624H Loader and TC62H TC Operation TM1640

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624H Loader and TC62H Tool Carrier Repair
TECHNICAL MANUAL 624H Loader TC62H Tool Carrier Repair

TM1640 15JAN04 (ENGLISH)
For complete service information also see: 624H Loader and TC62H Operation and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 L & 6.8 L 4045 and 6068 Diesel Engines Repair . . . . . . . . . . . . . . . . . . . . . . . Alternators and Starting Motors . . . . . . . . . . TeamMate III Axles . . . . . . . . . . . . . . . . . . . TM1639 CTM104 CTM77 CTM150
Worldwide Construction And Forestry Division

LITHO IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
DX,TMIFC 1929SEP981/1
TM1640 (15JAN04)
624H Loader and TC62H Tool Carrier

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Introduction
Technical Information Feedback Form

We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments, ideas and improvements.
SEND TO: John Deere Dubuque Works P.O. Box 538 Attn: Publications Supervisor, Dept. 303 Dubuque, IA 52004-0538 563-589-5800
FAX NUMBER:
Ideas, Comments (Please State Page Number):
OVERALL, how would you rate the quality of this publication? (Check one) Poor 1 2 3 Fair 4 5 Good 6 7 Very Good 8 9 Excellent 10
Company Name: Technician Name: Address: Phone: Fax No.: Dealer Acct. No.: THANK YOU!
TX,TM,FAX 1903JUL011/1
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Introduction
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SECTION 00General Information Group 0001Safety Information Group 0002General Specifications Group 0003Torque Values Group 0004Fuels and Lubricants SECTION 01Wheels Group 0110Powered Wheels and Fasteners SECTION 02Axles and Suspension Systems Group 0200Removal and Installation Group 0225Axle Shafts and U-Joints Group 0250Axle Shaft, Bearings, Reduction Gears Group 0260Hydraulic System SECTION 03Transmission Group 0300Removal and Installation Group 0350Gears, Shafts, Bearings and Power Shift Clutch Group 0360Hydraulic System Group 0399Dealer Fabricated Tools SECTION 04Engine Group 0400Removal and Installation SECTION 05Engine Auxiliary Systems Group 0505Cold Weather Starting Aids Group 0510Cooling System Group 0515Speed Controls Group 0520Intake System Group 0530External Exhaust System Group 0560External Fuel Supply Systems SECTION 07Dampener Drive Group 0752Elements SECTION 09Steering System Group 0960Hydraulic System SECTION 10Service Brakes Group 1011Active Elements Group 1060Hydraulic System
SECTION 11Park Brake Group 1111Active Elements Group 1160Hydraulic System SECTION 16Electrical System Group 1671Batteries, Support and Cables Group 1672Alternator, Regulator and Charging System Wiring Group 1673Lighting System Group 1674Wiring Harness and Switches Group 1675System Controls Group 1677Motors and Actuators SECTION 17Frame or Supporting Structure Group 1740Frame Installation Group 1746Frame Bottom Guards Group 1749Chassis Weights SECTION 18Operators Station Group 1800Removal and Installation Group 1810Operator Enclosure Group 1821Seat and Seat Belts Group 1822Steps and Handholds Group 1830Heating and Air Conditioning Group 1899Dealer Fabricated Tools SECTION 19Sheet Metal and Styling Group 1910Hood or Engine Enclosure Group 1913Miscellaneous Shields Group 1921Grille and Grille Housing Group 1927Miscellaneous Shields SECTION 20Safety and Convenience Group 2002Mirror Group 2003Fire Extinguisher Group 2004Horn and Warning Devices SECTION 31Loader Group 3102Bucket Group 3140Frames Group 3160Hydraulic System
01
02
03
04
05
07
09
10
All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.
COPYRIGHT 2004 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION Manual Previous Editions Copyright 1998, 1999, 2000, 2001, 2003
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Section 00
General Information
Contents
Page Page
Group 0001Safety Information Handle Fluids SafelyAvoid Fires . . . . . . . .00-0001-1 Prevent Battery Explosions . . . . . . . . . . . . . .00-0001-1 Prepare for Emergencies. . . . . . . . . . . . . . . .00-0001-1 Prevent Acid Burns . . . . . . . . . . . . . . . . . . . .00-0001-2 Handle Chemical Products Safely . . . . . . . . .00-0001-3 Avoid High-Pressure Fluids . . . . . . . . . . . . . .00-0001-3 Park Machine Safely . . . . . . . . . . . . . . . . . . .00-0001-4 Support Machine Properly . . . . . . . . . . . . . . .00-0001-4 Wear Protective Clothing. . . . . . . . . . . . . . . .00-0001-4 Work in Clean Area. . . . . . . . . . . . . . . . . . . .00-0001-5 Service Machines Safely . . . . . . . . . . . . . . . .00-0001-5 Work In Ventilated Area . . . . . . . . . . . . . . . .00-0001-5 Illuminate Work Area Safely . . . . . . . . . . . . .00-0001-5 Replace Safety Signs . . . . . . . . . . . . . . . . . .00-0001-6 Use Proper Lifting Equipment . . . . . . . . . . . .00-0001-6 Remove Paint Before Welding or Heating . . .00-0001-7 Avoid Heating Near Pressurized Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-7 Keep ROPS Installed Properly . . . . . . . . . . .00-0001-8 Service Tires Safely . . . . . . . . . . . . . . . . . . .00-0001-8 Avoid Harmful Asbestos Dust . . . . . . . . . . . .00-0001-9 Practice Safe Maintenance . . . . . . . . . . . . .00-0001-10 Use Proper Tools . . . . . . . . . . . . . . . . . . . .00-0001-10 Dispose of Waste Properly . . . . . . . . . . . . .00-0001-11 Live With Safety . . . . . . . . . . . . . . . . . . . . .00-0001-11 Group 0002General Specifications 624H Specifications. . . . . . . . . . . . . . . . . . . .00-0002-1 Drain and Refill Capacities624H/TC62H . .00-0002-4 TC62H Specifications . . . . . . . . . . . . . . . . . .00-0002-5 Drain and Refill CapacitiesTC62H . . . . . . .00-0002-8 Group 0003Torque Values Hardware Torque Specifications . . . . . . . . . .00-0003-1 ROPS Torque Specifications . . . . . . . . . . . . .00-0003-1 Metric Bolt and Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2 Additional Metric Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-3 Unified Inch Bolt and Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-5 Check Oil Lines And Fittings . . . . . . . . . . . . .00-0003-6 Service Recommendations for O-Ring Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0003-7 TM1640 (15JAN04)
Service Recommendations For Flat Face O-Ring Seal Fittings. . . . . . . . . . . . . . . . . .00-0003-9 Service Recommendations for Metric Series Four Bolt Flange Fitting . . . . . . . .00-0003-10 Service Recommendations For Inch Series Four Bolt Flange Fittings. . . . . . . .00-0003-11 Group 0004Fuels and Lubricants Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-1 Lubricity of Diesel Fuel . . . . . . . . . . . . . . . . .00-0004-1 Low Sulfur Diesel Fuel Conditioner . . . . . . . .00-0004-2 Diesel Fuel Storage. . . . . . . . . . . . . . . . . . . .00-0004-2 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-3 Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . .00-0004-3 Transmission, Hydraulic System, Park Brake, and Differential Oil . . . . . . . . . . . . .00-0004-4 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-5 Alternative and Synthetic Lubricants . . . . . . .00-0004-6 Lubricant Storage . . . . . . . . . . . . . . . . . . . . .00-0004-6 Mixing of Lubricants . . . . . . . . . . . . . . . . . . .00-0004-7
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Group 0001
Safety Information
Handle Fluids SafelyAvoid Fires
When you work around fuel, do not smoke or work near heaters or other fire hazards. Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously.
00 0001 1
DX,FLAME 1929SEP981/1
Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16C (60F).
DX,SPARKS 1903MAR931/1
Prepare for Emergencies

Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy.
UN23AUG88
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
DX,FIRE2 1903MAR931/1
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TS291
TS204
UN23AUG88
TS227
UN23AUG88
Safety Information
00 0001 2
Prevent Acid Burns

Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. 2. 3. 4. 5. Filling batteries in a well-ventilated area. Wearing eye protection and rubber gloves. Avoiding breathing fumes when electrolyte is added. Avoiding spilling or dripping electrolyte. Use proper jump start procedure.
If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 1530 minutes. Get medical attention immediately. If acid is swallowed: 1. Do not induce vomiting. 2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts). 3. Get medical attention immediately.
UN23AUG88
DX,POISON 1921APR931/1
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TS203
Safety Information
Handle Chemical Products Safely

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. 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. (See your John Deere dealer for MSDSs on chemical products used with John Deere equipment.)
UN26NOV90
00 0001 3
DX,MSDS,NA 1903MAR931/1
Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skin causing serious injury.
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 high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
DX,FLUID 1903MAR931/1
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X9811
TS1132
Safety Information
00 0001 4
Park Machine Safely

Before working on the machine: Lower all equipment to the ground. Stop the engine and remove the key. Disconnect the battery ground strap. Hang a "DO NOT OPERATE" tag in operator station.
DX,PARK 1904JUN901/1
Support Machine Properly

Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices can settle or leak down. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual. When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operators manual.
DX,LOWER 1924FEB001/1
Wear Protective Clothing

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.
DX,WEAR2 1903MAR931/1
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TS206
UN23AUG88
TS229
UN23AUG88
TS230
UN24MAY89
Safety Information
Work in Clean Area

Before starting a job: Clean work area and machine. Make sure you have all necessary tools to do your job. Have the right parts on hand. Read all instructions thoroughly; do not attempt shortcuts.
00 0001 5
DX,CLEAN 1904JUN901/1
Service Machines Safely

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
UN23AUG88
DX,LOOSE 1904JUN901/1
Work In Ventilated Area

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
UN23AUG88
DX,AIR 1917FEB991/1
Illuminate Work Area Safely

Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.
DX,LIGHT 1904JUN901/1
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TS223
UN23AUG88
TS220
TS228
T6642EJ
UN18OCT88
Safety Information
00 0001 6
Replace Safety Signs

Replace missing or damaged safety signs. See the machine operators manual for correct safety sign placement.
UN23AUG88
DX,SIGNS1 1904JUN901/1
Use Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe injury or machine damage. Follow recommended procedure for removal and installation of components in the manual.
DX,LIFT 1904JUN901/1
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TS226
UN23AUG88
TS201
Safety Information
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. 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.
UN23AUG88
00 0001 7
DX,PAINT 1924JUL021/1
Avoid Heating Near Pressurized Fluid Lines

Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.
DX,TORCH 1903MAR931/1
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TS953
UN15MAY90
TS220
Safety Information
00 0001 8
Keep ROPS Installed Properly

Make certain all parts are reinstalled correctly if the roll-over protective structure (ROPS) is loosened or removed for any reason. Tighten mounting bolts to proper torque. 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.
UN23AUG88
DX,ROPS3 1903MAR931/1
Service Tires Safely

Explosive separation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel. When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available. Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
DX,RIM 1924AUG901/1
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TS211
UN23AUG88
TS212
Safety Information
Avoid Harmful Asbestos Dust

Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer. Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated. Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos. Keep bystanders away from the area.
UN23AUG88
00 0001 9
DX,DUST 1915MAR911/1
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TS220
Safety Information
00 0001 10
Practice Safe Maintenance

Understand service procedure before doing work. Keep area clean and dry. Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool. Securely support any machine elements that must be raised for service work. Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris. On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine. On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.
DX,SERV 1917FEB991/1
Use Proper Tools

Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards. Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches. Use only service parts meeting John Deere specifications.
DX,REPAIR 1917FEB991/1
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TS779
UN08NOV89
TS218
UN23AUG88
Safety Information
Dispose of Waste Properly

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. 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. 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.
UN26NOV90
00 0001 11
DX,DRAIN 1903MAR931/1
Live With Safety

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.
1907OCT88
DX,LIVE 1925SEP921/1
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TS231
TS1133
Safety Information
00 0001 12
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Group 0002
General Specifications
624H Specifications
00 0002 1
Item
Measurement
Specification
ABucket Hinge Height BDump Height CDump Reach DMachine EWheelbase FGround Clearance GMachine
Distance Distance Distance Overall Height Length Distance Overall Length
3961 mm (13 ft 0 in.) 2858 mm (9 ft 5 in.) 1038 mm (3 ft 5 in.) 3300 mm (10 ft 10 in.) 3030 mm (9 ft 11 in.) 406 mm (16.0 in.) 7610 m (25 ft 0 in.)
Continued on next page
TX,9000,JC2184 1921APR991/3
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T107472
UN19FEB97
00 0002 2
Item
Measurement
Specification
Machine Machine
Standard Operating Weight Optional Counterweight
13 560 kg (29,894 lb) 474 kg (1,045 lb)
NOTE: Specifications and design subject to change without notice. Wherever applicable, specifications are in accordance with SAE standards. Except where otherwise noted, specifications are based on a machine equipped with all standard equipment, with 474
Item Measurement
kg (1,045 lb) optional counterweight, ROPS cab, differential lock front axle with standard rear axle, 2 spool valve with two lever control, heater and defroster, 79 kg (175 lb) operator and full fuel tank.
Specification
Engine: John Deere PowerTech 6.8T with altitude compensating turbocharger Power 160 SAE net hp (119 kW) @ 2200 rpm 172 SAE gross hp (128 kW) @ 2200 rpm 6.8 L (414 cu in.) Dual stage dry type with restriction indicator 24 volt 55-amp 2-12 volt with 625 amps 160 min. Single phase, single stage
Piston displacement Air cleaner w/dual safety element and restriction indicator Electrical system
Power Type
Voltage
Cold cranking capacity at -18C (0F) Current Reserve capacity Torque Converter Transmission Countershaft Forward Travel: 1 2 3 4 Speed Speed Speed Speed Type Time Type
Computer controlled powershift
07.7 km/h (04.8 mph) 012.0 km/h (07.5 mph) 022.6 km/h (014.0 mph) 039.5 km/h (024.5 mph)
PowerTech is a trademark of Deere & Company.
TX,9000,JC2184 1921APR992/3
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00 0002 3
Item
Measurement
Specification
Reverse Travel: 1 2 3 Speed Speed Speed 08.1 km/h (05.0 mph) 012.7 km/h (08.0 mph) 023.9 km/h (014.9 mph) Amber lights with transmission in neutral Red STOP indicator lights and buzzer sounds with transmission in gear Steering: Fully hydraulic Frame articulated 80 by two hydraulic cylinders Turning radius (to centerline of outside tire): 5,187 mm (17 ft 0 in.) Tires: 17.5x25 Bias (L2) and (L3) 17.5R25 Radial XTLA (L2) XHAT (L3) and GP-2B (L2) 20.5x25 Bias (L2) and (L3) 20.5R25 Radial XTLA (L2), XHAT (L3) and GP-2B (L2)
NOTE: All travel speeds are with 20.5 x 25 12PR (L2) tires.
Brakes, Service: Hydraulically-actuated, 4 wheel, inboard-mounted, wet disk Foot-operated by either pedal Left and right pedal also disconnects transmission (if selected by operator) External inspection Low brake pressure warning light and buzzer in monitor Brakes, Park: Multi wet disk Spring applied, hydraulically released parking brake is bathed in cooling oil Transmission disconnects with park brake applied Warning light in monitordual-level
TX,9000,JC2184 1921APR993/3
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00 0002 4
Drain and Refill Capacities624H/TC62H

Item Measurement Specification
Cooling System Fuel Tank Engine Crankcase and Filter
Capacity Capacity Capacity
22 L (23 qt) 265 L (70 gal) 20 L (21 qt) (S.N. 582360) 21 L (22 qt) (S.N. 582361) 27 L (29 qt) 25 L (26 qt) 20 L (21 qt) 117 L (31 gal) 0.300 L (10 oz)
Transmission Case and Filter Front Differential Rear Differential Hydraulic Reservoir and Filters Park Brake
Capacity Capacity Capacity Capacity Capacity
CED,OUOE002,1792 1916SEP981/1
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TC62H Specifications
00 0002 5
Item
Measurement
Specification
ABucket Hinge Height BDump Height CDump Reach DMachine EWheelbase FGround Clearance GMachine
Distance Distance Distance Overall Height Length Distance Overall Length
4005 mm (13 ft 2 in.) 2907 mm (9 ft 6 in.) 1278 mm (4 ft 2 in.) 3300 mm (10 ft 10 in.) 3030 mm (9 ft 11 in.) 406 mm (16.0 in.) 7671 m (25 ft 2 in.)
TX,9000,JC2185 1921APR991/3
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T107087
UN20FEB97
00 0002 6
Item
Measurement
Specification
Machine Machine
Standard Operating Weight Optional Counterweight
13 361 kg (29,456 lb) 474 kg (1,045 lb)
NOTE: Specifications and design subject to change without notice. Wherever applicable, specifications are in accordance with SAE standards. Except where otherwise noted, specifications are based on a machine equipped with all standard equipment, with 474
Item Measurement
kg (1,045 lb) optional counterweight, ROPS cab, differential lock front axle with standard rear axle, 2 spool valve with two lever control, heater and defroster, 79 kg (175 lb) operator and full fuel tank.
Specification
Engine: John Deere PowerTech 6.8T with altitude compensating turbocharger Power 160 SAE net hp (119 kW) @ 2200 rpm 172 SAE gross hp (128 kW) @ 2200 rpm 6.8 L (414 cu in.) Dual stage dry type with restriction indicator 24 volt 55-amp 2-12 volt with 625 amps 160 min. Single phase, single stage
Piston displacement Air cleaner w/dual safety element and restriction indicator Electrical system
Power Type
Voltage
Cold cranking capacity at -18C (0F) Current Reserve capacity Torque Converter Transmission Countershaft Forward Travel: 1 2 3 4 Speed Speed Speed Speed Type Time Type
Computer controlled powershift
07.7 km/h (04.8 mph) 012.0 km/h (07.5 mph) 022.6 km/h (014.0 mph) 039.5 km/h (024.5 mph)
TX,9000,JC2185 1921APR992/3
TM1640 (15JAN04)
00-0002-6

011504
PN=26
00 0002 7
Item
Measurement
Specification
Reverse Travel: 1 2 3 Speed Speed Speed 08.1 km/h (05.0 mph) 012.7 km/h (08.0 mph) 023.9 km/h (014.9 mph) Amber lights with transmission in neutral Red STOP indicator lights and buzzer sounds with transmission in gear Steering: Fully hydraulic Frame articulated 80 by two hydraulic cylinders Turning radius (to centerline of outside tire): 5,187 mm (17 ft 0 in.) Tires: 17.5x25 Bias (L2) and (L3) 17.5R25 Radial XTLA (L2) XHAT (L3) and GP-2B (L2) 20.5x25 Bias (L2) and (L3) 20.5R25 Radial XTLA (L2), XHAT (L3) and GP-2B (L2)
NOTE: All travel speeds are with 20.5 x 25 12PR (L2) tires.
Brakes, Service: Hydraulically-actuated, 4 wheel, inboard-mounted, wet disk Foot-operated by either pedal Left and right pedal also disconnects transmission (if selected by operator) External inspection Low brake pressure warning light and buzzer in monitor Brakes, Park: Multi wet disk Spring applied, hydraulically released parking brake is bathed in cooling oil Transmission disconnects with park brake applied Warning light in monitordual-level
TX,9000,JC2185 1921APR993/3
TM1640 (15JAN04)
00-0002-7

011504
PN=27
00 0002 8
Drain and Refill CapacitiesTC62H

Cooling System Fuel Tank Engine Crankcase and Filter
Capacity Capacity Capacity
22 L (23 qt) 265 L (70 gal) 20 L (21 qt) (S.N. 582360) 21 L (22 qt) (S.N. 582361) 27 L (29 qt) 25 L (26 qt) 20 L (21 qt) 117 L (31 gal) 0.300 L (10 oz)
Transmission Case and Filter Front Differential Rear Differential Hydraulic Reservoir and Filters Park Brake
Capacity Capacity Capacity Capacity Capacity
CED,OUOE002,1795 1916SEP981/1
TM1640 (15JAN04)
00-0002-8

011504
PN=28
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.
00 0003 1
T82,SKMA,AT 1901AUG941/1
ROPS Torque Specifications

CAUTION: Make certain all parts are reinstalled correctly if the roll-over protective structure (ROPS) is loosened or removed for any reason. Tighten mounting bolts to proper torque. The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered. A damaged ROPS should be replaced, not reused. When installation of equipment on a machine necessitates loosening or removing ROPS, mounting bolts must be tightened to 1150 Nm (850 lb-ft).
ROPS Mounting Bolts
Torque
1150 Nm (850 lb-ft)
TX,9000,JC2196 1917SEP971/1
TM1640 (15JAN04)
00-0003-1

011504
PN=29
TS176
UN23AUG88
Torque Values
00 0003 2
Metric Bolt and Cap Screw Torque Values
Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings
Class 4.8 Size M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36
a b
Class 8.8 or 9.8 Lubricateda Nm(lb-ft) 9 (6.6) 22 (16) 43 (32) 75 (55) 120 (88) 190 (140) 265 (195) 375 (275) 510 (375) 650 (480) 950 (700) 1290 (950) 1750 (1300) 2250 (1650) Dryb Nm(lb-ft) 11.5 (8.5) 28 (20.5) 55 (40) 95 (70) 150 (110) 240 (175) 330 (245) 475 (350) 650 (480) 820 (600) 1200 (885) 1630 (1200) 2200 (1625) 2850 (2100)
Class 10.9 Lubricateda Nm(lb-ft) 13 (9.5) 32 (23.5) 63 (46) 110 (80) 175 (130) 275 (200) 375 (275) 530 (390) 725 (535) 920 (680) 1350 (1000) 1850 (1350) 2500 (1850) 3200 (2350) Dryb Nm(lb-ft) 16.5 (12.2) 40 (29.5) 80 (59) 140 (105) 220 (165) 350 (255) 475 (350) 675 (500) 920 (680) 1150 (850) 1700 (1250) 2300 (1700) 3150 (2325) 4050 (3000)
Class 12.9 Lubricateda Nm(lb-ft) 15.5 (11.5) 37 (27.5) 75 (55) 130 (95) 205 (150) 320 (235) 440 (325) 625 (460) 850 (625) 1080 (800) 1580 (1160) 2140 (1580) 2900 (2150) 3750 (2770) Dryb Nm(lb-ft) 19.5 (14.5) 47 (35) 95 (70) 165 (120) 260 (190) 400 (300) 560 (410) 790 (580) 1080 (800) 1350 (1000) 2000 (1475) 2700 (2000) 3700 (2730) 4750 (3500)
Lubricateda Nm(lb-ft) 4.7 (3.5) 11.5 (8.5) 23 (17) 40 (29.5) 63 (46) 100 (74) 135 (100) 190 (140) 265 (195) 330 (245) 490 (360) 660 (490) 900 (665) 1150 (850)
Dryb Nm(lb-ft) 6 (4.4) 14.5 (10.7) 29 (21) 50 (37) 80 (59) 125 (92) 170 (125) 245 (180) 330 (245) 425 (315) 625 (460) 850 (625) 1150 (850) 1450 (1075)
"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.
Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.
DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class.
Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightened to the strength of the original.
DX,TORQ2 1901OCT991/1
TM1640 (15JAN04)
00-0003-2

011504
PN=30
TORQ2
UN07SEP99
Torque Values
Additional Metric Cap Screw Torque Values

CAUTION: Use only metric tools on metric hardware. Other tools may not fit properly. They may slip and cause injury. Check tightness of cap screws periodically. Torque values listed are for general use only. Do not use these values if a different torque value or tightening procedure is listed for a specific application. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. 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.
UN18OCT88
00 0003 3
04T,90,M170 1929SEP991/2
TM1640 (15JAN04)
00-0003-3

011504
PN=31
T6873AC
UN18OCT88
T6873AB
UN18OCT88
T6873AA
Torque Values
00 0003 4 Nominal Dia 8 10 12 14 16 18 20 22 24 27 30 33 36
a
METRIC CAP SCREW TORQUE VALUESa T-Bolt Nm 29 63 108 176 265 392 539 735 931 1372 1911 2548 3136 46 80 130 195 289 398 542 687 1012 1410 1890 2314 lb-ft 21 H-Bolt Nm 20 45 88 137 206 294 392 539 686 1029 1421 1911 2401 lb-ft 15 33 65 101 152 217 289 398 506 759 1049 1410 1772 M-Bolt Nm 10 20 34 54 78 118 167 216 274 392 539 735 931 7 15 25 40 58 87 125 159 202 289 398 542 687 lb-ft
Torque tolerance is 10%.
04T,90,M170 1929SEP992/2
TM1640 (15JAN04)
00-0003-4

011504
PN=32
Torque Values
Unified Inch Bolt and Cap Screw Torque Values
00 0003 5
Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings
Grade 1 (No Mark) Size 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2
a
Grade 2a (No Mark) Lubricatedb Nm(lb-ft) 6 (4.4) 12 (9) 22 (16) 35 (26) 53 (39) 76 (56) 105 (77) 190 (140) 190 (140) 285 (210) 400 (300) 570 (420) 750 (550) 990 (730) Dryc Nm(lb-ft) 7.5 (5.5) 15.5 (11.5) 27.5 (20) 44 (32.5) 67 (49) 95 (70) 135 (100) 240 (175) 240 (175) 360 (265) 510 (375) 725 (535) 950 (700) 1250 (930)
Grade 5, 5.1 or 5.2 Lubricatedb Nm(lb-ft) 9.5 (7) 19.5 (14.5) 35 (26) 56 (41) 85 (63) 125 (92) 170 (125) 300 (220) 490 (360) 730 (540) 910 (670) 1280 (945) 1700 (1250) 2250 (1650) Dryc Nm(lb-ft) 12 (9) 25 (18.5) 44 (32.5) 70 (52) 110 (80) 155 (115) 215 (160) 380 (280) 615 (455) 920 (680) 1150 (850) 1630 (1200) 2140 (1580) 2850 (2100)
Grade 8 or 8.2 Lubricatedb Nm(lb-ft) 13.5 (10) 28 (20.5) 49 (36) 80 (59) 120 (88) 175 (130) 240 (175) 425 (315) 690 (510) 1030 (760) 1450 (1075) 2050 (1500) 2700 (2000) 3600 (2650) Dryc Nm(lb-ft) 17 (12.5) 35 (26) 63 (46) 100 (74) 155 (115) 220 (165) 305 (225) 540 (400) 870 (640) 1300 (960) 1850 (1350) 2600 (1920) 3400 (2500) 4550 (3350)
Lubricatedb Nm(lb-ft) 3.8 (2.8) 7.7 (5.7) 13.5 (10) 22 (16) 34 (25) 48 (35.5) 67 (49) 120 (88) 190 (140) 285 (210) 400 (300) 570 (420) 750 (550) 990 (730)
Dryc Nm(lb-ft) 4.7 (3.5) 9.8 (7.2) 17.5 (13) 28 (20.5) 42 (31) 60 (45) 85 (63) 150 (110) 240 (175) 360 (265) 510 (375) 725 (535) 950 (700) 1250 (930)
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 c
"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.
Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.
DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. 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.
DX,TORQ1 1901OCT991/1
TM1640 (15JAN04)
00-0003-5

011504
PN=33
TORQ1A
UN27SEP99
Torque Values
00 0003 6
Check Oil Lines And Fittings

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. Check all oil lines, hoses, and fittings regularly for leaks or damage. Make sure all clamps are in position and tight. Make sure hoses are not twisted or touching moving machine parts. If abrasion or wear occurs, replace immediately. Tubing with dents may cause the oil to overheat. If you find tubing with dents, install new tubing immediately. IMPORTANT: Tighten fittings as specified in torque chart. When you tighten connections, use two wrenches to prevent bending or breaking tubing and fittings.
TX,90,DH1559 1901AUG941/1
TM1640 (15JAN04)
00-0003-6

011504
PN=34
X9811
UN23AUG88
Torque Values
Service Recommendations for O-Ring Boss Fittings

Straight Fitting
UN18OCT88
00 0003 7
1. Inspect O-ring boss seat for dirt or defects. 2. Lubricate O-ring with petroleum jelly. Place electrical tape over threads to protect O-ring. Slide O-ring over tape and into O-ring groove of fitting. Remove tape. 3. Tighten fitting to torque value shown on chart.
04T,90,K66 1929SEP991/2
TM1640 (15JAN04)
00-0003-7

011504
PN=35
T6243AE
Torque Values
00 0003 8
Angle Fitting 1. Back-off lock nut (A) and back-up washer (B) completely to head-end (C) of fitting.
UN18OCT88
2. Turn fitting into threaded boss until back-up washer contacts face of boss. 3. Turn fitting head-end counterclockwise to proper index (maximum of one turn).
NOTE: Do not allow hoses to twist when tightening fittings.

4. Hold fitting head-end with a wrench and tighten locknut and back-up washer to proper torque value.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART Thread Size 3/8-24 UNF 7/16-20 UNF 1/2-20 UNF 9/16-18 UNF 3/4-16 UNF 7/8-14 UNF 1-1/16-12 UN 1-3/16-12 UN 1-5/16-12 UN 1-5/8-12 UN 1-7/8-12 UN Nm 8 12 16 24 46 62 102 122 142 190 217 lb-ft 6 9 12 18 34 46 75 90 105 140 160
NOTE: Torque tolerance is 10%.
04T,90,K66 1929SEP992/2
TM1640 (15JAN04)
00-0003-8

011504
PN=36
T6520AB
Torque Values
Service Recommendations For Flat Face O-Ring Seal Fittings

1. Inspect the fitting sealing surfaces and O-ring. They must be free of dirt or defects. 2. Lubricate O-rings and install into grove using petroleum jelly to hold in place. 3. Index angle fittings and tighten by hand pressing joint together to insure O-ring 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. IMPORTANT: Tighten fittings to 150% of listed torque value if indexing is necessary or if fitting is attached to an actuating devise. Tighten fittings to 50% of listed torque value if used in aluminum housing.
00 0003 9
FLAT FACE O-RING SEAL FITTING TORQUE* Nominal Tube O.D. mm 6.35 9.52 12.70 15.88 19.05 22.22 25.40 31.75 38.10 in. 0.250 0.375 0.500 0.625 0.750 0.875 1.000 1.250 1.500 Thread Size in. 9/16-18 11/16-16 13/16-16 1-14 1 3/16-12 1 3/16-12 1 7/16-12 1 11/16-12 2-12 Nm 16 24 50 69 102 102 142 190 217 Swivel Nut lb-ft 12 18 37 51 75 75 105 140 160 Nm 12 24 46 62 102 102 142 190 217 Bulkhead Nut lb-ft 9 18 34 46 75 75 105 140 160
*Torque tolerance is +15 -20% unless otherwise specified. Stud End O-ring Seal Torque for Straight and Adjustable Fittings* Thread Size Inch 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 Straight Hex Size Inch 5/8 5/8 3/4 3/4 7/8 1 1/16 1 1/4 1 3/8 1 1/2 Locknut Hex Size Inch 9/16 5/8 11/16 3/4 15/16 1 1/16 1 3/8 1 1/2 1 5/8 Straight Fitting or Locknut Toque Nm 12 21 26 34 73 104 176 230 285 lb-ft 9 15 19 25 55 76 130 170 210
*Torque tolerance is +15 -20% unless otherwise specified.
04T,90,K67 1902MAR001/1
TM1640 (15JAN04)
00-0003-9

011504
PN=37
Torque Values
00 0003 10
Service Recommendations for Metric Series Four Bolt Flange Fitting
ASealing Surface
BSplit Flange
CPinched O-Ring
DSingle Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component. 2. Install the correct O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to the port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C). 4. Single piece flange (D): Place hydraulic line in center of flange and install four cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5. After components are properly positioned and cap screws are hand tightened, tighten one cap screw,
a
then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below. DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten.
TORQUE CHARTa Thread M6 M8 M10 M12 M14 M16 M18 M20
b
Nm 12 30 57 95 157 217 334 421
lb-ft 9 22 42 70 116 160 246 318
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
TM1640 (15JAN04)
00-0003-10

011504
PN=38
T6890BB
UN01MAR90
Torque Values
Service Recommendations For Inch Series Four Bolt Flange Fittings
00 0003 11
ASealing Surface
BSplit Flange
CPinched O-Ring
DSingle Piece Flange TORQUE CHART Nm lb-ft
1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component. 2. Install O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C). 4. Single piece flange (D): Place hydraulic line in center of flange and install cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5. Tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below. DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten.
Nominal Flange Size 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2 4 5
Cap Screw Size Min 5/16-18 UNC 3/8-16 UNC 3/8-16 UNC 7/16-14 UNC 1/2-13 UNC 1/2-13 UNC 1/2-13 UNC 5/8-11 UNC 5/8-11 UNC 5/8-11 UNC 5/8-11 UNC 20 28 37 47 62 73 107 158 158 158 158 Max 31 54 54 85 131 131 131 264 264 264 264 Min 15 21 27 35 46 54 79 117 117 117 117 Max 23 40 40 63 97 97 97 195 195 195 195
04T,90,K174 1901AUG941/1
TM1640 (15JAN04)
00-0003-11

011504
PN=39
T6890BB
UN01MAR90
Torque Values
00 0003 12
TM1640 (15JAN04)
00-0003-12

011504
PN=40
Group 0004
Fuels and Lubricants

Diesel Fuel
Consult your local fuel distributor for properties of the diesel fuel available in your area. In general, diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed. Diesel fuels specified to EN 590 or ASTM D975 are recommended. In all cases, the fuel shall meet the following properties: Cetane number of 40 minimum. Cetane number greater than 50 is preferred, especially for temperatures below -20C (-4F) or elevations above 1500 m (5,000 ft). Cold Filter Plugging Point (CFPP) below the expected low temperature OR Cloud Point at least 5C (9F) below the expected low temperature. Fuel lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE scuffing test. Sulfur content: Sulfur content should not exceed 0.5%. Sulfur content less than 0.05% is preferred. If diesel fuel with sulfur content greater than 0.5% sulfur content is used, reduce the service interval for engine oil and filter by 50%. DO NOT use diesel fuel with sulfur content greater than 1.0%. Bio-diesel fuels may be used ONLY if the fuel properties meet DIN 51606 or equivalent specification. DO NOT mix used engine oil or any other type of lubricant with diesel fuel.
00 0004 1
TX,45,JC1132 1922MAY961/1
Lubricity of Diesel Fuel

Diesel fuel must have adequate lubricity to ensure proper operation and durability of fuel injection system components. Diesel fuels for highway use in the United States and Canada require sulfur content less than 0.05%. Diesel fuel in the European Union requires sulfur content less than 0.05%. Experience shows that some low sulfur diesel fuels may have inadequate lubricity and their use may reduce performance in fuel injection systems due to inadequate lubrication of injection pump components. The lower concentration of aromatic compounds in these fuels also adversely affects injection pump seals and may result in leaks. Use of low lubricity diesel fuels may also cause accelerated wear, injection nozzle erosion or corrosion, engine speed instability, hard starting, low power, and engine smoke. Fuel lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE scuffing test. ASTM D975 and EN 590 specifications do not require fuels to pass a fuel lubricity test. If fuel of low or unknown lubricity is used, add John Deere PREMIUM DIESEL FUEL CONDITIONER (or equivalent) at the specified concentration.
DX,FUEL5 1924JAN001/1
TM1640 (15JAN04)
00-0004-1

011504
PN=41

00 0004 2
Low Sulfur Diesel Fuel Conditioner

When possible, use existing fuel formulations for engines used off-highway. This fuel will not require any additives to provide good performance and engine reliability. However, many local fuel distributors will not carry both low and regular sulfur diesel fuels. If the local fuel distributor will supply only low sulfur fuel, order and use John Deere PREMIUM DIESEL FUEL CONDITIONER. It provides lubricating properties along with other useful benefits, such as cetane improver, anti-oxidant, fuel stabilizer, corrosion inhibitor and others. John Deere PREMIUM DIESEL FUEL CONDITIONER is specifically for use with low sulfur fuels. Nearly all other diesel fuel conditioners only improve cold weather flow and stabilize long-term fuel storage. They do not contain the lubrication additives needed by rotary fuel injection pumps.
TX,45,JC2126 1915AUG971/1
Diesel Fuel Storage

Proper fuel storage is critically important. Use clean storage and transfer tanks. Periodically drain water and sediment from bottom of tank. Store fuel in a convenient place away from buildings. IMPORTANT: DO NOT store diesel fuel in galvanized containers. Diesel fuel stored in galvanized containers reacts with zinc coating on container to form zinc flakes. If fuel contains water, a zinc gel will also form. The gel and flakes will quickly plug fuel filters, damage injection nozzles and injection pump. DO NOT use brass-coated containers for fuel storage. Brass is an alloy of copper and zinc. Store diesel fuel in plastic, aluminum, and steel containers specially coated for diesel fuel storage. Avoid storing fuel over long periods of time. If fuel is stored for more than a month prior to use, or there is a slow turnover in fuel tank or supply tank, add a fuel conditioner such as John Deere PREMIUM DIESEL FUEL CONDITIONER or equivalent to stabilize the fuel and prevent water condensation. John Deere PREMIUM DIESEL FUEL CONDITIONER is available in winter and summer formulas. Fuel conditioner also reduces fuel gelling and controls wax separation during cold weather. Consult your John Deere engine distributor or servicing dealer for recommendations and local availability. Always follow manufacturers directions on label.
TX,45,JC1772 1908JAN971/1
TM1640 (15JAN04)
00-0004-2

011504
PN=42
Fuel Tank
CAUTION: Handle fuel carefully. If the engine is hot or running, DO NOT fill the fuel tank. DO NOT smoke while you fill fuel tank or work on fuel system. To avoid condensation, fill the fuel tank at the end of each days operation. Shut off engine before filling.
Specification Fuel TankCapacity .................................................... 265 L (70 gal)
00 0004 3
CED,OUOE002,1783 1916SEP981/1
Diesel Engine Oil
Use oil viscosity based on the expected air temperature range during the period between oil changes. The following oil is preferred: John Deere PLUS-50 If John Deere PLUS-50 engine oil and a John Deere oil filter are used, the service interval for oil and filter changes may be extended by 50 hours.
The following oil is also recommended: John Deere TORQ-GARD SUPREME Other oils may be used if they meet API Service Classification CG-4. Multi-viscosity diesel engine oils are preferred. If diesel fuel with sulfur content greater than 0.5% is used, reduce the service interval by 50%.
PLUS-50 is a trademark of Deere & Company TORQ-GARD SUPREME is a registered trademark of Deere & Company
CED,OUO1021,176 1925MAR991/1
TM1640 (15JAN04)
00-0004-3

011504
PN=43
T101239
1922MAY96

00 0004 4
Transmission, Hydraulic System, Park Brake, and Differential Oil
Use oil viscosity based on the expected air temperature range during the period between oil changes. The following oils are preferred: John Deere HY-GARD John Deere Low Viscosity HY-GARD Other oils may be used if they meet one of the following:
John Deere Standard JDM J20C John Deere Standard JDM J20D Use the following oil when a biodegradable fluid is required: John Deere BIO-HY-GARD1
HY-GARD is a trademark of Deere & Company. BIO-HY-GARD is a trademark of Deere & Company. BIO-HY-GARD meets or exceeds the minimum biodegradability of 80% within 21 days according to CEC-L-33-T-82 test method. BIO-HY-GARD should not be mixed with mineral oils because this reduces the biodegradability and makes proper oil recycling impossible.
TX,45,JC1864 1917FEB971/1
1
TM1640 (15JAN04)
00-0004-4

011504
PN=44
T100663
1910MAY96
Grease
00 0004 5
Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval. The following greases are preferred: John Deere MOLY HIGH TEMPERATURE EP GREASE
John Deere HIGH TEMPERATURE EP GREASE John Deere GREASE-GARD Other greases may be used if they meet one of the following: NLGI Performance Classification GC-LB
TX,45,JC1134 1922MAY961/1
TM1640 (15JAN04)
00-0004-5

011504
PN=45
T8358AI
1927MAR95

00 0004 6
Alternative and Synthetic Lubricants

Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual. Some John Deere brand coolants and lubricants may not be available in your location. Consult your John Deere dealer to obtain information and recommendations. Synthetic lubricants may be used if they meet the performance requirements as shown in this manual. The temperature limits and service intervals shown in this manual apply to both conventional and synthetic oils. Re-refined base stock products may be used if the finished lubricant meets the performance requirements.
DX,ALTER 1915JUN001/1
Lubricant Storage
Your equipment can operate at top efficiency only when clean lubricants are used. Use clean containers to handle all lubricants. Whenever possible, store lubricants and containers in an area protected from dust, moisture, and other contamination. Store containers on their side to avoid water and dirt accumulation. Make certain that all containers are properly marked to identify their contents. Properly dispose of all old containers and any residual lubricant they may contain.
DX,LUBST 1918MAR961/1
TM1640 (15JAN04)
00-0004-6

011504
PN=46
Mixing of Lubricants
In general, avoid mixing different brands or types of oil. Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements. Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance. Consult your John Deere dealer to obtain specific information and recommendations.
00 0004 7
DX,LUBMIX 1918MAR961/1
TM1640 (15JAN04)
00-0004-7

011504
PN=47

00 0004 8
TM1640 (15JAN04)
00-0004-8

011504
PN=48
Section 01
Wheels
Contents
Page 01
Group 0110Powered Wheels and Fasteners Service Equipment and Tools . . . . . . . . . . . .01-0110-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .01-0110-1 Wheel Remove and Install . . . . . . . . . . . . . . . . . .01-0110-1 Tire Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-3 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-4
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01
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Group 0110
Powered Wheels and Fasteners

Service Equipment and Tools
NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.
01 0110 1
SERVICEGARD is a trademark of Deere & Company.
CED,OUOE003,3284 1925MAR991/3
10-Ton Shop Stand To support machine while removing and installing wheels.
CED,OUOE003,3284 1925MAR992/3
Wheel and Axle Lift . . . . . . . . . . . . . . . . . . . . JT05726 To remove and install wheels.
CED,OUOE003,3284 1925MAR993/3
Specifications
Wheel Cap Screw Valve Stem Retaining Nut
Torque Torque
675 Nm (500 lb-ft) 6 Nm (50 lb-in.)
CED,OUOE003,3285 1925MAR991/1
Remove and Install Wheel

1. Raise machine and place 10-ton shop stand under axle. CAUTION: Use a lifting device for heavy components. 2. Place wheel and axle lift under wheel. Fasten safety chain around upper part of tire.
Continued on next page TX,01,111685 1901NOV021/2
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01-0110-1

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PN=51

3. Remove cap screws (A). Remove wheel. 4. Clean mounting surface on wheel and axle flange.
01 0110 2
5. Install wheel. Tighten cap screws (A).

Remove and Install WheelSpecification Wheel Retainer Cap ScrewsDry Torque ......................................................................... 620 Nm (460 lb-ft)
AWheel Cap Screw (14 used)
TX,01,111685 1901NOV022/2
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01-0110-2

011504
PN=52
T7134FA
UN24MAY90
Remove Tire
CAUTION: Explosive separation of a tire and rim parts can cause serious injury or death. Only attempt to mount a tire if you have the proper equipment and experience to perform the job. Have it done by your John Deere dealer or a qualified repair service. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available. Inspect tires and wheels daily. Do not operate with low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts. Failure to follow proper procedures when demounting a tire from a wheel or rim can produce an explosion which may result in serious bodily injury. DO NOT attempt to demount a tire unless you have proper equipment and experience to perform the job safely. Have it done by a qualified tire repair service.
01 0110 3
NOTE: See John Deere Off-The-Road Tire Maintenance Manual to remove tire from wheel.
Tire can be removed without removing wheel.
TX,01,111686 1923OCT981/2
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01-0110-3

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PN=53
TS211
UN23AUG88

Before attempting any demounting operation, always completely deflate tire. Remove cap (A) and valve core (B) from valve. Remove valve nut (C).
01 0110 4
Inspect all parts for damage. Replace parts as necessary.

ACap BValve Core CValve Nut
UN22OCT92
TX,01,111686 1923OCT982/2
Install Tire
CAUTION: Failure to follow proper procedures when mounting a tire from a wheel or rim can produce an explosion which may result in serious bodily injury. DO NOT attempt to mount a tire unless you have proper equipment and experience to perform the job safely. Have it done by a qualified tire repair service.
NOTE: See John Deere Off-The-Road Tire Maintenance Manual to mount the tire on the wheel.
To prevent slipping of the wheel under load, the inside and outside wheel must be free of paint, rust, oil, grease, dirt or other foreign material before installation. Install valve stem in rim base and tighten retaining nut.
Specification Valve Stem Retaining Nut Torque .............................................................................. 6 Nm (50 lb-in.) AFront Flange BBead Seat Band CLock Ring DO-Ring ECap
CAUTION: Serious bodily injury can occur from explosion when mounting and inflating tires if safe procedures are not followed. Use only recommended air pressure. Pressure over this limit can cause explosion. Inflate tire. Apply John Deere Non-Soap Lubricating Grease, or an equivalent, on threads of cap (E). Install cap on valve stem shield.
TX,01,111687 1923OCT981/1
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T6564BR
UN22OCT88
T7751GU
Section 02
Axles and Suspension Systems

Contents
Page
Group 0200Removal and Installation Service Equipment and Tools . . . . . . . . . . . .02-0200-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .02-0200-2 Front Axle and Differential Remove and Install . . . . . . . . . . . . . . . . . .02-0200-3 Rear Axle And Differential Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-9 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-14 Axle Oscillating Supports Disassemble and Assemble. . . . . . . . . . .02-0200-18 Group 0225Axle Shafts and U-Joints Specifications . . . . . . . . . . . . . . . . . . . . . . . .02-0225-1 Universal Joint and Drive Shaft Remove and Install . . . . . . . . . . . . . . . . . .02-0225-2 Disassemble, Inspect and Assemble . . . . .02-0225-4 Group 0250Axle Shaft, Bearings, Reduction Gears John Deere TeamMate III AxlesUse CTM150. . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-1 Essential Tools . . . . . . . . . . . . . . . . . . . . . . .02-0250-1 Service Equipment and Tools . . . . . . . . . . . .02-0250-2 Other Material . . . . . . . . . . . . . . . . . . . . . . . .02-0250-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . .02-0250-3 Axle Disconnect Input Shaft Cross-Section View . . . . . . . . . . . . . . . . . .02-0250-4 Remove and Install . . . . . . . . . . . . . . . . . .02-0250-5 Disassemble, Inspect and Assemble . . . . .02-0250-6 Group 0260Hydraulic System Specifications . . . . . . . . . . . . . . . . . . . . . . . .02-0260-1 Differential Lock Solenoid Valve Remove and Install . . . . . . . . . . . . . . . . . .02-0260-2 Axle Recirculation System. . . . . . . . . . . . . . .02-0260-3 Air Recirculation System With Optional Oil Coolers. . . . . . . . . . . . . .02-0260-4 Axle Oil Coolers Exploded View. . . . . . . . . . . . . . . . . . . . . .02-0260-6 Front Axle Oil Cooler Remove and Install . . . . . . . . . . . . . . . . . .02-0260-7 Disassemble and Assemble. . . . . . . . . . . .02-0260-9 Rear Axle Oil Cooler Remove and Install . . . . . . . . . . . . . . . . .02-0260-10
02
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Group 0200
Removal and Installation

CED,OUOE003,3287 1925MAR991/4
02 0200 1
12-1/2 Ton Floor Stands To support machine while removing axle and differential.
CED,OUOE003,3287 1925MAR992/4
Wheel and Axle Lift . . . . . . . . . . . . . . . . . . . . JT05726 To remove and install wheels.
CED,OUOE003,3287 1925MAR993/4
Low-Lift Jack . . . . . . . . . . . . . . . . . . . . . . . JT01642A For removal and installation of axle and differential.
CED,OUOE003,3287 1925MAR994/4
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Specifications
Front Axle and Differential 624H Loader TC62H Tool Carrier

02 0200 2
Weight Weight Weight Weight Torque Torque
13 560 kg (29,894 lb) approximate 13 361 kg (29,456 lb) approximate 32 kg (72 lb) approximate 580 kg (1280 lb) approximate 675 Nm (500 lb-ft) 78 Nm (58 lb-ft)
Front Frame Bottom Guard Axle and Differential Cap Screw Nut Drive Shaft Universal Joint Cap Screw Wheel Cap Screw
Torque
675 Nm (500 lb-ft)
Rear Axle and Differential Transmission Bottom Guard 624H Loader TC62H Tool Carrier Axle and Differential with Oscillating Supports Thrust Plate-to- Rear Oscillating Support Cap Screw Pivot Cover-to-Rear Oscillating Support Cap Screw Axle Support-to-Rear Oscillating Support Cap Screw Drive Shaft Universal Joint Cap Screw Wheel Cap Screw Weight Weight Weight Weight 62 kg (137 lb) approximate 13 560 kg (29,894 lb) approximate 13 361 kg (29,456 lb) approximate 598 kg (1320 lb) approximate
Torque
350 Nm (255 lb-ft)
Torque
140 Nm (105 lb-ft)
Torque
675 Nm (500 lb-ft)
Torque
78 Nm (58 lb-ft)
Torque
675 Nm (500 lb-ft)
CED,OUOE003,3288 1925MAR991/2
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Item
Measurement
Specification
Axle Oscillating Supports Axle Oscillating Support Thrust Plate Between Thrust Bearings Thrust Plate-to-Rear Oscillating Support Cap Screw Pilot Cover-to-Rear Oscillating Support Cap Screw End Play Wear 0.762 mm (0.03 in.) maximum 0.254 mm (0.01 in.) maximum on front side 350 Nm (255 lb-ft)
02 0200 3
Torque
Torque
140 Nm (105 lb-ft)
CED,OUOE003,3288 1925MAR992/2
Remove and Install Front Axle and Differential

1. Apply park brake.
UN03OCT96
2. Install frame locking bar (A). CAUTION: The approximate weight of machine is: 624H13 560 kg (29,894 lb) TC62H13 361 kg (29,456 lb)
Front Axle and DifferentialSpecification 624H LoaderWeight ............................................. 13 560 kg (29,894 lb) approximate TC62H Tool CarrierWeight .................................. 13 361 kg (29,456 lb) approximate ALocking Bar B12-1/2 Ton Floor Stand
3. Raise front of machine. Install floor stands (B) under loader frame. 4. Install boom lock. Move bucket to dumped position and lower. This will provide clearance to remove cap screws. 5. Stop engine.
TX,02,111691 1925MAR991/6
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T101610
02 0200 4
CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with ride control. Ride control accumulator energy must be discharged when working on hydraulic components. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 6. If equipped with ride control. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 7. Drain differential. Approximate oil capacity is 25 L (26.0 qt). CAUTION: The approximate weight of bottom guard is 32 kg (72 lb). Weight may increase significantly due to buildup of mud or debris.
Front Axle and DifferentialSpecification Front Frame Bottom Guard Weight................................................................ 32 kg (72 lb) approximate
8. Remove bottom guard, if equipped.
TX,02,111691 1925MAR992/6
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Removal and Installation NOTE: Label lines to aid in installation.

9. Disconnect lines from ports (AE). Install caps and plugs in ports and hoses. 10. Remove cap screws to disconnect drive shaft. CAUTION: Use a lifting device for heavy components. 11. Remove wheels using wheel and axle lift.
ABrake Port BRecirculation System Inlet Port CDifferential Lock Port DAxle Disconnect Port (If Equipped) ERecirculation System Outlet Port
UN07MAY99
02 0200 5
TX,02,111691 1925MAR993/6
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PN=61
T121376
CAUTION: The approximate weight of axle and differential is 580 kg (1280 lb).
Front Axle and DifferentialSpecification Axle and DifferentialWeight ..................... 580 kg (1280 lb) approximate
12. Install low-lift jack (B) under axle and differential. 13. Remove nuts (A) to remove cap screws. Lower axle and differential.
02 0200 6
14. Repair or replace axle or differential. (See procedure in this group.) 15. Clean mounting surface on axle housings and loader frame. 16. Install axle and differential. Install a washer under head of cap screws and a washer under the nuts. Hold the cap screws and tighten nuts.
Front Axle and DifferentialSpecification Cap Screw NutTorque ............................................. 675 Nm (500 lb-ft)
TeamMate II Axle Shown

ANuts BLow-Lift Jack
TX,02,111691 1925MAR994/6
TM1640 (15JAN04)
02-0200-6

011504
PN=62
T101609
UN03OCT96

IMPORTANT: To properly check oil level, do not thread dipstick into port. Allow 10 minutes for oil to stabilize in each sump before checking.
UN29JAN97 T106373B
NOTE: Each differential housing has three separate components. To expedite filling differential, remove right axle plug.
17. Fill differential adding oil slowly through port (A) on the left axle. Check oil level after waiting 10 minutes. Make sure machine is level. (See Differential Oil in Group 0004 for recommended oil.) IMPORTANT: DO NOT reuse drive shaft universal joint cap screws. Replace cap screws to avoid machine damage. 18. Connect drive shaft. Install new drive shaft universal joint cap screws. Tighten cap screws.
Front Axle and DifferentialSpecification Drive Shaft Universal Joint Cap ScrewTorque ................................................................ 78 Nm (58 lb-ft) APort
Left Front Differential Axle
02 0200 7
TX,02,111691 1925MAR995/6
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19. Connect lines to ports (AE). 20. Remove jack. 21. Install wheels. Tighten cap screws.
Front Axle and DifferentialSpecification Wheel Cap ScrewTorque......................................... 675 Nm (500 lb-ft)
02 0200 8
NOTE: No bleeding of brakes is necessary. They are self-bleeding.

22. Install bottom guard, if equipped.
UN07MAY99
TX,02,111691 1925MAR996/6
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PN=64
T121376
Remove Rear Axle and Differential

1. Apply park brake. 2. Install frame locking bar. 3. Raise boom and install boom lock. Move bucket to dump position. 4. Stop engine. Release hydraulic pressure by operating loader control while holding boom enable switch. CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with ride control. Ride control accumulator energy must be discharged when working on hydraulic components. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 5. If equipped with ride control. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. CAUTION: The approximate weight of transmission bottom guard is 62 kg (137 lb). Weight may increase significantly due to buildup of mud or debris on guard.
Rear Axle and DifferentialSpecification Transmission Bottom Guard Weight.............................................................. 62 kg (137 lb) approximate
02 0200 9
6. Remove transmission bottom guard if equipped. 7. Drain differential. Approximate oil capacity is 20 L (21 qt).
TX,02,111692 1910FEB991/5
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CAUTION: The approximate weight of machine is: 624H13 560 kg (29,894 lb) TC62H13 361 kg (29,456 lb)
Rear Axle and DifferentialSpecification 624H LoaderWeight ............................................. 13 506 kg (29,894 lb) approximate TC62H Tool CarrierWeight .................................. 13 361 kg (29,456 lb) approximate
UN20FEB90
02 0200 10
8. Raise rear of machine using floor jack. Install floor stands (A) under frame on each side and under rear corners of frame. CAUTION: Use a lifting device for heavy components. 9. Remove wheels. 10. Remove caps screws to disconnect drive shaft. CAUTION: The approximate weight of axle and differential with front and rear oscillating supports is 598 kg (1320 lb).
Rear Axle and DifferentialSpecification Axle and Differential with Oscillating SupportsWeight ...................... 598 kg (1320 lb) approximate
11. Install low-lift jack under axle and differential.

AFloor Stand (4 used)
UN06MAR90
TX,02,111692 1910FEB992/5
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T7134HE
T7134HD

12. Disconnect lines (A and B) if equipped.
02 0200 11
UN07MAY99
TX,02,111692 1910FEB993/5
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T121376
02 0200 12
Rear Differential Oscillating Supports and Lubrication Lines

Continued on next page TX,02,111692 1910FEB994/5
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02-0200-12

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TP60398
UN22MAY98

1Special Jam Nut (2 used) 2Fitting (2 used) 3Pipe Plug 4Hydraulic Hose 5Elbow Fitting (3 used) 6Rear Oscillating Support 7Bushing (2 used) 8Thrust Bearing (6 used) 9Thrust Plate 10Washer (4 used) 11Cap Screw (4 used) 12O-Ring 13Cover 14Cap Screw (6 used) 15Cap Screw (6 used) 16Seal (3 used) 17Cap Screw (4 used) 18Nut 19Hydraulic Hose 20Elbow Fitting 21Lubrication Fitting (2 used) 22Washer (16 used) 23Rear Axle Support 24Rear Axle Support 25Lubrication Fitting 26Bushing (2 used S/N XXXX) (4 used S/N XXXX )
NOTE: Bushings (26) are installed on center right and left cap screws (Serial No. XXXX) and installed two on the front and two on the rear cap screws (Serial No. XXXX ).
13. Disconnect hydraulic hoses (4 and 19) from front and rear oscillating supports. 14. Remove cap screws (17 and 15) from oscillating supports. 15. Lower supports, axle and differential assembly.
16. Remove rear axle support (23) from differential assembly. 17. Remove cap screws from pivot cover (13) and thrust plate (9). 18. Remove rear oscillating support (6) from differential assembly. 19. Repair or replace axle. See this group for repair.
02 0200 13
TX,02,111692 1910FEB995/5
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Install Rear Axle and Differential
02 0200 14
TX,02,111693 1911FEB991/3
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02-0200-14

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PN=70
TP60398
UN22MAY98

1. Install front and rear oscillating supports. 2. Tighten thrust plate (9) cap screws (11) and pivot cover (13) cap screws (14).
Rear Axle and DifferentialSpecification Thrust Plate-to- Rear Oscillating Support Cap ScrewTorque ..................................................... 350 Nm (255 lb-ft) Pivot Cover-to-Rear Oscillating Support Cap ScrewTorque ............................... 140 Nm (105 lb-ft)
6. Connect drive shaft. Install new drive shaft universal joint cap screws. Tighten cap screws.
Rear Axle and DifferentialSpecification Drive Shaft Universal Joint Cap ScrewTorque ......................................................... 78 Nm (58 lb-ft) 02 0200 15
NOTE: No bleeding of brakes is necessary. They are self-bleeding.

7. Connect lubrication lines. 8. Install wheels. Tighten cap screws.
Rear Axle and DifferentialSpecification Wheel Cap ScrewTorque .................................. 675 Nm (500 lb-ft)
3. Install axle and differential. 4. Tighten cap screws (15 and 17).
Rear Axle and DifferentialSpecification Axle Support-to-Rear Oscillating Support Cap ScrewTorque ..................................................... 675 Nm (500 lb-ft)
9. Remove floor stands. 10. Install bottom guard, if equipped.
5. Connect lines to differential. IMPORTANT: DO NOT reuse drive shaft universal joint cap screws. Replace cap screws to avoid machine damage.
TX,02,111693 1911FEB992/3
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IMPORTANT: To properly check oil level, do not thread dipstick into port. Allow 10 minutes for oil to stabilize in each sump before checking.
UN29JAN97
NOTE: Each differential housing has three separate components. To expedite filling differential, remove right axle plug.
11. Fill differential adding oil slowly through port (A) on the left axle. Check oil level after waiting 10 minutes. Make sure machine is level. (See Differential Oil in Group 0004 for recommended oil.)
APort
02 0200 16
Left Front Differential Axle
TX,02,111693 1911FEB993/3
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PN=72
T106373B
02 0200 17
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PN=73
Disassemble and Assemble Axle Oscillating Supports
02 0200 18
TX,02,111694 1911FEB991/3
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PN=74
TP60398
UN22MAY98

NOTE: Axle oscillation support assembly does not contain any shims for setting end play. If excessive end play is incurred due to wear, end play should be no greater than 0.762 mm (0.03 in). This can be checked with dial indicator measuring between front support and the differential housing. If greater than 0.762 mm (0.03 in.) thrust bearings should be replaced. Also check thrust plate (between both thrust bearings) for wear on front side. Disk should not have more than 0.254 mm (0.01 in.) wear step on face that contacts front thrust bearings. If out of specification, replace thrust plate and thrust bearings.
1. Remove rear axle and differential assembly. (See procedure in this group.) 2. Remove front oscillating support.
3. Remove cap screws (14) in pivot cover and cap screws (11) in thrust plate (9) in rear oscillating support. 4. Remove rear oscillating support. 5. Repair and replace parts as necessary. 6. Inspect thrust bearings (8) and bushings (7) for wear.
Axle Oscillating SupportsSpecification Axle Oscillating SupportEnd Play ...................................................... 0.762 mm (0.03 in.) maximum Thrust Plate Between Thrust BearingsWear................................... 0.254 mm (0.01 in.) maximum on front side
02 0200 19
7. Lube thrust bearings and bushings with grease and pack cavity of cover (13).
TX,02,111694 1911FEB992/3
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Removal and Installation NOTE: If bushings were removed in front or rear oscillation supports note proper location of bushing (C) grease slots (D) in relation to the grease fitting (B). Slots should be facing up toward the grease fitting to allow proper lubrication of pivot area.
8. Press bushings into front and rear supports being careful not to damage.
02 0200 20
9. Install rear and front oscillating supports to differential. 10. Tighten thrust plate cap screws (11) and pivot cover cap screws (14).
Axle Oscillating SupportsSpecification Thrust Plate-to-Rear Oscillating Support Cap ScrewTorque ...................................... 350 Nm (255 lb-ft) Pilot Cover-to-Rear Oscillating Support Cap ScrewTorque ...................................... 140 Nm (105 lb-ft)
ASupport BGrease Fitting CBushing DGrease Slots
11. Install rear axle and differential assembly. (See procedure in this group.)
TX,02,111694 1911FEB993/3
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PN=76
T108815B
UN04APR97
Group 0225
Axle Shafts and U-Joints

Specifications
Front and Rear Drive Shaft Universal Torque Joint Cap Screw Engine Drive Shaft Universal-to-Transmission Cap Screw Engine Drive Shaft-to-Damper Cap Screw Torque
78 Nm (58 lb-ft)
78 Nm (58 lb-ft)
Torque
130 Nm (95 lb-ft)
02 0225 1
CED,OUOE003,3291 1925MAR991/1
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PN=77
Remove and Install Universal Joint and Drive Shaft
02 0225 2
CAUTION: Prevent possible injury from unexpected machine movement. Place blocks front and rear of tires to prevent machine from rolling. IMPORTANT: DO NOT reuse drive shaft universal joint cap screws. Replace cap screws to avoid machine damage. 1. Remove drive shaft universal joint cap screws. 2. Inspect and replace parts as necessary.
3. Install new drive shaft universal joint cap screws.

Specification Front and Rear Drive Shaft Universal Joint Cap Screw Torque....................................................................... 78 Nm (58 lb-ft) Engine Drive Shaft Universal-to-Transmission Cap ScrewTorque ......................................................... 78 Nm (58 lb-ft) Engine Drive Shaft-to-Damper Cap ScrewTorque ............................................... 130 Nm (95 lb-ft)
TX,02,111696 1925MAR991/1
TM1640 (15JAN04)
02-0225-2

011504
PN=78
T108602
1931MAR97
02 0225 3
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02-0225-3

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PN=79
Disassemble, Inspect and Assemble Universal Joint and Drive Shaft
02 0225 4
Transmission-to-Differential and Engine Shafts

1Cap Screw (4 used) 2Cap Screw (28 used) 3Clamp (14 used) 4Drive Shaft 5Drive Shaft 6Cap Assembly (3 used) 7Drive Shaft 8Drive Shaft
CAUTION: Prevent possible injury from unexpected machine movement. Place blocks front and rear of tires to prevent machine from rolling. IMPORTANT: DO NOT reuse drive shaft universal joint cap screws. Replace cap screws to avoid machine damage.
1. Remove drive shaft universal joint cap screws. 2. Inspect and replace parts as necessary.
TX,02,111697 1925MAR991/2
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02-0225-4

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PN=80
T112056
1903NOV97

3. Install new drive shaft universal joint cap screws.
Specification Front and Rear Drive Shaft Universal Joint Cap Screw Torque....................................................................... 78 Nm (58 lb-ft) Engine Drive Shaft Universal-to-Transmission Cap ScrewTorque ......................................................... 78 Nm (58 lb-ft) Engine Drive Shaft-to-Damper Cap ScrewTorque ............................................... 130 Nm (95 lb-ft)
TX,02,111697 1925MAR992/2
02 0225 5
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02 0225 6
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Group 0250
Axle Shaft, Bearings, Reduction Gears

John Deere TeamMate III AxlesUse CTM150
For complete repair information, the Component Technical Manual (CTM) is also required.
UN17JAN89 TS225
Use the CTM in conjunction with this repair manual.
TeamMate is a trademark of Deere & Company.
CED,OUOE006,18 1924SEP981/1
02 0250 1
Essential Tools
NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC).

RW25643 UN28FEB97
CED,OUOE003,3293 1925MAR991/8
Lifting Screw . . . . . . . . . . . . . . . . . . . . . . . JDG1125 Used with JDG19 Special Mounting Bracket to remove and install axle disconnect input shaft.
CED,OUOE003,3293 1925MAR992/8 RW25781 UN19JUN97
Spanner Wrench . . . . . . . . . . . . . . . . . . . . . JDG1142 Used to remove and install auxiliary yoke retaining nut.
CED,OUOE003,3293 1925MAR993/8 RW25383 UN02APR96
Yoke Holding Tool . . . . . . . . . . . . . . . . . . . . JDG1090 Used to remove and install yoke retaining nut.
Bearing Installer Set . . . . . . . . . . . . . . . . . . JDG1141 Used to support disconnect input shaft and install outer bearing cone.
Continued on next page CED,OUOE003,3293 1925MAR995/8
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PN=83

RW25388 UN15JUN95
Seal Installer . . . . . . . . . . . . . . . . . . . . . . . JDG1092 Used with JDG926 Bearing Installer to install input shaft yoke seal on 1200 Series rear axle.
Seal Installer . . . . . . . . . . . . . . . . . . . . . . . JDG1151 Used with JDG926 Bearing Installer to install input shaft yoke seal on 1400 Series front axle.
02 0250 2
Bearing Installer . . . . . . . . . . . . . . . . . . . . . . JDG926 Used with seal installer to install input shaft seal.
CED,OUOE003,3293 1925MAR998/8

CED,OUOE003,3294 1925MAR991/6
Special Mounting Bracket . . . . . . . . . . . . . . . . . JDG19 Used with JDG1125 Lifting Screw to remove and install axle disconnect input shaft.
CED,OUOE003,3294 1925MAR992/6
Driver Disk. . . . . . . . . . . . . . . . . . . . . . . . . 4-5/16 in. To force piston downward for snap ring removal on a 1200 Series rear axle.
CED,OUOE003,3294 1925MAR993/6
Driver Disk. . . . . . . . . . . . . . . . . . . . . . . . . . 5-1/2 in. To force piston downward for snap ring removal on a 1400 Series front axle.
TM1640 (15JAN04)
02-0250-2

011504
PN=84

Driver Disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 in. To install bearing cups on a 1200 Series rear axle.
CED,OUOE003,3294 1925MAR995/6
Driver Disk. . . . . . . . . . . . . . . . . . . . . . . . . 3-9/16 in. To install bearing cups on a 1400 Series front axle.
02 0250 3
CED,OUOE003,3294 1925MAR996/6
Other Material
Number Name Use
PT506 (U.S.)
NEVER-SEEZ Lubricant
Apply to shaft threads.
NEVER-SEEZ is a trademark of Emhart Chemical Group.
CED,OUOE003,3295 1925MAR991/1
Specifications
Axle Disconnect Input Shaft Disconnect Assembly Retaining Cap Screw Auxiliary Yoke-to-Differential Drive Shaft Nut Collar Engagement Spring Weight Torque Torque 61 kg (135 lb) approximate 310 Nm (230 lb-ft) 360 Nm (267 lb-ft)
Free Length Test Length
73 mm (2.874 in.) approximate 44.45 mm at 352431 N (1.750 in. at 7896 lb-force) 360 Nm (267 lb-ft)
Yoke Retaining Nut
Torque
CED,OUOE003,3296 1925MAR991/1
TM1640 (15JAN04)
02-0250-3

011504
PN=85
Axle Disconnect Input Shaft, Cross-Sectional View
02 0250 4
ADisconnect Input Shaft BNut CSpacer Washer DInput Yoke EDisconnect Housing FCollar Engagement Spring (4 used) GCollar Assembly Spring Retainer Plate
HCollar Assembly Anti-Rotation Plug ICollar Assembly Housing JPiston Housing KHousing-to-Differential Case Sealing Ring LDisconnect Auxiliary Yoke MDifferential Drive Shaft
NNut OSpacer Washer PPiston Assembly Packing Ring (2 used) QPiston Packing Ring (4 used) RPiston (4 used) SNeedle Bearing Thrust Washer
TNeedle Roller Bearing (2 used) UCollar VInput Shaft Bearing Set WInput Shaft Seal XDust Seal YOil Ring
TX,02,111673 1921JUL971/1
TM1640 (15JAN04)
02-0250-4

011504
PN=86
RW36308
UN17MAR97
Remove and Install Axle Disconnect Input Shaft

NOTE: Axle assembly is removed from vehicle.
CAUTION: The approximate weight of disconnect assembly is 61 kg (135 lb).
Axle Disconnect Input ShaftSpecification Disconnect AssemblyWeight ....................... 61 kg (135 lb) approximate
Loosen retaining cap screw (A).

UN17MAR97
02 0250 5
Install JDG1125 Lifting Screw (B) and JDG19 Special Mounting Bracket (C) and attach to an overhead hoist. Remove the disconnect assembly from the axle assembly. Install axle disconnect assembly onto axle. Push disconnect assembly forward until snap ring stops against axle differential case oscillating input. Slowly rotate disconnect until hydraulic fitting is at top center. Install retaining cap screw (A), washers and nut on disconnect housing compression joint. Tighten retaining cap screw.
Axle Disconnect Input ShaftSpecification Retaining Cap ScrewTorque ................................... 310 Nm (230 lb-ft)
ARetaining Cap Screw BJDG1125 Lifting Screw CJDG19 Special Mounting Bracket
TX,02,111675 1910MAY991/1
TM1640 (15JAN04)
02-0250-5

011504
PN=87
RW36289
Disassemble, Inspect, and Assemble Axle Disconnect Input Shaft

Remove disconnect assembly from axle assembly. (See Remove and Install Axle Disconnect Input Shaft in this group.) Inspect disconnect auxiliary yoke (A) on differential drive shaft and remove and replace as necessary.
02 0250 6
Install JDG1142 Spanner Wrench and remove nut (B). Remove spacer washer and disconnect auxiliary yoke from differential drive shaft. Install in reverse order. Tighten nut.
Axle Disconnect Input ShaftSpecification Auxiliary Yoke-to-Differential Drive Shaft NutTorque ............................................. 360 Nm (267 lb-ft) AAuxiliary Yoke BNut
TX,02,111677 1925MAR991/25
Install JDG1090 Yoke Holding Tool (A) to input shaft yoke. Remove nut and spacer from shaft.
UN17MAR97
Remove yoke and oil ring from shaft.

AYoke Holding Tool
TX,02,111677 1925MAR992/25
TM1640 (15JAN04)
02-0250-6

011504
PN=88
RW36291
RW36290
UN17MAR97

Remove input shaft seal (A).
AInput Shaft Seal
UN17MAR97
02 0250 7
TX,02,111677 1925MAR993/25
Remove housing-to-differential case sealing ring (A).

ASealing Ring
TX,02,111677 1925MAR994/25
Install disconnect assembly in a press and place a 4-5/16 in. (1200 Series Rear Axle) or a 5-1/2 in. (1400 Series Front Axle) driver disk and handle (A) on top of the piston housing.
UN17MAR97
Force the piston downward and remove snap ring (B).

ADriver Disk and Handle BSnap Ring
TX,02,111677 1925MAR995/25
TM1640 (15JAN04)
02-0250-7

011504
PN=89
RW36294
RW36293
UN17MAR97
RW36292

Remove piston housing assembly (A) using a 3-jaw puller and a slide hammer.
APiston Housing Assembly
TX,02,111677 1925MAR996/25
Remove pistons from housing by tapping the backside of the housing with a hammer. Inspect housing (A), pistons (B), and packing rings (C). Replace parts as necessary. Install pistons with packing rings into the piston housing.
AHousing BPiston CPacking Rings
UN17MAR97
TX,02,111677 1925MAR997/25
TM1640 (15JAN04)
02-0250-8

011504
PN=90
RW36296
RW36295
02 0250 8
UN17MAR97

Remove piston packing rings (A). Remove collar assembly anti-rotation plug (B). Remove collar assembly (C) from disconnect assembly.
APiston Packing Ring (2 used) BAnti-Rotation Plug CCollar Assembly 02 0250 9
TX,02,111677 1925MAR998/25
Remove the collar assembly spring return plate (A) from the collar assembly housing.
ASpring Return Plate
TX,02,111677 1925MAR999/25
TM1640 (15JAN04)
02-0250-9

011504
PN=91
RW36298
UN17MAR97
RW36297
UN17MAR97

Remove parts (AC) from housing (D). Inspect parts and replace as necessary.
UN17MAR97
Assemble in reverse order.

ANeedle Roller Bearing BShift Collar CNeedle Roller Bearing Thrust Washer DCollar Assembly Housing ECollar Assembly Spring Retainer Plate
02 0250 10
TX,02,111677 1925MAR9910/25
Remove collar engagement springs (A) from housing. Inspect springs.

Axle Disconnect Input ShaftSpecification Collar Engagement SpringFree Length ..................................................... 73 mm (2.874 in.) approximate Test Length........................................................ 44.45 mm at 352431 N (1.750 in. at 7896 lb-force)
ACollar Engagement Spring (4 used)

UN17MAR97
TX,02,111677 1925MAR9911/25
TM1640 (15JAN04)
02-0250-10

011504
PN=92
RW36300
RW36299

Place the disconnect assembly in a press. Remove the input shaft (A) from the housing and outer bearing cone while supporting the shaft inside the case to prevent shaft from falling.
AInput Shaft
UN17MAR97
02 0250 11
TX,02,111677 1925MAR9912/25
Remove outer bearing cone (A) from housing.

AOuter Bearing Cone
TX,02,111677 1925MAR9913/25
TM1640 (15JAN04)
02-0250-11

011504
PN=93
RW36302
UN17MAR97
RW36301
Axle Shaft, Bearings, Reduction Gears NOTE: The input shaft bearings are supplied as a matched set. When replacement is required, replace all parts.
Inspect and if necessary remove inner and outer bearing cups (A) from housing (B). Inspect bearing cup spacer snap ring (C) and remove if necessary.
02 0250 12
Install new bearing cup spacer snap ring in housing. Install new bearing cups in housing using a 3 in. (1200 Series Rear Axle) or a 3-9/16 in. (1400 Series Front Axle) driver disk and a press.
ABearing Cup (2 used) BHousing CSnap Ring
UN17MAR97
TX,02,111677 1925MAR9914/25
Inspect disconnect input shaft (A), inner bearing cone (B), and bearing spacer (C) and replace as necessary. If necessary, remove bearing spacer (C) from shaft and remove inner bearing (B) using a knife-edge puller and a press. CAUTION: Heat parts in a bearing heater. Use a thermometer and do not exceed 150C (300F). Plan a safe handling procedure to avoid burns. Heat bearing cone to 150 C (300 F) and install on shaft.
AInput Shaft BInner Bearing Cone CBearing Spacer
TX,02,111677 1925MAR9915/25
TM1640 (15JAN04)
02-0250-12

011504
PN=94
RW36304
UN17MAR97
RW36303
Axle Shaft, Bearings, Reduction Gears NOTE: JDG1141-1 Centering Tool is part of the JDG1141 Bearing Installer Set.
Install the disconnect housing in a press using JDG1141-1 Centering Tool (A) to support the input shaft (B) that is installed through the housing.
AJDG1141-1 Centering Tool BInput Shaft 02 0250 13
TX,02,111677 1925MAR9916/25
NOTE: JDG1141-2 Driver is part of the JDG1141 Bearing Installer Set.

Install the outer bearing cone (A) onto the shaft using JDG1141-2 Driver (B).
UN17MAR97
AOuter Bearing Cone BJDG1141-2 Driver
TX,02,111677 1925MAR9917/25
TM1640 (15JAN04)
02-0250-13

011504
PN=95
RW36305
RW36310
UN11APR97

Install collar engagement springs (A) into disconnect housing.
ACollar Engagement Springs
TX,02,111677 1925MAR9918/25
Install collar assembly (C) into housing aligning the anti-rotation slot in the collar assembly housing with the opening in disconnect housing for the anti-rotation plug. Install anti-rotation plug (B). Install piston packing rings (A). Apply oil to the piston packing rings.
APiston Packing Ring (2 used) BAnti-Rotation Plug CCollar Assembly
TX,02,111677 1925MAR9919/25
TM1640 (15JAN04)
02-0250-14

011504
PN=96
RW36297
UN17MAR97
RW36300
UN17MAR97
02 0250 14

Install piston assembly (A) into the housing. Place 4-5/16 in. (1200 Series Rear Axle) or a 5-1/2 in. (1400 Series Front Axle) driver disk and handle (B) on top of the piston housing. Force the piston downward using a shop press and install snap ring (C).
APiston Assembly BDriver Disk and Handle CSnap Ring
UN17MAR97 RW36306
02 0250 15
TX,02,111677 1925MAR9920/25
Install housing-to-differential case sealing ring (A).

ASealing Ring
TX,02,111677 1925MAR9921/25
TM1640 (15JAN04)
02-0250-15

011504
PN=97
RW36293
UN17MAR97

Install input shaft seal (A) using JDG1092 (1200 Series Rear Axle) or JDG1151 (1400 Series Front Axle) Seal Installer along with JDG926 Bearing Installer.
AInput Shaft Seal
02 0250 16
TX,02,111677 1925MAR9922/25
IMPORTANT: DO NOT apply oil to the seal or the yoke recess. Install the dust seal (A) into the yoke recess. Install yoke onto the shaft.
ADust Seal
TX,02,111677 1925MAR9923/25
TM1640 (15JAN04)
02-0250-16

011504
PN=98
RW36191
UN09JAN97
RW36292
UN17MAR97
Axle Shaft, Bearings, Reduction Gears NOTE: Be sure no part of the oil ring is out of the chamfer on the yoke.
Install oil ring (A) and spacer washer.
UN17MAR97 RW36307
Apply PT506 NEVER-SEEZ Lubricant to the shaft threads. IMPORTANT: Install special locking nut by hand. Install special locking nut by hand until the locking member engages at least one thread on shaft.
AOil Ring
02 0250 17
TX,02,111677 1925MAR9924/25
Install JDG1090 Yoke Holding Tool (A). Tighten yoke retaining nut.
Axle Disconnect Input ShaftSpecification Yoke Retaining NutTorque ...................................... 360 Nm (267 lb-ft)
Remove tool. Install disconnect assembly to axle assembly. (See Remove and Install Axle Disconnect Input Shaft in this group.)
AYoke Holding Tool
TX,02,111677 1925MAR9925/25
TM1640 (15JAN04)
02-0250-17

011504
PN=99
RW36291
UN17MAR97
02 0250 18
TM1640 (15JAN04)
02-0250-18

011504
PN=100
Group 0260
Hydraulic System
Specifications
Differential Lock Solenoid Valve Nut
Torque
7 Nm (62 lb-in.)
CED,OUOE003,3297 1925MAR991/1
02 0260 1
TM1640 (15JAN04)
02-0260-1

011504
PN=101
Hydraulic System
Remove and Install Differential Lock Solenoid Valve

1. Operate controls to release hydraulic pressure.
UN04APR97
2. Disconnect electrical connector. 3. Remove differential lock solenoid (A). 4. Remove parts (CE).
02 0260 2
5. Remove parts (FK). Plug opening to prevent dirt from entering manifold. 6. Inspect for dirty, worn or damaged parts. Check that spool inside solenoid valve moves freely. If spool does not move freely or if valve looks worn or damaged, replace complete solenoid assembly. 7. Install solenoid valve using new O-rings and backup rings. 8. Install parts (CK). Tighten nut (C).
Specification Differential Lock Solenoid Valve NutTorque ..................................................................... 7 Nm (62 lb-in.)
9. Connect electrical connector.
ADifferential Lock Solenoid CNut DCap ESolenoid FSpool GO-Ring HBackup Ring IO-Ring JO-Ring KBackup Ring
TX,02,111682 1927OCT981/1
TM1640 (15JAN04)
02-0260-2

011504
PN=102
T7751LI
UN09NOV92
T108813
Hydraulic System
Axle Recirculation System
02 0260 3
AO-Ring (2 used) BO-Ring Adapter CO-Ring (2 used) DFront Axle Recirculation Inlet Port-to-Left Front Recirculation Pump Port Hydraulic Hose ERecirculation Pump Motor Inlet Port-to-Main Pump Pressure Port Hydraulic Hose
FO-Ring (3 used) GORFS Straight Thread Fitting HO-Ring (3 used) IRecirculation Pump Motor Outlet Port-to-Hydraulic Reservoir Hydraulic Hose JORFS Elbow KRight Front Recirculation Pump Port-to-Rear Axle Inlet Port Hydraulic Hose
LRight Rear Recirculation Pump Port-to-Rear Axle Recirculation Outlet Port Hydraulic Hose MORFS O-Ring Elbow Fitting (2 used) NO-Ring (2 used)
OScreen Filter (2 used) PLeft Rear Recirculation Pump Port-to-Front Axle Recirculation Outlet Port Hydraulic Hose QOld Breather Location RNew Breather Location
CED,OUOE003,2651 1913DEC981/1
TM1640 (15JAN04)
02-0260-3

011504
PN=103
T116474
1926AUG98
Hydraulic System
Axle Recirculation System With Optional Oil Coolers
02 0260 4
CED,OUOE003,2652 1913DEC981/2
TM1640 (15JAN04)
02-0260-4

011504
PN=104
T118027
1922OCT98
Hydraulic System
3Front Axle Oil Cooler 21Rear Axle Oil Cooler 27aRear Axle Oil Cooler Top Port-to-Rear Axle Recirculation Inlet Port Hydraulic Hose 27bRight Front Recirculation Pump Port-to-Rear Axle Oil Cooler Bottom Port Hydraulic Hose AO-Ring (2 used) BO-Ring Adapter CO-Ring (2 used) DFront Axle Recirculation Inlet Port-to-Front Axle Oil Cooler Upper Port Hydraulic Hose ERecirculation Pump Motor Inlet Port-to-Main Pump Pressure Port Hydraulic Hose FO-Ring (3 used) GORFS Straight Thread Fitting HO-Ring (3 used) IRecirculation Pump Motor Outlet Port-to-Hydraulic Reservoir Hydraulic Hose JORFS Elbow KLeft Front Recirculation Pump Port-to-Front Axle Oil Cooler Lower Port Hydraulic Hose LRight Rear Recirculation Pump Port-to-Rear Axle Recirculation Outlet Port Hydraulic Hose MORFS O-Ring Elbow Fitting (2 used) NO-Ring (2 used) OScreen Filter (2 used) PLeft Rear Recirculation Pump Port-to-Front Axle Recirculation Outlet Port Hydraulic Hose
02 0260 5
CED,OUOE003,2652 1913DEC982/2
TM1640 (15JAN04)
02-0260-5

011504
PN=105
Hydraulic System
Axle Oil CoolersExploded View
02 0260 6
CED,OUOE003,2653 1913DEC981/2
TM1640 (15JAN04)
02-0260-6

011504
PN=106
TP60515
UN13OCT98
Hydraulic System
1Nut (12 used) 2Washer (20 used) 3Angle (2 used) 4Cap Screw (4 used) 5Cover 6Washer (4 used) 7Rubber Mount (4 used) 8Cap Screw (4 used) 9Oil Cooler 10O-Ring (2 used) 11Elbow Fitting (2 used) 12O-Ring (6 used) 13Hyd. Quick-Connect Coupler (2 used) 14Hyd. Quick-Connect Coupler (2 used) 15Adapter (2 used) 16O-Ring (4 used) 17Elbow Fitting (2 used) 18Fitting Plug (2 used) 19O-Ring (4 used) 20Adapter (2 used) 21Oil Cooler 22Strap (2 used) 23Nut (4 used) 24Screw (4 used) 25Washer (4 used) 26Cap Screw (4 used) 27Hydraulic Hose, Fabricate (2 used) 28Wiring Harness 29Washer 30Screw 31Oil Cooler
CED,OUOE003,2653 1913DEC982/2
02 0260 7
Remove and Install Front Axle Oil Cooler

1. Position machine on a flat surface. Apply park brake. Stop engine. CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with ride control. Ride control accumulator energy must be discharged when working on hydraulic components. 2. If equipped with ride control. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 3. Disconnect battery ground strap or turn battery disconnect switch Off, if equipped. 4. Install frame locking bar (C) between machine frames to prevent unexpected movement.
Frame Lock Bar
APin BRetaining Pin CFrame Lock Bar
UN12DEC96
CED,OUOE003,2654 1913DEC981/3
TM1640 (15JAN04)
02-0260-7

011504
PN=107
T105496B
Hydraulic System
5. Remove cap screw (5) and washer (4) to open cover (3).
3Cover 4Washer 5Cap Screw
02 0260 8
CED,OUOE003,2654 1913DEC982/3
6. Disconnect hydraulic hoses (D and K) and wiring harness (25). 7. Remove cover (3) with attached oil cooler (31). 8. Repair or replace parts as necessary. 9. Install in reverse order.
DFront Axle Recirculation Inlet Port-to-Front Axle Oil Cooler Upper Port Hydraulic Hose KLeft Front Recirculation Pump Port-to-Front Axle Cooler Lower Port Hydraulic Hose 3Cover 25Oil Cooler with Fan Wiring Harness 31Oil Cooler with Fan
CED,OUOE003,2654 1913DEC983/3
TM1640 (15JAN04)
02-0260-8

011504
PN=108
T117526B
UN01OCT98
T117536B
UN01OCT98
Hydraulic System
Disassemble and Assemble Front Axle Oil Cooler
02 0260 9
2Cap Screw (2 used) 3Cover 6Washer (2 used) 7Cap Screw (2 used)
19M8 Nut (6 used) 20Angle 24Female Coupler 26Male Coupler
27ORFS Adapter (2 used) 28ORFS Elbow Fitting (2 used) 29Adapter (2 used)
30Isolator Mount (2 used) 31Oil Cooler with Fan 32Strap
NOTE: Lubricate O-rings with hydraulic oil.
CED,OUOE003,2655 1913DEC981/1
TM1640 (15JAN04)
02-0260-9

011504
PN=109
T117465B
UN01OCT98
Hydraulic System
Remove and Install Rear Axle Oil Cooler

1. Position machine on a flat surface. Apply park brake. Stop engine. CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with ride control. Ride control accumulator energy must be discharged when working on hydraulic components. 2. If equipped with ride control. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 3. Disconnect battery ground strap or turn battery disconnect switch Off, if equipped. 4. Install frame locking bar (C) between machine frames to prevent unexpected movement.
Frame Lock Bar
APin BRetaining Pin CFrame Lock Bar
UN12DEC96
02 0260 10
CED,OUOE003,2656 1913DEC981/2
TM1640 (15JAN04)
02-0260-10

011504
PN=110
T105496B
Hydraulic System
5. Disconnect hydraulic hoses (27a and 27b). 6. Remove nuts (1), washers (2) and oil cooler (21). 7. Repair or replace parts as necessary. 8. Install in reverse order. Lubricate O-rings with hydraulic oil.
1Nut (12 used) 2Hardened Washer (20 used) 20ORFS Fitting (2 used) 21Oil Cooler 22Strap (2 used) 27aHydraulic Hose (Rear Axle Cooler Lower Port-to-Right Pump) 27bHydraulic Hose (Rear Axle Cooler Upper Port-to-Rear Axle Lower Port) 32Hydraulic Fan Motor 34Tie Band
UN23OCT98
02 0260 11
CED,OUOE003,2656 1913DEC982/2
TM1640 (15JAN04)
02-0260-11

011504
PN=111
T118017B
Hydraulic System
02 0260 12
TM1640 (15JAN04)
02-0260-12

011504
PN=112
Section 03
Transmission
Contents
Page Page
Group 0300Removal and Installation Essential Tools . . . . . . . . . . . . . . . . . . . . . . .03-0300-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .03-0300-2 Transmission Remove and Install . . . . . . . . . . . . . . . . . .03-0300-3 Group 0350Gears, Shafts, Bearings and Power Shift Clutch Essential Tools . . . . . . . . . . . . . . . . . . . . . . .03-0350-1 Service Equipment and Tools . . . . . . . . . . . .03-0350-2 Other Material . . . . . . . . . . . . . . . . . . . . . . . .03-0350-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . .03-0350-4 Torque Converter and Housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-5 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-8 Clutches, Input and Output Shafts Remove . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-11 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-17 Clutch Pack KV and KR Disassemble . . . . . . . . . . . . . . . . . . . . . .03-0350-26 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-28 Clutch Pack K1, K2, and K3 Disassemble . . . . . . . . . . . . . . . . . . . . . .03-0350-35 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-37 Clutch Pack K4 Disassemble . . . . . . . . . . . . . . . . . . . . . .03-0350-47 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-48 Input Shaft Dissasemble . . . . . . . . . . . . . . . . . . . . . .03-0350-54 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-55 Group 0360Hydraulic System Specifications . . . . . . . . . . . . . . . . . . . . . . . .03-0360-1 Transmission Pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-2 Converter Minimum Pressure Regulator Valve Remove and Install . . . . . . . . . . . . . . . . . .03-0360-4 Transmission Pump Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-5 Hydraulic Control Valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-7 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-8 Cross Section View . . . . . . . . . . . . . . . . .03-0360-10 Transmission Control Valve Disassemble . . . . . . . . . . . . . . . . . . . . . .03-0360-12 TM1640 (15JAN04)
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0360-15 Converter Relief Valve Remove, Disassemble and Install . . . . . .03-0360-21 Oil Pipes and Tubes Replace . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-23 Group 0399Dealer Fabricated Tools Pre-Load Clutch Pack Compression Ring Tool DFT1148 . . . . . . . . . . . . . . . . . . . . . . . . . .03-0399-1 DFT1149 . . . . . . . . . . . . . . . . . . . . . . . . . .03-0399-2
03
03-1

011504
PN=1
Contents
03
TM1640 (15JAN04)
03-2

011504
PN=2
Group 0300

Essential Tools
CED,OUOE003,3298 1925MAR991/3
Engine Repair Stand . . . . . . . . . . . . . . . . .D052223ST Used with JDG1129 Transmission Mounting Bracket to hold transmission.
CED,OUOE003,3298 1925MAR992/3
03 0300 1
Transmission Mounting Bracket . . . . . . . . . . . JDG1129 Used to mount transmission in repair stand.

UN29APR97 T109218
CED,OUOE003,3298 1925MAR993/3
TM1640 (15JAN04)
03-0300-1

011504
PN=115
Specifications
Transmission Transmission Isolator Cap Screw Mounting Bracket-to-Transmission Cap Screw (Front) Mounting Bracket-to-Transmission Cap Screw (Rear)
03 0300 2
Weight Torque Torque
431 kg (950 lb) approximate 433 Nm (320 lb-ft) 433 Nm (320 lb-ft)
Torque
318 Nm (235 lb-ft)
Drive Shaft Universal Joint (Output) Cap Screw Drive Shaft Universal Joint (Input) Cap Screw Engine-to-Transmission Shaft Universal Joint Cap Screw
Torque
78 Nm (58 lb-ft)
Torque
78 Nm (58 lb-ft)
Torque
78 Nm (58 lb-ft)
CED,OUOE003,3301 1925MAR991/1
TM1640 (15JAN04)
03-0300-2

011504
PN=116
Remove and Install Transmission

1. Remove ROPS or cab. (See procedure in Group 1800.) 2. Drain hydraulic reservoir. Collect oil in clean container for reuse. Approximate capacity is 117 L (31 gal). 3. Disconnect transmission drive shafts (AC).
ADrive Shaft BDrive Shaft CDrive Shaft
03 0300 3
TX,03,RP3337 1912FEB991/5
NOTE: Tag and cap all lines for identification and to prevent contamination.
4. Remove transmission filter hoses (F and E) from transmission. 5. Drain transmission. Collect oil in container and dispose of properly. Approximate capacity is 27 L (29 qt). 6. Remove dipstick tube (C). 7. Remove and cap park brake hoses (G and D). 8. Remove cooler hoses (A and B).
AConverter in Hose from Cooler BConverter out Hose to Cooler CDipstick Tube DReturn Hose from Park Brake to Transmission EReturn from Filter to Transmission Hose FHose to Oil Filter from Transmission GHose to Park Brake from Transmission
TX,03,RP3337 1912FEB992/5
TM1640 (15JAN04)
03-0300-3

011504
PN=117
T112003
UN24NOV97
T107803
UN10MAR97

9. Remove hose (E) going to the control valve and case drain return hose (D) to manifold from the hydraulic pump. 10. Remove load sense hose (A) from hydraulic pump. 11. Remove suction hose at reservoir (B) and hydraulic pump at (C). 12. Remove pressure reducing valve hose (G), steering hose (F) from hydraulic pump.
ALoad Sense Hose BSuction Hose CPump Inlet DCase Drain EPressure to Control Valve FPressure to Steering Valve GHose to Pressure Reducing Valve
03 0300 4
TX,03,RP3337 1912FEB993/5
TM1640 (15JAN04)
03-0300-4

011504
PN=118
T112004
UN29OCT97
03 0300 5
ATransmission Isolator Cap Screw (Rear)
BTransmission Mounting Bracket-to-Transmission Cap Screws (Rear)
CTransmission Mounting Bracket-to-Transmission Cap Screws (Front)
DTransmission Isolator Cap Screws (Front)
CAUTION: Use hoist to lift transmission. Approximate weight is 431 kg (950 lb) with hydraulic pump installed.
TransmissionSpecification TransmissionWeight ............................ 431 kg (950 lb) approximate
16. Carefully remove transmission and place in repair stand using JDG1129 Transmission Mounting Bracket. 17. Remove hydraulic pump from transmission. 18. After transmission repair, install hydraulic pump on transmission before installing transmission in machine. Inspect hydraulic pump to transmission O-ring before installing pump. 19. Install transmission in machine.
13. Install hoist on transmission lifting brackets and support transmission. 14. Remove isolator cap screws (A and D). 15. Remove transmission front mount cap screws (C) and remove mounts from transmission.
TransmissionSpecification Isolator Cap ScrewTorque ................................ 433 Nm (320 lb-ft)
NOTE: Rear transmission mount does not have to be removed from transmission.
TX,03,RP3337 1912FEB994/5
TM1640 (15JAN04)
03-0300-5

011504
PN=119
T111670
UN03NOV97

Mounting Bracket-to-Transmission Cap Screw (Front)Torque ......................................... 433 Nm (320 lb-ft) Mounting Bracket-to-Transmission Cap Screw (Rear)Torque.......................................... 318 Nm (235 lb-ft)
22. Install transmission drive shafts using new cap screws.

TransmissionSpecification Drive Shaft Universal Joint (Output) Cap ScrewTorque ................................... 78 Nm (58 lb-ft) Drive Shaft Universal Joint (Input) Cap ScrewTorque...................................... 78 Nm (58 lb-ft) Engine-to-Transmission Shaft Universal Joint Cap Screw Torque....................................................................... 78 Nm (58 lb-ft)
20. Connect all hoses and lines to transmission and hydraulic pump. 21. Fill transmission and hydraulic reservoir to specifications.
NOTE: Do NOT reuse drive shaft cap screws, replace with new when removed.
03 0300 6
23. Install ROPS or cab. (See procedure in Group 1800.)
TX,03,RP3337 1912FEB995/5
TM1640 (15JAN04)
03-0300-6

011504
PN=120
Group 0350
Gears, Shafts, Bearings and Power Shift Clutch

Essential Tools
CED,OUOE003,3374 1921APR991/7
Transmission Mounting Brackets . . . . . . . . . . JDG1129

UN29APR97
Used to mount transmission in repair stand.
03 0350 1
T109218
CED,OUOE003,3374 1921APR992/7 T112434 UN10DEC97
Bearing Puller. . . . . . . . . . . . . . . . . . . . . . . JDG1134 Used with bearing puller mandrel to remove bearing from clutch packs KV and K4.
CED,OUOE003,3374 1921APR993/7 T104040 UN27SEP96
Bearing Puller Mandrel . . . . . . . . . . . . . . . . . JDG1035 Used with bearing puller to remove bearing from clutch packs.
Bearing Puller. . . . . . . . . . . . . . . . . . . . . . . JDG1197 Used with bearing puller mandrel to remove bearing from clutch packs K1, K2, K3, K4, and KR.
Continued on next page CED,OUOE003,3374 1921APR995/7
TM1640 (15JAN04)
03-0350-1

011504
PN=121

T112433 UN10DEC97
Bearing Puller Mandrel . . . . . . . . . . . . . . . . . JDG1034 Used with bearing puller to remove bearing from clutch packs.
Bearing Puller. . . . . . . . . . . . . . . . . . . . . . . JDG1041 Used with bearing puller mandrel to remove bearing from clutch packs K1 and K3.
CED,OUOE003,3374 1921APR997/7

03 0350 2
CED,OUOE003,3325 1926MAR991/5
Repair Stand Used to hold transmission for repair.
CED,OUOE003,3325 1926MAR992/5
Eye Bolt . . . . . . . . . . . . . . . . . . . . . . . M20 and M12 Used with hoist to remove transmission cover.
CED,OUOE003,3325 1926MAR993/5
Pre-Load Clutch Pack Compression Ring Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DFT11491 Used to compress the piston compression ring for removal and installation of snap ring.
Fabricated tool, dealer made. (See Group 0399 for instructions to make tool.)
TM1640 (15JAN04)
03-0350-2

011504
PN=122

Pre-Load Clutch Pack Compression Ring Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DFT11481 Used to compress the piston compression ring for removal and installation of snap ring.
1 Fabricated tool, dealer made. (See Group 0399 for instructions to make tool.)
CED,OUOE003,3325 1926MAR995/5
Other Material
Number Name Use 03 0350 3
T43513 (U.S.) TY9474 (Canadian) 271 (LOCTITE) T43512 (U.S.) TY9473 (Canadian) 242 (LOCTITE)
Thread Lock and Sealer (High Strength)
Apply to drive plate-to-torque converter cap screws.
Thread Lock and Sealer (Medium Strength)
Apply to output shaft cover socket head cap screws. Apply to threads of clutch pack shaft studs. Apply to transmission mounting face cover. Apply to contact side of output flange (yoke) retaining washer.
TY16021 (U.S.) TY9484 (Canadian) 17430 (LOCTITE)
High Flex Form-In-Place Gasket
LOCTITE is a trademark of Loctite Corp.
CED,OUOE003,3326 1926MAR991/1
TM1640 (15JAN04)
03-0350-3

011504
PN=123
Specifications
Torque Converter Transmission Converter Housing M10/10.9 Cap Screw Input Shaft-to-Drive Plate M12/10.9 Cap Screw Drive Plate-to-Torque Converter M12/10.9 Cap Screw Top Cover M10/8.8 Cap Screw Input Flange-to-Torque Converter Shaft Cap Screw Weight Torque 510 kg (1125 lb) approximate 68 Nm (50 lb-ft)
Torque
115 Nm (85 lb-ft)
Torque
115 Nm (85 lb-ft)
03 0350 4
Torque Torque
46 Nm (34 lb-ft) 34 Nm (25 lb-ft)
Clutches, Input and Output Shafts Output Shaft Cover Socket Head Screw Housing Cover Hex Head Screw Output Flange Output Flange Cap Screw Gasket-to-Cover Hex Head Screw Oil Level Tube Screw Speed Sensor Drain Plug Torque 23 Nm (17 lb-ft)
Torque Temperature Torque Torque Torque Torque Torque
46 Nm (34 lb-ft) 90C (194F) maximum 34 Nm (25 lb-ft) 23 Nm (17 lb-ft) 25 Nm (18 lb-ft) 30 Nm (22 lb-ft) 140 Nm (100 lb-ft)
Clutch Pack KV and KR Clutch Pack Plate Shaft Stud K1 Clutch Pack Plate Clearance Torque Clearance 2.72.9 mm (0.1060.114 in.) 17 Nm (150 lb-in.) 2.42.6 mm (0.0940.102 in.)
CED,OUOE003,3327 1926MAR991/2
TM1640 (15JAN04)
03-0350-4

011504
PN=124
Item
Measurement
Specification
K2 and K3 Clutch Pack Plate K4 Clutch Pack Shaft K4 Clutch Pack Gear K4 Clutch Pack Plate
Clearance Temperature Temperature Clearance
1.82.0 mm (0.0710.079 in.) Cools at -80C (-112F) Heats at 120C (248F) 1.21.4 mm (0.0470.055 in.)
Input Shaft Input Shaft Input Gear Temperature Temperature Cools at -80C (-112F) Heats at +120C (250F)
03 0350 5
CED,OUOE003,3327 1926MAR992/2
Remove Torque Converter and Housing

CAUTION: The approximate weight of transmission is 510 kg (1125 lb).
Torque ConverterSpecification TransmissionWeight................................. 510 kg (1125 lb) approximate
UN26JAN98
AMounting Bracket (2 used)
TX,0350,WW2497 1925MAR991/11
TM1640 (15JAN04)
03-0350-5

011504
PN=125
T109146B
1. Install transmission in repair stand using JDG1129 mounting brackets (A).
Gears, Shafts, Bearings and Power Shift Clutch NOTE: Earlier JDG1129 Transmission Mounting Brackets require the right side bracket revised. Note bracket sketch showing revised mounting hole (A). Revise hole by elongating the existing hole as required.
ARevised Mounting Hole
UN19DEC97
Bracket Sketch Showing Revised Mounting Hole (A)
03 0350 6
TX,0350,WW2497 1925MAR992/11
2. Remove lock plate and hex head screws from input flange washer. 3. Remove washer and pry input flange from the shaft.
UN17APR97
TX,0350,WW2497 1925MAR993/11
4. Remove torque converter housing cap screws. Place a mark on the cover and housing for ease of assembly and proper alignment later.
TX,0350,WW2497 1925MAR994/11
TM1640 (15JAN04)
03-0350-6

011504
PN=126
T108722
UN17APR97
T108721
T112589
CAUTION: Component weighs more than 23 kg (50 lb). Use hoist to remove. 5. Separate torque converter with cover from gearbox, using a hoist and eye bolt.
UN17APR97
TX,0350,WW2497 1925MAR995/11
6. Press input shaft with converter out of the housing.

03 0350 7
TX,0350,WW2497 1925MAR996/11
7. Remove snap ring and remove bearing from housing.
TX,0350,WW2497 1925MAR997/11
8. Remove hex head screws and separate drive plate from converter.
TX,0350,WW2497 1925MAR998/11
TM1640 (15JAN04)
03-0350-7

011504
PN=127
T112416
UN05DEC97
T108717
UN17APR97
T108724
UN17APR97
T108723

9. Remove hex head screws and separate input shaft from drive plate.
TX,0350,WW2497 1925MAR999/11
10. Remove speed senor from converter housing.

03 0350 8
TX,0350,WW2497 1925MAR9910/11
11. Remove hex head screws and remove converter lower housing.
TX,0350,WW2497 1925MAR9911/11
Install Torque Converter and Housing

1. Fasten converter housing using hex head screws. Tighten M10/10.9 cap screws.
Torque ConverterSpecification Converter Housing M10/10.9 Cap ScrewTorque ................................................................ 68 Nm (50 lb-ft)
UN15APR97
TX,0350,RB228 1904DEC031/8
TM1640 (15JAN04)
03-0350-8

011504
PN=128
T109095
T108729
UN17APR97
T108720
UN17APR97
T112415
UN05DEC97

2. Fasten input shaft to plate with hex head screws. Tighten M12/10.9 cap screws.
Torque ConverterSpecification Input Shaft-to-Drive Plate M12/10.9 Cap ScrewTorque ...................................... 115 Nm (85 lb-ft)
TX,0350,RB228 1904DEC032/8
3. Install input shaft plate assembly to converter, using hex head screws and flat washers. Apply thread lock and sealer (high strength) to cap screws. Tighten M12/10.9 cap screws.
Torque ConverterSpecification Drive Plate-to-Torque Converter M12/10.9 Cap ScrewTorque ..................................... 115 Nm (85 lb-ft)
UN15APR97
T112415
UN05DEC97
03 0350 9
TX,0350,RB228 1904DEC033/8
4. Install converter in housing until contact is made.
TX,0350,RB228 1904DEC034/8
TM1640 (15JAN04)
03-0350-9

011504
PN=129
T109098
UN30APR97
T109097
UN15APR97
NOTE: Speed pickup disk in the converter must be centered to the bore of the speed sensor. See art with arrow showing. This insures that the converter is seated properly.
T109121

5. Insert ball bearing until contact is obtained in bore and install snap ring.
TX,0350,RB228 1904DEC035/8
6. Assemble housing.
03 0350 10
Install input flange, washer and draw cover down with hex head screws evenly against shoulder.
UN15APR97
NOTE: Line up alignment marks on housings that were made while disassembling for proper assembly.
TX,0350,RB228 1904DEC036/8
7. Install cover with hex head screws and nuts on the converter housing. Tighten to specification.
Torque ConverterSpecification Top Cover M10/8.8 Cap Screw Torque ............................................................................. 46 Nm (34 lb-ft)
UN15APR97
TX,0350,RB228 1904DEC037/8
TM1640 (15JAN04)
03-0350-10

011504
PN=130
T109101
T109100
T109099
UN15APR97

8. Fasten input flange with hex head screws and tighten.
Torque ConverterSpecification Input Flange-to-Torque Converter Shaft Cap ScrewTorque .............................................. 34 Nm (25 lb-ft)
Install locking plate using hammer and two deep well sockets (A) taped together with a hex nut between them for proper spread.
ADeep Well Socket
Output Flange Shown
T109147B
UN02MAY97
03 0350 11
TX,0350,RB228 1904DEC038/8
Remove Clutches, Input and Output Shafts

1. Remove lock plate, loosen hex head screws, and pry the rear output flange from the shaft.
UN18APR97
2. Pry shaft seal out of the housing bore. 3. Turn gearbox 180 and remove front output flange in same manner.
TX,0350,ME280 1925MAR991/19
4. Remove three sensors.
TX,0350,ME280 1925MAR992/19
TM1640 (15JAN04)
03-0350-11

011504
PN=131
T108779
UN29APR97
T108778

5. Loosen hex nuts and remove the two small manifold covers (Arrows). 6. Remove cap screws from transmission cover.
UN29APR97
TX,0350,ME280 1925MAR993/19
03 0350 12
7. Drive both dowel pins (one on each end of transmission cover) down far enough to clear cover for removal of the cover.
TX,0350,ME280 1925MAR994/19
8. Separate housing cover carefully from gearbox housing, using lifting device.
TX,0350,ME280 1925MAR995/19
TM1640 (15JAN04)
03-0350-12

011504
PN=132
T108774
UN18APR97
T108781
UN29APR97
T108780

9. Figure shows the proper position of the single clutches as well as of the input and output.
KVLow Range Forward Clutch KRReverse Clutch K1First Speed Clutch K2Second Speed Clutch K3Third Speed Clutch K4High Range Forward Clutch ANInput ABOutput
T108775
UN29APR97
03 0350 13
TX,0350,ME280 1925MAR996/19
NOTE: For the removal of clutches, the output shaft must be removed first.
10. Loosen socket head screws from covers and remove output shaft with covers.
UN18APR97
TX,0350,ME280 1925MAR997/19
TM1640 (15JAN04)
03-0350-13

011504
PN=133
T108776

IMPORTANT: Remove sealing rings from clutch pack shafts (cover side only) before installing cover. Sealing rings may be damaged while removing and installing clutch packs later. 11. Place cover back on transmission until it contacts the mounting surface so clutch packs can be removed from housing for repair or inspection.
UN30APR97
NOTE: Six 24H1300 Flat Washers and M10 Hex Nuts are substituted for special handles shown in photo.
Special Handles Shown
03 0350 14
12. Install six (24H1300) flat washers (A) and six (M10) hex nuts on end of clutch packs. This will hold packs in place while mounting cover in rollover repair stand. This method must be used to remove clutch pack from transmission housing.
AFlat Washer (6 used)
UN09MAY97
24H1300 and M10 Hardware Shown

TX,0350,ME280 1925MAR998/19
13. Separate housing cover along with all clutch packs from gearbox housing, using lifting device.
T109149B
TX,0350,ME280 1925MAR999/19
NOTE: Transmission cover is used to properly remove packs from transmission housing.
14. Remove transmission housing from repair stand and install cover with clutch packs.
UN09MAY97
TX,0350,ME280 1925MAR9910/19
TM1640 (15JAN04)
03-0350-14

011504
T109149C
PN=134
T108786
UN18APR97
T108777

15. Install cover with packs into stand using JDG1129 Mounting Brackets (A). Using shop hardware (B) (cap screws, washers and nuts) fasten cover to mounting brackets JDG1129 (A).
AMounting Bracket (2 used) BShop Hardware
UN09MAY97
TX,0350,ME280 1925MAR9911/19
16. Turn cover in stand so clutch packs are facing up. This will allow them to be removed from cover. 17. Remove six M10 nuts and six washers from clutch packs.
UN18APR97
T109148B
03 0350 15
TX,0350,ME280 1925MAR9912/19
CAUTION: Use special care while removing clutch packs from cover due to closeness of packs and spline engagement to each other. 18. Remove clutch K2.
UN18APR97
TX,0350,ME280 1925MAR9913/19
19. Remove clutch K1, at the same time lift clutch K4 to the side to allow clearance.
TX,0350,ME280 1925MAR9914/19
TM1640 (15JAN04)
03-0350-15

011504
PN=135
T108782
UN18APR97
T108789
T108788

20. Remove clutch K3.
TX,0350,ME280 1925MAR9915/19
21. Remove clutch K4, at the same time lift input slightly.
03 0350 16
TX,0350,ME280 1925MAR9916/19
22. Separate clutches KV and KR together with input from the housing cover.
TX,0350,ME280 1925MAR9917/19
23. Remove bearing outer race and pull output shaft out of the housing bore.
TX,0350,ME280 1925MAR9918/19
TM1640 (15JAN04)
03-0350-16

011504
PN=136
T108790
UN18APR97
T108785
UN18APR97
T108784
UN18APR97
T108783
UN18APR97

24. Squeeze the square snap ring out and separate ball bearing from shaft.
TX,0350,ME280 1925MAR9919/19
Install Clutches, Input and Output Shafts

IMPORTANT: High tolerance bearings are used in all clutch pack applications. Use only John Deere sourced bearings when replacing.
03 0350 17
NOTE: If bearings are reused, they must be assembled in same bores.

1. Insert all bearing outer races into the housing cover until contact is obtained.
KVLow Range Forward Clutch KRReverse Clutch K1First Speed Clutch K2Second Speed Clutch K3Third Speed Clutch K4High Range Forward Clutch ANInput ABOutput
UN30APR97
TX,0350,JC2037 1925MAR991/32
2. Insert clutch-KR, input shaft and clutch-KV into the housing cover.
KVLow Range Forward Clutch KRReverse Clutch ANInput
TX,0350,JC2037 1925MAR992/32
TM1640 (15JAN04)
03-0350-17

011504
PN=137
T109005
UN29APR97
T109004
T108791
UN29APR97

3. Install clutch-K4.
K4High Range Forward Clutch
TX,0350,JC2037 1925MAR993/32
4. Install clutch-K3.
03 0350 18 K3Third Speed Clutch
TX,0350,JC2037 1925MAR994/32
5. Position clutch-K2.
TX,0350,JC2037 1925MAR995/32
6. Insert clutch-K1.
TX,0350,JC2037 1925MAR996/32
TM1640 (15JAN04)
03-0350-18

011504
PN=138
T112553B
UN17DEC97
T112554B
UN17DEC97
T109007
UN09MAY97
T109006
UN29APR97

7. Figure on the right shows the installation position of the single clutches in the housing cover.
KVLow Range Forward Clutch KRReverse Clutch K1First Speed Clutch K2Second Speed Clutch K3Third Speed Clutch K4High Range Forward Clutch
TX,0350,JC2037 1925MAR997/32
8. Retain all clutches using six M10 hex nuts and six 24H1300 flat washers.
T109010
UN29APR97
03 0350 19
TX,0350,JC2037 1925MAR998/32
9. Install sealing rings (7 used) on clutch pack shafts. 10. Grease sealing rings and align.
TX,0350,JC2037 1925MAR999/32
11. Turn housing cover 180. 12. Mount eye bolts. 13. Remove transmission cover with clutch packs from repair stand. 14. Install transmission housing into repair stand.
TX,0350,JC2037 1925MAR9910/32
TM1640 (15JAN04)
03-0350-19

011504
PN=139
T109013
UN29APR97
T109012
UN29APR97
T109011
UN09MAY97

15. Install alignment studs in housing.
NOTE: Pay attention to the engagement of the oil pipes with the bores in the housing cover.
UN09MAY97
16. Install cover with clutch packs carefully onto housing. Make sure all components are properly seated.
TX,0350,JC2037 1925MAR9911/32
03 0350 20
17. Remove M10 hex nuts and 24H1300 flat washers (A) from clutch packs.
AFlat Washer (6 used)
UN09MAY97
TX,0350,JC2037 1925MAR9912/32
18. Remove housing cover from gearbox housing.
T109149B
TX,0350,JC2037 1925MAR9913/32
19. Output Shaft Assemble oil cover onto shaft and press both bearing inner races against shoulder until contact is obtained.
UN15APR97
TX,0350,JC2037 1925MAR9914/32
TM1640 (15JAN04)
03-0350-20

011504
PN=140
T109066
T109016
UN09MAY97
T109014

20. Insert bearing outer race into the housing bore until contact is obtained.
TX,0350,JC2037 1925MAR9915/32
21. Position inner oil cover.

03 0350 21
TX,0350,JC2037 1925MAR9916/32
22. Install output shaft with cover in housing.
TX,0350,JC2037 1925MAR9917/32
NOTE: Insert socket head cap screws with thread lock and sealer (medium strength).
23. Fasten both covers by means of socket head screws.
UN15APR97
Clutches, Input and Output ShaftsSpecification Output Shaft Cover Socket Head ScrewTorque ................................................................ 23 Nm (17 lb-ft)
TX,0350,JC2037 1925MAR9918/32
TM1640 (15JAN04)
03-0350-21

011504
PN=141
T109071
T109070
UN15APR97
T109069
UN15APR97
T109068
UN29APR97

24. Install sealing rings (6 used) into the recesses of the clutch shafts and hook them in. 25. Grease sealing rings and align.
UN29APR97
TX,0350,JC2037 1925MAR9919/32
03 0350 22
26. Lubricate and install both O-rings into the groove of the oil pipes.
TX,0350,JC2037 1925MAR9920/32
27. Apply High Flex Form-In-Place Gasket to mounting face of cover.
NOTE: Pay attention to the engagement of the oil pipe with the bores in the housing cover.
28. Install housing cover carefully against gearbox housing until contact is obtained, using lifting device.
UN15APR97
TX,0350,JC2037 1925MAR9921/32
29. Install dowel pins.
TX,0350,JC2037 1925MAR9922/32
TM1640 (15JAN04)
03-0350-22

011504
PN=142
T109077
UN29APR97
T109076
T109075
UN29APR97
T109072
Gears, Shafts, Bearings and Power Shift Clutch NOTE: Locate hanger in same position as it was removed.
30. Install housing cover using hex head screws.
UN15APR97
Clutches, Input and Output ShaftsSpecification Housing Cover Hex Head ScrewTorque ................................................................ 46 Nm (34 lb-ft)
TX,0350,JC2037 1925MAR9923/32
NOTE: Grease sealing lip should face inward.

31. Install shaft seal with the seal lip facing inward, using proper driver. Drive until seated. Do not over drive.
UN15APR97
T109078
03 0350 23
TX,0350,JC2037 1925MAR9924/32
32. Apply High Flex Form-In-Place Gasket to contact area of washer. 33. Heat the output flange.
UN15APR97
Clutches, Input and Output ShaftsSpecification Output FlangeTemperature............................... 90C (194F) maximum
34. Install flange and washer with cap screws. Tighten cap screws.
Clutches, Input and Output ShaftsSpecification Output Flange Cap Screw Torque ............................................................................. 34 Nm (25 lb-ft)
TX,0350,JC2037 1925MAR9925/32
TM1640 (15JAN04)
03-0350-23

011504
PN=143
T109080
T109079

35. Install locking plate using two 5/8 in. deep well sockets (A). 36. Install flange in same manner on opposite side.
ADeep Well Socket (2 used)
UN02MAY97
TX,0350,JC2037 1925MAR9926/32
03 0350 24
37. If removed, install flat gasket and cover. Fasten with hex head screws.
Clutches, Input and Output ShaftsSpecification Gasket-to-Cover Hex Head ScrewTorque ................................................................ 23 Nm (17 lb-ft)
UN15APR97
TX,0350,JC2037 1925MAR9927/32
38. Install O-ring into groove of two oil feed covers.
TX,0350,JC2037 1925MAR9928/32
39. Install cover onto transmission studs with hex nuts. Tighten hex nuts.
Clutches, Input and Output ShaftsSpecification Cover-To-Transmission Housing Hex NutTorque............................................................ 25 Nm (18 lb-ft.)
UN15APR97
TX,0350,JC2037 1925MAR9929/32
TM1640 (15JAN04)
03-0350-24

011504
PN=144
T109116
T109115
UN15APR97
T109094
T109147B

40. Install oil level tube and tighten screw.
Clutches, Input and Output ShaftsSpecification Oil Level Tube ScrewTorque ....................................... 25 Nm (18 lb-ft)
TX,0350,JC2037 1925MAR9930/32
41. Install engine speed sensor (48), middle gear speed sensor (47) and turbine speed sensor (21).
Clutches, Input and Output ShaftsSpecification Speed SensorTorque ................................................... 30 Nm (22 lb-ft)
T109117
UN15APR97
03 0350 25
42. Install breather (shown at arrow head).

21Turbine Speed Sensor 47Middle Gear Speed Sensor 48Engine Speed Sensor
TX,0350,JC2037 1925MAR9931/32
43. Install drain plug and tighten.

Clutches, Input and Output ShaftsSpecification Drain PlugTorque ..................................................... 140 Nm (100 lb-ft)
TX,0350,JC2037 1925MAR9932/32
TM1640 (15JAN04)
03-0350-25

011504
PN=145
T109120
UN15APR97
T109119
UN29APR97
Disassemble Clutch Pack KV and KR

1. Remove sealing ring.
TX,0350,ME284 1926MAR991/10
03 0350 26
2. Pull tapered roller bearing from the shaft using JDG1134 Bearing Puller and JDG1035 Bearing Puller Mandrel. Remove opposite tapered roller bearing on clutch pack KV.
UN18APR97
Remove opposite bearing on clutch pack KR with JDG1197 Bearing Puller and JDG1034 Bearing Puller Mandrel.
TX,0350,ME284 1926MAR992/10
3. Separate plate carrier from shaft.
TX,0350,ME284 1926MAR993/10
4. Remove plates.
TX,0350,ME284 1926MAR994/10
TM1640 (15JAN04)
03-0350-26

011504
PN=146
T108795
UN18APR97
T108794
UN18APR97
T108793
T108792
UN29APR97

5. Preload compression spring with DFT1149 Pre-Load Clutch Pack Compression Ring Tool in press and remove snap ring. (See Group 0399 for instructions to make tool.)
UN17APR97
6. Remove piston from carrier.
TX,0350,ME284 1926MAR995/10
7. Remove O-rings from piston.

03 0350 27
TX,0350,ME284 1926MAR996/10
8. Remove inner circle snap ring.
TX,0350,ME284 1926MAR997/10
9. Remove idler gear from shaft using a press.
TX,0350,ME284 1926MAR998/10
TM1640 (15JAN04)
03-0350-27

011504
PN=147
T108752
UN17APR97
T108759
UN17APR97
T108758
UN29APR97
T108761

10. Remove released needle bearing.
TX,0350,ME284 1926MAR999/10
11. Remove circle snap ring and remove bearing.

03 0350 28
TX,0350,ME284 1926MAR9910/10
Assemble Clutch Pack KV and KR

IMPORTANT: Check function of the drain valve. Check function of drain ball. Ball must move freely. If ball does not move freely, check for contamination or replace.
1. Install both new O-rings (Arrows) into the ID and OD of the piston and oil them.
TX,0350,ME288 1926MAR991/19
TM1640 (15JAN04)
03-0350-28

011504
PN=148
T108981
NOTE: Clutch KV and KR are assembled in the same manner. Art shown in the following story is similar to both clutch packs.
UN29APR97
T108754
UN17APR97
T108753
UN17APR97

2. Assemble piston until it bottoms out in plate carrier. Pay attention to proper installation.
TX,0350,ME288 1926MAR992/19
3. Install spring and two guides.

03 0350 29
TX,0350,ME288 1926MAR993/19
4. Press spring with DFT1149 Pre-Load Clutch Pack Compression Ring Tool in press and install snap ring into plate carrier groove. (See Group 0399 for instructions to make tool.)
UN10APR97
TX,0350,ME288 1926MAR994/19
TM1640 (15JAN04)
03-0350-29

011504
PN=149
T108664
T108663
UN10APR97
T108662
UN10APR97
03 0350 30
Clutch Packs KV and KR

1Plate Carrier 2Piston 3Disk (Friction) (One Side Fiber Coated) 4Plate (Separator) (10 used) 5Disk (Friction) (10 used) 6Snap Ring 7End Shim
IMPORTANT: Install one sided friction disk (3) with the fiber side always facing toward plate. Smooth side should be against piston.
For proper adjustment of plate clearance install disk and plates temporarily without being oiled.
5. Install one sided fiber disk into carrier with the fiber side facing out or away from piston.
NOTE: Plate and disk position is the same for clutch KV and KR.
TX,0350,ME288 1926MAR995/19
6. Install plate and then disk alternately until eight plates and eight disks are installed in carrier. 7. Install two plates, then two disks.
UN10APR97
TX,0350,ME288 1926MAR996/19
TM1640 (15JAN04)
03-0350-30

011504
PN=150
T108665
T112158
UN20NOV97

8. Install end shim and snap ring.
TX,0350,ME288 1926MAR997/19
9. Adjust plate clearance.

Clutch PackSpecification KV and KR Clutch Pack Plate Clearance ................................................ 2.72.9 mm (0.1060.114 in.)
a. Press end shim and measure the dimension from the end face/plate carrier to the end shim with depth gage. Record dimension (No. 1).
TX,0350,ME288 1926MAR998/19
TM1640 (15JAN04)
03-0350-31

011504
PN=151
T108667
UN10APR97
NOTE: For the adjustment of the plate clearance there are snap rings of different thickness available through parts system that can be used if proper clearance is unable to be obtained. To ensure proper measuring result, install plates temporarily without oil.
T108666
UN10APR97
03 0350 31

b. Press end shim against snap ring (upward) until contact and measure with gage. Record dimension (No. 2).
Example for Clutch Pack Clearance Check
UN10APR97
Dimension No. 1 Dimension No. 2 Difference = Plate Clearance Specification = Pack Clearance
7.25 mm (0.285 in.) 4.55 mm (0.179 in.) 2.7 mm (0.106 in.) 2.72.9 mm (0.1060.114 in.)
If a clutch pack clearance is not in specification, correct by using the proper corresponding snap ring from service parts to increase or decrease clearance. Snap rings come in various sizes.
03 0350 32
After proper clearance is obtained remove disks and plates from assembly. 10. Add oil to plates and disks. 11. Reassemble clutch pack assembly.
TX,0350,ME288 1926MAR999/19
12. Install idler gear until all inner plates are engaged. This step makes later assembling of the idler gear easier. 13. Remove idler gear from clutch pack assembly.
UN10APR97
TX,0350,ME288 1926MAR9910/19
14. Apply thread lock and sealer (medium strength) to stud. 15. Install stud on end of shaft if removed in assembly.
UN10APR97
Tighten stud.
Clutch PackSpecification Shaft StudTorque ...................................................... 17 Nm (150 lb-in.)
TX,0350,ME288 1926MAR9911/19
TM1640 (15JAN04)
03-0350-32

011504
PN=152
T108670
T108669
T108668

16. Insert ball bearing until seated and install snap ring.
TX,0350,ME288 1926MAR9912/19
17. Install needle bearing.

03 0350 33
TX,0350,ME288 1926MAR9913/19
NOTE: Push against inner race of bearing.

18. Press idler gear against shoulder.
TX,0350,ME288 1926MAR9914/19
19. Retain idler gear by means of snap ring.
TX,0350,ME288 1926MAR9915/19
TM1640 (15JAN04)
03-0350-33

011504
PN=153
T108674
UN10APR97
T108673
UN10APR97
T108672
UN10APR97
T108671
UN10APR97
Gears, Shafts, Bearings and Power Shift Clutch NOTE: Clutch-KR, there is no recess in the shaft assemble snap ring until contact on the bearing inner race is obtained.
20. Assemble pre-assembled plate carrier until all plates are engaged.
TX,0350,ME288 1926MAR9916/19
21. Make sure carrier face is flush with shaft spline.

03 0350 34
TX,0350,ME288 1926MAR9917/19
22. Press tapered roller bearing against shoulder. Install opposite tapered roller bearing with press.
TX,0350,ME288 1926MAR9918/19
23. Check function of clutch by means of compressed air.
TX,0350,ME288 1926MAR9919/19
TM1640 (15JAN04)
03-0350-34

011504
PN=154
T108678
UN10APR97
NOTE: When you have correctly installed components, the clutch packs will move freely as you will be able to hear them moving while inducing compressed air.
T108677
UN10APR97
T108676
UN10APR97
T108675
UN10APR97
Disassemble Clutch Pack K1, K2, and K3

NOTE: The following art shows the disassembly of clutch K3. K1 and K2 are identical in disassembly methods.
1. Remove rectangular sealing ring from shaft.
UN29APR97
TX,0350,ME285 1926MAR991/9
2. Pull tapered roller bearing from the shaft using mandrel and puller as shown below.
Tool Usage Chart Clutch Shaft K1 Bearing Puller No. JDG1041 JDG1197 K2 K3 JDG1197 JDG1197 JDG1041 Bearing Puller Mandrel No. JDG1034 JDG1035 JDG1035 JDG1034 JDG1034
UN17APR97
T108755
03 0350 35
TX,0350,ME285 1926MAR992/9
3. Remove disk, needle bearing and washer.
TX,0350,ME285 1926MAR993/9
TM1640 (15JAN04)
03-0350-35

011504
PN=155
T108765
UN17APR97
T108764

4. Remove idler gear.
TX,0350,ME285 1926MAR994/9
5. Remove both needle bearings as well as axial bearing.

03 0350 36
TX,0350,ME285 1926MAR995/9
6. Remove snap ring and remove plates and disks.
TX,0350,ME285 1926MAR996/9
7. Preload compression spring using DFT1148 (K2, K3) or DFT1149 (K1) Pre-Load Clutch Pack Compression Ring Tool in press. 8. Squeeze snap ring out and remove components.
UN17APR97
TX,0350,ME285 1926MAR997/9
TM1640 (15JAN04)
03-0350-36

011504
PN=156
T108761
T108760
UN17APR97
T108767
UN17APR97
T108766
UN17APR97

9. Press piston out of the plate carrier, using compressed air.
TX,0350,ME285 1926MAR998/9
10. Pry plate carrier from the shaft.

03 0350 37
TX,0350,ME285 1926MAR999/9
Assemble Clutch Pack K1, K2, and K3

NOTE: Clutch K1, K2 and K3 are assembled in similar manner. All the following assembly story art show clutch K3.
1. Apply thread lock and sealer (medium strength) to stud. 2. Install stud on end of shaft. Tighten stud.
UN10APR97
TX,0350,ME289 1926MAR991/23
TM1640 (15JAN04)
03-0350-37

011504
PN=157
T108679
T108763
UN17APR97
T108762
UN17APR97

3. Assemble plate carrier until bottomed.
TX,0350,ME289 1926MAR992/23
03 0350 38
IMPORTANT: Check function of the drain valve. Check function of drain ball. Ball must move freely. If ball does not move freely, check for contamination or replace. 4. Install both new O-rings (Arrows) into the ID and OD of the piston and oil them.
UN29APR97
TX,0350,ME289 1926MAR993/23
5. Install piston in carrier until seated. Note proper position.
TX,0350,ME289 1926MAR994/23
TM1640 (15JAN04)
03-0350-38

011504
PN=158
T108734
UN10APR97
T108981
T108680
UN10APR97

6. Install compression spring, two spring guides, into plate carrier.
Spring Type Shown May Vary
T108735
UN10APR97
03 0350 39
TX,0350,ME289 1926MAR995/23
7. Using DFT1149 Pre-Load Clutch Pack Compression Ring Tool and press, install snap ring into plate carrier groove for clutch K1. Using DFT1148 Pre-Load Clutch Pack Compression Ring Tool and press, install snap ring into plate carrier groove for clutch K2 and K3.
TX,0350,ME289 1926MAR996/23
TM1640 (15JAN04)
03-0350-39

011504
PN=159
T108736
UN10APR97
03 0350 40
Clutch Packs K1
NOTE: For proper adjustment of plate clearance, install disk and plates temporarily without being oiled.
TX,0350,ME289 1926MAR997/23
9. Install plate and then disk alternately until seven plates and seven disks are installed in carrier. 10. Install two plates, then two disks.
UN10APR97
TX,0350,ME289 1926MAR998/23
TM1640 (15JAN04)
03-0350-40

011504
PN=160
T108737
T112161
UN20NOV97

TX,0350,ME289 1926MAR999/23
12. Adjust plate clearance to specification.

Clutch PackSpecification K1 Clutch Pack PlateClearance .......... 2.42.6 mm (0.0940.102 in.)
TX,0350,ME289 1926MAR9910/23
TM1640 (15JAN04)
03-0350-41

011504
PN=161
T108739
UN10APR97
T108738
UN10APR97
03 0350 41

UN09MAY97
8.50 mm (0.335 in.) 6.00 mm (0.236 in.) 2.50mm (0.079 in.) 2.42.6 mm (0.0940.102 in.)
03 0350 42
After proper clearance is obtained remove disks and plates from assembly. 13. Add oil to plates and disks. 14. Reassemble clutch pack assembly.
TX,0350,ME289 1926MAR9911/23
TM1640 (15JAN04)
03-0350-42

011504
PN=162
T108740
03 0350 43
Clutch Packs K2 and K3

For proper adjustment of plate clearance, install disk and plates temporarily without being oiled.
NOTE: Plate and disk position is the same for clutch K2 and K3.
TX,0350,ME289 1926MAR9912/23
16. Install plate and then disk alternately until five plates and five disks are installed in carrier. 17. Install two plates, then two disks.
UN10APR97
TX,0350,ME289 1926MAR9913/23
TM1640 (15JAN04)
03-0350-43

011504
PN=163
T108737
T112160
UN20NOV97

TX,0350,ME289 1926MAR9914/23
03 0350 44

Clutch PackSpecification K2 and K3 Clutch Pack Plate Clearance ................................................ 1.82.0 mm (0.0710.079 in.)
TX,0350,ME289 1926MAR9915/23
TM1640 (15JAN04)
03-0350-44

011504
PN=164
T108739
UN10APR97
T108738
UN10APR97

UN09MAY97 T108740
If a clutch pack clearance is not in specification, correct by using the proper corresponding snap ring from service parts to increase or decrease clearance. Snap rings come in various sizes. After proper clearance is obtained remove disks and plates from assembly. 20. Add oil to plates and disks. 21. Reassemble clutch pack assembly.
03 0350 45
TX,0350,ME289 1926MAR9916/23
22. Assemble thrust disk (1), thrust bearing (2), and thrust washer (3).
1Thrust Disk 2Thrust Bearing 3Thrust Washer
TX,0350,ME289 1926MAR9917/23
23. Install both needle bearings.
TX,0350,ME289 1926MAR9918/23
TM1640 (15JAN04)
03-0350-45

011504
PN=165
T108742
UN09MAY97
T108741
UN09MAY97

24. Install idler gear until all inner plates are engaged with splines.
TX,0350,ME289 1926MAR9919/23
03 0350 46
25. Install thrust washer (3), thrust bearing (2), and thrust disk.
NOTE: Install disk (1) with chamfer facing the thrust bearing.
26. To assure proper assembly, top surface of thrust disk must be flush with shaft step.
1Thrust Disk 2Thrust Bearing 3Thrust Washer
UN09MAY97
TX,0350,ME289 1926MAR9920/23
27. Press tapered roller bearing against shoulder.
TX,0350,ME289 1926MAR9921/23
TM1640 (15JAN04)
03-0350-46

011504
PN=166
T108745
UN09MAY97
T108744
T108743
UN09MAY97

TX,0350,ME289 1926MAR9922/23
T108746
UN09MAY97
TX,0350,ME289 1926MAR9923/23
Disassemble Clutch Pack K4

1. Remove sealing ring. 2. Pull tapered roller bearing from the shaft with JDG1035 Bearing Puller Mandrel and JDG1134 and JDG1197 Bearing Pullers. 3. Remove opposite tapered roller bearing accordingly.
TX,0350,ME286 1926MAR991/4
4. Remove snap ring and plate carrier from shaft.
TX,0350,ME286 1926MAR992/4
TM1640 (15JAN04)
03-0350-47

011504
PN=167
T108769
UN17APR97
T108768
UN17APR97
T108747
UN09MAY97
NOTE: When you have correctly installed components, the clutch packs will move freely in carrier, as you will be able to hear them moving while inducing compressed air.
03 0350 47

5. Remove snap ring and remove plates and disks.
TX,0350,ME286 1926MAR993/4
03 0350 48
6. Preload compression spring using DFT1148 Pre-Load Clutch Pack Compression Ring Tool in press. 7. Remove snap ring and components. Remove piston.
UN14APR97
TX,0350,ME286 1926MAR994/4
Assemble Clutch Pack K4

NOTE: Gear is very tight press fit. Shaft or gear may be damaged if pressed apart.
UN14APR97
1. Cool shaft to specification. Heat gear to specification and install it until bottomed.
Clutch PackSpecification K4 Clutch Pack Shaft Temperature ......................................................... Cools at -80C (-112F) K4 Clutch Pack Gear Temperature ......................................................... Heats at 120C (248F)
TX,0350,ME291 1926MAR991/20
TM1640 (15JAN04)
03-0350-48

011504
PN=168
T108748
T108983
T108770
UN18APR97

2. Install snap ring to retain gear.
TX,0350,ME291 1926MAR992/20
3. Apply thread lock and sealer (medium strength) to stud. 4. Install stud on end of shaft.
UN29APR97
T108749
UN14APR97
03 0350 49
Tighten stud.
TX,0350,ME291 1926MAR993/20
IMPORTANT: Check function of the drain valve. Check function of drain ball. Ball must move freely. If ball does not move freely, check for contamination or replace. 5. Install both new O-rings (Arrows) into the ID and OD of the piston and oil them.
UN29APR97
TX,0350,ME291 1926MAR994/20
6. Assemble piston until it bottoms out in disk carrier. Pay attention to proper installation.
TX,0350,ME291 1926MAR995/20
TM1640 (15JAN04)
03-0350-49

011504
PN=169
T108982
UN14APR97
T108981
T108750

7. Install compression spring, two spring guides, into disk carrier. 8. Press spring with DFT1148 Pre-Load Clutch Pack Compression Ring Tool in press and install snap ring into disk carrier groove. (See Group 0399 for instructions to make tool.)
TX,0350,ME291 1926MAR996/20
03 0350 50
T108983
UN14APR97
Clutch Packs K4
NOTE: For proper adjustment of plate clearance later install disk and plates temporarily without being oiled.
TX,0350,ME291 1926MAR997/20
TM1640 (15JAN04)
03-0350-50

011504
PN=170
T112159
UN20NOV97

10. Install plate and then disk alternately until five plates and five disks are installed in carrier.
TX,0350,ME291 1926MAR998/20

03 0350 51
TX,0350,ME291 1926MAR999/20

Clutch PackSpecification K4 Clutch Pack PlateClearance .......... 1.21.4 mm (0.0470.055 in.)
TX,0350,ME291 1926MAR9910/20
TM1640 (15JAN04)
03-0350-51

011504
PN=171
T108986
UN14APR97
T108985
UN09MAY97
T108984
UN14APR97

UN14APR97
03 0350 52
After proper clearance is obtained remove disk and plates from assembly. 13. Add oil to plates and disks. 14. Reassemble clutch pack assembly.
TX,0350,ME291 1926MAR9911/20
15. Install idler gear until inner plates are meshed with splines.
NOTE: This will make it easier for installing idler gear later.
16. Remove idler gear.
UN14APR97
TX,0350,ME291 1926MAR9912/20
17. Install thrust washers and thrust bearing.
TX,0350,ME291 1926MAR9913/20
TM1640 (15JAN04)
03-0350-52

011504
PN=172
T108989
UN14APR97
T108988
T108987

18. Install two needle bearings.
TX,0350,ME291 1926MAR9914/20
19. Assemble idler gear.

03 0350 53
TX,0350,ME291 1926MAR9915/20
20. Install thrust washer (3), thrust bearing (2), and thrust disk (1).
NOTE: Install thrust disk (1) with the chamfer facing the thrust washer.
1Thrust Disc 2Thrust Bearing 3Thrust Washer
UN29APR97
TX,0350,ME291 1926MAR9916/20
21. Assemble K4 carrier assembly onto shaft until seated and all plates are engaged.
TX,0350,ME291 1926MAR9917/20
TM1640 (15JAN04)
03-0350-53

011504
PN=173
T108993
UN14APR97
T108992
T108991
UN14APR97
T108990
UN14APR97

22. Install snap ring to retain plate.
TX,0350,ME291 1926MAR9918/20

03 0350 54
Install opposite tapered roller bearing.
TX,0350,ME291 1926MAR9919/20
TX,0350,ME291 1926MAR9920/20
Disassemble Input Shaft

NOTE: The turbine shaft is axially fixed by means of a snap ring which will be destroyed when pressing out.
If necessary, press turbine shaft out of the input shaft.
UN18APR97
TX,0350,ME287 1905OCT981/2
TM1640 (15JAN04)
03-0350-54

011504
PN=174
T108772
T108996
UN14APR97
NOTE: When you have correctly installed components, the clutch packs will move freely in carrier, as you will be able to hear them moving while inducing compressed air.
T108995
UN14APR97
T108994
UN14APR97

Remove rectangular ring out. Pull off the tapered roller bearing using JDG1034 and JDG1035 Bearing Puller Mandrel.
UN18APR97
Pull off the opposite tapered roller bearing.
NOTE: The separation of input shaft and gear is not possible (press fit).
TX,0350,ME287 1905OCT982/2
Assemble Input Shaft

Cool the input shaft to specification. Heat gear to specification and assemble to shaft until seated.
UN14APR97
T108773
03 0350 55
Input ShaftSpecification Input ShaftTemperature .................................... Cools at -80C (-112F) Input GearTemperature .................................. Heats at +120C (250F)
TX,0350,ME292 1912FEB991/8
Install snap ring to retain gear.
TX,0350,ME292 1912FEB992/8
Install snap ring into the recess of the turbine shaft.
TX,0350,ME292 1912FEB993/8
TM1640 (15JAN04)
03-0350-55

011504
PN=175
T108999
UN14APR97
T108998
UN14APR97
T108997

Install turbine shaft until the snap ring snaps into the groove of the input shaft to retain turbine shaft.
TX,0350,ME292 1912FEB994/8
Press both bearing inner races against shoulder.

03 0350 56
TX,0350,ME292 1912FEB995/8
Install ball bearing Install sealing ring.
TX,0350,ME292 1912FEB996/8
Install output shaft into the housing bore until seated.
TX,0350,ME292 1912FEB997/8
TM1640 (15JAN04)
03-0350-56

011504
PN=176
T109003
UN09MAY97
T109002
UN29APR97
T109001
UN09MAY97
T109000
UN14APR97
Gears, Shafts, Bearings and Power Shift Clutch NOTE: If bearings are reused, they must be assembled in same bores.
Insert all bearing outer races into transmission housing bores.
UN10APR97
TX,0350,ME292 1912FEB998/8
T108657
03 0350 57
TM1640 (15JAN04)
03-0350-57

011504
PN=177
03 0350 58
TM1640 (15JAN04)
03-0350-58

011504
PN=178
Group 0360
Hydraulic System
Specifications
Transmission Pump Socket Head Screw Torque 46 Nm (34 lb-ft)
Transmission Pump Pump Cap Screw Torque 25 Nm (18 lb-ft)
Manifold Plate-to-Transmission Housing Socket Head Screw Control Valve-to-Manifold Plate Socket Head Screw Housing-to-Control Valve (M5/10.9) Screw Solenoid Valve (M5/8.8) Screw
Torque
25 Nm (18 lb-ft)
03 0360 1
Torque
9.5 Nm (85 lb-in)
Torque
5 Nm (44 lb-in.)
Torque
5 Nm (44 lb-in.) 5 Nm (44 lb-in.)
Solenoid Cover-to-Housing (M5/10.9) Torque Screw Housing-to-Control Valve Block Screw (M5/10.9) Solenoid Valve-to-Retaining Plate Screw Alignment Stud-to-Cover Screw Diagnostic Plug-to-Port (M10/1) Screw Manifold Plate-to-Valve Body (M6/10.9) Screw Converter Relief Valve Manifold Socket Head Screw Torque Torque
5 Nm (44 lb-in.)
Torque
5 Nm (44 lb-in.)
Torque Torque
5 Nm (44 lb-in.) 6 Nm (55 lb-in.)
Torque
9.5 Nm (85 lb-in.)
25 Nm (18 lb-ft)
TX04577,0000420 1923JAN011/1
TM1640 (15JAN04)
03-0360-1

011504
PN=179
Hydraulic System
Remove Transmission Pump

1. Loosen socket head screws.
TX,0360,ME278 1920OCT981/5
03 0360 2
2. Placing a puller on the splines runout of the stator shaft, pull pump assembly out of the housing bore.
TX,0360,ME278 1920OCT982/5
TM1640 (15JAN04)
03-0360-2

011504
PN=180
T108731
UN17APR97
T108730
UN17APR97
Hydraulic System
Oil Pump Assembly

1O-Ring 2Snap Ring 3Seal 4Shim 5Needle Bearing 6Ring 7Pump Assembly 8O-Ring (10 used) 9Cap Screw (10 used)
TX,0360,ME278 1920OCT983/5
3. Separate transmission pump from stator. 4. Separate cam plate from pump. Make note of drive gear spline location and two small dowel pins.
UN17APR97
IMPORTANT: If traces of wear should be encountered in the pump housing or the cam disk, the complete pump has to be replaced. 5. Inspect and replace parts as required 6. Install cam disk and retain it by means of grooved pins (2x).
TP55490
UN15APR97
03 0360 3
TX,0360,ME278 1920OCT984/5
TM1640 (15JAN04)
03-0360-3

011504
PN=181
T108732
Hydraulic System
7. Loosen hex head screws and remove oil feed housing. 8. Remove flat gasket.
TX,0360,ME278 1920OCT985/5
03 0360 4
Remove and Install Converter Minimum Pressure Regulator Valve

1. Remove converter minimum pressure regulator valve out of the housing bore.
UN05JAN98
TX,0350,ME279 1926MAR991/2
2. Inspect and replace parts as required.
NOTE: Install pressure plate facing toward lock plate as shown in photo.
UN05JAN98
3. Install converter minimum pressure regulator valve into housing bore.

1Piston 2Compression Spring 3Pressure Plate 4Lock Plate
Minimum Pressure Regulator Valve
TX,0350,ME279 1926MAR992/2
TM1640 (15JAN04)
03-0360-4

011504
PN=182
T112685
T112686
T108725
UN17APR97
Hydraulic System
Install Transmission Pump

1. Install alignment studs and install flat gasket.
TX,07,ME297 1926MAR991/8
IMPORTANT: Screw hex head screws until contact is obtained. DO NOT TIGHTEN. 2. Install oil feed housing, washers and hex head screws.
UN15APR97
T112687
UN05JAN98
03 0360 5
Leave loose at this time. This allows for oil pump alignment later in assembly.
TX,07,ME297 1926MAR992/8
NOTE: Pay attention to the overlapping of the bores.

3. Install alignment studs and stator shaft until it is bottomed in housing.
UN15APR97
TX,07,ME297 1926MAR993/8
4. Lubricate and install O-ring.
TX,07,ME297 1926MAR994/8
TM1640 (15JAN04)
03-0360-5

011504
PN=183
T109088
UN29APR97
T109087
T109086
Hydraulic System
5. Install transmission pump.
TX,07,ME297 1926MAR995/8
NOTE: Grease O-rings.

03 0360 6
6. Install socket head screws with new O-rings.
TX,07,ME297 1926MAR996/8
7. Install transmission pump and socket head screws.

Transmission PumpSpecification Socket Head ScrewTorque .......................................... 46 Nm (34 lb-ft)
TX,07,ME297 1926MAR997/8
NOTE: Note locations of hanger strap from original location.

8. Tighten cap screws.
UN15APR97
Transmission PumpSpecification Pump Cap ScrewTorque ............................................. 25 Nm (18 lb-ft)
TX,07,ME297 1926MAR998/8
TM1640 (15JAN04)
03-0360-6

011504
PN=184
T109092
T109091
UN15APR97
T109090
UN29APR97
T109089
UN15APR97
Hydraulic System
Remove Transmission Hydraulic Control Valve

1. Loosen socket head screws, install two alignment studs and separate control valve from manifold plate.
UN17APR97
TX,0350,ME276 1915DEC981/3
2. Remove both gaskets (9 ,11) and center plate (10).

03 0360 7
TX,0350,ME276 1915DEC982/3
3. Loosen socket head screws and hex nuts. 4. Separate manifold plate from transmission housing. 5. Remove gasket.
UN17APR97
TX,0350,ME276 1915DEC983/3
TM1640 (15JAN04)
03-0360-7

011504
PN=185
T108714
T108710
UN17APR97
T108709
Hydraulic System
Install Transmission Hydraulic Control Valve
03 0360 8
1Stud (14 used) 2Gasket 3Manifold Plate 4Washer (16 used)
5Nut (16 used) 6O-Ring 7Plug
8Cap Screw (39 used) 9Gasket 10Plate (Center)
11Gasket 12Cap Screw (23 used) 13Cap Screw (2 used)
TX,0360,ME282 1915DEC981/4
TM1640 (15JAN04)
03-0360-8

011504
PN=186
TP60304
UN08APR98
Hydraulic System
1. Install gasket, manifold plate, and fasten it with socket head screws hex nuts and washers. Tighten socket head screws.
Specification Manifold Plate-to-Transmission Housing Socket Head Screw Torque ............................................................................. 25 Nm (18 lb-ft)
T109106
UN15APR97
03 0360 9
UN15APR97
TX,0360,ME282 1915DEC982/4
2. Install two alignment studs. Install gasket (9), plate (10) and gasket (11).
TX,0360,ME282 1915DEC983/4
3. Install complete control valve unit on the manifold plate with socket head screws. IMPORTANT: Pay attention to the installation and position of the different gaskets. 4. Tighten screw.
Specification Control Valve-to-Manifold Plate Socket Head ScrewTorque ......................................... 9.5 Nm (85 lb-in)
UN15APR97
TX,0360,ME282 1915DEC984/4
TM1640 (15JAN04)
03-0360-9

011504
PN=187
T109110
T109109
UN15APR97
T109107
Hydraulic System
Transmission Hydraulic Control Valve Cross Section View
03 0360 10
APressure Regulating ValvePiston BPressure Reducing Valve Piston
CConnectorWiring Harness DCover (2 used)
EValve BlockControl Valve FHousing (2 used) GModulation Circuit
HSolenoid Valve Proportional (6 used) ITransmission Control Valve
TX,0360,ME273 1911JAN011/1
TM1640 (15JAN04)
03-0360-10

011504
PN=188
T122180
1907JUL99
Hydraulic System
03 0360 11
TM1640 (15JAN04)
03-0360-11

011504
PN=189
Hydraulic System
Disassemble Transmission Control Valve
03 0360 12
TX,0360,ME274 1926MAR991/7
TM1640 (15JAN04)
03-0360-12

011504
PN=190
T137510
UN20JAN01
Hydraulic System
1Cap Screw (32 used) 2Clamp (Clip) 3Cover 4Wiring Harness 5Gasket 6Solenoid Valve Proportional (3 used) 7Cap Screw (3 used) 8Plate (3 used) 9Housing 10Gasket 11Piston (Dampening Valve) (6 used) 12 Spring (6 used) 13Spring 14PistonSystem Pressure Reducing Valve 15Valve Block (Control) 16O-Ring (8 used) 17Drain Plug (8 used) 18 Spring 19 Piston (System Pressure Regulating Valve) 20Gasket 21Housing 22Plate (3 used) 23Cap Screw (3 used) 24Gasket 25Cover 26Cap Screw (14 used) 27Solenoid Valve Proportional (3 used) 28Cap Screw (18 used) 29Piston (Pressure Control valve) (6 used) 30Spring (6 used) 31Orifice (6 used) 32Gasket 33Plate (Center) 34Gasket 35Manifold Plate 36Cap Screw (18 used) 37Screen (Transmission S.N. 000588 )(6 used)
TX,0360,ME274 1926MAR992/7
1. Remove screws (26) and cover (25) and gasket (24). 2. Disconnect connectors to solenoid valves (27). 3. Remove screws (23) and retaining plates (22), and remove three solenoid valves (27).
03 0360 13
Hydraulic Control Valve
TX,0360,ME274 1926MAR993/7
TM1640 (15JAN04)
03-0360-13

011504
PN=191
T108687
UN16APR97
T108686
UN16APR97
Hydraulic System
4. Loosen screw to housing (21), remove housing and gasket (20). 5. Remove three pressure control valve pistons (29) and compression springs (30). 6. Remove three damping valves pistons (11) and compression springs (12). 7. Remove system pressure valve piston (19) compression spring (18).
Remove Housing And Valves
UN12JAN01
03 0360 14
TX,0360,ME274 1926MAR994/7
8. Remove clamp (clip) (2) from wire harness connector.
Clamp Removal from Harness Connector
TX,0360,ME274 1926MAR995/7
9. Remove screws and cover (3) and gasket (5). 10. Disconnect connectors to solenoid valves (6). 11. Remove screws (7) and retaining plates (8). Pull solenoid valves (6).
TX,0360,ME274 1926MAR996/7
TM1640 (15JAN04)
03-0360-14

011504
PN=192
T108682
UN16APR97
T108689
UN16APR97
T135928
Hydraulic System
12. Loosen screw to housing (9), remove housing and gasket (10). 13. Remove three pressure control valve pistons (29) and compression springs (30). 14. Remove three damping valves pistons (11) and compression springs (12). 15. Remove pressure reducing valve piston (14) compression spring (13). 16. Inspect and replace parts as necessary.
UN16APR97 T108683
03 0360 15
TX,0360,ME274 1926MAR997/7
Assemble Transmission Control Valve

1. Check all components for damage and replace if necessary.
UN09MAY97
2. Prior to the installation, check free travel of moving parts in the housing. 3. Oil components prior to the reassembly. 4. Insert orifices (31) (if removed) until contact is obtained (6 pieces, see arrows). 5. Install screens (37) if removed (Transmission S.N. 000588 )
TX,0360,ME275 1926MAR991/21
6. Install three pressure control valve pistons (29) and compression springs (30). 7. Install three damping valve pistons (11) and compression springs (12). 8. Install system Pressure reducing valve piston (14) compression spring (13).
UN16APR97
TX,0360,ME275 1926MAR992/21
TM1640 (15JAN04)
03-0360-15

011504
PN=193
T108683
T108684
Hydraulic System
9. Screw two alignment studs in valve housing. Install gasket, assemble flat gasket (10).
NOTE: To aid assembly of solenoid housing, push spools into bore and retain by using a 5mm pin or screw.
UN16APR97
TX,0360,ME275 1926MAR993/21
03 0360 16
10. Install housing (9) while routing wire harness (4) into position.
TX,0360,ME275 1926MAR994/21
11. Fasten housing (9) with screws (1) and tighten evenly. Remove assembly aid pins or screws. Tighten (M5/10.9) screw.
Specification Housing-to-Control Valve (M5/10.9) ScrewTorque ................................................ 5 Nm (44 lb-in.)
TX,0360,ME275 1926MAR995/21
12. Insert three solenoid valves (6) into housing (9), equipped with O-ring, and fasten by means of retaining plate (8) and screws (7).
TX,0360,ME275 1926MAR996/21
TM1640 (15JAN04)
03-0360-16

011504
PN=194
T108697
UN16APR97
NOTE: Install retaining plate with the claw facing the housing bottom.
T108696
UN16APR97
T108695
UN16APR97
T108694
Hydraulic System
13. Install housing with solenoid valves onto control valve (15) and fasten with screws. Tighten (M5/8.8) screw.
Specification Solenoid Valve (M5/8.8) Screw Torque .............................................................................. 5 Nm (44 lb-in.)
UN16APR97
TX,0360,ME275 1926MAR997/21
14. Install wire harness connectors to solenoid valves.

03 0360 17
TX,0360,ME275 1926MAR998/21
15. Screw two alignment studs in, and assemble flat gasket (5) and cover (3). 16. Tighten screws (M5/10.9) 5 Nm (44 lb-in.)
UN16APR97
Specification Solenoid Cover-to-Housing (M5/10.9) ScrewTorque ................................................ 5 Nm (44 lb-in.)
TX,0360,ME275 1926MAR999/21
17. Install Wire harness connector (4) with clamp-clip (2) to cover (3).
NOTE: Make sure clamp snaps in.

UN16APR97
TX,0360,ME275 1926MAR9910/21
TM1640 (15JAN04)
03-0360-17

011504
PN=195
T108693
T108692
T108691
UN16APR97
T108698
Hydraulic System
18. Install three pressure control valve pistons (29) and springs 30). 19. Install three damping valve pistons(11) and compression springs (12). 20. Install system pressure regulating valve (19), and spring (18).
UN12JAN01
TX,0360,ME275 1926MAR9911/21
03 0360 18
21. Push spools of the pressure control valves (29) into position. A straight pin (5 mm) may be used as an assembly aid.
TX,0360,ME275 1926MAR9912/21
22. Screw two alignment studs in, assemble gasket (20) and housing (21).
T108703
UN16APR97
TX,0360,ME275 1926MAR9913/21
TM1640 (15JAN04)
03-0360-18

011504
PN=196
T108704
UN16APR97
T135928
Hydraulic System
23. Install housing and tighten evenly. 24. Tighten (M5/10.9) screw.
Specification Housing-to-Control Valve Block Screw (M5/10.9)Torque ................................................ 5 Nm (44 lb-in.)
UN16APR97 T108705
03 0360 19
TX,0360,ME275 1926MAR9914/21
25. Insert three solenoid valves (6), equipped with O-ring, and fasten by means of retaining plate (22) and screw (23).
26. Tighten (M5/8.8) screw.

Specification Solenoid Valve-to-Retaining Plate ScrewTorque ................................................................. 5 Nm (44 lb-in.)
TX,0360,ME275 1926MAR9915/21
27. Fasten harness connectors to solenoid valves. 28. Screw two alignment studs in housing and assemble flat gasket (24) and cover (25). Tighten (M5/10.9) screw (26).
Specification Alignment Stud-to-Cover Screw Torque .............................................................................. 5 Nm (44 lb-in.)
UN30APR97
TX,0360,ME275 1926MAR9916/21
TM1640 (15JAN04)
03-0360-19

011504
PN=197
T108699
T108698
UN16APR97
NOTE: Install retaining plate with the claw facing the housing bottom.
Hydraulic System
29. Install diagnostic plugs with O-rings, in ports, if removed during disassembly. 30. Tighten (M10/1) screw.
UN16APR97
Specification Diagnostic Plug-to-Port (M10/1) ScrewTorque ................................................................. 6 Nm (55 lb-in.)
TX,0360,ME275 1926MAR9917/21
03 0360 20
31. Screw two (2) alignment studs in and assemble (first) flat gasket (32).
TX,0360,ME275 1926MAR9918/21
32. Assemble intermediate plate (33).
Intermediate Plate Assembly
TX,0360,ME275 1926MAR9919/21
TM1640 (15JAN04)
03-0360-20

011504
PN=198
T108706
UN16APR97
T108701
UN16APR97
T108700
Hydraulic System
33. Assemble second gaske (34).
TX,0360,ME275 1926MAR9920/21
34. Assemble manifold plate (35) to valve body with screws (36) and (remove alignment screws).
T108707
UN09MAY97
NOTE: Tightening order of the screw start with inboard screws at first and continuing toward the outside.
35. Tighten (M6/10.9) screw.
Specification Manifold Plate-to-Valve Body (M6/10.9) ScrewTorque ............................................. 9.5 Nm (85 lb-in.)
UN17APR97
03 0360 21
TX,0360,ME275 1926MAR9921/21
Remove, Disassemble and Install Converter Relief Valve

1. Pull converter relief valve out of the housing bore.
UN17APR97
TX,0360,ME277 1926MAR991/4
TM1640 (15JAN04)
03-0360-21

011504
PN=199
T108715
T108708
Hydraulic System
2. Remove preload compression spring carefully, remove cylindrical pin as required to inspect and replace parts as needed.
1Plate 2Ball 3Compression Spring 4Valve Insert 5Valve Sleeve 6Roll Pin
Converter Relief Valve
03 0360 22
TX,0360,ME277 1926MAR992/4
3. Insert converter relief valve into the housing bore until it bottoms.
TX,0360,ME277 1926MAR993/4
TM1640 (15JAN04)
03-0360-22

011504
PN=200
T109105
UN15APR97
T109103
UN30APR97
Hydraulic System
4. Install gasket and manifold. Fasten it with socket head screws hex nuts and washers. Tighten socket head screws.
Converter Relief ValveSpecification Manifold Socket Head Screw Torque ............................................................................. 25 Nm (18 lb-ft)
T109106
UN15APR97
03 0360 23
UN15APR97
TX,0360,ME277 1926MAR994/4
Replace Oil Pipes and Tubes

NOTE: The installation of all lubrication pipes, tubes and lines require special tools. Order tools according to information given in the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog (MTC). It is very important to have these tools if repair or replacement is necessary. If repair is needed contact DTAC (Dealer Technical Assistance Center) for assistance.
1Suction Tube 2Pressure Pipe (2 used) 3Pressure Lubrication Pipe (Transmission S.N. 3320)
TX,0360,ME293 1926MAR991/3
TM1640 (15JAN04)
03-0360-23

011504
PN=201
T108652
UN09MAY97
T109107
Hydraulic System
Cover Showing Two Oil Pipes
03 0360 24
Continued on next page TX,0360,ME293 1926MAR992/3
TM1640 (15JAN04)
03-0360-24

011504
PN=202
T108658
UN09MAY97
Hydraulic System
03 0360 25
1Pipe (Transmission S.N. 3320) 2Tube
3Cap Screw 4Cap Screw 5O-Ring (4 used)
6Pipe (2 used) 7Pipe 8Pipe
9Pipe 10Pipe 11Cap Screw
TX,0360,ME293 1926MAR993/3
TM1640 (15JAN04)
03-0360-25

011504
PN=203
TP60303
UN08APR98
Hydraulic System
03 0360 26
TM1640 (15JAN04)
03-0360-26

011504
PN=204
Group 0399
Dealer Fabricated Tools

DFT1148 Pre-Load Clutch Pack Compression Ring Tool
03 0399 1
The Clutch Pack Compression Ring Tool is used to compress the piston compression ring so snap ring can be removed.
Material is standard pipe (see dimensions above) with window cut out to allow for access when removing snap ring.
TX,0399,ME295 1908MAY971/1
TM1640 (15JAN04)
03-0399-1

011504
PN=205
T109190
UN08MAY97
DFT1149 Pre-Load Clutch Pack Compression Ring Tool
03 0399 2
The Clutch Pack Compression Ring Tool is used to compress the piston compression ring so snap ring can be removed.
Material is standard pipe (see dimensions above) with window cut out to allow for access when removing snap ring.
TX,0399,ME296 1908MAY971/1
TM1640 (15JAN04)
03-0399-2

011504
PN=206
T109434
UN07MAY97
Section 04
Engine
Contents
Page
Group 0400Removal and Installation PowerTech 4.5 L (4045) and 6.8 L (6068) John Deere EnginesUse CTM104 . . . . .04-0400-1 Service Equipment and Tools . . . . . . . . . . . .04-0400-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .04-0400-2 Engine Remove and Install . . . . . . . . . . . . . . . . . .04-0400-3
04
TM1640 (15JAN04)
04-1

011504
PN=1
Contents
04
TM1640 (15JAN04)
04-2

011504
PN=2
Group 0400

PowerTech 4.5 L (4045) and 6.8 L (6068) John Deere EnginesUse CTM104
For additional engine information, the component technical manual (CTM) is also required. Use the CTM in conjunction with this machine manual.
UN07SEP88
TX,9010,SS3681 1905AUG961/1

04 0400 1
CED,OUOE003,3319 1926MAR991/3
Lifting Sling . . . . . . . . . . . . . . . . . . . . . . . . . . JDG23 Used with load positioning sling to remove and install engine.
CED,OUOE003,3319 1926MAR992/3
Load Positioning Sling . . . . . . . . . . . . . . . . D01043AA Used with lifting sling to remove and install engine.
CED,OUOE003,3319 1926MAR993/3
TM1640 (15JAN04)
04-0400-1

011504
PN=209
M44215
Specifications
Engine Engine Mounting Cap Screw
Weight Torque Torque
567 kg (1250 lb) approximate 434 87 Nm (320 64 lb-ft) fan end of engine 215 43 Nm (160 32 lb-ft) flywheel end of engine 78 Nm (58 lb-ft)
Engine-to-Transmission Drive Shaft U-Joint Cap Screw
Torque
CED,OUOE003,3320 1926MAR991/1
04 0400 2
TM1640 (15JAN04)
04-0400-2

011504
PN=210
Remove and Install Engine

1. Stop engine. Lower boom and bucket to ground. 2. Remove battery negative ground strap or turn battery disconnect switch Off if equipped. CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. 3. Attach hose to radiator drain cock. Drain engine coolant. 4. Remove hood with air cleaner and turbocharger inlet hose. (See Group 1910 for hood removal.) (See Group 0520 for air cleaner removal.) 5. Remove muffler with muffler mounting brackets. (See Group 0530.)
UN23AUG88 TS281
04 0400 3
TX,04,JC2341 1916FEB991/7
TM1640 (15JAN04)
04-0400-3

011504
PN=211
04 0400 4
AHeater Hoses
BFuel Suction Hose
CRadiator Hoses
6. Close shut-off valve at heater supply hose. 7. Disconnect heater hoses (A), fuel suction hose (B), and top and bottom radiator hoses (C). Disconnect fluid starting aid line, if equipped.
TX,04,JC2341 1916FEB992/7
TM1640 (15JAN04)
04-0400-4

011504
T112236B
UN14NOV97
PN=212
UN20NOV97
04 0400 5
DCompressor Cap Screw (3 used)
EBall Joint FThrottle Cable
GU-Bolt HStarter
IAir-to-Air Cooler Hoses JFuel Return Line
8. Disconnect throttle cable (F) from ball joint (E). Remove U-bolt (G) from throttle cable bracket. Remove bracket. 9. Disconnect fuel return line (J). 10. Disconnect air to air cooler hoses (I) from turbocharger and intake manifold. Remove air cooler tube clamp from engine block. 11. Remove battery cables and E01 White wires from starter (H).
12. Remove air conditioning compressor cap screws (D) (if equipped). Move compressor out of the way. 13. Disconnect engine harness-to-load center harness connector from bottom right-hand side of cab or ROPS.
TX,04,JC2341 1916FEB993/7
TM1640 (15JAN04)
04-0400-5

011504
T112237B
PN=213

14. Remove four cap screws from the engine-to-transmission drive shaft U-joints (A) (at the torque converter side). 15. Install JDG23 Lifting Sling and D01043AA Load Positioning Sling to engine. 16. Remove the four front and rear engine mounting cap screws. 17. Remove the R.H. front and rear engine mounts from engine. CAUTION: Engine weighs approximately 567 kg (1250 lb).
Specification EngineWeight ........................................... 567 kg (1250 lb) approximate AU-Joint (4 used)
18. Remove engine.

04 0400 6
TX,04,JC2341 1916FEB994/7
TM1640 (15JAN04)
04-0400-6

011504
PN=214
T108384B
UN21MAR97
04 0400 7
ACap Screw (2 used) BWasher (2 used) CSupport DCap Screw (2 used)
EWasher (2 used) FSupport GCap Screw (4 used) HWasher (4 used)
ISupport JWasher (4 used) KNut (4 used) LIsolator Assembly (2 used)
MIsolator Assembly (2 used) NCap Screw (6 used) OSupport
19. Inspect engine mounting parts. Replace as needed.
TX,04,JC2341 1916FEB995/7
TM1640 (15JAN04)
04-0400-7

011504
PN=215
T108394
UN11DEC98

20. Install two front and two rear mounting cap screws. Tighten screws (A).
Specification Engine Mounting Cap Screw Torque ......................................................... 434 87 Nm (320 64 lb-ft) fan end of engine Torque ......................................................... 215 43 Nm (160 32 lb-ft) flywheel end of engine
AMounting Cap Screw (4 used)
TX,04,JC2341 1916FEB996/7
04 0400 8
TM1640 (15JAN04)
04-0400-8

011504
PN=216
T109274C
UN28APR97

21. Install four NEW engine-to-transmission drive shaft U-joint cap screws (A) and two clamps. Tighten to specification.
Specification Engine-to-Transmission Drive Shaft U-Joint Cap ScrewTorque .................................. 78 Nm (58 lb-ft)
23. Connect positive battery cables and E01 white wires to starter. Connect ground wires to starter.
AU-Joint Cap Screw (4 Used)
24. Connect fuel return line. 25. Connect air to air cooler hoses. 26. Install throttle cable bracket. Connect throttle cable. 27. Connect fluid start aid line (if equipped). Connect top and bottom radiator hoses. Connect fuel suction hose and heater hoses. 28. Install muffler with muffler brackets. (See Group 0530.) 29. Install hood with air cleaner and turbocharger inlet hose. (See Group 1910 and Group 0520.) 30. Fill radiator with coolant. 31. Connect battery negative ground strap or turn battery disconnect switch On if equipped. 32. Check engine rpm. Adjust cable if necessary. See Slow and Fast Idle Adjustment, Group 0515. Also see Speed Control Linkage Adjustment, Group 0515.
T108384B
22. Connect engine harness-to-load center harness connector.
UN21MAR97
04 0400 9
TX,04,JC2341 1916FEB997/7
TM1640 (15JAN04)
04-0400-9

011504
PN=217
04 0400 10
TM1640 (15JAN04)
04-0400-10

011504
PN=218
Section 05
Engine Auxiliary Systems

Contents
Page Page
Group 0505Cold Weather Starting Aids Other Material . . . . . . . . . . . . . . . . . . . . . . . .05-0505-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0505-1 Fluid Starting Aid Assembly Remove and Install . . . . . . . . . . . . . . . . . .05-0505-1 Engine Coolant Heater Remove and Install . . . . . . . . . . . . . . . . . .05-0505-4 Group 0510Cooling System Other Material . . . . . . . . . . . . . . . . . . . . . . . .05-0510-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0510-2 Serpentine Belt Remove and Install . . . . . . . . . . . . . . . . . .05-0510-3 Fan and Fan Drive Remove and Install . . . . . . . . . . . . . . . . . .05-0510-5 Radiator and Oil Cooler Remove and Install . . . . . . . . . . . . . . . . .05-0510-10 Radiator, Oil Cooler and Air-to-Air Aftercooler Disassemble and Assemble. . . . . . . . . . .05-0510-17 Group 0515Speed Controls Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0515-1 Speed Control Linkage Remove and Install . . . . . . . . . . . . . . . . . .05-0515-1 Fuel Shut-Off Solenoid Remove and Install . . . . . . . . . . . . . . . . . .05-0515-2 Fast and Slow Idle Check and Adjust . . . . . . . . . . . . . . . . . . .05-0515-2 Speed Control Linkage Adjustment . . . . . . . .05-0515-5 Fuel Shut-Off Solenoid Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0515-6 Group 0520Intake System Essential Tools . . . . . . . . . . . . . . . . . . . . . . .05-0520-1 Service Equipment and Tools . . . . . . . . . . . .05-0520-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0520-1 Air Cleaner Remove and Install . . . . . . . . . . . . . . . . . .05-0520-2 Air Filter Elements Remove and Install . . . . . . . . . . . . . . . . . .05-0520-3 Primary Element Clean Dusty . . . . . . . . . . . . . . . . . . . . . . . .05-0520-5 Clean Oily or Sooty . . . . . . . . . . . . . . . . . .05-0520-5 Element Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0520-6 TM1640 (15JAN04)
Air Intake System Leakage Test. . . . . . . . . . . . . . . . . . . . . . .05-0520-7 Group 0530External Exhaust System Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0530-1 Muffler Remove and Install . . . . . . . . . . . . . . . . . .05-0530-2 Group 0560External Fuel Supply Systems Specifications . . . . . . . . . . . . . . . . . . . . . . . .05-0560-1 Fuel Tank Remove and Install . . . . . . . . . . . . . . . . . .05-0560-2 Primary Fuel Filter (Water Separator) Drain and Clean. . . . . . . . . . . . . . . . . . . . .05-0560-5 Remove and Install . . . . . . . . . . . . . . . . . .05-0560-6 Final Fuel Filter Remove and Install . . . . . . . . . . . . . . . . . .05-0560-9 Fuel System Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0560-10
05
05-1

011504
PN=1
Contents
05
TM1640 (15JAN04)
05-2

011504
PN=2
Group 0505
Cold Weather Starting Aids

Other Material
Number Name Use
T43513 (U.S.) TY9474 (Canadian) 271 (LOCTITE) TY16004 (U.S.)
Apply to threads of fluid starting aid nozzle holder.
John Deere Coolant Conditioner
Add to cooling system.
CED,OUOE003,3322 1926MAR991/1
Specifications
Heating Element Nut
Torque
34 Nm (25 lb-ft)
CED,OUOE024,404 1919FEB991/1
Remove and Install Fluid Starting Aid Assembly

1. Disconnect start aid solenoid connector that is located on sump tank harness.
05 0505 1
TX,0505,111474 1920OCT981/4
TM1640 (15JAN04)
05-0505-1

011504
PN=221
T108966
1917APR97

2. Open left engine access door. Remove starting aid components (AE).
AStarting Aid Canister BClamp CStarting Aid Solenoid DLine ENozzle
TX,0505,111474 1920OCT982/4
3. Remove nozzle (C) from holder (B). 4. Clean or replace nozzle as required. IMPORTANT: Nozzle must be secure in holder to prevent engine damage from dust. Do not overtighten or nozzle may break. 5. Carefully tighten nozzle in nozzle holder. 6. Apply thread lock and sealer (high strength) to threads of nozzle holder. 7. Install nozzle holder so nozzle is toward center of air inlet so fluid is sprayed into incoming air flow. Arrow on hex flat indicates direction of nozzle.
AAdapter Elbow BNozzle Holder CNozzle
TX,0505,111474 1920OCT983/4
TM1640 (15JAN04)
05-0505-2

011504
PN=222
T104622
UN08OCT97
05 0505 2
T106395D
UN16APR97

IMPORTANT: When operating machine without starting aid container installed, protect components from possible damage. Install starting aid plug (D) in starting aid base. 8. Install starting aid components. Remove safety cap from new canister (C). Turn canister clockwise in starting aid base to install. 9. Tighten clamp (B).
BClamp CStart Aid Canister DStart Aid Plug
UN24JAN97
TX,0505,111474 1920OCT984/4
T106395B
05 0505 3
TM1640 (15JAN04)
05-0505-3

011504
PN=223
Remove and Install Engine Coolant Heater

CAUTION: Coolant may be hot. Wait until radiator is cool to the touch before draining.
UN01NOV88
1. Drain cooling system 2. Remove power cord (A). Loosen nut (C) and pull heating element (G) from block. CAUTION: DO NOT plug coolant heater into electrical power unless heating element is immersed in coolant. Sheath could burst and result in personal injury. Use a heavy-duty grounded cord to connect coolant heater to electrical power. 3. Disassemble parts (BG). 4. Replace parts as necessary. 5. Assemble parts (BG). Put heating element in cylinder block so flats on threaded portion of element are vertical.
05 0505 4
6. Turn element clockwise and then counterclockwise until element contacts casting. Move element to the center position. 7. Hold element using a wrench. Tighten nut.
Specification Heating Element NutTorque ........................................ 34 Nm (25 lb-ft)
APower Cord BCap CNut DAdapter EGasket FO-Ring GHeating Element
8. Install power cord (A). Refill Cooling System IMPORTANT: Use only permanent-type, low silicate, ethylene glycol base antifreeze in coolant solution. Other types of antifreeze may damage cylinder seals. FREEZING TEMPERATURES: Fill with permanent-type, low silicate, ethylene glycol antifreeze (without stop-leak additive) and clean, soft water. Add TY16004 John Deere Coolant Conditioner or equivalent.
TX,0505,111284 1926MAR991/2
TM1640 (15JAN04)
05-0505-4

011504
PN=224
T6427AO
UN21OCT88
T6642EK
Cold Weather Starting Aids NOTE: All machines are shipped from the factory with a 50-50 mixture for protection to -34C (-30F). Adjust mixture accordingly to provide freeze protection for your machine.
Fill radiator to the bottom of the radiator fill neck. Fill the recovery tank to the FULL mark. Deaeration The cooling system requires several warm-up and cool down cycles to deaerate. It will NOT deaerate during normal operation. Only during warm-up and cool down cycles will the system deaerate. Start engine. Run engine until coolant reaches a warm temperature. Stop engine. Allow coolant to cool. Check coolant level at recovery tank. Repeat Steps 13 until recovery tank coolant level is repeatedly at the same level (stabilized).
NOTE: The level of the coolant in the cooling system MUST BE repeatedly checked after all drain and refill procedures to insure that all air is out of the system which allows the coolant level to stabilize. Check coolant level only when the engine is cold.
05 0505 5
TX,0505,111284 1926MAR992/2
TM1640 (15JAN04)
05-0505-5

011504
PN=225
05 0505 6
TM1640 (15JAN04)
05-0505-6

011504
PN=226
Group 0510
Cooling System
Other Material
Number Name Use
PT569 (U.S.)
John Deere NEVER-SEEZ Lubricant
Apply to fan shaft of drive motor.
CED,OUOE003,3332 1927MAR991/1
05 0510 1
TM1640 (15JAN04)
05-0510-1

011504
PN=227
Cooling System
Specifications
Fan Drive Motor Housing Bolt Motor Relief Valve Pump Housing Bolt Hub Hex Nut Torque Torque Torque Torque 55 Nm (40.5 lb-ft) 32 Nm (23.5 lb-ft) 55 Nm (40.5 lb-ft) 40 Nm (54 lb-ft)
Radiator and Oil Cooler Hood, Air Cleaner and Exhaust Pipe Grille Housing and Grille Radiator and Oil Cooler Assembly Side Plate-to-Frame Cap Screw
05 0510 2
Weight
45 kg (100 lb) approximate
Weight Weight Torque Clearance Torque Torque
152 kg (335 lb) approximate 57 kg (125 lb) approximate 128 Nm (95 lb-ft) 4.89.4 mm (0.1890.370 in.) 298 Nm (220 lb-ft) 46 Nm (34 lb-ft)
Fan Tip-to-Shroud Rod Hex Nut Cooler-to-Rod Mount Bracket Cap Screw Radiator/Oil Cooler Assembly-to-Frame Cap Screw Fan-to-Shroud Grille Housing-to-Frame Cap Screw Side Plate-to-Grille Housing Cap Screw
Torque
129 Nm (95 lb-ft)
Clearance Torque
4.89.4 mm (0.1890.370 in.) 129 Nm (95 lb-ft)
Torque
73 Nm (54 lb-ft)
CED,OUOE003,3334 1927MAR991/1
TM1640 (15JAN04)
05-0510-2

011504
PN=228
Cooling System
Remove and Install Serpentine Belt

1. Check belt (A) regularly for wear, especially for cracks at the bottom of grooves and for frayed edges.
ABelt
TX,05,RP3338 1927MAR991/2
T111242B
UN27AUG97
05 0510 3
TM1640 (15JAN04)
05-0510-3

011504
PN=229
Cooling System
IMPORTANT: If belt is stretched to the point that the belt tensioner is against its stop, belt must be replaced. 2. Replace belt if needed per diagram. Replace belt if worn. 3. Hold tension adjuster assembly away from belt. Remove old belt; install new belt, release tensioner.
1Crankshaft 2Air Conditioning Compressor 3Idler Pulley 4Alternator 5Water Pump 6Tensioner
05 0510 4
Belt With Air Conditioning
Belt Without Air Conditioning

TX,05,RP3338 1927MAR992/2
TM1640 (15JAN04)
05-0510-4

011504
PN=230
T111700
1909OCT97
T111698
1909OCT97
Cooling System
Remove and Install Fan and Fan Drive
T111724
1914OCT97
05 0510 5
ACap Screw, Side Plate to Grille Housing
BHex Nut, Rod CCap Screw, Side Plate to Frame
DAngle Bracket ET Bracket
FBracket to Frame
1. Turn battery disconnect switch off (if equipped) or disconnect battery ground strap. 2. Remove fan guard.
Remove fan and fan drive hub. Remove hoses from fan drive motor, remove fan drive motor.
TX,0510,111291 1927MAR991/5
TM1640 (15JAN04)
05-0510-5

011504
PN=231
Cooling System
05 0510 6
ASuction Hose BFan Drive Pump
CPump-to-Motor Hose DFan Drive Motor
EMotor-to-Reservoir Return Tube Hose
FMotor-to-Hydraulic Filter Hose
3. Repair kits are available for the pump and motor.
TX,0510,111291 1927MAR992/5
TM1640 (15JAN04)
05-0510-6

011504
PN=232
T111780
UN17OCT97
Cooling System
T111703
UN23OCT97
ADrive Hub
BHex Nut
CWasher
DLabel
05 0510 7
4. Replace label if not readable.
TX,0510,111291 1927MAR993/5
TM1640 (15JAN04)
05-0510-7

011504
PN=233
Cooling System
05 0510 8
Fan Drive Motor

1O-Ring (2 used) 2Seal (2 used) 3Dust Seal 4Shaft Seal 5Bushing Block (2 used) 6Housing 7Valve Body 8Relief Valve 9Flange 10Drive Gear 11Idler Gear 12Retaining Ring 13Dowel Pin (4 used) 14Bolt (4 used) 15Key 1619Relief Valve Repair Kit
5. Replace fan drive motor seals as necessary. 6. Repair or replace fan drive motor relief valve as needed. 7. Install fan drive motor bolts (14) and tighten.
Fan DriveSpecification Motor Housing BoltTorque ................................. 55 Nm (40.5 lb-ft)
8. Install relief valve and tighten.

Fan DriveSpecification Motor Relief ValveTorque .................................. 32 Nm (23.5 lb-ft)
TX,0510,111291 1927MAR994/5
TM1640 (15JAN04)
05-0510-8

011504
PN=234
T111705
UN24NOV97
Cooling System
Fan Drive Pump

1Retaining Ring 2Shaft Seal (2 used) 3Flange 4Dowel Pin 5O-Ring (2 used) 6Bearing (2 used) 7E Seal (2 used) 8Backup Ring (2 used) 9End Cover 10Bolt (4 used) 11Housing 12Gear (Number 2) 13Gear (Number 1)
T111779
UN11NOV97
05 0510 9
9. Repair or replace fan drive pump as needed. 10. Tighten fan drive pump housing bolts (10).
Fan DriveSpecification Pump Housing BoltTorque ................................. 55 Nm (40.5 lb-ft)
13. If label for fan drive hub hex nut torque is not readable, replace it.
Fan DriveSpecification Hub Hex NutTorque .............................................. 40 Nm (54 lb-ft)
11. Install pump, motor and hoses. 12. Apply John Deere NEVER-SEEZ Lubricant to shaft of drive motor. Install fan drive hub and fan. Tighten fan hub hex nut.
14. Install fan shroud, leave cap screws loose. Adjust clearance between shroud and fan blade tips to specification. Move shroud for left-right adjustment and use fan support for up-down adjustment. Tighten cap screws. Install fan guard.
TX,0510,111291 1927MAR995/5
TM1640 (15JAN04)
05-0510-9

011504
PN=235
Cooling System
Remove and Install Radiator and Oil Cooler

CAUTION: Do not remove radiator filler cap unless engine is cool Then turn cap slowly to the stop, then remove.
NOTE: Approximate capacity of cooling system is 22 L (23 qt).

1. Remove radiator cap. Attach hose to radiator drain cock (B). Drain engine coolant into a container. Remove hose and tighten drain cock. 2. Remove coolant recovery tank from hood. CAUTION: The approximate weight of hood, air cleaner and exhaust pipe is 45 kg (100 lb).
Radiator and Oil CoolerSpecification Hood, Air Cleaner and Exhaust PipeWeight ................................................... 45 kg (100 lb) approximate BRadiator Drain Cock
3. Remove hood with air cleaner and exhaust pipe. 4. Disconnect electrical harness connectors for coolant level sensor and lights in grille.
05 0510 10
CAUTION: The approximate weight of grille housing and grille is 152 kg (335 lb).
Radiator and Oil CoolerSpecification Grille Housing and GrilleWeight ................ 152 kg (335 lb) approximate
5. Remove grille and grille housing. (See Group 1921.)
TX,0510,JC2023 1927MAR991/9
TM1640 (15JAN04)
05-0510-10

011504
PN=236
T111245B
UN27AUG97
Cooling System
6. Disconnect upper (A) and lower (B) radiator hoses and hose to coolant recovery reservoir. 7. Remove fan guard. 8. Remove fan shroud. 9. Remove fan and fan motor.
AUpper Radiator Hose BLower Radiator Hose
T111706B
UN09OCT97
05 0510 11
TX,0510,JC2023 1927MAR992/9
TM1640 (15JAN04)
05-0510-11

011504
PN=237
T111707B
UN09OCT97
Cooling System
10. Disconnect transmission, hydraulic oil charge air cooler hoses (CF).
CHose DHose EHose FHose
05 0510 12
TX,0510,JC2023 1927MAR993/9
11. Remove clamp (G) and tube from air cooler.

GClamp
TX,0510,JC2023 1927MAR994/9
TM1640 (15JAN04)
05-0510-12

011504
T111714B
UN09OCT97
PN=238
T111713B
UN09OCT97
Cooling System
T111724
1914OCT97
ACap Screw, Side Plate-to-Grille Housing
BHex Nut, Rod CCap Screw, Side Plate-to-Frame
FBracket-to-Frame
05 0510 13
12. Remove cap screws from air deflector brackets. Remove air deflector.
Continued on next page TX,0510,JC2023 1927MAR995/9
TM1640 (15JAN04)
05-0510-13

011504
PN=239
Cooling System
13. Remove cap screws (A) from air conditioner condenser.
NOTE: Air conditioning system does NOT have to be discharged to remove radiator and oil coolers.
ACap Screw (3 used)
05 0510 14
TX,0510,JC2023 1927MAR996/9
14. Remove cap screws (B). Do not disconnect air conditioning hoses from condenser. Lay air conditioning condenser forward and secure with rope. CAUTION: The approximate weight of radiator, hydraulic oil cooler, transmission oil cooler and air cooler assembly is 57 kg (125 lb).
Radiator and Oil CoolerSpecification Radiator and Oil Cooler AssemblyWeight .......................................... 57 kg (125 lb) approximate
15. Attach hoist to radiator and oil cooler assembly. Remove cap screws attaching assembly to frame.
BCap Screw (3 used)
TX,0510,JC2023 1927MAR997/9
TM1640 (15JAN04)
05-0510-14

011504
PN=240
T111806B
UN23OCT97
T111807B
UN23OCT97
Cooling System
16. Carefully remove assembly. 17. Make necessary repairs. 18. Install radiator and oil cooler assembly.
544H Shown
T109372B
UN01MAY97
05 0510 15
TX,0510,JC2023 1927MAR998/9
TM1640 (15JAN04)
05-0510-15

011504
PN=241
Cooling System
05 0510 16
FBracket-to-Frame
19. Install side plate-to-frame cap screws (C) and washers. Tighten cap screws.
Radiator and Oil CoolerSpecification Side Plate-to-Frame Cap ScrewTorque ....................................................... 128 Nm (95 lb-ft)
25. Connect radiators hoses and coolant recovery reservoir hose. 26. Install grille and grille housing. (See Group 1921.) 27. Install hood. 28. Fill radiator with correct coolant mixture. 29. Cooling system must be deaerated to remove air from system and to properly fill it with coolant. See Operators Manual for deaeration of cooling system procedures. 30. Check transmission and hydraulic oil level and refill as needed.
20. Install fan and fan motor. 21. Replace foam strips on fan shroud. Install fan shroud leaving cap screws loose. 22. Adjust fan tip-to-shroud clearance evenly around fan to specification, tighten shroud cap screws.
Radiator and Oil CoolerSpecification Fan Tip-to-ShroudClearance ......... 4.89.4 mm (0.1890.370 in.)
23. Install fan guard. 24. Connect transmission cooler, hydraulic oil cooler, and charge air cooler hoses.
TX,0510,JC2023 1927MAR999/9
TM1640 (15JAN04)
05-0510-16

011504
PN=242
T111724
1914OCT97
Cooling System
Disassemble and Assemble Radiator, Oil Cooler and Air-to-Air Aftercooler
T111724
1914OCT97
05 0510 17
FBracket-to-Frame
1. Remove radiator/oil cooler/air-to-air aftercooler assembly per procedures in this group.
2. Disassemble radiator/oil cooler/air-to-air aftercooler assembly. Replace parts as necessary.
TX,05,RP3341 1910MAY991/6
TM1640 (15JAN04)
05-0510-17

011504
PN=243
Cooling System
3. Apply foam strips (A) to both sides of radiator (4 pieces required).
AFoam Strip (4 used)
05 0510 18
TX,05,RP3341 1910MAY992/6
4. Assemble side plate (B) to oil cooler (C).

BSide Plate COil Cooler
UN30APR97
TX,05,RP3341 1910MAY993/6
TM1640 (15JAN04)
05-0510-18

011504
PN=244
T109356B
T111950
UN19NOV97
Cooling System
5. Thread four rods (D) with fixed nuts into oil cooler side member. Tighten rods. 6. Assemble brackets (E) and straps (F) with isolators loosely to oil cooler and rods. 7. Thread jam nuts (G) on rods.
DRod (4 used) EBracket (4 used) FIsolator (3 used) GHex Nut (4 used)
UN30APR97
TX,05,RP3341 1910MAY994/6
8. Assemble side member (H) to radiator (I).
NOTE: For ease of assembly, cut a rod (L) 1092 4 mm (43 0.2 in.) to measure distance between radiator and oil cooler side plates.
9. Assemble cooling package. Adjust jam nuts on threaded rods so cooling package is 1092 4 mm (43 0.2 in.) wide, measured inside the side plates and tighten rod hex nuts.
Radiator and Oil CoolerSpecification Rod Hex NutTorque ................................................. 298 Nm (220 lb-ft)
UN30APR97
T109357B
05 0510 19
Radiator and Oil CoolerSpecification Cooler-to-Rod Mount Bracket Cap ScrewTorque ................................................................ 46 Nm (34 lb-ft)
11. Replace foam strips on top and bottom of fan shroud. 12. Install radiator/oil cooler assembly on machine. Tighten radiator/oil cooler assembly-to-frame cap screws.
Radiator and Oil CoolerSpecification Radiator/Oil Cooler Assembly-to-Frame Cap Screw Torque ........................................................................... 129 Nm (95 lb-ft)
HSide Member IRadiator JBracket (4 used, Front Shown) KCap Screw (3 used) LCooling Package Distance
TX,05,RP3341 1910MAY995/6
TM1640 (15JAN04)
05-0510-19

011504
PN=245
T109358B
10. Tighten cooler-to-rod mount bracket cap screws.
Cooling System
05 0510 20
ADrive Hub
BHex Nut
CWasher
DLabel
13. Install fan motor and fan. 14. Install shroud on radiator, leaving cap screws loose. 15. Adjust fan tip-to-shroud clearance evenly around fan. Move shroud for left-right adjustment and fan support for up-down adjustment.
Radiator and Oil CoolerSpecification Fan-to-ShroudClearance ............... 4.89.4 mm (0.1890.370 in.)
17. Install grille housing. (See Group 1921). Install grille housing-to-frame cap screws and tighten.
Radiator and Oil CoolerSpecification Grille Housing-to-Frame Cap ScrewTorque ....................................................... 129 Nm (95 lb-ft)
18. Install side plate-to-grille housing cap screws and tighten.

Radiator and Oil CoolerSpecification Side Plate-to-Grille Housing Cap ScrewTorque ................................................. 73 Nm (54 lb-ft)
16. Tighten fan shroud cap screws.
TX,05,RP3341 1910MAY996/6
TM1640 (15JAN04)
05-0510-20

011504
PN=246
T111703
UN23OCT97
Group 0515
Speed Controls
Specifications
Fuel Shut-Off Solenoid Injection Pump Lever Cap Screw Torque 1520 Nm (1115 lb-ft)
Fast and Slow Idle Slow Idle Stop Screw Fast Idle Stop Screw RPM RPM 900 25 rpm 2350 25 rpm
Speed Control Linkage Accelerator Pedal Angle (with respect to pedal mounting plate) 911 @ low idle position 3035 @ fast idle position Pedal Stop Screw Clearance (with injection pump lever on fast idle stop) 12 mm (0.00390.079 in.)
CED,OUOE003,3377 1921APR991/1
Remove and Install Speed Control Linkage

1. Remove front and right cab shields. 2. Disassemble parts as shown. 3. Repair or replace as necessary. 4. Adjust linkage. (See Adjust Speed Control Linkage in this group.) 5. Install shields.
AAccelerator Pedal Assembly BIsolator CAccelerator Cable DBracket EBall Joint
05 0515 1
TX,05,RP3343 1927MAR991/1
TM1640 (15JAN04)
05-0515-1

011504
PN=247
T111728
UN28OCT97
Speed Controls
Remove and Install Fuel Shut-Off Solenoid

1. Remove fuel shut-off solenoid. Disconnect solenoid connector from machine harness. 2. Install cap screw (8) to injection pump lever and tighten.
Fuel Shut-Off SolenoidSpecification Injection Pump Lever Cap ScrewTorque ................................................. 1520 Nm (1115 lb-ft)
3. Go to Adjust Fuel Shut-Off Solenoid in this group.

1Nut 2Cap Screw 3Bracket 4Cap Screw 5Washer 6Nut 7Fuel Shut-Off Solenoid 8Cap Screw 9Nut
05 0515 2
TX,05,RP3344 1927MAR991/1
Check and Adjust Fast and Slow Idle

1. Connect a tachometer to check engine speeds. 2. Warm engine to normal operating temperature. 3. Stop the engine. 4. Disconnect speed control cable at injection pump lever.
TX,9010,JC2149 1924JUN981/3
TM1640 (15JAN04)
05-0515-2

011504
PN=248
T111753
1919NOV97
Speed Controls
T103678
UN16SEP96
ANut BSlow Idle Stop Screw
CNut DSupplementary Idle Screw
ENut
FFast Idle Stop Screw
05 0515 3
5. Push injection pump lever against fast idle stop screw (F). Record engine speed. Push injection pump lever against slow idle stop screw (B). Record engine speed.
Fast and Slow IdleSpecification Slow Idle Stop ScrewRPM ......................................... 900 25 rpm Fast Idle Stop ScrewRPM........................................ 2350 25 rpm
8. Hold injection pump lever against the screw. Adjust the slow idle stop screw to obtain an engine speed that is 3040 rpm less than the slow idle specification. Hold screw and tighten nut. 9. Turn the supplementary idle screw in to increase engine speed to the slow idle specification. Hold screw and tighten nut. For example, to obtain the 900 rpm slow idle speed, turn the slow idle stop screw (B) out to get approximately 865 rpm. Hold screw and tighten the nut. Then turn the supplementary idle screw (D) in to increase engine speed to 900 rpm. Hold screw and tighten nut 10. Pull injection pump lever rapidly to fast idle then decelerate to slow idle. Slow idle must be to specification.
Adjust fast and slow idle stop screws on injection pump as needed. 6. Loosen nut (C) on the supplementary idle screw (D). Turn the screw out three turns. 7. Loosen nut (A) on the slow idle stop screw (B).
TX,9010,JC2149 1924JUN982/3
TM1640 (15JAN04)
05-0515-3

011504
PN=249
Speed Controls NOTE: Increasing slow idle setting a small amount, but no more than the maximum specifications, may help to reduce surging or hunting. If surging or hunting continues, repair injection pump.
11. Loosen nut (E) on fast idle stop screw (F). Pull lever against fast idle stop screw. Turn screw in to decrease engine speed; turn screw out to increase engine speed. Adjust engine fast idle speed to specification. Hold screw and tighten nut. 12. Stop the engine. Connect the cable to lever. 13. Adjust speed control linkage. (See procedure in this group.)
TX,9010,JC2149 1924JUN983/3
05 0515 4
TM1640 (15JAN04)
05-0515-4

011504
PN=250
Speed Controls
Speed Control Linkage Adjustment

SPECIFICATIONS Accelerator Pedal Angle (with respect to pedal mounting plate) Accelerator Pedal (with respect to pedal mounting plate) Pedal Stop Screw Clearance (with injection pump lever on fast idle stop) 911 @ low idle position 3035 @ fast idle position 12 mm (0.0390.079 in.)
1. Adjust pedal angle to 911 from the pedal mounting plate with the pedal released.
Specification Accelerator PedalAngle (with respect to pedal mounting plate) .................... 911 @ low idle position 3035 @ fast idle position
UN10SEP97 T111247B
2. Accelerator pedal at slow idle, disconnect swivel (F) on speed control cable (D) from injection pump lever (A). With injection pump lever (A) held against the slow idle stop screw (C), adjust swivel (F) on cable (D) to align with injection pump lever (A). Install swivel and tighten jam nut (E). 3. Depress accelerator pedal until injection pump lever is against fast idle stop screw (B) and hold. 4. Adjust pedal stop screw (G) until it makes contact with the pedal. Release pedal. 5. Shorten pedal stop screw until there is 12 mm (0.0390.079 in.) clearance between the pedal and the pedal stop screw (G).
Specification Pedal Stop ScrewClearance (with injection pump lever on fast idle stop) ........................................................ 12 mm (0.0390.079 in.) AInjection Pump Lever BFast Idle Stop Screw CSlow Idle Stop Screw DSpeed Control Cable EJam Nut FSwivel GPedal Stop Screw
TX,9010,JC2148 1910MAY991/1
TM1640 (15JAN04)
05-0515-5

011504
PN=251
T111260
UN29AUG97
05 0515 5
Speed Controls
Adjust Fuel Shut-Off Solenoid

1. Turn key switch to START to "bump" starter. DO NOT start engine. Leave key switch in ON position. This will energize shut-off solenoid. 2. Loosen nut (C) and lengthen rod (D) until shut-off lever (B) moves away from stop (A). 3. Shorten rod (D) until shut-off lever (B) touches stop (A), then shorten rod two more turns to preload spring. IMPORTANT: If rod (D) is adjusted too short, engine may not shut off. If rod is adjusted too long, engine may not start easily or may not have full power. If adjustment cannot be made, shut-off lever (B) may be binding, solenoid mounting bracket may be bent or injection pump may be worn or have internal failures. 4. Tighten nut (C) after adjustment is made.
AStop BShut-Off Lever CNut DRod
05 0515 6
TX,9010,JC2145 1929AUG971/1
TM1640 (15JAN04)
05-0515-6

011504
PN=252
T111265B
UN29AUG97
Group 0520
Intake System
Essential Tools

T7947AD UN05MAR93
CED,OUOE003,3338 1927MAR991/2
Inlet Air Adapter . . . . . . . . . . . . . . . . . . . . . . . JDG51 To apply air pressure to intake system for leak checks.
CED,OUOE003,3338 1927MAR992/2

05 0520 1
CED,OUOE003,3339 1927MAR991/2
Air Regulator with Gauge To pressurize the air intake system for leakage tests.
CED,OUOE003,3339 1927MAR992/2
Specifications
Air Intake System
Pressure
13.820.7 kPa (0.130.21 bar) (23 psi)
CED,OUOE003,3340 1927MAR991/1
TM1640 (15JAN04)
05-0520-1

011504
PN=253
Intake System
Remove and Install Air Cleaner
05 0520 2
TX,0520,111296 1927MAR991/3
TM1640 (15JAN04)
05-0520-2

011504
PN=254
TP60585
UN21JAN99
Intake System
1Air Cleaner 2Air Filter Primary Element 3Cover 4Hook (4 used) 5O-Ring 6Valve 7Air Filter Secondary Element 8Screen 9Sensor 10Band (2 used) 11Washer (4 used) 12Screw (4 used) 13Hose 14Clamp 15Clamp 16Housing 17Cover
1. Remove four screws (12) and bands (10). 2. Disconnect wiring harness connector from air filter restriction switch. 3. Remove and install parts as needed. 4. Inspect elements for wear or damage and replace as necessary.
5. Install parts. 6. Connect wiring harness connector to air filter restriction switch.
TX,0520,111296 1927MAR992/3
IMPORTANT: Tighten hose clamps until hose protrudes around clamp band. 7. Tighten hose clamps (A and B) until air intake hose protrudes around clamp band. 8. Test air intake system. (See Air Intake System Leakage Test in this group.)
AHose Clamp BHose Clamp
UN17MAR97
05 0520 3
TX,0520,111296 1927MAR993/3
Remove and Install Air Filter Elements

1. Open left service door. 2. Remove air cleaner cover (A).
AAir Cleaner Cover
UN07MAR97
T108196
TX,0520,111278 1916FEB991/3
TM1640 (15JAN04)
05-0520-3

011504
PN=255
T106363E
Intake System
IMPORTANT: Install a new primary element: 1. If the element shows damage. 2. If the element will not clean. 3. After 1000 hours service or annually. 3. Remove primary element (A).
APrimary Element
UN24JAN97
TX,0520,111278 1916FEB992/3
IMPORTANT: Install a new secondary element: 1. If primary element is damaged and needs to be replaced. 2. If element is visibly dirty. 3. After 1000 hours service or annually. 4. Always thoroughly clean air cleaner canister before installing new elements. Do not clean secondary element. Install a new element carefully centering it in the canister.
BSecondary Element
05 0520 4
4. Remove secondary element (B).
TX,0520,111278 1916FEB993/3
TM1640 (15JAN04)
05-0520-4

011504
PN=256
T106370B
UN28JAN97
T106369B
Intake System
Clean Dusty Primary Element

CAUTION: Prevent possible injury from flying chips if compressed air is more than 210 kPa (2.1 bar) (30 psi). Reduce compressed air to less than 210 kPa (2.1 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection. 1. Tap element with the palm of your hand, NOT ON A HARD SURFACE. 2. If this does not remove dust, use compressed air under 210 kPa (2.1 bar) (30 psi). 3. Direct air up and down the pleats from inside to outside. Be careful not to make a break in the element.
UN09NOV88
TX,0520,111281 1914MAR971/1
T47764
Clean Oily or Sooty Primary Element

IMPORTANT: You can damage element. DO NOT wash element in fuel oil, oil, gasoline, or solvent. DO NOT use compressed air to remove water from an element. 1. Wash element in warm water and John Deere R36757 Filter Element Cleaner or equivalent non-sudsing detergent. 2. Flush with clean water. Use water pressure under 280 kPa (2.8 bar) (40 psi). 3. Shake the element to remove water. Do not install element unless it is dry.
UN10NOV88
05 0520 5
03T,55,C19 1924JUL911/1
TM1640 (15JAN04)
05-0520-5

011504
PN=257
T90673
Intake System
Inspect Element
IMPORTANT: A damaged or dirty element may cause engine damage. Install a new primary element: 1. If the element shows damage. 2. If element will not clean. 3. After 1000 hours service or annually. Install a new secondary element: 1. If the primary element is damaged and needs to be replaced. 2. If the element is visibly dirty. 3. After 1000 hours service or annually. DO NOT clean a secondary element. Install a new element carefully centering it in the canister. 1. Inspect element and gasket for damage. 2. Air restriction indicator will not signal correctly if an element has a break or is not correctly sealed in air cleaner housing. Throw away element that has the slightest damage. If gasket is broken or missing, install a new element. 3. After installing elements, reinstall cover with the drop tube as close to vertical as possible.
UN10NOV88
05 0520 6
03T,55,C67 1924JUL911/1
TM1640 (15JAN04)
05-0520-6

011504
PN=258
T90684
Intake System
Air Intake System Leakage Test

SPECIFICATIONS Air Intake System Pressure 13.820.7 kPa (0.130.21 bar) (23 psi)
UN23FEB89
ESSENTIAL TOOLS JDG51 Inlet Air Adapter SERVICE EQUIPMENT AND TOOLS Air Regulator with Gauge
IMPORTANT: Anytime the air intake system is opened it must be tested for leaks before the machine is returned to service. 1. Remove air cleaner cover and main filter element. 2. Put a plastic bag over safety element and install main element and cover. 3. Remove plug or ether start aid from air intake tube and install JDG51 Adapter (A). 4. Connect air pressure regulator to adapter using hose and fitting. CAUTION: Plastic bag can be sucked into engine if engine is started when trying to close valves. 5. Pressurize air intake system to specifications. If system cannot be pressurized, turn engine slightly to close valves. Check plastic bag.
Specification Air Intake SystemPressure ................. 13.820.7 kPa (0.130.21 bar) (23 psi)
UN12FEB97
AJDG51 Adapter 05 0520 7
6. Spray soap solution over all connections from the air cleaner to the turbocharger or air inlet to check for leaks. Repair all leaks.
TX,9010,SS3694 1921APR991/1
TM1640 (15JAN04)
05-0520-7

011504
PN=259
T107289C
T5906AP
Intake System
05 0520 8
TM1640 (15JAN04)
05-0520-8

011504
PN=260
Group 0530
External Exhaust System

Specifications
Hood, Air Cleaner and Exhaust Pipe Bracket-to-Engine Cap Screw
Weight Torque
64 kg (140 lb) approximate 73 Nm (54 lb-ft)
CED,OUOE003,3337 1927MAR991/1
05 0530 1
TM1640 (15JAN04)
05-0530-1

011504
PN=261
Remove and Install Muffler
05 0530 2
TX,0530,111288 1927MAR991/2
TM1640 (15JAN04)
05-0530-2

011504
TP60568
UN30NOV98
PN=262

1Screw, M10 x 30 (11 used) 2Exhaust Pipe (Black) 3Washer (8 used) 4Lock Nut (4 used) 5Muffler 6Bracket 7Screw M12 x 30 8Nut 9Clamp 10Bracket 11Screw, M10 x 25 12Bracket 13Clamp 14Cap Screw
CAUTION: Muffler may be hot. Allow muffler to cool before removing. The approximate weight of hood, air cleaner and exhaust pipe is 64 kg (140 lb).
Specification Hood, Air Cleaner and Exhaust PipeWeight ............................................ 64 kg (140 lb) approximate
7. Install bracket-to-engine cap screws (7 and 8), screws (1) and washers (3). Do not tighten at this time. 8. Reinstall fuel filter on bracket (10). 9. Install clamp (9) that connects muffler inlet to turbocharger. Tighten clamp until connection is snug, but inlet pipe can still rotate. 10. Adjust muffler position so that muffler body is level and tighten mounting screws to keep it level. 11. Tighten cap screws.
1. Remove hood. 2. Remove clamp (9). 3. Remove cap screws (1), washers (3), and lock nuts (4). 4. Remove fuel filter from bracket (10). 5. Remove brackets (6 and 10). 6. Replace if necessary.
Specification Bracket-to-Engine Cap Screw Torque....................................................................... 73 Nm (54 lb-ft)
12. Tighten clamp (9). 13. Install hood.

05 0530 3
TX,0530,111288 1927MAR992/2
TM1640 (15JAN04)
05-0530-3

011504
PN=263
05 0530 4
TM1640 (15JAN04)
05-0530-4

011504
PN=264
Group 0560
External Fuel Supply Systems

Specifications
Fuel Tank (Without Fuel) and Bottom Weight Guard Fuel Tank Bottom Guard Cap Screw Torque
318 Nm (235 lb-ft)
CED,OUOE003,3343 1927MAR991/1
05 0560 1
TM1640 (15JAN04)
05-0560-1

011504
PN=265
Remove and Install Fuel Tank
05 0560 2
TX,05,RP3346 1916FEB991/4
TM1640 (15JAN04)
05-0560-2

011504
TP61740
UN03SEP98
PN=266

1Fuel Tank 2Drain Valve 3Elbow Fitting (2 used) 4Clamp (2 used) 5Clamp (8 used) 6Elbow Fitting 7Elbow Fitting 8Gasket 9Sender 10Screw (5 used) 11Clamp 12Hose 13Filler Neck 14Hose Fitting (10 used) 15Filler Cap 16O-Ring 17Bolt (4 used) 18Flange Nut (4 used) 19Screw (2 used) 20Clamp (2 used) 21Hose 22Clamp (2 used) 23Hose 24Elbow Fitting 25Housing 26Hose 27Screw 28Clamp 29Filler Neck Assembly
1. Turn battery disconnect switch off (if equipped) or disconnect battery ground strap. 2. Disconnect hose (23) from filler neck. 3. Disconnect hose (21) at tank. CAUTION: Remove fuel to reduce weight of the fuel tank. Approximate capacity of fuel tank is 265 L (70 gal). 4. Disconnect hose at primary fuel filter and drain fuel into clean container or pump fuel out of the tank. 5. Disconnect hose (12) at leak-off line on engine head.
6. Disconnect wiring leads from fuel gauge sending unit (9). CAUTION: The approximate weight of the fuel tank (without fuel) is 18 kg (40 lb). Approximate weight of fuel tank and fuel tank bottom guard is 123 kg (272 lb).
Specification Fuel Tank (Without Fuel) and Bottom GuardWeight........................... 123 kg (272 lb) approximate
7. Support fuel tank and bottom guard with a lifting table or floor jack.
05 0560 3
TX,05,RP3346 1916FEB992/4
TM1640 (15JAN04)
05-0560-3

011504
PN=267

8. Remove cap screws (D) and washers (C) from bottom guard and lower tank to floor. 9. Remove straps (B) to remove fuel tank from guard.
UN19MAR97
10. Replace parts as necessary. 11. Install straps, Tighten cap screws (D).
Specification Fuel Tank Bottom Guard Cap ScrewTorque ............................................................ 318 Nm (235 lb-ft)
12. Raise fuel tank into place with lifting device. Install cap screws (D) and washers (C). 13. Connect wiring leads to fuel level sending unit. 14. Connect hoses to fuel tank.
ACap Screw (2 used) BStrap (2 used) CWasher (4 used) DCap Screw (4 used) EBottom Guard FWasher
05 0560 4
TX,05,RP3346 1916FEB993/4
IMPORTANT: If fuel tank vent hose is plugged or pinched, the fuel tank could collapse and engine performance will be affected. 15. Check fuel tank vent hose (A) for being plugged or pinched. Clean, reposition or replace hose. 16. Connect battery ground strap. Turn battery disconnect switch on (if equipped).
AVent Hose
UN27AUG97
TX,05,RP3346 1916FEB994/4
TM1640 (15JAN04)
05-0560-4

011504
PN=268
T111244B
T108306
Drain and Clean Primary Fuel Filter (Water Separator)

1. Open left engine side shield to access primary fuel filter (water separator). 2. Put container under drain valves (B and C). 3. Rotate retaining ring around filter element counterclockwise 1/4 turn. Lifting ring as it is rotated helps get it past retaining detent. Ring should drop down and release filter from base. 4. Remove hand primer (A) from fuel filter base. Disassemble hand primer assembly and clean out any debris.
AHand Primer BDrain Valve (Primary Fuel Filter) CDrain Valve (Final Fuel Filter)
UN27AUG97
TX,55,JC2157 1902SEP971/2
T8387AE
UN17DEC94
T111238D
5. Remove fuel inlet line (A) and fuel drain plug (C). 6. Flush any debris from filter base (B). 7. Install fuel inlet drain plug and fuel inlet line. 8. Assemble primer assembly and install onto fuel filter base. 9. Install filter element to fuel filter base. 10. Bleed fuel system. 11. Close side shield. 12. Dispose of waste properly.
AFuel Inlet Line BFilter Base CDrain Plug
UN17DEC94
05 0560 5
TX,55,JC2157 1902SEP972/2
TM1640 (15JAN04)
05-0560-5

011504
PN=269
T8387AD
Remove and Install Primary Fuel Filter (Water Separator)

1. Open left engine side shield to access primary fuel filter (water separator). 2. Put container under drain valves (B and C). 3. Rotate retaining ring around filter element counterclockwise 1/4 turn. Lifting ring as it is rotated helps get it past retaining detent. Ring should drop down and release filter from base. 4. Remove hand primer (A) from fuel filter base. Disassemble hand primer assembly and clean out any debris.
AHand Primer BDrain Valve (Primary Fuel Filter) CDrain Valve (Final Fuel Filter)
UN27AUG97
05 0560 6
TX,05,RP3371 1921APR991/4
5. Remove fuel inlet line (A) and fuel drain plug (C). 6. Flush any debris from filter base (B). 7. Install fuel inlet drain plug and fuel inlet line. 8. Assemble primer assembly and install onto fuel filter base. 9. Install filter element to fuel filter base. 10. Bleed fuel system. 11. Close side shield. 12. Dispose of waste properly.
AFuel Inlet Line BFilter Base CDrain Plug
UN17DEC94
TX,05,RP3371 1921APR992/4
TM1640 (15JAN04)
05-0560-6

011504
PN=270
T8387AD
T8387AE
UN17DEC94
T111238D
05 0560 7
TM1640 (15JAN04)
05-0560-7

011504
PN=271
05 0560 8
TX,05,RP3371 1921APR993/4
TM1640 (15JAN04)
05-0560-8

011504
PN=272
TP61752
UN01OCT98

1Washer 2Clamp (2 used) 3Washer 4Screw 5Screw 6Bracket 7Fuel Line 8Screw 9Flange Nut 10Bracket 11Filter Head 12Screw (4 used) 13Plug (2 used) 14O-Ring (4 used) 15Kit 16Seal Kit 17Fuel Filter 18Drain Valve 19Fitting (2 used) 20Filter Head 21Fuel Line 22Bracket 23Cap Screw (4 used) 24Clamp (2 used) 25Ring
TX,05,RP3371 1921APR994/4
Remove and Install Final Fuel Filter

1. Turn filter lock ring (A) counterclockwise to remove filter. Drain sediment into a container and dispose of properly. 2. Clean filter base and install new filter. 3. Bleed fuel system.
AFilter Lock Ring
UN27AUG97 T111238B
05 0560 9
TX,05,RP3372 1916FEB991/1
TM1640 (15JAN04)
05-0560-9

011504
PN=273
Bleeding Fuel System

1. Place container under filters (D and G). 2. Loosen bleed screw (A). 3. Pump hand primer (C) until bleed screw (A) has solid stream of fuel coming from it. Tighten bleed screw (A). 4. Open bleed screw (B). Pump hand primer until bleed screw has solid stream of fuel coming from it. Tighten bleed screw (B). 5. Dispose of waste properly.
ABleed Screw (Final Fuel Filter) BBleed Screw (Primary Fuel Filter) CHand Primer DPrimary Fuel Filter (Water Separator) EDrain Valve (Primary Fuel Filter) FDrain Valve (Final Fuel Filter) GFinal Fuel Filter
UN27AUG97
05 0560 10
TX,0560,111294 1927MAR991/1
TM1640 (15JAN04)
05-0560-10

011504
PN=274
T111238E
Section 07
Dampener Drive
Contents
Page
Group 0752Elements Dampener Remove and Install . . . . . . . . . . . . . . . . . .07-0752-1
07
TM1640 (15JAN04)
07-1

011504
PN=1
Contents
07
TM1640 (15JAN04)
07-2

011504
PN=2
Group 0752
Elements
Remove and Install Dampener
1. Open engine side shields. 2. Remove drive shaft. 3. Remove covers (A) and dampener (B).
DampenerSpecification Dampener-to-Flywheel Cap ScrewTorque ................................................................ 68 Nm (50 lb-ft)
UN27OCT88
ACover BDampener
TX,07,JC2342 1921APR991/1
T6564AS
07 0752 1
TM1640 (15JAN04)
07-0752-1

011504
PN=277
Elements
07 0752 2
TM1640 (15JAN04)
07-0752-2

011504
PN=278
Section 09
Steering System
Contents
Page
Group 0960Hydraulic System Service Equipment and Tools . . . . . . . . . . . .09-0960-1 Other Material . . . . . . . . . . . . . . . . . . . . . . . .09-0960-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .09-0960-2 Steering Valve Remove and Install . . . . . . . . . . . . . . . . . .09-0960-3 Steering Column Remove and Install . . . . . . . . . . . . . . . . . .09-0960-8 Steering Cylinder Remove and Install . . . . . . . . . . . . . . . . . .09-0960-9 Loader Start-Up Procedure . . . . . . . . . . .09-0960-11 Disassemble and Assemble Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-12 Steering Cylinder Remove and Install Bushings. . . . . . . . . .09-0960-12
09
TM1640 (15JAN04)
09-1

011504
PN=1
Contents
09
TM1640 (15JAN04)
09-2

011504
PN=2
Group 0960
Hydraulic System
CED,OUOE003,3347 1929MAR991/2
Bushing, Bearing and Seal Driver Set To remove and install steering cylinder bushings.
CED,OUOE003,3347 1929MAR992/2
Other Material
Number Name Use
PT569 (U.S.)
Apply to threads of steering wheel nut to prevent threads from seizing. Apply to steering column pivot bores. To clean surface prior to application of adhesives or sealants.
TY16285 (U.S.) TY9485 (Canadian) 7649 (LOCTITE) T43513 (U.S.) TY9474 (Canadian) 271 (LOCTITE)
Cure Primer
Apply to threads of steering cylinder rod guide and spanner nut for installation.
09 0960 1
NEVER-SEEZ is a trademark of Emhart Chemical Group. LOCTITE is a trademark of Loctite Corp.
CED,OUOE003,3348 1929MAR991/1
TM1640 (15JAN04)
09-0960-1

011504
PN=281
Hydraulic System
Specifications
Steering Valve Isolator Cap Screw Valve-to-Plate Cap Screw Torque Torque 57 Nm (42 lb-ft) 27 Nm (20 lb-ft)
Steering Column Steering Wheel-to-Steering Column Nut Torque 68 Nm (50 lb-ft)
Steering Cylinder Steering Cylinder Piston Nut Weight Torque 65 kg (143 lb) approximate 136 Nm (100 lb-ft) plus (30) 1/12 turn
CED,OUOE003,3349 1929MAR991/1
09 0960 2
TM1640 (15JAN04)
09-0960-2

011504
PN=282
Hydraulic System
Remove and Install Steering Valve

1923JUL97
T110749
1. Install frame locking bar. 2. Stop engine. CAUTION: Prevent possible injury from unexpected boom or bucket movement. Ride control accumulator MUST be discharged when working on hydraulic components. Engine OFF. With boom raised slightly, turn ignition switch to ON position. Move ride control switch to ON (center position). Boom will jump up if ride control accumulator is pressurized. Press Pilot Enable/Boom Down switch to BOOM DOWN and hold. Move the control lever to lower bucket to ground then hold in FLOAT position for 5 seconds to completely discharge ride control accumulator(s). 3. Engine OFF. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. If not equipped with ride control, press pilot enable/boom down switch to BOOM DOWN position, move the control lever into FLOAT position and hold for 5 seconds to relieve any residual hydraulic pressure.
T110754
1923JUL97
T110750
CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before working in frame hinge area.
1923JUL97
09 0960 3
TX,0960,JC2036 1927MAR991/5
TM1640 (15JAN04)
09-0960-3

011504
PN=283
Hydraulic System
4. Drain hydraulic reservoir or connect a vacuum pump to the reservoir by removing the vent filter and attaching the vacuum pump to its fitting in the reservoir. 5. Remove front cab shield.
TX,0960,JC2036 1927MAR992/5
AReturn BLoad Sense 09 0960 4
CRight Turn
DLeft Turn
EPressure
6. Disconnect and label hoses. Plug or cap hoses and fittings.

Continued on next page TX,0960,JC2036 1927MAR993/5
TM1640 (15JAN04)
09-0960-4

011504
T110783
UN23JUL97
PN=284
Hydraulic System
09 0960 5
TM1640 (15JAN04)
09-0960-5

011504
PN=285
Hydraulic System
09 0960 6
TX,0960,JC2036 1927MAR994/5
TM1640 (15JAN04)
09-0960-6

011504
PN=286
T109458
UN08MAY97
Hydraulic System
1Isolator 2Cap Screw (4 used) 3Washer (4 used) 4Bracket 5Washer (4 used) 6Steering Column 7Lock Nut (3 used) 8Washer (3 used) 9Rubber Mount (3 used) 10Cap Screw (3 used) 11Cap Screw (2 used)
7. Remove cover from steering column. 8. Remove lock nuts (7), washers (8), rubber mounts (9), and cap screws (10). 9. Remove cap screw (11). 10. Remove steering valve. 11. Remove cap screws (2) and washers (3) to remove bracket (4) from steering column (6).
12. Repair or replace parts as necessary.

Steering ValveSpecification Isolator Cap ScrewTorque .................................... 57 Nm (42 lb-ft) Valve-to-Plate Cap Screw Torque....................................................................... 27 Nm (20 lb-ft)
TX,0960,JC2036 1927MAR995/5
09 0960 7
TM1640 (15JAN04)
09-0960-7

011504
PN=287
Hydraulic System
Remove and Install Steering Column
1Cover 2Spring Assembly
3Nut 4Lock Washer (2 used) 5Knob 6Steering Wheel 7Snap Ring 8Seal
9Screw (4 used) 10Spring 11Dowel Pin 12Screw (2 used) 13Bolt (2 used) 14Brush Set
15Isolator 16Cover 17Steering Column 18Apply NEVER-SEEZ 19Apply NEVER-SEEZ
1. Remove steering column cover.

09 0960 8
2. Remove shift selector and turn signal switch. 3. Disconnect spring (10). 4. Remove cap screws (9). 5. Remove parts (18) and (1017). 6. Repair or replace parts as needed.
7. Apply NEVER-SEEZ Lubricant or equivalent to steering column tilt pivots (18) and threads on steering shaft (19). 8. Assemble parts (117).
Steering ColumnSpecification Steering Wheel-to-Steering Column NutTorque ................................................ 68 Nm (50 lb-ft)
TX,0960,MA15 1929MAR991/1
TM1640 (15JAN04)
09-0960-8

011504
PN=288
T110814
1925JUL97
Hydraulic System
Remove and Install Steering Cylinders

CAUTION: Prevent possible injury from unexpected machine frame movement. Install frame locking bar to both frames before you work in the frame pivot area. 1. Install frame locking bar (C). Stop engine.
TX,0960,RB89 1929MAR991/3
T101186
UN21MAY96
09 0960 9
TM1640 (15JAN04)
09-0960-9

011504
PN=289
Hydraulic System
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 2. Turn steering wheel back and forth to release hydraulic pressure in the system. 3. Disconnect lines from cylinder. Close all openings using caps and plugs. CAUTION: The approximate weight of the steering cylinder is 65 kg (143 lb).
Steering CylinderSpecification Steering CylinderWeight .............................. 65 kg (143 lb) approximate
4. Remove pin from rod and head end of cylinder. 5. Remove cylinder from machine. 6. Install cylinder and connect lines. 7. Install washers between steering cylinder rod end and loader frame with maximum number of washers. Divide washers above and below rod end so the cylinder does not bind. 8. Fill gap under rod end with spacers, then install one additional spacer. Fill gap over rod end with spacers. Install rod end pin.
09 0960 10
TX,0960,RB89 1929MAR992/3
TM1640 (15JAN04)
09-0960-10

011504
PN=290
X9811
UN23AUG88
CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.
Hydraulic System
IMPORTANT: When a machine is started for the first time after cylinder rebuild or oil is drained from cylinder, the Loader Start-Up Procedure must be performed to prevent oil from dieseling inside the cylinder. 9. Perform Loader Start-Up Procedure (Steering Cylinder). (See procedure in this group.)
TX,0960,RB89 1929MAR993/3
Loader Start-Up Procedure (Steering Cylinder)

IMPORTANT: System pressure must be reduced when performing this procedure. Adjust the LS valve to decrease system pressure. Turning the LS valve counterclockwise decreases system pressure. 1. Remove loader frame access cover. 2. Loosen lock nut on LS valve. Turn LS valve counterclockwise 2.5 complete turns. This will decrease system pressure to approximately 8274 8963 kPa (82.7489.63 bar) (12001300 psi). IMPORTANT: Perform procedure with engine at low idle (no acceleration.) 3. Slowly articulate the loader 3/4 turn to the right and then 3/4 turn to the left. Do not make contact at loader frame stops. 4. Repeat previous step four times. 5. Articulate the loader fully to the right and then fully to the left. Repeat four times. 6. Reset system pressure by turning LS valve clockwise 2.5 turns. Check pressures. See Group 9025-25. 7. Install loader frame access cover.
09 0960 11
CED,OUOE024,236 1923SEP981/1
TM1640 (15JAN04)
09-0960-11

011504
PN=291
Hydraulic System
Disassemble and Assemble Steering Cylinder

See Disassemble Cylinder in TMH120A. (Group 01.) See Assemble Cylinder in TMH120A. (Group 01.)
OUT3019,000009A 1919AUG031/1
Remove and Install Steering Cylinder Bushings

Remove and install bushing (A) using disks from driver set.
ABushing
UN09NOV88
TX,0960,RB91 1923SEP981/1
09 0960 12
TM1640 (15JAN04)
09-0960-12

011504
PN=292
T90813
Section 10
Service Brakes
Contents
Page
Group 1011Active Elements Service Equipment and Tools . . . . . . . . . . . .10-1011-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .10-1011-1 Inspect External Service Brakes . . . . . . . . . .10-1011-1 Remove and Install Brake Assembly . . . . . . .10-1011-3 Group 1060Hydraulic System Brake Valve Remove and Install . . . . . . . . . . . . . . . . . .10-1060-1 Brake Accumulator Remove and Install . . . . . . . . . . . . . . . . . .10-1060-4
10
TM1640 (15JAN04)
10-1

011504
PN=1
Contents
10
TM1640 (15JAN04)
10-2

011504
PN=2
Group 1011
Active Elements
CED,OUOE003,3350 1929MAR991/2
Feeler Gauge Used to measure thickness of brake disks.
CED,OUOE003,3350 1929MAR992/2
Specifications
Brake Disk
Thickness Thickness Thickness
2.92 mm (0.114 in.) new 2.29 mm (0.090 in.) minimum used 3.05 mm (0.120 in.) new
Brake Separator Plate
CED,OUOE003,3352 1929MAR991/1
Inspect External Service Brakes

Do first inspection at 5000 hours followed by 1000 hours inspection intervals after the first 5000 hours inspection. If the service brakes are subjected to severe duty, inspect more frequently. 1. Remove plug from brake inspection port. 2. Start engine and run for one minute. 3. Stop and apply the brakes. Block pedal or have someone hold brakes on.
10 1011 1
TX,1011,JC2024 1923SEP981/3
TM1640 (15JAN04)
10-1011-1

011504
PN=295
Active Elements
4. Using a feeler gauge (A), measure the thickness of disks at dimension (B). Check dimension of two different disks.
Specification Brake DiskThickness ....................................... 2.92 mm (0.114 in.) new Thickness.................................................................... 2.29 mm (0.090 in.) minimum used
TX,1011,JC2024 1923SEP982/3
5. If either of the disks thickness at dimension (B) is less than the minimum specification, the brake packs must be replaced.
10 1011 2
TX,1011,JC2024 1923SEP983/3
TM1640 (15JAN04)
10-1011-2

011504
PN=296
T106873
1912FEB97
T105767B
UN25FEB97
T105193B
AFeeler Gauge BDisk Dimension
UN02NOV98
Active Elements
Remove and Install Brake Assembly

1. Remove differential and axle assembly. (See Group 0225.) 2. Remove final drive assemblies and brake packs. (See Group 0250.)
NOTE: A rolling head pry bar may be used to remove the piston.
3. Remove brake piston (A) from case/cover using compressed air at the brake pressure inlet. 4. Inspect six separator plate retaining slots (B). Check the slots for galling or wear that might restrict the movement of the separator plates. Smooth the slots using a file or grinder. If there is too much wear, replace the differential case.
UN02JAN97
ABrake Piston BRetaining Slot (6 used)
TX,1011,JC2282 1916FEB991/3
5. Inspect brake piston (A). 6. Remove and replace packing rings (B) and (C). 7. Replace piston as necessary. 8. Inspect parts (D) and (E). Check the tabs on the separator plates for distortion or wear that might restrict there movement. Smooth the tabs using a file or grinder or replace the plates.
Specification Brake DiskThickness ....................................... 2.92 mm (0.114 in.) new Brake Separator Plate Thickness............................................................. 3.05 mm (0.120 in.) new
UN08JAN97
RW36119
9. Inspect the brake disk splines (F) on the planetary carrier. 10. Replace parts as necessary.
ABrake Piston BOD Packing Ring CID Packing Ring DBrake Separator Plates (6 used) EBrake Disks (4 used) FPlanetary Carrier Brake Disk Splines
TX,1011,JC2282 1916FEB992/3
TM1640 (15JAN04)
10-1011-3

011504
PN=297
RW36120
10 1011 3
Active Elements
11. Install brake piston (A) into differential case piston bore. 12. Install final drive assemblies. (See Group 0250.) 13. Install differential and axle assembly. (See Group 0225.)
ABrake Piston
UN08JAN97
TX,1011,JC2282 1916FEB993/3
10 1011 4
TM1640 (15JAN04)
10-1011-4

011504
PN=298
RW36150
Group 1060
Hydraulic System
Remove and Install Brake Valve
TX,1060,JC2284 1916FEB991/3
T103102
UN14JAN97
10 1060 1
TM1640 (15JAN04)
10-1060-1

011504
PN=299
Hydraulic System
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. 1. Stop engine. 2. Lower boom to ground, push pilot enable switch to boom down position and hold control lever in float position. CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with ride control. Ride control accumulator energy must be discharged when working on hydraulic components. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 3. If equipped with ride control. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 4. With machine OFF apply brakes approximately 30 times to discharge both brake accumulators.
10 1060 2
TX,1060,JC2284 1916FEB992/3
TM1640 (15JAN04)
10-1060-2

011504
PN=300
X9811
UN23AUG88
Hydraulic System
5. Remove shielding trim on front and right side of cab for access. 6. Remove clamp and return hose from brake valve. 7. Pinch off return hose (A) with vise grip to stop reservoir hydraulic oil from draining back. 8. Disconnect hoses and electric connectors. 9. Remove cap screws and brake valve. 10. Replace parts as necessary. 11. Install brake valve. 12. Connect hoses and electric connectors. 13. Check for slight clearance between brake valve plunger and roller spinning freely on brake pedal.
AReturn Hose
UN21NOV97
TX,1060,JC2284 1916FEB993/3
T112343B
10 1060 3
TM1640 (15JAN04)
10-1060-3

011504
PN=301
Hydraulic System
Remove and Install Brake Accumulator

CAUTION: Oil pressure must be released from brake accumulator before disconnecting lines or removing fittings. Accumulator inlet check valve seat is the inlet fitting. Removing accumulator inlet fitting will release oil pressure causing possible injury. 1. Stop engine. 2. Lower bucket to ground. With bucket level, push pilot enable switch to boom down position and hold control lever in float position. CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with ride control. Ride control accumulator energy must be discharged when working on hydraulic components. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 3. If equipped with ride control. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 4. With machine OFF apply brakes approximately 30 times to discharge both brake accumulators.
10 1060 4
TX,10,JC2344 1916FEB991/2
TM1640 (15JAN04)
10-1060-4

011504
PN=302
Hydraulic System
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 5. Slowly loosen connections and disconnect lines (A, E, F, and G). 6. Remove cap screws (C). Remove accumulators (B and D). 7. Replace parts as necessary.
AAccumulator-to-Brake Valve Line BBrake/PRV Accumulator CCap Screw (2 used) DBrake Accumulator EBrake/PRV Accumulator-to-Main Hydraulic Pump FBrake/PRV Accumulator-to-Pressure Reducing Valve GBrake/PRV Accumulator-to-Brake Accumulator HCheck Valve
NOTE: Accumulator is not repairable. New accumulator is already charged. Attach new decal. NOTE: Check Valve (H) may be an adapter on older units. Sub check valve for adapter.
8. Install accumulators and connect lines.
TX,10,JC2344 1916FEB992/2
T158950
UN28AUG02
10 1060 5
TM1640 (15JAN04)
10-1060-5

011504
PN=303
Hydraulic System
10 1060 6
TM1640 (15JAN04)
10-1060-6

011504
PN=304
Section 11
Park Brake
Contents
Page
Group 1111Active Elements Other Material . . . . . . . . . . . . . . . . . . . . . . . .11-1111-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .11-1111-1 Park Brake Remove and Install . . . . . . . . . . . . . . . . . .11-1111-2 Disassemble and Assemble. . . . . . . . . . . .11-1111-6 Group 1160Hydraulic System Specifications . . . . . . . . . . . . . . . . . . . . . . . .11-1160-1 Park Brake Remove and Install Release Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1160-2 Remove and Install Pressure Switch . . . . .11-1160-4
11
TM1640 (15JAN04)
11-1

011504
PN=1
Contents
11
TM1640 (15JAN04)
11-2

011504
PN=2
Group 1111
Active Elements
Other Material
Number Name Use
PT569 (U.S.)
Apply to park brake shaft.
CED,OUOE003,3353 1929MAR991/1
Specifications
Park Brake Assembly Park Brake Mounting Cap Screw Drive Shaft Cap Screw Park Brake Housing Cap Screw Park Brake Yoke Nut
Weight Torque Torque Torque Torque
43 kg (95 lb) approximate 350 Nm (255 lb-ft) 78 Nm (58 lb-ft) 122 Nm (90 lb-ft) 407 Nm (300 lb-ft)
CED,OUOE003,3354 1929MAR991/1
11 1111 1
TM1640 (15JAN04)
11-1111-1

011504
PN=307
Active Elements
Remove and Install Park Brake

CAUTION: Prevent possible injury from unexpected machine movement. Never rely on loader bucket to keep machine from moving. Machine can unexpectedly roll, resulting in death or serious injury. Always block wheels to hold machine when working on park brake. 1. Park machine on level surface. 2. Install frame locking bar. 3. Lower bucket to ground. 4. Stop engine. This will engage park brake. 5. Place blocks in front and behind tires.
TX,11,JC2356 1916FEB991/3
11 1111 2
TM1640 (15JAN04)
11-1111-2

011504
PN=308
Active Elements
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 6. Remove park brake hydraulic line (C). 7. Remove drive shafts (A and D). 8. Remove mounting cap screws (E). CAUTION: The approximate weight of the park brake assembly is 43 kg (95 lb).
Specification Park Brake AssemblyWeight ......................... 43 kg (95 lb) approximate AFront Drive Shaft BPark Brake CPark Brake Hydraulic Line DArticulation Drive Shaft ECap Screw (4 used)
9. Remove park brake (B).
TX,11,JC2356 1916FEB992/3
T104177
UN01OCT96
X9811
UN23AUG88
CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body form high pressure fluids.
11 1111 3
TM1640 (15JAN04)
11-1111-3

011504
PN=309
Active Elements
IMPORTANT: Do not overfill park brake. Fill only to port (A). Capacity of the park brake is 300 mL (10 oz). 10. Check park brake oil level at port (A) and add oil as necessary in port. Allow oil to drain to bottom of level plug before installing plug to prevent overfilling. 11. Install new park brake. Tighten mounting cap screws.
Specification Park Brake Mounting Cap ScrewTorque ............................................................ 350 Nm (255 lb-ft)
12. Place NEVER-SEEZ Lubricant on park brake shaft (B). 13. Install universal yoke on park brake shaft such that holes between front and rear yokes are in alignment. Install drive shafts. IMPORTANT: DO NOT reuse drive shaft universal joint cap screws. Replace cap screws to avoid machine damage. 14. Install new drive shaft universal joint cap screws. Tighten cap screws.
Specification Drive Shaft Cap ScrewTorque ..................................... 78 Nm (58 lb-ft) AOil Check and Fill Port BPark Brake Shaft
UN03NOV97
15. Install park brake hydraulic line.
TX,11,JC2356 1916FEB993/3
11 1111 4
TM1640 (15JAN04)
11-1111-4

011504
PN=310
T112115C
Active Elements
11 1111 5
TM1640 (15JAN04)
11-1111-5

011504
PN=311
Active Elements
Disassemble and Assemble Park Brake
TX,11,JC2357 1916FEB991/7
TM1640 (15JAN04)
11-1111-6

011504
PN=312
TP55599
UN09SEP97
11 1111 6
Active Elements
1Brake 2Plate 3Gasket 4Housing 5Bearing (2 used) 6Bearing Cup 7Bearing Cone 8Universal Drive Shaft 9Snap Ring 10Washer 11Yoke 12Washer 13Nut 14Retainer 15Seal (2 used) 16Seal (2 used) 17Fitting (2 used) 18Relief Valve 19O-Ring (2 used) 20Spring (18 used) 21Compression Spring (18 used) 22Pin (2 used) 23Brake Disk 24Piston 25O-Ring 26O-Ring 27Screw (6 used) 28Brake Disk (7 used) 29Separator Plate (7 used) 30Washer (4 used) 31Cap Screw (4 used) 32Yoke 33Elbow Fitting 34O-Ring 35O-Ring
1. Remove nut (13), washer (12), and yoke (11). CAUTION: Cover and cap screws are under pressure. Remove cap screws evenly to avoid possible injury. 2. Remove cap screws (27) evenly. 3. Remove cover plate (2) from housing (4). 4. Remove shaft with brake disks (28) and separator plates (29). 5. Remove brake disk (23) from housing.
6. Remove springs (20), compression springs (21), and spring retainer (14). 7. Remove seals (15 and 16) from housing. 8. Remove bearing cup (6). 9. Remove piston (24) from cover plate. 10. Remove O-rings (25 and 26) from piston. 11. Remove seals (15 and 16) and bearing cup (6) from cover plate.
TX,11,JC2357 1916FEB992/7
12. Remove bearing cone (7) using a bearing puller from one end of shaft. 13. Remove bearing, disks, and plates from shaft. 14. Press other bearing off shaft. 15. Replace parts as necessary. 16. Press bearing cup (6) against shoulder in cover plate. 17. Lubricate O-rings (25 and 26) and piston (24) with J20C oil. Install inner and outer O-rings on piston.
TX,11,JC2357 1916FEB993/7
TM1640 (15JAN04)
11-1111-7

011504
PN=313
T101612
UN03OCT96
11 1111 7
Active Elements
18. Install piston (A) in cover so that dowel pins are centered between slots. 19. Press bearing cup (6) against shoulder in housing. 20. Install spring retainer (14), springs (20), and compression springs (21). 21. Remove dowel pins (22) from cover plate and install in housing. 22. Install brake disk (23). 23. Install bearing cone (7) on shaft end with long spline. 24. Dip brake disks and separator plates in J20C oil. Install brake disk (28) then alternate between separator plate (29) and brake disk ending with a separator plate on top. 25. Install bearing cone (7) against shoulder. 26. Insert shaft with brake disks and separator plates with long spline end first into housing. Align separator plates on dower pins. 27. Install two M12 aligning studs into housing.
APiston
UN03OCT96
28. Install gasket (3) on cover plate. 29. Install cover making sure dowel pins align in cover onto housing using cap screws. 30. Tighten cap screws (27) evenly.
Specification Park Brake Housing Cap Screw Torque ........................................................................... 122 Nm (90 lb-ft)
NOTE: Bearing and race are a select pair to create a shaft end play of 0.0510.305 mm (0.0020.012 in.).
31. Install seals (15 and 16) against shoulder in housing. 32. Install seals (15 and 16) against shoulder in cover plate.
11 1111 8
TX,11,JC2357 1916FEB994/7
TM1640 (15JAN04)
11-1111-8

011504
PN=314
T101611
Active Elements
33. Install snap ring (9) and snap ring retainer (10) on universal drive shaft (8). 34. Place NEVER-SEEZ Lubricant on shaft splines. 35. Install yoke (11), washer (12), and nut (13). Tighten nut.
Specification Park Brake Yoke NutTorque ................................... 407 Nm (300 lb-ft)
TX,11,JC2357 1916FEB995/7
IMPORTANT: Do not overfill park brake. Fill only to port (A). Capacity of the bark brake is 300 mL (10 oz). 36. Fill park brake at port (A) with 300 mL (10 oz) of oil. Allow oil to drain to bottom of level plug before installing plug to prevent overfilling. 37. Bench test the park brake. 38. Install a porta-power to the park brake. 39. Slowly increase pressure until the shaft rotates freely. Acceptable range is 8961068 kPa (8.910.6 bar) (130155 psi). 40. Increase the pressure to 3450 kPa (34.5 bar) 500 psi. 41. Slowly release brake pressure until free rotation of the shaft stops. Acceptable range is not more than 210 kPa (2.1 bar) (30 psi) less than the release pressure.
AFill Plug BDrain Plug
T112115B
UN03NOV97
11 1111 9
TX,11,JC2357 1916FEB996/7
TM1640 (15JAN04)
11-1111-9

011504
PN=315
Active Elements
42. Align yokes of park brake.
NOTE: Replace all drive line hardware when ever drive line is disassembled.
UN06NOV97
TX,11,JC2357 1916FEB997/7
11 1111 10
TM1640 (15JAN04)
11-1111-10

011504
PN=316
T112153
Group 1160
Hydraulic System
Specifications
Park Brake Release Solenoid Valve Nut
Torque
7 Nm (62 lb-in.)
CED,OUOE003,3355 1929MAR991/1
11 1160 1
TM1640 (15JAN04)
11-1160-1

011504
PN=317
Hydraulic System
Remove and Install Park Brake Release Solenoid Valve

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 1. Operate controls to release hydraulic pressure. 2. Disconnect electrical connector (A).
AElectrical Connector BSolenoid
TX,1160,RB184 1923SEP981/2
11 1160 2
TM1640 (15JAN04)
11-1160-2

011504
PN=318
T103614C
UN06SEP96
X9811
UN23AUG88
Hydraulic System
3. Remove parts (CE). 4. Remove parts (FK). Plug opening to prevent dirt from entering manifold.
UN09NOV92
5. Inspect for dirty, worn or damaged parts. Check that spool inside solenoid valve moves freely. If spool does not move freely or if valve looks worn or damaged, replace complete solenoid assembly. 6. Install solenoid valve using new O-rings and backup rings. 7. Install parts (CK). Tighten nut (C).
Specification Park Brake Release Solenoid Valve NutTorque ........................................................... 7 Nm (62 lb-in.) CNut DWasher ECover FValve GO-Ring HBackup Ring IO-Ring JO-Ring KBackup Ring
TX,1160,RB184 1923SEP982/2
T7751LI
11 1160 3
TM1640 (15JAN04)
11-1160-3

011504
PN=319
Hydraulic System
Remove and Install Park Brake Pressure Switch

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 1. Operate controls to release hydraulic pressure. 2. Disconnect electrical connector (A). 3. Remove switch (B). 4. Replace parts as necessary. 5. Install switch. Connect electrical connector.
AElectrical Connector BPressure Switch
UN06SEP96
TX,1160,RB185 1912OCT981/1
11 1160 4
TM1640 (15JAN04)
11-1160-4

011504
PN=320
T103614B
X9811
UN23AUG88
Section 16
Electrical System
Contents
Page Page
16
Group 1671Batteries, Support and Cables Service Equipment and Tools . . . . . . . . . . . .16-1671-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .16-1671-2 Battery Service Carefully . . . . . . . . . . . . . . . . . . . .16-1671-3 Check Electrolyte Level and Terminals . . .16-1671-5 Charging Procedure. . . . . . . . . . . . . . . . . .16-1671-7 Using Booster24 Volt System . . . . . . . . .16-1671-8 Procedure for Testing . . . . . . . . . . . . . . . .16-1671-9 Remove and Install . . . . . . . . . . . . . . . . .16-1671-10 Remove and Install Disconnect Switch . .16-1671-11 Group 1672Alternator, Regulator and Charging System Wiring Bosch Alternator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1672-1 Alternator Remove and Install . . . . . . . . . . . . . . . . . .16-1672-1 Regulator Remove and Install . . . . . . . . . . . . . . . . . .16-1672-4 Group 1673Lighting System Halogen Bulbs Replace . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1673-1 Work Lights Remove and Install . . . . . . . . . . . . . . . . . .16-1673-3 Front Turn Lights Remove and Install . . . . . . . . . . . . . . . . . .16-1673-5 Stop, Turn and Tail Light Remove and Install . . . . . . . . . . . . . . . . . .16-1673-5 Drive Lights and Guard Remove and Install . . . . . . . . . . . . . . . . . .16-1673-6 Dome Light and Door Light Switch Remove and Install . . . . . . . . . . . . . . . . . .16-1673-7 Group 1674Wiring Harness and Switches Essential Tools . . . . . . . . . . . . . . . . . . . . . . .16-1674-1 Other Material . . . . . . . . . . . . . . . . . . . . . . . .16-1674-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . .16-1674-3 Replace METRI-PACK Connectors. . . . . . .16-1674-4 Install DEUTSCH Contact. . . . . . . . . . . . . .16-1674-5 Replace DEUTSCH Connectors . . . . . . . . .16-1674-6 Replace WEATHER PACKConnector . . . . .16-1674-7 Install WEATHER PACKContact. . . . . . . . .16-1674-8 Transmission Control Valve Connector Body Remove and Install . . . . . . . . . . . . . . . . . .16-1674-8 TM1640 (15JAN04)
Transmission Control Valve Connector Contact Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-9 Amp Crimper Tool Operation. . . . . . . . . . . . . . . . . . . . . . . . .16-1674-11 Remove and Install Die Set . . . . . . . . . . .16-1674-12 Contact Support Adjustment . . . . . . . . . .16-1674-14 Crimping Procedure . . . . . . . . . . . . . . . . .16-1674-15 Crimp Height Inspection. . . . . . . . . . . . . .16-1674-17 Crimp Height Adjustment . . . . . . . . . . . . .16-1674-18 Connector Terminals Replace Transmission Controller Unit . . .16-1674-19 Chassis Computer Unit Connector Terminals Replace . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-20 Install CINCH Contact . . . . . . . . . . . . . . .16-1674-23 Remove Connector Body from Blade Terminals. . . . . . . . . . . . . . . . . . . . . . . . .16-1674-24 Blade Terminals Remove From Fuse Block . . . . . . . . . . . .16-1674-24 Boom Height Kickout Adjustment . . . . . . . .16-1674-25 Return-to-Carry Kickout Adjustment . . . . . .16-1674-26 Return-to-Dig Adjustment . . . . . . . . . . . . . .16-1674-27 Group 1675System Controls Transmission Control Unit (TCU) Remove and Install . . . . . . . . . . . . . . . . . .16-1675-1 Chassis Computer Unit (CCU) Remove and Install . . . . . . . . . . . . . . . . . .16-1675-3 Monitor Display Unit Remove and Install . . . . . . . . . . . . . . . . . .16-1675-5 Group 1677Motors and Actuators John Deere Starting Motor Repair . . . . . . . . .16-1677-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .16-1677-1 Starting Motor Remove and Install . . . . . . . . . . . . . . . . . .16-1677-1
16-1

011504
PN=1
Contents
16
TM1640 (15JAN04)
16-2

011504
PN=2
Group 1671
Batteries, Support and Cables

16 1671 1
CED,OUOE003,3357 1929MAR991/5
Battery Post/Clamp Cleaner . . . . . . . . . . . . . . JT05838 To clean corrosion off battery posts and clamps.
CED,OUOE003,3357 1929MAR992/5
Coolant and Battery Tester . . . . . . . . . . . . . . . JT05460 To check battery electrolyte specific gravity.
CED,OUOE003,3357 1929MAR993/5
Hydrometer Used to measure specific gravity of battery electrolyte.
CED,OUOE003,3357 1929MAR994/5
Battery Load Tester . . . . . . . . . . . . . . . . . . . . JT05832 To check battery capacity.
CED,OUOE003,3357 1929MAR995/5
TM1640 (15JAN04)
16-1671-1

011504
PN=323
Specifications
16 1671 2 Specification Standard BatteryVoltage ............................................................ 12 Volts Cold Cranking Power ......................................... 625 amps at -18C (0F) Reserve Capacity ................................................ 160 minutes at 25 amps BCI Group Size .................................................................................... 30H Electrolyte Specific Gravity.............................. 1.2651.280 fully charged Heavy Duty BatteryVoltage........................................................ 12 Volts Cold Cranking Power ......................................... 950 amps at -18C (0F) Reserve Capacity ................................................ 190 minutes at 25 amps BCI Group Size ...................................................................................... 31 Electrolyte Specific Gravity.............................. 1.2651.280 fully charged
TX,9015,MM3057 1904SEP961/1
TM1640 (15JAN04)
16-1671-2

011504
PN=324
Service Batteries Carefully

16 1671 3
TX,1671,MM3121 1908OCT961/2
TM1640 (15JAN04)
16-1671-3

011504
PN=325
TS203
UN23AUG88
TS204
UN23AUG88
16 1671 4
CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Always remove grounded (-) battery clamp first and replace it last. Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Use proper jump start procedure. If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 1015 minutes. Get medical attention immediately. If acid is swallowed: 1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or vegetable oil. 3. Get medical attention immediately. IMPORTANT: Electrolyte can damage paint and metal surfaces of your machine. Do not overfill the battery cells. If electrolyte spills on the floor, use one of the following mixtures to neutralize the acid: 0.5 kg (1 lb) baking soda in 4 L (1 gal) water, or 0.47 L (1 pt) household ammonia in 4 L (1 gal) water.
TX,1671,MM3121 1908OCT962/2
TM1640 (15JAN04)
16-1671-4

011504
PN=326
Check Battery Electrolyte Level and Terminals

CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Always remove grounded (-) battery clamp first and replace it last. Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Use proper jump start procedure. If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 1015 minutes. Get medical attention immediately. If acid is swallowed: 1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or vegetable oil. 3. Get medical attention immediately. 1. Remove hold-down clamps. 2. Remove battery covers.
UN23AUG88
16 1671 5
TX,9015,MM3060 1904SEP961/2
TM1640 (15JAN04)
16-1671-5

011504
PN=327
TS203

IMPORTANT: During freezing weather, batteries must be charged after water is added to prevent battery freezing. Charge battery using a battery charger or by running the engine. 3. Fill each cell to within specified range with distilled water. DO NOT overfill.
ABattery Post BFill Tube CElectrolyte Level Range
UN09SEP03
16 1671 6
Single Level Fill Tube Application
Dual Level Fill Tube Application

TX,9015,MM3060 1904SEP962/2
TM1640 (15JAN04)
16-1671-6

011504
PN=328
T6996DA
UN09SEP03
T6996DB
Battery Charging Procedure

CAUTION: Prevent possible personal injury from exploding battery. A battery may explode if charged when it is frozen. Warm battery to 16C (60F) before charging. Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. IMPORTANT: Do not use battery charger as a booster if a battery has 1.150 gravity reading or lower. Turn off charger before connecting or disconnecting it. When charging a battery in unit, all cables must be disconnected to avoid damaging electrical components if battery charger cables are inadvertently connected to battery wrong.
16 1671 7
NOTE: Batteries CANNOT be charged with battery cables connected. Each battery must charged individually. Voltage in both batteries must be equal. Alternator WILL NOT charge a single low battery.
1. Disconnect all battery cables starting at the negative (-) ground cable. 2. Turn charger off before connecting or disconnecting it. 3. Charge battery following manufacturers instructions for the battery charger. 4. After battery is charged, connect the cables, the negative (-) ground cable last.
TX,1671,MM3122 1908OCT961/1
TM1640 (15JAN04)
16-1671-7

011504
PN=329
TS204
UN23AUG88
Using Booster Batteries24 Volt System

16 1671 8
Before boost starting, machine must be properly shut down and secured to prevent unexpected machine movement when engine starts. CAUTION: An explosive gas is produced while batteries are in use or being charged. Keep flames or sparks away from the battery area. Make sure the batteries are in a well ventilated area. IMPORTANT: The machine electrical system is a 24 volt negative (-) ground. Connect two 12 volt booster batteries together as shown for 24 volts. Make last booster cable connection to frame.
AMachine Batteries BBooster Batteries
UN24OCT91
TX,9015,MM3062 1901AUG961/2
CAUTION: Avoid possible injury or death from machinery runaway. Do not start engine by shorting across starter terminals. Machine will start in gear if normal circuitry is bypassed. NEVER start engine while standing on ground. Start engine only from operators seat, with transmission in neutral or park. Start engine while seated on operators seat. After engine starts, disconnect clamp at machine frame first and then disconnect remaining clamps.
UN11JAN89
TX,9015,MM3062 1901AUG962/2
TM1640 (15JAN04)
16-1671-8

011504
PN=330
TS177
T6713AH1
Procedure for Testing Batteries

IMPORTANT: If either battery is damaged or wont hold a charge, both batteries must be replaced. Visual Check 1. Check for damage such as cracked or broken case and electrolyte leakage. If damage is seen, replace battery. 2. Check electrolyte level. (See procedure in this group) If low, add distilled water to specified level and charge battery. 3. Check terminals for corrosion. If corroded, clean using a wire brush or battery post cleaner such as JT05838 Battery Post/Clamp Cleaner. 4. Check posts for looseness. If posts are loose in one battery, replace BOTH batteries. Hydrometer Test 1. Check specific gravity with a hydrometer or battery tester such as JT05460 Coolant/Battery Tester. 1. Check battery capacity with a load tester such as JT05832 Battery Load Tester. Follow tester manufacturers instructions for proper load test procedures. 2. If one battery fails load test, replace BOTH batteries. 2. Record specific gravity reading for each cell. If high and low readings vary LESS than 0.050 and average specific gravity is between 1.225 and 1.280, battery is fully charged, go to LOAD TEST. If high and low readings vary LESS than 0.050 and average specific gravity is LESS than 1.225, charge battery and repeat test. If average specific gravity is still LESS than 1.225, replace BOTH batteries. If high and low readings vary MORE than 0.050, charge battery and repeat test. If high and low readings still vary MORE than 0.050, replace BOTH batteries. Load Test
16 1671 9
TX,9015,MM3061 1913OCT981/1
TM1640 (15JAN04)
16-1671-9

011504
PN=331
Remove and Install Batteries

16 1671 10
1Cable 2Cable 3Cable 4Cover (3 used) 5Battery (2 used)
6Clamp (4 used) 7Cover 8Angle (2 used) 9Hook Bolt (4 used)
10Lock Nut (4 used) 11Screw (2 used) 12Washer (4 used) 13Ground Cable
14Tie Band (As Required) 15Tie Band 16Washer 17Nut
Disconnect negative (-) battery cables first, then positive cables. Check cables and clamps. Clean battery and battery posts.
Apply grease to bottom side of positive cable eyelets. Connect positive cables, then negative cables.
TX,1671,1111028 1929MAR991/1
TM1640 (15JAN04)
16-1671-10

011504
PN=332
TP55549
UN14JUL97
Remove and Install Battery Disconnect Switch

16 1671 11
1Handle 2Nut 3Washer
4Switch 5Bracket 6Label
7Cable 8Washer
9Cap Screw 10Washer (2 used)
TP48653
UN03MAR97
TX,16,1111110 1929MAR991/1
TM1640 (15JAN04)
16-1671-11

011504
PN=333
16 1671 12
TM1640 (15JAN04)
16-1671-12

011504
PN=334
Group 1672
Alternator, Regulator and Charging System Wiring

Bosch Alternator RepairUse CTM77
For complete repair information the component technical manual (CTM) is also required. Use the CTM in conjunction with this machine manual.
UN17JAN89
16 1672 1
TX,1672,MM3124 1909OCT961/1
Remove and Install Alternator
55 Amp Bosch Alternator

1Capacitor 2Nut 3Washer 4Pulley 5Fan 6Alternator 7Regulator 8Flange Nut 9Lock Washer 10Flange Nut 11Cover 12Grommet 13Flange Nut 14Belt 15Bushing 16Screw 17Idler
TX,1672,RB100 1913OCT981/3
TM1640 (15JAN04)
16-1672-1

011504
PN=335
TP48600
UN13JAN97
TS225
16 1672 2
80 Amp Bosch Alternator Shown

1Pulley 2Alternator 3Nut 4Lock Washer 5Nut 6Regulator 7Nut 8Screen 9Grommet 10Flange Nut (4 used) 11Washer (2 used) 12Fan 13Belt 14Screw 15Idler
IMPORTANT: Disconnect battery ground cable to prevent accidental grounding of alternator wiring leads. 1. Disconnect battery ground cable.
2. Disconnect wiring leads to alternator. 3. Remove mounting cap screws and belt. 4. Replace parts as necessary.
TX,1672,RB100 1913OCT982/3
TM1640 (15JAN04)
16-1672-2

011504
PN=336
TP48601
UN13JAN97

5. Install alternator. Connect wiring leads. Alternator belt tension is controlled by an automatic tensioner.
16 1672 3
TX,1672,RB100 1913OCT983/3
TM1640 (15JAN04)
16-1672-3

011504
PN=337
T104350
1922OCT96
Remove and Install Regulator

16 1672 4
1. Remove old regulator (B) and cut wire lead (A) at base (at the soldered connection) and discard regulator and wire lead. 2. Scrape off insulation (C) from spring terminal.
AWire Lead BRegulator CInsulation
CED,OUOE024,243 1929SEP981/2
3. Install new regulator (A) so regulator contact is touching spring terminal that was scraped of insulation.
ARegulator
UN11JUN97
CED,OUOE024,243 1929SEP982/2
TM1640 (15JAN04)
16-1672-4

011504
PN=338
T109939B
T109938B
UN11JUN97
T109936B
UN11JUN97
Group 1673
Lighting System
Replace Halogen Bulbs
IMPORTANT: To get the correct lighting pattern, lens must be installed so the word "TOP" is on top when lamp is installed on machine. Bezel must be installed so wider section is on top when lamp is installed. 1. Before disassembling, take notice of how bezel and lens are installed with respect to mounting stud. 2. Remove four screws to remove bezel and lens.
16 1673 1
UN17APR89
T52,1673,C10 1917FEB991/2
TM1640 (15JAN04)
16-1673-1

011504
PN=339
T5894AG1
Lighting System
3. Disconnect wiring lead and release retainer clip to remove bulb (D).
16 1673 2
To disconnect ground wiring lead, push tab up then pull connector from terminal. IMPORTANT: Do not touch the halogen bulb with bare hands. Oil and moisture may cause premature bulb failure. If bulb glass is touched, clean using a soft, oil-free cloth and alcohol. 4. Install new bulb so square notch is aligned with square tab on reflector back. 5. Install retainer clip into locking tabs on reflector back. 6. Connect wiring leads. Check that wiring leads are free of clip. 7. Install the gasket (E) into housing (C). 8. Install lens (F) into housing so the word "TOP" is on top when lamp is installed on machine. Check that wiring leads are not crimped. 9. Install bezel (G) so wider section is on top. Sealing flange must be inside housing on all four sides before tightening screws. 10. Tighten screws (H) alternately. Do not overtighten as screws may strip out plastic.
AFlange Nut BLock Washer CHousing DBulb EGasket FLens GBezel HScrew (4 used)
UN20OCT88
T52,1673,C10 1917FEB992/2
TM1640 (15JAN04)
16-1673-2

011504
PN=340
T6249AU
UN19OCT88
T5894AI1
Lighting System
Remove and Install Work Lights

16 1673 3
Front and Rear Work Lights

1Screw 2Washer 3Light 4Grommet
TX,1673,MM3127 1917FEB991/2
TM1640 (15JAN04)
16-1673-3

011504
TP48311
UN08AUG96
PN=341
Lighting System
16 1673 4
Front Drive and Turn Light Guards

1Bracket 2Grommet 3Lock Nut 4Washer (2 used) 5Rubber Mount 6Screw
IMPORTANT: Rubber isolators must be installed between light guard and loader
frame or failure of halogen lights can occur.
TX,1673,MM3127 1917FEB992/2
TM1640 (15JAN04)
16-1673-4

011504
TP48308
UN28MAR96
PN=342
Lighting System
Remove and Install Front Turn Lights

16 1673 5
1Lamp
2Bulb, Turn
3Bulb, Marker
TX,1673,MM3128 1917FEB991/1
Remove and Install Stop, Turn and Tail Light
1Stop Light 2Gasket
3Bulb, Brake and Tail 4Bulb, Turn Signal
5Lens, Red 6Lens, Amber
7Flange Nut (2 used)
TX,1673,RP3007 1917FEB991/1
TM1640 (15JAN04)
16-1673-5

011504
TP35385
UN19MAR96
TP48309
UN01APR96
PN=343
Lighting System
Remove and Install Drive Lights and Guard

16 1673 6
1Flange Nut (2 used) 2Washer, 13 x 25 x 3 mm (2 used)
3Support (2 used) 4Side Light (2 used) 5Screw, M10 x 50 (6 used)
6Washer, 10.5 x 30 x 2.5 mm (6 used)
7Clip (4 used) 8Lock Nut (6 used)
TX,1673,1111032 1917FEB991/1
TM1640 (15JAN04)
16-1673-6

011504
TP55460
UN14APR97
PN=344
Lighting System
Remove and Install Dome Light and Door Light Switch

16 1673 7
1Housing 2Bulb
3Lens 4Rocker Switch
5Light
6Screw (2 used)
TX,1673,1111033 1917FEB991/1
TM1640 (15JAN04)
16-1673-7

011504
PN=345
TP48466
UN14SEP96
Lighting System
16 1673 8
TM1640 (15JAN04)
16-1673-8

011504
PN=346
Group 1674
Wiring Harness and Switches

Essential Tools
16 1674 1
CED,OUOE003,3358 1930MAR991/11
Metri-Pack Extractor Tool . . . . . . . . . . . . . . . . JDG939 Used to remove contacts from Metri-Pack electrical connectors.
UN30JUN95
CED,OUOE003,3358 1930MAR992/11 T6606AB UN23AUG88
DEUTSCH Electrical Repair Tool Kit . . . . . . . . JDG359 To repair DEUTSCH electrical connector bodies.
DEUTSCH is a trademark of the Deutsch Co.

T6606AC UN23AUG88
CED,OUOE003,3358 1930MAR993/11
WEATHER PACK Extraction Tool . . . . . . . . . JDG364 Used to replace terminal contact in WEATHER PACK connector body.
WEATHER PACK is a trademark of Packard Electric.
CED,OUOE003,3358 1930MAR994/11
TM1640 (15JAN04)
16-1674-1

011504
T8516AA
PN=347

T104946 UN07NOV96
Electrical Repair Kit . . . . . . . . . . . . . . . . . . . JT07195A

16 1674 2
Electrical repair kit includes the most commonly used tools necessary to work on John Deere electrical wiring harness and connectors.
CED,OUOE003,3358 1930MAR995/11
WEATHER PACK Crimping Tool . . . . . . . . . . JDG783 Use to crimp WEATHER PACK male and female connectors. Tool crimps both connector and seal retainer at the same time.
UN05MAR96 T100473

T104947 UN07NOV96
CED,OUOE003,3358 1930MAR996/11
Metrimate Extractor Tool. . . . . . . . . . . . . . . . . JDG140 Used to remove pin and socket contacts from Metri-Pack, CPC and Kostal electrical connector housings.
CED,OUOE003,3358 1930MAR997/11 T105908 UN19DEC96
Packard Crimping Tool . . . . . . . . . . . . . . . . . . JDG707 Used to crimp open barrel contacts and seal retainers for Kostal circular connectors.
CED,OUOE003,3358 1930MAR998/11
TM1640 (15JAN04)
16-1674-2

011504
PN=348

T112340B UN24NOV97
Amp Extraction Tool . . . . . . . . . . . . . . . . . . JDG1177 Used to extract wires from the large terminals of the Amp transmission controller unit connector.
CED,OUOE003,3358 1930MAR999/11 T112340B UN24NOV97
16 1674 3
Amp Extraction Tool . . . . . . . . . . . . . . . . . FKM10457 Used to extract wires from the small terminals of the Amp transmission controller unit connector.
CED,OUOE003,3358 1930MAR9910/11 T112379 UN26NOV97
WEATHER PACK Narrow Extractor . . . . . . . . JDG777 Used to extract narrow pull-to-seat terminals from the chassis computer unit connectors.
CED,OUOE003,3358 1930MAR9911/11
Other Material
Number Name Use
T43512 (U.S.) TY9473 (Canadian) 242 (LOCTITE)
Thread Lock and Sealer (Medium Strength)
Apply to threads of return-to-dig switch cap screws.
CED,OUOE003,3360 1930MAR991/1
Specifications
Boom Height Kickout Switch-to-Adjustable Plate Return-to-Dig Switch-to-Adjustable Bar Adjustable Bar Cap Screw
Gap
58 mm (0.197 0.315 in.)
Gap
58 mm (0.197 0.315 in.)
Torque
121 Nm (89 lb-ft)

CED,OUOE003,3361 1930MAR991/1
TM1640 (15JAN04)
16-1674-3

011504
PN=349
Replace METRI-PACK Connectors

16 1674 4
1. A small locking tab is located inside of the Metri-Pack connector. Use a small screwdriver (B) to move tab (A) outward to the first detent position; the tab will click.
ATab BScrewdriver
UN01NOV96
Metri-Pack is a trademark of Packard Electrical.
TX,1674,MM3188 1929SEP981/3
2. Slide JDG939 Metri-Pack Extractor Tool (B) into connector body until it is positioned over terminal contact. 3. Gently pull wire out of connector body. IMPORTANT: Install contact in proper location using correct size grommet. 4. Push contact straight into connector body until positive stop is felt. 5. Pull on wire slightly to be certain contact is locked in place. 6. Transfer remaining wires to correct terminal in new connector.
AWire BExtractor Tool
UN01NOV96
TX,1674,MM3188 1929SEP982/3
7. Use a small screwdriver (B) to move tab (A) inward to the first detent position; the tab will click and lock the wires in the connector body.
ATab BScrewdriver
TX,1674,MM3188 1929SEP983/3
TM1640 (15JAN04)
16-1674-4

011504
PN=350
T104764B
UN01NOV96
T104763B
T104764B
Install DEUTSCH Contact

1. Strip 6 mm (1/4 in.) insulation from wire. 2. Adjust selector (A) on JDG360 Crimper for correct wire size. 3. Loosen lock nut (B) and turn adjusting screw (C) in until it stops.
UN23AUG88
16 1674 5
DX,ECONN,W 1904JUN901/4
IMPORTANT: Select proper size contact "sleeve" or "pin" to fit connector body. 4. Insert contact (A) and turn adjusting screw (D) until contact is flush with cover (B). 5. Tighten lock nut (C).
UN23AUG88
IMPORTANT: Contact must remain centered between indentors while crimping. 6. Insert wire in contact and crimp until handle touches stop. 7. Release handle and remove contact.
UN23AUG88
IMPORTANT: If all wire strands are not crimped into contact, cut off wire at contact and repeat contact installation procedures.
8. Inspect contact to be certain all wires are in crimped barrel.
TM1640 (15JAN04)
16-1674-5

011504
PN=351
TS0135
UN23AUG88
NOTE: Readjust crimping tool for each crimping procedure.
TS118
TS0134
TS117
Replace DEUTSCH Connectors

16 1674 6
1. Select correct size extractor tool for size of wire to be removed:

UN23AUG88
JDG361 Extractor Tool for 12 to 14 gauge wire. JDG362 Extractor Tool for 16 to 18 gauge wire. JDG363 Extractor Tool for 20 gauge wire. 2. Start correct size extractor tool over wire at handle (A). 3. Slide extractor tool rearward along wire until tool tip snaps onto wire. IMPORTANT: Do NOT twist tool when inserting in connector. 4. Slide extractor tool along wire into connector body until it is positioned over terminal contact. 5. Pull wire out of connector body, using extractor tool.
DX,ECONN,J 1903NOV941/2
IMPORTANT: Install contact in proper location using correct size grommet. 6. Push contact straight into connector body until positive stop is felt. 7. Pull on wire slightly to be certain contact is locked in place. 8. Transfer remaining wires to correct terminal in new connector.
UN23AUG88
DX,ECONN,J 1903NOV942/2
TM1640 (15JAN04)
16-1674-6

011504
PN=352
TS122
TS120
UN23AUG88
TS0124
Replace WEATHER PACKConnector

IMPORTANT: Identify wire color locations with connector terminal letters. 1. Open connector body. 2. Insert JDG364 Extraction Tool over terminal contact in connector body. 3. Hold extractor tool fully seated and pull wire from connector body.
UN23AUG88
16 1674 7
NOTE: If terminal cannot be removed, insert wire or nail through extractor tool handle and push terminal contact from connector.
DX,ECONN,O 1903NOV941/2
IMPORTANT: Carefully spread contact lances to assure good seating on connector body.
NOTE: Connector bodies are "keyed" for proper contact mating. Be sure contacts are in proper alignment.
4. Push contact into new connector body until fully seated. 5. Pull on wire slightly to be certain contact is locked in place. 6. Transfer remaining wires to correct terminal in new connector. 7. Close connector body.
UN23AUG88
DX,ECONN,O 1903NOV942/2
TM1640 (15JAN04)
16-1674-7

011504
PN=353
TS0130
TS0128
Install WEATHER PACKContact

16 1674 8
NOTE: Cable seals are color coded for three sizes of wire:
UN23AUG88
Green - 18 to 20 gauge wire Gray - 14 to 16 gauge wire Blue - 10 to 12 gauge wire 1. Slip correct size cable seal on wire. 2. Strip insulation from wire to expose 6 mm (1/4 in.) and align cable seal with edge of insulation.
NOTE: Contacts have numbered identification for two sizes of wire: a) #15 for 14 to 16 gauge wire b) #19 for 18 to 20 gauge wire
UN02NOV94
3. Put proper size contact on wire and crimp in place with a "W" type crimp, using JDG783 Terminal Applicator.
DX,ECONN,AA 1904JUN901/2
IMPORTANT: Proper contact installation for "sleeve" (A) and "pin (B) is shown. 4. Secure cable seal to contact as shown, using JDG783 Terminal Applicator.
UN02DEC88
DX,ECONN,AA 1904JUN902/2
Remove and Install Transmission Control Valve Connector Body

1. A small locking tab is located inside of the connector. Use a small screwdriver (B) to move tab (A) outward to the first detent position; the tab will click.
ATab BScrewdriver
TX,16,RP3113 1913OCT981/3
TM1640 (15JAN04)
16-1674-8

011504
PN=354
T104764B
UN01NOV96
TS0139
TS1623
TS0136

2. Slide JDG140 Metrimate Extractor Tool (B) into connector body until it is positioned over terminal contact. 3. Push on end of extractor tool (B) and gently pull wire (A) out of connector body. IMPORTANT: Install contact in proper location using correct size grommet. 4. Push contact straight into connector body until positive stop is felt. 5. Pull on wire slightly to be certain contact is locked in place. 6. Transfer remaining wires to correct terminal in new connector.
AWire BJDG140 Metrimate Extractor Tool
16 1674 9
UN01NOV96
TX,16,RP3113 1913OCT982/3
7. Use a small screwdriver (B) to move tab (A) inward to the first detent position; the tab will click and lock the wires in the connector body.
ATab BScrewdriver
TX,16,RP3113 1913OCT983/3
Install Transmission Control Valve Connector Contact

1. Slip correct size cable seal on wire. 2. Strip insulation from wire to expose 6 mm (1/4 in.) and align cable seal with edge of insulation.
UN23AUG88
TX,16,RP3112 1929SEP981/2
TM1640 (15JAN04)
16-1674-9

011504
PN=355
TS0136
T104764B
UN01NOV96
T104763B

3. Put contact on wire and insert into crimper at location (D) and crimp on contact at location (B) using JDG707 crimping tool. 4. Secure cable seal to contact by crimping at location (A) on contact and crimp at location (C) on JDG707 crimping tool.
AContact Location BContact Location CCrimper Location DCrimper Location
16 1674 10
TX,16,RP3112 1929SEP982/2
TM1640 (15JAN04)
16-1674-10

011504
PN=356
T105879B
UN09JAN97
Amp Crimper Tool for Transmission Controller Unit ConnectorOperation

16 1674 11
AStationary Jaw BBack of Tool (Wire Side) CPivot Pin
DFrame EStationary Handle FMoving Handle
GRatchet Adjustment Wheel HMoving Jaw IDie Assembly
JFront of Tool (Locator Side) KLocator Assembly
The Amp Crimper Tool is used to crimp wires for the junior timer contacts and the micro timer contacts of the transmission controller unit connector. The tool has a frame with a stationary jaw and handle, a moving jaw, a moving handle and an adjustable ratchet that ensures full contact crimping. The tool frame holds a die assembly with two crimping sections. The die assembly features a wire anvil, an insulation anvil, a wire crimper, and an insulation crimper.
Attached to the outside of the frame is a locator assembly, which contains a locator, a spring retainer, and a contact support. Die retaining pins and die retaining screws are used to position and secure the dies in the tool frame. A nut is used on the upper die retaining screw to hold the locator assembly in place.
TX,16,1111102 1924NOV971/1
TM1640 (15JAN04)
16-1674-11

011504
PN=357
T112326
UN12JUN98
Amp Crimper Tool for Transmission Controller Unit ConnectorRemove and Install Die Set
16 1674 12
ANut BLocator Assembly CTool Frame DDie Retaining Pins
EDie Retaining Screws FChamfer GInsulation Anvil
HWire Anvil IOffset JWire Crimper
KChamfer LLocator MInsulation Crimper
1. Open the tool handles and remove the two die retaining screws (E) from the tool jaws. 2. Place the wire anvil (H) and insulation anvil (G) so that their chamfered sides and their marked surfaces face outward, when mounted in the moving jaw of the tool frame. 3. Insert the two die retaining pins (D). 4. Insert the short die retaining screw through the jaw and through both anvil dies, and tighten the screw just enough to hold the dies in place. Do NOT tighten the screw completely at this time.
5. Place the wire crimper (J) and insulation crimper (M) so that their chamfered sides and their marked surfaces face outward, when mounted in the stationary jaw of the tool frame. 6. Insert the two die retaining pins. 7. Insert the long die retaining screw through the jaw and through both crimper dies. Tighten the screw just enough to hold the dies in place. Do NOT tighten the screw completely at this time.
TX,16,1111103 1924NOV971/2
TM1640 (15JAN04)
16-1674-12

011504
PN=358
T112329
UN24NOV97

8. Carefully close the tool handles, making sure that the anvils and crimpers align properly. Continue closing the tool handles until the ratchet in the tool frame has engaged sufficiently to hold the anvils and crimpers in place, then tighten both die retaining screws. 9. Place the locator assembly over the end of the long screw, and position the locator assembly against the side of the tool jaw. 10. Place the nut onto the end of the long screw and tighten the nut enough to hold the locator to slide up and down. 11. To disassemble, close the tool handles until the ratchet releases. Remove the nut, the locator assembly, the two die retaining screws, and the four die retaining pins. Slide the anvils and crimpers out of the tool jaws.
16 1674 13
TX,16,1111103 1924NOV972/2
TM1640 (15JAN04)
16-1674-13

011504
PN=359
16 1674 14
Amp Crimper Tool for Transmission Controller Unit ConnectorContact Support Adjustment
NOTE: The contact support is preset prior to shipment, but minor adjustment may be necessary.
1. Make a sample crimp and determine if the contact is straight, bending upward, or bending downward. 2. If adjustment is required, loosen the screw that holds the contact support onto the locator assembly.
NOTE: The ratchet has detents that create audible clicks as the tool handles are closed.
3. Place a contact with wire into the proper nest and close the tool handles until the ratchet reaches the sixth click, or until the contact support touches the contact. 4. Slightly loosen the nut that holds the locator assembly onto the tool frame. 5. Move the contact support as required to eliminate the bending of the contact. 6. Tighten the nut and close the handles until the ratchet releases. 7. Remove and inspect the contact. 8. Make another sample crimp. If the contact is straight, tighten the contact support screw. If the contact is still being bent during crimping, repeat the adjustment procedure.
TX,16,1111104 1924NOV971/1
TM1640 (15JAN04)
16-1674-14

011504
PN=360
Amp Crimper Tool for Transmission Controller Unit ConnectorCrimping Procedure

IMPORTANT: Verify crimp height before using the tool to crimp desired contacts and wire sizes. See Crimp Height Inspection and Crimp Height Adjustment, in this group. 1. Select wire of the specified size and insulation diameter. Strip the wire to length indicated. Do not nick or cut wire strands.
CONTACT Junior Timer Contacts Micro Timer Contacts SIZE (AWG) 0.51.0 mm 0.51.0 mm WIRE INSUL DIAMETER 2.0 mm (0.079 in.) Max. 1.6 mm (0.063 in.) Max. STRIP LENGTH 4.7 mm (0.185 in.) 4.3 mm (0.170 in.)
UN24NOV97
16 1674 15
ASlot
Micro Timer Contact Slot
Junior Timer Contact Slot

Continued on next page TX,16,1111105 1917FEB991/3
TM1640 (15JAN04)
16-1674-15

011504
PN=361
T112336B
UN24NOV97
T112335B
16 1674 16
AAdjustment Screw for Contact Support BContact Support
CLocator DWire EMicro Timer Slot
FJunior Timer Slot GContact
HLocator in Wire Stop Slot IWire Inserted to Stop
2. Hold the tool so that the back (wire side) is facing you. Squeeze tool handles together and allow them to open fully. 3. Holding the contact by the mating end, insert the contactinsulation barrel firstthrough the front of the tool and into the appropriate crimp section. IMPORTANT: Make sure that both sides of the insulation barrel are started evenly into the crimping section. Do NOT attempt to crimp an improperly positioned contact. 4. Position the contact so that the mating end of the contact is on the locator side of the tool, so that the open U of the wire and insulation barrels face the
top of the tool. Place the contact up into the nest so that the movable locator drops into the slot in the contact. Butt the front end of the wire barrel against the movable locator. 5. Hold the contact in position and squeeze the tool handles together until ratchet engages sufficiently to hold the contact in position. Do NOT deform insulation barrel or wise barrel. 6. Insert stripped wire into contact insulation and wire barrels until it is butted against the wire stop. 7. Hold the wire in place: squeeze tool handles together until ratchet releases. Allow tool handles to open and remove crimped contact.
TX,16,1111105 1917FEB992/3
TM1640 (15JAN04)
16-1674-16

011504
PN=362
T112229
UN19NOV97
Wiring Harness and Switches NOTE: The crimped contact may stick in the crimping area. It can be easily removed by pushing downward on the top of the locator.
8. Check the contact crimp height. If necessary, adjust the crimp height. See Crimp Height Inspection and Crimp Height Adjustment.
16 1674 17
TX,16,1111105 1917FEB993/3
Amp Crimper Tool for Transmission Controller Unit ConnectorCrimp Height Inspection
1. Use a crimp height comparator to measure the wire barrel crimp height as shown.
WIRE SIZE AWG (MAX) 1.0 mm 1.0 mm CRIMP SECTION (WIRE SIZE MARKING) Junior Micro CRIMP HEIGHT DIM. (C) AND TOLERANCE () 1.27 0.051 mm (0.0500 0.0020 in.) 1.20 0.051 mm (0.0472 0.0020 in.) APosition Point on Center of Wire Barrel Opposite Seam BModified Anvil CDimension
2. If the crimp height conforms to specifications, the tool is considered dimensionally correct. If not, the tool must be adjusted. See Crimp Height Adjustment.
TX,16,1111106 1925NOV971/1
TM1640 (15JAN04)
16-1674-17

011504
PN=363
T112327
UN21NOV97
16 1674 18
Amp Crimper Tool for Transmission Controller Unit ConnectorCrimp Height Adjustment
1. Remove the lock screw (B) from the ratchet adjustment wheel (C). 2. Adjust the ratchet wheel from the location side of the tool using a screwdriver (A). 3. If a tighter crimp is required, rotate the adjustment wheel counterclockwise. If a looser crimp is required, rotate the adjustment wheel clockwise. 4. Install the lock screw. 5. Make a sample crimp and measure the crimp height. If the dimension is correct, tighten the lock screw. 6. If the dimension is incorrect, readjust the ratchet.
AScrewdriver BLock Screw CRatchet Adjustment Wheel
TX,16,1111107 1925NOV971/1
TM1640 (15JAN04)
16-1674-18

011504
PN=364
T112328
UN21NOV97
Replace Transmission Controller Unit Connector Terminals

The transmission controller unit connector has two size terminals: Junior Timer Contacts (Large)Use JDG1177 Extractor Micro Timer Contacts (Small)Use FKM10457 Extractor 1. Insert extractor (A) into front (terminal side) of connector (C). Use extractor to press in the locking tabs of terminal. 2. Remove extraction tool and pull wire with terminal (B) through rear of connector. 3. Install new terminal into rear of connector, pushing it in until it stops. Locking tabs must be properly lined up with the socket. 4. Pull on wire slightly to be certain terminal is locked in place.
AExtractor BWire CConnector 16 1674 19
TX,16,1111113 1917FEB991/1
TM1640 (15JAN04)
16-1674-19

011504
PN=365
T112380B
UN01DEC97
Replace Chassis Computer Unit Connector Terminals

16 1674 20
(S.N. 783564)
UN26NOV97
NOTE: The chassis computer unit connectors have pull-to-seat contacts.

1. Disconnect chassis computer unit connector (C). 2. Insert JDG777 Terminal Extraction Tool (B) into wire side of the connector. Push terminal locking tab (D) inward releasing tab (E). 3. Remove extraction tool and push wire with terminal (A) through socket.
AWire BExtraction Tool CConnector DLocking Tab ETab
TX,16,1111114 1917APR011/5
4. Remove terminal, cut, strip and crimp wire through connector. Insert wire in the 1816 slot of crimping tool. 5. Make sure locking tab on new terminals is in outward position. Then pull back on wire until terminal locks in connector body.
JDG1179 Crimper For CCU Connector
TX,16,1111114 1917APR012/5
TM1640 (15JAN04)
16-1674-20

011504
PN=366
T112337B
UN24NOV97
T109189
UN16APR97
T112370B

(S.N. 783565) 1. Remove extraction tool (1) from the loading side of connector. 2. Insert blade of extraction tool into locking tabs (2) of secondary lock (3). Rotate tool away from the connector to pry one side of the secondary lock out of the locked position. Repeat this step for the other locking tab.
16 1674 21
TX,16,1111114 1917APR013/5
3. Remove secondary lock (3).

3Secondary Lock
TX,16,1111114 1917APR014/5
TM1640 (15JAN04)
16-1674-21

011504
PN=367
T132301B
UN29JUN00
T132105B
1Extraction Tool 2Secondary Lock Locking Tabs 3Secondary Lock
UN29JUN00
NOTE: After unlocking one side of the secondary lock, a screw driver or similar device may need to be used to hold it in the unlocked position while unlocking the second locking tab.

4. Insert pointed side of extraction tool into the contact cavity so that the flat side of tool faces secondary lock cavity (4). This will release the primary contact locking tab.
UN29JUN00
16 1674 22
5. Gently pull wire out of the connector. 6. Repair/Replace terminals as necessary using procedure in this group. (See Install CINCH Contact.) 7. Insert contact and wire into connector until it clicks. 8. Install secondary lock.
TX,16,1111114 1917APR015/5
TM1640 (15JAN04)
16-1674-22

011504
PN=368
T132107B
Install CINCH Contact

16 1674 23
ATop of Tool BContact Support CLocator
DWire EMicro Timer Slot
FJunior Timer Slot GContact
IWire Tab JInsulation Tab
1. Hold JDG708 crimping tool so that the tool is facing you as shown (left side of graphic). Squeeze tool handles together and allow them to open fully. IMPORTANT: Make sure that both sides of the insulation barrel are started evenly into the crimping section. Do NOT attempt to crimp an improperly positioned contact. 2. Position the contact so that the mating end of the contact (G) is on the locator side of the tool (C). Wire and insulation tabs (I and J) should point to top of tool (A). Butt wire tab (I) against the movable locator (C).
3. Hold the contact in position and squeeze the tool handles together until ratchet engages sufficiently to hold the contact in position. Do NOT deform wire and insulation tabs (I and J). 4. Insert stripped wire into contact insulation and wire tabs until it is butted against locator (C). 5. Hold the wire in place. Squeeze tool handles together until ratchet releases. Allow tool handles to open and remove crimped contact. 6. Install contact into connector. See Install CINCH Contact. (Go to procedure in this group.)
CINCH is a trademark of the Cinch Co.
CED,TX17994,330 1829JUN001/1
TM1640 (15JAN04)
16-1674-23

011504
PN=369
T138057
UN14FEB01
Remove Connector Body from Blade Terminals

16 1674 24
1. Depress locking tang (A) on terminal, using a small screw driver. Slide connector body off. 2. Be sure to bend locking tang back to its original position (B) before installing connector body.
UN23AUG88
DX,ECONN,V1 1902NOV941/1
Remove Blade Terminals From Fuse Block

Use small screwdriver to depress each locking tang (A) on terminal. Pull terminal out of fuse block. Be sure to bend locking tangs back to original position (B) before installing in fuse block.
ALocking Tang (Depressed Position) BLocking Tang (Original Position)
TX,1674,WW1218 1913OCT981/1
TM1640 (15JAN04)
16-1674-24

011504
PN=370
T7670AC
UN14DEC91
RW4218
Boom Height Kickout Adjustment

SPECIFICATIONS Boom Height Kickout Switch-to-Adjustable Plate Gap 58 mm (0.197 0.315 in.)
UN06FEB97
16 1674 25
1. Move loader control lever to boom raise detent position and release. 2. After loader control lever returns to neutral, make a mark on the adjustable plate and loader frame for the tool carrier. For the loader, make a mark on plate edge and mounting block. 3. Position the boom in the desired boom height kickout position. Stop engine. 4. Loosen cap screws (A) and adjust plate to align marks on plate and loader frame or mounting block. 5. Inspect air gap between switch (B) and adjustable plate (C).
Specification Boom Height Kickout Switch-to-Adjustable PlateGap ................. 58 mm (0.197 0.315 in.)
Loader
Tool Carrier
6. If air gap is out of specifications, loosen hex nuts and adjust switch (B) to get correct air gap. 7. Start engine and check boom height kickout for correct adjustment. Readjust as required.
ACap Screw (2 used) BSwitch CAdjustable Plate
TX,20,SS3659 1922APR991/1
TM1640 (15JAN04)
16-1674-25

011504
PN=371
T107042B
UN07FEB97
T106999B
Return-to-Carry Kickout Adjustment

16 1674 26 SPECIFICATIONS Boom Height Kickout Switch-to-Adjustable Plate Gap 58 mm (0.197 0.315 in.)
UN07FEB97
1. Move Return-to-Carry switch on side dash to ON position. Raise boom to maximum height. 2. Put boom lever in Float detent position and observe at what position boom stops lowering and control lever releases from detent. 3. Stop engine. Make a mark on the adjustable plate and loader frame for the tool carrier. For the loader, make a mark on plate edge and mounting block. 4. Start engine and position boom in desired Return-to-Carry position. 5. Stop engine. Loosen cap screws (A) and adjust plate (B) to align marks on plate and loader frame or mounting block. 6. Inspect air gap between switch (B) and adjustable plate (C).
Specification Boom Height Kickout Switch-to-Adjustable PlateGap ................. 58 mm (0.197 0.315 in.)
Loader
Tool Carrier
ACap Screw (2 used) BSwitch CAdjustable Plate
7. If air gap is out of specifications, loosen hex nuts on switch and adjust switch (B) to get correct air gap. 8. Start engine and check boom Return-to-Carry kickout for correct adjustment. Readjust as required.
NOTE: The boom Float position detent will not operate at ground level with Return-to-Carry switch ON. Turn Return-to-Carry switch off to activate normal Float function of boom.
TX,20,SS3660 1922APR991/1
TM1640 (15JAN04)
16-1674-26

011504
PN=372
T107041B
UN06FEB97
T107043B
Return-to-Dig Adjustment
SPECIFICATIONS Return-to-Dig Switch-to-Adjustable Bar Gap Adjustable Bar Cap Screw Torque 58 mm (0.197 0.315 in.) 121 Nm (89 lb-ft) 16 1674 27
UN16AUG96
OTHER MATERIAL T43512 U.S. Thread Lock and Sealer (Medium Strength) TY9473 Canadian Thread Lock and Sealer (Medium Strength) 242 LOCTITE Thread Lock and Sealer (Medium Strength)
1. Raise boom approximately 300 mm (12 in.) above ground. Move bucket from full rollback to dump. 2. Move loader control lever to return-to-dig detent position and release. 3. After control lever returns to neutral, make a mark (D) on switch bracket to align with end of adjustable bar. 4. Position the boom and bucket in the desired return-to-dig position. Stop engine. 5. Loosen cap screws (C) and adjust bar to align marks (D) on switch bracket and end of bar. 6. Raise boom. Cycle bucket from full rollback to dump. Adjust as required to get desired position. 7. Remove cap screws (C), one at a time, apply thread lock and sealer (medium strength). Adjust air gap (A) between switch (F) and adjustable bar. Tighten cap screws.
Specification Return-to-Dig Switch-to-Adjustable BarGap .................... 58 mm (0.197 0.315 in.) Adjustable Bar Cap Screw Torque ........................................................................... 121 Nm (89 lb-ft)
AAir Gap Switch-to-Bar BAdjustable Bar CCap Screw (2 used) DAlignment Marks EAdjusting Nut (2 used) FSwitch
TX,20,SS3661 1922APR991/1
TM1640 (15JAN04)
16-1674-27

011504
PN=373
T101721
16 1674 28
TM1640 (15JAN04)
16-1674-28

011504
PN=374
Group 1675
System Controls
Remove and Install Transmission Control Unit (TCU)
16 1675 1
ATransmission Control Unit Connector
BTransmission Control Unit
IMPORTANT: Whenever a transmission control unit (TCU) is replaced, the monitor display unit must be reconfigured. This reconfiguration procedure is performed in the Service Menu.
Transmission control unit (B) is located in the load center compartment. 1. Turn battery disconnect switch to Off.
TX,1675,111939 1917FEB991/2
TM1640 (15JAN04)
16-1675-1

011504
PN=375
T111632
UN06OCT97
System Controls
2. Lift tab on connector up, then pull connector out of transmission control unit receiver.
16 1675 2
3. Remove mounting screws to remove transmission control unit. 4. Install new control unit. Install and tighten mounting screws. 5. Push transmission control unit connector into control unit receiver, then push tab down to lock connector in place. 6. Turn battery disconnect switch to On. 7. Reconfigure monitor display unit. See Monitor Display Unit Reconfiguration in Operation and Test Manual.
TX,1675,111939 1917FEB992/2
TM1640 (15JAN04)
16-1675-2

011504
PN=376
T107726B
UN27MAR97
System Controls
Remove and Install Chassis Computer Unit (CCU)

16 1675 3
AChassis Computer Unit 60Pin Connector (Part A)
BChassis Computer Unit 60Pin Connector (Part B)
CChassis Computer Unit
DChassis Computer Unit 30Pin Connector
IMPORTANT: Whenever a chassis computer unit (CCU) is replaced, the monitor display unit must be reconfigured. This reconfiguration procedure is performed in the Service Menu. The chassis computer unit (C) is located in the load center compartment. 1. Turn battery disconnect switch to Off. 2. Disconnect chassis computer unit connectors (A, B, and D). 3. Remove mounting cap screws to remove chassis computer unit.
4. Install new computer unit. Install and tighten mounting cap screws. 5. Connect chassis computer unit 30pin connector (D) and 60pin connector Part A (A) and Part B (B). Reference art on next page for chassis computer unit connector end views. 6. Turn battery disconnect switch to On. 7. Reconfigure monitor display unit. See Monitor Display Unit Reconfiguration in Operation and Test Manual.
TX,1675,111943 1917FEB991/2
TM1640 (15JAN04)
16-1675-3

011504
PN=377
T111633
UN06OCT97
System Controls
16 1675 4
TX,1675,111943 1917FEB992/2
TM1640 (15JAN04)
16-1675-4

011504
PN=378
T116162
1922JUL98
System Controls
Remove and Install Monitor Display Unit

16 1675 5
IMPORTANT: Whenever a monitor display unit is replaced, it must be reconfigured. This reconfiguration procedure is performed in the Service Menu. 1. Turn battery disconnect switch to Off.
4. Install new monitor display unit. 5. Connect all monitor display unit connectors in front console harness. Reference art on next page for connector end views. 6. Turn battery disconnect switch to On.
2. Disconnect all connectors from monitor display unit. 3. Remove mounting cap screws to remove monitor display unit. 7. Reconfigure monitor display unit. See Monitor Display Unit Reconfiguration in Operation and Test Manual.
TX,1675,MM3132 1917FEB991/2
TM1640 (15JAN04)
16-1675-5

011504
PN=379
T111634
1906OCT97
System Controls
16 1675 6
TX,1675,MM3132 1917FEB992/2
TM1640 (15JAN04)
16-1675-6

011504
PN=380
T110548
1905SEP97
Group 1677
Motors and Actuators

John Deere Starting Motor RepairUse CTM77
For complete repair information on the John Deere Starting Motor, CTM77 is also required.
UN17JAN89
16 1677 1
Use the component manual in conjunction with this machine manual.
TX,1677,MM3151 1907SEP941/1
Specifications
Starting Motor Starting Motor Mounting Cap Screw
Weight Torque
CED,OUOE003,3363 1930MAR991/1
Remove and Install Starting Motor

IMPORTANT: Disconnect battery negative (-) cable or turn battery disconnect switch to OFF (if equipped) to prevent accidental grounding of starting motor wiring leads. 1. Disconnect battery negative (-) cable. Turn battery disconnect switch Off (if equipped). 2. Disconnect positive (+) wiring leads and battery ground strap from starter (A).
AStarter
CAUTION: The approximate weight of the starting motor is 30 kg (66 lb).

Specification Starting MotorWeight ..................................... 30 kg (66 lb) approximate
3. Remove mounting hardware to remove starting motor. 4. Replace parts as necessary.
TX,1677,MM3154 1930MAR991/3
TM1640 (15JAN04)
16-1677-1

011504
PN=381
T111214E
UN01DEC97
TS225
16 1677 2
5. Install starting motor.

Continued on next page TX,1677,MM3154 1930MAR992/3
TM1640 (15JAN04)
16-1677-2

011504
PN=382
T107768
1904MAR97

6. Tighten mounting cap screws.
Specification Starting Motor Mounting Cap ScrewTorque ....................................................... 125 Nm (95 lb-ft)
7. Connect all wiring leads and ground strap. Turn battery disconnect switch On.
16 1677 3
TX,1677,MM3154 1930MAR993/3
TM1640 (15JAN04)
16-1677-3

011504
PN=383
16 1677 4
TM1640 (15JAN04)
16-1677-4

011504
PN=384
Section 17
Frame or Supporting Structure

Contents
Page 17
Group 1740Frame Installation Service Equipment and Tools . . . . . . . . . . . .17-1740-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .17-1740-2 Major Structure Welding . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-3 Engine and Loader Frame Separate . . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-5 Upper Pivot Bearing and Seals Remove and Install . . . . . . . . . . . . . . . . .17-1740-10 Lower Pivot Bearing and Seals Remove and Install . . . . . . . . . . . . . . . . .17-1740-12 Group 1746Frame Bottom Guards Specifications . . . . . . . . . . . . . . . . . . . . . . . .17-1746-1 Fuel Tank Guard Remove and Install . . . . . . . . . . . . . . . . . .17-1746-1 Front Axle Guard Remove and Install . . . . . . . . . . . . . . . . . .17-1746-1 Transmission Bottom Guard Remove and Install . . . . . . . . . . . . . . . . . .17-1746-2 Transmission Side Guards Remove and Install . . . . . . . . . . . . . . . . . .17-1746-2 Group 1749Chassis Weights Specifications . . . . . . . . . . . . . . . . . . . . . . . .17-1749-1 Counterweights Remove and Install . . . . . . . . . . . . . . . . . .17-1749-2
TM1640 (15JAN04)
17-1

011504
PN=1
Contents
17
TM1640 (15JAN04)
17-2

011504
PN=2
Group 1740
Frame Installation
17 1740 1
CED,OUOE003,3365 1930MAR991/3
17-1/2 Ton Puller Set To remove and install bearing assembly and bushings from pivot bores.
CED,OUOE003,3365 1930MAR992/3
Disk and Driver Set To remove and install bearing assembly, bushings and seals.
CED,OUOE003,3365 1930MAR993/3
TM1640 (15JAN04)
17-1740-1

011504
PN=387
Frame Installation
Specifications
Weld Metal
Tensile Strength Yield Strength Elongation Preheat Temperature Preheat Temperature
482.6 mPa (70 000 psi) 413.7 mPa (60 000 psi) 22% 38C (100F) 177C (350F)
17 1740 2
Structural Assemblies Ground Engaging Tools Loader Frame Universal Joint Cap Screw
Torque
78 Nm (58 lb-ft)
Upper Pivot Bearing and Seals Upper Pivot Bearing Upper Pivot Bearing Cover Cap Screw Preload Torque 0.030.13 mm (0.0010.005 in.) 128 Nm (95 lb-ft)
Lower Pivot Bearing and Seals Lower Pivot Joint Bearing Bearing Cover-to-Engine Frame Cap Screw Plate-to-Loader Frame Cap Screw Lower Pivot Retaining Pin Cap Screw Preload Torque 0.030.13 mm (0.0010.005 in.) 128 Nm (95 lb-ft)
Torque Torque
128 Nm (95 lb-ft) 2129 Nm (1570 lb-ft)
CED,OUOE003,3367 1930MAR991/1
TM1640 (15JAN04)
17-1740-2

011504
PN=388
Frame Installation
Welding Major Structure

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. Remove paint before welding. IMPORTANT: Disconnect battery ground strap or turn battery disconnect switch to OFF (if applicable). Disconnect both negative and positive battery cables and microprocessor unit (if applicable). Have only a qualified welder do this job. Connect welder ground clamp close to each weld area so electrical current does not pass through any bearings. Remove or protect all parts that can be damaged by heat or weld splatter. Use one of the following weld processes: AWS-E-7018 covered electrode with shielded metal arc welding (SMAW) process. AWS-ER-70S-3f wire electrode with gas metal arc welding (GMAW) process. AWS-E70T-1 or E71T-1 wire electrode with flux core arc welding (FCAW) process.
UN23AUG88
17 1740 3
WELD,II 1901OCT981/2
TM1640 (15JAN04)
17-1740-3

011504
PN=389
TS220
Frame Installation
Specification Weld MetalTensile Strength.............................. 482.6 mPa (70 000 psi) Yield Strength ....................................................... 413.7 mPa (60 000 psi) Elongation ............................................................................................ 22%
Preheat area to be repaired to allow better weld penetration.

17 1740 4
To repair weld metal failure, remove failed weld metal using arc or grinding equipment. Thoroughly clean area to be welded. Preheat structural assemblies to a minimum of 38C (100F). Preheat structural ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177C (350F).
Specification Structural AssembliesPreheat Temperature .......................................................................... 38C (100F) Ground Engaging ToolsPreheat Temperature ........................................................................ 177C (350F)
To repair base metal failure remove enough material to allow weld to penetrate to the bottom of crack. Preheat structural ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177C (350F).
WELD,II 1901OCT982/2
TM1640 (15JAN04)
17-1740-4

011504
PN=390
Frame Installation
Separate Engine and Loader Frame

1. Park machine on smooth level surface and align frames. 2. Install chain around bucket and connect to boom. Place service jack under center of bucket. Service jack wheels must roll freely and straight ahead when loader frame is moved forward. 3. Stop engine. 4. Connect hoist to loader frame using chains. 5. Install shop stands under front and rear of engine frame. 6. Hold down Boom Lower Switch and move pilot control lever to release hydraulic pressure. Depress brake pedal 40 times to discharge brake accumulator. 7. Remove cab. (See Procedure in Group 1800)
17 1740 5
TX,17,RP3352 1917FEB991/7
8. Disconnect electrical connectors. 9. Drain hydraulic reservoir. Approximate capacity of reservoir is 117 L (31 gal).
ALoader Frame Harness Center Harness BLoader Frame Harness Center Harness CLoader Frame Harness Center Harness DLoader Frame Harness Center Harness Connector X8 to Load Connector X7 to Load Connector X9 to Load Connector X25 to Load
TX,17,RP3352 1917FEB992/7
TM1640 (15JAN04)
17-1740-5

011504
PN=391
T111829
UN23OCT97
Frame Installation
17 1740 6
Loader
ABoom Lower From Pilot Controller BBucket Dump From Pilot Controller CTo Steering Valve DValve Inlet From Hydraulic Pump EBucket Roll Back From Pilot Controller FBoom Raise From Pilot Controller GPilot Pressure From Pressure Reducing Valve HLoad Sense to Pump ITo Hydraulic Return Filter
10. Disconnect lines (AI).
TM1640 (15JAN04)
17-1740-6

011504
T111830
UN26NOV97
TX,17,RP3352 1917FEB993/7
PN=392
Frame Installation
17 1740 7
Tool Carrier
ABoom Lower to Pilot Controller BBucket Dump to Pilot to Controller CAuxiliary to Pilot Controller DControl Valve Return to Filter ELoad Sense to Steering Valve FLoader Control Valve Pressure From Pump GTo Pressure Reducing Valve HAuxiliary to Pilot Controller IBucket Roll Back to Pilot Controller JBoom Raise to Pilot Controller KLoad Sense to Hydraulic Pump
11. Disconnect lines (AK).
TM1640 (15JAN04)
17-1740-7

011504
T111833
UN23OCT97
TX,17,RP3352 1917FEB994/7
PN=393
Frame Installation
12. Disconnect lines (A, B, E, F). 13. Disconnect drive shaft U-joints (C and D).
ABrake Pressure BDifferential Lock CFront Drive Shaft U-Joint DCenter drive Shaft U-Joint EPark Brake Return FPark Brake Pressure
17 1740 8
TX,17,RP3352 1917FEB995/7
14. Remove steering cylinder pins (B). 15. Remove cap screw (E), plate (F) and spacer (D). Remove lower pivot pin (C). 16. Remove upper pivot pin (A).
AUpper Pivot Pin BSteering Cylinder Pins CLower Pivot Pin DSpacer ECap Screw FPlate
TX,17,RP3352 1917FEB996/7
TM1640 (15JAN04)
17-1740-8

011504
PN=394
T108046
UN11MAR97
T107858
UN07MAR97
Frame Installation
17. Have a service technician at each front tire. Push on tires and slowly move overhead hoist forward. Make sure service jack rolls forward with bucket. 18. Replace parts as necessary. 19. Attach loader frame to engine frame. 20. Connect lines and electrical connectors. IMPORTANT: DO NOT reuse drive shaft universal joint cap screws or bearing retainer straps. Replace cap screws and bearing retainer straps to avoid machine damage. 21. Connect drive shafts. Install new drive shaft universal joint cap screws and bearing retainer straps. Tighten cap screws.
Loader FrameSpecification Universal Joint Cap Screw Torque ............................................................................. 78 Nm (58 lb-ft)
UN24OCT88
17 1740 9
22. Connect steering cylinders. Install maximum number of washers between loader frame and steering cylinder rod end. Install equal number above and below rod end. 23. Install cab. (See Group 1800.) 24. Add hydraulic oil. (See Hydraulic System Oil, Group 0004.) 25. Start machine and check for leaks.
TX,17,RP3352 1917FEB997/7
TM1640 (15JAN04)
17-1740-9

011504
PN=395
T77721
Frame Installation
Remove and Install Upper Pivot Bearing and Seals
17 1740 10
APin BEngine Frame CUpper Seal
DCover EShim (As Needed) FLoader Frame
GBearing (2 used) HLower Seal Spacer ILower Seal
JEngine Frame KBearing Spacer LCap Screw (6 used)
1. Remove upper and lower pivot pins and separate frames. Remove cap screws (L) and cover (D) with upper seal (C). Remove parts (G, H, I, and K) from loader frame bore using a puller disk against lower seal spacer with seal (H).
2. Remove seal (I) from seal spacer (H). 3. Replace parts as necessary. 4. Apply a light coat of JDM J13E4 grease to rollers in bearings (G).
NOTE: Lower seal cannot be pushed through spacer. Remove seal spacer to remove seal.
TX,17,RP3353 1905OCT981/2
TM1640 (15JAN04)
17-1740-10

011504
PN=396
T107940
UN13MAR97
Frame Installation
5. Press lower seal (I) into seal spacer (H) with lips facing out. The seal must seat against seal spacer shoulder. 6. Install seal spacer (H) in bottom of loader frame bore. 7. Press first bearing cup into bore against seal spacer. IMPORTANT: Do not apply load to bearing cone when pressing in cup. Use old bearing race to apply load on new bearing cup to prevent bearing damage. 8. Install first bearing cone in cup. IMPORTANT: Use the same spacer (K) which was removed from the bearing set. Spacer is not interchangeable with other bearings. 9. Install bearing spacer. 10. Press second bearing cup into bore against spacer. Install second bearing cone. 11. Install upper seal (C) into cover with lip facing out. Press seal to cover shoulder. 12. Hold cover in place, measure gap between cover and frame, take readings in three places. Cover must contact top of bearing. Calculate the average of these three reading to determine shim pack required. 13. Install shims to obtain a preload of 0.030.13 mm (0.0010.005 in.) on bearings.
Upper Pivot Bearing and SealsSpecification Upper Pivot BearingPreload ........... 0.030.13 mm (0.0010.005 in.)
17 1740 11
14. Apply grease to the top of bearing, fill cavity above bearing to machined surface, to prevent moisture from entering bearing through shims. 15. Tighten cap screws (L) to specification. Rotate inner race of bearing after tightening.
Upper Pivot Bearing and SealsSpecification Upper Pivot Bearing Cover Cap ScrewTorque ....................................................... 128 Nm (95 lb-ft)
TX,17,RP3353 1905OCT982/2
TM1640 (15JAN04)
17-1740-11

011504
PN=397
Frame Installation
Remove and Install Lower Pivot Bearing and Seals
17 1740 12
APin Retaining Cap Screw BCap Screw (6 used) CPlate DEngine Frame ESpacer (Engine Frame)
FSpacer (Engine Frame) GCover Seal HCap Screw (6 used) ICover
JShims (As Needed) KLoader Frame LBearing Spacer MBearing (2 used)
NSpacer Seal OSpacer PLoader Frame QLower Pivot Pin
1. Remove pin retaining cap screw (A), cap screws (B) and plate (C). Remove pivot pin (Q) and separate machine frames.
2. Remove cap screws (H), cover (I) with seal (G) and spacers (J).
TX,17,RP3354 1917FEB991/2
TM1640 (15JAN04)
17-1740-12

011504
PN=398
T107966
UN11MAR97
Frame Installation NOTE: Spacer seal can not be pushed through spacer. Remove seal and spacer to remove seal.
3. Remove bearing spacers, bearings, seals, and spacers (L, M, N, and O) from engine frame, using a puller disk against seal spacer (O). Remove seal (N) from seal spacer (O). 4. Remove spacer (E) from engine frame bore. 5. Replace parts as necessary. 6. Press spacer (E) into engine frame bore flush with bottom of frame. 7. Apply a light coat of JDM J13E4 grease to rollers in bearings (M). 8. Press seal into seal spacer, with lips facing out. Seal must seat against the seal spacer shoulder. 9. Install seal spacer to bottom of bore. 10. Press first bearing cup into engine frame bore against spacer. IMPORTANT: Use the same bearing spacer (L) which was removed from the bearing set. Spacer is not interchangeable with other bearings. Do not apply load to bearing cone when pressing in cup. Use old bearing race to apply load on new bearing cup to prevent bearing damage. 11. Install first bearing cone. 12. Install bearing spacer. 13. Press second bearing cup in engine frame bore. Install second bearing cone. Then press second bearing cup into bore against spacer. 14. Install seal into bearing cover (I) with lips facing out. Press seal to cover shoulder.
Lower Pivot Bearing and SealsSpecification Plate-to-Loader Frame Cap ScrewTorque ....................................................... 128 Nm (95 lb-ft) Lower Pivot Retaining Pin Cap ScrewTorque ................................................. 2129 Nm (1570 lb-ft)
15. Hold bearing cover in place, measure gap between cover and frame, take readings in three places. Bearing cover must contact top of bearing. Calculate the average of these three readings to determine shim pack required. 16. Install shims (J) to obtain specified preload on bearings.
Lower Pivot Bearing and SealsSpecification Lower Pivot Joint Bearing Preload........................................................................ 0.030.13 mm (0.0010.005 in.)
17 1740 13
17. Apply grease to the top of bearing, fill cavity above bearing to machined surface, to prevent moisture from entering bearing through shims. 18. Tighten cap screws (H). Rotate inner race of bearing after tightening.
Lower Pivot Bearing and SealsSpecification Bearing Cover-to-Engine Frame Cap ScrewTorque ............................................... 128 Nm (95 lb-ft)
19. Install spacer (F) into cover (I). 20. Move frames together and install pivot pin (Q) and plate (C). Install pin retaining cap screw (A) and cap screws (B) finger tight before torquing. 21. Tighten plate-to-loader frame cap screws (B). Tighten lower pivot pin retaining cap screw (A), steel dowels or cap screws may be inserted into holes in top of pivot pin and a bar inserted between them to prevent pin from turning during tightening of cap screw.
TX,17,RP3354 1917FEB992/2
TM1640 (15JAN04)
17-1740-13

011504
PN=399
Frame Installation
17 1740 14
TM1640 (15JAN04)
17-1740-14

011504
PN=400
Group 1746
Frame Bottom Guards

Specifications
Fuel Tank Guard Front Axle Guard Transmission Bottom Guard Transmission Side Guard
Weight Weight Weight Weight
166 kg (366 lb) approximate 32 kg (72 lb) approximate 71.5 kg (158 lb) approximate 14 kg (30 lb) approximate
CED,OUOE003,3368 1930MAR991/1
17 1746 1
Remove and Install Fuel Tank Guard

CAUTION: The approximate weight of the fuel tank guard is 166 kg (366 lb).
UN12MAR97
Weight may increase due to build up of mud and debris. Full tank full of fuel (267 L, 70 gal) will add 225 kg (495 lb) to fuel tank and guard total weight. Drain fuel tank before removing guard.
Specification Fuel Tank GuardWeight............................. 166 kg (366 lb) approximate
Drain fuel into a clean container for reuse. Remove fuel tank guard and fuel tank.
TX,17,RP3356 1917FEB991/1
Remove and Install Front Axle Guard

CAUTION: The approximate weight of the front axle guard is 32 kg (72 lb).
UN12MAR97
Weight may increase due to build up of mud and debris.

Specification Front Axle GuardWeight ................................ 32 kg (72 lb) approximate
TX,17,RP3357 1917FEB991/1
TM1640 (15JAN04)
17-1746-1

011504
PN=401
T108117
T108116
Frame Bottom Guards
Remove and Install Transmission Bottom Guard

CAUTION: The approximate weight of the transmission bottom guard is 71.5 kg (158 lb).
17 1746 2
Weight may increase due to build up of mud and debris.

Specification Transmission Bottom Guard Weight........................................................... 71.5 kg (158 lb) approximate
TX,17,RP3358 1930MAR991/1
Remove and Install Transmission Side Guards

CAUTION: The approximate weight of the transmission side guard is 14 kg (30 lb).
Specification Transmission Side Guard Weight................................................................ 14 kg (30 lb) approximate
UN12MAR97
If a guard is bent, heat with a torch and straighten. Weld any cracks using E7018 electrodes.
TX,17,RP3359 1917FEB991/1
TM1640 (15JAN04)
17-1746-2

011504
PN=402
T108119
T108118
UN12MAR97
Group 1749
Chassis Weights
Specifications
Secondary Counterweight Main Counterweight Counterweight Attaching Cap Screw
Weight Weight Torque
468 kg (1030 lb) approximate 873 kg (1925 lb) approximate 1150 Nm (850 lb-ft)
17 1749 1
CED,OUOE003,3369 1930MAR991/1
TM1640 (15JAN04)
17-1749-1

011504
PN=403
Chassis Weights
Remove and Install Counterweights
17 1749 2
ASecondary Counterweight
BMain Counterweight
CWasher (6 used)
DCap screw (6 used)
CAUTION: The approximate weight of counterweight components are: Secondary Counterweight (A)468 kg (1030 lb) Main Counterweight (B)873 kg (1925 lb).
Specification Secondary Counterweight Weight ................................................... 468 kg (1030 lb) approximate Main CounterweightWeight ............... 873 kg (1925 lb) approximate
Draw counterweight against engine frame with upper two screws first, then lower screws. Torque to specifications in same pattern.
Specification Counterweight Attaching Cap ScrewTorque ................................................... 1150 Nm (850 lb-ft)
TX,17,RP3361 1930MAR991/1
TM1640 (15JAN04)
17-1749-2

011504
T108108
UN12MAR97
PN=404
Section 18
Operators Station
Contents
Page Page
Group 1800Removal and Installation Essential Tools . . . . . . . . . . . . . . . . . . . . . . .18-1800-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .18-1800-1 Cab or Canopy Remove and Install . . . . . . . . . . . . . . . . . .18-1800-2 Group 1810Operator Enclosure Other Material . . . . . . . . . . . . . . . . . . . . . . . .18-1810-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .18-1810-1 Windowpanes Remove and Install . . . . . . . . . . . . . . . . . .18-1810-2 Windshield Washer Remove and Install . . . . . . . . . . . . . . . . . .18-1810-4 Front and Rear Windshield Wiper Motor Remove and Install . . . . . . . . . . . . . . . . . .18-1810-6 Front Windshield Wiper Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-8 Wrist Support Remove and Install . . . . . . . . . . . . . . . . .18-1810-10 Group 1821Seat and Seat Belts Seat Belt Disassemble and Assemble. . . . . . . . . . . .18-1821-1 Seat Disassemble and Assemble. . . . . . . . . . . .18-1821-2 Group 1822Steps and Handholds Access Platform and Steps Remove and Install . . . . . . . . . . . . . . . . . .18-1822-2 Engine Compartment Step Remove and Install . . . . . . . . . . . . . . . . . .18-1822-4 Mounted Step Remove and Install . . . . . . . . . . . . . . . . . .18-1822-5 Group 1830Heating and Air Conditioning Essential Tools . . . . . . . . . . . . . . . . . . . . . . .18-1830-1 Service Equipment and Tools . . . . . . . . . . . .18-1830-3 Air Conditioning System Fittings Reference Chart . . . . . . . . . . . . . . . . . . . .18-1830-4 Other Material . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6 Specifications . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6 Refrigerant Theory of Operation. . . . . . . . . . . . . . . . . .18-1830-7 R134a Refrigerant Cautions . . . . . . . . . . . . .18-1830-9 R134a Compressor Oil Charge Check . . . .18-1830-10 R134a Compressor Oil Removal . . . . . . . . .18-1830-11 TM1640 (15JAN04)
R134a Component Oil Charge . . . . . . . . . .18-1830-12 Leak Testing . . . . . . . . . . . . . . . . . . . . . . . .18-1830-13 Refrigerant Hoses and Tubing Inspection . . . . . . . . . . . . . . . . . . . . . . . .18-1830-13 R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure . . . . . . . . .18-1830-14 Recover R134a System . . . . . . . . . . . . . . .18-1830-15 Evacuate R134a System . . . . . . . . . . . . . . .18-1830-16 Charge R134a System . . . . . . . . . . . . . . . .18-1830-18 Air Conditioner System Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . .18-1830-19 Air Conditioner System Purge. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-20 Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-21 Blower/Air Conditioner Harness (W20) Component Location . . . . . . . . . . . . . . . .18-1830-24 Blower/Air Conditioner Harness (W20) Connectors . . . . . . . . . . . . . . . . . . . . . . .18-1830-26 Heater/Evaporator Coil Air Conditioning Module. . . . . . . . . . . . . .18-1830-28 Remove and Install . . . . . . . . . . . . . . . . .18-1830-30 Expansion Valve Remove and Install . . . . . . . . . . . . . . . . .18-1830-33 Freeze Control Switch Remove and Install . . . . . . . . . . . . . . . . .18-1830-34 Bench Test . . . . . . . . . . . . . . . . . . . . . . .18-1830-35 Heater Control Valve Remove and Install . . . . . . . . . . . . . . . . .18-1830-36 Leak Check . . . . . . . . . . . . . . . . . . . . . . .18-1830-37 Main Blower Assembly Remove and Install . . . . . . . . . . . . . . . . .18-1830-37 Pressurizer Motor Assembly Remove and Install . . . . . . . . . . . . . . . . .18-1830-40 Receiver-Dryer and Condenser Remove and Install . . . . . . . . . . . . . . . . .18-1830-41 High and Low Pressure Switches Remove and Install . . . . . . . . . . . . . . . . .18-1830-42 Fresh Air Filter Remove and Install . . . . . . . . . . . . . . . . .18-1830-43 Recirculating Air Filter Remove and Install . . . . . . . . . . . . . . . . .18-1830-46 Compressor Remove and Install . . . . . . . . . . . . . . . . .18-1830-48
18
18-1

011504
PN=1
Contents
Page
Compressor Clutch Disassemble and Assemble. . . . . . . . . . .18-1830-50 Compressor Check Clutch Hub Clearance. . . . . . . . . .18-1830-51 Compressor Manifold Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-52 Compressor Disassemble, Inspect and Assemble . . . .18-1830-53 Group 1899Dealer Fabricated Tools DFRW20 Compressor Holding Fixture. . . . . .18-1899-1
18
TM1640 (15JAN04)
18-2

011504
PN=2
Group 1800

Essential Tools

T6585NN UN03NOV88
CED,OUOE003,2705 1930MAR991/2
Lifting Brackets . . . . . . . . . . . . . . . . . . . . . . . JT01748 To be used with hoist to lift cab.
18 1800 1
CED,OUOE003,2705 1930MAR992/2
Specifications
Cab Cab Mounting Cap Screw
Weight Torque
CED,OUOE003,2706 1930MAR991/1
TM1640 (15JAN04)
18-1800-1

011504
PN=407
Remove and Install Cab or Canopy

Cab or canopy can be removed for servicing of transmission and hydraulic pumps. 1. Stop engine. 2. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds.
18 1800 2
CAUTION: Prevent unexpected machine movement and possible injury. Install frame locking bar before working in frame hinge area. 3. Install frame locking bar. 4. Turn battery disconnect switch OFF (if equipped) or disconnect battery ground. 5. Remove steps and platforms from both sides of machine. 6. Remove front, left and right bottom cab shields.
TX,1800,111302 1928SEP981/8
TM1640 (15JAN04)
18-1800-2

011504
PN=408

7. Remove two defroster ducts (A) located under front of cab floor. 8. Remove throttle cable under cab front right side. 9. Remove windshield wiper/washer hoses. 10. Remove brake accumulator line-to-pressure reducing valve.
ADefroster Duct (2 used)
18 1800 3
TX,1800,111302 1928SEP982/8
11. Remove breather (A) from hydraulic reservoir plug breather port and pull a vacuum on hydraulic reservoir.
ABreather
UN21MAY96
TX,1800,111302 1928SEP983/8
TM1640 (15JAN04)
18-1800-3

011504
PN=409
T101206
T104544B
UN07MAR97
18 1800 4
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 12. Disconnect the five hoses (A) from steering valve. Plug and cap hoses.
ASteering Valve Hose (5 used)
TX,1800,111302 1928SEP984/8
13. Disconnect brake valve return hose (A) and brake valve work port hoses (B). Plug and cap hoses.
ABrake Valve Return Hose BBrake Valve Work Port Hose (2 used)
UN24MAR97
TX,1800,111302 1928SEP985/8
TM1640 (15JAN04)
18-1800-4

011504
PN=410
T107920B
T104543C
UN07MAR97
X9811
UN23AUG88

14. Disconnect hydraulic hoses from hydraulic pilot controllers.
TX,1800,111302 1928SEP986/8
T104524B
UN12DEC96
NOTE: Machines equipped with air conditioning will require that the A/C system be evacuated. See R134a Refrigerant Recovery/Recycling and Charging procedure in Group 1830. Disconnect A/C hoses under cab, not shown.
15. Shut off heater hose shut off valves on engine. Disconnect heater hoses under cab. Disconnect three wiring connectors (A) on right side of cab and wiring connectors to loader frame (B) and disconnect the red, white and black wires from starter. CAUTION: Cab weighs approximately 771 kg (1700 lb).
Specification CabWeight ............................................... 771 kg (1700 lb) approximate
UN07MAR97
18 1800 5
16. Remove four cap screws from top of cab roof and install four JT01748 Lifting Brackets to the cab roof. Attach chains and hoist to lifting brackets. 17. Remove cab mounting cap screws. 18. Remove cab. 19. Do necessary repairs. 20. Inspect cab mounting parts. Replace as needed.
AWiring Connector (3 used) BWiring Connector (4 used)
TX,1800,111302 1928SEP987/8
TM1640 (15JAN04)
18-1800-5

011504
PN=411
T104544C
UN24OCT96
T104541D

21. Install cab. Install and tighten mounting cap screws.
Specification Cab Mounting Cap Screw Torque ....................................................................... 1150 Nm (850 lb-ft)
22. Remove lifting brackets from cab roof and install cap screws. 23. Connect wiring connectors and red, white and black wires to starter. 24. Connect heater hoses and turn on heater shutoff valves. 25. Connect hydraulic pilot controller hoses. 26. Connect brake valve return hose and brake valve work port hoses.
1927MAR97
18 1800 6
27. Connect steering valve hoses. 28. Remove plug from reservoir and install breather. 29. Install defroster ducts. 30. Install front, left and rear bottom cab shields. 31. Install steps and platforms. 32. Turn battery disconnect switch ON (if equipped) or connect battery ground strap. 33. Bleed brakes. (See procedure in Group 1060.)
1Nut (2 used) 2Washer (6 used) 3Washer (4 used) 4Rubber Mount (4 used) 5Cap Screw (M24 x 150) (2 used) 6Cap Screw (M24 x 120) (2 used)
TX,1800,111302 1928SEP988/8
TM1640 (15JAN04)
18-1800-6

011504
PN=412
T108598
Group 1810
Operator Enclosure
Other Material
Number Name Use
TY9375 (U.S.) TY9480 (Canadian) 592 (LOCTITE)
Pipe Sealant
To seal threads of washer tank fittings.
CED,OUOE003,2707 1930MAR991/1
Specifications
18 1810 1
Wiper Arm Mounting Nut
Torque
89 Nm (7286 lb-in.)
CED,OUOE003,2708 1930MAR991/1
TM1640 (15JAN04)
18-1810-1

011504
PN=413
Operator Enclosure
Remove and Install Windowpanes

The adhesive used to hold the windowpanes in place is a urethane adhesive that is used on most automobile windshields. Urethane adhesive manufactured by Loctite Corporation or equivalent is recommended. DO NOT use any other type of adhesive. It is also recommended that an auto glass dealer install the windowpanes. IMPORTANT: Windowpanes must have an ultra-violet barrier around the edge of the glass since ultra-violet rays will deteriorate the adhesive. Windowpanes ordered through John Deere Parts have the ultra-violet barrier. If the windowpane is purchased through a glass dealer, the dealer must put an ultra-violet barrier on the glass. DO NOT apply paint to the border of the glass. If an auto glass dealer is not installing the windowpanes, use the following procedure: 1. Purchase urethane adhesive from your local auto glass dealer. 2. If window frame is removable, remove frame from cab. 3. Scrape broken glass off existing adhesive. DO NOT remove adhesive from window frame or cab. IMPORTANT: Adhesive will not stick to bare metal. 4. If existing adhesive is removed from frame and paint is scraped off window frame, paint window frame. Paint must be fully cured before installing windowpane. 5. Trim existing adhesive so it has a smooth surface. 6. Follow the manufacturers instructions for using the adhesive. 7. Apply a 6 mm (1/4 in.) bead of adhesive on top of the existing adhesive. 8. Put a new windowpane into position. Use hand pressure to force windowpane down around the edges until even with metal frame. 9. If windowpane is installed directly on cab, use duct tape to hold it in place while adhesive cures. 10. Allow adhesive to cure for 24 hours before operating machine.
18 1810 2
T52,1810,C19 1905JUN981/1
TM1640 (15JAN04)
18-1810-2

011504
PN=414
Operator Enclosure
18 1810 3
TM1640 (15JAN04)
18-1810-3

011504
PN=415
Operator Enclosure
Remove and Install Windshield Washer
18 1810 4
TX,18,1111061 1930MAR991/2
TM1640 (15JAN04)
18-1810-4

011504
TP60279
UN23MAR98
PN=416
Operator Enclosure
1Elbow Fitting (2 used) 2Tie Band (As Required) 3Hose 4Hose 5Pump (2 used) 6Hose (2 used) 7Washer (As Required) 8Tank 9Cap 10Grommet (2 used) 11Flange Nut (4 used) 12Tank
Apply pipe sealant to threads of washer tank fittings.
Cut washer hoses from bulk stock.
TX,18,1111061 1930MAR992/2
18 1810 5
TM1640 (15JAN04)
18-1810-5

011504
PN=417
Operator Enclosure
Remove and Install Front and Rear Windshield Wiper Motor
18 1810 6
124 Volt Motor (2 used) 2Bracket (2 used) 9Washer (2 used) 10Nut (2 used)
12Weld Nut (2 used) 13Washer (2 used) 14Nut (2 used) 15Pivot
19Link 22Nut (2 used) 23Crank 24Washer (2 used)
25Screw with Washer 28Motor 29Screw (4 used)
TX,18,111317 1905JUN981/2
TM1640 (15JAN04)
18-1810-6

011504
PN=418
TP55440
UN14MAR97
Operator Enclosure
18 1810 7
1. Disconnect wiring harness connector from wiper motor. 2. Remove and disassemble parts as shown. 3. Install wiper motor.
4. Connect cab work light harness connector to rear wiper motor.
NOTE: Also reference Front Console Harness Component Location in Group 1674.
5. Connect front console harness connector to front wiper motor.
NOTE: Also reference Cab Work Light Harness Component Location in Group 1674.
TX,18,111317 1905JUN982/2
TM1640 (15JAN04)
18-1810-7

011504
PN=419
T109424
1906MAY97
Operator Enclosure
Adjust Front Windshield Wiper

CAUTION: Keep hands away from linkage when the motor is in operation. DO NOT adjust park position when the motor is in operation. Never start a windshield wiper when the blade is frozen to the windshield or manually stop the blade when the wiper is operating. 1. If the blade does not park in the required position, adjust the wiper blade.
18 1810 8
2. Loosen nut. 3. Reposition drive arm on shaft. 4. Tighten nut.

Specification Wiper Arm Mounting NutTorque .................... 89 Nm (7286 lb-in.)
5. Start wiper motor, shut it off and note the new park position. 6. If blade does not park in the correct position, repeat steps 2 through 6 until the correct park position is obtained.
TX,1810,RB128 1905JUN981/1
TM1640 (15JAN04)
18-1810-8

011504
PN=420
Operator Enclosure
18 1810 9
TM1640 (15JAN04)
18-1810-9

011504
PN=421
Operator Enclosure
Remove and Install Wrist Support
18 1810 10
TX,18,111318 1905JUN981/2
TM1640 (15JAN04)
18-1810-10

011504
PN=422
TP34968
UN01JAN94
Operator Enclosure
1Plate 2Nut 3Rod 4Groove Pin 5Cotter Pin 6Bushing 7Lock Washer 8Nut 9Spring 10Washer 11Nut 12Wrist Support Assembly
TX,18,111318 1905JUN982/2
18 1810 11
TM1640 (15JAN04)
18-1810-11

011504
PN=423
Operator Enclosure
18 1810 12
TM1640 (15JAN04)
18-1810-12

011504
PN=424
Group 1821
Seat and Seat Belts

Disassemble and Assemble Seat Belt
18 1821 1
1Seat Belt
2Hardware Kit
3Cover
4Screw (4 used)
TX,1821,RB205 1931MAR991/1
TM1640 (15JAN04)
18-1821-1

011504
PN=425
TP55745
UN26NOV97
Seat and Seat Belts
Disassemble and Assemble Seat
18 1821 2
1Armrest 2Support Bracket 3Seat Back
4Extension 5Support Bracket 6Armrest
7Seat Suspension 8Cushion
9Seat and Suspension Assembly
TX,18,1111073 1918FEB991/1
TM1640 (15JAN04)
18-1821-2

011504
TP55557
UN12JUN97
PN=426
Group 1822
Steps and Handholds
18 1822 1
TM1640 (15JAN04)
18-1822-1

011504
PN=427
Steps and Handholds
Remove and Install Access Platform and Steps
18 1822 2
TX,18,1111062 1918FEB991/2
TM1640 (15JAN04)
18-1822-2

011504
TP55779
UN08JAN98
PN=428
Steps and Handholds

1Platform 2Screw (4 used) 3Strap (2 used) 4Step 5Strap (4 used) 6Screw (8 used) 7Lock Nut (8 used) 8Washer (4 used)
TX,18,1111062 1918FEB992/2
18 1822 3
TM1640 (15JAN04)
18-1822-3

011504
PN=429
Steps and Handholds
Remove and Install Engine Compartment Step
18 1822 4
1Lock Nut (8 used) 2Strap (2 used)
3Strap (4 used)
4Screw (8 used)
5Step
TX,18,1111063 1918FEB991/1
TM1640 (15JAN04)
18-1822-4

011504
PN=430
TP60270
UN18MAR98
Steps and Handholds
Remove and Install Mounted Step
18 1822 5
1Step 2Washer (4 used)
3Screw (4 used) 4Screw (8 used)
5Strap (4 used) 6Lock Nut (8 used)
7Strap (2 used) 8Step

TX,18,1111074 1918FEB991/1
TM1640 (15JAN04)
18-1822-5

011504
TP55693
UN14OCT97
PN=431
Steps and Handholds
18 1822 6
TM1640 (15JAN04)
18-1822-6

011504
PN=432
Group 1830
Heating and Air Conditioning

Essential Tools

T7530AZ UN29MAY91
CED,OUOE003,2710 1931MAR991/10
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . D05267ST To evacuate air conditioning system.
18 1830 1
CED,OUOE003,2710 1931MAR992/10
R134a Refrigerant Recovery/Recycling and Charging Station . . . . . . . . . . . . . . . . . . . . . . . . . . . JT020451 Servicing air conditioning system using R134a refrigerant.
UN17AUG92
1 JT02046 and JT02050 Recovery and Charging Stations can be substituted for the JT02045 Station.
CED,OUOE003,2710 1931MAR993/10
Air Conditioning Flusher . . . . . . . . . . . . . . . . . JT02075 To flush air conditioning system.
CED,OUOE003,2710 1931MAR994/10
TM1640 (15JAN04)
18-1830-1

011504
PN=433
T109996
UN19JUN97
RW21613

Air Conditioning Flushing Fitting Kit. . . . . . . . . . JT02098 Used with JT02075 to flush air conditioning system.
CED,OUOE003,2710 1931MAR995/10
18 1830 2
RW19934 UN19MAY92
A/C Compressor Clutch Spanner . . . . . . . . . . . JDG747 Used to remove compressor clutch.
CED,OUOE003,2710 1931MAR996/10
Puller Adapter . . . . . . . . . . . . . . . . . . . . . . . JDG220 Used with JDG748 and JDG771 to remove compressor pulley.
CED,OUOE003,2710 1931MAR997/10 RW19935 UN19MAY92
Jaws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG748 Used with JDG220 and JDG771 to remove compressor pulley.
CED,OUOE003,2710 1931MAR998/10
Hub Protector . . . . . . . . . . . . . . . . . . . . . . . . JDG771 Used with JDG220 and JDG748 to remove compressor pulley.
CED,OUOE003,2710 1931MAR999/10 RW19943 UN19MAY92
Compressor Seal Protector . . . . . . . . . . . . . . . JDG746 Used to install seal on compressor.
CED,OUOE003,2710 1931MAR9910/10
TM1640 (15JAN04)
18-1830-2

011504
PN=434
T109995
UN19JUN97

CED,OUOE003,2711 1931MAR991/4
Manifold Pressure Gauge Assembly . . . . . . . . . JT02051 To purge air conditioner system.
18 1830 3
CED,OUOE003,2711 1931MAR992/4
Compressor Holding Fixture . . . . . . . . . . . . . DFRW201 To hold air conditioning compressor during disassembly and assembly.
1 Fabricated tool, dealer made. (See Group 1899 for instructions to make tool.)
CED,OUOE003,2711 1931MAR993/4
Bench Mounted Holding Fixture . . . . . . . . . . D01006AA Used to hold compressor during repair.
CED,OUOE003,2711 1931MAR994/4
TM1640 (15JAN04)
18-1830-3

011504
PN=435
Air Conditioning System Fittings Reference Chart
18 1830 4
ACompressor BCondenser
CReceiver-Dryer
DExpansion Valve
EEvaporator
The JT02098 Flush Fitting Kit contains fittings for flushing or leak testing sections or individual components to the air conditioning system. Following chart lists service fittings used at each specific location.
TX,9031,MM2887 1912SEP961/2
TM1640 (15JAN04)
18-1830-4

011504
PN=436
T103692
UN16SEP96

Location Compressor Manifold: 1. Suction Port (F) 2. Discharge Port (F) Compressor Discharge Hose: 3. Inlet End (M) 4. Outlet End (F) Condenser: 5. Inlet Port (M) 6. Outlet Port (M) Condenser to Receiver-Dryer Hose: 7. Inlet End (F) 8. Outlet End (M) Receiver-Dryer: 9. Inlet Port (F) 10. Outlet Port (M) Receiver-Dryer to Evaporator Hose: 11. Inlet End (F) 12. Outlet End (M) A/C Inlet Tube 13. Inlet End (F) 14. Outlet End (M) Expansion Valve: 15. Liquid Inlet (F) 16. Liquid Outlet (F) 19. Gas Inlet (F) 20. Gas Outlet (F) Evaporator Coil: 17. Inlet Tube (M) 18. Outlet Tube (M) A/C Outlet Tube: 21. Inlet End (M) 22. Outlet End (F) Evaporator to Compressor Hose 23. Inlet End (M) 24. Outlet End (M) 1-1/1614 7/818 Not Available JT02101 R33259 3/4 1-1/1614 TEV and JT02105 Not Available T143169 T143169 1/2 5/8 JT02106 and JT02103 JT02106 and JT02105 R113050 R33259 3/8 1/2 5/8 3/4 JT02103 JT02104 JT02105 JT02147 5/818 3/8 JT03188 JT02106 and JT02104 R10093 R10093 5/818 5/818 JT03188 JT03183 R10093 5/818 5/818 JT03196 or JT02110 JT03183 5/818 5/818 JT03188 JT03197 R10093 R10093 18 1830 5 3/418 5/818 JT02102 JT03183 3/418 3/418 JT02102 JT02100 R113050 R113050 7/818 3/418 JT02099 JT02100 R113050 Size ServiceGard Number O-Ring Number
TX,9031,MM2887 1912SEP962/2
TM1640 (15JAN04)
18-1830-5

011504
PN=437
Other Material
Number Name Use
TY16134 (U.S.) TY22025 (8.5 oz) (U.S.)
R134a Flushing Solvent R134a Compressor Oil
Flush R134a air conditioning system. Lubricate R134a air conditioning system. Lubricate compressor O-rings, gaskets, and lip seal during assembly. Charge R134a air conditioning system. Charge R134a air conditioning system. Charge R134a air conditioning system.
TY15949 (12 oz) (U.S.)

18 1830 6
R134a Refrigerant
TY15950 (15 lb) (U.S.)
R134a Refrigerant
TY15951 (30 lb) (U.S.)
R134a Refrigerant
CED,OUOE003,2712 1931MAR991/1
Specifications
Freeze Control Switch Test Switch Opens Switch Closes Temperature Temperature -0.56 0.84C (31 1.5F) -2.22 0.84C (36 1.5F)
Compressor Compressor Through Bolt Compressor Suction Line Compressor Discharge Line Clutch Shaft Bolt Clutch Hub Compressor Manifold Cap Screw Torque Torque Torque Torque Clearance Torque 26 Nm (19 lb-ft) 31 Nm (23 lb-ft) 22 m (16 lb-ft) 14 Nm (120 lb-in.) 0.350.65 mm (0.0140.026 in) 26 Nm (19 lb-ft)
CED,OUOE003,2713 1931MAR991/1
TM1640 (15JAN04)
18-1830-6

011504
PN=438
Refrigerant Theory of Operation

The compressor (G) draws low pressure gas (H) from the evaporator (I) and compresses it into high pressure gas (F). This causes the temperature of the refrigerant to rise higher than that of the outside air. High pressure gas leaves the compressor and is sensed by the high pressure switch (K). The switch monitors refrigerant pressure. If the pressure becomes too high, the switch will open and stop the compressor, interrupting the cycle. As the high pressure gas flows through the condenser (E), heat is removed and transferred to the outside air being drawn through the condenser core by the condenser fan (D). Cooling the refrigerant causes it to condense and it leaves the condenser as a high pressure liquid (C). The high pressure liquid flows into the receiver-dryer (B) where moisture and contaminants (acid, solids, etc.) are removed. The receiver-dryer also acts as a reservoir for refrigerant. The refrigerant flows from the receiver-dryer to the expansion valve (J) and is sensed by the low pressure switch (A). The switch monitors refrigerant pressure. If the pressure becomes too low from refrigerant loss, the switch will open and stop the compressor, interrupting the cycle. The actual cooling and drying of cab air takes place at the evaporator. Flow of the high pressure liquid refrigerant is controlled by the expansion valve. The expansion valve causes the temperature and pressure of the refrigerant to drop, where it becomes a low pressure liquid (L). The expansion valve is a diaphragm-type valve that uses a variable orifice to control the flow of high pressure liquid refrigerant into the evaporator to maintain a constant pressure and temperature. (See Expansion Valve Operation in this group for additional information on theory of operation.) The blower motor (N) pulls a mixture of warm cab and outside air through the evaporator where it is cooled by the refrigerant. The heat absorbed by the evaporator causes the refrigerant to vaporize into a low pressure gas. A freeze control switch (M) senses temperature of the evaporator coil through a refrigerant filled capillary tube. The switch closes when the evaporator is above the switch setting and opens when the evaporator is cooled to the switch setting. The switch has a low temperature setting that prevents the evaporator from becoming cold enough to freeze moisture that condenses on the coil. Cab temperature is controlled by reheating the conditioned air by passing it through the heater coil. The heater coil temperature is controlled by regulating the amount of water flow through the heater coil with the water valve. The moisture, from the warm air, is condensed as it contacts the cool evaporator coil during the cooling process and is drained away through drain tubes connected to the drain pan under the evaporator. With the cab air cooled and dehumidified, the refrigerant cycle is complete.
18 1830 7
TX,05,MM2873 1918FEB991/2
TM1640 (15JAN04)
18-1830-7

011504
PN=439
18 1830 8
LLow Pressure Switch
TX,05,MM2873 1918FEB992/2
TM1640 (15JAN04)
18-1830-8

011504
PN=440
T103906
1906NOV96
R134a Refrigerant Cautions

CAUTION: DO NOT allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. If liquid refrigerant contacts eyes or skin, DO NOT rub the area. Splash large amounts of COOL water on affected area. Go to a physician or hospital immediately for treatment. DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element and lighted smoking materials. 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.
18 1830 9
TX,9031,SS3564 1911SEP961/1
TM1640 (15JAN04)
18-1830-9

011504
PN=441
R134a Compressor Oil Charge Check

Remove compressor if refrigerant is leaking from its seals, and repair is needed, or if compressor has failed. See Remove and Install Compressor in this group. Drain oil from the compressor and record the amount. See Compressor Oil Removal procedure in Group 9031-20. 3. Flush the complete system with TY16134 air conditioning flushing solvent. Go to Air Conditioning System Cleaning Procedures in this group. 4. If the compressor is serviceable, pour flushing solvent in the manifold ports and internally wash out the old oil. Go to Air Conditioning System Cleaning Procedures in this group. 5. Install a new receiver-dryer. 6. Install required amount of TY22025 refrigerant oil in the compressor. (See R134a Component Oil Charge in this group.) 7. Connect all components, evacuate and charge the system. Go to Evacuate R134a System and Charge R134a System in this group.
NOTE: Drain oil and save if this is a new compressor.

18 1830 10
If the oil drained from a compressor removed from operation is very black or the amount of oil is less than 6 mL (0.2 fl oz), perform the following: 1. Remove and discard the receiver-dryer. Go to Remove and Install Receiver-Dryer and Condenser in this group. 2. Remove, clean, but do not disassemble the expansion valve. Go to Remove and Install Expansion Valve in this group.
TX,9031,SS4004 1922APR991/1
TM1640 (15JAN04)
18-1830-10

011504
PN=442
R134a Compressor Oil Removal

1. Remove compressor from machine. See Remove and Install Compressor in this group. 2. Remove inlet/outlet manifold from compressor, and clutch dust cover. 3. Drain oil into graduated container while rotating compressor shaft. 4. Record measured oil and discard oil properly. 5. Install new oil. See R134a Component Oil Charge in this group. 6. Install compressor. See Remove and Install Compressor in this group.
18 1830 11
TX,9031,SS3593 1922APR991/1
TM1640 (15JAN04)
18-1830-11

011504
PN=443
R134a Component Oil Charge

CAUTION: All new compressors are charged with a mixture of nitrogen, R134a refrigerant and TY22025 (R134a) refrigerant oil. Wear safety goggles and discharge the compressor slowly to avoid possible injury. Compressors can be divided into three categories when determining the correct oil charge for the system. New compressor from parts depot Used compressor removed from operation Compressor internally washed with flushing solvent Use the following procedure to determine the amount of system oil charge prior to installation of compressor on a machine. 1. When the complete system, lines, and components were flushed add the correct amount of oil as described. New compressor from parts depot contains the amount of new oil of 230 20 mL (7.7 .7 fl oz). System requires an additional amount of new oil of 135 mL (4.58 fl oz) of new oil. Used compressor removed from operation, oil drained, and flushed requires 365 mL (12.35 fl oz) of new oil. 2. When the complete system was not flushed add the correct amount of oil for the compressor plus the amount of oil for each component that was serviced. New compressor from parts depot, drain and return 45 mL (1.5 fl oz) of oil to the compressor. (See Compressor Oil Removal procedure in this group.) Used compressor removed from operation and oil drained. (See Compressor Oil Removal procedure in this group.) Add 45 mL (1.5 fl oz) of new oil. Used compressor removed from operation, oil drained, and flushed. Add 60 mL (2.0 fl oz) of new oil.
18 1830 12
NOTE: Components listed below which have been removed, drained or flushed, require the removal of the compressor to determine the correct oil charge. Use the following chart as a guide for adding oil to components:
Evaporator Condenser Receiver-Dryer Hoses 158 mL (5.4 fl oz) 70 mL (2.4 fl oz) 37 mL (1.25 fl oz) 73 mL (2.5 fl oz)
NOTE: Hoses = 3 mL per 30 cm (0.1 fl oz per ft). Approximate total length equals 727 cm (24 ft)
If any section of hose is removed and flushed or replaced, measure the length of hose and use the formula to determine the correct amount of oil to be added. CAUTION: DO NOT leave the system or R134a compressor oil containers open. This oil easily absorbs moisture. DO NOT spill R134a compressor oil on acrylic or ABS plastic. This oil will deteriorate these materials rapidly. Identify R134a oil containers and measures to eliminate accidental mixing of different oils.
TX,1830,111266 1928SEP981/1
TM1640 (15JAN04)
18-1830-12

011504
PN=444
Leak Testing
1. Inspect all lines, fittings and components for oily or dusty spots. When refrigerant leaks from the system, a small amount of oil is carried out with it. 2. A soap and water solution can be sprayed on the components in the system to form bubbles at the source of the leak. 3. If a leak detector is used, move the leak detector probe under the hoses and around the connections at a rate of 25 mm (1 in.) per second. 4. Some Freon manufacturers add dye to Freon to aid in leak detection.
TX,1830,MM3175 1919OCT961/1
Refrigerant Hoses and Tubing Inspection

IMPORTANT: Hose used for air conditioning systems contains special barriers in its walls to prevent migration of refrigerant gas. DO NOT use hydraulic hoses as replacement hoses in the air conditioning system. Use ONLY certified hose meeting SAE J51b requirements. When a component is disconnected from the system, special care should be given to inspecting hoses and tubing for moisture, grease, dirt, rust, or other foreign material. If such contamination is present in hoses, tubing, or fittings and cannot be removed by cleaning, then replace parts. Fittings that have grease or dirt on them should be wiped clean with a cloth dampened with alcohol. Chlorinated solvents (such as trichloroethylene) are contaminants, and must not be used for cleaning. To assist in making leak-proof joints in R134a systems, use a small amount of clean polyakyleneglycol (PAG) refrigerant oil on all hoses and tube connections. Dip O-rings in PAG oil before assembly.
18 1830 13
TX,1830,MM3176 1919OCT961/1
TM1640 (15JAN04)
18-1830-13

011504
PN=445
R134a Refrigerant, Recovery, Recycling and Charging Station Installation Procedure

ESSENTIAL TOOLS JT02045a R134a Refrigerant Recovery/Recycling and Charging Station
a
JT02046 and JT02050 Recovery and Charging Stations can be substituted for the JT02045 Station.
CAUTION: Do not remove high pressure relief valve (A). Air conditioning system will discharge rapidly causing possible injury.
18 1830 14
IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Close both high and low pressure valves on refrigerant recovery, recycling and charging station (H). 2. Remove cap from low pressure test port (G). 3. Connect low pressure blue hose (D) from refrigerant recovery, recycling and charging station (H) to low pressure test port (G) on compressor. 4. Connect high pressure red hose (C) to high pressure quick disconnect (B). 5. Follow the manufactures instructions when using the refrigerant recovery, recycling and charging station.
AHigh Pressure Relief Valve BHigh Pressure Test Port CRed Hose DBlue Hose EHigh Pressure Hose FLow Pressure Hose GLow Pressure Test Port HRefrigerant Recovery/Recycling and Charging Station
TX,9031,QQ3015 1907MAR951/1
TM1640 (15JAN04)
18-1830-14

011504
PN=446
T8422AC
1922FEB95
Recover R134a System

ESSENTIAL TOOLS JT02045 R134a Refrigerant Recovery/Recycling and Charging Station
a a
CAUTION: Do not remove high pressure relief valve (A). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils.
18 1830 15
2. Follow the manufacturers instructions when using the refrigerant recovery, recycling and charging station.
TX,9031,QQ3016 1907OCT981/1
TM1640 (15JAN04)
18-1830-15

011504
PN=447
T8422AC
1. Connect refrigerant recovery, recycling and charging station. (See installation procedure in this group.)
1922FEB95
NOTE: Run the air conditioning system for three minutes to help in the recovery process. Turn air conditioning system off before proceeding with recovery steps.
Evacuate R134a System

ESSENTIAL TOOLS JT02045 R134a Refrigerant Recovery/Recycling and Charging Station D05267ST Vacuum Pump
a a
CAUTION: Do not remove high pressure relief valve (A). Air conditioning system will discharge rapidly causing possible injury.
18 1830 16
IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. Do not run compressor while evacuating. 1. Connect refrigerant recovery, recycling and charging station. (See installation procedure in this group.) 2. Open low and high pressure valves on refrigerant recovery, recycling and charging station. 3. Follow the manufacturers instructions and evacuate the system.
NOTE: The vacuum specifications listed are for sea level conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.
4. Evacuate system until low pressure gauge registers 98 kPa (980 mbar) (29 in. Hg) vacuum. If 98 kPa (980 mbar) (29 in. Hg) vacuum cannot be obtained in 15 minutes, test the system for leaks. (See Leak Testing, 9031-25). Correct any leaks. 5. When vacuum is 98 kPa (980 mbar) (29 in. Hg), close low-side and high-side valves. Turn vacuum pump off.
TX,9031,QQ3017 1907OCT981/2
TM1640 (15JAN04)
18-1830-16

011504
PN=448
T8422AC
1922FEB95

6. If the vacuum decreases more than 3.4 kPa (34 mbar) (1 in. Hg) in 5 minutes, there is a leak in the system. 7. Repair leak. 8. Start to evacuate. 9. Open low-side and high-side valves. 10. Evacuate system for 30 minutes after 98 kPa (980 mbar) (29 in. Hg) vacuum is reached. 11. Close low-side and high-side valves. Stop evacuation. 12. Charge the system. (See procedure in this group.)
18 1830 17
TX,9031,QQ3017 1907OCT982/2
TM1640 (15JAN04)
18-1830-17

011504
PN=449
Charge R134a System

CAUTION: Do not remove high pressure relief valve (A). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Connect JT02045 R134a refrigerant recovery, recycling and charging station. (See installation procedure in this group.) 2. Evacuate the system. (See Evacuate Air Conditioning System in this group.)
18 1830 18
3. Follow the manufacturers instructions and charge the system. 4. Add refrigerant until system is charged with 2.381 kg (5.25 lb). 5. Do air conditioner checks and tests in Groups 9031-10 and 9031-25.
TX,1830,111267 1928SEP981/1
TM1640 (15JAN04)
18-1830-18

011504
PN=450
T8422AC
NOTE: Before beginning to charge air conditioning system, the following conditions must exist: Engine STOPPED, the pump must be capable of pulling at least 28.6 in. Hg vacuum (sea level). Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.
1922FEB95
Air Conditioner System Cleaning Procedures

Flushing: Flushing the system or component is a cleaning process using a liquid solvent to remove oil and debris. Purging is always necessary after flushing to remove solvent from the system or component. Following is a list of situations that require a flushing procedure be done: The compressor has an internal failure. No oil remains in used compressor. Oil drained from compressor appears or smells overheated. System was contaminated with a mixture of refrigerant oils. System was left open to the atmosphere long enough for dirt, moisture, or debris to enter the tubing or components. System has an internal blockage. The following solvent is recommended for flushing air conditioner systems. Use only solvents with an equivalent MSDS. TY16134 John Deere Air Conditioning System Flushing Solvent Purging: Purging the system or a component is a cleaning process using a gas to force liquid from the system. Purging alone will not remove refrigerant oil from the system. Following is a list of situations that require a purging procedure be done: After flushing system with solvent, to prevent oil dilution System was contaminated with nitrogen or two refrigerants. System was left open to the atmosphere and flushing could not be performed. Installation of new lines, condenser, or evaporator was required. Evacuating: Evacuating the system is a process to remove air and moisture from the system, creating a vacuum.
18 1830 19
TX,1830,MM3158 1917OCT961/1
TM1640 (15JAN04)
18-1830-19

011504
PN=451
Purge Air Conditioner System

IMPORTANT: Air compressors used for purging systems require a water separator. Purging without a separator adds moisture, creating hydrofluoric acid when combined with refrigerant oil. Acid is corrosive to metal tubing. 1. Connect dry nitrogen hose to gauge manifold center hose.
18 1830 20
2. Connect gauge manifold suction hose to compressor suction port, and open valves. 3. Connect gauge manifold discharge hose to compressor discharge post, and open valve. Disconnect discharge hose from gauge manifold to allow purging nitrogen to atmosphere. 4. Open nitrogen tank valve and adjust regulator to 275 kPa (40 psi) (2.75 bar). Purge system for two minutes. Disconnect nitrogen supply. 5. Evacuate system. (See procedure in this group.)
TX,1830,MM3156 1914OCT981/1
TM1640 (15JAN04)
18-1830-20

011504
PN=452
Flush Air Conditioner System

Add flushing solvent to system with JT02075 Flusher and JT02098 Fitting Kit. IMPORTANT: DO NOT attempt to flush through compressor or receiver-dryer. Flushing through expansion valve is acceptable if refrigerant oil has normal odor and appearance. 6. To Flush/Purge Condenser: 2. Remove compressor and measure oil drained from both manifold ports. 3. Clean compressor as follows: a. Pour 240 mL (8 fl oz) of flushing solvent into suction port and 120 mL (4 fl oz) into discharge port. Plug both ports in compressor manifold using JT02099 and JT02100 with JT03194 Caps. b. Turn compressor end for end and roll it side to side. c. Remove both plugs from manifold ports and drain solvent from compressor. d. Connect battery power to compressor clutch coil. Rotate pulley at least five revolutions to move solvent out of cylinders. e. Invert compressor, roll end for end, and side to side. Drain thoroughly. f. Let compressor sit inverted for three to five minutes. g. Repeat previous two steps at least three times. 4. Remove and discard receiver-dryer. 5. Divide system into two circuits: a. Condenser, including inlet and outlet hoses. (Steps 612) b. Evaporator, including inlet and outlet hoses. (Steps 1326) 7. Attach a return hose and aerator nozzle to outlet end of receiver-dryer inlet hose using JT03197 reducer. Put nozzle in container to collect flushing solvent. 8. Fill flusher tank with 4 L (1 gal) of solvent and fasten all connections.
18 1830 21
NOTE: Flushing can be performed on vehicle.

1. Recover refrigerant. (See procedure in this group.)
Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter.
NOTE: Air pressure must be at least 620 kPa (6.2 bar) (90 psi) for flushing and purging.
9. Connect a supply line of moisture-free compressed air or dry nitrogen to flusher air valve. 10. Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing stops. Additional flushing cycles are required if system is heavily contaminated with burned oil or metal particles.
NOTE: Purging the condenser circuit takes 1012 minutes to thoroughly remove solvent.
11. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard; continue purging until cardboard is dry. 12. Go to step 13 to flush evaporator. Go to step 22 if evaporator does not require flushing. 13. To Flush Evaporator:
TX,1830,MM3159 1914OCT981/2
TM1640 (15JAN04)
18-1830-21

011504
PN=453

If system is contaminated with burned refrigerant oil or debris, remove and bench flush evaporator. Go to step 18 to flush evaporator through expansion valve, if oil appears normal. Remove evaporator. (See procedure in this group.) 14. Force flushing solvent through evaporator inlet with compressed air. 15. Purge system until dry. 16. Reinstall evaporator.
18 1830 22
20. Repeat Steps 8, 9 and 10 to flush evaporator.
NOTE: Purging the evaporator circuit takes 1215 minutes to thoroughly remove solvent.
21. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard. Continue purging until cardboard is dry. 22. Install a new receiver-dryer compatible with R134a refrigerant. Fasten connections and mounting bracket. 23. Add required oil. (See procedure in this group.) 24. Install compressor, and connect refrigerant lines to manifold. 25. Connect clutch coil wire. Install drive belt. 26. Purge system. (See procedure in this group.)
17. Go to Step 22. 18. To Flush Evaporator Through Expansion Valve: Connect flusher outlet hose to connection of receiver-dryer outlet hose using JT03188 Adapter. 19. Attach a hose and aerator nozzle to compressor inlet line using JT02101 Adapter. Put nozzle in a container to collect solvent.
TX,1830,MM3159 1914OCT982/2
TM1640 (15JAN04)
18-1830-22

011504
PN=454
18 1830 23
TM1640 (15JAN04)
18-1830-23

011504
PN=455
Blower/Air Conditioner Harness (W20) Component Location

T110709 1904SEP97
TX,1830,111268 1922OCT961/2
TM1640 (15JAN04)
18-1830-24

011504
PN=456

ATemperature Control Switch BBlower Speed Switch (S21) CAir Conditioning On/Off Switch (S22) DPressurizer Motor 7.5A Fuse (F20) EBlower/Pressurizer Motor Relay (K19) FBlower Motor 25A Fuse (F19) GReceiver/Dryer HAir Conditioning Clutch 1 A Diode (V11) ICondenser JCompressor Relief Valve KAir Conditioning Compressor Clutch (Y16) LExpansion Valve MAir Conditioning Low Pressure Switch (B36) NHeater Valve OPressurizer Motor (M7) PFresh Air Filter QRecirculating Air Filter RAir Conditioning High Pressure Switch (B37) SHeating/Evaporator Coil TFreeze Control Switch (B35) UAir Ducts VBlower Speed Resistor (R3) WMain Blower Motor (M6) XService and Charge Port
TX,1830,111268 1922OCT962/2
18 1830 25
TM1640 (15JAN04)
18-1830-25

011504
PN=457
Connectors for Blower/Air Conditioner Harness (W20)
18 1830 26
TX,1830,MM3178 1922OCT961/1
TM1640 (15JAN04)
18-1830-26

011504
PN=458
T101385
1931JUL96
18 1830 27
TM1640 (15JAN04)
18-1830-27

011504
PN=459
Air Conditioning Module With Heater/Evaporator Coil
18 1830 28
CED,OUOE003,1031 1916DEC981/2
TM1640 (15JAN04)
18-1830-28

011504
PN=460
TP60423
UN18JUN98

1Nut (14 used) 2Seal (2 used) 3Impeller (2 used) 4Pressurizer Blower Motor 5Cap Screw (14 used) 6Tube (2 used) 7Screw (2 used) 8Clamp (8 used) 9Tube (2 used) 10Bracket 11Air Duct 12Tie Band (4 used) 13Clip (2 used) 14Thermostat 15Air Duct 16Air Plenum 17Screw (2 used) 18Resistor 19Cover 20Housing 21Screw (12 used) 22Isolator (3 used) 23Air Filter 24Nut 25Housing 26Latch (2 used) 27Rivet (4 used) 28Filter Element 29AC/Heater Main Blower Motor 30Seal 31Heater/Evaporator Coil 32Air Duct 33Valve Hose 34Knob 35Bolt (2 used) 36Heater Hose 37Expansion Valve Plate 38Housing 39Heater Valve 40Expansion Valve 41Valve Hose 42Tube 43Clamp (4 used) 44Heater Tube 45A/C Suction Tube 46A/C Inlet Tube 47A/C High Pressure Switch 48Cap Screw 49Adapter Plate 50Screw (4 used) 51Plug (2 used) 52O-Ring 53Ring 54O-Ring (3 used) 55O-Ring (3 used) 56A/C Lower Pressure Switch 57Grommet 58Grommet 59Clip 60Cable 61Lock Washer 62Nut 63Knob 64Control 65Seal 66Bushing 67Gasket 68Hose (As Required) 69Clamp 70Blower
18 1830 29
CED,OUOE003,1031 1916DEC982/2
TM1640 (15JAN04)
18-1830-29

011504
PN=461
Remove and Install Heater/Evaporator Coil
18 1830 30
APressurizer Motor BInlet Plenum CExpansion Valve DFreeze Control Switch
EResistor FMain Blower Motor GHeater/Evaporator Coil Top Cover
HCap Screws ILower Housing JHeater/Evaporator Coil KHeater Hoses (2 used)
LHeater Valve MAir Conditioning Lines NHousing OKnob
1. Recover refrigerant from the system. (See Recover R134a System in this group.) 2. Open left-hand cab service door. Remove fresh air filter. (See Remove Fresh Air Filter in this group.) 3. Remove knob (O) to remove housing (N). 4. Remove rear cover behind seat. 5. Remove seat cap screws and move seat forward to access air conditioning/heater components. 6. Remove cab recirculating filter. (See Remove Recirculating Filter in this group.) 7. Remove upper two cap screws attaching inlet plenum (B) to heater/evaporator coil top cover (G).
8. Remove cab left-hand shelf. 9. Remove cap screws from heater/evaporator coil top cover (G); remove cover. 10. Remove freeze control switch (D) probe from coil. 11. Remove upper two cap screws from main blower motor (F). 12. Disconnect wire harness from freeze control switch (D) and resistor (E). 13. Shut off heater hose shut-off valves on engine. 14. Disconnect air conditioning lines (M) from expansion valve (C) and heater hoses (K) from coil.
TX,18,1111066 1918FEB991/4
TM1640 (15JAN04)
18-1830-30

011504
PN=462
T112116
UN04NOV97

15. Remove expansion valve. 16. Remove heater/evaporator coil (J). 17. Install expansion valve on heater/evaporator coil. 18. Check lower housing (I) to make sure drain tube is not plugged. 19. Install heater/evaporator coil. 20. Connect air conditioner lines and heater hoses. 21. Open heater hose shut-off valves on engine.
TX,18,1111066 1918FEB992/4
18 1830 31
TM1640 (15JAN04)
18-1830-31

011504
PN=463

22. Mount switch (A) to module. 23. Route freeze control switch line (B) as shown. Route under foam on module. IMPORTANT: Freeze switch line is a capillary tube filled with refrigerant. A generous bend radius is required to ensure proper operation. DO NOT kink freeze switch line when bending. 24. Carefully bend the end of the freeze control switch line at a 90 degree angle. Insert last 88.9 mm (3.5 in.) into evaporator core starting 190 mm (7.5 in.) from the left end and 114 mm (4.5 in.) from the bottom. Push freeze control switch line down into evaporator core at a 45 degree angle. Freeze switch line should slide smoothly between the tubes in the evaporator core. 25. Connect wire harness to freeze control switch and resistor. 26. Install main blower motor. 27. Install evaporator top cover and cab left-hand shelf. 28. Install inlet plenum to heater/evaporator coil top cover. 29. Install cab recirculating filter. 30. Install rear cover behind seat. 31. Move seat back and install and tighten cap screws. 32. Install housing and knob. 33. Install fresh air filter. 34. If the system is contaminated, each component in the system must be flushed and purged individually. (See procedures in this group.) 35. Drain oil from compressor. (See procedure in this group.)
UN08AUG97
18 1830 32
ASwitch BFreeze Control Switch Line
TX,18,1111066 1918FEB993/4
TM1640 (15JAN04)
18-1830-32

011504
PN=464
T110752D

36. If system was not completely flushed, see flushing procedure in this group. 37. Purge, evacuate, and charge the system. (See procedures in this group.)
TX,18,1111066 1918FEB994/4
Remove and Install Expansion Valve

1. Recover refrigerant from the system. (See Recover R134a System in this group.) 2. Open left-hand cab service door. Remove fresh air filter. (See Remove Fresh Air Filter in this group.) 3. Remove pressurizer motor (A). (See Pressurizer Motor, Remove in this group.) 4. Disconnect air conditioning lines (C) from expansion valve. 5. Remove expansion valve (B) and replace. 6. Apply refrigerant oil to new O-rings. Install expansion valve and new O-rings. 7. Connect air conditioning lines to expansion valve. 8. Install pressurizer motor. 9. Install fresh air filter. (See Install Fresh Air Filter in this group.) 10. Purge, evacuate, and charge the system. (See procedures in this group.)
UN04NOV97
18 1830 33
APressurizer Motor BExpansion Valve CAir Conditioning Lines
TX,18,1111067 1918FEB991/1
TM1640 (15JAN04)
18-1830-33

011504
PN=465
T112119
Remove and Install Freeze Control Switch

1. Remove rear cover behind seat. 2. Remove probe (B) of freeze control switch (A) from heater/evaporator coil. 3. Disconnect wire leads from freeze control switch and remove switch from cover. 4. Test freeze control switch. (See Bench Test Freeze Control Switch in this group.)
18 1830 34 AFreeze Control Switch BProbe
TX,1830,MM3162 1918FEB991/2
5. Attach freeze control switch (A) to heater/evaporator coil top cover. 6. Connect wiring leads to freeze control switch.
UN08AUG97
7. Route freeze control switch line (B) as shown. Route under foam on module. IMPORTANT: Freeze switch line is a capillary tube filled with refrigerant. A generous bend radius is required to ensure proper operation. DO NOT kink freeze switch line when bending. 8. Carefully bend the end of the freeze control switch line at a 90 degree angle. Insert last 88.9 mm (3.5 in.) into evaporator core starting 190 mm (7.5 in.) from the left end and 114 mm (4.5 in.) from the bottom. Push freeze control switch line down into evaporator core at a 45 degree angle. Freeze switch line should slide smoothly between the tubes in the evaporator core. 9. Install rear cover behind seat.
AFreeze Control Switch BFreeze Control Switch Line
TX,1830,MM3162 1918FEB992/2
TM1640 (15JAN04)
18-1830-34

011504
PN=466
T110752D
T103844
UN23SEP96
Bench Test Freeze Control Switch

1. Connect ohmmeter to freeze control switch terminals. Put end of probe into an ice and salt water solution.
UN08NOV88 T83921
2. Switch must open at test specification.

Freeze Control Switch TestSpecification Switch OpensTemperature ...................... -0.56 0.84C (31 1.5F)
3. Warm the water. 4. Switch must close at test specification.

Freeze Control Switch TestSpecification Switch ClosesTemperature ...................... -2.22 0.84C (36 1.5F)
18 1830 35
If switch operates within specifications, reinstall switch and connect leads. If switch does not operate within specifications, replace with new switch and connect leads.
TX,1830,MM3163 1914OCT981/1
TM1640 (15JAN04)
18-1830-35

011504
PN=467
Remove and Install Heater Control Valve

1. Open left-hand side door. Remove cab fresh air filter housing. (See Remove Fresh Air Filter in this group.) 2. Shut off the heater hose shut-off valves on the engine block. 3. Remove rear cover behind seat. 4. Disconnect temperature control switch cable from heater control valve.
18 1830 36
5. Disconnect hose (A). 6. Remove heater control valve (B) and test. (See Heater Control Valve Leak Check in this group.) 7. Inspect heater hoses and replace as required. IMPORTANT: Heater valve will leak if arrow on valve is not in the direction of coolant flow. 8. Install heater control valve with flow arrow (direction of coolant flow) on valve towards heater inlet (bottom port). 9. Connect the temperature control cable. Tighten all hose connections. 10. Install rear cover behind seat. 11. Turn on the heater hose shut-off valve. 12. Install cab fresh air filter housing. 13. Add coolant to the radiator. Start engine and run the heating system to check for leaks. 14. Add more coolant to account for coolant in the heater circuit.
AHose BHeater Control Valve
UN04NOV97
TX,18,1111069 1904NOV971/1
TM1640 (15JAN04)
18-1830-36

011504
PN=468
T112118
Heater Control Valve Leak Check

1. Connect water pressure hose to control valve inlet and turn the valve arm to the closed position. 2. Check for leakage from the valve outlet.
NOTE: The heater control valve is not serviceable.

3. Replace heater control valve if required.
TX,1830,MM3165 1909JUN981/1
Remove and Install Main Blower Assembly
18 1830 37
APressurizer Motor BInlet Air Plenum CExpansion Valve DFreeze Control Switch
EResistor FMain Blower Motor GHeater/Evaporator Upper Housing
HCap Screws ILower Housing JHeater/Evaporator Coils KHeater Hoses

LHeater Valve MAir Conditioning Lines NHousing OKnob

TX,18,1111130 1918FEB991/5
TM1640 (15JAN04)
18-1830-37

011504
PN=469
T112116
UN04NOV97

1. Park machine on a flat level surface, engine OFF. 2. Remove cab recirculation filter (P). 3. Remove seat. Disconnect wiring connector if machine is equipped with an air ride seat. 4. Remove seat base. 5. Remove foam cover (Q). 6. Open left rear cab service door.
18 1830 38
7. Remove cab access door release rod (S). 8. Remove cab door release (T) from left hand console shelf (R). 9. Remove left hand side console shelf (R). 10. Remove fresh air filter housing with filter.
PCab Recirculation Filter QFoam Cover RLeft Hand Console Shelf SCab Access Door Release Rod TCab Door Release
UN25NOV97
TX,18,1111130 1918FEB992/5
11. Remove four screws attaching inlet plenum (B) to heater/evaporator coil housing. 12. Remove hidden screw (U) attaching inlet plenum (B) to cab floor. 13. Disconnect wiring harness from inlet air plenum. 14. Remove inlet air plenum (B).
BInlet Air Plenum UScrew
UN25NOV97
TX,18,1111130 1918FEB993/5
TM1640 (15JAN04)
18-1830-38

011504
PN=470
T112345B
T112347B

15. Disconnect main blower motor cooling tube (V) from heater/evaporator upper housing (G). 16. Disconnect wire harness from freeze control switch (D) and resistor (E). 17. Remove freeze control switch (D) if equipped with air conditioning. Do not remove thermostat probe from evaporator core. 18. Remove 13 screws from heater/evaporator upper housing (G). Note position of hidden screws (H). 19. Remove four cap screws from main blower motor (F). 20. Remove upper housing (G) from heater/evaporator core. 21. Remove main blower motor (F). 22. Remove cage fan and clip from old blower motor. 23. Install cage fan and clip on new blower motor assembly. 24. Attach new main blower motor assembly to lower housing (I) using two screws. 25. Check lower housing (I) to make sure drain tube is plugged for the heater unit, or that drain tube is not plugged for the air conditioning unit. 26. Reinstall heater/evaporator core upper housing. 27. Attach two upper screws to main blower motor. 28. Connect main blower motor cooling tube (V) to upper heater/evaporator housing. 29. Reinstall freeze control switch (D) on upper housing (G). 30. Connect wiring harness to resistor (E) and freeze control switch (D). 31. Reinstall inlet air plenum (B) to heater/evaporator housing.
DFreeze Control Switch EResistor FMain Blower Motor GHeater/Evaporator Upper Housing HScrews ILower Housing JMain Blower Motor Cooling Tube
UN25NOV97 T112346B
18 1830 39
TX,18,1111130 1918FEB994/5
TM1640 (15JAN04)
18-1830-39

011504
PN=471

32. Reinstall screw (U) to cab floor and reinstall cab recirculation filter. 33. Reinstall fresh air filter housing 34. Reinstall left hand side console shelf. 35. Reinstall cab access door release rod (S). 36. Reinstall cab door release (T) on left hand console shelf (R). 37. Reinstall foam cover (Q) behind seat.
18 1830 40
38. Reinstall seat base and seat. Reconnect wiring connector if machine is equipped with an air ride seat.
TX,18,1111130 1918FEB995/5
Remove and Install Pressurizer Motor Assembly

1. Remove cab left-hand shelf. 2. Disconnect cooling tube (B). 3. Remove four screws from pressurizer motor (A). 4. Disconnect wiring harness from pressurizer motor. 5. Remove and inspect pressurizer motor. 6. Attach pressurizer motor assembly using screws. 7. Install cab left-hand shelf.
APressurizer Motor BCooling Tube
UN04NOV97
TX,18,1111071 1918FEB991/1
TM1640 (15JAN04)
18-1830-40

011504
PN=472
T112120
Remove and Install Receiver-Dryer and Condenser
18 1830 41
1O-Ring (4 used) 2Hose 3Receiver-Dryer 4Hose
5Ring 6Flange Nut (6 used) 7Washer (21 used) 8Hinge
9Vapor Condenser 10Screw (6 used) 11Bracket 12Screw (8 used)
13Washer (3 used) 14Washer 15Bracket 16Screw (2 used)
TX,18,1111095 1918FEB991/2
TM1640 (15JAN04)
18-1830-41

011504
PN=473
TP60543
UN10NOV98

Receiver-Dryer 1. Recover refrigerant. (See procedure in this group.) Condenser 2. Discharge the system. 1. Recover refrigerant. (See procedure in this group.) 3. Disconnect lines (1 and 4) from receiver-dryer. 4. Remove receiver-dryer. IMPORTANT: A new receiver-dryer must always be installed after purging the system. DO NOT use a flushed or used receiver/dryer. Contamination of system can cause component failure. 5. Apply refrigerant oil to new O-rings. Remove plugs from receiver-dryer and immediately connect lines (1 and 14). 6. Add 15 mL (0.5 fl. oz.) refrigerant oil to system. See procedure in this group.) 2. Disconnect the condenser-to-compressor hose and condenser-to-receiver-dryer hose. 3. Remove mounting cap screws. Remove condenser. 4. Replace parts as necessary. 5. Install condenser and connect hoses 6. Evacuate and charge the air conditioning system. (See procedure in this group.) 7. Evacuate and charge the system. (See procedure in this group.)
18 1830 42
TX,18,1111095 1918FEB992/2
Remove and Install High and Low Pressure Switches

1. Remove left-hand shelf. 2. Remove fresh air filter assembly. (See procedure in this group.)
NOTE: The high pressure switch has a male connector; the low pressure switch has a female connector.
3. Disconnect wiring harness from the high pressure switch (B) and the low pressure switch (A).
NOTE: A Schrader valve is located in the connection to prevent the air conditioning from discharging when the switches are removed.
4. Remove switches. Inspect and replace as required.
ALow Pressure Switch BHigh Pressure Switch
UN12DEC96
TX,18,1111096 1918FEB991/1
TM1640 (15JAN04)
18-1830-42

011504
PN=474
T105454B
Remove and Install Fresh Air Filter

1. Open cab fresh air filter door by pulling up on lever (A) to the left of the operators seat.
ACab Door
UN12DEC96
TX,18,111479 1909JUN981/4
T105479B
2. Remove filter assembly by turning knob (A).

AKnob
18 1830 43
TX,18,111479 1909JUN982/4
TM1640 (15JAN04)
18-1830-43

011504
PN=475
T103187C
UN12DEC96
Heating and Air Conditioning NOTE: If operating in dusty conditions, cab fresh air filter should be checked and cleaned as necessary.
3. Release clips (B).
BClip (2 used)
18 1830 44
TX,18,111479 1909JUN983/4
TM1640 (15JAN04)
18-1830-44

011504
PN=476
T105493B
UN12DEC96

4. Remove filter (C). Replace if damaged. 5. Clean filter in one of these ways:
CAUTION: Prevent possible injury from flying chips if compressed air is more than 210 kPa (2.1 bar) (30 psi). Reduce compressed air to less than 210 kPa (2.1 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection. Tap filter on a flat surface with the dirty side down. Use compressed air opposite to the normal air flow. Wash the filter in warm, soapy water. Flush the filter. Let it dry before using the heater, defroster, or air conditioner. 6. Remove dust from filter housing. IMPORTANT: Do not damage wire harness when installing filter housing. Wiring can get pinched and damaged. 7. Install filter and filter duct work. 8. Install filter housing assembly. Close cab fresh air filter door.
CFilter
T105494B
UN12DEC96
18 1830 45
TX,18,111479 1909JUN984/4
TM1640 (15JAN04)
18-1830-45

011504
PN=477
Remove and Install Recirculating Air Filter

NOTE: The cab recirculating air filter is located next to the seat.
1. Turn latch (A) holding grille. Remove grille. 2. Remove filter. CAUTION: Reduce compressed air to less than 210 kPa (2 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment, including eye protection.
AAir Filter Latch
UN12DEC96
18 1830 46
3. Clean filter in one of these ways: Tap it on a flat surface with the dirty side down. Use compressed air opposite to the normal air flow. Wash the filter in warm, soapy water. Flush the filter and let it dry before using the air conditioner. 4. Install filter. 5. Install grille.
TX,18,111480 1928SEP981/1
TM1640 (15JAN04)
18-1830-46

011504
PN=478
T105499B
18 1830 47
TM1640 (15JAN04)
18-1830-47

011504
PN=479
Remove and Install Compressor
18 1830 48
TX,18,1111131 1931MAR991/2
TM1640 (15JAN04)
18-1830-48

011504
PN=480
TP60561
UN01DEC98

1O-Ring 2Hose 3Clamp 4Screw 5Lock Nut 6Refrigerant Hose 7Clamp 8Screw (3 used) 9Ring 10O-Ring 11Compressor 12Belt 13Spring Pin (2 used) 14Screw 15Screw 16Plate 17Spacer (2 used) 18Support 19Tie Band (2 used) 20Cap 21Kit
1. Recover refrigerant from the system. (See procedure in this group.) 2. Loosen belt adjuster and remove drive belt (12). 3. Disconnect hoses (2 and 6). Remove compressor belt cap screw. 4. Disconnect electrical connector. 5. Remove compressor. 6. Install compressor and tighten cap screws.
CompressorSpecification Compressor Through Bolt Torque....................................................................... 26 Nm (19 lb-ft)
8. Connect wiring lead. 9. If compressor was replaced due to an internal failure, flush and purge each component in the air conditioning system individually. (See procedures in this group.) 10. Add compressor oil. (See procedure in this group.) IMPORTANT: Do not flush receiver/dryer or install a used one. Always install a new receiver/dryer. 11. Remove existing receiver/dryer and install a new one. (See procedure in this group.) 12. Evacuate and charge the system. (See procedure in this group.)
18 1830 49
7. Reconnect refrigerant lines. Tighten suction line (2) lb-ft) and discharge line (6) fitting.
CompressorSpecification Compressor Suction Line Torque....................................................................... 31 Nm (23 lb-ft) Compressor Discharge Line Torque.......................................................................... 22 m (16 lb-ft)
TX,18,1111131 1931MAR992/2
TM1640 (15JAN04)
18-1830-49

011504
PN=481
Disassemble and Assemble Compressor ClutchR134a
AJDG747 Compressor Clutch Spanner BClutch Shaft Bolt
CClutch Hub DPulley Snap Ring
EPulley FClutch Coil Snap Ring
GClutch Coil HShim (As Required)
1. Mount compressor on DFRW20 Compressor Holding Fixture using two 6 in. x 1/4 in. eye bolts with nuts as illustrated. 2. Remove dust cover.
3. Hold the clutch hub using JDG747 Compressor Clutch Spanner (A) and remove the clutch shaft bolt (B).
TM1640 (15JAN04)
18-1830-50

011504
T107716
UN09MAY97
TX,18,DY5297 1926OCT981/2
RW21157
UN24JUN92
18 1830 50
PN=482

4. Remove the clutch hub (C). Remove the shims (H) from the clutch hub and save for installation. 5. Remove and discard snap ring (D). Remove the pulley (E) using a plastic hammer or JDG220 Puller, JDG748 Jaws, and JDG771 Hub Protector. 6. Disconnect the clutch coil lead wire. Remove and discard the snap ring (F) and remove the clutch coil (G). 8. Install the clutch coil and new snap ring with flat side of the snap ring down. Connect the clutch coil lead wire. 9. Install the pulley and new snap ring with flat side of the snap ring down. Apply grease to the shims (H) and install to the clutch hub. 10. Install clutch hub and shaft bolt and tighten. Install dust cover.
CompressorSpecification Clutch Shaft BoltTorque ..................................... 14 Nm (120 lb-in.) 18 1830 51
NOTE: The bearing in the pulley is NOT serviceable.

7. Check pulley bearing operation. Replace pulley and bearing as required.
TX,18,DY5297 1926OCT982/2
Check Clutch Hub ClearanceR134a

NOTE: The clutch coil is NOT polarity sensitive.
1. Check pulley-to-clutch hub clearance using a dial indicator. Mount the gauge to the pulley as illustrated and connect a set of jumper wires from the compressor to a 12V battery. 2. Rotate the pulley and check clearance in three equally spaced locations around the clutch hub. Add or remove shims as required.
CompressorSpecification Clutch HubClearance ........................ 0.350.65 mm (0.0140.026 in)
3. Tighten clutch shaft bolt after correct clearance is obtained.

CompressorSpecification Clutch Shaft BoltTorque............................................ 14 Nm (120 lb-in.)
TX,1830,BA636 1914OCT981/1
TM1640 (15JAN04)
18-1830-51

011504
PN=483
RW21159
UN24JUN92
Inspect Compressor ManifoldR134a

1. Remove cap screws (A) and the manifold (B). 2. Remove and discard seal (C). Inspect porting surfaces. 3. Lubricate and install a new seal (C). 4. Install manifold and tighten cap screws.
CompressorSpecification Compressor Manifold Cap ScrewTorque ................................................................ 26 Nm (19 lb-ft)
UN24JUN92
18 1830 52
AManifold Cap Screw BManifold CManifold Seal
TX,1830,BA637 1918FEB991/1
TM1640 (15JAN04)
18-1830-52

011504
PN=484
RW21160
Disassemble, Inspect and Assemble CompressorR134a
18 1830 53
ARear Pins BRear Housing CRear Gasket DRear Discharge Reed Valve ERear Valve Plate FRear Suction Reed Valve
GRear O-Ring HFront O-Ring IFront Suction Reed Valve JFront Valve Plate KFront Discharge Reed Valve
LFront Gasket MSnap Ring NLip Seal OWasher PThrough Bolt
QFelt Holder RFelt SFront Housing TFront Pins
1. Clean the compressor using solvent before disassembly. Mount compressor on holding fixture and remove clutch. (See Disassemble and Assemble Compressor Clutch R134a in this group.) IMPORTANT: When removing front and rear housing, be careful NOT to damage the sealing surfaces. 2. Disassemble the compressor as illustrated and discard the O-rings, gaskets, lip seal, snap ring, and through bolt washers. Replace parts from service kits.
NOTE: The valve plates, reed valves, cylinders, and cylinder housing are NOT serviceable. Some cylinder scuffing (light scratches) is normal.
3. Inspect the valves for an even wear pattern and the cylinders for scoring or excessive wear. Replace compressor as required. 4. Remove the shaft seal snap ring (M). Turn the housing over and remove the felt holder (Q) and felt (R) from the front housing (S).
TX,18,DY5026 1918FEB991/3
TM1640 (15JAN04)
18-1830-53

011504
PN=485
RW21161
UN24JUN92

5. Remove the shaft lip seal (N) from the front housing (S) using a small tool with 5/8 in. OD. 6. Wash all parts in clean solvent and dry before assembly. IMPORTANT: Lubricate O-rings, gaskets, and lip seal using only TY22025 (R134a) refrigerant oil during assembly. Other oils could damage the compressor. 7. Apply R134a oil to the bore of the front housing and install new lip seal (N) to the bottom of the bore using a socket. Install new snap ring (M) flat side down.
TX,18,DY5026 1918FEB992/3
18 1830 54
TM1640 (15JAN04)
18-1830-54

011504
PN=486
UN24JUN92
RW21162
CRear Gasket DRear Discharge Reed Valve
ERear Valve Plate
FRear Suction Reed Valve
UBushing Spacer
IMPORTANT: Bushing spacer (U) must be in position before assembling the compressor. 8. Install pins (A) and new O-ring (G) in the rear cylinder.
13. Install a new gasket (L) flat side down. Put JDG746 Compressor Seal Protector on the shaft and lubricate with R134a oil. 14. Install the front housing (S) on the front cylinder and remove the lip seal protector. Install through bolts (P) and new washers (O). 15. Partially tighten the through bolts and then tighten.
CompressorSpecification Compressor Through Bolt Torque....................................................................... 26 Nm (19 lb-ft)
NOTE: The rear valve plate is marked with an "R" and is installed face up.
9. Install parts (FD) over the pins on the rear cylinder. 10. Install a new gasket (C) flat side down and the rear housing (B) on the rear cylinder. Mount the compressor onto the holding fixture. 11. Install pins (T) and new O-ring (H) in the front cylinder.
16. Install the felt (R) and felt holder (Q) using the clutch hub. 17. Install the pulley-clutch hub and check clearance. (See Disassemble and Assemble Compressor ClutchR134a and Check Clutch Hub ClearanceR134a in this group.)
NOTE: The front valve plate is marked with an "F" and is installed face up.
12. Install parts (IK) over the pins on the front cylinder.
TX,18,DY5026 1918FEB993/3
TM1640 (15JAN04)
18-1830-55

011504
PN=487
RW21163
UN24JUN92
18 1830 55
18 1830 56
TM1640 (15JAN04)
18-1830-56

011504
PN=488
Group 1899

DFRW20 Compressor Holding Fixture
18 1899 1
A102 mm (4 in.) B76 mm (3 in.) C70 mm (2.75 in.)
D6.4 mm (0.25 in.) E19 mm (0.75 in.) F152 mm (6 in.)
G254 mm (10 in.) H114 mm (4.5 in.) I178 mm (7 in.)
JWeld KTwo Holes
This tool is used to hold the air conditioning compressor during disassembly and assembly. Materials required are: Two pieces of steel plate, approximately 70 x 120 mm (23/4 in.) and 152 x 254 mm (6 x 10 in.)
Two pieces of threaded rod, 13 mm (1/2 in.) threads x 178 mm (7 in.) long and four lock washers and nuts.
TX,18,1111100 1922NOV971/1
TM1640 (15JAN04)
18-1899-1

011504
PN=489
RW13619
UN20SEP89
18 1899 2
TM1640 (15JAN04)
18-1899-2

011504
PN=490
Section 19
Sheet Metal and Styling

Contents
Page
Group 1910Hood or Engine Enclosure Specifications . . . . . . . . . . . . . . . . . . . . . . . .19-1910-1 Hood Remove and Install . . . . . . . . . . . . . . . . . .19-1910-2 Engine Side Shields Remove and Install . . . . . . . . . . . . . . . . . .19-1910-3 Group 1913Miscellaneous Shields Transmission Shields Remove and Install . . . . . . . . . . . . . . . . . .19-1913-1 Battery Covers Remove and Install . . . . . . . . . . . . . . . . . .19-1913-2 Group 1921Grille and Grille Housing Service Equipment and Tools . . . . . . . . . . . .19-1921-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .19-1921-1 Grille and Grille Housing Remove and Install . . . . . . . . . . . . . . . . . .19-1921-2 Group 1927Miscellaneous Shields Front Fenders Remove and Install . . . . . . . . . . . . . . . . . .19-1927-1 Fenders Rear, Remove and Install . . . . . . . . . . . . .19-1927-2
19
TM1640 (15JAN04)
19-1

011504
PN=1
Contents
19
TM1640 (15JAN04)
19-2

011504
PN=2
Group 1910
Hood or Engine Enclosure

Specifications
Engine Side Shield
Weight
CED,OUOE003,2714 1931MAR991/1
19 1910 1
TM1640 (15JAN04)
19-1910-1

011504
PN=493
Remove and Install Hood
19 1910 2
1Screw (4 used)
2Washer (4 used)
3Hood
TX,19,1111039 1918FEB991/1
TM1640 (15JAN04)
19-1910-2

011504
TP55681
UN06OCT97
PN=494
Remove and Install Engine Side Shields
19 1910 3
1Hinge (2 used) 2Latch 3Rivet (4 used) 4Shield 5Screw (6 used)
6Washer (4 used) 7Spring Locking Pin (4 used) 8Rod (2 used)
9Isolator (As Required) 10Cap Screw (2 used) 11Plate (2 used) 12Washer (6 used)
13Screw (6 used) 14Door 15Shield 16Door
CAUTION: Each engine side shield weighs approximately 23 kg (50 lb).
Specification Engine Side ShieldWeight ...................... 23 kg (50 lb) approximate
TX,19,1111040 1918FEB991/1
TM1640 (15JAN04)
19-1910-3

011504
PN=495
TP55680
UN07OCT97
19 1910 4
TM1640 (15JAN04)
19-1910-4

011504
PN=496
Group 1913
Miscellaneous Shields
Remove and Install Transmission Shields
TP55810
UN12JAN98
1Screw (2 used)
2Washer (2 used)
3Cover
4Cover
19 1913 1
TX,1910,111306 1918FEB991/1
TM1640 (15JAN04)
19-1913-1

011504
PN=497
Remove and Install Battery Covers
19 1913 2
1Cover
2Cover
3Washer (8 used)
4Cap Screw (8 used)
TX,1910,111307 1918FEB991/1
TM1640 (15JAN04)
19-1913-2

011504
PN=498
TP55601
UN08JUL97
Group 1921
Grille and Grille Housing

CED,OUOE003,2715 1931MAR991/2
Metric Lifting Eyebolt (2 used) . . . . . . . . . . . . . JT05550 Used in conjunction with a chain and hoist to remove and install grille and grille housing.
CED,OUOE003,2715 1931MAR992/2
19 1921 1
Specifications
Grille Housing Grille Screen
Weight Weight
83 kg (183 lb) approximate 23 kg (50 lb) approximate
CED,OUOE003,2716 1931MAR991/1
TM1640 (15JAN04)
19-1921-1

011504
PN=499
Remove and Install Grille and Grille Housing
19 1921 2
UN06JAN98
AFan Guard BGrille Housing-to-Frame Cap Screw (2 used)
CBaffle Cap Screw (4 used)
DRear Wiring Harness Connectors
EFuel Tank Filler Neck with Hose
1. Disconnect battery ground strap or turn battery disconnect switch Off if equipped. 2. Remove hood. (See Group 1910.) 3. Remove battery box covers. 4. Remove fan guard (A). 5. Disconnect rear wiring harness connectors (D) at grille housing. 6. Remove fuel tank filler neck with hose (D).
CAUTION: Grille housing weighs approximately 83 kg (183 lb). Grille screen weighs approximately 23 kg (50 lb).
Specification Grille HousingWeight ............................ 83 kg (183 lb) approximate Grille ScreenWeight ................................ 23 kg (50 lb) approximate
8. Install two 12 mm JT05550 Eyebolts in tapped holes in top of grille housing. 9. Attach a chain and hoist to the eyebolts.
7. Remove four cap screws (C) and remove radiator baffle plate.
TX,19,1111129 1918FEB991/3
TM1640 (15JAN04)
19-1921-2

011504
PN=500
T112440B

10. Remove two grille housing-to-frame cap screws (B).
TX,19,1111129 1918FEB992/3
11. Remove two radiator and oil cooler outside frame-to-grille housing cap screws (C). 12. Remove two door striker plates (B). 13. Carefully lift grille housing until it clears top of radiator and oil cooler. 14. Install grille housing using eyebolts, in conjunction with a chain and a hoist. 15. Install and tighten two bottom grille housing-to-engine frame cap screws. 16. Install and tighten two radiator and oil cooler outside frame-to-grille housing cap screws. 17. Install two door striker plates.
UN06JAN98
19 1921 3
18. Install and tighten two grille housing-to-frame cap screws. 19. Connect rear wiring harness connector. 20. Install fuel tank filler neck with hose. 21. Install fan guard. 22. Install battery box covers. 23. Install hood. (See Group 1910.) 24. Connect battery ground strap or turn battery disconnect switch On, if equipped. 25. Install engine side shields. (See Group 1910.) 26. Install hood. (See Group 1910.) 27. Connect battery ground strap or turn battery disconnect switch On if equipped.
ARadiator and Oil Cooler Outside Frame-to-Grille Housing Cap Screw (2 used) BDoor Striker Plate (2 used) CBottom Grille Housing-to-Engine Frame Cap Screw (2 used)
TX,19,1111129 1918FEB993/3
TM1640 (15JAN04)
19-1921-3

011504
PN=501
T112441B
19 1921 4
TM1640 (15JAN04)
19-1921-4

011504
PN=502
Group 1927
Remove and Install Front Fenders
19 1927 1
1Fender 2Fender 3Bolt (8 used)
4Washer (8 used) 5Support (4 used) 6Nut (8 used)
7Lock Nut (8 used) 8Washer (8 used)
9Washer (4 used) 10Screw (4 used)
TX,1927,111310 1929SEP981/1
TM1640 (15JAN04)
19-1927-1

011504
PN=503
TP48678
UN17MAR97
Remove and Install Rear Fenders
19 1927 2
1Kit 2Screw (18 used) 3Washer (36 used) 4Support (2 used)
5Screw (10 used) 6Washer (10 used) 7Lock Nut (18 used) 8Platform
9Support (2 used) 10Platform 11Strap (2 used)
12Platform 13Fender 14Fender
TX,1927,111309 1918FEB991/1
TM1640 (15JAN04)
19-1927-2

011504
PN=504
TP60438
UN20JUL98
Section 20
Safety and Convenience

Contents
Page
Group 2002Mirror Rear View Mirror Remove and Install . . . . . . . . . . . . . . . . . .20-2002-1 Outside Mirror for Cab or Canopy Remove and Install . . . . . . . . . . . . . . . . . .20-2002-2 Group 2003Fire Extinguisher Fire Extinguisher and Bracket Remove and Install . . . . . . . . . . . . . . . . . .20-2003-1 Group 2004Horn and Warning Devices Horn Remove and Install . . . . . . . . . . . . . . . . . .20-2004-1 Reverse Warning Alarm Remove and Install . . . . . . . . . . . . . . . . . .20-2004-2 Change Volume . . . . . . . . . . . . . . . . . . . . .20-2004-2
20
TM1640 (15JAN04)
20-1

011504
PN=1
Contents
20
TM1640 (15JAN04)
20-2

011504
PN=2
Group 2002
Mirror
Remove and Install Rear View Mirror
1Rear View Mirror
2Washer
3Nut 20 2002 1
TX,2002,111312 1905JUN981/1
TM1640 (15JAN04)
20-2002-1

011504
TP33769
UN01JAN94
PN=507
Mirror
Remove and Install Outside Mirror for Cab or Canopy
20 2002 2
1Clamp 2Washer 3Lock Nut
4Cap Screw 5Washer (2 used) 6Washer
7Mirror Arm 8Cap 9Rear View Mirror
10Rear View Mirror Assembly
TX,2002,111313 1918FEB991/1
TM1640 (15JAN04)
20-2002-2

011504
PN=508
TP55501
UN01MAY97
Group 2003
Fire Extinguisher
Remove and Install Fire Extinguisher and Bracket
20 2003 1
1Fire Extinguisher Assembly
2Bracket
3Screw (2 used)
4Nut (2 used)
TX,20,1111076 1918FEB991/1
TM1640 (15JAN04)
20-2003-1

011504
TP55515
UN05MAY97
PN=509
Fire Extinguisher
20 2003 2
TM1640 (15JAN04)
20-2003-2

011504
PN=510
Group 2004
Horn and Warning Devices

Remove and Install Horn
AHigh Note Horn (A03 Org/G05 Blk) BLow Note HornIf Equipped (A03 Org/G05 Blk)
UN06MAY97
20 2004 1
Loader Frame Harness (Without Tool Carrier) Shown
TX,2004,111465 1905JUN981/1
TM1640 (15JAN04)
20-2004-1

011504
PN=511
T109420
Horn and Warning Devices
Remove and Install Reverse Warning Alarm

Disconnect M01 purple and G02 black wiring leads from reverse warning alarm (A). Remove and install reverse warning alarm mounted to grille housing.
AReverse Warning Alarm
20 2004 2
Rear Frame Harness Shown
TX,2004,111466 1905JUN981/1
Change Volume Reverse Warning Alarm

IMPORTANT: The reverse warning alarm is set on high volume at the factory. It may be necessary to adjust the volume to meet local regulations.
NOTE: Alarm removed from machine for clarity of photograph.

To change alarm volume, move switch (A) to desired position.
AAlarm Volume Switch
TX,2004,111467 1905JUN981/1
TM1640 (15JAN04)
20-2004-2

011504
PN=512
T7853AT
UN08OCT92
T109419
UN06MAY97
Section 31
Loader
Contents
Page Page
Group 3102Bucket Specifications . . . . . . . . . . . . . . . . . . . . . . . .31-3102-1 Ride Control Accumulator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3102-2 Bucket Tooth Shanks and Tips Remove and Install . . . . . . . . . . . . . . . . . .31-3102-3 Bucket Remove and Install . . . . . . . . . . . . . . . . . .31-3102-5 Welded Bucket Cutting Edge Remove and Install . . . . . . . . . . . . . . . . . .31-3102-6 Bolt-On Bucket Cutting Edges and Wear Plates Remove and Install . . . . . . . . . . . . . . . . . .31-3102-7 Cutting Edge Repair Cracks . . . . . . . . . . . . . . . . . . . . . .31-3102-9 Group 3140Frames Service Equipment and Tools . . . . . . . . . . . .31-3140-1 Other Material . . . . . . . . . . . . . . . . . . . . . . . .31-3140-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . .31-3140-2 Bucket Tilt Linkage Remove and Install . . . . . . . . . . . . . . . . . .31-3140-3 Bucket Linkage Seals and Bushings Remove and Install . . . . . . . . . . . . . . . . . .31-3140-4 Tool Carrier Upper Tilt Linkage Disassemble and Assemble. . . . . . . . . . . .31-3140-5 Tool Carrier Lower Tilt Linkage Disassemble and Assemble. . . . . . . . . . . .31-3140-6 Tool Carrier Disassemble and assemble . . . . . . . . . . . .31-3140-8 Loader Boom Bushings and Seals Remove and Install . . . . . . . . . . . . . . . . . .31-3140-9 Tool Carrier Boom Bushings and Seals Remove and Install . . . . . . . . . . . . . . . . .31-3140-10 Group 3160Hydraulic System Essential Tools . . . . . . . . . . . . . . . . . . . . . . .31-3160-1 Service Equipment and Tools . . . . . . . . . . . .31-3160-2 Other Material . . . . . . . . . . . . . . . . . . . . . . . .31-3160-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . .31-3160-4 Loader Hydraulic Pump Remove and Install . . . . . . . . . . . . . . . . . .31-3160-9 Hydraulic Pump Cross Section . . . . . . . . . . . . . . . . . . . . .31-3160-12 Disassemble, Inspect and Assemble . . . .31-3160-13 TM1640 (15JAN04)
Hydraulic Pump Control Valve Remove and Install . . . . . . . . . . . . . . . . .31-3160-34 Disassemble and Assemble. . . . . . . . . . .31-3160-36 Loader Control Valve Remove and Install . . . . . . . . . . . . . . . . .31-3160-37 Disassemble and Assemble. . . . . . . . . . .31-3160-40 Auxiliary Valve Section and Bucket Section Disassemble and Assemble. . . . . . . . . . .31-3160-41 Disassemble and Assemble Bucket Valve SectionTool Carrier . . . . . . . . . . . . . . .31-3160-42 Boom Valve Section Disassemble and Assemble. . . . . . . . . . .31-3160-43 System Relief Valve Disassemble and Assemble. . . . . . . . . . .31-3160-44 Bucket Circuit Relief Valve Disassemble and Assemble. . . . . . . . . . .31-3160-44 Load Sense Relief Valve Disassemble and Assemble. . . . . . . . . . .31-3160-45 Boom Circuit Relief Valve Disassemble and Assemble. . . . . . . . . . .31-3160-45 Boom Cylinder Remove and Install . . . . . . . . . . . . . . . . .31-3160-46 Loader Start-Up Procedure . . . . . . . . . . .31-3160-48 Bucket Cylinder Remove and Install . . . . . . . . . . . . . . . . .31-3160-49 Loader Start-Up Procedure . . . . . . . . . . .31-3160-51 Cross Section . . . . . . . . . . . . . . . . . . . . .31-3160-52 Disassemble and Assemble. . . . . . . . . . .31-3160-53 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-54 Boom Cylinder Piston Wear Ring Configuration . . . . . . . .31-3160-56 Cross Section . . . . . . . . . . . . . . . . . . . . .31-3160-58 Disassemble and Assemble. . . . . . . . . . .31-3160-59 Boom, Bucket or Tilt Cylinder Remove and Install Bushings and Seals . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-67 Hydraulic Reservoir Remove and Install . . . . . . . . . . . . . . . . .31-3160-68 Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy . . . . . . . . . . . . . . . .31-3160-69 Pilot Controller (Single Lever) Remove and Install . . . . . . . . . . . . . . . . .31-3160-70 Cross Section . . . . . . . . . . . . . . . . . . . . .31-3160-71 Disassemble and Assemble. . . . . . . . . . .31-3160-71
31
31-1

011504
PN=1
Contents
Page
Pilot Controller Repair (Two Lever Controller) (S.N. 585560). . . . . . . . . . . . . . . . . . . .31-3160-87 Pilot Controller Repair (Two Lever Controller) (S.N. 585561) . . . . . . . . . . .31-3160-91 Pressure Reducing Valve Manifold Remove and Install . . . . . . . . . . . . . . . . .31-3160-94 Pressure Reducing Valve Remove and Install . . . . . . . . . . . . . . . . .31-3160-95 Disassemble and Assemble. . . . . . . . . . .31-3160-96 Boom Down Solenoid Valve Remove and Install . . . . . . . . . . . . . . . . .31-3160-97 Differential Lock Solenoid Valve Remove and Install . . . . . . . . . . . . . . . . .31-3160-98 Pilot Enable Solenoid Valve Remove and Install . . . . . . . . . . . . . . . . .31-3160-99 Ride Control Repair (S.N. 582200) . . . . 31-3160-100 Ride Control Repair (S.N. 582201) . . . . 31-3160-104 Ride Control Accumulator Disassemble and Assemble. . . . . . . . . . 31-3160-108 Charge. . . . . . . . . . . . . . . . . . . . . . . . . . 31-3160-112 Pin Disconnect/Axle Disconnect Valve Remove and Install . . . . . . . . . . . . . . . . 31-3160-114 Pin Disconnect Valve Disassemble and Assemble. . . . . . . . . . 31-3160-115 Axle Disconnect Valve Disassemble and Assemble. . . . . . . . . . 31-3160-116
31
TM1640 (15JAN04)
31-2

011504
PN=2
Group 3102
Bucket
Specifications
Bucket Cutting Edge-to-Center Tooth Shank Cap Screw End Tooth Shank-to-Bucket Cap Screw Cutting Edge-to-Segment Cap Screw 2.3 M (3.0 yd) Bucket 2.7 M (3.5 yd) Bucket Boom End-to-Bucket Bucket Link-to-Bucket Cutting Edge Segment Torque 624 Nm (460 lb-ft)
Torque
1171 Nm (790 lb-ft)
Torque
624 Nm (460 lb-ft)
Weight Weight Clearance Clearance Weight
963 kg (2123 lb) approximate 1034 kg (2280 lb) approximate 1 mm (0.04 in.) maximum 2 mm (0.08 in.) maximum 66 kg (145 lb) approximate 495 Nm (365 lb-ft) 300 Nm (225 lb-ft)
31 3102 1
Cutting Edge-to-Bucket Cap Screw Torque Wear Plate-to-Bucket Cap Screw Torque
Welding Bucket Cutting Edge Preheat Temperature Distance 204C (400F) minimum throughout entire thickness of parts 51 mm (2 in.) minimum back from joint 149260C (300500F) 13 mm (0.5 in.) beyond end of crack
Cracked Cutting Edge
Preheat Temperature Distance
CED,OUOE003,3378 1922APR991/1
TM1640 (15JAN04)
31-3102-1

011504
PN=515
Bucket
Ride Control Accumulator Safety

1. Stop engine. CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with ride control. Always be sure the ride control accumulator energy is discharged when working on hydraulic components. To do this: With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 2. If equipped with ride control. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds.
31 3102 2
TX,31,RP3118 1930APR971/1
TM1640 (15JAN04)
31-3102-2

011504
PN=516
Bucket
Remove and Install Bucket Tooth Shanks and Tips
1Cutting Edge Segment (7 used) 2Adapter (Shank)
3Cap Screw (2 used) 4Washer (2 used) 5Pin (8 used)
6Tooth Tip (8 used) 7Washer (8 used) 8Cap Screw (12 used)
9Washer (24 used) 10Nut (26 used) 11Bolt (14 used)
T111849
UN22OCT97
31 3102 3
1. Remove cap screws to remove tooth shanks and cutting edge segments. IMPORTANT: Shanks must be seated against cutting edge as nuts are tightened. This places the load on the cutting edge and not on the cap screws. 2. Install tooth shanks. 3. Install cutting edge segments between tooth shanks. 4. Install cap screws in center tooth shanks and cutting edge segments with cap screw heads on bottom.
BucketSpecification Cutting Edge-to-Center Tooth Shank Cap ScrewTorque .................................. 624 Nm (460 lb-ft) End Tooth Shank-to-Bucket Cap ScrewTorque ........................................... 1171 Nm (790 lb-ft)
5. Install cap screws to corner tooth shanks with cap screw heads to outside.
BucketSpecification Cutting Edge-to-Segment Cap ScrewTorque ..................................................... 624 Nm (460 lb-ft)
6. To remove tooth tip, drive pin (5) out from the left side of machine.
TX,31,RP3362 1917FEB991/2
TM1640 (15JAN04)
31-3102-3

011504
PN=517
Bucket
7. To install tooth tip, install retaining washer (4) in recess on left side of tooth shank. Drive tip on shank until pin can be assembled or until center of hole in shank aligns with center of slot in tooth tip. 8. Drive pin (5) through tip and shank from left side. Pin must not contact front edge of tooth tip slot.
NOTE: Pin may fail if in contact with front edge of tooth tip slot. Try a different tooth tip or grind slot in tooth tip longer.
TX,31,RP3362 1917FEB992/2
31 3102 4
TM1640 (15JAN04)
31-3102-4

011504
PN=518
Bucket
Remove and Install Bucket
AShim, Bucket Link to Bucket (as needed) BPin, Bucket Link to Bucket
CSpacer (3 used) DWasher (3 used) ECap Screw (3 used)
FGrease Fitting (2 used) GPin, Bucket to Boom (2 used)
HShim, Bucket to Boom (as needed)
T108202
UN26NOV97
31 3102 5
CAUTION: The approximate weight of the 2.3 M (3.0 yd) bucket is 963 kg (2123 lb). The approximate weight of the 2.7 M (3.5 yd) bucket is 1034 kg (2280 lb).
BucketSpecification 2.3 M (3.0 yd) BucketWeight ............ 963 kg (2123 lb) approximate 2.7 M (3.5 yd) BucketWeight .......... 1034 kg (2280 lb) approximate
obtain maximum clearance.

BucketSpecification Boom End-to-Bucket Clearance.................................................... 1 mm (0.04 in.) maximum
Install an equal number of shims 1 on each side of boom end. Install pins (G), spacers (C), washers (D) and cap screws (E). 5. Align bucket link with bucket. Install shims (A) between bucket link and bucket to obtain maximum clearance.
BucketSpecification Bucket Link-to-Bucket Clearance.................................................... 2 mm (0.08 in.) maximum
1. Lower bucket to the ground. 2. Remove cap screws (E), washers (D), spacers (C), and pins (B and G). 3. Remove bucket. 4. Align boom ends with bucket. Install shims (H) between boom ends and bucket as needed to
TX,31,ME119 1917FEB991/2
TM1640 (15JAN04)
31-3102-5

011504
PN=519
Bucket
Install an equal number of shims 1 on each side of bucket link. Install pin (B), spacers (C), washers (D), and cap screws (E).
TX,31,ME119 1917FEB992/2
Remove and Install Welded Bucket Cutting Edges

1. Perform welding in an environment with a minimum ambient temperature of 10C (50F). 2. Clean all joints to be welded of all foreign matter such as dirt, rust, mill scale, oil, etc. with grinders and/or solvents. 3. Use dry AWS-E7018 low hydrogen electrodes or either of the following equivalent low hydrogen wire feed electrodes: gas metal arc welding (CO2 or argon CO2) AWS-E70S6 or flux cored arc welding AWS-E70T1. 4. Preheat parts to be welded (both tack and final welds) to minimum of 204C (400F). PREHEAT TEMPERATURE MUST BE THROUGHOUT THE ENTIRE THICKNESS OF THE PARTS JOINED AND AT LEAST 51 mm (2 in.) BACK FROM THE JOINT. Maintain preheat throughout the entire welding operation. Tempilstiks should be used if possible.
WeldingSpecification Bucket Cutting EdgePreheat Temperature ................................................. 204C (400F) minimum throughout entire thickness of parts Distance .......................................................... 51 mm (2 in.) minimum back from joint
5. Tack weld preheated plates starting at center of bucket and working toward the outside ends. 6. Final weld preheated plates starting at the center of the front edge of the bucket backing plate and working toward the outside ends. Repeat this operation at back edge of loader blade. Tack welds may be incorporated into the final weld, providing they have been made with electrodes that meet the requirements of the final welds and no cracking has occurred in the weld metal. Tack welds not meeting these requirements must be completely removed by grinding or air arc gouging just prior to making the final weld in that area. 7. Do not remove bucket from welding environment until weld metal temperature has dropped to the ambient temperature. Do not force cooling rate of weld metal.
31 3102 6
TX,31,ME120 1917FEB991/1
TM1640 (15JAN04)
31-3102-6

011504
PN=520
Bucket
Remove and Install Bolt-On Cutting Edges and Wear Plates
1Nut (12 used)
2Cutting Edge (2 used)
3Bolt (12 used)
4Cutting Edge (2 used)
TP48319
UN17APR96
31 3102 7
TX,31,RP3077 1917FEB991/2
TM1640 (15JAN04)
31-3102-7

011504
PN=521
Bucket
1Wear Plate 31 3102 8
2Bolt (8 used)
3Washer (8 used)
4Nut (8 used)
CAUTION: The approximate weight of the cutting edge segments is 66 kg (145 lb).
BucketSpecification Cutting Edge SegmentWeight............... 66 kg (145 lb) approximate
2. To install, hold cutting edge in position and install new hardware.

BucketSpecification Cutting Edge-to-Bucket Cap ScrewTorque ..................................................... 495 Nm (365 lb-ft) Wear Plate-to-Bucket Cap ScrewTorque ..................................................... 300 Nm (225 lb-ft)
1. Remove hardware and cutting edge from bucket. Remove hardware from wear plates and install new wear plates and hardware.
TX,31,RP3077 1917FEB992/2
TM1640 (15JAN04)
31-3102-8

011504
PN=522
T109256
UN29APR97
Bucket
Repair Cracked Cutting Edge

1. If cutting edge has any cracks, clean the area to find end of crack. 2. Drill a small hole at end of crack to prevent spreading. 3. Grind V-grooves along crack on top and bottom of cutting edge. 4. Preheat the cracked area.
WeldingSpecification Cracked Cutting EdgePreheat Temperature .................................................. 149260C (300500F)
5. Fill the V-grooves with weld. Use E7018 electrodes. Extend the weld beyond end of crack.
WeldingSpecification Cracked Cutting EdgeDistance ............. 13 mm (0.5 in.) beyond end of crack
TX,31,ME122 1917FEB991/1
31 3102 9
TM1640 (15JAN04)
31-3102-9

011504
PN=523
Bucket
31 3102 10
TM1640 (15JAN04)
31-3102-10

011504
PN=524
Group 3140
Frames
CED,OUOE003,3380 1922APR991/2
Bushing, Bearing and Seal Driver Set . . . . . . D01044AA Used to remove and install bushings and seals.
CED,OUOE003,3380 1922APR992/2
Other Material
Number Name Use
PT569 (U.S.)
Apply to bore of bellcrank pivot pin. Apply to bushings and bushing bores.
31 3140 1
CED,OUOE003,3382 1922APR991/1
TM1640 (15JAN04)
31-3140-1

011504
PN=525
Frames
Specifications
Bellcrank Bellcrank Pivot Pin Bucket Link Bellcrank-to-Bucket Link Bellcrank-to-Bucket Cylinder Bellcrank-to-Loader Boom Bucket Linkage Bushing
Weight Weight Weight Clearance Clearance Clearance Depth
318 kg (700 lb) approximate 30 kg (65 lb) approximate 77 kg (170 lb) approximate 3 mm (0.12 in.) maximum 3 mm (0.12 in.) maximum 3 mm (0.12 in.) maximum 6.4 mm (0.25 in.) minimum below surface or centered in bushing bore 8 mm (0.31 in.) below surface of link 3 mm (0.12 in.) maximum 3 mm (0.12 in.) maximum 3 mm (0.12 in.) maximum 3 mm (0.12 in.) maximum 1 mm (0.04 in.) maximum
Tool Carrier Tilt Linkage Bushing Tool Carrier Boom-to-Bellcrank Tool Carrier Link Boom-to-Link Tool Carrier Boom-to-Link Tool Carrier Link-to-Tool Carrier
31 3140 2
Depth Clearance Clearance Clearance Clearance Clearance
Tool Carrier Boom End-to-Tool Carrier Tool Carrier Cylinder-to-Tool Carrier Bucket Cylinder Loader Boom Loader Boom-to-Loader Frame Tool Carrier Boom Tilt Cylinder
Clearance Weight Weight Clearance Weight Weight
1 mm (0.04 in.) maximum 105 kg (232 lb) approximate 1089 kg (2400 lb) approximate 3 mm (0.12 in.) maximum 907 kg (2000 lb) approximate 98 kg (216 lb) approximate
CED,OUOE003,3381 1922APR991/1
TM1640 (15JAN04)
31-3140-2

011504
PN=526
Frames
Remove and Install Loader Bucket Tilt Linkage
ABucket Cylinder BShim (As Required) CBellcrank DShim (As Required)
EGrease Fitting (3 used) FSeal (4 used) GBucket Link
HPin ISpacer (2 used) JWasher (2 used)
KCap Screw (2 used) LPin MLoader Boom
T108207
1903APR97
31 3140 3
1. Lower bucket to the ground. CAUTION: The approximate weight of the bellcrank is 318 kg (700 lb). The approximate weight of the bellcrank pivot pin is 30 kg (65 lb). The approximate weight of the bucket link is 77 kg (170 lb).
Specification BellcrankWeight .................................. 318 kg (700 lb) approximate Bellcrank Pivot PinWeight ....................... 30 kg (65 lb) approximate Bucket LinkWeight ................................ 77 kg (170 lb) approximate
3. Install shims (B) on bellcrank-to-bucket link and bellcrank-to-bucket cylinder and shims (D) on bellcrank-to-loader boom to obtain maximum clearance.
Specification Bellcrank-to-Bucket Link Clearance.................................................... 3 mm (0.12 in.) maximum Bellcrank-to-Bucket Cylinder Clearance.................................................... 3 mm (0.12 in.) maximum Bellcrank-to-Loader Boom Clearance.................................................... 3 mm (0.12 in.) maximum
4. Apply NEVER-SEEZ Lubricant or an equivalent to bore of bellcrank pivot pin.
2. Remove parts as necessary.
TX,31,ME126 1917FEB991/1
TM1640 (15JAN04)
31-3140-3

011504
PN=527
Frames
Remove and Install Bucket Linkage Seals and Bushings
31 3140 4
ABellcrank BSeal (2 used)
CBucket Link DSeal (4 used)
EBushing (2 used) FShim (As Required)
GBushing
1. Remove bushings and seals from bucket link and bellcrank using disks from Bushing, Bearing and Seal Driver Set. 2. Apply NEVER-SEEZ Lubricant or an equivalent to new bushings and bushing bores. 3. Install bucket link and bellcrank bushings below surface, or centered in bushing bore.
Specification Bucket Linkage Bushing Depth ........................................................ 6.4 mm (0.25 in.) minimum below surface or centered in bushing bore
4. Install seals (D) into bores against bushings or flush with surface of bucket link and bellcrank.
TX,3140,RP3044 1917FEB991/1
TM1640 (15JAN04)
31-3140-4

011504
PN=528
T108214
1926NOV97
Frames
Disassemble and Assemble Tool Carrier Upper Tilt Linkage
ABellcrank (2 used) BPin Anchor (4 used) CCap Screw (4 used) DBushing (2 used)
EBoom Upper Right End FSeal (8 used) GBushing (8 used) HLink (2 used)
IGrease Fitting (6 used) JPin (2 used) KPin (4 used) LSpacer (6 used)
MWasher (6 used) NCap Screw (6 used) OWasher (As Required) PBellcrank (2 used)
T108217
UN26NOV97
31 3140 5
1. Lower attachment to the ground. CAUTION: Use a lifting device for heavy components. 2. Disassemble upper tilt linkage. 3. Apply NEVER-SEEZ Lubricant or an equivalent to new bushings and into bushing bores. Install bushings (G) below surface of link (H) using disks from Bushing, Bearing and Seal Driver Set.
Specification Tool Carrier Tilt Linkage BushingDepth ................................... 8 mm (0.31 in.) below surface of link
4. Install seals (F) against bushing or flush with surface with lips toward outside of bore. 5. Install pins (J and K) with flags outboard. 6. Install anchors (M) on pins. 7. Install washers (O) under flags to obtain a maximum clearance between the boom (E) and bellcranks (A and P) also between bellcranks (A and P) and bucket cylinder ends.
Specification Tool Carrier Boom-to-BellcrankClearance .................. 3 mm (0.12 in.) maximum Bellcrank-to-Bucket Cylinder Clearance.................................................... 3 mm (0.12 in.) maximum
TX,3140,DU755 1917FEB991/1
TM1640 (15JAN04)
31-3140-5

011504
PN=529
Frames
Disassemble and Assemble Tool Carrier Lower Tilt Linkage
31 3140 6
ALink (2 used) BSeal (4 used) CSeal (8 used) DPin (4 used)
EGrease Fitting (4 used) FWasher (As Required) GCap Screw (4 used) HWasher (4 used)
ISpacer (4 used) JLoader Boom, Left Lower End KBushing (2 used)
LLink (4 used) MAnchor (4 used) NCap Screw (4 used) OBushing (4 used)
1. Lower attachment to the ground. CAUTION: Use a lifting device for heavy components. 2. Disassemble lower tilt linkage. 3. Apply NEVER-SEEZ Lubricant or an equivalent to new bushings and into bushing bores. 4. Install bushings (K and O) below surface of link (A) using disks from Bushing, Bearing and Seal Driver
Set.
Specification Tool Carrier Tilt Linkage BushingDepth ................................... 8 mm (0.31 in.) below surface of link
5. Install seals (B and C) against bushing or flush with surface with lips toward outside of bore. 6. Install pins (D) with flags outboard. 7. Install anchors (M) on pins.
TX,3140,RP3045 1917FEB991/2
TM1640 (15JAN04)
31-3140-6

011504
PN=530
T108220
1926NOV97
Frames
8. Install washers (F) under flags to obtain a maximum clearance between the boom (J) and links (L), between boom links (L) and link (A) and between link (A) and tool carrier.
Specification Tool Carrier Link Boom-to-LinkClearance ........................... 3 mm (0.12 in.) maximum Tool Carrier Boom-to-Link Clearance.................................................... 3 mm (0.12 in.) maximum Tool Carrier Link-to-Tool CarrierClearance ..................................... 3 mm (0.12 in.) maximum
TX,3140,RP3045 1917FEB992/2
31 3140 7
TM1640 (15JAN04)
31-3140-7

011504
PN=531
Frames
Disassemble and Assemble Tool Carrier
31 3140 8
ACap Screw (4 used)
BPin (4 used)
CSpacer (As Needed)
DSpacer (As Needed)
1. Remove attachment from tool carrier. 2. Disconnect hoses to pin disconnect cylinder. 3. Remove cap screws (A) and pins (B). Remove cap screws and pin from bucket tilt linkage. 4. Install spacers (C) on each side of both boom ends-to-tool carrier as needed to obtain maximum clearance.
Specification Tool Carrier Boom End-to-Tool CarrierClearance ..................................... 1 mm (0.04 in.) maximum
5. Install spacers (D) on each side of both cylinders-to-tool carrier as needed to obtain maximum clearance.
Specification Tool Carrier Cylinder-to-Tool CarrierClearance ..................................... 1 mm (0.04 in.) maximum
TX,31,RP3363 1918FEB991/1
TM1640 (15JAN04)
31-3140-8

011504
PN=532
T111932
UN11NOV97
Frames
Remove and Install Loader Boom Bushings and Seals
ABushing (6 used)
BSeal (12 used)
CLoader Boom
T108266
UN26NOV97
1. Lower bucket to the ground and remove bucket from boom. CAUTION: The approximate weight of the bucket cylinder is 105 kg (232 lb).
Specification Bucket CylinderWeight ........................ 105 kg (232 lb) approximate
4. Remove boom pivot pins from machine frame and remove boom. 5. Remove bushings from boom using disks from Bushing, Bearing and Seal Driver Set. 6. Apply NEVER-SEEZ Lubricant or an equivalent on outer surface of new bushings and bores. Center new bushings in boom bores and press seals against bushings with lips outward. 7. Install boom and cylinders on machine. Install shims as needed in loader frame to boom joint.
Specification Loader Boom-to-Loader FrameClearance...................................... 3 mm (0.12 in.) maximum
31 3140 9
2. Remove bucket cylinder and linkage. 3. Disconnect boom cylinders from boom. CAUTION: The approximate weight of the boom is 1089 kg (2400 lb).
Specification Loader BoomWeight ....................... 1089 kg (2400 lb) approximate
TX,3140,RP3046 1918FEB991/1
TM1640 (15JAN04)
31-3140-9

011504
PN=533
Frames
Remove and Install Tool Carrier Boom Bushings and Seals
Left Side of Boom Shown

31 3140 10 ATool Carrier Boom BBushing (4 used) CSeal (8 used) DSeal (4 used) EBushing (2 used) FSeal (8 used) GBushing (4 used)
1. Lower boom to ground and remove attachment from tool carrier. CAUTION: The approximate weight of the boom is 907 kg (2000 lb). The approximate weight of the tilt cylinder is 98 kg (216 lb).
Specification Tool Carrier BoomWeight ................. 907 kg (2000 lb) approximate Tilt CylinderWeight ................................ 98 kg (216 lb) approximate
4. Remove boom pivot pins and remove boom. 5. Remove bushings from boom using disks from Bushing, Bearing and Seal Driver Set. 6. Apply NEVER-SEEZ Lubricant or an equivalent on outer surface of new bushings and bores. Center new bushings in boom bores and press seals against bushings with lips outward. 7. Install boom on machine and replace cylinders, linkage and bucket. Install shims in original locations. Measure clearances and adjust shims as required.
2. Remove bucket tilt linkage and cylinders. 3. Disconnect boom cylinder rod ends from boom.
TX,3140,RP3047 1918FEB991/1
TM1640 (15JAN04)
31-3140-10

011504
PN=534
T108276
UN26NOV97
Group 3160
Hydraulic System
Essential Tools
CED,OUOE003,3383 1922APR991/5
Spanner Wrench . . . . . . . . . . . . . . . . . . . . . . JT07289 Used to tighten spanner nut on 125 series cylinders.
UN08SEP97
CED,OUOE003,3383 1922APR992/5
Torque Wrench. . . . . . . . . . . . . . . . . . . . . . . JT02004 Used with JT07289 Spanner Wrench to tighten spanner nut on 125 series cylinders.
CED,OUOE003,3383 1922APR993/5
T111317A
31 3160 1
WEATHER PACK Crimping Tool . . . . . . . . . . JDG783 Used to install terminals on Quickshift switch wire on pilot controller lever. Crimps WEATHER PACK male and female connectors. Tool crimps both the connector and seal retainer at the same time.
UN08JAN97 T106133
CED,OUOE003,3383 1922APR994/5
Gas Cock . . . . . . . . . . . . . . . . . . . . . . . . . . JT01735 To charge and reduce pressure to accumulator.
CED,OUOE003,3383 1922APR995/5
TM1640 (15JAN04)
31-3160-1

011504
PN=535
Hydraulic System

CED,OUOE003,3384 1922APR991/9
Bench Mounted Holding Fixture . . . . . . . . . . D01006AA Used to hold hydraulic pump.
CED,OUOE003,3384 1922APR992/9
Portable Filter Caddy To filter contamination from hydraulic systems.
CED,OUOE003,3384 1922APR993/9
31 3160 2
3658 mm (12 ft) x 3/4 in. ID 100R1 Hose with 3/4 M NPT Ends (2 used) To connect to the portable filter caddy.
CED,OUOE003,3384 1922APR994/9
Quick Disconnect Fittings To test fittings.
CED,OUOE003,3384 1922APR995/9
Discharge Wand To discharge hydraulic oil back into reservoir.
CED,OUOE003,3384 1922APR996/9
Connector (1-1/16 M ORB x 3/4 M NPT) . . . . . . JT03297 To connect reservoir to filter caddy.
CED,OUOE003,3384 1922APR997/9
TM1640 (15JAN04)
31-3160-2

011504
PN=536
Hydraulic System
Torque Wrench To tighten pilot controller hex nut.
CED,OUOE003,3384 1922APR998/9
Gauge . . . . . . (06895 kPa) (069 bar) (01000 psi) To test pilot pressure coming from pilot controller.
CED,OUOE003,3384 1922APR999/9
Other Material
Number Name Use
T43513 (U.S.) TY9474 (Canadian) 271 (LOCTITE)
Apply to bucket and boom valve sections hardware. Apply to threads of spool assembly components. Apply to threads on pilot controller lever assembly. Apply to threads on pilot controller lever assembly. Apply to universal joint threads. Apply to bucket cylinder head and rod end pins. Apply to bushing and seal. Apply to hydraulic cylinder rod guide lock nut.
PT569 (U.S.)
TY24311 (U.S.) CXTY24311 (Canadian) 222 (LOCTITE) AT115876 (U.S.)
Thread Lock and Sealer (Low Strength)
31 3160 3
KRYTOX GPL202 Fluorinated Grease
Apply to push bar and sleeve adjusters inside pilot controller lever housing.
LOCTITE is a trademark of Loctite Corp. NEVER-SEEZ is a trademark of Emhart Chemical Group. KRYTOX is a trademark of E.I. DuPont, DeNemours and Co. Inc.
CED,OUOE003,3385 1922APR991/1
TM1640 (15JAN04)
31-3160-3

011504
PN=537
Hydraulic System
Specifications
Hydraulic Pump Hydraulic Pump Piston Shoe Weight Wear End Play End Play Saddle Bearing Thickness 49 kg (108 lb) approximate 0.025 mm (0.001 in.) maximum at outer dimension 0.152 mm (0.006 in.) worn 0.076 mm (0.003 in.) new 0.152 mm (0.006 in.) maximum difference between worn and unworn area 1.31.6 mm (0.0500.065 in.) into bearing locating hole 10 Nm (90.0 lb-in.) 95 Nm (70 lb-ft)
Bearing Locate Pin
Distance
Guide Plate Cap Screw Valve Plate-to-Pump Housing Hex Head Cap Screw Socket Head Screw Control Housing-to-Pump Cap Screw
31 3160 4
Torque Torque
Torque Torque
95 Nm (70 lb-ft) 60 Nm (44 lb-ft)
Hydraulic Pump Control Valve Control Housing-to-Pump Cap Screw Control End Cap-to-Control Housing Screw Torque 60 Nm (44 lb-ft)
Torque
40 Nm (30 lb-ft)
Load Sense Module (Valve)-to-End Torque Cap Screw
6 Nm (57 lb-in.)
Loader Control Valve Loader Control Valve Loader Control Valve Tie Bolt Nut Weight Torque 41 kg (90 lb) approximate 56 Nm (75 lb-ft)
CED,OUOE003,3387 1922APR991/5
TM1640 (15JAN04)
31-3160-4

011504
PN=538
Hydraulic System
Item
Measurement
Specification
Bucket Valve Circuit Relief Lock Circuit Relief Housing Compensator Cap Cap Screw Lift Check Hex Head Cap Port Plug Compensator Cap Nut Torque Torque Torque Torque Torque Torque Torque Torque 20 Nm (175 lb-in.) 102 Nm (75 lb-ft) 102 Nm (75 lb-ft) 11 Nm (100 lb-in.) 169 Nm (125lb-ft) 20 Nm (175 lb-in.) 115 Nm (85 lb-ft) 20 Nm (175 lb-in.)
Boom Valve Compensator Cap Plug Nut Hex Head Cap Screw Plug Stripper Bolt Check Hex Head Cap Socket Head Cap Screw Boom Lower Pilot Plug Anti Cavitation Plug Torque Torque Torque Torque Torque Torque Torque Torque Torque Torque 102 Nm (75 lb-ft) 102 Nm (75 lb-ft) 20 Nm (175 lb-in.) 102 Nm (75 lb-ft) 12 Nm (100 lb-in.) 20 Nm (175 lb-in.) 169 Nm (125lb-ft) 20 Nm (175 lb-in.) 12 Nm (100 lb-in.) 102 Nm (75 lb-ft)
31 3160 5
Boom Cylinder Boom Cylinder Weight 105 kg (232 lb) approximate
CED,OUOE003,3387 1922APR992/5
TM1640 (15JAN04)
31-3160-5

011504
PN=539
Hydraulic System
Item
Measurement
Specification
Bucket Cylinder185 Series Bucket Cylinder Piston Retaining Nut Set Screw Nut Rod Guide Screw Weight Torque Torque Torque 105 kg (232 lb) approximate 3580 180 Nm (2640 133 lb-ft) 31.5 5.9 Nm (23 4 lb-ft) 350 70 Nm (258 52 lb-ft)
Boom Cylinder125 Series 624H Boom Cylinder Piston Retaining Nut 624H Bucket Cylinder Piston Retaining Nut 624H and TC62H Boom Cylinder Rod Guide Jam Nut Torque 475 Nm (350 lb-ft) plus 1/12 turn 30 3580 180 Nm (2641 133 lb-ft)
Torque
Torque
1350 Nm (1000 lb-ft)
Tilt Cylinder125 Series TC62H Boom and Tilt Cylinder Piston Retaining Nut
31 3160 6
Torque
475 Nm (350 lb-ft) plus 1/12 turn 30 1350 Nm (1000 lb-ft)
TC62H Tilt Cylinder Rod Guide Jam Nut
Torque
Hydraulic Reservoir Hydraulic Reservoir Hydraulic Reservoir-to-Frame Cap Screw Weight Torque 186 kg (410 lb) approximate 350 Nm (255 lb-ft)
Pilot Controller (Two Lever) Lever Housing-to-Housing Cap Screw Multi-sectional Valve Tie Bolt Torque 8.5 Nm (75 lb-in.)
Torque
11 Nm (100 lb-in.)
CED,OUOE003,3387 1922APR993/5
TM1640 (15JAN04)
31-3160-6

011504
PN=540
Hydraulic System
Item
Measurement
Specification
Pilot Controller (Single Lever) Lever Housing Allen Screw-to-Valve Housing Universal Joint Hex Nut-to-Lever Bottom Housing Grip/Switch Assembly Lever Housing-to-Valve Housing Allen Screw Lever Adjusting Screw Lock Hex Nut Lever Housing-to-Valve Housing Allen Screw Lever Adjusting Screw Lock Hex Nut Oil Engine Lever Travel to Begin Metering Torque 8.5 Nm (75 lb-in.)
Torque
28 Nm (250 lb-in.)
Torque Torque
28 Nm (250 lb-in.) 8.5 Nm (75 lb-in.)
Torque
11 Nm (100 lb-in.)
Torque
8.5 Nm (75 lb-in.)
Torque
11 Nm (100 lb-in.) 40 6C (100 10F) Slow idle 3/85/8 in. (measured at top end of lever) 41374480 kPa (4145 bar) (600650 psi) in detent As the control lever is moved from neutral, the pilot pressure will suddenly jump up to approximately 90 psi at 3/85/8 in. travel. The pressure should then increase smoothly to the specification at the FEEL position (or 75% lever travel), and then jump up to 600650 psi as the lever is moved into detent. 18602082 kPa (1921 bar) (270302 psi)
Temperature Speed Distance
Boom Float Detent
Pressure
31 3160 7
Feel Position
Pressure
Boom Power Down
Pressure
CED,OUOE003,3387 1922APR994/5
TM1640 (15JAN04)
31-3160-7

011504
PN=541
Hydraulic System
Item
Measurement
Specification
Boom Raise
Pressure
18822227 kPa (1922 bar) (273323 psi) 21102455 kPa (2125 bar) (306356 psi) Pressure must increase smoothly to 21102455 kPa (2125 bar) (306356 psi) at 3/4 lever travel and then increase to 41404480 kPa (41.444.8 bar) (600650 psi) as the lever is moved past 8090% travel
Bucket Rollback
Pressure
Bucket Dump and Auxiliary Valve
Pressure
Solenoid Valve Retaining Nut Torque 7 Nm (62 lb-in.)
Ride Control Accumulator Solenoid Nut Accumulator Oil

31 3160 8
Weight Torque Temperature Pressure
40 kg (80 lb) approximate 8 Nm (72 lb-in.) 40C (104F) 2068 138 kPa (20 1 bar) (300 20 psi)
Accumulator Charge
CED,OUOE003,3387 1922APR995/5
TM1640 (15JAN04)
31-3160-8

011504
PN=542
Hydraulic System
Remove and Install Loader Hydraulic Pump

IMPORTANT: Do Hydraulic Pump Flow Test in Group 9025-25 before removing hydraulic pump for repair. If pump does not meet test specification, replace it, do not rebuild pump. 1. Stop engine. 2. Lower all equipment to the ground. 3. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. CAUTION: Prevent unexpected machine movement and possible injury. Install frame locking bar before working in frame hinge area. 4. Install frame locking bar. 5. Turn battery disconnect switch off (if equipped) or disconnect battery ground strap. 6. Remove lower front, left and right side trim shields from cab.
ALoad Sense Hose BSuction Hose CPump Inlet DCase Drain EPressure-to-Control Valve FPressure-to-Steering Valve GHose to Pressure Reducing Valve
T112004
UN29OCT97
31 3160 9
TX,31,ME134 1918FEB991/3
TM1640 (15JAN04)
31-3160-9

011504
PN=543
Hydraulic System
CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 7. Drain hydraulic reservoir. Approximate capacity is 117 L (31 gal). 8. Disconnect and cap lines (AG). 9. Attach lifting device (such as DFT1132 Hydrostatic Motor Removal Tool 850C/750C) to hydraulic pump housing.
31 3160 10
10. Remove hydraulic pump mounting cap screws. CAUTION: The approximate weight of the hydraulic pump is 49 kg (108 lb).
Hydraulic PumpSpecification Hydraulic PumpWeight ................................ 49 kg (108 lb) approximate
11. Remove hydraulic pump. 12. Repair and replace parts as necessary. 13. Replace gasket on pump mounting surface. 14. Install pump with cap screws. 15. Fill pump body with hydraulic oil through case drain (D) line to assure lubrication for start up.
TX,31,ME134 1918FEB992/3
TM1640 (15JAN04)
31-3160-10

011504
PN=544
X9811
UN23AUG88
Hydraulic System
16. Connect lines and fittings. 17. Fill hydraulic reservoir. 18. Switch battery disconnect on (if equipped) or install battery ground cable. 19. Do Hydraulic Pump Margin and Low Standby Pressure Adjustment Test in Group 9025-25.
TX,31,ME134 1918FEB993/3
31 3160 11
TM1640 (15JAN04)
31-3160-11

011504
PN=545
Hydraulic System
Hydraulic Pump (PVG 65) and (PVG 75) Cross Section
31 3160 12
TX,3100,RP3048 1920MAR971/2
TM1640 (15JAN04)
31-3160-12

011504
PN=546
T104483
UN18OCT96
Hydraulic System
ARoll Pin (2 used) BBearing CRoll Pin (4 used) DSwash Plate EScrew FRetaining Ring GPiston (9 used) HHousing IGasket JInlet Tube KPlate LCylinder Barrel MSlipper (9 used) NPlug OSpring PBall QRetainer Shoe RBearing SBearing TRoll Pin (2 used) URetainer Seal VRetaining Ring WRetaining Ring XShaft YBearing ZSeal
TX,3100,RP3048 1920MAR972/2
Disassemble, Inspect and Assemble Hydraulic Pump

CAUTION: Reduce compressed air to less than 210 kPa (2.1 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection. CAUTION: The approximate weight of the hydraulic pump is 49 kg (108 lb).
Hydraulic PumpSpecification Hydraulic PumpWeight ................................ 49 kg (108 lb) approximate
T103480
UN04NOV96
IMPORTANT: Use only diesel fuel to clean pump parts. Solvents can damage internal components. Perform Hydraulic Pump Case Drain Test in Group 9025-25, before removing hydraulic pump for repairs. If pump does not pass the test, replace it, DO NOT rebuild it. 1. Mount pump on D01006AA Bench Mounted Holding Fixture as shown. 2. As pump parts are removed wash in diesel fuel and dry using compressed air.
31 3160 13
TX,31,JC2358 1918FEB991/45
TM1640 (15JAN04)
31-3160-13

011504
PN=547
Hydraulic System
3. Remove socket head cap screws and lift the control group assembly straight up from the top of the pump assembly. Remove control pin from swashblock.
TX,31,JC2358 1918FEB992/45
31 3160 14
4. Remove valve plate by removing four cap screws and lifting it away from main pump assembly.
TX,31,JC2358 1918FEB993/45
5. Remove O-ring (A).

AO-Ring
TX,31,JC2358 1918FEB994/45
TM1640 (15JAN04)
31-3160-14

011504
PN=548
T7553BG
UN24JUN91
T103480
UN04NOV96
T103478
UN04NOV96
Hydraulic System
6. Remove gasket (A).
AGasket
TX,31,JC2358 1918FEB995/45
7. Make sure pump is in a horizontal position. Remove rotating group by turning input shaft slowly while pulling the cylinder barrel from the pumps housing.
UN04NOV96
TX,31,JC2358 1918FEB996/45
8. Number each pump piston shoe assembly (B) and its respective bore in cylinder barrel (A) and shoe retainer (C) while disassembling. This will assure the same parts are installed to the respective bore in the retainer and barrel.
ACylinder Barrel BShoe Assembly CShoe Retainer
T103482
T7553BA
UN24JUN91
31 3160 15
TX,31,JC2358 1918FEB997/45
TM1640 (15JAN04)
31-3160-15

011504
PN=549
T104036
UN04NOV96
Hydraulic System
9. Remove shoe retainer (B) with pistons (A) and shoe retainer spring (C).
APiston (9 used) BShoe Retainer CShoe Retainer Spring
TX,31,JC2358 1918FEB998/45
10. Remove hydrodynamic locking screw (A).

AHydrodynamic Locking Screw
TX,31,JC2358 1918FEB999/45
TM1640 (15JAN04)
31-3160-16

011504
T104801
UN04NOV96
31 3160 16
PN=550
T7553BB
UN24JUN91
Hydraulic System NOTE: Later pump models may not incorporate this retaining ring.
11. Remove retaining ring (A) with flat head screwdriver (B).
ARetaining Ring BFlat Head Screwdriver
T104037
UN04NOV96
31 3160 17
TX,31,JC2358 1918FEB9910/45
TM1640 (15JAN04)
31-3160-17

011504
PN=551
T104041
UN04NOV96
Hydraulic System
12. Remove hydrodynamic bearing by pulling it out of the pumps housing evenly.
TX,31,JC2358 1918FEB9911/45
31 3160 18
13. Remove drive shaft bearing retainer ring with snap ring pliers.
TX,31,JC2358 1918FEB9912/45
TM1640 (15JAN04)
31-3160-18

011504
PN=552
T103483
UN04NOV96
T104028
UN04NOV96
Hydraulic System
14. Remove outboard end of drive shaft and pull out from pump housing. Remove shaft seal retainer (A).
AShaft Seal Retainer
UN12AUG97
TX,31,JC2358 1918FEB9913/45
15. Remove shaft seal (A) from housing only if necessary. This is not reusable.
AShaft Seal
UN24JUN91
TX,31,JC2358 1918FEB9914/45
T7553AL
T104805
31 3160 19
TM1640 (15JAN04)
31-3160-19

011504
PN=553
Hydraulic System
16. Loader pump (130PVG) only: Remove flat head screws with a 5/32 Allen wrench and remove guide plate (A).
AGuide Plate
T104799
UN04NOV96
31 3160 20
TX,31,JC2358 1918FEB9915/45
TM1640 (15JAN04)
31-3160-20

011504
PN=554
T103484
UN04NOV96
Hydraulic System
17. Remove the swashblock from pump housing.
TX,31,JC2358 1918FEB9916/45
18. Remove the saddle bearings (A) from pump housing. 19. Clean all parts thoroughly. Inspect all seals and O-rings for hardening, cracking or deterioration and replace if necessary.
ASaddle Bearing
UN31JAN94
T103485
UN04NOV96
31 3160 21
TX,31,JC2358 1918FEB9917/45
TM1640 (15JAN04)
31-3160-21

011504
PN=555
T8170AE
Hydraulic System
20. Inspect valve plate group. Inspect the valve plate surface that mates with the pump cylinder barrel for excessive wear or scoring. Remove minor defects by lightly stoning the surface with a hard stone that is flat to within 0.001". Be sure to stone lightly. Any excessive stoning will remove the hardened surface. If wear or damage is extensive, replace the valve plate. Check drive shaft bushing for abnormal wear.
TX,31,JC2358 1918FEB9918/45
21. Inspect suction inlet tube for cracks and damage from handling. If any cracks or damage, part must be replaced.
31 3160 22
TX,31,JC2358 1918FEB9919/45
TM1640 (15JAN04)
31-3160-22

011504
PN=556
T103486
UN04NOV96
T7553AS
UN24JUN91
Hydraulic System
22. Rotating Group Inspect cylinder barrel piston bores and the face that mates with valve plate for wear and scoring. Remove minor defects on the face by lightly stoning the surface. If defects can not be removed by this method, cylinder barrel is unusable. 23. Inspect all piston and shoe assemblies to be sure they ride properly on the swashblock.
TX,31,JC2358 1918FEB9920/45
24. Check each piston shoe for smooth pivot action on the piston. Contaminates or burrs can cause them to stick.
TX,31,JC2358 1918FEB9921/45
25. Check piston shoe wear. All shoes must be within specification at outer dimension.
Hydraulic PumpSpecification Piston ShoeWear ............................. 0.025 mm (0.001 in.) maximum at outer dimension
T7553AO
UN24JUN91
T7553AT
UN24JUN91
31 3160 23
Check piston shoe end play. End play must not exceed specification.
Hydraulic PumpSpecification Piston ShoeEnd Play ................................... 0.152 mm (0.006 in.) worn End Play ............................................................ 0.076 mm (0.003 in.) new
TX,31,JC2358 1918FEB9922/45
TM1640 (15JAN04)
31-3160-23

011504
PN=557
T104804
1908NOV96
Hydraulic System
26. Hydrodynamic Bearing Inspect for contaminate damage or extreme wear.
TX,31,JC2358 1918FEB9923/45
31 3160 24
27. Swashblock Group Inspect the swashblock for wear and scoring. If defects are minor, stone the swashblock lightly. If damage is extensive, swashblock should be rejected. Check that the very small holes in the face of the swashblock are open. These holes provide "porting" for the hydrostatic balance fluid (of the piston/shoe assembly) to be channeled through the swashblock to the face of the saddle bearing (providing pressure lubrication).
UN24JUN91
TX,31,JC2358 1918FEB9924/45
TM1640 (15JAN04)
31-3160-24

011504
PN=558
T7553AQ
T104798
UN04NOV96
Hydraulic System
28. Check bearing mating surface of swashblock for cracks or excessive wear. Swashblock movement in saddle bearings must be smooth. Replace if necessary.
UN04NOV96
TX,31,JC2358 1918FEB9925/45
29. Compare saddle bearing thickness in worn area to thickness in an unworn area. Replace saddle bearings if difference is greater than specification.
Hydraulic PumpSpecification Saddle BearingThickness ..................... 0.152 mm (0.006 in.) maximum difference between worn and unworn area
TX,31,JC2358 1918FEB9926/45
IMPORTANT: Bearing locate pins must not protrude through swash plate bearing. See sketch below for proper installation of pins.
UN08NOV96
T104803
UN04NOV96
T104033
31 3160 25
30. Inspect bearing locate pins in housing. Pins (B) must be able to hold bearing in place without protruding through bearing.
ASaddle Bearing (2 used) BLocate Pin (2 used)
TX,31,JC2358 1918FEB9927/45
TM1640 (15JAN04)
31-3160-25

011504
PN=559
T104810
Hydraulic System
Pins should extend specified distance (A).
Hydraulic PumpSpecification Bearing Locate PinDistance ................ 1.31.6 mm (0.0500.065 in.) into bearing locating hole
UN04NOV96
ADistance
TX,31,JC2358 1918FEB9928/45
31. Drive Shaft Group Check shaft bearing for galling, pitting, binding, roughness.
UN04NOV96
Check seal of bearing for grease containment. If seal is worn or broken. Replace shaft and bearing. Check shaft and its splines for wear. If worn, replace shaft and bearing.
TX,31,JC2358 1918FEB9929/45
31 3160 26
32. Check shaft seal (A) for deterioration or cracks. Replace (press out) if necessary. 33. Pump assembly
UN24JUN91
Install new gaskets, seals and O-rings. Apply a thin film of CLEAN grease or hydraulic fluid to sealing components to ease assembly. Apply fluid generously to all wear surfaces.
AShaft Seal
TX,31,JC2358 1918FEB9930/45
TM1640 (15JAN04)
31-3160-26

011504
PN=560
T7553AL
T104034
T103488
Hydraulic System
34. Shaft Seal If removed, press shaft seal into front of pump housing with a 50 mm disk and seal driver.
UN24JUN91
TX,31,JC2358 1918FEB9931/45
35. Swashblock Group Position pump with drive shaft facing down. Grease back side of saddle bearings and place on the locator pins to locate the bearings (A) in pump case. Pins must not protrude through the bearing locator hole. Plastic bearing (C) position should be installed on opposite of control pin side (B) of swashblock.
ABearing (2 used) BControl Pin Side CPlastic Bearing
T104809
UN04NOV96
T7553AU
31 3160 27
TX,31,JC2358 1918FEB9932/45
TM1640 (15JAN04)
31-3160-27

011504
PN=561
Hydraulic System
36. Loader Pump (130PVG) Only Partially insert swashblock into rear of pump housing and insert guide plate into the pumps housing, so flat head cap screws (A) can be used to fasten the guide plate to the housing. Place the swashblock on the guide plate making sure the guide plate is in the groove of the swashblock. Install guide plate screws and tighten. Make sure swashblock swivels in the saddle bearings smoothly.
Hydraulic PumpSpecification Guide Plate Cap ScrewTorque ................................ 10 Nm (90.0 lb-in.)
37. Hydraulic Pump (75PVG) Only Insert swashblock into rear of pump housing. Make sure swashblock swivels in the saddle bearings smoothly.
AFlat Head Cap Screw
UN04NOV96 T104799
31 3160 28
TX,31,JC2358 1918FEB9933/45
TM1640 (15JAN04)
31-3160-28

011504
PN=562
T103484
UN04NOV96
Hydraulic System
38. Hydrodynamic Bearing Bearing should be positioned with "scarf" cuts positioned top and bottom. Bearing should fit into place with a little difficulty and be square to the axis of the pump. Tap bearing into place if necessary using extreme care not to damage the bearing.
TX,31,JC2358 1918FEB9934/45
NOTE: Insert retaining ring to hold bearing in place on older models.

39. Insert hydrodynamic lock screw (A) and hand tighten.
AHydrodynamic Lock Screw
T104798
UN04NOV96
31 3160 29
TX,31,JC2358 1918FEB9935/45
TM1640 (15JAN04)
31-3160-29

011504
T104801
UN04NOV96
PN=563
Hydraulic System
40. Drive Shaft GroupPump in Horizontal Position Install shaft seal retainer (A).
AShaft Seal Retainer
UN12AUG97
TX,31,JC2358 1918FEB9936/45
41. Insert drive shaft and bearing assembly into pump housing and lock in place with drive shaft bearing retainer ring.
31 3160 30
TX,31,JC2358 1918FEB9937/45
TM1640 (15JAN04)
31-3160-30

011504
PN=564
T103483
UN04NOV96
T104805
Hydraulic System
42. Rotating Group Place the cylinder barrel, wear surface down on a clean cloth. Place the shoe retainer spring in the center of the barrel with the fulcrum ball on top of it. Insert pistons into their corresponding (numbered) holes of the shoe retainer. As a unit, fit the pistons into their corresponding (numbered) bores in the cylinder barrel. DO NOT FORCE.
ACylinder Barrel BPiston (9 used) CShoe Retainer
TX,31,JC2358 1918FEB9938/45
At this point, the back of the cylinder should be located approximately 10.2 mm (0.4 in) outside the back of the pump housing.
NOTE: Make sure the rotate group has spring action. This assures correct assembly in relation to the spline.
TX,31,JC2358 1918FEB9939/45
TM1640 (15JAN04)
31-3160-31

011504
PN=565
T103482
43. Support the weight of the cylinder barrel as cylinder spline is passed over the tail shaft, to avoid scratching or damage. Push cylinder forward until the cylinder spline reaches the drive shaft spline and rotate the cylinder slightly to engage shaft splines. Continue to slide cylinder forward until it encounters the cylinder bearing. Lifting the tail shaft slightly helps cylinder and cylinder bearing engagement. Continue pushing cylinder forward until the piston shoes contact the swashblock.
T104036
UN04NOV96
31 3160 31
UN04NOV96
Hydraulic System
44. Valve Plate Group With the drive shaft facing down install O-ring (A) in pump housing.
UN24JUN91
With the drive shaft facing down install gasket (B) on pump housing.
AO-Ring BGasket
TX,31,JC2358 1918FEB9940/45
31 3160 32
45. Position valve plate on housing pins, making sure tail end of shaft engages shaft bushing in valve plate (B). Finger tighten hex head cap screw closest to O-ring first. Alternately hand tighten the other cap screws (A).
ACap Screw BValve Plate
TX,31,JC2358 1918FEB9941/45
TM1640 (15JAN04)
31-3160-32

011504
T104800
UN04NOV96
PN=566
T112369
UN26NOV97
T7553BG
Hydraulic System
46. With control pin (A) in swashblock, move swashblock slowly to left side of pump housing until control pin stops at housing.
AControl Pin
UN04NOV96
TX,31,JC2358 1918FEB9942/45
47. Tighten valve plate cap screws to specification.

Hydraulic PumpSpecification Valve Plate-to-Pump Housing Hex Head Cap ScrewTorque....................................... 95 Nm (70 lb-ft) Socket Head ScrewTorque .......................................... 95 Nm (70 lb-ft)
UN04NOV96
TX,31,JC2358 1918FEB9943/45
48. Install new control gasket and O-ring. Place control on pump housing making sure control pin fits into control piston slot. Loosen end cap (A) to remove spring pressure to aid in assembling of control housing.
AEnd Cap
T103480
T103487
31 3160 33
TX,31,JC2358 1918FEB9944/45
TM1640 (15JAN04)
31-3160-33

011504
PN=567
T104806
UN04NOV96
Hydraulic System
49. Install control valve cap screws and tighten.
Hydraulic PumpSpecification Control Housing-to-Pump Cap ScrewTorque ................................................................ 60 Nm (44 lb-ft)
TX,31,JC2358 1918FEB9945/45
31 3160 34
Remove and Install Hydraulic Pump Control Valve

1. Mount pump on D01006AA Bench Mounted Holding Fixture.
TX,31,ME137 1918FEB991/3
TM1640 (15JAN04)
31-3160-34

011504
PN=568
T103478
UN04NOV96
Hydraulic System
2. Remove socket head cap screws and lift the control group assembly straight up from the top of the pump assembly. Remove control pin from swashblock. 3. Install new control gasket and O-ring. Place control on pump housing making sure control pin fits into control piston slot.
TX,31,ME137 1918FEB992/3
4. Loosen end cap (A) to remove spring pressure to aid in assembling of control housing. 5. Install control valve cap screws and tighten to specification.
Hydraulic Pump Control ValveSpecification Control Housing-to-Pump Cap ScrewTorque ................................................................ 60 Nm (44 lb-ft)
T103478
UN04NOV96
31 3160 35
AEnd Cap
TX,31,ME137 1918FEB993/3
TM1640 (15JAN04)
31-3160-35

011504
PN=569
T104806
UN04NOV96
Hydraulic System
Disassemble and Assemble Hydraulic Pump Control Valve
31 3160 36
1Pump Control End Cap Assembly
2Load Sense Module
3Load Sense (Plus) Module
4Pump Control
TX,31,ME138 1918FEB991/2
TM1640 (15JAN04)
31-3160-36

011504
PN=570
TP55618
UN09SEP97
Hydraulic System NOTE: Control valve is serviced as module (valve) (13) or complete control valve (4) as shown.
Disassemble, inspect, clean and replace parts as necessary.
Hydraulic Pump Control ValveSpecification Control Housing-to-Pump Cap ScrewTorque ......................................................... 60 Nm (44 lb-ft) Control End Cap-to-Control Housing ScrewTorque........................................... 40 Nm (30 lb-ft) Load Sense Module (Valve)-to-End Cap Screw Torque........................................................................ 6 Nm (57 lb-in.)
See Hydraulic Pump Stroke Limiter Adjustment, Group 9025-20.
TX,31,ME138 1918FEB992/2
Remove and Install Loader Control Valve

1. Install boom locking bar. 2. Stop engine.
TX,31,ME139 1918FEB991/4
31 3160 37
TM1640 (15JAN04)
31-3160-37

011504
PN=571
Hydraulic System
CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 3. Drain hydraulic reservoir. Approximate capacity of hydraulic reservoir is 117 L (31 gal). 4. Remove control valve access panel. 5. Loosen hold-down clamps on bucket and boom cylinder lines.
31 3160 38
TX,31,ME139 1918FEB992/4
TM1640 (15JAN04)
31-3160-38

011504
PN=572
X9811
UN23AUG88
Hydraulic System
31 3160 39
TX,31,ME139 1918FEB993/4
TM1640 (15JAN04)
31-3160-39

011504
PN=573
T106963
1912FEB97
Hydraulic System NOTE: On later machines there is an orifice installed at the loader control valve return. The orifice is a double ORFS plate that is placed between return fitting (K) and hydraulic hose.
6. Disconnect all lines. 7. Remove cap screws. CAUTION: The approximate weight of the loader control valve is 41 kg (90 lb).
Loader Control ValveSpecification Loader Control ValveWeight ................... 41 kg (90 lb) approximate
8. Slide control valve forward. Remove loader control valve. 9. Replace parts as necessary. 10. Install loader control valve and connect all lines.
TX,31,ME139 1918FEB994/4
Disassemble and Assemble Loader Control Valve

1. Remove nuts and washers. Separate valve sections. 2. Replace parts as necessary.
31 3160 40
3. Install seals (F). 4. Assemble sections. Tighten nuts.

Loader Control ValveSpecification Loader Control Valve Tie Bolt NutTorque .................................................................. 102 Nm (75 lb-ft)
AInlet Manifold BAuxiliary Section Valve CBucket Section Valve DBoom Section Valve EOutlet Manifold FSeal (13 used)
1909APR97
TX,31,ME140 1918FEB991/1
TM1640 (15JAN04)
31-3160-40

011504
PN=574
T108899
Hydraulic System
Disassemble and Assemble Auxiliary Valve Section and Bucket Section
Bucket Section Shown
T112438
1905DEC97
NOTE: Bucket valve section shown.

1. Disassemble valve. IMPORTANT: Coat all internal surfaces with clean hydraulic oil. 2. Replace all O-rings and backup rings. 3. Apply thread lock and sealer (high strength) to the following components: Cap screws (L and V)
Stripper bolt 4. Torque components.

Bucket ValveSpecification Circuit Relief LockTorque................................... 20 Nm (175 lb-in.) Circuit Relief HousingTorque .............................. 102 Nm (75 lb-ft) Compensator CapTorque.................................... 102 Nm (75 lb-ft) Cap ScrewTorque .............................................. 11 Nm (100 lb-in.) Lift Check Hex Head Cap Torque................................................................ 169 Nm (125.0 lb-ft) Port PlugTorque ................................................. 20 Nm (175 lb-in.)
31 3160 41
TX,31,RP3377 1919FEB991/1
TM1640 (15JAN04)
31-3160-41

011504
PN=575
Hydraulic System
Disassemble and Assemble Bucket Valve SectionTool Carrier
31 3160 42
1. Disassemble valve. IMPORTANT: Coat all internal surfaces with clean hydraulic oil. 2. Replace all O-rings and backup rings. 3. Apply thread lock and sealer (high strength) to the following components: Nut (I) Hex Head Screws (J) Stripper Bolt-to-Spool (L) Tube Plug (R)
Socket Head Screws (S) 4. Torque components.

Bucket ValveSpecification Compensator CapTorque.................................... 115 Nm (85 lb-ft) Circuit Relief CapTorque..................................... 115 Nm (85 lb-ft) NutTorque .......................................................... 20 Nm (175 lb-in.) Hex Head ScrewTorque..................................... 11 Nm (100 lb-in.) Lift Check Hex Head Cap Torque................................................................ 169 Nm (125.0 lb-ft) Socket Head ScrewTorque ................................ 11 Nm (100 lb-in.) Port PlugTorque ................................................. 20 Nm (175 lb-in.) Circuit Relief CapTorque..................................... 115 Nm (85 lb-ft)
TX,31,RP3375 1919FEB991/1
TM1640 (15JAN04)
31-3160-42

011504
PN=576
T112400
1909JAN98
Hydraulic System
Disassemble and Assemble Boom Valve Section
T112439
1905DEC97
1. Disassemble valve. IMPORTANT: Coat all internal surfaces with clean hydraulic oil. 2. Replace all O-rings and backup rings. 3. Apply thread lock and sealer (high strength) to the following components: Nut (I) Hex Head Screws (J) Stripper Bolt-to-Spool (M) Socket Head Screws (U)
4. Torque components.
Boom ValveSpecification Compensator CapTorque.................................... 102 Nm (75 lb-ft) PlugTorque .......................................................... 102 Nm (75 lb-ft) NutTorque .......................................................... 20 Nm (175 lb-in.) Hex Head Cap ScrewTorque .............................. 102 Nm (75 lb-ft) PlugTorque ......................................................... 12 Nm (100 lb-in.) Stripper BoltTorque ............................................ 20 Nm (175 lb-in.) Check Hex Head CapTorque......................... 169 Nm (125.0 lb-ft) Socket Head Cap Screw Torque.................................................................... 20 Nm (175 lb-in.) Boom Lower Pilot Plug Torque.................................................................... 12 Nm (100 lb-in.) Anti Cavitation PlugTorque ................................. 102 Nm (75 lb-ft)
31 3160 43
TX,31,RP3376 1919FEB991/1
TM1640 (15JAN04)
31-3160-43

011504
PN=577
Hydraulic System
Disassemble and Assemble Relief Valve

Remove the adjusting screw (E). Inspect parts for wear or damage. O-rings, backup ring and spring are the only repair parts available. Assemble relief valve. Check the pressure setting. (See Loader Relief and Circuit Relief Valve Pressure Test, Group 9025-25.)
AReturn BInlet CPoppet DFloating Seat EAdjuster FPlunger
UN22OCT96
TX,3100,RP3060 1919FEB991/1
31 3160 44
Disassemble and Assemble Bucket Circuit Relief Valve

Remove adjusting screw from body.
1911APR97
Inspect parts for wear or damage. O-rings, backup ring and spring are the only repair parts available.
TX,3100,RP3062 1919FEB991/1
TM1640 (15JAN04)
31-3160-44

011504
PN=578
T108956
T104612
Hydraulic System
Disassemble and Assemble Load Sense Relief Valve
Remove adjusting screw from body. Inspect parts for wear or damage.
O-rings, backup ring and spring are the only repair parts available.
T106959
1912FEB97
31 3160 45
TX,3100,RP3061 1919FEB991/1
Disassemble and Assemble Boom Circuit Relief Valve

Separate retainer from body.
UN22OCT96
Inspect parts for wear or damage. O-rings, backup ring and spring are the only repair parts available.
AReturn BInlet CPoppet
TX,3100,RP3063 1919FEB991/1
TM1640 (15JAN04)
31-3160-45

011504
PN=579
T104611
Hydraulic System
Remove and Install Boom Cylinder

NOTE: Boom cylinder may be disassembled on the machine for seal and packing replacement.
1. Install frame locking bar. CAUTION: Before removing the boom cylinder, boom must be supported with a hoist or support stands. 2. Raise and support boom using a hoist or support stands. CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with ride control. Always be sure the ride control accumulator energy is discharged when working on hydraulic components. To do this: With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 3. Release hydraulic pressure.
31 3160 46
CAUTION: The approximate weight of boom cylinder is 105 kg (232 lb).

Boom CylinderSpecification Boom CylinderWeight ................................ 105 kg (232 lb) approximate
4. Connect hoist to cylinder using lifting straps.
TX,31,RP3058 1919FEB991/2
TM1640 (15JAN04)
31-3160-46

011504
PN=580
Hydraulic System
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 5. Disconnect cylinder lines (A and B). 6. Support cylinder with hoist and remove rod and head end pins (C and D). 7. Remove cylinder. 8. Repair or replace as necessary. 9. Install cylinder. Connect lines. IMPORTANT: When a machine is started for the first time after cylinder rebuild or oil is drained from cylinder, the Loader Start-Up Procedure must be performed to prevent oil from dieseling inside the cylinder. 10. Perform Loader Start-Up Procedure (Boom Cylinder). (See procedure in this group.)
ACylinder Head End Line BCylinder Rod End Line CRod End Pin DHead End Pin
X9811
UN23AUG88
TX,31,RP3058 1919FEB992/2
TM1640 (15JAN04)
31-3160-47

011504
PN=581
T108860B
UN09APR97
T108857B
UN09APR97
31 3160 47
Hydraulic System
Loader Start-Up Procedure (Boom Cylinder)

IMPORTANT: System pressure must be reduced when performing this procedure. Adjust the LS valve to decrease system pressure. Turning the LS valve counterclockwise decreases system pressure. 1. Remove loader frame access cover. 2. Loosen lock nut on LS valve. Turn LS valve counterclockwise 2.5 complete turns. This will decrease system pressure to approximately 8274 8963 kPa (82.7489.63 bar) (12001300 psi). IMPORTANT: Perform procedure with engine at low idle (no acceleration). 3. Raise boom until you are within 24 feet of full height. 4. Slowly lower the boom until bucket is 24 feet from ground and stop. 5. Repeat steps 3 and 4 five times. 6. Slowly raise the boom to full height. 7. Slowly lower the boom to ground.
31 3160 48
8. Repeat steps 6 and 7 three times. 9. Reset system pressure by turning LS valve clockwise 2.5 turns. Check pressures. See Group 9025-25. 10. Install loader frame access cover.
CED,OUOE024,240 1925SEP981/1
TM1640 (15JAN04)
31-3160-48

011504
PN=582
Hydraulic System
Remove and Install 624H Bucket Cylinder 185 Series

NOTE: Bucket cylinder may be disassembled on the machine for seal and packing replacement.
1. Lower equipment to the ground. 2. Release hydraulic pressure by pushing pilot enable/boom down switch and moving control lever to all positions. 3. Install frame locking bar. 4. Remove bucket level indicator (A). 5. Remove clamps and disconnect wiring lead (B) to return-to-dig switch. CAUTION: The approximate weight of bucket cylinder is 105 kg (232 lb).
Bucket Cylinder185 Series Specification Bucket CylinderWeight............................... 105 kg (232 lb) approximate ABucket Level Indicator BWiring Lead
UN05NOV96 T104844
6. Install lifting straps around cylinder and support with a hoist.
31 3160 49
TX,31,ME147 1919FEB991/2
TM1640 (15JAN04)
31-3160-49

011504
PN=583
Hydraulic System
7. Disconnect head and rod end cylinder lines. 8. Remove head and rod end pins (A and B). 9. Remove cylinder. 10. Repair or replace as necessary. 11. Install cylinder. Connect lines. IMPORTANT: When a machine is started for the first time after cylinder rebuild or oil is drained from cylinder, the Loader Start-Up Procedure must be performed to prevent oil from dieseling inside the cylinder. 12. Perform Loader Start-Up Procedure (Bucket Cylinder). (See procedure in this group.)
UN05NOV96
AHead End Pin BRod End Pin
TX,31,ME147 1919FEB992/2
31 3160 50
TM1640 (15JAN04)
31-3160-50

011504
PN=584
T104843
Hydraulic System
Loader Start-Up Procedure (Bucket Cylinder)

IMPORTANT: System pressure must be reduced when performing this procedure. Adjust the LS valve to decrease system pressure. Turning the LS valve counterclockwise decreases system pressure. 1. Remove loader frame access cover. 2. Loosen lock nut on LS valve. Turn LS valve counterclockwise 2.5 complete turns. This will decrease system pressure to approximately 8274 8963 kPa (82.7489.63 bar) (12001300 psi). IMPORTANT: Perform procedure with engine at low idle (no acceleration.) 3. Slowly raise boom half way up. Roll back bucket to within a few feet of full rollback position. 4. Dump bucket to within a couple of feet of full dump position. 5. Repeat steps 3 and 4 five times. 6. Roll back bucket to full rollback position. 7. Dump bucket until it is in the full dump position. 8. Repeat steps 6 and 7 three times. 9. Reset system pressure by turning LS valve clockwise 2.5 turns. Check pressures. See Group 9025-25. 10. Install loader frame access cover.
31 3160 51
CED,OUOE003,2588 1916NOV981/1
TM1640 (15JAN04)
31-3160-51

011504
PN=585
Hydraulic System
624H Bucket Cylinder185 Series, Cross Section
31 3160 52
185 Cylinder Design

AWear Ring BPiston CBackup Ring DCap Seal EExpander Seal FBarrel GBuffer Seal HRod Bearing IU-Cup Seal JWiper Seal KRod LRod Guide MBackup Ring NO-Ring OShim PNut QSet Screw
TX,31,RP3366 1925OCT971/1
TM1640 (15JAN04)
31-3160-52

011504
PN=586
T109796
UN18JUL97
Hydraulic System
Disassemble 624H Bucket Cylinder185 Series

IMPORTANT: Extend rod to remove oil or air between the piston and rod guide. Excessive amount of trapped oil or air will force seals to expand making disassembly more difficult.
1. Extend rod so piston is approximately 25.4 mm (1 in.) from rod guide. 2. Make a mark on rod guide and cylinder barrel to aid in assembly. 3. Remove screws holding rod guide to barrel. 4. Remove rod guide, rod and piston. 5. To remove piston, remove set screw. Set screw is staked in two places. Remove piston and rod guide from rod. (Refer to 624H Bucket Cylinder185 Series, Cross Section in this group.) 6. Remove seals and backup ring from rod guide. 7. Inspect piston, rod guide and cylinder barrel for nicks or burrs that may damage seals or O-rings. Remove nicks or burrs with fine crocus cloth.
31 3160 53
TX,31,RP3367 1919FEB991/1
TM1640 (15JAN04)
31-3160-53

011504
PN=587
T6190AS
NOTE: Repair procedures for cylinders are similar except as shown.
UN19OCT88
Hydraulic System
Assemble 624H Bucket Cylinder185 Series

NOTE: Use a cylinder repair kit when assembling cylinder. Put clean hydraulic oil on all internal parts before assembling.
1. Install buffer seal (D) and wear ring (C) in rod guide. Install U-cup seal (B) in rod guide with lip inward. Install wiper seal (A) in rod guide with seal lip outward.
UN01JUN93
2. Install O-ring (F) and backup ring (E) on rod guide. Install rod guide on rod. 3. Install expander seal, cap seals, and backup rings on piston.
NOTE: Do not use thread lock and sealer on bucket cylinder rod threads.
4. Install nut on rod.
Bucket Cylinder185 SeriesSpecification Piston Retaining NutTorque..................... 3580 180 Nm (2640 133 lb-ft)
AWiper Seal BU-Cup Seal CWear Ring DBuffer Seal EBackup Ring FO-Ring GO-Ring
5. Install set screw in nut, torque to specification and stake in two places.
Bucket Cylinder185 SeriesSpecification Set Screw NutTorque ................................ 31.5 5.9 Nm (23 4 lb-ft) 31 3160 54
6. Install rod with rod guide and piston into barrel. Align marks on rod guide and barrel to orient port correctly. Install rod guide screws and torque to specification.
Bucket Cylinder185 SeriesSpecification Rod Guide ScrewTorque ......................... 350 70 Nm (258 52 lb-ft)
7. Inspect cylinder pivot bushings and seals. Replace if needed, see instructions in this group.
TX,31,RP3368 1919FEB991/3
TM1640 (15JAN04)
31-3160-54

011504
PN=588
T8005AL
Hydraulic System
8. Install cylinder on machine. Apply NEVER-SEEZ Lubricant or equivalent to pins (A) and (B) and install. Connect hydraulic hoses. IMPORTANT: When machine is started for the first time after cylinder rebuild or oil is drained from the cylinder, the following steps must be taken to prevent oil from dieseling inside the cylinder. 9. Perform Loader Start-Up Procedure (Bucket Cylinder). (See procedure in this group.)
AHead End Pin BRod End Pin
NEVER-SEEZ is a trademark of the Emhart Chemical Group.
TX,31,RP3368 1919FEB992/3
10. Install bucket level indicator (A) and return-to-dig switch wiring clamps. Adjust return-to-dig components per instructions in Group 1674.
ABucket Level Indicator BReturn-to-Dig Switch Wiring Clamp
T104843
UN05NOV96
31 3160 55
TX,31,RP3368 1919FEB993/3
TM1640 (15JAN04)
31-3160-55

011504
PN=589
T104844
UN05NOV96
Hydraulic System
Boom Cylinder Piston Wear Ring Configuration
31 3160 56
UN17FEB99
ASingle Wear Ring Piston (Boom Cylinders SN XXXXXX) BWear Ring 15 mm (0.59 in.) for Single Wear Ring Pistons
CWear Ring 8 mm (0.31 in.) with Vertical Matting Gap DDual Wear Ring Piston (Boom Cylinders SN XXXXXX)
EWear Ring 8 mm (0.31 in.) with Slant Matting Gap
FRod Eye Pin Bore and Centerline
IMPORTANT: On dual wear ring pistons (D), use pin bore centerline (F) for aligning wear rings (C and E) on piston. Gaps
on wear rings must be indexed 180 from each other.
CED,OUOE003,2660 1916DEC981/1
TM1640 (15JAN04)
31-3160-56

011504
PN=590
T118506
Hydraulic System
31 3160 57
TM1640 (15JAN04)
31-3160-57

011504
PN=591
Hydraulic System
Boom Cylinder 624H and TC62H and TC62H Tilt Cylinder125 Series, Cross Section
31 3160 58
TX,31,RP3369 1919FEB991/2
TM1640 (15JAN04)
31-3160-58

011504
PN=592
T107291
UN18FEB97
Hydraulic System
ANut BWear Ring CRing (2 used) DCap Seal ESeal Expander FPiston GRod Seal HWear Ring IRod Seal JWiper Seal KNut LRod MRod Guide NO-Ring OBackup Ring PO-Ring QBarrel
TX,31,RP3369 1919FEB992/2
Disassemble and Assemble 624H and TC62H Boom Cylinder and TC62H Tilt Cylinder125 Series
1. Mark (A) rod guide and barrel to aid in assembly. The JT07289 Spanner Wrench must be attached parallel to the JT02004 torque wrench (or equivalent) to provide a 2:1 multiplier. (Torque reading will be half of actual torque.) 2. Loosen jam nut using appropriate adjustable spanner wrench. 3. Remove rod guide from barrel by rotating counterclockwise.
ARod Guide and Barrel Marks
UN15FEB97
JT07289 Spanner Wrench Used On 125-Series Cylinders
TX,31,RP3370 1919FEB991/13
TM1640 (15JAN04)
31-3160-59

011504
PN=593
T107241
31 3160 59
Hydraulic System
4. Remove nut to remove piston. 5. Remove piston wear ring (C) and seals (D). 6. Remove rod guide. 7. Remove O-ring, backup ring, rod seals, and rod wear ring.
ANut BPiston CWear Ring DCap Seal
UN19OCT88
TX,31,RP3370 1919FEB992/13
8. Inspect end of barrel. If necessary, remove nicks and burrs from the end of the barrel. 9. Thoroughly clean all components.
UN19OCT88
10. Install rod wear ring.

31 3160 60
11. Install buffer seal with lip of seal toward inside (oil side) of cylinder. 12. Install buffer seal backup ring in notch provided in the outboard side of the buffer seal. 13. Install rod seal with sealing lip toward inside (oil side) of cylinder. 14. Install wiper seal with extended lip toward outside (air side) of cylinder. Press metal ring flush with the outer end of guide (Use care not to damage the extended sealing lip). 15. Install guide to barrel O-ring and backup ring with the backup ring toward the outside (air side) of cylinder.
TX,31,RP3370 1919FEB993/13
TM1640 (15JAN04)
31-3160-60

011504
PN=594
T6119AO
T6172BQ
Hydraulic System
IMPORTANT: To prevent damage of seal during assembly, the lands on the piston must be clean and free of nicks and burrs. 16. Inspect the piston lands. If necessary, clean the lands of any nicks or burrs that can cut the piston seal.
Once started, install cap seal as quickly as possible to keep the amount of time that the seal is stretched to a minimum.
17. Install seal expander. 18. Push seal on end of piston. 19. Install a plastic tie band around cap seal with the smooth side against seal.
TX,31,RP3370 1919FEB994/13
IMPORTANT: For proper fit and operation, the backup rings must be installed with the radius toward seal expander. 20. Pull cap seal across land into position over seal expander using the plastic tie band.
T6122AB
NOTE: The cap seal can be made more pliable by warming it with your hands or putting seal in hot water for approximately 5 minutes.
UN19OCT88
31 3160 61
TX,31,RP3370 1919FEB995/13
TM1640 (15JAN04)
31-3160-61

011504
PN=595
T6122AE
UN19OCT88
T6122AC
UN06AUG90
Hydraulic System
21. Install backup rings with radius toward seal expander. 22. Check the cap seal for looseness. Seal must fit tight against seal expander and not turn. If seal can be turned, it has been stretched too much and can be damaged during assembly into barrel.
ABackup Ring (2 used) BRadius CCap Seal DSeal Expander
TX,31,RP3370 1919FEB996/13
31 3160 62
NOTE: When using a ring compressor, put a piece of shim stock between cap seal and compressor at the joint so it does not damage seal. When using a plastic tie band (A) and hose clamp, grind a taper (B) on one end of the tie band. Install tie band with the taper against cap seal. Before tightening the hose clamp (C), the tie band must be under hose clamp all around the piston. Seal will also shrink to its original size if left for a minimum of 8 hours before installing assembly into barrel.
23. If necessary, shrink cap seal to its original size using a ring compressor or plastic tie band and a hose clamp.
APlastic Tie Band BTaper CHose Clamp
UN09NOV88
TX,31,RP3370 1919FEB997/13
TM1640 (15JAN04)
31-3160-62

011504
PN=596
T86565
T6126AO
UN19OCT88
Hydraulic System
24. Install wear ring.
TX,31,RP3370 1919FEB998/13
T6122AF
UN19OCT88
31 3160 63
TM1640 (15JAN04)
31-3160-63

011504
PN=597
Hydraulic System
ASingle Wear Ring Piston (624H Boom Cylinders SN 570631) (TC62H Boom Cylinders SN 570463)
BWear Ring 15 mm (0.59 in.) for Single Wear Ring Pistons CWear Ring 8 mm (0.31 in.) with Vertical Matting Gap
DDual Wear Ring Piston (624H Boom Cylinders SN 570632) (TC62H Boom Cylinders SN 570463)
EWear Ring 8 mm (0.31 in.) with Slant Matting Gap FRod Eye Pin Bore and Centerline
IMPORTANT: On dual wear ring pistons (D), use pin bore centerline (F) for aligning wear rings (C and E) on piston. Gaps on wear rings must be indexed 180 from each other. 25. Boom CylindersOn early boom cylinders install single wear ring (B). Later boom cylinders:
624H: (S.N. 570362) TC62H: (S.N. 570464) Install wear rings (C and E) on piston (D). When installing piston on rod, use pin bore centerline (F) for aligning wear rings. Gaps on wear rings must be indexed 180 from each other. 26. Install assembled rod guide and piston on rod.
TX,31,RP3370 1919FEB999/13
TM1640 (15JAN04)
31-3160-64

011504
PN=598
T118506
UN17FEB99
31 3160 64
Hydraulic System NOTE: Do NOT apply thread lock and sealer to bucket cylinder piston retaining nut.
27. Apply thread lock and sealer (high strength) or equivalent to rod threads, under piston retaining nut on boom cylinder, but NOT bucket cylinder. Lubricate piston with hydraulic oil where retaining nut contacts it. Tighten piston retaining nut to the torque specification.
Boom Cylinder125 SeriesSpecification 624H Boom Cylinder Piston Retaining NutTorque ......................................... 475 Nm (350 lb-ft) plus 1/12 turn 30 624H Bucket Cylinder Piston Retaining NutTorque ......................... 3580 180 Nm (2641 133 lb-ft) Tilt Cylinder125 SeriesSpecification TC62H Boom and Tilt Cylinder Piston Retaining NutTorque .............................. 475 Nm (350 lb-ft) plus 1/12 turn 30
TX,31,RP3370 1919FEB9910/13
28. Put tape around a socket. Make marks on the tape to divide the socket into 1/12s (30).
UN19OCT88
TX,31,RP3370 1919FEB9911/13
29. Turn the nut to specified torque plus one mark (30). 30. Apply thread lock and sealer (low strength) or equivalent to barrel threads that will be under jam nut.
UN19OCT88
TX,31,RP3370 1919FEB9912/13
TM1640 (15JAN04)
31-3160-65

011504
PN=599
T6172BR
T6149AG
31 3160 65
Hydraulic System
31. Thread jam nut onto the barrel. IMPORTANT: To prevent seal damage, the barrel, piston and rod must be in alignment during installation. 32. Apply a light coat of clean hydraulic oil to piston seals and barrel chamfer. Use care not to get oil on barrel threads. 33. Carefully push piston into barrel. 34. Apply thread lock and sealer (low strength) or equivalent to barrel threads. Use care not to get sealant on end of barrel that engages internal O-ring and backup ring. 35. Carefully push and rotate rod guide to engage threads.
UN15FEB97
36. Thread rod guide onto barrel until it bottoms internally against the end of the barrel. IMPORTANT: Do not turn the guide in place with a spanner wrench. 37. Loosen rod guide until the marks made before disassembly are aligned, or the rod guide port is properly positioned.
31 3160 66
ARod Guide and Barrel Marks
38. Tighten the jam nut against the rod guide.

Boom Cylinder125 SeriesSpecification 624H and TC62H Boom Cylinder Rod Guide Jam NutTorque.................................. 1350 Nm (1000 lb-ft) Tilt Cylinder125 SeriesSpecification TC62H Tilt Cylinder Rod Guide Jam NutTorque .................................................... 1350 Nm (1000 lb-ft)
IMPORTANT: When machine is started for the first time after cylinder rebuild or oil is drained from the cylinder, the following steps must be taken to prevent oil from dieseling inside the cylinder. 39. Perform Loader Start-Up Procedure (Boom Cylinder). (See procedure in this group.)
TX,31,RP3370 1919FEB9913/13
TM1640 (15JAN04)
31-3160-66

011504
PN=600
T107241
Hydraulic System
Remove and Install Boom, Bucket or Tilt Cylinder Bushings and Seals
1. Remove seals (B).
UN27OCT88
2. Remove bushings (A). 3. Install and center new bushings in bore. 4. Install new seals. Press seals into bore tight against bushing with lip facing outward. 5. For initial lubrication, apply NEVER-SEEZ Lubricant or an equivalent to bushings and seals.
ABushing BSeals
TX,31,ME150 1919FEB991/1
T6172BE
31 3160 67
TM1640 (15JAN04)
31-3160-67

011504
PN=601
Hydraulic System
Remove and Install Hydraulic Reservoir

1. Remove hood and engine side shields. 2. Release hydraulic pressure by holding pilot enable/boom down switch and moving hydraulic control lever to boom float. 3. Drain reservoir. (See Operators Manual, Group 87, Change Hydraulic System Oil.) Approximate capacity is 117 L (31 gal). 4. Disconnect lines (C and E). CAUTION: The approximate weight of the reservoir is 186 kg (410 lb).
Hydraulic ReservoirSpecification Hydraulic ReservoirWeight ........................ 186 kg (410 lb) approximate
5. Install lifting strap around reservoir and attach hoist. 6. Remove cap screws to remove reservoir. 7. Replace parts as necessary. 8. Install reservoir. Tighten reservoir-to-frame cap screws. Connect lines.
31 3160 68 Hydraulic ReservoirSpecification Hydraulic Reservoir-to-Frame Cap ScrewTorque .................................................... 350 Nm (255 lb-ft)
AVent Filter BFill Tube CTo Loader Hydraulic Pump DReservoir Drain Plug ETo Return Filter
NOTE: If reservoir shows signs of contamination, perform Hydraulic Oil Clean-Up Procedure in this group.
9. Fill hydraulic reservoir with recommended oil. (See Hydraulic System Oil, Group 0004.)
TX,31,ME151 1919FEB991/1
TM1640 (15JAN04)
31-3160-68

011504
PN=602
T109044
UN14APR97
Hydraulic System
Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy

SERVICE EQUIPMENT AND TOOLS Portable Filter Caddy 3658 mm (12 ft) x 3/4 in. ID 100R1 Hose with 3/4 M NPT Ends (2 used) Quick Disconnect Fittings Discharge Wand JT03297 Connector (1-1/16 M ORB x 3/4 M NPT)
5. Start the filter caddy. Check to be sure oil is flowing through the filters. Operate filter caddy approximately 15 minutes so oil in reservoir is circulated through filter a minimum of four times. Leave filter caddy operating for the next steps.
IMPORTANT: Brake system uses oil from hydraulic reservoir. Flush all lines in the brake, pilot, differential lock, and clutch cut-off system. Disassemble and clean pressure reducing valve and pilot controller. Remove and clean pilot caps from main control valve. Brake components may fail if brake system is not cleaned after hydraulic reservoir contamination. 1. If hydraulic system is contaminated due to a major component failure, remove and disassemble steering cylinders to clean debris from cylinders. 2. Install new return filter elements. IMPORTANT: To prevent cavitation of filter caddy pump, the minimum I.D. of connector is 1/2 in.
NOTE: Filtering time for reservoir is 0.089 minute x number of liters (0.33 minute x number of gallons). Reservoir capacity is 106 L (28 gal).
6. Start the engine and run it at fast idle. IMPORTANT: For the most effective results, cleaning procedure must start with the smallest capacity circuit then proceed to the next largest capacity circuit. 7. Operate all functions, one at a time, through a complete cycle in the following order: clam, steering, bucket, and boom. Also include all auxiliary hydraulic functions. Repeat procedure until the total system capacity has circulated through filter caddy seven times, approximately 30 minutes. Each function must go through a minimum of three complete cycles for a thorough cleaning of oil.
31 3160 69
NOTE: For a failure that creates a lot of debris, remove access cover from reservoir. Drain reservoir and connect filter caddy suction line to drain port. Add a minimum of 19 L (5 gal) of oil to reservoir. Operate filter caddy and wash out the reservoir.
3. To minimize oil loss, pull a vacuum in reservoir using a vacuum pump. Connect filter caddy suction line to drain port at bottom of reservoir using connector and quick disconnect fitting. Check to be sure debris has not closed drain port. 4. Put filter caddy discharge line into reservoir filler hole so end is as far away from drain port as possible to obtain a thorough cleaning of oil.
NOTE: Filtering time for complete hydraulic system is 0.158 minute x number of liters (0.6 minute x number of gallons). Complete hydraulic system capacity is approximately 256 L (67 gal) . Filtering time for machines with auxiliary hydraulic functions must be increased because system capacity is larger.
8. Stop the engine. Remove the filter caddy. 9. Install new return filter elements. 10. Check oil level in reservoir; add oil if necessary. (See Fuels and Lubricants in Group 0004.)
TX,31,ME152 1905AUG961/1
TM1640 (15JAN04)
31-3160-69

011504
PN=603
Hydraulic System
Pilot Controller Valve Remove and Install (Single Lever Controller)

1. Stop engine and relieve hydraulic pressure by using boom lower switch and placing controller in boom float position. 2. Remove air vent filter from hydraulic oil reservoir and plug vent. 3. Place a vacuum on the hydraulic oil reservoir tank. 4. Open load center service door. 5. Disconnect electrical connectors. 6. Disconnect lines (AH). 7. Remove four cap screws. Remove pilot controller. 8. Replace parts as necessary. 9. Install pilot controller. Connect lines and electrical connectors.
AAuxiliary Pilot Controller-to-Auxiliary Valve BPilot Controller-to-Bucket Valve Bucket Dump CPilot Controller-to-Hydraulic Reservoir DPilot Controller-to-Boom Valve Boom Lower EPilot Controller-to-Bucket Valve Bucket Rollback FPilot Controller-to-Boom Valve Boom Raise GPilot Controller-to-Pressure Reducing Manifold HAuxiliary Pilot Controller-to-Auxiliary Valve
UN01OCT96
31 3160 70
TX,31,ME155 1919FEB991/1
TM1640 (15JAN04)
31-3160-70

011504
PN=604
T104168
UN01OCT96
T104166
Hydraulic System
Cross Section Pilot Controller Valve (Single Lever Controller)
Bucket Rollback
AControl Lever BPlunger CMetering Spring DSpool Assembly EC Port FP Port GA Port HReturn Spring ISpring Guide JElectric Coil KPush Bar LPull Plate MShim, Spool Metering NShim, Spool Position 31 3160 71
TX,31,ME156 1919FEB991/1
Pilot Controller Valve Disassemble and Assemble (Single Lever Controller)

Before Pilot Control Valve is disassembled the following checks should be done first to help isolate confirm the problem is in the pilot controller. Perform Pilot Control Valve Pressure Test. (See Section 9025-25.) Perform Pressure Reducing Valve Pressure Test. (See Section 9025-25.)
TX,31,RP3064 1916OCT981/24
TM1640 (15JAN04)
31-3160-71

011504
PN=605
T109108
UN01MAY97
Hydraulic System
31 3160 72
Single Lever (Joystick) Assembly
TX,31,RP3064 1916OCT982/24
TM1640 (15JAN04)
31-3160-72

011504
TP55415
UN15MAR97
PN=606
Hydraulic System
1Grip 2Sleeve 3Nut 4Retainer 5Boot 6Nut (4 used) 7Lever 8Setscrew 9Washer 10Washer 11Plug 12Plate 13Washer 14Nut 15U-Joint (Center Post) 16Ball Joint Socket (3 used) 17Cap Screw (4 used) 18Housing (top) 19Push Bar 20Grommet (4 used) 21Strap (4 used) 22Terminal Nipple (8 used) 23Washer 24Pin Contact (8 used) 25Nut 26Connector 27O-Ring 28Electrical Coil (3 used) 29Retainer (3 used) 30Tube 31Backup Ring 32Seal 33Ring (2 used) 34Retainer (2 used) (Tool Carrier 1 used) 35Retainer (2 used) (Tool Carrier 3 used) 36Plunger (2 used) (Tool Carrier 1 used) 37Plunger (2 used) (Tool Carrier 3 used) 38Shim (As required) (0.1 mm/.004 in) 39Shim (As required) (0.2 mm/.007 in) 40Shim (As required) (0.4 mm/.015 in) 41Spool (2 used) 42Spool 43Spool 44Spring 45Feel Position Kit 46Spring 47Spring 48Housing 49O-Ring 50Plug 51Plug (2 used) 52Valve 53Label 54O-Ring (6 used) 55Adapter (5 used) 56O-Ring (6 used) 57Adapter 58Plate 59Screw (4 used) 60Lock Nut (3 used) 61Nut 62Spool
TX,31,RP3064 1916OCT983/24
Replacing Quickshift Switch In Controller Lever 1. Remove pilot controller from machine. (See Remove and Install Pilot Controller Valve in this group.)
UN19DEC96
2. Place controller in bench vice. 3. Slide boot and retainers (B) down with hands from grip (A).
AGrip BBoot and Retainer
TX,31,RP3064 1916OCT984/24
4. Lift up bottom of boot and remove four allen screws (A) from lever housing.
AAllen Screw (4 used)
UN19DEC96
TX,31,RP3064 1916OCT985/24
TM1640 (15JAN04)
31-3160-73

011504
PN=607
T105757B
T105756B
31 3160 73
Hydraulic System
IMPORTANT: Scribe a mark along side of the lever housing and valve housing of the controller before disassembling. The mark will be used when aligning the controller housings during the assembly procedure. If correct alignment is not done while assembling incorrect operation and/or damage to controller may occur. 5. Remove lever housing (A) from valve housing (B). 6. Cut switch wire at bottom side of lever housing by tie band. Remove tie band and pull wire out of lever and housing. 7. Remove grommet from lever housing.
ALever Housing BValve Housing
TX,31,RP3064 1916OCT986/24
31 3160 74
NOTE: Note the position of the lever in relation to the wire opening in lever for proper assembly.
8. Loosen hex jam nut (A) and then turn complete grip (B) with switch assembly to remove. 9. Inspect parts and replace as necessary. 10. Apply thread lock and sealer (high strength) to lever threads. 11. Place new boot retainers over lever for installing later. 12. Install new grip with switch assembly on lever noting the proper index, then tighten hex jam nut. 13. Place shrink tube on wire and fish wire down through lever handle and center of universal joint. Position shrink tube so it is centered between the area it goes into the lever and out the universal joint. Pull back wire and heat shrink tube on wire. Return wire to the proper position in lever assembly.
AHex Jam Nut BGrip
UN19DEC96
TX,31,RP3064 1916OCT987/24
TM1640 (15JAN04)
31-3160-74

011504
PN=608
T105756C
T105758B
UN19DEC96
Hydraulic System
14. Feed wire through the housing passage and install grommet at (A) noting the position of wire. Wire (B) should be positioned so it clears the coil bore. Wire should have approximately a 51 mm (2.0 in.) loop. 15. Place clear wire protective sleeve over wire and install two terminals (C) with JDG783 WEATHER PACK Crimping Tool. Install wire with terminals in connector (D). 16. Install lever assembly on valve housing with four allen screws. Note scribe marks for proper index.
Pilot Controller (Single Lever)Specification Lever Housing Allen Screw-to-Valve HousingTorque ................................. 8.5 Nm (75 lb-in.)
17. Pull up boot and position on grip assembly. Install two shrink retainers by heating with heat blow gun.
UN19DEC96 T105759B
18. Install lever assembly in tractor. (See Remove and Install Pilot Control Valve in this group.)
AGrommet Location BWire CTerminal (2 used) DConnector EShrink Tube
31 3160 75
TX,31,RP3064 1916OCT988/24
TM1640 (15JAN04)
31-3160-75

011504
PN=609
Hydraulic System
Replace Pilot Control Lever Boot (Joystick) 1. Remove four cap screws from base of lever controller assembly inside load center door on right side of operator station. (See Remove and Install Pilot Controller Valve in this group.) This will allow boot to be free at base of controller assembly. 2. Slide boot and retainers (B) down with hands from grip (A). 3. Remove one Phillips screw from front of grip. Pull up on grip to remove. 4. Remove two shrink retainers. 5. Slide boot over switch assembly to remove. 6. Install new boot and retainers over switch assembly. 7. Install grip and fasten to lever with Phillips screw. 8. Pull up boot and position on grip with two shrink retainers. Heat retainers with heat blow gun. 9. Install four cap screws in pilot controller in load center compartment.
31 3160 76
TX,31,RP3064 1916OCT989/24
TM1640 (15JAN04)
31-3160-76

011504
PN=610
T105756B
UN19DEC96
Hydraulic System
Replace Pilot Control Lever Boot (Single Lever) 1. Cut the tie band off around base of lever housing. 2. Slide boot and retainers (B) down with hands from grip (A). 3. Remove grip by sliding up and off of lever. 4. Remove boot. 5. Install new boot and retainers over lever. 6. Install grip on lever. 7. Pull up boot and position on grip with two shrink retainers. Heat retainers with heat blow gun. 8. Install new tie band around base of boot and lever housing.
TX,31,RP3064 1916OCT9810/24
Replace Universal Joint 1. Remove pilot controller from machine. (See Remove and Install Pilot Controller Valve in this group.)
UN19DEC96
T105756B
UN19DEC96
31 3160 77
2. Place controller in vice and pull boot up. 3. Remove four allen screws (A) in lever housing.
TX,31,RP3064 1916OCT9811/24
TM1640 (15JAN04)
31-3160-77

011504
PN=611
T105757B
Hydraulic System
IMPORTANT: Scribe a mark along side of the lever housing and valve housing of the controller before disassembling. The mark will be used when aligning the controller housings during the assembly procedure. If correct alignment is not done while assembling incorrect operation and/or damage to controller may occur. 4. Remove lever housing (A) from valve housing (B). 5. Cut quickshift wire off right behind connector and pull wire out of housing, up through universal joint and lever. 6. Remove lever from universal joint by using 1/2 wrench on flats of lever.
UN19DEC96
NOTE: Make note of position of the ball sockets assembly in relationship to coil bores.
7. Remove ball socket assembly with plate and washers. 8. Remove hex nut from bottom side of universal joint and housing. 9. Replace parts as necessary.
31 3160 78 ALever Housing BValve Housing
10. Apply thread lock and sealer (high strength) to universal joint threads. 11. Install universal joint in bottom of housing with hex nut and washer. Index to the 12 oclock position in relation to coil bores. Tighten to specification.
Pilot Controller (Single Lever)Specification Universal Joint Hex Nut-to-Lever Bottom HousingTorque ............................................. 28 Nm (250 lb-in.)
12. Install washers, ball sockets with plate over universal joint. Note proper index of ball sockets to relationship of coil bores. On joystick controller the bore without coil should be in the 3 oclock position.
TX,31,RP3064 1916OCT9812/24
TM1640 (15JAN04)
31-3160-78

011504
PN=612
T105758B
Hydraulic System
13. Install grip/switch assembly along with boot and new shrink retainers on universal joint. Note proper index of grip handle (must be in 12 oclock position). Also note the index of the passage way hole for the quickshift wire in the housing (should be in the 1 oclock position). Tighten assembly.
Pilot Controller (Single Lever)Specification Grip/Switch AssemblyTorque.................................... 28 Nm (250 lb-in.)
TX,31,RP3064 1916OCT9813/24
14. Feed quickshift wire from grip assembly down through handle, center of universal joint and housing. Make sure protective shrink tube (E) is properly positioned on wire, centered through lever and universal joint. Pull wire back out and heat the shrink tube onto wire and return wire to proper position. 15. Slide clear plastic sleeve on wire that sticks out of housing and install terminals (C) on wire with JDG783 WEATHER PACK Crimping Tool. Install terminals in connector (D). 16. Install grommet in housing and tie band at area (A) on wire. Position wire (B) so it clears coil bores as shown (approximately a 51 mm [02 in.] loop). 17. Install lever housing assembly onto valve housing. Note index marks scribed before disassembly for proper alignment to proper ports. Tighten four allen screws.
Pilot Controller (Single Lever)Specification Lever Housing-to-Valve Housing Allen ScrewTorque..................................................... 8.5 Nm (75 lb-in.) 31 3160 79
ATie Band Area BWire CTerminals DConnector EShrink Tube
TX,31,RP3064 1916OCT9814/24
TM1640 (15JAN04)
31-3160-79

011504
PN=613
T105759B
UN19DEC96
Hydraulic System
18. Adjust ball socket (A) to zero clearance. Lever must be perpendicular to mounting surface when finished. Use allen wrench to turn setscrew (B) while holding adjuster sleeve (C). After adjusted, lock in place by tightening hex nut (D) to specification with torque wrench while holding adjuster sleeve with open end wrench. Note special tool (E) is used in manufacturing only.
Pilot Controller (Single Lever)Specification Lever Adjusting Screw Lock Hex NutTorque ................................................................. 11 Nm (100 lb-in.)
19. Install lever housing assembly with four allen screws onto valve housing. Note index scribe marks made before disassembly. 20. Install pilot controller in machine. (See Remove and Install Pilot Controller Valve in this group.)
ABall Socket BSetscrew CAdjuster Sleeve DNut ESpecial Tool
31 3160 80
TX,31,RP3064 1916OCT9815/24
Replace Seals on Spool Retainers and Inspect Spool Assembly 1. Remove pilot controller from machine. (See Remove and Install Pilot Controller Valve in this group.) 2. Place controller in bench vice. 3. Lift up bottom of boot and remove four allen screws (A) from lever housing.
UN19DEC96
TX,31,RP3064 1916OCT9816/24
TM1640 (15JAN04)
31-3160-80

011504
PN=614
T105757B
T105760B
UN12JUN98
T105761B
UN19DEC96
Hydraulic System
IMPORTANT: Scribe a mark along side of the lever housing and valve housing of the controller before disassembling. The mark will be used when aligning the controller housings during the assembly procedure. If correct alignment is not done while assembling incorrect operation and/or damage to controller may occur. Also note spool placement to bore for reassembly. When servicing it is important to keep the representative retainer and spool assembly in the same bore. 4. Remove lever housing (A) from valve housing (B).
ALever Housing BValve Housing
TX,31,RP3064 1916OCT9817/24
5. Remove coil (A) and let hang on side of valve housing. Remove coil retainer. Remove spool retainer (B) with pliers from valve housing.
ACoil BSpool Retainer
T105758B
UN19DEC96
31 3160 81
TX,31,RP3064 1916OCT9818/24
TM1640 (15JAN04)
31-3160-81

011504
PN=615
T105762B
UN19DEC96
Hydraulic System
6. Remove and replace seals. 7. Lubricate wiper seal (D) with petroleum jelly. 8. Install seal in bore along with seal retainer (E). 9. Slightly bend tangs on stop ring (F) to allow for ease of installation to keep the ring centered in bore. Note, stop ring comes from factory with slightly concave or bent tangs. Make sure bending is done in the same direction. Tangs must face out when installing. Install stop ring in retainer by using a 11 mm socket as driver. Be sure to have stop ring (F) centered in bore so it does not contact push bar or ball socket pins.
ABackup Ring BO-Ring CRetainer DWiper Seal ESeal Retainer FStop Ring
UN06JAN97
TX,31,RP3064 1916OCT9819/24
31 3160 82
TM1640 (15JAN04)
31-3160-82

011504
PN=616
T105841
Hydraulic System
IMPORTANT: When removing spool retainer do not lose shims located between retainer and spool spring guide. 10. Remove spool assembly and springs (BG, I, and J). If equipped remove feel position assembly (H). 11. Inspect and replace parts as necessary 12. Apply KRYTOX GPL202 fluorinated grease to sliding surfaces of adjuster sleeves and push bar top where it contacts the adjusting screw.
Controller Spool Assembly with Retainer with Feel Position
13. Install spool assembly and retainer in same bores if using existing parts. 14. Install retainers and coils (if equipped). 15. Install lever housing assembly onto valve housing. Note index marks scribed before disassembly for proper alignment to proper ports. Tighten four allen screws.
Pilot Controller (Single Lever)Specification Lever Housing-to-Valve Housing Allen ScrewTorque..................................................... 8.5 Nm (75 lb-in.)
ARetainer (With Seals) BShims (Spool Positioning) CGuide (Spring) DSpool EShims (Metering Adjustment) FSpring (Spool) GRetainer Plate (Spool Spring) HFeel Assembly ISpring (Feel Position) JSpring (Return)
T105763B
UN19DEC96
31 3160 83
KRYTOX is a trademark of E.I. DuPont, DeNemours and Co. Inc.
TX,31,RP3064 1916OCT9820/24
TM1640 (15JAN04)
31-3160-83

011504
PN=617
Hydraulic System
16. Adjust ball socket (A) to zero clearance. Lever must be perpendicular to mounting surface when finished. Use allen wrench to turn setscrew (B) while holding adjuster sleeve (C). After adjusted, lock in place by tightening hex nut (D) to specification with torque wrench while holding adjuster sleeve with open end wrench. Note special tool (E) is used in manufacturing only.
Pilot Controller (Single Lever)Specification Lever Adjusting Screw Lock Hex NutTorque ................................................................. 11 Nm (100 lb-in.)
Ball Socket Assembly
17. Install lever housing assembly with four allen screws onto valve housing. Note index scribe marks made before disassembly. 18. Do bench test on controller to check valve pressures using tractor as pressure source. (See Pilot Control Valve Pressure Test (Bench) in this group.) 19. Install pilot controller in machine. (See Remove and Install Pilot Controller Valve in this group.)
31 3160 84
ABall Socket BSetscrew CAdjuster Sleeve DHex Nut ESpecial Tool
TX,31,RP3064 1916OCT9821/24
Pilot Control Valve Pressure Test (Bench) 1. Place controller valve assembly in vice. 2. Plug all ports not being tested in controller and cap lines from tractor (if pressure source is being used from same machine controller is being repaired on). 3. Place quick coupler in drain port, inlet pressure port and outlet port to be tested in controller. 4. Connect test hose with quick couplers from drain port to reservoir or bucket.
TX,31,RP3064 1916OCT9822/24
TM1640 (15JAN04)
31-3160-84

011504
PN=618
T105766B
UN19DEC96
T105760B
UN12JUN98
T105761B
UN19DEC96
Hydraulic System
5. Connect test hose (B) to pressure reducing valve (right side below operator station) quick coupler (A) to inlet pressure port on controller. 6. Connect 6895 kPa (69 bar) (1000 psi) test gauge to port being tested quick coupler. 7. Run engine at idle, boom down with park brake ON. Check pilot controller pressures to specification.
Pilot Controller (Single Lever)Specification OilTemperature ................................................... 40 6C (100 10F) EngineSpeed ............................................................................ Slow idle Lever Travel to Begin Metering Distance ................................................ 3/85/8 in. (measured at top end of lever) Boom Float DetentPressure ................... 41374480 kPa (4145 bar) (600650 psi) in detent Feel PositionPressure .............................. As the control lever is moved from neutral, the pilot pressure will suddenly jump up to approximately 90 psi at 3/85/8 in. travel. The pressure should then increase smoothly to the specification at the FEEL position (or 75% lever travel), and then jump up to 600650 psi as the lever is moved into detent. Boom Power DownPressure................... 18602082 kPa (1921 bar) (270302 psi) Boom RaisePressure .............................. 18822227 kPa (1922 bar) (273323 psi) Bucket RollbackPressure ........................ 21102455 kPa (2125 bar) (306356 psi) Bucket Dump and Auxiliary ValvePressure ................................... Pressure must increase smoothly to 21102455 kPa (2125 bar) (306356 psi) at 3/4 lever travel and then increase to 41404480 kPa (41.444.8 bar) (600650 psi) as the lever is moved past 8090% travel
AQuick Coupler BTest Hose
T105766B
UN19DEC96
T105765B
UN19DEC96
31 3160 85
TX,31,RP3064 1916OCT9823/24
TM1640 (15JAN04)
31-3160-85

011504
PN=619
Hydraulic System
ASpool Position Shims 31 3160 86
BSpool Metering Shims
CHousing
8. If pressure reducing valve is to specification, add or remove shims to reach the correct pilot pressure as follows: To adjust lever travel specification to begin metering, add or remove spool position shims (A). To adjust pressure to specification for feel positions and pressure at 3/4 level trade, add or remove spool metering shims (B).
Shims are available in the following sizes: (0.004 in., 0.007 in., and 0.015 in.). 9. Install pilot controller in machine. (See Remove and Install Pilot Controller Valve in this group.)
TX,31,RP3064 1916OCT9824/24
TM1640 (15JAN04)
31-3160-86

011504
PN=620
T105535
UN03DEC96
Hydraulic System
Pilot Controller Repair (Two Lever Controller) (S.N. 585560)

Remove And Install 1. Stop engine and relieve hydraulic pressure by using boom lower switch and placing controller in boom float position. 2. Remove air vent filter from hydraulic oil reservoir and plug vent. 3. Place a vacuum on the hydraulic oil reservoir tank. 4. Open load center service door. 5. Disconnect electrical connectors.
LS10960,0000029 1928OCT021/4
31 3160 87
TM1640 (15JAN04)
31-3160-87

011504
PN=621
Hydraulic System
6. Disconnect lines (AH). 7. Remove four cap screws. Remove pilot controllers. 8. Replace parts as necessary. 9. Install pilot controller. Connect lines and electrical connectors.
AAuxiliary Pilot Controller-to-Auxiliary Valve BPilot Controller-to-Bucket Valve Bucket Dump CPilot Controller-to-Hydraulic Reservoir DPilot Controller-to-Boom Valve Boom Lower EPilot Controller-to-Bucket Valve Bucket Rollback FPilot Controller-to-Boom Valve Boom Raise GPilot Controller-to-Pressure Reducing Manifold HAuxiliary Pilot Controller-to-Auxiliary Valve
31 3160 88
UN01OCT96
LS10960,0000029 1928OCT022/4
TM1640 (15JAN04)
31-3160-88

011504
PN=622
T104167
T104845
UN05NOV96
Hydraulic System
31 3160 89
TM1640 (15JAN04)
31-3160-89

011504
PN=623
Hydraulic System
31 3160 90
LS10960,0000029 1928OCT023/4
TM1640 (15JAN04)
31-3160-90

011504
PN=624
TP55416
UN15MAR97
Hydraulic System
1Grip 2Grip (with quickshift) 3Hex Nut 4Retainer 5Tie Band 6Boot 7O-Ring 8Set Screw 9Nut 10Plug 11Lever 12Nut 13Washer 14Adjuster Sleeve 15Lever 16Plate 17Nut 18Bar 19Universal Joint 20Ball Joint Socket 21Strap 22Grommet 23Cap Screw 24Lever Housing 25Lever Housing 26Washer 27Tube 28Coil 29Retainer 30Stop Ring 31Seal 32Backup Ring 33Retainer 34Retainer 35Fitting 36Grommet 37Plunger 38Plunger 39Shim (0.4mm /.015 in) 40Shim (0.2mm /.007 in) 41Shim (0.1mm / .004 in) 42Spool 43Spool 44Spool 45Spring 46Feel Position Kit 47Spring 48Spring 49Housing 50Weatherpack Nipple 51Terminal 52Connector 53Two Lever Controller Assembly 54Nut 55Washer 56Sleeve 57Universal Joint 58Spool
Disassemble And Assemble Perform Pilot Control Valve Pressure Test. (See Section 9025-25.) Perform Pressure Reducing Valve Pressure Test. (See Section 9025-25.)
See Pilot Controller Valve (Single Lever Controller), Disassemble and Assemble in this group.
LS10960,0000029 1928OCT024/4
Pilot Controller Repair (Two Lever Controller) (S.N. 585561)

Remove and Install 1. Stop engine. 2. Relieve hydraulic pressure by using boom lever switch and place controller in boom float position.
31 3160 91
LS10960,0000024 1904SEP021/5
TM1640 (15JAN04)
31-3160-91

011504
PN=625
Hydraulic System
3. Remove side console cover (1). 4. Disconnect, label and cap pilot lines for ease of assembly. 5. Remove nuts and washers on top cover plate. (4 used each) IMPORTANT: Do not twist control lever knobs, damage may occur to wires. 6. Remove pilot controller. 7. Replace parts as necessary. 8. Install pilot controller. 9. Connect pilot lines and connect electrical connectors. See Hydraulic System Component Location. (Group 9025-15.) Disassemble and Assemble 1. Pull rubber boots over linkage. 2. Disconnect pilot controller connector.
1Side Console Cover
UN31JUL02
NOTE: Label all wiring to aid in assembly.

31 3160 92
3. Remove all pins from connector. See Replace DEUTSCH Connector. (Group 1674.)
LS10960,0000024 1904SEP022/5
TM1640 (15JAN04)
31-3160-92

011504
PN=626
T158220B
Hydraulic System
4. Label electromagnet detents (1), with controller and pin location.
NOTE: Two dowel pins for electromagnetic detent (1).

5. Remove electromagnet detents (1). 6. Remove control lever knobs. 7. Remove rubber boots.
1Electromagnet Detents 2Dowel Pins 3Top Plate 4Wire Harnesses
UN31JUL02
LS10960,0000024 1904SEP023/5
8. Loosen lock nut (1) and remove control lever. 9. Remove clip clamps (2) on pivot pin (3). 10. Drive out pivot pin (3).
1Lock Nut 2Circlip (2 used) 3Pivot Pin
UN31JUL02
T158221B
LS10960,0000024 1904SEP024/5
11. Disassemble parts as shown, replace if necessary. IMPORTANT: Control valve is serviced as an assembly. 12. Assemble control valve. 13. See Pilot Controller Adjustment (Two Lever). (Group 9025-20.)
LS10960,0000024 1904SEP025/5
TM1640 (15JAN04)
31-3160-93

011504
PN=627
T158223B
UN31JUL02
T158222B
31 3160 93
Hydraulic System
Remove and Install Pressure Reducing Valve Manifold

1. Engine OFF. Operate controls 20 times while holding pilot enable/boom down switch ON to release hydraulic pressure from brake and brake/PRV accumulators. 2. Drain reservoir or pull a vacuum. Approximate capacity of reservoir is 117 L (31 gal). 3. Disconnect electrical connectors. CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 4. Disconnect lines (AF). 5. Remove cap screws. Remove manifold. 6. Replace parts as necessary. 7. Install manifold 8. Connect all lines and electrical connectors. 9. Fill reservoir with oil to proper level. (See Hydraulic System Oil, Group 0004.)
31 3160 94
APressure Reducing Manifold-to-Front Differential Line BPressure Reducing Manifold-to-Boom Raise Line CPressure Reducing Manifold-to-Hydraulic Return Tube Tee Line DPressure Reducing Manifold-to-Accumulator Tee Line EPressure Reducing Manifold-to-Hydraulic Pump Line FPressure Reducing Manifold-to-Pilot Controller Line
TX,1060,JC2027 1919FEB991/1
TM1640 (15JAN04)
31-3160-94

011504
PN=628
T109377
UN02MAY97
X9811
UN23AUG88
Hydraulic System
Remove and Install Pressure Reducing Valve

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 1. Engine OFF. Operate controls 20 times while holding pilot enable/boom down switch ON to release hydraulic pressure from brake and brake/PRV accumulators. 2. Discharge ride control accumulator to prevent escaping fluid under pressure. (See Ride Control Accumulator Safety in Group 3102.) 3. Remove pressure reducing valve (D) from manifold. Plug opening to prevent dirt from entering manifold.
ABoom Down Solenoid BDifferential Lock Solenoid CPilot Enable Solenoid DPressure Reducing Valve 31 3160 95
TX,31,ME159 1928SEP981/1
TM1640 (15JAN04)
31-3160-95

011504
PN=629
T109123
UN15APR97
X9811
UN23AUG88
Hydraulic System
Disassemble and Assemble Pressure Reducing Valve

NOTE: Pressure Reducing Valve cannot be taken apart. If O-rings are OK, and orifice is OK, but pilot pressure cannot be adjusted within specifications, replace Pressure Reducing Valve.
1. Inspect for dirty, worn or damaged parts. 2. Remove orifice from inside Pressure Reducing Manifold and inspect for damage or clogging. 3. Replace orifice if damaged. 4. Install new O-rings and back up rings on pressure reducing valve and install parts in manifold. 5. Adjust pilot pressure. See Pressure Reducing Pressure Test in Group 9025-25.
AOrifice (Inside Pressure Reducing Valve Manifold) BBackup Ring (2 used) CO-Ring DBackup Ring (2 used) EO-Ring FBackup Ring (2 used) GO-Ring HO-Ring IPressure Reducing Valve 31 3160 96
UN15APR97
TX,31,RP3068 1919FEB991/1
TM1640 (15JAN04)
31-3160-96

011504
PN=630
T109134
Hydraulic System
Remove and Install Boom Down Solenoid Valve

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 1. Discharge ride control accumulator to release hydraulic pressure from loader and pilot circuit. (See Ride Control Accumulator Safety in Group 3102.) 2. Disconnect electrical connector. 3. Remove parts (CE). 4. Remove parts (FK). Plug opening to prevent dirt from entering manifold. 5. Inspect for dirty, worn or damaged parts. Check that spool inside solenoid valve moves freely. If spool does not move freely or if valve looks worn or damaged, replace complete solenoid assembly. 6. Install solenoid valve using new O-rings and backup rings. 7. Install parts (CK). Tighten nut (C).
Solenoid ValveSpecification Retaining NutTorque ..................................................... 7 Nm (62 lb-in.) ABoom Down Solenoid BPressure Reducing Manifold CNut DID Plate ECoil FSolenoid Valve GO-Ring HBackup Ring IO-Ring JO-Ring KBackup Ring 31 3160 97
TX,31,RP3067 1928SEP981/1
TM1640 (15JAN04)
31-3160-97

011504
PN=631
T7751LI
UN09NOV92
T109124
UN15APR97
X9811
UN23AUG88
Hydraulic System
Remove and Install Differential Lock Solenoid Valve

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 1. Discharge ride control accumulator to release hydraulic pressure from loader and pilot circuit. (See Ride Control Accumulator Safety in Group 3102.) 2. Disconnect electrical connector. 3. Remove parts (CE).
31 3160 98
6. Install solenoid valve using new O-rings and backup rings. 7. Install parts (CK). Tighten nut (C).
Solenoid ValveSpecification Retaining NutTorque ..................................................... 7 Nm (62 lb-in.)
ADifferential Lock Solenoid BPressure Reducing Manifold CNut DID Plate ECoil FSolenoid Valve GO-Ring HBackup Ring IO-Ring JO-Ring KBackup Ring
TX,31,RP3065 1928SEP981/1
TM1640 (15JAN04)
31-3160-98

011504
PN=632
T7751LI
5. Inspect for dirty, worn or damaged parts. Check that spool inside solenoid valve moves freely. If spool does not move freely or if valve looks worn or damaged, replace complete solenoid assembly.
UN09NOV92
4. Remove parts (FK). Plug opening to prevent dirt from entering manifold.
T109125
UN15APR97
X9811
UN23AUG88
Hydraulic System
Remove and Install Pilot Enable Solenoid Valve

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 1. Discharge ride control accumulator to release hydraulic pressure from loader and pilot circuit. (See Ride Control Accumulator Safety in Group 3102.) 2. Disconnect electrical connector. 3. Remove parts (CE). 4. Remove parts (FK). Plug opening to prevent dirt from entering manifold. 5. Inspect for dirty, worn or damaged parts. Check that spool inside solenoid valve moves freely. If spool does not move freely or if valve looks worn or damaged, replace complete solenoid assembly. 6. Install solenoid valve using new O-rings and backup rings. 7. Install parts (CK). Tighten nut (C).
Solenoid ValveSpecification Retaining NutTorque ..................................................... 7 Nm (62 lb-in.) APilot Enable Solenoid BPressure Reducing Manifold CNut DID Plate ECoil FSolenoid Valve GO-Ring HBackup Ring IO-Ring JO-Ring KBackup Ring 31 3160 99
TX,31,RP3066 1914APR971/1
TM1640 (15JAN04)
31-3160-99

011504
PN=633
T7751LI
UN09NOV92
T109139
UN15APR97
X9811
UN23AUG88
Hydraulic System
Ride Control Repair (S.N. 582200)

Remove and Install CAUTION: Hydraulic oil may escape at pressure high enough to penetrate skin from components in the ride control solenoid circuit if components are removed without discharging the accumulator. Hydraulic oil in accumulator can be stored at pressures equal to or above system relief pressures. If ride control is NOT operational, the ride control accumulator must be discharged by releasing gas charge before starting repair of control valve or any of its components. If ride control is operational: With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 1. Turn key to ON position.
31 3160 ,100
CAUTION: Boom will jump upward when ride control switch is turned ON. Make sure area around bucket is clear. 2. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds.
TE14778,0000017 1913OCT031/4
TM1640 (15JAN04)
31-3160-100

011504
PN=634
X9811
UN23AUG88
Hydraulic System
ARide Control Harness BRide Control Accumulator CBoom Cylinders
DRide Control Pressure Switch EBoom Cylinder
FRide Control Valve GRide Control Boom Solenoid
HRide Control ON/OFF Solenoid 31 3160 ,101
CAUTION: Approximate weight of ride control accumulator is approximately 40 kg (80 lb). Use hoist to remove.
Ride Control:Specification AccumulatorWeight ................................. 40 kg (80 lb) approximate
3. Replace ride control parts as required.

Continued on next page TE14778,0000017 1913OCT032/4
TM1640 (15JAN04)
31-3160-101

011504
PN=635
T109151
UN17APR97
Hydraulic System
31 3160 ,102
1Valve 2Coil 3Nut 4Boom Solenoid 5O-Ring 6Plug 7O-Ring (4 used)
8O-Ring 9Housing 10O-Ring 11Plug 12Backup Ring (2 used) 13O-Ring 14O-Ring
15Seal Kit 16Housing 17Check Valve 18Backup Ring (2 used) 19O-Ring 20O-Ring
21Seal Kit 22Spool 23Coil 24Nut 25ON/OFF Solenoid 26Cap Screw
Disassemble and Assemble
TE14778,0000017 1913OCT033/4
TM1640 (15JAN04)
31-3160-102

011504
PN=636
TP55452
UN18APR97
Hydraulic System
If ride control is NOT operational, the ride control accumulator must be discharged by releasing gas charge before starting repair of control valve or any of its components. If ride control is operational: With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds.
NOTE: Valve components can be replaced while valve is on machine. Internal parts of solenoid and check valves are not serviceable.
1. Remove and inspect solenoids. Replace O-rings and backup rings as required. 2. Boom solenoid valve cannot be repaired, replace O-rings and valve as required. 3. Remove check valve and inspect. Replace O-rings and backup rings as required. 4. Remove nut (3) and replace solenoid (1) as required. 5. Assemble solenoid and tighten nut to specification.
Ride Control:Specification Solenoid NutTorque ...................................................... 8 Nm (72 lb-in.) 31 3160 ,103
TE14778,0000017 1913OCT034/4
TM1640 (15JAN04)
31-3160-103

011504
PN=637
X9811
UN23AUG88
CAUTION: Hydraulic oil may escape at pressure high enough to penetrate skin from components in the Ride Control solenoid circuit if components are removed without discharging the accumulator. Hydraulic oil in accumulator can be stored at pressures equal to or above system relief pressures.
Hydraulic System
Ride Control Repair (S.N. 582201)

Remove and Install CAUTION: Hydraulic oil may escape at pressure high enough to penetrate skin from components in the Ride Control solenoid circuit if components are removed without discharging the accumulator. Hydraulic oil in accumulator can be stored at pressures equal to or above system relief pressures. If ride control is NOT operational, the ride control accumulator must be discharged by releasing gas charge before starting repair of control valve or any of its components If ride control is operational: With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 1. With boom raised slightly, turn ignition switch to ON position.
31 3160 ,104
CAUTION: Boom will jump upward when ride control switch is turned ON. Make sure area around bucket is clear. 2. Cycle the ride control switch from OFF to ON (center position). Press boom enable switch and move the control lever into the float position and hold for 5 seconds.
TE14778,0000019 1913OCT031/4
TM1640 (15JAN04)
31-3160-104

011504
PN=638
X9811
UN23AUG88
Hydraulic System
CAUTION: Approximate weight of ride control assembly is approximately 40 kg (80 lb). Use hoist to remove assembly.
Ride ControlSpecification Ride Control AssemblyWeight ....................... 40 kg (80 lb) approximate
3. Replace ride control parts as required. IMPORTANT: Make sure wire connections are to correct solenoids. Hydraulic functions will not operate properly, especially Boom Down.
ARide Control Valve-to-Bucket Dump Line BRide Control Valve-to-Boom Raise Line CRide Control Valve DRide Control Valve-to-Control Valve Return Line EValve-to-Accumulator Line (2 used) FAccumulator (2 used) GRide Control Valve-to-Boom Lower Line
UN05NOV98
TE14778,0000019 1913OCT032/4
T117959
31 3160 ,105
TM1640 (15JAN04)
31-3160-105

011504
PN=639
Hydraulic System
1Electrical Coil (3 used) 2Rod End Solenoid 3Washer 31 3160 ,106
4Boom Solenoid 5Boom Solenoid
6Head End Solenoid 7Housing
8Check Valve 9O-Ring
Disassemble and Assemble 1. Remove and inspect solenoids. Replace O-rings and backup rings as required. 2. Remove and inspect orifice. Install orifice in boom head end circuit with the cone end down.
3. Remove check valve and inspect. Repair O-rings and backup rings as required.
TE14778,0000019 1913OCT033/4
TM1640 (15JAN04)
31-3160-106

011504
PN=640
T117948
UN05NOV98
Hydraulic System
Disassemble and Assemble Ride Control Solenoid Valves 1. Remove solenoid nut (C) and replace solenoid coil (E) as required. 2. Assemble solenoid coil and tighten solenoid nut.
Ride ControlSpecification Solenoid NutTorque ...................................................... 8 Nm (72 lb-in.)
UN09NOV92
CSolenoid Nut DID Plate ESolenoid Coil FSolenoid Valve GO-Ring HBackup Ring IO-Ring JO-Ring KBackup Ring
TE14778,0000019 1913OCT034/4
T7751LI
31 3160 ,107
TM1640 (15JAN04)
31-3160-107

011504
PN=641
Hydraulic System
Disassemble and Assemble Ride Control Accumulator

CAUTION: Ride control circuit may be pressurized if accumulator is on the machine. Lower boom to ground by pressing boom lower switch and put control lever in float detent. If ride control is NOT operational, the ride control accumulator must be discharged by releasing gas charge before starting repair of it or any of its components. If ride control is operational: With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 1. Remove accumulator from machine. (See Ride Control Repair (S.N. 582200) or Ride Control Repair (S.N. 582201) in this group.
31 3160 ,108
TX,31,ME164 1928SEP981/5
TM1640 (15JAN04)
31-3160-108

011504
PN=642
Hydraulic System
CAUTION: The gas end of accumulator is gas charged and will cause end cap to blow out with deadly force if disassembly is attempted. Bleed off accumulator charge before attempting to disassemble accumulator.
NOTE: Loosen only the top special nut. The bottom "nut" is actually the accumulator gas valve.
2. Loosen special nut (A) (counterclockwise) 2 and 1/2 turns to open gas valve in accumulator and bleed off gas charge. (Resistance may be felt at approximately 1 and 1/2 turns.) 3. Remove gas fitting (E).
NOTE: Both ends of accumulator are removed the same way, piston can be removed from either end.
UN20NOV92 T7893AJ
4. Remove end cap using spanner wrench and remove piston.

ACap BAccumulator Barrel CPiston DEnd Cap EGas Valve
31 3160 ,109
TX,31,ME164 1928SEP982/5
TM1640 (15JAN04)
31-3160-109

011504
PN=643
Hydraulic System
5. Remove old seals from piston (E). 6. Install center O-ring (C), then a split backup ring (B) on each side of it. 7. Install O-ring (D) in outer groove, then install wear ring (A) on top of it. 8. Repeat previous step for other side.
AWear Ring (2 used) BSplit Backup Ring (2 used) CSpecial O-Ring Seal DInner O-Ring Seal (2 used) EPiston
TX,31,ME164 1928SEP983/5
31 3160 ,110
9. Remove O-ring and backup ring. 10. Install backup ring (B) with flat surface to inside of groove.
UN20NOV92
11. Install O-ring (C) next to curved surface of backup ring.

AEnd Cap BBackup Ring CO-Ring
TX,31,ME164 1928SEP984/5
TM1640 (15JAN04)
31-3160-110

011504
PN=644
T7893AK
T7893AL
UN20NOV92
Hydraulic System
IMPORTANT: Put piston next to gas valve end to reduce amount of air in accumulator before charging. 12. Install piston (C), with hollow end toward gas valve, in barrel (B). 13. Install end cap (D) and gas valve (E). Install other end cap if removed. 14. Charge accumulator, see Charge Ride Control Accumulator in this group. 15. Install accumulator on machine. See Ride Control Repair (S.N. 582200) or See Ride Control Repair (S.N. 582201) in this group.
ACap BAccumulator Barrel CPiston DEnd Cap EGas Valve
TX,31,ME164 1928SEP985/5
T7893AJ
UN20NOV92
31 3160 ,111
TM1640 (15JAN04)
31-3160-111

011504
PN=645
Hydraulic System
Charge Ride Control Accumulator

CAUTION: Hydraulic oil may escape at pressure high enough to penetrate skin from components in the Ride Control solenoid circuit if components are removed without discharging this accumulator. Hydraulic oil in accumulator can be stored at pressures equal to or above system relief pressures. IMPORTANT: Charge accumulator using only dry nitrogen. Dry nitrogen does not mix with oil and is non-combustible. It will not cause oxidation or condensation inside accumulator and is not harmful to piston seal. DO NOT use air or any combustible gas as these can cause oxidation and condensation. Oxidation and condensation are harmful to piston seal and accumulator.
moving above 5 kmph (3 mph), use On position to discharge accumulator during this procedure.
1. If accumulator is to be charged on machine and has some nitrogen pressure left. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 2. Remove hose. 3. Remove cover and cap from top of accumulator. 4. Turn handle on gas cock fully counterclockwise. Attach gas cock, hose, and regulator to accumulator.
NOTE: Ride control can not be discharged if switch is in (A) automatic position unless machine is
31 3160 ,112
TX,31,ME165 1928SEP981/2
TM1640 (15JAN04)
31-3160-112

011504
PN=646
Hydraulic System
CAUTION: Loosen only the top special nut. The bottom "nut" is actually the accumulator gas valve fitting. Do not loosen bottom fitting. Loose fitting under pressure can cause injury. 5. Loosen special nut (A) (counterclockwise) 2 1/2 turns to open gas valve in accumulator. (Resistance may be felt at approximately 1 1/2 turns.) 6. Slowly open regulator valve to pressurize accumulator to specification.
Ride ControlSpecification Accumulator OilTemperature ............................................. 40C (104F) Accumulator ChargePressure ........... 2068 138 kPa (20 1 bar) (300 20 psi)
8. Check that accumulator is pressurized to specifications. Adjust regulator as required. 9. Tighten nut until snug to close gas valve. 10. Close the control on the nitrogen tank.
T7594AA
7. If accumulator is to be charged on machine and has NO nitrogen pressure left. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds.
UN10SEP91
31 3160 ,113
UN10SEP91
11. Slowly loosen the connector at pressure regulator valve to release pressure from hose. 12. Remove gas cock from accumulator. Install cap.
ANut
Cross Section of Gas Valve Fitting
TX,31,ME165 1928SEP982/2
TM1640 (15JAN04)
31-3160-113

011504
PN=647
T7594AB
Hydraulic System
Remove and Install Pin Disconnect/Axle Disconnect Valve

CAUTION: Hydraulic oil may escape at pressure high enough to penetrate skin from components in the Ride Control solenoid circuit if components are removed without discharging the accumulator. Hydraulic oil in accumulator can be stored at pressures equal to or above system relief pressures. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. Lower equipment to the ground. CAUTION: If ride control switch is pushed, boom may unexpectedly move up. Discharge ride control accumulator. CAUTION: Brake accumulators supply pressure oil to pin disconnect valve when engine is OFF. Discharge brake accumulators before working on Pin Disconnect/Axle Disconnect Valve. Discharge brake accumulators by pushing brake pedal 40 or more times. Brake accumulator pressure can be read using the Monitor Basic Display. Go to menu d 052 (Clutch Cutoff Pressure).
31 3160 ,114
TX,31,RP3070 1928SEP981/2
TM1640 (15JAN04)
31-3160-114

011504
PN=648
Hydraulic System
Mark hoses and harness connectors for reference during assembly. Disconnect hoses and harness connectors. Remove cap screws (B) and remove valve. Replace O-rings, install valve and connect hoses and harness connectors.
ALock Nut (2 used) BCap Screw (2 used) CSolenoid Valve Manifold DAxle Disconnect Solenoid EO-Ring (6 used) FPin Disconnect Solenoid
TX,31,RP3070 1928SEP982/2
Disassemble and Assemble Pin Disconnect Valve

1. Remove solenoid coil and spool. Inspect for damage or wear. 2. Replace parts as needed. Replace O-rings and backup rings.
ANut BIdentification Plate CCover DCoil EBottom Plate FSpool GO-Ring HBackup Ring IO-Ring JO-Ring KBackup Ring LO-Ring MBackup Ring
UN28APR97
T109182
UN18APR97
31 3160 ,115
TX,31,RP3069 1928SEP981/1
TM1640 (15JAN04)
31-3160-115

011504
PN=649
T109214B
Hydraulic System
Disassemble and Assemble Axle Disconnect Valve

1. Remove solenoid coil and spool. Inspect for damage or wear. 2. Replace parts as needed. Replace O-rings and backup rings.
CNut DIdentification Plate ECoil FSpool GO-Ring HBackup Ring IO-Ring JO-Ring KBackup Ring
UN09NOV92
TX,31,RP3071 1928SEP981/1
31 3160 ,116
TM1640 (15JAN04)
31-3160-116

011504
PN=650
T7751LI
Index
Page Page
A
Access platform Remove and install . . . . . . . . . . . . . . . . .18-1822-2 Access platform and steps Remove and install . . . . . . . . . . . . . . . . .18-1822-2 Accumulator Brake, remove and install . . . . . . . . . . . .10-1060-4 Accumulator, ride control Charge . . . . . . . . . . . . . . . . . . . . . . . . 31-3160-112 Disassemble and assemble . . . . . . . . 31-3160-108 Accumulator, ride control safety . . . . . . . . .31-3102-2 Adjust fuel shut-off solenoid . . . . . . . . . . . .05-0515-6 Air conditioning Charge R134a system . . . . . . . . . . . . .18-1830-18 Cleaning procedures . . . . . . . . . . . . . . .18-1830-19 Component location, harness . . . . . . . .18-1830-24 Component oil charge . . . . . . . . . . . . . .18-1830-12 Compressor oil charge check . . . . . . . .18-1830-10 Compressor oil removal . . . . . . . . . . . .18-1830-11 Compressor, remove and install . . . . . .18-1830-48 Condenser . . . . . . . . . . . . . . . . . . . . . .18-1830-41 Connectors for harness. . . . . . . . . . . . .18-1830-26 Evacuate R134a system . . . . . . . . . . . .18-1830-16 Expansion valve . . . . . . . . . . . . . . . . . .18-1830-33 Flush. . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-21 Freeze control switch . . . . . . . . . . . . . .18-1830-34 Freeze control switch bench test. . . . . .18-1830-35 Heater control valve . . . . . . . . . . . . . . .18-1830-36 Heater control valve leak check . . . . . .18-1830-37 Heater/evaporator coil . . . . . . . . . . . . . .18-1830-30 High and low pressure switches . . . . . .18-1830-42 Leak testing . . . . . . . . . . . . . . . . . . . . .18-1830-13 Main blower assembly. . . . . . . . . . . . . .18-1830-37 Module with heater/evaporator coil . . . .18-1830-28 Pressurizer motor assembly . . . . . . . . .18-1830-40 Purge system . . . . . . . . . . . . . . . . . . . .18-1830-20 Receiver-dryer . . . . . . . . . . . . . . . . . . .18-1830-41 Recover R134a system. . . . . . . . . . . . .18-1830-15 Refrigerant hoses and tubing inspection . . . . . . . . . . . . . . . . . . . . .18-1830-13 Refrigerant R134a caution . . . . . . . . . . .18-1830-9 System fittings reference chart . . . . . . . .18-1830-4 Air conditioning R134a component oil Charge . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12 Air conditioning R134a compressor oil Removal . . . . . . . . . . . . . . . . . . . . . . . .18-1830-11 Air conditioning R134a refrigerant Cautions . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-9 Air conditioning R134a system Evacuate. . . . . . . . . . . . . . . . . . . . . . . .18-1830-16 Recover . . . . . . . . . . . . . . . . . . . . . . . .18-1830-15 TM1640 (15JAN04)
Air conditioning, R134a refrigerant, recovery, recycling and charging Station installation . . . . . . . . . . . . . . . . .18-1830-14 Air conditioning, R134a system Charge . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-18 Air filter elements Remove and install . . . . . . . . . . . . . . . . .05-0520-3 Air system Air intake leakage test. . . . . . . . . . . . . . .05-0520-7 Air-to-air aftercooler Assemble . . . . . . . . . . . . . . . . . . . . . . .05-0510-17 Disassemble . . . . . . . . . . . . . . . . . . . . .05-0510-17 Alarm, reverse warning Change volume. . . . . . . . . . . . . . . . . . . .20-2004-2 Remove and install . . . . . . . . . . . . . . . . .20-2004-2 Alternator Remove and install . . . . . . . . . . . . . . . . .16-1672-1 Amp crimper tool Contact support adjustment . . . . . . . . .16-1674-14 Crimp height adjustment . . . . . . . . . . . .16-1674-18 Crimp height inspection. . . . . . . . . . . . .16-1674-17 Crimping procedure. . . . . . . . . . . . . . . .16-1674-15 Operation . . . . . . . . . . . . . . . . . . . . . . .16-1674-11 Remove and install die set . . . . . . . . . .16-1674-12 Auxiliary valve section and bucket section Disassemble and assemble . . . . . . . . .31-3160-41 Axle and differential Front, remove and install . . . . . . . . . . . .02-0200-3 Rear, install. . . . . . . . . . . . . . . . . . . . . .02-0200-14 Rear, remove . . . . . . . . . . . . . . . . . . . . .02-0200-9 Axle disconnect input shaft Cross-sectional view . . . . . . . . . . . . . . . .02-0250-4 Disassemble, inspect and assemble . . . .02-0250-6 Remove and install disconnect . . . . . . . .02-0250-5 Axle disconnect valve Disassemble and assemble . . . . . . . . 31-3160-116 Axle oil cooler Front, disassemble and assemble. . . . . .02-0260-9 Front, remove and install . . . . . . . . . . . .02-0260-7 Rear, remove and install . . . . . . . . . . . .02-0260-10 Axle oil coolers Exploded view. . . . . . . . . . . . . . . . . . . . .02-0260-6 Axle oscillation supports Disassemble and assemble . . . . . . . . .02-0200-18 Axle recirculating system With optional oil coolers . . . . . . . . . . . . .02-0260-4
Indx 1
B
Batteries Remove and install . . . . . . . . . . . . . . . .16-1671-10 624H Loader and TC62H Tool Carrier
011504
Index-1
PN=1
Index
Page
Page
Indx 2
Battery Booster . . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-8 Charging procedure . . . . . . . . . . . . . . . .16-1671-7 Disconnect switch, remove and install. . . . . . . . . . . . . . . . . . . . . . . . .16-1671-11 Electrolyte level. . . . . . . . . . . . . . . . . . . .16-1671-5 Specification . . . . . . . . . . . . . . . . . . . . . .16-1671-2 Testing . . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-9 Battery covers Remove and install . . . . . . . . . . . . . . . . .19-1913-2 Battery disconnect switch Remove and install . . . . . . . . . . . . . . . .16-1671-11 Blade terminals Remove from fuse block . . . . . . . . . . . .16-1674-24 Bleed Fuel system . . . . . . . . . . . . . . . . . . . . .05-0560-10 Blower assembly Remove and install . . . . . . . . . . . . . . . .18-1830-37 Blower/air conditioner harness (W20) Component location . . . . . . . . . . . . . . .18-1830-24 Connectors . . . . . . . . . . . . . . . . . . . . . .18-1830-26 Boom Height kickout adjustment . . . . . . . . . . .16-1674-25 Boom circuit relief valve Disassemble and assemble . . . . . . . . .31-3160-45 Boom cylinder Loader start-up procedure. . . . . . . . . . .31-3160-48 Piston wear ring configuration . . . . . . . .31-3160-56 Remove and install . . . . . . . . . . . . . . . .31-3160-46 Boom cylinders 624H and TC62H Cross section . . . . . . . . . . . . . . . . . . . .31-3160-58 Disassemble and assemble . . . . . . . . .31-3160-59 Boom down solenoid valve Remove and install . . . . . . . . . . . . . . . .31-3160-97 Boom height kickout Adjustment . . . . . . . . . . . . . . . . . . . . . .16-1674-25 Boom valve section Disassemble and assemble . . . . . . . . .31-3160-43 Brake Park, Disassamble and assemble . . . . . .11-1111-6 Park, Remove and Install . . . . . . . . . . . .11-1111-2 Brake accumulator Install . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1060-4 Remove . . . . . . . . . . . . . . . . . . . . . . . . .10-1060-4 Brake valve Install . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1060-1 Remove . . . . . . . . . . . . . . . . . . . . . . . . .10-1060-1 Brake, park Remove and install . . . . . . . . . . . . . . . . .11-1111-2 Brakes External inspection . . . . . . . . . . . . . . . . .10-1011-1 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1011-3 Remove . . . . . . . . . . . . . . . . . . . . . . . . .10-1011-3 TM1640 (15JAN04)
Bucket Remove and install . . . . . . . . . . . . . . . . .31-3102-5 Bucket bolt-on cutting edges Remove and install . . . . . . . . . . . . . . . . .31-3102-7 Bucket circuit relief valve Disassemble and assemble . . . . . . . . .31-3160-44 Bucket cylinder Loader start-up procedure. . . . . . . . . . .31-3160-51 Bucket cylinder 624H Assemble . . . . . . . . . . . . . . . . . . . . . . .31-3160-54 Cross section . . . . . . . . . . . . . . . . . . . .31-3160-52 Disassemble and assemble . . . . . . . . .31-3160-53 Bucket linkage seals and bushings Remove and install . . . . . . . . . . . . . . . . .31-3140-4 Bucket tilt linkage, lower Disassemble and assemble . . . . . . . . . .31-3140-6 Bucket tilt linkage, upper Disassemble and assemble . . . . . . . . . .31-3140-5 Bucket tooth shanks and tips Remove and install . . . . . . . . . . . . . . . . .31-3102-3 Bucket welded cutting edge Remove and install . . . . . . . . . . . . . . . . .31-3102-6 Bulbs Replace halogen . . . . . . . . . . . . . . . . . . .16-1673-1 Bushings and seals, boom, bucket or tilt cylinder Remove and install . . . . . . . . . . . . . . . .31-3160-67 Bushings and seals, loader boom Remove and install . . . . . . . . . . . . . . . . .31-3140-9 Bushings, tool carrier boom Remove and install . . . . . . . . . . . . . . . .31-3140-10
C
Cab Fresh air filter . . . . . . . . . . . . . . . . . . . .18-1830-43 Recirculating air filter . . . . . . . . . . . . . .18-1830-46 Remove and install . . . . . . . . . . . . . . . . .18-1800-2 Cab or Canopy Remove and Install . . . . . . . . . . . . . . . . .18-1800-2 Canopy Remove and Install . . . . . . . . . . . . . . . . .18-1800-2 Capacities, drain and refill TC62H . . . . . . . . . . . . . . . . . . . . . . . . . .00-0002-8 624H. . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0002-4 Charging station, R134a refrigerant Recovery, recycling and charging . . . . .18-1830-14 Chassis computer unit (CCU) Remove and install . . . . . . . . . . . . . . . . .16-1675-3 Cinch connector Install contact . . . . . . . . . . . . . . . . . . . .16-1674-23 624H Loader and TC62H Tool Carrier
011504
Index-2
PN=2
Index
Page
Page
Clean primary element Oily or sooty . . . . . . . . . . . . . . . . . . . . . .05-0520-5 Clutch Compressor . . . . . . . . . . . . . . . . . . . . .18-1830-50 Compressor, check hub clearance . . . .18-1830-51 Clutch pack KV and KR Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0350-28 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0350-26 Clutch pack K1, K2, and K3 Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0350-37 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0350-35 Clutch pack K4 Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0350-48 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0350-47 Clutches, input and output shafts Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-17 Component location Blower/air conditioner harness (W20) . . . . . . . . . . . . . . . . . . . . . . . .18-1830-24 Compressor Clutch hub clearance . . . . . . . . . . . . . .18-1830-51 Clutch, disassemble and assemble . . . .18-1830-50 Disassemble and assemble . . . . . . . . .18-1830-53 Inspect . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-53 Manifold, inspect . . . . . . . . . . . . . . . . . .18-1830-52 Remove and install . . . . . . . . . . . . . . . .18-1830-48 Compressor, air conditioning, R134a oil Removal . . . . . . . . . . . . . . . . . . . . . . . .18-1830-11 Compressor, R134a, component oil Charge . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12 Condenser Remove and install . . . . . . . . . . . . . . . .18-1830-41 Connector Metri-Pack. . . . . . . . . . . . . . . . . . . . . . . .16-1674-4 Connector body, transmission control valve Remove and install . . . . . . . . . . . . . . . . .16-1674-8 Connector terminals Replace transmission controller unit . . .16-1674-19 Connector, transmission control valve Install contact . . . . . . . . . . . . . . . . . . . . .16-1674-9 Control unit, transmission Remove and install . . . . . . . . . . . . . . . . .16-1675-1 Control valve Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0360-15 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-8 Control valve, hydraulic pump Disassemble and assemble . . . . . . . . .31-3160-36 Controller, chassis Remove and install . . . . . . . . . . . . . . . . .16-1675-3 Converter Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-8 TM1640 (15JAN04)
Converter minimum pressure regulator valve Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-4 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-4 Converter relief valve Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-21 Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-21 Remove . . . . . . . . . . . . . . . . . . . . . . . .03-0360-21 Converter, torque and housing Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-5 Counterweights Remove and install . . . . . . . . . . . . . . . . .17-1749-2 Cover, battery Remove and install . . . . . . . . . . . . . . . . .19-1913-2 Cutting edge Crack repair . . . . . . . . . . . . . . . . . . . . . .31-3102-9 Cutting edge, welded Remove and install . . . . . . . . . . . . . . . . .31-3102-6 Cutting edges, bucket bolt-on Remove and install . . . . . . . . . . . . . . . . .31-3102-7 Cylinder Steering, remove and install . . . . . . . . . .09-0960-9 Steering, remove and install bushings . . . . . . . . . . . . . . . . . . . . . .09-0960-12 Cylinder, boom Loader start-up procedure. . . . . . . . . . .31-3160-48 Remove and install . . . . . . . . . . . . . . . .31-3160-46 Cylinder, bucket Loader start-up procedure. . . . . . . . . . .31-3160-51 Cylinder, steering Assemble . . . . . . . . . . . . . . . . . . . . . . .09-0960-12 Disassemble . . . . . . . . . . . . . . . . . . . . .09-0960-12 Loader start-up procedure. . . . . . . . . . .09-0960-11 Remove and install bushings . . . . . . . .09-0960-12 Cylinders bucket 624H Cross section . . . . . . . . . . . . . . . . . . . .31-3160-52 Disassemble and assemble . . . . . . . . .31-3160-53 Cylinders bushings and seals, boom, bucket or Tilt Remove and install . . . . . . . . . . . . . . . .31-3160-67 Cylinders, boom 624H and TC62H Cross section . . . . . . . . . . . . . . . . . . . .31-3160-58 Disassemble and assemble . . . . . . . . .31-3160-59 Cylinders, bucket 624H Assemble . . . . . . . . . . . . . . . . . . . . . . .31-3160-54 Remove and install . . . . . . . . . . . . . . . .31-3160-49 Cylinders, steering Remove and install . . . . . . . . . . . . . . . . .09-0960-9 Cylinders, Tilt TC62H Cross section . . . . . . . . . . . . . . . . . . . .31-3160-58 Cylinders, tilt TC62H Disassemble and assemble . . . . . . . . .31-3160-59 624H Loader and TC62H Tool Carrier
011504
Indx 3
Index-3
PN=3
Index
Page
Page
D
Dampener Install . . . . . . . . . . . . . . . . . . . . . . . . . . .07-0752-1 Remove . . . . . . . . . . . . . . . . . . . . . . . . .07-0752-1 Dealer fabricated tool DFRW20 compressor holding fixture. . . .18-1899-1 DFT1148 pre-load clutch pack spring compression tool . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0399-1 DFT1149 pre-load clutch pack compression ring tool . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0399-2 DFRW20 Compressor Holding Fixture Dealer fabricated tool . . . . . . . . . . . . . . .18-1899-1 Diesel engine oil. . . . . . . . . . . . . . . . . . . . .00-0004-3 Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-1 Diesel fuel conditioner Low sulfur . . . . . . . . . . . . . . . . . . . . . . . .00-0004-2 Diesel fuel storage . . . . . . . . . . . . . . . . . . .00-0004-2 Differential Front remove and install . . . . . . . . . . . . .02-0200-3 Oil specification. . . . . . . . . . . . . . . . . . . .00-0004-4 Rear axle, install . . . . . . . . . . . . . . . . . .02-0200-14 Differential lock solenoid valve Remove and install . . . . . . . 02-0260-2, 31-3160-98 Differential, rear Install . . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-14 Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-9 Display unit, monitor Remove and install . . . . . . . . . . . . . . . . .16-1675-5 Dome light Remove and install . . . . . . . . . . . . . . . . .16-1673-7 Door light switch Remove and install . . . . . . . . . . . . . . . . .16-1673-7 Drive lights and guard Remove and install . . . . . . . . . . . . . . . . .16-1673-6 Drive shaft Disassemble, inspect and assemble . . . .02-0225-4 Remove and install . . . . . . . . . . . . . . . . .02-0225-2
Engine and loader frame Separate . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-5 Engine compartment step Remove and install . . . . . . . . . . . . . . . . .18-1822-4 Engine coolant heater Remove and install . . . . . . . . . . . . . . . . .05-0505-4 Engine oil Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-3 Engine side shields Remove and install . . . . . . . . . . . . . . . . .19-1910-3 Engine speed Fast and slow idle, adjust . . . . . . . . . . . .05-0515-2 Evaporator coil Remove and install . . . . . . . . . . . . . . . .18-1830-30 Expansion valve Remove and install . . . . . . . . . . . . . . . .18-1830-33
F
Fan Remove and install . . . . . . . . . . . . . . . . .05-0510-5 Fan belt Remove and install . . . . . . . . . . . . . . . . .05-0510-3 Fan drive Remove and install . . . . . . . . . . . . . . . . .05-0510-5 Fast idle Adjust engine speed . . . . . . . . . . . . . . . .05-0515-2 Fenders, front Remove and install . . . . . . . . . . . . . . . . .19-1927-1 Fenders, rear Remove and install . . . . . . . . . . . . . . . . .19-1927-2 Filter Cab air recirculating . . . . . . . . . . . . . . .18-1830-46 Cab fresh air . . . . . . . . . . . . . . . . . . . . .18-1830-43 Filter caddy Hydraulic oil clean-up procedure . . . . . .31-3160-69 Fire extinguisher and bracket Remove and install . . . . . . . . . . . . . . . . .20-2003-1 Fluid starting aid Remove and install . . . . . . . . . . . . . . . . .05-0505-1 Frame pivot bearing Lower, remove and install . . . . . . . . . . .17-1740-12 Upper, remove and install . . . . . . . . . . .17-1740-10 Frame, engine and loader Separate . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-5 Freeze control switch Bench test. . . . . . . . . . . . . . . . . . . . . . .18-1830-35 Remove and install . . . . . . . . . . . . . . . .18-1830-34 Front axle and differential Remove and install . . . . . . . . . . . . . . . . .02-0200-3 624H Loader and TC62H Tool Carrier
011504
Indx 4
E
Electrical Battery specification . . . . . . . . . . . . . . . .16-1671-2 Element Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .05-0520-6 Elements, air filter Remove and install . . . . . . . . . . . . . . . . .05-0520-3 Engine Boost starting . . . . . . . . . . . . . . . . . . . . .16-1671-8 Remove and install . . . . . . . . . . . . . . . . .04-0400-3 TM1640 (15JAN04)
Index-4
PN=4
Index
Page
Page
Front axle guard Remove and install . . . . . . . . . . . . . . . . .17-1746-1 Front axle oil cooler Disassemble and assemble . . . . . . . . . .02-0260-9 Remove and install . . . . . . . . . . . . . . . . .02-0260-7 Front turn lights Remove and install . . . . . . . . . . . . . . . . .16-1673-5 Front windshield wiper Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-8 Fuel Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-1 Lubricity . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-1 System bleed . . . . . . . . . . . . . . . . . . . .05-0560-10 Tank capacity . . . . . . . . . . . . . . . . . . . . .00-0004-3 Fuel filter, primary (water separator) Drain and clean. . . . . . . . . . . . . . . . . . . .05-0560-5 Remove and install . . . . . . . . . . . . . . . . .05-0560-6 Fuel shut-off solenoid Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0515-6 Fuel tank guard Remove and install . . . . . . . . . . . . . . . . .17-1746-1 Fuel, diesel storage . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-2 Fuse block Remove blade terminals . . . . . . . . . . . .16-1674-24
Heater control valve Remove and install . . . . . . . . . . . . . . . .18-1830-36 Heater control valve leak check . . . . . . . .18-1830-37 Hood Remove and install . . . . . . . . . . . . . . . . .19-1910-2 Horn Remove and install . . . . . . . . . . . . . . . . .20-2004-1 Hydraulic Oil specification. . . . . . . . . . . . . . . . . . . .00-0004-4 Hydraulic control valve Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0360-15 Cross section view . . . . . . . . . . . . . . . .03-0360-10 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-8 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-7 Hydraulic oil clean-up procedure Using filter caddy . . . . . . . . . . . . . . . . .31-3160-69 Hydraulic pump Disassemble, inspect and assemble . . .31-3160-13 Hydraulic pump control valve Disassemble and assemble . . . . . . . . .31-3160-36 Hydraulic pump (PVG 65) Cross section drawing. . . . . . . . . . . . . .31-3160-12 Hydraulic pump, loader Remove and install . . . . . . . . . . . . . . . . .31-3160-9 Hydraulic reservoir Remove and install . . . . . . . . . . . . . . . .31-3160-68 Hydrometer test . . . . . . . . . . . . . . . . . . . . .16-1671-9
G
Grease Extreme pressure and multipurpose . . . .00-0004-5 Grille and grille housing Remove and install . . . . . . . . . . . . . . . . .19-1921-2 Guard, front axle Remove and install . . . . . . . . . . . . . . . . .17-1746-1 Guard, fuel tank Remove and install . . . . . . . . . . . . . . . . .17-1746-1 Guard, transmission bottom Remove and install . . . . . . . . . . . . . . . . .17-1746-2 Guard, transmission side Remove and install . . . . . . . . . . . . . . . . .17-1746-2
I
Inch torque values . . . . . . . . . . . . . . . . . . .00-0003-5 Input and output clutches Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-17 Input shaft Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0350-55 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0350-54 Remove . . . . . . . . . . . . . . . . . . . . . . . .03-0350-11 Inspection External service brake. . . . . . . . . . . . . . .10-1011-1
Indx 5
J H
Jump starting . . . . . . . . . . . . . . . . . . . . . . .16-1671-8 Halogen bulbs Replace . . . . . . . . . . . . . . . . . . . . . . . . .16-1673-1 Hardware Torque specifications . . . . . . . . . . . . . . .00-0003-1 Heater coil Remove and install . . . . . . . . . . . . . . . .18-1830-30 TM1640 (15JAN04)
L
Light, dome Remove and install . . . . . . . . . . . . . . . . .16-1673-7 624H Loader and TC62H Tool Carrier
011504
Index-5
PN=5
Index
Page
Page
Light, door switch Remove and install . . . . . . . . . . . . . . . . .16-1673-7 Lights, drive and guard Remove and install . . . . . . . . . . . . . . . . .16-1673-6 Lights, front turn Remove and install . . . . . . . . . . . . . . . . .16-1673-5 Lights, stop, turn and tail Remove and install . . . . . . . . . . . . . . . . .16-1673-5 Lights, work Remove and install . . . . . . . . . . . . . . . . .16-1673-3 Load sense relief valve Disassemble and assemble . . . . . . . . .31-3160-45 Load test, batteries. . . . . . . . . . . . . . . . . . .16-1671-9 Loader boom bushings and seals Remove and install . . . . . . . . . . . . . . . . .31-3140-9 Loader bucket tilt linkage Remove and install . . . . . . . . . . . . . . . . .31-3140-3 Loader control valve Disassemble and assemble . . . . . . . . .31-3160-40 Remove and install . . . . . . . . . . . . . . . .31-3160-37 Loader hydraulic pump Remove and install . . . . . . . . . . . . . . . . .31-3160-9 Loader start-up procedure Boom cylinder . . . . . . . . . . . . . . . . . . . .31-3160-48 Bucket cylinder . . . . . . . . . . . . . . . . . . .31-3160-51 Low sulfur diesel fuel conditioner . . . . . . . .00-0004-2 Lower pivot bearing and seals Remove and install . . . . . . . . . . . . . . . .17-1740-12 Lubricant Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-7 Storage . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-6 Lubricity of diesel fuel. . . . . . . . . . . . . . . . .00-0004-1
Indx 6
O
O-ring boss fittings . . . . . . . . . . . . . . . . . . .00-0003-7 Oil Lines and fittings. . . . . . . . . . . . . . . . . . .00-0003-6 Specification differential . . . . . . . . . . . . .00-0004-4 Specification hydraulic system . . . . . . . .00-0004-4 Specification park brake . . . . . . . . . . . . .00-0004-4 Specification transmission . . . . . . . . . . . .00-0004-4 Oil clean-up Procedure . . . . . . . . . . . . . . . . . . . . . . .31-3160-69 Oil cooler Assemble . . . . . . . . . . . . . . . . . . . . . . .05-0510-17 Disassemble . . . . . . . . . . . . . . . . . . . . .05-0510-17 Remove and install . . . . . . . . . . . . . . . .05-0510-10 Oil lines and fittings . . . . . . . . . . . . . . . . . .00-0003-6 Oil pipes and tube Replace . . . . . . . . . . . . . . . . . . . . . . . .03-0360-23 Oil, component, R134a air conditioning Charge . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12 Oscillation supports Disassemble and assemble . . . . . . . . .02-0200-18 Output shaft Remove . . . . . . . . . . . . . . . . . . . . . . . .03-0350-11 Outside mirror Remove and install . . . . . . . . . . . . . . . . .20-2002-2
P
Park Brake Assemble . . . . . . . . . . . . . . . . . . . . . . . .11-1111-6 Disassemble . . . . . . . . . . . . . . . . . . . . . .11-1111-6 Park brake Install . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1111-2 Oil specification. . . . . . . . . . . . . . . . . . . .00-0004-4 Pressure switch, remove and install . . . .11-1160-4 Release solenoid valve, remove and install. . . . . . . . . . . . . . . . . . . . . . . . . .11-1160-2 Remove . . . . . . . . . . . . . . . . . . . . . . . . .11-1111-2 Pilot controller valve (single lever) Disassemble and assemble . . . . . . . . .31-3160-71 Pilot controller valve, single lever Cross section . . . . . . . . . . . . . . . . . . . .31-3160-71 Remove and install . . . . . . . . . . . . . . . .31-3160-70 Pilot controller valve, two lever Remove and install . . . . . . . . . . . . . . . .31-3160-91 Pilot enable solenoid valve Remove and install . . . . . . . . . . . . . . . .31-3160-99 Pin disconnect valve Disassemble and assemble . . . . . . . . 31-3160-115 624H Loader and TC62H Tool Carrier
011504
M
Manifold, compressor Inspect . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-52 Metri-Pack connector Replace . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-4 Metric torque values . . . . . . . . . . . . . . . . . .00-0003-2 Mirror, outside Remove and install . . . . . . . . . . . . . . . . .20-2002-2 Mixing lubricants. . . . . . . . . . . . . . . . . . . . .00-0004-7 Monitor display unit Remove and install . . . . . . . . . . . . . . . . .16-1675-5 Motor, starting Remove and install . . . . . . . . . . . . . . . . .16-1677-1 Mounted step Remove and install . . . . . . . . . . . . . . . . .18-1822-5 Muffler Remove and install . . . . . . . . . . . . . . . . .05-0530-2 TM1640 (15JAN04)
Index-6
PN=6
Index
Page
Page
Pin disconnect/axle disconnect Remove and install . . . . . . . . . . . . . . . 31-3160-114 Pivot bearing and seals Lower, remove and install . . . . . . . . . . .17-1740-12 Upper, remove and install . . . . . . . . . . .17-1740-10 Pre-load clutch pack compression ring tool DFT1148. . . . . . . . . . . . . . . . 03-0399-1, 03-0399-2 Pressure reducing valve Disassemble and assemble . . . . . . . . .31-3160-96 Remove and install . . . . . . . . . . . . . . . .31-3160-95 Pressure reducing valve manifold Install . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-94 Remove . . . . . . . . . . . . . . . . . . . . . . . .31-3160-94 Pressurizer motor assembly Remove and install . . . . . . . . . . . . . . . .18-1830-40 Primary element Clean oily or sooty . . . . . . . . . . . . . . . . .05-0520-5 Primary fuel filter (water separator) Remove and install . . . . . . . . . . . . . . . . .05-0560-6 Primary fuel filter (water separatory) Drain and clean. . . . . . . . . . . . . . . . . . . .05-0560-5 Pump, hydraulic Disassemble, inspect and assemble . . .31-3160-13 Pump, hydraulic loader Remove and install . . . . . . . . . . . . . . . . .31-3160-9 Pump, transmission Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-5 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-2
R
Radiator Assemble . . . . . . . . . . . . . . . . . . . . . . .05-0510-17 Disassemble . . . . . . . . . . . . . . . . . . . . .05-0510-17 Remove and install . . . . . . . . . . . . . . . .05-0510-10 Rear axle oil cooler Remove and install . . . . . . . . . . . . . . . .02-0260-10 Rear view mirror Remove and install . . . . . . . . . . . . . . . . .20-2002-1 Receiver-dryer Remove and install . . . . . . . . . . . . . . . .18-1830-41 Refrigerant R134a cautions . . . . . . . . . . . . . . . . . . . .18-1830-9 Theory of operation. . . . . . . . . . . . . . . . .18-1830-7 Refrigerant, air conditioning R134a system Evacuate. . . . . . . . . . . . . . . . . . . . . . . .18-1830-16 Recover . . . . . . . . . . . . . . . . . . . . . . . .18-1830-15 Refrigerant, R134a Recovery, recycling and charging . . . . .18-1830-14 Refrigerant, R134a system Charge . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-18 TM1640 (15JAN04)
Regulator Install . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1672-4 Remove . . . . . . . . . . . . . . . . . . . . . . . . .16-1672-4 Relief valve Disassemble and assemble . . . . . . . . .31-3160-44 Remove and install Loader bucket tilt linkage . . . . . . . . . . . .31-3140-3 Reservoir, hydraulic Remove and install . . . . . . . . . . . . . . . .31-3160-68 Return-to-carry Height kickout adjustment . . . . . . . . . . .16-1674-26 Return-to-dig circuit Adjustment . . . . . . . . . . . . . . . . . . . . . .16-1674-27 Reverse warning alarm Change volume. . . . . . . . . . . . . . . . . . . .20-2004-2 Remove and install . . . . . . . . . . . . . . . . .20-2004-2 Ride control Remove and install . . . . . . . . . . . . . . . 31-3160-100 Ride control accumulator Disassemble and assemble . . . . . . . . 31-3160-108 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3102-2 Ride control assumulator Charge . . . . . . . . . . . . . . . . . . . . . . . . 31-3160-112 Ride control repair . . . . . . . . . . . . . . . . . 31-3160-100 Remove and Install . . . . . . . . . . . . . . . 31-3160-104 Ride control solenoid valves Disassemble and assemble . . . . . . . . 31-3160-107 Ride control valve Disassemble and assemble . . . . . . . 31-3160-102, 31-3160-106 Roll-over protective structure Torque values . . . . . . . . . . . . . . . . . . . . .00-0003-1
Indx 7
S
Safe discharge Ride control accumulator . . . . . . . . . . . .31-3102-2 Seals and bushings Bucket linkage, remove and install . . . . .31-3140-4 Seals and bushings, loader boom Remove and install . . . . . . . . . . . . . . . . .31-3140-9 Seals, tool carrier boom Remove and install . . . . . . . . . . . . . . . .31-3140-10 Seat Disassemble and assemble . . . . . . . . . .18-1821-2 Seat belt Disassemble and assemble . . . . . . . . . .18-1821-1 Service brakes External inspection . . . . . . . . . . . . . . . . .10-1011-1 Shield, transmission Remove and install . . . . . . . . . . . . . . . . .19-1913-1 624H Loader and TC62H Tool Carrier
011504
Index-7
PN=7
Index
Page
Page
Indx 8
Shields, engine side Remove and install . . . . . . . . . . . . . . . . .19-1910-3 Slow idle Adjust engine speed . . . . . . . . . . . . . . . .05-0515-2 Solenoid, ride control valves Disassemble and assemble . . . . . . . . 31-3160-107 Specification Battery . . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-2 Differential oil . . . . . . . . . . . . . . . . . . . . .00-0004-4 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . .00-0004-4 Park brake . . . . . . . . . . . . . . . . . . . . . . .00-0004-4 Transmission oil . . . . . . . . . . . . . . . . . . .00-0004-4 Specifications Hardware torque . . . . . . . . . . . . . . . . . . .00-0003-1 TC62H . . . . . . . . . . . . . . . . . . . . . . . . . .00-0002-5 624H. . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0002-1 Start-up procedure Steering cylinder . . . . . . . . . . . . . . . . . .09-0960-11 Starting aid, fluid Remove and install . . . . . . . . . . . . . . . . .05-0505-1 Starting motor Remove and install . . . . . . . . . . . . . . . . .16-1677-1 Steering Cylinder bushings, remove and install. . . . . . . . . . . . . . . . . . . . . . . . .09-0960-12 Steering column Remove and install . . . . . . . . . . . . . . . . .09-0960-8 Steering cylinder Assemble . . . . . . . . . . . . . . . . . . . . . . .09-0960-12 Bushings, remove and install . . . . . . . .09-0960-12 Disassemble . . . . . . . . . . . . . . . . . . . . .09-0960-12 Loader start-up procedure. . . . . . . . . . .09-0960-11 Remove and install . . . . . . . . . . . . . . . . .09-0960-9 Steering valve Remove and install . . . . . . . . . . . . . . . . .09-0960-3 Step Remove and install . . . . . . . . . . . . . . . . .18-1822-2 Step, engine compartment Remove and install . . . . . . . . . . . . . . . . .18-1822-4 Step, mounted Remove and install . . . . . . . . . . . . . . . . .18-1822-5 Stop, turn and tail light Remove and install . . . . . . . . . . . . . . . . .16-1673-5 Storing lubricants . . . . . . . . . . . . . . . . . . . .00-0004-6 Structure Welding. . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-3 Support, wrist Remove and install . . . . . . . . . . . . . . . .18-1810-10 Switch, freeze control Bench test. . . . . . . . . . . . . . . . . . . . . . .18-1830-35 Remove and install . . . . . . . . . . . . . . . .18-1830-34 Switch, park break pressure Remove and install . . . . . . . . . . . . . . . . .11-1160-4 TM1640 (15JAN04)
T
Tilt cylinder TC62H Disassemble and assemble . . . . . . . . .31-3160-59 Tilt cylinders TC62H Cross section . . . . . . . . . . . . . . . . . . . .31-3160-58 Tips Bucket tooth, remove and install . . . . . . .31-3102-3 Tire Install . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-4 Remove . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-3 Tool carrier Disassemble and assemble . . . . . . . . . .31-3140-8 Tool carrier boom bushings and seals Remove and install . . . . . . . . . . . . . . . .31-3140-10 Tool carrier lower tilt linkage Disassemble and assemble . . . . . . . . . .31-3140-6 Tool carrier upper tilt linkage Disassemble and assemble . . . . . . . . . .31-3140-5 Tooth shanks Bucket, remove and install . . . . . . . . . . .31-3102-3 Torque converter Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-8 Torque converter and housing Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-5 Torque converter relief valve Remove . . . . . . . . . . . . . . . . . . . . . . . .03-0360-21 Torque specifications Hardware . . . . . . . . . . . . . . . . . . . . . . . .00-0003-1 Torque value Flat face O-ring seal fitting . . . . . . . . . . .00-0003-9 Inch SAE four bolt flange fitting. . . . . . .00-0003-11 Metric cap screw. . . . . . . . . . . . . . . . . . .00-0003-3 Metric four bolt flange fitting . . . . . . . . .00-0003-10 O-Ring boss fitting . . . . . . . . . . . . . . . . .00-0003-7 Torque values Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-5 Metric . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2 Roll-over protective structure. . . . . . . . . .00-0003-1 Transmission Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0300-3 Oil specification. . . . . . . . . . . . . . . . . . . .00-0004-4 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0300-3 Transmission bottom guard Remove and install . . . . . . . . . . . . . . . . .17-1746-2 Transmission control unit (TCU) Remove and install . . . . . . . . . . . . . . . . .16-1675-1 Transmission control valve Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0360-15 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-8 Transmission control valve connector body Remove and install . . . . . . . . . . . . . . . . .16-1674-8 624H Loader and TC62H Tool Carrier
011504
Index-8
PN=8
Index
Page
Page
Transmission control valve connector contact Install . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-9 Transmission controller unit connector terminals Replace . . . . . . . . . . . . . . . . . . . . . . . .16-1674-19 Transmission pump Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-5 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-2 Transmission shields Remove and install . . . . . . . . . . . . . . . . .19-1913-1 Transmission side guard Remove and install . . . . . . . . . . . . . . . . .17-1746-2
U
Universal joint Disassemble, inspect and assemble . . . .02-0225-4 Remove and Install . . . . . . . . . . . . . . . . .02-0225-2 Upper pivot bearing and seals Remove and install . . . . . . . . . . . . . . . .17-1740-10
V
Valve Minimum pressure regulator . . . . . . . . . .03-0360-4 Pressure reducing manifold, install . . . .31-3160-94 Pressure reducing manifold, remove . . .31-3160-94 Valve, auxiliary section and bucket section Disassemble and assemble . . . . . . . . .31-3160-41 Valve, axle disconnect Disassemble and assemble . . . . . . . . 31-3160-116 Valve, boom circuit relief Disassemble and assemble . . . . . . . . .31-3160-45 Valve, boom down solenoid Remove and install . . . . . . . . . . . . . . . .31-3160-97 Valve, boom section Disassemble and assemble . . . . . . . . .31-3160-43 Valve, brake Remove and install . . . . . . . . . . . . . . . . .10-1060-1 Valve, bucket circuit relief Disassemble and assemble . . . . . . . . .31-3160-44 Valve, differential lock solenoid Remove and install . . . . . . . . . . . . . . . .31-3160-98 Valve, expansion Remove and install . . . . . . . . . . . . . . . .18-1830-33 Valve, heater control Remove and install . . . . . . . . . . . . . . . .18-1830-36 Valve, load sense relief Disassemble and assemble . . . . . . . . .31-3160-45 Valve, loader control Disassemble and assemble . . . . . . . . .31-3160-40 TM1640 (15JAN04)
Remove and install . . . . . . . . . . . . . . . .31-3160-37 Valve, pilot controller (single lever) Disassemble and assemble . . . . . . . . .31-3160-71 Valve, pilot controller, single lever Cross section . . . . . . . . . . . . . . . . . . . .31-3160-71 Remove and install . . . . . . . . . . . . . . . .31-3160-70 Valve, pilot controller, two lever Remove and install . . . . . . . . . . . . . . . .31-3160-91 Valve, pilot enable solenoid Remove and install . . . . . . . . . . . . . . . .31-3160-99 Valve, pin disconnect Disassemble and assemble . . . . . . . . 31-3160-115 Valve, pin disconnect/axle disconnect Remove and install . . . . . . . . . . . . . . . 31-3160-114 Valve, pressure reducing Disassemble and assemble . . . . . . . . .31-3160-96 Remove and install . . . . . . . . . . . . . . . .31-3160-95 Valve, relief Disassemble and assemble . . . . . . . . .31-3160-44 Valve, ride control Disassemble and assemble . . . . . . . 31-3160-102, 31-3160-106 Valve, solenoid Park brake release, remove and install. . . . . . . . . . . . . . . . . . . . . . . . . .11-1160-2 Valve, steering Remove and install . . . . . . . . . . . . . . . . .09-0960-3 Valve, transmission control Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-7 Valves solenoid, ride control Disassemble and assemble . . . . . . . . 31-3160-107
W
Wear plates Remove and install . . . . . . . . . . . . . . . . .31-3102-7 Welding Structure . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-3 Wheel Remove and Install . . . . . . . . . . . . . . . . .01-0110-1 Windowpanes Remove and install . . . . . . . . . . . . . . . . .18-1810-2 Windshield Washer Remove and install . . . . . . . . . . . . . . . . .18-1810-4 Windshield wiper Adjust front . . . . . . . . . . . . . . . . . . . . . . .18-1810-8 Windshield wiper motor Remove and install . . . . . . . . . . . . . . . . .18-1810-6 Windshield wiper, front Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-8 624H Loader and TC62H Tool Carrier
011504
Indx 9
Index-9
PN=9
Index
Page
Wiper motor Remove and install . . . . . . . . . . . . . . . . .18-1810-6 Work lights Remove and install . . . . . . . . . . . . . . . . .16-1673-3 Wrist support Remove and install . . . . . . . . . . . . . . . .18-1810-10
Indx 10
TM1640 (15JAN04)
Index-10

011504
PN=10

624H Loader and TC62H TC Operation TM1640

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624H Loader and TC62H Tool Carrier Repair

TECHNICAL MANUAL 624H Loader TC62H Tool Carrier Repair

Worldwide Construction And Forestry Division

624H Loader and TC62H Tool Carrier

Technical Information Feedback Form

Ideas, Comments (Please State Page Number):

624H Loader and TC62H Tool Carrier

624H Loader and TC62H Tool Carrier

624H Loader and TC62H Tool Carrier

624H Loader and TC62H Tool Carrier

624H Loader and TC62H Tool Carrier

624H Loader and TC62H Tool Carrier

624H Loader and TC62H Tool Carrier

624H Loader and TC62H Tool Carrier

Prevent Battery Explosions

Prepare for Emergencies

624H Loader and TC62H Tool Carrier

Prevent Acid Burns

624H Loader and TC62H Tool Carrier

Handle Chemical Products Safely

Avoid High-Pressure Fluids

624H Loader and TC62H Tool Carrier

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

624H Loader and TC62H Tool Carrier

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

624H Loader and TC62H Tool Carrier

Replace Safety Signs

Use Proper Lifting Equipment

624H Loader and TC62H Tool Carrier

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

624H Loader and TC62H Tool Carrier

Keep ROPS Installed Properly

Service Tires Safely

624H Loader and TC62H Tool Carrier

Avoid Harmful Asbestos Dust

624H Loader and TC62H Tool Carrier

Practice Safe Maintenance

Use Proper Tools

624H Loader and TC62H Tool Carrier

Dispose of Waste Properly

Live With Safety

624H Loader and TC62H Tool Carrier

624H Loader and TC62H Tool Carrier

Distance Distance Distance Overall Height Length Distance Overall Length

Continued on next page

624H Loader and TC62H Tool Carrier

Standard Operating Weight Optional Counterweight

13 560 kg (29,894 lb) 474 kg (1,045 lb)

Computer controlled powershift

PowerTech is a trademark of Deere & Company.

Continued on next page

624H Loader and TC62H Tool Carrier

624H Loader and TC62H Tool Carrier

Drain and Refill Capacities624H/TC62H

Cooling System Fuel Tank Engine Crankcase and Filter

Capacity Capacity Capacity