

with notch on wear plate and install.
subassembly. Align notch on outside of valve plate

with notch on geroler subassembly.
12. Install valve drive (14) in geroler subassembly.
Timing Step #2Locate slot opening in valve plate in

line with largest open pocket of geroler subassembly.

install in groove of valve plate (13).
IMPORTANT: Installation at this time involves three
steps for timing of rotate motor. Timing
determines direction of rotation of output shaft.
Timing parts include: geroler subassembly,
valve drive, valve plate and valve.
Timing Step #3 Locate any one of the side openings

of valve (15) and align this opening with open slot
of valve plate that is in line with largest open pocket
of geroler subassembly. Install valve by rotating it
clockwise until spline teeth engage (1/2 spline tooth
max.). This will provide the proper rotation when
pressurized.
14. Timing Step #1Locate largest open pocket in geroler

subassembly and mark it on outside edge of geroler
TM11813 (13OCT10)
38386017
SW03989,0000AB4 1901OCT108/13
748H Repair (S.N. 630436

)
101310
PN=365
Hydraulic System
15. Install two springs (19) and two pins (18) in holes
located in bore of valve housing (23).
18 Pin (2 used)
19 Spring (2 used)
TX1081239 UN30AUG10

install in valve housing (23).
21 Seal
23 Valve Housing
Install Pins, Springs, and Seal on Valve Housing

SW03989,0000AB4 1901OCT109/13
IMPORTANT: Install face seals in the positions shown,

or the motor will not operate properly. Do not
force or bend the face seals. Any damage to
these seals will affect the operation of the motor.
17. Apply petroleum jelly to inner and outer face seals (17
and 20). Install seals on balance ring (16) as shown.
20 Inner Face Seal
33 Pin Notch
TX1081238 UN30AUG10
16 Balance Ring
17 Outer Face Seal
Install Face Seals on Balance Ring

SW03989,0000AB4 1901OCT1010/13
18. Install balance ring assembly in valve housing. Align

pin notches (33) in balance ring with pins in bore of
valve housing.
23 Valve Housing
TX1081237 UN30AUG10
16 Balance Ring
Install Balance Ring in Valve Housing

TM11813 (13OCT10)
38386018
SW03989,0000AB4 1901OCT1011/13
748H Repair (S.N. 630436

)
101310
PN=366
Hydraulic System
19. Install valve housing on valve plate.

NOTE: Depending on valve housing model, it may
be possible to insert your finger through port
of valve housing and apply pressure to side of
balance ring. Hold ring in position until valve
housing is in place against valve plate.
After installing valve housing on valve plate, check
for proper placement. Push down on valve housing.
A slight spring action should be felt.
TX1081236 UN30AUG10
23 Valve Housing
Install Valve Housing

SW03989,0000AB4 1901OCT1012/13
20. Install washers (25) and tie bolts (26).
TX1081235 UN30AUG10
If alignment studs are used, install two tie bolts and

washers opposite studs. Finger tighten bolts. Remove
alignment studs and replace with two remaining
bolts and washers. Tighten tie bolts alternately to
specification.
Specification
Tie BoltTorque............................................................................50 Nm
450 lbin.
21. Install new Oring on plug (22) and install in valve

housing. Tighten plug to specification.
Install Tie Bolts and Plug
Specification
Case Drain
PlugTorque...................................................................................6 Nm
50 lbin.
22 Plug with ORing

25 Washer (4 used)
SW03989,0000AB4 1901OCT1013/13
TM11813 (13OCT10)
38386019
748H Repair (S.N. 630436

)
101310
PN=367
Hydraulic System
Rotate Motor Drive Gear Remove and Install

1. Remove rotate motor. See Grapple Rotate Motor
TX1081323 UN31AUG10
2. Remove bearings (1) and drive gear (2).

3. Inspect and replace if required.
4. Install bearings and drive gear.
1 Bearing (2 used)
2 Drive Gear
Bearings and Drive Gear

SW03989,0000AB5 1901OCT101/1
Control Valve Options

The dual function pilot operated control valve is comprised
of the following sections:
Inlet SectionIncludes main relief valve.

Tong SectionSolenoid operated, includes two
adjustable circuit relief valves and detent assembly.

includes two
nonadjustable circuit relief valves.
Boom SectionPilot operated, includes two
Blade SectionLink operated, includes two
Outlet Section
Arch SectionPilot operated,
4 Boom Section
5 Blade Section
6 Outlet Section
TX1081063 UN18AUG10
1 Inlet Section
2 Tong Section
3 Arch Section

SW03989,0000AC3 1930AUG101/1
TM11813 (13OCT10)
38386020
748H Repair (S.N. 630436

)
101310
PN=368
Hydraulic System
TM11813 (13OCT10)
38386021
748H Repair (S.N. 630436

)
101310
PN=369
Hydraulic System
Pilot Operated Control Valve Remove and Install
Hydraulic Control Valve (dual function shown)
TM11813 (13OCT10)
38386022
SW03989,0000ACB 1901OCT101/5
748H Repair (S.N. 630436

)
101310
PN=370
Hydraulic System
1 Pilot Pressure Hose
2 Pilot Control Hose (4 used)
3 Pilot Control Valve Supply
Hose
4 Grapple Tong Hose (2 used)

5 Arch Hose (2 used)
6 Boom Hose (2 used)

7 Blade Hose (2 used)

8 Valve Return Hose
9 Valve Supply Hose
10 Pilot Pressure Supply Hose


4. Remove right side cab cover.

5. Attach a vacuum pump to hydraulic reservoir to

minimize oil loss.

brake accumulator.
6. Disconnect supply, return, and all hydraulic function

hoses (49) at valve. Attach identification tags to
hoses to aid assembly. Close all openings using caps
and plugs.
SW03989,0000ACB 1901OCT102/5
7. Disconnect hoses (2) from pilot control valve to arch

and boom valve sections. Disconnect other pilot
control hoses (1, 3, and 10). Put identification tags
on hoses to aid assembly. Close all openings using
caps and plugs.
8. Disconnect electrical connector (12) at solenoid
operated tong valve section.
2 Pilot Control Hose (4 used)
12 Grapple Tong Control

Solenoid Electrical
Connector (2 used)
Pilot Control Hoses (dual function shown)

SW03989,0000ACB 1901OCT103/5
9. Remove cotter pin (14) and clip to disconnect linkage

at control valve blade section.
15 Blade Control Valve Spool
13 Blade Control Linkage

14 Cotter Pin
Blade Control Linkage (dual function shown)

TM11813 (13OCT10)
38386023
SW03989,0000ACB 1901OCT104/5
748H Repair (S.N. 630436

)
101310
PN=371
Hydraulic System

10. Remove three cap screws (11) to remove control

valve.
Specification
Control ValveSingle
Function
GrappleWeight
(approximate).................................................................................. 27 kg
60 lb.
Mounting Cap Screw (dual function shown)

12. Install control valve.

15. Connect remaining hydraulic lines.
Specification
Control ValveSingle
Function
GrappleWeight
(approximate).................................................................................. 27 kg
60 lb.
13. Connect electrical connector and linkage.

17. Operate function through several cycles to remove air
and fill components with oil. Check hydraulic oil level.
See Check Hydraulic System Oil Level. (Operators
Manual.)
14. Install adapters with the orifice check in the pilot cap
ports. Install pilot lines.
SW03989,0000ACB 1901OCT105/5
TM11813 (13OCT10)
38386024
748H Repair (S.N. 630436

)
101310
PN=372
Hydraulic System
TX1081328 UN31AUG10
Dual Function Pilot Operated Control Valve Disassemble and Assemble

1 Inlet Section
2 Tong Section
3 Arch Section
4 Boom Section
5 Blade Section
6 Outlet Section
7 Tie Rod (4 used)

8 Washer (8 used)
9 Nut (8 used)
1. Mark sections to ease assembly.

2. Remove nuts (9), washers (8), and tie rods (7) to
disassemble control valve. Service or replace sections
as necessary.
3. Replace seals (10) between sections.
4. Install tie rods, nuts, and washers to assemble control

valve. Tighten nuts to specification.
Specification
NutTorque..................................................................................57 Nm
42 lbft
TM11813 (13OCT10)
10 Seal (4 sets of 4 used)
38386025
SW03989,0000AB7 1926AUG101/2
748H Repair (S.N. 630436

)
101310
PN=373
TX1081329 UN31AUG10
Hydraulic System
Dual Function Pilot Operated Control Valve Fittings

11 Adapter
12 Fitting
13 Adapter with Restrictor

Orifice
14 Elbow Rework AT
5. Install fittings, if removed. Replace Orings.
15 Elbow
16 Test Coupling
17 Tee
NOTE: Install adapter with restrictor orifice (13) in blade

work port with grooves facing fitting.
SW03989,0000AB7 1926AUG102/2
TM11813 (13OCT10)
38386026
748H Repair (S.N. 630436

)
101310
PN=374
Hydraulic System
Control Valve Relief Valves Remove and

Install
NOTE: Relief valves can be removed with control
valve on machine. Valve must be removed or
moved away from machine before lift check
poppets can be removed.
1. Close grapple and lower to the ground.
TX1024878 UN14JUN07

brake accumulator.
5. Remove relief valves. Inspect, repair, or replace
components as needed.
NOTE: To inspect lift check valves on back of control
valve, remove control valve.
6. Install relief valves.
Relief Valves
1 Main Relief Valve
2 Nonadjustable Circuit
Relief Valve
3 Adjustable Circuit Relief

Valve

(Group 9025.)


SW03989,0000AB8 1907SEP101/1
TM11813 (13OCT10)
38386027
748H Repair (S.N. 630436

)
101310
PN=375
Hydraulic System
Lift Check Valve Disassemble and Assemble

1. Remove control valve from machine. See Pilot
Operated Control Valve Remove and Install. (Group
3860.)
2. Remove plugs (2).
3. Remove springs (4) and lift check poppets (5).
4. Inspect and repair or replace components as
necessary.
5. Replace Orings (3).
TX1081360 UN02SEP10
6. Install poppets and springs.

7. Install cap and tighten securely.
8. Install control valve in machine. See Pilot Operated
1 Lift Check Valve (3 used)
2 Plug (3 used)
3 ORing (3 used)
4 Spring (3 used)
5 Poppet (3 used)
Lift Check Valve
SW03989,0000AB9 1901OCT101/1
TM11813 (13OCT10)
38386028
748H Repair (S.N. 630436

)
101310
PN=376
Hydraulic System
TX1081361 UN02SEP10


1 Cap
2 ORing
3 Rod
4 Seal
5 Shims (as required)

6 Spring
7 ORing
8 Backup Ring
9 Poppet
10 Poppet Stem
11 Valve Body
12 ORing
13 Backup Ring
14 ORing

3860.)
6. Installing relief valve on control valve and tighten to

specification.
2. Remove nonadjustable circuit relief valve from control

valve.
Specification
Nonadjustable Circuit
Relief ValveTorque...................................................................100 Nm
75 lbft
3. Disassemble nonadjustable circuit relief valve as

shown.
4. Inspect components for wear or damage. Replace if
necessary.

5. Replace Orings (2, 7, 12, and 14), backup rings (8

and 13), and seal (4).
SW03989,0000ABA 1901OCT101/1
TM11813 (13OCT10)
38386029
748H Repair (S.N. 630436

)
101310
PN=377
Hydraulic System
TX1081362 UN07SEP10
Adjustable Circuit Relief Valve Disassemble

and Assemble
Adjustable Circuit Relief Valve

1 Lock Nut
2 Adjusting Screw
3 ORing
4 Spring
5 Poppet
6 Ball
7 Retainer
8 ORing
9 Rod
10 Spring
11 Seal
12 Ring
13 Poppet
14 ORing
15 Backup Ring
16 Housing
17 Pin
18 Backup Ring

3860.)
19 ORing
20 Valve Body
21 ORing
2. Remove adjustable circuit relief valve from control

valve.
3. Disassembled adjustable circuit relief valve as shown.
TM11813 (13OCT10)
38386030
SW03989,0000ABB 1907OCT101/2
748H Repair (S.N. 630436

)
101310
PN=378
Hydraulic System
4. Inspect components for wear or damage. Replace as

necessary.

5. Replace Orings (3, 8, 14, 19, and 21), backup rings

(15 and 18), and seal (11).
8. Adjust circuit relief valve. See System and Circuit

Relief Valve Pressure Test. (Group 902525.)
6. Install adjustable circuit relief valve on control valve

and tighten to specification.
9. Tighten lock nut (1) to specification.
Specification
Adjustable Circuit Relief
ValveTorque.............................................................................100 Nm
75 lbft
Specification
Lock NutTorque..........................................................................88 Nm
65 lbft
SW03989,0000ABB 1907OCT102/2
TM11813 (13OCT10)
38386031
748H Repair (S.N. 630436

)
101310
PN=379
Hydraulic System
TX1081364 UN02SEP10
Spool Valve Disassemble and Assemble
Spool Valve
1 Screw (2 used)
2 Plate
3 Upper Spacer
4 Packing
5 Spool
6 Lower Spacer
7 Valve Section Housing
8 Plate
9 Rod
10 Retainer
11 Spring
12 Retainer

3860.)
2. Disassemble control valve. See Dual Function Pilot
Operated Control Valve Disassemble and Assemble.
(Group 3860.)
NOTE: Keep spool and control valve section together
as a matched set. Spools are machined for
specific hydraulic functions.
3. Disassemble spool valve as shown.
4. Inspect spool for scratches and straightness. Replace
packing (4).
NOTE: Spacer (3) used with packing at top of valve
section is stepped. Spacer (6) used with packing
13 Rod Cap
14 End Cap Housing
15 Screw (2 used)
at bottom of valve section has shallow concave

groove around top surface.
5. Replace components as necessary.
NOTE: Detent assembly may be used in place of end cap
assembly (items 815) on some valve sections.
For more information, see Detent Disassemble
6. Assemble spool valve.
7. Assemble control valve. See Dual Function Pilot
Operated Control Valve Disassemble and Assemble.
(Group 3860.)
SW03989,0000ABC 1928SEP101/1
TM11813 (13OCT10)
38386032
748H Repair (S.N. 630436

)
101310
PN=380
Hydraulic System
TX1081366 UN02SEP10
Detent Disassemble and Assemble
Detent Assembly
1 Spacer
2 Spring Retainer
3 Spring
4 Spring Retainer
5 Rod
6 Housing
7 Washer (2 used)
8 Screw (2 used)
9 Plate
10 Washer (2 used)
11 Screw (2 used)
12 Carrier
13 Detent Ball (6 used)
14 Retainer
15 Spring

3860.)
2. Remove detent from control valve.
3. Disassemble detent as shown.
4. Inspect parts for wear or damage. Replace as needed.
5. Apply petroleum jelly to detent balls (13) to hold them
in carrier (12) during assembly.
16 Rod Cap
17 Sleeve
6. Assemble detent as shown.

7. Install detent on control valve. Move spool to detent
position center and tighten screws (11) to specification.
Specification
ScrewTorque..............................................................................20 Nm
175 lbin.

SW03989,0000ABD 1907SEP101/1
TM11813 (13OCT10)
38386033
748H Repair (S.N. 630436

)
101310
PN=381
Hydraulic System
TX1081367 UN02SEP10
Pilot Operated Valve Remove and Install
Pilot Operated Valve

2 Plug
3 ORing
4 Cap
5 ORing (3 used)
6 Sleeve

3860.)
2. Disassemble pilot operated valve as shown.
7 Bushing
4. Assemble pilot operated valve on control valve.

3. Inspect for wear or damage. Replace Orings (3 and

5) and parts as needed.
SW03989,0000ABE 1907SEP101/1
TM11813 (13OCT10)
38386034
748H Repair (S.N. 630436

)
101310
PN=382
Hydraulic System
TX1081368 UN02SEP10
Solenoid Operated Valve Remove and Install
Solenoid Operated Valve

1 Solenoid
3 ORing
4 ORing
9 Housing
10 Cap Screw
11 Cap Screw
12 Lock Washer (2 used)
5 ORing
6 Cap
7 Plug
8 ORing

3860.)
2. Remove solenoid operated valve from control valve.
13 ORing
14 ORing
15 Bushing
16 ORing (2 used)
4. Inspect for wear or damage and replace parts as

needed.
5. Replace Orings (3, 4, 5, 8, 13, 14, and 16).
3. Disassemble solenoid operated valve as shown.

TM11813 (13OCT10)
38386035
SW03989,0000ABF 1907SEP101/2
748H Repair (S.N. 630436

)
101310
PN=383
Hydraulic System
6. Check operation of solenoid (1) by applying voltage

across solenoid terminals. Solenoid should click.
Remove voltage from solenoid terminals. Solenoid
should click again. Replace if solenoid fails check.
NOTE: There are two small Orings (16) that must be
installed between housing and valve section.
7. Assemble solenoid operated valve as shown.

8. Secure to control valve with cap screws (10 and 11).
SW03989,0000ABF 1907SEP102/2
Grapple Rotate Solenoid Valve Remove and

Install

for Service Safely. (Operators Manual.)
2. Operate all hydraulic controls to release pressure in
hydraulic system.
3. Remove left engine side shield.
5. Remove and identify all hydraulic hoses connecting
to grapple rotate solenoid valve. Close all openings
6. Remove two solenoid valve electrical connectors (1).
7. Remove two mounting cap screws (2).
1 Solenoid Valve Electrical

Connectors
11. Install two solenoid valve electrical connectors.

12. Install hoses on grapple rotate solenoid valve.
14. Install left engine side shield.
8. Remove grapple rotate solenoid and bracket from

machine.
9. Inspect and replace parts as required. See Grapple
Rotate Solenoid Valve Disassemble and Assemble.
(Group 3860).
15. Operate grapple functions through several cycles to

remove air and fill components with oil.
10. Install grapple rotate solenoid valve using cap screws.

NM00125,0000587 1906OCT101/1
TM11813 (13OCT10)
38386036
748H Repair (S.N. 630436

)
101310
PN=384
Hydraulic System
Grapple Rotate Solenoid Valve Disassemble

and Assemble
1. Remove grapple rotate solenoid valve. See Grapple

Rotate Solenoid Valve Remove and Install. (Group
3860.)
2. Remove coil nut (4) from cartridge (2).
NOTE: Identify location of coils for ease of installation.
3. Remove coils (3) and coil Spacer (5).
4. Remove cartridge from valve body (1).
Grapple Rotate Solenoid Valve Exploded View
5. Inspect parts for damage, wear, or contamination.

Replace as necessary.
1 Valve Body
2 Cartridge
3 Coil (2 used)
4 Coil Nut
5 Coil Spacer
NM00125,0000588 1908OCT101/2
NOTE: Identify location of Orings and backup

rings for ease of installation.
6. Remove and replace cartridge Orings (7) and backup

rings (8), using petroleum jelly for installation.
7. Install cartridge into valve body. Tighten to
specification.
Specification
Cartridge Installation
TorqueTorque.................................................................. 32.735.4 Nm
2426 lbft
8. Install coils and spacer to cartridge.
Cartridge
9. Install coil nut. Torque to specification.

Specification
Coil Nut
InstallationTorque........................................................... 9.513.6 Nm
710 lbft
10. Install grapple rotate solenoid valve. See Grapple

Rotate Solenoid Valve Remove and Install. (Group
3860.)
6 CartridgetoValve Body
ORing
7 ORing (3 used)
8 Backup Ring (6 used)

11. Operate grapple through several cycles to remove air

trapped in system and to fill components with oil.
NM00125,0000588 1908OCT102/2
TM11813 (13OCT10)
38386037
748H Repair (S.N. 630436

)
101310
PN=385
Hydraulic System
TX1081372 UN02SEP10
Flow Divider Repair
Exploded View of Flow Divider

1 Direct Acting Crossover
Relief Valve (2 used)
2 Seal Kit (2 used)

4 Nut (2 used)
5 Seal Kit
6 Flow Divider Valve
1. Open grapple tongs and lower grapple to the ground.
7 Retainer (2 used)
4. Remove bottom access cover on grapple frame.

5. Tag and disconnect hydraulic lines from flow divider.
Close all openings using caps and plugs. See Grapple
Tong Cylinder Remove and Install. (Group 3860.)

6. Remove cap screws (3) and remove flow divider

manifold.

brake accumulator.
7. Remove retainers (7) and relief valves (1).

8. Remove flow divider valve (6).

TM11813 (13OCT10)
38386038
SW03989,0000AC0 1907SEP101/4
748H Repair (S.N. 630436

)
101310
PN=386
Hydraulic System
9. Check direct acting relief valve for wear or damage.

Replace if necessary.
8 Gland Ring
9 Backup Ring
10. Replace with new gland ring (8), backup ring (9), and
Oring (10).
10 ORing
Relief Valve Rings

SW03989,0000AC0 1907SEP102/4
11. Check flow divider valve for wear or damage. Replace

if necessary.
11 Backup Ring (6 used)

12 ORing (3 used)
12. Replace with new Orings (12 and 14) and backup
rings (11 and 13).
13 Backup Ring
14 ORing
Flow Divider Valve Rings

SW03989,0000AC0 1907SEP103/4
13. Install direct acting crossover relief valves (1) and flow
divider valve (6).
14. Install retainers (7) on direct acting crossover relief

valves.
15. Install flow divider manifold with cap screws and nuts.
(Group 9025.)
Flow Divider Assembly

1 Direct Acting Crossover

Relief Valve (2 used)
6 Flow Divider Valve
7 Retainer (2 used)
21. Install bottom access cover on grapple frame.

SW03989,0000AC0 1907SEP104/4
TM11813 (13OCT10)
38386039
748H Repair (S.N. 630436

)
101310
PN=387
Hydraulic System
Rotary Manifold Remove and Install

brake accumulator.
4. Remove top boom cover.

5. Remove grapple rotate motor. See Grapple Rotate
Motor Remove and Install. (Group 3860.)
6. Put identification tags on lines to aid assembly.
7. Disconnect hoses (13) at rotary manifold. Close all
Rotary Manifold

9. Remove housing cap screw (4).
1 Rotary ManifoldtoControl
Valve Tong Head End Hose
2 Rotary ManifoldtoControl
Valve Tong Rod End Hose
3 Rotary ManifoldtoRotate
Motor Hose
TM11813 (13OCT10)
38386040
4 Housing Cap Screw

SW03989,0000AC1 1907SEP101/2
748H Repair (S.N. 630436

)
101310
PN=388
Hydraulic System
10. Remove bottom access cover on grapple frame.

11. Disconnect rotary manifoldtoflow divider hose (6) at
flow divider.
12. Disconnect rotary manifoldtograpple cylinder rod end

hose (7) at tee.
13. Remove rotary manifold and hoses (6 and 7).
14. Inspect and repair rotary manifold as necessary. See
Rotary Manifold Disassemble and Assemble. (Group
3860.)
NOTE: Lines must not be twist as they pass through
the gear and yoke when installing rotary manifold.
Port marked A connects to flow divider.
Rotary Manifold Bottom Hoses

6 Rotary ManifoldtoFlow
Divider Hose
15. Install rotary manifold with hoses.
7 Rotary ManifoldtoGrapple
Cylinder Rod End Hose
16. Install cap screws and tighten to specification.

Specification
Cap ScrewTorque.................................................................... 115 Nm
85 lbft
Housing Cap
ScrewTorque............................................................................163 Nm
120 lbft
NOTE: Port marked A connects to flow divider.

(Group 9025.)
17. Connect hoses.

18. Install grapple rotate motor. See Grapple Rotate Motor
23. Install covers.

SW03989,0000AC1 1907SEP102/2
Rotary Manifold Disassemble and Assemble
1. Remove hoses and fittings from rotary manifold shaft

(1).
1 Rotary Manifold Shaft
Rotary Manifold Shaft

TM11813 (13OCT10)
38386041
SW03989,0000AC2 1901OCT101/4
748H Repair (S.N. 630436

)
101310
PN=389
Hydraulic System
2. Remove snap ring (3). Remove rotary manifold shaft

from rotary manifold housing (2).
3 Snap Ring
1 Rotary Manifold Shaft

2 Rotary Manifold Housing
Rotary Manifold Shaft, Housing, and Snap Ring

SW03989,0000AC2 1901OCT102/4
3. Remove rotary manifold housing Orings (4 and 6),

wear rings (5), and expander rings (7).
4. Inspect rotary manifold housing and rotary manifold
shaft for wear or damage. Replace if necessary.
5. Apply clean hydraulic oil to new Orings and wear
rings.
6. Assemble expander rings into Orings.
7. Install Orings, wear rings, and Oring with expander

ring assemblies in sequence shown. Position in rotary
manifold housing grooves.
8. Apply petroleum jelly to parts inside of rotary manifold
housing and to rotary manifold shaft. Carefully tap
rotary manifold shaft into rotary manifold housing
using a soft hammer.
9. Install snap ring on rotary manifold shaft.
2 Rotary Manifold Housing
4 ORing (2 used)
5 Wear Ring (2 used)
Rotary Manifold Housing and Rings
6 ORing (4 used)
7 Expander Ring (4 used)
TM11813 (13OCT10)
38386042
SW03989,0000AC2 1901OCT103/4
748H Repair (S.N. 630436

)
101310
PN=390
Hydraulic System

10. Test rotary manifold for leaks before installing on
machine.
Install a cap on port marked "1" (12) of rotary manifold

shaft and port marked "D" (9) of rotary manifold.
Connect a hydraulic handoperated pump to port
marked "1" (8) of rotary manifold.
11. Operate pump to test specification.
Specification
Rotary Manifold Test
Ports Marked "1" and
"2"Pressure......................................................................... 20 685 kPa
207 bar
3000 psi
Turn rotary manifold shaft 10 rpm in both directions.

Leakage must not exceed 5 drops per minute at ports
marked "2" (10 or 11). Rotary manifold shaft must not
bind while turning.
12. Repeat test, with cap on port marked "2" (11) and
applying pressure to port marked "2" (10). Leakage
must not exceed 5 drops per minute at ports marked
"1". Rotary manifold shaft must not bind while turning.
13. Install caps or plugs to all ports marked "1" and
"2". Connect hydraulic hand operated pump to port
marked "D". Operate pump to pressurize manifold to
test specifications. Turn rotary manifold shaft 10 rpm
in both directions. There must be no external leakage
and rotary manifold shaft must not bind.
Rotary Manifold Leak Test

8 Port Marked "1"
9 Port Marked "D"
10 Port Marked "2"
11 Port Connected to "2"

12 Port Connected to "1"
Specification
Rotary Manifold Test Port
Marked "D"Pressure.............................................................. 1379 kPa
14 bar
200 psi
SW03989,0000AC2 1901OCT104/4
TM11813 (13OCT10)
38386043
748H Repair (S.N. 630436

)
101310
PN=391
Hydraulic System
TM11813 (13OCT10)
38386044
748H Repair (S.N. 630436

)
101310
PN=392
Contents
Section 99
Dealer Fabricated Tools
Page
Group 9900Dealer Fabricated Tools

DFT1099 Bushing Drivers ......................... 9999001
DFRW20 Compressor Holding
Fixture.................................................... 9999002
TM11813 (13OCT10)
991
748H Repair (S.N. 630436

)
101310
PN=1
Group 9900
TX1071962 UN05APR10
DFT1099 Bushing Drivers
TM11813 (13OCT10)
9999001
GD61784,0000077 1931MAR101/2
748H Repair (S.N. 630436

)
101310
PN=394

A0.5 x 2.0 x 6.0 in. 1020 Cold
Rolled
B45 mm BushingUse 2.625
in. OD x 2.25 in. ID x 2.5 in.
B50 mm BushingUse 2.825

B70 or 80 mm BushingUse
D0.5 x 8.0 Full Threaded Cap
in. OD x 2.50 in. ID x 2.5 in.
4.00 in. OD x 3.50 in. ID x 2.5
Screw
B60 mm BushingUse 3.50 in.
in.
ETack Weld With 0.5 in.
OD x 3.00 in. ID x 2.5 in.
C0.5 x 2.0 x 4.25 in. 1020 Cold
Crosshole Centered In Pipe
Rolled
OD
These bushing drivers are used to remove and install

spherical bushings.
GD61784,0000077 1931MAR102/2
RW13619 UN20SEP89
DFRW20 Compressor Holding Fixture
A102 mm (4 in.)
B76 mm (3 in.)
C70 mm (2.75 in.)
D6.4 mm (0.25 in.)

E19 mm (0.75 in.)
F 152 mm (6 in.)
G254 mm (10 in.)

H114 mm (4.5 in.)
I 178 mm (7 in.)
J Fillet Weld
KTwo Holes
Material required:
4Matching Lock Washers and Nuts
2Steel Plates (4 x 2.75 in.) and (10 x 6 in.)

2Threaded Steel Rods (0.5 x 7 in.)
Tool is used to hold air conditioning compressor during

assembly and disassembly.
GD61784,0000078 1902JUL071/1
TM11813 (13OCT10)
9999002
748H Repair (S.N. 630436

)
101310
PN=395
TM11813 (13OCT10)
9999003
748H Repair (S.N. 630436

)
101310
PN=396
Index
Page
Page
Accumulator, service brake

Remove and install ........................................ 1010604
Adjustable circuit relief valve
Disassemble and assemble ......................... 38386030
Aftercooler
Air baffle
Air baffle enclosure
Air conditioner
Compressor, remove and install .................... 1818308
Air conditioning
R134a system charge .................................... 1818307
R134a system evacuate ................................ 1818306
Air conditioning system
Blower motor remove and install.................. 18183013
Compressor clutch remove and
install ............................................................ 1818309
Compressor manifold remove and
install .......................................................... 18183011
Compressor relief valve remove and
install ............................................................ 1818307
Condenser remove and install ..................... 18183011
Evaporator remove and install ..................... 18183020
Expansion valve remove and install............. 18183018
Flush and purge ............................................. 1818302
Freeze control switch remove and
install .......................................................... 18183017
High/low pressure switch remove and
install .......................................................... 18183015
Precleaner blower assembly remove and
install .......................................................... 18183014
R134a refrigerant cautions and proper
handling........................................................ 1818301
R134a refrigerant oil information.................... 1818304
R134a refrigerant recovery ............................ 1818306
R134a refrigerant recovery/recycling and
charging station installation.......................... 1818305
Receiverdryer remove and install ............... 18183021
Arch
Arch cylinderdual function grapple
Axle and differential drive shaft
Front, remove and install ............................... 0202251
Axle and transmission drive shaft
Rear, remove and install ................................ 0202252
Axle, front
Axle, rear
Bearing
Support, remove and install ........................... 0202252
Belt
Tensioner spring tension check...................... 0505103
Belt tensioner
Belt, seat
Blade
Control linkage, remove and install................ 3232151
Control valve, remove and install................... 3232152
Lift cylinder, remove and install...................... 3232601
Stacking, remove and install .......................... 3232011
Blower motor
Remove and install ...................................... 18183013
Boom
Boom cylinderdual function grapple
Bottom guard
Engine frame, remove and install .................. 1717461
Equipment frame, remove and install ............ 1717462
Brake accumulator
Brake pedal
Brake valve, service
Disassemble and assemble ........................... 1010603
Brake, park
Remove and install ......................................... 1111111
Bump shifter
Bushing
Spherical, remove and install......................... 3232015
C
Cab
Cab door
Cab isolators
Cab tilt cylinder
Cab tilt hand pump
Bleeding procedure...................................... 18180015
Cable rollers, dual function
Charge air cooler
TM11813 (13OCT10)
Index1
748H Repair (S.N. 630436 )

101310
PN=1
Index
Page
Page
Charge pump
Transmission, remove and install .................. 0303601
Charge pump drive, transmission
Repair ............................................................ 0303604
Cleanup procedure
General oil...................................................... 2121601
Hydraulic component failure .......................... 2121603
Component failure
Hydraulic, cleanup procedure ........................ 2121603
Compressor
Air conditioner, remove and install ................. 1818308
Compressor clutch
Compressor manifold
Compressor relief valve
Condenser
Control linkage
Blade, remove and install............................... 3232151
Winch, remove and install.............................. 3030151
Control valve
Blade, remove and install............................... 3232152
Options......................................................... 38386020
Control valve relief valves
Control valve, transmisison
Repair ............................................................ 0303609
Control valvedual function pilot operated
Control valvepilot operated
Control valvepilot operated valve
Control valveadjustable circuit relief valve
Control valvedetent
Control valvelift check valve
Control valvenonadjustable circuit relief
valve
Control valvesolenoid operated valve
Control valvespool valve
Coolant valve
Cooling loop pump
Cooling system
Service safely............................................... 00000112
Crosshead pins
Lubricate ........................................................ 3838037
Cylinder
Blade lift, remove and install .......................... 3232601
Cylinder, cab tilt

D
Dampener
Lubricate ........................................................ 3838037
Dampener, grapple
Adjustment ..................................................... 3838036
Detent
DFRW20 tool
Compressor holding fixture ............................ 9999002
DFT1099 driver
Spherical bushings removal........................... 9999001
Differential drive shaft
Front, remove and install ............................... 0202251
Rear, remove and install ................................ 0202252
Differential lock solenoid valve
Repair ............................................................ 0202601
Door latch
Door, cab
Drive and clutch repair
Winch 4000 .................................................... 3030501
Winch 6000 .................................................... 3030501
Drive shaft
Front axle and differential, remove and
install ............................................................ 0202251
Rear axle and differential, remove and
install ............................................................ 0202252
Winch, disassemble and assemble................ 3030251
Drive shaft, enginetotransmission
Drive shaft, winch
Dual mode steering solenoid valve
Duals wheel installation ..................................... 0101103
E
Enclosure, air baffle
Engine
Engine CTM reference
Theory of operation........................................ 0404001
Engine dampener
Enginetotransmission drive shaft
Evaporator
Expansion valve
TM11813 (13OCT10)
Index2
748H Repair (S.N. 630436 )

101310
PN=2
Index
Page
Page
F
Fabricated tools
DFRW20 compressor holding fixture ............. 9999002
DFT1099 bushing driver ................................ 9999001
Fan
Hydraulic motor remove and install.............. 21216012
Fan blade
Fan shroud
Fan variable speed and reversing manifold
Fire prevention................................................... 0000014
Flow divider
Repair .......................................................... 38386038
Flush and purge
Air conditioning system .................................. 1818302
Frame
Engine, separate............................................ 1717402
Equipment, separate...................................... 1717402
Free spool drag adjustment............................... 3030007
Freeze control switch
Front axle
Front axle guards
Front axle oscillation supports
Repair ............................................................ 0202008
Front differential
Front windshield wiper
Fuel tank
Rremove and install ....................................... 0505601
G
General oil
Cleanup procedure ........................................ 2121601
Grapple
Rotate bearing repair ..................................... 3838038
Grapple dampener
Grapple head
Dampener adjustment.................................... 3838036
Grapple rotate motor
Assemble ..................................................... 38386012
Disassemble .................................................. 3838607
Grapple rotate solenoid valve
Grapple rotate yoke

Grapple tong cylinder
Grille guard
Grille housing
Guard
Engine frame bottom, remove and
install ............................................................ 1717461
Equipment frame bottom, remove and
install ............................................................ 1717462
Guards, front axle
H
Heater core
Heating system
Blower motor remove and install.................. 18183013
Coolant valve remove and install ................. 18183016
Heater core remove and install .................... 18183019
High/low pressure switch
Highpressure oils
Avoid .............................................................. 0000013
Hood
Horn
Housing, grille
Hydraulic
Component faliure cleanup
procedure ..................................................... 2121603
Fittings, 30&deg cone seat ........................... 0000035
Fittings, 37&deg flare .................................... 0000035
Hydraulic attenuator
Hydraulic fan motor
Hydraulic fan pump
Hydraulic oil cooler
Hydraulic pump
Hydraulic reservoir
I
Inch bolt and cap screw
Torque value .................................................. 0000034
Input shaft, transmission
TM11813 (13OCT10)
Index3
748H Repair (S.N. 630436 )

101310
PN=3
Index
Page
Page
Intercooler
Isolators, cab

L
Lower pivot pin seal
Lubricate
Grapple head dampener, yoke, and
crosshead pins ............................................. 3838037
M
Machine modifications
Avoid .............................................................. 0000012
Metric bolt and cap screw
Torque value .................................................. 0000032
Mounttransmission
O
Oring boss fittings............................................. 0000036
Oil
General, cleanup procedure .......................... 2121601
Lines and fittings ............................................ 0000035
Oil lines and fittings ........................................... 0000035
Oscillation supports
Repair ............................................................ 0202008
P
Park brake
Remove and install ......................................... 1111111
Park brake solenoid valve
Repair .............................................................1111601
Pilot operated valve
Pin, upper pivot
Pins, metal
Drive safely .................................................. 00000114
Pivot pin, upper
Precleaner blower assembly
Pressurized water systemif equipped
Priority valve
Pump drive, transmission charge
Repair ............................................................ 0303604
Pump, cab tilt
Bleeding procedure...................................... 18180015
R
R134a refrigerant
Cautions and proper handling........................ 1818301
Oil information................................................ 1818304
Recovery........................................................ 1818306
Recovery/recycling and charging station
installation .................................................... 1818305
R134a system
Charge ........................................................... 1818307
Evacuate ........................................................ 1818306
Radiator
Rear axle
Rear differential
Rear windshield wiper
Receiverdryer
Repair procedures
Transmission.................................................. 0303501
Reverse warning alarm
Rollers, cable, dual function
ROPS
Torque ............................................................ 0000031
Rotary manifold
Rotate motor drive gear
S
Safety
Add and operate attachments safely ........... 00000111
Avoid backover accidents .............................. 0000019
Avoid machine tip over................................... 0000019
Avoid work site hazards ................................. 0000018
Clean debris from machine ............................ 0000016
Do not use starting fluid with tier 3
engine .......................................................... 0000013
Inspect and maintain ROPS......................... 00000110
Inspect machine............................................. 0000012
Keep riders off machine ................................. 0000018
Keep the operator protective structure in
place........................................................... 00000110
Make welding repairs safely......................... 00000113
Operate machine safely ................................. 0000018
Operate only if qualified ................................. 0000011
Operating on slopes..................................... 00000110
Operating or traveling on public roads ......... 00000110
Park and prepare for service safely ............. 00000111
TM11813 (13OCT10)
Index4
748H Repair (S.N. 630436 )

101310
PN=4
Index
Page
Page
Prevent unintended machine

movement .................................................... 0000017
Protective equipment ..................................... 0000012
Recognize safety information......................... 0000011
Start only from operator's seat....................... 0000016
Stay clear of moving parts ............................. 0000012
Use and maintain seat belt ............................ 0000017
Use steps and handholds correctly................ 0000016
Seal
Lower pivot pin............................................... 1717406
Seat
Seat belt
Secondary Steering
Secondary steering pump
Serpentine belt
Serpentine belt tensioner
Service brake accumulator
Service brake pedal
Service brake valve
Solenoid operated valve
Solenoid valve
Differential lock, repair ................................... 0202601
Solenoid valve, dual mode steering
Solenoid valve, park brake
Repair .............................................................1111601
Spherical bushing
Stacking blade
Steering column
Steering cylinder
Steering valve
Steering wheel
Steering, dual mode solenoild valve
Support bearing
T
Tensioner, belt
Spring tension check...................................... 0505103
Tire
Install duals .................................................... 0101103
Torque value
30&deg cone seat hydraulic fittings .............. 0000035
37&deg flare hydraulic fittings....................... 0000035
Dual wheel nuts ............................................. 0101103
Flat face Oring seal fitting ............................. 0000037
Hardware specifications................................. 0000031
Inch SAE four bolt flange fitting...................... 0000039
Metric bolt and cap screw .............................. 0000032
Metric cap screw ............................................ 0000033
Metric four bolt flange fitting........................... 0000038
ORing boss fitting ......................................... 0000036
Unified inch bolt and cap screw ..................... 0000034
Transmission
Input shaft remove and install ........................ 0303507
Repair procedures ......................................... 0303501
Winch drive repair .......................................... 0303502
Transmission bump shifter
Transmission charge pump
Suction tube repair......................................... 0303608
Transmission charge pump drive
Repair ............................................................ 0303604
Transmission cold weathe disconnect
linkageif equipped
Transmission cold weather disconnectjif
equipped
Repair ............................................................ 0707524
Transmission control solenoids
Repair ............................................................ 0303609
Transmission control valve
Repair ............................................................ 0303609
Transmission Gear Selector
Transmission mount
Transmission oil cooler
Transmission suction tube
Repair ............................................................ 0303608
Transmissiontoengine drive shaft
V
Valve
Priority valve disassemble and
assemble...................................................... 2121608
TM11813 (13OCT10)
Index5
748H Repair (S.N. 630436 )

101310
PN=5
Index
Page
Page
Priority valve remove and install .................... 2121607

Valve, blade control
Valve, dual mode steering
Valve, grapple rotate solenoid
Valve, service brake
Valve, steering
Drive shaft, remove and install....................... 3030251

Fastening cable4000 series.......................... 3030005
Fastening cable6000 series........................ 30300010
Free spool drag adjustment ........................... 3030007
Winch 4000 series
Winch 6000 series
Winch drive
Repair ............................................................ 0303502
Winch, 4000
Drive and clutch repair ................................... 3030501
Winch, 6000
Drive and clutch repair ................................... 3030501
Window
Cleaning procedure........................................ 1818104
Windshield wiper
Adjustment ..................................................... 1818109
Windshield wiper, front
Windshield wiper, rear
W
Water system, pressurizedif equipped
Welding.............................................................. 1717401
Wheel
Wheel bolt torque
Dual wheels ................................................... 0101103
Wheel repair
Install duals .................................................... 0101103
Winch
Control cable, remove and install................... 3030152
Control linkage, remove and install................ 3030151
Drive shaft, disassemble and
assemble...................................................... 3030251
TM11813 (13OCT10)
Y
Yoke
Lubricate ........................................................ 3838037
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Index
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Index
TM11813 (13OCT10)
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748H Novo Monitor Repair BookTM11813 PDF

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748H Skidder

For complete service information also see:

Information is organized in groups for the various

748H Repair (S.N. 630436

Technical Information Feedback Form

John Deere Dubuque Works

FAX NUMBER: 15635895800 (USA)

748H Repair (S.N. 630436

748H Repair (S.N. 630436

Group 1746Frame Bottom Guards

Section 18Operators Station

Section 19Sheet Metal and Styling

Group 0200Remove and Install

Group 1910Hood or Engine Enclosure

Section 20Safety, Convenience, and

Group 2003Pressurized Water System

Section 21Main Hydraulic System

Group 0400Removal and Installation

Group 3000Removal and Installation

Section 05Engine Auxiliary Systems

Section 32Stacking Blades

Section 07Dampener Drive

Section 09Steering System

Section 99Dealer Fabricated Tools

Section 10Service Brakes

Section 11Park Brake

Section 17Frame, Chassis, or Supporting

Original Instructions. All information, illustrations and specifications in this

748H Repair (S.N. 630436

748H Repair (S.N. 630436

Group 0001Safety ................................0000011

748H Repair (S.N. 630436

748H Repair (S.N. 630436

This is the safety alert symbol. When you see this

On your machine, DANGER signs are red in color,

Follow Safety Instructions

Carefully read all safety messages in this manual and on

If you do not understand any part of this manual and need

Operate Only If Qualified

Familiarize yourself with the job site and your surroundings

748H Repair (S.N. 630436

Wear Protective Equipment

Wear close fitting clothing and safety equipment

Avoid Unauthorized Machine Modifications

reliability, and may create a hazard for the operator or

Keep all guards and shields in good condition and properly

Inspect machine carefully each day by walking around it

Entanglements in moving parts can cause serious injury.

Stay Clear of Moving Parts

748H Repair (S.N. 630436

Avoid HighPressure Fluids

Avoid the hazard by relieving pressure before

Moline, Illinois, U.S.A., by calling 18008228262 or +1

Avoid HighPressure Oils

Never search for leaks with your hands. Protect hands.

If hydraulic oil penetrates your skin, see a doctor

This machine uses a highpressure hydraulic system.

Do Not Use Starting Fluid

This machine is equipped with a Tier III engine. Fire,

IMPORTANT: Avoid an explosion or fire. Machine

748H Repair (S.N. 630436

Work In Ventilated Area