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Excavator
Repair
TECHNICAL MANUAL
690E LC Excavator Repair
TM1509 02JUL98 (ENGLISH)
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service components requiring service instruction. At the
work are identified in this manual and are beginning of each group are summary listings of all
recommended for use. applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
Live with safety: Read the safety messages in the specifications, wear tolerances, and torque values.
introduction of this manual and the cautions presented
throughout the text of the manual. Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
This is the safety-alert symbol. When you see this
testing, and repair.
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Fundamental service information is available from
other sources covering basic theory of operation,
Technical manuals are divided in two parts: repair and
fundamentals of troubleshooting, general maintenance,
operation and tests. Repair sections tell how to repair
and basic type of failures and their causes.
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
DX,TMIFC 1922MAY921/1
OVERALL, how would you rate the quality of "ALL" Manuals provided to you? (Check one)
Company Name
Address
Phone
FAX No.
THANK YOU!
TX,II,FAX 1918FEB971/1
18
SECTION 18Operators Station
Group 1800Removal And Installation
COPYRIGHT 1997
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright 1992, 1995
00
01
02
04
05
07
16
17
18
20
33
43
99
INDX
33
43
99
INDX
Section 00
General Information
Contents
Page Page
00
1907OCT88
TS231
TX,05,FF1611 1914JUN901/1
UN23AUG88
hospital, and fire department near your telephone.
TS291
DX,FIRE2 1903MAR931/1
00
0001 Prevent Acid Burns
2
UN23AUG88
If acid is swallowed:
TS203
exceed 2 L (2 quarts).
3. Get medical attention immediately.
DX,POISON 1921APR931/1
00
Handle Chemical Products Safely 0001
3
UN26NOV90
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
TS1132
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.
DX,MSDS,NA 1903MAR931/1
UN23AUG88
TS202
TX,05,FF1622 1914JUN901/2
TX,05,FF1622 1914JUN902/2
00
0001 Avoid High-Pressure Fluids
4
UN23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
X9811
and body from high pressure fluids.
DX,FLUID 1903MAR931/1
UN08JUN90
T7273AP
TX,05,RR,566 1923JUL911/1
00
Support Machine Properly 0001
5
UN23AUG88
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.
TS229
Follow recommended procedures in this manual.
DX,LOWER 1917FEB991/1
UN18OCT88
engine only from operators seat.
T6607AO
TX,05,FF1615 1914JUN901/1
CED,OUTX782,582 1918AUG991/1
00
0001 Stay Clear of Moving Parts
6
UN08JUN90
T7273AS
TX,05,RR,572 1912JUN901/1
UN08JUN90
electric line than 3 m (10 ft) plus twice the line insulator
length.
T7273AD
TX,05,RR,594 1912JUN901/1
UN15JUN89
the machine. Do not use any controls as handholds.
TX,05,DH832 1916MAR921/1
00
Keep Riders Off Machine 0001
7
UN08JUN90
machine. Riders also obstruct the operators view resulting
in the machine being operated in an unsafe manner.
T7273AH
TX,05,RR,560 1905OCT901/1
UN08JUN90
Always keep the travel alarm in working condition. It
warns people when the machine starts to move.
T7273AL
the machine in congested areas. Coordinate hand signals
before starting the machine.
TX,05,FF1806 1905OCT901/1
DX,WEAR2 1903MAR931/1
00
0001 Protect Against Flying Debris
8
UN18OCT88
T6642DK
TX,05,FF1613 1914JUN901/1
UN23AUG88
uncomfortable loud noises.
TS207
DX,NOISE 1903MAR931/1
UN23AUG88
TS223
DX,LIGHT 1904JUN901/1
DX,LOOSE 1904JUN901/1
00
Remove Paint Before Welding or Heating 0001
9
UN23AUG88
Do all work outside or in a well ventilated area. Dispose of
paint and solvent properly.
TS220
If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
DX,PAINT 1903MAR931/1
UN15MAY90
accidentally cut when heat goes beyond the immediate
flame area.
TS953
DX,TORCH 1903MAR931/1
02T,05,J9 1907JAN911/1
00
0001 Use Proper Lifting Equipment
10
UN23AUG88
TS226
DX,LIFT 1904JUN901/1
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
UN23AUG88
to relieve pressure before removing completely.
TS281
DX,RCAP 1904JUN901/1
UN26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
TS1133
DX,DRAIN 1903MAR931/1
00
Work in a Clean Area 0001
11
TX,05,FF1624 1914JUN901/1
UN08NOV89
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
TS779
wrenches.
TX,05,FF1614 1914JUN901/1
DX,SIGNS1 1904JUN901/1
00
0001 Live With Safety
12
1907OCT88
TS231
DX,LIVE 1925SEP921/1
UN27APR93
T7527DQ
Continued on next page TX,115,FF2461 1921AUG971/2
00
0002 NOTE: Specifications and design subject to change specifications are in accordance with PCSA
2
without notice. Wherever applicable, and SAE standards.
TX,115,FF2461 1921AUG972/2
00
690E LC Long Front Specifications 0002
3
UN02APR93
T7961AE
Continued on next page TX,115,FF3345 1911JAN951/2
00
0002 NOTE: Specifications and design subject to change equipped with 379 kg (835 lb) bucket, 800 mm
4
without notice. Wherever applicable, (32 in.) track shoes, 4.45 m (14 ft 7 in.)
specifications are in accordance with PCSA undercarriage, full fuel tank, 80 kg (175 lb)
and SAE Standards. Except where otherwise operator, and standard equipment.
noted these specifications are based on a unit
TX,115,FF3345 1911JAN952/2
TX,115,FF2463 1921AUG971/1
1902APR97
TS1656
DX,TORQ1 1920JUL941/1
00
0003 Metric Bolt and Cap Screw Torque Values
2
1902APR97
TS1657
DX,TORQ2 1920JUL941/1
00
Additional Metric Cap Screw Torque Values 0003
3
UN18OCT88
CAUTION: Use only metric tools on metric
hardware. Other tools may not fit properly. They
may slip and cause injury.
T6873AA
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.
UN18OCT88
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
T6873AB
grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original.
UN18OCT88
Tighten cap screws having lock nuts to approximately 50
percent of amount shown in chart.
T6873AC
Continued on next page 04T,90,M170 1901AUG941/2
00
0003 METRIC CAP SCREW TORQUE VALUESa
4
Nominal
Dia T-Bolt H-Bolt M-Bolt
Nm lb-ft Nm lb-ft Nm lb-ft
8 29 21 20 15 10 7
10 63 46 45 33 20 15
12 108 80 88 65 34 25
14 176 130 137 101 54 40
16 265 195 206 152 78 58
18 392 289 294 217 118 87
20 539 398 392 289 167 125
22 735 542 539 398 216 159
24 931 687 686 506 274 202
27 1372 1012 1029 759 392 289
30 1911 1410 1421 1049 539 398
33 2548 1890 1911 1410 735 542
36 3136 2314 2401 1772 931 687
Torque tolerance is 10%.
a
04T,90,M170 1901AUG942/2
Straight Fitting
UN18OCT88
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.
T6243AE
00
Angle Fitting 0003
5
UN18OCT88
contacts face of boss.
T6520AB
NOTE: Do not allow hoses to twist when tightening
fittings.
04T,90,K66 1919MAR962/2
00
0003 Service Recommendations for Flat Face
6
O-Ring Seal Fittings
UN18OCT88
2. Inspect the O-ring. It must be free of damage or
defects.
T6243AD
petroleum jelly to hold in place.
04T,90,K67 1901AUG941/1
00
Service Recommendations for 37 Flare and 0003
7
30 Cone Seat Connectors
UN18OCT88
2. Defects in tube flare cannot be repaired.
Overtightening a defective flared fitting will not stop
leaks.
T6234AC
3. Align tube with fitting before attempting to start nut.
04T,90,C96 1921JAN921/1
00
0003 Service Recommendations For Flared
8
ConnectionsStraight or Tapered Threads
UN18OCT88
2. Defects in the tube flare cannot be repaired.
Overtightening a defective flared fitting will not stop
leaks.
T6873AE
3. Align the tube with the fitting before attempting to start
the nut.
Straight Thread
4. Lubricate the male threads with hydraulic fluid or
petroleum jelly.
UN18OCT88
fittings.
a
TORQUE CHART
T6873AD
b
Straight Thread Tapered Thread
Thread
Size Nm lb-ft Nm lb-ft
Tapered Thread
1/8 15 11
1/4 20 15 45 33
3/8 29 21 69 51
1/2 49 36 93 69
3/4 69 51 176 130
1 157 116 343 253
1-1/2 196 145 539 398
2 255 188 588 434
Torque tolerance is 10%.
a
b
With seat face.
04T,90,M171 1928JAN921/1
00
Service Recommendations For Inch Series Four Bolt Flange Fittings 0003
9
UN01MAR90
T6890BB
ASealing Surface BSplit Flange CPinched O-Ring DSingle Piece Flange
04T,90,K174 1901AUG941/1
00
0003 Service Recommendations for Metric Series Four Bolt Flange Fitting
10
UN01MAR90
T6890BB
ASealing Surface BSplit Flange CPinched O-Ring DSingle Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches then tighten the diagonally opposite cap screw.
cause leaks. Roughness causes seal wear. Tighten two remaining cap screws. Tighten all cap
Out-of-flat causes seal extrusion. If defects cannot screws as specified in the chart below.
be polished out, replace component.
DO NOT use air wrenches. DO NOT tighten one
2. Install the correct O-ring (and backup washer if cap screw fully before tightening the others. DO
required) into groove using petroleum jelly to hold it NOT over tighten.
in place.
TORQUE CHARTa
3. Split flange: Loosely assemble split flange (B) Thread b
Nm lb-ft
halves. Make sure split is centrally located and M6 12 9
perpendicular to the port. Hand tighten cap screws M8 30 22
to hold parts in place. Do not pinch O-ring (C).
M10 57 42
04T,90,K175 1905JAN961/1
Consult your local fuel distributor for properties of the Fuel lubricity should pass a minimum of 3100 gram
diesel fuel available in your area. load level as measured by the BOCLE scuffing test.
In general, diesel fuels are blended to satisfy the low Sulfur content:
temperature requirements of the geographical area in
which they are marketed. Sulfur content should not exceed 0.5%. Sulfur
content less than 0.05% is preferred.
Diesel fuels specified to EN 590 or ASTM D975 are If diesel fuel with sulfur content greater than 0.5%
recommended. sulfur content is used, reduce the service interval for
engine oil and filter by 50%.
In all cases, the fuel shall meet the following DO NOT use diesel fuel with sulfur content greater
properties: than 1.0%.
Cetane number of 40 minimum. Cetane number Bio-diesel fuels may be used ONLY if the fuel
greater than 50 is preferred, especially for properties meet DIN 51606 or equivalent specification.
temperatures below -20C (-4F) or elevations above
1500 m (5,000 ft). DO NOT mix used engine oil or any other type of
lubricant with diesel fuel.
Cold Filter Plugging Point (CFPP) below the
expected low temperature OR Cloud Point at least
5C (9F) below the expected low temperature.
TX,45,JC1132 1922MAY961/1
MX,FLBT,C 1904JUN901/1
00
0004 Storing Fuel
2
DX,FUEL 1903MAR931/1
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,DH3124 1920OCT931/1
00
Fuel Tank 0004
3
TX,45,FF2359 1912MAY931/1
00
0004 Diesel Engine Oil
4
1922MAY96
T101239
Use oil viscosity based on the expected air John Deere UNI-GARD
temperature range during the period between oil API Service Classification CG-4
changes. API Service Classification CF-4
API Service Classification CE
John Deere PLUS-50engine oil is preferred. CCMC Specification D5 and Mercedes Benz
MB228.3
If John Deere PLUS-50engine oil and a John Deere CCMC Specification D4 and Mercedes Benz
oil filter are used, the service interval for oil and filter MB228.1
changes may be extended by 50 hours.
Multi-viscosity diesel engine oils are preferred.
John Deere TORQ-GARD SUPREME oil is also
recommended. If diesel fuel with sulfur content greater than 0.5% is
used, reduce the service interval by 50%.
Other oils may be used if they meet one or more of
the following:
00
Hydraulic Oil 0004
5
1927JUN95
T8508AD
Depending upon the expected air temperature range
between oil changes, use oil viscosity shown on the Manufacturer Oil
temperature chart above. Mobil DTE 25
Shell Tellus 46
The following oils may be used. Caltex Oil Rando Oil HD46
Texaco Inc. Rando Oil HD46
John Deere HY-GARD Transmission and Hydraulic
Oils. Chevron U.S.A. Inc. Chevron AW46
You may also use other oils meeting John Deere Esso Standard Oil NUTO H46
Standard J20C or J20D.
00
0004 Propel Gearbox Oil
6
1925JUN97
T110205
Depending upon the expected air temperature range Oil meeting John Deere Standard J20A or J20C
between oil changes, use oil viscosity shown on the John Deere API GL-5 Gear Oil
temperature chart above. Oil meeting API Service GL-5 (MIL-L-2105B or
MIL-L-2105C)
The following oils are recommended: Oil meeting MIL-L-10324A may be used as arctic oil.
TX,45,DT5027 1909JUN971/1
TX,45,DH5142 1909AUG961/1
00
Track Adjuster, Working Tool Pivot, Swing Bearing, And Swing Bearing Gear Grease 0004
7
1927MAR95
T8358AI
Use grease based on NLGI consistency numbers and John Deere HIGH TEMPERATURE EP GREASE
the expected air temperature range during the service John Deere GREASE-GARD
interval.
Other greases may be used if they meet NLGI
The following greases are preferred: Performance Classification GC-LB.
Oil Filters
DX,FILT 1918MAR961/1
00
0004 Lubricant Storage
8
Your equipment can operate at top efficiency only Make certain that all containers are properly marked to
when clean lubricants are used. identify their contents.
Use clean containers to handle all lubricants. Properly dispose of all old containers and any residual
lubricant they may contain.
Whenever possible, store lubricants and containers in
an area protected from dust, moisture, and other
contamination. Store containers on their side to avoid
water and dirt accumulation.
DX,LUBST 1918MAR961/1
DX,ALTER 1918MAR961/1
00
Mixing of Lubricants 0004
9
In general, avoid mixing different brands or types of oil. Consult your John Deere dealer to obtain specific
Oil manufacturers blend additives in their oils to meet information and recommendations.
certain specifications and performance requirements.
DX,LUBMIX 1918MAR961/1
00
0004
10
Page
01
1
Tools are available in JT05518 or JT05523 Undercarriage Inspection
Service Tool Kit.
Continued on next page TX,0130,AB436 1912APR952/3
Spacer1 . . . . . . . . . . . . . . . . . . . . . . . . . . . DFT1111
Spacer1 . . . . . . . . . . . . . . . . . . . . . . . . . . . DFT1110
1
Fabricated tool, dealer made. (See Section 99 for instruction to make
tool.)
TX,0130,AB436 1912APR953/3
Other Material
PT569 (U.S.) John Deere NEVER-SEEZ Apply to spring pin, bracket bore,
01
Lubricant and end of shaft for track roller and 0130
front idler. 3
T43512 (U.S.) Thread Lock and Sealer (Medium To be applied to threads of plug for
TY9473 (Canadian) Strength) Products upper track roller and front idler.
242 (LOCTITE)
TY9370 (U.S.) Thread Lock and Sealer (Medium To be applied to threads of plug for
TY9477 (Canadian) Strength) Products upper track roller and front idler.
242 (LOCTITE)
T43513 or TY9371 (U.S.) John Deere Thread Lock and Sealer Apply to threads of cap screws for
(High Strength) sprocket.
TY6305 (U.S.) Clean and Cure Primer Products Used to clean and cure surface prior
TY9485 (Canadian) to application of adhesives and
764 (LOCTITE) sealants.
Specifications
Roller Tread New Diameter Minimum Used 150 mm (5.91 in.) 135 mm (5.31 in.)
Diameter
Track Shoe:
Shoe-to-Link Cap Screw Torque 298 Nm (220 lb-ft) plus 1/2 (180)
turn
Track Chain:
Shoe-to-Link Cap Screw Torque (New) 298 Nm (220 lb-ft) plus 1/2 (180)
turn
Sprocket:
Front Idler:
TX,0130,AB438 1912APR952/2
UN06DEC88
6
Place support stands under the undercarriage.
T6876FG
TX,0130,AB440 1921FEB921/3
UN29JUL91
grease relief passage (D).
AAccess Hole
T7584AC
BLubrication Fitting
CValve
DGrease Relief Fitting
UN29JUL91
T7584AD
01
0130
7
UN01JAN94
TP32961
3. Remove cap screws (3) and washers (2) to remove Specification
Track Guide-to-Undercarriage
track guide (1) from undercarriage.
Cap ScrewTorque ............................................. 325 Nm (240 lb-ft)
TX,0130,AB440 1921FEB923/3
SPECIFICATIONS
Roller Tread (Minimum Used) 135 mm (5.31 in.)
Diameter
01
Roller Tread (New) Diameter 150 mm (5.91 in.)
UN08NOV88
0130
8
SERVICE EQUIPMENT AND TOOLS
JT05518 or JT05523 Undercarriage Inspection Service Tool Kit
T87973
Minimum used is the maximum allowable wear for
rebuilding roller tread.
Specification
Roller Tread (Minimum Used)
Diameter ........................................................................ 135 mm (5.31 in.)
Specification
Roller Tread (New)Diameter ...................................... 150 mm (5.91 in.)
Roller Tread (Minimum Used)
Diameter ........................................................................ 135 mm (5.31 in.)
TX,902015,VV301 1921FEB921/1
UN29JUL91
9
1. Loosen track by loosening valve (C) at access hole (A)
to release grease pressure. Grease will escape from
grease relief passage (D).
T7584AC
AAccess Hole
BLubrication Fitting
CValve
DGrease Relief Passage
UN29JUL91
T7584AD
Continued on next page TX,0130,AB545 1921FEB921/2
UN08NOV88
10
CAUTION: To prevent accidental lowering of
machine, put wooden blocks between frame
and track.
T82858
4. Put wooden blocks between frame and track to prevent
accidental lowering of machine.
Specification
RollerApproximate Weight .................................................. 34 kg (75 lb)
UN08NOV88
5. Remove roller.
T82857
7. Install roller on track chain with flat surface of brackets
toward frame.
Specification
Roller-to-Frame Cap Screws
Torque ......................................................................... 325 Nm (240 lb-ft)
10. Adjust track sag. (See Measure and Adjust Track Sag
procedure in this group.)
TX,0130,AB545 1921FEB922/2
01
0130
11
UN03FEB92
T7681BB
1. Remove plug (H) and drain oil.
ASupport (2 used)
BRoller with Bushings
CBushing (2 used)
DMetal Face Seal (2 used)
EO-Ring (2 used)
FSpring Pin (2 used)
GShaft
HPlug with O-ring
UN03FEB92
T7681BC
01
UN08NOV88
0130
12
T82836
TX,0130,AB445 1921FEB922/6
4. Remove metal face seal (D) from support (A) and roller
(B).
6. Remove metal face seal (D) from support (A) and roller
(B) and keep halves together.
ASupport
BRoller with Bushings
UN23FEB92
CBushing (2 used)
DMetal Face Seal (2 used)
EO-Ring (2 used)
FPlug with O-Ring
GShaft
T7681FU
UN25OCT88
T5920AB
Continued on next page TX,0130,AB445 1921FEB924/6
16. Install half of metal face seal (D) on shaft and into
support (A) seat. Apply a thin film of oil to seal ring
UN03FEB92
face.
T7681BC
18. Install roller on shaft (G), then install half of second
metal face seal in clean roller seat. Apply a thin film
of oil to seal ring face. ASupport (2 used)
BRoller with Bushings
19. Install other half of second metal face seal (D) in CBushing (2 used)
clean seat on support, then install support (A) on DMetal Face Seal (2 used)
EO-Ring (2 used)
shaft. Apply a thin film of oil to seal ring face. FSpring Pin
GShaft
20. Install spring pin (F) with NEVER-SEEZ Lubricant or HPlug with O-Ring
an equivalent in bore of support (A) and shaft (G).
NEVER-SEEZ is a registered trademark of the Emhart Chemical Group. Continued on next page TX,0130,AB445 1921FEB925/6
TX,0130,AB445 1921FEB926/6 01
0130
15
Test Lower Track Roller For Oil Leakage
SPECIFICATIONS
Leakage Test Pressure 110 28 kPa (1.1 0.3 bar) (16
4 psi)
UN25OCT88
SERVICE EQUIPMENT AND TOOLS
D05361ST Rubber Stopper/Leak Detector Kit Hoses 0400 kPa (0
4 bar)(060 psi) Gauge Snubber (Needle) Valve Air Pressure
Regulator
T5921AL
1. Hold the shaft and turn shell several turns to seat
metal face seals.
APlug, Barbed Adapter and Connector
2. Remove the plug. BJT03001 Tee Fitting 7/16-20M 37 x 7/16-20F
37 SW x 7/16-20M 37
CHose (2 used)
3. Install parts (AF) as shown. Plug, barbed adapter DPressure Gauge
and connector are from a leak detector kit such at the ESnubber (Needle) Valve
D05361ST Rubber Stopper/Leak Detector Kit. FAir Pressure Regulator
Specification
Leakage TestPressure ........................ 110 28 kPa (1.1 0.3 bar) (16
4 psi)
TX,0130,AB500 1921FEB921/1
ASeal Ring
BWorn Area (shaded area)
CSeal Ring Face
UN24AUG93
DOuter Half of Seal Ring Face
ESealing Area (dark line)
T85079
T47,0130,5939HQ 1925AUG931/3
UN05DEC96
ASeal Ring
BWorn area (shaded area)
CInner Half of Seal Ring Face
T85080
UN23FEB89
0130
Thoroughly dry parts using a lint-free tissue. 17
Apply a thin film of oil to seal ring face. Put face of seal
rings together and hold using tape.
T82840
T47,0130,5939HQ 1925AUG933/3
UN29JAN98
SERVICE EQUIPMENT AND TOOLS
JT05518 or JT05523 Undercarriage Inspection Service Tool Kit
T6813AQ
Minimum used is the maximum allowable wear for
rebuilding wear surface.
Specification
Roller Tread (Minimum Used)
Diameter ........................................................................ 108 mm (4.25 in.)
Specification
Roller Tread (New)Diameter ...................................... 120 mm (4.70 in.)
Roller Tread (Minimum Used)
Diameter ........................................................................ 108 mm (4.25 in.)
TX,0130,GG238 1921FEB921/1
UN25OCT88
18
T6557DJ
4. Install carrier roller. Tighten cap screws to 272 Nm
(200 lb-ft).
Specification
Roller-to-Undercarriage Mount
Cap ScrewTorque .................................................... 272 Nm (200 lb-ft)
5. Remove blocking.
TX,0130,AB448 1912APR951/1
01
0130
19
UN03FEB92
T7681BE
ASupport with Shaft DPipe Plug GCap Screw (2 used) JShaft
BMetal Face Seal ECap Screw (4 used) HThrust Washer KO-Ring
CRoller FCover IBushing (2 used)
2. Remove cap screws (G), then lightly pry cover (F) from
roller (C). Remove O-ring (E) from cover.
01
0130 3. Remove cap screws (H) and thrust washer (D).
UN16JAN92
20
4. Remove roller (C) from shaft.
T7681BF
are not worn or damaged. Keep seals
together as a set because of wear
pattern on seal ring faces.
5. Remove metal face seal (B) and rubber ring (A) from
roller and support (K).
UN16JAN92
DThrust Washer
EO-Ring
FCover
GCap Screw (4 used)
HCap Screw (2 used)
T7681BG
IPipe Plug
JMetal Face Seal
KSupport with Shaft
10. Wipe any finger prints and foreign material off seal
ring face using a lint-free tissue.
01
0130
UN16JAN92
11. Apply a thin film of oil on each seal ring face. DO 21
NOT apply any oil on rubber rings.
T7681BH
TX,0130,AB449 1921FEB923/4
13. With roller washer seat (B) up, apply a thin layer of oil
on thrust washer. Install thrust washer (E) and cap
screws. Tighten cap screws to 42 Nm (31 lb-ft).
Specification
Thrust Washer-to-Axle Cap
ScrewTorque ................................................................ 42 Nm (31 lb-ft)
Specification
Cover-to-Roller Cap Screw
Torque ............................................................................. 72 Nm (55 lb-ft)
15. Fill roller with oil. Capacity is 0.23 L (7.5 oz.). (See
Track Roller and Idler Oil in Group 0004.)
16. Clean plug using cure and clean primer. Apply thread
lock and sealer (medium strength). Install plug.
UN16JAN92
17. Turn roller 10 revolutions and check for oil leakage.
T7681BJ
ARoller
BRoller Thrust Washer Seat
CBushings
DThrust Washer Face
EThrust Washer
TX,0130,AB449 1921FEB924/4
SPECIFICATIONS
Grouser (Minimum Used) Height 11.0 mm (0.43 in.)
UN08NOV88
0130
22 SERVICE EQUIPMENT AND TOOLS
JT05518 or JT05523 Undercarriage Inspection Service Tool Kit
T82859
Minimum used is the maximum allowable wear for
rebuilding grouser bars with weld.
Specification
Grouser (Minimum Used)Height ............................... 11.0 mm (0.43 in.)
Specification
Grouser (New)Height ................................................ 25.5 mm (1.00 in.)
Grouser (Minimum Used)Height ............................... 11.0 mm (0.43 in.)
TX,902015,VV303 1904MAY951/1
UN08NOV88
Specification 0130
800 mm (31 in.) ShoeWeight.............................................. 23 kg (50 lb) 23
T82861
2. Before installing shoes, clean paint, dirt and debris
from mounting surfaces of shoes and links.
UN08NOV88
5. Starting at any cap screw, tighten cap screws in
sequence shown, to 298 Nm (220 lb-ft) plus 1/2 (180)
turn.
T82862
Specification
Shoe-to-Link Cap Screws
Torque ........................................................... 298 Nm (220 lb-ft) plus 1/2
(180) turn
UN23FEB89
T6794AM
UN23FEB89
T6352AH
TX,0130,AB453 1912APR951/1
SPECIFICATIONS
Link (Minimum Used) Height 98.0 mm (3.86 in.)
UN08NOV88
24 SERVICE EQUIPMENT AND TOOLS
JT05518 or JT05523 Undercarriage Inspection Service Tool Kit
T82864
Minimum used is the maximum allowable wear for
rebuilding links.
Specification
Link (Minimum Used)Height ..................................... 98.0 mm (3.86 in.)
Specification
Link (New)Height .................................................... 106.0 mm (4.17 in.)
Link (Minimum Used)Height ..................................... 98.0 mm (3.86 in.)
TX,902015,VV300 1925FEB921/1
SPECIFICATIONS
Bushing (Minimum Used) OD 54.40 mm (2.15 in.)
Bushing (New) OD 58.70 mm (2.31 in.) 01
0130
UN08NOV88
SERVICE EQUIPMENT AND TOOLS 25
JT05518 or JT05523 Undercarriage Inspection Service Tool Kit
T82865
Minimum used is the maximum allowable wear for turning
pins and bushings.
Specification
Bushing (Minimum Used)OD .................................. 54.40 mm (2.15 in.)
Specification
Bushing (New)OD ................................................... 58.70 mm (2.31 in.)
Bushing (Minimum Used)OD .................................. 54.40 mm (2.15 in.)
TX,902015,VV299 1925FEB921/1
SPECIFICATIONS
Track (Maximum Used) Pitch 773 mm (30.43 in.)
UN29JAN98
26 SERVICE EQUIPMENT AND TOOLS
JT05518 or JT05523 Undercarriage Inspection Service Tool Kit
T6813AL
pins and bushings.
Specification
Track (Maximum Used)Pitch ................................... 773 mm (30.43 in.)
Specification
Track (Maximum Used)Pitch ................................... 773 mm (30.43 in.)
Track (New)Pitch ..................................................... 760 mm (29.92 in.)
TX,902015,VV302 1925FEB921/1
UN29JUL91
27
1. Loosen track by loosening valve (C) at access hole (A)
to release grease pressure. Grease will escape from
grease relief passage (D).
T7584AC
AAccess Hole
BLubrication Fitting
CValve
DGrease Relief Fitting
UN29JUL91
T7584AD
TX,0130,AB552 1921FEB921/3
UN25OCT88
T5922AS
Continued on next page TX,0130,AB552 1921FEB922/3
UN24MAY89
28
6. Remove spacer and disk springs from counterbore in
each link.
T5805AJ
7. Lift side of machine just enough so bottom of sprocket
clears chain.
Specification
Track ChainApproximate
Weight............................................................................. 1600 kg (3530 lb)
UN08NOV88
8. Slowly turn sprocket in reverse direction to remove
track.
T82690
AAligning Adapter
BMaster Pin
CAligning Bushing (2 used)
DForcing Pin
ERear Forcing Pin
TX,0130,AB552 1921FEB923/3
UN25OCT88
sprocket in forward direction to pull chain across top of 29
frame to the front idler.
T5914AA
each link.
UN24MAY89
head.
T5808AF
Starting at any cap screw, tighten cap screws, in
sequence shown, to 298 Nm (220 lb-ft) plus 1/2 (180)
turn.
Specification
Shoe-to-Link Cap ScrewTorque
(New) ............................................................. 298 Nm (220 lb-ft) plus 1/2
(180) turn
UN23FEB89
procedure in this group.)
T6352AH
BAligning Bushing (2 used)
CMaster Pin
DGuide Pin
EAligning Adapter
TX,0130,AB454 1912APR951/1
01
0130
30
UN16JAN92
T7681BK
ADisk Spring (196 used) ETrack Chain HTrack Shoe (Grouser) (49 JRight Track Link (49 used)
BSpacer (2 used) FNut (196 used) used) KBushing (48 used)
CMaster Pin GCap Screw (196 used) IPin (48 used) LMaster Bushing
DLeft Track Link (49 used)
NOTE: Wear on pins and bushings does not extend See your track press manufacturers operator manual
over the entire surface. Turning pins and to disassemble and assemble track chain.
bushings is determined by amount of wear.
(See Measure Track Chain Bushing Wear and
Measure Track Chain Pitch Wear in this
group.)
TX,0130,AB455 1912APR951/1
UN26OCT88
31
T5821AG
0130,CC10 1924SEP912/5
UN26OCT88
T5821AH
0130,CC10 1924SEP913/5
UN26OCT88
T5821AI
Continued on next page 0130,CC10 1924SEP914/5
UN24MAY89
32 7. Install spacers (B) into counterbore of links.
T5821AJ
AMaster Pin
BSpacer
CRight Link
DMaster Bushing
ELeft Link
0130,CC10 1924SEP915/5
TX,0130,AB555 1912APR951/4
Specification
Middle RollerTrack Sag ....................... 305325 mm (12.012.75 in.)
01
0130
UN26OCT88
33
T6450AN
TX,0130,AB555 1912APR953/4
UN28NOV90
a grease gun with a maximum capacity of 68 950 kPa
(690 bar) (10,000 psi).
Specification
T7396DZ
Grease GunCapacity ....................... 68 950 kPa (690 bar) (10,000 psi)
TX,0130,AB555 1912APR954/4
Specification
SprocketApproximate Weight ............................................. 34 kg (75 lb) 01
0130
UN16JAN92
3. Remove cap screws and washers (A) to remove 35
sprocket.
T7681BL
Thoroughly clean the mounting surfaces and tapped
holes of all paint, oil, grease, dirt, and debris.
Specification
Sprocket-to-Gearbox Cap
ScrewsTorque .......................................................... 540 Nm (400 lb-ft)
TX,0130,AB456 1921FEB922/2
SPECIFICATIONS
Flange (Maximum Used) Height 25 mm (0.980 in.)
UN08NOV88
0130
36 SERVICE EQUIPMENT AND TOOLS
JT05518 or JT05523 Undercarriage Inspection Service Tool Kit
T87972
Maximum used is the maximum allowable height of flange
for rebuilding wear surface.
Specification
Flange (Maximum Used)Height ................................. 25 mm (0.980 in.)
Specification
Flange (New)Height ................................................... 19 mm (0.750 in.)
Flange (Maximum)Height........................................... 25 mm (0.980 in.)
TX,0130,GG237 1921FEB921/1
Specification
Front IdlerApproximate Weight ....................................... 300 kg (660 lb)
UN17JAN92
T7681CF
Continued on next page TX,0130,AB497 1921FEB921/2
UN16JAN92
38 5. Install yoke to idler bracket. Tighten cap screws to 90
Nm (65 lb-ft).
Specification
T7681BN
Yoke-to-Idler Bracket Cap
ScrewTorque ................................................................ 90 Nm (65 lb-ft)
TX,0130,AB497 1921FEB922/2
01
0130
39
UN03FEB92
T7681BO
AIdler EO-Ring HPipe Plug KCap Screw (2 used)
BBushing (2 used) FShaft IYoke MCap Screw (4 used)
CSpring Pin GMetal Face Seal JLock Washer (2 used) NLock Washer (4 used)
DSupport
1. Remove pipe plug (H) using a 6 mm hex wrench to 4. Remove O-rings (E) from shaft.
drain oil.
5. Remove shaft (F).
2. Remove spring pins (C) to remove the supports (D).
6. Inspect the bushings (B) for scoring or excessive
IMPORTANT: Metal face seals can be reused if wear. Also inspect the shaft.
they are not worn or damaged. A
used seal must be kept together as a NOTE: Remove bushings only if replacement is
set because of wear pattern on seal necessary.
face.
7. Remove bushings using a 2-jaw puller and adapters
3. Remove the metal face seal rings and rubber rings from 17-1/2 and 30 ton puller set.
(G) from supports (D) and idler (A). Keep seal rings
as matched sets with seal faces together to protect
the surfaces. (See Inspect Metal Face Seals in this
group.)
TX,0130,AB459 1921FEB921/1
01
0130
40
UN03FEB92
T7681BP
AIdler EO-Ring (2 used) IYoke MCap Screw (4 used)
BBushing (2 used) FShaft JLock Washer (2 used) NLock Washer (4 used)
CSpring Pin (2 used) GMetal Face Seal KCap Screw (2 used) OSpring Plate
DSupport HPipe Plug LRecoil Spring
1. Push bushing (B) into idler (A) so flange is tight IMPORTANT: Rubber rings and seat surfaces for
against idler. rubber rings must be clean, dry, and
oil free so rubber rings do not slip
2. Install O-ring (E) on support (D). when idler is turning.
3. Apply a thin layer of John Deere NEVER-SEEZ 6. Thoroughly clean the rubber rings and seat
Lubricant or an equivalent to end of shaft from the surfaces in idler, brackets, and seal rings using
O-ring outward, to bore in support, and to spring volatile, non-petroleum base solvent and lint-free
pin. tissues.
4. Install shaft (F) in support (D). 7. Install metal face seal (G) in support (D), and other
half in idler (A).
5. Install spring pin (C).
8. Wipe any finger prints and foreign material off seal 13. Install spring pin (C).
ring face using a lint-free tissue.
14. Install track adjuster cylinder and recoil spring (I
9. Apply a thin film of oil on each seal ring face. DO L). (See procedure in this group.)
NOT apply any oil on rubber rings.
01
15. Fill idler with recommended oil. Capacity is 0.33 L 0130
10. Install idler (A) on shaft. (11.3 oz). (See Track Roller and Idler Oil in Group 41
0004.)
11. Install metal face seal (G) in idler (A) and other
half in second support (D). 16. Clean plug using clean and cure primer. Apply
thread lock and sealer (medium strength). Install
12. Install second support (D) on shaft (F). plug.
TX,0130,AB461 1912APR952/2
SPECIFICATIONS
Front Idler Leakage Test 110 28 kPa (1.1 0.3 bar) (16
Pressure 4 psi) for a minimum of 30
01 seconds
0130
42
SERVICE EQUIPMENT AND TOOLS
D05361ST Rubber Stopper/Leak Detector Kit Hoses 0400 kPa (0
4 bar)(060 psi) Gauge Snubber (Needle) Valve Air Pressure
Regulator
OTHER MATERIAL
T43512 U.S. Thread Lock and Sealer (Medium Strength) Products
TY9473 Canadian Thread Lock and Sealer (Medium Strength)
Products
242 LOCTITE Thread Lock and Sealer (Medium Strength) Products
TY9477 Canadian Thread Lock and Sealer (Medium Strength)
Products
UN08NOV88
1. Turn the shaft several turns to seat metal face seals.
T82933
3. Install parts (AF) as shown. Plug, barbed adapter,
and connector are from a leak detector kit such as the
D05361ST Rubber Stopper/Leak Detector Kit.
APlug, Barbed Adapter and Connector
BJT03001 Tee Fitting 7/16-20 M 37 x 7/16-20 F
4. Holding plug so it is not pushed out, slowly pressurize
37 SW x 7/16-20 M 37
oil cavity to 110 28 kPa (1.1 0.3 bar) (16 4 psi) CHose
using air. DPressure Gauge
ESnubber (Needle) Valve
Specification FAir Pressure Regulator
Front Idler Leakage Test
Pressure ................................................. 110 28 kPa (1.1 0.3 bar) (16
4 psi) for a minimum of 30
seconds
LOCTITE is a registered trademark of Loctite Corp. Continued on next page TX,0130,AB556 1921FEB921/2
7. Check oil level in idler. If the oil level is down and there
is no external leakage, check for a leak from oil cavity
to interior of idler.
TX,0130,AB556 1921FEB922/2
TX,0130,AB463 1926FEB921/2
UN16JAN92
5. Tighten cap screws to 90 Nm (65 lb-ft).
Specification
T7681BN
Track Adjuster Cylinder and
Recoil Spring-to-Yoke Cap
ScrewTorque ................................................................ 90 Nm (65 lb-ft)
TX,0130,AB463 1926FEB922/2
UN25OCT88
2. Remove nuts (B) and top plate (C).
T6557DY
Continued on next page TX,0130,GG268 1914FEB921/3
UN23FEB92
(15.4 in.).
T7711AC
10. Operate jack to compress spring until spring pin (E) is
just above the spring retainer plate.
ADFT1110 Spacer
BDFT1087 Track Recoil Spring Disassembly
11. Remove spring pin using a roll pin punch and and Assembly Guard Tool
hammer. Remove nut. CDFT1111 Spacer (2 used)
DNut
12. Lower jack to release spring force. ESpring Pin
FTrack Adjuster Cylinder and Recoil Spring
13. Replace parts as necessary.
01 TX,0130,GG268 1914FEB923/3
0130
46
01
0130
47
UN23FEB92
T7711AF
1Piston 5Recoil Spring 9Track Adjuster Cylinder 12Lubrication Fitting
2Wiper Seal 6Retainer Plate and Recoil Spring 13Check Valve
3Seal 7Spring Pin 10Cap Screw (2 used) 14Washer Seal
4Cylinder 8Nut 11Lock Washer (2 used)
TX,0130,GG270 1914FEB921/1
01
0130
48
Page Page
02
02
0250
SERVICE-GARD is a trademark of Deere & Company. DX,TOOLS 1920JUL951/3 1
DX,TOOLS 1920JUL952/3
DX,TOOLS 1920JUL953/3
,02,15 1919JUN962/7
,02,15 1919JUN964/7
1
Fabricated tool, dealer made. (See Section 99 for instructions to make
tools.)
,02,15 1919JUN965/7
1
Fabricated tool, dealer made. (See Section 99 for instructions to make
tools.)
,02,15 1919JUN966/7
1
Fabricated tool, dealer made. (See Section 99 for instructions to make
tools.)
,02,15 1919JUN967/7
Other Material
TY6305 (U.S.) Clean and Cure Primer Products Used to clean and cure surfaces
TY9485 (Canadian) prior to application of adhesives and
764 (LOCTITE) sealants.
T43513 (U.S.) Thread Lock and Sealer (High Used to apply to threads of
TY9474 (Canadian) Strength) Products sprocket-to-housing cap screws.
271 (LOCTITE) 02
0250
3
T43512 (U.S.) Thread Lock and Sealer (Medium Used to apply to threads of third
TY9473 (Canadian) Strength) Products planet carrier-to-support hub cap
242 (LOCTITE) screws.
Specifications
TX,0250,DW584 1912APR951/1
Towing Machine
1. Block tracks.
UN06DEC88
T6879EG
02
0250
TX,0250,AB304 1921FEB922/4 5
UN16MAY91
T7527BP
Front Tow Loop Shown
Specification
Propel Gearbox and
UN27NOV91
Brake:Cover-to-Gearbox Cap
ScrewTorque ................................................................ 75 Nm (55 lb-ft)
9. Fill gearbox with oil through top hole (A) until oil flows
out of hole (B). (See Propel Gearbox Oil in Group
T7626AG
02
0004.)
0250
6
10. Apply pipe sealant to thread of plugs. Tighten plugs to
65 Nm (45 lb-ft).
Specification
Plug-to-CoverTorque.................................................... 65 Nm (45 lb-ft)
TX,0250,AB304 1921FEB924/4
3. Install pusher.
02
0250
7
UN27JAN92
T7392AG
Propel Gearbox Removed For Clarity
TX,0250,DW445 1922NOV942/4
UN16NOV94
T8362AB
UN16NOV94
11. Remove rings (E) and brake disks (F).
T8362AC
02
0250 13. Install rings and brake disks in an alternating pattern.
8
UN16NOV94
17. Install propel gearbox mounting cap screws.
T8362AD
ABrake Port
BPiston Spring (21 used)
CPiston
DSpacer
ERing (6 used)
FBrake Disk (7 used)
UN16NOV94
T8362AE
TX,0250,DW445 1922NOV944/4
UN06DEC88
T6876FG
02
0250
TX,0250,AB507 1921FEB922/13 9
UN06JAN92
T7626DG
TX,0250,AB507 1921FEB923/13
UN31MAR95
T8444AA
UN23AUG88
Protect hands and body from high pressure
fluids.
X9811
02
0250 Any fluid injected into the skin must be
10 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.
UN05FEB92
DCap Screw (6 used)
ECap Screws (6 used)
FSupply Shuttle Valve
GA Port-to-Rotary Manifold 2 or 4 Port Line
HB Port-to-Rotary Manifold 1 or 3 Port Line
T7681FB
ICounterbalance Valve
JCap Screw (6 used)
Right Side
UN05FEB92
T7681FC
Left Side
Specification
Propel MotorWeight .......................................................... 64 kg (141 lb)
UN06JAN92
T7626DI
TX,0250,AB507 1921FEB926/13
UN06JAN92
11. Remove cover (C).
T7626DJ
Continued on next page TX,0250,AB507 1921FEB927/13
UN19OCT88
T6639GK
02
0250
12
UN06JAN92
T7626DH
TX,0250,AB507 1921FEB928/13
UN06JAN92
T7626DK
TX,0250,AB507 1921FEB929/13
UN06JAN92
T7626BK
02
0250
TX,0250,AB507 1921FEB9211/13 13
Specification
Sprocket-to-Housing Cap
ScrewTorque ............................................................ 540 Nm (400 lb-ft)
UN06JAN92
(high strength) to threads of cap screws. Tighten cap
screws to 540 Nm (400 lb-ft).
Specification
T7626DI
Frame-to-Gearbox Cap Screw
Torque ......................................................................... 540 Nm (400 lb-ft)
22. Install O-ring. Install propel motor. Tighten cap screws ACap Screw (6 used)
BRight Gearbox Brake Port at 12:30 Oclock
to 75 Nm (55 lb-ft). Position
CPropel Motor
Specification DCap Screw (16 used)
Propel Motor-to-Gearbox Cap
ScrewTorque ................................................................ 75 Nm (55 lb-ft)
23. Install supply shuttle valve (F) so the side with one
plug is towards gearbox. Install counterbalance valve
(I). Tighten cap screws to 75 Nm (55 lb-ft).
Specification
Counterbalance Valve-to-Supply
Shuttle Valve Cap Screw
Torque ............................................................................. 75 Nm (55 lb-ft)
UN05FEB92
02
25. Install cover.
0250
14
ADrain Port-to-Rotary Manifold Return Line
T7681FC
BPropel Speed Change Port-to-Rotary Manifold
"P1" Port Line
CPropel Brake Release Port-to-Gearbox Line Left Side
DCap Screw (6 used)
ECap Screws (6 used)
FSupply Shuttle Valve
GA Port-to-Rotary Manifold 2 or 4 Port Line
HB Port-to-Rotary Manifold 1 or 3 Port Line
ICounterbalance Valve
JCap Screw (6 used)
UN05FEB92
T7681FB
Right Side
TX,0250,AB507 1921FEB9213/13
02
0250
15
UN24JAN92
T7681EZ
AFirst Planet Sun Gear ESupport Hub LFirst Planet Carrier QSecond Planet Sun Gear
(Input Shaft) FMetal Face Seal MCover RThird Planet Sun Gear
BSpring (21 used) GHousing NFirst Planet Gear (3 used) SThird Planet Carrier
CBrake Piston HThird Planet Gear (4 used) OThrust Bushing TBrake Hub
DBrake Disk (7 used) and JSecond Planet Carrier PFirst Planet Ring Gear
Plate (6 used) KSecond Planet Gear (3
used)
Specification
SprocketApproximate Weight..................................... 84 kg (184 lb)
02
0250
16 TX,0250,DW582 1912APR952/15
UN27JAN92
T7375AW
TX,0250,DW582 1912APR953/15
UN19OCT88
T6639GK
UN27JAN92
T7375BF
UN27JAN92
T7375BE
02
0250
TX,0250,DW582 1912APR955/15 17
UN27JAN92
T7375BD
TX,0250,DW582 1912APR956/15
UN06DEC91
T7626BY
02
0250
18
UN27JAN92
T7401AH
TX,0250,DW582 1912APR958/15
UN06DEC91
T7626CA
11. Remove disks (A), plates (B) and brake hub (C).
ADisk (7 used)
BPlate (6 used)
CBrake Hub
02
UN06DEC91
0250
19
T7626CB
TX,0250,DW582 1912APR9510/15
12. Pull housing (A) off support hub (D) using a hydraulic
ram (B), pullers, and attachments (C).
UN06DEC91
T7626BX
UN27JAN92
face.
T7396AE
TX,0250,DW582 1912APR9512/15
17. Remove other metal face seal ring (A) and O-ring (B)
from hub (C).
UN27JAN92
T7397CF
02
0250
21
UN27JAN92
T7392AG
TX,0250,DW582 1912APR9514/15
20. Remove disk (A), springs (C), piston (D) and spacer
(B).
ADisk
BSpacer
CSpring (21 used)
DPiston
UN27JAN92
T7392AH
TX,0250,DW582 1912APR9515/15
ASeal Ring
BWorn Area (shaded area)
CSeal Ring Face
UN24AUG93
DOuter Half of Seal Ring Face
ESealing Area (dark line)
T85079
TX,0250,AA3036 1911NOV941/3
UN05DEC96
ASeal Ring
BWorn Area (shaded area)
CInner Half of Seal Ring Face
T85080
UN23FEB89
Thoroughly dry parts using a lint-free tissue.
T82840
02
0250
TX,0250,AA3036 1911NOV943/3 23
02
0250
24
UN28NOV94
T8364AA
1. Install two new O-rings (4) in the hub (13). 5. Install springs (7) in piston.
02
2. Install new O-ring (5) in the spacer (11). 6. Install retainer disk (3). 0250
25
3. Install spacer (11) on piston (8). 7. Compress spring. Install snap ring (2).
4. Install piston and spacer in hub. 8. Install new hub-to-propel motor O-ring (1).
UN06JAN92
amounts of petroleum jelly to bearings to help hold
them in place.
T7626DO
02 must be clean, dry, and oil free so
0250 O-ring does not slip in housing.
26
12. Wipe finger prints and foreign material off seal ring
face using clean oil and lint-free tissues.
13. Apply a thin film of clean oil on each seal ring face.
02
UN16NOV94
0250
27
T8364AB
TX,0250,DX266 1911NOV944/14
02
UN06DEC91
0250
28
T7626CB
TX,0250,DX266 1911NOV946/14
UN06DEC91
T7626CA
Continued on next page TX,0250,DX266 1911NOV947/14
02
0250
29
UN27JAN92
T7401AH
TX,0250,DX266 1911NOV948/14
29. Clean cap screw threads using clean and cure primer.
Apply thread lock and sealer (medium strength) to
threads.
Specification
Cap ScrewsTorque .................................................. 540 Nm (400 lb-ft)
UN06DEC91
T7626BZ
UN27JAN92
T7375BD
02
0250
30 TX,0250,DX266 1911NOV9410/14
UN27JAN92
T7375BE
TX,0250,DX266 1911NOV9411/14
UN27JAN92
T7375BA
UN27JAN92
T7375BF
02
0250
TX,0250,DX266 1911NOV9413/14 31
Specification
UN31JUL96
Planet Carrier Cover-to-Housing
Cap ScrewTorque ........................................................ 75 Nm (55 lb-ft)
T7375BC
TX,0250,DX266 1911NOV9414/14
UN10JAN92
5. Tighten nut to pull housing and bearing assembly down
onto hub.
T7626DT
Check to be sure bearings are being pulled down on
the hub squarely.
A256 mm (10 in.) OD
6. Remove tools and shipping tube. B243 mm (9.5 in.) ID
C134 mm (5.25 in.)
7. See Assemble Propel Gearbox in this group for DSteel Tube
remainder of assembly. ENut
FWasher
G3-Jaw Puller
HHousing, Bearing and Shipping Tube
IHub
JAdapter
KThreaded Rod510 mm (20 in.) Length
TX,0250,AB150 1921FEB921/1
02
0260
SERVICE-GARD is a trademark of Deere & Company. TX,0260,DW595 1912APR951/4 1
1
Fabricated tool, dealer made. (See Section 99 for instructions to make
tools.)
TX,0260,DW595 1912APR952/4
1
Fabricated tool, dealer made. (See Section 99 for instructions to make
tools.)
Continued on next page TX,0260,DW595 1912APR953/4
TX,0260,DW595 1912APR954/4
Other Material
T43512 (U.S.) Thread Lock and Sealer (Medium Used to apply to threads of cap
TY9473 (Canadian) Strength) Products screws for valve housing and cover.
242 (LOCTITE)
TY6305 (U.S.) Clean and Cure Primer Products Used to clean and cure surfaces
TY9485 (Canadian) prior to application of adhesives and
764 (LOCTITE) sealants.
Specifications
Propel Motor:
Rotary Manifold:
TX,0260,DW590 1912APR951/1
02
UN31MAR95
0260
4
T8444AA
Early Machine Shown
UN23AUG88
3. Disconnect lines (AC, G and H). Remove cap screws
(J) to remove counterbalance valve (I).
X9811
02
(F). 0260
5
6. Remove motor.
7. Install motor.
Specification
UN05FEB92
Propel Motor-to-Gearbox Cap
ScrewTorque ............................................................ 135 Nm (100 lb-ft)
9. Connect lines.
T7681FB
10. Tighten reservoir filler cap.
Right Side
11. Perform Propel Motor Start-Up Procedure. (See
procedure in this group.)
ADrain Port-to-Rotary Manifold Return Line
BPropel Speed Change Port-to-Rotary Manifold
"P1" Line
CPropel Brake Release Port-to-Gearbox Line
DCap Screw (6 used)
ESupply Shuttle Valve Cap Screws (6 used)
FSupply Shuttle Valve
GA Port-to-Rotary Manifold 2 or 4 Port Line
HB Port-to-Rotary Manifold 1 or 3 Port Line
UN05FEB92
ICounterbalance Valve
JCap Screw (6 used)
T7681FC
Left Side
TX,0260,DW586 1912APR954/4
UN19AUG91
installed or whenever oil has been
drained from the motor.
T7586CX
line to minimize loss of oil.
3. Fill motor with oil through drain port. Add oil until level
is to the top of drain port. (See Propel Gearbox Oil in
Fuels and Lubricants group.)
5. Connect line.
6. Run each propel motor with track off the ground for 3
track revolutions to remove air from the propel circuit.
TX,902025,GG192 1917JAN951/1
02
0260
7
02
0260
8
UN05FEB92
T7681FD
02
0260
TX,0260,AB165 1925FEB922/11 9
NOTE: Drain port fitting (K) and drain plug (H) swap
positions for right and left motors. On right motor
shown, brake port fitting (F) is down. On left side
motor, fitting is up.
UN05FEB92
ASpeed Change Port Fitting
BMinimum Displacement Adjuster
CCap Screw (9 used)
DValve Housing and Cover
EMaximum Displacement Adjuster
T7681FE
FPropel Brake Port Fitting
GPropel Brake Pressure Reducing Valve
Adjustment Screw
HDrain Plug
IDF1039 Pump Workbench Support
JMotor Housing
KDrain Port Fitting
AValve Plate
BValve Housing and Cover
UN05FEB92
CNotch in Plate
DDowel Pin
EMotor Housing
T7681FF
02
0260
10 TX,0260,AB165 1925FEB924/11
UN27NOV91
Workbench Support. (See Section 99 for instructions to
make tool.)
T7626AS
ARotating Group
BOil Tube (2 used)
CMotor Housing
DMinimum Displacement Piston Maximum
Displacement Piston
10. Remove bearing inner race (A) and spacer (B) using
a bearing puller.
AInner Race
BSpacer
CCardboard
DRoller Cage 02
0260
11
UN06JAN92
T7626CP
TX,0260,AB165 1925FEB926/11
UN18DEC91
T7626CR
UN12DEC94
ASwash Plate
BPiston (9 used)
CRetainer Plate
DBall Guide
ENeedle Bearing (3 used)
T8378AJ
FCylinder Block
GMinimum Displacement Piston Maximum
02 Displacement Piston
0260 HShim
12
TX,0260,AB165 1925FEB928/11
UN27NOV91
ACylinder Block
BSpring
CWasher
DSnap Ring
T7626AV
TX,0260,AB165 1925FEB929/11
ACylinder Block
BWasher
CSpring
DWasher
EShims (as required)
UN10JAN92
FSnap Ring
T7626BI
17. Remove bushing (B) from drive shaft (E), and bearing
cone (D). Cone is a press fit.
18. Remove bearing cup (C) from motor housing (A). Cup
is a press fit.
UN10JAN92
AMotor Housing
BBushing
CBearing Cup
DBearing Cone
T7626BJ
EDrive Shaft 02
0260
13
TX,0260,AB165 1925FEB9211/11
02
0260
14
UN05FEB92
T7681FL
AValve Housing and Cover FBrake Release Pressure IDrain Plug (Right Motor) KMaximum Displacement
BMotor Housing Reducing Valve Drain Port (Left Motor) Adjusting Screw
CShuttle Valve Block GCrossover Relief Valve JDrain Plug (Left Motor) LMinimum Displacement
DShuttle Valve HShuttle Valve Drain Port (Right Motor) Adjusting Screw
ELow Speed Selector Valve
IMPORTANT: DO NOT remove, nor change See individual valves in this group for service
settings of minimum or maximum procedures.
displacement adjusting screws (K
and L). This is a factory setting and
the screws are sealed to maintain it.
02
UN31MAR95
0260
15
T8445AA
Left Side
UN31MAR95
T8445AB
Right Side
TX,0260,AB522 1922FEB922/5
AOrifice
BEdge Filter
CPlug
T8447AD
Flushing Orifice
AOrifice
UN31MAR95
BPlug
T8447AE
02
0260
16 TX,0260,AB522 1922FEB924/5
AOrifice
UN31MAR95
BPlug
T8447AF
TX,0260,AB522 1922FEB925/5
TX,0260,AB524 1922FEB921/13
AMotor Housing
BBearing Cup
CDriver
DDowel Pin
UN27NOV91
T7626BC
ADrive Shaft
BHousing
CBearing Cup
DBearing Cone
EWasher
FShim
UN31MAR95
GValve Housing and Cover
HBearing Cup
IBearing Cone
JBushing
T8445AE
Continued on next page TX,0260,AB524 1922FEB923/13
Specification
Drive ShaftEnd Play ........................ 0.100.30 mm (0.0040.012 in.)
02
0260 9. Remove valve housing and cover.
18
10. Remove bearing cup.
UN27NOV91
11. Carefully pull bearing cone from cover end of drive
shaft.
AMotor Housing
T7626AX
BLifting Bracket
CM12 Cap Screw
DDial Indicator
EEnd Play
FDrive Shaft
TX,0260,AB524 1922FEB924/13
ADrive Shaft
BBearing
UN10JAN92
UN10JAN92
AMotor Housing
BParallel
CSnap Ring
T7626BN
DWasher 02
EBall Guide 0260
FSwash Plate 19
GCradle (Bearing Shell)
HBearing Cone
IDrive Shaft
JBearing Cup
KCylinder Block
LSquare A and K
15. Install valve plate (F) on valve housing and cover (E).
UN27NOV91
02 Example: Step 14 Dimension 3.20 mm (0.125 in.)
0260 Minus Step 16 Dimension 2.50 mm (0.100 in.)
20
Difference 0.70 mm (0.025 in.)
T7626AY
Tolerance 0.200.40 mm
(0.0080.016 in.)
Shim Pack Thickness 0.30 mm (0.012 in.)
17. Install shims (H) between ball guide (G) and needle
bearing (I). Remove all parts from motor housing,
except bearing cone and cradle.
AMotor Housing
BCylinder Block
CDepth Micrometer
DMachined Surface
EValve Housing and Cover
FValve Plate
GBall Guide
HShim (As required)
INeedle Bearing (3 used)
UN27NOV91
JCylinder Block
T7626AZ
UN10DEC94
T8378AL
18. Install oil seal (D) with lip to inside of housing until
seal bottoms on shoulder (A).
UN27NOV91
19. Install washer (B) and snap ring (C).
AShoulder
BWasher
T7626AW
CSnap Ring 02
DOil Seal 0260
21
TX,0260,AB524 1922FEB928/13
ADrive Shaft
BSwash Plate
CPiston (9 used)
DRetainer Plate
EBall Guide
FNeedle Bearing (3 used)
GCylinder Block
HWasher
ISpring
JWasher
KWasher
LSnap Ring
MWasher
NBearing Cone
OShim (As required)
UN10DEC94
T8378AK
UN27NOV91
23. Install heated bearing cone on drive shaft.
APiston
BRotating Group
T7626AN
CWasher
02
DDrive Shaft
0260
22
TX,0260,AB524 1922FEB9210/13
APiston
BBearing Cone
UN27NOV91
CMinimum Displacement Piston
DMotor Housing
T7626AL
26. Install valve plate (B) with notch (E) to align with hole
in motor housing (D).
UN27NOV91
AMaximum Displacement Piston
BValve Plate
CMinimum Displacement Piston
T7626AP
DMotor Housing 02
ENotch 0260
FOil Tube (2 used) 23
TX,0260,AB524 1922FEB9212/13
29. Install valve housing and cover (B) so dowel pin (D) is
aligned with notch in valve plate (C) and hole in
housing.
UN27NOV91
30. Work pistons and oil tubes into ports. Install cap
screws and tighten to 120 Nm (89 lb-ft).
T7626AK
Specification
Valve Housing and Cover Cap
ScrewTorque .............................................................. 120 Nm (89 lb-ft)
AMotor Housing
31. Fill motor with 2 L (34 oz) of hydraulic fluid. BValve Housing and Cover
CValve Plate
NOTE: If proper seal sleeve and driver are available to DDowel Pin
EMachine Surface
clear drive shaft, oil seal, washer and snap ring
can be installed at this time.
TX,0260,AB524 1922FEB9213/13
02
0260
24 TX,0260,AB197 1922FEB921/2
UN23AUG88
Protect hands and body from high pressure
fluids.
X9811
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.
Specification
UN05FEB92
TX,0260,AB197 1922FEB922/2
UN27NOV91
ACounterbalance Valve
BO-Ring (2 used)
CO-Ring (2 used) 02
T7626BE
DCap Screw (8 used) 0260
25
TX,0260,AB198 1922FEB921/4
ACover
BO-Ring (2 used)
CValve Housing
UN27NOV91
DCover
EPiston
T7626BF
UN27NOV91
T7626BG
TX,0260,AB198 1922FEB923/4
13. Install flat cap (C) on port "B" (B) side of housing.
UN05FEB92
T7681FN
TX,0260,AB198 1922FEB924/4
2. Remove cover.
UN23AUG88
Protect hands and body from high pressure
fluids.
X9811
02
Any fluid injected into the skin must be 0260
surgically removed within a few hours or 27
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.
UN05FEB92
T7681FP
TX,0260,AB530 1922FEB922/2
2. Remove cover.
02
0260
28 Continued on next page TX,0260,AB531 1922FEB921/2
UN23AUG88
Protect hands and body from high pressure
fluids.
X9811
02
Any fluid injected into the skin must be 0260
surgically removed within a few hours or 29
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.
Specification
Crossover Relief Valve Cap
NutTorque .................................................................. 120 Nm (90 lb-ft)
ACap Nut
BO-Ring
UN05FEB92
CSmall Spring Seat
DLarge Spring
ESmall Spring
FLarge Spring Seat
T7681FH
GMetal Ring
HO-Ring
IValve
JPoppet
KValve Housing and Cover
TX,0260,AB531 1922FEB922/2
2. Remove cover.
02
0260
30 TX,0260,AB532 1922FEB921/2
UN05FEB92
T7681FG
TX,0260,AB532 1922FEB922/2
UN05FEB92
1. Loosen reservoir fill cap to release air pressure in
reservoir.
T7681FJ
2. Remove propel motor cover. 02
0260
31
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury. Avoid APlug
BO-Ring
the hazard by relieving pressure before CSpring
disconnecting hydraulic or other lines. Tighten DWasher
all connections before applying pressure. EShims
Search for leaks with a piece of cardboard. FGuide
Protect hands and body from high pressure GValve Piston
HPoppet
fluids. IValve Housing and Cover
Specification
Low Speed Selector Plug
Torque ............................................................................. 80 Nm (60 lb-ft)
TX,0260,AB534 1912APR951/1
UN05FEB92
1. Loosen reservoir fill cap to release air pressure in
reservoir.
T7681FK
02 2. Remove propel motor cover.
0260
32 3. Remove parts (AG) from valve housing and cover
(H). AValve
BSeat
4. Clean, inspect and replace as necessary. CSpring
DO-Ring
ESeat
NOTE: Do not separate nut and screw (G), this is a FPlug
factory setting. GNut and Screw
HValve Housing and Cover
5. Install parts (AG) in cover.
TX,0260,AB535 1912APR951/1
UN06JAN92
reservoir.
T7626DG
02
0260
33
UN06JAN92
T7626DV
1O-Ring 7Hydraulic Hose 13O-Ring 19O-Ring
2Hydraulic Hose 8O-Ring 14Adapter 20O-Ring
3O-Ring 9Adapter 15O-Ring 21Flange Fitting
4O-Ring 10Elbow Fitting 16Elbow Fitting 22Cap Screw
5Adapter 11Hydraulic Hose 17O-Ring 23Hydraulic Hose
6Conduit 12Fitting 18Adapter 24Tee Fitting
TX,0260,AB203 1922FEB922/2
UN23AUG88
Protect hands and boy from high pressure
fluids.
X9811
02
0260 Any fluid injected into the skin must be
34 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.
UN06DEC91
CAUTION: The approximate weight of rotary
manifold is 38 kg (84 lb).
T7626CC
and two rotary manifold lifting tools. (See Section 99
for instruction to make tool.)
UN06JAN92
BRotary Manifold Middle Left Port-to-Left Propel
Motor Top Front Port Line
CRotary Manifold Bottom Left Port-to-Left Propel
Motor Bottom Front Port Line
T7626DW
DRotary Manifold Bottom Port-to-Left Propel Motor
Top Port Line
ERotary Manifold Bottom Port-to-Right Propel
Motor Top Port Line
FRotary Manifold Bottom Right Port-to-Right Propel
Motor Bottom Front Port Line
GRotary Manifold Right Top Port-to-Right Propel
Motor Top Port Line
HRotary Manifold Middle Right Port-to-Right Propel
Motor Top Front Port Line
ICap Screw (4 used)
11. Remove lifting device, and install cover (G) and strap
(I). Tighten cap screws (H) to 40 Nm (30 lb-ft).
Specification
Cover and Strap Cap Screw
Torque ............................................................................. 40 Nm (30 lb-ft)
UN06DEC91
36 BPort 1-to-Right Propel Section Port A
CSpeed Change Port P1-to-Dual Solenoid Block
Port A
DPort 2-to-Right Propel Section Port B
T7626CC
EPort 4-to-Left Propel Section Port A
FPort D-to-Reservoir
GCover
HCap Screw (2 used)
IStrap
14. Install cap screw (N), washer (J), and nut (K) in a
mechanical push-puller such as the D01200AA
Push-Puller (Mechanical). Install push-puller on rotary
manifold using cap screws (L). Use an extra thin
service wrench (I) such as the D05242ST Service
Wrench to prevent cap screw (N) from turning.
UN20SEP94
mounting cap screw to 40 Nm (30 lb-ft).
Specification
Cover and Strap Cap Screw
Torque ............................................................................. 40 Nm (30 lb-ft)
T8313AA
18. Connect lines.
IService Wrench
JWasher
KNut
LCap Screw (2 used)
MWasher (2 used)
NCap Screw
OCap Screw (2 used)
TX,0260,AB207 1922FEB925/5
ASpindle
BSeal Dust
CO-Ring
DBushing
EOil Seal Ring (6 used)
FHousing
GWasher
HSnap Ring
IO-Ring
02 JCover
0260 KCap Screw
38
UN09JAN92
T7626DX
Continued on next page TX,0260,AB214 1922FEB921/2
6. Remove O-ring (C), seal (B), rings (E) and bushing (D)
from housing (F).
UN09JAN92
(F).
T7626DY
10. Install spindle (A) in housing (F) so that match marks
align.
TX,0260,AB214 1922FEB922/2
passage.
TX,0260,AB216 1922FEB921/1
UN06JAN92
1. Loosen reservoir fill cap (A) to release air pressure.
T7626DG
02
0260
40 Continued on next page TX,02,DY2918 1921AUG971/3
ANut
BPlate
CCover
DSolenoid
EConnector
02
0260
41
UN14JAN92
T7681BR
(Serial No. 556935)
UN05AUG97
T110252
UN23AUG88
Protect hands and body from high pressure
fluids.
X9811
02
0260 Any fluid injected into the skin must be
42 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.
4. Remove valve.
6. Install valve.
TX,02,DY2918 1921AUG973/3
UN14JAN92
ANut
BPlate
CCover
DCoil
EWasher
T7681BS
FValve Spool 02
GO-Ring (2 used) 0260
HO-Ring (2 used) 43
IBackup Ring (2 used)
TX,0260,AB316 1922FEB921/1
02
0260
44
Page Page
04
UN07SEP88
M44215
TX,9010,SS494 1904OCT901/1
UN07SEP88
M44215
TX,04,DY2913 1921AUG971/1
RG4950 UN23AUG88
TX,04,DY2912 1921AUG974/24
TX,04,DY2912 1921AUG976/24
T6585NP UN18OCT88
TX,04,DY2912 1921AUG977/24
TX,04,DY2912 1921AUG978/24
TX,04,DY2912 1921AUG979/24
RW18149 UN09APR90
TX,04,DY2912 1921AUG9710/24
TX,04,DY2912 1921AUG9712/24
UN03NOV97
RG6436
04
0400
3
TX,04,DY2912 1921AUG9713/24
TX,04,DY2912 1921AUG9714/24
TX,04,DY2912 1921AUG9715/24
T6606AG UN18OCT88
TX,04,DY2912 1921AUG9716/24
TX,04,DY2912 1921AUG9719/24
TX,04,DY2912 1921AUG9720/24
TX,04,DY2912 1921AUG9721/24
UN13JAN92
RG6032
TX,04,DY2912 1921AUG9722/24
TX,04,DY2912 1921AUG9724/24
TX,0260,DW596 1912APR962/3
Other Material
TY15130 (U.S.) John Deere Form-In-Place Gasket Apply to ends of gaskets under oil
pan gasket.
PT569 (U.S.) John Deere NEVER-SEEZ Apply to exhaust manifold cap screw
Lubricant threads.
TY6304 (U.S.) Flexible Sealant Products Used to apply to oil pan rail.
TY9484 (Canadian)
04
0400 515 (LOCTITE)
6
T43512 (U.S.) Thread Lock and Sealer (Medium Used to apply to cap screw threads
TY9473 (Canadian) Strength) Products and gasket of fuel transfer pump.
242 (LOCTITE)
Specifications
Injection Nozzle:
Injection Pump:
Starter:
04
Cable Nut at Starter Torque 30.5 Nm (270 lb-in.) 0400
9
TX,04,DY2911 1920AUG973/3
UN23AUG88
loosen cap to first stop to relieve pressure
before removing completely.
TS281
gal).
04
0400
10
TX,04,DY2884 1920AUG972/12
UN18DEC91
fan guards (D).
T7626CV
7. Remove eight cap screws to remove shroud (E).
UN18DEC91
11. Remove bracket (C) and muffler.
T7626CW
AClamp
BCap Screw (2 used)
CMuffler Bracket
DCap Screw (2 used)
04
0400
11
TX,04,DY2884 1920AUG974/12
13. Disconnect fuel line (B) and start aid line (C).
IGround Strap
UN23AUG88
Protect hands and body from high pressure
fluids.
X9811
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,
04 or other knowledgeable medical source.
0400
12
18. Disconnect lines (AC).
UN18DEC91
19. Disconnect fuel return line (E).
T7626CY
APump Displacement Valve-to-Engine Speed
Control Actuator Line
BReservoir-to-Engine Speed Control Actuator Line
CLoad Sense Valve-to-Engine Speed Control
Actuator Line
DHeater-to-Cylinder Block Hose
EFuel Return Line
UN18DEC91
24. Remove four isolator mount-to-frame cap screws.
25. To remove engine, lift fan end so oil pan will clear
frame crossbar and move engine away from hydraulic
T7626CZ
pump.
UN13FEB90
Specification
Cover-To-Flywheel Housing Cap
ScrewsTorque .............................................................. 50 Nm (35 lb-ft)
T6439SZ
04
0400
14
UN13FEB90
T6439TA
TX,04,DY2884 1920AUG978/12
Specification
Bracket-to-Flywheel Housing 1/2
in. Cap ScrewTorque ............................................... 150 Nm (115 lb-ft)
Bracket-to-Engine Block 5/8 in.
Cap ScrewTorque .................................................... 215 Nm (160 lb-ft)
Isolator-to-Frame M20 Cap Screw
and NutTorque ......................................................... 675 Nm (500 lb-ft)
ASpecial Washer
BUpper Isolator
CBracket
DLower Isolator
UN24FEB92
T7681FV
UN18DEC91
BReservoir-to-Engine Speed Control Actuator Line
CLoad Sense Valve-to-Engine Speed Control
Actuator Line
DHeater-to-Engine Block Hose
T7626CY
EFuel Return Line
04
0400
15
TX,04,DY2884 1920AUG9710/12
UN18DEC91
40. Install inlet tube and tighten exhaust clamp (A).
41. Install fan shroud, fan, upper, and lower fan guard.
T7626CW
Install fan shroud so there is approximately 7 mm
(0.27 in.) clearance between blades and shroud.
Specification AClamp
Fan Blade-to-ShroudClearance ..................................... 7 mm (0.27 in.) BCap Screw (2 used)
CMuffler Bracket
04 DCap Screw (2 used)
Tighten fan shroud cap screws to 40 Nm (30 lb-ft).
0400
16
Specification
Fan Shroud Cap ScrewTorque .................................... 40 Nm (30 lb-ft)
Specification
Fan Guard Cap ScrewTorque .................................. 16.2 Nm (12 lb-ft)
TX,04,DY2884 1920AUG9712/12
UN23AUG88
loosen cap to first stop to relieve pressure
before removing completely.
TS281
(11 gal).
TX,04,DT5057 1912JUN972/12
UN05AUG97
T109976
Continued on next page TX,04,DT5057 1912JUN973/12
UN05AUG97
04
0400
18
T109977
AClamp (2 used) FFan Guard JHeater-to-Water Pump Hose MStart Aid Line
BClamp GFan Shroud KCap Screw (2 used) NWire Harness
CAir Intake Hose HUpper Radiator Hose LHeater-to-Engine Block OFuel Line
DClamp (2 usesd) ILower Radiator Hose Hose PFuel Return Line
EFan
6. Remove cap screws (K). Loosen clamp (B). 14. Disconnect fuel line (O).
Remove air intake hose assembly (C).
15. Disconnect start aid line (M).
7. Loosen clamps (D). Remove upper radiator hose
(H). 16. Disconnect fuel return line (P).
8. Loosen clamps and remove lower radiator hose (I). 17. Disconnect wiring harness (N).
9. Remove eight cap screws to remove fan guard (F). NOTE: Engine wiring harness can be removed with
engine. Disconnect harness bulkhead
10. Remove eight cap screws from fan shroud. Move connector at firewall.
shroud toward engine.
18. Remove electrical harness clamps from muffler
11. Remove four cap screws to remove fan (E) and bracket.
spacer.
19. Remove clamp (A). Remove muffler. (See
12. Remove fan shroud (G). procedure in Group 0530.)
13. Disconnect heater lines (J and L). Label lines to 20. Remove pressure regulator valve solenoid
aid in installation. connector.
UN05AUG97
T110036
04
0400
19
UN23AUG88
Protect hands and body from high pressure
fluids.
X9811
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,
04 or other knowledgeable medical source.
0400
20
23. Disconnect lines (AC). Label lines to aid in
assembly.
UN05AUG97
24. Support hydraulic pump using a lifting bracket such
as JT01748 and a hoist.
T110041
25. Remove main hydraulic pump-to-flywheel cover
mounting cap screws.
Heat Shield Removed For Clarity
UN18OCT88
T6683FQ
TX,04,DT5057 1912JUN977/12
UN05AUG97
32. Install engine mounting cap screws.
T110068
UN05AUG97
T110069
UN05AUG97
T110041
04
0400 Heat Shield Removed For Clarity
22
TX,04,DT5057 1912JUN979/12
UN05AUG97
T110036
UN05AUG97
04
0400
23
T109977
AClamp (2 used) FFan Guard JHeater-to-Water Pump Hose MStart Aid Line
BClamp GFan Shroud KCap Screw (2 used) NWire Harness
CAir Intake Hose HUpper Radiator Hose LHeater-to-Engine Block OFuel Line
DClamp (2 used) ILower Radiator Hose Hose PFuel Return Line
EFan
37. Install clamp (A). 45. Install fan shroud cap screws. Tighten fan shroud
cap screws to 40.5 Nm (30 lb-ft).
38. Connect wiring harness (N).
Specification
39. Connect fuel return line (P). Fan Shroud Cap Screws
Torque................................................................... 40.5 Nm (30 lb-ft).
Specification 49. Install air intake hose (C). Tighten clamp (B).
Fan Mounting Cap Screws Install cap screws (K).
Torque....................................................................... 70 Nm (52 lb-ft)
54. Open fuel shut off valve and connect negative battery
cable.
UN05AUG97
55. Bleed fuel system. (See procedure in this group.)
T109976
Group 0515.)
04
0400
24
TX,04,DT5057 1912JUN9712/12
04
0400
25
UN05AUG97
T110092
ACap Screw (26 used) EElectrical Connector HOil Pan KO-Ring (2 used)
BCap FCap Screw (3 used) ICap Screw (6 used) LDrain Valve
CGasket GO-Ring JPlug MCap Screw (4 used)
DSensor
1. Drain engine oil. Approximate capacity is 19 L (5 6. Position oil pan (H) on cylinder block.
gal) including filter.
7. Install cap screws (A, I and M). Tighten to 35 Nm
NOTE: Engine must be removed to remove oil pan. (26 lb-ft).
TX,04,DY2914 1921AUG971/1
UN19SEP89
1. Remove fuel leak-off line (A).
T7041BO
ALeak-Off Line
BCap Screw
CSpacer
DHold-Down Clamp
EFuel Injection Nozzle
04 FFuel Injection Line Nut
0400
26
TX,0400,BA151 1925SEP911/8
UN01NOV88
T79458
TX,0400,BA151 1925SEP912/8
UN18OCT88
brush to clean the nozzle body.
T6451AJ
IMPORTANT: DO NOT attempt to test nozzles unless
the proper service tools are available.
For injection nozzle repair, have an
authorized diesel injection service
station perform the work or refer to the
04
engine component technical manual. 0400
27
6. Clean the exterior of nozzle by soaking in clean solvent
or diesel fuel. Then clean the spray tip using a brass
wire brush.
ALeak-Off Cap
BGrommet
CNut
UN01NOV88
DRubber Sleeve
ESpecial Nut
T94607
TX,0400,BA151 1925SEP915/8
10. Help slide the carbon seal into place in its groove
UN18OCT88
UN01NOV88
T82101
TX,0400,BA151 1925SEP917/8
UN19SEP89
Specification
Injection Nozzle Connector Nut
Torque ............................................................................. 27 Nm (20 lb-ft)
T7041BO
15. Connect lines (A and F) to injection nozzle. Tighten
injection line nut (F) to 27 Nm (20 lb-ft) using two
wrenches.
ALeak-Off Line
Specification BCap Screw
Nozzle Hold Down Cap Screw CSpacer
Torque ............................................................................. 27 Nm (20 lb-ft) DHold-Down Clamp
EFuel Injection Nozzle
16. Tighten all line clamps. FFuel Injection Line Nut
TX,0400,BA151 1925SEP918/8
UN01NOV88
1. Clean cylinder head nozzle bore using the JDE39
Nozzle Bore Cleaning Tool.
T82101
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.
TX,0400,GG266 1907FEB921/1
UN08JUN89
The gear puller (A) and cap screws (B and C) can be
ordered from your John Deere dealer by ordering Kit No.
JDG670A, DB4 Drive Gear Puller. The kit includes the
following parts:
T7042AO
One DB4 Drive Gear Puller Plate
One Cap Screw (1/213 UNC x 1.25)
ADB4 Drive Gear Puller
Two Cap Screws (6 mm1 x 40)
BTwo Cap Screw (6 mm - 1 x 40)
CCap Screw (1/2 - 13 UNC x 1.25)
UN27JUN91
2. Lower bucket to the ground.
T7527DP
IMPORTANT: Turbocharger may be damaged if
engine is not properly shut down.
UN08JUN89
14. Plug and cap all openings in pump.
AReturn Line
T7042AL
BFuel Supply Line
CFuel Pressure Line
Four Cylinder Engine Shown
04
0400
31
TX,04,DY2885 1920AUG973/6
UN08MAY91
piston No. 1 at TDC will ease installation of
injection pump.
T7527BD
18. Remove pump hex nuts.
TX,04,DY2885 1920AUG974/6
20. With plate (B) tight against engine front, turn cap
screw (A) in forcing drive shaft and pump out.
UN08JUN89
T7078AB
TX,04,DY2885 1920AUG976/6
TX,04,DY2886 1920AUG971/7
UN23MAY95
CD7320
Specification
Drive Gear NutTorque ............................................. 197 Nm (145 lb-ft)
UN08JUN89
5. Remove timing pin and flywheel turning tool.
T7042AM
Specification
Attaching NutTorque .................................................... 25 Nm (18 lb-ft)
04
0400
33
TX,04,DY2886 1920AUG973/7
11. Operate primer lever (B) until only fuel flows out of
bleed screw. Tighten screw.
UN01NOV88
NOTE: If there is no fuel flow, push primer lever toward
engine; turn crankshaft using starting motor to
reposition camshaft.
T6201AO2
TX,04,DY2886 1920AUG975/7
UN18OCT88
T6683DM
Continued on next page TX,04,DY2886 1920AUG976/7
UN01NOV88
Protect hands and body from high pressure
fluids.
T92924
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 04
Medical Department in Moline, Illinois, U.S.A. 0400
35
TX,04,DY2886 1920AUG977/7
TX,04,DT5058 1917JUN971/1
UN18MAY93
possible to fuel injection nozzle.
ASOI Sensor
BTransducer Clamp
T8010AL
CGround
DMeter Connection
EClamp-On Transducer
FInjection Line
GGround
HMeter Connection
IAdapter
04
JMagnetic Probe
0400
KMeter Connection
36
UN20MAY93
T8010AM
UN18MAY93
T8010AN
TIME TRAC is a registered trademark of the Stanadyne Automotive
Corp. TX,TIMETRAC,300 1920JUN951/1
UN18OCT88
2. Clean filter base.
T6201AQ2
ASpring
BTab
CFilter
DBase
04
0400
37
TX,04,DY2915 1921AUG971/2
UN01NOV88
5. Loosen bleed screw (A). Operate primer lever (B) until
fuel flow from bleed screw is free of bubbles.
T6201AO2
NOTE: If there is no fuel flow, push primer lever toward
engine. Turn crankshaft using starter motor to
reposition camshaft. Repeat Step 5.
TX,04,DY2915 1921AUG972/2
UN02JUN97
3. Connect a drain line to filter drain adapter and drain all
fuel from filter into a container. Dispose of waste
properly.
T109306
4. Firmly grasp the retaining ring and rotate it
counterclockwise 1/4 turn. Remove ring with filter
element (B).
TX,04,DY2916 1921AUG972/2
UN02JUN97
3. Connect a drain line to filter drain adapter and drain all
fuel from filter into a container. Dispose of waste
properly.
T109305
4. Firmly grasp the retaining ring and rotate it
counterclockwise 1/4 turn. Remove ring with filter
element (B).
TX,04,DY2920 1921AUG972/2
UN13FEB90
2. Remove cap screws (C) to remove pump.
T6439SQ
TX,04,DY2888 1920AUG971/2
UN20OCT88
Apply thread lock and sealer (medium strength) to
gasket (1). Also, apply to cap screw threads and fuel
line fittings threads.
T6065AM
4. Install a new gasket (1) and packing (2). Install the fuel
transfer pump.
TX,04,DY2888 1920AUG972/2
UN05AUG97
cylinder head must be removed to remove push
rod.
T110118
entering the engine.
04
4. Inspect face of pump lever for wear. If lever face is 0400
worn, flat, or concave, replace pump. 41
Specification
Fuel Transfer Pump Cap Screw
Torque ............................................................................. 30 Nm (22 lb-ft)
TX,04,DT5074 1903JUL971/1
UN01NOV88
3. Operate primer lever (B) until only fuel, no air, flows
out of bleed screw. Tighten screw.
T6201AO2
engine and turn crankshaft using starting motor to
reposition camshaft.
04
0400
42
TX,04,DY2889 1920AUG971/1
UN02JUN97
fuel fills separator bowl and fuel escapes from water
separator bleed screw.
T109314
4. Pump primary fuel filter/water separator primer (B) until
fuel escapes from final fuel filter bleed screw.
UN02JUN97
T109315
TX,04,DY2922 1921AUG971/1
UN23AUG88
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure
TS281
before removing completely.
04
0400
43
TX,04,DY2890 1920AUG971/8
UN13JAN92
T7681AO
04
0400
44
UN15NOV90
T7405BG
TX,04,DY2890 1920AUG973/8
UN14DEC88
RG4797
UN25OCT88
8. Remove cap screws (A), nut, and lock washer (C) to
remove water pump and gasket.
T5820BX
necessary.
04
0400
45
TX,04,DY2890 1920AUG975/8
UN14DEC88
RG4797
Continued on next page TX,04,DY2890 1920AUG976/8
04
0400
46
UN15NOV90
T7405BG
TX,04,DY2890 1920AUG977/8
14. Install upper and lower fan guards (B and D) and cap
screws (A).
UN13JAN92
T7681AO
TX,04,DY2890 1920AUG978/8
UN23AUG88
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure
TS281
before removing completely.
04
0400
47
TX,04,DT5075 1903JUL971/10
UN05AUG97
7. Remove fan shroud (C).
T110120
ACap Screw (8 used)
BCap Screw (8 used)
CFan Shroud
DFan Guard
EUpper Radiator Hose
FLower radiator Hose
GFan Hub
HFan
UN02JUN97
T109285
04
0400
48
TX,04,DT5075 1903JUL973/10
UN05AUG97
T110135
TX,04,DT5075 1903JUL974/10
UN05AUG97
T110123
TX,04,DT5075 1903JUL976/10
15. Install pulley (A) onto water pump (B). Tighten cap
screws to 16 Nm (12 lb-ft). 04
0400
Specification 49
Water Pump Pulley Cap
ScrewsTorque .............................................................. 16 Nm (12 lb-ft)
UN05AUG97
16. Clean gasket surface.
T110139
TX,04,DT5075 1903JUL977/10
Specification
Water Pump Cap Screws
Torque ............................................................................. 16 Nm (12 lb-ft)
UN05AUG97
19. Install thermostat housing-to-water pump tube.
20. Install water pump inlet elbow (C) using new O-ring.
T110140
21. Tighten cap screws (D) to 35 Nm (26 lb-ft).
Specification
Water Pump Inlet Elbow Cap
ScrewsTorque .............................................................. 35 Nm (26 lb-ft)
22. Place 15 mm, 1/2 in. drive socket on cap screw (A).
Turn ratchet counterclockwise to pull tension adjuster
assembly (B) away while installing belt.
UN02JUN97
T109285
04
0400
50
TX,04,DT5075 1903JUL979/10
25. Install fan hub (G) and fan (H). Tighten cap screws to
70 Nm (52 lb-ft).
Specification
Turbocharger (Serial No.
559602Turbocharger Cap
ScrewsTorque .............................................................. 70 Nm (52 lb-ft)
UN05AUG97
26. Install fan shroud (C). Install cap screws (B). Tighten
cap screws to 40.5 Nm (30 lb-ft).
27. Install fan guard (D). Install cap screws (A). Tighten
T110120
cap screws to 16.2 Nm (12 lb-ft).
TX,04,DT5075 1903JUL9710/10
UN23AUG88
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure
TS281
before removing completely.
04
0400
51
UN23FEB92
Specification
82 C (180 F) Thermostat
Begin OpeningTemperature........................... 7983 C (175182 F)
T7681FW
82 C (180 F) ThermostatFull
OpenTemperature ............................................................ 94 C (202 F)
Specification
Cover Cap ScrewTorque ............................................. 27 Nm (20 lb-ft)
8. Connect hoses.
UN18OCT88
T6439TB
TX,04,DY2891 1920AUG972/2
UN23AUG88
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure
TS281
before removing completely.
04
0400
54
UN05AUG97
T110151
AThermostat Cover-to-Water BThermostat DCover FSeal
Pump Tube CGasket ECap Screw (2 used)
3. Remove thermostat cover-to-water pump tube (A) 6. Remove and discard gasket (C).
and seal (F).
7. Replace as necessary.
4. Remove cap screws (E). Remove cover (D).
8. Clean gasket mating surfaces.
5. Remove thermostat (B).
TX,04,DT5076 1903JUL972/5
Specification
Thermostat Cover Cap Screws
Torque ............................................................................. 70 Nm (52 lb-ft)
UN05AUG97
T110149
TX,04,DT5076 1903JUL974/5
UN05AUG97
T110148
TX,04,DT5076 1903JUL975/5
UN29JAN92
3. Remove cap screws (B).
AGasket
6. Install intake manifold.
BCap Screw (2 used)
CClamp (2 used)
7. Install and tighten cap screw (B). DCold Weather Start Aid Line
TX,04,DY2892 1920AUG971/1
UN05AUG97
5. Install new gasket (D).
T110157
04 7. Install cap screws (A).
0400
56 8. Tighten clamps (C) until hose starts to deform around ACap Screw (2 used)
clamp. BStart Aid Line
CClamp (2 used)
DGasket
9. Install start aid line (B).
TX,04,DT5077 1903JUL971/1
04
0400
57
UN01JAN94
TP41202
1. Remove turbocharger. (See procedure in this 3. Remove all residue and gasket material from
group.) surfaces.
2. Remove cap screws (6) and washers (5) to remove 4. Thoroughly clean passages in exhaust manifold,
exhaust manifold (4). elbow, and pipe.
04
0400
58
04
0400
59
UN05AUG97
T110158
6. Inspect exhaust manifold for cracks or damage.
CAUTION: Allow exhaust system to cool
Inspect mounting surfaces for burrs or other defects
before removal.
that might prevent gaskets from sealing properly.
Replaces parts as necessary.
1. Remove turbocharger. (See procedure in this
group.)
7. Install gaskets (B).
NOTE: Use guide studs when removing and installing
8. Install manifold (A).
exhaust manifold.
NOTE: Tighten cap screws on No. 3 and No. 4
2. Remove twelve cap screws (C). Remove exhaust
cylinders first.
manifold (A).
9. Apply NEVER-SEEZlubricant to twelve cap screws
3. Remove six gaskets (B).
(C). Tighten cap screws to 70 Nm (52 lb-ft).
4. Inspect exhaust manifold and stainless steel Specification
gaskets. Exhaust Manifold-to-Engine
Mounting Cap ScrewTorque ................................. 70 Nm (52 lb-ft)
5. Thoroughly clean passages in exhaust manifold.
TX,04,DT5078 1903JUL972/2
04
0400
60
UN23FEB92
Thoroughly clean exterior of turbocharger and surrounding
area to prevent entry of dirt into the air intake system
during removal.
T7681FX
1. Remove air intake hose (F) and exhaust adapter (D).
2. Loosen clamps to remove air inlet hose (A). AAir Inlet Hose
BTurbocharger-to-Exhaust Manifold Cap Screw
3. Disconnect lines (C and E). (4 used)
COil Return Line 04
DExhaust Adapter 0400
4. Remove cap screws and nuts (B) and remove EOil Inlet Line 61
turbocharger and gasket. FAir Cleaner-to-Turbocharger Hose
Specification
Turbocharger (
559602)Turbocharger-to-Manifold
Cap ScrewTorque ........................................................ 47 Nm (35 lb-ft)
TX,04,DY2894 1920AUG972/2
04
0400
62
UN05AUG97
1. Loosen clamp (D). Remove air intake hose (E).
T110159
3. Loosen clamp (F) from intake manifold tube (G).
04
0400
4. Remove cap screws (I) from oil return line (H).
ACap Screw (4 used) 63
BClamp
5. Disconnect line (C). COil Inlet Line
DClamp
6. Remove cap screws (A). Remove turbocharger and EAir Intake Hose
gasket. FClamp
GIntake Manifold Tube
HOil Return Line
7. Cap and plug all openings. ICap Screws (2 used)
Specification
Turbocharger (
559603)Turbocharger-to-Manifold
Cap ScrewTorque ........................................................ 70 Nm (52 lb-ft)
TX,04,DT5079 1903JUL971/1
UN23AUG88
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure
TS281
before removing completely.
04
0400
64
TX,04,DY2895 1920AUG971/2
UN13FEB90
5. Clean gasket material from cylinder block, filter base,
and oil cooler housing.
T6439SR
in engine block.
TX,04,DY2895 1920AUG972/2
UN23AUG88
Shut off engine. Only remove filler cap when
cool enough to touch with hands. Slowly loosen
cap.
TS281
1. Remove oil cooler drain plug (I) and drain coolant.
UN05AUG97
11. Install gasket (K) on housing (J) aligning cap screw
holes.
T110208
12. Install housing (J).
13. Install gaskets (D and F) aligning cap screw holes. AOil Filter
BOil Filter Outlet-to-Turbocharger Inlet Port
14. Apply thread lock and sealer (medium strength) to Line
threads of cap screws (H and L). COil Filter Base
DGasket
EOil Cooler
15. Install elbow adapter (G) and cap screws (H). Tighten FGasket
cap screws to 35 Nm (26 lb-ft). GElbow Adapter
HCap Screw (5 used)
IPlug
JHousing
KGasket
LCap Screw (7 used)
KGasket
Specification
Water Pump Inlet Elbow Cap
ScrewsTorque .............................................................. 35 Nm (26 lb-ft)
TX,04,DT5080 1903JUL972/2
ESSENTIAL TOOLS
JDE81-1 Flywheel Turning Tool
JDE81-4 Timing Pin
OTHER MATERIAL
AT66866 U.S. Solvent
UN08MAY91
both pushrods are loose, the piston is at TDC on the
compression stroke.
T7527BD
04
0400
67
TX,04,DY2917 1921AUG972/3
UN13MAR89
is hot or cold.
T6119AI
8. Install rocker arm cover gasket. Do not use sealant on
the gasket.
Specification
Rocker Arm Cap ScrewTorque ............................... 10.8 Nm (96 lb-in.)
TX,04,DY2917 1921AUG973/3
ESSENTIAL TOOLS
JDG820 Flywheel Turning Tool
JDE81-4 Timing Pin
OTHER MATERIAL
AT66866 U.S. Solvent
04
0400
CAUTION: Prevent accidental starting of engine
68
while performing valve adjustments. Always
disconnect NEGATIVE () battery terminal.
UN02JUN97
Rocker arms that exhibit excessive
valve clearance should be inspected
more thoroughly to identify damaged
parts.
T109309
2. Remove cap from holes (A and B). Install JDG820
Flywheel Turning Tool in hole (A).Install JDE-814
Timing Pin in hole (B).
Specification
Exhaust Valves (E)Clearance ................................. 0.45 mm (0.018 in.)
Intake Valves (I)Clearance ..................................... 0.35 mm (0.014 in.)
TX,85,DY5045 1922MAY972/4
UN18MAY94
remaining intake and exhaust valves (B).
T6872AG
10. Install rocker arm cover gasket. Do not use sealant
on the gasket.
ANo. 1 TDC Compression Stroke
11. Install rocker arm cover. Tighten screws to 10.8 Nm BNo. 6 Compression Stroke
CFan End of Engine
(96 lb-in.). Do not over tighten cap screws.
04
0400
70 Specification
Rocker Arm Cap ScrewTorque ............................... 10.8 Nm (96 lb-in.)
TX,85,DY5045 1922MAY974/4
UN23FEB92
3. Disconnect negative cable (A) and positive cable (B).
T7681FY
5. Inspect parts. Replace as necessary.
ANegative () Battery Cable
6. Install starter cap screws.
BPositive (+) Battery Cable
CBlack Wiring Lead
7. Connect wiring leads (CE). DRed Wiring Lead 04
ERed Wiring Lead 0400
8. Connect positive and negative cables at starter. FNegative Ground Strap 71
GCap Screw (3 used)
Tighten nuts to 30.5 Nm (270 lb-in.).
Specification
Starter Cable NutTorque........................................ 30.5 Nm (270 lb-in.)
Specification
Ground Cable Nut at Battery
Torque ........................................................................... 9.0 Nm (82 lb-in.)
TX,04,DY2897 1920AUG971/1
UN05AUG97
5. Disconnect positive cable (A).
T110224
04 CAUTION: The approximate weight of starting
0400
motor is 23 kg (50 lb).
72 APositive (+) Battery Cable
BWiring Lead (E01 WHT)
7. Remove cap screws (D). Remove starting motor. CWiring Lead (E01 WHT)
DCap Screw (3 used)
8. Make repairs as necessary. (See procedure in EWiring Lead (G02 BLK)
CTM77.) FGround StrapBraided
GWiring Lead (G03 BLK)
HWiring Lead (G04 BLK)
9. Install starting motor. INegative () Battery Cable
TX,04,DT5081 1903JUL971/1
Page Page
05
T43513 (U.S.) Thread Lock and Sealer (High Apply to threads of nozzle holder.
TY9474 (Canadian) Strength) Products
271 (LOCTITE)
Specifications
05
0505
1
08T,0505,J1 1907NOV941/1
UN21OCT88
When a can is not installed, turn canister so closed end is
05 installed tight against valve in solenoid.
0505
2
ANozzle Holder
T6422AE
BNozzle
CStarting Aid Tube
DWire Harness
ECap Screws
FCanister
08T,0505,J2 1913MAR921/1
UN21OCT88
immersed in coolant. Sheath could burst and
result in personal injury.
T6427AO
Use a heavy-duty grounded cord to connect
coolant heater to electrical power.
7. Tighten adapter.
05
0505
8. Turn element clockwise, then counterclockwise, until 3
element contacts casting. Move element to the center
position.
Specification
Engine Coolant Heater Element
NutTorque .................................................................... 34 Nm (25 lb-ft)
TX,0505,BA169 1925SEP912/2
05
0505
4
05
0510
1
TX,05,DY2923 1925AUG971/1
UN23AUG88
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure
TS281
before removing completely.
UN13JAN92
T7681AO
TX,05,DY2924 1925AUG971/5
UN13JAN92
lb-ft).
Specification
Fan-to-Pulley Cap Screw
T7681AP
(559603)Torque ........................................................ 40 Nm (30 lb-ft)
TX,05,DY2924 1925AUG973/5
Specification
Fan-to-Pulley Cap Screw (
559602)Torque............................................................. 47 Nm (35 lb-ft)
UN14DEC88
9. Adjust shroud so fan is centered in shroud with 05
approximately 7 mm (0.27 in.) clearance between fan 0510
blades and shroud. 3
RG4797
Specification
Fan-to-ShroudClearance................................................ 7 mm (0.27 in.)
10. Install fan guards (B and D). Tighten cap screws (A)
to 16.2 Nm (141.6 lb-in.).
Specification
Fan Guard-to-Shroud Cap
ScrewTorque ....................................................... 16.2 Nm (141.6 lb-in.)
UN13JAN92
05
0510
4
T7681AO
TX,05,DY2924 1925AUG975/5
UN23AUG88
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure TS281
before removing completely.
UN05AUG97
7. Remove fan shroud (C).
T110120
9. Install fan shroud (C). Move fan shroud toward engine.
ACap Screw (8 used)
10. Install fan hub (G) and fan (H). Tighten cap screws to BCap Screw (8 used)
70 Nm (52 lb-ft). CFan Shroud
DFan Guard
Specification EUpper Radiator Hose 05
Fan-to-Pulley Cap Screw ( FLower radiator Hose 0510
5596020)Torque........................................................... 70 Nm (52 lb-ft) GFan Hub 5
HFan
11. Install fan shroud (C). Install cap screws (B). Tighten
cap screws to 40 Nm (30 lb-ft).
Specification
Shroud-to-Radiator Support Cap
ScrewTorque ................................................................ 40 Nm (30 lb-ft)
12. Install fan guard (D). Install cap screws (A). Tighten
cap screws to 16.2 Nm (141.6 lb-in.).
Specification
Fan Guard-to-Shroud Cap
ScrewTorque ....................................................... 16.2 Nm (141.6 lb-in.)
TX,05,DT5069 1925JUN972/2
UN23AUG88
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.
TS281
1. Drain coolant from radiator. On machines (Serial
No. 559602) approximate capacity is 29 L (31 qt).
On machines (Serial No. 559603) approximate
capacity is 41.5 L (11 gal)
05
0510
6
05
0510
7
05
0510
8
UN05AUG97
T110255
1Cap Screw (2 used) 9Hose (Serial No. 15Washer (7 used) 23Drain Valve
2Washer (2 used) 559602) 16Isolator 24Isolator
3Isolator 10Filler Cap 17Support 25Angle
4Shim (4 used) 11Clamp 18Support 26Washer (10 used)
5Support 12Hose (Serial No. 19Cap Screw 27Hose (Serial No. 559603)
6Isolator 559602) 20Cap Screw 28Clamp (Serial No.
7Radiator 13Cap Screw (10 used) 21Isolator 559603)
8Clamp (3 used) 14Lock Nut 22Cap Screw (4 used) 29Hose (Serial No. 559603)
TX,05,DY2925 1925AUG973/3
TX,05,DY2899 1920AUG971/2
TX,05,DY2899 1920AUG972/2
TX,55,DT5037 1909JUN971/2
UN02JUN97
6. Remove ratchet from assembly.
T109285
TX,55,DT5037 1909JUN972/2
TX,0515,AB297 1917FEB921/1
05
0515
1
05
0515
2
UN13JAN92
T7681BA
Leave 510 mm (1/81/4 in.) of threads exposed on Adjust speed control linkage. (See procedure in this
cap screw (8). group.)
TX,0515,AB157 1917FEB922/2
05
Adjust Engine Speed Control Linkage 0515
3
SPECIFICATIONS
System ControllerEngine Rpm 820880 rpm
Correct Indicator ON Low Idle
Range
System ControllerEngine Rpm 21752225 rpm
Correct Indicator ON High Idle
Stop Screw (G) Range
Indicator BlinkingEngine RPM 0800 rpm
Low RPM
Indicator on SteadilyEngine 800820 rpm
RPM Low RPM
Indicator BlinkingEngine RPM 900 rpm or greater
High RPM
Indicator on SteadilyEngine 880900 rpm
RPM High RPM
System ControllerEngine RPM 22502300 rpm
Correct and Engine RPM High
indicators Blinking Together High
Idle Range
1928FEB95
05
0515
4
T8419AB
1929JUL91
T7577AD
Specification
System ControllerEngine
RPM Correct and Engine
RPM High indicators Blinking
TogetherHigh Idle Range ...................................... 22502300 rpm
TX,05,DY2926 1925AUG974/4
53T,JDG51 1912FEB902/3
05
Used for intake manifold pressure test. 0520
1
53T,JDG51 1912FEB903/3
TX,0520,CC1 1907JUL872/2
Specifications
Air Cleaner
Air Intake System Test Air Pressure 1421 kPa (0.140.21 bar) (23
psi)
TX,0520,AB505 1917FEB921/1
05
0520
2
05
0520
UN10JAN92
3
T7681AB
1U-Bolt (2 used) 4Hose 7Cap Screw (2 used) 10Clamp (3 used)
2Air Cleaner 5Hose 8Washer (8 used) 11Clamp
3Hose 6Washer (2 used) 9Lock Nut (8 used) 12Unloader Valve
Before tightening, be sure air cleaner inlet tube is not keep air cleaner from rotating or rattling after
contacting left side baffle. assembly.
Install first lock nut (9), nylon insert end first, so the Install air cleaner so unloader valve is at the 6 oclock
distance measured from the inside center of radius to position.
baffle is 307 mm (12.08 in.).
Tighten clamps (10) until hoses (3 and 5) deforms
Air CleanerSpecification around clamp band.
Inside Center of Radius of
U-Bolt to BaffleDistance .................................... 307 mm (12.08 in.)
TX,0520,AB158 1917FEB921/1
SPECIFICATIONS
Air Intake System Test Air 1421 kPa (0.140.21 bar) (2
Pressure 3 psi)
UN23FEB89
ESSENTIAL TOOLS
JDG51 Inlet Air Adapter
T5906AP
Air Pressure Regulator 1/4 in. Plastic Hose
0520,CC4 1925SEP911/2
05
0520 3. Remove fitting for start aid nozzle from intake manifold
4 and install JDG-51 Inlet Air Adapter (A).
UN25OCT88
IMPORTANT: DO NOT start unit when turning
crankshaft slightly to close intake
valves; plastic bag could be sucked into
engine.
T6089AR
5. Pressurize air intake system to 1421 kPa (0.14
0.21 bar) (23 psi).
Air CleanerSpecification
Air Intake System TestAir
Pressure ....................................................... 1421 kPa (0.140.21 bar)
(23 psi)
0520,CC4 1925SEP912/2
UN01JAN94
05
0530
1
TP31701
1Inlet Tube 5Clamp 9Cap Screw 13Washer (2 used)
2Clamp 6Nut (2 used) 10Washer 14Washer (4 used)
3Muffler 7Cap Screw 11Support 15Lock Nut (4 used)
4Hook Bolt (2 used) 8Washer 12Cap Screw (2 used)
TX,0530,AB159 1912APR951/1
05
0530
2
Fuel Tank
TX,0560,AB293 1912APR951/1
Other Material
T43512 (U.S.) Thread Lock and Sealer (Medium Used to apply to sender and
TY9473 (Canadian) Strength) Products gasket-to-tank screw.
242 (LOCTITE)
05
0560
TY6304 (U.S.) Flexible Sealant Used to apply tank filter and drain 1
TY9484 (Canadian) valve.
515 (LOCTITE)
05
0560
2
UN09JAN92
T7681AH
05
0560
3
UN05AUG97
T110268
NOTE: Fuel tank must be drained before removing Apply thread lock and sealer (medium strength) to
hydraulic reservoir. Reservoir wall provides threads of screw (19). Install ground eyelet under
fuel tank support. screw head at the 5 oclock position. Tighten screw to
4.5 Nm (40 lb-in.).
Drain fuel from tank. On machines (Serial No.
542359) approximate capacity is 322 L (85 gal). On Fuel TankSpecification
machines (Serial No. 542360) approximate capacity Sender and Gasket-to-Tank
ScrewTorque ....................................................... 4.5 Nm (40 lb-in.)
is 303 L (80 gal).
Apply flexible sealant to that part of filter (9) on
Remove hydraulic reservoir. (See procedure in Group
machines (Serial No. 542359) and drain valve (8)
3360.)
that is held in the tank by the hose clamps (4).
Tighten cap screws (15) to 8.5 Nm (75 lb-in.).
Fill fuel tank with proper fuel. (See Fuel Specifications
Fuel TankSpecification in Group 0004.)
Clamp-to-Fuel Tank Cap
ScrewTorque ....................................................... 8.5 Nm (75 lb-in.)
TX,05,DY2928 1925AUG973/3
05
0560
Remove And Install Water Separator (Serial
4 No. 559602)
UN09JAN92
AWater Separator-to-Fuel Transfer Pump Line
BFuel Tank-to-Water Separator Line
CCap Screw (2 used)
DDrain Line
T7626DA
TX,05,DY2929 1925AUG971/1
UN05AUG97
waste properly.
T110271
4. Remove cap screws (D). Remove fuel filter.
TX,05,DT5070 1926JUN971/1
UN18OCT88
(E). Open plug and drain fuel from filter into container.
Dispose of waste properly. Close plunger.
T6105BG1
from filter assembly (C).
TX,05,DY2930 1925AUG971/1
UN22OCT92
ELocking Ring
05 FFilter Element
0560 GFilter
6 HBleed Screw
IPacking
T7751HR
JPlug (2 used)
KDiaphragm
LSpring Seat
MSpring
NSpring Cover
OPump Knob
PLocking Ring
UN22OCT92
T7751HS
TX,05,DY5182 1931MAR971/1
Page
Group 0752Elements
Specifications . . . . . . . . . . . . . . . . . . . . . . . .07-0752-1
Dampener Drive (Flex Coupler) (SN -559602)
Remove and Install . . . . . . . . . . . . . . . . . .07-0752-2
Dampener Drive (Flex Coupler) (SN 559603-)
Remove and Install . . . . . . . . . . . . . . . . . .07-0752-4
07
07
Dampener Drive
TX,07,DY2931 1925AUG971/1
07
0752
1
Remove And Install Dampener Drive (Flex Coupler) (Serial No. 559602)
UN14JAN92
T6439TC
(Serial No. 559602)
07
0752 ADrive Flange CSet Screw (2 used) EHub GArm (4 used)
2 BDrive Element DCover FSocket Head Screw (4
used)
TX,07,DY2932 1925AUG972/2
07
0752
3
Remove And Install Dampener Drive (Flex Coupler) (Serial No. 559603)
UN12AUG97
T110274
07
0752
4 (Serial No. 559603)
1. Remove hydraulic pump. (See procedure in Group 7. Install drive flange (F).
3360.)
8. Install cover (E).
2. Remove retaining clip (H) and set screws (D).
Remove hub assembly from hydraulic pump shaft. 9. Install drive element (G).
3. Remove cap screws (B). Remove arms (A) from 10. Install arms (A) and cap screws (B) on hub (C).
hub (C).
11. Install hub assembly on hydraulic pump shaft 3
4. Remove drive element (G). 1 mm (0.12 0.04 in.) from pump.
NOTE: If original hub is installed, the set screws have Hub Set Screw (C)Torque .................................. 120 Nm (90 lb-ft)
distorted the center spline, making for a tight fit Drive Flange-to-Flywheel Cap
ScrewTorque ......................................................... 50 Nm (35 lb-ft)
on pump shaft. Pump Mount Cover-to-Flywheel
Housing Cap ScrewTorque ................................... 75 Nm (55 lb-ft)
12. Install drive hub assembly with end of hub even
with arms away from pump. Push drive hub on 13. Install set screws (D) and retaining clip (H).
pump shaft 3 1 mm (0.12 0.04 in.) from pump
housing. 14. Install cover, spacers, lower baffle, and cap
screws.
Specification
Drive Hub-to-Pump Housing
Clearance................................................... 3 1 mm (0.12 0.04 in.) 15. Install hydraulic pump.
Specification
Arm-to-Hub Socket Head
Screw (F)Torque ............................................... 220 Nm (160 lb-ft)
TX,07,DT5082 1903JUL972/2
07
0752
5
07
0752
6
Page Page
Group 1671Batteries, Support, And Cables Radio, Propel Alarm Cancel, and Start Aid
Service Equipment And Tools . . . . . . . . . . . .16-1671-1 Switches
Specifications . . . . . . . . . . . . . . . . . . . . . . . .16-1671-2 Remove and Install . . . . . . . . . . . . . . . . . .16-1674-8
Handle Batteries Safely. . . . . . . . . . . . . . . . .16-1671-3 Monitor Buzzer and Air Conditioner Switch
Procedure For Testing Batteries . . . . . . . . . .16-1671-4 Remove and Install . . . . . . . . . . . . . . . . .16-1674-10
Check Battery Electrolyte Specific Gravity. . .16-1671-5 DEUTSCH Connectors
Check Battery Electrolyte Level And Replace . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-10
Terminals. . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-6 DEUTSCH Contact
Booster Batteries Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-12
24-Volt System . . . . . . . . . . . . . . . . . . . . .16-1671-8 WEATHER PACK Connector
Batteries Replace . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-13
Charge. . . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-10 WEATHER PACK Contact
Remove and Install . . . . . . . . . . . . . . . . .16-1671-11 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1674-14
Adding 12-Volt Accessories. . . . . . . . . . . . .16-1671-12 Remove Connector Body From Blade
Terminals. . . . . . . . . . . . . . . . . . . . . . . . .16-1674-15
16
TX,1671,DU175 1911JUL922/4
TX,1671,DU175 1911JUL923/4
Specifications
TX,1671,AB41 1912APR951/1
16
1671
2
UN23AUG88
ventilated area.
TS204
Battery acid is harmful on contact with skin or fabrics. If
acid spills, follow these first aid tips:
3. If acid comes into contact with the eyes, flood the eyes
with running water for 15 to 30 minutes. See a doctor
at once. Never use any medication or eye drops unless
prescribed by the doctor.
5. Acid from the batteries can also damage the paint and
metal surfaces of the machine. Avoid over filling the
battery cells.
16
1671
3
TX,1671,DV1300 1929MAR931/1
16
1671
TX,901500,RP313 1918JUL941/1
4
UN23AUG88
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
TS204
Always remove grounded (-) battery clamp first
and replace it last.
UN23AUG88
5
If acid is swallowed:
TS203
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do
not exceed 1.9 L (2 quarts).
3. Get medical attention immediately.
TX,1671,J7 1921SEP942/2
16
1671
6
UN23AUG88
TS203
TX,FF,141 1929MAY913/4
ABattery Post
BFill Tube
CElectrolyte Level Range
UN09SEP03
T6996DB
Single Level Fill Tube Application
UN09SEP03
T6996DA
16 Dual Level Fill Tube Application
1671
TX,FF,141 1929MAY914/4
8
UN23AUG88
hydrometer.
TS204
IMPORTANT: Machine electrical system is 24-volt
negative (-) ground. Use only 24-volt
booster batteries.
UN21MAY90
Rock the clamps to make sure they make good
contact.
T7233JN
cable that connects booster batteries to machine
batteries. Two Battery Application
16
1671
TX,1671,GG110 1925SEP912/3
9
TX,1671,GG110 1925SEP913/3
Charge Battery
UN23AUG88
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
TS204
Always remove grounded (-) battery clamp first
and replace it last.
TX,1671,DV2638 1910MAY941/1
UN16DEC91
3. Disconnect positive cables (B and D).
T7626CJ
5. Remove batteries.
7. Install batteries.
Specification
BatteryBCI Group................................................................................ 31
Cold Cranking Amps18C (0F) ............................................. 625 amps
Reserve Capacity, Minutes at 25
Amps and 27C (80F) ........................................................... 160 minutes
Voltage............................................................................................ 12 volts 16
BCI Group .............................................................................................. 4D 1671
Cold Cranking Amps 18C (0F) .............................................. 1000 amps 11
Reserve Capacity, Minutes at 25
Amps and 27C (80F) ........................................................... 320 minutes
Voltage............................................................................................ 12 volts
Specification
Cable Clamp NutsTorque ............................................. 9 Nm (82 lb-in.)
TX,1671,AB42 1912APR952/2
UN18OCT88
John Deere dealer.
T6520AJ1
Specification
SystemVoltage ............................................................................ 24 volts
TX,1671,AB301 1913JAN921/1
UN17JAN89
TS225
TX,1672,DV2829 1930JUN941/1
Specifications
Alternator
TX,16,DY2933 1925AUG971/1
4. Remove cap screw and nut (B) and cap screw and
washer (A).
UN16DEC91
6. Tighten pulley-to-shaft nut to 61 Nm (45 lb-ft).
Specification
T7626CE
Pulley-To-Shaft Nut (541822)
Torque ............................................................................. 61 Nm (45 lb-ft)
UN16DEC91
2 9. Tighten cap screw (A) and cap screw and nut (B).
T7626CF
ACap Screw and Washer
BCap Screw and Lock Nut
CSquare Hole
D1B Red Wiring Lead
EBlack Wiring Lead
F1E Red Wiring Lead
GPurple Wiring Lead
TX,1672,AB44 1912APR951/1
UN15NOV90
CTM77.)
T7405BG
7. Install cap screw and lock washer (H) and wiring lead
(G).
Specification
Housing-to-Bracket Cap Screw 16
(541823559602)Torque ......................................... 27 Nm (239 lb-in.)
UN31MAR95
1672
Housing-to-Bracket Cap Screw 3
and Nut (541823559602)
Torque ............................................................................ 47 Nm (35 lb-ft.)
T8449AA
9. Connect wiring leads (DF). Tighten power terminal
nut to 25 Nm (221 lb-in.).
Components Removed For Clarity
Specification
Power Terminal Nut (541823 ASquare Hole
559602)Torque.......................................................... 25 Nm (221 lb-in.) BTension Adjuster Assembly
CCap Screw and Nut
DPurple Wiring Lead (M01)
Tighten excitation terminal nut to 2 Nm (18 lb-in.).
ERed Wiring Leads (B03, B03A)
FRed Wiring Lead (B03A)
Specification GBlack Wiring Lead (G02)
Excitation Terminal Nut
HCap Screw and Lock Washer
(541823559602)Torque ............................................. 2 Nm (18 lb-in.)
TX,16,DY2903 1920AUG972/2
TX,16,DT5071 1927JUN971/4
UN02JUN97
T109285
UN05AUG97
6. Remove nut and cap screw (D). Remove alternator.
T110289
77.)
Components Removed For Clarity
8. Install alternator. Install nut and cap screw (D). Tighten
to 43 Nm (32 lb-ft). ACap Screw
BAdjuster Assembly
Specification CRed Wiring Lead (B03)
Housing-to-Bracket Cap Screw DNut and Cap Screw
and Nut (559603)Torque .......................................... 43 Nm (32 lb-ft) ECap Screw and Lockwasher
FBlack Wiring Lead (G02)
GElectrical Connector
9. Install wiring lead (F). Install cap screw and lockwasher
(A). Tighten to 22 Nm (195 lb-in.).
Specification
Bracket Cap Screw (559603)
Torque .......................................................................... 22 Nm (195 lb-in.)
16
1672
TX,16,DT5071 1927JUN973/4
5
12. Place 15 mm, 1/2 in. drive socket on cap screw (A).
Turn ratchet counterclockwise to pull tension adjuster
assembly (B) away. Install belt. Slowly turn ratchet
clockwise to place tension adjuster assembly against
belt. Tension is automatically adjusted. UN02JUN97
T109285
TX,16,DT5071 1927JUN974/4
16
1672
6
UN17APR89
wider section is on top when lamp is
installed.
T5894AG1
lens are installed with respect to mounting stud.
TX,16,DT5083 1903JUL971/4
UN05AUG97
T110292
16
1673
TX,16,DT5083 1903JUL972/4
1
UN05AUG97
T110293
UN05AUG97
5. Remove retaining clip (A). Remove bulb (B).
6. Replace as necessary.
T110294
7. Install bulb. Install retaining clip.
TX,16,DT5083 1903JUL974/4
UN05AUG97
Vibrations will pass through isolators,
causing premature failure of halogen
bulbs.
T110295
2. Tighten cap screw just enough to keep work light from
moving.
T52,1673,C12 1918FEB861/1
Replacing Fuses
UN06SEP90
Remove fuse box cover (D) by lifting upward. Spare fuses
(E) are located on underside of cover.
T7356AE1
AFuse Box
BDecal
CHeater Control Panel
DFuse Box Cover
ESpare Fuses
UN06SEP90
T7356AF1
TX,901505,RP328 1924MAY911/1
16
1673
3
Fuse Specifications
UN06MAR92
F1120 Amp Work Lights
F125 Amp Wiper/Washer
F1320 Amp Blower and Air Cond. Clutch
F14Not Used
F1510 Amp Horn and Alternator
T7713AJ
F16Not Used
F1710 Amp Lighter
F185 Amp Cab Interior Light
F1910 Amp Circulation Fan
F2020 Amp Start Aid
F211 Amp Battery Relay Fuse (Located in-line with
battery relay)
16
1673
4
TX,901505,RP549 1929JUN931/1
04T,90,J22 1928SEP921/1
16
1673
5
16
1673
6
DX,TOOLS 1920JUL953/9
TS447 UN22JUN89
16
1674
DX,TOOLS 1920JUL954/9
1
DX,TOOLS 1920JUL955/9
DEUTSCH is a trademark of the Deutsch Co. Continued on next page DX,TOOLS 1920JUL956/9
DX,TOOLS 1920JUL957/9
DX,TOOLS 1920JUL958/9
16
1674
2
UN18APR95
T8451AA
16
ARight Drive Light (E3) HStart Aid Solenoid Diode OWindshield Washer Pump TPropel Pilot Pressure 1674
BHorn (B7) (V2) Motor (M4) Transducer (B17) 3
CFuel Gauge Sender (B2) IStart Aid Solenoid (Y3) PSwing Pilot Pressure ULeft Drive Light (E1)
DHydraulic Oil Temperature JVehicle Harness-to-Engine Switch (B6) VBoom Work Light (E2)
Switch (B16) Harness Connector (X2) QAuto Idle Pressure Switch WHydraulic Filter Restriction
EHydraulic Oil Level Switch KPropel Alarm (B15) (B14) Indicator Pressure Switch
(B11) LCoolant Level Switch (B10) RPower Boost Solenoid (Y7) (S27) (Serial No. 538551)
FSwing Brake Release MBatteries (G1 and G2) SPower Boost Solenoid
Solenoid (Y4) NAir Cleaner Restriction Diode (V4)
GPropel Speed Change Switch (B3)
Solenoid (Y8)
UN05AUG97
T110319
AAlternator Relay (K3) (2 DPower Boost Relay (K14) (2 HSwing Brake Delay Relay KStart Relay (K2) (2 WHT,
PUR, 2 BLK, RED Wire GRN, 4 RED Wire Leads) (K17) (2 GRN, 2 RED Wire BLK Wire Leads) (Serial
Leads) ESwing Brake Release Relay Leads) No. 549955)
BPropel Alarm Relay (K13) (K15) (3 GRN, 2 RED Wire IBattery Relay Fuse (F21) (2 LStart Relay (K2) (3 WHT,
(2 RED, 2 PUR, BLK Wire Leads) Tan Wire Leads) RED, BLK, Wire Leads)
Leads) FStart Relay Diode (V9) JBattery Relay (K1) (3 RED, (Serial No. 549956)
16 CPropel Speed Change (WHT, BLK Wire Leads) BLK, TAN Wire Leads)
1674 Relay (K12) (4 RED, GRN, GBattery Relay Diode (V3) (2
4 BLU Wire Leads) TAN, BLK Wire Leads)
TX,1674,AB342 1912APR952/2
UN23JAN92
T7681CB
APump Displacement ECoolant Gauge Sender (B1) IStarter Solenoid (Y1) MEngine-to-Battery Ground
Solenoid (Y6) FFuel Shutoff Solenoid (Y2) JStarter (M3) Cable (W1)
BEngine Speed Sensor (B13) GEngine Speed Actuator KEngine-to-Frame Ground NBattery-to-Engine Power
CAlternator Diode (V1) Solenoid (Y5) Connection (W2) Cable
DAlternator (G3) DELCO HEngine Overheat Switch LEngine Oil Level Switch OEngine Oil Pressure Switch
(Serial No. 541822) (B5) (B9) (B4)
BOSCH (Serial No.
541823)
16
1674
TX,1674,AB344 1912APR951/1
5
UN23JAN92
16
1674
6
T7681CD
1Power Boost Switch (S9) 12Blower Fan Switch (S6) 23Safety Relay (K5) (RED, 28Load Dump Relay (K6)
2Switch Panel 1 (N4) 13Monitor Buzzer (B8) YEL/GRN, YEL/WHT, BLK (BLU/WHT, TAN, 2 RED
3Monitor (N3) 14Fuse Box Wire Leads) Wire Leads)
4Cab to Frame Ground (W3) 15Key Switch Diode (V10) 24Standby Relay (K18) 29(Not Used)
(4 used) 16Blower Fan Motor (M1) (BLK/WHT, PUR, 30Windshield Wiper Relay
5Windshield Wiper Motor 17Dome Light (E4) BLU/ORG Wire Leads) (K11) (YEL/WHT, BLU/YEL,
(M2) 18System Controller (N1) 25Work Light Relay (K8) YEL, BLK, BLU Wire
6Propel Alarm Cancel 19System Controller (RED/WHT, 2 RED/GRN, Leads)
Switch (S25) Connector (X8) BRN Wire Leads) 31System Controller Ground
7Start Aid Switch (S4) 20System Controller 26Windshield Washer Relay Cable (W4)
8Key Switch (S3) Connector (X9) (K10) (BLU/YEL, YEL/BLK, 32Drive Light Relay (K9)
9Horn Switch (S5) 21Monitor Controller (N2) BLU Wire Leads) 33(Not Used)
10Switch Panel 2 (N5) 22Start Aid Relay (K4) 27Horn Relay (K7) (2
11Cigar Lighter (R1) (RED/BLU, BLK/ WHT, RED/WHT,BLK, PUR Wire
RED/BLK Wire Leads) Leads)
TX,1674,AB345 1912APR951/1
UN22JAN92
DCover
ENut
FWiring Harness Connector
GCover
T7681CW
16
1674
TX,1676,AB328 1920FEB921/2
7
ANut
BSpring Washer
CStart Switch
DConnector
TX,1676,AB328 1920FEB922/2
UN22JAN92
T7681DA
TX,1676,AB333 1920FEB922/4
AScrew (4 used)
BCover
CNut
DPropel Alarm Cancel Switch
UN22JAN92
ERadio
FScrew
GPanel
HStart Aid Switch
T7681DB
16
1674
Continued on next page TX,1676,AB333 1920FEB923/4
8
9. Install covers.
UN22JAN92
FAntenna Lead
GStart Aid Wiring Harness Connector
HPropel Alarm Cancel Wiring Harness Connector
T7681DC
16
1674
TX,1676,AB333 1920FEB924/4
9
UN22JAN92
3. Disconnect wiring harness connectors (EG).
T7681DE
5. Repair or replace parts as necessary.
UN22JAN92
EBuzzer Wiring Harness Connector
FA/C Wire Harness Connector
GA/C Wire Harness Connector
HBuzzer
INut
T7681DF
JAir Conditioning Dual Function Switch
16
1674
TX,1676,AB338 1920FEB921/1
10
DEUTSCH is a trademark of the Deutsch Co. Continued on next page DX,ECONN,J 1903NOV941/3
UN23AUG88
connector.
TS0124
5. Pull wire out of connector body, using extractor tool.
UN23AUG88
TS120
DX,ECONN,J 1903NOV942/3
UN23AUG88
7. Pull on wire slightly to be certain contact is locked in
place.
TS122
connector.
DX,ECONN,J 1903NOV943/3
UN23AUG88
3. Loosen lock nut (B) and turn adjusting screw (C) in
until it stops.
TS117
DEUTSCH is a trademark of the Deutsch Co. DX,ECONN,W 1904JUN901/4
UN23AUG88
5. Tighten lock nut (C).
TS0134
DX,ECONN,W 1904JUN902/4
UN23AUG88
7. Release handle and remove contact.
TS118
DX,ECONN,W 1904JUN903/4
DX,ECONN,W 1904JUN904/4
UN23AUG88
NOTE: If terminal cannot be removed, insert wire or nail
through extractor tool handle and push terminal
contact from connector.
TS0128
DX,ECONN,O 1903NOV942/3
UN23AUG88
4. Push contact into new connector body until fully
seated.
TS0130
5. Pull on wire slightly to be certain contact is locked in
place.
DX,ECONN,O 1903NOV943/3
UN23AUG88
Gray14 to 16 gauge wire
Blue10 to 12 gauge wire
TS0136
2. Strip insulation from wire to expose 6 mm (1/4 in.) and
align cable seal with edge of insulation.
UN02NOV94
3. Put proper size contact on wire and crimp in place with
a W type crimp, using JDG783 Terminal Applicator.
TS1623
Terminal Applicator.
16
1674
14
DX,ECONN,AA 1904JUN902/3
DX,ECONN,AA 1904JUN903/3
UN23AUG88
2. Be sure to bend locking tang back to its original
position (B) before installing connector body.
RW4218
DX,ECONN,V1 1902NOV941/1
16
1674
15
16
1674
16
UN05SEP91
system controller. Disconnect battery
ground cable and system controller
electrical connectors before welding on
the machine.
T7509AI
Before welding on the machine, follow the steps listed
below to protect the machine electrical system.
a. Inside the cab, remove four cap screws (C) and the
fuse box cover (D) to remove the rear console
cover.
UN10MAY93
DFuse Box Cover 1675
ESystem Controller Upper Connector 1
FSystem Controller Lower Connector
T8005AY
TX,1675,GG265 1912MAY931/1
UN17JAN92
6. Remove cap screws (B) and remove system controller
(A).
T7681CG
8. Push connectors into system controller while turning
cap screws (E).
ASystem Controller
Tighten cap screws until red torque indicator pin (D) BCap Screw (4 used)
extends outward indicating correct torque. CGround Strap
DRed Torque Indicator Pin (2 used)
ECap Screw (2 used)
9. Connect ground cable.
16
1675
2
TX,1675,AB319 1912APR951/1
UN17JAN92
T7681CH
TX,1675,DW618 1912APR951/1
16
1675
3
16
1675
4
UN22JAN92
3. Replace bulb (C).
T7681CU
TX,1676,AB326 1908JUN921/1
TX,1676,AB321 1920FEB921/4
16
1676
1
UN22JAN92
T7681CO
Continued on next page TX,1676,AB321 1920FEB922/4
UN22JAN92
T7681CP
TX,1676,AB321 1920FEB923/4
AScrew (5 used)
BWiring Harness Connector
CWiring Harness Connector
DWiring Harness Connector
ECap Screw (3 used)
UN22JAN92
T7681CR
TX,1676,AB321 1920FEB924/4
UN22JAN92
3. Remove screws and turn right hand control lever boot
and cover.
T7681CS
5. Remove screws holding bracket and housing (A).
TX,1676,DW620 1912APR951/1
16
1676
3
UN22JAN92
6. Repair or replace parts as required.
T7681CT
8. Install instrument panel and housing.
AFuel Gauge
BCoolant Temperature Gauge
CBlack Ground Wire Lead
DRed/Yellow Wire Lead
EBrown Wire Lead
FRed/Green Wire Lead
UN20FEB92
T7681FS
TX,1676,AB538 1911JUL922/2
1. Remove cover.
16
2. Pull on socket (B) to remove socket and bulb (C). 1676
5
UN22JAN92
3. Replace bulb and install socket in housing (A). Install
cover.
T7681CY
TX,1676,AB330 1908JUN921/1
UN22JAN92
DCover
EStarter Switch Nut
FWiring Harness Connector
GCover
T7681CW
16
1676
Continued on next page TX,1676,AB331 1908JUN921/2
6
ALamp Sockets
BSwitch Panel 2
CPanel
DWiring Harness Connector
EBracket
FClamp
UN22JAN92
T7681CZ
TX,1676,AB331 1908JUN922/2
16
1676
7
16
1676
8
Page
17
17
TX,1740,AB45 1906JAN921/1
17
1740
1
UN23AUG88
area. Dispose of paint and solvent properly.
TS220
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.
Specification
Weld MetalTensile Strength.............................. 482.6 mPa (70,000 psi)
Yield Strength ....................................................... 413.7 mPa (60,000 psi)
Elongation ............................................................................................ 22%
Specification
Structural AssembliesPreheat
Temperature .......................................................................... 38C (100F)
Specification
Ground Engaging ToolsPreheat
Temperature ........................................................................ 177C (350F)
Specification
Structural AssembliesPreheat
Temperature .......................................................................... 38C (100F)
Specification
Ground Engaging ToolsPreheat
Temperature ........................................................................ 177C (350F)
TX,1740,WW1219 1902JUN932/2
17
1740
3
17
1740
4
Spreader Bar
TX,1749,VV387 1912APR952/2
Specifications
Counterweight
TX,17,DY2934 1925AUG971/1
Other Material
T43512 (U.S.) Thread Lock and Sealer (Medium Used to apply to threads of
TY9473 (Canadian) Strength) Products counterweight cap screws.
242 (LOCTITE)
17
1749
2
CounterweightSpecification
StandardApproximate Weight .................................... 3768 kg (8,300 lb)
OptionalApproximate Weight ................................... 4627 kg (10,200 lb)
UN17SEP91
5. Connect counterweight to a hoist.
T7604AG
bushings (F). Remove counterweight.
TX,17,DW5011 1918JUL971/1
17
1749
4
Page Page
Group 1800Removal And Installation Air Conditioning Gauge Set (SN -541550)
Specifications . . . . . . . . . . . . . . . . . . . . . . . .18-1800-1 Installation Procedure . . . . . . . . . . . . . . .18-1830-10
Cab Refrigerant Recovery (SN -541550) . . . . . .18-1830-11
Remove and Install . . . . . . . . . . . . . . . . . .18-1800-1 Evacuate the System (SN -541550) . . . . . .18-1830-12
Charge the System (SN -541550) . . . . . . . .18-1830-14
Group 1810Operator Enclosure Add Refrigerant (SN -541550). . . . . . . . . . .18-1830-16
Service Equipment And Tools . . . . . . . . . . . .18-1810-1 Compressor (SN -541550)
Other Material . . . . . . . . . . . . . . . . . . . . . . . .18-1810-1 Inspect Vee Belt, Check and Adjust
Windowpane and Molding, Two Piece Tension . . . . . . . . . . . . . . . . . . . . . . . .18-1830-17
Remove and Install . . . . . . . . . . . . . . . . . .18-1810-1 Remove and Install . . . . . . . . . . . . . . . . .18-1830-18
Windowpane and Molding, One Piece Volumetric Efficiency Test-R12 . . . . . . . .18-1830-19
Remove and Install . . . . . . . . . . . . . . . . . .18-1810-2 Shaft Seal Leak Test . . . . . . . . . . . . . . . .18-1830-20
Sliding Windows Disassemble and Inspect . . . . . . . . . . . . .18-1830-22
Remove and Install . . . . . . . . . . . . . . . . . .18-1810-3 Inspect Clutch Pulley, Bearing and
Windowpane Dimensions . . . . . . . . . . . . . . .18-1810-4 Hub . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-26
Replace Clutch Pulley Bearing. . . . . . . . .18-1830-26
Group 1821Seat Replace Shaft Seal Seat . . . . . . . . . . . . .18-1830-27
Seat (SN -538404) Assemble. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-28
Remove and Install . . . . . . . . . . . . . . . . . .18-1821-1 Leak Testing . . . . . . . . . . . . . . . . . . . . . .18-1830-31
Seat (SN 538405-) Refrigerant Hoses and Tubing Inspection (SN
Remove and Install . . . . . . . . . . . . . . . . . .18-1821-2 -541550) . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-31
Seat (SN 537781-538404) Condenser (SN -541550)
Disassemble and Assemble. . . . . . . . . . . .18-1821-3 Remove and Install . . . . . . . . . . . . . . . . .18-1830-32
Seat (SN 538405-549976) Receiver/Dryer (SN -541550)
Disassemble and Assemble. . . . . . . . . . . .18-1821-4 Remove and Install . . . . . . . . . . . . . . . . .18-1830-33
Seat (SN 549977-) Expansion Valve (SN -541550)
Disassemble and Assemble. . . . . . . . . . . .18-1821-5 Remove and Install . . . . . . . . . . . . . . . . .18-1830-33
Seat Stand (SN -547853) Bench Test and Adjustment. . . . . . . . . . .18-1830-34
Disassemble and Assemble. . . . . . . . . . . .18-1821-6 Evaporator (SN -541550)
Seat Stand (SN 547854-) Remove and Install . . . . . . . . . . . . . . . . .18-1830-35
Disassemble and Assemble. . . . . . . . . . . .18-1821-8 Low and High Pressure Switches (SN
-541550)
Group 1830Heating And Air Conditioning Remove and Install . . . . . . . . . . . . . . . . .18-1830-36
Special Or Essential Tools . . . . . . . . . . . . . .18-1830-1 Thermostat Switch, Air Conditioner and
Compressor Relay (SN -541550) 18
Service Equipment And Tools . . . . . . . . . . . .18-1830-2
Other Material . . . . . . . . . . . . . . . . . . . . . . . .18-1830-3 Remove and Install . . . . . . . . . . . . . . . . .18-1830-37
Specifications . . . . . . . . . . . . . . . . . . . . . . . .18-1830-4 Air Conditioning Switch (SN -541550)
Blower Motor Remove and Install . . . . . . . . . . . . . . . . .18-1830-38
Remove and Install . . . . . . . . . . . . . . . . . .18-1830-5
Heater Core and Blower Motor Relay
Remove and Install . . . . . . . . . . . . . . . . . .18-1830-6
Heater Control
Remove and Install . . . . . . . . . . . . . . . . . .18-1830-7
Refrigerant (R-12) Cautions (SN -541550) . .18-1830-8
Compressor Oil (SN -541550)
Check and Add . . . . . . . . . . . . . . . . . . . . .18-1830-9
18
Cab
TX,1800,AB270 1909JUN921/1
18
1800
1
UN09JAN92
T7681AI
Earlier Machine Shown
TX,18,DW5012 1918JUL972/20
6. Remove cover.
UN09JAN92
18
1800
2
T7681AJ
UN13JAN92
T7681AT
TX,18,DW5012 1918JUL974/20
UN05AUG97
T109799
TX,18,DW5012 1918JUL975/20
UN06AUG97
T109478
Continued on next page TX,18,DW5012 1918JUL976/20
18
1800
3
UN06AUG97
EPropel Pilot Check Valve Tee Fitting-to-Boom,
Swing, and Arm Control Valve Manifold Z2 Port
Line
FPropel Pilot Check Valve Bottom Right
T109476
Port-to-Propel Left Reverse Port Line
GElectrical Connector
HPropel Pilot Check Valve Bottom Left
Port-to-Propel Right Reverse Port Line
18
1800
4
UN05AUG97
T110543
ALeft Pilot Controller Port CLeft Pilot Controller Port ERight Pilot Controller Port GRight Pilot Controller Port
1-to-Dig Pilot Check Valve 3-to-Dig Pilot Check Valve 1-to-Dig Pilot Check Valve 3-to-Dig Pilot Check Valve
E2 Port Line F2 Port Line I2 Port Line J2 Port Line
BLeft Pilot Controller Port DLeft Pilot Controller Port FRight Pilot Controller Port HRight Pilot Controller Port
2-to-Dig Pilot Check Valve 4-to-Dig Pilot Check Valve 2-to-Dig Pilot Check Valve 4-to-Dig Pilot Check Valve
H2 Port Line G2 Port Line K2 Port Line L2 Port Line
TX,18,DW5012 1918JUL978/20
UN06AUG97
T109480
TX,18,DW5012 1918JUL9710/20
CabSpecification
CabApproximate Weight ................................................. 230 kg (507 lb)
UN15MAR89
17. Connect cab to hoist using lifting straps. Slowly lift
cab from platform. Move cab slightly forward to clear
propel pedals.
T6878GN
18. Lift each corner of platform and inspect isolators for
wear.
18
1800
6
19. Install top half of isolators (D) and washers (C) into
main frame using soap and water as a lubricant.
CabSpecification
Cab and Platform-to-Frame Cap
ScrewTorque ............................................................ 320 Nm (235 lb-ft)
CabSpecification
Cab-to-Platform Cap Screw
Torque ............................................................................. 50 Nm (35 lb-ft)
UN28APR95
ACap Screw (4 used)
BWasher (4 used)
CWasher (4 used)
T8471AB
DIsolator (4 used)
EWasher (4 used)
FNut (4 used)
TX,18,DW5012 1918JUL9712/20
18
1800
7
T109477
UN06AUG97
T109480
TX,18,DW5012 1918JUL9714/20
UN05AUG97
T110543
ALeft Pilot Controller Port CLeft Pilot Controller Port ERight Pilot Controller Port GRight Pilot Controller Port
1-to-Dig Pilot Check Valve 3-to-Dig Pilot Check Valve 1-to-Dig Pilot Check Valve 3-to-Dig Pilot Check Valve
18 E2 Port Line F2 Port Line I2 Port Line J2 Port Line
1800 BLeft Pilot Controller Port DLeft Pilot Controller Port FRight Pilot Controller Port HRight Pilot Controller Port
8 2-to-Dig Pilot Check Valve 4-to-Dig Pilot Check Valve 2-to-Dig Pilot Check Valve 4-to-Dig Pilot Check Valve
H2 Port Line G2 Port Line K2 Port Line L2 Port Line
UN06AUG97
EPropel Pilot Check Valve Tee Fitting-to-Boom,
Swing, and Arm Control Valve Manifold Z2 Port
Line
FPropel Pilot Check Valve Bottom Right
T109476
Port-to-Propel Left Reverse Port Line
GElectrical Connector
HPropel Pilot Check Valve Bottom Left
Port-to-Propel Right Reverse Port Line
TX,18,DW5012 1918JUL9716/20
UN06AUG97
T109478
TX,18,DW5012 1918JUL9717/20
UN13JAN92
T7681AT
TX,18,DW5012 1918JUL9719/20
UN09JAN92
T7681AJ
TX,18,DW5012 1918JUL9720/20
18
1800
10
Insert Tool
1810,CC1 1926JUN873/3
Other Material
TX,1810,AB280 1920APR921/1
UN19OCT88
T5903AJ
1810,CC3 1925SEP912/4
UN19OCT88
T5903AK
1810,CC3 1925SEP913/4
UN19OCT88
T5903AL
1810,CC3 1925SEP914/4
UN19OCT88
T6439XD
1810,CC6 1903OCT952/2
UN05DEC89
6. Install windows and frame with spacers (C) at the
bottom and two on each end of frame.
T6439TD
Push window frame tight against cab flange. Use water
for a lubricant.
ATop Spacer (3 used)
8. Install molding (D) around window and cab flange. BWindow Frame
CBottom and Side Spacer 18
DMolding 1810
EAdhesive 3
1810,AA29 1920APR921/1
Windowpane Dimensions
UN04FEB92
T7681AM
18
1810
4
AUpper Front Windowpane CRight Rear Windowpane EThickness of Lower Front FThickness of All Other
BRight Front Windowpane DLower Front Windowpane Windowpane Windowpanes
UN21SEP94
T8316AC
18
1810
AUpper Front Door CRight Lower Windowpane ELeft Rear Windowpane GThickness of Windowpane
5
Windowpane DRear Windowpane FLower Door Windowpane
BUpper Rear Door
Windowpane
TX,1810,AB281 1914SEP942/2
18
1810
6
4. Remove seat.
6. Install seat.
UN09JAN92
7. Install cap screws (C).
T7681AL
9. Install cover (B) and cap screws (A).
ACap Screw (3 used)
BCover
CCap Screw (4 used)
DCap Screw (4 used)
TX,18,DW5013 1918JUL971/1
18
1821
1
UN12AUG97
(75 lb).
4. Remove seat.
T111086
5. Inspect parts for wear. Replace as necessary.
6. Install seat.
UN12AUG97
T109481
18
1821
2
TX,18,DW5014 1918JUL971/1
UN05AUG97
T109449
AHead Restraint FWasher KCap Screw (2 used) PCushion
BCap Screw (2 used) GSlideset LCover QCap Screw (2 used)
CLink HCap Screw (4 used) MCap Screw RLever
DArmrest ISlideset NArmrest SGrip
ECap Screw (2 used) JNut (4 used) OLink TSeat Back
TX,18,DW5015 1918JUL971/1
18
1821
3
UN05AUG97
T109450
18
1821
4
TX,18,DY2935 1925AUG971/1
UN05AUG97
T109454
18
1821
5
TX,18,DT5086 1915JUL971/1
UN05AUG97
T109451
18
1821
6
ACap Screw (4 used) EWasher (2 used) HCap Screw (4 used) KWasher (4 used)
BNut (4 used) FWasher (2 used) IWasher (4 used) LNut (4 used)
CStand GSeat Suspension JCap Screw (4 used) MWasher (4 used)
DPin
TX,18,DY2936 1925AUG971/1
18
1821
7
18
1821
8
UN21SEP94
T8316AF
TX,1821,DW267 1912APR952/2
18
1821
9
18
1821
10
UN29MAY91
T7541AD
SERVICE-GARD is a trademark of Deere & Company. DX,TOOLS 1920JUL951/9
DX,TOOLS 1920JUL953/9
UN20MAY91
T7530AX
DX,TOOLS 1920JUL954/9
DX,TOOLS 1920JUL957/9
DX,TOOLS 1920JUL958/9
DX,TOOLS 1920JUL959/9
TX,1830,DX357 1914APR952/9
TX,1830,DX357 1914APR954/9
TX,1830,DX357 1914APR955/9
TX,1830,DX357 1914APR956/9
TX,1830,DX357 1914APR957/9
TX,1830,DX357 1914APR958/9
Volt-Ohm-Amp Multimeter
TX,1830,DX357 1914APR959/9
Other Material 18
1830
3
Number Name Use
TX,1830,DX358 1914APR951/1
Specifications
Compressor:
18
1830
4
TX,1830,AB432 1914APR951/1
UN01JAN94
18
TP29998
1830
5
TX,18,DY2938 1925AUG971/1
UN05AUG97
T109457
ACap Screw (3 used) GWasher LCap Screw (3 used) QCap Screw (4 used)
BBlower Motor HClamp MValve RCover
CCap Screw (2 used) IHose NHose SHousing Cover
DRelay JHose OCap Screw (4 used) TClip (9 used)
ECore KClamp (4 used) PCover UHousing Cover
FCap Screw (3 used)
2. Remove cap screws (C). Remove relay (D). 4. Install relay (D).
18
1830
6
TX,18,DW5010 1918JUL971/1
AKnob
BKnob
CClamp (4 used)
DControl Cable
EClamp
FCap Screw
GSwitch
HController
IPanel
JNut
UN05AUG97
T109740
TX,18,DW5010 1918JUL971/1
18
1830
7
TX,1830,DX359 1914APR951/1
18
1830
8
IMPORTANT: The compressor takes a special 525 add an extra 30 mL (1 fl oz) to amounts specified in
viscosity oil that has special steps 2, 3 or 4.
additives which give better
compressor life. 6. When installing a new or remanufactured
compressor, drain oil. Replace with new oil per
If complete system was flushed to steps 2, 3 or 4.
remove contamination, the full
charge of oil 326 mL (11 fl oz) must 7. If components of system were drained and flushed,
be added to the system. add 330 mL (11 fl oz) to compressor.
TX,1830,DX360 1914APR951/1
18
1830
9
UN04APR91
2. Close both valves on air conditioning gauge set.
T7484AZ
4. Connect blue hose (C) to low-side test port.
TX,1830,DX361 1914APR951/1
18
1830
10
Refrigerant Recovery
(Serial No. 541550)
ESSENTIAL TOOLS
D18018KD Air Conditioning Test Equipment Kit (Serial No. 541550)
JT02020 or JT02021 Air Conditioning Recovery and Recycling System
(Serial No. 541550)
JT02022 Refrigerant Recovery System
UN08APR91
System or a Refrigerant Recovery/Recycling System.
ARed Hose
T7484BC
BBlue Hose
CYellow Hose
TX,1830,DX362 1914APR951/1
18
1830
11
UN25OCT88
4. Open low-side and high-side valves.
T6597BD
from 98 kPa (980 mbar) (29 in. Hg) for each 300
m (1000 ft) elevation above sea level.
ARed Hose
5. Evacuate system until low-side gauge registers 98 kPa BBlue Hose
(980 mbar) (29 in. Hg) vacuum. CYellow Hose
8. Repair leak.
18
1830
13
ESSENTIAL TOOLS
D18018KD Air Conditioning Test Equipment Kit (Serial No. 541550)
OTHER MATERIAL
TY6334 U.S. Refrigerant 12
UN25OCT88
1. Connect air conditioning gauge set. (See installation
procedure in this group.)
T6597BE
valve or container of R-12. If using container of R-12,
invert container so valve is on bottom.
ARed Hose
3. Open valve completely on charging cylinder of R-12 BBlue Hose
container. CYellow Hose
Specification
Air Conditioning System
RefrigerantRefrigerant Quantity ........................................... 2.3 kg (5 lb)
TX,1830,DX364 1914APR952/2
18
1830
15
OTHER MATERIAL
TY6334 U.S. Refrigerant 12
UN25OCT88
4. Open valve on refrigerant container. Invert container.
T6597BB
IMPORTANT: Be sure that refrigerant enters system
only as a vapor. Too much liquid
ARed Hose
entering the compressor can damage BBlue Hose
internal parts. Regulate the valve on the CYellow Hose
container or low-side valve so that the
low-side reading will not exceed 275
kPa (2.8 bar) (40 psi). This will assure
that refrigerant in the hose has
vaporized before entering the
compressor.
TX,1830,DX365 1914APR951/1
TX,1830,DX366 1914APR951/2
SPECIFICATIONS
Belt Tension Deflection 13 mm at 100 N (0.5 in. at 23 lb
force)
Adjusting Strap Cap Screw 27 Nm (20 lb-ft)
Torque
UN16JUL91
SERVICE EQUIPMENT AND TOOLS
Belt Tension Gauge
T7527DV
2. Check belt tension.
Specification
Belt TensionDeflection ........................ 13 mm at 100 N (0.5 in. at 23 lb
force)
UN16JUL91
1830
5. Tighten cap screws to 27 Nm (20 lb-ft).
17
Specification
Adjusting Strap Cap Screw
Torque ............................................................................. 27 Nm (20 lb-ft) ACompressor Pulley
BCrankshaft Pulley
CStraight Edge
DBelt Deflection Gauge
TX,1830,DX366 1914APR952/2
UN21JAN92
TP33179
1Belt 5Housing 9Washer (4 used) 13Lock Nut (2 used)
2Cap Screw 6Bushing 10Cap Screw (4 used) 14Washer (3 used)
3Washer (2 used) 7Compressor 11Screw (2 used) 15Cap Screw (3 used)
4Cap Screw 8Bracket (2 used) 12Bracket
2. Disconnect wiring lead, suction, and discharge IMPORTANT: Never overtighten belt.
lines. Overtightening may cause belt cord
damage and excessive load on
3. Repair or replace compressor. (See procedure in bearings.
this group.)
5. Adjust belt tension. (See procedure in this group.)
4. Tighten suction line to 31 Nm (23 lb-ft).
6. Install a new receiver/dryer.
Specification
Suction LineTorque ............................................... 31 Nm (23 lb-ft) 7. Evacuate and charge the system. (See procedures
in this group.)
18 Tighten discharge line to 22 Nm (16 lb-ft).
1830
18
TX,1830,DY070 1920APR951/1
OTHER MATERIAL
R49856 U.S. Compressor Oil
18
1830
19
UN23JAN89
greater, compressor is serviceable. Check for shaft
seal leakage.
10. If pressure is less than 370 kPa (3.70 bar) (55 psi),
RW3651
disassemble the compressor and check the following:
TX,1830,DX367 1914APR952/2
OTHER MATERIAL
TY6334 U.S. Refrigerant 12
UN23JAN89
4. Use an electronic leak detector to check for leaks from
shaft seal and front and rear heads.
RW3653
5. If there is any leakage, replace shaft seal and end
plate gaskets.
TX,1830,DX368 1914APR952/2
18
1830
21
UN23JAN89
RW3654
TX,1830,DX369 1914APR951/16
UN23JAN89
RW3655
TX,1830,DX369 1914APR952/16
NOTE: If clutch drive plate slips on hub, drill a 1/4 in. hole
through flanges of drive plate and hub. Insert a
punch to hold clutch hub for removal of hub
UN23JAN89
retaining nut.
RW3656
UN23JAN89
RW3657
TX,1830,DX369 1914APR954/16
7. Remove and discard snap ring (B) and shaft key (C).
UN23JAN89
RW3658
TX,1830,DX369 1914APR955/16
UN23JAN89
RW3659
TX,1830,DX369 1914APR956/16
UN23JAN89
11. Carefully pry head from body using a screw driver.
Pry only slightly around the circumference of the
head. Repeat this procedure until head is removed.
RW3661
TX,1830,DX369 1914APR958/16
UN07DEC88
RW10908
TX,1830,DX369 1914APR959/16
UN07DEC88
RW10000
TX,1830,DX369 1914APR9510/16
16. If wear pattern has any voids in it, replace reed valve.
UN23JAN89
RW3665
17. Install JDG227 Puller (A) and carefully pull valve plate
(B) from head (C).
UN23JAN89
RW3663
TX,1830,DX369 1914APR9512/16
UN07DEC88
plate.
RW10001
TX,1830,DX369 1914APR9513/16
UN23JAN89
RW3667
TX,1830,DX369 1914APR9514/16
22. Separate reed valve (A) from valve plate (B). Inspect
the three valves (C) for complete circular wear
pattern. If wear pattern has any voids in it, replace
reed valve.
UN23JAN89
RW3669
TX,1830,DX369 1914APR9516/16
UN23JAN89
2. Rotate bearing in pulley. If bearing is rough or has
evidence of loss of lube, replace bearing.
3. Clean up as necessary.
RW3677
U90,090005,AKX1 1928JUN901/1
UN23JAN89
RW3670
U90,090005,ADX1 1928JUN901/4
UN23JAN89
RW3672
U90,090005,ADX1 1928JUN903/4
UN23JAN89
6. Install bearing retaining ring.
RW3673
U90,090005,ADX1 1928JUN904/4
UN23JAN89
RW3674
U90,090005,AHX1 1908OCT901/3
2. Lubricate the new O-ring (A) on the seal seat (B) with 18
a small amount of clean refrigerant oil. 1830
27
UN23JAN89
RW3676
U90,090005,AHX1 1908OCT903/3
Assemble Compressor
(Serial No. 541550)
18
1830
28
UN23JAN89
occur during assembly of front head.
RW3662
head down EVENLY, then tighten to 26 Nm (19 lb-ft).
Specification
Front Head Cap ScrewTorque .................................... 26 Nm (19 lb-ft)
TX,1830,DX370 1914APR952/6
UN23JAN89
RW3678
TX,1830,DX370 1914APR953/6
12. Set clutch pulley in place over coil. Slight tap may be 18
needed to properly position pulley on shaft. 1830
29
RW3679
13. Install new snap ring (A) with rounded edge of snap
ring facing upward. Install removed shims (B) on front
head.
UN23JAN89
15. Tighten pulling nut until clutch hub is pulled tight
against shims on compressor shaft shoulder.
RW3684
TX,1830,DX370 1914APR955/6
UN23JAN89
18. Correct clearance is 0.530.91 mm (0.0210.036
in.).
RW3682
Specification
Pulley-To-Clutch HubClearance ...... 0.530.91 mm (0.0210.036 in.)
Specification
Hub Retaining NutTorque ............................................ 16 Nm (12 lb-ft)
TX,1830,DX370 1914APR956/6
18
1830
30
TX,1830,DX371 1914APR951/1
When a component is disconnected from the system, hose and tube connections. Dip O-rings in 525 oil
special care should be given to inspecting hoses and before assembling.
tubing for moisture, grease, dirt, rust, or other foreign
material. If such contamination is present in hoses, IMPORTANT: Hose used for air conditioning
tubing, or fittings and cannot be removed by cleaning, systems contains special barriers in
then replace parts. its walls to prevent migration of
refrigerant gas.
Fittings that have grease or dirt on them should be
wiped clean with a cloth dampened with alcohol. DO NOT use hydraulic hoses as
Chlorinated solvents (such as trichloroethylene) are replacement hoses in the air
contaminants, and must not be used for cleaning. conditioning system. Use ONLY
certified hose meeting SAE J51b
To assist in making leak-proof joints, use a small requirements. 18
amount of clean 525 viscosity refrigerant oil on all 1830
31
TX,1830,DX372 1914APR951/1
UN01JAN94
TP33180
1Screw (8 used) 5Bracket (2 used) 9Bushing (4 used) 12Strap
2Lock Nut (4 used) 6Lock Nut (8 used) 10Screw (2 used) 13Cap Screw
3Washer (6 used) 7Cap Screw 11Condenser 14Hinge
4Washer (8 used) 8Rubber Mount (8 used)
1. Recover refrigerant from the system. (See 2. Evacuate and charge the system. (See procedures
procedure in this group.) in this group.)
TX,1830,DY071 1920APR951/1
18
1830
32
1Receiver/Dryer
2Lock Nut (2 used)
3Washer (2 used)
4Spacer (2 used)
5Clip (2 used)
6Cap Screw (2 used)
UN21JAN92
TP33181
TX,1830,DY072 1920APR951/1
UN21JAN92
2. Remove seat.
T7681CJ
4. Remove expansion valve.
9. Install seat.
TX,1830,DY073 1920APR951/1
TX,1830,DX373 1914APR951/3
UN06DEC88
AJT03184 Tee Fitting With 0.020 in. Orifice Cap
BJT03183 Fitting
CJT03195 Tee Fitting
T84070
18
1830
34
UN08NOV88
a new valve.
T84072
TX,1830,DX373 1914APR953/3
UN21JAN92
2. Remove seat. (See procedure in Group 1821.)
T7681CK
4. Remove air conditioner cover (B).
6. Remove evaporator.
UN21JAN92
9. Check and add compressor oil. (See procedure in this
group.)
T7681CL
10. Evacuate and charge the system. (See procedures in
this group.)
ATop Cover
11. Install air conditioning cover and top cover. BAir Conditioner Cover
CScrew (4 used)
12. Install seat. (See procedure in Group 1821.) DEvaporator
18
ETube
1830
35
TX,1830,DY074 1920APR951/1
Remove And Install Low And High Pressure Switches (Serial No. 541550)
UN21JAN92
18
1830
36
T7681CM
TX,1830,DY075 1920APR951/1
AThermostat Switch
BAir Conditioner Relay (Blue/Black, Blue/White,
UN21JAN92
Red/White, and Blue/Green Wire Leads)
CCompressor Relay (Blue/White, Blue/Red,
Red/White, and Red/Black Wire Leads)
T7681CN
TX,1830,DY076 1920APR951/1
18
1830
37
UN21JAN92
TP41132
18
1830
38
TX,1830,DY077 1920APR951/1
Page
20
20
UN17JAN92
3. On earlier machines, remove four nuts (C) to remove
propel alarm (B).
T7681CI
remove propel alarm (B).
UN06AUG97
8. Connect wire lead (A).
T109482
Later Machine Shown
TX,20,DY2939 1925AUG971/1
UN08AUG91
photograph.
T7511CW
volume.
TX,90,FF2487 1913AUG911/1
20
2004
1
20
2004
2
Contents
Page Page
Page Page
33
Dig Pilot Check Valve Block (SN Power Boost Solenoid Valve (SN 556936-)
543990-559935) Remove and Install . . . . . . . . . . . . . . . . 33-3360-119
Remove and Install . . . . . . . . . . . . . . . . .33-3360-81 Circuit Relief and Anti-Cavitation Valves (SN
Dig Pilot Check Valve Block (SN 559936-) -556935)
Remove and Install . . . . . . . . . . . . . . . . .33-3360-82 Remove and Install . . . . . . . . . . . . . . . . 33-3360-120
Propel Pilot Check Valve Block Bucket Circuit Relief and Anti-Cavitation
Remove and Install . . . . . . . . . . . . . . . . .33-3360-83 Valves (SN 556936-)
Disassemble and Assemble. . . . . . . . . . .33-3360-85 Remove and Install . . . . . . . . . . . . . . . . 33-3360-121
Hydraulic Control Valve (SN -556935) Boom, Arm, and Bucket Valve Section (SN
Remove and Install . . . . . . . . . . . . . . . . .33-3360-86 -556935)
Boom, Arm, and Swing Control Valve Disassemble and Assemble. . . . . . . . . . 33-3360-122
Manifold (SN 556936-) Swing Valve Section
Remove and Install . . . . . . . . . . . . . . . . .33-3360-97 Disassemble and Assemble. . . . . . . . . . 33-3360-127
Return Manifold (SN 556936-) Propel Valve Section (SN -556935)
Remove and Install . . . . . . . . . . . . . . . . 33-3360-106 Disassemble and Assemble. . . . . . . . . . 33-3360-132
Oil Cooler Bypass Valve (SN 556936-) Boom, Arm, and Swing Control Valve (SN
Remove and Install . . . . . . . . . . . . . . . . 33-3360-107 556936-)
Arm Cylinder Restrictor (SN 546276-556935) Disassemble and Assemble. . . . . . . . . . 33-3360-136
Remove and Install . . . . . . . . . . . . . . . . 33-3360-107 Make-Up Valve (SN -556935)
Arm and Boom Cylinder Restrictors (SN Remove and Install . . . . . . . . . . . . . . . . 33-3360-136
556936-) Propel Circuit Make-Up Valve (SN 556936-)
Remove and Install . . . . . . . . . . . . . . . . 33-3360-109 Remove and Install . . . . . . . . . . . . . . . . 33-3360-137
Anti-Cavitation Back Pressure Check Valve Auxiliary Valve Section (SN -556935)
(SN -556935) Disassemble and Assemble. . . . . . . . . . 33-3360-137
Remove and Install . . . . . . . . . . . . . . . . 33-3360-109 Monoblock Control Valve (SN 556936-)
Anti-Cavitation Back Pressure Check Valve Remove and Install . . . . . . . . . . . . . . . . 33-3360-138
(SN 556936- Monoblock Control Valve Manifold (SN
Remove and Install . . . . . . . . . . . . . . . . 33-3360-110 556936-)
Combined Function Shuttle Valve (SN Disassemble and Assemble. . . . . . . . . . 33-3360-142
-556935) Safety Relief Valve (SN 556936-)
Remove and Install . . . . . . . . . . . . . . . . 33-3360-112 Remove and Install . . . . . . . . . . . . . . . . 33-3360-143
Combined Function Shuttle Valve (SN Disassemble and Assemble. . . . . . . . . . 33-3360-144
556936-) Boom Regenerative Valve (SN
Remove and Install . . . . . . . . . . . . . . . . 33-3360-112 545157-556935)
Disassemble and Assemble. . . . . . . . . . 33-3360-113 Remove and Install . . . . . . . . . . . . . . . . 33-3360-145
Pressure Control Manifold (SN -556935) Disassemble and Assemble. . . . . . . . . . 33-3360-146
Remove and Install . . . . . . . . . . . . . . . . 33-3360-114 Arm Regenerative Valve (SN
Load Sense System Relief Valve (SN 546277-556935)
-556935) Remove and Install . . . . . . . . . . . . . . . . 33-3360-147
Disassemble and Assemble. . . . . . . . . . 33-3360-114 Disassemble and Assemble. . . . . . . . . . 33-3360-148
Load Sense System Relief Valve (SN Arm Regenerative Poppet Valve (SN
556936-) 556936-)
Remove and Install . . . . . . . . . . . . . . . . 33-3360-115 Remove and Install . . . . . . . . . . . . . . . . 33-3360-149
Disassemble and Assemble. . . . . . . . . . 33-3360-116 Arm Regenerative Valve (SN 556936-)
Safety Valve (SN -556935) Disassemble and Assemble. . . . . . . . . . 33-3360-150
Disassemble and Assemble. . . . . . . . . . 33-3360-117 Stop Cushion Valve
Pilot Pressure Regulating Valve (SN -556935) Remove and Install . . . . . . . . . . . . . . . . 33-3360-151
Disassemble and Assemble. . . . . . . . . . 33-3360-117 Swing Stop Cushion Valve (SN 546277-)
Pilot Pressure Regulating Valve (SN 556936-) Disassemble and Assemble. . . . . . . . . . 33-3360-152
Remove and Install . . . . . . . . . . . . . . . . 33-3360-118 Swing Torque Control Valve (SN -556935)
Disassemble and Assemble. . . . . . . . . . 33-3360-118 Remove and Install . . . . . . . . . . . . . . . . 33-3360-153
Power Boost Solenoid Valve (SN -556935)
Remove and Install . . . . . . . . . . . . . . . . 33-3360-119 Continued on next page
Page
33
Swing Torque Control Valve (SN 556936-)
Remove and Install . . . . . . . . . . . . . . . . 33-3360-154
Swing Torque Control Valve (SN -546276)
Disassemble and Assemble. . . . . . . . . . 33-3360-155
Swing Torque Control Valve (SN 556936-)
Disassemble and Assemble. . . . . . . . . . 33-3360-156
Boom and Arm Anti-Drift Valve (SN -556935)
Remove and Install . . . . . . . . . . . . . . . . 33-3360-156
Boom and Arm Anti Drift Valve (SN 556936-)
Remove and Install . . . . . . . . . . . . . . . . 33-3360-159
Boom and Arm Anti Drift Valve
Disassemble and Assemble. . . . . . . . . . 33-3360-161
Dual Solenoid Block (SN -538538)
Remove and Install . . . . . . . . . . . . . . . . 33-3360-162
Dual Solenoid Block (SN 538539-)
Remove and Install . . . . . . . . . . . . . . . . 33-3360-163
Dual Solenoid Valve Block (SN 538539-)
Disassemble and Assemble. . . . . . . . . . 33-3360-164
Engine Speed Control Actuator
Remove and Install . . . . . . . . . . . . . . . . 33-3360-165
Disassemble and Assemble. . . . . . . . . . 33-3360-166
Boom Cylinder
Remove and Install . . . . . . . . . . . . . . . . 33-3360-167
Arm Cylinder
Remove and Install . . . . . . . . . . . . . . . . 33-3360-169
Bucket Cylinder
Remove and Install . . . . . . . . . . . . . . . . 33-3360-171
Hydraulic Cylinder Bleed Procedure . . . . . 33-3360-173
Bucket, Arm, and Boom Cylinders
Disassemble . . . . . . . . . . . . . . . . . . . . . 33-3360-174
Assemble. . . . . . . . . . . . . . . . . . . . . . . . 33-3360-179
Hydraulic Oil Cooler
Remove and Install . . . . . . . . . . . . . . . . 33-3360-186
Change Hydraulic Return Filter . . . . . . . . . 33-3360-187
Reservoir
Remove and Install . . . . . . . . . . . . . . . . 33-3360-190
Disassemble and Assemble. . . . . . . . . . 33-3360-194
33
Bucket Linkage
TX,3302,DX374 1914APR951/1
UN06DEC88
CAUTION: Avoid possible injury. Pin may fly
after it is released from tooth tip. Keep a firm
T6879EE
grip on pin to prevent injury.
3. Remove pin.
UN27JUN91
6. Replace U-shaped pin at same time you replace tooth
tip.
04T,90,K273 1928JAN921/1
UN31OCT88
2. Grind all surfaces smooth.
T92509
UN31OCT88
T92510
Continued on next page TX,3302,CC13 1921NOV881/4
33
3302
3
UN31OCT89
T5985AQ
IMPORTANT: Good welds are important. Have only 4. Install shank into corner so it is tight against the
a qualified welder do the welding. bevel edge and side of bucket.
Before welding, clean all dirt and
paint from weld area. Connect the Install center shanks so they are tight against bevel
welder ground clamp close to each edge and spaced equally across width of bucket.
weld area, so electrical current does
not pass through any bearings or 5. Tack weld at the top rear center to hold it in
bushings. position.
TX,3302,CC13 1921NOV883/4
UN31OCT88
7. Weld shank to cutting edge using 12.7 mm (0.5 in.)
fillet weld (1).
Specification
Tooth ShankFillet Weld .............................................. 12.7 mm (0.5 in.)
T82798
Starting at the rear center of shank, weld a continuous
bead across end, around the corner, and along the side
stopping 25 6 mm (0.98 0.24 in.) from edge of cutting
edge.
Specification
Tooth ShankDistance From
Edge ............................................................... 25 6 mm (0.98 0.24 in.)
UN31OCT88
Alternating from side to side, make as many passes as
necessary to get the specified bead size.
T82799
8. Allow the weld area to cool slowly at room
temperature.
TX,3302,CC13 1921NOV884/4
UN31OCT88
CAUTION: Approximate weight range of buckets
is 560845 kg (12451860 lb). Bucket link is 92
kg (205 lb) and arm link is 19 kg (42 lb).
T6450CF
2. Remove snap rings (A) and cross pins (B).
UN18DEC91
Then lubricate every 4 hours for the
next 20 hours, then daily for the next 30
to 100 hours, and then at the regular
maintenance intervals.
T7626CD
7. Apply grease to contact surfaces of pins and bushings.
8. Install links, bucket and pins. Turn snap rings so they ASnap Ring (2 used)
are over cross pins. BCross Pin (2 used)
CO-Ring (2 used)
DPin
9. Install washers (shims) between arm and each arm link EPin
to obtain a maximum clearance of 1.5 mm (0.06 in.). FPin
GPin
10. Adjust bucket linkage. (See procedure in this group.) HBucket Link
ILeft Arm Link and Washers
JRight Arm Link
UN04MAY93
4. Remove parts (B, C, D, I and J). Remove bucket link
(L) and arm links (A and K).
T7966EN
bushings in bucket link (L). (See Remove and Install
Bushings and Seals in Group 3340.)
IMPORTANT: To prevent the seizure and galling of ALeft Arm Link and Washers
new or cleaned pins and bushings, BNut (8 used)
Apply grease to pins and bushings CPin
DCap Screw
before assembly. Grease may not flow ECap Screw
to all points of pin and bushing at the FPin
initial lubrication causing metal-to-metal GPin
contact. After assembly, lubricate pivot HCap Screw
joint until grease escapes from joint. IPin
JCap Screw
Then lubricate every 4 hours for the KRight Arm Link
next 20 hours, then daily for the next 30 LBucket Link
to 100 hours, and then at the regular
maintenance interval.
TX,3302,DX375 1914APR952/2
UN10NOV88
mm (0.020 in.).
Specification
Bucket LinkageClearance ......................................... 0.5 mm (0.020 in.)
T95775
3. Remove plate (F).
UN06DEC88
5. Install plate and tighten cap screws.
T6879DU
ABucket
BBushing
CPin
DClearance
EShim (as required)
FPlate
UN10NOV88
T95788
TX,3302,GG202 1923JUN942/2
2. Clean all joints to be welded of all foreign matter 6. Final weld preheated plates starting at the center of
such as dirt, rust, mill scale, oil, etc. with grinders the front edge of the bucket backing plate and
and/or solvents. working toward the outside ends.
3. Use dry AWS-E7018 low hydrogen electrodes or Repeat this operation at back edge of loader blade.
either of the following equivalent low hydrogen wire
feed electrodes: gas metal arc welding (CO 2 or Tack welds may be incorporated into the final weld,
argon CO 2) AWS-E70S6 or flux cored arc welding providing they have been made with electrodes that
AWS-E70T1. meet the requirements of the final welds and no
cracking has occurred in the weld metal. Tack
4. Preheat parts to be welded (both tack and final welds not meeting these requirements must be
welds) to minimum of 204C (400F). PREHEAT completely removed by grinding or air arc gouging
TEMPERATURE MUST BE THROUGHOUT THE just prior to making the final weld in that area.
ENTIRE THICKNESS OF THE PARTS JOINED
AND AT LEAST 51 mm (2 in.) BACK FROM THE 7. Do not remove bucket from welding environment
JOINT. Maintain preheat throughout the entire until weld metal temperature has dropped to the
welding operation. Tempilstiks should be used if ambient temperature. Do not force cooling rate of
possible. weld metal.
TX,3302,AB35 1909JAN921/1
TX,3302,AB36 1909JAN921/1
Boom
TX,3340,AB3 1914APR951/1
Other Material
TX,33,DY2940 1925AUG971/3
UN26MAR90
Specification
Short ArmApproximate Weight ..................................... 710 kg (1570 lb)
Standard ArmApproximate
Weight............................................................................... 770 kg (1700 lb)
T6641DC
Bucket end of arm is the heavy end when connected as
shown. Earlier Machine Shown
ASnap Ring
6. Place a wooden block between arm cylinder and boom
BSnap Ring
to keep cylinder off the lines. CRetaining Pin
DRetaining Pin
7. On earlier machines, remove parts (AF) to remove EArm-to-Boom Pin
arm. FArm-to-Arm Cylinder Pin
UN06AUG97
1.5 mm (0.06 in.).
Specification
Arm-to-BoomClearance .............................................. 1.5 mm (0.06 in.)
T109484
12. On later machines, connect hydraulic lines at (A and
B). Later Machine Shown
TX,33,DY2940 1925AUG973/3
UN26MAR90
CAUTION: The approximate weight of boom
cylinder is 189 kg (416 lb).
T6641DE
7. Disconnect rod end of boom cylinders and lower them
to the ground.
(Serial No. 538759)
CAUTION: Approximate weight of boom, with
arm cylinder and lines, is 1800 kg (4480 lb).
Specification
CylinderApproximate Weight .......................................... 189 kg (416 lb)
UN04MAR95
Boom with Cylinder
Approximate Weight ....................................................... 1800 kg (4480 lb)
T8455AJ
chain is used.
With arm cylinder installed, arm end of boom is the heavy (Serial No. 538760)
end. When arm cylinder is removed, frame end of boom is
the heavy end. AWiring Harness
BSnap Ring
CPin
9. On early machines, remove snap ring (B) and pin (C). DPin
On later machines, remove cap screw (H) and nuts (I). EShims (As required)
FCap Screw (2 used)
10. Remove pin (D) using a slide hammer puller and GCap Screw (8 used)
HCap Screw
adapter. Remove shims (E). Note the shim locations
INut (2 used)
to aid assembly.
UN26MAR90
16. On early machines, install boom and parts (BE). On
later machines, install boom and parts (D, E, H and I).
Torque nut, not retaining nut, to 136 Nm (100 lb-ft).
T6641DE
Specification
Pin Retaining NutTorque ......................................... 136 Nm (100 lb-ft)
(Serial No. 538759)
Specification
Boom and FrameMaximum
Clearance ....................................................................... 1.5 mm (0.06 in.)
UN04MAR95
18. Connect rod end of boom cylinders. Install retaining
rings with chamfer side towards end of pin.
T8455AJ
19. Connect lines and wiring harness (A).
AWiring Harness
21. Install shield. Tighten cap screws (F) to 104 Nm (77 BSnap Ring
lb-ft). CPin
DPin
Specification EShims (As required)
Shield and Clamp-to-Boom Cap FCap Screw (2 used)
ScrewTorque .............................................................. 104 Nm (77 lb-ft) GCap Screw (8 used)
HCap Screw
INut (2 used)
22. Install arm and bucket.
TX,3340,DY056 1904MAY953/3
UN01NOV88
AHydraulic Ram
B1Pipe-Minimum I.D. to Clear Bushing O.D.
B2Pipe-Maximum O.D.
B3Pipe-Length of Bushing
T95237
CBushing
DDisks
EBushing Stop (Disk)
FPilot (Disk)
GRam Stop (Disk)
HThickness of Seal
UN31OCT88
T6641CW
TX,3340,DX377 1914APR951/1
33
3340
8
1901FEB95
T8407AE
SERVICE-GARD is a trademark of Deere & Company. JDG799 1904MAY951/7
JDG799 1904MAY954/7
JDG799 1904MAY957/7
1
Fabricated tool, dealer made. (See Section 99 for instructions to make
tool.)
TX,3360,AB427 1904MAY952/13
TX,3360,AB427 1904MAY953/13
TX,3360,AB427 1904MAY957/13
Chain Wrench
Pusher . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG843-3
TX,3360,AB427 1904MAY959/13
Installer . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG841
Installer . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG918
Installer . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG917
Other Material
TY9375 (U.S.) Pipe Sealant with TEFLON Used to apply to mating surfaces of
TY9480 (Canadian) pump and to threads of all fittings in
592 (LOCTITE) reservoir.
T43512 (U.S.) Thread Lock and Sealer (Medium Used to apply to threads of plug in
TY9473 (Canadian) Strength) Products control valve spool. Pilot controller
242 (LOCTITE) U-joint, and threads of cylinder piston
nut.
Specifications
Pilot Shut-Off Valve Linkage Clearance Between Lever and Cap 1.5 0.5 mm (0.06 0.02 in.) 33
3360
Screw 7
Propel Controller:
Bucket Cylinder:
Arm Cylinder:
Boom Cylinder:
TX,33,DW5016 1921JUL978/8
UN02JUN97
UN23FEB92
T109446
T7699AO
UN12OCT95
lowering the boom with the engine stopped.
1. For machines with anti-drift valve, loosen relief valve ASpool Stop Screw
(C) in anti-drift valve housing (E) 1/4 turn. BLock Nut
CRelief Valve
2. Hold spool stop screw (B), located at the rear of main DAnti-Drift Valve
EAnti-Drift Valve Housing
control valve, and loosen lock nut (A) until it is held on
by only one or two threads.
TX,33,DY2941 1926AUG972/2
UN17JUL93
T8048AC
(Serial No. 556935)
UN02JUN97
T109283
UN02JUN97
maintain boom position. Boom cylinder will not
contain enough oil to hold the boom in position
hydraulically.
T109187
6. Block the boom cylinder.
UN17JUL93
T8048AC
UN02JUN97
T109283
TX,33,DY2942 1926AUG973/3
UN17JUL93
T8048AD
Front Pilot Cap (Serial No. 556935)
UN02JUN97
T109448
1. Holding spool stop screw (B), loosen lock nut (A) until
it is held on by only one or two threads.
33
3360
2. Counting the number of turns, turn spool stop screw 19
(B) clockwise until the screw contacts spool (increased
resistance).
UN23FEB92
T7699AR
Rear Pilot Cap (Serial No. 556935)
UN02JUN97
T109447
UN29JUL91
upperstructure with the engine stopped.
T7581AC
(200500 psi) to swing brake release fitting to release
swing brake.
Earlier Machine Shown
7. With external source, lift and swing boom away from
excavation.
TX,35,DT5026 1909JUN973/3
Procedure is used to clean contamination from the 5. Start the engine and run it at fast idle.
hydraulic system after a hydraulic component failure.
The Hydraulic Oil Cleanup Procedure Using Clean-Up IMPORTANT: For the most effective results,
Filter can also be used or used as a follow-up to the cleaning procedure must start with
filter caddy to ensure a complete cleanup of the smallest capacity circuit then
contamination. (See procedure in this group.) proceed to the next largest capacity
circuit.
The hydraulic system return filter can be cut apart and
inspected for indications of contamination. 6. Starting with the smallest capacity circuit, operate
each functions through a complete cycle.
1. Install a new return filter element.
Specification
IMPORTANT: The minimum ID of connector must Reservoir (Serial No.
be 1/2 in. to prevent cavitation of 556935)Capacity ....................................................... 148 L (39 gal)
Reservoir (Serial No. 556936
filter caddy pump. )Capacity ................................................................... 151 L (40 gal)
TX,33,DY2943 1926AUG972/2
UN18DEC91
2. Drain reservoir. Approximate capacity is 148 L (39 gal).
T7626CG
4. Disconnect lines (BH).
5. Remove pump.
UN18DEC91
APump Regulator Housing
BDrain Port-to-Reservoir
CInlet Port-to-Reservoir
T7626CH
DDrain Port-to-Reservoir
EInlet Port-to-Reservoir
FOutlet Port-to-Pilot Filter
GOutlet Port-to-Control Valve Upper Port Hydraulic Pump And Pilot Pump Line
HOutlet Port-to-Control Valve Lower Port
UN22MAR90
Specification
Hub-to-Pump CaseClearance ....................... 3 1 mm (0.12 0.04 in.)
T6439YL
Specification
Set ScrewTorque ....................................................... 122 Nm (90 lb-ft)
Specification
Pump-to-Flywheel Cap Screw
Torque ............................................................................. 87 Nm (64 lb-ft)
TX,33,DY2944 1926AUG972/3
UN18DEC91
13. Check that O-rings are installed. Install pump
regulator housing (A).
TX,33,DY2944 1926AUG973/3
TX,33,DY2945 1926AUG971/5
UN05AUG97
Line
JPump Bottom Rear Port-to-Monoblock Rear Inlet
Port Line
KPump Top Rear Port-to-Boom, Arm, Swing Bottom
Tee Port Line
T109709
Hydraulic Pump And Pilot Pump Line
UN05AUG97
6. Remove cap screws (D).
T109711
CAUTION: The approximate weight of hydraulic
pump is 88 kg (194 lb).
7. Remove pump.
Specification
Pump-to-flywheel Cap Screw
Torque ............................................................................. 87 Nm (64 lb-ft)
TX,33,DY2945 1926AUG973/5
UN05AUG97
T109711
UN05AUG97
APump Regulator LS Port-to-Main Control Valve
Bottom Tee Port Line
BPump Regulator Right Port-to-Dual Solenoid Valve
T109709
Manifold "D" Port-to-Reservoir Line
CElectrical Connector
DCap Screw (6 used) Hydraulic Pump And Pilot Pump Line
EPump Inlet Port-to-Reservoir Line
FPilot Pump Inlet Port-to-Reservoir Line
GPump Rear Drain Port-to-Reservoir Line
HPump Front Drain Port-to-Reservoir Line
IPilot Pump Outlet Port-to-Pilot Filter Forward Port
Line
JPump Bottom Rear Port-to-Monoblock Rear Inlet
Port Line
KPump Top Rear Port-to-Boom, Arm, Swing Bottom
Tee Port Line
TX,33,DY2945 1926AUG975/5
TX,33,DY2946 1926AUG971/3
UN15JUL91
T7527DX
(Serial No. 559602)
UN02JUN97
T109313
UN15JUL91
5. Install plugs.
T7527DY
7. Check oil level after operating machine for several
minutes.
TX,33,DY2946 1926AUG973/3
UN18DEC91
T7626CK
ACylinder Block DPump Discharge Passage GPilot Pump JPump Discharge Passage
BFeedback Spring ESmall Control Piston HSwash Plate KPistons
CRegulator Housing FCylinder Block ILarge Control Piston LSwash Plate
33
3360
31
UN18DEC91
T7626CL
Front Hydraulic Pump
33
3360
32
UN18DEC91
T7626CM
Rear Hydraulic Pump
33
3360
33
UN18DEC91
T7626CI
TX,33,DY2905 1920AUG974/17
UN18DEC91
T7626CN
TX,33,DY2905 1920AUG975/17
UN22MAR90
T6439VS
TX,33,DY2905 1920AUG977/17
8. Remove parts.
UN18DEC91
T7626CT
TX,33,DY2905 1920AUG978/17
ESpring
FPlate
T7626CU
UN22MAR90
11. Put front pump cylinder block and piston assembly
into DF1040 Pump Rotate Group Workbench Support.
(See Section 99 for instructions to make tool.)
T6439UX
TX,33,DY2905 1920AUG9710/17
14. Remove bearing inner race (A) and spacer (B) using
a bearing puller.
AInner Race
BSpacer
CCardboard
DRoller Cage
UN06JAN92
T7626CP
Continued on next page TX,33,DY2905 1920AUG9711/17
UN18DEC91
T7626CR
TX,33,DY2905 1920AUG9712/17
16. Remove bearing cone (A), spacer (B), and seal collar
(C) from front pump using a press and bearing puller.
UN22MAR90
T6439VD
UN22MAR90
T6439VB
TX,33,DY2905 1920AUG9714/17
ASnap Ring
BSmall ID Washer
UN22MAR90
CSpring
DLarge ID Washer
T6439VC
UN01NOV88
T6439UR
UN23FEB92
T7681FT
TX,33,DY2905 1920AUG9716/17
UN22MAR90
T6439VF
TX,33,DY2905 1920AUG9717/17
APiston
BSlipper
CCylinder Block
DValve Plate
UN22MAR90
T6439YQ
Earlier Machine Shown
TX,33,DY2947 1926AUG972/6
Specification
UN16APR90
UN08MAR90
T83352
TX,33,DY2947 1926AUG974/6
UN18DEC91
T7626CS
TX,33,DY2947 1926AUG975/6
10. Install new piston ring with sealing area (A) toward
stem of piston.
UN22MAR90
T6439VI
TX,33,DY2947 1926AUG976/6
TX,33,DY2949 1926AUG971/21
UN22MAR90
T6439VK
TX,33,DY2949 1926AUG972/21
UN01NOV88
6. Put cylinder block on cardboard and workbench
support with lapped surface down.
T6439UR
ASnap Ring
BSmall ID Washer
CSpring
DLarge ID Washer
UN22MAR90
T6439VC
ARetainer Plate
BPistons (9 used)
CBall Guide
DPin (3 used)
UN22MAR90
T6439VB
Continued on next page TX,33,DY2949 1926AUG974/21
10. Install swashplate (A) and pump shaft using care not
to move three pins in cylinder block.
UN18DEC91
T7626CR
Front Pump Components Shown
TX,33,DY2949 1926AUG975/21
UN22MAR90
T6439VJ
UN23FEB89
12. Heat new bearing cone to approximately 93C
(200F) and install on shaft.
T81191
TX,33,DY2949 1926AUG977/21
14. Push seal into housing tight against snap ring using
45 and 62 mm disks. Put petroleum jelly on seal lips.
UN22MAR90
T6439VF
TX,33,DY2949 1926AUG978/21
UN27JAN92
T7681EU
TX,33,DY2949 1926AUG979/21
Specification 33
Front Pump-to-Rear Pump Stud 3360
Torque ............................................................................. 60 Nm (44 lb-ft) 45
UN22MAR90
T6439YS
TX,33,DY2949 1926AUG9711/21
AValve Block
BStud (9 used)
CValve Plate
DSmall and Large Piston
UN27JAN92
T7681EX
UN22MAR90
block with lapped surfaces toward each other.
T6439YT
side of pump.
TX,33,DY2949 1926AUG9713/21
Specification
Stud-to-Housing NutTorque ....................................... 110 Nm (81 lb-ft)
UN18DEC91
T7626CN
UN22MAR90
Add or subtract shims from shim pack in valve block to
obtain proper end play.
T6439YV
repeat Step 23 for front pump.
TX,33,DY2949 1926AUG9715/21
26. Use splined coupler (C), hose clamp, and tie band (A)
to make a pump phasing tool.
UN22MAR90
Align tie band with any root (B) of a spline. Tighten
hose clamp to keep band square with root.
T6439VN
UN22MAR90
T6439VM
29. Mark rear pump shaft. Align using tie band until BEST
position is located where tie band is centered over a
cylinder port.
UN10FEB92
clean and free from scratches.
T7704AG
Remove clamp and tie band from coupler.
ALarge Piston Front Pump
BSmall Piston
CFeedback Rod
DSuction-Side Locator Notch
UN10FEB92
T7704AH
Rear Pump
Continued on next page TX,33,DY2949 1926AUG9717/21
AValve Block
UN27JAN92
BCoupler
CValve Plate
DStud (9 used)
T7681EX
TEFLON is a registered trademark of the DuPont Company. Continued on next page TX,33,DY2949 1926AUG9718/21
UN22MAR90
side of pump.
T6439YT
IMPORTANT: Make sure cradle remains on locator pin
when rear pump is picked up or pump
will not align properly with valve block.
TEFLON is a registered trademark of the DuPont Company. Continued on next page TX,33,DY2949 1926AUG9719/21
UN18DEC91
T7626CN
TX,33,DY2949 1926AUG9720/21
Specification
UN22MAR90
Suction Flange-to-Pump Valve
Block Inner Cap ScrewTorque .................................... 32 Nm (24 lb-ft)
Suction Flange-to-Pump Valve
Block Outer Cap ScrewTorque .................................... 46 Nm (34 lb-ft)
T6439YE
TX,33,DY2948 1926AUG971/1
4. Install O-rings.
UN27JAN92
5. Tighten cap screws to 10 Nm (90 lb-in.).
Specification
Mounting Cap ScrewTorque ....................................... 10 Nm (90 lb-in.)
T7681EP
6. Connect wiring harness.
TX,33,DY2907 1920AUG972/2
UN05AUG97
4. Remove cap screws (D). Remove solenoid (F).
T109727
6. Repair or replace as necessary.
TX,3360,AB257 1917FEB921/1
UN09JAN92
2. Install new O-rings (4, 5, and 15).
Specification
Solenoid-to-Valve Housing Cap
T7681AC
ScrewTorque .............................................................. 2.7 Nm (24 lb-in.)
Mounting Cap ScrewTorque ....................................... 10 Nm (90 lb-in.)
Bottom PlugTorque ...................................................... 47 Nm (35 lb-ft)
Spool Retaining PlugTorque ........................................ 72 Nm (53 lb-ft)
Retaining NutTorque .................................................... 31 Nm (23 lb-ft) 1Cap Screw (4 used)
2Connector
3Solenoid
4O-Ring
5O-Ring (6 used)
6Plug
7Seal
8Plug
9Housing
10Adapter (3 used)
11Cap Screw (4 used)
12Piston
13Retainer
14Spring
15O-Ring
16Plug
17Pin
18Nut (2 used)
TX,33,DY2908 1920AUG971/1
Specification
Solenoid-to-valve Housing Cap
ScrewTorque .............................................................. 2.7 Nm (24 lb-in.)
Cap ScrewTorque ........................................................ 23 Nm (17 lb-ft)
UN05AUG97
IRetainer (2 used)
JSpring
KPiston
LHousing
MO-Ring
T109729
NConnector
OSeal
PSocket Head Cap Screw (4 used)
QSolenoid
TX,33,DY2950 1926AUG971/1
UN27JAN92
2. Drain reservoir. Approximate capacity is 148 L (39 gal).
T7681ES
4. Disconnect lines (BD).
ALoad Sense Valve
5. Remove load sense valve (A).
BLS Port-to-Pressure Control Manifold Line
CT Port-to-Reservoir and Engine Speed Control
6. Repair or replace valve as necessary. Actuator Line
DX Port-to-Dual Solenoid Valve Block Line
7. Install valve. Tighten cap screws to 32 Nm (24 lb-ft). EPump Displacement Solenoid
Specification
Load Sense Valve Cap Screw (
559602)Torque............................................................. 32 Nm (24 lb-ft)
8. Connect lines.
TX,33,DY2951 1926AUG971/1
UN05AUG97
2. Drain reservoir. Approximate capacity is 151 L (40 gal).
T109726
4. Disconnect electrical connector (D).
5. Remove cap screws (C) and remove load sense valve. APump Regulator LS Port-to-Main Control Valve
Bottom Tee Port Line
6. Repair or replace valve as necessary. BPump Regulator Right Port-to-Dual Solenoid
Valve Manifold "D" Port Reservoir
CSocket Head Cap Screw (3 used)
7. Install valve. Tighten cap screws to 23 Nm (17 lb-ft).
DElectrical Connector
Specification
Cap ScrewTorque ........................................................ 23 Nm (17 lb-ft)
TX,3360,AB346 1917FEB921/1
UN27JAN92
T7681ER
ANut GSpring MPlug RPlug
BAdjusting Screw Plug HRetainer NSleeve SPlug (2 used)
CBackup Ring IPiston (2 used) OPin THousing
DO-Ring JBushing (2 used) PGuide UCap Screw (3 used)
EAdjusting Screw KStop (2 used) QBushing VPlug
FSpring LO-Ring (4 used)
TX,33,DY2910 1920AUG971/1
UN05AUG97
T109728
1Screw (4 used) 10Plate (2 used) 18Check Valve 27Plug
2Sleeve (2 used) 11Compression Spring 19O-Ring (4 used) 28Seal
3Nut (2 used) 12Compression Spring 20Plug (4 used) 29Screw (4 used)
4Cover 13Guide 21Plug (6 used) 30Plug
5O-Ring (2 used) 14Piston 22Plug (5 used) 31O-Ring
6Bolt (2 used) 15Socket Head Screw (3 23Orifice 32Bushing
7Ring (2 used) used) 24O-Ring (3 used) 33Piston
8O-Ring (2 used) 16Housing 25O-Ring 34Pin
9Plate 17Plug 26Solenoid
3. Install parts.
Specification
Solenoid-to-Valve Housing Cap
ScrewTorque ....................................................... 2.7 Nm (24 lb-in.)
Plug (30)Torque .................................................... 23 Nm (17 lb-ft)
TX,33,DW5001 1906JUN971/1
UN09JAN92
3. Disconnect lines (A and B).
T7626DC
5. Repair or replace pump as necessary.
Earlier Machine Shown
6. Install O-ring.
TX,33,DY2952 1926AUG971/1
UN04NOV88
T6439UO
33
ACap Screw (4 used) 3360
BCover 61
CHousing
DCover
UN09JAN92
T7626DD
TX,3360,AB262 1917FEB922/5
UN09JAN92
T7626DE
TX,3360,AB262 1917FEB923/5
ADrive Gear
BHousing
CBushing (4 used)
DSeal (2 used)
EBackup Retainer (2 used)
UN09JAN92
FPacking (2 used)
GDriven Gear
T7626DF
UN09JAN92
12. Install covers and cap screws.
T7681AE
ABushing Grooves
BSuction Side-Larger Hole
CSeal (2 used)
DBackup Retainer (2 used)
UN18OCT88
T6439UP
TX,3360,AB262 1917FEB925/5
UN09JAN92
T7681AF
TX,3360,AB267 1917FEB921/1
UN19JAN90
debris in bottom of filter can.
IT4633
process.
902525,F4A 1918JUL941/1
4. Remove valve.
6. Install valve.
7. Connect lines.
UN13JAN92
AValve-to-Reservoir line
BValve-to-Propel Pilot Controller Line
CValve-to-Right Pilot Controller Line (P Port)
T7681AU
DValve-to-Right Pilot Controller Line (T Port)
EValve-to-Propel Pilot Controller Line
FValve-to-Left Pilot Controller (P Port)
GValve-to-Left Pilot Controller (T Port)
HControl Linkage
IValve-to-Load Sense Valve (Serial No.
556935) Dual Solenoid Valve (P Port) (Serial No.
556936)
TX,33,DY2953 1926AUG971/1
UN01JAN94
TP40163
33
3360
67
1906DEC91
T7660AL
AShut-Off Lever CShut-Off Valve DLever ECap Screw
BRod
1. Stop engine.
CAUTION: Machine may move if adjustment
is incorrect. Prior to checking shut-off lever
2. Remove cover from left console (beside seat) in
adjustment, make sure the area around
operators station.
machine is clear.
3. Remove cover underneath operators station. (If
5. Check adjustment by pulling shut-off lever (A) up to
equipped).
the OFF position. Start engine and set engine
speed at low idle. Move pilot control levers.
4. Push pilot shut-off lever (A) forward to the ON
Hydraulic functions must NOT operate. If functions
position. Adjust ball joints on rod (B) ends to
move, repeat adjustment procedure.
specified clearance between lever (D) and cap
screw (E).
Specification
Pilot Shut-Off Valve Linkage
Clearance Between Lever and
Cap Screw ........................................... 1.5 0.5 mm (0.06 0.02 in.)
TX,902520,UU735 1930SEP942/2
7. Connect lines.
UN13JAN92
8. Install valve. Tighten cap screw to 9 Nm (85 lb-in.)
Specification
Dig Function Pilot Controller
Attaching Cap ScrewTorque ......................................... 9 Nm (85 lb-in.)
T7681AV
9. Install lever.
UN13JAN92
T7681AW
Left Pilot Controller
UN13JAN92
T7681AX
Right Pilot Controller
TX,3360,AB350 1920APR953/3
APilot Controller
BU-Joint
CCam
DCoupling
T7681AY
6. Install parts.
Specification
Cap Screw Through
Plate-to-HousingTorque ............................................... 49 Nm (36 lb-ft)
UN23JAN92
U-joint (C) and install. Tighten to 24 Nm (18 lb-ft).
Specification
U-Joint Through
T7681AZ
Plate-to-HousingTorque ............................................... 24 Nm (18 lb-ft)
TX,3360,AB353 1917FEB922/2
UN16JAN92
T7681BT
TX,33,DY2954 1926AUG971/2
Specification
Attaching Cap ScrewTorque ........................................ 49 Nm (36 lb-ft)
TX,33,DY2954 1926AUG972/2
UN16JAN92
T7681BT
Continued on next page TX,33,DY2955 1926AUG971/2
UN05AUG97
7. Repair or replace valve as necessary.
T109490
Specification
Attaching Cap ScrewTorque ........................................ 49 Nm (36 lb-ft)
Specification
Lever BracketMounting Cap
Screw (547584)Torque............................................. 88 Nm (65 lb-ft)
TX,33,DY2955 1926AUG972/2
33
3360
75
UN01JAN94
TP40158
1. Remove pedals.
UN05AUG97
T110464
(Serial No. 547853)
UN06AUG97
T109489
33
3360
79
UN16JAN92
T7681BW
TX,33,DY2956 1926AUG974/7
7. Install parts.
ASpring
BGuide
CPiston
DSpring
ESpacer (Retainer)
FPusher
GO-Ring
HCap
ISeal
UN16JAN92
T7681BX
TX,33,DY2956 1926AUG975/7
8. Install piston (B), O-ring (C), and plug (A). Tighten plug
(A) to 49 Nm (36 lb-ft).
Specification
Valve Piston PlugTorque ............................................. 49 Nm (36 lb-ft)
UN16JAN92
T7681BW
UN05AUG97
T110464
(Serial No. 547853)
UN06AUG97
T109489
Remove And Install Dig Pilot Check Valve Block (Serial No. 543990559935)
33
3360
81
UN11APR95
T8448AB
ASwing Brake Release E1Swing Right H1Boom Lower J2Bucket Dump
Switch E2Swing Right H2Boom Lower K1Arm In
BAuto Idle Switch F1Swing Left I1Bucket Curl K2Arm In
CLines From Dig Pilot F2Swing Left I2Bucket Curl L1Arm Out
Controllers G1Boom Raise J1Bucket Dump L2Arm Out
DLines to Control Valve Pilot G2Boom Raise
Caps
1. Release pressure in hydraulic reservoir. Unlock must be surgically removed within a few
hydraulic tank fill cap. Slowly turn cap to release air hours or gangrene may result. Doctors
pressure. unfamiliar with this type of injury should
reference a knowledgeable medical source.
2. Disconnect swing brake release switch wiring lead Such information is available from Deere &
(A) and auto idle switch wiring lead (B). Company Medical Department in Moline,
Illinois, U.S.A.
CAUTION: Escaping fluid under pressure
3. Disconnect lines.
can penetrate the skin causing serious
injury. Avoid the hazard by relieving
4. Remove valve block.
pressure before disconnecting hydraulic or
other lines. Tighten all connections before
5. Replace valve block as necessary.
applying pressure. Search for leaks with a
piece of cardboard. Protect hands and body
6. Install valve block.
from high pressure fluids.
7. Connect lines. Connect wiring leads.
If an accident occurs, see a doctor
immediately. Any fluid injected into the skin
TX,33,DY2957 1926AUG971/1
Remove And Install Dig Pilot Check Valve Block (Serial No. 559936)
33
3360
82
UN11APR95
T8448AB
ASwing Brake Release F1Swing Valve Left Rear I1Bucket Curl Valve top Pilot K2Boom Raise
Switch Pilot Cap Cap Valve-to-Right Pilot
BAuto Idle Switch F2Swing Left-to-Left Pilot I2Bucket Curl Valve-to-Right Controller
CLines From Dig Pilot Controller Pilot Controller L1Boom Lower Valve Front
Controllers G1Arm Valve In Rear Pilot J1Bucket Dump Valve Pilot Cap
DLines to Boom, Arm, Swing Cap Bottom Pilot Cap L2Boom Lower
Control Valve Pilot Caps G2Arm Valve In-to-Right J2Bucket Dump Valve-to-Right Pilot
E1Swing Valve Right Front Pilot Controller Valve-to-Right Pilot Controller
Pilot Cap H1Arm Valve Out Front Pilot Controller
E2Swing Right-to-Left Pilot Cap K1Boom Raise Valve Rear
Controller H2Arm Valve Out-to-Right Pilot Cap
Pilot Controller
33
3360
83
TX,33,DY2958 1926AUG972/2
TX,33,DY2959 1926AUG971/3
UN16JAN92
T7681BZ
UN23AUG88
Protect hands and body from high pressure
fluids.
X9811
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.
7. Connect lines.
TX,33,DY2959 1926AUG973/3
UN16JAN92
T7681CA
APlug (3 used) BO-Ring (3 used) CBall Seat (3 used) DBall (3 used)
2. Remove ball seats (C) and balls (D). 4. Install parts and new O-rings (B).
TX,3360,AB368 1917FEB921/1
UN23AUG88
Protect hands and body from high pressure
fluids.
X9811
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.
UN22JAN92
5. Remove clamps (C and F).
T7681DG
APlate
BControl Valve-to-Bucket Cylinder Piston End Line
CClamp
DControl Valve-to-Arm Cylinder Piston End Line
EControl Valve-to-Arm Cylinder Rod End Line
FClamp
GControl Valve-to-Bucket Cylinder Rod End Line
33
3360
88
UN22JAN92
T7681DH
(Serial No. 543989)
ATo Oil Cooler Line HLine to Bucket Cylinder NLine to Dig Pilot Check ULine to Pilot Filter
BTo Swing Motor Line Piston End Valve Block K2 Port VLine to Swing Motor
CTo Swing Motor Line ILine to Dig Pilot Check OLine to Reservoir WLine to Propel Pilot Check
DLine to Dig Pilot Check Valve Block I1 Port PLine to Rotary Manifold Valve Block
Valve Block F2 Port JLine to Bucket Cylinder QLine to Rotary Manifold XLine to Dual Solenoid
ELine to Dig Pilot Check Rod End RLine to Arm Cylinder Block
Valve Block G2 Port KLine to Left Propel Reverse Piston End YPressure Control Manifold
FLine to Boom Cylinder Rod LLine to Propel Pilot SLine to Dual Solenoid Line (Z2 Port)
End Controller Block
GLine to Boom Cylinder MLine to Left Propel TLine to Arm Cylinder Rod
Piston End Forward End
33
3360
89
UN22JAN92
T7681DI
(Serial No. 543989)
ALine-to-Right Propel DLine-to-Dig Pilot Check FLine-to-Dig Pilot Check HLine-to-Swing Gearbox
Reverse Valve J1 Port Valve E1 Port
BLine From Hydraulic Pump ELine-to-Dig Pilot Check GLine-to-Dig Pilot Check
CLine-to-Left Propel Reverse Valve L1 Port Valve H1 Port
33
3360
90
UN11APR95
T8448AD
(Serial No. 543990556935)
1To Oil Cooler Line 8Line-to-Bucket Cylinder 14Line-to-Dig Pilot Check 21Line-to-Pilot Filter
2To Swing Motor Line Piston End Valve Block K2 Port 22Line-to-Swing Motor
3To Swing Motor Line 9Line-to-Dig Pilot Check 15Line-to-Reservoir 23Line-to-Propel Pilot Check
4Line-to-Dig Pilot Check Valve Block I1 Port 16Line-to-Rotary Manifold Valve Block
Valve Block F2 Port 10Line-to-Bucket Cylinder 17Line-to-Rotary Manifold 24Line-to-Dual Solenoid
5Line-to-Dig Pilot Check Rod End 18Line-to-Arm Cylinder Block
Valve Block G2 Port 11Line-to-Left Propel Piston End 25Pressure Control Manifold
6Line-to-Boom Cylinder Rod Reverse 19Line-to-Dual Solenoid Line (Z2 Port)
End 12Line-to-Propel Pilot Block 26Orifice (2 used)
7Line-to-Boom Cylinder Controller 20Line-to-Arm Cylinder Rod 27Orifice
Piston End 13Line-to-Left Propel End
Forward
33
3360
91
UN11APR95
T8448AC
(Serial No. 543990556935)
ALine-to-Right Propel DLine-to-Dig Pilot Check FLine-to-Dig Pilot Check HLine-to-Swing Gearbox
Reverse Valve J1 Port Valve E1 Port IOrifice (2 used)
BLine From Hydraulic Pump ELine-to-Dig Pilot Check GLine-to-Dig Pilot Check JOrifice
CLine-to-Left Propel Reverse Valve L1 Port Valve H1 Port
TX,33,DY2960 1926AUG976/14
Specification
Swing Valve-to-ManifoldTorque ................................... 49 Nm (36 lb-ft)
Boom Valve-to-ManifoldTorque ................................... 86 Nm (63 lb-ft)
Bucket Valve-to-Manifold
Torque ............................................................................. 86 Nm (63 lb-ft)
Left Propel Valve-to-Manifold
Torque ............................................................................. 49 Nm (36 lb-ft)
Arm Valve-to-ManifoldTorque ...................................... 86 Nm (63 lb-ft)
Right Propel Valve-to-Manifold
Torque ............................................................................. 49 Nm (36 lb-ft)
AManifold
UN22JAN92
BSwing Valve
CBoom Valve
DBucket Valve
ELeft Propel Valve
T7681DK
FRight Propel Valve
GArm Valve
HPressure Control Manifold
TX,33,DY2960 1926AUG978/14
Specification
Mounting Cap ScrewsTorque ...................................... 75 Nm (55 lb-ft) UN22JAN92
T7681DJ
33
3360
93
UN22JAN92
T7681DI
(Serial No. 543989)
ALine-to-Right Propel DLine-to-Dig Pilot Check FLine-to-Dig Pilot Check HLine-to-Swing Gearbox
Reverse Valve J1 Port Valve E1 Port
BLine From Hydraulic Pump ELine-to-Dig Pilot Check GLine-to-Dig Pilot Check
CLine-to-Left Propel Reverse Valve L1 Port Valve H1 Port
33
3360
94
UN11APR95
T8448AC
(Serial No. 543990556935)
ALine-to-Right Propel DLine-to-Dig Pilot Check FLine-to-Dig Pilot Check HLine-to-Swing Gearbox
Reverse Valve J1 Port Valve E1 Port IOrifice (2 used)
BLine From Hydraulic Pump ELine-to-Dig Pilot Check GLine-to-Dig Pilot Check JOrifice
CLine-to-Left Propel Reverse Valve L1 Port Valve H1 Port
33
3360
95
UN22JAN92
T7681DH
(Serial No. 543989)
ATo Oil Cooler Line HLine-to-Bucket Cylinder NLine-to-Dig Pilot Check ULine-to-Pilot Filter
BTo Swing Motor Line Piston End Valve Block (K2) VLine-to-Swing Motor
CTo Swing Motor Line ILine-to-Dig Pilot Check OLine-to-Reservoir WLine-to-Propel Pilot Check
DLine-to-Dig Pilot Check Valve Block (I1) PLine-to-Rotary Manifold Valve Block
Valve block (F2) JLine-to-Bucket Cylinder QLine-to-Rotary Manifold XLine-to-Dual Solenoid
ELine-to-Dig Pilot Check Rod End RLine-to-Arm Cylinder Block
Valve Block (G2) KLine-to-Left Propel Reverse Piston End YPressure Control Manifold
FLine-to-Boom Cylinder Rod LLine-to-Propel Pilot SLine-to-Dual Solenoid Line (Z2 Port)
End Controller Block
GLine-to-Boom Cylinder MLine-to-Left Propel TLine-to-Arm Cylinder Rod
Piston End Forward End
33
3360
96
UN11APR95
T8448AD
(Serial No. 543990559935)
1To Oil Cooler Line 8Line-to-Bucket Cylinder 14Line-to-Dig Pilot Check 21Line-to-Pilot Filter
2To Swing Motor Line Piston End Valve Block (K2) 22Line-to-Swing Motor
3To Swing Motor Line 9Line-to-Dig Pilot Check 15Line-to-Reservoir 23Line-to-Propel Pilot Check
4Line-to-Dig Pilot Check Valve Block (I1) 16Line-to-Rotary Manifold Valve Block
Valve Block (F2) 10Line-to-Bucket Cylinder 17Line-to-Rotary Manifold 24Line-to-Dual Solenoid
5Line-to-Dig Pilot Check Rod End 18Line-to-Arm Cylinder Block
Valve Block (G2) 11Line-to-Left Propel Piston End 25Pressure Control Manifold
6Line-to-Boom Cylinder Rod Reverse 19Line-to-Dual Solenoid Line (Z2 Port)
End 12Line-to-Propel Pilot Block 26Orifice (2 used)
7Line-to-Boom Cylinder Controller 20Line-to-Arm Cylinder Rod 27Orifice
Piston End 13Line-to-Left Propel End
Forward
UN22JAN92
25. Fill reservoir. Approximate capacity is 148 L (39 gal).
APlate
BControl Valve-to-Bucket Cylinder Piston End Line
T7681DG
CClamp
DControl Valve-to-Arm Cylinder Piston End Line
EControl Valve-to-Arm Cylinder Rod End Line
FClamp
GControl Valve-to-Bucket Cylinder Rod End Line
TX,33,DY2960 1926AUG9714/14
UN23AUG88
Protect hands and body from high pressure
fluids.
X9811
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.
UN22AUG97
DElectrical Connector
EMain Control Valve Swing Valve Left Rear Pilot
Cap-to-Dig Shuttle Valve F1 Port Line
FMain Control Valve Swing Section A Port-to-Swing
Motor Left Front Port Line
T109755
GMain Control Valve Swing Section B Port-to-Swing
Motor Right Front Port Line
HMain Control Valve Swing Valve Right Front Pilot
Cap-to-Dig Shuttle Valve E1 Port Line
IMain Control Valve P2 Port-to-Dual Solenoid Valve
P Port Line
JMain Control Manifold P2 Port-to-Hydraulic Outlet
Port Line
KMain Control Valve Boom Lower Front Pilot Cap
Port-to-Main Control Valve Boom Raise Anti-Drift
Valve X Port Line
LMain Control Valve Boom Lower Front Pilot Cap
Port-to-Dig Shuttle Valve L1 Port Line
MMain Control Valve Boom Lower B Port-to-Boom
Cylinder Rod End Port Line
NMain Control Valve Boom Raise Anti-Drift Valve A
Port-to-Boom Cylinder Head End Port Line
OMain Control Valve Boom Raise Anti-Drift Valve X
Port-to-Main Control Valve Boom Lower Front
Pilot Cap Port Line
UN05AUG97
T109756
Rear View Of Control Valve Manifold
TX,33,DY2961 1926AUG974/11
UN05AUG97
EMain Control Valve Arm Raise Front Pilot
Cap-to-Dig Shuttle Valve H1 Port Line
T109757
UN05AUG97
Cap-to-Dig Shuttle Valve C1 Port Line
BMain Control Valve Return Manifold Left Side
Port-to-Oil Cooler Bottom Port Line
CMain Control Manifold Rear S2 Port-to-Monoblock
Control Valve Bottom Rear Port Line
T109758
DMain Control Valve Boom Raise Rear Pilot
Cap-to-Dig Shuttle Valve K1 Port Line
EMain Control Valve Bottom Middle Port-to-Main Bottom View Of Control Valve Manifold
Hydraulic Pump Top Rear Port Line
FMain Control Valve Forward Bottom Port-to-Main
Hydraulic Pump Regulator LS Port Line
GCap Screw (3 used)
HWasher (3 used)
IMain Control Valve Manifold Rear Bottom
Port-to-Monoblock Control Valve Left Rear Port
Line
Specification
Boom Valve-to-ManifoldTorque ................................... 86 Nm (63 lb-ft)
Swing Valve-to-ManifoldTorque ................................... 49 Nm (36 lb-ft)
Arm Valve-to-ManifoldTorque ...................................... 86 Nm (63 lb-ft)
UN05AUG97
T109773
Continued on next page TX,33,DY2961 1926AUG977/11
UN05AUG97
Port-to-Oil Cooler Bottom Port Line
CMain Control Manifold Rear S2 Port-to-Monoblock
Control Valve Bottom Rear Port Line
DMain Control Valve Boom Raise Rear Pilot
Cap-to-Dig Shuttle Valve K1 Port Line
T109758
EMain Control Valve Bottom Middle Port-to-Main
Hydraulic Pump Top Rear Port Line
FMain Control Valve Forward Bottom Port-to-Main Bottom View Of Control Valve Manifold
Hydraulic Pump Regulator LS Port Line
GCap Screw (3 used)
HWasher (3 used)
IMain Control Valve Manifold Rear Bottom
Port-to-Monoblock Control Valve Left Rear Port
Line
TX,33,DY2961 1926AUG978/11
33
3360 AMain Control Valve Manifold LSA
104 Port-to-Monoblock Control Valve LAS Port Line
BMain Control Valve Manifold Z2 Port-to-Dig Shuttle
Valve S1 Port Line
CMain Control Valve Manifold Z1 Port-to-Propel
Pilot Check Valve Line
DMain Control Valve Manifold Bottom Forward
Port-to-Monoblock Control Valve LS Port Line
UN05AUG97
T109756
Front View Control Valve Manifold
UN22AUG97
Port-to-Hydraulic Tank Line
DElectrical Connector
EMain Control Valve Swing Valve Left Rear Pilot
Cap-to-Dig Shuttle Valve F1 Port Line
FMain Control Valve Swing Section A Port-to-Swing
T109755
Motor Left Front Port Line
GMain Control Valve Swing Section B Port-to-Swing
Motor Right Front Port Line
HMain Control Valve Swing Valve Right Front Pilot
Cap-to-Dig Shuttle Valve E1 Port Line
IMain Control Valve P2 Port-to-Dual Solenoid Valve
P Port Line
JMain Control Manifold P2 Port-to-Hydraulic Outlet
Port Line
KMain Control Valve Boom Lower Front Pilot Cap
Port-to-Main Control Valve Boom Raise Anti-Drift
Valve X Port Line
LMain Control Valve Boom Lower Front Pilot Cap
Port-to-Dig Shuttle Valve L1 Port Line
MMain Control Valve Boom Lower B Port-to-Boom
Cylinder Rod End Port Line
NMain Control Valve Boom Raise Anti-Drift Valve A
Port-to-Boom Cylinder Head End Port Line
OMain Control Valve Boom Raise Anti-Drift Valve X
Port-to-Main Control Valve Boom Lower Front
Pilot Cap Port Line
TX,33,DY2961 1926AUG9711/11
UN05AUG97
2. Release pressure in hydraulic reservoir. Loosen
hydraulic fill cap. Slowly turn cap to release pressure.
T109860
3. Drain reservoir. Approximate capacity is 151 L (40 gal).
Specification
Return Manifold Mounting Cap
ScrewTorque ................................................................ 55 Nm (40 lb-ft)
9. Connect lines.
TX,33,DT5054 1910JUN971/1
TX,33,DY2963 1926AUG971/2
8. Install hose.
UN05AUG97
9. Fill reservoir. Approximate capacity is 151 L (40 gal).
T109862
TX,33,DY2963 1926AUG972/2
UN22JAN92
Specification
Arm Cylinder Restrictor Jam Nut
(556935) Cap ScrewTorque ..................................... 60 Nm (44 lb-ft)
T7681DL
5. Adjust restrictor. (See procedure in Group 9025-20.)
(Serial No. 546276)
UN11APR95
T8448AE
UN05AUG97
2. Remove boom cylinder restrictor and lock nut (A) from
control valve manifold.
T109979
control valve manifold.
Specification
Arm Cylinder Restrictor Jam Nut
(556935) Cap ScrewTorque ..................................... 60 Nm (44 lb-ft)
TX,33,DY2965 1926AUG971/1
5. Install parts.
UN27JAN92
6. Connect oil line.
T7681DM
ACap
BO-Ring
CSpring
DValve
EControl Valve Manifold
TX,33,DY2966 1926AUG972/2
33
3360
111
UN05AUG97
T109801
TX,33,DT5020 1909JUN972/3
Specification
UN05AUG97
Safety Relief ValvePlug (
556935)Torque............................................................. 80 Nm (59 lb-ft)
T109802
TX,33,DT5020 1909JUN973/3
3. Install parts.
UN04MAR95
AManifold
BSpool
CSpring Seat
T8455AK
DSpring
ESpring Retainer
FO-Ring
GPlug
TX,3360,AB383 1920APR951/1
UN05AUG97
1. Remove plugs (A and B).
Specification
Combined Function Shuttle Valve
Plug (556936)Torque .............................................. 20 Nm (54 lb-in.)
TX,33,DY2967 1926AUG971/1
Specification
Combined Function Shuttle Valve
UN05AUG97
Plug (556936)Torque .............................................. 20 Nm (54 lb-in.)
APlug
BO-Ring
T110213
CSpring Retainer
DSpring
EBall
FPlug
GSpring Retainer
HSpring
ISpring Seat
JSpool
KO-Ring
LPlug
TX,3360,AB383 1920APR951/1
UN27JAN92
pressure.
T7681DN
3. Disconnect lines (A, B and D).
ALine From Propel Pilot Check Valve Block
4. Remove manifold (E). BLoad Sense-to-Pump Regulator Line
CPilot Pressure Regulating Valve
5. Repair or replace manifold as necessary. Note that DPilot Filter and Dual Solenoid Block Line
valves in manifold are covered in other areas in this EPressure Control Manifold
FPressure Control Manifold Line (Z2 Port)
group.
Specification
Mounting Cap ScrewTorque ...................................... 120 Nm (88 lb-ft)
7. Connect lines.
8. Fill reservoir.
TX,33,DY2968 1926AUG971/1
UN27JAN92
T7681DR
TX,33,DY2969 1926AUG972/2
UN05AUG97
2. To gain access to relief valve, disconnect and tag
hydraulic line (A).
T110211
3. Remove valve (B).
Specification
Load Sense Relief Valve Plug
(556936)Torque ..................................... 90150 Nm (66110 lb-ft)
TX,33,DY2970 1926AUG971/1
TX,33,DY2971 1926AUG971/2
UN05AUG97
5. Adjust valve. (See procedure in Group 9025-25.)
T110212
ARetainer (2 used)
BSpring
CRetainer
DValve Body
ENut
FAdjustment Screw
GSeal
HO-Ring
TX,33,DY2971 1926AUG972/2
UN27JAN92
1. Release pressure in hydraulic reservoir. Unlock
hydraulic tank fill cap. Slowly turn cap to release air
pressure.
T7681DS
2. Remove parts (AE and G and H).
APlug
3. Inspect parts and replace as necessary.
BShim (as required)
CSpring
4. Install parts. Tighten plug (A) to 80 Nm (59 lb-ft). DKeeper
EValve
Specification FPressure Control Manifold
Circuit Relief and Anti-Cavitation GO-Ring
Valve (556935)Torque.............................................. 80 Nm (59 lb-ft) HInsert
TX,33,DY2972 1926AUG971/1
UN27JAN92
1. Remove valve (D) from pressure control manifold (E).
APin
BShim (as required)
CSpring
DValve
EHousing
FPiston
GGuide
TX,33,DY2973 1926AUG971/1
UN05AUG97
2. Loosen locknut (A). Remove valve (B).
T110697
4. Install valve. Tighten locknut (A) to 3035 Nm (22
26 lb-ft).
Specification
Pilot Pressure Regulating Valve
(556936)Torque ......................................... 3035 Nm (2226 lb-ft)
TX,33,DY2974 1926AUG971/1
2. Install valve.
GO-Ring
HPlug
INut
JAdjustment Screw
TX,33,DY2975 1926AUG971/1
TX,33,DY2976 1926AUG971/2
UN27JAN92
T7681DU
TX,33,DY2976 1926AUG972/2
UN05AUG97
5. Replace O-rings and seals. Install valve. Tighten valve
to 5055 Nm (3640 lb-ft).
T110216
Specification
Power Boost Solenoid Valve
Torque .............................................................. 5055 Nm (3640 lb-ft)
Specification
Solenoid NutTorque ...................................................... 8 Nm (71 lb-in.)
TX,33,DY2977 1926AUG972/2
Specification
UN27JAN92
Circuit Relief and Anti-Cavitation
Valve (556935)Torque.............................................. 80 Nm (59 lb-ft)
T7681DV
TX,33,DY2978 1926AUG972/2
TX,33,DY2983 1927AUG971/2
Specification
UN05AUG97
Circuit Relief and Anti-Cavitation
Valve (556935)Torque.............................................. 80 Nm (59 lb-ft)
T110700
TX,33,DY2983 1927AUG972/2
Disassemble And Assemble Boom, Arm, And Bucket Valve Section (Serial No. 556935)
33
3360
122
UN11APR95
T8448AF
ASpool EBalance Valve ILoad Sense Passage MPilot Cap Relief Valve (Air
BShuttle Valve FPump Supply JShuttle Valve Bleed Valve) (2 used)
CLoad Sense Passage GBalance Valve KWork Port NPilot Check Valve 33
DReturn Passage HReturn Passage LWork Port 3360
123
Tighten pilot cap relief valves (M) to 6 Nm (55 lb-in.).
Specification
Pilot Cap Relief ValveTorque................................. 6 Nm (55 lb-in.)
TX,33,DY2979 1926AUG972/8
UN27JAN92
Section 99 for instruction to make tool.) Clamp in vise.
AO-Ring
BShim (as required)
T7681DX
CSpring
DCap
EHousing
FSpool
GCover
HCap Screw (2 used)
INut
JSpool Stop Screw
33
3360
124
UN27JAN92
T7681DY
TX,33,DY2979 1926AUG974/8
UN27JAN92
T7681DZ
TX,33,DY2979 1926AUG975/8
UN27JAN92
Tighten plug to 10 Nm (90 lb-in.).
Specification
Balance Valve PlugTorque ......................................... 10 Nm (90 lb-in.) T7681EA
UN27JAN92
Specification
Spool PlugTorque ...................................................... 100 Nm (75 lb-ft)
T7681DZ
UN27JAN92
T7681DY
Continued on next page TX,33,DY2979 1926AUG977/8
Specification
Valve cover-to-Housing Cap
ScrewTorque ................................................................ 25 Nm (18 lb-ft)
Specification
Spool Stop Screw NutTorque ...................................... 60 Nm (45 lb-ft)
AO-Ring
UN27JAN92
BShim (as required)
CSpring
DCap
EHousing
FSpool
T7681DX
GCover
HCap Screw (2 used)
INut
JSpool Stop Screw
TX,33,DY2979 1926AUG978/8
UN27JAN92
T7681EC
AMake-Up Valve CBalance Valve DPilot Check Valve EPilot Cap Relief Valve (Air
BBall Bleed Valve)
Tighten pilot check valve (D) to 9 Nm (80 lb-in.). Tighten pilot cap relief valve (E) to 6 Nm (55 lb-in.).
Specification Specification
Pilot Check ValveTorque ....................................... 9 Nm (80 lb-in.) Pilot Cap Relief ValveTorque................................. 6 Nm (55 lb-in.)
UN27JAN92
AO-Ring
BShim (as required)
CSpring
DCap
EHousing
T7681DX
FSpool
GCover
HCap Screw (2 used)
INut
JSpool Stop Screw
UN27JAN92
T7681DY
UN27JAN92
T7681DZ
TX,3360,AB397 1920APR953/6
7. Remove plug (C) and ball (B) from balance valve (A).
Hold the balance valve in a vise by the stem end.
Clean parts.
UN27JAN92
T7681EB
Continued on next page TX,3360,AB397 1920APR954/6
UN27JAN92
Specification
Spool Stop Screw NutTorque ...................................... 60 Nm (45 lb-ft)
T7681DZ
UN27JAN92
T7681DY
Continued on next page TX,3360,AB397 1920APR955/6
Specification
Valve Cover-to-Housing Cap
ScrewTorque ................................................................ 25 Nm (18 lb-ft)
Specification
Valve Cover-to-Housing Cap
ScrewTorque ................................................................ 60 Nm (45 lb-ft)
UN27JAN92
AO-Ring
BShim (as required)
CSpring
DCap
EHousing
T7681DX
FSpool
GCover
HCap Screw (2 used)
INut
JSpool Stop Screw
TX,3360,AB397 1920APR956/6
UN27JAN92
T7681ED
AMake-Up Valve DSpool GPilot Check Valve (2 used) HPilot Cap Relief Valve (Air
BSpring EBalance Valve (Serial No. 543989) Bleed Valve) (2 used)
CPoppet FSpring
Tighten pilot check valve (G) to 9 Nm (80 lb-in.). Tighten pilot cap relief valve (H) to 6 Nm (55 lb-in.).
Specification Specification
Pilot Check ValveTorque ....................................... 9 Nm (80 lb-in.) Pilot Cap Relief ValveTorque................................. 6 Nm (55 lb-in.)
UN27JAN92
Replacement parts are not available.
T7681DX
AO-Ring
BShim (as required)
CSpring
DCap
EHousing
FSpool
GCover
HCap Screw (2 used)
INut
JSpool Stop Screw
UN27JAN92
T7681DY
UN27JAN92
T7681DZ
TX,33,DY2980 1926AUG973/6
UN27JAN92
threads of plug. Tighten plug (E) to 10 Nm (90 lb-in.).
Specification
Balance Valve PlugTorque ......................................... 10 Nm (90 lb-in.)
T7681EE
ABalance Valve
BPoppet
CRetainer
DSpring
EPlug
FShims
UN27JAN92
Specification
Spool PlugTorque ........................................................ 60 Nm (45 lb-ft)
T7681DZ
TX,33,DY2980 1926AUG975/6
Specification
Valve Cover-to-Housing Cap
ScrewTorque ................................................................ 25 Nm (18 lb-ft)
Specification
Spool Stop Screw NutTorque ...................................... 60 Nm (45 lb-ft)
AO-Ring
UN27JAN92
BShim (as required)
CSpring
DCap
EHousing
FSpool
T7681DX
GCover
HCap Screw (2 used)
INut
JSpool Stop Screw
TX,33,DY2980 1926AUG976/6
Disassemble And Assemble Boom, Arm, And Swing Control Valve (Serial No. 556936)
33
3360
136
UN05AUG97
T109788
Valve Shown Removed From Manifold
TX,33,DY2962 1926AUG971/1
33
3360
137
UN23JAN92
T7681EY
TX,33,DY2981 1926AUG972/2
UN05AUG97
1. Make-up valve cannot be repaired. It must be replaced
as a complete assembly. Valve cannot be
disassembled and assembled.
T110699
2. Inspect O-rings (A and B) and valve (C). Replace as
necessary.
Specification
Propel Circuit Make-Up Valve
Plug (556936)Torque ............................................... 80 Nm (59 lb-ft)
TX,33,DY2984 1927AUG971/1
TX,33,DY2982 1926AUG971/1
UN05AUG97
H); and remove flanges. Label lines to aid in
installation.
APropel Left Reverse Return Loop
T-Fitting-to-Propel Pilot Check Valve Block
T110436
Bottom Right Port Line
BPropel Right Reverse Return Loop
T-Fitting-to-Propel Pilot Check Valve Block
Bottom Left Port Line
CBucket Curl Valve Pilot Cap Port-to-Dig Pilot
Check Valve I1 Port Line
DMonoblock Control Valve LSA Port-to-Boom, Arm,
Swing Main Control Valve LSA Port Line
ELeft Propel Valve A Port-to-Rotary Manifold #1
Port Line
FRight Propel Valve A Port-to-Rotary Manifold #3
Port Line
GLeft Propel Valve B Port-to-Rotary Manifold #2
Port Line
HRight Propel Valve B Port-to-Rotary Manifold #4
Port Line
UN05AUG97
IMonoblock Control Valve LS Port-to-Boom, Arm,
Swing Main Control Valve Bottom Forward
T-Fitting Port Line
JMonoblock Control Valve Pressure Port-to-Boom,
Arm, Swing Main Control Valve Bottom Rear Port
T110435
Line
KBucket Valve-to-Cylinder Rod End Port Line
LMonoblock Control Valve Bottom Forward Hydraulic Lines Removed For Clarity
Port-to-Swing Motor U Port Line
MBucket Valve-to Cylinder Head End Port Line
NBucket Dump Valve Bottom Pilot Cap-to-Dig Pilot
Check Valve J1 Port Line
ORight Forward Propel Pilot End Cap-to-Dig Pilot
Check Valve I1 Port Line
PLeft Forward Propel Pilot End Cap-to-Dig Pilot
Check Valve J1 Port Line
QMonoblock Control Valve Rear Feed Port-to-Main
Hydraulic Pump Top Rear Port Line
RMonoblock Control Valve Bottom Rear
Port-to-Return Manifold Rear Left Port Line
UN05AUG97
7. Remove cap screws (A). Remove monoblock.
T110437
9. Install new O-rings.
TX,33,DW5002 1916JUL974/6
Specification
Mounting Cap ScrewsTorque ...................................... 75 Nm (55 lb-ft)
UN05AUG97
11. Install hydraulic line (B).
T110437
Specification
ReservoirCapacity ............................................................ 151 L (40 gal)
UN05AUG97
BPropel Right Reverse Return Loop
T-Fitting-to-Propel Pilot Check Valve Block
Bottom Left Port Line
CBucket Curl Valve Pilot Cap Port-to-Dig Pilot
Check Valve I1 Port Line
T110435
DMonoblock Control Valve LSA Port-to-Boom, Arm,
Swing Main Control Valve LSA Port Line
ELeft Propel Valve A Port-to-Rotary Manifold #1
Port Line
FRight Propel Valve A Port-to-Rotary Manifold #3
Port Line
GLeft Propel Valve B Port-to-Rotary Manifold #2
Port Line
HRight Propel Valve B Port-to-Rotary Manifold #4
Port Line
IMonoblock Control Valve LS Port-to-Boom, Arm,
Swing Main Control Valve Bottom Forward
T-Fitting Port Line
JMonoblock Control Valve Pressure Port-to-Boom,
Arm, Swing Main Control Valve Bottom Rear Port
Line
UN05AUG97
KBucket Curl Valve-to-Cylinder Rod End Port Line
LMonoblock Control Valve Bottom Forward
Port-to-Swing Motor U Port Line
MBucket Dump Valve-to-Cylinder Head End Port
Line
T110436
NBucket Dump Valve Bottom Pilot Cap-to-Dig Pilot
Check Valve J1 Port Line
ORight Forward Propel Pilot End Cap-to-Dig Pilot
Check Valve I1 Port Line
PLeft Forward Propel Pilot End Cap-to-Dig Pilot
Check Valve J1 Port Line
QMonoblock Control Valve Rear Feed Port-to-Main
Hydraulic Pump Top Rear Port Line
RMonoblock Control Valve Bottom Rear
Port-to-Return Manifold Rear left Port Line
TX,33,DW5002 1916JUL976/6
Disassemble And Assemble Monoblock Control Valve Manifold (Serial No. 556936)
33
3360
142
UN05AUG97
T110432
TX,33,DW5018 1922JUL972/2
UN05AUG97
2. Remove valve (A).
Specification
Safety Relief Valve Plug
(556936)Torque ..................................... 120150 Nm (8892 lb-ft)
TX,33,DW5023 1923JUL971/1
Specification
Safety Relief Valve Plug
(556936)Torque ..................................... 120150 Nm (8892 lb-ft)
UN05AUG97
APlug
BBack-Up Ring
CO-Ring
DShim (as required)
ESpring
T110743
FCap
GRing
HO-Ring
IBack-Up Ring
JRelief Valve
KO-Ring
TX,33,DW5022 1923JUL971/1
UN04MAR95
CAUTION: To avoid injury from escaping fluid
under pressure, stop engine and relieve the
pressure in the system before disconnecting or
T8455AL
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
Components Removed For Clarity
4. Remove hydraulic lines (A, B, C and E).
UN28APR95
7. Replace parts as necessary.
T8472AA
9. Install boom regenerative valve and boom valve.
Tighten mounting cap screws to 86 Nm (63 lb-ft).
ABoom Lower Valve B Port-to-Boom Anti-Drift
Valve X Port Line
10. Install hydraulic lines. BBoom Raise Valve A Port-to-Dig Pilot Check
Valve Block K1 Port Line
11. Fill reservoir. (See Hydraulic Oil in Group 0004.) CBoom Anti-Drift Valve Y Port-to-Hydraulic
Reservoir
DBoom Anti-Drift Valve Port-to-Boom Cylinders
Rod End Port Line
EBoom Lower Valve B Port-to-Dig Pilot Check
Valve Block L1 Port Line
FCap Screw (4 used)
GBoom Valve B Port-to-Boom Cylinders Head
End Port Line
HCap Screw (4 used)
ICap Screw (4 used)
JFlange (2 used)
KFlange (2 used)
LBoom Regenerative Valve
MBoom Valve
TX,33,DW5019 1922JUL971/1
UN10APR95
boom regenerative valve.
AA Cast On Housing
T8455AN
BO-Ring (2 used)
CO-Ring (3 used)
DOrifice
TX,33,DY2985 1927AUG971/1
UN04MAR95
6. Disconnect line (E) and T-fitting (G).
T8455AA
one side. Remove arm regenerative valve (H).
Specification
Mounting Cap ScrewTorque ........................................ 80 Nm (59 lb-ft)
UN04MAR95
10. Connect line (E) and T-fitting (G).
T8455AB
ACap Screw (2 used)
BClamp (2 used)
CCap Screw (3 used) Right Side Of Control Manifold
DBracket
EDig Pilot Check Valve L1 Port-to-Arm Out B Port
Line
FCap Screw (4 used)
GDig Pilot Check Valve K1 Port-to-Arm In A Port
Line
HArm Regenerative Valve
IArm Valve Section
UN04MAR95
T8455AC
TX,33,DY2986 1927AUG971/1
Specification
Spool PlugTorque ........................................................ 75 Nm (55 lb-ft)
UN04MAR95
3. Tighten cap screws (G) to 9.5 Nm (84 lb-in.).
Specification
Cover-to-Housing Cap Screw
T8455AE
Torque ........................................................................... 9.5 Nm (84 lb-in.)
Specification
Jam NutTorque ............................................................ 80 Nm (59 lb-ft)
UN04MAR95
DPoppet
ESpring
FCover
GCap Screw (4 used)
T8455AF
HO-Ring
IO-Ring (3 used)
JO-Ring
KO-Ring
LPlug
MDimension
TX,33,DY2987 1927AUG971/1
UN05AUG97
hydraulic tank fill cap. Slowly turn cap to release
pressure.
T110218
IMPORTANT: The spring loaded cap retains the Boom Valve Section Removed For Clarity
poppet that must be removed. The
retaining screws are not long enough to
relax all of the spring tension.
Installation may be difficult.
13. Install valve cover (B) and two cap screws at (A).
Specification
Cover-to-Housing Cap Screw
33 Torque ........................................................................... 9.5 Nm (84 lb-in.)
3360
150
TX,33,DW5003 1916JUL972/2
UN05AUG97
3. Tighten cap screws to 9.5 Nm (84 lb-in.).
Specification
T110219
Cover-to-Housing Cap Screw
Torque ........................................................................... 9.5 Nm (84 lb-in.)
ACover
BPoppet
CSpring
DO-Ring
TX,33,DW5004 1916JUL971/1
UN04MAR95
6. Install manifold. Torque cap screws to 32 Nm (24
lb-ft).
T8455AO
Specification
Mounting Cap ScrewTorque ........................................ 32 Nm (24 lb-ft)
Earlier Machine Shown
7. Install hydraulic lines.
ADig Pilot Check Valve Block S1 Port-to-Swing
Stop Cushion Valve PST Port Line (Serial No.
546277556935)
Dig Pilot Check Valve Block Signal Switch
Port-to-Swing Stop Cushion Valve PST Port Line
(Serial No. 556936)
BSwing Stop Cushion Valve PZUL Port-to-Dual
Solenoid Block T Port Line (Serial No.
546277556935)
Swing Stop Cushion Valve PZUL Port-to-Dual
Solenoid Block P Port Line (Serial No. 556936)
CManifold
DCap Screw (3 used)
TX,33,DY2991 1927AUG971/1
UN04MAR95
3. Install parts (AC and EK).
T8453AA
APlug
BSpring
CPilot Pressure Spool
DHousing
ESpring
FCushion Valve Spool
GO-Ring
HCap Screw (2 used)
ICover
JO-Ring (4 used)
KPlug
TX,3360,DW601 1920APR951/1
UN04MAR95
5. Remove cap screws (F). Slide swing valve (G) to one
side. Remove swing torque control valve (E).
T8455AA
7. Install swing torque control valve (E) and swing valve
(G).
Specification
Valve-to-Manifold Cap Screw
Torque ............................................................................. 49 Nm (36 lb-ft)
TX,33,DY2992 1927AUG971/1
UN05AUG97
CAUTION: To avoid injury from escaping fluid
under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
T109792
connections before applying pressure.
Specification
Swing Torque control Valve
(556936)Torque ........................................................ 86 Nm (63 lb-ft)
TX,33,DY2993 1927AUG971/1
UN18APR95
T8455AG
1Plug 8Shuttle Spool 15O-Ring 22Screw
2Spring Seat 9Plug 16Sleeve 23Nut
3Spring 10Orifice 17Piston 24Relief Valve
4Shim 11Plug 18Spring 25Plug
5Spring 12Plug 19Retainer 26O-Ring (3 used)
6Spring Seat 13Check Valve 20O-Ring 27O-Ring (2 used)
7Spool 14Shuttle Valve 21Plug
TX,3360,DW602 1927AUG971/1
UN18APR95
Specification
Spool PlugTorque ........................................................ 47 Nm (35 lb-ft)
T8455AI
3. Set adjusting screw to dimension (A). Tighten nut to 10
Nm (88 lb-in.).
Specification
Adjusting Screw Jam Nut
Torque ............................................................................ 10 Nm (88 lb-in.)
ADimension
BAdjusting Screw and Nut
CPin
DPlug
EO-Ring
FSpring Guide
GSpring
HO-Ring (3 used)
UN04MAR95
IO-Ring (2 used)
JPlug
KO-Ring
LSpring Guide
MSpring
T8455AH
NBall
OO-Ring
PPlug
QPlug
ROrifice
SPiston
TPressure Regulating Valve Spool
USpring Guide
TX,33,DY2994 1927AUG971/1
33
3360
157
UN04MAR95
T8455AP
Continued on next page TX,33,DW5021 1922JUL972/4
UN04MAR95
cylinders to the control valve.
T8455AQ
(A).
3. Remove hydraulic lines (A, B, G, L and M). Boom Anti-Drift Valve Shown
UN04MAR95
ABoom Lower Valve B Port-to-Boom Anti-Drift
Valve X Port Line
BBoom Anti-Drift Valve Y Port-to-Hydraulic
Reservoir Port Line
CBoom Anti-Drift Valve Port-to-Boom Cylinders
T8455AR
Rod End Port Line
DFlange (2 used)
ECap Screw (2 used)
FCap Screw (4 used) Arm Anti-Drift Valve Shown
GBoom Valve B Port-to-Boom Cylinders Head End
Port Line
HFlange
ICap Screw (2 used)
JCap Screw (4 used)
KArm Anti-Drift Valve Port-to-Arm Cylinder Rod
End Port Line
LArm Raise Valve A Port-to-Arm Anti-Drift Valve X
Port Line
MArm Anti-Drift Valve Y Port-to-Hydraulic Reservoir
Port Line
Specification
Mounting Cap ScrewTorque ........................................ 95 Nm (70 lb-ft)
33
8. Install hydraulic lines. 3360
159
9. Install clamp.
TX,33,DW5021 1922JUL974/4
UN23AUG88
IMPORTANT: For machines with an anti-drift valve,
the relief valve must be loosened 1/4
turn to make a passage through the
valve for high pressure oil to flow from
X9811
cylinders to the control valve.
UN05AUG97
Specification
Mounting Cap ScrewTorque ........................................ 95 Nm (70 lb-ft)
T110220
flanges.
ABoom Anti-Drift Valve Y Port-to-Hydraulic
Boom Anti-Drift Valve
Reservoir Port Line
BBoom Anti-Drift Valve A Port-to-Boom Cylinders
Rod End Port Line
CCap Screw (2 used)
DBoom Anti-Drift Valve X Port-to-Boom Lower Pilot
Cap Port Line
ECap Screw (2 used)
FArm Anti-Drift Valve B Port-to-Arm Cylinder Rod
End Port Line
GArm Anti-Drift Valve Y Port-to-Boom Anti-Drift
Valve Hydraulic Reservoir T-Fitting Port Line
HArm Anti-Drift Valve X Port-to-Arm Raise Valve
Pilot Port Line
UN05AUG97
T110221
UN04MAR95
parts as necessary.
T8455AS
4. Instal parts (AV). Tighten plugs (F and M) to 100
Nm (74 lb-ft).
Specification APlug
Valve PlugTorque ...................................................... 100 Nm (74 lb-ft) BO-Ring
CPiston
DPiston
Tighten plugs (U) to 20 Nm (177 lb-in.). ESpring
FPlug
Specification GO-Ring
Face Side PlugTorque .............................................. 20 Nm (177 lb-in.) HBack-Up Ring
IO-Ring
JShim (As required)
KSpring
LValve Seat
MPlug
NO-Ring
OBack-Up Ring
PO-Ring
QSpring
RPoppet
SHousing
TO-Ring (2 used)
UPlug (2 used)
VGuide
TX,3360,DX388 1904MAY951/1
UN27JAN92
hydraulic tank fill cap. Slowly turn cap to release air
pressure.
T7681EF
4. Remove valve from reservoir.
TX,33,DW5006 1916JUL971/1
UN05AUG97
4. Remove cap screws (A) and spacers (J). Remove
valve.
T110222
5. Repair or replace valve components as necessary.
TX,33,DW5007 1916JUL971/1
Disassemble And Assemble Dual Solenoid Valve Block (Serial No. 538539)
33
3360
164
UN05AUG97
T110223
TX,33,DW5008 1916JUL971/1
TX,3360,AB413 1917FEB921/2
3. Remove actuator.
UN27JAN92
5. Install actuator.
6. Connect lines.
T7681EG
ALine to Dual Solenoid Block
BLine to Reservoir
CLine to Pilot Filter
TX,3360,AB413 1917FEB922/2
UN12AUG97
T111078
TX,3360,AB414 1917FEB922/2
UN23AUG88
Protect hands and body from high pressure
fluids.
X9811
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.
UN27JAN92
9. Connect lines. Bleed air from cylinder. (See procedure
in this group.)
T7681EH
APin
BLine to Right Cylinder Piston End
CLine to Right Cylinder Rod End
DLine to Left Cylinder Rod End
ELine to Left Cylinder Piston End
FPin (2 used)
GLubrication Line
TX,33,DY2995 1927AUG972/2
1. Retract cylinder. 33
3360
169
2. Place a floor stand under end of boom so load is on
boom, not arm cylinder, when boom is lowered, lower
bucket to ground.
UN23AUG88
Protect hands and body from high pressure
fluids.
X9811
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.
UN27JAN92
cylinder is 296 kg (652 lb).
T7681EI
7. Remove cylinder. Earlier Machine Shown
TX,33,DY2996 1927AUG972/2
UN23AUG88
Protect hands and body from high pressure
fluids.
X9811
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.
UN27JAN92
assembly. Remove cylinder.
T7681EJ
7. Install cylinder. Check for 1.5 mm (0.06 in.) or less play
at both ends of cylinder. Add or remove shims as
necessary. Earlier Machine Shown
TX,33,DY2997 1927AUG972/2
3360,NN280 1919OCT941/1
TX,3360,VV389 1925NOV911/10
UN27OCT88
T6557HI
TX,3360,VV389 1925NOV912/10
UN27OCT88
T6557HK
TX,3360,VV389 1925NOV914/10
7. Tighten setscrew.
Bucket CylinderSpecification
Piston NutM62 x 2Torque ................................ 4740 Nm (3485 lb-ft)
Piston NutM52 x 2Torque ................................ 4260 Nm (3130 lb-ft)
Rod Guide Cap ScrewsTorque ............................... 558 Nm (410 lb-ft)
Arm CylinderSpecification
Piston NutTorque ................................................. 7560 Nm (5560 lb-ft)
Rod Guide Cap ScrewsTorque ............................... 972 Nm (715 lb-ft)
UN27OCT88
Cushion Cap ScrewTorque...................................... 972 Nm (715 lb-ft)
Boom CylinderSpecification
Piston NutTorque ................................................. 6080 Nm (4470 lb-ft)
T6585XJ
Rod Guide Cap ScrewsTorque ............................... 558 Nm (410 lb-ft)
8. Remove nut.
UN22OCT91
CCushion (Arm cylinder only)
DNut
EPiston
FCushion
GO-Ring
T7625BC
HRod Guide
ICylinder Rod
TX,3360,VV389 1925NOV916/10
UN22OCT91
T7625BE
UN22OCT91
T7626AA
Continued on next page TX,3360,VV389 1925NOV918/10
33
3360
178
UN24OCT91
T7623AC
AWiper Ring (2 used) EBackup Ring (2 used) IRibbed Rubber Ring MWiper seal
BWear ring (2 used) FRetaining ring JPlain Ring NCap Screw (Arm Cylinder
CExpander GBearing KU-cup seal Only)
DCap Seal HNotched Ring LBackup Ring
TX,3360,VV389 1925NOV919/10
15. Inspect rod and head end bushings (B) and seals (A)
for damage; replace if necessary.
UN27OCT88
T6557HR
TX,3360,VV389 1925NOV9110/10
UN27OCT88
cylinder until it is centered in bore.
T6557HR
TX,3360,VV392 1925NOV911/10
UN22OCT91
T7626AA
Continued on next page TX,3360,VV392 1925NOV912/10
UN01APR93
T7963AK
UN22OCT91
T7623AF
UN02SEP93
9. Install beveled end (B) of seal protector into rod guide.
T7979BB
11. Install the rod guide with seal protector installed, onto
the rod.
UN01APR93
T7963AL
UN01APR93
T7963AM
UN02SEP93
IMPORTANT: If gray seal shavings are found on seal
protector at the shoulder on the rod, the
notched ring in rod guide has been
T7979BB
damaged and must be replaced. There
must be no gray seal shavings found
after rod guide is installed.
13. Inspect seal protector at the rod shoulder for any gray
seal shavings. If shavings are found, remove rod
guide and replace the notched ring. Install the rod
guide using procedure above.
UN01APR93
14. Remove the seal protector.
T7963AN
Continued on next page TX,3360,VV392 1925NOV915/10
17. Install wear ring (D) in groove below so cap seal does 33
3360
not go into that groove if pushed too far. 183
19. Push cap seal (B) down installer and into middle
groove over seal expander (C) using JDG843-3
Pusher (A).
20. Check cap seal. 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
installation into cylinder barrel.
UN18MAR93
21. If necessary, shrink cap seal to its original size using
a ring compressor or a plastic tie band and hose
clamp.
T7964AQ
When using a ring compressor, put a piece of shim
stock between cap seal and compressor at joint so it
does not damage seal.
UN27OCT88
T6396AC
UN22OCT91
T7625BE
TX,3360,VV392 1925NOV917/10
UN22OCT91
Specification
Rod Guide Cap ScrewTorque ................................. 972 Nm (715 lb-ft)
28. Install cylinder wrench on the piston nut with the T7625BC
setscrew at the bottom.
Arm CylinderSpecification
Piston NutTorque ................................................. 7560 Nm (5560 lb-ft)
Cushion Cap ScrewTorque...................................... 972 Nm (715 lb-ft)
Boom CylinderSpecification
Piston NutTorque ................................................. 6080 Nm (4470 lb-ft)
UN27OCT88
T6585XP
TX,3360,VV392 1925NOV919/10
Arm CylinderSpecification
Rod Guide Cap ScrewTorque ................................. 972 Nm (715 lb-ft)
UN27OCT88
33. Connect lines (B) to cylinder. Tighten cap screws.
T6557HI
TX,3360,VV392 1925NOV9110/10
UN27JAN92
7. Remove cooler.
T7681EK
9. Repair or replace cooler as necessary.
TX,3360,AB420 1922FEB921/1
UN22MAY91
T7527CC
2. Loosen and remove cap screws on hydraulic tank
CAUTION: High pressure release of oil from
filter cover (B).
pressurized system can cause serious burns
or penetrating injury. The hydraulic tank is
Hold down filter cover against light spring load
pressurized. Turn fill cap slowly. Release all
when removing the last two cap screws. Remove
pressure before removing cap.
cover.
1. Turn fill cap (A) slowly. Release all pressure before
removing cap.
UN01AUG91
6. Install O-ring.
T7527EE
Specification
Hydraulic Return Filter Cover Cap
ScrewTorque ................................................................ 49 Nm (36 lb-ft) ACap Screw
BCover
CO-Ring
DSpring
EValve
FElement
TX,80,FF2370 1913AUG912/2
33
3360
189
UN27JAN92
T7681EM
UN27JAN92
18. Install tool box.
T7681EN
20. Fill fuel tank.
TX,33,DY2998 1927AUG973/3
33
3360
193
UN05AUG97
T110725
1Screw (6 used) 12Washer (14 used) (Serial 22Filter 31Cap Screw (7 used)
2Cover No. 538063) 23Washer (as required) 32Cap Screw (3 used)
3O-Ring 13Cap 24Washer (4 used) 33Sensor 33
4Spring 14Gasket 25Cap Screw (4 used) 34O-Ring 3360
5Valve 15Cover 26Fitting 35Washer (7 used) 195
6Filter Element 16Screen 27Switch 36Cap Screw (7 used)
7Screw (3 used) 17Reservoir 28Lock Washer (Serial No. 37Washer (4 used) (Serial
8Filter 18Plug 538063) No. 538063)
9O-Ring 19Union Fitting (2 used) 29Nut (Serial No. 538063) 38Bumper (4 used) (Serial
10Gasket 20Tube 30Angle No. 538063)
11Nut (14 used) 21Relief Valve
TX,33,DW5009 1917JUL972/2
33
3360
196
Page 43
Group 4311Brakes
Service Equipment Tools. . . . . . . . . . . . . . . .43-4311-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . .43-4311-1
Swing Brake
Remove and Install . . . . . . . . . . . . . . . . . .43-4311-2
Disassemble and Assemble. . . . . . . . . . . .43-4311-3
43
NOTE: Order tools from the U.S. SERVICE-GARD Catalog (MTC). Some tools may be available
Catalog or from the European Microfiche Tool from a local supplier.
43
4311
1
TX,4311,AB6 1908JAN922/4
1
Fabricated tool, dealer made. (See Section 99 for instructions to
make tool.)
TX,4311,AB6 1908JAN924/4
Specifications
TX,4311,AB7 1908JAN921/1
TX,4311,AB8 1908JAN921/2
UN06DEC91
5. Install brake and gear. Tighten cap screws to 49 Nm
(36 lb-ft).
Specification
T7626BS
Swing Brake Cap Screws
Torque ............................................................................. 49 Nm (36 lb-ft)
TX,4311,AB8 1908JAN922/2
43
4311
3
UN07NOV88
T6439ZJ
ASeparator Plate (6 used) ESpring Pin (6 used) HO-Ring KSnap Ring
BDisk (5 used) FDisk Holder IBrake Piston LSpring (12 used)
CSun Gear GO-Ring (2 used) JSpring Retainer MO-Ring
DHousing
TX,4311,AB9 1908JAN921/11
AO-Ring
BSnap Ring
CSpring Retainer
DSpring (12 used)
UN22MAR90
43
4311
4
T6439ZM
TX,4311,AB9 1908JAN923/11
UN22MAR90
AO-Ring
BO-Ring
CDisk Holder
T6439ZN
DSeparator Plate (6 used)
EDisks (5 used)
TX,4311,AB9 1908JAN924/11
10. Install O-ring (A), separator plates (B), and disks (C)
in disk holder (D).
AO-Ring
BSeparator Plate (6 used)
CDisk (5 used)
UN22MAR90
DDisk Holder
43
4311
5
T6439ZP
TX,4311,AB9 1908JAN926/11
UN22MAR90
T6439ZQ
TX,4311,AB9 1908JAN927/11
UN22MAR90
T6439ZR
TX,4311,AB9 1908JAN928/11
14. Install O-ring (A) and brake piston. Do not push piston
tight against separator plate at this time.
UN22MAR90
T6439ZS
UN22MAR90
43
4311
6
T6439ZT
TX,4311,AB9 1908JAN9210/11
UN22MAR90
IMPORTANT: A new O-ring must be used to prevent
leakage. A used O-ring has taken a set
and may not seal if reused.
T6439ZL
20. Install a new O-ring (A).
AO-Ring
BSnap Ring
CSpring Retainer
DSpring (12 used)
TX,4311,AB9 1908JAN9211/11
43
4350
1
TX,4350,AB37 1920APR952/9
Spring Scale
TX,4350,AB37 1920APR953/9
TX,4350,AB37 1920APR954/9
1
Fabricated tool, dealer made. (See Section 99 for instructions to make
tools.)
Continued on next page TX,4350,AB37 1920APR955/9
43
4350
2
1
Fabricated tool, dealer made. (See Section 99 for instructions to make
tools.)
TX,4350,AB37 1920APR956/9
1
Fabricated tool, dealer made. (See Section 99 for instructions to make
tools.)
TX,4350,AB37 1920APR957/9
1
Fabricated tool, dealer made. (See Section 99 for instructions to make
tools.)
TX,4350,AB37 1920APR958/9
Bridge Planks1
1
Fabricated tool, dealer made. (See Section 99 for instructions to make
tools.)
TX,4350,AB37 1920APR959/9
Other Material
T43512 (U.S.) Thread Lock and Sealer (Medium Used to apply to threads of cap
TY9473 (Canadian) Strength) Products screws for valve housing and cover.
242 (LOCTITE)
TY6305 (U.S.) Clean and Cure Primer Products Used to clean surfaces prior to
TY9485 (Canadian) application of adhesives and
764 (LOCTITE) sealants.
Specifications
Swing Gearbox:
Swing Bearing:
TX,4350,AB289 1916NOV941/1
6. Install gearbox.
UN06DEC91
9. Tighten cap screws to 190 Nm (140 lb-ft).
Specification
Gearbox-to-Frame Cap Screw
T7626BT
Torque ......................................................................... 190 Nm (140 lb-ft)
TX,4350,AB10 1920APR952/2
TX,902525,GG163 1921AUG911/1
43
4350
8
UN07NOV88
T6439ZX
ARing Gear FSecond Sun Gear KSecond Planet Carrier QUpper Bearing
BFirst Planet Gear and GSecond Planet Gear and LMagnet RUpper Metal Seal
Bearing (3 used) Bearing (3 used) MSeal SLower Bearing
CFirst Planet Carrier HSnap Ring (3 used) NO-Ring TLower Metal Seal
DSnap Ring (3 used) ISnap Ring OSpecial Nut UCover
ESnap Ring JWasher PSpacer Ring VPinion Shaft
43
4350
9
TX,43,DY2989 1927AUG972/13
UN26MAR90
T6641AM
TX,43,DY2989 1927AUG973/13
UN20MAR90
NOTE: Planet gear is outer race of bearing. Bearing and
planet gear must be replaced as one piece.
T6641AN
4. Remove planet gear (B) using a two-jaw puller.
UN20MAR90
43
4350
10
T6641AO
TX,43,DY2989 1927AUG975/13
UN20MAR90
T6641AP
TX,43,DY2989 1927AUG976/13
UN20MAR90
11. Replace washer (D) and O-ring (A) as necessary.
AO-Ring
BSnap Ring (4 used)
CSecond Planet Gear (4 used)
DWasher
ESecond Planet Carrier
UN07NOV88
DF1054 Swing Gearbox Nut Spanner Wrench (E).
(See Section 99 for instructions to make tools.) 43
4350
15. Remove oil seal (D). 11
T6641AR
AMagnet
BStaking5 Places
CSpecial Nut
DOil Seal
EDF1054 Spanner Wrench
UN06DEC91
T7626BU
Continued on next page TX,43,DY2989 1927AUG978/13
43 18. Remove lower bearing cone (K), metal seal (L), and
4350 cover (M).
12
19. Replace parts as necessary.
24. Fill upper bearing cone and metal seal with lithium
grease. Install seal with inner edge towards bearing.
27. Install O-ring (C) in special nut. Install and tighten nut
to 2000 Nm (1475 lb-ft).
Specification
Bearing-to-Pinion Shaft Special
NutTorque ............................................................ 2000 Nm (1475 lb-ft)
AOil Seal
BSpecial Nut
CO-Ring
DSpacer
EBearing Cone and Cup
FMetal Seal
GO-Ring
HMagnet
IHousing
JCap Screw (6 used)
KBearing Cone and Cup
LMetal Seal
MCover
NPinion Shaft
UN07NOV88
T6439ZW
Specification
Bearing AdjustmentTorque ........................... 2229 Nm (1621 lb-ft)
Turning Force Housing at
Smallest DiameterTorque ...................... 245320 N (5572 lb force). 43
4350
13
NOTE: As necessary, grind spacer to increase bearing
load. Remove spacer and install four lead balls
into cavity. Tighten nut until rolling drag torque on
shaft or force to turn housing is to specifications
given. Have spacer ground so thickness is 0.02
0.05 mm (0.0010.002 in.) greater than
measurement of balls.
TX,43,DY2989 1927AUG9710/13
UN07NOV88
31. Inspect and clean magnet (A).
T6641AR
AMagnet
BStaking5 Places
CSpecial Nut
DOil Seal
TX,43,DY2989 1927AUG9711/13
35. Install ring gear (A) and screws (B). Tighten screws to
55 Nm (40 lb-ft).
UN20MAR90
Specification
43
Gousing-to-Ring Gear Cap
4350
ScrewTorque ................................................................ 55 Nm (40 lb-ft)
14
T6641AO
36. Install first planet carrier assembly.
TX,43,DY2989 1927AUG9713/13
Remove Upperstructure
UN24FEB92
CAUTION: Keep the angle between boom and
arm at 90100 to prevent machine from sliding
backwards.
T7712AG
2. Park machine with boom to the left side (cab side
towards sprocket) of undercarriage.
43
4350
15
UN24FEB92
T7640BA
NOTE: To make removal of swing bearing-to-main frame
cap screws easier after machine is raised into
position, loosen the cap screws one turn at this
time.
UN05OCT89
using boom down function. Put hardwood blocks (C),
approximately 180 mm (7 in.), between lower track
rollers and track chain.
T7149AG
5. Turn upperstructure back to the left side so center of
cab is over the left rear upper track roller next to
sprocket. This position will allow the beam used to
support the boom end to be installed under the ACounterweight
upperstructure as far as possible. BBridge Plank (as required)
CHardwood Block (2 used)
DDFT1089 Barrel Support (2 used)
CAUTION: The approximate weight of DFT1089
Barrel Supports is 545 kg (1200 lb).
Specification
Floor To Bottom of Main Frame
Height ............................................................................. 1270 mm (50 in.)
43
4350
17
UN24FEB92
T7712AH
ADFT1089 Barrel Supports BHardwood Blocks (Use as C3.7 m (12 ft) Length of W8 DUpper Track Roller
(2 used) required) x 28 lb Wide Flange Beam
8. Put two DFT1089 Barrel Supports (A) and a 3.7 m 9. Lower machine so main frame and corner of cab is
(12 ft) length of W8 x 28 lb Wide Flange Beam (C) on the beam.
under main frame at right boom cylinder and right
corner of cab. 10. Check that bottom of main frame is 1270 mm (50
in.) off the floor and level.
Remove the upper track roller (D) if additional
clearance is needed. Specification
Floor To Bottom of Main
FrameHeight......................................................... 1270 mm (50 in.)
For maximum support, the barrel supports must be
positioned so the beam is under the main frame
Do not exceed a maximum height of 1320 mm (52
and corner of cab as far as possible.
in.).
Install hardwood blocks (B) as needed to make up
for any unevenness.
UN05OCT89
T7149AJ
Continued on next page TX,4350,GG273 1918FEB925/7
UN23AUG88
Protect hands and body from high pressure
fluids. 43
4350
19
If an accident occurs, see a doctor immediately.
X9811
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.
UN06DEC91
CAUTION: The approximate weight of rotary
manifold is 38 kg (84 lb).
T7626CC
17. Remove two rotary manifold-to-undercarriage cap
screws. Install two M12 x 152 mm cap screws.
Remove the remaining cap screws to lower manifold
onto heads of longer cap screws. APort 3-to-Left Propel Section B Port Line
BPort 1-to-Right Propel Section A Port Line
CP1 Port-to-Dual Solenoid Block A Port Line
CAUTION: The approximate weight of DPort 2-to-Right Propel Section B Port Line
undercarriage is 4300 kg (9500 lb). EPort 4-to-Left Propel Section A Port Line
FDrain Port-to-Reservoir Line
GCover
18. Put an 18-t (20-ton) service jack under each end of HCap Screw (2 used)
undercarriage. IStrap
UN06DEC88
43 22. Pull undercarriage out from under the upperstructure.
4350
20 23. Remove swing bearing. (See procedure in this group.)
T6626JK
TX,4350,GG273 1918FEB927/7
Install Upperstructure
UN06DEC88
3. Raise undercarriage into position using two 18-t
(20-ton) service jacks. It may be necessary to turn
swing bearing inner race to align teeth with teeth on
T6626JK
swing motor pinion shaft.
Specification
Swing Bearing-to-Upperstructure
Cap ScrewTorque .................................................... 620 Nm (460 lb-ft)
Specification
Rotary Manifold-to-Undercarriage
Cap ScrewTorque ........................................................ 98 Nm (65 lb-ft)
UN06DEC91
BPort 1-to-Right Propel Section A Port Line
CP1 Port-to-Dual Solenoid Block A Port Line
DPort 2-to-Right Propel Section B Port Line
EPort 4-to-Left Propel Section A Port Line
FDrain Port-to-Reservoir Line
T7626CC
GCover
HCap Screw (2 used)
IStrap
43
4350
22
UN24FEB92
T7712AH
ABarrel Support BHardwood Block CWide Flange Beam DUpper Track Roller
11. Raise machine just enough to remove the 15. Lower machine so lower track rollers and front
hardwood blocks (B), wide flange beam (C), and idler are on the track chain.
barrel supports (A).
16. Tighten any of the swing bearing-to-main frame
12. Lower machine so lower track rollers and front cap screws that could not be tighten.
idler are on the track chain.
17. Install the upper track roller (D).
13. Remove bridge planks and barrel supports from
other side. 18. Install track chains.
14. Turn upperstructure to the other side and raise 19. Adjust and measure track sag. (See procedure in
machine just enough to remove hardwood blocks Group 0130.)
between roller and track chain.
TX,4350,GG280 1920APR953/3
UN11APR90
43 The paint on a few of the teeth have no
4350 significance for the installation of swing bearing on
24 this machine.
T5925AA
6. Install swing bearing on undercarriage so the letter (A)
and bearing loading plug (B) are to the left side of
machine.
Specification
Undercarriage-to-Swing Bearing
Cap ScrewTorque .................................................... 530 Nm (390 lb-ft)
TX,4350,GG267 1920APR952/2
UN11APR90
4. Apply instant gel adhesive sparingly to seal groove. 43
4350
5. Install seal with lip against outer bearing race. 25
T5925AM
Start about 76 mm (3 in.) from end of seal using a
blunt instrument to force seal into groove. Push seal in
direction of portion already installed to avoid stretching
seal.
TX,4350,GG283 1930MAR932/2
UN17MAY89
43 2. Scrape old adhesive from seal groove (B).
4350
26 Thoroughly clean seal groove and new seal using
T5936BA
clean and cure primer.
TX,4350,GG284 1930MAR931/1
43
4360
1
68 mm Disk
TX,4360,AB291 1920APR952/3
1
Fabricated tool; dealer made. (See Section 99 for instructions to make
tool.)
TX,4360,AB291 1920APR953/3
Other Material
TY15969 (U.S.) Retaining Compound (High Strength) Used to apply to inside surface of
TY9479 (Canadian) swing motor seal collar.
635 (LOCTITE)
43
4360 TY9375 (U.S.) Pipe Sealant with TEFLON Used to apply to pump-to-pump
2 TY9480 (Canadian) housing mating surface.
592 (LOCTITE)
Specifications
Swing Motor:
4360,CC3 1920APR951/1
UN23AUG88
disconnecting hydraulic or other lines. Tighten
43
all connections before applying pressure. 4360
Search for leaks with a piece of cardboard. 3
Protect hands and body from high pressure
X9811
fluids.
Specification
Swing Motor-to-Swing Brake
NutTorque ................................................................ 195 Nm (144 lb-ft)
UN06DEC91
7. Tighten line-to-swing motor socket head screws to 86
Nm (63 lb-ft).
Specification
T7626BV
Line-To-Swing Motor Socket
Head ScrewTorque ...................................................... 86 Nm (63 lb-ft)
UN04MAR95
P Port Line
DNut (2 used)
EO-Ring
FSwing Stop Cushion Valve PZUL Port-to-Dual
T8455AT
Solenoid Block T Port Line
GDig Pilot Check Valve Block Top Left
Port-to-Swing Stop Cushion Valve PST Port Line
TX,43,DW5020 1922JUL972/2
UN23AUG88
disconnecting hydraulic or other lines. Tighten
43
all connections before applying pressure. 4360
Search for leaks with a piece of cardboard. 5
Protect hands and body from high pressure
X9811
fluids.
UN05AUG97
IMPORTANT: Replace O-ring. O-ring should not be
43 reused as it has taken a set from prior
4360 use.
6
T110348
6. Replace O-ring.
Specification
Line-To-Swing Motor Socket
Head ScrewTorque ...................................................... 86 Nm (63 lb-ft)
TX,04,DT5072 1902JUL972/2
UN10MAR90
drained from the motor.
43
Procedure is to ensure the motor is filled with oil. 4360
7
T7225AU
1. Disconnect swing motor drain line (A).
3. Fill motor with hydraulic oil through drain port (B) until
oil reaches the level of drain port.
TX,902525,GG162 1921AUG911/1
UN26MAR90
5. Apply petroleum jelly to O-ring. Install seal retainer in
swing motor using a piece of pipe and seal driver.
T6641EM
snap ring of same thickness as original
snap ring. Motor shaft end play is
determined by snap ring thickness.
UN01NOV88
DMotor Port
ESeal Retainer
FO-Ring
GSeal
T6439ZV
4360,CC7 1911SEP871/1
43
4360
9
UN01NOV88
T6439ZU
AShaft GPiston LUpper Bearing QBall Guide
BSnap Ring HCylinder Block MSnap Ring RRetainer Plate
CSeal Retainer IValve Plate NWasher (2 used) SO-Ring
DLower Bearing JValve Plate Housing OSpring TSeal
ESwash Plate KSpacer PPin (3 used) USeal Collar
FSlipper
UN26MAR90
plate housing (A) and valve plate (B).
43
4360 2. Remove upper bearing cup (C) using a 2-jaw puller
10 and slide hammer.
T6641EO
3. Lift cylinder block and swash plate assembly from
housing. Early Machine Shown
UN26MAR90
4. Put pump shaft into wood support. (See Section 99 for
instructions to make tool.)
T6641EP
TX,4360,AB40 1908JAN922/20
ACardboard
BRoller Cage
CInner Race
DSpacer UN20MAR90
T6641EQ
UN20MAR90
T6641ER
TX,4360,AB40 1908JAN924/20
UN22MAR90
T6641ES
TX,4360,AB40 1908JAN925/20
Specification
New SpringFree Length
UN22MAR90
(approximate)................................................................ 73.3 mm (2.89 in.)
43
4360 ASnap Ring
12 BWasher
T6439VC
CSpring
DWasher
UN01NOV88
T6439UR
TX,4360,AB40 1908JAN927/20
UN22MAR90
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
T6641EU
protection equipment including eye protection.
UN22MAR90
Valve plate is surface hardened and cannot be 43
polished. Replace plate if damaged or worn. 4360
13
T6641EV
Minor scratches on cylinder block can be removed
using JT05425 Polishing Table or an equivalent
surface and 4/0 emery paper. Wet polishing paper
using diesel fuel. ASlipper
BSwash Plate
CPiston (9 used)
Inspect swash plate (B) for wear or damage; replace DCylinder Block
if necessary.
TX,4360,AB40 1908JAN929/20
UN22MAR90
is tight against shoulder.
T6641EW
Continued on next page TX,4360,AB40 1908JAN9210/20
ASnap Ring
BWasher
CSpring
UN01NOV88
DWasher
43
4360
14
T6439UR
UN22MAR90
T6439VC
TX,4360,AB40 1908JAN9211/20
UN22MAR90
IMPORTANT: Protect lapped surface of cylinder block
using a clean piece of cardboard.
ASnap Ring
BSeal Retainer
CO-Ring
DSeal
EBearing Cup
19. Apply petroleum jelly to pins (B). Install pins and ball
guide (A) and align splines.
UN22MAR90
43
4360
15
T6641ET
TX,4360,AB40 1908JAN9213/20
ACardboard
BWood Support
CSwash Plate
DRetainer Plate
EPiston (9 used)
UN20MAR90
T6641ER
Continued on next page TX,4360,AB40 1908JAN9214/20
UN22MAR90
43 22. Turn motor vertical and put on wood block.
4360
16
T6641EX
UN22MAR90
T6641EY
TX,4360,AB40 1908JAN9215/20
UN22MAR90
T6641EZ
TX,4360,AB40 1908JAN9216/20
UN26MAR90
Install valve plate on housing (A) with lapped surface
up. 43
4360
26. Apply a thin, even layer of pipe sealant with 17
T6641EP
TEFLONto mating surface of swing motor.
Specification
Valve Housing-to-Motor Housing
Socket Head ScrewTorque .......................................... 69 Nm (51 lb-ft)
Specification
Swing Stop Cushion Valve
Torque ............................................................................. 32 Nm (24 lb-ft)
28. Turn swing motor shaft several times. Make sure seal
retainer (B) is pushed tight against bearing (C).
Specification
ShaftEnd Play .................................. 0.020.35 mm (0.0010.014 in.)
UN20MAR90
T6641FA
TX,4360,AB40 1908JAN9220/20
UN23JAN92
Inspect O-ring (A) and valve (B). Replace as necessary.
T7681EY
TX,4360,AB430 1926FEB921/1
Page
99
Material required:
UN24MAR98
1020 HR Steel for Holder (C), Supporting Plate (E),
Base Plate (F), and Base (G).
"D" Grade (SAE Grade 5) for Eyebolts (D), Nuts (A),
and Cap Screws (H).
T6585UY
"F" Grade (SAE Grade 8) for Studs (B)
Print Numbers:
ANut (12 used)
A-ST4050 Nut BStud (4 used)
CHolder
B-ST4045 Bolt
DEyebolt (2 used)
C-ST4035 Holder (Plate) ESupporting Plate
-ST4036 Holder (Plate) FBase Plate
-ST4037 Holder (Plate) GBase (4 used)
D-ST4047 Eyebolt HCap Screw (8 used)
ILock Washer (8 used)
E-ST4040 Supporting Base
F-ST4042 Base Plate
G-ST4041 Base
H-ST4046 Cap Screw
I-ST4049 Lock Washer
99
9900
2
UN06JUL89
T7029CI
99
9900
3
UN06JUL89
T7029CH
99
9900
4
UN06JUL89
T7029CG
TX,9900,AA3574 1920FEB924/4
99
9900
5
UN17OCT89
T7162AF
A3/16 in. 1020 CR Steel Plate C1/2 in. Nut (2 used) D1/2 x 2 in. Cap Screw (2 E1/2 x 3 in. Steel Round
B9/16 in. Hole (2 places) used) Stock (2 used)
Track Disassembly and Assembly Guard Tool is used 3/16 in. 1020 CR Steel Plate (A)
with ST4920 Track Recoil Spring Disassembly and 1/2 in. Nut (C) (2 used)
Assembly Tool. 1/2 x 2 in. Cap Screw (D) (2 used)
1/2 x 3 in. Steel Round Stock (E) (2 used)
Material required:
TX,9900,BA499 1924SEP911/1
DFT1111 Spacer
UN23FEB92
Material required:
T7708AD
Stock (2 used)
99
9900
6
TX,9900,GG271 1922NOV941/1
DFT1110 Spacer
99
9900
7
UN23FEB92
T7708AC
Spacer is used with ST4920 Track Recoil Spring Material Required:
Disassembly and Assembly Tool. Spacer is installed
on the bottom plate so force is applied to spring flange 165 x 138 x 138 mm (6.50 x 5.50 x 5.50 in.) Heavy
on cylinder and not to the piston. Wall Steel Pipe
TX,9900,GG272 1922NOV941/1
99 Material required:
9900
8
59 x 46 mm (2.32 x 1.812 in.) Round Bar Stock (A)
3 x 16 mm Metric Spring Pin (such as 34M7085 Metric
Spring Pin) (D) or 1/8 x 1/2 Spring Pin (such as 34H243
Spring Pin) (D)
UN15OCT91
T7383AK
TX,9900,GG209 1903OCT911/1
99
9900
9
UN15OCT91
T7383AL
Planetary Gear Assembly Tool is used with the Material required:
DFT1094 Bearing Pilot Tool to hold the roller bearings
in the third planet gear while installing on the shaft. 10 x 200 mm (0.375 x 7.87 in.) Rod (A)
76 x 76 mm (3 x 3 in.) 16 Gauge Sheet Metal (B)
Tack weld (C) rod (A) to sheet metal (B).
TX,9900,GG210 1903OCT911/1
Cut steel tube (A) the full length using a 2.54 mm (0.100
in.) saw cut (E).
Material required:
UN09JAN92
60 x 46 x 45 mm Steel Tube (A) or 2.375 x 1.810 x
1.750 in. Steel Tube (A)
19 x 19 x 25 mm Steel Tab (B) or 0.750 x 0.750 x 1.00
T7383AM
in. Steel Tab (B)
19 x 19 x 13 mm Steel Tab (D) (2 used) or 0.750 x
0.750 x 0.500 in. Steel Tab (D) (2 used)
M8-1.25 x 50 mm Grade 10.9 Cap Screw and M8-1.25 ASteel Tube
Grade 10 Nut or 5/16-18 x 2 in. SAE Grade 8 Cap BSteel Tab
Screw and 5/16-18 in. SAE Grade 8 Nut CBevel Groove Weld
DSteel Tab (2 used)
ESaw Cut
FHole For Cap Screw
TX,9900,GG263 1906JAN921/1
Material required:
99
9900
11
UN24OCT88
T6641DO
9900,CC4 1924SEP911/1
Material required:
Wood
UN24OCT88
T6439VQ
9900,CC1 1924SEP911/1
Material required:
Wood
99
9900
12
UN24OCT88
T6439YX
9900,CC2 1924SEP911/1
99
9900
13
1921MAR89
T6641DP
Tool is used to hold swing brake disks and separator Material required:
plate together while installing in brake housing.
1/2 in. Square Steel Bar Stock
Bend J-bolts to dimension shown. 7/32 x 2-1/8 in. J-Bolt with Nut (2 used)
9900,CC5 1924SEP911/1
UN24OCT88
end.
Material required:
T6641EK
3/4-10 UNC x 9 in. Long Threaded Rod
3/4-10 UNC Nut
99
9900 A230 mm (9 in.)
14 B100 mm (4 in.)
9900,CC7 1924SEP911/1
Material required:
UN09JAN97
CAUTION: Cutting tops off barrels that
contained flammable or explosive material can
T7149AC
cause serious injury or death.
TX,9900,AA3912 1924SEP911/1
Material required:
4 x 4 x 6 in. Hardwood
ACut Here
B25.4 mm (1.00 in.) Hole
C51 mm (2 in.)
D102 mm (4 in.)
99 E153 mm (6 in.)
9900
16
UN06JUL89
T7084BK
TX,9900,AA3572 1926SEP911/1
Material required:
4 x 4 x 6 in. Hardwood
ACut Here
B32.0 mm (1.25 in.) Hole
C51 mm (2 in.)
D102 mm (4 in.)
E153 mm (6 in.)
UN06JUL89
T7084BK
TX,9900,GG206 1926SEP911/1
99
9900
17
UN15OCT91
T7623AA
Swing Gearbox Nut Spanner Wrench is used to loosen 127.0 x 50.8 x 12.7 mm (5 x 2 x 0.5 in.) Flat Bar
and tighten the special nut in swing gearbox. Stock (B)
7/16 x 3 in. Rod (C) (4 used)
Material required: 101.6 x 88.9 x 76.2 mm (4 x 3.5 x 3 in.) Pipe (D)
TX,9900,GG207 1930SEP911/1
99
9900
18
UN15OCT91
T7623AB
Swing Gearbox Pinion Holder Fixture is used to hold Material required:
the pinion so special nut can be loosen or tighten.
609.6 x 203.2 x 6.35 mm (24 x 8 x 0.250 in.) Flat
Use the pinion as a template to locate the rods in the Steel Plate (A)
pipe. 177.8 mm ID x 9.5 mm min wall (7 in. ID x 0.375 in.
min wall) Pipe (B)
The distance dimension given for the 5/8 in. holes is 3/4 x 3 in. Rod (C) (4 used)
the distance between the mud holes over three track
shoes so fixture can be fasten to the track.
TX,9900,GG208 1930SEP911/1
A Charge . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-10
Electrolyte level. . . . . . . . . . . . . . . . . . . .16-1671-6
Adjustment Electrolyte specific gravity . . . . . . . . . . . .16-1671-5
Travel alarm volume . . . . . . . . . . . . . . . .20-2004-1 Handle safely . . . . . . . . . . . . . . . . . . . . .16-1671-3
Air cleaner Remove and install . . . . . . . . . . . . . . . .16-1671-11
Remove and install . . . . . . . . . . . . . . . . .05-0520-3
Terminal . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-6
Air conditioner relay
Testing . . . . . . . . . . . . . . . . . . . . . . . . . .16-1671-4
Remove and install . . . . . . . . . . . . . . . .18-1830-37
Using booster-24-volt . . . . . . . . . . . . . . .16-1671-8
Air conditioner switch
Battery explosion . . . . . . . . . . 16-1671-8, 16-1671-10
Remove and install . . . . . . . . . . . . . . . .16-1674-10
Bleed fuel system (SN -559602). . . . . . . .04-0400-42
Air conditioning gauge set (SN -541550)
Bleed fuel system (SN 559603-). . . . . . . .04-0400-42
Installation. . . . . . . . . . . . . . . . . . . . . . .18-1830-10
Blower motor
Air conditioning switch (SN -541550)
Remove and install . . . . . . . . . . . . . . . . .18-1830-5
Remove and install . . . . . . . . . . . . . . . .18-1830-38
Boom
Air intake system
Install bushings and seals . . . . . . . . . . . .33-3340-7
Leakage test . . . . . . . . . . . . . . . . . . . . . .05-0520-4
Alternator (SN -541822) Lower with engine stopped . . . . . . . . . .33-3360-13
Remove and install . . . . . . . . . . . . . . . . .16-1672-2 Raise with engine stopped . . . . . . . . . .33-3360-15
Alternator (SN 541823-559602) Remove and install . . . . . . . . . . . . . . . . .33-3340-4 Indx
Boom and arm anti drift valve 1
Remove and install . . . . . . . . . . . . . . . . .16-1672-3
Alternator (SN 559603-) Disassemble and assemble . . . . . . . . 33-3360-161
Remove and install . . . . . . . . . . . . . . . . .16-1672-4 Boom and arm anti drift valve (SN 556936-)
Anti-cavitation back pressure check valve (SN Remove and install . . . . . . . . . . . . . . . 33-3360-159
-556935) Boom and arm anti-drift valve (SN -556935)
Remove and install . . . . . . . . . . . . . . . 33-3360-109 Remove and install . . . . . . . . . . . . . . . 33-3360-156
Anti-cavitation back pressure check valve (SN Boom cylinder
556936-) Assemble . . . . . . . . . . . . . . . . . . . . . . 33-3360-179
Remove and install . . . . . . . . . . . . . . . 33-3360-110 Disassemble . . . . . . . . . . . . . . . . . . . . 33-3360-174
Arm Remove and install . . . . . . . . . . . . . . . 33-3360-167
Install bushings and seals . . . . . . . . . . . .33-3340-7 Boom regenerative valve (SN 545157-556935)
Remove and install . . . . . . . . . . . . . . . . .33-3340-2 Disassemble and assemble . . . . . . . . 33-3360-146
Arm and boom cylinder restrictors (SN 556936-) Remove and install . . . . . . . . . . . . . . . 33-3360-145
Remove and install . . . . . . . . . . . . . . . 33-3360-109 Boom, arm and swing control valve (SN 556936-)
Arm cylinder Disassemble and assemble . . . . . . . . 33-3360-136
Assemble . . . . . . . . . . . . . . . . . . . . . . 33-3360-179 Boom, arm and swing manifold valve (SN 556936-)
Disassemble . . . . . . . . . . . . . . . . . . . . 33-3360-174 Remove and install . . . . . . . . . . . . . . . .33-3360-97
Remove and install . . . . . . . . . . . . . . . 33-3360-169 Boom, arm, and bucket valve section (SN -556935)
Arm cylinder restrictor (SN 546276-556935) Disassemble and assemble . . . . . . . . 33-3360-122
Remove and install . . . . . . . . . . . . . . . 33-3360-107 Brake elements, propel gearbox
Arm regenerative poppet valve (SN 556936-) Replace . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-6
Remove and install . . . . . . . . . . . . . . . 33-3360-149 Brake release pressure reducing valve
Arm regenerative valve (SN 546277-556935) Remove and install . . . . . . . . . . . . . . . .02-0260-32
Disassemble and assemble . . . . . . . . 33-3360-148 Bucket
Remove and install . . . . . . . . . . . . . . . 33-3360-147 Install bushings and seals . . . . . . . . . . . .33-3340-7
Arm regenerative valve (SN 556936-) Repair cracked cutting edge . . . . . . . . .33-3302-10
Disassemble and assemble . . . . . . . . 33-3360-150 Replace welded cutting edges . . . . . . .33-3302-10
Assemble Compressor (SN -541550) . . . .18-1830-28 Tooth . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3302-1
Auxiliary valve section (SN -556935) Bucket and linkage (SN -538759)
Disassemble and assemble . . . . . . . . 33-3360-137 Remove and install . . . . . . . . . . . . . . . . .33-3302-5
Bucket and linkage (SN 538760-)
B Remove and install . . . . . . . . . . . . . . . . .33-3302-7
Bucket circuit relief and anti-cavitation valve (SN
Battery 556936-)
Adding 12-V accessories . . . . . . . . . . .16-1671-12 Remove and install . . . . . . . . . . . . . . . 33-3360-121
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Gauge
Coolant temperature . . . . . . . . . . . . . . . .16-1676-4 I
Indx Fuel level . . . . . . . . . . . . . . . . . . . . . . . .16-1676-4
4 Hour meter . . . . . . . . . . . . . . . . . . . . . . .16-1676-4 Idler wear, front
Grease Measure . . . . . . . . . . . . . . . . . . . . . . . .01-0130-36
Specification . . . . . . . . . . . . . . . . . . . . . .00-0004-7 Idler, front
Grouser wear, track shoe Assemble . . . . . . . . . . . . . . . . . . . . . . .01-0130-40
Measure . . . . . . . . . . . . . . . . . . . . . . . .01-0130-22 Disassemble . . . . . . . . . . . . . . . . . . . . .01-0130-39
Remove and install . . . . . . . . . . . . . . . .01-0130-37
Test for oil leakage . . . . . . . . . . . . . . . .01-0130-42
Inch torque values . . . . . . . . . . . . . . . . . . .00-0003-1
H Injection nozzle bores
Clean . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-29
Halogen bulbs Intake manifold tube (SN -559602)
Replacing . . . . . . . . . . . . . . . . . . . . . . . .16-1673-1 Remove and install . . . . . . . . . . . . . . . .04-0400-55
Heater control Intake manifold tube (SN 559603-)
Remove and install . . . . . . . . . . . . . . . . .18-1830-7 Remove and install . . . . . . . . . . . . . . . .04-0400-56
Heater core and blower motor relay
Remove and install . . . . . . . . . . . . . . . . .18-1830-6
Hour meter J
Remove and install . . . . . . . . . . . . . . . . .16-1676-4
Hydraulic JT07158 TIME TRAC
Fittings, 30° cone seat. . . . . . . . . . .00-0003-7 Installation. . . . . . . . . . . . . . . . . . . . . . .04-0400-36
Fittings, 37° flare . . . . . . . . . . . . . . .00-0003-7
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-5
Return filter change. . . . . . . . . . . . . . . 33-3360-187
Hydraulic control valve (SN -556935) L
Remove and install . . . . . . . . . . . . . . . .33-3360-86
Hydraulic cylinder Leak testing (SN -541550) . . . . . . . . . . . .18-1830-31
Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-173 Linkage and bucket (SN 538760-)
Hydraulic fitting Remove and install . . . . . . . . . . . . . . . . .33-3302-7
Flared connections . . . . . . . . . . . . . . . . .00-0003-8 Load sense system relief valve (SN -556935)
Hydraulic lines, propel Disassemble and assemble . . . . . . . . 33-3360-114
Remove and install . . . . . . . . . . . . . . . .02-0260-32 Remove and install . . . . . . . . . . . . . . . 33-3360-115
Hydraulic oil Load sense system relief valve (SN 556936-)
Cleanup procedure . . . . . . . . . . . . . . . .33-3360-21 Disassemble and assemble . . . . . . . . 33-3360-116
Hydraulic oil cleanup procedure Load sense valve (SN -559602)
Using portable filter caddy. . . . . . . . . . .33-3360-21 Disassemble and assemble . . . . . . . . .33-3360-58
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Valve, shuttle
Remove and install . . . . . . . . . . . . . . . .02-0260-30
Valve, supply shuttle
Remove and install . . . . . . . . . . . . . . . .02-0260-26
Valve, swing stop cushion
Remove and install . . . . . . . . . . . . . . . 33-3360-151
Valve, swing stop cushion (SN 546277-)
Disassemble and assemble . . . . . . . . 33-3360-152
Valve, swing torque control (SN -546276)
Disassemble and assemble . . . . . . . . 33-3360-155
Valve, swing torque control (SN -556935)
Remove and install . . . . . . . . . . . . . . . 33-3360-153
Valve, swing torque control (SN 556936-)
Disassemble and assemble . . . . . . . . 33-3360-156
Remove and install . . . . . . . . . . . . . . . 33-3360-154
Vee belt tension (SN -541550)
Inspect, check and adjust . . . . . . . . . . .18-1830-17
Indx Vehicle electrical component
10 identification . . . . . . . . . . . . . . . . . . . . . .16-1674-3
Volumetric efficiency test-R12 (SN
-541550) . . . . . . . . . . . . . . . . . . . . . . . .18-1830-19